My FPX requires zero maint, only when I brush do I clean it and put in new interam gasket. Burns bright orange and no smoke in stack so working perfectly. What maint are you doing?
I think that is the problem, we have different units. I have the Large Flush Hybrid Fyre insert. I know another member on here has problems with it where flames lick the cat. As a result, he made a flame deflector out of metal mesh. I did the same and I do believe that helps with the flame licking. But, flame licking absolutely destroys the ceramic cats in short order. My first cat lasted one season before it was all cracked. The last ceramic, I got two years out of it. But, it was completely destroyed. I now have the steel cat and that lasts much longer. But, i hear they clog a little faster.
The new design of this insert does not use a cat. I have been around long enough to know that likely has to do with way too many warranty claims on cats for the previous design. This is a beautiful insert, but damn, it destroys catalysts.
I use this thing all winter, 24/7. I burn dry wood. I have a moisture meter. I am not buying that is the issue. I have a tall chimney, with a 30ft liner. I am sure I have a strong draft, which may contribute to the flame licking. I keep the air control at 60-80% closed for most of my burns. I try to keep the cat temps 1000-1250 degrees. I have spoke with the manufacturer of the cats, they approve of that. They claim 1400 is totally fine. They want hot fires in order for the cat to clean itself.
But, one of my problems is that I choke it down when I leave for work. When I get home 8 hours later, the cat is engaged, fire cold and cat temps at only 200 ish. They say that can clog the cat. So, I will try to be mindful and make sure I get the next fire nice and hot.
As far as maintenance, I treat this thing like a Ferrari and my father, who is not mechanically inclined, would have had this thing removed years ago. I have an auto detail attachment that I hook up to my ash vac. I vacuum the cat almost daily when I get home from work. It only takes about a minute. That is all I really do. I then have to take the cat out after about two months and do a full pipe cleaner cleaning of all 3000 cells, which takes about 2 hours. I then put on a new gasket and put it back in. I get mixed information with regards to compressed air. But, when I had the cat out 2 days ago, I hit it with a light cleaning with canned compressed air for a computer. I think that is fine and will likely add this to my repertoire. But, I may have to make some sort of adapter for the hose because I don't think I can hit the cat directly from below.
Any suggestions? I love the look of this insert. I like it a lot when it works. But, it plugs steel cats way to fast and ceramic cats are like just throwing in a lamb to be slaughtered. I will sell the brand new ceramic cat I have in the basement to fund my next steel cat.