CALEFFI altecnic SATK102 Guide

SATK102
heat nterface un t
Installat on Operat on & Ma ntenance Instruct ons

SAT102 heat nterface un t
1
These nstruct ons must be read and understood
before nstall ng and ma nta n ng the HIU.
CAUTION! FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN A SAFETY
HAZARD!
1The dev ce must be nstalled, comm ss oned and
ma nta ned by qual fied techn cal personnel n accordance
w th nat onal regulat ons and/or relevant local
requ rements.
2If the dev ce s not nstalled, comm ss oned and ma nta ned
correctly n accordance w th the nstruct ons prov ded n
th s manual, t may not work correctly and may endanger
the user.
3Flush the p pework thoroughly before nstall ng the HIU to
remove any part cles, rust, ncrustat ons, l mescale, weld ng
slag and any other contam nants.
The water c rcu ts must be clean and free from debr s.
4Make sure that all connect on fitt ngs are watert ght.
5When connect ng water p pes, make sure that threaded
connect ons are not mechan cally overstressed. Over t me
th s may result n breakage, caus ng water damage and/or
personal njury.
6Water temperatures h gher than 50˚C may cause severe
burns. When nstall ng, comm ss on ng and ma nta n ng the
dev ce, take the necessary precaut ons so that these
temperatures w ll not be hazardous for people.
7In the case of part cularly hard or mpure water, there must
be su table prov s on for filter ng and treat ng the water
before t enters the dev ce, n accordance w th current
leg slat on. Fa lure to do so may result the HIU becom ng
damaged or work ng ncorrectly.
8Any use of the HIU other than t’s ntended use s
proh b ted
Product Range
SATK10253 40 kW plate heater exchanger.
SATK10203 40 kW plate heater exchanger and pr mary
pump.
SATK10203HE 40 kW plate heater exchanger and h gh
effic ency pr mary pump.
SATK10254 70 kW plate heater exchanger.
SATK10204 70 kW plate heater exchanger and pr mary
pump.
SATK10204HE 70 kW plate heater exchanger and h gh
effic ency pr mary pump.
SATK10255 80 kW plate heater exchanger.
SATK10205 80 kW plate heater exchanger and pr mary
pump.
SATK10205HE 80 kW plate heater exchanger and h gh
effic ency pr mary pump.
Safety Instruct ons
SATK102
Funct on
SATK102 Heat Interface Un ts (HIU) control the domest c hot
water generat on n an nd v dual apartment w th n a central sed
bo ler or d str ct heat ng system.
Wall mounted un t.
NOTE: Due to the spec ficat on ordered, or the country of
dest nat on, the actual un t may d ffer from those shown.
Content
Funct on and product range 1
Safety nstruct ons 1
Techn cal spec ficat on 2
D mens ons and components 3
Installat on 4
F ll ng the pr mary heat ng system 4
System start up 4
Energy meter nstallat on 5
Electron c controller 5
D p sw tch sett ngs 5
Safety and alarms 6
Ma ntenance 7
Electr c connect ons 9
Trouble shoot ng and solut on 10
WARNING

