American Energy Systems O2 Catalytic - Manual (Page 35)

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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.
1. 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.
2. 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.
3. 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.
4. 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.
• 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
• 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.
• Both the distilled water and white vinegar will be required to be heated so ensure that an old pot is available to
heat the solution.
• A large metal wash pan will be required to soak the combustor in after the solution is heated. This wash pan must
be large enough to allow the combustor to be completely submerged in the distilled water/vinegar solution.
• A plastic coated wire or heavy cord will be required.