Steffes 7140 User Manual

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"Manufactured in North America"

COMFORT PLUS COMMERCIAL

HYDRONIC HEATING SYSTEM

Owners and Installers Manual

Models: 7120, 7130 & 7140

Applicable to Software Version 2.0X

Page 2

IMPORTANT

w The equipment described herein is intended for installation by a qualified

technician in compliance with applicable local, state, and national codes and requirements.

w 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.

w This manual should be retained by the owner upon completion of the installa-

tion and made available to service personnel as required.

w 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.

After the heating system is installed, 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 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 identification label located on the lower left side of the Comfort Plus Commercial 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.

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SAFETY PRECAUTIONS

1. DO NOT energize this heating system while disassembled or without the ceramic heat storage brick in place.

2. DO NOT operate this heating system without the factory provided pressure relief valve in place.

3. DO NOT use or store materials that may produce explosive or flammable gases near the system.

4. DO NOT violate the placement and clearance requirements specified in this manual. (Page 3.02-3.03)

5. DO NOT place anything on top of the 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.

8. Installation of and/or service to this system should be performed by a qualified technician in compliance with information contained herein and with national, state, and local codes and requirements.

9. A repeated message display of CORE FAIL indicates a need for service by a qualified technician.

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 fittings. DO NOT modify this assembly. DO NOT cap, plug, or otherwise obstruct the outlet of the pressure relief valve.

Risk of fire. Can cause injury or death. Violation of the clearance requirements can cause improper operation of the equipment. Maintain the placement and clearance requirements specified.

Risk of personal injury. Plumbing and other surfaces can be hot. Use caution when working near the system.

SAFETY DEVICES

The Comfort Plus Commercial Hydronic incorporates safety devices to ensure normal operating temperatures are maintained. The chart below describes these safety devices:

DEVICE NAME FUNCTION

Core Charging High Limit Switches (Auto Reset)

Heat Exchanger Limit Switch (Manual Reset)

These limit switches monitor brick core charging and interrupt power to the heating elements if the normal operating temperature is exceeded.

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 250 this limit switch opens, contact a qualified service technician.

Outlet Water Temperature Limit Switch (Auto Reset)

Pressure Relief Valve

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 225

If the water pressure exceeds 75 psig, the pressure relief valve opens. Once water pressure of less than 75 psig is achieved, the valve closes. (30 psig option available.)

F is exceeded. If

F is exceeded.

LOCATION

ON SYSTEM

In the limit bar panel on the left side of the brick storage cavity.

Inside base on left side.

Factory provided, field installed to outlet port of furnace.

Comfort Plus Commercial Hydronic Safety Information

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Table of Contents

Operation

General Operation .................................................................................................................................................................. 1.01

System Use During Construction Phase ................................................................................................................................ 1.01

System Start-up...................................................................................................................................................................... 1.01

Turning System "OFF" and "ON" ......................................................................................................................................... 1.01

Control Panel ......................................................................................................................................................................... 1.02

Operating Status .................................................................................................................................................................... 1.02

Temperature Control .............................................................................................................................................................. 1.03

Brick Core Charge Control ..................................................................................................................................................... 1.03

Charge Control Override ........................................................................................................................................................ 1.03

Maintenance and Cleaning .................................................................................................................................................... 1.03

Optional Accessories

Single Electrical Feed Kit ....................................................................................................................................................... 2.01

Primary Loop Kit .................................................................................................................................................................... 2.01

Static Heat Recovery Unit ...................................................................................................................................................... 2.01

18 "Stand ............................................................................................................................................................................... 2.02

Air Handler - Variable Speed .................................................................................................................................................. 2.02

Load Managment Control ...................................................................................................................................................... 2.03

SCR Controller ....................................................................................................................................................................... 2.04

External Duct Sensor .............................................................................................................................................................. 2.04

Control Circuit Step-Down Transformer ................................................................................................................................ 2.04

Installation

Shipping and Packaging ........................................................................................................................................................ 3.01

Placement and Clearance Requirements.......................................................................................................................... 3.02-3.03

Initial Set-up ........................................................................................................................................................................... 3.03

Brick Loading ......................................................................................................................................................................... 3.04

Heating Element and Air Channel Installation ................................................................................................................ 3.04-3.05

Brick Core Temperature Sensor Installation ........................................................................................................................... 3.05

Line Voltage Electrical Connections ............................................................................................................................... 3.06-3.07

Low Voltage Electrical Connections

Peak Control ............................................................................................................................................................ 3.07-3.08

Outdoor Temperature Sensor ......................................................................................................................................... 3.08

Room Thermostat .................................................................................................................................................... 3.09-3.10

Air Conditioner /Heat Pump Interface .................................................................................................................................... 3.10

Pressure Relief Valve Installation ........................................................................................................................................... 3.11

Plumbing ......................................................................................................................................................................... 3.11-3.13

Auxiliary Load Control ........................................................................................................................................................... 3.13

Configuration Menu ....................................................................................................................................................... 3.14-3.15

Installer's Final Check-out Procedure ..................................................................................................................................... 3.16

Appendix

Specifications ............................................................................................................................................................... A.01-A.02

Disassembling the Comfort Plus Commercial Hydronic System ........................................................................................... A.03

Internal System Wiring Diagrams - Line Voltage ......................................................................................................... A.04-A.09

Internal System Wiring Diagram - Low Voltage ........................................................................................................... A.10-A.15

Help Menu ............................................................................................................................................................................ A.16

Error Codes .................................................................................................................................................................. A.16-A.17

Glossary ................................................................................................................................................................................ A.18

Warranty

Table of Contents Comfort Plus Commercial Hydronic

Page 5

Operation

GENERAL OPERATION

The Comfort Plus Commercial Hydronic system stores demand free or off-peak electricity in the form of heat.

Operation of the heating system is automatic. During hours when energy costs are lower 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 system varies in relation to outdoor temperature, current building load, utility peak conditions, and/or the heating requirements.

A heat call from the thermostat or main system control energizes the primary water loop pump. The variable speed core blower automatically adjusts its speed to achieve the desired outlet water temperature. The heated water is then pumped to the area (zone) from which the heat call originated.

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 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 must be used during the construction phase.

Operation

SYSTEM START-UP

On start-up of the Comfort Plus Commercial Hydronic, odors relating to first time operation of the heating components may be experienced. Allow the system to charge to its maximum brick core charge level, on start-up, to expel these odors. If the system has not been used for an extended period of time, dust may accumulate in the 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"

The system is fully automatic and does not need to be manually disabled. Talk to your installer or energy management person for additional information.

Comfort Plus Commercial Hydronic Operation n 1.01

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CONTROL PANEL

Operation of the Comfort Plus Commercial Hydronic 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.)

AA MM

PP MM

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.

Operation

AM and PM Indicator Lights

CONTROL PANEL

FIGURE 1

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

Editing operating information may alter the performance and operation of the system.

CAUTION

operating functions.

Interface Port

FOR SERVICE USE ONLY! Allows technician external access for updating software and troubleshooting.

OPERATING STATUS

The Comfort Plus Commercial Hydronic 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

A bar illuminates on the lower portion of the display's second digit whenever one or more heating elements are energized.

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 thermo-

stat. Refer to pages 3.11 and 3.12 for more information on heat call inputs.

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 represents 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:_ indicates 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 demand of 750kW.

Operation n 1.02 Comfort Plus Commercial Hydronic

Page 7

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 primary loop pump is energized. The variable speed core blower automatically adjusts speed in relation to brick core temperature to achieve the desired outlet water temperatures. The heated water is then pumped to the area (zone) from which the call originated.

The versatility of this system allows it to fit many applications. The Comfort Plus Commercial Hydronic is designed for use as either the sole heating source (stand alone furnace) or as a supplement to ducted heating systems such as heat pumps.

The Steffes 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 Commercial Hydronic as needed to maintain the desired output air temperature. If one of the zones is a water coil used to temper duct temperatures, an optional duct sensor (Order Item# 1041536) can be used.

BRICK CORE CHARGE CONTROL

The amount of heat stored in the brick core varies in relation to outdoor temperature, current building load, utility peak conditions, and/or the heating requirements. The outdoor sensor, if installed, 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.

The amount of heat stored in the system can also be regulated by a signal from a BACnet control, energy management system, or serial communication input.

CHARGE CONTROL OVERRIDE

If desired, the Comfort Plus Commercial Hydronic 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.

Operation

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 Comfort Plus Commercial Hydronic 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.

Comfort Plus Commercial Hydronic Operation n 1.03

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Optional Accessories

SINGLE ELECTRICAL FEED KIT

The Steffes Comfort Plus Commercial systems have built-in circuit breakers. They are factory configured to be field connected to multiple line voltage circuits. If single feed to the element and blowers/control circuits is desired, the single feed kit is available to allow the system to be powered with a one, larger line voltage circuit. Contact the factory for ordering details.

When using single feed, the neutral conductor MUST be sized in

208/240 Volt Only

accordance with all applicable local, state, and national codes and regulations.

PRIMARY LOOP KIT

The Comfort Plus Commercial Hydronic system requires a primary water loop which serves to regulate heat transfer from the units heat exchanger. To minimize installation time and costs for field design and engineering of this loop, Steffes Corporation offers a primary loop kit. The kit contains the components generally installed with hydronic heat systems.

Features:

Accessories

w Includes a 5-gallon diaphragm type expansion tank, Grundfos brand pump

(circulator), air separator, air vent, pressure gauge, and pump connection conduit and fittings.

w Contains the appropriate valves to bleed air from the system during filling along

with automatic purge during system operation and draining.

w Incorporates isolation flanges for quick and easy servicing of the primary loop

pump (circulator).

Order Item #1302115

w Offers troubleshooting isolation between the heating system and secondary

zones.

STATIC HEAT RECOVERY UNIT

In applications using the Steffes Air Handler, the static heat recovery unit would not be used.

During operation of the Comfort Plus Commercial Hydronic system, some heat from the brick core storage will radiate through its outer panels. If the system is located in an area with minimal heating requirements, such as a utility room, the static heat recovery unit can maximize the systems efficiency by transferring this static heat to a more desirable location.

Features:

w Connects directly to the Comfort Plus Commercial Hydronic system to

interface with the internal controls of the system for automatic operation.

w Specifications:

3.312

10.135

3.000

 Wattage: 130 WATTS  Motor: .1 HP, 60 HZ  Voltage: 208/240 VAC

10.072

7.875

 Maximum Static Pressure: .15 inches Water Column  CFM @.15 SP: 130 CFM

If the area available to install the Comfort Plus Commercial Hydronic system is less than 100 square feet, Steffes Corporation recommends installing a low voltage cooling thermostat, connected between R and G on the 12-position terminal block, to maintain a temperature less than 85 degrees Fahrenheit.

Optional Accessories n 2.01 Comfort Plus Commercial Hydronic

Order Item #1302110

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18" STAND

Some applications (such as garages) may require that the heating appliance be elevated in order to meet building codes. The 18" stand can be used to elevate the 7140 series Comfort Plus Commercial Hydronic system. It is shipped as a kit and requires field assembly. Support for the optional air handler is not provided.

Order Item #1301585

Stand

AIR HANDLER - VARIABLE SPEED

The Steffes Air Handler includes a return plenum, supply air blower, water coil, and air filter.

