Harmon P35i fire plate rattling?

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Ok. Installed a new door gasket. Passes the dollar bill test now. Noise went away for a day. Came back last night. No where nearly as bad, but still not perfect. I have a 2015 XXV in my Vermont house. With the stove on constant burn(setting 2) the flame stays calm and constant. Same setting on my P35 flame ramps way up then settles back down. That’s when the noise occurs. Maybe its time to have a Harmon rep come out to the house?
 
Does the combustion fan run at a constant speed? It acts like when it feeds, the combustion blower ramps up and stokes the fire super high, sometimes almost to the top of the heat exchanger. Doesn’t seem normal..
 
Ok. Installed a new door gasket. Passes the dollar bill test now. Noise went away for a day. Came back last night. No where nearly as bad, but still not perfect. I have a 2015 XXV in my Vermont house. With the stove on constant burn(setting 2) the flame stays calm and constant. Same setting on my P35 flame ramps way up then settles back down. That’s when the noise occurs. Maybe its time to have a Harmon rep come out to the house?
I thought you had pretty well determined it was the door latch as you could put pressure on it and the noise would go away? Can you press anything now to make the noise go away? As far as the flame goes I run on stove mode 24/7 as low as it will go and the smallest flame I see is right after cleaning, then it's all over the map but still about 1 bag a day.
 
Does the combustion fan run at a constant speed? It acts like when it feeds, the combustion blower ramps up and stokes the fire super high, sometimes almost to the top of the heat exchanger. Doesn’t seem normal..
I'm not sure. I don't remember reading anything about the combustion fan speed during a burn. I know in test mode it goes full at least at the beginning of test mode. After 1 minute the distribution blower slows and then cycles up and down. Not sure what the combustion blower does. It probably cycles down to to the minimum you have set with the POT adjustment in test. I'm guessing the control board will change the speed depending on the settings and ESP probe feedback in any mode as a bigger fire would need more draft.
 
On the inside corners of the unit you have cleanouts. Make sure these are seated properly and tight.
Also on the back of the unit there is an exhaust chamber cleanout which has an access door with what the manual calls insulation between the door and body of the stove. Most likely a gasket of some sort. You should check this and make certain the gasket is there and the door is closed tight. Good chance to clean the exhaust fan paddle if that has never been done.
Page 31 of your manual if you have one.