If area available to install Comfort
Plus Hydronic system is less than 100
square feet, consult factory. If installing in area with less than 400 square
feet, ventilation MUST be provided.
Temperature in area should be
maintained at or below 85oF.
Minimum Clearance Requirements
A Back and Right Side = 3 inches from
combustibles
B Front = 36 inches
C Top = 6 inches from combustibles
D Bottom = 1 inch from combustibles
E Left Side = 36 inches
3
Starting at the back of the brick core cavity,
load bricks one row at a time using left side,
right side, center pattern. Place bricks with
grooved side facing up, notch facing forward,
and ridges on left and right.
BRICK LOADING
Remove loose
debris from brick.
Brick rows MUST line
up front to back
and side to side.
Use half bricks in proper rows and in
correct positions. Back half of brick
MUST be installed in back rows. Front
half (notched brick piece) MUST be
installed in front rows.
Notch in Brick
E
F
r
C
FRONT VIEW
A
M
P
M
M
D
o
n
t
o
f
U
n
i
t
A
TOP VIEW
A
B
A
HALF BRICK
5120: Load in row 5
5130: Load in row 4 and 8
5140: Load in row 6 and 12
2
1.Place system in desired location.
2.Adjust leveling legs.
3.Remove painted front panel of brick
4.Position element wiring harnesses
5.Position brick core temperature
6.Remove galvanized front panel.
7.Starting at bottom, lift and drape
8.Remove front air channel by pulling
9.Remove heating elements from
DO NOT extend leveling legs
DO use and follow generally
Equipment MUST be installed by
Reference Owners and Installers
SET-UP
storage cabinet.
to avoid damage during brick
loading.
sensor(s) to avoid damage during
brick loading.
insulation blankets over top of
system.
out at top.
inside brick core cavity.
CACA
UTIONUTION
CA
UTION
CACA
UTIONUTION
more than one inch.
accepted safety practices when
handling insulation material.
a qualified technician in accordance with all applicable local,
state and national codes and
regulations.
Manual for complete safety,
installation, and operation
instructions.
Page 2
4
HAZARDOUS VOLTAGE: Risk of
electric shock, injur y or death.
DO NOT remove electrical panel
Elements MUST be positioned
Use care when making
HEATING ELEMENT INSTALLATION
WARNINGWARNING
WARNING
WARNINGWARNING
cover while system is energized.
properly to avoid short circuiting
them against any surfaces
within system.
connections to avoid element
damage.
Between Element Termination and
Metal Panels is
3
"
4
Required Clearance
1
3
" (
" Nominal).
4
2
1.Insert heating elements
between brick layers until
element ends embed into side
cutouts of brick cavity.
Elements MUST be installed
with threaded screw tabs on
wire connection terminals
pointing forward and down.
2.Remove painted panel from
electrical compartment and
locate the installation hard-
3
"
4
Element
Connection
ware package.
3.Connect wiring harnesses to
heating elements using
screws in hardware package.
Install screws with heads up
and thread pointing down.
Tighten screws to 14 in·lbs.
5
6
AIR CHANNEL INSTALLATION
1.Install air channel with air deflectors (arrow
shaped pieces) facing inward. Place bottom of air
channel in first.
2.Lower insulation blankets back into position, one
BRICK
CORE
SIDE VIEW
Outlet
Inlet
Front Air
Channel
Electrical
Panel
at a time. Tuck sides into edges, corners and
around exposed portions of heating elements.
3.Install galvanized front panel. Slide bottom edge
inside lower lip of brick cavity. Top rests on
outside of cavity.
4.Check non-insulated element connections to make
sure they do not come within 1/2" of any surface.
BRICK CORE TEMPERATURE SENSOR(S) INSTALLATION
WARNINGWARNING
WARNING
WARNINGWARNING
Risk of improper operation. Proper installation of the brick core temperature sensor(s) is critical to the
operation of the Comfort Plus Hydronic system. Read and follow installation instructions carefully.
1.Remove screw(s) by temperature sensor hole(s) in galvanized front panel.
2.Insert temperature sensor(s) through hole(s). Sensor(s) must pass through blanket insulation and into brick core.
3.Install screw(s) into galvanized front panel to hold sensor(s) and provide electrical ground connection.