The air handlers variable speed blower incorporates an ECM motor that automatically adjusts its speed to achieve the appropriate CFM for the thermostat input received. Benefits include:

w Quieter operation w Better dehumidification w Offers greater operating efficiency by consuming 25% less

energy during normal operating mode which provides for operating cost savings to the consumer. In continuous fan mode, low speed energy savings can be greater than 70% in comparison to a standard fixed motor speed.

w Interfaces with single or multi-speed air conditioner or heat

pumps. With multi-speed systems, it operates at the lower speed most of the time. Only on extremely hot and cold days does it operate at a higher speed. This staged heating and cooling eliminates temperature swings, enhances comfort and optimizes efficiency.

w Improved air filtration in continuous fan mode w Constant air flow over a wide range of static conditions, even if filters are dirty or registers are closed.

Accessories

Order Item Number 1302132 1302134 Approximate Weight 200 lbs 228 lbs Maximum Static Pressure (inches water column) Maximum Water Coil Output 60,000 BTU/hr 90,000 BTU/hr Maximum Outlet Temperature 120oF 120oF A-Coil Tray Dimensions (HxWxD) Voltage 240/208 VAC 240/208 VAC Wattage 560W 1,050W CFM ratings 1000, 1200, 1400, 1600 1200, 1400, 1600, 2000

w ½ HP variable speed accommodates most 1.5 to 4 ton heating/cooling systems

½ HP, 60 HZ

Variable Speed ECM

Air Handler

.75 inches H

30” x 22 5/16” x 22 3/4” 33” x 25 5/16”x 22 3/4”

0 .75 inches H20

1 HP, 60 HZ

Variable Speed ECM

Air Handler

w 1 HP variable speed accommodates most 3 to 5 ton heating/cooling systems

Comfort Plus Commercial Hydronic Optional Accessories n 2.02

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LOAD MANAGEMENT CONTROL

The Comfort Plus Commercial Hydronic system is an Electric Thermal Storage (ETS) heating system using 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 Comfort Plus Commercial's thermal mass consists of a high-density ceramic brick capable of vast heat storage.

The system is designed to operate under one of three different load management control strategies.

1. BACNet Control

Steffes commercial heating furnaces are available with a BACNet control option. This device is easily integrated into most building automation systems to provide building managers full control and visibility of the heating systems operation. BACNet allows the following functions to be monitored with simple, twisted pair communication:

· Real time system monitoring

· Full thermostat control

· Monitoring of heat storage levels in the brick and all system temperatures

· Remote configuration, testing and adjustment

· Service requirement alerts

2. On-Peak/Off-Peak Program

System responds to heat calls during the on-peak and off-peak periods; however, only energizes heating elements during the off-peak periods. The Comfort Plus Commercial system is controlled by an external control device such as a meter or time clock module.

Accessories

3. 4-20 Milliamp Control (1-5 volt DC)

System receives a signal from an external load control device such as a building load management system. This external signal dictates the maximum amount of energy which can be consumed during a preset time interval.

Order Item #1301015

BACNET

4. Pulse Monitoring

a) 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 Comfort Plus Commercial system. The system then charges 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 are available when using pulse

monitoring load control. Each module has eight (8) zones which can be controlled. The system must be configured to recognize the number of load management modules installed (maximum of two per system).

LOAD MANAGEMENT

CONTROL MODULE

Order Item #1908140

Optional Accessories n 2.03 Comfort Plus Commercial Hydronic

Page 11

SCR CONTROLLER

The Steffes SCR (Solid State Relay Panel) is an optional control device used with the Steffes ThermElect (8100 and 9100 Series) and Comfort Plus Commercial (6100 and 7100 Series) Heating Systems. It utilizes SCR technology to enable more precise balancing of a buildings overall electric load by varying the amount of total element input that can be energized in a Steffes furnace at any given time in relation to the maximum allowable building load. The Steffes SCR optimizes a buildings power quality and control.

The SCR Controller can only accept input signals from the Steffes furnace but it can respond to all types of control inputs to include 4  20 Milliamp, 1  5 Volt DC, electric meter pulsing, Bacnet or any building energy management system. With the 4  20mA or 1  5 volt DC signals, the SCR will provide an output directly proportional to the input signal. 4mA signal produces 0% output while 20mA signal products 100% output. With the utility pulse meter input, the SCR output percentage will automatically adjust to maintain a total maximum system load as dictated by the furnaces set-up. With a Bacnet, the furnace can be commanded to varying input levels remotely.

SCR CONTROLLER

Order Item #1301016

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 Comfort Plus Commercial Hydronic system monitors temperature at both the duct sensor and the output sensor during Y, W, or E calls from the thermostat.

If there is a Y and a G call from the thermostat, the system operates the core blowers at the required speed to maintain the minimum output temperature 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 blowers 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 blowers if the output temperature at the output sensor exceeds 150 degrees Fahrenheit.

CONTROL CIRCUIT STEP-DOWN TRANSFORMER

The internal controls and motors of all Comfort Plus Commercial Hydronic systems operate at 240 volts (two wire). In systems with 277/480 or 347/600 volt element circuits, a transformer must be installed per the installation instructions to supply this voltage to the systems controls. This transformer can be purchased as an optional device from Steffes Corporation or sourced from your local electrical supply outlet. See the matrix below for proper sizing.

Model

277/480V 347/600V



Primary

Voltage

480 240 2 HS1F1BS or equal 1017082 600 240 2 HS10F2AS or equal 1017080

Secondary

Voltage

KVA

Hevi Duty Item #

Steffes Item #

Accessories

Comfort Plus Commercial Hydronic Optional Accessories n 2.04

Page 12

Installation

CAUTION

Risk of sharp edges. Can cause personal injury. Use caution when installing and/or servicing equipment.

SHIPPING AND PACKAGING

The Comfort Plus Commercial Hydronic 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:

INFORMATION PACKAGE

(includes Owner's Manual and

Warranty Registration Card)

(adhered to outer side of

shipping box)

OUTDOOR

TEMPERATURE SENSOR

HEATING ELEMENTS

MODEL ELEMENTS

7120 8 7130 12 7140 16

(shipped inside the brick core)

Refer to Pages 3.04-3.05

JUNCTION BOX

ELEMENT SCREW KIT

(shipped inside the

electrical compartment)

Refer to Pages 3.04-3.05

PRESSURE RELIEF

VALVE KIT

(shipped inside the electrical

compartment)

Installation

7 8

Installation n 3.01 Comfort Plus Commercial Hydronic

Refer to Pages 3.08

CERAMIC BRICK

Full Brick

(shipped separately and

packaged 4 brick per box)

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

7120 26 Boxes 1 Box 7130 37 Boxes 2 Boxes 7140 49 Boxes 2 Boxes

See Figure 4, Page 3.04

(shipped behind the

exchanger access panel)

See Figure 10, Page 3.07

TRANSFORMER WIRING HARNESS

(shipped in electrical panel)

(277V & 347V

SYSTEMS ONLY)

(shipped behind the

exchanger access panel)

Refer to Page 3.11

Page 13

PLACEMENT AND CLEARANCE REQUIREMENTS

The physical dimensions (Figure 2) of the Comfort Plus Commercial Hydronic system along with the clearances required (Figure 3) MUST be taken into consideration when choosing its location within a structure. The best installation location for this 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 system. Standby heat dissipation of up to 2.5kW can be experienced in normal operation.

The minimum area required for the installation is 100 square feet. This area must remain free of debris and room air should be maintained at less than 85° Fahrenheit. If the system is being installed in an area with less than 400 square feet, ventilation MUST be provided. If less than 100 square feet, thermostatically controlled ventilation MUST be provided.

MODEL 7100 DIMENSIONS

FIGURE 2

MINIMUM CLEARANCE REQUIREMENTS

Risk of fire. Can cause injury or death.

w Violation of the clearance require-

ments or failure to provide proper ventilation can cause improper operation of the system. Maintain the placement and clearance requirements as specified and provide ventilation as necessary.

w Moving the system after install

may result in equipment damage. Do NOT move system from original installed location.

WARNING

w Back and Right Side = 3 inches (from combustible material) w Bottom = 1 inch clearance w Top = 6 inches (from combustible material) w Front = 36 inches (for ease in servicing) w Left Side = 36 inches (for ease in servicing)

7140

Front View

7130

7120

MODEL 7100 REQUIRED CLEARANCES

FIGURE 3

3" REQUIRED

CLEARANCE

6" REQUIRED CLEARANCE

Installation

TOP VIEW

FRONT VIEW

36" REQUIRED

CLEARANCE

36" REQUIRED CLEARANCE

3" REQUIRED

CLEARANCE

36" REQUIRED

CLEARANCE

A M

P M

STEFFES

3" REQUIRED

CLEARANCE

TEFFES

ELECTRIC THERMAL STORAGE

1" REQUIRED

CLEARANCE

Minimum clearance requirements do NOT account for space needed for making electrical connections. If utilizing, the Air Handler, an additional 24-27 inches is required on the right hand side of the system.

Comfort Plus Commercial Hydronic Installation n 3.02

Page 14

If the Comfort Plus Commercial Hydronic is installed in an area where radiant heat coming from the system is undesired or where room temperatures may reach 85° Fahrenheit or greater, it is strongly recommended to install a Static Heat Recovery unit or Air Handler. Refer to pages 2.01-2.02 for information on these options.

In addition to the physical space requirements, the weight of the Comfort Plus Commercial Hydronic must be taken into consideration when selecting the installation surface. A level concrete floor is the best installation surface, but most well supported surfaces are acceptable. If unsure of floor load capacity, consult a building contractor or architect.

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.

INITIAL SET-UP

Step 1 Remove the Information Package from the outside of

the shipping box and unpackage the Comfort Plus Commercial Hydronic heating system.

Step 2 Move the heating system into its installation location.

To ensure proper operation, read and follow installation instructions carefully.

w DO NOT install the Comfort Plus

The Comfort Plus Commercial Hydronic is capable of fitting through a 30" doorway (minimum) without disassembling. If it is necessary to disassemble the system, refer to the disassembly instructions (Page

w DO NOT extend the leveling legs

w DO use and follow generally

A.03) in this manual.

Step 3 Once in place, adjust the leveling legs on the bottom of

the system as necessary to prevent rocking. If not

w DO have equipment installed by a

placed properly the system may bend or twist during the brick loading process, making element and brick core temperature sensor installation difficult.

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 Locate the element wiring harnesses and the two brick core temperature sensors behind the front panel

and disconnect them from their shipping position. Carefully position them to avoid damage during brick loading.

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

Installation

top of the system.

IMPORTANT

Commercial Hydronic system on its shipping pallet.

more than one inch.

accepted safety practices when handling insulation material.

qualified technician in compliance with all applicable codes and regulations.

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.

Installation n 3.03 Comfort Plus Commercial Hydronic

Page 15

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, the notch is facing forward, and the ridges are on the left and right. (See Figure 4.)

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 side to

side.

 Half brick makes brick loading easier by evening out

the stacks. Use HALF BRICK (white boxes) in the proper rows and positions as indicated in Figure 4. The back half of the brick MUST be installed in the back row and the front half (the notched brick piece) MUST be installed in the front row.

Risk of fire. Can cause personal injury or death. DO NOT operate the Comfort

WARNING

Plus Commercial Hydronic system if damage to the insulation panels on the inner sides of the brick core occurs.

BRICK LOADING

FIGURE 4

Notch in Brick

HALF BRICK

7120: Load in row 5

7130: Load in row 4 and 8

7140: Load in row 6 and 12

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.

The elements MUST be installed so their threaded screw tabs on the wire connection terminals point forward and down. If they are installed with the screw tabs

HAZARDOUS VOLTAGE: Risk of electric shock. Can cause injury or death. w DO NOT remove the electrical panel cover while

system is energized.

w Position elements properly to avoid short circuiting

them against metal surfaces.

w Protect element lead wires from front panel screws and

any field installed screws to avoid short circuit.

pointing upward, element-to-wiring harness connections will be difficult. Elements must be slid into the brick core properly to ensure correct clearance between the terminal connections and any surfaces within the system. Refer to the required element connection clearance information in Figure 5.

In the 277/347 Comfort Plus Commercial Hydronic systems, the sixth element position up from the bottom of the furnace is left open.

ELEMENT INSTALLATION

WARNING

FIGURE 5

TOP VIEW

Installation

Step 2 Install the front air channel with the air deflectors

(arrow shaped pieces) facing inward and with the narrow ends of the deflectors pointing up. Place bottom portion in first (Figure 6).

Comfort Plus Commercial Hydronic Installation n 3.04

Required Clearance Between

Element Termination and Metal

Panels is 1/2" (3/4" Nom inal)

Element Con n ec tio n

Page 16

Step 3 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

AIR CHANNEL PLACEMENT

FIGURE 6

exposed portions of the heating elements to ensure maximum efficiency.

Step 4 Reinstall the galvanized front panel and secure it

to the system using the screws that were originally removed. Slide the bottom of this panel inside the lower lip of the brick cavity. The top

BRICK

CORE

SIDE VIEW

Front Air

Channel

rests on the outside of the cavity.

Step 5 Remove the electrical panel cover and locate the

element screw kit.

Step 6 Carefully route wiring harnesses and connect

them to the heating elements, using screws provided in the hardware package. Make con-

Outlet

Inlet

Electrical

Panel

nections with screw heads up and threads pointing down. Element screws should be tightened to 20 inch lbs. Refer to Element Installation (Figure

5) for proper positioning.

Step 7 The brick core temperature sensor must be installed prior to putting the painted front panel in place.

BRICK CORE TEMPERATURE SENSOR INSTALLATION

Step 1 Remove the screws by the brick core temperature sensor holes in the

galvanized front panel.

CAUTION

Model 7120 has one brick core temperature sensor and Models 7130 and 7140 each have an upper and a lower brick core temperature sensor.

Step 2 Insert the brick core temperature sensors through the holes in the

galvanized front panel. Be sure the sensor(s) are connected to the relay driver board (Figure 7) as shown below. The sensor must pass through the blanket insulation and into the brick core. Holes have not been predrilled through the insulation. Use the sensor(s) to aid in making a passageway by rotating them side-to-side while gently pushing inward.

7120

7130

7140

Installation

} Upper Core

} Lower Core

Step 3 Once the brick core sensor(s) are installed, put the screws back

into position in the galvanized front panel to hold the sensors in position and to provide the electrical ground.

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.

Risk of improper operation. Proper installation of the brick core temperature sensor is critical to the operation of the heating system. Read and follow installation instructions carefully.

FIGURE 7

} Upper Core } Middle Core } Lower Core

Step 5 Re-install painted front panel using previously removed screws.

Installation n 3.05 Comfort Plus Commercial Hydronic

Page 17

LINE VOLTAGE ELECTRICAL CONNECTIONS

In standard configuration, the system is wired for connection to

WARNING

HAZARDOUS VOLTAGE: Risk of electric shock. Can cause injury or death. Do not energize the system until installation is complete. Equipment MUST be installed by a qualified technician in compliance with all applicable local, state, and national codes and regulations.

240V; however, the element circuits can also be connected to 208V. A 208V connection derates the charging input of the system by 25%. If a system rated specifically for 208V is required, contact the factory. The controls circuit in the system MUST be connected to 240V/208V.

277/480V and 347/600V Comfort Plus Commercial systems are configured to use single feed only.

IMPORTANT

208/240V System Connections Only: The 60 amp breakers located in the electrical compartment feed the core charging (element) circuits. The 15 amp breaker feeds the controls and blowers circuit. All 240V/208V systems are factory configured to be field 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.

277/480V and 347/600V System Connections Only: The fuse block connection points and neutral connection block, located in the line voltage side of the electrical compartment, feed the core charging (heating element) circuits. This also provides power and the terminal block connections for the primary side of the optional control voltage step-down transformer. Adjacent to these terminals are the connection points for the transformer secondary. See Figure 9B.

w To ensure proper operation and

safety, all line voltage circuits must be segregated from low voltage wiring in the system.

w To reduce electro magnetic fields

associated with electrical circuits and to avoid induced voltage on sensors and electronic devices, the circuit phases MUST be alternated as shown in Figure 9A.

To determine the correct wire size required for each circuit feeding the system, refer to the Specifications (Page A.01-A.02) and the system's identification label located on the lower left side of the system. (Reference Sample Label Figure 8.)

Step 1 Route all line voltage wires through a knockout and into the electrical panel.

Step 2 Make proper field wiring connections to the Comfort Plus Commercial system. Refer to the Line Volt-

age Wiring Diagrams (Pages A.04 - A.09) for more information on these connections.

SAMPLE SYSTEM IDENTIFICATION LABEL

FIGURE 8

CIRCUIT PHASING CONNECTIONS

208/240 SINGLE PHASE

FIGURE 9A

BLOWERS/CONTROLS CIRCUIT

CHARGE CIRCUIT #1

CHARGE CIRCUIT #2

CHARGE CIRCUIT #3

CHARGE CIRCUIT #4

LINE 2

LINE 1

LINE 2

LINE 1

LINE 2

LINE 1

LINE 2

LINE 1

LINE 2

To Service (Breaker) Panel

277/480V AND

347/600V THREE

PHASE

FIGURE 9B

Circuit Breakers

Installation

The 60 AMP breakers are for internal component protection only. Sizing of the field wire and breaker size MUST be in compliance with all applicable local, state, and national codes and regulations.

Comfort Plus Commercial Hydronic Installation n 3.06

Page 18

JUNCTION BOX INSTALLATION

LINE VOLTAGE WIRING DIAGRAM

Step 1 Attach the factory supplied

FIGURE 10

junction box to the left side of the Comfort Plus Hydronic Commercial system as shown in Figure 16 (Page 3.12).

Step 2 Make connections to the

Red & White To Primary

Loop Pump (Max 1.2 AMPS)

Black & White To Air Handler

Pump (Max 1.2 AMPS)

primary loop pump and air handler pump inside this junction box. The red and

These wires are located in the lower left

corner of the electrical compartment.

white wires connect to the primary loop pump and the black and white wires connect to the air handler pump. (See Figure 10.) The maximum connected amperage on either of these circuits is 1.2 amps.

Step 3 Attach the junction box cover using the screws provided.

If utilizing the optional air handler, the orange wire can be used with the white wire to power a secondary pump for hydronic zones.

WHITE

WHITE/BLACK

RED BLACK

ORANGE

7120 Line Voltage

Wiring Diagram 208/240 Volt

Use copper or aluminum conductors rated at

75° C or higher for field connections of this device.

EXCHANGER LIMITS

WHITE

OR WHITE/BLACK

RED

BLACK ORANGE

To Optional Air Handler

BLUE/WHITE BLUE/BLACK

ORANGE BLACK

To Optional Static

Heat Recovery System

225 °

BLACK/YELLOW

N.C.

BLUE

250 ° N.C.

MANUAL

RESET

AUTO RESET

BASE IO BOARD

Element

BLACK

WHITE

L1 L2 120 L2 240 BLOWER

RESISTOR RESISTER DAMPER

RED

BLACK/YELLOW

CORE BLOWER

HIGH

4uf

Cap.

COM.

5 Amp5 Amp

1/4 Amp1/4 Amp

Element

CONTROL CIRCUIT

NEUTRAL LUG

TRANSFORMERS

240v / 24v

BLOWERS/

CIRCUIT

CIRCUIT #1

CONTROLS

COMCOM

NONO

COMCOM

PRIMARY

SHRU

LOOP PUMP

CHARGE

NONO

15A

60A

COMCOM

BLACK

Element

GROUND

LUGS

CIRCUIT #2

CIRCUIT #3

CHARGE

60A

RED

BLUE

LOW VOLTAGE ELECTRICAL CONNECTIONS - PEAK CONTROL

Steffes ETS heating equipment may be controlled by the Power Company via a peak control signal. This signal can be sent to the equipment using a Steffes Power Line Carrier control system, low voltage wiring, a Steffes Time Clock Module, or 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.

The Comfort Plus Commercial Hydronic system is factory configured for low voltage peak control and is set to charge when the utility peak control switch closes. Refer to the Configuration Menu (Pages 3.14-3.15) for information on configuring the system for the application.

LOW VOLTAGE (HARD WIRED) PEAK CONTROL

If using the low voltage peak control option, the Comfort Plus Commercial

Installation

Hydronic is direct wired to the power company's peak 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

companys load control or peak signaling device to

6-Position Low Voltage Terminal Block Coding

RP = Peak Control Input Common

the six (6) position low voltage terminal block inside the electrical compartment of the Comfort Plus Commercial Hydronic system through one of its low voltage wire knockouts.

AP = Anticipated Peak (Pre-Peak) Control Input

COM = Peak Control Output Common

NC = Peak Control Output (Normally Closed)

NO = Peak Control Output (Normally Open)

Step 2 Connect the field wiring to positions "RP" and "P" on

the six (6) position low voltage terminal block. (See Figure 11.)

Low voltage wires MUST never enter any line voltage enclosure.

TERMINAL CONNECTIONS

P = Peak Control Input

IMPORTANT

PEAK CONTROL

FIGURE 11

To Dry Contact Peak

Control Switch

COM

NCP

To use the Comfort Plus to control other loads, refer to Auxiliary Load Control (Page

3.13).

Installation n 3.07 Comfort Plus Commercial Hydronic

Page 19

POWER LINE CARRIER (PLC) PEAK CONTROL

The Steffes Power Line Carrier (PLC) control system has the ability to communicate with the Comfort Plus Commercial Hydronic 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 device. The switch signals peak control times to the transmitter, the transmitter sends the signals to the Comfort Plus Commercial Hydronic system, which receives this information and responds accordingly.

In addition to providing peak control signals, the transmitter also provides outdoor temperature information for automatic charge control, room temperature set back, and anticipated peak utility control signals (if applicable).

The PLC control is optional and must be ordered separately. If utilizing a PLC system, refer to the owner's manual for information on the installation and operation of the PLC control system.

TIME CLOCK MODULE PEAK CONTROL

The Steffes Time Clock Module is another option for providing a peak control signal to the Comfort Plus Commercial Hydronic. It mounts inside the systems low voltage electrical compartment and interfaces with the relay board via an interface cable. Peak control times must be programmed into the system once the module is installed to enable the time clock feature. Refer to the instructions provided with the Time Clock Module for more information on the installation and operation of this device.

LINE VOLTAGE PEAK CONTROL

Line voltage control is also an option, but is not the preferred method of control as it is usually more complex and expensive. If line voltage control is utilized, the controls circuit must be powered with an uninterrupted circuit. An 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 operating mode of C (charge) regardless of whether it is an off-peak or on-peak period.

LOW VOLTAGE ELECTRICAL CONNECTIONS - OUTDOOR TEMPERATURE SENSOR (OPTIONAL)

The outdoor sensor monitors outdoor temperature and provides this information to the system. The system responds by automatically storing heat in its brick core according to outdoor temperature and heating requirements.

Installation Methods: Hard wired to system to the "OS" and "SC"

terminals (default) OR connected to Power Line Carrier (PLC)

Location of: Must be placed in a location where it can accurately sense

outdoor temperature and is not affected by direct sunlight

w If connecting to a Steffes PLC

system, follow the installation instructions in the PLC system's Owner's and Installer's Guide.

w Outdoor sensor wire MUST

NEVER be combined with other control wiring in a multiconductor cable.

or other abnormal temperature conditions.

Wiring: · Route low voltage wire from the outdoor sensor to the electrical compartment through one of the low

voltage wire knockouts.

· Connect to "OS" and "SC" as shown in Figure 12 or to the two outdoor terminals as shown in Figures 13-15.

· If 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 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 supplied through this cable. It is for connection of the outdoor sensor ONLY.

· This low voltage cable MUST not enter any line voltage enclosure.

· Unshielded Class II (thermostat) wire can be used as extension wire provided it is segregated from

any line voltage cabling.

IMPORTANT

Installation

Comfort Plus Commercial Hydronic Installation n 3.08

Page 20

LOW VOLTAGE ELECTRICAL CONNECTIONS -

Dischar g e Air

Temperature

Hydronic

ROOM THERMOSTAT

A low voltage (24VAC) room thermostat may be used for room temperature control with the Comfort Plus Commercial Hydronic system. Steffes recommends using a digital thermostat. If utilizing a mechanical thermostat, a load resistor may be necessary due to the low current draw (.01 amps) on the heat call input circuit of the system. Contact the factory for information on thermostats available from Steffes.

LOW VOLTAGE CONNECTIONS

HYDRONIC HEATING SINGLE ZONE SYSTEM

FIGURE 12

Hydronic Heat Thermostat, Zone

Valve End Switch, or Pump Control

IMPORTANT

Low voltage wires MUST never enter any line voltage enclosure.

SINGLE STAGE HEAT PUMP APPLICATION WITH VARIABLE SPEED BLOWER

Installation

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Thermostat

Stage

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FIGURE 13

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Heat Pump Stage

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CFM

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Heat Call

Status on

Outdoor Sensor

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Installation n 3.09 Comfort Plus Commercial Hydronic

Heat Control

H/E N/A N/A HC3 N/A

*Contrac tor Us e Only

Page 21



TWO STAGE HEAT PUMP APPLICATION WITH VARIABLE SPEED BLOWER

Dischar ge Ai r

Temperature

Hydronic

FIGURE 14

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Thermostat

Stage

1 Y1/G 1 50% HC1 L048 2 Y1/Y2/G 2 100% HC1 L048 3 Aux/Y1/Y2/G 2 100% HC3 L049

Fan G 0 40 0 cfm HCF N/ A Cool 1 Y1/ G/O 1 50% COOL N/A Cool 2 Y1/Y2/G/O 2 100% COOL N/A

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Output

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TWO ST AG E HEAT PUM P

Heat Pump Stage

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CFM

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Digital Display

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STAND ALONE FURNACE APPLICATION WITH VARIABLE SPEED BLOWER

CONNECTIONS SHOWN FOR SINGLE STAGE HEATING / SINGLE STAGE COOLING

(UNCONTROLLED AIR CONDITIONING)

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If installing a mechanical thermostat or thermostat with anticipator, a resistor kit is required (Order Item #1190015).

Installation

AIR CONDITIONER/HEAT PUMP INTERFACE

The Comfort Plus Commercial Hydronic system can be used in conjunction with an air conditioner or a heat pump. Refer to the optional Air Handler (Page 2.02) and the Low Voltage Connections for Heat Pump Application Diagram (Figure 13-14), for more information on interfacing these systems with the Comfort Plus Commercial Hydronic. If multiple heat pumps are being interfaced, contact Steffes Corporation.

Comfort Plus Commercial Hydronic Installation n 3.10

Page 22

PRESSURE RELIEF VALVE INSTALLATION

WARNING

Risk of explosion. Can cause 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. w DO NOT cap, plug, or otherwise 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 Commercial

Hydronic heating system. If multiple heating systems are being used, pressure relief valving for the other system MUST be provided separately.

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 Comfort Plus Commercial Hydronic. It is extremely important that the following conditions for installation of this

Pressure

Relief Valve

30 PSI 400,000 20 PSI 75 PSI 500,000 60 PSI

Minimum

BTU Rating

Maximum

Operating Pressure

part are met:

· Ensure all connections, including the valve inlet are clean and free from any foreign

CAUTION

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 be a flow restriction or valve of any type between the safety relief valve and the pressure vessel.

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.

Step 3 Use schedule 40 pipe to install a discharge line for the pressure relief valve. This discharge line MUST:

· be connected from the valve outlet with no intervening valve and directed downward to a safe

Installation

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 375

F 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 Commercial 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. Refer to Typical Primary Loop (Figure 16) and the Typical System Plumbing Diagrams (Figures 17 and 18) for installation information.

The primary loop serves to regulate heat transfer from the systems heat exchanger, therefore, the primary loop must be powered by Comfort Plus Commercial Hydronic control system.

Installation n 3.11 Comfort Plus Commercial Hydronic

Page 23

TYPICAL PRIMARY LOOP

FIGURE 16

PRESSURE DROP THROUGH

HEAT EXCHANGER

Piping MUST Be

Supported

Zone

Connection

Area

Pressure

Relief Valve

(Factory Supplied)

Optional

Temperature and

Pressure Relief Valve

(Consult Local Code)

Air Vent

Outlet

Air Separator

Inlet

Expansion

Tank

*Primary

Loop

Pump

Junction Box

(Factory Supplied)

Primary Loop Pump

Control Wiring

(White & Red)

CAUTION

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

PUMP SPECIFICATIONS

 Steffes recommends a Grundfos UP15-42F

single speed 115VAC pump for the primary pump.

 Air Handler pump should NOT be a split

phase pump.

 Air Handler pump should NOT have any

type of auxiliary control built into or onto the pump.

FREEZE PROTECTION: Risk of frozen pipes. Can cause 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 exchanger damage. Can cause property damage or personal injury. DO NOT use the exchanger as support for piping. Support brackets should be in place to ensure proper operation of the system and to keep pressure off the inlet and outlet piping.

TYPICAL SYSTEM PLUMBING

SINGLE TEMPERATURE ZONES

FIGURE 17

Primary Loop

This Valve Must Be Open During

White

Red

Primary

Loop Pump

White

Red

Secondary Loop

Normal Operation

Installation

Exchanger

Comfort Plus Commercial Hydronic Installation n 3.12

Page 24

IMPORTANT

Secondary Loop

Primary Loop

It is the responsibility of the installer to prevent involuntary flow of water to the air handler. Not doing so may cause limit tripping and/or decrease heat pump efficiency. Use of a check valve, zone valve, or other device may help prevent involuntary flow.

TYPICAL SYSTEM PLUMBING

(SHOWN WITH STEFFES AIR HANDLER)

FIGURE 18

Low Temp Radiant Zones

From

White

Orange

Mixing

Valve

To Other Zones

5100 Air Handler

White Black

CHECK

VALVE

Other Zones

This Valve Must Be Open During

Normal Operation

White

Red

Primary

Loop Pump

High Temp

Water

Comfort +

Hydronic

Exchanger

AUXILIARY LOAD CONTROL

The Comfort Plus Commercial Hydronic system can be used to provide control signals to other loads in the application. To do so, connect low voltage control wires to the "COM" and "NC" or the "COM" and "NO" positions of the six (6) position low voltage terminal block in the electrical compartment of the Comfort Plus Commercial Hydronic. (See Figure 19.) These contacts are rated for 30 volts, 3 amps maximum.

Installation

IMPORTANT

Maximum external load should not exceed 60 VA on the system's class II transformer.

TYPICAL AUXILIARY LOAD CONTROL

FIGURE 19

Auxiliary Control Relay

RELAY

Installation n 3.13 Comfort Plus Commercial Hydronic

O2 SC DS

RPYCR OGY2 OSH

COMAPP NONC

Internal Peak Control Output Relay

NOTE: During off-peak (charge) periods, the contact is

closed between "COM" and "NC".

Page 25

CONFIGURATION MENU

The Steffes Comfort Plus Commercial Hydronic heating system has a Configuration Menu, which allows the system to be customized to the power company and consumers needs. This menu can be accessed on start-up and allows configuration settings to be easily adjusted.

To access the Configuration Menu:

Step 1 Energize the system. Access to the Configuration Menu is allowed

for the first two (2) minutes of operation. If the system has been energized for more than two (2) minutes, the 15 amp circuit breaker must be powered off and back on to gain access to this menu.

Step 2 Press and release the M button until the faceplate displays CONF.

IMPORTANT

If access to the Configuration Menu times out, the 15 amp circuit breaker must be powered off and back on to re-enter the menu.

Step 3 Press the up arrow once and the faceplate will display C000.

The faceplate will flash between

C000 and the corresponding configuration value.

Step 4 If necessary, edit the configuration value by pressing and holding the M button while using the up or the

down arrow button to change the value.

Step 5 Once the value is correct, release the buttons and press the up arrow button to go to the next configura-

tion (C001,C002, etc.)

Step 6 Repeat steps 4 through 5 until all configuration settings have been adjusted to the desired values.

Step 7 Once configured, use the down arrow to leave the Configuration Menu.

In most applications only a few, if any, configuration changes will be necessary. Following is a description of the configuration settings and their function:

C000 Off-Peak Method of Charge Control - Sets the method of brick core charging to be used during off-

peak (charge) periods. System is configured for automatic charge control which is a value of five (5).

C001 Start Brick Core Charge Set Point - If utilizing automatic charge control as set in C000, this value

indicates the outdoor temperature at which the system will start charging.

C002 Full Brick Core Charge Set Point - If utilizing automatic charge control as set in C000, this value

indicates the outdoor temperature at which the system will target a full core charge.

C003 Power Line Carrier (PLC) Channel Selection - If using PLC communication, this setting must

match the channel setting in the Steffes PLC transmitting device. A value of zero indicates power line carrier communication is disabled.

C004 Optional Controls Configuration

Value Configuration Description

8 No Outdoor Sensor/No Time Clock Module

9 Outdoor Sensor/No Time Clock Module 12 No Outdoor Sensor/Time Clock Module 13 Outdoor Sensor/Time Clock Module

C005 Control Switch Configuration  If utilizing power line carrier control, the Steffes Time Clock Mod-

ule, line voltage peak control, or if the utility control switch opens for charging this value should be zero (0). For all other applications, this value should be one (1).

Configuration Menu continued on next page...

Comfort Plus Commercial Hydronic Installation n 3.14

Installation

Page 26

C006 Output Control Configuration - Configures the output controls of the Comfort Plus Commercial

Hydronic system. To determine the value, check the options desired from the list below. Then, add the numbers from the Value column and enter the sum into this location. If not used in conjunction with a heat pump or air conditioner, the value in this location should be set to two (2).

Value Option Selected

2 Comfort Plus Commercial Hydronic System (Model 7140 ) 8 Enables compressor control if there is a "COOL" call during a peak (control) time.

32 If it is a peak (control) period and the Comfort Plus Commercial Hydronic receives a

cooling call, the compressor will turn off and on in 20 minute intervals (off 20 minutes, on 20 minutes, off 20 minutes, etc.).

128 Interfaces Comfort Plus Commercial Hydronic with a heat pump that has a reversing

valve which is energized for heating.

C007 Charge Factor - This configuration should be set to a value of 30.

C008 through C010 configurations are only applicable if the Comfort Plus Commercial Hydronic system is being used in conjunc

tion with a heat pump.

C008 Heat Pump Compressor Outdoor Lock-Out Temperature for Off-Peak or Anticipated Peak

Modes - Indicates the outdoor temperature at which the heat pumps compressor is locked out and not

allowed to operate during an off-peak or anticipated peak period.

C009 Heat Pump Compressor Outdoor Lock-Out Temperature for On-Peak Mode - Indicates the

outdoor temperature at which the heat pumps compressor is locked out and not allowed to operate during an on-peak period.

C010 Minimum Discharge Air Temperature - Sets the minimum discharge air temperature the system

targets during a Stage 1 heat call.

Example of O utdoor Reset

C011 and C012 configurations must be set for the hottest temperature zone in the installation. C011 is the highest temperature the system will target and C012 is the lowest temperature the system will target during a heat call. Outdoor reset is done using these two temperatures. (See graph.)

200

180

160

140

Water Temp eratu r e

120

10 30 50

Outdoor Tempe rature

C011 Maximum Outlet Water Temperature - The value set indicates the maximum outlet water tempera-

Installation

ture to be targeted. The targeted outlet water temperature is affected by the values in C001 and C002. For example, if the value in C001 = 50; C002 = 10; C011 = 180; C012 = 140, then at an outdoor temperature of 30 degrees, the targeted outlet water temperature would be 160 degrees.

C012 Minimum Outlet Water Temperature - The value set

indicates the minimum outlet water temperature to be targeted. The targeted outlet water temperature is affected by the values in C001 and C002. For example, if the value in C001 = 50; C002 = 10; C011 = 180; C012 = 140, then at an outdoor temperature of 30 degrees, the targeted outlet water temperature would be 160 degrees.

C013-C021 Time Clock Module Configuration - These configura-

tion settings are used to configure the peak control times when utilizing the optional Steffes Time Clock Module. Refer to the installation and configuration instructions included with the module for more information.

Risk of high temperature water. Can cause property damage. Improper water temperature settings can result in damage to the floor covering. Make sure the maximum and minimum water temperatures are appropriate for the application.

CAUTION

Installation n 3.15 Comfort Plus Commercial Hydronic

Page 27

INSTALLER'S FINAL CHECK-OUT PROCEDURE

Step 1 Verify that the water pressure is correct for the application. The

WARNING

water pressure of the Comfort Plus Commercial Hydronic heating system should be between 12 and 20 psig.

HAZARDOUS VOLTAGE: Risk of electric shock. Can cause injury or death. System may be connected to more than one branch circuit. Disconnect power to all circuits before servicing. Equipment must be serviced by a qualified technician.

Step 4 Press the up arrow again and the current heat call status will be displayed on the

control panel. Refer to the Operating Status section (Page 1.02) for more information on the heat call status display.

Step 5 Initiate a heat call from the room thermostat and verify that the Comfort Plus Commercial Hydronic

system recognizes the appropriate heat call. Refer to the Operating Status section (Page 1.02) for information on the various heat call status displays. In applications utilizing the Air Handler, verify that the Air Handler and/or heat pump operates appropriately.

Step 6 If utilizing the Air Handler, initiate a cooling call from the room thermostat and verify that the

Comfort Plus Commercial Hydronic system recognizes the COOL call. Verify that the Air Handler, heat pump, and/or air conditioner operates appropriately.

Step 2 Verify that the operating mode displayed on the

control panel corresponds with the power company's peak control signal. Refer to the Operating Status section (Page 1.02) for more information on the proper operating mode.

Step 3 Press the up arrow one time and verify that the

outdoor temperature information displayed on the control panel is approximately the same as the current outdoor temperature. Refer to the Operating Status section (Page 1.02) for more information on the outdoor temperature display.

Step 7 Press the up arrow until the targeted brick core charge level is displayed on the

control panel. With the system in an off-peak (charge) mode, initiate the charge control override. Refer to the Charge Control Override section (Page 1.03) for instructions on initiating the charge control override. Once initiated, the target level of the Comfort Plus Commercial Hydronic should be 100 percent, the control panel should display tL: F, and all of the heating elements should be energized.

Step 8 With an amp meter, verify that the amperage of the system is correct for the installation. Refer to

the System Identification Label on the Comfort Plus Commercial Hydronic system for information regarding the proper amperage.

Step 9 Cancel the charge control override and verify that all elements in the system de-energize. Refer to

the Charge Control Override section (Page 1.03) for instructions on canceling the charge control override.

Step 10 Verify that all hydronic heating zones are operating as intended.

Step 11 Verify, once again, that the Operating Mode displayed on the control panel corresponds with the

power company's peak control signal.

Step 12 In applications utilizing the Steffes Power Line Carrier control system, complete the Installers Final

Check-out Procedure in the Owners and Installers Manual provided with that device.

Installation

Comfort Plus Commercial Hydronic Installation n 3.16

Page 28

Control Circuit

See Note 2

240

277

347

208/240

1 GP M per 10,000 BT U of required output a t

20oF tem pera ture rise (10 GP M m a ximum )

180

120V (N e tural C onductor R equire d)

614,160

3,046

1”

Appendix

SPECIFICATIONS

Voltage C harg ing Input (kW ) Element Current Draw (Amps) Phase Number of Wires - See Note 1 Control Circuit Voltage (VAC) - See Note 2 M inimum Circuit Ampacity (AM PS) for 240V

Single Fe ed Minimum C ircuit A mpacity (Amps) -

Pump Voltage - See Note 2 Sto rag e Cap acity - Se e N o te 3

kWh

BTU A pproximate Ins talle d W e ight (lbs) M ax Coil Dimensions (W x D x H ) - See Note 4

Pipe Size (Inle t/Outle t) Prim ary Lo o p R e quirem ents O utput Wate r Te m p - Se le ction R ang e

M aximum Working Pre s sure Flow Rate (Primary Loop)

*The c ontrol circuit for 208 a nd 240 volt syste m s m ust be 3-w ire.

M odel 7120

240 277 347 14 19.2 24.8 19.2 20.48 24.8 19.2 26 59 80 104 24 25 30 19 25

Single Three Three

2* 4

208/240

83 110 140 34 36 43 28 36

120V (N e tural Conductor R equired)

120

409,440

2,218

½ H P : 21.2” x 21.2” x 24 ¼ ”

1 H P : 26.4” x 21.2” x 24 ½ ”

1”

M inimum of 10’ of 1” pipe

60 PSI / O ptiona l 20 P S I

1 GP M pe r 10,000 BTU of require d output at

F temperature rise (10 GPM maximum)

F to 185oF

Voltage C harging Input (kW ) Element Current Draw (Amps) Phase N u m ber o f W ire s - S e e N o te 1 Control Circuit Voltage (VAC) - See Note 2 M inimum Circuit Ampacity (AM PS) for 240V Control Circuit Single Fee d M inim um Circuit Am pacity (Am ps ) See Note 2 Pump Voltage - See Note 2 Sto rag e C apac ity - Se e N o te 3

A pproximate Installe d Weig ht (lbs) M ax Coil Dimensions (W x D x H) - See Note 4

Pipe Size (Inlet/Outlet) Prim ary Loo p R e quire ments

Appendix

O utput Wate r T e m p - Sele ction R ange M aximum Working Pressure

Flow Rate (Primary Loop)

M odel 7130

28.8 37.2 28.8 30.72 37.2 28.8 37.2 120 155 35 37 45 28 36

Single Thre e T hree

2* 4 4

160 204 49 52 61 39 49

kWh BTU

½ H P : 21.2” x 21.2” x 24 ¼ ”

1 H P : 26.4” x 21.2” x 24 ½ ”

M inimum of 10’ of 1” pipe

50oF to 185oF

60 P SI / O ptional 20 PS I

*The c ontrol c ircuit for 208 and 240 volt system s mus t be 3-w ire.

Appendix n A.01 Comfort Plus Commercial Hydronic

Page 29

Vo ltage Charging Input (kW) Element Current Draw (Amps) Phase Number of Wire s Control Circuit Voltage (VAC) - See Note 2 M inimum Circuit Ampacity (AMPS) for 240V Control Circuit Single F eed Minimum C ircuit Am pacity (A mps) See Note 2 Pump Voltage - See Note 2 Storag e Capacity - See N o te 3

kWh

BTU Appro x imate I nstalle d Weight (lbs ) M ax Coil Dimensions (W x D x H) - See Note 4

Pipe Size (Inlet/Outlet) Primary Lo o p Requirem ents O utput Water Temp - Selec tio n R ang e

M aximum Working Pre s sure Flow Rate (Primary Loop)

*The c o ntrol circuit for 208 a nd 240 volt systems m us t be 3-wire .

208

36 36 4 2. 7 5 38.4 46. 5 36 46.5

174 150 179 47 56 35 45

Single

198 233 60 63 75 48 60

120V ( N e tur a l Conductor R equired)

1 GP M per 10 ,000 BT U of required output at

F temperature rise (10 GPM maximum)

M odel 7140

240

½ HP: 21.2” x 21.2” x 24 ¼ ”

1 H P: 26.4” x 21.2” x 24 ½ ”

Minimum of 10’ of 1” pipe

60 P SI / O ptional 20 PS I

277 347

Three

208/240

240

818,800

3,894

1”

F to 185oF

Note 1: 208V or 240V systems are factory configured to be field connected to multiple, single

phase, line voltage circuits. If single feed to element and blowers/system controls circuit is desired, an optional single feed kit is available to order. Connection to 3-phase power is acceptable and can improve phase balancing.

Note 2: Because 277V/480V and 347V/600V systems are configured for single feed, three phase

line voltage connections only, a step down transformer must be field installed.

Note 3: The size and heating ability of the system required for an installation is dependent on the

thermal load and the demand profile of the facility. The daily rate structure of the utility can also affect size of furnace needed in an application. If the unit is not installed within the heated area, heat lost statically must be taken into account when sizing a system. Contact Steffes Corporation for assistance in selecting an appropriately sized system.

Note 4: The indoor coil or outdoor compressor of an air conditioner or heat pump are not in-

cluded with the furnace. The Steffes return air plenum (for use with the 6140) and the Steffes air handler (for use with the 7140 to allow it to provide forced air heating), are each configured to house an indoor coil and can be ordered from the factory as an optional accessory. Dimensions listed are that of the inner coil area in the plenum. For larger coils, field provisions to the factory built plenums are necessary or one will need to be custom built by the installer. (In heat pump applications, the indoor coil MUST be placed on the return air side.)

Appendix

Comfort Plus Commercial Hydronic Appendix n A.02

Appendix

Page 30

DISASSEMBLING THE COMFORT PLUS COMMERCIAL HYDRONIC SYSTEM

Step 1 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 2 Remove the limit zone cover by removing the screws holding it in place.

Step 3 Remove the screws around the perimeter of the limit zone and around the bottom of the left side, right

side, and back upper panels.

Step 4 Remove the one or two screws in the center of the upper right side panel.

Step 5 From the back of the system, lift and remove the painted panels. (See Figure A.)

Step 6 Locate the brick core temperature sensor(s) behind the front panel and disconnect them from their

shipping position. Carefully lay the sensor(s) aside to avoid damaging them.

Step 7 Carefully rock the brick core (Figure B) to one side and lift top portion up and off the base (Figure C.)

Step 8 Move the Comfort Plus Commercial Hydronic heating system into the desired location, reassemble, and

continue with the installation instructions in this manual.

Can be broken down into individual panels.

29 3/16"

FIGURE A

42 5/16"

7140

56"

7130

45"

7120

34 1/2"

WARNING

HEAVY OBJECT WARNING: Can cause muscle strain or back injury.

w Use lifting aids to move

system into place.

w Do NOT place object,

hands, and/or body parts under the system when lifting.

w Use care to keep objects,

hands, and/or body parts

Appendix

clear of system when lifting.

28 7/8"

Limits and Right

Side Saddle included

7140

54 3/4"

7130

43 3/4"

7120

32 3/4"

Do not remove

core limits.

Saddles and Z-brackets

can be removed if needed.

