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COUNTRY FLAME TECHNOLOGIES CF-04 Installation, Operation And Maintenance Manual

Flex crossfire stove fireplace insert
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Version 2.0fc
COUNTRY FLAME TECHNOLOGIES
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
MODEL CF-04 Flex CROSSFIRE STOVE
USA & CANADA TEST:
ASTM E 1509-04, UL 1482,
ULC S627, ULC/ORD C1482 (and ULC S628
If listed for fireplace insert installation in Canada)
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.
© 2012

FIREPLACE INSERT

TESTED BY:
WARNOCK HERSEY
If the directions in this manual are not followed exactly, a fire
FOR YOUR SAFETY
1
MOBILE HOME APPROVED
COUNTRY FLAME

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  • Page 1: Fireplace Insert

    COUNTRY FLAME TECHNOLOGIES INSTALLATION, OPERATION AND MAINTENANCE MANUAL MODEL CF-04 Flex CROSSFIRE STOVE FIREPLACE INSERT USA & CANADA TEST: TESTED BY: ASTM E 1509-04, UL 1482, WARNOCK HERSEY ULC S627, ULC/ORD C1482 (and ULC S628 If listed for fireplace insert installation in Canada)

  • Page 2: Safety Notes

    The Crossfire Model CF-04 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 Maintain all minimum safety clearances of the Crossfire stove and chimney system. ARNING Never install the Crossfire in a sleeping room. The Crossfire-Flex is designed and approved for burning of number 2 yellow shelled corn ARNING with a maximum moisture content of 14% (10%-12% recommended) or Premium wood pellet fuel.

  • Page 4: Epa Standards

    Canada) and Oregon Administrative Rules 814-23-900 – through 909. This listing is for installation into residential dwellings, including standard construction units, mobile home units, or modular home units. The Crossfire Model CF-04 was tested to UL standards by Intertek Testing Services, NA, Inc., 8431 Murphy Drive, Middleton, WI 53562.

  • Page 5: Certification Safety Label (Sample)

    CERTIFICATION SAFETY LABEL (sample) Version 4.0...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS SAFETY NOTES............................2 EPA STANDARDS ..........................4 LISTING/TESTING AGENCY ........................4 CERTIFICATION SAFETY LABEL (sample) ..................5 TABLE OF CONTENTS..........................6 FORWARD..............................8 COUNTRY FLAME ..........................8 CROSSFIRE LIMITED WARRANTY ............Error! Bookmark not defined. CROSSFIRE LIMITED WARRANTY (continued) ........Error! Bookmark not defined. THE CROSSFIRE OPERATION ......................12 FEATURES.............................12 SAFETY FEATURES..........................13...
  • Page 7 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...

  • Page 8: Forward

    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.
  • Page 9 AMERICAN ENERGY SYSTEMS INC. LIMITED PRODUCT WARRANTY This warranty is in effect on all products sold after 01/01/2009 and supersedes any and all warranties currently in existence. Please keep a copy of this warranty for your personal records or in the event of a claim American Energy Systems Inc., hereinafter referred to as (AES), warrants to you, the original consumer purchaser, that this product is free from defects in material and workmanship for a period of five (5) years from the original purchase date minus any time past one (1) year from manufacturing date, and that the product’s electrical parts and...
  • Page 10 PARTICULAR PURPOSE, ARE DISCLAIMED. IT IS UNDERSTOOD AND AGREED THAT AES’S LIABILITY UNDER THIS WARRANTY SHALL BE LIMITED TO THE PROVISION OF REPLACEMENT PARTS AND SHALL NOT INCLUDE LIABILITY FOR SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES. ANY ACTION BROUGHT UNDER THIS WARRANTY MUST BE BROUGHT WITHIN ONE YEAR OF THE ACCRUAL OF THE CAUSE OF ACTION AND MAY ONLY BE BROUGHT IN THE CIRCUIT COURT OF MCCLOUD COUNTY, MINNESOTA.
  • 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

    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.

  • Page 14: Fuel Requirements

    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.
  • Page 15 OPERATING REFERENCE GUIDE CROSSFIRE – FLEX STOVE (SEE FIGURE #3) • DO NOT use any other ignition accelerant other than igniter/burn gel or igniter blocks to start or enhance the fire in the Crossfire stove. • FUEL the only fuel the CF04 stove is designed to burn is #2 shelled Corn (10-12% moisture) or any mix of Corn and Premium Hardwood Pellets.

