Country Flame CF-04 manual

Version 2.0e 1 MODEL CF-04 CROSSFIRE STOVE FIREPLACE INSERT, (CORN FUEL VERSION) 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 USA & CANADA TEST: TESTED BY: ASTM E 1509-03, U L CS627-M90 WARNOCK HERSEY ULCS628-M92, UL 1482, Oregon A[...]

Version 2.0e 2 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 requir es a reliable source of electrical energy to properly operate. The owner, installer, and operator must understand this manual and read it i n its entirety. Understa[...]

Version 2.0e 3 W ARNING : Maintain all minimum safety clearances of the Crossfire stove and chimney system. Never install the Crossfire in a sleeping room. W ARNING : The Crossfire is designed and approved for burning o f number 2 yellow shelled corn with a maximum moisture content of 14% or indus try approved wood pellet fuel. Any fuel used in thi[...]

Version 2.0e 4 CAUTION : Operate the Crossfire with the fuel hopper lid closed at all times. Failure t o 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 : Th[...]

Version 2.0e 5 CERTIFICATION SAFETY LABEL (sample)[...]

Version 2.0e 6 TABLE OF CONTENTS SAFETY NOTES................................................................................................................... ...................... 2 EPA STANDARDS .................................................................................................................. ................ 4 LISTING/TESTI NG[...]

Version 2.0e 7 MOBILE HOME IN STALLATION ....................................................................................................... 32 MOBILE HOME RULES .............................................................................................................. ......... 32 MOBILE HOME CLEARANCES .....................................[...]

Version 2.0e 8 FORWARD INTERNATIONAL ISS UES Global concerns about climate change, along with rising world oil prices, are creating unprecedented interest in the development of economical and convenient renewable en ergy fuel burning products. For the past several decades, pellets made fro m wood waste have been marketed and have gained wide accept[...]

Version 2.0e 9 CROSSFIRE LIMITED WARRANTY 1. To Whom Extended: Country Flame Technologies; hereaf ter known as Country Flame, warr ants, with proof of pur chase and pro per filing o f the warranty ca rd, the Cro ssfire Model CF-04 to the original retail purchaser only . 2. Products/Components Warranted. Country Flam e makes the following warranties[...]

Version 2.0e 10 CROSSFIRE LIMITED WARRANTY (continued) (c) Warranty Service and Freight Cos ts . Service on a Crossfire Model CF-04 will be provided by any Count ry Flame authorized dealer or dis tributor. If there is n o authorize d dealer or distributor in the original retail pu rchaser’s area, the original retail purchaser may notify Country F[...]

Version 2.0e 11 Country Flame Technologies A Division of American Products, LLC 900 George Street Marshfield, MISSOURI 65706 Fold Here N a m e Address City State Zip D e a l e r D e a l e r ’ s N a m e City State Zip D a t e o f P u r c h a s e Model No. Serial No. The express warra nties made by C ountry Flame Technol ogies do not appl y unless [...]

Version 2.0e 12 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 possi bility of choking the fire from as[...]

Version 2.0e 13 FIGURE 2: CROSSFIRE COMPONENTS SAFETY FEATURES The Crossfire comes standard with a number of advanced safety fe atures; however, to ensure maximum safety install the stove according to a ll national and local codes and fo llow all operating and m aintenance procedures. The Crossfire requires a fresh air supply to ensure proper combu[...]

Version 2.0e 14 need to provide backup power to ensure stable operati on of the Crossfire. Fortunately, there are simple, reliable, and cost effective power backup solutions av ailable. Today, a homeowner c an choose from a variety of power conditioning systems from a number of “big box” retail stores. For example, Home Depot, Circuit City, Bes[...]

Version 2.0e 15 DENSITY: Pellet density (measured in pounds per square foot) de termines the maxim u m amount of energy that can be delivered to the combustion chamber. Lo w 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).[...]

Version 2.0e 16 combustion process. As heat settings are changed on the Intelli-Choice control board, the stir rod speed will automatically be adjusted to more closely matc h 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 homeowne[...]

Version 2.0e 17 FIGURE 3: CONTROL BOARD BLOCK DIAGRAM Input Voltage 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 H e rtz and a maximum branch current capacity of 15 Amperes. If other devices are connected to the branch, interference or over curr[...]

Version 2.0e 18 FIGURE 5 displays the Country Flame Control Board front panel. Each function of the Control Board is identified. Controls having more than a single func tion are identified with asterisks. All control board functions are explained in FIGURE 6. “Intelli-Choice” Country Flame Logo, AC Power is present wh en logo is lit. Lighting S[...]

Version 2.0e 19 FIGURE 6: CONTRO L BOARD FUNCTIONS Country Flame’s control board provides reliable control of stove functions with minimal human intervention required. This control technology provides flexibility in adapting to future ch anges and improvements in technology. Finally, this control technology offers a simple interface between the o[...]

Version 2.0e 20 In order to utilize the full capabilities of the Contro l Board, the homeowner should be familiar with the backside of the Control Board. FIGURE 7 provides additional information about the m ajor components on the component side of the control board. FIGURE 7: CONTROL BOARD COMPONENT SIDE[...]

Version 2.0e 21 STOVE ELECTRICAL DIAGRAM FIGURE 8 provides the Harvester electrical schematic of the components and sensors that are either operated or monitored by the Country Flame control bo ard. Please refer to this diagram when necessary. FIGURE 8: ELECTRICAL DIAGRAM (optional manual igniter shown)[...]

Version 2.0e 22 STOVE SPECIFICATIONS TABLE 2 shows the physical dimensions of the Crossfire product. CROSSFIRE DIMENSIONS (IN INCHES) STOVE HEIGHT (At Front) 22.5“ STOVE DEPTH (From Shroud) 14.0“ STOVE WIDTH (Rear) 26.0“ STOVE WIDTH (At Shroud Mount) 25.5“ STOVE WEIGHT (em pty ) 220 pounds SHROUD WIDTH, ( standard) 42.0” SHROUD HEIGHT (st[...]

Version 2.0e 23 • If the heat level is equal to 1 when the thermostat calls for heat th e Intelli-Choice Control Board will use this setting whether heat is called for or not. • The stove will operate at the selected Heat Level until such time as the thermostat stops calli ng for heat. The Intelli-Choice Control Board will then return the stove[...]

Version 2.0e 24 INSTALLATION INSTALLATION PREPARATION Country Flame strongly recommends t he Crossfire be installed by a certified professional. Improper installation will create long-term operational and maintenance problem s that will plague the homeowner until corrected. The first step is to ensure all necessary parts are available to complete a[...]

Version 2.0e 25 installation into an approved masonry or zero clearan ce fireplaces, the use of single or double-wall flue pipe will not affect the clearance distance from the unit to any combustible materials. DEFINED MINIMUM DISTANCES TO COMBUSTIBLES CLEARANCE A. UNIT TO SID EWALL 7” B. UNIT TO SID E TRIM 7” C. UNIT TOP TO TOP TRIM 9.25” D.[...]

Version 2.0e 26 shroud can be moved left, right, or centered on the Crossfire depending on t he requirements of the hearth. The installer should make final adjust ments to properly locate the top shroud on the Crossfire and then tighten the two nuts. The top shroud is now properly positioned and secured in place and the installer can proceed to in [...]

Version 2.0e 27 4. The installer should now install the fiberglass in sulation on the back face of the shroud s y ste m as shown in FIGURE 11c and 11d. One roll of insulation is required for a standard, CF04- 9200, shroud and two rolls of insulation are required for an oversized, CF04-9210, shroud. Fiberglass insulation serves to ‘seal’ the shr[...]

Version 2.0e 28 6. The installer should now place the trim (black or gold as purc hased) around the edges of the shroud panels. Once installed, if the bottom left or right side trim pieces want to pull away from the shroud panel, a small amount of RTV (s ilicone) may be used on the backside of the shroud panel to hold the trim in place. Clo se and [...]

Version 2.0e 29 CHIMNEY It is extremely important that a Crossfire stove be ve nted into a non defective, clean, and properly lined chimney. The chimney system must conform to a ll local building codes. In the event a masonry chimney is not used, a listed factory-built chimney su itable for use with solid fuels should be used. This listed factory-b[...]

Version 2.0e 30 combustion. In all cases, the flue must be relin ed with a liste d liner system, such as HomeSaver Chimney Liner. If your masonry built chim ney cont ains oversized flue tiles it must be relined to ensure proper draft. This means that a new, prope rly sized liner system must be installed before connection to the Crossfire stove is c[...]

Version 2.0e 31 carpet to come in contact with any part of the Crossfire insert. Maintain clearances to combustibles as specified in TABLE 1, page 24 of this ma nual. OUTSIDE AIR CO MBUSTION It is imperative that the installe r and homeowner ensures that a minimum of at least eight square inches (fifty square centimeters) of outside air be admitted[...]

Version 2.0e 32 MOBILE HOME INSTALLATION WARNING: DO NOT INSTALL A COUNTRY FLAME CROSSFIRE STOVE IN ANY MOBILE HOME SLEEPING ROOM. WARNING: THE STRUCTURAL INTEGRITY OF THE FLOOR, WALL, CEILING AND ROOF MUST BE MAINTAINED DURING THE INSTALLATIO N OF A COUNTRY FLAME CROSSFIRE STOVE IN A MOBILE HOME. WARNING: A CROSSFIRE STOVE INSTALLED IN A MOBILE HO[...]

Version 2.0e 33 Do not violate minimum clearances with approved thermal barriers. Manv ille’s CERAFORM 126 is an example of an approved insulated wall protector. This product has a K equal to .27 and is a half- inch thick. Total thermal resistance should exceed 1.5 for any material used to ensure proper thermal protection of a combustible wall. M[...]

Version 2.0e 34 3. At no time should a floor protector be placed on top of carpeting. Carpeting must be removed and the floor protection should sit d irectly on th e uncarpeted portion of the mobile home floor. Floor protection should extend to the front, sid es, back, and under the chimney connector as defined for a specific model listed in this m[...]

Version 2.0e 35 height, ceiling slope, roof pitch, attic insulation, attic height, and surrounding objects. U se a certified professional to install a flue gas pellet venting system. Do not deviate from the pellet flue manufacturer’s installation instructions. Cont act Country Flam e or a local authorized dealer to resolve any questions or instal[...]

Version 2.0e 36 FIGURE 15: MOBILE HOME CHIMNEY INSTALLATION[...]

Version 2.0e 37 MAINTENANCE REQUIREMENTS GENERAL REQUIREMENTS The Crossfire Model CF-04 has minimal maintenance requirements; however, failure to perform cleaning or maintenance items will lead to degraded performance and potential safety hazards for both the home and its occupants. The Crossfire stove should not be operate d routinel y without tho[...]

Version 2.0e 38 STOVE DOOR ADJUSTMENT The Crossfire door may require fine adju stm ent due to variations in the door , the gasket material, due to hinge wear, or to maintain a center-aligned appearance. Th e Crossfire door needs to re main airtight to ensure proper firebox operation. The Crossfire door can be adjust ed up or down and left or right [...]

Version 2.0e 39 the door glass. Removal of these glass retaining clips can be accom plished with household tools. Order the necessary replacement scr e ws or glass clips when or dering glass to ensure worn parts are replaced. GLASS-CERAMIC SPECIFICAT IONS Manufacturer Euro Kera Window Type Glass-Cera mic, Kera Lite® KERA LITE® glass-ceramic has a[...]

Version 2.0e 40 In order to thoroughly clean the exhaust chamber, the Crossfire has two cleaning ports that provide access to the exhaust chamber. In order to gain access to these clean-out ports, the hearth plate must be removed from the front of the Crossfire. FIGURE 18 shows the hearth plate removed from the stove. There is one screw, located in[...]

Version 2.0e 41 inefficiently. FIGURE 20 shows an x-ray view into the clean -out port of the right side of the Crossfire. This right side clean-out port allows access to the right side exhaust chamber and underneath the exhaust fan itself. There is no access to the chimney connector and clean out T box but a powerful vacuum will be able to suck con[...]

Version 2.0e 42 APPENDIX A: TROUBLESHOOTING GUIDE Shut off the power to the unit and allow it to cool off wh en performing cleaning and maintenance. PROBLEM SOLUTION Ignition Fire does not start. Ensure proper amount of pellets and st arting gel are in burn pot. Stove does not switch on The starter fire in the firepot has not ignited or is not burn[...]

Version 2.0e 43 APPENDIX A: TROUBLESHOOTING GUIDE (CONT’D) Stirring Paddles do not turn The chain drive for the stirring paddles ne eds to be checked after the first 8 hours of ope ration as it can loosen. It i s located by opening the left side do or (the one with the control panel). Insp ect the tension of the chain. It should have approxim ate[...]

Version 2.0e 44 APPENDIX B: MAINTENANCE GU IDE Shut off the power to the unit and allow it to cool off wh en performing cleaning and maintenance. Regular Cleaning Removing and cleaning the Firepot The firepot can be removed by rem oving 2 bolts. Slide the keeper sleeve off of th e stir rod gear shaft exposing the linkage. Rotate the stir rod until [...]

Version 2.0e 45 APPENDIX B: MAINTENANCE GU IDE (C ONT’D) Cleaning the Glass To clean glass, use a mild non-abrasive cleaner when the stove and glass are COOL . Creos ote builds up on glass qu icker wh en a fire is burned at lower heat settings. DO NOT use abrasive cleaners on glass. (Glass may crack if subjected to cold liquid cleaners while th e[...]

Version 2.0e 46 APPENDIX B: MAINTENANCE GU IDE (C ONT’D) Replacing the Do or / Glass Gaskets To replace the gaskets, remove the door by lifting it straight up off its hinge pins and laying it face down on a soft surface. Remove the door gasket (you may need to use pliers) and then remove the glass retaining clips and remove glass. Stri p off old [...]

Version 2.0e 47 APPENDIX C: TECHNICAL SPECIFICATIONS Fuel Type: #2 Yellow Shelled Corn Fuel Wood Pellet Fuel Moisture Content: 14 % or less (1 2% preferred) A.P.F.I. residential fuel Heat Content: 10,000 Btu/lb* Heat Con tent: 8200 BTU/lb Ash Content: 3% maximum Ash Content: 1% max 5.9 lbs/h our maxim u m feed rate Bulk Density: 40 lb./cubi c ft. m[...]

Version 2.0e 48 APPENDIX D: CROSSFIRE THEORY OF OPERATION STARTUP PHASE Startup procedure assumes that proper electrical power is being provided from the electrical grid (Power Company) and the stove is in proper working order. Approaching the control panel no lights will be illuminated. Upon pressing the on/off switch the Crossfire’s startup pha[...]

Version 2.0e 49 APPENDIX D: THEORY OF OPERATION (cont’d) COOL DOWN PHASE Any time the system is switched off by holding the on/off switch for more than 3 seconds during normal stove operation, the control system will revert to the co ol down phase. During the cool down phase the room, exhaust, and stir pot motors will be operated at high speed. T[...]

Version 2.0e 50 on/off switch at which time the system will revert to the off state. The prime state is utilized only for filling the auger with fuel and can only be utilized from an “off state.” The Stir Rod is controlled by the control board in one of two states: (a) when the system is shutdown, and (b) when the system is in the burn phase. T[...]

Version 2.0e 51 APPENDIX E: COMBUSTION BASICS An understanding of Combustion Basics will assist in resolving problems with a variety of fuels, changing product and environm ental conditions dur ing the operational life of a stove. Just exactly what are pellet or corn stove products suppose to do? PROVIDE A CONVENIENT PLACE F OR STORAGE OF FUEL. PRO[...]

Version 2.0e 52 Combustion Temperature: T he temperature required to ensure the release of flammable vapors. To sustain combustion, the heat evolved must maintain this tem perature to provide a constant supply of vapors. Excess Air: Any air added to the combustion process above the theoretical value defined as 100% efficiency. A combustion system o[...]

Version 2.0e 53 The obvious advantage of wood pelle ts over conventional chopped wood l ogs is the consistency of the fuel both from a size and moisture content. Nature has done a great job of m ak ing field corn a palletized fuel that can have even more energy than wood pell ets. These palletized fuels burn more efficiently than their wood log cou[...]

Version 2.0e 54 As a final note, the four basic stages of wood pellet burning are: a) Up to 212 o F the pellet is boiling of the moisture. b) Near 575 o F gasification of the solid wood pellet fuel occurs. The p ellet will simply seem to disappear. Very little energy is released in these first two stages and external energy must be applied to susta[...]

Version 2.0e 55 APPENDIX F: REPLACEMENT PARTS REPLACEMENT PARTS Part Number Description N u m b e r p e r CROSSF IRE CF04-P72 BURN POT SCREEN 1 CB-74 STIR ROD ASSEMBLY 1 CF04-A64 BURN POT ASSEMBLY 1 PP-664 200 Watt IGNITER ASSEMBLY 1 ( OPTIONAL ON EARLY MODELS ) PP-353 EXHAUST MOTOR AS SEMBLY 1 PP-355 ROOM AIR MOTOR AS SEMBLY 1 PP-352 VACUUM S ENSO[...]

Version 2.0e 56 APPENDIX F: REPLAC EMENT PARTS (cont’d) REPLACEMENT PARTS Part Number Description N u m b e r p e r CROSSFIRE INSERT CF04-A24 4” CHIMNEY CONNECT BOX 1 PP-535 AUGER M OTOR ASSEMBLY 1 P P - 2 7 V A C U U M H O S E 1 PP-88 HOPPER GASKET TAPE 1 PP-48 NON-ETCHE D DOOR GLASS W/TAPE 1 PP-525 ETCHED DOOR GLASS W/TAPE 1 PP-107-G SIDE TRI[...]

Version 2.0e 57 APPENDIX G: LABELS REPLACEMENT LABELS Part Number Description N u m b e r p e r CROSSFIRE INSERT P P - 4 8 3 C A U T I O N L A B E L 1 P P - 4 8 4 C A U T I O N L A B E L 1 PP-35-0300-13 ATTENTION LABEL 1[...]

Version 2.0e 58 APPENDIX G: LABELS (cont’d) REPLACEMENT LABELS Part Number Description N u m b e r p e r CROSSFIRE INSERT PP-35-0300-39 LIGHTING LABEL 1 PP-486 ELECTRICAL LABEL 1[...]