CALEFFI SATK32105, SATK32103, SATK32 Series Instructions For Installation, Commissioning And Maintenance
H0003193
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SATK series wall-mounted indirect Heat Interface Unit
SATK32 series
INSTRUCTIONS FOR INSTALLATION, COMMISSIONING AND MAINTENANCE
All languages are available on:
FR
NL
I
Function
The SATK series 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.
CONTENTS
Safety instructions
Dimensions - Technical specifications
Hydraulic components and diagram
Hydraulic installation
Electrical installation
Commissioning
Remote user interface quick guide
2
3
4
5
8
9
10
Product range
SATK32103 Indirect wall-mounted HIU for instantaneous
SATK32105 Indirect wall-mounted HIU for instantaneous
(1)
Primary side head > 50 kPa, primary flow temperature 70°C,
DHW 10 - 50°C
domestic hot water production, capacity 50 kW
domestic hot water production, capacity 60 kW
Heating function
DHW function - Comfort functions
Anti-legionella function
Primary flow rate limitation
Circulator - curves and setting
Auxiliary microswitch
(1)
.
(1)
.
Modbus
Safety and alarms
Electronic circuit board
Periodic maintenance
Troubleshooting
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13
14
14
15
16
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19
20
22
Commissioning check-list
24
SAFETY INSTRUCTIONS
Primary circuit flow
Primary circuit return
Low temperature circuit flow
Low temperature circuit return
Medium temperature circuit flow
Medium temperature circuit return
Domestic hot water outlet
Domestic cold water inlet
High temperature circuit flow
High temperature circuit return
WARNINGS
These instructions must be read and understood before installing and servicing the device.
IMPORTANT! FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN A SAFETY HAZARD!
1 The device must be installed, commissioned and serviced by qualified technical personnel in accordance with national regulations and/or relevant local
requirements.
2 If the device is not installed, commissioned and serviced 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, take care not to subject the threads to excessive mechanical stress. 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 servicing 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 while taking the operational characteristics of both units into consideration.
10 An combination 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 enclosure.
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 weather, 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 two-pole switch. If work must
with 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 in which 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 must 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 appliance 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.
treating the water before it enters the device,
be carried out on the device, cut off
in accordance with current
the electric supply first. Do not use devices
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 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 a proper tightening torque, otherwise the components may be damaged by overtightening.
For the updated version of the technical documentation refer to www.caleffi.it.
Key to symbols
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
130
245
70 70 60 60 85 75
490
630
42 28
444
Dimensions
A B
3/4” 1/2”
Description of connections
SATK32 technical specifications
Medium: water
Max. percentage of glycol: 30%
Maximum medium temperature: 90°C
Max. working pressure: - primary circuit: 1,6 MPa (16 bar)
- secondary circuit: 0,3 MPa (3 bar)
- domestic circuit: 1 MPa (10 bar)
Primary circuit nominal flow rate: 1,2 m
Nominal pressure loss on primary circuit: Dp 50 kPa (0,5 bar)
Maximum pressure on primary circuit: Dp 600 kPa (6 bar)
Domestic water circuit max. flow rate: 24 l/min (0,4 l/s)
Minimum flow rate to activate domestic water flow meter: 2 l/min ±0,3
Electric supply: 230 V (ac) ±10% 50Hz
Max power consumption: 80 W
Protection class: IP 40
Pump: UPM3 15-70
Actuators: 24 V stepper motor
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)
- pre-charge value: 0,1 MPa (1 bar)
- closing: 80 kPa (0,8 bar)
Materials
Components: brass UNI EN12165 CW617N
Connecting pipes: steel
Frame: RAL 9010 painted steel
Exchanger: stainless steel brazed with copper
3
/h
Insulation
Material: EPP
Density: 45 kg/m
3
Working temperature range: 3-90°C
Thermal conductivity: 0,04 W/mK
3
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26
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6
15
29
28
T
S
P
TA
2
V
V
V
V
V
V
3 4
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22
Characteristic components
1. Frame
2. Controller
3. Heating exchanger primary circuit air venting/drain
4. Heating exchanger secondary circuit air venting/drain
5. Heating exchanger
6. Pressure switch
7. 2-way modulating valve - Heating
8. 2-way modulating valve - DHW
9. Return temperature probe
10. Pressure gauge
11. Safety thermostat
12. 130 mm heat meter template
13. 1/4” F pressure test port
14. Connection for M10x1 heat meter return probe
15. Primary drain cock
16. Connection for M10x1 heat meter flow probe
17. Mesh strainer + 1/4” F pressure test port
18. Differential pressure regulating valve
19. Secondary drain cock + mesh strainer
20. Safety relief valve
21. Flow meter (turbine + sensor)
22. Mesh strainer
23. Heating flow temperature probe
24. Pump
25. DHW temperature probe
26. Expansion vessel
27. Water hammer arrester
28. DHW exchanger
29. DHW exchanger primary circuit air venting/drain
Hydraulic diagram
4
Hydraulic installation
Notes for the installer
The SATK series 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 recommended
NOT to place electrical devices 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 appliance should be deactivated; contact a qualified technician for assistance.
Hydraulic connections - reversibility
Installation of the SATK32 series heat interface unit is reversible (top-down). Installation in the two positions is possible with or without template code
789023.
Charging unit
To install the charging unit with backflow preventer code 572120, proceed as follows:
- remove the nuts shown in the figure with letter “A”;
A
A
- Insert the charging unit as shown in the figure, using the supplied seals.
Preliminary operations - installation without template
After having established the point of installation of the appliance, perform the following operations:
· Mark the holes required for the bracket to secure the HIU to the wall
· 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:
• 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
NOTE:
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.
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 789110).
5
Installation procedure (without template)
Secure the metal bracket supplied with the HIU to the wall using suitable wall anchors.
Connections on the bottom
123
Connections on the top
123
Installation with template
NOTE:
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 789110).
Connections on the bottom
123
Connections on the top
12
N.B.:
In the case of installation with connections
on the bottom fit the safety screw (figure
3).
Install SATK32 as per the above pictures and
close the 6 nuts using the fiber gaskets
supplied.
6
Conveyance of the safety relief valve
The safety relief valve is equipped with a compression fitting suitable for 15 mm copper pipe and can be rotated in accordance with the HIU installation
position. If SATK32 is installed with upward facing connections, use discharge pipe code 789832, specifically designed to route the valve drain line
through the insulation shell, without damaging the internal electronic components.
Heat meter installation
The HIU is fitted 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:
- cut off the electric supply
- remove the cover
- close the shut-off valves on the primary flow and return
- empty the HIU using the drain cocks provided
- remove the template (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
indications 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.
A
B
7
Electrical installation
Connection to the electric supply
The appliance 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) singlephase + earth mains supply using the three-wire cable marked with
the label as specified aside, observing the LIVE (L) - NEUTRAL (N)
polarities and the earth connection. This line must be connected to a
circuit breaker device.
To extend the cable if necessary, use a flexible cable suitable for
kitchen and heating appliances and for home, kitchen and office
installations, also in humid environments subject to medium levels of
mechanical stress (e.g. H05V2V2-F: Uo/U 300/500 V). Cable
minimum cross-section 3 x 0,75 mm
Make sure that the electrical system can withstand the maximum
power consumption of the appliance, with particular emphasis on the
cross-section of the wires.
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.
Observe the applicable regulations in force in the country of
installation.
Use the cable pathway provided, as shown in figure 1.
Optional electric connections
The controller has a door on the front providing access to terminal
boards for optional wiring (see chapter “circuit board details”). The
connections in question are all low voltage or potential-free. Any wiring
must be directed toward the exterior of the HIU, using the pathways
provided in the insulation and on the frame. All the low voltage lines
must be routed through a single dedicated cable raceway, using the
pathway that is not used for the electric supply cable (see figure 2), so
that they are separate from the 230 V electric cables.
Any other high voltage connection, e.g. the one from the auxilliary
microswitch (see pages 13 and 16) must pass through the same cable
pathway used for the main electric supply.
Remote user interface connection
The HIU user interface has the dual function of control device and
room thermostat. The remote user interface can be installed on board
the HIU or in the room in a position where the temperature
measurements will be of significance for control of the heating function
(in a heated room in a position where the temperature read by the
thermostat is not affected by any nearby heat sources).
2
.
12
3
4
5
6
Installation on board the HIU
If the remote user interface is fitted in the dedicated location on the
cover of the HIU, the thermostat function must be disabled (in this
case an external thermostat must be used, as described in the next
section). The adjacent figures show how to install the remote control
unit:
- Feed the cable from the regulator through the hole in the cover (3);
- Feed the cable from the regulator through the rear of the interface
(4);
- Connect the two wires to the terminals on the electronic circuit
board (the cable is not polarised) (5);
- Close the interface and position it in its housing on the cover (6), (7);
- If necessary, secure the interface from inside the cover by means of
the supplied pair of self tapping screws, spacers, and washers;
- Plug in the connector (8).
The thermostat function is enabled by default (refer to the
remote control user manual for disabling it).
7
8
8
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