American Energy Systems Crossfire Flex User Manual

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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 fire

lace 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.

Do not store or use gasoline or other flammables (vapor or liquids) in or
around the vicinity of this appliance.

Installation and repair must be performed by a qualified service agency.

Always check with local jurisdiction or code agency before installing this
product. Local jurisdiction may be requiring a permit prior to installation.

© 2009 COUNTRY FLAME

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FOR YOUR SAFETY

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. Failure to follow installation and operation instructions or perform necessary

maintenance can result in property damage, bodily injury, or even death. Country Flame strongly
recommends that a certified professional install the Crossfire Model CF-04.

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ARNING: THE AUTHORITY HAVING JURISDICTION (such as a municipal building

department, fire department, or fire prevention bureau, etc

BEFORE BEGINNING INSTALLATION. A PERMIT MAY BE REQUIRED IN
ORDER TO PERFORM INSTALLATION.

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ARNING: A smoke detector is recommended to be installed in the vicinity of the Crossfire CF-04.

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ARNING: Country Flame Technologies has no control over installation or maintenance procedures;

therefore, Country Flame grants no warranty, implied or written, for the installation or
maintenance of the CF-04. Further, Country Flame assumes no responsibility for any
consequential damage resulting from said installation or maintenance of this product.

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ARNING: After operation, always allow the Crossfire stove to completely cool before performing

any maintenance operations.

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ARNING: The Crossfire stove requires reliable electric energy to properly operate. If electrical

power is not available, DO NOT operate the Crossfire with only a natural draft.

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ARNING: Only a certified professional should install a Crossfire stove. Only a qualified service

technician should perform maintenance on the Crossfire. Parts removed for installation or
servicing must be replaced prior to operational use of this stove.

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ARNING: Modification of the Crossfire is not authorized and any modification to the Crossfire voids

Country Flame’s product warranty.

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ARNING: The Crossfire must be connected to a code compliant grounded 120-volt, 15 ampere, and

60 hertz electrical outlet. Use of a dedicated circuit is recommended. NEVER use an
adapter, extension cord or cut or remove any prong from the power cord.

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ARNING: NEVER place or store any combustible or flammable products on or near the Crossfire.

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ARNING: The Crossfire is designed to shutdown in the event the front door is opened. Keep the

viewing door tightly closed during operation. Always clean the Crossfire after the stove
has been allowed to return to normal room temperature.

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ARNING: Do not connect the Crossfire to a chimney flue serving another stove of any type and

never install a flue damper in the exhaust system of the Crossfire.

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ARNING: FOLLOW all operating instructions in this manual. Short cuts in operating procedures,

of any kind, can be dangerous.

) SHOULD BE CONSULTED

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ARNING: Maintain all minimum safety clearances of the Crossfire stove and chimney system.

Never install the Crossfire in a sleeping room.

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ARNING: 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. Failure to comply with fuel
restriction voids Country Flame’s warranty and the safety listing of the unit. Poor quality
fuel will directly (and adversely) affect efficiency and cleanliness of operation. Country
Flame’s local authorized dealer can help in recommending a quality fuel

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ARNING: NEVER use gasoline, lantern fuel, kerosene, charcoal lighter fluid or other combustible

liquids to start or “freshen up” the fire in this product. Do not store or use gasoline or
other flammable liquids or allow combustible vapors in the vicinity of product.

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ARNING: NEVER put foreign objects in the hopper and NEVER burn trash or unapproved material

in the Crossfire. Using fuels other than #2 shelled corn or premium hardwood pellet
mixed with corn voids the Country Flame warranty. Damage to the stove resulting from
foreign objects is not covered by warranty.

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ARNING: Ensure free and adequate airflow to and around the Crossfire. This stove is a combustion

system that requires continuous flow of fresh air for proper operation. Failure to provide
an adequate fresh air supply can lead to operational problems such as: negative pressure
in the home, poor operation of this or other home combustion appliances, or a host of
other issues. Remember that other combustion appliances in the home compete for fresh
air. Consult with a professional to ensure positive air flow is provided to the stove during
operation.

