American Energy Systems Crossfire Pellet User Manual

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COUNTRY FLAME TECHNOLOGIES

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

MODEL CF-04 CROSSFIRE STOVE

FIREPLACE INSERT, (PELLET 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)
Ore

on Administrative Rules 814-23-900 thru 909

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-Pellet Model 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 longer than 1

minute. 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 CF-04 PELLET stove is designed to burn PREMIUM HARDWOOD PELLETS

ONLY. 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: 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 surface. 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.

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.

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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 ....................................................................................................................................17

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)....................................................................................27

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

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

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

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 .........................................................................................................................58

REPLACEMENT LABELS....................................................................................................................58

REPLACEMENT LABELS....................................................................................................................59

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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 pellet 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. 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 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]

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.

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

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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-PELLET OPERATION

(

)

FEATURES

Country Flame designed and built the Crossfire-Pellet stove to burn 100% premium hardwood pellets. Unlike
conventional pellet stoves, the Crossfire was designed to handle large amounts of ash. 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 an insert only model stove. The Crossfire was designed to be installed
into an existing zero clearance fireplace or an existing masonry fireplace. 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 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.

Room Air Fan

Control Board

Power On/Off Switch

Power
Connector

Air
Vent

Combustion
Air Control

Hopper
Lid

Hot Air
Discharge

Front Vent

Glass
(Ceramic)

Door

Cast Standard

Removable
Hearth Plate

FIGURE 1: CROSSFIRE MODEL CF04-PELLET

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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 that 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-PELLET, 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

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backup power to ensure stable operation of the Crossfire. 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-PELLET was designed to burn PREMIUM HARDWOOD PELLETS only. Not
all fuels have been fully tested so results may vary depending on the grade of fuel being burnt. Country Flame
recommends no more than 8% moisture content in the type of pellets being used. 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: Pellet stoves produce two kinds of ash:

1) Solid ash residue in the firepot.

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.
SIZE: The Crossfire can handle a wide variety of pellet size. Variations in pellet size create no problem but
smaller size pellets usually feed at higher rates per Crossfire heat setting and can affect the balance of air-to­fuel. Extra long pellets may create bridging in the hopper which will starve the Crossfire for fuel.
BTU's: (heat) PER POUND: The variation of BTU's per pound in pellet or 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
. 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) door/trim and clean all glass per instructions included in this manual.

NOTE: 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.

START UP PROCEDURE (SEE FIGURE #3)

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

2. Fill hopper with Premium Hardwood Pellets, close hopper lid.

3. Turn power toggle switch to the “ON” position, (Control Board will light up.)

4. If the auger has been previously primed or the stove was operational and shut down
without running out of fuel, proceed to step no# 6.

5. “Prime” the auger system of the new pellet 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 pellets 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.

6. IGNITION PROCEDURE: Simply press and hold the “ON/OFF” button at the
bottom of 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) and the Auger light (green) will start to flash after a slight delay.

7. Close the inlet air damper lever completely. (Pull towards the front of the stove) After
approximately 3 minutes or so open the inlet air damper about 1/2”, the inlet air added
to the smoking pellets should cause ignition. If this does not occur, close damper
completely for another minute or so then repeat.

8. After ignition, the stove will automatically go into the operational sequence after
reaching the appropriate internal temperature. When the ignition cycle is complete the
stove will start up in heat setting #3. NOTE: adjustment to the air inlet control
will be necessary for proper startup.

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9. Heat settings are changed by pressing the red or blue arrow buttons. Note: Inlet air

(

adjustments will/may be required for each temperature setting change. It is best to
only change one level at a time and allow the stove to stabilize.

10. See information on required Cleaning

Power Switch

in the maintenance section of this manual.

FIGURE 3

On/Off Button

Control Board)

Combustion Air Control

REFERENCE OPERATING INFORMATION

(SEE FIGURE #3)

• DO NOT turn main power switch “OFF” during stove operation. The stove must

complete normal cool down cycle prior to shutting power off. (Failure

to do so could cause a backup of smoke into the heating area if the stove is not
properly vented)

• The Room-Air blower has power to it at all times and will run continuously when

the main power switch is in the on position.

• After initial ignition and system start up, allow the stove adequate time to burn and

heat up at the preset #3 level prior to increasing heat setting.

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• 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 exhaust fan speed for each level increase.
This will require the air inlet control setting to be modified / observed throughout the
setting change.

• A visual reference to the Ideal burn condition of pellets would show a fuel level in the
Burn-Pot well “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.

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

• 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. Only after the system has
performed all cool down functions and the control board is back to an “OFF” state,

can the main AC power switch be turned off.

• All questions or concerns about operational issues should be directed to your local

Country Flame Dealer.

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. 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.

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 with an industry approved ash vacuum. Once the ash has been removed from the firebox, it

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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.

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’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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