POLYTESTS 18 SFC Rap EPA Wood Stove Instruction Manual

: June 16, 2024
: POLYTESTS

POLYTESTS 18 SFC Rap EPA Wood Stove

POLYTESTS-18-SFC-Rap-EPA-Wood-Stove

Product Information

Specifications

Model Name: 18 SFC
Tested By: Services Polytests inc.
Test Dates: April 17th to 26th, 2023
Report Date: May 8th, 2023
Revision1: September 7th, 2023
Project Number: PI-20286

Introduction

The following is a test report for a non-catalytic wood burning fireplace. The tests were conducted to measure emissions and efficiency according to EPA methods 28R, ASTM E2515, and ASTM E2780. The client for this test is Rafael Sanchez, and the testing was performed by Services Polytests inc. The test dates were from April 17th to 26th, 2023, and the report was generated on May 8th, 2023.

Test Unit Information
The test unit for this report is the Model Name: 18 SFC. It was tested by Maxime Martin and verified by a third-party certifier (PFS). The project number for this test is PI-20286.

Results

The test results include information on emissions, weighted average calculation, test facility conditions, fuel qualities, dilution tunnel flow rate measurements and sampling data (ASTM E2515), dilution tunnel dual train precision, and a general summary of the results. These details can be found in the subsequent sections of this report.

Pretest Information
No specific pretest information is provided in this section of the manual.

Summary of Test Results

Emissions
The emissions from the non-catalytic wood burning fireplace were measured during the test. Detailed information on the emission levels can be found in the subsequent sections of this report.

Weighted Average Calculation
A weighted average calculation was performed to determine the overall emission levels and efficiency of the fireplace. The methodology and results can be found in the relevant section of this report.

Test Facility Conditions
The conditions of the test facility, including temperature, humidity, and other relevant factors, were recorded and considered during the testing process. Details about these conditions can be found in the respective section of this report.

Fuel Qualities
The quality of the fuel used during the test was evaluated and documented. This information is crucial for understanding the performance of the fireplace. Further details are provided in the corresponding section of this report.

Dilution Tunnel Flow Rate Measurements and Sampling Data (ASTM E2515)
The dilution tunnel flow rate measurements and sampling data were collected according to ASTM E2515 standards. These measurements and data provide insights into the combustion process and emissions. The specific findings are discussed in detail later in this report.

Dilution Tunnel Dual Train Precision
The precision of the dilution tunnel dual train system was assessed to ensure accurate measurements. The results of this assessment are presented in the relevant section of this report.

General Summary of Results
A general summary of all the test results is provided in this section. It offers an overview of the emissions, efficiency, and overall performance of the non-catalytic wood burning fireplace. Please refer to this section for a concise understanding of the findings.

Process Description

Discussion
This section provides a detailed discussion of the test process, including the methodology, equipment used, and any relevant observations or insights. It serves as a comprehensive guide to understanding the testing procedure and its implications.

Product Usage Instructions

Installation
Before installing the non-catalytic wood burning fireplace, carefully read and follow the installation instructions provided in the separate installation manual. Ensure that all necessary safety precautions are taken during the installation process.

Fuel Selection
Choose high-quality wood fuel that is properly seasoned and free from moisture. Avoid using wet or green wood as it may result in poor combustion and increased emissions.

Lighting the Fireplace
To light the fireplace, follow these steps:

Ensure the damper is open.
Place a small amount of crumpled newspaper or fire starter in the firebox.
Add kindling on top of the newspaper or fire starter.
Light the newspaper or fire starter using a long match or lighter.
Add small pieces of dry wood gradually to build the fire.

Controlling the Fire
To control the fire and optimize combustion efficiency, follow these guidelines:

Adjust the air intake controls to regulate the amount of oxygen supplied to the fire.
Keep the fire well-ventilated by ensuring proper airflow through the fireplace.
Add wood logs in a controlled manner to maintain a steady and efficient burn.
Avoid overloading the fireplace with excessive amounts of wood.

Maintenance

Regularly clean and maintain the non-catalytic wood burning fireplace to ensure optimal performance. Remove ashes and debris from the firebox, clean the flue, and inspect the chimney regularly for any obstructions or damage. Refer to the maintenance instructions in the user manual for detailed guidance.

FAQ (Frequently Asked Questions)

Q: Can I use this fireplace without a chimney?
A: No, this non-catalytic wood burning fireplace requires a properly functioning chimney for safe and efficient operation. Ensure that your chimney meets the necessary requirements before installing and using the fireplace.

