Many believe that certification testing of residential wood heat appliances should provide data indicative of installed performance. Operationally, test methods typically only assess steady-state emissions and fail to include other typical conditions for batch appliances such as start-up. From a fueling perspective, protocols should ensure a consistent approach reflecting common use practices. Ensuring representative conditions and accurate quantification of emissions requires assessing the impact of different start-up conditions and whether or not start-up conditions affect appliance operation during start-up and beyond. This study evaluated the impact of modifying fuel piece sizes and configurations using a "smart" wood-fired hydronic heater (WHH) cordwood appliance. The appliance represents technologies using software and oxygen sensors to improve performance. Since the study used a "smart" appliance, the results likely reflect the least amount of variability found in a WHH cordwood appliance. The analysis consisted of a series of tests that involved changing one fuel variable per series, including: (1) kindling fuel arrangement in the firebox; (2) fuel piece size; and (3) the amount of kindling and starter fuel used. A goal of the study was to determine how each variable affects emissions performance during start-up and the following steady state load. Testing used a dual-stage combustion cordwood WHH equipped with external thermal storage. Particulate matter (PM), carbon monoxide (CO), and delivered heating efficiency were measured, and visible emissions from the stack and secondary combustion chamber were observed. Replicate tests were conducted for each protocol series to evaluate WHH performance reproducibility. These tests found that for a low-mass staged combustion WHH with external thermal storage, the use of different fueling protocols can substantially affect PM and CO emissions.Implications: As test methods move to incorporate measurements beyond steady-state emissions, fueling protocols must be assessed to determine (1) if they reflect typical field procedures and (2) the impact of start-up procedures on the complete test run. This paper assessed how changing start-up conditions affected run variability and PM emission impacts.