Steffes Comfort Plus Hydronic 5120 Manuale utente

V11

OWNER'S AND

INSTALLER'S MANUAL

"Manufactured in North America"

for

COMFORT

PLUS

HYDRONIC

(5100 SERIES)

Models: 5120, 5130, & 5140

Applicable to Software Version 140-159

RECOGNIZETHESE SYMBOLSASSAFETYPRECAUTIONS

Itisimportant,bothforyourpersonalsafetyandtoavoidpossibledamagetothe

equipmentandyourproperty,thatyouobservethesafetyinstructionsgivenfollowing

thesesymbols.

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

technician in compliance 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.

After the heating system is installed, Steffes disclaims any responsibilityor

liability for mold/mildew growth and/or any damages caused by either. We

strongly recommend that the user follow the moisture, mold and mildew pre-

vention guidelines of the Environmental Protection Agency (EPA), available at

http://www.epa.gov.

IMPORTANT

For Customer Use

Please record your model and serial number below. This number is found on the identification label

located on the lower left side of the Comfort Plus Hydronic heating system. Retain this information for

future reference.

Model No. ________________________________________________________________________

Serial No. ________________________________________________________________________

SAFETY PRECAUTIONS

1. DO NOT energize this heating system while

disassembled or without the ceramic heat storage

brick in place.

2. DO NOT operate this heating system without the

factory provided pressure relief valve in place.

3. DO NOT use or store materials that may produce

explosive or flammable gases near the system.

4. DO NOT violate the placement and clearance

requirements specified in this manual. (Page 3.02-

3.03)

5. DO NOT place anything on top of the system.

6. Disconnect power to all circuits before servicing as

this heating system may be connected to more than

one branch circuit.

7. Use caution when working around the heating

system as inlet and outlet piping can be very hot.

8. Installation of and/or service to this system should be performed bya qualified technician in compliance with

information contained herein and with national, state, and local codes and requirements.

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

SAFETY DEVICES

The Comfort Plus Hydronic incorporates safety devices to ensure normal operating temperatures are maintained.

The chart below describes these safety devices:

Comfort Plus Hydronic Safety Information

WARNING

Risk of explosion. Can cause injury or death.

Operating the system without the pressure

relief valve installed can cause an explosion.

Connect the pressure relief valve in a vertical,

upright position with the supplied fittings. DO

NOT modify this assembly. DO NOT cap, plug,

or otherwise obstruct the outlet of the pres-

sure relief valve.

Risk of fire. Can cause injury or death. Viola-

tion of the clearance requirements can cause

improper operation of the equipment. Main-

tain the placement and clearance require-

ments specified.

Risk of personal injury. Plumbing and other

surfaces can be hot. Use caution when work-

ing near the system.

DEVICENAME FUNCTION LOCATION

ON SYSTEM

Core Charging High

Limit Switches

(Auto Reset)

These limit switches monitor brick core charging and

interrupt power to the heating elements if the normal

operating temperature is exceeded.

This linear limit switch monitors the temperature of the

water in the exchanger and interrupts power to the core

blower if a water temperature of 250oF is exceeded. If

this limit switch opens, contact a qualified service techni-

cian.

Heat Exchanger

Limit Switch

(Manual Reset)

In the limit bar panel

on the left side of the

brick storage cavity.

Inside base on left side.

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 is exceeded.

Outlet Water

Temperature Limit

Switch (Auto Reset)

Inside base on left side.

Pressure Relief Valve Factory provided,

fieldinstalledtooutlet

port of furnace.

If the water pressure exceeds 30 psig, the pressure relief

valve opens. Once water pressure of less than 30 psig is

achieved, the valve closes.

Operation

GeneralOperation..................................................................................................................................................................1.01

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

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

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

ControlPanel.........................................................................................................................................................................1.02

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

RoomTemperatureControl ...................................................................................................................................................1.03

BrickCoreChargeControl.....................................................................................................................................................1.03

ChargeControlOverride .......................................................................................................................................................1.03

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

Optional Accessories

SingleElectricalFeedKit .......................................................................................................................................................2.01

PrimaryLoopKit ...................................................................................................................................................................2.01

AirHandler............................................................................................................................................................................2.01

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

Comfort Plus Stand ...............................................................................................................................................................2.02

Installation

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

Placement andClearanceRequirements ........................................................................................................................ 3.02-3.03

InitialSet-up ..........................................................................................................................................................................3.03

BrickLoading ........................................................................................................................................................................3.04

HeatingElement and Air Channel Installation............................................................................................................... 3.04-3.05

BrickCoreTemperatureSensorInstallation ..........................................................................................................................3.05

LineVoltageElectricalConnections .............................................................................................................................. 3.06-3.07

LowVoltageElectricalConnections

PeakControl........................................................................................................................................................... 3.07-3.08

Outdoor Temperature Sensor ................................................................................................................................. 3.08-3.09

RoomThermostat................................................................................................................................................... 3.09-3.10

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

PressureReliefValveInstallation ..........................................................................................................................................3.11

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

AuxiliaryLoadControl ..........................................................................................................................................................3.13

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

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

Appendix

Specifications...................................................................................................................................................................... A.01

PartsDiagram ...................................................................................................................................................................... A.02

Parts List ..................................................................................................................................................................... A.03-A.04

InternalSystemWiringDiagrams-LineVoltage......................................................................................................... A.05-A.07

InternalSystemWiringDiagram-LowVoltage................................................................................................................... A.08

Help Menu .......................................................................................................................................................................... A.09

ErrorCodes .................................................................................................................................................................A.09-A.10

Disassembling the Comfort Plus Hydronic System ............................................................................................................. A.11

Glossary .............................................................................................................................................................................. A.12

Warranty

Table of Contents Comfort Plus Hydronic

Table of Contents

Comfort Plus Hydronic Operation 1.01

GENERAL OPERATION

The Steffes Comfort Plus Hydronic heating system stores off-peak electricity in the form of heat. Off-peak

electricity is available during times of the day or night when electricity is plentiful and the power company may

supply it at a lower cost.

Operation of the Comfort Plus Hydronic is automatic. When off-peak hours are

available, the system converts electricity to heat which is then stored in its ceramic

brick core. The amount of heat stored in the brick core varies in relation to outdoor

temperature, owner preference, utility peak conditions, and the requirements of the

space being heated.

A heat call from the room thermostat energizes the primary water loop pump. The

variable speed core blower automatically adjusts its speed to achieve the desired outlet

water temperature. The heated water is then pumped to the area (zone) from which

the heat call originated.

The versatility of this system allows it to fit many applications. The Comfort Plus

Hydronic is designed for use as either the sole heating source (“stand alone”furnace)

or as a supplement to ducted heating systems such as heat pumps.

SYSTEM USE DURING CONSTRUCTION PHASE

Like most heating equipment manufacturers, Steffes strongly recommends that “Construction Heating Units”be

used instead of the permanent heating system during the construction phase of a new home. Use of the perma-

nent heating system during the construction phase may contaminate the duct system and/or internal areas of the

heating system. This may cause poor indoor air quality issues and/or improper system operation once the home is

completed. A suitable alternative heating system must be used during the construction phase.

SYSTEM START-UP

On start-up of the Comfort Plus Hydronic system, odors relating to first time operation of the heating components

may be experienced. Allow the system to charge to its maximum brick core charge level, on start-up, to expel

these odors. If the Comfort Plus Hydronic 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 Comfort Plus Hydronic element (charging) circuits may be turned “OFF”by switching all of the 60 AMP

breakers located on the front of the electrical panel to the DOWN position. To turn the element circuits “ON”,

switch the 60 AMP breakers to the UP position.

The 60 AMP breakers MUST all be turned "ON" or all turned "OFF". The 15 AMP breaker

MUST remain “ON”to operate controls in the system if:

using the Comfort Plus Hydronic in conjunction with a heat pump or air conditioner.

using the Comfort Plus Hydronic to control other loads.

using the optional Steffes Time Clock Module.

using the Comfort Plus Hydronic to exercise the pumps during periods of inactivity.

Operation

AM and PM Indicator Lights

The AM and PM indicator lights are only utilized if the Steffes Time Clock Module is

beinginstalled.Withthismoduleinstalled, thesystemdisplaystimeonAM/PM

intervals and the corresponding light flashes. The system can be configured to display

military time, in whichcase, both the AM and PM lights illuminate.

Mode (Edit) Button

Activates the editing menu for changing the operating

information of the system.

Up and Down Arrow Buttons

Used to scroll up and down when viewing or changing

operatingfunctions.

Interface Port

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

Operation 1.02 Comfort Plus Hydronic

CONTROL PANEL

Operation of the Comfort Plus Hydronic system is automatic. All operational functions are stored in its micropro-

cessor in function locations and are factory preset. If necessary, the user or installer can adjust them through the

control panel. (See Figure 1.)

Four-Digit LED Display

The fourdigitLEDdisplaysspecificoperatinginformation. Duringan editing

process, the function locations and the values set in these locations are displayed

forviewingandadjusting purposes.

OPERATING STATUS

The Comfort Plus Hydronic is set to display various operating information as described below. Press and release

the up arrow to view this data.

Outdoor Temperature - indicates current outdoor temperature.

Operating Mode and Outlet Water Temperature - indicates the current operating mode

followed by the outlet water temperature.

C = Off-Peak (Charge) Time

P = On-Peak (Control) Time

A = Anticipated Peak Time

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”.

HC_0 = No Heat Call HC_1 = Stage 1 Forced Air Heat Call (if equipped with Air Handler)

HC_2 = Stage 2 Forced Air Heat Call (if equipped with Air Handler)

HC_3 = Hydronic Heat Call COOL = Cooling Call (if equipped with Air Handler)

Targeted Brick Core Charge Level - “tL”(target level) followed by a number, indicates

the current percentage of brick core charge being targeted by the system. A display of “tL:_”

indicates a target level of zero percent and “tL: F”indicates a full core charge target level.

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

current percentage of heat stored in the brick core. “CL:_”represents zero percent and “CL:

F”represents a full core charge level.

A bar illuminates on the lower portion of the display's third digit when-

ever the heating elements are energized.

Operation

CAUTION

Editing operating information may

alter the performance and opera-

tion of the system.

CONTROL PANEL

FIGURE 1

Comfort Plus Hydronic Operation 1.03

ROOM TEMPERATURE CONTROL

Room temperature is adjusted at the wall thermostat(s). A heat call from the room thermostat 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 origi-

nated.

In heat pump applications, a heat call from the room thermostat first utilizes the heat pump’s heating capacity to

satisfy comfort requirements. As the outdoor temperature declines and the heat pump’s heating capacity begins

to diminish, the Comfort Plus Hydronic modulates heat to help maintain a comfortable air temperature in the duct.

BRICK CORE CHARGE CONTROL

The amount of heat stored in the brick core of the Comfort Plus Hydronic system is regulated automatically in

relation to outdoor temperature and the heating requirements. The outdoor sensor, supplied with the system,

monitors outdoor temperature. As the outdoor temperature decreases, heating requirements increase, and the

Comfort Plus Hydronic system stores more heat accordingly.

CHARGE CONTROL OVERRIDE

The Comfort Plus is equipped with a charge control override feature that allows the user to force the system to

target a full core charge level. This override 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 the system 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 its standard configuration.

Initiating the Override Feature

Step 1 Press and hold the M, the up arrow, and the down arrow buttons at the same time.

Step 2 The faceplate will flash “FULL”and “ON”. Continue to hold the three buttons until “ON”displays

continuously on the faceplate.

Step 3 Release the buttons. The override is now enabled. The faceplate will return to displaying its standard

operatingmode.

Manual Cancellation of the Override Feature

Step 1 Press and hold the M, the up arrow, and the down arrow buttons at the same time.

Step 2 The faceplate will flash “FULL”and “OFF”. Continue to hold the three buttons until “OFF”displays

continuously on the faceplate.

Step 3 Release the buttons. The override is now cancelled. The faceplate will return to displaying its standard

operatingmode.

MAINTENANCE AND CLEANING

General cleaning of the system's cabinet should be conducted at the user's discretion. It is important to monitor

water levels/pressure (PSI) as low water levels cause poor performance and possible damage to the system. Ask

the installer of the equipment for information on how to measure these levels.

If utilizinga heat pump or airconditioner with the Comfort Plus Hydronic, the indoor coil of these devices should

be cleaned periodically, to maintain system efficiency. Follow the manufacturer's cleaning recommendation for

these devices.

Operation

Optional Accessories

Optional Accessories 2.01 Comfort Plus Hydronic

SINGLE ELECTRICAL FEED KIT

The Steffes Comfort Plus systems have built-in circuit breakers. They are factory

configured to be field connected to multiple line voltage circuits. If single feed to the

elementandblowers/controlcircuitsisdesired,thesinglefeedkitisavailabletoallow

thesystemtobepoweredwithaone,largerlinevoltagecircuit.Contactthefactoryfor

orderingdetails.

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

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

regulations.

PRIMARY LOOP KIT

The Comfort Plus Hydronic system requires a primary water loop which serves to regulate heat transfer from the

unit’s heat exchanger. To minimize installation time and costs for field design and engineering of this loop, Steffes

Corporationoffersaprimaryloopkit.Thekitcontainsthecomponentsgenerallyinstalledwithhydronicheatsystems.

Features:

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

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

conduitandfittings.

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

with automatic purge during system operation and draining.

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

pump(circulator).

Offers troubleshooting isolation between the heating system and secondary

zones.

AIR HANDLER

The Steffes air handler allows the 5100 series heating system to

provide forced air heating or to be interfaced with other ducted heating

and/or cooling systems such as a heat pump or air conditioner. When

used with a heat pump, it serves as the back-up or supplement heat

and provides comfort modulation. It’s duct sensor monitors outlet air

temperature and modulates the off-peak stored heat needed to

maintain the desired output air temperature. As the air handler is

attached to the Comfort Plus system, it also directs the heat lost

statically through the outer panels into the ductwork for delivery to the

living space (automatic static heat recovery). The Comfort Plus

system’s internal controls automatically regulate the air handler’s

operation.

Configurations Available:

½HPwith60,000BTU/hrwatercoil (accommodatesmost1.5to4ton

heating/coolingsystems)

½HP variable speed ECM blower with 60,000 BTU/hr water coil

(accommodates most 1.5 to 4 ton heating/cooling systems)

1 HP variable speed ECM blower with 80,000 BTU/hr water coil (accommodates most 3 to 5 ton heating/

coolingsystems)

Accessories

Order Item #1302100 (1/2 HP)

Order Item #1302104 (1/2 HP VS)

Order Item #1302105 (1 HP VS)

TEFFES

CORPORATION

OrderItem#1302115

STATIC HEAT RECOVERY UNIT

During operation of the Comfort Plus Hydronic system, some heat from the brick

core storage will radiate through its outer panels. If the system is located in an

area with minimal heating requirements, such as a utility room, the static heat

recovery unit can maximize the system’s efficiency by transferring this static heat

to a more desirable location.

Features:

Connects directly to the Comfort Plus Hydronic system to interface with the

internal controls of the system for automatic operation.

Specifications:

•Wattage: 130 WATTS

•Motor: .1 HP, 60 HZ

•Voltage: 208/240 VAC

•Maximum Static Pressure: .15 inches Water Column

•CFM @.15 SP: 130 CFM

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

If the area available to install the Comfort Plus Hydronic system is less than 100 square feet, Steffes Corpora-

tion recommends installing a low voltage cooling thermostat, connected between R and G on the 12-position

terminal block, to maintain a temperature less than 85 degrees Fahrenheit.

COMFORT PLUS STAND

Some applications (such as garages) may require that the heating appliance be elevated in order to meet building

codes. The Steffes Comfort Plus stand elevates the 4100 or 5100 series Comfort Plus system 18". This stand is

shipped as a kit and requires field assembly.

7.875

10.072

10.135

3.000

3.312

ManualReset

LimitSwitch

OrderItem#1302110

Accessories

Comfort Plus Hydronic Optional Accessories 2.02

Stand

Order Item #1301585

Installation

SHIPPING AND PACKAGING

The Comfort Plus Hydronic should always be transported in an upright position to avoid damage to internal

components and insulation materials. The information below describes the items shipped with each system:

Installation

CAUTION Risk of sharp edges. Can cause personal injury. Use caution

when installing and/or servicing equipment.

(shipped inside the electrical

compartment)

Refer to Pages 3.08-3.09

3OUTDOOR

TEMPERATURE SENSOR 5

ELEMENT SCREW KIT

(shipped inside the

electrical compartment)

Refer to Pages 3.04-3.05

PRESSURE RELIEF VALVE KIT

(shipped behind the exchanger

access panel)

Refer to Page 3.11

JUNCTION BOX

(shipped behind the

exchanger access panel)

See Figure 9, Page 3.07

1INFORMATION PACKAGE

(includesOwner'sManualand

WarrantyRegistrationCard)

(adhered to outer side of

shipping box)

(shipped inside the brick core)

Refer to Pages 3.04-3.05

MODEL ELEMENTS

5120 8

5130 12

5140 16

HEATING ELEMENTS

CERAMIC BRICK

Full Brick

(shipped separately

and packaged 4 brick

per box)

Half Brick

(shipped with brick and

packaged in a white box

consisting of 6 half brick

and 1 full brick)

Model Full Brick HalfBrick

5120 26Boxes 1Box

5130 37Boxes 2Boxes

5140 49Boxes 2Boxes

See Figure 4, Page 3.04

Installation 3.01 Comfort Plus Hydronic

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