CALEFFI. SATK wall-mounted Heat Interface Unit - HIU Instantaneous domestic hot water production. SATK20 - SATK30 series 01209/13 GB

Transcription

1 SATK wall-mounted Heat Interface Unit - HIU Instantaneous domestic hot water production SATK20 - SATK30 series ACCREDITED CALEFFI 01209/13 GB ISO 9001 FM ISO 9001 No The latest generation heat interface units SATK20 and SATK30 regulate user heat requirements and instantaneous DHW production. The SAK20, SATK30 heat interface units, being two-way systems with modulating control of the heating medium (VFR - variable flow rate system), are particularly suitable for centralised systems with condensing boilers and for centralised systems served by remote district heating. Design Improving the performance and energy efficiency of systems can help to reduce the energy consumption of buildings and reduce environmental pollution. VF (variable flow) systems can play an important part in this. The design and sizing of VF system distribution networks can be split into three stages. words, only heating (Q HEAT, H HEAT ) requirements need to be considered in selecting the dimensions of the network. These dimensions vary on account of the fact that the services required evolve differently depending on the number of homes served. In particular, DHW production needs high medium outputs and flow rates if a small number of homes are supplied, but low outputs and flow rates if many homes are served, as illustrated in the diagrams on the next page. In the first stage, the network must be sized on the basis of the flow rate and heat required to produce DHW: in other words, only DHW (Q DHW, H DHW ) requirements need to be considered in selecting the dimensions of the network. In the second stage, the network must be sized on the basis of the flow rate required for heating and the heat required to produce DHW: in other words, it needs to be the right size to handle both heating and DHW requirements (Q HEAT, H DHW ). In the third and final stage, the network must be sized on the basis of the flow rate and heat required for heating: in other 1

2 System design diagrams An example of how to design a system is provided below. System features and design choices: Home heating requirement: 5500 kcal/h Radiator systems Design thermal head - heating: DT = 10 C Hot medium design temperature: T = 65 C Heat interface unit characteristics (in relation to the design temperature of the hot medium): Dp min = mm w.g. Min. required Dp Q n = l/h primary circuit nominal flow rate H n = kcal/h primary circuit nominal output H n.dhw = 0,29 l/s max. DHW produced Flow rate required [l/h] FLOW RATES REQUIRED IN RELATION TO NUMBER OF DWELLINGS Flow rate required for DHW production (Q DHW ) Flow rate required for heating (Q HEAT ) Flow rate required by system Number of dwellings Heat required [kcal/h] HEAT REQUIRED IN RELATION TO NUMBER OF DWELLINGS Heat required for DHW production (H DHW ) Heat required for heating (H HEAT ) Heat required by system Number of dwellings 2

3 Main features of VFR systems VFR systems (controlled by two-way valves, see relative diagram below) work by moving only the amount of medium needed to provide the requested amount of heat. Benefits of VFR systems: variable flow rate No risk of legionnaires disease In VFR systems, bacteria cannot develop in the production of DHW and in the internal water supply systems inside apartments. Single meter In VFR systems, zone heating costs are measured by a single heat meter. When DHW production is centralised, consumption is calculated by a heat meter for heating and by a volume meter for DHW, i.e. by direct and indirect methods, which can often be a source of debate and dispute. Much lower return temperatures In VFR systems, the return temperature of the medium in the boiler drops as the external temperature rises, whereas in conventional (constant flow) systems, it rises. In this regard, the diagram below shows how these temperatures vary in a system with design temperatures of 65 and 10 C for the hot medium and radiator thermal head respectively. Lower return temperatures allow: better performance of condensation boilers; less heat loss from return pipes; more cost-efficient use of renewable energies. These are primarily: 1 - energy saving 2 - thermal comfort 3 - installation and running costs 4 - accurate heating metering Possibility of using thermostatic valves. In brief, only VFR systems allow a rational and economic use of thermostatic valves. In fact, only VFR systems (without having to use penalizing bypasses and pumps which work continuously at full capacity) can control the imbalances introduced into circuits by the constant opening and closing of thermostatic valves: these imbalances can seriously impair system function and cause serious damage. Hence unlike conventional systems (with constant flow), with VFR systems you can more efficiently: Heating medium temperature Constant-flow system return temperature select the temperature required in each room in the various zones, for example C in bedrooms, 8 10 C in technical rooms and in other rooms not normally used; benefit from the heat obtained from internal and external energy sources, i.e. from sunlight or the heat from human bodies, artificial lighting, home appliances, ovens and hobs; obtain the temperature requested in each room without any potential thermal imbalances generated by sunlight hitting rooms to different degrees or other impediments (curtains or niches) that block the heat issued by radiators. Lower pump operating costs Lower pump operating costs due to the fact that VFR systems always work with the minimum flow rate needed to transfer the required heat, whereas conventional systems always work with the maximum flow rate: this difference can save on average from 40 to 55% in the pump running costs. Less heat loss from distribution networks In VFR systems there are two hot medium pipes whereas in constant-flow systems there are 4 (2 for heating and 2 for DHW and recirculation). Lower distribution networks installation costs For the reasons outlined above. VFR system return temperature External temperature Less danger of limescale blockages Less danger of limescale blockages and therefore less risk of a partial or total blockage of exchangers producing DHW. It should in fact be noted that in VFR systems (controlled by modulating valves), heat exchange temperatures are on average lower than those in conventional constant flow systems (controlled by ON/OFF valves). For this reason, there is less risk of limescale obstructions in VFR systems, which become a hazard at exchange temperatures above C. DHW production The electronic regulato rfor SATK20, SATK30 heat interface units, which assimilates information on the required domestic hot water flow rate, maximises the primary circuit exchange temperature difference following extreme splitting in the vector medium flow rate. In this functional context, the SATK20, SATK30 heat interface units also make DHW production consistent with low temperature returns. 3

