CALEFFI SATK32105, SATK32103, SATK32 Series Instructions For Installation, Commissioning And Maintenance

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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:

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

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)

Modbus

Safety and alarms

Electronic circuit board

Periodic maintenance

Troubleshooting

Commissioning check-list

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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.

Page 3

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

Insulation

Material: EPP Density: 45 kg/m

Working temperature range: 3-90°C Thermal conductivity: 0,04 W/mK

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3 4

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

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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”;

- 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).

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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

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.

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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.

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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).

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).

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XP PORT OTSRT

PREPAID

AUX

RS-485 BUS

Installation in the room

Use the cable outlet provided for connection of the remote user interface to the electronic circuit board. The chrono-thermostat function has to be enabled through the remote control. Refer to the dedicated user manual for the procedure.

Use of an external room thermostat

An external room thermostat, if installed, must necessarily be with potential-free contact. The external thermostat has to be connected to the terminals “RT” shown in the adjacent figure. The terminals can be accessed by removing the door on the HIU electronic regulator (see page 19).

In case the thermostat function of the remote user interface is enabled, any external thermostat will work in parallel (management of different temperature zones). Alternatively, when the thermostat function of the remote user interface is disabled, the interface can be used to define the hourly programming of the space heating function for all thermostats connected to the terminals “RT”.

Refer to the user interface dedicated manual.

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)

N.B. during the procedures for venting/draining the system use suitable measures to avoid the risk of any liquid dripping onto the electronic components.

Vessel pre-charge check

Perform the following steps:

- Use a pressure gauge to check the pre-charge value

- If necessary, restore the pre-charge value shown in the technical specifications.

Filling the user system

SATK32 series HIU can be fitted with a charging unit equipped with a backflow preventer (F), check valve (E) and cock (G) (code 572120). When filling the system for the first time or for subsequent top-up procedures following a heating circuit pressure switch fault, restore the system pressure (0,12–0,2 MPa - 1,2–2 bar) by opening cock (G) and checking the value by means of the pressure gauge (D). Once the correct pressure has been reached, close the cock (G), vent the system and re-check the pressure (repeat the filling process if necessary).

System start-up

Before starting the HIU, visually check the hydraulic connections for the absence of any leakage and all the electric connections. After finishing the check, activate the electric supply to the HIU and check for the presence of any error signal. If there is any, eliminate the fault indicated (see page 18) and proceed with setting the set point of the domestic water and heating cycles, programming the remote user interface according to the desired temperatures and times, and checking the operating cycles.

Fitting the cover

Fit the cover on the HIU by inserting the pins (A) in the locations provided (B). Secure the cover by tightening the 4 screws provided (C).

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Remote user interface quick guide

(mode)

DHW ON/OFF Heating ON/OFF

(set)

urrent time/date Set point temperature k outside temperature compensation

(day/night)

Daytime/night-time setting

(temp)

Tem pe ra tu re display (ambient set point +

probes)

(prog)

Heating hourly programming and “comfort” function

(reset)

Resettable error reset/floor slab heating function

(R)

+/-

DISPLAY: BUTTONS:

The digits in the center of the display show the current ambient temperature, if the thermostat function is enabled. In case the latter is disabled, the digits show DHW temperature and heating flow temperature when the HIU is in operation, “--.-” when in stand-by.

Selecting the active services (DHW/heating)

Press the <mode> key repeatedly to scroll through the various available operating modes.

Heating + DHW (“winter” mode) Heating only

OFF DHW only (“summer” mode)

Selecting set points, current time and comfort function

Press the <set> key repeatedly to set the current time, set point temperatures and comfort function. The value can be modified by turning knob <R>.

Night-time ambient temperature (*) Heating flow temperature DHW temperature

Current hours, minutes and day Daytime ambient temperature (*)

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Primary limit/set return temperature in heating mode (**)

Primary limit/set return temperature in DHW mode (**)

Comfort function (ON/OFF or according to weekly program) (see page 13)

(*) if the thermostat function of the remote user interface is enabled. (**) if these set points cannot be changed you must set parameter t07 to value 0 in the technical menu (see “access to technical menu” below). Parameter t07= 1 “freezes” the operating set points to prevent inadvertent modifications by the user.

Temperature display

Press the <temp> key repeatedly to display the current ambient temperature set point and the temperature values read by the three probes of the HIU.

