GARN® GN1000 | Emissions Report

REPORT NUMBER: 102092693MID-008a REPORT DATE: March 31, 2016

EVALUATION CENTER Intertek Testing Services NA Inc.

8431 Murphy Drive Middleton, WI 53562

RENDERED TO Dectra Corporation 3425 33 rd Avenue, NE Saint Anthony, MN 55418

PRODUCT EVALUATED: Model WHS1000 Solid Fuel Hydronic Furnace

Report of Testing Model WHS1000 Solid Fuel Hydronic Heater for compliance with the applicable requirements of the following criteria: Appendix A1 Modified test method for wood-fired hydronic appliances that utilize full thermal storage of ASTM E2618-13 Measurement of particulate emissions and heating efficiency of outdoor solid fuel-fired hydronic heating appliances and EPA 40 CFR Part 60 “Standards of Performance for New Residential Wood Heaters, New Residential Hydronic Heaters and Forced-Air Furnaces”, March 16, 2015. .

This report is for the exclusive use of Intertek's Client and is provided pursuant to the agreement between Intertek and its Client. Intertek's responsibility and liability are limited to the terms and conditions of the agreement. Intertek assumes no liability to any party, other than to the Client in accordance with the agreement, for any loss, expense or damage occasioned by the use of this report. Only the Client is authorized to copy or distribute this report and then only in its entirety. Any use of the Intertek name or one of its marks for the sale or advertisement of the tested material, product or service must first be approved in writing by Intertek. The observations and test results in this report are relevant only to the sample tested. This report by itself does not imply that the material, product, or service is or has ever been under an Intertek certification program.

Report No. 102092693MID-008a Report Date: March 31, 2016

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Client: Dectra Corporation TABLE OF CONTENTS

Model: WHS1000

INTRODUCTION ................................................................. 4 I.A. GENERAL................................................................. 4 I.B. TEST UNIT DESCRIPTION...................................... 4 I.C. RESULTS ................................................................. 4 I.D. PRETEST INFORMATION ....................................... 4 SUMMARY OF TEST RESULTS......................................... 5 II.A EPA RESULTS ........................................................ 5 II.B HEATING SEASON WEIGHTING ............................ 6 II.C YEAR ROUND USE WEIGHTING ........................... 6 II.D SUMMARY OF OTHER DATA ................................. 7 PROCESS DESCRIPTION.................................................. 8 III.A DISCUSSION .......................................................... 8 III.B UNIT DIMENSIONS.................................................. 8 III.C AIR SUPPLY SYSTEM ............................................. 8 III.D OPERATION DURING TEST ................................... 8 III.E TEST FUEL PROPERTIES ...................................... 9 III.F START UP OPERATION ......................................... 9 SAMPLING SYSTEM .......................................................... 9 IV.A SAMPLING LOCATIONS.......................................... 9 IV.A.1 DILUTION TUNNEL.................................................. 10 IV.B. OPERATIONAL DRAWINGS.................................... 11 IV.B.2 DILUTION TUNNEL SAMPLE SYSTEM................... 11 SAMPLING METHODS ....................................................... 12 V.A. PARTICULATE SAMPLING...................................... 12

II.

III.

IV.

VI. QUALITY ASSURANCE ...................................................... 12 VI.A. INSTRUMENT CALIBRATION ................................. 12 VI.A.1 DRY GAS METERS.................................................. 12 VI.A.2 STACK SAMPLE ROTAMETER............................... 13 VI.B. TEST METHOD PROCEDURES.............................. 13 VI.B.1 LEAK CHECK PROCEDURES................................. 13 VI.B.2 TUNNEL VELOCITY/FLOW MEASUREMENT......... 13 VI.B.3 PM SAMPLING PROPORTIONALITY...................... 13 VII. RESULTS & OBSERVATIONS ........................................... 13

Report No. 102092693MID-008a Report Date: March 31, 2016

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Client: Dectra Corporation

Model: WHS1000

APPENDICES

Laboratory Operating Procedure ......................................... A Data and Calculation Forms ................................................ B Calibration Documents ........................................................ C Unit Drawings and Installation Manual ................................ D Dry Gas Meter Calibration Data........................................... E Unit Preburn Documentation ............................................... F

