Steffes 5120 User manual
Models:
5120, 5130,
& 5140
Applicable to Software Version 2.00 - 2.19
OWNER'S AND
INSTALLER'S MANUAL
for
Comfort Plus
Hydronic Heating Systems
Equipped with Variable Speed
for Optional Air Handler
• The equipment described herein is intended for installation by a qualied technician
in compliance with applicable local, state, and national codes and requirements.
• To ensure proper installation and operation of this product, completely read 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 manual should be retained by the owner upon completion of the installation
and made available to service personnel as required.
• This appliance is not to be used by persons (including children) with reduced
physical, sensory or mental capabilities or lack of experience and knowledge,
unless they have been given supervision and instruction on the safe use of the
appliance and the hazards involved. Children shall not play with the appliance.
• Disclaimer: In compiling this manual, Stees 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, Stees disclaims any responsibility or
liability for mold/mildew growth and/or any damages caused by either. We strongly
recommend that the user follow the moisture, mold and mildew prevention
guidelines of the Environmental Protection Agency (EPA), available at http://www.
epa.gov.
For Customer Use
Please record your model and serial number below. This number is found on the identication label
located on the lower left side of the Comfort Plus Hydronic heating system. Retain this information for
future reference.
Model No. ________________________________________________________________________
Serial No. ________________________________________________________________________
RECOGNIZE THESE SYMBOLS AS SAFETY PRECAUTIONS
It is important, both for your personal safety and to avoid possible damage to the
equipment and your property, that you observe the safety instructions given following
these symbols.
IMPORTANT
SAFETY PRECAUTIONS
1. Install all ceramic heat storage brick before
energizing the system. Failure to do so may result
in equipment damage.
2. Install the pressure relief valve provided before
operating this heating system.
3. Keep combustible materials away from this
near this heating system can result in an explosion
4. Follow all placement and clearance requirements
5. Make sure nothing is placed or stored on top of
this system.
6. Disconnect power to all circuits before servicing
as this heating system may be connected to more
than one branch circuit.
7. Use caution when working around the heating
system as inlet and outlet piping can be very hot.
information contained herein and with national, state, and local codes and requirements.
SAFETY DEVICES
The chart below describes these safety devices:
DEVICE NAME FUNCTION LOCATION
ON SYSTEM
Limit Switches
These limit switches monitor brick core charging and
interrupt power to the heating elements if the normal oper-
ating temperature is exceeded.
In the limit zone on
the left side of the
brick storage cavity.
Limit Switch
This linear limit switch monitors the temperature of the
water in the exchanger and interrupts power to the core
oF/121oC is exceeded.
-
nician.
Inside base on left
side.
Outlet Water
Temperature Limit
This linear limit switch monitors the temperature of the
water in the exchanger and interrupts power to the core
blower if a water temperature of 225ooC is exceeded.
Inside base on left
side.
achieved, the valve closes.
Factory provided,
outlet port of furnace.
Comfort Plus Hydronic Safety Information
WARNING
Risk of explosion. Can cause injury or
death. Operating the system without the
pressure relief valve installed can cause
an explosion. Connect the pressure relief
valve in a vertical, upright position with
the supplied ttings. DO NOT modify this
assembly. DO NOT cap, plug, or otherwise
obstruct the outlet of the pressure relief
valve.
Risk of re. Can cause injury or death.
Violation of the clearance requirements can
cause improper operation of the equipment.
Maintain the placement and clearance
requirements specied.
Risk of personal injury. Plumbing and other
surfaces can be hot. Use caution when
working near the system.
Operation
General Operation .................................................................................................................................................................
................................................................................................................................
System Start-up......................................................................................................................................................................
Turning System "OFF" and "ON"..........................................................................................................................................
.........................................................................................................................................................................
Operating Status.....................................................................................................................................................................
Room Temperature Control ...................................................................................................................................................
Brick Core Charge Control ....................................................................................................................................................
Charge Control Override........................................................................................................................................................
Maintenance and Cleaning.....................................................................................................................................................
Optional Accessories
Single Electrical Feed Kit ......................................................................................................................................................
...................................................................................................................................................................
.....................................................................................................................................................
................................................................................................................................................................
............................................................................................................................................................................
Installation
S.........................................................................................................................................................
lacement and Clearance Requirements................................................................................................................................
Initial Set-up...........................................................................................................................................................................
Brick Loading ................................................................................................................................................................
......................................................................................................................
Brick Core Temperature Sensor Installation..........................................................................................................................
..............................................................................................................................
...........................................................................................................................................................