Heating flow probe temperature Primary return probe temperature

(*) if the thermostat function of the remote user interface is enabled.

Access to technical menu

Press the <mode> key repeatedly to set the HIU to OFF status.

Current ambient temperature set point (*)

Heat interface unit in OFF mode

DHW probe temperature

Hold the <set>, <day/night> and <temp> keys pressed together for 10 seconds.

Access to the technical parameters

To exit the menu, wait a few seconds or press the <reset> key. Re-enable the required services using the <mode> key.

Refer to the remote control user manual for the hourly programming of space heating and DHW comfort function.

Once “TSP” appears on the display, confirm access by pressing the central knob <R>. By rotating knob <R> it is possible to scroll through the various parameters, which can then be edited, pressing and rotating knob <R>.

Technical parameter t00

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Text (°C)

T flow (°C)

MIN

0-5

-15

MAX

-10

-20

k =

3.0

2.5

1.0

0.5

k =

0.0

HIU setting at HIGH/LOW temperature

The HIU is set at LOW temperature by default (underfloor heating, parameter t00 = 1). To change this setting and supply a system with high temperature terminals go to the technical menu (see page 11) and set parameter t00 to 0.

DEFAULT SETTING: set point regulation (technical parameter t01 = 0)

When heating cycle activation is requested by the room thermostat, the circulation pump is powered while the modulating valve is opened gradually until the set point temperature is reached. The circulation pump is stopped and the modulating valve is closed at the end of the heating cycle. The heating cycle ON condition is indicated by the blinking symbol.

OPTIONAL SETTING: primary return temperature limit (technical parameter t01 = 1)

When heating cycle activation is requested by the room thermostat, the circulation pump is powered while the modulating valve is opened gradually until the set point temperature is reached, if the return temperature is lower than or equal to the set limit value. In case this condition is not met, the flow temperature is reduced (by a maximum of 15°C for HIU in HIGH temperature, and maximum 3°C if in LOW temperature), in order to bring return temperature within the limit values. When the flow temperature must be reduced in order to limit return, the icon appears on the display.

Heating flow/ primary return limit temperature setting

To set the flow temperature press the <SET> key until the symbol in the red circle appears; for the return temperature limit press the key until the symbols in the green circle are displayed. Use the <R> knob to change the value (*). The flow temperature range is: 25–45°C for heat interface units in LOW temperature 45–75°C for heat interface units in HIGH temperature The primary return limit temperature range is: 15–42°C for heat interface units in LOW temperature 30–70°C for heat interface units in HIGH temperature

OPTIONAL SETTING: modulating temperature regulation with compensated set point (technical parameter t01= 2)

When the function is enabled, the flow temperature is modified (± 10°C with respect to the set point for HIU in HIGH temperature, ± 3°C if in LOW temperature) according to the temperature detected by the return probe in order to maintain this latter temperature value constant. This keeps the actual thermal output of the slab under control, and consequently also the ambient thermal load. The thermal response time of the system is thus minimised. This feature should not be used in combination with thermostatic radiator valves.

When the function is enabled the display shows the symbol .

OPTIONAL SETTING: weather compensation (technical parameter t01 = 3)

When the function is enabled, the flow temperature is calculated based on the temperature detected by the outside probe (optional), in accordance with the curve shown below. The “k” coefficient can be changed by pressing <SET> button until the related setting appears.

Heating function

The display shows the symbol .

MAX is the set temperature value MIN is 45°C for HIGH temp. HIUs, 25°C for LOW temp. ones.

(*) if these set points cannot be changed you must set parameter t07 to value 0 in the technical menu (see “access to technical menu” below). Parameter t07 = 1 “freezes” the operating set points to prevent inadvertent modifications by the user.

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DHW function

The DHW cycle always takes priority over the heating cycle.

DEFAULT SETTING: fixed DHW set point (parameter t06=0)

When DHW cycle activation is requested, due to DHW tapping by the user (detected by the domestic water flow meter), the regulator modulates the valve opening in order to adjust the temperature detected by the domestic water probe to the selected set point value. When tapping ends, the modulating valve is fully closed. The DHW cycle ON condition is indicated by the blinking symbol.

