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

Page 1: ...COUNTRY FLAME COUNTRY FLAME TECHNOLOGIES INSTALLATION OPERATION AND MAINTENANCE MANUAL WARNING If the directions in this manual are not followed exactly a fire may result causing property damage personal injury or loss of life FOR YOUR SAFETY 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 ...

Page 2: ...roduct WARNING After operation always allow the Crossfire stove to completely cool before performing any maintenance operations WARNING 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 WARNING Only a certified professional should install a Crossfire stove Only a qualified service te...

Page 3: ... 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 WARNING 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...

Page 4: ...E 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 CF 04 stoves conform to United States Environmental Protection Agency standards LISTING TESTING AGENCY The Crossfire M...

Page 5: ...CERTIFICATION SAFETY LABEL sample Version 2 0fc 5 ...

Page 6: ...FACE ILLUSTRATION 20 CONTROL BOARD TROUBLESHOOTING CODES 23 STOVE ELECTRICAL DIAGRAM 25 STOVE SPECIFICATIONS 26 ELECTRICAL REQUIREMENTS 26 GOLD DOOR CARE 26 OPTIONAL FEATURES 26 OPTIONAL THERMOSTAT OPERATION 26 CROSSFIRE IS COLD 26 CROSSFIRE IS HOT 26 CHANGE HEAT LEVEL thermostat active 26 CHANGE HEAT LEVEL thermostat inactive 27 COMBUSTION FRESH AIR CONTROL 27 INSTALLATION 28 INSTALLATION PREPARA...

Page 7: ...EANING 40 APPENDIX A TROUBLESHOOTING GUIDE 43 APPENDIX A TROUBLESHOOTING GUIDE CONT D 44 APPENDIX B MAINTENANCE GUIDE 45 APPENDIX B MAINTENANCE GUIDE CONT D 46 APPENDIX B MAINTENANCE GUIDE CONT D 47 APPENDIX C TECHNICAL SPECIFICATIONS 48 APPENDIX D CROSSFIRE THEORY OF OPERATION 49 BURN PHASE 49 COOL DOWN PHASE 49 APPENDIX D THEORY OF OPERATION cont d 50 FAULT PHASE 50 RESET CONDITION 50 SYSTEM MAI...

Page 8: ... 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 C...

Page 9: ...ctions 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 ...

Page 10: ...sts or expenses are NOT covered by this warranty and Country 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 t...

Page 11: ... State Zip Date of Purchase 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 Signature Date Version 2 0fc 11 Place Stamp Here ...

Page 12: ...al 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 pedesta...

Page 13: ...aracteristics 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...

Page 14: ...klers 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 po...

Page 15: ...fuel This is done simply by pressing and holding down the control board ON OFF button located at the bottom of the control board until the Green auger feed light starts to flash approx 15 seconds then release button Prime mode will take approx 10 minutes when you see corn begin to drop into the burn pot press and hold the control board ON OFF button for approx 5 seconds The green light next to the...

Page 16: ...s at the proper temperature the operational sequence will begin automatically If it does not see guide on back of this sheet The stove will start up in heat setting 3 Allow adequate burn time for stove to heat up and stabilize prior to temperature setting change approx 30 min Adjust the inlet air control as required to sustain even continuous burn FIGURE 3 OPERATING REFERENCE GUIDE CROSSFIRE CORN ...

Page 17: ...d blue arrow keys there is a 2 minute response delay in the fan speed for each level increase Adjust the inlet air control as required to sustain even continuous burn INLET AIR Make small slow incremental changes in the air control If to much air is given it will cool the corn below its ignition point and the fire will go out The higher the heat level setting on the stove the more inlet air requir...

Page 18: ...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 Wai...

Page 19: ...rol 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 Room Air Control 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 s...

Page 20: ...lli 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...

Page 21: ...e control of stove functions with minimal human intervention required This control technology provides flexibility in adapting to future changes and improvements in technology Finally this control technology offers a simple interface between the operator and the product being used Country Flame s control board is sensitive to utility grid power variations In the event a homeowner s area has diffic...

Page 22: ...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 22 ...

Page 23: ...elli Choice Control Board recognizes overtemp disk is hot A wiring problem has occurred OR the control board is bad OR the overtemp disk is bad Code 4 Intelli Choice Control Board recognizes a vacuum is not present AND there is a problem with the exhaust snap disk OR the room air snap disk OR there is a wiring problem IF the stove has ever been operating properly the likelihood of two items failin...

Page 24: ...Board recognizes system is operating properly in the BURN CYCLE The system will stay in the BURN CYCLE until some outside force interrupts the system i e fuel hopper empties power interruption system turned off by operator thermostat does not call for heat etc Code E Intelli Choice Control Board recognizes a vacuum is not present AND an overheat condition of the stove if the stove is hot If the st...

Page 25: ...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 25 ...

Page 26: ...h A damaged door can be returned to Country Flame for refinishing but repair is expensive Proper care of the Crossfire plated door and other plated trim will ensure these parts will survive a lifetime of use A painted Crossfire door requires no specific care OPTIONAL FEATURES There is an ever growing list of options for Country Flame stove products including the Crossfire Contact an authorized Cou...

Page 27: ... Heat Level and the stove will operate at that point until the thermostat no longer calls for heat FIGURE 10 CROSSFIRE COMBUSTION FRESH AIR CONTROL COMBUSTION FRESH AIR CONTROL Combustion fresh air can be controlled on the Crossfire This optional control assists in optimizing the burn rate of the fuel All air entering the firebox is controlled with this fresh air control system A control lever as ...

Page 28: ...lame 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 on the back of the stove to assist in annual maintenance This clean out T is bolted to the floor and is designed so that the exhaust flue connects to the stove on top of this clean out T The Crossfire is designed for a 4 inch stain...

Page 29: ...S SHROUD INSTALLATION FIGURE 11 shows the Country Flame shroud with standard black trim mounted on the Crossfire New home construction normally will not require a shroud kit because the fireplace opening can be finished out to exact 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 s...

Page 30: ...d a professional installer to ensure the proposed installation is code approved All flue joints require 3 screws to secure the joints FIGURE 12 MASONRY CHIMNEY FIGURE 13 ZERO CLEARANCE FACTORY BUILT CHIMNEY For any factory built chimney installation in conjunction with a Crossfire insert the homeowner should refer to the chimney manufacturer s instructions It is important that in addition to manuf...

Page 31: ...o their respective R value use the following procedures a Convert floor material specification to R value i R value is given no conversion is required ii k factor is given with required thickness T in inches R 1 k x T iii C factor given R 1 C b Determine the R value of the proposed alternate floor protector i Use the formulas provided in STEP 2a to convert values not expressed as R ii For multiple...

Page 32: ... back draft occurs whether or not combustion is present 3 The home is equipped with a well sealed vapor barrier and tight fitting windows or has any powered devices that exhaust house air 4 There is excessive condensation on home windows in the winter 5 A ventilation system is installed in the house If any of these or other indicators suggests that infiltration air is inadequate additional combust...

Page 33: ...imney products Follow the chimney manufacturer s installation instructions to the letter 4 All mobile home stove installations or stove replacements require a permit to be obtained from the local code department and at least a final inspection before operation of the stove is authorized Use only licensed contractors to perform the installation work Further an insurance representative should provid...

Page 34: ...p foreign material birds or small animals out of the fresh air system Do not use mesh screen from windows as it has too small a hole 4 If operation of the Crossfire stove causes room air starvation dangerous fumes can be sucked into the mobile home from other vented appliances WARNING DO NOT INSTALL ANY CROSSFIRE STOVE IN A SLEEPING ROOM Air starvation usually occurs a because the combustion air i...

Page 35: ...website is www duravent com 3 A complete chimney system should include a HUD approved spark arresting chimney cap a storm collar a roof flashing an attic radiation shield if needed a chimney support box a ceiling finish collar and other parts required by site specific conditions There will be clearance differences presented in both the stove and chimney manufacturers product literature ALWAYS use ...

Page 36: ...versus 3149 1 3142 CEILING SUPPORT BOX Fire Stop Spacer 1 3141 ALTERNATE CATHEDRAL CEILING SUPPORT BOX versus 3142 1 3160B 5 FOOT CHIMNEY SECTION 2 3179 STOVE PIPE ADAPTER if needed 1 CERAFORM 126 WALL PROTECTION IF REQUIRED 1 3145B 450 ELBOW if needed 1 3159 STORM COLLAR 1 NOTE The information provided in TABLE 4 and detailed in FIGURE 15 are for informational purposes These corn flue pipe system...

Page 37: ...FIGURE 15 MOBILE HOME CHIMNEY INSTALLATION Version 2 0fc 37 ...

Page 38: ...e Crossfire door has been mounted and checked for proper fit at the factory If the door is removed for any reason care must be taken in reinstalling the door to ensure proper alignment and fit Setting the door is quite simple Ensure the door is in the fully open position Once done align the female portion of the door hinge with the male portion of the stove hinge Gently lower the door hinges over ...

Page 39: ...when a medium to high fire is fueling the firebox If the operator wants the door glass to remain clean for the longest period of time a high temperature fire must be maintained This means adjusting the combustion air to obtain as blue a flame as possible without blowing pellets out of the burn pot CAUTION Do not clean hot glass If glass requires cleaning use an authorized stove glass cleaner on a ...

Page 40: ...l It is important to ensure the doorframe area is totally clean before installing the new gasket cement and material The gasket must fit tight against the door frame in order to ensure a proper airtight seal when the stove is being operated Apply gasket cement to the gasket channel per instructions provided with the gasket kit Once the cement has been properly applied install the new gasket Both g...

Page 41: ...t and right side Once the screw has been removed from the center of the hearth plate the hearth plate can b lifted gently tapped upward to remove it from its locked position FIGURE 19 CLEAN OUT PORT CAP REMOVAL Version 2 0fc 41 Once the hearth plate has been removed and set aside along with the screw the clean out port caps can be removed FIGURE 19 shows the cap locations behind the hearth plate O...

Page 42: ...OUT PORT In the event a Crossfire system requires cleaning of the chimney to remove debris or ash the Crossfire will require removal from its hearth installation in order to remove the chimney connector This should not be necessary except under the most extreme operating conditions or in the event an animal has obtained entrance to the top of the chimney and built a nest inside the chimney Again t...

Page 43: ...ines or debris caught in the auger flight Stove Performance If your stove is not working effectively You may be using the wrong fuel Check that you are using the correct fuel Either 2 Yellow Shelled Corn with 14 or less moisture 10 12 preferred or mixed with pellet wood fuel with 8 or less moisture may be used Your Country Flame Dealer can advise on where to obtain fuel Do not use seed corn If you...

Page 44: ...el 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 Your stove exhaust system works with a negative combustion chamber pressure and a low positive chimney pressure It is very important that the exhaust system be completely airtight and properly installed Cleaning Cleaning is messy and ...

Page 45: ...t for blockage Remove ash when it is COOL Use an industry approved ash vacuum for removing ash Dump the ash into a fire safe covered container The firepot may be lifted out first remove bolts and remove the stir rod Dumb and clean the firepot as needed Vacuum the inside of the COOL unit and replace all parts BEFORE starting operation again Thorough Cleaning Remove the I plugs located on each side ...

Page 46: ...r incorrect operation of the room heater will lead to some soot formation which will collect in the exhaust venting system The exhaust venting system should be inspected at least once every year to determine if cleaning is necessary Air Intakes When starting to use the stove at the beginning of the season check to ensure that the fresh air intake is clear and unobstructed Oiling the Room Air and E...

Page 47: ...et you may need to use pliers and then remove the glass retaining clips and remove glass Replacement glass should be 0 200 5mm thick Overall size of the glass is 16 405mm wide by 11 279mm high cut to an irregular shape to fit the door front Your unit uses Euro Kera or a similar ceramic type high temp glass Do not use any other than recommended glass type in this unit Replacement glass may be obtai...

Page 48: ...nner 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 CROSSFIRE DEPTH from shroud 14 0 CROSSFIRE WIDTH rear 26 0 CROSSFIRE WIDTH at shroud mount 25 5 Weight STOVE WEIGHT 220 POUNDS Clearances UNIT TO SIDEWALL 7 UNIT TO SIDE TRI...