Q: What type of wood fuel should I use?
A: It is recommended to use high-quality, properly seasoned wood fuel that is free from moisture. Avoid using wet or green wood as it can negatively impact combustion efficiency and emissions.

Q: How often should I clean the fireplace?
A: Regular cleaning of the fireplace is essential for optimal performance. It is recommended to remove ashes and debris from the firebox after each use and inspect the chimney periodically for any obstructions or damage. Follow the maintenance instructions provided in the user manual for detailed guidance on cleaning frequency.

Revision list:
Revision 1 (September 7th 2023): update section 1.4 p.5 for more detail about preburn at medium heat draw, with damper half way. All data of preburn including moisture content can be found in appendix 4 already for each reload all pieces of dougfir wood.

INTRODUCTION

GENERAL

Laboratory

Location: Services Polytests Inc., 695-B Gaudette St-jean-sur-Richelieu QC, Canada J3B 7S7
Elevation: 100 feet above sea level

Test program

Purpose: unit qualification NSPS 2020
Test dates: April 17th to 26th 2023
Test methods used:
- Particulate emissions: ASTM E2780-10; ASTM E2515-11 methods 28R as referred into 40 CFR Part 60 Subpart AAA
- Efficiency: CSA B415.1-10

TEST UNIT INFORMATION

General

Manufacturer: Foyers Suprême inc.
Product type: non-catalytic wood fireplace
Combustion system: non-catalytic
Unit tested: 18 SFC

The wood heater is equipped with a bi-metallic variable burn rate controller. The side walls of the combustion chamber are lined with either cast iron panels or soapstone slabs, allowing for a longer burn at a more uniform heat output. In addition, the casing of the combustion chamber is constructed out of stainless steel, allowing for a quick heat transfer. For the purpose of increasing the efficiency, a blower is installed into the unit.
The engine will have either the model number of 18SF/18SFC (built-in fireplace) or 18ST (freestanding stove), which comprises the standard components related to the combustion of the unit (such as the firebox, the controls, and the baffle system). The engine will however have an optional firebox lining; either with soapstone (model name: Elegance 30, Novo 18 – Soapstone or cast iron (model name: Astra 18, Monarch 18, Novo 18 – Cast Iron). The Elegance 30, the Astra 18, and the Monarch 18 are factory-built fireplaces, whereas the Novo 18 is a free-standing stove.

In Summary:

Elegance 30: Factory built fireplace with soapstone firebox lining.
Astra 18: Factory built fireplace with cast iron firebox lining.
Monarch 18: Built-in fireplace with an arched door/façade and a cast iron firebox lining
Novo 18 – Soapstone: Freestanding wood stove with soapstone interior.
Novo 18 – Cast Iron: Freestanding wood stove with cast iron interior.

RESULTS

Emission results obtained

Weighted Average Emissions Rate: 1.2 g/hr
Weighted Average Overall Efficiency: 70 %

Conformity: NSPS Phase 2020

PRETEST INFORMATION

Unit condition:
The unit was received by carrier April 2023 in good condition. The 50hrs of aging was done by the manufacturer at medium burn rate with the air damper position half way between maximum and minimum opening.

Fuel:
BC FIR between 19% and 25%. (All data in Appendix 4).

Set up

Venting system type: 6-inch steel pipe and insulated chimney
System height from floor: 15 feet
Particularities: Convection fan installed on all units

SUMMARY OF TEST RESULTS

EMISSIONS

WEIGHTED AVERAGE CALCULATION

TEST FACILITY CONDITIONS

FUEL QUALITIES

DILUTION TUNNEL FLOW RATE MEASUREMENTS AND SAMPLING DATA (ASTM E2515) POLYTESTS-18-SFC-Rap-EPA-Wood-Stove-fig-6

DILUTION TUNNEL DUAL TRAIN PRECISION POLYTESTS-18-SFC-Rap-EPA-Wood-Stove-
fig-7

GENERAL SUMMARY OF RESULTS POLYTESTS-18-SFC-Rap-EPA-Wood-Stove-
fig-8

Run 2 have been rejected from the average calculation due to combustion ceasing at 0.2lbs. combustion stopped and no change of weight occurred for the last more than 30 minutes.
Run 6 was a no fan confirmation test, this one has been rejected due to failing of the temperature differential criteria (+-126F), Table 2.7 ASTM 2780 Section 9.5.10 Wood heater thermal equilibrium

PROCESS DESCRIPTION

DISCUSSION

The heater has been received in a good shape by a carrier in April 2023. Pre- burn was done by the manufacturer as preliminary testing with crib wood. The wood heater is equipped with a bi-metallic variable burn rate controller. The side walls of the combustion chamber are lined with either cast iron panels or soapstone slabs, allowing for a longer burn at a more uniform heat output. In addition, the casing of the combustion chamber is constructed out of stainless steel, allowing for a quick heat transfer. For the purpose of increasing the efficiency, a blower is installed into the unit.

