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Temperature relief - valve - I.S.P.E.S.L.

approved
series 542
cert. n 0003

CALEFFI
ISO 9001

01001/03 GB

General Temperature relief valves are made by Caleffi S.p.A. in compliance with the essential safety requirements laid down by Directive 97/23/CE of the European Parliament and the Council of the European Union for harmonisation of member States with regard to pressurised equipment.

Function Temperature relief valves are used in heating systems with the function of discharging water from the system when the calibrated limit temperature is reached. These valves are positive action (fail-safe) devices, i.e. they will operate even in the case of failure of the sensor element.

111 5

I.S.P.E.S.L.

Product range Series 542 Temperature relief valve - fail-safe action - I.S.P.E.S.L. approved Sizes 1 1/2 M x 1 1/4 F, 1 1/2 M x 1 1/2 F

Technical specification Materials: Body: Control spindle: Obturator seal: Seals: Springs: Protective cover: Working pressure: Calibration temperature: Temperature range: Medium: PED category: Threaded connections:

Dimensions

0,3 P 10 bar 1 1/2 x 1 1/4; 98C 1 1/2 x 1 1/2; 99C 5100C water IV 1 1/2 M x 1 1/4 F 1 1/2 M x 1 1/2 F

1 1/2 X 1 1/2

542

A C

F C 45 53 D 115 131 E 158 183

brass EN 12165 CW617N brass EN 12164 CW614N EPDM EPDM stainless steel PP

RIARMO

D
542

Code A 542870 1 1/2" 542880 1 1/2"

B 1 1/4" 1 1/2"

F 209 239

References to I.S.P.E.S.L. standards According to the provisions of section R 1982 Edition, technical specification for application of chapter II of D.M. 1/12/75, regarding hot water systems (fluid temperature <100C), the installation of temperature relief valves is required in the following cases: Open vented systems - Heating systems having safety vent pipework which, for practical reasons, has an adverse slope. In this case, the heat discharge valve must be sized for the full output of the boiler (R.3.A. point 1.14). - Systems with boilers fed with non-pulverized solid fuel, replacing the emergency heat exchanger (R.3.C. point 1). Sealed systems - Heating systems where the required correlation between temperature increase and pressure rise does not exist (R.3.B. point 3.5). - Heating systems with circulating pumps with no flow switch (R.3.B. point 5.4). - Heating systems with a working pressure greater than 5 bar or of capacity greater than 300.000 kcal/h, replacing the second overheat thermostat (R.3.B. points 6.1 and 7.1). - Water heaters with water supply temperatures above 100C (R.3.E. point 1).

Operating principle A temperature-sensitive element directly immersed in the fluid of the system acts on the valve actuator. On reaching the calibrated limit temperature value, the valve opens and discharges water from the system. The movement of the actuator in turn operates an electric switch which can be used to shut off the fuel supply to the burner or to activate the top-up reset device. The position of the actuator and the consequent flow rate through the valve vary with the temperature of the fluid. When the limiting reclosing temperature is reached, the valve automatically closes. The valve also features fail-safe operation; i.e. the discharge opens in the event of damage of the temperature-sensitive element.

Operating characteristics The values below represent the average results obtained in the certification test and are shown on the conformity certificates issued by the I.S.P.E.S.L.: - calibration temperature at which the valve starts to open: - discharge temperature at which the nominal discharge flow rate is achieved: - reclosing temperature at which the valve re-closes in the temperature reduction phase: - emergency intervention temperature at which the valve starts to open if the thermostatic element is damaged fail-safe action: - discharge flow rate given by the graph, attached to each valve, based on the equation Gv= kv pn where: Gv kv p is the flow rate in l/h of water at temperature t1, discharged by the valve; is the nominal characteristic flow rate of the valve, of value: (the lower of that measured in normal operation and that measured in fail-safe action, when p = 1 bar); is the difference between the pressures upstream and downstream of the valve. When top-up reset is used, p is taken as the hydrostatic pressure at the point where the valve is installed, whilst otherwise, p takes the conventional set value of 0,5 bar; is the exponent of the variable p of value:

1 1/2 x 1 1/4 to= 98C t1= 104C t2= 95C

1 1/2 x 1 1/2 to= 99C t1= 99C t2= 96C

tE= 99C

tE= 98,5C

6.100 l/h

20.300 l/h

0,382 136 kW
(117.000 kcal/h)

0,495 419 kW
(360.100 kcal/h)

- heat capacity P without top-up reset:

Sizing With top-up reset When total top-up of the water discharged by the valve is provided for, the valve must discharge, at working pressure, a flow of water: Gv Gr i.e. (Gv=Kv pn) (Gr=P/80) [l/h] Where Gr is the required flow rate and P [Kcal/h] the rated output of the boiler. Without top-up reset When top-up resetting of the water discharged by the valve is not provided for, the valve must discharge, at a pressure of 0,5 bar, a flow of water: Gv Gr i.e. (Gv=Kv0,5n) (Gr=P/25) [l/h] Where Gr is the required flow rate and P [Kcal/h] the rated output of the boiler. The discharge flow rate can also be calculated by using the graph shown alongside. The discharge flow rates without top-up reset are shown in red. Certification CE mark The series 542 temperature relief valves meets the requirements of Directive 97/23/CE for pressurised equipment (also referred to as the PED). They are therefore classified in category IV and granted the CE mark. In addition, the electrical components meet the requirements of Directive 73/23/CE. I.S.P.E.S.L. mark The series 542 temperature relief valves is a component which is also I.S.P.E.S.L. approved. Devices of this type are covered by the following types of document: The approval certificate is the document issued by the I.S.P.E.S.L. which confirms the positive result of the tests carried out on the prototype sample and consequently certifies that the series in question has been approved. The document is valid for five years. Every item of the series covered by the certificate, which is manufactured during the five years validity period, is approved for an indefinite period. The bench calibration report is the document confirming the testing of each individual device included in the approved series. The test is carried out in the presence of an I.S.P.E.S.L. inspector who draws up the report after the test has been passed. The document gives the serial number of the valve, which is also to be found on the plate fixed to the valve body. There is only one copy of the report and it is therefore vital for it to be kept with the valve.

p (bar)
10 5,0
3,0

1 1/2 x 1 1/4

p (m w.g.)
100 50
30

1 1/2 x 1 1/2

2,0 1,0 0,5 0,3 0,2 0,1 100.000 5.000 20.000 10.000

20 10 5 3
2

14.404

50.000

1.000

2.000

500

4.680

G (l/h)

229 O) - S.S. ogna (N TI eto d'Agnti idrotermici IMPIAN Fontan O PER OGATA IC 28010 nenti per impia RM OL TE Compo ARICO ALVOLA OMIFICAZIONI V A DI SC - SPEC 1/12/75 VALVOLQUA CALDA. R TA DM E DEL AD ACNDO RACCOL ICATIV SECO ICHE APPL TECN
HIO: 2 4" F PN 10 54 A) MARC NALE: 1/2" M X 1 1/MESSI IN DELLO: 1 B) MO SIONE NOMI RA AM NALE: C) PRESETRO NOMI RI DI TARATU D) DIAM O DEI VALO 100C 95 : ZA E) CAMP AN 3/00 TOLLER VST 32 S.L. n. I.S.P.E. ICATO CERTIF li: C nomina 00 t o = 98 istiche 4 C Caratter 50 - Kv E = 6.1 t 1 = 10 C ra: Kv = 6.6 tura di taratu t 2 = 95 C co: Tempera tura di scari ura: t E = 99 era ius ch mp .: Te tura di nto di emerg in Tempera olare e d'interve nto rege positiva) Temp. zioname ion
fun rgenza vola in della val nto d'eme Portata ni di interve condizio
10 8 6 5 4 3 2 1,5 1 0,8 0,6 0,5 0,4 0,3 0,2 0,1 3 4 5 6 7 16 20 12 8 9 10 0 l/h) Gv (x 100 Por tata

CALEFFI

S.p.A.

original e

VERBAL E DI TA DI SCAR ICO TE RATURA AL SECOND RMICO BANC TECNIC O RACCOL PRESSO IL O DI VALVOL A FABBRI HE APPL TA R CA SP ICATIV E DEL ECIFICAZIO NTE NI DM 1/12 /1975 FONTAN
............ Valvola ..... di 542, DN scarico termico : 1 1/2" ad azion n. VST e positiva 323/00 M x 1 1/4"F, , m . certific La verifi ato I.S odello ca della .P .E.S.L. al ba n c o c taratura della valvo on 98 1 C, cam a c q u a a l l a la stata eseg stessa po di va uita tempe ha con inizio cominciato a lori entro i qu r a t u r a d i scarica ali la va La tem dell'alzata. re in m odo co lvola pe ntinuo, campo ratura di inter de ve valore no i valori amm nto riscontra essi in ta tolleranz rientra nel ed in minale di tara tura ac a rispe II de lla cordo con qu , dichiarato tto al dal anto ind Ra cc ol applica icato ne costruttore tive del ta R - Sp ll'A ppendi ec ific az DM 1/12 Il blocco ce io /1 ni m 97 Te cn ic ecca 5. ghiera he di tara nico dell'elem tura L'inam assicur ento sensibile ov ato a m e della di ta ra ibilit della pa ez rte supe zo spina tu riore e A segu ra re al izz della po tura. ito at siz l'identif del buon esito a m ed ia nt e icazione pi om ba ione de seguen tu della va lla verifica di ti da taratura ra . lvola, ve a) march ti: , per ngono io I.S.P. pu nz onati i b) num ero della E.S.L.; valvola. ETO D' AGOGNA ............ ............ ......

ISTITUTO I.S SUPE .P.E.S.L E SICU RIORE PREV Dipartim RE ENZION ento di ZZA LAVORO E BIELLA - Via Ce rruti, 7

(az

p (bar)

4680 l/h

A DI SC PORTAT
kvE p
n

ARICO

DELLA
00 p

VALVOL
0.382

G = 6.1

Installation Before installing a temperature relief valve, correct sizing must be carried out by specialist technical personnel in accordance with the current legislation governing the specific applications. It shall not be used other than for its stated purpose. The temperature relief valve must be installed by competent technical personnel qualified in accordance with current legislation. The temperature relief valve must be installed on line with the flow direction indicated by the arrow on the valve body. The temperature relief valve should be installed as close as possible to the boiler, either on the top of the boiler or in the flow pipework within 0,5 metres of the boiler and upstream of any shut-off device. a) For pipework up to 2, use of a tee-piece is recommended; b) for pipework of 2 and over, a welded connection may be used, whose collar height, for correct positioning of the temperature-sensitive element, must be 15 mm.

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58222.0 3

Il Tecn ico I.S .P.E.S.L .

Max 0,5 m
RIARMO

542

1 1/2 X 1 1/2

542

RIARMO

RIARMO

542

542

1 1/2 X 1 1/2

1 1/2 X 1 1/2

542

542

Fitting The temperature relief valve can be fitted vertically or horizontally, but not upside down. This prevents deposits of impurities from affecting correct functioning.

RIARMO

542

1 1/2 X 1 1/2

542

OMRAIR

2/1 1 X 2/1 1

245

245

542
1 1/2 X 1 1/2

542

RIARMO

Discharge pipework As the temperature relief valve is designed to discharge, in relation to the pressures involved, considerable flows of water, the discharge pipework must be as short as possible, and of diameter not less than that of the outlet of the valve itself. The discharge pipework from the temperature relief valve must be fitted in such a way as not to prevent the correct operation of the valve and not to cause damage or injury. In accordance with current legislation, the outlet of the temperature relief valve must be visible and connected to a suitable drain pipework.
RIARMO

542

1 1/2 X 1 1/2

542

Auxiliary micro-switch The temperature relief valve has a micro-switch with changeover contact which is activated after the discharge has opened. This can be used, for example, to shut off the burner or to control the top-up reset device. After the micro-switch has been activated, it must be reset manually by means of the pushbutton on the upper cover.

Electrical connections 1. solenoid valve on the fuel supply; 2. burner; 3. motorised valve for supplying top-up water (optional); 4. audible alarm (optional, not mandatory); 5. visual alarm (alternative to the audible alarm).
220 V 50 Hz
1 2 4 3
blue black brown yellow-green

220 V 50 Hz
blue black

brown

yellow-green

SPECIFICATION SUMMARIES Series 542 Temperature relief valve. I.S.P.E.S.L. approved and calibrated. Bearing CE mark as per Directive 97/23/CE and 73/23/CE. Positive action (fail-safe). Threaded connections 1 1/2 M x 1 1/4 F (1 1/2 M x 1 1/2 F). Brass body. Stainless steel springs. EPDM seals. Complete with 4-wire cable with manual reset electric changeover switch. Calibration temperature at which the valve starts to open: 98C. Maximum working pressure 10 bar.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

01005 00
GB

Replaces 01005/94

Check valves

Series

3041 3045 3046 3047 3048 3049

Check valves for protecting drinking water against the return of contaminated backflow which does constitute any toxic or microbiological danger to human health Qualification certificate for the NF Class A Anti-Pollution Mark Acoustic characteristics comply with Group 1 of ISO standards 3822 Check mechanism with press fit seal suitable for high and low pressures

ANTIPOLLUTION

ISO 9001
Quality Assured Firm

CALEFFI

Antipollution Division

Class A Check valve

General data Maximum operating pressure: 10 bar Maximum operating temperature: 90C Opening pressure: 100 mm w.g. Complies with French Standard NF P 43 007 Qualification certificate for Class A NF Anti-Pollution Mark Acoustic characteristics to Group 1 of ISO standards 3822 Operating media: water, compressed air, gas

Construction - UNI EN 12165 CW617N brass body - Check mechanism made of POM acetal resin - Seals made of NBR nitrile rubber (WRC-KTW approved for drinking water) - Spring made of AISI 302 stainless steel - 1/4 test ports.

Sealing system The lip seal also ensures effective sealing without back pressure.

3045
Check valve with Female-Female connections. Available in sizes 1/2, 3/4, 1, 1 1/4, 1 1/2 and 2. Controllable. In the case of considerable back pressure the obturator shapes the seal and rests on the shoulder. This arrangement ensures the system has a long service life.

3046
Check valve with loose nut-Male connections (3/4 x 3/4, 1 x 1, 1 1/4 x 1 1/4, 1 1/2 x 1 1/2 and 2 x 2). Controllable.

Installation An isolation cock is fitted upstream of the valve to enable control of the check valve. To test the efficiency of the check valve the shutoff is closed and the upstream plug A is unscrewed. The downstream plug B is used for draining the system (NF P 43 007).

3047
Check valve with Female-Female connections. Available in sizes 1/2, 3/4 and 1. Not controllable.

CALEFFI

NF

3048
Double check valve with Female-Female connections. Available in sizes 1/2 and 3/4. Controllable. Versions with loose nut These valves are suitable for downstream installation of the water meter. The loose nut is fitted directly on to the body of the meter.

3041
Ball valve with 1/2 incorporated check mechanism with loose nut-Male connections (3/4 x 3/4). Controllable. For use downstream from water meters.

Pressure loss

Dimensions

p (m water column) 10 5
9 8 7 6 4.5 4 3.5 3 2.5 1.8 1.6 1.4 1.2 .9 .8 .7 .6 .45 .4 .35 .3 .25 .18 .16 .14 .12 .6 .7 .8 .9 1.2 1.4 1.6 1.8 .12 .14 .16 .18 .25 .3 .35 .4 .45

1 1/2

1 1/4

1/2

3/4

D
CALEFFI

CALEFFI

NF

A C

NF

A
NF
A

CALEFFI

2 1

CALEFFI

NF

CODE 304540 304550 304560 304570 304580 304590 DN A B C D 1/2 1/2 32 27 68 3/4 3/4 32 27,5 78 1 1 32 32,5 90 1 1/4 1 1/2 1 1/4 1 1/2 32 36 110 40 41,5 120 2 2 50 48 150

.5

.2 .1

2.5 3 3.5 4 4.5

6 7 8 9

12 14 16 18

50 60

25 30 35 40 45

100

.1

.2

.5

20

10

70 80 90

G (m3/h) 1/2 p (m water column) 10 5


9 8 7 6
NF
A

D
CALEFFI

3/4

4.5 4 3.5 3 2.5 1.8 1.6 1.4 1.2 .9 .8 .7 .6 .45 .4 .35 .3 .25 .18 .16 .14 .12 .6 .7 .8 .9 1.2 1.4 1.6 1.8 .12 .14 .16 .18 .25 .3 .35 .4 .45 2.5 3 3.5 4 4.5 6 7 8 9

CODE 304640 304650 304660 304670 304680 DN A B C D 1/2 3/4 32 24 78 3/4 1 32 27,5 81 1 32 32 128 1 1/4 1 1/2 2 40 41,5 168 32 36 153,5 1 1/4 1 1/2

2 1

.5

.2 .1

B
CALEFFI

CODE 304740 304750 304760 DN A B


A

C
CALEFFI

NF

1/2 1/2 68

3/4 3/4 78

1 1 90

.1

.2

.5

10

G (m3/h) p (m water column) 10 5


9 8 7 6
CALEFFI
NF

1/2

B
A

CODE 304840 304850 DN


CALEFFI

4.5 4 3.5 3 2.5 1.8 1.6 1.4 1.2 .9 .8 .7 .6 .45 .4 .35 .3 .25 .18 .16 .14 .12

1/2 1/2 71 25,5

3/4 3/4 78 27,5

A B C

NF

2 1

.5

CODE 304140 DN A
D

1/2 3/4 32 50,5 30 88

CALEFFI

.2 .1

B C D E

.6 .7 .8 .9

1.2 1.4 1.6 1.8

.12 .14 .16 .18

.25 .3 .35 .4 .45

2.5 3 3.5 4 4.5

6 7 8 9

.1

.2

.5

10

B E

5
3

G (m /h)

Class A flanged check valves

Construction - Body and cover made of cast iron with 150 micron epoxy coating - Check valve and seat made of bronze - Rod and spring made of stainless steel - Seals made of EPDM rubber The unit can be inspected. By dismantling the top cover the complete closing mechanism which is integral with the cover itself can be removed. The bronze seal seat can also be replaced. All these maintenance and inspection operations can be carried out on site without having to remove the unit from the installation.

3049
Check valve with flanged connections from DN 50 to DN 200. Controllable. With epoxy coating.

General data Maximum operating pressure: 16 bar Maximum operating temperature: 65 oC Complies with French standard NF P 43 017 Qualification certificate for the Class A NF Anti-Pollution mark Operating fluids: drinking water PN 10/16 flanges Table of flow rates (m3/h) Dimensions

DN Q

50 19,8

65 41,8

80 63

100 99

125

150

200 396

154,8 223,2

Minimum flow rates shown with a pressure loss of 1.5 m water pressure

Pressure losses
DN

p (m water column) 3
2.5

DN 50 DN 200

2
A
1.5

CODE 304905 304906 304908 304910 304912 304915 304920 DN A B Weight 50 230 135 9 65 290 150 12,5 80 310 160 16 100 350 185 20 125 400 225 32 150 480 265 47 200 600 0

.5 .5 1.5 2.5 3.5 4.5

5 V (m/s) *

* Average speed on an entry section

CALEFFI S.P.A. I - 28010 FONTANETO D'AGOGNA (NO) S.S.229 TEL.INT. +39 0322 8491 R.A. http://www.caleffi.com e-mail: info@caleffi.it

FAX +39 0322 863723

Anti-pollution check valves

CALEFFI
3045-3046-3047-3048-3041 series
ACCREDITED

01005/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003

replaces dp 01005/00

Function The anti-pollution check valve is a hydraulic protective device capable of preventing the backflow of polluted water into the public water system. This may occur due to changes in pressure in the distribution network that cause water to flow backwards. The check valve, which is fitted between the public and the user system in water distribution systems, prevents any contact between the water in the two systems, as it closes automatically whenever backflow conditions occur. The 3045 and 3046 series of anti-pollution check valves are certified as being compliant with the performance specifications set out in European standard EN 13959.

Product range 3045 series Controllable check valve, EA type Code 304601 Controllable compact check valve, EA type 3046 series Controllable check valve, EA type 3047 series Non-controllable check valve, EB type 3048 series Controllable double check valve Code 304140 Controllable ball valve with approved built-in check valve sizes 1/2, 3/4, 1, 1 1/4, 1 1/2, 2 size 3/4 sizes 3/4, 1, 1 1/4, 1 1/2, 2 sizes 1/2, 3/4, 1 sizes 1/2, 3/4 size 3/4

Technical specifications series Materials Body: Check valve: Springs: O-Ring seals: Union seal: Knob: Ball: Ball control stem: Ball seal seat: Inspection point plug: Performance Medium: Maximum working pressure: Min. opening pressure for check valve: Maximum working temperature: Connections (and internal check valve DN) Inspection point connections 3045-3046 3047-3048-3041

brass EN 12165 CW617N POM stainless steel EPDM, NBR 3046 series: asbestos free NBR fibre 3045/3046 series: PA66G30; code 304601: brass EN 12164 CW614N drinking water 10 bar 0,5 kPa 90C 3045 series: 1/22 F (DN 1550) code 304601: 3/4 F with union for M (DN 15) 3046 series: 3/42 F with union for M (DN 1540) 1/4 F; code 304601: 1/8 F

brass EN 12165 CW617N POM stainless steel EPDM, NBR 3041 series: asbestos free NBR fibre 3041 series: EN 12165 CW617N 3041 series: EN 12164 CW614N, chrome plated 3041 series: EN 12164 CW614N 3041 series: PTFE 3048/3041 series: PA66G30

drinking water 10 bar 0,5 kPa 90C 3047 series: 1/21 F (DN 1525) 3048 series: 1/2, 3/4 F (DN 15, 20) 3041 series: 3/4 F with union for M (DN 15) 3048/3041 series: 1/4 F

Dimensions

CALEFFI

CALEFFI

NF

Code 304540 304550 304560 304570 304580 304590

A 1/2 3/4 1 1 1/4 1 1/2 2

DN* 15 20 25 32 40 50

B 32 32 32 32 40 50

C 27 27,5 32,5 36 41,5 48

D 68 78 90 110 120 150

Weight (kg) 0,16 0,25 0,40 0,62 0,82 1,33

Code 304740 304750 304760

A 1/2 3/4 1

DN* 15 20 25

B 68 78 90

Weight (kg) 0,16 0,25 0,38

B
NF

A
C 25,5 27,5 Weight (kg) 0,16 0,26 A

CALEFFI

D Code 304840 304850 A 1/2 3/4 DN* 15 20 B 71 78

Code 304601

A 3/4

DN* 15

B 15

C 18

D 58

Weight (kg) 0,16

B B E

Code 304640 304650 304660 304670 304680

A 3/4 1 1 1/4 1 1/2 2

DN* 15 20 25 32 40

B 32 32 32 32 40

C 27 27,5 32,5 36 41,5

D 68 78 90 110 120

Weight (kg) 0,20 0,31 0,70 1,10 1,60

Code 304140

A 3/4

DN* 15

B 32

C 50,5

D 30

E 88

Weight (kg) 0,40

*Internal check valve DN

C
CALEFFI

C
CALEFFI

A
A

CALEFFI

NF

Backflow Drinking water supplied by the public network may suffer from hazardous pollution caused mainly by contaminated fluids from plumbing systems flowing back directly into the public network. This phenomenon, called backflow, occurs when: a) the pressure in the public network is lower than that in the plumbing circuit receiving the supply (back siphoning). This situation may occur when a pipe is broken in the public system or when other consumer demand on the public network is very heavy. b) the pressure in the plumbing circuit receiving the supply rises (back pressure) due, for example, to water being pumped from a well.

Application of the EA type anti-pollution check valve with reference to European standard EN 1717 and EN 13959 Proper use of the EA type anti-pollution check valve is regulated by the new European standards relating to the prevention of pollution caused by backflow. The reference standard is EN 1717: 2000 Protection against pollution of drinking water in hydraulic systems and general requirements for the devices used to prevent pollution caused by backflow. In this standard, the water in the systems is classified according to the level of risk it represents for human health. Category 1: Water suitable for human consumption supplied by the water supplier. Category 2: Fluid that does not represent a health hazard, as in number 1, the quality of which has been compromised due to changes in temperature, taste, smell or appearance. Category 3: Fluid that represents a slight health risk due to the presence of one or more harmful substances. Category 4: Fluid that represents a health hazard due to the presence of one or more toxic or highly toxic substances, or one or more radioactive, mutagenic or carcinogenic substances. Category 5: Fluid that represents a severe health hazard due to the presence of microbiological or viral elements. According to this classification, suitable backflow prevention devices must be fitted in water distribution plant systems. EA type anti-pollution check valves can be used to offer protection against the risk of water contamination up to category 2. For category 3 water, it is necessary to use a CA type backflow preventer. The table below, called the Protection matrix, associates the various types of system with the relative fluid categories and has been created based on the indications provided in the European regulations. The new European standard EN 13959 Anti-pollution check valves from DN 6 to DN 250. Family E, type A, B, C and D. defines the functional, dimensional and mechanical requirements of antipollution check valves. Protection matrix Type of system

Risk assessment Given the potential dangers of the phenomenon and the requirements of current regulations, the risk of pollution caused by backflow must be assessed on the basis of the type of system and the characteristics of the fluid that flows inside it. A suitable backflow prevention device must be selected on the basis of the assessment performed by the system designer and the public network supplier. The device must be located along the supply line at the points at risk of backflow which would be hazardous to human health. The protection can be provided by fitting a check valve at critical points in the circuit, at the inlet from the public network or in the internal plumbing system. This will prevent the backflow of polluted water in all systems for which direct connection to the public or an internal network is considered hazardous.

General Hot and cold water mixing devices in domestic water systems Water cooling devices for air conditioning units, without additives Sterilisers for packaged or disinfected materials Water in primary domestic heating system circuits, without additives Domestic, residential or commercial gardens Hand-held fertiliser sprayers for use in domestic gardens Watering systems, without fertilisers or insecticides, with sprinkler fixed to the ground at a depth of not more than 150 mm Water softeners Domestic water softeners regenerated with common salt Commercial water softeners (only regenerated with common salt) Commercial applications Automatic dispensers with injection of ingredients or CO2 Automatic dispensers without injection of ingredients or CO2 Machines to wash out drink distribution pipes in restaurants Hairdresser rinsing systems Medicine X-ray machine cooling systems Food applications Ice-making machines Large kitchen machines with automatic filling system Household applications Water in sinks, baths and showers Domestic dishwashers and washing machines Flexible pipes with controlled flow spray nozzles or stop cock Domestic dialysis machines

Cat. of fluid 2 3 * * * * * *

* * *

* *

* * *

Operating principle The anti-pollution check valve consists of a valve body (1), a check valve (2) and, if necessary, one or more inspection points (3) for operation checking and system draining procedures. The check valve (2) borders two different zones: one upstream or at the inlet (A) and one downstream or at the outlet (B). Correct conditions of flow In correct flow conditions, the check valve (2) opens automatically when the pressure in the flow direction upstream (A) is greater than the downstream value (B).

Construction details Hydraulic seal devices When the flow stops, the check valve rests on a lip-shaped EPDM seal (1) which guarantees water-tightness, even in the absence of counter pressure.

A 2

In the event of strong counter pressure, the obturator (2) alters the shape of the seal and rests on the actual end point. This solution guarantees optimal device durability.

UPSTREAM
NORMAL OPERATION

DOWNSTREAM

No flow conditions The check valve (2) closes in advance under the action of the force exerted by the spring when the pressure downstream (B) tends to equal the value upstream (A), after the flow has stopped.

Elastomers complying with food regulations The elastomers used for the hydraulic seals have been approved by the Certifying Authorities in accordance with the most recent provisions regarding compatibility for use with drinking water. Versions with captive nut These versions are specifically designed for installation downstream of the water meter. The captive nut should be mounted directly over the meter body.
IFFELAC

1 A 2 B

UPSTREAM
NO FLOW CONDITION

DOWNSTREAM

Double check valve, 3048 series The range of products also includes the double check valve version (3) and (4), with inspection point (5).

Upstream pressure loss The check valve (2) remains closed, preventing water which has already been sent to the user from flowing back towards the public network.

1 A 2
U
U

5
DOWNSTREAM

UPSTREAM
UPSTREAM PRESSURE LOSS

The double check valve may be used, where permitted by current local legislation, as an alternative to the backflow preventer, whenever the water distribution mains has low inlet pressure.

Downstream pressure increase If the pressure in the downstream zone (B) increases until it exceeds the upstream pressure value (A), the check valve (2) remains closed, thus preventing water that has already been sent to the user from flowing back towards the public network.

Certification The 3045, 3046 and 3041 series anti-pollution check valves have been certified as compliant with specific national and European product standards by the following bodies: NF-BELGAQUA-ACS.

FN

Hydraulic characteristics

DN 15

DN 20

DN 25

DN 32

DN 40

DN 50

DN 15

DN 20

p (m w.g.)
10
9 8 7 6 4.5 4 3.5 3 2.5 1.8 1.6 1.4 1.2 0.9 0.8 0.7 0.6
CALEFFI

p (kPa)
90 80 70 60 45 40 35 30 25 18 16 14 12 9 8 7 6 4.5 4 3.5 3 2.5

100

p (m w.g.)
10
9 8 7 6 4 3.5 3 2.5
CALEFFI

p (kPa)
90 80 70 60

100

NF

NF

50

5 4.5

45 40 35 30 25 18 16 14 12 9 8 7 6

50

CALEFFI

NF

CALEFFI

NF

20

2 1.8
1.6 1.4 1.2 0.8 0.7 0.6

20

CALEFFI

10

1 0.9 0.5

10

CALEFFI

0.5

0.45 0.4 0.35 0.3 0.25 0.25 0.3 0.35 0.4 0.45 0.6 0.7 0.8 0.9 1.2 1.4 1.6 1.8 2.5 3 3.5 4 4.5 6 7 8 9 12 14 16 18 25 30 35 40 45 60 70 80 90

0.45 0.4 0.35 0.3 0.25 0.25 0.3 0.35 0.4 0.45 6 7 8 9 1.2 1.4 1.6 1.8 0.6 0.7 0.8 0.9 2.5 3 3.5 4 4.5

4.5 4 3.5 3 2.5

G (m3/h)

* single check valve

3045 304540 304550 304560 304570 304580 304590 3046 304640 304650 304660 304670 304680 Series* 3047 304740 304750 304760 3046 304601 3041 304140 Internal check valve DN 15 20 25 32 40 50 4,50 8,80 13,40 21,40 33,20 53,00 Kv (m3/h)

Series** 3048 Internal check valve DN Kv (m3/h)


** double check valve

304840 15 3,10

304850 20 5,40

Installation and operation checking procedures EA EC TYPE Installation Before installation, make sure that the device is suitable for protecting the supply system, in relation to the type of fluid used in the system. The controllable check valve should be installed after a shut-off valve, upstream. The unit should be installed in an accessible zone. EB TYPE Installation Before installation, make sure that the device is suitable for protecting the supply system, in relation to the type of fluid used in the system. The check valve should be installed in an accessible zone. Before installing the check valve it will be necessary to clean the piping with a high-capacity jet of water. Poor cleaning of the system can easily impair the operation of the device.

1
WATER MAIN
NF

2
CALEFFI

Shut-off valve upstream Controllable check valve Inspection points

SYSTEM

2 A-B

A B

Before installing the check valve it will be necessary to clean the piping with a high-capacity jet of water. Poor cleaning of the system can easily impair the operation of the device. Inspection and operation checking procedure The inspection and operation checking procedures should be carried out at least once a year. 1) Check whether the installation standards still require the application of the same device for the type of fluid used in the system. 2) Make sure that the hazard level of the fluid inside the system has not altered over time. 3) Check that there are no leaks or areas of corrosion or deterioration. 4) Perform the check valve seal operation checking procedure; when the water mains system pressure (and therefore the pressure upstream of the check valve) drops, the valve should close and prevent the water in the system from flowing back into the mains supply: a. in order to maintain the system pressure in the absence of flow, close all the shut-off valves downstream of the valve and the inspection points for the same check valve. b. close the shut-off valve upstream (1) and open the inspection point (A) of the check valve. The flow should stop after the part of piping, which has been cut off, is emptied. c. if this is not the case, check the seal of the shut-off valve upstream (1) and, if the flow through the inspection point (A) continues, replace the check valve. d. the inspection point (B) (where present) may be used to empty the system.

Inspection and operation checking procedure The inspection and operation checking procedures should be carried out at least once a year. 1) Check whether the installation standards still require the application of the same device for the type of fluid used in the system. 2) Make sure that the hazard level of the fluid inside the system has not altered over time. 3) Check that there are no leaks or areas of corrosion or deterioration. 4) Replace the valve every 10 years.

G (m3/h)

0.2 0.2

0.2 0.2

20

50

10

100

0.5

0.5

10

SPECIFICATION SUMMARY
3045 series Controllable check valve. EA type. Threaded connections 1/2 (from 1/2 to 2) F, internal check valve DN 15 (from DN 15 to DN 50). Certification to standard EN 13959. Brass body. POM check valve. Stainless steel spring. EPDM and NBR O-Ring seals. Medium drinking water. Maximum working pressure 10 bar. Minimum opening pressure for check valve 0,5 kPa. Maximum working temperature 90C. Inspection point plugs in PA66G30, 1/4 F connections. Code 304601 Controllable compact check valve. EA type. Threaded connections 3/4 F union x M, internal check valve DN 15. Certification to standard EN 13959. Brass body. POM check valve. Stainless steel spring. EPDM and NBR O-Ring seals. Asbestos free fibre NBR union seal. Medium drinking water. Maximum working pressure 10 bar. Minimum opening pressure for check valve 0,5 kPa. Maximum working temperature 90C. Brass inspection point plugs, 1/8 F connections. 3046 series Controllable check valve. EA type. Threaded connections 3/4 F union x M (from 3/4 to 2), internal check valve DN 15 (from DN 15 to DN 40). Certification to standard EN 13959. Brass body. POM check valve. Stainless steel spring. EPDM and NBR O-Ring seals. Asbestos free fibre NBR union seal. Medium drinking water. Maximum working pressure 10 bar. Minimum opening pressure for check valve 0,5 kPa. Maximum working temperature 90C. Inspection point plugs in PA66G30, 1/4 F connections. 3047 series Non-controllable check valve. EB type. Threaded connections 1/2 (from 1/2 to 1) F, internal check valve DN 15 (from DN 15 to DN 25). Brass body. POM check valve. Stainless steel spring. EPDM O-Ring seals. Medium drinking water. Maximum working pressure 10 bar. Minimum opening pressure for check valve 0,5 kPa. Maximum working temperature 90C. 3048 series Controllable double check valve. Threaded connections 1/2 (and 3/4) F , internal check valve DN 15 (and DN 20). Brass body. POM check valve. Stainless steel spring. EPDM and NBR O-Ring seals. Medium drinking water. Maximum working pressure 10 bar. Minimum opening pressure for check valve 0,5 kPa. Maximum working temperature 90C. Inspection point plug in PA66G30, 1/4 F connection. Code 304140 Controllable ball valve with approved built-in check valve. Threaded connections 3/4 F union x M, internal check valve DN 15. Brass body. POM check valve. Stainless steel spring. EPDM and NBR O-Ring seals. Asbestos free fibre NBR union seal. Brass knob. Chrome plated brass ball. Brass ball control stem. PTFE ball seal seat. Medium drinking water. Maximum working pressure 10 bar. Minimum opening pressure for check valve 0,5 kPa. Maximum working temperature 90C. Inspection point plugs in PA66G30, 1/4 F connections.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. S.R.229, N.25 28010 FONTANETO DAGOGNA (NO) ITALY TEL. +39 0322 8491 FAX +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

Balancing valves
series 131 - 135
cert. n 0003

CALEFFI
ISO 9001

01006/05 GB

Function Balancing valves are hydraulic devices that can precisely regulate the flow rate of the fluid that supplies a systems emitters. Hydraulic circuits must be correctly balanced to ensure that the system operates at the design conditions and provides a high level of heat comfort with low energy consumption. In the 131 series threaded valves, the flow rate is measured by a Venturi device that is incorporated into the body of the valve. This device guarantees accurate setting as well as ease of use during calibration.

Product range Series 131 Balancing valve with Venturi device. Threaded version Series 135 Balancing valve. Flanged version Sizes 1/2, 3/4, 1, 1 1/4, 1 1/2 and 2 Sizes DN 65, DN 80, DN 100, DN 125, DN 150, DN 200, DN 250 and DN 300

Technical specifications series Materials: - Body: - Bonnet: - Control stem: - Regulating disc: - Seal seat: Hydraulic seals: Flange seals: Knob: Pressure tappings: 131 threaded 135 flanged

brass EN 12165 CW617N brass EN 12165 CW617N brass EN 12164 CW614N brass EN 12164 CW614N brass EN 12165 CW617N EPDM reinforced nylon, ABS brass body with EPDM seals

cast iron ASTM A536 GR65-45-12 brass ASTM B-16 brass ASTM B-16 (DN 65 to DN 150) stainless steel (DN 200 to DN 300) bronze ASTM B584 C-84400 high-strength resin (DN 65 to DN 150) EPDM (DN 200 to DN 300) BunaN EPDM high-strength resin brass body with EPDM seals

Performance: - Medium: Max. percentage of glycol: Max. working pressure: Temperature range: Accuracy: Number of setting turns:

water, glycol solution non hazardous, therefore excluded from the guidelines of 67/548/EC Directive 50% 16 bar -10 110C 5% 5

Water, glycol solution non hazardous, therefore excluded from the guidelines of 67/548/EC Directive 50% 16 bar -5 110C 5% (open 50 to 100%) 5 (DN 65, DN 80); 6 (DN 100 to DN 150) 12 (DN 200, DN 250); 14 (DN 300)

Connections: - Connections: - Valve body pressure tapping connections:

1/2 2 F

DN 65 DN 300, PN 16 (to be coupled with EN 1092-1 counterflanges) 1/4 F

1/4 F

Dimensions

B B A B

Code A 131400 1/2" 131500 3/4" 131600 1" 131700 1 1/4" 131800 1 1/2" 135900 2"

B 76 83 97 110 129 153

C 117 125 135 143 150 170

Weight (kg) 0,49 0,55 0,84 1,06 1,59 2,46

Code 135060 135080 135100 135120 135150 135200 135250 135300

A DN 65 DN 80 DN 100 DN 125 DN 150 DN 200 DN 250 DN 300

B 305 305 356 445 525 716 762 967

C 244 267 268 332 349 625 673 722

Weight (kg) 9 11 19 37 54 141 209 395

Code 135060 135080 135100 135120 135150 135200 135250 135300

A DN 65 DN 80 DN 100 DN 125 DN 150 DN 200 DN 250 DN 300

B 187 213 244 305 359 481 516 611

C 244 267 268 332 349 625 673 722

Advantages of balanced systems A balanced system provides the following main benefits: 1. Allows the system emitters to perform correctly to heat, cool and dehumidify without wasting energy and ensuring greater comfort. 2. Permits the electropumps to work in the best efficiency zone with less risk of overheating and premature wear. 3. Reduces fluid velocities that may lead to noise and abrasion. 4. Limits the value of the differential pressures acting on the regulating valves, thus preventing malfunctions.

Operating principle A balancing valve is a hydraulic device that regulates the flow rate rate of the fluid passing through it. The flow rate is regulated by means of a knob that controls the movement of a disc that allows the passage of the fluid. The flow rate is controlled according to the p value measured by two pressure connectors located on the valve.

SISTEMI CALORE

CALEFFI
sistemi calore

FLOMET
ZERO OFFSET
C C O

ROLL

SET

+
O

SIGNAL
O

DP

DP

FLOW

ROLL

SET

SET

FLOW

MFR

ESTIMATE FLOW

ROLL

MODEL

TEMP

SIZE

ROLL

DP UNIT FLOW UNIT TEMP UNIT POWER UNIT

D. TEMP

ROLL

POWER

ROLL

A Weight (kg) 9 11 19 37 54 141 209 395

131 series construction details


Venturi flow rate measurement device The 131 series 1/2 - 2 valves are equipped with a flow rate measurement device based on the Venturi effect. The device is incorporated in the body of the valve upstream of the valve disc, as shown in the figure below. Rectification baffles The 131 series valves are equipped with special rectification baffles located immediately downstream of the disc. These devices reduce the turbulence of the fluid caused by the restriction of the disc and rectify the fluid flow characteristics more quickly. As a result, the Venturi device can make more accurate measurements and the noise caused by the turbulence of the flow is reduced. In addition, because the fluid flow is rectified more quickly, the valves can be installed with a minimum amount of straight sections of piping downstream of the valves.

Venturi device

This system provides the following benefits: 1. Allows greater precision in measuring and regulating the flow rate. Balancing valve pressure tappings are traditionally located upstream and downstream of the valve disc. This means that when the valve is closed at less than 50% of the total opening, the turbulence created downstream of the disc causes the pressure signal to become unstable, which in turn leads to significant measurement errors. This phenomenon is more apparent in medium- to small-sized 1/2 - 2 valves. Rectification baffles

18

flow rate readout error %

14 12 10 8 6 4 2 0 1/2 turn Closed

Adapting the valve size to the piping dimensions Balancing valves are often selected based on the diameter of the line piping in which they are to be installed rather than on the design flow rates that need to pass through them. This means that the valves are often oversized with respect to the flow rates, which in turn means that they need to be very restricted during balancing to ensure the design flow rate. To avoid this problem, the 131 series valves have been designed so that their hydraulic properties correspond to those of a valve with smaller connections than the piping (for example, the hydraulic properties of a 1 valve correspond to those of a valve with a 3/4 internal diameter).

Fast-coupling pressure tappings The valves are equipped with fast-coupling pressure tappings that allow for quick, precise measurements. When the measuring syringe is withdrawn, the tapping automatically closes and thus prevents water from leaking.

Number of turns

Fully open

Pressure measurement

Automatic reclosure

Standard valve with variable orifice 131 series valve with Venturi device

Safety cap 2. Permits the measurement process and manual balancing of the circuit to be performed more quickly. In fact, the flow rate is now a function of the p only, which is measured upstream and downstream of the fixed orifice of the Venturi device located upstream of the disc and no longer across the entire valve. In practical terms, this means that the only information required for measuring the flow rate in the valves is now simply the p, and no longer the p plus the position of the knob.

Measuring syringe

Seal

Adjustment knob The ergonomic shape of the adjustment knob has been designed for maximum operator comfort and accurate adjustment. The adjustment range of 5 complete turns provides a high level of precision in balancing the hydraulic circuits. The micrometric scale indicator graduations are large and clear for very easy fine adjustment of the flow rate. The knob is made of high strength, corrosion-free reinforced polymer. Adjustment reference scale Each 360 rotation of the knob moves the turn indicator by one position, within a range of 0 (valve closed) to 5 (valve fully open). The decimal graduations of the micrometric scale situated around the knob itself allow the flow rate to be even more finely adjusted.

USING AND SETTING THE BALANCING VALVE The balancing valve is used by taking into consideration the fluidodynamic characteristics that links the pressure drop, flow rate and setting position of the knob that controls the disc. Presetting The position number that the knob should be set to (presetting) can be derived by knowing the value of the pressure drop p that must be created by the valve when a certain flow rate G passes through. The characteristic curve for each valve size can be used to determine the setting position, or the corresponding Kv can be calculated using the following formula: G Kv = (1.1) where:G = flow rate in m3/h p p = pressure drop in bar (1 bar = 100 kPa, 10.000 mm c.a.) Kv = flow rate in m3/h through the valve corresponding to a pressure drop of 1 bar The value obtained is then compared to the characteristic curve values that correspond to each valve size. It is best to choose a valve size so that it can be preset to a half-open position and still provide a certain margin both in opening and closing. Measuring the flow rate Connect a differential pressure gauge to the pressure tappings of the Venturi device of the valve. Read the p value on the gauge, then determine the flow rate value G by consulting the characteristic Venturi curve for the valve size being used. Alternatively, calculate it using the following formula: G = KvVenturi x pVenturi (1.2)

Micrometric scale

Turn indicator

Note: The curve used in this step differs from the curve used for the presetting step because it refers to the pVenturi-flow rate characteristics of the Venturi device located upstream of the valve and not those across the entire valve (including the disc), which are shown in the curves used for presetting. Memory stop The valves are equipped with a system that memorises the setting, allowing the valve to be reopened in the initial position if it has been closed for any reason. Locking the position to be memorised requires the use of a 2,5 mm hex key. Setting the flow rate manually To manually calibrate the flow rate through the valve, adjust the position of the knob until the differential pressure indicated by the measuring device corresponds to the desired flow rate value on the characteristic Venturi curve for the valve being used. Alternatively, calculate the pressure drop of the Venturi device using the following formula: pVenturi = G2 KvVenturi2 (1.3)

Knob cover

Memory stop lock screw

Next, turn the adjustment knob until the theoretical p value calculated using the formula (1.3) above is reached. Nota: The curve used in this step differs from the curve used for the presetting step because it refers to the pVenturi-flow rate characteristics of the Venturi device located inside the valve and not those across the entire valve (including the disc), which are shown in the curves used for presetting. Correcting for liquids with a different density The following comments apply to liquids with a viscosity 3E (for example, water and glycol mixtures). If using liquids with a density different from water at 20C ( = 1 kg /dm3), correct the value of the pressure drop p measured using the following formula: p' = p/' where:p' = reference pressure drop p = pressure drop measured ' = liquid density in kg/ dm3

Knob

Turn indicator

Use the p' value to perform the presetting or flow rate measurement steps using the curves or the formulas.

Code 131600 1"


p (mm w.g.)
15.000 10.000 Knob setting position
0,5 1 1,5 2 2,5 3 3,5 4 4,5 5

p (kPa)
150 100

Example: presetting A flow rate G = 900 l/h must create a pressure drop of p = 18 kPa. Use the curve for the 131600 1 valve to obtain a setting position of 2 (blue line). Alternatively, use the formula (1.1) to obtain the value Kv = 0,9/ 0,18 = 2,14. Consult the table for the 131600 1 valve to obtain the corresponding setting position of 2 (the value closest to the one required).

5.000

50

2.000

20

1.000

10

500

Example: correcting for liquids with a different density Liquid density ' = 1,1 Kg/dm3 Pressure drop measured (or desired) p = 18 kPa. Reference pressure drop p' = 18/1,1 = 16,36 kPa. Use this value when consulting the curve or using the formula (1.1) to obtain the setting position that corresponds to flow rate G (new position ~ 2,15).

200

100 60 100

1 0,6 25.000

250

500

1.000

2.500

5.000

10.000

G (l/h)

Kv

Knob setting position 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 0,94 1,26 1,61 2,10 2,64 3,28 3,92 4,64 5,29 5,94

Venturi curve
p (mm w.g.)
15.000 10.000
1/2 3/4 1 1 1/4 1 1/2 2

p (kPa)
150 100

Example: measuring the flow rate For a pVenturi measurement of 3 kPa on a 1 valve, consult the Venturi curve for the valve in question where the x-axis will indicate a flow rate value of 2000 l/h (blue line). Alternatively, use the formula (1.2), where a pVenturi measurement of 3 kPa, bearing in mind that the KvVenturi of the 1 131600 valve is equal to 11,96, will result in a flow rate G = 11,96 x 0,03 = 2,07 m3/h. Example: correcting for liquids with a different density Liquid density ' = 1,1 Kg/dm3 Pressure drop measured pVenturi = 3 kPa Reference pressure drop p' = 3/1,1 = 2,72 kPa Use this value when consulting the Venturi curve for the valve used or using the formula (1.2) to obtain the corresponding flow rate G (= 1,97 m3/h).

5.000

50

2.000

20

1.000

10

500

200

100

50

0,5

Example: setting the flow rate manually Proceed as follows to adjust the flow rate for a 1 value to 2500 l/h. Turn the valve knob into the fully open position and then gradually close the valve controlling the pVenturi value indicated by the measuring device. As shown in the curve at left, once the differential value of 4,3 kPa (red line), has been reached, the flow of the fluid passing through the valve will be at the desired rate of 2500 l/h. Alternatively, with a flow rate rate of G = 2500 l/h and KvVenturi = 11,96 for the 131600 1 valve in question, use the formula (1.3) to derive a pVenturi = 2,52 / 11,962 = 4,3 kPa. Set the valve to the pVenturi value calculated. Example: correcting for liquids with a different density Desired liquid flow rate G = 2.500 l/h. Use the formula (1.3) or the Venturi curve to determine the reference pressure drop p = 2,52 / 11,962 = 4,3 kPa. If the density of the liquid used is = 1,1 kg/dm3 the formula below will provide the pressure drop pVenturi value, which should be indicated on the measuring device for the flow rate desired: pVenturi = x p = 1,1 x 4,3 = 4,73 kPa.

20 100

0,2 250 500 1.000 2.500 5.000 10.000 25.000 50.000

G (l/h)

Kv Venturi

1/2 3,10

3/4 4,74

Connection 1 1 1/4 11,96 18,41

1 1/2 18,56

2 31,85

Venturi curve
p (mm w.g.)
15.000 10.000
1/2 3/4 1 1 1/4 1 1/2 2

p (kPa)
150 100

5.000

50

2.000

20

1.000

10

500

200

100

Connection Kv

Venturi

1/2 3/4 1 1 1/4 1 1/2 2

3,10 4,74 11,96 18,41 18,56 31,85

50

0,5

20 100

0,2 250 500 1.000 2.500 5.000 10.000 25.000 50.000

G (l/h)

Code 131400 1/2"


p (mm w.g.)
15.000 10.000 Knob setting position
0,5 1 1,5 2 2,5 3 3,5 4 4,5 5

Code 131500 3/4"


p (kPa)
150 100

p (mm w.g.)

Knob setting position


0,5 1 1,5 2 2,5 3 3,5 4 4,5 5

p (kPa)
150 100

5.000

50

5.000

50

2.000

20

2.000

20

1.000

10

1.000

10

500

500

200

200

100 60 50

1 0,6 10.000

100 60 50

1 0,6 10.000

100

250

500

1.000

2.500

5.000

100

250

500

1.000

2.500

5.000

G (l/h)

G (l/h)

Kv

Knob setting position 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 0,57 0,76 0,85 1,09 1,49 1,94 2,39 2,72 2,89 3,06

Kv

Knob setting position 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 0,62 0,86 1,02 1,32 1,72 2,17 2,70 3,22 3,60 3,97

Code 131600 1"


p (mm w.g.)
15.000 10.000 Knob setting position
0,5 1 1,5 2 2,5 3 3,5 4 4,5 5

Code 131700 1 1/4"


p (kPa)
150 100

p (mm w.g.)
15.000 10.000

Knob setting position


0,5 1 1,5 2 2,5 33,5 4 4,5 5

p (kPa)
150 100

5.000

50

5.000

50

2.000

20

2.000

20

1.000

10

1.000

10

500

500

200

200

100 60 100

1 0,6 25.000

100 60 100

1 0,6 25.000

250

500

1.000

2.500

5.000

10.000

250

500

1.000

2.500

5.000

10.000

G (l/h)

G (l/h)

Kv

Knob setting position 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 0,94 1,26 1,61 2,10 2,64 3,28 3,92 4,64 5,29 5,94

Kv

Knob setting position 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 1,90 2,95 4,00 4,74 5,69 6,58 7,47 8,41 9,42 10,43

Code 131800 1 1/2"


p (mm w.g.)
15.000 10.000 Knob setting position
0,5 1 1,5 2 2,53 3,5 4 4,5 5

Code 131900 2"


p (kPa)
150 100

p (mm w.g.)
15.000 10.000

Knob setting position


0,5 1 1,5 2 2,5 3 3,5 4 4,5 5

p (kPa)
150 100

5.000

50

5.000

50

2.000

20

2.000

20

1.000

10

1.000

10

500

500

200

200

100 60 250

1 0,6 50.000

100 60 250

1 0,6 50.000

500

1.000

2.500

5.000

10.000

25.000

500

1.000

2.500

5.000

10.000

25.000

G (l/h)

G (l/h)

Kv

Knob setting position 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 1,88 3,66 5,12 6,54 7,67 8,99 10,1111,4712,9214,77

Kv

Knob setting position 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 3,73 5,24 7,98 11,19 14,35 16,99 19,17 21,74 22,86 24,48

135

series construction details


Adjustment knob The ergonomic shape of the adjustment knob has been designed for maximum operator comfort and accurate adjustment. The adjustment range of several complete turns provides a high level of precision in balancing the hydraulic circuits. The micrometric scale indicator graduations are large and clear for very easy fine adjustment of the flow rate. The indicator can be quickly repositioned to facilitate reading. The knob is made of high strength, corrosion-free reinforced resin.

Convertibility of the connections The 135 series valve bodies can be converted from straight connections to angled connections and vice versa at the installation site without using special tools or additional parts. These connections are able to be converted because the bodies have been constructed with a 45 seal. Rotating one half of the body will change the direction of the connections by 90, making it very easy to convert the connections at the installation site without jeopardising the precision of their operations. This is the first time that a balancing valve, for this type of product, can be used conventionally or by replacing the elbows or bends in a hydraulic circuit. This adaptability allows it to be situated in the ideal location.

Adjustment reference scale Each 360 rotation of the knob moves the linear indicator by one position, within a range of 0 (valve closed) to the maximum value depending upon the size of the valve. The decimal graduations situated around the knob itself allow the flow rate to be even more finely adjusted.

Coupling with flanges The 135 series valves are equipped with a special coupling system of flanges composed of the following parts: Adapters for two-part flanges with an anti-rotation lock system.

Decimal graduations

A lip gasket for the hydraulic seal.

Linear indicator

Memory stop The valves are equipped with a system that memorises the setting, allowing the valve to be reopened in the initial position if it has been closed for any reason. Locking the position to be memorised does not require the use of any special tools.
GASKET

VALVE BODY

GROOVED FLANGE

Lock screw

Fast-coupling pressure tappings The valves are equipped with quick-couple pressure tappings that allow for quick, precise measurements. When the measuring syringe is removed, the tapping automatically closes and thus prevents water from leaking. Pressure measurement Automatic closure Memory stop

Lock nut Safety cap

Measuring syringe

Seal

USING AND SETTING THE BALANCING VALVE The balancing valve is used by taking into consideration the fluidodynamic characteristics that links the pressure drop measured at the pressure connections, flow rate and setting position of the knob. Presetting The position number that the knob should be set to (presetting) can be derived by knowing the value of the pressure drop p that must be created by the valve when a certain flow rate G passes through. The characteristic curve for each valve size can be used to determine the setting position, or the corresponding Kv can be calculated using the following formula: G p (1.1) where: G = flow rate in m3/h p = pressure drop in bar (1 bar = 100 kPa = 10.000 mm c.a.) Kv = flow rate in m3/h through the valve, corresponding to a pressure drop of 1 bar

Measuring the flow rate The flow rate value G that is passing through the valve can be derived by measuring the p value on the valve for a specific setting position and consulting the curve or calculating it using the following formula: G = Kv p (1.2)

Correcting for liquids with a different density The following comments apply to liquids with a viscosity 3E (for example, water and glycol mixtures). If using liquids with a density different from water at 20C ( = 1 kg/dm3), correct the value of the pressure drop p measured using the following formula: p = p where: p= reference pressure drop p = pressure drop measured = liquid density in kg/dm3

Kv =

Use the p value to perform the presetting or flow rate measurement steps using the curves or the formulas.

The value obtained is then compared to the characteristic curve values that correspond to each valve size. It is best to choose a valve size so that it can be preset to a halfopen position and still provide a certain margin both in opening and closing.

Code 135060 DN 65 straight


p (mm w.g.)
15.000 10.000 Knob setting position
0,5 1 1,5 2 3 4 4,5 5

p (kPa)
150 100

Example: presetting A flow rate G = 6000 l/h must create a pressure drop of p = 7 kPa. Use the curve for the 135060 DN 65 straight valve to obtain a setting position of 3 (blue line). Alternatively, use the formula (1.1) to obtain the value Kv = 6 / 0,07 = 22,72. Consult the table for the 135060 DN 65 straight valve to obtain the corresponding setting position of 3 (the value closest to the one required).

5.000

50

2.000

20

1.000

10

500

Example: correcting for liquids with a different density Liquid density ' = 1,1 Kg/dm3 Pressure drop measured (or desired) p = 7 kPa. Reference pressure drop p' = 7/1,1 = 6,36 kPa Use this value when consulting the curve or using the formula (1.1) to obtain the setting position that corresponds to flow rate G (new position ~ 3.15).

200

100 60 0,5 1 2,5 5 10 25 50

1 0,6 100

G (m3/h)

Knob setting position Kv 0,5 11 1 12,8 1,5 16 2 18 3 22,3 4 33 4,5 47 5 61

Code 135060 DN 65 angled


p (mm w.g.)
15.000 10.000 Knob setting position
1 2 3 4 4,5 5

p (kPa)
150 100

Example: measuring the flow rate For a 135060 DN 65 square valve with the knob set in position 4 (corresponding to a Kv = 35 in the table), and a pressure drop p measurement = 14 kPa. Consult the curve to obtain a flow rate value G of approximately 13 m3/h (blue line). Alternatively, use the formula (1.2) to obtain: G = 35 x 0,14 = 13 m3/h

5.000

50

2.000

20

1.000

10

Example: correcting for liquids with a different density Liquid density ' = 1,1 Kg/dm3 Pressure drop measured p = 14 kPa Reference pressure drop p' = 14/1,1 = 12,7 kPa Use this value when consulting the curve for the valve used or using the formula (1.2) to obtain the corresponding flow rate G (= 12,47 m3/h).

500

200

100 60 0,5 1 2,5 5 10 25 50

1 0,6 100

G (m3/h)

Knob setting position Kv 1 15,5 2 21 3 27 4 35 4,5 52 5 66

Code 135060 DN 65 straight


p (mm w.g.)
15.000 10.000 Knob setting position
0,5 1 1,5 2 3 4 4,5 5

Code 135060 DN 65 angled


p (kPa)
150 100

p (mm w.g.)
15.000 10.000

Knob setting position


1 2 3 4 4,5 5

p (kPa)
150 100

5.000

50

5.000

50

2.000

20

2.000

20

1.000

10

1.000

10

500

500

200

200

100 60 0,5 1 2,5 5 10 25 50

1 0,6 100

100 60 0,5 1 2,5 5 10 25 50

1 0,6 100

G (m3/h)

G (m3/h)

Knob setting position Kv 0,5 11 1 12,8 1,5 16 2 18 3 22,3 4 33 4,5 47 5 61 Kv 1 15,5 2 21

Knob setting position 3 27 4 35 4,5 52 5 66

Code 135080 DN 80 straight


p (mm w.g.)
15.000 10.000 Knob setting position
0,5 1 1,5 2 3 3,5 4 4,5 5

Code 135080 DN 80 angled


p (kPa)
150 100

p (mm w.g.)
15.000 10.000

Knob setting position


0,5 1 2 3 3,5 4 4,5 5

p (kPa)
150 100

5.000

50

5.000

50

2.000

20

2.000

20

1.000

10

1.000

10

500

500

200

200

100 60 1 2,5 5 10 25 50 100

1 0,6 250

100 60 1 2,5 5 10 25 50 100

1 0,6 250

G (m3/h)

G (m3/h)

Knob setting position Kv 0,5 14,5 1 17 1,5 20 2 22 3 26 3,5 32 4 49 4,5 63 5 82 Kv 0,5 13 1 16

Knob setting position 2 21 3 23 3,5 31 4 45 4,5 63 5 82

Code 135100 DN 100 straight


p (mm w.g.)
15.000 10.000 Knob setting position
0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6

Code 135100 DN 100 angled


p (kPa)
150 100

p (mm w.g.)
15.000 10.000

Knob setting position


1 2 2,5 3 3,5 4 4,5 5 5,5 6

p (kPa)
150 100

5.000

50

5.000

50

2.000

20

2.000

20

1.000

10

1.000

10

500

500

200

200

100 60 1,5

1 0,6 400

100 60 2 5 10 25 50 100 250

1 0,6 400

2,5

10

25

50

100

250

G (m3/h)

G (m3/h)

Knob setting position 0,5 Kv 14 1 18 1,5 21 2 23 2,5 38 3 58 3,5 4 4,5 5 5,5 6 83 110 140 165 180 220 Kv 1 21 2 25 2,5 39

Knob setting position 3 61 3,5 86 4 112 4,5 132 5 168 5,5 190 6 217

Code 135120 DN 125 straight


p (mm w.g.)
15.000 10.000 Knob setting position
0,5 1 2 2,5 3 3,5 4 4,5 5 5,5 6

Code 135120 DN 125 angled


p (kPa)
150 100

p (mm w.g.)
15.000 10.000

Knob setting position


1 2 2,5 3 3,5 4 4,5 5 5,5 6

p (kPa)
150 100

5.000

50

5.000

50

2.000

20

2.000

20

1.000

10

1.000

10

500

500

200

200

100 60 2,5

1 0,6 500
3

100 60 2,5

1 0,6 500
3

10

25

50

100

250

10

25

50

100

250

G (m /h)

G (m /h)

Knob setting position Kv 0,5 23 1 28 2 35 2,5 46 3 78 3,5 4 4,5 5 5,5 6 120 145 178 220 248 275 Kv 1 27 2 33 2,5 49

Knob setting position 3 80 3,5 4 4,5 5 5,5 6 116 151 180 220 247 275

Code 135150 DN 150 straight


p (mm w.g.)
15.000 10.000 Knob setting position
1 2 2,5 3 3,5 4 4,5 5 5,5 6

Code 135150 DN 150 angled


p (kPa) p (mm w.g.)
15.000 10.000 Knob setting position
1 2 2,5 3 3,5 4 4,5 5 5,5 6

p (kPa)

150 100

150 100

5.000

50

5.000

50

2.000

20

2.000

20

1.000

10

1.000

10

500

500

200

200

100 60 2,5

1 0,6 500
3

100 60 2,5

1 0,6 500
3

10

25

50

100

250

10

25

50

100

250

G (m /h)

G (m /h)

Knob setting position Kv 1 29 2 52 2,5 91 3 130 3,5 175 4 220 4,5 260 5 310 5,5 360 6 395 Kv 1 27 2 56 2,5 92

Knob setting position 3 135 3,5 173 4 230 4,5 270 5 315 5,5 370 6 400

Code 135200 DN 200 straight


p (mm w.g.)
15.000 10.000 Knob setting position
4 5 6 7 8 910 1112

Code 135200 DN 200 angled


p (kPa)
150 100

p (mm w.g.)
15.000 10.000

Knob setting position


4 5 6

11 7 8 9 10 12

p (kPa)
150 100

5.000

50

5.000

50

2.000

20

2.000

20

1.000

10

1.000

10

500

500

200

200

100 60 20

1 0,6 2500

100 60 20 50 100 250 500 1000

1 0,6 2500

50

100

250

500

1000

G (m /h)

G (m3/h)

Knob setting position Kv 4 244 5 332 6 424 7 538 8 645 9 753 10 863 11 920 12 1005 Kv 4 240 5 318 6 410

Knob setting position 7 545 8 611 9 725 10 832 11 908 12 980

Code 135250 DN 250 straight


p (mm w.g.)
15.000 10.000 Knob setting position
3 4 5 6 7 8 10

Code 135250 DN 250 angled


p (kPa)
150 100

p (mm w.g.)
15.000 10.000

Knob setting position


3 4 5 6 7 8 10

p (kPa)
150 100

5.000

50

5.000

50

2.000

20

2.000

20

1.000

10

1.000

10

500

500

200

200

100 60 10

1 0,6 2500

100 60 10

1 0,6 2500

25

50

100

250

500

1000

25

50

100

250

500

1000

G (m3/h)

G (m3/h)

Knob setting position Kv 3 374 4 480 5 718 6 1044 7 1440 8 1690 10 1796 Kv 3 307 4 465

Knob setting position 5 752 6 980 7 1435 8 1676 10 1720

Code 135300 DN 300 straight


p (mm w.g.)
15.000 10.000 Knob setting position
2 3 4 5 7 10 14 6 8 12

Code 135300 DN 300 angled


p (kPa)
150 100

p (mm w.g.)
15.000 10.000

Knob setting position


2 3 4 5 6

7 10 14 8 12

p (kPa)
150 100

5.000

50

5.000

50

2.000

20

2.000

20

1.000

10

1.000

10

500

500

200

200

100 60 25

1 0,6 5000

100 60 25

1 0,6 5000

50

100

250

500

1000

2500

50

100

200

500

1000

2500

G (m3/h)

G (m3/h)

Knob setting position Kv 2 3 4 5 6 7 8 10 12 14 430 712 1005 1366 1723 1976 2160 2440 2585 2836 Kv

Knob setting position 2 3 4 5 6 7 8 10 12 14 417 711 1006 1306 1692 1967 2340 2371 2546 2719

Installation The balancing valves should be installed so that the pressure tappings, drain cocks and adjustment knob can all be accessed. The valves can be mounted on both horizontal and vertical pipes. It is best to keep the piping sections upstream and downstream of the valves straight for greater measurement precision, as shown in the diagram below. The direction of flow rate indicated on the valve body must be observed.

Accessories

130 series Flomet


Electronic device to measure differential pressures and flow rates. Calibration range 0.05 200 kPa. Unit of measure and fluidodynamic data can be selected and memorised. Measures the temperature of the fluid (0 90C). Supplied complete with isolating valves and connectors.

131 series

131 series

Pump

5D

10D
Nut Pressure tapping

135 series

135 series

Pump

FLOMET fast-coupling

Syringe

2D

5D

2D

10D

Sizing a system with balancing valves Please see the 2nd volume of the Caleffi Handbooks for further information about sizing a system with balancing valves, which provides calculation examples and notes about the use of devices in circuits.

100 series
Pair of connectors with fast-coupling syringe to connect the pressure tappings to measuring instruments. Female 1/4 threaded connection.

Application diagrams

To regulate the flow rate that flows to each column

To regulate the flow rate that supplies each emitter

To balance circuits that serve the coils of air treatment units

To balance circuits that serve cooling towers

To balance sanitary distribution circuits

To balance zone branches in circuits with three-way valves

To balance the by-pass way in circuits for temperature control

To balance primary/secondary coupled circuits

GR1

GR2

GR1

GR2

To balance circuits that serve cooling unit evaporators or condensers

To balance the various substations in district heating systems

SPECIFICATION SUMMARIES
Series 131 Balancing valve with Venturi device. Threaded 1/2 connections (from 1/2 to 2) F x F. Brass body, control stem and disc. EPDM hydraulic seals. Temperature range: -10 110 C. Maximum operating pressure: 16 bar. Accuracy: 5%. Knob with micrometric indicator. Five adjustment turns. Adjustment position lock and memory. Complete with fast-coupling pressure tappings. Series 135 Balancing valve. Flanged DN 65 connections (from DN 65 to DN 300), PN 16 convertible from straight to elbow and viceversa with lip gaskets in EPDM. Cast iron body. Brass or stainless steel control stem. Bronze disc. Buna-N seals. Temperature range: -5 110C. Maximum operating pressure: 16 bar. Accuracy: 5%. Knob with micrometric indicator. Adjustment position lock and memory. Complete with fast-coupling pressure tappings.

We reserve the right to change the products and relevant technical data contained in this publication at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.com

Differential by-pass valve

CALEFFI
519 series
IS

TERE

BSI EN ISO 9001:2000 Cert. n FM 21654

UNI EN ISO 9001:2000 Cert. n 0003

01007/07 GB
replaces dp 01007/00

Function The differential by-pass valve is used in systems working with variable flow rates, for example in those making widespread use of thermostatic valves or 2-way motorised valves. It ensures a flow recirculation proportional to the number of valves being closed, while limiting the maximum differential pressure value generated by the pump. In chilled water systems with high head pumps, installation of the version with a setting range between 100 and 400 kPa is advisable.

Product range Code 519500 Adjustable differential by-pass valve with graduated scale, setting range: 16 m w.g. Code 519700 Adjustable differential by-pass valve with graduated scale, setting range: 16 m w.g. Code 519504 Adjustable differential by-pass valve with graduated scale, setting range: 1040 m w.g. Size 3/4 Size 1 1/4 Size 3/4

Technical specifications Materials Body: Obturator: Obturator gasket: O-Ring seals: Union seals: Control knob: Spring: Performance Medium: water, glycol solutions Max percentage of glycol: 30% Temperature range: 0110C Maximum working pressure: 10 bar Setting range: 1060 kPa (16 m w.g.) for codes 519500 and 519700 100400 kPa (1040 m w.g.) for code 519504 Connections: 3/4, 1 1/4 F x M with union brass EN 12165 CW617N brass EN 12164 CW614N EPDM EPDM asbestos free NBR ABS stainless steel

Dimensions

A
A B
Code 519 500 519 700 519 504 A 3/4 1 1/4 3/4 B 59 88,5 59 C 26 41 26 D 104 158 104 Weight (Kg) 0,45 1,19 0,45

RE

mH2O

1 2 3 4 5 6

Operating principle When the spring (1) compression is adjusted using the control knob (2), the force balance acting on the obturator (3) changes, thus modifying the trigger pressure value of the valve. The obturator opens, activating the by-pass circuit, only when it is subjected to a differential pressure sufficient to generate a thrust greater than the thrust exerted by the contrast spring. This allows the flow discharge through the outlet (4), limiting the difference in pressure between the two points in the system where the valve is fitted.
2

5 1 3


System operation The job of the by-pass valve is to maintain the pump operating point as close as possible to its nominal value (point A on the graph shown below). If the by-pass valve is not used, when the flow rate in the circuit decreases due to partial closure of the two-way valves, the head loss in the circuit increases, point B. The by-pass valve, set to the nominal head value of the pump, enables to limit the pressure increase, by-passing the flow rate G. This behaviour is guaranteed at any closing condition of the system regulating valves. In fact, once the position of the valve control knob has been established, the trigger pressure value is more or less constant as the discharge flow rate varies (see hydraulic characteristic diagrams). A proper valve sizing must guarantee a sufficient flow rate by-pass to keep the pump at its nominal operating point in all system operating conditions, for example when the first thermostatic valves are closed.
Regulating valve TOTAL LOAD
mH2O 6
1 2 3 4 5

PARTIAL LOAD

mH2O 6

1 2 3 4 5

p pNOMINAL Circuit resistance curve


with regulating valves partially open

B
Pump curve

p constant on the circuit

Circuit resistance curve with regulating valves fully open

G 50% 100% Flow rate G

Setting To regulate the valve, turn the knob to the required value on the graduated scale: the values correspond to the differential pressure in metres w.g. to open the by-pass. To carry out rapid adjustment of the by-pass valve it is possible to use the following practical method, which can be applied, for example, to the system in an apartment fitted with thermostatic valves: the system must be operating, the regulating valves must be fully open and the by-pass valve must be set to the maximum value (a). Close approximately the 30% of the thermostatic valve. Gradually open the valve using the control knob. Use a thermometer, or simply your hand, to check that the hot water is flowing into the by-pass circuit (b). As soon as a rise in the temperature is noted, open the thermostat valves again and check that the hot water stops flowing into the by-pass (c). Lock the knob in this position (d) with the fixing screw (5).

a)
mH2O 6
1 2 3 4 5

b)
mH2O 6
1 2 3 4 5

c)
mH2O 6
1 2 3 4 5

d)
mH2O 6
1 2 3 4 5

Hydraulic characteristics code 519500 (3/4) code 519700 (1 1/4)


Setting positions

p (m w.g.)
8 7 6 5 4 3 2 1 0 0,5

(kPa
80 70

p (m w.g.)
8 7 6 5 4 3 2 1 0 1 2 3 4

Setting positions

(kPa)
80 70

6 5 4 3 2 1 1 1,5

60 50 40 30 20 10 2 0

6 5 4 3 2 1

60 50 40 30 20 10 0

10

Flow rate (m3/h)


code 519504 (3/4)

Flow rate (m3/h)

60

p (m w.g.)
50

Setting positions

(kPa)
600 500

Installation The differential by-pass valve can be fitted in any position, respecting the flow direction indicated by the arrow on the valve body. In systems with a traditional boiler it is normally fitted between the system flow and return ends, which allows the control of the pressure and the passage of a minimum flow through the heat generator. In systems with a condensation boiler, it is preferable to fit the by-pass directly between the upstream and downstream sections of the pump, as this allows a higher T in the circuit, with lower return temperatures and therefore better operation of the system. In the event of high by-pass flow rate levels, it is recommended to fit the valve between the flow and return ends of each column, rather than fitting a number of valves in parallel at the central boiler.

40 30 20 10 0 0,5 3 2 1 1

400 300 200 100 1,5 0

Flow rate (m3/h)

Application diagrams

Shut-off valve

Small-medium size system by-pass in central plant

RT

Pump

RT

Room thermostat

Check valve
RT

Insulated manifold

Two way zone valve

Autoflow

Thermostatic valve

1 2 3 4 5 6

O2Hm

Automatic air vent

Medium-large size system


mH2O
1 2 3 4 5 6

mH2O

1 2 3 4 5 6

by-pass on top of risers


RT RT RT RT

RT

RT

RT

RT

Chilled water system, central by-pass

RT

RT

RT

RT

CHILLER
1 2 3 4 5 6

O2Hm

SPECIFICATION SUMMARIES
519 series Differential by-pass valve. Threaded connections 3/4 (1 1/4) F x M with union. Brass body. Brass obturator. EPDM obturator gasket. EPDM O-Ring seals. Asbestos free NBR union seals. ABS control knob. Stainless steel spring. Medium: water, glycol solutions. Maximum percentage of glycol 30%. Temperature range 0110C. Maximum working pressure 10 bar. Setting range 1060 kPa size 3/4 and 1 1/4, 100400 kPa size 3/4.

We reserve the right to make changes and improvements to the products and related data in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 R.A. FAX +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2007 Calef fi S.P.A.

Non-controllable backflow preventer with different pressure zones (CA type)


573 series
cert. n 0003

CALEFFI
01008/07 GB

ISO 9001

Function The backflow preventer is a protective plumbing device capable of preventing backflow of polluted water into the mains water system. This type of backflow may occur due to changes in pressure in the distribution network that cause water to flow backwards. The preventer, which is fitted between the mains and the user system in water distribution systems, creates a safety separation area that prevents any contact between the water in the two systems. This particular series of backflow preventers is certified as conforming to the performance requirements of standard NF P 43.009, with certification in progress according to standard EN 14367

SVGW SSIGE

Product range Series 573 Non-controllable backflow preventer with different pressure zones, CA type size 1/2, 3/4

Technical specifications Materials Body: dezincification-resistant alloy EN 12165 CW602N Seat of central obturator: dezincification-resistant alloy EN 12164 CW602N Check valve body: POM Springs: stainless steel Diaphragm: shaped NBR O-Ring seals: NBR Gaskets: non asbestos NBR Strainer: stainless steel Performance Medium: Nominal pressure: Maximum working temperature: Connections:

Dimensions

drinking water PN 10 65C 1/2, 3/4 F with union

Code 573400 573500

A 1/2 3/4

B D C 119,5 113,5 40 119,5 113,5 40

E 54 54

F Weight (kg) 44 1,3 44 1,3

Backflow Potable water fed from the mains supply may suffer from hazardous pollution caused mainly by contaminated fluids from plumbing systems flowing back directly into the mains supply. This phenomenon, termed backflow occurs when: a) the pressure in the mains system is less that in the plumbing circuit receiving the supply (back syphonage). This situation may occur when there is a pipe breaking in the mains system or when demand on the mains supply from consumers is very heavy. b) the pressure in the plumbing circuit receiving the supply rises (back pressure) due, for example, to water being pumped from a well.

Use of CA type backflow preventers - reference to European standard EN 1717 and EN 14367 Proper use of the CA type backflow preventer is regulated by the new European standards on prevention of pollution from backflow. The reference standard is EN 1717: 2000 Protection against polution of drinking water in water systems and general requirements for the devices used to prevent pollution by backflow. In this standard, the water in the systems is classified according to the level of risk it represents for human health.

Category 1: Category 2: Category 3: Category 4:

Water used for human consumption provided by a water company. Fluid that does not present health hazard, as per 1, the quality of which has been compromised due to changes in temperature, taste, odour or appearance. Fluid that represents a slight health hazard due to the presence of one or more harmful substances. Fluid that represents a health hazard due to the presence of one or more toxic or very toxic substances or one or more radioactive, mutagenic or carcinogenic substances. Fluid that represents a severe health hazard due to the presence of microbiological or viral elements.

Category 5:

According to this classification, suitable backflow prevention devices must be inserted in water distribution systems. CA Type backflow preventers are used to protect against risk of contamination by waters of up to category 3. For water of category 4, it is necessary to use a backflow preventer of BA type. For water of category 2 on the contrary it is sufficient to use a controllable check valve of EA type or a controllable double check valve of EC type. The table given below, named Protection matrix, associates the various types of system with the relative categories of fluid, and has been drawn up based on the indications provided in the European standards. Standard NF P 34.009 and the new European standard EN 14367 Devices to prevent pollution by backflow of potable water. Non-controllable backflow preventer with different pressure zones. Family C Type A establishes the functional, dimensional and mechanical requirements that must be satisfied by non-controllable backflow preventers with different pressure zones of CA type. Risk assessment Given the potential dangers of the phenomenon and the requirements of current regulations, the risk of pollution from backflow must be assessed on the basis of the type of system and the characteristic of the fluid that flows in it. An appropriate backflow prevention device must be selected on the basis of that assessment performed by the system designer and the mains supplier. The device must be located along the supply line at those points at risk of backflow which would be hazardous to human health. The protection can be provided by inserting a backflow preventer at critical points in the circuit at the inlet from the mains supply or in the internal plumbing system. This will prevent polluted water from flowing back in all systems for which direct connection to the mains or an internal supply is considered hazardous.
Installation in a building with multiple users

Protection matrix Type of plant

General Hot and cold water mixing devices in domestic water systems Water cooling devices for air conditioning units, without additives Sterilisers for packed or disinfected materials Water in primary domestic heating system circuits, without additives Domestic, residential or commercial gardens Hand held fertiliser sprayers for use in domestic gardens Watering systems, without fertilisers or insecticides, with sprinkler fixed to the ground at a depth of not more than 150 mm Water softeners Domestic water softeners regenerated with common salt Commercial water softeners (only regenerated with common salt) Commercial applications Automatic dispensers with injection of ingredients or CO2 Automatic dispensers without injection of ingredients or CO2 Machines to wash out drink distribution pipes in restaurants Hairdresser rinsing systems Medicine X-ray machine cooling systems Food applications Ice-making machines Large kitchen machines with automatic filling system Domestic applications Water to sinks, baths and showers Domestic dishwashers and washing machines Flexible pipes with controlled flow spray nozzles or stop cock Domestic dialysis machines

Fluid cat. 2 3 * *

* * * *

* * * * * * *

* * *

* * *

Operating principle The non-controllable reduced pressure zone backflow preventer, CA type comprises: a check valve upstream (1); a check valve downstream (2); a discharge device (3). The two check valves mark the limits of three different zones, in each of which there is a different pressure: upstream or inlet area (A); intermediate zone, also known as the zone of different pressure (B); downstream or outlet zone (C). The discharge device (3) is located in the intermediate zone. The discharge device (3) is connected directly to the diaphragm (4). This mobile assembly is opened and closed by the difference in pressure between upstream and downstream of the check valve and by the counter spring (5). Correct conditions of flow Under correct conditions of flow, both check valves are open, while the pressure in the intermediate chamber (B) is always lower than the pressure upstream (A) due to a calculated loss of head at the first check valve (1). As a result, this pressure difference acts on the internal diaphragm (4) and generates a force that keeps the drain valve closed (3), communicating with the atmosphere, pressing on the counter spring (5). Upstream pressure loss As the pressure upstream decreases, both the check valves close. The discharge valve (3) opens at the moment in which the difference in pressure p, existing between the upstream (A) and intermediate areas (B) reaches a value just below the one calculated for the counter spring (5). Drainage continues until the intermediate chamber of the backflow preventer is empty. This creates a (safety) air zone and prevents the contaminated water of the circuit , coming from zone (C), from returning into the water distribution mains if the downstream check valve (2) fails. When the situation returns to normal (upstream pressure higher than the downstream pressure), the discharge valve closes again and the backflow preventer is once again ready to work.

1 9

2 7 8

1 UPSTREAM STRAINER 3 A B C 6
NORMAL OPERATION

2 7 8

DOWNSTREAM

UPSTREAM STRAINER 3 A B C

DOWNSTREAM

No flow conditions The check valves (1) and (2) are now closed. Due to the difference in pressure that still exists between the upstream zone (A) and the intermediate zone (B), the discharge valve (3) remains closed.

6
UPSTREAM PRESSURE LOSS

1 9

2 7 8
Downstream pressure increase If the pressure in the downstream zone (C) increases until it exceeds the upstream pressure value (A), the check valve (2) closes, thus preventing the water that has already been sent to the user from flowing back towards the water main. Should check valve (2) have a slight problem with seal, or in general should any other malfunction occur in the backflow preventer, the latter will always shut off (disconnect) the connection between the user and the water main. The backflow preventer has been made with all the constructional features typical of positive acting devices; this means it ensures that optimum safety conditions are maintained in all situations.

UPSTREAM STRAINER 3 A B C

DOWNSTREAM

6
NO FLOW CONDITION

Construction details Corrosion-proof materials The materials used to manufacture the backflow preventers must be insensitive to corrosion caused by contact with drinking water, and these characteristics must be maintained over time. For this reason, they have been made using dezincification-resistant alloy for the body (7), the central obturator seat (8) and the check valves (1-2), and stainless steel for the springs and strainer. Elastomers complying with food regulations The elastomers used for the hydraulic seals have been approved by the Certifying Bodies in accordance with the most recent regulations regarding compatibility for use with drinking water. Stainless steel strainer The backflow preventer is fitted with a stainless steel strainer (9) upstream, to prevent impurities or dirt from causing damage to the check valve seals (1-2) or the central obturator internal mechanism (8) over time. Certification The non-controllable backflow preventer with different pressure zones CA type 573 series is certified as in compliance with the specific national and European product requirements by the following Bodies: NF - SVGW - BELGAQUA - KIWA - SITAC - ACS.

Hydraulic characteristics
p (bar) 2
1,8 1,6 1,4 1,2

p (m w.g.)

20
18 16 14 12

Before installing the backflow preventer it will be necessary to clean the piping with a high-capacity jet of water. Poor cleaning of the system can easily impair the operation of the unit. For the protection of the public mains the disconnection unit must be installed after the water meter, whereas in order to protect the tap water outlets of the internal network it should be installed at the limit of the areas where there may be contamination, for example: central heating, watering gardens, etc.

1
0,9 0,8 0,7 0,6 9 8 7 6

10

Operating control procedure


5

0,5
0,4 0,3 4 3

1. Drain control operation. When there are drops in pressure in the water supply mains, therefore upstream from the valve, the drain valve must open and let the water contained in the valve body run out: a. Close the shut-off valves upstream and downstream (4). b. Open the upstream control cock (2). The water contained in the valve body should now flow out, indicating that the device has tripped and has opened the drain valve.

10

20

0,1

0,2

0,5

Installation The backflow preventer unit must be installed horizontally after a shut-off valve upstream and an inspectable filter; another shut-off valve must be installed downstream. The unit must be installed in an accessible area that is large enough to prevent it getting submerged by any accidental flooding. In addition there must be adequate waste pipe for medium drained from the unit to flow away. 2. Check the seal of the second check valve. When back pressure is applied on the downstream side of the valve, the second check valve must close to prevent the water from flowing back: a. Close the shut-off valves downstream and upstream from the disconnection unit. b. Open the upstream control cock (2). c. Install a by-pass hose joining the control cock (1) to the other control cock (3) downstream and open them both to carry the mains pressure downstream of the second check valve. No water must come out of the drain valve, thereby indicating that the second check valve does not leak.

WATER MAINS

1 Water mains control cock 2 Upstream control cock 3 Downstream control cock 4 Upstream/downstream shut-off valve

5 Y-strainer 6 Backflow preventer series 573 with inspectable filter at inlet 7 Drain to sewer

SPECIFICATION SUMMARIES
573 series Non-controllable backflow preventer with different pressure zones. CA Type. Complies with NF P 43.009. Connections 1/2 (and 3/4) F with union. Body and seat of central check valve in dezincification-resistant alloy. POM check valve body. Stainless steel springs and strainer. NBR shaped diaphragm and O-Ring seals. Non-asbestos fibre gaskets. Medium: drinking water. Nominal pressure: PN 10. Maximum working temperature 65C.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it
Copyright 2007 Calef fi S.P.A.

50 Flow rate 3 (m /h)

0,2

Convertible radiator valves Thermostatic control heads

338 401 series 200 series

CALEFFI
01009/10 GB
replaces dp 01009/01GB

ACCREDITED

ISO 9001

FM 21654

ISO 9001 No. 0003

Function The following series of convertible radiator valves are typically used for controlling the fluid in the emitters of heating systems. These special valves can be converted from manual to thermostatic operation by simple replacement of the adjusting knob with a thermostatic control head. This means that the ambient temperature of any room in which they are installed can be constantly maintained at the set value. The innovative 202 series thermostatic control head enables the room temperature to be controlled, showing the actual room temperature on the indicator on the front of the control head. These valves have a special tailpiece with rubber hydraulic seal, permitting quick, safe connection to the radiator without the use of additional sealing materials. Product range VALVES: For copper and plastic pipe: 338 series Angled convertible radiator valve 339 series Straight convertible radiator valve 342 series Angled radiator lockshield valve 343 series Straight radiator lockshield valve For iron pipe: 401 402 431 432 series series series series Angled convertible radiator valve Straight convertible radiator valve Angled radiator lockshield valve Straight radiator lockshield valve sizes sizes sizes sizes 3/8, 3/8, 3/8, 3/8, 1/2, 1/2, 1/2, 1/2, 3/4, 3/4, 3/4, 3/4, 1 1 1 1 (*) (*) (*) (*) sizes 3/8, 1/2 radiator x 23 p.1.5 pipe sizes 1/2 radiator x 3/4 pipe sizes 3/8, 1/2 radiator x 23 p.1.5 pipe sizes 1/2 radiator x 3/4 pipe sizes 3/8, 1/2 radiator x 23 p.1.5 pipe sizes 1/2 radiator x 3/4 pipe sizes 3/8, 1/2 radiator x 23 p.1.5 pipe sizes 1/2 radiator x 3/4 pipe Patent application No. MI2007U000405 (202 series)

THERMOSTATIC CONTROL HEADS 200 201 202 203 209 series series series series series Thermostatic control head with built-in liquid-filled sensor Thermostatic control head with remote liquid-filled sensor Thermostatic control with temperature indicator Thermostatic control head with contact sensor for fluid temperature limitation Tamper-proof / anti-theft cap for use in public places adjustment scale from 0 to 5 corresponding to 028C adjustment scale from 0 to 5 corresponding to 028C adjustment scale from 0 to 5 corresponding to 028C graduated scale 20-50C, 4090C for 200 series control head

* 3/4 and 1 have tailpieces without rubber seals

Technical specifications of valves and lockshields Material Body: brass EN 12165 CW617N, chrome plated Obturator control stem: stainless steel Hydraulic seals: EPDM Control knob and cap: ABS (RAL 9010) Performance Medium: water, glycol solutions Max. percentage of glycol: 30% Max. differential pressure with control fitted: 1 bar Max. working pressure: 10 bar Carrier medium temperature range: 5100C Adjustment range of 200/201/202 series thermostatic control heads

Technical specification of 200/201/202 series thermostatic control heads Adjustment scale: Control temperature range: Frost protection cut-in: Max. ambient temperature: Length of capillary pipe (201 series): Room temperature indicator (202 series): 05 028C 7C 50C 2m 1626C

Technical specifications of 203 series thermostatic control heads Adjustment scale: - code 203502 - code 203702 Max sensor temperature: Max pocket pressure: Length of capillary pipe: 2050C 4090C 100C 10 bar 2m

0
OFF

7C

1
12C

234
16C 20C 24C

5
28C

Dimensions

B C
Code 338302 338402 338452 Code A 3/8 1/2 1/2 D E 51,5 51,5 51,5 B 23 p.1,5 23 p.1,5 3/4 E 100 100 C 47,5 53,5 53,5
Mass (kg)

B C
B 23 p.1,5 23 p.1,5 3/4 E 55 55 E' 103 103 C 47,5 53,5 53,5
Mass (kg)

Code 339302 339402 339452 Code 339302 339402

A 3/8 1/2 1/2 D 24 24

Code 342302 342402 342452 Code 342302 342402 342452

A 3/8 1/2 1/2 D 21,5 21,5 23,5

B 23 p.1,5 23 p.1,5 3/4 E 39 39 39

C 47,5 53,5 53,5


Mass (kg)

Code 343302 343402 343452 Code 343302 343402 343452

A 3/8 1/2 1/2 D 24 24 24,5

B 23 p.1,5 23 p.1,5 3/4 E 44,5 44,5 44,5

A
C 47,5 53,5 53,5
Mass (kg)

338302 20,5 338402 20,5 338452 22,5

0,178 0,210

0,178 0,210

0,167 0,225 0,205

100 0,220

339452 24,5

55

103 0,220

B C
Code 401302 401402 401500 401603 Code A 3/8 1/2 3/4 1 D E 51,5 51,5 60,5 77,5 B 3/8 1/2 3/4 1 E 100 108 125 C 47,5 53,5 62,5 70,5
Mass (kg)

B C

Code 402302 402402 402500 402603 Code

A 3/8 1/2 3/4 1 D E

B 3/8 1/2 3/4 1 E

C 21 22 30 38
Mass (kg)

Code 431302 431402 431503 431603 Code 431302 431402 431503 431603

A 3/8 1/2 3/4 1 D 20,0 23,0 25,0 30,5

B 3/8 1/2 3/4 1 E 38,0 38,0 47,0 47,5

C 47,5 53,5 62,5 70,5


Mass (kg)

Code 432302 432402 432503 432603 Code 432302 432402 432503 432603

A 3/8 1/2 3/4 1 D 46,5 52,0 59,5 63,5

B 3/8 1/2 3/4 1 E 44,5 44,5 49,5 51,5

A
C 21 22 30 38
Mass (kg)

401302 20,0 401402 23,0 401500 25,0 401603 30,5

100 0,188 0,242 0,190 0,590

402302 46,5 402402 52,0 402500 59,5 402603 63,5

55,0 103,0 0,188 55,0 103,0 0,242 66,0 112,0 0,190 81,5 127,5 0,640

0,182 0,237 0,360 0,590

48

1/2

B B

D
B E
2 3 4

13
187

Code

B Mass (kg) 0,165 Code A B C 48 D 33 E 95


Mass (kg)

Code 201000 30 p.1,5 80 0,340

Mass (kg)

Code 475002 475003

pocket for code 203502 203702

200000 30 p.1,5 80 202000 30 p.1,5

203502 30 p.1,5 80 203702 30 p.1,5 80

48 11 158 0,300 48 9,5 134 0,300

85 0,168

E
0,192 0,242 0,190 0,560

E
0,184 0,228 0,205

2 3 4

2 3 4

2 3 4

2 3 4

2 3 4 2 3 4

Operating principle of thermostatic control head The control device of the thermostatic valve is a proportional temperature regulator, composed of bellows containing a specific thermostatic liquid. As the temperature increases, the liquid increases in volume and causes the bellows to expand. As the temperature decreases the opposite process occurs; the bellows contract due to the thrust of the counter spring. The axial movements of the sensor element are transmitted to the valve actuator by means of the connecting stem, thereby adjusting the flow of medium in the heat emitter.

Valve closed
2 3 4

Thermostatic control head with temperature indicator, 202 series Room temperature indicator The room temperature indicator, mounted on the front of the thermostatic control, is of the LCD type. It highlights the actual room temperature reading in green, to enable precise regulation of the temperature to the desired value.
Visibility with sufficient lighting

Valve open
2 3 4

Pivoting system A particular pivoting system keeps the indicator always vertical thus allowing its optimal visualization.

Construction details Valve The stainless steel control stem (1) has an EPDM double seal O-ring. In this way the upper portion of the headwork (2) can be replaced even with the system running. The obturator (3) is shaped so as to optimise the hydraulic characteristics of the valve during the progressive action of opening or closing in thermostatic operation. The wide passage between the seat and obturator causes reduced head losses in manual operation.

Thermostatic control head with remote sensor, 201 series The use of the thermostatic head with remote sensor requires installation of the latter in accordance with the dimensions shown in the diagram.

Convertible valve with manual control

1 2 3

CALEFFI

1,5 m

Tamper-proof / anti-theft cap Convertible valve with thermostatic control head The tamper-proof and anti-theft version of the thermostatic control head is obtained by fitting the cap code 209000 on the control knob as shown at side. It is secured with two screws equipped with a special head that can only be tightened using the special allen key code 209001.

Tailpiece with rubber seal The radiator connection thread coupling union is equipped with a special shaped rubber ring (4). This system ensures a hydraulic seal without using additional sealing materials such as hemp or PTFE tape.

