COUNTRY FLAME TECHNOLOGIES INSTALLATION, OPERATION AND MAINTENANCE MANUAL MODEL CF-04 CROSSFIRE STOVE FIREPLACE INSERT, (FLEX FUEL VERSION) USA & CANADA TEST: TESTED BY: ASTM E 1509-04, UL 1482, WARNOCK HERSEY ULC S627, ULC/ORD C1482 (and ULC S628 If listed for fireplace insert installation in Canada) MOBILE HOME APPROVED WARNING: If the directions in this manual are not followed exactly, a fire may result causing property damage, personal injury or loss of life.
SAFETY NOTES The Crossfire Model CF-04 FLEX fuel stove is significantly different from a conventional wood-burning stove. One major difference is that the CF-04 requires a reliable source of electrical energy to properly operate. The owner, installer, and operator must understand this manual and read it in its entirety. Understanding this manual should be completed and followed before installation or operation of the CF-04 is attempted.
WARNING: Maintain all minimum safety clearances of the Crossfire stove and chimney system. Never install the Crossfire in a sleeping room. WARNING: The Crossfire-Flex is designed and approved for burning of number 2 yellow shelled corn with a maximum moisture content of 14% (10%-12% recommended) or industry approved wood pellet fuel. Any fuel used in this stove must meet or exceed APFI standards. Do not burn untested fuels or foreign materials in this product.
CAUTION: Operate the Crossfire with the fuel hopper lid closed at all times. Failure to keep the hopper lid closed during operation may result in the release of combustion gasses into the home from the hopper under certain conditions. Maintain the Crossfire hopper seal in good condition and do not overfill the hopper. CAUTION: The stove controls the rate of fuel fed into the fire pot. Never do anything to overfeed fuel or cause over firing of the Crossfire.
CERTIFICATION SAFETY LABEL (sample) Version 4.
TABLE OF CONTENTS SAFETY NOTES.........................................................................................................................................2 EPA STANDARDS ..................................................................................................................................4 LISTING/TESTING AGENCY ................................................................................................................4 CERTIFICATION SAFETY LABEL (sample) ........................
MOBILE HOME RULES .......................................................................................................................33 MOBILE HOME CLEARANCES..........................................................................................................33 MOBILE HOME STOVE ATTACHMENT...........................................................................................34 MOBILE HOME FLOOR PROTECTION ..........................................................................................
FORWARD COUNTRY FLAME Country Flame has worked for over two decades in researching and developing biomass fuel burning stove products. In 2002, Country Flame received a national award from the Hearth Industry for its HARVESTER freestanding biomass fuel stove. Country Flame has now added the CROSSFIRE FIREPLACE INSERT biomass fuel stove to its line of products. The CROSSFIRE gives every homeowner the opportunity to convert their inefficient fireplace into a highly efficient heating machine.
AMERICAN ENERGY SYSTEMS INC. LIMITED PRODUCT WARRANTY This warranty is in effect on all products sold after 01/01/2009 and supersedes any and all warranties currently in existence. Please keep a copy of this warranty for your personal records or in the event of a claim American Energy Systems Inc.
PARTICULAR PURPOSE, ARE DISCLAIMED. IT IS UNDERSTOOD AND AGREED THAT AES’S LIABILITY UNDER THIS WARRANTY SHALL BE LIMITED TO THE PROVISION OF REPLACEMENT PARTS AND SHALL NOT INCLUDE LIABILITY FOR SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES. ANY ACTION BROUGHT UNDER THIS WARRANTY MUST BE BROUGHT WITHIN ONE YEAR OF THE ACCRUAL OF THE CAUSE OF ACTION AND MAY ONLY BE BROUGHT IN THE CIRCUIT COURT OF MCCLOUD COUNTY, MINNESOTA.
Place Stamp Here American Energy Systems, Inc 150 Michigan Street SE Hutchinson, MN 55350 Fold Here Name City Dealer Dealer’s Name City Date of Purchase Model No. Address State Zip State Zip Serial No. The express warranties made by Country Flame Technologies do not apply unless this warranty card is received by Country Flame Technologies from the original retail purchaser no later than thirty (30) days subsequent to the date the Country Flame product was originally purchased.