Outdoor Temperature Sensor ..........................................................................................................................................
Room Thermostat ...................................................................................................................................................
.......................................................................................................................................... 3.11
........................................................................................................................................................................3.11-3.13
Auxiliary Load Control..........................................................................................................................................................3.13
.......................................................................................................................................................3.14-3.15
....................................................................................................................................3.16
Appendix
........................................................................................................................................................................
........................................................................................................................................................................
......................................................................................................................................................................................
........................................................................................................
.........................................................................................................
............................................................................................................................................................................
Error Codes ..................................................................................................................................................................
.............................................................................................................. A.12
Glossary ................................................................................................................................................................................ A.13
Warranty
Table of Contents Comfort Plus Hydronic
Table of Contents
TC
Comfort Plus Hydronic Operation 1.01
GENERAL OPERATION
electricity is available during times of the day or night when electricity is plentiful and the power company may
supply it at a lower cost.
available, the system converts electricity to heat which is then stored in its ceramic
brick core. The amount of heat stored in the brick core varies in relation to outdoor
temperature, owner preference, utility peak conditions, and the requirements of the
space being heated.
A heat call from the room thermostat energizes the primary water loop pump. The
variable speed core blower automatically adjusts its speed to achieve the desired outlet
heat call originated.
as a supplement to ducted heating systems such as heat pumps.
SYSTEM USE DURING CONSTRUCTION PHASE
used instead of the permanent heating system during the construction phase of a new home. Use of the permanent
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 should be used during the construction phase.
SYSTEM START-UP
may be experienced. Allow the system to charge to its maximum brick core charge level, on start-up, to expel these
system. Upon restart, there may also be an odor as these dust particles are expelled.
During operation, the system may produce minor expansion noises. These noises are the result of the internal
components reacting to the temperature changes.
TURNING SYSTEM "OFF" AND "ON"
breakers located on the front of the electrical panel to the DOWN position. To turn the element circuits “ON”,
NOTE: The 60 AMP breakers MUST all be turned "ON" or all turned "OFF". The 15 AMP breaker
MUST remain “ON” to operate controls in the system if:
• using the Comfort Plus Hydronic in conjunction with a heat pump or air conditioner.
• using the Comfort Plus Hydronic to control other loads.
• using the optional Stees Time Clock Module.
• using the Comfort Plus Hydronic to exercise the pumps during periods of inactivity.
Operation
1
CONTROL PANEL
installation and no further changes are required.
Four-Digit LED Display
displayed for viewing and adjusting purposes.
AM and PM Indicator Lights
being installed and using 12 hour time display. With this module installed, the system
Mode (Edit) Button
Up and Down Arrow Buttons
Used to scroll up or down when viewing or modifying.
operating functions.
Interface Port
Allows technician external access for advanced operating modes, updating software, and troubleshooting.
Operation 1.02 Comfort Plus Hydronic
OPERATING STATUS
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.
Heat Call Status - indicates the current heat call status as determined by the room
Targeted Brick Core Charge Level
indicates a target level of zero percent and “tL: F” indicates a full core charge target level.
Brick Core Charge Level
represents a full core charge level.
NOTE: A bar illuminates on the lower portion of the display's third digit whenever the
heating elements are energized.
M
CONTROL PANEL
MM
M
MM
AA
Editing operating information
may alter the performance and
operation of the system.
IMPORTANT
Comfort Plus Hydronic Operation 1.03
ROOM TEMPERATURE CONTROL
water loop pump. The variable speed core blower automatically adjusts its speed to achieve the desired outlet water
BRICK CORE CHARGE CONTROL
relation to outdoor temperaure and the heating requirements. The outdoor sensor, supplied with the system,
monitors outdoor temperature. As the outdoor temperature decreases, heating requirements increase, and the
CHARGE CONTROL OVERRIDE
target a full core charge level. This override can be initiated or cancelled at any time. If an override is initiated,
Initiating the Override Feature
Step 1 M, the up arrow, and the down arrow buttons at the same time.
Step 2
continuously on the faceplate.
Step 3 Release the buttons. The override is now enabled. The faceplate will return to displaying its standard
operating mode.
Manual Cancellation of the Override Feature
Step 1 M, the up arrow, and the down arrow buttons at the same time.
Step 2
continuously on the faceplate.
Step 3 Release the buttons. The override is now cancelled. The faceplate will return to displaying its standard
operating mode.
MAINTENANCE AND CLEANING
General cleaning of the system's cabinet should be conducted at the user's discretion. It is important to monitor
installer of the equipment for information on how to measure these levels.