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ARNING: The Crossfire’s exhaust system works with a negative combustion chamber pressure and a

low positive chimney pressure. It is very important that the Crossfire’s exhaust system be
airtight and properly installed. All exhaust joints connected to the Crossfire or each flue
section is to be sealed. Use 500 degrees Fahrenheit (500

O

F or 260 OC) silicone sealant or
aluminum high temperature tape and secure each joint with (3) sheet metal screws. An
improperly installed stove or chimney system is the major cause of home fires.

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ARNING: When installed in a mobile home, the Crossfire must be electrically grounded to the steel

chassis of the mobile home. In addition, the stove must be bolted to A NON­COMBUSTABLE FLOOR floor. A mobile home installation of the Crossfire should be

in accordance with the Manufactured Home and Safety Standard (HUD), CFR 3280, Part

24. Consult the local code authority.

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ARNING: SOOT AND FLY ASH: The products of combustion will contain small particles of fly

ash. The fly ash will collect in the exhaust venting system and restrict the flow of the flue
gases. Incomplete combustion, such as occurs during start-up, shut down, or incorrect
operation of the Crossfire will lead to soot formation in the exhaust venting system. Use
the Crossfire cleanout ports to clean the exhaust venting system at least twice every year.

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ARNING: ASH REMOVAL: The ash should be emptied every day or as required to ensure proper

operation. If the ash compartment is not emptied regularly, ash will build up and restrict
the flow of fresh air in the combustion chamber. The airtight seal of the viewing door
ensures a proper combustion process per the stove design and it should not be open during
normal operation of the stove.

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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.

CAUTION:

THE CROSSFIRE IS HOT WHILE IN OPERATION. DO NOT TOUCH. KEEP CHILDREN,

CLOTHING

SEVERE SKIN BURNS

, AND FURNITURE AWAY. CONTACT WITH HOT SURFACES MAY CAUSE

. REFER TO THE SAFETY LABEL FOR INSTRUCTIONS.

NOTE: RETAIN this MANUAL for future reference as needed. Ensure the manufactured date

and serial number of the Crossfire are written down for use should maintenance be
required.

EPA STANDARDS

The Country Flame Crossfire meets rigorous emission standards. All Country Flame Crossfire Model CF­04 stoves conform to United States Environmental Protection Agency standards.

LISTING/TESTING AGENCY

The Crossfire Model CF-04 has been independently tested and listed in accordance with ASTM E1509-04,
UL 1482, ULC S627, ULC/ORD C1482 (and ULC S628 if listed for fireplace insert installation in
Canada) and Oregon Administrative Rules 814-23-900 – through 909. This listing is for installation into
residential dwellings, including standard construction units, mobile home units, or modular home units.
The Crossfire Model CF-04 was tested to UL standards by Intertek Testing Services, NA, Inc., 8431
Murphy Drive, Middleton, WI 53562.

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CERTIFICATION SAFETY LABEL (sample)

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TABLE OF CONTENTS

SAFETY NOTES.........................................................................................................................................2

EPA STANDARDS ..................................................................................................................................4

LISTING/TESTING AGENCY ................................................................................................................4

CERTIFICATION SAFETY LABEL (sample) .......................................................................................5

TABLE OF CONTENTS............................................................................................................................6

FORWARD..................................................................................................................................................8

COUNTRY FLAME .................................................................................................................................8

CROSSFIRE LIMITED WARRANTY ......................................................Error! Bookmark not defined.

CROSSFIRE LIMITED WARRANTY (continued).................................. Error! Bookmark not defined.