OPTIONAL SETTING: primary return temperature limit (technical parameter t06 = 1)

When DHW cycle activation is requested, due to DHW tapping by the user (detected by the domestic water flow meter), the regulator modulates the valve opening in order to adjust the temperature detected by the domestic water probe to the DHW set point value if the return temperature is less than or equal to the set limit. If this condition is not met, the flow temperature is reduced (by a maximum of 7°C down to a temperature that can be no less than 40°C), in order to bring return temperature within the limit values.

Due to the activation of the return temperature limitation function, DHW temperature can be lower than the set value.

DHW/primary return limit temperature setting

To set the DHW temperature press the <SET> key until the symbol in the red circle appears; for the return temperature limit press the key until the symbols in the green circle are displayed. Use the <R> knob to change the value (*). The range of possible DHW temperatures is 42–60°C, while the range of possible return temperatures is 15–45°C.

DHW Comfort functions (pre-heating, DHW recirculation)

The comfort function can be, alternatively, preheating of the DHW plate heat exchanger or management of DHW recirculation. They are enabled by setting to ON or PROG the comfort function (see page 11).

DEFAULT SETTING: DHW exchanger preheating function (parameter t02 = 0)

During periods when the domestic water cycle is not used, if the DHW probe detects a temperature 10°C below the SET value, the regulator partially opens the domestic hot water modulating valve for the time required (max. 5 min.) to bring the exchanger to the condition wherein it can assure rapid DHW production. The active pre-heating cycle is indicated by the blinking symbol. This function is of lower priority than any domestic water or heating cycles.

OPTIONAL SETTING: management of DHW recirculation in the apartment (parameter t02 = 1)

In alternative to the DHW comfort function it is possible to manage DHW recirculation, using a similar logic. During periods when the domestic water cycle is not used, if the DHW probe detects a temperature 10°C below the SET value, by means of an auxiliary microswitch (see page

19), the regulator closes the circuit supplying the circulation pump (not supplied) generating a DHW cycle lasting for a pre-set amount of time. This amount of time is pre-set to 2 minutes. It can be changed by acting on parameter t09 on the technical menu (1 unit = 10 seconds).

The circulator has to be fed through the auxilliary microswitch so that the control of recirculation is carried out by the heat interface unit. DHW recirculation (t02=1) disables the other functions operating on the auxilliary microswitch described on page 16. Refer to page 16 for the electrical characteristics of the microswitch.

Both comfort functions can be enabled according to user defined weekly time programming. Refer to the remote user interface manual.

N.B.: In the presence of a DHW recirculation system a suitably sized expansion vessel must be installed.

Page 14

Anti-legionella function

Max opening (%)

Flow rate (l/h)

706050 80 10090

200

400

600

800

1000

1200

Max opening (%)

Flow rate (l/h)

706050 80 10090

200

400

600

800

1000

1200

DEFAULT SETTING: anti-legionella function OFF (technical parameter t08 = 0)

Enabling the anti-legionella function by means of technical parameter t08 = 1, in time band 3:00 - 3:30:

- the DHW set point will be temporarily increased to the maximum value (60°C) - the comfort/recirculation function will be forced ON.

As a result of the temperature rise of the set point, at time 3:00 a comfort function (either pre-heating or recirculation) will be triggered, bringing the temperature to a value close to 60°C, such as to rapidly reduce the presence of any bacteria.

During execution of the cycle, the user interface display will show the blinking symbol (refer to the adjacent figure).

IMPORTANT!

- Any DHW production that occurs during the time band (3:00 3:30) will be at 60°C.

- The cycle execution time band (3:00 - 3:30) is established in accordance with the time set on the remote control unit. Incorrect time setting will result in execution of the antilegionella function in a different actual time band. Due to the effect of exchanger thermal inertia, temporary DHW production at high temperature could proceed also beyond the time of 3:30.

If the function is enabled thermostatic mixing valves should be installed on the users level (washbasin/shower, etc.).

Primary flow rate limitation

Primary flow rate limitation in heating mode

DEFAULT SETTING: no limitation (technical parameter t03 =

100)

During start-up of the heating cycle from cold, e.g. on changeover from night-time ambient set point to the daytime set point, the HIU may demand a significantly higher primary flow rate than the design one, because of the low temperatures of the secondary medium. This effect is far greater with high temperature systems in which, during the transient to the design operating condition, high thermal power values may be transferred from the primary circuit to the secondary circuit. This effect can be restricted by lengthening the transient, setting a limit on the maximum primary flow rate that can be withdrawn in heating mode.