10 cm

Hydraulic characteristics
Convertible radiator valves with angled connections, 338 series and 401 series with thermostatic regulation, proportional band 2K
p (mm w.g.) 3000 2000 1000 500 200 100 50 20 10
3/8" 1/2" 3/4" 1"

Lockshield valves with angled connections 3/8", 342 and 431 series
p (mm w.g.) p (kPa) 50 20
1/ 4 1/ 2 1 2

p (kPa) 30 20 10 5 2 1 0,5 0,2 0,1

5000 2000 1000 500 200 100 50 20 10

10 5 2
ll p yo en

1 0,5 0,2 0,1

Fu

1000

1000

2000

100

200

500

Kv0,01

3/8" 1/2" 3/4" 1"

= 56 l/h = 56 l/h = 70 l/h = 78 l/h

Max differential pressure

3/8" 1/2" 3/4" 1"

= 1,6 bar = 1,6 bar = 1,6 bar = 0,6 bar

G (l/h)

3/8"

Kv0,01 = 242 l/h

G (l/h)

Lockshield valves with angled connections 1/2", 342 and 431 series
p (mm w.g.) p (kPa) 50 20
4 1/ 2 1/ 1 2

Convertible radiator valves with straight connections, 339 series and 402 series with thermostatic regulation, proportional band 2K
p (mm w.g.) 3000 2000 1000 500 200 100 50 20 10
3/8" 1/2" 3/4" 1

p (kPa) 30 20 10 5 2 1 0,5 0,2 0,1

5000 2000 1000 500 200 100 50 20 10

2000
10 5 2 1 0,5 0,2 0,1 G (l/h) p (kPa) 50 20 10

100

200

10

20

50

y u ll

op

en

500

10

20

50

1000

1000

2000

100

200

500

10

20

50

Kv0,01

3/8" 1/2" 3/4" 1"

= 52 l/h = 56 l/h = 65 l/h = 77 l/h

Max differential pressure

3/8" 1/2" 3/4" 1"

= 1,6 bar = 1,6 bar = 1,6 bar = 0,6 bar

G (l/h)

1/2"

Kv0,01 = 399 l/h

Lockshield valves with angled connections 3/4", 431


p (mm w.g.) 5000 2000 1000 500 200 100 50 20 10
3 4 5 2

Convertible radiator valves with angled connections, 338 series and 401 series with manual regulation
p (mm w.g.) 10000 5000 2000 1000 500 200 100 50 20 10
3/8" 1/2" 3/4" 1

p (kPa) 100 50 20 10 5 2 1

2000
5 2 1 0,5 0,2 0,1 G (l/h) p (kPa) 50 20 10

100

200

0,5 0,2 0,1

10

20

50

100

200

Fu

lly

500

op

en

1000

500

10

20

50

2000

1000

2000

3000

100

200

500

20

50

3/4"

Kv0,01 = 452 l/h

Kv0,01

3/8" 1/2" 3/4" 1"

= 222 l/h = 270 l/h = 336 l/h = 447 l/h

G (l/h)

Lockshield valves with angled connections 1", 431 series


p (mm w.g.) 5000 2000 1000 500 200 100 50 20 10
2 3 4

Convertible radiator valves with straight connections, 339 series and 402 series with manual regulation
p (mm w.g.) 10000 5000 2000 1000 500 200 100 50 20 10
3/8" 1/2" 3/4" 1 "

p (kPa) 100 50 20 10 5 2 1 0,5 0,2 0,1

5000
5 2 1 0,5 0,2 0,1 G (l/h)

5 6 7 Fu lly

500

op

en

1000

2000

1000

2000

3000

100

200

500

20

50

1"

Kv0,01 = 564 l/h

Kv0,01

3/8" 1/2" 3/4" 1"

= 135 l/h = 179 l/h = 258 l/h = 443 l/h

G (l/h)

5000

10

20

50

100

200

Lockshield valves with straight connections 3/8", 343 and 432 series
p (mm w.g.) p (kPa) 50
1/ 4 2 1/ 1 2

Values of nominal flow rate and equivalent lengths


COPPER PIPE Rad. Pipe int/ext STRAIGHT conn. conn. pipe Kv0,01 le (mm) (l/h) (m) 3/8" 3/8" 3/8" 3/8" 3/8" 3/8" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2"
23 p. 1,5 8/10

5000 2000 1000 500 200 100 50 20 10


10 20 50 100 200 500 1000 2000

20 10 5
n pe yo

ANGLED
Kv0,01 (l/h) le (m)

TYPE
Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment

2 1 0,5 0,2 0,1

135 135 135 135 135 135 179 179 179 179 179 179

0,8 2,5 6,6 10,1 14,8 29,9 0,5 1,4 3,7 5,7 8,4 17,0

222 222 222 222 222 222 270 270 270 270 270 270

0,3 0,9 2,4 3,7 5,5 11,1 0,2 0,6 1,6 2,5 3,7 7,5

ull

23 p. 1,5 10/12 23 p. 1,5 12/14 23 p. 1,5 13/15 23 p. 1,5 14/16 23 p. 1,5 16/18 23 p. 1,5 8/10

3/8"

Kv0,01 = 132 l/h

G (l/h)

23 p. 1,5 10/12 23 p. 1,5 12/14 23 p. 1,5 13/15 23 p. 1,5 14/16 23 p. 1,5 16/18

Lockshield valves with straight connections 1/2", 343 and 432 series
p (mm w.g.) p (kPa) 50 20
4 1/ 2 1/

5000 2000 1000 500 200 100 50 20 10


10 20 50 100 200 500 1000 2000
F

10
1 2

5
en

TYPE
Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment

2 1 0,5 0,2 0,1

STEEL PIPE Rad. Pipe int/ext STRAIGHT conn. conn. pipe Kv0,01 le (mm) (l/h) (m) 3/8" 1/2" 3/4" 1" 3/8" 1/2" 3/4" 1"
12,7/16,7 16,3/21,0 21,7/26,4 27,4/33,2

ANGLED
Kv0,01 (l/h) le (m)

y ull

op

135 179 258 443

7,2 15,3 33,2 38,5

222 270 336 447

2,7 6,7 19,6 37,8

PLASTIC PIPE
Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment Convertible radiator valve with manual adjustment

1/2"

Kv0,01 = 217 l/h

G (l/h)

3/8" 3/8" 3/8" 3/8" 3/8" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2"

23 p. 1,5

8/12

135 135 135 135 135 179 179 179 179 179 179

0,8 2,5 6,6 10,1 14,8 0,5 1,4 3,7 5,7 8,4 8,4

222 222 222 222 222 270 270 270 270 270 270

0,3 0,9 2,4 3,7 5,5 0,2 0,6 1,6 2,5 3,7 3,7

23 p. 1,5 10/15 23 p. 1,5 12/16 23 p. 1,5 13/18 23 p. 1,5 14/18 23 p. 1,5 8/12

Lockshield valves with straight connections 3/4", 432 series


p (mm w.g.) 5000 2000 1000 500 200 100 50 20 10
1000 2000 5000 10 20 50 100 200 500
2 3

p (kPa) 50 20 10 5
4
op en
5

23 p. 1,5 10/15 23 p. 1,5 12/16 23 p. 1,5 13/18 23 p. 1,5 14/18 3/4 20 est

2 1 0,5 0,2 0,1

3/4"

Kv0,01 = 258 l/h

Fu lly

G (l/h)

Lockshield valves with straight connections 1", 432 series


p (mm w.g.) 5000 2000 1000
2 3

p (kPa) 50 20 10 5 2
6 7 5

500 200 100 50 20 10


10 20 50 100

1
op en

Fu lly

0,5 0,2 0,1

200

1000

2000

500

1"

Kv0,01 = 481 l/h

G (l/h)

5000

Installation The thermostatic control heads must be installed in horizontal position.

The sensible element of thermostatic control heads must never be installed in: niches, radiator cabinets, behind curtains or exposed to direct sunlight, otherwise false readings may occur.

CALEFFI

CALEFFI

1 3 4

Converting valves from manual to thermostatic control Before installing the thermostatic control head, turn the knob to position no. 5

5 0

Locking and restricting the thermostat control temperature

Temperature restriction

Locking the temperature

Resetting the temperature restriction and temperature lock

1. Using a screw-driver, unlock the ring, pressing it fully towards the valve body.

2. Turn the knob to the fully open position and the ring anti-clockwise, up to the stop. The RESET arrows will match up.

1. Turn the knob to the fully open position (Pos. 5). Using a screw-driver, unlock the ring, pressing it fully towards the valve body.

2. Position the valve at the required temperature and turn the ring clockwise up to the stop.

1. Turn the knob to the fully open position (Pos. 5). Using a screw-driver, unlock the ring, pressing it fully towards the valve body.

2. Turn the knob to the new maximum open position required (e.g. Pos. 3). Turn the ring anti-clockwise up to the stop.

3. Re-lock the ring. The valve will now have a temperature range restriction from 0 to the set value.

3. Re-lock the ring. The valve will now be locked at the set temperature.

3. Re-lock the ring. The valve will now no longer have any temperature restriction or lock.

1 2 3

SPECIFICATION SUMMARY
338 series Convertible radiator valve fitted for thermostatic control heads and thermo-electric actuators. Angled connections for copper and single and multilayer plastic pipes 23 p.1,5 for pipes from 10 to 18 mm, 3/4 for 20 mm plastic pipes. Radiator connection 3/8 and 1/2 M with tailpiece equipped with EPDM pre-seal. Brass body. Chrome plated. Control knob white RAL 9010, for manual control, in ABS. Stainless steel control stem. Double seal on control stem with EPDM O-rings. Maximum working temperature 100C. Maximum working pressure 10 bar. 339 series Convertible radiator valve fitted for thermostatic control heads and thermo-electric actuators. Straight connections for copper and single and multilayer plastic pipes 23 p.1,5 for pipes from 10 to 18 mm, 3/4 for 20 mm plastic pipes. Radiator connection 3/8 and 1/2 M with tailpiece equipped with EPDM pre-seal. Brass body. Chrome plated. Control knob white RAL 9010, for manual control, in ABS. Stainless steel control stem. Double seal on control stem with EPDM O-rings. Maximum working temperature 100C. Maximum working pressure 10 bar. 342 series Lockshield valve. Angled connections for copper and single and multilayer plastic pipes 23 p.1,5 for pipes from 10 to 18 mm, 3/4 for 20 mm plastic pipes. Radiator connection 3/8 or 1/2 M with tailpiece equipped with EPDM pre-seal. Brass body. Chrome plated. Cap white RAL 9010 in ABS. Outward seal consisting of EPDM O-ring on control stem. Maximum working temperature 100C. Maximum working pressure 10 bar. 343 series Lockshield valve. Straight connections for copper and single and multilayer plastic pipes 23 p.1,5 for pipes from 10 to 18 mm, 3/4 for 20 mm plastic pipes. Radiator connection 3/8 or 1/2 M with tailpiece equipped with EPDM pre-seal. Brass body. Chrome plated. Cap white RAL 9010 in ABS. Outward seal consisting of EPDM O-ring on control stem. Maximum working temperature 100C. Maximum working pressure 10 bar. 401 series Convertible radiator valve fitted for thermostatic control heads and thermo-electric actuators. Angled connections for steel pipes 3/8, 1/2, 3/4 or 1 F. Radiator connection 3/8 or 1/2 M with tailpiece equipped with EPDM pre-seal, 3/4 and 1 M with tailpiece without seal. Brass body. Chrome plated. Control knob white RAL 9010, for manual control, in ABS. Stainless steel control stem. Double seal on control stem with EPDM O-rings. Maximum working temperature 100C. Maximum working pressure 10 bar. 402 series Convertible radiator valve fitted for thermostatic control heads and thermo-electric actuators. Straight connections for steel pipes 3/8, 1/2, 3/4 or 1 F. Radiator connection 3/8 or 1/2 M with tailpiece equipped with EPDM pre-seal, 3/4 and 1 M with tailpiece without pre-seal. Brass body. Chrome plated. Control knob white RAL 9010, for manual control, in ABS. Stainless steel control stem. Double seal on control stem with EPDM O-rings. Maximum working temperature 100C. Maximum working pressure 10 bar. 431 series Lockshield valve. Angled connections for iron pipes 3/8, 1/2, 3/4 or 1 F. Radiator connection 3/8 or 1/2 M with tailpiece equipped with EPDM pre-seal, 3/4 and 1 M with tailpiece without seal. Brass body. Chrome plated. White cap RAL 9010 in ABS. Outward seal consisting of EPDM O-ring on control stem. Maximum working temperature 100C. Maximum working pressure 10 bar. 432 series Lockshield valve. Straight connections for iron pipes 3/8, 1/2, 3/4 or 1 F. Radiator connection 3/8 or 1/2 M with tailpiece equipped with EPDM pre-seal, 3/4 and 1 M with tailpiece without seal. Brass body. Chrome plated. White cap RAL 9010 in ABS. Outward seal consisting of EPDM O-ring on control stem. Maximum working temperature 100C. Maximum working pressure 10 bar. 200 series Thermostatic control head for thermostatic and convertible radiator valves. Built-in sensor with liquid-filled element. Maximum ambient temperature 50C. Graduated scale from 0 to 5 corresponding to a temperature adjustment range from 0 to 28C, with the possibility of locking and limiting the temperature. Frost protection cut-in at 7C. 201 series Thermostatic control head for thermostatic and convertible radiator valves. Remote sensor with liquid-filled element. Maximum ambient temperature 50C. Graduated scale from 0 to 5 corresponding to a temperature adjustment range from 0 to 28C, with the possibility of locking and limiting the temperature. Frost protection cut-in at 7C.

202 series Thermostatic control head for thermostatic and convertible radiator valves. Built-in sensor with liquid-filled element, with digital LCD room temperature indicator. Maximum ambient temperature 50C. Graduated scale from 0 to 5 corresponding to a temperature adjustment range from 0 to 28C, with the possibility of locking and limiting the temperature. Frost protection cut-in at 7C. Room temperature display range from 16C to 26C. 203 series Thermostatic control head with contact sensor, for fluid temperature limitation. Control temperature range 2050C (4090C). Maximum sensor temperature 100C. Numbered scale, with possibility of locking and limiting the temperature. Capillary length 2 m. 209 series Tamper-proof / anti-theft cap for thermostatic control head, for use in public places.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. S.R.229, N.25 28010 FONTANETO DAGOGNA (NO) ITALY TEL. +39 0322 8491 FAX +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

Dual manifolds and differential by-pass valve


356 - 357 series
cert. n 0003

CALEFFI
ISO 9001

01014/06 GB

Function Dual manifolds are typically used for the distribution of the heatcarrying medium in heating and air conditioning systems. They are available with both double and single side connections and can be used to connect fittings for copper, plastic or multi-layer piping. They are also offered for air-conditioning systems in a version complete with hot pre-formed shell insulation, sized to limit thermal losses and above all to prevent condensation on the surface. The differential by-pass valve keeps the manifold flow and return circuits pressure balanced when the flow rate varies. This variation in flow rate can take place following the closure of room temperature regulating valves on the heat emitters like for example, thermostatic or thermo-electric valves.

Reference documentation Tech. broch. 01091 Inspection box 362 series

Product range MANIFOLDS: 356 series Double side connections 356. . . IS series Double side connections with pre-formed insulation 357 series Single side connections DIFFERENTIAL BY-PASS VALVE: Code 356050 size 3/4 sizes 3/4 and 1 size 1 size 3/4

Technical specifications of manifold Material: brass EN 1982 CB 753S Medium: water, glycol solutions Max. percentage of glycol: 30% Max. working pressure: 10 bar Temperature range: -10110C Main connections: 3/4 and 1 F, version without insulation 1 F, version with insulation Outlet connections: 23 p.1,5 M - 18 mm Main connections centre distance: 60 mm Outlet centre distance: 40 mm Average inside diameter: 3/4: 20 mm 1: 26 mm

Technical specifications of insulation Material: expanded PE-X with closed cells Thickness: 20 mm Density: - internal portion: 30 kg/m3 - external portion: 50 kg/m3 Thermal conductivity (DIN 52612): - at 0C: 0,038 W/(mK) - at 40C: 0,045 W/(mK) Coefficient of resistance to the diffusion of water vapour (DIN 52615): >1.300 Temperature range: 0100C Reaction to fire (DIN 4102): Class B2

Dimensions

Construction details Monoblock casting These manifolds are made with a monoblock casting, without any connections made between the internal tubes. This eliminates a possible cause of leakage due to coupling with metals with different coefficients of expansion. The connections of the side outlets are obtained tangentially to the main tubes to make fitting the unions easier. D

CALEFFI

Mod. Dep.

B 60

356

40 E Code 356502 356504 356506 356508 356510 356604 356606 356608 356610 356612 A 3/4 3/4 3/4 3/4 3/4 1 1 1 1 1 No. out. 2+2 4+4 6+6 8+8 10+10 4+4 6+6 8+8 10+10 12+12 B 116 116 116 116 116 122 122 122 122 122

C 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5

D 30 30 30 30 30 32 32 32 32 32

E 100 180 260 340 420 184 264 344 424 538

Weight (kg) 0,84 1,55 2,20 3,00 3,70 1,75 2,54 3,44 4,38 5,30

Pre-formed insulation The manifold 356 series is also offered for the specific use of air-conditioning systems, with hot pre-formed shell insulation.

CALEFFI

Mod. Dep.

356

40 E F

Code 356604 IS 356606 IS 356608 IS 356610 IS

A 1 1 1 1

No. out. 4+4 6+6 8+8 10+10

B 122 122 122 122

C 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5

D 32 32 32 32

E Weight (kg) 184 2,05 264 2,84 344 3,74 424 4,68

220

B 60

This insulation has been specially designed to help coupling with the manifold and the operations of installation in the boxes.

CALEFFI

Mod. Dep.

CALEFFI

Mod. Dep.

B 60 A

357

357

40

73 E B 105 105 105 105 105 C 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 D 30 30 30 30 30

Code 357502 357503 357504 357505 357506

A 3/4 3/4 3/4 3/4 3/4

No. out. 2+2 3+3 4+4 5+5 6+6

E 180 260 373 453 533

Weight (kg) 1,30 1,95 2,80 3,45 4,06

Hydraulic characteristics Coefficient of localized loss inlet loss (F+R): Coefficient of localized loss outlet loss (F+R): 3,0 6,5

Differential by-pass valve


Function In heating systems, the heat-carrying medium distribution circuits can be totally or partially shut off by closing the thermostatic or thermoelectric valves in the radiators. After reducing the flow rate, the differential pressure in the circuit may increase up to values able to generate problems of noise, high medium speed, mechanical erosion and hydraulic unbalancing of the system itself. The differential by-pass kit for manifolds 356 series performs the function of keeping the flow and return pressure of the manifold circuit balanced when the flow rate varies. This valve is fitted for quick coupling with the manifolds 356 series, reducing the overall dimensions to a minimum.

Technical specifications of by-pass valve Materials: body: check valve obturator: spring: seals: brass EN 12165 CW617N PA stainless steel EPDM water, glycol solutions 30% 10 bar -10110C 20 kPa (2000 mm w.g.) 3/4 M (captive nut) 3/8 (with plug) 60 mm

Hydraulic characteristics By-pass pressure differential:


P (mm w.g.) 10000
9000 8000 7000 6000

20 kPa (2000 mm w.g.)


P (kPa)
90 80 70 60

100

Medium: Max. percentage of glycol: Max. working pressure: Temperature range: Fixed pressure setting: Connections to manifold: Head connections: Centre distance:

5000
4500 4000 3500 3000 2500

50
45 40 35 30 25 18 16 14 12

2000
1800 1600 1400 1200

20

250

300

350

400

120

140

160

180

450

60

70

80

90

1000

10
600 700 800

Dimensions B B 356050 Code A 3/4 B 3/8 C 60 D 55 Weight (kg) 0,333

Q (l/h)

Application diagram
15

20

CALEFFI

A C

Principle of operation The by-pass valve contains a non-return obturator integral with a counter spring. When the fixed calibrated pressure value is reached, the valve obturator opens gradually. The flow is in this way recirculated and, being proportional to the closure of the thermostatic or electrothermal valves, keeps the differential pressure constant in the manifold circuit.
Thermostatic valve
. Dep. CALEFFI

25

30

CALEFFI

Mod

CALEFFI

Mod

Dep. 357

Dep. 357

2 3 4

1000

100

200

500

50

900

10

2 3 4

2 3 4

Mod

356

Plastic inspection box and port


Function The new shockproof plastic box has been specially made for using single and dual manifolds, combined with the various types of zone valves. The ventilation openings in the cover have a special shape designed to prevent rings forming on the walls. The surface finish of the door is suitable for painting. The housing of the dual manifold 356 series in the boxes is easy for both the insulated version and the non-insulated version, especially if done by using the shockproof plastic box 362 series.

Product Range Code Code Code Code Code Code 362036 362056 362073 363036 363056 363073 Plastic Plastic Plastic Plastic Plastic Plastic inspection inspection inspection inspection inspection inspection box box box port port port useful dimensions 360 x 270 mm, depth 100/80 useful dimensions 560 x 330 mm, depth 100/80 useful dimensions 730 x 360 mm, depth 100/80 useful dimensions 360 x 270 useful dimensions 560 x 330 useful dimensions 730 x 360 mm mm mm mm mm mm

SPECIFICATION SUMMARIES
356 series Cast monoblock dual distribution manifold with double side connections. Brass body. Main connections 3/4 or 1 F. Outlet connections: 23 p.1,5 M - 18 mm. Main centre distance: 60 mm. Outlet centre distance: 40 mm. Medium: water and glycol solutions. Maximum percentage of glycol: 30%. Maximum working pressure: 10 bar. Temperature range: -10110C. 356 IS series Cast monoblock dual distribution manifold with double side connections and hot pre-formed insulation. Brass body. Main connections: 1 F. Outlet connections: 23 p.1,5 M - 18 mm. Main centre distance: 60 mm. Outlet centre distance: 40 mm. Medium: water and glycol solutions. Maximum percentage of glycol: 30%. Maximum working pressure: 10 bar. Temperature range: -10110C. 357 series Cast monoblock dual distribution manifold with single side connections. Brass body. Main connections: 3/4 F. Outlet connections: 23 p.1,5 M - 18 mm. Main centre distance: 60 mm. Outlet centre distance: 40 mm. Medium: water and glycol solutions. Maximum percentage of glycol: 30%. Maximum working pressure: 10 bar. Temperature range: -10110C. Code 356050 Differential by-pass valve for dual distribution manifolds. Brass body. Connections to manifold 3/4 M with captive nut. Head connections: 3/8 F with plug. Seals of EPDM. Temperature range: -10110C. Medium: water and glycol solutions. Maximum percentage of glycol: 30%. Maximum working pressure: 10 bar. Centre distance: 60 mm. Differential pressure fixed setting: 20 kPa. 362 series Plastic inspection box with ventilation openings. White colour RAL 9010. Useful dimensions ( h x b x d ): Code 362036 360 x 270 x 100/80 mm. Code 362056 560 x 330 x 100/80 mm. Code 362073 730 x 360 x 100/80 mm. 363 series Plastic inspection port with ventilation openings. White colour RAL 9010. Useful dimensions ( h x b ): Code 363036 360 x 270 mm. Code 363056 560 x 330 mm. Code 363073 730 x 360 mm.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Ball zone valves

CALEFFI
series 6460
cert. n 0003

ISO 9001

01015/03 GB

Function Zone valves are used to automatically shut-off the flow of carrier fluid distributed to a system. Specifically: - In central heating systems, they support the ambient temperature regulation and indirect heat metering when connected to a meter. - In domestic hot water systems, they allow control of the temperature in the storage cylinders. - In commercial and industrial systems, they can shut-off the flow in the distribution networks. Motorised ball valves are used in the above applications mainly because of the following characteristics: - No seeping across the valve. - Rapid operation (valve opening - closing). - Ability to operate with high differential pressures. - Low head losses. Registered design.

European Directives conformity CE mark as per Directives 89/336 EC and 73/23 EC.

Product range Series Series Series Series Series Series Series 6460.. 6470.. 6480.. 6489.. 6490.. 6490.. 6480.. actuator for zone valve 2-way ball zone valve 3-way ball zone valve 4-way ball zone valve, telescopic by-pass tee without calibrated nozzle by-pass tee with calibrated nozzle U4 U6 U8 off-centre union fittings supply voltage 220 or 24 V sizes 1/2, 3/4, 1, 1 1/4 M with union sizes 1/2, 3/4, 1, 1 1/4 M with union size 3/4 M with union sizes 1/2, 3/4, 1 M with union sizes 1/2, 3/4, 1 M with union sizes 3/4, 1 M

Technical specification Valve body Materials:- body brass EN 12165 CW617N - ball brass EN 12165 CW617N, chrome plated - ball seal PTFE with O-Ring in EPDM - control shaft seal double O-Ring in EPDM Actuator Synchron motor Electrical supply: 220 V ( 20%) - 50 60 Hz 24 V ( 10%) - 50 60 Hz Power consumption: 4 VA Rating of auxiliary microswitch contacts: 220 V; 0,8 A 24 V; 1,3 A Protection class: IP 44 Operating time: 50 s Max ambient temperature: 55C Permissible humidity: class G to DIN 40040 Dynamic starting torque: 9 Nm

Medium: Max percentage of glycol: Max working pressure: Temperature range: Max differential pressure: Connections: 3-way bottom connection:

water, glycol solution 50% 10 bar -5110C 10 bar 1/21 1/4 M with union 3/4 F

Dimensions C M E

Operating principle Ambient temperature control in central heating systems. A reduction in ambient temperature causes the room thermostat contacts to close, and the actuator controlling the opening of the valve to receive electrical power. The zone is then supplied with hot water and the area is heated. When the required ambient temperature is reached, the thermostat causes the contacts to open, and the valve then closes again. The room thermostat must be of the two-position (ON/OFF) type and of reduced thermal inertia. M 59 59 59 59

B A

Code D 647040+6460.. 1/2 647050+6460.. 3/4 647060+6460.. 1 647070+6460.. 1 1/4

A 141 141 178 172

B 80 80 92 92

C 105 105 105 105

E 36 36 36 36

H G F 65,5 101,5 124 65,5 101,5 124 106 128,5 70 106 128,5 70

L 68,5 68,5 68,5 68,5

Ambient temperature control and indirect heat metering Heat metering is carried out by means of a meter which totals the hours run time when the zone valve is open. The principle of metering for the heat consumption with the zone valve and hours-run meter is defined by the following technical standards, issued by the Italian Standards organization: UNI 8465: System of sharing heating expenses using zone valves and meters for hours run time. This standard also contains an interesting appendix designed to allow checking of the heating power installed in each dwelling and the relevant heating quotas; UNI 8156: The use of zone valves in dividing heating costs;

C M E F G

B A

UNI 8631: Hours-run time meters.

Code D A B 648040+64904.+6460.. 1/2 141 80 648050+64905.+6460.. 3/4 141 80 648060+64906.+6460.. 1 178 92 11/4 172 92 648070+6460..

C 105 105 105 105

F E I M G H L 36 65,5 161,5 184 60 68,5 59 36 65,5 161,5 184 60 68,5 59 36 70 166 188,5 60 68,5 59 36 70 - 68,5 59 -

- Control of fluids in commercial and industrial systems. In these types of system, non seeping devices are required, with short operating times, ability to operate at high differential pressures, and low head loss.

C M E F G

B A

Code D A B C E F G H I L M 648950+6460.. 3/4 141 80 105 36 65,5 150,5164,5 173187 4963 68,5 59

Constructional details Electrical connections The electrical connection of the actuator consists of an external plug-in socket system, which does not require the cover to be opened for the supply cable to be connected. This solution is particularly useful if the actuator needs to be replaced. An efficient rubber protective cover safeguards the connection system.

2-way valve, series 6470

Actuator The actuator has an auxiliary microswitch which can be used to switch on an hours-run meter when the valve opens or for shut-down of the pump. The microswitch contacts are closed when the valve is approximately 80% open. The actuator mechanisms are contained in a self-extinguishing polycarbonate box; for this reason it is suitable for all installations with the highest guarantee of safety.

49
356 356
C A L E F F I C A L E F F I C A L E F F I

CALEFFI

CALEFFI

C A L E F F I

The actuator can be mounted on the valve body in the two positions indicated, vertical or horizontal. Fixing is via a stainless steel clamp ring.

C A L E F F I

C A L E F F I

C A L E F F I

C A L E F F I

4-way valve, series 6489

Manual opening By removing the actuator, the valve can be opened and closed manually by means of a screwdriver. 3-way zone valve, PATENTED Although this is a 3-way ball valve, the technical solution adopted and patented enables it to be used as a normal piston valve (CALEFFI series 633), which can thus be connected to dual manifolds. This obviously simplifies the system and makes it possible to connect the valve directly to the manifold, thus avoiding more complicated pipework. 4-way telescopic valve The 4-way telescopic valve, series 6489, allows connection with manifolds whose main centre distances are between 49 and 63 mm. The tee has a U6 calibrated nozzle.

Balanced by-pass tee This is provided with union connections of 1/2, 3/4 or 1 and is particularly useful for connecting 3-way zone valves with dual manifolds. The connection to the third outlet has a calibrated nozzle whose purpose is to balance the loss of head in the user circuit. This makes it possible to keep the flow in the system constant and thus the pump head, with the valves both open and closed. This is particularly important when the pump curve has a very steep characteristic and the distribution network has a considerable length of pipework. The fixed nozzle system is preferable to the adjusting screw system as: - it avoids the need for complicated adjusting operations; - calibration cannot be lost; - it does not cause noise due to possible vibrations of the moving regulator.

63

C A L E F F I C A L E F F I C A L E F F I C A L E F F I

C A L E F F I C A L E F F I C A L E F F I C A L E F F I

Hydraulic characteristics
P (mm w.g.)
4000
3000 30

Calibrated nozzles
P (kPa)
40

/4

2000 1800 1000 500

1600 1400 1200 900 800 700 600

18 16 14 12

20 10 5

-3

Three different nozzles are provided of suitable dimensions for incorporation on the different types of manifold (4+4, 6+6, 8+8 connections). The flow characteristics of the nozzles, which determine the third way flow, are shown in the graph below.
1/2 - 3/4 1

4 1/

U4

U6

400 300

4 3

10000 9000 2 1 0,5


8000 7000 6000

U8 U4 U6 U8
1400 1600 1800 2500 3000

9 8 7 6

1/

P (mm w.g.)

P (kPa)
90 80 70 60

100 50

200 100 50

180 160 140 120 90 80 70 60

1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

5000
4000 3000 40 30

2000 1800 1000 0,2 0,1 500


400 300

1600 1400 1200 900 800 700 600

18 16 14 12 9 8 7 6

20 10 5

40 30

0,4 0,3

20 10

18 16 14 12

0,18 0,16 0,14 0,12

4 3

12000

14000

16000

300

500

18000

4000

4500

6000

7000

8000

1200

1400

1600

1800

2500

3000

3500

9000

350

400 450

600

700

800

900

10000

20000

1000

2000

5000

200 100 50

180 160 140 120 90 80 70 60

1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

2 1 0,5

2-way zone valve, series 6470

1/2" 3/4" 1" 1 1/4" Kv (m /h) 17,00 17,27 36,58 39,50


3

G (l/h)

1200

50

1000

2000

3500

400

450

600

700

800

120

140

160

180

250

300

350

900

60

70

80

90

P (mm w.g.)
4000
3000

P (kPa)
40
30

500
400 300

1/

900 800 700 600

1/

1000

1600 1400 1200

-3

2000 1800

18 16 14 12 9 8 7 6

20 10

3-way zone valve series 6480, in BY-PASS operation with by-pass tee series 6490 supplied with nozzles U4 - U6 - U8, to be specified when ordering 1/2" U4 1/2" U6 1/2" U8 3/4" U4 3/4" U6 3/4" U8 1" U4 1,16 1,40 0,87 1,20 1,50 1,90 1" U6 2,50 1" U8 3,10

/4

5
4 3

200 100 50

Kv (m3/h) 0,78

180 160 140 120 90 80 70 60

1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

2 1 0,5

3-way zone valve series 6480, in BY-PASS operation with by-pass tee series 6490 without nozzles

1/2" 3/4"

4000

100

200

500

G (l/h)

1"

Kv (m3/h) 2,20 2,25 3,25

40 30

0,4 0,3

20 10

18 16 14 12

0,18 0,16 0,14 0,12

0,2 0,1

P (mm w.g.)
10000 9000
8000 7000 6000

P (kPa)
90 80 70 60

100 50

12000

14000

16000

300

500

10000

18000

4000

4500

6000

7000

8000

1200

1400

1600

1800

2500

3000

3500

9000

350

400 450

600

700

800

900

20000

1000

2000

5000

5000
4000 3000 40 30

3-way zone valve, series 6480 and 4-way valve,series 6489 operating in OPEN position

1600 1400 1200 900 800 700 600

1000

3/

Kv (m3/h) 14,10 14,43 33,52 36,00

2000 1800

1/2" 3/4"

1"

1 1/4"

G (l/h)

18 16 14 12 9 8 7 6

20 10 5

P (mm w.g.)
10000 9000 5000
4000 3000 8000 7000 6000

P (kPa)
90 80 70 60

500
400 4 3 300

100 200 50 100 20 10 5 50

-3

40 30

180 160 140 120 90 80 70 60

1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

/4

2 1 0,5

2 1/

1/

2000 1800 1000 500

1200

1400

1600

1800

2500

3000

50

1000

3500

900 800 700 600

9 8 7 6

2000

400 300

4 3

200 100 50

180 160 140 120 90 80 70 60

1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

2 1 0,5

4-way telescopic zone valve, series 6489 in BY-PASS operation with nozzle U6

4000

100

200

500

1600 1400 1200

18 16 14 12

600

700

800

120

140

160

180

250

300

350

400

450

900

60

70

80

90

G (l/h)

3/4"

Kv (m3/h) 1,20

Example Choice of nozzle for 3/4 3-way valve tee. G = 400 l/h by-pass circuit flow rate P = 12 kPa by-pass circuit pressure drop Using the above diagram, U6 3/4 nozzle is specified.

1200

1400

1600

1800

2500

3000

1000

3500

120

140

160

180

250

300

350

400

450

600

700

800

900

60

70

80

90

2000

3-way zone valve, series 6480 operating in BY-PASS mode without by-pass tee

1/2" 3/4"

1"

1 1/4"

Kv (m3/h) 2,45 2,50 3,60 3,80

4000

100

200

500

50

G (l/h)

Installation The zone valve must be installed in line with the direction of the water circulation shown on the valve body. The 2-way zone valve, series 6470 can be installed in either the flow or the return pipework.

Electrical connections Internal diagram with valve in closed position - R relay - MC1 opening end microswitch.
MC 3

M
MC 2 MC 1

- MC2 closing end microswitch. - MC3 free auxiliary microswitch. With the valve open, the free microswitch contacts are closed.

The 3-way valve, series 6480 and 4-way valve, series 6489 must be installed in the flow pipework.

1 2 3 4 5 6
Connection diagram for room thermostat (RT) and electricity supply. The connections shown allow the valve to open and close, as demanded by the room thermostat (RT).

Fitting the zone valve in a manifold box When installing valves in the relevant zone manifold boxes, sufficient space must be left above the electrical actuator to allow its replacement, whenever necessary. In order to prevent excessively high temperatures in the zone manifold box, sufficient air circulation must be provided for inside the box.
Min 30 mm

1 2 3 4 5 6
RT

CALEFFI

C A L E F F I

C A L E F F I

C A L E F F I

C A L E F F I

C A L E F F I C A L E F F I C A L E F F I

356

C A L E F F I

01

The figures represent: - installation in inspection box, series 5901 with dual manifold, series 356 and differential by-pass, code 356050;

N L

Connection diagram with hours-run meter installed. - installation in manifold box, series 5902 with off-centre kit for connection to the by-pass tee allowing installation of the zone valve with simple manifolds. The connections shown allow the hours-run meter (HM) to operate whenever the zone valve is opened as governed by the room thermostat (RT). The total hours-run on the meter consitute a basis for sharing the heating expenses.

Min 30 mm

1 2 3 4 5 6
RT HM

01

System applications

N L
Zone control systems act in such a way as to shut-off automatically the hydraulic loops supplying the heat transfer terminals, according to the temperature reached in the room. This can cause variations in pressure and flow rates throughout the system, and it is therefore vital to ensure that these variations are kept under control within acceptable limits. System with 3-way zone valve The system operates with a constant flow rate only if the zone valves are provided with balanced tees or the circuits are balanced with Autoflow automatic flow regulators, which keep the zone flow rate constant with the zone valve open or in by-pass. In this case, the closing of the zone valves does not cause variations in either differential pressure or flow rate to the loops which remain open. System with 2-way zone valves The system operates with a variable flow rate and the pressure increase generated by the closing of the zone valve must be kept under control. This increase, which may reach levels which are unacceptable for the correct operation of the system, is translated as an increase in head in the circuits which are left open, with consequent problems at the pump and boiler. It is therefore necessary to keep the differential pressures under control by means of differential by-pass valves or variable speed pumps. However, the insertion of Autoflow regulators always limits the flow rate in the open circuits to the nominal value. Diagram allowing pump shut-down when no zone is operating. The diagram below, using the auxiliary microswitch, enables the pump to be shut down when no zone is operating. If the pump has a consumption higher than 0,8 A (170 VA) an intermediate remote relay switch must be used.

1 2 3 4 5 6

1 2 3 4 5 6

RT
1 0

RT HM N

HM

N L
0 1

Application diagrams System with 3-way zone valves and Autoflow

Shut-off valve Thermostatic valve Electric pump


RT

RT

Room thermostat Non-return check valve Insulated manifold Differential by-pass Adjustable differential by-pass valve Autoflow
RT

System with 2-way zone valves and adjustable differential by-pass valve

RT

RT

System with 2-way zone valves, variable speed pump and Autoflow

RT

RT

System with 2-way zone valves, temperature regulating unit and Sepcoll

M S

+
20

18

22 24

CALEFFI

16

CALEFFI

CALEFFI

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

CALEFFI
CALEFFI

CALEFFI

2,25 2,0

100

1,75

80
1,5

1,25

60
1,0

0,75

40
0,5 0,25

20 20 15 10 5 0 -5 -10 -15 -20

1,0 0,75 0,5 0,25

1,25

1,5 1,75 2,0 2,25

20

Accessories Off-centre kit Off-centre kit, code 648018 for connection of valves, series 6480 to the relevant by-pass tee, series 6490, for installation in manifold box, series 5902 and connection to manifolds, series 349, 350 and 592. Off-centre fittings Off-centre fittings 3/4, (ref. 648005 and 1, ref. 648006) for connecting the 3-way zone valve and the by-pass tee assembly to any type of dual manifold with centre to centre distance between 50 and 70 mm.
C A L E F F I

50 to 70 mm

C A L E F F I
C A L E F F I

C A L E F F I

SPECIFICATION SUMMARIES Series 6460 Electrical actuator for ball zone valve. Power supply 220 V (or 24 V). With auxiliary microswitch. Dynamic starting torque 9 Nm. Auxiliary contact current 0,8 A (220 V), 1,3 A (24 V). Power consumption 4 VA. Operating time 50 seconds. Protection class IP 44. Maximum ambient temperature 55C. Electrical connection by means of external plug and socket system. Self-extinguishing polycarbonate protective box. Series 6470 2-way ball zone valve. Threaded connections 1/2 M (from 1/2 to 1 1/4) with unions. Brass body. PTFE ball seal with extra EPDM O-Ring. Control shaft seal with EPDM double O-Ring. Maximum working pressure 10 bar. Temperature range from -5C to +95C (110C maximum peak). Maximum differential pressure 10 bar. Maximum glycol 50%. Series 6480 3-way ball zone valve. Threaded connections 1/2 M (from 1/2 to 1 1/4) with unions. Third way connection 3/4 F. Brass body. PTFE ball seal with extra EPDM O-Ring. Control shaft seal with EPDM double O-Ring. Maximum working pressure 10 bar. Temperature range from -5C to +95C (110C maximum peak). Maximum differential pressure 10 bar. Maximum glycol 50%. Series 6489 4 -way telescopic zone valve. Threaded connections 3/4 M with unions. Brass body. PTFE ball seal with extra EPDM O-Ring. Control shaft seal with EPDM double O-Ring. Maximum working pressure 10 bar. Temperature range from -5C to +95C (110C maximum peak). Maximum differential pressure 10 bar. Maximum glycol 50%. Centre to centre distance between connections adjustable fro 49 to 63 mm. By-pass tee supplied with U6 calibrated nozzle. Series 6490 By-pass tee for 3-way ball zone valve. Threaded connections 1/2 M (from 1/2 to 1) with unions. Third way connection 3/4 M. Brass body. Maximum working pressure 10 bar. Supplied with calibrated nozzle (U4, U6, U8), for the third way (version without nozzle also available) for balancing the system. Series 6480 Off-centre fittings for connection of the ball zone valves to manifolds with centre to centre distances between 50 and 70 mm. 1/2 M connections (1/2 and 3/4). In brass. Code 648018 Eccentric kit for connection of 3-way zone valves to relevant by-pass tees. Connection 3/4 M x 3/4 F. For installation in Caleffi manifold box, series 5902 and connection to simple manifolds.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

F F I

C A L E F F I

Hydraulic safety groups for hot water storage heaters


5261 series
ACCREDITED

CALEFFI
01019/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003

replaces dp 01019/03 GB

Function These hydraulic safety groups are used in domestic water systems to protect hot water storage heaters. They combine different components with the following functions: - safety, to prevent the pressure of the medium in the storage heaters from reaching dangerous levels - anti-pollution, to prevent backflow of hot water into the cold water supply network - a shut-off function to isolate the supply network for maintenance and inspection of the heater system. The hydraulic safety groups, the installation of which is required by applicable regulations, are certified as conforming to European Standard EN 1487.

Product range 5261 Series Hydraulic safety group for hot water storage heaters Code 526153 Hydraulic safety group for hot water storage heaters for horizontal installation Code 319601 Discharge tundish for hydraulic safety groups

size 1/2, 3/4 size 3/4 size 1 F x 32/25 mm

Technical specifications Materials Body: brass EN 12165 CW617N, chrome plated Ball valve: brass EN 12164 CW614N Check valve: brass EN 12164 CW614N Safety relief valve obturator: EPDM Safety relief valve seat: stainless steel Hydraulic seals: EPDM Springs: steel UNI 3823 Performance Medium: Max. working temperature: Max. working pressure: Safety relief valve opening pressure: water 120C 10 bar 7 bar

Max. power output of the water heater: 10 kW Discharge flow rate at 8,4 bar (+20% Po):- with water: > 600 l/h - with steam: > 220 kg/h Threaded connections: inlet 3/4 M outlet 3/4 F discharge 1 M

Dimensions
D A
C

B A
E
CALEFFI

CALEFFI

A B B E F C

E Code A B C D F Mass (kg) 526142 1/2" 1 29 38 98,5 122 0,46 526152 3/4" 1 29 38 98,5 122 0,45

Code A B C D E F Mass (kg) 526153 3/4" 1 29 38 114 116,5 0,49

Code A B C C D E Mass (kg) 319601 1 83100 25 32 55 117 0,08

Characteristic components

Connection to heater

Reference standards Certification in accordance with European Standard EN 1487 European Standard EN 1487: 2000 Building valves-Hydraulic safety groups-Tests and requirements describes the construction and performance characteristics required of hydraulic safety groups for hot water storage heaters. Caleffi 5261 series hydraulic safety groups have been certified by the CSTB and Belgaqua certification bodies as conforming to European Standard EN 1487.

Discharge tundish The discharge tundish, located at the outlet of the safety valve, must conform to the dimension requirements of standard EN 1487 and discharge must occur without any spillage of water. To meet this requirement the 319 series tundishes are fitted with special side walls which catch any water spillage during discharge from the safety relief valve and direct it to the drainage pipes.
83-100 mm - 32 mm
(glued)

Application diagrams
5 2 61
5
6 - 3/ 4 1 . -0

TIP O

LL UTI

7 bar
VI
EN 1487

DANGE

CALEFFI

CALEFFI

SPECIFICATION SUMMARY
5261 series Hydraulic safety group for hot water storage heaters. Certified to standard EN 1487. With shut-off and class A controllable check valve. Safety relief valve seat in stainless steel. Connection to heater 1/2 (3/4) F. Discharge connection 1 M. Brass body. Chrome plated. EPDM seals. Maximum working temperature 120C. Maximum working pressure 10 bar. Safety relief valve opening pressure 7 bar. Code 526153 Hydraulic safety group for hot water storage heaters for horizontal installation. Certified to standard EN 1487. With shut-off and class A controllable check valve. Safety relief valve seat in stainless steel. Connection to heater 3/4 F. Discharge connection 1 M. Brass body. Chrome plated. EPDM seals. Maximum working temperature 120C. Maximum working pressure 10 bar. Safety relief valve opening pressure 7 bar. Code 319601 Discharge tundish for hydraulic safety groups to standard EN 1487. Connection 1. In plastic material.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. S.R.229, N.25 28010 FONTANETO DAGOGNA (NO) ITALY TEL. +39 0322 8491 FAX +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

Shut-off cock Class A check valve Inspection port to check functionality of the check valve Safety relief valve Discharge tundish and air gap Knob for manual discharge Plug for access to the check valve Stainless steel seat


Cold water inlet

Connection to discharge pipe: - 25 mm


(rubber seals)

0k

Water hammer arrester

CALEFFI
525 series
IS

TERE

BSI EN ISO 9001:2000 Cert. n FM 21654

UNI EN ISO 9001:2000 Cert. n 0003

01020/08 GB

IS ANT

HOC

Function Water hammer phenomenon occurs in closed pipes when the fluid is accelerated or decelerated very quickly, due to the rapid closure of valves or taps or as a consequence of a circulation pump stopping. The effect consists in the propagation of over- and underpressures along the pipes, which may result in noise and damage to the whole system. The water hammer arrester, when installed close to single-lever mixing taps, solenoid valves, ball valves, etc., prevents such negative effects. The use of water hammer arrester is recommended in particular by UNI 9182 regulation Cold and hot water supply and distribution systems. Design, testing and management criteria.

Product range Code 525040 Code 525130 Code 525150 Water hammer arrester Water hammer arrester for under sink and washhand basin application Water hammer arrester for washing machines size 1/2 M size 3/8 F with nut x 3/8 M size 3/4 F with nut x 3/4 M

Technical specifications Materials Body: Damping element: Spring: Seals:

brass EN 12165 CW617N, chrome plated high resistance polymer steel EPDM

Performance Medium: Max. working pressure: Max. medium temperature: Max. water hammer pressure: Operating start pressure: Connections: - 525040 - 525130 - 525150

RE

water 10 bar 90C 50 bar 3 bar 1/2 M with PTFE seal 3/8 F with nut x 3/8 M 3/4 F with nut x 3/4 M

Dimensions D A

D E

A B Code 525130 525150 A 3/8 3/4 B 75,5 84,5

Code 525040

B A 1/2 52

C 46

D 74

E 89

Weight (kg)

0,492

C 46 46

B D 71 74

Weight (kg)

0,492 0,538

The water hammer phenomenon In domestic water systems, water hammer phenomenon occurs when a pipe is closed rapidly by a device such as a single-lever mixing tap, solenoid valve, ball valve, etc.. The abruptness of the operation creates a perturbation in the water pressure which propagates along the pipe in the form of an overpressure wave. The perturbation starts from the check device, travels upstream, reflects against other devices or elbows in the pipe and returns downstream, damping progressively. The overpressure thus adds to the existing pressure in the pipe (as visible in the next page diagram), causing the following problems: breakage of pipes, tanks and hoses wear of seals, connecting welds and sanitary appliances damage to shut-off, check and regulating equipments high noise and powerful vibrations in both the pipes and the structures.

Numerical example: pipe length 10 m, diameter equivalent to 1/2, steel, copper and PE-X pipes with water velocity v1 = 2 m/s. We give the values of the velocity of the perturbation propagation v2, sudden operating times t* (phase time) and the overpressure p obtained with the formulas. L (m) v1(m/s) v2 (m/s) t* (ms) Steel Copper PE-X 10 10 10 2 2 2 1411 1400 885 14,2 14,3 22,6 p (m w.g.) 288 285 180 p (bar) 28,8 28,5 18

The amount of the overpressure is influenced by numerous factors, which make the phenomenon difficult to reproduce under laboratory conditions: equipment closing times length, diameter and material of the pipe velocity of the water.

For the practical purpose of calculating the water hammer overpressure, the following formula combines the most common variables in a domestic water system: 2 v1 L p = gt (1)

formula valid for t > t*, see next definition

p = overpressure due to water hammer (m w.g.) v1 = water velocity at time of closure start (m/s) L = length of pipe (m) g = acceleration of gravity (9,81 m/s2) t = valve closing time (s) We can briefly indicate the physical significance of the closing time (better defined as phase time) with the following formula:

Due to the greater stiffness of metal pipes, the velocity of the perturbation v2 is greater than in plastic pipes and close to the velocity of sound in water (1420 m/s at 7C). From these results, it is evident that plastic pipes for domestic water systems are more easily subject to water hammer, since they have a longer phase time t* than metal pipes. In practice, this means that closing operating times must be slower than in metal pipes. Although the overpressure values p for plastic pipes are lower than those for metal pipes (since they are less stiff, they partially dampen the water hammer), such overpressures can nonetheless stress the pipes beyond their resistance limit. Furthermore, in wall installations, the presence of a corrugated sheath or insulation influences the stiffness of plastic pipes, making the calculation of the water hammer even more complicated. From the example given, it is clear that the use of a water hammer arrester, already useful for metal pipes, is even more advisable for domestic water systems with plastic pipes, especially if installed externally. The graph at the bottom of the page shows the influence of the various parameters on the overpressure in copper pipes at the time of the pipe closure. The three curves were obtained setting a closing time t equal to the phase time t* of a 100 m pipe of size 20x1. Copper pipe 20x1 v2 (m/s) 1393 t* (ms) 100 m pipe 143,5

2 L t* = v2

(2) We can draw the following conclusions: 1) The longer the pipe, the greater the phase time t* and hence operations must be slower to prevent water hammer (formula (2)). 2) For a given operating time t and medium velocity v1, the longer the pipe, the greater the p caused by the operation (formula (1)). 3) For a given medium velocity v1 and length of pipe, larger diameters yield a slightly lower p (formula (1), but the difference is close to be negligible). 4) For a given pipe length and operating time t, if the medium velocity v1 increases, the p generated by the operation also increases (formula (1) and graph at foot of page). Overpressure in copper pipe 20x1 80 70 Overpressure p (bar) 60 50 40 30 20 10 t* (phase time) Closing time t 0 1 100 20x1 v1 = 1 m/s 20x1 v1 = 2 m/s 20x1 v1 = 5 m/s Diagram obtained by setting the operation time t = t* = phase time of the 100 m pipe

t* = valve phase time (s) L = length of pipe (m) v2 = velocity of the perturbation propagation (m/s) (as a function of the medium, pipe material, inner diameter and thickness of the pipe). For mechanical devices such as single-lever mixing taps, solenoid valves, ball valves, etc., all closing times t t* are defined sudden operations and induce a water hammer in the pipe with an overpressure at the maximum intensity, which is the same for any operating time. On the other hand, a closing time t > t* is defined slow operation and causes a less intense water hammer effect, which may even be negligible. By setting t = t* within the formula (1), we obtain the maximum overpressure p value for the water hammer effect. This will be evident from the following graph. p pmax.

Overpressure

Sudden operation

Slow operation

10 Pipe length (m)

Operating principle The Caleffi 525 series water hammer arrester is composed of a cylinder (1) divided into two chambers (2) and (3) by a piston with two o-ring seals (4). The closed chamber (2) contains air and acts as a damper due to the compressibility of the air. The open chamber (3) is connected directly to the pipe and fills with the system water. The water thrust on the piston is counteracted both by the air pressure variation in the chamber (2) and by the contrast spring (5) housed behind the piston in the air chamber. The oscilloscope graph reveals the following: - speed of the pressure increase - oscillatory character of the phenomenon - continuance of high pressure in the pipe even after the water hammer - effectiveness of the water hammer arrester.

Water hammer arrester - effectiveness Overpressure

After the repeated oscillations, the pressure in the pipe remains high Reducer set pressure

Registration of water hammer phenomenon Effect with water hammer arrester Sudden flow rate stop Time

2 1 3

5 4
Certified performance The Caleffi 525 series water hammer arrester has been tested by KIWA (NL) to verify the conformity to the performance requirements for water hammer devices (reference standard BRL K632/02). The laboratory tests showed that the Caleffi 525 series provides a water hammer overpressure damping ratio of more than 60%.

BRL K632/02

2000-06-02

Beoordelingsrichtlijn
voor het Kiwa productcertificaat voor Waterslagdempers

1999 Copyright, KIwa N.V. Niets uit deze uitgave mag verveelvoudigd en/of openbaar gemaakt worden door middel van druk, fotocopie, microfilm of op welke andere wijze dan ook, zonder voorafgaande schriftelijke toestemming van de uitgever. Het gebruik van deze Beoordelingsrichtlijn door derden, voor welk doel dan ook, is uitsluitend toegestaan nadat een schriftelijke overeen komst met Kiwa is gesloten waarin het gebruiksrecht is geregeld. Bindend verklaring Deze beoordelingsrichtlijn is door de directeur Certificatie en Keuringen van Kiwa bindend verklaard. per 2 juni 2000.

Erkenning

Kiwa N.V Certificatie en Keuringen Sir Winston Churchill-laan 273 Postbus 70 2280 AB Rijswijk Tel. 070 - 41 444 00 Tel. 070 - 41 444 20 Internet www.kiwa.nl

Construction details Reduced dimensions Water hammer arresters are easy to install in the system, preferably in the vicinity of the shut-off devices which originate the overpressure to damp. Maintenance free Compared to pneumatic arresters, Caleffi 525 series arresters, since mechanical, are maintenance free. Foodsafe elastomers and other materials The elastomers used in the seals and the other materials comply with the compatibility requirements for use with potable water as required by WRAS certifications. Reference standards Article 15 of UNI 9182 (IT) Cold and hot water supply and distribution systems. Design, testing and management criteria, specifies that: All cold and hot water distribution systems must be equipped with water hammer arrester of the mechanical (spring) or hydropneumatic (permanent or serviceable air cushion) type... The installation of the water hammer arrester must also comply with the Guidelines for the prevention and control of Legionnaires Disease, as set out by the Ministry of Health and adopted by the Regional State Conference on 4.4.2000. The arresters must be installed in such a way as not to create zones of stagnant water, which may be difficult to reach for the purposes of disinfection. Installation

The Caleffi 525 series water hammer arrester must be installed as close as possible to the device which gives rise to the water hammer by suddenly shutting off the water flow, so as to damp the resulting overpressure as soon as possible. It may be installed horizontally, vertically or upside down. For better results, the installation of the Caleffi 525 series should include the following: - installation at the public network inlet of a pressure reducing valve to keep the system pressure at 3-4 bar, which is the optimal value for the operation of the water hammer arrester as well as the sanitary appliances; - reduction of the water velocity in the pipes. The water velocity directly affects the overpressure in case of rapid closure of the pipe.

The recommended solution is that shown below, where the water hammer arrester is installed either next to the end user service or at the main connection of a distribution manifold for a small group of domestic appliances.

When installing the water hammer arrester under sinks and washhand basins, code 525130, create a space of 5-6 cm between the copper pipes and the threaded section of the shut-off valves. The radial connections enable water hammer arrester to be rotated to fit the available space.

Installation recommendations The Caleffi 525 series water hammer arresters are designed for single service installation (under washhand basins) or small groups of services, such as in a bathroom supplied by a domestic manifold. For larger scale water hammer problems, the solutions are different and must be designed to fit the particular case. One possible solution to water hammer may be to install an expansion vessel to act as an arrester. The traditional approach of installing water hammer arresters at the top of rising column, requires a review in the light of legislation about Legionnaires Disease. Although this solution was effective in attenuating water hammer, it is counterproductive in terms of system disinfection (both thermal and chemical) since it creates two types of hard to reach dead zones: - sections of pipe connecting the hot water rising pipes with the water hammer arresters above the recirculation connections; - zones of stagnant water inside the water hammer arresters themselves.

Water hammer arrester

Dead zones

INADVISABLE INSTALLATION

SPECIFICATION SUMMARIES
525 series Water hammer arrester. Threaded connections: 525040 1/2 M with PTFE seal on thread, 525130 3/8 F with nut x 3/8 M, 525150 3/4 F with nut x 3/4 M. Chrome plated brass body, high resistance polymer damping element, stainless steel spring, EPDM seals. Medium water. Maximum water hammer pressure 50 bar. Operating start pressure 3 bar. Maximum working pressure 10 bar. Maximum medium temperature 90C.

We reserve the right to make changes and improvements to the products and related data in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 R.A. FAX +39 0322 863723 www.caleffi.com info@caleffi.com Copyright 2008 Caleffi

Ball valves with built-in check valve


3230 - 332 - 333 - 334 - 327 series

CALEFFI
01021/10 GB
ACCREDITED

P O T S L BAL
Function

ISO 9001

FM 21654

ISO 9001 No. 0003

The ball valves with built-in check valve BALLSTOP combine two devices in a single body: a ball shut-off valve and a check valve housed inside the ball itself. This dual function allows for quicker installation and a more compact device, which means less space required on the pipe. BALLSTOP valves are available in two versions for two different uses: the version with black plastic external ring for use in domestic water systems and the version with red external ring for heating systems.

Product range 3230 series 3230 series Code 332400 333 series 334 series 327 series 327 series Ball Ball Ball Ball Ball Ball Ball valve valve valve valve valve valve valve with with with with with with with built-in built-in built-in built-in built-in built-in built-in check check check check check check check valve, valve, valve, valve, valve, valve, valve, butterfly handle lever handle butterfly handle butterfly handle butterfly handle butterfly handle lever handle sizes 1/21 sizes 1 1/42 size 1/2 sizes 1/2 and 3/4 x 3/4 sizes 1/2 and 3/4 x 3/4 sizes 1/2 and 3/4 sizes 12

series Materials Body: Ball: Check valve:

3230 - 332 - 333 - 334 brass EN 12165 CW617N, chrome plated brass EN 12164 CW614N, chrome plated brass EN 12165 CW617N, chrome plated PA POM PSU brass EN 12164 CW614N, chrome plated stainless steel NBR aluminium PTFE water, hydrocarbons 16 bar 0,02 bar 590C 3230 series: 1/22 F Code 332400: 1/2 M x 1/2 F Code 333400: 1/2 F x nut 3/4 F Code 333500: 3/4 F x nut 3/4 F Code 334400: 1/2 M x nut 3/4 F Code 334500: 3/4 M x nut 3/4 F 333 and 334 series: drilled anti-tamper safety nut

327 brass EN 12165 CW617N, chrome plated brass EN 12164 CW614N, chrome plated brass EN 12165 CW617N, chrome plated PA POM PSU brass EN 12164 CW614N, chrome plated stainless steel EPDM aluminium PTFE water, glycol solutions 30% 16 bar 0,02 bar 5110C 1/22 F

sizes 1/21 sizes 1 1/42 size 1/2 size 3/4 sizes 1 and 1 1/4 sizes 1 1/2 and 2

Check valve spring: Check valve seal: Control handle (lever, butterfly): Control stem seals: Performance Medium: Max. percentage of glycol: Max. working pressure: Min. pressure for check valve opening (p): Working temperature range: Connections

Dimensions D

C A

B B Code 323040 323050 323060 Code 327400 327500 A 1/2" 3/4" 1" B 51 57 70 C 50,5 52,5 61,5 Mass (kg) 0,28 0,37 0,55

Code 327600 323070 327700 323080 327800 323090 327900

Code

A 1" 1 1/4 1 1/2 2

B 70 83 89 110

C 61,5 65,5 80 89

A D 111 111 149 149

Mass (kg) 0,55 1,01 1,60 2,80

D A

F C E

C E

Code A 332400 1/2 334400 1/2 334500 3/4

B 1/2 3/4nut 3/4nut

C 63,5 69,5

D 50,5 50,5 52,5

E 70 73

F 61

Mass (kg) 0,40 0,40 0,42 Code 333400 333500 A 1/2" 3/4" B 3/4" 3/4"
nut nut

C 63,5 69,5

D 50,5 52,5

E 70 73

Operating principle The valve consists of a ball (1) containing a check obturator (2) with a fluid-dynamic shape. During normal circulation of the medium in the system, the obturator is pushed against the retaining spring (3) housed inside it, thereby opening the aperture and allowing the medium to flow through it. When the pressure downstream of the valve is higher than the upstream pressure, the obturator is pushed in the opposite direction against the seal seat on the ball (4), in order to prevent backflow of the medium. Even with no flow, the valve is closed by the action of the retaining spring alone. The obturator, owing to the thrust exerted by the retaining spring (3) and by the downstream pressure, completely shuts off the flow passage by means of the specially shaped seal (5) (positioned on the ball seal seat or on the obturator depending on the version). The ball valve, equipped with butterfly handle (6) or lever handle depending on the size of the valve, acts as a standard shut-off device.

3230 series
6 1 4 2 5 3

327 series 6 4 1 2

B Mass (kg) 0,42 0,42

Construction details Silent operation and low head losses Thanks to the ogival, fluid-dynamic shape of the obturator, the BALLSTOP valve ensures silent operation. Furthermore the flow rate curve is fairly flat, indicating limited head loss increases even in the case of substantial increases in flow rate. Quick operation The seal (positioned on the end point of the ball or on the obturator itself depending on the version) and the retaining spring (housed inside the obturator) ensure instant shut-off and a perfect seal, even with slight back pressure. Insensitive to dirt The sliding parts, due to the special coupling, are insensitive to dirt particles present in the water and deposits which may form after long periods of non-use. Foodsafe elastomers and other materials The elastomers used in the seals and the other materials of 3230, 332, 333 and 334 series BALLSTOP ball valves meet the compatibility requirements for use with potable water as required by WRAS and ACS certifications.

Easy system commissioning and maintenance During system commissioning or maintenance or if it is necessary to reverse the flow direction through the valve, setting the lever to 45 disables the check valve, enabling the medium to flow through the aperture between the outer surface of the ball and the valve body. This procedure also releases any air which may have formed while the system was not in use.

Hydraulic characteristics 3230 - 332 - 333 - 334 series


p (m w.g.) p (bar)

327 series
p (m w.g.) p (bar)

11/4 11/2

1/2

3/4

11/2

11/4

1/2

3/4

10 5

9 8 7 6 4.5 4 3.5 3 2.5 1.8 1.6 1.4 1.2 0.9 0.8 0.7 0.6 0.4 0.35 0.3 0.25 0.16 0.14 0.12

0,9 0,8 0,7 0,6 0,4 0,35 0,3 0,25

10 5

9 8 7 6 4.5 4 3.5 3 2.5 1.8 1.6 1.4 1.2 0.9 0.8 0.7 0.6 0.4 0.35 0.3 0.25 0.16 0.14 0.12

0,9 0,8 0,7 0,6 0,4 0,35 0,3 0,25 0,16 0,14 0,12 0,08 0,07 0,06 0,04 0,035 0,03 0,025 0,016 0,014 0,012

0,5 0,45

0,5 0,45

2 1

0,2 0,18 0,1 0,09


0,08 0,07 0,06 0,04 0,035 0,03 0,025 0,016 0,014 0,012 0,16 0,14 0,12

2 1

0,2 0,18 0,1 0,09 0,05 0,045

0.5 0.45

0,05 0,045

0,5 0.45

0.2 0.18
0.6 0.7 0.8 0.25 0.35 0.4 0.45 0.9 1.2 1.4 1.6 1.8 2.5 3.5 4 4.5 6 7 8 9 12 14 16 18 25 30 35 40 45

0,02 0,018 0,01

0,2 0.18
0.6 0.7 0.8 0.25 0.35 0.4 0.45 0.9 1.2 1.4 1.6 1.8 2.5 3.5 4 4.5 6 7 8 9 12 14 16 18 25 30 35 40 45

0,02 0,018 0,01

0.1

0,1

0.3

0.3

20

0.2

0.2

0.5

0.5

20

50

G (m3/h)

G (m3/h)

Kv (m3/h)

1/2 4,2

3/4 7

1 13,5

1 1/4 24

1 1/2 29

2 43 Kv

(m3/h)

1/2 4,2

3/4 7

1 10

1 1/4 18

1 1/2 29

43

Installation Caleffi 3230, 332, 333 and 334 series BALLSTOP ball valves with built-in check valve are recommended for domestic water systems where there is a need to disable the check valve. Typical uses include connection to the water network or installation on hot water storage supply lines etc. Caleffi 327 series BALLSTOP ball valves with built-in check valve are recommended for heating systems, thanks to the seal materials which are compatible with high temperature operating conditions. The application of a check valve after the pump (see figure opposite) is aimed at preventing the convective motion of natural circulation when the circulator is switched off and which causes an unwanted increase in room temperature, resulting in higher costs and discomfort for the user.

By contrast the ball valve, where the check device is housed, serves as a shut-off device: if the pump is removed or the boiler emptied, it prevents all the water draining out from the system.

The ball shut-off valve with built-in check valve must be installed in the system following the flow direction indicated on the plastic band applied to the valve body. The valve can be fitted in any position, vertical, horizontal or upside down.

50

10

10

Application diagrams Central hot water production system with thermal disinfection
Ball shut-off valve Shut-off valve Check valve
T

Pressure gauge Pump Pressure reducing valve Temperature gauge Safety relief valve Temperature probe Deaerator-dirt separator

Thermostatic mixing valve Three-way mixing valve Clock Outside compensated temperature controller

Solar system with thermal integration

T
T
T

Normally closed valve

Heating system with two heat generators and various secondary circuits

SEPARATORE IDRAULICO
Serie 548

Tmax 120C Pmax 10 bar

Tmax 105C Pmax 10 bar

Heating system with one heat generator and two different secondary circuits

P T

F
A

SPECIFICATION SUMMARY
3230 BALLSTOP series Ball valve with built-in check valve. Butterfly handle. Threaded connections 1/2 F (from 1/2 to 1). Brass body, chrome plated. Brass ball, chrome plated. Check valve in PA (1/2), POM (3/4), PSU (1). Aluminium control lever. PTFE control stem seals. NBR check valve seal. Stainless steel check valve spring. Medium water and hydrocarbons. Working temperature range 590C. Maximum working pressure 16 bar. Minimum opening pressure for check valve 0,02 bar.

3230 BALLSTOP series Ball valve with built-in check valve. Lever handle. Threaded connections 1 1/4 F (from 1 1/4 to 2). Brass body, chrome plated. Brass ball, chrome plated. Check valve in PSU (1 1/4), chrome plated brass (1 1/2 and 2). Aluminium control lever. PTFE control stem seals. NBR check valve seal. Stainless steel check valve spring. Medium water and hydrocarbons. Working temperature range 590C. Maximum working pressure 16 bar. Minimum opening pressure for check valve 0,02 bar.

Code 332400 BALLSTOP Ball valve with built-in check valve. Butterfly handle. Threaded connections 1/2 M x 1/2 F. Brass body, chrome plated. Brass ball, chrome plated. PA check valve. Aluminium control lever. PTFE control stem seals. NBR check valve seal. Stainless steel check valve spring. Medium water and hydrocarbons. Working temperature range 590C. Maximum working pressure 16 bar. Minimum opening pressure for check valve 0,02 bar.

333 BALLSTOP series Ball valve with built-in check valve. Butterfly handle. Connections 1/2 (1/2 and 3/4) F x nut 3/4 F. Brass body, chrome plated. Brass ball, chrome plated. Check valve in PA (1/2), POM (3/4). Aluminium control lever. PTFE control stem seals. NBR check valve seal. Stainless steel check valve spring. Medium water and hydrocarbons. Working temperature range 590C. Maximum working pressure 16 bar. Minimum opening pressure for check valve 0,02 bar.

334 BALLSTOP series Ball valve with built-in check valve. Butterfly handle. Connections 1/2 (1/2 and 3/4) M x nut 3/4 F. Brass body, chrome plated. Brass ball, chrome plated. Check valve in PA (1/2), POM (3/4). Aluminium control lever. PTFE control stem seals. NBR check valve seal. Stainless steel check valve spring. Medium water and hydrocarbons. Working temperature range 590C. Maximum working pressure 16 bar. Minimum opening pressure for check valve 0,02 bar.

327 BALLSTOP series Ball valve with built-in check valve for heating systems. Butterfly handle. Connections 1/2 (1/2 and 3/4) F. Brass body, chrome plated. Brass ball, chrome plated. Check valve in PA (1/2), POM (3/4). Aluminium control lever. PTFE control stem seals. EPDM check valve seal. Stainless steel check valve spring. Medium water and glycol solutions. Maximum percentage of glycol 30%. Working temperature range 5110C. Maximum working pressure 16 bar. Minimum opening pressure for check valve 0,02 bar.

327 BALLSTOP series Ball valve with built-in check valve for heating systems. Lever handle. Connections 1 (from 1 to 2) F. Brass body, chrome plated. Brass ball, chrome plated. Check valve in PSU (1 and 1 1/4), chrome plated brass (1 1/2 and 2). Aluminium control lever. PTFE control stem seals. EPDM check valve seal. Stainless steel check valve spring. Medium water and glycol solutions. Maximum percentage of glycol 30%. Working temperature range 5110C. Maximum working pressure 16 bar. Minimum opening pressure for check valve 0,02 bar.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. S.R.229, N.25 28010 FONTANETO DAGOGNA (NO) ITALY TEL. +39 0322 8491 FAX +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

Controllable reduced pressure zone backflow preventer (BA type)


series 574 - 575 - 570
cert. n 0003

CALEFFI
ISO 9001

01022/03 GB
Replaces 01022/99 GB

Function The backflow preventer is a plumbing protection device designed to prevent polluted water from flowing back into the mains supply. This type of backflow may occur when the pressure in the mains supply changes and causes a reversal of the flow. The backflow preventer is installed between the mains supply and the internal consumer circuit in water supply systems and creates a safety zone which prevents the water in the two circuits from coming into contact.

Product range Series Series Series Series 574 575 570 570 Controllable reduced pressure zone backflow preventer (BA type). Threaded connections Controllable reduced pressure zone backflow preventer (BA type). Flanged connections Assembly fitted with backflow preventer (BA type), shut-off valves, strainer. Threaded connections Assembly fitted with backflow preventer (BA type), shut-off valves, strainer. Flanged connections Sizes 1/22 Sizes DN 50DN 100 Sizes 1/22 Sizes DN 50DN 100

Technical specification series Materials Body and cover: 574-570 threaded 575-570 flanged

Check valve spindle: Discharge seat:

Springs: Diaphragm: Seals: Shut-off valve body: Strainer body: Strainer cartridge: Performance Medium: Max. working pressure: Max. working temperature: Filter mesh:

dezincification resistant alloy EN 12165 CW602N (1/21 1/4) bronze RG5 Pb3 DIN 50930-6 (1 1/2-2) stainless steel dezincification resistant alloy EN 12164 CW602N (1/2-3/4) stainless steel (12) stainless steel EPDM NBR brass EN 12165 CW617N, chrome plated bronze EN1982 CB491K stainless steel

bronze RG5 Pb3 DIN 50930-6

stainless steel stainless steel

stainless steel EPDM NBR Ductile iron GGG 40 coated with epoxy resin Cast iron GG 25 coated with epoxy resin stainless steel

water 10 bar 65C 0,8 mm

water 10 bar 65C 0,7 mm (DN 50-DN 65) 0,9 mm (DN 80-DN 100) DN 50DN 100 flanged PN 16 DN 50: 1/4 F DN 65DN 100: 1/2 F

Connections Pressure test port connections

1/22 M with union 1/4 F

Dimensions

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

C D

F B E F E F
Code A B 365 390 430 C 130 130 162 162 D 44,5 44,5 E F
Weight (kg)

570004 1/2" 570005 3/4" 570006 1"

103 40 103 40

72,5 99,5 40 72,5 99,5 40

Code

B 103 103

C 30 30

Weight (kg)

Code 574900

A 2"

B 130

C 31 31

Weight (kg)

570007 1 1/4" 540 570008 1 1/2" 670 570009 2" 735

574040 1/2" 574050 3/4"

263 40 227 263 40 227

2,9 2,9

574800 1 1/2" 130

382 50 387 382 50 395

11,3 11,4

221 103,4 129,6 50 14,4 221 103,4 129,6 50 16,5

CALEFFI

LT

C D

C D

DN 100 PN 10

DN 100 PN 10

E F E F
Code Code 574600 A 1" B 100 C 30 30 D E F
Weight (kg)

C 27 27 26 26

Weight (kg)

Code 570050 570060 570080 570100

DN 50 65 80 100

Lt 1050 1150 1350 1430

d 50 50 80 80

Weight (kg)

575005 DN 50 129 575006 DN 65 132,5 575008 DN 80 170 575010 DN 100 170 292 40 280 292 40 280 3,6 3,8

382 50 302 385 50 305 484 80 470 484 80 470

13,2 17,0 26,5 28,0

104 135

574700 1 1/4" 100

Backflow Potable water fed from the mains supply may suffer from hazardous pollution caused mainly by contaminated fluids from plumbing systems flowing back directly into the mains supply. This phenomenon, termed backflow occurs when: a) the pressure in the mains system is less that in the plumbing circuit receiving the supply (back syphonage). This situation may occur when there is a pipe breaking in the mains system or when demand on the mains supply from consumers is very heavy. b) the pressure in the plumbing circuit receiving the supply rises (back pressure) due, for example, to water being pumped from a well.

Risk assessment Given the potential dangers of the phenomenon and the requirements of current regulations, the risk of pollution from backflow must be assessed on the basis of the type of system and the characteristic of the fluid that flows in it. An appropriate backflow prevention device must be selected on the basis of that assessment performed by the system designer and the mains supplier. The device must be located along the supply line at those points at risk of backflow which would be hazardous to human health. The protection can be provided by inserting a backflow preventer at critical points in the circuit at the inlet from the mains supply or in the internal plumbing system. This will prevent polluted water from flowing back in all systems for which direct connection to the mains or an internal supply is considered hazardous.
Installation in a building with multiple outlets Installation in a fire fighting system

C
3,0 3,6 5,4 6,2 70 80

Use of backflow preventers (BA type) according to European standards EN 1717 and EN 12729 Proper use of the BA type backflow preventer is regulated by the new European standards on the prevention of pollution from backflow. The relevant standard is EN 1717: 2000 Protection against pollution of potable water in water installations and general requirements of devices to prevent pollution by backflow. The types of water contained in water systems are classified in this standard according to the degree of risk to health. Category 1: Water used for human consumption provided by a water company. Category 2: Fluid which does not present health hazard, as in category 1, whose quality has been compromised as a result in changes to its temperature, taste, odour or appearance. Category 3: Fluid which presents a slight health hazard due to concentrations of low toxic substances. Category 4: Fluid that presents a significant health hazard due to concentrations of toxic substances. Category 5: Fluid that presents a serious health hazard due to concentrations of pathogenic organisms, radioactive or very toxic substances. Appropriate backflow prevention devices must be fitted in water supply systems on the basis of this classification. Backflow preventers (BA type) can be used to protect against the risk of pollution from backflow for types of water up to category 4. For category 5 types of water an air gap separation must be used. The table on the right, entitled Protection matrix, relates the categories of water to different types of system. It has been compiled on the basis of indications given by the European regulations. The new European standard EN 12729 Devices to prevent pollution by backflow of potable water. Controllable backflow preventer with reduced pressure zone. Family B Type A - stipulate the functional, dimensional and mechanical requirements that must be met for controllable reduced pressure zone backflow preventers (BA type).

Protection matrix Type of system General Sprinkler fire fighting systems using anti freeze solutions Industrial cisterns Non-domestic hose union taps Permeable hoses in others than domestic gardens, laid below or at ground level, with or without chemical additives Primary circuits and central heating circuits in other than a house Reclaimed water systems Urinals, WCs and bidets Domestic or residential gardens Mini-irrigation systems without fertilisers or insecticides applications, such as pop-up sprinklers or porous hoses Food processing Bottle washing apparatus Butchery and meat trade Dairies Food preparation Slaughterhouse equipment Vegetable washing Medical Medical or dental equipment with submerged inlets Bed-pans washers Commercial clothes washing in health care premises Domestic appliances such as sinks, baths and wash basins Dialysing machines Laboratories Mortuary equipment Catering Bottle washing apparatus Dish washing machines in commercial buildings Dish washing machines in health care premises Drink vending machines in which ingredients or CO2 are injected into the supply or distribution pipe Refrigerating equipment Vegetable washing Industrial and commercial applications Brewery and distillation Car washing and degreasing plants Commercial clothes washing plants Drain cleaning plant Dyeing equipment Industrial and chemical plants Industrial disinfection equipment Laboratories Mobile plant, tankers and gully emptiers Printing and photographic equipment Water storage for agricultural purposes Animals drinking systems Water treatment plant or water softeners using products other than salt Pressurised water fire fighting systems Water storage for fire fighting purposes Agricultural Commercial irrigation with outlets below or at ground level and/or permeable pipes, with or without chemical additives Commercial hydroponic systems Insecticide of fertiliser applications

Fluid cat. 5 4 * * * * * * *

* * * * * *

* * * * * * *

* * * * * *

* * * * * * * * * * * * * * *

* * *

Operating principle The controllable reduced pressure zone backflow preventer is comprised of: a body with an inspection cover, an upstream check valve (1), a downstream check valve (2), a discharge device (3). The two check valves divide three different zones, each of which at a different pressure: an upstream or inlet zone (A); an intermediate zone, also known as the reduced pressure zone (B); a downstream or outlet zone (C). Each of these has a test port for measuring pressure. A discharge device (3), is located in the lower part of the intermediate zone. The obturator of the discharge device is connected via the valve stem (4) to the diaphragm (5). This mobile unit is pushed upwards by the spring (6). The diaphragm (5) marks the limit of the top chamber (D), which is connected to the upstream zone by the channel (7). Normal flow conditions Under conditions of normal flow, both check valves are open, while the pressure in the intermediate chamber (B) is always lower that the inlet pressure by at least 140 mbar due to the pressure loss caused by the check valve (1). In the top chamber (D), however, the pressure is the same as in the inlet zone. In this situation, the mobile unit consisting of the diaphragm (5), the valve stem (4) and the valve obturator (3) is pushed down by the push created by the difference in pressure acting on the diaphragm which is greater than that of the spring(6) acting in the opposite direction. The discharge valve is therefore held in the closed position.

1 D 7

5 4 6
UPSTREAM

A B 3 C

DOWNSTREAM

No flow conditions The check valves (1) and (2) are now closed. Since the pressure in the upstream zone and therefore also in the top chamber (D), is still at least 140 mbar higher than the pressure in the intermediate chamber (B), the discharge valve remains closed.

1 D 7

5 4 6
UPSTREAM

A B 3 C

DOWNSTREAM

Upstream pressure loss Both check valves close as the pressure upstream drops. The discharge valve (3) opens when the difference in pressure P, between the upstream and the intermediate zones falls, drops below 140 mbar. Under these conditions the action exerted by the pressure difference P on the diaphragm (5), becomes weaker than that exerted by the spring (6), and the discharge valve (3) opens as a result. Discharge then occurs until the body of the backflow preventer is empty. When the situation returns to normal (pressure upstream greater than pressure downstream), the discharge valve closes and the backflow preventer is again ready to operate.

1 D 7

5 4 6
UPSTREAM

A B 3 C

DOWNSTREAM

Downstream back pressure If the pressure in the downstream zone increases until it is greater than the upstream pressure, the check valve (2) closes and therefore prevents water already delivered from returning back into the mains system. If the seal of the check valve (2), is slightly defective or in general terms there is any other type of fault in the backflow preventer, the device always interrupts (disconnects) the connection between the mains system and the receiving system. The backflow preventer has been designed with all construction details required for a properly functioning positive action device; the best possible safety conditions are therefore ensured under all conditions.

Constructional details Discharge funnel In compliance with standard EN 1717 backflow from the connected pipe must be prevented during discharge and this must occur without any external water spillage. Consequently the tundish connected to the discharge pipe must be of an appropriate size with special openings to create the necessary air gap and it must be equipped with a proper flow conveyor. Anti-corrosion materials The materials used to manufacture the backflow preventers must be corrosion resistant due to contact with drinking water. They are therefore constructed using an dezincification resistant alloy , bronze and stainless steel to ensure longlasting high performance. Elastomers complying with food regulations The elastomers employed for the water seals are approved by Certifying Bodies in compliance with the most recent regulations governing compatibility for use with drinking water. Easy maintenance The backflow preventer is inspected periodically during its normal operating life to check that it is functioning correctly. Should the need arise, dismantling and maintenance operations are simple and easy to perform with components that are easy to inspect and replace without disconnecting the valve body from the pipework.

Certification The series 574 and 575 BA type controllable reduced pressure zone backflow preventers are certified as complying with the National and European standards by the following Certifying Bodies: UNI-NF-WRASKIWA-DVGW-SVGW-OVGW-KIWA-SITAC-BELGAQUA-SAI-Global.

Hydraulic characteristics
p (bar) 2
1,8 1,6 1,4 1,2

1/2

3/4

p (m w.g.)
18 16 14 12

p (bar) 2
1,8 1,6 1,4 1,2

1 1/2

p (m w.g.)
18 16 14 12

20

20

0,9 0,8 0,7 0,6

10
9 8 7 6

0,9 0,8 0,7 0,6

10
9 8 7 6

0,5

0,45 0,40 0,35 0,30 0,25

5 4,5
4,0 3,5 3,0 2,5

0,5

0,45 0,40 0,35 0,30 0,25

4,5 4,0 3,5 3,0 2,5

0,6

0,7

0,8

0,9

1,2

1,4

1,6

1,8

2,5

3,5

4 4,5

0,6

0,7

0,8

0,9

1,2

1,4

1,6

1,8

2,5

3,5

4 4,5

25

30

35

40 45

25

30

35

12

14

16

18

12

14

16

50

18

20

0,5

0,5

G (m /h) p (bar) 2
1,8 1,6 1,4 1,2

20

G (m /h) p (bar) 2
1,8 1,6 1,4 1,2

1 1 1/4

p (m w.g.)
18 16 14 12

DN 50 DN 65 DN 80 DN 100

p (m w.g.)
18 16 14 12

20

50
20 10
9 8 7 6 4,5 4,0 3,5 3,0 2,5

10

0,9 0,8 0,7 0,6

10
9 8 7 6

0,9 0,8 0,7 0,6

0,5

0,45 0,40 0,35 0,30 0,25

5 4,5
4,0 3,5 3,0 2,5

0,5

10

40 45

0,2

0,2

0,45 0,40 0,35 0,30 0,25

120

140

160

180

250

300

350

G (m /h)

200

G (m /h)

Series 570 Strainer Shut-off valve 1/2 4,5 7 3/4 8 11 1 11 20 1 1/4 16 35

Kv (m3/h) 2 1 1/2 25 22 80 49

DN 50 104 300

DN 65 180 610

DN 80 258 950

DN 100 365 1.700

Installation Backflow preventers must be installed by qualified personnel in accordance with current norms and regulations. They must be installed downstream from a shut-off valve and from a strainer with a discharge that can be inspected and another shut-off valve must be fitted downstream from it. The unit must be installed in an accessible position, appropriately located to avoid possible immersion due to accidental flooding (see diagram). The device must be fitted horizontally. The discharge tundish must comply with standard EN 1717 and be connected to the sewage piping. Before installing the backflow preventer and the strainer, the pipework must be flushed with a large flow rate. When used to protect the mains supply, backflow preventers must be installed downstream from the water meter, whereas when used to protect the potable water supply system for internal usage, they are installed at the limit of the zone where pollution might occur, e.g. central heating systems, garden irrigation systems, etc.

L 1

L 4 3

CALEFFI

DN 100 PN 10

0,50

0,50

B=0,50 a 1,50

sewer mains tunnel

pipe

sewer mains tunnel

pipe

B=0,50 a 1,50

GROUND, FLOOR, GANGWAY


1 2 3 4 shut-off valve strainer backflow preventer shut-off valve

GROUND, FLOOR, GANGWAY


1 2 3 4 shut-off valve strainer backflow preventer shut-off valve

Discharge to sewer

Discharge to sewer

500

20

50

100

10

10

20

0,5

50

400 450

0,6

0,7

0,8

0,9

1,2

1,4

1,6

1,8

2,5

3,5

4 4,5

12

14

16

18

25

30

35

40 45

12

14

16

18

25

30

35

40 45

60

70

80

90

0,2

0,2

Inspection and maintenance The backflow preventer is a safety device and requires periodical inspection. The first sign of poor functioning, generally caused by the presence of foreign bodies (sand or other impurities), is seen with a constant discharge from the discharge valve. This discharge is only a first alarm and does not mean in any way that the backflow preventer is not safe but the device and the strainer upstream from it requires dismantling and cleaning. A quick method of inspection (requires less than 15 minutes) is described in the table below. N.B. If water is discharged from the discharge valve, a strong flow of water is recommended by turning on one or more taps since this is often sufficient to expel foreign bodies and return everything to normal.

Control instrumentation (code 575000) The periodical (annual) control instrumentation consists of the following: - Upstream pressure gauge - Downstream pressure gauge - Differential pressure gauge

The flexible tubes and necessary connections are included as well as accessories useful for dismantling the unit. The instrumentation comes in its own case.

QUICK INSPECTION METHOD Check that the system is under pressure before each operation and watch the discharge valve located on the lower part of the device (use a mirror if necessary).

OPERATION

FINDINGS

PROBABLE CAUSE

DECISION

1
Close the downstream shut-off valve

Constant discharge

Upstream check valve or discharge valve do not seal

Dismantle and check

No constant discharge

Move to step 2

2
Close the upstream shut-off valve and open the test cock for checking the upstream pressure (on the front flange)

The discharge valve does not open or better there is a minor discharge and lasts more than one minute

Discharge valve is blocked

Dismantle and check

The discharge valve opens suddenly and the unit empties in less than one minute

Move to step 3

3
Open the downstream shut-off valve.

Continuous discharge

Downstream check valve is leaking

Dismantle and check

No discharge

Put back into operation

N.B. : During normal operation there should be no constant discharge. If there is a constant discharge dismantle and inspect the device.

SPECIFICATION SUMMARIES Series 574


Controllable reduced pressure zone backflow preventer (BA type). EN 12729 certified. 1/2 M (1/2-3/4 M) threaded connections with union. Body, cover and discharge valve seat in dezincification resistant alloy. Check valve spindle and springs in stainless steel. Seals in NBR. Max. working temperature 65C. Max. working pressure 10 bar. Positive action safety device in compliance with standard EN 12729. Complete with upstream, intermediate and downstream pressure test ports and discharge tundish with collar fitting to pipe.

Series 574
Controllable reduced pressure zone backflow preventer (BA type). EN 12729 certified. 1 M (1-1 1/4 M) threaded connections with union. Body and cover in dezincification resistant alloy. Check valve spindle, discharge valve seat and springs in stainless steel. Seals in NBR. Max. working temperature 65C. Max. working pressure 10 bar. Positive action safety device in compliance with standard EN 12729. Complete with upstream, intermediate and downstream pressure test ports and discharge tundish with collar fitting to pipe.

Series 574
Controllable reduced pressure zone backflow preventer (BA type). EN 12729 certified. 1 1/2 M (1 1/2-2) threaded connections with union. Body and cover in bronze. Check valve spindle, discharge valve seat and springs in stainless steel. Seals in NBR. Max. working temperature 65C. Max. working pressure 10 bar. Positive action safety device in compliance with standard EN 12729. Complete with upstream, intermediate and downstream pressure test ports and discharge tundish with collar fitting to pipe.

Series 575
Controllable reduced pressure zone backflow preventer (BA type). EN 12729 certified. DN 50 (DN 50DN 100) PN 16 flanged connections. Body and cover in bronze. Check valve spindle, discharge valve seat and springs in stainless steel. Seals in NBR. Max. working temperature 65C. Max. working pressure 10 bar. Positive action safety device in compliance with standard EN 12729. Complete with upstream, intermediate and downstream pressure test ports and discharge tundish with collar fitting to pipe.

Series 570
Assembly fitted with backflow preventer. 1/2 F (1/22 F) threaded connections. Max. working temperature 65C. Max. working pressure 10 bar. Consisting of: - Controllable reduced pressure zone backflow preventer (BA type). EN 12729 certified. M threaded connections with union. Body in dezincification resistant alloy. Check valve spindle, discharge valve seat and springs in stainless steel. Seals in NBR. Positive action safety device in compliance with standard UNI 9157. Complete with upstream, intermediate and downstream pressure test ports and discharge tundish with collar fitting to pipe. - Y strainer. Body in bronze. Mesh in stainless steel. Seal in Saital K. Filter mesh 0,8 mm. - Upstream and downstream shut-off ball valves. Brass body. Chrome plated.

Series 570
Assembly fitted with backflow preventer. DN 50 (DN 50DN 100) PN 16 flanged connections. Max. working temperature 65C. Max. working pressure 10 bar. Consisting of: - Controllable reduced pressure zone backflow preventer (BA type). EN 12729 certified. Body and cover in bronze. Check valve spindle, discharge valve seat and springs in stainless steel. Seals in NBR. Positive action safety device in compliance with standard EN 12729. Complete with upstream, intermediate and downstream pressure test ports and discharge tundish with collar fitting to pipe. - Y strainer. Body in cast iron GG 25. Epoxy resin coated. Mesh in stainless steel. Filter mesh: 0,7 mm (DN 50-DN 65), 0,9 mm (DN 80-DN 100). Complete with 1/2" F discharge valve connection. - Upstream and downstream shut-off valves. Body in ductile iron GGG 40. Epoxy resin coated. Control spindle seal in NBR.

Series 5750
The periodical (annual) control instrumentation consists of the following: upstream pressure gauge 010 bar; downstream pressure gauge 010 bar; differential pressure gauge 01.000 mbar; flexible hoses and connectors to pressure test ports; instrument case.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Inclined pressure reducing valves

CALEFFI
5330 series
ACCREDITED

01024/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003

replaces 01024/03 GB

Function Pressure reducing valves are installed in residential water system to reduce and stabilise inlet pressure from the water network which is generally too high and variable for domestic systems to work properly. The 533 series was created for small systems, such as apartments, and to protect water storage heaters, where size and absence of noise are of particular concern.

Product range 5330 5331 5332 5334 5336 5337 5338 series series series series series series series Inclined Inclined Inclined Inclined Inclined Inclined Inclined pressure pressure pressure pressure pressure pressure pressure reducing reducing reducing reducing reducing reducing reducing valve valve valve valve valve valve valve sizes 1/2 and 3/4 F size 3/4 M x 3/4 F with nut sizes 1/2 and 3/4 F sizes 1/2 and 3/4 F sizes 15 and 22 for copper pipe sizes 15 and 22 for copper pipe sizes 15 and 22 for copper pipe

with pressure gauge with pressure gauge connection with pressure gauge connection with pressure gauge

Technical specifications Materials Body: - 5330/1/2/4 series; - 5336/7/8 series; Performance Max. upstream pressure: Downstream pressure setting range: Factory setting: Max. working temperature: Pressure gauge scale: Medium: Connections Main connections: Pressure gauge connection:

brass EN 12165 CW617N, chrome plated dezincification resistant alloy EN 12165 CW602N, chrome plated Cover: PA66GF30 Control stem: dezincification resistant alloy EN 12165 CW602N Cartridge: POM Internal components: brass EN 12165 CW617N Diaphragm: NBR Seals: NBR Strainer: stainless steel

16 bar 16 bar 3 bar 60C 010 bar water

see product range 1/4 F

Dimensions

Operating principle The functioning of the pressure reducing valve is based on the balance between two opposing forces: 1 the thrust of the spring to open the flow through the cross section.

2 the thrust of the diaphragm to the close the flow through the cross section.
A A
E

Code

B 72,5 72,5

C 22,5 22,5
D

D 46 46

E 64 66

Mass (kg)

533041 1/2 533051 3/4

0,39 0,41

B A

UPSTREAM
D 46 E 85,5
Mass (kg)

DOWNSTREAM

Code

B 72,5

C 22,5

533151 3/4

0,46

Operation with water flow When a draw-off outlet is opened on the water system, the force of the spring becomes greater than that of the diaphragm; the obturator moves downwards opening the valve to the flow of water. The greater the demand for water the lower the pressure under the diaphragm with a resulting greater flow of water through the valve.

B A

6 8 2

6 8

bar

10

bar

10

Code

Mass (kg)

533241 533441 1/2 72,5 22,5 46 70 533251 533451 3/4 72,5 22,5 46 72
D

0,51 0,52

C A L E F F I

C A L E F F I

Operation without water flow When the draw-off outlet is closed, the downstream pressure rises and pushes the diaphragm upwards. As a result the obturator closes the valve to the passage of water and maintains the pressure constant at the calibrated pressure. The slightest difference in favour of the force exercised by the diaphragm, in relation to that of the spring, causes the device to close.

Code

B 72,5 72,5

C 22,5 22,5
D

D 46 46

E 91 93

Mass (kg)

533641 15 533651 22

0,43 0,46

4 2

6 8 2

6 8

0
C A L E F F I
C A L E F F I

bar

10

bar

10

Code

533741 533841 15 72,5 22,5 46 103 533751 533851 22 72,5 22,5 46 107

A
Mass (kg)

0,55 0,57

Construction details Contoured diaphragm The membrane was designed with a special shape to give an accurate pressure regulation as a function of changes in the downstream pressure. This design feature also extends the valve life because the diaphragm is more resistant to pressure sudden changes and to wear. Silent operation The large chamber on the outlet side of the reducing valve creates a low flow speed zone, which is particularly effective in reducing noise generated by narrowing the width of the passage through which the water flows when the valve is reducing pressure.

Small size The inclined design makes the 533. series reducers small in size so that they are easy to fit especially in domestic systems.

Non-stick materials The central support , which contains the moving parts is made of a plastic material with a low coefficient of adhesion. This reduces the probability of scale deposits being formed, the main cause of malfunction.

Use with boiler hydraulic safety groups The 5331 model is specially designed for use with the Caleffi hydraulic safety groups for hot water storage heaters 5261 series. The 3/4" nut provided can be used for an easy direct connection to the hydraulic safety groups. Extractable cartridge The cartridges in the Caleffi 533. series of pressure reducing valves can be removed for periodic cleaning and maintenance.

REMOVABLE CARTRIDGE
CALEFFI

REMOVABLE STRAINER

Approvals The pressure reducing valves are approved as compliant with WRAS specifications in the United Kingdom and ACS in France.

Hydraulic characteristics Graph 1 (circulation velocity)


V (m/s)
5 4 3 2

The steps to take for selecting the correct size are as follows: The total flow rate is calculated from the number and type of appliances present by taking the sum of the individual flow rates. Example:

0,5 0,4 0,3 0,2

1/2

3/4

One living unit with 1 bathroom 1 bidet G = 6 l/min 1 shower G = 9 l/min 1 wash basin G = 6 l/min 1 wc with cistern G = 6 l/min 1 kitchen sink G = 12 l/min 1 washing machine G = 12 l/min Gtot = 51 l/min

0,1

No appliances = 6
0,2 0,5

Flow rate (l/min) (m3/h)

10

The design flow rate is calculated from the table of coefficients of simultaneity (using that for 10 appliances). Example: Gds = Gtot % = 51 41 % = 21 l/min

10

20

50

Graph 2 (Pressure drop)


p (bar)
1,5 1,2 1 0,9 0,8 0,7 0,6 0,5 0,4 0,3

100

p (m w.g.)
15 12 10

8 7 6 5 4 3

It is recommended that flow velocity is kept within 1 to 2 metres per second when calculating the correct reducer size. This will prevent noise in the pipes and rapid wear of appliances. The correct diameter of the reducing valve is taken from diagram 1 on the basis of the design flow rate taking into account an ideal flow velocity of between 1 and 2 m/s (blue band). Example: for Gds = 21 l/min select diameter 1/2 (see indications on diagram 1)

0,2

0,1

0,2

0,5

Reference values:

Upstream pressure = 6 bar Downstream pressure = 4 bar

Flow rate (l/min) (m3/h)

10

20

50

100

10

Sizing the valve The flow rates of commonly used appliances in domestic plumbing systems are given below to assist in the selection of the correct valve diameter:

The pressure drop is taken from diagram 2 again on the basis of where the design flow rate intersects the curve for the relative diameter already selected (the downstream pressure falls by an amount equal to the pressure drop, with respect to the set pressure at no flow condition).

