If you're not getting gasification out of both nozzles, then you're going to get smoke. One thing to make sure of is that both nozzles are clear before you put in a new load of wood. You can do that with the hoe cleaning tool they provide with the boiler. Another point is that 2.5 weeks is pretty early in your gasification career--and early in the boiler's life. There is moisture in the refractory that takes awhile to work itself out. When it does, you'll get more reliable gasification. The 80 has lots of refractory, so that might be why it's taking longer than normal. Back to the nozzles: You want to make sure that your fuel is on the nozzles as much as possible. I rarely fill my 60 up all the way. Instead, I make pyramids of wood in the firebox over the nozzles. Finally, you want to keep your boiler as hot as possible at all times. The new controller (you're right--you've got the old one) allows you to go up to 195 degrees and it reads out in F. I just replaced the old one with the new one a few weeks ago, and I'm getting a lot better performance at high temps and by controlling the fan speed, which is something you can't do the the old one. I'd try to ding the dealer for a cheap or free replacement. It's definitely worth it. Out other member with an 80 and a couple of guys with 60s have tried disconnecting one blower, since the two-blower arrangement is apparently too powerful for most conditions. With the new controller, you can modulate the fans down to 50%, which I suspect accomplishes about the same thing, plus you can set it higher at 10% increments. Another thing you can try is to block off one nozzle with a piece of firebrick. That effectively cuts your output by half, but it sounds like an 80 is way more boiler than you really need, so it's certainly worth a try.
Bear in mind that some what you're calling "smoke" is probably just steam. That's the stuff that dissipates 20 feet from the stack and it's usually white. Even "dry" firewood has 15 percent moisture, and it has to go somewhere. You notice it more on very cold days.
Finally (and I mean it this time), if you wood isn't really dry, you're going to get smoke--usually whispy blue stuff. You can get around that to some extent by building a small, hot fire with dry wood, and then toss a couple of not-so-dry chunks on top. If I were you, I'd experiment with smaller fires and more frequent loading just to see if you can get a consistently clean burn. Then take it from there.
BTW, I'm originally from Coloma.
