CALEFFI SATK22205, SATK22105, SATK22103, SATK22203, SATK22305 Installation, Operation & Maintenance Instructions Manual

Caleffi group

SATK22

heat interface unit

Installation Operation & Maintenance Instructions

SATK22

SATK22

Function

The SATK22 HIU allows independent control of heat regulation
and domestic hot water production within centralised heating
systems or systems served by district heating networks.

The heat interface unit features exceptional flexibility of
installation and remote controllable smart electronic functions
designed to enhance efficiency of the system.

NOTE: Due to the specification ordered, or the country of

destination, the actual unit may differ from those shown.

Content

Function 1
Safety instructions 1
Dimensions and connections 3
Technical specification 3
Components & schematic SATK2210 & SATK2220 4
Components & schematic SATK2230 & SATK2240 5
Installation 6
Heat meter installation 8
Electrical connections 8
Remote user interface 11
Commissioning 10
Remote user interface - quick guide 12
Heating functions 13
DHW functions 15
Primary flow rate limitations 17
Circulator - curves and settings 18
Auxiliary microswitch 19
Modbus 20
Safety and alarms 21
Electric circuit board and connections 22
Maintenance 23
Fault finding 26

Check List 27

Safety Instructions

WARNING

These instructions must be read and understood
before installing and maintaining the HIU.
CAUTION! FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN A SAFETY
HAZARD!

Product Range
SATK22103 Direct wall-mounted HIU for LOW temperature

heating. Domestic hot water capacity 50 kW

SATK22105 Direct wall-mounted HIU for LOW temperature

heating. Domestic hot water capacity 60 kW

SATK22203 Direct wall-mounted HIU for MEDIUM

temperature heating. Domestic hot water capacity 50 kW

SATK22205 Direct wall-mounted HIU for MEDIUM

temperature heating. Domestic hot water capacity 60 kW

SATK22305 Direct wall-mounted HIU for HIGH temperature

heating. Domestic hot water capacity 60 kW

SATK22403 Direct wall-mounted HIU for HIGH temperature

heating. Domestic hot water capacity 50 kW

1

1

1

1

with primary

1

1

pump

SATK22405 Direct wall-mounted HIU for HIGH temperature

heating. Domestic hot water capacity 60 kW

1

with primary

pump

1

Primary side head > 50 kPa, primary flow temperature 70˚C,

DHW 10 to 50˚C.

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, commissioned and maintained

correctly in accordance with the instructions provided in
this manual, it may not work correctly and may endanger
the user.

3 Flush the pipework thoroughly before installing the HIU to

remove any particles, rust, incrustations, limescale, welding
slag and any other contaminants.

The water circuits must be clean and free from debris.

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.

1

SATK22

Hightemperaturecircuit flow

Hightemperaturecircuitreturn

Mediumtemperaturecircuit flow

Mediumtemperaturecircuitreturn

Lowtemperaturecircuit flow

Lowtemperaturecircuitreturn

Domestic hotwateroutlet

Domestic cold water inlet

Primary circuit flow

Primary circuit return

7 In the case of particularly hard or impure water, there must

be suitable provision for filtering and treating the water
before it enters the device, in accordance with current
legislation. Failure to do so may result in the HIU becoming
damaged or working incorrectly.

8 Any use of the HIU other than it’s 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.

NOTE: Risk of electric shock. Live parts. Shut off the electric

supply before opening the HIU cover.

1 During installation and maintenance operations, always

avoid direct contact with live or potentially hazardous parts.

2 The device must not be exposed to dripping water 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 to be done on the device, switch off the
electric supply first. Do not use devices with automatic or
time reset, or which may be reset accidentally.

4 Use suitable automatic protection devices 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. Check that the earth connection has been
made to the highest of standards under current legislation.

6 Electrical installation must only be carried out by a qualified

technician, in accordance with current requirements.

7 The HIU does not contain asbestos or mercury.
8 The HIU should only be used by an authorised adult.

NOTES:

1 Install water hammer arresters to compensate for any

overpressure in the domestic water circuit.

2 In the presence of hot water re-circulation or if a check valve

is fitted into the domestic cold water inlet, suitable devices

must be used to accommodate the expansion of the

medium contained within the system and the heat interface

unit.

3 All hydraulic connections must be visually checked while

pressurising the system. Vibration during transport may

cause the connections to become loose. If a fitting needs to

be tightened apply an appropriate tightening torque,

otherwise the components may become damaged.

Key to SymbolsSafety Instructions

General Information

• Please leave the manual as a reference guide for the user.

• Dispose of any packaging in an appropriate manner, most

of which can be recycled.

• In this Installation, Operation and Maintenance guide we

have endeavoured to make the information as accurate as
possible.

We cannot accept any responsibility should it be found
that in any respect the information is inaccurate or
incomplete or becomes so as a result of further
developments or changes to the products.

Material

Components: brass BS EN 12165 CW617N
Pipes: stainless steel
Frame: RAL 9010 sprayed steel
Exchanger: brazed stainless steel

Insulation

Protective shell cover: EPP
Density: 45 kg/m
Working temperature range: 3 to 90˚C
Thermal conductivity: 0.04 W/mK

3

2

SATK22

857070 60 60

490

75

130

245

42 28

444

514

All connections G¾B

Dimensions

Connections

Technical Specification

Medium: Water
Max. percentage of glycol 30%
Max. temperature: 90˚C
Max. static working pressure: Primary: 10 bar

Secondary: 10 bar

Domestic hot water: 10 bar
Primary circuit Nominal flow rate: 1.2 m
Nominal pressure loss on primary circuit: 0.5 bar
Max. differential pressure: 6 bar
Domestic water circuit max. flow rate: 24 l/min (0.4 l/s)
Min.flow rate to activate domestic flow sensor: 2.0 l/min ±0.3

3

/h

Power supply: 230 V (ac)±10% 50 Hz
Max. power consumption: 80 W

SATK2230 20W
Protection class: IP 40
Pump: UPM3 15-70
Actuator: stepper 24 V
Probes: NTC 10 kΩ
Safety relief valve setting: 3 bar
Safety thermostat - STK2210: 55˚C ±3

3

SATK22

1

2

3

4

5

6

7

8

9

10

11

12 14 15 16

21

25
24

20

19

18

17

TS

TA

2

V

V

V

V

V

V

3

4

7

12

13*

5

6

8

9

10

11

21

14

15

19

24

20

17

16

17

22*

23*

25

* SATK2210. only (LOW temperature)

1

2

3

4

5

6

7

8

9

10

11

12 13 14 15 16

21

25
24
23

22

20

19

18

17

Components - SATK2210 (LOW temperature)

Components - SATK2220 (MEDIUM temperature)

Components - SATK2210 & SATK2220

Item Component

1 Frame
2 Electronic regulator
3 2-way modulating valve - heating
4 2-way modulating valve - DHW
5 130 mm space for heat meter
6 ¼”F pressure port
7 Return temperature probe
8 Connection for M10 x 1 heat meter return probe

9 Primary drain cock
10 Differential pressure control valve
11 Mesh strainer + ¼” F pressure port
12 Heating flow temperature probe

13* Safety thermostat

14 Secondary drain cock + mesh strainer
15 Pump
16 Flow meter (turbine + sensor)
17 Mesh strainer
18 Heating exchanger primary drain
19 DHW temperature probe
20 DHW heat exchanger
21 Connection for M10 x 1 heat meter flow probe

22* Thermal safety solenoid valve (normally closed)
23* Thermal safety valve actuator

24 Water hammer arrester
25 Heat exchanger primary circuit air vent

*only included in SATK2210

Schematic Diagram SATK2210 and SATK2220

4

SATK22

1

2

3

4

5

6

7

8

9

10

11

13 14 16

21

23
22

20

19

18

17

1

2

3

4

5

6

7

8

9

10

11

12 13 15 16

21

23
22

20

19

18

17

TA

2

V

V

V

V

V

V

3

4

7

5

6

8

9

10

11

21

13

14#

19

22

20

23

16

17

18

12*

15*

* SATK2230. only

# SATK2240. only

Components - SATK2230 (HIGH temperature)

Components - SATK2240 (HIGH temperature with pump)

Components - SATK2230 & SATK2240

Item Component

1 Frame

2 Electronic regulator

3 2-way modulating valve - heating

4 2-way modulating valve - DHW

5 130 mm space for heat meter

6¼”F pressure port

7 Return temperature probe

8 Connection for M10 x 1 heat meter return probe

9 Primary drain cock
10 Differential pressure control valve
11 Mesh strainer + ¼” F pressure port

12* ¹/” connection for DPCV code 789122

13 Secondary drain cock + mesh strainer

14# Pump

15* Spool piece

16 Flow meter (turbine + sensor)
17 Mesh strainer
18 Heating exchanger primary drain
19 DHW temperature probe
20 DHW heat exchanger
21 Connection for M10 x 1 heat meter flow probe
22 Water hammer arrester
23 Heat exchanger primary circuit air vent

Schematic Diagram SATK2230 and SATK2240

*only included in SATK2230
#only included in SATK2240

5

SATK22

Installation

The SATK22 HIU is designed for installation in a sheltered domestic environment (or similar), therefore it cannot be installed or
used outdoors, i.e. in areas directly exposed to the weather. Outdoor installation may cause malfunctioning and hazards.

If the appliance is enclosed inside or between cabinets, sufficient space must be provided for routine maintenance procedures.
It is NOT recommended to place electrical devices underneath the HIU, as they may become damaged in the event of leaks

occurring at the 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 appliance should be de-activated; contact a qualified technician for
assistance.

Before installation, it is recommended to carry out a thorough flushing of all the pipe work in order to remove any debris or
impurities that could prevent the correct operation of the HIU.

In order to facilitate these operations a manual bypass flushing valve is available (Code 789110).

NOTE:

When the first fix bracket is not used we recommend installing manual shut-off valves, especially on the connections to the primary
line, thus allowing any necessary maintenance work to be carried out without having to empty the centralised system.

Hydraulic connections - reversibility

Installation of the SATK22 heat interface unit is reversible (top down) with the exception of the LOW temperature Unit SATK2210.
Installation in the two positions is possible with or without the first fix bracket Code 789023.

Installation with Mounting Bracket

Ensure the wall is structurally suitable for mounting the HIU, follow the instruction below.

• Using the mounting bracket as a template mark the position of the holes required to secure the HIU to the wall. Ensure the

mounting bracket is horizontal.

• Hang the HIU onto the wall bracket and secure to the wall using the fixing holes provided.

• Mark the position of the hydraulic connections

Check the measurements again and based on the above connection diagram and the dimensions shown on page 3, proceed with the
installation of the following lines:

1 connection to the central system line
2 heating circuit connection

3 domestic water circuit connection
NOTE:

We recommend installing manual shut-off valves, especially on the connections to the primary lines, thus allowing any necessary
maintenance work to be carried out without having to empty the centralised system.

Before installation, it is recommended to carry out thorough flushing of all the pipes of the system in order to remove any residue or
debris that could endanger correct operation of the HIU.

In order to facilitate these operations a manual bypass flushing valve is available (code 789110).

6

SATK22

Installation with mounting bracket

Connections at the bottom

Connections at the top

Installation with mounting bracket and first fix bracket

Ensure the wall is structurally suitable for mounting the HIU, follow this instruction below.

• Using the mounting bracket as a template mark the position of the holes required to secure the HIU to the wall. Ensure the

mounting bracket is horizontal.

In order to facilitate these operations a manual bypass flushing valve is available (code 789110).

Connections at the bottom

7

SATK22

A

B

Electric supply

Connections at the top

Hydraulic connections

Based on the dimensions and connection diagram on page 3.

• Connection to the central primary heating system.

• Connect to the apartment heating system.

• Connect to the domestic hot water system (DHW).

NOTE:

When installing with the connections at
the bottom secure with safety screws as
shown.

Install the SATK22 as shown and using
sealing washers connect the HIU to the
valves on the first fix bracket.

Heat meter installation

The HIU is designed to house a compact heat meter (with
incorporated return probe) with 1” threaded connections and
length of 130 mm.

Before carrying out any maintenance, repair or part
replacement work, proceed as follows:

• Switch off the electric supply

• Remove the cover

• Close the shut-off valves

• Drain the HIU using the drain cocks provided

• Remove the spool piece (A)

• Remove the cap (B)

• Install the flow meter on the return pipe. To tighten the nuts

apply maximum tightening torque of 25 Nm, taking account
of the recommendations of the heat meter manufacturer.

• Install the flow probe in the M10 pocket (B).

Please refer to the heat meter technical data sheets for further
information.

Electrical Installation

Connecting to the electricity supply

The HIU is supplied with an electric supply cable which is not
fitted with a plug.

The appliance should be electrically connected to a 230 V (ac)
single-phase + earth mains supply using the three-wire cable
marked with the label as specified below, observing the LIVE (L)

- NEUTRAL (N) polarities and the earth connection. This line
must be connected to an On/OFF switch.

8