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Key to SymbolsSafety Instruct ons
9Any coupl ng of the dev ce w th other system components
must be made wh le tak ng the operat onal character st cs of
both un ts nto cons derat on.
10An ncorrect coupl ng could comprom se the operat on of
the dev ce and/or system.
11 If the system s prone to ‘water hammer’ a water hammer
arrester must be nstalled.
12If hot water rec rculat on s present or a non-return valve s
nstalled n the cold water nlet, prov s on must be made to
accommodate water expans on by fitt ng an expans on vessel.
NOTE: R sk of electr c shock. L ve parts. Shut off the electr c
supply before open ng the HIU cover.
1Dur ng nstallat on and ma ntenance operat ons, always
avo d d rect contact w th l ve or potent ally hazardous parts.
2The dev ce must not be exposed to water drops or hum d ty,
d rect sunl ght, the elements, heat sources or h gh ntens ty
electromagnet c fields.
Th s dev ce cannot be used n areas at r sk of explos on or
fire.
3The dev ce must be connected to an ndependent b polar
sw tch. If work has to be done on the dev ce, sw tch off the
electr c supply first. Do not use dev ces w th automat c or
t me reset, or wh ch may be reset acc dentally.
4Use su table automat c protect on dev ces n compl ance
w th current leg slat on.
5The dev ce must always be earthed before t s connected to
the electr c supply. If the dev ce has to be removed, always
d sconnect the earth connect on after d sconnect ng the
electr c supply. Check that the earth connect on has been
made to the h ghest of standards under current leg slat on.
6Electr cal nstallat on must only be carr ed out by a qual fied
techn c an, n accordance w th current requ rements.
General Informat on
•Please leave the manual as a reference gu de for the user.
•D spose of any packag ng n an appropr ate manner, most
of wh ch can be recycled.
•In th s Installat on, Operat on and Ma ntenance gu de we
have endeavoured to make the nformat on as accurate as
poss ble.
We cannot accept any respons b l ty should t be found that n
any respect the nformat on s naccurate or ncomplete or
becomes so as a result of further developments or changes to the
products.
Techn cal Spec f cat on
Med um: Water
Max. percentage of glycol 30%
Max. temperature: 85˚C
Max. stat c work ng pressure: Pr mary: 10 bar
Domest c hot water: 10 bar
Pr mary d fferent al pressure capab l ty: 0.9 bar
M n.flow rate to act vate domest c flow sensor: 2.7 l/m n ±0.3
Power supply: 230 V (ac)±10% 50 Hz
Power consumpt on: 105 W (SATK 102)
75 W (SATK 102...HE)
Protect on class: IP 40
Pump: UPS 15/60 (SATK 102)
UPS2 15/60 (SATK 102...HE)
Actuator: stepper 24 V
Probes: NTC 10 kΩ
Mater al
Components: brass BS EN 12165 CW617N
P pes: sta nless steel
Frame: galvan sed steel
Heat Exchanger: braze welded sta nless steel
Model Kv Power Output Max DHW flow rate
SATK102...3 1.8 40 kW 18 l/m n
SATK102...4 2.3 70 kW 27 l/m n
SATK102...5 2.4 80 kW 30 l/m n
Primary circuit flow
Primary circuit return
Cold water inlet
Domestic hot water outlet

SAT102 heat nterface un t
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D mens ons
Components
2
1
1
3
2
4
5
6
97
8
Item Component
1 Frame
2 Electron c controller
3 Pump (SATK1020X/SATK1020X HE)
4 DHW temperature sensor and stra ner
5 Flow temperature pocket probe
6 Energy meter spool p ece
7 Plate heat exchanger
8 Flow sw tch
9 Modulat ng pr mary control valve
A B C D E F G H J K L M
G¾B G1B 230 476 99 147 399 252 112 188 69 139
2
1
A
B
C
L
K
M
B
A
D
EF
G
H
J J