REVISION SUMMARY DATE

SUMMARY

Report No. 102092693MID-008a Client: Dectra Corporation

Report Date: March 31, 2016

Page 4 of 13

Model: WHS1000

INTRODUCTION

I.A. GENERAL From March 8, 2016 to March 11, 2016 Intertek Testing Services NA Inc. (Intertek) conducted tests on the WHS1000 Solid Fuel Hydronic Heater to determine emission and efficiency results for Dectra Corporation. Tests were conducted by Ken Slater at the Intertek Testing Services NA Inc. laboratory located at 8431 Murphy Drive, Middleton, Wisconsin. Tests were evaluated to the Appendix A1 Modified test method for wood-fired hydronic appliances that utilize full thermal storage for ASTM E2618-13 Standard Test Method for Measurement of Particulate Emissions and Heating Efficiency of Outdoor Solid Fuel-Fired Hydronic Heating Appliances. I.B. TEST UNIT DESCRIPTION The model WHS1000 is a solid fueled unit with a 8.83 cubic foot firebox constructed of carbon sheet steel, and weighs 2200 lbs. dry. The heat exchanger extends through the water vessel, which holds 8424 lbs. of water. I.C. RESULTS The unit as tested produced an average emissions rate of: 0.257 lbs/million Btu of output for the heating season 0.262 lbs/million Btu of output for year round I.D. PRETEST INFORMATION The unit was inspected upon arrival at the Dectra Corporation facility and found to be in good condition. The unit was set up per the manufacturer’s instructions. The unit was placed on the test stand and instrumented with thermocouples in the specified locations. The chimney system and laboratory dilution tunnel was cleaned using standard wire brush chimney cleaning equipment. On March 8, 2016 the unit was ready for testing.

Report No. 102092693MID-008a Client: Dectra Corporation

Report Revised Date: March 31, 2016

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Model: WHS1000

II. SUMMARY OF TEST RESULTS II.A EPA Results

Table 1A. Data Summary Part A

W fuel

MC ave

Q in

Q out

Category

E g/MJ,i x F i

E g/kg,i x F i

E lb/mmbtu,i x F i

E g/hr,i x F i

0.31 0.18 0.21 0.04 74%

0.051 0.027 0.029 0.005

0.73 0.40 0.46 0.08 1.67

0.12 0.06 0.07 0.01

0.08 0.05 0.05 0.01 0.19

0.437 0.238 0.275 0.050 1.000

III IV

0.11

0.262

Totals

II.C Summary of other Data

Run 2

Run 3

Run 4

Standby

Units

Steel Mass Water Mass

2200 8428

2200 8294

2200 lbs 8294 lbs

Fuel Load Weight Fuel MC (dry basis)

110.64

104.86

105.45

lbs

22.58

21.84

21.86

Kindling Mass

1.73 23.7

1.59 23.7

1.68 23.7

lbs

Kindling MC (dry basis)

Starting system temp. Ending System Temp. Average Room Temp.

126.92 203.58

121.91 196.58

117.75 188.73

172.50 F 168.20 F

67.55

64.76

57.20

66.80

Burn Time Burn Time

134.00

126 2.10

127 2.12

480.00 Minutes

2.23

8.00 Hours

Standby Test Duration

8 Hours

HHV

8600 41.59 18.62

8600 39.63 18.87

8600 39.88 18.84

BTU/lb

Dry Fuel Weight

Burn Rate

Kg/hr

Input

788,236 662,968 662,968

751,237 635,733 635,733

755,858 604,332 604,332

BTU BTU

Heat Stored

Average

Standby Loss Rate Total Emissions Total Emissions

44.2 BTU/hr-F

63.2

52.2

86.4

Grams

0.139

0.115

0.190

lbs

Category I Output Rate Category II Output Rate Category III Output Rate Category IV Output Rate

24000 32000 60000 160000

3756 BTU/hr 3756 BTU/hr 3756 BTU/hr 3756 BTU/hr

Report No. 102092693MID-008a Client: Dectra Corporation

Report Revised Date: March 31, 2016

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Model: WHS1000

Average

Output Time Cat I Output Time Cat II Output Time Cat III Output Time Cat IV Category I Efficiency Category II Efficiency Category III Efficiency Category IV Efficiency

23.9 18.5 10.4

22.9 17.8 10.0

21.8 16.9

22.9 Hours 17.7 Hours 9.9 Hours 3.9 Hours

9.5 3.7

4.0

3.9

Average

72.7% 75.3% 79.2% 82.2%

73.2% 75.7% 79.6% 82.7%

69.1% 71.6% 75.2% 78.1%

71.7% 74.2% 78.0% 81.0%

lbm/mmBTU output lbm/mmBTU output lbm/mmBTU output lbm/mmBTU output

Category I Emissions

0.243

0.209

0.364

0.27

Category II Emissions

0.235

0.202

0.352

0.26

Category III Emissions

0.223

0.192

0.335

0.25

Category IV Emissions

0.215

0.185

0.323

0.24

III.

PROCESS DESCRIPTION

III.A. DISCUSSION RUN #1 (March 8, 2016). The starting temperature in the heat storage vessel was 126.9 o F. Burn time was 2.23 hours and ended with a heat storage vessel temperature of 202.5 o F. RUN #2 (March 10, 2016). The starting temperature in the heat storage vessel was 121.9 o F. Burn time was 2.10 hours and ended with a heat storage vessel temperature of 195.8 o F. RUN #3 (March 11, 2016). The starting temperature in the heat storage vessel was 120 o F. Burn time was 2.85 hours and ended with a heat storage vessel temperature of 170 o F. III.B. UNIT DIMENSIONS Overall dimensions are 67-in wide, 77-in deep, 65-in high.

Report No. 102092693MID-008a Client: Dectra Corporation

Report Revised Date: March 31, 2016

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Model: WHS1000

III.C. AIR SUPPLY SYSTEM Combustion air enters from a fresh air intake located on the rear of the unit. The air travels to a collar in the front of the unit where it enters the firebox via primary and secondary combustion air nozzles. The movement of combustion air is aided by a constant 3600 RPM induced-draft combustion air blower. Combustion products flow through a heat exchanger system before exiting through a 6-in flue collar located at the top back of the outer enclosure. Combustion air is terminated by an electronic digital controller. The controller compares the flue and water temperatures until they fall to within 5 °F of each other. The blower is then turned off and combustion air is terminated. III.D. OPERATION DURING TEST The boiler is operated until the entire fuel load is consumed and there is no further combustion in the firebox. The end of the test is determined when the water storage The fuel used was Douglas fir. The fuel was split cordwood with dimensions around 6-in thick x 12-in wide x 24-in in length. The fuel was dried to average moisture content between 19% and 25% on a dry basis. III.F. START-UP OPERATION The cordwood fuel started with newspaper and a measured kindling load. As the test load was being lit, the sampling system was started simultaneously. The unit was allowed to operate until all combustion in the firebox had ceased. IV. SAMPLING SYSTEMS temperature is no longer increasing. III.E TEST FUEL PROPERTIES

The ASTM E2515-11 sampling procedure was used.

IV.A. SAMPLING LOCATIONS Particulate samples are collected from the dilution tunnel at a point 16 feet from the tunnel entrance. The tunnel has two elbows ahead of the sampling section. (See Figure 3.) The sampling section is a continuous 14-foot section of 10-inch diameter pipe straight over its entire length. Tunnel velocity pressure is determined by a standard Pitot tube located 96 inches from the beginning of the sampling section. The dry bulb thermocouple is located six inches downstream from the Pitot tube. Tunnel samplers are located 36 inches downstream of the Pitot tube and 36 inches upstream from the end of this section. (See Figure 1.)

Report No. 102092693MID-008a Client: Dectra Corporation

Report Revised Date: March 31, 2016

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Model: WHS1000

IV.A.(1) DILUTION TUNNEL

Report No. 102092693MID-008a Client: Dectra Corporation

Report Revised Date: March 31, 2016

Page 10 of 13

Model: WHS1000

IV.B.OPERATIONAL DRAWINGS IV.B.(2). DILUTION TUNNEL SAMPLE SYSTEMS

Figure 2

Report No. 102092693MID-008a Client: Dectra Corporation

Report Revised Date: March 31, 2016

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Model: WHS1000

V . SAMPLING METHODS

V.A. PARTICULATE SAMPLING Particulates were sampled in strict accordance with ASTM E2515-11. This method uses two identical sampling systems with Gelman A/E 61631 binder free, 47-mm diameter filters. The dryers used in the sample systems are filled with “Drierite” before each test run.