THE CROSSFIRE OPERATION FEATURES Country Flame designed and built the CF04 -FLEX stove to burn 100% shelled corn. Unlike conventional pellet stoves, the Crossfire was designed to handle large amounts of ash. This means the Crossfire is capable of burning corn or a mix of wood pellets and corn while reducing the possibility of choking the fire from ash residue.
FIGURE 2: CROSSFIRE COMPONENTS SAFETY FEATURES The Crossfire comes standard with a number of advanced safety features; however, to ensure maximum safety install the stove according to all national and local codes and follow all operating and maintenance procedures. The Crossfire requires a fresh air supply to ensure proper combustion. This fresh air is used in the combustion process to achieve thorough burn of all fuel. The Crossfire needs a sealed and properly designed exhaust flue system.
ensure stable operation of the Crossfire. Fortunately, there are simple, reliable, and cost effective power backup solutions available. Today, a homeowner can choose from a variety of power conditioning systems from a number of “big box” retail stores. For example, Home Depot, Circuit City, Best Buy, Wal-Mart, or other stores carry standard power conditioning equipment. Two good quality power conditioning equipment manufacturers are APC and TrippLite.
CROSSFIRE STARTUP The first step in preparing the Crossfire for use is to remove it from its shipping crate. Ensure that all materials packed in the burn chamber have been removed. Ensure proper cleaning of the Gold (optional plated l) door/trim and clean all glass per instructions included in this manual. NOTE: (1) Failure to properly pre-clean the Gold (or any plated) door or trim and the glass before lighting the first fire could permanently damage these items.
air to the stove to intensify the flame. You must establish a strong, intense burn before corn can be fed into stove. (this process takes approx.15-20 minutes) 6. SYSTEM START Upon establishing an intense hot fire in the Burn-Pot, press and hold the “ON/OFF” button on the control board for approx. 5 seconds. The (red) light next to the igniter symbol will change from slow to fast flash, then release button. If the stove is at the proper temperature, the operational sequence will begin automatically.
• FUEL the only fuel the CF04-FLEX stove is designed to burn is #2 shelled Corn (1012% moisture) or any mix of Corn and Premium Hardwood Pellets. It is highly recommended that the corn be “CLEANED” (free of dust, fines, & any other foreign matter) for optimum stove performance. Burning SEED CORN as fuel is extremely dangerous to occupants and voids the Country Flames warranty. • To enhance the initial start-up fire, manually rotate the stir rod occasionally.
The stir rod will be controlled by the “Intelli-Choice” control board. This stir rod assists in mixing fuel with air in the burn pot. The stirring action improves the mixing of oxygen and fuel and accelerates the combustion process. As heat settings are changed on the Intelli-Choice control board, the stir rod speed will automatically be adjusted to more closely match the feed rates of the different heat settings. The stir rod assists in minimizing “clinker” build-up in the burn pot.
VACUUM SENSOR OVERTEMP SENSOR INPUT VOLTAGE 120 Volts AC 60 Hz 15-Ampere Circuit FUEL CONTROL COMBUSTION AIR CONTROL Hopper Switch THERMOSTAT (Optional) CONTROL BOARD ON/OFF SWITCH TEMPERATURE CONTROL POWER/FUEL/IGNITER/ INDICATORS Fuse 6–9 Amperes STOVE EXHAUST TEMPERATURE SENSOR ROOM AIR TEMPERATURE SENSOR ROOM AIR CONTROL STIR ROD FIGURE 4A: CONTROL BOARD BLOCK DIAGRAM Input Voltage Fuse Vacuum Sensor Exhaust Temperature Sensor Room Air Temperature Sensor Overtemp Sensor Fuel Control Room
FIGURE 5 displays the Country Flame Control Board front panel. Each function of the Control Board is identified. Controls having more than a single function are identified with asterisks. All control board functions are explained in FIGURE 6. “Intelli-Choice” Country Flame Logo, AC Power is present when logo is lit. Lighting Symbol Slow/Fast Blink depending on ‘on state.