  • Page 16: Ash Removal

    The stir rod will be controlled by the control board. This stir rod assists in mixing fuel with air in the burn pot. The stirring action improves the mixing of oxygen and fuel and accelerates the combustion process. As heat settings are changed on the control board, the stir rod speed will automatically be adjusted to more closely match the feed rates of the different heat settings.
  • Page 17 THERMOSTAT VACUUM OVERTEMP FUEL COMBUSTION Hopper Switch (Optional) SENSOR SENSOR CONTROL AIR CONTROL INPUT VOLTAGE 120 Volts AC 60 Hz 15-Ampere Circuit CONTROL BOARD ON/OFF SWITCH TEMPERATURE CONTROL Fuse 6 – 9 POWER/FUEL/IGNITER/ INDICATORS Amperes STOVE EXHAUST ROOM ROOM AIR TEMPERATURE TEMPERATURE CONTROL...
  • Page 18 FIGURE 5 displays the Country Flame Control Board front panel. Each function of the Control Board is identified. Power- on light glows amber when on Heat level indictor LED Auger feed light (red per heat level setting) (amber when on) Manual, Thermostatic operation mode button Heat level (up) adj.

  • Page 19: Operating Instructions

    OPERATING INSTRUCTIONS (Using self igniter systems, if auto ignition system (optional) has been installed) NOTE: Each time the stove is started, the firepot must be checked for debris and clear air holes. Some fuels will cause the firepot to build up more frequently making it necessary to stir and clean the firepot more often.

  • Page 20: Control Board Face Illustration

    The auger feed rate on each setting is pre-programmed but may be changed if necessary. The “Auger Trim” button will override the programmed feed rates by +/-5% on all heat levels. To override the feed rate press and hold the ‘Auger Trim’ button along with the heat level button arrow up or heat level button arrow down, depending on desired change.
  • Page 21 OPERATING INSTRUCTIONS (Without using system igniter) NOTE: Each time the stove is started, the firepot should be checked for debris and clear air holes. Some fuels will cause the firepot to build up more frequently making it necessary to stir and clean the firepot more often.
  • Page 22 The draft and room air blower speed varies directly with the feed rate. The “Draft Trim” button will override the variable fan function +/- 5 volts on all heat levels. To override, press and hold the “Draft Trim” button along with the heat level button arrow up or heat level button arrow down, depending on desired change. The auger feed rate on each setting is pre-programmed but may be changed if necessary.

  • Page 23: Control Board Troubleshooting Codes

    the pre-set fuel rate setting. After the start up sequence has been established (approx. 12-15 min.) the unit will run at whatever fuel level setting you selected. The number #2 or #3 heat level setting is recommended for the 1 30-45 minutes.
  • Page 24 AC MODEL WIRING DIAGRAM WARNING: DISCONNECT POWER BEFORE SERVICING THIS UNIT. Version 4.0...

  • Page 25: Stove Electrical Diagram

    TABLE 2: CROSSFIRE-FLEX 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 26: 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 27: Installation

    INSTALLATION INSTALLATION PREPARATION Country Flame strongly recommends the Crossfire be installed by a certified professional. Improper installation will create long-term operational and maintenance problems that will plague the homeowner until corrected. The first step is to ensure all necessary parts are available to complete a proper installation.

  • Page 28: Shroud Installation

    DEFINED MINIMUM DISTANCES CLEARANCE TO COMBUSTIBLES 7” A. UNIT TO SIDEWALL 7” B. UNIT TO SIDE TRIM 9.25” C. UNIT TOP TO TOP TRIM 9.25 D. UNIT TOP TO MANTLE 32” E. HEARTH FLOOR TO MANTLE 6” F. NONCOMBUSTIBLE FLOOR PROTECTION, front 6”...

  • Page 29: 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 30: Floor Protection Requirements

    combustion. In all cases, the flue must be relined with a listed liner system, such as HomeSaver Chimney Liner. If your masonry built chimney contains oversized flue tiles it must be relined to ensure proper draft. This means that a new, properly sized liner system must be installed before connection to the Crossfire stove is completed.