Optional Accessories
2
Optional Accessories 2.01 Comfort Plus Hydronic
SINGLE ELECTRICAL FEED KIT
blowers/control circuits is desired, the single feed kit is available to allow the system to
be powered with one, larger line voltage circuit. Contact the factory for ordering details.
NOTE: When using single feed, the neutral conductor MUST be sized in accordance
with all applicable local, state, and national codes and regulations.
PRIMARY LOOP KIT
primary loop kit. The kit contains the components generally installed with hydronic heat systems.
Features:
with automatic purge during system operation and draining.
STATIC HEAT RECOVERY UNIT
NOTE: In applications using the Stees Air Handler, the static heat recovery unit would not be used.
its outer panels. If the system is located in an area with minimal heating requirements, such as a utility room, the
location.
Features:
internal controls of the system for automatic operation.
• Wattage
• Motor
•
•
•
connected between R and G on the low voltage terminal block, to maintain a mechanical room temperature less
than 85oF/29oC.
7.875
3.312
Manual Reset
Limit Switch
Order Item #1302110
Order Item #1302115
COMFORT PLUS STAND
Comfort Plus Hydronic Optional Accessories 2.02
Order Item #1302122
Attached to Brick
Cavity
Attached to Complete
Assembled System
Order Item #1301585
Stand
AIR HANDLER
variable speed blower incorporates an ECM motor that
automatically adjusts its speed to achieve the appropriate
• Quiet operation
•
•
energy during normal operating mode
• In continuous fan mode, low speed energy savings
motor speed
• Interfaces with single or multi-speed air
conditioners or heat pumps. With multi-speed
systems, it operates at a lower speed while higher
speeds may occur on extremely hot or cold days.
• Staged heating and cooling eliminates temperature
swings, enhances comfort and optimizes
•
•
closed.
23 1/2” (1/2 HP)
26 1/2” (3/4 HP)
72 11/16” (1/2 HP)
75 11/16” (3/4 HP)
21 15/16” (1/2 HP)
24 15/16” (3/4 HP)
23 7/8”
16 5/8”
Supply Air Opening
Supply Air Blower
Water Coil
Heating/Cooling A-Coil Tray -
Front Access
1/2 HP: 30” x 22 5/16” x 22 3/4”
3/4 HP: 33 x 25 5/16” x 22 3/4”
Filter Access
1/2 HP: Fits 20” x 20” x 2” Filter
3/4 HP: Fits 25” x 20” x 2” Filter
Return Air Plenum
(opening into right side,
back or bottom panel
must be cut in the eld)
AIR HANDLER SPECIFICATIONS 1/2 HP, 60 HZ 3/4 HP, 60 HZ
Order Item Number 1302132 1302134
Approximate Weight 200 lbs 225 lbs
Maximum Static Pressure (inches water column) .75 inches H20 .75 inches H20
Maximum Water Coil Output 60,000 BTU/hr 90,000 BTU/hr
Maximum Outlet Temperature 120oF/49oC 120oF/49oC
A-Coil Tray Dimensions (H x W x D) 30” x 22 5/16” x 22 3/4” 33” x 25 5/16”x 22 3/4”
Voltage 240/208 VAC 240/208 VAC
Wattage 560W 1,050W
CFM ratings 1000, 1200, 1400, 1600 1200, 1400, 1600, 2000
1/2 HP variable speed accommodates most 1.5 to 4 ton heating/cooling systems. 3/4 HP variable speed accommodates most 3 to 5 ton heating/cooling systems
LIFTING HANDLES
To make it easier for installers to handle and move the
-
age module. The handles allow 2 to 4 people to more easily
lift the furnace and move it to its installation site.
SHIPPING AND PACKAGING
components and insulation materials. The information below describes the items shipped with each system:
Installation
3
CAUTION Risk of sharp edges. Can cause personal injury. Use caution
when installing and/or servicing equipment.
Installation 3.01 Comfort Plus Hydronic
(adhered to outer side of shipping box)
1INFORMATION PACKAGE
(includes Owner's Manual, Quick Reference
Guide, and Warranty Registration Card)
MODEL ELEMENTS
(shipped in box above
electrical compartment)
2HEATING ELEMENTS
3ELEMENT SCREW KIT AND
LOW VOLTAGE BUSHING
(shipped inside the electrical compartment) (shipped inside the electrical
compartment)
OUTDOOR
TEMPERATURE SENSOR
45JUNCTION BOX
(shipped behind the
exchanger access panel)
CERAMIC BRICK
6
Full Brick
(shipped separately
and packaged 2 brick
per package)
Half Brick
(shipped with brick and
packaged in a white box
consisting of 6 half brick
and 1 full brick)
Model Full Brick Half Brick
(shipped behind the exchanger access panel)
PRESSURE RELIEF VALVE KIT
7
PLACEMENT AND CLEARANCE REQUIREMENTS
consideration when choosing its location within a structure. The
best installation location for this system is in a space requiring
through static dissipation from the warm outer panels of the sys-
tem. Standby heat dissipation of up to 2.5kW can be experienced
in normal operation. Room air should be maintained at less than
85°F/29°C.
heat coming from the system is undesired or where room tempera-
tures may reach 85°F/29°C or greater, it is strongly recommended
In addition to the physical space requirements, the weight of the
-
ity, consult a building contractor or architect.
NOTE: Special requirements need to be considered if placing the system in a garage or other area where
combustible vapors may be present. Consult local, state, and national codes and regulations to ensure
proper installation. An 18" stand (Order Item #1301585) is available to elevate the system.
REQUIRED CLEARANCES
FIGURE 2
Comfort Plus Hydronic Installation 3.02
WARNING
Risk of re. Can cause injury or death.
Violation of the clearance require-
ments or failure to provide proper
ventilation can cause improper
operation of the system. Main-
tain the placement and clearance
requirements as specied and
provide ventilation as necessary.
Moving the system after install
may result in equipment damage.
Do NOT move system from origi-
nal installed location.
MINIMUM CLEARANCE REQUIREMENTS
DIMENSIONS
FIGURE 1
NOTE: Minimum clearance requirements do NOT account for space needed for making electrical connections.
If utilizing the Air Handler, additional space is required on the right hand side of the system.
Outlet
Inlet
5140
68
58
"
5130
57
58
"
5120
46
58
"
29 3
16"
47 5
16"
3 " R E QU I RE D
CL E ARAN CE
36 " RE QU I RE D CL EARAN CE
6" RE QU I RE D CL E ARAN CE
36" REQUI RED
CL E ARAN CE
3 " R E QU I RE D
CL E ARAN CE
M
M
A
36" REQUI RED
CL E ARAN CE
ELE CT RI C T H ER M AL ST ORAGE
TEFFES
S
M
TEFFESS
3 " R E QU I RE D
CL E ARAN CE
1 " R E QU I RE D
CL E ARAN CE
INITIAL SET-UP
Step 1
heating system.
Step 2 Move the heating system into its installation location.
it is necessary to disassemble the system, refer to the
Step 3 Once in place, adjust the leveling legs on the bottom
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
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 and down.
Step 5
disconnect them from their shipping position. Carefully position them to avoid damage during brick
loading.
Note: Models 5130 and 5140 have two brick core temperature sensors.
Step 6 Remove the galvanized front panel and set it aside.
Step 7 Carefully lift the two insulation blankets, one at a time starting at the bottom, and drape them over the
top of the system.
Note: Use face mask, gloves, and long sleeved garments when handling insulation materials in
compliance with generally accepted safety practices.
Step 8 Remove the front air channel by pulling out at the top.
Step 9 Remove the heating elements from inside the brick core cavity.
BRICK LOADING
Load the brick, one row at a time, using a left side, right side, center
pattern. Start at the back of the brick core and work forward. Make sure
the brick are placed so the grooved side is facing up and the ridges are on
BRICK INSTALLATION TIPS:
•Install bricks carefully to avoid damage to the insulation panels.
•Remove loose brick debris to prevent uneven stacking of brick, as
•Brick rows MUST line up front to back and side to side.
•
stacks. Use
and positions as indicated in Figure 5.
•
brick row. See Figures 3 and 4.
•
have the indicator facing forward as shown in Figure 3.
•The bricks in even numbered rows will have the indicator
facing back. See Figure 4.
Installation 3.03 Comfort Plus Hydronic
Risk of re. Can cause personal
injury or death. DO NOT operate
the system if damage to the insu-
lation panels on the inner sides
of the brick core occurs.
WARNING
FIGURE 3
i.e.: Rows 1, 3, 5, 7, 9, and 11 in 5
Front
Indicator
To ensure proper operation, read and
follow installation instructions carefully.
DO NOT install the Comfort Plus
Hydronic system on its shipping
pallet.
DO NOT extend the leveling legs
more than one inch.
DO use and follow generally
accepted safety practices when
handling insulation material.
DO have equipment installed by a
qualied technician in compliance
with all applicable codes and
regulations.
