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Accessories

CONTROL CIRCUIT STEP-DOWN TRANSFORMER (Required)

The internal controls and motors of all ThermElect Hydronic systems operate at 208V or 240V (two wire).  

A transformer must be installed per the manufacturer’s installation instructions to supply this voltage to 

the system’s controls. This transformer can be purchased from Steffes or sourced from a local electrical 

supply company. See the matrix below for proper sizing, load as dictated by the furnace’s set-up. When 

using BACnet control, the furnace can be commanded to varying input levels remotely.

Model

Primary Voltage

Secondary Voltage

KVA

Hevi Duty Item #

Steffes Item #

277/480V

480

240

1

HS1F1BS or equal

1017085

347/600V

600

240

1

HS10F1BS or equal

1017084

LIFTING HANDLES (optional)

Lifting handles (Order Item #1302120) are available to aid in moving the 

ThermElect Hydronic system into its final location.

EXTERNAL DUCT SENSOR (optional)

The external duct sensor (Order Item #1041536) provides the 

ability to monitor the duct temperature at an area beyond 

fresh air makeup and/or beyond other devices and regulate the 

discharge air temperature accordingly.

The duct sensor feature is enabled if the 4 bit is set in Location 

53 (L053). Once enabled, the ThermElect Hydronic system 

monitors temperature at both the duct sensor and the output 

sensor during Y, W, or E calls from the thermostat. 

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AIR HANDLER

9100 SERIES 

THERMELECT

WATER

COIL

 

Page 1 of 1 

Document Name: 1200155 Rev 1 

 

 

07/21/08 

Figure 1A 

Figure 1B 

STEFFES CORPORATION 

LIFTING HANDLE INSTRUCTIONS 

For use with 8100 and 9100 Series ThermElect Systems 

Item #1302120 

 

THIS PROCEDURE MUST BE PERFORMED BY A QUALIFIED TECHNICIAN. 

 

1.  Remove the front and rear painted panels. 

 

2.  Remove screws and wing nuts joining the lifting 

handles together to separate the two pieces. 

 

3.  Insert the top part of the lifting handle into the 

element holes making sure the hook faces up as 

shown in Figure 1A.   

 

 

Install the lifting handles at a height 

suitable for the people lifting the device. 

Make sure to maintain unit balance as 

the unit may be top heavy.   

 

4.  Insert the bottom part of the lifting handle two 

element holes below the top lifting handle section. 

The bottom part of the lifting handle must be 

installed with the hook facing down as 

shown in Figure 1B.  

 

5.  Align the top and bottom parts of the lifting 

handle so the holes match-up. Use the 

screws and wing nuts removed in Step 2 to 

join the two pieces (Figure 2). Hand-tighten 

the wing nuts so they are snug. 

 

6.  Insert the extension bar into the lifting 

handle. The bar can be extended to 

accommodate more people for lifting as 

shown in Figure 3. 

 

7.  Insert stabilizing pins to keep extension bar from moving as shown in Figure 4. 

   

 

 

 

 

 

 

 

 

Figure 2 

 

Figure 3 

 

Figure 4 

 

HEAVY OBJECT 

 

Can cause muscle strain or 

back injury. 

 

Use assistance to lift or move 

this equipment.  

 

Use lifting aids and proper 

lifting techniques when lifting 

or moving this equipment.  

 

Keep all body parts and other 

objects clear of the system 

when lifting or moving.

 

 

WARNING

 

 

LIFTING 

HANDLES

 

Page 1 of 1 

Document Name: 1200155 Rev 1 

 

 

07/21/08 

Figure 1A 

Figure 1B 

STEFFES CORPORATION 

LIFTING HANDLE INSTRUCTIONS 

For use with 8100 and 9100 Series ThermElect Systems 

Item #1302120 

 

THIS PROCEDURE MUST BE PERFORMED BY A QUALIFIED TECHNICIAN. 

 

1.  Remove the front and rear painted panels. 

 

2.  Remove screws and wing nuts joining the lifting 

handles together to separate the two pieces. 

 

3.  Insert the top part of the lifting handle into the 

element holes making sure the hook faces up as 

shown in Figure 1A.   

 

 

Install the lifting handles at a height 

suitable for the people lifting the device. 

Make sure to maintain unit balance as 

the unit may be top heavy.   

 

4.  Insert the bottom part of the lifting handle two 

element holes below the top lifting handle section. 

The bottom part of the lifting handle must be 

installed with the hook facing down as 

shown in Figure 1B.  

 

5.  Align the top and bottom parts of the lifting 

handle so the holes match-up. Use the 

screws and wing nuts removed in Step 2 to 

join the two pieces (Figure 2). Hand-tighten 

the wing nuts so they are snug. 

 

6.  Insert the extension bar into the lifting 

handle. The bar can be extended to 

accommodate more people for lifting as 

shown in Figure 3. 

 

7.  Insert stabilizing pins to keep extension bar from moving as shown in Figure 4. 

   

 

 

 

 

 

 

 

 

Figure 2 

 

Figure 3 

 

Figure 4 

 

HEAVY OBJECT 

 

Can cause muscle strain or 

back injury. 

 

Use assistance to lift or move 

this equipment.  

 

Use lifting aids and proper 

lifting techniques when lifting 

or moving this equipment.  

 

Keep all body parts and other 

objects clear of the system 

when lifting or moving.

 

 

WARNING

 

 

Summary of Contents for ThermElect Hydronic 9150

Page 1: ...OWNER S AND INSTALLER S MANUAL Models 9150 9180 ThermElect Elect Hydronic With Integrated SSR Control Applicable to Software Version 2 18 2 XX...

Page 2: ...ead all instructions prior to attempting to assemble install operate maintain or repair this product Upon unpacking of the system inspect all parts for damage prior to installation and start up This m...

Page 3: ...w describes these safety devices DEVICE NAME FUNCTION LOCATION ON SYSTEM Core Charging High Limit Switches Auto Reset These limit switches monitor the core and top temperatures If normal operating tem...

Page 4: ...04 Brick Loading 3 04 3 05 Heating Element Installation 3 05 3 06 Brick Core Temperature Sensor Installation 3 06 Line Voltage Electrical Connections 3 07 Low Voltage Electrical Connections Outdoor Te...

Page 5: ...another ducted heating system such as a heat pump SYSTEM USE DURING CONSTRUCTION PHASE Like most heating equipment manufacturers Steffes strongly recommends that Construction Heating Units be used ins...

Page 6: ...advanced operating modes updating software and troubleshooting OPERATING STATUS The four digit LED will display various operating information as described below Press and release the up arrow to view...

Page 7: ...t level which is determined by outdoor temperature utility peak conditions building automation system and or the heating requirements Sensors monitor the brick core temperature and communicate this in...

Page 8: ...ndle section The bottom part of the lifting handle must be installed with the hook facing down as shown in Figure 1B 5 Align the top and bottom parts of the lifting handle so the holes match up Use th...

Page 9: ...stem receives a signal from an external load control device such as a building load management system This external signal dictates the maximum amount of energy which can be consumed during a preset t...

Page 10: ...electrical panel HEATING ELEMENTS WITH CERAMIC INSULATORS Model Elements 9150 12 2 boxes of 6 9180 18 3 boxes of 6 shipped separately Installation 3 01 ThermElect Hydronic Installation SHIPPING AND PA...

Page 11: ...pped inside the electrical panel TOP AIR CHANNEL BLOCK shipped separately CERAMIC BRICK Model Brick LBS Pallets 9150 192 3 360 2 9180 288 5 040 3 96 brick per pallet shipped separately OUTDOOR TEMPERA...

Page 12: ...ystem must also be taken into consideration when selecting the installation location A level concrete floor is the designed installation surface however most well supported surfaces are acceptable If...

Page 13: ...2 Remove any and 1 trade size knockouts where the electrical panel mates to the units left side panel These openings may be knockouts or holes 3 Line up the electrical panel to these holes and fasten...

Page 14: ...ottom HEATING ELEMENT INSTALLATION Proper heating element installation is important to operation of the system Reference the Useful Tools section of the Heating Element Service and Repair Guide includ...

Page 15: ...through 1 2 knockout Connect the blue core blower wires to black and the blue wires Connect the two purple violet wires to the two purple wires BRICK CORE TEMPERATURE SENSOR INSTALLATION 1 Remove the...

Page 16: ...ing Diagrams Pages A 07 A 08 for more information on these connections 5 Mount and install step down transformer CONNECTION OF PRIMARY LOOP PUMP A 120 or 240V single phase pump can be used Connect the...

Page 17: ...an be hard wired to the system s OS and SC terminals default or it can be connected to the Power Line Carrier PLC transceiver When using BACnet control for outdoor temperature the outdoor sensor will...

Page 18: ...sure all connections including the valve inlet are clean and free from any foreign material Use pipe compound sparingly or tape on external threads only Mount the pressure relief valve in a vertical u...

Page 19: ...rom the system s heat exchanger The primary loop pump should be powered by ThermElect Hydronic control system as shown in Figure 11 If using other control method flow MUST continue for at least 30 sec...

Page 20: ...and or property It is the responsibility of the installer to provide protection against freezing PIPING SUPPORT Risk of equipment damage or personal injury DO NOT use the exchanger as support for pip...

Page 21: ...requires 30 PSI Pressure Relief Valve 60 PSIG requires 75 PSI Pressure Relief Valve Standard 125 PSIG requires 150 PSI Pressure Relief Valve Minimum Flow Rate Primary Loop 1 GPM per 10 000 BTU of req...

Page 22: ...PSI Pressure Relief Valve 60 PSIG requires 75 PSI Pressure Relief Valve Standard 125 PSIG requires 150 PSI Pressure Relief Valve Minimum Flow Rate Primary Loop 1 GPM per 10 000 BTU of required output...

Page 23: ...ThermElect Hydronic Appendix A 03 EXPLODED VIEW DIAGRAM 53 kW STORAGE MODULE The exploded view diagram is for reference only The ThermElect Hydronic storage module should not be disassembled...

Page 24: ...EXPLODED VIEW DIAGRAM 80 kW STORAGE MODULE The exploded view diagram is for reference only The ThermElect Hydronic storage module should not be disassembled Appendix A 04 ThermElect Hydronic...

Page 25: ...ock Kit Front 2009 and Older 1040220 1040219 11 Brick Each 96 Brick per Pallet 5903017 5903017 12 Cast Block Bottom 1056501 1056501 13 Limit Switch EGO 575Deg 1013026 1013026 14 Insulation Blanket 2 4...

Page 26: ...12 Inlet Pipe Cover 5948526 DWG Ref Description Item 13 Outlet Pipe Cover Left Half 5948525 14 Outlet Pipe Cover Right Half 5948527 15 Left Side Exchanger Panel 5948524 16 Base Panel Rear Painted 594...

Page 27: ...ThermElect Hydronic Appendix A 07 TYPICAL SYSTEM LINE VOLTAGE WIRING DIAGRAM NOTE Use copper or aluminum conductors rated for 75o C or higher for field connection of this device...

Page 28: ...ing 9180 Shown NOTE 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 WARNING HAZARDOUS VOLTAGE Risk of...

Page 29: ...il the targeted brick core charge level is displayed Using the charge control override or the building management system initiate a full charge Once initiated the heating system will target 100 percen...

Page 30: ...s C1_x Specialty Timer 1 Charge Mode Specialty Applications Only C2_x Specialty Timer 2 Charge Mode Specialty Applications Only HUxx Heat Usage Indicates the amount of input being dissipated by the sy...

Page 31: ...verify proper calibration of the circuit board Approximate ohm readings are 60 F 1552 ohms 70 F 1199 ohms 80 F 941 ohms Max 190 F Min 0 09 Auxiliary analog input is out of normal operating range Curre...

Page 32: ...r the Energy Management Controller may be unresponsive Check the jumper configuration on the Energy Management Controller and make sure J1 is ON and J2 is OFF Verify that the value in L053 is correct...

Page 33: ...n received for 30 minutes If the MA command or Pulse Width Modulation are not being used verify that Location 53 L053 and or Location 55 L055 are set correctly for the application 47 The Relay Driver...

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Page 36: ...F THIS DOCUMENT STEFFES SHALL NOT BE LIABLE FOR ANY LOSSES CLAIMS DAMAGES OR LIABILITY RELATING TO LOST PROFITS OR OTHER CONSEQUENTIAL INCIDENTAL EXEMPLARY PUNITIVE OR INDIRECT DAMAGES IN CONNECTION W...

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