One thing I am noticing though is a considerable amount of unburnt or half burnt coal making it into the ash pan. I am not sure why this is happening. Anyone have any thoughts? I have about an inch of ash on the grate.
I have similar results as you regarding performance and unburned coal...I feel that I have corrected that latter issue somewhat, however. since the new fan allows the boiler to be at idle more often, I believe the problem is related to that...This new fan is much more responsive to the fan rheostat. What I did was to set the fan control way back...to about the 30 position on a clock, or with the indicator facing down. I also cut back on the stoker rheostat. This fan speed results in a nice, low blue flame when the idle circuit is in control....and I get about a 1 inch band of glowing coal.
My timer settings are 9 min off, 45 seconds on, base draft about .02, breach @ .04., and a stack temp before the baro, (measured with a probe thermometer) of about 380 ° after a long burn.
One thing I am noticing is quite an increase in fly ash...presumably due to the larger fire and increased air?
Matt, perhaps you would like to add your 3 cents in and concur/refute my conclusions??