GARN® GN2000 | Emissions Report

REPORT NUMBER: G100463637MID-005R2 REPORT DATE: October 26, 2011 REVISED REPORT DATE: November 8, 2011 REVISED REPORT DATE: January 26, 2015

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 WHS2000 Solid Fuel Hydronic Furnace

Report of Testing Model WHS2000 Solid Fuel Hydronic Heater for compliance with the applicable requirements of the following criteria: Annex A1 Modified test method for wood-fired hydronic appliances that utilize thermal storage of ASTM E2618-13 Measurement of particulate emissions and heating efficiency of outdoor solid fuel-fired hydronic heating appliances.

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. G100463637MID-005R2 Report Revised Date: Jan. 26, 2015

Page 2 of 15

Client: Dectra Corporation

Model: WHS2000

TABLE OF CONTENTS

INTRODUCTION ................................................................. 4 I.A. GENERAL................................................................. 4 I.B. TEST UNIT DESCRIPTION...................................... 4 I.C. RESULTS ................................................................. 5 I.D. PRETEST INFORMATION ....................................... 5 SUMMARY OF TEST RESULTS......................................... 6 II.A EPA RESULTS ........................................................ 6 II.B 8-HR HEAT OUTPUT & EFFICIENCY RATINGS..... 7 II.C SUMMARY OF EMISSIONS DATA ......................... 7 II.D SUMMARY OF OTHER DATA ................................. 8 PROCESS DESCRIPTION.................................................. 9 III.A DISCUSSION .......................................................... 9 III.B UNIT DIMENSIONS.................................................. 9 III.C AIR SUPPLY SYSTEM ............................................. 9 III.D OPERATION DURING TEST ................................... 9 III.E TEST FUEL PROPERTIES ...................................... 9 III.F START UP OPERATION ......................................... 10 SAMPLING SYSTEM .......................................................... 10 IV.A SAMPLING LOCATIONS.......................................... 10 IV.A.1 DILUTION TUNNEL.................................................. 11 IV.B. OPERATIONAL DRAWINGS.................................... 12 IV.B.2 DILUTION TUNNEL SAMPLE SYSTEM................... 12

II.

III.

IV.

SAMPLING METHODS ....................................................... 13 V.A. PARTICULATE SAMPLING...................................... 13

VI.

QUALITY ASSURANCE ...................................................... 13 VI.A. INSTRUMENT CALIBRATION ................................. 13 VI.A.1 DRY GAS METERS.................................................. 13 VI.A.2 STACK SAMPLE ROTAMETER............................... 13 VI.B. TEST METHOD PROCEDURES.............................. 14 VI.B.1 LEAK CHECK PROCEDURES................................. 14 VI.B.2 TUNNEL VELOCITY/FLOW MEASUREMENT......... 14 VI.B.3 PM SAMPLING PROPORTIONALITY...................... 14

VII. RESULTS & OBSERVATIONS ........................................... 14

Report No. G100463637MID-005R2 Report Revised Date: Jan. 26, 2015

Page 3 of 15

Client: Dectra Corporation

Model: WHS2000

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

November 8, 2011

Added explanation for models WHS2000H and WHS2000V to section VII.

November 14, 2011 Added corrected data to tables in section II. January 26, 2015

Corrections due to error in standby loss formula. Report revised to update to the 2013 edition of ASTM E2618 including more accurate values for fuel higher and lower heating values.

Report No. G100463637MID-005R2 Report Revised Date: January 26, 2015

Page 4 of 15

Client: Dectra Corporation

Model: WHS2000

INTRODUCTION

I.A.

