Steffes 9180 User Manual

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Hydronic

OWNER'S AND

INSTALLER'S MANUAL

Models: 9150, 9180

Applicable to Software Version 2.XX

LISTED

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IMPORTANT

 The equipment described herein is intended for installation by a qualied

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

 To insure proper installation and operation of this product, completely read

all instructions prior to attempting to assemble, install, operate, maintain or repair this product. Upon unpacking of the system, inspect all parts for damage prior to installation and start-up.

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

tion and made available to service personnel as required.

 Disclaimer: In compiling this manual, Steffes Corporation has used its best

judgement based upon information available, but disclaims any responsibility or liability for any errors or miscalculations contained herein, or any revisions hereof, or which result, in whole or in part, from the use of this manual or any revisions hereof.

For Customer Use

Please record your model and serial number below. This number is found on the identication labels

located on the front of and inside the electrical panel. Retain this information for future reference.

Model No. ________________________________________________________________________

Serial No. ________________________________________________________________________

RECOGNIZE THESE SYMBOLS AS SAFETY PRECAUTIONS

It is important, both for your personal safety and to avoid possible damage to the equipment and your property, that you observe the safety instructions given following these symbols.

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SAFETY PRECAUTIONS

Fully assemble the system and load ceramic heat storage 1. brick prior to energizing the system. Pressure relief valve must be installed prior to operation of 2. the system. Use or storage of explosive or ammable gasses or liquids 3. within close proximity of the system presents a hazard.

Clearance requirements are critical to safe operation of the 4. system. Follow all requirements specied in this manual

(Page 3.03). Keep the top of system clear.5. Use caution when working around the heating system as inlet 6. and outlet piping can be very hot. De-energize all branch circuits before servicing. This heating 7. system may be connected to more than one branch circuit. Installation of and/or service to this heating system should be 8. performed by a qualied technician in accordance with information contained herein and with national, state, and local

codes and requirements.

Repeated error codes on the system display (pages A.10 – 9.

A.13) indicate a need for service by a qualied technician. Special requirements must be considered if placing the sys-10.

tem in a garage or other area where combustible vapors may be present. Consult local, state and national codes and regulations to ensure proper installation.

WARNING

Hazardous Voltage: Risk of electric shock, injury, or death. This system may be connected to more than one branch circuit. Disconnect power to all circuits before installing or servicing. Installation of and/or service to this equipment MUST be

performed by a qualied technician.

Risk of explosion. Operating the system without the pressure relief valve properly installed can cause an explosion. Connect the pressure relief valve in a vertical, upright po-

sition with the supplied ttings. DO

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

Risk of re. Violation of the clearance requirements can cause improper operation of the equipment. Maintain the placement and clear-

ance requirements specied.

Hot Surface. Plumbing and other surfaces can be hot. Use caution when working near the system.

BUILT-IN SAFETY DEVICES

The ThermElect Hydronic heating system incorporates safety devices to ensure normal operating temperatures are maintained. The chart below describes these safety devices.

DEVICE

Core Charging High Limit Switches (Auto Reset)

Heat Exchanger Limit Switch (Manual Reset)

Outlet Water Temperature Limit Switch (Auto Reset)

Pressure Relief Valve

FUNCTION

These limit switches monitor the core and top temperatures. If normal operating temperatures are exceeded, the system will display "CORE FAIL" and the elements will not be allowed to operate.

This linear limit switch monitors the temperature of the water in the exchanger and interrupts power to the core blower if a water temperature of 250oF/121oC is exceeded. If this

limit switch opens, contact a qualied service technician.

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 225oF/107oC is exceeded.

If the water pressure exceeds maximum psig, the pressure relief valve opens. Once water pressure of less than maximum psig is achieved, the valve closes.

location

on system

Right side of system.

Behind front lower painted panel. Reset button visible in lower right front corner.

Behind front lower painted panel.

Factory provided,

eld installed to outlet

of heat exchanger.

Th e r m el e c T hy d r o n i c Sa f e T y in f o r m a T i o n

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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

Discharge Air/Water System ........................................................................................................................................................1.03

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

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

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

Optional Accessories

Load Management Control .........................................................................................................................................................2.01

External Duct Sensor ...................................................................................................................................................................2.02

Static Heat Recovery Unit ...........................................................................................................................................................2.02

Lifting Handles ............................................................................................................................................................................2.02

SCR Controller.............................................................................................................................................................................2.02

Control Circuit Step Down Transformer ......................................................................................................................................2.03

Installation

Shipping and Packaging ...................................................................................................................................................... 3.01-3.02

Placement and Clearance Requirements ......................................................................................................................................3.03

Initial Set-up .................................................................................................................................................................................3.04

Electrical Panel Installation .........................................................................................................................................................3.04

Brick Loading ..................................................................................................................................................................... 3.04-3.05

Heating Element Installation ............................................................................................................................................... 3.05-3.06

Brick Core Temperature Sensor Installation ..............................................................................................................................3.06

Line Voltage Electrical Connections ............................................................................................................................................ 3.07

Low Voltage Electrical Connections

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

Room Thermostat ...................................................................................................................................................................3.08

Air Conditioner/Heat Pump Interface ....................................................................................................................................3.09

Pressure Relief Valve Installation ................................................................................................................................................ 3.09

Plumbing ..............................................................................................................................................................................3.10-3.11

Appendix

Specications .....................................................................................................................................................................A.01-A.02

Parts Diagram - 50kW Storage Module ......................................................................................................................................A.03

Parts Diagram - 80kW Storage Module ......................................................................................................................................A.04

Parts List - Storage Module ........................................................................................................................................................A.05

Parts Diagram / List - Base ........................................................................................................................................................A. 06

Typical System Line Voltage Wiring Diagrams ................................................................................................................A.07-A.08

Internal System Wiring Diagram - Low Voltage ........................................................................................................................A.09

Help Menu ..................................................................................................................................................................................A.10

Error Codes ........................................................................................................................................................................A.10-A.13

Warranty

Ta b l e o f co n T e n T S Th e r m el e c T hy d r o n i c

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SUPPLY WATER

WATER

RETURN

VARIABLE SPEED

CORE BLOWER

MOTOR ASSEMBLY

225° AUTO RESET LIMIT

250° MANUAL RESET LIMIT

AIR TO WATER HEAT EXCHANGER

HEAT STORAGE BRICK

HEATING ELEMENT

Operation

GENERAL OPERATION

The ThermElect Hydronic heating system stores demand 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, 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 t 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.

Operation

SYSTEM USE DURING CONSTRUCTION PHASE

Like most heating equipment manufacturers, Steffes strongly recommends that “Construction Heating Units” be used instead of the permanent heating system during the construction phase. Use of the permanent heating system during this phase may contaminate the duct

system and/or internal areas of the heating system. This may cause poor indoor air quality issues and/or improper system operation or equipment damage.

SYSTEM START-UP

On start-up of the ThermElect Hydronic system, odors relating to rst 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.

Th e r m el e c T hy d r o n i c op e r a T i o n  1.01

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CONTROL PANEL

Operation of the ThermElect 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.)

Four-Digit LED Display

The four digit LED displays specic operating information. During the conguration process, the conguration number and the values set in these congurations are

displayed for viewing and adjusting purposes.

AM and PM Indicator Lights

The AM and PM indicator lights are only utilized if the Steffes Time Clock Module is being installed and using 12 hour time display. With this module installed,

Operation

the system displays time on AM/PM intervals. The light ashes next to the active designator/symbol. The system can be congured to display military time,

CONTROL PANEL

FIGURE 1

CAUTION

in which case both the AM and PM lights illuminate.

Editing conguration

Mode (Edit) Button

Used to access menus on the system (i.e. Help Menu or Conguration Menu) and to allow modifying of conguration settings.

Up and Down Arrow Buttons





information may alter the performance and operation of the system.

Used to scroll up or down when viewing or modifying operating functions.

Interface Port

Allows technician external access for advanced operating modes, updating software, and troubleshooting.

OPERATING STATUS

The four digit LED will 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 followed by the outlet water temperature. C = Off-Peak (Charge) Time P = On-Peak (Control) Time A = Anticipated Peak Time

Outdoor Temperature -“O” followed by a number indicates current outdoor temperature.

Heat Call Status - indicates the current heat call status as determined by the room thermostat(s).

The faceplate displays the highest heat call value present. If receiving a Stage 1 Forced Air Heat Call and a Hydronic Heat Call, the display will read “HC_3”.

A bar illuminates on the lower portion of the display's third digit whenever one or

more heating elements are energized.

Brick Core Charge Level - “CL” (charge level) followed by a number indicates the current per-

centage of heat stored in the brick core. “CL:_” indicates the core is below minimum charge level 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 charging is not allowed 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.

op e r a T i o n  1.02 Th e r m el e c T hy d r o n i c

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DISCHARGE AIR/WATER SYSTEM

The 9100 Series heating systems can be used as straight hydronic heating appliances or as a combination hydronic

and forced air system with the addition of a eld supplied air handler, water coil, and duct sensor. In all systems, to

deliver stored heat, the 9100 Series needs to receive a signal from a thermostat, BACNet system, energy management system, or serial communication input. This signal will initiate one of several levels of heat call.

When a heat call is initiated, the system displays the type of heat call on the status screen of the control panel, the primary loop pump is energized, and the outlet water temperature is monitored. The desired discharge water temperature is regulated based off of the target temperature (L127) established.

BRICK CORE CHARGE CONTROL

Steffes heating systems are capable of providing a wide variety of heating options for various applications. The heating system's primary function is to store energy in the form of heat. Because the system is operated with mi-

croprocessor based control, it is very exible in meeting the demands of the application. The rate at which energy

is stored can be controlled with BACNET, 4-20, or pulse inputs.

The amount of energy stored is based on the target level which is determined by outdoor temperature, utility peak conditions, building automation system, and/or the heating requirements. Sensors monitor the brick core temperature and communicate this information to the processor control board. If the current charge level is lower than the target level of any core, elements will be energized as allowed by the load management system.

CHARGE CONTROL OVERRIDE

If desired, the ThermElect 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 conguration.

Operation

MAINTENANCE AND CLEANING

Any air lter(s) in the system should be replaced on a regular basis to ensure proper operation and to maintain overall efciencies. No additional routine maintenance is required.

If utilizing a heat pump or air conditioning system with the ThermElect Hydronic system, the indoor coil should be cleaned periodically as dirt accumulation may reduce system efciency. It is important to follow the manufacturer’s maintenance and cleaning recommendations for these devices.

Th e r m el e c T hy d r o n i c op e r a T i o n  1.03

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Optional Accessories

LOAD MANAGEMENT CONTROL

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

1. BACNet Control

Steffes commercial heating furnaces are available with a BACNet control op-

tion (Order Item #1301015). 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 conguration, testing and adjustment • Service requirement alerts •

2. 4-20 Milliamp Control (1-5 volt DC)

System receives a signal from an external load control device such as a building load management

Accessories

system. This external signal dictates the maximum amount of energy which can be consumed during a preset time interval.

3. 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 programmed into the ThermElect 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 (Order Item

#1908140) are available when using pulse monitoring load control. Each module has eight (8) zones which can be controlled. The system must be congured to recognize the number of load management modules installed (maximum of two per system).

LOAD MANAGEMENT

CONTROL MODULE

BACNET

4. Conventional Peak Control The ThermElect Hydronic system responds to heat calls during the on-peak and off-peak periods;

however, only consumes energy (energize heating elements) during the off-peak periods. The ThermElect Hydronic system is controlled by an external control device such as a meter, time clock module, or BACNet control.

op T i o n a l ac c e S S o r i e S  2.01 Th e r m el e c T hy d r o n i c

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EXTERNAL DUCT SENSOR

SENSOR

AIR HANDLER

9100 SERIES

THERMELECT

WATER

COIL

The optional external duct sensor (Order Item #1041536) provides the ability to monitor the duct temperature at an area beyond fresh air makeup and/or beyond other devices and regulate the discharge air temperature accordingly.

The duct sensor feature is enabled if the 4 bit is set in Location 53 (L053). Once enabled, the ThermElect Hydronic system monitors temperature at both the duct sensor and the output sensor during Y, W, or E calls from the thermostat.

STATIC HEAT RECOVERY UNIT

During operation of the ThermElect Hydronic, there is some static dissipation that comes off of the warm outer panels. The Static Heat Recovery unit (Order Item #1302110) moves this heat from the

ThermElect Hydronic system to an area requiring heat. Utilizing this option can maximize efciency when the system is installed in

an unheated area.

With the Static Heat Recovery unit installed, the ThermElect Hydronic system can be set up to monitor temperature at the control board and/or in the brick core. If either of these temperatures reach a point greater than the preset point, the blower is the Static Heat Recovery unit is energized and draws heat from inside the painted outer panels of the ThermElect Hydronic system and delivers it to the desired area of the structure.

LIFTING HANDLES

Accessories

LIFTING HANDLES

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

ThermElect Hydronic system into its nal location.

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 (Order Item #1301016). 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

Th e r m el e c T hy d r o n i c op T i o n a l ac c e S S o r i e S  2.02

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CONTROL CIRCUIT STEP-DOWN TRANSFORMER

Model

Primary

Voltage

Secondary

Voltage

KVA

Hevi Duty Item #

Steffes Item #

277/480V

480

240

HS1F1BS or equal

1017082

347/600V

600

240

HS10F2AS or equal

1017080

The internal controls and motors of all ThermElect 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. load as dictated by the furnace’s set-up. With a Bacnet, the furnace can be commanded to varying input levels remotely.

Accessories

op T i o n a l ac c e S S o r i e S  2.03 Th e r m el e c T hy d r o n i c

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Installation

SHIPPING AND PACKAGING

The ThermElect Hydronic system 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.

STORAGE MODULE

MODEL INPUT

9150 53kW 9180 80kW

BASE

PRESSURE RELIEF VALVE

INFORMATION PACKAGE

(includes Owner's Manual and Warranty Registration Card)

(included on pallet with the electrical panel )

HEATING ELEMENTS

WITH CERAMIC INSULATORS

MODEL ELEMENTS

9150 12 (2 boxes of 6) 9180 18 (3 boxes of 6)

(shipped separately)

Installation

(shipped behind the

exchanger access

panel)

Refer to Page 3.09

ELECTRICAL PANEL

(includes electrical

panel mounting screws, romex connectors, and wiring

schematic)

208/240V shown

Th e r m el e c T hy d r o n i c in S T a l l a T i o n  3.01

INSTALLATION HARDWARE KIT

(shipped inside the electrical

panel)

SEAM TRIM

(shipped inside brick

storage module)

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SHIPPING AND PACKAGING CONTINUED...

CORE THERMOCOUPLES

(shipped inside the electrical panel)

TOP AIR CHANNEL BLOCK

1 box of 4 shown

(shipped separately)

9150 = Qty 2 9180 = Qty 3

OUTDOOR TEMPERATURE SENSOR

(shipped inside the

electrical panel)

TRANSFORMER CONDUIT ASSEMBLY

(277V & 347V SYSTEMS ONLY)

(shipped inside the electrical panel)

Installation

CERAMIC BRICK

MODEL BRICK LBS PALLETS

9150 192 3,360 2 9180 288 5,040 3

96 brick per pallet (shipped separately)

in S T a l l a T i o n  3.02 Th e r m el e c T hy d r o n i c

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PLACEMENT AND CLEARANCE REQUIREMENTS

34"

RAGE

9180 - 98"

9150 - 77"

51"

36" MINIMUM

CLEARANCE

36" MINIMUM

CLEARANCE

1" CLEARANCE

REQUIRED

8" MINIMUM CLEARANCE

12" MINIMUM

CLEARANCE

36" MINIMUM CLEARANCE

8" MINIMUM CLEARANCE

12" MINIMUM

CLEARANCE

The system dimensions and required clearances MUST be taken into

consideration when choosing its location within a structure. (See

Figure 2 for dimensions and clearance requirements.)

Risk of re. Can cause injury or death.

The best installation location for the system is in a space requiring heat so some amount of the heating requirements can be satised through static dissipation from the warm outer panels of the

ThermElect Hydronic system. In situations where the system is not installed in an area it is intended to heat (i.e. garage or storage area), it is important to account for the heat lost through static dissipation by making proper adjustments when sizing the system.

Violation of the clearance require-• ments or failure to provide proper ventilation can cause improper operation of the system. Maintain the placement and clearance require-

ments as specied and provide

ventilation as necessary.

Moving the system after install •

This area must remain free of debris and most importantly the room air should be maintained at less than 85o Fahrenheit. Area

may require ventilation. Refer to Specications (Pages A.01-A.02).

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

It is the responsibility of the installer and system designer to provide this ventilation.

In addition to the physical space requirements, the weight of the system must also be taken into consideration when selecting the installation surface. A level concrete oor is the designed installation surface, but most well supported surfaces are acceptable. If unsure of oor load capacity, consult a building contractor or architect.

WARNING

Special requirements must be considered if placing the system in a garage or other area where com-

bustible vapors may be present. Consult electrical, building, and re prevention codes.

SYSTEM REQUIREMENTS

FIGURE 2

DIMENSIONS

 Back = 8 inches  Bottom = 1 inch (from combustible material)  Right Side = 12 inches  Top = 8 inches (from combustible material)  Left Side & Front = 36 inches (for ease in servicing)

Adhere to clearances and provide appropriate ventilation to maintain no greater than 85oF air temperature in area where system is installed.

CLEARANCES

Installation

Some electrical codes may require a greater front and/or left side clearances depending on operating voltages and other factors.

Th e r m el e c T hy d r o n i c in S T a l l a T i o n  3.03

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INITIAL SET-UP

Step 1 Remove the Information Package from the outside of the electri-

cal panel and unpackage the storage module and base.

Step 2 Move the base of the ThermElect system into location.

Step 3 Level the base ensuring the leveling legs are in full contact with

the oor so the base does not rock. The legs cannot extend more

than 1”.

Step 4 Remove the painted front and back panels of the storage module.

Step 5 Position the brick storage module onto the base, making sure the

square holes (front) in the base line up with the square holes of

the storage module.

Optional lifting handles are available from Steffes

(Order Item #1302120).

Step 6 Reinstall painted back panel.

HEAVY OBJECT WARNING: Risk of personal injury, or death. ThermElect Hydronic systems are heavy. Use lifting aids to move system into place.

Do not place object, hands,

and/or body parts under the system when lifting.

Do use care to keep objects,

hands, and/or body parts clear of system when lifting.

WARNING

CAUTION

Risk of improper operation or equipment damage. Read and follow installation instructions carefully.

• Remove system from shipping pallet prior to nal placement.

• Ensure that leveling legs make solid contact with ooring and do not extend more than 1 inch.

• Use and follow generally accepted safety practices when handling insulation materials.

• Equipment MUST be installed by a qualied technician in accordance with all applicable codes

and regulations.

ELECTRICAL PANEL INSTALLATION

Step 1 Remove the electrical panel front cover and locate the installation hardware package.

Step 2 Remove 1" trade size knockouts from the electrical panel and the ThermElect Hydronic's left side

panel to allow routing of element harnesses. DO NOT remove any unneeded knockouts.

Step 3 Remove 1/2" trade size knockout for routing of control wiring.

Step 4 Secure the electrical panel to the left side of the system with the 8 x 3/4" sheet metal screws supplied

in the electrical panel.

Knockouts must be effectively sealed by connectors.

Installation

BRICK LOADING

Step 1 Remove the seam trim from inside the storage module and

set aside.

Step 2 Remove the sheet metal screws around the outer edge of

the galvanized front panel. Remove the panel and set it aside.

Step 3 Starting at the bottom, carefully lift the insulation blankets

and drape them over the top of the system.

Use and follow generally accepted safety prac-

tices when handling insulation materials.

Risk of equipment damage or personal injury. Insulation boards

located behind the insulation blankets may fall out when blankets are lifted. Use caution when lifting insulation blankets to avoid personal injury or damage to the insulation boards.

CAUTION

Step 4 Cut banding and remove the two packages of rigid insulation from inside the storage module. One

of the packages contains the back rigid insulation (no holes) and one package contains the front rigid insulation (with holes).

in S T a l l a T i o n  3.04 Th e r m el e c T hy d r o n i c

Page 15

Step 5 Locate and install the back rigid insulation inside the brick storage module. It will

be placed on top of the existing rigid insulation at the back of the module. The angled edge will line up with the existing rigid insulation.

Step 6 Load the brick, one row at a time, starting at the back of the brick core and work-

ing forward. Load bricks as shown in Figure 3. Make certain brick debris does not interfere with brick alignment front to back.

Step 7 Install top air channel block by sliding it up and

back into place on top of the bricks. (See Figure 4.)

For ease of installation, install top block

while loading bricks.

Step 8 Install the front rigid insulation (with holes) in front

of the bricks. Again, the existing angled rigid insulation will line up with the front angled rigid insulation.

The holes in the rigid insulation board

MUST line up with the brick openings so elements can be installed.

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 tem-

perature sensor(s) difcult.

• Brick rows MUST line up front to back and top to bottom.

FIGURE 4

WARNING

Risk of re. Can cause personal

injury or death. DO NOT operate the Comfort Plus Hydronic system if damage to the insulation panels on the inner sides of the brick core occurs.

BRICK LOADING

FIGURE 3

HEATING ELEMENT INSTALLATION

Step 1 After all bricks are loaded and rigid insulation boards

are in place, insert the heating elements through the insulation, sliding them in until the cement side rails

are ush with the front side of the ceramic brick.

Make sure the elements designated as "out-

er" elements are installed on the electrical panel side of the system with the shortest lead in the left most brick position.

Step 2 Route the element termination head with ceramic in-

sulator to the appropriate side of the system. Insert the lead into position as shown in Figure 5.

Element leads must never cross each

other.

Step 3 Install element lead insulators. These ceramic insu-

lators MUST maintain lead wire spacings as shown in Figure 6.

WARNING

HAZARDOUS VOLTAGE: Risk of electric shock. Can cause injury or death.

DO NOT remove the electrical panel

cover while system is energized.

Elements MUST be positioned prop-

erly to avoid short circuiting against any surfaces within the system.

