United States Stove Company KP5522-P User manual

United States Stove
Company
Project # 22-753
Model: KP5522
Additional Models: KP5522-P, KP5522-L,
KP5522-W, US5522, US5522-P,
US5522-L, US5522-W, AP5622,
AP5622-P, AP5622-L, AP5622-W
VG5722, VG5722-P, VG5722-L,
VG5722-W, SP1100, SP1100-W,
KP130-B
Type: Pellet-Fired Room Heater
March 29, 2022
Revised Date: May 17, 2022, November
21, 2022
ASTM E2779 Standard Test Method for
Determining Particulate Matter Emissions
from Pellet Heaters (EPA ALT-146)
Contact: Mr. John Voorhees
227 Industrial Park Road
South Pittsburg, TN 37380
[e-mail]
[phone]
Prepared by: Sebastian Button,
Laboratory Supervisor
11785 SE Highway 212 – Suite 305
Clackamas, OR 97015-9050
[phone]

Project # 22-753 Model: KP5522
Revision History
Date: March 29, 2022 – Original Issue
Date: May 17, 2022 – The following changes were made per request from EPA:
- B415 Calculations page was included in Appendix A, see page 73 of Non-CBI report.
- Adjusted CO emissions values on page 8 to show 2 significant figures.
November 21, 2022
• Added model KP130 -B the Certificate of Conformity and the report.

Project # 22-753 Model: KP5522
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Contents
Affidavit ......................................................................................................................................................... 3
Introduction ................................................................................................................................................... 4
Notes ......................................................................................................................................................... 4
Pellet Heater Identification and Testing ........................................................................................................ 5
Test Procedures and Equipment .................................................................................................................. 6
Results .......................................................................................................................................................... 7
Summary Table ......................................................................................................................................... 7
Test Run Narrative .................................................................................................................................... 8
Run 1 ..................................................................................................................................................... 8
Test Conditions Summary ............................................................................................................................. 8
Appliance Operation and Test Settings .................................................................................................... 8
Settings & Run Notes ................................................................................................................................ 8
Appliance Description ................................................................................................................................... 9
Appliance Dimensions ............................................................................................................................... 9
Test Fuel Properties .................................................................................................................................... 12
Pellet Fuel Analysis ................................................................................................................................. 13
Sampling Location and Descriptions ........................................................................................................... 14
Photos ..................................................................................................................................................... 14
Sampling Methods ...................................................................................................................................... 15
Analytical Methods Description ................................................................................................................... 15
Calibration, Quality Control and Assurances .............................................................................................. 15
Appliance Sealing and Storage ................................................................................................................... 15
Sealing Label .......................................................................................................................................... 15
Sealed Unit .............................................................................................................................................. 16
List of Appendices ....................................................................................................................................... 17

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Affidavit
PFS-TECO was contracted by United States Stove Company to provide testing services
for the KP5522 Pellet-Fired Room Heater per EPA ALT-146, using ASTM E2779,
Determining PM Emissions from Pellet Heaters. All testing and associated procedures
were conducted at PFS-TECO’s Portland Laboratory on 2/18/2022. PFS-TECO’s
Portland Laboratory is located at 11785 SE Highway 212 – Suite 305, Clackamas, Oregon
97015. Testing procedures followed EPA ALT-146 / ASTM E2779. Particulate sampling
was performed per ASTM E2515, Standard Test Method for Determination of Particulate
Matter Emissions Collected by a Dilution Tunnel.
PFS-TECO is accredited by the U.S. Environmental Protection Agency for the certification
and auditing of wood heaters pursuant to subpart AAA of 40 CFR Part 60, New Source
Performance Standards for Residential Wood Heaters and subpart QQQQ of 40 CFR
Part 60, Standards of Performance for New Hydronic Heaters and Forced Air Furnaces,
Methods 28R, 28WHH, 28 WHH-PTS, and all methods listed in Sections 60.534 and
60.5476. PFS-TECO holds EPA Accreditation Certificate Numbers 4 and 4M (mobile).
PFS-TECO is accredited by IAS to ISO 17020:2012 “Criteria for Bodies Performing
Inspections”, and ISO 17025:2005 “Requirements for Testing Laboratories.” PFS-TECO
is also accredited by Standards Council of Canada to ISO 17065:2012 “Requirements for
Bodies Operating Product Certification Systems.”
The following people were associated with the testing, analysis and report writing
associated with this project.
Sebastian Button, Laboratory Supervisor

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Introduction
United States Stove Company of South Pittsburg, TN, contracted with PFS-TECO to
perform EPA certification testing on KP5522 Pellet-Fired Room Heater. All testing was
performed at PFS-TECO’s Portland Laboratory. Testing was performed by Mr. Sebastian
Button.
Notes
• Prior to start of testing, 50 hours of conditioning was performed by US Stove
personnel at a medium burn setting per ASTM E2779
• Prior to start of testing, the dilution tunnel was cleaned with a steel brush.
• Filters were changed on sample train A at one hour after the test began.
• A single, integrated test run, in accordance with ASTM E2779 was performed:
o 1 Hour at Maximum Burn Setting
o 2 Hours at Medium Burn Setting (in accordance with ALT-146)
o 3 Hours at Minimum Burn Setting

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Pellet Heater Identification and Testing
• Appliance Tested: KP5522
• Serial Number: un-serialized prototype, PFS tracking #121
• Manufacturer: United States Stove Company
• Catalyst: No
• Heat exchange blower: Integral
• Type: Pellet Stove
• Style: Free Standing
• Date Received: Monday, February 14, 2022
• Testing Period – Start: Friday, February 18, 2022 Finish: Friday, February
18, 2022
• Test Location: PFS-TECO Portland Laboratory, 11785 SE HWY 212 - Suite
305, Clackamas, OR 97015
• Elevation: ≈131 Feet above sea level
• Test Technician(s): Sebastian Button
• Observers: N/A

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Test Procedures and Equipment
All Sampling and analytical procedures were performed by Sebastian Button. All
procedures used are directly from ASTM E2779 and ASTM E2515. See the list below for
equipment used. See Appendix C submitted with this report for calibration data.
Equipment List:
Equipment ID#
Equipment Description
190
Mettler Toledo 3'x3' floor scale w/digital weight indicator
129
APEX XC-50-DIR Digital Emissions Sampling Box A
130
APEX XC-50-DIR Digital Emissions Sampling Box B
055
APEX Ambient sampling box
187
California Analytical ZRE CO2/CO/O2 IR ANALYZER
064
Digital Barometer
109A/B
Troemner 100mg/200mg Audit Weights
107
Sartorius Analytical Balance
097
10 lb audit weight
095
Anemometer
111
Microtector
CC106574
Gas Analyzer Calibration Span Gas
CC139173
Gas Analyzer Calibration Mid Gas

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Results
The integrated test run emission rate for test Run 1 was measured to be 1.5 g/hr with a
Higher Heating Values efficiency of 76% and a CO emission rate of 0.15 g/min. The
calculated first hour particulate emission rate was 2.8 g/hr. The United States Stove
Company Model KP5522 Pellet-Fired Room Heater meets the 2020 PM emission
standard of ≤ 2.0 g/hr per CFR 40 part 60, §60.532 (b).
Detailed individual run data can be found in Appendix A submitted with this report.
Summary Table
EPA Application Table
Run
Number
Date
Segments
Run
Time
(min)
Heat
Output
(BTU/hr)
1st Hr
Emissions
(g/hr)
Integrated
Total (g/hr)
CO
Emissions
(g/min)
Overall
CO
Emissions
(g/min)
Heating
Efficiency
(%HHV)
Overall
Heating
Efficiency
(%HHV)
Setting
BR
1
2/18/2022
H
2.26
60
32591
2.8
1.5
0.21
0.15
77%
76%
M
1.58
120
22312
0.17
76%
L
0.97
180
13640
0.12
76%
OA
1.39
360
19708
0.15
76%

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Test Run Narrative
Run 1
Run 1 was performed on 2/18/2022 as an attempted integrated test run per EPA ALT-
146/ ASTM E2779. The overall test duration was 360 minutes. The particulate emissions
rate for the integrated test run was 1.5 g/hr. The run had an overall HHV efficiency of
76%. Sample train A was changed at 1 hr. All test results were appropriate and valid
and the burn rate requirements for the integrated test run were achieved. There were no
anomalies and all criteria were met.
Test Conditions Summary
Testing conditions for all runs fell within allowable specifications of ASTM E2779 and
ASTM E2515. A summary of facility conditions, fuel burned, and run times is listed below.
Runs
Ambient (°F)
Relative
Humidity (%)
Average
Barometric
Pressure
(In. Hg.)
Preburn
Fuel
Weight
(lbs)
Test Fuel
Weight
(lbs)
Test Fuel
Moisture
(%DB)
Test Run
Time
(Min)
Pre
Post
Pre
Post
1
69
69
26.2
23.4
30.47
5.4
19.2
4.37
360
Appliance Operation and Test Settings
The appliance was operated according to procedures as described in the Operations
Manual, found in Appendix B submitted with this report. Detailed run information can be
found in Appendix A submitted with this report.
Settings & Run Notes
Pre-Burn
Test Run
Run 1
Heat Setting #5
High Segment: Heat Setting #5
Medium Segment: Heat Setting #3
Low Segment: Heat Setting #1

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Appliance Description
Model(s): KP5522
Additional Models Discussion: This model is offered under a variety of different
branding designations under the following model numbers: KP5522-P, KP5522-L,
KP5522-W, US5522, US5522-P, US5522-L, US5522-W, AP5622, AP5622-P,
AP5622-L, AP5622-W VG5722, VG5722-P, VG5722-L, VG5722-W, SP1100, and
SP1100-W. The various models are identical in all aspects with the exception of the
brand names.
Appliance Type: Pellet-Fired Room Heater
Air Introduction System: Air enters the burn chamber by being pulled though the firepot,
via the exhaust blower, see air flow diagram in Appendix D.
Combustion Control: Feed rate is electronically controlled via user-selectable controls.
Baffles: N/A
Flue Outlet: 3-inch exhaust outlet located on the bottom/rear of the appliance, with an
optional adapter piece to convert to 6-inch venting.
Appliance Dimensions
KP5522 Dimensions
Height
Width
Depth
40”
24”
30”
Appliance design drawings can be found in Appendix D submitted with the CBI copy of
this report.

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Appliance Front
Appliance Left

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Appliance Right
Appliance Rear

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Test Fuel Properties
Test fuel used was Bear Mountain Wood Pellet Fuel, a PFI Certified Premium Pellet
Brand. A sample of pellets was sent to Twin Ports Testing for analysis, see report below.

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Pellet Fuel Analysis

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Sampling Location and Descriptions
Sample ports are located 16.5 feet downstream from any disturbances and 2 feet
upstream from any disturbances. Flow rate traverse data was collected 8 feet
downstream from any disturbances and 4 feet upstream from any disturbances. (See
below).
Photos
Sample Points
Traverse Points
Traverse Points
Detail
Sample Points
Detail

Project # 22-753 Model: KP5522
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Sampling Methods
ASTM E2515 was used in collecting particulate samples. The dilution tunnel is 12 inches
in diameter. All sampling conditions per ASTM E2515 were followed. No alternate
procedures were used.
Analytical Methods Description
All sample recovery and analysis procedures followed ASTM E2515 procedures. At the
end of each test run, filters, O-Rings and probes were removed from their housings,
dessicated for a minimum of 24 hours, and then weighed at 6 hour intervals to a
constant weight per ASTM E2515-11 Section 10.
Calibration, Quality Control and Assurances
Calibration procedures and results were conducted per EPA Method 28R, ASTM E2515-
11 and ASTM E2780-10. Test method quality control procedures (leak checks, volume
meter checks, stratification checks, proportionality results) followed the procedures
outlined.
Appliance Sealing and Storage
Upon completion of testing, the appliance was secured with metal strapping and the seal
below was applied, the appliance was then returned to the manufacturer’s location at:
227 Industrial Park Road, South Pittsburg, TN 37380 for archival.
Sealing Label

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Sealed Unit

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List of Appendices
The following appendices have been submitted electronically in conjunction with this
report:
Appendix A – Test Run Data, Technician Notes, and Sample Analysis
Appendix B – Labels and Manuals
Appendix C –Equipment Calibration Records
Appendix D – Design Drawings (CBI Report Only)
Appendix E – Manufacturer QAP (CBI Report Only)

Appendix A

1
Mr. John Steinert
Vice President
PFS TECO
11785 SE Hwy 212
Suite 305
Clackamas, OR 97015
Dear Mr. Steinert,
I am writing you in response to your correspondence dated February 3, 2022, in which you
request the use of an alternative testing procedure to demonstrate compliance with 40 CFR part
60, Subpart AAA – Standards of Performance for New Residential Wood Heaters (Subpart
AAA). The Office of Air Quality Planning and Standards, as the delegated authority, must make
the determination on any major alternatives to test methods and procedures required under 40
CFR parts 59, 60, 61, 63, and 65. Your proposed alternative test method and our approval
decisions are discussed below.
According to the information provided, you seek an alternative test method for use when
conducting testing on the United States Stove Company, Model KP5517 pellet heater. Currently,
as required by section 60.534(a)(l)(i) of Subpart AAA, a manufacturer has the option to test their
appliance in accordance with 40 CFR part 60, Appendix B, Method 28R for a crib fuel appliance
or ASTM E2779-10 “Standard Test Method for Determining Particulate Matter Emissions from
Pellet Heaters” (ASTM E2779-10) for a pellet fuel appliance. This request seeks an alternative to
section 9.4.1.2 of ASTM E2779-10 which specifies test conditions for pellet heaters including
the determination of the Medium Burn Rate Category and states that the medium burn rate must
be ≤50% of the maximum burn rate.
In your request, you state that the specification for determining the medium burn rate found in
ASTM E2779-10 is incorrect, and the Medium Burn Rate Category should be defined as less
than 50% of the midpoint point (this is defined in the attached Memo as 50% of the span
between the Maximum Burn Rate and the Low Burn Rate) between the high and low burn rates.
Furthermore, your request includes a memorandum dated February 2, 2022, titled “Appropriate
Calculation of Medium Burn Rate Category in ASTM E-2779 Testing” (attached) which was
sent to the EPA’s Office of Enforcement and Compliance Assurance. This memorandum states
that an error had been uncovered in determining the appropriate Medium Burn Rate Category in
ASTM E2779-10 for compliance pursuant to Subpart AAA. Specifically, section 9.4.1.2 of
ASTM E2779-10 states that “the pellet heater shall be operated with the control or controls set in
02/04/2022