Catalog Tehnic Complet - GB

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.
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.)
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
Kv
Code 131600 1"

p (mm w.g.)
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

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
Kv
Code 131800 1 1/2"

p (mm w.g.)
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

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
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.)
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.)
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

p (mm w.g.)
0,5 1 1,5 2 3 4 4,5 5

p (kPa)
150 100
p (mm w.g.)
15.000 10.000

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

p (mm w.g.)
0,5 1 1,5 2 3 3,5 4 4,5 5

p (kPa)
150 100
p (mm w.g.)
15.000 10.000

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

p (mm w.g.)
0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6

p (kPa)
150 100
p (mm w.g.)
15.000 10.000

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

p (mm w.g.)
0,5 1 2 2,5 3 3,5 4 4,5 5 5,5 6

p (kPa)
150 100
p (mm w.g.)
15.000 10.000

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

p (mm w.g.)
1 2 2,5 3 3,5 4 4,5 5 5,5 6

p (kPa) p (mm w.g.)
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

p (mm w.g.)
4 5 6 7 8 910 1112

p (kPa)
150 100
p (mm w.g.)
15.000 10.000

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

p (mm w.g.)
3 4 5 6 7 8 10

p (kPa)
150 100
p (mm w.g.)
15.000 10.000

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

p (mm w.g.)
2 3 4 5 7 10 14 6 8 12

p (kPa)
150 100
p (mm w.g.)
15.000 10.000

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
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)
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
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.
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
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.
CALEFFI
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
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
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.
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
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.
CALEFFI
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
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
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
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.
CALEFFI
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)
5 2 61
5
6 - 3/ 4 1 . -0
TIP O
LL UTI
7 bar
VI
EN 1487
DANGE
CALEFFI
CALEFFI
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.
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
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
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.
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
Heating system with one heat generator and two different secondary circuits
P T
F
A
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.
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.
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.
CALEFFI
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
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.
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.
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
Automatic filling units
CALEFFI
series 553
cert. n 0003
ISO 9001
01025/05 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
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.
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
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

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
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
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
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.
CALEFFI
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.
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
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
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.
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
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.
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.
CALEFFI
ROBOCAL Automatic air vents

series 5024 - 5025 - 5026 - 5027
cert. n 0003
CALEFFI
ISO 9001
01033/03 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.
CALEFFI
Thermostatic radiator valves

series 220
cert. n 0003
CALEFFI
ISO 9001
01034/05 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
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
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
2. Position the valve at the required temperature and turn the ring clockwise up to the stop.
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.
CALEFFI
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).
CALEFFI
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
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
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.
CALEFFI
Automatic flow rate regulator with stainless steel cartridge

120 - 125 - 103 series
cert. n 0003
CALEFFI
ISO 9001
01041/07 GB
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
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
1 bar/100 kPa 2,20 bar/220 kPa 4,10 bar/410 kPa
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

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

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

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
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
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.
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".
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
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
CALEFFI
Thermo-electric actuator
series 656
cert. n 0003
ISO 9001
01042/03 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
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
CALEFFI
CALEFFI
CALEFFI
CALEFFI
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.
CALEFFI
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
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
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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
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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.
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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
CALEFFI
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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
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10 8 6 4 2 0
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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
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
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CA LEFF I
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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
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17
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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.
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
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.
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.
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
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:
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
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.
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.
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.
CALEFFI
Adjustable, anti-scale thermostatic mixing valve