FIGURE 5

FIGURE 6

Installation

Th e r m el e c T hy d r o n i c in S T a l l a T i o n  3.05

Page 16

Step 4 Lower insulation blankets back into position, one at a time. Carefully tuck the sides of the insulation into

Core

Temperature

Sensors

Connect To Core "E"

On 80kW Module Only

Relay

Driver

Board

Connect To

Core "D"

Connect To

Core "C"

the edges, corners, and around the exposed portions of the heating element to ensure maximum efciency.

Use face mask, gloves, and long sleeved garments when handling insulation materials in ac-

cordance with generally accepted safety practices.

Step 5 Reinstall the galvanized front panel and secure it to the system using the screws originally removed.

Step 6 Route element harnesses through connectors, using one connector/harness until tape is centered.

Step 7 Attach element lead wires to element terminals. Start at the top using the appropriate color chart below.

Repeat pattern as necessary. The neutral white wires are jumpered together in sets of three.

277/347V = Black (Top) 208/240V = Black (Top) 240V = Black (Top) Systems White 3phase Red 1phase Red Red Systems Blue Systems Black White Black Red Blue Red White Blue

Step 8 Route the orange wire to the electrical compartment. Cut the wire and crimp ends (found on orange/

black wires in electrical compartment). Connect the orange wires to the orange/black wires.

Step 9 Remove the blower access cover from the base left side. Locate the blue core blower wires and purple

(violet) water temperature sensor wires.

Step 11 Route the wires through the anged hole at the front left corner of the base. Continue routing up to the

electrical compartment through 1/2" knockout. Connect the blue core blower wires to black and the blue wires. Connect the two purple (violet) wires to the two purple wires..

BRICK CORE TEMPERATURE SENSOR INSTALLATION

CAUTION

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.

Step 1 Remove the screw(s) by the brick core temperature sensor con-

nector holes in the galvanized front panel.

Installation

Step 2 Route the brick core sensors through the 1/2" knockout up to

the relay driver board. The yellow wire from each sensor must be connected to the Y terminal of the proper sensor connection terminal block, and red to R. Polarity of sensors is critical.

Sensor connections MUST be installed as follows:

• Single Module - 9150 or 9180 (Figure 7)

• Bottom sensor to core C

• Second sensor to core D

• Third (if equipped) to core E

Step 3 Insert the brick core temperature sensors through the holes in

the galvanized front panel. The sensors must pass through the blanket and board insulation and into the brick core. Use the sensors to aid in making a passageway by rotating the sensors

Step 4 Once brick core sensors are installed, re-install sensor mount-

while gently pushing inward.

ing screws to secure and ground the sensors.

CORE TEMPERATURE SENSOR

CONNECTIONS

FIGURE 7

in S T a l l a T i o n  3.06 Th e r m el e c T hy d r o n i c

Page 17

LINE VOLTAGE ELECTRICAL CONNECTIONS

}

Neutral

Recovery Unit (240V)

Optional Static Heat

Secondary Pump Power (Variable Speed)

Primary Pump

TRANSFORMERS

240v / 24v

COM

NONO

1/4 Amp

COM COM

Transformer 120/240 VAC

BASE IO BOARD

EXCHANGER LIMITS

N.C.

AUTO

DAMPER

RESET

225 °

MANUAL

COM.

WHITE

HIGH

RESET

250° N.C.

L2 120

L2 240

BLOWER

RESISTER

L1L2

Neutral

Power (240V)

}

Power (240V)

}

Recovery Unit (240V)

Optional Static Heat

Secondary Pump Power (Variable Speed)

Primary Pump

Ground

4uf

Cap.

ORANGE

PRIMARY PUMP POWER

(VARIABLE SPEED)

SECONDARY PUMP POWER

OPTIONAL STATIC HEAT RECOVERY UNIT (240V)

NEUTRAL

(240V)

}

RESISTER

RED

BLUE

BLACK

5 Amp

Secondary

CORE

BLOWER

Element Relay

Neutral

#11 Right

Element

Element Relay

#12 Left

Ground

Lug

#12 Left

Element

Element Relay

Element #7 Right

Element #9 Right

#7 Right

#9 Right

#5 Right

Element Relay

#10 Left

#8 Left

#6 Left

#3 Right

Element Relay

Element #1 Right

Element #3 Right

#1 Right

Element Relay

#5 Right

#4 Left

Element Relay

#2 Left

Element Relay

Element

#2 Left

Element

#4 Left

Element

#8 Left

#10 Left

Element

#6 Left

Element

To determine the correct wire size required for the circuit feeding the system, refer to the Specications (Page A.01-A.02) and the system's identication label located on the cover of the electrical

panel (Figure 8).

HAZARDOUS VOLTAGE: Risk of elec-

Step 1 Remove the electrical panel cover if not already removed.

Step 2 277/347 only. Mount the dry type enclosed transformer

below the electrical panel on the system's painted left side. Use a 1/2" knockout from the bottom left side of the electrical panel.

Install only the proper size and type fuses in the factory supplied fuse block.

Step 3 Route all supply circuit eld installed conductors through

a knockout and into the electrical panel.

Use copper or aluminum conductors rated at

75oC or higher for line voltage eld connection of this device.

Step 4 Make line voltage connections to lugs of single feed bus and ground lug. Refer to the Line Voltage Wiring

Diagrams (Pages A.07 - A.08) for more information on these connections.

tric shock, injury or death. Do not energize the system until installation is complete. Equipment MUST be installed

by a qualied technician in accordance

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

Risk of equipment damage, personal

injury or re. Do NOT install any wiring in line voltage compartment unless rated for line voltage. To ensure proper operation and safety, all wiring in the line voltage compartment MUST be rated for line voltage.

WARNING

CONNECTION OF PRIMARY LOOP PUMP

In 277/347 volt installations, a 120 or 240V single phase pump can be used. Connect the pump only to terminals inside the electrical panel marked for connection of the primary loop pump as shown in Figure 9B.

• A 240V pump is required for 208/240V applications

(Figure 9A) as no neutral terminal is provided.

• Do not use pumps with relay outputs or electronics

FIGURE 9

(277/347V Shown)

• Total rating of all connected pumps cannot exceed

1.2 amps on each pump output.

• Make wiring connections according to manufacturer's instructions and appropriate line voltage wiring diagram.

SAMPLE SYSTEM IDENTIFICATION LABEL

FIGURE 8

9A - 208/240V

9B - 277347V

Installation

Th e r m el e c T hy d r o n i c in S T a l l a T i o n  3.07

Page 18

LOW VOLTAGE ELECTRICAL CONNECTIONS - OUTDOOR

Outdoor Sensor

Hydronic Heat Thermostat, Zone

Valve, End Switch, or Pump Control

12 Position Terminal Block

TEMPERATURE SENSOR (OPTIONAL)

If using BACNet control, the outdoor temperature sensor may not be used. Follow the in-• structions included with the BACNet Controller. If connecting to the Steffes power line carrier (PLC) system, follow the installation instruc-• tions in the PLC system's Owner's and Installer's Guide. Outdoor sensor wire MUST NEVER be combined with other control wiring in a multi-con-• ductor cable.

Theory of Operation: 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 the heating requirements.

Location of: The outdoor sensor must be placed in a location where it can accurately sense outdoor temperature

and is not affected by direct sunlight or other abnormal temperature conditions.

Installation Methods: A) Hard wired to Steffes heating system "OS" and "SC" terminals (default) OR B) Connected to Power Line Carrier (PLC)

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 10.

