Country Flame Indoor Fireplace 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:  
ASTM E 1509-03, ULCS627-M90  
ULCS628-M92, UL 1482,  
TESTED BY:  
WARNOCK HERSEY  
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.  
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 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.  
Country Flame Technologies  
A Division of American Products, LLC  
900 George Street  
Marshfield, MO 65706  
417-859-0990 phone  
417-859-0192 fax  
© 2006  
COUNTRY FLAME  
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WARNING:  
WARNING:  
Maintain all minimum safety clearances of the Crossfire stove and chimney system.  
Never install the Crossfire in a sleeping room.  
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  
WARNING:  
WARNING:  
WARNING:  
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.  
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.  
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.  
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 to the Crossfire or each flue  
section is to be sealed. Use 500 degrees Fahrenheit (500OF 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.  
WARNING:  
WARNING:  
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.  
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.  
WARNING:  
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 CF-  
04 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  
1.  
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.  
2.  
Products/Components Warranted. Country Flame makes the following warranties regarding its Model  
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.  
3.  
Terms, Conditions and Restrictions.  
(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)  
(2)  
(3)  
(4)  
To conditions 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.  
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.  
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.  
To conditions 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)  
(6)  
To conditions not resulting from defects in material or workmanship of the Crossfire  
Model CF-04.  
To conditions resulting from the improper firing or burning of materials in a Crossfire  
Model CF-04.  
(c)  
Warranty Registration Card. The Crossfire Model CF-04 warranty is void and does not apply  
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.  
4.  
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:  
(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)  
(c) Warranty Service and Freight Costs. Service on a Crossfire Model CF-04 will be  
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, 65706 of any defect by  
providing the following information:  
1.  
2.  
3.  
4.  
5.  
The Serial Number of the Crossfire Model CF-04  
The date of original purchase  
The name of the dealer where the product was purchased  
The date of installation; and  
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 or expenses are NOT covered by this warranty and Country Flame is  
not liable for any of them.  
5.  
6.  
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.  
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.  
8.  
Legal Rights. This warranty gives you specific legal rights, and you may also have other rights  
that vary from state to state.  
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:  
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  
Fold Here  
Name  
City  
Address  
State  
Zip  
Zip  
Dealer  
Dealer’s Name  
City  
State  
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  
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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 remarkably 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-to-  
fuel. 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 “Intelli-Choice.Country  
Flame’s control board technology was introduced across all pellets and corn stove product lines. The 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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THERMOSTAT  
(Optional)  
VACUUM  
SENSOR  
OVERTEMP  
SENSOR  
FUEL  
CONTROL  
COMBUSTION  
AIR CONTROL  
INPUT VOLTAGE  
120 Volts AC 60 Hz  
15-Ampere Circuit  
CONTROL BOARD  
ON/OFF SWITCH  
TEMPERATURE CONTROL  
POWER/FUEL/IGNITER/ INDICATORS  
Fuse  
6 – 9  
Amperes  
STOVE  
EXHAUST  
TEMPERATURE  
SENSOR  
ROOM  
TEMPERATURE  
SENSOR  
AIR  
ROOM AIR  
CONTROL  
STIR ROD  
FIGURE 3: CONTROL BOARD BLOCK DIAGRAM  
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.  
Input Voltage  
The AC fuse should be rated between 6 and 9 amperes. The recommended fuse is a Little  
Fuse Model _______.  
Fuse  
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.  
Vacuum Sensor  
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.  
Exhaust Temperature Sensor  
Room Air Temperature Sensor  
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.  
Overtemp Sensor  
Fuel 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 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.  
Room Air Control  
Combustion Air Control  
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.  
Thermostat (optional)  
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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ON/OFF SWITCH  
The Intelli-Choice ON/OFF Switch either turns the system on or off by holding  
the switch for approximately 5 seconds. The ON/OFF Switch can also be used to  
initiate the FUEL PRIME MODE by holding it for approximately 30 seconds.  
When in the prime mode the Thermostat lights will sequentially light from top to  
bottom simulating a “filling action” of the auger tube.  
When these two switches are pressed during the STARTUP CYCLE only, they can  
be used to turn the stir rod of the Harvester model. In all other pellet stoves these  
switches only function as heat up and down switches.  
This is a 3-color light when AC power is applied. A red light indicates that the  
Control Board has DC Power available but the system is off. A green light  
indicates that the System is on. A yellow light indicates that the combustion air  
should be cleaned. As Country Flame works to improve the sensor technology,  
this yellow light will become more valuable to the service technician as well as the  
homeowner.  
HEAT UP/ HEAT DOWN SWITCH  
DC POWER LIGHT  
When all Control Panel lights are flashing on and off, this indicates that the  
Product has an encountered an unknown state. Nothing more, nothing less. The  
purpose of these flashing lights is to alert the home owner or the service technician  
that the stove operation ended out of sequence, ran out of fuel, or encountered a  
power interruption that the Control System could not recover from.  
HIGHWAY PATROL MODE  
In the Cool Down Mode, the Heat Setting lights will sequentially go out from top  
to bottom, all relight and then sequentially go out from top to bottom. This cycle  
will continue until such time that the Control Board senses the stove has properly  
cooled down.  
COOL DOWN MODE  
Each heat setting, controlled by the stove Heat Up or Heat Down switch, is  
provides as much combustion air and fuel as is required for that heat setting. Due  
to the number of unique environmental variables as well as variations in pellet fuel  
used in different regions, Country Flame cannot provide exact BTU ratings for  
each heat setting except those that were established in Government Test Labs  
under controlled conditions. At the same time, the rule of thumb is that each heat  
setting on the Country Flame line of Biomass Product starts at one pound of fuel  
per hour and increments to a top setting of five pounds of fuel per hour. Using a  
BTU rating of from 4,000 to 10,000 BTU per pound of fuel, depending on the type  
and moisture content of the fuel, an estimate of heat output can be made.  
HEAT SETTING 1 THROUGH 5  
FIGURE 6: CONTROL 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 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 difficulty with utility power fluctuations, Country Flame’s stove products can be interfaced to an  
inexpensive battery back up system. The actual cost of a battery backup system will be fully dependent on  
customer requirements. From random power “glitches” or short duration electrical power interruptions to  
major power outages, the Country Flame stove can operate off battery or generator backup systems. Contact  
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.  
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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  
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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 board. Please refer to this diagram when necessary.  
FIGURE 8: ELECTRICAL DIAGRAM (optional manual igniter shown)  
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STOVE SPECIFICATIONS  
TABLE 2 shows the physical dimensions of the Crossfire product.  
DIMENSIONS (IN INCHES)  
CROSSFIRE  
STOVE HEIGHT (At Front)  
STOVE DEPTH (From Shroud)  
STOVE WIDTH (Rear)  
22.5“  
14.0“  
26.0“  
STOVE WIDTH (At Shroud Mount)  
STOVE WEIGHT (empty)  
SHROUD WIDTH, (standard)  
SHROUD HEIGHT (standard)  
SHROUD WIDTH, (oversized)  
SHROUD HEIGHT (oversized)  
25.5“  
220 pounds  
42.0”  
30.0”  
48.0”  
32.5”  
TABLE 2: CROSSFIRE, CF-O4 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.  
GOLD DOOR CARE  
All Crossfire plated doors and trim (gold or nickel) should be wiped down BEFORE THE FIRST FIRE to  
prevent potential permanent damage to occur to plating. For general cleaning, use a dry cloth and wipe the  
plated surface to ensure the luster and beauty lasts a lifetime. Always use an approved glass cleaner (i.e.  
Windex, Glass Plus) and a lint free soft cloth to polish the doorframe. DO NOT use abrasives, like steel  
wool, brass polish, or cleaners, like Comet. Improper cleaners can permanently scratch the finish.  
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 Country Flame dealer for more information.  
OPTIONAL THERMOSTAT OPERATION  
A thermostat option is available for the Crossfire. With the optional thermostat installed, the Crossfire can be  
turned on and off based on a preset temperature according to the customer’s desire.  
