Country Flame CF-04 Crossfire Installation, Operation And Maintenance Manual
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Country Flame CF-04 Crossfire Installation, Operation And Maintenance Manual

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C
ountry 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
Version 2.0fc
Version 2.0fc
COUNTRY FLAME TECHNOLOGIES
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
MODEL CF-04 CROSSFIRE STOVE
FIREPLACE INSERT, (CORN FUEL VERSION)
USA & CANADA TEST:
ASTM E 1509-03, ULCS627-M90
ULCS628-M92, UL 1482,
Oregon Administrative Rules 814-23-900 thru 909
WARNING:
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.
© 2006
TESTED BY:
If the directions in this manual are not followed exactly, a fire
FOR YOUR SAFETY
1
WARNOCK HERSEY
MOBILE HOME APPROVED

COUNTRY FLAME

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  • Page 1: Country Flame

    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...

  • Page 2: Safety Notes

    The Crossfire Model CF-04 CORN 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.
  • Page 3 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...

  • Page 4: Epa Standards

    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.

  • Page 5: Certification Safety Label (Sample)

    CERTIFICATION SAFETY LABEL (sample) Version 2.0fc...

  • Page 6: 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 ....................9 CROSSFIRE LIMITED WARRANTY (continued) ................10 THE CROSSFIRE OPERATION ......................12 FEATURES.............................12 SAFETY FEATURES..........................13 BATTERY BACKUP SYSTEMS ......................13 FUEL REQUIREMENTS ........................14...
  • Page 7 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...

  • Page 8: Forward

    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.

  • Page 9: Crossfire Limited Warranty

    Country Flame within thirty (30) days subsequent to the date of original retail purchase. Remedies in the Event of Failure. In the event a Crossfire Model CF-04 fails to perform as warranted, the following terms and conditions will apply: Heating Unit.

  • Page 10: Crossfire Limited Warranty (Continued)

    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.
  • Page 11 Model No. Serial No. The express warranties made by Country Flame Technologies do not apply unless this warranty card is received by Country Flame Technologies from the original retail purchaser no later than thirty (30) days subsequent to the date the Country Flame product was originally purchased.

  • Page 12: The Crossfire Operation

    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.

  • Page 13: Safety Features

    Crossfire an extremely safe stove. BATTERY BACKUP SYSTEMS The Country Flame Crossfire Model CF04-CORN, 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.

  • Page 14: Fuel Requirements

    USING SEED CORN AS FUEL IS DANGEROUS TO OCCUPANTS. BURNING SEED CORN VOIDS THE COUNTRY FLAME WARRANTY. If pellet fuel is added to the corn in the Crossfire, Country Flame recommends no more than 8% moisture content. The American Pellet Fuel Institute establishes standards for pellet fuel manufacturer’s product.

  • Page 15: Crossfire Startup

    (1) Failure to properly pre-clean the Gold (or any plated) door or trim and the glass before lighting the first fire could permanently damage these items. (2) DO NOT burn seed corn as it is dangerous and voids the Country Flame warranty. SYSTEM START UP GUIDE CROSSFIRE –...
  • Page 16 air to the stove to intensify the flame. You must establish a strong, intense burn before corn can be fed into stove. (this process takes approx.15-20 minutes) SYSTEM START Upon establishing an intense hot fire in the Burn-Pot, press and hold the “ON/OFF”...
  • Page 17 The stove is now in its cool down cycle. (See Manual) • All questions or concerns about lighting or other stove operational issues should be directed to your local Country Flame Dealer. Version 2.0fc...

  • Page 18: Ash Removal

    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.
  • Page 19 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 Thermostat (optional) Board has individual personality modules that allow for stand-alone, semi automatic, or fully automatic thermostat operation.

  • Page 20: Control Board Face Illustration

    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.
  • Page 21 Country Flame or one of its local authorized dealers to discuss the specifics of a single application. In conclusion, Country Flame is striving to become a leader in the area of biomass control and product technology. This leadership will provide direct benefits to Country Flame dealers and our customers. As always, Country Flame welcomes input on how to better meet the customer’s needs.
  • Page 22 In order to utilize the full capabilities of the Control Board, the homeowner should be familiar with the backside of the Control Board. FIGURE 7 provides additional information about the major components on the component side of the control board. FIGURE 7: CONTROL BOARD COMPONENT SIDE Version 2.0fc...