FIGURE B

Including

Breakers

38 1/8"

Plus front saddles

and back Z-Bracket

ALL 7100'S

48 1/4"

FIGURE C

17 1/4"

29 3/16"

Appendix n A.03 Comfort Plus Commercial Hydronic

Page 31

INTERNAL SYSTEM WIRING DIAGRAMS - LINE VOLTAGE

Line Voltage Wiring Diagram - Model 7120

240V OR 208V SYSTEMS ONLY

Use copper or aluminum conductors rated for 75

Red & White To

Primary Loop Pump

(Max 1.2 AMPS)

Black & White

To Air Handler Pump

(Max 1.2 AMPS)

SEE NOTE 2

WHITE

WHITE/BLACK

RED

BLACK ORANGE

To Optional Air Handler

BLUE/WHITE BLUE/BLACK

ORANGE BLACK

To Optional Static

Heat Recovery System

EXCHANGER LIMITS

225 °

AUTO RESET

N.C.

BLUE

BLACK/YELLOW

BLACK

250 °

WHITE

N.C.

MANUAL

RESET

BASE IO BOARD

5 Amp5 Amp

L1 L2 120 L2 240 BLOWER

RESISTOR RESISTER

DAMPER

RED

BLACK/YELLOW

CORE BLOWER

HIGH

COM.

1/4 Amp1/4 Amp

COMCOM

NONO

COMCOM

SHRU

C or higher for field connection of this device.

SEE NOTE 1

4uf

Cap.

GROUND

LUGS

CONTROL CIRCUIT

TRANSFORMERS

240v / 24v

COMCOM

NONO

COMCOM

PRIMARY

LOOP PUMP

NEUTRAL LUG

BLOWERS/

CIRCUIT

CHARGE

BLACK

CIRCUIT #1

CONTROLS

CHARGE

RED

CIRCUIT #2

CHARGE

BLUE

CIRCUIT #3

Element

NOTE 1: Line Voltage Field Wiring Connections. See Figure 8 for information on proper circuit phasing. NOTE 2: For more information regarding pump (circulator) wiring, reference Figures 9, 15 and 16 in the

Installation section of this manual.

Comfort Plus Commercial Hydronic Appendix n A.04

Appendix

Page 32

Line Voltage Wiring Diagram - Model 7120

277V AND 347V SYSTEMS ONLY

Use copper or aluminum conductors rated for 75

Red & White To

Primary Loop Pump

(Max 1.2 AMPS)

Black & White

To Air Handler Pump

(Max 1.2 AMPS)

SEE NOTE 2

WHITE

WHITE/BLACK

RED

BLACK ORANGE

To Optional Air Handler

BLUE/WHITE BLUE/BLACK

EXCHANGER LIMITS

225 °

AUTO RESET

N.C.

BLUE

BLACK/YELLOW

250 °

N.C.

MANUAL

RESET

CORE BLOWER

BLACK

WHITE

HIGH

COM.

BASE IO BOARDBASE IO BOARD

5 Amp5 Amp

L1 L2 120 L2 240 BLOWER

RESISTOR RESISTER

DAMPER

1/4 Amp1/4 Amp

COMCOM

NONO

FAN ONFAN ON

RELAYRELAY

TRANSFORMERS

COMCOM

NONO

COMCOM

HEAT CALLHEAT CALL

RELAYRELAY

C or higher for field connection of this device.

GROUND

LUG

FIELD

SUPPLIED

4uf

Cap.

240v / 24v

NONO

COMCOM

TRANSFORMER PRIMARY

WHITE

Transformer

120/240 VAC

Secondary

TRANSFORMER SECONDARY

ORANGE BLACK

To Optional Static

Heat Recovery System

Element

RED

BLACK/YELLOW

NEUTRAL

BAR

Element

#3#2

Appendix

Appendix n A.05 Comfort Plus Commercial Hydronic

Page 33

Line Voltage Wiring Diagram - Model 7130

208V AND 240V SYSTEMS ONLY

Use copper or aluminum conductors rated for 75

CORE BLOWER

BLACK

HIGH

WHITE

COM.

5 Amp5 Amp 1/4 Amp1/4 Amp

L1 L2 120 L2 240 BLOWER

RESISTOR RESISTER

DAMPER

RED

BLACK/YELLOW

COMCOM

NONO

FAN ON

RELAY

NONO

COMCOM

Red & White To

Primary Loop Pump

(Max 1.2 AMPS)

Black & White

To Air Handler Pump

(Max 1.2 AMPS)

SEE NOTE 2

WHITE

WHITE/BLACK

RED

BLACK ORANGE

To Optional Air Handler

BLUE/WHITE BLUE/BLACK

ORANGE BLACK

To Optional Static

Heat Recovery System

EXCHANGER LIMITS

225 ° N.C.

BLUE

BLACK/YELLOW

AUTO RESET

250 °

N.C.

MANUAL

RESET

BASE IO BOARD

C or higher for field connection of this device.

SEE NOTE 1

4uf

Cap.

GROUND

LUGS

CONTROL CIRCUIT

TRANSFORMERS

240v / 24v

COMCOM

NONO

COMCOM

RELAY

NEUTRAL LUG

BLOWERS/

CIRCUIT

CONTROLS

CHARGE

15A

BLACK

CIRCUIT #1

CIRCUIT #2

CIRCUIT #3

CHARGE

60A

RED

BLUE

CHARGE

60A60A60A

BROWN

CIRCUIT #4

Element

#10

Element

#11

Element

#12

Element

Installation section of this manual.

Comfort Plus Commercial Hydronic Appendix n A.06

Appendix

Page 34

Line Voltage Wiring Diagram - Model 7130

277V AND 347V SYSTEMS ONLY

Use copper or aluminum conductors rated for 75oC or higher for field connection of this device.

CORE BLOWER

GROUND

LUG

FIELD

SUPPLIED

Red & White To

Primary Loop Pump

(Max 1.2 AMPS)

Black & White

To Air Handler Pump

(Max 1.2 AMPS)

SEE NOTE 2

WHITE

WHITE/BLACK

RED

BLACK ORANGE

To Optional Air Handler

BLUE/WHITE BLUE/BLACK

ORANGE BLACK

To Optional Static

Heat Recovery System

Element

#10

EXCHANGER LIMITS

225 °

AUTO RESET

N.C.

BLUE

BLACK/YELLOW

250 °

N.C.

MANUAL

RESET

BLACK

WHITE

BASE IO BOARDBASE IO BOARD

5 Amp5 Amp

L1 L2 120 L2 240 BLOWER

RESISTOR RESISTER

DAMPER

RED

BLACK/YELLOW

Element

#11

HIGH

COM.

1/4 Amp1/4 Amp

COMCOM

NONO

FAN ONFAN ON

RELAYRELAY

Element

TRANSFORMERS

COMCOM

NONO

COMCOM

HEAT CALLHEAT CALL

RELAYRELAY

#12

4uf

Cap.

240v / 24v

NONO

COMCOM

TRANSFORMER PRIMARY

WHITE

Transformer

120/240 VAC

Secondary

NEUTRAL

BAR

TRANSFORMER SECONDARY

Element

#3#2

Appendix

Appendix n A.07 Comfort Plus Commercial Hydronic

Page 35

Line Voltage Wiring Diagram - Model 7140

240V OR 208V SYSTEMS ONLY

Use copper or aluminum conductors rated for 75

CORE BLOWER

BLACK

WHITE

5 Amp5 Amp

L1 L2 120 L2 240 BLOWER

RESISTOR RESISTER

DAMPER

RED

BLACK/YELLOW

HIGH

COM.

1/4 Amp1/4 Amp

COMCOM

NONO

FAN ON

COMCOM

RELAY

TRANSFORMERS

COMCOM

NONO

RELAY

Red & White To

Primary Loop Pump

(Max 1.2 AMPS)

Black & White

To Air Handler Pump

(Max 1.2 AMPS)

SEE NOTE 2

WHITE

WHITE/BLACK

RED

BLACK ORANGE

To Optional Air Handler

BLUE/WHITE BLUE/BLACK

ORANGE BLACK

To Optional Static

Heat Recovery System

EXCHANGER LIMITS

225 °

N.C.

BLUE

BLACK/YELLOW

AUTO RESET

250 ° N.C.

MANUAL

RESET

BASE IO BOARD

C or higher for field connection of this device.

SEE NOTE 1

4uf

Cap.

GROUND

LUGS

CONTROL CIRCUIT

240v / 24v

NONO

COMCOM

NEUTRAL LUG

BLOWERS/

CIRCUIT

CONTROLS

CHARGE

60A

15A

BLACK

CIRCUIT #1

CIRCUIT #2

CHARGE

60A

RED

CIRCUIT #3

CHARGE

60A

BLUE

CIRCUIT #4

CHARGE

60A

BROWN

Element

#13

Element

#10

Element

#14

Element

#11

Element

ElementElement

Element

#15

Element

#12

Element

Installation section of this manual.

Appendix

Comfort Plus Commercial Hydronic Appendix n A.08

Page 36

Line Voltage Wiring Diagram - Model 7140

277V AND 347V SYSTEMS ONLY

Use copper or aluminum conductors rated for 75

CORE BLOWER

BLACK

HIGH

WHITE

COM.

BASE IO BOARDBASE IO BOARD

1/4 Amp1/4 Amp

5 Amp5 Amp

L1 L2 120

L2 240 BLOWER

RESISTOR RESISTER

DAMPER

RED

BLACK/YELLOW

LOW SPEED

COMCOM

NONO

FAN ON

FAN ON RELAY

RELAY

Red & White To

Primary Loop Pump

(Max 1.2 AMPS)

Black & White

To Air Handler Pump

(Max 1.2 AMPS)

WHITE

RED

BLACK ORANGE

To Optional Air Handler

BLUE/WHITE BLUE/BLACK BLUE/RED

ORANGE BLACK

To Optional Static

Heat Recovery System

EXCHANGER LIMITS

225 °

N.C.

BLUE

BLACK/YELLOW

AUTO RESET

250 °

N.C.

MANUAL

RESET

C or higher for field connection of this device.

GROUND

LUG

FIELD

SUPPLIED

Transformer

120/240 VAC

Secondary

TRANSFORMER SECONDARY

TRANSFORMERS

HIGH SPEED

COMCOM

NONO

COMCOM

HEAT CALLHEAT CALL

RELAYRELAY

4uf

Cap.

240v / 24v

NONO

COMCOM

TRANSFORMER

PRIMARY

WHITE

Appendix

Element

#13

Element

#10

Element

#14

Element

#11

Element

#15

Element

#12

Element

NEUTRAL

BAR

Appendix n A.09 Comfort Plus Commercial Hydronic

Page 37

INTERNAL SYSTEM WIRING DIAGRAM - LOW VOLTAGE

BLUE

The outdoor temperature sensor, room thermostat, and peak control device are connected via low voltage wiring.

WARNING

System Low Voltage Wiring Diagram - Model 7120

The "R" and "C" positions in the low voltage terminal strip may be used as a source of 24 VAC for powering external low voltage devices (60 VA maximum).

A M

P M

CONTROL BOARD

BLUE/RED

BLUE/YELLOW

BLUE/WHITE

GRAY/WHITE

PURPLE/WHITE

COM

PNONC

Peak Control Connections

Terminals for Connection as a Stand Alone Furnace

RWCY2YG

Terminals for Connection with Heat Pump

RY2YCO2OG

YELLOW

YELLOW/BLUE

ORANGE

ORANGE/BLUE

BLUE/WHITE

BLUE

BLUE/RED

RED

WHITE

YELLOW

ORANGE

GREEN

BLACK

BROWN

GRAY

PURPLE

OSW2 DSSC

E OSW DSSC

YELLOW AND ORANGE

WATER SENSOR

BLUE/RED

BLUE/WHITE

BLUE/YELLOW

BLUE/RED

BLUE/WHITE

BROWN

GRAY/WHITE

WHITE

ORANGE/BLUE

ORANGE

GREEN

YELLOW/BLUE

YELLOW

BLACK

"R" "Y2" "R" "O2" "NO" "NC" "COM"

"RP" "E" "W" "Y" "O" "G" "AP" "P" "C" "DS" "OS" "SC"

DISCHARGE

BLUE

GRAY

RED

8 15 14 7 6 5

17 19

18 9

10 4 12 13 2 11 16 1 & 3

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19

CONTROL

NOTE

TO LOW VOLTAGE TERMINAL BLOCKS

YELLOW

BOARD

HAZARDOUS VOLTAGE: Risk of electric shock. Can cause injury or death. All low voltage wiring must be segregated from line voltage circuits in the system.

The "R" and "C" positions in the low voltage terminal strip may be used as a source of 24 VAC for powering external low voltage devices (60 VA maximum)

TX1

75 VA

TRANSFORMER

GROUNDED

YELLOW

TX2

75 VA

TRANSFORMER

UN-GROUNDED

BLUE

CORE LIMITS

20V DC

RELAY 8 RELAY 7 RELAY 6 RELAY 5

CORE DCORE C

RELAY 4 RELAY 3 RELAY 2 RELAY 1

Appendix

Comfort Plus Commercial Hydronic Appendix n A.10

Page 38

System Low Voltage Wiring Diagram - Model 7120 with Variable Speed

The "R" and "C" positions in the low voltage terminal strip may be used as a source of 24 VAC for powering external low voltage devices (60 VA maximum).

A M

P M

CONTROL BOARD

YELLOW YELLOW ORANGE ORANGE

WHITE/BLACK WHITE WHITE/RED

RED/BLACK RED

WHITE

YELLOW

ORANGE GREEN

YELLOW/BLACK WHITE/BLACK BLACK BROWN GRAY BLUE BLUE/BLACK

"R" "Y2" "R" "O2" "NO" "NC" "COM"

"RP" "E" "W" "Y" "O" "G" "AP" "P" "C" "DS" "OS" "SC" "RS"

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 20

TO LOW VOLTAGE BOARD

TX1

75 VA

TRANSFORMER

GROUNDED

YELLOW

HAZARDOUS VOLTAGE: Risk of electric shock. Can cause injury or death. All low voltage wiring must be segregated from line voltage circuits in the system.

TX2

75 VA

TRANSFORMER

UN-GROUNDED

BLUE

WARNING

20V DC

AUX

P11

(OPTIONAL

HANDLER)

DISCHARGE

SENSOR

Appendix

AIR

Thermostat

Y1 Y2

RLY1

Air

H/E

Blower

W/E

Speed

Water

P3P2P1

Blower

DISCHARGE

WATER

SENSOR

Heat Aux.

Pump

VAC

2Y22

To Control Board

Peak

Inputs

Outdoor

YELLOW/BLACK ORANGE/BLACK

RED/BLACK

RED

WHITE

YELLOW

ORANGE

GREEN

YELLOW/BLACK WHITE/BLACK

BLACK BROWN GRAY

BLUE

BLUE/BLACK

Relay

NCAP CO M

P8CP9

YELLOW

ORANGE

WHITE/BLACK WHITE WHITE/RED

YELLOW

BLUE

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 20

RELAY 8 RELAY 7 RELAY 6 RELAY 5

CORE DCORE C

RELAY 4 RELAY 3 RELAY 2 RELAY 1

CORE LIMITS

TO CONTROL BOARD

Appendix n A.11 Comfort Plus Commercial Hydronic

Page 39

System Low Voltage Wiring Diagram - 7130

The "R" and "C" positions in the low voltage terminal strip may be used as a source of 24 VAC for powering external low voltage devices (60 VA maximum).

A M

CONTROL BOARD

BLUE/RED

BLUE/YELLOW

BLUE/WHITE

GRAY/WHITE

PURPLE/WHITE

COM

PNONC

Peak Control Connections

Terminals for Connection as a Stand Alone Furnace

RWCY2YG

Terminals for Connection with Heat Pump

RY2YCO2OG

YELLOW

YELLOW/BLUE

ORANGE

ORANGE/BLUE

BLUE/WHITE

BLUE

BLUE/RED

RED

WHITE

YELLOW

ORANGE

GREEN

BLACK

BROWN

GRAY

PURPLE

BLUE/RED

BLUE/WHITE

BLUE/YELLOW

BLUE/RED

BLUE/WHITE

OSW2 DSSC

E OSW DSSC

YELLOW AND ORANGE

BROWN

GRAY/WHITE

WHITE

ORANGE/BLUE

ORANGE

GREEN

YELLOW/BLUE

YELLOW

BLACK

"R" "Y2" "R" "O2" "NO" "NC" "COM"

"RP" "E" "W" "Y" "O" "G" "AP" "P" "C" "DS" "OS" "SC"

DISCHARGE

WATER SENSOR

8 15 14 7 6

BLUE

17 19

GRAY

18 9

RED

10 4 12 13 2 11 16 1 & 3

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19

CONTROL

NOTE

TO LOW VOLTAGE TERMINAL BLOCKS

YELLOW

BOARD

BLUE

WARNING

HAZARDOUS VOLTAGE: Risk of electric shock. Can cause injury or death. All low voltage wiring must be segregated from line voltage circuits in the system.

The "R" and "C" positions in the low voltage terminal strip may be used as a source of 24 VAC for powering external low voltage devices (60 VA maximum)

TX1

75 VA

TRANSFORMER

GROUNDED

YELLOW

TX2

75 VA

TRANSFORMER

UN-GROUNDED

BLUE

CORE LIMITS

CORE D

CORE C

20V DC 20V DC

RELAY 12 RELAY 11 RELAY 10 RELAY 9 RELAY 8 RELAY 7 RELAY 6 RELAY 5 RELAY 4 RELAY 3 RELAY 2 RELAY 1

Comfort Plus Commercial Hydronic Appendix n A.12

Appendix

Page 40

System Low Voltage Wiring Diagram - 7130 with Variable Speed

The "R" and "C" positions in the low voltage terminal strip may be used as a source of 24 VAC for powering external low voltage devices (60 VA maximum).

A M

P M

CONTROL BOARD

YELLOW YELLOW ORANGE ORANGE

WHITE/BLACK WHITE WHITE/RED

RED/BLACK RED

WHITE

YELLOW

ORANGE

GREEN

YELLOW/BLACK WHITE/BLACK

BLACK BROWN

GRAY

BLUE

BLUE/BLACK

"R" "Y2" "R" "O2" "NO" "NC" "COM"

"RP" "E" "W" "Y" "O" "G" "AP" "P" "C" "DS" "OS" "SC" "RS"

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 20

TO LOW VOLTAGE BOARD

TX1

75 VA

TRANSFORMER

GROUNDED

TRANSFORMER

UN-GROUNDED

YELLOW

BLUE

WARNING

HAZARDOUS VOLTAGE: Risk of electric shock. Can cause injury or death. All low voltage wiring must be segregated from line voltage circuits in the system.

TX2

75 VA

20V DC 20V DC

Thermostat

AUX

P11

Y1 Y2

RLY1

Water

Air

DISCHARGE

(OPTIONAL

AIR

HANDLER)

DISCHARGE

AIR

SENSOR

Appendix

W/E

P3P2P1

WATER

SENSOR

H/E

Blower Speed

A B C D

Blower

Heat Aux.

Pump

VAC

2Y22

Outdoor

To Control Board

Peak

Inputs

Relay

Outdoor

YELLOW

YELLOW/BLACK

ORANGE

ORANGE/BLACK

WHITE/BLACK WHITE WHITE/RED

RED/BLACK

RED

WHITE YELLOW ORANGE

GREEN

YELLOW/BLACK WHITE/BLACK BLACK BROWN GRAY BLUE

BLUE/BLACK

NCAP COM

P8CP9

RELAY 12

YELLOW

BLUE

1 2 3 4 5 6 7

8 9 10 11 12 13 14

CORE D

CORE C

CORE LIMITS

TO CONTROL BOARD

RELAY 11 RELAY 10 RELAY 9 RELAY 8 RELAY 7 RELAY 6 RELAY 5 RELAY 4 RELAY 3 RELAY 2 RELAY 1

15 16 17 18 19 20

Appendix n A.13 Comfort Plus Commercial Hydronic

Page 41

System Low Voltage Wiring Diagram - 7140

The "R" and "C" positions in the low voltage terminal strip may be used as a source of 24 VAC for powering external low voltage devices (60 VA maximum).

P M

CONTROL BOARD

BLUE/RED

BLUE/YELLOW

BLUE/WHITE

GRAY/WHITE

PURPLE/WHITE

COM

PNONC

Peak Control Connections

Terminals for Connection as a Stand Alone Furnace

RWCY2YG

Terminals for Connection with Heat Pump

RY2YCO2OG

YELLOW

YELLOW/BLUE

ORANGE

ORANGE/BLUE

BLUE/WHITE

BLUE

BLUE/RED

RED

WHITE

YELLOW

ORANGE

GREEN

BLACK

BROWN

GRAY

PURPLE

WATER SENSOR

BLUE/RED

BLUE/WHITE

BLUE/YELLOW

BLUE/RED

BLUE/WHITE

OSW2 DSSC

E OSW DSSC

YELLOW AND ORANGE

BROWN

GRAY/WHITE

WHITE

ORANGE/BLUE

ORANGE

GREEN

YELLOW/BLUE

YELLOW

BLACK

"R" "Y2" "R" "O2" "NO" "NC" "COM"

"RP" "E" "W" "Y" "O" "G" "AP" "P" "C" "DS" "OS" "SC"

DISCHARGE

BLUE

GRAY

RED

8 15 14 7 6 5

17 19

18 9 10 4 12 13

2 11 16 1 & 3

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19

TO LOW VOLTAGE TERMINAL BLOCKS

YELLOW

CONTROL

BOARD

HAZARDOUS VOLTAGE: Risk of electric shock. Can cause injury or death. All low voltage wiring must be segregated from line voltage circuits in the system.

The "R" and "C" positions in the low voltage terminal

NOTE

strip may be used as a source of 24 VAC for powering external low voltage devices (60 VA maximum)

TX1

75 VA

TRANSFORMER

GROUNDED

YELLOW

TX2

75 VA

TRANSFORMER

UN-GROUNDED

BLUE

CORE LIMITS

BLUE

WARNING

20V DC 20V DC

RELAY 15 RELAY 14 RELAY 13

CORE ECORE D

CORE C

RELAY 12 RELAY 11

RELAY 10 RELAY 9 RELAY 8 RELAY 7 RELAY 6

RELAY 5 RELAY 4 RELAY 3 RELAY 2 RELAY 1

Comfort Plus Commercial Hydronic Appendix n A.14

Appendix

Page 42

System Low Voltage Wiring Diagram - 7140 with Variable Speed

The "R" and "C" positions in the low voltage terminal strip may be used as a source of 24 VAC for powering external low voltage devices (60 VA maximum).

A M

CONTROL BOARD

YELLOW YELLOW ORANGE ORANGE

WHITE/BLACK WHITE WHITE/RED

RED/BLACK RED

WHITE

YELLOW

ORANGE GREEN

YELLOW/BLACK WHITE/BLACK BLACK BROWN GRAY BLUE BLUE/BLACK

"R" "Y2" "R" "O2" "NO" "NC" "COM"

"RP" "E" "W" "Y" "O" "G" "AP" "P" "C" "DS" "OS" "SC" "RS"

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 20

TRANSFORMER

The "R" and "C" positions in the low voltage terminal

NOTE

strip may be used as a source of 24 VAC for powering external low voltage devices (60 VA maximum)

TO LOW VOLTAGE BOARD

TX1

75 VA

GROUNDED

TRANSFORMER

UN-GROUNDED

YELLOW

BLUE

WARNING

HAZARDOUS VOLTAGE: Risk of electric shock. Can cause injury or death. All low voltage wiring must be segregated from line voltage circuits in the system.

TX2

75 VA

CORE ECORE D

20V DC 20V DC

RELAY 15 RELAY 14 RELAY 13 RELAY 12 RELAY 11

(OPTIONAL

HANDLER)

DISCHARGE

Appendix

AUX

P11

Y1 Y2

RLY1

Air

AIR

SENSOR

Thermostat

H/E

Blower

W/E

Speed

A B C

Water

P3P2P1

Blower

DISCHARGE

WATER

SENSOR

Heat

Pump

VAC

2Y22

Outdoor

To Control Board

Aux.

Peak

Inputs

Relay

NCAP COM

P8CP9

YELLOW

YELLOW/BLACK

ORANGE

ORANGE/BLACK

WHITE/BLACK WHITE WHITE/RED

RED/BLACK

RED

WHITE YELLOW ORANGE

GREEN

YELLOW/BLACK WHITE/BLACK BLACK BROWN GRAY BLUE

BLUE/BLACK

YELLOW

BLUE

1 2 3 4 5 6 7

8 9 10 11 12 13 14 15 16 17 18 19 20

TO CONTROL BOARD

CORE LIMITS

CORE C

RELAY 10 RELAY 9 RELAY 8 RELAY 7 RELAY 6

RELAY 5 RELAY 4 RELAY 3 RELAY 2 RELAY 1

Appendix n A.15 Comfort Plus Commercial Hydronic

Page 43

HELP MENU

The Comfort Plus Commercial Hydronic system contains a "HELP" menu which may be accessed through the control panel. To access the "HELP" menu, press and release the M button until the faceplate displays HELP. Scroll through this menu by pressing either the up or the down arrow button.

Display Reading Description

Fxxx Firmware Version Number - Indicates the version of software installed.

O xx Outdoor Temperature - Indicates current outdoor temperature as recognized by the system.

tL:xx Target Level - Indicates the percentage of brick core charge level the system is targeting. During

peak periods the value displays as "tL_".

CL:xx Charge Level - Indicates the percentage of heat storage currently in the brick core.

HE x Heating Elements Active - Indicates the total number of heating elements currently energized.

PC x Power Line Carrier Channel - Indicates the channel on which the system is set to receive PLC

communication signal.

P x Power Line Carrier Net Hit Rate Percentage - Indicates the percentage of "GOOD" communica-

tion packets received by the system from the PLC transmitter system.

PS x Indicates which Specialty Timer the system is currently using. The value displayed will be zero if

the Specialty Timer is not being utilized.

CC_x Charge Mode Operation - Indicates the charge control method being utilized during off-peak

periods.

CA_x A-Peak Mode Operation - Indicates the charge control method being utilized during anticipated

peak periods.

C1_x Specialty Timer #1 Charge Mode - Specialty Applications Only

C2_x Specialty Timer #2 Charge Mode - Specialty Applications Only

HUxx Heat Usage - Indicates the amount of input being dissipated by the system.

A_xx Target Discharge Air Temperature - Indicates the discharge air temperature that the system is

targeting.

cxxx Compressor Output Relay Delay Timer - Indicates time remaining before heat pump compressor

is energized. "c ON" indicates the heat pump is energized.

ERROR CODES

The Comfort Plus Commercial Hydronic system has an on-board diagnostic system to monitor various operating conditions. If operating conditions move outside the normal operating range, an error code is displayed on the faceplate. If there are multiple errors simultaneously, only the highest priority error code appears. Once corrected, the next highest priority code will be displayed. Error codes will be displayed on the faceplate as Er (i.e., Er05).

Error Code Description

03 Outlet water temperature is out of normal operating range.

This can indicate an open sensor, a short in the wiring, or a circuit board which is out of calibration.

04 Discharge air temperature is out of normal operating range.

This can indicate an open sensor, a short in the wiring, or a circuit board which is out of calibration.

05 Outdoor sensor (direct wired) temperature reading is out of

normal operating range. The sensor circuit may be open or shorted, the processor control board may be out of calibration, or there may be an incorrect value in L035.

Comfort Plus Commercial Hydronic Appendix n A.16

WARNING

Appendix

Page 44

Error Code Description

06 Outdoor sensor temperature from the transmitting device (PLC system) is out of normal operating

range. Check the outdoor sensor attached to the transmitting device and the transmitter for proper operation.

07 Main processor control board temperature sensor is out of normal operating range. Verify that

none of the clearances have been violated and inspect the condition of the processor control board.

08 Currently not utilized.

09 Currently not utilized.

10 Outlet water temperature has exceeded the maximum standard operating temperature.

20 There is no communication occurring between the Base I/O board and the processor control

board. This can be caused by a defective board interface cable or an unresponsive Base I/O board.

21 There is no communication occurring with the first relay expansion board. The board interface

cable may be defective or the first expansion board may be unresponsive.

22 There is no communication occurring with the second relay expansion board. The board interface

cable may be defective or the second expansion board may be unresponsive.

23 There is no communication occurring with the Steffes time clock module.

24 Temperature sensor offset/reference is out of range and indicates one of the sensors is shorted to

ground, the processor control board is out of calibration, or the blower/control circuit is connected to an improper input voltage.

25 Power line carrier system is active; however, no good data has been received.

26 Insufficient main control board memory. Contact a qualified service technician.

27 Insufficient permanent memory. Contact a qualified service technician.

28 Permanent memory change has been made. Press the M button to accept. This error message

indicates a change has been made to the software program; therefore, it is important to verify that all location settings are correct for the application.

29 On-board communication system is not fully operable. Contact a qualified service technician.

30 Base I/O control board is in test mode. Check the jumper configuration.

31 Relay expansion board(s) are in test mode. Check the jumper configuration.

39 Indicates the value in Location 13 (L013) has been set to a value greater than the value in Loca-

tion 12 (L012). The system will not charge until the value in L013 is set lower than L012.

40 Press and release the M button to clear the error. If the error code reappears, contact a qualified

service technician.

41-44 Contact a qualified service technician.

Cold Core Temperature of the brick core is below 40 degrees or the core sensing thermocouple may be

open.

Core Fail Core high limit switch may be open.

PLC Fail The system is configured for power line carrier control; however, is not receiving a valid power

line carrier communication signal.

LoAd CAP All controllable loads have been shed and Maximum Load Capacity is still exceeded.

Appendix

Appendix n A.17 Comfort Plus Commercial Hydronic

Page 45

GLGL

OSSAROSSAR

OSSAR

GLGL

OSSAROSSAR

Air Separator ~ Device used to remove air from

the water so the air does not get into the closed loop system and cause damage to other components.

Air Vent ~ Device used to release air from the

system. The air vent is generally mounted on top of the air separator.

Anticipated Peak ~ Used only by certain power

companies as an alternative method of storing heat in the brick core. Indicated by an "A" on the system display.

Automatic Charge Control ~ Method of brick

core charge regulation where a sensor monitors outdoor temperature and automatically adjusts the brick core charge target level accordingly. As the outdoor temperature drops, the target level rises.

Brick Core Charge Level ~ The amount of heat

stored in the brick core of the system.

Charge Period ~ Off-peak time in which the system

is allowed to store heat in its brick core. Indicated by a "C" on the system display.

Control Panel ~ Contains the buttons to adjust and

the display to indicate system functions. Located on the front of the system.

Control Period ~ On-peak time in which the

system is not allowed to store heat in its brick core. Indicated by a "P" on the system display.

Edit Mode ~ Process of changing or viewing the

values in a microprocessor location. This is accomplished with the use of the mode button, the up arrow button, and the down arrow button.

Expansion Tank ~ When water is heated, expan-

sion takes place. The expansion tank stores the excess water to maintain proper pressure in the system. In most applications, the expansion tank should be installed prior to the pump for optimum performance.

Location (Function) ~ Where the specific operat-

ing information of the system is stored. These locations are part of the microprocessor and are accessed through the control panel. Displayed as an "L" on the faceplate when in the edit mode.

Location Value ~ The specific information set and

stored in a location on the system's microprocessor which defines system operation. A value for a specific location is accessed through the control panel.

Manual Charge Control ~ Method of brick core

charge regulation where the owner must periodically adjust the brick core temperature setting in relation to the outdoor temperature.

Microprocessor ~ Device on the circuit board of the

system which stores and processes the information for controlling the operation of the system.

Off-peak ~ The time during the day or night when

the power company can supply electricity more economically and may offer a special incentive such as a reduced electric rate or billing credits for the electricity consumed during this time. Typically, electrical usage is not controlled during an off-peak time. (The system will provide heat to satisfy comfort requirements during this time as well as charge or store heat in its brick core.)

On-peak ~ The time during the day or night when the

power company experiences a high demand for electricity. To limit demand, certain appliances are controlled to avoid usage by them and/or a premium for the electricity consumed during this time may be charged to discourage electrical usage. (The system is not allowed to charge or store heat in its brick core during on-peak periods.)

Outdoor Sensor ~ Device that senses outdoor air

temperature and communicates this information to the system for automatic charge control.

Pressure Relief Valve ~ Device that protects the

system against the dangers of thermal expansion. If system pressure exceeds normal operating conditions, the relief valve opens and releases excessive pressure from the system.

Room Temperature Set Point ~ The targeted

room temperature the system is to maintain. If the thermostat(s) senses a temperature below this point, a heat call is initiated.

Appendix

Comfort Plus Commercial Hydronic Appendix n A.18

Page 46

Registering your purchase is an essential step to ensure warranty coverage. A Warranty Registration card is included with the Owner's Manual. Simply complete, detach the bottom portion, and return the card today. Retain the top portion of the card for your files.

WARRANTY STATEMENT

Steffes Corporation (Steffes) warrants that the Steffes Electric Thermal Storage Heating Appliance is free from defects in materials and workmanship under normal use and service. Steffes obligation under this Warranty is limited to the repair or replacement of the appliance or parts only which prove to be defective under normal use within two (2) years of the date of installation and which Steffes examination of the returned appliance or part(s) shall verify to Steffes satisfaction that it is defective. Optional Steffes controls and accessories have a three (3) year warranty coverage period. The user shall be responsible for any labor costs associated with the repair or replacement of the appliance or part(s), including the cost of returning the defective appliance or part(s) to Steffes Corporation.

This Warranty is void if the heating appliance is moved from the premises in which it was originally installed. This Warranty shall not apply to an appliance or part which has been altered in any respect, or improperly installed, serviced or used, or has been subject to accident, negligence, abuse or misuse.

Warranty

THE ABOVE WARRANTY BY STEFFES IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN OR ORAL, EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE.

The user assumes all risk and liability whatsoever resulting from the use of this heating appliance. In no event shall Steffes be liable for any indirect, special or consequential damages or lost profits.

This Limited Warranty contains the complete and exclusive statement of Steffes obligations with respect to the heating appliance and any parts thereof. The provisions hereof may not be modified in any respect except in writing and signed by a duly authorized officer of Steffes.

Thank you for purchasing Steffes ETS heating equipment. We welcome your comments

relating to the Comfort Plus and this manual. Enjoy your new purchase!

3050 Hwy 22 North  Dickinson, ND 58601-9413 www.steffes.com

DOCUMENT #1200158