4.Inspect sensor wiring for possible short circuiting hazards.
5.Install painted front panel.
NOTE: Models 5130 and 5140 have an upper and a lower temperature sensor. Each sensor is marked for proper installation.
Page 3
LINE VOLTAGE ELECTRICAL
Circuit Breakers
7
CONNECTIONS
WARNINGWARNING
WARNING
WARNINGWARNING
HAZARDOUS VOLTAGE: Risk of electric shock, injury or
death. Do not energize the Comfort Plus Hydronic system
until installation is complete.
1.Route all line voltage wires through knockout(s) and into electrical
panel.
2.Make proper field wiring connections.
To ensure proper operation and safety, all line voltage cir-
cuits must be segregated from low voltage wiring.
To reduce electromagnetic fields associated with electrical
circuits and to avoid induced voltage on sensors and electronic devices, the circuit phases MUST be alternated as
shown below.
DO NOT install any wiring in the line voltage compartment of
the Comfort Plus Hydronic system unless it is rated for line
voltage.
CIRCUIT PHASING CONNECTIONS
NEUTRAL CONNECTION FOR CONTROL CIRCUIT
CONTROLS CIRCUIT
CHARGE CIRCUIT #1
CHARGE CIRCUIT #2
CHARGE CIRCUIT #3
CHARGE CIRCUIT #4
(MODEL 5130 and 5140 ONLY)
LINE 1
LINE 2
To Service (Breaker) Panel
NEUTRAL
LUG
THIS MUST BE A 120/240V OR 120V/208V CIRCUIT
LINE 2
LINE 1
LINE 2
LINE 1
LINE 1
LINE 2
LINE 1
LINE 2
8
AIR CONDITIONER/HEAT
PUMP INTERFACE
The Air Handler (Order #1302100) is an optional
device used to interface the Comfort Plus
Hydronic with a ducted heating or cooling
system such as a heat pump or air conditioner.
The Air Handler includes a plenum assembly,
supply air blower, water coil, air filter, wiring
harness, and hardware kit. When the Comfort
Plus Hydronic system receives a heat call from
the room thermostat, it energizes the supply
blower and the Air Handler's zone pump.
The Air Handler can be interfaced with a
standard heat pump system and will provide
comfort modulation. The system will monitor
the outlet air temperature and modulate in heat
from the Comfort Plus Hydronic as needed to
maintain the desired output air temperature.
The maximum coil size the Air Handler can
accommodate through the front access is 20"
(W) x 22" (H) x 21 3/16" (D). The inner dimensions of the A-coil area are 21 3/16" (W) x 24 1/
4" (H) x 21 3/16" (D). If installing a coil larger
than the access dimensions, the coil must be
placed into the Air Handler during assembly.
WARNINGWARNING
WARNING
WARNINGWARNING
Risk of fire. Any one ducting system
MUST NOT contain more than one air
handling (blower) system. If the application requires multiple Comfor t Plus
heating systems or it is necessary to
have multiple air handlers share the
same ductwork, you MUST contact
Steffes Corporation. There are special
installation requirements that MUST be
performed in an application such as this.
9
JUNCTION BOX INSTALLATION
1. Attach the factory supplied junction
box to the left side of the Comfort
Plus Hydronic system.
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 pump. The
maximum connected amperage on
either of these circuits is 1.2 amps.
3 . Attach the junction box cover using
the screws provided.
Red & White To
Primary Loop Pump
(Max 1.2 AMPS)
Black & White To Air
Handler Pump (Max 1.2 AMPS)
These wires are located in the lower left
corner of the electrical compartment.
WHITE
OR
WHITE/BLACK
RED
BLACK
ORANGE
WHITE/BLACK
RED
BLACK
ORANGE
BLUE/WHITE
BLUE/BLACK
ORANGE
BLACK
WHITE/BLACK
WHITE
OR
EXCHANGER
LIMITS
225 °
N.C.
BLUE
BLACK/YELLOW
CORE
LIMIT
CORE
LIMIT
BLACK/YELLOW
75VA
TRANSFORMER
240v 24v
5120 Line Voltage
Wiring Diagram 240/208 Volt
Use copper or aluminum conductors rated at
75° C or higher for field connections of this device.
