Steffes ThermElect 8150 User manual

V3
OWNER'S AND
INSTALLER'S MANUAL
Models: 8150, 8155, 8180, 8185, 8188
Applicable to Software Version 2.0
LISTED

For Customer Use
Please record your model and serial number below. This number is found on the identification labels
located on the front of and inside the electrical panel. 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
equipmentandyourproperty,thatyouobservethesafetyinstructionsgivenfollowing
thesesymbols.


The equipment described herein is intended for installation by a qualified
technician in accordance with applicable local, state, and national codes and
requirements.


To insure 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 installa-
tion and made available to service personnel as required.


Disclaimer: In compiling this manual, 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.
Steffes 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 prescribed by local or
national protection agencies.
IMPORTANT

SAFETY PRECAUTIONS
1. DO NOT energize the system while disassembled or
without ceramic heat storage brick in place.
2. DO NOT use or store materials that may produce explo-
sive or flammable gases near the system.
3. DO NOT violate the placement and clearance require-
ments specified in this manual. (Page 3.03)
4. DO NOT place anything on top of the Storage Module(s).
5. Disconnect power to all circuits before servicing. This
heating system may be connected to more than one branch
circuit.
6. Installation of and/or service to this heating system should
be performed by a qualified technician in accordance with
information contained herein and with national, state, and
local codes and requirements.
7. A repeated message of “CORE FAIL” indicates a need
for service by a qualified technician.
BUILT-IN SAFETY DEVICES
The ThermElect heating system incorporates safety devices to ensure normal operating temperatures are main-
tained. The chart below describes these safety devices.
DEVICENAME FUNCTION LOCATION
ON SYSTEM
Core Charging High
Limit Switches
(Auto Reset)
These limit switches monitor the core and top temperatures.
If normal operating temperatures are exceeded, the system
will display "CORE FAIL" and the elements will not be
allowed to operate.
This limit switch monitors the discharge air temperature
and interrupts power to the core blower if the normal
operating temperature is exceeded:
160oF / 71oC (nominal)
Core Blower
Limit Switch
(Auto Reset)
This limit switch monitors the discharge air temperature
and interrupts power to both the supply air blower and the
core blower if the normal operating temperature is ex-
ceeded: 190oF / 88oC (nominal)
Supply Air Blower
LimitSwitch
(Manual Reset)
Core Blower Housing
TemperatureLimit
Switch (Auto Reset)
This limit switch monitors the temperature in the base of the
air handler and interrupts power to the core blower if the
normal operating temperature is exceeded:
160oF / 71oC (nominal)
In the base of the air
handler near the core
blower.
Mountedonlimit
bracket at discharge
airoutlet.
Mountedonlimit
bracket at discharge
airoutlet.
THERMELECT SAFETYINFORMATION
Air handler side of
each storage module
and storage module top
panel.
WARNING


Hazardous Voltage: Risk of elec-
tric shock, injury, or death. This
system may be connected to
more than one branch circuit.
Disconnect power to all circuits
before installing or servicing.
Installation of and/or service to
this equipment MUST be per-
formed by a qualified technician.


Risk of injury or fire. Violation of
the clearance requirements can
cause improper operation of the
equipment. Maintain the place-
ment and clearance requirements
specified.

Table of Contents
TC
TABLEOFCONTENTS THERMELECT
Operation
GeneralOperation ........................................................................................................................................................................ 1.01
System Use During Construction Phase...................................................................................................................................... 1.01
SystemStart-Up ........................................................................................................................................................................... 1.01
Turning System "OFF" and "ON" ............................................................................................................................................... 1.01
ControlPanel ............................................................................................................................................................................... 1.02
Operating Status .......................................................................................................................................................................... 1.02
TemperatureControl .................................................................................................................................................................... 1.03
BrickCoreChargeControl ........................................................................................................................................................... 1.03
ChargeControlOverride .............................................................................................................................................................. 1.03
Maintenance and Cleaning .......................................................................................................................................................... 1.03
Optional Accessories
Load Management Control .......................................................................................................................................................... 2.01
ExternalDuctSensor.................................................................................................................................................................... 2.02
LiftingHandles ............................................................................................................................................................................ 2.02
Installation
Shipping and Packaging .......................................................................................................................................................3.01-3.02
PlacementandClearanceRequirements....................................................................................................................................... 3.03
InitialSet-up................................................................................................................................................................................. 3.04
Attaching Storage Module(s) to Air Handler .......................................................................................................................3.04-3.05
ElectricalPanelInstallation ...................................................................................................................................................3.06-3.07
BrickLoading ........................................................................................................................................................................3.07-3.08
HeatingElementInstallation ........................................................................................................................................................ 3.08
BrickCoreTemperatureSensorInstallation-............................................................................................................................... 3.09
AirConditioner/HeatPumpInterface........................................................................................................................................... 3.09
Ducting ........................................................................................................................................................................................ 3.10
LineVoltageElectricalConnections ............................................................................................................................................ 3.10
Outdoor Temperature Sensor Installation.................................................................................................................................... 3.11
Thermostat Connections ......................................................................................................................................................3.11-3.12
ElectronicAirFilterInstallation ................................................................................................................................................... 3.14
Installer'sFinalCheck-OutProcedure .......................................................................................................................................... 3.14
Load Management Control
On-Peak/Off-PeakProgram ...................................................................................................................................................4.01-4.02
4-20MilliampControl(1-5VoltDC) ............................................................................................................................................. 4.02
Pulse Monitoring ......................................................................................................................................................................... 4.03
Appendix
Specifications..................................................................................................................................................................... A.01-A.03
TypicalSystemLineVoltageWiringDiagrams.................................................................................................................. A.04-A.05
InternalSystemWiringDiagram-LowVoltage .......................................................................................................................... A.06
Help Menu ..................................................................................................................................................................................A.07
ErrorCodes ........................................................................................................................................................................ A.07-A.09
Warranty

GENERAL OPERATION
The ThermElect heating system stores off-peak electricity in the form of heat. Off-peak electricity is available
during times of the day or night when electricity is plentiful and the associated costs are low.
Operation of the heating system is automatic. During off-peak hours, the system converts electricity to heat which
is then stored in its ceramic brick core. The amount of heat stored in the brick core of the Storage Module(s)
variesinrelation to outdoor temperature, current building load, utility peak conditions, and/or the heating require-
ments.
A heat call from the thermostat or main system control energizes the blowers in the system. The variable speed
core blower automatically adjusts its speed to circulate air through the brick core. The supply air blower then
delivers the heated air into the desired area through the duct system to maintain constant, comfortable temperature.
The versatility of this system allows it to fit many applications. The system is designed for use as either a sole
heating source (“stand alone” furnace) for make up air heating or as a supplement to 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 instead of the permanent heating system during the construction phase. Use of the permanent heating system
during this 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 or equipment damage.
SYSTEM START-UP
On start-up of the system, odors relating to first time operation of the heating components may be experienced.
Also, if not used for an extended period of time, dust may accumulate in the system. Allow the heating system to
charge to its maximum brick core charge level to expel odors in a timely manner.
As with most heating systems, air borne particles and odors may be drawn into the system and oxidized. Odors
can be amplified; thus, it is not recommended to operate the system if odors such as those from paints,
varnishes, or chemicals are present in the air. Air borne particles, which have been oxidized, are expelled
back into the room and may accumulate on air vents or other surfaces. Over time, these particles may appear as a
black residue, commonly referred to as soot. High concentrations of air borne particles from aerosols, dust,
candles, incense, pet hair, smoke, or cooking can contribute to poor indoor air quality and accelerate the sooting
process.
During operation, the heating system may produce minor expansion noises. These noises are the result of the
internal components reacting to temperature changes.
TURNING SYSTEM "OFF" AND "ON"
The system is fully automatic and does not need to be manually disabled. Talk to your installer or energy manage-
mentpersonforadditionalinformation.
THERMELECT OPERATION 1.01
Operation
1
Operation

CONTROL PANEL
Operation of the ThermElect system is automatic. All operational functions are stored in its microprocessor in
function locations and are factory preset. If necessary, the installer can adjust them through the control panel.
(See Figure 1.)
Four-Digit LED Display
The four digit LED displays specific operating information. During an editing
process, the function locations and the values set in these locations are displayed
for viewing and adjusting purposes.
AM and PM Indicator Lights
The AM and PM indicator lights are only utilized if the Steffes Time Clock Module
is being installed. With this module installed, the system displays time on AM/PM
intervals and the corresponding light flashes. The system can be configured to
display military time, in which case both the AM and PM lights illuminate.
Mode (Edit) Button
Activates the editing menu for changing the operating
information of the system.
Up and Down Arrow Buttons
Used to scroll up or down when viewing or changing
operatingfunctions.
Interface Port
FOR SERVICE USE ONLY! Allows technician external access for updating software and troubleshooting.
OPERATING STATUS
The ThermElect system is set to display various operating information as described below. Press and release the
up arrow to view this data.
Operating Mode - Indicates the current operating mode of the system.
C = Off-Peak (Charge) Time
P = On-Peak (Control) Time
A = Anticipated Peak Time
Outdoor Temperature -“O” followed by a number indicates current outdoor temperature.
Heat Call Status - Indicates the current heat call status being received from the room thermostat.
HC_0 = No Heat Call HC_1 = Stage 1 Heat Call
HC_2 = Stage 2 Heat Call HC_3 = Emergency Heat
COOL = Cooling/Air Conditioning Call
Brick Core Charge Level - “CL” (charge level) followed by a number indicates the current
percentage of heat stored in the brick core. “CL:_” represents zero percent and “CL: F” repre-
sents a full core charge level.
Targeted Brick Core Charge Level - “tL” (target level) followed by a number indicates the
current percentage of brick core charge being targeted by the system. A display of “tL:_” indi-
cates a target level of zero percent and “tL: F” indicates a full core charge target level.
Load Control - Current demand (kW) divided by 10. A value of "d 75" is equal to a current
demand of 750kW.
OPERATION 1.02 THERMELECT
A bar illuminates on the lower portion of
the display's second digit whenever one or
more heating elements are energized.
CAUTION
Editingoperating
information may alter
the performance and
operation of the system.
CONTROL PANEL
FIGURE 1
STEFFES CORPORATION
MM
M
PP
MM
AA
Operation
×Ø
M

THERMELECT OPERATION 1.03
TEMPERATURE CONTROL
Temperature set point is adjusted at the wall thermostat(s) or the main system control. If temperature in the area
drops below the desired set point, a heat call is initiated and the blower in the ThermElect system is energized.
The variable speed core blower automatically adjusts speed in relation to brick core temperature and duct tem-
perature to circulate air through the brick core. The supply air blower then delivers the heated air into the desired
area through the duct system to satisfy heating requirements.
When used to supplement heat pump systems, the ThermElect system replaces resistance strip heat, which is
typically required as a supplement or back-up to the heat pump system. The outlet sensor monitors the discharge
air temperature. If the demand for heat is at a point where the heat pump alone cannot maintain the desired duct
temperature, stored heat is used to supplement the heat pump and satisfy the heating requirements.
When the ThermElect system receives a “G” call, the supply air blower is energized; however, no heat is deliv-
ered as this is a “fan only” call.
When a “G” call is received with a “Y” call, the supply air blower is energized and the minimum discharge air
temperature (as set in Location 48) is targeted.
Anytime the ThermElect system receives a “W” call with any other call from the thermostat (except “O”) then
the maximum discharge air temperature (as set in Location 49) is targeted. The maximum discharge air tempera-
ture is also targeted if the current outdoor temperature (shown in Location 109) is lower than the off-peak lock out
temperature (set in Location 46) or the on-peak lockout temperature (set in Location 47).
Reference the Supplemental Installer's Guide for more information on system operation.
BRICK CORE CHARGE CONTROL
The amount of heat stored in the brick core of the Storage Module(s) varies in relation to outdoor temperature,
currentbuildingload,utilitypeakconditions,and/ortheheatingrequirements.Theoutdoorsensor,suppliedwiththe
system, monitors outdoor temperature and provides this information to the system. As the outdoor temperature
decreases, heating requirements increase and the system stores more heat accordingly.
CHARGE CONTROL OVERRIDE
If desired, the ThermElect system can be programmed to allow a charge control override. This override allows the
user to force the system to target a full core charge level and can be initiated or cancelled at any time. If an
override is initiated, the system targets a full core charge level during the next off-peak period. It continues to
charge during off-peak hours until it 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 the standard configuration.
MAINTENANCE AND CLEANING
Any air filter(s) in the system should be replaced on a regular basis to ensure proper operation and to maintain
overall efficiencies. No additional routine maintenance is required.
If utilizing a heat pump or air conditioning system with the ThermElect system, the indoor coil should be cleaned
periodically as dirt accumulation may reduce system efficiency. It is important to follow the manufacturer’s
maintenance and cleaning recommendations for these devices.
Operation

Optional Accessories
2
LOAD MANAGEMENT CONTROL
The ThermElect is a commercial Electric Thermal Storage (ETS) heating system. It uses Demand Free, Off-Peak
electricity to provide a low cost heating solution for commercial, industrial, and large residential applications. ETS
equipment is designed to store electricity, as heat, during hours when energy costs are lower and kW demand
charges are not incurred. The ThermElect’s thermal mass consists of a high-density ceramic brick capable of vast
heat storage.
The ThermElect system is designed to operate under one of three different load management control strategies.
1. On-Peak/Off-Peak Program
a) The ThermElect system responds to heat calls during the on-peak and off-peak periods; however, only
consumes energy (energize heating elements) during the off-peak periods. The ThermElect system is
controlled by an external control device such as a meter or time clock module.
b) The ThermElect system also offers on-peak control of external loads by utilizing the dry contacts provided
on the relay driver board.
2. 4-20 Milliamp Control (1-5 volt DC)
a) The ThermElect system receives a signal from an external load control device such as a building load
management system. This external signal dictates to the ThermElect the maximum amount of energy
which can be consumed during a preset time interval.
b) Other external loads would generally be controlled through the building's
load management control system.
3. Pulse Monitoring
a) The ThermElect system monitors pulse outputs from the power company's
electric meter. Program parameters such as desired maximum building kW
and pulse ratios for the metering system being used are entered into the
ThermElect system. The system then changes proportionally when demand
free power is available. This keeps the total building kW usage at or below
the desired level.
b) External load management control modules (Order Item # 1908410) are
availablewhen using pulse monitoring load control. Each module has eight
(8) zones which can be controlled. The ThermElect system must be
configured to recongnize the number of load management modules installed
(maximum of two per ThermElect system).
Reference the Load Management Section of this manual for more specific information on the individual methods
ofcontrol.
Optional Accessories
OPTIONALACCESSORIES2.01 THERMELECT

