American Energy Systems Catalytic BBF - Manual (Page 43)

43
THE CATALYTIC COMBUSTOR
Catalytic combustors are designed to withstand 12,000 hours of continuous use or approximately five to six years of
operation; however, the life expectancy of any combustor is affected by many variables that can diminish this life
expectancy. There are many signs that the combustor is becoming a problem, these include:
a) Increased smoke from the chimney
b) Creosote buildup
c) Sluggish performance
d) Excessive smoking
e) Increased fuel consumption
f) Decreased burn times.
Proper and regular maintenance will not only increase the effectiveness of the combustor, it will also ensure problems are
spotted before expensive replacement of the combustor is required. Keeping the combustor cells clear increases the
amount of surface area available to promote the catalytic reaction. This will prevent sluggish operation and improved heat
output. A combustor may become clogged three ways: a) with fly ash, or b) from creosote, or c) from soot.
a) Fly ash is the normal accumulation of light grey ash. This ash comes from normal combustion and from
combustion particles being blown about by normal chimney draft. Gently brushing the combustor with a
clean soft brush or lightly vacuuming the combustor will remove fly ash. DO NOT use high-pressure air
to clean the fly ash as this air can damage the combustor cells. Using cotton swabs to clean ash out of a
specific cell is permissible. Care should be taken not to damage the cell.
b) Creosote is a brown tar-like substance that is a byproduct of incomplete combustion. The more creosote,
the more this is an indication that the stove is not burning efficiently and is burning at too low a
temperature. Creosote must be burned off the combustor. To burn the combustor clean, reinstall it back in
the stove and operate the stove at a higher temperature burn for about 30 minutes with the combustor
engaged. Repeat this step as necessary until the combustor is clean. REMEMBER: if the combustor is
covered in creosote, it is likely the chimney and associated pipe are also covered in creosote. Be sure to
have the chimney system cleaned. FAILURE to clean the chimney can lead to a chimney fire. Ensure the
combustor has completely cooled before attempting to remove it.
c) Soot is the dark granular material that can result from burning off the creosote or from burning foreign
material in the stove. Clean soot out of the system the same way that fly ash is cleaned from the
combustor.
d) A combustor has active elements on the honeycomb material. Without this material, the combustor
becomes inactive and the combustor will allow an ever-increasing percentage of particulates to escape up
the chimney. An inactive combustor will reduce a catalytic stove’s heat output and cause the chimney
system to build up creosote. If any large portion of the combustor becomes inactive, the entire combustor
should be replaced. Do not operate the stove when it is observed that a large portion of the combustor has
become inactive. If the homeowner is not sure about the quality of the combustor, contact Country Flame
or one of its local dealers to have the combustor inspected. It is illegal to operate a catalytic stove without
a properly functioning combustor.
CATALYTIC COMBUSTOR CLEANING
Refer to the section on removal of the catalytic combustor and then follow the following instructions.
a. Enough distilled water will be required to cover the entire catalytic combustor to a depth of ½” over its
total thickness at least three separate times. Do not use tap water as it contains minerals that may
adversely effect the designed operation of the combustor. Expect to use at least 3 gallons of distilled
water
b. White vinegar will also be required, as it will be mixed with the water to form a 50/50 solution that the
combustor will be soaked in. Expect to use at least 3 quarts of white vinegar.
c. Both the distilled water and white vinegar will be required to be heated so ensure that an old pot is