4 Use of alternative energies The two-way conformation of the SATK series heat interface units, combined with the role played by the electronic regulators which guarantee very cold return flows, allows much more use to be made of alternative energies in the central heating context. The use of stored energy increases due to the effect of accepting lower medium temperatures compared to those of traditional DHW tank. The amount of stored domestic water is basically replaced by technical water. Central heating system diagram for VFR systems with boiler and integrated solar power The system comprises: - boiler; - a solar power system consisting of solar manifolds, coil accumulator, circulator, electronic regulator, - two three-way diverter valves (V1 and V2); - a variable-flow twin circulator; - differential thermostat (Tt, Tr); - expansion, safety and control devices. When the tank temperature (Tt) rises above the temperature returning from the system (Tr), the differential thermostat commands a three-way valve (V1) that diverts circulation of the medium towards the boiler heated by the solar system; otherwise, the medium is sent directly to the boiler. The thermostat on the boiler (T) commands a second three-way diverter valve (V2) that diverts the flow directly into the delivery section of the system when the design temperature is exceeded; otherwise the flow is diverted to the boiler. Note: The control, expansion and safety devices must be of an appropriate size to reflect the characteristics and capacity of the system, in accordance with applicable legislation. Application diagram V2 I T P P V1 Tr T T T T Tt T T A F V.E. 4

5 WALL-MOUNTED HEAT INTERFACE UNIT INSTANTANEOUS DOMESTIC HOT WATER PRODUCTION - SATK20/HE SERIES BOILER COMMUNAL AREAS HOUSING UNIT DISTRICT HEATING SUBSTATION Being compact in size, the wall-mounted heat interface units are suitable for in-home installation and concealed inside a kitchen cupboard. This makes it much easier for landlords to manage their own temperature regulation and domestic hot water production, freeing up space in communal landing enclosures which can be used to house meters instead. Moreover, this also extends the line from the main community supply into the dwelling, reducing the need for joints and fittings. Pipes heat losses remain within the dwelling, and given that they are metered, actual use made and meter readings produced will be more consistent. 5

6 WALL-MOUNTED HEAT INTERFACE UNIT INSTANTANEOUS DOMESTIC HOT WATER PRODUCTION - SATK20/HE SERIES SATK20103 LOW temperature HIU SATK20103HE LOW temperature HIU with high-efficiency pump SATK20203 MEDIUM temperature HIU SATK20203HE MEDIUM temperature HIU with high-efficiency pump Set point regulation or modulating temperature regulation with compensated set point Heating range C DHW production range C Set point regulation Heating range C DHW production range C Optional functions water cycle: Heating cycle: SATK domestic water preheating function - modulating regulation with compensated set point - floor slab heating function HIGH temperature heat interface unit Optional functions water cycle: Heating cycle: SATK domestic water preheating function - modulating regulation with compensated set point HIGH temperature HIU SATK20403HE HIGH temperature HIU with high-efficiency pump ON/OFF regulation Max. temperature heating 85 C DHW production range C ON/OFF regulation Max. temperature heating 85 C DHW production range C Optional functions water cycle: - domestic water preheating function Optional functions water cycle: - domestic water preheating function 6