series 521
cert. n 0003
CALEFFI
ISO 9001
01050/02 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
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
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.
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
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.
CALEFFI
Flow switch
CALEFFI
626 series
cert. n 0003
ISO 9001
01052/07 GB
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.
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
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.
CALEFFI
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
ni prestazio iva. Le so di rottura zza posit che in ca a sicure RCHIO: A ) MA DELLO: 527 no garantite an a. so MO ran ) B mb della me LE: PN 10 NOMINA DN 3/4" NALE: ESSIONE C ) PR ETRO NOMI ZIO: 20 mm2 D ) DIAM ETRO ORIFI 3,1416 cm 3 bar A: AM DI TT Pt = ) NE E TURA: % ZIONE F ) SE ESSIONE TARA NE MAX: 10 0 bar Ps = 3,3 G ) PR VRAPPRESSIO rica ARICO: Pt H ) SO ESSIONE SC NE: Atmosfe re 20% SIO I ) PR NTROPRES IUSURA: mino CO CH ) L ARTO DI le M ) SC lle valvo tati su or rip Dati RCHIO a ) MA DELLO b ) MOESSIONE c ) PR TARATURA ARICO DI h) DI SC 00 Kcal/ RTATA d ) PO7,5 kW (212.8 o 24 effluss iente di Coeffic 7 K = 0,6 Alzata mm L. h = 7,3 .P.E.S. ato I.S Certific 319/00 n. VS ego d'impi di ui Fl A A CALD - ACQU - ARIA ico di scar one 1982 Portata a R Edizi 2.3.1 Raccolt o Punt R.2.A A x 0,9 x K W= 0,005 x M
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
DN 79 one 19 Edizi 9 olta E M = 0,85.70 Kg/h ) - Racc W = 42 ico (aria 2 Kg/h di scar 5.2.2. = 649,3 o W Portata nt A x 2. Pu x C x P1 E.1.D. x 394,9 0,9 x K Z1 x T1 W= rtata, M piena po o ante ric arico di ri ad almen del fabb pa he ni di sc razione lla, in condizio a lunghezza ca ra tte ris tici di le Dichia on r un mo e izi pe li lla nd o ria de co lor e te Le spire distanti tra l filo . I ma ne i pe r le ntrollo finale o o ido de co hann restan dia me tro lvo la so no contatto. Il 15 bar me zz o tiv e de lla va dei fluidi a pressione di fra se de ed la alla ion e po sta tire, anche co str ut e ed esercizio lla valvo nza di da garan pression idraulica de . La gu ar niz se e as tal e e terial 'usura la prova ito fav orev ole enza all a con ma da to es e costruit ercizio, resist to es I S.p.A. otturator . prolunga CALEFF Tecnica per un enti alla sede zione La Dire incollam
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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.
CALEFFI
MINICAL VALCAL Automatic air vent valves

series 5020 - 5021 - 5022
cert. n 0003
CALEFFI
ISO 9001
01054/05 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.

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.
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.
CALEFFI
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.

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.
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.
CALEFFI
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
- 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.
CALEFFI
Temperature safety relief valve
CALEFFI
543 series
IS
TERE
UNI EN ISO 9001:2000 Cert. n 0003
01057/07 GB
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.
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.
CALEFFI
Temperature safety valve with automatic filling

544 series
IS
CALEFFI
TERE
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
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
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.
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
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
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.
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.
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
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
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.
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
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
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.
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
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.
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
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
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.
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
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

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
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

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

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)
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
Voltage (V)
656302 656304
230 224
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
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
1,20 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
1,20 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
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
CALEFFI
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.
Set point regulating unit for underfloor heating radiant panels

series 160
cert. n 0003
ISO 9001
01069/01 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
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
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
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
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
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.
CALEFFI
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
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
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.
CALEFFI
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
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
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....
............
............
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).
CALEFFI
Hydraulic separator
548 series
cert. n 0003
CALEFFI
ISO 9001
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 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
Serie 548
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
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
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).
CALEFFI
Hydraulic separator
CALEFFI
548 series
ACCREDITED
01076/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003
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
Serie 548
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
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
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
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.
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).
CALEFFI
Thermostatic mixing valve with interchangeable cartridge for centralised systems

5230 series
ACCREDITED
CALEFFI
01080/10 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
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
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
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.
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%
CALEFFI
50 40 30
60
70 80 90
CALEFFI50
40 30
CALEFFI
60
70 80 90 -25% +25%
CALEFFI50
40 30
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

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
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

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
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

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
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%
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%
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.
CALEFFI
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
CALEFFI
100% 80% 50%
19
18
17
16
25%
50%
20
12
21
50
23
13
60
22
70 80 90 -25% +25%
40 30
WATCH
24
Code 152600/601
A 1"
B 142
C 78
M
C
M S +
20 18 22 24
CALEFFI
16
ON
CALEFFI
100% 80% 50% 25% 50%
50 40 30
60
70 80 90 -25% +25%
-50%
Code 153600/601
A 1"
B 142
C 78
SYSTEM RETURN
SYSTEM FLOW
40 20
60
80 100 20
40
60
80 100
CALEFFI
100% 80% 50%
19
18
17
16
11
25% 50%
20
12
21
50
13
60
22
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
CALEFFI
16
10 11
CALEFFI
16
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
CALEFFI
100% 80% 50%
19
18
17
16
8 c)
25% 50%
20
21
12
7
15
14
d)
50
23
13
60
22
70 80 90 -25% +25%
40 30
WATCH
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
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

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

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
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.