SAT102 heat nterface un t
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Installat on
The SATK ser es HIUs are des gned for nstallat on n a sheltered
domest c env ronment (or s m lar), therefore cannot be nstalled
or used outdoors, .e. n areas d rectly exposed to atmospher c
agents. Outdoor nstallat on may cause malfunct on ng and
hazards.
If the dev ce s enclosed ns de or between cab nets, suffic ent
space must be prov ded for rout ne ma ntenance procedures. It s
recommended that electr cal dev ces are NOT placed underneath
the HIU, as they may be damaged n the event of leakage from
any hydraul c component of connect on.
If th s adv ce s not heeded, the manufacturer cannot be held
respons ble for any result ng damage.
In the event of a malfunct on, fault or ncorrect operat on, the
dev ce should be deact vated; contact a qual fied techn c an for
ass stance.
NOTE for all models:
If a non-return valve s fitted nto the domest c hot water (DHW)
cold water nlet, prov s on MUST be made to accommodate the
expans on of the DHW conta ned w th n the HIU.
Preparat on
After establ sh ng the pos t on where the HIU w ll be nstalled,
perform the follow ng operat ons:
•Mark the holes requ red for secur ng the HIU to the wall.
•Mark the pos t on of the water p pe connect ons.
Check the measurements aga n before nstall ng p pework and
electr cal cables.
Hydraul c connect ons:
1connect on to the p pework from the central sed bo ler plant
2domest c water c rcu t connect on
Electr cal:
1electr c supply l ne 230 V (ac) – 50 Hz
2t me clock/thermostat l ne (potent al-free)
3central sed bus l ne for heat meter data transm ss on ( f
requ red)
4central sed electr c supply l ne for heat meter ( f requ red)
The whole system should be thoroughly flushed to remove any
debr s that may be n the supply p pework to the HIU and to the
domest c hot water p pework n the apartment before connect ng
the HIU.
F x the HIU to the wall
N.B.: the wall anchors (not suppl ed) can only guarantee effect ve
support f nserted correctly ( n accordance w th good techn cal
pract ce) nto walls bu lt us ng sol d or sem -sol d br cks. If
work ng w th walls bu lt us ng perforated br cks or blocks, mob le
d v d ng panels or any masonry walls other than those nd cated,
a prel m nary stat c test must be carr ed out on the support
system.
Isolat on Valves
Depend ng on the spec ficat on ordered, the HIU may be
suppl ed w th a var ety of solat on valves. We recommend that
all connect ons are fitted w th solat on valves to allow any
ma ntenance work to be carr ed out.
We would also recommend that the pr mary system ncludes a
flush ng bypass, w th an solat on valve, mmed ately upstream
of the HIU, to allow the pr mary system to be flushed pr or to
the first operat on of the un t.
Electr cal Connect ons
Make sure that the electr cal system can w thstand the
max mum power consumpt on of the appl ance, w th part cular
emphas s on the cross-sect on of the cables.
If n doubt, contact a qual fied techn c an to thoroughly check
the electr cal system.
Electr cal safety of the appl ance s only ach eved when t s
correctly connected to an effect ve earth ng system,
constructed as spec fied n current safety regulat ons. Th s s a
compulsory safety requ rement.
Connect on to the ma n supply
The dev ce s suppl ed w th an electr c supply cable - plug not
suppl ed.
The dev ce should be electr cally connected to a 230 V (ac)
s ngle phase + earth ma ns supply us ng the three-w re cable
marked w th the label as spec fied below, observ ng the LIVE (L)
- NEUTRAL (N) polar t es and the earth connect on.
Th s l ne must be connected to a c rcu t breaker dev ce.
F ll ng the pr mary heat ng system
Open the solat on valves on the connect ons to the central sed
bo ler plant to fill and pressur se the system to the des gn
pressure.
Once completed, vent the system and check the system
pressure aga n, repeat the fill ng process f necessary.
System start-up
Before us ng the HIU, v sually check that the hydraul c
connect ons are water t ght and the electr cal w r ng.
After complet ng the checks, sw tch on the electr c ty supply to
the HIU and check for the presence of any error s gnals.
If error s gnals are nd cated, el m nate the fault us ng the
procedure descr bed on page 6.
For HIUs w th an ntegral pump the follow ng appl es;
Once the HIU s hydraul cally filled (pr mary and
secondary), the HIU should be left permanently connected
to the ma ns supply and sw tched on. Th s allows the un t
to operate ts pump ant -clog protocol.

SAT102 heat nterface un t
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User Interface
The user nterface, bu lt nto the PCB, cons sts of the follow ng
dev ces.
•Ind cator LED
The var ous funct ons and faults are s gnalled by e ther
flash ng or permanent llum nat on of the LEDs.
Energy meter nstallat on
The HIU s des gned to nclude a compact energy meter w th
ntegral return probe, w th 1” threaded connect ons and 130 mm
overall body length.
Before carry ng out any ma ntenance, repa r or part replacement
work, proceed as follows:
•turn off the electr c supply
•close the solat on valves
•dra n the HIU us ng the dra n cocks prov ded
•remove the spool p ece (6)
•remove the blank ng plug
•nstall the flow probe n the ¼
” pocket prov ded (5)
•nstall the flow meter on the return p pe.
Please refer to the heat meter techn cal data sheets for further
nformat on.
Electron c controller
Operat ng Pr nc ple
All funct ons offered by SATK102 HIUs are controlled by a d g tal
controller.
The controller s factory set w th d fferent parameters and
sett ngs depend ng on the model.
There are a number of spec fic DIP SWITCHES on the controller
c rcu t board; the way these are configured w ll determ ne the
funct ons enabled.
Automat c controller funct on
Reset m x ng/modulat ng valve to zero
Immed ately after the power supply has been sw tched on, the
pos t on of the m x ng/modulat ng valve s reset to zero.
Pump ant -clog
When the pump s not n use, t s powered on for a per od of 5
seconds every 24 hours.
M x ng valve/modulat ng valve ant -clog
The ant -clogg ng cycle for the m x ng/modulat ng valve s run
every 24 hours.
Tr mmers for set po nt sett ngs
These allow the temperature of the domest c hot water cycle
to be set and the r values w ll be d splayed on the LCD d splay.
LCD d splay
The set domest c hot water temperature and error codes are
d splayed.
D p sw tches
D p sw tches allow the setup of the var ous models and
opt onal funct ons to be act vated.
Default sett ngs:
3 45 6
ON
21
Light grey: Factory set - do not alter
May be changed to activate optional functions - see page 6
88
Domestic watertemperature
ON Electric supply 230V(ac)
DHW Domestic hotwaterON
FAULT Fault detected
654 23 1

SAT102 heat nterface un t
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Operat ng Cycles
Domest c water generat on
When the domest c hot water s act vated by a water outlet (user’s tap)
be ng opened, detected by the domest c water flow meter, the electron c
controller regulates the modulat ng valve open ng so as to adjust the
temperature detected to the selected set po nt value.
At the end of the draw ng-off procedure, the modulat ng valve s fully
closed.
The act ve domest c water cycle s s gnalled by the yellow DHW LED
wh ch comes on.
The domest c water temperature can be set us ng tr mmer P1 and s
shown on the LCD d splay.
Opt onal funct ons
When act vat ng or de-act vat ng the opt onal funct ons the electr c ty
supply must always be turned off.
Domest c water generat on
Domest c water preheat ng funct on
The funct on s enabled by sett ng d p sw tch 5 to the ON pos t on.
Dur ng per ods when the domest c water cycle s not used, f the
DHW probe detects a temperature 10°C below the SET value, the
controller part ally opens the domest c water modulat ng valve for the
t me requ red (max. 5 m ns) to br ng the temperature detected up to a
value 5˚C below the set po nt value.
The domest c water preheat ng funct on s s gnalled by the flash ng
yellow DHW LED.
Safety and alarms
Error codes assoc ated w th faults s gnalled by the l ght ng up of the
FAULT LED are also shown on the d splay.
Domest c water probe fault
Error code: 6
Remov ng the fault
Normal operat on w ll be restored once the probe has been replaced.
Incorrect sw tch sett ng
Error code: 79
Remov ng the fault
Restore correct sw tch sett ng - see page 5
79
48
P2
P1
5
ON
48
6

SAT102 heat nterface un t
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Ma ntenance
All ma ntenance procedures should be carr ed out by an author sed
techn c an.
Regular ma ntenance guarantees better effic ency and helps to save
energy.
Before carry ng out any ma ntenance, repa r or part replacement work,
proceed as follows:
•Sw tch off the electr c ty supply
•Close the solat on valves
•Dra n the HIU us ng the dra n cocks prov ded.
Heat exchanger replacement
•To remove the heat exchanger, loosen ng the 2 socket head screws
hold ng t n place (A)
•Replace the heat exchanger and the O-r ngs.
•Re-t ghten the 2 fix ng screws (A) to a max mum torque of 3Nm.
N.B. The p ns fix ng the heat exchanger are pos t oned n such a way as
to prevent t be ng fitted ncorrectly.
Temperature probe replacement
•D sconnect the probe cable, l ghtly fold ng the tab (C) and
extract ng the connector.
•Unscrew the probe.
•F t the new probe.
•Re-fit the connector respect ng the only poss ble way t can be
nserted.
Replac ng the valve actuator
•D sconnect the actuator cable, l ghtly press ng the tab on the
connector and extract ng t.
•Extract the fix ng cl p (D) and then the actuator.
•Pos t on the new actuator (E).
•Insert the fix ng cl p, respect ng the correct d rect on.
•Re-connect the connector.
Replac ng the valve obturator
•D sconnect the valve actuator - see prev ous sect on.
•Unscrew ng the lock nut (F) and extract the obturator.
•Replace the obturator and then refit the lock nut (F).
•Insert the fix ng cl p, respect ng the correct d rect on.
•Re-connect the connector.
Replac ng the DHW pr or ty flow meter
•D sconnect the flow meter cable from the connector.
•Extract the flow sensor (G).
•Pos t on and fit the new sensor.
•Re-connect the cable respect ng the only poss ble way t can be
nserted.
G
F
D
E
C
A
A

