August 2010 Sirius SAT Built-in User Modules R/1 – RP/1 – RS – RSP – R2Z Installation and Operating Manual Working towards a cleaner future heating specialists
TO THE OWNER OF THIS POTTERTON COMMERCIAL APPLIANCE We are confident your new POTTERTON COMMERCIAL appliance will meet all your requirements. All POTTERTON COMMERCIAL products have been designed to give you what you are looking for: good performance combined with simple and rational use. Please do not put away this booklet without reading it first as it contains some useful information which will help you to operate your appliance correctly and efficiently.
CONTENTS 1. Description 2. Instructions prior to installation 4 4 INSTALLATION INSTRUCTIONS: HYDRAULIC CONNECTIONS 3. Centralised system requirements 4. Mounting the template casing 5. Mounting the appliance 6. Flow rate/pressure drop characteristics 7. Output/pump head performance 8. Domestic hot water production 9. Domestic water meter 5 11 12 13 15 16 16 INSTALLATION INSTRUCTIONS: ELECTRICAL CONNECTIONS 10. Electrical connections 11. Wiring diagrams 12. Connecting the ambient thermostat 13.
FOREWORD The SIRIUS SAT user modules make it possible to independently manage heating requirements in centralised systems, me- ter the heat distributed to each unit (flat or independently managed area) and transmit heat consumption data via radio. The following notes and instructions are addressed to fitters to allow them to carry out trouble-free installation. The operating instructions are contained in the “Start-up and operating instructions” section of this manual.
INSTALLATION INSTRUCTIONS: HYDRAULIC CONNECTIONS 3. CENTRALISED SYSTEM REQUIREMENTS Some general indications concerning the installation of the centralised heating system are shown below. For these types of plants, a cutting-edge bespoke design is always necessary in order to ensure ideal conditions of comfort, save energy and reduce the environmental impact.
SIRIUS SAT CENTRAL HEATING SIRIUS SAT 0903_2001 / CR_0034 DOMESTIC HOT WATER CENTRAL HEATING DOMESTIC HOT WATER SIRIUS SAT CENTRAL HEATING DOMESTIC HOT WATER HEATING PLANT WITH BOILERS CONNECTED IN A CASCADE ARRANGEMENT AND CENTRALISED DOMESTIC HOT WATER PRODUCTION Figure 1A: Diagram of plant: centralised domestic hot water production INSTALLATION AND OPERATING MANUAL 6 912.808.
SIRIUS SAT CENTRAL HEATING SIRIUS SAT 0903_2002 / CR_0012 DOMESTIC HOT WATER CENTRAL HEATING DOMESTIC HOT WATER SIRIUS SAT CENTRAL HEATING DOMESTIC HOT WATER HEATING PLANT WITH BOILERS CONNECTED IN A CASCADE ARRANGEMENT Figure 1B: Diagram of plant: local domestic hot water production INSTALLATION AND OPERATING MANUAL 7 912.808.
HOME A SIRIUS SAT HOME B SIRIUS SAT HOME C 0903_2003p / CR_0013 SIRIUS SAT Figure 1C: Floor layout The indicative diagram in figure 1c only illustrates the feed pipes of the individual user modules. The heating plant inside the zone controlled by the module must be realised by feeding the heating elements according to normal methods. For models with domestic hot water production, a stub of the hydraulic network must be attached to the Domestic Hot Water inlet connector ES.
3.1 GENERAL SIZING DATA - Campo temperatura acqua impianto centralizzato: - Water temperature range in centralised plant: - Maximum water pressure in centralised plant: - Module feed flow rate (nominal): 60 - 75 °C 60 - 75 °C 4 bar 700 ÷ 1000 l/h for heating only models 1000 ÷ 1500 l/h for models with domestic hot water production - Maximum recommended speed of heat transfer fluid: - Pressure drop in module: 1 ÷ 1.
