CI2600/HI400 | wood insert
30
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operating instructions
CATALYTIC COMBUSTOR (PART # 106-534)
ACHIEVING AND MAINTAINING CATALYST LIGHT-OFF
:
The temperature in the stove and the gases entering the combustor must be
raised to between 500F to 700F for catalytic activity to be initiated. During the
start up of a cold stove a medium to high firing rate must be maintained for
about 30 minutes. This ensures that the stove, catalyst and fuel are all sta-
bilized at proper operating temperatures. Even though it is possible to have
temperatures at 600F within minutes after a fire has been started, if the fire
is allowed to die down immediately it may go out or the combustor may stop
working. Once the combustor starts working, heat generated in it by burning
the smoke will keep it working. During re-fueling and rekindling of the cool
fire, or a fire that has burned down to the charcoal phase, operate the stove
at a medium to high firing rate for about 10 minutes to ensure that he catalyst
reaches operating temperatures.
There are some obvious signs of trouble that your inspection may reveal.
The temperature in the stove and the gases entering the combustor must be
raised to between 500F to 700F for catalytic activity to be initiated. During the
start up of a cold stove a medium to high firing rate must be maintained for
about 30 minutes. This ensures that the stove, catalyst and fuel are all sta-
bilized at proper operating temperatures. Even though it is possible to have
temperatures at 600F within minutes after a fire has been started, if the fire
is allowed to die down immediately it may go out or the combustor may stop
working. Once the combustor starts working, heat generated in it by burning
the smoke will keep it working. During re-fueling and rekindling of the cool
fire, or a fire that has burned down to the charcoal phase, operate the stove
at a medium to high firing rate for about 10 minutes to ensure that he catalyst
reaches operating temperatures.
CATALYST MONITORING
: It is important to periodically monitor the opera-
tion of the catalytic combustor to ensure that it is functioning properly and to
determine when it needs to be replaced. A non-functioning combustor will
result in a loss of heating efficiency, and an increase in creosote and emis-
sions. Following is a list of items that should be checked on a periodic basis.
• Combustors should be visually inspected at least three times during the
heating season to determine if physical degradation has occurred. Actual
removal of the combustor is not recommended unless more detailed in-
spection is warranted because of decreased performance. If any of these
conditions exist, refer to Catalyst trouble shooting section of this owner’s
manual.
• A good combustor is designed to withstand approximately 12,000 hours of
continuous use. This will translate into five to ten years of use, depending
on the length of your heating season and how often you use your stove.
Proper maintenance will increase the combustor’s effectiveness and pre-
vent many problems. Inspect your combustor before each heating season,
and during the season if your stove’s performance seems to change.
• You can get an indication of whether the catalyst is working by compar-
ing the amount of smoke leaving the chimney when the smoke is going
through the combustor and catalyst light – off has been achieved, to the
amount of smoke leaving the chimney when the smoke is not routed (by-
pass open) through the combustor.
CATALYTIC COMBUSTOR CLEANING:
Method #1
A vacuum cleaner may be used, but
never use high pressured air
to
blow the cells free of any build-up. This can damage the cell walls. Any cell
blockage can be removed with the use of a pipe cleaner or a cotton swab
as well.
Method #2
Should the combustor’s cells become covered with fly-ash, use a paint-
brush or soft-bristled brush and dust the combustor gently.
Never use anything abrasive to clean the combustor.
Method #3
Normally the catalytic combustor requires little or no maintenance, it gen-
erates such high temperatures and therefore is basically self-cleaning.
However, should the combustor become covered with soot or creosote, it
is possible to burn the accumulation off by opening the bypass and build-
ing a hot fire.
Once the hot fire is created, close the bypass halfway and burn for 30 to 60
minutes with the bypass left in this position.
Never use cleaning solvents
to clean it.
Check and clean the combustor, if necessary, before each burning season
and inspect the flue system for any signs of creosote buildup.
A clean flue helps prevent chimney flue fires.
CHK
PROCESS :
SCALE:
DWN
BLANK SIZE :
SIGN
C.N.
DATE
THIS DRAWING IS THE PROPERTY OF FPI LTD., IT MAY NOT BE COPIED IN WHOLE OR IN PART, OR DISCLOSED TO A THIRD PARTY WITHOUT OUR PRIOR WRITTEN CONSENT.
CURRENT REVISION
PREVIOUS REVISION
PART :
MAT'L :
ANGULAR =
INSIDE BEND RADII =
UNITS IN INCHES
DIMENSIONS =
TOLERANCES UNLESS
OTHERWISE STATED
SCALE
DO NOT
PROJECTION
3RD ANGLE
MODEL #
QTY.
REV.
±1°
±0.031
PART
NO.
FIREPLACE PRODUCTS INTERNATIONAL
04 JAN 2012
N/A
ASSEMBLY
A
A
WT
16 MAY 2012
051-530
WAYNE THURBER
051-530
COMBUSTOR ASSY 3.5 x 14 x 3 DEEP
N/A
F5100
1
1:4
4.125
16.259
14.000
3.500
15.200
14.197
0.875
3.067
3.942
2
3
1
4
Mass = 4.649 pounds
TOTAL AREA FOR AIR FLOW = 37.396
NOTE: SCREW METAL WRAP
TOGETHER CAREFULLY BY HAND
TO PREVENT DAMAGE TO CATALYST.
AVOID USING POWER TOOL.
4
904-149
2
SMS #8-18 x 3/8 LG
3
051-066
1
GASKET WRAP
2
051-065
2
COMBUSTOR 3.5" x 7" x 3" (16 CELL)
1
051-072
1
METAL WRAP 3"
ITEM
NO.
PART NUMBER QTY.
DESCRIPTION
Step 1
: Light the stove in accordance with instructions within this
manual.
Step 2
: With smoke routed through the catalyst (by-pass closed)
go outside and observe the emissions leaving the chim-
ney.
Step 3
: Engage the bypass mechanism and move to by-pass
open position. And again observe the emission leaving
the chimney. Significantly more smoke should be seen
when the smoke is not routed through the combustor (by-
pass open). Be careful not to confuse smoke with steam.
ACHIEVING PROPER DRAFT
: Draft is the force which moves air from the
appliance up through the chimney. The amount of draft in your chimney
depends on the length of the chimney, local geography, nearby obstructions
and other factors. Too much draft may cause excessive temperatures in the
appliance and may damage the catalytic combustor. Inadequate draft may
cause back puffing into the room and plugging of the chimney or catalyst.