7 Technical data SATK20 Medium: water Max. percentage of glycol: 30% Max. medium temperature: 85 C Max. working pressure: - primary circuit: 10 bar - domestic hot water circuit: 10 bar Nominal DHW exchanger capacity: 40 kw Max. recommended primary circuit flow rate: 1,2 m 3 /h DHW circuit max flow rate: 18 l/min (0,3 l/s) Min. flow to activate domestic flow meter: 2,7 l/min ±0,3 Max. differential pressure on domestic water modulating valve: 0,9 bar Max. differential pressure on mixing valve: 0.9 bar Electric supply: 230 V (ac) ±10% 50Hz Power consumption: 105 W (SATK20...HE 75 W) Protection class: IP 40 Pump: UPS (SATK20...HE UPS ) Pump by-pass setting: 0,45 bar Actuators: stepper 24 V Probes: NTC 10 kω Safety thermostat: 55 C ±3 Materials Components: brass EN12165 CW617N Fitting pipes: steel Frame: RAL 9010 painted steel Protective shell cover: PPE Exchanger: braze welded stainless steel Dimensions SATK20 Operating cycles water cycle This cycle always takes priority over the heating cycle. When DHW cycle activation is requested, due to the running of user s tap (detected by the domestic meter), the regulator pilots the modulating valve opening so as to adjust the temperature detected by the domestic water probe to the selected set point value (in the SATK20403/HE the pump is also activated). At the end of the drawing-off procedure, the modulating valve is fully closed (in the SATK20403/HE the pump comes to a stop). The active domestic water cycle is signalled by the yellow DHW LED which comes on. The set point temperature value of the general domestic water cycle can be set using the P1 trimmer to a value within the defined range of C and shown on the display (see page 20). Heating cycle Set point regulation. SATK20103/HE - LOW temperature SATK20203/HE - MEDIUM temperature When heating cycle activation is requested by the room thermostat, the circulation pump is powered while the mixing valve is opened gradually until the set point temperature is reached. At the end of the heating cycle, the circulation pump comes to a stop and the mixing valve is closed. The active heating cycle is signalled by the yellow CH LED which comes on (see page 20). The heating cycle temperature set point can be set using trimmer P2 and shown on the display. Heating cycle ON/OFF regulation SATK HIGH temperature SATK20403/HE - HIGH temperature with pump When the room thermostat requests the start of a heating cycle, the valve is opened completely (in the SATK20403/HE the pump is also activated), allowing water to circulate at the temperature supplied by the central heating system (ON-OFF regulation). The valve is closed on completion of the heating cycle (in the SATK20403/HE the pump comes to a stop). The active heating cycle is signalled by the yellow CH LED which comes on (see page 20). Optional functions water cycle water preheating function The function is enabled by setting DIP switch 5 (see page 20) to the ON position. 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 water modulating valve for the time required (max. 5 mins) to bring the temperature detected up to a value 5 C below the set point value. The active domestic water cycle is signalled by the flashing yellow DHW LED. This function is less of a priority than any domestic water or heating cycles. Heating cycle Modulating temperature regulation with compensated set point. SATK20103/HE - LOW temperature SATK20203/HE - MEDIUM temperature The function is enabled by setting DIP switch 1 (see page 20) to the OFF position. When the function is enabled, the flow temperature is modified according to the temperature detected by the compensation probe (located on the user return pipe). This keeps the actual thermal output of the slab - and therefore the ambient thermal load - under control. The thermal response time of the system is thus minimised. Floor slab heating function SATK20103/HE - LOW temperature This facilitates the laying of underfloor heating systems at low temperatures. This function can only be activated and executed if there are no faults. It can be activated by pressing and holding the RESET button for 8 seconds. The yellow CH LED blinks while the floor slab heating function is in operation (see page 20). The function has a duration of 240 hours, and is carried out by simulating a request to run in heating mode starting from a set point of 25 C and rising in regular intervals to a temperature of 45 C. Once the maximum set point has been reached, the function is executed, following the same procedures, in reverse (from the maximum set point to the minimum set point). This function has priority over heating and hot water cycles, and can be suspended at any time by pressing and holding the RESET button for 8 seconds. 7

8 SATK20103 LOW temperature heat interface unit SATK20103HE LOW temperature heat interface unit with high-efficiency pump Functional characteristics Heating range C Set point regulation DHW production range C Optional functions water cycle: Heating cycle: - domestic water preheating function - modulating regulation with compensated set point - floor slab heating function Characteristic components 1. Frame 2. Electronic regulator 3. Thermal safety relief valve 4. Heating mixing valve 5. DHW production modulating valve 6. Heating flow temperature probe 7. Thermal safety thermostat 8. DHW temperature probe 9. DHW exchanger 10. Drain cock 11. Pump 12. Protective pump by-pass 13. Flow temp. compensation return probe 14. DHW priority flow meter 15. Heat meter template spacer 16. Air vent cock 17. System strainer/heat meter flow probe pocket 18. Primary circuit shut-off valves Hydraulic-functional diagram TS O / RT

