Austroflamm Integra (model year 1991)

CJamesEE · Feb 24, 2015

I am attempting to determine the normal burn sequence after the 8 minute initial start-up for an Austorflamm Integra insert. Typically, I have a buildup of ash (+ 3/8" thick) in the burn pot after 4 to 6 hours of burn time which completely seals the bottom holes. I have experienced three good burn sequences (in my opinion) where the combustion motor ramps up every 15-20 minutes (estimated) blowing the ash from the burn pot then ramps down. This sequence kept the burn pot clean and prevented the ash from building up in the burn pot, i.e. prevented the bottom burn pot holes from becoming clogged. Note; these sequences occurred when restarting the insert after a 35-40 minute shutdown, but does not always occur with every warm restart.

During typical burn sequences the combustion motor ramping is less frequent and occurs after the ash build up in the burn pot. Once the build up occurs the increased combustion motor speed is not sufficient to evacuate the ash from the burn pot.

Is this an operational issue with the insert, a pellet issue, or other?

Background:

First winter full winter using this insert - came with the house we purchased last year.
Chimney Sweep installed new steel flexible pipe and capped chimney (August 2014).
Fuel source - Tractor Supply Company premium wood pellets.
Typical dial setting is between 10 - 12 (manual dial, no thermostat, no digital display)
Cleaned the intake air sensor in December 2014.
Cleaned the combustion motor blades and installed new gasket.
Cleaned low limit switch. Installed new gasket
Installed new door gasket and adjusted door. (Helped reduce lazy flame that burned to the left)
Installed new lower cast wall gasket.
Installed new auger motor.
Installed new convection fan assembly.
Thoroughly clean the stove every two to three months (when in use).

Mark_ms · Feb 25, 2015

get

CJamesEE said:
I am attempting to determine the normal burn sequence after the 8 minute initial start-up for an Austorflamm Integra insert. Typically, I have a buildup of ash (+ 3/8" thick) in the burn pot after 4 to 6 hours of burn time which completely seals the bottom holes. I have experienced three good burn sequences (in my opinion) where the combustion motor ramps up every 15-20 minutes (estimated) blowing the ash from the burn pot then ramps down. This sequence kept the burn pot clean and prevented the ash from building up in the burn pot, i.e. prevented the bottom burn pot holes from becoming clogged. Note; these sequences occurred when restarting the insert after a 35-40 minute shutdown, but does not always occur with every warm restart.

During typical burn sequences the combustion motor ramping is less frequent and occurs after the ash build up in the burn pot. Once the build up occurs the increased combustion motor speed is not sufficient to evacuate the ash from the burn pot.

Is this an operational issue with the insert, a pellet issue, or other?

Background:

First winter full winter using this insert - came with the house we purchased last year.
Chimney Sweep installed new steel flexible pipe and capped chimney (August 2014).
Fuel source - Tractor Supply Company premium wood pellets.
Typical dial setting is between 10 - 12 (manual dial, no thermostat, no digital display)
Cleaned the intake air sensor in December 2014.
Cleaned the combustion motor blades and installed new gasket.
Cleaned low limit switch. Installed new gasket
Installed new door gasket and adjusted door. (Helped reduce lazy flame that burned to the left)
Installed new lower cast wall gasket.
Installed new auger motor.
Installed new convection fan assembly.
Thoroughly clean the stove every two to three months (when in use).

Welcome to the Forums.
Here is a link to Integra Tech manual if you don't already have one.

You are moving in the right direction.

It sounds like your issues are a combination pellet and insert.

Did you replace the gaskets around the windows? if so do not gasket at the top of the window just the sides and bottom of glass. The gap at the top is your air wash system. the manual does not tell you this.

When you cleaned air sensor did you pull it completely out to inspect? The two flanges will get dirty and need to be cleaned also. Clean the intake tube if you have not done so.

What size flue pipe was installed? how much of a run (elevation) do you have. 3 inch will cover you in most instances but sometime 4 inch may be needed.

When you take off the lower cast wall, there are 4 square holes directly behind the tubes. these holes will clog with ash limiting airflow. You can also see them when you open combustion chamber from right side, there is an inspection port on right side of stove just in front and below circuit panel. Buy one of those small vaccum tools that you would use for a computer to get hard to reach areas.

I do not have numbers on my control booard just hash marks to indicate settings I usually run from 1/2 to 3/4 depending on need.

You can adjust auger feed rate and combustion fan speed by the potentiometers located on control board. You may have to experiment with these setting to find what works for your situation.

Pellets: Try burning different brands of pellets get 3-4 bags and burn them and see what your stove likes. Check out pellet reviews at the top of the forum to get some ideas for consensus. What works for one stove does not always for another.

You have one of the better stoves made even for it's age.

Hang in there.

PS Always unplug stove before working on it !!

CJamesEE · Feb 26, 2015

Mark_ms said:
get

Welcome to the Forums.
Here is a link to Integra Tech manual if you don't already have one.

You are moving in the right direction.

It sounds like your issues are a combination pellet and insert.

Did you replace the gaskets around the windows? if so do not gasket at the top of the window just the sides and bottom of glass. The gap at the top is your air wash system. the manual does not tell you this.

When you cleaned air sensor did you pull it completely out to inspect? The two flanges will get dirty and need to be cleaned also. Clean the intake tube if you have not done so.

What size flue pipe was installed? how much of a run (elevation) do you have. 3 inch will cover you in most instances but sometime 4 inch may be needed.

When you take off the lower cast wall, there are 4 square holes directly behind the tubes. these holes will clog with ash limiting airflow. You can also see them when you open combustion chamber from right side, there is an inspection port on right side of stove just in front and below circuit panel. Buy one of those small vaccum tools that you would use for a computer to get hard to reach areas.

I do not have numbers on my control booard just hash marks to indicate settings I usually run from 1/2 to 3/4 depending on need.

You can adjust auger feed rate and combustion fan speed by the potentiometers located on control board. You may have to experiment with these setting to find what works for your situation.

Pellets: Try burning different brands of pellets get 3-4 bags and burn them and see what your stove likes. Check out pellet reviews at the top of the forum to get some ideas for consensus. What works for one stove does not always for another.

You have one of the better stoves made even for it's age.

Hang in there.

PS Always unplug stove before working on it !!

Gasket around individual glass panes have not been replaced. I will investigate.

Air sensor was removed and cleaned with alcohol and a soft toothbrush then rinsed with water and allowed to air dry.

When the air sensor was removed, the vacuum hose (small 5 gallon shop vac) was inserted in the intake up to be bend in the intake tube. Air appeared to move freely from the burn pot receptacle to the vacuum hose. Inserted a 6 AWG conductor from the burn pot receptacle air intake opening to verify no blockage.

4" steel flexible pipe was installed. Two story house with chimney extending to above roof peak.

Verified square openings behind heat exchanger were clear. Inspection port cover and combustion motor were removed. 3/4" spiral wound pipe cleaner brush was inserted to scrub the walls of combustion air exhaust plenum. Inspected with flashlight.

Dial description was misleading, i.e. no numbers. The 10 -12 was in reference to an analog clock. So the dial setting is actual slightly above 1/4 to 1/2 for normal operation, in my case. Presently, the 3/4 (+/-) setting causes the convection fan to vibrate - higher or lower settings are fine. (Will have to return in April prior to the warranty expiring.)

Prior to adjusting the potentiometers, I wanted to understand the proper operation of the insert, i.e. managing expectations.

So, what is a typical Austroflamm Integra flame? During the 8 minute start-up sequence, the flame is vibrant and bright yellow. Typically, forms a "V". After the pellet dump at the end of the start-up sequence, the combustion motor ramps down and the flame becomes a dual yellow. Typically, the flame is the width of the burn pot and varies in height. The exception occurs when the combustion motor ramps up.

Mark_ms · Feb 26, 2015

I don't think I would have rinsed air sensor with water, but that is just me. Soft anti static brush would suffice.

Here is a link to video of a Integra flame pretty typical Left side of flame tends to be higher after initial startup.

Convection fan should not vibrate at any setting, could it be harmonics or vibration of hopper lid, surround panels, decorative top? You may need new bushing or if new might not be seated properly.

Edit: I see you replaced convection fan so bushing may not seated properly

lakensea · Feb 26, 2015

Your combustion motor should not ramp up on its own after the startup sequence as the Integra I models do not have a self cleaning function - only the newer Rika Integra II's have that. I have one of each.

CJamesEE · Feb 26, 2015

Mark_ms: could you explain your reference to the "bushings". The convention fan came as one assembly (purchased in June 2014) and was secured to the existing convention fan assembly bracket using sheet metal screws. (Of course, I removed the old convection fan first.) The vibration (clatter) sounds as if the squirrel cage is hitting the housing. However, I have not verified the same.

Thanks for the video link and all the feedback. Based on the video, my insert appears to have a typical Austroflamm flame. I have notice my flame does not pull as hard to the left since adjusting the door and replacing door gasket.

lakensea: the three burn sequences I described in the original post seem to be just that a "self cleaning function". The burn pot had very little ash, bottom holes were clear and ash tray was filled. However, I could not find anything in the manuals alluding to a "self cleaning function". The only thing that was consistent was that the sequences occurred when re-igniting the insert while the insert was still warm, but this does not occur with every warm start. I do notice the combustion motor ramps up and down more frequently when the house is cold (64 - 67F). I have also noticed the auger motor and the red light continue to cycle, which does not align with an insufficient air event. According to the manual, an insufficient air event should shut down the auger motor.

So how do you rate the newer Rika Integra II's?

Mark_ms · Feb 27, 2015

Here is a picture of the convection fan bushing. It is installed on the right side of fan. there is only one bushing,, pic shows the outside view and the right is the inside view.
I don't think that your fan is hitting the housing. the blades of the squirrel cage probably would not tolerate that for too long.

Regarding fan surging are you sure your hearing combustion fan? I cannot here mine over the sound of the convection (room) air it's is pretty quiet. I get a little surge in my convection fan from time to time As lakensea said your combustion fan should not surge after initial startup.

CJamesEE · Feb 27, 2015

I uploaded two videos on youtube.

Austroflamm Integra (model year 1991) - Flame after startup

Austroflamm Integra (model year 1991) - Short Vibrant Flame

The insert definitely becomes more audible during this event. Please review the videos and provide your feedback. Please note; video sound quality is not great.

Correction: I actually timed the startup sequence. The startup sequence last for 14 minutes not 8 minutes, which was based on the original manual. The startup sequence appears to align with an EPROM 3.1.

Mark_ms · Feb 27, 2015

Flame looks like it should in both videos.

Audio portion is not great, but sounds normal when you can hear it, but I don't hear well anyway. :rolleyes:

CJamesEE · Feb 27, 2015

The "short vibrant flame" video shows what happens when the combustion motor speeds up. (This particular event happened about an hour after starting the insert.) As seen in the video, the air velocity increases, the flame becomes very short and violent ("V" shaped flame when above burn pot), and the pellet embers fly from the burn pot when additional pellets drop during this "stage". Unless someone has an alternative theory, I can only associate this "stage" with the combustion motor speed increasing. I just have not been able to determine what initiates the same.

What's the proper method for starting the insert.

My procedure:
Small hand of pellets (basically cover the bottom of the burn pot)
Turn switch "on" then "off" (starts the combustion fan)
Add lighting gel
Light pellets
Partially latch door (allows airflow around door so pellets will catch)
Allow to burn for 1 to 2 minutes
Latch door completely
Allow to burn for an additional 1 to 3 minutes until pellets are red hot (embers with flames).
Turn switch "on"

Thanks for all the feedback.

buster 1 · Feb 28, 2015

it sounds like the mother board is going bad .

CJamesEE · Feb 28, 2015

The insert was started around 7:00 am this morning. The "self cleaning function" has occurred about every 62 minutes (1 hour 2 minutes) with the dial set between 10:00 and 11:00 (reference to analog clock, no numbers on face plate) for a total of four events at the time of this posting. The combustion motor speed does increase, i.e. the audible motor pitch increased which was detectable when kneeling near the left side of the insert with the room quiet. The "self cleaning function" lasted for approximately 2 minutes similar to the "short vibrant flame" video. From my observations, this insert does have a "self cleaning function" programmed into the chip. I can only assume a new EPROM chip with this algorithm was installed in the insert if the same was not originally designed with this feature.

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