Example: Table of typical flow rates Bathtub, kitchen sink, dishwasher 12 l/min Shower 9 l/min Washbasin, bidet, washing machine, WC with cistern 6 l/min The simultaneous-use factor must be taken into account to avoid selecting a valve that is too large. Basically, the fewer people using the system, the lower the probability of two appliances being used at the same time. for Gds = 21 l/min 1/2 (see indications on diagram 2) p = 0,8 bar

Recommended flow rates For an average flow velocity of 1,5 m/s, the recommended flow rates for each diameter are as follows: Diameter Flow rate m3/h Flow rate l/min 1/2 1,2 20 15 1,2 20 3/4 2,1 35 22 2,1 35

Table of simultaneous-use factor values (%)


Number Residential Community of % % appliances Number Residential Community of % % appliances Number Residential Community of % % appliances

5 10 15 20 25

30 54 41 35 29 27,5 24,5

64,5 49,5 43,5 37 34,5 32

35 40 45 50 60 70

23,2 21,5 20,5 19,5 18 17

30 28 27 26 24 23

80 90 100 150 200 300

16,5 16 15,5 14 13 12,5

22 21,5 20,5 18,5 17,5 16,5

Installation 1. Turn all taps on before installing the valve to flush the system and expel any air remaining in the pipes. 2. Install shut-off valves upstream and downstream of the pressure reducer to facilitate future maintenance operations. The upstream valve may have a check valve incorporated (Caleffi BALLSTOP). 3. Install the pressure reducer in any position. 4. Close downstream shut-off valve. 5. Calibrate it by turning the screw on the top of the plastic cover. Turn it clockwise to increase the pressure and anticlockwise to decrease it.

2. Water hammer This is one of the main causes of faults in pressure reducing valves. It is best to fit special devices to absorb water hammer when installing pressure reducers in at-risk systems.

Trouble-shooting Certain types of fault, which are generally due to faulty design of the system, are often wrongly attributed to pressure reducing valves. The most frequent cases are as follows: 1. Increased downstream pressure in the presence of a water heater This problem is due to heating of the water caused by the water heater. There is not relief of the pressure because the reducing valve is rightly closed. The solution is to install an expansion vessel (between the heater and the reducer) to absorb the pressure increase. 2. The reducer does not maintain its calibrated value In most cases this is the result of impurities that deposit on the valve seat causing leakage with a resulting increase in pressure downstream. The solution is to fit a strainer upstream of the reducer and subsequently to maintain and clean the extractable cartridge (see Maintenance).

6. Adjust until the correct pressure is read on the pressure gauge. Series 533. reducers are factory set at 3 bar.

Recommendations for installation 1. Installation below ground Installing pressure reducing valves below ground is not recommended, for three reasons: - there is a risk of the reducing valve being damaged by frost - inspection and maintenance is difficult - reading the pressure gauge is difficult.

Maintenance Proceed as follows for periodic cleaning of the strainer and inspection or replacement of the cartridge: 1 Shut off the reducer 2 Unscrew (anticlockwise) the calibrating screw to decompress the spring inside. 3 Unscrew the cover. 4 Extract the cartridge with the aid of pincers to grip the head of the screw. 5 The cartridge can be fitted back into the valve after inspection and cleaning or alternatively a replacement cartridge can be fitted. 6 Recalibrate the reducer.

Application diagrams

SPECIFICATION SUMMARY 5330 series Inclined pressure reducing valve. Threaded connections 1/2 F (or 3/4 F). Brass body. Chrome plated. Dezincification resistant alloy stem. Glass/nylon cover. NBR diaphragm and seals. Maximum working temperature 60C. Maximum upstream pressure 16 bar. Downstream pressure setting range from 1 to 6 bar. Extractable cartridge and strainer for maintenance operation. 5331 series Inclined pressure reducing valve. Threaded connection 3/4 M for 3/4 F with nut. Brass body. Chrome plated. Dezincification resistant alloy stem. Glass/nylon cover. NBR diaphragm and seals. Maximum working temperature 60C. Maximum upstream pressure 16 bar. Downstream pressure setting range from 1 to 6 bar. Extractable cartridge and strainer for maintenance operation. 5332 series Inclined pressure reducing valve with pressure gauge. Threaded connections 1/2 F (or 3/4 F). Pressure gauge connection 1/4 F. Brass body. Chrome plated. Dezincification resistant alloy stem. Glass/nylon cover. NBR diaphragm and seals. Maximum working temperature 60C. Maximum upstream pressure 16 bar. Downstream pressure setting range from 1 to 6 bar. Extractable cartridge and strainer for maintenance operation. Complete with pressure gauge, scale 010 bar. 5334 series Inclined pressure reducing valve with pressure gauge connection. Threaded connections 1/2 F (or 3/4 F). Pressure gauge connection 1/4 F. Brass body. Chrome plated. Dezincification resistant alloy stem. Glass/nylon cover. NBR diaphragm and seals. Maximum working temperature 60C. Maximum upstream pressure 16 bar. Downstream pressure setting range from 1 to 6 bar. Extractable cartridge and strainer for maintenance operation. 5336 series Inclined pressure reducing valve. 15 (or 22) connections. Dezincification resistant alloy body and stem. Chrome plated. Glass/nylon cover. NBR diaphragm and seals. Maximum upstream temperature 60C. Maximum working pressure 16 bar. Downstream pressure setting range from 1 to 6 bar. Extractable cartridge and strainer for maintenance operation. 5337 series Inclined pressure reducing valve with pressure gauge connection. 15 (or 22) connections. Pressure gauge connection 1/4 F. Dezincification resistant alloy body and stem. Chrome plated. Glass/nylon cover. NBR diaphragm and seals. Maximum working temperature 60C. Maximum upstream pressure 16 bar. Downstream pressure setting range from 1 to 6 bar. Extractable cartridge and strainer for maintenance operation. 5338 series Inclined pressure reducing valve with pressure gauge. 15 (or 22) connections. Pressure gauge connection 1/4 F. Dezincification resistant alloy body and stem. Chrome plated. Glass/nylon cover. NBR diaphragm and seals. Maximum working temperature 60C. Maximum upstream pressure 16 bar. Downstream pressure setting range from 1 to 6 bar. Extractable cartridge and strainer for maintenance operation. Complete with pressure gauge, scale 010 bar.
We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.p.A. S.R.229, N.25 28010 Fontaneto dAgogna (NO) Italy Tel. +39 0322 8491 Fax +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

Automatic filling units

CALEFFI
series 553
cert. n 0003

ISO 9001

01025/05 GB
Replaces 01025/02 GB

Function The automatic filling unit is a device consisting of a pressure reducing valve with compensating seat, an inlet strainer, a shut-off valve and a check valve. It is installed in the water supply pipework in sealed heating systems and its main function is to maintain the system pressure stable at a set value, automatically topping up with water, as required. After installation, during the filling or topping-up phase, feed will stop when the set pressure is reached.

Product range Code 553040 Automatic filling units with pressure gauge connection Code 553140 Automatic filling units with pressure gauge Size 1/2 Size 1/2

Technical specification Materials: - body: - cover: - seals: Max. inlet pressure: Pressure setting range: Factory setting: Max. working temperature: Pressure gauge scale: brass EN 12165 CW617N brass EN 12165 CW617N NBR 16 bar 0,3 4 bar 1,5 bar 70C 0 4 bar

Dimensions

E
1 2

3
CA LEFF I

Connections: - inlet: 1/2 M with union tailpiece - outlet: 1/2 F - pressure gauge connection: 1/4 F

Code 553040 553140

A 1/2" 1/2"

B 122 122

C 61 61

D 87 87

A E 149

Weight (kg) 0,85 0,95

Construction details Components The valve body is made of hot forged brass. The re-inforced rubber control diaphragm is formed in a shape permitting deformation to take place without creating stresses. The only sealing element of the compensating piston is in the upper part of the device, ensuring that impurities cannot be deposited. Manual / automatic opening In the lower part of the unit, a manual shut-off valve is provided, which can close off the supply to the system. The automatic condition of operation is restored when the valve is re-opened. The pressure level in the system will gradually return to the set calibration value.

Installation 1. Automatic filling unit code 553040/140 can be installed in either horizontal or vertical position. It is, however, vital that the unit is not installed upside down.

3 4

CA LEF FI

0
CA LEF FI

3 4

The unit is adjusted by means of the regulator located inside the top cover: rotating it in a clockwise or anticlockwise direction increases or decreases the pressure at which the unit operates. 2. When the system is being commissioned, the unit is normally calibrated at a pressure no lower than the hydrostatic pressure plus 0,3 bar. The internal mechanism will automatically regulate the pressure by closing down the supply on reaching the set value.
3
CA LEF FI

0 4

3. The system fills slowly, as the amount of water entering is in direct proportion to the amount of air vented. 4. When the system is filled, the shut-off valve can be closed. In order to restore the automatic top-up condition, merely re-open the valve. The pressure in the system will gradually return to the set pressure.

Code 553140

SPECIFICATION SUMMARIES
Series 553 Automatic filling unit. 1/2 M with union tailpiece x 1/2 F threaded connection. Brass body and cover. Diaphragm and seals in NBR. Maximum working temperature 70C. Maximum inlet pressure 16 bar. Pressure setting range 0,3 4 bar. Complete with pressure gauge, scale 0 4 bar (or pressure gauge connection), shut-off, strainer and check valve.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

0 1 2

CA LEF FI

4 3

Pressure reducing valves


series 5360 - 5362 - 5365 - 5366
cert. n 0003

CALEFFI
ISO 9001

01026/05 GB
Replaces 01026/01 GB

Function Pressure reducers are devices which, when installed on a water system, reduce and stabilise the pressure entering from the mains. This incoming pressure is generally too high and variable to be applied directly to domestic systems. A basic characteristic of a good pressure reducer is that it makes it possible to maintain constant downstream pressure when the upstream pressure varies.

SVGW SSIGE

Product range Series 5360.1 Series 5360.0 Series 5362.1 Series 5362.0 Series 5365.1 Series 5365.0 Code 536660 Pressure Pressure Pressure Pressure Pressure Pressure Pressure reducing reducing reducing reducing reducing reducing reducing valve, valve, valve, valve, valve, valve, valve, male connections, with pressure gauge male connections, with pressure gauge connection female connections, with pressure gauge female connections, with pressure gauge connection male connections, with double pressure gauge male connections, with double pressure gauge connection flanged connections, with double pressure gauge Sizes 1/2, 3/4, 1, 1 1/4, 1 1/2 M Sizes 1/2, 3/4, 1, 1 1/4, 1 1/2 M Sizes 1/2, 3/4, 1 F Sizes 1/2, 3/4, 1 F Sizes 1 1/2, 2 M Sizes 1 1/2, 2 M Size DN 65

Technical specification series Materials: - Body: - Cover: - Membrane: - Seal: - Seat and filter: Performance: - Max pressure upstream: - Downstream pressure setting range: - Factory setting: - Max working temperature: - Pressure gauge scale: - Medium: - Certification: - Acoustic group: Connections: 5360/5362 5365 5366

brass EN 1982 CB753S brass EN 12165 CW617N NBR NBR stainless steel

bronze DIN 50930-6 RG5 PB3 brass EN 1982 CB753S NBR NBR stainless steel

bronze DIN 50930-6 RG5 PB3 brass EN 1982 CB753S NBR NBR stainless steel

25 bar 0,56 bar 3 bar 80C 010 bar water EN1567 I - 5360; 1/21 1/2 M with union connection - 5362 1/21 F one of 1/4 F

25 bar 0,56 bar 3 bar 80C 025 bar upstream 010 bar downstream water EN1567 1 1/22 M with union connection

16 bar 0,56 bar 3 bar 80C 025 bar upstream 010 bar downstream water DN 65 flanged, coupled with flat counterflanges EN 1092-1, PN 16

Pressure gauge connections:

two of 1/4 F

two of 3/8 F

Dimensions
D

Operating principle The operation of the pressure reducing valve is based on the balancing of two opposing forces: 1 the thrust of the spring towards the opening of the obturator. 2 the thrust of the membrane towards the closing of the obturator. Pressure regulating nut

F A

C B

Code A 536040/1 1/2 536050/1 3/4 536060/1 1 536070/1 1 1/4 536080/1 1 1/2

D C B 140 76 51 160 90 60 180 95 60 200 110 72 220 120 72

E 53,5 54 54 63 63

F 89,5 111,5 111,5 126 126

UPSTREAM

DOWNSTREAM

Operating with flow


E

When a draw-off point is opened on the water main, the force of the spring prevails over the opposing pressure of the membrane; the obturator moves downwards, allowing water to pass. The greater the demand for water, the lower the pressure under the membrane, thus permitting more fluid to flow through the obturator.

Code A 536240/1 1/2 536250/1 3/4 536260/1 1

B 81 95 100

E D C 51 53,5 89,5 60 54 111,5 60 54 111,5


2 0

6 8 2

6 8

bar

10

bar

10

F A

C B

Operating without flow E 97 94 F 201 204 When the draw-off point is fully closed, the downstream pressure rises and pushes the membrane upwards. The obturator therefore closes, preventing the fluid from passing through and holding the pressure constant at the calibrated value. A minimum difference in favour of the force exercised by the membrane in relation to that of the spring causes the device to close.

D C B Code A 536580/1 11/2 260 160 110 536590/1 2 280 160 110

4 2

6 8 2

6 8

A C

bar

10

bar

10

Code A B C D 536660 DN 65 225 185 110

E 94

F 204

Construction details Compensated seat Caleffi pressure reducing valves are supplied with compensated seats. This means that the set pressure value downstream remains constant independently of the variations in value of the pressure upstream.

In the figure, the thrust towards opening is counterbalanced by the closing pressure acting on the compensating piston. As the latter has a surface equal to that of the obturator, the two forces cancel each other out.

Noiseless The internal layout, designed to obtain the optimum fluid dynamic characteristics, has made it possible to achieve a noise level of less than 20 dB in all the tests carried out. Thanks to this quality, Caleffi reducing valves are approved to the I acoustic group, in compliance with the EN 1567 European standard.

Sliding surfaces The components most subject to wear due to the friction of moving parts are PTFE coated. This treatment considerably increases the life of the pressure reduction device.

Low pressure losses The internal fluid-dynamic shape of the reducing valve makes it possible to attain low pressure losses even when a large number of draw-off points are open. This characteristic is important in relation to the high pressure losses caused by various devices present in modern systems, for example thermostatic mixers, which make it necessary to install reducers with minimum pressure losses.

Removable cartridge The cartridge containing the membrane, filter, seat, obturator and adjusting piston can be removed for maintenance and strainer cleaning purposes.

High pressures The zone exposed to the upstream pressure is constructed in such a way that it can operate at high pressure. Thanks to the PTFE anti-extrusion rings on the compensating piston, the valve can be used in continuous service with upstream pressures of up to 25 bar.

Seat seal The fluid passage seat on which the obturator operates is made of stainless steel, which ensures the long-lasting operation of the device.

Certification Pressure reducing valves are certified in accordance with the requirements of the EN 1567 European standard.

Hydraulic characteristics Graph 1 (Circulation velocity)


V (m/s)
5 4 3 2

The steps to be taken for correct dimensioning are as follows: Calculate the total flow on the basis of the number and types of appliance present in the system, adding up their individual typical flow rates.

Example: Single dwelling with 2 bathrooms 2 bidets G = 12 l/min 1 shower G = 9 l/min 2 washbasins G = 12 l/min 2 WCs G = 12 l/min 1 bath G = 12 l/min 1 kitchen sink G = 12 l/min 1 dishwasher G = 12 l/min Gtot = 81 l/min No. of devices = 10
The design flow is calculated simultaneous-use factors table. using the

0,5 0,4 0,3 0,2 1/2 3/4 1 1 1/4 1 1/2 2 DN 65

100

200

Graph 2 (Pressure drop)


p (bar)
1,5 1,2 1 0,9 0,8 0,7 0,6 0,5 0,4 0,3 1/2 3/4 1 1 1/4 1 1/2 2 DN 65

p (m w.g.)
15 12 10 9 8 7 6 5 4 3

500

Flow rate (l/min) (m3/h)

0,2

0,5

0,1

10

20

10

20

50

40

Example: Gdes = Gtot % = 81 41 % = 33 l/min


When sizing pressure reducing valves, it is advisable to keep the velocity of flow in the pipes at between 1 and 2 m/s. This prevents both noise in the pipework and rapid wear in the point of use equipment. The size of the pressure reducing valve is determined by means of graph 1, starting with the design flow figure and remembering that the ideal velocity is between 1 and 2 m/s (blue band).

0,2

Flow rate (l/min) (m3/h)

0,2

0,5

0,1

10

20

40

100

200

500

10

20

50

Example: for Gdes = 33 l/min size 3/4 is selected (see graph 1)


Using graph 2, still starting with the design flow figure, identify the pressure drop, intersecting the curve relating to the size already selected (the downstream pressure falls by a value equal to the pressure drop in relation to the zero flow set pressure).

Reference conditions:

Pressure upstream = 8 bar Pressure downstream = 3 bar

Dimensioning The typical flow rates of equipment commonly used in hot water systems are shown below to help in the selection of correct pipe sizes: Table of typical flow rates Bathtub, kitchen sink, dishwasher Shower Washbasin, bidet, washing machine, WC 12 litres/min 9 litres/min 6 litres/min

Example: for Gdes = 33 l/min (see graph 2)


p = 0,55 bar

In order to prevent over-sizing of the pressure reducing valve and pipework, a simultaneous-use correction factor should be taken into account. In essence, the greater the number of users of the system, the lower the percentage of draw-off points opened at the same time. Table showing simultaneous-use factors as %
Number of Private Public devices dwelling % building % Number of Private Public devices dwelling % building % Number of Private Public devices dwelling % building %

Nominal flow rates In accordance with the requirements of the EN 1567 European standard, these are the flow rates for each diametre, at an average speed of 2 m/s. Size 1/2 Flow rate (m3/h) 1,27 Flow rate (l/min) 21,16 3/4 2,27 37,83 1 3,6 60 1 1/4 1 1/2 2 5,8 9,1 14 96,66 151,66 233,33

5 10 15 20 25 30

54 41 35 29 27,5 24,5

64,5 49,5 43,5 37 34,5 32

35 40 45 50 60 70

23,2 21,5 20,5 19,5 18 17

30 28 27 26 24 23

80 90 100 150 200 300

16,5 16 15,5 14 13 12,5

22 21,5 20,5 18,5 17,5 16,5

Installation 1 Prior to installation, open all the draw-off taps to empty the system and expel any air remaining in the pipework. 2 Install shut-off valves upstream and downstream to assist in future maintenance operations. 3 Install the pressure reducing valve in any position except upside down.

Trouble-shooting Some faults, which are usually due to the lack of suitable system safeguards, are sometimes incorrectly attributed to pressure reducing valves. The most frequent cases are: 1. Increased pressure downstream of the pressure reducing valve when a water heater is installed This problem is due to the overheating of the water caused by the water heater. The pressure cannot leak, as the reducing valve is properly closed. The solution is to install an expansion vessel (between the reducer and the water heater) to absorb the pressure increase.

4 Close the downstream shut-off valve. 5 Calibrate by means of the spring pressure regulating nut located under the head cover, turning with a 10 mm hexagonal Allen key clockwise to increase the set value or anticlockwise to reduce it. 6 Check the required pressure on the pressure gauge. (Caleffi reducers come factory set at 3 bar). Installation recommendations 1. Installation in pits Installing pressure reducing valve inside pits is not recommended, for two reasons: - it is very difficult, if not impossible, to read the pressure gauge. - impurities may enter the device through the pressure relief outlet in the head cover. 2. Water hammer This is one of the main causes of failure of pressure reducing valves. During the installation of at risk systems, the use of specific devices designed to absorb water hammer should be provided for. 2. The pressure reducing valve does not maintain the set value In the majority of cases, this problem arises from the presence of impurities on the seat seal causing leakage and consequent increases in the pressure downstream. The solution consists of the preventive installation of a filter upstream of the pressure reducing valve and subsequently of maintenance and cleaning of the removable cartridge (see maintenance).

Maintenance For cleaning, inspection or replacement of the entire cartridge: 1 Isolate the pressure reducing valve. 2 Unscrew the spring pressure regulating nut to release the spring tension. 3 Remove the head cover. 4 Extract the cartridge using two screwdrivers. 5 After inspection and cleaning if necessary, the complete cartridge can be refitted or replaced using a spare cartridge. 6 Recalibrate the pressure reducing valve.

System application diagram

Shut-off valve BALLSTOP ball valve with built-in check valve Filter Water hammer arrester Solenoid valve Regulator

Washing machines

Mixer taps

Irrigation systems

10
CALEFFI

SPECIFICATION SUMMARIES
Series 5360 Pressure reducing valve with compensated seat to standard EN 1567. Threaded connections 1/2 M (from 1/2 to 1 1/2) with union. Brass body. Stainless steel seat and filter. NBR seal and membrane. Maximum working temperature 80C. Maximum upstream pressure 25 bar. Downstream pressure setting range from 0,5 to 6 bar. Sliding surface heat-coated with PTFE. Cartridge with membrane, filter and obturator, removable for maintenance operations.

Series 5362 Pressure reducing valve with compensated seat. Threaded connections 1/2 F (from 1/2 to 1). Brass body. Stainless steel seat and filter. NBR seal and membrane. Maximum working temperature 80C. Maximum upstream pressure 25 bar. Downstream pressure setting range from 0,5 to 6 bar. Sliding surface heat-coated with PTFE. Cartridge with membrane, filter and obturator, removable for maintenance operations.

Series 5365 Pressure reducing valve with compensated seat to standard EN 1567. Threaded connections 1 1/2 M (from 1 1/2 to 2) with union. Bronze body. Stainless steel seat and filter. NBR seal and membrane. Maximum working temperature 80C. Maximum upstream pressure 25 bar. Downstream pressure setting range from 0,5 to 6 bar. Sliding surface heat-coated with PTFE. Cartridge with membrane, filter and obturator, removable for maintenance operations.

Code 536660 Pressure reducing valve with compensated seat. Flanged connections PN 16 DN 65. Bronze body. Stainless steel seat and filter. NBR seal and membrane. Maximum working temperature 80C. Maximum upstream pressure 16 bar. Downstream pressure setting range from 0,5 to 6 bar. Supplied with double pressure range: 025 bar upstream and 010 bar downstream. Sliding surface heat-coated with PTFE. Cartridge with membrane, filter and obturator, removable for maintenance operations.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Radiator and lockshield valves


series 340 - 411 - 415
cert. n 0003

ISO 9001

01030/01 GB

Function The following series of manual and lockshield valves are typically used for controlling and regulating the fluid flow in heat emitters of central heating systems. They are supplied with a special tailpiece with rubber hydraulic seal, permitting quick, safe connection to the radiator without the use of additional sealing materials.

Product range For copper and plastic piping: Series Series Series Series 340 341 342 343 Elbow manual radiator valve Straight manual radiator valve Elbow radiator lockshield valve Straight radiator lockshield valve Sizes Sizes Sizes Sizes 3/8, 3/8, 3/8, 3/8, 1/2 1/2 1/2 1/2 radiator radiator radiator radiator x x x x 23 23 23 23 p.1,5 p.1,5 p.1,5 p.1,5 piping piping piping piping

For steel piping: Series Series Series Series 411 412 431 432 Elbow manual radiator valve Straight manual radiator valve Elbow radiator lockshield valve Straight radiator lockshield valve Sizes Sizes Sizes Sizes 3/8, 3/8, 3/8, 3/8, 1/2, 1/2, 1/2, 1/2, (3/4 use code 401500) (3/4 use code 402500) 3/4 (*) 3/4 (*)

For copper and plastic piping (with tailpiece without rubber seal): Series Series Series Series * 415 416 435 436 Elbow manual radiator valve Straight manual radiator valve Elbow radiator lockshield valve Straight radiator lockshield valve Sizes Sizes Sizes Sizes 3/8 3/8 3/8 3/8 x x x x 3/8 3/8 3/8 3/8 and and and and 1/2 1/2 1/2 1/2 radiator radiator radiator radiator x x x x 23 23 23 23 p.1,5 p.1,5 p.1,5 p.1,5 piping piping piping piping

3/4 with tailpiece without rubber seal

Technical specification - Material: Body: brass UNI EN 12165 CW617N, chrome plated Obturator: brass UNI EN 12164 CW614N Hydraulic seals: EPDM Gland: PTFE Control knob and cap: ABS (RAL 9010) water, glycol solutions 30% 10 bar 5100C

Fluid: Max percentage of glycol: Max working pressure: Temperature range:

Dimensions

F E

F E E

B C

B C

Code 340302 340402 Code 340302 340402

A 3/8 1/2 D 21,5 21,5

B 23 p.1,5 23 p.1,5 E 48,5 48,5

C 47,5 53,5 F 37,5 37,5

Code 341302 341402 Code 341302 341402

A 3/8 1/2 D 24 24

B 23 p.1,5 23 p.1,5 E 57 57

C 47,5 53,5 F 37,5 37,5

Code 342302 342402 Code 342302 342402

A 3/8 1/2 D 21,5 21,5

B 23 p.1,5 23 p.1,5 E 39 39

C 47,5 53,5 F 28,5 28,5

Code 343302 343402 Code 343302 343402

A 3/8 1/2 D 24 24

B 23 p.1,5 23 p.1,5 E 44,5 44,5

47,5 53,5 F 28,5 28,5

F F E E E F E C C D
C 47,5 53,5 62,5 F 28,5 28,5 28,5 Code 432302 432402 432500 Code 432302 432402 432500 A 3/8 1/2 3/4 D 46,5 52,0 59,5 B 3/8 1/2 3/4 E 44,5 44,5 49,5

B C

Code 411302 411402

A 3/8 1/2

B 3/8 1/2

C 48 54

Code 412302 412402

A 3/8 1/2

B 3/8 1/2

C 21 22

Code 431302 431402 431500

A 3/8 1/2 3/4 D 20 23 25

B 3/8 1/2 3/4 E 38 38 47

A
C 21 22 30 F 28,5 28,5 28,5

Code 411302 411402

D 20 23

E 48 48

F 37,5 37,5

Code 412302 412402

D 46,5 52,0

E 55 55

F 37,5 37,5

Code 431302 431402 431500

F E

F E E

B C

B C

Code 415303 415403 Code 415303 415403

A 3/8 1/2 D 21,5 21,5

B 3/8 23 p.1,5 E 48 48

C 47 51 F 37,5 37,5

Code 416303 416403 Code 416303 416403

A 3/8 1/2 D 23,5 24,0

B 3/8 23 p.1,5 E 55 55

C 46,5 50 F 37,5 37,5

Code 435303 435403 Code 435303 435403

A 3/8 1/2 D 21,5 21,5

B 23 p.1,5 23 p.1,5 E 38 38

C 47 51 F 28,5 28,5

Code 436303 436403 Code 436303 436403

A 3/8 1/2 D 23,5 24,0

B 3/8 23 p.1,5 E 44,5 44,5

46,5 50 F 28,5 28,5

A
C

A
C

Construction characteristics Valve The hydraulic seal on the control spindle is guaranteed by a PTFE gland nut and an EPDM O-Ring. Control knob The knob is push-located on the control spindle by means of simple manual pressure, without any fixing screws. Dismantling for any operations on the gland or for replacement is very easy.

Hydraulic characteristics Values of nominal flow and equivalent length

COPPER PIPING TYPE


Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve

Rad. con. 3/8" 3/8" 3/8" 3/8" 3/8" 3/8" 3/8" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2"

Pipe Int/ext STRAIGHT con. pipe Kv0,01 e.l. (mm) (l/h) (m)
23 p.1,5 3/8" 23 p.1,5 3/8" 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 6/8 8/10 10/12 12/14 13/15 14/16 16/18 8/10 10/12 12/14 13/15 14/16 16/18

ELBOW
Kv0,01 (l/h) e.l. (m)

132 132 132 132 132 132 132 217 217 217 217 217 217

0,2 0,8 2,7 6,9 10,6 15,5 31,3 0,3 1,0 2,6 3,9 5,7 11,6

242 242 242 242 242 242 242 399 399 399 399 399 399

0,1 0,2 0,8 2,1 3,1 4,6 9,3 0,1 0,3 0,8 1,2 1,7 3,4

Tailpiece with rubber seal The coupling union to the radiator connection thread has a specially shaped rubber ring. This system guarantees the hydraulic seal with no need for further sealing materials, such as PTFE tapes etc.

Manual valve

Lockshield valve STEEL PIPING TYPE


Radiator or lockshield valve Radiator or lockshield valve Lockshield valve

Rad. con. 3/8" 1/2" 3/4"

Pipe Int/ext STRAIGHT con. pipe Kv0,01 e.l. (mm) (l/h) (m) 3/8" 1/2" 3/4"
12,7/17,2 16,3/21,3 21,7/26,4

ELBOW
Kv0,01 (l/h) e.l. (m)

132 217 258

7,5 10,4 33,2

242 399 452

2,2 3,1 11

PLASTIC PIPING TYPE


Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve Radiator or lockshield valve

Rad con. 3/8" 3/8" 3/8" 3/8" 3/8" 1/2" 1/2" 1/2" 1/2" 1/2"

Pipe Int/ext STRAIGHT con. pipe Kv0,01 e.l. (mm) (l/h) (m)
3/8" 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 8/12 10/15 12/16 13/18 14/18 8/12 10/15 12/16 13/18 14/18

ELBOW
Kv0,01 (l/h) e.l. (m)

132 132 132 132 132 217 217 217 217 217

0,8 2,7 6,9 10,6 15,5 0,3 1,0 2,6 3,9 5,7

242 242 242 242 242 399 399 399 399 399

0,2 0,8 2,1 3,1 4,6 0,1 0,3 0,8 1,2 1,7

Manual regulating valves, elbow connections, series 340, series 411 and series 415
p (daPa) 5000 2000 1000 500 200 100 50 20 10 100 200 500 20 50 1000 2000 3000
3/8" 1/2"

Manual regulating valves, straight connections, series 341, series 412 and series 416
p (daPa) 5000 2000 1000 500 200 100 50 20 10 1000 2000 3000 100 200 500 20 50
3/8" 1/2"

p (kPa) 50 20 10 5 2 1
0,5 0,2 0,1

p (kPa) 50 20 10 5 2 1
0,5 0,2 0,1

3/8" 1/2"

Kv0,01 = 242 l/h Kv0,01 = 399 l/h

G (l/h)

3/8" 1/2"

Kv0,01 = 132 l/h Kv0,01 = 217 l/h

G (l/h)

Lockshield valves, 3/8" elbow connections, series 342, series 431 and series 435
p (mm w.g.) 5000 2000 1000 500 200 100 50 20 10
1000 2000 100 200 500 10 20 50
1/ 4

Lockshield valves, 3/8" straight connections, series 343, series 432 and series 436
p (mm w.g.) 5000 2000 1000 500 200 100 50 20 10
500 1000 2000 10 20 50 100 200
4 1/ 2 1/ 1 2

p (kPa) 50 20 10
2 1/
1 2

p (kPa) 50 20 10 5
op en

5 2
lly op en

2 1
0,5 0,2 0,1

1
0,5 0,2 0,1

fu

lly

fu

3/8"

Kv0,01 = 242 l/h

G (l/h)

3/8"

Kv0,01 = 132 l/h

G (l/h)

Lockshield valves, 1/2" elbow connections, series 342, series 431 and series 435
p (mm w.g.) 5000 2000 1000 500 200 100 50 20 10
1000 2000 100 200 500 10 20 50
4 1/ 2 1/ 1 2

Lockshield valves, 1/2" straight connections, series 343, series 432 and series 436
p (mm w.g.) 5000 2000 1000 500 200 100 50 20 10
500 1000 2000 10 20 50 100 200
4 1/ 2 1/
1 2

p (kPa) 50 20 10 5 2
y op en

p (kPa) 50 20 10 5
op en

2 1
0,5 0,2 0,1

1 0,5 0,2 0,1

y ull

ll fu

1/2"

Kv0,01 = 399 l/h

G (l/h)

1/2"

Kv0,01 = 217 l/h

G (l/h)

Lockshield valves, 3/4" elbow connections, series 431


p (mm w.g.)
5000 2000 1000 500
3 2

Lockshield valves 3/4", straight connections, series 432


p (mm w.g.)
5000 2000 1000 500 200 100 50 20 10
2 3

p (kPa)
50 20 10 5 2
5
op

p (kPa)
50 20 10 5
4
op en

200 100 50 20 10

2 1 0,5 0,2 0,1

0,5 0,2 0,1

fu

lly

fu lly

en

1000

1000

2000

5000

3/4"

Kv0,01 = 452 l/h

G (l/h)

3/4"

Kv0,01 = 258 l/h

2000

G (l/h)

5000

100

100

200

500

200

500

10

20

10

20

50

50

Choice of connections

Accessories

Piping connections

4383
Compression connection for copper pipes, with PTFE seal.
Code Con.

COLORSET
FOR COLOURED RADIATORS

3/8
438310 3/8 438312 3/8 - 10 - 12 12 12

3680
Coloured lockshield valve caps and valve control knobs. Available in a range of 11 colours.

Available in colours: purple ivory blue yellow grey RAL 3003 RAL 1013 RAL 5015 RAL 1021 RAL 7035 brown RAL 8017 black RAL 9005 red RAL 3000 green RAL 6024 chrome plated

4370
Piping connections

382
Connection with adjustable nut 23 p.1,5. Chrome plated.

Compression connection for copper pipes, with O-Ring seal.


Code Con.

23 p.1,5

437010 437012 437014 437015 437016

23 23 23 23 23

p.1,5 p.1,5 p.1,5 p.1,5 p.1,5

10 12 14 15 16

18 18 18 18 18

Code

382000

23 p.1,5

3870
Hex. nut spanner 25 and 26 mm.

4380
Compression connection, for copper pipes, with PTFE seal.
Code Con. Code

387000

438010 438012 438014 438015 438016 438018

23 23 23 23 23 23

p.1,5 p.1,5 p.1,5 p.1,5 p.1,5 p.1,5

10 12 14 15 16 18

18 18 18 18 18 18

3871
Hex. nut spanner 26 and 30 mm. For DARCAL connections 23 p.1,5 and 3/4.
Code

387100

6810
Auto-adaptable diameter connection for single and multilayer plastic pipes.
Code Int. Ext. Con.

3871
Multi-purpose tool. Can be used for unions from 3/8 to 1.

681000 681002 681001 681006 681015 681017 681024 681026 681035 681044

23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5 23 p.1,5

17,5-18,0 19,0-19,5 19,5-10,0 19,5-10,0 10,5-11,0 10,5-11,0 11,5-12,0 11,5-12,0 12,5-13,0 13,5-14,0

12-14 14-16 12-14 14-16 14-16 16-18 14-16 16-18 16-18 16-18

18 18 18 18 18 18 18 18 18 18

Code

387127

SPECIFICATION SUMMARIES Series 340 Manual radiator valve. Elbow connections for copper and single and multilayer plastic pipe 23 p.1,5 for piping from 10 to 18 mm. Connection to radiator 3/8 or 1/2 M with tailpiece supplied with seal in EPDM. Brass body. Chrome plated. Control knob white RAL 9010 in ABS. Double seal consisting of EPDM O-Ring on control spindle and gland in PTFE. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 341 Manual radiator valve. Straight connections for copper and single and multilayer plastic pipe 23 p.1,5 for piping from 10 to 18 mm. Connection to radiator 3/8 or 1/2 M with tailpiece supplied with seal in EPDM. Brass body. Chrome plated. Control knob white RAL 9010 in ABS. Double seal consisting of EPDM O-Ring on control spindle and gland in PTFE. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 342 Lockshield valve. Elbow connections for copper and single and multilayer plastic pipe 23 p.1,5 for piping from 10 to 18 mm. Radiator connection 3/8 or 1/2 M with tailpiece provided with EPDM seal. Brass body. Chrome plated. Cap white RAL 9010 in ABS. Outward seal consisting of EPDM O-Ring on control spindle. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 343 Lockshield valve. Straight connections for copper and single and multilayer plastic pipe 23 p.1,5 for piping from 10 to 18 mm. Radiator connection 3/8 or 1/2 M with tailpiece provided with EPDM seal. Brass body. Chrome plated. Cap white RAL 9010 in ABS. Outward seal consisting of EPDM O-Ring on control spindle. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 411 Manual radiator valve. Elbow connections for steel pipe, 3/8 or 1/2. Connection to radiator 3/8 or 1/2 M with tailpiece supplied with seal in EPDM. Brass body. Chrome plated. Control knob white RAL 9010 in ABS. Double seal consisting of EPDM O-Ring on control spindle and gland in PTFE. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 412 Manual radiator valve. Straight connections for steel pipe, 3/8 or 1/2. Connection to radiator 3/8 or 1/2 M with tailpiece supplied with seal in EPDM. Brass body. Chrome plated. Control knob white RAL 9010 in ABS. Double seal consisting of EPDM O-Ring on control spindle and gland in PTFE. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 415 Manual radiator valve. Elbow connections for copper and single and multilayer plastic pipe, 3/8 or 23 p.1,5. Connection to radiator 3/8 or 1/2 M with tailpiece. Brass body. Chrome plated. Control knob white RAL 9010 in ABS. Double seal consisting of EPDM O-Ring on control spindle and gland in PTFE. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 416 Manual radiator valve. Straight connections for copper and single and multilayer plastic pipe, 3/8 or 23 p.1,5. Connection to radiator 3/8 or 1/2 M with tailpiece. Brass body. Chrome plated. Control knob white RAL 9010 in ABS. Double seal consisting of EPDM O-Ring on control spindle and gland in PTFE. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 431 Lockshield valve. Elbow connections for steel pipes 3/8, 1/2 or 3/4. Radiator connection 3/8 or 1/2 M with tailpiece provided with EPDM seal, 3/4 with tailpiece without seal. Brass body. Chrome plated. Cap white RAL 9010 in ABS. Outward seal consisting of EPDM O-Ring on control spindle. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 432 Lockshield valve. Straight connections for steel pipes 3/8, 1/2 or 3/4. Radiator connection 3/8 or 1/2 M with tailpiece provided with EPDM seal, 3/4 with tailpiece without seal. Brass body. Chrome plated. Cap white RAL 9010 in ABS. Outward seal consisting of EPDM O-Ring on control spindle. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 435 Lockshield valve. Elbow connections for copper and single and multilayer plastic pipe 3/8 or 23 p.1,5. Radiator connection 3/8 or 1/2 M with tailpiece. Brass body. Chrome plated. Cap white RAL 9010 in ABS. Outward seal consisting of EPDM O-Ring on control spindle. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 436 Lockshield valve. Straight connections for copper and single and multilayer plastic pipe 3/8 or 23 p.1,5. Radiator connection 3/8 or 1/2 M with tailpiece. Brass body. Chrome plated. Cap white RAL 9010 in ABS. Outward seal consisting of EPDM O-Ring on control spindle. Maximum working temperature 100C. Maximum working pressure 10 bar.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
S.S. 229 Km 26,5 I-28010 Fontaneto dAgogna (NO) Tel. Int. +39 0322 8491 Fax +39 0322 863723 Http://www.calef fi.com E-mail:info@calef fi.it

MAXCAL Automatic air vent for heating, air


conditioning and refrigeration systems
series 501

CALEFFI
01031/05 GB
Replaces 01031/00 GB

Function Automatic air vent valves are designed to remove the air that accumulates in heating, air conditioning and refrigeration systems without the need for manual intervention. This prevents harmful phenomena that may compromise the life and the performance of the heating system and which include: - corrosion due to the oxygen; - pockets of air trapped in the heating emitters; - cavitation in the circulation pumps; - noise from air passing through the pipes. These high capacity air vent valves are ideal for use in large piping systems and can also be installed in horizontal sections.

Product range Code 501500 MAXCAL Automatic air vent for heating, air conditioning and refrigeration systems Sizes 3/4 x 3/8

Technical specification Materials: Medium: Body: Cover: Float: Obturator stem: Obturator: Hydraulic seals: Filter: Screws: Spring: brass EN 12165 CW617N brass EN 12165 CW617N stainless steel stainless steel VITON EPDM stainless steel stainless steel stainless steel water, glycol solution non hazardous, therefore excluded from the guidelines of 67/548/EC Directive 50% 16 bar 6 bar -20 120C 3/4 F 3/8 F

Dimensions

F A

Max. percentage of glycol: Max. working pressure: Max. discharge pressure: Temperature range: Connection: - Inlet: - Discharge:

B C D

Code 501500

A 3/8

B C D 3/4 Hex. 40 97

E 158

E F Weight (kg) 135 3,00

Operating principle The accumulation of air bubbles in the valve body causes the float to drop and thus the obturator to open. This phenomenon occurs, and consequently the valve functions correctly, as long as the water pressure remains below the maximum discharge pressure.

Filter As shown in the drawing, the air to be vented is forced through a fine mesh filter before arriving at the obturator. This device greatly reduces the risk of leakage from the seal due to metal chips, hemp fibres, plaster flakes, etc., becoming lodged between the seat and the obturator.

1 2

3 5

Flow curves Air flow (when the system is being filled)


Flow rate (Nl/s) 4
3,5

3
2,5

Construction details Anticorrosive materials The valve body and cover are made of hot forged brass whilst the filter, obturator stem, float and spring are all made of stainless steel to prevent rust from forming and later detaching and clogging the seal seat filter. Threaded outlet For installation at the top of risers and/or in attics, the air vent valve is equipped with a threaded outlet (1) that shall be connected to a vent pipe. Protection against foreign objects The vent outlet is equipped with a mechanism (2) to protect against dust and down, which may collect at the bottom of the valve over time and thus obstruct the vent. Vent valve The slide surfaces of the vent valve (3) have been ground to minimise friction and prevent the formation of harmful encrustations. O-Rings For maintenance purposes, the seals between the body and cover (4) and the vent unit and cover (5) are equipped with large cross-section O-rings.

1,5

1
0,5

0,5

1,5

2,5

3,5

4,5

5,5

bar (air)

Maintenance To facilitate maintenance of the deaerator, it is recommended to first install a 3/4 full bore-through passage shut-off valve as shown in the figure.
Vent pipe

3/4" full bore-through passage shut-off valve

SPECIFICATION SUMMARIES
Code 501500 Automatic air vent valve for heating, air conditioning and refrigeration systems. Threaded connections, 3/4 F (inlet), 3/8 F (discharge). Brass body and cover. Stainless steel filter, spring, obturator stem, float and screws. VITON obturator. EPDM seals. Medium: water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 16 bar. Maximum discharge pressure 6 bar. Temperature range -20 120C.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

AERCAL end plug for radiators with automatic air vent


507 series
ACCREDITED

CALEFFI
01032/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003

replaces 01032/04 GB

Function The end plugs for radiators with automatic air vents are designed to automatically expel any air trapped inside heat emitters, both during the system filling phase and during normal operation. This helps to prevent undesirable effects such as noisy operation and inefficient performance of the heat emitters themselves. All models in the 507 series are supplied complete with a hygroscopic safety cap. Patented models

Product range Code Code Code Code 507611 507621 507711 507721 End End End End plug plug plug plug for for for for radiator radiator radiator radiator with with with with air air air air vent, vent, vent, vent, chrome chrome chrome chrome plated, plated, plated, plated, with with with with hygroscopic hygroscopic hygroscopic hygroscopic safety safety safety safety cap cap cap cap size 1 M right size 1 M left size 1 1/4 M right size 1 1/4 M left

Technical specifications Materials Body: Float: Obturator: Spring: Protective cage: Air vent seal: Heater unit seal:

Dimensions

Max. working pressure: Max. discharge pressure: Max. working temperature: Connections:

10 bar 6 bar 100C 11 1/4 M F G

Code A B 507611 1 R 35 507621 1 L 35 507711 11/4 R 39,5 507721 11/4 L 39,5

C 61,5 61,5 63 63

D 14 14 15,5 15,5

E 47,5 47,5 47,5 47,5

F 25,5 25,5 27 27

A G 36 36 36 36

Performance Medium: Max. percentage of glycol:

water and glycol solutions 30%

brass EN 12165 CW617N, chrome plated high-resistance polymer silicone rubber stainless steel POM silicone rubber EPDM

C D E

Mass (kg)

0,13 0,13 0,17 0,17

Operating principle The water almost entirely fills the inside of the valve body and keeps the float (1), totally immersed in it, in a horizontal position. The build-up of air bubbles inside the valve makes the float end (1) rotate downward. This motion puts the float into contact with the control stem and rim (2), strictly connected to the control stem, this opening the obturator (3). This action, as well as correct valve operation, is ensured as long as the water pressure remains under the maximum discharge pressure value.

3
Water level

2 3

Construction details

4
Protective cage The acetal resin cage (4) protects the float (1) from knocks when the plug is screwed into the heater unit.

Installation The plug performs its function correctly when the valve is in a vertical position. The hygroscopic cap functions correctly when fully screwed on (as supplied by the manufacturer). We also recommend it is replaced regularly.

Hygroscopic safety cap All models are supplied with a hygroscopic safety cap. The operating principle is based on the properties of the cellulose fibre discs forming the sealing cartridge (5). These discs increase in volume by 50% when 5 they come into contact with water, thus closing the valve.

Hydraulic characteristics Discharge capacity (system filling phase)

Nl/s

0,15

Dry obturator The position of the float and the other internal parts allow the obturator (3) to always remain clear of the water, so as to limit the risks caused by the infiltration of impurities present in the water.

0,14 0,13 0,12 0,11 0,09 0,08 0,07 0,06 0,04 0,03 0,02 0,01

0,10

0,05

Leverage system The float (1) is moved by the stainless steel rod (6) supporting it, which rotates on supports built into the cage (4) holding the float. Therefore, friction is minimised in the event of 4 limescale build-up. This system ensures correct operation of the device over long periods of time.

0,5

1,5

2,5

3,5

4,5

5,5

6 bar

(air)
Accessories The hygroscopic safety cap is available as spare part, code R59720.

SPECIFICATION SUMMARIES
507 series End plug for radiators with automatic air vent. Threaded 1 M (and 1 1/4 M) right and left connection. Brass body, chrome plated. High-resistance polymer float. Silicone rubber obturator. Stainless steel spring. POM protective cage. Silicone rubber air vent seal. EPDM seal to heater unit. Medium water and glycol solutions; maximum percentage of glycol 30%. Maximum working pressure 10 bar. Maximum discharge pressure 6 bar. Maximum working temperature 100C. Code R59720 Hygroscopic safety cap. Brass body, chrome plated. EPDM hydraulic seal. Cellulose fibre discs sealing cartridge; fibre volume increase on contact with water 50%. Maximum working pressure 10 bar. Maximum working temperature 110C.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.p.A. S.R.229, N.25 28010 Fontaneto dAgogna (NO) Italy Tel. +39 0322 8491 Fax +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

ROBOCAL Automatic air vents


series 5024 - 5025 - 5026 - 5027
cert. n 0003

CALEFFI
ISO 9001

01033/03 GB
Replaces 01033/99 GB

Function These automatic air vents eliminate residual air in heating and air conditioning systems without the need for manual intervention. This prevents undesired noise, wear of devices in the circuits and inefficient performance of heating units.

Product range Series Series Series Series 5024 5025 5026 5027 Automatic Automatic Automatic Automatic air air air air vent vent vent vent with with with with horizontal discharge horizontal discharge and automatic shut off valve vertical discharge vertical discharge and automatic shut off valve Sizes 1/4 e Size Sizes 3/8 and Size 3/8 3/8 1/2 3/8 M M M M

Technical specification Materials: Body and cover: Float: Obturator: Spring: Seals: Seals on shut off valve: Performance: Medium: Max. percentage of glycol: Max. working pressure: Max. venting pressure Max. working temperature:

brass EN 12165 CW617N PP silicone rubber stainless steel EPDM PTFE

water, glycol solutions 30% 10 bar 5024, 5025 4 bar 5026, 5027 6 bar 5024, 5026 115C 5025, 5027 110C

Dimensions
C D C D C C

A A

B D

C E Code A B D 502420 1/4 55 40 25 45 502430 3/8 55 40 25 45

F Weight (kg) 10 0,140 10 0,147

Code A B C D 502530 3/8 72 40 25

E Weight (kg) 57 0,167

C Code A B D 502630 3/8 77 40 10 502640 1/2 77 40 10

E Weight (kg) 67 0,155 67 0,160

Code A B C D 502730 3/8 101 40 19

E Weight (kg) 82 0,175

Constructional details

Version with shut-off valve The automatic shut-off valve makes maintenance and inspection of the air vent easier by shutting off the flow of water when the valve has been removed. O-rings in EPDM ensure a good seal with the valve body. Fluid dynamic characteristics Air flow (when filling the system) 5024-5025 5026-5027
1 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0 0,5 1,5 2,5 3,5 4,5 5,5

Nl/s

6 bar (air)

Installation - Air is vented from the system by turning the plug on the air outlet anticlockwise by one complete turn from the fully closed position. Air is automatically vented if the cap is kept in this position. - It is recommended that the air vents are not fitted in places difficult to inspect and at risk of freezing.

Float with anti rotation and anti vibration system The float is fitted so that when it is in rest position the obturator is not affected by any external movement.

Accessories Dry obturator The positioning of the float and the internal parts is such that the water never reaches the obturator itself. This prevents faults caused by the infiltration of impurities present in the fluid. - Series 561 shut off valves are available for the 3/8 and 1/2 sizes. - The anti suction valve code 562200, is available for all air vents in the ROBOCAL series.

SPECIFICATION SUMMARIES Series 5024 Automatic air vent. 1/4 M (or 3/8 M) threaded connection. Body and cover in brass. Obturator in silicone rubber. Max. working temperature 115C. Max. working pressure 10 bar. Max. venting pressure 4 bar. Float with anti rotation and anti vibration system. Horizontal discharge. Series 5025 Automatic air vent complete with automatic shut-off valve. Threaded connection 3/8" M. Body and cover in brass. Obturator in silicone rubber. Max. working temperature 110C. Max. working pressure 10 bar. Max. venting pressure 4 bar. Float with anti rotation and anti vibration system. Horizontal discharge. Series 5026 Automatic air vent. Threaded connection 3/8 M (o 1/2 M). Body and cover in brass. Obturator in silicone rubber. Max. working temperature 115C. Max. working pressure 10 bar. Max. venting pressure 6 bar. Float with anti rotation and anti vibration system. Vertical discharge. Series 5027 Automatic air vent complete with automatic shut-off valve. Threaded connection 3/8" M. Body and cover in brass. Obturator in silicone rubber. Max. working temperature 110C. Max. working pressure 10 bar. Max. venting pressure 6 bar. Float with anti rotation and anti vibration system. Vertical discharge.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Thermostatic radiator valves


series 220
cert. n 0003

CALEFFI
ISO 9001

01034/05 GB
Replaces 01034/01 GB

Function Thermostatic valves are typically used for regulating the fluid flow to the radiators of central heating systems. They are provided with a regulating element which automatically controls the opening of the valve to keep the ambient temperature of the room where they are installed constant at the set value. This prevents unwanted temperature rises and achieves considerable energy savings. These valves have a special tailpiece with rubber hydraulic seal, permitting quick, safe connection to the radiator without the use of additional sealing materials.

Product range VALVES: For steel pipes: Series Series Series Series 220 221 224 225 Angled thermostatic radiator valve Straight thermostatic radiator valve Reverse thermostatic radiator valve Double angled thermostatic radiator valve Sizes 3/8, 1/2, 3/4 (*) Sizes 3/8, 1/2, 3/4 (*) Sizes 3/8, 1/2 Sizes 3/8, 1/2 Rh and 3/8, 1/2 Lh

For plastic and copper pipes: Series 222 Angled thermostatic radiator valve Series 223 Straight thermostatic radiator valve Series 227 Reverse thermostatic radiator valve THERMOSTATIC CONTROL HEADS Series 200 Thermostatic control head with built-in sensor with liquid-filled element Series 201 Thermostatic control head with remote sensor with liquid-filled element Series 203 Thermostatic control head with contact probe for fluid temperature limitation Series 209 Tamper-proof and antitheft cap for use in public places * 3/4 with tailpiece without rubber seals Regulating scale 0-5 corresponding to 0-28C Regulating scale 0-5 corresponding to 0-28C Graduated scale 20-50C, 40-90C For control head 200 series Sizes 1/2 radiator x 23 p.1,5 piping Sizes 1/2 radiator x 23 p.1,5 piping Sizes 1/2 radiator x 23 p.1,5 piping

Technical specification of valve bodies - Material: Body: brass EN 12165 CW617N, chrome plated Obturator stem: stainless steel Hydraulic seals: EPDM Control knob and cap: ABS (RAL 9010)

Control adjustment scale, 200/201 series

0
0C

7C

1
12C

234
16C 20C 24C

5
28C

Medium: water, glycol solutions Max percentage of glycol: 30% Max differential pressure with control fitted: 1 bar Max working pressure: 10 bar Temperature range: 5100C

Technical specification of control heads 200/201 series Scale of adjustment: Setting temperature range: Frost protection cut-in: Max ambient temperature: Length of capillary, 201 series: 05 028C 7C 50C 2m

Technical specification of control heads 203 series Setting temperature range: Max sensor temperature: Max pocket pressure: Length of capillary: - code 203502 - code 203702 2050C 4090C 100C 10 bar 2m

Dimensions
LH version

B A E A B

B D

Code

B 3/8 1/2 3/4

C 48 48 48

D 48 52,5 62

E 20 23 26

F 100 100 100

Code

B 3/8 1/2

C 48 48

D 51 57

E 25 30

F 104 104

Code

B 80

220302 + 200001 3/8 220402 + 200001 1/2 220500 + 200001 3/4

225322 + 200001 3/8 225422 + 200001 1/2

200001 30 p. 1,5

C C C

B D
Code A B 80 C 48 D 33 E 95 201000 30 p. 1,5

Code

B 3/8 1/2 3/4

C 48 48 48

D 48 52,5 62

E 26 29 35

F 104 104 104 Code A B C 48 D E F

221302 + 200001 3/8 221402 + 200001 1/2 221500 + 200001 3/4

222402 + 200001 1/2 23 p.1,5

52,5 20,5 100

B F E

E
Code A B 80 80 C 48 48 D 11 9,5 E 158 134

Code

B 3/8 1/2

C 48 48

D 35 40

E 45 51

F 104 104

224302 + 200001 3/8 224402 + 200001 1/2

203502 30 p. 1,5

203702 30 p. 1,5

RH version

Code

C 48

D 52,5

E 24

F 104

223402 + 200001 1/2 23 p.1,5

A B
2 3 4

B D
Code A B 3/8 1/2 C 48 48 D 51 57

E
E 25 30 F 104 104 Code A

E
Code B C 48 D 37 E F 475002 475003 A 1/2 1/2 B 13 13 C 187 187 D 11,5 10

225312 + 200001 3/8 225412 + 200001 1/2

227402 + 200001 1/2 23 p.1,5

49,5 104

E
2 3 4 2 3 4
2 3 4 2 3 4 1 2 2 3 4
2 3 4

2 3 4

2 3 4 2 3 4

C 48

Operating principle thermostatic control head

of
2 3 4

Valve closed

Hydraulic charateristics Details are given in accordance with the specification in standard UNI EN 215: 1990. Thermostatic valves with angled connections 220 series, with straight connections 221 series for steel pipe and thermostatic valves with angled connections 222 series and with straight connections 223 series for copper pipe (*); with thermostatic control head 200 or 201 series
p (mm w.g.) 3000 2000
3/8" 1/2" 3/4"

The thermostatic valve control head is a proportional temperature regulator, consisting of bellows containing liquid. When the ambient temperature increases, the consequent build-up in pressure causes an expansion in volume in the bellows, which, in turn, dilate. When the temperature falls, the reverse takes place; the bellows contract due to the effect of the thrust generated by the return spring. The axial movement of the sensitive element is trasmitted to the valve obturator through the connecting spindle, thus regulating the flow of liquid to the heat emitter.

p (kPa) 30 20

Valve open
2 3 4

1000 500 200 100 50 20 10

s-1K

10 5 2 1 0,5 0,2 0,1

1000

G (l/h)

Construction details Valve The control stem is stainless steel with EPDM O-Ring double seal. This means that the upper part of the control device can be replaced even when the system is in operation. The obturator is shaped in such a way as to optimise the fluid-dynamic characteristics of the valve during the progressive opening and closing actions in thermostatic operation. The large passage between seat and obturator causes reduced pressure drops in manual use.

p (mm w.g.) 3000 2000 1000 500 200 100 50 20 10

3/8" 1/2"

3/4"

p (kPa) 30 20

2000
10 5 2 1 0,5 0,2 0,1 G (l/h)

100

200

500

10

20

50

s-2K

1000

Valves with angled connections


Code Size 1 220302 3/8 220402/222402 1/2 3/4 220500 Code Size 0,32 0,34 0,40 Kv (m3/h) Proportional band (K) 1,5 0,50 0,52 0,63 2 0,60 0,64 0,81 Obturator autority 0,92 0,92 0,93 3 0,86 0,90 1,09 Kvs 2,29 2,39 3,19

Nominal flow (l/h) 180 180 (170*) 240

Max diff. press. (bar) 0,1 0,1 0,1

3/8 220302 220402/222402 1/2 3/4 220500

* With control head 201 series

Valves with straight connections


Code Size 1 3/8 221302 221402/223402 1/2 3/4 221500 Tailpiece with rubber seal The coupling union to the radiator connection thread has a specially shaped rubber ring. This system guarantees the hydraulic seal with no need for further sealing materials, such as PTFE tapes etc. Code Size 0,28 0,32 0,43 Kv (m3/h) Proportional band (K) 1,5 0,45 0,50 0,63 2 0,59 0,67 0,82 Obturator autority 0,60 0,60 0,86 3 0,77 0,86 1,05 Kvs 1,05 1,52 2,20

Nominal flow (l/h) 180 180 240

Max diff. press. (bar) 0,1 0,1 0,1

3/8 221302 221402/223402 1/2 3/4 221500

Kv = Volume flow in m3/h producing pressure drop 1 bar Kvs = Kv with valve totaly open

2000

100

200

500

10

20

50

Thermostatic valves with reverse connections 224 series for steel pipe and 227 (*) series for copper and plastic pipe, with thermostatic control head 200 or 201 series
p (mm w.g.) 3000 2000 1000 500 200 100 50 20 10
3/8" 1/2"

Thermostatic valves with double angled connections 225 series for steel pipe with thermostatic control head 200 or 201 series
p (mm w.g.) 3000 2000 1000 500 200 100 50 20 10
3/8" 1/2"

p (kPa) 30 20

p (kPa) 30 20

s-1K

10 5 2 1 0,5 0,2 0,1

s-1K

10 5 2 1 0,5 0,2 0,1

10

20

50

100

200

500

1000

2000

10

20

50

100

200

500

1000

G (l/h) p (mm w.g.) 3000 2000 1000 500 200 100 50 20 10 p (kPa) 30 20 p (mm w.g.) 3000 2000 1000 500 200 100 50 20 10

G (l/h) p (kPa) 30 20

3/8" 1/2"

3/8" 1/2"

s-2K

10 5 2 1 0,5 0,2 0,1

s-2K

2000
10 5 2 1 0,5 0,2 0,1 G (l/h)

10

20

50

100

200

500

1000

2000

10

20

50

100

200

500

1000

G (l/h)

Valves with reverse connections


(not to HD 1215-2)

Valves with double angled connections


Code Kvs 0,93 1,39 1,39 2253.2 2254.2 Code 2253.2 2254.2 3/8 1/2 Size 3/8 1/2 Size 1 0,34 0,35 Kv (m3/h) Proportional band (K) 1,5 0,46 0,52 2 0,58 0,60 Obturator authority 0,60 0,80 3 0,75 0,83 Kvs 0,96 1,40

Code 224302 224402 227402 Code 224302 224402 227402

Size 1 3/8 1/2 1/2 Size 3/8 1/2 1/2 0,36 0,37 0,37

Kv (m3/h) Proportional band (K) 1,5 0,48 0,51 0,51 2 0,57 0,63 0,63 Obturator authority 0,65 0,93 0,93 3 0,66 0,82 0,82

Nominal flow (l/h) 180 180 180

Max diff. press. (bar) 0,1 0,1 0,1

Nominal flow (l/h) 180 180

Max diff. press. (bar) 0,1 0,1

(*) Certification Caleffi valves 220, 221 series sizes 3/8, 1/2, 3/4 and 224, 225 series sizes 3/8, 1/2, in combination with control heads 200 and 201 series, are approved to standard UNI EN 215: 1990. Additional information available on request.

System sizing For correct system sizing, the valves are normally selected by identifying the pressure drop in accordance with the flow on diagrams s-2K as above (regulation with proportional band of 2K).

2000

Installation Thermostatic controls should be installed in the horizontal position.

Remote sensor control The use of the thermostatic head with remote sensor requires installation of the latter in accordance with the dimensions shown in the diagram.
CALEFFI

CALEFFI

CALEFFI

The sensitive element of the thermostatic control head must not be sited in niches, alcoves, behind curtains or directly exposed to sunlight, any of which would falsify the readings.

1,5 m

Tamper-proof and antitheft cap The thermostat control can be protected against tampering and theft by mounting the cover (code 209000) on the knob as shown in the figure at side. The cover is fastened with two screws with special heads that can only be tightened or loosened by means of the appropriate wrench. (code 209001).

Before fitting the thermostatic control head, turn the control knob to the number 5 position.
4 5 0

Locking and restricting the thermostat control temperature Temperature restriction

1. Turn the knob to the fully open position (Pos.5). Using a screw-driver, unlock the ring, pressing it fully towards the valve body.

2. Turn the knob to the new maximum open position required (e.g. Pos.3). Turn the ring anti-clockwise up to the stop.

10 cm

1 2 3

3. Re-lock the ring. The valve will now have a temperature range restriction from 0 to the set value.

Locking the temperature

1. Turn the knob to the fully open position (Pos.5). Using a screw-driver, unlock the ring, pressing it fully towards the valve body.

2. Position the valve at the required temperature and turn the ring clockwise up to the stop.

3. Re-lock the ring. The valve will now be locked at the set temperature.

Resetting the temperature restriction and temperature lock

1. Using a screw-driver, unlock the ring, pressing it fully towards the valve body.

2. Turn the knob to the fully open position and the ring anti-clockwise, up to the stop. The RESET arrows will match up.

3. Re-lock the ring. The valve will now no longer have any temperature restriction or lock.

SPECIFICATION SUMMARIES
Series 220 Thermostatic valve for radiators suitable for thermo-electric and thermostatic control heads. Angled connections for steel pipes 3/8, 1/2 and 3/4. Radiator connection 3/8 and 1/2 M with tailpiece provided with EPDM seal, 3/4 with tailpiece without seal. Brass body. Chrome plated. Control knob in ABS white RAL 9010. Double seal on control stem with EPDM O-Rings. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 221 Thermostatic valve for radiators suitable for thermo-electric and thermostatic control heads. Straight connections for steel pipes 3/8, 1/2 and 3/4. Radiator connection 3/8 and 1/2 M with tailpiece provided with EPDM seal, 3/4 with tailpiece without seal. Brass body. Chrome plated. Control knob in ABS white RAL 9010. Double seal on control stem with EPDM O-Rings. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 222 Thermostatic valve for radiators suitable for thermo-electric and thermostatic control heads. Angled connections for copper and single and multilayer plastic pipes 23 p1,5 M. Radiator connection 1/2 M with tailpiece provided with EPDM seal. Brass body. Chrome plated. Control knob in ABS white RAL 9010. Double seal on control stem with EPDM O-Rings. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 223 Thermostatic valve for radiators suitable for thermo-electric and thermostatic control heads. Straight connections for copper and single and multilayer plastic pipes 23 p1,5 M. Radiator connection 1/2 M with tailpiece provided with EPDM seal. Brass body. Chrome plated. Control knob in ABS white RAL 9010. Double seal on control stem with EPDM O-Rings. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 224 Thermostatic valve for radiators suitable for thermo-electric and thermostatic control heads. Reverse connections for steel pipes 3/8 and 1/2 F. Radiator connection 3/8 and 1/2 M with tailpiece provided with EPDM seal. Brass body. Chrome plated. Control knob in ABS white RAL 9010. Double seal on control stem with EPDM O-Rings. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 225 Thermostatic valve for radiators suitable for thermo-electric and thermostatic control heads. Double angled connections for steel pipes 3/8 and 1/2 F. Radiator connection 3/8 and 1/2 M, LH or RH with tailpiece provided with EPDM seal. Brass body. Chrome plated. Control knob in ABS white RAL 9010. Double seal on control stem with EPDM O-Rings. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 227 Thermostatic valve for radiators suitable for thermo-electric and thermostatic control heads. Reverse connections for copper and single and multilayer plastic pipes 23 p1,5 M. Radiator connection 1/2 M with tailpiece provided with EPDM seal. Brass body. Chrome plated. Control knob in ABS white RAL 9010. Double seal on control stem with EPDM O-Rings. Maximum working temperature 100C. Maximum working pressure 10 bar. Series 200 Thermostatic control head for thermostatic and convertible radiator valves. Sensor incorporated with liquid-filled element. Maximum ambient temperature 50C. Graduated scale from 0 to 5 corresponding to a temperature range of 0 to 28C, with possibility of temperature restriction and locking. Frost protection cut-in at 7C. Series 201 Thermostatic control head for thermostatic and convertible radiator valves. Remote sensor incorporated with liquid-filled element. Maximum ambient temperature 50C. Graduated scale from 0 to 5 corresponding to a temperature range of 0 to 28C, with possibility of temperature restriction and locking. Frost protection cut-in at 7C. Series 203 Thermostatic control head with contact probe, for fluid temperature restriction. Setting temperature range 2050C (4090C). Maximum sensor temperature 100C. Numbered scale, with possibility of temperature restriction and locking. Length of capillary 2 m. Series 209 Tamper-proof and antitheft cap for thermostatic control head 200 series, for use in public places.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Couplings for polyethylene pipe

CALEFFI
series DECA
cert. n 0003

ISO 9001

01037/03 GB

Function DECA couplings, which are supplied in brass for diameters up to 63 mm and in cast iron for larger sizes, are used for connecting polyethylene piping. As proof of the high standard of quality, the threaded DECA connections (up to 63) have DVGW and SVGW approval, which means that they are approved for use in Germany and Switzerland.

SVGW SSIGE

Product range Series 860 Female coupling in brass Sizes 20x1/2, 21x1/2, 25x3/4, 27x3/4, 25x1, 32x1, 34x1, 40x1 1/4, 50x1 1/2, 63x2 Series 860 Female coupling in cast iron Sizes 75x2 1/2, 90x3, 110x4 Series 861 Male coupling in brass Sizes 20x1/2, 21x1/2, 25x3/4, 27x3/4, 25x1, 32x1, 34x1, 40x1 1/4, 50x1 1/2, 63x2 Series 861 Male coupling in cast iron Sizes 75x2 1/2, 90x3, 110x4 Series 862 Male reduced coupling in brass Sizes 20x3/8, 25x1/2, 32x3/4, 40x1, 50x1 1/4, 63x1 1/2 Series 863 Sleeve coupling in brass Sizes 20, 21, 25, 27, 32, 34, 40, 50, 63 Series 863 Sleeve coupling in cast iron Sizes 75, 90, 110, 125 Series 864 Tee coupling in brass Sizes 20, 21, 25, 27, 32, 34, 40, 50, 63 Series 865 Reduced male-female tee coupling, in brass Sizes 20x1/2Mx3/8F, 25x3/4Mx1/2F, 32x1Mx3/4F, 40x1 1/4Mx1F, 50x1 1/2Mx1 1/4F, 63x2Mx1 1/2F Series 866 Elbow coupling in brass Sizes 20, 25, 32, 40, 50, 63 Series 867 Male elbow coupling in brass Sizes 20x1/2, 25x3/4, 32x1, 40x1 1/4, 50x1 1/2, 63x2 Series 868 Female elbow coupling in brass Sizes 20x1/2, 25x3/4, 32x1, 40x1 1/4, 50x1 1/2, 63x2 Series 869 Female elbow coupling with wall fixing in brass Sizes 20x1/2, 25x1/2, 25x3/4 Series 870 Sleeve coupling for repairs Sizes 25, 32, 40, 50 Series 871 Female coupling with ball valve Sizes 25x1/2, 32x3/4 Series 875 Female reduced coupling in brass Sizes 25x1/2, 32x3/4, 40x1 Series 876 Female union coupling in brass Sizes 25x1/2, 32x3/4, 40x1 Series 888 Flanged coupling PN 10 in cast iron Sizes 75xDN 65, 90xDN 80, 110xDN100, 125xDN 100

Technical specification Brass couplings Materials Body: Lock nut: Seal: Bolts and nuts: Performance Max working pressure: Max working temperature: Medium: Connections: Cast iron coupling

Brass EN 12165 CW617N Brass EN 12165 CW617N NBR // 16 bar 40C Water See product range

GG 25 GG 25 NBR Stainless steel 10 bar 40C Water See product range

Dimensions A

C C Code 860420 860421 860525 860527 860625 860632 860634 860740 860850 860963 A 20 21 25 27 25 32 34 40 50 63 B 47,5 47,5 49,5 49,5 56 56 56 64,5 66,5 74,5 C 1/2 1/2 3/4 3/4 1 1 1 1 1/4 1 1/2 2 A Code 861075 861090 861110 A 75 90 110 B 130 130 140 C 2 1/2 3 4

Code 863075 863090 863110 863125

A 75 90 110 125

B 180 180 190 205

A A

A A A B C Code 862320 862425 862532 862640 862750 862863 A 20 25 32 40 50 63 B 47 51,5 56,5 67 72 75,5 C 3/8 1/2 3/4 1 1 1/4 1 1/2 A 20 21 25 27 32 34 40 50 63 B 87 87 93 93 108 108 129 145 155 C 46 46 49 49 56,5 56,5 66,5 75 84 D E C A B 50,5 46 53 49 59,5 59,5 55 69 72,5 79,5 C 1/2 1/2 3/4 3/4 1 1 1 1 1/4 1 1/2 2 Code 863020 863021 863025 863027 863032 863034 863040 863050 863063 A 20 21 25 27 32 34 40 50 63 B 66,5 66,5 68,5 68,5 76,5 76,5 89 95 101,5 B Code 865020 865025 865032 865040 865050 865063 A 20 25 32 40 50 63 B 87 93 108 129 145 155 C 31,5 37 41 49 56 68 D E 1/2 3/8 3/4 1/2 1 3/4 1 1/4 1 1 1/2 1 1/4 2 1 1/2 A A

C B

Code 860075 860090 860110

A 75 90 110

B 120 120 125

C 2 1/2 3 4

Code 864420 864421 864525 864627 864632 864634 864740 864850 864963

Code 861420 861421 861525 861527 861625 861632 861634 861740 861850 861963

A 20 21 25 27 25 32 34 40 50 63

A 28

C B

A B

A E D

39

Code 866020 866025 866032 866040 866050 866063

A 20 25 32 40 50 63

B 48,5 53,5 60,5 73,5 80,5 91,5

C Code A B D 869420 20 48,5 1/2 25 869425 25 53,5 1/2 26 869525 25 53,5 3/4 26

F E 20 41,5 25 46,5 25 46,5

Code 875425 875532 875640

A 25 32 40

B 49 55 66

C 1/2 3/4 1

A D

50

Code 867020 867025 867032 867040 867050 867063

A 20 25 32 40 50 63

B 37 42 48 58 64 74

C 1/2 3/4 1 1 1/4 1 1/2 2

D 30,5 37,5 43 51,5 57 69,5

A Code 876520 876525 876625 876632 A 20 25 25 32 B 59,5 61 64,5 70 C 3/4 3/4 1 1

Code 870025 870032 870040 870050

A 25 32 40 50

B 125 127 138 143

A C B

A D Code 868020 868025 868032 868040 868050 868063 A 20 25 32 40 50 63 B 48,5 53,5 60,5 73,5 80,5 91,5 C 1/2 3/4 1 1 1/4 1 1/2 2 D 26,5 28 32 38 42,5 67

C B Code 888075 888090 888110 888125 A 75 90 110 125 B 145 135 135 135 C DN 65 DN 80 DN 100 DN 100

Code A 871425 25 871532 32

B 73 79

C 49 52

D 1/2 3/4

Constructional details Ease of use DECA series polyethylene pipe couplings are extremely practical, as they do not have to be taken apart when connecting to the piping (see example at foot of page).

Accessories Series 886 reducer

Repair joints Series 870 sleeve coupling allows piping connections to be made with a maximum space between ends of 50 mm. Thanks to the absence of internal ledges, the pipe can slide freely.

Code 886022 886032 886043 886054 886065

from 25 to 20 from 32 to 25 from 40 to 32 from 50 to 40 from 63 to 50

Series 887 pipe stiffener 887120 887223 887330 887437 887546 887658 887128 887235 20 x 2 25 x 2,3 32 x 3 40 x 3,7 50 x 4,6 63 x 5,8 20 x 2,8 25 x 3,5

max.

50
Series PN 10

For REHAU pipes

Strength Caleffi DECA couplings are not affected by frost, as any deformations are absorbed by the pipe itself. In addition, in the case of ground movement or excessive loads in the connection area, there is no risk of breakage or disconnection.

Preparation of the pipe

Instructions for the correct assembly of couplings

90

Insert the pipe into the coupling with the nut slackened. Do not cut at an angle Cut at 90

do

do not
Remove any external burrs

Dismantle the coupling and slide the various components onto the pipe.

SPECIFICATION SUMMARIES Series 860 Female coupling for polyethylene pipe. Connections 20 x 1/2" F (from 20 x 1/2" F to 63 x 2" F). Brass body. NBR O-Ring seal. Maximum working pressure 16 bar. Maximum working temperature 40C. For use with water. Series 860 Female coupling for polyethylene pipe. Connections 75 x 2 1/2" F (from 75 x 2 1/2" F to 110 x 4" F). Body in GG 25 cast iron. Polyacetal resin ring. NBR seal. Stainless steel bolts and nuts. Maximum working pressure 10 bar. Maximum working temperature 40C. For use with water. Series 861 Male coupling for polyethylene pipe. Connections 20 x 1/2" M (from 20 x 1/2" M to 63 x 2" M). Brass body. NBR O-Ring seal. Maximum working pressure 16 bar. Maximum working temperature 40C. For use with water. Series 861 Male coupling for polyethylene pipe. Connections 75 x 2 1/2" M (from 75 x 2 1/2" M to 110 x 4" M). Body in GG 25 cast iron. Polyacetal resin ring. NBR seal. Stainless steel bolts and nuts. Maximum working pressure 10 bar. Maximum working temperature 40C. For use with water. Series 862 Male reduced coupling for polyethylene pipe. Connections 20 x 3/8 M (from 20 x 3/8 M to 63 x 1 1/2 M). Brass body. NBR O-Ring seal. Maximum working pressure 16 bar. Maximum working temperature 40C. For use with water. Series 863 Sleeve coupling for polyethylene pipe. Connections 20 (from 20 to 63). Brass body. NBR O-Ring seal. Maximum working pressure 16 bar. Maximum working temperature 40C. For use with water. Series 863 Sleeve coupling for polyethylene pipe. Connections 75 (from 75 to 125). Body in GG 25 cast iron. Polyacetal resin ring. NBR seal. Stainless steel bolts and nuts. Maximum working pressure 10 bar. Maximum working temperature 40C. For use with water. Series 864 Tee coupling for polyethylene pipe. Connections 20 (from 20 to 63). Brass body. NBR O-Ring seal. Maximum working pressure 16 bar. Maximum working temperature 40C. For use with water. Series 865 Reduced male-female tee coupling, for polyethylene pipe. Connections 20 x 1/2" M x 3/8" F (from 20 x 1/2" M x 3/8" F to 63 x 2" M x 1 1/2" F ). Brass body. NBR O-Ring seal. Maximum working pressure 16 bar. Maximum working temperature 40C. For use with water. Series 866 Elbow coupling for polyethylene pipe. Connections 20 (from 20 to 63). Brass body. NBR O-Ring seal. Maximum working pressure 16 bar. Maximum working temperature 40C. For use with water. Series 867 Male elbow coupling for polyethylene pipe. Connections 20 x 1/2" M (from 20 x 1/2" M to 63 x 2" M). Brass body. NBR O-Ring seal. Maximum working pressure 16 bar. Maximum working temperature 40C. For use with water.

SPECIFICATION SUMMARIES Series 868 Female elbow coupling for polyethylene pipe. Connections 20 x 1/2" F (from 20 x 1/2" F to 63 x 2" F). Brass body. NBR O-Ring seal. Maximum working pressure 16 bar. Maximum working temperature 40C. For use with water. Series 869 Female elbow coupling, with wall fixing, for polyethylene pipe. Connections 20 x 1/2" F (from 20 x 1/2" F to 25 x 3/4" F). Brass body. NBR O-Ring seal. Maximum working pressure 16 bar. Maximum working temperature 40C. For use with water. Series 870 Sleeve coupling, for repairs, for polyethylene pipe. Connections 25 (from 25 to 50). Brass body. NBR O-Ring seal. Maximum working pressure 16 bar. Maximum working temperature 40C. Maximum space between the ends of the pipes to be joined 50 mm. For use with water. Series 871 Female coupling with ball valve, for polyethylene pipe. Connections 25 x 1/2" F ( 25 x 1/2" F and 32 x 3/4" F). Brass body. NBR O-Ring seal. Maximum working pressure 16 bar. Maximum working temperature 40C. For use with water. Series 875 Female reduced coupling for polyethylene pipe. Connections 25 x 1/2" F (from 25 x 1/2" F to 40 x 1" F ). Brass body. NBR O-Ring seal. Maximum working pressure 16 bar. Maximum working temperature 40C. For use with water. Series 876 Female union coupling for polyethylene pipe. Connections 20 x 3/4" F (from 20 x 3/4" F to 32 x 1" F). Brass body. NBR O-Ring seal. Maximum working pressure 16 bar. Maximum working temperature 40C. For use with water. Series 888 Flanged coupling PN 10 for polyethylene pipe. Connections 75 x DN 65 (from 75 x DN 65 to 125 x DN 125). Body in GG 25 cast iron. Polyacetal resin ring. NBR seal. Stainless steel bolts and nuts. Maximum working pressure 10 bar. Maximum working temperature 40C. For use with water. Series 886 Coupling reducer for polyethylene pipe from 25 to 20 (available: reducers from 25 to 20 up to 63 to 50).

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Flow rate metering device

CALEFFI
683 series
ACCREDITED

01040/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003

Function The flow rate metering device is used to measure the flow rate within a circuit. When used for central heating purposes, therefore, it allows monitoring of the thermal power supplied to the systems; in water treatment systems and industrial chemical or textile plants etc., it can be used to continuously monitor the water flowing through the circuits. This particular series of devices is equipped with quick-fit ports for easier differential pressure measurement.

Product range 683 series Flow rate metering device, threaded connections 683 series Flow rate metering device, flanged connections, to be coupled with counterflanges PN 6 683 series Flow rate metering device, flanged connections, to be coupled with counterflanges PN 16 sizes 3/4 and 1 sizes DN 32DN 100 sizes DN 125DN 200

Technical specifications series Materials Body: Gaskets: Screws: Nuts: Pressure test ports: Pressure test port seals: Performance Medium: Max. percentage of glycol: Max. working pressure: Working temperature range: Minimum p for measurement: Connections Main: Pressure test ports: 683 threaded brass EN 12165 CW617N brass EN 12164 CW614N EPDM 683 flanged painted steel asbestos free NBR fibre steel steel brass EN 12164 CW614N EPDM

water, glycol solutions 50% 10 bar -5110C 0,01 bar

water, glycol solutions 50% 6 bar (DN 32DN 100), 16 bar (DN 125DN 200) -5110C 0,01 bar

3/4, 1 F

counterflange EN 1092-1 PN 6 (DN 32DN 100) counterflange EN 1092-1 PN 16 (DN 125DN 200) 1/4 F

1/4 F

Dimensions E B C B D D A A E Code 683005 683006 A 3/4" 1" B 23 29 C 32 32 D 51 54 E 78 90 Mass(kg) 0,30 0,43 Code 683030 683040 683050 683060 683080 683100 683120 683150 683170 683200 DN 32 40 50 65 80 100 125 150 175 200 C 64 71 88 110 140 182 75 80 85 100 D 74 77 83 90,5 101 106 145 160 175 185 E 205 230 307 390 451 530 275 300 325 350 F 120 130 140 160 190 210 250 285 315 340 Mass(kg) 5,55 6,27 7,56 10,43 16,03 20,06 48,00 61,00 74,00 96,00 Operating principle The 683 series flow rate metering device operation is based on the Venturi effect. The metering device contains a diaphragm that, by restricting the cross-section of the channel, speeds up the medium and generates an increased p (for measurement) at the ends, in order to guarantee precise flow rate metering. Each differential pressure value (measured at the ends of the diaphragm) has a corresponding accurate flow rate value, with the diaphragm Kv noted. The total head loss for the metering device is, however, very low since the length of the pipe downstream from the diaphragm allows the medium to slow down and increase the pressure again. C

A)

57324

B)

F
h

p (kPa)

'h

(for mesurement)

E)
h

p (total head loss)

Differential pressure measurement The differential pressure can be measured using any pressure gauge or meter capable of operating within the range 010 kPa (01000 mm w.g.; see adjacent figure). Whichever method or instrument is used, the air must be vented from the connection pipes to prevent errors when reading the differential pressure values.

A) B) C) D) E)

Caleffi FLOMET electronic measuring station (130 series) differential pressure gauges with dial inclined U-shaped pressure gauges with mercury column upturned U-shaped pressure gauges with water column a transparent plastic hose (resistant to the static pressure of the system), system water functioning as pressure gauge fluid, air trapped in the hose acting as a separator.

CALEFFI

C)

h = 'h sen p = 12,6 h

D)

aria

Construction details Flow rate monitoring can take place at any moment, without any of the pipes being dismantled. The patented self-cleaning single-casting diaphragm profile and the quick-fit pressure test ports offer rapid and accurate differential pressure measurement.

Pressure measurement

Automatic reclosure

Safety cap

Measuring syringe

Seal element

Hydraulic characteristics Flow rate measurement

G (l/s) (m3/h) 1000 100 500 200 100 50 20 10 5 2 1 0,5


DN 200 DN 175 DN 150 DN 125 DN 100 DN 80 DN 65 DN 50 DN 40 DN 32 1" 3/4"

100

(l/s)

G= 0,129 p0,5 3/4 G= 0,229 p0,5 1 p G= 0,337 p0,5 DN 32 G= 0,533 p0,5 DN 40 G= 0,989 p0,5 DN 50 G= 1,654 p0,5 DN 65 G= 2,438 p0,5 DN 80 DN 100 G= 4,029 p0,5 DN 125 G= 9,032 p0,5 p DN 150 G= 11,290 p0,5 DN 175 G= 15,806 p0,5 0,5 DN 200 G= 22,580 p G= 0,129 p0,5 3/4 G= 0,229 p0,5 1 G= 0,337 p0,5 DN 32 p = f (G) le (m) Kv (1 kPa) G= 0,533 p0,5 DN 40 p = 41,8769 G2 12 7 3/4 0,154 G= 0,989 p0,5 DN 50 Kv 1 coefficients, localised losses lengths, p = 13,3637 G2 10 8and equivalent 0,273 G= 1,654 p0,5 DN 65 head losses 0,403 p = 6,1579 G2 13 15 DN G= 2,438 p0,5 DN 32 80 p = 2,4652 G2 10 13 DN 100 40 p 0,637 DN G= 4,029 p0,5 p = 0,7153 G2 7 14 DN 125 50 1,182 DN G= 9,032 p0,5 I.S. UNITS p = 0,2557 G2 7 18 DN 150 65 1,978 DN G= 11,290 p0,5 p = 0,1178 G2 6 20 DN 80 2,914 0,5 DN 175 15,806 pl/s G G= = Flow rate in 0,5 p = 0,04142 G2 6 27 DN 100 4,913 DN 200 22,580 p pG= = Differential pressure in kPa 2 p = 0,001 G 0,7 5 DN 125 23,290 water density () 1 kg/dm3 p = 0,001 G2 DN 150 29,144 1 8 p = 0,6 10-3 G2 DN 175 40,822 0,9 9 p = f (G) le (m) Kv (1 kPa) 2 DN 200 58,352 p = 0,293 10-3 G 0,7 9 p = 41,8769 G2 12 7 3/4 0,154 p = 13,3637 G2 10 8 1 0,273 p = 6,1579 G2 13 15 DN 32 0,403 p = 2,4652 G2 10 13 DN 40 0,637 p = 0,7153 G2 7 14 DN 50 1,182 p = 0,2557 G2 7 18 DN 65 1,978 p = 0,1178 G2 6 20 DN 80 2,914 p = 0,04142 G2 6 27 DN 100 4,913 p = 0,001 G2 0,7 5 DN 125 23,290 p = 0,001 G2 DN 150 29,144 1 8 p = 0,6 10-3 G2 DN 175 40,822 0,9 9 DN 200 58,352 p = 0,293 10-3 G2 0,7 9

0,5

10

p (kPa) (mm w.g.) 1500 15

DN 100

10

1000

500

200

100

0,1

0,2 0,3 0,5

2 3 5 10

20

50

(m3/h)

0,5

10

20

0,2

50

100

200

500

1000

0,5

50

DN 125 DN 150 DN 175 DN 200

1" DN 32

DN 40

DN 50

DN 65

DN 80

3/4"

15

1500 p (kPa) (mm w.g.)

1000

100

200

500

50

{ {

I.S. UNITS G = Flow rate in l/s p = Differential pressure in kPa water density () 1 kg/dm3
50 20 10 5 3 2 1 0,5 0,3 0,2 0,1

0,2

Correction for liquids with different density The following notes apply to liquids with viscosity 3E (water and glycol mixtures, for example). If using liquids with a density different to that of water at 20C ( = 1 kg/dm3), the head loss value p measured may be corrected using the formula: p = p/ (1) where: p = reference head loss p = measured head loss = liquid density in kg/dm3 The value p is used when measuring flow rate G, using the graphs or the formula (2): G = Kv

Installation The metering device should be installed in the system during the initial setup phase, observing the flow direction indicated on its body and in accordance with the following instructions: - installation on the return pipe, in a position where it can be easily accessed for measurement purposes, with the pressure test ports facing upwards in order to prevent impurities from building up. The return water temperature has fewer variations, which increases measurement accuracy. - installation on a straight length of piping, either horizontally or vertically but not turned upside down, well away from twists or devices which may disrupt flow, particularly at the inlet, during measurement.

(2)

Example of correction for liquid with different density Metering device DN 100 Liquid density ' = 1,1 kg/dm3 Head loss measured on Venturi p = 3 kPa Let us use formula (1): Reference head loss p = 3/1,1 = 2,72 kPa This value is marked on the x-axis of the graph corresponding to the p measured with the Venturi (green line); the point at which this value meets the line for the DN 100 metering device indicates the corresponding flow rate G = 7 l/s on the y-axis. Similarly, by using formula (2): G' = 4028,96 10-3 Sizing method The size of the metering device should be selected so that, when operating at the design flow rate, it has a corresponding minimum measured p of 100 mm w.g. (1 kPa). Sometimes, to achieve this condition, it may be necessary to use a metering device with a diameter which is different to that of the pipe. In this case, a tapered fitting should be used (as illustrated in the figure below). 2,72 = 6,64 l/s

In thermal installations, the metering device can be used in supply systems with several risers, branches or zones, to monitor the value of the individual flow rates or wherever metering of heating costs is required. The rapid flow rate monitoring keeps the system at optimal running conditions, making it possible to identify balancing variations caused by lockshield valves or other balancing and regulation devices, or by tampering. The application diagrams at the end of the brochure indicate the optimal points for flow rate monitoring: 1) installation on the boiler circuit, 2) installation on each riser, for system balancing monitoring, 3) installation on the horizontal sections of supply columns, as an alternative to point 2, 4) installation on each zone, for balancing throughout the system.

d min.1,5 d

d min.1,5 d

Accessories

100
Pair of fast-plug pressure/temperature test ports. Their special construction allows rapid and accurate measurements, guaranteeing a perfect hydraulic seal. Cap clamp available in the following colours: - Red for upstream pressure test port. - Green for downstream pressure test port. Brass body. EPDM seals. Female 1/4 threaded connection. Working temperature range: -5130C Max. working pressure: 30 bar.

100
Pair of fittings with fast-plug syringe for connection of pressure test ports to measuring instruments. Female 1/4 threaded connection. Max. working pressure: 10 bar. Max. working temperature: 110C.
Code

100010

130 FLOMET
Flow rate and differential pressure electronic measuring station. Supplied complete with shut-off and connection fittings. Can be used for checking the correct operation of AUTOFLOW devices. Measurement range: 0,05200 kPa. Differential Pmax: 250 kPa.
Code

Code

100000

130000 130001

Supply voltage 230 V (ac) Battery operated

Application diagrams Central heating system

P T
Tmax 120C Pmax 10 bar Tmax 105 C Pmax 10 bar

F
A

Riser and zone systems

CALEFFI CALEFFI CALEFFI

CALEFFI CALEFFI CALEFFI

CALEFFI CALEFFI CALEFFI

Shut-off valve Ball valve BALLSTOP Temperature gauge Differential by-pass valve
F
T
T

Zone valve Pump AUTOFLOW Dirt separator Temperature probe Safety thermostat Temperature controller
P

Expansion vessel 3-way cock Pressure switch


A

Deaerator Fuel shut-off valve

Anti-vibration joint Inspection pocket Pocket Gas filter Safety valve Gas regulator Y-strainer Pressure reducing valve

Flow switch Backflow preventer

SPECIFICATION SUMMARY
683 series Flow rate metering device. Threaded connections 3/4 and 1 F. Brass body. Brass pressure test ports. EPDM pressure test port seals. Threaded connections 1/4 F for pressure test ports. Medium water, glycol solutions. Maximum percentage of glycol 50%. Working temperature range -5110C. Maximum working pressure 10 bar. Minimum p for measurement 0,01 bar. Complete with quick-fit pressure test ports. 683 series Flow rate metering device. Flanged DN 32DN 200 connections. Painted steel body. Asbestos-free fibre NBR gaskets. Steel screws. Steel nuts. Brass pressure test ports. EPDM pressure test port seals. Threaded connections 1/4 F for pressure test ports. Flanged connections. Coupling with counterflanges EN 1092-1 DN 32DN 100, PN 6; DN 125DN 200, PN 16. Working temperature range -5110C. Maximum working pressure 6 bar (DN 32DN 100), 16 bar (DN 125DN 200). Minimum p for measurement 0,01 bar. Complete with fast-plug pressure test ports, counterflanges, bolts and gaskets. 130 series FLOMET Flow rate and differential pressure electronic measuring station. Supplied complete with shut-off and connection fittings. It can be used to check AUTOFLOW device operation falls within the working range. It can also be used to measure the flow rate of series 131 and 135 balancing valves, and of the 683 series metering device. Measurement range 0,05200 kPa. Unit of measurement can be selected from Pa, kPa, mmW, mW, inW, mbar, PSI. Maximum line pressure 16 bar. Maximum differential pressure tolerated 250 kPa. 100 series Pair of fast-plug pressure and temperature test ports. threaded connections 1/4 M. Brass body. EPDM internal elements. Working temperature range -5130C. Maximum working pressure 30 bar. 100 series Pair of fittings with fast-plug syringe. Threaded connection 1/4 F. Maximum working temperature 110C. Maximum working pressure 10 bar.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.p.A. S.R.229, N.25 28010 Fontaneto dAgogna (NO) Italy Tel. +39 0322 8491 Fax +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

Automatic flow rate regulator with stainless steel cartridge


120 - 125 - 103 series

cert. n 0003

CALEFFI
ISO 9001

01041/07 GB
replaces dp 01041/00

Function The Autoflow devices are automatic flow rate regulators. They are used to keep the flow rate constant, at the design value, in air conditioning and plumbing system circuits. They automatically balance the hydronic circuit by ensuring the design flow rate to each terminal unit, regardless of any change in the system working conditions. The devices are available both as simple flow regulator and complete with ball shut-off valve.

Product range 120 series Automatic flow rate regulator with steel cartridge and ball valve 125 series Automatic flow rate regulator with steel cartridge 103 series Automatic flow rate regulator with steel cartridge, flanged version sizes 1/2 - 3/4 - 1 - 1 1/4 - 1 1/2 - 2 sizes 1/2 - 3/4 - 1 - 1 1/4 - 1 1/2 - 2 - 2 1/2 sizes DN 65 - 80 - 100 - 125 - 150 - 200 - 250 - 300 - 350

Technical specifications series Materials Body: Autoflow cartridge: Spring: Seals: Ball: Ball seat: Control stem seal: Lever: Pressure ports plugs: Performance Medium: Maximum percentage glycol: Maximum working pressure: Working temperature range: p range: Flow rates: Accuracy: Connections 120 125 103

brass EN 12165 CW617N stainless steel stainless steel EPDM brass EN 12165 CW614N, chrome plated PTFE EPDM + PTFE special zinc plated steel brass EN 12164 CW614N

brass EN 12165 CW617N stainless steel stainless steel EPDM brass EN 12164 CW614N

cast iron ASTM A126-61T stainless steel stainless steel asbestos free quick-fit pressure test ports

water, glycol solutions 50% 25 bar 0110C 7100 kPa; 14220 kPa; 35410 kPa 0,1215,5 m3/h 5% 1/22 F with union x F

water, glycol solutions 50% 25 bar -20110C 7100 kPa; 14220 kPa; 35410 kPa 0,1226,5 m3/h 5% 1/22 1/2 F x F

water, glycol solutions 50% 16 bar -20110C 14220 kPa; 35410 kPa 53850 m3/h 5% DN 65350 flanged PN 16 EN1092-1 1/4 F

Pressure ports connections

1/4 F

1/4 F

Dimensions E D

FFI LE CA

FI LEF CA

A D 30 30 38,5 38,5 48,5 C F 1/4" 1/4" 1/2" 1/2" 1/2

B Code A 125141 ... 1/2" 125151 ... 3/4" 125181 ... 1 1/2" 125191 ... 2" 125101 ... 2 1/2 B 101 106 177 176 230

B C 52,5 52,5 105 105 133


Weight (kg)

Code A 120141 ... 1/2" 120151 ... 3/4" 120181 ... 1 1/2" 120191 ... 2"

B C 156,5 52,5 159,5 52,5 253 84 253 84

D 50 50 88 88

E 100 100 140 140

F Weight (kg) 1/4" 1,10 1/4" 1,10 1/2" 4,60 1/2" 4,60

D
F

B
F

B Code A 218,5 120161 ... 1" 120171 ... 1 1/4" 220,5

C 68 68

D 66 66

E 120 120

F Weight (kg) 1/2" 2,30 1/2" 2,30

Code A 125161 ... 1" 125171 ... 1 1/4"

B 140,5 148

C 102 102

D 33,5 33,5

D B Code 10311. ... 10321. ... 10331. ... 10341. ... 10351. ... 10361. ... 10371. ... 10381. ... 10391. ... A DN 65 DN 80 DN 100 DN 125 DN 150 DN 200 DN 250 DN 300 DN 350 B 208 212 216 271 271 287 295 319 311 C 185 200 220 250 285 360 425 515 555 D 172 172 172 223 223 223 223 223 223
Weight (kg)

A C

007,50 011,58 012,38 016,55 024,11 041,62 058,09 093,27 108,17

CA LE FF I

CA LE FF I

0,55 0,58 2,25 2,45 4,36

F 1/2" 1/2"

Weight (kg)

1,02 1,16

Circuit balancing
DYNAMIC CIRCUIT BALANCING
Modern heating and air-conditioning systems have to guarantee a high level of thermal comfort with a low energy consumption. This means supplying the system terminal emitters with the correct design flow rates, to produce balanced hydraulic circuits.