• If the sensor wiring is routed through an external wall, the opening through which the wire is routed

MUST be sealed. Failure to do so may affect the accuracy of the outdoor temperature sensor.

• The outdoor sensor is supplied with a lead length of 40 ft. If a greater wire length is needed, it can

be extended to a total of 250 ft.

• No other loads can be controlled or 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.

LOW VOLTAGE ELECTRICAL CONNECTIONS - ROOM THERMOSTAT (OPTIONAL)

Installation

A low voltage (24VAC) room thermostat can be used for room temperature control with the ThermElect Hydronic system. If so, Steffes recommends using a digital thermostat. To iniate a heat call, the system needs a switch closure from R to H. This energizes the primary loop pump outputs.

12-Position Low Voltage Terminal Block Coding

HYDRONIC HEATING SINGLE ZONE SYSTEM

R = Low Voltage Hot C = Low Voltage Common Y = Compressor/Stage 1 Heat Call W = Stage 2 Heat Call Y2 = Compressor Output G = Fan Call O = Reversing Valve Input O2 = Reversing Valve Output H = Hydronic Heat OS = Outdoor Temperature Sensor SC = Temperature Sensor Common DS = Duct Temperature Sensor

in S T a l l a T i o n  3.08 Th e r m el e c T hy d r o n i c

LOW VOLTAGE CONNECTIONS

FIGURE 10

Page 19

AIR CONDITIONER/HEAT PUMP INTERFACE

Available Pressure

Relief Valves

Minimu m

BTU Rating

Maximum

Operating Pressure

Order

Item #

30 PSI

400,000

20 PSI

1100104

75 PSI

500,000

60 PSI

1100105

150 PSI

500,000

125 PSI

1100106

Note: 9100 Series Systems are shipped with 75 PSI pressure relief valves.

If a different valve is required order the item number listed above.

The ThermElect Hydronic system can be used in conjunction with an air conditioner or a heat pump. Contact Steffes Corporation for more information.

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 ttings.

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

relief valve.

 DO mount the pressure relief valve in a vertical, upright position.  This pressure relief valve is sized to service the needs of the

ThermElect 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 ThermElect Hydronic. It is extremely important that the following conditions for installation of this part are met:

• Insure all connections, including the valve inlet are clean and free from any foreign material.

• Use pipe compound sparingly, or tape on external threads only.

• Mount the pressure relief valve in a vertical, upright, position directly to the outlet water port of the system. Under no circumstances should there be a ow restriction or valve of any type between the safety relief valve and the pressure vessel.

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 point of discharge.

• allow complete drainage of both the valve and the discharge line.

• be independently supported and

securely anchored to avoid applied

CAUTION

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 375oF or greater.

• be, over its entire length, of a pipe

size equal to or greater than that of

the valve outlet.

Risk of injury or property damage. During operation, the pressure relief valve may discharge large amounts of steam and/or hot water. To reduce the potential for bodily injury or property damage, install a discharge line.

 DO use schedule 40 pipe for the discharge line.  DO NOT use schedule 80, extra strong pipe or

connections on the discharge line.

 DO NOT cap, plug, or otherwise obstruct the

discharge pipe outlet.

 DO follow all local, state, and national codes

and regulations.

Installation

Th e r m el e c T hy d r o n i c in S T a l l a T i o n  3.09

Page 20

PLUMBING

Air Vent

Air Separator

Expansion

Tank

Pressure

Relief Valve

(Factory Supplied)

Optional

Temperature and

Pressure Relief Valve

(Consult Local Code)

Inlet

Outlet

*Primary

Loop

Pump

Piping MUST Be Supported

Zone

Connection

Area

Primary Loop Pump

Control Wiring

White

Red

Primary Loop Secondary Loop

Primary

Loop Pump

ThermElect

Hydronic

Exchanger

This Valve Must Be Open During

Normal Operation

White

Red

The ThermElect Hydronic system should be plumbed with a primary loop and secondary (zone) loops. The primary loop needs to consist of a minimum of 12' of 1.25" pipe. The heat exchanger inlet and outlet are 1.5"

diameter, reducers will be required if 1.25" pipe is elected for the primary loop. The secondary (zone) loops require additional pump(s) to operate effectively. Refer to Typical Primary Loop and the Typical System Plumbing

Diagrams below for installation information.

The primary loop serves to regulate heat transfer from the system’s heat exchanger. The primary loop pump should be powered by ThermElect Hydronic control system as shown in Figure 11. If using other control meth-

od, ow MUST continue for at least 30 seconds at the end of a heat call.

TYPICAL PRIMARY LOOP

FIGURE 11

Installation

TYPICAL SYSTEM PLUMBING SINGLE TEMPERATURE ZONES

FIGURE 12

Single Temperature Zone

NOTE: There are many additional ways to connect plumbing and regulate temperature from the primary loop onward.

in S T a l l a T i o n  3.10 Th e r m el e c T hy d r o n i c

Primary Loop

Secondary Loop

Page 21

Heat Exchanger Flow and Restriction Properties

Capacity 3.4 Gallons

Maxim um Flow 30 GPM

Tubing Materia l Copper

Maxim um Outlet

Water Set Temperature

180°F

HEAT EXCHANGER SPECIFICATION

2" MINIMUM

HEATING

VALVE

CHECK

UP15-42F

LOOP

PRIMARY

PUMP

ZONES

2" MINIMUM

BALANCING

VALVE

FROM

HEATING

ZONES

9180

9150

Restriction 80°

GPM Velocity (Feet/Sec)

Restriction 150° Water

(Feet of Heatd)

50% Propylene Glycol

(Feet of Head)

5 0.6 0.1 0.2

10 1.2 0.3 0.6

15 1.8 0.7 1.3

20 2.4 1.2 2.1

24.5 3 1.7 3.1

25 3.1 1.7 3.2

30 3.7 2.4 4.5

CAUTION

FREEZE PROTECTION: Risk of property damage. Hydronic heating system freeze-ups WILL cause extensive damage to the entire heating system and/or property. It is the responsibility of the installer to provide protection against freezing.

PIPING SUPPORT: Risk of equipment damage or personal 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.

MULTIPLE UNITS SYSTEM PLUMBING WITH MASTER LOOP

FIGURE 13

NOTES:

1. Check valves on the return side are recommended to

prevent back ow into the furnace.

2. Balancing valves are recommended to provide an even

ow of water between all units.

3. Flow must continue for a minimum of 30 seconds after call for heat ends.

Installation

Th e r m el e c T hy d r o n i c in S T a l l a T i o n  3.11

Page 22

Input Voltage

240

120/208

120/240

277/480

347/600

Phase 1 3 3 3

Number of Wires

2 3 3 4 4

Charging Input

(kW)

53.3

48.0

53.3

50.4

53.3

Elements - Quantity Elements - Watts Each

4,444

4,000

4,444

4,200

4,444

Amps – Core Charging

222.20

133.39

128.44

60.65

51.23

Maximum Pump & Blower Load

(AMPS)

4.6

2.3

1.9

Minimum Circuit Ampacity

283.50

172.49

166.30

78.69

66.41

Minimum Fuse Size

300

175

Maximum Fuse Size

300

200

100

Blowers/System Control Voltage*

240V/208V

Storage Capacity – kWh Storage Capacity - BTU

320

1,091,840

Pipe Size

(Inlet/Outlet)

1 ½”

Required Primary Loop

Minimum of 12’ of 1 ½” pipe required in primary loop plumbing

Output Water Temperature

(selection range)

50oF to 185oF

Maximum Working Pressure

20 PSIG requires 30 PSI Pressure Relief Valve

60 PSIG requires 75 PSI Pressure Relief Valve (Standard)

125 PSIG requires 150 PSI Pressure Relief Valve

Minimum Flow Rate

(Primary Loop)

1 GPM per 10,000 BTU of required output at 20oF Temperature

Rise (30 GPM maximum)

Internal Pressure Drop

(assuming 50% glycol mix)

.7 ft @ 15 GPM 1.8 ft @ 25 GPM

1.2 ft @ 20 GPM 2.5 ft @ 30 GPM

Maximum Static Dissipation (Watts)

3,000

Approximate Heater Module Weight

(lbs)

900

Approximate Insulation Block / Elements /

Other Weight

(lbs)

330

Approximate Brick Weight

(lbs)

3,440

Number of Brick

192

Approximate Installed Weight

(lbs) **

4,670

Appendix

SPECIFICATIONS

MODEL 9150 (53kW Storage Module)

* Supply via stepdown transformer - eld installed.

** Add approximately 500 lbs to arrive at shipping weight.

Appendix

ap p e n d i x  A.01 Th e r m el e c T hy d r o n i c

Page 23

MODEL 9180 (80kW Storage Module)

Input Voltage

240

120/208

120/240

277/480

347/600

Phase 1 3 3 3

Number of Wires

2 3 3 4 4

Charging Input

(kW)

80.0

72.0

80.0

75.6

80.0

Elements - Quantity Elements - Watts Each

4,444

4,000

4,444

4,200

4,444

Amps – Core Charging

333.30

200.09

192.66

90.97

76.84

Maximum Pump & Blower Load

(AMPS)

4.6

2.3

1.9

Minimum Circuit Ampacity

422.38

255.86

246.57

116.59

98.43

Minimum Fuse Size

450

300

250

125

100

Maximum Fuse Size

450

300

150

125

Blowers/System Control Voltage*

240V/208V

Storage Capacity - kWh Storage Capacity - BTU

480

1,637,760

Pipe Size

(Inlet/Outlet)

1 ½”

Required Primary Loop

Minimum of 12’ of 1 ½” pipe required in primary loop plumbing

Output Water Temperature

(selection range)

50oF to 185oF

Maximum Working Pressure

20 PSIG requires 30 PSI Pressure Relief Valve

60 PSIG requires 75 PSI Pressure Relief Valve (Standard)

125 PSIG requires 150 PSI Pressure Relief Valve

Minimum Flow Rate

(Primary Loop)

1 GPM per 10,000 BTU of required output at 20oF Temperature

Rise (30 GPM maximum)

Internal Pressure Drop

(assuming 50% glycol mix)

.7 ft @ 15 GPM 1.8 ft @ 25 GPM

1.2 ft @ 20 GPM 2.5 ft @ 30 GPM

Maximum Static Dissipation (Watts)

4,500

Approximate Heater Module Weight

(lbs)

970

Approximate Insulation Block / Elements /

Other Weight

(lbs)

400

Approximate Brick Weight

(lbs)

5,160

Number of Brick

288

Approximate Installed Weight

(lbs) **

6,530

* Supply via stepdown transformer - eld installed.

** Add approximately 500 lbs to arrive at shipping weight.

Appendix

Th e r m el e c T hy d r o n i c ap p e n d i x  A.02

Page 24

PARTS DIAGRAM - 50KW STORAGE MODULE

Appendix

ap p e n d i x  A.03 Th e r m el e c T hy d r o n i c

Page 25

PARTS DIAGRAM - 80KW STORAGE MODULE

Th e r m el e c T hy d r o n i c ap p e n d i x  A.04

Appendix

Page 26

PARTS LIST - STORAGE MODULE

DWG Ref # De scription 50kW Item # 80kW Item #

1 Seam Trim Front/Back 5948303 5948303

2 Front/Back Panel, Painted 5948316 5948324

3 Core Panel, Back 5948172 5948174

4 Front/Ba ck Core Standoff, Small 5948208 5948208

5 Mounting Bracket Front & Ba ck 5948152 5948152

6 Front/Ba ck Core Standoff, Center 5948210 5948210

7 Core Support Bracket, Top 5948194 5948194

8 Insulator Ceramic Element Lead 1015057 1015057

9 Heating Elements

10 Insulation Block Kit, Front

(2010 and Newer)

1040221 1040221

" Insulation Block Kit, Back

(2010 and Newer)

1040222 1040222

" Insulation Block Kit, Front

(2009 and Older)

1040219 1040219

11 Brick Each (96 Brick per Pallet) 5903017 5903017

12 Cast Block Bottom 1056501 1056501

13 Limit Switch EGO 575Deg 1013026 1013026

14 Insulation Blanket 2" 4# - 15" 1056042 1056042

15 Se am Trim Side 5948302 5948302

16 Limit Access Cover Panel, Painted 5948608 5948608

17 Core Limit Mounting Bracket 5948202 5948202

18 Cabinet Panel Air Handler Side, Painted 5948310 5948318

19 Core Panel, Back 5948170 5948176

20 Core Panel, Top 5948188 5948188

21 Top P anel, Painted 5948328 5948328

22 Limit Switch 290D 25A60TX11 6 DIFF 1012019 1012019

23 Limit Cover P a nel Top, P ainted 5948190 5948190

24 Air Channel Assembly Right 5948164 5948168

25 Core Bracket Stiffener Right Side, Upper 5948214 5948213

26 Core Bracket Stiffener Right Side, Lower 5948212 5948212

27 Cabinet Panel Non-Air Handler Side, P ainted 5948312 5948320

Contact Factory for Ordering Information

Appendix

ap p e n d i x  A.05 Th e r m el e c T hy d r o n i c

Page 27

PARTS DIAGRAM / LIST - BASE

DWG Ref # De s cription Ite m #

1 Motor Access Cover 5948606

2 Pressure Relief Valve, 75 PSI 1100105

" Pressure Relief Valve, 150 PSI 1100106

3 Pressure Relief Adapter Fitting 1100131

4 Motor, 1/4 HP , 1700 RP M** 1020009R

5 Core Blower Wheel** 1021007R

6 Core Blower Asse mbly** 1041960R

7 Rear Core Blower Air Box Panel 5948536

8 Rear Inlet Channel 5948530

9 Front Core Blower Air Box Panel 5948534

10 Front Outlet Channel 5948528

11 Top Air Box Flange 5948532

12 Inlet Pipe Cover 5948526

13 Outlet Pipe Cover - Left Half 5948525

14 Outlet Pipe Cover - Right Half 5948527

15 Left Side Exchanger Panel 5948524

16 Base Panel Rear, Painted 5948602

17 Supply Water Temperature Sensor 1041748

18 Heat Exchanger 1100107R

19 Base Panel, Top 5948144

20 Base Panel Right, Painted 5948604

21 Base Panel, Bottom 5948140

22 Limit Switch 225 Degree, Auto Reset 1012029

23 Limit Switch 250 Degree, Manual Reset 1012025

24 Base Panel Front, Painted 5948600

** Systems manufactured prior to July 2009 require the entire assembly replaced. For systems

manufactured after July 2009 order individual parts required.

Th e r m el e c T hy d r o n i c ap p e n d i x  A.06

Appendix

Page 28

Typical System Line Voltage Wiring Diagram

BLACK/YELLOW

CORE

HIGH

COM.

Element

L2 240

L2 120

BLOWER

RESISTER

5 Amp

RESET

MANUAL

EXCHANGER LIMITS

N.C.

AUTO

N.C.

225 °

250 °

4uf

DAMPER

RESISTER

BASE IO BOARD

COM

TRANSFORMERS

240v / 24v

Element

#11

COM

1/4 Amp

COM

Optional Static Heat

Recovery Unit (240V)

Secondary Pump Power

(Variable Speed)

Primary Pump Power (240V)

#10

#3 Relay#4 Relay

#1 Relay

Element

#2 Relay

Element

#7 Relay

#5 Relay

#8 Relay

#6 Relay

Element

#11 Relay

Element

#12 Relay

#17 Relay

Element

#18 Relay

#12

Lug

Ground

WHITE

Cap.

RED

}

BLOWER

#3 Right

#4 Left

Element Relay

#2 Left

Element

#2 Left

Element

#4 Left

Element Relay

Element #1 Right

Element #3 Right

#1 Right

Element Relay

#10 Left

#8 Left

Element

#8 Left

#10 Left

Element

#6 Left

Element

#12 Left

Element

Element Relay

Element #7 Right

Element #9 Right

#7 Right

#9 Right

#5 Right

Element

Element Relay

Neutral

#11 Right

Element

Ground

Lug

MANUAL

COM.

WHITE

4uf

Cap.

HIGH

RESET

BLOWER

CORE

5 Amp

Secondary

L1L2

Neutral

Ground

L2 120L1L2 240

BLOWER

ORANGE

Transformer

120/240 VAC

COM

NONO

1/4 Amp

COM COM

EXCHANGER LIMITS

N.C.

AUTO

DAMPER

RESISTER

RED

BLUE

BLACK

RESET

225 °

250° N.C.

BASE IO BOARD

TRANSFORMERS

240v / 24v

}

PRIMARY PUMP POWER

(VARIABLE SPEED)

SECONDARY PUMP POWER

OPTIONAL STATIC HEAT RECOVERY UNIT (240V)

NEUTRAL

(240V)

}

9150 APPLICATION

240V 1-PHASE 2 WIRE

9150 APPLICATION

277/347 3-PHASE 3 WIRE

Appendix

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

ap p e n d i x  A.07

Page 29

Typical System Line Voltage Wiring Diagram

4uf

Element

COMCOM

BASE IO BOARD

Optional Static Heat

Recovery Unit (240V)

Secondary Pump Power

(Variable Speed)

Primary Pump Power (240V)

#12 Relay

#12

#14

#18 Relay

Element

#18 Relay

#18

Element

#16

Element

#16 Relay

Lug

Ground

#13 Relay

#5 Relay

#7 Relay

Element

#3 Relay

#11 Relay

Element

#11

#13

Element

#17 Relay

Element

L2 240

L2 120

BLOWER

5 Amp

1/4 Amp

250 °

N.C.

225 °

RESET

AUTO

N.C.

MANUAL

EXCHANGER LIMITS

RESET

RESISTER

DAMPER

RESISTER

COM

240v / 24v

TRANSFORMERS

#17

#17 Relay

Element

#15

#15 Relay

Element

#2 Relay

Element

#1 Relay

Element

BLACK/YELLOW

RED

}

BLOWER

CORE

COM.

HIGH

Cap.

WHITE

#14 Relay

#10

#6 Relay

#8 Relay

Element

#4 Relay

#9 Right

#10 Left

Element Relay

#8 Left

Element Relay

#4 Left

#2 Left

#6 Left

#2 Left

#4 Left

Element

Element #10 Left

#8 Left

Element

Element #6 Left

#1 Right

#3 Right

Element

Element Relay

#1 Right

#9 Right

#7 Right

Element

Element Relay

#7 Right

Element Relay

Element #5 Right

#3 Right

Element Relay

#5 Right

Element Relay

#18 Left

Element Relay

#14 Left

#12 Left

Element Relay

#16 Left

Element Relay

#14 Left

Element

Element #16 Left

#12 Left

Element

Element #18 Left

#13 Right

Element

#15 Right

Element

#11 Right

Element Relay

#13 Right

Element Relay

#15 Right

#11 Right

Element Relay

Element

#17 Right

Element Relay

Neutral

Lug

Ground

MANUAL

RESET

HIGH

Cap.

4uf

WHITE

COM.

CORE

BLOWER

Secondary

5 Amp

Ground

Neutral

L2 240L1L2 120

ORANGE

Transformer

120/240 VAC

COMCOM

1/4 Amp

NO NO

EXCHANGER LIMITS

225 °

RESET

BLUE

RED

BLACK

RESISTER

DAMPER

AUTO

N.C.

250°

COM

BASE IO BOARD

TRANSFORMERS

240v / 24v

PRIMARY PUMP POWER

(VARIABLE SPEED)

SECONDARY PUMP POWER

OPTIONAL STATIC HEAT RECOVERY UNIT (240V)

NEUTRAL

(240V)

}}}

9180 APPLICATION

240V 1-PHASE 2 WIRE

9180 APPLICATION

277/347 3-PHASE 3 WIRE

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

Th e r m el e c T hy d r o n i c ap p e n d i x  A.08

Appendix

Page 30

INTERNAL SYSTEM WIRING DIAGRAM - LOW VOLTAGE

LIMIT

CORE

LIMIT

STORAGE

LIMIT

CORE

#1 #2 #3

MODULE

(OPTIONAL)

9180 ONLY

ORANGE

GRAY/WHITE

BLUE/YELLOW

BROWN

PURPLE

GRAY

GREEN

BLACK

BLUE/WHITE

ORANGE/BLUE

BLUE/RED BLUE/RED

WHITE

YELLOW

RED

ORANGE

BLUE/WHITE

BLUE

Peak Control Connections

COM

YELLOW

LIMIT

YELLOW

BLUE

CORE

75 VA

TRANSFORMER

TX1

75 VA

TRANSFORMER

TX2

YELLOW/BLUE

DISCHARGE WATER SENSOR

PURPLE/WHITE

Terminals for Connection with Heat Pump

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

System Low Voltage Wiring Diagram

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

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

WARNING

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

Appendix

ap p e n d i x  A.09 Th e r m el e c T hy d r o n i c

Page 31

HELP MENU

The 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 the 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 com-

munication signal.

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

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 target-

ing.

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 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 on the faceplate as “Er—” (i.e., Er05).

Error Code Description

01 Currently not utilized.

02 Currently not utilized.

03 Er03 is an error message which will not generally ap-

pear on the 5100, 7100, or 9100 Series Steffes heating systems. If an Er03 is displayed, check the value in Location 35 (L035) to verify that the 2 bit has not been enabled.

HAZARDOUS VOLTAGE: Risk of electric shock, 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

qualied technician.

WARNING

Appendix

Th e r m el e c T hy d r o n i c ap p e n d i x  A.10

Page 32

Error Code Description

04 Discharge air sensor 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. Take an ohm reading across the sensor to ensure proper operation, check the wiring, and verify the value in L035. Compare the sensor reading to the value in L112 to verify proper calibration of the circuit board. Approximate ohm readings are 70° F = 1,199 ohms; 80° F = 941 ohms; 95° F

= 646 ohms.

05 Outdoor sensor (direct wired) temperature reading is out of normal operating range. The

sensor circuit may be open or shorted, or the processor control board may be out of calibration. Otherwise, verify that the outdoor sensor is connected to OS and SC on the 12-position terminal block. Compare the sensor reading to the value in L113 to verify proper calibration of the circuit board. Approximate ohm readings are 5° F = 7,646 ohms; 50° F = 2,024 ohms; 95° F = 646 ohms.

06 Outdoor temperature reading 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 External duct sensor temperature is out of normal operating range. This can indicate an open

sensor, a short in the wiring, or the relay driver board is out of calibration. Take an ohm reading across the sensor to ensure proper operation, check the wiring, and verify the value in L053. Compare the sensor reading to the value in L144 to verify proper calibration of the circuit board. Approximate ohm readings are 60° F = 1552 ohms; 70° F = 1199 ohms; 80° F

= 941 ohms. Max 190°F, Min 0°

09 Auxiliary analog input is out of normal operating range. Currently not used.

10 Discharge air temperature has exceeded maximum standard operating temperatures.

11 Core C thermocouple temperature is out of normal operating range. An open, shorted, or

otherwise defective thermocouple or a circuit board which is out of calibration can cause this. Check the thermocouple by taking a millivolt reading of the thermocouple. Compare the thermocouple reading to the value in L136 to verify proper calibration of the circuit board.

Approximate DC mV readings are 200° F = 3.8 mV; 700° F = 15.2 mV; 1200° F = 27.0 mV. Max. 1720°F, min 0°F

12 Core D thermocouple temperature is out of normal operating range. An open, shorted, or

otherwise defective thermocouple or a circuit board which is out of calibration can cause this. Check the thermocouple by taking a millivolt reading of the thermocouple. Compare the thermocouple reading to the value in L137 to verify proper calibration of the circuit board.

Approximate DC mV readings are 200° F = 3.8 mV; 700° F = 15.2 mV; 1200° F = 27.0 mV. . Max. 1720°F, min 0°F

13 Core E thermocouple temperature is out of normal operating range. An open, shorted, or

otherwise defective thermocouple or a circuit board which is out of calibration can cause this. Check the thermocouple by taking a millivolt reading of the thermocouple. Compare the

Appendix

thermocouple reading to the value in L138 to verify proper calibration of the circuit board.

Approximate DC mV readings are 200° F = 3.8 mV; 700° F = 15.2 mV; 1200° F = 27.0 mV. . Max. 1720°F, min 0°F

14 Core F thermocouple temperature is out of normal operating range. Not used in 9100 Series.

15 Core G thermocouple temperature is out of normal operating range. Not used in 9100 Series.

16 Core H thermocouple temperature is out of normal operating range. Not used in 9100 Series.

ap p e n d i x  A.11 Th e r m el e c T hy d r o n i c

Page 33

Error Code Description

17 Load control device (4-20mA) is out of normal range. This can indicate an open sensor, a

short in the wiring, or a relay driver board is out of calibration. Take a DC voltage reading across the input to ensure proper operationreading should be between .5vDC and 6.25vDC. Check wiring, and verify the value in L053 is correct for the application. Compare the input reading to the value in L145 to verify proper calibration of the circuit board. 1vDC=0%, 3vDC=50%, 5vDC=100%.

19 There is no communication occurring with the relay driver board. The interface cable may

be defective or the relay driver board may be unresponsive. Verify that the values in L090, L091, and L092 are correct for the application.

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

board. A defective board interface cable or an unresponsive base I/O board can cause this.

21 There is no communication occurring with the rst Energy Management Controller. If

installed, the interface cable may be defective or the Energy Management Controller may

be unresponsive. Check the jumper conguration on the Energy Management Controller to

ensure that J1 and J2 are both in the "OFF" position. Verify that the value in L053 is correct for the application.

22 There is no communication occurring with the second relay Energy Management Controller.

If installed, the interface cable may be defective or the Energy Management Controller may

be unresponsive. Check the jumper conguration on the Energy Management Controller and

make sure J1 is "ON" and J2 is "OFF". Verify that the value in L053 is correct for the application.

23 There is no communication occurring with the Steffes Time Clock Module. If this module

is installed, verify the value in L035. If correct, the interface cable or the time clock module may be defective.

24 Temperature sensor offset/reference is out of range. A sensor or brick core thermocouple may

be shorted to ground or the processor control board may be defective.

25 The heater is congured for power line carrier; however, is not receiving a valid power line

carrier communication signal. This will display as error 25 when using BACNet and PLC fail on the system display.

26 Insufcient main control board memory (RAM). Contact a qualied service technician.

27 Insufcient permanent memory. Contact a qualied 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.

30 Base I/O relay board is in test mode. Check that both jumpers on the board are in the “OFF”

position.

31 Energy Management Controller(s) are in test mode. Check the jumper conguration.

39 If the value in Location 13 (L013) is set to a value greater than the value in Location 12

(L012), error 39 (Er 39) is displayed and the system space heats only until the values are corrected.

Appendix

40 Indicates memory corruption has occurred. Replace the processor control board.

41 You have attempted to write to the Flash memory a second time which is not permitted. You

may only write to the Flash memory one time after reprogramming. If you need to write to the Flash memory again, reprogram the heating system with ETS208 software or greater and

then recongure. Reference Locations 98 and 99 (L098 and L099).

Th e r m el e c T hy d r o n i c ap p e n d i x  A.12

Page 34

Error Code Description

42 If the check sum fails in the Flash copy of the settings or if the initial write to the Flash fails,

Er42 is displayed. Reprogram the heating system or replace the processor control board.

43 An attempt to load a saved conguration by setting Location 98 (L098) to a value of 20, 30,

40, or 50 has failed. Any changes to location values will need to be manually set. Press and release the “M” button to clear the error. Er43 is only applicable to processor control boards with a revision level of G or lower only.

44 The check sum of the entire Flash is corrupt. Reprogram the heating system or replace the

processor control board.

45 An attempt was made to load memory from an unsaved location in L098. Applicable to pro-

cessor control boards with a revision level of H or higher only.

46 MA command or Pulse Width Modulation has timed out. No input has been received for 30

minutes. If the MA command or Pulse Width Modulation are not being used, verify that Location 53 (L053) and/or Location 55 (L055) are set correctly for the application.

Cold Core The sensed temperature of the brick core is below 40 degrees. This may be an actual condi-

tion, a defective thermocouple, reversed polarity of thermocouple wiring coupled with a core temperature between 150°F (65°C) and 300°F (148°C), or a circuit board which is out of calibration can cause this. Verify that the core thermocouple wiring is connected properly and that the values in L090, L091 and L092 are correct for the application.

Core Fail One of the core high limit switches may be open (also see error 38).

PLC Fail The heater is congured for power line carrier; however, is not receiving a valid power line

carrier communication signal. This will display as error 25 when using BACNet and PLC fail on the system display.

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

not necessarily an error but merely an indication of the current condition of the application. Example: If 4-20mA control is being used and comfort override or freeze protection brings on elements, this error code may be displayed.

Appendix

ap p e n d i x  A.13 Th e r m el e c T hy d r o n i c

Page 35

Page 36

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 les.

WARRANTY STATEMENT

Steffes Corporation (“Steffes”) warrants that the Steffes Electric Thermal Storage ThermElect 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 purchase, limited to three (3) years from the date of manufacture, 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 one (1) 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, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE.

The buyer assumes all risk and liability whatsoever resulting from the use of this heating appliance. In no

event shall Steffes be liable to purchaser for any indirect, special or consequential damages or lost prots.

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 modied in any respect

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

relating to this manual. Enjoy your new purchase!

3050 Hwy 22 North • Dickinson, ND 58601-9413 • 701-483-5400

DOCUMENT #1200067