  • Page 31: 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 32: 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 33: Mobile Home Stove Attachment

    Do not violate minimum clearances with approved thermal barriers. Manville’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.

  • Page 34: Mobile Home Chimney And Ducts

    3. At no time should a floor protector be placed on top of carpeting. Carpeting must be removed and the floor protection should sit directly on the uncarpeted portion of the mobile home floor. Floor protection should extend to the front, sides, back, and under the chimney connector as defined for a specific model listed in this manual.
  • Page 35 certified professional to install a flue gas pellet venting system. Do not deviate from the pellet flue manufacturer’s installation instructions. Contact Country Flame or a local authorized dealer to resolve any questions or installation procedures. TABLE 4 shows the required components needed for a typical pellet flue pipe mobile home installation.
  • Page 36 FIGURE 15: MOBILE HOME CHIMNEY INSTALLATION Version 4.0...

  • Page 37: 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 38: Stove Door Adjustment

    STOVE DOOR ADJUSTMENT The Crossfire door may require fine adjustment due to variations in the door, the gasket material, due to hinge wear, or to maintain a center-aligned appearance. The Crossfire door needs to remain airtight to ensure proper firebox operation. The Crossfire door can be adjusted up or down and left or right with the adjustable hinge pins as shown in FIGURE 16.

  • Page 39: Glass-Ceramic Specifications

    the door glass. Removal of these glass retaining clips can be accomplished with household tools. Order the necessary replacement screws or glass clips when ordering glass to ensure worn parts are replaced. GLASS-CERAMIC SPECIFICATIONS Manufacturer Euro Kera Window Type Glass-Ceramic, Kera Lite® KERA LITE®...
  • Page 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 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 41 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 42: Appendix A: Troubleshooting Guide

    APPENDIX A: TROUBLESHOOTING GUIDE Shut off the power to the unit and allow it to cool off when performing cleaning and maintenance. PROBLEM SOLUTION The starter fire in the firepot has not ignited or is Stove does not switch on not burning properly.

  • Page 43: Appendix A: Troubleshooting Guide (Cont'd)

    APPENDIX A: TROUBLESHOOTING GUIDE (CONT’D) The chain drive for the stirring paddles needs to be Stirring Paddles do not turn checked after the first 8 hours of operation as it can loosen. It is located by opening the left side door (the one with the control panel).

  • Page 44: 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 45: Appendix B: Maintenance Guide (Cont'd)

    APPENDIX B: MAINTENANCE GUIDE (CONT’D) Cleaning the Glass To clean glass, use a mild non-abrasive cleaner when the stove and glass are COOL. Creosote builds up on glass quicker when a fire is burned at lower heat settings. DO NOT use abrasive cleaners on glass.

  • Page 46: 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 47: Appendix C: Technical Specifications

    APPENDIX C: TECHNICAL SPECIFICATIONS Fuel Type: #2 Yellow Shelled Corn Fuel (CLEANED) Hardwood Pellet Fuel Moisture Content: 14% or less (10- 12% preferred) A.P.F.I. residential fuel Heat Content: 10,000 Btu/lb* Heat Content: 8200 BTU/lb Ash Content: 3% maximum Ash Content: 1% max Bulk Density: 40 lb./cubic ft.

  • Page 48: 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 49 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 50 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 51 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 52: 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 w/o igniter CF04-A55 BURN POT ASSEMBLY w/ igniter PP-664 200 Watt IGNITER ASSEMBLY PP-353 EXHAUST MOTOR ASSEMBLY PP-355 ROOM AIR MOTOR ASSEMBLY PP-352...

  • Page 53: Replacement Parts

    APPENDIX F: REPLACEMENT PARTS (cont’d) REPLACEMENT PARTS Part Number Description Number per CROSSFIRE INSERT CF04-A24 4” CHIMNEY CONNECT BOX PP-535-1 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 54: Appendix G: Labels

    APPENDIX G: LABELS REPLACEMENT LABELS Part Number Description Number per CROSSFIRE INSERT PP-483 CAUTION LABEL PP-484 CAUTION LABEL PP-486 ELECTRICAL LABEL Version 4.0...

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