Steffes Comfort Plus Hydronic 5120 Owner'S And Installer'S Manual Download

Page: 29 / 38

PARTS LIST - CONTINUED

DWG.

REF.

DESCRIPTION

5120

5130

5140

NO.

ITEM NO.

Limit Harness Bottom

1041504

Left Side Front Base Panel

5940881

Bottom Panel

5940568

Base Top Panel

5940848

Bottom Exchanger Tray Panel

5940802

Back Bottom Base Painted Panel

5940884

Left Side Bottom Painted Panel

5940594

Left Side Back Painted Panel

5940599

5940530

5940598

Core Limit Switch 290D

1012019

Limit Zone Painted Cover

5940585

5940527

5940591

Left Side Top Painted Panel

5940584

Left Side Core Panel

5940561

5940565

5940560

Insulation Blanket Inner

1054130

1054134

1054140

Insulation Blanket Outer

1054132

1054136

1054142

Back Painted Panel

5940593

5940528

5940592

Galvanized Core Panel Back

5940563

5940567

5940562

Galvanized Core Panel Top

5940564

Exchanger

1100100

Limit Switch 250D Manual Reset (upper)

1041758

Left Side Exchanger Panel, Inner

5940814

Exchanger Access Tube Cover

5940858

Exchanger Access Painted Panel

5940880

Core Blower Capacitor

1018007

Low Voltage Panel Assembly

1041721

Terminal Block 6 Position

1016041

Electrical Panel, Main Body

5940856

Electrical Panel, Bottom

5940854

Cable, Control Board Interface 18"

1010014

Cable, Expansion Board Interface 12"

1010012

Limit Switch 225D Auto (lower)

1041756

Junction Box for Pump Connections

1015004

Junction Box Cover

1015002

Outlet Water Sensor

1041748

Resistor, 1200 ohm

1041764

Time Clock Module, Optional

1301014

Cable, Time Clock Module Interface 18"

1010014

Left Side Exchanger Panel, Outer

5940836

Filler, Painted Electrical Panel Cover

5940846

N/A

NOTE

When ordering parts, please include the system model and serial number.

Comfort Plus Hydronic

Appendix



A.04

Summary of Contents for Comfort Plus Hydronic 5120

Page 1: ...V11 OWNER S AND INSTALLER S MANUAL Manufactured in North America for COMFORT PLUS HYDRONIC 5100 SERIES Models 5120 5130 5140 Applicable to Software Version 140 159 ...

Page 2: ... Steffes Corporation has used its best judgement based upon information available but disclaims any responsibility or liability for any errors or miscalculations contained herein or any revisions hereof or which result in whole or in part from the use of this manual or any revisions hereof After the heating system is installed Steffes disclaims any responsibility or liability for mold mildew growt...

Page 3: ...ect the pressure relief valve in a vertical upright position with the supplied fittings DO NOT modify this assembly DO NOT cap plug or otherwise obstruct the outlet of the pres sure relief valve Risk of fire Can cause injury or death Viola tion of the clearance requirements can cause improper operation of the equipment Main tain the placement and clearance require ments specified Risk of personal ...

Page 4: ...annel Installation 3 04 3 05 Brick Core Temperature Sensor Installation 3 05 LineVoltageElectricalConnections 3 06 3 07 LowVoltageElectricalConnections PeakControl 3 07 3 08 Outdoor Temperature Sensor 3 08 3 09 RoomThermostat 3 09 3 10 Air Conditioner Heat Pump Interface 3 10 Pressure ReliefValve Installation 3 11 Plumbing 3 11 3 13 AuxiliaryLoadControl 3 13 Configuration Menu 3 14 3 15 Installer ...

Page 5: ...nent heating system during the construction phase may contaminate the duct system and or internal areas of the heating system This may cause poor indoor air quality issues and or improper system operation once the home is completed A suitable alternative heating system must be used during the construction phase SYSTEM START UP On start up of the Comfort Plus Hydronic system odors relating to first...

Page 6: ...ress and release the up arrow to view this data Outdoor Temperature indicates current outdoor temperature Operating Mode and Outlet Water Temperature indicates the current operating mode followed by the outlet water temperature C Off Peak Charge Time P On Peak Control Time A Anticipated Peak Time Heat Call Status indicates the current heat call status as determined by the room thermostat s The fac...

Page 7: ...charge level during the next off peak period It continues to charge during off peak hours until the system achieves full maximum core charge or until the override is cancelled Once full charge is achieved or the override is cancelled the system charges according to its standard configuration Initiating the Override Feature Step 1 Press and hold the M the up arrow and the down arrow buttons at the ...

Page 8: ...peration and draining Incorporates isolation flanges for quick and easy servicing of the primary loop pump circulator Offers troubleshooting isolation between the heating system and secondary zones AIR HANDLER The Steffes air handler allows the 5100 series heating system to provide forced air heating or to be interfaced with other ducted heating and or cooling systems such as a heat pump or air co...

Page 9: ... 130 CFM NOTE In applications using the Steffes Air Handler the static heat recovery unit would not be used If the area available to install the Comfort Plus Hydronic system is less than 100 square feet Steffes Corpora tion recommends installing a low voltage cooling thermostat connected between R and G on the 12 position terminal block to maintain a temperature less than 85 degrees Fahrenheit COM...

Page 10: ... to Pages 3 04 3 05 PRESSURE RELIEF VALVE KIT 7 shipped behind the exchanger access panel Refer to Page 3 11 JUNCTION BOX shipped behind the exchanger access panel See Figure 9 Page 3 07 1 INFORMATION PACKAGE includesOwner sManualand WarrantyRegistrationCard adhered to outer side of shipping box shipped inside the brick core Refer to Pages 3 04 3 05 2 MODEL ELEMENTS 5120 8 5130 12 5140 16 HEATING ...

Page 11: ...in an area with less than 400 square feet ventilation MUST be provided If the area available to install the system is less than 100 square feet consult the factory MINIMUM CLEARANCE REQUIREMENTS Back and Right Side 3 inches from combustible material Bottom 1 inch clearance Top 6 inches from combustible material Front 36 inches for ease in servicing Left Side 36 inches for ease in servicing 5100 SE...

Page 12: ...tom of the system as necessary to prevent rocking If not placed properly the system may bend or twist during the brick loading process making element and brick core temperaturesensorinstallationdifficult Step 4 Remove the painted front panel of the brick storage cabinet by removing the sheet metal screws along the top bottom and sides of the panel Detach by pulling the bottom of the panel forward ...

Page 13: ...ce MUST be installed in the front row Risk of fire Can cause personal injury or death DO NOT operate the Comfort Plus Hydronic system if damage to the insulation panels on the inner sides of the brick core occurs WARNING HEATING ELEMENT AND AIR CHANNEL INSTALLATION Step 1 After all brick are loaded insert the heating elements between the brick layers sliding them in until the element ends embed in...

Page 14: ...Hydronic heating system Read and follow installation instruc tions carefully Step 2 Install the front air channel by placing the bottom in first with the air deflec tors arrow shaped pieces facing inward Refer to the Air Channel Placement Figure 6 and the Parts Diagram Page A 02 for proper placement and installation of the front air channel Step 3 Lower the insulation blankets back into position o...

Page 15: ...he Comfort Plus Hydronic breakers Refer to the Line Voltage Wiring Diagrams Pages A 05 A 07 for more information on these connections To ensure proper operation and safety all line voltage circuits must be segre gated from low voltage wiring in the ComfortPlus Hydronic To reduce electro magnetic fields associated with electrical circuits and to avoid induced voltage on sensors and electronic devic...

Page 16: ...ors rated at Wiring Diagram 240 208 Volt 5120 Line Voltage LOW VOLTAGE ELECTRICAL CONNECTIONS PEAK CONTROL Steffes ETS heating equipment may be controlled by the Power Company via a peak control signal This signal can be sent to the equipment using a Steffes Power Line Carrier control system low voltage wiring a Steffes Time Clock Module or linevoltage control In applicationsutilizingautomatic cha...

Page 17: ... feature Refer to the instructions provided with the Time Clock Module for more informa tion on the installation and operation of this device LINE VOLTAGE PEAK CONTROL Line voltage control is also an option but is not the preferred method of control as it is usually more complex and expensive If line voltage control is utilized the controls circuit must be powered with an uninterrupted circuit An ...

Page 18: ...utdoor sensor ONLY This low voltage cable MUST not enter any line voltage enclosure Unshielded Class II thermostat wire can be used as extension wire provided it is segre gated from any line voltage cabling LOW VOLTAGE ELECTRICAL CONNECTIONS ROOM THERMOSTAT A low voltage 24VAC room thermostat is required for room temperature control with the Comfort Plus Hy dronic system Steffes recommends using a...

Page 19: ...c Heat Thermostat Zone Valve End Switch or Pump Control R W AIR CONDITIONER HEAT PUMP INTERFACE The Comfort Plus Hydronic system can be used in conjunction with an air conditioner or a heat pump Refer to the optional Air Handler Page 2 01 and the Low Voltage Connections for Heat Pump Application Diagram Figure 11 for more information on interfacing these systems with the Comfort Plus Hydronic If m...

Page 20: ...his discharge line MUST be connected from the valve outlet with no intervening valve and directed downward to a safe point of discharge allow complete drainage of both the valve and the discharge line be independently supported and securely anchored to avoid applied stress on the valve be as short and straight as possible terminate freely to atmosphere where any discharge is clearly visible and is...

Page 21: ...ommends a Grundfos UP15 42F single speed 115VAC pump for the primary pump Air Handler pump should NOT be a split phase pump Air Handler pump should NOT have any type of auxiliary control built into or onto the pump White Red Primary Loop Secondary Loop Primary Loop Pump Comfort Hydronic Exchanger This Valve Must Be Open During Normal Operation White Red FREEZE PROTECTION Risk of frozen pipes Can c...

Page 22: ...sformer NOTE During off peak charge periods the contact is closed between COM and NC TYPICAL AUXILIARY LOAD CONTROL FIGURE 17 RP Y C R O G Y2 OS H W O2 SC DS Auxiliary Control Relay RELAY Peak Control Internal Output Relay COM AP P NO NC TYPICAL SYSTEM PLUMBING SHOWN WITH STEFFES AIR HANDLER FIGURE 16 It is the responsibility of the installer to prevent involuntary flow of water to the air handler...

Page 23: ...ted to the desired values Step 7 Once configured use the down arrow to leave the Configuration Menu In most applications only a few if any configuration changes will be necessary Following is a description of the configurationsettingsandtheirfunction C000 Off Peak Method of Charge Control Sets the method of brick core charging to be used during off peak charge periods System is configured for auto...

Page 24: ...nimum discharge air temperature the system targets during a Stage 1 heat call C011 and C012 configurations must be set for the hottest temperature zone in the installation C011 is the highest tempera ture the system will target and C012 is the lowest temperature the system will target during a heat call Outdoor reset is done using these two temperatures See graph C011 Maximum Outlet Water Temperat...

Page 25: ...Air Handler and or heat pump operates appropriately Step 6 If utilizing the Air Handler initiate a cooling call from the room thermostat and verify that the Comfort Plus Hydronic system recognizes the COOL call Verify that the Air Handler heat pump and or air conditioner operates appropriately Step 7 Press the up arrow until the targeted brick core charge level is displayed on the control panel Wi...

Page 26: ...40 BTU 426 500 614 160 818 880 System Dimensions W x D x H in inches 29 x 46 5 x 46 29 x 46 5 x 57 29 x 46 5 x 68 Pipe Size Water Inlet Water Outlet 1 Maximum Outlet Water Temperature 250 o F Outlet Water Temperature Selection Range 50 o F 185 o F Maximum Working Pressure PSIG 20 Minimum Flow Rate primary loop 1 GPM per 10 000 BTU of required output at 20 o F temperature rise 10 GPM maximum Approx...

Page 27: ...c Appendix A 02 70 1B 73 22 Brick Side View 17 71 72 69 1A 2 10 3 4 5 6 8 11 12 9 7 18 19 13 16 14 15 30 31 29 28 27 26 25 33 53 52 51 50 49 48 47 45 34 35 32 46 44 43 36 37 38 42 24 23 40 39 54 55 57 60 59 20 21 41 61 64 65 63 62 56 58 66 67 68 ...

Page 28: ...o Element Red 1041701 1041713 1041700 17 Front Air Channel 5940820 5940822 5940824 18 FrontStandoff 5940513 5940513 5940513 19 FrontGalvanized Panel 5940579 5940524 5940578 20 Upper Brick Core Temperature Sensor N A 1041725 1041725 Lower Brick Core Temperature Sensor 1041725 1041725 1041725 21 Core Blower Assembly 1041730 1041730 1041730 22 Pressure Relief Valve 1100104 1100104 1100104 23 Faceplat...

Page 29: ... 250D Manual Reset upper 1041758 1041758 1041758 56 Left Side Exchanger Panel Inner 5940814 5940814 5940814 57 Exchanger Access Tube Cover 5940858 5940858 5940858 58 Exchanger Access Painted Panel 5940880 5940880 5940880 59 Core Blower Capacitor 1018007 1018007 1018007 60 Low Voltage Panel Assembly 1041721 1041721 1041721 61 TerminalBlock6Position 1016041 1016041 1016041 62 Electrical Panel Main B...

Page 30: ...CK CORE L2 240 EXPANSION BOARD 1 COM COM NO RELAY 7 RELAY 8 NO L2 120 RED RELAY 5 RELAY 6 COM COM BLACK BLACK YELLOW CORE LIMIT To Optional Static Heat Recovery System COM 1 4 Amp L1 COM NO COM COM NO NO NO RELAY 2 RELAY 1 RED RELAY 3 RELAY 4 BLUE WHITE BLUE BLACK BLUE RED ORANGE To Optional Air Handler ORANGE DAMPER RESISTER RESISTOR FAN ON RELAY RELAY HEAT CALL Relays To To To 2 4 6 Relays 1 8 R...

Page 31: ...Black White To Air Handler Pump Max 1 2 AMPS ORANGE BLUE BLACK BLUE WHITE BLUE RED RED BLACK To Optional Air Handler WHITE L2 240 RESISTER DAMPER BLOWER RESISTOR COM NO FAN ON RELAY COM NO RELAY HEAT CALL BASE IO BOARD BLACK YELLOW 5 Amp BLUE L1 L2 120 1 4 Amp NO COM NO COM 4uf EXCHANGER LIMITS WHITE MANUAL N C 225 RESET AUTO RESET N C 250 COM Cap BLACK CORE BLOWER HIGH CIRCUIT 3 CHARGE CIRCUIT 4 ...

Page 32: ...5 RELAY 10 NO RELAY 12 COM NO COM NO COM COM RELAY 4 NO NO RED BLACK Relays 1 5 9 13 To To MANUAL Red White To Primary Loop Pump Max 1 2 AMPS Black White To Air Handler Pump Max 1 2 AMPS BLUE BLACK YELLOW EXCHANGER LIMITS 225 N C RESET AUTO RESET 250 N C 4uf HIGH BASE IO BOARD BASE IO BOARD 5 Amp 5 Amp L1 L2 120 1 4 Amp 1 4 Amp WHITE COM COM COM NO NO COM COM NO NO Cap CORE BLOWER BLACK NEUTRAL LU...

Page 33: ...R CORE THERMOCOUPLE YELLOW RED UPPER CORE THERMOCOUPLE RED INTERNAL SYSTEM WIRING DIAGRAM LOW VOLTAGE The outdoor temperature sensor room thermostat and peak control device are connected via low voltage wiring System Low Voltage Wiring Diagram The R and C positions in the low voltage terminal strip may be used as a source of 24 VAC for powering external low voltage devices 60 VA maximum Appendix C...

Page 34: ...k periods C1_x Specialty Timer 1 Charge Mode Specialty Applications Only C2_x Specialty Timer 2 Charge Mode Specialty Applications Only ERROR CODES The Comfort Plus Hydronic system has an on board diagnostic system to monitor various operating conditions If operating conditions move outside the normal operating range an error code is displayed on the faceplate If there are multiple errors simultan...

Page 35: ...ors is shorted to ground the processor control board is out of calibration or the blower control circuit is connected to an improper input voltage 25 Power line carrier system is active however no good data has been received 26 Insufficient main control board memory Contact a qualified service technician 27 Insufficient permanent memory Contact a qualified service technician 28 Permanent memory ch...

Page 36: ...id damaging them Step 7 Carefully rock the brick core Figure B to one side and lift top portion up and off the base Figure C Step 8 Move the Comfort Plus Hydronic heating system into the desired location reassemble and continue withtheinstallationinstructionsinthismanual Appendix Appendix A 11 Comfort Plus Hydronic FIGURE A FIGURE B FIGURE C Plus front saddles and back Z Bracket Limits and Right S...

Page 37: ... L on the faceplate when in the edit mode Location Value The specific information set and stored in a location on the system s microprocessor which defines system operation A value for a spe cific location is accessed through the control panel Manual Charge Control Method of brick core charge regulation where the owner must periodically adjust the brick core temperature setting in relation to the ...

Page 38: ...ceorpart s toSteffesCorporation ThisWarrantyisvoidiftheheatingapplianceismovedfromthepremisesinwhichitwasoriginallyinstalled This Warrantyshallnotapplytoanapplianceorpartwhichhasbeenalteredinanyrespect orimproperlyinstalled serviced orused orhasbeensubjecttoaccident negligence abuseormisuse THEABOVEWARRANTYBYSTEFFESISEXCLUSIVEANDINLIEUOFALLOTHERWARRAN TIES WHETHERWRITTENORORAL EXPRESSEDORIMPLIED I...

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