Encore 2040 cat c overheat

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Willcgt77

New Member
Dec 4, 2022
76
Exeter NH
I was doing that first but it kept going higher than I wanted. The cat temp. So I changed this and let it off gas. Wouldn't let it go too long or it will overfire. I've found 8 min in a good number. Then I gradually turn down. Haven't hade a spike above 1450 since I started doing this. Just slow rides up then settles around 1200 and sits there for a few hours then will come down with the load. I had an overnight last night that burned from 8:30 and I tossed a couple small splits on a pile of coals at 6:30 this morning. It was filled all the way to the griddle top. Large splits I would say 6 inches. That helps top. Large splits on the bottom smaller as you start to stuff it full. I find if I have smaller 4 inch splits it burns hot and fast
This is great info, ill give it a try. never thought I would be spending so much time learning a stove. I hope i can get to the point where I can load all the way to the top! Can’t get past half load comfortably. Next year will be better with larger splits.
 

Anthony09

New Member
Oct 29, 2022
64
Alabama
That seems real hot for a half load. Was it a hot reload or cold?
I agree gotta be something leakin air or something. 350-400 cat
300 stt. Both climbed steady(normal for hr or two, then just kept goin. I guess I’ll just keep it under half load till they figure something out definitive. It’s just like no matter the procedure peak burn for hr or two in middle is insane. Before and after it’s great.
 

JohnDaileyNH

Feeling the Heat
Oct 10, 2022
278
Seacoast, NH
No problem, good luck. Seems to be they all run a little different based on individual set up and wood quality. Definitely a lot more effort than I thought. Had I known this I would have probably went with something a little more straight forward. But the stove is in my living room and this one looks fantastic
 

Willcgt77

New Member
Dec 4, 2022
76
Exeter NH
I also wait until my cat temps get down around 600. I try not to reload to far over 600 especially if I am stuffing the box. Seems to be easier to control that wa
The new probe will help with this, kind of a guessing game with the factory installed probe. I want to see real numbers.
 

Anthony09

New Member
Oct 29, 2022
64
Alabama
This
I had a couple times recently my cat got hot so changed my process a little. I load the stove and let the splits burn got 5-8 min depending on the load. Then I shut the damper. When cat hits 800 I shut the air down halfway. Then I go in increments until it's all the way down shut. Try snd get it shut by the time the cat hits 1000-1100. Seems to be working well. Let the splits off gas right away and keeps it more under control it seems. I also use big splits when I load up for the overnight burn. During the day I burn whatever since I'm home. Usually half loads
This is similar to my best procedure. I’ve tried hot warm cold reloads, there are definitely ways that work best for overall burn. But a couple hrs in no matter what I do it’s crazy
 

JohnDaileyNH

Feeling the Heat
Oct 10, 2022
278
Seacoast, NH
I've read different things about these cats too. Some things say they are rated to 1700 consistent but I find that hard to believe. I think a short spike is fine but 1800 is hot. You should take a look at it when it's cool and see how it looks.
 

Anthony09

New Member
Oct 29, 2022
64
Alabama
No problem, good luck. Seems to be they all run a little different based on individual set up and wood quality. Definitely a lot more effort than I thought. Had I known this I would have probably went with something a little more straight forward. But the stove is in my living room and this one looks fantastic
I agree I love the look and it’s heat my home great. And unfortunately way I’ve installed it it’s gonna be a real pain to switch stoves so hopin I don’t have to. Half loads I’m ok with, not that cold here but it would be nice to really load up for overnight. Last night was btwn 1/2-2/3 started at 8, n at 4 when got up stove top was still 375 with lots of big coals still puttin off good heat n house was warm. Load little less than halfway since I leave bout 5 n started right up n gives me time to get cat goin n air down for wife before I leave. I think that’s real good just wish I could load more at night when we do have 20s for weeks at a time
 

Anthony09

New Member
Oct 29, 2022
64
Alabama
I've read different things about these cats too. Some things say they are rated to 1700 consistent but I find that hard to believe. I think a short spike is fine but 1800 is hot. You should take a look at it when it's cool and see how it looks.
I plan on it, it’ll probably be cool when I get home today. It wasn’t really quick spike. It was btwn 16-18 for 2 hrs probably
 

JohnDaileyNH

Feeling the Heat
Oct 10, 2022
278
Seacoast, NH
The new probe will help with this, kind of a guessing game with the factory installed probe. I want to see real numbers.
I've never used the factory probe but bi-metal like that has to have a significant delay, same as the stove top thermometer. I would imagine we'd see 50-100 degree difference if we put a IR gun to it and checked that way. At least now you get real time accurate numbers to work off of. Not quite sure how I ran this stove without a thermometer. My cat temps had to be insanely high cause I would just let the stove temp get up to like 500 and shut it down
 

Anthony09

New Member
Oct 29, 2022
64
Alabama
I've never used the factory probe but bi-metal like that has to have a significant delay, same as the stove top thermometer. I would imagine we'd see 50-100 degree difference if we put a IR gun to it and checked that way. At least now you get real time accurate numbers to work off of. Not quite sure how I ran this stove without a thermometer. My cat temps had to be insanely high cause I would just let the stove temp get up to like 500 and shut it down
Haha there is no tellin what was happenin
 

JohnDaileyNH

Feeling the Heat
Oct 10, 2022
278
Seacoast, NH
N I can’t just leave damper open cause stt Is peaked as well n it goes crazy when I do
Yeah that is a solid burn. The temp spike like that is rough. Could be a leak especially if the stove temp is peaked. When I had my cat go up to 1700 my stove temp was low, maybe 450. That is how I concluded it all offgassed at once and switched the process around
 

Anthony09

New Member
Oct 29, 2022
64
Alabama
Yeah that is a solid burn. The temp spike like that is rough. Could be a leak especially if the stove temp is peaked. When I had my cat go up to 1700 my stove temp was low, maybe 450. That is how I concluded it all offgassed at once and switched the process around
I hope so. I agree with offgassing it generally happens to me that’s why I’ve been burning how you said you do now. N I do use large splits too. Hopefully find a leak n at least that way I can open damper if cat overheating
 

Jayci.Maine

New Member
Dec 18, 2022
4
Rockland, Maine
I had a couple times recently my cat got hot so changed my process a little. I load the stove and let the splits burn got 5-8 min depending on the load. Then I shut the damper. When cat hits 800 I shut the air down halfway. Then I go in increments until it's all the way down shut. Try snd get it shut by the time the cat hits 1000-1100. Seems to be working well. Let the splits off gas right away and keeps it more under control it seems. I also use big splits when I load up for the overnight burn. During the day I burn whatever since I'm home. Usually half loads
TL;DR: 1. JohnDaileyNH, could I see some photos or a detailed description of the way you installed your cat thermometer? Particularly where it's sitting inside relative to the cat.
2. THANK YOU all for the detail in this post, you saved me and my energy bills!!!

Full Story: JohnDaileyNH you are pretty much my hero this week!! And Anthony09, you played no small role 😄 I spent a WHILE reading through this whole thread yesterday, and the way you guys have been consistently workshopping, and specifically sharing your trial and error-- I swear this is the most useful thing I have ever found on the internet.

I've been having all the same exact problems described in this thread. I have a Defiant 1975 that's at least 10 years old, probably more like 15-20. We just bought the house and I've been researching like crazy how to best use it-- with all the energy costs skyrocketing.

I carefully replaced every gasket and sealed a few other gaps with furnace cement. I replaced my whole door handle and pawl assembly to be sure I'm getting a tight seal. It actually didn't HAVE a catalytic combustor, so I bought a metal one because I read those can be better than ceramic. All that has helped immensely (now I'm getting the heat off one log, that I *was* getting off 3-4!!
🥳🥳🥳

Anyway! I basically just created a membership so I could thank you guys. Since I'm here, I did have a couple follow ups.

JohnDaileyNH-- could you possibly share any photos of your installed digital cat probe setup? If you're not cooling your stove off, maybe just an exterior photo and a description of the inside? I'm wondering where you situated the probe near the catalyst-- is it on/under/loose/anchored? Touching the catalyst or just in the chamber underneath? It seems like it's working great for you so any details would help.

For anyone else here with these issues-- I followed John's exact instructions in the post I've referenced here, and immediately got a DRASTICALLY better result. I don't even have a cat probe, but I just did the best I could with John's instructions and ballparking it from the STT. Magic. I've been needing to reload every 90-120min, and last night I got 10pm-6am with a hot stove and a warm house in the morning!! (And no bonfire😅). 🎉🎉🎉

Okay, sorry, this is getting really long, one last thing. Because of my issues with overheating, I've been really gunshy about adding more wood. I've been getting freaking 800°+ (maxed STT) from 3-4 logs with everything closed!!

Watching YouTube videos and pulling my hair out, it dawned on me-- by using less logs, I'm leaving soooo much space for extra AIR in there!! So, after double checking my homeowners insurance policy 😏, I got gutsy and filled the thing as tight as I could, so there would be less air. I think it made a huge difference.

Here's a screenshot of the wood-filled examples from YouTube, and a couple pictures of my stove, just to be friendly.

7C5B5FF9-96E8-4D4C-A4E0-02CE68AD1D1A.jpeg CA6A69E9-E0E8-4F24-A6B5-F7B945F0BB0F.jpeg BE089495-DFCC-4EAB-8ED7-206A84522AE9.jpeg 7E9A6D7E-F1AF-4623-89A4-AC5FB0D05532.jpeg
 
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JohnDaileyNH

Feeling the Heat
Oct 10, 2022
278
Seacoast, NH
TL;DR: 1. JohnDaileyNH, could I see some photos or a detailed description of the way you installed your cat thermometer? Particularly where it's sitting inside relative to the cat.
2. THANK YOU all for the detail in this post, you saved me and my energy bills!!!

Full Story: JohnDaileyNH you are pretty much my hero this week!! And Anthony09, you played no small role 😄 I spent a WHILE reading through this whole thread yesterday, and the way you guys have been consistently workshopping, and specifically sharing your trial and error-- I swear this is the most useful thing I have ever found on the internet.

I've been having all the same exact problems described in this thread. I have a Defiant 1975 that's at least 10 years old, probably more like 15-20. We just bought the house and I've been researching like crazy how to best use it-- with all the energy costs skyrocketing.

I carefully replaced every gasket and sealed a few other gaps with furnace cement. I replaced my whole door handle and pawl assembly to be sure I'm getting a tight seal. It actually didn't HAVE a catalytic combustor, so I bought a metal one because I read those can be better than ceramic. All that has helped immensely (now I'm getting the heat off one log, that I *was* getting off 3-4!!
🥳🥳🥳

Anyway! I basically just created a membership so I could thank you guys. Since I'm here, I did have a couple follow ups.

JohnDaileyNH-- could you possibly share any photos of your installed digital cat probe setup? If you're not cooling your stove off, maybe just an exterior photo and a description of the inside? I'm wondering where you situated the probe near the catalyst-- is it on/under/loose/anchored? Touching the catalyst or just in the chamber underneath? It seems like it's working great for you so any details would help.

For anyone else here with these issues-- I followed John's exact instructions in the post I've referenced here, and immediately got a DRASTICALLY better result. I don't even have a cat probe, but I just did the best I could with John's instructions and ballparking it from the STT. Magic. I've been needing to reload every 90-120min, and last night I got 10pm-6am with a hot stove and a warm house in the morning!! (And no bonfire😅). 🎉🎉🎉

Okay, sorry, this is getting really long, one last thing. Because of my issues with overheating, I've been really gunshy about adding more wood. I've been getting freaking 800°+ (maxed STT) from 3-4 logs with everything closed!!

Watching YouTube videos and pulling my hair out, it dawned on me-- by using less logs, I'm leaving soooo much space for extra AIR in there!! So, after double checking my homeowners insurance policy 😏, I got gutsy and filled the thing as tight as I could, so there would be less air. I think it made a huge difference.

Here's a screenshot of the wood-filled examples from YouTube, and a couple pictures of my stove, just to be friendly.

View attachment 305544 View attachment 305545 View attachment 305546 View attachment 305547

My stove is rubbing so I can't show a pic. But you want the probe inside 2-2 1/2 inches. I put it in the same spot that the factory probe would go and it sits just below the cat. This should be the "exhaust" of the cat. Here are the pics I have. Glad I can be a help. I'm very much learning and figure more info out here the better so the brain trust can work on my issues. I posted the links to the items you need. The probe is 6 inches long so it will stick out the back

20221020_123304.jpg
 

JohnDaileyNH

Feeling the Heat
Oct 10, 2022
278
Seacoast, NH
From what I have learned on load size, I think you have to load it based on your needs. I tend to use smaller loads if I need more heat so I can burnt hem hotter and worry less about cat temps. On a full load I want it to burn low and slow.
 
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GrumpyDad

Minister of Fire
Feb 23, 2022
1,174
Champion, PA
This is great info, ill give it a try. never thought I would be spending so much time learning a stove. I hope i can get to the point where I can load all the way to the top! Can’t get past half load comfortably. Next year will be better with larger splits.
look behind your stove where you see the large round hole, and then have someone (or you if you can reach) move the air intake when the stove is completely cold. You should see the thing completely close when you shut it down all the way, and then open a good bit when you open it all the way.
 

JohnDaileyNH

Feeling the Heat
Oct 10, 2022
278
Seacoast, NH
This is great info, ill give it a try. never thought I would be spending so much time learning a stove. I hope i can get to the point where I can load all the way to the top! Can’t get past half load comfortably. Next year will be better with larger splits.
Loading it all the way up bigger splits work better. Then as I get closer to the top they get smaller as I tetris it all together. Last night I filled it at 6:30 and then just relit my some kindling on the coals at 4:45 before I went to the gym. Cat was at like 400. So the kindling went up and I just tossed a few splits on a few min later and cat re-engaged and off I went by 5:15
 
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Jayci.Maine

New Member
Dec 18, 2022
4
Rockland, Maine
From what I have learned on load size, I think you have to load it based on your needs. I tend to use smaller loads if I need more heat so I can burnt hem hotter and worry less about cat temps. On a full load I want it to burn low and slow.
That makes sense. I've been doing smaller loads for sure, but I've had trouble overfiring with the mid size- probably half full. My big goal has been trying to achieve an overnight burn, so that's where I was talking about the full load. My full loads are still reading STT at 600° majority of the time. I'm excited to try the cat thermometer that you have so I can have a better picture of what's going on!

I found a video of someone who just fills her whole stove every time- so she can just "set it and forget it" in the morning, midday, and at bedtime. Without the babysitting.

We're using it as our only heat source, on a windy hilltop, for 6 people, in an 1800sq ft house, with drafty windows, and I've had trouble keeping the house temp to 58° on cold days.

Since I followed your advice last night, it's been at 70°ish for almost 24hrs straight-- just a big load at 5pm, reload at 10pm, reload at 6am, and just now reload at 2pm. 👏🏻👏🏻👏🏻
 

JohnDaileyNH

Feeling the Heat
Oct 10, 2022
278
Seacoast, NH
That makes sense. I've been doing smaller loads for sure, but I've had trouble overfiring with the mid size- probably half full. My big goal has been trying to achieve an overnight burn, so that's where I was talking about the full load. My full loads are still reading STT at 600° majority of the time. I'm excited to try the cat thermometer that you have so I can have a better picture of what's going on!

I found a video of someone who just fills her whole stove every time- so she can just "set it and forget it" in the morning, midday, and at bedtime. Without the babysitting.

We're using it as our only heat source, on a windy hilltop, for 6 people, in an 1800sq ft house, with drafty windows, and I've had trouble keeping the house temp to 58° on cold days.

Since I followed your advice last night, it's been at 70°ish for almost 24hrs straight-- just a big load at 5pm, reload at 10pm, reload at 6am, and just now reload at 2pm. 👏🏻👏🏻👏🏻
Thats awesome. My stove has pretty much been running nonstop for a week now. But pretty much all year. Effectively heats about 2000 Sq ft of my house. I need box fans to help move some heat because of the layout but it is plenty big enough.

You can load it all the way up to the griddle. As much wood as can fit as long as it closes fully. I run the same process and just leave it be. I find bigger splits work better. As big as can fit through the top load.

My oil heat only turned on once last Monday when I let the stove go out to have the chimney cleaned. Otherwise it's always 67-72 in here
 
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Willcgt77

New Member
Dec 4, 2022
76
Exeter NH
From what I have learned on load size, I think you have to load it based on your needs. I tend to use smaller loads if I need more heat so I can burnt hem hotter and worry less about cat temps. On a full load I want it to burn low and slow.
That makes good sense
 

JohnDaileyNH

Feeling the Heat
Oct 10, 2022
278
Seacoast, NH
What are you getting for flames with the air closed all the way. My flapper is closing all the way but I still have mild flames for awhile after reloading. Maybe this is normal.
On my load today I could only see some flames in the back corners dancing around. Definitely not a box full of flames. I think you want to see some flame in the box I have a few splits on now just to get me a gap to my night load. I see flames on these but also running it hot since the family is home and they get cold if it's not 72 in here now
 

Willcgt77

New Member
Dec 4, 2022
76
Exeter NH
Ha ha 72/74 sounds about right for this household aswell. My flames tend to be in the front near the glass. With some messing around I can get them to die back on a long burn. If I do it to quickly I still get some back puffing. I'm still going with my theory that my wood is split to small. Definitely feel better about the stove and operational learning curve since joining the group! Have a great night around the fire.