Dutch West Mod 2460 Catalyst Bypass Damper Repair

The catalyst bypass damper in the Dutch West 2460 became disconnected internal of the assembly. The damper would no longer function, staying in the closed position. The top had to be removed to locate the problem which was a missing circlip on the damper shaft. The bypass damper is a major function in a catalytic combustion stove. If the damper was to be used in the closed position, the result would be a very short lived catalyst. They are not cheap. This one has a 2'' x 6'' round one that retails for around $170.00. The reason it would fail prematurely is that the non-complete combustibles (combustion by-products) contained in the flu gasses would accumulate on the surface of the catalyst before the catalyst could be able to attain operating temperature. Operating temperature is between 300 and 500 degrees. It's much better to hit 500 degrees before the bypass is opened because the higher the temperature the better it will ignite and burn the flu gas by-products that normally go out the flue pipe. Those non-complete combustibles exist because of low flu temps. The catalyst eliminates those low flu temperatures because once it 'energizes', it burns those flu gas by-products which in turn elevates the flu temp well in excess of 900 degrees. As a matter of fact, I like to burn this one maintaining roughly 1100*F (590*C) to 1200* F (650*C).
The repair was a simple one, requiring simply removing the flue pipe and the top of the stove. The only thing worrisome was doing damage to the molded 'refractory' bowl that sits over the top of the location inside the primary combustion chamber that houses the catalyst. This refractory bowl is responsible for containing a sampling of the heat generated by the burning catalyst to give an accurate measurement of the operating temperature to the sensing element of the thermostat probe that inserts through the center. The refractory itself is a very thin molded material that will damage or collapse very easily. It's replacement cost is iirc, $130.00.
Of course this is all going on during one of the days where the Missus is schooling our 7 year old twins as can be heard in the background and my shopdog Layla stops by for a sought after scruffy ear rub. I do interrupt the schooling though to have the Missus guide the thermometer probe into the opening of the refractory as I try to gently lower the heavy cast iron top without inflicting undue damage to the expensive but replaceable component.
Now let me tell you one thing....I like the catalytic burning stove for two main reasons. 1). Any possibility of a build up of creosote using a catalyst can only be accomplished by repeated mis-use of the heating device by improperly firing it or consistently using green (unseasoned) wood AND not elevating the temperature to the point that the catalyst becomes energized. However, seasoned wood should be INSISTED upon while operating a catalytic burner. The lower the moisture content, the lower the potential for elevated percentages of un-burnt gasses or in other words, combustion by-products. 2). A catalyst will lower....yes LOWER the quantity of fuel consumed to heat the space. I have no scientific data to prove my point, nor have I read the specifics, but I know for a fact a standard atmospheric burning non-catalyst stove would burn more than a third more wood to heat the same space to a comfortable level. That is judged only by how much less I have to pack in...so take it with a grain of salt, unless you want to research it yourself and report back in the form of a comment to either verify or or prove incorrect. But I must insist the above statement is a non- biased assessment of my experiences and believed to be true, though it is just an opinion. (Official disclaimer) LOL.
All told, I love this little stove and so does the Missus and the students in our little classroom.....Layla not so much, because she is kinda hairy and likes it a bit cooler. But her vote doesn't carry as much water.....
#catalytic burner #Dutch West model 2460 #creosote #wood heat