SAT102 heat nterface un t
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Replac ng or clean ng the DHW pr or ty flow meter turb ne
•Extract the flow sensor.
•Unscrew and remove the cartr dge (H).
•Remove any mpur t es present or change the cartr dge f necessary.
•Screw the cartr dge back nto pos t on.
•Re-pos t on the flow sensor.
When carry ng out ma ntenance on the electr cal part, for the
connect ons follow the d agram on page 8.
After conclud ng ma ntenance, proceed w th the fill ng and check ng
operat ons descr bed n the chapter “Comm ss on ng” - see page 4.
If you requ re any nformat on regard ng replacement components,
please contact Altecn c.
H

SAT102 heat nterface un t
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Electr cal W r ng
FUSE 5x20
123456
12 3
4
5
7
6
L
N Electric supply:
230 V (ac) ±10%
50 Hz
1DHW temperature probe
2
3
4
5
6
7
DHW flow meter
DHW modulating valve actuator
Earth
Pump
Fuse
Power Supply 230 V (ac)*
XX
XX
XX
XX
XX
XX
X
*Wiring to be made during installation
SATK1025X
SATK100X/HE

SAT102 heat nterface un t
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Fault F nd ng
Fault Ind cat ons Poss ble Cause of Fault Operat ons to be Performed
The water s not
heat ng
DHW LED on
pr mary c rcu t solat ng valve closed open the solat ng valve
modulat ng valve actuator connector d sconnected re-connect actuator connector
modulat ng valve actuator d sconnected from valve body re-connect actuator
modulat ng valve actuator faulty call qual fied personnel to have t replaced
clogged stra ner and/or heat exchanger call qual fied personnel to have t replaced
presence of a r n the system vent the system
electron c controller not work ng call qual fied personnel to have t replaced
valve obturator blocked n closed pos t on call qual fied personnel to have t replaced
central sed system not work ng contact person n charge of system
FAULT led l t + error
code 6 act ve
DHW temperature probe d sconnected re-connect probe
DHW temperature probe faulty call qual fied personnel to have t replaced
FAULT led l t + error
code 79 act ve ncorrect d p sw tch sett ng restore correct sw tch sett ng
DHW Led off
DHW pr or ty flow meter d sconnected re-connect flow meter
DHW pr or ty flow meter faulty call qual fied personnel to have t replaced
electron c controller not work ng call qual fied personnel to have t replaced
all LEDs are off
electr c ty power supply sw tched off sw tch on electr c ty supply
protect on fuse burnt out call qual fied personnel to have t replaced
electron c controller not work ng call qual fied personnel to have t replaced
The water s hot but
does not reach the
des red temperature
DHW led on
domest c water cycle temperature set po nt too low ncrease set po nt
HIU stra ner clogged call qual fied personnel to have t serv ced
exchanger partly clogged call qual fied personnel to have t serv ced
modulat ng valve actuator faulty call qual fied personnel to have t replaced
valve obturator blocked n ntermed ate pos t on call qual fied personnel to have t replaced
modulat ng valve actuator connector d sconnected re-connect actuator connector
excess ve demand for DHW decrease demand
electron c controller not work ng call qual fied personnel to have t replaced
central sed system temperature nsuffic ent contact person n charge of system
pr mary c rcu t flow rate nsuffic ent contact person n charge of system
The hot water
temperature s too
h gh
DHW led on
domest c water cycle temperature set po nt too h gh decrease set po nt
modulat ng valve actuator faulty call qual fied personnel to have t replaced
valve obturator blocked n ntermed ate or open pos t on call qual fied personnel to have t replaced
electron c controller not work ng call qual fied personnel to have t replaced
Hot water flow rate
s nsuffic ent DHW led on
HIU stra ner clogged call qual fied personnel to have t replaced
domest c water system shut-off valves partly open open the valves
central sed domest c c rcu t cold water flow rate nsuffic ent call qual fied personnel to have t serv ced
The s no hot water
flow DHW led off
poss ble domest c water system shut-off valves closed open the valves
no cold water n central sed domest c c rcu t call qual fied personnel to have t serv ced
HIU stra ner completely clogged call qual fied personnel to have t serv ced
heat exchanger completely blocked call qual fied personnel to have t serv ced

SATK102 heat nterface un t
Altecn c Ltd Mustang Dr ve, Stafford, Staffordsh re ST16 1GW
T: [phone] E: sales@altecn c.co.uk
Reg stered n England No: 2095101
altecn c.co.uk
IOM 069 09-12-16
E & O.E
Notes: