Country Flame CF-04 User Manual

COUNTRY FLAME TECHNOLOGIES

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

MODEL CF-04 CROSSFIRE STOVE

FIREPLACE INSERT, (CORN FUEL VERSION)

USA & CANADA TEST: TESTED BY: ASTM E 1509-03, ULCS627-M90 WARNOCK HERSEY ULCS628-M92, UL 1482, Oregon 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.

Country Flame Technologies

A Division of American Products, LLC

900 George Street Marshfield, MO 65706 417-859-0990 phone 417-859-0192 fax

www.countryflame.com

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

FOR YOUR SAFETY

SAFETY NOTES

The Crossfire Model CF-04 biomass 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.

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.

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

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.

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

any maintenance operations.

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.

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.

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

Country Flame’s product warranty.

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.

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

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.

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.

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.

ARNING: The Crossfire is designed and approved for burning of number 2 yellow shelled corn with

a maximum moisture content of 14% 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

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.

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

in the Crossfire. Using fuels that do not meet APFI standards voids the Country Flame warranty. Damage to the stove resulting from foreign objects is not covered by warranty.

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.

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

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.

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 the 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.

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.

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, AND FURNITURE AWAY. CONTACT WITH HOT SURFACES MAY CAUSE SEVERE SKIN BURNS

. 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 E1509-03, ULCS627-M90, ULCS628-M92, UL 1492 standard 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

INTERNATIONAL ISSUES ....................................................................................................................8

NORTH AMERICA..................................................................................................................................8

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

CROSSFIRE LIMITED WARRANTY ....................................................................................................9

CROSSFIRE LIMITED WARRANTY (continued)..............................................................................10

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

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

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

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

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

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

PRIMING............................................................................................................................................15

FIRST FIRE ........................................................................................................................................15

ASH REMOVAL....................................................................................................................................16

Intelli-Choice CONTROL BOARD........................................................................................................16

STOVE ELECTRICAL DIAGRAM.......................................................................................................21

STOVE SPECIFICATIONS ...................................................................................................................22

ELECTRICAL REQUIREMENTS.........................................................................................................22

GOLD DOOR CARE..............................................................................................................................22

OPTIONAL FEATURES........................................................................................................................22

OPTIONAL THERMOSTAT OPERATION..........................................................................................22

CROSSFIRE IS COLD.......................................................................................................................22

CROSSFIRE IS HOT..........................................................................................................................22

CHANGE HEAT LEVEL (thermostat active)....................................................................................23

CHANGE HEAT LEVEL (thermostat inactive).................................................................................23

COMBUSTION FRESH AIR CONTROL .............................................................................................23

INSTALLATION......................................................................................................................................24

INSTALLATION PREPARATION .......................................................................................................24

STOVE CLEARANCES.........................................................................................................................24

SHROUD SYSTEM................................................................................................................................25

CHIMNEY ..............................................................................................................................................29

FACTORY-BUILT CHIMNEY..............................................................................................................29

MASONRY BUILT CHIMNEY.............................................................................................................29

FLOOR PROTECTION REQUIREMENTS ..........................................................................................30

OUTSIDE AIR COMBUSTION.............................................................................................................31

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MOBILE HOME INSTALLATION .......................................................................................................32

MOBILE HOME RULES .......................................................................................................................32

MOBILE HOME CLEARANCES..........................................................................................................32

MOBILE HOME STOVE ATTACHMENT...........................................................................................33

MOBILE HOME FLOOR PROTECTION.............................................................................................33

MOBILE HOME CHIMNEY AND DUCTS..........................................................................................34

MAINTENANCE REQUIREMENTS ....................................................................................................37

GENERAL REQUIREMENTS...............................................................................................................37

STOVE DOOR INSTALLATION..........................................................................................................37

STOVE DOOR ADJUSTMENT.............................................................................................................38

STOVE DOOR GLASS CLEANING.....................................................................................................38

GLASS REPLACEMENT ......................................................................................................................38

GLASS-CERAMIC SPECIFICATIONS................................................................................................39