GENERAL

From October 3, 2011 to October 6, 2011 Intertek Testing Services NA Inc. (Intertek) conducted tests on the WHS2000 Solid Fuel Hydronic Heater to determine emission and efficiency results for Dectra Corporation. Tests were conducted by Ken Slater at the Dectra Corporation facility located at 1162 Red Fox Road, Arden Hills, Minnesota. Tests were originally evaluated to the Appendix X1 Modified test method for wood-fired hydronic appliances that utilize thermal storage for ASTM E2618-09 Standard Test Method for Measurement of Particulate Emissions and Heating Efficiency of Outdoor Solid Fuel-Fired Hydronic Heating Appliances. This report has been revised to reflect calculated values as specified in the 2013 edition of ASTM E2618 Annex A1. No changes have been made in the test procedure or measurement process from the 2009 edition. The only change of significance is the use of more accurate higher and lower heating values for the fuel. This revision also corrects an error in the stand-by loss calculation formula.

I.B.

TEST UNIT DESCRIPTION

The model WHS2000 is a solid fueled unit with a 14.15 cubic foot firebox constructed of carbon sheet steel, and weighs 3574 lbs. dry. The heat exchanger extends through the water vessel, which holds 15588 lbs. of water. This corresponds to a total water capacity of 1870 gallons. This appliance is designed as a full heat storage system which has the capacity to safely store 100% of the output produced by burning a single full fuel load of seasoned cordwood. The appliance consists of a large horizontal cylindrical steel tank with a firebox installed in a vertical head which connects to a ceramic fiber refractory lined secondary combustion chamber and then to steel piping which makes several passes through the water in the tank and exits through the rear head where it connects to a chimney collar. Combustion air is supplied through a pipe that routes air to a front and delivers some air through openings above and below the firebox door that aim at the front of the firebox and over the fuel to supply secondary air to the secondary combustion chamber. The firebox is lined on the bottom with firebrick. The blower is operated by a controller that turns it off when the flue gas temperature approaches the water temperature.

Report No. G100463637MID-005R2 Report Revised Date: January 26, 2015

Page 5 of 15

Client: Dectra Corporation

Model: WHS2000

I.C.

RESULTS

The unit as tested produced an average emissions rate of: 0.070 lbs/million Btu of output (0.030 g/MJ) for the heating season. 0.071 lbs/million Btu of output (0.030) for year round use.

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 October 3, 2011 the unit was ready for testing.

Report No. G100463637MID-005R2 Report Revised Date: January 26, 2015

Page 6 of 15

Client: Dectra Corporation

Model: WHS2000

II. SUMMARY OF TEST RESULTS

II.A EPA Results

Table 1A. Data Summary Part A

W fuel

MC ave

Q in

Q out



Category

Load % Capacity

Target Load Btu/hr 30,000 40,000 75,000 200,000

Actual Load Btu/hr 30,000 40,000 75,000 200,000

Actual Load

Test Duration

Wood Weight as-fired

Wood Moisture

Heat Input

Heat Output

% of Max

hrs

% DB 23.60 23.60 23.60 23.60

Btu

15% of Max 20% of Max 37.5% of Max Max Capacity

15% 20%

26.5 20.3 11.1

158.51 158.51 158.51 158.51

1,098,058 1,098,058 1,098,058 1,098,058

795,589 810,695 832,835 849,404

III IV

37.5% 100%

4.2

Table 1B. Data Summary Part B

 del-HHV 

 del-LHV

E g/hr

E g/kg

Delivered Efficiency LHV

Load % Capacity

Total PM Emissions

PM Output Based

PM Factor

Delivered Efficiency HHV

Category

PM Rate

lb/mmBtu Out

g/MJ 0.031 0.030 0.030 0.029

g/hr 0.98 1.28 2.34 6.13

g/kg

15% of Max

26.0 26.0 26.0 26.0

0.072 0.071 0.069 0.067

0.447 0.447 0.447 0.447

72.03% 73.40% 75.41% 76.91%

77.6% 79.0% 81.2% 82.8%

16-24% of Max 25-50% of max Max capacity

III IV

Report No. G100463637MID-005R2 Report Revised Date: January 26, 2015

Page 7 of 15

Client: Dectra Corporation

Model: WHS2000

II.B 8-Hour Heat Output and Efficiency Ratings

Table 1C: Hang Tag Information

Dectra

MANUFACTURER: MODEL NUMBER:

WHS2000

MAXIMUM OUTPUT RATING Q out-Max 8-HOUR OUTPUT RATING: Q out-8hr

200,000 Btu/hr 105,050 Btu/hr

76.1% (Using higher heating value) 81.9% (using lower heating value) 73.5% (Using higher heating value) 79.2% (using lower heating value) 1.69 GRAMS/HR (average) 0.071 LBS/MILLION Btu OUTPUT

8-HOUR AVERAGE EFFICIENCY:

 avg-8hr 

ANNUAL EFFICIENCY RATING:

 avg 

PARTICULATE EMISSIONS:

E avg

II.C Summary of Emissions Data

Table 2A. Year Round Use Weighting

Weighting Factor

E lb/mmbtu Output, i x F i

 del,i x F i - HHV 

 del,i x F i - LHV 

Category

E g/MJ,i x F i

E g/kg,i x F i

E g/hr,i x F i

0.437 0.238 0.275 0.050

0.315 0.175 0.207 0.038

0.339 0.188 0.223 0.041

0.014 0.007 0.008 0.001

0.195 0.106 0.123 0.022

0.031 0.017 0.019 0.007

0.429 0.306 0.645 0.307

III

Totals

1.000

73.5%

79.2%

0.030

0.447

0.070

1.69

Table 2B. Heating Season Use Weighting

Weighting Factor

E lb/mmbtu Output,i x F i

 del,i x F i - HHV 

 del,i x F i - LHV 

Category

E g/MJ,i x F i

E g/kg,i x F i

E g/hr,i x F i

0.175

0.126

0.136

0.005

0.078

0.013

0.172

0.275

0.202

0.217

0.008

0.123

0.019

0.353

III

0.450

0.339

0.365

0.013

0.201

0.031

1.055

0.100

0.077

0.083

0.003

0.045

0.003

0.613

Totals

1.000

74.4%

80.1%

0.030

0.447

0.071

2.19

Report No. G100463637MID-005R2 Report Revised Date: January 26, 2015

Page 8 of 15

Client: Dectra Corporation

Model: WHS2000

II.D Summary of Other Data

Run 1

Run 2

Run 3

Standby

Units

Steel Mass Water Mass

3574

3574 lbs 15588 lbs

15588

Fuel Load Weight Fuel MC (dry basis)

156.69

153.37

159.79

lbs

24.56

23.02

23.24

Kindling Mass

1.85

1.95

1.87

lbs

Kindling MC (dry basis)

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

120.28 172.20

125.64

124.70 180.50

172.20 F 169.20 F

179.6 79.06

75.94

78.53

77.21

Burn Time Burn Time

162 2.70

166 2.77

171 2.85

Minutes

Hours

Standby Test Duration

18 Hours

HHV

8600

BTU/lb

Dry Fuel Weight

Burn Rate

21.42

20.74

20.91

Kg/hr

Input

1,096,339

1,087,444

1,129,655 889,753 859,730

BTU BTU BTU

Heat Stored

828,952

860,486

Average

Standby Loss Rate Total Emissions Total Emissions

28.4 BTU/hr-F

25.291

20.147

32.674

Grams

0.056

0.044

0.072

lbs

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

30000 40000 75000

2416 BTU/hr 2416 BTU/hr 2416 BTU/hr 2416 BTU/hr

200000

Average

25.6 19.5 10.7

26.5 20.3 11.1

27.4 21.0 11.5

26.5 Hours 20.3 Hours 11.1 Hours 4.2 Hours

4.1

4.3

4.2

Average

70.0% 71.3% 73.3% 74.7% 0.073 0.071 0.069 0.068

73.2% 74.6% 76.7% 78.2% 0.056 0.055 0.053 0.052

72.9% 74.3% 76.3% 77.8% 0.087 0.086 0.084 0.082

72.0% 73.4% 75.4% 76.9% 0.072 0.071 0.069 0.067

lb/mmBTU output

Report No. G100463637MID-005R2 Report Revised Date: January 26, 2015

Page 9 of 15

Client: Dectra Corporation

Model: WHS2000

III.

PROCESS DESCRIPTION

III.A.

DISCUSSION

RUN #1 (October 3, 2011). The starting temperature in the heat storage vessel was 120.28 o F. Burn time was 2.70 hours and ended with a heat storage vessel temperature of 172.2 o F. RUN #2 (October 4, 2011). The starting temperature in the heat storage vessel was 125.6 o F. Burn time was 2.77 hours and ended with a heat storage vessel temperature of 179.1 o F. RUN #3 (October 5, 2011). The starting temperature in the heat storage vessel was 124.7 o F. Burn time was 2.85 hours and ended with a heat storage vessel temperature of 180.5 o F.

III.B.

UNIT DIMENSIONS

Overall dimensions are 71.75-in wide, 122.5-in deep, 76.75-in high.

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 temperature is no longer increasing.

III.E TEST FUEL PROPERTIES

The fuel used was Quercus Ruba L. (Oak, Red). The fuel was split cordwood with cross sectional dimensions approximately 3 to 7 inches x 24 inches in length. The fuel was dried to average moisture content between 19% and 25% on a dry basis. Individual pieces weighed between 6 and 13.5 pounds with an average weight of 8.7 pounds.

Report No. G100463637MID-005R2 Report Revised Date: January 26, 2015

Page 10 of 15

Client: Dectra Corporation

Model: WHS2000

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

The ASTM E2515-09 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. G100463637MID-005R2 Report Revised Date: January 26, 2015

Page 11 of 15

Client: Dectra Corporation

Model: WHS2000

IV.A.(1) DILUTION TUNNEL

Report No. G100463637MID-005R2 Report Revised Date: January 26, 2015

Page 12 of 15

Client: Dectra Corporation

Model: WHS2000

IV.B.OPERATIONAL DRAWINGS

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

Figure 3

Figure 2

Report No. G100463637MID-005R2 Report Revised Date: January 26, 2015

Page 13 of 15

Client: Dectra Corporation

Model: WHS2000

V . SAMPLING METHODS

V.A. PARTICULATE SAMPLING

Particulates were sampled in strict accordance with ASTM E2515-09. 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 exhau st 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. G100463637MID-005R2 Report Revised Date: January 26, 2015

Page 14 of 15

Client: Dectra Corporation

Model: WHS2000

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 ASTM E2515. Final tunnel velocities and flow rates are calculated from E2515, Equations 3 and 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

Proportionality was calculated in accordance with ASTM E2515. The data and results are included in Appendix C.

VII. RESULTS AND OBSERVATIONS

The Model WHS2000 has been found to be in compliance with the applicable performance and construction requirements of the following criteria: “ Annex A1 Modified test method for wood-fired hydronic appliances that utilize thermal storage of ASTM E2618-13 Measurement of particulate emissions and heating efficiency of outdoor solid fuel-fired hydronic heating appliances ” The model WHS2000V was the model tested, which is configured with a vertical flue located at the top back of the unit. Model WHS2000H is an identical model with the only difference being that the flue exits horizontally out the back of the unit. The model WHS2000H does contain slightly more water in the vessel due to the flue area is not notched out for the vertical flue exit.

Report No. G100463637MID-005R2 Report Revised Date: January 26, 2015

Page 15 of 15

Client: Dectra Corporation

Model: WHS2000

INTERTEK TESTING SERVICES NA

Evaluated by:

Ken Slater Associate Engineer - Hearth

______________

Reviewed by:

Brian Ziegler Engineering Team Leader - Hearth

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