UNIT DIMENSIONS

Baffle

Location: between top of combustion chamber and hearth
Dimensions: covers the hearth area minus the restriction at front
Material: Stainless steel baffle

Bricks
Cast iron surrounding firebox, optional soapstone

Flue gas exhaust

Location: top flue
Dimensions: 6 in. diameter
Material: Steel

Gasket
The door of the unit consists of three sections of gaskets, where 2 of them are holding the glass (DR4116 – GSKT_GRAP_5/16”) and 1 is sealing around the door onto the firebox (DR4114 – GSKT_GRAP_3/4”). Please refer to page 71 of 18NV – MASTER DWG.pdf for information on dimensions, materials, and assembly details. Technical specification of GSKT_GRAP_5/16” and GSKT_GRAP_3/4” can be found in the SGI – Knitted Fiberglass Rope.pdf document.

Overall unit dimension

Firebox dimensions: 18 in wide x 11,5 in. deep x 13 in. high
Usable volume: 1.56 cuft
Overall wood heater dimension: 23,75-inch-wide x 20,125-inch-deep x 39,25 high

Convection fan
tangential fan (Ebm-Papst, part num. 55416.32130) supplied with unit see appendix 6 for all detail

Catalyst
none

Bi-metallic combustion air control

PRIMARY AIR CONTROL
The Primary Air Control is a patented mechanism (Patent No: US 7,325,541 B2) that regulates the air flow into the firebox based on the temperature of the unit. It is located on the top of the firebox, at the front center of the unit. The combustion air control of the 18SF,18SFC, and 18ST has two components: the Activator and the Burn Rate Selector. The left combustion control lever is the Activator. When starting a fire or adding a new load of wood, the Activator must be pushed in to allow a primary source of air to enter the firebox. The Activator will retract automatically with heat. The right combustion control lever is the Burn Rate Selector. The Burn Rate Selector can slide sideways to achieve different burn rates. When the Burn Rate Selector is positioned to the left, a maximum burn rate is achieved and when it is positioned to the right, a minimum burn rate is set. Please refer to page 41 to 52 of 18NV – MASTER_DWG.pdf for details on the Primary Air Control assembly. The sub-sections below illustrate the fully open, high burn rate, medium burn rate, and low burn rate primary air control settings used for offical emissions testing.

SECONDARY BAFFLE
The baffle system of the 18SFC comprises of a horizontal plate shooting secondary air through a series of holes. The plate consists of 54 holes of 0.115” diameter, with a higher concentration located at the front (towards the door). Note that the 5.45” diameter hole at the back center is blocked during operation by the chimney sweeping. Refer to page 16 to 22 of 18NV – MASTER_DWG.pdf.

AIR SUPPLY SYSTEM

Description

Primary air: window wash design with air intake at the top of unit
Secondary air: secondary baffle design with air intake at the top of unit. Refer appendix 6 for drawing details

Characterization
The following table shows the inlet and outlet sections of each system. The air introduction system number is referred to on a set of drawings in Appendix 6. POLYTESTS-18-SFC-Rap-EPA-Wood-Stove-fig-9 Legend

Identification: Tag name referred to on drawings in Appendix 14, section airflow pattern
Type: Characterization of air intake
Imin: Minimum air intake of a particular air channel
Imax: Maximum air intake of a particular air channel
Controlled: Determines if a provision for air control is present
Outlet: Total air outlet of a particular air channel

OPERATION DURING TEST

All runs have been found appropriate, no anomalies happened and all runs below have been validate and found compliant except for run 6 failed on temperature differential criteria (ASTM 2780 Section 9.5.10 Wood heater thermal equilibrium). Run 2 have been rejected from the average calculation due to combustion ceasing at 0.2lbs. combustion stopped and no change of weight occurred for the last more than 30 minutes.

Run #1
This run was performed on April 17th 2023. It lasted 163 minutes and a category 3 burn rate was obtained at 1.49 kg/hr & emission at 1.24 gr/hr. The convection fan was at on position during the entire test. The air inlet damper was fully open at the maximum setting.

Run #2
This run was performed on April 18th 2023. It lasted 342 minutes and a category 1 burn rate was obtained at 0.71 kg/hr & emission at 0.66 gr/hr. The convection fan was at on position during the entire test. The air inlet damper was fully closed at the minimum setting. Run 2 have been rejected from the average calculation due to combustion ceasing at 0.2lbs. combustion stopped and no change of weight occurred for the last more than 30 minutes.

Run #3
This run was performed on April 19th 2023. It lasted 273 minutes and a category 2 burn rate was obtained at 0.87 kg/hr & emission at 0.83 gr/hr. The convection fan was at on position during the entire test. The air inlet damper was fully closed at the minimum setting, the burn rate for the low burn rate category was no greater than the rate that an operator can achieve in home use.

Run #4
This run was performed on April 20th 2023. It lasted 279 minutes and a category 2 burn rate was obtained at 0.86 kg/hr & emission at 0.95 gr/hr. The convection fan was at on position during the entire test. The convection fan was at on position during the entire test. The air inlet damper was fully closed at the minimum setting, the burn rate for the low burn rate category was no greater than the rate that an operator can achieve in home use.

Run #5
This run was performed on April 24th 2023. It lasted 184 minutes and a category 3 burn rate was obtained at 1.30 kg/hr & emission at 1.60 gr/hr. The convection fan was at on position during the entire test. The air inlet damper was fully closed at the minimum setting.

Run #6
This run was performed on April 26th 2023. No fan confirmation test, it lasted 184 minutes and a category 3 burn rate was obtained at 1.31 kg/hr & emission at 1.93 gr/hr. The convection fan was at off position during the entire test. As a result of this test, the heater will be available only with the convection fan. This test failed on Delta T criteria at +129°F. failed on temperature differential criteria (ASTM 2780 Section 9.5.10 Wood heater thermal equilibrium).

Details: Refer to the front page of each test run data sheets found in appendix for the detailed test sequence showing air supply settings and adjustments, fuel bed adjustments and operational specifics of the test unit.

Test fuel cribs

Type of wood: Douglas fir, grade c or better, 19 to 25% dry basis moisture content
Description: for each test, description of the fuel crib is found on the front page of each test run data sheet together with photograph in appendix.

START-UP OPERATION
The complete manufacturer’s firing procedure of each burn rate category is fully described in appendix 13.

SAMPLING LOCATIONS
Particulate samples are collected from the dilution tunnel. The tunnel has two elbows ahead of the sampling section. The sampling section is a continuous 8-inch diameter pipe straight over its entire length. Tunnel velocity pressure is determined by a standard pitot tube, thermocouple is installed on the pitot tube to measure the dry bulb temperature. MC is assumed, as allowed, to be 2%. Tunnel samplers are located downstream of the pitot tube and upstream from the end of this section. All detail of dilution tunnel can be found in appendix 8.

DRAWINGS
Various drawings of the stack gas sampling train and of dilution tunnel system are found in Appendix 6.

EMISSIONS EFFICIENCY TESTING EQUIPMENT LIST
The complete test equipment list together with all corresponding calibration data can be found in Appendix 3.

SAMPLING METHODS

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

QUALITY ASSURANCE

INSTRUMENT CALIBRATION

GAS METERS
At the conclusion of each test program the gas meters are verified using the reference dry gas meter. This process involves sampling the train operation for 1 cubic foot of volume. With readings made to .01 fr’, the resolution is 1 %, giving an accuracy higher than the 2% required by the standard.

SCALES
Before each test program, the different scales used are checked with traceable calibration weights to ensure their accuracy.

GAS ANALYZERS
The continuous analyzers are zeroed and spanned before each test with NBS traceable gases. A mid-scale multi-component calibration gas is then analyzed (values are recorded). At the conclusion of a test, the instruments are checked again with zero, span and calibration gases (values are recorded only). The drift in each meter is then calculated and must not exceed 5% of the scale used for the test.

TEST METHOD PROCEDURES

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. Pre-test and post-test leak checks are conducted with a vacuum of 5 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 is typically less than 2 inches of mercury. Thus, leakage rates reported are expected to be much higher than actual leakage during the tests.

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.

PM SAMPLING PROPORTIONALITY (ASTM E2515)
Proportionalities were calculated in accordance with ASTM E2515. The data and results are found in appendix.