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