ON/OFF SWITCH HEAT UP/ HEAT DOWN SWITCH DC POWER LIGHT HIGHWAY PATROL MODE COOL DOWN MODE HEAT SETTING 1 THROUGH 5 The Intelli-Choice ON/OFF Switch either turns the system on or off by holding the switch for approximately 5 seconds. The ON/OFF Switch can also be used to initiate the FUEL PRIME MODE by holding it for approximately 30 seconds. When in the prime mode the Thermostat lights will sequentially light from top to bottom simulating a “filling action” of the auger tube.
In order to utilize the full capabilities of the Control Board, the homeowner should be familiar with the backside of the Control Board. FIGURE 7 provides additional information about the major components on the component side of the control board. FIGURE 7: CONTROL BOARD COMPONENT SIDE Version 4.
TROUBLESHOOTING CODES FOR COUNTRY FLAME CONTROL BOARD The following table provides additional information as to the reason different fault codes may be observed. The table of information assumes that proper AC voltage, AC line frequency, and a properly working control board are available to and installed in the stove product. Intelli-Choice Code Display Code 0 Code 1 Code 2 Code 3 Code 4 Code 5 Code 6 Code 7 Code 8 Intelli-Choice Code Display Version 4.
Code 9 Code A Code B Code C Code D Code E Code F Code L Code P Intelli-Choice Control Board has completed the IGNITION CYCLE and is switching to the BURN CYCLE. The igniter should shut down to conserve energy and the stove will now watch for the room air snap disk to close before recognizes a problem with the exhaust snap disk, OR the room air snap disk, OR there is a wiring problem. If the stove is cool, it is most likely the exhaust snap disk.
STOVE ELECTRICAL DIAGRAM FIGURE 8 provides the CF04-FLEX electrical schematic of the components and sensors that are either operated or monitored by the Country Flame control board. Please refer to this diagram when necessary. FIGURE 8: ELECTRICAL DIAGRAM Version 4.
STOVE SPECIFICATIONS TABLE 2 shows the physical dimensions of the Crossfire product. CROSSFIRE STOVE HEIGHT (At Front) STOVE DEPTH (From Shroud) STOVE WIDTH (Rear) STOVE WIDTH (At Shroud Mount) STOVE WEIGHT (empty) SHROUD WIDTH, (standard) SHROUD HEIGHT (standard) SHROUD WIDTH, (oversized) SHROUD HEIGHT (oversized) DIMENSIONS (IN INCHES) 22.5“ 14.0“ 26.0“ 25.5“ 220 pounds 42.0” 30.0” 48.0” 32.
• move to that heat setting anytime the thermostat calls for heat. Otherwise, when the thermostat no longer calls for heat, the control board sets the stove to Heat #1. If the operator changes the heat level to 1 while the thermostat is calling for heat, it will become the new Thermostat Heat Level. But because this is the same setting as when the thermostat stops calling for heat, the operator will get no indication that the thermostat is in control of the stove.
INSTALLATION INSTALLATION PREPARATION Country Flame strongly recommends the Crossfire be installed by a certified professional. Improper installation will create long-term operational and maintenance problems that will plague the homeowner until corrected. The first step is to ensure all necessary parts are available to complete a proper installation. Country Flame recommends a homeowner purchase the Crossfire from an authorized dealer who both knows and supports Country Flame product.
installation into an approved masonry or zero clearance fireplaces, the use of single or double-wall flue pipe will not affect the clearance distance from the unit to any combustible materials. DEFINED MINIMUM DISTANCES TO COMBUSTIBLES CLEARANCE A. UNIT TO SIDEWALL B. UNIT TO SIDE TRIM C. UNIT TOP TO TOP TRIM D. UNIT TOP TO MANTLE E. HEARTH FLOOR TO MANTLE F. NONCOMBUSTIBLE FLOOR PROTECTION, front G. NONCOMBUSTIBLE FLOOR PROTECTION, sides 7” 7” 9.25” 9.
CHIMNEY It is extremely important that a Crossfire stove be vented into a non defective, clean, and properly lined chimney. The chimney system must conform to all local building codes. In the event a masonry chimney is not used, a listed factory-built chimney suitable for use with solid fuels should be used. This listed factory-built chimney system must conform to ULC-S629 (Canada) or UL 103HT (United States.
combustion. In all cases, the flue must be relined with a listed liner system, such as HomeSaver Chimney Liner. If your masonry built chimney contains oversized flue tiles it must be relined to ensure proper draft. This means that a new, properly sized liner system must be installed before connection to the Crossfire stove is completed. Again, for 10 feet or less a 3 inch stainless steel liner can be used with the Crossfire. For lengths greater than 10 feet, a 4 inch stainless steel liner is to be used.
carpet to come in contact with any part of the Crossfire insert. combustibles as specified in TABLE 3, page 29 of this manual. Maintain clearances to OUTSIDE AIR COMBUSTION It is imperative that the installer and homeowner ensures that a minimum of at least eight square inches (fifty square centimeters) of outside air be admitted to the hearth room or directly to the Crossfire. If installation allows, the Crossfire fresh air intake should be connected through an exterior wall.
MOBILE HOME INSTALLATION WARNING: DO NOT INSTALL A COUNTRY FLAME CROSSFIRE STOVE IN ANY MOBILE HOME SLEEPING ROOM. WARNING: THE STRUCTURAL INTEGRITY OF THE FLOOR, WALL, CEILING AND ROOF MUST BE MAINTAINED DURING THE INSTALLATION OF A COUNTRY FLAME CROSSFIRE STOVE IN A MOBILE HOME. WARNING: A CROSSFIRE STOVE INSTALLED IN A MOBILE HOME MUST BE COMPLETED IN ACCORDANCE WITH 24 CFR, PART 3280 (HUD). WARNING: A CROSSFIRE STOVE MUST BE PERMANENTLY BOLTED TO THE FLOOR OF THE MOBILE HOME.
Do not violate minimum clearances with approved thermal barriers. Manville’s CERAFORM 126 is an example of an approved insulated wall protector. This product has a K equal to .27 and is a halfinch thick. Total thermal resistance should exceed 1.5 for any material used to ensure proper thermal protection of a combustible wall. MOBILE HOME STOVE ATTACHMENT 1. Install combustion air to the back of the Crossfire in all mobile home applications.
3. At no time should a floor protector be placed on top of carpeting. Carpeting must be removed and the floor protection should sit directly on the uncarpeted portion of the mobile home floor. Floor protection should extend to the front, sides, back, and under the chimney connector as defined for a specific model listed in this manual. In the event there are floor protection questions, contact Country Flame or one of its local authorized dealers for assistance. MOBILE HOME CHIMNEY AND DUCTS 1.
certified professional to install a flue gas pellet venting system. Do not deviate from the pellet flue manufacturer’s installation instructions. Contact Country Flame or a local authorized dealer to resolve any questions or installation procedures. TABLE 4 shows the required components needed for a typical pellet flue pipe mobile home installation.
FIGURE 15: MOBILE HOME CHIMNEY INSTALLATION Version 4.
MAINTENANCE REQUIREMENTS GENERAL REQUIREMENTS The Crossfire Model CF-04 has minimal maintenance requirements; however, failure to perform cleaning or maintenance items will lead to degraded performance and potential safety hazards for both the home and its occupants. The Crossfire stove should not be operated routinely without thorough (as required) cleaning for consistent performance, depending on frequency of use.
STOVE DOOR ADJUSTMENT The Crossfire door may require fine adjustment due to variations in the door, the gasket material, due to hinge wear, or to maintain a center-aligned appearance. The Crossfire door needs to remain airtight to ensure proper firebox operation. The Crossfire door can be adjusted up or down and left or right with the adjustable hinge pins as shown in FIGURE 16. The door gasket can also be adjusted to improve on the airtight fit.
the door glass. Removal of these glass retaining clips can be accomplished with household tools. Order the necessary replacement screws or glass clips when ordering glass to ensure worn parts are replaced. GLASS-CERAMIC SPECIFICATIONS Manufacturer Window Type Euro Kera Glass-Ceramic, Kera Lite® KERA LITE® glass-ceramic has a thermal endurance far exceeding that of normal tempered glass. KERA LITE® is designed to operate at temperatures ranging from -4000F to +14000F.
In order to thoroughly clean the exhaust chamber, the Crossfire has two cleaning ports that provide access to the exhaust chamber. In order to gain access to these clean-out ports, the hearth plate must be removed from the front of the Crossfire. FIGURE 18 shows the hearth plate removed from the stove. There is one screw, located in the front center of the hearth plate that must be removed before the hearth plate can be lifted up and out of its location.
a period of use can lead to one or both exhaust chambers becoming blocked and thus causing the stove to burn inefficiently. FIGURE 20 shows an x-ray view into the clean-out port of the right side of the Crossfire. This right side clean-out port allows access to the right side exhaust chamber and underneath the exhaust fan itself.
APPENDIX A: TROUBLESHOOTING GUIDE Shut off the power to the unit and allow it to cool off when performing cleaning and maintenance. Fuel PROBLEM SOLUTION Stove does not switch on The starter fire in the firepot has not ignited or is not burning properly. Using gloves carefully open the doors and relay the pellet fire. Wait 8-10 minutes for the pellets to burn well, before restarting the system.
APPENDIX A: TROUBLESHOOTING GUIDE Stirring Paddles do not turn Fire Goes out Ash Build Up Fire goes due to ash build up Build up of Corn Stove Smokes Your Corn/Pellet Stove Smokes Your Corn/Pellet Stove Smokes Your Corn/Pellet Stove Smokes Cleaning Cleaning is messy and difficult Glass Glass Breaks Doors Luster on Gold Doors Fades Doors are not airtight Version 4.0 44 (CONT’D) The chain drive for the stirring paddles needs to be checked after the first 8 hours of operation as it can loosen.
APPENDIX B: MAINTENANCE GUIDE Shut off the power to the unit and allow it to cool off when performing cleaning and maintenance. Regular Cleaning Removing and cleaning the Firepot Removing “Clinkers” Soot and Fly-ash Build Up Thorough Cleaning Cleaning the Heat Exchanger. Version 4.0 45 The firepot can be removed by removing 2 bolts. Slide the keeper sleeve off of the stir rod gear shaft exposing the linkage. Rotate the stir rod until the slot is vertical.
APPENDIX B: MAINTENANCE GUIDE Cleaning the Glass Cleaning the Gold Doors (optional feature) General/Yearly Maintenance To clean glass, use a mild non-abrasive cleaner when the stove and glass are COOL. Creosote builds up on glass quicker when a fire is burned at lower heat settings. DO NOT use abrasive cleaners on glass. (Glass may crack if subjected to cold liquid cleaners while the glass is still hot. Using cleaner on hot glass may also cause burns, emit fumes and the glass is more likely to stain.
APPENDIX B: MAINTENANCE GUIDE Replacing the Door / Glass Gaskets Replacing the Glass Adjusting the Doors Version 4.0 47 (CONT’D) To replace the gaskets, remove the door by lifting it straight up off its hinge pins and laying it face down on a soft surface. Remove the door gasket (you may need to use pliers) and then remove the glass retaining clips and remove glass. Strip off old gasket around glass and clean glass well. Clean out old stove gasket material from gasket track.
APPENDIX C: TECHNICAL SPECIFICATIONS Fuel Type: #2 Yellow Shelled Corn Fuel (CLEANED) Moisture Content: 14% or less (10- 12% preferred) Heat Content: 10,000 Btu/lb* Ash Content: 3% maximum Bulk Density: 40 lb./cubic ft. min Hardwood Pellet Fuel A.P.F.I. residential fuel Heat Content: 8200 BTU/lb Ash Content: 1% max Fines: Moisture Content: 8% max Size: 1/4” to 3/8” diameter 1.5” long max 1% max through 1/8th screen Hopper Size: 72 pounds corn or 55 pounds wood pellets Flue Size: 4” recommended.
APPENDIX D: CROSSFIRE THEORY OF OPERATION BURN PHASE Multiple heat lights indicate the control panel burn phase. There are five lights (4 yellow and one red) used to indicate the relationship to the system’s heat settings. Pushing the control panel’s HEAT LEVEL switch will cause a heat light to cycle one level up from Heat 1 through Heat 5. Once the Heat 5 setting has been reached, if the HEAT LEVEL button is pushed again, the heat setting will cycle over again starting at Heat 1.
APPENDIX D: THEORY OF OPERATION (cont’d) FAULT PHASE The fault phase is indicated by all lights except the Country Flame logo light flashing on and off at a rapid pace. This event signifies that the control board has encountered an improperly operating system and requires intervention by either the operator or a properly trained service technician.
movement facilitates removal of the stir rod for maintenance or for facilitating starting a fire by rotating the stir rod to enhance air flow during a fire’s startup. In order to manually turn the stir arm, the up and down (red and blue) heat arrows must be simultaneously pressed while the control is in only the OFF PHASE or the STARTUP PHASE. As long as the up and down heat arrows are held in either the off or startup phase, the stir rod will rotate.
APPENDIX E: COMBUSTION BASICS An understanding of Combustion Basics will assist in resolving problems with a variety of fuels, changing product and environmental conditions during the operational life of a stove. Just exactly what are pellet or corn stove products suppose to do? PROVIDE A CONVENIENT PLACE FOR STORAGE OF FUEL. PROVIDE FOR CONTROLLING IGNITION, FUEL, COMBUSTION AIR PROVIDE CONTROLLING HEAT FROM FIREBOX TO HEAT EXCHANGER. CONTROL SYSTEM TEMPERATURE.
Combustion Temperature: The temperature required to ensure the release of flammable vapors. To sustain combustion, the heat evolved must maintain this temperature to provide a constant supply of vapors. Excess Air: Any air added to the combustion process above the theoretical value defined as 100% efficiency. A combustion system operated exactly at the peak burn efficiency ratio has a high probability that some of the oxygen in the combustion air will not get paired up with the fuel.
The obvious advantage of Corn or wood pellets over conventional chopped wood logs is the consistency of the fuel both from a size and moisture content. Nature has done a great job of making field corn a palletized fuel that can have even more energy than wood pellets. These palletized fuels burn more efficiently than their wood log counterparts. The heat generated in the burn process, once combustion is achieved, sustains the process as more fuel is added.
As a final note, the two basic stages of corn burning are: a) b) Somewhere around 1100o F the corn fuel particles have combined with oxygen molecules and released the majority of the available energy. Some gases will still not have reached ignition temperature and at this critical stage, if too much heat is removed from the combustion chamber, no more fuel will be burnt. All remaining fuel will simply exhaust through the system as unburned material.
APPENDIX F: REPLACEMENT PARTS REPLACEMENT PARTS Part Number Description CF04-P72 BURN POT SCREEN 1 CB-74 STIR ROD ASSEMBLY 1 CF04-A51 BURN POT ASSEMBLY - CORN 1 PP-353 EXHAUST MOTOR ASSEMBLY 1 PP-355 ROOM AIR MOTOR ASSEMBLY 1 PP-352 VACUUM SENSOR SWITCH 1 PP-347 2500F OVER TEMPERATURE SENSOR 1 PP-12 1100F EXHAUST/ROOM AIR SENSOR 1 PP-182 OWNERS MANUAL 1 PP-989 AC RECEPTACLE 1 NPS-1005-C Intelli-Choice CONTROL BOARD 1 PP-1030 WIRING HARNESS 1 PP-40 DOOR FRAME ONLY 1 P
APPENDIX F: REPLACEMENT PARTS (cont’d) REPLACEMENT PARTS Part Number Description CF04-A24 4” CHIMNEY CONNECT BOX 1 PP-535-1 AUGER MOTOR ASSEMBLY 1 PP-27 VACUUM HOSE 1 PP-88 HOPPER GASKET TAPE 1 PP-48 NON-ETCHED DOOR GLASS W/TAPE 1 PP-525 ETCHED DOOR GLASS W/TAPE 1 PP-107-G SIDE TRIM, GOLD 2 PP-107-N SIDE TRIM, NICKEL 2 PP-107-B SIDE TRIM, BLACK 2 PP-185 SIDE TRIM, CUSTOM 2 Number per CROSSFIRE INSERT APPENDIX G: LABELS REPLACEMENT LABELS Part Number Description PP-483 CAU
Part Number PP-484 Description CAUTION LABEL PP-486 ELECTRICAL LABEL Version 4.
