Evinox ModuSat XR User manual

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Evinox ModuSat XR (Eco)
Twin Plate Heat Interface Unit
Installation Manual

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Contents
GENERAL INFORMATION............................................................................................... 4
Application........................................................................................................................ 4
Symbols............................................................................................................................. 4
Warning............................................................................................................................. 4
Safety instructions............................................................................................................. 5
Maintenance requirements............................................................................................... 5
TECHNICAL FEATURES ................................................................................................... 6
Typical ModuSat® XR & XR-ECO Unit................................................................................. 6
Function and operation ..................................................................................................... 6
Typical Schematic (All Top Connections) ........................................................................... 7
Technical Parameters ........................................................................................................ 8
Connection Configurations................................................................................................ 9
Typical Dimensions (connection configurations shown).................................................. 10
INSTALLATION ............................................................................................................. 14
Handling.......................................................................................................................... 14
Positioning....................................................................................................................... 14
Hydraulic connections ..................................................................................................... 15
Wall fixing........................................................................................................................ 15
Use of Pre-installation Rig ............................................................................................... 15
Evinox Flushing By-pass Kit.............................................................................................. 17
Flushing Primary Circuit................................................................................................... 17
First fill of the HIU ........................................................................................................... 18
HIU Flushing .................................................................................................................... 18
First fill of apartment heating system.............................................................................. 19
Water treatment ......................................................................................................... 19
Water Quality Guidelines ................................................................................................ 20
Dosing Secondary System................................................................................................ 20
Warranty due to Water Quality....................................................................................... 21
Electrical Connections ................................................................................................. 22
Removing the Front panel ............................................................................................... 22
ModuSat® Wiring Connections........................................................................................ 23
5.2.1 RJ45 Connections ..................................................................................................... 23
ModuSat® Connection Board........................................................................................... 24
5.4 Typical ModuSat® Electric Wiring Diagram with 2 Zone Control (2 Evinox ViewSmart
Room Controllers)....................................................................................................................... 25
ViewSmart Room controller connections ........................................................................ 26
SmartTalk® system wiring ............................................................................................... 27
SETTING INTO OPERATION / COMMISSIONING .......................................................... 28
Pre-commissioning checklist............................................................................................ 28
Pressure independent control valve................................................................................ 29
6.2.1 Pump........................................................................................................................ 30
Available Pump Head ...................................................................................................... 31
Initial Commissioning Procedure ..................................................................................... 32

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WARRANTY ................................................................................................................. 33
KIWA CERTIFICATE....................................................................................................... 35

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GENERAL INFORMATION
Application
The Evinox ModuSat® XR heat interface unit provides instantaneous domestic hot water and indirect
space heating when connected to a district or communal heating system. The Evinox ModuSat® XR
unit requires electrical supply to function.
Symbols
IMPORTANT NOTE REGARDING CORRECT INSTALLATION
WARNING REGARDING PERSONAL SAFETY
WARNING OF DANGER OF ELECTRIC SHOCK
Warning
Follow the instructions. These instructions must be read and observed carefully before
installing and operating the ModuSat® heat interface unit. Failure to read and follow the
instructions provided within this document may cause a safety hazard and/or failure of the
equipment.
Qualified personnel only. The Evinox heat interface unit must be installed, commissioned
and maintained by qualified and competent personnel in accordance with this document as
well as national regulations and standards.
Warning of transport damage. Always check to ensure that the ModuSat® heat interface
unit has not been damaged during transport.
Warranty. Any modifications or adjustments carried out without Evinox Energy official
authorisation will invalidate the warranty and absolve Evinox Energy from any liability.
Product modifications. Evinox Energy reserves the right to make changes or modifications to
the products without prior notice.

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Safety instructions
The Evinox heat interface unit must be installed, commissioned and maintained by qualified and
competent personnel in accordance with this document as well as national regulations and
standards.
High temperatures.
Take necessary precautions when working on the unit as high operating
temperatures may cause severe skin burns.
Risk of Electric shock.
Disconnect the electricity supply before starting any works on the unit.
Qualified personnel.
Electrical installation must only be carried out by qualified personnel.
In the case of water leak.
Take caution of hot water
Slowly close the isolation valves at the top of the unit
Contact Evinox Energy
Maintenance requirements
We recommend the unit is checked at least every 24 months 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 every 24 months.