The flow rate limitation is imposed by controlling the maximum opening of the primary circuit modulating valve. Since latter is controlled by a differential pressure limiter, it is possible to supply direct correspondence between the opening position of the valve and the circulating flow rate (*)

Primary flow rate limitation in DHW mode

DEFAULT SETTING: no limitation (technical parameter t04 =

100)

Likewise, you can establish a limit to the primary flow rate that can be tapped for instantaneous DHW production.

A maximum degree of opening (%) can be set via technical menu parameter t03.

N.B. Any limitation must be assessed in accordance with the effective thermal characteristics of the residential unit served.

(*) The correspondence between valve position and flow rate is indicative. Graphs obtained with pressure head upstream of the HIU = 50 kPa.

A maximum degree of opening (%) can be set via technical menu parameter t04.

Page 15

Circulator - Curves and setting

PERFORMANCE

2 s.

ELECTED SETTING

CURVE TYP E

PROPORTIONAL

ROPORTIONAL

CONSTANT

FIXED SPEED

CONSTANT

LED SEQUENCE

CURVE TYP E LED SEQUENCE

H (m w.g.)

G (m

/h)

p (bar)

0,6

0,4

0,3

0,2

0,1

2,521,5

0,5

3,53

0,7

0,8

Constant head

Proportional head

Constant speed

Factory setting

ALARM STATUS

Blocked

Supply voltage low

Electrical error

The HIU is equipped with a Grundfos circulator model UPM3 AUTO-L 15-70. By default, the circulator setting is with the maximum proportional head characteristic. Pressing the front key briefly produces the sequence of LEDs corresponding to the selected hydraulic characteristic. A couple of seconds after pressing the key, the circulator again produces a sequence of LEDs showing the instantaneous power consumption:

- 1 yellow LED lit: power between 0 and 25% of Pmax;

- 2 yellow LEDs lit: power between 25 and 50% of Pmax;

- 3 yellow LEDs lit: power between 50 and 75% of Pmax;

- 4 yellow LEDs lit: power between 75 and 100% of Pmax.

To change the characteristic, hold down the front key for more than two seconds and then press the same key repeatedly until reaching the required characteristic (refer to the adjacent figure).

Having identified the required characteristic (head - flow rate chart shown below) wait for about ten seconds for the setting to be accepted by the circulator, which will then revert to the sequence of LEDs showing power consumption.

A long press of the front key (>10 s) locks the pump setting, preventing possible incorrect modifications of the curve. Unlocking can be done in the same way, with a long press (>10 s) of the front key.

The pump also has a self-diagnostics system to reveal any possible operating problems. Any problem detected is shown by a sequence of LEDs:

Page 16

Auxiliary microswitch

The HIU is equipped with a contact, driven by a relay incorporated in the circuit board, the intervention logic of which can be programmed in accordance with requirements by setting technical parameter t05.

Each event linked to operation of the HIU is linked to a numerical value, according to the following table:

Event/condition Value

DHW tapping in progress 1

Heating cycle in progress 2

Comfort cycle (pre-heating/recirculation) in progress 4

HIU OFF 8

Error not active 16

Error active 32

Closing of the contact on the occurrence of multiple events conditions is programmed by setting parameter t05 to a value corresponding to the sum of the single events/conditions. We give some practical examples below:

example 1 - Driving an external primary flow pump, normally OFF.

The contact must be closed if any HIU function is active (DHW production, heating, pre-heating)

Parameter t05 must be set to: 1 + 2 + 4 = 7

This value (t05 = 7) is set by default.

example 2 - Distinction of consumption for DHW production from total consumption (in combination with heat meter equipped with dedicated function)

The contact must be closed both if DHW tapping is in progress and if activation of the comfort function is requested (pre-heating or recirculation).

Parameter t05 must be set to 1 + 4 = 5.

Closing of the microswitch is shown on the user interface by the symbols shown alongside.

N.B. if the DHW recirculation function is enabled with t02 = 1 (see page 13) the auxiliary microswitch intervention logic described above is not operational. In this case, the contact is used to control the recirculation pump.

Connection

For information on how to access the dedicated terminals, consult the “auxiliary microswitch” section on page 19.

N.B.: the auxiliary microswitch can be used to drive electric loads directly, taking account of the following operating limits:

- Max voltage: 230 Vac

- Max current: 3 A

If the electric load to be controlled is not included within the parameters indicated an external relay must be interposed.

Page 17

Modbus

To the ModBus master

S-485

MASTER IN / OUT

SLAVE # 1

IN / OUT

SLAVE # n

IN / OUT

CHARACTERISTIC I

MPEDENCE = Z

TERMINATING

RESISTOR

RT =

TERMINATING

RESISTOR

RT =

KEEP AS SHORT AS POSSIBLE

The HIU offers a remote connectivity solution by means an RS-485 wired network and Modbus RTU communication protocol.

On request, Caleffi will supply a map of the Mod-Bus registers and data transmission specifications so the product can be integrated in an existing BMS system.

The RS-485 communication network should be preferably constructed in compliance with the prescriptions of standard EIA RS-485.

Any other configuration of the physical layer is at the discretion of the BMS system operator, which will assume responsibility for checking the implications in terms of transmission quality.

In particular, it is essential to use a two-wire twisted cable. Compliance with this requirement becomes even more significant the more extensive the RS-485 network. If, alternatively, a shielded wire is used, the shield must be connected solely on the master side.

As a guideline, take account of the following general prescriptions to ensure optimal transmission quality:

- use a BUS cable with impedance of around 120 Ohm;

- connect a terminal resistor, having same impedance as the cable, at each end of the RS-485 cable;

- keep the length of side branches as short as possible.

The device is configured by default to support a communication speed of 9600 baud/s with parity “none”. The communication speed can be changed via Modbus, to the following values: 2400, 4800, 9600, 19200 baud/s.

Page 18

Safety and alarms

If the electronic circuit board detects a fault, the display shows the error code concerned and the symbol .

Heating circuit pressure switch fault Error code 4

The electronic regulator continuously monitors the status of the pressure switch controlling the water pressure in the heating circuit. If the pressure switch trips, the heating circulation pump immediately comes to a stop and the modulating valve is completely closed. This fault implies the stoppage of the heating cycle only. Domestic water drawing requests will continue to be served normally. N.B.: A low pre-charge value of the expansion vessel can cause a pressure switch fault.

Corrective action

Return to the operating mode is subordinate to restoration of the correct water pressure in the secondary heating circuit (see page 9 “Filling the user system”).

Probe fault

If a temperature probe fails, the associated cycle will be stopped immediately and disabled. Any requests to run cycles not associated to the previous one will continue to run normally.

Heating flow probe fault Error code: 5

Safety thermostat cut-out Error code 69

HIUs configured to support low temperature heating continuously monitor the safety thermostat controlling the flow temperature. If the safety thermostat is activated during a general cycle, the heating circulation pump immediately comes to a stop and the modulating valve is completely closed. After the user has removed the block imposed by the safety thermostat, operation can only be re-enabled when the modulating valves are completely closed again. This means that if a domestic water cycle is in progress, the activation of the shut-off valve will be postponed until the end of that domestic water cycle.

Corrective action

To restore the operating mode press the manual RESET button.

Heat interface unit disabled Error code 80

Domestic hot water probe fault Error code: 6

Return probe fault Error code: 15

External temperature fault Error code: 38

Corrective action

Normal operating conditions are restored automatically once the faulty probe is working properly again (see page 20 - “Temperature probe replacement”).

The HIU is disabled due to an incorrect connection on the circuit board front terminals or due to an input from an external device indicating zero credit.

Corrective action Check the electrical connections or, in the case of zero credit, top-up the external device/contact the service supplier.

Page 19

Electronic circuit board

OTS RT

REPAID

AUX

RS-485 BUS

50Vac 3A

max

RS-485 BUS

IN IN IN OUT

IN IN OUT

PREPAID

IN OUT

AUX

????????

OUT

Optional connections

The electronic circuit board has a front door (shown in the adjacent figure) that provides access to the connectors related to HIU optional functions.

N.B. before working on the circuit board you must disconnect the electric supply to the HIU.

All the terminals are mounted on removable connectors to facilitate wiring operations.

Connector colours

If the connectors of actuators and temperature probes are disconnected during special maintenance work, comply with the following instructions to reconnect them:

DHW probe:

The following services are accessible:

• External probe for outside compensated temperature regulation

Use optional probe code 789833

• External room thermostat

IMPORTANT! The connection is volt free. Do not connect powered contacts.

• Interface with pre-paid services

In case the HIU has to be interfaced with controllers managing the heating and DHW production services by means of “pre-paid” type logic. The HIU interprets an open contact as “credit available”. Closing the contact disables the heating and DHW production services. When this condition occurs the user interface display shows error “E80”.

IMPORTANT! The connection is volt free. Do not connect powered contacts.

If the controller that manages the pre-paid service supplies a powered contact, a relay must be interposed.

• Auxiliary contact

To implement the functions described on page 16 and for the connection of the DHW recirculation pump (see page

13)

IMPORTANT! Max voltage 230 V ac, max current 3 A.

• Mod-Bus

RS-485 port to connect HIU to a wired network for Mod-Bus communication.

Return probe:

Heating probe:

Heating valve actuator connector:

DHW valve actuator connector:

Pressure switch:

Safety thermostat:

Other electronic regulator functions

• Reset diverter/modulating valve to zero

Immediately after the power supply has been switched on, the position of the modulating valves is reset to zero.

• Pump anti-seizing

When the pump is not in use, it is powered on for a period of 5 seconds every 24 hours.

• Diverter/modulating valve anti-seizing cycle

The anti-seizing cycle for the diverter/modulating valve is run every 24 hours.

Page 20

Periodic maintenance

The following checks must be carried out at least once very 12 months, in accordance with the prescriptions of standard EN 806-5.

PERATIONS TO BE PERFORMED

Force an actuators reset by switching the HIU power supply OFF and then ON

Visually check for the absence of leaks and/or anomalies

Check for possible active errors shown on the user interface

Test correct operation of the pump by closing the thermostat contact or forcing it to close

Clean the strainers: on the primary flow line (component 17, page 4), on the secondary return line (19), upstream of the domestic water flow meter

After having isolated the HIU by means of shut-off valves, discharge the pressure in the secondary circuit and make sure the expansion vessel pre-

charge value is between 0.9 and 1.2 bar. Restore the pressure value, if necessary

Re-open the shut-off valves and restore secondary circuit pressure to a value between 1.3 and 1.7 bar

Check for the absence of any liquid dripping from the safety relief valve and ensure the drain is unobstructed

Check for the absence of internal leakage through the modulating valves when none of the services are active

(22)

Check correct setting of the set points (DHW and heating). Unless explicitly requested by the user or for normative reasons, a DHW temperature

With the primary circuit at working temperature, check that the DHW flow rate at the correct temperature is sufficient

Summary of the technical parameters

Here follows a summary of the meaning and possible settings of the technical parameters:

Parameter Meaning Settings

t00 Temperature range of the HIU

t01 Heating flow temperature control

t02 DHW comfort mode

t03 Maximum % opening of the heating modulating valve From 50 to 100

t04 Maximum % opening of the DHW modulating valve From 50 to 100

t05 Configuration of the closing logic of the auxilliary microswitch See page 16

t06 DHW temperature control

t07 Freezing of some settings

t08 Anti-legionella

t09 Duration of a DHW recirculation cycle 1 unit = 10 seconds

set point of 50°C or lower is recommended

0 = 45 - 75°C

1= 25 - 45°C

0 = fixed set point

1 = fixed set point with RTL

2 = compensated on return temperature

3 = weather compensated

From 0 = pre-heating of the heat exchanger

1 = DHW recirculation

0 = fixed set point

1 = fixed set point with RTL

0 = All temperature settings can be modified

1 = Return temperature limits are freezed

0 = disabled

1 = enabled between 3:00 to 3:30 a.m.

Maintenance

All maintenance procedures should be carried out by an authorised technician. Regular maintenance guarantees better efficiency and helps to save energy. 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 heat interface unit using the drain cocks provided.

Exchanger replacement

- As a preliminary step, remove the flow sensor (refer to “replacing the DHW priority flow

meter”, on page 21) and position it where it cannot be reached by any dripping liquid.

- Remove the exchanger, loosening the 2 hex socket head screws fixing it in place (A)

- Replace the exchanger and the O-rings.

- Tighten the two fixing screws (A) after having checked that the O-rings are correctly

positioned. Tightening torque 3-3,5 Nm.

N.B. Make sure to respect the correct orientation of the plate heat exchanger when fitting it back.