CORE BLOWER
BLACK
WHITE
250 °
N.C.
MANUAL
RESET
AUTO
RESET
L1
L2 120
L2 240
BLOWER
RESISTOR
RESISTER
DAMPER
BLACK/YELLOW
RED
ELEMENT 1 ELEMENT 2 ELEMENT 3 ELEMENT 4
COMNOCOM COM
1/4 Amp
L1
L2 120
RED
L2 240
EXPANSION
BOARD
#1
HIGH
COM.
4uf
Cap.
CONTROL CIRCUIT
NEUTRAL LUG
1/4 Amp5 Amp
COM COM
NO NO
NO
COM
SHRU
COM
NONONO
NO
COM
ELEMENT 5 ELEMENT 6
ELEMENT 7 ELEMENT 8
COM COM
NO NO
NO
COM
PRIMARY
LOOP PUMP
NO
COM
HEATING ELEMENTS
Element 8
Element 7
Element 6
Element 5
Element 4
Element 3
Element 2
Element 1
BLOWERS/
If NOT utilizing the optional Static Heat Recovery Unit, the orange wire can be used to power a secondary pump.
CONTROLS
CIRCUIT
BLACK
ToTo
Relays
2,4,6
GROUND
LUGS
CIRCUIT #2
CIRCUIT #1
CHARGE
CIRCUIT #3
CHARGE
CHARGE
60A60A15A60A
BLUE
RED
To
ElementElementElement
Relays
Relays
3,5,7
1,8
Page 4
10
Maximum Out let
PLUMBING
The Comfort Plus Hydronic heating system MUST be plumbed with a primary loop and secondary (zone) loops. The primary loop
needs to consist of a minimum of 10' of 1" pipe and requires its own pump* (circulator). The secondary (zone) loops require
additional pump(s) to operate effectively.
WARNINGWARNING
WARNING
WARNINGWARNING
FREEZE PROTECTION: Risk of property damage. Hydronic heating system freeze-ups WILL cause extensive
damage to the entire heating system and/or property. It is the responsibility of the installer to provide protection against freezing.
PIPING SUPPORT: Risk of equipment damage or personal injur y. DO NOT use the exchanger as support for
piping. Support of primary loop and associated plumbing must be installed to ensure proper operation of the
system and to keep pressure off the inlet and outlet piping.
PRIMARY LOOP
Piping MUST
Be Supported
Zone
Connection
Area
Pressure
Relief Valve
(Factory Supplied)
Optional
Temperature and
Pressure Relief Valve
(Consult Local Code)
(* Steffes recommends a Grundfos UP15-42F or equal single
speed 115VAC pump for the primary pump.)
Air Vent
Outlet
Air Separator
Inlet
Expansion
Tank
*Primary
Loop
Pump
Junction Box
(Factory Supplied)
See Note
Primary Loop Pump
Control Wiring
(White & Red)
PRESSURE DROP THROUGH
HEAT EXCHANGER
STATIC PRESSURE
(Feet Water Column)
Based on 80 degree entry
water temperature with
a 50% glycol mix.
.1 ft @ 2 GPM
.2 ft @ 4 GPM
.4 ft @ 6 GPM
.7 ft @ 8 GPM
1.1 ft @ 10 GPM
HEAT EXCH ANG ER S PECIF ICATION
C apacity 1. 2 Gall ons
Maximum Flow10 GPM
Tubing MaterialCopper
Water Set Temperature
NOTE: The primary loop pump MUST be con-
trolled by the furnace through the red
and white wires. When this pump is
running, water must be allowed to flow
through the heat exchanger.
180°F
White
Red
SINGLE TEMPERATURE ZONES
Secondary LoopPrimary Loop
This Valve Must
Be Open During
Normal Operation
Comfort Plus
Hydronic
Exchanger
White
Red
Primary
Loop Pump
Page 5
TYPICAL SYSTEM PLUMBING
(SHOWN WITH STEFFES AIR HANDLER)
White
Orange
Mixing
Valve
To
Other
Zones
Secondary Loop
Low Temp Radiant Zones
-
-
+
5100 Air
Handler
White
Black
High Temp
Water
CHECK
VALVE
From
Other
Zones
Primary Loop
This Valve Must
Be Open During
Normal Operation
Comfort +
Hydronic
Exchanger
White
Red
Primary
Loop Pump
It is the responsibility of the installer to prevent involuntar y flow of water to the air handler. Not doing
so may cause limit tripping and/or decrease system efficiency. Use of a check valve, zone valve, or
other device may help prevent involuntary flow.
11
PRESSURE RELIEF VALVE INSTALLATION
WARNINGWARNING
WARNING
WARNINGWARNING
Risk of explosion, injury, or death. The factory
supplied pressure relief valve MUST be
connected to the system with the supplied
fittings.
w DO NOT modify this assembly.
1.Remove the heat exchanger access panel and locate the
pressure relief valve assembly.
2.Using the supplied union fittings, connect the pressure relief
valve to the outlet water port on the left side of the Comfort
Plus Hydronic system.
3.Use schedule 40 pipe to install a discharge line for the pressure
relief valve.
4.Install heat exchanger access panel.
w DO NOT cap, plug, or otherwise
WARNINGWARNING
WARNING
obstruct the outlet of the pressure
relief valve.
w DO mount the pressure relief valve in
a vertical, upright position.
w This pressure relief valve is sized to
service the needs of the Comfort Plus
Hydronic system. If multiple heating
systems are being used, pressure
relief valving for the other system
MUST be provided separately.
Risk of 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.
wDO use schedule 40 pipe for the discharge line.
wDO NOT use schedule 80, extra strong pipe
or connections on the discharge line.
wDO NOT cap, plug, or otherwise obstruct the dis-
charge pipe outlet.
wDO follow all local, state, and national codes and
regulations.
WARNINGWARNING
Page 6
12
LOW VOLTAGE OUTDOOR SENSOR CONNECTIONS
If connecting to the Steffes power line carrier
system, follow the installation instructions in the
PLC systems Owners and Installers Guide.
Outdoor sensor wire MUST NOT be combined with
other control wiring in a multi-conductor cable.
Outdoor Sensor
Aux.
Peak
Relay
P2
To Control Board
Inputs
COM
Comfort Plus
P7
To Control Board
P8 P9
R C
NCAPNO
Outdoor
Outdoor
P1
Air
LV Circuit Board
AUX
W/
O
Y1
Y2 G
H/E2Y1CO22RP P
P11
D3D7D5
C3
R1
R2
P10
D6
RLY1
D4
Fid 2
Y2
R
Blower
J5
J6
P3
P4
Speed
C
A
B
D
W E
J3J1J2
J4
Y1 Y2
Water
D2
D1
P6
P5
Blower
The outdoor temperature sensor can be installed by wiring it
directly to the system or to the Steffes power line carrier
(PLC) system, if utilized.
Direct Wired:
1.Mount outdoor sensor in a location where it can accurately sense outdoor temperature.
2.Route low voltage wire from outdoor sensor to electrical
compartment:
Seal external wall openings.
Outdoor sensor lead can be extended to 250 ft.
Unshielded Class II (thermostat) wire can be used
provided it is segregated from any line voltage wiring.
3.Connect outdoor sensor wires to Outdoor positions on
low voltage terminal block.
13
LOW VOLTAGE PEAK CONTROL CONNECTIONS
1.Route low voltage circuit from the peak control device
to the terminal block.
2.Connect field wiring to positions RP and P.
If utilizing a Steffes Time Clock Module or Power
Line Carrier control, refer to the installation
instructions provided with the device.
14
LOW VOLTAGE ROOM THERMOSTAT WIRING
A 24 VAC thermostat must be used (digital recommended).
Peak
W/
AUX
RLY1
Fid 2
Y2 G
D6
D4
O
H/E
R
D3D7D5
J5
C3
R1
Y1 Y2
R2
D1
P10
Y2
Y1CO
2
22
Blower
J6
Speed
A
W E
P5
B
Blower
P3
P4
C
D
J3J1J2
J4
Water
D2
P6
To Control Board
Y1
P11
Outdoor
P2
Outdoor
P1
Air
Inputs
RP P
LV Circuit Board
Low Voltage Terminal Block Coding
RP = Peak Control Input Common
P = Peak Control Input
AP = Anticipated Peak (Pre-Peak) Control Input
COM = Peak Control Output Common
NC = Peak Control Output (Closed for Charge)
NO = Peak Control Output (Closed for Control)
SINGLE ZONE APPLICATION
Comfort Plus
P7
To Control Board
Dry Contact Peak
Control Switch
Aux.
Relay
COM
NCAPNO
P9
P8
RC
1.Disconnect power to Comfort Plus Hydronic system.
Route low voltage thermostat wire to the system.
2.Insulate thermostat wire wall opening if necessary.
3.Attach thermostat. When using a mechanical thermostat
or thermostat with anticipator, resistor kit #1190015 must
be installed to ensure proper operation.
4.Route low voltage wire into electrical compartment to
low voltage terminal block.
5.Install electrical panel cover.
Hydronic Heat Thermostat, Zone
Valve, End Switch, or Pump Control
The Y1/Y2 Jumper
must be installed
W/
P11
Y1AUXY2 G
RLY1
O
H/E
D3D7D5
C3
R1
R2
P10
D6
D4
Fid 2
Y1CO
R
2
Blower
J5
J6
P4
Speed
C
A
B
D
W E
J3J1J2
J4
Y1 Y2
D2
D1
P5
Blower
Y2
Water
P6
22
P3
Outdoor
P2
Air
To Control Board
Outdoor
P1
Peak
Inputs
RP P
Comfort Plus
LV Circuit Board
P7
To Control Board
Aux.
Relay
COM
NCAPNO
P8
RC
P9
Page 7
Honeywell TH5220D
Discha r g e Air
Temperature
Hydronic
Discha rge Air
Temperature
Hydronic
Aux
ELCGO/BRYRc
IMPORTANT
The Y1/Y2 Jumper must be installed
The W/E Jumper must be removed
Blower
Speed
W / E
ABC
Y1 / Y2
J1J2J3
J5
J6
Honeywell TH5220D
Aux
LY2
GCO/B
SINGLE STAGE HEAT PUMP APPLICATION
Hydronic Heat Thermostat, Zone
Valve, End Switch, or Pump Control
To Heat Pump
Y - Compressor
C - Low Voltage Common
R - Low Voltage Hot
O - Reversing Valv e
Outdoor Sensor
SI NG L E S T AG E HEAT P UM P
PeakAux.
Relay
P2P3
To Control Board
Inputs
APPRP
Outdoor
Outdoor
COMNCNO
P1
Air
Comfort Plus
LV Circuit Board
P7
To Control Board
P9P8
CR
W/
AUX
P11
D
Y1
D5 D7 D3
D6
RLY1
D4
Fid 2
H/E
OGY2Y12Y222O
RC
Blower
J6
J5
Speed
C3
CBA
D
R1
W E
J3J2J1
J4
Y1 Y2
R2
D2
D1
P10
P5
Blower
P4
Water
P6
Thermostat
Stage
Fan OnlyG0400 c fmHCFN/ A
Cool Y1/G/O1100%COOLN/A
Heat Control
Thermostat
Output
Pump
Stage
1Y1/G1100%HC1L048
2Aux/Y1/G1100%HC2L049
H/EN/AN/AHC3N/A
J4
Heat
% o f
Selected
CFM
Heat Call Status
on Digital
Display*
Contract or Us e O nl y
Target
* If multiple inputs are active, system will display highest Heat
Call values.
TWO STAGE HEAT PUMP APPLICATION
Hydronic Heat Thermostat, Zone
Valve, End Switch, or Pump Control
To Heat Pump
Y1 - Compressor
C - Low Voltage Common
R - Low Voltage Hot
Y2 - Compressor Stage 2
RYR c
O - Reversing Valve
Outdoor Sensor
IMPORTANT
The Y1/Y2 Jumper must be removed
The W/E Jumper must be removed
Blower
Speed
W / E
ABC
J1J2J3
D
J4
Y1 / Y2
J5
J6
STAND ALONE FURNACE APPLICATION WITH UNCONTROLLED AIR CONDITIONER
Honeywell
TH5110D
Rc
R
Y
C
W
G
W/
AUX
O
H/E
G
Y1
Y2
P11
D6
RLY1
D4
Fid 2
R
D3D7D5
Blower
J5
J6
Speed
C3
A
R1
W E
Y1 Y2
R2
D1
P10
P5
B
Blower
C
C
J3J1J2
D
J4
D2
Y2
Y1
2
P4
Water
P6
O22RP P
P3
P2
To Control Board
*If multiple inputs are active, system will display highest Heat Call values.
** Systems built before 1/1/2011 are configured for 50% airflow in Stage 1. For more
information, refer to Instruction #1200601-High Speed Stage 1 Relay Installation.
Hydronic Heat Thermostat, Zone
Valve, End Switch, or Pump Control
Outdoor
P1
Air
Inputs
Outdoor
LV Circuit Board
Peak
Comfort Plus
P7
To Control Board
Aux.
Relay
COM
P8 P9
R C
TW O STAGE HEAT PUM P
NCAPNO
Thermostat
Stage
Thermostat
Output
Heat
Pump
Stage
% o f
Selected
CFM
Heat Ca ll
Status on
Digital Displa y*
1Y 1/ G150% or 70%**HC1L048
2Y1/Y2/G2100%HC1L048
3Aux/Y1/Y2/G2100%HC2L049
Fan OnlyG0400 cfmHCFN/ A
Cool 1Y1/G/ O150% or 70% * *COOLN/A
Cool 2Y1/Y2/G/O2100%COOLN/A
Heat Control
H/EN/AN/AHC3N/A
If installing a mechanical thermostat or
thermostat with anticipator, a resistor
kit is required (Order Item #1190015).
Y
C
Air Conditioner Connections
(If being used in the application)
Target
Contract or Us e Onl y
IMPORTANT
The Y1/Y2 Jumper must be installed
The W/E Jumper must be removed
W/
AUX
H/E
O
Y2 GY1
P11
D3
D7D5
R1
R2
D6
RLY1
D4
Fid 2
Blower
J5
J6
Speed
C3
C
W E
J1J2J3
Y1 Y2
D1
P10
P5
Blower
O
Y2Y1
CR
22
P3
P4
DAB
J4
Water
D2
P6
Outdoor
P2
Air
To Control Board
P1
RP2APP
Outdoor
LV Circuit Board
Comfort Plus
P7
To Control Board
COM
P8
R
NO
NC
P9
C
Inputs
Blower
Speed
W / E
ABC
J1J2J3
D
J4
Y1 / Y2
J5
J6
Aux.
Peak
Relay
Page 8
15
SOFTWARE CONFIGURATION
The Steffes Comfort Plus Hydronic system has a Configuration
Menu, which allows it to be customized to the power company
and consumers needs. This menu can be accessed on startup and allows configuration settings to be easily adjusted.
If access to Configuration Menu times out, the 15
amp circuit breaker must be powered off and back
on to re-enter the menu.
Accessing the Configuration Menu
Step 1Energize the system. Access to the Configuration
Menu is allowed for the first two (2) minutes of
operation. If the system has been energized for
over two (2) minutes, it must be powered off and
back on again.
Step 2Press and release the M button until the faceplate
displays CONF.
Step 3Press the up arrow once and the faceplate will
display C000. The display will flash between
C000 and the corresponding configuration value.
In most applications only a few, if any, configuration changes will be necessary. Following is a description of the configuration
settings and their functions:
Step 4If necessary, edit the configuration by pressing and
holding the M button while using the up or the down
arrow button to change the value.
Step 5Once the value is correct, release the buttons and
press the up arrow button to go to the next
configuration (C001, C002, etc.).
Step 6Repeat steps 4 through 5 until all configuration
settings have been adjusted to the desired values.
Step 7Once configured, use the down arrow to leave the
Refer to the Tim e Clock
Instal l at ion Instructions
No Ou tdoor
Sensor
Line Volt age Peak
Control
Outdoor
Sensor
No
Outdoor
Sensor
* Risk of high temperature w at er . Can c ause property damage. I m pr oper w ater temperat ure settings can result in damage t o the floor
cover ing. Make sure the maximum and minimum water temper at ures (C011 and C012) are appr opr iate for the appl icat ion
3050 Hwy 22 North w Dickinson, ND 58601-9413 w www.steffes.com
Part No. 1200284-4
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