VI. QUALITY ASSURANCE

VI.A. INSTRUMENT CALIBRATION VI.A. (1). DRY GAS METERS

At the conclusion of each test program the dry gas meters are checked against our standard dry gas meter. Three runs are made on each dry gas meter used during the test program. The average calibration factors obtained are then compared with the six- month calibration factor and, if within 5%, the six-month factor is used to calculate standard volumes. Results of this calibration are contained in Appendix D. An integral part of the post test calibration procedure is a leak check of the pressure side by plugging the system exhaust and pressurizing the system to 10” W.C. The system is judged to be leak free if it retains the pressure for at least 10 minutes. The standard dry gas meter is calibrated every 6 months using a Spirometer designed by the EPA Emissions Measurement Branch. The process involves sampling the train operation for 1 cubic foot of volume. With readings made to .001 ft 3 , the resolution is .1%, giving an accuracy higher than the ±2% required by the standard. VI.A.(2). STACK SAMPLE ROTOMETER The stack sample rotometer is checked by running three tests at each flow rate used during the test program. The flow rate is checked by running the rotometer in series with one of the dry gas meters for 10 minutes with the rotometer at a constant setting. The dry gas meter volume measured is then corrected to standard temperature and pressure conditions. The flow rate determined is then used to calculate actual sampled volumes.

Report No. 102092693MID-008a Client: Dectra Corporation

Report Revised Date: March 31, 2016

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Model: WHS1000

VI.B. TEST METHOD PROCEDURES VI.B.(1).

LEAK CHECK PROCEDURES Before and after each test, each sample train is tested for leaks. Leakage rates are measured and must not exceed 0.02 CFM or 4% of the sampling rate. Leak checks are performed checking the entire sampling train, not just the dry gas meters. Pre-test and post-test leak checks are conducted with a vacuum of 10 inches of mercury. Vacuum is monitored during each test and the highest vacuum reached is then used for the post test vacuum value. If leakage limits are not met, the test run is rejected. During, these tests the vacuum was typically less than 2 inches of mercury. Thus, leakage rates reported are expected to be much higher than actual leakage during the tests. VI.B.(2). TUNNEL VELOCITY/FLOW MEASUREMENT The tunnel velocity is calculated from a center point Pitot tube signal multiplied by an adjustment factor. This factor is determined by a traverse of the tunnel as prescribed in EPA Method 1. Final tunnel velocities and flow rates are calculated from EPA Method 2, Equation 6.9 and 6.10. (Tunnel cross sectional area is the average from both lines of traverse.) Pitot tubes are cleaned before each test and leak checks are conducted after each test. VI.B.(3). PM SAMPLING PROPORTIONALITY (5G-3) Proportionality was calculated in accordance with EPA Method 5G-3. The data and results are included in Appendix C. VII RESULTS AND OBSERVATIONS This test demonstrates that model WHS1000 is an affected facility under the definition given in the regulation. The emission rate of 0.262 lbs/million Btu of output does meet the EPA requirements for the Step 1 limits for the 2015 regulation. The model WHS1000 has been found to be in compliance with the applicable performance and construction requirements of the following criteria: “ Appendix A1 Modified test method for wood-fired hydronic appliances that utilize full thermal storage of ASTM E2618-13 Measurement of particulate emissions and heating efficiency of outdoor solid fuel-fired hydronic heating appliances ” and EPA 40 CFR Part 60 “Standards of Performance for New Residential Wood Heaters, New Residential Hydronic Heaters and Forced-Air Furnaces”, March 16, 2015. The model WHS1000 was the model tested, which is configured with a horizontal flue located at the top back of the unit.

Report No. 102092693MID-008a Client: Dectra Corporation

Report Revised Date: March 31, 2016

Page 13 of 13

Model: WHS1000

INTERTEK TESTING SERVICES NA

Evaluated by:

Ken Slater Associate Engineer - Hearth

______________

Reviewed by:

Brian Ziegler Engineering Team Leader - Hearth

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