THE CROSSFIRE OPERATION ...........................................................................................................12

FEATURES.............................................................................................................................................12

SAFETY FEATURES............................................................................................................................. 13

BATTERY BACKUP SYSTEMS ..........................................................................................................13

FUEL REQUIREMENTS .......................................................................................................................14

CROSSFIRE STARTUP......................................................................................................................... 15

ASH REMOVAL ....................................................................................................................................18

Intelli-Choice CONTROL BOARD ........................................................................................................ 18

CONTROL BOARD FACE ILLUSTRATION ………………………………………………………..20
CONTROL BOARD TROUBLESHOOTING CODES………………………………………………..23
STOVE ELECTRICAL DIAGRAM …………………………………………………………………..25

STOVE SPECIFICATIONS ...................................................................................................................26

ELECTRICAL REQUIREMENTS.........................................................................................................26

GOLD DOOR CARE..............................................................................................................................26

OPTIONAL FEATURES........................................................................................................................26

OPTIONAL THERMOSTAT OPERATION..........................................................................................26

CROSSFIRE IS COLD .......................................................................................................................26

CROSSFIRE IS HOT..........................................................................................................................26

CHANGE HEAT LEVEL (thermostat active)....................................................................................26

CHANGE HEAT LEVEL (thermostat inactive).................................................................................27

COMBUSTION FRESH AIR CONTROL .............................................................................................27

INSTALLATION ......................................................................................................................................28

INSTALLATION PREPARATION .......................................................................................................28

STOVE CLEARANCES.........................................................................................................................28

SHROUD INSTALLATION...................................................................................................................29

CHIMNEY ..............................................................................................................................................30

FACTORY-BUILT CHIMNEY..............................................................................................................30

MASONRY BUILT CHIMNEY.............................................................................................................30

FLOOR PROTECTION REQUIREMENTS ..........................................................................................31

OUTSIDE AIR COMBUSTION.............................................................................................................32

MOBILE HOME INSTALLATION .......................................................................................................33

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MOBILE HOME RULES .......................................................................................................................33

MOBILE HOME CLEARANCES..........................................................................................................33

MOBILE HOME STOVE ATTACHMENT...........................................................................................34

MOBILE HOME FLOOR PROTECTION .............................................................................................34

MOBILE HOME CHIMNEY AND DUCTS..........................................................................................35

MAINTENANCE REQUIREMENTS ....................................................................................................38

GENERAL REQUIREMENTS...............................................................................................................38

STOVE DOOR INSTALLATION..........................................................................................................38

STOVE DOOR ADJUSTMENT.............................................................................................................39

STOVE DOOR GLASS CLEANING.....................................................................................................39

GLASS REPLACEMENT ......................................................................................................................39

GLASS-CERAMIC SPECIFICATIONS ................................................................................................40

GASKET REPLACEMENT ...................................................................................................................40

CROSSFIRE CLEANING ......................................................................................................................40

APPENDIX A: TROUBLESHOOTING GUIDE..................................................................................43

APPENDIX A: TROUBLESHOOTING GUIDE (CONT’D) ..............................................................44

APPENDIX B: MAINTENANCE GUIDE.............................................................................................45

APPENDIX B: MAINTENANCE GUIDE (CONT’D) .........................................................................46

APPENDIX B: MAINTENANCE GUIDE (CONT’D) .........................................................................47

APPENDIX C: TECHNICAL SPECIFICATIONS ..............................................................................48

APPENDIX D: CROSSFIRE THEORY OF OPERATION ................................................................49

BURN PHASE ........................................................................................................................................49

COOL DOWN PHASE ...........................................................................................................................49

APPENDIX D: THEORY OF OPERATION (cont’d)..........................................................................50

FAULT PHASE ......................................................................................................................................50

RESET CONDITION..............................................................................................................................50

SYSTEM MAINTENANCE................................................................................................................... 50

APPENDIX E: COMBUSTION BASICS ..............................................................................................52

APPENDIX F: REPLACEMENT PARTS ............................................................................................56

REPLACEMENT PARTS ......................................................................................................................56

REPLACEMENT PARTS ......................................................................................................................57

APPENDIX G: LABELS .........................................................................................................................57

REPLACEMENT LABELS....................................................................................................................57

REPLACEMENT LABELS.................................................................... Error! Bookmark not defined.

