Jack, it does sound to me like you have a couple of problems. For sure you should be able to get a higher temperature on that stove. If the draft is set too high then more heat would escape out the chimney but the fire would be roaring. I'd suggest to not engage the cat before 20 minutes and make sure the stove top is at 250+ and/or the flue is 500 degrees or thereabouts. Once you engage the cat, try the setting on 1.5. After 10-15 minutes try it on 1 or if there is lots of flame, go below 1. Try to get it so that you have just a little flicker of flame; if you turn the draft down and the flame dies, give it a little more air. Would it actaully roar like a "normal" stove? I'm just thinking that the air intake is so small that the fire is only going to get so big before it is out of air.
Before you do this though, you probably need to clean out your firebox some. I can picture what you have and that is coals above the bottom of the firebox door. Tons of coals and no place to put much wood. That has to be remedied else nothing you try will work. So even if you have to scoop some coals out, do it so that you can start with lots of room for wood. I have been but it keeps coaling.
I do not know what wood you are burning but that has a lot, I repeat, a lot, to do with the type of fires you get. For example, at present we are burning a combination of ash, elm and soft maple. The maple and elm burn much faster than the ash, so that is our primary daytime wood. Rarely do we burn ash during the day. However, come night, after burning the coals down, I like to put a large ash in the bottom rear of the stove. That baby is the key to longer burns. Front bottom gets a maple or elm. The rest is filled with ash. After about 10 minutes (it varies) the cat gets engaged. It is at this point that I will determine where to set the draft. Right now it is ash, black cherry, silver maple, sugar maple, and a touch of birch.
That is correct. I do not go by a blanket setting every time because every fire is not the same. It is close, but there are just too many variables, from wood type, size of the wood, weather, etc. If I have lots of flame, the draft usually goes right to .25 (1/4 of the way to 1). Sometimes that is too much draft and sometimes it is too little. Regardless, once I am ready for bedtime, the draft gets set low and at present we are finding we have to go to zero. I'm not new to stoves...just this one and cats.
So how warm does our stove get with these settings and the poor chimney that we have? Zoom! The stovetop temperature zooms right up to at least 550 and an hour or so later will be over 600 with ease. However, let me caution; not everyone can go by the same setting we use. Check with Todd and you'll find he sets mostly at .5, but with our stove that is too high unless the weather is warm (fall/spring) or a storm coming.
Jack, please do try emptying the stove so you have only an inch or so of ash and only enough coals to get the fire going good. Leave that draft full open until you are ready to engage the cat. Then turn it down to (I'm guessing) 1 or 1.5 and wait for 10 minutes to see what happens. Judge further action by the flame you are getting.
When your stove is down to coals, rake the poker through them; don't be gentle. Shove some to the front so there is more in the front than in the back. Leave the draft open full and those coals should burn down fairly quick. I'd also leave the cat on at this point. Not that the cat will help, but the heat has to go through the top of the stove before reaching the flue so you gain the benefit of the heat. If you bypass the cat, then pretty much any heat there goes right up the chimney (hope Santa isn't on his way down then!). So I can open the door with the cat engaged and rake the coals? Or re-engage the cat even though it wont light off?
I don't know what you have for wood but I would suggest something like pallet wood to mix in if only to see if indeed most of the problem is with the wood itself. I would also highly advise you to call the good folks at Woodstock. The toll free number is in the manual you received.