IMPORTANT
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 into the side cutouts of the brick cavity.
Elements MUST be installed with the threaded screw
tabs on the wire connection terminals pointing forward
and down to ease the installation of the element-to-wiring
Step 2 Install the front air channel by placing the bottom in
installation of the front air channel.
Step 3 Lower the insulation blankets back into position, one at a
time. Carefully tuck the sides of this insulation into the edges, corners, and around the exposed portions of
Step 4 Reinstall the galvanized
front panel by sliding
the bottom of the panel
inside the lower lip of
the brick cavity and
resting the top of the
panel on the outside of
the brick cavity. Secure
the screws that were
originally removed.
Step 5 Remove the painted
front panel of the
electrical compartment
by removing the screws
along the edges. Locate the installation hardware package that is shipped in this compartment.
Step 6 Carefully route the element wiring harnesses and connect them to the heating elements, using the screws
provided in the hardware package. Connections should be made with the screw heads up and the threads
Comfort Plus Hydronic Installation 3.04
HAZARDOUS VOLTAGE: Risk of elec-
tric shock. Can cause injury or death.
DO NOT remove the electrical panel
cover while system is energized.
Position elements properly to avoid
short circuiting them against metal
surfaces.
Protect element lead wires from
front panel screws and any eld in-
stalled screws to avoid short circuit.
WARNING
FIGURE 4 FIGURE 5
i.e.: Rows 2, 4, 6, 8, and 12 in 5
Front
Indicator
5120 - Load in Row 5
5130 - Load in Row 4 and 8
5140 - Load in Row 6 and 12
Half Brick
Forward Facing Indicator
Rear Facing Indicator
Half Brick
Indicator in Brick
3
4"
Required Clearance Between
Element Termination and Metal
Panels is 1/2" (3/4" Nominal)
Element Connection
ELEMENT INSTALLATION
FIGURE 6
TOP VIEW
AIR CHANNEL PLACEMENT
FIGURE 7
Electrical
Panel
Front Air
Channel
BRICK
CORE
SIDE VIEW
Outlet
Inlet
BRICK CORE TEMPERATURE SENSOR INSTALLATION
Step 1
NOTE: Models 5130 and 5140 have an upper and a lower
brick core temperature sensor.
Step 2
in the galvanized front panel. If installing a system with two
sensors, be sure the one marked as the upper sensor is installed
in the upper position and the one marked as the lower sensor is
Step 3
Step 4 Check the non-insulated element terminations to make sure they do not come within 1/2" of any surface
area on the system.
Step 5 Re-install the painted front panel, using the previously removed screws.
LINE VOLTAGE ELECTRICAL CONNECTIONS
however, the element circuits can also be
is required, contact the factory. The controls
circuit i MUST
the factory for programming information.
15 amp breaker feeds the controls, blowers,
connected to multiple line voltage circuits. If
a single feed line voltage circuit is desired, an
optional single feed kit is available from the
factory.
Step 1
Step 2
HAZARDOUS VOLTAGE: Risk of electric shock. Can
cause injury or death.
• DO NOT energize the system until installation is
complete.
• DO NOT operate the Comfort Plus Hydronic
heating system without the factory supplied
junction box in place. Connections to the primary
loop pump MUST be made inside the junction
box. If installing the optional air handler, the air
handler pump connections MUST also be made in
the junction box.
• Equipment must be installed by a qualied
technician in compliance with all applicable local,
state, and national codes and regulations.
WARNING
Installation 3.05 Comfort Plus Hydronic
CAUTION
Risk of improper operation.
Proper installation of the brick
core temperature sensor(s)
is critical to the operation of
the Comfort Plus Hydronic
heating system. Read and follow
installation instructions carefully.
Comfort Plus Hydronic Installation 3.06
SAMPLE SYSTEM IDENTIFICATION LABEL
FIGURE 8
JUNCTION BOX INSTALLATION
Step 1
Step 2 Make connections to the primary loop pump and air handler pump inside this junction box. The red and
white wires connect to the primary loop pump and the black and white wires connect to the air handler
Step 3 Attach the junction box cover using the screws provided.
NOTE: If utilizing the optional air handler, the orange wire can be used with the white wire to power a
secondary pump for hydronic zones.
CIRCUIT PHASING CONNECTIONS
FIGURE 9
NOTE: The controls
circuit MUST
include a
neutral wire.
To ensure proper operation and safety, all line voltage circuits must be segregated from low voltage
wiring in the Comfort Plus Hydronic.
To reduce electro magnetic elds associated with electrical circuits and to avoid induced voltage on
sensors and electronic devices, the circuit phases MUST be alternated as shown in Figure 9.
IMPORTANT
Comfort Plus Hydronic
Circuit Breakers
LINE 2
LINE 1
LINE 2
LINE 1
CHARGE CIRCUIT #3
CHARGE CIRCUIT #2
CHARGE CIRCUIT #1
CONTROLS CIRCUIT
CHARGE CIRCUIT #4
(MODEL 5130 and 5140 ONLY)
LINE 2
LINE 1
LINE 1
LINE 2
LINE 1
LINE 2
To Service (Breaker) Panel
NEUTRAL CONNECTION FOR CONTROL CIRCUIT
THIS MUST BE A 120/240V OR 120V/208V CIRCUIT
NEUTRAL
LUG
LINE VOLTAGE WIRING DIAGRAM
FIGURE 10
5120 Line Voltage
Wiring Diagram 240/208 Volt
Use copper or aluminum conductors rated at
LOW VOLTAGE ELECTRICAL CONNECTIONS - PEAK CONTROL
line voltage control. In applications utilizing automatic charge control, outdoor
temperature information is required and can be received via an outdoor sensor or
power line carrier control system.
LOW VOLTAGE (HARD WIRED) PEAK CONTROL
If using the low voltage peak control option, the Comfort
control switch. Field connections from the peak control
switch are made to the low voltage terminal block through
a low voltage knockout located on the left side of the
electrical panel.
Step 1 Route a low voltage circuit from the power
to the low voltage terminal block inside the
wire knockouts. A black plastic bushing is
provided.
Step 2
NOTE: To use Comfort Plus to control other loads, refer
to Auxiliary Load Control (Page 3.13).
POWER LINE CARRIER (PLC) PEAK CONTROL
-
dronic system through the existing electrical circuits in the structure. With the power line carrier option, hard wired
low voltage connections from the power company's peak signaling switch connect directly to the transmitting de-
In addition to providing peak control signals, the transmitter also provides outdoor temperature information for
manual will accompany the transmitting device. Refer to this manual for information on the installation and opera-
tion of the power line carrier control system.
TIME CLOCK MODULE PEAK CONTROL
-
clock feature. Refer to the instructions provided with the Time Clock Module for more information on the installa-
tion and operation of this device.
Low Voltage Terminal Block Coding
Installation 3.07 Comfort Plus Hydronic
Low voltage wires
MUST never enter any
line voltage enclosure.
IMPORTANT
PEAK CONTROL TERMINAL CONNECTIONS
FIGURE 11
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 external switching device, such as a relay panel, is necessary to directly control the heating element charging
circuits. If relying on this method of control, the faceplate on the system MUST continuously display a brick core
-
LOW VOLTAGE ELECTRICAL CONNECTIONS - OUTDOOR
TEMPERATURE SENSOR (REQUIRED)
Installation Methods: A)
OR
B)
Theory of Operation: The outdoor sensor monitors outdoor
temperature and provides this infor-
mation to the system. The system responds by automatically storing heat in its brick core
according to outdoor temperature and the heating requirements.
Location of: The outdoor sensor must be placed in a location where it can accurately sense outdoor temperature
Wiring: • Route low voltage wire from the outdoor sen-
sor to the electrical compartment through one
of the low voltage wire knockouts.
• Connect to "Outdoor" terminals as shown in
Figures 13-14.
• If the sensor wiring is routed through an exter-
nal wall, the opening through which the wire
-
ture sensor.
•
• No other loads can be controlled or supplied through this cable. It is for connection of the
outdoor sensor ONLY.
• This low voltage cable MUST not enter any line voltage enclosure.
•
from any line voltage cabling.
IMPORTANT
If connecting to the Stees power line
carrier (PLC) system, follow the instal-
lation instructions in the PLC system's
Owner's and Installer's Guide.
Comfort Plus Hydronic Installation 3.08
IMPORTANT
Outdoor sensor wire MUST NEVER be
combined with other control wiring in a
multi-conductor cable.
LOW VOLTAGE ELECTRICAL CONNECTIONS - ROOM
THERMOSTAT
Installation 3.09 Comfort Plus Hydronic
LOW VOLTAGE CONNECTIONS
HYDRONIC HEATING SINGLE ZONE SYSTEM
FIGURE 12
STANDALONE FURNACEAPPLICATION CONNECTIONS SHOWN FOR SINGLE STAGE HEATING
/ SINGLE STAGE COOLING (UNCONTROLLED AIR CONDITIONING)
FIGURE 13
* If multiple inputs are active, system will display
highest Heat Call values. "COOL" overrides all
inputs and stops all heating operations.
** Thermostat must be programmed to energize
reversing valve for cooling. If outdoor unit used re-
quires the reversing valve be energized for heating,
see Conguration Menu on pages 3.14-3.15.
Inputs
Peak
P7
LV Circuit Board
Comfort Plus
To Control Board
P10
Fid 2
RLY1
D4
D6
R2
R1
P11 D3D7D5
W E
Y1 Y2
Water
Air
P6
D1
P5
Blower
J3
J1
J2
J4
D2
To Control Board
P3
C
Blower
Speed
A
B
J5
J6
C3
D
P4 P2 P1
O
W/
Y1
AUX Y2 G
Outdoor
Outdoor
Y2
R
H/E
2
Y1
C
O
2 2
RP P
R C
P8 P9
Aux.
COM
NC
AP
NO
Relay
Hydronic Heat Thermostat, Zone
Valve End Switch, or Pump Control
Single Stage Heat / Single Stage Cool **
Thermostat
Stage
Thermostat
Output
Heat Call Status
on Digital Display*
Discharge Air
Temperature Target
Hydronic
Varies
HC3
N/A
1
W
HC2
L049
Fan Only
G
HCF
N/A
Cool
Y/G
COOL
N/A
Contractor Use Only
B
C
C3
J5
J6
Blower
Speed P4 P3
AUX Y2 GY1 O22 Y2
Y1
R
Air
LV Circuit Board
Comfort Plus
To Control Board
Fid 2 D4
Blower To Control Board
O
D3
R2
R1
D7D5
P11
W E
Y1 Y2
Water
J4
D1
J1
J2
J3
P10
D2
D
A
W/
NO
NC
COM
Outdoor
Outdoor
CR
H/E
The Y1/Y2 Jumper must be installed.
RLY1 D6
C
RP
2APP
Aux.
Relay
Peak
Inputs
G
TH5110D R
C
W
Y
Honeywell Rc
(If being used in the application)
Air Conditioner Connections
C
Y
The W/E Jumper must be removed.
P1
P2
A
B
C
D
W / E
Y1 / Y2
J1
J2
J3
J4
J5
J6
Blower
Speed
IMPORTANT
Comfort Plus Hydronic Installation 3.10
TWO STAGE HEAT PUMP APPLICATION
FIGURE 15
* If multiple inputs are active, system will
display highest Heat Call values. "COOL"
overrides all inputs and stops all heating
operations.
** Systems built before 1/1/2011 are con-
gured for 50% airow in Stage 1. For
more information, refer to Instruction
#1200601-High Speed Stage 1 Relay
Installation.
*** Thermostat must be programmed to
energize reversing valve for cooling. If
outdoor unit used requires the reversing
valve be energized for heating, see Con-
guration Menu on pages 3.14-3.15.
SINGLE STAGE HEAT PUMP APPLICATION
FIGURE 14
* If multiple inputs are active, system will
display highest Heat Call values. "COOL"
overrides all inputs and stops all heating
operations.
** Thermostat must be programmed to energize
reversing valve for cooling. If outdoor unit
used requires the reversing valve be ener-
gized for heating, see Conguration Menu on
pages 3.14-3.15.
The W/E Jumper must be removed
The Y1/Y2 Jumper must be removed Inputs
Peak
P7
LV Circuit Board
Comfort Plus
To Control Board
P10
Fid 2
RLY1
D4
D6
R2
R1
P11 D3D7D5
W E
Y1 Y2
Water
Air
P6
D1
P5
Blower
J3
J1
J2
J4
D2
To Control Board
P3
C
Blower
Speed
A
B
J5
J6
C3
D
P4 P2 P1
O
W/
Y1
AUX Y2 G
Outdoor
Outdoor
Y2
R
H/E
2
Y1
C
O
2 2
RP P
R C
P8 P9
Aux.
COM
NC
AP
NO
Relay
Honeywell TH5320D
Aux
LY2 G CO/B
Hydronic Heat Thermostat, Zone
Valve End Switch, or Pump Control
RY R c
C - Low Voltage Common
Outdoor Sensor
O - Reversing Valve
R - Low Voltage Hot
To Heat Pump
Y1 - Compressor
Y2 - Compressor Stage 2
W - Not Used
IMPORTANT
A
B
C
D
W / E
Y1 / Y2
J1
J2
J3
J4
J5
J6
Blower
Speed
H/E
R C
Outdoor
Outdoor
COM
NC
NO
W/
D6
RLY1
To Control Board
D4
Fid 2
Blower To Control Board
Air
C3
P10
R1
R2
P11 D5 D7 D3
Water
Y1 Y2
W E
D2
J3
J2
J1
P5
D1
J4
P6
P4
Speed
Blower
J6
J5
C
B
A
D
P2P3
Y1
AUX OGY2 Y1 2
Y2
2 2 O
CR
Comfort Plus
LV Circuit Board
P7
W - Not Used
APPRP
Peak Aux.
Inputs Relay
The Y1/Y2 Jumper must be installed
Honeywell TH5220D
Aux
EL CG O/B RY Rc
Hydronic Heat Thermostat, Zone
Valve End Switch, or Pump Control
C - Low Voltage Common
R - Low Voltage Hot
O - Reversing Valve
Y - Compressor
To Heat Pump
Outdoor Sensor
The W/E Jumper must be removed
P9
P1
P8
IMPORTANT
A
B
C
D
W / E
Y1 / Y2
J1
J2
J3
J4
J5
J6
Blower
Speed
Single Stage Heat Pump with Auxiliary Heat / Single Stage Cool **
Thermostat
Stage
Thermostat
Output
Heat
Pump
Stage
ECM Board
Output to
Heat Pump*
% of
Selected
CFM
Heat Call
Status on
Digital Display*
Discharge Air
Temperature
Target
1 Y/G 1 R/Y12 100% HC1 L048/C010
Aux Aux/Y/G 1 R/Y12 100% HC2 L049
Fan
G
0
R
400 cfm
HCF
N/A
Cool Y/G/O 1 R/Y12/O2 100% COOL N/A
Hydronic
Varies
N/A
N/A
OFF
HC3
N/A
Contractor Use Only
Two Stage Heat Pump with Auxiliary Heat / Two Stage Cool ***
Thermostat
Stage
Thermostat
Output
Heat
Pump
Stage
ECM Board
Output to Heat
Pump*
% of Selected
CFM
Heat Call
Status on
Digital Display*
Discharge Air
Temperature
Target
1 Y/G 1 R/Y12 50% or 70%** HC1 L048/C010
2 Y/Y2/G 2 R/Y12/Y22 100% HC1 L048/C010
3 Aux/Y/Y2/G 2 R/Y12/Y22 100% HC2 L049
Fan
G
0
R
400 cfm
HCF
N/A
Cool 1 Y/G/O 1 R/Y1
2
/O
2
50% or 70%** COOL N/A
Cool 2 Y/Y2/G/O 2 R/Y1
2
/Y2
2
/O
2
100% COOL N/A
Hydronic Varies N/A N/A OFF HC3 N/A
Contractor Use Only
Step 1 Remove the exchanger
access panel and locate
the pressure relief valve
assembly.
Step 2 Connect the pressure relief
valve to the outlet water
port on the left side of the
is extremely important that
the following conditions for
installation of this part are met:
• Ensure 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,
upright, position directly to the outlet water port of
the system. Under no circumstances should there
the safety relief valve and the pressure vessel.
Step 3
pressure relief valve. This 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 at no risk of freezing.
• terminate with a plain end that is not threaded.
• be constructed of a material suitable for exposure to temperatures of 375ooC or greater.
• be, over its entire length, of a pipe size equal to or greater than that of the valve outlet.
PLUMBING
The Comfort Plus Hydronic heating system MUST be plumbed with a primary loop and secondary (zone)
loops.
PRESSURE RELIEF VALVE INSTALLATION
Installation 3.11 Comfort Plus Hydronic
WARNING
Risk of explosion. Can cause injury or death. The factory supplied
pressure relief valve MUST be connected to the system with the supplied
ttings.
DO NOT modify this assembly.
DO NOT cap, plug, or otherwise obstruct the outlet of the pressure
relief valve.
DO mount the pressure relief valve in a vertical, upright position.
This pressure relief valve is sized to service the needs of the
Comfort Plus Hydronic heating system. If multiple heating systems
are being used, pressure relief valving for the other system MUST be provided separately.
Minimum BTU
Rating
Maximum Operating
Order Item #
Note: 5100 Series Systems are shipped with 30 PSI pressure relief valves. If a
dierent valve is required, order the item number listed.
Risk of discharged hot water and/or steam.
Can cause personal injury or property
damage. During operation, the pressure
relief valve may discharge large amounts
of steam and/or hot water. To reduce the
potential for bodily injury or property
damage, install a discharge line.
CAUTION
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