CALEFFI Altecnic SATK20 Leitfaden
SATK20 & SATK30
heat interface unit
Installation Operation & Maintenance Instructions
SATK20 & SATK30
1
These instructi ns must be read and underst d
bef re installing and maintaining the HIU.
CAUTION! FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN A SAFETY
HAZARD!
1The device must be installed, commissioned and
maintained by qualified technical personnel in accordance
with national regulations and/or relevant local
requirements.
2If the device is not installed, commissioned and maintained
correctly in accordance with the instructions provided in
this manual, it may not work correctly and may endanger
the user.
3Flush the pipework thoroughly before installing the HIU to
remove any particles, rust, incrustations, limescale, welding
slag and any other contaminants.
The water circuits must be clean and free from debris.
4Make sure that all connection fittings are watertight.
5When connecting water pipes, make sure that threaded
connections are not mechanically overstressed. Over time
this may result in breakage, causing water damage and/or
personal in ury.
Content
Function and product range 1
Safety instructions 1
Dimensions and technical specification 3
Installation 4
First operation 5
Electronic controller 6
Safety and alarms 7
SATK20103 and SATK20203 components 8
SATK20303 components 10
SATK30103 components 12
SATK30105 components 12
Maintenance 14
Electric connections 16
Trouble shooting and solution 17
Product Range
SATK20103 Direct wall-mounted HIU for LOW temperature
heating, instantaneous domestic hot water
production.
SATK20203 Direct wall-mounted HIU for MEDIUM
temperature heating, instantaneous domestic
hot water production.
SATK20303 Direct wall-mounted HIU for HIGH temperature
heating, instantaneous domestic hot water
production.
SATK30103 Indirect wall-mounted HIU, instantaneous DHW
production - with 50 kW heat exchanger.
SATK30105 Indirect wall-mounted HIU, instantaneous DHW
production - with 75 kW heat exchanger.
Safety Instructions
SATK20
SATK30
Function
SATK20 and SATK30 Heat Interface Units (HIU) control the
heating and domestic hot water generation in an individual
apartment within a centralised boiler or district heating system.
NOTE: Due to the specification ordered, or the country of
destination, the actual unit may differ from those shown.
WARNING
SATK20 & SATK30
2
General Information
•Please leave the manual as a reference guide for the user.
•Dispose of any packaging in an appropriate manner, most
of which can be recycled.
•In this Installation, Operation and Maintenance guide we
have endeavoured to make the information as accurate as
possible.
We cannot accept any responsibility should it be found
that in any respect the information is inaccurate or
incomplete or becomes so as a result of further
developments or changes to the products.
Key to SymbolsSafety Instructions
6Water temperatures higher than 50˚C may cause severe
burns. When installing, commissioning and maintaining the
device, take the necessary precautions so that these
temperatures will not be hazardous for people.
7In the case of particularly hard or impure water, there must
be suitable provision for filtering and treating the water
before it enters the device, in accordance with current
legislation. Failure to do so may result the HIU becoming
damaged or working incorrectly.
8Any use of the HIU other than it’s intended use is prohibited.
9Any coupling of the device with other system components
must be made while taking the operational characteristics of
both units into consideration.
10An incorrect coupling could compromise the operation of
the device and/or system.
NOTE: Risk of electric shock. Live parts. Shut off the electric
supply before opening the HIU cover.
1During installation and maintenance operations, always
avoid direct contact with live or potentially hazardous parts.
2The device must not be exposed to water drops or humidity,
direct sunlight, the elements, heat sources or high intensity
electromagnetic fields.
This device cannot be used in areas at risk of explosion or
fire.
3The device must be connected to an independent bipolar
switch. If work has to be done on the device, switch off the
electric supply first. Do not use devices with automatic or
time reset, or which may be reset accidentally.
4Use suitable automatic protection devices in compliance
with current legislation.
5The device must always be earthed before it is connected to
the electric supply. If the device has to be removed, always
disconnect the earth connection after disconnecting the
electric supply. Check that the earth connection has been
made to the highest of standards under current legislation.
6Electrical installation must only be carried out by a qualified
technician, in accordance with current requirements.
