CALEFFI SATK30 Series, SATK30103HE, SATK30105HE Instructions For Installation, Commissioning And Maintenance
www.caleffi.com
Wall-mounted compact indirect heat interface unit
SATK30 series
INSTRUCTIONS FOR INSTALLATION, COMMISSIONING AND MAINTENANCE
Function
The SATK series HIU allows independent control of heat regulation and
domestic hot water production within centralised heating systems or
served by district heating networks.
CONTENTS
78232.01EN
Safety instructions
Dimensions
Technical specifications
Installation
Commissioning
Electronic regulator
Operating cycles
Safety and alarms
SATK30103HE
2
3
4
6
7
8
9
10
Product range
SATK30103HE Indirect wall-mounted compact HIU for
instantaneous domestic hot water production,
power capacity 40 kW.
SATK30105HE Indirect wall-mounted compact HIU for
instantaneous domestic hot water production,
power capacity 65 kW.
SATK30105HE
Maintenance
Electric connections
Troubleshooting
Commissioning checklist
1
11
12
13
14
16
SAFETY INSTRUCTIONS
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 could result in breakage, with water leaks
causing damage and/or 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, the device must be fitted for filtering and
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 combination of the device with other system components must be made taking the operational characteristics of both units into consideration. 10 An incorrect
coupling could compromise 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 or mercury.
8 The device is not designed for use by persons of reduced mental, physical or sensory capacity (including children) or persons lacking experience, unless they are
supervised or instructed in use of the device by a person responsible for their personal safety.
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 current
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 non-return valves are fitted on the domestic cold water inlet, provision must be made to accommodate expansion of
the water contained in the system and in 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 THE PRODUCT IN COMPLIANCE WITH CURRENT LEGISLATION
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
ON DHW CH FAULT
2
1
65
630
65 101
65
10
550
159
530
565 15
292,5
SATK30105HE
SATK30103HE
A B C
3/4” M 1/2” M 3/4” F
ON DHW CH FAULT
2
1
0
1
2
3
4
bar
65
10
550
630
565 15
65 207
65
59
530
298,5
265
Technical specifications SATK30103HE
Medium: water
Maximum percentage of glycol: 30%
Maximum medium temperature: 85°C
Max. working pressure: - primary circuit: 1,6 MPa (16 bar)
Nominal DHW exchanger capacity: 40 kW
Nominal heating exchanger capacity: 15 kW
Maximum recommended primary circuit flow rate: 1,2 m
Maximum differential pressure on
domestic water modulating valves: Dp 90 kPa (0,9 bar)
Domestic water circuit max. flow rate: 18 l/min (0,3 l/s)
Minimum flow to activate domestic water flow meter: 2,7 l/min ±0,3
Electric supply: 230 V (ac) ±10% 50 Hz
Max power consumption: 80 W
Protection class: IP 40
Pump: UPM3 15-70
Pump by-pass setting: 45 kPa (0,45 bar)
Actuators: stepper 24 V
Probes: NTC 10 kΩ
Safety relief valve setting: 0,3 MPa (3 bar)
Safety thermostat: 55°C ±3
Expansion vessel: - capacity: 7 l
Pressure switch: - opening: 40 kPa (0,4 bar)
Materials
Components: brass EN 12165 CW617N
Fitting pipes: steel
Frame: RAL 9010 painted steel
Protective shell cover: EPP
Heat exchanger: brazed stainless steel
- secondary circuit: 0,3 MPa (3 bar)
- domestic water circuit: 1 MPa (10 bar)
- pre-charge value: 0,1 MPa (1 bar)
- closing: 80 kPa (0,8 bar)
Technical specifications SATK30105HE
Medium: water
Maximum percentage of glycol: 30%
Maximum medium temperature: 85°C
Max. working pressure: - primary circuit: 1,6 MPa (16 bar)
- secondary circuit: 0,3 MPa (3 bar)
- domestic water circuit: 1 MPa (10 bar)
Nominal DHW exchanger capacity: 65 kW
3
/h
Nominal heating exchanger capacity: 15 kW
Maximum recommended primary circuit flow rate: 1,2 m
3
/h
Maximum differential pressure on
domestic water modulating valves: Dp 165 kPa (1,65 bar)
Domestic water circuit max. flow rate: 27 l/min (0,45 l/s)
Minimum flow to activate domestic water flow meter: 2,7 l/min ±0,3
Electric supply: 230 V (ac) ±10% 50 Hz
Max power consumption: 80 W
Protection class: IP 40
Pump: UPM3 15-70
Pump by-pass setting: 45 kPa (0,45 bar)
Actuators: stepper 24 V
Probes: NTC 10 kΩ
Safety relief valve setting: 0,3 MPa (3 bar)
Safety thermostat: 55°C ±3
Expansion vessel: - capacity: 7 l
- pre-charge value: 0,1 MPa (1 bar)
Pressure switch: - opening: 40 kPa (0,4 bar)
- closing: 80 kPa (0,8 bar)
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
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
recommended that electrical devices are NOT placed underneath
the HIU, as they may be damaged in the event of safety relief valve
activation if not connected to a discharge tundish, or 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 device
should be deactivated; contact a qualified technician for
assistance.
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 as specified below, observing the LIVE (L) - NEUTRAL (N)
polarities and the earth connection. This line must be connected to
a circuit breaker device.
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:
1. connection to the central system line
2. heating circuit connection
3. domestic water circuit connection
4. conveyance of safety relief valve and charging unit backflow
preventer discharge
• Electric:
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.
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
- 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.
B
A
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, constructed as
specified in current safety regulations. This is a compulsory safety
requirement.
4
Hydraulic connections
ON DHW CH FAULT
2
1
0
1
2
3
4
bar
ON DHW CH FAULT
2
1
Primary circuit flow
Primary circuit return
Domestic hot water outlet
Domestic cold water inlet
Low temperature circuit flow
Low temperature circuit return
High temperature circuit flow
High temperature circuit return
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).
N.B. Install the valves as shown in the figure
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
accommodate 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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