INL/EXT-01-12335

U.S. Department of Energy

FreedomCAR & Vehicle Technologies Program
Advanced Vehicle Testing Activity

Plug-in Hybrid Electric Vehicle

(PHEV)
Integrated Test Plan and Evaluation
Program

DRAFT 3-29-07
Donald Karner
Roberta Brayer
Derek Peterson
Mindy Kirkpatrick
James Francfort
March 2007
The Idaho National Laboratory is a U.S. Department of Energy National Laboratory
Operated by Battelle Energy Alliance
 INL/EXT-01-12335

U.S. Department of Energy

FreedomCAR & Vehicle Technologies Program
Advanced Vehicle Testing Activity

Plug-in Hybrid Electric Vehicle (PHEV)

Integrated Test Plan and Evaluation Program

Donald Karner1
Roberta Brayer1
Derek Peterson1
Mindy Kirpatrick2
James Francfort2

March 2007

Idaho National Laboratory

Transportation Technology Department
Idaho Falls, Idaho 83415

Prepared for the

U.S. Department of Energy
Assistant Secretary for Energy Efficiency and Renewable Energy
Under DOE Idaho Operations Office
Contract DE-AC07-05ID14517

1
Electric Transportation Applications
2
Idaho National Laboratory

ii
 Disclaimer

This document highlights work sponsored by the agencies of the U.S. Government. Neither the
U.S. Government nor any agency thereof, nor any of its employees, makes any warranty, express
or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or
usefulness of any information, apparatus, product, or process disclosed, or represents that its use
would not infringe privately owned rights. Reference herein to any specific commercial product,
process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily
constitute or imply its endorsement, recommendation, or favoring by the U.S. Government or any
agency thereof. The views and opinions of authors expressed herein do not necessarily state or
reflect those of the U.S. Government or any agency thereof. The views and opinions of authors
expressed herein do not necessarily state or reflect those of the U.S. Government or any agency
thereof.

iii
 INTRODUCTION

U.S. DEPARTMENT OF ENERGY INTEGRATED TEST AND EVALUATION

PROGRAM FOR PLUG-IN HYBRID ELECTRIC VEHICLES

The U.S. Department of Energy (DOE) Advanced Vehicle Testing Activity (AVTA) performs
closed track, dynamometer, and fleet testing of onroad light-duty vehicles that feature one or
more advanced technology energy storage systems and/or propulsion systems. To date, the
AVTA has tested and validated the performance and operations of various classes of pure
electric, hybrid electric, and hydrogen-fueled internal combustion engine vehicles.
Continuing the trend of testing vehicles that introduce new technologies, the AVTA has initiated
the testing of plug-in hybrid electric vehicles (PHEV). Results of this testing are provided to
vehicle modelers and manufacturers to assess technical progress and resolve operational issues.
The results are also widely distributed to government and private fleets using printed data sheets
and via the Internet. The public data dissemination supports fleet managers with the introduction
of emerging vehicle technologies into their fleets. All established testing procedures and
completed vehicle testing results can be found at either of the AVTA’s WebPages at
[Link] or [Link]
This document contains PHEV specifications as well as test procedures designed specifically for
the AVTA’s evaluation of PHEVs. Test procedures for vehicle technologies other than PHEVs
can be found on the AVTA WebPages.
For readers unfamiliar with the AVTA’s testing history, a brief background by vehicle
technology follows. These test activities have been and continue to be conducted for DOE’s
AVTA led by the Idaho National Laboratory (INL). AVTA testing is conducted by Electric
Transportation Applications (ETA), with ETA also conducting all vehicle field and infrastructure
testing, and Argonne National Laboratory (ANL) performing dynamometer testing. The DOE,
INL, ETA, and ANL collaborate on the selection of vehicles and technologies for testing.

AVTA TESTING BACKGROUND

Pure Electric Vehicles: The AVTA has tested over fifty pure electric vehicle (EV) models,
ranging in size from neighborhood EVs to full-size passenger sedan and van EVs. Battery
systems tested include flooded lead-acid, valve regulated lead-acid, nickel cadmium, nickel
metal hydride, and lithium polymer batteries. Test protocols include the conduct of baseline
performance testing using closed test tracks and chassis dynamometers as well as accelerated
testing using fleet and dedicated test drivers for onroad testing. Over five million miles of fleet
testing has provided validation of EV performance and operating cost as well as identified
strengths and weaknesses of specific vehicle designs.
Hybrid Electric Vehicles: The AVTA has tested twelve production hybrid electric vehicle
(HEV) models offered by original equipment vehicle manufacturers. Test protocols include the
conduct of baseline performance testing using closed test tracks and chassis dynamometers as
well as accelerated testing using fleet drivers for onroad testing. To date, over 2.5 million miles
has been accumulated to validate the performance and economics of HEVs.
Hydrogen-Fueled Internal Combustion Engine Vehicles: The AVTA has tested 100%
hydrogen-fueled vehicles as well as vehicles fueled with blends of hydrogen and compressed

iv Introduction
natural gas. This testing has included delivery vans, passenger vans and pickup trucks using four-
and eight-cylinder internal combustion engines. Testing has provided data on the correlation
between performance, emissions and hydrogen content in blended fuel vehicles, as well as
performance and emissions data for 100% hydrogen fueled engines. These vehicles are fueled at
the Arizona Public Service Alternative Fuel (Hydrogen) Pilot Plant, which has been operating
since June, 2002. Additionally, safety and user acceptance of hydrogen fuel has been validated.

PLUG-IN HYBRID ELECTRIC VEHICLE TESTING

With the emergence of PHEV propulsion and energy storage systems, DOE’s AVTA has
developed this Integrated Test Plan to govern the testing and evaluation of PHEVs. This plan
includes Baseline Performance Testing, Accelerated Testing, and Fleet Testing.
Procedures governing PHEV testing have been drafted and reviewed with technical contributors.
These procedures are presented herein for comment by a wide range of stakeholders. Procedures
are divided into Administrative Control Procedures, Quality Assurance Procedures and Vehicle
Test Procedures; including Baseline Performance, Accelerated, and Fleet Test Procedures. A
PHEV Vehicle Specification, documenting detailed requirements for PHEVs, has also been
developed and is included in this document.
Administrative Control Procedures
The AVTA Administrative Control Procedures control the conduct of testing and associated
activities. These procedures define qualifications and training for personnel conducting tests, and
requirements for the control of test documents as well as for the control of measuring and test
equipment. There are also procedures for the control of testing, review of test results, and
preparation of test reports.
Quality Assurance Procedures
The Quality Assurance Program for the AVTA establishes quality requirements governing the
conduct of testing and the collection and dissemination of test data. The effectiveness of the
Quality Assurance Plan is assured by conducting audits in accordance with Quality Assurance
Audit procedures.
Baseline Performance Test Procedures
To govern the conduct of Baseline Performance Testing and to ensure that requirements of the
PHEV Vehicle Specification are met, a set of highly repeatable test procedures have been
developed in conjunction with vehicle manufacturers and industry stakeholders (such as fleet
managers), with the objective of measuring real-world vehicle performance. Individual
procedures are prepared to define the requirements for each test or series of related Baseline
Performance Tests. A Test Sequence defines the order in which procedures are to be executed for
Baseline Performance Testing. This testing is conducted on dynamometers and closed-track
environments. PHEVs are evaluated using these Baseline Test Procedures in the following areas:
• Fuel consumption
• Acceleration
• Gradeability
• Road load coefficients (to support dynamometer testing)

v Introduction
 • Vehicle durability
• Charger performance.

Testing is conducted in Normal Operation mode that is most appropriate for fleet operations.
When all-electric operation is possible (Rechargeable Energy Storage System Only mode),
testing is conducted beginning at 100% state-of-charge (SOC) and 50% SOC. Drive-cycle
dynamometer testing includes the Urban Dynamometer Driving Schedule (UDDS), the Highway
Fuel Economy Driving Schedule (HWFEDS), and the Supplemental Federal Test Procedure
US06 (US06). Track testing is conducted at automotive proving grounds near Phoenix, Arizona.
Dynamometer testing is conducted at Argonne National Laboratory’s Advanced Powertrain Test
Facility outside Chicago, Illinois. Test results are presented in test reports and summarized for
wide dissemination in one-page data sheets.
Accelerated Test Procedures
Accelerated Testing rapidly provides performance and reliability data for PHEVs by using
dedicated drivers to drive PHEVs on fixed routes in and around Phoenix, Arizona. This allows
the accumulation of fuel economy data for trips of diverse lengths. The PHEV trips are organized
as shown in the following table.

Cycle Urban Highway Charge Repetitions Total Repetitions Miles Cumulative

(mi) (10 mi) (10 mi) (Hr) (N) (mi) (%) (%) (mi)
10 1 0 4 60 600 45% 14% 600
20 1 1 8 30 600 23% 14% 1200
40 4 0 12 5 200 4% 5% 1400
40 2 2 12 5 200 4% 5% 1600
40 0 4 12 5 200 4% 5% 1800
60 2 4 12 10 600 8% 14% 2400
80 2 6 12 8 640 6% 15% 3040
100 2 8 12 6 600 5% 14% 3640
200 2 18 12 3 600 2% 14% 4240
Total 1740 2500 984 132 4240 4240
Average 41% 59% 7.5 32.1

At a minimum, fuel consumption, maintenance requirements and operating anomalies are

recorded for all trips.
Fleet Test Procedures
During Fleet Testing, PHEVs are monitored as they operate in commercial and government
vehicle fleets. Operating mission selection is carefully performed to maximize the benefits
associated with the performance characteristics of PHEVs. The PHEVs are operated, by one or
more fleet drivers, for two years and 24,000 miles. Data is collected for fuel use, maintenance
costs and vehicle reliability. Selected PHEVs are equipped with an onboard data acquisition
system designed specifically to collect supplemental operating data from vehicles during Fleet
Testing.

vi Introduction
 TABLE OF CONTENTS
INTRODUCTION ......................................................................................................................................................iv

AVTA TESTING BACKGROUND ..........................................................................................................................iv

PLUG-IN HYBRID ELECTRIC VEHICLE TESTING........................................................................................vii

ACRONYM LIST.......................................................................................................................................................ix

Chapter I: PHEV Vehicle Specification....................................................................................................................1

Section I: PHEV Vehicle Specification ....................................................................................................................2

Chapter II: Administrative Control Procedures....................................................................................................29

Section I: AVTA-PHAC01 – Control, Closeout and Storage of Documentation .............................................30

Section II: AVTA-PHAC02 – Control of Test Conduct.....................................................................................36
Section III: AVTA-PHAC03 – Preparation and Issuance of Test Reports .........................................................44
Section IV: AVTA-PHAC04 – Review of Test Results........................................................................................49
Section V: AVTA-PHAC05 – Training and Certification Requirements for Personnel Utilizing AVTA
Procedures ........................................................................................................................................................57
Section VI: AVTA-PHAC06 – Receipt Inspection..............................................................................................64
Section VII: AVTA-PHAC07 – Control of Measuring and Test Equipment........................................................83

Chapter III: Quality Procedures .............................................................................................................................92

Section I: AVTA-PHQA01 – Audit of the Quality Assurance Program for the Control and Use of Measuring
and Test Equipment ................................................................................................................................................93
Section II: AVTA-PHQP01 – Quality Program..............................................................................................109

Chapter IV: Test Procedures.................................................................................................................................118

Section I: PHEV Baseline Test Sequence ......................................................................................................119

Section II: AVTA-PHTP01 – Road Load Measurement Using Onboard Anemometry and Coastdown
Techniques ......................................................................................................................................................125
Section III: AVTA-PHTP02 – Plug-in Hybrid Electric Vehicle Acceleration, Gradeability, and Deceleration
Test ......................................................................................................................................................140
Section IV: AVTA-PHTP03 – Implementation of SAE J1711 MAR99, "Recommended Practice for Measuring
the Exhaust Emissions and Fuel Economy of Hybrid-Electric Vehicles" .............................................................159
Section V: AVTA-PHTP04 – Plug-in Hybrid Electric Vehicle RESS Only Mode Constant Speed Range Tests ..
......................................................................................................................................................235
Section VI: AVTA-PHTP05 – Plug-in Hybrid Electric Vehicle Rough Road Course Test ..............................250
Section VII: AVTA-PHTP06 – Braking Test .....................................................................................................264
Section VIII: AVTA-PHTP07 – Implementation of SAE J1634 May1993 - “Electric Vehicle Energy
Consumption and Range Test Procedure” ...........................................................................................................275

vii Table of Contents

 Section IX: AVTA-PHTP08 – Rechargeable Energy Storage System (RESS) charging ..................................302
Section X: AVTA-PHTP09 – Reserved for Future Use...................................................................................311
Section XI: AVTA-PHTP10 – Measurement and Evaluation of Plug-in Hybrid Electric Vehicle RESS Charger
Performance ......................................................................................................................................................312
Section XII: AVTA-PHTP11 – Vehicle Verification..........................................................................................320
Section XIII: AVTA-PHTP12 – Evaluation of Plug-in Hybrid Electric Vehicle Energy Management System(s)
[EMS] ......................................................................................................................................................339
Section XIV: AVTA-PHTP13 – Reserved for Future Use...................................................................................345
Section XV: AVTA-PHTP14 – Evaluation of Plug-in Hybrid Electric Vehicle Battery Packs .........................346

Chapter V: Accelerated Test Procedures .............................................................................................................360

Section I: AVTA-PHATP01 – Plug-in Hybrid Electric Vehicle Accelerated Test Procedure .......................361

Chapter VI: Fleet Test Procedures .......................................................................................................................370

Section I: AVTA-PHFTP01 – Plug-in Hybrid Electric Vehicle Fleet Test Procedure ..................................371

GLOSSARY .............................................................................................................................................................379

REFERENCES ........................................................................................................................................................386

viii Table of Contents

 ACRONYM LIST

4WD Four Wheel Drive

A/C Air Conditioning
Ah Ampere-hours
ANL Argonne National Laboratory
ANS American Nuclear Society
ASME American Society of Mechanical Engineers
AVTA Advanced Vehicle Testing Activity
BMS Battery Management System
BOD Bottom of Discharge
BS Bachelor of Science
CARB California Air Resources Board
CD Compact Disc
CFCs Chlorofluorocarbons
CFEC Consumable Fuel Energy Converter
CFR Code of Federal Regulations
CNG Compressed Natural Gas
CT Current Transformer
CVT Continuous Variable Transmission
DAS Data Acquisition System
DC Direct Current
DOD Depth of Discharge
DOE Department of Energy
DOT Department of Transportation
EMS Energy Management System
EODV End-of-Discharge Voltage
EPA Environmental Protection Agency
ETA Electric Transportation Applications
EV Electric Vehicle
FCC Federal Communications Commission
FMVSS Federal Motor Vehicle Safety Standards
GAWR Gross Vehicle Axle Weight Ratings

ix Acronym List
GVWR Gross Vehicle Weight Rating
HEV Hybrid Electric Vehicle
HPPC Hybrid Pulse-Power Characterization
HWFEDS Highway Fuel Economy Driving Schedule
INL Idaho National Laboratory
ISO International Standard Organization
LEL Lower Explosive Limit
M&TE Measuring and Test Equipment
mA Milliamp
MIU Measurement Indication Unit
MPH Miles per Hour
MSDS Material Safety Data Sheet
N/A Not Applicable
NBS/HB National Bureau of Standards Handbook
NEC National Electrical Code
NFPA National Fire Protection Association
NHTSA National Highway Transportation Safety Administration
NIST National Institute of Standards and Technology
OCV Open-Circuit Voltage
OEM Original Equipment Manufacturer
OJT On-the-Job-Training
PHAC Plug-in Hybrid Administrative Control
PHEV Plug-in Hybrid Electric Vehicle
PHQA Plug-in Hybrid Quality Assurance
PHQP Plug-in Hybrid Quality Procedures
PHTP Plug-in Hybrid Test Procedures
PT Potential Transformer
QA Quality Assurance
QAM Quality Assurance Management
QAP Quality Assurance Plan
RESS Rechargeable Energy Storage System
S/N Serial Number
SAE Society of Automotive Engineers

x Acronym List
SOC State of Charge
TER Test Exception Report
THD Total Harmonic Distortion
TOCV Top-of-Charge Voltage
TP Test Procedure
TRRT Test Results Review Team
UDDS Urban Dynamometer Driving Schedule
UL Underwriters Laboratory
VAC Volts Alternating Current
VDC Volts Direct Current
VIN Vehicle Identification Number

xi Acronym List
 Chapter I: PHEV Vehicle
Specification

Section I: PHEV Vehicle Specification

1 Chpt I, TOC
 PHEV VEHICLE SPECIFICATION

Section I: PHEV Vehicle Specification

2 Chpt I, Sect I
 PHEV VEHICLE SPECIFICATION

TABLE OF CONTENTS

1 Minimum Vehicle Requirements ........................................................................................................................4

2 Regulatory Requirements ....................................................................................................................................8

3 Chassis ...................................................................................................................................................................9

4 Vehicle Characteristics ......................................................................................................................................11

5 Drive System .......................................................................................................................................................11

6 Vehicle Performance ..........................................................................................................................................12

7 Rechargeable Energy Storage System (RESS).................................................................................................14

8 Electrical .............................................................................................................................................................17

9 Grid-Connected Charging System ....................................................................................................................18

10 Additional Vehicle Systems................................................................................................................................19

11 Documentation....................................................................................................................................................20

APPENDICES

Appendix A – Vehicle Data and Submittals ............................................................................................................21

Appendix B – FMVSS Certification Methodology .................................................................................................27

3 Chpt I, Sect I
 PHEV VEHICLE SPECIFICATION

1 MINIMUM VEHICLE REQUIREMENTS

The Plug-In Hybrid Electric Vehicle (PHEV) Integrated Test and Evaluation Program is
sponsored by the U.S. Department of Energy Advanced Vehicle Testing Activity (AVTA)
to provide for independent assessment of PHEVs. Vehicles tested under this program are
evaluated against specific qualitative and quantitative metrics. The results provide potential
users a method for comparing various PHEVs against consistent standards and against
each other, comparisons that might not otherwise be possible.
For a PHEV to be considered qualified for testing by the AVTA, it must meet the
minimum criteria defined by “shall” terminology utilized in this specification. [For clarity,
the use of the word “shall” defines the minimum requirements, whereas the use of the
word “should” defines design and performance objectives.] Vehicles that do not or cannot
meet all of the “shall” requirements will be considered Prototypes, and will not be
considered as having successfully completed the Program. The following requirements
have been extracted from the body of the Plug-In Vehicle Specification for convenience
and clarity. The term “Supplier” refers to the vehicle manufacturer or converter in these
requirements and in the Plug-In Vehicle Specification. All of the following requirements
must be met before any vehicle can successfully complete testing conducted by the AVTA.
Vehicles to be tested to these Specifications shall be PHEVs which are defined as road
vehicles that can draw propulsion energy from both of the following sources of stored
energy 1) a consumable fuel and 2) a rechargeable energy storage system (RESS) that is
recharged by an electric motor-generator system, and an off-vehicle electric energy source.
PHEVs tested to these Specifications shall not be tested for capability to return electrical
energy off-vehicle.
(1) Vehicles shall comply with Federal Motor Vehicle Safety Standards applicable on
the date of manufacture and such compliance shall be certified by the manufacturer
in accordance with 49 CFR 567. Suppliers shall provide a completed copy of
Appendix A and Appendix B with their proposal, providing vehicle specifications
and the method of compliance with each required section of 49 CFR 571. If
certification includes exemption, the exemption number issued by the National
Highway Transportation Safety Administration (NHTSA), the date of it’s
publication in the Federal Register, and the page number(s) of the Federal Register
acknowledging issuance of the exemption shall be provided along with Appendix
B. Exemptions for any reason other than non-applicability shall not be allowed.
(2) Vehicles shall be certified under current California Air Resources Board (CARB) or
Environmental Protection Agency (EPA) regulations.
(3) Suppliers shall supply Material Safety Data Sheets (MSDS) for all unique
hazardous materials the vehicle is equipped with, including RESS batteries or
capacitors, and auxiliary batteries.
(4) Suppliers shall provide recycling plans for batteries and other vehicle hazardous
materials including how the plan has been implemented.

4 Chpt I, Sect I
 PHEV VEHICLE SPECIFICATION

(5) All vehicles shall comply with the FCC requirements for unintentional emitted
electromagnetic radiation, as identified in 47 CFR 15, Subpart B, “Unintentional
Radiators.”
(6) Vehicles shall have a minimum payload of at least 400 pounds.
(7) For conversion vehicles, OEM GVWR shall not be increased. For conversion
vehicles, Suppliers shall specify the OEMs gross vehicle weight rating (GVWR).
(8) For conversion vehicles, OEM Gross Vehicle Axle Weight Ratings (GAWR) shall
not be increased. Suppliers shall provide axle weights for the vehicle as delivered,
and at full-rated payload.

(9) Tires shall be subject to the following requirements:

• Tires provided with the vehicle shall be the standard tire offered by the PHEV
Supplier for the vehicle being proposed.
• Tires shall correspond to the requirements of the placard installed in accordance
with 49 CFR 571.109, 110, 119 and 120, as applicable.
• Suppliers shall specify manufacturer, model and size of the standard tire.
• Tires sizes and inflation pressures shall be in accordance with the requirements
of the placard.
• At no time shall the tire’s inflation pressure exceed the maximum pressure
imprinted upon that tire’s sidewall.
• The tire shall be operable across the entire operation/load range of that vehicle.
• Replacement tires shall be commercially available to the end user in sufficient
quantities to support the purchaser’s needs.
• Tires provided as original equipment by the PHEV manufacturer shall not have
warranty restrictions in excess of those of the tire’s manufacturer, unless the
Supplier is the sole warrantor for the tires.
• If the vehicle may be equipped with more than one standard tire, this
information shall be provided for each type/manufacturer of each standard tire.
(10) Seating capacity shall be a minimum of 1 driver and 1 passenger. Suppliers shall
specify seating capacity (available seat belt positions) for their vehicle. For
conversion vehicles, if the vehicle’s seating capacity is changed from that specified
by the OEM on their FMVSS placard, the seat(s) being added or abandoned shall be
modified as required by 49 CFR 571.207, et al, and a new FMVSS placard installed
as required by 49 CFR 567, 568 or 571, as applicable.
(11) For conversion vehicles, the OEM passenger space shall not be intruded upon by
the Rechargeable Energy Storage System (RESS), or other conversion materials.
(12) Vehicles shall have a parking mechanism.
(13) The controller/inverter shall limit the minimum RESS battery discharge voltage to
prevent degradation of battery life, and should limit the maximum regeneration
voltage to prevent external gassing of the batteries.
(14) Vehicles shall comply with the requirements of 49 CFR 571.105.S5.2.1, or
alternatively, 49 CFR 571.105.S5.2.2 for parking mechanisms.

5 Chpt I, Sect I
 PHEV VEHICLE SPECIFICATION

(15) Vehicles shall be capable of completing procedure AVTA-PHTP05, including (1)

driving through standing water without damage and without battery to chassis
leakage current exceeding 0.5 MIU per UL Standard 2202, and (2) standing for
extended periods in extreme temperatures without damage to, or failure of, the
vehicle or its systems.
Vehicles shall be capable of completing all AVTA tests without repairs exceeding a
cumulative total of 72 hours.
(16) Suppliers should provide a detailed description of the RESS battery pack, battery
pack voltage, number of battery modules and summary of previous performance
tests. If different, customer available and battery available DOD ratings shall both
be provided.
(17) Batteries shall comply with the requirements of SAE J1718.
Vehicles shall not auto-start the engine to charge the batteries while the vehicle is
parked and the key switch is in the OFF position.
RESS batteries shall meet the requirements of NEC 625-29(c) or (d) for charging in
enclosed spaces without a vent fan. The vehicle shall be labeled as not requiring
ventilation for charging (or have the appropriate classification label from a UL-
recognized Testing Laboratory).
(18) For vehicles with RESS system voltages of 48 volts and higher, batteries or
capacitors and their enclosures shall be designed and constructed in a manner that
complies with 49 CFR 571.305. For vehicles with RESS system voltages below
48VDC, batteries or capacitors, and their enclosures, shall be designed and
constructed in accordance with the requirements of SAE J1766. Further,
irrespective of RESS system voltage, batteries or capacitors, and electrolyte will not
intrude into the passenger compartment during or following FMVSS frontal barrier,
rear barrier and side impact collisions, and rollover requirements of 49 CFR
571.301. Suppliers shall provide verification of conformance to this requirement.
(19) Concentrations of explosive gases in the battery box shall not be allowed to exceed
25% of the Lower Explosive Limit. Suppliers shall describe how battery boxes will
be vented, to allow any battery gases to escape safely to atmosphere during and
following normal or abnormal charging and operation of the vehicle. Battery gases
shall not be allowed to enter the occupant compartment.
(20) Batteries shall comply with the requirements of SAE J1718, and at a minimum shall
meet the requirements of NEC 625-29(c) or (d) for charging in enclosed spaces
without a vent fan.
(21) If a Supplier provides a vehicle with parallel battery packs, the Supplier shall
provide detailed information on the equipment and charging algorithms required to
prevent the parallel strings from becoming unbalanced.
(22) Vehicle suppliers shall provide the battery warranty provided including the
procedures for making a warranty claim to the end user.
(23) If a Battery Management System (BMS) is provided, the Supplier shall provide a
description of the BMS operation.

6 Chpt I, Sect I
 PHEV VEHICLE SPECIFICATION

(24) For vehicles using fuels other than gasoline, manufacturers shall indicate
compliance with appropriate and applicable standards from SAE, NFPA, etc. [e.g.,
for vehicles using Compressed Natural Gas as fuel, manufacturers should indicate
compliance with NFPA 52, “Compressed Natural Gas (CNG) Vehicular Fuel
Systems Code,” as well as 49 CFR 571.303 and 304.].
(25) Rechargeable Energy Storage Systems (RESS) shall be battery or capacitor based as
defined in SAE J1711.
(26) Vehicles shall not contain exposed conductors, terminals, contact blocks, or devices
of any type that create the potential for personnel to be exposed to 60 volts or
greater (the distinction between low-voltage and high voltage, as specified in SAE
J1127, J1128, et al.). Access to any high voltage components shall require the
removal of at least one bolt, screw, or latch. Devices considered being high voltage
components shall be clearly marked as HIGH VOLTAGE. These markings should
be installed at any point the voltage can be accessed by the end user. Additionally
cable and wire marking shall consist of orange wire and/or orange sleeving as
identified in SAE-J1127.

(27) For propulsion power systems with voltages, which may equal or exceed 60 VDC,
the system shall be isolated from the vehicle chassis such that leakage current does
not exceed 0.5 MIU.
Charging circuits for RESS battery systems with voltages, which may equal or
exceed 60 VDC, shall be isolated from the vehicle chassis such that ground current
from the grounded chassis does not exceed 5 mA at any time the vehicle is
connected to an off-board power supply.
(28) The automatic disconnect for the RESS batteries shall be capable of interrupting
maximum rated controller/inverter current. The Supplier shall describe the
automatic disconnect provided for the main propulsion batteries.

(29) The vehicle shall be prevented from being driven with the key turned on and the
drive selector in the drive or reverse position while the vehicle’s charge cord is
attached. Additionally, the following interlocks shall be present:
• The controller shall not initially energize to move the vehicle with the gear
selector in any position other than “PARK” or “NEUTRAL.”
• The start key shall be removable only when the “ignition switch” is in the
“OFF” position, with the drive selector in “PARK.”
• With a pre-existing accelerator input, the controller shall not energize or excite
such that the vehicle can move under its own power from this condition.
• Vehicles capable of grid connection shall be prevented from being driven with
the key turned on and the drive selector in the drive or reverse position while the
vehicle’s charge cord is attached.
(30) The grid-connected charger shall be capable of recharging the RESS to a state of
full charge from any possible state of discharge in less than 12 hours, at
temperatures noted in Section 6.5, as applicable.

7 Chpt I, Sect I
 PHEV VEHICLE SPECIFICATION

The charger shall be fully automatic, determining when “end of charge” conditions
are met and transitioning into a mode that maintains the main propulsion battery at
a full state of charge while not overcharging it, if continuously left on charge.
(31) The RESS charger shall be onboard the vehicle and shall use 120V or 208/240V
single-phase 60-Hertz alternating current service, with an input voltage tolerance of
±10% of rated voltage. Input current for charges operating at 120 V shall be
compatible with 15-ampere circuit breakers. Input current for chargers operating at
208V and 240V shall be compatible with 40-ampere circuit breakers.
Charger personnel protection systems shall be in accordance with the applicable
sections of UL Standards 2231-1 and 2231-2. Equipment external to the vehicle
shall comply with NEC 625.
(32) The RESS charger shall have a true power factor of 0.95 or greater and a harmonic
current distortion of <20% (at rated load).
(33) Regardless of the charger used, the charger shall conform to the requirements of UL
Standard 2202.
(34) Suppliers shall specify all optional equipment required to meet the requirements of
the PHEV Vehicle Specification. The installation of options shall not relieve
Suppliers of meeting other “shall requirements.”
(35) Vehicles shall be accompanied by non-proprietary manuals for parts, service,
operation and maintenance, interconnection wiring diagrams and schematics.
The following sections constitute the Technical Requirements of the PHEV Vehicle
Specification. Information has been categorized according to component and/or function.
These sections provide an overview of the requirements and recommendations for
Suppliers to use. This Vehicle Specification establishes the minimum requirements for
successful completion of the AVTA Plug-In Hybrid Electric Vehicle Integrated Test and
Evaluation Program, as well as identifying design and performance objectives.
No inference should be drawn by Suppliers or any other person that the measures listed in
this specification are sufficient to ensure vehicle safety. The Supplier is solely responsible
for determining whether each vehicle offered for sale is safe, and must not rely on this
PHEV Vehicle Specification as a measure of vehicle safety.

2 REGULATORY REQUIREMENTS

2.1 FMVSS CERTIFICATION

Vehicles shall comply with Federal Motor Vehicle Safety Standards applicable on
the date of manufacture and such compliance shall be certified by the manufacturer
in accordance with 49 CFR 567. Suppliers shall provide a completed copy of
Appendix A and Appendix B for PHEV America review, providing vehicle
specifications and the method of compliance with each required section of 49 CFR
571. If certification includes exemption, the exemption number issued by the
National Highway Transportation Safety Administration (NHTSA), the date of it’s

8 Chpt I, Sect I
 PHEV VEHICLE SPECIFICATION

publication in the Federal Register and the page number(s) of the Federal Register
acknowledging issuance of the exemption shall be provided along with Appendix B.
Exemptions for any reason other than non-applicability shall not be allowed.

2.2 VEHICLE EMISSIONS CERTIFICATION

Vehicle emissions shall be certified under current California Air Resources Board
(CARB) or Environmental Protection Agency (EPA) regulations.

2.3 SAFETY FEATURES

Suppliers should describe safety measures and safety-related design features
included in their vehicle design and provide an explanation of the purpose and
anticipated effect on vehicle reliability and performance of any such safety measure
or design feature.

2.4 MATERIAL SAFETY DATA SHEETS

Suppliers shall supply Material Safety Data Sheets (MSDS) for all unique hazardous
materials the vehicle is equipped with, including RESS batteries or capacitors, and
auxiliary batteries.

2.5 BATTERY AND HAZARDOUS MATERIALS RECYCLING PLANS

Suppliers shall provide recycling plans for batteries and other vehicle hazardous
materials including how the plan has been implemented. This plan should also
identify post-purchase costs associated with recycling that will be passed on to the
vehicle purchaser.

2.6 FEDERAL COMMUNICATIONS REQUIREMENTS

All vehicles shall comply with the FCC requirements for unintentional emitted
electromagnetic radiation, as identified in 47 CFR 15, Subpart B, and “Unintentional
Radiators.”

2.7 ELECTROMAGNETIC FIELD MINIMIZATION

Vehicles should be designed to minimize occupant exposure to electromagnetic
fields generated by the propulsion system.

3 CHASSIS

3.1 RATED PAYLOAD

Vehicles shall have a minimum payload of at least 400 pounds.

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 PHEV VEHICLE SPECIFICATION

3.2 CURB WEIGHT AND GROSS VEHICLE WEIGHT RATING (GVWR)

For conversion vehicles, OEM GVWR shall not be increased. Suppliers should
provide the curb weight and rated payloads of their vehicles. Suppliers shall specify
the OEMs GVWR.

3.3 VEHICLE WEIGHT DISTRIBUTION

For conversion vehicles, OEM Gross Vehicle Axle Weight Ratings (GAWR) shall
not be increased. Suppliers shall provide axle weights for the vehicle as delivered,
and at full rated payload.

3.4 SPEEDOMETER AND ODOMETER

Vehicles shall have a speedometer and an odometer. Speedometers and odometers
should have an accuracy of at least ± 5%.

3.5 BRAKING AND STEERING PERFORMANCE

For conversion vehicles, braking and steering efforts should be similar to OEM
models of comparable size and weight.

3.6 TIRES
Tires shall be subject to the following requirements:
• Tires provided with the vehicle shall be the standard tire offered by the Supplier.
• Tires shall correspond to the requirements of the placard installed in accordance
with 49 CFR 571.109, 110, 119 and 120, as applicable.
• Suppliers shall specify manufacturer, model and size of the standard tire.
• Tires sizes and inflation pressures shall be in accordance with the requirements of
the placard.
• At no time shall the tire’s inflation pressure exceed the maximum pressure
imprinted upon that tire’s sidewall.
• The tire shall be operable across the entire operation/load range of that vehicle.
• Replacement tires shall be commercially available to the end user in sufficient
quantities to support the purchaser’s needs.
• Tires provided as original equipment by the Supplier shall not have warranty
restrictions more restrictive than those of the tire’s manufacturer, unless the
Supplier is the sole warrantor for the tires.
• If the vehicle may be equipped with more than one standard tire, the above listed
requirements shall apply to each type/manufacturer of each standard tire.

3.7 GROUND CLEARANCE

Vehicles should have a ground clearance of at least five (5) inches to all sprung
portions of the vehicle, with the vehicle loaded with rated payload (e.g. to GVWR).

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4 VEHICLE CHARACTERISTICS

4.1 SEATING CAPACITY

Seating capacity shall be a minimum of 1 driver and 1 passenger. Suppliers shall
specify seating capacity (available seat belt positions) for their vehicle. For
conversion vehicles, if the vehicle’s seating capacity is changed from that specified
by the OEM on their FMVSS placard, the seat(s) being added or abandoned shall be
modified as required by 49 CFR 571.207, et al, and a new FMVSS placard installed
as required by 49 CFR 567, 568 or 571, as applicable.

4.2 PASSENGER AND CARGO SPACE

For conversion vehicles, the OEM passenger space shall not be intruded upon by the
Rechargeable Energy Storage System (RESS), or other conversion materials.
Suppliers should specify interior passenger and cargo dimensions and volumes.

4.3 ELECTROMAGNETIC SUSCEPTIBILITY

Vehicles should comply with the relevant sections of SAE J551 for electromagnetic
radiated fields. Vehicles should not be susceptible to externally generated
electromagnetic radiation from an on-board transmitter (i.e., interaction will not
preclude operation of any system(s) required for proper operation of the vehicle).

5 DRIVE SYSTEM

5.1 TRANSMISSION
The vehicle should utilize a single speed, multi-speed automatic, or a Continuously
Variable Transmission (CVT), and shall have a parking mechanism.

5.2 REGENERATIVE BRAKING SYSTEM

Regenerative braking should not adversely impact the vehicle’s braking ability on
varying road surfaces. Suppliers should describe the operation of the regenerative
braking system and its interface with braking and anti-lock brake systems.

5.3 OVERHEATING
The vehicle drive-train system should be capable of continuous operation at
maximum vehicle speed and/or sustained grades without overheating or loss of
component life over the range of ambient temperatures specified in Section 6.5.

5.4 BATTERY VOLTAGE LIMITS

The controller/inverter shall limit the minimum RESS battery discharge voltage to
prevent degradation of battery life, and should limit the maximum regeneration

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voltage to prevent external gassing of the batteries. Suppliers should specify the
voltage limits and describe how these limits are implemented.

5.5 DRIVE TRAIN

Drive train components should not produce or develop unusual vibrations over the
entire design speed range of the vehicle.

5.6 PARKING MECHANISM

Vehicles shall comply with the requirements of 49 CFR 571.105.S5.2.1, or
alternatively, 49 CFR 571.105.S5.2.2 for parking mechanisms.

6 VEHICLE PERFORMANCE
Vehicle performance is divided into separate categories depending upon vehicle overall
design and available operating modes. Vehicles, which are capable of driver selectable
modes, have performance goals for each of those modes. The performance goals apply
only if the vehicle is capable of operation in the mode stated [e.g., vehicles that cannot be
operated in RESS Only mode will not be tested in that mode]. Normal operation for a
PHEV begins after off-board charging at 100% RESS state-of-charge (SOC), then operates
in a charge depleting mode (hybrid or all electric) until the RESS attains its minimum
operating SOC, at which time the vehicle operates in a hybrid charge sustaining mode.

6.1 ACCELERATION
The vehicle should have a 0-60 mph acceleration time of 13.5 seconds or less with
the vehicle loaded to its design curb-weight plus 300 pounds in each of the selectable
modes of operation, as applicable.
6.1.1 Normal Operation mode starting with the RESS at 100% SOC
6.1.2 Normal Operation mode starting with the RESS at the SOC at which the
vehicle enters charge-sustaining mode
6.1.3 Consumable Fuel Energy Converter (CFEC) mode only
6.1.4 Rechargeable Energy Storage System Only (RESS Only) mode, starting at
100% SOC
6.1.5 Rechargeable Energy Storage System Only (RESS Only) mode, starting at
50% SOC
6.1.6 All other possible HEV modes that are specified as user-selectable in the
vehicle’s operating manual, and starting with the RESS at 100% SOC

6.2 MINIMUM TOP SPEED

The vehicle should have a minimum top speed of 90 mph with the vehicle loaded to
its design curb-weight plus 300 pounds in each of the selectable modes of operation,
as applicable.

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6.2.1 Normal Operation mode starting with the RESS at 100% SOC
6.2.2 Normal Operation mode starting with the RESS at the SOC at which the
vehicle enters charge-sustaining mode
6.2.3 Consumable Fuel Energy Converter (CFEC) mode only
6.2.4 Rechargeable Energy Storage System Only (RESS Only) mode, starting at
100% SOC
6.2.5 Rechargeable Energy Storage System Only (RESS Only) mode, starting at
50% SOC
6.2.6 All other possible HEV modes that are specified as user-selectable in the
vehicle’s operating manual, and starting with the RESS at 100% SOC

6.3 HIGH SPEED GRADEABILITY

Vehicles should achieve a minimum sustainable speed of 55 mph on a 3% grade, and
45 mph on a 6% grade, with the vehicle loaded to its design curb-weight plus 300
pounds, in each of the selectable modes of operation, as applicable.
6.3.1 Normal Operation mode starting with the RESS at 100% SOC
6.3.2 Normal Operation mode starting with the RESS at the SOC at which the
vehicle enters charge-sustaining mode
6.3.3 Consumable Fuel Energy Converter (CFEC) mode only
6.3.4 Rechargeable Energy Storage System Only (RESS Only) mode, starting at
100% SOC
6.3.5 Rechargeable Energy Storage System Only (RESS Only) mode, starting at
50% SOC
6.3.6 All other possible HEV operating modes that are specified as user-selectable
in the vehicle’s operating manual, and starting with the RESS at 100% SOC

6.4 LOW SPEED GRADEABILITY

Vehicles should be capable of starting and ascending a 25% grade with the vehicle
loaded to its design curb-weight plus 300 pounds in each of the selectable modes of
operation, as applicable.
6.4.1 Normal Operation mode starting with the RESS at 100% SOC
6.4.2 Normal Operation mode starting with the RESS at the SOC at which the
vehicle enters charge-sustaining mode
6.4.3 Consumable Fuel Energy Converter (CFEC) mode only
6.4.4 Rechargeable Energy Storage System Only (RESS Only) mode, starting at
100% SOC
6.4.5 Rechargeable Energy Storage System Only (RESS Only) mode, starting at
50% SOC

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6.4.6 All other possible HEV operating modes that are specified as user-selectable
in the vehicle’s operating manual, and starting with the RESS at 100% SOC

6.5 DURABILITY
Vehicles shall be capable of completing procedure AVTA-PHTP05, including (1)
driving through standing water without damage and without battery to chassis
leakage current exceeding 0.5 MIU per UL Standard 2202, and (2) standing for
extended periods in extreme temperatures without damage to or failure of the vehicle
or its systems. This includes ambient air temperatures of -20°F to +120°F, paved
surface temperatures of 150°F, and occupant compartment temperatures of 170°F.
Vehicles should be capable of completing procedure AVTA-PHTP05, without
becoming inoperable. Vehicle shall be capable of completing all tests without repairs
exceeding a cumulative total of 72 hours.

6.6 WATER DURABILITY

Vehicles should be capable of driving through two (2) inches of standing water at a
speed of 20 mph without damage, without becoming inoperable, and without battery
to chassis leakage current exceeding 0.5 MIU per UL Standard 2202.
Vehicles should be capable of setting in eight (8) inches of standing water for 15
minutes without damage, becoming inoperable, and without battery to chassis
leakage current exceeding 0.5 MIU per UL Standard 2202.

6.7 ENERGY EFFICIENCY DRIVE CYCLES

Vehicles should be able to complete two (2) Urban Dynamometer Driving Schedules
(UDDS) followed by two (2) Highway Fuel Economy Driving Schedules
(HWFEDS) in all charge depleting modes to obtain fuel/energy efficiency. Testing
will be conducted with the vehicle loaded to its design curb-weight plus 300 pounds.

7 RECHARGEABLE ENERGY STORAGE SYSTEM (RESS)

7.1 BATTERY TYPE

Suppliers should provide a detailed description of the RESS battery pack including:
specific energy, specific power and discharge capacity to 80% depth of discharge
(DOD) at the one-hour rate, battery pack voltage, number of battery modules, and a
summary of previous performance tests. If different, customer available and battery
available DOD ratings shall both be provided.

7.2 BATTERY CHARACTERISTICS

Batteries shall comply with the requirements of SAE J1718. For valve regulated
batteries, the internal pressure level at which batteries vent should be specified.
Suppliers should describe projected life (in cycles) at a specified level of discharge,

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how battery life is maximized, how end of life of each battery module and of the full
battery pack is determined, and how battery temperature gradients are minimized.
Vehicles shall not auto-start the engine to charge the batteries while the vehicle is
parked and the key switch is in the OFF position.
RESS batteries shall meet the requirements of NEC 625-29(c) or (d) for charging in
enclosed spaces without a vent fan. The vehicle shall be labeled as not requiring
ventilation for charging (or have the appropriate classification label from a UL-
recognized Testing Laboratory).

7.3 MAXIMUM STATE OF DISCHARGE

Suppliers should indicate the level of charge below which the batteries should not be
discharged. This should include the specific parameters the BMS utilizes to prevent
over-discharge. At a minimum, battery capacity ratings, module voltage(s), and
battery pack voltage(s) should be provided. Further, this should be consistent with
information provided in the Owner’s Manuals.

7.4 BATTERY PACK

Suppliers should specify the weight of each battery module, and the weight of the
battery pack (including removable pack structures). Suppliers should describe how
batteries are installed in the vehicle (including details of module connection), the
method of installation and removal of the batteries (and the battery box, if required)
for maintenance and repair, the time required for battery removal, and any special
training, tools or equipment required for battery removal.

7.5 ELECTROLYTE CONTAINMENT

For vehicles with RESS system nominal voltages of 48 volts and higher, batteries or
capacitors and their enclosures shall be designed and constructed in a manner that
complies with 49 CFR 571.305. For vehicles with RESS nominal system voltages
below 48VDC, batteries or capacitors, and their enclosures, shall be designed and
constructed in accordance with the requirements of SAE J1766. Further, irrespective
of RESS system voltage, batteries or capacitors, and electrolyte shall not intrude into
the passenger compartment during or following FMVSS frontal barrier, rear barrier
and side impact collisions, and rollover requirements of 49 CFR 571.301. Suppliers
shall provide verification of conformance to this requirement.

7.6 BATTERY BOX

Concentrations of explosive gases in the battery box shall not be allowed to exceed
25% of the Lower Explosive Limit. Suppliers shall describe how battery boxes will
be vented, to allow any battery gases to escape safely to atmosphere during and
following normal or abnormal charging and operation of the vehicle. Battery gases
shall not be allowed to enter the occupant compartment.

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 PHEV VEHICLE SPECIFICATION

Batteries shall meet the requirements of NEC 625-29(c) or (d) for charging in
enclosed spaces without a vent fan.

7.7 PARALLEL BATTERY PACKS

If a Supplier provides a vehicle with parallel battery packs, the Supplier shall
provide detailed information on the equipment and charging algorithms required to
prevent the parallel strings from becoming unbalanced.

7.8 BATTERY MAINTENANCE

Maintenance requirements for the RESS batteries should be described and any
associated cost(s) to the consumer/end user should be clearly defined.

7.9 ADDITIONAL RESS COMPONENT MAINTENANCE

Maintenance requirements for other RESS components (e.g., flywheels, ultra
capacitors) should be described and any associated cost(s) to the consumer/end user
should be clearly defined.

7.10 BATTERY CHARGING ALGORITHM

Vehicle suppliers shall provide the battery warranty provided to the end user,
including the procedures for making a warranty claim.

7.11 BATTERY MANAGEMENT SYSTEM

The vehicle should be equipped with a BMS. This system should control propulsion
battery pack and module voltages, temperatures and state of charge during both
charge and discharge. Further, the BMS should automatically limit battery discharge
below a pre-determined minimum level. If a BMS is provided, the Supplier shall
provide a description of the BMS operation. This description should be consistent
with that provided in the owner’s manual.

7.12 FUEL SYSTEMS

For vehicles using fuels other than gasoline, manufacturers shall indicate compliance
with appropriate and applicable standards from SAE, NFPA, etc. [e.g., for vehicles
using Compressed Natural Gas as fuel, manufacturers should indicate compliance
with NFPA 52, as well as 49 CFR 571.303 and 304.] For pressurized fuel systems,
Suppliers should provide expected refueling times.

7.13 RESS ENERGY SOURCE

Rechargeable Energy Storage Systems (RESS) shall be battery or capacitor-based as
defined in SAE J1711.

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 PHEV VEHICLE SPECIFICATION

8 ELECTRICAL

8.1 ELECTRICAL SAFETY

Vehicles shall not contain exposed conductors, terminals, contact blocks, or devices
of any type that create the potential for personnel to be exposed to 60 volts or greater
(the distinction between low-voltage and high voltage, as specified in SAE J1127,
J1128, et al.). Access to any high voltage components shall require the removal of at
least one bolt, screw, or latch. Devices considered having high voltage components
shall be clearly marked as HIGH VOLTAGE. These markings should be installed at
any point the voltage can be accessed by the end user. Additionally, cable and wire
marking shall consist of orange wire and/or orange sleeving as identified in SAE­
J1127.

8.2 ELECTRICAL ISOLATION

For propulsion power systems with voltages, which may equal or exceed 60 VDC,
the system shall be isolated from the vehicle chassis such that leakage current does
not exceed 0.5 MIU.
Charging circuits for RESS battery systems with voltages, which may equal or
exceed 60 VDC, shall be isolated from the vehicle chassis such that ground current
from the grounded chassis does not exceed 5 mA at any time the vehicle is
connected to an off-board power supply. Supplier should provide details on
grounding and isolation methods.

8.3 BATTERY DISCONNECT3

Vehicles should be equipped with an automatic disconnect for the RESS batteries
which operates to isolate the propulsion circuits any time the chassis becomes
energized from contact with the propulsion battery or its associated circuits. This
disconnect shall be capable of interrupting maximum rated controller/inverter
current. The Supplier shall describe the automatic disconnect provided for the main
propulsion batteries.
A manual service disconnect should also be present. This disconnect should be
operable with the following capabilities:
• Manual action to break the connection
• The disconnection is physically verifiable
• The disconnection does not create exposed conductors capable of becoming
energized while exposed.

3
Manufacturers may choose to install over-ride features to allow vehicles to move under their own power in
situations where occupant safety is the primary concern (e.g., following a collision where moving the vehicle off the
roadway is determined necessary to prevent injury/further injury or additional damage.)

17 Chpt I, Sect I
 PHEV VEHICLE SPECIFICATION

The key-switch may be used to satisfy the operability portion of the manual service
disconnect requirement, if it interrupts all control power going to the controller and
the main battery contactor(s). This disconnect is not required to operate under load.

8.4 SAFETY INTERLOCK SYSTEM

The vehicle shall be prevented from being driven with the key turned on and the
drive selector in the drive or reverse position while the vehicle’s charge cord is
attached. Additionally, the following interlocks shall be present:
• The controller shall not initially energize to move the vehicle with the gear
selector in any position other than “PARK” or “NEUTRAL”
• The start key shall be removable only when the “ignition switch” is in the “OFF”
position, with the drive selector in “PARK”

8.5 OPERATION OF HAZARD LIGHTS

Hazard lights should be capable of at least one hour of continuous operation in the
event of shutdown or isolation of the main battery pack, or failure of the DC/DC
converter system.

8.6 STATE OF CHARGE INDICATOR

The vehicle should include a state of charge indicator for the RESS batteries.
Indications should be accurate to ± 5% of full scale.

8.7 CONNECTORS
Low voltage connectors should meet the requirements of applicable SAE Standards,
including J163, J561, J858, et al. High voltage connectors should utilize locking
devices, should be keyed to prevent misconnection, and should be moisture proof.

9 GRID-CONNECTED CHARGING SYSTEM

9.1 CHARGER OPERATION

The grid-connected charger shall be capable of recharging the RESS to a state of full
charge from any possible state of discharge in less than 12 hours, at temperatures
noted in Section 6.5, as applicable. The preferred recharge time should be less than
eight (8) hours.
The charger shall be fully automatic, determining when “end of charge” conditions
are met and transitioning into a mode that maintains the main propulsion battery at a
full state of charge while not overcharging it, if continuously left on charge. The
charger should also minimize the energy required to maintain the main propulsion
battery in a fully charged state, particularly during extended periods on charge.

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9.2 CHARGING INPUT POWER

The RESS charger shall be onboard the vehicle and shall be powered from 120V or
208/240V single-phase 60-Hertz alternating current, with an input voltage tolerance
of ±10% of rated voltage. Input current for chargers operating at 120V shall be
compatible with 15-ampere circuit breakers. Input current for chargers operating at
208V/240V shall be compatible with 40-ampere circuit breakers.
Charger personnel protection systems shall be in accordance with Standards 2202
and the applicable sections of UL Standards 2231-1 and 2231-2. Equipment external
to the vehicle shall comply with NEC 625.
Any conductive or inductive type charging systems should be in accordance with the
requirements of SAE J1772 or J1773.

9.3 POWER QUALITY

The RESS charger shall have a true power factor of 0.95 or greater and a harmonic
current distortion of ≤ 20% (at rated load).

9.4 VEHICLE CHARGER CONNECTIONS

Suppliers should describe the type, size and location of the point of the vehicle
charging port. The charge connector should comply with the requirements of SAE
J1772 or SAE J1773, as appropriate.

10 ADDITIONAL VEHICLE SYSTEMS

Suppliers shall specify all optional equipment required to meet the requirements of the
PHEV Vehicle Specification. Suppliers should describe the following options, if available.
The installation of options shall not relieve Suppliers of meeting other “shall”
requirements. Suppliers should specify the impact on range and payload for each option.

10.1 AIR CONDITIONING SYSTEM

Suppliers should describe the design of the air conditioning system and verify that it
uses no chlorofluorocarbons (CFCs).

10.2 OCCUPANT COMPARTMENT PRE-HEATING AND COOLING SYSTEM

Suppliers should briefly describe the design of a pre-heating and pre-cooling system
that allows passenger compartment temperatures to be maintained while the vehicle
is on charge.

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11 DOCUMENTATION

11.1 SERVICE MANUALS

Vehicles shall be accompanied by non-proprietary manuals for parts, service,
operation and maintenance, interconnection wiring diagrams and schematics.
Manuals should include details on the design and operation of vehicle systems, as
well as a list of additional or special maintenance tools required.

11.2 TRAINING PROGRAM

Suppliers should offer a training program for the purchaser’s maintenance personnel
covering vehicle safety and proper operation and maintenance of vehicles.

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Appendix A – Vehicle Data & Submittals

PERFORMANCE (in Normal Operation mode)
Time required to accelerate from 0-60 mph on a level grade(s) _____________________
Maximum speed on a 3% grade(s) ___________________________________________
Maximum speed on a 6% grade(s) ___________________________________________
Maximum speed attainable on a level grade (mph) ______________________________
Maximum grade attainable from a standing start at GVWR (%) ____________________

PERFORMANCE (in RESS Only mode starting at 50% SOC)

Time required to accelerate from 0-60 mph on a level grade(s) _____________________
Maximum speed on a 3% grade(s) ___________________________________________
Maximum speed on a 6% grade(s) ___________________________________________
Maximum speed attainable on a level grade (mph) ______________________________
Range at a constant speed of 45 mph (miles) ___________________________________

BATTERY RESS CHARACTERISTICS (referenced to 25˚C)

Manufacturer ___________________________________________________________
Model ___________________________________________________________
Type ___________________________________________________________
Description ___________________________________________________________
Number of cells/modules in the pack __________________________________________
Arrangement (series or parallel) _____________________________________________
Battery cell/module voltage (VDC) __________________________________________
Battery pack voltage (VDC) ________________________________________________
Battery cell/module weight (kg) _____________________________________________
Battery pack weight (kg) ___________________________________________________
Battery capacity to 100% Manufacturer’s DOD, 1 hour rating (Ah) _________________
Battery energy to 100% Manufacturer’s DOD, 1 hour rating (Wh) __________________
Expected life of battery to a Manufacturer’s DOD of:
50% DOD (cycles) ___________________________________________
80% DOD (cycles) ___________________________________________
Charge sustaining mode (cycles) ___________________________________________
Time required to recharge from maximum allowable vehicle DOD (hr:min): __________

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Appendix A (continued)
CHARGER CHARACTERISTICS
Manufacturer ____________________________________________________________
Model _________________________________________________________________
UL file number __________________________________________________________
Description _____________________________________________________________
Location _______________________________________________________________
Charger efficiency (%) _____________________________________________________
Charger input voltage(s) (VAC) _____________________________________________
Charger input current(s) (A) ________________________________________________
Charger input power factor (%) _____________________________________________
Charger input total harmonic current distortion (%) ______________________________
Maximum charger current output (A) _________________________________________

MOTOR CHARACTERISTICS
Manufacturer ____________________________________________________________
Model _________________________________________________________________
Description _____________________________________________________________
Type (AC, DC, Brushless, etc.) ______________________________________________
Rated efficiency ____________________________ % @ ____________________kW
Operating range (RPM) ____________________________________________________
Maximum intermittent power _________________ kW for ________________ minutes
Maximum continuous power (kW) ___________________________________________
Cooling medium and method _______________________________________________

CONTROLLER CHARACTERISTICS
Manufacturer ____________________________________________________________
Model _________________________________________________________________
Description _____________________________________________________________
Type and Phase __________________________________________________________
Input voltage range _______________________________________________________
Maximum input current (A) ________________________________________________

HEAT ENGINE CHARACTERISTICS

Model __________________________________________________________________
Configuration ____________________________________________________________
Displacement (liters) ______________________________________________________
Number of cylinders ______________________________________________________
Power (hp@rpm) ________________________________________________________
Torque (lb-ft@rpm) ______________________________________________________
Recommended fuel (all types) ______________________________________________
Fuel storage capacity (gge) (specify for each fuel type) ___________________________

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Appendix A (continued)

TRANSMISSION CHARACTERISTICS
Type __________________________________________________________________
Model _________________________________________________________________
Description _____________________________________________________________

CHASSIS CHARACTERISTICS - Pre-Conversion

Make, year and model _____________________________________________________
Gross vehicle weight rating (kg) _____________________________________________
Gross axle weight rating (kg) __________________ front ___________________ rear
Curb weight (kg) _________________________________________________________
Drive wheels (F/R) _______________________________________________________
Weight distribution ___________________________ % front ______________ % rear
Payload capacity (kg) _____________________________________________________
Ground clearance from lowest point on chassis at GVWR (cm) ____________________
Wheelbase _______________________________________________________ inches
Track ________________________inches front ________________________inches rear

CHASSIS CHARACTERISTICS - Post-Conversion

Gross vehicle weight rating (kg) _____________________________________________
Gross axle weight rating (kg) __________________ front ___________________ rear
Curb weight (kg) _________________________________________________________
Drive wheels (F/R) _______________________________________________________
Weight distribution ___________________________ % front ______________ % rear
Payload capacity (kg) _____________________________________________________
Ground clearance from lowest point on chassis at GVWR (cm) ____________________
Wheelbase _______________________________________________________ inches
Track ________________________inches front ________________________inches rear

BRAKES
Type front ______________________________________________________________
Type rear _______________________________________________________________
Power source, if used _____________________________________________________
Average power, if used (W) ________________________________________________
Maximum regenerative braking (kW) ________________________________________

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Appendix A (continued)
TIRES
Manufacturer ____________________________________________________________
Model _________________________________________________________________
Description _____________________________________________________________
Size and profile __________________________________________________________
Pressure (psi) ____________________________ front ______________________ rear
Weight capacity (lbs) _____________________________________________________

SUSPENSION
Type front ______________________________________________________________
Type rear _______________________________________________________________
Modifications made during conversion, if any __________________________________
________________________________________________________________________

STEERING
Type __________________________________________________________________
Description _____________________________________________________________
Power source, if used _____________________________________________________
Average power, if used (W) ________________________________________________

AIR CONDITIONING
Model __________________________________________________________________
Description ______________________________________________________________
Compressor type _________________________________________________________
Maximum cooling output (BTU/hr) ___________________________________________
Motor type ______________________________________________________________
Maximum power required (kW) _____________________________________________

HEATING SYSTEM
Model _________________________________________________________________
Description _____________________________________________________________
Heat source/fuel _________________________________________________________
Fuel consumption (gge/kW) ________________________________________________
Certified under CARB ZEV requirements Yes No N/A
EPA ZEV Certificate of Conformity Yes No

EPA/CARB Certification
Emissions rating (LEV II classification) _______________________________________

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Appendix A (continued)
REQUIRED SUBMITTALS
The following submittals are required from the Supplier prior to vehicle delivery.
• Suppliers shall provide a completed copy of Appendix B indicating the method of
compliance with each required section of 49 CFR 571. If certification includes exemption,
the exemption number issued by the National Highway Transportation Safety Administration
(NHTSA), the date of it’s publication in the Federal Register and the page number(s) of the
Federal Register acknowledging issuance of the exemption shall be provided along with
Appendix B.
• Suppliers should describe safety measures and safety-related design features included in their
vehicle design and provide an explanation of the purpose and anticipated effect on vehicle
reliability and performance of any such safety measure or design feature.
• Suppliers shall supply Material Safety Data Sheets (MSDS) for all unique hazardous
materials the vehicle is equipped with, including RESS batteries or capacitors, and auxiliary
batteries.
• Suppliers shall provide recycling plans for batteries and other vehicle hazardous materials
including how the plan has been implemented. This plan should also identify post-purchase
costs associated with recycling that will be passed on to the vehicle purchaser.
• Suppliers should specify interior passenger and cargo dimensions and volumes.
• Suppliers should describe the operation of the regenerative braking system and its interface
with braking and anti-lock brake systems.
• Suppliers should specify the RESS battery discharge voltage limits and describe how these
limits are implemented.
• Vehicles should be accompanied with fuel economy data from Manufacturer’s testing.
• Suppliers should provide a detailed description of the RESS battery pack (including specific
energy, specific power and discharge capacity to 80% DOD at the one-hour rate), battery
pack voltage, number of battery modules, and a summary of previous performance tests. If
different, customer available and battery available DOD ratings shall both be provided.
• Suppliers should describe battery pack projected life (in cycles) at a specified level of
discharge, how battery life is maximized, how end of life of each battery module and of the
full battery pack is determined, and how battery temperature gradients are minimized.
Suppliers should specify maximum normal and abnormal gassing rates for the battery pack.
• Suppliers should indicate the level of charge below which the batteries should not be
discharged. This should include the specific parameters the Battery Management System
utilizes to prevent over-discharge. At a minimum, the Ah rating(s), module voltage(s), and
battery pack voltage(s) should be provided. Further, this should be consistent with
information provided in the Owner’s Manuals.
• Suppliers should specify the weight of each battery module, and the weight of the battery
pack (including removable pack structures). Suppliers should describe how batteries are

25 Chpt I, Sect I
 PHEV VEHICLE SPECIFICATION

installed in the vehicle (including details of module connection), the method of installation
and removal of the batteries (and the battery box, if required) for maintenance and repair, the
time required for battery removal, and any special training, tools or equipment required for
battery removal.
• Suppliers shall describe how battery boxes will be vented, to allow any battery gases to
escape safely to atmosphere during and following normal or abnormal charging and
operation of the vehicle.
• Suppliers should describe the methods used to prevent or accommodate condensation in the
battery box, and the quantity and maximum rate of explosive gas generation, by gas type,
under normal and abnormal charging conditions.
• If a Supplier provides a vehicle with parallel battery packs, the Supplier shall provide
detailed information on the equipment and charging algorithms required to prevent the
parallel strings from becoming unbalanced.
• Maintenance requirements for the RESS batteries should be described and any associated
cost(s) to the consumer/end user should be clearly defined.
• Maintenance requirements for other RESS components (e.g., flywheels, ultra capacitors)
should be described and any associated cost(s) to the consumer/end user should be clearly
defined.
• If a BMS is provided, suppliers should provide a description of the BMS’ operation. This
description should be consistent with that provided in the owner’s manual.
• If the vehicle is not equipped with a BMS, manufacturers should provide information on how
charging of the RESS batteries/energy storage components is accomplished.
• For pressurized fuel systems, Suppliers should provide expected refueling times at various
system fuel pressures and tank fills.
• Supplier should provide details on grounding and isolation methods.
• Suppliers should describe the type, size and location of the point of the vehicle charging port.
• Suppliers should describe the following options (if available):
• Air conditioning system
• Occupant compartment pre-heating and pre-cooling system.
• Vehicles shall be accompanied by non-proprietary manuals for parts, service, operation and
maintenance, interconnection wiring diagrams and schematics.

26 Chpt I, Sect I
 PHEV VEHICLE SPECIFICATION

Appendix B – FMVSS Certification Methodology

OEM Analysis Test Test & Not Not

Certified Only Only Analysis Required Certified
49 CFR 571.100 SERIES
101 - Controls and Displays
102 - Transmission Shift Lever Sequence, Starter Interlock & Transmission Braking
103 - Windshield Defrosting and Defogging Systems
104 - Windshield Wiping and Washing Systems
105 - Hydraulic Brake Systems
106 - Brake Hoses
107 - Reflecting Surfaces
108 - Lamps, Reflective Devices, and Associated Equipment
109 - New Pneumatic Tires
110 - Tire Selection and Rims
111 - Rearview Mirrors
113 - Hood Latch System
114 - Theft Protection
116 - Motor Vehicle Brake Fluids
117 - Retread Pneumatic Tires
118 - Power Operated Window, Partition, and Roof Panel Systems
119 - New Pneumatic Tires for Vehicles Other Than Passenger Cars
120 - Tire Selection and Rims for Motor Vehicles Other than Passenger Cars
121 - Air Brake Systems
124 - Accelerator Control Systems
125 - Warning Devices
126 - Truck-Camper Loading
129 - New Non-Pneumatic Tires for Passenger Cars
135 - Passenger Car Brake Systems

27 Chpt I, Sect I
 PHEV VEHICLE SPECIFICATION

Appendix B (continued)

OEM Analysis Test Test & Not Not

Certified Only Only Analysis Required Certified
49 CFR 571.200 SERIES
201 - Occupant Protection in Interior Impact
202 - Head Restraints
203 - Impact Protection for the Driver from the Steering Control System
204 - Steering Control Rearward Displacement
205 - Glazing Materials
206 - Door Locks and Door Retention Components
207 - Seating Systems
208 - Occupant Crash Protection
209 - Seat Belt Assemblies
210 - Seat Belt Assembly Anchorages
212 - Windshield Mounting
213 - Child Restraint Systems
214 - Side Impact Protection
216 - Roof Crush Resistance - Passenger Cars
219 - Windshield Zone Intrusion
225 - Child Restraint Anchorage System

49 CFR 571.300 SERIES

301 - Fuel System Integrity
302 - Flammability of Interior Materials
305 - EV: Electrolyte Spillage and Shock Protection

49 CFR 581
Bumper Standard Requirements - All Sections

49 CFR 565
Vehicle Identification Number Requirements

28 Chpt I, Sect I
 Chapter II: Administrative Control
Procedures

Section I: AVTA-PHAC01 – Control, Closeout and Storage

of Documentation
Section II: AVTA-PHAC02 – Control of Test Conduct
Section III: AVTA-PHAC03 – Preparation and Issuance of
Test Reports
Section IV: AVTA-PHAC04 – Review of Test Results
Section V: AVTA-PHAC05 – Training and Certification
Requirements for Personnel Utilizing AVTA
Procedures
Section VI: AVTA-PHAC06 – Receipt Inspection
Section VII: AVTA-PHAC07 – Control of Measuring and Test
Equipment

29 Chapter II, TOC

 AVTA-PHAC01

Section I: AVTA-PHAC01 – Control, Closeout and Storage

of Documentation

30 Chpt II, Sect I

 AVTA-PHAC01

TABLE OF CONTENTS

1Objective...................................................................................................................................................................32

2 Purpose................................................................................................................................................................32

3 Documentation....................................................................................................................................................32

4 Initial Conditions and Prerequisites .................................................................................................................32

5 Activity Requirements........................................................................................................................................33

5.1 Temporary Storage ...........................................................................................................................................33

5.2 Permanent Storage ...........................................................................................................................................33

6 Supplemental Activity Requirements ...............................................................................................................34

6.1 Distribution.......................................................................................................................................................34
6.2 Destruction .......................................................................................................................................................34

APPENDICES

Appendix A – Document Close-out/Retention Rider..............................................................................................35

31 Chpt II, Sect I

 AVTA-PHAC01

1 Objective
The objective of this procedure is to identify proper methods for the control of records
during and subsequent to testing activities. These methods are not meant to supersede
those of any testing facility, nor of any regulatory agency who may have or exercise
control over the covered activities.

2 Purpose
This procedure identifies acceptable methods for the development, use, completion and
retention of documents prepared in support of performance testing of vehicles provided for
testing by the U.S. Department of Energy Advanced Vehicle Testing Activity (AVTA).

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read, and readily reproducible. This documentation shall contain enough information to
“stand alone”; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion, without the need to review
additional documentation.

4 Initial Conditions and Prerequisites

4.1 All documentation required to complete the testing identified in the technical
requirements of the PHEV Vehicle Specification shall be completed, approved and
issued prior to commencing the testing it addresses.

4.2 A system for storage of records during testing activities shall be identified and
completed prior to starting testing.

4.3 A system for the permanent storage of records, if different than that presently in
place, shall be identified and completed prior to the need becoming evident.

4.4 Personnel who have cognizance over this system shall be familiar with the system
prior to it becoming "operational.”

4.5 A Program Manager or Test Manager shall be assigned overall responsibility for
retention of any documents that will be retained pursuant to this procedure.

32 Chpt II, Sect I

 AVTA-PHAC01

5 Activity Requirements

5.1 Temporary Storage

Temporary storage is defined as safekeeping or storage of records that are still
active, either because they are in process and not yet complete, or because the
process they are associated with has been suspended. If the suspension period is
greater than thirty (30) days, the record shall be considered closed, the document
completed and forwarded for permanent storage per section 5.2 of this procedure.

5.2 Permanent Storage

Permanent storage is defined as retention of records for one (1) year beyond their
final signature date, or the end of the test program, whichever is later. All formal
documents generated as a result of testing will be permanently retained according to
this procedure, unless otherwise controlled.
All documents that fall under this procedure shall be handled according to the
following requirements:
5.2.1 Following completion of a document, it shall be forwarded to the Document
Administrator for processing and close-out.
5.2.2 The Document Administrator shall review the document for the following:
[Link] All blanks and spaces requiring an input are filled out. Where no
entry is required, an "N/A" shall be inserted.
[Link] All corrections have been effected by single strike-through,
initialing and dating, and there are no erasures or whiteouts.
[Link] All signatures have been affixed.
[Link] All entries are legible, and dark enough to support reproduction.
5.2.3 Any submitted document that does not meet these requirements shall be
returned to the submitter for correction, prior to being either reproduced or
placed into permanent storage.
5.2.4 Document retention may be in any of several formats, including, but not
limited to:
[Link] Original document hard copy
[Link] Microfiche copy of the original document
[Link] Microfilm copy of the original document
[Link] Computer disc of the original data, as long as the original
signatures associated with the document are retained in hard copy
or film format.

33 Chpt II, Sect I

 AVTA-PHAC01

6 Supplemental Activity Requirements

6.1 Distribution
6.1.1 Distribution of the original documents or copies of the documents should be
controlled to ensure that only appropriate individuals receive them.
6.1.2 Individuals not associated with the U.S. Department of Energy Advanced
Vehicle Testing Activity (AVTA), either directly or indirectly (such as by
contract or sub-contract), shall not have access to incomplete documents.
6.1.3 Supplier’s representatives shall not be provided with or given access to
incomplete documents.
6.1.4 Subsequent to a document's completion (including signatures, as required),
the document may be released to non-involved parties if agreed to by all
parties so contractually bound.

6.2 Destruction
Destruction of original documents is not permitted. The Program Manager will be
solely responsible for authorizing exceptions, as stipulated by this procedure.
Exceptions will not be granted unless: specific approval has been given, the
documents have been completed, and the following conditions also exist:
6.2.1 The original documents have been successfully copied into another medium,
and the original signature pages are being retained. OR
6.2.2 One year has passed since the contract expired (section 5.2). AND
6.2.3 One year has passed since the completion of the document (section 5.2).
In addition, the Administrator shall note that the record was no longer needed and
that destruction of the original was justified. Any time a question exists as to the
need to retain a document, an exception WILL NOT be granted.

34 Chpt II, Sect I

 AVTA-PHAC01

Appendix A – Document Close-out/Retention Rider

(Page 1 of 1)

DOCUMENT CLOSE-OUT/RETENTION RIDER

Document Name/Title:

Document Number:

Receipt Date:

Y Y M M D D

Original Attached: Yes No

Original Destroyed: Yes No

Retention Format:

Hard Copy Yes No

Computer Disk Yes No
Microfilm Yes No

Close-out Date:

Y Y M M D D

Close-out Performed By:

__________________________________ ______________________________
(Printed Name) (Signature)

Comments:

35 Chpt II, Sect I

 AVTA-PHAC02

Section II: AVTA-PHAC02 – Control of Test Conduct

36 Chpt II, Sect II

 AVTA-PHAC02

TABLE OF CONTENTS

1 Objective .............................................................................................................................................................38

2 Purpose................................................................................................................................................................38

3 Documentation....................................................................................................................................................38

4 Initial Conditions and Prerequisites .................................................................................................................38

5 Personnel Qualifications ....................................................................................................................................39

6 Activity Requirements........................................................................................................................................39

6.1 Test Activities....................................................................................................................................................39

6.2 Test Exceptions .................................................................................................................................................41

7 Supplemental Activity Requirements ...............................................................................................................42

7.1 Distribution.......................................................................................................................................................42
7.2 Destruction of Documents.................................................................................................................................42

APPENDICES

Appendix A – Test Exception Report ......................................................................................................................43

37 Chpt II, Sect II

 AVTA-PHAC02

1 Objective
The objective of this procedure is to identify a common protocol for the conduct of test
activities for plug-in hybrid electric vehicles (PHEV) evaluated by the U.S. Department of
Energy Advanced Vehicle Testing Activity (AVTA).

2 Purpose
This procedure establishes acceptable methods for the development, use and completion of
processes used in support of performance testing of PHEVs provided to the AVTA for
testing. It also provides a means to document deviations from approved test procedures
when such deviations are necessary and appropriate.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read, and readily reproducible. This documentation shall contain enough information to
“stand alone”; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion, without the need to review
additional documentation. Storage and retention of records shall be completed as described
in procedure AVTA-PHAC01.

4 Initial Conditions and Prerequisites

4.1 All documentation required to complete the testing identified in the technical
requirements of the PHEV Vehicle Specification shall be completed, approved and
issued prior to commencing the testing it addresses.

4.2 Individuals assigned as Test Engineers shall be familiar with all phases and portions
of the tests for which they have responsibility, and should be familiar with the entire
Test Program.

4.3 Prior to commencing any test, a meeting of the test team shall be held to discuss the
following requirements:
4.3.1 Test purpose and requirements
4.3.2 Test methodologies
4.3.3 Personnel requirements
4.3.4 Expected contingencies and exceptions, including reasons and justifications
4.3.5 Safety requirements.

38 Chpt II, Sect II

 AVTA-PHAC02

5 Personnel Qualifications

5.1 All individuals involved in covered test activities shall be trained and certified in
accordance with the requirements of procedure AVTA-PHAC05.

5.2 All individuals involved in covered test activities shall receive a briefing on the
hazards associated with PHEV propulsion batteries, including:
5.2.1 Type of traction batteries
5.2.2 Location of traction batteries
5.2.3 Voltage of traction battery
5.2.4 Location of traction battery emergency disconnect switch
5.2.5 Basic hazard communication information particular to the traction battery on­
board.

5.3 All individuals involved in covered test activities shall receive a briefing on the
hazards associated with PHEV fueling, including:
5.3.1 Type of fuel used
5.3.2 Vehicle fueling procedures
5.3.3 Emergency and spill (for liquid fuels) procedures
5.3.4 Basic hazard communication information particular to the vehicle fuel.

5.4 All individuals involved in covered test activities shall receive a briefing on the
hazards associated with PHEV accessory batteries, including:
5.4.1 Type of accessory battery
5.4.2 Location of accessory battery
5.4.3 Voltage of accessory battery
5.4.4 Basic hazard communication information particular to the accessory battery
on-board
5.4.5 Location of accessory battery emergency disconnect switch, if so equipped.

6 Activity Requirements

6.1 Test Activities

Testing shall be conducted by the Test Engineer under the supervision of the Test
Manager and/or the Test Director. All testing shall be conducted in accordance with
AVTA administrative, quality and test procedures. The results of testing shall be

39 Chpt II, Sect II

 AVTA-PHAC02

documented in a final report in accordance with the requirements of procedure

AVTA-PHAC03.
During testing activities, if a vehicle fails to meet any "shall" requirement of the then
effective PHEV Vehicle Specifications for any reason other than a propulsion battery
reaching its design DOD limit, the vehicle shall be removed from the Test Program
until such time as the manufacturer can repair it. The failure shall be documented by
the Test Engineer using a Non-Conformance Report (Procedure AVTA-PHTP11,
Appendix B). The Non-Conformance Report shall be transmitted to the vehicle
supplier for resolution of the non-conformance. Vehicles which are removed from
testing due to a failure as stated above shall not be subject to further testing until
repairs are complete. Once repairs have been completed, every effort shall be made
to complete as much of the remaining tests as possible. Vehicles not repaired in a
cumulative total of 72 hours shall be considered to have failed the AVTA Test
Program, and shall be removed from the program.
Non-Conformance Reports shall also be used to document any vehicle condition or
test result which the Test Engineer considers unusual and requires response from the
vehicle supplier. The Test Engineer shall complete the Non-Conformance Report
and transmit it to the vehicle supplier, requesting response as soon as possible. The
Test Engineer shall make a determination as to the need to halt testing of the vehicle
pending resolution of the Non-Conformance Report by the vehicle supplier.
Activities related to specific Performance Testing are addressed by procedures
specific to those test activities.
6.1.1 For any testing activity, all personnel assigned test team activities shall be
familiar with the following:
[Link] The test being conducted
[Link] The parameters being measured
[Link] The anticipated results of the test
[Link] The metrology used in the conduct of the test
[Link] Contingency actions, in case of test/equipment failure
[Link] Emergency response actions in case of equipment damage
(specifically battery damage, or failure of the battery and battery
compartment)
[Link] Safety requirements.
6.1.2 Data sheets shall be filled out as the data is collected, unless the data must be
downloaded from a Data Acquisition System (DAS).
6.1.3 If a DAS is used, the data shall be recorded on the data sheets as soon as
practicable. At a minimum, all data transcription should be completed no
later than seven (7) days following test completion, and verified by the Test
Manager or Test Engineer.

40 Chpt II, Sect II

 AVTA-PHAC02

6.1.4 Data sheets may be filled out by any member of the test team; however, the
Program Manager, Test Manager or Test Engineer shall sign the completed
data sheet attesting to the validity of the data collected.

6.2 Test Exceptions

Deviations from approved test methods, requirements and/or procedures shall not be
permitted without approval of the Program or Test Manager. All exceptions shall be
noted on Test Exception Report (TER), Appendix A. The following requirements
apply to TERs:
6.2.1 All Test Exceptions shall be numbered.
6.2.2 The number shall use the format TER-PHTPXXX-YYYYY-ZZZ, where:
[Link] XXX indicates the procedure number being excepted
[Link] YYYYY indicates the last 5 digits of the vehicles VIN
[Link] ZZZ is the sequential number of all TERs written for that vehicle
during the test program.
6.2.3 The number will be issued by the Test or Program Manager at the time of
his/her signature.
6.2.4 All Test Exceptions shall be maintained with the Test Manager’s Log, and
shall be a permanent part of the Test Record.
6.2.5 TERs shall contain the following minimum information:
[Link] The procedure for which the TER is being written
[Link] The specific step being excepted
[Link] Why the exception is necessary
[Link] The justification for the exception
[Link] The date and time of the exception
[Link] The printed name and signature of the person requesting the
exception
[Link] The printed name and signature of the person approving the
exception, and the date of the approval.
6.2.6 If a deviation is taken and subsequently disallowed by the Program Manager
or Test Manager, the original step shall be re-performed (as allowed by
contract terms and conditions), within the requirements of the applicable Test
Procedure, and so documented.
6.2.7 The Program Manager or Test Manager shall notify the test vehicle Supplier
(as soon as practical) of deviations resulting from mechanical or electrical
failure of the test vehicle. Time required for the Supplier to remedy the
failure shall be tracked and recorded on the Test Exception Report. Repair
time shall be logged in 24 hour increments and shall begin when the Supplier

41 Chpt II, Sect II

 AVTA-PHAC02

takes custody of the vehicle. Repair time shall end when the Supplier returns
custody of the vehicle to the Program Manager or Test Manager. All work
performed by the Supplier to repair the test vehicle shall be recorded on the
Test Exception Report. Only work required to restore the vehicle to its pre-
failure state shall be performed by the Supplier.

7 Supplemental Activity Requirements

7.1 Distribution
Distribution of documents shall be in accordance with procedure AVTA-PHAC01.
7.1.1 Distribution of the original documents or copies of the documents shall be
controlled to ensure that only appropriate individuals receive them.
7.1.2 Subsequent to a documents completion (including signatures, as required),
the original shall be transmitted in accordance with procedure AVTA­
PHAC01.

7.2 Destruction of Documents

Destruction of original documents shall not be allowed. All test documents,
including those for tests, which were either suspended or failed, shall be retained as
part of the test record. Retention of documents shall be in accordance with procedure
AVTA-PHAC01. Any exceptions shall be approved per the requirements of that
procedure.

42 Chpt II, Sect II

 AVTA-PHAC02

Appendix A – Test Exception Report

(Page 1 of 1)

TER # ___________________________
Procedure Being Excepted: Step Being Excepted:

Requested by:
Printed Name Signature
Date of Request: Time of Request:

Numbered by:
Printed Name Signature
Approval: (Circle ONE) YES NO
Signature
Reason for Request:
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
Impact to Test Procedure and/or Test Program:
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
Reason for Approval or Denial:
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
Additional Requirements due to Approval/Denial:
_______________________________________________________________________________
_______________________________________________________________________________

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

43 Chpt II, Sect II

 AVTA-PHAC03

Section III: AVTA-PHAC03 – Preparation and Issuance of

Test Reports

44 Chpt II, Sect III

 AVTA-PHAC03

TABLE OF CONTENTS

1 Objective .............................................................................................................................................................46

2 Purpose................................................................................................................................................................46

3 Documentation....................................................................................................................................................46

4 Initial Conditions and Prerequisites .................................................................................................................46

5 Activity Requirements........................................................................................................................................46

45 Chpt II, Sect III

 AVTA-PHAC03

1 Objective
The objective of this procedure is to identify the proper methods for the preparation of
reports during and subsequent to U.S. Department of Energy Advanced Vehicle Testing
Activity (AVTA) testing activities. These methods are not meant to supersede those of the
testing facility, nor of any regulatory agency who may have or exercise control over the
covered activities.

2 Purpose
This procedure identifies acceptable methods for the development, use, completion and
retention of reports prepared in support of performance testing of plug-in hybrid electric
vehicles tested by the AVTA.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read, and readily reproducible. Reports shall contain enough information to "stand alone";
that is, they shall be self-contained to the extent that all individuals expected to review it
could be reasonably expected to reach a common conclusion, without the need to review
additional documentation. Review and approval of test documentation shall be in
accordance with procedure AVTA-PHAC04. Storage and retention of records during and
following testing activities shall be completed as described in procedure AVTA-PHAC01.

4 Initial Conditions and Prerequisites

4.1 All relevant testing activities for the subject vehicle have been completed (as
described in procedure AVTA-PHAC02) prior to the report being formally issued.

4.2 All necessary test documentation has been completed, reviewed and approved per
the requirements of procedure AVTA-PHAC04, prior to the report being issued.

4.3 The method for distribution of the subject Report(s) shall be agreed upon prior to any
report being formally issued.

4.4 Personnel who prepare Test Report(s) shall be familiar with the contents of this
procedure as required by procedure AVTA-PHAC05.

5 Activity Requirements
A test report shall be issued for any vehicle submitted for AVTA testing, regardless of
whether the vehicle is actually tested. Test reports should be issued within 30 days of the
completion of testing. This section provides additional requirements for the formal Test
Report.

46 Chpt II, Sect III

 AVTA-PHAC03

5.1 Test Reports shall be the preferred mechanism for the objective reporting of data
collected during AVTA testing.

5.2 These reports may utilize a variety of media and formats, including text, data file,
graphical depiction, film/video tape and oral presentation.

5.3 The material for each vehicle shall be presented in a stand-alone format.

5.4 Data/test results shall not be provided in a comparative format. That is, each
vehicle's data shall be presented independent of the data of other tested vehicles.

5.5 Report preparation shall include the following:

5.5.1 A Table of Contents
5.5.2 An Executive Summary
[Link] Vehicle Description
[Link] Test Conduct Summary
[Link] Summary Data Sheet
5.5.3 Test Program Summary
[Link] Test Sequence
[Link] Test Exception Reports (Procedure AVTA-PHAC02, Appendix
A)
[Link] Non-Conformance Reports
5.5.4 Vehicle description
[Link] Vehicle inspections sheets
• Procedure AVTA-PHAC06, Appendix B
• Procedure AVTA-PHTP11, Appendix A
[Link] Vehicle supplier submittals required by PHEV Vehicle
Specification, Appendix A
[Link] Appendices/Submittals
• Vehicle Specification, Appendix A
• Vehicle Specification, Appendix B
5.5.5 Test Results (one section for each Test Procedure) containing:
[Link] Test summary
[Link] All test procedure data sheets
[Link] Test Results Review check-sheet
[Link] Graphical information list (charts, graphs, plots, etc.).

47 Chpt II, Sect III

 AVTA-PHAC03

5.5.6 Appendices
[Link] Appendix 1 - Vehicle photographs
[Link] Appendix 2 - Supplier’s correspondence
[Link] Appendix 3 - Test Manager’s Log
5.5.7 Exhibits
[Link] Exhibit A - PHEV Vehicle Specifications
[Link] Exhibit B - Supplier’s Technical Submittal
[Link] Exhibit C - Supplier’s FMVSS Submittal
[Link] Exhibit D - RESS Charge Log

5.6 The Test Report shall include any exceptions or deviations from the Supplier’s
proposal taken by the supplier.

5.7 The Test Report shall not be provided/made available to the Supplier for comment,
prior to it’s issuance except as noted in 5.9.

5.8 Test Reports should not contain raw data sheets.

5.9 Test Reports shall include a Summary Data Sheet. The Summary Data Sheet shall be
provided to the vehicle supplier for comment prior to issuance of the Test Report.

5.10 At least one representative of each organization involved in testing activities shall
sign the final report(s). This signature indicates their organization’s concurrence with
the data contained in the report. At a minimum, the Final Test Report for each
vehicle shall be signed by the Test Manager.

5.11 Following completion, the Test Report shall be provided to the Supplier, the U.S.
Department of Energy (if co-funding the testing) and to the manufacturer of the
vehicle (if different than the Supplier and authorized by the Supplier).

5.12 All original test documents, including data sheets and files, shall be incorporated into
the Test Report maintained in accordance with procedure AVTA-PHAC01.

48 Chpt II, Sect III

 AVTA-PHAC04

Section IV: AVTA-PHAC04 – Review of Test Results

49 Chpt II, Sect IV

 AVTA-PHAC04

TABLE OF CONTENTS

1 Objective .............................................................................................................................................................51

2 Purpose................................................................................................................................................................51

3 Documentation....................................................................................................................................................51

4 Initial Conditions and Prerequisites .................................................................................................................51

5 Personnel Qualifications ....................................................................................................................................52

6 Activity Requirements........................................................................................................................................52

7 Supplemental Activity Requirements ...............................................................................................................54

APPENDICES

Appendix A – Test Results Review and Approval Form........................................................................................55

50 Chpt II, Sect IV

 AVTA-PHAC04

1 Objective
The objective of this procedure is to identify a common protocol for the review of test data
obtained during conduct of U.S. Department of Energy Advanced Vehicle Testing Activity
(AVTA) test activities.

2 Purpose
This procedure establishes acceptable methods for the development, implementation and
completion of test result processes used in conjunction with the performance testing of
plug-in hybrid electric vehicles tested by the AVTA for testing.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read, and readily reproducible. This documentation shall contain enough information to
"stand alone"; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion, without the need to review
additional documentation. Storage and retention of records shall be completed as described
in procedure AVTA-PHAC01.

4 Initial Conditions and Prerequisites

4.1 All documentation associated with the test under review shall have been completed
by the test personnel, and signed by the applicable Test Manager or Test Engineer.

4.2 Individuals assigned to review test results shall be familiar with all phases and
portions of the tests they are reviewing.

4.3 Prior to commencing test results review, a meeting of the personnel signing for the
test completion shall be held to discuss the following:
4.3.1 Test requirements
4.3.2 Expected test results
4.3.3 Actual test results
4.3.4 Actual test methodologies
4.3.5 Test Exceptions, including reasons and justifications
4.3.6 Safety requirements.

4.4 A Team Leader with overall responsibility for test results review shall be assigned.

51 Chpt II, Sect IV

 AVTA-PHAC04

5 Personnel Qualifications

5.1 All individuals involved in covered test activities shall be trained and certified in
accordance with the requirements of procedure AVTA-PHAC05.

5.2 All individuals involved in the review of test results shall be cognizant of the tests
being reviewed and the methodologies involved, and shall be familiar with normal
and accepted test conduct practices.

5.3 All individuals involved in the review of test results shall have a basic understanding
of the metrology used in that testing.

5.4 For all test results review activities, assigned personnel shall be familiar with the
following:
5.4.1 The test conducted
5.4.2 The parameters which were being measured
5.4.3 The anticipated results of the test
5.4.4 Allowable exceptions and their bases.

6 Activity Requirements

NOTE:
Test result documentation is controlled by this and other
procedures. If a conflict arises between this and other procedures,
this procedure shall take precedence for issues relating to test
results. For conflicts in other areas, procedures which control those
specific activities shall take precedence. Should the conflict not be
clearly definable, the Program Manager shall be responsible for
final resolution.

Activities related to specific Performance Testing will be addressed by procedures specific

to those test activities (e.g., AVTA-PHTP01 is the specific procedure for controlling the
requirements and methodologies necessary to implement testing per SAE J1263).

6.1 Data sheets shall be completely filled out. If a Data Acquisition System (DAS) was
used to record part of the data, the data shall be down-loaded and charted, graphed,
etc., prior to review.

6.2 Data sheets may have been filled out by any member of the test team. However, the
Test Manager or Test Director shall sign the completed data sheet attesting to the
validity of the data collected in accordance with procedure AVTA-PHAC02.

52 Chpt II, Sect IV

 AVTA-PHAC04

6.3 Deviations from approved test methods, requirements and/or procedures shall not be
permitted unless approved by the Test Manager or Test Director, in accordance with
procedure AVTA-PHAC02. All exceptions shall be noted in the comments section of
the applicable test data sheet. For each exception taken, at a minimum, the following
information must be present:
6.3.1 The specific step exception
6.3.2 Why the exception was necessary
6.3.3 The justification for the exception
6.3.4 The date and time of the exception
6.3.5 The printed name of the person who requested the exception, and their
signature
6.3.6 The printed name of the person who approved the exception, their signature,
and the date of the approval.

6.4 If a deviation was taken and subsequently disallowed by the Program Manager or
Test Manager, the original step shall be re-performed, within the requirements of the
applicable Test Procedure, and documented as such.

6.5 A Test Results Review Team (TRRT), comprised of at least one representative of
each test organization shall review the test results.

6.6 One member of the TRRT shall be assigned as the Team Leader. This should
normally be the Program Manager or the Test Manager.

6.7 The TRRT shall review test data for each test of each vehicle. The following reviews
shall be completed:
6.7.1 Does the data collected appear reasonable to the requirements of the test
conducted?
6.7.2 Is comparative data available?
6.7.3 Does the data correlate?
6.7.4 Does any test exceptions impact the validity of data?

6.8 When the test results review is complete, each member of the TRRT shall sign and
date the Test Results Approval Form (Appendix A).

6.9 If any member of the review team takes exception to the results, those exceptions
shall be noted. Every attempt to resolve the exceptions shall be made.

53 Chpt II, Sect IV

 AVTA-PHAC04

6.10 If the exceptions noted in Step 6.9 cannot be resolved, then one of two actions shall
be taken:
6.10.1 If, in the opinion of the Team Leader, the results in question do not materially
affect the test results, the exception shall be noted, and the test results
approved.
6.10.2 If, in the opinion of the Team Leader, the test results in question materially or
adversely affect the outcome of the test or the test results, then the results
shall not be approved until the exception has been resolved. This may require
re-performance of the test in question.

7 Supplemental Activity Requirements

7.1 Distribution of documents will be in accordance with the applicable revision of

procedure AVTA-PHAC01.
7.1.1 Distribution of the original documents or copies of the documents shall be
controlled to ensure that only appropriate individuals receive them.
7.1.2 Subsequent to a document's completion (review and approval, and signatures
as required), the document shall be transmitted in accordance with procedure
AVTA-PHAC01.

7.2 Destruction of Documents

Destruction of original documents is not allowed. All test documents, including
those for tests which were either suspended or failed, shall be retained as part of the
test record. Retention of documents shall be in accordance with procedure AVTA­
PHAC01. Any exceptions shall be approved per the requirements of that procedure.

54 Chpt II, Sect IV

 AVTA-PHAC04

Appendix A – Test Results Review and Approval Form

(Page 1 of 2)
Procedure Requirement
Reference: Requirement: Met: Initials: Date:
Yes No
4.0 Initial Condition / Prerequisites have been met?
5.0 Personnel meet the minimum qualifications?
6.1 Data sheets are completely filled out?
6.2 Test Manager / Test Engineer signatures are
present?
6.3 Were there any deviations from approved test
methods?
6.3.1 Which specific step was excepted: __________
6.3.2 Was the explanation for the exception noted?
6.3.3 Was the justification for the exception noted?
6.3.4 Were the date and time of the exception noted?
6.3.5 Is the name of the person who requested the
exception noted?
6.3.6 Is the name of the person who approved the
exception noted?
6.4 Was the original step re-performed within test
protocol requirements?
6.7.1 Does the data collected appear reasonable to the
requirements of the test conducted?
6.7.2 Is comparative data available?
6.7.3 Does the data correlate?
6.7.4 Do any test exceptions impact the validity of
the data?
6.8 Test Results Review Team (TRRT) signatures
are present?
6.9 Does each member of the TRRT concur with
the test results?
6.9 Are the TRRT exceptions noted?
6.10 Did any TRRT exceptions materially affect test
results?
6.10.2 Did any TRRT exceptions result in test re-
performance?

55 Chpt II, Sect IV

 AVTA-PHAC04

Appendix A - Test Results Review and Approval Form

(Page 2 of 2)

General Comments (initials / date):

_____________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
__________________________________

Team Leader:
(Organization) (Printed Name) (Signature) (Date)

Team Member:
(Organization) (Printed Name) (Signature) (Date)

Team Member:
(Organization) (Printed Name) (Signature) (Date)

Team Member:
(Organization) (Printed Name) (Signature) (Date)

56 Chpt II, Sect IV

 AVTA-PHAC05

Section V: AVTA-PHAC05 – Training and Certification

Requirements for Personnel Utilizing AVTA
Procedures

57 Chpt II, Sect V

 AVTA-PHAC05

TABLE OF CONTENTS

1 Objective .............................................................................................................................................................59

2 Purpose................................................................................................................................................................59

3 Documentation....................................................................................................................................................59

4 Prerequisites........................................................................................................................................................59

5 Personnel Requirements ....................................................................................................................................60

APPENDICES

Appendix A – Training/Briefing Attendance Sheet ................................................................................................62

58 Chpt II, Sect V

 AVTA-PHAC05

1 Objective
The objective of this procedure is to assure that personnel conducting testing using U.S.
Department of Energy Advanced Vehicle Testing Activity (AVTA) procedures are
qualified and trained to perform in a technically competent and safe manner. This
procedure shall not supersede other training requirements that may be imposed by a
contract or subcontract facility (e.g., location-specific Hazard Communication training).
Rather, this procedure shall supplement those requirements.

2 Purpose
The purpose of this procedure is to identify minimum requirements for the certification and
training of personnel performing activities directed by AVTA procedures.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read, and readily reproducible. This documentation shall contain enough information to
"stand alone"; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion, without the need to review
additional documentation. Storage and retention of records shall be completed as described
in procedure AVTA-PHAC01.

4 Prerequisites

4.1 All documentation required to document the training required by this or other
procedures shall be completed, approved and issued prior to the testing it addresses
being commenced. At no time shall these procedures be utilized prior to their noted
effective date.

4.2 Individuals assigned to perform an activity controlled by an AVTA procedure shall

have the background necessary to support the particular activity. This background
may be through formal education, training, or "on-the-job" training.

4.3 Individuals assigned to perform an activity controlled by an AVTA procedure shall

have received training and/or indoctrination in that activity. This applies to all
personnel, including contract and subcontract.

4.4 Prior to commencing any activity, a meeting of the personnel involved in the activity
shall be held to discuss the following:
4.4.1 Test purpose
4.4.2 Test requirements

59 Chpt II, Sect V

 AVTA-PHAC05

4.4.3 Personnel requirements

4.4.4 Test methodologies
4.4.5 Expected contingencies and exceptions, including reasons and justifications
4.4.6 Methods required ensuring safety.

4.5 Individuals involved in activities that include the potential for exposure to hazardous
materials or substances shall receive specific training for those hazards.

5 Personnel Requirements

5.1 Individuals involved in an activity controlled by an AVTA procedure shall

understand the activity, the methodologies involved, and the normal and accepted
practices associated with that activity. These individuals shall also be cognizant of
requirements to mitigate off-normal occurrences that may become manifest during
the covered activity.

5.2 Individuals involved in an activity controlled by an AVTA procedure shall

participate in a briefing or training in that activity prior to their participation in the
activity. This requirement may be met by group briefings, lectures, training sessions
or one-on-one discussions.

5.3 Briefings will normally be performed by the Program Manager, Test Manager, or the
appropriate Test Engineer. At a minimum, assigned personnel shall be briefed on the
following:
5.3.1 The test being conducted
5.3.2 The specific steps of the procedure
5.3.3 The parameters which are being measured
5.3.4 The anticipated results of the test
5.3.5 Allowable exceptions, if any, and their bases
5.3.6 Safety requirements.

5.4 If the potential for exposure to hazardous materials exists, a briefing shall be held
which addresses the specific materials and their associated hazards. This shall
include, but not be limited to, hazard communication training.

5.5 Individuals conducting briefings/training sessions will normally be the Program

Manager, Test Manager or the appropriate Test Engineer. This individual shall be
familiar with the procedure in question.

60 Chpt II, Sect V

 AVTA-PHAC05

5.6 Whenever a briefing or training session is conducted, a briefing form (Appendix A)

shall be filled out, and signed by the individual conducting the session, and each
individual who was in attendance.

5.7 One briefing form (Appendix A) shall be completed for each subject area addressed,
even if multiple topics are covered at the same briefing session. [Example: If one
group of individuals receives briefings on two unrelated topics at the same session
(e.g., Handling Test and Rough Road Course Test), two briefing sheets shall be
completed, one for each topic.]

5.8 These briefing forms noted in 5.6 and 5.7 shall be retained in accordance with
procedure AVTA-PHAC01.

61 Chpt II, Sect V

 AVTA-PHAC05

Appendix A – Training/Briefing Attendance Sheet

(Page 1 of 2)

Name of Training Lesson: ________________________________________

Instructor’s Name: ______________________________ Date: ___________

PRINTED NAME SIGNATURE COMPANY DATE

62 Chpt II, Sect V

 AVTA-PHAC05

Appendix A – Training/Briefing Attendance Sheet

(Page 2 of 2)

Name of Training Lesson: ________________________________________

Instructor’s Name: ______________________________ Date: ___________

PRINTED NAME SIGNATURE COMPANY DATE

63 Chpt II, Sect V

 AVTA-PHAC06

Section VI: AVTA-PHAC06 – Receipt Inspection

64 Chpt II, Sect VI

 AVTA-PHAC06

TABLE OF CONTENTS

1 Objective .............................................................................................................................................................66

2 Purpose................................................................................................................................................................66

3 Documentation....................................................................................................................................................66

4 Prerequisites........................................................................................................................................................66

5 Verification Requirements.................................................................................................................................66

APPENDICES

Appendix A – Vehicle Supplier Review Check List................................................................................................71

Appendix B – Vehicle Receipt Check List ...............................................................................................................73

Appendix C – Vehicle Requirement Checklist ........................................................................................................76

65 Chpt II, Sect VI

 AVTA-PHAC06

1 Objective
This procedure identifies a common protocol for the collection of verification data for each
vehicle evaluated by the U.S. Department of Energy Advanced Vehicle Testing Activity
(AVTA). These activities shall be completed in conjunction with procedure AVTA­
PHTP11 and prior to commencement of testing activities performed in accordance with the
AVTA PHEV test procedures.

2 Purpose
This procedure identifies the verification parameters that shall be recorded prior to testing
any plug-in hybrid electric vehicle (PHEV) provided to the AVTA. Additional verification
requirements are addressed in procedure AVTA-PHTP11.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read and readily reproducible. This documentation shall contain enough information to
"stand alone"; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion, without the need to review
additional documentation. Storage and retention of records shall be completed as described
in procedure AVTA-PHAC01.

4 Prerequisites
4.1 Individuals assigned to complete this procedure will be knowledgeable of the
PHEV Vehicle Specification.
4.2 Individuals assigned to complete this activity will have received the appropriate
training in accordance with procedure AVTA-PHAC05.
4.3 Prior to commencing this activity, a meeting of the involved personnel will be
held to discuss the following:
4.3.1 Data required
4.3.2 Data available
4.3.2 Data sources
4.3.4 Contingencies
4.3.5 Safety requirements
4.4 Verification of all mandatory requirements presented herein must be completed
prior to conduct of other testing, unless specifically exempted herein.
4.5 All documentation required to document the activities addressed by this procedure
shall be completed, approved and issued prior to commencing the testing it
addresses.

66 Chpt II, Sect VI

 AVTA-PHAC06

5 Verification Requirements
This procedure shall be completed for each vehicle, which is scheduled to be received for
evaluation by the AVTA. The vehicle must be present to obtain some of the required
information (curb weight, vehicle heights, ground clearance, etc.) However, a significant
amount of information concerning the vehicle may be obtained from data provided by the
Supplier prior to receipt of the vehicle. As such, this procedure may be implemented upon
receipt of the Supplier’s information, but shall not be completed prior to actual inspection
of the vehicle.

5.1 Review the Supplier’s provided documentation. Make a copy of the PHEV Vehicle
Specification Appendices A and B, which the manufacturer has completed. Review
these documents for the following:
5.1.1 All blanks have been filled in.
5.1.2 All required data has been provided.
5.1.3 For blanks, which have either no entry or an “N/A” (or similar notation), note
the specific entry which is incomplete and the reason the entry is incomplete
(if known).
5.1.4 The Program Manager or the Test Manager shall be notified of any missing
data. They shall notify the Supplier’s representative of the missing data, and
request their assistance in obtaining it. All requests for data from the Supplier
shall be made in writing, through the Program/Project Manager.

5.2 Upon receipt of the vehicle, the following information and “should” requirements
shall be obtained by inspection of the vehicle and recorded in Appendix A.
5.2.1 Vehicle year, make and model
5.2.2 Vehicle manufacturer
5.2.3 Number of occupants
5.2.4 Amount of payload beyond passengers
5.2.5 Design curb weight
5.2.6 Design rated payload
5.2.7 The standard tire manufacturer
5.2.8 The standard tire model and size
5.2.9 Charger manufacturer
5.2.10 Motor manufacturer
5.2.11 Controller manufacturer
5.2.12 Heat engine configuration
5.2.13 Heat engine displacement

67 Chpt II, Sect VI

 AVTA-PHAC06

5.2.14 Heat engine fuel type

5.2.15 Vehicle is a conversion to PHEV
5.2.16 Type of transmission: [e.g., single speed, multi-speed automatic, manual or
continuous variable transmission (CVT)]
5.2.17 Battery module weight
5.2.18 Battery pack weight
5.2.19 Battery pack(s) voltage
5.2.20 Number of modules in the battery pack
5.2.21 Battery one-hour rate discharge capacity.

5.3 Upon receipt of the vehicle, complete the Vehicle Receipt Checklist (Appendix B)
by recording the required information. Measurements shall be taken and calculations
made as required to complete the Vehicle Receipt Checklist. When complete, the
Vehicle Receipt Checklist shall be compared with the information provided by the
vehicle supplier (where available) and any discrepancies noted. If discrepancies are
significant to test conduct, a Non-Conformance Report (Procedure AVTA-PHTP11,
Appendix B) shall be issued and the discrepancy resolved with the vehicle supplier.

5.4 Take receiving pictures of the vehicle as required by Appendix B.

5.5 Using the data obtained in Sections 5.1 through 5.3, determine the potential vehicle
operating modes. Determine the vehicle configuration, which will be tested as the
Normal Operation mode. Determine if the vehicle is configurable in the RESS Only
mode. If it is capable of RESS Only mode operation, determine the vehicle
configuration, which will be tested as the RESS Only mode.

5.6 Appendix C identifies all optional (should) requirements of the PHEV Vehicle
Specification. Most optional requirements can be verified by a physical inspection or
document review. However, some optional requirements require measurement or
dynamic test for validation. The methods for conduct of these measurements or
dynamic tests are listed in this Section. Conduct testing to verify the following
optional requirements of the PHEV Vehicle Specification not verified by specific
Performance Test Procedures. Record the results of these tests in Appendix B. These
tests may require installation of instrumentation. Testing with installed instruments
may be delayed and conducted under a separate test procedure.
5.6.1 Verify that the speedometer is accurate to ± 5% of full scale and the
odometer is accurate to ± 5% by conducting Section 5.3 of procedure AVTA­
PHTP04.
5.6.2 Verify that the vehicle has a ground clearance of at least five (5) inches to all
sprung portions of the vehicle by setting a 5-inch cubic go/no-go block, with
the vehicle loaded to GVWR and standing on a flat surface. When the block

68 Chpt II, Sect VI

 AVTA-PHAC06

is in contact with the flat surface and passed beneath the sprung portions of
the vehicle, verify that the block does not contact any of the sprung portions
of the vehicle.
5.6.3 During conduct of procedure AVTA-PHTP03, qualitatively verify
compliance with the relevant sections of SAE J551 for electromagnetic
radiated fields by operating the following devices to determine if any
interference is being generated from the vehicle:
[Link] Cellular telephone
[Link] Mobile radio scanning over the 70 cm and 2M bands
[Link] Citizen band radio
[Link] Portable compact disc player
[Link] Notebook computer
[Link] Onboard audio equipment (AM/FM radio, cassette, CD.)
Devices and/or their antennae shall be located in a manner to maximize their
potential for interference. [Prior to testing the initial vehicle, these devices
shall be operated in the dynamometer with the dynamometer operating to
verify there is no background interference.]
5.6.4 During conduct of procedure AVTA-PHTP06, verify that regenerative
braking does not adversely impact the vehicle’s braking ability by noting any
unusual application of regenerative braking including, rapid application or
release of regenerative braking and oscillation of regenerative braking force.
5.6.5 During conduct of procedures AVTA-PHTP02, and AVTA-PHTP05, verify
that the vehicle drive-train system is capable of continuous operation at
maximum vehicle speed and/or sustained grades without overheating or loss
of component life by noting any abnormal operation resulting from
overheating. If the vehicle is operable in the RESS Only mode, also conduct
Section 5.2 of procedure AVTA-PHTP04.
5.6.6 During conduct of procedures, AVTA-PHTP02 and AVTA-PHTP05 verify
that the vehicle drive train components do not produce or develop unusual
vibrations over the entire design speed range of the vehicle by noting any
unusual vibrations.
5.6.7 During conduct of procedure AVTA-PHTP02, Section 5.1, verify
acceleration times of 13.5 seconds or less.
5.6.8 During conduct of procedure AVTA-PHTP02, Section 5.1, verify a minimum
top speed of 90 mph.
5.6.9 During conduct of procedure AVTA-PHTP02, Section 5.3, verify a minimum
sustainable speed of 55 mph on a 3% grade, and 45 mph on a 6% grade.
5.6.10 During conduct of procedure AVTA-PHTP02, Section 5.2, verify the vehicle
is capable of starting and ascending a 25% grade.

69 Chpt II, Sect VI

 AVTA-PHAC06

5.6.11 During conduct of procedure AVTA-PHTP05, verify that the vehicle is

capable of standing for extended periods in extreme temperatures without
damage to or failure of the vehicle or it’s systems by noting any failures
during this test procedure.
5.6.12 During conduct of procedure AVTA-PHTP05, verify that the vehicle is
capable of driving through two (2) inches of standing water at a speed of 20
mph without damage, without becoming inoperable, and without battery to
chassis leakage current exceeding 0.5 MIU per UL Standard 2202 and is
capable of setting in eight (8) inches of standing water for 15 minutes without
damage, becoming inoperable, and without battery to chassis leakage current
exceeding 0.5 MIU per UL Standard 2202.
5.6.13 Verify that hazard lights are capable of at least one hour of continuous
operation in the event of shutdown or isolation of the main battery pack or
failure of the DC/DC converter system by disconnecting the main propulsion
battery from the auxiliary battery, then turning on the emergency flashers,
and verifying that they operate for at least one hour.
5.6.14 Verify that the State of Charge indicator is accurate to ±5% of full scale by
conducting Section 5.1 of procedure AVTA-PHTP04.
5.6.15 Verify that the recharge time with the grid connected charger is less than
eight (8) hours by conduct of Section 6.7 of procedure AVTA-PHTP03 for
vehicles not capable of operation in RESS Only mode or by conduct of
Section 5.1 of procedure AVTA-PHTP04, for vehicles capable of RESS Only
operation.
5.6.16 Measure the energy required to maintain the main propulsion battery in a
fully charged state during extended periods on charge by conduct of Section
5.4.3 of procedure AVTA-PHTP08.

70 Chpt II, Sect VI

 AVTA-PHAC06

Appendix A – Vehicle Supplier Review Check List

(Page 1 of 2)

Vehicle Number: ___________________

PHAC06
Parameter Data
Ref.
5.2.1 Vehicle year of manufacture:
5.2.1 Vehicle make and model:
5.2.2 Vehicle manufacturer:
5.2.3 Number of occupants:
5.2.4 Amount of payload beyond passengers:
5.2.5 Design curb weight:
5.2.6 Design rated payload:
5.2.7 The standard tire manufacturer:
5.2.8 The standard tire model and size:
5.2.9 Charger manufacturer:
5.2.10 Motor manufacturer:
5.2.11 Controller manufacturer:
5.2.12 Heat engine configuration:
5.2.13 Heat engine displacement:
5.2.14 Heat engine fuel type:
5.2.15 Vehicle is a conversion to PHEV:
5.2.16 Type of transmission:
5.2.17 Battery module weight:
5.2.18 Battery pack weight:
5.2.19 Battery pack(s) voltage:
5.2.20 Number of modules in the battery pack:
5.2.21 Battery one-hour rate discharge capacity:

71 Chpt II, Sect VI

 AVTA-PHAC06

Appendix A – Vehicle Supplier Review Check List

(Page 2 of 2)

General Comments (initials/date):

_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

72 Chpt II, Sect VI

 AVTA-PHAC06

Appendix B – Vehicle Receipt Check List

(Page 1 of 3)
VIN Number: _______________________
Date Received: Odometer (miles):
Vehicle Year: Vehicle Make: Vehicle Model:
Vehicle Body Style: Vehicle Color:
GVWR (lbs): Front GAWR (lbs): Rear GAWR (lbs):
Installed Tire Size – F/R:
Sidewall Tire Pressure - F/R:
Traction Motor Type: Traction Motor Rating:
Designated Seating - Front: Rear: Front Seat Type:
RESTRAINT SYSTEM DESCRIPTION
Driver: C.F. Pass: R.F. Pass:
L.R. Pass: C.R. Pass: R.R. Pass:
VEHICLE CONDITION AND INSTALLED OPTIONS
Air Conditioning Power Steering Power Brakes Power Windows
Power Door Cruise Control Spare Tire Front Wheel Drive
Locks
Telescoping Tilt Wheel Front Disk Rear Disk Brakes
Wheel Brakes
Power Seats 4 Wheel Drive Anti-Lock Regenerative
Brakes Braking
Additional Significant Options / Accessories:

Significant Body Damage /

Corrosion:_________________________________________________________________
__________________________________________________________________________

VEHICLE WEIGHTS AS RECEIVED (WITH MAX. FLUIDS)

Left Front (lbs): Right Front (lbs): Total Front (lbs): Percent Front:
Left Rear (lbs): Right Rear (lbs): Total Rear (lbs): Percent Rear:
Total Weight (lbs):
VEHICLE HEIGHT AS RECEIVED (WITH MAX. FLUIDS)
Left Front (in): at Right Front (in): at
Left Rear (in): at Right Rear (in): at
VEHICLE WEIGHTS WITH PAYLOAD (RECEIVED CURB + 300 POUNDS)
Left Front (lbs): Right Front (lbs): Total Front (lbs): Percent Front:
Left Rear (lbs): Right Rear (lbs): Total Rear (lbs): Percent Rear:
Total Weight (lbs):
VEHICLE HEIGHT WITH PAYLOAD (RECEIVED CURB + 300 POUNDS)
Left Front (in): at Right Front (in): at
Left Rear (in): at Right Rear (in): at

73 Chpt II, Sect VI

 AVTA-PHAC06

Appendix B – Vehicle Receipt Check List

(Page 2 of 3)

VEHICLE RECEIVING PHOTOGRAPHS

Eight-Point Walk-Around:
Front Rear Right Profile Left Profile
Right Front Right Rear Quarter Left Front Left Rear Quarter
Additional Misc:
Instrument Cluster VIN Tire Placard
Console Instrument Cluster FMVSS Label Battery Container
Battery Charger Drive System Battery Charger
(Off-board) Components (On-Board)
Controller Charger Connection Misc. Placards
Misc. Labels Misc.( ) Misc.( )
Misc.( ) Misc.( ) Misc.( )
MISCELLANEOUS
Vehicle/Truck Trunk/Bed Space or Volume Encroachment: Yes ______ No ______
Using a 5-inch cubic go/no-go block, with the vehicle loaded to GVWR and standing on a
flat surface, when the block is in contact with the flat surface and passed beneath the sprung
portions of the vehicle, the block does not contact the sprung portions of the vehicle.
CLEARANCE (inches) ________________
Disconnect the main propulsion battery from the auxiliary battery. Turn on the emergency
flashers, and verify that they operate for at least one hour. This will verify loss of the main
battery pack and a failure of the DC/DC converter.
ACCEPTABLE______ UNACCEPTABLE______
Verify that the State of Charge indicator is accurate to ± 2% of full scale
ACCEPTABLE______ UNACCEPTABLE______
Verify that the battery system voltage indicator is accurate to ± 2% of full scale. This can be
completed by comparing the indication of this meter to the indication of a calibrated meter
attached to the same voltage source.
ACCEPTABLE______ UNACCEPTABLE______
Verify that the kilowatt-hour indicator is accurate to ± 5% of full scale.
ACCEPTABLE______ UNACCEPTABLE______

74 Chpt II, Sect VI

 AVTA-PHAC06

Appendix B – Vehicle Receipt Check List

(Page 3 of 3)

General Comments (initials/date):

_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

75 Chpt II, Sect VI

 AVTA-PHAC06

Appendix C – Vehicle Requirement Checklist

(Page 1 of 7)

Vehicle Number: __________

PHAC06 Vehicle
Requirement Requirement Met Initial Date
Reference Spec
5.6 2.3 Yes No N/A
Suppliers should describe safety
measures and safety-related design
features included in their vehicle design
and provide an explanation of the
purpose and anticipated effect on
vehicle reliability and performance of
any such safety measure or design
feature.
5.5 2.5 Recycling plans for batteries and other Yes No N/A
vehicle hazardous materials should
identify post-purchase costs associated
with recycling that will be passed on to
the vehicle purchaser.
5.6 2.7 Vehicles should be designed to Yes No N/A
minimize occupant exposure to
electromagnetic fields generated by the
propulsion system.
5.6.1 3.4 Speedometers and odometers should Yes No N/A
have an accuracy of at least ± 5%.
5.6 3.5 For conversion vehicles, braking and Yes No N/A
steering efforts should be similar to
OEM models of comparable size and
weight.
5.6.2 3.7 Vehicles should have a ground Yes No N/A
clearance of at least five (5) inches to all
sprung portions of the vehicle, with the
vehicle loaded with rated payload (e.g.
to GVWR).
5.6 4.2 Suppliers should specify interior Yes No N/A
passenger and cargo dimensions and
volumes.

76 Chpt II, Sect VI

 AVTA-PHAC06

Appendix C – Vehicle Requirement Checklist

(Page 2 of 7)

Vehicle Number: __________

PHAC06 Vehicle
Requirement Requirement Met Initial Date
Reference Spec
5.6.3 4.3 Vehicles should comply with the Yes No N/A
relevant sections of SAE J551 for
electromagnetic radiated fields. Vehicles
should not be susceptible to externally
generated electromagnetic radiation
from an on-board transmitter (i.e.,
interaction will not preclude operation
of any system(s) required for proper
operation of the vehicle).
5.6 5.1 The vehicle should utilize a single Yes No N/A
speed, multi-speed automatic, or a
Continuous Variable Transmission
(CVT)
5.6.4 5.2 Regenerative braking should not Yes No N/A
adversely impact the vehicle’s braking
ability on varying road surfaces.

5.6 Suppliers should describe the operation Yes No N/A

of the regenerative braking system and
its interface with braking and anti-lock
brake systems.
5.6.5 5.3 The vehicle drive-train system should be Yes No N/A
capable of continuous operation at
maximum vehicle speed and/or
sustained grades without overheating or
loss of component life over the range of Yes No N/A
ambient temperatures specified in the
PHEV Vehicle Specification Section 6.
5.6 5.4 Suppliers should specify the voltage Yes No N/A
limits and describe how these limits are
implemented.
5.6.6 5.5 Drive train components should not Yes No N/A
produce or develop unusual vibrations
over the entire design speed range of the
vehicle.

77 Chpt II, Sect VI

 AVTA-PHAC06

Appendix C – Vehicle Requirement Checklist

(Page 3 of 7)

Vehicle Number: __________

PHAC06 Vehicle
Requirement Requirement Met Initial Date
Reference Spec
5.6.7 6.1 The vehicle should have a 0-60 mph Yes No N/A
acceleration time of 13.5 seconds or less
with the vehicle loaded to its design
curb-weight plus 300 pounds in each of
the selectable modes of operation, as
applicable.
5.6.8 6.2 The vehicle should have a minimum top Yes No N/A
speed of 90 mph with the vehicle loaded
to its design curb-weight plus 300
pounds in each of the selectable modes
of operation, as applicable.
5.6.9 6.3 Vehicles should achieve a minimum Yes No N/A
sustainable speed of 55 mph on a 3%
grade, and 45 mph on a 6% grade, with
the vehicle loaded to its design curb-
weight plus 300 pounds, in each of the
selectable modes of operation, as
applicable.
5.6.10 6.4 Vehicles should be capable of starting Yes No N/A
and ascending a 25% with the vehicle
loaded to its design curb-weight plus
300 pounds in each of the selectable
modes of operation, as applicable.
5.6.11 6.5 Vehicles should be capable of Yes No N/A
completing the Rough Road Test
(Procedure AVTA-PHTP05) without
becoming inoperable.
5.6.12 6.6 Vehicles should be capable of driving Yes No N/A
through two (2) inches of standing water
at a speed of 20 mph without damage,
without becoming inoperable, and
without battery to chassis leakage
current exceeding 0.5 MIU per UL
Standard 2202.

78 Chpt II, Sect VI

 AVTA-PHAC06

Appendix C – Vehicle Requirement Checklist

(Page 4 of 7)

Vehicle Number: __________

PHAC06 Vehicle
Requirement Requirement Met Initial Date
Reference Spec
5.6.12 6.6 Vehicles should be capable of setting in Yes No N/A
eight (8) inches of standing water for 15
minutes without damage, becoming
inoperable, and without battery to
chassis leakage current exceeding 0.5
MIU per UL Standard 2202.
5.6 7.1 Suppliers should provide a detailed Yes No N/A
description of the RESS battery pack
(including specific energy, specific
power and discharge capacity to 80%
DOD at the one-hour rate), battery pack
voltage, number of battery modules, and
a summary of previous performance
tests.
5.6 7.3 Suppliers should indicate the level of Yes No N/A
charge below which the batteries should
not be discharged.

5.6 This should include the specific Yes No N/A

parameters the Battery Management
System utilizes to prevent over-
discharge.
5.6 Yes No N/A
At a minimum the Ah rating(s), module
voltage(s), and battery pack voltage(s)
should be provided.
5.6 Yes No N/A
Further, this should be consistent with
information provided in the Owner’s
Manuals.
5.6 7.4 Suppliers should specify the weight of Yes No N/A
each battery module, and the weight of
the battery pack (including removable
pack structures).

79 Chpt II, Sect VI

 AVTA-PHAC06

Appendix C – Vehicle Requirement Checklist

(Page 5 of 7)
Vehicle Number: __________
PHAC06 Vehicle
Requirement Requirement Met Initial Date
Reference Spec
5.6 7.4 Suppliers should describe how batteries Yes No N/A
are installed in the vehicle (including
details of module connection), the
method of installation and removal of
the batteries (and the battery box, if
required) for maintenance and repair,
the time required for battery removal
and any special training, tools or
equipment required for battery removal.
5.6 7.8 Maintenance requirements for the RESS Yes No N/A
batteries should be described and any
associated cost(s) to the consumer/end
user clearly defined.
5.6 7.9 Maintenance requirements for other Yes No N/A
RESS components (e.g., flywheels, ultra
capacitors) should be described and any
associated cost(s) to the consumer/end
user should be clearly defined.
5.6 7.11 The vehicle should be equipped with a Yes No N/A
BMS. This system should control
propulsion battery pack and module
voltages, temperatures and state of
charge during both charge and
discharge.

5.6 Further, the BMS should automatically Yes No N/A

limit battery discharge below a pre­
determined minimum level.

5.6 The description of the BMS operation Yes No N/A

should be consistent with that provided
in the owner’s manual.
5.6 8.1 Markings for HIGH VOLTAGE Yes No N/A
devices should be installed at any point
the voltage can be accessed by the end
user.
5.6 8.2 Supplier should provide details on Yes No N/A
grounding and isolation methods.

80 Chpt II, Sect VI

 AVTA-PHAC06

Appendix C – Vehicle Requirement Checklist

(Page 6 of 7)

Vehicle Number: __________

PHAC06 Vehicle
Requirement Requirement Met Initial Date
Reference Spec
5.6 8.3 Vehicles should be equipped with an Yes No N/A
automatic disconnect for the RESS
batteries which operates to isolate the
propulsion circuits any time the chassis
becomes energized from contact with
the propulsion battery or its associated
circuits.

5.6 A manual service disconnect should also Yes No N/A

be present. This disconnect should be
operable with the following capabilities:
• Manual action to break the connection
• The disconnection is physically
verifiable
• The disconnection does not create
exposed conductors capable of
becoming energized while exposed.
5.6.13 8.5 Hazard lights should be capable of at Yes No N/A
least one hour of continuous operation
in the event of shutdown or isolation of
the main battery pack or failure of the
DC/DC converter system.
5.6.14 8.6 The vehicle should include a state of Yes No N/A
charge indicator for the RESS batteries.
Indications should be accurate to ± 5%
of full scale.
5.6 8.7 Low voltage connectors should meet the Yes No N/A
requirements of applicable SAE
Standards, including J163, J561, J858,
et al. High voltage connectors should
utilize locking devices, should be keyed
to prevent misconnection, and should be
moisture proof.

81 Chpt II, Sect VI

 AVTA-PHAC06

Appendix C – Vehicle Requirement Checklist

(Page 7 of 7)
Vehicle Number: __________
PHAC06 Vehicle
Requirement Requirement Met Initial Date
Reference Spec
5.6.15 9.1 The preferred recharge time with the Yes No N/A
grid connected charger should be less
than eight (8) hours.

5.6.16 The charger should also minimize the Yes No N/A

energy required to maintain the main
propulsion battery in a fully charged
state, particularly during extended
periods on charge.
5.6 9.2 Any conductive or inductive type Yes No N/A
charging systems should be in
accordance with the requirements of
SAE J1772 or J1773.
5.6 9.4 Suppliers should describe the type, size Yes No N/A
and location of the point of the vehicle
charging port.

5.6 The charge connector should comply Yes No N/A

with the requirements of SAE J1772 or
SAE J1773, as appropriate.
5.6 10.1 Suppliers should describe the design of Yes No N/A
the air conditioning system and verify
that it uses no chlorofluorocarbons
(CFCs).
5.6 10.2 Suppliers should briefly describe the Yes No N/A
design of a pre-heating and pre-cooling
system that allows passenger
compartment temperatures to be
maintained while the vehicle is on
charge.
5.6 11.1 Manuals should include details on the Yes No N/A
design and operation of vehicle systems,
as well as a list of additional or special
maintenance tools required.
5.6 11.2 Suppliers should offer a training Yes No N/A
program for the purchaser’s
maintenance personnel covering vehicle
safety and proper operation and
maintenance of vehicles.

82 Chpt II, Sect VI

 AVTA-PHAC07

Section VII: AVTA-PHAC07 – Control of Measuring and Test

Equipment

83 Chpt II, Sect VII

 AVTA-PHAC07

TABLE OF CONTENTS

1 Objective .............................................................................................................................................................85

2 Purpose................................................................................................................................................................85

3 Documentation....................................................................................................................................................85

4 Initial Conditions and Prerequisites .................................................................................................................85

5 Activity Requirements........................................................................................................................................86

APPENDICES

Appendix A – Metrology Setup Sheet ......................................................................................................................90

Appendix B – Instrument Calibration List Annual/Semi-Annual Calibration....................................................91

Exhibit A – Instrument Calibration Label (Sample)..............................................................................................91

84 Chpt II, Sect VII

 AVTA-PHAC07

1 Objective
The objective of this procedure is to assure that Measuring and Test Equipment (M&TE)
used for U.S. Department of Energy Advanced Vehicle Testing Activity (AVTA) testing is
properly functioning and accurately calibrated. These methods are not meant to supersede
those of the testing facility, those specifically mandated by governmental regulations, nor
of any regulatory agency who may have or exercise control over the covered activities.

2 Purpose
The purpose of this procedure is to identify acceptable methods for the control of M&TE.
This includes requirements for calibration of M&TE, control of the standards, services and
resources needed for the calibration processes and the use of external resources for
calibration activities. This procedure also satisfies the requirements for these activities as
specified in procedure AVTA-PHQP01.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read, and readily reproducible. This documentation shall contain enough information to
"stand alone"; that is, it will be self-contained to the extent that all individuals qualified to
review it could be reasonably expected to reach a common conclusion, without the need to
review additional documentation. Review and approval of documentation shall be in
accordance with procedure AVTA-PHAC04. Storage and retention of records during and
following testing activities will be completed as described in procedure AVTA-PHAC01.

4 Initial Conditions and Prerequisites

4.1 This program is applicable to all M&TE utilized for data collection purposes,
modified as follows:
4.1.1 Vendor’s M&TE that meets the requirements of a formal program
administered by that vendor and subject to audit under the requirements of
procedure AVTA-PHQA01, shall be considered to meet the requirements of
this procedure.
4.1.2 Devices such as rulers, tape measures, laboratory glassware, volumetric
transfer equipment, and other similar devices used in applications where
normal commercial accuracy is acceptable shall be accepted at face value.
There shall be no further requirement for control of these items as long as
they are controlled in a manner that precludes their use in conditions other
than as noted.
4.1.3 Equipment that is permanently installed and used in applications not
requiring other than normal commercial accuracy (similar to that noted in
4.1.2).

85 Chpt II, Sect VII

 AVTA-PHAC07

4.1.4 Equipment controlled or regulated by agencies outside the control of the

AVTA (such as the equipment regulated by the Federal Communications
Commission).

4.2 All calibration activities and resources shall be traceable to the National Institute of
Standards and Technology (NIST), or to standards nationally recognized and
commensurate with the desired usage. If an appropriate standard exists, calibration
bases shall be identified and documented.

5 Activity Requirements
The requirements of this procedure apply to the activities listed here and to the
personnel responsible for implementing them. Activities that are not listed or
identified herein shall not be considered exempted by their absence, as long as their
required function or use is controlled by this activity.

5.1 Equipment Indexing

5.1.1 All equipment maintained for use and data collection and/or processing by
Electric Transportation Applications shall be formally identified, numbered
and indexed.
5.1.2 Equipment shall be cross referenced to other associated equipment (e.g.,
calibrated meter probes shall reference the meter with which they are used
and calibrated).
5.1.3 Cross references shall contain the applicable Certificates of Conformance,
and identify the calibration standards and associated M&TE, when
appropriate.

5.2 Calibration Labeling

5.2.1 M&TE equipment shall be labeled, tagged or otherwise controlled to indicate
its calibration status and ensure its traceability to calibration test data.
[Link] Labeling shall be plainly visible and as a minimum should
contain:
• The equipment serial number
• The most current calibration date
• The next required calibration due date.

5.3 Intervals of Calibration

5.3.1 Measuring and test equipment (M&TE) should be calibrated at specified
intervals, or should be based on the items:
[Link] Required accuracy
[Link] Intended use

86 Chpt II, Sect VII

 AVTA-PHAC07

[Link] Frequency of use

[Link] Stability characteristics
[Link] Any other conditions affecting its performance.
5.3.2 Calibration shall be according to pre-planned equipment schedules based
upon an annual/biannual cycle. Frequencies may be increased dependent
upon equipment sensitivity and use.
5.3.3 An Instrument Calibration list shall be maintained and shall contain the
following minimum information:
[Link] Equipment type
[Link] Equipment description
[Link] Manufacturer
[Link] Manufacturer’s model number
[Link] Manufacturer’s serial number
[Link] Electric Transportation Application’s index number
[Link] Calibration status
[Link] Calibration due date

5.4 Calibration Requirements

5.4.1 M&TE shall be calibrated against standards which provide accuracy closer
than the required tolerances of the equipment being calibrated. [If a meter has
a stated accuracy of 0.5% of full scale, the calibration standard shall not have
the result of reducing that stated accuracy.] If nationally recognized standards
exist, calibration standards shall be traceable to such standards.

5.5 Documentation Requirements

5.5.1 Documents related to calibration activities shall be maintained and controlled
in accordance with the requirements of procedure AVTA-PHAC01.

5.6 Personnel Qualifications

5.6.1 Personnel who perform calibrations or review and/or approve calibrations
shall be certified in accordance with procedure AVTA-PHAC05.

5.7 Environmental Controls

5.7.1 All calibration standards shall be maintained, calibrated, transported, used
and stored in environments required by the calibration standards governing
the particular calibration requirements (e.g., NIST, QAM, ISO-900X), which
will not adversely affect their accuracy.

87 Chpt II, Sect VII

 AVTA-PHAC07

5.7.2 All M&TE shall be maintained within the environmental parameters

specified by the particular manufacturer. This applies to calibration, storage
and use.

5.8 Non-Conforming Equipment

5.8.1 When M&TE is found to be out of tolerance during its periodic calibration or
it is not possible to determine the calibration status due to equipment
condition or location, a Non-Conforming Condition is said to exist.
[Link] The condition type and apparent cause shall be documented.
[Link] The condition shall be evaluated to determine the impact on tests
completed using the non-conforming equipment since the
previous calibration.
[Link] The non-conforming equipment shall be removed from further
service (red tag) until the cause of the non-conformance has been
corrected or the non-conforming equipment has been
recalibrated.

5.9 Vendor’s M&TE

5.9.1 M&TE controlled by a vendor’s M&TE program need not be subject to this
procedure if all of the following are met:
[Link] The vendor’s M&TE is controlled by an approved calibration
program that incorporates requirements equivalent to the
requirements in this program and associated practices.
[Link] The vendor maintains documentation controls for the calibration
status and records of tools and gauges utilized.
[Link] The vendor’s program and records are available for audit.
[Link] The scope of the vendor’s work is clearly defined and controlled
by a purchase order or contract.

5.10 Procurement of Outside Services

5.10.1 Outside services may be utilized for equipment calibration/re-calibration.
Should outside facilities be utilized for the calibration of equipment
controlled by this program, those facilities shall provide a calibration
certificate or data sheet for each item calibrated which contains, at a
minimum, the following information:
[Link] Name of the item
[Link] Manufacturer’s serial number of item
[Link] Date of the calibration

88 Chpt II, Sect VII

 AVTA-PHAC07

[Link] A statement indicating the standards used in calibration, test

numbers or other means of documenting traceability
[Link] A statement of calibration accuracy ratio(s) or a statement of the
accuracy of the standard(s) used and the M&TE calibrated
[Link] A statement of the facility’s calibration standards and their
traceability to NIST or other nationally recognized standards
[Link] A statement of equipment conformance to the calibration
specifications in the “as found” or pre-calibration condition
[Link] In the event that the M&TE did not conform to the calibration
specifications in the “as found” condition, a statement shall be
written containing one of the following:
[Link].1 A statement specifically defining the out-of-tolerance
condition
[Link].2 A statement specifically identifying the cause of the
out-of-tolerance condition
[Link].3 A statement specifically identifying all of the work
performed to correct the out-of-tolerance condition,
including components/parts replaced.
5.10.2 Procurement activities for M&TE calibration standards and equipment shall
be completed by personnel familiar with metrology requirements and who are
certified to procedure AVTA-PHAC05.
5.10.3 Procurement of external services for calibration and/or repair services for
M&TE shall be only from vendors who have been subjected to or agreed to
an audit under the requirements of procedure AVTA-PHQA01.

89 Chpt II, Sect VII

 AVTA-PHAC07

Appendix A – Metrology Setup Sheet

(Page 1 of 1)

Instrument/Device: Calibration Due Date: Initials / Date:

Fifth Wheel S/N:

Fifth Wheel Calibrator S/N:

DAS S/N:

DAS Set-up Sheet S/N:

kWh Meter S/N:

Shunt S/N:

Tire Pressure Gauge S/N:

Misc:

Misc:

Misc:

Misc:

Comments (initials/date):

Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By (QA):
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

90 Chpt II, Sect VII

 AVTA-PHAC07

Appendix B – Instrument Calibration List Annual/Semi-

Annual Calibration
(Page 1 of 1)

Equipment Equipment Model Serial AVTA Cal Last Cal

Type: Description: MFG: No: No: No: Status: Loc: Cal: Due:

Exhibit A – Instrument Calibration Label (Sample)

Company Name
Serial Number:
0001

CALIBRATION DUE DATE:

01/01/08

91 Chpt II, Sect VII

 Chapter III: Quality Procedures
Section I: AVTA-PHQA01 – Audit of the Quality Assurance
Program for the Control and Use of Measuring and Test
Equipment

Section II: AVTA-PHQP01 – Quality Program

92 Chpt III, TOC

 AVTA-PHQA01

Section I: AVTA-PHQA01 – Audit of the Quality Assurance

Program for the Control and Use of Measuring
and Test Equipment

93 Chpt III, Sect I

 AVTA-PHQA01

TABLE OF CONTENTS

1 Objectives ............................................................................................................................................................95

2 Purpose................................................................................................................................................................95

3 Requirements ......................................................................................................................................................95

4 Personnel .............................................................................................................................................................95

5 Documentation....................................................................................................................................................96

6 Process .................................................................................................................................................................96

7 Protocol ...............................................................................................................................................................96

8 Activities ..............................................................................................................................................................97

8.1 Quality Assessment .........................................................................................................................97

8.2 Quality Assurance Program Document ..........................................................................................97
8.3 Documentation................................................................................................................................97
8.4 Laboratory Administration .............................................................................................................98
8.5 Laboratory Records ........................................................................................................................98
8.6 Calibration/Test Report Preparation ..............................................................................................99
8.7 Personnel ......................................................................................................................................100

APPENDICES
Appendix A – Recommended Format for Routine Test Report ..........................................................................101

Appendix B – Recommended Format for Certificate of Traceability.................................................................102

Appendix C – Checklist #1, Documentation..........................................................................................................103

Appendix D – Checklist #2, Administration..........................................................................................................104

Appendix E – Checklist #3, Laboratory Records .................................................................................................105

Appendix F – Checklist #4, Calibration & Test Reports......................................................................................106

Appendix G – Checklist #5, Training Records......................................................................................................107

Appendix H – Blank Comment Sheet ....................................................................................................................108

94 Chpt III, Sect I

 AVTA-PHQA01

1 Objectives
The objective of an audit is to verify the adequacy of the operational characteristics of a
facility's quality assurance practices, specifically as they relate to the control of metrology.

2 Purpose
The purpose of the audit is to ensure that the Quality Assurance Program requirements
which address the control of metrology, or Measuring and Test Equipment (M&TE), are
used at facilities which may be subcontracted to perform testing for the U.S. Department of
Energy Advanced Vehicle Testing Activity (AVTA) program. This includes control
measures for all aspects of the calibration and use processes, repair and rework of defective
instrumentation. The Audit Plan shall include, but not be limited to, one or more aspects of
the following:
• Control of the facility's metrology calibration processes
• Control of the facility's metrology calibration standards
• Control of the facility's metrology procedures
• Control of the facility's metrology records, including retention requirements
• Control and reporting of defective metrology
• Rework/repair of defective metrology
• Rework/repair of metrology which fails in service.

3 Requirements
The Quality Assurance (QA) Plan being audited shall be developed in accordance with the
requirements of The National Bureau of Standards Handbook (NBS/HB)-145, or another
similar document. The QA Plan is required to contain controls for those items specified as
necessary by the NBS/HB-145. For those items required by the NBS/HB but not
specifically contained in the QA Plan, the NBS requirements for alternatives must be
followed.

4 Personnel
Personnel who conduct the audit shall either be trained or have experience in this type of
activity. Training may be formal, such as through post-secondary or post-graduate studies,
or through an approved or generally accepted Industry or Corporate Training Program.
Experience should be gained through actual auditing of QA Activities or Plans at other
facilities or companies, which may include those controlled by Federal or State
Governments. Individuals should be capable of being certified as an auditor to the
requirements of the QA standard used as the basis for the QA Plan being audited.
Personnel who are assigned as members of the audit team shall have the experience,
training or educational background, as identified in Section 8.7, necessary for them to
participate as audit team members.

95 Chpt III, Sect I

 AVTA-PHQA01

5 Documentation
The documentation used and generated during the Audit Process should be retained as a
permanent part of the audit package. Copies of the completed audit, including all checklists
and reports, noted deficiencies and any corrective action activity reports, shall be made
available to all members of the audit team, as well as to the management of the facility
being audited. The audited facility shall maintain the results of the Audit in accordance
with the external auditing requirements of their QA Plan, if so stipulated. If not otherwise
stipulated, the results of the audit shall be maintained until the date of completion of all
activities addressed by the governing contract.
All documents shall be signed by the person completing the document and the Audit Team
Leader. The names of the audit team members shall be listed in the document. The final
Audit Package will be signed by all members of the Audit Team, and signed by the
Manager of the facility or group being audited, or a designated representative. These final
signatures shall be attached following completion of the exit meeting process, and will
signify that all signers have been made aware of the audit findings, and have received a
copy of the final report. Signatures of additional facility personnel, as required by
NBS/HB-145 or the facility's QA plan or audit program, shall be affixed as appropriate.

6 Process
The audit shall utilize checklists and interviews to obtain data. Procedures and controls
specified by NBS/HB-145 and others as may be specified by the Facility's QA plan are
subject to review. Only data which is relevant to the particular process under review shall
be collected. Every attempt shall be made to keep the identity of interviewees confidential,
as individual reproach is not the intent of this effort. Audit findings, in the opinion of the
audit team, which are considered or judged to be unsafe, or could be reasonably expected
to jeopardize the safety of the interviewee, other individuals or equipment, or which in turn
could jeopardize the safety of subsequent individuals, shall be reported to a senior member
of the Subcontractor’s organization.

7 Protocol
Audit activities shall take place at the sub-contractor’s facilities, unless otherwise agreed to
in advance. Activities are limited to those activities identified in this Plan. Activities not
under the scope of this Plan should not be audited, but may be otherwise noted or reported.
Personnel conducting an audit at a subcontractor’s facility are required to follow the
confidentiality guidelines and the security and safety requirements of that subcontractor.
All findings of the Audit shall be maintained confidential until the report has been
completed, reviewed and signed by all members of the Audit team or their designated
representative. The final report should be maintained as previously stipulated. It may be
maintained for longer periods, as directed by the facility's requirements for record
retention.

96 Chpt III, Sect I

 AVTA-PHQA01

8 Activities

8.1 Quality Assessment

Quality Assessment is the term that describes those activities and procedures utilized
to monitor the effectiveness of the quality control program and to evaluate the
quality of the data output. Such an assessment can be from either an internal or
external approach. Because this assessment is intended to quantify the reviewed
activities as satisfactory or unsatisfactory only as they relate to the U.S. Department
of Energy Advanced Vehicle Testing Activity Performance Test Program, it will be
implemented using an external approach. This Plan could be utilized in either
manner, however. Appendices C through G shall be used to document the results of
the assessment.

8.2 Quality Assurance Program Document

The various aspects of the QA practices should be developed and described in a QA
program document. This document should describe the maintenance procedures for
facilities and equipment, the control charts to be maintained and "out-of-control"
records that should be kept. [As used here, out-of-control means that the records in
question have been removed from controlled status, either by time frame or super
cession.] This program is only as effective as it is systematically implemented. This
means that the QA Program shall have been formally established, and that it
documents the policy and procedures to be followed.

8.3 Documentation
All data shall be technically sound and supportable by evidence of unquestionable
reliability. Requirements for specific activities and personnel qualification are set
forth in Sections 8.4 through 8.7. At a minimum, records shall be both adequate and
accurate, and should contain the following items:
8.3.1 What measurements are being performed
8.3.2 Name of the individual(s) performing the measurement
8.3.3 What time the measurements are made.
8.3.4 How measurements are made:
[Link] The kinds of equipment being used
[Link] Calibrated or not calibrated and any supporting data
[Link] Methodology for measurement.
8.3.5 The data obtained
8.3.6 Calculations used to collect or quantify the data
8.3.7 Quality assurance support
8.3.8 Reports.

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8.4 Laboratory Administration

The following administrative practices have been identified as necessary for
providing proper management of a metrology laboratory and to facilitate good
measurement. These items may be duplicates of those listed previously. Maintenance
of Standards and Instruments
8.4.1 Maintenance of a proper laboratory environment, including:
[Link] Laboratory temperature
[Link] Laboratory humidity
[Link] Laboratory air flow/currents
[Link] Vibrations
[Link] Restricted access
[Link] Cleanliness.
8.4.2 Filing Systems, including the following separate categories:
[Link] Reference materials
[Link] Annual data sheets and reports
[Link] Reference standards, reports of calibrations and tests
[Link] Reports of calibrations and tests
[Link] Correspondence.
8.4.3 Numbering Systems for Tests, including:
[Link] Calibration tests and tests with the year and sequence number
[Link] State name (abbreviation or initials)
[Link] Master record of all test numbers, items, dates, submitters.
8.4.4 Training programs and records, including:
[Link] Records of a continuous educational program
[Link] Participation in NBS training Programs (required).

8.5 Laboratory Records

8.5.1 All data should be recorded in notebooks or on data sheets specifically
designed for the purpose.
8.5.2 All entries shall be dark and clear enough for photocopy.
8.5.3 Erasures (including the use of whiteout or any similar substance) are not
permitted in notebooks or data sheets. If an error is made, it shall be crossed
out with a single line, and the correct data recorded. The initials of the person
who made the change, along with the date of the change shall be recorded in
the margin at the point of error.

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8.5.4 Clear identification of what was tested, how the measurements were made
and by whom are prime requirements. Any deviations from standard practices
shall be documented.
8.5.5 The identity of the sample or item tested must be unquestionable. This may
require a chain-of-custody, providing evidence of positive and unbroken
custodial action for the sample or test item. There should be no gaps of
custody, unless such gaps can be identified as having been due to locked
storage or shipping container.

8.6 Calibration/Test Report Preparation

Test reports are the viable output of the laboratory/facility. They should be prepared
with the utmost care to ensure they accurately convey all of the pertinent information
of the testing activity. A properly prepared test report can be considered a "stand­
alone" document, one which contains or refers to all of the information necessary to
justify the data therein. It may contain fill-in blanks, a detailed narrative, or both.
Appendices A and B contain recommended formats for these processes. Regardless
of the final form, the following information shall be included:
8.6.1 Client
8.6.2 Purpose of the test (or reference to a "motherhood" document)
8.6.3 Description of the test/calibration item, including:
[Link] Manufacturer's name
[Link] Manufacturer's model number
[Link] Manufacturer's serial number
[Link] Laboratory number.
8.6.4 Test Method, including how the test was done, explicit reference to another
document, or narrative descriptions of the test activity
8.6.5 Test Results
8.6.6 Limits of uncertainty
8.6.7 Traceability/In-Tolerance, including:
[Link] Reference standards used
[Link] Traceability to national standards
[Link] Whether or not the instrumentation used was/was not in tolerance
at the time of calibration.
8.6.8 References
8.6.9 Signatures
[Link] The laboratory director or designated alternate shall sign all
laboratory test reports.

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[Link] Other signers may be required, at the direction of the Laboratory

Director.
8.6.10 Conclusions of the test, especially when the test is of more than routine
significance. This is especially true when the conclusions drawn can result in
limitations on the results, whether necessary or desirable.
8.6.11 Each Test Report shall:
[Link] Be given a unique characteristic identification number according
to the system developed by the Laboratory
[Link] Be filed according to the Test Report Number
[Link] Retain copies of the test reports for a minimum of five years,
until superseded by a subsequent report, or until deemed by the
laboratory director as having no future value.

8.7 Personnel
A competent staff is an absolute necessity for quality measurements. Each member
shall have an educational background, supplemented with specific training and
experience, sufficient for the duties to be performed. Each person shall be aware of
and understand the responsibilities of their position (which can be accommodated by
suitable position descriptions and indoctrination) and must have the personal desire
to perform them at a high level of competence. Further, these individuals are critical
factors in the operational aspects of quality assurance. They must perform technical
operations intelligently and skillfully, and in the full spirit of quality assurance
requirements. To this end, the following should be verified:
8.7.1 Educational background of each individual
8.7.2 Supplemental training of each individual
8.7.3 A position description for each individual
8.7.4 An indoctrination record for each individual.

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Appendix A – Recommended Format for Routine Test Report

Test Report
Issued by
(Name of Testing Laboratory)
Laboratory Report Number ____________

Test Item(s)/Lab No(s): _______________________________________________

_______________________________________________

Submitted by: __________________________________________________________

Date: ________________________________________________________ __
Purpose of Test: _____________________________________________________
_____________________________________________________
_____________________________________________________
_____________________________________________________

_______________________________________________________________________
Test Results*:
As-Found After Adjustment

_______________________________________________________________________

Reference Information:

Test Method: ___________________________________________________________

Traceability: ___________________________________________________________
Data Reference: _____________________________________________________
Test Results Certified by (Name, Title, Date): _____________________________
_______________________________________________
_______________________________________________
_______________________________________________

*See Test Report, if appropriate

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 AVTA-PHQA01

Appendix B – Recommended Format for Certificate of

Traceability
Company Name

Company
Address

CERTIFICATE OF TRACEABILITY

Name of Device:

Model: Serial Number:

Submitted By:

The calibration was performed on (date) ______________________. The ambient

conditions were ______ °C and ______ % relative humidity. The item tested was/was not in
tolerance at the time of calibration. Any out of tolerance data are attached.

Data:

The primary standards to which the above data are traceable are identified in this report.
The calibration of these standards is traceable to the National Bureau of Standards. The cycling
and certification of all standards of measurement at this facility meet the requirements of MIL­
STD-45662.

Name of Standard NBS Report Date Calibrated Date Due

Test Results Certified by (Name, Title, Date): _____________________________

_______________________________________________
_______________________________________________
_______________________________________________

102 Chpt III, Sect I

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Appendix C – Checklist #1, Documentation

________________________________________________________________________
Sect. Requirement Acceptable Initials/Date
Yes No

8.3.1 What measurement is being performed _________ ______/____

8.3.2 Who performed the measurement is noted _________ ______/____
8.3.3 Time of measurement is recorded _________ ______/____
8.3.4 How measurements are made _________ ______/____
[Link] What kind of equipment is being used _________ ______/____
[Link] Data supporting calibrated/not calibrated is noted _________ ______/____
[Link] Methodology for measurement is noted _________ ______/____
8.3.5 The data obtained is noted and relevant _________ ______/____
8.3.6 Calculations used to collect or quantify the data _________ ______/____
8.3.7 Quality assurance support is noted _________ ______/____
8.3.8 Reports are issued and complete _________ ______/____

________________________________________________________________________

Comments, Exceptions, Corrective Actions, Etc. ______________________________

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

Checklist Completed by (name, title, Company) ______________________________

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

Date Initiated______________________ Date Completed _____________________

Reviewed By (Name, Title, Company)/Date __________________________________

Approved by (Name, Title, Company)/Date __________________________________

103 Chpt III, Sect I

 AVTA-PHQA01

Appendix D – Checklist #2, Administration

________________________________________________________________________
Sect. Requirement Acceptable Initials/Date
Yes No

8.4.1 Laboratory environment is properly maintained _________ ______/____

[Link] Laboratory temperature is controlled (± 1° C) _________ ______/____
[Link] Laboratory humidity is controlled (35-55%) _________ ______/____
[Link] Laboratory air flows/currents are dampened _________ ______/____
[Link] Facility is free of vibrations _________ ______/____
[Link] Facility has restricted access _________ ______/____
[Link] Facility is clean _________ ______/____
[Link] Reference Materials Files exist _________ ______/____
[Link] Annual data sheets and reports files exist _________ ______/____
[Link] Reference standards files exist _________ ______/____
[Link] Reports of Calibrations and Tests files exist _________ ______/____
[Link] Correspondence files exist _________ ______/____
[Link] Documents have a sequence number, with year _________ ______/____
[Link] Sequence number uses State name (abbr./initials) _________ ______/____
[Link] Master record exists with appropriate data _________ ______/____
[Link] Continuous educational program records exist _________ ______/____
[Link] NBS Training Program Participation is evidenced _________ ______/____
________________________________________________________________________

Comments, Exceptions, Corrective Actions, Etc. ______________________________

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

Checklist Completed by (name, title, Company) ______________________________

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

Date Initiated______________________ Date Completed _____________________

Reviewed By (Name, Title, Company)/Date __________________________________

Approved by (Name, Title, Company)/Date __________________________________

104 Chpt III, Sect I

 AVTA-PHQA01

Appendix E – Checklist #3, Laboratory Records

________________________________________________________________________
Sect. Requirement Acceptable Initials/Date
Yes No

8.5.1 Data recorded in notebooks or data sheets _________ ______/____

- Documents specifically designed for this purpose _________ ______/____
8.5.2 Entries are dark and clear enough for photocopy _________ ______/____
8.5.3 No erasures or whiteouts are present _________ ______/____
- All changes are lined out, initialed and dated _________ ______/____
8.5.4 Deviations from standard practices are noted _________ ______/____
8.5.5 Sample or item tested identity known _________ ______/____
- Was a chain-of-custody used _________ ______/____
- Was locked storage or a shipping container used _________ ______/____

________________________________________________________________________

Comments, Exceptions, Corrective Actions, Etc. ______________________________

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

Checklist Completed by (name, title, Company) ______________________________

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

Date Initiated______________________ Date Completed _____________________

Reviewed By (Name, Title, Company)/Date __________________________________

Approved by (Name, Title, Company)/Date __________________________________

105 Chpt III, Sect I

 AVTA-PHQA01

Appendix F – Checklist #4, Calibration & Test Reports

________________________________________________________________________
Sect. Requirement Acceptable Initials/Date
Yes No

8.6.1 Client is clearly identified _________ ______/____

8.6.2 Purpose of the test is described _________ ______/____
[Link] Tested item's manufacturer's name _________ ______/____
[Link] Tested item's manufacturer's model number _________ ______/____
[Link] Tested item's serial number _________ ______/____
[Link] Testing laboratory's number _________ ______/____
8.6.4 Test method(s) identified _________ ______/____
8.6.5 Test results are included and complete _________ ______/____
8.6.6 Limits of uncertainty are stated _________ ______/____
[Link] Reference standards used are appropriate _________ ______/____
[Link] Traceability of reference to national standards _________ ______/____
[Link] Test instrument in/not in tolerance at time of test _________ ______/____
8.6.8 References listed, as applicable _________ ______/____
8.6.9 Required signatures affixed _________ ______/____
8.6.10 Test conclusions are included and complete _________ ______/____
[Link] Report has a unique identification number _________ ______/____
[Link] Test Reports are filed according to Appendix D _________ ______/____

________________________________________________________________________

Comments, Exceptions, Corrective Actions, Etc. ______________________________

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

Checklist Completed by (name, title, Company) ______________________________

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

Date Initiated______________________ Date Completed _____________________

Reviewed By (Name, Title, Company)/Date __________________________________

Approved by (Name, Title, Company)/Date __________________________________

106 Chpt III, Sect I

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Appendix G – Checklist #5, Training Records

________________________________________________________________________

Sect. Requirement Acceptable Initials/Date

Yes No

[Link] Continuous educational program records exist _________ ______/____

[Link] NBS Training Program Participation is evidenced _________ ______/____
8.7.1 Individuals have appropriate education _________ ______/____
8.7.2 Individuals have supplemental training _________ ______/____
8.7.3 Position descriptions exist _________ ______/____
8.7.4 Indoctrination records exist _________ ______/____

________________________________________________________________________

Comments, Exceptions, Corrective Actions, Etc. ______________________________

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

Checklist Completed by (name, title, Company) ______________________________

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

Date Initiated______________________ Date Completed _____________________

Reviewed By (Name, Title, Company)/Date __________________________________

Approved by (Name, Title, Company)/Date __________________________________

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Appendix H – Blank Comment Sheet

Additional Comments for Appendix

__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
________________________________________________

108 Chpt III, Sect I

Section II: AVTA-PHQP01 – Quality Program

109 Chpt III, Sect II

 AVTA-PHQP01

TABLE OF CONTENTS

1 Objective ...........................................................................................................................................................111

2 Scope..................................................................................................................................................................111

3 Documentation..................................................................................................................................................111

4 Prerequisites......................................................................................................................................................111

5 Exclusions..........................................................................................................................................................112

6 Quality Assurance Criteria..............................................................................................................................112

6.1 Program ........................................................................................................................................112

6.2 Requirements.................................................................................................................................112
6.3 Personnel Training and Qualification ..........................................................................................113
6.4 Quality Improvement.....................................................................................................................113
6.5 Documents and Records................................................................................................................114
6.6 Work Processes .............................................................................................................................114
6.7 Design ...........................................................................................................................................115
6.8 Procurement..................................................................................................................................115
6.9 Inspection and Acceptance Testing ...............................................................................................115
6.10 Management Assessment...............................................................................................................117
6.11 Independent Assessment................................................................................................................117

110 Chpt III, Sect II

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1 Objective
The objective of this procedure is to develop and maintain a program that provides
guidance for the quality requirements and aspects of work performed for the U.S.
Department of Energy Advanced Vehicle Testing Activity (AVTA).

2 Scope
This program applies to all activities in support of performance testing of plug-in hybrid
electric vehicles performed pursuant to the requirements of the AVTA. This program may
also apply to other activities, if it is specifically invoked by the documents controlling
those other activities.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read, and readily reproducible. Documents shall contain enough information to "stand
alone"; that is, be self-contained to the extent that all individuals expected to review it
could be reasonably expected to reach a common conclusion, without the need to review
additional documentation. Storage and retention of records during and following testing
activities shall be completed as described in procedure AVTA-PHAC01.

4 Prerequisites

4.1 Personnel conducting work under this program or in accordance with the procedures
associated with the AVTA shall be aware and trained/certified as to its contents.

4.2 All procedures controlling work or program related activities shall be subject to the
requirements of this program.

4.3 All personnel within the cognizance of this program shall be responsible for its
implementation.

4.4 All personnel within the cognizance of this program shall be responsible for the
quality of their work activities and products. These products may be tangible or
otherwise.

4.5 All personnel are responsible for identifying conditions adverse to quality and if
possible, correcting those conditions.

4.6 Conditions adverse to quality will be reported to management, regardless of whether

they were corrected.

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5 Exclusions

5.1 This Program does not apply to activities outside of those specifically addressed by
the programs and procedures developed and associated with the AVTA.

5.2 Should this program be applied to other activities it shall be invoked by those
activities without the necessity to revise this document.

5.3 Specific exclusions from this program should be made within the document requiring
the exclusion.

6 Quality Assurance Criteria

6.1 Program
This document functions as the written Quality Assurance Plan. It will describe, as
necessary, the functional responsibilities, levels of authority (as appropriate) and
interface requirements for individuals managing, assessing or performing work. The
program has or directs the establishment of specific attributes. These may be
included in other approved procedures or programs under the control of Electric
Transportation Applications. The program should include the following attributes:
6.1.1 A formal Quality Assurance Plan (QAP) (This document is that Plan.)
6.1.2 Management retention and responsibility for an effective QAP (Each
individual is responsible for the quality of his/her work.)
6.1.3 The promotion of effective achievement of the performance objectives.

6.2 Requirements
6.2.1 The QAP is binding on all personnel completing work under any AVTA
procedures.
6.2.2 The quality of processes, ensured to an extent consistent with their risk.
6.2.3 A description of or reference to the organizational structure, functional
responsibilities, levels of authority and interfaces.
6.2.4 A common vocabulary along with key terminology. Personnel indoctrination
should include appropriate definitions.
6.2.5 Work assigned or contracted outside of the organizations should be
identified, along with any required management controls, such as
responsibilities and lines of communication.
6.2.6 Readiness reviews should be completed for all projects prior to initiation.
6.2.7 Responsibility and authority for the stoppage of unsafe or unsatisfactory
work should be assigned and clearly denoted for each task or project.

112 Chpt III, Sect II

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6.3 Personnel Training and Qualification

6.3.1 Personnel performing work should be capable of performing their assigned
tasks. Qualification requirements should be established for specific job
categories. Training includes both education in principles and enhancement
of skills and practices.
6.3.2 Training should emphasize correct performance of work and provide an
understanding of the fundamentals of quality, safety and the importance of
“doing work right the first time.”
6.3.3 Training plans should address and stimulate professional development.
6.3.4 Personnel performing work that requires special skills or abilities should be
qualified prior to performing work. Qualification should require
demonstrated proficiency of each candidate.
6.3.5 The following job categories will have the noted minimum requirements:
[Link] The Program Manager shall have a minimum of a BS Degree in
Engineering or Technology, and four (4) years of electric vehicle
experience and/or four (4) years of Program Management
experience. A master’s degree may be considered as fulfilling the
requirements for one of those years of experience.
[Link] The Test Director shall have a minimum of a BS Degree in
Engineering or Technology, and four (4) years of electric vehicle
experience and/or four (4) years of Project Management
experience. A master’s degree may be considered as fulfilling the
requirements for one of those years of experience.
[Link] The Test Manager shall have a minimum of a BS Degree in
Engineering or Technology, two (2) years of Program/Project
Management experience and two (2) years of test experience in a
professional commercial industrial or government setting. A
Master’s degree may be considered as fulfilling the requirements
for one of those years of experience.
[Link] The Test Engineer should have a BS Degree in Engineering or
Technology and two (2) years of test experience in a professional
commercial industrial or government setting.
6.3.6 Certification of personnel shall be completed in accordance with the
requirements of the specific test procedure or program.

6.4 Quality Improvement

6.4.1 Processes should be established and implemented with the objective of
preventing problems and improving quality. These processes can include peer
review, design review, probabilistic risk assessment, etc.
6.4.2 Information collected during various processes should be analyzed for trend
identification.

113 Chpt III, Sect II

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6.4.3 All individuals covered by this policy should foster a no-fault attitude.
6.4.4 Non-conforming items and processes should be controlled to prevent their
inadvertent use.

6.5 Documents and Records

6.5.1 Documents
[Link] Processes should be established and implemented to control the
preparation, review, approval, issuance, and revision of
documents.
[Link] The scope of document control should be defined, and should
include procedures, test results, procurement documents, audit
reports, findings, vendor supplied data, etc.
[Link] The same organizations and levels that reviewed and approved
the original document should review revisions to controlled
documents.
[Link] Controlled documents should be distributed to and used by
personnel performing the work.
[Link] Record copies should be marked as such, and maintained for a
specified period of time.
6.5.2 Records
[Link] A process should be established to ensure that sufficient records
are specified, prepared, reviewed, approved and maintained to
accurately reflect completed work.
[Link] A process should be established which specifies the minimum
period for storage, as well as the requirements for storage.

6.6 Work Processes

6.6.1 Work
[Link] Personnel performing work are responsible for the quality of that
work.
[Link] Review personnel are responsible for ensuring that personnel
performing work are adequately trained and certified to complete
the assigned work.
[Link] Work should be planned and accomplished in a controlled
manner using approved standards and/or procedures.
[Link] Work-related instructions and procedures should be developed,
verified, validated and approved by technically competent
personnel.

114 Chpt III, Sect II

 AVTA-PHQP01

6.6.2 Calibration and Maintenance of Monitoring and Data Collection Equipment

[Link] A process should be established or verified to be established
which controls the calibration maintenance and use of measuring
and test equipment used for monitoring and data collection.
[Link] This equipment should be suitable for the use intended, and
should have calibration certifications and standards traceable to
national standards, where possible.

6.7 Design
6.7.1 A process should be established for the design process which uses sound
engineering/scientific principles and appropriate standards.
6.7.2 Changes to final design, whether prior to installation or use or not, should
have the same restrictions and review processes that the original design was
subjected to.
6.7.3 Verification processes should be consistent for all design levels, and should
be accomplished by individuals technically competent in the field the design
is in.
6.7.4 Testing to verify or validate the design or protocol should be accomplished
prior to a production use of the design or protocol.

6.8 Procurement
6.8.1 A process should be established and implemented to ensure that purchased
items and services meet the established requirements and perform as
expected.
6.8.2 Prospective suppliers should be evaluated to ensure only qualified suppliers
are selected.
6.8.3 Actual performance of items should be compared with original performance
criteria.
6.8.4 The quality of purchased items and services should be verified at intervals
consistent with the item’s complexity, service conditions and risk.

6.9 Inspection and Acceptance Testing

6.9.1 Inspection
[Link] A process should be established and implemented to specify
when and what type of inspections are required.
[Link] Inspections may be implemented by or for the organization
performing the work to be inspected. Personnel shall not inspect
their own work.

115 Chpt III, Sect II

 AVTA-PHQP01

[Link] When acceptance criteria is not met, deficiencies should be

resolved and re-inspection occur, as required.
6.9.2 Acceptance Testing
[Link] Testing processes should be established and implemented to
demonstrate that items and processes will perform as intended.
[Link] Testing may be implemented by or for the organizations
performing the work to be tested.
[Link] Item and process test requirements and acceptance criteria should
be provided by or approved by the organization responsible for
the activity.
[Link] Test procedures should be developed and include the following:
[Link].1 Instructions and prerequisites to perform the test
[Link].2 Completeness and accuracy of data
[Link].3 Use of test equipment
[Link].4 Acceptance criteria (if applicable)
[Link].5 Inspection points, as required
[Link].6 Test article configuration.
[Link] Retesting of items or processes to determine that they meet
acceptance criteria is required after deficiencies have been
corrected.
6.9.3 Measuring and Test Equipment
[Link] A process should be established and implemented or verified to
be present which controls the calibration, maintenance,
accountability and use of equipment used to control any process
or data collection system.
[Link] The types of equipment to be used, such as instruments, tools,
gages, reference and transfer standards, and non-destructive
examination equipment, should be defined.
[Link] Measuring and test equipment (M&TE) should be calibrated at
specified intervals on the basis of the item’s required accuracy,
intended use, frequency of use, stability characteristics, and other
conditions affecting it’s performance.
[Link] M&TE should be labeled, tagged or otherwise controlled to
indicate its calibration status and ensure its traceability to
calibration test data.
[Link] M&TE should be calibrated against standards having an accuracy
that will ensure that equipment being calibrated will be within
required tolerances. If nationally recognized standards exist,
calibration standards should be traceable to such standards.

116 Chpt III, Sect II

 AVTA-PHQP01

[Link] M&TE found out-of-calibration or out-of-tolerance should not be

used until it is successfully recalibrated. The acceptability of
items inspected, tested or measured with an out-of-calibration
device should be determined.

6.10 Management Assessment

6.10.1 Planned and periodic management assessments should be completed as a way
to improve quality.
6.10.2 Results of management assessments should be documented.
Recommendations resulting from the assessments should be promptly acted
upon, and the results of those actions noted as appropriate.
6.10.3 This process should involve all levels of management.

6.11 Independent Assessment

6.11.1 A process of planned periodic independent assessments should be established
as required, and should focus on improving items and processes by
emphasizing achievement of quality.
6.11.2 Personnel performing independent assessments should act in a management
advisory function, with responsibilities including monitoring of work
performance, potential problems, problem precursors and opportunities for
improvement.
6.11.3 Personnel performing independent assessments should be technically
knowledgeable and focus on improving the quality of the processes being
evaluated.
6.11.4 Personnel performing independent assessments should not have direct
responsibilities in the area they are assessing.
6.11.5 These assessments should be conducted using criteria that describe
acceptable work performance and promote improvement.
6.11.6 The management having responsibility in the area assessed should resolve
assessment results. Follow-up review of the deficient areas should be initiated
as necessary.
6.11.7 Responses to assessments should include the following, as applicable:
[Link] Action to correct the deficiency
[Link] Cause identification
[Link] Actions taken to prevent recurrence
[Link] Lessons learned
[Link] Actions to be taken for improvement.

117 Chpt III, Sect II

 Chapter IV: Test Procedures
Section I: PHEV Baseline Test Sequence
Section II: AVTA-PHTP01 – Road Load Measurement Using
Onboard Anemometry and Coastdown
Techniques
Section III: AVTA-PHTP02 – Plug-in Hybrid Electric Vehicle
Acceleration, Gradeability, and Deceleration Test
Section IV: AVTA-PHTP03 – Plug-in Hybrid Electric Vehicle
Acceleration, Gradeability, and Deceleration Test
Section V: AVTA-PHTP04 – Plug-in Hybrid Electric Vehicle
RESS Only Mode Constant Speed Range Test
Section VI: AVTA-PHTP05 – Plug-in Hybrid Electric Vehicle
Rough Road Course Test
Section VII: AVTA-PHTP06 – Braking Test
Section VIII: AVTA-PHTP07 – Implementation of SAE J1634
May1993 - “Electric Vehicle Energy Consumption
and Range Test Procedure”
Section IX: AVTA-PHTP08 – Rechargeable Energy Storage
System (RESS) charging
Section X: AVTA-PHTP09 – Reserved for Future Use
Section XI: AVTA-PHTP10 – Measurement and Evaluation of
Plug-in Hybrid Electric Vehicle RESS Charger
Performance
Section XII: AVTA-PHTP11 – Vehicle Verification
Section XIII: AVTA-PHTP12 – Evaluation of Plug-in Hybrid
Vehicle Energy Management System(s) [EMS]
Section XIV: AVTA-PHTP13 – Reserved for Future Use
Section XV: AVTA-PHTP14 – Evaluation of Plug-in Hybrid
Electric Vehicle Battery Packs

118 Chpt IV, TOC

 PHEV America Baseline Test Sequence

Section I: PHEV Baseline Test Sequence

119 Chpt IV, Sect I

 PHEV America Baseline Test Sequence

1 PHEV PERFORMANCE TEST PROCEDURE SEQUENCE

The following test sequence shall be used for conduct of PHEV Baseline Performance
Testing. This sequence of testing confirms vehicle conformance with all "shall" statements
contained in the PHEV Vehicle Specifications. Additionally, submittal of all information
required by the PHEV Vehicle Specifications is verified and selected "should" statements
are verified.

1.1 Procedure AVTA-PHAC06, Receipt Inspection

Conduct of this test procedure accomplishes the following test requirements.
• Should data submittal verification
• Should data submittal accuracy verification by inspection
• Should data submittal accuracy verification by vehicle measurement
• Testing for selected should requirements not verified by specific Performance
Test Procedures (AVTA-PHTPXXX)
• Determination of vehicle operating modes and selection of operating modes for
testing

1.2 Procedure AVTA-PHTP11, Vehicle Verification (Initial Phase)

Conduct of this test procedure is accomplished in two phases. The initial phase
accomplishes the following test requirements.
• Shall data submittal verification
• Shall data submittal accuracy verification by inspection
• Testing for shall requirements not verified by specific Performance Test
Procedures
The final phase of this procedure is conducted in Section 1.9.

NOTE:
Portions of the following procedure are applicable only to
vehicles tested in RESS Only mode.

1.3 Procedure AVTA-PHTP04, PHEV RESS Only Mode Constant Speed Range Test
Conduct of this test procedure accomplishes the following test requirements.
• Determination of RESS Only mode range
• In conjunction with procedure AVTA-PHTP08, determination of charging time
• Determination of durability at maximum speed
• Speedometer accuracy should requirement verification
• Odometer accuracy shall requirement verification

120 Chpt IV Sect I

 PHEV America Baseline Test Sequence

• SOC meter accuracy should requirement verification

• In conjunction with procedure AVTA-PHTP12, maximum RESS discharge shall
requirement and RESS durability data collection
• Depth of discharge calibrations for subsequent RESS Only mode tests

NOTE:
Portions of the following procedure are applicable only to
vehicles tested in RESS Only mode.

1.4 Procedure AVTA-PHTP05, PHEV Rough Road Course Test

Conduct of this test procedure accomplishes the following test requirements.
• Rough road completion shall requirement verification
• Rough road impairment should requirement
• RESS leakage current to chassis shall requirement data collection
• Charger leakage current to ground shall requirement data collection for vehicles
capable of grid connection
• In conjunction with procedure AVTA-PHTP08, charging efficiency data
collection

NOTE:
For vehicles tested in RESS Only mode, the following testing
is performed in RESS Only mode at RESS Initial SOCs of
100% and 50%.

1.5 Procedure AVTA-PHTP02, PHEV Acceleration, Gradeability and Deceleration Test

Conduct of this test procedure accomplishes the following test requirements.
• Acceleration should requirement verification
• Gradeability should requirement verification

NOTE:
The following procedure is conducted for all vehicles that will be
tested using procedure AVTA-PHTP03.

1.6 Procedure AVTA-PHTP01, Road Load Measurement Using Onboard Anemometry

and Coastdown Techniques
Conduct of this test procedure accomplishes the following requirements.
• Develop road load coefficients for use in procedure AVTA-PHTP03
dynamometer testing

121 Chpt IV Sect I

 PHEV America Baseline Test Sequence

NOTE:
The following procedure is conducted for all vehicles in the
Normal Operation mode.

1.7 Procedure AVTA-PHTP06, Braking Test

Conduct of this test procedure accomplishes the following test requirements.
• Regenerative braking interaction shall requirement verification
• Braking distance data collection

1.8 Procedure AVTA-PHTP10, PHEV RESS Charger Performance

Conduct of this test procedure accomplishes the following test requirements.
• Maximum RESS discharge shall requirement data collection

NOTE:
This testing requires a separate RESS discharge to verify
repeatability of the discharge limiter data collected by procedure
AVTA-PHTP04 using AVTA-PHTP11.

• Charge time shall requirement verification

• Automatic termination shall requirement verification
• Charger input voltage shall requirement verification
• Charger operating data collection
• Charger ground leakage current data collection
• Charging efficiency data collection and calculation

1.9 Procedure AVTA-PHTP11, Vehicle Verification (Final Phase)

Conduct of this test procedure accomplishes the following test requirements.
• Verification of maximum depth of discharge limit repeatability (using procedure
AVTA-PHTP04) for vehicles capable of grid connection or operation in RESS
Only mode
• Repair time shall requirement verification (using Non-Conformance Reports)
• Charger leakage current verification for vehicles capable of grid connection

NOTE:
Vehicles operable only in the Normal Operation mode shall be
tested in accordance Section 1.10 (AVTA-PHTP03), below.
Vehicle capable of operation in RESS Only mode shall
additionally be tested in accordance with Section 1.11 (AVTA­
PHTP07), below.

122 Chpt IV Sect I

 PHEV America Baseline Test Sequence

1.10 Procedure AVTA-PHTP03, SAE J1711 Dynamometer Testing

Conduct of this test procedure accomplishes the following requirements for vehicles
tested in the Normal Operation mode.
• Determine hybrid vehicle fuel efficiency without air conditioning loads
• Determine hybrid vehicle fuel efficiency with air conditioning loads
This procedure is conducted over five days with tests accomplished each day as
follows.
Day 1
• Vehicle setup
• Coastdowns with 2 HWFEDS
• 2 US06 (charge depleting)
• 2 US06 (charge sustaining)
Day 2
• HWFEDS Cold Start (charge depleting)
• HWFEDS Hot Start (charge depleting)
• 2 HWFEDS (charge depleting)
• 2 HWFEDS (charge sustaining)
Day 3
• UDDS Cold Start (charge depleting)
• UDDS Hot Start
• 2 UDDS (charge depleting)
• 2 UDDS (charge sustaining)
Day 4
• UDDS Cold Start (charge sustaining)
• UDDS Hot Start (charge sustaining)
• 2 HWFEDS (charge sustaining)
• 2 US06 (charge sustaining)
Day 5
• UDDS Air Conditioning (A/C) Cold Start (charge depleting)
• UDDS A/C Hot Start (charge depleting)
• 2 HWFEDS A/C (charge depleting)
• 2 UDDS A/C (charge sustaining)
• 2 HWFEDS A/C (charge sustaining)

1.11 Procedure AVTA-PHTP07, SAE J1634 Dynamometer Testing

Conduct of this test procedure accomplishes the following requirements for vehicles
tested in the RESS Only mode.
• Determine RESS Only mode drive cycle energy efficiency

123 Chpt IV Sect I

 PHEV America Baseline Test Sequence

• Determine RESS Only mode drive cycle range

1.12 Procedure AVTA-PHTP14, Evaluation of PHEV Battery Packs

Conduct of this test procedure accomplishes the following requirements.
• Determine C1 battery capacity
• Determine battery pulse power capability

2 PHEV CONDUCT OF RESS CHARGING PROCEDURES

During conduct of testing, the vehicle RESS shall be charged using the following
procedures.

NOTE:
The following procedure provides guidance for determination of
100% RESS Initial SOC for all vehicles, regardless of operating
mode capabilities.

2.1 Procedure AVTA-PHTP08, RESS Charging

Conduct of this test procedure accomplishes the following test requirements.
• Provides guidance for RESS charging activities using Level I or II off-board or
onboard charging
• Determination of RESS 100% SOC
• Determination of charging efficiency
NOTE:
The following procedure provides guidance for determination of
PHEV energy management systems for all vehicles, regardless of
operating mode capabilities.

2.2 Procedure AVTA-PHTP12, Evaluation of PHEV Energy Management System

Conduct of this test procedure accomplishes the following test requirements.
• Evaluation of the effectiveness of the PHEV energy management system
throughout the conduct of testing.

124 Chpt IV Sect I

 AVTA-PHTP01

Section II: AVTA-PHTP01 – Road Load Measurement Using

Onboard Anemometry and Coastdown
Techniques

125 Chpt IV, Sect II

 AVTA-PHTP01

TABLE OF CONTENTS

1 Objective ...........................................................................................................................................................127

2 Purpose..............................................................................................................................................................127

3 Documentation..................................................................................................................................................127

4 Initial Conditions and Prerequisites ...............................................................................................................127

5 Test Activity Requirements .............................................................................................................................130

6 Data Reduction and Acceptability Criteria....................................................................................................132

APPENDICES

Appendix A – PHEV Road Load Test Data Sheet ................................................................................................133

Appendix B – PHEV Metrology Setup Sheet ........................................................................................................139

126 Chpt IV, Sect II

 AVTA-PHTP01

1 Objective
The objective of this procedure is to provide methods for obtaining road load coefficients
of vehicles evaluated by the U.S. Department of Energy Advanced Vehicle Testing
Activity (AVTA). Testing is conducted in accordance with recommended practice SAE
J2263, "Road Load Measurement Using Onboard Anemometry and Coastdown
Techniques.” These methods are not meant to supersede those of the testing facility, those
specifically addressed by SAE Test Standards, nor of any regulatory agency, which may
have or exercise control over the covered activities.

2 Purpose
The purpose of this procedure is to identify acceptable methods for the implementation of
the test requirements of SAE J2263, and to provide a common format for the collection
and retention of data for further use with procedure AVTA-PHTP07. This procedure
collects and retains this data to complete testing as specified in the PHEV Vehicle
Specification.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read, and readily reproducible. This documentation contains enough information to "stand
alone"; in other words, it is self-contained to the extent that all individuals qualified to
review it could reasonably be expected to reach a common conclusion, without the need to
review additional documentation. If review of outside documents is required, then it is
reasonable to expect that all individuals would need to review those documents. Review
and approval of test documents shall be in accordance with procedure AVTA-PHAC04.
Close-out and storage of records during and following testing activities shall be completed
as described in procedure AVTA-PHAC01.

4 Initial Conditions and Prerequisites

Prior to conduct of any portion of the testing, the following initial conditions and
prerequisites should be met. Satisfactory completion of these items should be verified as
complete and recorded on the PHEV Road Load Test Data Sheet (Appendix A).

4.1 Personnel conducting testing under this procedure shall be familiar with the
requirements of this procedure, shall be trained in accordance with the requirements
of procedure AVTA-PHAC05, and be certified by the Program Manager or the Test
Manager prior to commencing any testing activities.

4.2 Tests should be conducted at ambient temperatures between 32°F (0°C) and 100°F
(38°C).

4.3 Tests shall not be run during foggy conditions.

127 Chpt IV, Sect II

 AVTA-PHTP01

4.4 Tests shall not be conducted when wind speeds average more than 10 mph (16 km/h)
or when peak wind speeds are more than 12.3 mph (20 km/h). The average of the
component of the wind velocity parallel to the test road shall not exceed 5 mph (8
km/h). Tests should always be conducted during periods of minimum wind velocity.

4.5 Roads shall be dry, clean, smooth, and must not exceed 0.5% grade. In addition, the
grade should be constant and the road should be straight since variations in grade or
straightness can significantly affect results. [The road surface should be concrete or
rolled asphalt (or equivalent) in good condition since rough roads can significantly
affect rolling resistance.]

4.6 The range of speeds over which the vehicle is coasted should be as wide as possible
considering the length of the straightaway. The speed interval shall include 65 mph
(80 km/h) and should include the range of 80-5 mph (128 km/h to 8 km/h)

4.7 Vehicles should have accumulated a minimum of 300 miles (500 km) prior to this
testing. Actual mileage shall be recorded prior to starting testing.

4.8 Supplier's recommended tires shall be used. Tires should have accumulated a
minimum of 100 miles (160 km) and shall have at least 75% of the original tread
depth remaining. All tire break-ins shall be performed on the test vehicle. Tread
depth will be recorded in 1/32 inch increments prior to start of test.

4.9 Vehicle tires shall be inflated to the Supplier's recommended cold inflation pressure
as specified on the tire placard, corrected for the difference between ambient
temperature and tire temperature. The actual inflation pressure and preparation area
temperature will be recorded in Appendix A. [Tire pressures will be increased 1 psi
for each 13°F, the preparation area is higher than the test area (or 1 kPa for each
1°C).]

NOTE:
Tire sizes and inflation pressures shall be in accordance with the
requirements of the placard. At no time shall the tire’s cold
inflation pressure exceed the maximum pressure imprinted upon
the tire’s sidewall.

4.10 Instrumentation
4.10.1 All instrumentation used during testing shall be calibrated. Information for all
instrumentation used and their calibration dates shall be recorded on the
Metrology Setup Sheet(s) contained in Appendix B.
4.10.2 All instrumentation shall have the accuracies and resolutions noted. Unless
specifically accepted, at a minimum the following instrumentation shall be
installed and employed during the testing:

128 Chpt IV, Sect II

 AVTA-PHTP01

[Link] Speed-time
Accuracy ± 0.1% of total coast down time
Resolution of 0.1s
Accuracy of ± 0.25 mph (0.4 km/h)
Resolution of 0.1 mph (0.2 km/h)
[Link] Temperature
The temperature indicating devices must have a resolution of 2°F
(or 1°C) and an accuracy of ± 2°F (or ± 1°C). The sensing
element shall be shielded from radiant heat sources.
[Link] Atmospheric Pressure
A barometer with an accuracy of ± 0.2 inches Hg or ± 0.7 kPa is
necessary.
[Link] Wind
Wind measurements should permit the determination of average
longitudinal and cross wind components to within ± 1 mph (±1.6
km/h).
[Link] Vehicle weight
Accuracy requirement is ± 10 lb (± 5 kg) per axle
[Link] Tire Pressure
Accuracy requirement is ± 0.5 psi (± 4 kPa).

4.11 Upon receipt of the vehicle for coast down testing, it should be "checked in.” The
following items shall be compared to Supplier's recommendations prior to the test:
4.11.1 Tire type, size, and cold inflation pressure as specified on the tire placard
4.11.2 Wheel size, conditions, and presence of wheel covers

4.12 The speed-time measuring device and other necessary equipment must be installed
so that they do not hinder vehicle operation or alter the operating characteristics of
the vehicle. Mounting shall be accomplished so as to not interfere with the tow
vehicle (nominally at the rear of the vehicle).

4.13 Vehicles shall be tested at delivered curb weight plus 300 pounds.

NOTE:
This is a deviation from SAE Standard J2263.

129 Chpt IV, Sect II

 AVTA-PHTP01

4.14 During the coast down portion of the test, lane changes shall be avoided. If a lane
change occurs, it should be achieved over at least one-half mile, and should be noted
in the comments section of the test record.

4.15 If the vehicle is equipped with regenerative braking, it should be disengaged from
service for the duration of the testing. The manner in which it is disengaged should
be noted in Appendix A.

4.16 All protocols, procedures and attendant documentation required to conduct this
testing shall be completed, approved and issued prior to commencing the testing it
addresses.

5 Test Activity Requirements

Activities necessary to complete the test are identified in the following sections. All items
should be completed, whether they are required by J2263 or not. Any section which cannot
be completed should be annotated as required by procedure AVTA-PHAC02, along with
the appropriate justification, in Appendix A. Data collection may be via a Data Acquisition
System (DAS), in lieu of hand-written entries. Such data shall be transcribed in accordance
with the requirements of procedures AVTA-PHAC02.

NOTE:
A minimum of twelve runs shall be completed in alternating
directions. The runs shall be paired in order to reduce error during
data reduction. A pair consists of two consecutive runs in opposite
directions.

NOTE:
Unless otherwise noted, the following steps may be completed in
any order.

5.1 Record the mileage from the odometer in Appendix A.

5.2 Verify the vehicle windows are closed. Record in Appendix A.

5.3 Verify that regenerative braking has been disengaged. This may require special
service settings for the vehicle controller. Note the method by which this was done
and record in Appendix A.

NOTE:
If the vehicle’s regenerative braking cannot be disengaged, obtain
the concurrence of the Program or Test Manager prior to
continuing. This shall be noted as a Test Exception.

130 Chpt IV, Sect II

 AVTA-PHTP01

5.4 Verify that the vehicle's drive train has been disengaged from the drive axle during
the coast down. Note method of disengagement (clutch, electrical or mechanical
neutral, etc.). Record in Appendix A.

NOTE:
If the drive train cannot be disengaged from the drive axle, obtain
the concurrence of the Program or Test Manager prior to
continuing. This shall be noted as a Test Exception.

5.5 Verify vehicle tires are inflated to the Supplier's recommended cold inflation
pressure as specified on the tire placard, corrected for the difference between
ambient temperature and tire temperature. Record the actual inflation pressure and
preparation area temperature in Appendix A. [Tire pressures shall be increased 1 psi
for each 13°F if the preparation area is higher than the test area (or 1 kPa for each
Celsius degree).]

CAUTION:
Tire sizes and inflation pressures shall be in accordance with the
requirements of the placard. At no time shall the tire’s inflation
pressure exceed the maximum pressure imprinted upon that tire’s
sidewall.

5.6 Verify and record the speed that the DAS will be engaged at. This speed should be 5
mph (8 km/h) higher than the maximum desired coast down speed. At a minimum,
record the following data in Appendix A:
5.6.1 Sequence (run) number/computer file number of each run
5.6.2 Direction of each run
5.6.3 Vehicle speed as a function of time
5.6.4 Total wind, and either the wind direction or the cross-wind component of the
total wind. Wind quantities shall be recorded, screened for gusts exceeding
the ambient condition limits in section 4.4, and averaged.

5.7 At the start of each run, accelerate the test vehicle to 80 mph (128 km/h) or a speed
of 5 mph (8 km/h) above the high point of the coast down speed range. Record in
Appendix A.

5.8 Each run may be considered complete after the vehicle has decelerated to a speed of
less than 5 mph (8 km/h). If the vehicle’s speed will not decrease to less than this
point, contact the Test Manager for assistance.

131 Chpt IV, Sect II

 AVTA-PHTP01

5.9 After completion of the test runs, collect the following data:
5.9.1 The ambient temperature at the end of the test
5.9.2 Verify the vehicle weight package is still in place, and equal to 300 pounds
including the driver and instrumentation.

5.10 After completing the final run, record the odometer reading in Appendix A.

5.11 Calculate the vehicle’s deceleration function over the coastdown by choosing a
minimum of three different test run pairs.

5.12 Multiply the deceleration function by the vehicle test mass (including the additional
300 pounds) to obtain the force over the vehicle coastdown.

5.13 Graph the vehicle force vs. velocity and apply a quadratic curve fit to the data.
Record the three coefficients from the quadratic equation, as they will be used for
modeling force vs. velocity during fuel efficiency dynamometer testing AVTA­
PHTP03.

6 Data Reduction and Acceptability Criteria

6.1 The requirements for data reduction are specifically addressed in Section 10 of SAE
J2263. Refer to this standard when clarification utilizing these techniques is required.

6.2 Upon calculating the coastdown coefficients, obtain the EPA coefficients (if
available) for this make and model of vehicle and graph the EPA coefficients and the
calculated coefficients from the coastdown together. If an excessive amount of
deviation is present, an inquiry as to the cause of this deviation shall be undertaken
and tests shall be re-run, if necessary.

6.3 The acceptability requirements presented in Section 10.4 of SAE J2263 shall be
used.

6.4 Distribution, retention and destruction of all test documents shall be in accordance
with the requirements identified in procedure AVTA-PHAC01.

132 Chpt IV, Sect II

 AVTA-PHTP01

Appendix A – PHEV Road Load Test Data Sheet

(Page 1 of 6)

VIN Number: ____________________

Project No.: Test Date(s):
Data File Name:
Test Driver:
(Initials) (Date)

Test Engineer:
(Initials) (Date)

Vehicle Setup
VEHICLE WEIGHTS AS TESTED WITH DRIVER & INSTRUMENTATION
(Curb weight plus 300 pounds)
Left Front: Right Front: Total Front: Percent Front: %
(lbs or kg) (lbs or kg) (lbs or kg)

Left Rear: Right Rear: Total Rear: Percent Rear: %

(lbs or kg) (lbs or kg) (lbs or kg)

Total Weight:
(lbs or kg)

Preparation Area Temperature:

(°F or °C)

Left Front Right Front

Pressure: Tread Depth: Pressure: Tread Depth:
(psi or kPa) (>75% of original depth (in or mm) (psi or kPa) (>75% of original depth (in or mm)

Left Rear Right Rear

Pressure: Tread Depth: Pressure: Tread Depth:
(psi or kPa) (>75% of original depth (in or mm) (psi or kPa) (>75% of original depth (in or mm)

133 Chpt IV, Sect II

 AVTA-PHTP01

APPENDIX A – PHEV Road Load Test Data Sheet

(Page 2 of 6)

VIN Number: ____________________ Track/Weather Conditions

Test Track Location: Track Grade: %
<( 0.5%)

Ambient Temperature (initial): Ambient Temperature (final):

(30-90°F or -1-32°C) (30-90°F or -1-32°C)

Track Temperature (initial): Track Temperature (final):

(°F or °C) (°F or °C)

Wind Velocity (initial): Wind Velocity (final):

(Average: <10 mph or 16 km/h) (Average: <10 mph or 16 km/h)

Cross Wind Component: Cross Wind Component:

(Average: <5 mph or 8 km/h) (Average: <5 mph or 8 km/h)

Wind Direction (initial): ° Wind Direction (completion): °

Barometric Pressure (initial): Barometric Pressure (completion):
(nigh) (nigh)

Test Data “Coast Down Characteristics from 75-5 mph (120-8 km/h)”
Odometer (initial): Odometer (final):
(miles or kilometers) (miles or kilometers)

Vehicle windows closed: (Yes) (No)

Regenerative breaking disabled: (Yes) (No)

Drive train is disengaged: (Yes) (No)

Sequence No: 1 File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: 2 File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: 3 File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: 4 File No.: Time: Direction of Travel:

Comments (initials/date):

134 Chpt IV, Sect II

 AVTA-PHTP01

APPENDIX A – PHEV Road Load Test Data Sheet

(Page 3 of 6)

VIN Number: _________________________________ Test Data (continued)

Sequence No: 5 File No.: Time: Direction of Travel:
Comments (initials/date):

Sequence No: 6 File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: 7 File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: 8 File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: 9 File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: 10 File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: 11 File No.: Time: Direction of Travel:

Comments (initials/date):

135 Chpt IV, Sect II

 AVTA-PHTP01

Appendix A – PHEV Road Load Test Data Sheet

(Page 4 of 6)

VIN Number: _________________________ Test Data (continued)

Sequence No: 12 File No.: Time: Direction of Travel:
Comments (initials/date):

Sequence No: 13 File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: 14 File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: 15 File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: 16 File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: 17 File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: 18 File No.: Time: Direction of Travel:

Comments (initials/date):

136 Chpt IV, Sect II

 AVTA-PHTP01

Appendix A – PHEV Road Load Test Data Sheet

(Page 5 of 6)

VIN Number: ____________________ Test Data (continued)

Sequence No: 19 File No.: Time: Direction of Travel:
Comments (initials/date):

Sequence No: 20 File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: File No.: Time: Direction of Travel:

Comments (initials/date):

Sequence No: File No.: Time: Direction of Travel:

Comments (initials/date):

137 Chpt IV, Sect II

 AVTA-PHTP01

Appendix A – PHEV Road Load Test Data Sheet

(Page 6 of 6)

VIN Number: ____________________

General Comments (initials/date):
__________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

Completed By:
_____________________________________________________________________________
(Printed Name) (Signature ) (Date)

Reviewed By (QA):
___________________________________________________________________________
(Printed Name) (Signature) (Date)

Approved By:
_____________________________________________________________________________
(Printed Name) (Signature) (Date)

138 Chpt IV, Sect II

 AVTA-PHTP01

Appendix B – PHEV Metrology Setup Sheet

(Page 1 of 1)

VIN Number: ___________________

Instrument/Device: Calibration Due Date: Initials / Date:
Fifth Wheel S/N:
Fifth Wheel Calibrator S/N:
DAS S/N:
DAS Set-up Sheet S/N:
kWh Meter S/N:
Shunt S/N:
Tire Pressure Gauge S/N:
Misc:
Misc:
Misc:
Misc:
Comments (initials/date):

Completed By:
_____________________________________________________________________________
(Printed Name) (Signature ) (Date)

Reviewed By (QA):
___________________________________________________________________________
(Printed Name) (Signature) (Date)

Approved By:
_____________________________________________________________________________
(Printed Name) (Signature) (Date)

139 Chpt IV Sect II

 AVTA-PHTP02

Section III: AVTA-PHTP02 – Plug-in Hybrid Electric Vehicle

Acceleration, Gradeability, and Deceleration
Test

140 Chpt IV, Sect III

 AVTA-PHTP02

TABLE OF CONTENTS

1 Objective ...........................................................................................................................................................142

2 Purpose..............................................................................................................................................................142

3 Documentation..................................................................................................................................................142

4 Initial Conditions and Prerequisites ...............................................................................................................142

5 Test Activity Requirements .............................................................................................................................145

5.1 Acceleration and Maximum Speed Test ........................................................................................146

5.2 Gradeability Limit.........................................................................................................................147
5.3 Gradeability at Speed....................................................................................................................148
5.3.1 3% Grade..............................................................................................................................................148
5.3.2 6% Grade..............................................................................................................................................149

APPENDICES

Appendix A – PHEV Acceleration Test, Test Data Sheet ....................................................................................150

Appendix B – PHEV Gradeability Limit, Test Data Sheet ..................................................................................155

Appendix C – PHEV Gradeability at Speed Test Data Sheet (Analytical Method)...........................................157

Appendix D – PHEV Metrology Setup Sheet ........................................................................................................158

141 Chpt IV, Sect III

 AVTA-PHTP02

1 Objective
The objective of this procedure is to provide methods for the testing of acceleration and
gradeability of plug-in hybrid electric vehicles (PHEV) evaluated by the U.S. Department
of Energy Advanced Vehicle Testing Activity (AVTA). Testing is conducted in
accordance with SAE J1666, "Electric Vehicle Acceleration, Gradeability and Deceleration
Test Procedure,” as the methods can be applied to PHEVs. Vehicles are tested in Normal
Operation mode and, where applicable, in RESS Only mode. These methods are not meant
to supersede those of the testing facility, those specifically addressed by SAE Test
Standards, nor of any regulatory agency, which may have or exercise control over the
covered activities.

2 Purpose
The purpose of this procedure is to identify acceptable methods for the implementation of
the test requirements of SAE Standard J1666. The SAE-J1666 Recommended Practice
establishes uniform procedures for testing electric battery-powered vehicles as a total
system rather than its individual subsystems. This procedure collects and retains test data
as specified in the PHEV Vehicle Specification.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read and readily reproducible. This documentation shall contain enough information to
"stand alone”; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion, without the need to review
additional documentation. Review and approval of test documentation shall be in
accordance with procedure AVTA-PHAC04. Storage and retention of records during and
following testing activities shall be completed as described in procedure AVTA-PHAC01.

4 Initial Conditions and Prerequisites

Prior to conduct of any portion of the testing, the following initial conditions and
prerequisites shall be met. Satisfactory completion of these items should be verified as
complete and recorded on the PHEV Acceleration Test, Test Data Sheet (Appendix A).

4.1 Personnel conducting testing under this procedure shall be familiar with the
requirements of this procedure, shall be trained in accordance with the requirements
of procedure AVTA-PHAC05, and be certified by the Program Manager or the Test
Manager prior to commencing any testing activities.

4.2 PHEV Test Modes

Vehicles shall be tested in the Normal Operation mode. Vehicles capable of
operation in RESS Only mode shall also be tested in RESS Only mode. RESS initial
SOC for each test shall be as follows:

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4.2.1 Normal Operation mode, starting with the RESS at 100% SOC
4.2.2 Normal Operation mode, starting with the RESS at the SOC at which the
vehicle enters charge-sustaining mode
4.2.3 RESS Only mode, starting at 100% SOC
4.2.4 RESS Only mode, starting at 50% SOC

4.3 Road Testing

4.3.1 Road tests shall be performed on a road or test track, which is level to within
1%.
4.3.2 RESS temperatures at the beginning of the test shall be greater than 40˚F
(5˚C), shall be less than 120°F (49°C) and should be less than 100˚F (38°C).
4.3.3 Ambient temperature during road testing shall be within the range of 32°F
(0˚C) to 100°F (38°C).
4.3.4 The average wind speed at the test site during the test shall not exceed 10
mph (16 km/h). Wind gusts shall not exceed 12.3 mph (20 kph).

4.4 Vehicles shall be tested in its normal configuration with normal appendages (mirrors,
bumpers, hubcaps, etc.). Certain items (hub caps, etc.) may be removed where
necessary for safety on the dynamometer.

4.5 Vehicles shall be tested at curb weight plus 300 pounds. Consideration should be
given to how adding instrumentation will affect the test weight and balance of the
vehicle.

4.6 Supplier's recommended tires shall be used.

4.7 Normal Supplier's recommended lubricants shall be employed.

4.8 Accessories shall not be used during testing.

4.9 Rechargeable Energy Storage System (RESS) shall be charged in accordance with
procedure AVTA-PHTP08.

4.10 For testing of vehicles in a Normal Operation mode, the required initial RESS SOC
shall be established as follows:
4.10.1 For tests requiring an initial RESS SOC of 100%, the RESS shall be charged
to 100% SOC in accordance with procedure AVTA-PHTP08.
4.10.2 For tests requiring the initial RESS SOC be that SOC at which the vehicle
enters charge-sustaining mode, the required SOC shall be established in
accordance with procedure AVTA-PHTP08.

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4.11 For testing of vehicles in RESS Only mode, the required initial RESS SOC shall be
established as follows:
4.11.1 The RESS shall be charged to 100% SOC in accordance with procedure
AVTA-PHTP08.
4.11.2 The RESS capacity (mileage based) shall be obtained from the Constant
Speed Range Test completed as part of procedure AVTA-PHTP11, and in
accordance with procedure AVTA-PHTP04.
4.11.3 To achieve X% SOC, the RESS shall be discharged, by driving the vehicle on
a test track at a constant speed of 45 mph until Y% capacity, has been
removed from the RESS. [Where X+Y = 100% capacity]
4.11.4 Tests conducted with the RESS partially discharged at the test start should be
initiated no more than 10 minutes after the desired initial state-of-discharge is
reached.

4.12 For tests conducted in the RESS Only mode, testing required at an initial RESS SOC
of 100% shall be initiated with the RESS at >90%. Testing required at an initial
RESS SOC of 50% shall be initiated with the RESS at 50% ±10%.

4.13 The following data shall be collected during conduct of the various tests specified by
this procedure. Overall error in recording or indicating instruments shall not exceed
±2% of the maximum value of the variable being measured, unless otherwise noted.
Periodic calibration shall be performed and documented in accordance with
procedure AVTA-PHAC07, to ensure compliance with this requirement.
4.13.1 RESS voltage versus time
4.13.2 RESS current versus time
4.13.3 Vehicle speed versus time
4.13.4 Distance versus time
4.13.5 RESS temperature versus time
4.13.6 RESS power versus time.

4.14 Environmental conditions during the testing shall be recorded and include, at a
minimum:
4.14.1 Range of ambient temperature during the test
4.14.2 Range of wind velocity during the test
4.14.3 Range of wind direction during the test.

4.15 The running surface upon which the test is being conducted shall be noted.

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4.16 A description of the test route, road surface type and condition (SAE J688, "Truck
Ability Prediction Procedure") and lengths and grades of test route shall be recorded.

4.17 The date, starting time and ending time of the test shall be recorded.

4.18 All instrumentation used in the test shall be listed in Appendix D and attached to the
test data sheets/results and shall include the following information:
4.18.1 Manufacturer
4.18.2 Model number
4.18.3 Serial number
4.18.4 Next calibration date

4.19 Any deviation from the test procedure and the reason for the deviation shall be
recorded in accordance with procedure AVTA-PHAC02.

4.20 The speed-time measuring device and other necessary equipment shall be installed so
that they do not hinder vehicle operation or alter the operating characteristics of the
vehicle.

4.21 All documentation required to complete testing shall be completed, approved and
ready for issue prior to commencing the testing it addresses.

4.22 Complete or verify complete procedure AVTA-PHAC06 and AVTA-PHTP11 for the
vehicle being tested.

5 Test Activity Requirements

This section addresses all test types required to meet the stated purpose and objectives of
this procedure. To this end, it selectively implements portions of SAE J1666. For ease of
use and consistency of format with other Test Procedures, this section is divided into
subsections for each major test. Unless otherwise noted, each section may be completed
independent of all the other sections.

NOTE:
Activities necessary to complete the test are identified in the
following sections. All items shall be completed, whether they are
required by J1666 or not. Any section, which cannot be completed,
shall be so annotated along with the appropriate justification in
accordance with procedure AVTA-PHAC02, Appendix A.

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NOTE:
The following sections may be completed in any order. However,
the steps within each section shall be completed in the order
written. Deviations shall have the approval of the Program
Manager or Test Manager in accordance with procedure AVTA­
PHAC02.

NOTE:
Vehicle odometer readings shall be recorded within the appropriate
test appendices upon initiation and completion of testing.

5.1 Acceleration and Maximum Speed Test

The purpose of this section is to measure the vehicle acceleration and determine the
maximum speed the vehicle can achieve within one mile. This testing is to be
completed subject to the initial conditions and prerequisites stated in Section 4 of
this procedure. Testing shall be completed for each of the following operating
modes, as applicable:
5.1.1 Normal Operation mode starting with the RESS at 100% SOC
5.1.2 Normal Operation mode starting with the RESS at the SOC at which the
vehicle enters charge-sustaining mode
5.1.3 RESS Only mode, starting at 100% SOC
5.1.4 RESS Only mode starting at 50% SOC

NOTE:
Vehicles should have a minimum top speed of 90 mph with the
vehicle loaded to its design curb-weight plus 300 pounds in each of
the selectable modes of operation, as applicable.

NOTE:
Vehicles should have a 0-60 mph acceleration time of 13.5 seconds
or less with the vehicle loaded to its design curb-weight plus 300
pounds in each of the selectable modes of operation, as applicable.

NOTE:
A level grade, paved test route upon which the vehicle can be
safely accelerated to speeds near its peak speed shall be selected.
Note location in Appendix B.

5.1.5 Verify the RESS is at the required Initial SOC. Charge/discharge the RESS,
as required, to achieve an Initial SOC in accordance with Section 4.10

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(Normal Operation mode) or 4.11 and 4.12 (RESS Only mode). Record the %
SOC (in kilowatt-hours) and miles driven, if applicable, in Appendix B.
5.1.6 The vehicle shall be tested at curb weight plus 300 pounds, including the
weight of the driver.

NOTE:
The last 3000 feet of track length for this test shall be straightaway.

5.1.7 From a standing start, accelerate the vehicle at its maximum attainable
acceleration until the vehicle has traveled one mile or the vehicle has attained
100 mph. Note the speed achieved at one mile in Appendix B. If greater than
100 mph, note "Greater than 100 mph.”
5.1.8 Reverse the direction of travel on the test track.
5.1.9 Verify the RESS SOC is within limits for Initial SOC in accordance with
Section 4.10 (Normal Operation mode) or 4.11 and 4.12 (RESS Only mode).
The maximum time interval between completion of the acceleration portion
of one run and the beginning of the next successive run shall be minimized.
Record the elapsed time in Appendix B. If the data is being accumulated into
a Data Acquisition System (DAS), this time interval may be transcribed
subsequent to the data download.
5.1.10 From a standing start, accelerate the vehicle at its maximum attainable
acceleration until the vehicle has traveled one mile or the vehicle has attained
100 mph. Note the speed achieved at one mile in Appendix B. If greater than
100 mph, note "Greater than 100 mph.”
5.1.11 Repeat Sections 5.1.9 through 5.1.12 to obtain two additional sets of data
(one set of data comprises two acceleration runs, one in each direction).
5.1.12 Record the completion of this section in Appendix B.

5.2 Gradeability Limit

The purpose of this test is to determine the maximum grade on which a vehicle can
start and move forward. Because the discharge rates associated with the constant low
speed pulls are high, it is possible to obtain gradeability limits, which are lower than
what might actually be experienced by a vehicle operator. An alternative method is
to determine the tractive force from the data obtained during the maximum
acceleration tests using EQ.1. After calculating this force, implement this value into
EQ.2 to calculate the maximum gradeability.
5.2.1 Determine the maximum acceleration value from Section 5.1. This
acceleration should be the average of the maximum acceleration achieved in
all tests within an operating mode.
5.2.2 Obtain the vehicle weight used during Section 5.1 testing.
5.2.3 Using the formula EQ.1, determine the maximum force available:

147 Chpt IV, Sect III

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Force = (mass) x (acceleration) EQ.1

5.2.4 Insert this value into EQ.2, as value P:
P
(
Percent Gradeability Limit = 100 tan sin-1
W
) EQ.2
where: P = Tractive force, lb
W = Vehicle mass, lb
5.2.5 Solve for the Maximum Gradeability Limit.

NOTE:
Vehicles should be capable of starting and ascending a 25% grade
with the vehicle loaded to its design curb-weight plus 300 pounds
in each of the applicable modes of operation shown in Section 5.1.

5.3 Gradeability at Speed

This test determines the maximum speed achievable on roads with 3% and 6%
grades.
5.3.1 3% Grade
Using the speed-time data from the road tests of Section 5.1 for each
operational mode tested, the vehicle's acceleration characteristics shall be
plotted. Data for successive time intervals shall to be used to determine the
vehicles average acceleration during the nth time interval,
a = (Vn - Vn-1)/(tn - tn-1) EQ.3

when the vehicle has reached the average speed.

V = (Vn + Vn-1)/2 EQ.4

The data derived from these calculations shall be plotted as average

acceleration versus speed as a smooth curve through the calculated points. (If
the vehicle is equipped with a recording accelerometer, the acceleration curve
information shall be obtained directly.) The percent grade the vehicle is able
to traverse at any selected speed is now to be calculated using the following
relationship:
Percent Gradeability at Speed = 100 tan (sin-1 0.0455a) EQ.5
where:
a = Vehicle acceleration at the selected speed, mph/s
(The constant 0.0455 in this equation becomes 0.0283 when acceleration is in
units of km/h-s.)

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NOTE:
Vehicles should achieve a minimum sustainable speed of 55 mph
on a 3% grade, with the vehicle loaded to its design curb-weight
plus 300 pounds in each of the applicable modes of operation
shown in Section 5.1.

5.3.2 6% Grade
Using the speed-time data from the road tests of Section 5.1 for each
operational mode tested, the vehicle's acceleration characteristics shall be
plotted. Data for successive time intervals are to be used to determine the
vehicles average acceleration during the nth time interval,
a = (Vn - Vn-1)/ (tn - tn-1) EQ.3

when the vehicle has reached the average speed.

V = (Vn + Vn-1)/2 EQ.4

The data derived from these calculations shall be plotted as average

acceleration versus speed as a smooth curve through the calculated points. (If
the vehicle is equipped with a recording accelerometer, the acceleration curve
information shall be obtained directly.) The percent grade the vehicle is able
to traverse at any selected speed shall now be calculated using the following
relationship:
Percent Gradeability at Speed = 100 tan (sin-1 0.0455a) EQ.5
where:
a = Vehicle acceleration at the selected speed, mph/s

(The constant 0.0455 in this equation becomes 0.0283 when acceleration is in

units of km/h-s.)
5.3.3 Record test section completion in Appendix C.

NOTE:
Vehicles should achieve a minimum sustainable speed of 45 mph
on a 6% grade, with the vehicle loaded to its design curb-weight
plus 300 pounds in each of the applicable modes of operation
shown in Section 5.1.

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Appendix A – PHEV Acceleration Test, Test Data Sheet

(Page 1 of 5)

VIN Number: _______________________

Project Name: Test Date(s):
Data File Name:
Test Driver:
(Initials) (Date)

Test Engineer:
(Initials) (Date)

Vehicle Setup
VEHICLE WEIGHTS AS TESTED WITH DRIVER & INSTRUMENTATION
(Curb weight plus 300 pounds)
Left Front: Right Front: Total Front: Percent Front: %
(lbs or kg) (lbs or kg) (lbs or kg)

Left Rear: Right Rear: Total Rear: Percent Rear: %

(lbs or kg) (lbs or kg) (lbs or kg)

Total Weight:
(lbs or kg)

INSTALLED TIRES
(Placard or sidewall whichever is less)
Preparation Area Temperature:
°F( or °C)

Left Front Right Front

Pressure: Pressure:
(psi or kPa) (psi or kPa)

Left Rear Right Rear

Pressure: Pressure:
(psi or kPa) (psi or kPa)

Track/Weather Conditions
Test Track Location: Track Grade: %
(Within 1%)

Ambient Temperature (initial): Ambient Temperature (final):

(40-90°F or 5-32°C) (40-90°F or 5-32°C)

Track Temperature (initial): Track Temperature (final):

(°F or °C) (°F or °C)

Wind Velocity (initial): Wind Velocity (final):

(<10 mph or 16 km/h) (<10 mph or 16 km/h)

Wind Direction (initial): ° Wind Direction (final): °

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Appendix A – PHEV Acceleration Test, Test Data Sheet

(Page 2 of 5)

VIN Number: ________________________ Operating Mode: _____________________________

Sequence No: 1 File Name: Direction of Travel:
Time (initial): Time (final):
Odometer (initial): Odometer (final):
(miles or kilometers) (miles or kilometers)

State of Charge (initial): State of Charge (final):

(SOC; kWh; Ah) (SOC; kWh; Ah)

RESS Temp (initial): RESS Temp (final):

(°F or °C) (°F or °C)

Comments (initials/date):

Sequence No: 2 File Name: Direction of Travel:

Time (initial): Time (final):
Odometer (initial): Odometer (final):
(miles or kilometers) (miles or kilometers)

State of Charge (initial): State of Charge (final):

(SOC; kWh; Ah) (SOC; kWh; Ah)

RESS Temp (initial): RESS Temp (final):

(°F or °C) (°F or °C)

Comments (initials/date):

151 Chpt IV, Sect III

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Appendix A – PHEV Acceleration Test, Test Data Sheet

(Page 3 of 5)

VIN Number: ________________________ Operating Mode: _____________________________

Sequence No: 3 File Name: Direction of Travel:
Time (initial): Time (final):
Odometer (initial): Odometer (final):
(miles or kilometers) (miles or kilometers)

State of Charge (initial): State of Charge (final):

(SOC; kWh; Ah) (SOC; kWh; Ah)

RESS Temp (initial): RESS Temp (final):

(°F or °C) (°F or °C)

Comments (initials/date):

Sequence No: 4 File Name: Direction of Travel:

Time (initial): Time (final):
Odometer (initial): Odometer (final):
(miles or kilometers) (miles or kilometers)

State of Charge (initial): State of Charge (final):

(SOC; kWh; Ah) (SOC; kWh; Ah)

RESS Temp (initial): RESS Temp (final):

(°F or °C) (°F or °C)

Comments (initials/date):

152 Chpt IV, Sect III

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Appendix A – PHEV Acceleration Test, Test Data Sheet

(Page 4 of 5)

VIN Number: ________________________ Operating Mode: _____________________________

Sequence No: 5 File Name: Direction of Travel:
Time (initial): Time (final):
Odometer (initial): Odometer (final):
(miles or kilometers) (miles or kilometers)

State of Charge (initial): State of Charge (final):

(SOC; kWh; Ah) (SOC; kWh; Ah)

RESS Temp (initial): RESS Temp (final):

(°F or °C) (°F or °C)

Comments (initials/date):

Sequence No: 6 File Name: Direction of Travel:

Time (initial): Time (final):
Odometer (initial): Odometer (final):
(miles or kilometers) (miles or kilometers)

State of Charge (initial): State of Charge (final):

(SOC; kWh; Ah) (SOC; kWh; Ah)

RESS Temp (initial): RESS Temp (final):

(°F or °C) (°F or °C)

Comments (initials/date):

153 Chpt IV, Sect III

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Appendix A – PHEV Acceleration Test, Test Data Sheet

(Page 5 of 5)

VIN Number: ________________________ Operating Mode: _____________________________

General Comments (initials/date):
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

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Appendix B – PHEV Gradeability Limit, Test Data Sheet

(Page 1 of 2)

VIN Number: ________________________ Operating Mode: _____________________________

Project No.: Test Date(s):
Data File Name:
Test Driver:
(Initials) (Date)

Test Engineer:
(Initials) (Date)

Vehicle Setup
VEHICLE WEIGHTS AS TESTED WITH DRIVER & INSTRUMENTATION
(Rated vehicle GVWR)
Left Front: Right Front: Total Front: Percent Front: %
(lbs or kg) (lbs or kg) (lbs or kg)

Left Rear: Right Rear: Total Rear: Percent Rear: %

(lbs or kg) (lbs or kg) (lbs or kg)

Total Weight:
(lbs or kg)

INSTALLED TIRES
(Placard or sidewall whichever is less)
Preparation Area Temperature:
°F( or °C)

Left Front Right Front

Pressure: Pressure:
(psi or kPa) (psi or kPa)

Left Rear Right Rear

Pressure: Pressure:
(psi or kPa) (psi or kPa)

Track/Weather Conditions
Test Track Location: Track Grade: %
(Within 1%)

Ambient Temperature (initial): Ambient Temperature (final):

(40-90°F or 5-32°C) (40-90°F or 5-32°C)

Wind Velocity (initial): Wind Velocity (final):

(<10 mph or 16 km/h) (<10 mph or 16 km/h)

Wind Direction (initial): ° Wind Direction (completion): °

155 Chpt IV, Sect III

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Appendix B – PHEV Gradeability Limit, Test Data Sheet

(Page 2 of 2)

VIN Number: ________________________ Operating Mode: _____________________________

Sequence No: 1 File Name: Direction of Travel:
Time (initial): Time (final):
Odometer (initial): Odometer (final):
(miles or kilometers) (miles or kilometers)

State of Charge (initial): State of Charge (final):

(SOC; kWh; Ah) (SOC; kWh; Ah)

RESS Temp (initial): RESS Temp (final):

(°F or °C) (°F or °C)

Comments (initials/date):

Force Reading: ________________

Time Duration: _______________
Vehicle Speed: ________________

Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

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Appendix C – PHEV Gradeability at Speed Test Data Sheet

(Analytical Method)
(Page 1 of 1)

VIN Number: ________________________ Operating Mode: ____________________________

Speed Calculated for 3% Grade
General Comments (initials/date):

Speed Calculated for 6% Grade

General Comments (initials/date):

Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

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Appendix D – PHEV Metrology Setup Sheet

(Page 1 of 1)

VIN Number: ________________________ Operating Mode: ___________________________

Instrument/Device: Calibration Due Date: Initials / Date:
Fifth Wheel S/N:
Fifth Wheel Calibrator S/N:
DAS S/N:
DAS Set-up Sheet S/N:
kWh Meter S/N:
Shunt S/N:
Tire Pressure Gauge S/N:
Scales S/N:
Misc:
Misc:
Misc:
Comments (initials/date):

Completed By:
__________________________________________________________________________
(Printed Name) (Signature) (Date)

Reviewed By (QA):
____________________________________________________________________________
(Printed Name) (Signature) (Date)

Approved By:
_____________________________________________________________________________
(Printed Name) (Signature) (Date)

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Section IV: AVTA-PHTP03 – Implementation of SAE J1711

MAR99, "Recommended Practice for Measuring
the Exhaust Emissions and Fuel Economy of
Hybrid-Electric Vehicles"

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TABLE OF CONTENTS

1 Objective ...........................................................................................................................................................161

2 Purpose..............................................................................................................................................................161

3 Documentation..................................................................................................................................................161

4 Initial Conditions and Prerequisites ...............................................................................................................161

5 Dynamometer Setup.........................................................................................................................................165

6 Road Load Simulation .....................................................................................................................................167

APPENDICES

Appendix A – PHEV Metrology Setup Sheet ........................................................................................................193

Appendix B – SAE J1711 Test Data Sheet.............................................................................................................194

Appendix C – SAE J1711 Driving Schedule..........................................................................................................196

Appendix D – SAE J1711 Energy Efficiency.........................................................................................................227

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1 Objective
The objective of this procedure is to provide methods for the testing of fuel economy of
plug-in hybrid electric vehicles (PHEV) evaluated by the U.S. Department of Energy
Advanced Vehicle Testing Activity (AVTA). Testing is conducted in accordance with
SAE Standard J1711, "Recommended Practice for Measuring Fuel Economy and
Emissions of Plug-in Hybrid Electric and Conventional Heavy-Duty Vehicles" and
includes tests both with and without air conditioning loads. These methods are not meant
to supersede those of the testing facility, those specifically addressed by SAE Test
Standards (except as noted) nor of any regulatory agency, which may have or exercise
control over the covered activities.

2 Purpose
The purpose of this procedure is to identify acceptable methods for the implementation of
the test requirements of SAE J1711. SAE J1711 establishes uniform procedures for testing
plug-in hybrid electric vehicles through a variety of drive cycles. This procedure provides
specific guidance for testing plug-in hybrid electric vehicles (classified as off-vehicle­
charge capable in SAE J1711) capable of operating in a mode which the consumable fuel
energy converter (CFEC) and rechargeable energy storage system (RESS) are
automatically controlled to supply energy independently or in combination (Normal
Operation mode). Vehicles tested in an operating mode in which the CFEC is disabled and
the vehicle operates solely on energy from the RESS (RESS Only mode) are tested in
accordance with procedure AVTA-PHTP07. Minimum test requirements include the
Urban Dynamometer Driving Schedule (UDDS), Highway Fuel Economy Driving
Schedule (HWFEDS) and Supplemental Federal Test Procedure US06. This procedure
establishes some requirements that deviate from the guidance of that SAE J1711. These
deviations are necessary to assure that relative performance between vehicle types can be
assessed. Deviations from SAE J1711 are clearly noted where they occur.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read and readily reproducible. This documentation shall contain enough information to
"stand alone"; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion without the need to review
additional documentation. Review and approval of test documentation shall be in
accordance with procedure AVTA-PHAC04. Storage and retention of records during and
following testing activities shall be completed as described in procedure AVTA-PHAC01.

4 Initial Conditions and Prerequisites

Prior to conduct of any portion of the testing, the following initial conditions and
prerequisites should be met. Satisfactory completion of these items should be verified and
recorded on the Test Data Sheet.

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 AVTA-PHTP03

4.1 Personnel conducting the testing under this procedure shall be familiar with the
requirements of this procedure, shall be trained in accordance with the requirements
of procedure AVTA-PHAC05, and be certified by the Program Manager or the Test
Manager prior to commencing any testing activities.

4.2 Ambient temperature within the dynamometer cell during testing shall be 77°F ± 9°F
(25˚C ± 5˚C).

4.3 RESS and engine temperatures at the beginning of testing shall be established by
soaking the vehicle at 77°F ± 9°F (25˚C ± 5˚C) for a minimum of 12 hours in
accordance with SAE J1711 Section [Link].a.

4.4 Tire Preparation

4.4.1 Tire pressures shall be set at the values used during coastdown testing
conducted in accordance with procedure AVTA-PHTP01.
4.4.2 Suppliers recommended tires shall be used. Tires shall have a tread depth of
at least 50% when new.

4.5 Dynamometer
4.5.1 This test procedure is predicated on the use of a 48” Four Wheel Drive
(4WD) dynamometer which meets current EPA guidelines established in 40
CFR Part 86.108-00, for this type of dynamometer.
4.5.2 Road load power settings shall be based upon coefficients developed using
procedure AVTA-PHTP01.
4.5.3 Inertia settings shall be made based on the vehicle curb weight as determined
by procedure AVTA-PHAC06 weight plus 300 pounds. This is a deviation
from the requirements of SAE J1711.

4.6 During dynamometer operation, a fixed-speed cooling fan shall be positioned so as

to direct cooling air in an appropriate manner to cool the engine. The fan shall not
develop an air flow in excess of 5,300 cubic feet per minute (2.5 m3/s).

4.7 The vehicle shall be tested in its normal configuration with normal appendages
(mirrors, bumpers, hubcaps, etc.). Certain items (hub caps, etc.) may be removed
where necessary for safety on the dynamometer.

4.8 Normal Supplier's recommended lubricants shall be employed.

4.9 Prior to dynamometer testing, vehicles shall have accumulated a minimum of 1,000
miles. The vehicles shall be operated a sufficient number of miles to use at least two
gallons of "EPA certification fuel" and shall have completed the requirements of

162 Chpt IV, Sect IV

 AVTA-PHTP03

procedures AVTA-PHTP04 and AVTA-PHTP05. This is a deviation from the

requirements of SAE J1711.

4.10 RESS initial SOC shall be established in accordance with procedure AVTA­
PHTP08, Section 5.

4.11 The following data shall be collected using a DAS during conduct of the various
tests specified by this procedure. Overall error in recording or indicating instruments
shall not exceed ±2% of the maximum value of the variable being measured or as
specifically excepted elsewhere. Periodic calibration shall be performed and
documented to ensure compliance with this requirement.
4.11.1 RESS voltage versus time
4.11.2 RESS current versus time (RESS current shall be collected at a frequency of
at least 20 Hz)
4.11.3 Vehicle speed versus time
4.11.4 Distance versus time
4.11.5 RESS temperature versus time
4.11.6 RESS power versus time
4.11.7 Fuel flow (fuel flow shall be collected at a frequency of at least 20 Hz)

4.12 The range of ambient temperature during the testing shall be recorded.

4.13 A description of the dynamometer shall be recorded, including:

4.13.1 Drum or roll diameter and number of tire contact points
4.13.2 Road load power set points
4.13.3 Dynamometer inertia weight
4.13.4 Confirmation that the dynamometer conforms to EPA guidelines as specified
in 40 CFR Part 86.108-00.

4.14 The date, starting and ending times shall be recorded.

4.15 The beginning and ending vehicle odometer readings shall be recorded.

4.16 All instrumentation used in the test shall be listed in Appendix A and attached to the
test data sheets/results and shall include the following information:
4.16.1 Manufacturer
4.16.2 Model number
4.16.3 Serial number

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4.16.4 Next calibration date

4.17 Any deviation from the test procedure and the reason for the deviation shall be
recorded in accordance with procedure AVTA-PHAC02.

4.18 All documentation required to complete the testing shall be completed, approved and
issued prior to commencing the testing it addresses.

4.19 A copy of test documentation and methodologies/instructions used for testing shall
be included in the final test documentation program. This is in accordance with
procedure AVTA-PHAC02.

4.20 Verify that procedures AVTA-PHAC06 and AVTA-PHTP11 have been, or are being
completed and that the operating modes in which the vehicle will be tested have been
determined. If the vehicle is to be tested in RESS Only mode, procedure AVTA­
PHTP07 shall be used for such testing.

4.21 The volume of fuel consumed shall be determined using one or more of the
following measurement methods:
4.21.1 The volume of liquid fuels consumed shall be determined by electronically
integrating the output of a calibrated fuel flow meter. Accuracy of the meter
in the range of measurement shall be at least 2% as required by Section 4.11.
The vehicle shall be operated using "EPA Certification Fuel" during all
testing.
4.21.2 Fuel consumption shall be determined by the gravimetric method. The test
vehicle shall be supplied from an external fuel tank. The tank shall be
weighed immediately before and immediately after testing. The quantity of
fuel consumed shall be calculated using the density of the fuel (as obtained
from the provider of the EPA Certification Fuel) and the weight of the fuel
consumed during testing. The scale used for gravimetric testing shall have an
accuracy of at least 1% of the weight of the fuel tank after testing. The
vehicle shall be operated using "EPA Certification Fuel" during all testing.
4.21.3 Fuel consumption shall be determined using an emissions bench meeting the
requirements of 40 CFR Part 86.106, and capable of measuring carbon
emissions species (CO, CO2, THC) to an accuracy, in the range of
measurement, of at least 2%. The vehicle shall be operated using "EPA
Certification Fuel" during all testing.
4.21.4 When completing the data sheet in Appendix C, the “Fuel Measurement”
blanks should contain either the flow meter values or the weight
measurements before and after the test. Emission results may be recorded in
the comments section of the data sheet.

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5 Dynamometer Setup
The purpose of this section is to prepare the dynamometer for use in testing PHEVs to the
requirements of SAE J1711 as described in Section 6.

CAUTION:
In this procedure, the dynamometer is started and run. ALL
personnel shall exercise appropriate cautions while in the vicinity
of both the Power Absorption Unit and the Roller Section.

NOTE:
Activities necessary to complete the test are identified in the
following sections. All items shall be completed, whether they are
required by J1711 or not. Any section which cannot be completed
shall be so annotated, along with the appropriate justification in
accordance with procedure AVTA-PHAC02.

5.1 Establish the initial condition applicable to the Normal Operation mode as
determined in procedure AVTA-PHAC06.
5.1.1 Place the vehicle in the Normal Operation mode and, for tests to be
conducted beginning at 100% initial RESS SOC, establish the RESS at 100%
initial SOC in accordance with procedure AVTA-PHTP08.

NOTE:
Establishing the appropriate RESS initial SOC may require
charging the test vehicle or operating the vehicle on the
dynamometer. Requirements for verification of the proper RESS
initial SOC are presented in procedure AVTA-PHTP08.

5.1.2 Soak the vehicle in the dynamometer test cell for at least 12 hours at 77°F ±
9°F (25˚C ± 5˚C) before performing the UDDS test. Do not remove the
vehicle from the dynamometer during this time.

NOTE:
Do not operate the vehicle propulsion system during dynamometer
warm-up and calibration.

5.2 Conduct an initial warm-up of the dynamometer in accordance with facility

procedures.

5.3 Conduct and complete speed calibration of the dynamometer in accordance with
facility procedures.

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5.4 Conduct and complete torque arm calibration of the dynamometer in accordance
with facility procedures.

5.5 Conduct and complete Data Acquisition System (DAS) calibration (including the
emissions bench) in accordance with facility procedures.

5.6 Set the dynamometer with the coastdown coefficients and inertia settings determined
in procedure AVTA-PHTP01. Record the settings in Appendix B as "Target"
settings.

5.7 Prepare the vehicle to be tested as follows:

5.7.1 Record tire inflation pressures in Appendix B.
5.7.2 Place the test vehicle on the dynamometer roll(s), and center it on the roll(s)
using facility procedures.
5.7.3 Attach tie-down straps to the vehicle.
5.7.4 Place wheel chocks at the non-driving wheels.
5.7.5 Place fan appropriately to cool the engine, open the engine compartment
cover and turn the fan on. Fans should be placed to simulate road air flow in
accordance with Section 4.6.

CAUTION:
High voltage may be present. To prevent personnel injury or
equipment damage, use extreme caution when connecting
instrumentation leads.

5.7.6 Connect vehicle instrumentation leads to the DAS.

5.8 Determination of Dynamometer and Tire Parasitic Losses for Single Roll
Dynamometer
5.8.1 Conduct back-to-back HWFEDS drive cycles.
5.8.2 Measure tire temperatures after the HWFEDS drive cycles and immediately
before conducting the coastdown and record in Appendix B.
5.8.3 Place the vehicle in neutral or "dynamometer mode" if such mode is
applicable based on vehicle manufacturer's supplied data.
5.8.4 Using the dynamometer motor, accelerate the vehicle to 80 mph.
5.8.5 Coast the vehicle to 5 mph, while recording speed vs. time.
5.8.6 Immediately after completion of step 5.7.5, record tire temperatures in
Appendix B.
5.8.7 Save the DAS data and determine coastdown times from 75 to 5 mph in 10
mph increments.

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5.8.8 Repeat steps 5.8.4 through 5.8.6 a minimum of three times.

5.9 Set up the dynamometer to achieve the desired coast-down times.

5.9.1 Compare the coastdown times obtained in step 5.8 with the coastdown times
expected based upon the coastdown coefficients determined in procedure
AVTA-PHTP01.
5.9.2 If measured coastdown times are not within 1.5% of the desired coastdown
times, adjust road load coefficients and inertia settings as necessary. Record
the final road load and inertia settings in Appendix B as "Dyno" settings.

5.10 If the adjustment to road load and inertia settings are greater than 3% from the initial
calibration (the initial conduct of step 5.8 for the vehicle), an attempt to determine
the cause of the “drift” shall be undertaken. This evaluation shall include both the
vehicle and the dynamometer. Results of the investigation shall be noted in
Appendix B and reviewed with the Test Director or Program Manager.

5.11 Record the applicable EPA coastdown coefficients and inertia settings in Appendix
B. If the EPA settings deviate more significantly from the "Dyno" settings, an
attempt shall be made to reconcile this deviation. Results of the investigation shall be
noted in Appendix B and reviewed with the Test Director or Program Manager.

6 Road Load Simulation

The purpose of this section is to determine the fuel efficiency of a PHEV vehicle when
subjected to the test schedules identified in SAE J1711 and operated both with and without
air conditioning loads. This section selectively implements portions of SAE J1711 in
support of this purpose. This is a deviation from the requirements of SAE J1711.
Dynamometer operating instructions developed by the entity operating the dynamometer
shall be used in conjunction with this procedure. Road load simulation testing shall be
conducted in the Normal Operation mode, starting with the RESS at 100% SOC, as
determined by procedure AVTA-PHAC06. The vehicle shall be tested in the Normal
Operation mode, using the UDDS, HWFEDS and US06 driving schedules without the air
conditioning operating. Additionally, the vehicle shall be tested in the Normal Operation
mode, starting with the RESS at 100% SOC, using the UDDS and HWFEDS driving
schedules, with the air conditioning operating. The vehicle may be tested using other drive
cycles defined in SAE J1711 as required to gather data required for evaluation of the
vehicle.
Road load simulation testing is typically conducted over a period of five days in the order
presented in Sections 6.1 through 6.5. Testing may be completed on a different schedule;
however, the RESS shall be at the proper SOC for the beginning of each test. At the
beginning of each test day, the dynamometer shall be prepared for operation in accordance
with Sections 5.1 through 5.5.

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6.1 Testing Day One

NOTE:
The Dynamometer Setup described in Section 5 is typically
conducted at the beginning of Test Day One, rather than preceding
Test Day One.

NOTE:
Do not operate the vehicle propulsion system during dynamometer
warm-up and calibration.

6.1.1 Vehicle setup

[Link] Prepare the dynamometer in accordance with Sections 5.1
through 5.5.
[Link] Verify that the required ambient temperature exists in the
dynamometer test cell and that the vehicle has been at the
required ambient temperature for at least 12 hours.
[Link] Verify that the DAS instrumentation is connected.
[Link] Turn on the cooling fan(s).
[Link] If fuel economy is to be determined by gravimetric means in
accordance with Section 4.22.2, weigh the external fuel tank
filled with "EPA Certification Fuel" and record in Appendix B.
[Link] If fuel economy is to be determined by use of a fuel flow meter in
accordance with Section 4.22.1, ensure the fuel flow integrator is
set to zero and ready to begin operation.
[Link] If fuel economy is to be determined using an emissions bench in
accordance with Section 4.22.3, ensure the emissions bench is
ready to begin operation.

NOTE:
During conduct of US06 fuel economy testing, it will be necessary
to determine when the vehicle has entered charge sustaining mode.
The criteria to make this determination should be specified prior to
the initiation of testing and may include calculating the energy
represented by the change from initial RESS SOC to final RESS
SOC over the drive cycle and comparing such energy to the total
energy represented by the fuel consumed over the drive cycle.

6.1.2 US06 Drive Cycle

[Link] Verify that all accessories are off.
[Link] Ensure all dynamometer recording systems are operating.

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[Link] Record the vehicle operating mode and the following initial
parameters in Appendix C for a US06 drive cycle from a cold
start.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Conduct a US06 drive cycle from cold start conditions.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the US06 drive cycle, wait 10 minutes (+ 1
minute) with the vehicle and its accessories off. During this
period, record the following final cold start US06 parameters. At
the end of the ten minute period, begin the next US06 drive cycle.
This will be considered a US06 hot start drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter integrator reading (as
applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive

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cycle occurs, as well as the reason(s) for any such excursions in

Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the US06 drive cycle, wait 10 minutes (+ 1
minute) with the vehicle and its accessories off. During this
period, record the following. At the end of the ten minute period,
begin another US06 drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the US06 drive cycle, wait 10 minutes (+ 1
minute) with the vehicle and its accessories off. During this
period, record the following information:
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)

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[Link].7 If an emissions bench and carbon species measurement

is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Repeat US06 drive cycles as directed by Sections [Link] and
[Link] a maximum of three times (6 US06 tests) until two drive
cycles are completed in the charge sustaining mode as indicated
by the criteria specified prior to commencing road load
simulation testing, then complete US06 drive cycle tests by
recording the following information:
[Link].1 Total distance for all US06 cycles conducted
[Link].2 If an emissions bench and carbon species measurement
was used to determine fuel use, isolate the bags used
for the US06 drive cycle testing and tag them for
analysis
[Link].3 Conduct analysis of the US06 drive cycle emissions
bench bags in accordance with facility procedures to
determine the quantity of fuel used for each US06
drive cycle.
[Link] Secure the dynamometer.
[Link] Recharge the RESS to 100% in accordance with procedure
AVTA-PHTP08. This may be done in the dynamometer test cell
or in another area. However, no propulsion system power shall be
used in moving the vehicle. Record the AC and DC energy
returned to the RESS in Appendix D.

6.2 Testing Day Two

NOTE:
Do not operate the vehicle propulsion system during dynamometer
warm-up and calibration.

6.2.1 Vehicle setup

[Link] Prepare the dynamometer in accordance with Sections 5.1
through 5.5.
[Link] Verify that the required ambient temperature exists in the
dynamometer test cell and that the vehicle has been at the
required ambient temperature for at least 12 hours.
[Link] Verify that the DAS instrumentation is connected.
[Link] Turn on the cooling fan(s).

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[Link] If fuel economy is to be determined by gravimetric means in

accordance with Section 4.22.2, weigh the external fuel tank
filled with "EPA Certification Fuel" and record in Appendix B.
[Link] If fuel economy is to be determined by use of a fuel flow meter in
accordance with Section 4.22.1, ensure the fuel flow integrator is
set to zero and ready to begin operation.
[Link] If fuel economy is to be determined using an emissions bench in
accordance with Section 4.22.3, ensure the emissions bench is
ready to begin operation.

NOTE:
During conduct of HWFEDS fuel economy testing, it will be
necessary to determine when the vehicle has entered charge
sustaining mode. The criteria to make this determination should be
specified prior to the initiation of testing and may include
calculating the energy represented by the change from initial RESS
SOC to final RESS SOC over the drive cycle and comparing such
energy to the total energy represented by the fuel consumed over
the drive cycle.

6.2.2 HWFEDS Drive Cycle

[Link] Verify that all accessories are off.
[Link] Ensure all dynamometer recording systems are operating.
[Link] Record the vehicle operating mode and the following initial
parameters in Appendix C for a HWFEDS drive cycle from a
cold start.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Conduct a HWFEDS drive cycle from cold start conditions.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit

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is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the HWFEDS drive cycle, wait 10 minutes
(+ 1 minute) with the vehicle and its accessories off. During this
period, record the following final cold start HWFEDS
parameters. At the end of the ten minute period, begin the next
HWFEDS drive cycle. This will be considered a HWFEDS hot
start drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter integrator reading (as
applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the HWFEDS drive cycle, wait 10 minutes
(+ 1 minute) with the vehicle and its accessories off. During this
period, record the following. At the end of the ten minute period,
begin another HWFEDS drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel Weight or fuel meter reading (as applicable)

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[Link].7 If an emissions bench and carbon species measurement

is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the HWFEDS drive cycle, wait 10 minutes
(+ 1 minute) with the vehicle and its accessories off. During this
period, record the following information:
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Repeat HWFEDS drive cycles as directed by Sections [Link] and
[Link] a maximum of three times (6 HWFEDS tests) and any
additional vehicle specific charge depleting drive cycles as
required until two HWFEDS drive cycles are completed in the
charge sustaining mode as indicated by the criteria specified prior
to commencing road load simulation testing, then complete
HWFEDS drive cycle by recording the following information:
[Link].1 Total Distance for all HWFEDS cycles conducted
[Link].2 If an emissions bench and carbon species measurement
was used to determine fuel use, isolate the bags used
for the HWFEDS drive cycle testing and tag them for
analysis
[Link].3 Conduct analysis of the HWFEDS drive cycle
emissions bench bags in accordance with facility
procedures to determine the quantity of fuel used for
each HWFEDS drive cycle.

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[Link] Secure the dynamometer.

[Link] Recharge the RESS to 100% in accordance with procedure
AVTA-PHTP08. This may be done in the dynamometer test cell
or in another area. However, no propulsion system power shall be
used in moving the vehicle. Record the AC and DC energy
returned to the RESS in Appendix D.

6.3 Testing Day Three

NOTE:
Do not operate the vehicle propulsion system during dynamometer
warm-up and calibration.

6.3.1 Vehicle setup

[Link] Prepare the dynamometer in accordance with Sections 5.1
through 5.5.
[Link] Verify that the required ambient temperature exists in the
dynamometer test cell and that the vehicle has been at the
required ambient temperature for at least 12 hours.
[Link] Verify that the DAS instrumentation is connected.
[Link] Turn on the cooling fan(s).
[Link] If fuel economy is to be determined by gravimetric means in
accordance with Section 4.22.2, weigh the external fuel tank
filled with "EPA Certification Fuel" and record in Appendix B.
[Link] If fuel economy is to be determined by use of a fuel flow meter in
accordance with Section 4.22.1, ensure the fuel flow integrator is
set to zero and ready to begin operation.
[Link] If fuel economy is to be determined using an emissions bench in
accordance with Section 4.22.3, ensure the emissions bench is
ready to begin operation.

NOTE:
During conduct of UDDS fuel economy testing it will be necessary
to determine when the vehicle has entered charge sustaining mode.
The criteria to make this determination should be specified prior to
the initiation of testing and may include calculating the energy
represented by the change from initial RESS SOC to final RESS
SOC over the drive cycle and comparing such energy to the total
energy represented by the fuel consumed over the drive cycle.

6.3.2 UDDS Drive Cycle

[Link] Verify that all accessories are off.

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[Link] Ensure all dynamometer recording systems are operating.

[Link] Record the vehicle operating mode and the following initial
parameters in Appendix C for a UDDS drive cycle from a cold
start.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Conduct a UDDS drive cycle from cold start conditions.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the UDDS drive cycle, wait 10 minutes (+ 1
minute) with the vehicle and its accessories off. During this
period, record the following final cold start UDDS parameters. At
the end of the ten minute period, begin the next UDDS drive
cycle. This will be considered a UDDS hot start drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter integrator reading (as
applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.

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[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the UDDS drive cycle, wait 10 minutes (+ 1
minute) with the vehicle and its accessories off. During this
period, record the following. At the end of the ten minute period,
begin another UDDS drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the UDDS drive cycle, wait 10 minutes (+ 1
minute) with the vehicle and its accessories off. During this
period, record the following information:
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)

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[Link].7 If an emissions bench and carbon species measurement

is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Repeat UDDS drive cycles as directed by Sections [Link] and
[Link] a maximum of three times (6 UDDS tests) and any
additional vehicle-specific charge-depleting drive cycles as
required until two HWFEDS drive cycles are completed in the
charge sustaining mode as indicated by the criteria specified prior
to commencing road load simulation testing, then complete
UDDS drive cycle by recording the following information:
[Link].1 Total Distance for all UDDS cycles conducted
[Link].2 If an emissions bench and carbon species measurement
was used to determine fuel use, isolate the bags used
for the UDDS drive cycle testing and tag them for
analysis
[Link].3 Conduct analysis of the UDDS drive cycle emissions
bench bags in accordance with facility procedures to
determine the quantity of fuel used for each UDDS
drive cycle.
[Link] Secure the dynamometer.
[Link] Do not recharge the RESS, as testing in Day 4 will commence in
charge sustaining mode.

6.4 Testing Day 4

NOTE:
Do not operate the vehicle propulsion system during dynamometer
warm-up and calibration.

6.4.1 Vehicle setup

[Link] Prepare the dynamometer in accordance with Sections 5.1
through 5.5.
[Link] Verify that the required ambient temperature exists in the
dynamometer test cell and that the vehicle has been at the
required ambient temperature for at least 12 hours.
[Link] Verify that the DAS instrumentation is connected.
[Link] Turn on the cooling fan(s).
[Link] If fuel economy is to be determined by gravimetric means in
accordance with Section 4.22.2, weigh the external fuel tank
filled with "EPA Certification Fuel" and record in Appendix B.

178 Chpt IV, Sect IV

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[Link] If fuel economy is to be determined by use of a fuel flow meter in

accordance with Section 4.22.1, ensure the fuel flow integrator is
set to zero and ready to begin operation.
[Link] If fuel economy is to be determined using an emissions bench in
accordance with Section 4.22.3, ensure the emissions bench is
ready to begin operation.
6.4.2 UDDS Drive Cycle (charge sustaining)
[Link] Verify that all accessories are off.
[Link] Ensure all dynamometer recording systems are operating.
[Link] Record the vehicle operating mode and the following initial
parameters in Appendix C for a UDDS drive cycle from a cold
start.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Conduct a UDDS drive cycle from cold start conditions.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the UDDS drive cycle, wait 10 minutes (+ 1
minute) with the vehicle and its accessories off. During this
period, record the following final cold start UDDS parameters. At
the end of the ten minute period, begin the next UDDS drive
cycle. This will be considered a UDDS hot start drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading

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[Link].4 Ambient temperature

[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter integrator reading (as
applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the UDDS drive cycle, wait 10 minutes (+ 1
minute) with the vehicle and its accessories off. During this
period, record the following. At the end of the ten minute period,
begin a HWFEDS drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
6.4.3 HWFEDS Drive Cycle (charge sustaining)
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.

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[Link] Upon completion of the HWFEDS drive cycle, wait 10 minutes

(+ 1 minute) with the vehicle and its accessories off. During this
period, record the following. At the end of the ten minute period,
begin another HWFEDS drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the HWFEDS drive cycle, wait 10 minutes
(+ 1 minute) with the vehicle and its accessories off. During this
period, record the following. At the end of the ten minute period,
begin a US06 drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
6.4.4 US06 Drive Cycle (charge sustaining)
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in

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Appendix C. The speed tolerance at any given time on the driving

schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the US06 drive cycle, wait 10 minutes (+ 1
minute) with the vehicle and its accessories off. During this
period, record the following. At the end of the ten minute period,
begin another US06 drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the US06 drive cycle, record the following
information:
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.

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[Link] Complete Day 4 testing by recording the following information:

[Link].1 Total Distance for all drive cycles conducted
[Link].2 If an emissions bench and carbon species measurement
was used to determine fuel use, isolate the bags used
for drive cycle testing and tag them for analysis
[Link].3 Conduct analysis of drive cycle emissions bench bags
in accordance with facility procedures to determine the
quantity of fuel used for each drive cycle.
[Link] Secure the dynamometer.
[Link] Recharge the RESS to 100% in accordance with procedure
AVTA-PHTP08. This may be done in the dynamometer test cell
or in another area. However, no propulsion system power shall be
used in moving the vehicle. Record the AC and DC energy
returned to the RESS in Appendix D.

6.5 Testing Day 5

NOTE:
Do not operate the vehicle propulsion system during dynamometer
warm-up and calibration.

6.5.1 Vehicle setup

[Link] Prepare the dynamometer in accordance with Sections 5.1
through 5.5.
[Link] All testing in Day 5 shall be conducted with the air conditioning
on. Open as many vehicle doors and windows as can be safely
done on the dynamometer and place the air conditioning
temperature at the lowest possible setting, the air conditioning fan
on the highest possible setting and the air supply to outside air (if
selectable).
[Link] Verify that the required ambient temperature exists in the
dynamometer test cell and that the vehicle has been at the
required ambient temperature for at least 12 hours.
[Link] Verify that the DAS instrumentation is connected.
[Link] Turn on the cooling fan(s).
[Link] If fuel economy is to be determined by gravimetric means in
accordance with Section 4.22.2, weigh the external fuel tank
filled with "EPA Certification Fuel" and record in Appendix B.
[Link] If fuel economy is to be determined by use of a fuel flow meter in
accordance with Section 4.22.1, ensure the fuel flow integrator is
set to zero and ready to begin operation.

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[Link] If fuel economy is to be determined using an emissions bench in

accordance with Section 4.22.3, ensure the emissions bench is
ready to begin operation.

NOTE:
During conduct of fuel economy testing it will be necessary to
determine when the vehicle has entered charge sustaining mode.
The criteria to make this determination should be specified prior to
the initiation of testing and may include calculating the energy
represented by the change from initial RESS SOC to final RESS
SOC over the drive cycle and comparing such energy to the total
energy represented by the fuel consumed over the drive cycle.

6.5.2 UDDS Drive Cycle

[Link] Verify that all accessories are off (except air conditioning when
testing with air conditioning on).
[Link] For testing with air conditioning operable, open as many vehicle
doors and windows as can be safely done on the dynamometer
and place the air conditioning temperature at the lowest possible
setting, the air conditioning fan on the highest possible setting
and the air supply to outside air (if selectable).
[Link] Ensure all dynamometer recording systems are operating.
[Link] Record the vehicle operating mode and the following initial
parameters in Appendix C for a UDDS drive cycle from a cold
start.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Conduct a UDDS drive cycle from cold start conditions.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace

184 Chpt IV, Sect IV

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within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the UDDS drive cycle, wait 10 minutes (+ 1
minute) with the vehicle and its accessories off. During this
period, record the following final cold start UDDS parameters. At
the end of the ten minute period, begin the next UDDS drive
cycle. This will be considered a UDDS hot start drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter integrator reading (as
applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the UDDS drive cycle, wait 10 minutes (+ 1
minute) with the vehicle and its accessories off. During this
period, record the following. At the end of the ten minute period,
begin a HWFEDS drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)

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[Link].7 If an emissions bench and carbon species measurement

is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
6.5.3 HWFEDS Drive Cycle
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the HWFEDS drive cycle, wait 10 minutes
(+ 1 minute) with the vehicle and its accessories off. During this
period, record the following. At the end of the ten minute period,
begin another HWFEDS drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the HWFEDS drive cycle, wait 10 minutes
(+ 1 minute) with the vehicle and its accessories off. During this
period, record the following information:
[Link].1 Time of day
[Link].2 Odometer reading

186 Chpt IV, Sect IV

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[Link].3 SOC indicator reading

[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Repeat UDDS and HWFEDS drive cycles (all hot starts) as
directed by Sections [Link] through [Link] a maximum of two
times (4 UDDS and 4 HWFEDS tests) until two drive cycles are
completed in the charge sustaining mode as indicated by the
criteria specified prior to commencing road load simulation
testing. No fuel weight, fuel metering or carbon species
measurement is required for this testing.
6.5.4 UDDS Drive Cycle (charge sustaining)
[Link] Record the vehicle operating mode and the following initial
parameters in Appendix C for a UDDS drive cycle from a cold
start.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Conduct a UDDS drive cycle with the RESS at an initial RESS
SOC of charge sustaining.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.

187 Chpt IV, Sect IV

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[Link] Upon completion of the UDDS drive cycle, wait 10 minutes (+ 1

minute) with the vehicle and its accessories off. During this
period, record the following final cold start UDDS parameters. At
the end of the ten minute period, begin the next UDDS drive
cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter integrator reading (as
applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the UDDS drive cycle, wait 10 minutes (+ 1
minute) with the vehicle and its accessories off. During this
period, record the following. At the end of the ten minute period,
begin a HWFEDS drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.

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6.5.5 HWFEDS Drive Cycle (charge sustaining)

[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the HWFEDS drive cycle, wait 10 minutes
(+ 1 minute) with the vehicle and its accessories off. During this
period, record the following. At the end of the ten minute period,
begin another HWFEDS drive cycle.
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures
[Link].6 Fuel weight or fuel meter reading (as applicable)
[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1711 Section 3.5.1. The upper limit
is 2 mph (3.2 km/h) higher than the highest point on the trace
within 1 second of the given time. The lower limit is 2 mph (3.2
km/h) lower than the lowest point on the trace within 1 second of
the given time.
[Link] Upon completion of the HWFEDS drive cycle, wait 10 minutes
(+ 1 minute) with the vehicle and its accessories off. During this
period, record the following information:
[Link].1 Time of day
[Link].2 Odometer reading
[Link].3 SOC indicator reading
[Link].4 Ambient temperature
[Link].5 Tire temperatures

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 AVTA-PHTP03

[Link].6 Fuel weight or fuel meter reading (as applicable)

[Link].7 If an emissions bench and carbon species measurement
is used to determine fuel use, switch the emissions
bench to a fresh collection bag.
[Link] Complete Day 5 testing by recording the following information:
[Link].1 Total Distance for all drive cycles conducted
[Link].2 If an emissions bench and carbon species measurement
was used to determine fuel use, isolate the bags used
for drive cycle testing and tag them for analysis
[Link].3 Conduct analysis of drive cycle emissions bench bags
in accordance with facility procedures to determine the
quantity of fuel used for each drive cycle.
[Link] Recharge the RESS to 100% in accordance with procedure
AVTA-PHTP08. This may be done in the dynamometer test cell
or in another area. However, no propulsion system power shall be
used in moving the vehicle. Record the AC and DC energy
returned to the RESS in Appendix D.
[Link] Secure the dynamometer and dismount the vehicle.

6.6 Fuel Efficiency Calculations

NOTE:
RESS energy supplied and vehicle fuel efficiency shall be
calculated for the combined UDDS-HWFEDS (Day 5), each
UDDS, HWFEDS and US06 cycle. The equation is the same, but
only the energy supplied and distance traveled during the test being
evaluated should be used.

6.6.1 If the gravimetric method was used for determination of fuel economy
(Section 4.22.2), calculate the vehicle fuel efficiency in mi/gal using the
following equation and record the fuel economy and method of calculation
(gravimetric) in Appendix E.

Fuel Economy (mpg) = Dynamometer Distance (miles) * Fuel Density (lbs/gal)

[Initial Fuel Weight (lb) – Final Fuel Weight (lb)]

Fuel Density shall be corrected to the average temperature of the test

chamber for the 12 hours prior to testing.
6.6.2 If the fuel flow meter method is used for determination of fuel economy
(Section 4.22.1) calculate the vehicle fuel efficiency in mi/gal using the
following equation and record the fuel economy and method of calculation
(fuel flow) in Appendix E.

190 Chpt IV, Sect IV

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Fuel Economy (mpg) = Dynamometer Distance (miles) * Fuel Density (lbs/gal)

Fuel Used (lb)

Fuel used shall be determined by integrating the fuel flow meter in

accordance with Section 4.11. The Dynamometer Distance shall be the total
miles traveled to the point of test termination.
6.6.3 If the carbon species method is used for determination of fuel economy
(Section 4.22.3) process the emissions bench data in accordance with facility
procedures and record the fuel economy and method of calculation (carbon
species) in Appendix E.
6.6.4 The RESS should not have a change in energy over the charge sustaining
driving schedules greater than 1% of the total fuel energy consumed. If the
net change in RESS energy over a driving schedule is greater than 1% of the
total fuel energy consumed for that driving schedule, a correction shall be
made for the electric energy consumed during the driving schedule. This is a
deviation from the requirements of SAE J1711.
[Link] The change in RESS energy shall be determined using the
following equation.

∆ RESS Energy (Wh) = [RESSinitial (Ahr) - RESSfinal (Ahr)] * RESSaverage voltage(V)

The change in RESS energy shall be less than 1% of the total

fuel energy consumed as calculated using the following equation.

Fuel Energy (Wh) = Net Fuel Heating Value (J/kg) * fuel consumed (kg)
3600

If change in RESS energy is less than 1% of the total fuel energy

consumed, note such in Appendix E. In this case the RESS
Correction is zero.
[Link] If change in RESS energy is greater than 1% of the total fuel
energy consumed, note such in Appendix E and calculate the
RESS Correction using the following equation. The RESS
correction shall be added to the AC recharge energy.

RESS Correction (AC kWh) = ∆ RESS Energy (Wh)

Charger Efficiency (DC-Wh/AC-Wh)

NOTE:
Charger Efficiency shall be obtained using procedure AVTA­
PHTP10, Section [Link]. Net Fuel Heating Value shall be
obtained for the "EPA Certification Fuel" from the fuel data sheet.

191 Chpt IV, Sect IV

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6.7 RESS Capacity and Energy Supplied Calculations

6.7.1 Calculate the capacity supplied by the RESS (Ahr/mi) during charge
depletion and the percentage of RESS capacity supplied by the RESS (%/mi)
during charge depletion using the following equations and record in
Appendix D:

RESS Capacity (Ahr/mi) = [ RESSenter sustaining (Ahr) - RESSinitial (Ahr)]

Dynamometer Distance (miles)

RESS Capacity (%/mile) = 100 * [RESSenter sustaining (Ahr) - RESSinitial (Ahr)]

Dynamometer Distance (miles)* RESS Capacity (Ahr)

The RESSinitial and RESSenter sustaining shall be determined by integrating the

ammeter in accordance with Section 4.11. The RESSenter sustaining shall be the
total ampere-hours out of the RESS to entry into charge sustaining mode.
The Dynamometer Distance shall be the total miles traveled to the point of
entry into charge sustaining mode. The RESS Capacity (Ahr) shall be the
nominal capacity of the RESS as determined in procedure AVTA-PHAC06.
6.7.2 Calculate the DC energy supplied by the RESS (Wh/mi) using the following
equation and record in Appendix D:

DC Energy Supplied (DC-Wh/mile) = RESSDC energy (Wh)

Dynamometer Distance (miles)

The DC energy shall be determined by integrating the product of the

ammeter and voltmeter in accordance with Section 4.11. The DC energy
supplied by the RESS shall be the total energy out of the RESS to the point
of test termination. The Dynamometer Distance shall be the total miles
traveled to the point of test termination.

6.8 Calculation of RESS AC Electrical Recharge Energy Consumed

6.8.1 Electric energy (AC) used to recharge the RESS shall be calculated in
accordance with procedure AVTA-PHTP08.
6.8.2 Record the AC recharge energy for each Test Day the vehicles are charged in
Appendix D.

192 Chpt IV, Sect IV

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Appendix A – PHEV Metrology Setup Sheet

(Page 1 of 1)
VIN Number: __________
Instrument/Device: Calibration Due Date: Initials / Date:
Fifth Wheel S/N:
Fifth Wheel Calibrator S/N:
DAS S/N:
DAS Set-up Sheet S/N:
kWh Meter S/N:
Shunt S/N:
Tire Pressure Gauge S/N:
Fuel Scale/flow Meter S/N:
Emissions Bench ID:
Misc:
Misc:
Comments (initials/date):

Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By (QA):
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

193 Chpt IV, Sect IV

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Appendix B – SAE J1711 Test Data Sheet

(Page 1 of 2)
VIN Number: ______________________ Operating Mode ______
Project No.: Test Date(s):
Data File Name:
Test Driver:
(Initials) (Date)

Test Engineer:
(Initials) (Date)

Vehicle Setup
TIRE TEMPERATURE
Initial L/F: Initial R/F: Final L/F: Final R/F:
(˚F or ˚C) (˚F or ˚C) (˚F or ˚C) (˚F or ˚C)

Initial L/R: Initial R/R: Final L/R: Final R/R:

(˚F or ˚C) (˚F or ˚C) (˚F or ˚C) (˚F or ˚C)

COLD TIRE PRESSURE (Shaved Yes No)

Left Front: Right Front:
(psig or kPa) (psig or kPa)

Left Rear: Right Rear:

(psig or kPa) (psig or kPa)

Determination of Dynamometer and Tire Parasitic Losses

Coefficients Target Dyno % Deviation

Inertia
A
B
C
EPA Coefficient Comparison
Coefficients EPA Dyno % Deviation
Inertia
A
B
C

194 Chpt IV, Sect IV

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(Page 2 of 2)
VIN Number: ______________________ Operating Mode ______
General Comments (initials/date):
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

195 Chpt IV, Sect IV

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(Page 1 of 31)
DAY ONE
VIN Number: ______________________ Operating Mode ______
TIRE PRESSURE
Left Front: Right Front:
(psig or kPa) (psig or kPa)

Left Rear: Right Rear:

(psig or kPa) (psig or kPa)

Fuel Density:
(lbs per gallon)

Inertial Weight Setting:

(lab)

US06 Cold Start

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

1st US06 Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

196 Chpt IV, Sect IV

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(Page 2 of 31)

VIN Number: ______________________ Operating Mode ______

__ th US06 Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th US06 Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

197 Chpt IV, Sect IV

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(Page 3 of 31)

VIN Number: ______________________ Operating Mode ______

__ th US06 Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th US06 Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

198 Chpt IV, Sect IV

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(Page 4 of 31)

VIN Number: ______________________ Operating Mode ______

__ th US06 Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th US06 Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

199 Chpt IV, Sect IV

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(Page 5 of 31)

VIN Number: ______________________ Operating Mode ______

2nd US06 Hot Start (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

3rd US06 Hot Start (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

200 Chpt IV, Sect IV

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(Page 6 of 31)
DAY TWO
VIN Number: ______________________ Operating Mode ______
TIRE PRESSURE
Left Front: Right Front:
(psig or kPa) (psig or kPa)

Left Rear: Right Rear:

(psig or kPa) (psig or kPa)

Fuel Density:
(lbs per gallon)

Inertial Weight Setting:

(lab)

HWFEDS Cold Start:

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

1st HWFEDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

201 Chpt IV, Sect IV

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(Page 7 of 31)

VIN Number: ______________________ Operating Mode ______

2nd HWFEDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

3rd HWFEDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

202 Chpt IV, Sect IV

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(Page 8 of 31)

VIN Number: ______________________ Operating Mode ______

__ th HWFEDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th HWFEDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

203 Chpt IV, Sect IV

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(Page 9 of 31)

VIN Number: ______________________ Operating Mode ______

__ th HWFEDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th HWFEDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

204 Chpt IV, Sect IV

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(Page 10 of 31)

VIN Number: ______________________ Operating Mode ______

__ th HWFEDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th HWFEDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

205 Chpt IV, Sect IV

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(Page 11 of 31)

VIN Number: ______________________ Operating Mode ______

1st HWFEDS (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

2nd HWFEDS (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

206 Chpt IV, Sect IV

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(Page 12 of 31)
DAY THREE
VIN Number: ______________________ Operating Mode ______
TIRE PRESSURE
Left Front: Right Front:
(psig or kPa) (psig or kPa)

Left Rear: Right Rear:

(psig or kPa) (psig or kPa)

Fuel Density:
(lbs per gallon)

Inertial Weight Setting:

(lab)

UDDS Cold Start:

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

1st UDDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

207 Chpt IV, Sect IV

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(Page 13 of 31)

VIN Number: ______________________ Operating Mode ______

2nd HWFEDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

3rd HWFEDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

208 Chpt IV, Sect IV

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(Page 14 of 31)

VIN Number: ______________________ Operating Mode ______

__ th UDDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th UDDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

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VIN Number: ______________________ Operating Mode ______

__ th UDDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th UDDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

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VIN Number: ______________________ Operating Mode ______

__ th UDDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th UDDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

211 Chpt IV, Sect IV

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VIN Number: ______________________ Operating Mode ______

1st UDDS (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

2nd UDDS (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

212 Chpt IV, Sect IV

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DAY FOUR
VIN Number: ______________________ Operating Mode ______
TIRE PRESSURE
Left Front: Right Front:
(psig or kPa) (psig or kPa)

Left Rear: Right Rear:

(psig or kPa) (psig or kPa)

Fuel Density:
(lbs per gallon)

Inertial Weight Setting:

(lab)

UDDS Cold Start (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

UDDS Hot Start (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

213 Chpt IV, Sect IV

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VIN Number: ______________________ Operating Mode ______

1st HWFEDS Hot Start (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

2nd HWFEDS Hot Start (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

214 Chpt IV, Sect IV

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VIN Number: ______________________ Operating Mode ______

1st US06 Hot Start (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

2nd US06 Hot Start (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

215 Chpt IV, Sect IV

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DAY FIVE
VIN Number: ______________________ Operating Mode ______
TIRE PRESSURE
Left Front: Right Front:
(psig or kPa) (psig or kPa)

Left Rear: Right Rear:

(psig or kPa) (psig or kPa)

Fuel Density:
(lbs per gallon)

Inertial Weight Setting:

(lab)

UDDS A/C Cold Start:

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

1st UDDS A/C Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

216 Chpt IV, Sect IV

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VIN Number: ______________________ Operating Mode ______

1st HWFEDS A/C Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

2nd HWFEDS A/C Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

217 Chpt IV, Sect IV

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VIN Number: ______________________ Operating Mode ______

__ th UDDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th UDDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

218 Chpt IV, Sect IV

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VIN Number: ______________________ Operating Mode ______

__ th HWFEDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th HWFEDS Hot Start (charge depleting): :

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

219 Chpt IV, Sect IV

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VIN Number: ______________________ Operating Mode ______

__ th UDDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th UDDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

220 Chpt IV, Sect IV

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(Page 26 of 31)

VIN Number: ______________________ Operating Mode ______

__ th HWFEDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th HWFEDS Hot Start (charge depleting): :

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

221 Chpt IV, Sect IV

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(Page 27 of 31)

VIN Number: ______________________ Operating Mode ______

__ th UDDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th UDDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

222 Chpt IV, Sect IV

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(Page 28 of 31)

VIN Number: ______________________ Operating Mode ______

__ th HWFEDS Hot Start (charge depleting):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__ th HWFEDS Hot Start (charge depleting): :

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

223 Chpt IV, Sect IV

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Appendix C – SAE J1711 Driving Schedule

(Page 29 of 31)

VIN Number: ______________________ Operating Mode ______

1st UDDS A/C Hot Start (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

2nd UDDS A/C Hot Start (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

224 Chpt IV, Sect IV

 AVTA-PHTP03

Appendix C – SAE J1711 Driving Schedule

(Page 30 of 31)

VIN Number: ______________________ Operating Mode ______

1st HWFEDS A/C Hot Start (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

2nd HWFEDS A/C Hot Start (charge sustaining):

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Fuel Weight: ________(kg/lbs) Fuel Weight: ________(kg/lbs)
Fuel Meter: ________ Fuel Meter: ________
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

225 Chpt IV, Sect IV

 AVTA-PHTP03

Appendix C – SAE J1711 Driving Schedule

(Page 31 of 31)

VIN Number: ______________________ Operating Mode ______

Time: Speed: Distance: Comments: Initials:

226 Chpt IV, Sect IV

 AVTA-PHTP03

Appendix D – SAE J1711 Energy Efficiency

(Page 1 of 8)
VIN Number: ______________________ Operating Mode ______

DAY ONE
Fuel Economy
Drive Cycle ∆ RESS Energy/
Fuel Economy RESS Correction
Description Fuel Energy
US06 Cold Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge depleting) Method ____
1st US06 Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge depleting) Method ____
2nd US06 Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge depleting) Method ____
3rd US06 Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge depleting) Method ____

RESS Energy
Drive Cycle RESS Capacity RESS Capacity DC Energy
Description Supplied (Ah/mi) Supplied (%/mi) Supplied (kWh/mi)
US06 Cold Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge depleting)
1st US06 Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge depleting)
2nd US06 Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge depleting)
3rd US06 Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge depleting)

Charger
AC into the Charger: _____________ (kWh) DC into the RESS: ____________ (kWh)

Approval
Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

227 Chpt IV, Sect IV

 AVTA-PHTP03

Appendix D – SAE J1711 Energy Efficiency

(Page 2 of 8)
VIN Number: ______________________ Operating Mode ______

DAY TWO
Fuel Economy
Drive Cycle ∆ RESS Energy/
Fuel Economy RESS Correction
Description Fuel Energy
______mpg
HWFEDS Cold Start _____ (J) / _____ (J) ___________ (gal)
Method ____
1st HWFEDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge depleting) Method ____
2nd HWFEDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge depleting) Method ____
3rd HWFEDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge depleting) Method ____
__th HWFEDS (charge ______mpg
_____ (J) / _____ (J) ___________ (gal)
depleting) Method ____
__th HWFEDS (charge ______mpg
_____ (J) / _____ (J) ___________ (gal)
depleting) Method ____
__th HWFEDS (charge ______mpg
_____ (J) / _____ (J) ___________ (gal)
depleting) Method ____
__th HWFEDS (charge ______mpg
_____ (J) / _____ (J) ___________ (gal)
depleting) Method ____
__th HWFEDS (charge ______mpg
_____ (J) / _____ (J) ___________ (gal)
depleting) Method ____
__th HWFEDS (charge ______mpg
_____ (J) / _____ (J) ___________ (gal)
depleting) Method ____
1st HWFEDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge sustaining) Method ____
2nd HWFEDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge sustaining) Method ____

228 Chpt IV, Sect IV

 AVTA-PHTP03

Appendix D – SAE J1711 Energy Efficiency

(Page 3 of 8)
VIN Number: ______________________ Operating Mode ______

DAY TWO
RESS Energy
Drive Cycle RESS Capacity RESS Capacity DC Energy
Description Supplied (Ah/mi) Supplied (%/mi) Supplied (kWh/mi)
HWFEDS Cold Start _______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
1st HWFEDS Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge depleting)
2nd HWFEDS Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge depleting)
3rd HWFEDS Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge depleting)
__th HWFEDS (charge
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
depleting)
__th HWFEDS (charge
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
depleting)
__th HWFEDS (charge
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
depleting)
__th HWFEDS (charge
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
depleting)
__th HWFEDS (charge
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
depleting)
__th HWFEDS (charge
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
depleting)
1st HWFEDS Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge sustaining)
2nd HWFEDS Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge sustaining)

Charger
AC into the Charger: _____________ (kWh) DC into the RESS: ____________ (kWh)

Approval
Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

229 Chpt IV, Sect IV

 AVTA-PHTP03

Appendix D – SAE J1711 Energy Efficiency

(Page 4 of 8)
VIN Number: ______________________ Operating Mode ______

DAY THREE
Fuel Economy
Drive Cycle ∆ RESS Energy/
Fuel Economy RESS Correction
Description Fuel Energy
______mpg
UDDS Cold Start _____ (J) / _____ (J) ___________ (gal)
Method ____
1st UDDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge depleting) Method ____
2nd UDDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge depleting) Method ____
3rd UDDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge depleting) Method ____
__th UDDS (charge ______mpg
_____ (J) / _____ (J) ___________ (gal)
depleting) Method ____
__th UDDS (charge ______mpg
_____ (J) / _____ (J) ___________ (gal)
depleting) Method ____
__th UDDS (charge ______mpg
_____ (J) / _____ (J) ___________ (gal)
depleting) Method ____
__th UDDS (charge ______mpg
_____ (J) / _____ (J) ___________ (gal)
depleting) Method ____
__th UDDS (charge ______mpg
_____ (J) / _____ (J) ___________ (gal)
depleting) Method ____
__th UDDS (charge ______mpg
_____ (J) / _____ (J) ___________ (gal)
depleting) Method ____
1st UDDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge sustaining) Method ____
2nd UDDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge sustaining) Method ____

230 Chpt IV, Sect IV

 AVTA-PHTP03

Appendix D – SAE J1711 Energy Efficiency

(Page 5 of 8)
VIN Number: ______________________ Operating Mode ______

DAY THREE
RESS Energy
Drive Cycle RESS Capacity RESS Capacity DC Energy
Description Supplied (Ah/mi) Supplied (%/mi) Supplied (kWh/mi)
UDDS Cold Start _______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
1st UDDS Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge depleting)
2nd UDDS Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge depleting)
3rd UDDS Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge depleting)
__th UDDS (charge
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
depleting)
__th UDDS (charge
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
depleting)
__th UDDS (charge
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
depleting)
__th UDDS (charge
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
depleting)
__th UDDS (charge
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
depleting)
__th UDDS (charge
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
depleting)
1st UDDS Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge sustaining)
2nd UDDS Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge sustaining)

Approval
Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

231 Chpt IV, Sect IV

 AVTA-PHTP03

Appendix D – SAE J1711 Energy Efficiency

(Page 6 of 8)
VIN Number: ______________________ Operating Mode ______
DAY FOUR
Fuel Economy
Drive Cycle ∆ RESS Energy/
Fuel Economy RESS Correction
Description Fuel Energy
UDDS Cold Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge sustaining) Method ____
1st UDDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge sustaining) Method ____
1st HWFEDS ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge sustaining) Method ____
2nd HWFEDS ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge sustaining) Method ____
1st US06 ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge sustaining) Method ____
2nd US06 ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge sustaining) Method ____
RESS Energy
Drive Cycle RESS Capacity RESS Capacity DC Energy
Description Supplied (Ah/mi) Supplied (%/mi) Supplied (kWh/mi)
UDDS Cold Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge sustaining)
1st UDDS Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge sustaining)
1st HWFEDS
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge sustaining)
2nd HWFEDS
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge sustaining)
1st US06
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge sustaining)
2nd US06
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge sustaining)
Charger
AC into the Charger: _____________ (kWh) DC into the RESS: ____________ (kWh)

Approval
Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

232 Chpt IV, Sect IV

 AVTA-PHTP03

Appendix D – SAE J1711 Energy Efficiency

(Page 7 of 8)
VIN Number: ______________________ Operating Mode ______

DAY FIVE
Fuel Economy
Drive Cycle ∆ RESS Energy/
Fuel Economy RESS Correction
Description Fuel Energy
UDDS Cold Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge depleting) Method ____
1st UDDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge depleting) Method ____
1st HWFEDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge depleting) Method ____
2nd HWFEDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge depleting) Method ____
UDDS-UDDS
HWFEDS-HWFEDS
Charge Depletion
1st UDDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge sustaining) Method ____
2nd UDDS Hot Start ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge sustaining) Method ____
1st HWFEDS ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge sustaining) Method ____
2nd HWFEDS ______mpg
_____ (J) / _____ (J) ___________ (gal)
(charge sustaining) Method ____

233 Chpt IV, Sect IV

 AVTA-PHTP03

Appendix D – SAE J1711 Energy Efficiency

(Page 8 of 8)
VIN Number: ______________________ Operating Mode ______

DAY FIVE
RESS Energy
Drive Cycle RESS Capacity RESS Capacity DC Energy
Description Supplied (Ah/mi) Supplied (%/mi) Supplied (kWh/mi)
UDDS Cold Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge depleting)
1st UDDS Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge depleting)
1st HWFEDS Hot
Start _______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge depleting)
2nd HWFEDS Hot
Start _______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge depleting)
UDDS-UDDS
HWFEDS-HWFEDS
Charge Depletion
1st UDDS Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge sustaining)
2nd UDDS Hot Start
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge sustaining)
1st HWFEDS
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge sustaining)
2nd HWFEDS
_______ (Ah/mi) ________ (%/mi) _______ (DC kWh/m)
(charge sustaining)

Charger
AC into the Charger: _____________ (kWh) DC into the RESS: ____________ (kWh)

Approval
Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

234 Chpt IV, Sect IV

 AVTA-PHTP04

Section V: AVTA-PHTP04 – Plug-in Hybrid Electric Vehicle

RESS Only Mode Constant Speed Range Tests

235 Chpt IV, Sect V

 AVTA-PHTP04

TABLE OF CONTENTS

1 Objective ...........................................................................................................................................................237

2 Purpose..............................................................................................................................................................237

3 Documentation..................................................................................................................................................237

4 Initial Conditions and Prerequisites ...............................................................................................................237

5 Testing Activities Requirements......................................................................................................................240

5.1 Range at 45 mph Constant Speed..................................................................................................240

5.2 Range at Maximum Achievable Speed ..........................................................................................242
5.3 Calibration of the Vehicle Speedometer........................................................................................243

APPENDICES

Appendix A – Constant Speed Range Test Data Sheet.........................................................................................244

Appendix B – Maximum Achievable Speed Range Test Data Sheet...................................................................246

Appendix C – Calibration of Vehicle Speedometer Test Data Sheet ..................................................................248

Appendix D – PHEV Metrology Setup Sheet ........................................................................................................249

236 Chpt IV, Sect V

 AVTA-PHTP04

1 Objective
The objective of this procedure is to provide methods for the constant speed range testing
of vehicles capable of operation in a mode utilizing energy only from the rechargeable
energy storage system (RESS Only mode), which are evaluated by the U.S. Department of
Energy Advanced Vehicle Testing Activity (AVTA). Testing is conducted in accordance
with procedures similar to SAE-J227a. These methods are not meant to supersede those of
the testing facility, those specifically addressed by SAE Test Standards, nor of any
regulatory agency who may have or exercise control over the covered activities. This
procedure also provides methods for verifying the accuracy of the vehicle speedometer,
odometer and SOC meter.

2 Purpose
The purpose of this procedure is to identify acceptable methods for the implementation of a
RESS Only Mode Constant Speed Range Test, similar to that identified in SAE J227a, for
vehicles operable in RESS Only mode. The SAE J227a Recommended Practice, although
canceled, established uniform procedures for testing electric battery-powered vehicles as a
total system rather than a collection of its individual subsystems. This procedure shall
collect and retain test data as specified in the PHEV Vehicle Specifications.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read and readily reproducible. This documentation shall contain enough information to
"stand alone"; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion, without the need to review
additional documentation. Review and approval of test documentation shall be in
accordance with procedure AVTA-PHAC04. Storage and retention of records during and
following testing activities shall be completed as described in procedure AVTA-PHAC01.

4 Initial Conditions and Prerequisites

Prior to conducting any portion of the testing, the following initial conditions and
prerequisites shall be met. Satisfactory completion of these items shall be verified as
complete and recorded on the Constant Speed Range Test Data Sheet as contained in
Appendix A.

4.1 Personnel conducting the testing under this procedure shall be familiar with the
requirements of this procedure, shall be trained in accordance with the requirements
of procedure AVTA-PHAC05 and be certified by the Program Manager or the Test
Manager prior to commencing any testing activities.

237 Chpt IV, Sect V

 AVTA-PHTP04

4.2 Road Testing

4.2.1 Road tests shall be performed on a road or test track, which is level to within
1%.
4.2.2 RESS temperatures at the beginning of the test shall be greater than 40˚F
(5˚C), shall be less than 120°F (49°C) and should be less than 100˚F (38°C).
4.2.3 Ambient temperature during road testing shall be within the range of 32°F
(0˚C) to 100°F (38°C).
4.2.4 The average wind speed at the test site during the test shall not exceed 10
mph (16 km/h). Wind gusts shall not exceed 12.3 mph (20 km/h).

4.3 The vehicle shall be tested in its normal configuration with normal appendages
(mirrors, bumpers, hubcaps, etc.) Certain items (hub caps, etc.) may be removed
where necessary for safety.

4.4 Vehicles shall be tested at curb weight plus 300 pounds. Consideration should be
given to how adding instrumentation will affect the test weight and balance of the
vehicle.

4.5 Tires provided with the vehicle shall be the standard tire offered by the Vehicle
Supplier, and shall be inflated to the Supplier’s (placard) recommended cold
inflation pressures. This pressure shall not exceed the maximum allowable pressure
imprinted upon the tire’s sidewall.

4.6 Normal Supplier's recommended lubricants shall be employed.

4.7 Accessories shall not be used during testing activities.

4.8 Full charge conditions for the RESS shall be established using the Supplier's
recommended charging procedure and equipment in accordance with procedure
AVTA-PHTP08.

4.9 Testing required at an initial RESS SOC of 100% shall be initiated with the RESS at
>90%. Testing required at an initial RESS SOC of 50% shall be initiated with the
RESS at 50% ±10%.

4.10 The following data shall be collected during conduct of the various tests specified by
this procedure. Overall error in recording or indicating instruments shall not exceed
±2% of the maximum value of the variable being measured. Periodic calibration
shall be performed and documented to ensure compliance with this requirement.
4.10.1 RESS voltage versus time
4.10.2 RESS current versus time

238 Chpt IV, Sect V

 AVTA-PHTP04

4.10.3 Vehicle speed versus time

4.10.4 Distance versus time
4.10.5 RESS temperature versus time
4.10.6 RESS watts versus time.

4.11 Environmental conditions during the testing shall be recorded and include, at a
minimum, the following:
4.11.1 Range of ambient temperature during the test
4.11.2 Range of wind velocity during the test
4.11.3 Range of wind direction during the test.

4.12 Complete or verify complete procedure AVTA-PHAC06 and AVTA-PHTP11 for the
vehicle being tested.

4.13 A description of the test route, road surface type and condition (SAE J688, "Truck
Ability Prediction Procedure") and lengths and grades of test route shall be recorded.

4.14 The date and starting and ending times shall be recorded.

4.15 The starting and ending vehicle odometer readings shall be recorded.

4.16 All instrumentation used in the test shall be listed in Appendix D, attached to the test
data sheets/results, and shall include the following information:
4.16.1 Manufacturer
4.16.2 Model number
4.16.3 Serial number
4.16.4 Next calibration date

4.17 The speed-time measuring device and other necessary equipment shall be installed so
that they do not hinder vehicle operation or alter the operating characteristics of the
vehicle. Mounting is nominally at the rear of the vehicle.

4.18 Any deviation from the test procedure and the reason for the deviation shall be
recorded in accordance with procedure AVTA-PHAC02.

4.19 All documentation required to complete the testing shall be completed, approved and
issued prior to commencing the testing it addresses.

239 Chpt IV, Sect V

 AVTA-PHTP04

4.20 During data reduction, the actual distance traveled and the corresponding DC
kilowatt-hour and ampere-hour consumption shall be determined. These values
provide the 100% depth of discharge mileage and kWh or Ah value. These values
shall be used throughout the remainder of testing, and shall be the basis for
determining SOCs less than 100%.

4.21 In addition to the formal completion of all sections of this procedure, Section 5.1
may be completed additional times as requested by the AVTA Program Manager or
AVTA Test Manager. [Additional tests may be completed to determine changes to
the range capability of a vehicle, or if a vehicle’s permanently installed
instrumentation is suspected of incorrect operation.]

4.22 Each range test shall be terminated when the specific requirements of the procedure
have been reached. However, if the Supplier’s instructions provide guidance
concerning when to stop driving the vehicle, the vehicle’s range will be the range
achieved when the conditions meeting that guidance have occurred. [Example: If the
owner’s manual/driver’s instructions provided with the vehicle provide direction to
stop driving upon receipt of a specific telltale or other indication normally available
to the driver, the vehicle will be stopped and the test terminated when that
telltale/indication has occurred.]

NOTE:
Only test vehicles that are capable of being driven in RESS Only
mode shall be range tested using this procedure. Vehicles, which
are not capable of being tested in a RESS Only mode, will not be
range tested in this procedure.

5 Testing Activities Requirements

NOTE:
All steps shall be completed in the order written. Deviations from
any step or requirement shall have the approval of the Program
Manager or Test Manager in accordance with procedure AVTA­
PHAC02.

5.1 Range at 45 mph Constant Speed

The purpose of this section is to: (1) determine the maximum range the vehicle can
achieve with the Rechargeable Energy Storage System (RESS) starting at 100%
State of Charge (SOC), the vehicle loaded at curb weight plus 300 pounds, and
operated at a constant speed; and (2) determine the correlation between the RESS
SOC and the mileage driven (which will be used to establish partial SOC conditions
in other protocols).

240 Chpt IV, Sect V

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This testing shall be completed subject to the initial conditions and prerequisites
stated in Section 4 of this procedure. Testing shall be conducted at a constant speed
of 45 mph whenever possible. If the vehicle is not capable of operation in the RESS
Only mode at 45 mph, then the maximum possible RESS Only speed shall be used
for testing.

NOTE:
Constant speed testing is only conducted for vehicles operable in
RESS Only mode.

5.1.1 Instrument the vehicle to obtain, at a minimum, the data identified in Section
4.10. Calibrate the fifth wheel, as necessary.
5.1.2 Verify the RESS is fully charged (100% SOC) in accordance with procedure
AVTA-PHTP08 and the vehicle is in the RESS Only mode.
5.1.3 Record time and the vehicle’s odometer reading in Appendix A.
5.1.4 Adjust the vehicle’s cold tire pressures to match the Supplier’s placard value,
or the maximum cold inflation pressure imprinted upon the tire’s sidewall,
whichever is less.
5.1.5 From a standing start, accelerate the vehicle under its own power to a speed
of 45 mph (72 km/h), or the maximum RESS Only speed as determined in
Section 5.1, ±1 mph (±1.6 km/h). Speed and time may be recorded via a
Data Acquisition System (DAS).
5.1.6 Each time the vehicle passes the lap marker, record the SOC meter reading
and the odometer reading in Appendix A. Each reading shall be recorded in
the smallest increment displayed by its respective indicator.

NOTE:
All vehicles tested will be operated in accordance with the
requirements of the Supplier’s operating manuals/instruction
cards/placards. Should the Supplier’s requirements for stopping the
vehicle be met prior to reaching the criteria in Step 5.1.7, the test
shall be terminated. The official range will be the range achieved at
that point, regardless of remaining capability.

5.1.7 Maintain this speed without interruption until an average vehicle lap speed
within 2 mph (3.2 km/h) of the target speed cannot be maintained.
5.1.8 Pull the vehicle off to the side of the test track. Record the final speed, time,
mileage, SOC meter and odometer reading in Appendix A. (This may be
recorded via a DAS.)
5.1.9 The mileage achieved during this test shall be recorded as the official range
mileage for the vehicle being tested.
5.1.10 Within two hours, recharge the vehicle in accordance with procedure AVTA­
PHTP08, Section 5, to obtain the time to fully recharge the RESS.

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5.1.11 Any abnormalities in either discharge or charge shall be noted in accordance

with procedure AVTA-PHTP12.
5.1.12 Using the SOC meter data in Appendix A determine the following:
[Link] Vehicle range to full RESS discharge
[Link] Vehicle range to 50% RESS SOC
[Link] Accuracy of the SOC meter

NOTE:
SOC meter accuracy should be ± 5% of full scale.

5.2 Range at Maximum Achievable Speed

The purpose of this section is to determine the maximum range the vehicle can
achieve after the vehicle has been soaked for four hours at a minimum ambient
temperature of 100°F. The RESS shall have been fully charged (100% SOC) prior to
the soak period. The vehicle shall be loaded at curb weight plus 300 pounds and
operated at the vehicle’s maximum achievable speed, or 65 mph, whichever is less.
This testing shall be completed subject to the initial conditions and prerequisites
stated in Section 4 of this procedure, as amended by this section.

NOTE:
Range at maximum speed testing is only conducted for vehicles
operable in RESS Only mode and with a maximum speed greater
than 50 mph in RESS Only mode.

5.2.1 The vehicle does not require instrumentation for this test. Odometer readings
shall be sufficient to determine range.
5.2.2 Verify the RESS is at fully charged (100% SOC) in accordance with
procedure AVTA-PHTP08 and the vehicle is in the RESS Only mode.
5.2.3 Record odometer reading and time in Appendix B.
5.2.4 Adjust the vehicle’s cold tire pressures to match the Supplier’s placard value,
or the DOT sidewall pressure, whichever is less.
5.2.5 Identify the maximum speed the vehicle achieved when tested to procedure
AVTA-PHTP02. Record the lesser of this value or 75 mph in Appendix B.

NOTE:
The vehicle shall be operated at the lower of the two speeds in Step
5.2.5. Transitory operation above 75 mph due to track attitude is
allowed.

5.2.6 From a standing start, accelerate the vehicle at wide open throttle to the
maximum speed determined in Step 5.2.5 (above). Speed and time may be
recorded via a Data Acquisition System (DAS.)

242 Chpt IV, Sect V

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5.2.7 Each time the vehicle passes the lap marker, record the SOC meter reading
and the odometer reading. Each reading shall be recorded in the smallest
increment displayed by its respective indicator.

NOTE:
All vehicles tested will be operated in accordance with the
requirements of the Supplier’s operating manuals/instruction
cards/placards. Should the Supplier’s requirements for stopping the
vehicle be met prior to reaching the criteria in Step 5.2.8, the test
shall be terminated. The Official Range will be the range achieved
at that point, regardless of remaining capability.

5.2.8 Maintain this speed without interruption until a minimum vehicle speed of at
least 40 mph cannot be maintained, or Supplier’s requirements for stopping
the vehicle are met. Record the final speed, odometer reading and time in
Appendix B. (This may be recorded via a DAS.)
5.2.9 Pull the vehicle off to the side of the test track. Record the time, miles
traveled, and odometer reading in Appendix B. (This may be recorded via a
DAS.)

5.3 Calibration of the Vehicle Speedometer and Odometer

This section should be completed in conjunction with procedure AVTA-PHTP06 as
well as in conjunction with Sections 5.1 and 5.2 of this procedure. It may also be
implemented any time the speedometer is suspected of incorrect operation.
5.3.1 Ensure the vehicle is instrumented with a DAS.
5.3.2 With the vehicle stopped, record the odometer reading.
5.3.3 Accelerate the vehicle to 20 mph. Record the speedometer reading and the
DAS speed readout.
5.3.4 Increase vehicle speed in 5 mph increments, recording the speedometer and
DAS speed read-out at each speed. Continue this until the vehicle has
achieved 80 mph, or maximum achievable speed, whichever is less.
5.3.5 Reduce speed to a nominal 40 mph and proceed for at least 10 miles.
5.3.6 Develop a speedometer calibration reference table, Appendix C, for the
speedometer and a correction factor for the odometer.
5.3.7 Mount the calibration reference table in the subject vehicle adjacent to the
speedometer.
5.3.8 Verify that the speedometer accuracy is at least ± 5% of full scale.
5.3.9 Verify that the odometer accuracy is at least ± 5%.

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Appendix A – Constant Speed Range Test Data Sheet

(Page 1 of 2)

VIN Number: ______________________________ Test Speed: ________________ mph

Project No.: Test Date(s):
Data File Name:
Test Driver:
(Initials) (Date)

Test Engineer:
(Initials) (Date)

Vehicle Setup
VEHICLE WEIGHTS AS TESTED WITH DRIVER & INSTRUMENTATION
(Test Weight is Curb Weight plus 300 pounds)
Left Front: Right Front: Total Front: Percent Front: %
(lbs or kg) (lbs or kg) (lbs or kg)

Left Rear: Right Rear: Total Rear: Percent Rear: %

(lbs or kg) (lbs or kg) (lbs or kg)

Total Weight:
(lbs or kg)

INSTALLED TIRES
(Placard or sidewall whichever is less)
Preparation Area Temperature:
°F( or °C)

Left Front Right Front

Pressure: Pressure:
(psi or kPa) (psi or kPa)

Left Rear Right Rear

Pressure: Pressure:
(psi or kPa) (psi or kPa)

Track/Weather Conditions
Test Track Location: Track Grade: %
Ambient Temperature (initial): Ambient Temperature (final):
(32-100°F or 0-38°C) (32-100°F or 0-38°C)

Track Temperature (initial): Track Temperature (final):

(°F or °C) (°F or °C)

Wind Velocity (initial): Wind Velocity (final):

(<10 mph or 16 km/h) (<10 mph or 16 km/h)

Wind Direction (initial): ° Wind Direction (completion): °

244 Chpt IV, Sect V

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Appendix A – Constant Speed Range Test Data Sheet

(Page 2 of 2)

VIN Number: ______________________________ Test Speed: ________________ mph

Sequence No: File Name: Direction of Travel:
Time (initial): Time (final):
Odometer (initial): Odometer (final):
(miles or kilometers) (miles or kilometers)

State of Charge (initial): State of Charge (final):

(SOC,kWh,Ah) (SOC,kWh,Ah)

RESS Temp (initial): RESS Temp (final):

(°F or °C) (°F or °C)

Comments (initials/date):
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________

Completed By:
(Printed Name) (Signature) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

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Appendix B – Maximum Achievable Speed Range Test Data

Sheet
(Page 1 of 2)

VIN Number: ______________________________ Test Speed: ________________ mph

Project No.: Test Date(s):
Data File Name:
Test Driver:
(Initials) (Date)

Test Engineer:
(Initials) (Date)

Vehicle Setup
VEHICLE WEIGHTS AS TESTED WITH DRIVER & INSTRUMENTATION
(Test Weight is Curb Weight plus 300 pounds)
Left Front: Right Front: Total Front: Percent Front: %
(lbs or kg) (lbs or kg) (lbs or kg)

Left Rear: Right Rear: Total Rear: Percent Rear: %

(lbs or kg) (lbs or kg) (lbs or kg)

Total Weight:
(lbs or kg)

INSTALLED TIRES
(Placard or sidewall whichever is less)
Preparation Area Temperature:
°F( or °C)

Left Front Right Front

Pressure: Pressure:
(psi or kPa) (psi or kPa)

Left Rear Right Rear

Pressure: Pressure:
(psi or kPa) (psi or kPa)

Track/Weather Conditions
Test Track Location: Track Grade: %
Ambient Temperature (initial): Ambient Temperature (final):
(32-100°F or 0-38°C) (32-100°F or 0-38°C)

Track Temperature (initial): Track Temperature (final):

(°F or °C) (°F or °C)

Wind Velocity (initial): Wind Velocity (final):

(<10 mph or 16 km/h) (<10 mph or 16 km/h)

Wind Direction (initial): ° Wind Direction (completion): °

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Appendix B – Maximum Achievable Speed Range Test Data

Sheet
(Page 2 of 2)

VIN Number: ______________________________ Test Speed: ________________ mph

Sequence No: File Name: Direction of Travel:
Time (initial): Time (final):
Odometer (initial): Odometer (final):
(miles or kilometers) (miles or kilometers)

State of Charge (initial): State of Charge (final):

(SOC,KWH,AH) (SOC,KWH,AH)

RESS Temp (initial): RESS Temp (final):

(°F or °C) (°F or °C)

Comments (initials/date):
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________

Completed By:
(Printed Name) (Signature) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

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Appendix C – Calibration of Vehicle Speedometer Test Data

Sheet
(Page 1 of 1)

VIN Number: _____________________________

Sequence No: File Name: Direction of Travel:
Time (initial): Time (final):
Odometer (initial): Odometer (final):
(miles or kilometers) (miles or kilometers)

State of Charge (initial): State of Charge (final):

(SOC,KWH,AH) (SOC,KWH,AH)

DAS Heads-up Display: Vehicle Speedometer:

20 mph
25 mph
30 mph
35 mph
40 mph
45 mph
50 mph
55 mph
60 mph
65 mph
70 mph
75 mph
80 mph
Comments (initials/date):
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
___________________________________

Completed By:
(Printed Name) (Signature) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

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 AVTA-PHTP04

Appendix D – PHEV Metrology Setup Sheet

(Page 1 of 1)

VIN Number: ________________________________

Instrument/Device: Calibration Due Date: Initials / Date:
Fifth Wheel S/N:
Fifth Wheel Calibrator S/N:
DAS S/N:
DAS Set-up Sheet S/N:
kWh Meter S/N:
Shunt S/N:
Tire Pressure Gauge S/N:
Misc:
Misc:
Misc:
Misc:
Comments (initials/date):

Completed By:
__________________________________________________________________________
(Printed Name) (Signature) (Date)

Reviewed By (QA):
____________________________________________________________________________
(Printed Name) (Signature) (Date)

Approved By:
_____________________________________________________________________________
(Printed Name) (Signature) (Date)

249 Chpt IV, Sect V

 AVTA-PHTP05

Section VI: AVTA-PHTP05 – Plug-in Hybrid Electric Vehicle

Rough Road Course Test

250 Chpt IV, Sect VI

 AVTA-PHTP05

TABLE OF CONTENTS

1 Objective ...........................................................................................................................................................252

2 Purpose..............................................................................................................................................................252

3 Documentation..................................................................................................................................................252

4 Initial Conditions and Prerequisites ...............................................................................................................252

5 Rough Road Testing .........................................................................................................................................254

APPENDICES

Appendix A – PHEV Rough Road Test Data Sheet..............................................................................................261

Appendix B – PHEV Metrology Setup Sheet ........................................................................................................263

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1 Objective
The objective of this procedure is to provide methods for evaluating the durability of plug-
in hybrid electric vehicles (PHEV) evaluated by the U.S. Department of Energy Advanced
Vehicle Testing Activity (AVTA). These methods are not meant to supersede those of the
testing facility, those specifically addressed by SAE Test Standards, nor of any regulatory
agency which may have or exercise control over the covered activities.

2 Purpose
The purpose of this test is to (1) accumulate standardized test-mileage on each vehicle over
a test track that includes rough road, water hazard and smooth track; and (2) test the
vehicles ability to endure extreme conditions over a short time frame. This test is not
intended to determine range or speed capabilities of any vehicle. No inferences concerning
a vehicle’s speed, range or gradeability characteristics should be drawn from this test. This
activity is meant to test the vehicle as a total system. Tests of specific subsystems or
portions of individual subsystems are addressed by other Test Procedures. This testing and
data acquisition meets the requirements specified in the PHEV Vehicle Specification.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read and readily reproducible. This documentation shall contain enough information to
"stand alone.” That is, to be self-contained to the extent that all individuals qualified to
review it could reasonably be expected to reach a common conclusion, without the need to
review additional documentation. Review and approval of test documentation shall be in
accordance with procedure AVTA-PHAC04. Storage and retention of records during and
following testing activities shall be completed as described in procedure AVTA-PHAC01.

4 Initial Conditions and Prerequisites

Prior to conducting any portion of the testing, the following initial conditions and
prerequisites shall be met. Satisfactory completion of these items shall be verified as
complete and recorded on the Test Data Sheet.

4.1 Personnel conducting testing under this procedure shall be familiar with the
requirements of this procedure, shall be trained in accordance with the requirements
of procedure AVTA-PHAC05 and be certified by the Program Manager or the Test
Manager prior to commencing any testing activities.

4.2 Ambient temperature during road testing shall be within the range of 32°F (0˚C) to
100°F (38°C).

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4.3 RESS temperatures at the beginning of the test shall be greater than 40˚F (5˚C), shall
be less than 120°F (49°C) and should be less than 100˚F (38°C).

4.4 The average wind speed at the test site during the test shall not exceed 10 mph (16
km/h). Wind gusts shall not exceed 12.3 mph (20 kph).

4.5 Testing shall be completed over a "rough road" course which contains smooth
asphalt, potholes, cobblestones, washboard and standing water. The test facility
utilized by the AVTA at Exponent Failure Analysis in Phoenix, Arizona incorporates
such features.

4.6 Speeds identified for each hazard have been determined to be the optimum speed for
testing the vehicle at that hazard. Attempting to negotiate a hazard at a speed
different than that identified should be avoided.

4.7 Vehicles shall be tested in their normal configuration with normal appendages
(mirrors, bumpers, hubcaps, etc.). Certain items (hub caps, etc.) may be removed
where necessary for safety.

4.8 Vehicles shall be loaded at curb weight plus 300 pounds.

4.9 Tires provided with the vehicle shall be the standard tires offered by the Supplier.
Tires shall be inflated to the Supplier’s recommended (placard) cold inflation
pressure.

4.10 Supplier's recommended lubricants shall be employed.

4.11 Verify the RESS is at 100% SOC in accordance with the requirements of procedure
AVTA-PHTP08.

4.12 Overall error in recording or indicating instruments shall not exceed ±2% of the
maximum value of the variable being measured unless otherwise accepted. Periodic
calibration shall be performed and documented to ensure compliance with this
requirement.

4.13 Complete or verify completed procedures AVTA-PHAC06 and AVTA-PHTP11 for

the vehicle being tested.

4.14 The road surface type and condition as defined in SAE J688, "Truck Ability
Prediction Procedure,” and lengths and grades of test route shall be noted.

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4.15 Instrumentation used in the test shall be identified in Appendix B, and attached to the
test results. It shall include the following information:
4.15.1 Manufacturer
4.15.2 Model number
4.15.3 Serial number
4.15.4 Calibration date

4.16 Any deviation from the test procedure and the reason for the deviation shall be
approved in advance and so noted on the appropriate data sheet(s).

4.17 Any necessary equipment shall be installed in a manner that does not hinder vehicle
operation or alter the operating characteristics of the vehicle.

4.18 Accessories shall not be used during the rough road testing.

4.19 Speeds for each hazard or groups of hazards shall be posted on the test track to allow
the driver(s) to achieve the required speed prior to encountering the hazard.

4.20 Prior to the initial test sequence, the vehicle’s underside shall be inspected to identify
any pre-existing damage. Any damage shall be recorded in writing. Photographs
shall be taken to document the conditions.

4.21 Subsequent to each completed test cycle, the vehicle’s underside shall again be
inspected to ascertain any additional damage resulting from the conduct of the test.
Any additional damage shall be photographed and recorded in the comments section.

5 Rough Road Testing

This procedure was written specifically for implementation at the Test Track at Exponent
in Phoenix, Arizona. Hazards and appropriate speeds for negotiation of those hazards are
specific to this facility.

CAUTION:
Deviations from the speeds prescribed can present a safety issue
for vehicles. All vehicles should maintain posted speed. If any
vehicle cannot maintain or achieve speed, it shall be removed from
the course.

CAUTION:
Should any vehicle become disabled during testing, it shall be
immediately removed from the test course.

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NOTE:
Conduct of this procedure should be coordinated with efficiency
testing of the grid-connected charger in accordance with procedure
AVTA-PHTP08.

FRONT SIDE
3" Deep Random Chuck Holes 5 mph (8 km/h)
Sine Wave 10 mph (16 km/h)
Railroad Crossing 15 mph (24 km/h)
Perpendicular Dip 15 mph (24 km/h)
Diagonal Dip 15 mph (24 km/h)
Single Wheel Dip 15 mph (24 km/h)
1" Deep Random Chuck Holes 20 mph (32 km/h)
Adjustable Irregularities (tar strips) 25 mph (40 km/h)
Road Crown 30 mph (48 km/h)
BACK SIDE
1" Deep Random Chuck Holes 25 mph (40 km/h)
Belgian Blocks (cobblestone) 25 mph (40 km/h)
Railroad crossing 25 mph (40 km/h)
2” Standing Water 20 mph (32 km/h)

5.1 Record the VIN/Test number of the vehicle being tested in Appendix A.

5.2 Record the vehicle's cold inflation tire pressure. Adjust the cold inflation tire
pressure to meet the requirements of the Supplier’s placard, if necessary.

5.3 Verify the RESS is at 100% SOC in accordance with the requirements of procedure
AVTA-PHTP08 and place the vehicle in the Normal Operation mode.

5.4 Record the following environmental conditions:

5.4.1 Ambient temperature
5.4.2 RESS temperature (at the discretion of the Test Manager)
5.4.3 Wind velocity
5.4.4 Wind direction
5.4.5 Record vehicle odometer reading

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NOTE:
If more than one vehicle is being tested, test vehicles shall
maintain a nominal safe distance between themselves and the
vehicle in front of them, in accordance with accepted standards.

NOTE:
During this testing, if a vehicle fails electrically or mechanically
for any reason, that vehicle shall be removed from this testing
scheme until such time as the Supplier can repair it. See procedure
AVTA-PHAC02 for additional details.

NOTE:
The test sequence for this procedure will be to complete a 4-hour
soak; complete ten stop/start evolutions; complete five laps
through the rough road course, and then complete 20 laps at 55
mph. Specific direction is provided below.

NOTE:
When instructed to decelerate in Steps 5.4 through 5.23, the driver
shall begin the deceleration approximately 135 feet prior to the
stop sign. These deceleration points shall be marked on the test
track.

NOTE:
Vehicle odometer readings shall be recorded in Appendix A upon
initiation and also completion of testing.

5.5 Move the vehicle to the handling pad (Exponent) or similar area. The vehicle’s
windows shall be completely closed, except for the driver’s and front passenger’s
windows, which may each be left open no more than one-half (1/2) inch. The vehicle
shall be parked with the windshield facing South.

5.6 The vehicle shall be soaked for at least four hours, during which time it shall have
been exposed to a minimum ambient temperature of at least 100°F (38˚C) for at least
one hour of the four-hour soak. If ambient temperatures will not reach 100˚F, the
vehicle may be soaked in a suitable soak chamber at a minimum of 100˚F for four
hours before being moved to the handling pad in lieu of performing a soak on the
handling pad. At the completion of this soak period, immediately move the vehicle to
the test track starting point.

5.7 From the starting point, smoothly accelerate the vehicle at maximum achievable
acceleration to 45 mph, and continue approximately one (1) mile to the stop sign.

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5.8 Decelerate the vehicle and bring it to a complete stop at the stop sign.

5.9 From the stop sign, rapidly accelerate the vehicle to 45 mph and continue
approximately one (1) mile to the next stop sign.

5.10 Decelerate the vehicle and bring it to a complete stop at the stop sign. The first lap is
complete.

5.11 From the stop sign, rapidly accelerate the vehicle to 45 mph and continue
approximately one (1) mile to the next stop sign.

5.12 Decelerate the vehicle and bring it to a complete stop at the stop sign.

5.13 From the stop sign, rapidly accelerate the vehicle to 45 mph and continue
approximately one (1) mile to the next stop sign.

5.14 Decelerate the vehicle and bring it to a complete stop at the stop sign. The second lap
is complete.

5.15 From the stop sign, rapidly accelerate the vehicle to 45 mph and continue
approximately one (1) mile to the next stop sign.

5.16 Decelerate the vehicle and bring it to a complete stop at the stop sign.

5.17 From the stop sign, rapidly accelerate the vehicle to 45 mph and continue
approximately one (1) mile to the next stop sign.

5.18 Decelerate the vehicle and bring it to a complete stop at the stop sign. The third lap is
complete.

5.19 From the stop sign, rapidly accelerate the vehicle to 45 mph and continue
approximately one (1) mile to the next stop sign.

5.20 Decelerate the vehicle and bring it to a complete stop at the stop sign.

5.21 From the stop sign, rapidly accelerate the vehicle to 45 mph and continue
approximately one (1) mile to the next stop sign.

5.22 Decelerate the vehicle and bring it to a complete stop at the stop sign. The fourth lap
is complete.

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5.23 From the stop sign, rapidly accelerate the vehicle to 45 mph and continue
approximately one (1) mile to the next stop sign.

5.24 Decelerate the vehicle and bring it to a complete stop at the stop sign.

5.25 From the stop sign, rapidly accelerate the vehicle to 45 mph and continue
approximately one (1) mile to the next stop sign.

5.26 Decelerate the vehicle and bring it to a complete stop at the stop sign. The fifth lap is
complete.

5.27 Stop-Start Portion of the test is complete.

5.28 From the Stop sign, accelerate the vehicle to 5 mph and negotiate the 3" Deep
Random Chuck Holes.

5.29 After completing negotiation of the 3" Deep Random Chuck Holes, smoothly
accelerate the vehicle so as to enter the Sine Wave at 10 mph.

5.30 After completing negotiation of the Sine Wave, smoothly accelerate the vehicle so as
to enter the Railroad Crossing at 15 mph.

5.31 After completing negotiation of the Railroad Crossing, maintain the vehicle speed so
as to enter the Perpendicular Dip at 15 mph.

5.32 After completing negotiation of the Perpendicular Dip, maintain the vehicle speed so
as to enter the Diagonal Dip at 15 mph.

5.33 After completing negotiation of the Diagonal Dip, maintain the vehicle speed so as
to enter the Single Wheel Dip at 15 mph.

5.34 After completing negotiation of the Single Wheel Dip, smoothly accelerate the
vehicle speed so as to enter the 1" Deep Random Chuck Holes at 20 mph.

5.35 After completing negotiation of the 1" Deep Random Chuck Holes, smoothly
accelerate the vehicle speed so as to enter the Adjustable Irregularities (Tar Strips) at
25 mph.

5.36 After completing negotiation of the Adjustable Irregularities (Tar Strips), smoothly
accelerate the vehicle speed so as to enter the Road Crown Intersection at 30 mph.

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5.37 After completing negotiation of the Road Crown Intersection, maintain speed at 30
mph and negotiate the transition to the back side of the track.

5.38 Smoothly decelerate the vehicle so as to enter the 1" Deep Random Chuck Holes at
25 mph.

5.39 Maintain speed so as to negotiate the Belgian Block section at 25 mph.

5.40 Maintain this vehicle speed so as to negotiate the Railroad Crossing section at 25
mph.

5.41 Smoothly decelerate the vehicle to achieve a speed of 20 mph through the 2-inch
Standing Water Bath.

5.42 After completing negotiation of the 2-inch Standing Water Bath, smoothly accelerate
the vehicle to 45 mph [55 mph if completing for the fifth (5th) time]. Maintain this
speed through the back turn.

5.43 Decelerate the vehicle to 5 mph so as to enter the 3" Deep Random Chuck Holes at 5
mph.

5.44 Repeat steps 5.28 through 5.42, IN ORDER, until the vehicle has traveled five (5)
laps (approximately 10 miles).

5.45 Accelerate the vehicle to 55 mph.

5.46 Drive the vehicle at 55 mph for 20 Laps (approximately 40 miles). If this is the first
test sequence, continue to step 5.47. If this is the second test sequence, skip to Step
5.48.

5.47 When the vehicle has completed 20 Laps at 55 mph, the first phase of this test is
complete. Move the vehicle to the garage area and record the following:
5.47.1 Record the RESS leakage current (RESS-to-chassis). Current shall be less
than 0.5 MIU.
5.47.2 Place the vehicle on charge in accordance with procedure AVTA-PHTP08.
Within 5 minutes of placing the vehicle on charge (if applicable), read and
record the charger leakage current (chassis to ground). Current shall be less
than 5 mA.

5.48 Record or verify as recorded the following data in Appendix A:

5.48.1 Date and time of test phase completion

259 Chpt IV, Sect VI

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5.48.2 SOC reading (kWh consumed and percent)

5.48.3 Miles traveled / laps completed
5.48.4 Equipment failures, if any
5.48.5 Equipment abnormalities, if any
5.48.6 Damage to vehicle underside
5.48.7 Damage to any vehicle components
5.48.8 RESS leakage current
5.48.9 Driver notes, if any.

5.49 Move the vehicle to the charging station and recharge the RESS to 100% SOC in
accordance with procedure AVTA-PHTP08. Record the AC energy used for this
charge in accordance with procedure AVTA-PHTP08 for use in determining
charging efficiency.

5.50 Repeat steps 5.2 through 5.49.

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Appendix A – PHEV Rough Road Test Data Sheet

(Page 1 of 2)

VIN Number: _______________________

Project No.: Test Date(s):
Data File Name:
Test Driver:
(Initials) (Date)

Test Engineer:
(Initials) (Date)

Vehicle Setup
VEHICLE WEIGHTS AS TESTED (Curb weight plus 300 pounds)
Left Front: Right Front: Total Front: Percent Front: %
(lbs or kg) (lbs or kg) (lbs or kg)

Left Rear: Right Rear: Total Rear: Percent Rear: %

(lbs or kg) (lbs or kg) (lbs or kg)

Total Weight:
(lbs or kg)

INSTALLED TIRES (Placard or sidewall whichever is less)

Left Front Right Front
Pressure: Pressure:
(psi or kPa) (psi or kPa)

Left Rear Right Rear

Pressure: Pressure:
(psi or kPa) (psi or kPa)

VEHICLE SOAK
Vehicle Soaked Minimum of Four (4) Hours at 100°F (initial)

Track/Weather Conditions
Test Track Location: Track Grade: %
Ambient Temperature (initial): Ambient Temperature (final):
(32-100°F or 0-38°C) (32-100°F or 0-38°C)

Track Temperature (initial): Track Temperature (final):

(°F or °C) (°F or °C)

Wind Velocity (initial): Wind Velocity (final):

(<10 mph or 16 km/h) (<10 mph or 16 km/h)

Wind Direction (initial): ° Wind Direction (completion): °

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Appendix A – PHEV Rough Road Test Data Sheet

(Page 2 of 2)

VIN Number: ________________________

Sequence No: 1 File Name: Direction of Travel:
Soak Time (initial): Soak Time (final):
(Minimum 8 hours)

Range Time (initial): Range Time (final):

Odometer (initial): Odometer (final):

(miles or kilometers) (miles or kilometers)

State of Charge (initial): State of Charge (final):

(SOC,kWh,Ah) (SOC,kWh,Ah)

RESS Temp (initial): RESS Temp (final):

(°F or °C) (°F or °C)

Comments (initials/date):
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________

Completed By: __________________________________________________________________

(Printed Name) (Signature ) (Date)

Reviewed By: __________________________________________________________________

(Printed Name) (Signature) (Date)

Approved By: __________________________________________________________________

(Printed Name) (Signature) (Date)

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Appendix B – PHEV Metrology Setup Sheet

(Page 1 of 1)

VIN Number: _____________________

Instrument/Device: Calibration Due Date: Initials / Date:
Fifth Wheel S/N:
Fifth Wheel Calibrator S/N:
DAS S/N:
DAS Set-up Sheet S/N:
kWh Meter S/N:
Shunt S/N:
Tire Pressure Gauge S/N:
Misc:
Misc:
Misc:
Misc:
Comments (initials/date):

Completed By: _______________________________________________________________

(Printed Name) (Signature ) (Date)

Reviewed By: ________________________________________________________________

(Printed Name) (Signature) (Date)

Approved By: ________________________________________________________________

(Printed Name) (Signature) (Date)

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Section VII: AVTA-PHTP06 – Braking Test

264 Chpt IV, Sect VII

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TABLE OF CONTENTS

1 Objective ...........................................................................................................................................................266

2 Purpose..............................................................................................................................................................266

3 Documentation..................................................................................................................................................266

4 Initial Conditions and Prerequisites ...............................................................................................................266

5 Testing Activity Requirements ........................................................................................................................268

APPENDICES

Appendix A – Braking Test Data Sheet .................................................................................................................271

Appendix B – PHEV Metrology Setup Sheet ........................................................................................................274

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1 Objective
This procedure identifies methods for evaluating the braking performance of vehicles
evaluated by the U.S. Department of Energy Advanced Vehicle Testing Activity (AVTA).
These methods are not meant to supersede those of the testing facility, those specifically
addressed by SAE Test Standards, nor of any regulatory agency, which may have or
exercise control over the covered activities.

2 Purpose
The purpose of this test is to qualitatively evaluate the controllability of a vehicle during
braking. Both the stopping distance and the ability to maintain the vehicle in control
(defined as staying in the course lane) are tested. This test is not intended to satisfy the
requirements of Section 105 of 49 CFR 571. [For example, the vehicle is tested with dry
brakes on a wet surface.] This activity is meant to test the vehicle as a total system. Tests
of specific subsystems or portions of individual subsystems are addressed by other Test
Procedures, as appropriate. This testing and data acquisition meets the requirements
specified in the PHEV Vehicle Specification.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read and readily reproducible. This documentation shall contain enough information to
"stand alone"; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion, without the need to review
additional documentation. Review and approval of test documentation shall be in
accordance with procedure AVTA-PHAC04. Storage and retention of records during and
following testing activities shall be completed as described in procedure AVTA-PHAC01.

4 Initial Conditions and Prerequisites

Prior to conduct of any portion of the testing, the following initial conditions and
prerequisites shall be met. Satisfactory completion of these items shall be verified as
complete and recorded in Appendix A.

4.1 Personnel conducting testing under this procedure shall be familiar with the
requirements of this procedure, shall be trained in accordance with the requirements
of procedure AVTA-PHAC05 and be certified by the Program Manager or the Test
Manager prior to commencing any testing activities.

4.2 Ambient temperature during road testing shall be within the range of 32°F (0˚C) to
100°F (38°C).

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4.3 RESS temperatures at the beginning of the test shall be greater than 40˚F (5˚C), shall
be less than 120°F (49°C) and should be less than 100˚F (38°C).

4.4 The average wind speed at the test site during the test shall not exceed 10 mph (16
km/h). Wind gusts shall not exceed 12.3 mph (20 kph).

4.5 Testing shall be completed on a rolled asphalt "braking course" defined by the
AVTA at the test facility of Exponent Failure Analysis Associates (or equivalent).

4.6 Vehicles shall be tested in their normal configuration with normal appendages
(mirrors, bumpers, hubcaps, etc.). Certain items (hubcaps, etc.) may be removed
where necessary for safety.

4.7 Vehicles shall be tested at delivered curb weight plus 300 pounds.

4.8 Tires provided with the vehicle shall be the standard tires offered by the Supplier.

4.9 Supplier's normal recommended lubricants shall be employed.

4.10 Accessories shall not be used or operated during testing.

4.11 Vehicles shall be tested in the Normal Operation mode. Verify the vehicle is in the
Normal Operation mode.

4.12 Verify the RESS is at an initial state of charge at charge-sustaining mode in

accordance with Section 5.1 of procedure AVTA-PHTP08.

4.13 The overall error of recording or indicating instruments shall not exceed ±2% of the
maximum value of the variable being measured. Periodic calibration shall be
performed and documented to ensure compliance with this requirement.

4.14 Complete or verify completed procedures AVTA-PHAC06 and AVTA-PHTP11 for

the vehicle being tested.

4.15 The road surface type and condition as defined in SAE J688, "Truck Ability
Prediction Procedure,” and lengths and grades of test route shall be noted.

4.16 For instrumentation used in the test, at a minimum, record the following information
for each instrument in Appendix B:
4.16.1 Manufacturer
4.16.2 Model number

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 AVTA-PHTP06

4.16.3 Serial number

4.16.4 Next calibration date

4.17 Any deviation from the test procedure and the reason for the deviation shall be
recorded in accordance with procedure AVTA-PHAC02.

4.18 Speed-time measuring devices and other necessary equipment shall be installed in a
manner that does not hinder vehicle operation or alter the operating characteristics of
the vehicle.

4.19 All steps shall be completed in the order written. Deviations from any step or
requirement must have the prior written approval of the Program Manager, Test
Director or Test Manager in accordance with procedure AVTA-PHAC02.

4.20 All documentation required to complete the testing identified in the technical
requirements of the PHEV Vehicle Specification shall be completed, approved and
issued prior to the effective date of the procedure. In no case shall the procedure be
utilized for official testing or data collection prior to its effective date.

4.21 Testing may take place over the course of several days. Page 1 of Appendix A shall
be completed for each day testing is commenced.

5 Testing Activity Requirements

This test qualitatively evaluates the controllability of a vehicle when attempting to stop
from 60 mph on a dry asphalt surface. It objectively measures the distance required to do
so. Sections 5.1 and 5.2 apply to the entire test sections identified.
An asphalt vehicle dynamics pad shall be assembled as a straight path with a nominal
length of 400 feet. The width of the lane should be at least 12 feet. Lane width shall be
marked by the use of traffic cones or similar devices. Markers shall be a soft resilient
material, which can withstand a vehicle impact, without damaging the vehicle.

NOTE:
During this testing, if a vehicle fails electrically or mechanically
for any reason, testing of the vehicle shall be halted, and the
vehicle removed from the test program until the Supplier has
completed repairs. See procedure AVTA-PHAC02 for additional
details.

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NOTE:
If the vehicle is equipped with regenerative braking, the
regenerative braking system shall be engaged during this test. If
the level of regenerative braking can be adjustable by the driver,
the setting with the highest level of regenerative power shall be
employed.

5.1 Instrument the vehicle to obtain the following data:

5.1.1 Speed versus time
5.1.2 Distance versus time
5.1.3 RESS temperature versus time

5.2 Record the following environmental conditions in Appendix A:

5.2.1 Range of ambient temperature during the test
5.2.2 Range of wind velocity during the test
5.2.3 Range of wind direction during the test

5.3 Testing
5.3.1 Verify vehicle is in Normal operation mode.
5.3.2 Move the vehicle to the start area, and record the vehicle odometer reading.
5.3.3 Record the following information:
[Link] Initial RESS SOC indicator reading
[Link] Ambient temperature
[Link] Wind speed and direction
5.3.4 Engage the fifth wheel.
5.3.5 Accelerate the vehicle to at least 60 mph (96 km/h) and enter the stopping
lane.
5.3.6 From a speed of 60 mph +2/-0 mph, decelerate the vehicle in a controlled
manner as rapidly as possible to a complete stop.
5.3.7 Measure the total distance required to stop the vehicle. Record in Appendix
A.
5.3.8 Note any test deficiencies, moved or dislodged cones/markers, and any driver
comments, in Appendix A.
5.3.9 Return the vehicle to the start/staging area, and allow at least 15 minutes to
pass before proceeding. Note the actual time duration in Appendix A.
5.3.10 Record the RESS SOC indicator reading in Appendix A.

269 Chpt IV, Sect VII

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5.3.11 Accelerate the vehicle to at least 60 mph (96 km/h) and enter the stopping
lane from the opposite direction.
5.3.12 From a speed of 60 mph +2/-0 mph, decelerate the vehicle in a controlled
manner to a complete stop as rapidly as possible.
5.3.13 Measure the total distance required to stop the vehicle. Record in Appendix
A.
5.3.14 Note any test deficiencies, moved or dislodged cones/markers, and any driver
comments, in Appendix A.
5.3.15 Record the following information in Appendix A:
[Link] Date and time of test completion
[Link] Equipment failures, if any
[Link] Equipment abnormalities, if any
[Link] Final RESS SOC Indicator reading
[Link] Driver notes, if any.

270 Chpt IV, Sect VII

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Appendix A – Braking Test Data Sheet

(Page 1 of 3)

VIN Number: __________________________

Project No.: Test Date(s):
Data File Name:
Test Driver:
(Initials) (Date)

Test Engineer:
(Initials) (Date)

Vehicle Setup
VEHICLE WEIGHTS AS TESTED WITH DRIVER & INSTRUMENTATION
(Curb weight plus 300 pounds)
Left Front: Right Front: Total Front: Percent Front: %
(lbs or kg) (lbs or kg) (lbs or kg)

Left Rear: Right Rear: Total Rear: Percent Rear: %

(lbs or kg) (lbs or kg) (lbs or kg)

Total Weight:
(lbs or kg)

INSTALLED TIRES
(Placard or sidewall whichever is less)
Left Front Right Front
Pressure: Pressure:
(psi or kPa) (psi or kPa)

Left Rear Right Rear

Pressure: Pressure:
(psi or kPa) (psi or kPa)

Track/Weather Conditions
Test Track Location: Track Grade: %
Ambient Temperature (initial): Ambient Temperature (final):
(32-100°F or 0-38°C) (32-100°F or 0-38°C)

Track Temperature (initial): Track Temperature (final):

(°F or °C) (°F or °C)

Wind Velocity (initial): Wind Velocity (final):

(<10 mph or 16 km/h) (<10 mph or 16 km/h)

Wind Direction (initial): ° Wind Direction (completion): °

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Appendix A – Braking Test Data Sheet

(Page 2 of 3)

VIN Number: _________________________

Sequence No: 1 File No.: Direction of Travel:
Time (initial): Time (final):
Odometer (initial): Odometer (final):
(miles or kilometers) (miles or kilometers)

State of Charge (initial): State of Charge (final):

(SOC,kWh,Ah) (SOC,kWh,Ah)

RESS Temp (initial): RESS Temp (final):

(60-120°F or 16-49°C) (°F or °C)

Comments (initials/date):

Speed at the Start of Braking: __________

Distance Required to Stop Vehicle: __________

Sequence No: 2 File No.: Direction of Travel:

Time (initial): Time (final):
Odometer (initial): Odometer (final):
(miles or kilometers) (miles or kilometers)

State of Charge (initial): State of Charge (final):

(SOC,kWh,Ah) (SOC,kWh,Ah)

RESS Temp (initial): RESS Temp (final):

(°F or °C) (°F or °C)

Comments (initials/date):

Speed at the Start of Braking: __________

Distance Required to Stop Vehicle: __________

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Appendix A – Braking Test Data Sheet

(Page 3 of 3)

VIN Number: ___________________________

General Comments (initials/date):
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

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Appendix B – PHEV Metrology Setup Sheet

(Page 1 of 1)

VIN Number: _______________________

Instrument/Device: Calibration Due Date: Initials / Date:
Fifth Wheel S/N:
Fifth Wheel Calibrator S/N:
DAS S/N:
DAS Set-up Sheet S/N:
kWh Meter S/N:
Shunt S/N:
Tire Pressure Gauge S/N:
Misc:
Misc:
Misc:
Misc:
Comments (initials/date):

Completed By:
____________________________________________________________________________
(Printed Name) (Signature) (Date)

Reviewed By (QA):
____________________________________________________________________________
(Printed Name) (Signature) (Date)

Approved By:
_____________________________________________________________________________
(Printed Name) (Signature) (Date)

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Section VIII: AVTA-PHTP07 – Implementation of SAE J1634

May1993 - “Electric Vehicle Energy
Consumption and Range Test Procedure”

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TABLE OF CONTENTS

1. Objective ...........................................................................................................................................................277

2. Purpose..............................................................................................................................................................277

3. Documentation..................................................................................................................................................277

4. Initial Conditions and Prerequisites ...............................................................................................................278

5. Dynamometer Setup.........................................................................................................................................278

6. Road Load Simulation (Without Air Conditioning Loads) ..........................................................................280

7. Road Load Simulation (With Air Conditioning Loads)................................................................................287

8. Data Reduction and Acceptability Criteria....................................................................................................287

APPENDICES

Appendix A – Vehicle Metrology Setup Sheets .....................................................................................................292

Appendix B – SAE J1634 Test Data Sheet.............................................................................................................293

Appendix C – SAE J1634 Road Test......................................................................................................................295

Appendix D – SAE J1634 Energy Efficiency Calculation Data Sheet.................................................................300

276 Chpt IV, Sect VIII

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1 Objective
The objective of this procedure is to provide methods for the testing of energy
efficiency and range of plug-in hybrid electric vehicles (PHEV) participating in
PHEV America which are operable in Rechargeable Energy Storage System Only
mode (RESS Only mode). Testing is conducted in accordance with SAE Standard
J1634, "Electric Vehicle Energy Consumption and Range Test Procedure" and
includes tests both with and without air conditioning loads. These methods are not
meant to supersede those of the testing facility, those specifically addressed by
SAE Test Standards (except as noted) nor of any regulatory agency, which may
have or exercise control over the covered activities.

2 Purpose
The purpose of this procedure is to identify acceptable methods for the
implementation of the test requirements of SAE-J1634. SAE-J1634 establishes
uniform procedures for testing battery-powered electric vehicles through the
Urban Dynamometer Driving Schedule (UDDS) and Highway Fuel Economy
Driving Schedule (HWFEDS). This procedure provides specific guidance for
testing plug-in hybrid electric vehicles (PHEV) capable of operating in a mode
which the Consumable Fuel Energy Converter (CFEC) is disabled and the vehicle
operates solely on energy from the RESS (RESS Only mode). Vehicles tested in
an operating mode in which the CFEC and RESS are automatically controlled to
supply energy independently or in combination (Normal Operation mode) are
tested in accordance with procedure AVTA-PHTP03. The requirements for this
procedure deviate from some of the test requirements of SAE J1634. These
deviations are necessary to accomplish this test for plug-in hybrid electric vehicles
and to assure that relative performance between vehicle types can be assessed.
Deviations from SAE J1634 are noted where they occur.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to
understand, easy to read and readily reproducible. This documentation shall
contain enough information to "stand alone"; that is, be self-contained to the extent
that all individuals qualified to review it could be reasonably expected to reach a
common conclusion, without the need to review additional documentation.
Review and approval of test documentation shall be in accordance with procedure
AVTA-PHAC04. Storage and retention of records during and following testing
activities shall be completed as described in procedure AVTA-PHAC01.

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4 Initial Conditions and Prerequisites

Prior to conducting any portion of the testing, the following initial conditions and
prerequisites should be met. Satisfactory completion of these items should be
verified as complete and recorded on the Test Data Sheet.

4.1 Personnel conducting testing under this procedure shall be familiar with the
requirements of this procedure, shall be trained in accordance with the
requirements of procedure AVTA-PHAC05 and be certified by the Program
Manager or the Test Manager prior to commencing any testing activities.

4.2 Ambient temperature within the dynamometer cell during testing shall be
77°F ± 9°F (25˚C ± 5˚C).

4.3 RESS temperature at the beginning of testing shall be established by soaking

the vehicle at 77°F ± 9°F (25˚C ± 5˚C) for a minimum of 12 hours in
accordance with SAE J1711 Section [Link].a.

4.4 Tire Preparation

4.4.1 Tire pressures shall be set at the values used during coastdown
testing conducted in accordance with procedure AVTA-PHTP01.
4.4.2 Suppliers recommended tires shall be used. Tires shall have a tread
depth of at least 50% when new.

4.5 Dynamometer
4.5.1 This test procedure is predicated on the use of a 48” 4WD
dynamometer which meets current EPA guidelines established in 40
CFR Part 86.108-00, for this type of dynamometer.
4.5.2 Road load power settings shall be based upon coefficients developed
using procedure AVTA-PHTP01.
4.5.3 Inertia settings shall be made based on the vehicle curb weight as
determined by procedure AVTA-PHAC06 plus 300 pounds. This is a
deviation from the requirements of SAE J1711.

4.6 During dynamometer operation, a fixed-speed cooling fan shall be

positioned so as to direct cooling air to the front of the vehicle. The fan shall
not develop an air flow in excess of 5,300 cubic feet per minute (2.5 m3/s).

4.7 Vehicle shall be tested in its normal configuration with normal appendages
(mirrors, bumpers, hubcaps, etc.) Certain items (hub caps, etc.) may be
removed where necessary for safety on the dynamometer.

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4.8 Normal Supplier's recommended lubricants shall be employed.

4.9 Prior to dynamometer testing, vehicles shall have accumulated a minimum

of 1,000 miles. The vehicles shall be operated a sufficient number of miles
to use at least two gallons of "EPA certification fuel" and shall have
completed the requirements of procedures AVTA-PHTP04 and AVTA­
PHTP05. This is a deviation from the requirements of SAE J1634.

4.10 RESS initial SOC shall be established in accordance with procedure AVTA­
PHTP08, Section 5.

4.11 The following data shall be collected using a DAS during conduct of the
various tests specified by this procedure. Overall error in recording or
indicating instruments shall not exceed ±2% of the maximum value of the
variable being measured or as specifically excepted elsewhere. Periodic
calibration shall be performed and documented to ensure compliance with
this requirement.
4.11.1 RESS voltage versus time
4.11.2 RESS current versus time (RESS current shall be collected at a
frequency of at least 20 Hz)
4.11.3 Vehicle speed versus time
4.11.4 Distance versus time
4.11.5 RESS temperature versus time
4.11.6 RESS power versus time

4.12 The range of ambient temperature during the testing shall be recorded.

4.13 A description of the dynamometer shall be recorded, including:

4.13.1 Drum or roll diameter and number of tire contact points
4.13.2 Road load power set points
4.13.3 Dynamometer inertia weight
4.13.4 Confirmation that the dynamometer conforms to EPA guidelines as
specified in 40 CFR Part 86.108-00.

4.14 The date, starting and ending times shall be recorded.

4.15 The beginning and ending vehicle odometer readings shall be recorded.

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4.16 All instrumentation used in the test shall be listed in Appendix A and
attached to the test data sheets/results and shall include the following
information:
4.16.1 Manufacturer
4.16.2 Model number
4.16.3 Serial number
4.16.4 Next calibration date

4.17 Any deviation from the test procedure and the reason for the deviation shall
be recorded in accordance with procedure AVTA-PHAC02.

4.18 All documentation required to complete the testing shall be completed,

approved and issued prior to commencing the testing it addresses.

4.19 A copy of test documentation and methodologies/instructions used for

testing shall be included in the final test documentation program. This is in
accordance with procedure AVTA-PHAC02.

4.20 Verify that procedures AVTA-PHAC06 and AVTA-PHTP11 have been, or

are being, completed and that the requirements for operating in the RESS
Only mode have been determined.

5 Dynamometer Setup
The purpose of this section is to prepare the dynamometer for use in testing
PHEVs to the requirements of SAE J1711 as described in Section 6.

CAUTION:
In this procedure, the dynamometer is started and run.
ALL personnel shall exercise appropriate cautions while
in the vicinity of both the Power Absorption Unit and the
Roller Section.

NOTE:
Activities necessary to complete the test are identified in
the following sections. All items shall be completed,
whether they are required by J1634 or not. Any section
which cannot be completed shall be so annotated, along
with the appropriate justification in accordance with
procedure AVTA-PHAC02.

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5.1 Establish the initial condition applicable to the RESS Only mode as
determined in procedure AVTA-PHAC06.
5.1.1 Place the vehicle in the RESS Only mode and, for tests to be
conducted beginning at 100% initial RESS SOC, establish the RESS
at 100% initial SOC in accordance with procedure AVTA-PHTP08.

NOTE:
Establishing the appropriate RESS initial SOC may
require charging the test vehicle or operating the vehicle
on the dynamometer. Requirements for verification of the
proper RESS initial SOC are presented in procedure
AVTA-PHTP08.

5.1.2 Soak the vehicle in the dynamometer test cell for at least 12 hours at
77°F ± 9°F (25˚C ± 5˚C) before performing the UDDS test. Do not
remove the vehicle from the dynamometer during this time.

NOTE:
Do not operate the vehicle propulsion system during
dynamometer warm-up and calibration.

5.2 Conduct an initial warm-up of the dynamometer in accordance with facility

procedures.

5.3 Conduct and complete speed calibration of the dynamometer in accordance

with facility procedures.

5.4 Conduct and complete torque arm calibration of the dynamometer in

accordance with facility procedures.

5.5 Conduct and complete Data Acquisition System (DAS) calibration

(including the emissions bench) in accordance with facility procedures.

5.6 Set the dynamometer with the coastdown coefficients and inertia settings
determined in procedure AVTA-PHTP01. Record the settings in Appendix
B as "Target" settings.

5.7 Prepare the vehicle to be tested as follows:

5.7.1 Record tire inflation pressures in Appendix B.
5.7.2 Place the test vehicle on the dynamometer roll(s), and center it on the
roll(s) using facility procedures.

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5.7.3 Attach tie-down straps to the vehicle.

5.7.4 Place wheel chocks at the non-driving wheels.
5.7.5 Place fan appropriately to cool the engine, open the engine
compartment cover and turn the fan on. Fans should be placed to
simulate road air flow in accordance with Section 4.6.

CAUTION:
High voltage may be present. To prevent personnel injury
or equipment damage, use extreme caution when
connecting instrumentation leads.

5.7.6 Connect vehicle instrumentation leads to the DAS.

5.8 Determination of Dynamometer and Tire Parasitic Losses for Single Roll
Dynamometer
5.8.1 Conduct back-to-back HWFEDS drive cycles.
5.8.2 Measure tire temperatures after the HWFEDS drive cycles and
immediately before conducting the coastdown and record in
Appendix B.
5.8.3 Place the vehicle in neutral or "dynamometer mode" if such mode is
applicable based on vehicle manufacturer's supplied data.
5.8.4 Using the dynamometer motor, accelerate the vehicle to 80 mph.
5.8.5 Coast the vehicle to 5 mph, while recording speed vs. time.
5.8.6 Immediately after completion of step 5.8.5, record tire temperatures
in Appendix B.
5.8.7 Save the DAS data and determine coastdown times from 75 to 5 mph
in 10 mph increments.
5.8.8 Repeat steps 5.8.4 through 5.8.7 a minimum of three times.

5.9 Set up the dynamometer to achieve the desired coast-down times.

5.9.1 Compare the coastdown times obtained in step 5.8 with the
coastdown times expected based upon the coastdown coefficients
determined in procedure AVTA-PHTP01.
5.9.2 If measured coastdown times are not within 1.5% of the desired
coastdown times, adjust road load coefficients and inertia settings as
necessary. Record the final road load and inertia settings in
Appendix B as "Dyno" settings.

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5.10 If the adjustment to road load and inertia settings are greater than 3% from
the initial calibration (the initial conduct of step 5.8 for the vehicle), an
attempt to determine the cause of the “drift” shall be undertaken. This
evaluation shall include both the vehicle and the dynamometer. Results of
the investigation shall be noted in Appendix B and reviewed with the Test
Director or Program Manager.

5.11 Record the applicable EPA coastdown coefficients and inertia settings in
Appendix B. If the EPA settings deviate more significantly from the "Dyno"
settings, an attempt shall be made to reconcile this deviation. Results of the
investigation shall be noted in Appendix B and reviewed with the Test
Director or Program Manager.

6 Road Load Simulation (Without Air Conditioning

Loads)
The purpose of this section is to determine the fuel efficiency of a PHEV vehicle
when subjected to the test schedules identified in SAE J1634 (May 93) and
operated without air conditioning loads. This section selectively implements
portions of SAE J1634 in support of this purpose. The actual dynamometer
instructions are developed by the entity operating the dynamometer and shall be
used in conjunction with this procedure. As such, this procedure may be used at
any facility utilizing an electric dynamometer capable of simulating road load.
This procedure performs SAE Standard J1634 testing at an ambient temperature of
77°F ± 9°F. The load cycles shall follow the combined UDDS/HWFEDS road
load schedule contained in SAE Standard J1634, May 1993. Test room
temperatures shall be controlled in accordance with facility procedures.
Road load simulation testing shall be conducted as soon as practical after
completion of Section 5. The vehicle shall not be removed from the dynamometer
between completion of Section 5 and start of Section 6 testing.

NOTE:
Do not operate the vehicle propulsion system during
dynamometer warm-up and calibration.

6.1.1 Vehicle setup

[Link] Prepare the dynamometer in accordance with Sections
5.1 through 5.5.
[Link] Verify that the required ambient temperature exists in the
dynamometer test cell and that the vehicle has been at
the required ambient temperature for at least 12 hours.
[Link] Verify that the DAS instrumentation is connected.

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[Link] Turn on the cooling fan(s).

6.2 Determine the energy efficiency and range without A/C.

NOTE:
The SOC indicator reading shall be recorded at each
significant datum readable on the SOC meter.

NOTE:
The minimum allowable RESS voltage shall not be
violated during testing. If the minimum voltage is reached,
testing shall be stopped.

6.2.1 Verify that all accessories, including air conditioning, have been
turned off.
6.2.2 Record the following in Appendix C:
[Link] Time of day
[Link] Odometer reading
[Link] SOC indicator reading
[Link] Ambient temperature
[Link] Tire temperature
6.2.3 Conduct a UDDS drive cycle, immediately followed by a second
UDDS drive cycle, immediately followed by a HWFEDS, followed
by a HWFEDS after a 15 second pause with the vehicle key on and
brake applied.
6.2.4 Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1634. The upper limit is 2 mph (3.2
km/h) higher than the highest point on the trace within 1 second of
the given time. The lower limit is 2 mph (3.2 km/h) lower than the
lowest point on the trace within 1 second of the given time.
6.2.5 Upon completion of the combined UDDS/HWFEDS drive cycle,
wait 10 minutes (+ 1 minute) with the vehicle and its accessories off.
During this period, record the following parameters. At the end of
the ten minute period, begin the next combined UDDS/HWFEDS
drive cycle.
[Link] Time of day
[Link] Odometer reading
[Link] SOC indicator reading
[Link] Ambient temperature

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[Link] Tire temperature

6.2.6 Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1634. The upper limit is 2 mph (3.2
km/h) higher than the highest point on the trace within 1 second of
the given time. The lower limit is 2 mph (3.2 km/h) lower than the
lowest point on the trace within 1 second of the given time.
6.2.7 Upon completion of the second combined UDDS/HWFEDS drive
cycle, wait 10 minutes (+ 1 minute) with the vehicle and its
accessories off. During this period, record the following parameters.
[Link] Time of day
[Link] Odometer reading
[Link] SOC indicator reading
[Link] Ambient temperature
[Link] Tire temperature
6.2.8 Repeat combine UDDS/HWFEDS drive cycle tests until the
following test termination criteria are reached.
[Link] Test termination criteria contained in SAE J1634 shall be
the official method of determining vehicle distance
traveled. However, this is not necessarily the criteria for
terminating the test cycle. Testing shall be terminated
based on traction battery voltage, or battery capacity as
indicated by the sustained inability of the vehicle to
attain or maintain speed, as opposed to the criteria
contained in SAE J1634. This is a deviation from the
requirements of SAE J1634.
[Link] Terminate the test based on the depletion of the vehicle
batteries. Battery depletion shall be based on the
manufacturer’s specification of minimum voltage
identified in AVTA-PHAC06.
6.2.9 Upon completion of the test, record the following in Appendix C:
[Link] Time of day
[Link] Test time
[Link] Odometer reading
[Link] Dynamometer distance
[Link] Total distance
[Link] Distance to SAE J1634 cutoff criteria

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[Link] Final SOC indicator reading

[Link] Final tire temperatures.

6.3 Recharge the RESS to 100% in accordance with procedure AVTA-PHTP08.

This may be done in the dynamometer test cell or in another area. However,
no propulsion system power shall be used in moving the vehicle. Record the
AC and DC energy returned to the RESS in Appendix C.
6.4 Secure the dynamometer.

NOTE:
RESS energy supplied may be calculated for the combined
UDDS-HWFEDS, a UDDS cycle or a HWFEDS cycle.
The equation is the same, but only the energy withdrawn
during the test being evaluated should be used.

6.5 RESS Capacity and Energy Supplied Calculations

6.5.1 Calculate the capacity supplied by the RESS (Ahr/mi) during charge
depletion and the percentage of RESS capacity supplied by the RESS
(%/mi) during charge depletion using the following equations and
record in Appendix D:

RESS Capacity (Ahr/mi) = [ RESSenter sustaining (Ahr) - RESSinitial (Ahr) ]

Dynamometer Distance (miles)

RESS Capacity (%/mile) = 100 * [RESSenter sustaining (Ahr) - RESSinitial (Ahr)]

Dynamometer Distance (miles)* RESS Capacity (Ahr)

The RESSinitial and RESSenter sustaining shall be determined by

integrating the ammeter in accordance with Section 4.11. The
RESSenter sustaining shall be the total ampere-hours out of the RESS to
entry into charge sustaining mode. The Dynamometer distance shall
be the total miles traveled to the point of test termination. The RESS
Capacity (Ahr) shall be the nominal capacity of the RESS as
determined in procedure AVTA-PHAC06.
6.5.2 Calculate the DC energy supplied by the RESS (Wh/mi) using the
following equation and record in Appendix D:

DC Energy Supplied (DC-Wh/mile) = RESSDC energy (Wh)

Dynamometer Distance (miles)

The DC energy shall be determined by integrating the product of the

ammeter and voltmeter in accordance with Section 4.11. The DC

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energy supplied by the RESS shall be the total energy out of the
RESS to the point of test termination. The Dynamometer Distance
shall be the total miles traveled to the point of test termination.

6.6 Calculation of RESS AC Electrical Recharge Energy Consumed

6.6.1 Electric energy (AC) used to recharge the RESS shall be calculated
in accordance with procedure AVTA-PHTP08.
6.6.2 Record the AC recharge energy for each test day in Appendix C.

7 Road Load Simulation (With Air Conditioning

Loads)
The purpose of this section is to determine the fuel efficiency of a PHEV vehicle
when subjected to the test schedules identified in SAE J1634 (May 93) and
operated with air conditioning loads. This section selectively implements portions
of SAE J1634 in support of this purpose. The actual dynamometer instructions are
developed by the entity operating the dynamometer and shall be used in
conjunction with this procedure. As such, this procedure may be used at any
facility utilizing an electric dynamometer capable of simulating road load.
This procedure performs SAE Standard J1634 testing at an ambient temperature of
77°F ± 9°F. The load cycles shall follow the combined UDDS/HWFEDS road
load schedule contained in SAE Standard J1634, May 1993. Test room
temperatures shall be controlled in accordance with facility procedures.
Road load simulation testing shall be conducted as soon as practical after
completion of Section 6. The vehicle shall not be removed from the dynamometer
between completion of Section 6 and start of Section 7 testing.

NOTE:
Do not operate the vehicle propulsion system during
dynamometer warm-up and calibration.

7.1.1 Vehicle setup

[Link] Prepare the dynamometer in accordance with Sections
5.1 through 5.5.
[Link] Verify that the required ambient temperature exists in the
dynamometer test cell and that the vehicle has been at
the required ambient temperature for at least 12 hours.
[Link] Verify that the DAS instrumentation is connected.
[Link] Turn on the cooling fan(s).

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7.2 Determine the energy efficiency and range with A/C.

NOTE:
The SOC indicator reading shall be recorded at each
significant datum readable on the SOC meter.

NOTE:
The minimum allowable RESS voltage shall not be
violated during testing. If the minimum voltage is reached,
testing shall be stopped.

7.2.1 Verify that all accessories, except the air conditioning, are off.
7.2.2 Record the following in Appendix C:
[Link] Time of day
[Link] Odometer reading
[Link] SOC indicator reading
[Link] Ambient temperature
[Link] Tire temperature
[Link] Fuel weight (if applicable)
7.2.3 Conduct a UDDS drive cycle, immediately followed by a second
UDDS drive cycle, immediately followed by a HWFEDS, followed
by a HWFEDS after a 15 second pause with the vehicle key on and
brake applied.
7.2.4 Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1634. The upper limit is 2 mph (3.2
km/h) higher than the highest point on the trace within 1 second of
the given time. The lower limit is 2 mph (3.2 km/h) lower than the
lowest point on the trace within 1 second of the given time.
7.2.5 Upon completion of the combined UDDS/HWFEDS drive cycle,
wait 10 minutes (+ 1 minute) with the vehicle and its accessories off.
During this period, record the following parameters. At the end of
the ten minute period, begin the next combined UDDS/HWFEDS
drive cycle.
[Link] Time of day
[Link] Odometer reading
[Link] SOC indicator reading
[Link] Ambient temperature
[Link] Tire temperature

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7.2.6 Monitor the driver’s performance and note the time, odometer
reading, speed and distance at which an excursion from the drive
cycle occurs, as well as the reason(s) for any such excursions in
Appendix C. The speed tolerance at any given time on the driving
schedule is defined by SAE J1634. The upper limit is 2 mph (3.2
km/h) higher than the highest point on the trace within 1 second of
the given time. The lower limit is 2 mph (3.2 km/h) lower than the
lowest point on the trace within 1 second of the given time.
7.2.7 Upon completion of the second combined UDDS/HWFEDS drive
cycle, wait 10 minutes (+ 1 minute) with the vehicle and its
accessories off. During this period, record the following parameters.
[Link] Time of day
[Link] Odometer reading
[Link] SOC indicator reading
[Link] Ambient temperature
[Link] Tire temperature
7.2.8 Repeat combine UDDS/HWFEDS drive cycle tests until the
following test termination criteria are reached.
[Link] Test termination criteria contained in SAE J1634 shall be
the official method of determining vehicle distance
traveled. However, this is not necessarily the criteria for
terminating the test cycle. Testing shall be terminated
based on traction battery voltage, or battery capacity as
indicated by the sustained inability of the vehicle to
attain or maintain speed, as opposed to the criteria
contained in SAE J1634. This is a deviation from the
requirements of SAE J1634.
[Link] Terminate the test based on the depletion of the vehicle
batteries. Battery depletion shall be based on the
manufacturer’s specification of minimum voltage
identified in AVTA-PHAC06.
7.2.9 Upon completion of the test, record the following in Appendix C:
[Link] Time of day
[Link] Test time
[Link] Odometer reading
[Link] Dynamometer distance
[Link] Total distance
[Link] Final SOC indicator reading

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7.3 Recharge the RESS to 100% in accordance with procedure AVTA-PHTP08.

This may be done in the dynamometer test cell or in another area. However,
no propulsion system power shall be used in moving the vehicle. Record the
AC and DC energy returned to the RESS in Appendix C.
7.4 Secure the dynamometer and dismount the vehicle.

8 Data Reduction and Acceptability Criteria

NOTE:
RESS energy supplied may be calculated for the combined
UDDS-HWFEDS, a UDDS cycle or a HWFEDS cycle
both with and without air conditioning operating. The
equation is the same, but only the energy withdrawn
during the test being evaluated should be used.

8.1 RESS Capacity and Energy Supplied Calculations

8.1.1 Calculate the capacity supplied by the RESS (Ahr/mi) during charge
depletion and the percentage of RESS capacity supplied by the RESS
(%/mi) during charge depletion using the following equations and
record in Appendix D:

RESS Capacity (Ahr/mi) = [RESSenter sustaining (Ahr) - RESSinitial (Ahr)]

Dynamometer Distance (miles)

RESS Capacity (%/mile) = 100 * [RESSenter sustaining (Ahr) - RESSinitial (Ahr)]

Dynamometer Distance (miles)* RESS Capacity (Ahr)

The RESSinitial and RESSenter sustaining shall be determined by

integrating the ammeter in accordance with Section 4.11. The
RESSenter sustaining shall be the total ampere-hours out of the RESS to
the point of test termination criteria as defined in SAE J1634. The
Dynamometer Distance shall be the total miles traveled to the point
of to the point of test termination criteria as defined in SAE J1634.
The RESS Capacity (Ahr) shall be the nominal capacity of the RESS
as determined in procedure AVTA-PHAC06.
8.1.2 Calculate the DC energy supplied by the RESS (Wh/mi) using the
following equation and record in Appendix D:

DC Energy Supplied (DC-Wh/mile) = RESSDC energy (Wh)

Dynamometer Distance (miles)

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The DC energy shall be determined by integrating the product of the

ammeter and voltmeter in accordance with Section 4.11. The DC
energy supplied by the RESS shall be the total energy out of the
RESS to the point of test termination. The Dynamometer Distance
shall be the total miles traveled to the point of test termination.

8.2 Calculation of RESS AC Electrical Recharge Energy Consumed

8.2.1 Electric energy (AC) used to recharge the RESS shall be calculated
in accordance with procedure AVTA-PHTP08.
8.2.2 Record the AC recharge energy for each test sequence in Appendix
D.

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Appendix A – Vehicle Metrology Setup Sheets

(Page 1 of 1)
VIN Number: __________
Instrument/Device: Calibration Due Date: Initials / Date:
Fifth Wheel S/N:
Fifth Wheel Calibrator S/N:
DAS S/N:
DAS Set-up Sheet S/N:
kWh Meter S/N:
Shunt S/N:
Tire Pressure Gauge S/N:
Misc:
Misc:
Misc:
Misc:
Comments (initials/date):

Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By (QA):
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

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Appendix B – SAE J1634 Test Data Sheet

(Page 1 of 2)
VIN Number: ______________________ Operating Mode ______
Project No.: Test Date(s):
Data File Name:
Test Driver:
(Initials) (Date)

Test Engineer:
(Initials) (Date)

Vehicle Setup
TIRE TEMPERATURE
Initial L/F: Initial R/F: Final L/F: Final R/F:
(˚F or ˚C) (˚F or ˚C) (˚F or ˚C) (˚F or ˚C)

Initial L/R: Initial R/R: Final L/R: Final R/R:

(˚F or ˚C) (˚F or ˚C) (˚F or ˚C) (˚F or ˚C)

COLD TIRE PRESSURE (Shaved Yes No)

Left Front: Right Front:
(psig or kPa) (psig or kPa)

Left Rear: Right Rear:

(psig or kPa) (psig or kPa)

Determination of Dynamometer and Tire Parasitic Losses

Coefficients Target Dyno % Deviation

Inertia
A
B
C
EPA Coefficient Comparison
Coefficients EPA Dyno % Deviation
Inertia
A
B
C

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Appendix B – SAE J1634 Test Data Sheet

(Page 2 of 2)
VIN Number: ______________________ Operating Mode ______
General Comments (initials/date):
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________

Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

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Appendix C – SAE J1634 Driving Schedule (without A/C)

Data Sheet (Page 1 of 4)
VIN Number: ______________________ Operating Mode ______
TIRE PRESSURE
Left Front: Right Front:
(psig or kPa) (psig or kPa)

Left Rear: Right Rear:

(psig or kPa) (psig or kPa)

Fuel Density:
(lbs per gallon)

Inertial Weight Setting:

(lab)

Minimum Allowable RESS Voltage:

(volts)

1st Combined UDDS/HWFEDS:

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

2nd Combined UDDS/HWFEDS:

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

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Appendix C – SAE J1634 Driving Schedule (without A/C)

Data Sheet (Page 2 of 4)
VIN Number: ______________________ Operating Mode ______

__th Combined UDDS/HWFEDS:

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__th Combined UDDS/HWFEDS:

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

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Appendix C – SAE J1634 Driving Schedule (with A/C)

Data Sheet (Page 3 of 4)
VIN Number: ______________________ Operating Mode ______
TIRE PRESSURE
Left Front: Right Front:
(psig or kPa) (psig or kPa)

Left Rear: Right Rear:

(psig or kPa) (psig or kPa)

Fuel Density:
(lbs per gallon)

Inertial Weight Setting:

(lab)

Minimum Allowable RESS Voltage:

(volts)

1st Combined UDDS/HWFEDS:

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

2nd Combined UDDS/HWFEDS:

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

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Appendix C – SAE J1634 Driving Schedule (with A/C)

Data Sheet (Page 4 of 5)
VIN Number: ______________________ Operating Mode ______

__th Combined UDDS/HWFEDS:

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

__th Combined UDDS/HWFEDS:

Initial Final
Time: Time:
Odometer: Odometer:
mi mi
Tire Temperatures: L/F______ (˚F/˚C) Tire Temperatures: L/F______ (˚F/˚C)
R/F______ (˚F/˚C) R/F______ (˚F/˚C)
L/R______ (˚F/˚C) L/R______ (˚F/˚C)
R/R______ (˚F/˚C) R/R______ (˚F/˚C)
SOC: SOC:
% %
Ambient Temperature: __________ (˚F/˚C) Ambient Temperature: __________ (˚F/˚C)

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Appendix C – SAE J1634 Driving Schedule (with A/C)

Excursions from Drive Cycle
Data Sheet (Page 5 of 5)
VIN Number: ______________________ Operating Mode ______
Time: Speed: Distance: Comments: Initials:

299 Chpt IV, Sect VIII

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Appendix D – SAE J1634 Energy Efficiency Calculation

(Page 1 of 2)
Without Air Conditioning
VIN Number: ______________________ Operating Mode ______
AC into the Charger: (kWh) DC into the RESS: (kWh)

Distance traveled to SAE J1634 termination criteria: (miles)

Distance Traveled in Sequence 1 (miles)

Distance Traveled in Sequence 2 (miles)

RESS Capacity Used per Mile = ____RESS Capacity Out_____

(Ah per mile) Dynamometer Distance (miles)
RESS Capacity Used per Mile Sequence 1 = _________________ =
(Ah per mile)
RESS Capacity Used per Mile Sequence 2 = __________________ =
(Ah per mile)
Average Sequence 1 and Sequence 2 for final Percent RESS Capacity Used per Mile.

Percentage RESS Capacity Used = 100 * Amp-hours out from RESS While Driving
(%) RESS Manufacturer Battery Capacity
Percentage RESS Capacity Used per Mile = Percentage RESS Capacity Used
(% per mile) Dynamometer Distance (miles)
Percentage RESS Capacity Used per Mile Sequence 1 = _________________ =
(% per mile)
Percentage RESS Capacity Used per Mile Sequence 2 = __________________ =
(% per mile)
Average Sequence 1 and Sequence 2 for final Percent RESS Capacity Used per Mile.

Average DC Energy Supplied (DC Wh/mile) = Total DC Energy supplied by RESS (Wh)
Distance Traveled (miles)
Average DC Energy Supplied Sequence 1 = ________________________ =
(DC Wh/mi)
Average DC Energy Supplied Sequence 2 = ________________________ =
(DC Wh/mi)
Average Sequence 1 and Sequence 2 for final Average DC Energy Supplied.

Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

300 Chpt IV, Sect VIII

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Appendix D – SAE J1634 Energy Efficiency Calculation

(Page 2 of 2)
With Air Conditioning
VIN Number: ______________________ Operating Mode ______
AC into the Charger: (kWh) DC into the RESS: (kWh)

Distance traveled to SAE J1634 termination criteria: (miles)

Distance Traveled in Sequence 1 (miles)

Distance Traveled in Sequence 2 (miles)

RESS Capacity Used per Mile = ____RESS Capacity Out_____

(Ah per mile) Dynamometer Distance (miles)
RESS Capacity Used per Mile Sequence 1 = _________________ =
(Ah per mile)
RESS Capacity Used per Mile Sequence 2 = __________________ =
(Ah per mile)
Average Sequence 1 and Sequence 2 for final Percent RESS Capacity Used per Mile.

Percentage RESS Capacity Used = 100 * Amp-hours out from RESS While Driving
(%) RESS Manufacturer Battery Capacity
Percentage RESS Capacity Used per Mile = Percentage RESS Capacity Used
(% per mile) Dynamometer Distance (miles)
Percentage RESS Capacity Used per Mile Sequence 1 = _________________ =
(% per mile)
Percentage RESS Capacity Used per Mile Sequence 2 = __________________ =
(% per mile)
Average Sequence 1 and Sequence 2 for final Percent RESS Capacity Used per Mile.

Average DC Energy Supplied (DC Wh/mile) = Total DC Energy supplied by RESS (Wh)
Distance Traveled (miles)
Average DC Energy Supplied Sequence 1 = ________________________ =
(DC Wh/mi)
Average DC Energy Supplied Sequence 2 = ________________________ =
(DC Wh/mi)
Average Sequence 1 and Sequence 2 for final Average DC Energy Supplied.

Completed By:
(Printed Name) (Signature ) (Date)

Reviewed By:
(Printed Name) (Signature) (Date)

Approved By:
(Printed Name) (Signature) (Date)

301 Chpt IV, Sect VIII

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Section IX: AVTA-PHTP08 – Rechargeable Energy Storage

System (RESS) charging

302 Chpt IV, Sect IX

 AVTA-PHTP08

TABLE OF CONTENTS

1 Objective ...........................................................................................................................................................304

2 Purpose..............................................................................................................................................................304

3 Documentation..................................................................................................................................................304

4 Initial Conditions and Prerequisites ...............................................................................................................304

5 Charging Requirements...................................................................................................................................305

5.1 Setting Initial SOC At Charge-Sustaining Mode...........................................................................305

5.2 Setting Initial State of Charge At 100% ........................................................................................305
5.3 Grid Charging...............................................................................................................................306
5.4 Charging Efficiency ......................................................................................................................307

APPENDICES

Appendix A – RESS Charging Log ........................................................................................................................309

Appendix B – PHEV Metrology Setup Sheet ........................................................................................................310

303 Chpt IV, Sect IX

 AVTA-PHTP08

1 Objective
This procedure identifies the method for charging the Rechargeable Energy Storage
System (RESS) installed in plug-in hybrid electric vehicles evaluated by the U.S.
Department of Energy Advanced Vehicle Testing Activity (AVTA). It shall not supersede
the charging protocols of the vehicle’s Supplier, nor is it meant to supersede those
specifically addressed by SAE Test Standards, nor of any regulatory agency, which may
have or exercise control over the covered activities.

2 Purpose
The purpose of this procedure is to provide specific and repeatable guidance for charging
the RESS of vehicles participating in the AVTA. This guidance applies to vehicles in any
operating mode. This procedure is also used to calculate charging efficiencies during the
performance of procedure AVTA-PHTP05.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read, and readily reproducible. This documentation shall contain enough information to
"stand alone"; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion, without the need to review
additional documentation. Review and approval of test documentation shall be in
accordance with procedure AVTA-PHAC04. Storage and retention of records during and
following testing activities shall be completed as described in procedure AVTA-PHAC01.

4 Initial Conditions and Prerequisites

4.1 Personnel conducting testing under this procedure shall be familiar with the
requirements of this procedure, shall be trained in accordance with the requirements
of procedure AVTA-PHAC05 and be certified by the Program Manager or the Test
Manager prior to commencing any testing activities.

4.2 Charging of vehicle RESS shall be in accordance with the requirements of the
vehicle/battery supplier as stated in the Owner/Operators manual.

4.3 Ambient temperature during charging shall be within the range of 32°F (0˚C) to
100°F (38°C) at the commencement of charging, or the maximum allowed by the
Supplier.

4.4 RESS temperatures at the beginning of charging shall be greater than 40˚F (5˚C),
shall be less than 120°F (49°C) and should be less than 100˚F (38°C).

304 Chpt IV, Sect IX

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4.5 All personnel conducting charging of RESS shall observe proper safety precautions
at all times.

4.6 Charging rates shall not exceed the maximum recommended by the Supplier.

4.7 Grid charging the RESS should be accomplished at the highest voltage (e.g. 240
VAC vs. 120 VAC) allowed.

4.8 All documentation required to complete the charging activities shall be completed,
approved and issued prior to commencing any charging activities.

4.9 Record the required data for all metrology used in Appendix B.

5 Charging Requirements
The following instructions apply to charging activities for all plug-in hybrid electric
vehicles. They shall not replace or supersede the requirements of any specific Supplier.
Should a conflict arise, the requirements of the Vehicle/RESS Supplier shall take
precedence.

5.1 Setting Initial SOC At Charge-Sustaining Mode

A RESS Initial State of Charge entering charge-sustaining mode shall be achieved
by operating the vehicle in the Normal Operation mode at a constant speed of 35
mph (56 km/h) for at least 25 miles (40 kilometers) or 5 miles (8 kilometers) past the
Supplier's stated charge depleting range, whichever is greater. Alternatively, for
vehicles operating on a dynamometer, a RESS Initial State of Charge entering
charge-sustaining mode shall be achieved by operating the vehicle in the Normal
Operation mode on the dynamometer through two UDDS cycles and two HWFEDS
cycles in accordance with Section 6 of procedure AVTA-PHTP03, except that data
recording shall not be required. After completion of this operation, care shall be
exercised not to allow significant changes in the RESS SOC prior to commencement
of testing requiring an Initial State of Charge at charge-sustaining mode.

NOTE:
If the vehicle will not deplete RESS charge operating at a constant
speed of 35 mph, the operating speed shall be modified to allow
charge depletion.

5.2 Setting Initial State of Charge At 100%

An RESS Initial State of Charge at 100% shall be achieved by grid charging the test
vehicle in accordance with Section 5.3. Verify that the charger terminated charge
without indicated faults. After completion of this operation, care shall be exercised

305 Chpt IV, Sect IX

 AVTA-PHTP08

not to allow significant changes in the RESS SOC prior to commencement of testing
requiring an Initial SOC at charge-sustaining mode.

5.3 Grid Charging

Vehicles shall not be charged from any outlet except the outlet specifically
designated for that vehicle at its designated Charge Station Location. The following
steps assume the vehicle is parked in the charging area, and is capable of being
charged from its dedicated Charge Station Location.
5.3.1 Verify by physical inspection that there is no damage to the RESS or
charging system.
5.3.2 Determine and select the proper cable and connector type for the specific
vehicle being charged. This shall be determined by visual inspection of the
charger connector.
5.3.3 Read and record the RESS State of Charge (SOC) indicator reading prior to
commencing the charge in Appendix A.
5.3.4 If an onboard kilowatt-hour meter reading is available, this should also be
recorded in Appendix A.
5.3.5 Select the appropriate Charging Station Location and record in Appendix A.
5.3.6 Read and record the watt-hour meter reading at the charging station in
Appendix A.
5.3.7 Verify that the electrical disconnect supplying power to the charger is closed.
5.3.8 Connect the charging cable to the vehicle.
5.3.9 Read and record the time that charging is starting in Appendix A.
5.3.10 If available, read and record the initial DC charging current and voltage in
Appendix A.
5.3.11 Verify that the kilowatt-hour meter or the data logger is operating.
5.3.12 Allow the charger to continue charging until the charge is automatically
terminated by the charger.
5.3.13 When the charge has completed (as determined by automatic termination of
the charger), verify the charger is not indicating a charging fault. If a fault has
occurred, the reason for the fault shall be recorded in accordance with
procedure AVTA-PHAC02 and the Supplier notified to perform necessary
repairs.
5.3.14 If the charger has automatically terminated without fault, record the
following information:
[Link] Time
[Link] Final voltage (if available)
[Link] Final charging current (if available)

306 Chpt IV, Sect IX

 AVTA-PHTP08

[Link] Charging station location energy meter reading

[Link] Vehicle SOC reading
[Link] Vehicle kilowatt-hour reading (if equipped)
[Link] Kilowatt-hour meter or data logger information
[Link] Vehicle odometer reading
5.3.15 If so equipped, depress the "STOP" button on the charger.
5.3.16 Disconnect the charging cable from the vehicle.

NOTE:
Completion of charge by automatic termination of the charger,
without an indicated fault, shall be considered 100% SOC for the
RESS.

5.4 Charging Efficiency

Charging efficiencies shall be calculated based upon conduct of rough road testing
conducted in accordance with procedure AVTA-PHTP05. The charging efficiency
test shall be conducted over a two-day period. One complete rough road test shall be
completed each day in accordance with procedure AVTA-PHTP05.
5.4.1 Day One Testing
[Link] Ensure the vehicle is fully charged in accordance with Section
5.3.
[Link] Record vehicle mileage prior to conduct of procedure AVTA­
PHTP05.
[Link] Record charger kWh prior to conduct of procedure AVTA­
PHTP05.
[Link] Conduct procedure AVTA-PHTP05.
[Link] Upon completion of testing, return the vehicle promptly to its
designated Charge Station Location and place it on charge in
accordance with Section 5.3.
5.4.2 Day Two Testing
[Link] Ensure the vehicle is fully charged in accordance with Section
5.3.
[Link] Record vehicle mileage prior to conduct of procedure AVTA­
PHTP05.
[Link] Record charger kWh prior to conduct of procedure AVTA­
PHTP05.
[Link] Conduct procedure AVTA-PHTP05.

307 Chpt IV, Sect IX

 AVTA-PHTP08

[Link] Upon completion of testing, return the vehicle promptly to its

designated Charge Station Location and place it on charge in
accordance with Section 5.3.

NOTE:
The kilowatt-hour meter reading taken in accordance with Section
5.4.3 is taken on day three and should be taken as near as practical
to the time that the vehicle was taken off the charger on day one
for conduct of rough road testing.

5.4.3 Charging Efficiency Calculation

[Link] Verify the vehicle is fully charged in accordance with Section
5.3.
[Link] Record vehicle mileage in Appendix A.
[Link] Record charger kWh in Appendix A.
[Link] Calculate the miles traveled during the two rough road tests.
[Link] Calculate the kWh consumed during the two rough road tests.
[Link] Calculate the vehicle charging efficiency as follows:

Miles Traveled ([Link])

Vehicle Charging Efficiency = --------------------------------------------
Kilowatt-hours Consumed ([Link])

[Link] Using the Miles per kWh-AC calculated in Step [Link], and a
given rate of 10¢ per kWh-AC (an average daily rate sans
demand charges), calculate the cost per mile to charge as follows:

Cost per Mile = (10¢ per kWh-AC / Miles per kWh-AC)

308 Chpt IV, Sect IX

 AVTA-PHTP08

Appendix A – RESS Charging Log

(Page 1 of ___)

Charging Station Location No. ___ Vehicle: VIN:

Date Time Connect/ Onboard SOC Vehicle Battery Charger Comments Initials
Disconnect Indicator Odometer Temp (°F) kWh Meter
Status Reading Reading

309 Chpt IV, Sect IX

 AVTA-PHTP08

Appendix B – PHEV Metrology Setup Sheet

(Page 1 of 1)

VIN Number: ______________________

Instrument/Device: Calibration Due Date: Initials / Date:
Off-board kWh Meter:
Volt Meter:
DAS S/N:
DAS Set-up Sheet S/N:
kWh Meter S/N:
Shunt S/N:
Misc:
Misc:
Misc:
Misc:
Misc:
Comments (initials/date):

Completed By:
_____________________________________________________________________________
(Printed Name) (Signature ) (Date)

Reviewed By (QA):
___________________________________________________________________________
(Printed Name) (Signature) (Date)

Approved By:
_____________________________________________________________________________
(Printed Name) (Signature) (Date)

310 Chpt IV, Sect IX

 AVTA-PHTP09

Section X: AVTA-PHTP09 – Reserved for Future Use

311 Chpt IV, Sect X

 AVTA-PHTP10

Section XI: AVTA-PHTP10 – Measurement and Evaluation of

Plug-in Hybrid Electric Vehicle RESS Charger
Performance

312 Chpt IV, Sect XI

 AVTA-PHTP10

TABLE OF CONTENTS

1 Objective ...........................................................................................................................................................314

2 Purpose..............................................................................................................................................................314

3 Documentation..................................................................................................................................................314

4 Prerequisites......................................................................................................................................................314

5 Measurement of RESS Charger Parameters .................................................................................................315

5.1 Measured Parameters ...................................................................................................................315

5.2 Measurement System Components................................................................................................315
5.3 Measurement of AC Input Parameters..........................................................................................315
5.4 Measurement of DC Output Parameters.......................................................................................316

6 RESS Charger Evaluation ...............................................................................................................................317

6.1 Normal Operation mode ...............................................................................................................317

6.2 RESS Only Mode...........................................................................................................................317
6.3 RESS Charging .............................................................................................................................317
6.4 Data Collection and Analysis........................................................................................................317

APPENDICES

Appendix A – PHEV Metrology Setup Sheet ........................................................................................................319

313 Chpt IV, Sect XI

 AVTA-PHTP10

1 Objective
This procedure provides methods for the evaluation of Rechargeable Energy Storage
System (RESS) charger performance for plug-in hybrid electric vehicles (PHEV).

2 Purpose
The purpose of this procedure is to provide a quantitative method for determination of key
RESS charger performance parameters, including the chargers ability to return the RESS to
100% SOC from any depth of discharge in less than 12 hours. This testing and data
acquisition meets the requirements specified in the PHEV Vehicle Specification.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read, and readily reproducible. This documentation shall contain enough information to
“stand alone”; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion, without the need to review
additional documentation. Review and approval of test documentation shall be in
accordance with procedure AVTA-PHAC04. Storage and retention of records during and
following testing activities shall be completed as described in procedure AVTA-PHAC01.

4 Prerequisites

4.1 Personnel conducting testing under this procedure shall be familiar with the
requirements of this procedure, shall be trained in accordance with the requirements
of procedure AVTA-PHAC05 and be certified by the Program Manager or the Test
Manager prior to commencing any testing activities.

4.2 The following data shall be collected during conduct of the various tests specified by
this procedure. Overall error in recording or indicating instruments shall not exceed
±2% of the maximum value of the variable being measured, unless otherwise noted.
Periodic calibration shall be performed and documented in accordance with
procedure AVTA-PHAC07 to ensure compliance with this requirement.

4.3 A list of all instrumentation used in the test shall be identified in Appendix A, and
attached to the test results. It shall include the following information:
4.3.1 Manufacturer
4.3.2 Model number
4.3.3 Serial number
4.3.4 Next calibration date

314 Chpt IV, Sect XI

 AVTA-PHTP10

4.4 Any deviation from the test procedure and the reason for the deviation shall be
approved in advance by the Program Manager or Test Manager in accordance with
procedure AVTA-PHAC02 and so noted on the appropriate data sheet(s).

4.5 Necessary recording equipment shall be installed in a manner that does not hinder
vehicle operation or alter the operating characteristics of the vehicle.

4.6 Ambient temperature during charging shall be within the range of 32°F (0˚C) to
100°F (38°C) at the commencement of charging, or the maximum allowed by the
Supplier, whichever is less.

4.7 RESS temperatures at the beginning of charging shall be greater than 40˚F (5˚C),
shall be less than 120°F (49°C) and should be less than 100˚F (38°C).

5 Measurement of RESS Charger Parameters

The Rechargeable Energy Storage System (RESS) off-board chargers shall be evaluated
for their ability to recharge the RESS in less than twelve hours, their power factor, their
effect on supply line power quality, and the Total Harmonic Distortion (THD) introduced
by the charger. Several of these evaluations are completed concurrently, and are described
in the following sections:

5.1 Measured Parameters

5.1.1 AC input voltage
5.1.2 AC input current
5.1.3 RESS voltage
5.1.4 DC current

5.2 Measurement System Components

5.2.1 Sensors, including potential transformers, and AC and DC current
transformers
5.2.2 Signal conditioners, including isolation amplifier and attenuator
5.2.3 Data acquisition system (LabVIEW)

5.3 Measurement of AC Input Parameters

The input AC parameters shall be measured using a potential transformer and current
transformer. The potential transformer (PT) shall have a ratio of 4:1 to reduce the
line-to-neutral voltage. The voltage signal shall be further reduced using attenuation
through an isolation amplifier. The output of the amplifier shall then be fed to the
acquisition system. The AC line current shall be measured using a clamp-on current
transformer (CT), with a ratio of 1000:1 and a frequency response of DC to 400Hz.

315 Chpt IV, Sect XI

 AVTA-PHTP10

On the secondary side of the CT, a resistor with a value of 10 ohms, 100 ohms, or
1000 ohms shall be connected, in order to obtain a measurable voltage drop. This
voltage will be proportional to the line current and will be fed to the data acquisition
system.

5.4 Measurement of DC Output Parameters

5.4.1 The DC voltage of the RESS shall be measured using the proper attenuation
in the isolation amplifier. The DC current shall be measured using an AC/DC
CT. The CT shall have a ±2V analog output, which will be directly fed to the
acquisition system, with a frequency response of 0 to 2 kHz. The signals are
first passed through a signal conditioning and amplifier unit which provides
the necessary signal levels for compatibility with the AC/DC converter. The
program shall sample at a frequency of at least 21.6 kHz, acquiring at least
720 points per channel, and covering at least two cycles of the 60 Hz
waveform. This sampling frequency will ensure adequate resolution for the
power quality measurements.
5.4.2 Using the collected samples, the required parameters shall be calculated
every 30 seconds and stored in a data file. The following parameters shall be
calculated:
[Link] Vrms of the AC input voltage
[Link] Irms of the AC input voltage
[Link] THD of the AC input voltage
[Link] THD of the AC input current
[Link] AC active power
[Link] Harmonic power
[Link] Total apparent power
[Link] Harmonic apparent power
[Link] True power factor
[Link] Displacement power factor
[Link] RESS voltage
[Link] DC value of the charging current
[Link] Ripple factor of the charging current
[Link] Ampere-hours
[Link] Watt-hours
[Link] Charger efficiency (DC power out / AC power in)

NOTE:

316 Chpt IV, Sect XI

 AVTA-PHTP10

This data shall be saved in columns along with the time stamp, to
be used to plot the required waveforms as a function of time.
Power quality calculations use the fundamental components of the
voltage and current. These fundamental components shall be
calculated using the Fourier series expansion. Through operator
control, the acquired data shall also be saved in a separate file to
allow plotting of the input voltage and current waveforms. This
function should be performed at various times in the charging
cycle, including the beginning, mid-point and end.

6 RESS Charger Evaluation

The RESS Initial State of Charge shall be set prior to evaluation of the grid-connected
charger.

6.1 Normal Operation mode

For vehicles without an RESS Only mode, the time to recharge the RESS from full
discharge shall be determined after placing the RESS at an Initial SOC entering
charge-sustaining mode in accordance with Section 5.1 of AVTA-PHTP08.

6.2 RESS Only Mode

For vehicles operable in the RESS Only mode, the time to recharge the RESS from
full discharge shall be determined after completion of the range at constant speed test
conducted in accordance with procedure AVTA-PHTP04.

6.3 RESS Charging

Within two hours of placing the RESS at the appropriate Initial SOC, return the
vehicle to its Charge Station Location. Charge the vehicle in accordance with
Section 5.3 of procedure AVTA-PHTP08 and collect data in accordance with
Section 5 of this procedure.

6.4 Data Collection and Analysis

6.4.1 Monitor the AC and DC parameters during the entire charge period.
6.4.2 Charge for 13 hours or until the charger has automatically terminated as
determined from the Owner's/Operator's Manual.
6.4.3 Plot the parameters listed in Section 5.4.
6.4.4 Note the time the RESS is fully charged. The PHEV Vehicle Specification
requires that the RESS charger to automatically terminate charge when the
RESS has reached 100% SOC. This automatic termination point shall be used
to determine when the RESS has reached 100% SOC.
6.4.5 Note the maximum AC current.

317 Chpt IV, Sect XI

 AVTA-PHTP10

NOTE:
The grid-connected charger shall fully recharge the Rechargeable
Energy Storage System (RESS) from any state of discharge in less
than 12 hours.

NOTE:
The maximum AC current shall be less than 32 amperes for a
208/240 volt grid connection and shall be less than 12 amperes for
a 120 volt grid connection.

318 Chpt IV, Sect XI

 AVTA-PHTP10

Appendix A – PHEV Metrology Setup Sheet

(Page 1 of 1)

VIN Number: _______________________

Instrument/Device: Calibration Due Date: Initials / Date:
Current Clamp S/N:
Voltmeter S/N:
DAS S/N:
DAS Set-up Sheet S/N:
kWh Meter S/N:
Shunt S/N:
Misc:
Misc:
Misc:
Misc:
Misc:
Comments (initials/date):

Completed By:
_____________________________________________________________________________
(Printed Name) (Signature) (Date)

Reviewed By (QA):
____________________________________________________________________________
(Printed Name) (Signature) (Date)

Approved By:
_____________________________________________________________________________
(Printed Name) (Signature) (Date)

319 Chpt IV, Sect XI

 AVTA-PHTP11

Section XII: AVTA-PHTP11 – Vehicle Verification

320 Chpt IV, Sect XII

 AVTA-PHTP11

TABLE OF CONTENTS

1 Objective ...........................................................................................................................................................322

2 Purpose..............................................................................................................................................................322

3 Documentation..................................................................................................................................................322

4 Prerequisites......................................................................................................................................................322

5 Verification Requirements...............................................................................................................................323

5.1 Minimum Vehicle Requirements ...................................................................................................323

5.2 Dynamic Verification Requirements .............................................................................................323

APPENDICES

Appendix A – Vehicle Minimum Requirements Review Check List...................................................................330

Appendix B – Vehicle Non-Conformance Form ...................................................................................................338

321 Chpt IV, Sect XII

 AVTA-PHTP11

1 Objective
The objective of this procedure is to identify a common protocol to verify mandatory
(shall) requirements for vehicles evaluated by the U.S. Department of Energy Advanced
Vehicle Testing Activity (AVTA).

2 Purpose
This procedure identifies mandatory vehicle requirements contained in the PHEV Vehicle
Specification which shall be verified as part of AVTA testing. Vehicles submitted for
testing must meet all of these requirements.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read and readily reproducible. Basis documents are referenced where appropriate. This
documentation shall contain enough information to "stand alone"; that is, be self-contained
to the extent that all individuals qualified to review it could be reasonably expected to
reach a common conclusion, without the need to review additional documentation. Storage
and retention of records shall be completed as described in procedure AVTA-PHAC01.

4 Prerequisites

4.1 Individuals assigned to complete this procedure will be knowledgeable of the PHEV
Vehicle Specification.

4.2 Individuals assigned to complete this activity will have received the appropriate
training in accordance with procedure AVTA-PHAC05.

4.3 Prior to commencing this activity, a meeting of the involved personnel will be held
to discuss the following:
4.3.1 Data required
4.3.2 Data available
4.3.3 Data sources
4.3.4 Contingencies
4.3.5 Safety requirements

4.4 Verification of all mandatory requirements presented herein must be completed prior
to conduct of other testing, unless specifically exempted herein.

322 Chpt IV, Sect XII

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4.5 All documentation required to document the activities addressed by this procedure
shall be completed, approved and issued prior to commencing the testing it
addresses.

5 Verification Requirements
The requirements in Section 5 are derived from the PHEV Vehicle Specification. Vehicles
participating in AVTA testing shall meet these requirements. Vehicles which cannot meet
these requirements can be accepted for testing but only as a Prototype (non-Production)
Vehicle.
Should a vehicle participate in AVTA testing more than once, a new check-sheet shall be
completed each time it is presented. The Test Manager may choose not to re-verify all
items. Items not re-verified shall be documented in a Test Exception Report in accordance
with AVTA-PHAC02.
Appendix A identifies all mandatory requirements of the PHEV Vehicle Specification.
Some mandatory requirements can be verified by a physical inspection or document review
as described in Section 5.1. However, many mandatory requirements require measurement
or dynamic test for validation. The methods for conduct of these measurements or dynamic
tests are listed in Section 5.2.

5.1 Minimum Vehicle Requirements

Vehicle compliance with mandatory requirements of the PHEV Vehicle
Specification listed in Appendix A which are verifiable by inspection shall be
recorded in Appendix A. Any requirements not fully met shall be indicated in
Appendix A by marking “No” and completing a Non-Conformance Report,
Appendix B. The Non-Conformance Report shall be transmitted to the vehicle
supplier within two business days of issuance. Further verification of mandatory
vehicle requirements verifiable by inspection (Section 5.1) may continue while a
Non-Conformance Report is unresolved. However, no testing (Section 5.2) shall
proceed until all Non-Conformance Reports concerning mandatory vehicle
requirements verifiable by inspection (Section 5.1) are resolved such that Appendix
A can be marked “Yes” for all such requirements.

5.2 Dynamic Verification Requirements

The following tests shall be conducted to verify mandatory requirements of the
PHEV Vehicle Specification listed in Appendix A which are not verifiable by
inspection and require measurement or dynamic testing. The results of such
measurement or testing shall be recorded in Appendix A. Any requirements not fully
met shall be indicated in Appendix A by marking “No” and by completing a Non-
Conformance Report, Appendix B. The Non-Conformance Report shall be
transmitted to the vehicle supplier within two business days of issuance.

323 Chpt IV, Sect XII

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5.2.1 Verify the compliance of the vehicle to the requirements of the FMVSS
applicable on the date of manufacture by conducting the following:
[Link] Locate the FMVSS Certification Label(s) on the vehicle
[Link] Verify that the label(s) indicates the vehicle is fully certified
[Link] If the vehicle is a conversion, verify that both the OEM FMVSS
label and the Converter’s FMVSS label are present. The
Converter’s FMVSS label SHALL NOT be installed in a manner
that precludes full view of the OEM label.
5.2.2 During conduct of procedure AVTA-PHTP03, qualitatively verify
compliance with FCC requirements for unintentional emitted electromagnetic
radiation, as identified in 47 CFR 15, Subpart B, “Unintentional Radiators.”
by operating the following devices to determine if any interference is being
generated from the vehicle:
[Link] Cellular telephone
[Link] Mobile radio scanning over the 70 cm and 2M bands
[Link] Citizen band radio
[Link] Portable compact disc player
[Link] Notebook computer
[Link] Onboard audio equipment (AM/FM radio, cassette, CD)
Devices and/or their antennae shall be located in a manner to maximize their
potential for interference. [Prior to testing the initial vehicle, these devices
shall be operated in the dynamometer with the dynamometer operating to
verify there is no background interference.]
5.2.3 Verify the payload capability of at least 400 pounds as follows:
[Link] Upon receipt, the vehicle shall be weighed to determine the
vehicle’s standard (as-delivered condition) curb weight.
[Link] Obtain the GVWR rating from the FMVSS label affixed to the
vehicle.
[Link] Subtract the curb weight determined in Step [Link] from the
GVWR determined in [Link].
[Link] The calculated difference shall be considered the vehicle’s
payload capability.
5.2.4 If the vehicle is a conversion, it shall not have a GVWR or GAWR greater
than the OEM specified values. This shall be verified as follows:
[Link] Locate the OEM FMVSS label. Note the GVWR and GAWRs.
Record these values.
[Link] Locate the Converter’s FMVSS label. Note the GVWR and the
GAWRs.

324 Chpt IV, Sect XII

 AVTA-PHTP11

[Link] Compare the two GVWRs and verify that the GVWR listed on
the Converter’s FMVSS label is not greater than that listed by the
OEM.
[Link] Compare the two GAWRs and verify that the GAWRs listed on
the Converter’s FMVSS label are not greater than the OEM’s
listed GAWRs.
5.2.5 Verify that the tires supplied with the vehicle being inspected are
commercially available by conducting the following:
[Link] Identify the manufacturer, type and size of the tire. Verify that
the tire size is the same as that on the placard installed in the
driver side "B" pillar.
[Link] Verify that the tire is marked as "DOT rated."
[Link] Determine the maximum inflation pressure. Verify that the
recommended inflation pressure is less than or equal to that on
the placard installed in the driver side "B" pillar.
[Link] Obtain the load rating from the tire sidewall. Verify that this load
rating is greater than one-half of the GAWR for both the front
and rear axles.
[Link] Obtain the phone number of three dealers that are authorized
dealers for the tire in question.
[Link] Call those dealers and verify that the tires are available for
purchase. Make this verification for quantities of one and four
tires. If available, obtain the price of the tire, excluding amounts
for taxes, mounting, balancing, road hazard insurance and all
other fees and costs.
5.2.6 Verify that the passenger space is not intruded upon by the Rechargeable
Energy Storage System (RESS) or other conversion materials, as follows:
[Link] The RESS cannot be accessed by a vehicle occupant.
[Link] The RESS enclosure cannot be opened from inside the passenger
compartment.
[Link] The RESS enclosure does not intrude into the space normally
occupied by an individual while that individual is occupying a
seat formally defined as such.
[Link] Conversion materials do not intrude into the space normally
occupied by an individual while that individual is occupying a
seat formally defined as such.
5.2.7 Verify that maximum RESS discharge is controlled for vehicles capable of
operation in RESS Only mode by testing in accordance with procedure
AVTA-PHTP04, Section, 5.1. Verify that maximum RESS discharge is

325 Chpt IV, Sect XII

 AVTA-PHTP11

controlled for vehicles capable of operation only in the Normal Operation

mode by testing in accordance with procedure AVTA-PHTP12.
5.2.8 Confirm compliance with 49 CFR 571.105.S5.2.1 or 49 CFR
571.105.S5.2.1.2 by placing the vehicle in neutral and engaging the parking
brake on a 30% grade for at least 5 minutes and ensuring that the vehicle does
not move. The vehicle shall be loaded to GVWR including the driver.
Perform this test with vehicle facing forward on the slope and repeat the test
with the vehicle facing backward on the slope.
5.2.9 Verify successful completion of procedure AVTA-PHTP05 without damage
to or failure of the vehicle or its systems.
5.2.10 Verify vehicle repair time shall requirement in accordance with procedure
AVTA-PHAC02, Section 6.1.
5.2.11 Verify with the vehicle operator’s manual that the vehicle is not designed to
auto start with the key in the off position (or the vehicle in a de-energized
state for “keyless” ignitions). Additionally, vehicles shall be observed
throughout the testing program to verify that there are no auto start operations
with the key in the off position (or the vehicle in a de-energized state for
“keyless” ignitions).
5.2.12 A Test Engineer qualified in accordance with procedure AVTA-PHAC05 to
review UL 2202 and UL 2231 shall verify conformance with NEC625-29(c)
or (d).
5.2.13 Verification that vehicles do not contain exposed conductors, terminals,
contact blocks or devices of any type that create the potential for personnel to
be exposed to low voltage and high voltage, (as specified in SAE J1127,
J1128, et al.) shall be conducted as follows:
[Link] Each exposed conductor, terminal contact block and device shall
have its potential to ground measured with a voltmeter (digital or
analog) verifying that voltage present at the exposed area is less
than 60 volts.
[Link] Any device exhibiting a non-compliance (a voltage of 60V or
greater) shall be clearly identified on a comment sheet and by a
“NO” in Appendix A.
5.2.14 Verify that access to high-voltage components requires the removal of at least
one bolt, screw, or latch as follows:
[Link] Locate all high-voltage components using the maintenance
manual.
[Link] Verify that each of these components is fully enclosed and
requires the removal of at least one bolt, screw, or latch for
access to high voltage.
[Link] Verify that each of these components is clearly marked as “HIGH
VOLTAGE” at any point that it can be accessed.

326 Chpt IV, Sect XII

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5.2.15 Verify that cable and wire marking consist of orange wire and/or orange
sleeves as identified in SAE-J1127 as follows:
[Link] Locate all high-voltage cable using the maintenance manual.
[Link] Verify that each of these cables has an orange jacket or is marked
with an orange tracer.
5.2.16 Isolation of the RESS from the vehicle chassis such that leakage current is
less than 0.5 MIU shall be verified in accordance with procedure AVTA­
PHTP05, Section 5.47.1.
5.2.17 Isolation of the RESS charger from the vehicle chassis such that charger
leakage current is less than 0.5 MIU shall be verified in accordance with
procedure AVTA-PHTP05, Section 5.47.1.

CAUTION:
Verification of Section 5.2.18 may result in movement of the
vehicle. Personnel must anticipate inadvertent vehicle movement
and exercise extreme caution when performing the tasks required
by Section 5.2.18.

5.2.18 Verify the “NEUTRAL” and “PARK” lockout as follows:

[Link] Place the vehicle transmission in a position other than “PARK”
or “NEUTRAL.”
[Link] Energize the vehicle.
[Link] Attempt to move the vehicle by depressing the accelerator.
[Link] If the vehicle moves under power, complete a Non-Conformance
Report and notify the Supplier in accordance with Section 5.2.
5.2.19 Verify that the start key is removable only in the “OFF” position with the
drive selector in “PARK” as follows:
[Link] With the drive selector in the “PARK” position, verify that the
key can be inserted and removed without problem.
[Link] Turn the key to the “ON” position. Attempt to remove the key. If
the key can be removed, complete a Non-Conformance Report
and notify the Supplier in accordance with Section 5.2.
[Link] Repeat this for each available key position. If the key can be
removed in any position other than “OFF,” complete a Non-
Conformance Report and notify the Supplier in accordance with
Section 5.2.
[Link] If the key cannot be removed except when in the “OFF” position,
circle “Yes” in Appendix A for section 5.2.19.

327 Chpt IV, Sect XII

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CAUTION:
Verification of Step 5.2.20 may result in movement of the vehicle.
Personnel must anticipate inadvertent vehicle movement and
exercise extreme caution when performing the tasks required by
Section 5.2.20.

5.2.20 Verify the pre-existing accelerator input lockout as follows:

[Link] Place the vehicle drive selector in the “PARK” position.
[Link] Verify the vehicle is not energized.
[Link] Depress the accelerator.
[Link] Energize the vehicle. If the vehicle moves under power, complete
a Non-Conformance Report and notify the Supplier in accordance
with Section 5.2.
[Link] Place the vehicle drive selector in the “NEUTRAL” position.
[Link] Verify the vehicle is not energized.
[Link] Depress the accelerator.
[Link] Energize the vehicle. If the vehicle moves under power, complete
a Non-Conformance Report and notify the Supplier in accordance
with Section 5.2.
[Link] Place the vehicle drive selector in the “DRIVE” position.
[Link] Verify the vehicle is not energized.
[Link] Depress the accelerator.
[Link] Energize the vehicle. If the vehicle moves under power, complete
a Non-Conformance Report and notify the Supplier in accordance
with Section 5.2.
[Link] Place the drive selector in the “REVERSE” position.
[Link] Verify the vehicle is not energized.
[Link] Depress the accelerator.
[Link] Energize the vehicle. If the vehicle moves under power, complete
a Non-Conformance Report and notify the Supplier in accordance
with Section 5.2.
[Link] If the vehicle did not move in any of Section [Link] through
[Link], circle “Yes” in Appendix A for Section 5.2.20.
5.2.21 Verify charge cord interlock as follows:
[Link] With the charge cord inserted and the drive selector in the
“PARK” position, attempt to energize the vehicle, select
“DRIVE” and move the vehicle under power.

328 Chpt IV, Sect XII

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[Link] If the vehicle moves under power, complete a Non-Conformance

Report and notify the Supplier in accordance with Section 5.2.
[Link] Repeat Section [Link] selecting “REVERSE” and attempting to
move the vehicle under power.
[Link] If the vehicle moves under power, complete a Non-Conformance
Report and notify the Supplier in accordance with Section 5.2.
[Link] If the vehicle did not move in any of Sections [Link] through
[Link], circle “Yes” in Appendix A for Section 5.2.21.
5.2.22 Verify the RESS charger is capable of recharging the RESS to a state of full
charge from any possible state of discharge in less than 12 hours by
completing procedure AVTA-PHTP10, Section 6.4. Testing shall be initiated
following completion of a 45 mph Constant Speed Range Test conducted in
accordance with procedure AVTA-PHTP04.
5.2.23 Verify automatic charger termination in accordance with procedure AVTA­
PHTP10.
5.2.24 Verify charger input parameters in accordance with procedure AVTA­
PHTP10.
5.2.25 A Test Engineer qualified in accordance with procedure AVTA-PHAC05 to
review UL 2202 and UL2231 shall review the charger and charger data
submittal to determine conformance with the personnel protection
requirement. If access is available to the UL file for the onboard charger, this
file may alternatively be examined for conformance to UL2202 and 2231.
5.2.26 Verify charger power quality in accordance with procedure AVTA-PHTP10.

329 Chpt IV, Sect XII

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Appendix A – Vehicle Minimum Requirements Review Check

List
(Page 1 of 8)
VIN Number: _____________________

PHTP11 V/S Requirement: Requirement Met: Initials: Date:

Ref: Ref:
5.2.1 2.1 Vehicle shall comply with Federal Motor Vehicle Yes No N/A
Safety Standards applicable on the date of
manufacture. Such compliance shall be certified by
the Supplier in accordance with 49 CFR 567.

5.1 2.1 Suppliers shall provide a completed copy of Yes No N/A

Appendix A and Appendix B with their proposal,
providing vehicle specifications and the method of
compliance with each required section of 49 CFR
571.
5.1 2.1 If certification includes exemption, the exemption Yes No N/A
number issued by the National Highway
Transportation Safety Administration (NHTSA), the
date of it’s publication in the Federal Register and
the page number(s) of the Federal Register
acknowledging issuance of the exemption shall be
provided along with Appendix B. Exemptions for
any reason other than non-applicability shall not be
allowed.
5.1 2.2 Vehicles shall be certified under current California Yes No N/A
Air Resources Board (CARB) or Environmental
Protection Agency (EPA) regulations
5.1 2.4 Suppliers shall supply Material Safety Data Sheets Yes No N/A
(MSDS) for all unique hazardous materials supplied
with the vehicle
5.1 2.5 Suppliers shall provide recycling plans for batteries Yes No N/A
and other vehicle hazardous materials including how
the plan has been implemented.
5.2.2 2.6 All vehicles shall comply with the FCC requirements Yes No N/A
for unintentional emitted electromagnetic radiation,
as identified in 47 CFR 15, Subpart B,
“Unintentional Radiators.”
5.2.3 3.1 Vehicle shall have a minimum payload of 400 Yes No N/A
pounds.
5.2.4 3.2 For conversion vehicles, OEM GVWR shall not be Yes No N/A
increased.

5.1 Suppliers shall specify the OEMs GVWR. Yes No N/A

5.2.4 3.3 For conversion vehicles, OEM Gross Vehicle Axle Yes No N/A
Weight Ratings (GAWR) shall not be increased.

5.1 Suppliers shall provide axle weights for the vehicle

as delivered, and at full rated payload.

330 Chpt IV, Sect XII

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Appendix A – Vehicle Minimum Requirements Review Check

List
(Page 2 of 8)

VIN Number: ______________________

PHTP11 V/S Requirement: Requirement Met: Initials: Date:

Ref: Ref:
3.6 Tires shall be subject to the following requirements:
5.1 • Tires provided with the vehicle shall be the Yes No N/A
standard tire offered by the PHEV Supplier for
the vehicle being proposed.
5.2.5 • Tires shall correspond to the requirements of the Yes No N/A
placard installed in accordance with 49 CFR
571.109, 110, 119 and 120, as applicable.
5.1 • Suppliers shall specify manufacturer, model and Yes No N/A
size of the standard tire.
5.2.5 • Tires sizes and inflation pressures shall be in Yes No N/A
accordance with the requirements of the placard.
5.2.5 • At no time shall the tire’s inflation pressure Yes No N/A
exceed the maximum pressure imprinted upon
that tire’s sidewall.
5.2.5 • The tire shall be operable across the entire Yes No N/A
operation/load range of that vehicle.
5.2.5 Yes No N/A
• Replacement tires shall be commercially
available to the end user in sufficient quantities
to support the purchaser’s needs.
5.2.5 Yes No N/A
• Tires provided as original equipment by the
PHEV manufacturer shall not have warranty
restrictions in excess of those of the tire’s
manufacturer, unless the Supplier is the sole
warrantor for the tires.
5.1 Yes No N/A
• If the vehicle may be equipped with more than
one standard tire, this information shall be
provided for each type/manufacturer of each
standard tire.

331 Chpt IV, Sect XII

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Appendix A – Vehicle Minimum Requirements Review Check

List
(Page 3 of 8)

VIN Number: ______________________

PHTP11 V/S Requirement: Requirement Met: Initials: Date:

Ref: Ref:
5.1 4.1 Seating capacity shall be a minimum of 1 driver and Yes No N/A
1 passenger. Suppliers shall specify seating capacity
(available seat belt positions) for their vehicle.

5.1 4.1 For conversion vehicles, if the vehicle’s seating Yes No N/A
capacity is changed from that specified by the OEM
on their FMVSS placard, the seat(s) being added or
abandoned shall be modified as required by 49 CFR
571.207, et al, and a new FMVSS placard installed
as required by 49 CFR 567, 568 or 571, as
applicable.
5.2.6 4.2 For conversion vehicles, the OEM passenger space Yes No N/A
shall not be intruded upon by the Rechargeable
Energy Storage System (RESS) or other conversion
materials.
5.1 5.1 The vehicle shall have a parking mechanism Yes No N/A
5.2.7 5.4 The RESS battery discharge voltage shall be limited Yes No N/A
to prevent degradation of battery life.
5.2.8 5.6 Vehicles shall comply with the requirements of 49 Yes No N/A
CFR 571.105.S5.2.1, or alternatively, 49 CFR
571.105.S5.2.2 for parking mechanisms.
5.2.9 6.5 Vehicles shall be capable of completing procedure Yes No N/A
AVTA-PHTP05, including (1) driving through
standing water without damage and without battery
to chassis leakage current exceeding 0.5MIU per UL
Standard 2002 and (2) standing for extended periods
in extreme temperatures without damage to or failure
of the vehicle or its systems.

5.2.10 6.5 Vehicles shall be capable of completing all PHEV Yes No N/A
America tests without repairs exceeding a
cumulative total of 72 hours.
5.1 7.2 Batteries shall comply with the requirements of SAE Yes No N/A
J1718.

332 Chpt IV, Sect XII

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Appendix A – Vehicle Minimum Requirements Review Check

List
(Page 4 of 8)

VIN Number: ______________________

PHTP11 V/S Requirement: Requirement Met: Initials: Date:

Ref: Ref:
5.2.11 7.2 Vehicles shall not auto-start the engine to charge the Yes No N/A
batteries while the vehicle is parked and the key
switch is in the OFF position.

5.1 7.2 RESS batteries shall meet the requirements of NEC Yes No N/A
625-29(c) or (d) for charging in enclosed spaces
without a vent fan. The vehicle shall be labeled as
not requiring ventilation for charging (or have the
appropriate classification label from a UL-
recognized Testing Laboratory).
5.1 7.5 For vehicles with RESS nominal system voltages of Yes No N/A
48 volts and higher, batteries or capacitors and their
enclosures shall be designed and constructed in a
manner that complies with 49 CFR 571.305. For
vehicles with RESS nominal system voltages below
48VDC, batteries or capacitors, and their enclosures,
shall be designed and constructed in accordance with
the requirements of SAE J1766. Further, irrespective
of RESS system voltage, batteries or capacitors, and
electrolyte will not intrude into the passenger
compartment during or following FMVSS frontal
barrier, rear barrier and side impact collisions, and
rollover requirements of 49 CFR 571.301. Suppliers
shall provide verification of conformance to this
requirement.
5.1 7.6 Concentrations of explosive gases in the battery box Yes No N/A
shall not be allowed to exceed 25% of the Lower
Explosive Limit (LEL.)Suppliers shall describe how
battery boxes will be vented, to allow any battery
gases to escape safely to atmosphere during and
following normal or abnormal charging and
operation of the vehicle.

5.1 Battery gases shall not be allowed to enter the Yes No N/A
occupant compartment.

5.2.12 7.6 Batteries shall meet the requirements of NEC 625­ Yes No N/A
29(c) or (d) for charging in enclosed spaces without
a vent fan.

333 Chpt IV, Sect XII

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Appendix A – Vehicle Minimum Requirements Review Check

List
(Page 5 of 8)

VIN Number: ______________________

PHTP11 V/S Requirement: Requirement Met: Initials: Date:

Ref: Ref:
5.1 7.7 If a Supplier provides a vehicle with parallel battery Yes No N/A
packs, the Supplier shall provide detailed
information on the equipment and charging
algorithms required to prevent the parallel strings
from becoming unbalanced.
5.1 7.10 Suppliers shall provide the battery warranty to the Yes No N/A
end user, including the procedures for making a
warranty claim.
5.1 7.11 If a BMS is provided, the Supplier shall provide a Yes No N/A
description of the BMS operation.
5.1 7.12 For vehicles using fuels other than gasoline, Yes No N/A
manufacturers shall indicate compliance with
appropriate and applicable standards from SAE,
NFPA, etc. [e.g., for vehicles using Compressed
Natural Gas as fuel, manufacturers should indicate
compliance with NFPA 52, 49 CFR 571.303 &304.
5.1 7.13 Rechargeable Energy Storage Systems (RESS) shall Yes No N/A
be battery or capacitor-based as defined in SAE
J1711.
5.2.13 8.1 Vehicles shall not contain exposed conductors, Yes No N/A
terminals, contact blocks or devices of any type that
create the potential for personnel to be exposed to 60
volts or greater (the distinction between low-voltage
and high voltage, as specified in SAE J1127, J1128,
et al.).

5.2.14 8.1 Access to any high voltage components shall require Yes No N/A
the removal of at least one bolt, screw, or latch.

5.2.14 8.1 Devices considered to be high voltage components Yes No N/A

shall be clearly marked as HIGH VOLTAGE. These
markings should be installed at any point the voltage
can be accessed by the end user.

5.2.15 8.1 Cable and wire marking shall consist of orange wire Yes No N/A
and/or orange sleeving as identified in SAE-J1127.

334 Chpt IV, Sect XII

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Appendix A – Vehicle Minimum Requirements Review Check

List
(Page 6 of 8)

VIN Number: ______________________

PHTP11 V/S Requirement: Requirement Met: Initials: Date:

Ref: Ref:
5.2.16 8.2 For propulsion power systems with voltages, which Yes No N/A
may equal or exceed 60 VDC, the system shall be
isolated from the vehicle chassis such that leakage
current does not exceed 0.5 MIU.

5.2.17 8.2 Charging circuits for RESS battery systems with Yes No N/A
voltages, which may equal or exceed 60 VDC, shall
be isolated from the vehicle chassis such that ground
current from the grounded chassis does not exceed 5
mA at any time the vehicle is connected to an off-
board power supply.
5.1 8.3 The automatic disconnect for the RESS batteries Yes No N/A
shall be capable of interrupting maximum rated
controller/inverter current

5.1 The Supplier shall describe the automatic disconnect Yes No N/A
provided for the main propulsion batteries.
5.2.21 8.4 The vehicle shall be prevented from being driven Yes No N/A
with the key turned on and the drive selector in the
drive or reverse position while the vehicle’s charge
cord is attached.

The following interlocks shall be present:

5.2.18 • The controller shall not initially energize to Yes No N/A
move the vehicle with the gear selector in any
position other than “PARK” or “NEUTRAL.”
5.2.19 • The start key shall be removable only when the Yes No N/A
“ignition switch” is in the “OFF” position, with
the drive selector in “PARK.”
5.2.20 • With a pre-existing accelerator input, the Yes No N/A
controller shall not energize or excite such that
the vehicle can move under its own power from
this condition.
5.2.22 9.1 The grid-connected charger shall be capable of Yes No N/A
recharging the RESS to a state of full charge from
any possible state of discharge in less than 12 hours,
at temperatures noted in PHEV Vehicle
Specification Section 5.5, as applicable.

335 Chpt IV, Sect XII

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Appendix A – Vehicle Minimum Requirements Review Check

List
(Page 7 of 8)

VIN Number: ______________________

PHTP11 V/S Requirement: Requirement Met: Initials: Date:

Ref: Ref:
5.2.23 9.1 The charger shall be fully automatic, determining Yes No N/A
when “end of charge” conditions are met and
transitioning into a mode that maintains the main
propulsion battery at a full state of charge while not
overcharging it, if continuously left on charge.
5.2.24 9.2 The RESS charger shall be onboard the vehicle and Yes No N/A
shall be powered from 120V or 208/240V single-
phase 60-Hertz alternating current, with an input
voltage tolerance of ±10% of rated voltage.

5.2.24 9.2 Input current for chargers operating at 120V shall be Yes No N/A
compatible with 15-ampere circuit breakers. Input
current for chargers operating at 208V/240V shall be
compatible with 40-ampere circuit breakers.

5.2.25 9.2 Personnel protection systems shall be in accordance Yes No N/A

with the applicable sections of UL2231-1 and 2231­
2. Equipment external to the vehicle shall comply
with NEC 625.

5.2.26 9.3 The RESS charger shall have a true power factor of Yes No N/A
0.95 or greater and a harmonic current distortion of ≤
20% (at rated load).

5.1 10.0 Suppliers shall specify all optional equipment Yes No N/A
required to meet the requirements of the PHEV
Vehicle Specification.

5.1 The installation of options shall not relieve Suppliers Yes No N/A
of meeting other “shall” requirements.
5.1 11.1 Vehicles shall be accompanied by non-proprietary Yes No N/A
manuals for parts, service, operation and
maintenance, interconnection wiring diagrams and
schematics.

336 Chpt IV, Sect XII

 AVTA-PHTP11

Appendix A – Vehicle Minimum Requirements Review Check

List
(Page 8 of 8)

VIN Number: ______________________

General Comments (initials/date):
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
__________________________________

Completed By:

(Printed Name) (Signature) (Date)

Reviewed By:

(Printed Name) (Signature) (Date)

Approved By:

(Printed Name) (Signature) (Date)

337 Chpt IV, Sect XII

 AVTA-PHTP11

Appendix B – Vehicle Non-Conformance Form

(Page 1 of 1)
NCR Number:
PHEV
NON-CONFORMANCE REPORT
(PLEASE PRINT USING A PEN OR TYPEWRITER)
DESCRIPTION OF NONCOMPLIANCE:
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________
______________________________________________________________________________________________________________

REFERENCES: STEP DISCOVERED IN

NONCOMPLIANCE:

DISCOVERY DATE: TIME: Vehicle VIN:

ORIGINATOR’S NAME: DATE: TIME:

(Printed) (Signature)
TEST MANAGER’S NAME: DATE: TIME:

(Printed) (Signature)
MANUFACTURER’S REPRESENTATIVE’S NAME: DATE: TIME:

(Printed) (Signature)

DISPOSITION
DESCRIPTION OF RESOLUTION (INCLUDE THE ACTIONS TAKEN TO BRING THE VEHICLE INTO PROGRAM REQUIREMENTS):
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
_____

MANUFACTURER’S REPRESENTATIVE’S NAME: DATE: TIME:

(Printed) (Signature)
TEST MANAGER’S NAME: DATE: TIME:

(Printed) (Signature)

338 Chpt IV, Sect XII

 AVTA-PHTP12

Section XIII: AVTA-PHTP12 – Evaluation of Plug-in Hybrid

Electric Vehicle Energy Management System(s)
[EMS]

339 Chpt IV, Sect XIII

 AVTA-PHTP12

TABLE OF CONTENTS

1 Objective ...........................................................................................................................................................341

2 Purpose..............................................................................................................................................................341

3 Documentation..................................................................................................................................................341

4 Prerequisites......................................................................................................................................................341

5 Measurement of Energy Monitoring System (EMS) Performance ..............................................................341

5.1 Evaluation of RESS Temperature(s) .............................................................................................342

5.2 Evaluation of RESS Performance on Charge................................................................................342
5.3 Evaluation of RESS Performance on Discharge...........................................................................342
5.4 Evaluation of RESS System Voltages ............................................................................................342
5.5 Evaluation of Tell-Tales................................................................................................................343

APPENDICES

Appendix A – Energy Management System (EMS), Comment Sheet.................................................................344

340 Chpt IV, Sect XIII

 AVTA-PHTP12

1 Objective
This procedure provides a consistent method for the evaluation of the performance of the
RESS Energy Management System (EMS) of vehicles evaluated by the U.S. Department
of Energy Advanced Vehicle Testing Activity (AVTA).

2 Purpose
The purpose of this procedure is to provide a qualitative method for the collection and
evaluation of EMS data and observations. This activity is meant to quantify results
obtained from the operation of the EMS during conduct of AVTA testing. Although it is
necessary to test and monitor vehicle performance to ensure the successful operation of the
EMS, vehicle tests are addressed by other test procedures. This testing and data acquisition
meets the requirements specified in the PHEV Vehicle Specification specific to the EMS.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read, and readily reproducible. This documentation shall contain enough information to
“stand alone”; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion, without the need to review
additional documentation. Review and approval of test documentation shall be in
accordance with procedure AVTA-PHAC04. Storage and retention of records during and
following testing activities shall be completed as described in procedure AVTA-PHAC01.

4 Prerequisites

4.1 Personnel conducting testing under this procedure shall be familiar with the
requirements of this procedure, shall be trained in accordance with the requirements
of procedure AVTA-PHAC05 and be certified by the Program Manager or the Test
Manager prior to commencing any testing activities.

4.2 Any deviation from the test procedure and the reason for the deviation shall be
approved in advance by the Program Manager or Test Manager in accordance with
procedure AVTA-PHAC02 and so noted on the appropriate data sheet(s).

4.3 Necessary recording equipment shall be installed in a manner that does not hinder
vehicle operation or alter the operating characteristics of the vehicle.

5 Measurement of Energy Monitoring System (EMS)

Performance
This procedure is designed as a non-intrusive, qualitative evaluation tool to assist the Test
Manager in determining if the EMS is operating correctly. Based upon the Supplier’s

341 Chpt IV, Sect XIII

 AVTA-PHTP12

submittal, the vehicle will be assumed to contain an EMS unless otherwise noted. The
EMS (if installed) shall be evaluated to ensure it is capable of properly maintaining the
Rechargeable Energy Storage System (RESS).
The vehicle should be equipped with an RESS EMS. This system should control RESS
voltages, temperatures and state of charge. Further, the EMS should automatically limit
RESS discharge below a pre-determined minimum level. The charger system should
include equipment to maintain each component in the RESS at equal temperature and
within the allowed temperature range of the RESS throughout each charge-discharge cycle.
There are several methods of verifying the EMS is operating correctly. Record all
comments made on a copy of Appendix A, and include in the Test Report.

5.1 Evaluation of RESS Temperature(s)

RESS temperature affects RESS capacity and life. Unequal module temperatures
within the RESS can result in uneven charging and discharging and even premature
failure. High RESS temperature can significantly increase charging times and reduce
maximum charging rates. Indications of erratic or inconsistent RESS temperatures
may be a sign that the EMS is not operating correctly. This condition warrants
further discussion with the vehicle Supplier.

5.2 Evaluation of RESS Performance on Charge

The ability of a RESS to recharge in a consistent manner (based upon temperature,
State of Charge (SOC), etc.) can be used to identify problems with the RESS or the
EMS. RESS charging in a consistent manner following similar discharges indicate
the EMS and the RESS are operating appropriately. Inconsistent recharge times,
relatively short or long charge times, or erratic performance during or following a
charge, are indications the RESS or EMS may not be operating properly. This
condition warrants further discussion with the vehicle Supplier.

5.3 Evaluation of RESS Performance on Discharge

The ability of a RESS to discharge in a consistent manner (based upon temperature,
SOC, etc.) can be used to identify problems with the RESS or the EMS. RESS
discharging in a consistent manner following full charges indicate the EMS and the
RESS are operating appropriately. Inconsistent discharge capabilities (as measured
by kWh or Ah out), high or low RESS temperatures or erratic charge performance
following a discharge, are indications the RESS or EMS may not be operating
properly. This condition warrants further discussion with the vehicle Supplier. [Note
that a faulty or disabled charger may also cause improper charging for vehicles
capable of grid charging.]

5.4 Evaluation of RESS System Voltages

The EMS should control propulsion RESS pack and component voltages to preclude
conditions, which may be detrimental to the RESS. Voltage, which changes rapidly
on discharge, is an indication that one or more components may have failed. A

342 Chpt IV, Sect XIII

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sudden decrease in RESS voltage should trigger the EMS to control discharge rates.
This may be evidenced by a premature loss of power or tell-tales illuminating out of
sequence, or not at all. These conditions warrant further discussion with the vehicle
Supplier.

5.5 Evaluation of Tell-Tales

Tell-tales are normally provided to alert the operator/driver that RESS limits are
being approached. There is usually a specific sequence of illumination, starting with
the illumination of an information tell-tale and culminating with the illumination of a
final tell-tale concurrent with a power restriction or limiting feature (initiated by the
EMS). Illumination of these tell-tales out of sequence or not at all may indicate the
EMS is operating incorrectly, or the RESS is operating erratically. These conditions
warrant further discussion with the vehicle Supplier.

343 Chpt IV, Sect XIII

 AVTA-PHTP12

Appendix A – Energy Management System (EMS), Comment

Sheet
(Sheet 1 of 1)
VIN Number: ____________________________

__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________

344 Chpt IV, Sect XIII

 AVTA-PHTP13

Section XIV: AVTA-PHTP13 – Reserved for Future Use

345 Chpt II, Sect XIV

 AVTA-PHTP14

Section XV: AVTA-PHTP14 – Evaluation of Plug-in Hybrid

Electric Vehicle Battery Packs

346 Chpt IV, Sect XV

 AVTA-PHTP14

TABLE OF CONTENTS

1 Objective ...........................................................................................................................................................348

2 Purpose..............................................................................................................................................................348

3 Documentation..................................................................................................................................................348

4 Initial Conditions and Prerequisites ...............................................................................................................348

5 Testing Activity Requirements ........................................................................................................................349

5.1 General Test Conditions ...............................................................................................................350

5.1.1 Units of charge and discharge ..............................................................................................................350
5.1.2 Ambient temperature control ...............................................................................................................350
5.1.3 Battery temperature control..................................................................................................................350
5.1.4 Scaling..................................................................................................................................................350
5.2 Battery Charging ..........................................................................................................................350
5.2.1 Charging procedure..............................................................................................................................350
5.3 Static Capacity Test ......................................................................................................................351
5.3.1 Capacity test sequence .........................................................................................................................351
5.4 Hybrid Pulse-Power Characterization Test..................................................................................351
5.4.1 Hybrid pulse-power characterization test profile .................................................................................352
5.4.2 HPPC test procedure ............................................................................................................................353

APPENDICES

Appendix A – Battery Evaluation Test Data Sheet...............................................................................................358

Appendix B – Vehicle Metrology Setup Sheets .....................................................................................................359

347 Chpt IV, Sect XV

 AVTA-PHTP14

1 Objective
This procedure identifies methods for evaluating the batteries of plug-in hybrid electric
vehicles (PHEV) evaluated by the U.S. Department of Energy Advanced Vehicle Testing
Activity (AVTA). These methods are not meant to supersede those of the testing facility,
those specifically addressed by SAE Test Standards, nor of any regulatory agency which
may have or exercise control over the covered activities.

2 Purpose
The purpose of this procedure is to identify acceptable methods for the implementation of
the test requirements of the FreedomCAR Battery Test Manual for Power-Assist Plug-in
Hybrid Electric Vehicles. This test establishes methods to quantitatively evaluate the
capacity of the battery as well as the battery’s power capability over its usable range of
current and voltage. This procedure may be used at any time during the battery life to
assess battery condition.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read and readily reproducible. This documentation shall contain enough information to
"stand alone"; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion, without the need to review
additional documentation. Review and approval of test documentation shall be in
accordance with procedure AVTA-PHAC04. Storage and retention of records during and
following testing activities shall be completed as described in procedure AVTA-PHAC01.

4 Initial Conditions and Prerequisites

Prior to conduct of any portion of the testing, the following initial conditions and
prerequisites shall be met. Satisfactory completion of these items shall be verified as
complete and recorded on the appropriate Test Data Sheet.

4.1 Personnel conducting testing under this procedure shall be familiar with the
requirements of this procedure, shall be trained in accordance with the requirements
of procedure AVTA-PHAC05 and be certified by the Program Manager or the Test
Manager prior to commencing any testing activities.

4.2 Tests shall be conducted a temperature of 77°F ± 9°F (25˚C ± 5˚C).

4.3 Vehicles should have completed test procedure AVTA-PHTP03 and the current data
should be available for analysis.

348 Chpt IV, Sect XV

 AVTA-PHTP14

4.4 The tests and conditions outlined in Section 5 are based on the manufacturer’s
specifications of the battery pack. Hence, the following information must be obtained
from the manufacturer:
4.4.1 Battery capacity at the C1 rate (i.e., the capacity of the battery when
discharged at the 1 hour rate)
4.4.2 The end-of-discharge voltage (EODV) when performing a test discharge at
the C1 rate
4.4.3 EODV during the hybrid pulse-power characterization (HPPC, see Section
5.4, below) schedule
4.4.4 Top-of-charge voltage (TOCV) limit when charging the battery after a C1
discharge
4.4.5 TOCV when charging after a discharge pulse within the HPPC (see Section
5.4 below) schedule.

4.5 The following data shall be collected during conduct of the various tests specified by
this procedure. Overall error in recording or indicating instruments shall not exceed
±2% of the maximum value of the variable being measured. Periodic calibration
shall be performed and documented to ensure compliance with this requirement.
4.5.1 Rechargeable Energy Storage System (RESS) voltage versus time
4.5.2 RESS current versus time
4.5.3 RESS watts versus time
4.5.4 RESS amp-hours versus time
4.5.5 RESS temperature versus time
4.5.6 Ambient temperature versus time.

4.6 All protocols, procedures and attendant documentation required to conduct this
testing shall be completed, approved and issued prior to commencing the testing it
addresses.

4.7 Any deviation from the test procedure and the reason for the deviation shall be
approved in advance by the Program Manager or Test Manager in accordance with
procedure AVTA-PHAC02 and so noted on the appropriate data sheet(s).

5 Testing Activity Requirements

Battery testing shall be conducted at the beginning of vehicle life and at the end of vehicle
accelerated testing in accordance with procedure AVTA-PHTP01. Beginning and end of
life tests shall be presented and compared in accordance with Sections 5.6 and 5.7.

349 Chpt IV, Sect XV

 AVTA-PHTP14

NOTE:
Vehicle Supplier and battery manufacturer limits on battery
performance shall not be violated during testing.

5.1 General Test Conditions

5.1.1 Units of charge and discharge
The charge and discharge of batteries in all test profiles will be based on
current. Negative current will correspond to a charge and a positive current
will relate to a discharge.
5.1.2 Ambient temperature control
The ambient temperature for all testing shall be controlled at a nominal
temperature of 77°F ± 9°F (25˚C ± 5˚C). All tests shall be preceded by an
eight-hour soak at this temperature.
5.1.3 Battery temperature control
The battery temperature must be monitored and test stopped if the battery
temperature rises above the manufacturer recommended maximum charging
temperature. If no maximum charging temperature is available, a reasonable
temperature for the type of battery being charged shall be chosen. It is
recommended to cause air to flow across or through the battery pack as is
typically done by the vehicle during normal driving.
5.1.4 Scaling
The goal of the procedure is to test complete packs of batteries from PHEVs.
If a full battery pack is not available or impractical to test, the power required
for a charge or discharge will be scaled according to the number of modules,
so that individual modules experience the same duty as modules in a full
battery pack.

5.2 Battery Charging

The conditions for battery charging shall be defined using the manufacturer's
recommended procedure. If no manufacturer specifications are available, the battery
will be recharged based on literature data specific to the battery technology under
test.
5.2.1 Charging procedure
[Link] Charge the RESS battery to a 100% Initial State of Charge using
the grid-connected charger in accordance with procedure AVTA­
PHTP08.
[Link] Record the number of ampere-hours (Ah) returned and the top of
charge voltage in Appendix A.

350 Chpt IV, Sect XV

 AVTA-PHTP14

5.3 Static Capacity Test

This test measures the capacity of the battery pack in Ahs at a constant discharge rate
that corresponds to the manufacturers rated C1 capacity (i.e., if the rated C1 is 10
Ah, the discharge current will be 10 A). If no capacity is available, a C1 discharge
current shall be estimated based on the weight, volume, and typical energy density of
the specific technology under test. Discharge is terminated when the battery voltage
has decreased to the manufacturer’s specified discharge voltage limit. If the
manufacturer does not supply a value, a limit shall be derived from literature data
specific to the battery technology under test. Battery capacity and discharge voltage
limit shall be recorded in Appendix A.
It should be noted that while the C1 capacity does not necessarily reflect the
performance of the battery pack under plug-in hybrid vehicle conditions, it does
provide baseline data on battery change/degradation during battery lifetime.
A Static Capacity Test is to be conducted prior to each set of hybrid pulse-power
characterization measurements.
5.3.1 Capacity test sequence
[Link] The battery shall be charged to 100% Initial State of Charge in
accordance with 5.2.1. Upon completion of charging, the battery
shall be allowed to soak for at least 8 hours at 77°F ± 9°F (25˚C ±
5˚C).
[Link] Ah replaced shall be recorded in Appendix A.
[Link] After the soak, the battery shall be discharged at a constant C1
current until the minimum discharge voltage is reached.
[Link] Ah removed shall be recorded in Appendix A.
[Link] Repeat steps [Link] through [Link] until the Ah removed from
three consecutive capacity cycles are within 3% of the lowest
Ahs removed.
[Link] If the number of cycles exceeds 8 before three consecutive cycles
are within 3%, stop the test to evaluate the cause of divergence.
[Link] Record the average Ah removed of the three consecutive capacity
cycles within 3% as the capacity of the battery in Appendix A.

5.4 Hybrid Pulse-Power Characterization Test

Use of the hybrid pulse-power characterization (HPPC) test is intended to provide an
estimate of the power capability (charge and discharge) of a specific battery in a
specific vehicle under normal driving conditions.
The primary objective of this test is to establish, as a function of depth of discharge
(DOD), the following:
i) the Vmin discharge power capability at the end of a 10 second discharge current
pulse

351 Chpt IV, Sect XV

 AVTA-PHTP14

ii) the Vmax regeneration power capability at the end of a 10 second regeneration
current pulse.
5.4.1 Hybrid pulse-power characterization test profile
The objective of this profile is to demonstrate the discharge pulse and
regeneration pulse power capabilities at various DOD. The HPPC test profile
uses a 10 second constant-current discharge pulse, followed by a 40 second
rest at open circuit, followed by a 10 second constant-current charge pulse.
[Link] The first 10 second pulse is termed Idismax and the second 10
second pulse is referred to as Ichmax. These values are 5 times
the C1 capacity of the battery.
[Link] The HPPC cycle profile is shown in Table 1 and Figure 1, and is
referred to as the HPPC test profile (note, the discharge and
charge currents are positive and negative, respectively).

Table 1 - HPPC test profile

Time Increment (s) Cumulative Time (s) Current

10 10 Idismax
40 50 0
10 60 Ichmax

1.25

1.00
Idismax
Discharge
0.75

0.50

0.25

0.00

-0.25

-0.50
IRegen
chmax
-0.75

-1.00
0 10 20 30 40 50 60
Time in Profile (s)

Figure 1 - HPPC test profile

[Courtesy of US Department of Energy FreedomCAR Battery Test Manual}

352 Chpt IV, Sect XV

 AVTA-PHTP14

5.4.2 HPPC test procedure

The HPPC test procedure incorporates the HPPC test profile as defined in
Section 5.4.1. This procedure incorporates constant-current steps based on
Idismax and Ichmax. The complete test procedure is made of single repetitions of
the HPPC test profile, separated by 10% DOD constant-current C1 discharge
segments4, with each of these C1 discharge segments followed by a 1 hour
rest period to allow the cells to return to an electrochemical and thermal
equilibrium condition. C1 discharge segments followed by a 1 hour rest
period to allow the cells to return to an electrochemical and thermal
equilibrium condition. The test begins with a full cycle of the battery
followed by a 1 hour rest, and terminates with the final repetition of the
HPPC test profile to 90% DOD, followed by a complete discharge to 100%
DOD then a 1 hour rest at open circuit5. The test will also terminate when the
battery voltage reaches the pre-determined Vmin during a C1 discharge. If at
any point during an Idismax pulse the battery voltage drops to Vmin, the battery
will be held at that voltage until the discharge pulse is complete and the
HPPC test profile will continue.
The voltages during each rest period at open circuit are recorded to establish
the cell’s open-circuit voltage (OCV) behavior. The sequence of rest periods,
pulse profiles, and C1 discharge segments are illustrated in Figures 2 and 3.
These figures also illustrate a C1 cycle to be executed just prior to conduct of
the HPPC procedure.

4
The energy of the pulse profile must be accounted for in determining the actual state-of-charge (SOC) at which the profile was performed. The
profile in Table 1 may remove several percent of the capacity from a typical device. The test should be programmed such that 10% of the rate
capacity is removed in each test segment, including that removed by the pulse power profile itself.
5
Note that the manufacturer’s limits must be observed during all test procedures. If the discharge voltage limit is reached during the actual pulse
profiles, stop the pulse but continue through to the end of the test allowing the each pulse to occur until the limit is reached

353 Chpt IV, Sect XV

 AVTA-PHTP14

Discharge Note: The scale is approximate because some HPPC Profile HPPC Profile
elements in the test sequence have variable length.
For example, the C1/1 discharge is conducted to a
minimum voltage, not necessarily for one hour.

10% 10% 10%

C1/1 C1/1 C1/1

C1/1 Discharge

1 hour Rest 1 hour Rest 1 hour Rest

Recharge

Regen

-180 -120 -60 0 60 120 180

Time (minutes)
Figure 2 - HPPC test profile (start of procedure only)
[Courtesy of US Department of Energy FreedomCAR Battery Test Manual]

Discharge HPPC Profile

10%
C1/1

Charge/Regen

-3 -1 1 3 5 7 9 11 13

Time (hours)

Figure 3 - HPPC test profile (complete HPPC procedure)

[Courtesy of US Department of Energy FreedomCAR Battery Test Manual]

354 Chpt IV, Sect XV

 AVTA-PHTP14

[Link] Begin the HPPC test by discharging the battery at the C1 rate
until it reaches 100% DOD or the minimum voltage is achieved.
[Link] Charge the battery with the charge profile (see Section 5.2).
[Link] Allow the battery to rest for one hour.
[Link] Discharge the battery at the C1 rate until it reaches 10% DOD.
[Link] Allow the battery to rest for one hour.
[Link] Discharge the battery at the maximum discharge rate for ten
seconds.
[Link] Allow the battery to rest for forty seconds.
[Link] Charge the battery at the maximum charge rate for ten seconds.
[Link] Discharge the battery at the C1 rate until it reaches 20% DOD.
[Link] Allow the battery to rest for one hour.
[Link] Discharge the battery at the maximum discharge rate for ten
seconds.
[Link] Allow the battery to rest for forty seconds.
[Link] Charge the battery at the maximum charge rate for ten seconds.
[Link] Discharge the battery at the C1 rate until it reaches 30% DOD.
[Link] Allow the battery to rest for one hour.
[Link] Discharge the battery at the maximum discharge rate for ten
seconds.
[Link] Allow the battery to rest for forty seconds.
[Link] Charge the battery at the maximum charge rate for ten seconds.
[Link] Discharge the battery at the C1 rate until it reaches 40% DOD.
[Link] Allow the battery to rest for one hour.
[Link] Discharge the battery at the maximum discharge rate for ten
seconds.
[Link] Allow the battery to rest for forty seconds.
[Link] Charge the battery at the maximum charge rate for ten seconds.
[Link] Discharge the battery at the C1 rate until it reaches 50% DOD.
[Link] Allow the battery to rest for one hour.
[Link] Discharge the battery at the maximum discharge rate for ten
seconds.
[Link] Allow the battery to rest for forty seconds.
[Link] Charge the battery at the maximum charge rate for ten seconds.

355 Chpt IV, Sect XV

 AVTA-PHTP14

[Link] Discharge the battery at the C1 rate until it reaches 60% DOD.
[Link] Allow the battery to rest for one hour.
[Link] Discharge the battery at the maximum discharge rate for ten
seconds.
[Link] Allow the battery to rest for forty seconds.
[Link] Charge the battery at the maximum charge rate for ten seconds.
[Link] Discharge the battery at the C1 rate until it reaches 70% DOD.
[Link] Allow the battery to rest for one hour.
[Link] Discharge the battery at the maximum discharge rate for ten
seconds.
[Link] Allow the battery to rest for forty seconds.
[Link] Charge the battery at the maximum charge rate for ten seconds.
[Link] Discharge the battery at the C1 rate until it reaches 80% DOD.
[Link] Allow the battery to rest for one hour.
[Link] Discharge the battery at the maximum discharge rate for ten
seconds.
[Link] Allow the battery to rest for forty seconds.
[Link] Charge the battery at the maximum charge rate for ten seconds.
[Link] Discharge the battery at the C1 rate until it reaches 90% DOD.
[Link] Allow the battery to rest for one hour.
[Link] Discharge the battery at the maximum discharge rate for ten
seconds.
[Link] Allow the battery to rest for forty seconds.
[Link] Charge the battery at the maximum charge rate for ten seconds.
[Link] Discharge the battery at the C1 rate until it reaches 100% DOD.
[Link] Allow the battery to rest for one hour.
[Link] Charge the battery with the charge profile (see Section 5.2).
[Link] In Appendix A record the following:
[Link].1 SOC at which the maximum charge voltage was
reached, if applicable
[Link].2 SOC at which the minimum discharge voltage was
reached, if applicable
[Link].3 SOC at which the test was terminated.
[Link] Save all data files.

356 Chpt IV, Sect XV

 AVTA-PHTP14

5.5 Data Reduction

5.5.1 Data shall be reduced in accordance with the FreedomCAR Battery Test
Manual for Power-Assist Hybrid Electric Vehicles.
5.5.2 A graph of available energy shall be prepared using the guidance of
Appendix E of the FreedomCAR Battery Test Manual for Power-Assist
Hybrid Electric Vehicles.
5.5.3 As the requirements of PHEV battery packs can differ markedly from vehicle
model to vehicle model, the magnitude of the power pulses recorded in actual
vehicle operation are calculated for comparison against the battery capability
as determined by the HPPC test. The current data recorded during the
dynamometer drive cycles of test procedure AVTA-PHTP03 shall be used to
calculate maximum vehicle charge and discharge demand. Determine the
vehicle charge and discharge demand by averaging the top 0.5% of charge
data and discharge data respectively from the AC off dynamometer tests
(ignoring all current data from -0.5 to + 0.5 Amps and ignoring any
irregularly high data points). Repeat this step for the AC on dynamometer
data sets. Use the greatest charge current among all dynamometer tests as the
maximum charge demand and the greatest discharge current as maximum
discharge demand.

5.6 End-Of-Life Testing

5.6.1 Repeat testing in accordance with Sections 5.3 and 5.4 at the end of vehicle
accelerated testing in accordance with procedure AVTA-PHFTP01.
5.6.2 Results of end-of-life testing shall be compared to the beginning-of-life
results and with the vehicle charge and discharge demand in accordance with
Section 5.7.

5.7 Data Presentation

5.7.1 The results obtained from the HPPC testing shall be combined with vehicle
charge and discharge demand data obtained from dynamometer testing in
accordance with Section 5.5.3, and used to provide information on how
battery degradation affects fuel economy over the life of the vehicle.
5.7.2 Test results shall be presented in a report, presenting beginning and end of
life test results with vehicle charge and discharge demand in a format that
clearly displays the margin between battery capability and vehicle demand .

357 Chpt IV, Sect XV

 AVTA-PHTP14

Appendix A – Battery Evaluation Test Data Sheet

(Page 1 of 1)
VIN Number: ______________________
Project No.: Test Date(s):
Data File Name:
Test Engineer:
(Initials) (Date)

Determination of Battery C1 Capacity

Battery Cycle Log
Battery Capacity Rating: Discharge Voltage Limit:
(Amp-Hours) (Volts)

Amp-Hours Amp-Hours Comments

Replaced Removed
Cycle 1
Cycle 2
Cycle 3
Cycle 4
Cycle 5
Cycle 6
Cycle 7
Cycle 8
Average Amp-Hours Removed (of three consecutive cycles within 3% of lowest):
(Amp-Hours)

Determination of Plug-in Hybrid Pulse-Power Characterization

HPPC Settings
Ichmax: Ichmax C Rate: Idismax: Idismax C Rate:
(Amps) (Amps)

Maximum Charge Voltage: Minimum Discharge Voltage:

(Volts) (Volts)

HPPC Results
SOC at maximum voltage limit: SOC at minimum voltage limit:
(% SOC) (% SOC)

SOC at test termination:

(% SOC)

358 Chpt IV, Sect XV

 AVTA-PHTP14

Appendix B – Vehicle Metrology Setup Sheets

(Page 1 of 1)
VIN Number: ________________________
Instrument/Device: Calibration Due Date: Initials / Date:
Battery Charger S/N:
Temperature Measurement S/N:
Fifth Wheel S/N:
Fifth Wheel Calibrator S/N:
DAS S/N:
DAS Set-up Sheet S/N:
kWh Meter S/N:
Shunt S/N:
Tire Pressure Gauge S/N:
Fuel Scale S/N:
Misc:
Misc:
Comments (initials/date):

Completed By:
_____________________________________________________________________________
(Printed Name) (Signature ) (Date)

Reviewed By (QA):
___________________________________________________________________________
(Printed Name) (Signature) (Date)

Approved By:
_____________________________________________________________________________
(Printed Name) (Signature) (Date)

359 Chpt IV, Sect XV

 Chapter V: Accelerated Test
Procedures
Section I: AVTA-PHATP01 – Plug-in Hybrid Electric Vehicle
Accelerated Test Procedure

360 Chpt V, TOC

 AVTA-PHATP01

Section I: AVTA-PHATP01 – Plug-in Hybrid Electric Vehicle

Accelerated Test Procedure

361 Chpt V, Sect I

 AVTA-PHATP01

TABLE OF CONTENTS

1 Objectives ..........................................................................................................................................................363

2 Purpose..............................................................................................................................................................363

3 Documentation..................................................................................................................................................363

4 Test Conduct .....................................................................................................................................................363

4.1 Test Objectives ..............................................................................................................................363

4.2 Test Routes ....................................................................................................................................363
4.3 Test Sequence................................................................................................................................364
4.4 Insurance Requirements................................................................................................................364
4.5 Driver Training.............................................................................................................................364
4.6 Vehicle Fueling Infrastructure......................................................................................................364

5 Data Collection .................................................................................................................................................364

5.1 Test Output Data...........................................................................................................................364

5.2 Test Summary Data.......................................................................................................................365

APPENDICES

Appendix A – PHEV Test Sequence ......................................................................................................................366

Appendix B – Sample Data Presentation...............................................................................................................367

362 Chpt V, Sect I

 AVTA-PHATP01

1 Objectives
The objective of this procedure is to provide guidance for the conduct of accelerated
onroad testing of plug-in hybrid electric vehicles (PHEV), the collection of operating data
from these vehicles and the analysis of this data to provide evaluation of PHEV operation.
This procedure also provides guidance for the preparation of Fleet Data Sheets
summarizing vehicle performance for use by the U.S. Department of Energy Advanced
Vehicle Test Activity (AVTA).

2 Purpose
The purpose of this procedure is to identify acceptable and repeatable methods for
accelerated onroad testing of PHEVs.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read and readily reproducible. This documentation shall contain enough information to
"stand alone"; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion, without the need to review
additional documentation.

4 Test Conduct
PHEVs selected for evaluation by the AVTA shall be operated over established routes
using drivers dedicated to test conduct. Test data shall be collected as specified in Section
5.

4.1 Test Objectives

Specific test objectives shall be established for each vehicle participating in
accelerated testing. These objectives shall define, as a minimum, operating
environment, charging infrastructure and supplemental data collection requirements.

4.2 Test Routes

An urban route and a highway route shall be selected which are each nominally ten
miles in length. The urban route shall include the following characteristics:
• Maximum speed of 45 mph
• At least eight traffic control devices which require a full stop
• No uninterrupted drive distances greater than 1.5 mile.
The highway route shall include the following characteristics:
• Maximum speed of 75 mph
• Minimum speed of 45 mph

363 Chpt V, Sect I

 AVTA-PHATP01

• No more than two traffic control devices which require a full stop.
These routes, in various combinations as defined in Section 4.3, shall be used for all
accelerated testing. Vehicles shall be operated on these routes as consistently as road
conditions allow, including such parameters as speed, acceleration rates and
accessory use.

4.3 Test Sequence

Vehicles shall be operated over the routes defined in Section 4.2 using the test
sequence presented in Appendix A. Testing shall be conducted sequentially (i.e.
complete all 10 mile tests then complete all 20 mile tests, etc.).

4.4 Insurance Requirements

Before a vehicle begins testing, insurance shall be placed. The limits of liability shall
be no less than $300,000 per occurrence with a $500,000 aggregate limit.

4.5 Driver Training

Drivers with the following qualifications shall be used for accelerated testing:
• Licensed to drive in the state where testing will be conducted
• No moving violations for the past two years
• Demonstrated reliability.
Drivers shall be trained prior to their participating in test conduct in accordance with
procedure AVTA-PHAC05. Training shall include test objectives, proper operation
of the test vehicle, charging requirements, and data collection requirements.

4.6 Vehicle Fueling Infrastructure

All vehicle fueling infrastructure shall be in place and operational prior to
commencement of vehicle testing. Grid connections shall be assigned to a single
vehicle and shall be metered. Whenever possible the same gasoline dispenser shall
be used to fuel the test vehicle. Fueling infrastructure shall be located in sufficiently
close proximity to the urban and highway test routes that no more than 10% of test
miles on any test are accumulated driving to a fueling location.

5 Data Collection
Data shall be collected using a combination of electronic and manual means. Each PHEV
test vehicle shall be equipped with an electronic means of auditing driver performance. All
instrumentation shall be maintained in accordance with procedure AVTA-PHAC07.

5.1 Test Output Data

The following data shall be collected for each test listed in Appendix A:
• Date and time the test started and completed

364 Chpt V, Sect I

 AVTA-PHATP01

• Electric energy used to recharge the vehicle

• Any anomalous conditions experienced during the test.
Fuel shall be added to the vehicle at intervals of approximately 200 miles. Fueling
should be coordinated with the end of a test.

5.2 Test Summary Data

Test output data will be analyzed by the Idaho National Laboratory and posted to the
AVTA website. The following data shall be presented:
• Vehicle fuel and electric energy consumption for each test cycle (e.g. 10 miles, 20
miles, etc.)
• Cumulative vehicle fuel and electric energy consumption
• Vehicle operating anomalies, if any
• Route and environmental condition description.
A sample data presentation is included in Appendix B.

365 Chpt V, Sect I

 AVTA-PHATP01

Appendix A – PHEV Test Sequence

Cycle Urban Highway Charge Repititions Total Repetitions Miles Cumulative

(mi) (10 mi) (10 mi) (hr) (N) (mi) (%) (%) (mi)

10 1 0 4 60 600 45% 14% 600

20 1 1 8 30 600 23% 14% 1200
40 4 0 12 5 200 4% 5% 1400
40 2 2 12 5 200 4% 5% 1600
40 0 4 12 5 200 4% 5% 1800
60 2 4 12 10 600 8% 14% 2400
80 2 6 12 8 640 6% 15% 3040
100 2 8 12 6 600 5% 14% 3640
200 2 18 12 3 600 2% 14% 4240
Total 1740 2500 984 132 4240 4240
Average 41% 59% 7.5 32.1

366 Chpt V, Sect I

 AVTA-PHATP01

Appendix B – Sample Data Presentation

Plug-in Hybrid Electric Vehicle Fleet Testing

Advanced Vehicle Testing Activities
2006
EnergyCS Converted
Toyota Prius Plug-in
A Strong Energy
Hybrid Electric
Portfolio for a Strong
Vehicle (PHEV) America
Energy efficiency and
VIN # xxxxxxxxxxxxxxxxxxxx clean, renewable energy
will mean a stronger
economy, a cleaner
Fleet Vehicle environment, and greater
energy independence for
Description: America. Working with a
Engine: 4-cylinder, 57 kW @
This vehicle is operated by the City wide array of state,
5000 rpm
of San Van, California, by the Park community, industry, and
Electric Motor: 50 kW
and Recreation Department. It is university partners, the
Battery: Valence Lithium Ion 9 U.S. Department of
generally operated six days a
kWh Energy’s Office of Energy
week, for various reasons.
Seatbelt Positions: Five Efficiency and Renewable
Payload: 905 lbs Energy invests in a diverse
Major Operations & Maintenance Features: Regenerative braking, portfolio of energy
Events: CVT transmission
None
Monthly and Cumulative Miles
Operating Cost:
Purchase Cost: $65,000 (8/06)* 1,750 7,000

Kelly Used Vehicle Price: NA 1,500 Monthly Miles 6,000

Sale Price: In Operation Cumulative Miles

Maintenance Cost: $[Link]/mile 1,250 5,000

Cumulative Miles
Operating Cost: $[Link]/mile
Monthly Miles

1,000 4,000
Total Ownership Cost: $[Link]/mile
750 3,000

Operating Performance: 500 2,000

Total miles driven: 000
Cumulative MPG: xxxxx.x 250 1,000

Cumulative kWh/mile: [Link] 0 0

Fuel cost per mile:* [Link] Sep-06 Oct-06 Nov-06 Dec-06 Feb-07 Mar-06 Apr-06 May-06 Jun-06 Jul-06 Aug-06

* Purchase includes dealer price with

options
For more information contact:
EERE Information Center
1-877-EERE-INF (1-877-337-3463)
[Link]

367 Chpt V, Sect I

 AVTA-PHATP01

Appendix B – Sample Data Presentation (cont'd)

Plug-in Hybrid Electric Vehicle Fleet

Testing
kWh Charged per Offboard Charging Event - Energy CS #321 Prius
45%

40%
Percent of Total Offboard Charges

35%

30%

25%

20%

15%

10%

5%

0%
>0 - 2 >2 - 4 >4 - 6 >6 - 8 >8 - 10 >10 - 12 >12 - 15 >15
Kilowatt Hours per Offboard Charge Event
(note - a charge event occurs when current goes into the battery pack & the key is off)
Charge Time per Offboard Charging Event - Energy CS Prius #321

13%
12%
Percent of Total O ffboard Charging

11%
10%
9%
8%
7%
6%
5%
4%
3%
2%
1%
0%
-2

-3

-4

-5

-6

-7

-8

-9

0
.5

-1

00

0
-1

-2

-2

-3

-5
-1
-0

-1

>1
>1

>2

>3

>4

>5

>6

>7

>8
5

0
.

>9
0

>0

0
>1

>1

>2

>2

>3
>

>5
Hours per Offboard Charging Event
Distance Traveled per Charge - Energy CS Prius #321 (note - a charge event occurs w hen current goes into the battery pack & the key is off)

35%

30%

25%
Percent per Distance

20%

15%

10%

5%

0%
> 0 - 2.5 >2.5 - 5 >5 - 10 >10 - 15 >15 - 20 >30 - 50 >50 - 100 >100
Distance (miles) Traveled Betw een Charges

Distance per Trip - Energy CS Prius #321

30%

25%
Percent per Trip Distance

20%

15%

10%

5%

0%
> 0 - 2.5 >2.5 - 5 >5 - 10 >10 - 15 >15 - 20 >30 - 50 >50 - 100 >100
Miles per Trip
(note - trip is miles accumulated w hen the key is on)

368 Chpt V, Sect I

 AVTA-PHATP01

Appendix B – Sample Data Presentation (cont'd)

Plug-in Hybrid Electric Vehicle Fleet

Testing
Average Speed (MPH) - Energy CS Prius #321

60%
55%
50%
Percent per Speed Group

45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
0-5 >5 - 15 >15 - 30 >30 - 45 >45 - 60 >60 - 75 >75
Average Miles per Hour

Total Heat and AC Use - Energy CS Prius #321

100% A C on Heat on
Percent Heat/AC Total Use

90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
Total Use

Heat and AC Use At Various Temperatures (Fahrenheit) - Energy CS Prius #321

100%

90%
Percent Heat/AC Use per Temp Group

80%

70%

60%

50%

40%

30%

20%

10%

0%
100+
< -20

-20 - <0

0 - <20

20 - <40

40 - <50

50 - <60

60 - <70

70 - <80

80 - <90

90 - <100

Temperature Ranges (Fahrenheit)

369 Chpt V, Sect I

 Chapter VI: Fleet Test Procedures
Section I: AVTA-PHFTP01 – Plug-in Hybrid Electric Vehicle Fleet
Test Procedure

370 Chpt VI, TOC

 AVTA-PHFTP01

Section I: AVTA-PHFTP01 – Plug-in Hybrid Electric Vehicle

Fleet Test Procedure

371 Chpt VI, Sect I

 AVTA-PHFTP01

TABLE OF CONTENTS

1 Objectives ..........................................................................................................................................................373

2 Purpose..............................................................................................................................................................373

3 Documentation..................................................................................................................................................373

4 Fleet Selection ...................................................................................................................................................373

4.1 Test Diversity ................................................................................................................................373

4.2 Vehicle Mission.............................................................................................................................374
4.3 Vehicle Maintenance.....................................................................................................................374
4.4 Insurance Requirements................................................................................................................374
4.5 Driver Training.............................................................................................................................374
4.6 Charging and Fueling Infrastructure............................................................................................374
4.7 Test Objectives ..............................................................................................................................375

5 Data Collection .................................................................................................................................................375

5.1 Fleet Output Data .........................................................................................................................375

5.2 Fleet Summary Data .....................................................................................................................376

6 Data Analysis ....................................................................................................................................................376

6.1 Ongoing Data Analysis .................................................................................................................376

6.2 Fleet Test Summary Data Sheet ....................................................................................................377

372 Chpt VI, Sect I

 AVTA-PHFTP01

1 Objectives
The objective of this procedure is to provide guidance for the establishment of plug-in
hybrid electric vehicle (PHEV) evaluation fleets, the collection of operating data from
these fleets and the analysis of this data. This procedure also provides guidance for the
preparation of Fleet Data Sheets summarizing vehicle performance for use by the U.S.
Department of Energy Advanced Vehicle Test Activity (AVTA).

2 Purpose
The purpose of this procedure is to identify acceptable and repeatable methods for the
implementation of PHEV test fleets and the collection and analysis of such data.

3 Documentation
Documentation addressed by this procedure shall be consistent, easy to understand, easy to
read and readily reproducible. This documentation shall contain enough information to
"stand alone"; that is, be self-contained to the extent that all individuals qualified to review
it could be reasonably expected to reach a common conclusion, without the need to review
additional documentation.

4 Fleet Selection
PHEVs selected for evaluation by the AVTA shall be operated in established fleets and
their performance evaluated under fleet conditions. In order to optimize the opportunity to
collect useful data, the following prerequisite conditions shall be evaluated for each vehicle
and fleet prior to establishing each fleet test.

4.1 Test Diversity

To provide proper evaluation of the performance of a PHEV, care must be taken to
provide diverse data for evaluation. The following diversity factors shall be
considered in selecting the number of vehicles of a type to be tested and the number
of fleets to be utilized to conduct such testing.
• The total miles to be accumulated in testing
• The possibility of losing a test vehicle to a traffic accident
• Operation of vehicles with various intensity (miles/month)
• Operation of vehicles in urban and highway environments
• Operation of vehicles in hot, cold and temperate climates
• Operation of vehicles over varying terrain
• Operation of vehicles in public, private and government fleets
These factors will have varying significance for each type of advanced vehicle and
shall be considered for each vehicle type tested.

373 Chpt VI, Sect I

 AVTA-PHFTP01

4.2 Vehicle Mission

Fleets shall be selected which will utilize test vehicles in missions complementing
the performance capability of the vehicle. For example, testing of plug-in hybrid
electric vehicles (PHEV) should be conducted in fleets having missions
predominantly in urban areas and ending the day at a location equipped to support
charging. The mission for each test vehicle shall be monitored on an ongoing basis to
ensure that the vehicle continues to be operated within its performance capabilities.
The Baseline Performance Testing data sheets, issued by the AVTA, provide such
data for consideration.

4.3 Vehicle Maintenance

Vehicles shall be regularly serviced in accordance with the Supplier’s maintenance
schedule. Before vehicles enter test operation, arrangements shall be in place
defining what service is be performed based on the Supplier’s maintenance schedule,
when service will be performed, what organization will provide the service, and who
will pay for such service. Routine maintenance, such as oil changes and tire
rotations, may be performed by the fleet's normal service provider. Specialized
maintenance shall be performed by an authorized repair facility for the test vehicle.
All maintenance activities shall be recorded in accordance with Section 5, regardless
of whether the activity is covered by the warranty. Cost shall be recorded for all non-
warranty vehicle maintenance.

4.4 Insurance Requirements

Before a vehicle begins test operation, proof of insurance of the vehicle shall be
provided. Insurance may be provided by the operating fleet or by the test
organization. In any case, the limits of liability shall be no less than $300,000 per
occurrence with a $500,000 aggregate limit. The fleet manager shall ensure that all
drivers of the test vehicle have a valid Driver’s License issued from the state in
which the vehicle will be operated.

4.5 Driver Training

Instructions shall be provided to the fleet manager for proper operation of the test
vehicle. The fleet manager shall use their normal methods for disseminating such
information to potential drivers of the test vehicle. Particular attention shall be given
to the need to plug the vehicle charger into the charge infrastructure whenever
possible.

4.6 Charging and Fueling Infrastructure

All vehicle charging and fueling infrastructure shall be in place and operational prior
to commencement of vehicle operation. Special attention should be given to ensure
that measurement of fuel and electricity used by the test vehicle is collected. The test
vehicle mission shall be reviewed to verify that sufficient charging and fueling
infrastructure is in place to properly support vehicle operation. Safety aspects of

374 Chpt VI, Sect I

 AVTA-PHFTP01

vehicle charging and fueling shall be established and reviewed with potential drivers
of the test vehicle.

4.7 Test Objectives

Prior to test vehicle operation, the objectives of the test shall be presented to the
Fleet Manager in writing. At a minimum, this shall include the following objectives:
• Test mileage per month required
• Overall test duration in miles and months
• Data requirements
• Vehicle mission requirements
• Vehicle service requirements
• Charging and fueling requirements (if any)
• Driver training requirements (if any).

5 Data Collection
Data shall be collected in accordance with the following diagram.

Driver1 → Fleet Manager2 → Test Manager3 → INL/AVTA4

1 - Log sheets format or electronic data entry

2 - E-mail, or spreadsheet in electronic format
3- Spreadsheets containing the data for all fleet testing vehicles in column order VIN,
license plate, monthly odometer, monthly mileage, fuel used (if applicable), number of fast
charges (if applicable)
If no Fleet Manager exists for a particular test fleet, data shall be provided directly to the
Test Manager.

5.1 Fleet Output Data

The following data shall be provided no less frequently than monthly by the Fleet
Manager to the Test Manager:
• Odometer reading for every test vehicle
• Fuel consumption for the vehicle
• Electrical energy consumption for the vehicle
• Maintenance required and the date and cost of such maintenance
• Any unusual events vehicle operating events, particularly if the vehicle quit on the
road.

375 Chpt VI, Sect I

 AVTA-PHFTP01

The Test Manager shall endeavor to obtain complete data. However, this will often
not be possible. Therefore, the Test Manager should utilize the following techniques
to interpolate missing data.
• Interpolate same data linearly for missing periods.
• Infer missing data using alternate data and average proportionality (e.g. fuel used
from miles driven and average fuel economy).
Care should be taken not to interpolate data over an excessive number of months or
across periods when average factors may be changing (e.g. summer to winter).

5.2 Fleet Summary Data

The following data shall be provided monthly the INL/AVTA:
• Monthly mileage by vehicle
• Cumulative mileage by vehicle
• Monthly fuel economy by vehicle
• Cumulative fuel economy by vehicle
• Monthly electrical energy usage,
• Cumulative electrical energy usage,
• Monthly fleet mileage
• Cumulative fleet mileage
• Repair work by vehicle
• Maintenance cost by vehicle
• Incidents with any vehicle

6 Data Analysis
Test data should be evaluated on an ongoing basis to ensure the integrity of the fleet test.
Upon completion of the fleet test, data from each test vehicle shall be summarized in the
form of a data sheet.

6.1 Ongoing Data Analysis

On a monthly basis, data should be examined for reasonableness and completeness.
Missing data should be investigated and a determination made if supplemental
collection methods should be implemented or data should be interpolated (see
Section 5.1). Supplemental collection methods, which should be considered if data is
routinely missing, include the following:
• Transferring the test vehicle to a more conscientious fleet
• Follow up by the Test Manager with the Fleet Manager specific to the missing
data to determine why it was missing and to develop corrective action to improve
collection reliability
• Collection of data by the Test Manager or his/her representative.

376 Chpt VI, Sect I

 AVTA-PHFTP01

It is the responsibility of the Test Manager to ensure that sufficient data is collected
to accurately evaluate performance of the test vehicle.

6.2 Fleet Test Summary Data Sheet

At periodic milestones and upon completion of testing, a Fleet Test Summary Data
Sheet shall be prepared for each test vehicle or group of identical vehicles operating
in a single fleet. Information shall be presented in the data sheet in accordance with
the following guidelines.
Description
This section of the data sheet provides a brief summary of the operating fleet
characteristics. Fleet mission, location and typical trip characteristics should be
presented.
Major Operations & Maintenance Events
This section of the data sheet provides a summary of major operating and
maintenance events. Significant repairs and maintenance should be summarized
along with their cost and vehicle mileage at the time of the repair or maintenance. If
the repair or maintenance is covered by the base vehicle warranty, no cost should be
shown. Rather the repair or maintenance should be noted as being covered by
warranty. All onroad vehicle failures should be summarized along with the cause and
mileage at which the failure occurred.
Operating Cost
This section of the data sheet provides the following cost data:
Purchase Cost - Purchase cost includes vehicle cost with options, delivery, dealer
preparation costs, title fees, and taxes. It does not include annual registration and
license costs or costs for extended warranties.
Maintenance Cost - Maintenance cost includes the actual cost for all non-warranty
maintenance divided by the total mileage of the evaluation vehicle for the period
covered by the data sheet. Work covered under extended warranties purchased to
cover the evaluation vehicle shall be costed as part of maintenance cost.
Operating Cost - Operating cost includes the actual cost for all fuel, electricity,
licenses and permits required to operate the vehicle divided by the total mileage of
the evaluation vehicle for the period covered by the data sheet. Electricity costs shall
be calculated using the kilowatt-hours consumed by the vehicle multiplied by an
electric energy cost as obtained from "Electric Power Monthly" (DOE/IEA-0226) for
the month is which the vehicle test concluded.
Operating Performance
This section of the data sheet summarizes the total miles driven for the period
covered by the data sheet and the cumulative fuel economy (in gallons of gasoline
and electricity used).

377 Chpt VI, Sect I

 AVTA-PHFTP01

Vehicle Specifications
This section of the data sheet presents significant vehicle specifications including
engine type and power, hybrid drive type and power, battery type, number of seating
positions, vehicle payload, and significant vehicle features/options.

378 Chpt VI, Sect I

 GLOSSARY

Accuracy - Closeness to the true or accepted (or nominal) value. See inaccuracy.

Assessment/Verification - The act of reviewing, inspecting, testing, checking, conducting

surveillances, auditing or otherwise determining and documenting whether items,
processes or services meet specified processes.

Bottom of Discharge (BOD) - The point of lowest voltage during a discharge cycle.

Calibration - comparison of a measurement standard or instrument with another standard

or instrument to detect, correlate, report or eliminate by adjustment any inaccuracy of the
compared.

Calibration Standards - The reference used to conduct a calibration. They are normally
associated with a known Standard, such as NIST, ISO, etc.

Certification - The process of validating a person's qualifications to perform a certain

activity or group of activities. A person should not be certified to perform a task without
being qualified to do so.

Charge Sustaining Mode - An operating mode in which the RESS SOC is maintained
within a prescribed range by operation of a Consumable Fuel Energy Converter (CFEC).

Charging Algorithm - The circuitry/mathematical controls used by a charger to

automatically control the charging profile of current versus voltage versus time during the
battery charge.

Charging Station Location - As used in this procedure, refers to the specific plug-in
location assigned to each specific vehicle.

Comment Sheet - A form used to record the comments of test personnel during the conduct
of performance tests.

Consumable Fuel Energy Converter (CFEC) - An engine which consumes fuel to produce
work (either electrical or mechanical).

Correction - The act of changing a datum or data. The only approved method to change an
entry or notation is to strike through the entry with a single horizontal line, and write the
initials of the person making the correction, along with the date the correction was made.
The correct information shall be placed immediately adjacent to the entry which was struck
through.

Curb Weight - The total weight of the vehicle as delivered including batteries, lubricants,
and other expendable supplies but excluding the driver, passengers, and other payloads.

379 Glossary
Data Acquisition System (DAS) - A data recording system, nominally analog or digital,
used to collect data for further processing. Usually a strip-chart recorder, a computer, tape
recorded, etc.

Depth of Discharge (DOD) - The quantified percentage of discharge of a battery, in terms

of ampere-hours or kilowatt-hours, expressed as a percentage of the total battery capacity
in similar units.

Distribution - The presentation of any document to individuals or groups other than those
directly involved in the document's generation and completion.

Document Administrator - The individual tasked with the maintenance and storage of
records as stipulated by this procedure. This individual may be a member of a sub­
contractors staff, or may be a member of Electric Transportation Applications assigned this
function as a primary or collateral duty.

Effective Date - The date, after which the procedure has been reviewed and approved, that
the procedure can be utilized in the field for official testing.

Effective Mass - The sum of the test mass and the effective inertia's of the driven and non-
driven axles.

Fifth Wheel - A calibrated instrument used to measure a vehicle's speed and distance
independent of the vehicles on-board systems.

Fleet Manager - The individual within a fleet organization responsible for providing fleet
operating data and overseeing operation of test vehicles.

Gradeability - The maximum percent grade which the vehicle can traverse for a specified
time at a specified speed.

Gradeability Limit – The grad upon which the vehicle can just move forward.

Gross Vehicle Weight Rating (GVWR) - The maximum design loaded weight of the
vehicle specified by the Supplier.

Hybrid Pulse Power Characterization (HPPC) - HPPC test in accordance with the US
Department of Energy FreedomCAR Battery Test Manual for Power-Assist Hybrid
Electric Vehicles.

Highway Fuel Economy Driving Schedule (HWFEDS) - The Highway Fuel Economy
Driving Schedule is defined in 40 CFR Part 600, Appendix 1. It has a duration of 12 min,
45 s. It is used to represent vehicle highway driving.

Ichmax - The maximum charge current attained during a test sequence.

Idiscmax - The maximum discharge current attained during a test sequence.

380 Glossary
Inaccuracy - deviation from the true or accepted (or nominal) value. Inaccuracy may result
from both imprecision and bias (or systematic error) in the measurement process

Initial Conditions - Conditions that shall exist prior to an event occurring.

Initial State of Charge (SOC) - RESS SOC at the beginning of a test.

Item - An all-inclusive term used in place of any of the following: appurtenance, facility,
sample, assembly, component, equipment, material, module, part, structure, subassembly,
subsystem, system, unit, documented concepts or data.

Measurement Assurance Program - A quality assurance program for a measurement

process that quantifies the total uncertainty of the measurements (both random and
systematic components of error) with respect to national or other designated standards.

Measurement Process - A sequence of operations whose purpose is to assign a number(s)

that represent how much of a certainty property, a given substance or object has.

Measuring and Test Equipment (M&TE) - Devices or systems used to calibrate, measure,
gauge, test, inspect or control in order to acquire research development, test, or operational
data; to determine compliance with design, specifications or other technical requirements.

Non-Conforming M&TE - Equipment which no longer meets the calibration requirements

imposed by the reference standard, and normally characterized as one of the following:
• Out of Tolerance M&TE
• M&TE overdue for calibration
• M&TE that has been identified as “Out of Service”
• M&TE with unacceptable documentation.

Normal Operation Mode (Normal Operation) - A vehicle operating mode in which the
CFEC and RESS are automatically controlled to supply energy independently or in
combination.

On-the-Job Training (OJT) - Training that is accomplished outside of a classroom or

structured learning environment. Skills taught "in the field" to one crafts-person by another
more experienced or senior crafts-person are examples of OJT (such as how to run a lathe
or drill press).

Out of Service M&TE - Equipment which can no longer be used because of one of the
following conditions:
• M&TE that is suspected to be out of tolerance or functioning improperly
• M&TE that is out of tolerance or functioning improperly.

381 Glossary
Out of Tolerance Equipment - Equipment whose output is no longer reliable as
characterized by one of the following:
• Equipment found with “As Found” data outside required tolerances
• Equipment in a condition such that “As Found” data cannot be taken
• Equipment that is lost, stolen or improperly maintained.

Permanent Storage - Any record that has been deemed to be complete and less than one (1)
year has passed since either the end of its governing contract, or the affixing of its final
completion signature.

Precision - The degree of mutual agreement of independent measurements of a single

quantity yielded by repeated applications of a process under specific conditions. It is the
quantitatively stated by a precision measure such as a standard deviation, for example.

Prerequisites - Requirements that must be met or resolved prior to an event occurring.

Process - A series of actions that achieves an end result.

Program Manager - As used in this procedure, the individual responsible for oversight of
testing conducted by the U.S. Department of Energy Advanced Vehicle Testing Activity.

Qualification - The process an individual completes in establishing competence in a stated

area of expertise. A person may be qualified to perform a task without being certified as
such.

Quality - The degree to which an item meets or exceeds the user’s requirements and
expectations.

Quality Assessment - The procedures and activities utilized to verify that a quality control
system is operating within acceptable limits, and to evaluate the quality of the
product/measurement produced.

Quality Assurance - Actions that provide confidence that quality is achieved.

Quality Assurance Program - The overall program established by an organization to

implement the requirements of this procedure. The Program assigns responsibilities and
authorities, defines policies and requirements, and provides for the performance and
assessment of work.

Quality Control - The procedures and activities developed and implemented to produce
products/measurements of desired quality.

Random Errors - Errors that vary in a non-reproducible way (fortuitously) around the
limiting mean. For a large set of measurements, the errors are distributed evenly above and
below the average. Also, small errors occur more frequently than large ones. These errors
can be treated statistically by use of the laws of probability.

382 Glossary
Rechargeable Energy Storage System (RESS) - A component or system of components
that stores energy and for which its supply of energy is rechargeable by an electric motor-
generator system and an off-vehicle energy source. Examples of RESS’s for PHEVs
include batteries, capacitors and electromechanical flywheels.

RESS Capacity - The capacity of a RESS in kilowatt-hours or ampere-hours determined as

a function of the total distance traveled by the vehicle during performance of the Constant
Speed Range Test portion of procedure AVTA-PHTP04.

RESS Only Mode (RESS Only) - An operator selectable vehicle operating mode in which
the CFEC is disabled and the vehicle operates solely on energy from the RESS.

Safe Stopping Distance - The distance required to bring a vehicle to a complete stop from a
pre-determined speed, without losing control of the vehicle.

Service - The performance of work, such as design, fabrication, inspection, nondestructive

examination, repair or installation.

Shall - Items that require adherence without deviation. Shall statements identify binding
requirements; a go, no-go criterion.

Should - Items that require adherence if at all possible. Should statements identify
preferred conditions.

State of Charge (SOC) - For this testing, the SOC of a battery is defined as the expected
residual battery capacity, expressed in amperes-hours or watt-hours, as a percentage of the
total available. The 100% SOC basis (available ampere-hours or kilowatt-hours) is
determined by the actual discharge capability of the main propulsion battery when
discharged to the requirements of the 45 mph RESS Only Mode Constant Speed Range
Test portion of procedure AVTA-PHTP04.

Supplemental Federal Test Procedure US06 (US06) - The Supplemental Federal Test
Procedure (SFTP) represents aggressive, high speed and/or high acceleration driving
behavior, rapid speed fluctuations, and driving behavior following startup. The cycle
represents an 8.01 mile (12.8 km) route with an average speed of 48.4 miles/h (77.9 km/h),
maximum speed 80.3 miles/h (129.2 km/h), and a duration of 596 seconds

Team Leader - The individual responsible for approving the review of the test results.

Temporary Storage - Safekeeping or storage of records that are still active (not completed),
either because they are still in process and not yet complete, or because the process they
are associated with has been suspended for less than thirty days.

Test Mass/Weight - The mass/weight of the vehicle as tested; including driver, operator (if
necessary) and all instrumentation.

Test Director - The individual within Electric Transportation Applications responsible for
all U.S. Department of Energy Advanced Vehicle Testing Activity testing activities.

383 Glossary
Test Director’s Log - A daily diary kept by the Test Director, Program Manager, Test
Manager or Test Engineer to document major activities and decisions that occur during the
conduct of testing. This log is normally a running commentary, utilizing timed and dated
entries to document the day’s activities. This log is edited to develop the Daily Test Log
published with the final report for each vehicle.

Test Engineer - The individual(s) assigned responsibility for the conduct of any given test.
[Each contractor/subcontractor should have at least one individual filling this position. If
so, they shall be responsible for adhering to the requirements of this procedure.]

Test Manager - The individual for the implementation of the test program for any given
vehicle(s) being tested to U. S. Department of Energy Advanced Vehicle Testing Activity
requirements.

Test Mass [Weight] - The mass [weight] of the vehicle as tested including driver, operator
(if necessary), and all instrumentation.

Test Results Review Team - The team individuals assembled to review and approve the
data collected during the test process(es).

Tolerance - The maximum allowable departure of a standard from its nominal value.

Top of Charge (TOC) - The point of highest voltage during a charge cycle.

Total Harmonic Distortion (THD) - THD is a measurement of the harmonic distortion

present in the voltage and current of the AC power source for a grid-connected charger and
is defined as the ratio of the sum of the powers of all harmonic components to the power of
the fundamental.

Traceability - The ability to relate an individual measurement result to national standards

of measurement.

Tractive Force - The force available from the driving wheels at the driving wheel/ground
interface.

Training - The endeavor an individual undertakes to achieve qualification and certification

in a specific area of expertise.

Uncertainty - Allowance assigned to a measured value to include two major components of

error: bias and random error.

Urban Dynamometer Driving Schedule (UDDS) - The Urban Dynamometer Driving

Schedule is defined in 40 CFR Part 86, Appendix 1. It has a duration of 22 min, 52 s. It is
used to represent vehicle city driving.

Vmin - The minimum voltage attained during a specific test sequence.

Vmax - The maximum voltage attained during a specific test sequence.

384 Glossary
Whiteout - The use of a whiting or correction fluid, or correction tape, to change a previous
notation, entry, signature, date, etc. These are not permitted. See the definition for
Correction.

Work - The process of performing a defined task or activity. Research and development,
operations, maintenance and repair, administration, software development and use,
inspection, data collection and analysis are examples of work.

Yaw - the movement of a vehicle slightly to the side of its intended direction

385 Glossary
 REFERENCES

ANSI Standard C101.1, 1986

American Nuclear Society (ANS) 3.1, “Requirements for the Selection and Training of
Personnel for Nuclear Power Plants”

American Society of Mechanical Engineers (ASME)/NQA-1, “Quality Assurance Program

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DOE Order No. 5700.6C, “Quality Assurance,” dated 8-21-91

DOE 11069, "FreedomCAR Battery Test Manual for Power-Assist Hybrid Electric
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Code of Federal Regulations, Title 10, Part 571, “Federal Motor Vehicle Safety Standards”

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Handbook for the Quality Assurance of Metrological Instruments, National Bureau of

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NEC 625, "National Electric Code, Article 625"

NFPA 52, “Compressed Natural Gas (CNG) Vehicular Fuel Systems Code"

PHEV Vehicle Specification

SAE J163 JUL2006, "Low Tension Wiring and Cable Terminals and Splice Clips”

SAE J227a (cancelled May 1993), "Electric Vehicle Test Procedure"

SAE J551 OCT2006, “Vehicle Electromagnetic Immunity”

SAE J561 APR2006, "Electrical Terminals, Eyelet and Spade Type"

SAE J688 (cancelled Feb 1997), "Truck Ability Prediction Procedure"

SAE J858 APR2006, "Electrical Terminals Blade Type"

SAE J1127 DEC2005, "Low Voltage Battery Cable"

SAE J1128 DEC2005, "Low Voltage Primary Cable"

SAE J1634 MAY1993, “Electric Vehicle Energy Consumption and Range Test Procedure"

386 References
SAE J1666 OCT2002, "Electric Vehicle Acceleration, Gradeability, and Deceleration Test
Procedure"

SAE J1711 MAR1999, “Recommended Practice for Measuring the Exhaust Emissions and
Fuel Economy of Hybrid-Electric Vehicles"

SAE J1718 APR1997, "Measurement of Hydrogen Gas Emission from Battery-Powered

Passenger Cars and Light Trucks during Battery Charging"

SAE J1766 APR2005, "Recommended Practice for Electric and Hybrid Electric Vehicle
Battery Systems Crash Integrity Testing"

SAE J1772 NOV2001, "SAE Electric Vehicle Conductive Charge Coupler"

SAE J1773 NOV1999, "SAE Electric Vehicle Inductively Coupled Charging"

SAE J2263 OCT1996, "Road Load Measurement Using Onboard Anemometry and
Coastdown Techniques"

Proposed UL Standard 2202, "Electric Vehicle Charging System Equipment”

UL Standard 2231, “Outline of Investigation for Personnel Protection Systems for Electric
Vehicle (EV) Supply Circuits, Parts 1 & 2”

UL2231-1 April 2002, "Personnel Protection Systems for Electric Vehicle (EV) Supply
Circuits: General Requirements"

387 References