If you have one of the fancy Tarms with the upper secondary combustion chamber (I believe it is intended to add air (oxygen) to the smoke to completely burn the smoke particles) I can't say I have any experience, but I could see that slowing down the flow of smoke out of the boiler and result in what you are experiencing. If so, is there a secondary air inlet to the upper chamber? If you shut that off when the door is open, it may improve flow of smoke to the chimney. I have a similar set-up, but with a very simple boiler (basically two large steel pipes, one inside the other forming the water jacket - with an insulation jacket)not a TARM. The boiler was built with a solid (i.e., not adjastable) baffle at the smoke discharge hole - it was meant to interfere with the draft so the heat does not go up the chimney too fast - I suppose it was supposed to make it more efficient. This baffle caused lots of smoke to come out of the door when loading wood, despite the hinged smoke door hanging down inside the loading door. I dealt with this by just opening the door quick, shoving in a piece of wood, closing it quick, repeat .... It minimized the amount of smoke comming into the basement, but also minimized my pleasure in burning wood. The smoke discharge baffle fell off after a few years (held on by two thin tacked-in-place bolts) and it has been much better since - and I don't think it impacts the efficiency of the boiler at all (not too efficent to begin with). If you have such a baffle, that would be your problem. Would greatly improve if you took it out.
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