First of All hello all of you Pellet master people
my name is Rod. I am the owner of the site you keep talking about. hearthtools.com.
We sold pelletmaster for many years as a dealer and California distributor to other dealers and still servicing over 150 units every year.
I have a lot of hand on experience with many kinds of PM installations.
We try to stock most part for this stove for I still think it is one of the best for its time.
I want to say sorry to some of you that are waiting for manuals
Our Master copies got messed up and I am trying to find some fresh ones to make copies to send out to you all.
You get a Trouble shooting guide with the manual when we send the manuals out.
Let me try to answer some of your questions about pelletmaster
Coal:
You need to make sure you stove has the coal burn pot kit. this stove has a burn pot that is deeper and has more air holes.
The bad news is that this kit is no longer available.
Smoke in Hopper:
Most of the time it is because the flue is Full of ash and you need to be sure you clean that horizontal pipe from the front of the stove above the bricks all the way back to the T cleanout.
but other causes are.
Screen on cap? if there is one REMOVE IT
Not enough draft. Every PM I have every seen that had less than 5 feet of vertical pipe smoked out of the hopper and you want to make sure your horizontal pipe has some kind of rise.
Hopper lid seal bad
Ash Drawer seal bad
Door gasket bad.
Low combustion air from a intake screen plugged up with dust bunnies or dog hair.
Weak combustion fan ( not turning full RPMs)
Unburned pellets:
same as above but if you go more that 6 tons with out splitting the burn pot and cleaning the hollow space out the stove will not get enough air into the burn pot
some how Fine ash gets trapped in there.
ONLY CLEAN THE AIR SLITS OUT ON THE INSIDE EDGE OF THE BURN POT. The outer edge is sealed with Stove cement to direct the air inward and not outward to the clinker ring.
Tip TRICK.
If you are burning HIGH ash fuel you can Drill out a FEW (4 or so) small holes 1/16" into some of air slits and the bottom of them to allow more air flow in the burn pot.
the down side of this is you will need to split the burn pot more often to clean out the ash that gets into the hollow part.
Hope this helps.
I will try to stop back by this site some but this year has been a busy year in the store and website sales have tripled thin add a 14 month old baby to the mix so I don't have much time to screw around on the net.