Primary circuit flow
Primary circuit return
Domestic hotwateroutlet
Domestic cold water inlet
Lowtemperaturecircuit flow
Lowtemperaturecircuitreturn
Mediumtemperaturecircuit flow
Mediumtemperaturecircuitreturn
Hightemperaturecircuit flow
Hightemperaturecircuitreturn
SATK20 & SATK30
3
Dimensions - SATK20
Dimensions - SATK30
A B C kg
G¾B G½B G¾B 16
A B C kg
G¾B G½B G¾B 19
550
AABB
65 65
450
CC
59 101 160
65190 195
430
15490
46
10 245
110
265
110
85
AA
B
B
629
65 65
550
CC
159 101 160
65
290 195
530
15
565
49
10 245
110
265
110
85
SATK20 & SATK30
4
Technical Specification - SATK20
Medium: Water
Max. percentage of glycol 30%
Max. temperature: 85˚C
Max. working pressure: Primary circuit: 10 bar
Domestic hot water: 10 bar
Nom. DHW heat exchanger net output: 50 kW
Max. recommended primary circuit flow rate: 1.2 m³/h
DHW circuit max. flow rate: 18 l/m (0.3 l/s)
Min.flow rate to activate domestic flow sensor: 2.7 l/m ±0.3
Max. differential pressure on domestic
water modulating valve: ∆p 0.9 bar
Max. differential pressure on mixing valve: ∆p 0.9 bar
Power supply: 230 V (ac)±10% 50 Hz
Power consumption: 105 W (SATK 20203)
Protection class: IP 40
Pump: UPS 15/60
Pump bypass setting: 0.45 bar
Actuator: stepper 24 V
Probes: NTC 10 kΩ
Safety thermostat: 55˚C ±3
Technical Specification - SATK30
Medium: Water
Max. percentage of glycol 30%
Max. temperature: 85˚C
Max. working pressure: Primary circuit: 16 bar
Secondary circuit: 3 bar
Domestic hot water: 10 bar
Nom. heating exchanger net output: 15 kW
Nom. DHW heat exchanger net output:
SATK30103: 50 kW
SATK30105: 75 kW
Max. recommended primary circuit flow rate: 1.2 m³/h
DHW circuit max. flow rate: 18 l/m (0.3 l/s)
Min.flow rate to activate domestic flow sensor: 2.7 l/m ±0.3
Max. differential pressure on domestic
water modulating valve: ∆p 0.9 bar
Power supply: 230 V (ac)±10% 50 Hz
Power consumption: 105 W
Protection class: IP 40
Pump: UPS 15/60
Pump bypass setting: 0.45 bar
Actuator: stepper 24 V
Probes: NTC 10 kΩ
Safety relief valve setting: 3 bar
Safety thermostat: 55˚C ±3
Expansion vessel: 7.5 litre
Pressure switch: opening 0.4 bar - closing 0.8 bar
Material
Components: brass BS EN 12165 CW617N
Pipes: stainless steel
Frame: RAL 9010 sprayed steel
Protective shell cover: PPE
Exchanger: brazed stainless steel
Installation
The SATK series HIUs are designed for installation in a sheltered
domestic environment (or similar), therefore cannot be
installed or used outdoors, i.e. in areas directly exposed to
atmospheric agents. Outdoor installation may cause
malfunctioning and hazards.
If the device is enclosed inside or between cabinets, sufficient
space must be provided for routine maintenance procedures. It
is recommended that electrical devices are NOT placed
underneath the HIU, as they may be damaged in the event of
discharge from the safety valve, if it is not connected to a
discharge tundish (SATK30103 and SATK30105), or in the event
of leaks occurring at the hydraulic fittings.
If this advice is not heeded, the manufacturer cannot be held
responsible for any resulting damage.
In the event of a malfunction, fault or incorrect operation, the
device should be deactivated; contact a qualified technician for
assistance.
NOTE for all models:
If a non-return valve is fitted into the domestic hot water
(DHW) cold water inlet, provision MUST be made to
accommodate the expansion of the DHW contained within the
HIU.
Preparation
After establishing the position where the HIU will be installed,
perform the following operations:
•Mark the holes required for securing the HIU to the wall.
•Mark the position of the water pipe connections.
Check the measurements again before installing pipework and
electrical cables.
Hydraulic connections:
1connection to the pipework from the centralised boiler
plant
2heating circuit connection
3domestic water circuit connection
4discharge from safety relief valve
Electrical:
1electric supply line 230 V (ac) – 50 Hz
2time clock/thermostat line (potential-free)
3centralised bus line for heat meter data transmission (if
required)
4centralised electric supply line for heat meter (if required)
SATK20 & SATK30
5
Room thermostat
Preparation
The whole system should be thoroughly flushed to remove any
debris that may be in the supply pipework to the HIU and to
the domestic hot water and heating pipework in the apartment
before connecting the HIU.
Fix the HIU to the wall
N.B.: the wall anchors (not supplied) can only guarantee
effective support if inserted correctly (in accordance with good
technical practice) into walls built using solid or semi-solid
bricks. If working with walls built using perforated bricks or
blocks, mobile dividing panels or any masonry walls other than
those indicated, a preliminary static test must be carried out on
the support system.
Isolation Valves
Depending on the specification ordered, the HIU may be
supplied with a variety of isolation valves. We recommend that
all connections are fitted with isolation valves to allow any
maintenance work to be carried out.
We would also recommend that the primary system includes a
flushing bypass, with an isolation valve, immediately upstream
of the HIU, to allow the primary system to be flushed prior to
the first operation of the unit.
Electrical Connections
Make sure that the electrical system can withstand the
maximum power consumption of the appliance, with particular
emphasis on the cross-section of the cables.
If in doubt, contact a qualified technician to thoroughly check
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.
Connection to the main supply
The device is supplied with an electric supply cable - plug not
supplied.
The device should be electrically connected to a 230 V (ac)
single phase + earth mains supply using the three-wire cable
marked with the label as specified below, observing the LIVE (L)
- NEUTRAL (N) polarities and the earth connection.
This line must be connected to a circuit breaker device.
Connection to the timeclock/thermostat
The SATK series HIU includes a connection, suitable for a time
clock/thermostat, allowing the tenant to control individual
apartment heating requirements
The connection to this device (potential-free contact) must be
made with the two-wire cable marked with the label as
specified below.
Should it be necessary to extend this cable, use one with the
same cross-section (max 1 mm²) and maximum length 30 m.
First Operation
Filling the central heating system
Open the isolation valves on the connections to the
centralised boiler plant to fill and pressurise the system to the
design pressure.
Once completed, vent the system and check the system
pressure again, repeat the filling process if necessary.
Filling the secondary circuit (SATK30103 & SATK30105 only)
The SATK30103 and SATK30105 HIUs are fitted with a filling
loop complete with double check valve and isolation valves.
The first time the system is filled, or for re-pressurising
following a heating circuit pressure switch fault indication,
restore the system pressure (1.2 to 2 bar) by opening the cock
(A) and monitoring the value using the pressure gauge (B).
Once the correct pressure has been reached, close the cock
(A), vent the system and check its pressure again, repeat the
filling process if necessary.
NOTE: For UK markets, a filling loop is supplied in lieu of the
back-flow preventer.
Electrical supply:
230 V(ac) ±10% - 50 Hz
A
B
SATK20 & SATK30
6
System start-up
Before switching on the HIU, visually check all oints are water
tight and the electric wiring is complete and correct. After
finishing the check, activate the electric supply to the HIU and
check for the presence of any error signals.
If any error signals are indicated, eliminate the faults indicated
and proceed as described below, setting the domestic water
temperature and the heating controller to the desired
temperatures and times. Check that the operating cycles are
correct.
Fitting the cover
Place the casing over the frame, inserting the upper tabs (1) into
the corresponding slots (2).
Place the lower part of the casing over the frame.
Tighten the screws (3).
Heat meter installation
The HIU is designed to include a compact heat meter.
Before carrying out any maintenance, repair or part
replacement work, proceed as follows:
•cut off the electric supply
•remove the cover
•close the isolating valves
•empty the HIU using the drain cocks provided
•remove the spacer piece (A)
•remove the blanking plug (B)
•install the flow probe in the 1/4” pocket (B) provided
•install the flow meter on the return pipe.
Please refer to the heat meter technical data sheets for further
information.
Heat meter installation
Electronic Controller
Operating Principle
All heating and domestic hot water functions offered by
SATK20 and SATK30 HIUs are controlled by a digital
controller.
The controller is factory set with different parameters and
settings depending on the model (Table 1).
There are a number of specific DIP SWITCHES on the
controller 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 various functions and faults are signalled by either
flashing or permanent illumination of the LEDs.
A
B
3
2
1
ON Electric supply 230V(ac)
DHW Domestic hotwaterON
CH Heating ON
FAULT Fault detected
654 23 1
SATK20 & SATK30
7
User Interface
•Reset key
This allows restoration of normal function after the
safety thermostat has been triggered and
activation/deactivation of the under floor heating
function.
•Setting the temperatures
These allow the specified temperatures for the heating and
domestic water cycles to be set and view the relative
values on the display.
•LED display
Shows the heating and domestic hot water set point
temperatures and the error codes.
•Stand-by:
The following alternate every 5 seconds on the display:
Safety and alarms
Error codes associated with faults are signalled by the
illumination of the FAULT LED shown on the display.
Heating circuit pressure switch fault - Error code: 4
SATK30103 - at LOW/HIGH temperature setting
The SATK30 HIU continuously monitors the pressure in the
apartments secondary heating circuit. If the pressure falls in
this circuit, the pressure switch is activated, the circulation
pump shuts down and the and the regulating valve closes.
Heating cycle activation is indicated by a flashing fault LED on
the electronic controller. This fault does not affect the
generation of the domestic hot water.
CODE SWITCH SETTING SET
654 3 2 1HEATING DHW
SATK20103
LOWtemperature 25 to 45˚C 42 to 60˚C
SATK20203
MEDIUMtemperature 50 to 75˚C 42 to 60˚C
SATK20303
HIGH temperature Max 85˚C 42 to 60˚C
SATK30103 & SATK30105
HIGH temperature setting 50 to 75˚C 42 to 60˚C
Tab le 1 – factory default settings
Factory set (do notchange) Mayb
echangedtoactivateoptionalfunctions
Switch 1: modulatingtemperatureregulationwithcompensated set point
Switch 2-3: change SATK30103 & SATK30105 setting to Low Temperature
Switch 5: domestic water preheating function
OFF
ON
OFF
ON
Domestic water temperature
Heating temperature
• Heating cycle ON:
The setpointtemperature is shown while the
symbol flashes:
The setpointtemperature is shown while the
symbol flashes:
• Domestic water cycle ON:
Heating temperature setpoint
60
60
48
Domestic water temperature setpoint
48
RESET
4
SATK20 & SATK30
8
Compensation probe fault - Error code: 15
SATK20103 - LOW temperature
SATK30103 - at LOW temperature setting
Domestic water probe fault - Error code: 6
Safety thermostat cutout - Error code: 69
SATK20103 - LOW temperature
SATK30103 - at LOW temperature setting
Removing a fault
Once the correct pressure has been achieved on the heating
circuit, the fault can be reset. (see page 7).
Probe fault
If the domestic water temperature probe fails, domestic water
generation will cease immediately. Heating performance will
not be affected.
If the heating probe fails, the heating will cease immediately.
The domestic water generation will not be affected. The probe
fault is indicated by a flashing fault LED on the electronic
controller.
Heating probe fault - Error code: 5
After the user has reset the isolation 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
Before resetting the controller, the manual
reset button will need to be pressed.
Safety valve fault - Error code: 76
SATK20103 - LOW temperature
Removing a fault
Normal operating conditions are restored automatically once
the faulty safety valve is working correctly again.
Safety setting incorrect - Error code: 76
Removing a fault
Normal operation will be restored once the probe is replaced.
(see page 15).
Removing a fault
Restore correct switch setting according to Table 1
Automatic controller function
Rese
t mixing/modulating valve to zero
Immediately after the power supply has been switched on,
the position of the 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.
The HIU is configured to support low temperature heating
(low temperature models only), constantly monitors the
heating flow temperature and includes a safety thermostat.
If the thermostat is activated during a general cycle, the
circulation pump will immediately stop, the mixing valve and
safety lock valve (SATK20103) will close. Safety thermostat
activation is indicated by a steady, red fault LED on the
electronic controller. This fault locks all functions.
In the event of a power failure, the thermal safety valve
prevents hot water for heating purposes from entering the
system.
15
5
6
76
79
69
SATK20 & SATK30
9
Components - SATK20103 LOW Temperature HIU
Item Component
1 Frame
2 Electronic controller
3 Thermal safety relief valve
4 Heating mixing valve
5 DHW production modulating valve
6 Heat flow temperature probe
7 Thermal safety thermostat
8 DHW temperature probe
9 DHW heat exchanger
10 Drain cock
11 UPS 15-60 pump
12 Protective pump by-pass
13 Flow temp. compensation return probe
14 DHW priority flow meter
15 Heat meter spool piece
16 Air vent cock
17 System strainer/heat meter flow probe pocket
18 Primary circuit isolating valve
Functional characteristics
Heating range: 25 to 45˚C
Set point regulation
DHW production range: 42 to 60˚C
Optional functions
Domestic water cycle: domestic water preheating function
Heating cycle: modulating temperature regulation
with compensated set point
floor slab heating function
Factory settings
Components - SATK20203 MEDIUM Temperature HIU
Item Component
1 Frame
2 Electronic controller
3 Heat mixing valve
4 DHW production modulating valve
5 Heating flow temperature probe
6 DHW temperature probe
7 DHW heat exchanger
8 Drain cock
9 UPS 15-60 pump
10 Protective pump by-pass
11 DHW priority flow meter
12 Heat meter spool piece
13 Air vent cock
14 System strainer/heat meter flow probe pocket
15 Primary circuit isolating valve
Functional characteristics
Heating range: 50 to 75˚C
Set point regulation
DHW production range: 42 to 60˚C
Optional functions
Domestic water cycle: domestic water preheating function
Factory settings
1
2
3
4
5
6
4
ON
10
11
12
13
14
15
1
2
3
4
6
7
5
9
8
1
2
3
4
5
6
4
ON
910
11
12
13
14
15
16
1
2
3
4
6
7
8
5
17
18
Dieses Handbuch passt für folgende Modelle
1
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