CROSSFIRE IS COLD  
Start up the Crossfire by first installing pellets into the burn pot.  
Hold the Intelli-Choice Control Board on/off switch until the power light turns green and the igniter  
light begins to slowly blink on and off.  
Once a pellet fire has been established, hold the Intelli-Choice Control Board on/off switch until the  
auger light blinks rapidly on and off. Release the Intelli-Choice Control Board on/off switch.  
If the #3 heat setting lights up, the Crossfire will begin feeding corn. Ensure proper air setting for the  
temperature set. If the auger light goes back to blinking on and off slowly, wait until the stove warms  
up further and then repeat the process until Heat Setting #3 is obtained.  
CROSSFIRE IS HOT  
If the stove is set to a heat setting greater than 1 when the thermostat calls for heat, the Intelli-Choice  
Control Board will remember this setting and return to this setting any time heat is called for by the  
thermostat.  
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If the heat level is equal to 1 when the thermostat calls for heat the 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 calling for  
heat. The Intelli-Choice Control Board will then return the stove back to heat level 1. The last heat  
level programmed by the operator will be remembered by the software for use as the next Thermostat  
Heat Level when heat is again called for by the thermostat.  
CHANGE HEAT LEVEL (thermostat active)  
When the homeowner changes the control board heat level setting, while the thermostat is active  
(calling for heat,) the new setting becomes the new thermostat (call for heat) setting. The stove will  
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. But because this is the same setting as when the thermostat stops calling  
for heat, the operator will get no indication that the thermostat is in control of the stove.  
CHANGE HEAT LEVEL (thermostat inactive)  
If the operator makes a change to the heat level while the stove is inactive, the stove will move to that  
level. The next time the thermostat calls for heat, the most recently programmed heat level will  
become the Thermostat 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 knob is  
located above the electronic control. This black knob can be turned to open and close the baffle as shown in  
FIGURE 10. By opening or closing this baffle the amount of fresh air allowed into the combustion chamber  
can be controlled. This air control should allow the homeowner to adjust for any variation in fuel to ensure an  
efficient burn. If the fresh air is connected to a pipe leading outside the house, the fresh air control should be  
kept in the closed condition to minimize air infiltration into the home when the Crossfire stove is not in use.  
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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. Country Flame recommends a homeowner purchase the Crossfire from an authorized  
dealer who both knows and supports Country Flame product. If purchased from Country Flame, a  
Crossfire shroud will need to be ordered based on the size of the fireplace opening and the trim package  
desired. A flue system can be ordered from Country Flame or bought from many different “big box”  
store outlets. Follow this manuals requirement in purchasing flue pipe and the flue pipe manufacturer’s  
instructions and conform to all local codes. The following checklist is provided to assist in ensuring a  
home is prepared for installation:  
a)  
b)  
c)  
d)  
e)  
f)  
Country Flame Crossfire biomass stove.  
Country Flame or custom shroud to frame Crossfire stove around hearth.  
Flue pipe per site and local code requirements.  
Code approved power outlet @ 120 Volt, 15 amperes (dedicated circuit recommended).  
No extension cords between stove and electrical outlet.  
Clean and dry certified pellet fuel.  
The Crossfire should be installed into a masonry fireplace or zero clearance fireplace on a level or  
slightly sloping floor angle as measured from the front to the rear of the hearth opening. If the Crossfire  
is sloped forward to ANY degree, bridging of pellet fuel may occur inside the hopper. Bridging will  
starve the fire and cause a flame out due to lack of fuel. Ensure the fireplace hearth is flat or sloping to  
the rear of the firebox.  
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” 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 stainless steel flue pipe to be connected to this clean out T and  
will line the existing chimney. Insulating the flue liner is strongly recommended by Country Flame.  
Should a 3 inch stainless steel flue lined is to be used in a Crossfire installation; a 4 inch to 3 inch  
adapter will be required. Terminate the flue at the top of the chimney with a weather plate, proper  
termination cap, and support the flue liner weight. Once proper electrical power is connected to the  
Crossfire and an appropriate shroud is used to finish out the installation, the Crossfire install is  
complete.  
STOVE CLEARANCES  
The Crossfire minimum clearances must be maintained during installation. Failure to maintain proper  
clearances can create a hazardous environment that will lead to a house fire or endanger the occupants.  
A stove that is installed correctly and maintained properly will minimize operating costs. Country  
Flame recommends the use of a Hearth Industry Professional that is certified to install pellet-burning  
products. Check with the local dealer or contact Country Flame if there is any question about the  
installation, the installer, or the product being installed. Maintain the minimum clearances to  
combustibles shown in TABLE 3. Follow all chimney manufacturers’ installation instructions when  
installing a chimney system. Inevitably there will be differences between the chimney manufacturer  
and Country Flame’s stove clearances. Always utilize the largest clearance listed. Contact Country  
Flame or one of its local authorized dealers to resolve any questions. The Crossfire was designed for  
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installation into an approved masonry or zero clearance 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 SIDEWALL  
7”  
7”  
9.25”  
9.25  
32”  
6”  
B. UNIT TO SIDE TRIM  
C. UNIT TOP TO TOP TRIM  
D. UNIT TOP TO MANTLE  
E. HEARTH FLOOR TO MANTLE  
F. NONCOMBUSTIBLE FLOOR PROTECTION, front  
G. NONCOMBUSTIBLE FLOOR PROTECTION, sides  
6”  
TABLE 3: REQUIRED MINIMUM CLEARANCES  
SHROUD SYSTEM  
FIGURE 11 shows the Country Flame shroud system. Black trim is standard and gold trim is  
OPTIONAL and must be ordered separately. New home construction normally will not require a  
shroud kit for the Crossfire because the fireplace opening can be finished out to exact Crossfire  
dimensions. For pre-existing installation, a Crossfire shroud kit is available and recommended.  
Country Flame offers three variations of shroud kit a) standard, b) oversize, and c) custom shroud.  
Standard and oversize shrouds are available through a Country Flame Dealer and customer shrouds can  
be ordered from Country Flame. Custom shrouds take 4 to 6 weeks to manufacture and require  
prepayment. Each Crossfire shroud comes with installation instructions and all required hardware.  
Contact a Country Flame Dealer for further details.  
CF04-9200 (standard, 41.5” by 29.5” max opening) Shroud Kit Includes:  
3
3
2
1
SHROUD PANELS, (Top, Left Side, Right Side, each painted black)  
BLACK TRIM PIECES, (Top, Left Side, Right Side, pre-cut)  
TRIM CORNER BRACKETS with Screws  
ROLL OF FIBERGLASS INSULATION  
CF04-9210 (oversized, fits 47.5” by 32.0” max opening) Shroud Kit Includes:  
3
3
2
2
SHROUD PANELS, (Top, Left Side, Right Side, each painted black)  
BLACK TRIM PIECES, (Top, Left Side, Right Side, pre-cut)  
TRIM CORNER BRACKETS with Screws  
ROLLS OF FIBERGLASS INSULATION  
SHROUD INSTALLATION INSTRUCTIONS  
1.  
Complete the Crossfire chimney and combustion air (if required) installation before installing  
the Crossfire shroud. The Crossfire insert should be sitting in the hearth ready for positioning  
in its final location but pulled forward as far as the chimney connection will allow. Open both  
the left and right access doors on the Crossfire. The installer can now begin installation of the  
shroud.  
2.  
Remove the two ¼-20 nuts and washers from the top of the Crossfire insert shroud mounting  
studs located on the top of the Crossfire hopper. Install the top shroud panel (as shown in  
FIGURE 11a) making sure the slots in the top shroud mounting flange are positioned over the  
mounting studs located on top of the Crossfire hopper. Now install the two washers and then  
the ¼-20 nuts onto the studs. Do NOT tighten yet. Once installed, the nuts will hold the top  
shroud in place on the Crossfire until the top shroud is adjusted in it final position. The top  
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shroud can be moved left, right, or centered on the Crossfire depending on the requirements of  
the hearth. The installer should make final adjustments 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 install the left and right shroud panels.  
FIGURE 11a: CROSSFIRE SHROUD (rear view)  
3.  
Remove the two washers and ¼-20 nuts from the right shroud panel (right is defined as the right  
side when FACING the Crossfire) as shown in FIGURE 1 and FIGURE 2. Position the right  
shroud panel onto the studs. One stud is located on the right side of the hopper, FIGURE 1, and  
one stud is located at the base of the right Crossfire side door, FIGURE 2. The right shroud  
panel (top edge) should overlap the top shroud panel on the FRONT side of the stove. Secure  
the right shroud panel in place by installing the two washers and two ¼-20 nuts that were  
previously removed. Make final adjustments of the right shroud panel and then tight the two  
¼-20 nuts as shown in Figure 11b. Repeat this process to install the left shroud panel. Shroud  
panel installation is now complete.  
FIGURE 11b: CROSSFIRE SHROUD (right bottom view)  
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4.  
The installer should now install the fiberglass insulation on the back face of the shroud system  
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 shroud panels against the face of the fireplace opening.  
Sealing the shroud system minimizes draft and reduces vibration noise during operation of the  
stove. Install the fiberglass insulation by removing the paper backing. Install the ‘sticky’ side  
of the insulation against the back face of the shroud panels. Install the insulation in such a  
manner that will ensure the insulation will meet the face of the fireplace hearth wall and not be  
hanging out in the opening when the Crossfire is slid back into its final location. For hearths  
made of stone or have irregular surfaces, it will be necessary to obtain additional fiberglass  
insulation in order to ensure a proper seal between the hearth and the Crossfire shroud panels.  
Very irregular surfaces with large voids may require a masonry fill to ensure a proper seal  
between the Crossfire shroud panels. Insulation installation is now complete and the installer  
can prepare the trim (black standard, gold optional) for installation.  
FIGURE 11c: INSULATION (installed)  
FIGURE 11d: INSULATION (corner)  
5. The installer should now prepare the black trim for installation around the outside edge of the  
shroud panels. FIGURE 11e, 11f, and 11g show the corner bracket, the installation of the  
corner bracket, and the final fit of the mitered trim corner and bracket. Preparation requires that  
two angle brackets be installed at each mitered corner (left and right corner) of the trim where it  
connects to the top trim. FIGURE 5 shows proper installation of a corner bracket. Install the  
angle bracket to ensure the mitered trim corners fit tightly together and then tighten the screws  
on the bracket as shown in FIGURE 6. Once both sides are complete, the trim is ready to be  
installed on the shroud panel edges. Install the trim. NOTE: Do not bend the trim during  
installation as damage to the mitered corners and corner brackets can occur.  
FIGURE 11e: BRACKET  
FIGURE 11f: BRACKET (install)  
FIGURE 11g: CORNER (finished)  
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6.  
The installer should now place the trim (black or gold as purchased) 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 (silicone) may be used on the backside of the  
shroud panel to hold the trim in place. Close and secure both Crossfire side access doors.  
Installation is now complete and the Crossfire can be moved into its final location. As the  
Crossfire is slid back into the hearth, it is important not to push to hard and bend the shroud due  
to excessive pressure but at the same time, ensure enough pressure is applied between the  
hearth face and the shroud trim to avoid unwanted vibration during operation. FIGURE 11h  
shows how the shroud should look on the Crossfire once installation is complete.  
FIGURE 11h: CROSSFIRE SHROUD (shown with optional gold trim)  
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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. DO NOT  
CONNECT ANY CROSSFIRE APPLIANCE TO A CHIMNEY FLUE SERVING ANOTHER  
APPLIANCE.  
FIGURE 12 and FIGURE 13 illustrate both masonry and zero clearance chimney connections for both  
masonry and factory-built chimney applications. If installations require something different than one of  
these illustrated methodologies, please contact a local code official and 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  
FACTORY-BUILT CHIMNEY  
FIGURE 13: ZERO CLEARANCE  
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 manufacturer’s  
instructions, the homeowner must follow all national and local codes during the installation process.  
The Crossfire insert clearances to combustible materials, listed in TABLE 3 must be maintained. If  
local code allows, these distances can be reduced when acceptable shielding is provided. Consult a  
local code authority and professional installer to ensure that a specific installation meets proper code.  
MASONRY BUILT CHIMNEY  
Before connecting the Crossfire to a chimney, be sure to have the chimney inspected by a chimney  
professional and cleaned, if necessary. The chimney should have a liner that is free from cracks,  
deterioration, softening, or other damage that may prevent it from containing the byproducts of  
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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. Again, for 10 feet or less a 3 inch stainless steel liner  
can be used with the Crossfire. For lengths greater than 10 feet, a 4 inch stainless steel liner is to be  
used. It is also strongly recommended that these stainless steel liners be fully wrapped in insulation.  
This insulation will limit moisture buildup and ensure better performance of the Crossfire stove.  
Country Flame strongly recommends the use of smoke and carbon monoxide detectors when installing  
the 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. Ensure that any noncombustible floor  
protection equals or exceeds R = 1.5 or greater. Refer to TABLE 3 for floor protector clearance  
requirements.  
2. If a floor protector, different from the tested floor protector, is to be used, it must meet or  
exceed the requirements of the listed R-value of the tested floor protector. To convert alternate  
floor protectors to 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 layers of material, add each R-value of each layer to determine the  
materials overall R-Value.  
c. If the overall R-value of the alternate material is greater than the R-value tested  
material defined in STEP 1, then the alternate floor protection is acceptable.  
d. EXAMPLE:  
i. The tested material was ¾-inch thick with a k-factor of 0.84.  
ii. The R-value of the tested material was R = (1/0.84) x 3/4 = 0.893.  
iii. The proposed alternative floor protector is 4-inch brick material with a C-factor  
of 1.25 over 1/8-inch mineral board with k-factor of .29.  
iv. The 4-inch brick material has a value of Rbrick = (1/1.25) = 0.80.  
v. The mineral board has a value of Rmnbrd = 1/0.29 x 0.125 = 0.431  
vi. Total Rbrick + Rmnbrd = 0.80 + 0.431 = 1.231.  
vii. Since the total R-value of the alternate example floor protector (R=1.231) is  
greater than the tested example floor protector (R=0.893), the alternate is  
acceptable.  
3. Listed Floor Protector Definitions:  
a. Thermal Conductance = C = Btu/(hr)(ft2)(OF) = W/(m2)(OK)  
b. Thermal Conductivity = k = (Btu)(inch)/(hr)(ft2)(OF) = W/(m)(OK) = Btu/(hr)(ft)(OF)  
c. Thermal Resistance = R = (ft2)(hr)(OF)/Btu = (m2)(OK)/W  
4. Install in accordance with 24 CFR, Part 3280 (HUD).  
5. WARNING: Crossfire insert stoves must always be placed on a listed floor protector if the  
existing floor where the stove is to be placed is made of any combustible material. Never allow  
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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 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. If  
installation allows, the Crossfire fresh air intake should be connected through an exterior wall.  
Provision for outside combustion air may be necessary to ensure that fuel-burning appliances do not  
discharge byproducts of combustion into the house. Guidelines to determine the need for additional  
combustion air may not be adequate for every situation. If in doubt, it is advisable to provide outside  
air.  
Outside combustion air may be required if:  
1. The Crossfire does not draw steadily, smoke rollout occurs, fuel burns poorly, or back-drafts  
occur whether or not combustion is present.  
2. Existing fuel-fired equipment in the house, such as fireplaces or other heating appliances smell,  
do not operate properly, suffer smoke rollout when opened, or 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 combustion air  
should be provided from the outdoors to the Crossfire appliance. Outside combustion air can be  
provided to the appliance by the following means:  
1. Direct connection: appliances can only use direct connection of outside combustion air if they  
are certified for this type installation. Follow the Crossfire instructions for direct connection of  
outside combustion air.  
2. Indirect connection: for appliances not certified for direct connection of outside combustion  
air, outside air can be ducted to within twelve inches of the appliance.  
3. Mechanical ventilation: if the house has a ventilation system (air change or heat recovery):  
a. The ventilation system may be able to provide sufficient combustion make-up air for  
the Crossfire appliance.  
b. The homeowner should be informed that the ventilation system might need to be re-  
balanced by a ventilation technician after installation of the Crossfire stove.  
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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 INSTALLATION OF A COUNTRY  
FLAME CROSSFIRE STOVE IN A MOBILE HOME.  
WARNING: A CROSSFIRE STOVE INSTALLED IN A MOBILE HOME MUST BE COMPLETED  
IN ACCORDANCE WITH 24 CFR, PART 3280 (HUD).  
WARNING: A CROSSFIRE STOVE MUST BE PERMANENTLY BOLTED TO THE FLOOR OF  
THE MOBILE HOME.  
WARNING: A CROSSFIRE STOVE MUST BE ELECTRICALLY GROUNDED TO THE STEEL  
FRAME OF A MOBILE HOME.  
MOBILE HOME RULES  
1. Install only a HUD-approved laboratory tested stove in a mobile home. If the metal tag permanently  
affixed to a pellet 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).  
2. A permanent (hard line) combustion fresh air duct system must be installed and connected from the  
outside of the mobile home directly to the combustion air inlet on a Crossfire stove.  
3. A Crossfire stove must have a listed prefabricated chimney system installed in the mobile home. This  
chimney system must be properly connected and installed directly from the stove through the roof of  
the mobile home using only one manufacturer’s chimney 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 provide an approval document stating that the installation and inspection are in accordance  
with industry standards and therefore covered by the homeowner’s insurance policy.  
MOBILE HOME CLEARANCES  
1. Clearance is defined as the open space distance between any part of the stove or its flue connector and  
any combustible material, including but not limited to: walls, ceilings, trim moldings, furniture, word  
storage containers, or any other combustible item. Refer to the stove clearance section of this manual  
or the certification tag on a stove for minimum clearances that must be maintained during installation  
of a stove into a mobile home.  
2. Use of an approved thermal barrier may allow for the reduction of no barrier minimum stove  
clearances. Remember that a wall (wood studs covered with sheetrock, even if that wall is covered  
with brick) is still considered combustible. Functional thermal barriers are made of hearth pads  
consisting of two ¼” sheets of mineral board or 24-guage sheet metal spaced 1” from the combustible  
wall, with approved spacers that provide additional protection to the combustible wall. Refer to a  
hearth pad manufacturer’s instructions or the National Fire Protection Association Publication 211.  
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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.  
MOBILE HOME STOVE ATTACHMENT  
1. Install combustion air to the back of the Crossfire in all mobile home applications. The other end of  
the combustion air tube is to be installed through the mobile home floor or a wall. Ensure that snow  
or other material cannot prevent fresh air from entering the duct located outside the mobile home.  
2. The Crossfire must be secured to the floor of the mobile home, as shown in FIGURE 14 and must be  
properly grounded to the steel frame of a mobile home.  
3. Install a mesh screen or an approved fresh air cap on the outside of the mobile home combustion air  
tube. This cap will keep 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  
PELLET BURNING STOVE IN A SLEEPING ROOM. Air starvation usually occurs: (a)  
because the combustion air intake is blocked, (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.  
FIGURE 14: MOBILE HOME PEDESTAL INSTALLATION  
MOBILE HOME FLOOR PROTECTION  
1. A mobile home floor must be protected against stray sparks, radiant heat build up, or from  
damage during general use.  
2. This floor protection must meet certain minimum requirements as a thermal barrier. Calculations  
are provided in this manual for determining if a floor protector meets minimum requirements for  
a mobile home installation.  
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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. In the event there are floor protection  
questions, contact Country Flame or one of its local authorized dealers for assistance.  
MOBILE HOME CHIMNEY AND DUCTS  
1. ALL PELLET VENTING systems should be composed of listed TYPE L or TYPE PL, factory-  
built flue pipe and components assembled in accordance with the manufacture’s instructions for  
conveying flue gases from a listed pellet fuel-burning appliance to the outside atmosphere.  
Although a listed component does not guarantee a chimney fire will not occur, it is as close to  
ideal as industry standards provide today. Mobile home pellet stove and flue pipe restrictions are  
that: (a) regular thin walled stovepipe is not permitted, (b) roof systems cannot be weakened  
when installing a chimney or flue system, (c) a chimney cap and spark arrester are mandatory,  
and (d) the chimney must be strong enough to withstand normal area wind velocities.  
2. There are many chimney manufacturers providing excellent products that meet government  
listing requirements. From single wall, to double wall, to triple wall chimney components, each  
type and brand meets many various application criteria. Further, each chimney manufacturer  
provides excellent written instructions on HOW TO install a chimney system. This information  
should aid the homeowner in ensuring a certified professional completes the job properly. If  
there are questions, contact Country Flame or a local authorized dealer. If additional information  
is required, a search of the internet will provide plenty of valuable information. An example of  
an informative and excellent chimney product manufacturer’s 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 the larger clearance requirement when installing a pellet burning stove system into  
a mobile home.  
4. A mobile home chimney system should serve only one pellet burning stove. The chimney system  
must extend at least 3 feet above the highest point on the roofline where it passes through the  
roof. The chimney system should be at least 2 feet higher than any part of a roof or building  
within a 10-foot clearance around the chimney. The minimum chimney vertical height is 8 feet  
and the maximum chimney vertical height is 30 feet as measured from the top of a specific  
Crossfire model stove to the chimney flue exit. REMEMBER: The structural integrity of a  
mobile home wall and roof must be maintained during installation of a Crossfire stove. Country  
Flame strongly discourages the removal or cutting of roof trusses or other structural components  
of a mobile home in order to install a stove. Consult local code.  
5. To comply with over-the-road height limitations and to protect the chimney system and roof from  
damage remove all above roof chimney parts during transport of a motor home. 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.  
6. Many chimney manufacturers provide mobile home chimney kits. Mobile home chimney kits are  
not all-inclusive. A homeowner should consult with a certified professional. Additional chimney  
parts will be required to handle variations in local codes, site-specific mobile home issues, ceiling  
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height, ceiling slope, roof pitch, attic insulation, attic height, and surrounding objects. Use a  
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. Contact Dura-Vent or other  
authorized flue pipe dealers for the latest specifications and costs for mobile home pellet stove  
flue pipe parts or for a mobile home flue pipe kit from an authorized chimney dealer.  
TABLE 4: MOBILE HOME (minimum) CHIMNEY SYSTEM REQUIRED PARTS  
PART NUMBER  
DESCRIPTION  
QTY  
3180  
VERTICAL CHIMNEY CAP  
1
1
1
1
1
2
1
1
1
1
3149  
0/12 – 6/12 ADJUSTABLE ROOF FLASHING  
ROOF FLASHING, Flat (versus 3149)  
CEILING SUPPORT BOX, Fire Stop Spacer  
CATHEDRAL CEILING SUPPORT BOX, (versus 3142)  
5 FOOT CHIMNEY SECTION  
STOVE PIPE ADAPTER (if needed)  
WALL PROTECTION ( IF REQUIRED)  
450 ELBOW (if needed)  
3151 (ALTERNATE)  
3142  
3141 (ALTERNATE)  
3160B  
3179  
CERAFORM 126  
3145B  
3159  
STORM COLLAR  
NOTE: The information provided in TABLE 4 and detailed in FIGURE 15 are for informational  
purposes. These pellet flue pipe system parts may or may not be needed depending on site specific  
conditions found in the specific mobile home application. Consult a certified professional and insure that  
any installation meets all federal, state, and local building codes. 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.  
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FIGURE 15: MOBILE HOME CHIMNEY INSTALLATION  
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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 monthly cleaning (or more  
often) depending on frequency of use.  
The three most common maintenance chores will be:  
a)  
b)  
c)  
Refilling the hopper with fuel as needed.  
Cleaning the firebox and glass as required, satisfying the customer.  
Emptying firebox ash to ensure ash does not interfere with proper operation.  
Country Flame strives to use high quality low maintenance components in the Crossfire.  
STOVE DOOR INSTALLATION  
The 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 the stove hinge pin. Once the  
door hinges have been set, the door can be closed to check for proper fit. The Crossfire door installation  
should now be complete. To remove the door, simply lift up on the door from the stove hinges. Store the  
door in a secure place. If the door is left sitting, ensure that the door cannot fall and injure someone or  
damage the door or glass. The Crossfire door has been adjusted at the factory. If the door fit is not  
satisfactory, the homeowner can adjust the door using the hinge screws, refer to FIGURE 16.  
FIGURE 16: DOOR ALIGNMENT POINTS  
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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.  
The door gasket can also be adjusted to improve on the airtight fit. To adjust the gasket tightness, simply  
rotate the door latch clockwise (tighten) or counterclockwise (loosen) one complete revolution or as necessary  
to adjust the gasket seal. A good test to evaluate proper door gasket seal is to lay a dollar bill against the  
stove frame and then close and latch the door. If gently tugging on the dollar bill does not dislodge it from  
the door, the seal is appropriate. In the event that a proper door gasket seal cannot be obtained, it may be time  
to replace the door gasket.  
STOVE DOOR GLASS CLEANING  
The Crossfire stove is designed with an air wash system that assists in keeping the door glass clean. If the  
Crossfire stove is operated continuously on low heat setting, the door glass will get dirty quicker than 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 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. DO NOT use abrasives such as steel wool or  
powder abrasives as they will permanently damage the glass. Once the glass has been scratched, complete  
replacement of the glass is required. Use only approved 1400°F high temperature stove ceramic glass to  
replace any cracked or broken glass.  
FIGURE 17: DOOR GLASS REPLACEMENT  
GLASS REPLACEMENT  
The glass used in the Crossfire stove is a 1400° F high temperature ceramic glass. If the glass should crack or  
break for any reason, it must be replaced with an equal or better grade ceramic glass. The use of tempered  
glass or ordinary glass IS NOT AUTHORIZED and its use is hazardous. Crossfire replacement glass can be  
purchased direct from Country Flame or one of its authorized dealers. See FIGURE 17 for securing points for  
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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  
Window Type  
Euro Kera  
Glass-Ceramic, Kera Lite®  
KERA LITE® glass-ceramic has a thermal endurance far exceeding that of normal tempered glass. KERA  
LITE® is designed to operate at temperatures ranging from -4000F to +14000F. Despite its superior thermal  
properties, KERA LITE® stove windows should be treated with care. This glass-ceramic can still be  
scratched or broken by mechanical abuse. When cleaning the window, use only non-caustic, non-abrasive  
cleaners. 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.  
CAUTION:  
Do not attempt to clean hot glass. Do not abuse, strike, slam shut, or operate the  
Crossfire stove with any broken glass in the appliance.  
GASKET REPLACEMENT  
Remove the doors from the unit. Place the doors, face down on a protective surface to ensure no marring or  
scratching occurs during gasket replacement. To replace the Thermoglassknitted rope and tape gasket, first  
remove all of the old material and gasket cement. Use a putty knife or other sharp instrument to assist in  
removal. Use caution to prevent injury when removing old material. 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 gasket and gasket cement are available from your authorized Country Flame  
dealer. The following table defines the gasket material used in the Crossfire stove:  
Gasket  
Length  
Quantity  
Dimensions  
Around glass  
Doorframe  
Ash drawer  
4.25 feet each  
5 feet each  
37 inches  
1
1
1
¾” wide by 1/16” thick tape  
3/8” rope, high density  
½” wide by 1/8” thick tape  
CROSSFIRE CLEANING  
A Crossfire stove will require general cleaning, depending on frequency of use. During heavy use, daily  
cleaning of the firebox will be required and less frequently during light use. Allow the ash in the fire box to  
completely cool before removing the waste with an industry approved ash vacuum.  
The stove should be professionally cleaned twice a season if heavy use (daily use) is expected. A certified  
chimney sweep will have the proper tools to make short work of semi-annual cleaning. Country Flame has  
designed the Crossfire to make semi-annual cleaning as simple as possible. In fact, Country Flame designed  
the Crossfire so that it does NOT require removal from the fireplace in order to be properly cleaned. The  
following figures show how to access the cleaning ports on the Crossfire. By understanding how to  
thoroughly clean your Crossfire, the operator can maintain the stove in tip-top shape to ensure proper  
combustion and high efficiency. If questions do arise, do not hesitate to contact your Country Flame Dealer  
for additional information.  
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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.  
FIGURE 18: HEARTH PLATE REMOVAL  
Note that the hearth plate has two tabs located on the left 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  
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. Once these caps are removed, the  
clean-out ports are now accessible. An industry approved ash vacuum can be used to remove any ash or  
debris that has accumulated in the exhaust chamber to be removed. Removal of this ash and debris will  
allow the stove to draw more air and thus burn with a greater efficiency. Failure to clean out these areas over  
a period of use can lead to one or both exhaust chambers becoming blocked and thus causing the stove to burn  
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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  
considerable amount of ash from the chimney box thus assisting in proper maintenance of the stove.  
FIGURE 20: X-RAY VIEW OF RIGHT SIDE CLEAN-OUT PORT  
In the event a Crossfire system requires cleaning of the chimney to remove debris or ash, FIGURE 21 shows  
how to remove the chimney connector. In order to remove the chimney connector, the Crossfire will require  
removal from its hearth installation. 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, the homeowner should contact a certified chimney sweep as they may have the equipment  
to clean the chimney from roof level thus eliminating the requirement to remove the Crossfire from its hearth  
installation.  
Whatever time is spent maintaining and cleaning a Crossfire should be viewed as improving both the burn  
efficiency and the heat output of this product.  
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APPENDIX A: TROUBLESHOOTING GUIDE  
Shut off the power to the unit and allow it to cool off when performing cleaning and maintenance.  
PROBLEM  
SOLUTION  
Fire does not start.  
Ensure proper amount of pellets and starting gel are  
in burn pot.  
Ignition  
Fuel  
Stove does not switch on  
The starter fire in the firepot has not ignited or is  
not burning properly. Using gloves carefully open  
the doors and relay the pellet fire. Wait 8-10  
minutes for the pellets to burn well, before  
restarting the system.  
If Corn/Pellets contain  
amount of “fines” (foreign matter) or if they contain a large number of cobs and stalk  
a
large You may want to screen/sift Corn/Pellets before use  
sawdust  
No fuel in Firepot  
pieces to reduce problems and maintenance.  
Ensure that auger motor and auger flight is being  
turned. The auger may need to be primed if it has  
run empty or has become blocked. The stirring rod  
can be rotated by turning on the switch.  
Hard build-up on the firepot base  
Blockage in the auger.  
Sand in the pellets may cause “clinkering” (hard  
brittle deposits found in the bottom of the firepot).  
Screen your fuel to make sure that there is no sand  
or other foreign matter  
If the corn is not feeding into the firepot at the  
normal rate the auger may need to be cleaned. This  
may be due to fines or debris caught in the auger  
flight.  
If your stove is not working You may be using the wrong fuel. Check that you  
Stove  
Performance  
effectively  
are using the correct fuel. Either # 2 Yellow  
Shelled Corn - with 14% or less moisture (12%  
preferred) or 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 your stove is not generating Fines or dust in the corn can cause the unit not to  
enough heat  
burn properly or can cause a buildup in the drop  
tube and restrict the flow of corn. Clean the auger  
and fuel supply.  
Stove not performing effectively  
Stove not getting enough air  
Stove Heat not adjusting  
Clean the Heat Exchanger System, as it may be  
clogged and blocked.  
Check to ensure that the fresh air intake is clear and  
unobstructed.  
Allow time between changing heat settings for the  
stove to adjust both fuel and air to the new heat  
setting.  
Restricted flue gas flow  
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 stove will lead  
to some soot formation which will collect in the  
exhaust venting system. 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  
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APPENDIX A: TROUBLESHOOTING GUIDE  
(CONT’D)  
Stirring Paddles do not turn  
The chain drive for the stirring paddles needs to be  
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). Inspect the tension  
of the chain. It should have approximately 1/2”  
play. If the chain is too loose, adjust the chain drive  
motor by loosening the 4 bolts securing it and  
sliding it back until there is proper play in the chain.  
Re-tighten the bolts securely. This should be  
checked monthly or if you notice the stirring  
paddles not turning or binding.  
Ash Build Up  
The ash must be emptied every day, to prevent the  
build up of ash under the firepot blocking the air  
flow to the fire pot putting the fire out.  
Fire Goes out  
Fire goes due to ash build up  
Build up of Corn  
Do not leave viewing door open for more than 2 – 3  
minutes or you may have to restart fire. Remove ash  
wearing proper gloves.  
Your Firepot may need additional cleaning as  
extended burning on the high setting may cause a  
build-up of corn  
Your Corn/Pellet Stove Smokes  
Your Corn/Pellet Stove Smokes  
Your fuel may be damp or you may be using the  
incorrect fuel.  
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.  
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.  
Your Corn/Pellet Stove Smokes  
Cleaning is messy and difficult  
Clean the Heat Exchanger more frequently. This  
cleaning procedure should be done daily. If buildup  
is allowed to go unattended, cleanup will be much  
more difficult and the efficiency of your stove will  
be adversely affected.  
Cleaning  
Glass Breaks  
Use care not to slam or strike door, this could result  
in glass breakage. If glass is broke or cracked, DO  
NOT operate the stove. Repairs must be made.  
Always use an approved glass cleaner (i.e. Windex,  
Glass Plus) and a lint free soft cloth to polish the  
door frame. Do not use abrasives like steel wool,  
brass polish or adhesive cleaners like comet, as  
these will scratch the finish. If the Gold Doors are  
scratched they will have to be replaced or returned  
to Country Flame for refinishing. This is expensive  
and during this time you will not be able to use your  
stove.  
Glass  
Doors  
Luster on Gold Doors Fades  
Doors are not airtight  
Check door alignment for proper seal. Adjust door  
hinges as necessary to ensure a good airtight seal.  
The doors may need new gasket material. Contact a  
local Country Flame dealer.  
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APPENDIX B: MAINTENANCE GUIDE  
Shut off the power to the unit and allow it to cool off when performing cleaning and maintenance.  
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. Rotate the stir rod until the  
slot is vertical. Now lift the firepot and the stirring  
rod out of the firepot holder. To replace, reverse  
the procedure. The stir rod can be rotated by  
operating the control board. See control board  
instructions.  
Regular Cleaning  
Removing “Clinkers”  
A clinker on the bottom of the firepot may be  
removed with a spoon and dropped into the  
combustion chamber.  
NOTE: For your Safety, only remove clinkers from  
stove when unit is cool. Wear gloves and eye  
protection.  
Soot and Fly-ash Build Up  
The ash must be emptied every day. If the ash is not  
emptied regularly, ash will build up under the  
firepot and block proper air flow to the fire pot  
putting the fire out. When the stove is cold, the  
firepot can be pulled out and removed for a  
thorough cleaning. Also, check the drop tube  
(where the corn drops into the firepot) 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 of the  
firebox housing. Insert the vacuum hose into each  
of these COOL access ports. Completely vacuum  
and then replace “I” plugs. Air leaks will not allow  
the stove to burn properly.  
Cleaning the Heat Exchanger.  
A sliding plate fits over the fifteen tubes of the heat  
exchanger. The sliding plate is attached to a small  
rod protruding through the front of the stove just  
below the louver vent. Push the rod to the back of  
the exchanger and then pull forward to the front,  
several times. This will effectively remove ash and  
debris from the surface of the heat exchanger.  
Performing this step often will ensure that cleaning  
is an easy task. This cleaning procedure should be  
done daily. If buildup is allowed to go unattended,  
cleanup will be much more difficult and the  
efficiency of your stove will be adversely affected.  
CAUTION: Cleaning rod may be hot! Use a  
fireplace glove to protect your hand when using the  
cleaning rod to avoid getting burned!  
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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. (Glass may crack if subjected to cold  
liquid cleaners while the glass is still hot. Using  
cleaner on hot glass may also cause burns, emit  
fumes and the glass is more likely to stain.)  
Cleaning the Gold Doors (optional Doors should be wiped down regularly to ensure the  
feature)  
luster of the door system lasts. Always use an  
approved glass cleaner (i.e. Windex, Glass Plus)  
and a lint free soft cloth to polish the door frame.  
Do not use abrasives like steel wool, brass polish or  
adhesive cleaners like comet, as these will scratch  
the finish.  
Door Air Wash  
Periodically clean out the door air wash (a groove at  
the bottom of the door). This air wash directs air  
over the glass door to minimize soot buildup on the  
door.  
Exhaust Venting System  
After using your stove, you will observe 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 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.  
General/Yearly  
Maintenance  
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 Exhaust If supplied with oil ports, the room air & exhaust  
Blowers  
motors will need to be oiled at least once per season  
with PROPER oil. Locate the oil ports on either the  
side or top of the units and add three drops of oil.  
This simple step will greatly increase the life and  
serviceability of your unit.  
Checking the tension on the Chain Locate the chain drive by opening the left side  
Drive of the Stirring Paddles.  
door (control panel side). Chain tension should be  
approximately 1/2” play. If the chain is too loose,  
adjust the chain drive motor by loosening the 4  
bolts securing it and sliding it back until there is  
proper play in the chain. Re-tighten the bolts. The  
chain should be checked monthly.  
Inspecting the Door Gasket  
This is done by taking a 2” long strip of paper and  
shutting the door on it. Then pull the paper to test  
the gasket pressure. You should have to pull the  
paper from the door. 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.  
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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. Strip off old  
gasket around glass and clean glass well. Clean out  
old stove gasket material from gasket track. Once  
the door and glass are clean, apply gasket material  
to glass surface and return glass to door, securing  
with clips (Use care not to over-tighten). Then  
apply a generous bead of gasket cement into the  
track. Position the NEW gasket into track and  
gently press into door. Trim off any excess gasket  
and wipe away excess cement. Let the cement set  
24 hours before placing door back on unit and using  
the unit. Gasket material and cement may be  
obtained from your dealer.  
Replacing the Glass  
Remove the door gasket (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  
obtained from your dealer. Clean out old stove  
gasket material from gasket track. Once the area is  
clean, apply gasket material to new glass surface  
and return glass to door, securing with clips (Use  
care not to over-tighten).  
Adjusting the Doors  
The doors of your Crossfire Stove may need some  
adjustment due to shipping vibrations, jarring  
during installation and extended use. It is important  
that the Crossfire door fit properly and remain  
airtight. Periodically check the alignment of the  
doors. To adjust the door, loosen the Allen bolts in  
the hinge and adjust the door accordingly. When  
completed, use a piece of paper between the door  
and the stove to ensure a proper seal. The paper  
should not pull out easily once the door is closed  
and latched.  
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APPENDIX C: TECHNICAL SPECIFICATIONS  
Fuel Type: #2 Yellow Shelled Corn Fuel  
Moisture Content: 14% or less (12% preferred)  
Wood Pellet Fuel  
A.P.F.I. residential fuel  
Heat Content: 10,000 Btu/lb*  
Ash Content: 3% maximum  
5.9 lbs/hour maximum feed rate  
Heat Content: 8200 BTU/lb  
Ash Content: 1% max  
Bulk Density: 40 lb./cubic ft. min  
Moisture Content: 8% max  
Size: 1/4” to 3/8” diameter  
1.5” long max  
Fines: 1% max through 1/8th screen  
Hopper Size:  
Flue Size:  
72 pounds corn or 55 pounds wood pellets  
4” recommended. If less than 10 feet use of 3 inch pipe is approved.  
PL double wall vent with stainless steel inner liner  
3 inch by .15 inch walled steel pipe  
Flue Type:  
Air Inlet:  
Auger Type:  
Controls:  
1 1/8” cup Auger Feed System  
Country Flame Intelli-Choice Control Board  
120 Volts, 2.4 Amp, 60 Hz  
Electrical:  
Measurements:  
CROSSFIRE HEIGHT (at front)  
CROSSFIRE DEPTH (from shroud)  
CROSSFIRE WIDTH (rear)  
22.5”  
14.0”  
26.0”  
25.5”  
CROSSFIRE WIDTH (at shroud mount)  
Weight :  
STOVE WEIGHT  
220 POUNDS  
Clearances:  
UNIT TO SIDEWALL  
UNIT TO SIDE TRIM  
7”  
7”  
UNIT TOP TO SIDE TRIM  
UNIT TOP TO MANTLE  
HEARTH FLOOR TO MANTLE  
NONCOMBUSTIBLE FLOOR PROTECTION (front)  
NONCOMBUSTIBLE FLOOR PROTECTION (sides)  
9.25”  
9.25”  
32”  
6”  
6”  
Shroud Measurements:  
SHROUD WIDTH (standard)  
SHROUD HEIGHT (standard)  
SHROUD WIDTH (oversized)  
SHROUD HEIGHT (oversized)  
42.0”  
30.0”  
48.0”  
32.5“  
*BTU/lb can vary depending on the moisture content of the corn.  
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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 phase will be activated.  
The stove has now entered the “startup” phase. Pellets should have already been placed in the burn pot (only  
required if 100% corn fuel is being used.) Manually ignite the stove to burn the pellets and heat up the firebox.  
It is important to have a “hot” fire of pellets ignited to ensure that once corn starts feeding, the corn will sustain  
self-combustion. Corn fuel will further cool the combustion chamber if the pellet fire is too small (cool.) Self-  
combustion will not occur without relighting the stove. Once the pellet fire is burning properly and a bed of  
red coals can be seen, the stove should automatically begin to feed fuel into the firepot or approximately 3 ½  
minutes after the startup phase began. The total startup time can take between 10 to 20 minutes depending on  
outside weather conditions, the temperature of the stove, the quality and moisture content of the fuel being  
used, and other site specific factors. It will be evident to the operator when the burn phase has begun as the  
room air fan will kick on. Warm air can be felt being blown from the heat exchanger tubes above the door.  
BURN PHASE  
Multiple heat lights indicate the control panel burn phase. There are five red lights 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. Once the Heat 5 setting has been reached, if the HEAT  
LEVEL button is pushed again, the heat setting will cycle over again starting at Heat 1. The operator controls  
the heat output of the stove by utilizing Heat 1 through Heat 5 settings. Heat 1 setting provides the lowest heat  
output from the system and the longest time between refills of the fuel hopper. Heat 5 provides the maximum  
heat output from the system and the shortest time between refills of the fuel hopper. Changing any heat setting  
up or down by one increment will cause a delayed (it takes time for both the fuel and air adjustments to impact  
the burn chamber) increase 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 the  
operator regardless of how many incremental changes occur but the operator should remember that it takes  
“time” for the stove to stabilize to the new heat setting.  
COOL DOWN PHASE  
Any time the system is switched off by pressing the Intelli-Choice Control Board on/off switch until the power  
light turns red during normal stove burn operations, the control board will ensure the system will revert to the  
cool down phase. During the cool down phase the room air and exhaust fans will be operated at full speed.  
The fuel feed (auger) motor will cease to operate thereby ensuring minimal time for the burn phase to be  
extinguished. This cool down process will continue until such time as the control system senses that the stove  
has been properly cooled down.  
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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 cool down phase. During the cool down phase the room,  
exhaust, and stir pot motors will be operated at high speed. The auger motor will cease to operate thereby  
ensuring minimal time for the burn phase to be extinguished. During the cool down phase the heat indicator  
lights will step down from red (5th light being on) to the first yellow light being on. This process will be  
repeated until such time as the control system senses that the stove has been properly cooled down. The auger  
and igniter lights are both off during the cool down phase.  
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. In the event that the fault phase  
continues to flash lights, the operator should not try any repairs except those listed below without contacting  
their dealer or an authorized and properly trained service technician. Country Flame has made every effort to  
ensure the safety of the homeowner through proper use of this system. Any attempt to modify or circumvent  
the safety features of this product is prohibited by the manufacturer. In the event that the fault phase does not  
reset with the manufacturers recommended procedures, please contact your local authorized Country Flame  
service representative.  
RESET CONDITION  
Reset Condition #1 requires the system to properly proceed through cool down phase. By allowing cool down  
to occur the control panel will automatically shut off the system. In order for system shut off to occur all  
electronic controls must sense safe system temperatures. In the event “safe temperatures” are not sensed by the  
system, the control panel will continue to operate in the cool down phase until such time that safe temperatures  
are achieved or the operator intervenes. In order to perform a “hot restart” from the cool down phase, Reset  
Condition #2 must be followed.  
Reset Condition #2 assumes the operator has shut down the system and has now decided that a restart of the  
system 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 DOWN PHASE. In the event of a “fault phase” no hot restart can be initiated.  
SYSTEM MAINTENANCE  
There are two functions built into the control board that can be used to assist with maintenance or  
troubleshooting a system. These two control board functions are:  
a)  
b)  
Prime State  
Manual Control  
The Prime State is utilized upon installing a new stove or after a fuel bin (hopper) has been depleted of fuel.  
The prime state can be entered by pressing and holding the on/off switch for a minimum of 15 seconds. By  
holding the on/off switch on for 15 seconds or more, the auger light (green) will be turned on and the heat  
lights will be sequenced from lowest to highest light being consecutively turned on to signify the auger being  
filled with fuel. This prime state will remain on for a maximum of 10 minutes or until the operator presses the  
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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. The purpose of the stir rod is to mix the fuel and air to ensure a more  
efficient burn. During normal burn phase operation, the control board controls the motion of the stir rod. The  
operator can press both the blue (down) and red (up) heat arrows to turn the stir rod manually. This manual  
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. 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.  
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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.  
PROVIDE FOR CONTROLLING IGNITION, FUEL, COMBUSTION AIR  
PROVIDE CONTROLLING HEAT FROM FIREBOX TO HEAT EXCHANGER.  
CONTROL SYSTEM TEMPERATURE.  
OPERATE SYSTEM EFFICIENTLY TO MINIMIZE WASTE.  
ENSURE SAFETY FEATURES PROTECT USER AND SURROUNDING AREA.  
Some standard terminology is required in order to discuss Combustion Basics. This terminology  
is reasonably standard throughout the different industries. The following terms should be part of  
a stove owner’s vocabulary and a basic understanding of these items is a must in maintaining a  
stove system:  
Ash content: Refers to the non-combustible materials in a fuel, which reduce the heating value  
per unit of weight.  
Biomass:  
Carbon  
All forms of organic matter, including wood, agricultural crops and residues,  
animal dung and human waste.  
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 the production  
of heat, or heat and light. Complete combustion of a fuel is possible only in the  
presence of an adequate supply of oxygen. Chemical reaction between a fuel and  
oxygen that usually takes place in air. Combustion is commonly referred to as  
burning.  
Combustion  
Air: The amount of air required inside the combustion chamber to create a burn.  
Combustion air, for this manual, is defined as the amount of air required to  
ensure 100% burn of all fuel present in the burn chamber.  
Combustion  
Efficiency: Calculated measurement (in percent) of how well the heating equipment is  
converting a specific fuel into useable heat energy at a specific period of time in  
the operation of a heating system.  
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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. A combustion system operated exactly at the peak burn  
efficiency ratio has a high probability that some of the oxygen in the combustion  
air will not get paired up with the fuel. Adding excess air ensures that a  
percentage of additional air is available to ensure complete burn of all fuel.  
Excess air reduces efficiency but ensures complete fuel burn as environmental  
variables change. In addition, a little excess air provides a cushion against the  
fuel-air ratio drifting over into the rich (excess fuel) range. With time, all  
combustion systems will tend to burn richer (that is more fuel than air.) The big  
enemy that creates a richer burn is dirt. Dirt is more likely to accumulate in the  
air system rather than in the fuel system. The combustion and makeup air fans,  
in addition to everything else within 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 will combust.  
Pyrolysis:  
Room Air:  
The second stage of ignition during which energy causes gas molecules given off  
by a heated solid fuel to vibrate and break into pieces.  
Air that is passed through a stove’s heat exchanger tubes which elevates the room  
air temperature and thereby delivers heat to a living space.  
WOOD PELLET COMBUSTION BASICS  
In a normal wood pellet combustion process, water is first boiled out of the pellet. Then volatile  
matter and fixed carbon matter are released in the combustion process and later burned to create  
heat. Any remaining product left behind in the burn process is defined as ash. FIGURE 18  
illustrates the combustion process of wood.  
Moisture  
Gas Phase Volatile  
Volatiles  
Oxidation  
Solid Particles  
Pyrolysis  
Heat  
Carbon Phase  
Oxidation  
Carbon  
FIGURE 18: WOOD PELLET COMBUSTION PROCESS  
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The obvious advantage of 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. The heat generated in the burn process, once combustion is achieved,  
sustains the process as more fuel is added. As the gases burn, the pellet stove’s firebox temperature can  
achieve temperatures exceeding 1,000o Fahrenheit. The list below gives a sample of ignition  
temperatures for some of the carbon and volatile matters released when wood is burnt:  
COMBUSTIBLE  
Fixed Carbon  
FORMULA  
C
IGNITION TEMP (O F)  
765 – 1115  
Volatiles  
Hydrogen  
Methane  
Ethylene  
Benzene  
Ethane  
H2  
1076 – 1094  
1202 – 1382  
1008 – 1018  
1364  
968 – 1166  
1191 – 1216  
CH4  
C2H4  
C6H6  
C2H6  
CO  
Carbon Monoxide  
Note that all ignition temperatures fall between 950o F through 1400o F for volatile matter. All visible  
flames emitted during a wood pellet fire come from the ignition of volatile matter. Good combustion  
occurs when the fuel vapors are thoroughly mixed with the combustion air. Mixing ensures that fuel  
molecules come in contact with oxygen fuel molecules. There must be an abundant amount of oxygen  
molecules available to react with the fuel molecules or an incomplete burn will occur. NOTE: The fuel-  
air mixture must at all times exceed the combustion temperature as well as exceed the ignition  
temperature if a burn is to be sustained. There must be adequate time for the reaction to proceed to  
completion (complete burn.) It is commonly stated that good conditions for combustion are defined as  
the THREE T’s:  
Turbulence  
Temperature  
Time  
It requires 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 to the  
heat. This entire combustion process takes time to occur and is self-sustaining only if all conditions are  
met for the fuel being burnt.  
Heat is obtained from a stove by the thermal radiation that occurs from the burning wood pellets.  
Although a fairly complex phenomena to define, the heat radiated from the fire is a very strong function  
of the local (burn pot) temperature and the overall combustion temperature that is maintained within a  
stove’s burn chamber. A relatively minor combustion temperature increase in a pellet stove can produce  
a significant amount of increased heat output. NOTE: The reverse of the preceding statement is also true.  
That is, if too much heat is pulled from the combustion chamber via the heat exchanger tubes, the  
combustion temperature can drop rapidly thus causing a “burn out.” Burn out occurs once the  
combustion chamber temperature drops below the critical “ignition temperatures” required of the different  
fuel components. Wood pellets, because of their low combustion temperature ensure an ample supply of  
volatile and carbon matters available for continued ignition. However, for other types of fuel, such as  
corn, it is important that the homeowner understand the complexity of this principle and how  
environmental variables can affect the combustion chamber, combustion temperature, and ignition  
temperatures. Once a burn chamber’s temperature begins to fall below critical ignition temperatures, the  
heat required to sustain the combustion temperature can also be lost and the fire will go out.  
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As a final note, the four basic stages of wood pellet burning are:  
a)  
b)  
Up to 212o F the pellet is boiling of the moisture.  
Near 575o F gasification of the solid wood pellet fuel occurs. The pellet will simply seem  
to disappear. Very little energy is released in these first two stages and external energy  
must be applied to sustain any combustion that is occurring.  
c)  
d)  
Somewhere between 900o F and 1100o F the pellet 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. All remaining fuel  
will simply exhaust through the system as unburned material.  
At temperatures around 1500o F the remaining gases and tars will burn off in the  
combustion chamber. This final combustion yields an additional 10 to 20% additional  
heat energy and gives a very clean final exhaust from the product.  
Wood pellets, as compared to wood logs, enhance the amount of energy released during the burn cycle  
because of the uniformity of product, the reduced moisture content, and the variation 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 technology evolves, all stove manufacturers will strive to control  
more of the variables that might adversely affect the combustion process. In addition, stove  
manufacturers will strive to optimize the efficiency of the products burn process. It is the homeowner’s  
responsibility to understand not only the particular product but also how environmental issues beyond the  
control of both the manufacturer can affect a product’s burn process. This understanding will make  
trouble diagnosis less time consuming and more accurate for all parties involved in maintaining the  
product in a reliable manner to the satisfaction of our mutual customers.  
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APPENDIX F: REPLACEMENT PARTS  
REPLACEMENT PARTS  
Part Number  
CF04-P72  
CB-74  
Description  
Number per CROSSFIRE  
BURN POT SCREEN  
STIR ROD ASSEMBLY  
BURN POT ASSEMBLY  
1
1
1
1
CF04-A64  
PP-664  
200 Watt IGNITER ASSEMBLY  
(OPTIONAL ON EARLY MODELS)  
PP-353  
PP-355  
PP-352  
PP-347  
PP-12  
EXHAUST MOTOR ASSEMBLY  
ROOM AIR MOTOR ASSEMBLY  
VACUUM SENSOR SWITCH  
1
1
1
2500F OVER TEMPERATURE SENSOR  
1100F EXHAUST/ROOM AIR SENSOR  
OWNERS MANUAL  
1
1
1
1
1
PP-182  
PP-637  
PP-989  
ON/OFF SWITCH (STIR ROD)  
AC RECEPTACLE  
NPS-1005C  
Intelli-Choice CONTROL BOARD  
1
PP-1029  
PP-40  
WIRING HARNESS  
DOOR FRAME ONLY  
DOOR ROPE GASKET  
CLEAN OUT PLUGS  
1
1
1
2
PP-87-NC  
40-0000-05  
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APPENDIX F: REPLACEMENT PARTS (cont’d)  
REPLACEMENT PARTS  
Part Number  
CF04-A24  
PP-535  
Description  
Number per CROSSFIRE INSERT  
4” CHIMNEY CONNECT BOX  
AUGER MOTOR ASSEMBLY  
VACUUM HOSE  
1
1
1
1
PP-27  
PP-88  
HOPPER GASKET TAPE  
PP-48  
NON-ETCHED DOOR GLASS W/TAPE  
ETCHED DOOR GLASS W/TAPE  
SIDE TRIM, GOLD  
1
1
2
2
2
2
PP-525  
PP-107-G  
PP-107-N  
PP-107-B  
PP-185  
SIDE TRIM, NICKEL  
SIDE TRIM, BLACK  
SIDE TRIM, CUSTOM  
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APPENDIX G: LABELS  
REPLACEMENT LABELS  
Part Number  
Description  
Number per CROSSFIRE INSERT  
PP-483  
CAUTION LABEL  
1
PP-484  
CAUTION LABEL  
1
PP-35-0300-13  
ATTENTION LABEL  
1
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APPENDIX G: LABELS (cont’d)  
REPLACEMENT LABELS  
Part Number  
Description  
Number per CROSSFIRE INSERT  
PP-35-0300-39  
LIGHTING LABEL  
1
PP-486  
ELECTRICAL LABEL  
1
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