CALEFFI Altecnic SATK40103 Guide

SATK40 & Procyl®
heat interface unit
Installation Operation & Maintenance Instructions

SATK40 & Procyl®
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.
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.
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
SATK40 and Procyl®components 8
Maintenance 14
Electric connections 16
Trouble shooting and solution 27
Product Range
SATK40103 Wall-mounted indirect Heat Interface Unit
(HIU) for use with Domestic Hot Water
(DHW) indirect storage cylinder.
SATK40103 HE As SATK4013 but with high efficiency pump.
SATK40103 Floor standing or wall mounted indirect Heat
Procyl®Interface Unit (HIU) with Domestic Hot
Water (DHW) indirect storage cylinder.
SATK40103 HE As SATK4013 Procyl®but with high efficiency
Procyl®pump.
Safety Instructions
SATK40103
Function
SATK40 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

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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
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 cold water inlet
Lowtemperaturecircuit flow
Lowtemperaturecircuitreturn
Cylinder circuit flow
Cylinder circuitreturn
Hightemperaturecircuit flow
Hightemperaturecircuitreturn

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Dimensions - SATK40103 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, 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.
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 connections
3storage cylinder connections
4domestic water circuit connection
5discharge from safety relief valve
Electrical:
1electric supply line 230 V (ac) – 50 Hz
2time clock/thermostat line (potential-free)
3boiler thermostat (potential contact)
4centralised bus line for heat meter data transmission (if
required)
5centralised electric supply line for heat meter (if required)
Technical Specification
Medium: water
Maximum percentage of glycol: 30%
Maximum medium temperature: 85˚C
Maximum working pressure: - primary circuit: 16 bar
- secondary circuit: 3 bar
Nominal DHW exchanger capacity: 50 kW
Maximum recommended primary circuit flow rate: 1,2 m3/h
Maximum differential pressure on modulating valve: Δp 1.5 bar
Power supply: 230 V (ac) ±10% 50Hz
Pump SATK40103 HE: UPS2 15-60
Power consumption: 75 W
Pump SATK40 103: UPS 15-60
Power consumption: 105 W
Protection class: IP 40
Pump by-pass 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
Min. incoming domestic water pressure 0.5 bar
A B C D E F kg
G¾B G¾B G¾ 65 550 630 16
F
D
CC
E
AABB
DD
Depth inc.
cover 265
1
0
2
3
4
ON DHW CH FAULT
RESET
1
2

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Installation
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 indirect storage cylinder 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
The SATK40 is supplied with 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.
Heat Meter Installation
The HIU is designed to house a compact heat meter (installed
in return pipe) with 1” threaded connections and 130 mm long.
Before carrying out any maintenance, repair or part
replacement
work, proceed as follows:
•switch off the electric supply
•remove the cover
•close the shut-off 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
Room thermostat
A
B
Electrical supply:
230 V(ac) ±10% - 50 Hz
l
NB - Please install the
valves as shown

SATK40 & Procyl®
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Electrical Connections
Connecting to the storage cylinder ancillary equipment
When a hot water storage cylinder is used it will require
ancillary control/safety equipment which will require wiring
externally to the electricity connection box (15).
The hot water timer (17), cylinder temperature controller (high
limit thermostat (18) and temperature control thermostat (19))
and the motorised valve must be wired from the electricity
supply connection terminal (11) to the storage cylinder
connection (14) in series as shown in Electrical Wiring on page
12.
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
The SATK40 HIU is 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.
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).
NOTE: For UK markets, a filling loop is supplied in lieu of the
back-flow preventer.
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,
setting the domestic water temperature and the heating
controller to the desired temperatures and times. Check that
the operating cycles are correct.
Once the HIU is hydraulically filled (primary and sec ndary),
the HIU sh uld be left permanently c nnected t the mains
supply and switched n. This all ws the unit t perate its
pump anti-cl g pr t c l.
Electronic Controller
Operating Principle
All heating and domestic hot water functions offered by
SATK40 are controlled by a digital controller.
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.
Automatic Controller Functions
Reset mixing/modulating valve to zero
Immediately after the power supply has been switched on,
the position of the installed mixing/modulating valve is reset
to zero.
654 23 1
A
B
3
2
1

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Pump anti-clog
When the pump is not in use it is powered 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.
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.
•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 set point and the error codes.
•Dip switches
These enable the setting of the option functions.
Compensation probe fault - Error code: 15
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
The SATK40 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.
NOTE: A low vessel pre-charge value could cause a pressure
fault.
Removing a fault
Once the correct pressure has been achieved
on the heating circuit, the controller can be
reset.
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
Removing a fault
Normal operation will be restored once the probe is replaced.
(see page 11).
5
15
4
ON
1 2 3 5 6 4
88
DHW/heating modulating
function
Heating temperature
ON Electric supply 230V(ac)
DHW Domestic hotwaterON
CH Heating ON
FAULT Fault detected
RESET

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Safety thermostat cutout - Error code: 69
LOW temperature setting
The HIU 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 and the mixing valve
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.
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.
Switch setting incorrect - Error code: 79
Removing a fault
Restore correct dip switch settings (see page 8)
79
69

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Components - SATK40103
Item Component
1 Frame
2 Expansion vessel
3 Electronic control unit
4 Primary modulating control valve
5 Three port diverting valve
6 Plate heat exchanger (DHW + space heating)
7 Safety relief valve - 3 bar
9 Drain cock
12 Heat meter spool piece - replaced by heat meter when fitted
14 Heating flow temperature sensor
15 Pump
16 Pump safety bypass
18 DP switch
19 Strainer (heating circuit)
22 Primary filter and heat meter probe pocket
23 Heating return temperature sensor
24 Primary isolation valve
25 Probe
26 Pressure gauge
27 Electric connection box
26 Filling loop double check valve*
27 Filling loop*
28 Filling loop isolation valve*
29 Room controller*(not supplied)
*Not shown on Components illustration
Functional characteristics
Heating range:
LOW temperature setting 25 to 45˚C.
MEDIUM/HIGH temperature setting 50 to 75˚C
Optional functions
Heating cycle: modulating temperature regulation with
compensated set point floor slab heating
function.
Factory settings
SATK 40103 HIUs are factory set to support MEDIUM/HIGH
temperature heating (50 to 75˚C) with the dip switches set as
shown.
To modify the factory settings and enable the HIU to support
LOW temperature systems (25 to 45˚C) proceed as follows;
1Switch off the electricity power supply to the HIU
2Set the switches 2 and 3 with the ON-OFF setting
3 Remove the safety thermostat umper cable and
connect the cables to the thermostat.
4Switch on the electricity power supply to the HIU.
Factory settings
Factory set - DO NOT CHANGE
May be switched to activate optional functions
Switch 1: modulating temperature regulation
with compensated set point
Switch 2-3: change setting
ON
1 2 3 5 6 4
1
0
2
3
4
ON DHW CH FAULT
RESET
1
2
1
20
11
5
28
14
15
2
24
19
4
2
3
16
17
23 22
8
2
12
18
21
ON
1 2 3 5 6 4

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Operating Cycles
Domestic water generation:
When a tap or shower is turned on the domestic water cycle is
activated, due to the storage thermostat intervention.
To restore the temperature of the stored water in the cylinder
the unit begins repeated 10 minute cycles.
After the first 10 minute cycle has been completed a second
cycle begins again supplying only the cylinder with heat
followed by a third or fourth until the water in the cylinder has
reached the set temperature.
To enable the division of the 10 minute cycle, to apportion the
time for heating and DHW, dip switch 5 needs to be on.
By altering P1 a portion of each 10 minute can be directed to
the space heating circuit, for example 9 minutes to the cylinder
and 1 minute to the heating circuit or 7 minutes to the cylinder
and 3 minutes to the heating circuit.
When the specified domestic hot water temperature is reached,
the circulation pump switches off and the modulating valve is
closed again.
The domestic water cycle, when active, is indicated by the
steady yellow DHW LED while the symbol is blinking.
The temperature of the hot domestic water within the indirect
cylinder should be set using the cylinder thermostat (only
supplied with the Procyl®option).
Heating cycle: Set point regulation
When space heating 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.
The heating cycle temperature set point can be set using
trimmer P2 and shown on the display.
Under floor heating function: at LOW temperature setting
This cycle aids the drying of the underfloor heating screed 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 under floor heating drying
function is in operation.
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.
Optional functions - to activate/deactivate the optional
functions the electric power supply must always be turned off.
Operating Cycles
25
8 seconds
60
P2
P1
––
P2
P1
ON
1 2 3 5 6 4