I recently installed a 2008 Harman Accentra insert. I followed the manufacturer's instruction, installing a chimney liner, and sealing the damper with sheet metal and rock insulation. I wrapped the bottom portion of the flex tubing with ceramic insulation. The pellet stove seems to work well, except after some time I get some irritation in my throat. I suspect there's ash/exhaust getting into the hot air output. It's a very small leak since I can't smell smoke(except during for a couple seconds during startup). My CO monitor doesn't register any CO on it's digital display. I noticed the decorative grate on the door where the air comes out had a light layer of ash. The hot air exhaust also had some light streaks of ash. The door gasket seemed a bit mashed up, so I replaced it. Now the door seems to push more firmly against the gasket when I latch it closed. Nevertheless I continue to develop irritation in my throat about 2 hours after the stove has started. My wife claims she doesn't notice anything. I cleaned all the ash streaks in the decorative grate. I ran the stove for a couple more hours and reexamined the door. I found a couple specs of ash. Again, I think a small amount of ash is getting into the hot air stream. I have no idea how to fix this issue. I'm worried the heat exchanger may have a small crack in it. I removed the compass plate, and the two other plates next to the burn pot to inspect, but have trouble seeing much. I honestly haven't cleaned the stove, but I'm not sure if a good cleaning would help this problem.
Any thoughts?
Any thoughts?