GASKET REPLACEMENT...................................................................................................................39

CROSSFIRE CLEANING ......................................................................................................................39

APPENDIX A: TROUBLESHOOTING GUIDE..................................................................................42

APPENDIX A: TROUBLESHOOTING GUIDE (CONT’D) ..............................................................43

APPENDIX B: MAINTENANCE GUIDE.............................................................................................44

APPENDIX B: MAINTENANCE GUIDE (CONT’D).........................................................................45

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

APPENDIX C: TECHNICAL SPECIFICATIONS.............................................................................. 47

APPENDIX D: CROSSFIRE THEORY OF OPERATION ................................................................ 48

STARTUP PHASE..................................................................................................................................48

BURN PHASE........................................................................................................................................48

COOL DOWN PHASE...........................................................................................................................48

APPENDIX D: THEORY OF OPERATION (cont’d)..........................................................................49

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

FAULT PHASE ......................................................................................................................................49

RESET CONDITION..............................................................................................................................49

SYSTEM MAINTENANCE...................................................................................................................49

APPENDIX E: COMBUSTION BASICS..............................................................................................51

APPENDIX F: REPLACEMENT PARTS ............................................................................................55

REPLACEMENT PARTS ......................................................................................................................55

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

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

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

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

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FORWARD

INTERNATIONAL ISSUES

Global concerns about climate change, along with rising world oil prices, are creating unprecedented interest in the development of economical and convenient renewable energy fuel burning products. For the past several decades, pellets made from wood waste have been marketed and have gained wide acceptance as a home heating alternative. In addition, there has long been a “grass roots” effort to utilize biomass feedstock as a viable heating fuel. Use of agricultural products such as corn, switch grass, and other annual crops can abate greenhouse gas emissions by increasing carbon storage in the surrounding landscape while displacing fossil fuel use in combustion heating products. Agricultural based pellet fuel is capable of sustained high volume throughput rates that use less energy to produce when compared to the present wood industry. Long term, biomass pellet fuel offers the potential to become a key part of the global community’s effort to reduce if not reverse the greenhouse effect. This is especially true when emerging third world countries, their growth rates, and their demand for energy is factored into the greenhouse equation.

NORTH AMERICA

United States and Canadian stove manufacturers have over three decades experience in providing wood pellet fuel and wood pellet burning products to the hearth industry market. The maturity of this market has ensured a continuous supply of both pellet fuels and pellet appliances while world fossil fuel issues have ensured an ever increasing market demand for more of these products.

These same American and Canadian manufacturers continue to innovate and improve wood pellet products with each passing year. At the same time, an ever increasing demand for the wood fuel puts pressure on both sustaining the volume and the quality of raw materials needed to meet the needs of the fuel market. Transportation costs associated with moving the raw materials to the pellet mill significantly impact the local and regional availability of pellet fuel. Research has proved that there are many agricultural based crops and crop byproducts that can be utilized to fuel biomass heating stove products to meet this ever growing market demand. The demand for biomass burning fuel stoves is ever increasing.

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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CROSSFIRE LIMITED WARRANTY

2. Products/Components Warranted. Country Flame makes the following warranties regarding its Model

3. Terms, Conditions and Restrictions.

4. Remedies in the Event of Failure. In the event a Crossfire Model CF-04 fails to perform as warranted,

To Whom Extended: Country Flame Technologies; hereafter known as Country Flame, warrants, with proof of purchase and proper filing of the warranty card, the Crossfire Model CF-04 to the original retail purchaser only.

CF-04 Corn/Pellet Stove Heaters and Inserts: (a) Heating Units. Except as set forth below, Country Flame warrants the Crossfire Model CF-04 to

be free from defects in materials and workmanship for a period of (5) years from date of purchase, so long as the unit is owned by the original consumer purchaser, subject to terms, conditions, and restrictions set forth below.

(b) Blowers, Fan Speed Controls and Electrical Components. Country Flame warrants the

blowers, fan speed controls and electrical components of its Model CF-04 to be free from defects in materials and workmanship for a period of one (1) year from the date of retail purchase OR not more than (2) years from date of manufacture, whichever occurs first, subject to the terms, conditions and restrictions set forth below.

(a) Products Not Covered. The above warranties do not apply to glass, refractory materials such as

refractory cement or firebrick, gaskets, and irons, paint, and standard accessories, and all parts not permanently attached to the heating unit. Parts not permanently attached to the heating unit are those items designed to be removed from the unit, including those removable with common hand tools.

(b) Exclusions. The above warranties do not apply to the following conditions or circumstances:

(1) To conditio ns resulting from the Crossfire Model CF-04 being installed other than in

accordance with the instructions and specifications included in the operating and maintenance instructions.

(2) To conditions resulting from failure to provide reasonable and necessary maintenance

for the Crossfire Model CF-04 in accordance with the operating and maintenance instructions.

(3) To conditions resulting from the alteration or modification of any Crossfire Model CF -

04 by anyone other than an authorized Country Flame representative with written instructions to complete such alteration or modification.

(4) To cond itions resulting from failure to use and operate the Crossfire Model CF-04 in

accordance with Country Flame operating and maintenance instructions or as a result of misuse of the product.

(5) To co nditions not resulting from defects in material or workmanship of the Crossfire

Model CF-04.

(6) To conditions resulting from the improper firing or burning of materials in a Crossfire

Model CF-04.

unless the Warranty Registration Card provided with the owner’s manual is properly completed and mailed by the original retail customer and received by Country Flame within thirty (30) days subsequent to the date of original retail purchase.

the following terms and conditions will apply: (a) Heating Unit. Country Flame will repair, or at its option, replace any warranted part of the

heating unit that fails to perform as warranted for the lifetime of the original retail purchaser, subject to the term, conditions and restrictions set forth herein.

(b) Blowers, Fan Speed Controls and Electrical Components. If the blowers, fan speed controls

or components of the Crossfire Model CF-04 fail to perform as warranted for one (1) year subsequent to the date of retail purchase, Country Flame will repair, or at its option, replace the defective product or component.

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CROSSFIRE LIMITED WARRANTY (continued)

provided by any Country Flame authorized dealer or distributor. If there is no authorized dealer or distributor in the original retail purchaser’s area, the original retail purchaser may notify Country Flame at 900 George Street, Marshfield, Missouri, 65 706 of any defect by providing the following information:

1. The Serial Number of the Crossfire Model CF-04

2. The date of original purchase

3. The name of the dealer where the product was purchased

4. The date of installation; and

5. A description of the nature of the defect or problem. If service is required, the original retail purchaser must send the product or component, freight or postage prepaid, to Country Flame or a designee of Country Flame’s choice. Country Flame will not pay freight or postage costs relating to products or components returned for warranty service.

(d) Repairs. All repairs made by Country Flame or its authorized dealers or distributors will be

to the original manufacturing specifications.

(e) Cost of Repair or Replacement. Country Flame will repair, or at its option, replace the

defective products or component pursuant to the conditions set forth above. The original retail purchaser is responsible for payment of any costs and expenses of disassembly, removal and reinstallation of any defective product or component and any other services involved. Such costs o r expenses are NOT covered by this warranty and Coun try Flame is not liable for any of them.

5. Limits on Damages. In no event shall Country Flame be liable for damage to property, lost

profit, injury to goodwill, or any other special, incidental or consequential damages resulting from any defective Crossfire Model CF-04product or any breach of the above express warranties. Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation may not apply to you.

6. Limitation of Implied Warranties. Country Flame expressly limits all implied warranties.

Implied warranties include but are not limited to warranties of merchantability or fitness for a particular purpose to one year from the date of original retail purchase. Some states do not allow limitations of how long an implied warranty lasts, so the above limitation may not apply to you.

7. Legal Rights. This warranty gives you specific legal rights, and you may also have other rights

that vary from state to state.

8. No Other Warranty – These Remedies Are Exclusive. Unless otherwise explicitly agreed to

in writing, it is understood that this is the only warranty given by Country Flame, and Country Flame neither assumes or authorizes anyone to assume for it any other obligations or liability in connection with this Country Flame product.

9. Additional Information. If you wish to obtain additional information or resolve questions

concerning the interpretation of any warranties of Country Flame, please write:

email@countryflame.com

Country Flame

900 George Street

Marshfield, MO 65706

417-859-0990 phone

417-859-0192 facsimile

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Place

Stamp

Here

Country Flame Technologies A Division of American Products, LLC

900 George Street Marshfield, MISSOURI 65706

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

Serial No.

Date

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THE CROSSFIRE OPERATION

FEATURES

Country Flame designed and built the Crossfire 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 wood pellets 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 remark ably 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 CF-04 (biomass 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 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 CF-04, like all pellet or biomass fuel stoves, 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

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need to provide backup power to 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.

What does the Crossfire stove require from a UPS system in order to sustain proper operation during a power outage? To answer that question, the homeowner has to decide how long they want the Crossfire to operate in the absence of utility “grid” power. At the same time, an inexpensive solution that will handle a large percentage of many of the most common electrical problems cost less than $100. For about $60 to $70 the homeowner can purchase a UPS product that will operate the Crossfire for close to an hour. This same UPS system should provide an audible, as well as visual alarm, to alert the homeowner to local utility interruptions or power outages. The homeowner can then make the decision to continue to operate the Crossfire or shut it down until the local utility restores local power. Further, this UPS system will ensure that minor utility glitches do not cause “nuisance” shutdown or faults in a Crossfire stove. If a homeowner wants specific information concerning the size and quality of a specific battery backup system for their Crossfire stove, contact Country Flame or one of its local authorized dealers who will assist in providing a specific solution.

FUEL REQUIREMENTS

The Crossfire Model CF-04 was designed to burn multiple types of fuel, including corn, switch grass and wood pellets. Not all fuels have been fully tested so results may vary depending on the grade of fuel being burnt. Country Flame recommends number 2 yellow shelled corn be used as a fuel. 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 (wood or other solid biomass pellet fuel) is used 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. 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 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.

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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.

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.

PRIMING

Loading fuel in the Crossfire for the first time is simplified by the Prime Mode. The prime mode is entered by holding the ‘on/off button’ for a minimum of 15 seconds. The fault code display will show a “P” indicating the prime mode has been entered. During prime mode, the auger motor runs continuously until the ‘on/off’ button is again pressed or until timeout occurs (approximately 20 minutes.) Once fuel starts dropping onto the burn pot, the operator should hold the on/off button until the Crossfire is turned off. The Crossfire prime mode can be used to fill the auger system any time the hopper as been depleted of fuel.

FIRST FIRE

Country Flame recommends using wood pellets to start the Crossfire. Wood pellets should be added into the burn pot before startup procedures are begun. Pellet fuel will assist the ignition process of corn. The Crossfire is equipped with an electronic igniter. This igniter is controlled by a separate on/off switch located above the “Intelli-Choice” control board. FIGURE 3 demonstrates a block diagram of the Crossfire control system. The igniter should easily ignite wood pellets within 20 minutes or less. If corn is being used as the primary fuel, it is important that the firepot have a hot pellet fire burning before feeding corn into the burn pot. A hot pellet fire is required due to the higher combustion temperatures required in order to ignite and burn corn fuel.

Wood pellets should be added into the burn pot until they reach the bottom of the stir rod arm inside the burn pot. Once the wood pellets have been added, the igniter switch should be turned on. Then immediately turn on the Intelli-Choice on/off switch. The Intelli-Choice power light will turn from red to green and the igniter light will blink slowly. Monitor the wood pellet fire until a good blaze has been established. Once a good pellet fire has been established, press the Intelli-Choice on/off switch until the igniter red light blinks rapidly. Release the on/off switch and if the Crossfire has reached proper startup temperature, the control board will turn the heat setting on to #3 and automatically begin feeding corn.

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

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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 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 3 depicts control board basic theory and FIGURE 4 provides a brief description of sensor controls.

