V3 OWNER'S AND INSTALLER'S MANUAL Models: 8150, 8155, 8180, 8185, 8188 Applicable to Software Version 2.
IMPORTANT The equipment described herein is intended for installation by a qualified technician in accordance with applicable local, state, and national codes and requirements. To insure proper installation and operation of this product, completely read all instructions prior to attempting to assemble, install, operate, maintain or repair this product. Upon unpacking of the system, inspect all parts for damage prior to installation and start-up.
SAFETY PRECAUTIONS WARNING 1. DO NOT energize the system while disassembled or without ceramic heat storage brick in place. 2. DO NOT use or store materials that may produce explosive or flammable gases near the system. 3. DO NOT violate the placement and clearance requirements specified in this manual. (Page 3.03) 4. DO NOT place anything on top of the Storage Module(s). 5. Disconnect power to all circuits before servicing. This heating system may be connected to more than one branch circuit. 6.
TC Table of Contents Operation General Operation ........................................................................................................................................................................ 1.01 System Use During Construction Phase ...................................................................................................................................... 1.01 System Start-Up ..............................................................................................
1 Operation The ThermElect heating system stores off-peak electricity in the form of heat. Off-peak electricity is available during times of the day or night when electricity is plentiful and the associated costs are low. Operation of the heating system is automatic. During off-peak hours, the system converts electricity to heat which is then stored in its ceramic brick core.
CONTROL PANEL Operation Operation of the ThermElect system is automatic. All operational functions are stored in its microprocessor in function locations and are factory preset. If necessary, the installer can adjust them through the control panel. (See Figure 1.) Four-Digit LED Display The four digit LED displays specific operating information. During an editing process, the function locations and the values set in these locations are displayed for viewing and adjusting purposes.
TEMPERATURE CONTROL When used to supplement heat pump systems, the ThermElect system replaces resistance strip heat, which is typically required as a supplement or back-up to the heat pump system. The outlet 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.
2 Optional Accessories LOAD MANAGEMENT CONTROL The ThermElect is a commercial Electric Thermal Storage (ETS) heating system. It uses Demand Free, Off-Peak electricity to provide a low cost heating solution for commercial, industrial, and large residential applications. ETS equipment is designed to store electricity, as heat, during hours when energy costs are lower and kW demand charges are not incurred. The ThermElect’s thermal mass consists of a high-density ceramic brick capable of vast heat storage.
EXTERNAL DUCT SENSOR The optional external duct sensor (Order Item #1041536) provides the ability to monitor the duct temperature at an area beyond fresh air makeup and/or beyond other devices and regulate the discharge air temperature accordingly. If there is a Y and a G call from the thermostat, the ThermElect system operates the core blower at the required speed to maintain the minimum output temperature as set in Location 48 (L048) at the duct sensor.
3 Installation SHIPPING AND PACKAGING The ThermElect Storage Module(s) should always be transported in an upright position to avoid damage to internal components and insulation materials. The information below describes the items shipped with each system.
SHIPPING AND PACKAGING CONTINUED...
PLACEMENT AND CLEARANCE REQUIREMENTS The system dimensions and required clearances MUST be taken into consideration when choosing its location within a structure. (See Figure 2 for dimensions and clearance requirements.) The best installation location for the system is in a space requiring heat so some amount of the heating requirements can be satisfied through static dissipation from the warm outer panels of the Storage Module(s).
INITIAL SET-UP Step 1 Remove the Information Package from the outside of the electrical panel and unpackage the Storage Module(s) and Air Handler. Step 2 Move the system into its installation location. Optional liftting handles are available from the factory. (Order Item #1302120). If using Steffes lifting handles, remove painted front and back panels from brick storage cavity. WARNING HEAVY OBJECT WARNING: Risk of personal injury, or death. ThermElect Hydronic systems are heavy.
Step 5 Securely mount the damper(s) to the Storage Module(s) using the screws provided in the outlet damper kit. Two screws are required for each side of the damper assembly (Figures 4A and 4B); four screws are inserted along the top and four screws are inserted along the bottom of the damper. To insert the top screws, open the damper as shown in Figure 4C. FIGURE 4 B A C Step 6 Remove the top two screws from the damper bracket at the center of the damper assembly (Figure 5A).