Unbalanced circuits
In case of an unbalanced circuit, the hydraulic umbalance between emitters creates areas with temperatures which are not uniform, and, as a consequence, problems with thermal comfor t and higher energy consumption.

Flow rate

50 %

17

140 %
22 24

180 %

Circuits balanced with manual valves


Traditionally, hydraulic circuits are balanced using manual calibration valves. With these static-type devices, such circuits are difficult to balance per fectly and have operating limitations in case of partial closure by means of the regulating valves. The flow rate in the open circuits does not remain constant at the nominal value.
Flow rate Flow rate

100 %

140 %

100 %

Regulating valve

0%

100 %
Manual valve FULL LOAD PARTIAL LOAD

120 %

Circuits balanced with Autoflow


Autoflow balances the hydraulic circuit automatically, by ensuring to each ter minal emitter the design flow rate. Even in the case of partial circuit closure by means of the regulating valves, the flow rates in the open circuits remain constant at the nominal value . The system always guarantees the greatest comfort and the highest energy savings.
Flow rate Flow rate

100 %
CALEF FI CALEF FI

100 %

100 %
CALEF FI

Regulating valve

0%
CALEF FI

100 %

100 %

CALEF FI

Autoflow FULL LOAD PARTIAL LOAD

CALEF FI

Autoflow devices
Function The AUTOFLOW device has to guarantee a constant flow rate when its upstream/downstream pressure differential varies. It is therefore necessary to refer to the p - flow rate diagram and to a basic diagram illustrating the operation methods and the relevant variable effects. Operating principle The regulating element of these devices is composed of a cilinder and a piston with fixed and variable geometry orifices, through which the fluid flows. The surface area of these orifices is governed by the piston movement when pushed by the flow. A specially calibrated spring counteracts this movement. Autoflows are high performance automatic regulators. They regulate selected flow rates within a very tight tolerance (approx. 5%) and offer a wide range of operation.

Below the control range

In this case, the regulating piston remains fully out without compressing the spring and gives the medium the maximum free flow area. In practice, the piston acts as a fixed regulator and thus the flow through the AUTOFLOW depends solely on the differential pressure.

FLOW RATE

G0

kv0,01=0,378G0 p range 7-100 kPa kv0,01=0,267G0 p range 14-220 kPa kv0,01=0,169G0 p range 35-410 kPa

0,07 bar/7 kPa 0,14 bar/14 kPa 0,35 bar/35 kPa

DIFFERENTIAL PRESSURE

1 bar/100 kPa 2,20 bar/220 kPa 4,10 bar/410 kPa

where G0 = nominal flow rate

Within the control range

If the differential pressure is contained within the control range, the piston compresses the spring and modulates the flow area to maintain regular flow at the nominal rate for which the AUTOFLOW is calibrated.

FLOW RATE

Control range Initial p Final p DIFFERENTIAL PRESSURE 1 bar/100 kPa 2,20 bar/220 kPa 4,10 bar/410 kPa
DIFFERENTIAL PRESSURE

G0

0,07 bar/7 kPa 0,14 bar/14 kPa 0,35 bar/35 kPa

Above the control range

In this case, the piston fully compresses the spring and only allows flow through the fixed geometry orifice. As in the first case above, the piston acts as a fixed regulator. The flow rate through the AUTOFLOW thus depends solely on the differential pressure.

FLOW RATE

G0

p range 7-100 kPa kv0,01=0,1G0 kv0,01=0,067G0 p range 14-220 kPa kv0,01=0,049G0 p range 35-410 kPa

0,07 bar/7 kPa 0,14 bar/14 kPa 0,35 bar/35 kPa

1 bar/100 kPa 2,20 bar/220 kPa 4,10 bar/410 kPa

where G0 = nominal flow rate

Selecting the control range or p range of the AUTOFLOW device


Autoflow devices are available with different control ranges, so as to satisfy a wide array of system requirements. By definition, the control range is contained between two differential pressure values: p range: p start p end

The choice must be made taking into account the following: differential pressure at the start of the control range. This value must be added to the fixed loss of head in the circuit in the most unfavourable conditions. In this case it is necessary to evaluate the available pump head. differential pressure at the end of the control range. If this value is exceeded the Autoflow spring is fully compressed and the device no longer performs any regulating action. It will be necessary to switch to a higher control range. The following Autoflow control ranges are available. 7100 kPa 0,071 bar 14220 kPa 0,142,20 bar 35410 kPa 0,354,10 bar Can be used in sealed circuits served by pumps with a limited head. For example in small heating systems with wall-mounted boilers that have their own internal circulator. Can be used in the majority of sealed systems. The ample control range allows it to be inserted with a minimum addition of differential pressure, amounting to 14 kPa (0.14 bar). Can be used in open systems, for example in water distribution systems or with high level of available head, for example in district heating systems. The high upper limit, 410 kPa (4,1 bar), makes proper operation possible within the control range.

Sizing the circuit with Autoflow

Sizing the circuit containing Autoflow valves is particularly easy to accomplish. As illustrated alongside by the example diagrams, calculation of the loss of head in order to choose the pump is made by referring to the hydraulically most unfavourable circuit and by adding this value to the minimum differential pressure required by the Autoflow. In the example the circuits have the same nominal flow rate. The Autoflow devices, located on intermediate circuits, automatically absorb the excess differential pressure to ensure the corresponding nominal flow rate. As the regulating valves open or close, the Autoflow repositions itself dynamically to maintain the nominal flow rate (50% load = circuits 3, 5, 7, 8 closed). For more detailed information on sizing a system with Autoflow, please refer to the 2nd volume of the Handbooks Caleffi and the technical bulletin Dynamic balancing of hydronic circuits. They give theoretical calculations, numerical examples and notes on the application of the above-mentioned devices in circuits.

Regulating valve

1
Autoflow

Differential pressures (p)

p along the circuit (flow and return) extra p absorbed by Autoflow at 50% load minimum p required by Autoflow p in branch circuit at nominal flow rate

Pump H

p absorbed by Autoflow at 100% load

4 Terminal

Construction details Steel regulator The flow rate regulator is made entirely of steel, suitable for use in airconditioning and plumbing systems. It is fully compatible with the glycols and additives used in the circuits. Wide range of working pressures The regulator is able to provide precise regulation of the flow rate over a wide range of working pressures. It is factory calibrated to keep the flow rate automatically within 5% of the set value. For these reasons it can be used in system circuits both at zone branching and directly at the terminal emitters. Ball valve The control stem of the ball valve is blow-proof and the reversible closing lever is covered with vinyl. If there are any insulated pipes, it can be changed with the extended lever series 117. Replaceable cartridge The internal regulator is assembled in the form of a one-piece cartridge so as to permit easy removal from the body for inspection or replacement.

Pressure ports - checking flow rate Known the device dynamic characteristics, it is sufficient to check the differential pressure from upstream to downstream, using the pressure provided ports (1) - (2). If the differential pressure is contained within the control range (range p) indicated on the data plate, then the through flow rate is equal to the nominal value. G To take the measurement, Range p simply use a differential GNominal pressure gauge. Series 100 snap-on pressure test ports and a Flomet 130 series electronic p measuring device can be used as accessories. p (kPa)

FI LEF CA
FI LEF CA
co
15 01 8

d.

Q = =
ge

Ran

m kP a

/h

Cartridge plug The cartridge plug (3) contains a connection that allows the use of a circuit drain valve (4).

2 1 3
FI LEF CA

Autoflow, flanged version This is supplied equipped with flanges EN 1092-1 PN 16 (on request PN 25), gaskets and quick-fit pressure test ports.
FI LEF CA
d. co
150 18

Q =
ge

Ran

p =

m a kP

/h

Flow rate tables for 120 series


Code Minimum p range Kv0.01 (l/h) working p (kPa) (kPa)

Flow rates (m3/h)

120141 120151 120161

1690 1773 1704

7 7 7

7100 7100 7100

0,45; 0,5; 0,6; 0,7; 0,8; 0,9; 1,0 0,45; 0,5; 0,6; 0,7; 0,8; 0,9; 1,0 0,45; 0,5; 0,6; 0,7; 0,8; 0,9; 1,0

Code

Minimum p range Kv0.01 (l/h) working p (kPa) (kPa)


Flow rates (m3/h)

120141 120151 120161 120171 120181 120191

1690 1773 1704 1774 4724 4889

14 14 14 14 14 14

14220 14220 14220 14220 14220 14220

0,12; 0,15; 0,2; 0,25; 0,3; 0,35; 0,4; 0,5; 0,6; 0,7; 0,8; 0,9; 1,0; 1,2; 1,4; 1,6; 1,8 0,12; 0,15; 0,2; 0,25; 0,3; 0,35; 0,4; 0,5; 0,6; 0,7; 0,8; 0,9; 1,0; 1,2; 1,4; 1,6; 1,8 0,7; 0,8; 0,9; 1,0; 1,2; 1,4; 1,6; 1,8; 2,0; 2,25; 2,5; 2,75; 3,0; 3,25; 3,5; 3,75; 4,0; 4,25 0,7; 0,8; 0,9; 1,0; 1,2; 1,4; 1,6; 1,8; 2,0; 2,25; 2,5; 2,75; 3,0; 3,25; 3,5; 3,75; 4,0; 4,25 2,75; 3,0; 3,25; 3,5; 3,75; 4,0; 4,25; 4,5; 5,0; 5,5; 6,0; 6,5; 7,0; 7,5; 8,0; 8,5; 9,0; 9,5; 10,0; 11,0 2,75; 3,0; 3,25; 3,5; 3,75; 4,0; 4,25; 4,5; 5,0; 5,5; 6,0; 6,5; 7,0; 7,5; 8,0; 8,5; 9,0; 9,5; 10,0; 11,0

Code

Minimum p range Kv0.01 (l/h) working p (kPa) (kPa)


Flow rates (m3/h)

120141 120151 120161 120171 120181 120191

1690 1773 1704 1774 4724 4889

35 35 35 35 35 35

35410 35410 35410 35410 35410 35410

0,25; 0,35; 0,45; 0,55; 0,7; 0,9; 1,1; 1,4; 1,6; 1,8; 2,0; 2,25; 2,5; 2,75 0,25; 0,35; 0,45; 0,55; 0,7; 0,9; 1,1; 1,4; 1,6; 1,8; 2,0; 2,25; 2,5; 2,75 1,4; 1,6; 1,8; 2,0; 2,25; 2,5; 2,75; 3,0; 3,25; 3,5; 3,75; 4,0; 4,25; 4,5; 5,0; 5,5; 6,0 1,4; 1,6; 1,8; 2,0; 2,25; 2,5; 2,75; 3,0; 3,25; 3,5; 3,75; 4,0; 4,25; 4,5; 5,0; 5,5; 6,0 3,0; 3,25; 3,5; 3,75; 4,0; 4,25; 4,5; 5,0; 5,5; 6,0; 6,5; 7,0; 7,5; 8,0; 8,5; 9,0; 9,5; 10,0; 11,0; 12,0; 13,0; 14,5; 15,5 3,0; 3,25; 3,5; 3,75; 4,0; 4,25; 4,5; 5,0; 5,5; 6,0; 6,5; 7,0; 7,5; 8,0; 8,5; 9,0; 9,5; 10,0; 11,0; 12,0; 13,0; 14,5; 15,5

Flow rate tables for 125 series


Code Minimum p range Kv0.01 (l/h) working p (kPa) (kPa)

Flow rates (m3/h)

125141 125151 125161

1669 1758 1342

7 7 7

7100 7100 7100

0,45; 0,5; 0,6; 0,7; 0,8; 0,9; 1,0 0,45; 0,5; 0,6; 0,7; 0,8; 0,9; 1,0 0,45; 0,5; 0,6; 0,7; 0,8; 0,9; 1,0

Code

Minimum p range Kv0.01 (l/h) working p (kPa) (kPa)


Flow rates (m3/h)

125141 125151 125161 125171 125181 125191 125101

1669 1758 1342 1326 3472 3738 7582

14 14 14 14 14 14 14

14220 14220 14220 14220 14220 14220 14220

0,12; 0,15; 0,2; 0,25; 0,3; 0,35; 0,4; 0,5; 0,6; 0,7; 0,8; 0,9; 1,0; 1,2; 1,4; 1,6; 1,8 0,12; 0,15; 0,2; 0,25; 0,3; 0,35; 0,4; 0,5; 0,6; 0,7; 0,8; 0,9; 1,0; 1,2; 1,4; 1,6; 1,8 0,7; 0,8; 0,9; 1,0; 1,2; 1,4; 1,6; 1,8; 2,0; 2,25; 2,5; 2,75; 3,0; 3,25; 3,5; 3,75; 4,0; 4,25 0,7; 0,8; 0,9; 1,0; 1,2; 1,4; 1,6; 1,8; 2,0; 2,25; 2,5; 2,75; 3,0; 3,25; 3,5; 3,75; 4,0; 4,25 2,75; 3,0; 3,25; 3,5; 3,75; 4,0; 4,25; 4,5; 5,0; 5,5; 6,0; 6,5; 7,0; 7,5; 8,0; 8,5; 9,0; 9,5; 10,0; 11,0 2,75; 3,0; 3,25; 3,5; 3,75; 4,0; 4,25; 4,5; 5,0; 5,5; 6,0; 6,5; 7,0; 7,5; 8,0; 8,5; 9,0; 9,5; 10,0; 11,0 6,0; 7,0; 7,5; 8,0; 8,5; 9,0; 9,5; 10,0; 11,0; 12,0; 13,5; 14,5; 15,5; 16,5; 17,0; 18,0

Code

Minimum p range Kv0.01 (l/h) working p (kPa) (kPa)


Flow rates (m3/h)

125141 125151 125161 125171 125181 125191 125101

1669 1758 1342 1326 3472 3738 7582

35 35 35 35 35 35 35

35410 35410 35410 35410 35410 35410 35410

0,25; 0,35; 0,45; 0,55; 0,7; 0,9; 1,1; 1,4; 1,6; 1,8; 2,0; 2,25; 2,5; 2,75 0,25; 0,35; 0,45; 0,55; 0,7; 0,9; 1,1; 1,4; 1,6; 1,8; 2,0; 2,25; 2,5; 2,75 1,4; 1,6; 1,8; 2,0; 2,25; 2,5; 2,75; 3,0; 3,25; 3,5; 3,75; 4,0; 4,25; 4,5; 5,0; 5,5; 6,0 1,4; 1,6; 1,8; 2,0; 2,25; 2,5; 2,75; 3,0; 3,25; 3,5; 3,75; 4,0; 4,25; 4,5; 5,0; 5,5; 6,0 3,0; 3,25; 3,5; 3,75; 4,0; 4,25; 4,5; 5,0; 5,5; 6,0; 6,5; 7,0; 7,5; 8,0; 8,5; 9,0; 9,5; 10,0; 11,0; 12,0; 13,0; 14,5; 15,5 3,0; 3,25; 3,5; 3,75; 4,0; 4,25; 4,5; 5,0; 5,5; 6,0; 6,5; 7,0; 7,5; 8,0; 8,5; 9,0; 9,5; 10,0; 11,0; 12,0; 13,0; 14,5; 15,5 6,5; 7,0; 7,5; 8,0; 8,5; 9,0; 9,5; 11,0; 12,0; 13,0; 14,5; 15,5; 16,5; 18,0; 19,0; 20,0; 21,0; 22,0; 23,0; 24,5; 25,5; 26,5

Minimum differential pressure required Given by the sum of two values: 1. The minimum working p of the Autoflow cartridge 2. The p required for the nominal flow rate to pass through the valve body. This value can be calculated according to the values of kv0,01 stated above and referring to the valve body only.

Example prequired = pAutoflow + pbody = 14 + (G0 /kv0.01)2 = 14 + (2500 /1342)2 = 17,4 kPa Pump head H = pcircuit + prequired Autoflow 125 series dimension 1 with flow rate G0 = 2500 l/h and p Range 14220 kPa:

Coding criteria for Autoflow 120 - 125 series


For correct identification of the device, fill in the form giving series No., size, construction, flow rates and p range.

1st Complete code:

2nd

3rd

4th

5th

6th

7th

8th

9th

{
SERIES

{
SIZE

FLOW RATE AND p RANGE

SERIES

1st

2nd

3rd

The first three digits indicate the series:

120 125

SIZE

5th

The fifth digit indicates the size:

Size Digit

{
1/2" 4 digit S80 S90 m3/h 1,00 digit 1L8 2L0 2L2 2L5 2L7 3L0 3L2 3L5 m3/h 3,75 4,00 4,25 4,50 5,00 5,50 6,00 6,50 digit 3H5 3H7 4H0 4H2 4H5 5H0 5H5 6H0 m3/h 6,50 7,00 7,50 8,00 8,50 9,00 9,50 10,0

Autoflow regulator and ball valve Autoflow regulator

3/4" 5

1" 6

1 1/4" 1 1/2" 7 8

2" 9

2 1/2" 0

FLOW RATE AND p RANGE

7th

8th

9th

The last three digits indicate the flow rate available.

with p range 7-100 kPa


m3/h 0,45 0,50 digit S45 S50 m3/h 0,60 0,70 digit S60 S70 m3/h 0,80 0,90 digit 1S0

with p range 14-220 kPa


m /h 0,12 0,15 0,20 0,25 0,30 0,35 0,40 0,50
3

digit L12 L15 L20 L25 L30 L35 L40 L50

m /h 0,60 0,70 0,80 0,90 1,00 1,20 1,40 1,60

digit L60 L70 L80 L90 1L0 1L2 1L4 1L6

m3/h 1,80 2,00 2,25 2,50 2,75 3,00 3,25 3,50

digit 3L7 4L0 4L2 4L5 5L0 5L5 6L0 6L5

m3/h 7,00 7,50 8,00 8,50 9,00 9,50 10,0 11,0

digit 7L0 7L5 8L0 8L5 9L0 9L5 10L 11L

m3/h digit 12,0 13,5 14,5 15,5 16,5 17,0 18,0 12L 13L 14L 15L 16L 17L 18L

with range p 35-410 kPa


m3/h 0,25 0,35 0,45 0,55 0,70 0,90 1,10 1,40 digit H25 H35 H45 H55 H70 H90 1H1 1H4 m3/h 1,60 1,80 2,00 2,25 2,50 2,75 3,00 3,25 digit 1H6 1H8 2H0 2H2 2H5 2H7 3H0 3H2 m3/h 3,50 3,75 4,00 4,25 4,50 5,00 5,50 6,00 digit 6H5 7H0 7H5 8H0 8H5 9H0 9H5 10H m3/h 11,0 12,0 13,0 14,5 15,5 16,5 18,0 19,0 digit 11H 12H 13H 14H 15H 16H 18H 19H m3/h 20,0 21,0 22,0 23,0 24,5 25,5 26,5 digit 20H 21H 22H 23H 24H 25H 26H

Flow-rate tables for 103 series


Code DN

Minimum working p (kPa)

Flow rates (m3/h)

p range(kPa)

103111 103113 103121 103123 103131 103133 103141 103143 103151 103153 103161 103163 103171 103173 103181 103183 103191 103193

065 065 080 080 100 100 125 125 150 150 200 200 250 250 300 300 350 350

* * * * * * * * * * * * * * * * * *

14 35 14 35 14 35 14 35 14 35 14 35 14 35 14 35 14 35

005180 006260 018220 018220 018220 018220 016610 019770 016122 019154 032 215 038 270 064 338 077 425 095 460 115580 160580 190730

14220 35410 14220 35410 14220 35410 14220 35410 14220 35410 14220 35410 14220 35410 14220 35410 14220 35410

Minimum differential pressure required This is equal to the minimum working p of the Autoflow cartridge (14 or 35 kPa).

Example

Pump head H = pcircuit + prequired

prequired = pAutoflow = 14 or 35 kPa; 0,14 or 0,35 bar

- The flow rates are available in increments of approximately 1 m3/h. - They are available on request with sizes from DN 400 to DN 800, with flow rates up to 3850 m3/h. * They are available on request with 4 ANSI flanges

Coding criteria for Autoflow series 103


For correct identification of the device, fill in the form giving size, p range and flow rate 1st Complete code 2nd 3rd 4th 5th 6th 7th 8th 9th

1 0 3 1

{
SERIES

{ {

SIZE p RANGE

SIZE

5th

The fifth digit indicates the size:

DN Digit

{
FLOW RATE 65 1 80 2 100 3 125 4 150 5 200 250 300 350 6 7 8 9 14220 1 35410 3

p RANGE

6th

The sixth digit indicates the differential pressure range (Range p):

kPa Digit

FLOW RATE

7th

8th

9th

The last three digits indicate the flow rate values. (See tables below and in the following page)

Notes
Installation of AUTOFLOW In air-conditioning systems, Autoflow devices must be installed on the circuit return pipe. Some typical installation examples are given in the following pages. Sizing the system with AUTOFLOW For more detailed information on sizing a system with Autoflow, please refer to the 2nd volume of the Handbooks Caleffi and the technical bulletin Dynamic balancing of hydronic circuits. They give theoretical calculations, numerical examples and notes on the application of the above-mentioned devices in circuits. Medium Autoflow devices can be used with fluids other than water. In this case it is recommended to contact our head office to select the most suitable product.

Applications of Autoflow (

For use in line with various types of heat emitter: radiators, convectors, fan convectors, thermal strips, etc.

To ensure constant flow rates to each emitter.

To regulate the flow rate in each riser or secondary branch of a system.

T.A.

T.A.

To ensure constant flow rates (in any valve position) in circuits with traditional temperature control.

T.A.

To guarantee the design flow rates (with open or closed valve) to the various zones of a system.

To balance circuits for hot water distribution.

Applications of Autoflow (

To create heat exchanger flow balancing by-passes

To balance circuits that serve air conditioning units.

To balance circuits that serve cooling towers.

To limit the hot water flow rate delivered in systems with instantaneous production or limited capacity.

CH1

CH2
To control the amount of delivered water and balance the various circuits in irrigation systems.

To balance plumbing circuits.

To limit the flow rate delivered to each user in remote heating systems.

CH1

CH2
For industrial type applications, such as: - control of water taken from wells, - cooling of machinery at nominal conditions, - balancing of extremely complex distribution systems.

To balance the circuits that serve chiller unit evaporators or condensers.

For further details, consult Applications Sheets Nr. 04301, 04302, 04303 and the technical report "Dynamic Balancing of Hydronic Systems".

SPECIFICATION SUMMARIES
Autoflow version 120 series Automatic flow regulator and ball valve, Autoflow. Suitable to maintain constant flow rate values as the operating conditions in the system change. 1/2 F connections with F union (from 1/2 to 2). Brass body. Replaceable stainless steel inner cartridge. Stainless steel spring. EPDM seals. Chrome plated brass ball. Ball seat and control stem seal in EPDM and PTFE. Special zinc plated steel lever. Brass pressure port plugs. Medium: water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 25 bar. Temperature range 0110C. Working range p 7100 kPa (14220 and 35410 kPa). Range of available flow rates: 0,1215,5 m3/h. Accuracy 5%. Suitable for fitting pressure ports with 1/4 F connections and drain pipe.

Autoflow version 125 series Automatic flow regulator, Autoflow. Suitable to maintain constant flow rate values as the operating conditions in the system change. 1/2 F x F connections (from 1/2 to 2 1/2). Brass body. Replaceable stainless steel inner cartridge. Stainless steel spring. EPDM seals. Brass pressure port plugs. Medium: water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 25 bar. Temperature range -20110 C. Working range p 7100 kPa (14220 and 35410 kPa). Range of available flow rates: 0,1226,5 m3/h. Accuracy 5%. Suitable for fitting pressure ports with 1/4 F connections and drain pipe.

103 series Automatic flow regulator, Autoflow. Suitable to maintain constant flow rate values as the operating conditions in the system change. DN 65 flanged connections (from DN 65 to DN 350) EN1092-1. Cast iron body. Stainless steel inner cartridge. Stainless steel spring. Non-asbestos fibre seals. Medium: water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 16 bar. Temperature range -20110 C. Working range p 14220 kPa (and 35410 kPa). Range of available flow rates: 53850 m3/h. Complete with quick-fit 1/4 pressure test ports, counterflanges, rods and gaskets.

Strainers
Function These devices comprise a combination of a Y strainer and a ball valve (120 series) or a Y strainer alone (125 series). It is possible to inspect, clean and change the inner screen without having to remove the device body from the pipeline. They are suitable to fit pressure ports to check the clog level within the inner strainer and to connect a drain pipe to clean the inner strainer without removing it from the body. In the version with shut-off valve, the ball valve control stem is blow-proof and the reversible closing lever is covered with vinyl. If there are any insulated pipes, the lever can be replaced with an extended 117 series handle.

Product range 120 series Y-strainer with ball valve 125 series Y-strainer sizes 1/2 - 3/4 - 1 - 1 1/4 - 1 1/2 - 2 sizes 1/2 - 3/4 - 1 - 1 1/4 - 1 1/2 - 2 - 2 1/2

Technical specifications series Materials Body: Strainer cartridge: Seals: Ball: Ball seat: Control stem seal: Lever Pressure ports plugs: Performance Medium: Maximum percentage glycol: Maximum working pressure: Working temperature range: Strainer mesh : Connections Pressure ports connections 120 125

brass EN 12165 CW617N stainless steel EPDM brass EN 12165 CW614N, chrome plated PTFE EPDM + PTFE special galvanized steel brass EN 12164 CW614N

brass EN 12165 CW617N stainless steel EPDM brass EN 12164 CW614N

water, glycol solutions 50% 25 bar 0110C 1/21 1/4: 0,87 mm; 1 1/2 and 2: 0,73 mm 1/22 F with union x F 1/4 F

water, glycol solutions 50% 25 bar -20110C 1/21 1/4: 0,87 mm; 1 1/22 1/2 : 0,73 mm 1/22 1/2 F x F 1/4 F

Dimensions E D D

CA LEF FI

CA LEF FI

B Code A 125141 000 1/2" 125151 000 3/4" 125181 000 1 1/2" 125191 000 2" 125101 000 2 1/2 B 101 106 177 176 230

B C 52,5 52,5 105 105 133 D 30 30 38,5 38,5 48,5 F Weight (kg) 1/4" 0,52 1/4" 0,55 1/2" 2,20 1/2" 2,45 1/2 4,30

B Code A C 120141 000 1/2" 156,5 52,5 120151 000 3/4" 159,5 52,5 120181 000 1 1/2" 253 84 253 120191 000 2" 84 E

D 50 50 88 88

E 100 100 140 140

F Weight (kg) 1/4" 1,07 1/4" 1,07 1/2" 4,55 1/2" 4,55

CA LE FF I

CA LE FF I

B B B Code A 120161 000 1" 218,5 120171 000 1 1/4" 220,5 C 68 68 D 66 66 F Weight (kg) E 120 1/2" 2,26 120 1/2" 2,26 Code B A 125161 000 140,5 1" 125171 000 1 1/4" 148 C 102 102 D 33,5 33,5
F

Code

Kv0,01 (l/h)

Mesh (mm)

Code

Kv0,01 (l/h)

Mesh (mm)

120141 120151 120161 120171 120181 120191

000 000 000 000 000 000

1/2 3/4 1 1 1/4 1 1/2 2

1.687 1.725 1665 1723 3913 3969

0,87 0,87 0,87 0,87 0,73 0,73

125141 125151 125161 125171 125181 125191 125101

000 000 000 000 000 000 000

1/2 3/4 1 1 1/4 1 1/2 2 2 1/2

1.688 1.705 1410 1494 3227 3621 6825

0,87 0,87 0,87 0,87 0,73 0,73 0,73

Pressure drop - The kv value indicated refer to the valve complete with strainer

Strainer cleaning The strainer can be cleaned without removing it from the body. 1. By opening the drain valve to allow the dirt to flow into the drain pipe. 2. By performing a reverse flow operation (the water flow hits the strainer from the opposite side). The shut-off valve on the flow pipe shuold be closed before the drain valve is opened.

1.
I FI EFF LEF CAL CA
15018 15011

2.
I EFF CAL
. 20,5 = cod cod. ER = = Q FILT p Range cod
15018

USER SIDE

USER SIDE

15011

15011

A F Weight (kg) 1/2" 0,98 1/2" 1,12


Q = . Range = p

A
m
3

7 mes cod. ER = 20,5 7 mes h

3 /h m h kPa

/h

kPa

FI LEF CA

FI LEF CA

cod.

FILT

FILT

ER = 20,5 7 mes h

Inspecting the strainer The strainer is assembled in such a way to permit an easy removal from the body for inspection or replacement.
FI LEF CA
FFI CALE
150 11

,5 cod. = 20 ER FILT

es 7m h

Application diagrams 120 series

STRAINER

15011

CALEFFI

cod.
cod.

AUTOFLOW
15012

mesh FILTER = 20,57


Q= Range p = 14220 kPa

USER SIDE

CALEFFI

m3 /h

125 series

STRAINER

15011

CALEFFI

cod.
cod.

AUTOFLOW

15012

SPECIFICATION SUMMARIES
Strainer version 120 Series Y-strainer and ball valve. 1/2 F connections with F union (from 1/2 to 2). Brass body. Stainless steel inner strainer; strainer mesh 0,87 mm (for sizes 1/2 to 1 1/4; strainer mesh 0,73 mm for sizes 1 1/2 and 2). EPDM seals. Chrome-plated brass ball. Ball seat and control stem seal in PTFE. Special zinc plated steel lever. Brass pressure port plugs. Medium: water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 25 bar. Temperature range 0110C. Suitable for fitting pressure ports with 1/4 F connections and drain pipe. Strainer version 125 Series Y-strainer. 1/2 F x F connections. Brass body. Stainless steel inner strainer; strainer mesh 0,87 mm (for sizes 1/2 to 1 1/4; strainer mesh 0,73 mm for sizes 1 1/2 to 2 1/2). EPDM seals. Ball seat and control stem seal in EPDM and PTFE. Special zinc plated steel lever. Brass pressure port plugs. Medium: water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 25 bar. Temperature range -20110 C. Suitable for fitting pressure ports with 1/4 F connections and drain pipe.

mesh FILTER = 20,57


Q= Range p = 14220 kPa

USER SIDE

CALEFFI

m3 /h

Accessories

130 FLOMET
Flow rate and differential pressure electronic measuring station. Supplied complete with probes and connection fittings. Can be used for checking the correct operation of Autoflow devices. It can also be used for measuring the flow rate of balancing valves series 131, 135 and of the flow metering device 683 series. Transducer range: 0,05200 kPa. Max. differential pressure: 200 kPa.
Code

100
Pair of fast-plug pressure/temperature test ports. Their special construction allows rapid and accurate measurements while ensuring leaktightness. Can be used for: - checking the working range of Autoflow - checking the clog degree of strainers - checking the heat output of the terminals. Cap cover facing available in: - Red for upstream pressure port - Green for downstream pressure port. Brass body. EPDM seals. Working temperature range: -5130C Max. working pressure: 30 bar.

130000 130001

Supply 230 V (ac) Battery operated

117
Dual-purpose ball valve extended control handle: - valve open/close control possible, even when insulation is fitted, thanks to extended lever; - memory stop position by means of mechanically-locking selector. Useful if you want to create a certain loss of head in the user circuit which needs to be maintained even after subsequently closing and reopening the valve.

Ring nut

100 series connection

FLOMET fast-plug

Syringe

Code Code

100000 1/2, 3/4 1, 1 1/4

1/4

117000 117001

100 538
Drain cock with hose connection. Pair of fittings with fast-coupling syringe for connection of pressure ports to measuring instruments. Female 1/4 threaded connection. Max. working pressure: 10 bar. Max. working temperature: 110C.

Code

538201 538401

1/4 1/2

Code

100010

1/4

We reserve the right to make changes and improvements to the products and related data in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 R.A. FAX +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2007 Calef fi S.P.A.

Thermo-electric actuator
series 656
cert. n 0003

ISO 9001

01042/03 GB
Replaces 01042/00 GB

Function The thermo-electric actuator, in conjunction with convertible thermostatic radiator valves, with radiator and underfloor heating systems distribution manifolds and with zone valves, allows automatic shut-off of the system fluid under the control of a room thermostat or of another electrical switching device.

European Directives conformity CE mark as per Directives 89/336 EC and 73/23 EC.

Reference documentation Leaflet 01051 Convertible thermostatic radiator valves for single and two pipe systems, series 455. Leaflet 01072 Zone valves, series 676. Leaflet 01044 Distribution manifolds for underfloor heating systems, series 668. Leaflet 01065 Distribution manifolds for radiator systems, series 663.

Product range Code 656102 Code 656104 Code 656112 Code 656114 Code 656002 Code 656004 Standard thermo-electric actuator Standard thermo-electric actuator Standard thermo-electric actuator with auxiliary microswitch Standard thermo-electric actuator with auxiliary microswitch Thermo-electric actuator with special connection Thermo-electric actuator with special connection Supply 220 V Supply 24 V (ac) or 24 V (dc) Supply 220 V Supply 24 V (ac) or 24 V (dc) Supply 220 V Supply 24 V (ac) or 24 V (dc)

Technical specification - Materials: - protective cover - colour Normally closed Power supply: Starting current: Working current: self-extinguishing polycarbonate white RAL 9010

Dimensions Code 656102 656104 656112 656114 656002 656004 A B C 41 41 41 41 41 41 A B C

M 30 x 1,5 62 M 30 x 1,5 62 M 30 x 1,5 62 M 30 x 1,5 62 M 30 x 1,5 62 M 30 x 1,5 62

220 V (ac) - 24 V (ac) - 24 V (dc) 1A 220 V (ac) = 13 mA 24 V (ac) - 24 V (dc) = 140 mA - Power consumption: 3W - Rating of auxiliary microswitch contacts (code 656112/114): 0,8 A (220 V) - Level of protection: IP44 (in vertical position) - Product with double insulation: CE - Max ambient temperature: 50C - Operating time: opening and closing from 120 s to 180 s - Supply cable length: 80 cm

Operating principle With power off, the device (actuator + valve) is normally closed. With power on, the valve opens thanks to the action of a wax expansion thermostatic element, directly controlled by a PTC resistor.

Connection table The following table highlights the connections between the various types of valve body and the thermo-electric actuator types.

CALEFFI

65611

65610

2-

220 V -

2-

220 V 3W

CALEFFI

65611

65610

4-

24 V -

4-

24 V -

CALEFFI

CALEFFI

656102 656104 656112 656114


402 455

3W 3W

Constructional details

338
Electrical connections for code 656002, 656004, 656102 and 656104.

339

401

CALEFFI

65611

65610

1 0

2-

220 V -

2-

220 V 3W

CALEFFI

RT
220

65611

65610

4-

24 V -

4-

24 V -

CALEFFI

CALEFFI

656102 656104 656112 656114


223 224

3W 3W

225

221

222

227
BROWN BLUE

*480

*481

*482

*483

*484

663
Electrical connections for code 656112 and 656114
1 0

666 - 668

Electrical connection diagram with pump switching.

676

677

678

N L

The auxiliary microswitch can be used to switch off the pump when heat is not required and the valves are closed. If the power consumption of the pump is greater than the rating of the contacts at 0,8 A, an intermediate relay switch should be used.
BLACK BLACK BROWN BLUE

RT

RT
*
Discontinued

65600

2-

220 V -

CALEFFI

65600

4-

24 V 3
W

CALEFFI

3W

656002 656004

*670 *671

*6750

652

6620

6621

Special connection The different configuration of some of these series of valves makes necessary the modification of the connection geometry of the thermo-electric actuator. Compared to the standard actuators , actuators code 656002 and 656004 are supplied with a longer control spindle . Attention: actuators 656002 and 656004 cannot be connected to a valve body designed for use with actuators 656102, 656104, 656112 and 656114, and vice-versa.

*672

*673

*674

Discontinued

Fluid-dynamic characteristics Hydraulic characteristics table for 656 actuator + valve body.

Installation - The thermo-electric actuator should be tightened by hand without the use of tools. - The thermo-electric actuator should not be dismantled for possible repair. Such interference could lead to permanent damage. - The actuator should always be fitted in a horizontal or vertical position, never upside-down. In chilled water circuits, positions which allow condensation to get into the actuator are not advisable. - For the correct functioning of the actuator, the electrical circuit shoul be sized on the basis of the starting current. - If it is necessary to control multiple zones with actuators in parallel using the same thermostat, the possibility of including an intermediate relay to prevent electrical overload should be considered. - In assemblies with zone valves or manifolds in manifold boxes, a space of at least 20 mm between the thermo-electric actuator and the frame should be left for possible servicing or replacement. Min. 20 mm

656102, 656104, 656112, 656114 +

Series

DN 3/8 1/2 3/4 1 3/8 1/2 3/4 1 1/2 3/4 1 3/8 1/2 3/4 3/8 1/2 3/4 3/8 1/2 3/8 1/2 3/8 1/2 3/4 3/8 1/2 3/4 1/2 3/4 1 1/4 1 1/4 1 1/4 1/21 1/21 1/21

kv0,01 (l/h) 185 210 270 440 110 145 225 420 200/110 200/110 200/110 180 200 255 100 135 200 80 125 85 125 178 267 446 119 178 356 277 138 287 287 287 370 370/100 370/100

pmax * (m w.g.) 25 25 18 12 25 25 18 12 10 10 10 25 25 18 25 25 18 25 25 25 25 25 25 12 25 25 12 12 12 25 25 25 12 12 12

Elbow valve with thermostatic option

338 - 401

Straight valve with thermostatic option

339 - 402

Single / Two pipe

455

Elbow thermostatic

220 - 222

40 20 0 60 80

CALEFFI

Straight thermostatic

221 - 223

40 20 0 60 80

CALEFFI

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Reverse valve Double elbow thermostatic Elbow valve thermostatic (old) Straight valve thermostatic (old) Reverse valve (old)

224 - 227 225

Recommendations for use - When thermo-electric actuators are to be installed on devices which shut-off heat emitters automatically, it is always advisable to use a differential by-pass to control the over-pressure of the system during the partial or total closure of the circuits. For pre-assembled manifolds series 663-668, a differential by-pass with a fixed calibration setting of 2000 mm w.g. is available (code 663000).

480-482

481-482

CALEFFI

CALEFFI

484 663 (ret.) 666 668 (ret.) 676 677 678

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

Underfloor heating manifold

CALEFFI

CALEFFI
10 8 6 4 2 0

CALEFFI

Code 663000

Zone valve (straight / by-pass)

* Maximum pressure differential to ensure correct operation of the actuator

656002, 656004 + 3-way zone valves Valves for underfloor heating systems Elbow valve thermostatic (old) Straight valve thermostatic (old) Single pipe (old)

Series 6750 652 6620 6621 670-672

DN 3/4 1/2 1/2 1/2 3/8 1/2 3/4 3/8 1/2 3/4 1/2

kv0,01 (l/h) 445 140 140 140 178 267 446 119 178 356 247 total

pmax * (m w.g.) 12 25 25 25 25 25 12 25 25 12 12

For installations with series 356-357 dual manifolds, a differential by-pass having a fixed differential pressure setting of 2000 mm w.g. is also available (code 356050).

CALEFFI

Code 356050

Mod. Dep.

356

671-673 674

For centralised installations or installations with rising pipes, a differential by-pass valve is available with an adjustable setting of 1 to 6 m w.g. (series 519).

* Maximum pressure differential to ensure correct operation of the actuator

PN 10

Applications Thermo-electric actuators can be installed: On individual radiators as an alternative to thermostatic controls to allow the radiator valves to be converted from manual to automatic operation, in combination with a room thermostat for each room or zone. In domestic water heating systems, for controlling the temperature of the water heater.
65610
2220 V 3W

CALEFFI

CALEFFI

In loop systems with single pipe valves (series 455).

CALEFFI

In radiator systems, with automatic shut-off of the heat emitter directly at the manifold, with reduced work and cost associated with the electrical connections.

40 20 0 60 80

CALEFFI

RT
CALEFFI

In fan coil systems, if they are to be fitted with valves for automatic shut-off of the fluid. In zoned systems, where reduced dimensions and limited flow rate coefficient at the automatic regulating valve are required.

40 20 0 60 80

CALEFFI

CALEFFI

CALEFFI

RT
CALEFFI Mod. Dep.

357

SPECIFICATION SUMMARIES Series 656002/004/102/104 Thermo-electric actuator. Normally closed. Supply voltage 220 V (ac); 24 V (ac); 24 V (dc). Starting current 1 A. Working current 13 mA (220 V (ac)), 140 mA (24 V (ac) - 24 V (dc)). Rated power consumption 3 W. Level of protection IP44 (in vertical position). Maximum ambient temperature 50C. Operating time of 120 to 180 seconds. Length of supply cable 80 cm. Series 656112/114 Thermo-electric actuator. Normally closed, with auxiliary microswitch. Supply voltage 220 V (ac); 24 V (ac); 24 V (dc). Starting current 1 A. Working current 13 mA (220 V (ac)), 140 mA (24 V (ac) - 24 V (dc)). Rated power consumption 3 W. Level of protection IP44 (in vertical position). Rating of auxiliary microswitch contacts 0,8 A. Maximum ambient temperature 50C. Operating time of 120 to 180 seconds. Length of supply cable 80 cm.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

01043 96
GB

Patented self-cleaning rotameter

Series

669

Dual reading scale The main scale (white) is used when the instrument is new. If when a subsequent reading is taken the float is no longer visible because of deposits on the clear section, the auxiliary scale (yellow) can be used. Because of its special construction, this scale is always clean Scale: 1 to 4 l/min Patented

ISO 9001
Quality Assured Firm

CALEFFI

Heating & Plumbing Components

Applications The rotameter (1 to 4 l/min flow rate meter) can be fitted to distribution manifolds for radiant panel or underfloor heating systems. When fitted to the return manifold it can be used to read off the actual flow rate values in each individual circuit during the commissioning operation and at the same time to achieve perfect balancing of the whole system.

Operation The rotameter has a 3/4 BSP union connection which is attached to the manifold and the sealing is achieved by the O-Ring on the convex spigot. The union connection was chosen to allow for possible dismantling allowing the rotameter to be withdrawn from the front. The lower connection consists of a 3/4 BSP male thread with an internal shape which can be connected to the Series 680 fittings for plastic tubes. Balancing is achieved by operating the adjusting valve on the flow manifold until the set flow rate is reached. The flow rate is read off on the transparent cylinder when the lower part of the float corresponds to the desired value in litres per minute.

Construction The body is made of hot stamped brass and the transparent tube and internal protection are made of Polysulphone. The float indicator is made of Hostaform/PTFE. All the seals are made of silicone rubber. General data Maximum operating pressure: 6 bar Maximum operating temperature: 80C Flow rate range: 1 to 4 l/min Accuracy: 10%

Dimensions code 669050


Es. ch. 30 3/4"

If over a period of time it becomes necessary to check the flow rate or to carry out a new balancing operation and the float is no longer visible because of deposits on the transparent section, an auxiliary graduated scale can be used. If the knurled ring nut is turned to the left a second yellow scale appears which is always clean thanks to an airtight protection which prevents any contact with the water of the system during normal operation. After taking the reading it is important to return the ring nut to its original position (white scale).

3 2 1

CALEFFI

3/4"

Instructions for taking readings if the glass is dirty

Turn the ring nut to the yellow scale

Take the reading

L/MIN

Return the ring nut to the white scale

CALEFFI S.P.A.

28010 FONTANETO D'AGOGNA (NO) S.S.229

TEL.INT. +39 322 8491 R.A.

FAX +39 322 863723

69,5

Pre-assembled distribution manifolds for radiant panel systems


series 668

CALEFFI
01044/05 GB
Replaces 01044/00 GB

Function Distribution manifolds for radiant panel systems are used to optimally distribute the heating fluid in floor heating system circuits and ultimately improve the control of heat emission from the panels. The manifolds ensure that the flow to each circuit is regulated precisely and also control the shut-off, venting and automatic removal of air from the system. Special solutions devised during sizing have also enabled depth to be reduced and connection between manifold and branches facilitated.

Reference Documents - Tech. Broch. 01042 Thermo-electric actuator, series 656 - Tech. Broch. 01041 Automatic flow regulators - Tech. Broch. 01054 Automatic air vent valves, series 5020, 5021 and 5022

Product range Series 668 Pre-assembled distribution manifold for radiant panel systems Sizes 1 and 1 1/4

Technical specification Materials: Flow manifold - body: Micrometric balancing valve - body: - control device upper part: - obturator: - obturator seal: - knob: Return manifold - body: End fitting - body: brass EN 1982 CB753S PA brass EN 12164 CW614N POM EPDM ABS Automatic air vent valve - obturator stem: - spring: - seals: - float: Performance: Medium: Max. percentage of glycol: Max. working pressure: Max. end fitting discharge pressure: Working temperature range: Nr. adjustment curves: Micrometric regulating valve scale: Accuracy: Main connections: Connection centre distance: Outlets: Outlet centre distance:

brass EN 12165 CW617N brass EN 12164 CW614N stainless steel EPDM PP

water, glycol solutions 30% 10 bar 2,5 bar 080C 10 010 5% 1, 1 1/4 F 195 mm 3/4M - 18 50 mm

brass EN 1982 CB753S

Shut-off valve - control device upper part: brass EN 12164 CW614N and PA - obturator stem: stainless steel - obturator: EPDM - springs: stainless steel - seals: EPDM - knob: ABS Ball valve - body: - ball: - handle:

brass EN 12165 CW617N brass EN 12164 CW614N, chrome plated aluminium EN AB 46100

Dimensions

101 1 o 1 1/4

CALEFFI

CALEFFI

CALEFFI

383

195

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

1 o 1 1/4

CALEFFI

CALEFFI
10 8 6 4 2 0

CALEFFI

87

25

3/4

50

L total

27

Code (1) Code (1 1/4) Nr. outlets Total length Weight (kg)

6686C5 6687C5 3 385 7,30

6686D5 6687D5 4 435 7,85

6686E5 6687E5 5 485 8,40

6686F5 6687F5 6 535 9,50

6686G5 6687G5 7 585 10,20

6686H5 6687H5 8 635 10,70

6686I5 6687I5 9 715 11,50

6686L5 6687L5 10 765 12,30

6686M5 6687M5 11 815 13,10

6686N5 6687N5 12 865 13,80

6686O5 6687O5 13 915 14,60

Characteristic components 1 Flow manifold complete with micrometric pre regulating valves with flow curve number indicator. 2 Return manifold complete with shut-off valves that can be used with thermoelectric actuators.

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3 Pair of shut-off ball valves 4 End fittings consisting of a 3-way end fitting, automatic air vent valve and drain cock. 5 Pair of mounting brackets for use with series 659 boxes or direct wall installation.
CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

CALEFFI

Construction details Flow manifold The micrometric regulating valve obturator is made of plastic (POM) and features an upside down V channel (1) to provide greater precision when regulating the flow delivered to the floor system circuits. This solution offers the following advantages with respect to the traditional conically shaped obturator: - greater precision, particularly for the low flow rates usually encountered in this kind of system. - proportional flow rates due to the ability to mould the fluid passage profiles. Exterior shape of the manifolds and mounting brackets The exterior of the manifold deserves special mention because it can be cast in any shape to meet any requirements. In the example shown below, indentations have been created in the manifold to correspond to the plastic pipes exiting from the upper manifold, thus partially accommodating the pipes and reducing their overall thickness. This does not interfere with the pressure loss values because the sections with the indentations (a) are equal to the sections in which the pipes are branched (b) and (c) and where the regulating parts (micrometric regulating and shut-off valve obturators) obstruct the passage of the fluid.

b a c

- absolute dimensional consistency during manufacture due to the die-cast obturator.

Return manifold The return manifold is equipped with manual shut-off valves (1) which are used to shut off the flow to individual circuits. They can also be used with a thermoelectric actuator which, when used with an ambient thermostat, maintains the ambient temperature at the set limits when thermal load varies. The obturator stem (2) is made of polished stainless steel to minimise friction and prevent harmful encrustation from forming. 1 The control device upper part features a double EPDM O-ring seal (3) (4) on the 3 sliding stem. The obturator (5) is made of EPDM and is moulded to 4 optimise the hydraulic characteristics of the valve and reduce noise to a 2 minimum as the fluid passes through and as it gradually opens and closes 5 when operating with a thermo-electric actuator.

The partial accommodation of the pipes in the indentations created in the manifold is further enhanced by the shape of the mounting brackets, which are slanted to create a 25 mm offset between the upper and lower manifolds. As shown in the figure below, this offset positions the pipes so that they perfectly match the profile of the manifold during installation.

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10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

CALEFFI
10 8 6 4 2 0

CALEFFI

25 mm

End fitting and automatic air vent valve The end fitting consists of a fill/drain cock (1) and an automatic air vent valve with a hygroscopic safety cap (2). It has been specifically designed to close the air vent valve automatically if there is water near the vent itself.

CALEFFI

Hydraulic characteristics To determine the hydraulic characteristics of the circuit, we must calculate the total pressure loss experienced by the flow of fluid as it passes through the manifold unit parts and the radiant panel circuits. From a hydraulic standpoint, the manifold unit and circuits can be shown as an assembly of hydraulic elements that are arranged in series and parallel to each other.

PBV

PRM PSV

PTot

PVM P PAnello Loop GTot

GLoop

PBV

PFM

PTot PMV PLoop PSV

PTot PMV

= Total loss at the manifold heads (Flow + Return + Loop) = Localised loss at the micrometric regulating valve loop (loop flow)

PLoop = Loop loss (loop flow)


PBV PFM GLoop PRM PBV

PSV PFM

= Localised loss at the shut-off valve in the panel circuit (loop flow) = Distributed loss of the flow manifold (total flow) = Distributed loss of the return manifold (total flow) = Ball valve loss (total flow)

GTot.

GTot

PRM PBV

PTot = PMV +PLoop + PSV + PFM + PRM + PBV x 2

(1.1)

After noting the hydraulic characteristics of the individual components and the design flows, the total loss can be calculated as the sum of the partial pressure losses of each specific component in the system, as shown in the formula (1.1).

P (mm w.g.) 1000


900 800 700 600 450 400 350 300 250

P (kPa)
9 8 7 6

P (mm w.g.) 1000


900 800 700 600 450 400 350 300 250

P (kPa)
9 8 7 6

10

10

500

4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

500

4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

200

180 160 140 120

200

180 160 140 120

100

90 80 70 60

100

90 80 70 60

50

45 40 35 30 25

0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12

0,5

50

45 40 35 30 25

0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12

0,5

20

18 16 14 12

0,2

20

18 16 14 12

0,2

2500

3000

1200

1400

1600

1800

3500

600

700

800

250

300

350

400

120

140

160

180

450

900

25

30

35

40

45

60

70

80

90

10

0,1

10

0,1

1000

2000

G (l/h)

G (l/h)

Micrometric balancing valve fully open Shut-off valve


- Kv = flow in m3/h for a pressure loss of 1 bar - Kv0,01 = flow in l/h for a pressure loss of 1 kPa

Kv 1,15 2,87

Kv0,01 115 287

Flow manifold 37 outlets Flow manifold 813 outlets Return manifold 37 outlets Return manifold 813 outlets Ball valve
* Average value

Kv 24* 17* 33,5* 23,5* 47,5

Kv0,01 2400* 1700* 3350* 2350* 4750

Example of how to calculate the total pressure loss Suppose we need to calculate the pressure loss of a manifold with three circuits with the following characteristics: Total manifold flow: 400 l/h The flow and pressure loss characteristics of the three piping loops are as follows: Circuit 1 P1= 10 kPa G1= 120 l/h Circuit 2 P2= 15 kPa G2= 200 l/h Circuit 3 P3= 7 kPa G3= 80 l/h

(1.2)

Each segment of the formula (1.1), is calculated using the following relationship: P=G2/Kv0,012 G= flow in l/h P = pressure loss in kPa (1 kPa =100 mm w.g.) Kv0,01 = flow in l/h through the device in question, with a pressure loss of 1 kPa Note that the PTot must be calculated taking into account the circuit with the greatest pressure losses distributed along the entire piping loop of the panel. The circuit in question in our example is circuit 2. Thus: PMV PLoop PSV PFM PRM PBV = = = = = = 2002/1152 = 3 kPa 15 kPa 2002/2872 = 0,5 kPa 4002/24002 = 0,03 kPa 4002/33502 = 0,01 kPa 4002/47502 = 0,007 kPa

} Values obtained disregarding variations due to flow rate delivered to each branch circuit

Using the formula (1.1) we can add all the calculated terms to obtain: PTot= 3 +15 + 0,5 + 0,03 + 0,01 + 0,0071 18,5 kPa Note: We can ignore the three terms for the pressure losses associated with the ball valves and manifolds because their values are so low. Generally speaking, the total pressure loss is fairly close to the pressure loss of the branched circuit of the panel.

4000

100

200

500

500

20

50

Use of the micrometric balancing valve The micrometric balancing valves balance each individual circuit in the panels so that the actual design flow is obtained in each one. Each individual circuit consists of a micrometric balancing valve, panel piping and shut-off valve. The following information must be taken into account in order to calibrate the system correctly: The flow of fluid that must pass through each circuit (design data). The pressure loss that occurs in each circuit in accordance with the flow: PCircuit = PLoop + PSV The available head on the panel circuit or predetermined head: HPredetermined PCircuit In accordance with the passage of the flow GLoop the micrometric valve must ensure an additional pressure loss in all the circuits equal to the difference, indicated as PMV (p micrometric valve). To allow for an eventual increase in flow, the micrometric valve of the circuit with the greatest pressure loss may sometimes be considered as 80% open. Once the two pieces of information, PMV and GLoop, are known for each circuit, the optimal adjustment curve corresponding to the adjustment position of the valve must be chosen from the graph.
+ disadvantaged

(1.3)

= PMV + PLoop + PSV

(1.4)

SV

PCircuit PTot HPredetermined PCircuit


+ disadvantaged

MV

PMV

Example of preregulating the valve Suppose that we need to balance three circuits that have the same pressure loss and loop flow characteristics shown in example (1.2): Since circuit 2 is the most disadvantaged because it experienced the greatest pressure loss in the panel piping, the remaining circuits must be adjusted as follows: Circuit 2 PLoop = 15 kPa G2 = 200 l/h PMV = 2002/1152 = 3 kPa PSV = 2002/2872 = 0,5 kPa With the relationship (1.4): PCircuit = 3 + 15 + 0,5 = 18,5 kPa
+ disadvantaged

Circuit 1 PLoop = 10 kPa G1 = 120 l/h

Circuit 3 PLoop = 7 kPa G3 = 80 l/h

H Predetermined P Circuit +
disadvantaged

P 1 P 2 P MV1

P 3

PSV =1202/2872 = 0,2 kPa with the relationship (1.3): PCircuit = 10 + 0,2 = 10,2 kPa

PSV = 802/2872 = 0,1 kPa with the relationship (1.3): PCircuit = 7 + 0,1 = 7,1 kPa

P MV2

HPredetermined
To adjust circuits 1 and 3, we need the following information to determine the adjustment position of the micrometric valves: Circuit 1 PMV1 = 8,3 kPa G1 = 120 l/h Adjustment position ~ 5.5 Circuit 2 Adjustment position completely open Circuit 3 PMV3 = 11,4 kPa G3 = 80 l/h Adjustment position ~ 3,5

PCircuit

+ disadvantaged
P (mm w.g.) 5000
4500 4000 3500 3000 2500

= 18,5 kPa
P (kPa)
45 40 35 30

50

2000

1800 1600 1400 1200

1000

10 8 6 4 2 0

10 8 6 4 2 0

25 18 16 14 12 9 8 7 6

20

900 800 700 600 450 400 350 300 250

10

1 1,5 2 3 4 5 6 7 8 9 10

500

4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

200

180 160 140 120

100

90 80 70 60

50
12 14 16 18 25 30 35 40 45 60 70 80 90 250 300 350 400 120 140 160

0,5
100
180

200

450

Q (l/h)

500

10

20

50

Hydraulic characteristics of the micrometric valve

P (mm w.g.) 5000


4500 4000 3500 3000 2500

P (kPa)
45 40 35 30 25 18 16 14 12 9 8 7 6

50

2000

1800 1600 1400 1200

10 8 6 4 2 0

10 8 6 4 2 0

20

1000

900 800 700 600 450 400 350 300 250

10

1,5

10

500

4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

200

180 160 140 120

100

90 80 70 60

50
12 14 16 18 25 30 35 40 45 60 70 80 90 120 140 160 180 250 300 350 400

0,5
100 200
450

G (l/h)

Adjustment position Kv Kv0,01

1 0,06 6

1,5 0,09 9

2 0,18 18

3 0,21 21

4 0,27 27

5 0,31 31

6 0,42 42

7 0,53 53

8 0,7 70

9 0,89 89

- Kv = flow in m3/h for a pressure loss of 1 bar - Kv0,01 = flow in l/h for a pressure loss of 1 kPa

SPECIFICATION SUMMARIES
Series 668 Pre-assembled distribution manifold for radiant panel systems with 3 (from 3 to 13) outlets. Brass body. EPDM seals. 1 (1 and 1 1/4) threaded F connections. 3/4"M outlet connections. Medium: water, glycol solutions. Maximum percentage of glycol: 30%. Maximum working pressure 10 bar. Temperature range 080C. End fitting maximum discharge pressure 2,5 bar. Consists of: - Flow manifold complete with micrometric preregulating valves with graduated scale from 1 to10. Accuracy 5%. - Return manifold complete with shut-off valves for use with thermo-electric actuator. - Pair of end fittings consisting of a fitting with automatic air vent and drain cock. - Pair of shut-off ball valves. - Pair of mounting brackets.

500
10 1,15 115

10

20

50

MANIFOLDS AND ACCESSORIES


13 5 4 11 1 2 12 3 7 8 6 9 10 14

40 20 60 80
20 0

40 60 80

15
CALEFFI CALEFFI

CA LEFF I

CALEFFI

CALEFFI

40 20 0 60 80 20 0

40 60 80 20 0

40 60 80

16
10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0

40 20 60 80
20 0

40 60 80

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CA LEFF I

CALEFFI

17
CALEFFI

18

1. Manifold complete with shut-off valves, series 666 2. Manifold complete with micrometric balancing valves, series 667 3. Shut-off ball valve, series 391 4. Autoflow, series 120 5. Strainer, series 120 6. Thermo-electric actuator, series 656 7. Flow meter, code 669050 8. Temperature gauge fitting, code 657050 9. End fitting complete with automatic air vent valve, code 599671

10. End fitting complete with manual air vent valve, code 599672 11. Pair of mounting brackets, code 658100 12. DARCAL fitting, series 680 13. Inspection wall box, series 659 14. Automatic air vent valve, code 59575 15. Mini drain cock, code 337131 16. Eccentric bypass kit, code 668000 17. Double radial end fitting, code 599474 18. Drain cock, code 538400

Flow meter series 669


Function The flow meter is a device that is mounted on the return manifold of panel systems. It instantaneously controls the actual flow values in each individual circuit during the regulating phase, making the balancing operations of the system easier and more accurate. Patented Product range Code 669050 Flow meter Size 3/4

Technical specification Materials: body: brass EN 12165 CW617N measuring spring: stainless steel seals: EPDM transparent cylinder and internal protection: PSU float-indicator: POM/PTFE

Dimensions A

C Medium: Max. percentage of glycol: Max. working pressure: Temperature range: Flow measurement scale: Accuracy: Dual readout scale Connections: water, glycol solutions 30% 6 bar 580 C 14 l/min 10% 3/4 M 18 x 3/4 F nut Code 669050 A 3/4"

3 2 1

CALEFFI

B B 3/4" C 69,5 Weight (kg) 0,146

L/MIN

Operating principle A spring (1) connected to a float (2) is located inside the flow meter. The force applied by the water to the float as it flows through the flow meter is countered in proportion to the force applied by the spring. When the flow becomes stabilised at a particular value, the float reaches a specific position of equilibrium which also serves as an indicator. The system is balanced by moving the calibration valve on the flow manifold until it corresponds to the design flow, which can be read on the graduated scale printed on the transparent cylinder (3). The flow (l/min) readout value corresponds to the lower edge of the float.

Installation

5 4

The flow meter must always be installed in a vertical position with the flow indication arrow pointing up (7) to ensure the greatest accuracy when measuring the flow.

Hydraulic characteristics

6 1 2 3 7

4 3 2 1

P (mm w.g.)
5000
4500 4000 3500 3000 2500

P (kPa)
45 40 35 30 25 18 16 14 12 9 8 7 6 4,5 4,0 3,5 3,0 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

50

2000
1800 1600 1400 1200

20

L/MIN

1000

CALEFFI

900 800 700 600

10

500

450 400 350 300 250

200

180 160 140 120

100

90 80 70 60

250

300

350

400

120

140

160

180

450

60

70

80

90

50

0,5

100

200

G (l/h)

Kv = 1

Kv0,01 = 100

- Kv = flow in m3/h for a pressure loss of 1 bar - Kv0,01 = flow in l/h for a pressure loss of 1 kPa

Construction details Easy installation The flow meter is equipped with a captive nut (4) that is mounted onto the manifold and sealed with an O-ring (5) mounted on the tail piece. The captive nut solution simplifies assembly because it allows the flow meter to be mounted at the front of the manifold without having to change the optimal readout position. Dual readout scale The flow meter is equipped with a spare graduated scale that can be used if flow needs to be checked or the system rebalanced but the float can no longer be seen due to deposits on the transparent cylinder. Turning the knurled nut (6) to the left will bring into view another scale in yellow that always stays clean due to the hermetic seal that prevents water from entering while the system is operating. The nut must be returned into the original position on the white scale after reading the measurement.

SPECIFICATION SUMMARIES
Series 669 Flow meter with float. 3/4M x 3/4F nut threaded connections. Brass body, stainless steel measuring spring, EPDM seals, transparent cylinder and internal protection in PSU, float-indicator in POM/PTFE. Medium: water and glycol solutions. Maximum percentage of glycol 30%. Maximum working pressure: 6 bar. Temperature range 580 C. Flow measurement scale: 14 l/min. Accuracy 10%. Dual readout scale.

500

50

Fitting with self-adjusting diameter for simple and multi-layer plastic pipes series 680
Function The self-adjusting fitting for simple and multi-layer plastic pipes is a mechanical device that allows the pipes, the radiant panel system circuits and the manifolds to be connected easily and securely. This versatile fitting has been specifically designed to adapt to the varying pipe diameters of these types of systems. Patented

Product range Series 6805 . . Self-adjusting fitting for simple and multi-layer plastic pipes Size 3/4

Technical specification Materials:- nut: brass EN 12164 CW614N - adapter: brass EN 12164 CW614N - seals: EPDM - insulation ring: EPDM - olive: PA 66 GF Medium: Max. percentage of glycol: Max. working pressure: Temperature range: water, glycol solutions 30% 10 bar 580C (PEX) 550C (Multilayer)

Characteristic components 1) Adapter 2) Olive 3) Nut

Code

Pipe (mm) internal external

680502 680503 680500 680501 680506 680515 680517 680524 680526 680535 680537 680544 680546 680555 680564 680505

3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4

7,58,0 8,59, 99,5 9,510 9,510 10,511, 10,511,0 11,512,0 11,512,0 12,513,0 12,513,0 13,514,0 13,514,0 14,515,0 15,516,0 1716,0

1214 1214 1416 1214 1416 1416 1618 1416 1618 1618 1820 1618 1820 1820 1820 22,50

Construction details Versatility of pipe-fitting This fitting has been specifically designed to adapt to several pipe diameters. The large variety of simple and multi-layer plastic pipes available on the market and the wide range of permissible tolerances have made it necessary to find an innovative solution for mechanical fittings. While maintaining the nominal dimensions of the fittings currently available on the market, this new solution has been constructed so that the same fitting can be used for pipes with differences on external diameters of up to 2 mm and differences on internal diameters of up to 0,5 mm. Resistance to pull out This adapter offers a high degree of resistance to pull out of pipe. Its special clamping system makes it suitable for every application and ensures a leak tight fit. Low pressure losses The internal profile of the adapter (1) has been shaped to obtain a Venturi effect when the fluid passes through, reducing pressure losses by 20% compared to those created by passages with a similar diameter.

1 2 3 4

Insulation ring The fitting is equipped with a rubber insulation element (2) to prevent contact between the aluminium in the multi-layer pipe and the brass fitting, thus preventing galvanic corrosion generated by the two different metals. Dual O-ring seal The adapter is equipped with two O-ring seals (3) and (4) in EPDM to prevent leaks even when operating at high pressure.

SPECIFICATION SUMMARIES
Series 680 Self-adjusting fitting for simple and multi-layer plastic pipes with internal Venturi effect profile to limit pressure losses. 3/4F connection. Brass nut and adapter, EPDM seals, EPDM insulation ring, PA 66 GF olive coupling. Medium: water and glycol solutions. Maximum percentage of glycol: 30%. Maximum working pressure: 10 bar. Temperature range: 580C (PEX); 550C (Multilayer).

Off-centre bypass assembly with fixed setting code 668000


Function The distribution circuits of the heating fluid in radiant panel systems may be totally or partially shut off by closing the thermoelectric valves inside the manifolds. When the flow decreases, the differential pressure inside the circuit may rise to levels that could cause problems with noise, high rates of fluid speed, mechanical erosion and hydraulic imbalance of the system itself. The differential bypass kit for series 668 manifolds maintains the pressure of the flow and return manifold circuits in balance if the flow changes. The valve can be quickly connected to the series 668 manifolds, reducing overall size to a minimum.

Product range Code 668000 Off-centre bypass assembly with fixed setting Size 1/2 x 1/2

Technical specification Materials: body: nuts: 18 pipe with plate: check valve obturator: spring: seals: gaskets: brass EN 12164 CW614N brass EN 12165 CW617N copper PA stainless steel EPDM asbestos-free fibre water, glycol solutions 30% 10 bar -10110C 25 kPa (2500 mm w.g.) 1/2 M x 1/2 M

Dimensions A

Medium: Max. percentage of glycol: Max. working pressure: Temperature range: Fixed setting pressure: Connections:

137150

B C Code 668000 A 1/2" B 1/2" C 35 Weight (kg) 0,336

Operating principle The by-bass valve contains a non-return obturator connected to a contrast spring. When the fixed setting pressure is reached, the valve obturator gradually opens, recirculating the flow in proportion to the closing of the thermo-electric valves and maintaining a constant differential pressure in the manifold circuit.

Hydraulic characteristics Bypass differential pressure:


P (mm w.g.) 10000
9000 8000 7000 6000

25 kPa (2500 mm w.g.)


P (kPa)
90 80 70 60

100

5000
4500 4000 3500 3000

50
45 40 35 30 25 18 16 14 12

Construction details The differential bypass assemby features a fixed setting that cannot be changed because it does not contain accessible adjustment parts. The small, compact size and offset connections makes this kit particularly easy to mount after installing thermo-electric valves on the manifold. It does not require a larger or deeper zone box than those used for normal manifolds.

2500

2000
1800 1600 1400 1200

20

1200

1400 1600

1000

1800

1000
120 140 160 180 250 300 350 400 450 600 700 800 900

10

G (l/h)

2000

100

200

500

Installation of the differential bypass valve on series 668 manifolds The differential bypass on series 668 manifolds is mounted by following the procedure below: 1) Remove the drain cock (A) from the terminal connector on the upper manifold. 2) Remove the end fitting (B) on the lower manifold. 3) Install the new terminal connector C (code 599474 purchased separately) on the lower manifold. 4) Install the differential bypass (code 668000) and reinstall the drain cock on the new terminal connector (code 599474) of the lower manifold.

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

B
CALEFFI

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

C
CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

CALEFFI
10 8 6 4 2 0

CALEFFI

SPECIFICATION SUMMARIES
Code 668000 Off-centre bypass assembly with fixed setting. 1/2M threaded connections. Brass body and nuts. Copper pipe. PA check valve obturator, stainless steel spring, EPDM seals, asbestos-free fibre gaskets. Medium: water and glycol solutions. Maximum percentage of glycol: 30%. Maximum working pressure: 10 bar. Temperature range: -10110 C. Fixed setting pressure: 25 kPa.

Thermo-electric actuators

656
Thermo-electric actuator. For series 666 and 668 manifolds. Normally closed.
Code

depl. 01042

Technical specification - Materials: - protection shell - colour self-extinguishing polycarbonate RAL 9010 white version with micro: RAL 9002 grey

Voltage (V)

656102 656104

230 224

Normally closed Electric supply: Peak current: Working current:

656
Thermo-electric actuator. For series 666 and 668 manifolds. Normally closed. With auxiliary microswitch
Code

depl. 01042

230 V (ac) - 24 V (ac) - 24 V (cc) 1A 230 V (ac) = 13 mA 24 V (ac) - 24 V (cc) = 140 mA Power consumption: 3W Auxiliary microswitch contacts rating (code 656112/114): 0,8 A (230 V) Protection class: IP 44 (in vertical position) Double insulation construction: CE Max. ambient temperature: 50C Operating time: opening and closing from 120 s to 180 s Length of supply cable: 80 cm

Voltage (V)

656112 656114

230 224

Automatic flow regulators

120 AUTOFLOW version


Combined ball valve and automatic flow regulator unit. Factory set to automatically maintain the flow between 5% of the established value. Can be inspected, cleaned and the internal cartridge replaced without having to remove the valve body from the pipe. Suitable for use with pressure test ports to check operation. Can be connected to a drain pipe. The ball valve has a control stem with anti-slip device and vinyl-covered reversible closure handle. Male union connections.

Technical specification With thermometer scale 080C - 40 mm Max. working pressure: 25 bar Max. working temperature: 110C p range: 14220 kPa Accuracy: 5%

Code

Flow m3/h

Code

Flow m3/h

120961 120961 120961 120961 120961 120961 120961

1L2 1L4 1L6 1L8 2L0 2L2 2L5

1 F x 1 1/4 M 1 F x 1 1/4 M 1 F x 1 1/4 M 1 F x 1 1/4 M 1 F x 1 1/4 M 1 F x 1 1/4 M 1 F x 1 1/4 M

1,20 1,40 1,60 1,80 2,00 2,25 2,50

120971 120971 120971 120971 120971 120971 120971

1L2 1L4 1L6 1L8 2L0 2L2 2L5

1 1/4 F x 1 1/4 M 1 1/4 F x 1 1/4 M 1 1/4 F x 1 1/4 M 1 1/4 F x 1 1/4 M 1 1/4 F x 1 1/4 M 1 1/4 F x 1 1/4 M 1 1/4 F x 1 1/4 M

1,20 1,40 1,60 1,80 2,00 2,25 2,50

Additional flow values are available upon request

120 STRAINER version


Combination Y strainer and ball valve. Can be inspected, cleaned and the internal cartridge replaced without having to remove the valve body from the pipe. Can be used with pressure test ports to check amount of clogging of strainer. Can be connected to a drain pipe to clean the strainer without removing it from the body. The ball valve has a control rod with anti-slip device and vinyl-covered reversible closure lever. Male pipe union connections.

Technical specification With thermometer scale 080C - 40 mm Max. working pressure: 25 bar Maximum working temperature: 110C Strainer mesh size : 0,87 mm

Code

Code

120961 000

1 F x 1 1/4 M

120971 000

1 1/4 F x 1 1/4 M

Manifolds

666
Return distribution manifold complete with shut-off valves suitable for thermo-electric actuators.
Code Connections N. outlets Outlets

Technical specification Materials: Flow manifold - body: - seals:

brass EN 1982 CB753S EPDM

666735 666745 666755 666765 666775 666785

1 1 1 1 1 1

1/4 1/4 1/4 1/4 1/4 1/4

F F F F F F

x x x x x x

3 4 5 6 7 8

3/4 3/4 3/4 3/4 3/4 3/4

M M M M M M

Micrometric balancing valve - body: PA - control device upper part:brass EN 12164 CW614N - obturator: POM - obturator seal: EPDM - knob: ABS Return manifold - body:

brass EN 1982 CB753S

667
Flow distribution manifold complete with micrometric balancing valves and visual display for flow regulation.

Code

Connections

N. outlets

Outlets

Shut-off valve - control device upper part:brass EN 12164 CW614N and PA - obturator stem: stainless steel - obturator: EPDM - springs: stainless steel - seals: EPDM - knobs: ABS

667735 667745 667755 667765 667775 667785

1 1 1 1 1 1

1/4 1/4 1/4 1/4 1/4 1/4

F F F F F F

x x x x x x

3 4 5 6 7 8

3/4 3/4 3/4 3/4 3/4 3/4

M M M M M M

Max. working pressure: Working temperature range: Main connections: Outlets: Outlet centre distance:

10 bar 080 C 1 1/4 F x M 3/4M 50 mm

Shut-off valves

391
Pair of ball valves. Female-male connections with union. Temperature gauge scale 080C, 40 mm. Max. working pressure: 10 bar. Max. working temperature: 100C.
Code

391
Pair of ball valves. Female-male connections with union. With temperature gauge connections. Max. working pressure: 10 bar. Max. working temperature: 100C.
Code

391167 391177

1 x 1 1/4 1 1/4 x 1 1/4

391067 391077

1 x 1 1/4 1 1/4 x 1 1/4

End fittings

5996
End fitting consisting of 3-way end fitting series 5994 with automatic air vent valve code 59575 and drain cock series 538. Max. working pressure: 10 bar. Max. discharge pressure: 2,5 bar. Max. working temperature: 110C.
Code

5996
End fitting consisting of 3-way end fitting series 5994 with manual air vent valve series 337 and drain cock series 538 Max. working pressure: 6 bar. Max. working temperature: 85C.

Code

599671

1 1/4

599672

1 1/4

Mounting brackets

Fittings

658
Pair of mounting brackets for use with boxes 659 series or for direct fixing. Complete with screws and fixings.

3642
Reduction fitting.
Code

364276
Code

1 F x 1 1/4 M

658100 for manifolds series 666, 667 e 668

5991
End fitting. Temperature gauge fitting
Code

657
Temperature gauge fitting. Suitable for manifold outlets. Temperature gauge 080C, 40 mm. Max. working pressure: 6 bar. Max. working temperature: 80C Kv0,01 = 100 (l/h)
Code

599173 599174

1 1/4 F x 3/8 F 1 1/4 F x 1/2 F

5994
Double radial end fitting.
Code

657050

3/4 M x 3/4 F nut

Automatic air vent valve

1 1/4 F x 1/2 F x 3/8 F 599473 599474* 1 1/4 F x 1/2 F x 1/2 F * For use with kit 668000

59575
Automatic air vent valve. Hot forged brass. Max. working pressure: 10 bar. Max. pressure loss: 2,5 bar. Max. working temperature: 110C.
Code

5995
Single radial end fitting.
Code

59575

3/8 M

599573

1 1/4 F x 3/8 F

337
Mini drain cock. Adjustable outlet. PTFE seal on thread. Max. working pressure: 6 bar. Max. working temperature: 85C.
Code

End fittings

337131

3/8 M

5993
End cap.
Code

599370 Drain cock

1 1/4 F

538
Drain cock with hose connection and cap. Max. working pressure: 10 bar. Max. working temperature: 110C.
Code

386
Screw plug with nut for manifold outlets.
Code

538400

1/2 M

386500

3/4

Box

659
Inspection wall box for manifold systems. Wall and floor installations (with 660 series). With lock. In painted sheet steel. Adjustable depth from 110 to 140 mm. For manifolds series 668.

660
Floor installation kit for inspection wall boxes 659 series. Consists of: - 2 supports of 20 cm height, - 2 side panels, - 1 pipe-bending bar.

Code

(h x b x p)

Code

659040 659060 659080 659100 659120

450 450 450 450 450

x x x x x

1400 1600 1800 1000 1200

x x x x x

110140 110140 110140 110140 110140

660040 660060 660080 660100 660120

for for for for for

box box box box box

659040 659060 659080 659100 659120

659 series inspection wall box dimension choice in accordance with the number of outlets

For max n. 17+17 outlets With Autoflow with max n. 15+15 outlets For max n. 14+14 outlets With Autoflow with max n. 11+11 outlets

For max n. 10+10 outlets With Autoflow with max n. 7+7 outlets For max n. 6+6 outlets With Autoflow with max n. 4+4 outlets

1000
CALEFFI

40 20 0 60 80

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

40 20 0 60 80

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.com

1200

600

800

Anti-thermosiphon check valve

CALEFFI
510 series
ACCREDITED

01045/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003

Function The anti-thermosiphon check valve prevents the natural circulation of water in systems where ambient temperature adjustment is carried out by a thermostat connected to the pump. The anti-thermosiphon check valve allows water to reach the heat emitters only when the pump is running: when the pump is not running, the check valve is activated and the system remains separate from the heat generator. The check valve function can be overridden using the corresponding knob and the valve can be used with straight or angled connections by moving the relevant cap.

Product range 510 series Anti-thermosiphon check valve sizes 3/41 1/4

Technical specifications Materials Body: Check valve: Check valve spring: Check valve seal: Cap seal: Control knob: Control knob seal: Control stem seals: Performance Medium: Max. percentage of glycol: Max. working pressure: Min. opening pressure for check valve: Working temperature range: Connections: water, glycol solutions 30% 10 bar 0,02 bar 5110C 3/41 1/4 F brass EN 12165 CW617N PSU stainless steel EPDM EPDM ABS PTFE EPDM

Dimensions D

D D C B A F 82 82 93 E G 92 92 105

Code D A 510500 3/4 87 510600 1 87 510700 1 1/4 103

B 77 77 91

C 43 43 48

E 45 45 52

Mass (kg) 0,65 0,53 0,82

Operating principle The anti-thermosiphon check valve body houses a special hydraulically-shaped check obturator (1). During normal circulation of the medium (while the pump is running), the obturator is pushed against the counter-acting spring inside it, so as to open the channel to allow the medium to flow through. When the pump stops running and the flow of medium stops, the obturator is pushed in the opposite direction, against the seal seat (2), in order to prevent medium backflow. In this way, the obturator completely shuts off the flow of medium through the special contoured seal (3). Knob (4) can be used to deactivate obturator intervention, by turning the control stem (5) by 180 to keep the channel always open.

Construction details Silent operation Thanks to the ogival hydraulic shape of the obturator, the anti-thermosiphon check valve guarantees silent operation. Quick operation The seal positioned on the obturator and the couter-acting spring located inside the obturator ensure there are no delays in closure and guarantee an watertight seal, even when slight back pressure is applied. Non-sensitivity to impurities The sliding parts, thanks to a special coupling, are not sensitive to the small impurities in the water, or to the deposits which can form as a result of prolonged periods of inactivity. Hydraulic characteristics
p (mm w.g.) 3/4" 1" 3/4" 1" 1 1/4" 1 1/4" p (bar) 0,5 0,2 0,1 0,05 Angled connections Straight connections
0,1 0,2 0,5 10 20

1 3 2

5.000 2.000 1.000 500 200 150


1 2 5

0,02 0,015
50 Flow rate (l/min) (m3/h)

10

20

50

100

200

5 Installation

Knob positions In normal position, the valve is in its operating condition, with the check valve active and an opening pressure of 0,02 bar. In open position, the valve overrides its check function.

CA L E FFI

normal

ouvert-offen open

The valve should be installed in accordance with the flow direction indicated by the arrow on the valve body. The valve can be used with straight or angled connections, by moving the third way sealing cap. The valve should be installed with the check valve axis vertically, in accordance with one of the two diagrams provided.

SPECIFICATION SUMMARY
510 series Anti-thermosiphon check valve. Threaded connections 3/4 F (from 3/4 to 1 1/4). Brass body. PSU check valve. Stainless steel spring. EPDM seals. PTFE control knob seal. ABS control knob. Medium water, glycol solutions. Maximum percentage of glycol 30%. Working temperature range 5-110C. Maximum working pressure 10 bar. Minimum opening pressure for check valve 0,02 bar. Angled or straight layout depending on cap position. Check valve override option.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.p.A. S.R.229, N.25 28010 Fontaneto dAgogna (NO) Italy Tel. +39 0322 8491 Fax +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

500

CA L E FFI

normal

ouvert-offen open

Fuel shut-off valve I.S.P.E.S.L. approved


series 541
cert. n 0003

CALEFFI
ISO 9001

01046/03 GB

General Series 541 (98C) fuel shut-off valves are made by Caleffi S.p.A. in compliance with the essential safety requirements of Directive 97/23/CE of the European Parliament and the Council of the European Union for the harmonisation of the member states with regard to pressurised equipment. Function The Caleffi series 541 fuel shut-off valve is a fail-safe safety device with pre-set calibration. This valve, installed in the burner fuel supply pipework, shuts off the flow of fuel when the temperature of the heat-carrying fluid reaches the calibrated value of the sensor. As this is a fail-safe device in the case of damage to the sensor assembly, the fuel supply pipe is automatically closed. This valve can be used with different types of fuel and is also available in versions for superheated water. Sizes 1/22 Sizes DN 65 and DN 80 Sizes DN 65 and DN 80
111 5

Product range Series 541 Threaded version Series 541 Flanged version Series 541 High pressure flanged version

I.S.P.E.S.L.

Technical specification Materials: - threaded body: brass EN 12165 CW617N - flanged body: bronze EN 1982 CB491K - spring: stainless steel - seals: NBR Threaded connections: 1/2, 3/4, 1, 1 1/4, 1 1/2 and 2; FxF Flanged connections PN 16: DN 65 and DN 80 Sensor pocket connection: 1/2 M Calibration temperature: 98C (+0 -5C) I.S.P.E.S.L. approved 120C (+0 -5C) I.S.P.E.S.L. approved 140C (+0 -5C) supplied with declaration of conformity 160C (+0 -5C) supplied with declaration of conformity 180C (+0 -5C) supplied with declaration of conformity Max temperature: - (sensor side): Calibration temperature + 20% - (valve side): 85C Average working temperature: - threaded: 40C - flanged (for gas): 15C Max allowed pressure PS: - threaded: 1 bar - flanged: 0,6 bar Max working pressure: - (sensor side): 12 bar - (valve side) threaded: 50 kPa 11 kPa - (valve side) flanged: - (valve side) high pressure flanged: 50 kPa Suitable for following fuels: diesel oil, fuel oil, methane, LPG PED category: IV Length of capillary connection tube: Code completion (.) 5 or 10 m

Dimensions

A
B

Code A 54104. 1/2" 54105. 3/4" 54106. 1" 54107. 1 1/4" 54108. 1 1/2" 54109. 2"

B 72 72 98 98 134 134

C 38,5 41 50 50 57,5 57,5

D 112,5 112,5 123 123 136 136

E 1/2" 1/2" 1/2" 1/2" 1/2" 1/2"

F 43 43 43 43 43 43

Weight (kg)

1,3 1,3 2,1 1,9 3,6 3,2

With 5 m capillary 0 98C 2 120C 4 140C 6 160C 8 180C

A
B

With 10 m capillary 1 98C 3 120C 5 140C 7 160C 9 180C Code 5416 . 5418 . A DN 65 DN 80 B 180 180 C 120 120

Code completion (0) 0 standard 1 high pressures

D 175 175

E 1/2" 1/2"

F 60 60

Weight (kg)

13,6 15,5

Operating principle If the calibrated temperature is reached, the vapour pressure sensitive element, with the change of state, causes the actuator to be triggered via the capillary tube and the flexible bellows. The resetting is achieved by pressing the pushbutton positioned in the lower part of the valve and protected by a plastic cover.

Fluid-dynamic characteristics
Diesel oil at 20C

P (mm w.g.)
500 300 200 100 50 30 20

P (kPa)
5 3

1/ 2"

3/ 4"

1" 11 /4 "

0,5

11 / 2" 2"

0,3 0,2

10 5

0,1 0,05

1000

2000

5000

100

200

500

40

50

G (kg/h)
Fuel oil (35 C at 50C) at 20C

P (mm w.g.)
1000 500 300 200 100 50 30 20 10

P (kPa)
10 5
4" 3/ 1" 4" / 11 " /2 11 2"

2" 1/

10

20

50

100

200

500

2000

1000

G (kg/h)

Constructional details Reset Should the shut-off device be activated, it has to be reset to its original status as follows: a) Wait until the water temperature falls to 10C below the shut-off temperature (otherwise it will not be possible to reset the device). b) Unscrew the protective cap. c) Press the reset button.

Methane at 15C

P (mm w.g.)
200 100

P (kPa)
2 1

1/ 2"

3/ 4"

5000
0,5 0,3 0,2 0,1 0,05 0,03 0,02

50 30 20 10

1 11 " /4 "

11 /2 2" "

Series 541 valves are positive action (fail-safe) devices; if the sensor element is damaged or the capillary is broken, the fail-safe action consists of an upward movement of the control unit, thus triggering the actuator, which in turn closes the valve. If this situation occurs, the valve must be replaced.

5 3 2

DN DN 65 80

200

300 300

100

G (m3/h)
LPG at 15C

P (mm w.g.)
200 100

P (kPa)
2 1

1/ 2"

3/ 4"

50

11 /4 "

1"

Sensor pocket The compact dimensions of the pocket make it suitable even for small diameter pipework. In addition, its limited height means that it can be positioned vertically, avoiding difficult installation in the case of bends or near elbows. The superheated water version of the pocket is made of stainless steel.

30 20 10 5 3 2

11 /2 2" "

DN DN 65 80

200

100

G (m3/h)

400

10

20

50

400
0,5 0,3 0,2 0,1 0,05 0,03 0,02

10

20

50

10000
3 2 1 0,5 0,3 0,2 0,1

Guideline ratings of boilers (kW)

Certification CE mark Series 541 (98C) fuel shut-off valves meet the requirements of Directive 97/23/CE for pressurised equipment (also referred to as the PED). They are therefore classified in Category IV and granted the CE mark.

Size

Diesel oil

Fuel oil

Methane

LPG

1/2 3/4 1 1 1/4 1 1/2 2 DN 65 DN 80

0.650 1.450 2.550 3.800 5.800 8.100 -

0.290 0.580 1.000 1.500 2.300 3.400 -

60 30 90 45 85 - 170 115 - 230 290 - 580 340 - 690 460 - 930 690 - 1.380

50 60 70 80 145 - 230 230 - 290 460 - 580 520 - 750 1.010 - 1.450 1.100 - 1.590

Installation The fuel shut-off valve must be installed by competent technical personnel qualified in accordance with current legislation. The valve sensor must be installed at the top of the boiler or in the flow pipework within 0,5 m of the boiler, upstream of any other shut-off control.

I.S.P.E.S.L. mark The fuel shut-off valve (in our case the valves calibrated to 98C and 120C) is a component which is I.S.P.E.S.L. approved. Devices of this type are covered by the following types of document: The approval certificate is the document issued by the I.S.P.E.S.L. which attests to the positive result of the tests carried out on the prototype sample and consequently certifies that the series in question has been approved. The document is valid for five years. Every item of the series covered by the certificate, which is manufactured during the five years validity period, is approved for an indefinite period. The bench calibration report is the document confirming the testing of each individual device included in the approved series. The test is carried out in the presence of an I.S.P.E.S.L. inspector who draws up the report after the test has been passed. The document gives the serial number of the valve, which is also to be found on the plate fixed to the valve body. There is only one copy of the report and it is therefore vital for it to be kept with the valve.

The valve is installed in the fuel supply pipework, in line with the flow direction indicated by the arrow, even if it is in the vertical position. When installing the device, appropriate precautions must be taken to ensure that the capillary connecting the sensor to the valve does not become squashed or excessively bent. In order to prevent tampering or accidental leaks of the sensor, the latter must be sealed in the pocket (the seal and the securing wire are included in the package).

References to I.S.P.E.S.L. standards Series 541, calibration 98C Use: hot water systems (temperature < 100C) - section R ed. 82 (R.2.A. 4) The fuel shut-off valve is used in the following types of open vented system: - Hot water heating systems where the safety pipe runs downwards (R3A 1.14). - Hot water heating systems in existence on the date of the coming into force of D.M. 1-12-75, where the safety pipe, although having a minimum diameter greater than 18 mm, does not permit discharge into the atmosphere of the maximum quantity of vapour which can be produced in relation to the capacity of the boiler (R3A 3.1). It is not used in sealed systems: - In secondary circuits in heat exchangers supplied with fluids at a temperature above 100C with controls on the secondary or where automatic on/off control is not excluded. In these cases a temperature relief valve must be installed. Series 541 calibration 120-140-160-180C Use: superheated water systems (temperature >100C) - section H ed. 82 (H.4. 4) The fuel shut-off device is used in all types of open vented and sealed systems, except for those fed by solid fuel or with heat sources other than fire.

9 - S.S. 22 gna (NO) rmici to d'Ago nti idrote Fontane ILE 28010 enti per impia MBUSTIB on CO mp L Co DE VOLA A. VAL R TAZIONE A CALD TA TERCET A DI IN NTI AD ACQU O RACCOL ATIVE VALVOL .L. PLIC PIA COND PER IM OGATA SE CNICHE AP ICA I.S.P.E.S OMOL CAZIONI TE ARE TECN /92 OL 6/8 SPECIFI E CIRC . 8273 DEL OT 1/12/75 DEL DM N. 68/92, PR
: RCHIO 10 A) MA : 541/100/FI LE: PN " IN 1/4 NOMINA MESSI B) SERIE SIONE MINALE: 1 RATURA AM NO C) PRES RI DI TA METRO D) DIAMPO DEI VALO 100C E) CA ERANZA: 95 NE IO TOLL OLOGAZ 997 DI OM CATO del 24-2-1 CERTIFI /97 VIC/678 98C

CALEFFI

S.p.A.
ISTITUTO

origina

le

I.S SUPE .P.E.S.L E SICUR RIORE PREV Dipartim ENZIONE ento di EZZA LAVORO BIELLA - Via Ce rruti, 7 VERBAL E DI INTE DI TARATU RA RCETTA PRESSO ZIONE AL BANCO DI DE RACCOL IL VA L TA R FABBRICA COMBUST LVOLA APPLIC - SPECIF NTE SECO IBILE ND ICAZIO ATIVE NI TE O DEL DM FONTAN 1/12/1 CNICHE 975 ETO D' AG
............ Valvola ............ di ............ ... positiva intercettazion e , I.S.P.E. serie 541/10 del combustib S. 0/ ile ad az La ve rif L. n VIC/678 FI, DN: 1 1/ 4", certi ione /97 ic a de ficato eseguit lla ta ra del 24-2-97. a al ba tu ra de nco co 98 1 n acqu lla va lvo la a alla st at a l'i nt er C, campo di tem va ve intercett nt o in ch iu lori entro i qu peratura di ali av az su ra ve de l di La tem ione. sp os iti nuto pe vo di campo ratura di inter de ve valore no i valori amm nto riscontra es ta ed in minale di taratu si in tolleranz rientra nel ac a rispe ra, dichia tto al III de lla cordo con qu anto ind rato dal costr utt applica Ra cc olt a R icato ne tiv ll'Appen ore L'inamo e del DM 1/12 - Sp ec ific az ion i Te dice /1975. vibilit de cn di ta ra ich lle parti e tu interess A segu ra re ali zz ate e de ito at lla posiz l'identifi del buon esito a m ed ian te pi om ba ione cazione de seguen tu della va lla verifica di ti da taratura, ra . lvola, ve a) march ti: per ngono io punzon b) nume I.S.P.E.S.L.; ati i ro della valvola. OGNA ........

ra: di taratu piegati teriali im ercizio ed i ma le ed es lvo delle va ni di pressione buon esito n uzione izio La costr i per le cond stati eseguiti co valvola a 15 ne sono ido contatto. Sono a idraulica della a ov re dei fluidi finale e la pr otturato o sede ed nserva le il controll co ione fra guarniz ato esercizio bar. ng iale della Il mater anche in prolu . za e tale ch iche di resisten ist caratter Tempera tura no minale dal gnata compa le. ENZE lo se ac pi a or igi na e nea so la co sciar la ido ch e ibile rila La valvo di ta ra tu ra , poss n no di rimento ve rb ale ar tto re sm lib di di ente al In caso unitam verifica ti. ervato sede di duplica va cons ibito in Il verbale per essere es centrale . impianto
I S.p.A. CALEFF e Tecnica ion La Direz

AVVERT

Il Tecn ico I.S .P.E.S. L.

The declaration of conformity is the document issued by the manufacturer which declares that the article in question was made in accordance with the reference standards for I.S.P.E.S.L. approval, but without having had a prototype sample approved. In practice, this is equivalent to a declaration of compliance (i.e. L. 46).

58606.0 3

Application diagram

Max 0,5 m

SPECIFICATION SUMMARIES Series 541. threaded Manual reset fuel shut-off valve. I.S.P.E.S.L. approved and calibrated. Bearing CE mark as per Directive 97/23/CE (calibration 98C). Positive action (fail-safe). Calibration 98C (or 120C). Threaded connections F x F 1/2 (from 1/2 to 2). Sensor pocket connection 1/2 M. Brass body. Stainless steel springs. Capillary length 5 m (or 10 m). Maximum temperature (valve side) 85C. Maximum temperature (sensor side) +20% of calibrated temperature. Maximum working pressure (valve side) using fuel gas 50 kPa. Maximum working pressure (sensor side) 12 bar. Manual reset fuel shut-off valve. Supplied with declaration of conformity. Positive action (fail-safe). Calibration 140C (160C or 180C). Threaded connections F x F 1/2 (from 1/2 to 2). Sensor pocket connection 1/2 M. Brass body. Stainless steel springs. Capillary length 5 m (or 10 m). Maximum temperature (valve side) 85C. Maximum temperature (sensor side) +20% of calibrated temperature. Maximum working pressure (valve side) using fuel gas 50 kPa. Maximum working pressure (sensor side) 12 bar. Series 541. flanged Manual reset fuel shut-off valve. I.S.P.E.S.L. approved and calibrated. Bearing CE mark as per Directive 97/23/CE (calibration 98C). Positive action (fail-safe). Calibration 98C (or 120C). Flanged connections PN 16 DN 65 (or DN 80). Sensor pocket connection 1/2 M. Bronze body. Stainless steel springs. Capillary length 5 m (or 10 m). Maximum temperature (valve side) 85C. Maximum temperature (sensor side) +20% of calibrated temperature. Maximum working pressure (valve side) using fuel gas 11 kPa. Maximum working pressure (sensor side) 12 bar. Manual reset fuel shut-off valve. Supplied with declaration of conformity. Positive action (fail-safe). Calibration 140C (160C or 180C). Flanged connections PN 16 DN 65 (or DN 80). Sensor pocket connection 1/2 M. Bronze body. Stainless steel springs. Capillary length 5 m (or 10 m). Maximum temperature (valve side) 85C. Maximum temperature (sensor side) +20% of calibrated temperature. Maximum working pressure (valve side) using fuel gas 11 kPa. Maximum working pressure (sensor side) 12 bar.

Series 541. flanged for high pressures Manual reset fuel shut-off valve. High pressure version. I.S.P.E.S.L. approved and calibrated. Bearing CE mark as per Directive 97/23/CE (calibration 98C). Positive action (fail-safe). Calibration 98C (or 120C). Flanged connections PN 16 DN 65 (or DN 80). Sensor pocket connection 1/2 M. Bronze body. Stainless steel springs. Capillary length 5 m (or 10 m). Maximum temperature (valve side) 85C. Maximum temperature (sensor side) +20% of calibrated temperature. Maximum working pressure (valve side) using fuel gas 50 kPa. Maximum working pressure (sensor side) 12 bar. Manual reset fuel shut-off valve. High pressure version. Supplied with declaration of conformity. Positive action (fail-safe). Calibration 140C (160C or 180C). Flanged connections PN 16 DN 65 (or DN 80). Sensor pocket connection 1/2 M. Bronze body. Stainless steel springs. Capillary length 5 m (or 10 m). Maximum temperature (valve side) 85C. Maximum temperature (sensor side) +20% of calibrated temperature. Maximum working pressure (valve side) 50 kPa. Maximum working pressure (sensor side) 12 bar.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Adjustable, anti-scale thermostatic mixing valve


series 521
cert. n 0003

CALEFFI
ISO 9001

01050/02 GB
replaces 01050/01 GB

Function The thermostatic mixing valve is used in systems producing domestic hot water. Its function is to maintain the temperature of the mixed water sent to the user constant at the set value when there are variations in the temperature and supply pressure of the hot water and incoming cold water or in the flow rate. These devices are also available with connections complete with filters and check valves on the hot and cold water inlets.

Product range Code 521400/500 Thermostatic mixing valve Code 521503 Thermostatic mixing valve with check valves on the inlets Code 521115/122 Thermostatic mixing valve with filters and check valves on the inlets Sizes 1/2, 3/4 Size 3/4 Sizes 15 mm and 22 mm for copper pipe

Technical specification - Materials: - Body: - Shutter: - Springs: - Seals: Temperature setting range: Temperature stability: Max working pressure (static): Max working pressure (dynamic): Max inlet temperature: Dimensions
C C C

DZR brass EN 12165 CW602N, chrome plated PPO stainless steel EPDM 3065C 2C 14 bar 5 bar 85C

Max inlet pressure ratio (H/C or C/H): Min temperature difference between hot water inlet and mixed water outlet for optimum performance: Complying with EN 1287. Connections:

2:1

15C

- 1/2 and 3/4 M with union tailpiece - 15 mm and 22 mm compression

MIN

MAX 7

MIN

MAX 7

MIN

MAX 7

COLD

COLD

COLD

HOT

HOT

HOT

MIX

MIX

MIX

521122 521115

A
Code A 15 B 79 C D E F 65,5

Code 521400 521500

A 1/2 3/4

B 67 67

C 134 134

F Code 521503 A B C D E F 65,5 3/4 71,5 143 156,5 91

152 86,5 65,5 152 86,5 65,5

521115 521122

158 163,5 98

22 80,5 161

132 66,5 65,5

Legionella-scalding risk In systems producing domestic hot water with storage, in order to avoid the dangerous infection known as Legionella, the hot water must be stored at a temperature of at least 60C. At this temperature it is certain that the growth of the bacteria causing this infection will be totally eliminated. At this temperature, however, the water cannot be used directly. As shown on the diagram opposite, temperatures of more than 50C can cause burning very quickly. For example, at 55C partial burning will occurr in approximately 30 seconds, while at 60C partial burning will occurr in approximately 5 seconds. The time may be reduced by 50 percent or more for children and elderly people. In view of the above, it is necessary to install a thermostatic mixing valve which can: reduce the temperature at the point of use to a value lower than that of storage and suitable for sanitary users. For safety reasons, it is advisable to limit the mixed water temperature to 50C; maintain the temperature constant when the incoming pressure and temperature conditions vary.

Thermal disinfection The diagram opposite shows the behaviour of the bacteria Legionella Pneumophila when the temperature conditions of the water in which it is contained vary. In order to ensure proper thermal disinfection, the values must not be below 60C.

70 60 50 40 30 20 10 0

Instant death of bacteria Death of 90% of bacteria in 2 minutes Death of 90% of bacteria in 2 hours Optimum temperature for growth of bacteria

Surviving bacteria inactive

Temperature - Exposure time


C 75 70 Total burning

Energy saving Energy saving is regulated by D.P.R. n 412/93 (Italy) which makes the use of mixers obligatory on domestic hot water distribution units with storage which are not otherwise regulated, to restrict to 48C, with a tolerance of +5C, the temperature of the water flowing into the distribution system. The purpose of this temperature limitation is to reduce as much as possible passive losses through the distribution system, and to avoid delivery of water which is hotter than required.

65 60 55 50 45

Partial burning

Safety condition. Maximum exposure time at a given temperature

Operating principle The controlling element of the thermostatic mixing valve is a 0,1 temperature sensor fully immersed in the mixed water outlet tube which, as it expands or contracts, continuously establishes the correct proportion of hot and cold water entering the valve. The regulation of these flows is by means of a piston sliding in a cylinder between the hot and cold water passages. Even Code 521400/500 when there are pressure drops due to the drawing off of hot or cold water for other uses, or variations in the incoming temperature, the mixer automatically regulates the water flow to obtain the required temperature.

10

100

1.000

10.000

Seconds

Construction details Anti-scale materials The material used in the construction of the mixer eliminate the problem of jamming caused by lime deposits. All the working parts such as shutter, seats and slide guides are made of a special anti-scale material, with a low friction coefficient, guaranteeing that the performance will be maintained over the long term. Temperature setting and locking The control knob permits temperature setting between minimum and maximum in one turn (360). It also has a tamper-proof system to lock the temperature at the set value.

Option with check valves and filters


MIXED

COLD

HOT

Hydraulic characteristics
p (bar)
1,0 0,5 0,3 0,2 0,1 0,05 0,03 0,02 0,01 0,005 0,003 0,002 0,001
2000 1000 5000 10 20 50 100 200 500

Instant production of hot water The Caleffi series 521 thermostatic mixing valves cannot be used in conjunction with boilers with instant production of domestic hot water. Their addition would compromise the correct operation of the boiler itself.

Installation Before installing the mixer, the pipework must be flushed to ensure that no circulating impurities can harm its operation. It is always advisable to install filters of suitable capacity where the water enters the water system. Mixers codes 521115/22 have filters on the hot and cold water inlets. Series 521 thermostatic mixing valves must be installed in accordance with the installation diagrams given in the instruction sheet or in this leaflet. Series 521 thermostatic mixing valves can be installed in any position, either vertical or horizontal. The following are shown on the body of the mixer: hot water inlet, colour red, marked HOT cold water inlet, colour blue, marked COLD mixed water outlet marked MIX.

Kv = 2,6 (m3/h)

G (l/h)

Use The Caleffi series 521 thermostatic mixing valves, given their flow characteristics, can be installed to control temperature either for individual uses (e.g. washbasin, bidet, shower) or for multiple uses. Warning: wherever an antiscald feature is required, Caleffi series 5212 high performance thermostatic mixing valves need to be installed. In order to guarantee the delivery of water mixed at the set temperature, the thermostatic mixing valves must have a minimum flow rate of 5 l/min.

Check valves In order to prevent undesirable backsiphonage, check valves should be installed in systems with thermostatic mixing valves. Thermostatic mixing valves 521503 and 521115/22 have built-in check valves on the hot and cold water inlets.

Commissioning In view of the special purpose of the thermostatic mixing valve, it must be commissioned in accordance with current standards by qualified personnel using temperature measuring equipment. Use of a digital thermometer is recommended for measurement of the mixed water temperature.

Temperature stability The diagram below shows the stability of the temperature of the mixed water on variation of the temperature of the stored water.
1 00 1 00 1 00

Temperature adjustment The temperature is set to the required value by means of the knob with the graduated scale, on the top of the valve.

24 24

10

11

12

13

14

Temperature setting table

1 10 1

2 min.
90 90 90

10 C

Position
80 80

Min 27

1 32

2 38

3 44

4 49

5 53

6 58

7 63

Max 67

80 70 60

T (C)
70 60 70

Reference conditions: Thot = 68C Tcold = 13C


60

Hot and cold inlet pressure = 3 bar


15

11

12

13

14

50 40 30 20 10 0

50 40 30 20

50 40 30 20

Locking the adjustment After adjustment, the temperature can be locked at the set value by means of the knob. To do this, unscrew the lock nut on the top of the knob, remove the knob itself and put it back in such a way that the internal reference slide locates onto the projection on the shaft below.
2 3 1 MI N MA

hot water mixed water cold water


2 3 4

10

10

Application diagrams System without recirculation System with recirculation

Ball valve Ball valve with check valve Thermometer Backflow preventer Zone valve Pump

MIN

MAX 7

COLD

HOT

Expansion vessel
T

CALEFFI
4

Thermostat Safety valve

System with thermal disinfection


19
18

17

20

21

12

16

22

23

WATCH

24

SPECIFICATION SUMMARIES
Series 521 Adjustable thermostatic mixing valve to EN 1287. Connections 1/2 (or 3/4) M with union tailpieces. DZR alloy body. Chrome plated. Shutter, regulating seats and sliding surfaces in anti-scale plastic. Seals EPDM. Stainless steel spring. Maximum working temperature 85C. Setting range 30C to 65C. Maximum working pressure 14 bar. Tolerance 2C. Provided with tamper-proof setting lock. Series 521 Adjustable thermostatic mixing valve to EN 1287. Connections 3/4 M with union tailpieces. DZR alloy body. Chrome plated. Shutter, regulating seats and sliding surfaces in anti-scale plastic. Seals EPDM. Stainless steel spring. Maximum working temperature 85C. Setting range 30C to 65C. Maximum working pressure 14 bar. Tolerance 2C. Check valve on hot and cold water inlets. Provided with tamper-proof setting lock. Series 521 Adjustable thermostatic mixing valve to EN 1287. Connections for copper pipe 15 mm (or 22 mm). DZR alloy body. Chrome plated. Shutter, regulating seats and sliding surfaces in anti-scale plastic. Seals EPDM. Stainless steel spring. Maximum working temperature 85C. Setting range 30C to 65C. Maximum working pressure 14 bar. Tolerance 2C. Check valve on hot and cold water inlets. Provided with tamper-proof setting lock.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO D'AGOGNA (NO) S.S.229 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

MIX

6
7
6

MIX

3
15

14

13

12
11
10

Convertible radiator valve for one-pipe and two-pipe systems


455 series
ACCREDITED

CALEFFI
01051/10 GB

ISO 9001

FM 21654

ISO 9001 No. 0003

Function The 455 series convertible radiator valve can be used both on one-pipe and two-pipe radiator systems. It is fitted for thermostatic control head, thermo-electric actuator and radio wave control, to automatically regulate the ambient temperature. The valve must be installed only at the radiator lower connection, which is used both as medium inlet and medium outlet.

Reference documentation - Tech. Broch. 01034 Thermostatic radiator valves - Tech. Broch. 01009 Convertible radiator valves with thermostatic option. Thermostatic control heads - Tech. Broch. 01042 Thermo-electric actuator - Tech. Broch. 01118 Radio wave temperature control systems

Product range Valve 455 series Convertible radiator valve for one-pipe and two-pipe systems, for copper, single and multi-layer plastic pipes Thermostatic control heads, thermo-electric actuator and radio wave control 200 series Thermostatic control head with built-in sensor with liquid-filled element, adjustment scale from 0 to 5 corresponding to 0-28C 201 series Thermostatic control head with remote sensor with liquid-filled element, adjustment scale from 0 to 5 corresponding to 0-28C 202 series Thermostatic control head with built-in sensor with liquid-filled element and LCD type ambient temperature indicator, adjustment scale from 0 to 5 corresponding to 0-28C 209 series Tamper-proof / anti-theft cap for use in public places for 200 series and 202 series thermostatic control heads 6561 series Thermo-electric actuator 741 series Electronic actuator with radio receiver - 868 MHz electric supply 230 V (ac) or 24 V (ac/dc) electric supply C-size batteries sizes 1/2, 3/4, 1 right, 1 left

Technical specifications Materials Body: Headwork: Obturator control stem: Spring: Seals: Control knob: Probe holder (deflector): Probe: Lockshield:

brass EN 1982 CB753S, chrome plated brass EN 12164 CW614N stainless steel stainless steel EPDM ABS POM brass EN 1249 CW508L brass EN 12164 CW614N

Performance Medium: water, glycol solutions Max. percentage of glycol: 30% Max. working pressure: 10 bar Working temperature range: 5100C Max. differential pressure (with thermostatic control head): 1 bar Flow rate to radiator for one-pipe version: - with manual control knob: - with thermostatic control head (proportional band 2K): Threaded connections: - radiator: - pipes: Probe length: Probe diameter:

50% 30%

1/2, 3/4, 1 right, 1 left 23 p.1,5, centre distance 40 mm

300 mm - 1/2 and 3/4 11 mm - 1 14 mm Conversion from one-pipe to two-pipe mode and vice versa by means of 10 mm Allen key.

Dimensions

B E D H C

B E D

B C H

Code 455400 455500 455600 455601

A B 1/2 23 p. 1,5 3/4 23 p. 1,5 1 D 23 p. 1,5 1 S 23 p. 1,5

C 40 40 40 40

D 44,5 44,5 44,5 44,5

E 267 267 264 264

F 27,5 27,5 27,5 27,5

G 48 48 48 48

H Mass (kg) 0,61 103 0,62 103 0,65 103 0,65 103

Code 455400 + 200 455500 + 200 455600 + 200 455601 + 200

A B 1/2 23 p. 1,5 3/4 23 p. 1,5 1 D 23 p. 1,5 1 S 23 p. 1,5

C 40 40 40 40

D 44,5 44,5 44,5 44,5

E 267 267 264 264

F 27,5 27,5 27,5 27,5

Operating principle The 455 series valve can be used in both one-pipe and two-pipe distribution systems. In one-pipe systems, radiators are connected in series with respect to the same manifold outlet. However the 455 series valve, when configured for this type of system, sends only the 50% of the flow rate (30% with thermostatic control head) to the radiator, whereas the remaining medium is by-passed and conveyed to the next radiator. In this way the radiators can be shut off individually (for isolation or maintenance) while allowing radiators further

downstream in the system to continue operating. Furthermore, the temperature can be regulated automatically using thermostatic control heads or thermo-electric actuators. In two-pipe systems, all radiators are connected in parallel with respect to all the manifold outlets. In this type of system, the 455 series valve sends to the radiator the 100% of the inlet flow rate. The 455 series valve, in two-pipe mode, incorporates in a single device the dual function of a convertible valve and a lockshield valve, a feature of systems where the medium inlet valve is connected to the radiator upper connection and the lockshield valve to the lower connection.

One-pipe system
To radiator 50% in by-pass 50%

Example: Flow rate in ring G =200 l/h Medium temperature at ring inlet 75C Temperature difference in radiator T = 10C Inlet: By-pass: Heat exchange: To next radiator: 200 l/h - 75C 100 l/h - 75C 100 l/h - 65C 200 l/h - 70C 200 l/h - 70C 100 l/h - 70C 100 l/h - 60C 200 l/h - 65C 200 l/h - 65C 100 l/h - 65C 100 l/h - 55C 200 l/h - 60C

To next radiator 100%

CALEFFI

CALEFFI

75C

70C

65C

Two-pipe system

To return circuit 100%

Example: Flow rate to each radiator G =100 l/h Medium temperature at radiator inlet 75C Temperature difference in radiator T = 10C

To radiator 100%

CALEFFI

CALEFFI

75C

4 3 2

G H Mass (kg) 64 147 0,78 64 147 0,79 64 147 0,82 64 147 0,82

2 3 4

2 3 4

2 3 4

2 3 4

2 3 4

2 3 4

Conversion of valve from one-pipe to two-pipe mode The valve is converted from one-pipe to two-pipe mode by shutting off the by-pass (1) on the mobile sleeve (2) located above the outlet connections (3). The valve is provided preconfigured for one-pipe function, e.g. with the sleeve (2) in the forward position and the by-pass (1) open. To convert the valve from the one-pipe factory configuration to the twopipe configuration, remove the plastic cap (4) and fully unscrew the sleeve (2) to the withdrawn position, by turning the outermost 10 mm hexagonal head screw. To revert to the one-pipe configuration, carry out the procedure in reverse order, fully screwing down the sleeve to the forward position.

Radiator shut-off The radiator can be isolated, for maintenance or other operations, by fully closing the obturator (1) using the knob (2) and, after having removed the plug (4), shutting off the lockshield (3) using the 5 mm Allen key. In this configuration, the flow rate still reaches the heat emitters further downstream via the by-pass (5).

1 2

5 mm

4
4 3 5

1 3

2
10 mm
Two-pipe application

One-pipe application In the one-pipe configuration, the 50% of the flow rate circulating in the ring passes through the radiator (30% with thermostatic control head). The figure below shows the path taken by the medium: the water enters from the right-hand connection (1) and is divided into two parts. One part is by-passed (2) and sent to the next radiator via the left-hand connection (3), the second part enters the radiator passing through the obturator (4) (controlled using the knob (5)) and the probe (6). After the heat exchange, the medium exits the radiator through the apertures outside the probe (7) and, mixing with the by-passed flow rate, reaches the downstream radiator. In the one-pipe configuration, the pipe connections are interchangeable, therefore the valve can be used with flows in opposite directions to those indicated in the figure, in order to adapt it to any installation requirement. Using the 455 series valve in combination with a thermostatic control head, the flow rate entering the radiator is reduced from 50% to 30% of the flow rate arriving at the radiator inlet. This is due to an increase in head losses caused by the continuous modulation of the thermostatic control head.

In the two-pipe configuration, the 100% of the flow rate circulating in the pipe also passes through the heat emitter. In this version it is suggested that the connection (1) nearest the radiator is used as the inlet (flow) connection. The medium enters the radiator through the aperture (2) outside the probe (3), circulates in the radiator to achieve the heat exchange and exits the radiator via the probe (3), passing through the obturator (4) (controlled using the knob (5)) and the outermost connection (6). In the two-pipe configuration, circuit balancing may be required on each radiator by means of the lockshield on each valve. To perform this operation, first remove the plastic end cap (7) and fully screw down the pre-regulation lockshield valve (8) using a 5 mm Allen key. Balancing is achieved by unscrewing the lockshield (8) by the number of turns needed to reach the desired flow rate value.

5 4

5
3 2

8 9 6

5 mm

Hydraulic characteristics 455 series valve, ONE-PIPE configuration: overall hydraulic characteristics of the valve with lockshield valve built into the horizontal sleeve in the fully open position. Head losses measured at the pipe connections.
p (mm w.g.) 1000
4 3 2

455 series valve TWO-PIPE configuration: variation of the overall hydraulic characteristics of the valve with a thermostatic control head during balancing by means of the lockshield valve built into the horizontal sleeve. Proportional band 2K. Head losses measured at the pipe connections.
p (mm w.g.) 1000
900 800 700 600
4 3 2

1 2 3

p (kPa)
9 8 7 6 4,5 4 3,5 3

0,5

1 2 F.O.

p (kPa)
9 8 7 6 4,5 4 3,5 3

500

900 800 700 600

10

10

450 400 350 300 250

500

450 400 350 300 250

200

180 160 140 120 90 80 70 60 45 40 35 30 25

2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

200

100

180 160 140 120 90 80 70 60 45 40 35 30 25

2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

}
250 300 350 400 450 600 700 800 120 140 160 180 900 60 70 80 90

100

50

0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12

0,5

50

0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12


12 14 16 18 25 30 35 40 45 60 70 80 90 120 140 160 180 250 300 350 400 450

0,5

20

18 16 14 12

0,2

20

18 16 14 12

0,2

10
50

0,1
1000

10
10

0,1

100

200

500

20

50

100

200

G (l/h)

Curve 1: knob fully closed, 100% of the flow rate in by-pass.

Kv0.01=145 l/h Kv=1,45 m3/h

No. of lockshield valve turns Kv (m3/h) Kv0.01 (l/h)

0,5 0,31 31

1 0,47 47

1,5 0,55 55

2 0,57 57

2,5 0,58 58

3 0,61 61

F.O. 0,62 62

Curve 2: thermostatic control head instead of the control knob, proportional band 2K, 30% of flow rate to radiator, 70% in by-pass. Curve 3: knob fully open, 50% of flow rate to radiator, 50% in by-pass.

4 3 2

Kv0.01=170 l/h Kv=1,7 m3/h

Kv0.01=200 l/h Kv=2,0 m3/h

455 series valve TWO-PIPE configuration: overall hydraulic characteristics of the valve with lockshield valve built into the horizontal sleeve in the fully open position. Head losses measured at the pipe connections.

455 series valve TWO-PIPE configuration: variation of the overall hydraulic characteristics of the valve with shut-off control knob fully open during balancing by means of the lockshield valve built into the horizontal sleeve. Head losses measured at the pipe connections.
p (mm w.g.) 1000
900 800 700 600 450 400 350 300 250

p (mm w.g.) 1000


900 800 700 600

1
4 3 2

p (kPa)
9 8 7 6 4,5 4 3,5 3 2,5

0,5

1 1,5 2 F.O. p (kPa)


9 8 7 6 4,5 4 3,5 3

10

500

G (l/h)

10

500

450 400 350 300 250

500

200

180 160 140 120 90 80 70 60 45 40 35 30 25

100

1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

200

180 160 140 120 90 80 70 60 45 40 35 30 25

2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

}
250 300 350 400 120 140 160 180 450 12 14 16 18 25 30 35 40 45 60 70 80 90

100

50

0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12

0,5

50

0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12


250 300 350 400 120 140 160 180 450 12 14 16 18 25 30 35 40 45 60 70 80 90

0,5

20

18 16 14 12

0,2

20

10
10

0,1

18 16 14 12

0,2

10
10

0,1

20

50

100

200

500

20

50

100

200

G (l/h)

Curve 1: thermostatic control head instead of control knob, proportional band 2K, 100% of flow rate to radiator. By-pass not active in two-pipe mode. Curve 2: knob fully open, 100% of flow rate to radiator. By-pass not active in two-pipe mode.

4 3 2

Kv0.01=55 l/h Kv=0,55 m3/h

No. of lockshield valve turns Kv (m3/h)

0,5 0,34 34

1 0,62 62

1,5 0,78 78

2 0,91 91

3 1,09 109

F.O. 1,15 115

Kv0.01=110 l/h Kv=1,1 m3/h

Kv0.01 (l/h)

500

G (l/h)

Construction details Versatile installation The 455 series valve can be installed in both new and old systems. The tilted control knob reduces the overall dimensions of the valve, enabling it to be used in confined spaces. The 455 series valve is suitable in the case of building renovations or modernisation of existing heating systems. The system can be constructed by laying out the pipes in the floor slab only or by using the skirting board to route the pipes, leaving the walls intact.

Conversion to thermostatic valve The 455 series valves can be converted to thermostatic valves applying the thermostatic control heads 200, 201 and 202 series instead of the manual control knob. The thermostatic control head can be used with the pipe connections either facing the wall or pointing to the floor. The sensor built into the control head is far enough from the valve body and is able to perform a correct ambient temperature reading, without being influenced by the heat radiated by the valve body itself.

Sizing method Valve sizing To correctly size the system, 455 series valves are chosen by identifying the overall head loss, according to the flow rate, by means of the hydraulic characteristic diagrams in the left-hand column of the previous page. The overall head losses of the valve, used in combination with the thermostatic control head, have been calculated with a proportional band of 2K (EN 215 standard). Probe sizing After having checked with the manufacturer whether the radiator is suitable for installation in a mono or two-pipe system, the correct operation of the valve is guaranteed by the structure of the body and by the body-probe connection, whereas the length of the probe does not affect the performance of the valve and is therefore appropriate. Nevertheless the probe can be extended by means of the 453 series extension, even if this is not strictly necessary. Installation The 455 series valves must always be installed with the probe horizontal, but the pipe connections can face the wall or point towards the floor.
2 3 4

Thermostatic control heads or thermo-electric actuators must always be installed in a horizontal position. The sensible element of thermostatic control heads must never be installed in niches, radiator cabinets, behind curtains or exposed to direct sunlight, otherwise false readings may occur.

Accessories

200

tech. broch. 01034

Thermostatic control head for convertible radiator valves; built-in sensor with liquid-filled element. Graduated scale from 0 to 5 corresponding to a temperature adjustment range from 0C to 28C. With adapter.
Code

200000

201

tech. broch. 01034

Combination with thermo-electric actuators The 455 series valves can be used in combination with the 6561 series thermo-electric actuator, instead of the manual control knob. Combination with thermostatic thermo-electric actuators control heads and

Code

Thermostatic control head for thermostatic and convertible radiator valves; with remote sensor. Graduated scale from 0 to 5 corresponding to a temperature adjustment range from 0C to 28C. Length of capillary pipe: 2 metres. With adapter.

201000

202
Thermostatic control head for radiator valves; built-in sensor with liquid-filled element. With LCD type ambient temperature indicator. Graduated scale from 0 to 5 corresponding to a temperature adjustment range from 0C to 28C. Ambient temperature display range from 16C to 26C. With adapter. Patent application: N MI2007U000405

Code

202000

209

tech. broch. 01034

6561

tech. broch. 01042

Tamper-proof / anti-theft cap for use in public places. To be used with special Allen key code 209001.
Code

209000

Thermo-electric actuator. Normally closed. Electric supply: 230 V (ac) or 24 V (ac)/(dc). Power consumption: 3 W. Protection class: IP 44 (in vertical position). Supply cable: 80 cm. With adapter.

209
Code

tech. broch. 01034


Code

Special Allen key for tightening tamper-proof anti-theft cap. To be used with 209 series tamper-proof caps.

656102 656104

230 V 24 V

209001

741 472
Thermostatic control head with remote adjusting knob, liquid-filled element. Working temperature range: 6-28C. Length of capillary pipe: 2 metres.

tech. broch. 01118

Electronic actuator with radio receiver - 868 MHz. For convertible or thermostatic radiator valves. Can be combined with 740 series systems. Electric supply: 2 x 1,5 V C-size alkaline batteries. Protection class: IP 30.
Code

Code

472000

741000

SPECIFICATION SUMMARY
455 series Convertible one/two-pipe radiator valve, fitted for thermostatic control heads, thermo-electric actuators and radio wave controls. Connections for copper, single and multi layer plastic pipes 23 p.1,5 from 10 to 18 mm. Centre distance 40 mm. Brass body, chrome plated. Manual control knob, white RAL 9010, in ABS. Probe holder (deflector) in POM. EPDM gaskets. Brass probe 300 mm. Brass lockshield valve. Working temperature range 5100C. Maximum working pressure 10 bar. Maximum differential pressure (with thermostatic control head fitted) 1 bar. Convertible from one-pipe to two-pipe mode and vice versa by means of Allen key. Flow rate to radiator for the one-pipe version 50% with manual control knob (30% with thermostatic control head). 200 series Thermostatic control head for thermostatic and convertible radiator valves. Built-in sensor with liquid-filled element. Maximum ambient temperature 50C. Graduated scale from 0 to 5 corresponding to a temperature adjustment range from 0C to 28C, with the possibility of locking and limiting the temperature. Frost protection cut-in at 7C. With adapter. 201 series Thermostatic control head for thermostatic and convertible radiator valves. Remote sensor with liquid-filled element. Maximum ambient temperature 50C. Graduated scale from 0 to 5 corresponding to a temperature adjustment range from 0C to 28C, with the possibility of locking and limiting the temperature. Frost protection cut-in at 7C. With adapter. 202 series Thermostatic control head with temperature indicator. Maximum ambient temperature 50C. Graduated scale from 0 to 5 corresponding to a temperature adjustment range from 0C to 28C, with the possibility of locking and limiting the temperature. Frost protection cut-in at 7C. Ambient temperature display range from 16 to 26C. With adapter. 209 series Tamper-proof / anti-theft cap for thermostatic control head, for use in public places. 6561 series Thermo-electric actuator. Normally closed. Electric supply 230 V (ac); 24 V (ac); 24 V (dc). Starting current 1 A. Working current 13 mA (230 V (ac)), 140 mA (24 V (ac) - 24 V (dc)). Power consumption 3 W. Protection class IP 44 (in vertical position). Maximum ambient temperature 50C. Operating time from 120 to 180 seconds. Length of supply cable 80 cm. Code 741000 Electronic actuator with radio receiver. Electric supply 2 x 1,5 V C-size alkaline batteries. Maximum power consumption 9 mA. Autonomy 1 year. Reception frequency 868 MHz. Protection class IP 30. Insulation class III. Maximum signal range in free air 120 m.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. S.R.229, N.25 28010 FONTANETO DAGOGNA (NO) ITALY TEL. +39 0322 8491 FAX +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

Flow switch

CALEFFI
626 series
cert. n 0003

ISO 9001

01052/07 GB
replaces dp 01052/99

Function The flow switch detects whether there is any flow in the piping and opens or closes an electrical contact. It is normally used in heating, air-conditioning, refrigeration, water treatment, additive pumping and process systems in general. By means of the flow switch it is possible: to control devices such as pumps, burners, compressors, refrigerators, motorized valves; to turn on indicator and alarm devices and regulate equipments for dosing water additives. In heating systems, especially, the flow switch has the objective of switching the burner off in case of a lack of medium circulation within the water heater circuit. A lack of circulation would otherwise impair the operation of the temperature-sensitive safety and protection devices.

Product range Code 626600 Flow switch Code 626009 Set of paddles size 1 M for pipe diameters from 1 to 8

Technical specifications Materials Body: Cover: Microswitch protection casing: Bellows rod and bellows: Paddle for pipes: Microswitch spring: O-Ring seals: Performance Medium: Max. percentage of glycol: Max. working pressure: Medium temperature range: Max. ambient temperature: Connection: Pipe adjustability: Electric specifications Voltage: Current: Protection class: Mark:

Dimensions

brass EN 12165 CW617N self-extinguishing polycarbonate self-extinguishing polycarbonate stainless steel stainless steel stainless steel EPDM

drinking water and glycol solutions 50% 10 bar -30120C 55C 1 M from 1 to 8 B 250 V 15 (5) A IP 54 CE A

Code 626600

A 1"

E B 63

C 86,5

D 134,5

E 74

F Weight (Kg) 60,5 0,930

Operating principle The flow switch is composed of a blade (1) integral with a control rod (2) connected, at the top, to an adjustable counter spring (3). The assembly, by turning around a pin under the action of the water flow, operates a microswitch contained in a protective casing (4). At rest, the counter spring keeps the microswitch contact open. When the increasing flow rate of the medium within the piping becomes equal or greater than the trip flow rate, the thrust (5) on the blade applied (1) by the flow overcomes the opposing force applied by the adjustable spring (3) thus making the microswitch contact close. With a decreasing flow rate, on reaching the trip flow rate values, the flow thrust on the blade is not enough to overcome the opposing force applied by the adjustable spring, so the blade returns to the rest position and the microswitch contact opens. The trip values for closing (increasing flow) and opening (decreasing flow) the microswitch contact can be modified by means of the adjusting screw (6).

Construction details Electric component protection A metal bellows (7) separates the electric and the hydraulic parts. Since this is the most stressed part that must prevent any contact between the medium and the electric components, it is made of stainless steel. Stainless steel is moreover used in the construction of other mechanical components as well so as to make them immune from corrosion. Insulating protective cover The O-Ring seal (8) between the body and the cover, with a protection class of IP 54, ensures operation in particularly damp and dusty places. The insulating protective casing (4) on the microswitch avoids the risk of accidental contact when calibrating. Both the microswitch protection and the cover are made of self-extinguishing V-0 class plastic. Electric switchover contact The electric switchover contact indistinctly permits turning on or off any electric device at the trip flow rate. Setting screw The setting screw (6) allows easy adjustment of the trip flow rate as desired.

4 6 3 8

2 5 1

Certification The water flow switch 626 series is made by Caleffi S.p.A. in compliance with the essential safety requirements of directive 89/336/EC and 72/23/EC of the European Parliament and Council of the European Union.

Hydraulic characteristics

p (mm w.g.)
1000
900 800 700 600

1"

1 1/4"

1 1/2"

2"

p (kPa)
9 8 7 6 4,5 4 3,5 3 2,5

p (mm w.g.)
1000
900 800 700 600

2 1/2"

3"

4"

6"

8"

p (kPa)
9 8 7 6 4,5 4 3,5 3 2,5

10

10

500

450 400 300 250

500

450 400 300 250

350

350

200

180 160 140 120

1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

200

180 160 140 120

1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

100

90 80 70 60

100

90 80 70 60

50

45 40 35 30 25

0,5 0,45
0,40 0,35 0,30 0,25

50

45 40 35 30 25

0,45 0,40 0,35 0,30 0,25

0,5

20

18 16 14 12 0,25 0,30 0,35 0,40 0,45 0,6 0,7 0,8 0,9 1,2 1,4 1,6 1,8 2,5 3,5 4 4,5 12 14 16 18 3 6 7 8 9

0,18 0,16 0,14 0,12

0,2

20

18 16 14 12 60 70 80 90 120 140 160 180 250 300 350 400 450 600 700 800 900 12 14 16 18 2,5 3 3,5 4 4,5 25 30 35 40 45 6 7 8 9

0,18 0,16 0,14 0,12

0,2

10
0,2

0,1
5

10
2

0,1

G (m3/h)

G (m3/h)

Size Kv* (m3/h)

1 10

1 1/4 21

1 1/2 32,5

2 58

Size Kv* (m3/h)

2 1/2 120

3 180

4 350

6 950

8 1950

*The stated Kv values refer to the head loss within the pipes with diameters from 1 to 8 and standard length of 1 m, in which flow switches, equipped with a blade of adequate size, are installed.

1000

0,5

10

20

100

200

500

10

20

50

Reference standards In heating systems with a closed expansion tank, where circulation is ensured by motor pumps, the flow switch must be used to stop the heat supply to the generator when the pumps stop and there is no circulation. Water circulation is indeed essential for safety and temperature-sensitive protection devices such as thermostats, thermal discharge valves and fuel shut-off valves to work properly.

Setting The setting is made by turning the screw (1) clockwise to close the contacts at higher flow rates or anticlockwise for lower values. After making the adjustment, lock the setting screw with the ring nut (2). The operator is protected against accidental contact with electrical parts of the flow switch by an insulating protective cover (3) on the microswitch.

3 2 1

Installation The unit is equipped with a set of blades (1), to be used for different pipe diameters, particularly sized to allow easy installation and minimal head losses. For diameters equal to or greater than 3 (DN 80), it is necessary to add to the preassembled blades in increasing order the long blade (2) (supplied in the package), just cutting it to the size corresponding to the desired diameter. Outline of the microswitch connections: Flow switch used to turn on a device with no flow
LINE 1 COM. 3 N/O 2 N/C INLET
3" -DN 80

Flow switch used to turn on a device with flow


LINE 1 COM. 3 N/O 2 N/C INLET

4" -DN100

5" -DN125

2
1"
6" -DN150

1 1 2" 2

DN175

8" -DN200

The flow switch should preferably be installed on the pipe with the control rod upright, respecting the flow direction indicated by the arrow on the cover and on the body exterior. For blade proper operation it is necessary to install the flow switch by respecting the distance shown on the drawing, using a sleeve welded for total passage.

Trip flow rate (m3/h) for horizontal installation* When the trip flow rate is reached or exceeded with an increasing flow, contacts 1 and 3 of the microswitch close, while contacts 1 and 2 open. On the contrary, when the trip flow rate is reached with a decreasing flow, contacts 1 and 2 close. 1 1/4 1 1/2 Diameter pipe FACTORY SETTING
with increasing flow with decreasing flow with increasing flow with decreasing flow

2 1/2

6 36

1,3

1,7

2,6

6,8

10 16,5 37

20 mm

80 mm

0,9 1,25 1,9

2,2

3,7

5,2

8,5 14,5 33

MAXIMUM SETTING

2,8 3,8

5,9

6,7 11,7 15,8 21,5 43

76

2,7 3,7

5,8

6,6 11,5 15,6 21

70

*For vertical installations, it is necessary to use the setting screw (1) to identify the optimal trip point.

Application diagrams Example of using the flow switch in a plumbing system In systems for instantaneous hot water production with heat exchangers, the flow switch has the job of governing the pump and enabling water circulation in the exchanger primary circuit when required by the user. Instantaneous production of hot water
C F

Mixed production of hot water


C R F

Tmax

Shut-off valve Pump

Pressure reducing valve Check valve

Mixing valve Autoflow

Example of flow switch use in a refrigerating system or heat pump The flow switch is useful on machinery in general where water circulation is considered essential for the equipment to work properly. A typical example is the chiller unit shown in the figure. The two flow switches trip to stop the compressor from working if one of the following conditions occurs: - insufficient or no flow of cooling water in the condenser (danger of overheating) - insufficient or no flow of refrigerated water (danger of ice forming on the evaporator and liquid returning to the compressor suction side).

CHILLER UNIT / HEAT PUMP COMPRESSOR SECONDARY CONDENSER CONDENSER

EXPANSION VALVE

EVAPORATOR

SECONDARY EVAPORATOR

SPECIFICATION SUMMARIES
626 series Flow switch. 1 M connection. CE certificate in accordance with directives 89/336 EC and 72/23 EC. Brass body. Self-extinguishing polycarbonate cover and microswitch protection casing. Stainless steel bellows and bellows rod, paddles for pipes and microswitch spring. EPDM O-Ring seals. Maximum working pressure 10 bar. Medium temperature range -30120C. Maximum ambient temperature 55C. Medium drinking water and glycol solutions; Maximum percentage of glycol 50%. Voltage 250 V. Current 15 (5) A. Protection class IP 54. Pipes adjustability from 1 to 8.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 R.A. FAX +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2007 Calef fi

Safety relief valves for heating and hot water systems


series 311-312-313-314-513-514-527
cert. n 0003

CALEFFI
ISO 9001

01053/03 GB

General Series 311, 312, 313, 314, 513, 514, 527 safety (pressure relief) valves are made by Caleffi S.p.A. in compliance with the essential safety requirements laid down by Directive 97/23/CE of the European Parliament and the Council of the European Union for harmonisation of member States with regard to pressurised equipment. Function Safety relief valves are typically used for controlling pressure on boilers in heating systems, on stored hot water cylinders in domestic hot water systems and in water systems generally. When the calibrated pressure is reached, the valve opens, and, by means of the discharge to atmosphere, prevents the pressure of the system from reaching levels which would be dangerous for the boiler and the components in the system itself. Series 527 valves are fail-safe devices, i.e. they are guaranteed to operate even in the case of wear or breakage of the diaphragm.
111 5

I.S.P.E.S.L.

Product range Series 311 Series 312 Series 313 Series 314 Series 513 Series 514 Series 527 Standard safety relief valve. F-F connections Sizes 1/2 , 3/4 Standard safety relief valve. M-F connections Size 1/2 Standard safety relief valve with pressure gauge or pressure gauge connection. F-F connections Sizes 1/2, 3/4 Standard safety relief valve with pressure gauge or pressure gauge connection. M-F connections Size 1/2 Standard safety relief valve. F-F connections Sizes 1/2x3/4, 1x1 1/4, 1 1/4x 1 1/2 Standard safety relief valve. M-F connections Size 1/2 I.S.P.E.S.L. approved fail-safe safety relief valve. F-F connections Sizes 1/2x3/4, 3/4x1, 1x1 1/4, 1 1/4x 1 1/2

Technical specification Materials: Body: Cover: Control spindle: Obturator seal: Diaphragm: Spring: Control knob: Nominal pressure: Temperature range: Performance: Max opening pressure: Min closing differential: Medium: PED Category:

1/2-3/4; brass EN 12165 CW617N 1-1 1/4; brass EN 1982 CB753S brass EN 12165 CW617N 513-514 (1/2); PA 6 G 30 brass EN 12164 CW614N EPDM EPDM steel UNI 3823 311-312-313-314-513 (1/2)-514; ABS 513 (1 and 1 1/4)-527; PA 6 G 20 PN 10 5110C

527; Pset +10%Pset 311-312-313-513-514; Pset +20%Pset Pset - 20%Pset water, air IV

Calibrations: Series 311 2-2,5-3-3,5-4-5-6-7-8 bar (2 - 5 bar only 3/4) Series 312 2,5-3-3,5-4-6-7-8 bar Series 313 with pressure gauge 2,5-3-6-7-8 bar Series 314 with pressure gauge 2,5-3-6-7-8 bar Series 313 with pressure gauge connection 3 bar Series 314 with pressure gauge connection 3-6 bar Series 513 1,5-2-2,5-3-3,5-6-7-8 bar Series 514 2-2,5-2,7-3-3,5-4-6-7-8 bar Series 527 standard 2,25-2,5-2,7-3-3,5-4-4,5-5-5,4-6 bar Series 527 special 1-1,5-2-7-8 bar

Dimensions

B A F D 65,5 74,5 E 25,5 27,5 B C A Code 3144.. 1/2 1/2 32 E D F E 78 25,5 61 A E C 23 D E 81,5 29,5 A B Code 5144.. 1/2 1/2 D B

A E C Code A B 3114.. 1/2 1/2 19,5 3115.. 3/4 3/4 24

E C 19 D E 78,5 29,5

Code A B C 3124.. 1/2 1/2 23,5

D 69,5

E 25,5

A E
C Code A B 26 5274.. 1/2 3/4 30 5275.. 3/4 1 5276.. 1 1 1/4 39 5277.. 1 1/4 1 1/2 42,5
B

C
D 93 136 166 185 E 33 39,5 48 56

Code A B 5134.. 1/2 1/2

A G F E G 24 24
A E

Code completion
bar

bar

C
bar

Code A B C D E F 3134.. 1/2 1/2 21,5 72 25,5 61 3135.. 3/4 3/4 24 74,5 27,5 61

Code A B 5136.. 1 1 1/4 5137.. 1 1/4 1 1/2

C 38 44

D 144 187

E 48 57,5

1 1,5 2 2,25 2,5

10 15 20 22 25

2,7 3 3,5 4 4,5

27 30 35 40 45

5 5,4 6 7 8

50 54 60 70 80

Safety relief valves for heating systems, I.S.P.E.S.L. approved and calibrated
Series 527 safety relief valves meet the technical requirements of point 2, chapter R.2.A. of section R 1982 Edition, technical application specification of Part II - D.M.:1/12/75. Operating details Discharge overpressure <10% The full discharge capacity of the valve must be reached at pressure values Ps<1,1Pset. This characteristic, combined with the particular range of calibration values, enables the correct valve to be selected for the maximum working pressure value of the system or the boiler. Closing differential <20% The valve must close again within pressure values Pr>0,8Pset. This characteristic makes it possible to limit the water loss from the system if the valve opens. Fail-safe action The performance of the valve is guaranteed even in the case of wear or breakage of the diaphragm. Increased outlet diameter This feature makes the reduction in the discharge capacity or the variation in behaviour on opening or closing negligible due to the fitting of discharge pipework.

TECHNICAL DATA SERIES 527


Size Outl. (mm) Nett area (cm2) Calibn. Nom.disch. Clos. press. press. press. (bar) (bar) (bar) Outfl. Disch. flow coeff. rate K W (kg/h) Maximum boiler rating (kW) (kcal/h)

Certification CE mark Series 527 safety relief valves meet the requirements of Directive 97/23/CE for pressurised equipment (also referred to as the PED). They are therefore classified in Category IV and granted the CE mark.

1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4

15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 32 32 32 32 32 32 32 32 32 32 32 32 32 32 32

1,767 1,767 1,767 1,767 1,767 1,767 1,767 1,767 1,767 1,767 1,767 1,767 1,767 1,767 1,767 3,1416 3,1416 3,1416 3,1416 3,1416 3,1416 3,1416 3,1416 3,1416 3,1416 3,1416 3,1416 3,1416 3,1416 3,1416 4,9087 4,9087 4,9087 4,9087 4,9087 4,9087 4,9087 4,9087 4,9087 4,9087 4,9087 4,9087 4,9087 4,9087 4,9087 8,0424 8,0424 8,0424 8,0424 8,0424 8,0424 8,0424 8,0424 8,0424 8,0424 8,0424 8,0424 8,0424 8,0424 8,0424

1 1,50 2 2,25 2,50 2,70 3 3,50 4 4,50 5 5,40 6 7 8 1 1,50 2 2,25 2,50 2,70 3 3,50 4 4,50 5 5,40 6 7 8 1 1,50 2 2,25 2,50 2,70 3 3,50 4 4,50 5 5,40 6 7 8 1 1,50 2 2,25 2,50 2,70 3 3,50 4 4,50 5 5,40 6 7 8

1,10 1,65 2,20 2,75 2,97 3,30 3,85 4,40 4,95 5,50 5,94 6,60 7,70 8,80 1,10 1,65 2,20 2,75 2,97 3,30 3,85 4,40 4,95 5,50 5,94 6,60 7,70 8,80 1,10 1,65 2,20 2,75 2,97 3,30 3,85 4,40 4,95 5,50 5,94 6,60 7,70 8,80 1,10 1,65 2,20 2,75 2,97 3,30 3,85 4,40 4,95 5,50 5,94 6,60 7,70 8,80

0,80 1,20 1,60 2,00 2,16 2,40 2,80 3,20 3,60 4,00 4,32 4,80 5,60 6,40 0,80 1,20 1,60 2,00 2,16 2,40 2,80 3,20 3,60 4,00 4,32 4,80 5,60 6,40 0,80 1,20 1,60 2,00 2,16 2,40 2,80 3,20 3,60 4,00 4,32 4,80 5,60 6,40 0,80 1,20 1,60 2,00 2,16 2,40 2,80 3,20 3,60 4,00 4,32 4,80 5,60 6,40

0,79 0,79 0,79 0,79 0,79 0,79 0,79 0,79 0,79 0,79 0,79 0,79 0,79 0,79 0,79 0,67 0,67 0,67 0,67 0,67 0,67 0,67 0,67 0,67 0,67 0,67 0,67 0,67 0,67 0,67 0,88 0,88 0,88 0,88 0,88 0,88 0,88 0,88

140,38 175,73 211,17 226,39 246,36 261,76 282,35 318,09 353,93 386,60 425,91 456,89 483,25 558,42 628,22 211,66 264,95 318,38 341,33 371,45 394,66 425,70 479,59 533,63 582,89 642,16 688,87 728,61 841,95 947,19 434,38 543,74 653,40 700,49 762,30 809,94 873,65 984,23

81,6 102,1 122,7 131,6 143,2 152,2 164,1 184,9 205,8 224,8 247,6 265,6 281,0 324,7 365,3 123,0 154,0 185,1 198,4 215,9 229,4 247,5 278,8 310,3 338,9 373,4 400,5 423,6 489,5 550,7 252,5 316,1 379,9 407,3 443,2 470,9 508,0 572,3 636,8 695,6 766,3 822,0 869,5 1004,7 1130,3 348,0 435,6 523,4 561,2 610,7 648,8 699,9 788,5 877,3 958,3 1055,8 1132,6

70.100 87.800 105.500 113.100 123.100 130.800 141.100 159.000 176.900 193.200 212.900 228.400 241.600 279.200 314.100 105.800 132.400 159.100 170.600 185.700 197.300 212.800 239.700 266.800 291.400 321.000 344.400 364.300 420.900 473.500 217.100 271.800 326.600 350.200 381.100 404.900 436.800 492.100 547.500 598.100 658.900 706.800 747.600 863.900 971.900 299.200 374.500 450.100 482.500 525.100 557.900 601.800 678.000 754.400 824.000 907.800 973.800

2,475 1,80

I.S.P.E.S.L. mark The series 527 safety relief valve is a component which is I.S.P.E.S.L. approved. Devices of this type are covered by the following types of document: The approval certificate is the document issued by the I.S.P.E.S.L., which attests to the positive result of the tests carried out on the prototype sample and consequently certifies that the series in question has been approved. The document is valid for five years. Every item of the series covered by the certificate which is manufactured during the five years validity period is approved for an indefinite period. The bench calibration report is the document confirming the testing of each individual device included in the approved series. The test is carried out in the presence of an I.S.P.E.S.L. inspector who draws up the report after the test has been passed. The document gives the serial number of the valve, which is also to be found on the plate fixed to the valve body. There is only one copy of the report and it is therefore vital for it to be kept with the valve.

2,475 1,80

2,475 1,80

0,88 1095,13 0,88 1196,22 0,88 1317,87 0,88 1413,72 0,88 1495,28 0,88 1727,88 0,88 1943,86 0,74 0,74 0,74 0,74 598,47 749,13 900,22 965,10

229 O) - S.S. ogna (N QUA eto d'Agnti idrotermici TI AD AC Fontan IMPIAN 28010 nenti per impia R PE R A ARIA. RACCOLTA DM Compo CUREZZ L O A DI SI CALDA E AD COND ICATIVE DE SE VALVOL A PL HE AP OLOGAT IC OM CN LA TE 5 VALVOIFICAZIONI 1/12/7 - SPEC
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CALEFFI

S.p.A.

original e

2,475 1,80

0,74 1050,25 0,74 1115,89 0,74 1203,66 0,74 1356,02 0,74 1508,81 0,74 1648,09 0,74 1815,69 0,74 1947,74 0,74 2060,11 0,74 2380,57 0,74 2678,14

DO 20 3/4

1197,9 1.030.000 1384,3 1.190.200 1557,3 1.339.000

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Il Tecn ico I.S.P. E.S.L.

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58856.0 2

Standard safety relief valves


The series 311, 312, 313, 314, 513 and 514 standard safety relief valves are used in heating systems, domestic hot water systems protecting the hot water cylinder and in water systems generally.

Heating systems
Standard safety relief valves, in compliance with Italian regulations, can be applied to heat generators of capacity below 35 kW.

TECHNICAL DATA SERIES 311-312-313-314


Size Outl. (mm) Nett area (cm2) Calibn. Nom.disch. Clos. press. press. press. (bar) (bar) (bar) Outfl. Disch. flow rate coeff. W (kg/h) K Maximum boiler rating (kW) (kcal/h)

1/2 1/2 1/2 1/2 1/2 1/2 1/2 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4

13 13 13 13 13 13 13 13 13 13 13 13 13 13 13 13

1,327 1,327 1,327 1,327 1,327 1,327 1,327 1,327 1,327 1,327 1,327 1,327 1,327 1,327 1,327 1,327

2,50 3 3,50 4 6 7 8 2 2,50 3 3,50 4 5 6 7 8

3,00 3,60 4,20 4,80 7,20 8,40 9,60 2,40 3,00 3,60 4,20 4,80 6,00 7,20 8,40 9,60

2,00 2,40 2,80 3,20 4,80 5,60 6,40 1,60 2,00 2,40 2,80 3,20 4,00 4,80 5,60 6,40

0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5

124,4 142,17 161,39 178,25 248,81 284,35 322,78 106,63 124,4 142,17 161,39 178,25 213,26 248,81 284,35 322,78

72,3 82,5 93,6 103,3 144,6 165,2 187,5 61,8 72,3 82,5 93,6 103,3 123,6 144,6 165,2 187,5

62.200 71.000 80.600 89.000 124.400 142.100 161.300 53.300 62.200 71.000 80.600 89.000 106.600 124.400 142.100 161.300

311425 1/2 2,5 bar 311430 1/2 3 bar 311435 1/2 3,5 bar 311440 1/2 4 bar 311460 1/2 6 bar 311470 1/2 7 bar 311480 1/2 8 bar 311520 3/4 2 bar 311525 3/4 2,5 bar 311530 3/4 3 bar 311535 3/4 3,5 bar 311540 3/4 4 bar 311550 3/4 5 bar 311560 3/4 6 bar 311570 3/4 7 bar 311580 3/4 8 bar

313425 1/2 2,5 bar 313430 1/2 3 bar 313460 1/2 6 bar 313470 1/2 7 bar 313480 1/2 8 bar 313525 3/4 2,5 bar 313530 3/4 3 bar 313560 3/4 6 bar 313570 3/4 7 bar 313580 3/4 8 bar 313432 1/2 3 bar 313532 3/4 3 bar

312425 1/2 2,5 bar 312430 1/2 3 bar 312435 1/2 3,5 bar 312440 1/2 4 bar 312460 1/2 6 bar 312470 1/2 7 bar 312480 1/2 8 bar

314425 1/2 2,5 bar 314430 1/2 3 bar 314460 1/2 6 bar 314470 1/2 7 bar 314480 1/2 8 bar

314432 1/2 3 bar 314462 1/2 6 bar

TECHNICAL DATA SERIES 513-514


Size Outl. (mm) Nett area (cm2) Calibn. Nom.disch. Clos. press. press. press. (bar) (bar) (bar) Outfl. Disch. flow coeff. rate K W (kg/h) Maximum boiler rating (kW) (kcal/h)

1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/2

15 15 15 15 15 15 15 15 15 15

1,767 1,767 1,767 1,767 1,767 1,767 1,767 1,767 1,767 1,767

1,50 2 2,50 2,70 3 3,50 4 6 7 8

1,80 2,40 3,00 3,24 3,60 4,20 4,80 7,20 8,40 9,60

1,20 1,60 2,00 2,16 2,40 2,80 3,20 4,80 5,60 6,40

0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5

117,80 141,99 165,65 176,70 189,32 214,90 237,35 331,31 378,64 429,81

68,3 82,3 96,2 102,4 110,0 124,6 137,6 192,5 220,1 249,8

58.900 70.900 82.800 88.300 94.600 107.400 118.600 165.600 189.300 214.900

513415 1/2 1,5 bar 513420 1/2 2 bar 513425 1/2 2,5 bar 513430 1/2 3 bar 513435 1/2 3,5 bar 513460 1/2 6 bar 513470 1/2 7 bar 513480 1/2 8 bar

514420 1/2 2 bar 514425 1/2 2,5 bar 514427 1/2 2,7 bar 514430 1/2 3 bar 514435 1/2 3,5 bar 514440 1/2 4 bar 514460 1/2 6 bar 514470 1/2 7 bar 514480 1/2 8 bar

Domestic hot water systems


Series 513 and 514 valves comply with the requirements of Section R for safety standards of equipment containing hot liquids under pressure (Italian standard): in the case of water heaters intended for domestic use, the expansion system protecting the vessel should consist of a vent valve, understood as a counter-weight or spring valve whose outlet has a diameter, in mm, not less than V 5

where V is the volume of the heater in litres, with a minimum of 15 mm. To illustrate the above, see the table with the hot water storage capacity limits for each type of valve.

TECHNICAL DATA SERIES 513-514


Size Outl. (mm) Nett area (cm2) Calibn. Nom.disch. press. press. (bar) (bar) Clos. press. (bar) Capacity of heater (l)

513460 1/2 6 bar 513470 1/2 7 bar 513480 1/2 8 bar

514460 1/2 6 bar 514470 1/2 7 bar 514480 1/2 8 bar

1/2 1/2 1/2 1 1 1 1 1/4 1 1/4 1 1/4

15 15 15 25 25 25 32 32 32

1,767 1,767 1,767 4,9087 4,9087 4,9087 8,0424 8,0424 8,0424

6 7 8 6 7 8 6 7 8

7,20 8,40 9,60 7,20 8,40 9,60 7,20 8,40 9,60

4,80 5,60 6,40 4,80 5,60 6,40 4,80 5,60 6,40

1.000 1.000 1.000 3.000 3.000 3.000 5.000 5.000 5.000

513660 1 6 bar 513670 1 7 bar 513680 1 8 bar 513760 1 1/4 6 bar 513770 1 1/4 7 bar 513780 1 1/4 8 bar

Water systems
These safety relief valves can also be used for discharging cold water; in this case, the discharge capacities indicated are the results of experimental testing, without the use or any conversion formula for fluids of different types.

TECHNICAL DATA SERIES 513


Size Outl. (mm) Nett area (cm2) Calibn. Nom.disch. press. press. (bar) (bar) Clos. press. (bar) Capacity of heater (l)

1 1 1 1 1 1 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4

25 25 25 25 25 25 32 32 32 32 32 32

4,9087 4,9087 4,9087 4,9087 4,9087 4,9087 8,0424 8,0424 8,0424 8,0424 8,0424 8,0424

2,50 3 3,50 6 7 8 2,50 3 3,50 6 7 8

3,00 3,60 4,20 7,20 8,40 9,60 3,00 3,60 4,20 7,20 8,40 9,60

2,00 2,40 2,80 4,80 5,60 6,40 2,00 2,40 2,80 4,80 5,60 6,40

8,3 8,7 9,1 10,5 11,5 12,3 13,2 13,8 14,1 17,5 18,6 19,4

513625 1 2,5 bar 513630 1 3 bar 513635 1 3,5 bar 513660 1 6 bar 513670 1 7 bar 513680 1 8 bar 513725 1 1/4 2,5 bar 513730 1 1/4 3 bar 513735 1 1/4 3,5 bar 513760 1 1/4 6 bar 513770 1 1/4 7 bar 513780 1 1/4 8 bar

Certification CE mark Series 311, 312, 313, 314, 513 and 514 safety relief valves meet the requirements of Directive 97/23/CE for pressurised equipment (also referred to as the PED). They are therefore classified in Category IV and granted the CE mark.

Installation Before installing a safety relief valve, correct sizing must be carried out by specialist technical personnel in accordance with the current legislation governing the specific applications. It shall not be used other than for its stated purpose. Safety relief valves must be installed by competent technical personnel qualified in accordance with current legislation. The safety relief valve must be installed in line with the flow direction indicated by the arrow on the valve body. Heating system The safety relief valve bust be installed on the top of the boiler or in the flow pipework at a distance of not more than one metre from the boiler (section R). The connecting pipework between the safety relief valve and the boiler must not be interrupted.

Fitting The safety relief valve can be fitted vertically or horizontally, but not upside down. This prevents deposits of impurities from affecting correct functioning.

Correct installations

Max 1 m
Incorrect installation

Domestic hot water system The safety relief valve must be installed close to the hot water storage, taking care not to fit any shut-off devices between the valve and the storage cylinder.

Discharge pipework The discharge pipework from the safety relief valve must be fitted in such a way as not to prevent the correct operation of the valve and not to cause damage or injury. In accordance with current legislation, the safety relief valve discharge must be visible and carried in suitable collection pipework. As shown in the diagrams, it is advisable to install a tundish directly in the discharge pipework for low capacity valves, as diagram 1. In the case of larger capacities, proceed as shown in diagram 2.

40
20 60

80

Diagram 1

Diagram 2

SPECIFICATION SUMMARIES Series 311


Standard diaphragm safety relief valve. Bearing CE mark as per Directive 97/23/CE. Threaded connections 1/2 F x 1/2 F (1/2x1/2 and 3/4x3/4). Calibration 2,5 bar (calibrations available: 2,5 3 3,5 4 6 7 8 for 1/2 and 3/4, 2 - 5 bar only for 3/4). Maximum temperature 110C. Brass body. Diaphragm and seal in EPDM. Control knob in ABS.

Series 312
Standard diaphragm safety relief valve. Bearing CE mark as per Directive 97/23/CE. Threaded connections 1/2 M x 1/2 F Calibration 2,5 bar (calibrations available: 2,5 3 3,5 4 6 7 8). Maximum temperature 110C. Brass body. Diaphragm and seal in EPDM. Control knob in ABS.

Series 313
Standard diaphragm safety relief valve with pressure gauge connection. Bearing CE mark as per Directive 97/23/CE. Threaded connections 1/2 F x 1/2 F (1/2 and 3/4). Calibration 3 bar. Maximum temperature 110C. Brass body. Diaphragm and seal in EPDM. Control knob in ABS.

Series 313
Standard diaphragm safety relief valve with pressure gauge. Bearing CE mark as per Directive 97/23/CE. Threaded connections 1/2 F x 1/2 F (1/2 and 3/4). Calibration 2,5 bar (calibrations available: 2,5 3 6 7 8). Maximum temperature 110C. Brass body. Diaphragm and seal in EPDM. Control knob in ABS.

Series 314
Standard diaphragm safety relief valve with pressure gauge connection. Bearing CE mark as per Directive 97/23/CE. Threaded connections 1/2 M x 1/2 F. Calibration 3 bar (calibrations available 3 and 6). Maximum temperature 110C. Brass body. Diaphragm and seal in EPDM. Control knob in ABS.

Series 314
Standard diaphragm safety relief valve with pressure gauge. Bearing CE mark as per Directive 97/23/CE. Threaded connections 1/2 M x 1/2 F. Calibration 2,5 bar (calibrations available: 2,5 3 6 7 8). Maximum temperature 110C. Brass body. Diaphragm and seal in EPDM. Control knob in ABS.

Series 513
Standard diaphragm safety relief valve. Bearing CE mark as per Directive 97/23/CE. Connections 1/2 M x 1/2 F. Calibration 1,5 bar (calibrations available: 1,5 - 2 - 2,5 - 3 - 3,5 - 6 - 7 - 8). Maximum temperature 110C. Brass body. Diaphragm and seal in EPDM. Cover and control knob in glass-fiber re-inforced nylon.

Series 513
Standard diaphragm safety relief valve. Bearing CE mark as per Directive 97/23/CE. Connections 1 F x 1 1/4 F (1 x 1 1/4 and 1 1/4 x 1 1/2). Calibration 2,5 bar (calibrations available: 2,5 - 3 - 3,5 - 6 - 7 - 8). Maximum temperature 110C. Body and cover in brass. Diaphragm and seal in EPDM. Cover and control knob in glass-fiber re-inforced nylon.

Series 514
Standard diaphragm safety relief valve. Bearing CE mark as per Directive 97/23/CE. Connections 1/2 M x 1/2 F. Calibration 2 bar (calibrations available: 2 - 2,5 - 2,7 - 3 - 3,5 - 6 - 7 - 8). Maximum temperature 110C. Brass body. Diaphragm and seal in EPDM. Cover in glass-fiber re-inforced nylon, control knob in ABS.

Series 527
I.S.P.E.S.L. approved and calibrated diaphragm safety relief valve. Bearing CE mark as per Directive 97/23/CE. Connections 1/2 F x 3/4 F (available 1/2 x 3/4, 3/4 x 1, 1 x 1 1/4, 1 1/4 x 1 1/2). Calibration 1 bar (calibrations available: 1 1,5 2 2,25 2,5 2,7 3 3,5 4 4,5 5 5,4 6 7 8). Maximum temperature 110C. Body and cover in brass. Diaphragm and seal in EPDM. Control knob in glass-fiber re-inforced nylon. Discharge overpressure 10%, closing differential 20%. Fail-safe. Accompanied by bench calibration report.

Accessories

5521
Discharge tundish with rotating elbow, male-female. Sizes: 1/2, 3/4, 1, 1 1/4.

5520
Straight discharge tundish, female-female. Sizes: 3/4 and 1 1/4.

5520
Discharge collector. In coated sheet metal. Size: 1 1/2.

Dimensions

B A A C

A B C B A Code 552080 B 25 40 C 96 134 A 1 1/2 B 210 C 150

Code A B 3/4 552140 1/2 1 552150 3/4 1 1/4 552160 1 552170 1 1/4 1 1/2

C 25 25 40 40

D 125 125 180 180

Code 552050 552070

A 3/4 1 1/4

SPECIFICATION DETAILS Series 5520 Straight discharge tundish. Connections 3/4 F x 3/4 F (3/4 x 3/4 and 1 1/4 x 1 1/4). Body in die-cast aluminium. Visible discharge.

Series 5520 Discharge collector. Connection 1 1/2 F. Body in coated sheet metal.

Series 5521 Discharge tundish with rotating elbow. Connections 1/2 M x 1/2 F (from 1/2 to 1 1/4). Body in die-cast aluminium. Visible discharge.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

MINICAL VALCAL Automatic air vent valves


series 5020 - 5021 - 5022
cert. n 0003

CALEFFI
ISO 9001

01054/05 GB
Replaces 01054/99 GB

Function Automatic air vent valves are designed to remove the air that accumulates in heating and air conditioning systems without the need for manual intervention. This prevents harmful phenomena that may compromise the life and the performance of the heating system and which include: - corrosion due to the oxygen; - pockets of air trapped in the heating emitters; - cavitation in the circulation pumps.

Product range Series Series Series Series Series Series Series 5020 5020 5020 5020 5021 5021 5022 MINICAL Automatic air vent valve MINICAL Automatic air vent valve, chrome plated MINICAL Automatic air vent valve, with safety hygroscopic cap MINICAL Automatic air vent valve, with safety hygroscopic cap, chrome plated MINICAL Automatic air vent valve, complete with automatic shut-off cock MINICAL Automatic air vent valve, complete with automatic shut-off cock, chrome plated VALCAL Automatic air vent valve, chrome plated Sizes 3/8 and 1/2 Sizes 3/8 and 1/2 Sizes 3/4 and 1 Sizes 3/4 and 1 Sizes 3/8 and 1/2 Sizes 3/8 and 1/2 Sizes 1/4, 3/8, 1/2 M M M M M M M

Technical specification Materials: Body and cover: Float: Obturator stem: Spring: Seals: Shut-off cock seal: brass EN 12165 CW617N PP brass EN 12164 CW614N stainless steel EPDM PTFE Performance: Medium: Max. percentage of glycol: Max. working pressure: Max. discharge pressure: Max. working temperature:

water and glycol solution 30% 10 bar 5020, 5021: 2,5 bar 5022: 4 bar. 5020, 5022: 120C 5021: 110C

Dimensions
C C C C

A
To complete codes end number 0 with brass body and plastic cap end number 1 with chrome plated body and metallic cap To complete codes end number 0 with brass body and hygroscopic cap end number 1 with chrome plated body and hygroscopic cap To complete codes end number 0 with brass body and plastic cap end number 1 with chrome plated body and metallic cap

A Code 50203. 3/8 50204. 1/2

B 79 79

C 48 48

D 11 11

Weight (kg)

0,18 0,18

A Code 50205. 3/4 50206. 1

B 86 86

C 48 48

D 11 11

Weight (kg)

0,18 0,18

A Code 50213. 3/8 50214. 1/2

B 96 96

C 48 48

D 11 11

Weight (kg)

0,21 0,23

A Code 502221 1/4 502231 3/8 502241 1/2

B 94 97 97

C 55 55 55

D 9 11 11

Weight (kg)

0,29 0,29 0,29

Operation The accumulation of air bubbles in the valve body causes the float to drop so that the air vent valve opens. This phenomenon occurs, and consequently the valve functions correctly, as long as the water pressure remains below the maximum discharge pressure. Construction details Hygroscopic cap All MINICAL and VALCAL models are equipped with a hygroscopic safety cap. Its functionality is based on the properties of the cellulose fibre discs that serve as the seal cartridge and whose volume increases by 50% as soon as they become wet and thus cause the valve to close. This way, possible damages are avoided in case of leakage. Models with shut-off The automatic shut-off valve, which forms a seal with the valve body by means of an O-ring made of EPDM, facilitates maintenance operations by shutting off the water flow when the valve is removed and also allows for easy inspection of the air vent device.

Flow curves Air flow (when the system is being filled)


Nl/s
1,1 1 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0 0,5 1,5 2,5 3,5 4,5 5,5 6,5

5022

5020

7 bar (air)

Installation - The valve is installed in the vertical position, on the air separator, on manifolds, on riser pipes and generally in parts of the system where a concentration of air pockets is to be expected. - During operation the upper cap in the standard version must be loosened whilst it must be completely hand tightened in the hygroscopic version. - It is not advisable to fit the valve in places which could be subject to freeze. In such cases the Caleffi Maxcal Series 501 automatic deaerator can be used. - It is advisable to replace the valve cap with a Caleffi Series 5620 safety hygroscopic cap in all fitting locations which cannot be inspected. Accessories - Check valve series 561 for air vent valves series 5020 and 5022 is available. 3/8 and 1/2 connections. Available in brass or chrome plated version. PTFE sealing on thread. - Hygroscopic safety plug AQUASTOP series 5620 for MINICAL and VALCAL series is available in brass or chrome plated. - Small anti-suction valve series 5621 for air vent valves for MINICAL and VALCAL series.

SPECIFICATION SUMMARIES
Series 5020 Automatic air vent valve. 3/8M (or 1/2M) threaded connection. Brass and chrome plated versions. Brass body and cover, PP float, brass obturator stem, EPDM O-Rings. Medium: water and glycol solutions. Maximum percentage of glycol 30%. Maximum working pressure 10 bar, maximum discharge pressure 2,5 bar. Maximum working temperature 120C. Series 5020 Automatic air vent valve. 1/2M ( or 3/4M) threaded connection. Brass and chrome plated versions. Brass body and cover, PP float, brass obturator stem, EPDM O-Rings. Medium: water and glycol solutions. Maximum percentage of glycol 30%. Maximum working pressure 10 bar, maximum discharge pressure 2,5 bar. Maximum working temperature 120C. Complete with hygroscopic safety cap. Series 5021 Automatic air vent valve with automatic shut-off cock. 3/8M (or 1/2M) threaded connection. Brass and chrome plated versions. Brass body and cover, PP float, brass obturator stem, EPDM O-Rings. Medium: water and glycol solutions. Maximum percentage of glycol 30%. Maximum working pressure 10 bar, maximum discharge pressure 2,5 bar. Maximum working temperature 110C. Series 5022 Automatic air vent valve. 1/4M (3/8, 1/2M) threaded connection. Chrome plated with metallic cap. Brass body and cover, PP float, brass obturator stem, EPDM O-Rings. Medium: water and glycol solutions. Maximum percentage of glycol 30%. Maximum working pressure 10 bar, maximum discharge pressure 4 bar. Maximum working temperature 120C.
We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

AERCAL Automatic air vent for radiators


series 504
cert. n 0003

CALEFFI
ISO 9001

01055/05 GB

Function Automatic air vents with external float are designed to remove the air that is released from the water when it is heated and which accumulates at the top of radiators, limiting the normal heat exchange process and giving rise to noise and corrosion. The air vent has been constructed so that it can be installed on any type of heating emitters ranging from the traditional cast iron radiators to the thin steel panel radiators. All models are equipped with a hygroscopic safety cap.

Product range Series 504 Automatic air vent for radiators, chrome plated, with hygroscopic safety cap Sizes 1/2, 3/4, 1 right and left

Technical specification Materials:- Body and cover: brass EN 12165 CW617N, chrome plated - Float: PP - Obturator stem: brass EN 12164 CW614N - Spring: stainless steel - Seals: EPDM - Hygroscopic safety cap seal: NBR - Hygroscopic safety cap discs: cellulose fibre Medium: Max. percentage of glycol: Max. working pressure: Max. discharge pressure: Max. working temperature: Connections: water and glycol solutions 30% 10 bar 2,5 bar 100C 1/2 - 3/4 - 1M right and left

Dimensions C

B G Code 504401 504501 504611 504621 A 1/2 3/4 1 R 1 L B 51 51 51 51 C 48 48 48 48 D 37 34 30 30 E 63 60 56 56 F 76 76 76 76 G 88,5 88,5 88,5 88,5
Weight (kg)

0,28 0,27 0,33 0,33

Operating principle The accumulation of air bubbles in the valve body causes the float to drop and thus the obturator to open. This phenomenon occurs, and consequently the valve functions correctly, as long as the water pressure remains below the maximum discharge pressure.

Flow curves Air flow (when the system is being filled)


Nl/s
1 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0 0,5 1,5 2,5 3,5 4,5 5,5 6,5

7 bar (air)

Installation The valve must be installed in a vertical position. The hygroscopic safety cap must be screwed tight when the system is operating.

Construction details Hygroscopic cap All models are equipped with a hygroscopic safety cap. Its functionality is based on the properties of the cellulose fibre discs that serve as the seal cartridge and whose volume increases by 50% as soon as they become wet and thus cause the valve to close. Cover The removable cover has a strong opening mechanism to vent the air. Float The location of the float and other internal parts means that the water never reaches the obturator, thus limiting the harmful effects from the impurities contained in the liquid. Maintenance The valve can be inspected as follows if the water contains impurities that jeopardize the correct functioning of the system: a) isolate the heating emitter by closing the valve and lockshield; b) unscrew the valve cover with the O-ring seal. The valve has been constructed so that this operation can be performed without leakage of water.

SPECIFICATION SUMMARIES
Series 504 Automatic air vent valve for radiators. Threaded connections, 1/2 M (3/4 M, 1 M right or 1 M left). Hygroscopic safety cap. Chrome plated brass body and cover, stainless steel spring, PP float, EPDM O-ring seals. Hygroscopic safety cap seal in NBR. Medium: water and glycol solutions. Maximum percentage of glycol 30%. Maximum operating pressure 10 bar. Maximum discharge pressure 2,5 bar. Maximum working temperature 100C.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Radiator air vents and drainage devices


series 505 - 5054 - 5055 - 5080 - 560
cert. n 0003

ISO 9001

01056/01 GB

Function Two types of device are covered here: - Automatic or manual air vent valves. - Radiator drain valve with extractor drain tube. The purpose of the radiator air vent valve is to remove, either manually or automatically, any air trapped inside the heat emitters both during the filling of the system and in normal operation. The drain valve, on the other hand, makes it possible to easily discharge the water contained in the radiator, thanks to the extractor which is inserted into the valve itself.

Product range Series 505 Series 5054 Series 5055 Series 5080 Code 560421 Code 560000 Manual radiator air vent valve Manual radiator air vent valve with revolving discharge Manual radiator air vent valve with soft seat Automatic hygroscopic radiator air vent valve Radiator drain valve Extractor drain tube Sizes Sizes Sizes 1/8, Sizes 1/8, 1/8, 1/8, 1/4, 1/4, 1/4, 1/4, 3/8, 3/8, Size 3/8 3/8 1/2 1/2 1/2 M M M M M

Technical specification

series Materials: - Body:

505 / 5054

5055

5080

560421

brass UNI EN 12164 CW614N; nickel plated POM white RAL 9010 PTFE

brass UNI EN 12164 CW614N; nickel plated POM white RAL 9010 PTFE

brass UNI EN 12164 CW614N; nickel plated POM white RAL 9010 PTFE

brass UNI EN 12164 CW614N; nickel plated

- Knob:

- Outer seal: Performance: - Max working pressure: - Max working temperature:

EPDM

10 bar 90C

10 bar 90C

10 bar 100C

10 bar 100C

Dimensions

A F

A Code 505111 1/8 505121 1/4 505131 3/8

B 29 29 32

C 18 18 18

D 7 7 7

E 22 22 25

F Es.13 Es.13 Es.17

A B C Code 505411 1/8 36,5 18 505421 1/4 36,5 18 505431 3/8 37 18

D 7 7 7

E G F 29,5 Es.13 12 29,5 Es.13 12 30 Es.17 12

Code 505511 505521 505531 505541

A 1/8 1/4 3/8 1/2

B 30 30 33 35

C 18 18 18 18

D 7 7 7 10

A F E 23 23 26 25 F Es.14 Es.14 Es.17 Es.17 E D B E 11 F 8 p. 1 8 p. 1 A G 205 F

B G Code 508011 508021 508031 508041 A B 1/8 30 1/4 30 3/8" 30,5 1/2" 33 C 18 18 18 18 D 10 10 10,5 10 E 20 20 20 23 F Es.15 Es.15 Es.17 Es.17

Code 560421 560000

A 1/2" -

B 32,5 -

C Es.22 -

D 21,5 -

Operating principle / Construction details 505 Valve 505 operates manually. The knob is turned until the air in the heat emitter is completely expelled and water starts to come out. 5055 (REG. MOD.) Once again, this model operates in the same way as the previous two. The identifying detail of this valve is an internal seal in a special elastic material which provides a tight seal in relation to limited tightening of the knob and possible temperature changes.

5054 This valve operates in the same way as the series 505, but differs in having a 360 revolving discharge facility which makes air venting easier.

The knob of the valve is shaped so as to be similar in appearance to Caleffi thermostatic valve heads, which enhances the uniformity of the range of radiator components.

5080 Valve code 5080 can be used manually or automatically. The principle of manual discharge is the same as for the valves already described, whilst automatic discharge is based on the property of the cellulose fibre discs forming the seal cartridge.

560 The drain valve is applied to the lower connection of the radiator. When inserting the extractor drain tube into the valve itself, the sliding piston which provides the outer seal must be screw-located and extracted, making the water flow outwards.

Valve closed

The manual discharge position is achieved by unscrewing the knob approx. one turn. Typical use of this method is when refilling the system.

The automatic discharge position, however, is achieved with the knob fully closed.

Valve open

Use of the series 560 drain valve

The hygroscopic discs increase their volume by 50% when they are immersed in water.

s+50%

Dry disc

Immersed disc

Dried disc

In this way, when the system is operating under normal conditions, the discs are immersed and, thanks to their increase in volume, they close the valve. However, when air is present, the discs dry out and allow the air to vent. The hygroscopic discs close very quickly, in just a few seconds. The drying times are such that there are no problems with the cycle of formation and elimination of air.

Table of drying times Water temperature C Times in hours 40 6 50 5 60 70 80 1 90 1/2 100 1/4

2 1/2 1 1/2

Replaceable cartridge The valve is constructed in such a way that the part containing the hygroscopic discs can easily be replaced without having to empty the heat emitter. This may be necessary because the discs can deteriorate in time if there is unfiltered or hard water present. It is, in any case, advisable to replace the disc cartridge at least every 36 months.

1 Remove
cap protective

2 Screw

on the drain tube provided

3 Pull

out the tube, turning it into a basin.

SPECIFICATION SUMMARIES Series 505 Radiator air vent valve. Threaded connection 1/8 M (from 1/8 to 3/8) with PTFE seal. Brass body. Nickel plated. White heat resistant knob in POM. Max working temperature 90C. Max working pressure 10 bar. Series 5054 Radiator air vent valve. Threaded connection 1/8 M (from 1/8 to 3/8) with PTFE seal. Brass body. Nickel plated. White heat resistant knob in POM. Max working temperature 90C. Max working pressure 10 bar. Rotable outlet. Series 5055 Radiator air vent valve with EPDM soft seal. Threaded connection 1/8 M (from 1/8 to 1/2) with PTFE seal. Brass body. Nickel plated. White heat resistant knob in POM. Max working temperature 90C. Max working pressure 10 bar. Series 5080 Automatic hygroscopic air vent valve. Threaded connection 1/8 M (from 1/8 to 1/2) with PTFE seal. Brass body. Nickel plated. White heat resistant knob in POM. Max working temperature 100C. Max working pressure 10 bar. Replaceable hygroscopic cartridge. Code 560421 Radiator drain valve. Threaded connection 1/2 M. EPDM seal. Brass body. Nickel plated. Max working temperature 100C. Max working pressure 10 bar. Designed for use with extractor drain tube. Code 560000 Extractor drain tube for extraction of sliding piston from radiator drain valve.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
S.S. 229 Km 26,5 I-28010 Fontaneto dAgogna (NO) Tel. Int. +39 0322 8491 Fax +39 0322 863723 Http://www.calef fi.com E-mail:info@calef fi.it

Temperature safety relief valve

CALEFFI
543 series
IS

TERE

BSI EN ISO 9001:2000 Cert. n FM 21654

UNI EN ISO 9001:2000 Cert. n 0003

01057/07 GB
replaces dp 01057/05

General description Temperature safety relief valves are manufactured by Caleffi S.p.A. in compliance with the essential requirements contained in Directive 97/23/EC of the European Parliament and of the Council of the European Union to harmonise member state regulations on pressure equipment.

Function The temperature safety relief valves limit the temperature of water in multi-fuel or solid fuel boilers with either a boiler incorporated or an emergency heat exchanger. When the temperature reaches 95C, the valve starts to discharge the necessary amount of water to keep the boiler temperature within the safety limits. Its use is specified by I.S.P.E.S.L. regulations (collection R - pub2005), it complies with EN 14597 and can be used on systems that comply with EN 12828, relating to solid fuel boilers with a power output of less than 100 kW.

Product range Code 543513 Temperature safety relief valve Size 3/4

Technical specification Materials: Body: Control spindle: Obturator seal: Seals: Spring: Protection cover:

Dimensions

brass EN 12165 CW617N, chrome plated brass EN 12164 CW617N EPDM EPDM stainless steel POM 1/2 10 bar 95C 5110C 3000 l/h 080C 2 KP 130C water IV 3/4 F x 3/4 F 1/2 M 1300 mm Code 543513 A 3/4 197

111 5

Performance: Max. working pressure: Set temperature: Temperature range: Discharge flow rate at 110C and p 1 bar: Ambient temperature range: Action type (EN 14597): Max. temperature of the sensor: Medium: PED category: Connections: Probe connection: Capillary length:

B 40

C 42

D 86

E 42

F 70

A
Weight (kg)

RE

F E

1,06

Operating principle When the temperature rises, the fluid contained within the sensor (1) undergoes a change of state from liquid to gas. The consequent volume increase creates a mechanical movement causing the expandable bellows (2), inside the valve, to push on the obturator and lift it up.

Installation

Installation of the temperature safety relief valve in boilers with built-in heater.
Hot water storage

DOMESTIC water supply

mains inlet safety discharge

Installation of the temperature safety relief valve in the emergency heat exchanger.
mains inlet safety discharge

The sensor should be mounted at the top of the boiler or on the outlet piping upstream of any isolating device and at a maximum distance of 0,5 m. Construction details Redundant expansion system The entire expansion system has a built-in redundancy (1)-(2) to ensure maximum safety, so if one part of the sensor system fails the other part will perform the same functions as the entire sensor. 1. After mounting the valve on the pipe, according to the flow direction indicated on the valve body, place the part connected to the sensor in its seat.
1 2

2. Loosely tighten the knurled lock nut. 3. Position the sheath outlet that connects the probe by turning the black cap. Completely tighten the knurled lock nut.

1
Pocket and capillary tubes The size of the pocket is such that it is always in contact with the sensors, which improves heat transmission and keeps thermal inertia to a minimum. The capillary tubes are protected by a galvanized sheath. Bellows holder support The bellows holder support is made of acetalic resin and can be repositioned by loosening the knurled lock nut. Accessories We recommend inserting a visible discharge tundish (5521 series Caleffi) when connecting the device to the discharge pipe.

Drain The lower part of the valve contains a button in order to drain the system.

SPECIFICATION SUMMARIES
Code 543513 Temperature safety relief valve. EC certified and approved to German DIN standards. Redundant safety sensor. Connections 3/4 F. Chrome plated brass body. Stainless steel spring. EPDM seals. Temperature range 5 110C. Nominal set temperature 95C. Maximum working pressure 10 bar. Complete with 1/2 M remote probe with pocket. Length of capillary 1300 mm.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 R.A. FAX +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2007 Calef fi S.P.A.

Temperature safety valve with automatic filling


544 series
IS

CALEFFI
TERE

BSI EN ISO 9001:2000 Cert. n FM 21654

UNI EN ISO 9001:2000 Cert. n 0003

01058/07 GB

Function The dual effect temperature safety discharge valve is used to ensure safety in heating systems that use a fireboxes or stoves as a heat generator. The device integrates in a single block a heat discharge valve and a filling valve that operate simultaneously controlled by a positive safety type remote sensor. The refilling, in case of valve intervention, ensures water circulation in the phase of fuel running out, thus protecting the integrity of the generator.

Product range Code 544400 Temperature safety valve with automatic filling Size 1/2

Technical specifications Materials: Body: Pocket: Spring: Hydraulic seals: Performance: Medium: Max. percentage of glycol: Max. working pressure: Set temperature: Temperature range: Discharge flow rate at 1 bar p: Connections: Probe connection: Length of capillary: water, glycol solutions 30% 6 bar 100C (+0C/-5C) 5110C 1600 l/h 1/2 F 1/2 M 1300 mm brass EN 12165 CW617N, chrome plated brass EN 12164 CW614N steel UNI 3823 EPDM

Dimensions

Code A 544400 1/2

RE

B 60

C 77

D 50

E F 162 1/2

G 43

Weight (kg) 1,32

Operating principle When the setting temperature is reached, (Fig.1) the cold water inlet aperture is opened (passage from 4 to 3) and, simultaneously, the drain aperture is opened (passage from 1 to 2), until the temperature drops to below the trigger value and the inlet and drain close simultaneously. In the event of a malfunction in the sensitive element (5) (6), the valve will perform the same functions described above in a continuous manner. The following are highlighted on the valve body (Fig.2): - arrow indicating the point of arrival of the generator pipes on the flow pipe (1) and connection to the safety drain marked with a letter S (2). - arrow indicating delivery to the generator (3) and the mains water system inlet, marked with a letter C (4). IMPORTANT: it is not possible to reverse the flows, the indications for filling and drain shown on the valve must be followed. Fig.2

Fig.1

1 3

2 4

6 3 4

Installation The valve can be fitted in any position, vertical, horizontal or upside down. The temperature probe pocket (6), supplied together with the valve, must be fitted on the flow pipe at a distance lower than 0,5 m from the generator or at the highest point of the water heater and anyhow before the drain pipe. The pocket provided with the valve must be used. In order to be able to control the inlet pressure better, it is advisable to have a charging unit (normally open) on the valve filler pipe, set at the system operating pressure. In the case of operation with an open vessel system, the entire system is charged directly through the pipe connected to the vessel. In order to avoid any type of malfunction due to the presence of debris, it is advisable to install an inspectable Y strainer on the filling inlet. It is necessary to check periodically that the strainer is not dirty or blocked. The installation of a low head loss strainer, fitted with devices to check the state of cleanliness, is recommended to enable functional testing during the work phase (e.g., pressure gauges upstream and downstream of the filtering element).

safety pipe

system flow system return max 0.5 m


S

C
S

mains infeed
C

safety drain

main inlet filter

normally open valves, only closed for filter inspection

System accessories

551 DISCAL
Deaerator. Brass body. Female connections. With drain. Max. working pressure: 10 bar. Max. discharge pressure: 10 bar. Working temperature range: 0110C. Patented. Function
Code

broch. 01060

551005 551006 551007 551008 551009

3/4 1 1 1/4 1 1/2 2

Air separators are used to remove continuously the air contained in the hydraulic circuits of heating and cooling systems. The air discharge capacity of these devices is very high. They are capable of removing automatically all the air present in the system down to micro-bubble level. The circulation of fully deaerated water allows systems to work under optimal conditions without any trouble of noise, corrosion, local overheating and mechanical damage.

5462 D I RTCAL
Dirt separator. Brass body. Female connections. Drain cock with hose connection. Top connection with plug. Max. working pressure: 10 bar. Working temperature range: 0110C. Particle separation rating: to 5 m. Patented.

broch. 01137

Function In heating and air conditioning systems, the circulation of water containing impurities may result in rapid wear and damage to components such as pumps and valves. It also causes blockages in the heat exchangers, heating elements and pipes, resulting in a lower thermal efficiency within the system. The dirt separator separates off these impurities, which are mainly made up of particles of sand and rust. The impurities are collected in a large collection chamber that requires low frequency cleaning operations, from which they can be removed even while the system is in operation. This device is capable of efficiently removing even the smallest particles, with extremely limited head loss.

Code

546205 546206 546207 546208

3/4 1 1 1/4 1 1/2

553
Pre-adjustable automatic filling unit, anti-scale, inspectionable with pressure setting indicator. Complete with manual cock, strainer and check valve. Max. inlet pressure: 16 bar. Max. working temperature: 65C. Setting pressure range: 0,24 bar.

broch. 01061

Function The automatic filling unit is a device consisting of a pressure reducing valve with compensating seat, an inlet filter, a shut-off valve and a check valve. It is installed on the water inlet piping in sealed heating systems, and its main function is to maintain the pressure of the system stable at a set value, automatically topping up with water as required. After installation, during the filling or topping-up phase, the water feed will stop when the set pressure is reached.

Code

553540 553640

1/2 with press. gauge conn. 1/2 with press. gauge

Application diagrams
SYSTEM WITH OPEN EXPANSION VESSEL IMPORTANT: for overall power levels exceeding 35 kW the dimensions of the safety pipe must comply with current regulations.

Expansion vessel Safety relief valve


T

Pump Y-Strainer with drain 3-way zone valve

Inlet

Shut-off valve Sistem drain Filling group


T
T

Thermostat Pressure gauge

T
C

Thermostatic timer Deaerator Dirt separator Main inlet filter

SYSTEM WITH CLOSED EXPANSION VESSEL IMPORTANT: This diagram may only be used only if it is allowed by national or local rules or regulations. For overall power levels exceeding 35 kW it is necessary to have appropriate safety devices according to current regulations.
T

SPECIFICATION SUMMARIES
Code 544400 Temperature safety valve with automatic filling. Connections 1/2" F. Brass body. Chrome plated. Steel spring. EPDM seals. Maximum working pressure 6 bar. Maximum working temperature 110C. Maximum discharge temperature 100C (0C/-5C). Complete with remote probe with pocket. Connection 1/2" M. Length of capillary 1300 mm.

We reserve the right to make changes and improvements to the products and related data in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 R.A. FAX +39 0322 863723 www.caleffi.com info@caleffi.com Copyright 2007 Caleffi S.P.A.

DISCAL deaerator

CALEFFI
551 series
ACCREDITED

01060/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003

replaces 01060/06 GB

Function Deaerators are used to continuously remove the air contained in the hydraulic circuits of heating and cooling systems. The air discharge capacity of these devices is very high. They are capable of automatically removing all the air present in the system down to micro-bubble level, with very low head losses. The circulation of fully deaerated water enables the equipment to operate under optimum conditions, free from any noise, corrosion, localised overheating or mechanical damage. The threaded connection product is available in versions for installation to horizontal or vertical pipes. Flanged and weld-end DISCAL deaerators are supplied complete with hot pre-formed shell insulation to ensure perfect thermal insulation when used in both hot and chilled water systems.

Product range 551 series DISCAL deaerator for horizontal pipes with drain sizes 3/42 551 series DISCAL deaerator for horizontal pipes, compact version sizes 3/4 551 series DISCAL deaerator for horizontal pipes with olive connections, compact version sizes compression ends for 22 copper pipe 551 series DISCAL deaerator for horizontal pipes with flanged connections and pre-formed insulation with drain sizes DN 50DN 150 551 series DISCAL deaerator for horizontal pipes with weld ends and pre-formed insulation with drain sizes DN 50DN 150 551 series DISCAL deaerator for vertical pipes, compact version sizes 3/4, 1 551 series DISCAL deaerator for vertical pipes with olive connections, compact version sizes 22 with nuts for copper pipe

Technical specifications series Materials: Body: Internal element: Float: Float guide: Stem: Float lever: Spring: Hydraulic seals: Drain cock: Performance: Medium: Max. percentage of glycol: Max. working pressure: Max. discharge pressure: Working temperature range: Connections: Main: 551 threaded 551 flanged and weld ends

brass EN 12165 CW617N PA66G30; stainless steel (compact version) PP brass EN 12164 CW614N brass EN 12164 CW614N stainless steel stainless steel EPDM -

epoxy resin coated steel stainless steel PP brass EN 12164 CW614N brass EN 12164 CW614N stainless steel stainless steel EPDM brass EN 12165 CW617N, chrome plated

water, non-hazardous glycol solutions excluded from the guidelines of directive 67/548/EC 50% 10 bar 10 bar 0110C

water, non-hazardous glycol solutions excluded from the guidelines of directive 67/548/EC 50% 10 bar 10 bar 0110C

3/4, 1, 1 1/4, 1 1/2, 2 F with compression ends for 22 mm copper pipe 1/2 F (with plug)

Drain:

DN 50 - 65 - 80 - 100 - 125 - 150 weld ends; DN 50 - 65 - 80 - 100 - 125 - 150 flanged PN 16 to be coupled with counterflanges EN 1092-1 1 M (with plug)

Technical specification of insulation for flanged models from DN 50 to DN 100 Inner part Material: rigid closed cell expanded polyurethane foam Thickness: 60 mm Density: 45 kg/m3 Thermal conductivity (ISO 2581): 0,023 W/(mK) Working temperature range: 0105C External cover Material: Thickness: Reaction to fire (DIN 4102): Head covers Heat moulded material: embossed unfinished aluminium 0,7 mm class 1 PS

Technical specification of insulation for flanged models DN 125 and DN 150 Inner part Material: Thickness: Density: - inner part: - outer part: Thermal conductivity (ISO 2581): closed cell expanded PE-X 60 mm 30 kg/m3 80 kg/m3 - at 0C: 0,038 W/(mK) - at 40C: 0,045 W/(mK) Coefficient of resistance to water vapour (DIN 52615): > 1.300 Working temperature range: 0100C Reaction to fire (DIN 4102): class B2 External cover Material: Thickness: Reaction to fire (DIN 4102): embossed unfinished aluminium 0,7 mm class 1

Dimensions

D A F B
Code 551006 A 1" B 110 D 146 146 166 166 160 E F Mass (kg) 205 1/2 1,7 205 1/2 1,7 225 1/2 2,2 225 1/2 2,2 225 1/2 2,5 551005 3/4" 110 551007 1 1/4" 124 551008 1 1/2" 124 551009 2" 130

Code 551905 551906 F

Mass (kg)
2,05 2,05 A Code 22 551902

Mass (kg)
2,05

38415.01

BI-DIRECTIONAL

BI-DIRECTIONAL

Tmax 110C Pmax 10 bar

Tmax 105C Pmax 10 bar

Tmax 110C Pmax 10 bar

Tmax 105C Pmax 10 bar

38415.01

Code

B 78

C 55

D 143

E 162

Mass (kg)

551003 3/4"

0,9

G B D E
Code A B D E F G Mass (kg) 1" 15,5 1" 15,5 1" 28,5 1" 30,5 1" 48,5 1" 53,5

G B
Code F E D A B 551053 DN 50 260 374 506 169 551063 DN 65 260 374 506 169 551083 DN 80 366 435 595 219 551103 DN 100 366 435 595 219 551123 DN 125 525 544 775 324 551153 DN 150 525 544 775 324 DN 100 18 DN 125 52 G Mass (kg) 1" 09,3 1" 09,4 1 20,0 1 21,0 1 35,0 1 38,0 DN 150 52

551052 DN 50 350 374 506 169 551062 DN 65 350 374 506 169 551082 DN 80 466 435 595 219 551102 DN 100 470 435 595 219 551122 DN 125 635 545 775 324 551152 DN 150 635 545 775 324 Code A B 97 C 55 D 143 E 162
Mass (kg)

Size Volume (l)

DN 50 7

DN 65 7

DN 80 18

551002 22

0,9

The process of air formation The amount of air which can remain dissolved in a water solution is a function of pressure and temperature. This relationship is governed by Henrys Law and the graph below allows the physical phenomenon of the air content release of the fluid to be quantified. As an example, at a constant absolute pressure of 2 bar, if the water is heated from 20C to 80C, the amount of air released by the solution is equal to 18 l per m3 of water. According to this law it can be seen that the amount of air released increases with temperature rise and pressure reduction. The air comes in the form of micro-bubbles of diameters in the order of tenths of a millimetre. In heating and cooling systems there are specific points where this process of formation of micro-bubbles takes place continuously: in the boiler and in any device which operates under conditions of cavitation.

Cavitation micro-bubbles Micro-bubbles develop where the fluid velocity is very high with the corresponding reduction in pressure. These points are typically the pump impeller and the regulating valve seating. These air and vapour Implosions micro-bubbles, the Seat-obturator formation of which distance Cavitation is enhanced in micro-bubbles the case of non Pressure Velocity de-aerated water, may subsequently implode due to Fluid vapour the cavitation pressure phenomenon.
Pressure Velocity

Graph: Solubility of air in water Operating principle Absolute pressure Max amount in litres of dissolved air per m3 of water (l/m3)
55 3 bar 50 45 40 2 bar 35 30 25 1 bar 20 15 10 5 0 0 20 40 60 80 100 120 140 160 180 4 bar 5 bar 6 bar 7 bar 8 bar

The deaerator uses the combined action of several physical principles. The active part consists of an assembly of concentric metal mesh surfaces. These elements create the whirling movement required to facilitate the release of micro-bubbles and their adhesion to these surfaces. The bubbles, fusing with each other, increase in volume until the hydrostatic thrust is such as to overcome the adhesion force to the structure. They rise towards the top of the unit from which they are released through a float-operated automatic air release valve.It is designed in such a way that the direction in which the medium is flowing inside it makes no difference.

Water temperature C

Boiler micro-bubbles Micro-bubbles are formed continuously on the surface separating the water from the combustion chamber due to the fluid temperature. This air, carried by the water, collects in the critical points of the circuit from where it must be removed. Some of this air is reabsorbed in the presence of colder surfaces.

Flame temperature 1000C

Combustion chamber wall

Boundary layer

FLAME

WATER
Micro-bubbles

Wall temperature 160C

Boundary layer temperature 156C Average water temperature 70C

- When cleaning, simply unscrew the part of the body containing the automatic air vent (4). On threaded models without a drain, this part 4 cannot be removed (5).

2 4

A
1

Flanged and weld-end deaerators are equipped with a cock (A) that has the dual function of releasing large quantities of air when the system is being filled and of removing the impurities that float on top of the water. A drain valve (B) can be connected at the bottom of the unit to drain the impurities that have collected at the bottom of the deaerator.

B
Air separation efficiency Construction details The automatic air vent is located at the top of the unit and is equipped with a long chamber for the floating action. This feature prevents the impurities present in the water from reaching the seal seat. The construction of the DISCAL deaerator allows it to be maintained and cleaned without removing the device from the system. Note the following: DISCAL devices are capable of continuously removing the air contained within a hydraulic circuit, with a high degree of separation efficiency. The amount of air which may be removed from a circuit depends on various parameters: it increases as the circulation speed and pressure values fall. As illustrated on the graph below, after just 25 recirculations at the maximum recommended speed, almost all the air artificially introduced into the circuit is eliminated by the deaerator, with variable percentages according to the pressure within the circuit. The small amount which remains is then gradually eliminated during normal system operation. In conditions where the speed is slower or the temperature of the medium is higher, the amount of air separated is even greater.
Air introduced - Air removed - (%)
100 90 80 70 60 1 bar 2 bar 3 bar

- The moving parts that control the air venting are accessed simply by removing the upper cover.(3).

50 40 30 20 10

0
1000 1100 1200 Tme (s) 25 No. of recirc. 100 200 300 400 500 600 700 800 900 0

V = 1 m/s - T = constant

10

15

20

Insulation Flanged and weld-end DISCAL devices are supplied complete with hot pre-formed shell insulation. This system ensures not only perfect thermal insulation, but also the tightness required to prevent atmospheric water vapour from entering the unit. For this reason, this type of insulation may also be used in cooling water circuits as it prevents condensation from forming on the surface of the valve body.

Hydraulic characteristics
22 - 3/4" - 1 22 (551002) 3/4" (551003)
Vertical version

DN 100

DN 125

1 1/4"

1 1/2" 2 DN 50

DN 65

400
350 300 250

DN 80

3/4"

1"

p (mm w.g.)

DN 150

p (kPa) 4
3,5 3 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6 0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12

200

180 160 140 120

100

90 80 70 60

50

45 40 35 30 25

0,5

20

18 16 14 12

0,2

120

140 160

180

0,6

0,7 0,8 0,9

1,2

1,4 1,6

1,8

2,5

3,5 4 4,5

12

14 16

18

25

35 40 45

30

60

70 80 90

10

0,1
G (m3/h)

7 8 9

DN Kv (m3/h) DN Kv (m3/h)

22 - 3/4 10,0 DN 50 75,0

3/4 16,2 DN 65 150,0

22 - 3/4 - 1
Vertical version

1 28,1

1 1/4 1 1/2 48,8 DN 125 450,0 63,2

100

200

0,5

10

20

50

2 70,0

17,0 DN 80 180,0

DN 100 280,0

DN 150 720,0

The maximum recommended speed of the medium at the device connections is ~ 1,2 m/s. The following table gives the maximum flow rates to meet this condition. DN l/min m3/h DN l/min m3/h 22 - 3/4 - 1 22,7 1,36 DN 50 141,20 8,47 3/4 22,7 1,36 1 35,18 2,11 DN 80 361,5 21,69 1 1/4 57,85 3,47 DN 100 564,8 33,89 1 1/2 90,33 5,42 DN 125 980,0 58,8 2 136,6 8,20 DN 150 1436,6 86,2

DN 65 238,6 14,32

Installation DISCAL units may be used in both heating and cooling systems, to ensure the progressive removal of air which is continuously formed. The units should preferably be installed after the boiler and on the pump suction side, as these are the points where the formation of micro-bubbles is greatest. DISCAL deaerators must be installed in a vertical position, and preferably: - upstream of the pump where, due to the high speed of the medium and the ensuing drop in pressure, air micro-bubbles develop more easily. The flow direction of the medium is not important in DISCAL devices. In installation sites where inspection is not possible, it is recommended that the air vent cap is replaced with a Caleffi 5620 series hygroscopic safety cap.

CHILLER

Application diagram

P T

F
A

Shut-off valve Ball valve BALLSTOP Thermometer

Flow switch Zone valve Pump

Safety thermostat Regulator Expansion vessel

Control pocket Gas filter Gas regulator Y-strainer

Anti-vibration joint Sensor pocket Safety valve Backflow preventer

AUTOFLOW Flow meter Differential by-pass valve Temperature probe


P

3-way valve
A

Fuel shut-off valve Automatic filling unit

Pressure switch

DISCAL 551 series Deaerator, version with drain. Connections for horizontal pipes 3/4 F (from 3/4 to 2) with union. Drain 1/2 F (with plug). Brass body. PA66G30 internal element. PP float. Brass float guide and stem. Stainless steel float lever and spring. EPDM hydraulic seals. Medium water and non-hazardous glycol solutions excluded from the guidelines of EC directive 67/548; maximum percentage of glycol 50%. Maximum working pressure 10 bar. Maximum discharge pressure 10 bar. Working temperature range 0110C. Patented. DISCAL 551 series Deaerator. Flanged connections DN 50 (from DN 50 to DN 150) PN 16; to be coupled with counterflanges EN 1092-1. Weld end connections DN 50 (from DN 50 to DN 150). Drain 1 M (with plug). Epoxy resin coated steel body. Stainless steel internal element. EPDM hydraulic seals. Medium water and non-hazardous glycol solutions excluded from the guidelines of EC directive 67/548; maximum percentage of glycol 50%. Maximum working pressure 10 bar. Maximum discharge pressure 10 bar. Working temperature range 0110C. Patented. Complete with: - automatic air vent: brass body, PP float, brass float guide and stem, stainless steel float lever and spring; - chrome plated brass drain cock; - rigid closed cell expanded polyurethane foam insulation for sizes up to DN 100 (closed cell expanded PE-X for DN 125 and DN 150) and embossed unfinished aluminium external cover. Working temperature range 0105C (0-100C for DN 125 and DN 150). DISCAL 551 series Deaerator, compact version. Connection for horizontal or vertical pipes with compression ends for 22 copper pipe, threaded connections 3/4 F (and 1) for vertical pipes, threaded connections 3/4 F for horizontal pipes. Brass body. Stainless steel internal element. PP float. Brass float guide and stem. Stainless steel float lever and spring. EPDM hydraulic seals. Medium water and non-hazardous glycol solutions excluded from the guidelines of EC directive 67/548; maximum percentage of glycol 50%. Maximum working pressure 10 bar. Maximum discharge pressure 10 bar. Working temperature range 0110C.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

SPECIFICATION SUMMARY

CALEFFI
CALEFFI S.p.A. S.R.229, N.25 28010 Fontaneto dAgogna (NO) Italy Tel. +39 0322 8491 Fax +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

Pre-adjustable filling and charging units

CALEFFI
553 - 573 574 series
ACCREDITED

01061/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003

Function The automatic filling unit is a device consisting of a pressure reducing valve with compensated seat, an inlet strainer, a shut-off valve and a check valve. It is installed on the water inlet pipe in sealed heating systems and its main function is to maintain the pressure of the system stable at a set value, automatically topping up with water as required. This product has the characteristic of being pre-adjustable, which means that it can be adjusted at the required pressure value before the system filling phase. After installation, during the filling or topping-up phase, feed will stop when the set pressure is reached. Two pre-assembled versions are also available, complete with shut-off valves and different upstream backflow preventers, depending on the hazard level of the water inside the system.

Reference documentation - Tech. Broch. 01008 Backflow preventer, 573 series - Tech. Broch. 01022 Backflow preventer, 574 series

Product range Code 553540 Code 553640 Code 573001 Code 574000 Filling unit with pressure gauge connection and pressure setting indicator Filling unit with pressure gauge and pressure setting indicator Charging unit with pressure gauge, complete with 573 series CAa-BA type ckflow preventer and shut-off valves Charging unit with pressure gauge, complete with 574 series BA-BA type ckflow preventer, strainer and shut-off valves size 1/2 size 1/2 size 1/2 size 1/2

Technical specifications Code Materials (code 553540/640 only) Body: Cover: Control stem: Moving parts: Seals: Strainer: Shut-off valves: Performance Max. inlet pressure: Setting range: Factory setting: Indicator accuracy: Max. working temperature: Pressure gauge range: Filter mesh size : Medium: Connections Inlet: Outlet: Pressure gauge: 553540 553640 brass EN 12165 CW617N PA66GF30 brass EN 12164 CW614N brass EN 12164 CW614N NBR stainless steel 16 bar 0,24 bar 1,5 bar 0,15 bar 65C 04 bar 0,28 mm water 1/2 M with union 1/2 F 1/4 F 573001 574000

brass EN 12165 CW617N PA66GF30 brass EN 12164 CW614N brass EN 12164 CW614N NBR stainless steel brass EN 12165 CW617N 10 bar 0,24 bar 1,5 bar 0,15 bar 65C 04 bar upstream strainer: 0,47 mm unit strainer: 0,28 mm water 1/2 F 1/2 F -

brass EN 12165 CW617N PA66GF30 brass EN 12164 CW614N brass EN 12164 CW614N NBR stainless steel brass EN 12165 CW617N 10 bar 0,24 bar 1,5 bar 0,15 bar 65C 04 bar upstream strainer: 0,4 mm unit strainer: 0,28 mm water 1/2 F 1/2 F -

Dimensions

3
CA LEF FI

0
CA LEF FI

3 4

0
CA LEFF I

C F B B G

C F B G

D C Code A B E Mass (kg) 553540 1/2" 122 50 101,5 0,62 553640 1/2" 122 152 50 101,5 0,70

F G Mass (kg) Code A B C D E 573001 1/2" 335 40 87 101,5 122 213 2,2

F G Mass (kg) Code A B C D E 574000 1/2" 382 40 80 101,5 164 218 1,9

Construction details

Code 553540 and 553640 (patent pending model) Pre-adjustment This model is provided with a pressure adjustment indicator, which facilitates setting operations. The system filling pressure may be set by turning the regulating screw, even before the system charging phase begins.

CALEFFI

Non-sticking materials The central support containing moving parts and the internal sliding compensation piston is made using plastic with a low adhesion coefficient. This solution minimises the chance of scale forming, the major cause of malfunctions.

Diaphragm-seat seal The useful working surface of the diaphragm is particularly large, in order to guarantee greater precision and sensitivity when working with minimum pressure differences. This feature is also useful for giving greater force to the sliding of the piston and overcoming friction. In view of the low flow rates involved, the filling unit seat has been designed with the smallest possible diameter. This factor, combined with the extended surface of the diaphragm, creates an optimum dimensional ratio for a piece of equipment which must maintain its operating characteristics unchanged over time.

bar

Obturator guide In order to reduce the frictional surfaces, the obturator stem guide has been positioned in the upper part of the device. It consists of four spokes directly stamped on the plastic central support.

Removable cartridge and strainer The cartridge containing the operation mechanisms, protected by a strainer having a large surface area, is removable. This makes it possible to perform inspections, internal cleaning and, if necessary, cartridge replacement in an extremely simple and functional manner.

Code 553540

Backflow preventer and related reference to European standards

use

in

Code 574000 Charging unit code 574000 is composed of: - Controllable reduced pressure zone backflow preventer, BA type, 574 series - Filling unit, 553 series - Ball shut-off valves - Y-strainer, 577 series

To avoid the backflow of water from the heating system, which is potentially polluted and dangerous for human health, it is always advisable to install a preassembled charging unit with a backflow preventer. The correct use of water backflow preventers is regulated by European reference standard EN 1717: 2000 Protection against

pollution of potable water in water installations and general requirements of devices to prevent pollution by backflow.
Code 573001 Charging unit code 573001 is composed of: - Non-controllable backflow preventer with different pressure zones, type CAa, 573 series - Filling unit, 553 series - Ball shut-off valves

573 series The 573 non-controllable backflow preventer with different pressure zones is of CA type, manufactured according to European standard EN 14367 Devices to prevent pollution by backflow of potable water.

574 series The 574 controllable reduced pressure zone backflow preventer is of BA type , manufactured according to European standard EN 12729 Devices to prevent pollution by backflow of potable water.

Non-controllable backflow preventer with different pressure zones. Family C Type A. It may be used to protect against the risk of
contamination by waters classified up to Category 3 (with reference to European standard EN 1717): Fluid that represents a

Controllable reduced pressure zone backflow preventer. Family B Type A. It may be used to protect against the risk of contamination by
waters classified up to Category 4 (with reference to European standard EN 1717): Fluid that represents a significant health hazard

slight health risk due to the presence of one or more harmful substances.

due to the concentration of toxic substances.

Installation 1. The 553 series filling unit can be installed in either horizontal or vertical position. It is, however, vital that the unit is not installed upside down.

Maintenance The following steps are necessary for the cleaning, inspection and replacement of the entire regulating cartridge: 1) Shut off the unit. 2)Open the lower control knob. 3)Loosen the calibration screw all the way. 4) Remove the top cover. 5)Remove the cartridge with the aid of pliers. 6) After inspection and any necessary cleaning, the entire assembly can be reassembled or replaced using the spare cartridge. 7) Reset the equipment.

2. The special mechanical pre-adjustment system with pressure indicator allows the assembly to be set to the desired system value before the charging phase starts. 3. The assembly is normally set at a pressure no lower than that obtained by adding 0,3 bar to the hydrostatic pressure. 4. During charging, the internal mechanism will automatically adjust the pressure when the set value is reached, without the need to oversee the lengthy filling operation. This prevents the system being charged to a higher pressure value than required. 5. In view of the pre-adjustment function, a pressure gauge downstream of the fitting is not crucial. 6. Once the system is filled, the shut-off valve can be closed. To reinstate the automatic filling conditions, the valve just has to be re-opened. The system pressure value will gradually go back to the set value.

Application diagram

P T

3 4
C ELA IFF

F
A
2 1 3 4
C ELA IFF

Shut-off valve Ball valve BALLSTOP Temperature gauge Differential by-pass valve
F
T
T

Pump AUTOFLOW
P

3-way cock Pressure switch Control pocket

Fuel shut-off valve

Anti-vibration joint Pocket Safety relief valve

Flow meter device Temperature probe Safety thermostat Regulator Expansion vessel Gas filter Gas regulator Air separator

Flow switch Zone valve

SPECIFICATION SUMMARY
Code 553540 and 553640 Pre-adjustable filling unit. Threaded connections 1/2 M with union x 1/2 F. Brass body and internal moving parts. Glass nylon cover. Sliding surfaces in anti-scale plastic. NBR diaphragm and seals. Cartridge removable for maintenance operations. Maximum working temperature 65C. Maximum inlet pressure 16 bar. Adjustment range 0,24 bar. Pressure indicator for pre-adjustment of device, accuracy 0,15 bar. Complete with pressure gauge, scale 04 bar (code 553640), pressure gauge connection 1/4 F (code 553540), shut-off valve, strainer and check valve. Code 573001 Charging unit with backflow preventer. Connections 1/2 F. Maximum working temperature 65C. Maximum working pressure 10 bar. Complete with: pre-adjustable filling unit, brass body, glass nylon cover, NBR seals, pressure adjustment range 0,24 bar, complete with shut-off valve, strainer and check valve; backflow preventer with non-controllable reduced pressure zones, CAa type, conforms to EN 14367, with DZR alloy body, NBR seals, complete with collar for fixing to discharge pipe, ball shut-off valves with brass body, downstream pressure gauge 04 bar. Code 574000 Charging unit with backflow preventer. Connections 1/2 F. Maximum working temperature 65C. Maximum working pressure 10 bar. Complete with: pre-adjustable filling unit, brass body, glass nylon cover, NBR seals, pressure adjustment range 0,24 bar, complete with shut-off valve, strainer and check valve; controllable reduced pressure zone backflow preventer, BA type , conforms to EN 12729, with DZR alloy body, NBR diaphragm and seals, complete with tundish with collar for fixing to discharge piping, ball shut-off valves with brass body, downstream pressure gauge 04 bar, Y-strainer for backflow preventers.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. S.R.229, N.25 28010 FONTANETO DAGOGNA (NO) ITALY TEL. +39 0322 8491 FAX +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

Adjustable thermostatic mixing valve for high flow rates


524 series
ACCREDITED

CALEFFI
01063/10
ISO 9001 No. 0003

ISO 9001

FM 21654

Function The thermostatic mixing valve is used in heating systems with centralised hot water production. It is designed to keep the temperature of the mixed water supplied to the user circuits constant when there are variations in the temperature of the water contained within the storage. It is designed for direct connection to the recirculation circuit. The materials used and high flow rate offered are central factors in achieving the desired thermal performance and reliability levels.

Product range 524 series Adjustable thermostatic mixing valve for high flow rates Technical specifications Materials Body: Obturator: Performance Adjustment temperature range: Accuracy: Factory setting: Max. working pressure: Max. inlet temperature: Flanged connections: sizes DN 65 and DN 80

bronze stainless steel

3653C 2C 48C 10 bar 90C DN 65 and DN 80

Dimensions

Hydraulic characteristics
DN 65 DN 80

p (bar)

p (m w.g.)

E I

1,5 1,0 0,5 0,2 0,1

524

A F

CALEFFI

0,05
0,02

A H B H

0,01 200 Flow rate (m3/h) 0,005 100 0,5 10 20 50 1 2


5

Code A B 524060 DN 65 330 524080 DN 80 355

C 145 155

D 82 92

E F G H I Mass (kg) 112 185 121 145 1 1/2 31 124 200 127 155 2 36

Code 524060 524080

DN 65 DN 80

Kv 32 43

Operating principle The (hot and cold) water proportions are regulated by a double obturator that slides inside a special cylinder placed between the hot and cold water passage channels. For optimal regulation, make sure that the two inlet pipe pressures are aligned. The recirculation circuit is easy to construct, thanks to the shut-off system for both the cold and hot water. Maximum silent operation and minimal head losses. Check valves In systems with thermostatic mixing valves, check valves must be installed to prevent undesired backflow.

RECIRCULATION

COLD
Regulation and recirculation The check valve (1) prevents undesired circulation from the hot water storage. The balancing valve (2) should be opened until the temperature of the mixed water being recirculated reaches the desired value (which cannot exceed the setting value) during periods when no water is drawn. If, after carrying out the procedure described in point 2, it is not possible to guarantee the stability of the desired temperature whether or not water is being drawn by the users, valve (3) must be set to a p greater than the value set for valve (2).

Application diagram

SPECIFICATION SUMMARY
524 series Adjustable thermostatic mixing valve for high flow rates. Flanged connections DN 65 (and DN 80). Bronze body. Adjustment temperature range 3653C. Accuracy 2. Factory setting 48C. Maximum working pressure 10 bar. Maximum inlet temperature 90C.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.p.A. S.R.229, N.25 28010 Fontaneto dAgogna (NO) Italy Tel. +39 0322 8491 Fax +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

MIXED

HOT

Adjustable thermostatic mixing valves for water storage heaters


520 - 522 series
IS

CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003

TERE

BSI EN ISO 9001:2000 Cert. n FM 21654

01064/08 GB

Function The 520 and 522 series mixing valves are used in systems that produce hot water for sanitary purposes with a water storage heater. They are designed to maintain the preset temperature of the mixed water delivered to the user despite variations in the temperature of the water contained in the storage.

Product range 520 series Adjustable thermostatic mixing valve 522 series Adjustable thermostatic mixing valve for installations under a water storage heater

RE

sizes 1/2, 3/4, 1 size 1/2

Technical specifications Materials Body: Obturator: Spring: Sealing elements: 522 series extension: brass EN 12165 CW617N, chrome plated brass EN 12164 CW614N stainless steel EPDM chrome plated brass

Max. inlet pressure ratio (H/C or C/H): 1,1:1 Max. hot water inlet temperature: 90C (code 520430/530/630, 522430) Setting range: 3048C 4060C (code 520440/540/640, 522440) Minimum flow rate to ensure the highest performance: Connections: Centre distance between the 522 series connections: 5 l/min

Performance Medium: Max. working pressure (static): Max. working pressure (dynamic):

1/2, 3/4, 1 F (520 series) 1/2 M x F (522 series) adjustable from 105 to 160 mm

water 10 bar 5 bar

Dimensions B C A
A A

A
A

Code 5204.. 5205.. 5206..

A 1/2 3/4 1

B 56 61 64

C 96 103 103

D 54 60 55

Weight (kg) 0,38 0,47 0,59

Code 5224..

A 1/2

B 56

C adjustable 105 160

Weight (kg) 0,65

Legionella vs scalding risk In systems producing hot water for sanitary purposes with storage, in order to avoid the dangerous infection known as Legionnaires disease, the hot water must be stored at a temperature of at least 60C. At this temperature it is certain that the proliferation of the bacteria that cause this infection will be totally inhibited. At this temperature, however, the water cannot be used directly. Water temperatures over 50C can cause scalding injuries very quickly and even considerably faster to children and elderly people. Therefore, it is necessary to use a thermostatic mixing valve which can reduce the temperature at the point of use to a value much lower than that of the storage so it can be used by the domestic user. For reasons of safety, it is recommended to set the temperature of the mixed water sent to the user to values no higher than 50C.

Energy Savings Energy savings rules advice to use mixing valves on water delivery systems for sanitary use with storage, to limit the temperature of the water at the inlet of the delivery network to 48C with a tolerance of +5C. The purpose of limiting the temperature is to reduce passive thermal losses through the delivery network as much as possible, besides preventing delivering water at a higher temperature than necessary.

Hydraulic characteristics
1/2 3/4 1
p (bar)
1,5

p (m w.g.)
15 10

Thermal disinfection The drawing alongside shows the behaviour of Legionella Pneumophila bacteria as the conditions vary in the temperature of the water containing the bacteria. To ensure correct thermal disinfection, it is necessary to go up to values of no less than 60C.

1,0

0,5
70 60 50 40 30 20 10 0 Bacteria survive but remain inactive Optimum temperature for spread of bacteria Instant death of bacteria Death of 90% of bacteria within 2 minutes Death of 90% of bacteria within 2 hours

5 3 2

0,3 0,2

0,1

0,05
0,2 0,5 1 2 5 50

0,5

Kv (m3/h)

1/2 1,30

3/4 1,80

1 2,75

Operating principle The regulating element within the thermostatic mixing valve consists of a temperature sensor in contact with the mixed water outlet pipe. By expanding and contracting, it continuously ensures correct proportioning of the hot and cold water at the inlet, modulating with the obturator on the cold water. Correct mixing therefore requires the hot and cold water pressures to be balanced.

520 series

522 series

HOT
COLD

MIXED

HOT

MIXED

COLD

COLD

Flow rate (l/min) (m3/h)

10

20

Use Under standard conditions, Caleffi 520 and 522 series thermostatic mixing valves can manage reduced flow rates (from 5 l/min). Instantaneous hot water production Caleffi 520 and 522 series thermostatic mixing valves must not be used in combination with boilers with instantaneous hot water production for sanitary purposes. Adding them would impair the operation of the boiler. Installation The 520 and 522 series thermostatic mixing valves must be installed as shown in the diagrams in this leaflet. They can be installed in any position, horizontally or vertically. The following marks are indicated on the mixing valve body: hot water inlet, indicated by a red colour, cold water inlet, indicated by a blue colour, and mixed water outlet, indicated by the word MIX. The 522 series is equipped with a telescopic extension on the cold water inlet line with an adjustable connection centre distance from 105 to 160 mm. This permits fitting directly under the water storage heater, easily adapting to different models and sizes. On the extension there is a label showing the reference marks so as to be able to cut the pipe to size easily.

Check valves In systems with thermostatic mixing valves, check valves should be fitted to prevent undesired backflows, as shown in the diagrams in this leaflet. Commissioning The thermostatic mixing valve must be commissioned in accordance with current regulations and by qualified personnel using suitable temperature measuring instruments. We recommend using a digital thermometer for measuring the temperature of the mixed water. Temperature setting The control knob is used to adjust temperature between 30C and 48C or from 40C to 60C depending on the version.

60

40

110

120

130

140

150 145 155

105

115

125

Application diagrams Ball valve Ball check valve


CALEFFI

135

Centre distance boiler mm.

160

Expansion vessel Safety relief valve Pressure reducing valve Y-strainer 5261 Series

2 1
3230 BALLSTOP Series

SPECIFICATION SUMMARIES
520 series Adjustable thermostatic mixing valve. Threaded connections 1/2 F (3/4, 1). Chrome plated brass body. Brass obturator. Stainless steel spring. EPDM seals. Maximum working pressure (static) 10 bar. Maximum working pressure (dynamic) 5 bar. Maximum working temperature 90C. Maximum inlet pressures ratio 1,1:1. Setting range 3048C (4060C). Minimum flow rate to ensure the highest performance 5 l/min. 522 series Adjustable thermostatic mixing valve for installations under a water storage heater. Threaded connections 1/2 M x F. Chrome plated brass body. Brass obturator. Stainless steel spring. EPDM seals. Maximum working pressure (static) 10 bar. Maximum working pressure (dynamic) 5 bar. Maximum working temperature 90C. Maximum inlet pressures ratio 1,1:1. Setting range 3048C (4060C). Minimum flow rate to ensure the highest performance 5 l/min. Centre distance between the connections adjustable from 105 to 160 mm.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 R.A. FAX +39 0322 863723 www.caleffi.com info@caleffi.com Copyright 2008 Caleffi S.P.A.

Preassembled distribution manifolds


for heating and air-conditioning systems 663 series

CALEFFI
01065/06 GB

Function The preassembled distribution manifolds are designed to optimize the distribution of the medium in the circuits of the heating and air-conditioning systems. They ensure accuracy in controlling the flow to the single circuits, cutting them off and reduced depth that, at the time of assembly, facilitates hooking up with the outlet pipes. They are also offered in a version complete with hot pre-formed insulation to limit thermal losses and above all to prevent condensation on the surface when used in air-conditioning systems.

Reference documentation - Tech. Broch. 01042 Thermo-electric actuator 6561 series - Tech. Broch. 01142 Thermo-electric actuator with manual opening and position indicator 6563 series - Tech. Broch. 01041 Automatic flow stabilizers - Tech. Broch. 01054 Automatic air vent valves 5020 series

Product range 663 series Preassembled distribution manifold 663... IS series Preassembled distribution manifold for air-conditioning systems size 1 1/4 size 1 1/4

Technical specifications Materials: Flow manifold - body: Lockshield valve - control device upper part - stem - seals - plug - adjustment key: Return manifold - body: Performance: Medium: Max. percentage of glycol: Max. working pressure: Temperature range: Main connections: Centre distance: Outlets: Centre distance:

brass EN 1982 CB753S brass EN 12164 CW614N brass EN 12164 CW614N EPDM self-extinguishing polycarbonate 5 mm allen key

water, glycol solutions 30% 10 bar 5100C

1 1/4 F; 1 F with reduction as standard 195 mm 3/4 M - 18 50 mm

brass EN 1982 CB753S

Shut-off valve - control device upper part: brass EN 12164 CW614N and PA - obturator stem: stainless steel - obturator: EPDM - springs: stainless steel - seals: EPDM - knob: ABS End fitting - body:

brass EN 12165 CW617N

Technical specifications of insulation Material: expanded PE-X with closed cells Thickness: 20 mm Density: - inner part: 30 kg/m3 - outer part: 50 kg/m3 Thermal conductivity (DIN 52612): - at 0C 0,038 W/(mK) - at 40C 0,045 W/(mK) Coefficient of resistance to the diffusion of water vapour (DIN 52615): >1.300 Temperature range: 0100C Reaction to fire (DIN 4102): Class B2

Dimensions

1 1/4

CALEFFI

CALEFFI

CALEFFI

195

1 1/4

CALEFFI

CALEFFI
CALEFFI

25

3/4 L total

50

27

Code without insul. 6637C5 6637D5 6637E5 Code with insul. 6637C5 IS 6637D5 IS 6637E5 IS Nr. outlets 3 4 5 Total L 220 270 320 Weight (kg) 4,8 5,4 5,9

6637F5 6637F5 IS 6 370 6,8

6637G5 6637H5 6637G5 IS 6637H5 IS 7 8 420 470 7,4 8,1

6637I5 6637I5 IS 9 550 8,5

6637L5 6637M5 6637N5 6637O5 6637L5 IS 6637M5 IS 6637N5 IS 6637O5 IS 10 11 12 13 600 650 700 750 9,6 10,5 11 11,6

Characteristic components 1 Flow manifold with lockshield valves for flow rate adjustment 2 Return manifold with shut-off valves fitted for thermo-electric actuator

CALEFFI

CALEFFI

CALEFFI

3 End fittings composed of union with double radial connection and plugs 4 Pair of brackets fastening to the box 5 Reduction 1 1/4 M x 1 F 6 Hot pre-formed shell insulation (version with insulation)

CALEFFI

CALEFFI

CALEFFI

Construction details Flow manifold The flow manifold is equipped with outlet circuit shut-off and setting lockshield valves. In order to prevent leaks or seepage over time, the assembly seal is guaranteed by the EPDM O-Rings on the headwork (1) and on the control stem (2) while the O-Ring on the obturator (3) permits fully closing the outlet circuit, if necessary. External shape of the manifolds and brackets A special mention should be given to the outer shape of the manifold that, thanks to the casting process, can be shaped as needed. In this case, recesses have been made in correspondence with the passage of the pipe that comes down from the upper manifold, allowing it to be partially housed, for the benefit of depth. This is without interfering with the values of head losses, since the cross-sections of the recesses (a) are the same as in correspondence with the zones where the outlets (b)+(c) branch out and where the adjusters (lockshield valves and shut-off valves) obstruct the flow of the medium.

1 2 3

b a c
Return manifold The return manifold is equipped with manual shut-off valves (1), by means of which the flow to the single circuits can be cut off. They are moreover fitted for an electro-thermal control (2) that, used with a room thermostat, permits keeping the ambient temperature on the set values as the thermal load varies. The obturator stem (3) is made of ground stainless steel in order to minimize friction and prevent dangerous encrustation. The headwork has a double seal (4) - (5) on the slide stem in the form of an O-Ring in EPDM. The EPDM obturator (6) is shaped so as to optimize the hydraulic characteristics of the valve and minimize the noise caused by the flow of the medium, also during the progressive action of opening or closing in operation with thermo-electric actuator. The partial housing of the pipe in the manifold shaping is moreover helped by the brackets, made with such an angle as to obtain a misalignment of 25 mm between the upper and lower manifolds. As shown in the figure, this misalignment, at the time of installation, makes a perfect match automatic between the position of the piping and the shape of the manifold.

CALEFFI

CALEFFI

CALEFFI

2
CALEFFI

CALEFFI
CALEFFI

1
25 mm

4
Pre-formed insulation

5 3 6

The manifold 663 series is also offered in a version complete with hot pre-formed insulation. This solution is recommended in applications where it is necessary to limit thermal losses (installations outdoors in particularly cold places) or, specifically, to prevent condensation on its surface when used in air-conditioning systems.

The insulation has been specially designed to aid its coupling with the manifold and any accessories, such as the thermo-electric actuators, as well as its installation in boxes.

Hydraulic characteristics In order to determine the hydraulic characteristics of the circuit, it is necessary to calculate the total loss of head suffered by the flow of medium on passing through the devices forming the manifold assembly and the fan coil circuits. From a hydraulic point of view, the system composed of the manifold assembly and the circuits can be represented as a set of hydraulic elements arranged in series and in parallel.

SV = Shut-off valve LV = Lockshield valve P/F = Pipe/Fan coil

PRM

PSV

PTot.

PLV P PP/ T/V F GTot. GP/F

PFM

PLV

PTot.

PTot.
PSV

PP/F

PLV PP/F PSV


GTot.

= Total loss at the ends of the manifold (Flow + Return + Pipe/Fan coil) = Localised loss of circuit setting lockshield valve (P/V circuit flow rate) = Pipe/Fan coil (P/F) loss (P/F circuit flow rate) = Localized loss of P/F circuit shut-off valve (P/F circuit flow rate) = Distributed loss of the flow manifold (total flow rate) = Distributed loss of the return manifold (total flow rate)

PFM

GP/F

PRM

GTot. GP/F

PFM PRM

GP/F

PTot. = PLV +PP/F + PSV + PFM + PRM

(1.1)

When the hydraulic characteristics of each component and the design flow rates are known, the total loss can be calculated as the sum of the partial losses of head for each specific component of the system, as indicated with the formula (1.1).

P (mm w.g.) 1000


900 800 700 600 450 400 350 300 250

P (kPa)
9 8 7 6

P (mm w.g.) 1000


900 800 700 600 450 400 350 300 250

P (kPa)
9 8 7 6

10

10

500

4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

500

4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

200

180 160 140 120

200

180 160 140 120

100

90 80 70 60

100

90 80 70 60

50

45 40 35 30 25

0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12

0,5

50

45 40 35 30 25

0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12

0,5

20

18 16 14 12

0,2

20

18 16 14 12

0,2

2500

3000

1200

1400

1600

1000

1800

2000

3500

600

700

800

600

700

800

120

140

160

180

900

250

300

350

400

450

900

60

70

80

90

10

0,1

10

0,1

1000

G (l/h)

G (l/h)

Lockshield valve fully open Shut-off valve

Kv 3,10 2,87

Kv0,01 310 287

Flow/return manifold 37 outlets Flow/return manifold 813 outlets


* Average value

Kv 33,5* 23,5*

Kv0,01 3350* 2350*

- Kv = flow rate in m3/h for a loss of head of 1 bar - Kv0,01 = flow rate in l/h for a loss of head of 1 kPa

Example of calculation of total head loss Supposing we need to calculate the loss of head of a manifold with three outlets with the following characteristics: Total manifold flow rate: 900 l/h The pipes and fan coils of the three circuits have the following characteristics of flow rate and loss of head: Circuit 1 G1 = 200 l/h PF 1 = 1,3 kPa PPipe 1 = 1,7 kPa PP/F1 = 1,7 + 1,3 = 3 kPa P=G2/Kv0.012 Circuit 2 G2 = 300 l/h PF 2 = 3 kPa PPipe 2 = 7,8 kPa PP/F2 = 7,8 + 3 = 10,8 kPa Circuit 3 G3 = 400 l/h PF 3 = 5,3 kPa PPipe 3 = 7,2 kPa PP/F3 = 7,2 + 5,3 = 12,5 kPa

(1.2)

We calculate each term of the formula (1.1), using the relationship:

G = flow rate in l/h P = loss of head in kPa (1 kPa =100 mm w.g.) Kv0,01 = flow rate in l/h through the device, which corresponds to a head loss of 1 kPa It should be stressed that the calculation of PTot. must be made taking account of the circuit in which there are the greatest head losses distributed along the entire circuit composed of piping + fan coil. In the case we are examining, the relevant circuit is No. 3. PLV PP/F PSV PFM PRM It follows that: = = = = = 4002/3102 = 1,7 kPa 12,5 kPa 4002/2872 = 1,9 kPa 9002/33502 = 0,07 kPa 9002/33502 = 0,07 kPa

} Values obtained by neglecting the changes due to flow rate to the single branched circuits.

By means of (1.1) adding up all the calculated terms, we have: PTot.= 1,7 +12,5 + 1,9 + 0,07 + 0,07 16 kPa

Note: Because of the low head losses for the manifolds, the two terms relating to them can be neglected. In general, the total head loss is reasonably approximate to that of the circuit composed of the piping, fan coil and lockshield valve fully open.

4000

100

200

500

500

50

Using the lockshield valve The lockshield valve permits balancing the single circuits of the fan coils to obtain the actual flow rates in each of them that are determined at the design stage. We consider each single circuit composed of: lockshield, pipe/fan coil and shut-off valve. To be able to set the system correctly it is necessary to take into account the following data: the flow rate of the medium that must pass through each circuit (project data). the loss of head that, for this flow rate, is generated in each circuit: PCircuit = PP/F + PSV the loss of head of the most disadvantaged circuit: PCircuit = PLV + PP/F + PSV (1.4)
+ disadvantaged

(1.3)

In all the circuits the lockshield, for the flow rate GCircuit, must provide an additional loss of head equal to the difference, which we can indicate as PLV (p lockshield). To permit an increase in flow rate, we sometimes consider the lockshield valve of the circuit with the greatest losses of head open 80%. Once we know the data PLV and GCircuit for each circuit, we need to go to the graph of hydraulic characteristics of the lockshield valve and choose the optimum adjustment curve to which the valve adjustment position corresponds.

SV PCircuit

PTot.

PMost disadvantaged
circuit

LV

PLV

Example of adjustment Suppose we need to balance three circuits with the characteristics of loss of head and flow rate for the pipe/fan coil shown in the example (1.2): Since circuit No. 3 is the most disadvantaged one, because it has the greatest loss of head for the pipe/fan coil, we need to adjust the remaining circuits: Circuit 3 PP/F = 12,5 kPa G3 = 400 l/h PLV = 4002/3102 = 1,7 kPa PSV = 4002/2872 = 1,9 kPa With the relationship (1.4): PCircuit 3 = 1,7 + 12,5 + 1,9 = 16,1 kPa
most disadvantaged

Circuit 1 PP/F = 3 kPa G1 = 200 l/h PSV =200 /287 = 0,5 kPa
2 2

Circuit 2 PP/F = 10,8 kPa G2 = 300 l/h PSV = 300 /287 = 1,1 kPa
2 2

P1 P
Most disadvantaged circuit

PLV1

P2
PLV2

P3

with the relationship (1.3): PCircuit 1 = 3,0 + 0,5 = 3,5 kPa

PCircuit 16 kPa
+ disadvantaged

with the relationship (1.3): PCircuit 2 = 10,8 + 1,1 = 11,9 kPa

To adjust circuits 1 and 2, the data we need for each one to go and read the lockshield valve adjustment position will be the following: Circuit 1 PLV1 = 16 - 3,5 = 12,5 kPa G1 = 200 l/h Nr. of turns of adjustment = 2 Circuit 2 PLV2 = 16 - 11,9 = 4,1 kPa G2 = 300 l/h Nr. of turns of adjustment = 3 Circuit 3 Adjustment position fully open

P (mm w.g.)
5000
4500 4000 3500 3000 2500

P (kPa)
45 40 35 30 25 18 16 14 12 9 8 7 6

50

2000

1800 1600 1400 1200

20

1,5

2,5

3,5 4 F . O.

1000

900 800 700 600

10

500
450 400 350 300 250

5
4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

200
180 160 140 120

100

90 80 70 60

50
250 300 350 400 120 140 160 180 450 12 14 16 18 25 30 35 40 45 60 70 80 90 1200 1400 1600

0,5

1000

1800

600

700

800

900

G (l/h)

2000

20

100

200

500

10

50

Hydraulic characteristics of lockshield valve

P (mm w.g.) 5000


4500 4000 3500 3000 2500

P (kPa)
45 40 35 30 25 18 16 14 12 9 8 7 6

50

2000

1800 1600 1400 1200

20

1,5

2,5

3,5 4 F . O.

1000

900 800 700 600

10

500
450 400 350 300 250

5
4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

200
180 160 140 120

100

90 80 70 60

50
250 300 350 400 120 140 160 180 450 12 14 16 18 25 30 35 40 45 60 70 80 90 600 700 800 900 1200 1400 1600

0,5

1000

1800

Adjustment position Kv Kv0,01


3

1,5 0,22 22

2 0,53 53

2,5 0,90 90

3 1,50 150

3,5 2,30 230

4 2,90 290

F.O. 3,10 310

- Kv = flow rate in m /h for a loss of head of 1 bar - Kv0,01 = flow rate in l/h for a loss of head of 1 kPa

SPECIFICATION SUMMARIES
663 series Preassembled distribution manifold for heating systems with 3 (from 3 to 13) outlets. Brass body. Seals of EPDM. Head connections 1 1/4 (1 with reduction as standard) threaded F, centre distance 195 mm. Outlet connections 3/4 M - 18, centre distance: 50 mm. Medium: water and glycol solutions. Maximum percentage of glycol: 30%. Maximum working pressure: 10 bar. Temperature range: 5100C. Composed of: - Flow manifold with lockshield valves with 5 full turns of adjustment. - Return manifold, with shut-off valves fitted for thermo-electric actuator. - End fittings composed of union with double radial connection and plugs. - Pair of brackets. - Reduction 1 1/4 M x 1 F. 663 IS series Preassembled distribution manifold for air-conditioning systems, with hot pre-formed insulation, with 3 (from 3 to 13) outlets. Brass body. Seals of EPDM. Head connections 1 1/4 (1 with reduction as standard) threaded F, centre distance 195 mm. Outlet connections 3/4 M - 18, centre distance 50 mm. Medium: water and glycol solutions. Maximum percentage of glycol: 30%. Maximum working pressure: 10 bar. Temperature range: 5100C. Composed of: - Flow manifold with lockshield valves with 5 full turns of adjustment. - Return manifold, with shut-off valves fitted for electro-thermal control. - End fittings composed of union with double radial connection and plugs. - Pair of brackets. - Reduction 1 1/4 M x 1 F. - Hot pre-formed shell insulation made of expanded PE-X with closed cells.

2000

20

100

200

500

10

50

MANIFOLDS AND ACCESSORIES


8 4 2 10 6 5 7 11 3 12 13 14

40 20 0 60 80 20

40 60 80

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

40 20 0 60

40

CALEFFI
80

20 0

60

CALEFFI
80

CALEFFI

CALEFFI

CALEFFI

19

18

20

21

17

16

15

22

23

1) Flow manifold with lockshield valve to adjust flow rate, 6631 series 2) Return manifold with shut-off valves fitted for thermo-electric actuator, 6630 series 3) End fittings composed of union with double radial connection and plugs, 5994 series 4) Pair of brackets fastening to the box, 658 series 5) Reduction 1 1/4 M x 1 F, 3642 series 6) Hot pre-formed shell insulation (version with insulation) 663 IS series 7) Ball shut-off valves, 391 series 8) Autoflow, 120 series 9) Filter, 120 series 10) Thermo-electric actuator, 6560 - 6561 series 11) Thermo-electric actuator with manual opening and position indicator, 6563 series

12) Manual air vent valve, code 337131 13) Automatic air vent valve, code 59575 14) End fitting with automatic air vent valve, code 599671 15) End fitting with manual air vent valve, code 599672 16) Drain cock, code 538400 17) By-pass eccentric kit, code 663000 18) DARCAL fitting, 680 series 19) Plug disc, 386 series 20) Compression fitting, code 3475 .. 21) DARCAL fitting, code 679 22) Box, 659 series 23) Box, 5902 series

By-pass eccentric kit with fixed setting, code 663000


Function In heating and air-conditioning systems, the medium distribution circuits can be totally or partially shut off by closing the thermoelectric valves in the manifolds or the thermostatic valves of the radiators. After reducing the flow rate, the differential pressure in the circuit may increase up to values able to generate problems of noise, high medium speed, mechanical erosion and hydraulic unbalancing of the system itself. The differential by-pass kit for 663 series manifolds performs the function of keeping the flow and return pressure of the manifold circuit balanced when the flow rate varies. This valve is fitted for quick coupling with the 663 series manifolds, reducing the overall dimensions to a minimum. Product range Code 663000 By-pass eccentric kit with fixed setting sizes 3/8 x 1/2

Technical specifications Materials: body: nuts: 18 pipe with plate: check valve obturator: spring: seals: gaskets: brass EN 12164 CW614N brass EN 12165 CW617N copper POM stainless steel EPDM asbestos-free fibre water, glycol solutions 30% 10 bar -10110C 20 kPa (2000 mm w.g.) 3/8 M 1/2 M

Dimensions A

Medium: Max. percentage of glycol: Max. working pressure: Temperature range: Fixed pressure setting: Flow manifold connection: Return manifold connection:

137 150

B C

Code 663000 Principle of operation The by-pass valve contains a non-return obturator connected to a contrast spring. When the fixed setting pressure is reached, the valve obturator gradually opens, recirculating the flow in proportion to the closing of the thermo-electric valves and maintaining a constant differential pressure in the manifold circuit.

A 1/2"

B 3/8"

C 35

Weight (kg) 0,3

Hydraulic characteristics By-pass pressure differential:


P (mm w.g.) 10000
9000 8000 7000 6000

20 kPa (2000 mm w.g.)


P (kPa)
90 80 70 60

100

Construction details The differential by-pass assembly features a fixed setting that cannot be changed because it does not contain accessible adjustment parts. The small, compact size and offset connections makes this kit particularly easy to install, deciding to mount it after installing thermo-electric valves on the manifold. It does not require a larger or deeper zone box than those used for normal manifolds.

5000
4500 4000 3500 3000 2500

50
45 40 35 30 25 18 16 14 12

2000
1800 1600 1400 1200

20

1000
250 300 350 400 450 600 120 140 160 180

10

Q (l/h)

SPECIFICATION SUMMARIES
Code 663000 By-pass eccentric kit with fixed setting. Threaded connections 3/8 M x 1/2 M. Brass body and nuts. 18 pipe with plate in copper. POM check valve obturator, stainless steel spring, EPDM seals, asbestos-free fibre gaskets. Medium: water and glycol solutions. Maximum percentage of glycol: 30%. Maximum working pressure: 10 bar. Temperature range: -10110C. Fixed pressure setting: 20 kPa.

1000

100

200

500

50

700 800 900

60

70 80 90

Standard thermo-electric actuator

6561
Thermo-electric actuator. For manifolds 663 series. Normally closed.
Code

tech. broch. 01042

Technical specifications Materials: - protective shell - colour self-extinguishing polycarbonate (codes 656102/04) white RAL 9010 (codes 656112/14) grey RAL 9002

Voltage (V)

656102 656104

230 224

Normally closed Electric supply: Starting current: Working current:

6561
Thermo-electric actuator. For manifolds 663 series. Normally closed. With auxiliary microswitch.
Code

tech. broch. 01042

230 V (ac) - 24 V (ac) - 24 V (dc) 1A 230 V (ac) = 13 mA 24 V (ac) - 24 V (dc) = 140 mA Power consumption: 3W Auxiliary microswitch contacts rating (codes 656112/14): 0,8 A (230 V) Protection class: IP 44 (in vertical position) Double insulation construction: CE Max ambient temperature: 50C Operating time: opening and closing from 120 s to 180 s Length of supply cable: 80 cm

Voltage (V)

656112 656114

230 224

Thermo-electric actuator with manual opening and position indicator

6563
Thermo-electric actuator. For manifolds 663 series. Normally closed.
Code

tech. broch. 01142

Technical specifications Materials: - protective shell - colour self-extinguishing polycarbonate (codes 656302/04) white RAL 9010 (codes 656312/14) grey RAL 9002

Voltage (V)

656302 656304

230 224

Normally closed Electric supply: Starting current: Working current:

6563
Thermo-electric actuator. For manifolds 663 series. Normally closed. With auxiliary microswitch.
Code

tech. broch. 01142

230 V (ac) - 24 V (ac) - 24 V (dc) 1A 230 V (ac) = 13 mA 24 V (ac) - 24 V (dc) = 140 mA Power consumption: 3W Auxiliary microswitch contacts rating (656312/14 codes): 0.8 A (230 V) Protection class: IP 40 Double insulation construction: CE Max ambient temperature: 50C Operating time: opening and closing from 120 s to 180 s Length of supply cable: 80 cm

Voltage (V)

656312 656314

230 224

The thermo-electric actuator 6563 series is equipped with a control knob for manual opening, valve opening/closing indicator and a device for returning to automatic operation from the manual position when the electricity supply is restored. The control knob for manual opening and the automatic return from the manual to the automatic position is particularly useful when testing or servicing the system if: - hydraulic tests need to be carried out without having necessarily to connect and power up the controls. - the knob is left on the manual position at the end of the tests. In this case the control automatically goes back onto automatic operation when the system is electrically put into operation.

Automatic flow stabilizers

120 AUTOFLOW version

tech. broch. 01041

Combination of automatic flow stabilizer and ball valve. Factory set to keep the flow rate automatically within 5% of the set value. Inspecting, cleaning and replacing the internal cartridge without having to remove the valve body from the piping. Suitable for fitting pressure points to check operation. Suitable for connecting to a drain pipe. The control stem of the ball valve has a blowout-proof stem and the closing lever is covered with vinyl. Reversible lever. Male connections with union nut.
Code Flow rate m3/h

Code

Flow rate m3/h

Technical specifications Thermometer scale: Max. working pressure: Max. working temperature: p Range: Accuracy: 080C - 40 mm 25 bar 110C 14220 kPa 5%

120961 120961 120961 120961 120961 120961 120961

1L2 1L4 1L6 1L8 2L0 2L2 2L5

1 F x 1 1/4 M 1 F x 1 1/4 M 1 F x 1 1/4 M 1 F x 1 1/4 M 1 F x 1 1/4 M 1 F x 1 1/4 M 1 F x 1 1/4 M

1,20 1,40 1,60 1,80 2,00 2,25 2,50

120971 120971 120971 120971 120971 120971 120971

1L2 1L4 1L6 1L8 2L0 2L2 2L5

1 1/4 F x 1 1/4 M 1 1/4 F x 1 1/4 M 1 1/4 F x 1 1/4 M 1 1/4 F x 1 1/4 M 1 1/4 F x 1 1/4 M 1 1/4 F x 1 1/4 M 1 1/4 F x 1 1/4 M

1,20 1,40 1,60 1,80 2,00 2,25 2,50

They are available on request with other flow rates

120 FILTER Version

tech. broch. 01041

Combination of Y-filter and ball valve. Inspecting, cleaning and replacing the filter without having to remove the valve body from the piping. Fitted for fitting pressure points to check the degree of filter clogging. Fitted for connecting to a drain pipe to clean the filter without having to remove it from the body. The control stem of the ball valve has a blowout-proof stem and the closing lever is covered with vinyl. Reversible lever. Male connections with union nut. Technical specifications
Code Code

120961 000

1 F x 1 1/4 M

120971 000

1 1/4 F x 1 1/4 M

Thermometer scale: Max. working pressure: Max. working temperature: Filter mesh :

080C - 40 mm 25 bar 110C 0,87 mm

Manifolds

6630
Return manifold, with shut-off valves fitted for thermo-electric actuator.
Code Connection No. outlet Outlets

Technical specifications Materials: Return manifold - body: brass EN 1982 CB753S Shut-off valve - control device upper part: brass EN 12164 CW614N and PA - obturator stem: stainless steel - obturator: EPDM - springs: stainless steel - seals: EPDM - knobs: ABS Flow manifold - body: brass EN 1982 CB753S

663030 663040 663050 663060 663070 663080

1 1 1 1 1 1

1/4 1/4 1/4 1/4 1/4 1/4

F F F F F F

x x x x x x

3 4 5 6 7 8

3/4 3/4 3/4 3/4 3/4 3/4

M M M M M M

6631
Flow manifold with lockshield valves.
Code Connection No. outlet Outlets

663130 663140 663150 663160 663170 663180

1 1 1 1 1 1

1/4 1/4 1/4 1/4 1/4 1/4

F F F F F F

x x x x x x

3 4 5 6 7 8

3/4 3/4 3/4 3/4 3/4 3/4

M M M M M M

Lockshield valve - control device upper part: brass EN 12164 CW614N - obturator stem: brass EN 12164 CW614N - seals: EPDM - plug: self-extinguishing polycarbonate Max working pressure: Temperature range: Main connections: Outlets: Outlet centre distance: 10 bar 5100C 1 1/4 F x M 3/4 M - 18 50 mm

Shut-off valves

Mounting brackets

391
Pair of ball valves. Female - male connections with union. With thermometer scale 0-80C, 40 mm. Max. working pressure: 10 bar. Max. working temperature: 100C.
Code Kv (m3/h)

658
Pair of mounting brackets for use with boxes 659 series or direct fixing. Complete with screws and fixings.

Code

391167 391177

1 x 1 1/4 1 1/4 x 1 1/4

47,5 47,5

658100 for manifolds 666, 667 and 668 series

391
Pair of ball valves. Female - male connections with union. With thermometer connection. Max. working pressure: 10 bar. Max. working temperature: 100C.
Code Kv (m /h)
3

Automatic air vent valves

59575

391067 391077

1 x 1 1/4 1 1/4 x 1 1/4

47,5 47,5

Automatic air vent valve. Hot forged brass. Max. working pressure: 10 bar. Max. discharge pressure: 2,5 bar. Max. working temperature: 110C.

Code

59575

3/8 M

End fittings

5996
End fitting composed of union with double radial connection, 5994 series with automatic air vent valve code 59575 and drain cock, 538 series. Max. working pressure: 10 bar. Max. discharge pressure: 2,5 bar. Max. working temperature: 110C.
Code

337
Mini drain cock. Adjustable outlet. PTFE seal on thread. Max. working pressure: 6 bar. Max. working temperature: 85C.
Code

337131 1 1/4

3/8 M

599671

5996
End fitting composed of union with double radial connection, 5994 series, with automatic air vent valve, 337 series and drain cock, 538 series. Max. working pressure: 6 bar. Max. working temperature: 85C. Drain cock

538
Drain cock with hose connection and cap. Max. working pressure: 10 bar. Max. working temperature: 110C.
Code

Code

599672

1 1/4

538400

1/2 M

Fittings

680
Self-adjustable diameter fitting for single and multilayer plastic pipes. Max. working pressure: 10 bar. Temperature range: 580C (PE-X) 575C (Multilayer marked 95C) Patented.

679
Fitting for multilayer pipe for continuous high temperature use. Max. working pressure: 10 bar. Temperature range: 095C. WARNING: For a correct use, calibrate the multilayer pipe before installation.

Code

inside

outside

Code

680502 680503 680500 680501 680506 680515 680517 680524 680526 680535 680537 680544 680546 680555 680564 680505

3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4 3/4

17,518,0 8,519, 19,019,5 19,510.0 19,510.0 10,511.0 10,511.0 11,512.0 11,512.0 12,513.0 12,513.0 13,514.0 13,514.0 14,515.0 15,516 17

1214 1214 1416 1214 1416 1416 1618 1416 1618 1618 1820 1618 1820 1820 1820 22,50

679514 679524 679525 679544 679564 679565 679566

3/4 3/4 3/4 3/4 3/4 3/4 3/4

14x2 16x2 16x2,25 18x2 20x2 20x2,25 20x2,5

679
Case kit to calibrate multilayer pipes before use with fittings 679 series.

347
Compression fitting for copper pipe with O-Ring seal. Max. working pressure: 10 bar. Temperature range: -25120C.

Code

Code

347510 347512 347514 347515 347516 347518

3/4 3/4 3/4 3/4 3/4 3/4

10 12 14 15 16 18

679000 679001 679002 679003 679004 679006 679007 679008 679005

Set calibrators calibrator 14x2 calibrator 16x2 calibrator 16x2,25 calibrator 18x2 calibrator 20x2 calibrator 20x2,25 calibrator 20x2,5 handle for calibrator

Calibration of the multilayer pipe and assembly of the fitting components, 679 series

386
Screw plug with nut, for manifold outlets.
Pipe Pipe clamp Nut Hose connection

Code

Manifold or valve connection

386500

3/4

Box

5902
Ventilated box with frame. For single manifolds 663 series. Adjustable depth from 110 to 140 mm. Closure with a push-fit clamp. In painted sheet steel.

659
Inspection wall box for manifold systems. For manifolds 668 series. Wall or floor installations (with 660 series). Adjustable depth from 110 to 140 mm. Closure with a push-fit clamp. In painted sheet speel.

Code Code Useful dim. (h x b x d)

(h x b x d)

590204 590206 590208 590210

450 450 450 450

x x x x

1400 1600 1800 1000

x x x x

110140 110140 110140 110140

659040 659060 659080 659100 659120

450 450 450 450 450

x x x x x

1400 1600 1800 1000 1200

x x x x x

110140 110140 110140 110140 110140

Choice of box size, 659 series, according to the number of outlets

660
Floor installation kit for inspection wall boxes 659 series. Consists of: - 2 supports of 20 cm height, - 2 side panels, - 1 pipe bending bar.

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI
CALEFFI

L total
Code

40 20 0 60 80

40 20 0 60 80

225

95

660040 660060 660080 660100 660120

for for for for for

659040 659060 659080 659100 659120

Code without insulation 6637C5 6637D5 6637D5 6637F5 6637G5 6637H5 6637I5 6637L5 6637M5 6637N5 6637O5 Code with insulation 6637C5 IS 6637D5 IS 6637D5 IS 6637F5 IS 6637G5 IS 6637H5 IS 6637I5 IS 6637L5 IS 6637M5 IS 6637N5 IS 6637O5 IS Nr. outlets 3 4 4 6 7 8 9 10 11 12 13 Tot. length manifold (mm) 220 270 270 370 420 470 550 600 650 700 750 Box length (mm) 400 400 400 600 600 800 800 800 800 1000 1000 Box code, 5902 series 590204 590204 590204 590206 590206 590208 590208 590208 590208 590210 590210 Box code, 659 series 659040 659040 659040 659060 659060 659080 659080 659080 659080 659100 659100

Application diagrams

Radiator system with wall-mounted boiler with direct distribution

RT
40 20 0 60 80

RT

CALEFFI

CALEFFI

CALEFFI

40 20 0 60

CALEFFI
80

CALEFFI
CALEFFI

Heating and air-conditioning system with two-pipe fan coils

RT
40 20 0 60 80

RT

CALEFFI

CALEFFI

CALEFFI

40 20 0 60

CALEFFI
80

CALEFFI
CALEFFI

CHILLER

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Distribution manifolds with pre-formed insulation


series 650
cert. n 0003

ISO 9001

01067/03 GB

Function This manifold has been designed specifically for heating and air conditioning systems, for the distribution of hot or cold fluids. It is provided with pre-formed insulation, whose shape and dimensions prevent not only heat loss but also condensing on the metal surfaces. The tight sealing of the insulation is an essential factor in preventing damp air from passing from the atmosphere to the surface of the manifold and forming condensation. For this reason, this solution is considerably more efficient than the traditional polyurethane foam. It is also simpler to check the hydraulic seals and carry out any maintenance work that may be required.

Technical specification: Material: Manifold connections: Branch connections: Branch centre distance: Manifold internal diameter: Hydraulic characteristics Localized loss factor ! of inlet connections: Localized loss factor ! of branches: Characteristics of insulation Hot pre-formed insulation, can be sealed with glue (615500). 1,0 3,0 brass EN 12165 CW617N (cast) 1 1/4" F x 1 1/4" M 3/4" 18 60 mm 36 mm

Dimensions

CALEFFI

D B

Code Material: Thickness: Density: Thermal conductivity (UNI 7745): cross-linked PE expanded 20 mm 33 kg/m3 0C 0,038 W/mK 40C 0,045 W/mK Steam diffusion resistance factor (DIN 52615): > 1300 Temperature range: - 40 95C Fire resistance (D.M. 26/06/84): class 1 650722 650732 650742

A 1 1/4" 1 1/4" 1 1/4"

Branches 2 3 4

B 180 240 300

C 100 100 100

D 60 60 60

E 3/4" 3/4" 3/4"

F 80 80 80

Application diagram

CHILLER

Two pipe system

SPECIFICATION SUMMARIES Manifold series 650

Single manifold in cast brass for heating and air conditioning systems. Manifold connections 1 1/4 F x 1 1/4 M. Number of branches 2 (or 3 or 4); connection 3/4 M 18, centre distance 60 mm. Complete with heat-formed cross-linked PE expanded shell insulation.

Accessories

347 Compression connection for copper pipe, with O-Ring seal.

5994/5995 Single end connection and with double radial connection.

680 Self-adjusting diameter fitting for plastic pipes, single and multi-layer.

392 Connection with thermometer.

5991/5993 Connection and end plug.

615500 Sealant for insulation.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Set point regulating unit for underfloor heating radiant panels


series 160
cert. n 0003

ISO 9001

01069/01 GB
replaces 01069/00 GB

Function The set point regulating unit carries out the function of maintaining the fluid flow temperature constant at the input value when distributed in a low temperature system with underfloor radiant panels. The unit is preassembled with distribution manifolds and is housed in a casing enclosure which guarantees functional simplicity, safety and ease of installation.

Technical / constructional characteristics - Pipe material: - Setting range: - Max. primary input temp.: - Max. pressure: - Differential by-pass regulation: - Thermometers: - Circulator centre distance: - Circulator connections: - Connections to manifold: - Connections to primary circuit: - Connections to branch circuits Dimensions - brass UNI EN 12165 CW617N, - copper with polished surfaces 2050C 100C 10 bar 0,10,6 bar 080C 180 mm 1 1/2 with union 1 1/4 with union 1 with union 3/4 M

Safety thermostat characteristics - Setting range: - Factory setting: - Level of protection: Electrical connections 555C 50C IP 40 Yellow/Green C Blue 1 Brown 2 Black (C-1) 10(2,5)A / 250V (C-2) 1(1)A / 250V

+C C
- Contacts rating: - Contacts rating:

1 2

1000

3 outlets

6 outlets

10 outlets

13 outlets

CALEFFI
40 20 0 60 80

CALEFFI
40 20 0 60 80

CALEFFI

CALEFFI
40 20 0 60 80

CALEFFI

CALEFFI
40 20 0 60 80

CALEFFI

CALEFFI

450 205

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

ATTENZIONE: Il circolatore deve essere installato CALEFFI seguendo il senso di flusso

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 CALEFFI 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 CALEFFI 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 CALEFFI 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

40 20 0 60

40

40 60

40 60

CALEFFI
80

20

CALEFFI

CALEFFI
80

20

CALEFFI

CALEFFI
80

20

60

CALEFFI

CALEFFI
80

CALEFFI

10 8 6 4 2 0

CALEFFI

310 A

50 A A A

1200
35

600

800

60 150190

Code Outlets A

1606C1 3 590

1606D1 4 640

1606E1 5 690

1606F1 6 740

1606G1 7 790

1606H1 8 840

1606I1 9 915

1606L1 10 965

1606M1 11 1015

1606N1 12 1065

1606O1 13 1115

Functional scheme

Thermostatic valve

2 60 95C

20 50C 9

Calibration valve

ST

System pump By-pass valve

1 3

Shut-off valve Check valve

4
ST

Delivery flow sensor Safety sensor

Safety thermostat Thermometer Pressure tapping Manual air vent

Operating principle The unit operates on the principle of mixing the high temperature fluid from the boiler primary circuit at point A with the low temperature fluid returning from the user secondary circuit. The unit consists of the following devices with functions as described: 1 Template for circulator insertion , for distributing the low temperature fluid in the user secondary circuit. 2 Thermostatic valve, which keeps the selected temperature constant in the secondary circuit flow, modulating the quantity of primary fluid at high temperature entering the secondary circuit. It is controlled by the sensor immersed in the secondary fluid. The quantity of incoming primary fluid, under average operating conditions, is approx. 25% of the total flow of the secondary circuit. 3 Calibration valve, which makes it possible to balance the quantity of the two fluids mixed according to the nominal working temperatures, the required output and the secondary fluid flow.
BOILER RETURN

40

9 2

45

20 0

60 80

SYSTEM RETURN

9 7
ATTENZIONE: Il circolatore deve essere installato seguendo il senso di flusso


55
40 20 0 60 80

50
C

FLOW FROM BOILER

FLOW TO SYSTEM

4 Differential by-pass valve, which keeps the pressure in the secondary circuit constant at the set value when the number of open circuits to the underfloor panels varies. These may in fact be automatically closed if the circuit valves have a thermo-electric control head and a thermostat for controlling the output requirement. 5 Ball valve with built-in Ballstop, to control circulation in the hydraulic circuit and to allow for complete shut-off for maintenance purposes. 6 Safety thermostat, which limits the maximum temperature of the fluid flowing to the underfloor panels circuit. If the valve sensor is damaged, it stops the electricity supply to the circulator or the boiler. 7 Thermometers, which make it possible to control the flow and return temperatures of the underfloor panels circuit to maintain the system output, facilitating the calibration operation. 8 Manual air vent, useful during the filling operation of the system. 9 Tapping for connection of pressure gauges, to check the operating conditions of the circuit and the circulator. The gauges can also be connected to the Flomet electronic differential pressure measurer to speed up the system calibration process.

6 9 The regulating unit comes preassembled with: Delivery manifold series 667 equipped with individual circuit micrometric calibration valve.
10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0 10 8 6 4 2 0

CALEFFI

Series 666 return manifold equipped with individual circuit shut-off valves suitable for application of thermo-electric control heads.

CALEFFI

Series 5996 head units with automatic air vent valve and drain valve.

CALEFFI

For further details see brochure 01044 GB

Hydraulic characteristics THERMOSTATIC VALVE


!p (m w.g.) !p (kPa)
45 40 35 30 25 18 16 14 12 9 8 7 6 4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2

Regulating the calibration valve The calibration valve (VB on scheme 1) must create a differential pressure sufficient to force the injection of fluid at a high temperature through the thermostatic valve, !pV ~ !pVB. CALIBRATION VALVE
!p (m w.g.) !p (kPa)
2
4.5 4 3.5 3 2.5 1.8 1.6 1.4 1.2 0.9 0.8 0.7 0.6 0.45 0.4 0.35 0.3 0.25 0.18 0.16 0.14 0.12

1K

2K

4.5 4 3.5 3 2.5 1.8 1.6 1.4 1.2 .9 .8 .7 .6 .45 .4 .35 .3 .25 .18 .16 .14 .12

50

2 1 .5

20 10 5

5 5,5 6

7 TA
45 40 35 30 25 18 16 14 12 9 8 7 6 4.5 4 3.5 3 2.5 1.8 1.6 1.4 1.2

50

2 1 0.5

20 10 5

.2 .1

2 1

25

30

35 40 45

60

70

80

90

120

140 160

180

250

300

350 400 450

600

700

800

1000

20

50

100

200

500

900

0.2 0.1

2 1

250

300

350 400 450

600

700

800

900

1200

1400 1600

1800

2500

3000

200

500

1000

2000

G (l/h)

System sizing The nominal incoming flow from the boiler circuit is calculated using the following equation (see scheme 1): Gc = Gs (Tm-Tr) / (Tc-Tr) where: Gc Gs Tm Tr Tc = = = = = boiler primary circuit flow secondary circuit flow secondary circuit delivery flow temperature secondary circuit return temperature boiler primary circuit temperature

The calibration valve permits 8 regulating turns between the fully closed and fully open positions; normally it is supplied preset at 5,5 turns, which will permit the unit to meet most of the systems operating conditions. If adjustment is necessary, in order to satisfy the real requirements of the system, a practical method and a reference table are given below.

Practical method With reference to the operating temperature conditions of the boiler circuit and the system, the calibration valve must be gradually closed until the set temperature imposed by the thermostatic valve is reached on the unit flow delivery thermometer. This balances the amount of fluid passing respectively through the thermostatic valve and the calibration valve itself under the rated conditions.

These values are used to determine the thermostatic valve head loss, using the graph shown above. The value found must be added to the pressure drop across the secondary circuit to determine the necessary head of the corresponding pump in the case of zero head at the unit connections.

SCHEME 1

Reference table The table below can be used as a guide for setting the calibration valve. It takes account of the main parameters which interact when the system is operating under steady state conditions.
Tc (C) 70
!H=0 VB Tr !ps

Gc !pV

Tc

Tm

Gs

Tm (C) 35 40 45 50 ( - 2 ) 35 50 40 45 50 ( - 2 ) 50
+0 +0

Tr (C) 30 33 35 38 30 33 35 38

VB (n giri) 6,5 5,5 4,0 3,5 6,5 5,5 4,5 4,5

Gs (l/h) 1850 1500 1150 1150 2750 2000 1550 1800

!ps (kPa) 15 15 15 15 25 25 25 25

P max (kW) Pump 1


5000

10 12 13 16 16 16 18 25

70 70 70 70 70 70 70

5000
4000

100

kv (2K) = 0,82 kv (1K) = 0,42

G (l/h)

3500 4000 4500

120

140 160

180

Example Tm = 40C Tr = 33C Tc = 70C Gs = 2000 l/h

Values found with circulators having the following characteristics:


H (kPa)
60 50 40 30 20 10 0
0 1000 2000 3000 4000 5000

Gc = 2000 (40-33) / (70-33) = 378 l/h The following is found from the graph: thermostatic valve head loss !pV ~ 25 kPa The loss of head across the check valve is negligible. Knowing the pressure drop across the secondary circuit !ps = 20 kPa at nominal flow Gs, the following head is obtained H = !pV + !ps = 45 kPa

H (kPa)
80

Pump 1

70 60 50 40 30 20
0 1000 2000 3000

Pump 2

G (l/h)

G (l/h)

Pump 2

Applications schemes

Shut-off valve Thermostatic valve Manual valve 3-way zone valve

Mixed system with wall-mounted boiler and zone valve

RT

Pump
RT

Room thermostat Check valve


RT

Autoflow Filter Hydraulic separator


CALEFFI
ATTENZIONE: Il circolatore deve essere installato CALEFFI seguendo il senso di flusso

CALEFFI
40 20 0 60 80

CALEFFI

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

40 20 0 60

CALEFFI
80

CALEFFI
CALEFFI

Air separator

Average / large systems


CALEFFI
40 20 0 60 80

RT
CALEFFI
C

CALEFFI

CALEFFI

ATTENZIONE: Il circolatore deve essere installato CALEFFI seguendo il senso di flusso

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

40 20 0 60

CALEFFI
80

CALEFFI
CALEFFI

RT
CALEFFI
40 20 0 60 80

CALEFFI

CALEFFI

CALEFFI

ATTENZIONE: Il circolatore deve essere installato CALEFFI seguendo il senso di flusso

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

40 20 0 60

CALEFFI
80

CALEFFI
CALEFFI

SPECIFICATION SUMMARY Series 160 set point regulating unit Set point thermal regulating unit with brass and polished copper piping. Connections to primary circuit 1 with union. Primary max. temperature 100C, max. pressure 10 bar. Complete with: template for insertion of circulator, max. outlets centres 180 mm, connections 1 1/2 with union. Thermostatic valve with remote sensor, setting range 2050C. Calibration valve. Differential by-pass valve, range of calibration 0,10,6 bar. Ball valve with built-in stop. Safety thermostat, setting range 555C, factory calibration 50C, protection to IP 40. Thermometers scale 080C. Tappings for connection to pressure gauge. Flow and return manifolds with 3 (from 3 to 13) outlets complete with micrometric preregulating valves, shut-off valves suitable for thermo-electric control heads and automatic air vent units. Supplied pre-assembled in pre-coated sheet steel casing with lock.

S.S. 229 Km 26,5 I - 28010 Fontaneto dAgogna (NO) Tel. Int. +39 0322 8491 Fax +39 0322 863723 Http://www.calef fi.com E-mail:info@calef fi.it

Zone valves
series 676
cert. n 0003

CALEFFI
ISO 9001

01072/02 GB

Function Zone valves are used to control the thermal carrier fluid in heating and air-conditioning systems. Coupled with a thermo-electric actuator and managed by a room thermostat, they allow automatic on/off control of the part of the hydraulic circuit on which they are inserted. Their special feature is their low flow rate coefficient and they can therefore be installed to control small areas or used directly on the emitters. Product range Zone valves are available in the following configurations: Series 676 Series 677 Series 678 2-way 3-way 4-way sizes 1/2, 3/4, 1 sizes 1/2, 3/4, 1 sizes 1/2, 3/4, 1

They can be coupled with thermo-electric actuator heads: Code 656102/4 Code 656112/4 220 V / 24 V 220 V / 24 V without auxiliary microswitch with auxiliary microswitch

Technical specification Valves Materials: body: obturator: control spindle: hydraulic seals: brass UNI EN 12165 CW617N brass UNI EN 12165 CW617N stainless steel EPDM water, glycol solutions 30% 095C 10 bar 1,2 bar 1/2, 3/4, 1, M with union 1/2 M with union Actuator with auxiliary microswitch Normally closed with auxiliary contact Supply: 220 V o 24 V Starting current: 220 V =0,6 A and 24 V = 2 A Power consumption: 220 V and 24 V = 3 W Auxiliary microswitch contacts current: 0,8 A (220 V) Level of protection: IP44 (in vertical position) Max. ambient temperature: 50C Operating time: opening and closing from 120 s to 180 s Supply cable length: 80 cm

- Medium: - Max. percentage of glycol: Temperature range: Max. pressure: Max. pressure differential: Connections: Bottom 3-way connection:

Reference documentation For further details of the characteristics of series 656 thermo-electric actuators, see the following leaflet: - Thermo-electric actuators leaflet 01042

Actuator without auxiliary microswitch Normally closed Supply: 220 V o 24 V Starting current: 220 V = 0,6 A; 24 V = 2 A Power consumption: 220 V e 24 V = 3 W Level of protection: IP44 (in vertical position) Max. ambient temperature: 50C Operating time: opening and closing from 120 s to 180 s Supply cable length: 80 cm

Dimensions

A B E 81 81 81 A Code A 678040 1/2 678050 3/4 678060 1 B 113 113 122 C 4963 4963 4963
49 63

B C

Code A 676040 1/2 676050 3/4 676060 1

B 113 113 122

C 41 41 41

D 81 81 81

B Code A 677040 1/2 1/2 677050 3/4 1/2 1/2 677060 1

C 113 113 122

D 52 52 52

Operating principle When a room thermostat operates, the thermo-electric actuator causes the opening or closing of the valve obturator controlling the thermal carrier fluid. The actuator operates via a wax expansion thermostat heated up by a PTC resistor, which automatically limits the current once reaching regime temperature.

Construction details Control spindle The stainless steel control spindle has a double hydraulic seal consisting of two EPDM O-rings; this means that the upper part of the unit can be replaced even when the system is operating. Variable centre distance The series 678 4-way valve allows for adjustable centre distance between connections from 49 to 63 mm, permitting direct connection to twin parallel type manifolds. Manual opening The manual knob on the valve can be used for any preliminary opening/closing operations. It is removed to fit the thermo-electric actuator by unscrewing the lower metal ring. The valve, with the servo-actuator fitted, is in the normally closed position; for manual opening, remove the thermo-electric actuator. 2-way valve, series 676 + actuator, series 656

Locking ring

4-way valve, series 678

C D 81 81 81

Hydraulic characteristics Valves in OPEN position


P (mm w.g.)
4000
3000 30

Valves in BY-PASS position


P (kPa)
40 20 10 5

P (mm w.g.)
10000 9000
8000 7000 6000

P (kPa)
90 80 70 60

100

2000 1800
1600 1400 1200 900 800 700 600

18 16 14 12 9 8 7 6

1000 500

5000
4000 40

50

400 300

4 3

3000

30

200 100 50

180 160 140 120 90 80 70 60

1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

2 1

2000

1800 1600 1400 1200

18 16 14 12 9 8 7 6

20

1000
0,5

900 800 700 600

10

40 30

0,4 0,3

250

300

350

400

450

600

700

800

900

1200

1400

1600

1800

250

300

350

400

450

600

700

800

200

500

200

1000

2000

500

900

20

0,2

500 1000

G (l/h)

G (l/h)

Thermo-electric actuators codes: 656102, 656104, 656112, 656114, + zone valves

Series 676 677 678

DN

pmax * (bar) straight by-pass Kv (m3/h) 3,7 3,7 3,7 1,0 1,0 1,2 1,2 1,2

Assembly in manifold box When installing the valves in the relevant zone manifold box, adequate space (20 mm) must be left above the servo-actuator head to permit its replacement. To prevent excessively high temperatures being reached, ensure that sufficient air can circulate inside the manifold box. The figure represents installation in inspection box, series 5901 with controlled pressure twin parallel manifold, series 356.

1/23/4-1

Installation The zone valves must be installed in line with the direction of flow indicated by the arrow on the valve body. The 2-way valve, series 676, can be installed in the flow or return pipework.

Electrical connections with auxiliary microswitch Diagram with pump disconnected The 3-way valve, series 677 and 4-way valve, series 678 must be installed in the flow pipework. The auxiliary microswitch can be used to switch off the pump when heat is not required and the valve is closed. If the pumps power consumption exceeds the capacity of the contacts, equal to 0,8 A, an intermediate relay should be used.

C A L E F F I

C A L E F F I

C A L E F F I

C A L E F F I

* Max. differential pressure ensured by servo-actuator in normal operation

C A L E F F I C A L E F F I C A L E F F I C A L E F F I

L N
Thermostat 220 V / 50 Hz 24 V / 50 Hz

1 Brown 2 Blue 3 Black

The valve is installed with the control knob at the top or in the horizontal position, never upside down. The 2-way valve cannot be converted into a 3-way valve or vice versa.

3 Watt max. 0,8 A

4 Black

Applications diagrams
Shut-off valve Manual valve Electric pump
RT

RT

Room thermostat Check valve Insulated manifold Differential by-pass

Zoned system

RT

RT

CHILLER
Two pipe system

SPECIFICATION SUMMARIES Series 676 2-way zone valve. Designed for thermo-electric actuator. Connections 1/2 (from 1/2 to 1) M, with union. Brass body. Stainless steel control spindle. Control spindle seal with EPDM double O-ring. ABS manual control knob. Temperature range 095C. Max. working pressure 10 bar. Max. differential pressure 1,2 bar. Series 677 3-way zone valve. Designed for thermo-electric actuator. Connections 1/2 (from 1/2 to 1) M, with union. Lower connection 1/2 M, with union. Brass body. Stainless steel control spindle. Control spindle seal with EPDM double O-ring. ABS manual control knob. Temperature range 095C. Max. working pressure 10 bar. Max. differential pressure 1,2 bar. Series 678 4-way zone valve. Designed for thermo-electric actuator. Connections 1/2 (from 1/2 to 1) M, with union. Brass body. Stainless steel control spindle. Control spindle seal with EPDM double O-ring. ABS manual control knob. Temperature range 095C. Max. working pressure 10 bar. Max. differential pressure 1,2 bar.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
S.S. 229 Km 26,5 I-28010 Fontaneto dAgogna (NO) Tel. Int. +39 0322 8491 Fax +39 0322 863723 Http://www.calef fi.com E-mail:info@calef fi.it

Set point regulating unit with distribution kit for high temperatures
series 160
cert. n 0003

CALEFFI
ISO 9001

01073/01 GB

Function The high temperature fluid distribution kit has been produced for use in mixed system solutions: radiant panels and radiators in combination with the low temperature set point regulating unit and underfloor radiant panel distribution manifolds. The kit has the function of distributing to the heat emitters a proportion of the high temperature fluid coming from the boiler primary circuit. It is supplied complete with fixed rating differential by-pass valve. This accessory is, in fact, essential in cases where the radiator circuits are controlled by thermostatic or thermo-electric valves. The kit is available in either a separate component version or a pre-assembled version, with series 160 distribution and set point regulating unit.

Technical specification of kit code 160002/3 - Material: Manifolds: brass UNI EN 12165 CW617N By-pass body: brass UNI EN 12164 CW614N Pre-formed 18 mm flared pipe: copper Hydraulic seals: EPDM 10 bar 100C 20 kPa (2000 mm w.g.)

Reference documentation For further details, see leaflet: - Set point regulating unit for underfloor panel systems Dimensions kit code 160002/3 Code Outlets A B C D E F 160002 2 1 1 1/2 205 164 50 160003 3 1 1 1/2 205 214 50 ref. 01069

Max working pressure: Max temperature: Differential by-pass valve setting:

- Manifold internal diameter: 30 mm - Manifold connections : - Inlet: 1 F - Outlet: 1 M - Branch outlets: 1/2 F - Branch outlets centre distance: 50 mm

C D F

Dimensions 1000 1200 800 2+3 outlets 2+7 outlets 3+6 outlets 2+11 outlets 3+10 outlets

CALEFFI
40 20 0 60 80

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

450 205

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

ATTENZIONE: Il circolatore deve essere installato CALEFFI seguendo il senso di flusso

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

40 20 0 60 80

CALEFFI

CALEFFI

CALEFFI
80

CALEFFI

CALEFFI
80

CALEFFI

10 8 6 4 2 0

CALEFFI

310 A
Code Radiator outlets Panel outlets A Code Radiator outlets Panel outlets A 1606C1 002 1606D1 002 1606E1 002 2 2 2 3 4 5 740 790 840 1606C1 003 1606D1 003 1606E1 003 3 3 3 3 4 5 790 840 890

35 A
1606F1 002 1606G1 002 1606H1 002 2 2 2 6 7 8 890 940 990 1606F1 003 1606G1 003 1606H1 003 3 3 3 6 7 8 940 990 1040

A
1606I1 002 2 9 1065 1606I1 003 3 9 1115

60 150190

1606L1 002 1606M1 002 2 2 10 11 1115 1165 1606L1 003 3 10 1165

Manifold hydraulic characteristics Localised loss coefficient: - of end connection: - of branch outlet: 1,0 3,0

By-pass valve hydraulic characteristics


P (mm w.g.) 10000
9000 8000 7000 6000

P (kPa)
90 80 70 60

100

5000
4500 4000 3500 3000 2500

50
45 40 35 30 25 18 16 14 12

2000
1800 1600 1400

20

1200

250

300

350

400

120

140

160

180

450

60

70

80

90

1000

10
600 700 800

Q (l/h)

Application diagram
Shut-off valve Electric pump
RT

Mixed system with wall-mounted boiler

Room thermostat Thermostatic valve Lockshield valve Manual valve


RT

CALEFFI
40 20 0 60 80

CALEFFI

CALEFFI

CALEFFI

ATTENZIONE: Il circolatore deve essere installato CALEFFI seguendo il senso di flusso

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

40 20 0 60 80

CALEFFI

CALEFFI

3W

CALEFFI

RT

SPECIFICATION SUMMARIES Series 160 (HT)


High temperature set point thermal regulating unit with copper piping and polished surface. Connections to primary circuit 1 F. Connections to high temperature manifold 1 F with nut. Maximum primary temperature 100C. Maximum pressure 10 bar. Complete with template for insertion of circulator, maximum distance 180 mm, connections 1 1/2 with nut; thermostatic valve with remote sensor, regulating range 2050C; balancing valve; differential by-pass valve, setting range 1060 kPa; ball valve with built-in non return valve; safety thermostat, setting range 555C, factory setting 50C, protection to IP40; thermometers, scale 080C; arrangement for connection of pressure gauges; 3-outlet flow manifold (3 to 11) connection 3/4 M for panel system circuit, complete with micrometric preregulation valve and air venting unit; 3-outlet return manifold ( 3 to 11) connection 3/4 M for panel system circuit, complete with shut-off valve arranged for thermo-electric actuator operation and air balancing unit; 2-outlet return manifold (2 to 3) connection 1/2 F for high temperature circuit, with differential by-pass valve set at 20 kPa. Supplied pre-assembled in pre-coated sheet steel casing.

Code 160002
2-outlet flow and return manifolds for high temperature circuit. Brass body. Manifold connections 1 M x 1 F. Outlet connections 1/2 F. Supplied with differential by-pass valve set at 20 kPa.

Code 160003
3-outlet flow and return manifolds for high temperature circuit. Brass body. Manifold connections 1 M x 1 F. Outlet connections 1/2 F. Supplied with differential by-pass valve set at 20 kPa.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
S.S. 229 Km 26,5 I-28010 Fontaneto dAgogna (NO) Tel. Int. +39 0322 8491 Fax +39 0322 863723 Http://www.calef fi.com E-mail:info@calef fi.it

1000

100

200

500

50

900

CALEFFI
2-

65610

220 V -

Fuel shut-off valve I.S.P.E.S.L. approved


series 540
cert. n 0003

CALEFFI
ISO 9001

01074/03 GB

General Series 540 (97C) fuel shut-off valves are made by Caleffi S.p.A. in compliance with the essential safety requirements laid down by directive 97/23/CE of the European Parliament and the Council of the European Union for harmonisation of member states with regard to pressurised equipment. Function The Caleffi series 540 fuel shut-off valve is a fail-safe safety device with pre-set calibration. The valve, installed in the burner fuel supply pipework, shuts off the flow of fuel when the temperature of the heat-carrying fluid reaches the calibrated value of the sensor. As this is a fail-safe device, in the case of damage to the sensor assembly, the fuel supply pipe is closed automatically. This valve can be used with different types of gaseous fuels and is available in versions for superheated water.
111 5

I.S.P.E.S.L.

Product range Series 540 Fuel shut-off valve with flanged connections Sizes DN 65, DN 80, DN 100

Technical specification Materials: - body: - spring: - seals: Flanged connections PN16: Sensor pocket connection: Calibration temperature: aluminium alloy stainless steel NBR DN 65 - 80 - 100 1/2 M

Dimensions

97C (+3 -3C) I.S.P.E.S.L. approved 120C (+0 -5C) I.S.P.E.S.L. approved 140C (+0 -5C) supplied with declaration of conformity 160C (+0 -5C) supplied with declaration of conformity 180C (+0 -5C) supplied with declaration of conformity Max temperature: - (sensor side): calibration temperature + 20% - (valve side): 50C Average working temperature (using gas): 15C 12 bar Max working pressure: - (sensor side): - (valve side) using gas: 50 kPa Suitable for following fuels: methane, LPG PED category: IV

D B C G 60 60 60
Weight (kg)

Code completion (.) With 5 m capillary 0 97C 2 120C 4 140C 6 160C 8 180C

Length of connecting capillary tube 5 or 10 m Code A B C D E F 54060. DN 65 310 112,5 225 337,5 1/2 54080. DN 80 310 112,5 225 337,5 1/2 54010. DN 100 350 157,0 214 371,5 1/2

With 10 m capillary 1 97C 3 120C 5 140C 7 160C 9 180C

E 9,5 9,9 15,5

Operating principle If the calibrated temperature is reached, the vapour pressure sensitive element, with the change of state, causes the triggering of the actuator via the capillary tube and the flexible bellows. The intervention functions are restored by pressing the pushbutton positioned in the lower part of the valve and protected by a metal cover.

Sensor pocket The compact dimensions of the pocket make it suitable even for small diameter pipework. In addition, its limited height means that it can be positioned vertically, avoiding difficult installation in the case of slopes or near bends. The superheated water versio of the pocket is made of stainless steel.

Fluid-dynamic characteristics
Methane at 15C P (mm w.g.)
500 300 200 100
450 400 350 250 180 160 140 120 90 80 70 60 40 35

DN 65 DN 80 DN 100

P (kPa)
4,5 4 3,5 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

5 3 2 1

5045 30 20
25

0,45 0,4 0,35 0,25

0,5 0,3 0,2 0,1 0,05 0,03 0,02

10 9
8 7 6

18 16 14 12

0,18 0,16 0,14 0,12 0,09 0,08 0,07 0,06

5 4,5 3 2
4 3,5 2,5 120 140 160 180 250 60 25 30 12 14 16 18 35 40 45 70 80 90 1200 1400 1600 1800 2500 300 350 400 450 600 700 800 900

0,045 0,04 0,035 0,025

2000

3000 3000

1000

Constructional details
LPG at 15C

G (m3/h)

Reset Should the shut-off device be activated, it has to be reset to its original status as follows: a) Wait until the water temperature falls to 10C below the shut-off temperature (otherwise it will not be possible to reset the device). b) Unscrew the protective cap. c) Press the reset button. Series 540 valves are positive action (fail-safe) devices: if the sensor element is damaged or the capillary is broken, the positive action consists of an upward movement of the control unit, thus triggering the actuator, which in turn closes the valve. If this situation occurs, the valve must be replaced.

P (mm w.g.)
500 300 200 100
450 400 350 250 180 160 140 120 90 80 70 60 40 35

DN 65 DN 80 DN 100

P (kPa)
4,5 4 3,5 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

4000
5 3 2 1
0,45 0,4 0,35 0,25

10

20

50

100

200

5045 30 20
25

500

0,5 0,3 0,2 0,1 0,05 0,03 0,02

10 9
8 7 6

18 16 14 12

0,18 0,16 0,14 0,12 0,09 0,08 0,07 0,06

5 4,5 3 2
4 3,5 2,5 120 140 160 180 250 60 25 30 12 14 16 18 35 40 45 70 80 90 1200 1400 1600 1800 2500 700 300 350 400 450 600 800 900

0,045 0,04 0,035 0,025

2000

1000

G (m3/h)

Guideline ratings of boilers (kW)


Series Size Methane LPG

540 540 540

DN 65 DN 80 DN 100

900 - 1.900 1.100 - 2.600 1.900 - 4.500

1.700 - 2.300 1.900 - 2.900 3.400 - 4.600

4000

10

20

50

100

200

500

Certification CE mark Series 540 (97C) fuel shut-off valves meet the requirements of directive 97/23/CE for pressurised equipment (also referred to as the PED). They are therefore classified in Category IV and granted the CE mark.

The bench calibration report is the document confirming the testing of each individual device included in the approved series. The test is carried out in the presence of an I.S.P.E.S.L. inspector who draws up the report after the test has been passed. The document gives the serial number of the valve, which is also to be found on the plate fixed to the valve body. There is only one copy of the report and it is therefore vital for it to be kept with the valve.

9 - S.S. 22 gna (NO) rmici to d'Ago nti idrote Fontane ILE 28010 enti per impia MBUSTIB on CO mp L Co DE VOLA A. VAL R TAZIONE A CALD TA TERCET A DI IN NTI AD ACQU RACCOL IVE O AT IC ND VALVOL .L. PL PIA CO PER IM OGATA SE CNICHE AP ICA I.S.P.E.S OMOL CAZIONI TE ARE TECN /92 OL 6/8 SPECIFI E CIRC . 8273 DEL 1/12/75 PROT DEL DM N. 68/92,
: RCHIO : PN 16 A) MARIE: 540 IN MINALE MESSI B) SE ESSIONE NO NALE: DN 65 TURA AM C) PR METRO NOMI RI DI TARA D) DIAMPO DEI VALO 100C 94 : E) CA LLERANZA NE IO TO AZ OLOG 98 DI OM 19 CATO del 23-10CERTIFI /98 VIC/725

CALEFFI

S.p.A.

origina

le

ISTITUTO I.S SUPE .P.E.S.L E SICUR RIORE PREV Dipartim ENZIONE ento di EZZA LAVORO BIELLA - Via Ce rruti, 7 VERBAL E DI INTE DI TARATU RA RCETTA PRESSO ZIONE AL BANCO DI DEL RACCOL VA IL TA R FABBRICA COMBUST LVOLA APPLIC - SPECIF NTE SECONDIBILE ICAZIO ATIVE NI TE O DEL DM FONTAN 1/12/1 CNICHE 975 ETO D' AG
OGNA

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I S.p.A. CALEFF e Tecnica ion La Direz

atura: 97 le di tar

EN AVVERT

Valvola ............ di ....... positiva intercettazion , serie e 540, DN del combus VIC/725 tibile 65, certif /9 La ve rif 8 del 23-10icato I.S ad azione 98. ica de .P. E.S.L. eseguit lla ta ra n a al ba tu ra de nco co 97 3 n acqu lla va lvo la a st l'i nt er C, campo di valori en alla temperat at a ve ur tro i qu intercett nt o in ch iu ali av a di azione. su ra ve de l di La tem sp os iti nuto pe vo di campo ratura di inter de ve valore no i valori amme nto riscontra ta ss minale ed in di taratu i in tolleranz rientra nel accord a ra, ris dic petto al o con qu hia III de lla anto ind rato dal costr utt applica Ra cc olt a R icato ne tiv ll'Appen ore L'inamo e del DM 1/12 - Sp ec ific az ion i Te dice /1975. vibilit de cn ich e di ta ra tu ra lle parti intere ssate e A segu re ali zz della po ito del at a m buon es ed ian te sizione l'identifi ito de pi om ba cazione seguen tu ra . della va lla verifica di ti da tar lvola, ve a) march ti: ngono atura, per io punzon b) nume I.S.P.E.S.L.; ati i ro della valvola.
....

............

............

Il Tecn ico

I.S.P.E.

S.L.

I.S.P.E.S.L. mark The fuel shut-off valve (in our case the valves calibrated to 97C and 120C) is a component which is I.S.P.E.S.L. approved. Devices of this type are covered by the following types of document: The approval certificate is the document issued by the I.S.P.E.S.L. which attests to the positive result of the tests carried out on the prototype sample and consequently certifies that the series in question has been approved. The document is valid for five years. Every item of the series covered by the certificate, which is manufactured during the five years validity period, is approved for an indefinite period.

The declaration of conformity, is the document issued by the manufacturer which confirms that the article in question was made in accordance with the reference standards for I.S.P.E.S.L. approval, but without having had a prototype sample approved. In practice, this is equivalent to a declaration of compliance (i.e. L. 46).

Installation Before installing a fuel shut-off valve, correct sizing must be carried out by specialist technical personnel in accordance with the current legislation governing the specific applications. It shall not be used other than for its stated purpose. The fuel shut-off valve must be installed by competent technical personnel qualified in accordance with current legislation. The valve sensor must be installed at the top of the boiler or in the flow pipework within 0,5 m of the boiler, upstream of any other shut-off control. The valve is installed in the fuel supply pipework, in line with the flow direction indicated by the arrow, even if this is in the vertical position.

References to I.S.P.E.S.L. standards Series 540, calibration 97C Use: hot water systems (temperature < 100C) - section R ed. 82 (R.2.A. 4) The fuel shut-off valve is used in the following types of open vented system: - Hot water heating system where the safety pipe runs downwards (R3A 1.14). - Hot water heating system in existence on the date of the coming into force of D.M. 1-12-75, where the safety pipe, although having a minimum diameter greater than 18 mm, does not permit discharge into the atmosphere of the maximum quantity of steam which could be produced in relation to the capacity of the boiler (R3A 3.1). It is not used in sealed systems: - In secondary circuits in heat exchangers supplied with fluids at a temperature above 100C with controls on the secondary or where automatic on/off control is not excluded. In these cases a heat discharge (temperature relief) valve must be installed.

When installing the device, appropriate precautions must be taken to ensure that the capillary connecting the sensor to the valve does not become squashed or excessively bent. In order to prevent tampering or accidental leaks of the sensor, the latter must be sealed in the pocket (the seal and the securing wire are included in the package). Application diagram

Series 540, calibration 120-140-160-180C Use: superheated water systems (temperature > 100C) section H ed. 82 (H.4. 4) The fuel shut-off device must be used in all types of open and sealed systems except for those fired by solid fuel or with heat sources other than fire.

Max 0,5 m

SPECIFICATION SUMMARIES Series 540, calibrations 97 and 120C Manual reset fuel shut-off valve. I.S.P.E.S.L. approved. Bearing CE mark as per directive 97/23/CE (calibration 97C). Positive action (fail-safe). Flanged connections DN 65 (from DN 65 to DN 100), PN 16. Body in aluminium. Sensor pocket connection 1/2 M. Stainless steel spring. Seals NBR. Capillary length 5 m (or 10 m). Maximum working temperature (valve side) 50C. Maximum working temperature (sensor side) + 20% of calibrated temperature. Maximum working pressure (valve side) 50 kPa. Maximum working pressure (sensor side) 12 bar. Calibration 97C (97 and 120C). Series 540, calibrations 140 - 160 and 180C Manual reset fuel shut-off valve. Supplied with declaration of conformity from the manufacturer. Positive action (fail-safe). Flanged connections DN 65 (from DN 65 to DN 100), PN 16. Body in aluminium. Sensor pocket connection 1/2 M. Stainless steel springs. Seals NBR. Capillary length 5 m (or 10 m). Maximum working temperature (valve side) 50C. Maximum working temperature (sensor side) + 20% of calibrated temperature. Maximum working pressure (valve side) 50 kPa. Maximum working pressure (sensor side) 12 bar. Calibration 140C (140 - 160 and 180C).

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Hydraulic separator
548 series
cert. n 0003

CALEFFI
ISO 9001

01076/06 GB
Replaces 01076/05 GB

Function This device consists of several different functional components, each of which meets specific requirements, typical of the circuits used in heating and air-conditioning systems. Hydraulic separator To keep connected hydraulic circuits totally independent from each other. Dirt remover To permit the separation and collection of any impurities present in the circuits. Provided with a valved connection with discharge piping. Automatic air vent valve For automatic venting of any air contained in the circuits. Provided with a valved connection for maintenance purposes. Insulation Flanged and welded versions of separators are supplied complete with pre-formed shell insulation to ensure perfect heat insulation when used in both hot and cold water systems. Reference documentation - Tech. Broch. 01031 Automatic air vent valve, 501 series - Tech. Broch. 01054 Automatic air vent valve, 5020 series

Product range 548 series Threaded hydraulic separator with pre-formed insulation 548 series Flanged hydraulic separator with pre-formed insulation sizes 1, 1 1/4, and 1 1/2 F with union sizes DN 50, DN 65, DN 80, DN 100, DN 125 and DN 150

Technical specifications series Materials: - Separator body: - Automatic air vent body: - Automatic air vent float: - Automatic air vent hydraulic seals: - Drain valve body - Shut-off valve body: Performance: - Medium - Max. percentage glycol: - Max. working pressure: - Temperature range: Connections: - Separator: Front (thermometer pocket) Automatic air vent: Automatic air vent discharge Drain valve 1, 1 1/4, 1 1/2 F with union 1/2 F 1/2 M hose connection DN 50 - 65 - 80 - 100 - 125 - 150 flanged PN 16 to be coupled with counterflanges EN 1092-1 3/4 F 3/8 F 1 1/4 F water, glycol solutions non hazardous, therefore excluded from the guidelines of 67/548/EC Directive 30% 10 bar 0110C water, glycol solutions non hazardous, therefore excluded from the guidelines of 67/548/EC Directive 50% 10 bar 0110C 548 threaded 548 flanged

epoxy resin coated steel brass EN 12165 CW617N, chrome plated PP EPDM brass EN 12165 CW617N -

epoxy resin coated steel brass EN 12165 CW617N stainless steel VITON brass EN 12165 CW617N, chrome plated brass EN 12165 CW617N, chrome plated

Technical specifications of insulation for threaded and flanged versions DN 125 and DN 150 Internal part - Material: closed cell expanded PE-X - Thickness: - threaded 20 mm - flanged 60 mm - Density: - internal part: 30 kg/m3 - external part: 50 kg/m3 (threaded), 80 kg/m3 (flanged) - Thermal conductivity (ISO 2581): - 0C: 0,038 W/(mK) - 40C: 0,045 W/(mK) - Coefficient of resistance to the diffusion of water vapour (DIN 52615): > 1.300 - Temperature range: 0100C - Reaction to fire (DIN 4102): class B2 External cover (for flanged versions DN 125 and DN 150) - Material: embossed aluminium - Thickness: 0,70 mm - Reaction to fire (DIN 4102): class 1 Technical specifications of insulation for flanged versions from DN 50 to DN 100 Internal part - Material: rigid closed cell expanded polyurethane foam - Thickness: 60 mm - Density: 45 kg/m3 - Thermal conductivity (ISO 2581): 0,023 W/(mK) - Temperature range: 0 105C External cover - Material: - Thickness: - Reaction to fire (DIN 4102): Head covers - Heat moulded material: embossed aluminium 0,7 mm class 1 PS

Dimensions

E A A

SEPARATORE IDRAULICO
Serie 548

Tmax 120C Pmax 10 bar

Tmax 105C Pmax 10 bar

Tmax 120C Pmax 10 bar

Tmax 105C Pmax 10 bar

B
Code 548052 548062 548082 548102 548122 548152 A DN 50 DN 65 DN 80 DN 100 DN 125 DN 150 B 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4" C 341 341 389 389 374 374

B F
D 330 330 450 450 560 560 E 398 398 440 440 499 499 F Weight (kg) 350 33 350 36 466 49 470 53 635 100 635 105

Code A 548006 1" 548007 1 1/4 548008 1 1/2 Size Volume (l) 1 1,7

B C D E Weight (kg) 225 195 220 204 2,7 248 225 240 214 3,8 282 235 260 224 5,7

1 1/4 1 1/2 DN 50 DN 65 DN 80 DN 100 DN 125 DN 150 2,6 4,8 15 15 30 30 85 88

Operating principle When a single system contains a primary production circuit, with its own pump, and a secondary user circuit, with one or more distribution pumps, operating conditions may arise in the system whereby the pumps interact, creating abnormal variations in circuit flow rates and pressures. The hydraulic separator creates a zone with a low pressure loss, which enables the primary and secondary circuits connected to it to be hydraulically independent of each other; the flow in one circuit does not create a flow in the other if the pressure loss in the common section is negligible. In this case, the flow rate in the respective circuits depends exclusively on the flow rate characteristics of the pumps, preventing reciprocal influence caused by connection in series. Therefore, using a device with these characteristics means that the flow in the secondary circuit only circulates when the relevant pump is on, permitting the system to meet the specific load requirements at that time. When the secondary pump is off, there is no circulation in the secondary circuit; the whole flow rate produced by the primary pump is by-passed through the separator. With the hydraulic separator, it is thus possible to have a production circuit with a constant flow rate and a distribution circuit with a variable flow rate; these operating conditions are typical of modern heating and Gp Gs air-conditioning systems.

primary

secondary

Three possible hydraulical balance situations are shown below.

Primary
Gp

Secondary
Gs

Primary
Gp

Secondary
Gs

Primary
Gp

Secondary
Gs

Gprimary = Gsecondary

Gprimary > Gsecondary

Gprimary < Gsecondary

Construction details

Insulation Flanged versions separators up to DN 100 are available complete with the insulation made of a shell in expanded polyurethane foam coated with an aluminium layer. For threaded and flanged versions DN 125 and DN 150, insulation is made of a pre-formed shell in closed cell expanded PE-X. This insulation ensures not only perfect heat insulation but also the tightness required to prevent atmospheric water vapour from entering the unit. For these reasons, this type of insulation can also be used in cooling water circuits, as it prevents the formation of condensate on the surface of the valve body.

Isolating the air vent valve In flanged separators, the air vent is isolated manually, using a ball valve. In threaded separators, however, the air vent body is automatically isolated by the built-in valve, which closes when the air vent body is removed.

Dirt removing element A vital function of the hydraulic separator is carried out by the dirt removing element inside the device. This makes it possible to separate and collect any impurities which may be present in the system. These impurities are removed by means of the drain valve, which can be connected to a discharge pipe, placed at the bottom of the separator.

Hydraulic characteristics The hydraulic separator should be sized according to the maximum flow rate value at the inlet. The selected design value must be the greatest between the primary circuit and the secondary circuit.

Size 1 1 1/4 1 1/2

Flow rate m3/h 2,5 4 6

Size DN 50 DN 65 DN 80 DN 100 DN 125 DN 150

Flow rate m3/h 9 18 28 56 75 110

Application diagram

Shut-off valve Check valve Three-way mixing valve Clock Temperature controller Pressure gauge

SPECIFICATION SUMMARIES
548 series Hydraulic separator. Connections 1 F (from 1 to 1 1/2) with union. Front connection 1/2" F (thermometer pocket). Epoxy resin coated steel body. Medium: water, glycol solutions non hazardous, therefore excluded from the guidelines of 67/548/EC Directive. Maximum percentage of glycol: 30%. Maximum working pressure: 10 bar. Temperature range: 0110C. Supplied with: - Automatic air vent valve. 1/2 M connection. Brass body, chrome plated. PP float. EPDM hydraulic seals. - Drain valve. Hose connection. Brass body. - Hot pre-formed shell insulation in closed cell expanded PE-X. Temperature range: 0100C. 548 series Hydraulic separator. Flanged connections DN 50 (from DN 50 to DN 150) PN 16, to be coupled with counterflanges EN 1092-1. Epoxy resin coated steel body. Medium: water, glycol solutions non hazardous, therefore excluded from the guidelines of 67/548/EC Directive. Maximum percentage of glycol: 50%. Maximum working pressure: 10 bar. Temperature range: 0110C. Supplied with: - Automatic air vent valve. 3/4" F connection. 3/8 F discharge connection. Brass body. Stainless steel float. VITON hydraulic seals. - Drain valve. 1 1/4" F connection. Brass body, chrome plated. - Rigid closed cell expanded polyurethane foam shell insulation to DN 100 (closed cell expanded PE-X for DN 125 and DN 150). External embossed aluminium cover. Temperature range: 0105C (0100C for DN 125 and DN 150).

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Hydraulic separator

CALEFFI
548 series
ACCREDITED

01076/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003

replaces 01076/06 GB

Function This device consists of several different functional components, each of which meets specific requirements, typical of the circuits used in heating and air-conditioning systems. Hydraulic separator To keep connected hydraulic circuits totally independent from each other. Dirt remover To permit the separation and collection of any impurities present in the circuits. Provided with a valved connection with discharge piping. Automatic air vent For automatic venting of any air contained in the circuits. Provided with a valved connection for maintenance purposes. Insulation The separators, threaded and flanged up to DN 150, are supplied complete with pre-formed shell insulation to ensure perfect thermal insulation when used in both hot and cold water systems. Reference documentation - Tech. Broch. 01031 Automatic air vent, 501 series - Tech. Broch. 01054 Automatic air vent, 5020 series

Product range 548 series Threaded hydraulic separator with pre-formed insulation 548 series Flanged hydraulic separator with pre-formed insulation 548 series Flanged hydraulic separator with floor supports sizes 1, 1 1/4, 1 1/2, 2 sizes DN 50, DN 65, DN 80, DN 100, DN 125, DN 150 sizes DN 200, DN 250, DN 300

Technical specifications series Materials Separator body: Automatic air vent body: Automatic air vent float: Automatic air vent seals: Drain valve body: Shut-off valve body: Performance Medium: Max. percentage of glycol: Max. working pressure: Working temperature range: Connections Separator: 548 threaded 548 flanged

epoxy resin coated steel brass EN 12165 CW617N, chrome plated PP EPDM brass EN 12165 CW617N -

epoxy resin coated steel brass EN 12165 CW617N stainless steel VITON brass EN 12165 CW617N, chrome plated brass EN 12165 CW617N, chrome plated

water, non-hazardous glycol solutions excluded from the guidelines of directive 67/548/EC 30% 10 bar 0110C

water, non-hazardous glycol solutions excluded from the guidelines of directive 67/548/EC 50% 10 bar 0110C

1, 1 1/4, 1 1/2, 2 F with union

Probe holder: Automatic air vent: Automatic air vent discharge: Drain valve:

front 1/2 F 1/2 M hose connection

DN 50 - 65 - 80 - 100 - 125 - 150 Flanged PN 16 DN 200 - 250 - 300 Flanged PN 10 to be coupled with counterflange EN 1092-1 inlet/outlet 1/2 F 3/4 F 3/8 F DN 50DN 150: 1 1/4 F DN 200DN 300: 2 F

Dimensions

Volumes Size 1 Volume (l) 001,7 002,6 004,8 013,5 015,0 015,0 030,0 030,0 085,0 088,0 394,0 778,0 990,0

Technical specifications of insulation for threaded and DN 125 / DN 150 flanged models Inner part Material: closed cell expanded PE-X Thickness: - threaded 20 mm - flanged 60 mm Density: - inner part: 30 kg/m3 - outer part: 50 kg/m3 (threaded), 80 kg/m3 (flanged) Thermal conductivity (ISO 2581): - at 0C: 0,038 W/(mK) - at 40C: 0,045 W/(mK) Coefficient of resistance to water vapour (DIN 52615): > 1.300 Working temperature range: 0100C Reaction to fire (DIN 4102): class B2 External cover (for DN 125 and DN 150 flanged models) Material: embossed unfinished aluminium Thickness: 0,7 mm Reaction to fire (DIN 4102): class 1 Technical specifications of insulation for flanged models from DN 50 to DN 100 Inner part Material: rigid closed cell polyurethane foam Thickness: 60 mm Density: 45 kg/m3 Thermal conductivity (ISO 2581): 0,023 W/(mK) Working temperature range: 0105C External cover Material: Thickness: Reaction to fire (DIN 4102): Head covers Heat moulded material: embossed unfinished aluminium 0,7 mm class 1 PS

1 1/4 1 1/2 2
D
Tmax 120C Pmax 10 bar Tmax 105C Pmax 10 bar

DN 50 DN 65
A

DN 80 DN 100 DN 125 DN 150


B

DN 200
Code A B C 548006 1" 225 195 548007 1 1/4 248 225 548008 1 1/2 282 235 548009 2 315 281 D 220 240 260 300
Mass (kg) E 204 2,7 214 3,8 224 5,7 230 11,8

DN 250 DN 300

E A

SEPARATORE IDRAULICO
Serie 548

Tmax 120C Pmax 10 bar

Tmax 105C Pmax 10 bar

Operating principle When a single system contains a primary production circuit, with its own pump, and a secondary user circuit, with one or more distribution pumps, operating conditions may arise in the system whereby the pumps interact, creating abnormal variations in circuit flow rates and pressures.
D 330 330 450 450 560 560 E 398 398 440 440 499 499 F 460 460 526 529 670 670
Mass (kg)

When the secondary pump is off, there is no circulation in the secondary circuit; the whole flow rate produced by the primary pump is by-passed through the separator. With the hydraulic separator, it is thus possible to have a production circuit with a constant flow rate and a distribution circuit with a variable flow rate; these operating conditions are typical of modern heating and air-conditioning systems.

B F
Code A 548052 DN 50 548062 DN 65 548082 DN 80 548102 DN 100 548122 DN 125 548152 DN 150 B 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4" C 341 341 389 389 374 374

34,5 39 51 55 104 108

The hydraulic separator creates a zone with a low pressure loss, which enables the primary and secondary circuits connected to it to be hydraulically independent of each other; the flow in one circuit does not create a flow in the other if the pressure loss in the common section is negligible. In this case, the flow rate in the respective circuits depends exclusively on the flow rate characteristics of the pumps, preventing reciprocal influence caused by connection in series. Therefore, using a device with these characteristics means that the flow in the secondary circuit only circulates when the relevant pump is on, permitting the system to meet the specific load requirements at that time.

Gp

Gs

primary

secondary

SEPARATORE IDRAULICO
Serie 548
38...

Tmax 110C

Pmax 10 bar

Three possible hydraulical balance situations are shown below.

Primary
Gp

Secondary
Gs

Primary
Gp

Secondary
Gs

Primary
Gp

Secondary
Gs

E
Code A B E F Mass (kg) C D 548200 DN 200 1000 610 400 900 250 255 548250 DN 250 1100 660 460 1060 250 410 548300 DN 300 1200 710 500 1180 250 600 Without insulation

Gprimary = Gsecondary

Gprimary > Gsecondary

Gprimary < Gsecondary

Construction details

Insulation Flanged versions separators up to DN 100 are available complete with the insulation made of a shell in expanded polyurethane foam coated with an aluminium layer. For threaded and flanged versions DN 125 and DN 150, insulation is made of a pre-formed shell in closed cell expanded PE-X. This insulation ensures not only perfect thermal insulation but also the tightness required to prevent atmospheric water vapour from entering the unit. For these reasons, this type of insulation can also be used in cooling water circuits, as it prevents the formation of condensate on the surface of the valve body.

Air vent shut-off In flanged separators, the automatic air vent is shut off manually using a ball valve. In threaded separators, however, the air vent is shut off automatically by the valve, which closes when the air vent body is removed.

Dirt separator element An essential function of the hydraulic separator is carried out by the dirt separator element inside the device. This makes it possible to separate and collect any impurities which may be present in the system. These impurities are removed by means of the drain valve, which can be connected to a discharge pipe, placed at the bottom of the separator.

Hydraulic characteristics The hydraulic separator should be sized in accordance with the maximum recommended flow rate value at the inlet. The selected design value must be the greater between the primary circuit value and secondary circuit value. Size 1 1 1/4 1 1/2 2 Flow rate (m3/h) 2,5 4 6 8,5 Size DN 50 DN 65 DN 80 DN 100 DN 125 DN 150 DN 200 DN 250 DN 300 Flow rate (m3/h) 9 18 28 56 75 110 180 300 420

Probe holder connections The range of separators is supplied with 1/2 probe holder connections, which can be used with temperature probes or temperature gauges. Flanged models have a connection on both flow and return channels, as they are important points for the measurement. Since the separator connections are reversible on the primary or secondary circuit, the temperature reading options for the medium are expanded.

Application diagram Shut-off valve Check valve Three-way mixing valve Clock Outside temperature regulator Pressure gauge Outside temperature probe

SPECIFICATION SUMMARIES
548 series Hydraulic separator. Connections 1 F (from 1 to 2) with union. Epoxy resin coated steel body. Medium water and non-hazardous glycol solutions excluded from the guidelines of EC directive 67/548. Maximum percentage of glycol 30%. Maximum working pressure 10 bar. Working temperature range 0110C. Complete with: - Automatic air vent. 1/2 M connection. Brass body, chrome plated. PP float. EPDM hydraulic seals. - Drain valve. Hose connection. Brass body. - Front probe holder connection 1/2 F. - Hot pre-formed shell insulation in closed cell expanded PE-X. Working temperature range 0100C. 548 series Hydraulic separator. Flanged connections DN 50 (from DN 50 to DN 150) PN 16, DN 200 (from DN 200 to DN 300) PN 10, for coupling with counterflanges EN 1092-1. Epoxy resin coated steel body. Medium water and non-hazardous glycol solutions excluded from the guidelines of EC directive 67/548. Maximum percentage of glycol 50%. Maximum working pressure 10 bar. Working temperature range 0110C. Complete with: - Automatic air vent. Connection 3/4 F. Outlet connection 3/8 F. Brass body. Stainless steel float. VITON hydraulic seals. - Drain valve. Connection 1 1/4 F. Brass body, chrome plated; 2 F for DN 200DN 300. - Inlet/outlet probe holder connections 1/2" F. - Rigid closed cell polyurethane foam insulation for sizes up to DN 100 (closed cell expanded PE-X for DN 125 and DN 150). Embossed unfinished aluminium external cover. Working temperature range 0105C (0100C for DN 125 and DN 150). - Floor supports for sizes DN 200DN 300.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.p.A. S.R.229, N.25 28010 Fontaneto dAgogna (NO) Italy Tel. +39 0322 8491 Fax +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

Expansion vessels
series 555 - 5558 - 556 - 568 01079/01

Function Expansion vessels are devices designed to accommodate the increase in the volume of water due to the raising of its temperature, both in heating systems and in domestic hot water production systems. They are also used as pressure restorers in potable water distribution systems.

Product range Series 555 Series 5558 Series 556 Series 568 Standardised crimped expansion vessel for heating and potable water systems Capacities l: 2, 5, 8, 12, 18, 24 Flat circular crimped expansion vessel for heating systems Capacities l: 5, 8, 10, 12, 14, 18 Welded expansion vessel for heating systems, CE certified Capacities l: 35, 50, 80, 105, 150, 200, 250, 300, 400, 500, 600 Welded expansion vessel for potable water systems, CE certified Capacities l: 60, 80, 100, 200, 300, 500

Technical specification

Series Materials: - Body: - Membrane: Performance: - Max working pressure:

555

5558

556

568

Steel Non-toxic butyl

Steel SBR synthetic rubber

Steel SBR synthetic rubber

Steel Non-toxic butyl

10 bar

3 bar

35 and 50 l; 4 bar 80600 l; 6 bar 35 and 50 l; 1,5 bar 80150 l; 2 bar 200600 l; 2,5 bar 99C 35400 l; 3/4 M 500 e 600 l; 1 M

10 bar

- Pre-charge pressure:

1,5 bar

1 bar

1,5 bar

- Max working temperature: Connection to pipework:

99C 2 l; 1/2 M 524 l; 3/4 M

90C 3/4 M

99C 60100 l; 1 M 200500 l; 1 1/2 M

Dimensions

A H

Code 555002 555005 555008 555012 555018 555024

Litres 2 5 8 12 18 24

A 1/2 3/4 3/4 3/4 3/4 3/4

140 160 200 270 270 300

H 220 288 308 292 377 420 A

Code 556035 556050

Litres 35 50

A 3/4 3/4

404 407

Code 568060 568080 568100 568200 568300 568500 Litres A B 60 1 1/2 80 1 1/2 100 1 1/2 200 1 1/2 1/2 300 1 1/2 1/2 500 1 1/2 1/2 H 380 860 450 830 450 910 550 1235 630 1365 750 1560

Code 555805 555808 555810 555812 555814 555818 Litres 5 8 10 12 14 18 A 3/4 3/4 3/4 3/4 3/4 3/4 387 387 387 387 387 387

H H 85 104 110 140 150 200

Code Litres 556080 80 556105 105 556150 150 556200 200 556250 250 556300 300 556400 400 556500 500 556600 600

A 3/4 3/4 3/4 3/4 3/4 3/4 3/4 1 1

450 500 500 600 630 630 630 750 750

Operating principle Expansion vessel The closed expansion vessel with membrane (diaphragm) consists of a closed container divided into two parts by a membrane which separates the water from the gas (usually nitrogen) and acts as an expansion accommodator. Following an increase in temperature, an increase in pressure takes place in the vessel in relation to the pre-charge pressure when cold (Fig. 1) until it reaches the value corresponding to the maximum expansion (Fig. 2). Pressure restorer The operating principle of a pressure restorer is as follows: The pump, activated by the pressure switch, starts up and the vessel starts to fill. When the pressure reaches the set value, the pump stops; the tank is at its maximum capacity (Fig. 1). If the user draws off water, the pressure is gradually restored to the system, in the period between the de-activation and the activation of the pump (Fig. 2).

H H 608 665 897 812 957 1105 1450 1340 1555

H H 408 530

Sizing Method Heating systems The capacity of a closed expansion vessel with membrane (diaphragm) for heating systems is calculated using the following formula: eC V= Pi 1Pf Where: V = Volume of vessel (l) e = Water expansion coefficient. Calculated on the basis of the maximum difference between the temperature of the water when the system is cold and the maximum working temperature. In practice, for heating, a conventional value of 0,035 is assumed. C = Water content of system (l). Pi = Initial absolute pressure (bar) at the point where the vessel is installed, given by hydrostatic pressure + 0,3 bar + atmospheric pressure (1 bar). In practice this is the initial charge pressure of the vessel plus 1 bar. Pf = Final absolute pressure (bar), given by the maximum working pressure of the system + atmospheric pressure (1 bar). In practice, this is the calibrated pressure of the safety valve plus 1 bar. Table of coefficient e, on variation of temperature, relative to a temperature of 4C. ( = 1000 kg/m3)
T (C) 0 10 15 20 25 30 35 Coeff. e 0,00013 0,00025 0,00085 0,00180 0,00289 0,00425 0,00582 T (C) 40 45 50 55 60 65 70 Coeff. e 0,00782 0,00984 0,01207 0,01447 0,01704 0,01979 0,02269 T (C) 75 80 85 90 95 100 Coeff. e 0,02575 0,02898 0,03236 0,03590 0,03958 0,04342

Potable water system with storage The capacity of a closed expansion vessel with membrane (diaphragm) for potable water systems with storage is calculated by applying the following formula: e Ca V= Pin 1Pfin Where: V = Volume of vessel (l) e = Water expansion coefficient. Calculated on the basis of the maximum difference between the temperature of the cold water feed and the stored hot water. Ca = Volume of heated water (l). Pin = Initial absolute pressure (bar), given by the maximum incoming pressure + atmospheric pressure (1 bar). In practice, this is the initial charge pressure of the vessel plus 1 bar. Pfin = Final absolute pressure (bar) given by the maximum working pressure of the system + atmospheric pressure (1 bar). In practice, this is the calibrated pressure of the safety valve plus 1 bar. Example Size an expansion vessel for a potable water system with the following characteristics: Ca = T1 = T2 = Pes = Psic = Volume of hot water = 500 l Temperature of cold feed water = 10C Hot water storage temperature = 55C Max incoming pressure = 3,5 bar Calibrated pressure of safety valve = 6 bar

Solution The following is taken from the table of coefficient e: for T1 = 10C e1 = 0,00025 Thus: for T2 = 55C e2 = 0,01447

Example Size an expansion vessel for a heating system with the following characteristics: C = water content = 3000 l Pid = hydrostatic pressure at installation point = 2 bar Psic = calibrated pressure of safety valve = 3,5 bar Solution The above formula is applied, where: e Pi Pf = = = 0,035 conventional absolute value Pid + 0,3 + Patm = 2 + 0,3 + 1 = 3,3 bar Psic + Patm = 3,5 + 1 = 4,5 bar V = (0,035 3000) [1 - (3,3 4,5)] = 393 l

e(T=45C) = (e2 - e1) = (0,01447 - 0,00025) = 0,014 Pin = Pes + Patm = 3,5 + 1 = 4,5 bar Pfin = Psic + Patm = 6 + 1 = 7 bar

In addition:

The formula is applied: V = (0,014 500) [1 - (4,5 7)] = 19,6 l A vessel is therefore selected with a capacity of 24 l. Quick method

Thus:

For quicker calculation, the following formula can be applied: V = f Ca Where f is a coefficient which, for temperature differences between 40 and 50C, can be taken from the table below, according to the working pressure and the calibrated pressure of the safety valve. Table coefficient f
Calibrated pressure of safery valve (bar)* Working pressure (bar)*

A vessel is therefore selected with a capacity of 400 l. Quick method To obtain the vessel capacity, multiply the system water content, expressed in litres, by the value shown in the table below. Capacity of diaphragm expansion vessels per litre of system capacity (expansion coefficient = 0,035)
Initial charge pressure (bar)*

2,25 2,50 2,70 3,00 3,50 4,00 4,50 5,00 5,40 6,00

1,0 0,091 0,082 0,076 0,070 0,063 0,058 0,055 0,052 0,051 0,049

1,2 0,106 0,094 0,086 0,078 0,068 0,063 0,058 0,055 0,053 0,051

1,4 0,134 0,111 0,100 0,088 0,075 0,067 0,062 0,058 0,056 0,053

1,6 0,175 0,136 0,118 0,100 0,083 0,073 0,066 0,062 0,059 0,056

1,8 0,253 0,175 0,144 0,117 0,093 0,080 0,071 0,066 0,062 0,058

2,0 0,245 0,185 0,140 0,105 0,088 0,077 0,070 0,066 0,061

2,2 0,259 0,175 0,121 0,097 0,084 0,075 0,070 0,064

2,4 0,233 0,143 0,109 0,092 0,081 0,075 0,068

2,6 0,175 0,125 0,101 0,088 0,080 0,072

2,8 0,225 0,146 0,113 0,095 0,086 0,077

3,0 0,175 0,128 0,105 0,093 0,082

Calibrated pressure of safety valve (bar)*

4 5 6 7 8 9 10

2 0,035 0,028 0,025 0,022 0,021 0,020 0,019

2,5 0,047 0,034 0,028 0,025 0,023 0,022 0,021

3 0,070 0,042 0,033 0,028 0,025 0,023 0,022

3,5 0,140 0,056 0,039 0,032 0,028 0,025 0,024

4 0,084 0,049 0,037 0,032 0,028 0,026

4,5 0,168 0,065 0,045 0,036 0,031 0,028

5 0,098 0,056 0,042 0,035 0,031

5,5 0,196 0,075 0,050 0,040 0,034

6 0,112 0,063 0,047 0,039

* Relative pressures

Membrane pressure restorers The capacity of a membrane pressure restorer is calculated by means of the following formula: V=6 Where: V = Volume of vessel (l) Gpr = Design flow rate (l/s) Pmin = Minimum boost in pressure (bar), equal to the minimum pressure switch operating pressure Pmax = Maximum boost in pressure (bar), equal to the maximum pressure switch operating pressure a = Maximum number of pump start-ups per hour (h-1) a = 30 for pump rating < 3kW a = 25 for pump rating 35 kW a = 20 for pump rating 57 kW a = 15 for pump rating 710 kW a = 10 for pump rating > 7 kW Example Size a membrane pressure restorer for a system with the following characteristics: Gpr = 3,4 l/s Pmin = 5 bar Pmax = 6 bar Pump rating P = 1,5 kW Solution Application of the formula gives: V=6 3,4 60 30 6+1 6-5 = 285,6 l Gpr 60 Pmax + 1 a Pmax - Pmin

Installation It is advisable to install expansion vessels in pipework containing water at the lowest system temperature.

Constructional details The expansion vessels are supplied pre-charged with nitrogen. The initial charge pressure can be modified with compressed air. Series 555 Vessels in the series 555 up to 24 litres are standardised. This means that they can be installed in either heating systems or potable water systems, as they are supplied with membranes made of a non-toxic material (butyl) and can withstand temperatures of up to 99C. Series 568 The membrane of vessels for potable water systems are replaceable.

Standard references The standards relating to the construction of expansion vessels are at present undergoing modification: I.S.P.E.S.L. approval, which relates to certain types of vessel, has been supplemented by CE Marking. This means that, when the system is being checked, both devices tested to I.S.P.E.S.L. and those with the CE Mark must be accepted. The European reference standard is Directive 97/23/CE, also known as the P.E.D. (Pressure Equipment Directive). Caleffi series 556 expansion tanks for heating systems and 568 for potable water systems already bear the CE mark instead of I.S.P.E.S.L. approval.

A vessel is therefore selected with a capacity of 300 l.

SPECIFICATION SUMMARIES Series 555 Crimped expansion vessel, standardised for heating and potable water systems. Connection 3/4"M (2 l 1/2"). Crimped membrane - non-toxic butyl (food standard). Maximum working pressure 10 bar. Pre-charge pressure 1,5 bar. Maximum working temperature 99C. Capacity 2 l (from 2 to 24 l). Series 5558 Crimped circular flat expansion vessel for heating systems. Connection 3/4"M radial. Steel body. Crimped membrane - SBR synthetic rubber. Maximum working pressure 4 bar. Pre-charge pressure 1 bar. Maximum working temperature 90C. Capacity 8 l (from 8 to 18 l). Series 556 Welded expansion vessel for heating systems. CE Mark. Connection 3/4"M (3/4" from 35 to 400 l and 1" 500 and 600 l). Steel body. Membrane sack - SBR synthetic rubber. Maximum working pressure 4 bar (4 bar 35 and 50 l; 6 bar 80600 l). Pre-charge pressure 1,5 bar ( from 1,5 to 2,5 bar - see technical specification table). Maximum working temperature 99C. Capacity 35 l (from 35 to 600 l).). Series 568 Welded expansion vessel for potable water systems. CE Mark. Connection 1"M (1" from 60 to 100 l; 1 1/2" from 200 to 500 l). Steel body. Replaceable butyl membrane sack. Maximum working pressure 10 bar. Pre-charge pressure 1,5 bar. Maximum working temperature 99C. Capacity 60 l (from 60 to 500 l).

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Thermostatic mixing valve with interchangeable cartridge for centralised systems


5230 series
ACCREDITED

CALEFFI
01080/10 GB
replaces 01080/06 GB

ISO 9001

FM 21654

ISO 9001 No. 0003

Function The thermostatic mixing valve is used in systems for domestic hot water production. Its function is to maintain the temperature of the mixed water supplied to the user constant at the set value when there are variations in the temperature and supply pressure of the incoming hot and cold water or in the draw-off flow rate. This particular series of mixing valves is specifically designed for systems which require high flow rates, such as centralised systems or groups of equal users. These systems also require stable and accurate temperature adjustment, especially in relation to variations in the flow rate drawn off by the users. Patent application No. MI2001A001645.

Product range Code 5230 . 0 Code 5230 . 3 Code 5230. 2 Code 523005 Code 523006 Code 523008 Thermostatic mixing valve with interchangeable cartridge for centralised systems Thermostatic mixing valve with interchangeable cartridge, with check valves at the inlet Thermostatic mixing valve with interchangeable cartridge, with check valves at the inlet Spare cartridge for 1/2, 3/4 and 22 mixing valves Spare cartridge for 1, 1 1/4 and 28 mixing valves Spare cartridge for 1 1/2 and 2 mixing valves sizes 1/2 - 3/4 - 1 - 1 1/4 - 1 1/2 - 2 sizes 1/2 - 3/4 - 1 - 1 1/4 sizes 22 and 28 mm for copper pipe

Technical specifications Materials Body: Cartridge and obturator: Springs: Seals: Performance Medium: Max. working pressure (static): Max. working pressure (dynamic): Max. inlet temperature: Dimensions
B
2 1

Max. inlet pressure ratio (H/C or C/H): Adjustment range: 1/21 1/4, 22, 28: 1 1/2, 2:

2:1 3065C 3660C 2C

brass EN 12165 CW617N, chrome plated brass EN 12164 CW614N stainless steel EPDM

Accuracy: Minimum temperature difference between inlet hot water and outlet mixed water to ensure optimal performance: Connections:

15C

water 14 bar 5 bar 85C

1/22 M with union 22, 28 mm for copper pipe

B
MAX 7

B
2 1

B
MAX 7

B
2 1

B
MAX 7

MIN

MIN

MIN

CALEFFI

CALEFFI

CALEFFI

A
Mass (kg)

A
E 95 95 F 74 74 88 88 Code A B C D E F
Mass (kg)

A
Code A B C D E F 74 88
Mass (kg)

Code

523040 1/2 85 523050 3/4 85 523060 1"

170 169 170 169

1,65 1,68 3,09 3,07

523043 1/2 91 523053 3/4 91 523063 1"

182 175 101 182 175 101

74 1,69 74 1,72 88 3,22 88 3,20

523052 22 92

184 176 102

1,80 3,31

523062 28 116 232 207 119

101 202 195 107

111 222 202 114

523070 11/4 101 202 195 107 523090 2

523073 11/4 111 222 202 114

523080 11/2 129 258 243 135 108 8,00 129 258 243 135 108 8,24

Legionella - scalding risk In systems producing domestic hot water with storage, in order to prevent the dangerous infection known as Legionnaires disease, the hot water must be stored at a temperature of at least 60C. At this temperature it is certain that the growth of the bacteria causing this infection will be completely prevented. However, the hot water cannot be used directly at this temperature, as it may cause scalding. For example, at 55C, partial burn occurs in about 30 seconds, whereas at 60C partial burn occurs in about 5 seconds. In view of the above, it is therefore necessary to use a thermostatic mixing valve able to: reduce the temperature at the user outlet to a lower value than the storage temperature; keep this temperature constant in spite of variations in the inlet pressure and temperature.

Operating principle The regulating element in the thermostatic mixing valve consists of a temperature sensor (1) fully immersed in the mixed water outlet pipe which, by expanding and contracting, continuously ensures correct proportioning of hot and cold water at the inlet. The water proportions are regulated by a piston (2) that slides inside a special cylinder placed between the hot (3) and cold (4) water passage channels. Even if the pressure drops due to hot or cold water drawn-off by other users or temperature variations at the inlet, the mixing valve automatically adjusts the water flow rate until the set temperature is achieved.

Construction details Double seat The mixing valve has a special obturator which acts on a double water passage seat. This ensures a high flow rate with a reduced overall dimension, while maintaining an accurate temperature control.

Interchangeable cartridge The internal cartridge containing all the control components is preassembled in a single body and can easily be inspected for cleaning or replacement if necessary, without any need to take the valve body out of the pipe.

Thermal disinfection The diagram below shows the behaviour of Legionella Pneumophila bacteria as the temperature of the water containing the bacteria varies. To ensure correct thermal disinfection, it is necessary to go up to values of no less than 60C.

Low-inertia thermostat The temperature-sensitive element, the engine of the thermostatic mixing valve, has low thermal inertia; in this way it can quickly react to changes in the conditions of inlet pressure and temperature, shortening the valve response time.

Temperature adjustment and locking The control knob is used to adjust the temperature in a full turn (360) between min. and max. It also has tamper protection for locking the temperature at the set value.

70 60 50 40 30 20 10 0

Instant death of bacteria Death of 90% of bacteria in 2 minutes Death of 90% of bacteria within 2 hours Optimum temperature for bacteria growth

Bacteria survive but remain inactive

Energy saving Energy saving is governed in Italy by Presidential Decree 412/93, making it compulsory to use mixing valves on domestic water systems with storage in order to limit the temperature of the water at the inlet of the delivery network to 48C with a tolerance of +5C. The purpose of limiting the temperature is to reduce passive thermal losses through the delivery network, as much as possible, and to prevent the delivery of water at a higher temperature than necessary.

Version with check valves

MIXED

COLD

HOT

Hydraulic characteristics
p (bar)
1/2 3/4 22 1 28

Temperature adjustment table


p (m w.g.)
1 1/4 1 1/2 2

Position

Min

1 29 32 39

2 33 38 42

3 39 44 45

4 43 49 48

5 48 53 51

6 52 58 54

7 58 63 57

Max 65 67 60

1,5 1,0

15 10

1/2 -3/4 - 22; T (C) 25 1 - 1 1/4 - 28; T (C) 27 1 1/2 - 2; T (C) 36

0,5 0,3 0,2

5 3 2

Reference values: Thot = 68C; Tcold = 13C; Hot and cold water inlet pressures = 3 bar

Locking the setting Turn the knob onto the required number, unscrew the upper screw, remove the knob and put it back on so that the internal reference couples with the protrusion on the knob holder nut.
3

0,1

1 MIN

MA

Recommended FLOW RATES to ensure stable operation and an accuracy of 2C Kv (m3/h) 4,0 4,5 6,9 9,1 14,5 19,0 Minimum (m3/h) 0,4 0,5 0,8 1,0 2,8 3,0 Maximum* (m3/h) 4,9 5,5 8,5 11,2 17,7 23,2

30 500 Flow rate (l/min) (m3/h)

0,05 0,5 10 20 1 2
5

0,5

10

20

50

100

200

1/2 3/4 - 22 1 - 28 1 1/4 1 1/2 2

1/2 3/4 1 1 1/4 1 1/2 2 * P = 1,5 bar

Application In view of their flow rate characteristics, Caleffi 5230 series thermostatic mixing valves can be installed in centralised systems with a number of user outlets or used to control groups of user outlets, such as shower units, washbasin units, etc. Installation The system in which the Caleffi 5230 series mixing valve is to be installed must be flushed and cleaned to remove any dirt that may have accumulated during installation. It is recommended to always install strainers of adequate performance at the water inlet from the supply network. Caleffi 5230 series thermostatic mixing valves must be installed according to the diagrams shown in this manual, taking account of the current applicable regulations. Caleffi 5230 series thermostatic mixing valves can be installed in any position, horizontally or vertically. The following marks are indicated on the mixing valve body: hot water inlet, indicated with the colour red; cold water inlet, indicated with the colour blue. Check valves In systems with thermostatic mixing valves, check valves must be installed to prevent undesired medium backflows. Thermostatic mixing valves are also available with built-in check valves at the hot and cold water inlets. Commissioning In view of the special purpose of the thermostatic mixing valve, it must be commissioned in accordance with current regulations by qualified personnel, using appropriate temperature measurement equipment. We recommend using a digital thermometer for measuring the mixed water temperature. Temperature adjustment The temperature is set at the desired value using the control knob with the graduated scale on the valve.

Replacement of the cartridge The internal cartridge, containing all the control components, can be inspected and replaced if necessary, without any need to take the valve body out of the pipe. 1) Close the shut-off valves on the hot and cold inlets. Turn the knob to the highest value. 2) Remove the temperature adjustment knob after unscrewing the locking screw at the top. Remove the plastic knob holder nut. Unscrew the chrome plated protection cover using the hexagonal control (1 - 1 1/4). 3) Remove the internal cartridge for inspection or replacement, using the hexagonal control. 4) Replace the chrome plated protection cover. Replace the knob holder nut so that the position indicator can be seen. 5) The spare cartridge is supplied preset to the highest value. Next, position the adjustment knob so that the text MAX is aligned with the position indicator. By rotating the knob clockwise, adjustment should be possible from the maximum to the minimum value. Secure the knob with the locking screw. 6) Reopen the shut-off valves and adjust the mixing valve to the desired temperature value.

3a

3b

Application diagrams
Check valve Ball valve Ball valve with built-in check valve Temperature gauge Backflow preventer Motorised valve Clock Pump Expansion vessel
T
T

System with equal user outlets

Thermostat Safety relief valve Strainer

Centralised system with thermal disinfection

7 XAM

NIM

SPECIFICATION SUMMARY
Code 5230 . 0 Adjustable thermostatic mixing valve with interchangeable cartridge. Connections 1/2 M (from 1/2 to 2) with union. Brass body. Chrome plated. Brass cartridge and obturator. Stainless steel springs. EPDM seals. Maximum inlet temperature 85C. Adjustment temperature range from 30C to 65C (from 36 to 60 for 1 1/2 and 2). Maximum working pressure (static) 14 bar. Maximum working pressure (dynamic) 5 bar. Accuracy 2C. Minimum temperature difference between hot water inlet and mixed water outlet to ensure optimal performance 15C. Tamper protection system to lock the set temperature. Code 5230 . 3 Adjustable thermostatic mixing valve with interchangeable cartridge. Connections 1/2 M (from 1/2 to 1 1/4) with union. Brass body. Chrome plated. Brass cartridge and obturator. Stainless steel springs. Complete with check valves at the inlets. EPDM seals. Maximum inlet temperature 85C. Adjustment range from 30C to 65C. Maximum working pressure (static) 14 bar. Maximum working pressure (dynamic) 5 bar. Accuracy 2C. Minimum temperature difference between hot water inlet and mixed water outlet to ensure optimal peformance 15C. Tamper protection system to lock the set temperature.

Code 5230 . 2 Adjustable thermostatic mixing valve with interchangeable cartridge. 22 mm ( 22 and 28 mm) connections for copper pipe. Brass body. Chrome plated. Brass cartridge and obturator. Stainless steel springs. Complete with check valves at the inlets. EPDM seals. Maximum inlet temperature 85C. Adjustment range from 30C to 65C. Maximum working pressure (static) 14 bar. Maximum working pressure (dynamic) 5 bar. Accuracy 2C. Minimum temperature difference between hot water inlet and mixed water outlet to ensure optimala performance 15C. Tamper protection system to lock the set temperature.
We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.p.A. S.R.229, N.25 28010 Fontaneto dAgogna (NO) Italy Tel. +39 0322 8491 Fax +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

7 XAM

NIM

Temperature regulating unit for manifold box


series 154 - 155

CALEFFI
01081/03 GB

Function The temperature regulating unit is designed to guarantee the correct contribution of heating energy required by the user, by measuring the outside and room temperature values to regulate the correct system flow temperature. The unit, complete with all the devices required for a regulating circuit, is of compact size in order to reduce the space taken up and enable it to be installed within a manifold box. It is supplied complete with: 4-way mixing valve, servomotor, electronically-regulated pump, flow temperature sensor, return temperature sensor, outside temperature sensor, temperature controller, flow thermometer and unions for connecting to the primary and secondary circuits. The unit is designed for connection for remote data transmission. The unit solves the problems of installation of regulating components in modern small and medium-sized systems, due to its compact size and ease of use. The product is available in various configurations, both stand-alone and pre-assembled in manifold boxes with the distribution manifolds. The unit is factory set for use with underfloor heating systems.

Product range Series 154 Series 155 Code 154600 Code 155600 Code 151000 Code 151002 Temperature regulating unit complete with room thermostat and clock, pre-assembled with manifolds Temperature regulating unit pre-assembled with manifolds Temperature regulating unit complete with room thermostat and clock Temperature regulating unit Room thermostat and indoor sensor Room thermostat and indoor sensor with 3-position selector and digital clock

Technical specification - Materials: - body: - hydraulic seals: - Mixing valve: Medium: Max percentage of glycol: Working temperature range: Max working pressure: brass, G-MS 58 EPDM 4-way water, glycol solutions 30% 2090C 6 bar 20100C 1 1/2 adjustable nut 1 F with union 230V 50 Hz 1,3 VA 210 s 6 Nm Grundfos electronic pump: Total consumption: Max flow rate: Max ambient relative humidity: Ambient temperature: Protection class: model UPE 25-60 ~ 110 W 3,5 m3/h 95% 040C IP 42

Head available at regulating unit connections Operating at max speed.


H (m w. g.) 6 5 4 3 2 1 0 1 2 3 4 5 Q (m3/h)

- Thermometer scale: - Connections to manifolds: - Primary connections: - Servomotor: electric supply: rating: cycle time: torque:

Factory setting: proportional head regulation

Dimensions

CALEFFI
100% 80% 50% 25% 50%

50 40 30

60

70 80 90

40
-25% +25%

60

80 100

20

-50%

REGOLATORE DIGITALE TRE PUNTI

2 6 4

Zu

A C D

A I E L

Code 154600/155600

A 1

B 1 1/2

C 90

D 190

E 100

F 25

G 200

H 332

H I 30

L 142

1000

6 outlets

10 outlets

13 outlets

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI
100% 80% 50% 25% 50%

CALEFFI
100% 80% 50% 25% 50%

CALEFFI
100% 80% 50% 25% 50%

REGOLATORE DIGITALE TRE PUNTI

CALEFFI

50 40 30

60

70 80 90

CALEFFI50
40 30

REGOLATORE DIGITALE TRE PUNTI

CALEFFI

60

70 80 90 -25% +25%

CALEFFI50
40 30

REGOLATORE DIGITALE TRE PUNTI

CALEFFI

60

70 80 90 -25% +25%

CALEFFI

40
-25% +25%

60

80 100

20 0

40 60

20 0

40 60

20

-50%

-50%

-50%

450

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

2 6 4

Zu

2 6 4

Zu

2 6 4

Zu

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

CALEFFI

315 A Code Outlets A 1546E1 1556E1 5 655 1546F1 1556F1 6 730

50

1200
35

800

60 150190

1546G1 1556G1 7 780

1546H1 1556H1 8 830

1546I1 1556I1 9 880

1546L1 1556L1 10 930

1546M1 1556M1 11 980

1546N1 1556N1 12 1030

1546O1 1556O1 13 1080

Characteristic components 11
24

CALEFFI
100% 80% 50%
19
18
17

25%

50%

20

21

12

16

REGOLATORE DIGITALE TRE PUNTI


14

50
23
13

60

70 80 90 -25% +25%

40 30

WATCH

40 20

60

80 100

5
SYSTEM FLOW

1. Temperature controller 2. Electronic pump UPE 25-60 3. 4-way mixing valve 4. Servomotor 5. Flow temperature sensor 6. Return temperature sensor 7. Outside temperature sensor 8. Room thermostat and indoor sensor * 9. Room thermostat and indoor sensor with digital clock and selector* 10. Flow thermometer 11. Connection point for remote data transmission (* optional)

15

22

12

11

10

M S

+
20

18

22 24

CALEFFI

16

20

18

22 24

CALEFFI

16

FLOW FROM BOILER

BOILER RETURN

6
7

-50%

10

2 3
SYSTEM RETURN

2 6 4

Zu

Hydraulic diagram

7)

SF

4-way mixing valve

M
SR

Servomotor

Pump

Automatic by-pass

Temperature and characteristic curve selector. This selector enables the user to input the maximum required flow temperature, corresponding to the minimum outside design temperature. Also enables optimisation of the standard configuration set at the factory, allowing personal control of the operation of the system. If this value matches the setting on the main printed circuit board (item 6 PCB), the regulation complies with the calculation criteria given by its own characteristic curve. If this value is different from the setting on the main printed circuit board (item 6 PCB), the controller will recalculate the new characteristic curve. The maximum set temperature on PCB however, remains active. 8) Reference graph for calculation of the characteristic curve. This is calculated on the basis of the following parameters: a) Max flow temperature set on controller. (item 7 PCB). Factory setting: 45C. Min flow temperature set on printed circuit board. (item 5 PCB). Factory setting: 20C. Min outside temperature set on printed circuit board. (item 1 PCB). Factory setting: -10C. Outside temperature limit for heating start in summer, set on printed circuit board (item 3 PCB). Factory setting: 18C.

BF

BR

Thermometer

Temperature controller 1 11 2 3 4 5 b)

ON

CALEFFI
100% 80% 50%
19
18
17
16

8
25% 50%

c)

20

21

12

7
REGOLATORE DIGITALE TRE PUNTI
15
14

d)

50
23
13

60

22

70 80 90 -25% +25%

40 30

WATCH

The characteristic curve has a straight line format. In the example shown below, it has been calculated using the factory set values.

24

12

11

10

The controller, which is normally installed on the unit, can also be positioned remotely, following the electrical wiring scheme. The front panel of the controller shows the following functions: 1) ON Mains electric on: LED continuously lit. Flashes in screed drying mode. 2) 3) 4) 5) Pump operating (ON): LED continuously lit. Mixing valve closing: LED lit. Mixing valve opening: LED lit. Sensor malfunction: LED lit.

6) Function selector, 6 different functions possible: a) Main controller off. In models where clock fitted, clock remains on. Controller in operation according to the cycles of the comfort or set-back modes, controlled by the fitted analogue clock or the remote digital clock. Controller operating in comfort mode. Controller operating in set-back mode. Controller de-activated (pump ON, mixing valve ON). This function guarantees heating to the maximum temperature value set on the printed circuit board (PCB). Controller in summer mode (pump OFF, mixing valve OFF). However, pump is activated daily for two minutes every 24 hours in order to prevent it from becoming seized when inactive.

b)

TFLOW (C)

25%

c) d) e)

55 50 45 40 30 25 20 15 25 20 15
A (18;20) 80%

50%

f)

6
7

6
-50% 0

Example of calculation of characteristic curve 10 X axis - Outside temperature - TX Y axis - Flow temperature - TY Calculation of minimum and maximum points Point A: given by the intersection of Tmax X (18C) and Tmin Y (20C). Point B: given by the intersection of Tmin X (-10C) and Tmax Y (45C). Calculation of change points Calculate the difference X between Tmax X and Tmin X. Thus: X = 18 - (-10) = 28C. Calculate the difference Y between Tmax Y and Tmin Y. Thus: Y = 45 - 20 = 25C. Points of change C and D of the curve are identified as follows: Point C given by the intersection between: X = Tmax X - 25% X = 18 - 0,25 28 = 11C Y = Tmin Y + 55% Y = 20 + 0,55 25 = 33,75C Point D given by the intersection between: X = Tmax X - 50% X = 18 - 0,5 28 = 4C Y = Tmin Y + 80% Y = 20 + 0,8 25 = 40C Characteristic curve
60

B (-10;45) D (4;40)

C (11;33,75) 35 55%

10

-5

-10

-15

TOUTSIDE (C)

9)

Correction selector for comfort mode. Range of adjustment -25% to +25%. Factory setting: correction = 0% The selector determines a parallel displacement of the characteristic curve according to the new percentage value selected in the comfort range (red indicators). Example: if the selector is set to +25%, its effect on the flow temperature will be as follows: +25% Y = 0,25 25 = 6,25C. The characteristic curve is then moved upwards by 6,25C.

Printed circuit board The surface of the printed circuit board identifies the following functions:
DIGITAL REGULATOR T 40

t
N L

ROOM THERMOSTAT
2501/2601

13 12 11 4 10 3 8 7 15
OFF

Typ 2124
230 V (ac) 4VA

N L LP

TA1
SR/TA

optional 230V (ac) 10A max

INLET PUMP MIXING VALVE

SR SE SE

4(2)A 4(2)A

PS MA MC

PUMP
OPEN

-10

-15 -20 -20 30

-10

18

Curve with comfort correction


TFLOW (C) 60 55 50 45 40 35 30 25 20 15 25 20 15 10 5 0 -5 -10 -15 TOUTSIDE (C)
6,25C

4(2)A

MIXING VALVE
-5
CLOSED

0 14 65

22

N
55 40 40 3 4,5

SM SM

1 2

A B Y..72097

20

90 1,5 6 max NZ 50

100

RF(%)

14 1)

Minimum outside temperature (Tmin X), adjustable from -5C to -20C, to which the set maximum flow temperature corresponds (Tmax Y). Factory setting: -10C. Set-back mode exclusion selector, adjustable from 0C to -20C. Factory setting: -15C. If the outside temperature falls below the set value, the heating is reactivated according to the characteristic curve of the comfort mode. Maximum outside temperature to start heating, or summer limit (Tmax X), adjustable from 14C to 22C. Factory setting: 18C. An outside temperature higher than the set temperature will cause the following state: circulator OFF and mixing valve closed. Selection microswitch for screed drying program. Factory setting: OFF. ON position.
OFF 1 2

2)

10)

Correction selector for set-back mode. Range of adjustment 0% to -50%. Factory setting: correction = -25%. The selector determines a parallel displacement of the characteristic curve according to the new percentage value selected on the set-back range (blue indicators). Example: if the selector is set to -25%, its effect on the flow temperature will be as follows: -25% Y = -0,25 25 = -6,25C. The characteristic curve is then moved downwards by 6,25C. In addition if, following this move, the flow temperature has to be lower than the minimum temperature for starting heating (Tmin Y), the following state will be obtained: circulator OFF and mixing valve closed OFF.

3)

4)

OFF

1 2

Curve with set-back correction


TFLOW (C) 60 55 50 45 40 35 30 25 20 15 25 20 15 10 5 0 -5 -10 -15 TOUTSIDE (C)
6,25C

11)Daily or weekly analogue clock, used to select the required heating phases. Comfort with red indicators or set-back with blue indicators. Factory setting: daily mode, minimum selection interval 15 min. The changeover from daily to weekly with a 60 min minimum selection interval, is carried out as follows: raise the outer ring and move the drive ring to the required position; to do this, turn the 1 pointer clockwise until the 24 2 23 3 12 innermost notch coincides with one of the outer notches. Reposition the outer ring, making 9 3 sure that the reference day shown falls within the operating sector of the switching point.
22

This program is used for carrying out correct drying of the screed, above which the final flooring will be laid (its activation excludes all other functions). The program has a duration of seven days; during the first three days, the flow temperature is maintained at 25C, whilst for the remaining four days, the flow temperature is raised and maintained at the maximum temperature value set at point 7 of the front panel. The activation of this program is displayed by the flashing LED on the front panel, point 1. The frequency of flashing indicates the drying days which have passed; one pulse every 8 seconds indicates day 1, two pulses every 8 seconds indicates day 2, and so on. If the electricity has to be switched off in this phase, the controller will start its drying cycle again from the beginning. The front panel LED, point 1, continuously lit, indicates the end of the drying program. At this point, the microswitch must be turned to OFF. N.B.: In manual mode the screed drying procedure cannot be activated. 5) Selector for minimum flow temperature at heating start-up (Tmin Y). Adjustable from 20C to 40C Factory setting: 20C Maximum limit temperature selector. Adjustable from 40C to 90C. Factory setting: 50C In case a higher value has been set at point 7 of the panel front, this will be restricted to the limit value. Neutral zone regulating selector. Adjustable from 1,5C to 6C. Factory setting: 2C (equivalent to 1C). If the variation of the flow temperature remains within the temperature value selected in the neutral zone, the mixing valve remains inactive. Moving the temperature in relation to the calculated setting does not produce any movement of the valve.

6)

d -7 21

7) NZ

20

19

18

17

15

14

6
13

16

12

11

10

8) RF(%) Return sensor regulating selector. Adjustable from 0% to 100%. Factory setting: 80%. This selector is used to optimise the system output according to the difference between flow and return temperatures (T). T is calculated as a percentage of the flow temperature calculated on the characteristic curve. TY = (Tflow set Y-Tmin Y) T = TY %set 0,3. Treturn set Y = Tflow set Y - T. Example with factory settings: Flow temperature calculated on the characteristic curve, Tflow set Y = 40C (project conditions). Thus: TY = (40 - 20) = 20C T = 20 0,8 0,3 = 4,8C Treturn set Y = 40 - 4,8 = 35,2C. If the return temperature measured (Treturn Y) is Treturn set Y, the controller will modify the characteristic curve, moving it upwards or downwards, to move the return temperature to the set value. This continuous comparison prevents any overheating in the room caused by gratuitous heat sources modifying the heating load. Curve wih return temperature regulation
TFLOW (C) 60 55 50 45 40 35 30 25 20 15 25 20 15 10 5 0 -5 -10 -15 TOUTSIDE (C)
Treturn: 35,2C

Pump shutdown wiring

RH terminal strip

Auxiliary user contact


6 7 8

PS MA MC

Brown

Pump, unit 155

Pump shutdown variation

15) Connector for remore data transmission.

Table of sensor resistance values


C Ohm -15 11.382 -12 9.912 -10 8.933 -6 7.439 -3 6.492 -2 6.206 0 5.632 C 0 2 4 6 8 10 15 Ohm 5.632 5.187 4.742 4.347 4.000 3.553 2.971 C 20 25 30 35 40 45 50 Ohm 2.431 2.000 1.655 1.376 1.150 966 815 C 55 60 65 70 75 80 85 Ohm 690 587 501 430 370 319 276 C 90 95 100 Ohm 240 209 183

Safety If the outside or flow sensor shows an ohm resistance value outside the working range (damaged or detached sensor), the following operating state is automatically activated: Pump OFF, Mixing valve OFF, LED 5 continuously lit. Safety thermostat, code 622001 Additional, for use with underfloor heating systems. - Range of adjustment: 555C - Factory setting: 50C - Protection class: IP 40 - Contacts load: (C-1) 10(2,5)A / 250 V - Contacts load: (C-2) 1(1)A / 250 V

9)

Auxiliary contact. This contact opens when the mixing valve is completely closed to the secondary and open to the primary. It can be used to shut down the pump or heat generator of the primary circuit.

10) SM Flow sensor wiring. Factory fitted. 11) SE Outside sensor wiring. Connect the outside sensor by two-core cable (2x0,75) to the connector supplied with the unit.

+C C

1 2

Example of safety thermostat application on system low temperature branch circuit

SE
Connecting cable

SE
Connector

12) SR Return sensor wiring. Factory fitted.


TS
CALEFFI
100% 80% 50%
19
18
17

LH terminal strip

Outside sensor

25%

50%

20

14) Pump shutdown variant. Sometimes the temperature regulating unit is installed in a system where there are one or more users with different usage requirements. In this case, for users requiring ON/OFF, it may be necessary to shut down the unit circulator. The electrical diagram shown below illustrates this possibility; the user auxiliary contact must be inserted in series with the normal wiring.

6
7

13) TA1 Room thermostat wiring. Optional.

21

12

16

REGOLATORE DIGITALE TRE PUNTI


14

15

50
23
13

60

22

70 80 90 -25% +25%

40 30

WATCH

24

12

20 0

40 60

11

10

-50%

6 4

Zu

Frost protection function When the selector, point 6 on the front panel, is positioned at there are two types of intervention: or ,

Operation of room thermostat The room thermostat makes it possible to optimise the operation of the system, as it modifies the regulating curve automatically. According to the time bands for comfort and set-back selected on the clock and the room temperature setting, it will read the actual temperature in the room. On the basis of this parameter, it will make a substantial modification in the characteristic curve (A) to bring it into operation and prevent excessive heating of the room. The difference between the actual room temperature measured by the thermostat and the set temperature produces an amplified effect in relation to that produced by a similar variation in the outside temperature. A difference of 1C in the room temperature causes a move in the characteristic curve equal to 7C of the outside temperature, with the corresponding variation in flow temperature. For example, if Troom set = 20C and Troom measured = 19C, then the difference of 1C will cause a characteristic curve movement of 7C towards the left (B). The flow temperature will consequently be raised. In case of a negative difference the movement will be on curve C. This behaviour is applicable for a maximum difference of 3C in room temperature. In addition, the maximum temperature limit set at item 6 on the PCB remains active. In the set-back band, the set room temperature is automatically reduced by 2C, defining the Tset-back set. This reduction will cause a move to the right of the characteristic curve, equating to 14C of the outside temperature (D), with a corresponding variation in flow temperature. If the measured ambient temperature falls belowTset-back set the original curve (A) will be taken. In case of room thermostat code 151000 the set-back correction set at point 10 is applied.

a) If the flow temperature is below 7C, the controller activates the operation of the unit until a flow temperature of 20C is reached. Once this value has been reached, it will return to the inactive status. b) If the outside temperature is below 4C (+2 -0), the controller keeps the pump running.

Manual control Disconnect the electrical wires to the right-hand side PCB in position MA, identified as n 2 and MC, identified as n 3.
2 6 4

Zu

n 2 n 3

MA MC

Press the screw on the protective motor cover and turn it to the required position.

RH terminal strip

Curve with room thermostat regulation


TFLOW (C)
20 18 22 24

Options 1) Room thermostat, code 151000. The regulating unit can be completed with a room thermostat able to adjust the value of the flow temperature according to the actual room temperature. This configuration makes it possible to take account of gratuitous heat gains by refining further the flow temperature value, with optimum results in terms of comfort and energy saving.

60 55 50 45 40 35 30 25 20 15 10 25 20 15 10 5 0 -5 -10 -15 TOUTSIDE (C)


B A C D

CALEFFI

16

2) Room thermostat with 3-position selector and daily/weekly digital clock, code 151002. This device is similar in operation to code 151000, with the following variations: a) Selector with three positions: , making it possible to change the operation of the regulator remotely from the boiler room. In this case, the regulator must be set at . b) Daily/weekly digital clock permitting programming of comfort cycles and set-back directly from the room. In this case, remove the analogue clock from the regulating unit self, and add the appropriate cover.

Room thermostat electrical regulation Install the room thermostat and connect by sheathed 2-core cable (2x0,75) to the terminal strip of the regulator PCB as shown below.

20 18 22 24

TA1 TA

TA1
SR/TA

CALEFFI

16

Room thermostat

WARNING - If the connecting cable between the thermostat and the control unit is not sheathed, it must run in its own ducting. The maximum length is 150 m.

LH terminal strip

M S

Application diagrams
Shut-off valve Thermostatic valve Manual valve Lockshield valve 3-way zone valve

Mixed system with wall boiler and zone valve

TA

Electric pump
TA

Room thermostat Non-return valve


M S +
20 18 22 24

CALEFFI

16

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI
100% 80% 50% 25% 50%

REGOLATORE DIGITALE TRE PUNTI

50 40 30

60

CALEFFI

70 80 90 -25% +25%

CALEFFI

20 0

40 60

-50%

CALEFFI

2 6 4

Zu

CALEFFI
CALEFFI

CALEFFI

220 V

Mixed system with wall boiler and shut-off to the radiators

TA
CALEFFI

CALEFFI

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

CALEFFI
10 8 6 4 2 0

CALEFFI

M S

+
20

18

22 24

CALEFFI

16

CALEFFI

CALEFFI

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI
100% 80% 50% 25% 50%

REGOLATORE DIGITALE TRE PUNTI

50 40 30

60

70 80 90 -25% +25%

CALEFFI

CALEFFI
10 8 6 4 2 0

CALEFFI

20 0

40 60

-50%

6 4

Zu

220 V

6 5 4 3 2 1

mH2O

TA

65610

65610

CALEFFI

CALEFFI

65610

2-

220 V 3W

2-

220 V 3W

2-

220 V 3W

CALEFFI

SPECIFICATION SUMMARIES Code 154600 Temperature regulating unit for manifold box installation. Connections to primary circuit 1" F with unions. Connections to manifold 1 1/2 F with nut. Brass body. EPDM hydraulic seals. Maximum working pressure 6 bar. Ambient temperature from 0 to 40C. Regulating temperature from 20 to 90C (factory setting 45C). Consisting of: 4-way mixing valve; mixing valve servomotor with the following characteristics, supply 230 V 50 Hz, rating 1,3 VA, cycle time 210 s, torque 6 Nm. Electronic pump UPE 25-60, maximum flow rate 3,5 m3/h, protection class IP42; temperature controller; flow temperature sensor; return temperature sensor; outside temperature sensor, connectable to terminal; flow thermometer with pocket, scale 20100C; room thermostat with programmable daily/weekly digital clock and 3-position selector (comfort, set-back and clock).

Code 155600 Temperature regulating unit for manifold box installation. Connections to primary circuit 1" F with unions. Connections to manifold 1 1/2 F with nut. Brass body. EPDM hydraulic seals. Maximum operating pressure 6 bar. Ambient temperature from 0 to 40C. Regulating temperature from 20 to 90C (factory setting 45C). Consisting of: 4-way mixing valve; mixing valve servomotor with the following characteristics: supply 230 V 50 Hz, rating 1,3 VA, cycle time 210 s, torque 6 Nm. Electronic pump UPE 25-60, maximum flow rate 3,5 m3/h, protection class IP42, temperature controller with analogue daily/weekly clock, flow temperature sensor; return temperature sensor, outside temperature sensor connectable to terminal, flow thermometer with pocket, scale 20100C.

Series 154 Temperature regulating unit with underfloor heating manifolds preassembled in manifold box. Connections to primary circuit 1" F with unions. Brass body. EPDM hydraulic seals. Maximum operating pressure 6 bar. Ambient temperature from 0 to 40C. Regulating temperature from 20 to 90C (factory setting 45C). Consisting of: 4-way mixing valve; mixing valve servomotor with the following characteristics, supply 230 V 50 Hz, rating 1,3 VA, cycle time 210 s, torque 6 Nm; Electronic pump UPE 25-60, maximum flow rate 3,5 m3/h, protection class IP42; temperature controller; flow temperature sensor; return temperature sensor; outside temperature sensor, connectable to terminal; flow thermometer with pocket, scale 20100C; room thermostat with programmable daily/weekly digital clock and 3-position selector (comfort, set-back and clock); 5-outlet flow manifold (5 to 13) complete with regulating valves; 5-outlet return manifold (5 to 13) complete with shut-off valves, suitable for connection of thermo-electric heads; manifold units with air vents and drain valves; manifold box, colour white RAL 9010, depth adjustable from 150 to 190 mm. Series 155 Temperature regulating unit with underfloor heating manifolds preassembled in manifold box. Connections to primary circuit 1" F with unions. Brass body. EPDM hydraulic seals. Maximum operating pressure 6 bar. Ambient temperature from 0 to 40C. Regulating temperature from 20 to 90C (factory setting 45C). Consisting of: 4-way mixing valve; mixing valve servomotor with the following characteristic: supply 230 V 50 Hz, rating 1,3 VA, cycle time 210 s, torque 6 Nm; electronic pump UPE 25-60, maximum delivery 3,5 m3/h, protection class IP42, temperature controller with daily/weekly analogue clock; flow temperature sensor; return temperature sensor; outside temperature sensor, connectable to terminal; flow thermometer with pocket, scale 20100C; 5-outlet flow manifold (5 to 13) complete with regulating valves; 5-outlet return manifold (5 to 13) complete with shut-off valves, suitable for connection of thermo-electric heads; manifold units with air vents and drain valves; manifold box, colour white RAL 9010, depth adjustable from 150 to 190 mm.

Code 151000 Room thermostat and indoor sensor for temperature regulating unit. Code 151002 Room thermostat and indoor sensor for temperature regulating unit with 3-position selector (comfort, set-back and clock) and daily/weekly digital clock.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Temperature regulating unit


series 152 - 153

CALEFFI
01082/03 GB

Function The temperature regulating unit is designed to guarantee the correct contribution of heating energy required by the user, by measuring the outside and room temperature values to regulate the correct system flow temperature. It is supplied complete with: 4-way mixing valve, servomotor, pump, flow temperature sensor, outside temperature sensor, temperature controller, flow and return thermometers and unions for connecting to the primary and secondary circuits. The unit is designed for connection for remote data transmission. This unit solves the problems of installation of regulating components in modern small and medium-sized systems, due to its compact size and ease of use. The unit is factory set for use with underfloor heating systems.

Gamma prodotti Code Code Code Code Code Code 152600 152601 153600 153601 151000 151002 Temperature regulating unit with pump UPS 25-60 Temperature regulating unit with pump UPS 25-80 Temperature regulating unit complete with room thermostat and clock, with pump UPS 25-60 Temperature regulating unit complete with room thermostat and clock, with pump UPS 25-80 Room thermostat and indoor sensor Room thermostat and indoor sensor with 3-position selector and digital clock

Technical specifications - Materials: - body: - hydraulic seals: - Mixing valve: Medium: Max percentage of glycol: Working temperature range: Max working pressure: By-pass regulating range: grey cast iron GG19 EPDM 4-way water, glycol solutions 30% 2090C 6 bar 0,050,5 bar 20100C 1 F with union 230V 50 Hz 10 VA 240 s 10 Nm model UPS 25-60 model UPS 25-80 95% 040C IP 42

Head available at regulating unit connections


H (m w.g.)
6 5 4 3 2 1 0

H (m w.g.)
6

UPS 25-60 code 152600 code 153600

5 4

UPS 25-80 code 152601 code 153601 3

3 2 1

2
2 1 0

- Thermometer scale: - Primary and secondary circuit connections: - Servomotor: electric supply: rating: cycle time: torque: - Grundfos pump: code 152600/153600 code 152601/153601

Q (m3/h)

Q (m3/h)

Power consumption
Speed I

(A) 0,45 0,30 0,17

P (W) 100 65 35

n (rpm) 1800 1100 700

Speed

(A) 1,13 1,04 0,69

P (W) 250 220 140

n (rpm) 2450 1500 1000

- Max ambient relative humidity: - Ambient temperature: - Protection class:

3 2 1

3 2 1

Dimensions
H D A A

E L

ON

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13

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70 80 90 -25% +25%

40 30

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24

Code 152600/601

A 1"

B 142

C 78

M
C
M S +
20 18 22 24

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16

ON

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REGOLATORE DIGITALE TRE PUNTI

50 40 30

60

70 80 90 -25% +25%

-50%

Code 153600/601

A 1"

B 142

C 78

Characteristic components

SYSTEM RETURN

SYSTEM FLOW

40 20

60

80 100 20

40

60

80 100

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16

11
25% 50%

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50
13

60

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70 80 90 -25% +25%

23

40 30

WATCH

24

BOILER RETURN

6
20 18 22 24

6
7

-50%

FLOW FROM BOILER

10

6
7

-50%

G
15
14

12

11

10

F B

D 90

E 40

F 234

G 267

H 205

I 320

L 120

H D A E L

F B

D 90

E 40

F 234

G 267

H 205

I 320

L 120

M 70

15

01 02 03

4-way mixing valve. Digital temperature controller. Circulating pump: code 152600 - 153600 GRUNDFOS UPS 25-60 code 152601 - 153601 GRUNDFOS UPS 25-80. Differential by-pass valve with graduated scale. Flow temperature sensor. Outside temperature sensor, on mounting plate. Circuit flow and return thermometers in pockets. Connection point for remote transmission. Room thermostat and indoor sensor with digital clock and selector for series 153 (option for series 152). Room thermostat and indoor sensor (option for series 152). Servomotor.

04 05 06 07
M S +
20 18 22 24

14

12

11

10

08 09

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10 11

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Hydraulic diagram
SR SF

4-way mixing valve

M
M

Servomotor Pump Automatic by-pass Differential by-pass

Temperature and characteristic curve selector. This selector enables the user to input the maximum required flow temperature, corresponding to the minimum outside design temperature. Also enables optimisation of the standard configuration set at the factory, allowing personal control of the operation of the system. If this value matches the setting on the main printed circuit board (item 6 PCB), the regulation complies with the calculation criteria given by its own characteristic curve. If this value is different from the setting on the main printed circuit board (item 6 PCB), the controller will recalculate the new characteristic curve. The maximum set temperature on PCB, however, remains active. 8) Reference graph for calculation of the characteristic curve. This is calculated on the basis of the following parameters: a) Max flow temperature set on controller (item 7). Factory setting 45C. Min flow temperature set on printed circuit board (item 5 PCB). Factory setting 20C. Min outside temperature set on printed circuit board (item 1 PCB). Factory setting -10C. Outside temperature limit for heating start in summer, set on printed circuit board (item 3 PCB). Factory setting 18C.

7)

BR

BF

Thermometer

Temperature controller 1 11 2 3 4 5

b)

ON

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8 c)
25% 50%

20

21

12

7
REGOLATORE DIGITALE TRE PUNTI
15
14

d)

50
23
13

60

22

70 80 90 -25% +25%

40 30

WATCH

The characteristic curve has a straight line format. In the example shown below, it has been calculated using the factory set values.

24

12

11

10

The controller, which is normally installed on the unit, can also be positioned remotely, following the electrical wiring scheme. The front panel of the controller shows the following functions: 1) ON Mains electric on: LED continuously lit. Flashes in screed drying mode. 2) 3) 4) 5) Pump operating ON: LED continuously lit. Mixing valve closing: LED lit. Mixing valve opening: LED lit. Sensor malfunction: LED lit.

6) Function selector, 6 different functions possible: a) Main controller off. In models where clock fitted, clock remains on. Controller in operation according to the cycles of the comfort or set-back modes, controlled by the fitted analogue clock or the remote digital clock. Controller operating in comfort mode. Controller operating in set-back mode. Controller de-activated (pump ON, mixing valve ON). This function guarantees heating to the maximum temperature value set on the printed circuit board (PCB). Controller in summer mode (pump OFF, mixing valve OFF). However, pump is activated daily for two minutes every 24 hours in order to prevent it from becoming seized when inactive.

b)

TFLOW (C)

25%

c) d) e)

55 50 45 40 30 25 20 15 25 20 15
A (18;20) 80%

50%

f)

6
7

6
-50% 0

Example of calculation of characteristic curve 10 X axis - Outside temperature - TX Y axis - Flow temperature - TY Calculation of minimum and maximum points Point A: given by the intersection of Tmax X (18C) and Tmin Y (20C). Point B: given by the intersection of Tmin X (-10C) and Tmax Y (45C). Calculation of change points Calculate the difference X between Tmax X and Tmin X. Thus: X = 18 - (-10) = 28C. Calculate the difference Y between Tmax Y and Tmin Y. Thus : Y = 45 - 20 = 25C. Points of change C and D of the curve are identified as follows: Point C given by the intersection between: X = Tmax X - 25% X = 18 - 0,25 28 = 11C Y = Tmin Y + 55% Y = 20 + 0,55 25 = 33,75C Point D given by the intersection between: X = Tmax X - 50% X = 18 - 0,5 28 = 4C Y = Tmin Y + 80% Y = 20 + 0,8 25 = 40C Characteristic curve
60

B (-10;45) D (4;40)

C (11;33,75) 35 55%

10

-5

-10

-15

TOUTSIDE (C)

9)

Correction selector for comfort mode. Range of adjustment -25% to +25%. Factory setting: correction = 0% The selector determines a parallel displacement of the characteristic curve according to the new percentage value selected in the comfort range (red indicator). Example: if the selector is set to + 25%, its effect on the flow temperature will be as follows: +25% Y = 0,25 25 = 6,25C. The characteristic curve is then moved upwards by 6,25C.

Printed circuit board The surface of the printed circuit board identifies the following functions:
DIGITAL REGULATOR N L LP T 40

t Typ 2124
N L
230 V AC 4VA optional 230V AC 10A max

ROOM THERMOSTAT 2501/2601

13 12 11 4 10 3 8 7 15
OFF

TA1
SR/TA

INLET PUMP MIXING VALVE

SR SE SE

4(2)A 4(2)A 4(2)A

PS
OPEN

PUMP
-10 -15 -20 -20 30 65 -10 18

MA MC
CLOSED

MIXING VALVE
-5 0 14 22

Curve with comfort correction


TFLOW (C) 60 55 50 45 40 35 30 25 20 15 25 20 15 10 5 0 -5 -10 -15 TOUTSIDE (C)
6,25C

N
55 40 40 3 4,5

SM SM

1 2

A B Y..72097

20

90 1,5 6 max NZ 50

100

RF(%)

14

1)

Minimum outside temperature (Tmin X), adjustable from -5C to -20C, to which the set maximum flow temperature corresponds (Tmax Y). Factory setting: -10C. Set-back mode exclusion selector, adjustable from 0C to -20C. Factory setting: -15C. If the outside temperature falls below the set value, the heating is reactivated according to the characteristic curve of the comfort mode. Maximum outside temperature to start heating, or summer limit, (Tmax X), adjustable from 14C to 22C. Factory setting: 18C. An outside temperature higher than the set temperature will cause the following state: circulator OFF and mixing valve closed. Selection microswitch for screed drying program. Factory setting: OFF. ON Position.
OFF 1 2

2)

10)

Correction selector for set-back mode. Range of adjustment 0% to -50%. Factory setting: correction = -25%. The selector determines a parallel displacement of the characteristic curve according to the new percentage value selected in the set-back range (blue indicators). Example: if the selector is set to -25%, its effect on the flow temperature will be as follows: -25% Y = -0,25 25 = -6,25C. The characteristic curve is then moved downwards by 6,25C. In addition if, following this move, the flow temperature has to be lower than the minimum temperature for starting heating (Tmin Y), the following state will be obtained: circulator OFF and mixing valve closed.

3)

4)

OFF

1 2

Curve with set-back correction


TFLOW (C) 60 55 50 45 40 35 30 25 20 15 25 20 15 10 5 0 -5 -10 -15 TOUTSIDE (C)
6,25C

11) Daily or weekly analogue clock, used to select the required heating phases. Comfort with red indicators or set-back with blue indicators. Factory setting: daily mode, minimum selection interval 15 min. The changeover from daily to weekly with a 60 min minimum selection interval, is carried out as follows: raise the outer ring and move the 1 24 2 23 3 12 drive ring to the required position; to do this, turn the pointer clockwise until the innermost notch coincides with one of the 9 3 outer notches. Reposition the outer ring, making sure that the reference day shown falls within 6 the operating sector of the switching point.
22

This program is used for carrying out correct drying of the screed, above which the final flooring will be laid (its activation excludes all other functions). The program has a duration of seven days; during the first three days, the flow temperature is maintained at 25C, whilst for the remaining four days, the flow temperature is raised and maintained at the maximum temperature value set at point 7 of the front panel. The activation of this program is displayed by the flashing LED on the front panel, point 1. The frequency of flashing indicates the number of drying days which have passed; one pulse every 8 seconds indicates day 1, two pulses every 8 seconds indicates day 2, and so on. If the electricity has to be switched off in this phase, the controller will start its drying cycle again from the beginning. The front panel LED, point 1, continuously lit, indicates the end of the drying program. At this point, the microswitch must be turned to OFF. N.B.: In manual mode, the screed drying procedure cannot be activated. 5) Selector for minimum flow temperature at heating start-up (Tmin Y). Adjustable from 20C to 40C Factory setting: 20C Maximum limit temperature selector. Adjustable from 40C to 90C. Factory setting: 50C In case a higher value has been set at point 7 of the panel front, this will be restricted to the limit value. Neutral zone regulating selector. Adjustable from 1,5C to 6C. Factory setting: 2C (equivalent to 1C). If the variation of the flow temperature remains within the temperature value selected in the neutral zone, the mixing valve remains inactive. Moving the temperature in relation to the calculated setting does not produce any movement of the valve.

6)

d -7 21

20

19

7) NZ

18

17

16

15

14

13

12

11

10

8) RF(%) Return sensor regulating selector (optional). Adjustable from 0% to 100%. Factory setting: 80%. This selector is used to optimise the system output according to the difference between flow and return temperatures (T). T is calculated as a percentage of the flow temperature calculated on the characteristic curve. TY = (Tflow set Y-Tmin Y) T = TY %set 0,3. Treturn set Y = Tflow set Y - T. Example with factory settings: Flow temperature calculated on the characteristic curve, Tflow set Y = 40C (project conditions). Thus: TY = (40 - 20) = 20C T = 20 0,8 0,3 = 4,8C Treturn set Y = 40 - 4,8 = 35,2C. If the return temperature measured (Treturn Y) is Treturn set Y, the controller will modify the characteristic curve, moving it upwards or downwards, to move the return temperature to the set value. This continuous comparison prevents any overheating in the room caused by gratuitous heat sources modifying the heating load. Curve with return temperature regulation
TFLOW (C) 60 55 50 45 40 35 30 25 20 15 25 20 15 10 5 0 -5 -10 -15 TOUTSIDE (C)
Treturn: 35,2C

Pump shutdown wiring Auxiliary user contact RH terminal strip


6 7 8

PS MA MC

Brown

Pomp, unit 152

Pump shutdown variation

15) Connector for remote data transmission.

Table of sensor resistance values


C Ohm -15 11.382 -12 9.912 -10 8.933 -6 7.439 -3 6.492 -2 6.206 0 5.632 C 0 2 4 6 8 10 15 Ohm 5.632 5.187 4.742 4.347 4.000 3.553 2.971 C 20 25 30 35 40 45 50 Ohm 2.431 2.000 1.655 1.376 1.150 966 815 C 55 60 65 70 75 80 85 Ohm 690 587 501 430 370 319 276 C 90 95 100 Ohm 240 209 183

Safety If the outside or flow sensor shows an ohm resistance value outside the working range (damaged or detached sensor), the following operating state is automatically activated: Pump OFF, Mixing valve OFF, LED 5 continuously lit.

Safety thermostat, code 622001 Additional, for use with underfloor heating systems. - Range of adjustment: 5 55C - Factory setting: 50C - Protection class: IP 40 - Contacts load: (C-1) 10(2,5)A / 250V - Contacts load: (C-2) 1(1)A / 250V
+C C 1 2

9) Auxiliary contact. This contact opens when the mixing valve is completely closed to the secondary and open to the primary. It can be used to shut down the pump or heat generator of the primary circuit. 10) SM Flow sensor wiring. Factory fitted. 11) SE Outside sensor wiring. Connect the outside sensor by two-core cable (2x0,75) to the connector supplied with the unit.

Example of safety thermostat application on system low temperature branch circuit

Outside sensor

SE SE
Connecting cable Connector

LH terminal strip

ON

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REGOLATORE DIGITALE TRE PUNTI

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13

60

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70 80 90 -25% +25%

40 30

WATCH

24

12

11

10

13) TA1 Room thermostat wiring. Optional. 14) Pump shutdown variant. Sometimes the temperature regulating unit is installed in a system where there are one or more users with different usage requirements. In this case, for users requiring ON/OFF, it may be necessary to shut down the unit circulator. The electrical diagram shown below illustrates this possibility; the user auxiliary contact must be inserted in series with the normal wiring.

12) SR Return sensor wiring. Optional.

-50%

Frost protection function When the selector, point 6 on the front panel, is positioned at there are two types of intervention: or ,

Operation of room thermostat The room thermostat makes it possible to optimise the operation of the system, as it modifies the regulating curve automatically. According to the time bands for comfort and set-back selected on the clock and the room temperature setting, it will read the actual temperature in the room. On the basis of this parameter, it will make a substantial modification in the characteristic curve (A) to bring it into operation and prevent excessive heating of the room. The difference between the actual room temperature measured by the thermostat and the set temperature produces an amplified effect in relation to that produced by a similar variation in the outside temperature. A difference of 1C in the room temperature causes a move of the characteristic curve equal to 7C of the outside temperature, with the corresponding variation in flow temperature. For example, if Troom set = 20C and Troom measured = 19C, then the difference of 1C will cause a characteristic curve movement of 7C towards the left (B). The flow temperature will consequently be raised. In case of a negative difference the movement will be on curve C. This behaviour is applicable for a maximum difference of 3C in room temperature. In addition, the maximum temperature limit set at item 6 on the PCB remains active. In the set-back band, the set room temperature is automatically reduced by 2C, defining the T set-back set. This reduction will cause a move to the right of the characteristic curve, equating to 14C of the outside temperature (D), with a corresponding variation in flow temperature. In case of room thermostat code 151000 the set-back correction set at point 10 is applied.

a) If the flow temperature is below 7C, the controller activates the operation of the unit until a flow temperature of 20C is reached. Once this value has been reached, it will return to the inactive status. b) If the outside temperature is below 4C (+2 -0), the controller keeps the pump running.

Manual control To carry out adjustment: - Remove the servomotor fixing screws. - Lift the servomotor. This gives access to the control knob. Refer to the information given on the knob itself.
Auf Open Ouvrir Beipass n ich
Hand schliee on n tv

Zu Close Ferm

Mis ch e

pe

ra t

nh u r f r Fu b o d e

ei z

Options 1) Room thermostat, code 151000. The regulating unit can be completed with a room thermostat able to adjust the value of the flow temperature according to the actual room temperature. This configuration makes it possible to take account of gratuitous heat gains by refining further the flow temperature value, with optimum results in terms of comfort and energy saving.

ng
u

be

a ch

ten

TFLOW (C)
22 24

2) Room thermostat with 3-position selector and daily/weekly digital clock, code 151002. This device is similar in operation to code 151000, with the following variations: a) Selector with 3 positions , making it possible to change the operation of the regulator remotely from the boiler room. In this case, the regulator must be set at .

TA1 TA Room thermostat

TA1
SR/TA

WARNING - If the connecting cable between the thermostat and the control unit is not sheathed, it must run in its own ducting. The maximum length is 150 m.

LH terminal strip

b) Daily/weekly digital clock allowing for programming comfort cycles and set-back directly from the room. In this case, remove the analogue clock from the regulating unit itself, and add the appropriate cover.

ft au Vo r l

Curve with room thermostat regulation


60 55 50 45 40 35 30 25 20 15 10 25 20 15 10 5 0 -5 -10 -15 TOUTSIDE (C)
B A C D

20 18

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+
20

18

22 24

Room thermostat electrical connection Install the room thermostat and connect by sheathed 2-core cable (2 x 0,75) to the terminal strip of the regulator PCB as shown below.

CALEFFI

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Application diagrams
TA

CALEFFI

CALEFFI

PN 10

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

CALEFFI
CALEFFI
CALEFFI

TA

CALEFFI

PN 10

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

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19
20
18

25%

50%

17
16

21

12

REGOLATORE DIGITALE TRE PUNTI

15
14

60
13

22

7080

23

4050 30 90 -25% +25%

WATCH

24

12

11

10

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

CALEFFI

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

CALEFFI

CALEFFI

20

6
7

-50%

M S

+
20

18

22 24

CALEFFI

16

CALEFFI

CALEFFI

CALEFFI

M S

+
20

18

22 24

CALEFFI

16

CALEFFI

CALEFFI

CALEFFI

2,25 2,0

100

1,75

CALEFFI

2,25 2,0

100

1,75

80
1,5 1,5

80

1,25

1,25

60
1,0 1,0

60

0,75

0,75

40
0,5 0,25 0,5 0,25

40

20 20 15 10 5 0 -5 -10 -15 -20 20 15 10 5 0 -5 -10 -15 -20

20

1,0 0,75 0,5 0,25

1,25

1,5 1,75 2,0 2,25 0,75 0,5 0,25

1,0

1,25

1,5 1,75 2,0 2,25

20

SPECIFICATION SUMMARIES Code 152600 Temperature regulating unit. Connections 1" F with unions. Body in grey cast iron GG19. EPDM hydraulic seals. Maximum working pressure 6 bar. Ambient temperature 0 to 40C. Regulating temperature from 20 to 90C (factory setting 45C). Consisting of: 4-way mixing valve; mixing valve servomotor with the following characteristics: supply 230 V 50 Hz, rating 10 VA, cycle time 240 s, torque 10 Nm, pump UPS 25 60; by-pass valve with regulating scale from 0,05 to 0,5 bar; temperature controller with clock for daily/weekly programming; flow temperature sensor; outside temperature sensor, connectable to terminal; flow and return thermometers with pocket, scale 20100C.

Code 152601 Temperature regulating unit. Connections 1" F with unions. Body in grey cast iron GG19. EPDM hydraulic seals. Maximum working pressure 6 bar. Ambient temperature 0 to 40C. Regulating temperature from 20 to 90C (factory setting 45C). Consisting of: 4-way mixing valve; mixing valve servomotor with the following characteristics: supply 230 V 50 Hz, rating 10 VA, cycle time 240 s, torque 10 Nm; pump UPS 25 80; by-pass valve with regulating scale from 0,05 to 0,5 bar; temperature controller with clock for daily/weekly programming; flow temperature sensor; outside temperature sensor, connectable to terminal flow and return thermometers with pocket, scale 20100C.

Code 153600 Temperature regulating unit. Connections 1" F with unions. Body in grey cast iron GG19. EPDM hydraulic seals. Maximum working pressure 6 bar. Ambient temperature 0 to 40C. Regulating temperature from 20 to 90C (factory setting 45C). Consisting of: 4-way mixing valve; mixing valve servomotor with the following characteristics: supply 230 V 50 Hz, rating 10 VA, cycle time 240 s, torque 10 Nm; pump UPS 25 60; by-pass valve with regulating scale from 0,05 to 0,5 bar; temperature controller; flow temperature sensor; outside temperature sensor, connectable to terminal; flow and return thermometers with pocket, scale 20100C; room thermostat with programmable daily/weekly digital clock and 3-position selector (comfort, set-back and clock).

Code 153601 Temperature regulating unit. Connections 1" F with unions. Body in grey cast iron GG19. EPDM hydraulic seals. Maximum working pressure 6 bar. Ambient temperature 0 to 40C. Regulating temperature from 20 to 90C (factory setting 45C). Consisting of: 4-way mixing valve; mixing valve servomotor with the following characteristics: supply 230 V 50 Hz, rating 10 VA, cycle time 240 s, torque 10 Nm; pump UPS 25 80; by-pass valve with regulating scale from 0,05 to 0,5 bar; temperature controller; flow temperature sensor; outside temperature sensor, connectable to terminal; flow and return thermometers with pocket, scale 20100C, room thermostat with programmable daily/weekly digital clock and 3-position selector (comfort, set-back and clock).

Code 151000 Room thermostat and indoor sensor for temperature regulating unit.

Code 151002 Room thermostat and indoor sensor for temperature regulating unit with 3-position selector (comfort, set-back and clock) and daily/weekly digital clock.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Hydraulic separator-manifold SEPCOLL


series 559
cert. n 0003

CALEFFI
ISO 9001

01084/05 GB
Replaces 01084/02 GB

Function The SEPCOLL, a new device combining a hydraulic separator and distribution manifold, is used in heating and air-conditioning systems to allow different controls of the various rooms when there is only one boiler or chiller. The various configurations are compact, and can be easily fitted in any kind of hydraulic circuit, with the advantages of ease of installation and a saving of useful living space. The SEPCOLL devices are supplied complete with preformed shell insulation to ensure perfect heat insulation when used in both hot and cold water systems. Patent application No. MI2001A001270

Product range Code 559022 Code 559031 Code 559021 Code 559121 Hydraulic separator-manifold 2+2 external use with insulation. Complete with fixing brackets Hydraulic separator-manifold 3+1 external use with insulation. Complete with fixing brackets Hydraulic separator-manifold 2+1 built-in version with insulation Hydraulic separator-manifold 2+1 in manifold box with insulation Size 1 1/4; branches 1 Size 1 1/4; branches 1 Size 1; branches 1 Size 1; branches 1

Technical specification - Materials: - Body: Max working pressure: Temperature range: Medium: painted steel 6 bar 0 110C

Insulation characteristics Material: closed cell expanded PEX Thickness: 20 mm Density: - internal part 30 Kg/m3 - external 50 Kg/m3 Thermal conductivity (DIN 52612): - at 0C 0,038 W/(mK) - at 40C 0,045 W/(mK) Coefficient of resistance to the diffusion of vapour (DIN 52615):> 1.300 Temperature range: 0 100C Reaction to fire (DIN 4102): Class B2

water; glycol solutions non hazardous, therefore excluded from the guidelines of 67/548/EC Directive

Connections: - mains; - branches;

- for air vent valve; - for drain cock; Outlet centre distance: - mains; - branches;

3+1 and 2+2: 2+1: 3+1 and 2+2: 2+1 (side): 2+1 (top): 3+1, 2+2 and 2+1: 3+1, 2+2 and 2+1:

1 1/4 F 1 F 1 M 1 M 1 F 1/2 F 1/2 F

Hydraulic characteristic Maximum recommended flow rates at outlets: Branches 2+1 2+2 3+1 Primary 2 m3/h 2,5 m3/h 2,5 m3/h Secondary (total) 5 m3/h 6 m3/h 6 m3/h

3+1 and 2+2: 2+1: 3+1 and 2+2: 2+1:

80 mm 60 mm 90 mm 90 mm

Dimensions
C

H G

I H

Domanda di brevetto n. MI2001A 001270

38433.01

C D

B E G F

C D

B E F I

Domanda di brevetto n. MI2001A 001270

38431.01

Volume (l) L Code A B C D E F G H I (kg) 559022 11 / 4" 1" 1/2 160 90 140 530 80 250 80 13,2 6,9

Weight

Code A 559021 1"

B C D E F G H I L (kg) Volume (l) 1" 1/2 155 90 570 60 195 140 60 7,7 4,1

Weight

Domanda di brevetto n. MI2001A 001270

I H

C D L

Domanda di brevetto n. MI2001A 001270

38435.01

A Code A B C D E F G H I L M (kg) Volume (l) 559031 11 / 4" 1" 1/2 390 90 90 140 80 250 760 80 17,5 9,8
Weight

38431.01

E D 85 E 150190

Code 559121

A 800

B 770

C 595

Operating principle When a single system contains a primary generating circuit, with its own pump, and a secondary user circuit, with one or more distribution pumps, operating conditions may arise in the system where the pumps interact, creating abnormal variations in flow rates and pressures in the circuits. In the SEPCOLL there is a low pressure loss zone, which enables the primary and secondary circuits connected to it to be hydraulically independent of each other; the flow in one circuit does not create a flow in the other if the pressure loss in the common section is negligible. In this case, the flow rates passing through the respective circuits depend exclusively on the flow characteristics of the pumps, preventing reciprocal influence due to connection in series. Downstream of the hydraulic separation zone are the flow and return manifolds to which the various secondary distribution circuits can be connected. Three possible hydraulic balance situations are shown below as examples.

secondary circuit

primary circuit

GS1 Gp

GS2

GS3 Gp

GS1

GS2

GS3 Gp

GS1

GS2

GS3

GS4 Gprimary = Gsecondary (GS1+GS2+GS3+GS4)

GS4 Gprimary > Gsecondary (GS1+GS2+GS3+GS4)

GS4 Gprimary < Gsecondary (GS1+GS2+GS3+GS4)

Installation SEPCOLL units should be installed in accordance with the diagrams shown in this leaflet, paying attention to the correct connection of the flow and return pipework and the main and branch connections. SEPCOLL can even be installed upside down, as long as the right connection pattern is achieved. The 1/2 F connections must only be used for connecting an air vent valve and drain cock, and not for connecting branch circuits.

40
20 60 20

40
60

80

80

40
20 60 20

40
60

80

80

Insulation The SEPCOLL devices are supplied complete with a hot preformed shell insulation. This system ensures not only perfect heat insulation but also the tightness required to prevent atmospheric water vapour from entering the unit. For these reasons, this type of insulation can also be used in cooling water circuits, as it prevents the formation of condensate on the surface of the device body.

CALEFFI
19
18
17

2,25 2,0

100

1,75

80
1,5

1,25

60
1,0

0,75

20

21

12

16
15
20 15 10 5 0 -5 -10 -15

40
0,5 0,25

20 -20

14

22

1,0 0,75 0,5

1,25

1,5 1,75 2,0 2,25

23

13

WATCH

24

12
0,25

11

10

Application diagrams
Pump
1 2 3 4 5 6
t1 t2 t 0 2 4 6 8 10 12 14 16 18 20 22 - t1 - t2 - t3

System with wall-mounted boiler and built-in SEPCOLL 2+1

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

CALEFFI

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

CALEFFI

6
7

9
20

Support brackets The SEPCOLL external versions 2+2 and 3+1 are supplied complete with suitable wall-mounting brackets, which make it possible to adjust the front-to-back positioning.

Lockshield valve Shut-off valve Clock

ON OFF

C C

t1/t2/t3

CALEFFI

Variable speed pump Thermostatic valve


40 20 0 60 80

CALEFFI

CALEFFI

10 8 6 4 2 0

CALEFFI

3 2 1
bar

4
20

40 60 80

5
conforme norme ISPESL

1 2 3 4 5 6
t1 t2 t 0 2 4 6 8 10 12 14 16 18 20 22 - t1 - t2 - t3

ON OFF

C C

t1/t2/t3

CALEFFI

40 20 0 60 80

CALEFFI

CALEFFI

10 8 6 4 2 0

CALEFFI

3 2 1
bar

4
20

40 60 80

5
conforme norme ISPESL

System with floor standing boiler and SEPCOLL 3+1

M S

+
20

18

22 24

CALEFFI

16

CALEFFI

CALEFFI

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

CALEFFI
CALEFFI

M S

+
20

18

22 24

CALEFFI

16

CALEFFI

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

CALEFFI
CALEFFI

CALEFFI

2,25 2,0

100

1,75

CALEFFI

2,25 2,0

100

1,75

80
1,5 1,5

80

1,25

1,25

60
1,0 1,0

60

0,75

0,75

40
0,5 0,25 0,5 0,25

40

20 20 15 10 5 0 -5 -10 -15 -20 20 15 10 5 0 -5 -10 -15 -20

20

1,0 0,75 0,5 0,25

1,25

1,5 1,75 2,0 2,25 0,75 0,5 0,25

1,0

1,25

1,5 1,75 2,0 2,25

20

20

CALEFFI
9

Code 559022 Hydraulic separator-manifold 2+2 external use, for heating and air-conditioning systems. Painted steel body. Connection to generator 1 1/4 F, outlet centre distance 80 mm. Branch connections 1 M, outlet centre distance 90 mm. 1/2 F connections for air vent valve and drain cock. Maximum working pressure 6 bar. Temperature range 0110C (0100C with insulation). With a hot preformed insulation shell in closed cell expanded PEX. Complete with fixing brackets. Code 559031 Hydraulic separator-manifold 3+1 external use, for heating and air-conditioning systems. Painted steel body. Connection to generator 1 1/4 F, outlet centre distance 80 mm. Branch connections 1 M, outlet centre distance 90 mm. 1/2 F connections for air vent valve and drain cock. Maximum working pressure 6 bar. Temperature range 0110C (0100C with insulation). With a hot preformed insulation shell in closed cell expanded PEX. Complete with fixing brackets. Code 559021 Hydraulic separator-manifold 2+2 built-in version, for heating and air-conditioning systems. Painted steel body. Connection to generator 1 F, outlet centre distance 60 mm. Branch connections 1 M, outlet centre distance 90 mm. Head branch connections 1 F, outlet centre distance 60 mm. 1/2 F connections for air vent valve and drain cock. Maximum working pressure 6 bar. Temperature range 0110C (0100C with insulation). With a hot preformed insulation shell in closed cell expanded PEX. Code 559121 Hydraulic separator-manifold 2+2 built-in version, for heating and air-conditioning systems. Painted steel body. Connection to generator 1 F, outlet centre distance 60 mm. Branch connections 1 M, outlet centre distance 90 mm. Head branch connections 1 F, outlet centre distance 60 mm. 1/2 F connections for air vent valve and drain cock. Maximum working pressure 6 bar. Temperature range 0110C (0100C with insulation). With a hot preformed insulation shell in closed cell expanded PEX. Complete with painted sheet steel manifold box. White. Box dimensions 800 x 770 x 150190 mm.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

SPECIFICATION SUMMARIES

Pre-adjustable pressure reducing valves with self-contained cartridge


5350 - 5351 series
ACCREDITED

CALEFFI
01085/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003

replaces 01085/03 GB

Function Pressure reducing valves are devices which, when installed on private water systems, reduce and stabilise the pressure of the water entering from the public network. This inlet pressure, in general, is too high and variable to be applied directly to domestic systems. This series of pressure reducing valves have the feature to be preadjustable. The pressure reducing valve can be set to the desired pressure value before installation, using an adjustment knob with a pressure setting indicator. After installation, the system pressure will automatically adjust itself to the set value. The internal cartridge containing all the regulating components is pre-assembled as a self-contained unit, to facilitate inspection and maintenance procedures. A version fitted with an inspectable high-capacity strainer, located inside a special transparent container, is also available. This ensures the pressure reducing valve and water system are well protected from any impurities in the water supply. 5350 and 5351 series pressure reducing valves are certified as compliant with European standard EN 1567. Patent application: No. MI2001A001592 No. 188928201
SVGW SSIGE

AS 1357.2 WMKA 02467

Product range 5350 series 5350 series 5351 series 5351 series Pre-adjustable pressure reducing valve with self-contained cartridge. With pressure gauge size 1/2, 3/4, 1, 1 1/4, 1 1/2 and 2 M with union Pre-adjustable pressure reducing valve with self-contained cartridge. Without pressure gauge size 1/2, 3/4, 1, 1 1/4, 1 1/2 and 2 M with union Pre-adjustable pressure reducing valve with self-contained cartridge and inspectable strainer. With pressure gauge size 1/2, 3/4 and 1 M with union Pre-adjustable pressure reducing valve with self-contained cartridge and inspectable strainer. With pressure gauge connection size 1/2, 3/4 and 1 M with union

Technical specifications series Materials Body: Cover: Control stem: Moving parts: Diaphragm: Seals: Strainer: Strainer container: Performance Max. upstream pressure: Downstream pressure setting range: Factory setting: Max. working temperature: Pressure gauge scale: Strainer mesh size: Medium: Certification in compliance with standard: Connections Pressure gauge connections 5350 5351

dezincification resistant alloy EN 12165 CW602N PA66G30 stainless steel dezincification resistant alloy EN 12164 CW602N NBR NBR stainless steel -

brass EN 12165 CW617N PA66G30 stainless steel dezincification resistant alloy EN 12164 CW602N NBR NBR stainless steel transparent PA12

25 bar 16 bar 3 bar 60C 010 bar 0,51 mm water EN 1567 1/22 M with union 1/4 F

25 bar 16 bar 3 bar 40C 010 bar 0,28 mm water EN 1567 1/21 M with union 1/4 F

Dimensions

Operating principle The functioning of the pressure reducing valve is based on the balance between two opposing forces: 1 the thrust of the spring towards the opening of the obturator 2 the thrust of the diaphragm towards the closure of the obturator Pressure adjusting knob

CALEF FI

B B
Code A B B C D E

Mass (kg)

UPSTREAM

DOWNSTREAM

535040/1 1/2" 140 76* 20,5 112 54 0,92 535050/1 3/4 160 90* 20,5 112 54 1,06 535060/1 1 180 95* 20,5 112 54 1,38 535070/1 11/4 200 110* 40 178 73 2,6 535080/1 11/2 220 120* 40 178 73 3,4 535090/1 2 250 130 40 178 73 4,3

*Interchangeable with 5360 series Operation with water flow When a draw-off outlet is opened on the water system, the force of the spring becomes greater than that of the diaphragm; the obturator moves downwards opening the valve to the flow of water. The greater the demand for water the lower the pressure under the diaphragm with a resulting greater flow of water through the valve.
CALEF FI

4 2 bar

6 8 2

6 8

10

bar

10

B B
Code A B B C D E
Mass (kg)

535074/5 1 1/4" 197 103 25 113 56 1,65

Operation without water flow When the draw-off outlet is closed, the downstream pressure rises and pushes the diaphragm upwards. As a result the obturator closes the valve to the passage of water and maintains the pressure constant at the calibrated pressure. The slightest difference in favour of the force exercised by the diaphragm, in relation to that of the spring, causes the device to close.

4 2 bar

6 8 2

6 8

10

bar

10

Code

Mass (kg)

535140/11/2" 169 105 86,5 100,5 54 58 1,50 535150/13/4 180 110 89 98 54 58 1,57 535160/1 1 205 120 88,5 99,5 54 58 1,92

Construction details Pre-adjustment Pressure reducing valves in the 5350 and 5351 series are fitted with an operating knob and a pressure setting indicator which is visible on both sides. This pressure indicator features incremental step operation, therefore the pressure can be adjusted continuously with the value displayed at 0,5 bar increments. The system pressure can therefore be pre-set to the desired value, even before the pressure reducing valve is installed. Compensated seat Caleffi pressure reducing valves are fitted with compensated seats. This means the set pressure value remains constant, regardless of variations in the upstream pressure value. In the figure, the thrust towards the opening is counterbalanced by the force created by the closing pressure acting on the compensating piston. Since the piston has a surface area equal to the obturator one, the two forces cancel each other out. Removable self-contained cartridge The cartridge, containing the diaphragm, strainer, seat, obturator and compensating piston, is pre-assembled as a "self-contained unit" with a cover and can be easily removed for inspection and maintenance procedures. Inspectable strainer The 5351 series pressure reducing valves are fitted with a high-capacity inspectable strainer, located in a special transparent container. This means it is possible to view its condition and carry out inspection and maintenance procedures as necessary.

4 3 2 0

6 8

F
bar

10

Low head loss The internal fluid-dynamic shape of the pressure reducing valve allows to obtain particularly low pressure losses, even if a large number of user outlets are opened. High pressures The zone exposed to the upstream pressure is constructed so that it can even operate at high pressure. The PTFE anti-extrusion rings on the compensating piston make it possible for the valve to be used continuously at upstream pressures of up to 25 bar. Non-sticking materials The central support assembly , containing the moving parts, is made of plastic material with a low adherence coefficient. This solution minimises the chance of lime scale formation, the main cause of malfunctions. Pressure gauge The pressure gauge used in the 5351 series has stainless steel casing and a connection with a PTFE ring, which guarantees the hydraulic seal without the need for any further sealing.

4 3 2 0

6 8

F
bar

10

4 6 2 8 0 10 bar

Certification The 5350 and 5351 pressure reducing valves are approved by the SVGW and DVGW bodies as compliant with the specifications of European standard EN 1567.

Hydraulic characteristics Graph 1 (Water velocity)


V (m/s)
5 4 3 2

Correct sizing should take place as follows: The total flow rate is calculated from the number and type of appliances present by taking the sum of the individual flow rates.

Example:
1

0,5 0,4 0,3 0,2

1/2

3/4

1 1/4

1 1/2

Residence with 2 bathrooms 2 bidets G 1 shower G 2 washbasins G 2 WCs G 1 bathtub G 1 kitchen sink G 1 washing machine G
Flow rate (l/min) (m3/h)
5

= = = = = = =

12 l/min 9 l/min 12 l/min 12 l/min 12 l/min 12 l/min 12 l/min

0,1
0,2 0,5 1 2

Gtot = 81 l/min No. of devices = 10 The design flow rate is calculated from the table of simultaneous use factors.

10

100

Graph 2 (Pressure drop)


1 1/4" 1 1/2" 1" 1" 1 1/4" 1/2" 3/4" 1/2" 3/4" 2"

p (bar)
1,5 1,2 1 0,9 0,8 0,7 0,6 0,5 0,4 0,3

5351

5350

(535074/5)

200

10

20

50

p (m w.g)
15 12 10

20

Example: Gds = Gtot % = 81 41 % = 33 l/min It is recommended that flow velocity is kept within 1 to 2 metres per second when calculating the correct reducing valve size. This will prevent noise in the pipes and rapid wear of appliances. The correct diameter of the reducing valve is taken from diagram 1 on the basis of the design flow rate taking into account an ideal flow velocity of between 1 and 2 m/s (blue band).

8 7 6 5 4 3

0,2

0,1
0,2 0,5 1 2 5 10 20

Flow rate (l/min) (m3/h)

100

200

20

10

50

Example: for Gds = 33 l/min, select the 3/4 diameter. (see Graph 1) The pressure drop is taken from diagram 2 again on the basis of where the design flow rate intersects the curve for the relative diameter already selected (the downstream pressure falls by an amount equal to the pressure drop, with respect to the set pressure at no flow condition).

- Reference values:

Upstream pressure = 8 bar Downstream pressure = 3 bar

Sizing The typical flow rates of equipment commonly used in domestic water systems are shown below, to help in the selection of correct pipe diameters:

Table of typical flow rates Bathtub, kitchen sink, dishwasher Shower. Washbasin, bidet, washing machine, WC 12 litres/min 9 litres/min 6 litres/min Example: for Gds = 33 l/min (see Graph 2) for 5350 p = 0,60 bar for 5351 p = 0,65 bar

To prevent oversizing of the pressure reducing valve and the pipes, the correct simultaneous use correction factor must be taken into account. Basically, the more outlets within the system, the lower the percentage of draw-off outlets opened simultaneously will be.

Nominal flow rates Water flow rates corresponding to each diameter are shown below, for an average velocity of 2 m/s, in accordance with the specifications of the standard EN 1567.

Table of simultaneous use factors (%)


Number of devices Private dwelling % Public building % Number of devices Private dwelling % Public building % Number of devices Private dwelling % Public building %

5 10 15 20 25 30

54 41 35 29 27,5 24,5

64,5 49,5 43,5 37 34,5 32

35 40 45 50 60 70

23,2 21,5 20,5 19,5 18 17

30 28 27 26 24 23

80 90 100 150 200 300

16,5 16 15,5 14 13 12,5

22 21,5 20,5 18,5 17,5 16,5

Diameter 1/2 Flow rate (m3/h) 1,27 Flow rate (l/min) 21,16

3/4 2,27 37,83

1 3,6 60

1 1/4 1 1/2 2 5,8 9,1 14. 96,66 151,66 233,33

Installation 1) Turn all the taps on before installing the pressure reducing valve, to flush the system and expel any air remaining in the pipes. 2) Install shut-off valves upstream and downstream to facilitate maintenance operations. 3) The pressure reducing valve may be installed on either vertical or horizontal pipe. However, it must not be installed upside down.

Installation recommendations 1. Installation below ground Installing pressure reducing valves below ground is not recommended, for three reasons: - there is a risk of the reducing valve being damaged by frost - inspection and maintenance is difficult - reading the pressure gauge is difficult. 2. Water hammer This is one of the main causes of faults in pressure reducing valves. It is best to fit special devices to absorb water hammer when installing pressure reducers in at-risk systems. Trouble-shooting Certain types of fault, which are generally due to faulty design of the system, are often wrongly attributed to pressure reducing valves. The most frequent cases are as follows:

4) Close the downstream shut-off valve. 5) This mechanical pre-adjustment system, with the operating knob and pressure indicator visible from both sides, allows the pressure reducing valve to be set to the required value in the system prior to installation. The pressure indicator features incremental step movement, so that the pressure can be adjusted continuously and the value displayed at 0,5 bar increments. 6) Set using the operating knob on the upper part of the device. The pressure reducing valves are factory set to a pressure of 3 bar. 7) In view of the pre-adjustment function, the presence of a pressure gauge downstream of the device is not essential. 8) After installation, the internal mechanism will automatically control the pressure, until the set value has been reached. 9) Slowly reopen the downstream shut-off valve. 1. Increased downstream pressure in the presence of a water heater This problem is due to heating of the water caused by the water heater. There is not relief of the pressure because the reducing valve is rightly closed. The solution is to install an expansion vessel (between the heater and the reducer) to absorb the pressure increase. 2. The pressure reducing valve does not maintain its calibrated value In most cases this is the result of impurities that deposit on the valve seat causing leakage with a resulting increase in pressure downstream. It is advised to carry-out maintenance and cleaning of the removable cartridge (see maintenance).

Maintenance

3
The following steps are necessary for the cleaning, inspection and replacement of the entire regulating cartridge: 1) Shut off the pressure reducing valve. 2) The special construction of the regulating unit requires no adjustment of the calibrated pressure, which can be left at the set value. 3)Remove the upper cover, using a suitable spanner. The upper cover is integral with the internal regulating cartridge. 4) Check and clean the strainer as necessary (5350 series only). 5)The entire self-contained cartridge can be re-fitted or replaced with a spare. When the cartridge is screwed back onto the valve body, the pressure indicator windows will return to the original position. 6) Reopen the shut-off valves. The pressure will return to the original set value.

Cleaning the 5351 series strainer To clean the strainer cartridge, proceed as follows: 1) Shut off the pressure reducing valve. 2)Unscrew the transparent strainer cartridge container using the spanner provided. 3)After cleaning, the entire strainer cartridge can be re-fitted or replaced with a spare part. 4) Screw the container back on again using the spanner provided and reopen the shut-off valves.

Application diagram Shut-off valve Ball check valve Water hammer arrester Solenoid valve

SPECIFICATION SUMMARIES
5350 series Pre-adjustable pressure reducing valve with compensated seat and self-contained cartridge, compliant to standard EN 1567. Connections 1/2 M (from 1/2 to 2) with union. Dezincification resistant alloy body and internal moving parts. PA66G30 cover. Stainless steel strainer, mesh size 0,51 mm. NBR diaphragm and seals. Maximum working temperature 60C. Maximum upstream pressure 25 bar. Downstream pressure setting range from 1 to 6 bar. Self-contained cartridge can be removed for maintenance purposes. Complete with: adjustment knob with downstream pressure regulating scale for manual setting, pressure gauge with scale 0-10 bar (version with pressure gauge). Pressure gauge connection 1/4 F (version without pressure gauge). 5351 series Pre-adjustable pressure reducing valve with compensated seat, self-contained cartridge and inspectable strainer, compliant to standard EN 1567. Connections 1/2 M (from 1/2 to 1) with union. Brass body. Dezincification resistant alloy internal moving parts. PA66G30 cover. Stainless steel strainer, mesh size 0,28 mm. Transparent PA12 strainer container. NBR diaphragm and seals. Maximum working temperature 40C. Maximum upstream pressure 25 bar. Downstream pressure setting range from 1 to 6 bar. Self-contained cartridge can be removed for maintenance purposes. Complete with: adjustment knob with downstream pressure regulating scale for manual setting, pressure gauge with scale 0-10 bar (version with pressure gauge). Pressure gauge connection 1/4 F (version without pressure gauge).

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.p.A. S.R.229, N.25 28010 Fontaneto dAgogna (NO) Italy Tel. +39 0322 8491 Fax +39 0322 863723 www.caleffi.com info@caleffi.com
Copyright 2010 Caleffi

Electronic mixing valve with programmable thermal disinfection


6000 series
cert. n 0003

CALEFFI
ISO 9001

01086/07 GB
replaces dp 01086/05

Function The electronic mixing valve is used in central systems that produce and distribute hot water for sanitary purposes. It is designed to ensure and maintain the temperature of the hot tap water distributed in the network when there are variations in the temperature and pressure of the incoming hot and cold water or in the draw-off flow rate. This particular series of electronic mixing valves is equipped with a special regulator that controls a set of programs for circuit thermal disinfection against Legionella. In addition it enables checking the temperature and time for thermal disinfection are actually reached and undertaking the appropriate corrective action. All the parameters are updated every day and logged, recording the temperatures by time. Depending on the type of system and habits of the consumer, it is possible to program the temperature levels and the operation times in the most appropriate manner. In addition, it is fitted for a monitoring and remote control connection. Patented

Product range 6000 series Electronic mixing valve with programmable thermal disinfection. Threaded version. 6000 series Electronic mixing valve with programmable thermal disinfection. Flanged version. sizes 3/4 - 1 - 1 1/4 - 1 1/2 - 2 sizes DN 65 and DN 80

Technical specifications Valve body Materials: Body: Ball: Hydraulic seals: Digital regulator Material: - box: - cover: Electric supply: Power consumption: Adjustment temperature range: Disinfection temperature range: Ambient temperature range: Protection class: Contact capacity: - mixing valve control: - alarm relay (R2): - relay 1, 3, 4: self-extinguishing ABS white RAL 1467 self-extinguishing SAN smoked transparent 230 V (ac) 50/60 Hz 6,5 VA 20 65C 40 85C 0 50C IP 54 (wall mounting) (class II appliance). 5(2) A / 250 V 5(2) A / 250 V 10(2) A / 250 V

brass EN 12165 CW617N brass EN 12165 CW617N, chrome plated NBR 10 bar 100C 0 80C

Max working pressure (static): Max inlet temperature: Thermometer temperature scale:

Hot and cold water connections: 3/4 2F Mixed water connection: 3/4 2 F with union Flanged connections: DN 65 and DN 80, PN 16 can be coupled with counterflanges EN 1092-1 Actuator for threaded version Electric supply: 230 V (ac)- 50/60 Hz directly from the regulator Power consumption: 8 VA Protective cover: self-extinguishing V0 Protection class: IP 44 Ambient temperature range: -10 55C Length of supply cable: 0,9 m Actuator for flanged version Electric supply: 230 V (ac)- 50/60 Hz directly from the regulator Power consumption: 10,5 VA Protective cover: self-extinguishing V0 Protection class: IP 65 Ambient temperature range: -10 55C Length of supply cable: 2m Mixing valve performance Accuracy: Max working pressure (dynamic): Max ratio between inlet pressures (C/H or H/C) with G = 0,5 Kv: 2C 5 bar 2:1

Fuses: Charge reserve:

1A 15 days In case of a mains failure, with a 3-cell rechargeable buffer battery of 150 mAh enabling via jumpe Battery charging time: 72 h Conforming to Directives: Temperature sensors: CE

type of sensitive element: NTC working range: -10 125C resistance: 10000 Ohm at 25C time constant: 2,5 s 25 m 1000 m

Max distance of the flow sensor: Max distance of the return sensor:

Dimensions

Mixed C

Return C

Mixed C

Return C

tuesday

Adjustment running

13/02/2006
Ok

tuesday

adjustment running

13/02/2006
Ok

Shock

Menu

Ok

Shock

Menu

Ok

40 20 0 60

80

40 20 0

60

80 100

120

G B Code A 74 600050 3/4" 75 600060 1 600070 1 1/4 85 600080 1 1/2 100 110 600090 2 C 200 212 226 248 266 D 85 95 140 150 170 E 145 145 145 145 145

A B

G G 105 105 105 105 105


Weight (kg)

F 180 180 180 180 180

A B

1,3 1,7 2,3 2,9 5,0

B Code A 600006 DN 65 235 600008 DN 80 235

C 600 600

D 275 275

E 145 145

F 180 180

G 105 105

Weight (kg)

28 30,4

Legionella-distribution temperature In central systems that produce hot water for sanitary purposes with storage, in order to prevent the growth of dangerous Legionella bacteria, the hot water must be stored at a temperature of at least 60C. At this temperature it is certain that the growth of the bacteria that can lead to the illness called legionnaires disease will be totally inhibited. These temperatures, however, are too high to be able to be used directly by the consumer; hot water at these levels can cause severe burns. It is therefore necessary to reduce the temperature of the hot water distributed in the network to a lower value compatible with use. In addition, not only the storage but also the entire distribution network needs thermal disinfection at regular intervals. Otherwise the bacteria would quickly form there too. In the light of all this, it is therefore advisable to install an electronic mixing valve that is able to: reduce the temperature of the distributed water to an adjustable value lower than that of storage keep the mixed water temperature constant as the temperature and pressure at the inlet or the draw-off flow rate of the mixed water vary allow programming thermal disinfection with a higher temperature than the adjustment value, in the necessary time and in periods with less frequent consumption (nighttime). Thermal disinfection The drawing alongside shows the behaviour of Legionella Pneumophila bacteria as the conditions vary in the temperature of the water containing the bacteria, in laboratory cultures. To ensure correct thermal disinfection, it is necessary to go up to values of no less than 60C.
70 60 50 40 30 20 10 0

Energy savings Energy savings rules advice to use mixing valves on water delivery systems for sanitary use with storage, to limit the temperature of the water at the inlet of the delivery network. The purpose of limiting the temperature is to reduce passive dispersion through the delivery network as much as possible, besides prevent delivering water at a higher temperature than necessary. Reference documents With regard to the prevention and control of Legionella, see the National Regulations and applicable Code of Practice. Applications The electronic mixing valve is typically used in central systems serving hospitals, nursing homes, sports centres, shopping malls, hotels, campsites and boarding schools. In these structures with their collective use, it is more than ever necessary to control and prevent legionnaires disease in a programmed manner, managing the disinfection times in the best possible way.

Instant death of bacteria Death of 90% of bacteria in 2 minutes Death of 90% of bacteria in 2 hours Optimum temperature for growth of bacteria

Surviving bacteria inactive

Characteristic components

1 3
tuesday adjustment running 13/02/2006

3 2 6 4 5

2 6 4

1) 2) 3) 4) 5) 6)

Legiomix digital regulator Mixing valve Mixing valve actuator Mixed water flow sensor Return sensor Mixed water flow thermometer

40 20 0 60 80

40 20 0

60

80 100

120

Operating principle At the mixing valve inlet there is hot water from the storage and cold water from the mains. At its outlet there is the flow mixed water. By means of a specific sensor, the regulator measures the temperature of the mixed water at the valve outlet and operates the mixing valve to maintain the set temperature. It modifies the flows of hot and cold water at the inlet to bring the temperature of the outlet water to the set value. Even if there are drops in pressure due to hot or cold water usage or temperature variations at the inlet, the mixing valve automatically adjusts the flow rate of water until it obtains the set temperature. The appliance incorporates a digital clock and allows programming anti-legionella disinfection treatment on the plumbing system. The system is disinfected by raising the water temperature to a specific value for a specific time duration. For the best thermal disinfection control, in this type of system it may also be necessary to measure the temperature of the water returning from the network, measured with the recirculation sensor. When this measurement is available, it is used in order to check and control the temperature reached over all or part of the network, since the sensor can be located at a significant remote point of the system. The appliance is equipped with an RS-485 serial port for remote querying and setting and via specific relays it carries alarm signals and controls for other system devices outside.

recirculation sensor flow sensor

MIX

60

80

40

20

COLD

HOT

Hydraulic characteristics
p (bar) 1,5 1,0
3/4 1 1 1/4 1 1/2 2 p (m w.g.)

p (bar) 1,5 1,0

DN 65

DN 80

p (m w.g.) 15 10

15 10

0,5 0,3 0,2

5 3 2

0,5 0,3 0,2

5 3 2

0,1

0,1

0,05 1 2 10 20 5

0,5
50 Flow rate (l/min) (m3/h)

0,05 10 20 50 100

0,5 200 Flow rate (l/min) (m3/h)

20

100

200

50

500

1000

Recommended FLOW RATES to ensure stable operation and an accuracy of 2C Kv (m3/h) 5,2 9,0 14,5 23,0 32,0 Minimum (m3/h) 0,5 0,7 1,0 1,5 2,0 Maximum* (m3/h) 6,4 11,0 17,8 28,0 39,0 Kv (m3/h) 90,0 120,0

Recommended FLOW RATES to ensure stable operation and an accuracy of 2C Minimum (m3/h) 4,0 5,0 Maximum* (m3/h) 110,0 146,0

3/4 1 1 1/4 1 1/2 2

* p = 1,5 bar

3/4 1 1 1/4 1 1/2 2

DN 65 DN 80

* p = 1,5 bar

DN 65 DN 80

Back panel To remove the electrical wiring base you need to turn it round and extract it from its housing.

Appliance fuse 1 A - 250 V delayed Mix valve fuse 1 A - 250 V delayed 15 14 13 12 11 10 9 8 7 Closes Common Opens Earth Earth Neutral Live Relay 4

Electric Mix valve supply 230 V

Disabling button PIN code Appliance reset button Screw for closing front with hole for sealing

18 17 16 Relay 3 Relay contacts RS485 Temperature sensors 6 5

Reset

PIN disable

2000

200

500

RS485 interface terminal

Flow Common Return

21 20 19

Relay 2

Terminal for temperature sensors Contacts for thermal shock function enabling jumper

4 3 2 1

Thermal shock enabling Shock disabled Battery connection Battery connected Shock enabled Battery disconnected

Relay 1

Connecting sensors: The cable connecting the flow and return sensors with the regulator must be installed in a dedicated raceway. If the connecting cable is put into a raceway with other live cables then you must use a grounded shielded cable.

Front panel

1 LCD display 2 LED display: HH:MM 3 LED display: TMixed-flow temperature 4 Indicator LED

Mixed C

Return C

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13/02/2006

On - Status OK - Battery - Alarm 5 LED display: TReturn-return temperature 6 Mixing valve open-close LED 7 Thermal shock button 8 Navigation buttons - Menu - OK UP DOWN 9 RS 485 front connection

Ok

Shock

Menu

Ok

Indicator description Signals with LED display On the front of the appliance there are 3 LED displays that constantly give the current time and the temperatures of the flow and return (system recirculation) sensor. LED indicators On the front of the appliance there are the following indicator LEDs: Mains LED: red LED: on steady when there is mains voltage.

Return C

Flow

Return
Ok

Mix valve LED: open - red LED: on when opening hot water close - blue LED: on when opening cold water

Signals with LCD display On the front of the appliance there is a green backlit alphanumeric display with four rows of 20 characters each, for setting parameters, programming work, displaying error messages and machine status. By scrolling through the menu items with the buttons on the front panel (MENU, UP, DOWN and OK), you can configure the appliance, set the various parameters and view the temperature log.

Appliance OK status LED: green LED: on steady when there are no faults or alarms on. Faulty Battery LED: red LED: on steady when the battery is broken; otherwise off. Generic Alarm LED: red LED: on steady when there is an alarm (sensor trouble, shock in progress, reset). Blinks when on low power.

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tuesday

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13/02/2006

Work status
Depending on the time, according to the programs entered, the appliance may be in one of the following work modes: Adjustment; Disinfection; Flushing; Thermal shock (this function takes priority over the preceding ones); In the event of trouble due to the appliance or the system, the device manages and reports the alarm and, depending on the situation, may maintain operation or not. So the statuses include: On with alarm Off with alarm The appliance is equipped with a chargeable battery that enables keeping the clock working in the event of a mains power failure. In the event of a blackout, in order to ensure the longest operating time possible for the battery, the appliance is in the status of: Off with Low Power. Adjustment In this mode the appliance continually checks the temperature detected by the flow sensor and as a result adjusts the mixing valve so that the flow temperature is equal to the set point. Disinfection In this mode the appliance runs a disinfection phase, which consists of taking the water temperature up to a pre-set value for a specific duration, suitably controlling the mixing valve. It is possible, with the menu, to set the days of the week when disinfection must be carried out. At the end of disinfection, the statistical data relating to the disinfection that has just been concluded are stored in memory. Access to and exit from this mode take place automatically according to a time for starting (TIMEON) and ending (TIMEOFF) that the user can set.

CHECK ON DISINFECTION

Temperature t1 SET2 - PRG1A SET3 - PRG1B of 2 t2

tDIS = ti > tMIN TIME ON TIME OFF

Time

If, in the time span (Time OFF - Time ON), the actual disinfection time is reached tDIS greater than the set tMIN, the disinfection is concluded with a positive outcome. It automatically exits this status and returns to adjustment. If it is not possible to reach a sufficient time tDIS, the disinfection phase anyhow ends at Time OFF.

Example: Time ON: Time OFF: tMIN: Program: Tdisinfection: 2:00 3:00 30 min 1A 60C If, in the time span of 1 hour, there is a temperature higher than 60C for at least 30 minutes, disinfection has been successful and the regulator returns to adjustment. Otherwise, disinfection anyhow ends at 3:00.

Programs The operation of the regulator, during disinfection, can be set according to different programs, chosen according to the type of system and its management: Program 0 (default) This program features continual adjustment of the flow temperature with automatic disinfection in a time band that can be set. With this program the return sensor is not used; if present, it is only used as a monitor. During the phase of disinfection, the temperature of the flow sensor must be above SET2 for a time tDIS at least equal to tMIN, if this occurs then disinfection has been successful. As soon as there are the conditions to be able to consider disinfection successful, it is stopped. If disinfection is not successful there is no alarm signal. Program 1A This program features continual adjustment of the flow temperature with automatic disinfection in a time band that can be set. With this program the return sensor is not used; if present, it is only used as a monitor. During the phase of disinfection, the temperature of the flow sensor must be above SET2 for a time tDIS at least equal to tMIN, if this occurs then disinfection has been successful. As soon as there are the conditions to be able to consider disinfection successful, it is stopped. If it is not possible to reach the disinfection temperature or it is not possible to hold it for a sufficient time, the alarm for unsuccessful disinfection is generated. The alarm is recorded in the log. Program 1B This program can only be set if the return sensor is set as present. It is identical to the previous program, the only difference lies in the fact that the successful outcome of the disinfection phase is checked via the return sensor in relation to SET3 instead of via the flow sensor in relation to SET2. As soon as there are the conditions to be able to consider disinfection successful, it is stopped. If it is not possible to reach the disinfection temperature or it is not possible to hold it for a sufficient time, the alarm for unsuccessful disinfection is generated. The alarm is recorded in the log. Program 2 This program can only be set if the return sensor is set as present. It is identical to the previous program, the only difference lies in the fact that, if after a wait time (tWAIT) since the start of disinfection the return temperature does not reach SET3, the flow temperature SET2 is increased by a value equal to (SET3 - TR reached), considering the fact that SET2 anyhow cannot exceed the limit of SETMAX. This correction procedure (increasing only) of the disinfection SET is iterative: if necessary, it is repeated in the time span defined by TimeON and TimeOFF at each time interval equal to tWAIT. As soon as there are the conditions to be able to consider disinfection successful, it is stopped. If it is not possible to reach the disinfection temperature or it is not possible to hold it for a sufficient time, the alarm for unsuccessful disinfection is generated. The alarm is recorded in the log.

Thermal disinfection The temperatures and corresponding disinfection times for the network must be chosen according to the type of system and the related intended use. In the light of the requirements of the most advanced world legislation on this matter, the following criteria can generally be followed: T = 70C for 10 minutes T = 65C for 15 minutes T = 60C for 30 minutes Thermal disinfection is generally performed at times of reduced use of the system, for example at nighttime; this is to minimize the risk of users getting scalded. It is recommended to perform thermal disinfection every day and at least once a week.

Thermal disinfection program guide table Type of check Progr. Use return sensor NO NO YES YES YES Adjustment temperature Disinfection temperature

Adjustment and simple disinfection no check Adjustment and disinfection check on the flow temperature Adjustment and disinfection check on the return temperature to the heating plant Continual disinfection Adjustment and check on disinfection with modification of the flow temperature according to the return temperature

0 1A 1B 1B 2

Flow: (SET 1) 5055C Flow: (SET 1) 5055C Flow: (SET 1) 5055C -Flow: (SET 1) 5055C

Flow: (SET 2) 60C Flow: (SET 2) 60C Recirculation: (SET 3) 57C Recirculation: (SET 3) 55C -24 h Recirculation: (SET 3) 55C with modification of flow up to the max value

Flushing The appliance goes into this mode automatically at the end of the disinfection phase and it can be used for example to make the water temperature return to the adjustment value more quickly or to periodically clear the storage of any impurities. Thermal shock In this mode, the appliance regulates the flow temperature on the shock setting for a time that can be set. It is possible to start thermal shock on pressing the specific button on the front of the appliance (pressing it for at lease 5) while the work screen is displayed, or to program it with the menu item for deferred execution (countdown in minutes), or by remote control. After activating the procedure, it is anyhow possible to stop it by pressing the shock button and confirming it with the OK button (display guided procedure), or by remote control. At the end of the Thermal Shock phase the appliance goes back into the adjustment function. Low Power This mode is entered if there is a mains power failure. The appliance continues running the internal date clock, however in this state there is no power to switch over the relays so the regulator will perform neither adjustment nor disinfection. When the mains power comes back on, the blackout is recorded in the log and the regulator returns to operating as programmed, unless the mains failure lasted long enough to run down the battery completely. In this case the appliance will reset when the mains power comes back on. In the event of a reset or an extended power failure, the default settings are restored.

On the back of the panel there is the reset button, if it is necessary to restore the initial settings. If the date and time are not set after the reset, the regulator will only make the adjustment according to the default settings.

Actuation relays
On the power and terminals board there are the contacts of the relays used to govern the auxiliary equipment and to report alarms. Relay 1: circulation pump (on in disinfection). Relay 2: general alarm (sensor fault, battery fault, blackout or loss of current time). This relay is connected via the NC contact. Relay 3: second thermostat. Relay 4: flushing valves.

Relay contact for recirculation pump and hot water storage thermostat 2 Here we give the electrical connection of relay 1 when there is the clock for managing the recirculation pump times. Here we give the electrical connection of relay 3 for connection to the second thermostat of the hot water storage.

Relay 1
1 2

T1 60C L N

T2 70C

Relay 3
5 6

L N Recirculation pump

Hot water storage primary pump

Reset

Reset

Alarm management
In order to simplify the solution of any functional problems after installation and commissioning, the regulator is configured so as to signal any operating trouble with alarms and to undertake the appropriate action. In this case the cause of the alarm is shown on the LCD display. If the alarm does not inhibit all the functions, the alarm screen will alternate with the appliance status screen.

Alarm description table Alarm indicator AL1 AL2 AL3 AL4 AL5 AL6 AL7 Description Flow sensor faulty Return sensor faulty Disinfection failed Thermal Shock in progress Mains power failure Appliance reset Battery faulty Depending on the type of alarm, certain actions are undertaken, relay statuses modified and information shown on the LED displays, the LCD display and the LEDs on the front panel. For the operating details please refer to the installation and commissioning manual.

Log
The log is a FIFO list (loop buffer) that is continually updated and records parameters relating to the phases of adjustment and disinfection that took place during the day. The last 40 days are saved, after which the data relating to the less recent day are overwritten and so on. Every hour the hourly averages of the flow and return temperatures are saved to Eeprom, while the alarms are saved at the time when they occur. At any time it is possible to view the average hourly values of the current day (obviously the ones already recorded). The data on disinfection are saved when disinfection ends. It is possible to view the log on the display (via the specific menu item) or remotely via the RS485 serial interface. The parameters saved in the log are: - Date (day, month, year) - Set program. This is saved when disinfection starts. - tDIS: actual disinfection time (in steps of minutes). When the set program is 0 or 1A, this parameter is the time when the temperature of the flow sensor was greater than SET2. When the set program is 1B or 2, this parameter is the time when the return sensor was greater than SET3. This is helpful when it is less than tMIN, to understand how much greater the span of TIME ON: TIME OFF should be to complete disinfection. - TRMAX: Maximum temperature of the return sensor during disinfection (if there was disinfection that ended on that day). - TRMIN: Minimum temperature of the return sensor during disinfection (if there was disinfection that ended on that day). It is calculated from the time when the return sensor measured a value greater than SET3, that is starting from the time when the disinfection starts being effective. - Alarms AL1, AL2, AL3, AL4, AL5, AL6, AL7 if they were activated on the day in question. - 24 hourly average values of the flow temperature. - 24 hourly average values of the return temperature. - Marker indicating whether the previous data are reliable. Used in the event of resetting, changing time, changing date and any other event that might have made the saved data unreliable. If no disinfection ended on that day, then the related fields will contain a default value. If there have been any faults with one or both sensors, the hourly average data will be displayed with dashes. If there are any gaps or unavailable data due to a change in date, time, etc., the cells will contain a default value and will be shown on the display with dashes.

hiSTORIc 06/04/2006 tDIS 060 PGRM 1A TR MAX 58 TR MIN 48 ALARM ---45-7Ready for remote control

hiSTORIc 06/04/2006 h 01 02 03 04 05 06 TF ----------------TR -----------------

hiSTORIc 06/04/2006 h 07 08 09 10 11 12 TF 50 50 50 51 49 52 TR 47 47 47 47 46 48

The regulator can be controlled by computer, too, since it is fitted with an RS485 serial output connection, which is accessible both via terminals for fixed wiring and via the connector on the front. Since the interface is the multipoint bus type it is necessary for each appliance connected on the bus to be identified by an appropriate address in order to avoid conflicting identification. For a detailed description of the operations and controls that are possible from a remote location with this interface, please refer to the relevant documentation.

Application diagrams

Check valve Ball valve


60 80 0

Temperature gauge
40

Backflow preventer Pump Expansion vessel


T
T2 T1

Thermostat Safety valve Filter

60

80

40

20

T2 T1

SPECIFICATION SUMMARIES
6000 series threaded version Electronic mixing valve with programmable thermal disinfection. Consisting of: Valve body. Hot and cold water connections threaded 3/4F (from 3/4 to 2), mixed water connection 3/4F (from 3/4 to 2) with union. Brass body. Chrome plated brass ball. NBR hydraulic seals. Maximum working pressure (static) 10 bar. Maximum temperature at inlet 100C. Thermometer temperature scale 080C. Actuator. Electric supply 230 V (ac) - 50/60 Hz directly from the regulator. Power consumption 8 VA. Protection class IP 44. Ambient temperature range: -1055C. Self-extinguishing protective cover VO. Power cable length 0,9 m. Mixing valve. Accuracy: 2C. Maximum working pressure (dynamic) 5 bar. Maximum ratio between inlet pressures (H/C or C/H), with G = 0,5 Kv, 2:1. Digital regulator. Electric supply 230 V (ac) - 50/60 Hz. Power consumption 6,5 VA. Adjustment temperature range 2065C. Disinfection temperature range 4085C. Ambient temperature range 050C. With program for checking the temperature and time for thermal disinfection are actually reached; equipped with system for logging the measured parameters on a daily basis; fitted for a monitoring and remote control connection. Protection class IP 54 (wall mounting). Conforms to EC directives. 6000 series flanged version Electronic mixing valve with programmable thermal disinfection. Consisting of: Valve body. Flanged connections DN 65 (DN 65 and DN 80), PN 16 can be coupled with counterflanges EN 1092-1. Brass body. Chrome plated brass ball. NBR hydraulic seals. Maximum working pressure (static) 10 bar. Maximum temperature at inlet 100C. Thermometer temperature scale 080C. Actuator. Electric supply 230 V (ac) - 50/60 Hz directly from the regulator. Power consumption 10,5 W. Protection class IP 65. Ambient temperature range: -1055 C. Self-extinguishing protective cover VO. Power cable length 2 m. Mixing valve. Accuracy: 2C. Maximum working pressure (dynamic) 5 bar. Maximum ratio between inlet pressures (H/C or C/H), with G = 0,5 Kv, 2:1. Digital regulator. Electric supply 230 V (ac) - 50/60 Hz. Power consumption 6,5 VA. Adjustment temperature range 2065C. Disinfection temperature range 4085C. Ambient temperature range 050C. With program for checking the temperature and time for thermal disinfection are actually reached; equipped with system for logging the measured parameters on a daily basis; fitted for a monitoring and remote control connection. Protection class IP 54 (wall mounting). Conforms to EC directives.

20

Accessories

6001

LEGIOMIX Interface

LEGIOMIX Interface for local or remote transmission and management of the electronic mixing valve 6000 series. Complete with: - RS232 interface-computer connection cable, - legiomix-interface connection cable with telephone connector, - transmission and management software. Power supply: 230 (V) - 50 Hz - 5 VA. Dimensions: 160 x 125 x 40 mm.

Product range
Code

600100 755845 755846 755855

LEGIOMIX interface analog modem GSM digital modem bus cable (FROR 450/750 - 2x1 mm2) - 100 m roll

The Legiomix electronic mixing valve can be remote controlled using the transmission interface and a specific transmission software. The interface is connected to the Legiomix regulator via the front connector, for local control, or via the terminals on the back of the panel, for remote control. Up to 9 Legiomix regulators can be connected to the same interface, using a bus cable. The interface is then connected to the transmission modem, which can be both of analog and GSM digital type.

Legiomix id 3
Mixed C Return C

id 6
Mixed C Return C

id 9
Mixed C Return C

Remote transmission with GSM modem


Martedi regolazione in corso 13/02/2006
Ok

Martedi

regolazione in corso

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Ok

Martedi

regolazione in corso

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Ok

Shock

Menu

Ok

Shock

Menu

Ok

Shock

Menu

Ok

CALEFFI

id 2
Mixed C Return C

id 5
Mixed C Return C

id 8
Mixed C Return C

Legiomix interface
Martedi 13/02/2006
Ok

Remote transmission with analog modem

Martedi

regolazione in corso

13/02/2006
Ok

Martedi

regolazione in corso

13/02/2006
Ok

regolazione in corso

Shock

Menu

Ok

Shock

Menu

Ok

Shock

Menu

Ok

id 1
Mixed C Return C

id 4
Mixed C Return C

id 7
Mixed C Return C

Local transmission
Martedi regolazione in corso 13/02/2006
Ok

Martedi

regolazione in corso

13/02/2006
Ok

Martedi

regolazione in corso

13/02/2006
Ok

Shock

Menu

Ok

Shock

Menu

Ok

Shock

Menu

Ok

The software supplied with the interface is used to manage the regulator, both during data acquisition and during modification of the operating parameters. In this way, it is possible to obtain information on the status of the appliance even at a distance, pick up temperature values and alarms recorded in the backup files, pilot thermal shocks, change the settings of various parameters. This type of control is particularly useful in the case of multiple installations with one or more appliances, which are all controlled by a single manager or maintenance technician. Typical examples of this are hotels, public buildings, schools, etc.

Device Parameters Parametri dispositivo ID bus Programme Set adjustment Set disinfection Set return Set shock Set max temp. Language 1a 1 Return sensor (Y/N)

Daily data log Date Prgm T dis TR TR Alarms 04-07-06 02 30 60 57 0 0 0 0 0 0 0 0 max min 1 2 3 4 5 6 7 8 () 2 30 0 5 Hour 00-01 01-02 02-03 03-04 04-05 05-06 06-07 07-08 08-09 09-10 10-11 11-12 T.average flow ret 51 51 51 51 50 50 52 52 50 50 50 50 34 32 31 31 30 30 31 36 46 46 46 46 12-13 13-14 14-15 15-16 16-17 17-18 18-19 19-20 20-21 21-22 22-23 23-24 Hour 50 50 50 50 50 50 50 50 51 58 58 51

English C C C C C

Disinfection selection day

Time ON hh Time OFF hh

2 mm 3 mm

50 60 57 60 65

M T W T F S S min min sec min

Help

0 0

T wait T min T flux T shock T motor T play

T.average flow ret 47 47 46 46 46 47 47 47 40 42 52 37

min min

Change done

Confirm

60 2

Print

Store

Safety in use As shown in the diagram opposite, temperatures of more than 50C can cause burning very quickly. For example, at 55C partial burning will occur in approximately 30 seconds, while at 60C partial burning will occur in approximately 5 seconds. These times are, on average, halved for children and elderly people. Depending on the type of system and its intended use, together with the relevant risk assessment, various devices can be installed to safeguard users from scalding caused by hot tap water.

Temperature - Exposure time


C 75 70 65 60 55 50 45 Full thickness burns

Partial thickness burns

Safety conditions. Max. exposure time at a specific temperature

0,1

10

100

1.000

10.000

Seconds

Anti-scald device for domestic hot water use, code 600140


Function The purpose of the device is to cut off the flow of water if its temperature reaches the set value. Designed for use in domestic hot water systems with electronic mixing valves with programmable thermal disinfection. Installed directly at the point of use outlet, it prevents the hot water from scalding the user during the thermal disinfection period (T>50C).

Technical Specifications Materials: - body: - springs: brass EN 12164 CW614N, chrome plated stainless steel 10 bar 5 bar 481C

Hydraulic characteristics Kv = 0,8 (m3/h)

Dimensions

Max working pressure (static): Max working pressure (dynamic): Set temperature: Connections:

B
Code A

C
B 8 C 38

1/2 F inlet 1/2 M outlet Application diagram

600140 1/2

Operation Open Closed

SPECIFICATION SUMMARIES
Code 600140 Anti-scald device for domestic hot water use. 1/2 F inlet x 1/2 M outlet connections. Chrome plated brass body. Stainless steel springs. Maximum working pressure 10 bar. Set temperature 48C 1C.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it
Copyright 2007 Calef fi S.P.A.

Controlled pressure zone kit

CALEFFI
series 640
cert. n 0003

ISO 9001

01087/03 GB

Function The new series 640 zone kit provides, in a single assembly, all the necessary components for installation in the zone manifold box, making installation operations quicker and easier. The kit consists of: - A 4-way zone valve with thermo-electric actuator, equipped with auxiliary micro-switch. - A cast monoblock dual manifold. - A differential by-pass. - Two automatic air vents with hygroscopic safety caps. The function of the differential by-pass is of particular importance, as it controls the pressure of the manifold flow and return circuits when the required flow rate varies. Variations of this nature may take place following the closure of room temperature regulating valves on the heat emitters, such as, for example, thermostatic or electrothermal valves.

Reference documentation - Leaflet 01014 Dual manifolds. Series 356. - Leaflet 01072 Zone valves. Series 676. - Leaflet 01054 Automatic air vents. Series 5020. Product range Code 640542 Zone kit 4+4 Code 640562 Zone kit 6+6 Code 640582 Zone kit 8+8 Main connections 3/4M with union, branch connections 23 p.1,5M Main connections 3/4M with union, branch connections 23 p.1,5M Main connections 3/4M with union, branch connections 23 p.1,5M

Technical specification Materials: - Auto air vent, zone valve and by-pass bodies: - Manifold body: - Zone valve obturator: - Hydraulic seals: - Zone valve control spindle: - Air vent float: Max working pressure: Max zone valve differential pressure: Differential pressure of by-pass: Max discharge pressure of air vent: Temperature range: Medium: Max percentage of glycol: Electrothermal actuator supply: Start-up current: Working current: Working input: Auxiliary micro-switch contacts rating: Connections: - main; - branches;

Dimensions

brass, EN 12165 CW617N brass, EN 1982 CB 753S brass, EN 12165 CW617N EPDM stainless steel PP 10 bar 1,2 bar 20 kPa (2000 mm w.g.) 2,5 bar 095C water, glycol solutions 30% 220V 0,6 A 13 mA 3W 0,8 A 3/4 M with union 23 p.1,5 M Code Branches 640542 4+4 640562 6+6 640582 8+8 A 60 60 60
Mod. Dep. 356

CALEFFI

A F B 23 p. 1,5 23 p. 1,5 23 p. 1,5 C 126 126 126 D 40 40 40 E 405 485 565 F 142 142 142

Hydraulic characteristics Zone valve P (mm w.g.)


10000 9000
8000 7000 6000

Constructional details Automatic air vents Both air vents have automatic hygroscopic safety caps. These devices permit air venting without manual intervention. Upon contact with water, they automatically close off the discharge passage. Dual manifold These manifolds are made in a single monoblock casting without the need for additional connections between the internal tubes. This eliminates a possible cause of problems due to the joining of metals with different thermal expansion coefficients. The connections of the lateral branches are made at right angles to the main headers to make fitting the connections easier. Zone valve The stainless steel control spindle has a double hydraulic seal consisting of two EPDM O-rings. This means that the upper part of the assembly can be removed even when the system is in operation. Installation The zone kit, supplied with the control on the r.h. side come with the air vents, differential by-pass and manifold pre-assembled. For the kit to operate correctly, the flow of the fluid must be in direction indicated by the arrow on the by-pass. If special installation conditions mean that this requirement cannot be met, dismantle the by-pass and turn it 180 so that the flow is in the correct direction. The zone valve must always be installed on the flow.

By-pass

Open

P (kPa)
90 80 70 60

100 50

5000
4000 3000 40 30

2000 1800
1600 1400 1200 900 800 700 600

18 16 14 12 9 8 7 6

20 10 5

1000 500

400 300

4 3

200 100 50

180 160 140 120 90 80 70 60

1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

2 1 0,5

40 30

0,4 0,3

1200

1400

1600

200

500

1000

1800

250

300

350

400

450

600

700

800

900

20

0,2

G (l/h) Series 678 DN 3/4 Kv (m3/h)


Straight By-pass

356

Mod. Dep.

3,7

1,0

1,2

* Max differential pressure guaranteed by the servo-control for correct operation Manifold Localized loss factor of inlet connections (F+R): Localized loss factor of branches (F+R): Differential by-pass P (mm w.g.)
10000
9000 8000 7000 6000 90 80 70 60

CALEFFI

3,0 6,5

P (kPa)
100

Electrical connections to the thermo-electric actuator

L
50

CALEFFI

Mod. Dep.

5000
4500 4000 3500 3000 2500 45 40 35 30 25

N
Thermostat

220 V 50 Hz

2000
1800 1600 1400 1200 18 16 14 12

20

250

300

350

400

450

600

700

800

120

140

160

180

900

60

70

80

90

1000 50

10 1000

100

200

500

3 Watt max 0,8 A

1 Brown 2 Blue

3 Black 4 Black

G (l/h)

SPECIFICATION SUMMARIES Series 640 Controlled pressure zone kit, branches 4+4 (6+6 or 8+8). Manifold connections 3/4 M with union. Branch connections 23p.1,5 M. Brass body. EPDM hydraulic seals. Maximum working pressure 10 bar. Working temperature range 095C. Comprising: - Single cast monoblock dual manifold. - 4-way zone valve. Maximum differential pressure 1,2 bar. - 220V servomotor complete with auxiliary micro-switch. Start-up current 0,6 A. Working current 13 mA. - Differential by-pass. Connections 3/4 M x 3/8 F. Differential pressure 20 kPa. - Automatic air vents. Maximum discharge pressure 2,5 bar. Complete with hygroscopic safety caps.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

356

pmax * (bar)

2000

Temperature regulating unit for heating and cooling


series 152

CALEFFI
01088/03 GB

Function The temperature regulating unit is designed to guarantee the correct contribution of heating energy required by the user, by measuring the outside and room temperature values to regulate the correct system flow temperature for either heating or cooling. It is supplied complete with: 4-way mixing valve, servomotor, pump, flow temperature sensor, outside temperature sensor, system temperature return sensor, cooling surface humidity control sensor, temperature controller, flow and return thermometers, unions for connecting to the primary and secondary circuits, with preformed shell insulation. The unit is designed for connection for remote data transmission. This unit solves the problems of installation of regulating components in modern small and medium-sized systems, due to its compact size and ease of use. The unit is factory set for use with underfloor heating systems.

Product range Code 152650 Code 152651 Code 151000 Temperature regulating unit for heating and cooling with pump UPS 25-60 Temperature regulating unit for heating and cooling with pump UPS 25-80 Room thermostat and indoor sensor

Technical specification - Materials: - body: - hydraulic seals: - insulation shell: - Mixing valve: Medium: Max percentage of glycol: Working temperature range: Max working pressure: By-pass regulating range: grey cast iron GG19 EPDM PPM 4-way water, glycol solutions 30% 560C 6 bar 0,050,5 bar 060C 1 F with union 230V 50 Hz 10 VA 240 s 10 Nm model UPS 25-60 model UPS 25-80 95% 040C IP 42

Head available at regulating unit connections


H (m w.g.)
6 5 4 3 2 1 0

H (m w.g.)
6

UPS 25-60 code 152650

5 4

UPS 25-80 code 152651

3 2 1

3
3

2
2 1 0

- Thermometer scale: - Primary and secondary circuit connections: - Servomotor: electric supply: rating: cycle time: torque: - Grundfos pump: cod. 152650 cod. 152651

Q (m3/h)

Q (m3/h)

Power consumption
Speed I

(A) 0,45 0,30 0,17

P (W) 100 65 35

n (rpm) 1800 1100 700

Speed

(A) 1,13 1,04 0,69

P (W) 250 220 140

n (rpm) 2450 1500 1000

- Max ambient relative humidity: - Ambient temperature: - Protection class:

3 2 1

3 2 1

Dimensions
H D A A

C*

E L

CALEFFI
26 24
19
18
17
16

28

30 32 34

20

21

12

22
15
14

22

23

50 40 30

60

70 80 90 -25% +25%

WATCH

24

Code 152650/651

A 1"

B 142

C 78

Characteristic components

SYSTEM RETURN

SYSTEM FLOW

12

10

20 30 20

10

60

10

20 30 20

10

60

2
21

CALEFFI
26 24
19
18
17
16

11
28 30 32 34

20

12

22
15
14

22

23

50 40 30

60

70 80 90 -25% +25%

WATCH

24

BOILER RETURN
6

01 02 03

4-way mixing valve. Digital temperature controller for heating and cooling.
21
19
18
17
16

Circulating pump: code 152650 GRUNDFOS UPS 25-60 code 152651 GRUNDFOS UPS 25-80. Differential by-pass valve with graduated scale.

22

23

24

04 05 06 07 08 09 10 11 12

Outside temperature sensor - connected via terminal.* Circuit flow and return thermometers in pockets. Connection point for remote transmission. Limit control sensor for max relative humidity RH%.* Room thermostat and indoor sensor (option for 152).* Servomotor. Return temperature sensor.

The controller, which is normally installed on the unit, can also be positioned remotely, following the electrical wiring scheme.

* Max length of sensor cable: 150 m.

6
7

Flow temperature sensor.

6
7

-50%

FLOW FROM BOILER

10

6
7

-50%

G
13

12

11

10

F B

D 90

E 40

F 234

G 267

H 205

I 320

L 120

Hydraulic diagram
SR SF

13

4-way mixing valve

M
M

Servomotor Pump Automatic by-pass Differential by-pass

BR

BF

12

11

Thermometer

10

Temperature controller

1
20 18 22 24

CALEFFI

16

CALEFFI
26 24
20

10
28 30 32 34

12

22
15
14

50 40 30

60

70 80 90 -25% +25%

13

WATCH

11

12

11

10

8
-50% 0

12

The front panel of the controller shows the following functions: 1) The LED is lit when there is a risk of condensation forming in the cooling function (the mixing valve is closed). In the heating function, this lights up intermittently during the screed drying phase.

10) Start or stop cooling selector. If the outside temperature is higher than the set value, the cooling function is activated. Factory setting: 24C.

2)

The LED is lit in the cooling function.

Characteristic curve The characteristic curve is determined taking into account the following parameters: a) Max flow temperature set on controller (item 9 PCB). Factory setting: 45C. Min flow temperature set on printed circuit board (item 5 PCB). Factory setting: 20C. Min outside temperature set on printed circuit board (item 1 PCB). Factory setting: -10C. Outside temperature limit for heating start in summer, set on printed circuit board (item 3 PCB). Factory setting: 18C.

3)

The LED is lit in the heating function. b)

4)

Pump operating (ON): LED lit continuously. c)

5)

Mixing valve closing: LED lit. The LED is lit continuously when the controller is in the non-operative phase of regulation, for example with TOutside between 18C and 24C (see characteristic curve).

d)

6)

Mixing valve opening: LED lit.

The characteristic curve has a straight line format. In the example shown below, it has been calculated using the factory set values.

7)

Sensor malfunction: LED lit. Example of calculation of characteristic curve

8) Function selector, 6 different functions possible: a) Main controller off. In models where clock fitted, clock remains on. The frost protection function remains active. Controller operating in set-back mode. Has no effect on the cooling function. Controller operating in comfort mode. Has no effect on the cooling function. Controller in operation according to the cycles of the comfort or set-back modes, determined by the two-channel analogue clock, red indicator for heating times, blue indicator for cooling times (item 13). Controller de-activated (pump ON - mixing valve ON). This function guarantees heating to the maximum temperature value set on the printed circuit board (PCB). Has no effect on the cooling function. Summer function. Cooling is activated if required by the ambient conditions (TOutside greater than the value set at point 10) and dependant on the clock settings.This activation takes place after ten minute if the outside temperature is more than 1C above the set value. With the exclusion of heating, the frost protection function remains active. Note: Normally, with the clock programme, the changeover from heating to cooling takes place after the outside temperature has been higher than the set value for at least half an hour. This selector position can therefore be used to effect a changeover to cooling. Temperature and characteristic curve selector. This selector enables the user to input the maximum required flow temperature, corresponding to the minimum outside design temperature. Also enables optimisation of the standard configuration set at the factory, allowing personal control of the operation of the system. If this value matches the setting on the main printed circuit board (item 6 PCB), the regulation complies with the calculation criteria given by the characteristic curve. If this value is different from the setting on the main printed circuit board (item 6 PCB) the controller will recalculate the new characteristic curve. The maximum set temperature, however, remains active. This selector also determines the characteristic cooling curve, as it uses the inclination of the first line of the curve, constructed for the heating (see characteristic curve graph). X Axis - Outside temperature - TX Y Axis - Flow temperature - TY Calculation of minimum and maximum points Point A: given by the intersection of Tmax X (18C) and Tmin Y (20C). Point B: given by the intersection of Tmin X (-10C) and Tmax Y (45C). Calculation of slope change points Calculate the difference X between Tmax X and Tmin X. Thus: X = 18 - (-10) = 28C. Calculate the difference Y between Tmax Y and Tmin Y. Thus: Y = 45 - 20 = 25C. Points of change C and D of the curve are identified as follows: Point C given by the intersection between: X = Tmax X - 25% X = 18 - 0,25 28 = 11C Y = Tmin Y + 55% Y = 20 + 0,55 25 = 33,75C Point D given by the intersection between: X = Tmax X - 50% X = 18 - 0,5 28 = 4C Y = Tmin Y + 80% Y = 20 + 0,8 25 = 40C Point E is the cooling starting point, whose characteristic curve has the same slope as section A-C. Point E given by the intersection between: TX = value set in item 10 (24C) and TY = Tmin Y (20C). Characteristic curve
TFLOW (C)
25%

b)

c)

d)

e)

f)

9)

55 50 45 40 35 30 25 20 15 10 5 35 30 25 20 15
E (24;20) 80% 55%

50%

60

B (-10;45) D (4;40) C (11;33,75)

A (18;20)

10

-5

-10

-15

TOUTSIDE (C) Passive band

11)

Correction selector for comfort mode. Range of adjustment from -25% to +25%. Factory setting: correction = 0%. The selector determines a parallel displacement of the characteristic curve according to the new percentage value selected in the comfort range (red indicator). Example: if the selector is set to +25%, its effect on the flow temperature will be as follows: +25% Y = 0,25 25 = 6,25C. The characteristic curve is then moved upwards by 6,25C. This has no effect on the cooling function.

11) Printed circuit board The surface of the printed circuit board (PCB) identifies the following functions:
14 16 17
4(2)A 4(2)A 4(2)A

DIGITAL REGULATOR N L LP PS
OPEN

T 40

t Typ 2125
N L
230 V AC 4VA 230V AC 10A max

ROOM THERMOSTAT 2501

13
TA

TA 1 X SE SM SR

11 15 12
1 2 3 4 ON

INLET PUMP MIXING VALVE

PUMP N

MA MC C
CLOSED CLOSED OPEN

Curve with comfort correction


TFLOW (C) 60 55 50 45 40 35 30 25 20 15 25 20 15 10 5 0 -5 -10 -15 TOUTSIDE (C)
6,25C
4(2)A 4(2)A

-10 -5

-15 -20 -20 30

-10

18

F KA KA A B

0 14 65

22

55 40 35

4,5

UR

4 10 3

DIP

20

65 1,5 6 max NZ 50

100

RF(%)

18

1)

Minimum outside temperature (Tmin X), adjustable from -5C to -20C, to which the set maximum flow temperature corresponds (Tmax Y). Factory setting: -10C. Set-back mode exclusion selector, adjustable from 0C to -20C. Factory setting: -15C. If the outside temperature falls below the set value, the heating is reactivated according to the characteristic curve of the comfort mode. Maximum outside temperature to start heating, or summer limit, (Tmax X), adjustable from 14C to 22C. Factory setting: 18C. An outside temperature higher than the set value will cause the following state: circulator OFF and mixing valve closed. An outside temperature 4C higher than the set value will cause activation of the cooling, if this outside temperature is greater than the value set on the front panel, item 10. - e.g.: To set on front panel=24C, To set on PCB=22C. Activation will take place at To=26C (22+4). Selection microswitch for screed setting drying program. Factory setting: OFF (1234). This program is used for carrying out correct drying of the screed, above which the final flooring will be laid (its activation excludes all other functions). The program has a duration of seven days: during the first three days, the flow temperature is maintained at 25C, whilst for the remaining four days, the flow temperature is raised and maintained at the maximum temperature value set at point 9 on the front panel. The activation of this program is displyed by the flashing LED on the front panel, point 1. The frequency of flashing indicates the number of drying days which have passed: one pulse every 8 seconds indicates day 1, two pulses every 8 seconds indicates day 2, etc. If the electricity has to be switched off in this phase, the controller will start its drying cycle again from the beginning. The front panel LED, point 1, continuously lit, indicates the end of the drying program. At this point the microswitch should be turned to OFF. Note: In manual mode the screed drying procedure cannot be activated. When cooling, this series of microswitches has the function of limiting the minimum temperature transmitted to the panel. This minimum temperature depends on the characteristics of the system and the type of air conditioning adopted. The different activation configurations are shown below. Factory configuration: 16C.
1 2 3 4 ON DIP

2)

12)

Correction selector for set-back mode. Range of adjustment from 0% to -50%. Factory setting: correction = -25%. The selector determines a parallel displacement of the characteristic curve according to the new percentage value selected in the set-back range (blue indicator). Example: if the selector is set to -25%, its effect on the flow temperature will be as follows: -25% Y = -0,25 25 = -6,25C. The characteristic curve is thus moved downwards by 6,25C. In addition, if, following this move, the flow temperature has to be lower than the minimum heating start temperature (Tmin Y), the following state will be obtained: circulator OFF and mixing valve closed. This has no effect on the cooling function.

3)

4) Curve with set-back correction


TFLOW (C) 60 55 50 45 40 35 30 25 20 15 25 20 15 10 5 0 -5 -10 -15 TOUTSIDE (C)
6,25C

13) Daily or weekly analogue clock, used to select the heating and cooling phases required with: the red indicators for heating comfort and set-back and the blue indicators to start and stop cooling. Factory configuration: daily mode, minimum selection interval 15 min.. The changeover from daily to weekly mode, with a 60 min. minimum selection interval, is carried out as follows: raise the outer ring and move the drive ring to the required position; 1 to do this, turn the pointer clockwise 24 2 23 3 12 until the innermost notch coincides with one of the outer notches. Reposition the outer ring, making sure that the reference day shown 9 3 on it falls in the operating sector of the switching point.
22

d -7 21

1 2 3 4

1 2 3 4

ON

ON

20

Screed drying Free flow temperature Flow temperature limited 16C

Flow temperature limited 14C Flow temperature limited 12C Flow temperature limited 10C

19

DIP

DIP

18

17

1 2 3 4

1 2 3 4

ON

ON

15

14

6
13

16

12

11

10

DIP ON DIP

DIP

1 2 3 4

1 2 3 4

ON DIP

5)

Selector for minimum flow temperature at heating start-up (Tmin Y). Adjustable from 20C to 40C. Factory setting: 20C. Maximum limit temperature selector. Adjustable from 35C to 65C. Factory setting: 50C In case a higher value has been set at point 7 of the front panel, this will be restricted to the limit value. Neutral zone regulation selector. Adjustable from 1,5C to 6C. Factory setting: 2C (equivalent to 1C). If the flow temperature variation remains within the temperature value selected in the neutral zone, the mixing valve remains inactive. When cooling, the neutral zone automatically takes the value 1,5C.

If various zones at risk of condensation are to be controlled, the humidity sensor must be connected to a suitable interface kit (transformer, converter and humidity sensor). Up to 12 converters plus sensor can be connected to a single transformer.

6)

TRANSFORMER code 150052


10

CONVERTER code 150051 1 2 3 4 5 6

7) NZ

SR UR

220 V

24 V

8) RF(%) Return sensor regulation selector. Adjustable from 0% to 100%. Factory setting: 80%. This selector is used to optimise the system output according to the difference in temperature between flow and return (T). T is calculated as a percentage of the flow temperature calculated on the characteristic curve. TY = (Tflow set Y-Tmin Y) T = TY %set 0,3. Treturn set Y = Tflow set Y - T. Example with factory setting values: flow temperature calculated on the characteristic curve, Tflow set Y = 40C (project conditions). Thus: TY = (40 - 20) = 20C T = 20 0,8 0,3 = 4,8C Treturn set Y = 40 - 4,8 = 35,2C. If the return temperature measured (Treturn Y) is Treturn set Y, the controller will modify the characteristic curve, moving it upwards or downwards, to move the return temperature to the set value. This continuous comparison prevents room overheating caused by gratuitous heat sources modifying the heating load. There is no effect on the cooling function. Curve with return temperature regulation

LH side terminal strip

SENSOR RH% code 150050

SENSOR RH% code 150050

Humidity sensor control At the start of each cooling season, the operating condition of the sensor should be checked by placing a damp pad on its surface; this operation should cause the mixing valve to close and the yellow LED, point 1 on the front panel, to light. Positioning humidity sensor The umidity sensor must be positioned at the point where there is most risk of the formation of condensation, depending on the characteristics of the system. It must be positioned with the printed part upward, according to the diagrams shown below. Fix ends E, taking care that the central part adheres perfectly to the manifold or to the piping.

Upper side: printed circuit

Lower side: sited on the cooling surface

Layouts for the correct positioning of the max RH% limit sensor. The sensor should be fixed to the manifold installed in the position where the RH% relative humidity value has not to exceed the safety limits. Fixing in ensured by inserting the two straps contained in the package through the suitable holes on the sensor.
-10 -15 TOUTSIDE (C)

TFLOW (C)

60 55 50 45 40 35 30 25 20 15 25 20 15 10 5 0 -5
Treturn 35,2C

9) Auxiliary contact. This contact opens when the mixing valve is completely closed to the secondary and open to the primary. It can be used to shut down the pump of the primary circuit or the boiler. 10) UR Relative humidity sensor wiring. This sensor is used to detect the limiting value of relative humidity to prevent condensation on the cooling surface. This is calibrated for RH= 8085%. When the calibrated value is reached, this will cause the following state: mixing valve closed, pump ON.

16) C Summer - winter circuit changeover valve wiring. F This connection enables the 3-way valve to be activated automatically for hydraulic deviation between the boiler circuit and the chiller circuit. This takes place after the outside temperature has risen above the value set at point 10 for at least half an hour. Ten minutes later, the regulating unit pump is activated. 17) KA Chiller activation wiring. This activation takes place in the same way as in point 16.

RH side terminal strip

Boiler circuit open

C F KA KA

Chiller circuit open

23

The maximum heat energy that the panel can produce in relation with the climate values recorded, can be reached by controlling the below outlined parameters. - Minimum flow temperature on the characteristic curve, which can be selected through the microswitch (point 4 on the back panel). - Sensor (code 150050) controlled maximum RH% limit. - Room temperature controlled through room thermostat (code 151000). - Room temperature and relative humidity controlled through a dedicated fan-coil). N.B.: When installing the RH% limit sensor according to the diagrams, as indicated, possible formation of condensation on the surface. In areas where the max RH% limit sensor is installed, adequate ventilation must always be present.

CALEFFI
2426
19
18
17
16

28

3032

20

12

22
15
14

34

22

21

60
13

7080

WATCH

24

4050 30 90 -25% +25%

12

11

10

11) SE

Outside sensor wiring. Connect the outside sensor using 2-core cable (2x0,75) to the connector provided on the unit. Outside sensor

18)

Remote data transmission connector.

Table of sensor resistance values* LH side terminal strip

SE
Connecting wiring

*excluding max RH% limit sensor


C Ohm -15 11.382 -12 9.912 -10 8.933 -6 7.439 -3 6.492 -2 6.206 0 5.632 C 0 2 4 6 8 10 15 Ohm 5.632 5.187 4.742 4.347 4.000 3.553 2.971 C 20 25 30 35 40 45 50 Ohm 2.431 2.000 1.655 1.376 1.150 966 815 C 55 60 65 70 75 80 85 Ohm 690 587 501 430 370 319 276 C 90 95 100 Ohm 240 209 183

SE
Connector

12) SR

Return sensor wiring. Factory fitted.

13) TA1 Room thermostat wiring. Optional. 14) Pump shut-down variant. Sometimes the temperature regulating unit is installed in a system where there may be one or more users with different usage requirements. In this case, for users requiring ON/OFF operation, it may be necessary to shut down the unit circulator. The electrical diagram shown below illustrates this possibility; the user auxiliary contact must be inserted in series with the normal wiring. Safety If the flow or outside sensor shows an ohm resistance value outside its working range (damaged or disconnected sensor), the following operating state is automatically activated: Pump OFF, Mixing valve OFF, LED 7 continuously lit.

15) SM Flow sensor wiring. Factory fitted.

Safety thermostat code 622001 Additional for use with underfloor heating systems.

Pump shut-down wiring User auxiliary contact RH side terminal strip


6 7 8

PS MA MC

Brown

Unit 152 pump

- Range of adjustment: 5 55C - Factory setting: 50C - Protection class: IP 40 - Contacts load: (C-1) 10(2,5)A / 250V - Contacts load: (C-2) 1(1)A / 250V
+C C

Pump shut-down variant

1 2

6
7

-50%

Example of safety thermostat application on system low temperature branch circuit

Operation of the room thermostat The room thermostat makes it possible to optimise the operation of the system, as it modifies the regulating curve automatically. Depending on the time periods for comfort and set-back selected on the clock and the room temperature setting, it will read the actual room temperature. On the basis of this parameter, it will make any necessary modification to the characteristic curve (A) for the purpose of accelerating operation and preventing excessive heating or cooling of the room. The difference between the actual room temperature measured by the thermostat and the set temperature produces an amplified effect in relation to that produced by a similar variation in the outside temperature. A difference of 1C in the room temperature causes a move of the characterisitc curve equal to 7C of the outside temperature, with the corresponding variation in flow temperature. For example, if Troom set = 20C and Troom measured = 19C, than the difference of 1C will cause a movement of the characteristic curve of 7C towards the left (B). The flow temperature will consequently be raised. In the case of a negative difference, the movement will take place on the curve C. This behaviour is applicable for a maximum difference of 3C in the room temperature. In addition, the maximum temperature limit set at item 6 on the PCB remains active. In the set-back band, the set room temperature is automatically reduced by 2C, thus defining Tset set-back. This reduction will cause a move to the right of the characteristic curve, equating to 14C of the outside temperature (D), with a corresponding variation in flow temperature. Whenever the measured room temperature falls below Tset set-back, the initial characteristic curve (A) will be restored with the set-back correction set at point 12 on the front panel. Curve with room thermostat regulation
TFLOW (C) 60 55 50 45 40 35 30 25 20

CALEFFI
26 24
19
18
17
16

28

30 32 34

20

12

22
15
14

22

21

23

50 40 30

60

70 80 90 -25% +25%

13

WATCH

24

12

11

10

Frost protection function When the selector, point 6 on the front panel, is positioned to or , there are two types of intervention: a) If the flow temperature is below 7C, the controller activates the operation of the unit until a flow temperature of 20C is reached. When this value is reached, it will return to the inactive status. b) If the outside temperature is below 5C (+2 -0), the controller keeps the pump running. Anti-seize function If the pump remains inactive for twenty four hours, the following program automatically comes into operation, with: mixing valve open for 30 seconds, mixing valve closed for 30 seconds, pump ON for 60 seconds. When this function is operating, it cannot be interrupted. Manual control To carry out adjustment: - Remove the servomotor fixing screws. - Lift the servomotor. This gives access to the control knob. Refer to the information given on the knob itself. Options Room thermostat, code 151000. The regulating unit can be supplemented with a room thermostat, able to adjust the value of the flow temperature according to the actual room temperature. This configuration makes it possible to take account of gratuitous heat gains, by refining the value of the flow temperature, with optimum results in terms of comfort and energy saving. In cooling conditions, the setting on the thermostat should be increased by 2C.
Mis ch e
r

Zu Close Ferm

pe

ra t

nh u r f r Fu b o d e

ei z

ng

be

a ch

ten

TA1
20 18 22

TA 1
TA

TA Room thermostat

CALEFFI

16

24

WARNING - if the connecting cable between the thermostat and the control unit is not sheathed, it must be run in its own ducting. The maximum length is 150 m.

LH side terminal strip

6
7

-50%

Auf Open Ouvrir Beipass n ich


Hand schliee on n tv

15 10

25

20

15

10

-5

-10

-15

TOUTSIDE (C)

ft au Vo r l

Room thermostat electrical connection Install the room thermostat and connect by sheathed 2-core cable (2x0,75) to the terminal strip of the regulator PCB, as shown in the diagram below.

Application diagram

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

PN 10

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

PN 10

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

CALEFFI
2426
19
18
17
16

28

3032

20

12

22
15
14

34

22

21

60
13

23

7080

WATCH

24

4050 30 90 -25% +25%

12

11

10

Code 152650 Temperature regulating unit for heating and cooling. Connections 1" F with unions. Body in grey cast iron GG19. Hydraulic seals in EPDM. Maximum working pressure 6 bar. Ambient temperature from 0 to 40C. Regulating temperature from 5 to 60C (factory settings: heating 45C, cooling 16C). Maximum ambient relative humidity 95%. Consisting of: 4-way mixing valve; mixing valve servomotor with the following characteristics: power supply 230 V 50 Hz, rating 10 VA, cycle time 240 s, torque 10 Nm. Pump UPS 25-60. By-pass valve with regulating scale from 0,05 to 0,5 bar. Temperature controller with two channel clock, for daily/weekly programming. Flow temperature sensor. Return temperature sensor. Outside temperature sensor, connectable to terminal. Maximum RH% limit control sensor. Flow and return pocket thermometers, scale 060C. Automatic summer/winter cycle changeover. Provided with connection for remote data transmission. Protection class IP 42. Complete with PPM insulation. Code 152651 Temperature regulating unit for heating and cooling. Connections 1" F with unions. Body in grey cast iron GG19. Hydraulic seals in EPDM. Maximum working pressure 6 bar. Ambient temperature from 0 to 40C. Regulating temperature from 5 to 60C (factory settings: heating 45C, cooling 16C). Maximum ambient relative humidity 95%. Consisting of: 4-way mixing valve; mixing valve servomotor with the following characteristics: power supply 230 V 50 Hz, rating 10 VA, cycle time 240 s, torque 10 Nm. Pump UPS 25-80. By-pass valve with regulating scale from 0,05 channel clock, for daily/weekly programming. Flow temperature sensor. Return temperature sensor. Outside temperature sensor, connectable to terminal. Maximum RH% limit control sensor. Flow and return pocket thermometers, scale 060C. Automatic summer/winter cycle changeover. Provided with connection for remote data transmission. Protection class IP 42. Complete with PPM insulation. Code 151000 Room thermostat and indoor sensor for temperature regulating unit.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL.INT. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

6
7

-50%

CALEFFI

CALEFFI

CALEFFI

CALEFFI

SPECIFICATION SUMMARIES

Safety relief valve for solar systems

CALEFFI
253 series
cert. n 0003

ISO 9001

01089/06 GB
Replaces 01089/03 GB

General The safety relief valves manufactured by Caleffi are produced in compliance with the essential safety requirements laid down by Directive 97/23/EC of the European Parliament and the Council of the European Union for the harmonisation of member States with regard to pressurised equipment. Function These safety relief valves are used to control pressure in the primary circuits of solar heating systems. When the calibrated pressure is reached, the valve opens to release the fluid into the atmosphere and prevents the pressure in the system from reaching levels that might damage the solar collectors and equipment installed. These particular series of products have been specially made and certified to work at high temperature with a glycol medium.

Product range 253 series Safety relief valve for solar systems size 1/2 F x 3/4 F

Technical specifications Materials: - body: brass EN 12165 CW 617N, chrome plated - control spindle: brass EN 12164 CW614N - obturator seal: high resistance elastomer - spring: stainless UNI 3823 - control knob: PA6G30 Medium: Max. percentage of glycol: Nominal pressure: Temperature range: PED category: Approval: Connections: water, glycol solutions 50%

Dimensions

IV TV according to SV 100 7.7 N TV 01.SOLAR 02.146.p 1/2 F x 3/4 F


A

PN 10 -30160C

111 5

B E Code 25304. A 1/2" B 3/4" C 24 D 70 E 33,5 C


Weight (kg)

Performance Opening overpressure: Closing differential: Discharge capacity: Code Set pressure 253043 3 bar 253044 4 bar 253046 6 bar 253048 8 bar 10% 20% 50 kW 253040 10 bar

0,22

Operating principe The obturator (1), opposed by a set spring (2), raises on reaching the setting pressure and fully opens the outlet. The setting pressure is chosen according to the maximum permissible pressure in the system. The diameter of the outlet connection (3) is greater in order to help discharge the required potential. As the pressure decreases there is the opposite action, with the valve subsequently reclosing within the set tolerances.

2 1 3

Discharge pipework The discharge pipework from the safety relief valve must be fitted in such a way as not to prevent the correct operation of the valve and not to cause damage or injury. In accordance with current legislation, the safety relief valve discharge must be visible and carried in suitable collection pipework. The glycol medium must therefore be drained off into a specific container. As shown in the diagram, it is advisable to install a tundish direcly in the discharge pipework.

Construction details Temperature and glycol In solar systems, heating fluid of the primary circuit contains glycol as additive and operates at high temperatures; to take account of these particular operating conditions, the obturator seal of safety valve is in high resistance elastomer. The knob is in plastic material especially resistant to increases in temperature and to UV rays, in the case of outdoor installations. Chrome plating The valve body is chrome plated to protect it from the aggression of dirt and moisture, in the case of outdoor installations of solar heating systems. Certification 253 series safety relief valves are certified for specific use in solar heating systems by the certifying body TV, in accordance with standard SV 100 Ed. 10.01 par. 7.7. Installation The safety relief valves for solar systems must be installed near the point in the circuit where the system is filled, before expansion vessel. Make sure that there are no shut-off devices between the valve and the rest of the system. The safety relief valves can be fitted vertically or horizontally, but not upside down. This prevents deposits of impurities from affecting correct functioning. The safety relief valves must be installed in line with the flow direction indicated by the arrow on the valve body.

Application diagram

SPECIFICATION SUMMARIES
253 series Safety relief valve for solar heating systems. CE mark as per Directive 97/23/EC. TV certified for solar systems. 1/2 F x 3/4 F threaded connections. Brass body. Chrome plated. Diaphragm and obturator seal in high resistance elastomer. Spring in steel UNI 3823. Control knob in PA6G30. Temperature range: -30160C. Nominal pressure: PN 10. Calibration setting: 3 bar (3, 4, 6, 8, 10 bar). Medium: water and glycol solutions. Maximum percentage of glycol: 50%.

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 R.A. FAX +39 0322 863723 Http://www.caleffi.com E-mail: info@caleffi.it

Inspection box and wall port in plastic


series 362 - 363
cert. n 0003

CALEFFI
ISO 9001

01091/04 GB

Function The new plastic shock resistant box was specially designed for single and dual manifolds in combination with various types of zone valves. The vent openings in the cover are specially designed to prevent the formation of marks on walls. The surface finish of the door is suitable for painting.

Product range Code Code Code Code Code Code 362036 362056 362073 363036 363056 363073 Inspection Inspection Inspection Inspection Inspection Inspection plastic plastic plastic plastic plastic plastic box box box wall port wall port wall port Internal dimensions 270 x 360 mm, depth 80/100 Internal dimensions 330 x 560 mm, depth 80/100 Internal dimensions 360 x 730 mm, depth 80/100 Internal dimensions 270 x 360 Internal dimensions 330 x 560 Internal dimensions 360 x 730 mm mm mm mm mm mm

Code 360001 Mounting brackets for 1 distribution manifolds, 350 and 592 series; for 3/4 and 1 distribution manifolds, 351 and 598 series. Comes complete with two long and two short brackets.

Code 362001 Mounting brackets for single sided dual manifolds 356, 357 series and zone kit 640 series.

Code 360002 Mounting brackets for 3/4 349 series, 350 and 592 distribution manifold. Comes complete with two long and two short brackets.

CALEFFI

Mod. Dep.

Choice of casing for use with series 356 dual manifolds For use with:

356

. Maximum number of outlets

356

356

356

Mod. Dep.

Mod. Dep.

Mod. Dep.

CALEFFI

CALEFFI

CALEFFI

shut-off valves Code Dimensions 3/4 6+6 10+10 10+10 1 6+6 12+12 12+12 3/4 4+4 10+10 10+10 1 3/4 4+4 10+10 10+10 1 4+4 10+10 12+12 3/4 4+4 10+10 10+10

362036 - 363036 270 x 360 mm 362056 - 363056 330 x 560 mm 362073 - 363073 360 x 730 mm

For use with:

356

356

356

CALEFFI

Mod. Dep.

code 356050

series 5020

Mod. Dep.

Mod. Dep.

Mod. Dep.

CALEFFI

CALEFFI

CALEFFI

PN 10
PN 10 PN 10 PN 10 PN 10

series 633+635 shut-off valves

Code

Dimensions

3/4 2+2 8+8 10+10

1 2+2 8+8 12+12

3/4 2+2 8+8 10+10

1 -

3/4 6+6 10+10

1 6+6 10+10

3/4 6+6 10+10

362036 - 363036 270 x 360 mm 362056 - 363056 330 x 560 mm 362073 - 363073 360 x 730 mm

For use with:

356

356

356

CALEFFI

Mod. Dep.

code 356050

series 5020

Mod. Dep.

Mod. Dep.

Mod. Dep.

CALEFFI

CALEFFI

CALEFFI

series 6480 + 6490 Code

shut-off valves Dimensions 3/4 2+2 10+10 10+10 1 8+8 12+12 3/4 2+2 8+8 10+10 1 3/4 2+2 8+8 10+10 1 2+2 6+6 10+10 3/4 6+6 10+10

362036 - 363036 270 x 360 mm 362056 - 363056 330 x 560 mm 362073 - 363073 360 x 730 mm

For use with:

356

356

356

CALEFFI

Mod. Dep.

code 356050

series 5020

Mod. Dep.

Mod. Dep.

Mod. Dep.

CALEFFI

CALEFFI

CALEFFI

series 678 Code

shut-off valves Dimensions 3/4 4+4 10+10 10+10 1 4+4 10+10 12+12 3/4 2+2 8+8 10+10 1 3/4 2+2 8+8 10+10 1 2+2 8+8 10+10 3/4 6+6 10+10

362036 - 363036 270 x 360 mm 362056 - 363056 330 x 560 mm 362073 - 363073 360 x 730 mm

CALEFFI

Mod. Dep.

code 356050

series 5020

356

356

356

356

356

356

356

Mod. Dep.

Mod. Dep.

Mod. Dep.

CALEFFI

CALEFFI

CALEFFI

1 -

3/4 4+4 10+10 10+10

1 4+4 10+10 12+12

3/4 2+2 8+8 10+10

1 -

3/4 2+2 8+8 10+10

1 8+8 10+10

3/4 6+6 10+10

CALEFFI

Mod. Dep.

356

1 -

356

356

356

Mod. Dep.

Mod. Dep.

Mod. Dep.

CALEFFI

CALEFFI

CALEFFI

CALEFFI

Mod. Dep.

1 -

3/4 2+2 8+8 10+10

1 2+2 8+8 10+10

3/4 6+6 10+10

1 -

3/4 6+6 10+10

1 4+4 8+8

3/4 4+4 8+8

356
PN 10

356

356

356

Mod. Dep.

Mod. Dep.

Mod. Dep.

CALEFFI

CALEFFI

CALEFFI

1 -

3/4 2+2 8+8 10+10

1 2+2 8+8 10+10

3/4 6+6 10+10

1 -

3/4 6+6 10+10

1 4+4 8+8

3/4 4+4 8+8

CALEFFI

Mod. Dep.

356

356

356

356

Mod. Dep.

Mod. Dep.

Mod. Dep.

CALEFFI

CALEFFI

1 -

3/4 2+2 10+10 10+10

1 2+2 8+8 10+10

3/4 2+2 6+6 10+10

1 -

3/4 6+6 10+10

CALEFFI

1 6+6 10+10

3/4 4+4 10+10

CALEFFI

Mod. Dep.

356

PN 10

PN 10

PN 10

1 -

1 4+4 8+8

1 -

CALEFFI

Mod. Dep.

Choice of casing for use with 357 series single sided dual manifolds For use with:

357

. Maximum number of outlets.

CALEFFI

Mod. Dep.

CALEFFI

Mod. Dep.

CALEFFI

Mod. Dep.

CALEFFI

Mod. Dep.

code 356050

shut-off valves
357 357 357 357

Code

Dimensions

3/4 3+3 6+6 -

3/4 2+2 5+5 6+6

3/4 2+2 5+5 6+6

3/4 4+4 6+6

362036 - 363036 270 x 360 mm 362056 - 363056 330 x 560 mm 362073 - 363073 360 x 730 mm

For use with:

code 356050

shut-off valves
CALEFFI
PN 10

Mod. Dep.
PN 10

CALEFFI

Mod. Dep.
PN 10

CALEFFI

Mod. Dep.
PN 10

CALEFFI

Mod. Dep.

357

357

357

357

PN 10

series 633 + 635

Code

Dimensions

3/4 4+4 6+6

3/4 4+4 6+6

3/4 3+3 5+5

3/4 3+3 5+5

362036 - 363036 270 x 360 mm 362056 - 363056 330 x 560 mm 362073 - 363073 360 x 730 mm

For use with:

code 356050

shut-off valves
CALEFFI Mod. Dep.

CALEFFI

Mod. Dep.

CALEFFI

Mod. Dep.

CALEFFI

Mod. Dep.

357

357

357

357

series 648950 Code Dimensions 3/4 2+2 4+4 6+6 3/4 4+4 6+6 3/4 2+2 4+4 6+6 3/4 3+3 6+6

362036 - 363036 270 x 360 mm 362056 - 363056 330 x 560 mm 362073 - 363073 360 x 730 mm

For use with:

code 356050

shut-off valves
CALEFFI Mod. Dep.

CALEFFI

Mod. Dep.

CALEFFI

Mod. Dep.

CALEFFI

Mod. Dep.

357

357

357

357

series 678 Code Dimensions 3/4 4+4 5+5 6+6 3/4 2+2 4+4 6+6 3/4 2+2 5+5 6+6 3/4 4+4 6+6

362036 - 363036 270 x 360 mm 362056 - 363056 330 x 560 mm 362073 - 363073 360 x 730 mm

Choice of casing for use with 350 For use with:

and 592 series

distribution manifolds. Maximum number of outlets.

series 5020

shut-off valves

Code

Dimensions

3/4 6+6 10+10 14+14

1 6+6 10+10 14+14

3/4 6+6 10+10 13+13

1 6+6 9+9 13+13

3/4 4+4 8+8 12+12

1 4+4 8+8 12+12

3/4 4+4 8+8 11+11

1 4+4 7+7 11+11

362036 - 363036 270 x 360 mm 362056 - 363056 330 x 560 mm 362073 - 363073 360 x 730 mm

For use with:

series 5020

shut-off valves
PN 10 PN 10 PN 10 PN 10

PN 10

series 632

series 5995

Code

Dimensions

3/4 7+7 11+11

1 7+7 10+10

3/4 7+7 10+10

1 5+5 10+10

3/4 6+6 10+10

1 5+5 8+8

3/4 6+6 9+9

1 5+5 8+8

362056 - 363056 330 x 560 mm 362073 - 363073 360 x 730 mm

For use with:

series 5020

shut-off valves
PN 10 PN 10 PN 10 PN 10

PN 10

series 633

code 648018

se