Hopefully the user here who has been very happy with there GM will see this thread.
Hi Everyone,
Thank you for these replies. As background, I started my wood burning life as merely someone who owned a stove, bought our wood, and had chimney fires because I didn't know you had to clean the chimney. I then became a chimney sweep, worked in a wood stove testing laboratory, ran a retail wood stove store, and finished my professional wood stove related career as the sales manager for a wood stove manufacturer.
Now I'm back to being just a guy with a wood stove who knows a little bit about what's supposed to happen when you have a chimney with a good draft (ours was tested recently and it draws perfectly well). I also clean our chimney twice a year - before and mid-way during the season. I have come to believe the issue is not our draft/ chimney, but a stove that has been well designed to meet the stringent EPA requirements, under laboratory conditions, yet needs a few manufacturing modifications to actually perform well in the real world.
The smoking happens primarily at two times. 1. When there are coals at the back of the stove and I want to pull them forward and add more wood. Really, any time I open the door and move coals around smoke and/ or fly ash come out the door. 2. Also, soon after I close the damper and close the air inlet to shut it down for an overnight burn, it'll back puff smoke out the air inlet. This stove has an indicator dial showing when the catalytic converter is "Active" and I now always wait until it is at least half way into the Active range before closing the damper, yet the back puffing still happens.
I have "fixed" the smoke and ash out the door issue by sliding a 1" x 4" board across the top of the door frame opening as I open the door, but this is kind of a bogus fix. With other stoves you merely open the door a crack, let the draft kick in, and open the door to load it. The permanent fixes for this include A) cutting back the baffle and B) reducing the top-of-the-door opening. The top opening of the door frame is about 1" above the bottom of the baffle and the front edge of the baffle is about 1" back from the glass door. Smoke, of course, takes the path of least resistance and flows out the door rather than curving back over the baffle and then up the stove pipe/ chimney. Lower the door opening and the smoke will more naturally follow the draft up the stove pipe/ chimney.
Of course, cutting back the baffle will reduce the efficiency, which the company claims will reduce sales. (Well, manufacturing a stove that smokes constantly will reduce sales, too.) The fix to lower the top opening to the fire box should not affect the efficiency and might be the only fix needed to stop the smoke and ash out the door issue.
The permanent fix for the back puffing issue might be cutting back the baffle, which would widen the opening for the smoke to go up the catalytic converter, rather than out the air inlet. The permanent fix for the back puffing issue might also be to put in a larger catalytic converter; maybe it is undersized. Catalytic converters were just coming onto the market when I worked in the wood stove testing lab, so I'm not all that familiar with their function.
There you go; a fairly long winded explanation of our issues and my thinking.