Well, that's why unless your adventurous, most people like to stick with the same source of stoker coal.
Once it's dialed in right for the coal, you'll be set.
- Make sure that only clinker is removed (unless it's in the 60's and it's been idling all day, in which case, keep the ash to the bottom of the stoker door and remove loose ash that's above it)
- If you're burning a strongly coking coal (like I am right now) you will get chunks of black coke, keep these in the firebox, they will burn up in cycles.
- don't remove the clinker too much. with coal around 9% ash, you should be able to burn the hopper down to the start of the sloped section before you remove the clinker - you might have to hit it with a poker after you pry it up to get it out the door.
-clinker tongs or some sort of long fireplace tongs are a real necessity to carefully remove clinker from firebox.
- I've never had any soot fall out of my baro damper, you may have had a wind-related draft reversal or puff ?, is this plumbed in the same flue as an oil furnace ? (the sudden burner ignition can/will eject a bit of soot from the baro if tied together). Also, I would put the baro as close to the flue as possible, not the appliance.
- There will always be a light layer of soot in the firebox after shutdown, this will mostly burn off every few cycles, I don't bother brushing mine. Some coals smoke more than others after shutdown, be sure the air is adjusted properly (you want the fire to build and not smoke at all under fire, but there is a sweet spot, too much or too little air will create more smoke when the stoker shuts off).
-set the baro at -.04 or -.03, I'm not a huge fan of will-burt's instructions, although for some situations they seem to work ok.
- air adjustments of 1/16th of a turn DO make a difference in performance. This is not always readily apparent if you haven't been firing a stoker for a while.
-the ash should really reach the bottom of the loading door. Make sure the feed is on the lowest setting, even that, IMHO is too high for any decent coal. I use a smaller pulley than the factory supplied one. longer cycles is what you want.
- If you have room, a "magic heat" type reclaimer does wonders for the relatively high stack temps of these stokers.