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INPUT VOLTAGE

120 Volts AC 60 Hz

15-Ampere Circuit

VACUUM SENSOR

Fuse

6 – 9

Amperes

EXHAUST

TEMPERATURE

SENSOR

FIGURE 3: CONTROL BOARD BLOCK DIAGRAM

Input Voltage

Fuse Vacuum Sensor

Exhaust Temperature Sensor

Room Air Temperature Sensor

Overtemp Sensor Fuel Control

Room Air Control

Combustion Air Control

Stir Rod

Thermostat (optional)

OVERTEMP

SENSOR

FUEL

CONTROL

COMBUSTION AIR CONTROL

THERMOSTAT

(Optional)

CONTROL BOARD

ON/OFF SWITCH

TEMPERATURE CONTROL

POWER/FUEL/IGNITER/ INDICATORS

ROOM AIR TEMPERATURE SENSOR

Alternating Current (AC) Input provided by the local power company. This source of energy must provide a 120 Volt input signal with a frequency of 60 Hertz and a maximum branch current capacity of 15 Amperes. If other devices are connected to the branch, interference or over current may cause circuit breaker to trip. The AC fuse should be rated between 6 and 9 amperes. The recommended fuse is a Little Fuse Model _______. Ensures that no blockage of the combustion input or combustion exhaust air occurs. If the vacuum sensor does not operate properly, the Control Board will not allow the stove to operate. Presently, this sensor is a snap disk operating at 110o F +/- 20o F. This sensor ensures proper exhaust temperature has been reached and that a fire is present in the burn pot before the control system begins the burn cycle. Presently, this sensor is a snap disk operating at 110o F +/- 20o F. This sensor ensures that a proper amount of heat is available at the heat exchanger before the room fan is allowed to operate. If the sensor allows the fan to come on to early, the combustion chambers temperature could drop to the point that self-combustion (ignition temperatures) cannot be maintained. Presently, this sensor is a snap disk operating at 250o F +/- 20o F. The purpose of this sensor is to shut the entire system down in the event the firebox causes an overheat condition. The fuel control is a signal provided from the Control Board to the Auger Feed Motor. The Control Board controls the amount of time that the Auger Feed Motor is on and thereby controls the amount of fuel fed to the fire pot. The room air control is a signal provided from the Control Board to the Room Air Fan. The Control Board controls the phase angle and thereby the amount and time an AC voltage is applied to the Room Air Fan. This signal controls the speed of the room air passing over the heat exchanger tubes and the amount of heat delivered to the living space. The combustion air control is a signal provided from the Control Board to the Combustion Fan. The Control Board controls the phase angle and thereby the amount and time an AC voltage is applied to the Combustion Air Fan. This signal controls the speed of the combustion air passing through the burn pot for the different heat settings An AC device used to create turbulence in the burn pot. The stir rod reduces the potential of a klinker thereby ensuring more efficient combustion process. The operator must remove and clean the stir rod from time to time. Be careful not to damage or break the stir rod.

A thermostat input is provided on the back of each Country Flame product. The Control Board has individual personality modules that allow for stand-alone, semi automatic, or fully automatic thermostat operation.

ROOM AIR

CONTROL

STIR ROD

STOVE

FIGURE 4: STOVE COMPONENT DEFINITIONS

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FIGURE 5 displays the Country Flame Control Board front panel. Each function of the Control Board is identified. Controls having more than a single function are identified with asterisks. All control board functions are explained in FIGURE 6.

“Intelli-Choice”

Country Flame Logo, AC

Power is present when logo is lit.

Lighting Symbol Slow/Fast Blink depending

on ‘on state.’ Auger Feed Symbol Auger Feed Light, Green when Auger is on

* Heat Up Switch High Heat Setting Red When Lit

Medium Heat Setting Yellow When Lit

Low Heat Setting Yellow When Lit *Heat Down Switch

*ON/OFF Switch *DC Power on Light Red, System Off Green, System On Yellow, System Dirty

FIGURE 5: CONTROL BOARD FACE PLATE

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+ 40 hidden pages

Country Flame CF-04 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual