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2. STEFFES CORPORATION Manufactured in North America OWNER S AND INSTALLER S MANUAL for COMFORT PLUS Forced Air Heating Systems 74 8 3100 Series Models 3120 4120 4130 amp 4140 Applicable to Software Version 140 159 4100 Series IMPORTANT The equipment described herein is intended for installation by a qualified technician in compliance with applicable local state and national codes and requirements 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 Steffes disclaims any responsibility or liability for mold mildew growth and or any damages caused by either which occur after the heating system is in stalled We strongly recommend that the user follow the moisture mold and mildew prevention guideline
3. The versatility of this system allows it to fit many applications The Comfort Plus 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 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 once the home is completed SYSTEM START UP On start up of the Comfort Plus system odors relating to first time operation of the heating components may be experienced Also if not used for an extended period of time dust may accumulate in the system Allow the Comfort Plus heating system to charge to its maximum brick core charge level to expel odors in a timely manner As with most heating systems air borne particles and odors in the room may be drawn into the Comfort Plus and oxidized Odors can be amplified thus it is not recommended to operate the system if odors such as those from paints varnishes or chemicals are present in the air Air borne particles which have been oxidized are expelled back into the room and may accumulate on air vents or other surfaces Over
4. 2 BLACK MED HIGH BLUE YELLOW BLUE WHITE MED LOW RED LOW COOLING SPEED GROUND BAR BLUE BLACK HEATING SPEED BLUE RED SEE NOTE 1 9 Pin Header _ Connectors located gt in the base of the nN K i x Heater amp Plenum pP 8 BE BD E D 5 0 42 45 29 m E T MUU i SPEED SPEED 1 1 8 3 2 Q 12190 NO 1 12240 CORE BLACK HL BLOWER NO COM BLOWER FANON CALL RELAY RELAY resistor BLUE WHITE REsISTER 1 DAMPER n BASE 10 BOARD BLACK YELLOW To Relays 1 8 RELAY 3 NO NO RELAY 4 RELAY 9 RELAY 10 50 TRANSFORMER 240v 24v OPTIONAL 75VA EXPANSION BOARD I ement 4 Element 3 Element 2 lement 1 NOTES 1 Supply Air Blower Speed Selection Wiring The supply air blower is configured to operate medium low speed for heating and in medium high speed for cooling or fan only thermostat setting 2 Line Voltage Field Wi
5. 5201024 5066493 o Max External Static Pressure inches H O Canadian Patents 2059158 2060881 CHARGE CIRCUM 12 a T Feed Max Amps of Motors Included in Unit CHARGE CIRCUIT 3 8 1 volts Amps THe Core Blower 1 Amps ____ HP 4100 SERIES 2 Min Circuit Ampacity Amps cna ___ Amps CHARGE CIRCUIT H 2 ie Amps House Blower Amps HP MODEL 4130 and 4140 ONLY E Watts Charge Circuit 2 Volts Watts Unit Clearance Requirements 4100 series Charge Circuit 3 Volts Watts Allow three 3 inches from back and sides six 6 Charge Circult 4 Volts Watts inches from top of unit to combustibles and two E ee hey te EE Z Z ZZ 2 2 ou 2 Connections Required for Single Circuit Feed 2 inches from left side of unit to ducting Allow 5 z z a Volts Amps Hz thirty six 36 Inches front clearance to provide Min Circuit Ampacity Amps space for servicing No clearances are required 1 from ducting or to floor surfaces Max Fuse or Circuit Breaker Size Amps o LAL LS e 9 2 9 2 S Circuit Breakers The 60 AMP breakers on the Comfort Plus are for internal component protection only Sizing of the field wire and breaker size MUST in compliance with all appl
6. No Heat Call HC 1 Stage 1 Heat Call HC 2 Stage 2 Heat Call HC 3 Emergency Heat COOL Cooling Air Conditioning Call Brick Core Charge Level CL charge level followed by a number indicates the current L L 5 percentage of heat stored in the brick core represents zero percent and CL repre sents a full core charge level 1 Targeted Brick Core Charge Level tL target level followed by a number indicates the E L h current percentage of brick core charge being targeted the Comfort Plus A display of tL _ indicates a target level of zero percent and tL F indicates a full core charge target level Operation 1 02 Comfort Plus ROOM TEMPERATURE CONTROL The room temperature set point is adjusted at the wall thermostat If room temperature drops below the thermo stat set point the thermostat initiates a heat call and energizes the blowers in the Comfort Plus heating system The variable speed core blower s automatically adjust speed in relation to brick core temperature and duct temperature to circulate room air through the brick core The supply air blower then delivers the heated air into the living area through the duct system to satisfy heating requirements In applications where a 2 stage room thermostat is being used if the room temperature continues to drop a stage 2 heat call is initiated With a stage 2 heat call the Comfort Plus system provides discharge air at
7. OPTIONAL 75VA cow cow lt No 240 24 11 vo LIMIT LIMIT 13430 E 9 RELAY 10 WHITE BLACK 12 240 BLACK YELLOW ODT HEATING ELEMENTS RELAYS RELAY6 RELAY7 RELAYS Y Element 16 COM NO No _ No Element 15 14 Amp Li Element 14 x 59 Element 13 i L2120 5 RELAY 13 RELAY 14 Element 12 RED 12240 Element 11 RELAY 15 RELAY 16 Element 10 EXPANSION cow BOARD2 XO Element 9 lt Element 8 Element 7 Element 6 Element 5 Element 4 Element 3 Element 2 Element 1 NOTES 1 Supply Air Blower Speed Selection Wiring The supply air blower is configured to operate in medium low speed for heating and in medium high speed for cooling or only thermostat setting 2 Line Voltage Field Wiring Connections See Figure 10 for information on circuit phasing connections Appendix A 11 Comfort Plus INTERNAL SYSTEM WIRING DIAGRAM LOW VOLTAGE The outdoor temperature se
8. E e e e e E 4 2 453 4 2 Z 2 X 2 s oco oco 9 5 Amp 1 4 Amp LOW HIGH i Y SPEED SPEED I LA cov 12120 NO NO H 12240 BLOWER NO NS BLOWER FAN ON CALL RELAY E C resistor BLUE WHITE RESISTER DAMPER BLUE a BASE BOARD BLACK YELLOW RED To To Relays Relays Relays TRANSFORMER OPTIONAL 75VA RELAY RELAY2 RELAYS dir 1 5 9 2 610 4 82 240v 24v cow SS So eov So 5 1 4 Li Corey CORE NO LIMIT LIMIT TUM TUS RELAY 9 RELAY 10 WHITE BLACK 4 m 12240 RELAY RELAY 12 EXPANSION four Eur BLACK YELLOW BOARD 1 NO NO RELAYS RELAY6 RELAY7 RELAYS HEATING ELEMENTS Element 12 No COMI No Element 11 1 4 Amp J 11 Element 10 50 Element 9 Lum RELAY 13 RELAY 14 Element 8 e RED L2240 RELAY 15 RELAY 16 lt EXPANSION coul com Element G BOARDS Element 5 Element 4 Element 3 Element 2 Element 1 NOTES 1 Supply Air Blower Speed Selection Wiring The supply air blower is configured to operate in medium low speed for heating and in medium high speed for cooling or only thermostat setting 2 Line Voltage Field Wiring Connections See Figure 10 for information on circuit phasing Comfort Plus connections Appendix A 10 Line Voltage Wirin
9. Left Side Core Panel 5940561 5940565 5940560 Insulation Blanket Inner 1054130 1054134 1054140 Insulation Blanket Outer 1054132 1054136 1054142 Back Painted Panel 5940593 5940528 5940592 Galvanized Core Panel Back 5940563 5940567 5940562 Galvanized Core Panel Top 5940564 5940564 5940564 Core Blower Limit Switch 170D 1012009 1012009 1012009 Discharge Air Sensor 1041536 1041536 1041536 Supply Air Blower Limit Switch 190D 1012026 1012026 1012026 Supply Air Blower Wiring Harness 1041514 1041514 1041514 Supply Air Blower 1 2 HP 1075 RPM 1040086 1040086 1040086 Supply Air Blower 3 4 HP 1075 1040091 1040091 1040091 Supply Air Blower Capacitor 1018006 1018006 1018006 1022009 1022009 1022009 Supply Air Blower Assembly 1 2 HP 1041530 1041530 1041530 Supply Air Blower Assembly 3 4 HP 1041548 1041548 1041548 Terminal Block 6 Position 1016041 1016041 1016041 Electrical Panel Main Body 5940556 5940556 5940556 Electrical Panel Bottom 5940554 5940554 5940554 Interface Cable 18 1010014 1010014 1010014 Interface Cable 12 1010012 1010012 1010012 Faceplate Label 1159029 1159029 1159029 Time Clock Module optional 1301014 1301014 1301014 5 a lt 07 Comfort Plus INTERNAL SYSTEM WIRING DIAGRAMS LINE VOLTAGE Line Voltage Wiring Diagram Model 3120 240V OR 208V SYSTEMS ONLY copper or aluminum conductors rated for 75 C or higher for field connection of this device SEE NOTE
10. 2 SUPPLY AIR BLOWER SEE NOTE 1 MED LOW RE LOW WHITE GROUND BAR 22 8 Omn DH PRS 95 95 EO Mo OZ SX BLUE WHITE ea _ 0 5 Amp 1 4 Amp 9 2 S RESISTOR RESISTER Damper BASE IO BOARD BLACK YELLOW RELAY 1 RELAY 2 RELAY 3 RELAY 4 NO NO NO NO lt 1 4 d C e Ao 12240 7 EXPANSION X 50 TRANSFORMER e OPTIONAL 75V A 240v 24v lt Element 3 Element 2 Element 1 NOTES 1 Supply Air Blower Speed Selection Wiring The supply air blower is configured to operate in medium low speed for heating and in medium high speed for cooling or fan only thermostat setting 2 Line Voltage Field Wiring Connections See Figure 10 for information on circuit phasing connections Comfort Plus Appendix A 08 5 a lt Line Voltage Wiring Diagram Model 4120 240V OR 208V SYSTEMS ONLY Use copper or aluminum conductors rated for 75 C or higher for field connection of this device SUPPLY AIR BLOWER
11. Option Selected 2 3100 Series Systems 3 4100 Series Systems 8 Enables compressor control if there is a COOL call during a peak control time 32 If it is a peak control period and the Comfort Plus receives a cooling call the com pressor will turn off and on in 20 minute intervals off 20 minutes on 20 minutes off 20 minutes etc 128 Interfaces Comfort Plus with a heat pump that has a reversing valve which is energized for heating Charge Factor This configuration should be set to a value of 30 C008 through C010 configurations are only applicable if the Comfort Plus system is being used in conjunction with a heat pump Heat Pump Compressor Outdoor Lock Out Temperature for Off Peak or Anticipated Peak Modes Indicates the outdoor temperature at which the heat pump s compressor is locked out and not allowed to operate during an off peak or anticipated peak period Heat Pump Compressor Outdoor Lock Out Temperature for On Peak Mode Indicates the outdoor temperature at which the heat pump s compressor is locked out and not allowed to operate during an on peak period Minimum Discharge Air Temperature Sets the minimum discharge air temperature the system targets during a Stage 1 heat call Currently not utilized in the 3100 4100 Comfort Plus systems Currently not utilized in the 3100 4100 Comfort Plus systems C013 C021 Time Clock Module Configuration These configuration settings are used to configure the p