Step 11 Attach the Storage Module(s) to the Air Handler using the C-drives provided (Figure 9). Bend excess length of drives over to seal the damper area (Figure 10). FIGURE 10 FIGURE 9 Step 12 Route the orange limit switch wires through the pre-installed plastic cable ties on the inside of the Air Handler. Step 13 Connect the orange limit switch wires from the Storage Module(s) to the orange wires from the electrical panel.
BRICK LOADING Step 1 Remove the painted front panel of the brick Storage Module(s) 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 sheet metal screws around the outer edge of the galvanized front panel. Remove the panel and set it aside. Step 3 Starting at the bottom, carefully lift each of the insulation blankets and drape them over the top of the Storage Module(s).
HEATING ELEMENT INSTALLATION Step 1 After all bricks are loaded and rigid insulation boards are in place, insert the heating elements through the insulation, sliding them in until the cement side rails are flush with the front side of the ceramic brick. Make sure the elements designated as Air Handler side elements are installed on the Air Handler side of the Storage Module(s). FIGURE 14 Step 2 Route the element termination head with ceramic insulator to the appropriate side of the Storage Module(s).
BRICK CORE TEMPERATURE SENSOR INSTALLATION Step 1 Remove the screw(s) by the brick core temperature sensor connector holes in the galvanized front panel. Step 2 Route the brick core temperature sensors through the clear plastic tube until within six inches of the relay driver board. Cut tube and sensor wires to length as needed. The yellow wire from each sensor must be connected to the Y terminal of the proper sensor connection terminal block, and red to R. Polarity of sensors is critical.
AIR CONDITIONER/HEAT PUMP INTERFACE The system can accommodate most heat pump or air conditioner indoor coils up to a 7.5-ton capacity provided the heat pump or air conditioner is sized in accordance to supply air delivery rates of the system. Refer to the System Air Delivery Matrix for information on air delivery rates of the supply air blower with regard to the blower’s speed, To ensure that adequate air flow is provided for the heat pump or air conditioner system being installed. WARNING Risk of fire.
LINE VOLTAGE ELECTRICAL CONNECTIONS To determine the correct wire size required for the circuit feeding the system, refer to the Specifications (Page A.01-A.03) and the system's identification label located on the front of the electrical panel (Figure 17). WARNING HAZARDOUS VOLTAGE: Risk of Step 1 Remove the electrical panel cover. Step 2 Route all line voltage wires through a knockout and into the electrical panel. Step 3 Make line voltage connections (See Page 3.
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. Refer to Location 10 (L010) of the Supplemental Installer's Guide to select the desired method of charge control. THERMOSTAT CONNECTIONS A low voltage room thermostat is required for room temperature control with the system. Any room thermostat used with this system must be 24 VAC.
12-Position Low Voltage Terminal Block Coding R C Y W Y2 G = = = = = = Low Voltage Hot Low Voltage Common Compressor/Stage 1 Heat Call Stage 2 Heat Call Compressor Output Fan Call O O2 E OS SC RS = = = = = = Reversing Valve Input Reversing Valve Output Emergency Heat Outdoor Temperature Sensor Outdoor Temperature Sensor Common Freeze Protection Room Temperature Sensor THERMOSTAT CONNECTIONS (Stand Alone Furnace Application) FIGURE 19 A Single Stage Heating and Cool Room Thermostat Honeywell T8401C1015
INSTALLER'S FINAL CHECK-OUT PROCEDURE Step 1 Verify that the operating mode displayed on the control panel corresponds with the power company's peak control signal. Refer to the Operating Status section (Page 1.02) for more information on the proper operating mode. Step 2 Press the up arrow one time and verify that the outdoor temperature information displayed on the control panel is approximately the same as the current outdoor temperature. Refer to the Operating Status section (Page 1.
4 LOAD MANAGEMENT The ThermElect is a commercial Electric Thermal Storage (ETS) heating system. It is generally signaled to use demand free, off-peak electricity to provide a low cost heating solution for commercial, industrial, and large residential applications. ETS equipment is designed to store electricity, as heat, during hours when energy costs are lower and kW demand charges are not incurred. The ThermElect’s thermal mass consists of a high-density ceramic brick capable of vast heat storage.
TIME CLOCK MODULE PEAK CONTROL The Steffes Time Clock Module is another option for providing a peak control signal to the system. 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.
PULSE MONITORING The ThermElect system monitors pulse outputs from the power company's electric meter. Program parameters such as desired maximum building kW and pulse ratios for the metering system being used are entered into the ThermElect system. The system then changes proportionally when demand free power is available. This keeps the total building kW usage at or below the desired level. To enable pulse monitoring, the 2 bit must be set in Location 53 (L053).
A Appendix SPECIFICATIONS MODEL 8150 Input Voltage 240 120/208 120/240 277/480 347/600 Phase 1 3 3 3 3 Number of Wires 2 3 3 4 4 Charging Input (kW) 53.3 48.0 53.3 50.4 53.3 Elements - Quantity 12 12 12 12 12 Elements - Watts Each 4,444 4,000 4,444 4,200 4,444 Amps – Core Charging 222.20 133.39 128.44 60.65 51.23 Max. Core & Blower Load (AMPS) 3.0 7.4 7.4 2.3 3.0 Minimum Circuit Ampacity 281.50 175.99 169.80 78.69 67.
MODEL 8180 Input Voltage Phase Number of Wires Charging Input (kW) Elements - Quantity Elements - Watts Each Amps – Core Charging Max.
MODEL 8188 Input Voltage Phase Number of Wires Charging Input (kW) Elements - Quantity Elements - Watts Each Amps – Core Charging Max. Core & Blower Load (AMPS) Minimum Circuit Ampacity Blowers/System Control Voltage Storage Capacity - kWh Storage Capacity - BTU Approximate Storage Module Weight (lbs) Approximate Insulation Block, Air Handler, Elements & Other Weight (lbs) Approximate Brick Weight (lbs) Approximate Installed Weight (lbs) Number of Brick 120/208 3 3 144.0 36 4,000 400.18 7.4 509.
Typical System Line Voltage Wiring Diagram 277/347 3 Phase 4 Wire - 3000 CFM 8180 APPLICATION SUPPLY AIR BLOWER UPPER MANUAL RESET WHITE COM. BLACK HIGH MED. HIGH BLUE 10uf Cap. 190 ° N.C. WHITE/BLUE Ground Lug 170 ° N.C. MED. LOW YELLOW LOW RED ORANGE/BLACK BLACK/YELLOW 190 ° N.C. WHITE COM. BLACK HIGH MED. HIGH BLUE 10uf Cap.
THERMELECT 4uf Cap. 5 Amp RED BLACK/YELLOW BASE IO BOARD DAMPER RESISTER RESISTOR BLOWER L2 240 L2 120 L1 1/4 Amp BLUE/RED COM NO COM NO HEAT CALL RELAY NO COM BLUE/WHITE BLUE BLUE/WHITE FAN ON RELAY NO COM BLUE/BLACK 170 ° N.C. 190 ° N.C.
INTERNAL SYSTEM WIRING DIAGRAM - LOW VOLTAGE The outdoor temperature sensor, room thermostat, and peak control device are connected via low voltage wiring. System Low Voltage Wiring Diagram WARNING The "R" and "C" positions in the low voltage terminal strip may be used as a source of 24 VAC for powering external low voltage devices (30 VA maximum). A M P M HAZARDOUS VOLTAGE: Risk of electric shock, injury, or death. All low voltage wiring must be segregated from line voltage circuits in the system.
HELP MENU The system contains a Help Menu which may be accessed through the control panel. To access the Help Menu, press and release the M button until the faceplate displays “HELP”. Scroll through the menu by pressing either the up or the down arrow button. Display Reading Fxxx Description Firmware Version Number - Indicates the version of software installed. O xx Outdoor Temperature - Indicates current outdoor temperature as recognized by the system.
Appendix Error Code # Description 06 Outdoor temperature reading from the transmitting device (PLC system) is out of normal operating range. Check the outdoor sensor attached to the transmitting device and the transmitter for proper operation. 07 Main processor control board temperature sensor is out of normal operating range. Verify that none of the clearances have been violated and inspect the condition of the processor control board.
Error Code # Description 20 There is no communication occurring between the Base I/O board and the processor control board. A defective board interface cable or an unresponsive Base I/O board can cause this. 21 There is no communication occurring with the first relay expansion board. The interface cable may be defective or the first expansion board may be unresponsive. Check the jumper configuration on the relay expansion board to ensure that J1 and J2 are both in the “OFF” position.
W 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, detach 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.