  • Page 23: Control Board Troubleshooting Codes

    TROUBLESHOOTING CODES COUNTRY FLAME CONTROL BOARD The following table provides additional information as to the reason different fault codes may be observed. The table of information assumes that proper AC voltage, AC line frequency, and a properly working control board are available to and installed in the stove product.
  • Page 24 Intelli-Choice Control Board has completed the IGNITION Code 9 CYCLE and is switching to the BURN CYCLE. The igniter should shut down to conserve energy and the stove will now watch for the room air snap disk to close before recognizes a problem with the exhaust snap disk, OR the room air snap disk, OR there is a wiring problem.

  • Page 25: Stove Electrical Diagram

    STOVE ELECTRICAL DIAGRAM FIGURE 8 provides the CF04-CORN electrical schematic of the components and sensors that are either operated or monitored by the Country Flame control board. Please refer to this diagram when necessary. FIGURE 8: ELECTRICAL DIAGRAM Version 2.0fc...

  • Page 26: Stove Specifications

    TABLE 2: CROSSFIRE-CORN SPECIFICATIONS ELECTRICAL REQUIREMENTS The Crossfire Model CF-04 requires a code compliant grounded 120 volt, 15 ampere, and 60 hertz electrical outlet. The Crossfire utilizes only a fraction of the 15 amperes rating of a code compliant outlet but it is strongly recommended that a dedicated circuit (versus a branch electrical circuit) be provided for the stove to ensure no interference from other electrical appliances.

  • Page 27: Change Heat Level (Thermostat Inactive)

    move to that heat setting anytime the thermostat calls for heat. Otherwise, when the thermostat no longer calls for heat, the control board sets the stove to Heat #1. • If the operator changes the heat level to 1 while the thermostat is calling for heat, it will become the new Thermostat Heat Level.

  • Page 28: Installation

    If an exhaust flue system is run over ten feet, Country Flame requires its pellet stove products to be connected to a four-inch versus a three-inch flue pipe to vent the stove. Country Flame has designed a built-in clean out “T”...

  • Page 29: Shroud Installation

    Crossfire dimensions. For pre-existing installation, a shroud kit is recommended. Country Flame offers three variations of shroud kit a) standard, b) oversize, and c) custom shroud. The Crossfire is designed to accept the shroud to simplify installation. Each Crossfire shroud comes with installation instructions and required hardware.

  • Page 30: Chimney

    CHIMNEY It is extremely important that a Crossfire stove be vented into a non defective, clean, and properly lined chimney. The chimney system must conform to all local building codes. In the event a masonry chimney is not used, a listed factory-built chimney suitable for use with solid fuels should be used. This listed factory-built chimney system must conform to ULC-S629 (Canada) or UL 103HT (United States.) Any chimney can and should be lined with a 3 inch (under 10 feet) or 4 inch (over 10 feet) stainless steel flue liner attached directly to the outlet pipe of the Crossfire stove.

  • Page 31: Floor Protection Requirements

    Crossfire. Always refer to local codes and a professional installer to ensure proper installation. FLOOR PROTECTION REQUIREMENTS 1. A Country Flame Crossfire insert may require a listed floor protector that is noncombustible. Refer to TABLE 3 on page 27 of this manual to ensure all clearances to combustible material are met during the installation of a Crossfire stove.

  • Page 32: Outside Air Combustion

    carpet to come in contact with any part of the Crossfire insert. Maintain clearances to combustibles as specified in TABLE 3, page 29 of this manual. OUTSIDE AIR COMBUSTION It is imperative that the installer and homeowner ensures that a minimum of at least eight square inches (fifty square centimeters) of outside air be admitted to the hearth room or directly to the Crossfire.

  • Page 33: Mobile Home Installation

    Corn burning stove does not specifically state; “mobile home approved to HUD Standard UM-84,” do not install the product in a mobile home. The Crossfire Model CF-04 is approved for use in mobile homes. Install all Crossfire stoves in accordance with 24 CFR, part 3280 (HUD).

  • Page 34: Mobile Home Stove Attachment

    (b) because the stove door is left open or does not seal properly, or (c) due to strong exhaust fans being operated inside the mobile home. Always ensure that fresh air intake systems remain unblocked and ensure free fresh airflow. Contact your local Country Flame dealer for annual inspections.

  • Page 35: Mobile Home Chimney And Ducts

    Use only noncombustible material to seal all chimney system joints to prevent cold air leakage into a mobile home. Refer to local codes or consult with an authorized local Country Flame dealer to obtain the name of approved noncombustible sealants.
  • Page 36 Failure to follow the flue pipe manufacturer’s installation instructions will void Country Flame’s product warranty and can have an adverse impact on the homeowner’s insurance policy. Contact Country Flame or one of its local authorized dealers to resolve any questions about installation or parts usage.
  • Page 37 FIGURE 15: MOBILE HOME CHIMNEY INSTALLATION Version 2.0fc...

  • Page 38: Maintenance Requirements

    MAINTENANCE REQUIREMENTS GENERAL REQUIREMENTS The Crossfire Model CF-04 has minimal maintenance requirements; however, failure to perform cleaning or maintenance items will lead to degraded performance and potential safety hazards for both the home and its occupants. The Crossfire stove should not be operated routinely without thorough (as required) cleaning for consistent performance, depending on frequency of use.

  • Page 39: Stove Door Adjustment

    CAUTION: Do not clean hot glass. If glass requires cleaning, use an authorized stove glass cleaner on a cool glass. Contact Country Flame or one of its local authorized dealers to obtain a suitable glass cleaner. Regular household glass cleaners are not effective in cleaning creosote and other residue from the glass.

  • Page 40: Glass-Ceramic Specifications

    The Crossfire stove uses KERA LITE® glass-ceramic that is 0.197 inches thick +/- 0.008 inches. Country Flame custom cuts each KERA LITE® glass at its factory to fit the Crossfire stove. If problems occur with glass or any replacement part is needed, contact Country Flame or a local authorized dealer for assistance in ordering the necessary parts.
  • Page 41 In order to thoroughly clean the exhaust chamber, the Crossfire has two cleaning ports that provide access to the exhaust chamber. In order to gain access to these clean-out ports, the hearth plate must be removed from the front of the Crossfire. FIGURE 18 shows the hearth plate removed from the stove. There is one screw, located in the front center of the hearth plate that must be removed before the hearth plate can be lifted up and out of its location.
  • Page 42 a period of use can lead to one or both exhaust chambers becoming blocked and thus causing the stove to burn inefficiently. FIGURE 20 shows an x-ray view into the clean-out port of the right side of the Crossfire. This right side clean-out port allows access to the right side exhaust chamber and underneath the exhaust fan itself.

  • Page 43: Appendix A: Troubleshooting Guide

    The exhaust vent should be checked frequently and cleaned at least once a season. Room Air Blower does not activate Please contact your Country Flame Dealer as your stove may need maintenance Version 2.0fc...

  • Page 44: Appendix A: Troubleshooting Guide (Cont'd)

    Your Corn/Pellet Stove Smokes You have used the incorrect starter fluid. Only use the approved pellet starter gel. Your Country Flame Dealer can advise you on where to find this. Your Corn/Pellet Stove Smokes Check that the chimney is clean and free of soot and fly-ash build-up.

  • Page 45: Appendix B: Maintenance Guide

    APPENDIX B: MAINTENANCE GUIDE Shut off the power to the unit and allow it to cool off when performing cleaning and maintenance. Regular Cleaning Removing and cleaning the Firepot The firepot can be removed by removing 2 bolts. Slide the keeper sleeve off of the stir rod gear shaft exposing the linkage.

  • Page 46: Appendix B: Maintenance Guide (Cont'd)

    Check all around the gasket. If the paper slides out easily or falls out, the gasket needs to be replaced. Country Flame recommends that both the door and glass gaskets be replaced at the same time.

  • Page 47: Appendix B: Maintenance Guide (Cont'd)

    APPENDIX B: MAINTENANCE GUIDE (CONT’D) Replacing the Door / 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.

  • Page 48: Appendix C: Technical Specifications

    PL double wall vent with stainless steel inner liner Air Inlet: 3 inch by .15 inch walled steel pipe Auger Type: 1 1/8” cup Auger Feed System Controls: Country Flame Intelli-Choice Control Board Electrical: 120 Volts, 2.4 Amp, 60 Hz Measurements: CROSSFIRE HEIGHT (at front) 22.5”...

  • Page 49: Appendix D: Crossfire Theory Of Operation

    APPENDIX D: CROSSFIRE THEORY OF OPERATION BURN PHASE Multiple heat lights indicate the control panel burn phase. There are five lights (4 yellow and one red) used to indicate the relationship to the system’s heat settings. Pushing the control panel’s HEAT LEVEL switch will cause a heat light to cycle one level up from Heat 1 through Heat 5.

  • Page 50: Appendix D: Theory Of Operation (Cont'd)

    (cont’d) FAULT PHASE The fault phase is indicated by all lights except the Country Flame logo light flashing on and off at a rapid pace. This event signifies that the control board has encountered an improperly operating system and requires intervention by either the operator or a properly trained service technician.
  • Page 51 movement facilitates removal of the stir rod for maintenance or for facilitating starting a fire by rotating the stir rod to enhance air flow during a fire’s startup. In order to manually turn the stir arm, the up and down (red and blue) heat arrows must be simultaneously pressed while the control is in only the OFF PHASE or the STARTUP PHASE.

  • Page 52: Appendix E: Combustion Basics

    APPENDIX E: COMBUSTION BASICS An understanding of Combustion Basics will assist in resolving problems with a variety of fuels, changing product and environmental conditions during the operational life of a stove. Just exactly what are pellet or corn stove products suppose to do? PROVIDE A CONVENIENT PLACE FOR STORAGE OF FUEL.
  • Page 53 Combustion Temperature: The temperature required to ensure the release of flammable vapors. To sustain combustion, the heat evolved must maintain this temperature to provide a constant supply of vapors. Excess Air: Any air added to the combustion process above the theoretical value defined as 100% efficiency.
  • Page 54 The obvious advantage of Corn or wood pellets over conventional chopped wood logs is the consistency of the fuel both from a size and moisture content. Nature has done a great job of making field corn a palletized fuel that can have even more energy than wood pellets. These palletized fuels burn more efficiently than their wood log counterparts.
  • Page 55 As a final note, the two basic stages of corn burning are: Somewhere around 1100 F the corn fuel particles have combined with oxygen molecules and released the majority of the available energy. Some gases will still not have reached ignition temperature and at this critical stage, if too much heat is removed from the combustion chamber, no more fuel will be burnt.

  • Page 56: Appendix F: Replacement Parts

    APPENDIX F: REPLACEMENT PARTS REPLACEMENT PARTS Part Number Description Number per CROSSFIRE CF04-P72 BURN POT SCREEN CB-74 STIR ROD ASSEMBLY CF04-A51 BURN POT ASSEMBLY - CORN PP-353 EXHAUST MOTOR ASSEMBLY PP-355 ROOM AIR MOTOR ASSEMBLY PP-352 VACUUM SENSOR SWITCH PP-347 F OVER TEMPERATURE SENSOR PP-12 F EXHAUST/ROOM AIR SENSOR...

  • Page 57: Replacement Parts

    APPENDIX F: REPLACEMENT PARTS (cont’d) REPLACEMENT PARTS Part Number Description Number per CROSSFIRE INSERT CF04-A24 4” CHIMNEY CONNECT BOX PP-535 AUGER MOTOR ASSEMBLY PP-27 VACUUM HOSE PP-88 HOPPER GASKET TAPE PP-48 NON-ETCHED DOOR GLASS W/TAPE PP-525 ETCHED DOOR GLASS W/TAPE PP-107-G SIDE TRIM, GOLD PP-107-N...

  • Page 58: Appendix G: Labels

    APPENDIX G: LABELS REPLACEMENT LABELS Part Number Description Number per CROSSFIRE INSERT PP-483 CAUTION LABEL PP-484 CAUTION LABEL Version 2.0fc...

  • Page 59: Replacement Labels

    APPENDIX G: LABELS (cont’d) REPLACEMENT LABELS Part Number Description Number per CROSSFIRE INSERT PP-486 ELECTRICAL LABEL Version 2.0fc...

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