Optional Accessories
THERMELECT OPTIONALACCESSORIES 2.02
EXTERNAL DUCT SENSOR
The optional 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
system monitors temperature at both the duct sensor and
the output sensor during Y, W, or E calls from the ther-
mostat.
If there is a Y and a G call from the thermostat, the
ThermElect system operates the core blower at the
required speed to maintain the minimum output tempera-
ture as set in Location 48 (L048) at the duct sensor. If
there is only one call from Y, W, or E, then the system will operate the core blower at the required speed to
maintain the maximum output temperature as set in Location 49 (L049) at the duct sensor. The system is set to
turn off the core blower if the output temperature at the output sensor exceeds 150 degrees Fahrenheit.
LIFTING HANDLES
Optional lifting handles are available (Order Item #1302120) to aid in
moving the ThermElect Storage Module(s) into their final location. It is
extremely important to use caution when lifting a Storage Module.
Instruct workers to NOT walk under or place any body parts under
the Storage Module when lifting and/or moving.
WARNING
HEAVY OBJECT WARNING: Risk
of personal injury, or death.
ThermElect Hydronic systems
are heavy. Use lifting aids to
move system into place.


Do not place object, hands,
and/or body parts under the
system when lifting.


Do use care to keep objects,
hands, and/or body parts clear
of system when lifting.

Installation
3
SHIPPING AND PACKAGING
The ThermElect Storage Module(s) should always be transported in an upright position to avoid damage to internal
components and insulation materials. The information below describes the items shipped with each system.
Installation
1STORAGE MODULE(S)
INSTALLATION3.01 THERMELECT
MODULES
MODEL 53kW 80kW
8150 1 0
8155 2 0
8180 0 1
8185 1 1
8188 0 2
HEATING ELEMENTS
WITH CERAMIC INSULATORS
5
INFORMATION PACKAGE
(includes Owner's Manual and
Warranty Registration Card)
(included on pallet with the electrical panel )
4
ELECTRICAL PANEL
AIR HANDLER
2
2000CFM-Standard
3000CFM-Optional
(shipped separately) MODULE ELEMENTS
53kW 12 (2 boxesof6)
80kW 18 (3 boxesof6)
(shipped separately)
3
(shipped separately)
(includeselectrical
panel mounting
screws,romex
connectors, and
wiringschematic)
208/240V shown
ELEMENT SCREW KIT &
INSTALLATION HARDWARE KIT
(shipped
inside the
electrical
panel)
6
SEAM WRAP
(shipped inside brick storage cavity)
7

Installation
SHIPPING AND PACKAGING CONTINUED...
THERMELECT INSTALLATION 3.02
CORE THERMOCOUPLE
WITH 6' CLEAR PLASTIC TUBE
8
53kW= Qty2 permodule
80kW= Qty3 permodule
CERAMIC BRICK
MODULE BRICK LBS
53kW 192 3,360
80kW 288 5,040
96brickperpallet
(shipped separately)
(shipped inside the
electrical panel)
OUTDOOR TEMPERATURE SENSOR
11
HIGH VOLTAGE KIT
(277V & 347V SYSTEMS ONLY)
13
SizedforAirHandler
(includes fuses and transformers)
(shipped separately)
OUTLET DAMPER KIT
1 per Storage Module
(includesDamperAssembly,DamperLinkage,2
-LBrackets,2-CClipDriveBrackets,
2-CDrives,HardwareScrewKit)
(shipped separately)
12
(shipped inside the electrical panel)
TOP AIR CHANNEL BLOCK
(shipped separately)
91 box of 4 per Storage Module
14 TRANSFORMER WIRING HARNESS
(277V & 347V SYSTEMS ONLY)
(shipped in electrical panel)
10

System
AirHandling
22"
Return
51"
34"
1"Clearancemustbe
maintainedbetweenStorage
Modules,AirHandlingSystem
and/orCombustibleMaterials.
69"
1913
16"
80KW
STORAGE
MODULE
51"
22"
24"
Supply
26"
94"
34"
90"
71 1/8"
Panel
Electrical
53KW
MODULE
STORAGE
23"
PLACEMENT AND CLEARANCE REQUIREMENTS
The system dimensions and required clearances MUST be taken
into consideration when choosing its location within a structure.
(See Figure 2 for dimensions and clearance requirements.)
The best installation location for the system is in a space requiring
heat so some amount of the heating requirements can be satisfied
through static dissipation from the warm outer panels of the
Storage Module(s). In situations where the system is not installed
in an area it is intended to heat (i.e. garage), it is important to
account for the heat lost through static dissipation by making
proper adjustments when sizing.
The minimum area required for the installation of the system is 100 square feet per Storage Module. This area
must remain free of debris and room air should be maintained at less than 85oFahrenheit. Ventilation
MUST be provided if the system is being installed in an area with less than 600 square feet. It is the responsibility
of the installer and system designer to provide this ventilation.
In addition to the physical space requirements, the weight of the system must also be taken into consideration
when selecting the installation surface. A level concrete floor is the designed installation surface, but most well
supported surfaces are acceptable. If unsure of floor load capacity, consult a building contractor or architect.
Special requirements must 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. SYSTEM REQUIREMENTS
FIGURE 2
StorageModule(53kWand80kW)


Back=8 inches


Bottom=1inch(fromcombustible
material)


Sides = 8 inches


Top = 8 inches (from combustible
material)


Front = 36 inches (for ease in
servicing)
AirHandler(2000and3000CFM)


Back= 1inchclearance


Bottom=1inch(fromcombustible
material)


Sides = 1 inch clearance


Top = 0 inches (from combustible
material)


Front = 36 inches (for ease in
servicing)
DIMENSIONS
Someelectricalcodesmayrequireagreaterfrontclearance
dependingonoperatingvoltagesandotherfactors.
CLEARANCES
Installation
INSTALLATION3.03 THERMELECT
Risk of injury or fire. Violation of the
clearance requirements and/or failure to
provide proper ventilation can cause
improper operation of the system. Main-
tain the placement and clearance require-
ments as specified and provide ventilation
asnecessary.
WARNING

INITIAL SET-UP
Step 1 Remove the Information Package from the outside of the
electrical panel and unpackage the Storage Module(s) and
Air Handler.
Step 2 Movethesystemintoitsinstallationlocation.Optionalliftting
handles are available from the factory. (Order Item
#1302120).
If using Steffes lifting handles, remove
painted front and back panels from brick
storage cavity.
ATTACHING STORAGE MODULE(S) TO AIR HANDLER
Each side of the Air Handler has a Storage Module Inlet/Outlet Opening, Limit Access Panel
and knockout. If using only one Storage Module follow the instructions below for the side of
the Air Handler where the Storage Module will be attached.
Step 1 Remove the screws around the Storage Module Inlet/Outlet Opening(s) on the side of the Air Handler
where the Storage Module will be placed. (See Figure 3.)
Step 2 Remove the front painted panel from the Air Handler and set aside.
Step 3 Lift the Storage Module Inlet/Outlet Opening cover(s) out through the front of the Air Handler.
Step 4 Attach the top and bottom C-clip drive brackets and the side L brackets to the Air Handler.
(See Figure 3.)
When attaching the top C-clip drive bracket, use the top row of screw holes.
Installation
THERMELECT INSTALLATION 3.04
FIGURE 3
Knockout Limit Access
Panel
Storage Module
Inlet/Outlet Opening
(Cover Removed)
CAUTION
Risk of improper operation or equipment damage. Read and follow installation instructions carefully.
DO NOT install the system on its shipping pallet.
DONOTextendthelevelinglegs more than one inch.
DOuseandfollowgenerallyacceptedsafetypracticeswhenhandlinginsulationmaterials.
EquipmentMUST be installedby qualified technicianin accordance withall applicable codesand regulations.
WARNING
HEAVY OBJECT WARNING: Risk
of personal injury, or death.
ThermElect Hydronic systems
are heavy. Use lifting aids to
move system into place.


Do not place object, hands,
and/or body parts under the
system when lifting.


Do use care to keep objects,
hands, and/or body parts clear
of system when lifting.

Step 6 Remove the top two screws from the damper bracket
at the center of the damper assembly (Figure 5A).
Rotate the damper actuator assembly 90 degrees
(Figure 5B) to keep it out of the way when attaching
the Storage Module(s) to the Air Handler.
Step 7 Remove the 7/8" (inner) knockout on the limit access
panel (Figure 3) on the side(s) of the Air Handler
where the Storage Module(s) will be attached.
Step 8 Move the Storage Module(s) within 6" of final position to Air Handler. Once
in place, adjust the leveling legs on the bottom of the Storage Module(s) as
necessary to prevent rocking. If not placed properly the system may bend
ortwistduringthebrickloadingprocess, causing alignment problems during
re-assembly.
DO NOT extend the leveling legs more than 1".
Step 9 Locate the orange limit switch wires in the limit area of the Storage
Module(s). Secure the connector located on these limit switch wires into the knockout on the limit
access panel (Figure 6).
Step 10 Making certain that the orange limit switch wires between the Air Handler and Storage Module(s) are
routed properly, move the Storage Module(s) into their final location next to the Air Handler. The edge
of the side L brackets on the Air Handler MUST fit inside the S-Clip brackets on the side(s) of the
Storage Module(s). (See Figures 7 and 8.)
INSTALLATION3.05 THERMELECT
Installation
FIGURE 6
FIGURE 5
AB
Risk of Improper Operation and
EquipmentDamage.Improperrouting
of the limit switch wires can result in
improperoperationorequipmentdam-
age.DONOTphysicallydamage or
route the limit switch wires near high
temperatureareas.Whenattachingthe
StorageModuleto the AirHandlermake
sure the limit switch wires are not
pinched or cut. When routing the limt
switch wires inside the Air Handler,
makesurethey are routedthrough the
pre-installed plastic cable ties.
CAUTION
FIGURE 7
FIGURE 8
FIGURE 4
ABC
Step 5 Securely mount the damper(s) to the Storage Module(s) using the screws provided in the outlet damper
kit. Two screws are required for each side of the damper assembly (Figures 4A and 4B); four screws
are inserted along the top and four screws are inserted along the bottom of the damper. To insert the top
screws, open the damper as shown in Figure 4C.

THERMELECT INSTALLATION 3.06
Installation
AIR HANDLER
DAMPER LINKAGE
FIGURE 11
ELECTRICAL PANEL INSTALLATION
Step 1 Reinstall the painted front panel on the Air Handler to aid in installation of the electrical panel.
Step 2 Remove the electrical panel front cover and locate the installation hardware package.
Step 3 Remove 1/2" knockout and 1" knockout from sides of electrical panel and Storage Module(s) to allow
connection. DO NOT remove any uneeded knockouts.
Step 4 Lift the electrical panel onto the support bend of the Air Handler's painted front panel.
Step 5 Secure the electrical panel to the Air Handler with the five 8 x 3/4" sheet metal screws shipped with
the outlet damper kit.
Step 6 Remove the lower painted front panel of the Air Handler.
Step 7 Connect the 9-pin blower harness from the Air Handler to the harness from the electrical panel.
Knockout must be effectively sealed by connector.
Step 8 277/347 only. Remove one 1/2" knockout from lower left hand bottom panel and connect straight seal-
tite connector on conduit to bottom of electrical panel. Connect the other end of the conduit to dry type
enclosed transformer. Mount the transformer to the Air Handler's painted front panel. Make connec-
tions according to instructions with transformer.
Install only the proper size and type fuses in the factory supplied fuse block.
Step 11 Attach the Storage Module(s) to the Air Handler using the C-drives provided (Figure 9). Bend excess
length of drives over to seal the damper area (Figure 10).
Step 12 Route the orange limit switch wires through the
pre-installed plastic cable ties on the inside of
the Air Handler.
Step 13 Connect the orange limit switch wires from the
Storage Module(s) to the orange wires from the
electricalpanel.WheninstallingdualStorage
Modules it is important to connect the wires
from the left side of the electrical panel to the
left Storage Module and the wires from the
right side of the electrical panel to the right
Storage Module.
Step 14 Secure the damper actuator linkage(s) to the
damper actuator arm(s) inserting the supplied
spring clips through the hole in the pivot connec-
tor. The top hole in the actuator arm MUST be
used for the right side damper. (See Figure 11.)
The upper pivot hole on the actuator arm is for the
right side Storage Module. The lower pivot hole on
the actuator arm is for the left side Storage Module.
Step 15 Adjust damper linkage length(s) appropriately to ensure the
damper(s) fully close. Check the ball end linkage connector on the
damper. The nut side MUST be facing the front of the system. If
not, it MUST be inverted.
Step 16 With the system de-energized, adjust the linkage by rotating the
quick disconnect end of the linkage until the damper is pressed
firmlyintheclosedposition.
FIGURE 10
FIGURE 9
Risk of fire and/or equipment damage. When
installing dual Storage Modules it is important
to connect the orange/black wires from the left
side of the electrical panel to the left Storage
Module and the right side wires to the right
Storage Module.
WARNING

INSTALLATION3.07 THERMELECT
BRICK LOADING
Step 1 Remove the painted front panel of the brick Storage Module(s) 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 2 Remove the sheet metal screws around the outer edge of the galvanized front
panel. Remove the panel and set it aside.
Step 3 Starting at the bottom, carefully lift each of the insulation blankets and drape
them over the top of the Storage Module(s).
Step 4 Remove the rigid insulation boards and place to the side in the order
removed.
Step 5 Load the brick, one row at a time, starting at the back of the brick
core and working forward. Load bricks as shown in Figure 12. Make
certain brick debris does not interfere with brick alignment front to
back.
Step 6 Install top air channel block by sliding it up and back into place on top
of the bricks. (See Figure 13)
For ease of installation, install top block while loading
bricks.
Step 7 Install rigid insulation boards into the Storage Module(s) in the order
they were removed in Step 4.
The holes in the rigid insulation board MUST line up
with the brick openings so elements can be installed.
Installation
Risk of injury or fire. DO
NOT operate the system if
damage to the insulation
panels on the inner sides
of the brick core occurs.
WARNING
BRICK LOADING
FIGURE 12
Risk of equipment damage or personal injury. Insulation boards located behind
the insulation blankets may fall out when blankets are lifted. Use caution when lifting
insulationblanketsto avoid personal injuryordamage to the insulationboards.
CAUTION
FIGURE 13
BRICK INSTALLATION TIPS:
•Install bricks carefully to avoid damage to the insulation panels.
•Remove loose brick debris to prevent uneven stacking of brick
as this can make installation of the elements and the brick core
temperature sensor(s) difficult.
•Brick rows MUST line up front to back and top to bottom.

Step 3 Install element lead insulators. These ceramic
insulators MUST maintain lead wire spacings as
shown in Figure 15.
Step 4 Lower the insulation blankets back into position, one at a time. Carefully
tuck the sides of the insulation into the edges, corners, and around the
exposed portions of the heating element to ensure maximum efficiency.
Step 5 Reinstall the galvanized front panel and secure it to the system using the
screwsoriginallyremoved.
Step 6 Route element harnesses through connectors, using one connector/harness until tape is centered in
connector. If installing two Storage Modules, use left hand bank of relays for left hand and right hand for
right hand. One harness per module is shorter and must be used for inside element connections.
Step 7 Attach element lead wires to element terminals. Start at the top using the appropriate color chart below.
Repeat pattern as necessary.
277/347V = Black (Top) 208/240V = Black (Top) 240V = Black (Top)
Systems White 3phase Red 1phase Red
Red Systems Blue Systems Black
White Black Red
Blue Red
White Blue
Installation
FIGURE 15
FIGURE 14


HAZARDOUSVOLTAGE: Riskofelectric
shock, injury, or death.


DO NOT remove the electrical panel
cover while system is energized.


Elements MUST be positioned prop-
erly to avoid short circuiting against
any surfaces within the system.


Risk of improper operation or equipment
damage. On Dual Storage Module
systems, it is critical to route the correct
harness to each of the Storage Modules.
Mis-routing of harness will result in
improper operation and equipment
damage. Make certain the harness
connected to the right side relay bank in
the electrical panel is routed to the right
side Storage Module.
WARNING
HEATING ELEMENT INSTALLATION
Step 1 After all bricks are loaded and rigid insulation boards
are in place, insert the heating elements through the
insulation,slidingtheminuntilthecementsiderails
are flush with the front side of the ceramic brick.
Make sure the elements designated as
Air Handler side elements are installed
on the Air Handler side of the Storage
Module(s).
Step 2 Route the element termination head
with ceramic insulator to the appro-
priate side of the Storage Module(s).
Insert the lead into position as
shown in Figure 14.
Element leads must never
cross each other.
THERMELECT INSTALLATION 3.08

INSTALLATION3.09 THERMELECT
Installation
Step 3 Insert the brick core temperature sensors through the holes in the galvanized front panel. The sensors
must pass through the blanket and board insulation and into the brick core. Use the sensors to aid in
making a passageway by rotating the sensors while gently pushing inward.
Step 4 Once brick core sensors are installed, re-install sensor mounting screws to secure and ground the sensors.
Step 5 Re-install the painted front panel, using previously removed screws.
BRICK CORE TEMPERATURE SENSOR INSTALLATION
Step 1 Remove the screw(s) by the brick core temperature sensor connector
holes in the galvanized front panel.
Step 2 Route the brick core temperature sensors through the clear plastic
tube until within six inches of the relay driver board. Cut tube and
sensor wires to length as needed. The yellow wire from each sensor
must be connected to the Y terminal of the proper sensor connection
terminal block, and red to R. Polarity of sensors is critical.
Sensor connections MUST be installed as follows:
•Single Module - 8150 or 8180 (Figure 16)
•Bottom sensor to core C
•Second sensor to core D
•Third (if equipped) to core E
•Dual Module - 8155, 8185, and 8188 (Figure 16)
•Leftmodule •Rightmodule
• Bottom sensor to core F • Bottom sensor to core C
• Second sensor to core G • Second sensor to core D
• Third (if equipped) to core H • Third (if equipped) to core E
Risk of improper operation.
Properinstallation ofthe brick
coretemperaturesensoris
critical to the operation of the
heating system. Read and
followinstallationinstructions
carefully.
CAUTION
CORE TEMPERATURE SENSOR CONNECTIONS
FIGURE 16 Models: 8150 & 8180
Models: 8155 & 8188
Insystemsusingbothan80kWand53kWStorageModule,the53kWStorageModulemustbe
installedontheleftsideoftheAirHandler.
Connect To Core "H"
80 Kw Module Only
Connect To
Core "C"
Connect To
Core "D"
Core
Temperature
Sensors
Connect To Core "E"
80 Kw Module Only
Core
Temperature
Sensors
Connect To
Core "F"
Connect To
Core "G"
Relay
Driver
Board
Connect To Core "E"
80 Kw Module Only
Core
Temperature
Sensors
Connect To
Core "D"
Connect To
Core "C"
Relay
Driver
Board

THERMELECT INSTALLATION 3.10
AIR CONDITIONER/HEAT PUMP INTERFACE
The system can accommodate most heat pump or air conditioner indoor
coils up to a 7.5-ton capacity provided the heat pump or air conditioner is
sized in accordance to supply air delivery rates of the system. Refer to the
System Air Delivery Matrix for information on air delivery rates of the
supply air blower with regard to the blower’s speed, To ensure that ad-
equate air flow is provided for the heat pump or air conditioner system
beinginstalled.
When interfacing the system with a heat pump, the indoor coil MUST be
placed on the return side of the system in a position that provides even air
flow through the coil. The installer needs to make provisions in the plenum
to accommodate the coil and air filter.When interfacing with an air condi-
tioner, the indoor coil can be placed on either the supply air or return air
side. The condensate drain trap, in a heat pump or air conditioner installa-
tion, should be designed for the vacuum in which the system is operating. Typically, taller traps are better suited
for these types of applications.
Refer to the Room Thermostat Connections Diagrams for more information on interfacing the system with a
heat pump or air conditioner. Refer to Location 46 and 47 in the Supplemental Installer's Guide for information
on compressor control from the ThermElect system using outdoor temperature lockout.
Installation
WARNING
Risk of fire. Any one ducting
system MUST NOT contain more
than one air handling (blower)
system. If the application
requires multiple systems or it is
necessary to have multiple air
handlers share the same
ductwork, you MUST contact
Steffes Corporation. There are
special installation require-
ments that MUST be performed.
SYSTEM AIR DELIVERY MATRIX
.25" .50" .75"
2000 3000* 2000 3000* 2000 3000*
High(CFM) 2050 2950 1900 2490 1540 2160
Medium High (CFM) 1990 2850 1890 2350 1535 1980
Medium Low (CFM) 1870 2520 1670 2270 1450 N/A
Low (CFM) N/A 1920 N/A N/A N/A N/A
(External static pressure should not exceed .75 inches water column for all models)
*An optional 3000 CFM Air Handler is available. The 3000 CFM Air Handler is equipped with two 4-speed
supply air blowers.
SupplyAir
Blower Speed
DUCTING
SUPPLY AIR BLOWER SPEED
For air delivery, the system is equipped with a 2000 CFM Air
Handler containing a 3-speed supply air blower. The system is
factory wired to operate in medium speed for “heating” and in
high speed for “cooling” or a “fan only” thermostat setting.
Blower speed selection is made at the supply air blower. To
change blower speed for either "heating" or "cooling" modes,
detach the quick disconnect terminals at the supply air blower.
Select the blower speed and connect the corresponding wires.
When interfacing the system with a heat pump,
the blower speed connected to the high speed
relay is used for both heating and cooling.
WARNING


HAZARDOUSVOLTAGE:Riskof
electric shock, injury or death. DO
NOT operate the system without
ducting installed to both the air
inlet and outlet.


EQUIPMENT DAMAGE: Risk of
equipment damage or improper
operation. On 3000 CFM systems
where there are multiple supply air
blowers, both blowers MUST be
connected to the same blower
speed to avoid equipment damage.

OUTDOOR TEMPERATURE SENSOR INSTALLATION
An outdoor temperature sensor, shipped in the electrical compartment, is required to be installed with the system.
This sensor monitors outdoor temperature and provides this information to the system. The system responds by
automatically storing heat in its brick core(s) according to the outdoor temperature and the heating requirements.
The outdoor temperature sensor can be installed in one of two ways: direct wired to the system or wired to the
Steffes power line carrier system. All 208/240V systems are factory configured for automatic charge
control with a direct wired outdoor sensor.
If connecting to the Steffes power line carrier (PLC) system, follow the installation instruc-
tions in the PLC system's Owner's and Installer's Guide.
Outdoor sensor wire MUST NEVER be combined with other control wiring in a multi-
conductor cable.
INSTALLING THE OUTDOOR SENSOR
Step 1 The outdoor sensor must be placed in a location where it can accurately sense outdoor temperature
and is not affected by direct sunlight or other abnormal temperature conditions. Select a location and
mount the sensor.
Step 2 Route low voltage wire from the outdoor sensor to the electrical compartment through one of the low
voltage wire knockouts.
•If the sensor wiring is routed through an external wall, the opening through which the wire
is routed MUST be sealed. Failure to do so may affect the accuracy of the outdoor
temperature sensor.
•The outdoor sensor is supplied with a lead length of 40 ft. If a greater wire length is
needed, it can be extended to a total of 250 ft. No other loads can be controlled or sup-
plied through this cable. It is for connection of the outdoor sensor ONLY. This low voltage
cable should 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.
Installation
LINE VOLTAGE ELECTRICAL CONNECTIONS
To determine the correct wire size required for the circuit feeding the
system, refer to the Specifications (Page A.01-A.03) and the system's
identification label located on the front of the electrical panel (Figure 17).
Step 1 Remove the electrical panel cover.
Step 2 Route all line voltage wires through a knockout and into the
electrical panel.
Step 3 Make line voltage connections (See Page 3.10) to lugs of single
feed bus and ground lug. Refer to the Line Voltage Wiring
Diagrams (Pages A.04 - A.05) for more information on these
connections.
SAMPLE SYSTEM IDENTIFICATION LABEL
FIGURE 17


HAZARDOUSVOLTAGE: Riskof
electric shock, injury or death.
Do not energize the system
until installation is complete.
Equipment MUST be installed
by a qualified technician in
accordance with all applicable
local, state, and national codes
and regulations.


Risk of equipment damage,
personal injury or fire. Do NOT
install any wiring in line
voltage compartment unless
rated for line voltage. To
ensure proper operation and
safety, all wiring in the line
voltage compartment MUST be
rated for line voltage.
WARNING
INSTALLATION3.11 THERMELECT
Use copper or aluminum conductors rated at
75oC or higher for line voltage field connection
of this device.