Page 49: ... or decrease in the heat output of the system Changing any heat setting up or down by two or more increments will require an increased amount of time before the burn rate of the stove stabilizes The control system automatically adjusts to the requested heat settings without further intervention of the operator NOTE The control panel display immediately reflects the final heat setting requested by ...

Page 50: ...is required In order to perform a restart the operator must press and hold the up heat red arrow for a minimum of 15 seconds This will return the system to startup phase Please refer to startup phase for specifics All procedures in the startup phase should be followed in order to ensure burn phase is properly achieved from the hot restart phase NOTE A HOT RESTART CAN ONLY BE ACHIEVED FROM A COOL D...

Page 51: ...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 As long as the up and down heat arrows are held in either the off or startup phase the stir rod will rotate Upon releasing either of these arrows the stir rod rotation will stop turning WARNING Keep hands or loose clothing away from the stir pot Version 2 0fc ...

Page 52: ...terials in a fuel which reduce the heating value per unit of weight Carbon Dioxide A heavy colorless gas that does not support combustion and dissolves in water to form carbonic acid Carbon Monoxide A colorless odorless poisonous gas produced by incomplete combustion Incomplete burning of wood pellets will create this gas Combustion Combustion refers to the rapid oxidation of fuel accompanied by t...

Page 53: ...a stove are giant vacuum cleaners sweeping in any dust dirt and vapors that happen by In time the systems air path becomes partially obstructed starving the system for air and causing the fuel air ratio to become rich Excess air ensures that complete combustion can occur at all times regardless of changes in environmental variables Ignition Temperature The temperature at or above which a substance...

Page 54: ...quires turbulence in the fuel air path to ensure that fuel and air molecules are thoroughly mixed to sustain the burn process In addition it takes a certain amount of temperature defined as Ignition Temperature to sustain the burn It takes a certain combustion temperature to ensure volatile and carbon matter is released from the fuel that will then combine with the oxygen in the air further adding...

Page 55: ...ation in materials used to produce the wood pellet These variations allow the turbulence in the burn system to ensure a better agitation of fuel with air and a more rapid and efficient burn As other biomass fuels are utilized optimum mixes of pellets will ensure clean burning reduced emission systems are available that compete favorably in the consumer market The homeowner must be aware that as te...

Page 56: ...P 353 EXHAUST MOTOR ASSEMBLY 1 PP 355 ROOM AIR MOTOR ASSEMBLY 1 PP 352 VACUUM SENSOR SWITCH 1 PP 347 2500 F OVER TEMPERATURE SENSOR 1 PP 12 1100 F EXHAUST ROOM AIR SENSOR 1 PP 182 OWNERS MANUAL 1 PP 989 AC RECEPTACLE 1 NPS 1005C Intelli Choice CONTROL BOARD 1 PP 1029 WIRING HARNESS 1 PP 40 DOOR FRAME ONLY 1 PP 87 NC DOOR ROPE GASKET 1 40 0000 05 CLEAN OUT PLUGS 2 Version 2 0fc 56 ...

Page 57: ...T CF04 A24 4 CHIMNEY CONNECT BOX 1 PP 535 AUGER MOTOR ASSEMBLY 1 PP 27 VACUUM HOSE 1 PP 88 HOPPER GASKET TAPE 1 PP 48 NON ETCHED DOOR GLASS W TAPE 1 PP 525 ETCHED DOOR GLASS W TAPE 1 PP 107 G SIDE TRIM GOLD 2 PP 107 N SIDE TRIM NICKEL 2 PP 107 B SIDE TRIM BLACK 2 PP 185 SIDE TRIM CUSTOM 2 Version 2 0fc 57 ...

Page 58: ...APPENDIX G LABELS REPLACEMENT LABELS Part Number Description Number per CROSSFIRE INSERT PP 483 CAUTION LABEL 1 PP 484 CAUTION LABEL 1 Version 2 0fc 58 ...

Page 59: ...APPENDIX G LABELS cont d REPLACEMENT LABELS Part Number Description Number per CROSSFIRE INSERT PP 486 ELECTRICAL LABEL 1 Version 2 0fc 59 ...