9 Hydraulic characteristics Heating function Head available at connections 3rd speed function - primary exchanger 9

10 SATK20203 MEDIUM temperature heat interface unit SATK20203HE MEDIUM temperature heat interface unit with high-efficiency pump Functional characteristics Heating range C Set point regulation DHW production range C Optional functions water cycle: Heating cycle: - domestic water preheating function - modulating regulation with compensated set point Characteristic components 1. Frame 2. Electronic regulator 3. Heating mixing valve 4. DHW production modulating valve 5. Heating flow temperature probe 6. DHW temperature probe 7. DHW exchanger 8. Drain cock 9. Pump 10. Protective pump by-pass 11. DHW priority flow meter 12. Heat meter template spacer 13. Air vent cock 14. System strainer/heat meter flow probe pocket 15. Primary circuit shut-off valves Hydraulic-functional diagram 10

11 Hydraulic characteristics Heating function Head available at connections 3rd speed function - primary exchanger 11

12 SATK20303 SATK20403/HE HIGH temperature HIU HIGH temperature HIU with pump Functional characteristics Max. heating temperature 85 C ON/OFF regulation DHW production range C Optional functions water cycle: - domestic water preheating function Characteristic components 1. Frame 2. Electronic regulator 3. Heating ON/OFF valve 4. DHW production modulating valve 5. Drain cock 6. DHW temperature probe 7. DHW exchanger 8. DHW priority flow meter 9. Heat meter template spacer 10. Air vent cock 11. System strainer/heat meter flow probe pocket 12. Primary circuit shut-off valves 13. Pump (SATK20403/HE) 14. Protective pump by-pass (SATK20403/HE) Hydraulic-functional diagram O SATK20403/HE

13 Hydraulic characteristics Heating function function - primary exchanger Pump characteristics (SATK20403/HE) p (kpa) 6 H (mm w.g.) rd speed nd speed st speed G (l/h) 13

14 WALL-MOUNTED INDIRECT HEAT INTERFACE UNIT INSTANTANEOUS DHW PRODUCTION - SATK30 SERIES/HE DISTRICT HEATING COMMUNAL AREAS PRIVATE RESIDENCE SATK30103 Indirect heat interface unit SATK30103HE Indirect heat interface unit with high-efficiency pump The SATK30 satellite HIU is the most compact, complete and efficient solution for enclosures in individual dwellings for use in: - district heating - centralised heating systems which require a high static pressure and high temperature medium, characteristics which could cause injury. The SATK30 heat interface unit offers the unusual feature of keeping the primary and secondary water completely separate. This type of device is useful when designing or redesigning the heating and domestic hot water systems of apartment buildings under renovation, as well as facilitating any maintenance required in the individual dwellings without the risk of impurities entering their systems. It makes no difference how the domestic hot water in dwellings is produced when a SATK30 satellite HIU is used. Furthermore, the modulating heating and DHW valves on the primary circuit minimise return temperatures in the substation or central source of a central heating systems through the modulating action of the regulator. Minimising the return temperatures by exaggerating the difference between flow and return temperatures, is therefore compliant with remote heating rules and condensation requirements. Set point regulation or modulating temperature regulation with compensated set point Heating range - LOW temperature setting C - MEDIUM/HIGH temperature setting C DHW production range C Optional functions water cycle: - domestic water preheating function Heating cycle (at LOW temperature setting): - modulating regulation with compensated set point - floor slab heating function 14

