Crossfire CF-2100 SERIES User manual

The Ultimate in Radiant Heating Systems
CF-2100 SERIES
FIREPLACES
INSTALLATION MANUAL
October, 2005
Crossfire Fireplaces
249 Bridge Street West, P.O. Box 121
Campbellford, Ontario, Canada K0L 1L0
Tel: [phone] Fax: [phone]

Crossfire Installation Manual
Revised Oct 2005 page 2
Final Look
The Crossfire you purchased will be one of 4 options. Upon completion of the assembly
of the core, it should look like one of the diagrams below:
CF-2100-BO CF-2100
(our most popular fireplace) (no bake over)
CF-2100-BO-ST CF-2100-ST
(see-through) (see-through but no bake oven)

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Planning For Your Crossfire Fireplace
Please read this manual completely before constructing your Crossfire.
Before you start your installation, there are some decisions that need to be made.
Which floor will your fireplace be located on? Basement? First floor? Second floor?
The footings for your Crossfire will be basically the same regardless of which floor you
choose to put the unit on. For first or second floor installations, there will be a need to
construct concrete block supporting walls, capped with a concrete pad to support the
Crossfire.
Where will the chimney be located?
This is based on aesthetics. Your options are; a chimney on each side, a single chimney
on the right hand side, a single chimney on the left hand side or a single chimney at the
back. If you have chosen the See-Through option for your fireplace, the chimney at the
back of the unit is not an option because it would be in front of the door.
Once you have decided upon where the fireplace is going and which chimney option you
want, simply follow the instructions below corresponding to your choices.
If you have decided on a chimney on both sides, you will need a second damper. Only 1
damper is supplied with a Crossfire. Please call the factory to order an additional
damper.
The Foundation
As in any good building, your Crossfire requires a solid foundation. The weight of the
fireplace and the facing material needs to be adequately transmitted to the soils carrying
the house. In order to do so, the Crossfire requires a footing 12”deep with !” reinforcing
steel to be placed on a 12” x 12” grid located 4” up from the bottom.
The length and width of the footings are determined by your choice of chimney options.
The table below provides the length and width.
Chimney Option
Length
Width
Chimney at each end
110”
50”
Chimney right hand side
95”
50”
Chimney left hand side
95”
50”
Chimney at the back
80”
65”

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Cross-Section of Typical Footing
Supporting Walls
It is now necessary to construct the walls from the footing that will support the Crossfire.
These walls are typically made of 8” concrete blocks (8”x8”x16”).
The rectangle constructed using the blocks is 72” x 32”. It should be constructed to a
height approximately at the bottom of the floor joists.
This structure should be centered below the core and chimney.
Provision should be made for an ash cleanout door and for a 6” outside air inlet duct.
Concrete Pad
A concrete pad needs to be constructed on top of the concrete walls to build the Crossfire
on. The size of the pad is determined based on the options you have chosen; location of
the chimney and See-Through or not.
In all cases the concrete pad will have:
•Reinforcing steel of !” bar on 12” spacing in both directions
•A hole 22” x 1 !” to act as a fresh air intake and ash drop
•A 2” gap between the pad and the floor joists.
•A 16” hearth on the door side. Note there will be a 16” hearth
on both sides if the See-Through option was chosen.
The hole in the core for the air and ash as well as the space between the pad and the floor
joist can be achieved by using 1.5” extruded Styrofoam and 2” extruded Styrofoam
respectively, as filler materials during the placement of the concrete. Once the concrete
sets, the Styrofoam can be removed, leaving the required holes and spaces.

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The following diagrams illustrate the dimensions of the concrete pads and the location of
the air intake/ash dump. Please note the additional 16” hearth requirements if you have
chosen the See-Through option. (Measurements are in inches.)
Chimney on the left.
Chimney on the right.

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Chimneys on both sides
Chimney at the back.
(Note: The See-Through option does not allow for a chimney at the back)

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Double chimney, double hearth, See-Through option.

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Constructing the Crossfire
Before you begin, ensure the Styrofoam spacers have been removed from around the
concrete pad and from the air intake/ash dump.
Please note that the core pieces are manufactured with a slight taper. When installing the
core, these tapers should be ignored. Keep the Crossfire level and plumb and do not
compensate for the tapers in the refractory core blocks. See the diagram below.
You are now ready to install your Crossfire.

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Revised Oct 2005 page 9
Step 1 – Leveling Pad
Locate Part 1. Spread a thin layer of refractory cement on the bottom of Part 1. Use the
fresh air intake/ash dump hole as your reference point and install Part 1 onto the concrete
pad. Use a level and ensure the block is level in both directions.
Step 2- Leveling Pad
Repeat the procedure above for Part 2.

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Step 3 – Installation
Locate Part 3 and spread a thin layer of refractory cement on the bottom of the part. Use
Parts 1 & 2 as your reference and install Part 3. Use a level to ensure the part is level and
plumb.
Step 4 & 5 – Install the chimney connection blocks.
If you are installing your Crossfire with the Chimney to the left or the right or both, you
will need to modify the installation of Parts 4 & 5. These parts are interchangeable. Note
that the diagram shows the chimney to the left.
If installing the chimney to the left, leave out Part 4.
If installing the chimney to the right, put Part 5 in the location for Part 4 and leave the
right side open.
If installing a chimney on both sides, leave Parts 4 & 5 out.
Part 5 should have refractory cement applied to the bottom and to the side connecting to
Part 3.

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Installation of the Damper
This diagram shows the installation of the damper for right side chimney. The
installation is the same for a left hand chimney.
Installation of a Rear Damper
The following diagram shows the installation of the rear chimney option.

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NOTE: THE DAMPERS ARE NOT SHOWN IN THE FOLLOWING STEPS
Step 6 - Install air intake block
Locate Part 6. Spread refractory cement on the bottom of the part and install on top of
the leveling pad, using the leveling pad and the air intake as a guide.
Step 7 – Installation Part 7
Locate Part 7. Apply a layer of refractory cement on the bottom of Part 7 and to the sides
of Part 7 that will contact with the other pieces of the fireplace core installed.

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Step 8 – Install the base of the floor.
Locate Part 8. Apply refractory cement to bottom and sides of the Part where it will
contact with the other pieces and install.
Step 9 – Complete the installation of the Crossfire core.
The next steps are straight forward. Locate the core pieces (which are numbered) and
install them in order. Remember to apply a layer of refractory cement at each contact
point. Also, remember to check the installation with a level to ensure the core is being
installed level and plumb. Use the diagrams below for reference.

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Installation of the Bake Oven

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Installation of the Cardboard Spacer
Your Crossfire was supplied with cardboard pieces. This cardboard is intended to be
wrapped completely around the core. The cardboard is used as an expansion gasket
between the core and the mortar since the core will expand faster than the exterior facing
material.
NOTE: The cardboard should be cut back at least 2” from the fire box opening to allow
for the door frame.

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Bake Oven Installation
If you chose the bake oven option, it is now time to install it.
As with the other pieces, apply a thin layer of refractory cement to the bottom of the bake
oven and place it, centered, on top of the lid.
Install the bake oven door.