TABLE: HEAT DEMAND – FLOW OF WATER IN HEATING CIRCUIT DOMESTIC HOT WATER TAKE-OFF FLOW Heating domestic water heat capacity (kW) ∆T1 ∆T2 R S Flow rate of Heating circuit with ∆T1 = 15 K (l/h) Flow rate of Heating circuit with ∆T1 = 20 K (l/h) Flow rate of domestic water circuit with ∆T2 = 35 K (l/min) 7 (R) 401 301 2,9 8 (R) 459 344 3,3 9 (R) 516 387 3,7 10 (R) 573 430 4,1 11 (R) 631 473 4,5 12 (R) 688 516 4,9 13 (R) 745 559 5,3 14 (R) 803 602 5,7 15 (RS) 860 645 6,1
4. MOUNTING THE TEMPLATE CASING CASING/TEMPLATE MODEL WIDTH SIRIUS SAT MODELS SINGLE-ZONE SIRIUS SAT KIT l = 600 mm R/1 - RP/1 - RS - RSP DUAL-ZONE SIRIUS SAT KIT l = 800 mm R2Z - R2Z Install the SIRIUS SAT model inside the casing/template supplied in a separate pack. Make sure the template casing model is correct (L= 600 or L=800 mm). Fit the template/casing in a niche in the wall made for this purpose (dimensions indicated in figures 2 and 3) and secure it with the relative lateral bent pins.
5. MOUNTING THE APPLIANCE 0902_0805 / CR_0018 0902_0804 / CR_0017 After completing the masonry work, hook the SIRIUS SAT module onto the casing/template and make the hydraulic connec- tions using the supplied telescopic connections (see figure 3). Before fixing the module, drill holes in the rear wall for the Ø 10mm expansion grips (use the holes in the casing/template as a guide). Then secure the module with the supplied screws.
Items in the SIRIUS SAT user module pack. r r r r r r r r r 4DSFXT BOE FYQBOTJPO HSJQT NN 5BQ ( c u VTFS NPEVMF JOMFU 5BQ ( c u SFUVSO UP DFOUSBMJTFE QMBOU 5BQ ( c u IFBUJOH QMBOU EFMJWFSZ GPS EVBM [POF NPEFMT 5BQ ( c u IFBUJOH QMBOU SFUVSO GPS EVBM [POF NPEFMT 5BQ ( c u EPNFTUJD XBUFS JOMFU NPEFMT XJUI EPNFTUJD IPU XBUFS QSPEVDUJPO 5BQ ( c u EPNFTUJD IPU XBUFS PVUMFU NPEFMT XJUI EPNFTUJD IPU XBUFS QSPEVDUJPO 4FBMT 5FMFTDPQJD KPJOUT 6.
0807_3103 / CR_0185 0807_3104 / D_2151 Figure 5: Balancing valve (models without Pump) INSTALLATION AND OPERATING MANUAL 14 912.808.
0607_0203 / CR_0030 balancing device Figure 6: balancing device (models RS) 7. OUTPUT/PUMP HEAD PERFORMANCE (only for models with pump: RP/1 – RSP – R2Z - RS2Z) These models are fitted with a circulation pump. This silent-running high-head pump is suitable for use on any type of heating system. The pump, mounted inside the appliance, is fitted out for operation at maximum speed (III). Speed I should not be used as flow rate/head performance does not satisfy normal operating conditions.
8. DOMESTIC HOT WATER PRODUCTION (models : RS – RSP – RS2Z) The models with domestic hot water production are fitted with an instantaneous plate exchanger in stainless steel sized for a heat exchange of 35 kW with inlet water at 75 °C. The heat exchange surface offers suitable domestic hot water performance also with water at 60 °C.
0902_0501 / CR_0130 9.
0707_2602 / CR_0120 ESC1 ESC2 US1 US2 Figure 8 C: Domestic water meters (models R2Z) 0707_2603 / CR_0032 9.
INSTALLATION INSTRUCTIONS: ELECTRICAL CONNECTIONS 10. ELECTRICAL CONNECTIONS The appliance is sold complete with electrical connections and power cable. This machine is only electrically safe if it is correctly connected to an efficient earth system in compliance with current safety regulations. Connect the appliance to a 230V single-phase earthed power supply using the supplied three-pin cable, observing correct LIVE (L) - NEUTRAL (N) polarity.
INSTALLATION AND OPERATING MANUAL 20 R = RED V = GREEN G = YELLOW G/V = YELLOW/GREEN M = BROWN C = LIGHT BLUE N = BLACK WIRE COLOURS INPUT SERVOMOTOR PUMP (ONLY RP) AUXILIARY TERMINAL BLOCK POWER TERMINAL BLOCK FUSE T.A. ON/OFF BUTTON 0902_0808 / CR_0128 MAINS POWER INPUT 230V-50Hz 11. WIRING DIAGRAMS 11.1 MODELS R/1 E RP/1 912.808.
INSTALLATION AND OPERATING MANUAL 21 R = RED V = GREEN G = YELLOW G/V = YELLOW/GREEN M = BROWN C = LIGHT BLUE N = BLACK WIRE COLOURS INPUT SERVOMOTOR DOMESTIC HOT WATER PROBE SAFETY THERMOSTAT EXTERNAL PROBE THREE-WAY VALVE MIXING VALVE SERVOMOTOR 0902_0809 / CR_008 MAINS POWER INPUT 230V-50Hz ON/OFF BUTTON DOMESTIC WATER PRIORITY SENSOR 11.2 MODELS RS 912.808.
INSTALLATION AND OPERATING MANUAL 22 R = RED V = GREEN G = YELLOW G/V = YELLOW/GREEN M = BROWN C = LIGHT BLUE N = BLACK WIRE COLOURS INPUT SERVOMOTOR DOMESTIC HOT WATER PROBE SAFETY THERMOSTAT EXTERNAL PROBE HEATING PROBE THREE-WAY VALVE MIXING VALVE SERVOMOTOR 0902_0810 / CR_009 PUMP MAINS POWER INPUT 230V-50Hz ON/OFF BUTTON DOMESTIC WATER PRIORITY SENSOR 11.3 MODELS RSP 912.808.
INSTALLATION AND OPERATING MANUAL 23 R = RED V = GREEN G = YELLOW G/V = YELLOW/GREEN M = BROWN C = LIGHT BLUE N = BLACK WIRE COLOURS INPUT SERVOMOTOR HIGH TEMP. ZONE SERVOMOTOR SAFETY THERMOSTAT EXTERNAL PROBE HEATING PROBE T.A. II ZONE T.A. I ZONE 0902_0811 / CR_007 PUMP P1 BT PUMP P2 AT MAINS POWER INPUT 230V-50Hz ON/OFF BUTTON MIXING VALVE SERVOMOTOR 11.4 MODELS R2Z 912.808.
INSTALLATION AND OPERATING MANUAL 24 R = RED V = GREEN G = YELLOW G/V = YELLOW/GREEN M = BROWN C = LIGHT BLUE N = BLACK WIRE COLOURS INPUT SERVOMOTOR HIGH TEMP. ZONE SERVOMOTOR DOMESTIC HOT WATER PROBE HEATING PROBE SAFETY THERMOSTAT EXTERNAL PROBE THREE-WAY VALVE T.A. II ZONE T.A. I ZONE MIXING VALVE SERVOMOTOR 0902_0812 / CR_0010 PUMP P1 BT PUMP P2 AT MAINS POWER INPUT 230V-50Hz ON/OFF BUTTON DOMESTIC WATER PRIORITY SENSOR 11.5 MODELS RS2Z 912.808.
12. CONNECTING THE AMBIENT THERMOSTAT The system must be fitted with an ambient thermostat in order to control room temperature. To connect this device, proceed as follows: 12.1 SINGLE-ZONE MODELS: R/1 – RP/1 Access the electrical components as described in section 10.1. Remove the jumper on terminals (1) and (2) of the main terminal block (R/1, RP/1) (see wiring diagrams in § 11).
13. CONNECTING THE FLOOR OVERHEATING THERMOSTAT (MODELS RSP, R2Z AND RS2Z) When connecting the user module to a system operating at low temperature, install an off-the-shelf manually resettable contact thermostat (calibrated to 50°C) in order to protect the floor system from elevated temperatures due to possible faults in the adjustment system.
14. INSTALLING AND CONNECTING THE EXTERNAL PROBE (accessory available on request for models RS, RSP, R2Z, RS2Z) The appliance is fitted for connection to an external probe, available on request, which independently adjusts delivery tem- perature depending on the external temperature and the chosen curve. To mount and electrically connect this accessory, see the figure below and the instructions supplied with the external probe.
15. CONNECTING THE CLIMATE ADJUSTOR: ECO CRONO (accessory available on request: models RS – RSP – R2Z – RS2Z) The LUNASAT module can be remote controlled using the ECO CRONO climate adjustor.
DOMESTIC HOT WATER POTENTIOMETER 0902_0819 / CR_0014 TS = Domestic hot water (DHW) adjustment potentiometer Adjusts domestic hot water temperature.
SWITCHES 4 – 5 : CLIMATE CURVE SELECTION (only for models RSP-R2Z-RS2Z)) Climate curve selection table CLIMATE CURVE Switch 4 Switch 5 Temperature range LOW OFF OFF 25 ÷ 40 °C MEDIUM ON OFF 50 ÷ 60 °C HIGH (*) OFF ON 25 ÷ 80 °C (*) factory setting should be selected for heating elements at high temperatures: radiators curve should be selected for heating elements fitted with fans: fan coil units should be selected for heating elements at low temperatures: underfloor or similar systems.
SWITCH 6: EXTERNAL PROBE ENABLE (only for models RSP-R2Z-RS2Z)) External probe enable table EXTERNAL PROBE Switch 6 WITH PROBE ON WITHOUT PROBE (*) OFF (*) factory setting 0902_0902 / CR_0028 External probe Figure 13 E: External Probe Switch SELECTOR 7 : PUMP POST-CIRCULATION TIME Pump post-circulation time selection table EXTERNAL PROBE Switch 7 WITH PROBE ON WITHOUT PROBE (*) OFF (*) factory setting 0902_0903 / CR_0028 Pump post-circulation Figure 13 F: Pump post-circulation switch INS
INSTALLATION INSTRUCTIONS: HEAT METERING 17. HEAT METERING The modules are supplied standard with a SIEMENS MEGATRON electronic heat meter. This device measures heat consumption in the zone controlled by the user module. The electronic unit features an 8-digit LCD display. The 3 Vdc input voltage is provided by a lithium battery (lifetime 8 years). A button for querying the appliance is located on the front of the display. The appliance can be turned by 360° and inclined by 90°.
18. AUTOMATIC MEASUREMENT SYSTEM VIA RADIO This system allows all the consumption data of the building to be handled from a single station, thus reducing measurement times whilst protecting user privacy. Transmission frequency is the 868 MHz established by the national radio transmission plan (European standard). The duration and power of the radio signal are irrelevant and are in no way connected with prob- lems of “electro smog”.
HOME A 0902_0905 / CR_0027 FLOOR AERIAL RADIO TRANSMISSION 868 MHz HOME B RADIO TRANSMISSION 868 MHz HOME A HOME B RADIO TRANSMISSION 868 MHz FLOOR AERIAL HOME A HOME B RADIO TRANSMISSION 868 MHz PHONE TRANSMISSION GSM HOME A HOME B RADIO TRANSMISSION 868 MHz (SEE OPTIONS IN FIGURE 15B) HOME A HOME B Figure 15 A: Automatic measurement system via radio INSTALLATION AND OPERATING MANUAL 34 912.808.
2) LOCAL TRANSMISSION VIA “RADIO” 0902_0904 / CR_0033 1) LOCAL TRANSMISSION VIA “SERIAL” AERIAL AERIAL 3) TRANSMISSION VIA “GSM” REMOTE OFFICE AERIAL GSM MODEM METERED BUILDING Figure 15 B: Reading options INSTALLATION AND OPERATING MANUAL 35 912.808.
18.1 START-UP Start-up of the radio system comprises several steps: r 4FU UIF 855 BFSJBMT UP UIF TUBSU VQ NPEF QSFTT UIF SFE .0%& CVUUPO PO FBDI 855 BFSJBM r "U UIJT QPJOU UIF 855 BFSJBMT DPOàHVSF UIFNTFMWFT BOE BVUPNBUJDBMMZ DSFBUF B WJSUVBM DPNNVOJDBUJPO OFUXPSL r 4FU UIF IFBU NFUFS UP UIF TUBSU VQ NPEF CZ QSFTTJOH UIF CVUUPO PO UIF GSPOU "GUFS TFUUJOH UIF NPEF BMM UIF NFUFST TFOE a start-up signal to the WTT16 aerials.
START-UP AND OPERATING INSTRUCTIONS 19. FILLING THE SYSTEM Before starting the user module, open the on/off valves on the hydraulic connectors and check the system filling pressure in the boiler room and distribution columns (< 3 bar). The centralised plant must have an automatic filling device. 20. AIR VENT AND PUMP RESET 20.1 AIR VENT In the first plant filling operation, vent any air in the system, including the user module. The appliance is fitted with an automatic air vent valve. 20.
21. OPERATING PROCEDURE 21.
22.
0902_0906 / CR_0024 Safety thermostat tripping Red indicator LED Green indicator LED Red indicator LED Red indicator LED Green indicator LED Green indicator LED Figure 16: Electronic board signals INSTALLATION AND OPERATING MANUAL 40 912.808.
MAINTENANCE INSTRUCTIONS For regular and cost-effective operation of the user modules, they must be periodically checked and overhauled approxima- tely once every two years. 23.
24. CLEANING THE HEATING INLET FILTER These appliances are fitted with a heating water filter on the water inlet line coming from the centralised plant.
25. CLEANING THE COLD WATER FILTER (only for models RS – RSP – RS2Z ) The module is fitted with a cold water filter on the hydraulic assembly. To clean, proceed as follows: r r r r %SBJO UIF EPNFTUJD IPU XBUFS TZTUFN 6OTDSFX UIF OVU PO UIF áPX TFOTPS BTTFNCMZ àHVSF 1VMM PVU UIF áPX TFOTPS BOE JUT àMUFS 3FNPWF BOZ JNQVSJUJFT 0607_0304 / CR_0021 IMPORTANT: when replacing and/or cleaning the O-rings on the hydraulic assembly, only use Molykote 111 as a lubricant, not oil or grease.
PLANT HEATING RETURN HEATING RETURN TO CENTRAL PLANT HEATING INLET FROM CENTRAL PLANT PLANT HEATING DELIVERY 0902_0907 / CR_0138 26. FUNCTIONAL CIRCUIT DIAGRAM 26.1 MODEL R/1 Key Y1 ON-OFF valve C1 Meter INSTALLATION AND OPERATING MANUAL 44 912.808.
PLANT HEATING RETURN HEATING RETURN TO CENTRAL PLANT HEATING INLET FROM CENTRAL PLANT PLANT HEATING DELIVERY 0902_1102 / CR_0139 26.2 MODEL RP/1 Key Y1 ON-OFF valve C1 Meter P1 Heating pump INSTALLATION AND OPERATING MANUAL 45 912.808.
0902_0909 / CR_0004 26.3 MODEL RS INSTALLATION AND OPERATING MANUAL 46 PLANT HEATING RETURN COLD WATER INLET HEATING RETURN TO CENTRAL PLANT HEATING INLET FROM CENTRAL PLANT DOMESTIC HOT WATER OUTLET PLANT HEATING DELIVERY Key Y1 ON-OFF valve Y2 Modulating valve Y3 DHW/heating three-way valve Y4 DHW pressure switch C1 Meter B5 Domestic hot water NTC probe 912.808.
0902_0910 / CR_0005 26.4 MODEL RSP INSTALLATION AND OPERATING MANUAL 47 PLANT HEATING RETURN COLD WATER INLET HEATING RETURN TO CENTRAL PLANT HEATING INLET FROM CENTRAL PLANT DOMESTIC HOT WATER OUTLET PLANT HEATING DELIVERY Key Y1 ON-OFF valve Y2 Mixing valve Y3 DHW/heating three-way valve P1 Heating-DHW pump C1 Meter B4 Heating NTC sensor B5 Domestic hot water NTC probe F4 DHW pressure switch 912.808.
INSTALLATION AND OPERATING MANUAL 48 PLANT HEATING RETURN LOW TEMPERATURE PLANT HEATING RETURN HEATING RETURN TO CENTRAL PLANT HEATING INLET FROM CENTRAL PLANT LOW TEMPERATURE PLANT HEATING DELIVERY HIGH TEMPERATURE PLANT HEATING DELIVERY 0902_0911 / CR_0003 26.5 MODEL R2Z Key Y1 ON-OFF valve Y2 Mixing valve l.v. Y3 ON-OFF valve B4 Heating NTC sensor C1 Meter P1 High temp. circuit pump P2 Low temp. circuit pump 912.808.
INSTALLATION AND OPERATING MANUAL 49 HIGH TEMPERATURE PLANT HEATING RETURN LOW TEMPERATURE PLANT HEATING RETURN COLD WATER INLET HEATING RETURN TO CENTRAL PLANT HEATING INLET FROM CENTRAL PLANT DOMESTIC HOT WATER OUTLET LOW TEMPERATURE PLANT HEATING DELIVERY HIGH TEMPERATURE PLANT HEATING DELIVERY Key Y1 ON-OFF valve Y2 Mixing valve Y3 DHW/heating three-way valve Y4 ON-OFF valve P1 High temperature heating pump P2 Low temperature heating - DHW pump C1 Meter B4 Heating NTC sensor B5 Domestic hot wa
27. DISPOSAL This product has been built with materials that do not pollute the environment. At the end of its lifetime, do not treat it as domestic waste but take it to the nearest appliance recycling plant. Disposal must be performed according to current environmental waste disposal laws. 28.
INSTALLATION AND OPERATING MANUAL 51 912.808.
Baxi Commercial Division Wood Lane, Erdington, Birmingham B24 9QP Email: andrews@baxigroup.com www.andrewswaterheaters.co.