15 Technical data SATK30 Medium: water Max. percentage of glycol: 30% Maximum medium temperature: 85 C Max. working pressure: - primary circuit: 16 bar - secondary circuit: 3 bar - domestic hot water circuit: 10 bar Nominal heating exchanger capacity: 15 kw Nominal DHW exchanger capacity: 40 kw Max. recommended primary circuit flow rate: 1,2 m 3 /h DHW circuit max flow rate: 18 l/min (0,3 l/s) Min. flow to activate domestic flow meter: 2,7 l/min ±0,3 Modulating valve max differential pressure: Dp 0,9 bar Power supply: 230 V (ac) ±10% 50Hz Power consumption: 105 W (SATK30...HE 75 W) Protection class: IP 40 Pump: UPS (SATK30...HE UPS ) Pump bypass setting: 0,45 bar Actuators: stepper 24 V Probes: NTC 10 k Ω Safety relief valve setting: 3 bar Safety thermostat: 55 C ±3 Expansion vessel: 7,5 l Pressure switch: opening 0,4 bar - closing 0,8 bar Materials Components: Fitting pipes: Frame: Protective shell cover: Exchanger: Dimensions SATK30 brass EN12165 CW617N steel RAL 9010 painted steel PPE braze welded stainless steel Operating cycles water cycle This cycle always takes priority over the heating cycle. When DHW cycle activation is requested, due to the running of user s tap (detected by the domestic meter), the regulator pilots the modulating valve opening so as to adjust the temperature detected by the domestic water probe to the selected set point value. At the end of the drawing-off procedure, the modulating valve is fully closed. The active domestic water cycle is signalled by the yellow DHW LED which comes on. The set point temperature value of the general domestic water cycle can be set using the P1 trimmer to a value within the defined range of C and shown on the display (see page 20). Heating cycle Set point regulation 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. At the end of the heating cycle, the circulation pump comes to a stop and the modulating valve is closed. The active heating cycle is signalled by the yellow CH LED which comes on (see page 20). The heating cycle temperature set point can be set using trimmer P2 and shown on the display. Optional functions water cycle water preheating function The function is enabled by setting DIP switch 5 (see page 20) to the ON position. 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 water modulating valve for the time required (max. 5 mins) to bring the temperature detected up to a value 5 C below the set point value. The active domestic water cycle is signalled by the flashing yellow DHW LED. This function is less of a priority than any domestic water or heating cycles. Heating cycle Modulating temperature regulation with compensated set point. (at LOW temperature setting) The function is enabled by setting DIP switch 1 (see page 20) to the OFF position. When the function is enabled, the flow temperature is modified according to the temperature detected by the compensation probe. This keeps the actual thermal output of the slab - and therefore the ambient thermal load - under control. The thermal response time of the system is thus minimised. Floor slab heating function (at LOW temperature setting) This facilitates the laying of underfloor heating systems at low temperatures. This function can only be activated and executed if there are no faults. It can be activated by pressing and holding the RESET button for 8 seconds. The yellow CH LED blinks while the floor slab heating function is in operation (see page 20). The function has a duration of 240 hours, and is carried out by simulating a request to run in heating mode starting from a set point of 25 C and rising in regular intervals to a temperature of 45 C. Once the maximum set point has been reached, the function is executed, following the same procedures, in reverse (from the maximum set point to the minimum set point). This function has priority over heating and hot water cycles, and can be suspended at any time by pressing and holding the RESET button for 8 seconds. 15

16 1 0 2 CALEFFI 4 3 SATK30103 Indirect HIU SATK30103HE Indirect HIU with high-efficiency pump Functional characteristics Heating range - LOW temperature setting C - HIGH temperature setting C Set point regulation DHW production range C Optional functions water cycle: - domestic water preheating function Heating cycle at LOW temperature setting: - modulating regulation with compensated set point - floor slab heating function Characteristic components 1. Frame 2. Expansion vessel 3. Electronic regulator 4. 2-way modulating valve (primary heating) 5. Heating flow temperature probe (secondary) 6. Heating exchanger 7. 2-way modulating valve - DHW 8. Thermal safety thermostat 9. Secondary heating drain cock 10. DHW temperature probe 11. Filling unit with backflow preventer 12. Safety relief valve 13. Flow temp. compensation return probe 14. Primary circuit drain cock 15. Pump 16. Protective by-pass 17. DHW priority flow meter 18. Pressure switch 19. Secondary heating filter 20. DHW exchanger 21. Heat meter template spacer 22. Primary circuit strainer/flow probe pocket 23. Primary air vent cock 24. Primary circuit shut-off valves Hydraulic-functional diagram TS 2 7 O / RT P

17 Hydraulic characteristics Heating function Head available at connections 3rd speed function - primary exchanger Δp (kpa) Δp (mm w.g.) 17

18 SATK20 - SATK30 series domestic hot water performance at 48 C Flow Temp. Primary Circuit Primary Circuit Flow Rate DHW Circuit Flow Rate Q (l/min) Return Temperature Primary Circuit Flow Temp. Primary Circuit DHW Circuit Flow Rate Q (l/min) 18

19 SATK20 - SATK30 series domestic hot water performance table Primary circuit flow rate = 1000 l/h Δp= 20kPA / domestic water inlet temperature 13 C water production temperature 44 C 48 C 52 C 56 C 60 C Primary circuit temperature C 65 15,4 33,3 12,6 30,8 10,4 28,3 8,5 25,5 7,0 23, ,0 38,9 16,1 35,9 13,2 35,9 10,9 32,7 9,0 29, ,0 38,9 18,0 41,1 15,1 41,1 12,8 38,4 10,8 35, ,0 38,9 18,0 43,8 16,1 43,8 14,5 43,5 13,2 43, ,0 38,9 18,0 45,7 16,8 45,7 15,6 46,8 14,5 47,5 Primary circuit flow rate = 1100 l/h Δp= 25kPA / domestic water inlet temperature 13 C water production temperature 44 C 48 C 52 C 56 C 60 C Primary circuit temperature C 65 17,3 37,5 13,8 33,7 11,3 30,7 9,2 27,6 7,5 24, ,0 38,9 18,0 44,0 14,7 40,0 12,0 36,0 9,8 32, ,0 38,9 18,0 44,0 15,5 42,2 13,4 40,2 11,7 38, ,0 38,9 18,0 44,0 16,7 45,4 15,4 46,2 14,2 46, ,0 38,9 18,0 44,0 17,6 47,9 16,8 50,4 15,5 50,8 Primary circuit flow rate = 1200 l/h Δp= 30kPA / domestic water inlet temperature 13 C water production temperature 44 C 48 C 52 C 56 C 60 C Primary circuit temperature C 65 18,0 38,9 14,8 36,1 12,0 32,7 9,7 29,1 7,8 25, ,0 38,9 18,0 44,0 15,0 40,8 12,5 37,5 10,4 34, ,0 38,9 18,0 44,0 15,9 43,3 14,1 42,3 12,7 41, ,0 38,9 18,0 44,0 17,3 47,1 16,4 49,2 15,3 50, ,0 38,9 18,0 44,0 17,9 48,7 17,4 52,2 16,5 54,1 19

20 Electronic regulator RESET key This key allows you to restore normal function after a safety thermostat has been triggered (SATK20103/HE-SATK30103 at low temperature setting). Trimmers set point settings The set point values for heating and domestic hot water cycles can be set using the two trimmers on the front of the regulator This allows you to set the temperature setpoint for the heating cycle and view the relative value set on the display. This allows you to set the temperature setpoint for the domestic hot water cycle and view the relative value set on the display. Operation All heating and domestic hot water functions offered by SATK20, SATK30 satellite HIUs are controlled by a digital regulator. The regulator is factory set with different standard parameters depending on the model (Table 1). There are a number of specific DIP SWITCHES on the regulator circuit board; the way these are configured will determine the settings of the various models and the optional functions enabled. User interface The user interface, built into the PCB, consists of the following devices: Indicator LED The following functions and faults are signalled by either flashing or permanent illumination of the LEDs: LCD display The LCD display is normally used to show heating and domestic water set points for the functions described below. Stand-by: The following alternate every 5 seconds on the display: Heating temperature set point water temperature set point LED ON STATUS OFF No electric supply STEADY ON STATUS Electric supply present FLASHING ON STATUS Heating cycle ON: 60 The temperature set point is shown while the symbol flashes: DHW water cycle OFF water cycle ON Preheat function in progress water cycle ON: CH FAULT Heating cycle OFF No fault Heating cycle ON Safety thermostat cut-in Floor slab heating function running Pressure switch fault Probe fault 48 The temperature set point is shown while the symbol flashes: Table 1 factory default settings CODE SWITCH SETTINGS SET HEATING DHW SATK20103/HE LOW temperature SATK20203/HE MEDIUM temperature SATK SATK20403/HE HIGH temperature SATK30103/HE LOW temperature setting SATK30103/HE HIGH temperature setting C C MAX 85 C C C C C C C C Factory setting (do not modify) Can be modified to enable optional functions Switch 1: Modulating temperature regulation with compensated set point. Switch 5: water preheating function 20

21 Safety and alarms Error codes associated with faults signalled by the lighting up of the FAULT LED are also shown on the display. Heating circuit pressure switch fault (SATK30103/HE) Error code 4 4 FAULT SATK30103 series indirect HIU continuously monitor the status of the pressure switch controlling the pressure of the water in the closed heating circuit. If this pressure switch is activated, the heating circulation pump immediately comes to a stop and the modulating valve is fully closed. This fault presupposes that only the heating cycle is locked. water drawing requests can continue to be served normally. Removing a fault A return to operating mode is subordinate to the correct water pressure value being restored in the secondary heating circuit. Safety thermostat cut-in SATK20103/HE - LOW temperature SATK30103/HE - at LOW temperature setting Error code FAULT The 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 circulation pump immediately comes to a stop and the modulating/mixing valve is completely closed. The thermal safety lock valve (SATK20103/HE) is closed. In the event of a power failure, the thermal safety valve prevents hot water for heating purposes from entering the system. After the user has reset the block imposed by the safety thermostat, the shut-off valve can only be re-enabled when the mixing/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. Removing a fault Restoring operating mode is subordinate to the execution of the manual reset by the user via the pressing of the Reset button provided for this purpose. Probe fault If a temperature probe fails, the associated cycle would be stopped immediately and prevented from continuing. Any requests to run cycles not associated to the previous one would continue to run normally. Heating probe fault Error code: 5 5 FAULT Safety valve fault SATK20103/HE - LOW temperature Error code FAULT water probe fault Error code: 6 6 FAULT Removing a fault Normal operating conditions are restored automatically once the faulty safety valve is working properly again. Compensation probe fault SATK20103/HE - LOW temperature SATK30103/HE - at LOW temperature setting Error code: FAULT Removing a fault Normal operating conditions are restored automatically once the faulty probe is working properly again. Automatic regulator functions Reset mixing/modulating valve to zero Immediately after the electric supply has been switched on, the position of the installed mixing/modulating valves is reset to zero. Pump anti-clog When the pump is not in use, it is powered on for a period of 5 seconds every 24 hours. Mixing valve/modulating valve anti-clog The anti-clogging cycle for the mixing/modulating valve is run every 24 hours. 21

22 Finishing parts for SATK20 - SATK30 series Meter box K CONTECA direct heat meter Direct heat meter for SATK series and/or meter box code Equipped with an 8-digit liquid crystal display. 24 V (ac) 50 Hz - 1 W centralized electric supply. Recessed meter box with galvanized base and painted door for interiors (RAL 9010) and finishing frame. Includes: - pair of 3/4 M manual shut-off valves, - pair of temperature pockets, - heat meter template, - fittings for DCW. Complies with directive 2004/22/EC (MI004) Code Connection Size (mm) /4 350 x 380 Code K K Connection 1/2 3/4 Meas. type single nozzle single nozzle Q nom m 3 /h 1,5 2,5 Q min l/h Meter plate Galvanized sheet metal meter plate Includes: - pair of manual 3/4 M shut-off valves - pair of temperature pockets, - heat meter insertion template, - fittings for DCW. Code Use SATK20 SATK Hydraulic backplate Hydraulic backplate painted in RAL9010, including bottom-up system connection pipes. Includes: - frame - steel pipes - air vent - pair of 3/4 M manual shut-off valves Depth: 60 mm Code Connection Size (mm) /4 276 x water function water cut-off consisting of: - BALLSTOP shut-off valve with check valve; - flow meter (MI001); - shut-off ball valve with male terminal; - flushing pipe; - mounting bracket. Code * ** 7891 Differential pressure regulating kit. Brass body. Including capillary for connection to flow pipe. Max. working pressure: 10 bar. Differential pressure fixed setting: 15 kpa - 30 kpa. Length of capillary pipe Ø 3 mm: 1,5 m. Dp regulating kit - 15 kpa Dp regulating kit - 30 kpa * 15 kpa suitable for radiator heating ** 30 kpa suitable for radiant panels and convectors Code DCW 3/4 with local reading DCW 3/4 with pulse output H unit flushing valve with manual by-pass. System connection: 1 M. User connection: 3/4 M. Complies with directive 2004/22/EC (MI001) Code Use SATK20 - SATK30 22

23 SPECIFICATION SUMMARY Code SATK20103/HE Wall-hanging, two-way heat interface unit for low temperature heating with set point regulation (25 45 C) and instantaneous domestic hot water production (42 60 C), including: electronic regulator, thermal safety relief valve, thermal safety thermostat, heating mixing valve, heating temperature probe, UPS pump with safety by-pass, fittings for heat meter, DHW production modulating valve, DHW temperature probe, plate heat exchanger, flow temperature offset probe, DHW priority flow meter, air vent cock, strainer, domestic water preheating function, dimensions L 450 x H 550 x D 265 mm. Medium: water. Maximum percentage of glycol: 30%. Maximum medium temperature: 85 C. Maximum working pressure: - primary circuit: 10 bar, domestic circuit: 10 bar. Nominal DHW exchanger capacity: 40 kw. Maximum recommended primary circuit flow rate: 1,2 m 3 /h. Maximum DHW circuit flow rate: 18 l/min. Minimum flow to activate domestic flow meter: 2,7 l/min ±0,3. Maximum pressure differential on modulating valve: 0,9 bar. Maximum pressure differential on mixing valve: 0,9 bar. Electric supply: 230 V (ac) ±10% 50Hz. Power consumption: 105 W (SATK20103HE 75 W). Protection class: IP 40. Pump: UPS (SATK20103HE UPS ). Motors: stepper 24 V. Probes: NTC 10 kω. Materials: components: brass EN CW617N. Connection pipes: copper or steel, grey PPE cover. Code SATK20203/HE Wall-hanging, two-way heat interface unit for medium temperature heating with set point regulation (50 75 C) and instantaneous domestic hot water production (42 60 C), including: electronic regulator, heating mixing valve, heating temperature probe, UPS pump with safety by-pass, fittings for heat meter, DHW production modulating valve, DHW temperature probe, plate heat exchanger, DHW priority flow meter, air vent cock, strainer, domestic water preheating function, dimensions L 450 x H 550 x D 265 mm. Medium: water. Maximum percentage of glycol: 30%. Maximum medium temperature: 85 C. Maximum working pressure: - primary circuit: 10 bar, domestic circuit: 10 bar. Nominal DHW exchanger capacity: 40 kw. Maximum recommended primary circuit flow rate: 1,2 m 3 /h. Maximum DHW circuit flow rate: 18 l/min. Minimum flow to activate domestic flow meter: 2,7 l/min ±0,3. Maximum pressure differential on modulating valve: 0,9 bar. Maximum pressure differential on mixing valve: 0,9 bar. Electric supply: 230 V (ac) ±10% 50Hz. Power consumption: 105 W (SATK20203HE 75 W). Protection class: IP 40. Pump: UPS (SATK20203HE UPS ). Motors: stepper 24 V. Probes: NTC 10 kω. Materials: components: brass EN CW617N. Connection pipes: copper/steel, grey PPE cover. Code SATK20303 Wall-hanging, two-way heat interface unit for high temperature heating with ON/OFF regulation and instantaneous domestic hot water production (42 60 C), including: electronic regulator, heating valve, fittings for heat meter, DHW production modulating valve, DHW temperature probe, plate heat exchanger, DHW priority flow meter, air vent cock, strainer, domestic water preheating function, dimensions L 450 x H 550 x D 265 mm. Medium: water. Maximum percentage of glycol: 30%. Maximum medium temperature: 85 C. Maximum working pressure: - primary circuit: 10 bar, domestic circuit: 10 bar. Nominal DHW exchanger capacity: 40 kw. Maximum recommended primary circuit flow rate: 1,2 m 3 /h. Maximum DHW circuit flow rate: 18 l/min. Minimum flow to activate domestic flow meter: 2,7 l/min ±0,3. Maximum pressure differential on modulating valve: 0,9 bar. Electric supply: 230 V (ac) ±10% 50Hz. Power consumption: 20 W. Protection class: IP 40. Motors: stepper 24 V. Probes: NTC 10 kω Materials: components: brass EN CW617N. Connection pipes: steel, grey PPE cover. Code SATK20403/HE Wall-hanging, two-way heat interface unit for high temperature heating with ON/OFF regulation and instantaneous domestic hot water production (42 60 C), including: electronic regulator, heating valve, fittings for heat meter, DHW production modulating valve, DHW temperature probe, plate heat exchanger, DHW priority flow meter, air vent cock, strainer, domestic water preheating function, dimensions L 450 x H 550 x D 265 mm. Medium: water. Maximum percentage of glycol: 30%. Maximum medium temperature: 85 C. Maximum working pressure: - primary circuit: 10 bar, domestic circuit: 10 bar. Nominal DHW exchanger capacity: 40 kw. Maximum recommended primary circuit flow rate: 1,2 m 3 /h. Maximum DHW circuit flow rate: 18 l/min. Minimum flow to activate domestic flow meter: 2,7 l/min ±0,3. Maximum pressure differential on modulating valve: 0,9 bar. Electric supply: 230 V (ac) ±10% 50Hz. Power consumption: 105 W (SATK20403HE 75 W). Protection class: IP 40. Pump: UPS (SATK20403HE UPS ). Motors: stepper 24 V. Probes: NTC 10 kω. Materials: components: brass EN CW617N. Connection pipes: steel, grey PPE cover. 23

24 Code SATK30103/HE Wall-hanging, two-way indirect heat interface unit (double exchanger) for low temperature heating with set point regulation (25 45 C)/medium temperature with set point regulation (50 75 C) and instantaneous domestic hot water production (42 60 C), including: electronic regulator, thermal safety thermostat, heating modulating valve, heating temperature probe, UPS pump with safety bypass, fittings for heat meter, DHW production modulating valve, DHW temperature probe, plate heat exchanger, flow temperature offset probe, DHW priority flow meter, air vent cock, strainer, filling unit with backflow preventer, safety relief valve (3 bar), expansion vessel (7,5l), pressure switch, pressure gauge, domestic water preheating function, dimensions L 550 x H 630 x D 265 mm. Medium: water. Maximum percentage of glycol: 30%. Maximum medium temperature: 85 C. Maximum working pressure: - primary circuit: 16 bar, primary circuit: 3 bar, domestic circuit: 10 bar. Nominal DHW exchanger capacity: 40 kw. Nominal heating exchanger capacity: 40 kw. Maximum recommended primary circuit flow rate: 1,2 m 3 /h, Maximum domestic circuit flow rate: 18 l/min. Minimum flow to activate domestic flow meter: 2,7 l/min ±0,3. Maximum pressure differential on modulating valve: 0,9 bar. Maximum pressure differential on mixing valve: 0,9 bar, Power supply: 230 V (ac) ±10% 50Hz. Electric consumption: 105 W (SATK30103HE 75 W). Protection class: IP 40. Pump: UPS (SATK30103HE UPS ). Motors: stepper 24 V. Probes: NTC 10 kω. Materials: components: brass EN CW617N. Connection pipes: copper or steel, grey PPE cover. We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice. Caleffi S.p.A. S.R. 229 n Fontaneto d Agogna (NO) Italy Tel Fax info@caleffi.com Copyright 2013 Caleffi