Evinox ModuSat FS Series User manual

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ModuSat FS Unit
Installation Manual

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CONTENTS
1GENERAL INFORMATION .............................................................................................................. 9
1.1 Warnings........................................................................................................................... 9
1.2 Symbols............................................................................................................................. 9
1.3 Safety Instructions............................................................................................................. 9
2TECHNICAL FEATURES..................................................................................................................11
2.1 Hydraulic Schematics & dimensions...................................................................................11
2.2 Dimensions.......................................................................................................................14
2.3 Technical data ..................................................................................................................16
3INSTALLATION.............................................................................................................................21
3.1 Recommended handling procedure ...................................................................................21
3.2 ModuSat FS positioning ....................................................................................................22
3.3 Checks before connecting the ModuSat FS.........................................................................23
3.4 Use of Pre-installation Rig.................................................................................................24
3.5 Installation of Safety Discharges .......................................................................................25
3.6 Pressure Independent Control Valves (PICV) ......................................................................28
4PRIMARY AND SECONDARY CIRCUIT ............................................................................................29
4.1 Water treatment ..............................................................................................................29
4.2 Cleaning ...........................................................................................................................29
4.3 Precautions ......................................................................................................................30
4.4 Bionibal............................................................................................................................31
4.5 Initial opening / filling of the unit......................................................................................32
4.6 Flushing Bypass ................................................................................................................33
4.7 Tank draining ...................................................................................................................34
5ELECTRIC CONNECTIONS..............................................................................................................36
5.1 Modusat Wiring Connections ............................................................................................37
5.2 ModuSat Connection Board (Visible once the cover is removed) .........................................39
5.3 Room controller connections.............................................................................................40
5.4 Typical ModuSat Electric Wiring Diagram (Single Room Controller)....................................42
5.5 Typical ModuSat Electric Wiring Diagram with 2 Zone Control (2 Room Controllers) ...........43
6COMMISSIONING........................................................................................................................44
6.1 Initial Commissioning Procedure .......................................................................................44

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6.2 Apartment Circuit Balancing .............................................................................................45
6.3 Use of the commissioning switch.......................................................................................46
6.4 Adjustment of TMV...........................................................................................................47
6.5 Pump Start-up - Wilo PWM Pump .....................................................................................48
6.6 Warranty..........................................................................................................................49

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Label for ModuSat FS 80
Main features (BS EN12897 2006)
Manufacturer: Evinox Energy Ltd
Unit 37, Barwell Business Park
Leatherhead Road,
Chessington, Surrey
KT9 2NY
Tel : + 44 (0)1372 722277
www.evinoxenergy.co.uk
Model: ModuSat FS 80
Serial number: ______________
Year of manufacture: ______________
Max primary flow temperature: 80 °C
Max primary pressure: 10 bar (Optional 16 bar)
DHW storage max pressure: 7.0 bar
Max secondary circuit pressure: 3.0 bar
Max water supply pressure (to
pressure reducing valve: 16.0 bar
Pressure reducing valve fixed
outlet pressure: 3.0 bar
P&T relief valve part number: Intatec TP25450570
Immersed electric heater: 3000 W, 220/240 Volt (AC)
Secondary max operating pressure: 3.0 bar
Water expansion vessel charge press.: 6.0 bar
DHW setting range: 20-80 °C
Safety thermostat intervention: 85 °C
PT relief valve: 7.0 bar / 90 °C
Expansion relief valve setting: 6.0 bar
Primary heating power: 12 kW
Primary flow rate (Nom): 720 l/h
Storage capacity: 80 l
Standing heat loss: 1.08 kWh/24h
Weight (full load): 177.5 kg
Warning to the User
Do not remove or adjust any component part of this unvented water heater: contact the
installer.
If this unvented water heater develops a fault, such as a flow of hot water from the discharge
pipe, switch the heater off and contact the installer.
Warning to the installer
This installation is subject to building regulation approval; notify the Local Authority of
intention to install.
Use only manufacturer’s recommended replacement parts.
Please leave this manual with the householder after installation.
INSTALLED BY: Name: ________________________________________
Address: ________________________________________
Tel No. ________________________________________
Completion date: ________________________________________

5
Label for ModuSat FS 150
Main features (BS EN12897 2006)
Manufacturer: Evinox Energy Ltd
Unit 37, Barwell Business Park
Leatherhead Road,
Chessington, Surrey
KT9 2NY
Tel : + 44 (0)1372 722277
www.evinoxenergy.co.uk
Model: ModuSat FS 150
Serial number: ______________
Year of manufacture: ______________
Max primary flow temperature: 80 °C
Max primary pressure: 10 bar (Optional 16 bar)
DHW storage max pressure: 7.0 bar
Max secondary circuit pressure: 3.0 bar
Max water supply pressure (to
pressure reducing valve: 16.0 bar
Pressure reducing valve fixed
outlet pressure: 3.0 bar
P&T relief valve part number: Intatec TP25450570
Immersed electric heater: 3000 W, 220/240 Volt (AC)
Secondary max operating pressure: 3.0 bar
Water expansion vessel charge press.: 6.0 bar
DHW setting range: 20-80 °C
Safety thermostat intervention: 85 °C
PT relief valve: 7.0 bar / 90 °C
Expansion relief valve setting: 6.0 bar
Primary heating power: 15 kW
Primary flow rate (Nom): 720 l/h
Storage capacity: 150 l
Standing heat loss: 1.80 kWh/24h
Weight (full load): 270 kg
Warning to the User
Do not remove or adjust any component part of this unvented water heater: contact the
installer.
If this unvented water heater develops a fault, such as a flow of hot water from the discharge
pipe, switch the heater off and contact the installer.
Warning to the installer
This installation is subject to building regulation approval; notify the Local Authority of
intention to install.
Use only manufacturer’s recommended replacement parts.
Please leave this manual with the householder after installation.
INSTALLED BY: Name: ________________________________________
Address: ________________________________________
Tel No. ________________________________________
Completion date: ________________________________________

6
Label for ModuSat FS 200
Main features (BS EN12897 2006)
Manufacturer: Evinox Energy Ltd
Unit 37, Barwell Business Park
Leatherhead Road,
Chessington, Surrey
KT9 2NY
Tel : + 44 (0)1372 722277
www.evinoxenergy.co.uk
Model: ModuSat FS 200
Serial number: ______________
Year of manufacture: ______________
Max primary flow temperature: 80 °C
Max primary pressure: 10 bar (Optional 16 bar)
DHW storage max pressure: 7.0 bar
Max secondary circuit pressure: 3.0 bar
Max water supply pressure (to
pressure reducing valve: 16.0 bar
Pressure reducing valve fixed
outlet pressure: 3.0 bar
P&T relief valve part number: Intatec TP25450570
Immersed electric heater: 3000 W, 220/240 Volt (AC)
Secondary max operating pressure: 3.0 bar
Water expansion vessel charge press.: 6.0 bar
DHW setting range: 20-80 °C
Safety thermostat intervention: 85 °C
PT relief valve: 7.0 bar / 90 °C
Expansion relief valve setting: 6.0 bar
Primary heating power: 20 kW
Primary flow rate (Nom): 800 l/h
Storage capacity: 200 l
Standing heat loss: 2.88 kWh/24h
Weight (full load): 325 kg
Warning to the User
Do not remove or adjust any component part of this unvented water heater: contact the
installer.
If this unvented water heater develops a fault, such as a flow of hot water from the discharge
pipe, switch the heater off and contact the installer.
Warning to the installer
This installation is subject to building regulation approval; notify the Local Authority of
intention to install.
Use only manufacturer’s recommended replacement parts.
Please leave this manual with the householder after installation.
INSTALLED BY: Name: ________________________________________
Address: ________________________________________
Tel No. ________________________________________
Completion date: ________________________________________

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Label for ModuSat FS 300
Main features (BS EN12897 2006)
Manufacturer: Evinox Energy Ltd
Unit 37, Barwell Business Park
Leatherhead Road,
Chessington, Surrey
KT9 2NY
Tel : + 44 (0)1372 722277
www.evinoxenergy.co.uk
Model: ModuSat FS 300
Serial number: ______________
Year of manufacture: ______________
Max primary flow temperature: 80 °C
Max primary pressure: 10 bar (Optional 16 bar)
DHW storage max pressure: 7.0 bar
Max secondary circuit pressure: 3.0 bar
Max water supply pressure (to
pressure reducing valve: 16.0 bar
Pressure reducing valve fixed
outlet pressure: 3.0 bar
P&T relief valve part number: Intatec TP25450570
Immersed electric heater: 9000 W, 415 Volt (AC) 3 Phase
Secondary max operating pressure: 3.0 bar
Water expansion vessel charge press.: 6.0 bar
DHW setting range: 20-80 °C
Safety thermostat intervention: 65 °C
PT relief valve: 7.0 bar / 90 °C
Expansion relief valve setting: 6.0 bar
Primary heating power: 29.6 kW
Primary flow rate (Nom): 1300 l/h
Storage capacity: 300 l
Standing heat loss: 2.88 kWh/24h
Weight (full load): 541 kg
Warning to the User
Do not remove or adjust any component part of this unvented water heater: contact the
installer.
If this unvented water heater develops a fault, such as a flow of hot water from the discharge
pipe, switch the heater off and contact the installer.
Warning to the installer
This installation is subject to building regulation approval; notify the Local Authority of
intention to install.
Use only manufacturer’s recommended replacement parts.
Please leave this manual with the householder after installation.
INSTALLED BY: Name: ________________________________________
Address: ________________________________________
Tel No. ________________________________________
Completion date: ________________________________________

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Label for ModuSat FS 400
Main features (BS EN12897 2006)
Manufacturer: Evinox Energy Ltd
Unit 37, Barwell Business Park
Leatherhead Road,
Chessington, Surrey
KT9 2NY
Tel : + 44 (0)1372 722277
www.evinoxenergy.co.uk
Model: ModuSat FS 400
Serial number: ______________
Year of manufacture: ______________
Max primary flow temperature: 80 °C
Max primary pressure: 10 bar (Optional 16 bar)
DHW storage max pressure: 7.0 bar
Max secondary circuit pressure: 3.0 bar
Max water supply pressure (to
pressure reducing valve: 16.0 bar
Pressure reducing valve fixed
outlet pressure: 3.0 bar
Unvented kit part number: Intatec TP25450570
Immersed electric heater: 9000 W, 415 Volt (AC) 3 Phase
Secondary max operating pressure: 3.0 bar
Water expansion vessel charge press.: 6.0 bar
DHW setting range: 20-80 °C
Safety thermostat intervention: 65 °C
PT relief valve: 7.0 bar / 90 °C
Expansion relief valve setting: 6.0 bar
Primary heating power: 29.6 kW
Primary flow rate (Nom): 1500 l/h
Storage capacity: 400 l
Standing heat loss: 2.81 kWh/24h
Weight (full load): 650 kg
Warning to the User
Do not remove or adjust any component part of this unvented water heater: contact the
installer.
If this unvented water heater develops a fault, such as a flow of hot water from the discharge
pipe, switch the heater off and contact the installer.
Warning to the installer
This installation is subject to building regulation approval; notify the Local Authority of
intention to install.
Use only manufacturer’s recommended replacement parts.
Please leave this manual with the householder after installation.
INSTALLED BY: Name: ________________________________________
Address: ________________________________________
Tel No. ________________________________________
Completion date: ________________________________________

9
1 GENERAL INFORMATION
1.1 Warnings
The ModuSat unit requires mains electrical connections and connection to the primary, low
temperature hot water system and mains cold water supply to function.
A pre-installation rig is available to the installer to help position and space the pipe
connections to the unit during first fix, prior to the ModuSats being delivered to site.
Installation must be carried out by a competent engineer in line with current regulations.
Failure to read and follow the instructions provided within this document may cause potential
injury or failure of the equipment.
Therefore it is advised that the installer reports any equipment faults or defects to an
authorised Evinox representative.
Any modifications or adjustments carried out without EVINOX official authorisation will
invalidate the warranty and absolves Evinox from any liability.
Evinox has the right to make any changes or modifications to the products without prior
notice.
1.2 Symbols
Follows a list of symbols used in this manual:
IMPORTANT NOTE REGARDING CORRECT
INSTALLATION
IMPORTANT NOTE REGARDING PERSONAL SAFETY
AND CARE
CAUTION !
DANGER OF ELECTRICAL SHOCK!
CAUTION !
1.3 Safety Instructions
All installation and maintenance operations must be carried out by competent engineers
according to current regulations
In case of water leaks:
•Disconnect the electric power supply
•Slowly close the main water isolation valves to the unit
•Inform Evinox or approved Evinox engineer
We recommend the unit is checked at least once a year by an authorised
maintenance engineer. If the unit is subject to excessively heavy usage or non
domestic installations (for example in a light commercial environment), we
recommend having it checked more than once per year.
Disconnect the electrical supply prior to starting any work on a ModuSat FS.

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ModuSat
FS 80
ModuSat
FS 150
ModuSat
FS 200
ModuSat
FS 400
ModuSat
FS 300
Please note: Images
shown include the
optional factory fitted
immersion heater.
Tank Without immersion
heater fitted

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2 TECHNICAL FEATURES
2.1 Hydraulic Schematics & dimensions
ModuSat FS 80 & 150 Schematic
Components
A Primary / DH flow
B Primary / DH return
C Domestic cold water Inlet
D Domestic hot water outlet
E Secondary / Apartment
heating flow
F Secondary / Apartment
heating return
G Connection for safety
discharge
Primary Circuit Side
1 Insulated plate heat
exchanger
2 Pressure independent
control valve (PICV) with
actuator
3 Heat meter
4 Non-return valve
DHW Secondary Side Circuit
5 External lime scale reducer
(Optional)
6 Blending valve
Heating Secondary Side Circuit
7 Heating expansion vessel
8 Pressure sensor
9 Safety relief discharge
10 P&T Safety relief discharge
11 Manometer
12 Circulation pump
13 UFH safety thermostat
(Self resetting) (Optional)
14 Drain point
Controls & Other Items
15 Wireless RS 485 (Optional)
16 Electronic control board
17 Room control unit
18 IV (Strainer + flushing
bypass assembly)
19 Filling loop (External)
20 DHW storage tank with
heating coil
21 Motorised diverter valve
22 Electric immersion heater
(Optional)
23 Tank insulation
24 Unvented kit (With balanced
cold feed)
25 Potable expansion vessel
26 Multi directional discharge

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ModuSat FS 200 Schematic
Components
A Primary / DH flow
B Primary / DH return
C Domestic cold water Inlet
D Domestic hot water outlet
E Secondary / Apartment
heating flow
F Secondary / Apartment
heating return
G Connection for safety
discharge
H DHW secondary return
connection
Primary Circuit Side
1 Insulated plate heat
exchanger 2
Pressure independent
control valve (PICV) with
actuator
3 Heat meter
4 Non-return valve
DHW Secondary Side Circuit
5 External lime scale reducer
(Optional)
6 Blending valve
Heating Secondary Side Circuit
7 Heating expansion vessel
8 Pressure sensor
9 Safety relief discharge
10 P&T Safety relief discharge
11 Manometer
12 Circulation pump
13 UFH safety thermostat
(Self resetting) (Optional)
14 Drain point
Controls & Other Items
15 Wireless RS 485 (Optional)
16 Electronic control board
17 Room control unit
18 IV (Strainer + flushing
bypass assembly)
19 Filling loop (External)
20 DHW storage tank with
heating coil
21 Motorised diverter valve
22 Electric immersion heater
(Optional)
23 Tank insulation
24 Unvented kit (With balanced
cold feed)
25 Potable expansion vessel
26 Multi directional discharg

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ModuSat FS 300 & 400 Schematic
Components
A Primary / DH flow
B Primary / DH return
C Domestic cold water Inlet
D Domestic hot water outlet
E Secondary / Apartment
heating flow
F Secondary / Apartment
heating return
G Connection for safety
discharge
H DHW secondary return
connection
Primary Circuit Side
1 Insulated plate heat
exchanger
2 Pressure independent
control valve (PICV) with
actuator
3 Heat meter
4 Non-return valve
DHW Secondary Side Circuit
5 External lime scale reducer
(Optional)
6 Blending valve
Heating Secondary Side Circuit
7 Heating expansion vessel
8 Pressure sensor
9 Safety relief discharge
10 P&T Safety relief discharge
11 Manometer
12 Circulation pump
13 UFH safety thermostat
(Self resetting) (Optional)
14 Drain point
Controls & Other Items
15 Wireless RS 485 (Optional)
16 Electronic control board
17 Room control unit
18 IV (Strainer + flushing
bypass assembly)
19 Filling loop (External)
20 DHW storage tank with
heating coil
21 Motorised diverter valve
22 Electric immersion heater
(Optional)
23 Tank insulation
24 Unvented kit (With balanced
cold feed)
25 Potable expansion vessel
26 Multi directional discharge

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2.2 Dimensions
ModuSat FS 80 & 150

15
ModuSat FS 200

16
ModuSat FS 300 & 400

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2.3 Technical data
ModuSat FS 80 & 150
Electrical
ModuSat FS 80
ModuSat FS 150
Electric supply
220/240 Volt (AC)
Frequency
50 Hz
Current absorption
(Without immersion Heater)
0.6A
Optional immersion heater
220/240 Volt (AC)
Hydraulic connections
ModuSat FS 80
ModuSat FS 150
Primary circuit supply
¾” ext. thread
Primary circuit return
¾” ext. thread
Apartment circuit supply
¾” ext. thread
Apartment circuit return
¾” ext. thread
DHW supply
¾” ext. thread
DCW inlet
¾” ext. thread
Hydraulic characteristics
ModuSat
FS 80
ModuSat FS 150
Max primary temperature
80 °C
Max primary pressure
10 bar (Optional 16 bar)
Recommended max apartment circuit cold fill pressure
1.5 bar
Max water supply pressure
16 bar
Pressure reducing valve fixed outlet pressure
3 bar
Max DHW storage tank pressure
8 bar
Internal unvented kit pressure relief valve setting
6 bar
PT relief valve setting
7 bar – 90 °C
Nominal DHW storage tank pressure
3.5 bar
Secondary heating circuit expansion vessel size
8 Litres
DWH storage capacity
80 l
150 l
Weight
ModuSat FS 80
ModuSat FS 150
Shipping Weight
97.5 kg
120 kg
Weight (full load)
177.5 kg
270 kg

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ModuSat FS 200
Electrical
ModuSat FS 200
Electric supply
220/240 Volt (AC)
Frequency
50 Hz
Current absorption (Without immersion Heater)
0.6A
Optional immersion heater
220/240 Volt (AC)
Hydraulic connections
ModuSat FS 200
Primary circuit supply
¾” ext. thread
Primary circuit return
¾” ext. thread
Apartment circuit supply
¾” ext. thread
Apartment circuit return
¾” ext. thread
DHW supply
¾” ext. thread
DHW secondary return
¾” ext. thread
DCW inlet
¾” ext. thread
Hydraulic characteristics
ModuSat FS 200
Max primary temperature
80 °C
Max primary pressure
10 bar (Optional 16 bar)
Recommended max apartment circuit cold fill pressure
1.5 bar
Max water supply pressure
12 bar
Pressure reducing valve fixed outlet pressure
3 bar
Max DHW storage tank pressure
8 bar
Internal unvented kit pressure relief valve setting
6 bar
PT relief valve setting
7 bar – 90 °C
Nominal DHW storage tank pressure
3.5 bar
Secondary heating circuit expansion vessel size
10 Litres
DWH storage capacity
200 l
Weight
ModuSat FS 200
Shipping Weight
125 kg
Weight (full load)
325 kg

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ModuSat FS 300 & 400
Electrical
ModuSat 300
ModuSat 400
Electric supply
220/240 Volt (AC)
Frequency
50 Hz
Current absorption
(Without immersion Heater)
1.5A
Optional immersion heater
9000 W – 415 Volt (AC) 3 Phase
Hydraulic connections
ModuSat FS 300
ModuSat FS 400
Primary circuit supply
1” ext. thread
Primary circuit return
1” ext. thread
Apartment circuit supply
1” ext. thread
Apartment circuit return
1” ext. thread
DHW supply
1” ext. thread
DHW secondary return
¾” ext. thread
DCW inlet
1” ext. thread
Hydraulic characteristics
ModuSat 300
ModuSat 400
Max primary temperature
80 °C
Max primary pressure
10 bar (Optional 16 bar)
Recommended max apartment circuit cold fill pressure
1.5 bar
Max water supply pressure
12 bar
Pressure reducing valve fixed outlet pressure
3 bar
Max DHW storage pressure
8 bar
PT relief valve setting
7 bar – 90 °C
Secondary heating circuit expansion vessel size
14 Litres
DWH storage capacity
300 l
390 l
Weight
ModuSat 300
ModuSat 400
Shipping Weight
241 kg
250 kg
Weight (full load)
541 kg
650 kg
Typically, communal heating installations operate at a static system pressure of a
maximum 6 - 8 bar.
However, for higher system pressures the ModuSat is designed to work up to a maximum
of 10 bar as standard. As an option, where higher static pressures are expected the
ModuSat can be supplied with a max 16 bar operating pressure.

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2.4 Technical performance table
ModuSat®
FS 80
ModuSat®
FS 150
ModuSat®
FS 200
ModuSat®
FS 300
ModuSat®
FS 400
Water capacity Litres 80 150 200 300 400
Primary flow rate at 80⁰C Nom / Max l / h 720 850 720 900 800 1000 1300 1600 1500 1900
Exchanger power Nom / Max kW 12 24 15 32 20 42 30 54 40 65
Continuous DHW flow rate at 45⁰C l / m 5 10 6 13 8 17 12 22 16 26
Pre-heat time from 15⁰C to 60⁰C Minutes 21 10 31 15 31 15 31 17 31 19
Re-heat time to 60
⁰
C after 70%
volume drawn off Minutes 16 8 24 11 24 11 24 13 24 15
2.5 Pressure drop through primary heater (cylinder coil)
Please note that this is the pressure drop through the cylinder coil and not the
plate heat exchanger pressure drop