Thanks! Calibration could be an issue. I have never seen it stay in the active temp zone longer than about 4 hours. My Sirocco manual says of the catalytic thermometer, "for calibration instructions refer to the MAINTENANCE section." But in the maintenance section, there is no mention of it. Great.
As someone commented above, following the operating instructions to the letter seems important. Unfortunately, they're just not that clear on some things.
For example, is it OK to leave the cat engaged overnight? As above, there's no way my fires will stay in the active zone overnight. When I wake up, the thermometer always reads inactive. So either I potentially damage the cat by running it too low before I wake up, or I lose the benefit of a low-slow clean burn overnight if I open the bypass door before bed.
Another example: the instructions for lighting the fire state that once the fire is well established, "gradually turn the thermostat down to the desired heat output setting." There is no guidance on what "gradually" means. Over a period of 5 seconds? 10 seconds? 1 minute? 10 minutes? 30 minutes? All at once, or little by little with time in between?
I don't think there's a major draft issue. I see plenty of smoke rolling out of the chimney when the bypass is open. When the loading door is cracked open, the draft is very visible in the flames. But when I open the door wide enough to get wood in, smoke tends to come out. I may have a more sensitive nose than some. But then the whole house smells like smoke for hours.
I think having smaller wood will help the smoke issue while reloading. First, it will allow me to pack the firebox fuller to begin with, so reloading will be less frequent. Second, wood should be drier and burn hotter. Third, when I do reload, I won't have to work so hard to fit the pieces in the firebox, so the door won't be open as long.
If anyone has recommended videos demonstrating the whole process on a Blaze King stove/insert, let me know. Sometimes one or two little tricks can make a huge difference.