CALEFFI SATK20 Series, SATK20403HE, SATK20103HE, SATK20203HE, SATK20305 Instructions For Installation, Commissioning And Maintenance
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SATK series compact wall-mounted heat interface unit
SATK20 series
INSTRUCTIONS FOR INSTALLATION, COMMISSIONING AND MAINTENANCE
Function
The SATK series heat interface unit allows independent control of heat
regulation and domestic hot water production within centralised heating
systems.
CONTENTS
78165.02 EN
Safety instructions
Dimensions
Technical specifications
Installation
Commissioning
Electronic regulator
Safety and alarms
SATK20103HE
SATK20203HE
SATK20303/SATK20403HE
SATK20305
2
3
4
4
6
7
8
10
Product range
SATK20103HE Direct wall-mounted HIU for LOW temperature
heating, instantaneous domestic hot water
production, power capacity 40 kW
SATK20203HE Direct wall-mounted HIU for MEDIUM temperature
heating, instantaneous domestic hot water
production, power capacity 40 kW
SATK20303 Direct wall-mounted HIU for HIGH temperature
heating, instantaneous domestic hot water
production, power capacity 40 kW
SATK20403HE Direct wall-mounted HIU for HIGH temperature
heating, instantaneous domestic hot water
production, power capacity 40 kW. With pump on the
primary side.
SATK20305 Direct wall-mounted HIU for HIGH temperature
heating, instantaneous domestic hot water
production, power capacity 65 kW
Maintenance
Electric connections
Troubleshooting
Commissioning checklist
1
12
13
14
16
SAFETY INSTRUCTIONS
Primary circuit flow
Primary circuit return
Domestic hot water outlet
Domestic cold water inlet
Low temperature circuit flow
Low temperature circuit return
Medium temperature circuit flow
Medium temperature circuit return
High temperature circuit flow
High temperature circuit return
WARNINGS
1 The device must be installed, commissioned and maintained by qualified technical personnel in accordance with national regulations and/or relevant local
requirements.
2 If the device is not installed, pre-run checked and maintained correctly in accordance with the instructions provided in this manual, it may not work properly and
may endanger the user.
3 Clean the pipes of any particles, rust, incrustations, limescale, welding slag and any other contaminants. The hydraulic circuit must be clean.
4 Make sure that all connection fittings are watertight.
5 When connecting water pipes, make sure that threaded connections are not mechanically overstressed. Over time this may result in breakage, causing water
damage and/or personal injury.
6 Water temperatures higher than 50°C may cause severe burns. When installing, commissioning and maintaining the device, take the necessary precautions so
that these temperatures will not be hazardous for people.
7 In the case of particularly hard or impure water, there must be suitable provision for filtering and
current legislation. Otherwise the device may be damaged and will not work properly.
8 Any use of the device other than its intended use is prohibited.
9 Any coupling of the device with other system components must be made while taking the operational characteristics of both units into consideration.
10 An incorrect coupling could compromise the operation of the device and/or system.
IMPORTANT: Risk of electric shock. Live parts. Shut off the electric supply before opening the device box.
1 During installation and maintenance operations, always avoid direct contact with live or potentially hazardous parts.
2 The device must not be exposed to water drops or humidity, direct sunlight, the elements, heat sources or high intensity electromagnetic fields. This device cannot
be used in areas at risk of explosion or fire.
3 The device must be connected to an independent bipolar switch. If work has
automatic or time reset, or which may be reset accidentally.
4 Use suitable automatic protection devices in accordance with the electrical characteristics of the region where the device is installed and in compliance with current
legislation.
5 The device must always be earthed before it is connected to the electric supply. If the device has to be removed, always disconnect the earth connection after
disconnecting the electric supply conductors. Check that the earth connection has been made to the highest of standards under applicable legislation.
6 Electrical installation must only be carried out by a qualified technician, in accordance with legal requirements.
7 The device does not contain asbestos nor mercury.
These instructions must be read and understood before installing and maintaining the device.
IMPORTANT! FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN A SAFETY HAZARD!
treating the water before it enters the device,
to be done on the device, cut off
the electric supply first. Do not use devices with
in accordance with
Key to symbols
NOTES:
1 Install water hammer arresters to compensate for any overpressure in the domestic water circuit;
2 In the presence of hot water recirculation or if a non-return valve is fitted into the domestic cold water inlet, provision must be made to accomodate the expansion
of the water contained within the system and the heat interface unit.
3 All hydraulic connections must be checked before pressurising the system. Vibration during transport may cause the connections to become loose. DO NOT APPLY
EXCESSIVE TIGHTENING TORQUE otherwise the components may be damaged.
For the updated version of the technical documentation refer to www.caleffi.com
LEAVE THIS MANUAL AS A REFERENCE GUIDE FOR THE USER. DISPOSE OF IN ACCORDANCE WITH LOCAL REGULATIONS. THE MANUFACTURER
RESERVES THE RIGHT TO CEASE PRODUCTION AT ANY TIME AND TO MAKE ANY CHANGES DEEMED USEFUL OR NECESSARY WITHOUT THE
OBLIGATION OF PRIOR NOTICE.
2
Dimensions
SATK20305
SATK20103/203/303/403
10
450
65182,5
15490
550,5
49
65 101
65
265
430
10
450
65182,5
15490
550,5
49
65 207
65
430
A B C
3/4” M 1/2” M 3/4” F
SATK20103HE - SATK20203HE SATK20303
SATK20403HE technical specifications
Medium: water
Maximum percentage of glycol: 30%
Maximum medium temperature: 85°C
Maximum working pressure: - primary circuit: 1 MPa (10 bar)
Nominal DHW exchanger capacity: 40 kW
Maximum recommended primary circuit flow rate: 1,2 m
Maximum DHW circuit flow rate: 18 l/min (0,3 l/s)
Minimum flow to activate domestic water flow meter: 2,7 l/min ±0,3
Maximum Dp on domestic water modulating valve: 90 kPa (0,9 bar)
Maximum Dp on mixing valve: 90 kPa (0,9 bar)
Electric supply: 230 V (ac) ±10% 50 Hz
Maximum power consumption: 80 W
Protection class: IP 40
Pump (not present on SATK20303): UPM3 15-70
Pump by-pass pressure setting: 45 kPa (0.45 bar)
Actuators: stepper 24 V
Probes: NTC 10 kΩ
Safety thermostat (only on SATK20103HE): 55°C ±3
Materials
Components: brass EN 12165 CW617N
Fitting pipes: steel
Frame: RAL 9010 painted steel
Protective shell cover: EPP
Heat exchanger: brazed stainless steel
- domestic circuit: 1 MPa (10 bar)
3
20 W on SATK20303
SATK20305 technical specifications
Medium: water
Maximum percentage of glycol: 30%
Maximum medium temperature: 85°C
Maximum working pressure: - primary circuit: 1 MPa (10 bar)
- domestic circuit: 1 MPa (10 bar)
Nominal DHW exchanger capacity: 65 kW
/h
Maximum recommended primary circuit flow rate: 1,2 m
3
/h
Maximum DHW circuit flow rate: 27 l/min (0,45 l/s)
Minimum flow to activate domestic water flow meter: 2,7 l/min ±0,3
Maximum Dp on domestic water modulating valve: 90 kPa (0,9 bar)
Maximum Dp on mixing valve: 90 kPa (0,9 bar)
Electric supply: 230 V (ac) ±10% 50 Hz
Maximum power consumption: 20 W
Protection class: IP 40
Actuators: stepper 24 V
Probes: NTC 10 kΩ
Materials
Components: brass EN 12165 CW617N
Fitting pipes: steel
Frame: RAL 9010 painted steel
Protective shell cover: EPP
Heat exchanger: brazed stainless steel
3
Installation
Raumthermostat
(Potenzialfreier Kontakt)
Sonde d’ambiance
(Contact sec)
Termostato de ambiente
(Contacto sin potencial)
Ruimtesensor
(Schoon contact)
WARN IN G!
DO NOT CONNECT EXTERNAL
VOLTAGE SUPPLY TO THESE
TERMINALS
ATT EN ZI ON E!
NON ALIMENTARE IN TENSIONE
Termostato ambiente
(Contatto pulito)
Room thermostat
(Volt free connection)
Connection to the chrono-thermostat
The SATK series HIU is designed for installation in a sheltered
domestic environment (or similar), therefore cannot be installed or
used outdoors, i.e. in areas directly exposed to atmospheric
agents. Outdoor installation may cause malfunctioning and
hazards.
If the device is enclosed inside or between cabinets, sufficient
space must be provided for routine maintenance procedures. It is
advisable to avoid positioning electrical devices under the HIU to
avoid the risk of damage in the event of leaks from hydraulic
fittings. If this advice is not heeded, the manufacturer cannot be
held responsible for any resulting damage.
In the event of a malfunction, fault or incorrect operation, the device
should be deactivated; contact a qualified technician for
assistance.
Preparation
After having established the point where the device has to be
installed, perform the following operations:
· Mark the holes required for securing the HIU to the wall
· Mark the position of the hydraulic connections
Check the measurements again and begin laying the following
lines:
Hydraulic (see page 5):
1. connection to the central system line
2. heating circuit connection
3. domestic water circuit connection
Electric (see page 13):
1. 230 V (ac) – 50 Hz electric supply line
2. chrono-thermostat/thermostat line (potential-free)
3. centralised bus line for heat meter data transmission (if required)
4. centralised electric supply line for heat meter (if required)
Before installation, it is recommended to carry out accurate flushing
of all the pipes of the system in order to remove any residue or
impurities that could endanger correct operation of the HIU.
Fix the HIU to the wall.
N.B.: the wall anchors (not supplied) can only guarantee effective
support if inserted correctly (in accordance with good technical
practice) into walls built using solid or semi-solid bricks. If working
with walls built using perforated bricks or blocks, mobile dividing
panels or any masonry walls other than those indicated, a
preliminary static test must be carried out on the support system.
Electric connections
Make sure that the electrical system can withstand the maximum
power consumption of the appliance, with particular emphasis on
the cross-section of the cables.
If you have any doubts, contact a qualified technician to request a
thorough check of the electrical system.
Electrical safety of the appliance is only achieved when it is
correctly connected to an effective earthing system, made as
specified in current safety regulations. This is a compulsory safety
requirement.
The SATK series HIU is fitted for connection to a thermostat or
chrono-thermostat, both standard and OpenTherm, for ambient
temperature adjustment.
The connection to this device (potential-free contact) must be
made with the two-wire cable marked with the label shown below.
Should it be necessary to extend this cable, use one with the same
cross-section (max 1 mm
2
) and maximum length 30 m.
Commissioning
Filling the central heating system
Open the shut-off valves on the connections to the centralised line
and, in the central heating system, proceed with charging the
system to the design pressure.
Once these procedures are complete, vent the system and check
its pressure again (repeat the filling process if necessary)
System start-up
Before starting the HIU, visually check the hydraulic connection
water-tightness and the electric wiring. After finishing the check,
activate the electric supply to the HIU and check for the presence
of any error signals.
If there are any, eliminate the fault indicated and proceed as
described below, setting the set point of the domestic water and
heating cycles, programming the thermostat/chrono-thermostat
according to the desired temperatures and times, and checking the
operating cycles.
Fitting the cover
Place the casing over the frame, inserting the upper tabs (1) into
the corresponding slots (2).
Place the lower part of the casing over the frame.
Tighten the screws (3).
2
1
Connection to the main supply
The device is supplied with an electric supply cable which is not
fitted with a plug.
The device should be electrically connected to a 230 V (ac) singlephase + earth mains supply using the three-wire cable marked with
the label shown alongside, observing the LIVE (L) - NEUTRAL (N)
polarities and the earth connection. This line must be connected to
a circuit breaker device.
3
4
Heat meter installation
The HIU is designed to fit a compact heat meter (with incorporated
return probe) with 1” threaded connections and 130 mm gauge.
Before carrying out any maintenance, repair or part replacement
work, proceed as follows:
- cut off the electric supply
- remove the cover
- close the shut-off valves
- empty the HIU using the drain cocks provided
Proceed as described below to install the heat meter:
- remove the template (A)
- remove the cap (B)
- install the flow meter on the return pipe
- install the flow probe in the M10 pocket (B)
Please refer to the heat meter technical data sheets for further
information.
Hydraulic connections
Hydraulic connections to the centralised line must be implemented
using the manual shut-off valves supplied with the HIU, which allow
any necessary maintenance work to take place without having to
empty the centralised system.
It is advisable to install manual shut-off valves (not supplied) also
on the bottom connections to the apartment circuits.
Before installation, it is recommended to carry out accurate flushing
of all the pipes of the system in order to remove any residue or
impurities that could endanger correct operation of the HIU.
In order to facilitate these operations a manual bypass flushing
valve is available (code 789100).
B
A
N.B. Install the valves as shown in the figure
N.B.:
1 Install water hammer arresters to compensate for any overpressure in the domestic water circuit;
2 In the presence of hot water recirculation or if a non-return valve is fitted into the domestic cold water inlet, provision must be made to accomodate the expansion
of the water contained within the system and the heat interface unit;
3 All hydraulic connections must be checked before pressurising the system. Vibration during transport may cause the connections to become loose. DO NOT APPLY
EXCESSIVE TIGHTENING TORQUE otherwise the components may be damaged.
5
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