NOTE: DIAGRAMS & ILLUSTRATIONS ARE NOT TO SCALE.
10
CATALYTIC COMBUSTOR TROUBLESHOOTING GUIDE
Problem
Condition
Solution
Ash Build-up on Combustor Surface
Normal
Ash, a fluffy light gray powder, and soot, accumulate on the com-
bustor surfaces in normal use. Ashes accumulate as a result of the
smoke being burned within the combustor and carried out of the
firebox by the chimney draft. Soot is the result of previous creosote
deposits having been burned off or foreign materials being burned
in the firebox. This is normal and will be eliminated during the next
burn.
Combustor Clogging
Creosote
Combustor should be cleaned
(see Page 11)
. Do not use air pres-
sure or sharp objects to clean combustor.
Broken Combustor
Crack or Break
The combustor is manufactured from a ceramic material and there-
fore can crack or break. However, the combustor will still function if
cracked. If combustor is broken into pieces and dis-lodged from the
housing, it will need to be replaced.
Combustor Malfunction
Not Working
The combustor should last a minimum of 10,000 hours of opera-
tion. The combustor will lose catalytic capability over time. When
you see continuous smoke coming from the chimney, the combus-
tor should be cleaned. If the smoking persists, the combustor
should be replaced.
Combustor Problem
Thermal Erosion
This combustor does NOT experience thermal erosion. “Not ap-
plicable.” Applies to honeycomb combustors only.
Combustor Problem
Thermal Cracking
This combustor does NOT experience thermal cracking. “Not ap-
plicable.” Applies to honeycomb combustors only.
Combustor Problem
Combustor Peeling
This combustor does NOT experience combustor peeling. “Not
applicable.” Applies to honeycomb combustors only.
Reduced Combustor Performance
Combustor Clogging or Fatigue
Signs of combustor fatigue include reduced heat output and slug-
gish performance. Inspect and clean combustor. Replacement
may be required. Monitor performance and smoke coming from
chimney.
Combustor not glowing
Late stage of burn
Combustor does not need to be glowing to be working. Check
smoke exiting chimney to help determine if combustor is working
properly.
Appliance burning too hot or fast
Doors are not properly closed.
Close doors securely. Check door gasket.
Excessive draft
Adjust primary air control to lower setting.
Back-puffing or sudden internal ignitions
Operating technique
Open bypass and primary air control before opening to reload and
keep it open a few minutes after reloading.
Burn rate too low
Open air damper to allow for hotter burn.
Chimney down draft
In high wind areas, a specially designed wind cap may be neces-
sary.
Combustor or louvered housing plugged
Clean combustor / louvered housing of accumulated fly ash.
Appliance Smokes
Operating technique
Open bypass and air damper prior to reloading appliance.
Blocked Chimney
Examine chimney and vent pipe for blockage and creosote accumu-
lations. Check spark arrestor screen on your cap, if you have one.
Blocked outside air duct
Check the outside air inlet for blockage caused by snow, debris, or
insects.