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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.
In addition, the CROSSFIRE ensures that the homeowner can choose from an ever growing array of fuel
products to meet their home heating needs. Country Flame is dedicated to researching and developing
advanced pellet stove products capable of burning a wide variety of biomass fuel. The Crossfire Model
CF-04 was designed to burn APFI approved wood pellets or shelled corn. Switch grass pellets and other
fuel may be burned in the Crossfire but results have not been verified.

THE PURCHASE OF A COUNTRY FLAME CROSSFIRE BIOMASS FUEL STOVE IS A VOTE TO
REDUCE AMERICA’S DEPENDENCE ON FOREIGN OIL. Country Flame is very proud of this
American born, American tested, and American made product. With pride and dedication, Country Flame
employees wish you and your family a lifetime of happiness and warmth through the use of our products.

LET US PUT A FLAME IN YOUR HEARTh!

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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., hereinafter referred to as (AES), warrants to you, the original consumer purchaser,
that this product is free from defects in material and workmanship for a period of five (5) years from the original
purchase date minus any time past one (1) year from manufacturing date, and that the product’s electrical parts and
steel firepot, are free from defects in material and workmanship for a period of one (1) year from the original
consumer purchase date minus any time past one (1) year from manufacturing date, and that the cast iron firepot
models carry a lifetime warranty against defect in material or workmanship (excluding war page or deterioration),
and that door glass carries a lifetime replacement warranty against heat breakage (does not cover accidental
breakage) . There is expressly no warranty on installation of product, any venting, grates, gaskets, door latches,
insulation, ceramic or brick boards/logs/backing, paint, plated surfaces/doors/trims, baffles, bushings, bearings,
auger flightings, war page or discoloration of steel or plated parts or any other normal wearing part. In the event the
product fails to conform to this warranty, AES, through the place where you purchased the product or if purchased
on the AES E-Com store directly through AES, will provide the parts and components necessary to remedy such
nonconformity. AES will not be responsible for any labor, mileage or freight cost to the factory under this
warranty. This warranty is not transferable.

In order to obtain performance under this warranty, you must (1) have registered this warranty within 30 days of
purchase by completing and returning the warranty registration card or filling in the on-line warranty registration
form at www.magnumheat.com, and (2) promptly report the claimed nonconformity to your place of purchase,
also providing your name, address, phone number, proof of purchase, date of purchase, the model and serial
number of the stove, digital pictures of installation and venting inside and outside of the home, pictures of the
claimed nonconformity part and the claimed nonconformity. All claims must be submitted in writing to your

place of purchase.

AES shall have no warranty obligations if this product; (1) was not purchased from an authorized AES dealer; (2)
was not installed by a AES dealer or other qualified installer; does not have outside combustion air hooked directly
to the unit; (3) was not operated and maintained in strict accordance with the manufacturer’s instructions, local or
national codes or (4) was subject to abuse, misuse, negligence or accident. AES shall have no warranty obligation
for damage caused by improper handling, freight damage (must be reported to freight provider), over-firing,
unapproved fuel, variance in feed rates, variances in BTU output or the unauthorized disassembly or modification
of the product. AES shall have no warranty obligation if this warranty is not timely registered, for claims which are
not submitted through the selling AES dealer, or for claims submitted verbally or without the required information
and documentation.

Before exercising this warranty, an AES representative (the place where the product was purchased or AES
approved person) must inspect the part/unit to determine if the part/unit is defective. If a local AES representative
is not available the original purchaser of the product must submit digital pictures of the part/unit, installation of the
unit to AES at [e-mail]

If the inspection reveals that the failure is due to defective material or
workmanship and the part is covered by the conditions of this warranty, AES will, at its option, repair the defective
part/unit. The sole duty of AES and liability under this warranty is limited to the repair of the covered defective
part/unit. The purchaser shall assume all costs related to shipping the replacement parts or return of the unit to the
factory for repairs. If it is determined that the defect was caused by AES, AES will cover the costs of shipping the
repaired part/unit to an AES approved shipping point. AES will not cover additional freight or delivery services
such as residence delivery charges, special handling, etc.

INSTALLATION, VENTING, REMOVAL OR REINSTALLATION COSTS ARE NOT COVERED BY

THIS WARRANTY.

THE WARRANTY PRINTED ABOVE IS THE ONLY WARRANTY APPLICABLE TO THE
PRODUCT. ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING, WITHOUT
LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

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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.

Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or
consequential damage, so the above limitations may not apply to you. This warranty gives you specific legal rights, and you
may also have other rights which vary from state to state.

ALL WARRANTY CLAIMS MUST BE SUBMITTED IN WRITING THROUGH THE PLACE WHERE THE
PRODUCT WAS PURCHASED. In the event where the place of purchase has ceased business or if you feel that
there is a legitimate reason that you cannot submit your claim to the place where the product was purchased you
may make a written request to the factory by emailing your request along with all of the required information to

[e-mail]

. NOTE: Verbal requests will not be recognized. If it is determined that

warranty could have been performed by the place of purchase, the factory will deny the claim.

Included with the claim must be the following information: (if this information is not complete, the claim will be
denied)
Name, address, telephone number, email address, of place of business where product was purchased &
also purchaser contact info.
Date of purchase, model and serial number of product, digital pictures of product (front, sides, back,
venting inside and outside)

(If there is ductwork, there must be digital pictures of entire ductwork installation, static pressures, air

flow measurements, and contact information of licensed/factory certified contractor that installed unit)
Nature of defect, what has been serviced (service record), who installed product along with contact
information.

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Place

Stamp

Here

American Energy Systems, Inc
150 Michigan Street SE
Hutchinson, MN 55350

Name Address

City

Dealer

Dealer’s Name

City

Date of Purchase

Model 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.

Signature

Fold Here

State Zip

State Zip

Serial No.

Date

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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. Country Flame is pleased that customers are finding wide success in burning locally available fuels
but Country Flame cannot support or warranty the burning of untested fuel in the Crossfire.

Before beginning to install or operate the Model CF-04 Crossfire, please consult with the local building
authority to obtain a permit and ensure a professional installs or certifies the installation of this product.
Before a homeowner operates this stove, a thorough operational understanding should be obtained from
reading and understanding this manual. Failure to adhere to all safety notes and instructions contained herein
can impact homeowner insurance, void warranty, and create hazardous situations leading to a smoke damage,
fire, or even death.

The Model CF-04 was designed as a insert only model stove. The Crossfire was designed to be installed into
an existing zero clearance fireplace or an existing masonry fireplace. There are no leg or pedestal base
options for the Crossfire. Contact Country Flame or one of its local authorized dealers to discuss and select
possible options that are available for the Crossfire. Once installed, the Crossfire is remarkably simple and
safe to operate. FIGURE 1 and FIGURE 2 defines Crossfire components. From a relatively small firebox the
Crossfire generates a very beautiful flame with lots of heat being produced into the room where the unit is
installed. Clean AFPI approved fuel is to be loaded into the hopper. A motor turns an auger that delivers fuel
to the combustion chamber on a timed basis. Corn or pellet fuels can be fed into the Crossfire burn pot.

FIGURE 1: CROSSFIRE MODEL CF04-FLEX

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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. This exhaust flue will be used to remove combustion gasses outside the home.
REMEMBER: one of the leading causes of house fires is due to improper installation or improper operation
of a stove product. Proper installation and operation of the Crossfire is required to obtain Homeowner
insurance coverage. And, the Crossfire needs a reliable source of electrical power. Without reliable utility
power or a means to ensure reliability, the Crossfire operation will be problematic.

It will require some effort and learning for the homeowner to thoroughly understand the operating
characteristics of the Crossfire. More importantly, the operator needs to know how to control each one of the
stove’s operations. The Crossfire has an electronic control system whose “brain” is constantly monitoring
stove operations in order to ensure fuel combustion efficiency and to ensure maximum heat output of this
product. The Crossfire’s electronic control provides a simple one stop location for the homeowner to control
Crossfire performance. To ensure safe operation, the Crossfire’s electronic control is constantly monitoring
pressure and heat activated switches, and input power to ensure proper operation. Additional features include
an enclosed firebox, high temperature ceramic glass, optional thermostatic control, a high temperature wiring
harness, making the Crossfire an extremely safe stove.

BATTERY BACKUP SYSTEMS

The Country Flame Crossfire Model CF04-FLEX, relies on electrical energy (wall power outlet) to properly
operate. Without electrical energy or with interruptions to the source of electrical energy, the Crossfire
stove’s operation will be erratic at best. Is power quality, power reliability, or routine winter storm conditions
a cause of power problems in a specific locale? If it is, the homeowner will need to provide backup power to

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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. These uninterruptible power supplies (UPS) include the capability to
handle power failures, brown outs, power surges, line noise, and sell for around $35 to $150. UPS system
cost is largely defined by the features included and the amount of time (battery size) the UPS can operate
before recharging of the battery is required. UPS systems are sold by the number of electrical outlets, the
volt-amperes (watts), and the additional features included.

FUEL REQUIREMENTS

The Crossfire Model CF04-FLEX was designed to burn #2 shelled corn, or any mix of both corn and
Premium Hardwood Pellets. The corn’s moisture content should be limited to no more than 14% moisture
content. Country Flame recommends corn fuel moisture content be maintained somewhere in the range of

10% to 12%. USING SEED CORN AS FUEL IS DANGEROUS TO OCCUPANTS. BURNING SEED

CORN VOIDS THE COUNTRY FLAME WARRANTY.

If pellet fuel is added to the corn in the Crossfire, Country Flame recommends no more than 8% moisture
content. The American Pellet Fuel Institute establishes standards for pellet fuel manufacturer’s product.
Pellet Manufacturers voluntarily follow these standards but homeowners should know what to look for. The
following terms should be understood by the homeowner:

ASH: Biomass stoves produce two kinds of ash:

1) Solid ash residue in the firepot; and

2) Fly ash (un-burnt particles) and air born fly ash (sparklers) are created during the combustion process. The
Crossfire has an ash compartment which aids in cleaning the stove. Ash can also accumulate in "ash traps"
which need to be cleaned periodically. The remaining fly ash is blown into the flue system which will also
require periodic cleaning.
FINES: (sawdust): Fines are caused by pellet disintegration that occurs during transport or storage of pellets.
Two potential problems – fines can create dust in the home and fines cause interference to the flow of pellets
in the fuel hopper.
BTU's: (heat) PER POUND: The variation of BTU's per pound in pellet or corn fuel is usually not noticeable
to most users. Overall stove efficiency (combustion efficiency times heat transfer efficiency) has a greater
impact on the heat delivered to the home.
DENSITY: Pellet density (measured in pounds per square foot) determines the maximum amount of energy
that can be delivered to the combustion chamber. Low density fuels may cause the fire to go out on low heat
settings without proper adjustments to the air-to-fuel ratio.
SALT: Salt in pellets can cause stove deterioration (rust). The Pellet Fuels Institute is participating in tests to
determine the effects of salt and the most accurate methods of measurement. The APFI will publish standards
that will result in recommended standards for sodium in pellets.
CLINKERS: Clinkers are the result of impurities in pellets or corn. Clinkers may also occur due to ash
fusion (ash melted together in the burn pot), and can be minimized by properly adjusting the air-to-fuel ratio.
DIRTY GLASS: Glass becomes dirty during normal or faulty combustion. Some fuels produce a film on the
glass to which ash adheres, making a clean glass more difficult.

Pellet fuel manufacturers should be able to show test results for BTU's, ash content, and the amount of fines
in their product. Do not hesitate to contact the pellet manufacturer if you have questions or concerns. If

questions remain about the Crossfire, please contact a local authorized Country Flame Dealer for assistance.

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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.

(2) DO NOT burn seed corn as it is dangerous and voids the Country Flame warranty.

SYSTEM START UP GUIDE

CROSSFIRE – FLEX STOVE

1. Ensure that the CF04-FLEX stove has been installed correctly, and that the manual
has been read and thoroughly understood.

2. Fill hopper with #2 shelled corn (NOT SEED CORN) or any mix of Corn and
Premium Hardwood Pellets, close hopper lid.

3. If the auger has been previously primed or the stove was operational and shut down
without running out of fuel, proceed to step no# 5.

4. “Prime” the auger system of the new Corn stove, or a stove that previously has run
out of fuel. This is done simply by pressing and holding down the control board
“ON/OFF” button (located at the bottom of the control board) until the “Green”
auger feed light starts to flash, (approx 15 seconds) then release button. Prime mode
will take approx. 10 minutes, when you see corn begin to drop into the burn-pot
press and hold the control board “ON/OFF” button for approx. 5 seconds. (The
green light next to the “ON/OFF” button should turn to red, then release.) NOTE:
While in the prime mode the heat setting indicator lights will continue to flash from
low to high.

5.

LIGHTING PROCEDURE Country Flame recommends starting the Crossfire Flex

stove with Wood Pellets. Open stove door, remove un-burnt ash prior to placing
Pellets in layers with igniter/burn gel or igniter bricks into the Burn-Pot, just
covering the stir-rod. Simply press and hold the “ON/OFF” button on the control
board for approx. 5 seconds. (The light next to the button will turn from red to
green, then release.) The light next to the igniter symbol will come on (red).
Manually light the pellets, once the fuel has been ignited, close the Crossfire door
securely. Close the inlet air damper lever almost completely (towards the front of
the stove is closed) until fire gets going. Then gradually increase the amount of inlet

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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. (If it does not, see guide on back of this sheet) The stove will
start up in heat setting #3. Allow adequate burn time for stove to heat up and
stabilize prior to temperature setting change. (approx. 30 min.) Adjust the inlet air

control as required to sustain even continuous burn.

FIGURE 3

On/Off Button

Combustion
Air Control

OPERATING REFERENCE GUIDE

CROSSFIRE – FLEX STOVE (SEE FIGURE #3)

• DO NOT use any other ignition accelerant other than igniter/burn gel or igniter

blocks to start or enhance the fire in the Crossfire stove.

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• FUEL

the only fuel the CF04-FLEX stove is designed to burn is #2 shelled Corn (10-

12% 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. This is
done by pressing, and holding down both the “UP and “DOWN” arrow keys on the
control board at the same time. This will mix the burning pellets, speeding up the burn
process. Note: It rotates at only 1 RPM.

• NOTE:

If the system does not come on after doing Step #6 per the start-up guide it

is because the stove temperature is not hot enough. Carefully open the door and
manually add more pellets to the fire, repeat step #6. Once the system comes on and is
automatically set to heat setting #3, allow the stove adequate time to burn and heat up
properly (approx 30 min.) before changing settings. If a heat setting change is made
more than one bar at a time, (red and blue arrow keys) there is a 2 minute response
delay in the fan speed for each level increase. Adjust the inlet air control as

required to sustain even continuous burn.

• INLET AIR

Make small, slow incremental changes in the air control. If to much

air is given, it will cool the corn below its ignition point and the fire will go out.

The higher the heat level setting on the stove the more inlet air required for a
complete burn of the Corn. Setting No# 5 will require a little more air than setting
No#1. Adjust the inlet control lever accordingly. (To the front of the stove is
CLOSED, see manual for illustration)

• A visual reference to the Ideal burn condition of Corn would show a fuel level in the
Burn-Pot “BELOW” the stir rod at ALL TIMES. This will prevent any possibility
of an over feed condition. The fuel feed rate can be regulated by the potentiometer on
the back of the control board. (See manual)

• STOVE SHUT-DOWN PROCEDURE, during normal operation, simply push the
“ON/OFF” control button, (bottom of the control pad) and hold it for approx. 5

seconds or until the lights on the heat level settings start to flash from top to bottom,
then release. The stove is now in its cool down cycle. (See Manual)

• All questions or concerns about lighting or other stove operational issues should be
directed to your local Country Flame Dealer.

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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. If the proper air-fuel mixture is set by
the homeowner, the Crossfire will generate a very fine ash rather than clinkers. In addition, the stir rod
ensures that the fuel and flame are constantly agitated within the burn pot to enhance the combustion process.
The Crossfire burn pot has been designed to ensure maximum efficiency of burn while minimizing the
amount of ash being produced at the same time minimizing the clinkers that might choke out a fire. Testing
by Country Flame has shown that the Crossfire can be continuously operated for several days without
requiring cleaning. However for optimum stove performance, make sure all air passages and burnpot are free
of obstruction. It should be recognized by the homeowner that environmental variables as well as the type of
fuel being burnt can have dramatic effect on the amount of ash or clinkers formed during the burn cycle.
Burn pot cleaning will depend upon the quality, quantity, and moisture content of the fuel. Ash removal will
be required from time to time depending on the amount of usage and the heat output required. The Crossfire
stove should be shut down and cooled before cleaning or removing any ash from the firebox.

CLEANING - ASH REMOVAL

The Crossfire stove has a deep ash container built into the firebox. There is no removable ash pan located
within the Crossfire. This means the operator must allow the ash to properly cool and then vacuum the ash
from the stove and BURNPOT with an industry approved ash vacuum. Once the ash has been removed from
the firebox, it should be stored or disposed of in proper containers. Failure to properly handle ash, even when
the ash is believed to be completely cool, can lead to a fire.

Always remove ashes after they have been allowed to cool properly. Hot ash is dangerous to both
surrounding areas and occupants and can cause fires or severe burns. Wait until the fire has been out for
several hours before vacuuming the firebox with an industry approved ash vacuum. Protective gloves should
be worn anytime ash is removed. Dump all ash into a proper ash container and remove to a safe outdoors
area. Remember that although the ash may look and feel cool to the touch, a smoldering ember can start a
fire. CAUTION: Care should be used to store any ash in a proper container with an approved airtight lid. If
ash is taken outside, water should be poured over the ash to ensure no fire flare up can occur.

Intelli-Choice CONTROL BOARD

In 2001 Country Flame introduced its own control board technology, called the “
Flame’s control board technology was introduced across all pellets and corn stove product lines. The

Intelli-Choice.” Country

Intelli-

Choice control board is being used exclusively on Country Flame product. This control board technology was

developed to ensure better support to customers. Country Flame will seek to provide the most advanced
controls while maintaining the look and feel our dealers and customers have come to know and expect.
Country Flame also wants to ensure its product can be upgraded to newer and more advanced technology if
and when this technology becomes available and the customer chooses to obtain it. Country Flame is
committed to its customer base. Country Flame will strive to make the service support process easier through
systematic troubleshooting procedures and repair events that should allow for evolving “plug n play”
operations. Country Flame’s goal is to ensure a certified service technician can diagnose and repair any stove
problem in less than 30 minutes. FIGURE 4A depicts control board basic theory and FIGURE 4B provides a
brief description of sensor controls.

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