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TECHNICAL FEATURES
Typical ModuSat® XR & XR-ECO Unit
Note: The product may look different from the image shown.
Function and operation
District or communal heating system –the primary thermal energy is used to produce
domestic hot water and heating.
Domestic hot water (DHW) - the DHW is prepared via a plate heat exchanger and is
activated when flow is registered through the flow sensor located on the cold water inlet.
The electronically controlled Pressure Independent Control Valve (PICV) modulates the
primary flow rate to maintain the DHW temperature. This unit operates with the DHW
taking priority over HTG –when the hot water is used it will temporarily cut the heating
operation. Once the hot water outlets are closed the heating operation will be resumed.
Heating (HTG) –when the space heating demand is requested by the end user controller,
the heating operation is started. The electronically controlled PICV is used to modulate the
primary flow rate to match the heating demand. The unit has an integrated heating
circulation pump which is switched on when the heating is on and modulates based on
secondary heating delta T.
Keep Warm Facility –when the heat interface unit is set in the Comfort mode, the DHW
plate heat exchanger is kept warm by opening the domestic hot water PICV to pulse the
primary heating through the plate in order to maintain a set temperature. This is in order to
ensure a fast DHW response time.

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Typical Schematic (All Top Connections)
ModuSat XR (ECO)
Note: Other connection arrangements are available
see page 10 for details.
Components
APrimary / LTHW flow
BPrimary / LTHW return
CSecondary / Domestic cold water
Inlet
DSecondary /Domestic hot water
outlet
ESecondary / Apartment
heating flow
FSecondary / Apartment
heating return
G Connection for safety
discharge
Primary Circuit Side
1Insulated plate heat exchanger
(Heating)
2Heating Pressure Independent
Control Valve with actuator
3Insulated plate heat exchanger
(Domestic Hot Water)
4 DHW Pressure Independent
Control Valve with actuator
5Heat meter
DHW Secondary Side Circuit
6 Flow sensor
Heating Secondary Side Circuit
7 Heating expansion vessel
8 Safety UFH thermostat (optional)
9 Pressure sensor
10 Safety relief discharge
11 Pressure gauge
12 Heating circulation pump
Controls & Other Items
13 Filling loop (External)
14 Electronic control board
15 ViewSmart room control unit
16 Flushing bypass kit
S1, S2 –temperature sensors as a part of
the heat meters
S3 –DHW temperature sensor
S4, S5 –heating flow and return
temperature sensors

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Technical Parameters
Electrical
XR 30/55-/70…
XR-ECO 30/55-77…
XR 100-XX
Electric supply
220 / 240 Volt (AC)
Frequency
50 Hz
Current absorption
0,6 Amps
Hydraulic connections
XR 30/55-/70…
XR-ECO 30/55-77…
XR 100-XX
Primary circuit supply
A
3/4 ”BSP
1 ”BSP
Primary circuit return
B
3/4 ”BSP
1 ”BSP
DCW inlet
C
3/4 ”BSP
1 ”BSP
DHW supply
D
3/4 ”BSP
1 ”BSP
Apartment circuit supply
E
3/4 ”BSP
3/4 ”BSP
Apartment circuit return
F
3/4 ”BSP
3/4 ”BSP
Drain
G
1/2 ”Compression
1/2 ”Compression
Hydraulic characteristics
XR 30/55-/70…
XR-ECO 30/55-77…
XR 100-XX
Pipework material
Copper
Plate heat exchanger material
Stainless steel 316L
Operating medium
Water
Primary circuit max pressure
16 bar
Primary minimum differential
pressure
50 kPa* (0.5 bar)
*may vary depending on the required output
Primary maximum differential
pressure
400 kPa (4 bar)
Apartment heating circuit
recommended cold fill pressure
1.0 bar
Apartment heating maximum pressure
3 bar
Apartment heating expansion vessel
8 L
DHW max pressure
10 bar
DCW min pressure
1 bar
Max supply temperature (Primary)
85°C
Mass
Dry
Wet
XR ECO TP-30-10R
34.5 kg
36.5 kg
XR ECO TP-55-10R
35 kg
37.5 kg
XR ECO TP-70-10A
37 kg
39.5 kg
XR TP-100-10A
43 kg
47.5 kg
For other models please contact Evinox.

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Connection Configurations
The ModuSat® XR heat interface unit comes with a variety of connection combinations to ease the
installation and the aesthetics of the installation. Please find the options below.
PF –Primary flow (in) CW –Cold water (in) SF –Secondary heating flow (out)
PR –Primary return (out) HW –Hot water (out) SR –Secondary heating return (in)
DR –Secondary heating drain (safety relief discharge)

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Typical Dimensions (connection configurations shown)
TL1 –ModuSat® XR Twin Plate 30/55/70-…& XR-ECO 30/55/70-… All Top Connections
Minimum space requirements for access and servicing: Top: 190 mm (To allow for H-type
flushing by pass), Front: 700 mm, Side: 50 mm, Bottom: Sufficient space to connect the drain.
Please Note: Flushing bypass to be installed on primary connections A & B.
TL5 –ModuSat® XR Twin Plate 30/55/70-…& XR-ECO 30/55/70-… Primary Flow & Return, Cold Water
& DHW at the Top. Secondary Heating Flow & Return at the Bottom
Minimum space requirements for access and servicing: Top: 190 mm (To allow for H-type flushing
by pass), Front: 700 mm, Side: 50 mm, Bottom: Sufficient space to connect the drain and a strainer
valve.
Please Note: Flushing bypass to be installed on primary connections A & B.
HIU Connections:
A, B, C, D, E, F: 3/4’’ BSPP male
thread.
G: 1/2’’ compression.
HIU Connections:
A, B, C, D, E, F: 3/4’’ BSPP male
thread.
G: 1/2’’ compression.

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TL7 –ModuSat® XR Twin Plate 30/55/70-…& XR-ECO 30/55/70-… Primary Flow & Return and DHW
Connections Top. Cold Water Inlet and Secondary Heating Flow & Return Connections at the Bottom
Minimum space requirements for access and servicing: Top: 190 mm (To allow for H-type
flushing by pass), Front: 700 mm, Side: 50 mm, Bottom: Sufficient space to connect the drain and
a strainer valve.
Please Note: Flushing bypass to be installed on primary connections A & B.
TL8 –ModuSat® XR Twin Plate 30/55/70-…& XR-ECO 30/55/70-… Primary Top, Other Connections at
Bottom
Minimum space requirements for access and servicing: Top: 190 mm (To allow for H-type
flushing by pass), Front: 700 mm, Side: 50 mm, Bottom: Sufficient space to connect the drain and
a strainer valve.
Please Note: Flushing bypass to be installed on primary connections A & B.
HIU Connections:
A, B, C, D, E, F: 3/4’’ BSPP male
thread.
G: 1/2’’ compression.
HIU Connections:
A, B, C, D, E, F: 3/4’’ BSPP male
thread.
G: 1/2’’ compression.

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BL4 –ModuSat® XR Twin Plate 30/55/70-…& XR-ECO 30/55/70 All Connections at the Bottom
Minimum space requirements for access and servicing: Bottom: 190 mm (To allow for H-type
flushing by pass) or more if required for connecting the drain and a strainer valve, Front: 700 mm,
Side: 50 mm.
Please Note: Flushing bypass to be installed on primary connections A & B.
TL1 - XR 100-XX All Top Connections
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Minimum space requirements for access and servicing: Top: 250 mm (To allow for H-type
flushing by pass), Front: 700 mm, Side: 50 mm, Bottom: Sufficient space to connect the drain.
Please Note: Flushing bypass to be installed on primary connections A & B.
HIU Connections:
A, B, C, D: 1’’ BSPP male thread.
E, F: 3/4’’ BSPP male thread.
G: 1/2’’ Compression.
HIU Connections:
A, B, C, D, E, F: 3/4’’ BSPP male
thread.
G: 1/2’’ compression.

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TL5 - XR 100-XX All Top Connections But Heating Flow & Return Bottom
Minimum space requirements for access and servicing: Top: 250 mm (To allow for H-type
flushing by pass), Front: 700 mm, Side: 50 mm, Bottom: Sufficient space to connect the drain and
a strainer valve.
Please Note: Flushing bypass to be installed on primary connections A & B.
HIU Connections:
A, B, C, D: 1’’ BSPP male thread.
E, F: 3/4’’ BSPP male thread.
G: 1/2’’ Compression.

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INSTALLATION
The Evinox heat interface unit must be installed, commissioned and maintained by qualified and
competent personnel in accordance with this document as well as national regulations and
standards.
Handling
The unit should be moved into position before lifting still within its packaging to prevent any
damage whilst being positioned. Only once it is safely situated, the unit should be removed
from its packaging and lifted into position.
The ModuSat® unit may have been transported and handled many times prior to the
installation, therefore it is vitally important that all unions and connections are checked and
tightened as required. In case of damage please contact Evinox Energy on 01372 722277
immediately.
Packaging materials must be disposed in accordance with the requirements of the
construction site or the property.
Lifting.
Take care when lifting this appliance. It is recommended that at least two people
perform the lifting.
Leave caps over the connections.
Ensure that the protective cover (caps) over the ModuSat® pipe connections are
kept in place to prevent ingress of any debris.
Positioning
The heat interface unit should be installed in a sheltered environment and is not suitable for outdoor
installation. It is recommended that the surrounding environment conditions do not exceed 40 °C
with the relative humidity from 15% to 85%.
Note: As the unit contains water to operate, it is recommended not to place electrical devices, such
as control boards and other devices, underneath the unit in the case of a water leak. The
manufacturer cannot accept any responsibility for goods damaged in such a way.
Maintenance space.
It should be ensured that a sufficient space around the unit is provided to allow
the future maintenance and servicing of the unit. The removal of the front panel
should not be restricted. Refer to Section 2.6 for space requirements.

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Hydraulic connections
Connection arrangement.
Ensure that the hydraulic connections of the pipework piped up to the unit are
correct and follows the hydraulic schematic. The manufacturer cannot accept any
responsibility for any damage caused to the unit due to crossed connections.
Any Evinox engineer callout/visit due to this issue will be chargeable.
The ModuSat® heat interface unit is designed
to be wall mounted with the typical primary
connections and domestic water hydraulic
connections as shown below. (Other
configurations are available; please refer to
section 2.5 of this manual for details).
The Evinox Energy flushing by-pass valve kit
should be installed prior to connecting the unit
and the valves left in an isolated position.
The whole system should be cleaned and
flushed before installing the heat interface unit
to ensure the ModuSat® unit is not damaged.
Wall fixing
The ModuSat® unit is designed to be wall mounted. There are drillings on the back plate of the unit
that ensure mounting with the wall mounting bracket (show below).
Wall fixing
Installer must ensure that appropriate fixings are used.
Use of Pre-installation Rig
A pre-installation rig is available upon request. It consists of a steel HIU back panel. This will enable
the installer to arrange the piping entering and leaving the unit during first fix prior to the unit being
delivered / installed. The configuration of the pre-installation rig will be as per the unit being
supplied and the project requirements. Once the pipework is complete, the rig can be removed and
used in another apartment.

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HOW TO INSTALL PRE-INSTALLATION RIG
STEP1: Securely fix the mounting
bracket to the wall in the required
position. Hang the ModuSat® XR Pre-
Installation Rig on the wall fixing
bracket. Then slide down and across to
the right, as indicated in diagram.
STEP2: Fit the Evinox Energy Flushing
Bypass & Valve Kit to the rig and then
make final connections to the pipework
running to the ModuSat®.
STEP3: Shut off isolation valves,
pressure test pipework and then
disconnect the valve unions.
STEP4: To remove the pre-installation
rig slide the rig to the left taking all
connections off centre, slowly lift and
remove.
Pre-installation Rig Typical Dimensions for ModuSat XR ECO TP-30/55/70-…

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Evinox Flushing By-pass Kit
Evinox flushing by-pass kit allows for isolation of the HIU from the network during cleaning and
flushing the system. The kit includes an H shape by-pass with built in extended isolation valve, 2
strainers and 4 isolation valves.
Evinox FLUSH-KIT-TP1-SS for ModuSat® TP
Close valves
Before connecting flushing by-pass kit to the HIU ensure all isolation valves are
closed. Valves can be opened after LTHW system has been flushed.
Heating strainer
In HIUs with the bottom connections, strainer cannot be installed in vertical
position with the water flow going up.
Flushing Primary Circuit
The whole primary system should be cleaned and flushed in
accordance to BG29/2012 before filling ModuSat® heat
interface unit.
To open the by-pass:
Ensure both isolation valves are in the closed position as
shown in the picture.
Use a suitable screwdriver or other tool to twist the
screw on the H-shape by-pass valve into the open
position.
Close the bypass after flushing is complete.
Provide isolation valves and a strainer.
If Evinox valve kit is not used, it must be ensured that there are isolation valves
provided. Strainers on the primary and secondary heating inlets are required to ensure
the components in the unit are protected from debris and sediments.
Tighten the connections.
When connecting the ModuSat® heat interface unit, ensure that all the connections are
tightened to avoid any leaks.

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First fill of the HIU
Clean and flush the system before connecting the unit.
Filling the system should be performed only after the system has been fully
flushed and cleaned. Poor water quality may cause failure of the operation of the
unit.
Water quality.
It is recommended that the flushing and cleaning of the primary circuit, domestic
water circuit and secondary heating circuit is performed by a qualified person in
accordance with current standards, regulations and BSRIA guidelines.
In the case of a water leak.
Take caution of hot water
Slowly close the isolation valves at the top or bottom of the unit
Contact Evinox Energy
The ModuSat® pump should not be used for flushing.
The pump is integral to the unit and should not be used for flushing and cleaning
the system. Failure to meet this requirement will invalidate the warranty.
Filling the primary circuit
Please take care when filling the ModuSat® unit.
Make sure that the by-pass valve is
in closed position
Slowly open the isolation valves on
the primary circuit.
Visually check that there are no
leaks. Tighten the connections of
the valve kit if necessary.
If there is a leak internal to the unit,
ensure the isolation valves are left
in a closed position.
HIU Flushing
Clean and flush LTHW system before flushing through the HIU
Filling the system should be performed only after the system has been fully
flushed and clean. Poor water quality may cause failure of the operation of the
unit.

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First fill of apartment heating system
The ModuSat® unit is fitted with a pressure gauge that is mounted in the front panel. This gauge
reading should be used when filling the secondary circuit. An external filling loop should be used for
filling the secondary circuit with the mains cold water.
Open the isolation valves on the filling loop.
Cold fill should be done to about 1 bar. Pressure will depend on
the head of the system (difference between the lowest and
highest point).
Once the required pressure is reached, close the filling loop ball
valve, vent the system and if required repeat it again.
Disconnect filling loop.
Water treatment
The quality and cleanliness of the water within both the primary and secondary circuits is vitally
important to prevent damage to the ModuSat® components, and to ensure that the efficiency and
service life of the unit is maintained.
It is therefore necessary to fully flush and treat both primary and secondary circuits using suitable
water treatment chemicals.
Water treatment in accordance to these instructions.
Please confirm with the water treatment consultants that the chemicals used and
cleaning method statement complies with the requirements set out in this
section.
Water quality may damage the unit.
Poor water quality may damage the components used in the unit and invalidate
the warranty. The manufacturer cannot take responsibility for any damage of the
unit caused by poor water quality.
Chemical cleaning and dosing.
Chemical cleaning and dosing of the system should be in line with the current
regulations, standards and guidelines. Which are, but are not limited to:
BSRIA Application Guide BG29/2012
BS7593:2006
Requirements of Thames Water Utilities
The Water Industry Act 1991, Section 119
HSE The Control of Legionella 1991
HSC Approved Code of Practice and Guidance HSG274, Part 2

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Water Quality Guidelines
TH - Total hardness is caused by calcium
and magnesium.
pH –this measures the alkalinity of the
water, neutral alkalinity is pH7. Heating
systems require an alkaline pH. Lower
pH will increase the corrosion risk.
TDS –dissolved solids in the system and
is a measure of the cleanliness of the
water (satisfactory level should be
within TDS of 10% of the mains water) .
Conductivity –this is the measure of the
ability of water to pass an electrical
current.
Free copper –the level of copper in the
system.
Total Iron and Manganese –this
measures iron concentration in mg/litre.
These are strong oxidants and may
increase the risk for corrosion.
Visual inspection should be carried out
ensuring that the water is clear, bright and free from particulate matter. The system must be fully
vented, pressurised and dosed with anti-corrosion and anti-bacterial growth inhibitor.
High DHW temperature may cause scaling.
High operating temperatures on the domestic hot water circuit may lead to scaled
DHW plate heat exchanger. It is recommended to set the DHW temperature to
maximum of 55°C especially in hard water areas.
Dosing Secondary System
Once the system is cleaned and flushed the inhibitors should be added to the secondary side to
prevent the corrosion or bacteria growth.
A suitable long term corrosion inhibitor and inhibitor for preventing the bacteria should be
introduced in a proportion of the system volume.
Excessive filling of the secondary circuit with untreated water may lead to scale
build up and corrosion. This may damage the ModuSat® unit or reduce the
performance.
Please confirm with the water treatment consultants that the chemicals used and
cleaning method statement complies with the requirements set out in this
section.
Evinox Energy do not take responsibility for approving inhibitors used for dosing
the system.
Recommended
Hardness (TH)
Up to 150 mg/l (as CaCO3)
Chlorides (Cl-)
Up to 150 mg/l
PH
7.5 –9.0
Resistivity
>2000 Ohm/cm
Sulphate (SO42-)
Up to 70 mg/l
Conductivity
200 crs
TDS
0-200 ppm
Free carbon dioxide
(CO2)
Up to 5 mg/l
Manganese (Mn)
Up to 0.1 mg/l
Iron (Fe)
Up to 0.2 mg/l (or 5ppm)
Copper
Up to 1 mg/l
Typical Water Quality Guidelines