Hi everyone. I'm a long time reader but haven't posted much. After a bunch of research I decided to go with the Blaze King Princess for my 1800 sqft house. The local dealer tried real hard to talk me out of a catalytic stove (even though I said my main priorities were efficient burning and long burns with consistent heat output). I stuck to my guns and got the Princess. It has not been smooth sailing, however. Hoping some of you may have tips for me.
The first problem I ran into was that I cannot get the stove started up with the front door closed. The instructions clearly say that once your kindling is going, you can close the front door (tstat at #3) and burn that way until the cat is active. Well, my firebox will just fill with smoke and the fire will go out. I have to leave the door cracked. When I do that, it burns like a furnace (which makes me think insufficient draft is NOT the problem...). If the firebox is up to temp, I *can* run with the bypass open and it operates pretty much like a non-cat stove withs secondary action (but why would I want to do that???
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The second problem is that I get a lot more smoke out the chimney than I had expected. Certainly during start-up, but also during the initial burn-in on high, and it continues for at least the first hour or two (regardless of thermostat setting). It's not steam, it's smoke--does not dissipate and I can smell it. Once the fire has "settled in", the smoke does stop.
The third problem is that I can't use the full thermostat range. At 3 (won't go past #3, despite a tick mark at 3.5) the stove will produce smoke out the chimney. Below 1.5 the fire will go out. The stove really seems to only run best in the range marked "NORMAL" (about 1.75-2.25).
The fourth problem is that I don't get very long burn times. Loaded up with dry oak (verified with a moisture meter at 10-12%) and set at #2 I might get 10 (down to coals). Not bad for your average stove, but less than I expected. The burn profile will be something like this: 1-2 hours of active flames, 1-2 hours of "borealis"/intermittent blue flames, then dark with just the glowing cat, then a dark (but still active) cat. I can't manage a twice-daily load cycle. With cedar (also bone dry) a full load will burn down in 6 hours or less at the same setting.
The fifth problem is that I get significant soot buildup on the glass. It would probably stay clean if I burned the whole load at #2, but if I turn it down below 2 it'll soot up. It seems this isn't too uncommon so I'm not that worried about it, but I sure would prefer clean glass.
The one strange thing about my setup is that I had a two story 7" single-wall stovepipe that I wanted to reuse for cost reasons. We replaced the first few feet with straight 6", followed by two 45's to get in line with the 7" run, then 7" to the roof (so about 15 feet of 7"). The stovepipe is 2-300 degrees near the stove, but cools very rapidly as you go up. Near the top, it's almost room temperature (90F, sometimes cooler!). I think this could be contributing to my problems, because at higher thermostat settings that massive pipe is creating too much draft and causing the smoke out the top (incomplete burn through the cat); at lower settings the flow is so slow that the flue gas cools rapidly and there is insufficient draft. I'm even worried about spillage into the house given the temps at the top are so low--we have two CO detectors and I bought a professional meter, too. So far so good though.
I checked the bypass gasket and it looks fine to me--no gaps that I can see, and no sooty areas to indicate exhaust gas flowing through. When I look into the firebox I do see flames going straight up to the top (as opposed to being "pulled" towards the cat) but I can't really tell if they're heading to the bypass or just the ceiling of the firebox in general.
Oh, and yes my cat is lighting off. It typically runs between 1/2 and 3/4 on the dial, glows orange when there's significant smoke. The only time it stalls (drops out of the active zone) is if I try to go below the 1.5 setting.
I have tried an experiment--wrapped about half of the stovepipe with crinkled aluminum to simulate a double-wall pipe. The stove does seem happier and I have been able to go a bit below 1.5 (albeit with very little heat output).
Having said all that, I still love my stove. Burns 2-3 times longer on the same load compared to my old smoke dragon, and requires far less fiddling (as long as I stay between 1.5 and 2.5).