Page 21

Cleaning the HIU primary circuit strainer

All heat interface units have a strainer on the inlet for water from the centralised system. To clean these strainers, carry out the following maintenance procedure:

- Unscrew the cap (B)

- Remove the strainer mesh and discard any impurities it contains

- Refit the strainer mesh

- Refit the cap and tighten it.

Replacing the valve obturator

- Disconnect the valve actuator (see previous paragraph)

- Extract the obturator, unscrewing the locking nut (F)

- Replace the obturator, screw on the locking nut (F) and then fit the actuator

- Insert the fixing clip, respecting the correct direction

- Reconnect the connector.

Temperature probe replacement

- Disconnect the probe cable by bending tab (C) slightly and extracting the connector.

- Unscrew the probe

- Fit the new probe

- Reconnect the connector respecting the only possible way it can

be inserted.

Replacing the actuator

- Extract the fixing clip (D) and then the actuator

- Position the new actuator (E)

- Insert the fixing clip, respecting the correct direction

- Reconnect the connector.

Replacing the DHW priority flow meter

- Disconnect the flow meter cable acting on the connector

- Extract the flow sensor (G)

- Position the new sensor

- Reconnect the connector respecting the only possible way it can be inserted.

Replacing or cleaning the DHW priority flow meter turbine

- Extract the flow sensor

- Unscrew and remove the cartridge (H)

- Remove any impurities or change the cartridge if necessary

- Screw the cartridge back in

- Reposition the flow sensor

When carrying out maintenance on the electrical part, follow the indications on page 19 for the connections. After concluding maintenance, proceed with the filling and checking operations described in the chapter “commissioning” (page 9) and fit the cover.

If you require any information regarding spare parts, please contact Caleffi spa.

Page 22

Troubleshooting

AULT DESCRIPTION

Domestic hot

water is not

heated

The water is hot

but does not

reach the

desired

temperature

Hot water

temperature is

too high

Hot water flow

rate is

insufficient

Hot water flow

rate is zero

LERTS

blinking

icon

error code 6 active

error code 80 active

fixed

icon

icon absent

display is off

blinking

icon

blinking

icon

blinking

icon

OSSIBLE CAUSE OF FAULT

primary circuit shut-off valves closed open the valves

modulating valve actuator disconnected from valve body reconnect actuator

modulating valve actuator faulty call qualified personnel to have it replaced

DHW temperature probe cable inverted with heating probe restore correct connection

presence of air in the system vent the system

electronic regulator not working call qualified personnel to have it replaced

valve obturator blocked in closed position call qualified personnel to have it replaced

centralised system not working/cold contact person in charge of system

DHW temperature probe disconnected reconnect probe

DHW temperature probe faulty call qualified personnel to have it replaced

incorrect wiring/no credit check electrical connections/top up credit

DHW priority flow meter disconnected reconnect flow meter

DHW priority flow meter faulty call qualified personnel to have it replaced

DHW production not enabled

electric supply cut off restore HIU electric supply

protection fuse burnt out call qualified personnel to have it replaced

domestic water cycle temperature set point too low increase set point

primary return temperature limitation intervention

primary circuit strainer of the HIU clogged call qualified personnel to have it serviced

exchanger partly clogged call qualified personnel to have it serviced

modulating valve actuator faulty call qualified personnel to have it replaced

DHW temperature probe cable inverted with heating probe restore correct connection

excessive demand for DHW decrease demand

electronic controller not working call qualified personnel to have it replaced

centralised system temperature insufficient contact person in charge of system

primary circuit flow rate insufficient contact person in charge of system

primary flow rate limit too low contact person in charge of system

domestic water cycle temperature set point too high decrease set point

DHW temperature probe cable inverted with heating probe restore correct connection

modulating valve actuator faulty call qualified personnel to have it replaced

valve obturator blocked in intermediate or open position call qualified personnel to have it replaced

electronic regulator not working call qualified personnel to have it replaced

primary circuit excessive flow rate due to DPCV valve

Antilegionella cycle in progress contact person in charge of system

possible domestic water system shut-off valves

insufficient pressure in centralised domestic water circuit call qualified personnel to have it serviced

possible domestic water system shut-off valves closed open the valves

no cold water in centralised domestic circuit call qualified personnel to have it serviced

HIU strainer completely clogged call qualified personnel to have it serviced

exchanger completely blocked call qualified personnel to have it serviced

malfunction

HIU strainer clogged call qualified personnel to have it serviced

partially closed

PERATIONS TO BE PERFORMED

enable DHW production by means of HIU

change the return temperature set

call qualified personnel to have it replaced

interface

point/disable the function

open the valves

Page 23

AULT DESCRIPTION

The room

does not reach

the desired

temperature

LERTS

blinking

icon

fixed

icon

display is off

icon

absent

error code 4 active

error code 5 active

error code 15 active

error code 38 active

error code 69 active

error code 80 active

OSSIBLE CAUSE OF FAULT

heating cycle temperature set point too low increase set point

chrono-thermostat temperature setting incorrect check programming of chrono-thermostat

HIU strainer clogged call qualified personnel to have it serviced

primary return temperature limitation intervention (the

following icon appears )

primary flow rate in heating mode set at an excessively

heating valve actuator faulty call qualified personnel to have it replaced

heating valve obturator blocked call qualified personnel to have it replaced

modulating valve actuator connector disconnected reconnect actuator connector

DHW temperature probe cable inverted with heating probe restore correct connection

presence of air in the system vent the system

pump cable not connected restore connection

possible system shut-off valves/terminals closed open the valves

centralised system temperature insufficient contact person in charge of system

electronic regulator not working call qualified personnel to have it replaced

primary circuit flow rate insufficient contact person in charge of system

centralised system not working contact person in charge of system

thermostat function enabled on the remote user interface

when it should be disabled

chrono-thermostat time setting incorrect check programming of chrono-thermostat

chrono-thermostat not working check chrono-thermostat

thermostat function disabled on the remote user interface contact person in charge of system

Protection fuse burnt out call qualified personnel to have it replaced

Heating not enabled (summer mode)

heating circuit pressure too low restore system pressure

heating temperature probe faulty call qualified personnel to have it replaced

compensation temperature probe faulty call qualified personnel to have it replaced

external temperature probe faulty/not connected call qualified personnel to have it replaced

safety thermostat cut-out

low limit

pump not working call qualified personnel to have it replaced

Electric supply cut off restore HIU electric supply

no credit top-up prepaid system

PERATIONS TO BE PERFORMED

change the return temperature set

point/disable the function

change heating valve opening limit

contact person in charge of system

enable heating by means of heat interface

press the reset button/call qualified

personnel to have it serviced

unit

Page 24

Checks to be performed

1 Is the heat interface unit properly secured to the wall?

2 H

as the system flushing been carried out?

3 Check strainers and clean them if necessary

4 Is the heat meter (if present) connected?

5 Is the heat meter (if present) connected to the building datalogger (if required)?

6 Is the DCW line fitted with a pressure reducing valve?

7 Is the system protected by water hammer arresters?

Are the shut-off valves open?

Has the visual inspection of the hydraulic sealing efficiency produced positive results?

Has the system (primary) been filled and vented?

11 Has the system (secondary) been vented and filled to a pressure of between 1,2 and 2 bar?

Has the visual inspection of the HIU internal electrical connections given a positive result and are the connections compliant with specifications and made in accordance with best practices?

Is the heat interface unit connected to the 230 Vac electric supply? Is the remote user interface connected?

Have the optional connections (external sensor, prepayment, auxilliary microswitch, Modbus, if required) been carried out?

Has the remote user interface been configured for installation on board (thermostat function disabled) / inside the apartment (with thermostat function enabled)?

Have the heating, DHW and comfort functions (if required) been activated?

Have the heating and DHW set points been configured correctly?

Have the optional functions (return temperature limitation, return/weather compensation, anti-legionella, primary flow rate limitation) been enabled (if required) and configured?

Have the external room thermostats (if required) been connected?

No error code on heat interface unit remote user interface?

Is the primary circuit at working temperature?

Check that heating starts (blinking icon) by simulating a heating request

Check that the pump functions correctly when the thermostat is activated (check that the secondary flow pipes heat up)

Simulate minimal DHW tapping (approx 3 l/min) and check that “DHW” LED lights and that water is supplied at the required temperature

Simulate abundant DHW tapping and check, by means of the installed heat meter, that the primary circuit flow rate is sufficiently high

CALEFFI SATK32105, SATK32103, SATK32 Series Instructions For Installation, Commissioning And Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual