1 2PLACEMENT AND CLEARANCES SET-UP
Minimum Clearance RequirementsA Back and Right Side = 3 inches from
combustibles B Front = 36 inchesC Top = 6 inches from combustiblesD Bottom = 1 inch from combustiblesE Left Side = 36 inches
Quick Reference Installation Guide
3 BRICK LOADING
1. Place system in desired location.2. Adjust leveling legs.3. Remove painted front panel of brick
storage cabinet.4. Position element wiring harnesses
to avoid damage during brick loading.
5. Position brick core temperature sensor(s) to avoid damage during brick loading.
6. Remove galvanized front panel.7. Starting at bottom, lift and drape
insulation blankets over top of system.
8. Remove front air channel by pulling out at top.
9. Remove heating elements from inside brick core cavity.
•DONOTextendlevelinglegsmorethanoneinch.
•DOuseandfollowgenerallyacceptedsafetypracticeswhenhandlinginsulationmaterial.
• EquipmentMUSTbeinstalledbyaqualifiedtechnicianinaccordancewithallapplicablelocal,stateandnationalcodesandregulations.
•ReferenceOwner’sandInstaller’sManualforcompletesafety,installation,andoperationinstructions.
Starting at the back of the brick core cavity, load bricks one row at a time using left side, right side, center pattern. Place bricks with grooved side facing up, notch facing forward,and ridges on left and right.
• Removeloosedebrisfrombrick.
• BrickrowsMUSTlineupfronttobackandsidetoside.
• Usehalfbricksinproperrowsandincorrectpositions.BackhalfofbrickMUSTbeinstalledinbackrows.Fronthalf(notchedbrickpiece)MUSTbeinstalledinfrontrows.
IfareaavailabletoinstallComfortPlusHydronicsystemislessthan100squarefeet,consultfactory.Ifinstallinginareawithlessthan400squarefeet,ventilationMUSTbeprovided.Temperatureinareashouldbemaintainedatorbelow85oF.
“Manufactured in North America”
COMFORT PLUS HYDRONIC
Models 5120, 5130, 5140
CAUTION
WARNING
Front of Unit
Notch in Brick
HALF BRICK5120: Load in row 5
5130: Load in row 4 and 85140: Load in row 6 and 12
IMPORTANT
A
TOP VIEW
E
E
D
A
C
FRONT VIEW
A
BM
AM
MP
A
TOP VIEW
E
E
D
A
C
FRONT VIEW
A
BM
AM
MP
4 HEATING ELEMENT INSTALLATION1. Insert heating elements
between brick layers until element ends embed into side cutouts of brick cavity. Elements MUST be installed with threaded screw tabs on wire connection terminals pointing forward and down.
2. Remove painted panel from electrical compartment and locate the installation hardware package.
3. Connect wiring harnesses to heating elements using screws in hardware package. Install screws with heads up and thread pointing down. Tighten screws to 14 in·lbs.
5 AIR CHANNEL INSTALLATION
1. Install air channel with air deflectors (arrow shaped pieces) facing inward. Place bottom of air channel in first.
2. Lower insulation blankets back into position, one at a time. Tuck sides into edges, corners and around exposed portions of heating elements.
3. Install galvanized front panel. Slide bottom edge inside lower lip of brick cavity. Top rests on outside of cavity.
4. Check non-insulated element connections to make sure they do not come within 1/2” of any surface.
6 BRICK CORE TEMPERATURE SENSOR(S) INSTALLATION
Riskofimproperoperation.Properinstallationofthebrickcoretemperaturesensor(s)iscriticaltotheoperationoftheComfortPlusHydronicsystem.Readandfollowinstallationinstructionscarefully.1. Remove screw(s) by temperature sensor hole(s) in galvanized front panel.2. Insert temperature sensor(s) through hole(s). Sensor(s) must pass through blanket insulation and into brick core.3. Install screw(s) into galvanized front panel to hold sensor(s) and provide electrical ground connection.4. Inspect sensor wiring for possible short circuiting hazards.5. Install painted front panel.
NOTE: Models 5130 and 5140 have an upper and a lower temperature sensor. Each sensor is marked for proper installation.
WARNING
WARNING
HAZARDOUSVOLTAGE:Riskofelectricshock,injuryordeath.•DONOTremoveelectricalpanelcoverwhilesystemisenergized.
•ElementsMUSTbepositionedproperlytoavoidshortcircuitingthemagainstanysurfaceswithinsystem.
•Usecarewhenmakingconnectionstoavoidelementdamage.
34"
34"
Required Clearance Between Element Termination and
Metal Panels is 12" (34" Nominal).
Element Connection
BRICKCORE
SIDE VIEW
OutletInlet
ElectricalPanel
Front Air Channel
7 LINE VOLTAGE ELECTRICAL CONNECTIONS
HAZARDOUSVOLTAGE:Riskofelectricshock,injuryordeath.DonotenergizetheComfortPlusHydronicsystemuntilinstallationiscomplete.
1. Route all line voltage wires through knockout(s) and into electrical panel.
2. Make proper field wiring connections.
•Toensureproperoperationandsafety,alllinevoltagecircuitsmustbesegregatedfromlowvoltagewiring.
•Toreduceelectromagneticfieldsassociatedwithelectricalcircuitsandtoavoidinducedvoltageonsensorsandelectronicdevices,thecircuitphasesMUSTbealternatedasshownbelow.
•DONOTinstallanywiringinthelinevoltagecompartmentoftheComfortPlusHydronicsystemunlessitisratedforlinevoltage.
CIRCUIT PHASING CONNECTIONS
9 JUNCTION BOX INSTALLATION1. Attach the factory supplied junction
box to the left side of the Comfort Plus Hydronic system.
2. Make connections to the primary loop pump and air handler pump inside this junction box. The red and white wires connect to the primary loop pump and the black and white wires connect to the air handler pump. The maximum connected amperage on either of these circuits is 1.2 amps.
3 . Attach the junction box cover using the screws provided.
IfNOTutilizingtheoptionalStaticHeatRecoveryUnit,theorangewirecanbeusedtopowerasecondarypump.
8 AIR CONDITIONER/HEAT PUMP INTERFACE
The Air Handler (Order #1302100) is an optional device used to interface the Comfort Plus Hydronic with a ducted heating or cooling system such as a heat pump or air conditioner. The Air Handler includes a plenum assembly, supply air blower, water coil, air filter, wiring harness, and hardware kit. When the Comfort Plus Hydronic system receives a heat call from the room thermostat, it energizes the supply blower and the Air Handler’s zone pump.
The Air Handler can be interfaced with a standard heat pump system and will provide comfort modulation. The system will monitor the outlet air temperature and modulate in heat from the Comfort Plus Hydronic as needed to maintain the desired output air temperature.
The maximum coil size the Air Handler can accommodate through the front access is 20” (W) x 22” (H) x 21 3/16” (D). The inner dimensions of the A-coil area are 21 3/16” (W) x 24 1/4” (H) x 21 3/16” (D). If installing a coil larger than the access dimensions, the coil must be placed into the Air Handler during assembly.
Riskoffire.AnyoneductingsystemMUSTNOTcontainmorethanoneairhandling(blower)system.Iftheappli-cationrequiresmultipleComfortPlusheatingsystemsoritisnecessarytohavemultipleairhandlerssharethesameductwork,youMUSTcontactSteffesCorporation.TherearespecialinstallationrequirementsthatMUSTbeperformedinanapplicationsuchasthis.
WARNING
WARNING
IMPORTANT
IMPORTANT
LINE
2
LINE
1
LINE
2
LINE
1
LINE
1
LINE
2
LINE
1
LINE
1
LINE
2
THIS MUST BE A 120/240V OR 120V/208V CIRCUIT
NEUTRAL CONNECTION FOR CONTROL CIRCUIT
To S
ervi
ce (B
reak
er) P
anel
(MODEL 5130 and 5140 ONLY)CHARGE CIRCUIT #4
CONTROLS CIRCUIT
CHARGE CIRCUIT #1
CHARGE CIRCUIT #2
CHARGE CIRCUIT #3
Circuit Breakers
NEUTRAL LINE
2
LUG
COM COM
BLACKBLACK/YELLOW
CORELIMIT
COM
1/4 Amp
L1
COMNO
COM COMNONO NO
RED
BLUE/WHITE
BLUE/BLACK
ORANGE
ORANGE
DAMPER
RESISTER
RESISTORSHRU LOOP PUMP
PRIMARY
BLA
CK
BLU
E
RE
D
COM.WHITE250 °
BLUEBLA
CK
/YE
LLO
W
REDWHITE/BLACK
BLOWER
L2 240
L2 120
NO NO
COM COMNO NO
1/4 Amp5 Amp
225 °N.C.
AUTORESET
N.C.
RESETMANUAL
EXCHANGERLIMITS
HIGHBLACK
Cap.4uf
CORE BLOWER
NEUTRAL LUG
CIR
CU
IT #
2
CIR
CU
IT #
3
CH
AR
GE
CIR
CU
IT #
1
CH
AR
GE
CIR
CU
ITC
ON
TRO
LSB
LOW
ER
S/
CH
AR
GE
60A60A15A 60A
CONTROL CIRCUIT
ElementElementElement
1,8Relays
2,4,6Relays
3,5,7Relays
ToTo To
ELEMENT 1 ELEMENT 2 ELEMENT 3 ELEMENT 4
ELEMENT 5 ELEMENT 6
ELEMENT 7 ELEMENT 8
BOARD EXPANSION
#1
GROUNDLUGS
L1
ORWHITE
ORANGE
BLACKCOM COM
HEATING ELEMENTS
Element 2
Element 1
Element 3
Element 4
NO NO
75VA
240v 24vTRANSFORMER
Element 7
Element 5
Element 6
Element 8
BLACK/YELLOW
LIMITWHITE/BLACK
CORE L2 240
COM COMNO NO
L2 120
RED
Red & White ToPrimary Loop Pump
(Max 1.2 AMPS)Black & White To Air
Handler Pump (Max 1.2 AMPS)
WHITEOR
These wires are located in the lower leftcorner of the electrical compartment.
75° C or higher for field connections of this device.Use copper or aluminum conductors rated atWiring Diagram 240/208 Volt
5120 Line Voltage
WHITE/BLACKRED
BLACK
Expansion Tank
Air Separator
Primary Loop PumpControl Wiring(White & Red)
Junction Box(Factory Supplied)
*Primary Loop Pump
Air VentPiping MUST Be Supported
PressureRelief Valve
(Factory Supplied)
Optional Temperature and
Pressure Relief Valve (Consult Local Code)
ZoneConnection
Area
Inlet
Outlet
See Note
PRIMARY LOOP
(* Steffes recommends a Grundfos UP15-42F or equal single speed 115VAC pump for the primary pump.)
The Comfort Plus Hydronic heating system MUST be plumbed with a primary loop and secondary (zone) loops. The primary loop needs to consist of a minimum of 10’ of 1” pipe and requires its own pump* (circulator). The secondary (zone) loops require ad-ditional pump(s) to operate effectively.
PLUMBING10
FREEZEPROTECTION:Riskofpropertydamage.Hydronicheatingsystemfreeze-upsWILLcauseextensivedamagetotheentireheatingsystemand/orproperty.Itistheresponsibilityoftheinstallertoprovideprotec-tionagainstfreezing.
PIPINGSUPPORT:Riskofequipmentdamageorpersonalinjury.DONOTusetheexchangerassupportforpiping.Supportofprimaryloopandassociatedplumbingmustbeinstalledtoensureproperoperationofthesystemandtokeeppressureofftheinletandoutletpiping.
NOTE: TheprimarylooppumpMUSTbecon-trolledbythefurnacethroughtheredandwhitewires.Whenthispumpisrunning,watermustbeallowedtoflowthroughtheheatexchanger.
STATIC PRESSURE(Feet Water Column)
Based on 80 degree entry wa-ter temperature with
a 50% glycol mix.
.1 ft @ 2 GPM
.2 ft @ 4 GPM
.4 ft @ 6 GPM
.7 ft @ 8 GPM1.1 ft @ 10 GPM
PRESSURE DROP THROUGH HEAT ExCHANGER
SINGLE TEMPERATURE ZONES
WARNING
Secondary Loop Primary Loop
White
Red
White
RedPrimary
Loop Pump
Comfort PlusHydronic
Exchanger
This Valve MustBe Open During
Normal Operation
TYPICAL SYSTEM PLUMBING(SHOWN WITH STEFFES AIR HANDLER)
Itistheresponsibilityoftheinstallertopreventinvoluntaryflowofwatertotheairhandler.Notdo-ingsomaycauselimittrippingand/ordecreasesystemefficiency.Useofacheckvalve,zonevalve,orotherdevicemayhelppreventinvoluntaryflow.
Secondary Loop Primary Loop
11 PRESSURE RELIEF VALVE INSTALLATION
Riskofexplosion,injury,ordeath.ThefactorysuppliedpressurereliefvalveMUSTbeconnectedtothesystemwiththesuppliedfittings.
DONOTmodifythisassembly.
DONOTcap,plug,orotherwiseobstructtheoutletofthepressurereliefvalve.
DOmountthepressurereliefvalveinavertical,uprightposition.
ThispressurereliefvalveissizedtoservicetheneedsoftheComfortPlusHydronicsystem.Ifmultipleheatingsystemsarebeingused,pressurereliefvalvingfortheothersystemMUSTbeprovidedseparately.
1. Remove the heat exchanger access panel and locate the pressure relief valve assembly.
2. Using the supplied union fittings, connect the pressure relief valve to the outlet water port on the left side of the Comfort Plus Hydronic system.
3. Use schedule 40 pipe to install a discharge line for the pressure relief valve.
4. Install heat exchanger access panel.
Riskofinjuryorpropertydamage.Duringoperation,thepressurereliefvalvemaydischargelargeamountsofsteamand/orhotwater.Toreducethepotentialforbodilyinjuryorpropertydamage,installadischargeline. DOuseschedule40pipeforthedischargeline. DONOTuseschedule80,extrastrongpipe orconnectionsonthedischargeline. DONOTcap,plug,orotherwiseobstructthe
dischargepipeoutlet. DOfollowalllocal,state,andnationalcodesand
regulations.
WARNING
WARNING
IMPORTANT
Low Temp Radiant Zones
CHECKVALVE
WhiteOrange
WhiteBlack
Secondary Loop Primary Loop
PrimaryLoop Pump
High TempWater
5100 AirHandler
ToOtherZones
MixingValve
This Valve MustBe Open During
Normal Operation
FromOtherZones
Comfort +Hydronic
Exchanger
Red
White
-
-
+
13 LOW VOLTAGE PEAK CONTROL CONNECTIONS1. Route low voltage circuit from the peak control device
to the terminal block.2. Connect field wiring to positions “RP” and “P”.
12 LOW VOLTAGE OUTDOOR SENSOR CONNECTIONSThe outdoor temperature sensor can be installed by wiring it directly to the system or to the Steffes power line carrier (PLC) system, if utilized.
Direct Wired:1. Mount outdoor sensor in a location where it can
accurately sense outdoor temperature.2. Route low voltage wire from outdoor sensor to electrical
compartment:• Seal external wall openings.• Outdoor sensor lead can be extended to 250 ft.• Unshielded Class II (thermostat) wire can be used
provided it is segregated from any line voltage wiring.
3. Connect outdoor sensor wires to “Outdoor” positions on low voltage terminal block.
• IfconnectingtotheSteffespowerlinecarriersystem,followtheinstallationinstructionsinthePLCsystem’sOwner’sandInstaller’sGuide.
•OutdoorsensorwireMUSTNOTbecombinedwithothercontrolwiringinamulti-conductorcable.
IfutilizingaSteffesTimeClockModuleorPowerLineCarriercontrol,refertotheinstallationinstructionsprovidedwiththedevice.
Low Voltage Terminal Block Coding RP = Peak Control Input Common P = Peak Control Input AP = Anticipated Peak (Pre-Peak) Control Input COM = Peak Control Output Common NC = Peak Control Output (Closed for Charge) NO = Peak Control Output (Closed for Control)
LOW VOLTAGE ROOM THERMOSTAT WIRING14SINGLE ZONE APPLICATION
A 24 VAC thermostat must be used (digital recommended).
1. Disconnect power to Comfort Plus Hydronic system. Route low voltage thermostat wire to the system.
2. Insulate thermostat wire wall opening if necessary.3. Attach thermostat. When using a mechanical thermostat or thermostat with
anticipator, resistor kit #1190015 must be installed to ensure proper operation.4. Route low voltage wire into electrical compartment to low voltage terminal block.5. Install electrical panel cover.
IMPORTANT
IMPORTANT
P8 P9
Aux.
CO
M
NCAP NO
Relay
Outdoor Sensor
OW/
Y1AUX Y2 G Out
door
Out
door
Y2RH/E 2Y1C O2 2 RP P
R C
P1P11 D3D7D5
W
E
Y1
Y
2
Wat
er
Air
P6D1 P5
Blower
J3J1 J2 J4
D2
To Control Board
P3
C
Blower Speed
A B
J5 J6
C3 D
P4 P2
InputsPeak
P7LV Circuit Board
Comfort Plus
To Control Board
P10
Fid 2
RLY1
D4
D6
R2
R1
NOTES:* If multiple inputs are active, system will display highest Heat Call values.
"COOL" overrides all inputs and stops all heating operations.** Systemsbuiltbefore1/1/2011areconfiguredfor50%airflowinStage1.For
more information, refer to Instruction #1200601-High Speed Stage 1 Relay Installation.
*** Thermostat must be programmed to energize reversing valve for cooling. If outdoor unit used requires the reversing valve be energized for heating, see ConfigurationMenu.
InputsPeak
P7LV Circuit Board
Comfort Plus
To Control Board
P10
Fid 2
RLY1
D4
D6
R2
R1
P11 D3D7D5
W
E
Y1
Y
2
Wat
er
Air
P6D1 P5
Blower
J3J1 J2 J4
D2
To Control Board
P3
C
Blower Speed
A B
J5 J6
C3 D
P4 P2 P1
OW/
Y1AUX Y2 G Out
door
Out
door
Y2RH/E 2Y1C O2 2 RP P
R C
P8 P9
Aux.
CO
M
NCAP NO
Relay
Hydronic Heat Thermostat, ZoneValve End Switch, or Pump Control
STAND ALONE FURNACE APPLICATION WITH UNCONTROLLED AIR CONDITIONER
SINGLE STAGE HEAT PUMP APPLICATION
TWO STAGE HEAT PUMP APPLICATION
If installing a mechanical thermostat or thermostat with anticipator, a resistor kit is required (Order Item #1190015).
IMPORTANT
A B C DW /
EY
1 / Y
2
J1 J2 J3 J4J5 J6
Blower Speed
IMPORTANT
H/E R C Out
door
Out
door
CO
M
NC
NOW/
D6RLY1
To Control BoardD4Fid 2
Blower To Control Board
Air
C3
P10
R1
R2
P11 D5 D7 D3
Wat
er
Y1
Y
2W
E
D2
J3J2J1
P5D1
J4
P6
P4SpeedBlower J6J5
CBA D
P2P3
Y1AUX OGY2 Y1 2Y22 2 O
CRComfort Plus LV Circuit Board
P7
W - Not Used
APPRP
Peak Aux.Inputs Relay
The Y1/Y2 Jumper must be installed
Honeywell TH5220D
AuxEL CG O/B RY Rc
Hydronic Heat Thermostat, ZoneValve End Switch, or Pump Control
C - Low Voltage CommonR - Low Voltage HotO - Reversing Valve
Y - Compressor
To Heat Pump
Outdoor Sensor
The W/E Jumper must be removed
P9P1 P8
IMPORTANT
A B C DW /
EY
1 / Y
2
J1 J2 J3 J4J5 J6
Blower Speed
The W/E Jumper must be removedThe Y1/Y2 Jumper must be removed Inputs
Peak
P7LV Circuit Board
Comfort Plus
To Control Board
P10
Fid 2
RLY1
D4
D6
R2
R1
P11 D3D7D5
W
E
Y1
Y
2
Wat
er
Air
P6D1 P5
Blower
J3J1 J2 J4
D2
To Control Board
P3
C
Blower Speed
A B
J5 J6
C3 D
P4 P2 P1
OW/
Y1AUX Y2 G Out
door
Out
door
Y2RH/E 2Y1C O2 2 RP P
R C
P8P9
Aux.
CO
M
NCAP NO
Relay
Honeywell TH5320D
AuxL Y2 G CO/B
Hydronic Heat Thermostat, ZoneValve End Switch, or Pump Control
RY R c
C - Low Voltage Common
Outdoor Sensor
O - Reversing Valve
R - Low Voltage Hot
To Heat Pump
Y1 - Compressor
Y2 - Compressor Stage 2
W - Not Used
IMPORTANT
A B C DW /
EY
1 / Y
2
J1 J2 J3 J4J5 J6
Blower Speed
15 SOFTWARE CONFIGURATIONIfaccesstoConfigurationMenutimesout,the15ampcircuitbreakermustbepoweredoffandbackontore-enterthemenu.
The Steffes Comfort Plus Hydronic system has a Configuration Menu, which allows it 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.
AccessingtheConfigurationMenuStep1 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 over two (2) minutes, it must be powered off and back on again.
Step2 Press and release the M button until the faceplate displays “CONF.”
Step3 Press the up arrow once and the faceplate will display “C000.” The display will flash between “C000” and the corresponding configuration value.
Step4 If necessary, edit the configuration by pressing and holding the M button while using the up or the down arrow button to change the value.
Step5 Once the value is correct, release the buttons and press the up arrow button to go to the next configuration (C001, C002, etc.).
Step6 Repeat steps 4 through 5 until all configuration settings have been adjusted to the desired values.
Step7 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 functions:
Part No. 1200284-53050 Hwy 22 North Dickinson, ND 58601-9413 www.steffes.com
IMPORTANT
Power Line Carrier (PLC) Peak Control
Configuration Number
Outdoor Sensor (Factory Default)
No Outdoor Sensor
Outdoor Sensor
No Outdoor Sensor
Outdoor Sensor
No Outdoor Sensor
Outdoor Sensor
No Outdoor Sensor
C000 5 5 6 5 6 5 6 5 6
C001 50°F 50°F 50°F 50°F 50°F 50°F 50°F 50°F 50°FC002 10°F 10°F 10°F 10°F 10°F 10°F 10°F 10°F 10°F
C003 Match to the Channel Selected at PLC 0 0 0 0 0 0 0 0
C004 8 9 8 9 8 13 12 9 8
C005 0 1 1 0 0 0 0 0 0
C006 2 2 2 2 2 2 2 2 2
C007 30 30 30 30 30 30 30 30 30
C008 5°F 5°F 5°F 5°F 5°F 5°F 5°F 5°F 5°F
C009 5°F 5°F 5°F 5°F 5°F 5°F 5°F 5°F 5°F
C010 90°F 90°F 90°F 90°F 90°F 90°F 90°F 90°F 90°F
C011
C012
C013 - C021 Refer to the Time Clock Installation Instructions
* 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 (C011 and C012) are appropriate for the application
APPLICATION DEPENDENT *
APPLICATION DEPENDENT *
Low Voltage Direct Wire Peak Control
Peak Switch Closed for Charging
Peak Switch Open for Charging
Line Voltage Peak Control
Time Clock Module Peak Control
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