I just recently rediscovered this post, and it's been 2+ years now with our BK Ashford insert. I think it will be helpful for some to update my situation coming from your average Joe who is definitely a lot less knowledge and handy than most on this forum.
First off, the stove window is very large and looks sharp. Last season in NH was one of the warmest on record but even so, the oil furnace never kicked on once last winter for the zone with the BK, but we had it running almost 24/7 - we live in a +-2200 SF ranch. The way it's layed out, this heated about 2/3 of the house and kept the main family room about 65-68 degrees typically.
However, the initial problems in my original post were extremely frustrating. After speaking our local rep multiple times and then with BK corporate (and showing them a video of smoke gathering when I activated the CAT, it was confirmed draft was the issue, even with installed 6" double insulated liner (lacking correct name)
Local installer (who is also chimney mason and sweep probably should have known or tested for sufficient draft in my opinion - but benefit of the doubt here) claims he will no longer install BK unless chimney height is above BK minimum - I can look into our chimney height if someone is interested, I don't know off hand.
Season 1 was frustrating. Burning through wood almost as if it were still an open fireplace, throwing ok heat, almost never reaching min CAT temp to even activate it. Entire season with no steady CAT activation.
Had chimney extended 3' that Summer. Next burning season was night and day. Easily achieved CAT min temp, would stay in zone and really threw out more heat.
Here are some tips/issues/red flags I wish I had known from the start:
1- make sure you're burning dry wood - I didn't use a moisture meter until later, and turns out mine was pretty dry, but not always the dryest.
2- When activating the CAT push it in ALL the way. I used to try pushing it in half way, 3/4 of the way as I wasn't sure, spoke to BK corp and they informed me I was doing it wrong most of the time. Keep it all the way out when getting up to temp.
3- if you smell smoke, almost pleasant smell of smoke and/or see slow billowing flames curling to the window in CAT mode, you may have a draft issue like I did.
4- If things are working properly you should see the CAT honeycombes glow orange, at least a few of them turn orange, after frustrating times there is not much better than seeing all of them glow orange.
5- just found this out. If stove isn't reaching CAT activation zone easily, and it used to - take a look at honeycombes. They should be clean, mine were covered in soot. Shop vac isn't enough, I used a cheap watercolor paintbrush, stuck it in every comb and brushed entire surface area. Next load and a week later they are all glowing orange as you can see in the pic.
Don't mean to write a novel, but I hope that this is helpful info for some.
Would I buy it again???? The answer is yes, but it would be a stronger "yes" if not for all of the issues. I love waking up and starting the fire, it extremely cool looking with the big display window, I have access to firewood and I prefer the heat from a wood stove. I haven't experienced the really long burn times I read about, but 3-5 hours or so of good heat works for me.
Couple of pics from today, wanted to show the orange glow of the combs with activated CAT but hard to see.