12. The buyer assumes all risk and liability whatsoever resulting from the use of this heating appliance Innoeventshall Steffes be liable to purchaser for any indirect special or consequential damages or lost profits This Limited Warranty contains the complete and exclusive statementof Steffes obligations with respect to the heating appliance and any parts thereof The provisions hereof may not be modified in any respect except in writing signed by aduly authorized officer of Steffes Thank you for purchasing Steffes ETS heating equipment We welcome your comments relating to the Comfort Plus and this manual Enjoy your new purchase STEFFES 3050 Hwy 22 North Dickinson ND 58601 9413 701 483 5400 CORPORATION DOCUMENT 1200051
13. The time during the day or night when the power company can supply electricity more economi cally and may offer a special incentive such as a reduced electric rate or billing credits for the electricity consumed during this time Typically electrical usage is not controlled during an off peak time The system will provide heat to satisfy comfort requirements during this time as well as charge or store heat in its brick core On peak The time during the day or night when the power company experiences a high demand for elec tricity To limit demand certain appliances are controlled to avoid usage by them and or a premium for the electricity consumed during this time may be charged to discourage electrical usage The system is not allowed to charge or store heat in its brick core during peak periods Heating requirements are satis fied by only the heat it has stored in its brick core Outdoor Sensor Device that senses outdoor air temperatures and communicates this information to the Comfort Plus for automatic charge control Room Temperature Set Point The targeted room temperature the system is to maintain If the room thermostat senses a temperature below this point the heater s blower will come on and extract heat from the brick core Comfort Plus Warranty Registering your purchase is an essential step to ensure warranty coverage A Warranty Registration card is included with the Owner s Manual Simply complete deta
14. be field con nected to multiple line voltage circuits If a single feed line voltage circuit is desired an optional single feed kit is available from the factory To determine the correct wire size required for each circuit feeding the Comfort Plus refer to the Specifications Page A 01 and the system s IMPORTANT identification label located on the lower front of a 3100 series system and on the lower left side of a 4100 series system Reference Sample To ensure proper operation and Label Figure 9 safety all line voltage circuits must be segregated from low Step 1 Remove the electrical panel cover voltage wiring in the Comfort Plus To reduce electro magnetic fields associated with electrical circuits and to avoid induced voltage on sensors and electronic devices the circuit phases MUST be alternated as shown in Figure 10 Step 2 Route all line voltage wires through a knockout and into the electrical panel of the Comfort Plus Step 3 Make proper field wiring connections to the Comfort Plus breakers Refer to the Line Voltage Wiring Diagrams Pages A 08 A 11 for more information on these connections SAMPLE SYSTEM IDENTIFICATION LABEL CIRCUIT PHASING CONNECTIONS FIGURE 9 FIGURE10 BLOWERS CONTROLS CIRCUIT 5 Manufactured in U S A a STEFFES Uu CORPORATION m CHARGE CIRCUIT 1 Model SN Option s E Maximum Discharge Air Temperature U S Patents
15. cut Use caution when install ing or servicing this equipment SHIPPING AND PACKAGING The Comfort Plus system should always be transported in an upright position to avoid damage to internal compo nents and insulation materials The information below describes the items shipped with each system INFORMATION PACKAGE includes Owner s Manual and Warranty Registration Card T adhered to outer side of shipping box ELEMENT SCREW KIT je shipped inside the electrical compartment CERAMIC BRICK Brick shipped separately and packaged 4 brick per box Half Brick shipped with brick and packaged 6 half brick and 1 full brick per box MODEL FULLBRICK 1 2BRICK 18 Boxes 0 Boxes 26 Boxes 1 Box 37 Boxes 2 Boxes 49 Boxes 2 Boxes Installation 2 01 HEATING ELEMENTS shipped inside the base of the Comfort Plus 6 OUTDOOR TEMPERATURE SENSOR shipped inside the electrical compartment SUPPLY AIR BLOWER ASSEMBLY 4100 SERIES Dimensions 26 x 24 5 x 20 5 shipped separately 7 RETURN AIR PLENUM ASSEMBLY 3100 SERIES Dimensions 22 x 48 x 3 banded to the 3100 Series Comfort Plus for shipping Comfort Plus PLACEMENT AND CLEARANCE REQUIREMENTS The physical dimensions of the Comfort Plus along with the clearances required MUST be taken into consideration when choosing its location within a structure See Figures 2 and
16. dIN VOF dINVOO C dIAVOS C 0 pormbo ee fee Ca nd uie w tat x ipu ddy SPECIFICATIONS Comfort Plus Appendix A 01 DISASSEMBLING THE 4100 SERIES COMFORT PLUS SYSTEM Step 1 Remove the painted front panel of the brick storage cabinet by removing the sheet metal screws along the top bottom and sides of the panel Detach by pulling the bottom of the panel forward and down Step 2 Remove the limit zone cover Step3 Remove the screws around the perimeter of the limit zone and around the bottom of the left side right side and back upper panels Step 4 There are two white blue wires which route from the limit zone through a knockout These wires route into the electrical compartment through a romex connector Loosen the romex connector Step 5 Remove the electrical panel cover and locate the point where the white blue wires connect to the black yellow wires Disconnect the white blue wires and route them up through the romex connector Step 6 Remove the one to two screws in the center of the upper right side panel From the back of the system lift and remove the painted panels Figure A Step 7 Locate the brick core temperature sensor s behind the front panel and disconnect them from their shipping position Carefully lay the sensor s aside to avoid damaging them Step 8 Rock the brick core Figure B to one side and lift top portion up and
17. elec tric shock Can cause injury or death This system may be con nected to more than one branch circuit Disconnect power to all circuits before installing or ser vicing Installation of and or service to this equipment MUST be performed by a qualified technician Risk of injury or fire Violation of the clearance requirements can cause improper operation of the equipment Maintain the place ment and clearance requirements specified for service by a qualified technician BUILT IN SAFETY DEVICES The Comfort Plus heating system incorporates safety devices to ensure normal operating temperatures are main tained The chart below describes these safety devices DEVICENAME FUNCTION LOCATION ON SYSTEM Core Charging High Limit Switches Auto Reset Core Blower Limit Switch Auto Reset Supply Air Blower Limit Switch Base Temperature Limit Switch Auto Reset Comfort Plus These limit switches monitor brick core charging and interrupt power to the heating elements if the normal operating temperature is exceeded This limit switch monitors the discharge air temperature and interrupts power to the core blower s if the normal operating temperature is exceeded 3100 Series 130 F nominal 4100 Series 170 F nominal This limit switch monitors the discharge air temperature and interrupts power to both the supply air blower and the core blower s if the normal operating temperature is exceeded 3100 S
18. for reference to these air holes Proper duct design and air SUPPLY AIR BLOWER SPEED flow are critical to achieve For air delivery the Comfort Plus is equipped with a 4 speed supply air optimum system perfor blower and is factory wired to operate in medium low speed for heating mance A poorly designed and in medium high speed for cooling and or a fan only thermostat duct system and or improper setting air flow can cause system inefficiencies air noise and Blower speed selection on the 3100 series is made at the low and high speed condensate drain problems relays on the Base IO board inside the electrical compartment Refer to the In applications where poor Line Voltage Wiring Diagram Page A 08 for location of these relays The air flow conditions exist low speed relay controls the heating blower speed and the high speed relay along with high humidity it controls the cooling blower speed Select the blower speed desired and may be necessary to install a connect the corresponding wire to the low or high speed relay Blower speed selection the 4100 series is made at the supply air blower in the supply air blower plenum To change blower speed for either heating or cooling modes detach the quick disconnect terminals at the supply air blower Select the blower speed and connect the corresponding wires When interfacing the Comfort Plus system with a heat pump the blower speed connected
19. in equipment damage Thermo statically controlled ventilation should be provided if the temperature in this area exceeds 85 F Installation DIMENSIONS 151 Return Air Plenum Installation 2 02 e FE m 2 4100 SERIES SYSTEM REQUIREMENTS FIGURE 3 CLEARANCES DIMENSIONS 6 X 6 REGISTER di IN COLD AIR RETURN 6 MIN CLEARANCE 2 MIN CLEARANCE FILTER TRAY FRONT VIEW 0 REQUIRED O REQUIRED _ CLEARANCE CLEARANCE 3 MIN CLEARANCE 36 MIN CLEARANCE Between Duct and Left Side of System 2 inches Between Duct and Right Side of System 0 clearance Outer Sides of System Ducts Return and Supply 0 clearance Back and Sides 3 inches from combustible material Bottom 0 clearance Top 6 inches from combustible material jd Front 36 inches for ease in servicing gd sei Supply Air Plenum 225 21 8 Factory Supplied 8 Minimum clearance requirements do NOT account for space needed for making electrical connections 296 INITIAL SET UP Step 1 Remove the Information Package from the outside of the shipping box and unpackage Risk of improper operation or equipment dam the Comfort Plus heating system age Read and follow installation instructions Step 2 Remove the heating elements from inside the carefully base of the system DO NOT install the C
20. instructions carefully pass through the blanket insulation and into the brick core Holes have not been predrilled through the insulation Use the sensor s to aid in making a passageway by rotating the sensor s side to side while gently pushing inward Step 3 Once the brick core sensor s is installed put the screw s back into position in the galvanized front panel to hold the sensor s in position and to provide the electrical ground Step 4 Check the non insulated element terminations to make sure they do not come within 1 2 of any surface area on the system Step 5 Re install painted front panel using previously removed screws DUCTING cause injury or death DO NOT operate the Comfort Plus without ducting installed to If a down flow configuration is desired with the 4100 series a down flow kit both the air inlet and outlet must be ordered from the factory Order Item 1301578 and the system MUST be raised a minimum of 10 off the ground An 18 pedestal is AN available Order Item 1301585 to elevate the Comfort Plus CAUTION AIR FLOW DIRECTION 5 The 3100 series is factory configured for a right to left air flow 4100 series is factory configured for a left to right or right to left airflow In HAZARDOUS VOLTAGE either airflow direction the holes directly above the air outlet on the right Risk of electric shock Can 2 side of the 4100 series systems MUST be contained in the duct system See Figure 7
21. off the base Figure Step 9 Move the Comfort Plus heating system into the desired location reassemble and continue with the installation instructions in this manual Can be broken down into A individual panels 29 3 16 sne i FIGUREA 4140 5140 A 56 MOT 4130 5130 45 4120 5120 28 7 8 lt 34 1 2 gt lt Nm 38 1 8 E eog p N bye t Saq s as Way E er d gt FIGURE B 4140 5140 E 54 3 is x 4130 5130 e an 43 3 4 Y T o A 4120 5120 q 32 3 4 8 Y Do not remove 7 core limits Saddles and Z brackets can removed if needed 17 1 4 1 lt BW ALL 4100 S gt 2 45 3 4 Including 2 29 3 16 Breakers ALL 5100 48 1 4 Comfort Plus Appendix A 02 5 lt PARTS DIAGRAM 3100 SERIES Appendix A 03 30 Comfort Plus PARTS LIST 3100 SERIES When ordering parts please include the system model and serial numbers DWG 3120 REF NO DESCRIPTION ITEM NO Front Painted Panel Right Side 5940728 Electrical Panel Cover 5940794 Front Galvanized Panel 5940770 Standoffs Front 5940774 Core Blower 1021001 Heating Elements Blower Access Cover 5940796 Supply Air Blower Support Bracket 5940702 Base Temperature Limit Switch 1012008 Base Temperature Limit Mounting Brac
22. position the sensor s to avoid damage during brick loading and wiring Models 4130 and 4140 have two brick core temperature sensors Step 8 Remove the sheet metal screws around the outer edge of the galvanized front panel Remove the panel and set it aside Step 9 Starting at the bottom carefully lift each of the insulation blankets and drape them over the top of the Comfort Plus system hore Use face mask gloves and long sleeved garments when handling insulation materials in compliance with generally accepted safety practices Step 10 Remove the front air channel by pulling out on the bottom of the air channel on a 3100 series or the top of the air channel on a 4100 series BRICK LOADING WARNING Load the brick one row at a time using a left side right side center pattern Start at the back of the brick core and work forward Make sure the brick are Risk of injury or fire DO NOT placed so the grooved side is facing up the notch is facing forward and the operate the Comfort Plus ridges are on the left and right see Figure 4 system if damage to the insulation panels on the BRICK INSTALLATION TIPS inner sides of the brick core e Install bricks carefully to avoid damage to the insulation panels occurs Remove loose brick debris to prevent uneven stacking of brick as this can make installation of the elements and the brick core temperature sensor s difficult e Brick rows MUST line up front to back and ye si
23. to fiora the high speed relay is used for both heating and cooling In the 4100 series this is the blower speed connected to the blue black wire Comfort Plus Installation 2 06 E SYSTEM AIR DELIVERY MATRIX STATIC PRESSURE INCHES WATER COLUMN Supply Air External static pressure should not exceed 75 inches water column High CFM Medium High Medium Low CEM Low CFM Low Speed Maximum Pressure is 25 inches water column ATTACHING THE DUCTING 3100 SERIES Step 1 If using the factory supplied return air plenum shipped separately follow the assembly procedure provided with the plenum Step 2 Once assembled set the plenum on the right side of the system with the air filter and indoor coil access covers facing forward Line up the predrilled holes on the system with the holes in the flanges of the plenum and attach using the screws provided in the plenum s hardware package Step 3 Insert the air filter into the filter rack Step 4 Connect the supply air duct in the structure directly to the system s air outlet located on the top panel Step 5 If necessary adjust the supply air blower speed by changing the wiring on the blower speed selection terminals Refer to the System Air Delivery Matrix for details ATTACHING THE DUCTING 4100 SERIES Step 1 Remove the supply air blower plenum assembly from the box 4100 SERIES SUPPLY AIR PLENUM ATTACHMENT Step 2
24. with Heat Pump EIS O0000080008 666 Comfort Plus 12 Position Terminal Block Comfort Plus Installation Bl 2 12 19 LOW VOLTAGE CONNECTIONS CONVENTIONAL FURNACE APPLICATION SHOWN WITH UNCONTROLLED AIR CONDITIONING SYSTEM FIGURE 13 Honeywell TH5110D Y Air Conditioner Connections C If being used in the application Outdoor Sensor Optional Freeze Protection Room Sensor G OS SC RS S Conventional Furnace Comfort Plus 12 Position Terminal Block If installing a mechanical thermostat or thermostat with anticipator a resistor kit is required Order Item 1190015 AUXILIARY LOAD CONTROL TYPICAL AUXILIARY LOAD CONTROL The Comfort Plus can be used to provide control signals FIGURE 14 to other loads in the application To do so connect low voltage control wires to the COM and NC or the P com nc and positions of the six 6 position low voltage terminal block in the electrical compartment of the Comfort Plus system See Figure 14 These contacts are rated for 30 volts 3 amps maximum in Control Relay FRE Relay If control of external line voltage devices is desired contact the factory and order the Auxiliary Control Relay Order Item 1302010 or the Auxiliary Control Relay wi
25. 3 for system dimensions and clearance requirements The best installation location for this system is in a space requir ing heat so some amount of the heating requirements can be satisfied through static dissipation from the warm outer panels of the Comfort Plus In situations where the Comfort Plus is not installed in an area it is intended to heat i e garage it is impor tant to account for the heat lost through static dissipation by making proper adjustments when sizing the system The minimum area required for the installation of the Comfort Plus is 100 square feet This area must remain free of debris and room air should be maintained at less than 85 Fahrenheit If the system is being installed in an area with less than 400 square feet ventilation MUST be provided To ventilate a minimum of a 24 X 24 opening must be installed if not already present into the area where the Comfort Plus is located In addition a 6 X 6 non closing type register must be cut into the return air duct of the furnace to minimize heat build up in the room This register must be installed in a manner that ensures the air drawn into the Comfort Plus passes through the filter first see Figure 3A In addition to the physical space requirements the weight of the Comfort Plus must also be taken into consider ation when selecting the installation surface A level concrete floor is the best installation surface on which to place the system but mos
26. CERO RD PORTO pne a pO de ROI D TE eee A 04 Parts Diagrami 4100 SETIES qm A 05 Parts List 4100 SEriES Pe e ORE leve p EO e ORE A EA A 06 A 07 Internal System Wiring Diagrams Line Voltage A 08 A 11 Internal System Wiring Diagram Low Voltage A 12 Help MEDU srera ei A 13 Etor CodeS M Et A 13 A 14 GOSS AMY sce ER A 15 Warranty Table of Contents Comfort Plus GENERAL OPERATION The Steffes Comfort Plus heating system stores off peak electricity in the form of heat Off peak electricity is available during times of day or night when electricity is plentiful and the power company can supply it at a lower cost Operation of the Comfort Plus heating system 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 heating requirements c A heat call from the room thermostat energizes the blowers in the Comfort Plus system The variable speed blower s automatically adjust its speed to circulate room air through the brick core The supply air blower then delivers this heated air into the desired area through the duct system to maintain a constant comfortable room temperature
27. Error Code Description than one branch circuit 01 The lower core Core A thermocouple temperature is out Disconnect power to all lt of normal range open shorted or otherwise defec circuits before servicing tive thermocouple or a circuit board which is out of Equipment must be serviced calibration can cause this by a qualified technician 02 The upper core Core B thermocouple temperature is out of normal range This can be caused by an open shorted or otherwise defective thermocouple or a circuit board which is out of calibration 03 Room sensor temperature is out of normal range This can indicate an open thermistor a short in the wiring or a circuit board which is out of calibration 04 Discharge air sensor temperature is out of normal range This can indicate an open ther mistor a short in the wiring or a circuit board which is out of calibration 05 Outdoor sensor direct wired temperature reading is out of normal range The thermistor circuit may be open or shorted the processor control board may be out of calibration or there may be an incorrect value in L035 Appendix Bl A 13 Comfort Plus Error Code 06 08 10 20 21 22 23 24 25 26 27 28 29 30 31 39 40 41 42 43 44 Cold Core Core Fail PLC Fail Comfort Plus Description Outdoor sensor temperature from the transmitting device PLC system is out of normal range Check the outdoor sensor attached to the tran
28. N xe lt 05 Comfort Plus PARTS LIST 4100 SERIES When ordering parts please include the system model and serial numbers DESCRIPTION 4120 4130 4140 ITEMNO ITEMNO ITEMNO Electrical Panel Cover 5940553 5940552 5940552 Front Painted Panel 5940589 5940526 5940588 PCB Relay Expansion Board 1023067 1023067 1023067 PCB Base I O Relay Board 1023078 1023078 1023078 Terminal Block 12 Position 1016040 1016040 1016040 Transformer 50VA 1017045 1017045 1017045 Optional Transformer 75 VA 1017039 1017039 1017039 PCB Processor Control Board 1023065 1023065 1023065 Processor Control Board Mounting Bracket 5940550 5940550 5940550 1024000 1024000 1024000 Breaker 60 Amp 1024002 1024002 1024002 Breaker Standoff 5940034 5940034 5940034 Electrical Panel Insert Center 5940505 5940505 5940505 Electrical Panel Insert Left 5940504 5940504 5940504 5940506 5940506 5940506 Harness Breaker to Element Black 1041503 1041515 1041502 Harness Relay to Element Red 1041501 1041513 1041500 Front Air Channel 5940515 5940521 5940514 Front Standoff 5940513 5940513 5940513 Front Galvanized Panel 5940579 5940524 5940578 Upper Brick Core Temperature Sensor N A 1041525 1041525 Lower Brick Core Temperature Sensor 1041525 1041525 1041525 Core Blower Spring 1159006 1159006 1159006 Core Blower 1021001 1021001 1021001 Base Temperature Limit Switch 1012008 1012008 1012008 Brick
29. The supply air blower is shipped inside the plenum FIGURE 7 assembly in its operating position and is secured to the plenum by a metal plate to keep the blower from moving during shipping The metal plate MUST be removed before operating the system Once removed Plenum Support Bracket it may be discarded Step 3 Adjust blower speed if necessary by changing the Y wiring on the blower speed selection terminals Refer to the System Air Delivery Matrix for details The front access cover on the supply air plenum will need to be removed to access these terminals Step 4 Locate the plenum support bracket which is shipped in the plenum box Attach the bracket to the supply air side using the blunt tip screws supplied in the plenum assembly hardware package Refer to Figure 7 for proper positioning of the plenum support bracket When routing the harness to the supply air blower the harness must route to the base of the system to the blower using the connections side of the air deflector in the bottom of located on the ends of the harness Be sure to place the supply air blower housing any excess wiring in the base of the system below the radiant heat shield Figure 7 Step 5 Attach the supply blower wiring harness located in the Installation B 2 07 Comfort Plus FIGURE 8 Step 6 Verify that the blower is installed in the plenum with the motor facing away from the system Figure 8 Step 7 Attach the supply air b
30. Tray 5940548 5940548 5940548 Insulation Block 19 1054144 1054144 1054144 Heating Elements Brick 5903015 5903015 5903015 Right Side Core 5940559 5940557 5940558 Outdoor Sensor Knockout Style 1302044 1302044 1302044 Right Side Painted Panel 5940587 5940525 5940586 Right Side Standoff 5940570 5940570 5940570 Micropore Insulation Panel 1050122 1050121 1050120 5940590 5940590 5940590 Core Limit Jumper 1041510 1041510 1041510 Left Side Front Painted Panel 5940597 5940529 5940596 Limit Harness Top 1041506 1041505 1041505 Limit Harness Bottom 1041504 1041504 1041504 Left Side Front Base Panel 5940580 5940580 5940580 Bottom Panel 5940568 5940568 5940568 Base Top Panel 5940566 5940566 5940566 Base Deflector Panel 5940502 5940502 5940502 a lt Optional voltages are available Contact factory with model number and serial number of the system for information Comfort Plus Appendix A 06 PARTS LIST 4100 SERIES CONTINUED When ordering parts please include the system model and serial numbers DESCRIPTION 4120 4130 4140 ITEMNO ITEMNO ITEMNO Back Bottom Base Painted Panel 5940582 5940582 5940582 Left Side Bottom Painted Panel 5940594 5940594 5940594 Left Side Back Painted Panel 5940599 5940530 5940598 Core Limit Switch 290D 1012019 1012019 1012019 Limit Zone Painted Cover 5940585 5940527 5940591 Left Side Top Painted Panel 5940584 5940584 5940584
31. between the terminal connections and any surfaces any surfaces within the within the system Refer to the required clearance information in system FEES 4100 SERIES AIR CHANNEL Step 2 Remove the painted front panel of the electrical PLACEMENT compartment by removing the screws along the FIGURE 5 edges Locate the installation hardware package that is shipped in this compartment Step 3 Install the front air channel with the air deflectors arrow shaped pieces facing inward and with the Front Ai narrow ends of the deflectors pointing up RICE f e TOES CORE 3100 Series Place top portion in first 4100 Series Place bottom portion in first see Figure 5 e je FE m 72 Step 4 Lower the insulation blankets back into position one at a time Carefully tuck the sides of the insulation into the edges corners and around the exposed Electrical portions of the heating elements to ensure maximum Panel efficiency Step 5 Reinstall the galvanized front panel and secure it to the ELEMENT INSTALLATION Comfort Plus system using the screws that were originally FIGURE 6 removed TOP VIEW 3100 Series Slide the top of this panel inside the upper lip of the top painted panel The bottom should rest on the outside of the cavity and secure to the base with screws AYA 4100 Series Slide the bottom of this panel inside the lower l
32. ch the bottom portion and return the card today Retain the top portion of the card for your files WARRANTY STATEMENT Steffes Corporation Steffes warrants that the Steffes Electric Thermal Storage Heating Appliance is free from defects in materials and workmanship under normal use and service Steffes obligation under this Warranty is limited to the repair orreplacement of the appliance or parts only which prove to be defective under normal use within five 5 years of the date of installation and which Steffes examination of the returned appliance or part s shall verify to Steffes satisfaction that it is defective Optional Steffes controls and accessories have a 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 orimproperly installed serviced or used or has been subject to accident negligence abuse or misuse THE ABOVE WARRANTY STEFFES IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRAN TIES WHETHER WRITTEN OR ORAL EXPRESS OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE
33. de to side p am e Half brick makes brick loading easier by ia evening out the stacks Use the HALF BRICK boxes marked in the proper rows and in the correct positions as indicated in Figure 4 The back half of the brick MUST be installed in the back rows and the front half the notched brick piece MUST be installed in the front rows BRICK LOADING FIGURE 4 NOTCH IN BRICK LE HALF BRICK 3120 Does not contain half brick 4120 Load in row 5 4130 Load in row 4 and 8 4140 Load in row 6 and 12 Comfort Plus Installation B 2 04 en e 0 HEATING ELEMENT AND AIR CHANNEL INSTALLATION Step 1 After all brick are loaded insert the heating elements between the brick layers sliding them in until the element ends embed into the WARNING side cutouts of the brick cavity 3100 Series The threaded screw tabs on the wire connection HAZARDOUS VOLTAGE Risk of terminals should point forward electric shock injury or death DO NOT remove the electri 4100 Series The elements MUST be installed so their threaded cal panel cover while screw tabs on the wire connection terminals point forward and system is energized down If they are installed with the screw tabs pointing upward Elements MUST be posi element to wiring harness connections will be difficult Be sure tioned properly to avoid the elements are slid into the brick core properly to ensure correct short circuiting them against clearance
34. eak control times when utilizing the optional Steffes Time Clock Module Refer to the installation and configuration instructions included with the module for more information Installation 2 15 Comfort Plus INSTALLER S FINAL CHECK OUT PROCEDURE Step1 Verify that the operating mode displayed on the control panel corresponds with the power L company s peak control signal Refer to the Operating Status section Page 1 02 for more HAZARDOUS VOLTAGE information on the proper operating mode 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 Step 3 Press the up arrow again and the current heat call qualified technician status will be displayed on the control panel Refer H to the Operating Status section Page 1 02 for more information on the heat call status display Step 2 Press the up arrow one time and verify that the outdoor temperature information displayed on the J 5 control panel is approximately the same as the 2 current outdoor temperature Refer to the Operat ing Status section Page 1 02 for more information on the outdoor temperature display Step 4 Initiate a heat call from the room thermostat and verify that the Comfort Plus system recognizes the heat call Refer to the Operating Status section Page 1 02 for more information on the various heat call statu
35. er the indoor coil can be placed on either the supply air or the return air side of the system The condensate drain trap in a heat pump or air conditioner installation should be designed for the vacuum in which the system is operating Typically taller traps are better suited for these types of applications Refer to the Room Thermostat Connections Diagrams Figures 12 and 13 for more information on interfacing the Comfort Plus with a heat pump or air conditioner Comfort Plus Installation 2 08 FE 0 72 LINE VOLTAGE ELECTRICAL CONNECTIONS In standard configuration the Comfort Plus is wired for connec tion to 240V however the element circuits can also be con nected to 208V A 208V connection derates the charging input HAZARDOUS VOLTAGE Risk of electric of the system by 25 If a system rated specifically for 208V shock Can cause injury or death Do not or 277V is required contact the factory The controls circuit in energize the system until installation is the Comfort Plus system MUST be connected to 240V 208V complete Equipment MUST be installed by a qualified technician in compliance The 60 amp breakers located in the electrical compartment on with all applicable local state and the Comfort Plus feed the core charging element circuits The national codes and regulations 15 amp breaker feeds the controls and blowers circuit All Comfort Plus systems are factory configured to
36. er company s peak control switch Field connections from the peak control switch are made to the low voltage terminal block through a low voltage knockout located on the left side of electrical panel Step 1 Route a low voltage circuit from the power company s load control or peak signaling device to the six 6 position terminal block inside the electrical compartment of the Comfort Plus see Figure 11 FE WwW 2 Step 2 Connect the field wiring to positions RP and P on the six 6 position low voltage terminal block see Figure 11 control other devices refer to the Auxiliary Load Control Page 2 13 POWER LINE CARRIER PLC PEAK CONTROL The Steffes Power Line Carrier PLC control system has the ability to communicate with the system through the existing electrical circuits in the structure With the power line carrier option direct wired low voltage connections from the power company s peak signaling switch connect directly to the transmitting device The switch signals peak control times to the transmitter the transmitter sends the signals to the Comfort Plus system which receives this information and responds accordingly In addition to providing peak control signals the transmitter also provides outdoor temperature information for automatic charge control room temperature set back and anticipated peak utility control signals if applicable The PLC system is optional and must be ordered se
37. eries 160 F nominal Auto Reset 4100 Series 190 F nominal Manual Reset This limit switch monitors the temperature in the base of the Comfort Plus and interrupts power to the core blower s if the normal operating temperature is exceeded In the limit bar panel on the left side of the brick storage cavity 3100 In the discharge air supply outlet 4100 On the dis charge air supply blower 3100 In the discharge air supply outlet 4100 On the dis charge air supply blower In the base of the Comfort Plus near the core blower s Safety Information Table of Contents Operation General Operation scorrere 1 01 System Use During Construction Phase ete ette eerie torte Debe ee 1 01 System Start M O E 1 01 System and 1 01 1 02 Operating an esti sx M 1 02 Room Temperature Control 1 03 Brick Core Charge Control TE SS 1 03 Charge Control Oyeftide T 1 03 Maintenance and Cleaning can sre Ere ae eee Peces Doe D
38. f utilizing automatic charge control as set in C000 this value indicates the outdoor temperature at which the system will start charging C002 Full Brick Core Charge Set Point If utilizing automatic charge control as set in C000 this value indicates the outdoor temperature at which the system will target a full core charge C003 Power Line Carrier PLC Channel Selection If using PLC communication this setting must match the channel setting in the Steffes PLC transmitting device A value of zero indicates power line carrier communication is disabled C004 Optional Controls Configuration Value Configuration Description 8 No Outdoor Sensor No Time Clock Module 9 Outdoor Sensor No Time Clock Module 12 No Outdoor Sensor Time Clock Module 13 Outdoor Sensor Time Clock Module C005 Control Switch Configuration If utilizing power line carrier control the Steffes Time Clock Module or line voltage control this value should be zero For all other applications this value should be one 1 Configuration Menu continued on next page Comfort Plus Installation Bl 2 14 es ES e C006 C009 C010 C011 C012 Output Control Configuration Configures the output controls of the Comfort Plus system To determine the value check the options desired from the list below Then add the numbers from the Value column and enter the sum into this location Value
39. g Diagram Model 4140 240V OR 208V SYSTEMS ONLY Use copper or aluminum conductors rated for 75 C or higher for field connection of this device SUPPLY AIR BLOWER MANUAL RESET BLUE SEE NOTE 2 BN COOLING SPEED e 9666606 BLUE BLACK HEATING SPEED GROUND BAR BLUE RED 1 9 Pin Header Connectors located in the base of the a 4 x S 9 x Heater amp Plenum s E m E m E m E m E 22055 50 55858 s d amp 5 amp HOR C OJIS NV NV T p HIGH i SPE E 12120 Lp NO NO L2240 CORE BLACK BLOWER NO on coM BLOWER WHITE rp FAN ON HEAT CALL NC RELAY RELAY ue RESISTOR BLUE WHITE S 2 RESISTER mE DAMPER N BLUE a 5 BASE 10 BOARD 0 BLACK YELLOW To To To Relays Relays Relays E RELAY 1 RELAYS RELAY 4 2 6 10 14 3 7 11 15 4 8 12 1 r
40. his 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 On board communication system is not fully operable Contact a qualified service technician Base I O control board is in test mode Check the jumper configuration on the circuit board Relay expansion board s are in test mode Check the jumper configuration Indicates the value in Location 13 L013 has been set to a value greater than the value in Location 12 L012 The system will not charge until the value in L013 is set lower than L012 5 2 lt Press and release the button to clear the error If the error code reappears contact qualified service technician Contact a qualified service technician Contact a qualified service technician Contact a qualified service technician Contact a qualified service technician The brick core temperature is below 40 degrees or the core sensing thermocouple may be open Core high limit switch may be open The system is configured for power line carrier control however is not receiving a valid power line carrier communication signal Appendix B A 14 5 lt GLOSSARY Anticipated Peak Used only by certain power companies as an alternative method of storing heat in the brick core Automatic Charge Control Method of brick core charge regulation where a sens
41. icable local state and national codes and regulations Installation 2 09 Comfort Plus LOW VOLTAGE ELECTRICAL CONNECTIONS Steffes ETS heating equipment may PEAK CONTROL TERMINAL be controlled by the Power Com pany via a peak control signal This IMPORTANT 2 signal be sent to the equipment using a Steffes Power Line Carrier Never install any wiring control system low voltage wiring a line voltage compartment Steffes Time Clock Module or line of the Comfort Plus unless voltage wiring In applications it is rated for line voltage utilizing automatic charge control outdoor temperature information is required and can be received via an outdoor sensor or power line carrier control system Dry Contact Peak Control Switch Comfort Plus 6 Low Voltage Terminal Block Coding Peak Control Input Common The Comfort Plus heating system is factory config ured for low voltage wire control and is set to charge when the utility peak control switch closes Refer to the Configuration Menu Pages 2 14 2 15 for information on configuring the system for the Peak Control Input Anticipated Peak Pre Peak Control Input Peak Control Output Common application Peak Control Output Normally Closed Peak Control Output Normally Open LOW VOLTAGE DIRECT WIRED PEAK CONTROL If using the low voltage peak control option the Comfort Plus is direct wired to the pow
42. in these locations are displayed for viewing and adjusting purposes AM and PM Indicator Lights STEFFES CORPORATION The AM and PM indicator lights are only utilized if the Steffes Time Clock Module is M 9 9 being installed With this module installed the system displays time on AM PM intervals and the corresponding light flashes The system can be configured to display military time in which case both the and PM lights illuminate Mode Edit Button CONTROL PANEL Activates the editing menu for changing the operat AN CAUTION FIGURE 1 ing information of the system Editing operating QD Up and Down Arrow Buttons information may alter Used to scroll up or down when viewing or changing the performance and operating functions operation of the system C Interface Port FOR SERVICE USE ONLY Allows technician external access for updating software and troubleshooting OPERATING STATUS The Comfort Plus is set to display various operating information as described below Press and release the up arrow to view this data 1 Operating Mode Indicates the current operating mode of the Comfort Plus system E EL Off Peak Charge Time A bar illuminates on the lower portion of P On Peak Control Time the display s second digit whenever the Anticipated Peak Time heating elements are energized Heat Call Status Indicates the current heat call status being received from the room thermostat 0
43. ip of the brick cavity The top rests on the outside of the cavity Step 6 Carefully route wiring harnesses and connect them to the heating elements using screws provided in the hardware package Make connections with screw heads up and Sy threads pointing down Element screws should be tightened to 14 inch lbs Refer to Element Connection Figure 6 for proper positioning Element Connection Step 7 The painted front panel can now be installed on 3100 systems If installing a 4100 system the brick core tem perature sensor s must be installed prior to putting the painted front panel in place Required Clearance Between Element Termination and Metal Panels is 1 2 3 4 Nominal Installation 2 05 Comfort Plus BRICK CORE TEMPERATURE SENSOR INSTALLATION 4100 SERIES ONLY Step 1 Remove the screw s by the brick core temperature sensor hole s in AN CAUTION the galvanized front panel Risk of improper operation Models 4130 and 4140 have an upper and a lower brick the core temperature sensor brick core temperature sensor s is critical to the Step 2 Insert the brick core temperature sensor s through the hole s in the operation of the Comfort galvanized front panel If installing a system with two sensors be sure Plus heating system Read the one marked upper is installed in the upper opening and the one and follow installation marked lower is installed in the lower opening The sensor s must
44. its maximum preset temperature When used to supplement heat pump systems the Comfort Plus replaces the resistance strip heat which is typi cally required as a supplement or back up to the heat pump system A duct sensor monitors the discharge air temperature If the demand for heat is at a point where the heat pump alone cannot maintain the desired duct temperature stored heat is used to supplement the heat pump and satisfy the heating requirements Operation BRICK CORE CHARGE CONTROL The amount of heat stored in the brick core of the Comfort Plus system is regulated automatically in relation to outdoor temperature and the heating requirements The outdoor sensor supplied with the system monitors outdoor temperature and provides this information to the Comfort Plus As the outdoor temperature decreases heating requirements increase and the 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 the standard c
45. ket 5940711 Front Air Channel 5940779 1 5903015 Low Voltage Panel 5940748 Terminal Block 12 Position 1016040 Terminal Block 6 Position 1016041 Supply Air Blower Assembly 1041630 Supply Air Blower 1 2 HP 1075 RPM 1040086 Supply Air Blower 1 3 HP 850 RPM 1040090 Supply Air Blower Capacitor 1018006 Supply Air Blower Mounting Bracket 5940704 Breaker Standoff 5940766 Processor Control Board Mounting Bracket 5940746 PCB Processor Control Board 1023065 PCB Base I O Relay Board 1023078 PCB Relay Expansion 1023067 Right Front Base Painted Panel 5940764 Back amp Left Side Base Painted Panel 5940762 Upper Left Side Painted Panel 5940780 Top Painted Panel 5940768 Insulation Blanket Inner 1054110 Insulation Blanket Outer 1054115 Core Limit Switch 320D 1012011 Core Blower Limit Switch 130D 1012006 Discharge Air High Limit Switch 160D 1012008 Discharge Air Sensor 1041536 Core Temperature Sensor 1041625 1050124 Transformer 50VA 1017045 Optional Transformer 75VA 1017039 Breaker 15 Amp 1024000 Breaker 60 Amp 1024002 Interface Cable 36 1010016 Interface Cable 12 1010012 Outdoor Sensor Knockout Style 1302044 Faceplate Label 1159029 Time Clock Module optional 1301014 5 2 lt Optional voltages are available Contact factory with model number and serial number of the system for information Comfort Plus Appendix A 04 PARTS DIAGRAM 4100 SERIES AS ACRES SACER RC SSG SESS E
46. lower plenum to the Comfort Plus by drilling two 1 8 holes per edge and using the self tapping screws supplied in the hardware package Step 8 Connect both the return air and supply air ducting systems in the structure to the Comfort Plus system Be sure the air holes just above the air outlet on the right side are contained in the duct system See Figure 7 for reference to the location of these holes If the Comfort Plus system is installed in a small en closed area less than 400 square feet a minimum of a 24 x 24 opening must be installed into the area where the system is located In addition a 6 x 6 non closing type register must be cut into the return air duct Refer to the Placement and Clearance Requirements section Pages 2 02 2 03 for more information AIR CONDITIONER HEAT PUMP INTERFACE The Comfort Plus system can accommodate most heat pump or air conditioner indoor coils up to a 4 ton capacity provided the heat pump or air conditioner is sized in compliance to supply air delivery rates of the Comfort Plus Equipment modifications are required to fit larger coils Refer to the System Air Delivery Matrix Page 2 07 for information on air delivery rates of the Comfort Plus supply air blower with regard to the blower s speed This information should be used to ensure that adequate air flow is provided for the heat pump or air conditioner being installed The maximum coil size the factory supplied return air plenum can acc
47. mpany s peak control signal Step 10 In applications utilizing the Steffes Power Line Carrier control system complete the Installer s Final Check out Procedure in the Owner s and Installer s Manual provided with that device Step 11 Instruct the homeowner on how to operate their new heating system from the thermostat Step 12 Complete the manufacturer s warranty card and return promptly Comfort Plus Installation Bl 2 16 Lo C lt 1 sn d gt JO SIWI Ajddns pegar yum urojs s y 10 Suruonrpuoo UL 501715 uo 210 ur uonoes SUNING 9u 19193 51102 11 0 091565 sn q 110Ju10 oy Jo Apddns oouer duroo pozis st 31 poprAoud Ajroedeo uoj p dn sroo 1501 ojep ouiuroooe 1 3uouidinbo se urojs s 1osso1duroo 10 102 jou soop sn d oy 5 yeoy JO Suruonripuoo ue Sursn perddns oq 1snur uinuo d UIN umnuo d porddns 2509 pas oq 091555 SIS 001 YIM doaId ue se
48. nsor room thermostat and peak control device are connected via low voltage wiring Lv WARNING System Low Voltage Wiring Diagram The and positions in the low voltage terminal strip may be used as a source of 24 VAC for powering HAZARDOUS VOLTAGE external low voltage devices 30 VA maximum Risk of electric shock injury or death All low voltage wiring must be segregated from line voltage circuits in the system R i UPPER CORE THERMOCOUPLE RUM 3120 4130 4140 LOWER CORE THERMOCOUPLE YELLOW 3120 4120 4130 4140 DISCHARGE AIR SENSOR DS 5 2 lt P AP coM NC NO 50VA TRANSFORMER OPTIONAL 75VA R 6 02 E JOS SCIRS BLUE YELLOW Comfort Plus Appendix B A 12 HELP MENU The Comfort Plus 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 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 hea
49. nsor 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 should not enter any line voltage enclosure Unshielded Class II thermostat wire can be used as extension wire provided it is segre gated from any line voltage cabling Step 3 Connect the outdoor sensor wires to the OS and SC positions of the twelve 12 position low voltage terminal block located inside the electrical compartment of the Comfort Plus see Figures 12 and 13 Outdoor sensor wire MUST NEVER be combined with other control wiring in a multi conductor cable Installation Bl 2 11 Comfort Plus ROOM THERMOSTAT A low voltage room thermostat is required for room temperature control with the Comfort Plus Any room thermostat used with this system must be 24 VAC Contact the factory for more information on the thermostats available from Steffes Optimal placement of the room thermostat is on an interior wall in the main living area where it is not affected by direct sunlight or other abnormal temperatures A location near a cold air return may provide best air tem perature sampling Installing the Room Thermostat Step 1 Disconnect power to the Comfort Plus and route low voltage wire between the thermostat and the Comfort Plus system Step 2 Insulate the
50. nu Step 1 Energize the system Access to the Configuration Menu is allowed for the first two 2 minutes of operation If the system has been energized for more than two 2 minutes the 15 amp circuit breaker must be powered off and back on to gain access to this menu Step 2 Press and release the M button until faceplate displays Step 3 Press the up arrow once and the faceplate will display C000 The faceplate will flash between C000 and the corresponding configuration value Step 4 If necessary edit the configuration value by pressing and holding the M button while using the up the down arrow button to change the value Step 5 the value is correct release the buttons and press the up arrow button to go to the next configura tion C001 C002 etc Step 6 Repeat steps 4 through 5 until all configuration settings have been adjusted to the desired values Step 7 configured use the down arrow to leave the Configuration Menu In most applications only a few if any configuration changes will be necessary Following is a description of the configuration settings and their function C000 Off Peak Method of Charge Control Sets the method of brick core charging to be used during off peak charge periods System is configured for automatic charge control which is a value of five 5 To utilize manual charge control change this value to six 6 C001 Start Brick Core Charge Set Point I
51. omfort Plus system on its Step 3 Move the system into its installation location shipping pallet The Comfort Plus is capable of fitting DO NOT extend the leveling legs more than one inch through a 30 doorway minimum without DO use and follow generally accepted safety disassembling If necessary the 4100 series practices when handling insulation material can be disassembled for ease in moving To DO have equipment installed by a qualified disassemble the 4100 Series Comfort Plus technician in compliance with all applicable refer to the disassembly instructions Page codes and regulations A 02 for more information Installation 2 03 Comfort Plus Step 4 Once in place adjust the leveling legs on the bottom of the system as necessary to prevent rocking If not placed properly the system may bend or twist during the brick loading process making element and brick core temperature sensor installation difficult Step 5 Remove the painted front panel of the brick storage cabinet by removing the sheet metal screws along the top bottom and sides of the panel Detach by pulling the bottom of the panel forward and down Step 6 Locate the element wiring harnesses behind the front painted panel Carefully position them to avoid damage during the brick loading and wiring processes Step 7 4100 SERIES ONLY Locate the brick core temperature sensor s behind the front panel and discon nect them from their shipping position Carefully
52. ommodate through the front access is 20 W x 21 3 16 D x 22 H The inner dimensions of the coil area are 21 3 16 W x 21 3 16 D x 24 1 4 H If installing a coil larger than the access dimensions the coil MUST be placed in the plenum during assembly This return air plenum is a standard piece shipped with the 3100 series systems In the 4100 series it is an optional piece that can be ordered from the factory Order Item 1041570 When interfacing the Comfort Plus system with a heat pump the indoor coil MUST be placed on the return side of the Comfort Plus system in a position that will provide even air flow through the coil Installation Risk of fire Any one ducting system MUST NOT contain more than one air handling blower system If the application requires multiple Com fort Plus systems or it is necessary to have multiple air handlers share the same ductwork you MUST contact Steffes Corporation There are special installation requirements that MUST be performed in an application such as this If using a factory supplied return air plenum the plenum is config ured to be the housing for the indoor coil Remove the screws to the plenum s access cover and slide the coil into place inside the plenum If not using a Steffes supplied return air plenum the installer will need to make provisions in the plenum to accommo date the coil and air filter When interfacing a Comfort Plus system with an air condition
53. onfiguration 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 Continue to hold all three buttons until ON displays continuously Step 3 Release the buttons The override is now enabled The faceplate will return to displaying its standard operating mode 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 all three buttons until OFF displays continuously Step 3 Release the buttons The override is now cancelled The faceplate will return to displaying its standard operating mode MAINTENANCE AND CLEANING The Comfort Plus heating system is easily maintained The air filter in the return air duct of the system should be replaced on a regular basis to ensure proper operation and to maintain overall efficiencies No additional routine maintenance is required If utilizing a heat pump or air conditioning system with the Comfort Plus the indoor coil of the device should be cleaned periodically as dirt accumulation may reduce system efficiency It is important to follow the manufacturer s maintenance and cleaning recommendations for these devices Comfort Plus Operation B 1 03 Installation LVS AUTION Risk of personal injury Steel edges can
54. or monitors outdoor temperature to automatically adjust the brick core temperature Brick Core Charge Level The amount of heat that is stored in the brick core Charge Period Off peak time in which the system is allowed to store heat in its brick core Control Panel Contains the buttons to adjust and the display to indicate system functions Control Period On peak time in which the system is not allowed to store heat in its brick core Edit Mode Process of changing or viewing the values in a microprocessor location This is accom plished with the use of the M mode button the 1 up arrow button and the 3 down arrow button Location Function Where the specific operating information of the system is stored These locations are part of the system microprocessor and are accessed through the control panel Displayed as L on the faceplate when in the edit mode Location Value The specific information set and stored in a location on the microprocessor which defines system operation A value for a specific location is accessed through the control panel Appendix A 15 Manual Charge Control Method of brick core charge regulation where the owner must periodically adjust the brick core temperature setting in relation to the outdoor temperature Microprocessor Device on the circuit board of the system which stores and processes the information for controlling the operation of the system Off peak
55. parately If utilizing a PLC system an Owner s and Installer s manual will accompany the transmitting device Refer to this manual for information on the installa tion and operation of the power line carrier control system Comfort Plus Installation 2 10 x TIME CLOCK MODULE PEAK CONTROL The Steffes Time Clock Module is another option for providing a peak control signal to the Comfort Plus The optional time clock module mounts inside the line voltage electrical compartment and interfaces with the relay board via an interface cable Peak control times MUST be programmed into the system once the module is installed to enable the time clock feature Refer to the instructions provided with the time clock module for more information on the installation and operation of this device LINE VOLTAGE PEAK CONTROL Line voltage control is also an option but is not the preferred method of control as it is usually more complex and expensive If line voltage control is utilized the controls circuit must be powered with an uninterrupted circuit An external switching device such as a relay panel is necessary to directly control the heating element charging circuits If relying on this method of control the display on the system must continuously display a brick core operating mode of charge regardless of whether it is an off peak or on peak period OUTDOOR TEMPERATURE SENSOR An outdoor temperature senso
56. r shipped in the electrical compartment is required to be installed with the Comfort Plus IMPORTANT This sensor monitors outdoor temperature and provides this If connecting to the Steffes power line information to the system The system responds by automati carrier PLC system follow the installa cally storing heat in its brick core according to the outdoor tion instructions in the PLC system s temperature and the heating requirements Owner s and Installer s Guide The outdoor temperature sensor can be installed in one of two ways direct wired to the system or wired to the Steffes power line carrier system The Comfort Plus is factory configured for automatic charge control with a direct wired outdoor sensor Refer to the Configuration Menu Pages 2 14 2 15 for information on the appropriate settings for the application Installing the Outdoor Sensor Step 1 Select a location and mount the sensor The outdoor sensor must be placed in a location where it accurately sense outdoor temperature and is not affected by direct sunlight or other abnormal tempera ture conditions Step 2 Route low voltage wire from the outdoor sensor to the electrical compartment through one of the low voltage wire knockouts 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 tem perature sensor The outdoor se
57. ring Connections See Figure 10 for information on circuit phasing connections Appendix A 09 Comfort Plus Line Voltage Wiring Diagram Model 4130 240V OR 208V SYSTEMS ONLY Use copper or aluminum conductors rated for 75 C or higher for field connection of this device SUPPLY AIR BLOWER MANUAL RESET SEE NOTE 2 COM WHITE BLUE Te HIGHLBLACK Cap MED HIGH BLUE m 2 9 BLUE WHITE MED LOW ELLOW _ vc a Ss a COOLING SPEED E gt BLUE BLACK GROUND BAR HEATING SPEED BLUE RED 1 9 Pin Header Connectors located in the base of the 4 Q g x Heater amp Plenum E
58. s displays The supply air blower should operate In an application interfacing the Comfort Plus system with an air conditioner or heat pump verify that this device is operating appropriately Step5 Initiate a cooling call from the room thermostat if applicable and verify that the Comfort Plus system recognizes the COOL call The supply air blower should operate In an application interfacing the Comfort Plus system with an air conditioner or heat pump verify that this device is operating appro priately je FE 2 Step 6 Press the up arrow until the targeted brick core charge level is displayed on the control panel With the system in an off peak charge mode initiate a charge control override Page 1 03 Once initiated the target level of the Comfort Plus should be 100 percent and the control panel should display tL All of the elements should be energized Step7 With an amp meter verify that the amperage of the system is correct for the installation Refer to the System Identification Label on the Comfort Plus heating system for information regarding the proper amperage Step 8 Cancel the charge control override and verify that all elements in the system de energize Refer to the Charge Control Override section Page 1 03 for instructions on canceling the charge control override Step 9 Verify once again that the Operating Mode displayed on the control panel corresponds with the power co
59. s of the Environmental Protection Agency EPA available at http www epa gov For Customer Use Please record your model and serial number below This number is found on the identification label located on the lower front of the 3100 series base and on the lower left side of the 4100 series base Retain this information for future reference Model No Serial No A A 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 SAFETY PRECAUTIONS 1 DO NOT energize the Comfort Plus while disassembled or without ceramic heat storage brick in place 2 DO NOT use or store materials that may produce explo sive or flammable gases near the Comfort Plus 3 DO NOT violate the placement and clearance require ments specified in this manual Pages 2 02 2 03 4 DO NOT place anything on top of the Comfort Plus 5 Disconnect power to all circuits before servicing The Comfort Plus heating system may be connected to more than one branch circuit 6 Installation of and or service to the Comfort Plus heating system should be performed by a qualified technician in compliance with information contained herein and with national state and local codes and requirements 7 A repeated message of CORE FAIL indicates a need Hazardous Voltage Risk of
60. smitting device and the transmitter for proper operation 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 Currently not utilized Currently not utilized Discharge air temperature has exceeded maximum standard operating temperatures There is no communication occurring between the Base I O board and the processor control board This can be caused by a defective board interface cable or an unresponsive Base I O board There is no communication occurring with the first relay expansion board The interface cable may be defective or the first expansion board may be unresponsive There is no communication occurring with the second relay expansion board The interface cable may be defective or the second expansion board may be unresponsive There is no communication occurring with the Steffes Time Clock Module Temperature sensor offset reference is out of range and indicates that one of the sensors or the core thermocouple may be shorted to ground or the processor control board may be out of calibration Power line carrier system is active however no good data has been received Insufficient main control board memory Contact a qualified service technician Insufficient permanent memory Contact a qualified service technician Permanent memory change has been made Press the M button to accept T
61. t storage currently in the brick core HE x Heating Elements Active Indicates the total number of heating elements currently energized PC x Power Line Carrier Channel Indicates the channel on which the system is set to receive PLC communication signal Px Power Line Carrier Net Hit Rate Percentage Indicates the percentage of GOOD communica tion packets received by the system from the PLC transmitter system PS x Indicates which Specialty Timer the system is currently using The value displayed will be zero if the Specialty Timer is not being utilized CC_x Charge Mode Operation Indicates the charge control method being utilized during off peak peri ods CA_x A Peak Mode Operation Indicates the charge control method being utilized during anticipated peak periods x Specialty Timer 1 Charge Mode Specialty Applications Only C2 x Specialty Timer 2 Charge Mode Specialty Applications Only ERROR CODES WARNIN The Comfort Plus has an on board diagnostic system to monitor various operat G ing conditions If operating conditions move outside the normal operating range an error code is displayed on the faceplate If there are multiple errors simulta HAZARDOUS VOLTAGE neously only the highest priority error code appears Once corrected the next Risk of electric shock highest priority code will be displayed on the faceplate as 1 05 injury or death System may be connected to more
62. t well supported surfaces are acceptable If unsure of floor load capacity consult a building contractor or architect may be present Consultlocal state and national codes and regulations to ensure proper installation An 18 pedestal Order Item 1301585 is available to elevate the 4100 Series 3100 SERIES SYSTEM REQUIREMENTS Special requirements must be considered if placing the system ina garage or other area where combustible vapors FIGURE 2 CLEARANCES 8 MIN CLEARANCE TO COMBUSTIBLES 0 MIN CLEARANCE TO DUCTING BACK TOP VIEW 0 MIN CLEARANCE TO RETURN AIR DUCT 36 MIN CLEARANCE FRONT Back and Bottom 0 clearance Left Side 4 inches Right Side 8 inches from combustible material Top 8 inches from combustible material Front 36 inches for ease in servicing Outer Sides of System Ducts Return and Supply 0 clearance Between Ducting and System 0 clearance top and right side Minimum clearance requirements do NOT account for space needed for making electrical connections Comfort Plus Risk of injury or fire Violation of the clearance requirements and or failure to provide proper ventilation can cause improper operation of the system Main tain the placement and clearance re quirements as specified and provide ventilation as necessary Risk of Equipment Damage Failure to maintain room temperature in the me chanical room of 85 F or less may result
63. th Override Order Item 1302012 Terminals for Connection as a Conventional Furnace IR c Y 02 JOS SC RS IMPORTANT NOTE During off peak charge periods the contact is closed between COM and NC Maximum external load should not exceed 60 VA on the system s class Il transformer HUMIDIFIER ELECTRONIC FILTER INSTALLATION The Comfort Plus is capable of being connected to a humidifier and or an electronic air filter If installing either of these devices connections to the Comfort Plus system are made to the bottom two relays on the Base IO Relay Board inside the system s electrical panel Refer to the Line Voltage Wiring Diagrams Page A 08 A 11 for the location of these relays If installing a humidifier connect it to the HEAT CALL relay on the Base IO Board This relay closes during a heat call If installing an electronic air filter connect it to the FAN ON relay on the Base IO Board This relay closes during a fan call Installation 2 13 Comfort Plus CONFIGURATION MENU The Steffes Comfort Plus heating system has a Configuration Menu which IMPORTANT allows the system to be customized to the power company and consumer s needs This menu can be accessed on start up and allows configuration I access to Configura settings to be easily adjusted tion Menu times out the 15 amp circuit breaker To access the Configuration Menu must be powered off and back on to re enter the me
64. time these particles may appear as a black residue commonly referred to as soot High concentrations of air borne particles from aerosols dust candles incense pet hair smoke or cooking can contribute to poor indoor air quality and accelerate the sooting process During operation the Comfort Plus heating system may produce minor expansion noises These noises are the result of the internal components reacting to temperature changes TURNING SYSTEM OFF AND ON The Comfort Plus 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 15 AMP breaker MUST remain ON to operate controls the system if 2 using the Comfort Plus in conjunction with a heat pump or air conditioner using the Comfort Plus to control other loads using the optional Steffes Time Clock Module Comfort Plus Operation Bl 1 01 Operation CONTROL PANEL Operation of the Comfort Plus system is automatic All operational function settings are stored in a microproces sor in factory preset locations If necessary the user or installer can adjust these locations settings through the control panel Figure 1 Four Digit LED Display The four digit LED displays specific operating information During an editing process the function locations and the values set
65. u see et les eue tues so ete eo reden oue 1 03 Installation Slapping and Packaging o hehe 2 01 Placementand Clearance Requirements ince er 2 02 2 03 EM 2 03 2 04 Buck 2 04 Heating Element and Air Channel Installation 2 05 Brick Core Temperature Sensor Installation 4100 Series Only trennen nennen 2 06 E 2 06 2 08 Air Conditioner Heat Pump n ET a oie ca 2 08 Line Voltage Electrical Connections coco 2 09 Low Voltage Blectrical Connections x 2 10 2 13 Auxillary Load e DER 2 13 Humidiher Electronic 2 150 9E a en E ee eee 2 13 Conme uration messene te IL eM M ANIMUS ct S EN Ud 2 14 2 15 Installers Final Check Out Procedure eee orbe ep E ORE HIR CURED ROT RIED 2 16 Appendix SPeECIHCatIOHS cones tn EDEN ILE E A 01 Disassembling the 4100 Series Comfort Plus System rettet tente te tne EE RUE EE RESTE De Me ETE 02 Parts Diagram 3100 Series A 03 Partslast 3100 SENES en HOHER
66. wall opening through which the thermostat wires run Failure to do so may affect the accuracy of the thermostat Step 3 Attach the thermostat to a wall If installing a mechanical thermostat or thermostat with anticipator a resistor kit is required Order Item 1190015 Step 4 Route the low voltage wire into the electrical compartment of the Comfort Plus through one of its low voltage wire knockouts and to the system s twelve 12 position low voltage terminal block hore Never install any wiring in the line voltage compartment of the Comfort Plus unless it is rated for line voltage Step 5 Refer to the Room Thermostat Connections Diagrams Figures 12 and 13 in this manual for proper connections with regard to the application Comfort Plus 12 Position Low Voltage Terminal Block Coding Low Voltage Hot O Reversing Valve Input Low Voltage Common O2 Reversing Valve Output 19 w ez Y Compressor Stage 1 Heat Call E Emergency Heat W Stage 2 Heat Call OS z Outdoor Temperature Sensor Y2 Compressor Output SC Outdoor Temperature Sensor Common G FanCall RS Freeze Protection Room Temperature Sensor LOW VOLTAGE CONNECTIONS HEAT PUMP APPLICATION FIGURE 12 Honeywell TH5220D To Heat Pump Y Compressor C Low Voltage Common R Low Voltage Hot O Reversing Valve Outdoor Sensor Freeze Protection Room Sensor S Terminals for Connection

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