Travis Industries Xtrordinair 44 Elite User manual

OMNI-Test Laboratories, Inc.
Non-Confidential Business Information
(Non-CBI)
Certification Test Report
Travis Industries, Inc.
Catalytic Wood Burning Factory Built Fireplace
Model: 44 Elite
Prepared for: Travis Industries, Inc.
12521 Harbour Reach Drive
Mukilteo, WA 98275
Prepared by: OMNI-Test Laboratories, Inc.
13327 NE Airport Way
Portland, OR 97230
[phone]
September 11, 2018 –September 17, 2018
November 2018
Test Period:
Report Issued:
Report Number: 0028WF061E
All data and information contained in this report are confidential and proprietary to Travis
Industries, Inc.. Its significance is subject to the adequacy and representative character of the
samples and to the comprehensiveness of the tests, examinations, or surveys made. The
contents of this report cannot be copied or quoted, except in full, without specific, written
authorization from Travis Industries, Inc. and OMNI-Test Laboratories, Inc. No use of the
OMNI-Test Laboratories, Inc. name, logo, or registered mark (O-TL) is permitted, except as
expressly authorized by OMNI-Test Laboratories, Inc. in writing.
- Document Edition # 001 (7/12/19) -
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
OMNI-Test Laboratories, Inc.
AUTHORIZED SIGNATORIES
This report has been reviewed and approved by the following authorized signatories:
Evaluator:
__________________________
Bruce Davis
Technician
Reviewer:
__________________________
Alex Tiegs
President
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
OMNI-Test Laboratories, Inc.
TABLE OF CONTENTS
PREFACE...............................................................................................................(3 pages)
1. SAMPLING PROCEDURES AND TEST RESULTS .......................................................4
Introduction..........................................................................................................................5
Individual Run summaries...................................................................................................6
Summary Tables
Table 1 - Particulate Emissions Results...............................................................................8
Table 2 - Particulate Emissions Results (First Hour)...........................................................8
Table 3 –B415.1 Efficiency and CO Emissions .................................................................8
Table 4 - Test Facility Conditions .......................................................................................9
Table 5 –Kindling and Start-up Fuel Description Summary..............................................9
Table 6 - Fuel Measurements and Cordwood Descriptions - Test.....................................10
Table 7 - Dilution Tunnel Gas Measurements and Sampling Data...................................10
Table 10 - Test Configurations..........................................................................................11
2. PHOTOGRAPHS/APPLIANCE DESCRIPTION/DRAWINGS......................................13
Fuel Photographs ...............................................................................................................15
Appliance Description .......................................................................................................21
3. TEST DATA BY RUN......................................................................................................22
Run 1..................................................................................................................................29
Run 3..................................................................................................................................43
Run 4..................................................................................................................................50
Run 5..................................................................................................................................61
Run 6..................................................................................................................................76
4. QUALITY ASSURANCE/QUALITY CONTROL..........................................................86
Sample Analysis.................................................................................................................88
Calibrations –EPA Method 28R, ASTM E2515, ASTM E3053....................................100
Example Calculations ......................................................................................................116
5. LABELING & OWNER’S MANUAL............................................................................127
6. Appendix A Alt-125 E3053 Letter ..................................................................................155
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
Section 1
Sampling Procedures and Test Results
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
INTRODUCTION
Travis Industries, Inc. retained OMNI to perform U.S. Environmental Protection Agency (EPA)
certification testing on the 44 Elite factory-built fireplace. The 44 Elite factory-built fireplace is
a Catalytic wood burning fireplace. The firebox is constructed of mild steel. Usable firebox
volume was measured to be 4.2 cubic feet and the stove is vented through 8” flue collar located
on the stove top.
Testing was performed at Travis Industries. The altitude of the laboratory is 500 feet above sea
level. The unit was received in good condition and logged in on 9/10/2018, then assigned and
labeled with OMNI ID #2305. OMNI representative Bruce Davis conducted the certification
testing and completed all testing by 9/17/208.
This report is organized in accordance with the EPA-recommended outline and is summarized in
the Table of Contents immediately preceding this section. The results in this report are limited to
the item submitted.
SAMPLING PROCEDURE
The 44 Elite factory-built fireplace was tested in accordance with the U.S. EPA 40 CFR Part 60,
Subpart AAA – Standards of Performance for New Residential Wood Heaters using EPA ASTM
E2515 and E3053 per EPA Alt-125’s requirements for cordwood testing in accordance with the
CFR. No 28R. Particulate emissions were measured using sampling trains consisting of two
Teflon coated 47mm filters (front and back). See Appendix A for details on EPA Alt-125.
The model 44 Elite was tested for thermal efficiency and carbon monoxide (CO) emissions in
accordance with CSA B415.1-10 using Douglas Fir cordwood.
SUMMARY OF RESULTS
The weighted average emissions of the four test runs included in the results indicate a particulate
emission rate of 1.82 grams per hour. Particulate emissions were sampled on two of the high
burn fuel loads. Run number two was omitted due to equipment failure, after the start of a low
burn it was apparent that the gasket on the door had been damaged and was leaking. This leak
created a burn rate that was outside of predicted results. After replacing the gasket with factory
specified parts, testing resumed, and a low burn was conducted during run 4. The 44 Elite results
are within the emission limit of 2.5 g/hr for affected facilities tested with cordwood,
manufactured on or after May 15, 2020.
The proportionality results for all 4 test runs were acceptable when calculated at a 10-minute
sample rate. Quality check results for each test run are presented in Section 2 of this report.

Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
INDIVIDUAL RUN SUMMARIES
Run 1 - Test procedures followed to produce a high burn rate with a primary air setting of
fully open. Observed burn rate was calculated at 5.74 kg/hr. Emissions results
were calculated using particulate sampling from kindling, start-up fuel, and test
fuel load combined (cold to hot). Burn rate, and efficiency were calculated using
data from the test fuel load only (hot to hot).
Quality checks also found a filter temperature exceeded limits by a maximum of 1
degree for 1 reading and dropped below minimum limits by a maximum of 5
degrees for three readings during particulate sampling. An evaluation was
conducted on the data to determine if there was evidence data had been
compromised by these limit infractions. Comparing proportional rates and
sample precision between the two sample probes, no evidence was found that
would show the brief limit infraction caused any compromise of the data. No
additional sampling anomalies occurred, this test run was determined to be valid
for inclusion in the weighted average.
Run 2 - Test procedures were followed to produce a low burn rate with a primary air
setting of full closed. After starting the test, it was apparent that the gasket in the
door had been damaged, causing a burn rate in excess of an anticipated kilogram
per hour. This test was stopped and omitted from the average due to equipment
failure.
Run 3 - Test procedures followed to produce a high burn rate with a primary air setting of
fully open. Observed burn rate was calculated at 5.66 kg/hr. Emissions sampling
did not occur during this procedure, it was conducted to create a coal bed for run
4.
Run 4 - Test procedures were followed to produce a low burn rate with a primary air
setting of full closed. Observed burn rate was calculated at 1.01 kg/hr. Emissions
and efficiency results were calculated using a hot to hot burn cycle, a coal bed
generated by the high burn procedure was used. No sampling anomalies
occurred, this test run was determined to be valid for inclusion in the weighted
average.
Run 5 - Test procedures followed to produce a high burn rate with a primary air setting of
fully open. Observed burn rate was calculated at 5.66 kg/hr. Emissions results
were calculated using particulate sampling from kindling, start-up fuel, and test
fuel load combined (cold to hot). Burn rate, and efficiency were calculated using
data from the test fuel load only (hot to hot).
Quality checks also found a filter temperature exceeded limits by a maximum of 3
degree for 3 reading and dropped below minimum limits by a maximum of 4
degrees for four readings during particulate sampling. An evaluation was
conducted on the data to determine if there was evidence data had been
compromised by these limit infractions. Comparing proportional rates and
sample precision between the two sample probes, no evidence was found that
would show the brief limit infraction caused any compromise of the data. No
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
additional sampling anomalies occurred, this test run was determined to be valid
for inclusion in the weighted average
Run 6 - Test procedures were followed to produce a medium burn rate with a primary air
setting of 0.144” from full closed. Observed burn rate was calculated at 1.31
kg/hr. Emissions and efficiency results were calculated using a hot to hot burn
cycle, a coal bed generated by the high burn procedure was used. At 440 minutes
into the test, the fuel load was re-situated, this was done due to no weight loss in a
10-minute time period, after 60% of the fuel load was consumed. The fuel
loading door was open for less than 30 seconds while fuel was moved to the
center of the firebox. No additional sampling anomalies occurred, this test run
was determined to be valid for inclusion in the weighted average.
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
Table 1 –Particulate Emissions
Run
Burn Rate
Calculated from a
Hot to Hot burn
cycle
(kg/hr dry)
ASTM E2515
Emissions
(g/hr)
ASTM E3053
Weighting Factor
(%)
ASTM E3053 Weighted
Emissions
(g/hr)
1
5.74
1.7.15
20
1.43
4
1.01
0.51
40
0.204
5
5.66
1.6.37
20
1.27
6
1.31
0.67
40
0.268
The sum of weighted particulate emission of 4 test runs: (1.43+1.27)/2 + 0.204 + 0.268 = 1.822
1. Based on a cold start including kindling and start-up fuel.
Table 2 –Particulate Emissions (First Hour)
Run
ASTM E2515
Emissions –First Hour
(g/hr)
1
4.88
4
4.27
5
6.89
6
2.80
Table 3 –B415.1 Efficiency and CO Emissions
Run
Heat
Output
(BTU/hr)
HHV
Efficiency
(%)
LHV
Efficienc
y (%)
ASTM
E3053
Weighted
HHV
Efficiency
CO Emissions
(g/MJ Output)
CO
Emissions
(g/kg Dry
Fuel)
CO Emissions
(g/min)
1
78,046
72.3
78.1
14.46
2.45
35.02
3.3538
4
12,947
68.4
74.0
27.36
1.35
18.29
0.3068
5
74,932
70.4
76.1
14.08
0.63
8.74
0.8247
6
19,203
77.7
84.0
31.08
0.91
14.04
0.3077
Weighted average HHV efficiency of 4 tests: (14.46 + 14.08)/2 + 27.36 + 31.08 = 72.7 %.
Average CO emissions: (3.3538 + 0.8247)/2 + 0.3068 + 0.3077 = 2.70 g/min
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
Table 4 –Test Facility Conditions
Run
Room Temperature
(°F)
Barometric Pressure
(Hg)
Air Velocity
(ft/min)
Before
After
Before
After
Before
After
1
72
75
29.24
29.27
<50
<50
4
77
73
29.27
29.34
<50
<50
5
72
75
29.42
29.37
<50
<50
6
78
68
29.34
29.39
<50
<50
Table 5 –Kindling and Start-up Fuel Description Summary
Douglas Fir CordWood
Run
Kindling
Weight
Wet Basis
(lbs)
Start-up
Fuel Weight
Wet Basis
(lbs)
Residual
Start-up
fuel weight
(lbs)
1
7.60
11.0
4.2
3
7.4
11.0
4.2
5
7.2
11.4
4.2
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
OMNI-Test Laboratories, Inc.
Table 6 –Fuel Measurement and Cordwood Description Summary –TEST
Douglas Fir CordWood
Run
Test Fuel
Wet Basis
(lbs)
Firebox
Volume
(ft3)
Fuel Loading
Density Wet
Basis
(lbs/ft3)
Test Fuel
Dry Basis
(lbs)
1.Test Fuel
Consumed
During Test
Dry Basis (lbs)
Piece
Length
(in)
1
40.1
4.2
9.5
32.64
39.9
6@15
3
40.6
4.2
9.7
33.24
40.7
6@15
4
48.7
4.2
11.6
39.92
39.9
7@15
5
40.6
4.2
9.7
33.03
40.4
6@15
6
49.6
4.2
11.8
40.01
40.0
7@15
1. Includes start-up and kindling fuel for high burn tests 1, 3, and 5.
Table 7 –Dilution Tunnel Gas Measurements and Sampling Data Summary
Run
Length of Test
(min)
Average Dilution Tunnel Gas Measurements
Velocity
(ft/sec)
Flow Rate
(dscf/min)
Temperature
(°F)
1
202
21.70
197.0
196
4
1080
18.70
199.4
100
5
214
19.69
180.0
195
6
830
18.54
195.7
106
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
OMNI-Test Laboratories, Inc.
Table 10 –Test Configurations
Run
Startup Procedures
Combustion Air
1
Fuel Loading: Kindling and start-up fuel loaded together, a torch was used
for 60 seconds to establish a fire. At 62 minutes placed fuel load into the
firebox and closed the loading door after 70 seconds. Loading required less
than 1 minute to complete.
Door: For kindling and start-up fuel, loading door was open for 3 minutes,
then closed. Test fuel load; fuel loading door was closed 70 seconds after
loading.
Primary Air: Air control fully open for the entire test.
Secondary: No user control for secondary air.
Fan: Fan was set to an automatic setting that turns on to a desired setting
after the firebox reaches a specified temperature. Fan turned on high at
approximately 28.5 minutes after fire was lit.
Bypass: Open for 1:00 minute after lighting kindling load. Not used while
loading fuel load.
Fully open for
entire test.
3
Fuel Loading: Kindling and start-up fuel loaded together, a torch was used
for 60 seconds to establish a fire. At 68 minutes placed fuel load into the
firebox and closed the loading door after 60 seconds. Loading required less
than 1 minute to complete.
Door: For kindling and start-up fuel, loading door was open for 3 minutes,
then closed. Test fuel load; fuel loading door was closed 50 seconds after
loading.
Primary Air: Air control fully open for the entire test.
Secondary: No user control for secondary air.
Fan: Fan was set to an automatic setting that turns on to a desired setting
after the firebox reaches a specified temperature. Fan turned on high at
approximately 31 minutes after fire was lit.
Bypass: Open for 1:00 minute after lighting kindling load. Not used during
fuel loading.
Fully open for
entire test.
4
Fuel Loading: Test fuel loaded onto coal bed generated by test number 1 in
45 seconds.
Door: Open for 2:00 minutes, then closed.
Primary Air: Fully open, then set to full closed by 15.0 minutes.
Secondary: No user control for secondary air.
Fan: Fan operates automatically, was set to high the entire test.
Bypass: Not used for loading test fuel load.
Fully open for first
15.0 minutes, then
set to full closed.
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
OMNI-Test Laboratories, Inc.
5
Fuel Loading: Kindling and start-up fuel loaded together, a torch was used
for 60 seconds to establish a fire. At 71 minutes placed fuel load into the
firebox and closed the loading door after 55 seconds. Loading required less
than 1 minute to complete.
Door: For kindling and start-up fuel, loading door was open for 3 minutes,
then closed. Test fuel load; fuel loading door was closed 50 seconds after
loading.
Primary Air: Air control fully open for the entire test.
Secondary: No user control for secondary air.
Fan: Fan was set to an automatic setting that turns on to a desired setting
after the firebox reaches a specified temperature. Fan turned on high at
approximately 31 minutes after fire was lit.
Bypass: Open for 1:00 minute after lighting kindling load. Open for 30
seconds during fuel loading.
Fully open for
entire test.
6
Fuel Loading: Test fuel loaded onto coal bed generated by test number 5 in
50 seconds.
Door: Closed at 60 seconds.
Primary Air: Fully open, then set to 0.144”by 15 minutes.
Secondary: No user control for secondary air.
Fan: Fan operates automatically, was set to high the entire test.
Bypass: Not used for loading test fuel load.
Fully open for first
16.0 minutes, then
set to 0.144” for
remainder of test.
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
OMNI-Test Laboratories, Inc.
Section 2
Photographs/Appliance Description/Drawings
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
OMNI-Test Laboratories, Inc.
Travis Industries, Inc.
44 Elite
Test Dates: May 22, 2018 –May 24, 2018
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
OMNI-Test Laboratories, Inc.
Travis Industries, Inc.
44 Elite
Run 1 –Kindling and start up fuel Run 1 −Ignition of kindling
Run 1 –Fuel load Run 1 −Coal bed prior to loading
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
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Travis Industries, Inc.
44 Elite
Run 1 –Test Fuel Load In Stove Run 1 −Remaining Coal bed
Run 3 –Kindling and start up fuel Run 3 −Fuel load
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
OMNI-Test Laboratories, Inc.
Run 3 –Test Fuel Loaded into Stove Run 2 −Remaining Coal After Test
Run 4 –Test Fuel Load Run 4 −Test Fuel Loaded into Stove
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
OMNI-Test Laboratories, Inc.
Run 4 –Remaining Coal Bed Run 5 –Kindling and start up fuel
Run 5 –Ignition of kindling Run 5 –Test Fuel Load
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
OMNI-Test Laboratories, Inc.
Run 5 −Test Fuel Loaded into Stove Run 5 −Remaining Coal Bed
Run 6 –Test Fuel Load Run 6 −Test Fuel Loaded into Stove
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Travis Industries, Inc.
Model: 44 Elite
Report Number:0028WF061E
OMNI-Test Laboratories, Inc.
Run 6 −Fuel prior to adjustment Run 6 −Fuel after adjustment
Run 6 −Remaining Coal Bed
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