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.
Outside sensor
SE SE
Connecting cable Connector
LH terminal strip
ON
CALEFFI
100% 80% 50%
19
18
17
16
25%
50%
20
21
12
15
14
50
23
13
60
22
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

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
CALEFFI
16
M S
+
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
16
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
CALEFFI
CALEFFI
CALEFFI
100% 80% 50%
19
20
18
25%
50%
17
16
21
12
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.
CALEFFI
Hydraulic separator-manifold SEPCOLL

series 559
cert. n 0003
CALEFFI
ISO 9001
01084/05 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
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
I H
C D L
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
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
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.
CALEFFI
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
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
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

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
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
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).
CALEFFI
Electronic mixing valve with programmable thermal disinfection

6000 series
cert. n 0003
CALEFFI
ISO 9001
01086/07 GB
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
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Ok
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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.
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
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
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
tuesday
adjustment running
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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adjustment running
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tuesday
disinfection running
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.
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
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
13/02/2006
Ok
Martedi
13/02/2006
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
13/02/2006
Ok
Martedi
13/02/2006
Ok
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
13/02/2006
Ok
Martedi
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.

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
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.
CALEFFI
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.
CALEFFI
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

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
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.
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
PUMP N
MA MC C
CLOSED CLOSED OPEN

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

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

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%
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.
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.
CALEFFI
6
7
-50%
CALEFFI
CALEFFI
CALEFFI
CALEFFI
Safety relief valve for solar systems
CALEFFI
253 series
cert. n 0003
ISO 9001
01089/06 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
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%.
CALEFFI
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
series 635
series 5995
Code
Dimensions
3/4 11+11
1 10+10
3/4 10+10
1 10+10
3/4 10+10
1 8+8
3/4 9+9
1 8+8
362073 - 363073 360 x 730 mm
For use with:
series 5020 shut-off valves
series 6470
series 5995
Code
Dimensions
3/4 8+8 11+11
1 7+7 10+10
3/4 7+7 10+10
1 6+6 10+10
3/4 7+7 10+10
1 6+6 8+8
3/4 6+6 10+10
1 5+5 9+9
362056 - 363056 330 x 560 mm 362073 - 363073 360 x 730 mm
Choice for use with 350 For use with:
and 592 series
distribution manifolds.
Maximum number of outlets.
series 5020
shut-off valves
series 6480
code 648018
series 6490
series 5995
Code
Dimensions
3/4 11+11
1 10+10
3/4 10+10
1 10+10
3/4 10+10
1 8+8
3/4 10+10
1 9+9
362073 - 363073 360 x 730 mm
For use with:
series
shut-off valves
series 676
series 5995
Code
Dimensions
3/4 8+8 11+11
1 8+8 11+11
3/4 8+8 11+11
1 8+8 11+11
3/4 7+7 11+11
1 7+7 10+10
3/4 7+7 10+10
1 6+6 10+10
362056 - 363056 330 x 560 mm 362073 - 363073 360 x 730 mm
For use with:
series 5020
shut-off valves
series 677
code 648018
series 5995 Code Dimensions 3/4 11+11 1 11+11 3/4 11+11 1 11+11 3/4 11+11 1 10+10 3/4 10+10 1 10+10
362073 - 363073 360 x 730 mm
Use The type of system to be adopted, whether with single or dual manifolds, must be known for proper positioning of casings. Dual manifolds mounting Use bracket code 362001 to fit series 356 distribution manifold in the box by fixing it to the central ridge at the bottom of the box. It is important that the space between the edge of the box and the anchor ridge is greater on the side where a motor for a zone valve is located, if fitted. Positioning of code 362001 bracket
Examples of positioning serie 356 dual manifolds: simple with series 678 zone valve with series 633 zone valve with series 6480 zone valve
356
653
653
653
Mod. Dep.
.peD .doM
.peD .doM
.peD .doM
CALEFFI
IFFELAC
IFFELAC
IFFELAC
CALEFFI
01 NP
Distribution manifold mounting Use code 360001 brackets for 1 distribution manifolds, 350 and 592 series; for 3/4 and 1 distribution manifolds, 351 and 598 series. Use code 360002 brackets for 3/4 349 series, 350 and 592 distribution manifold. Make sure that the space between the edge of the box and the manifolds is greater on the pipe outlet side. If zone valves are fitted, the greater space should be left on the servo-control side. The bracket fasteners marked by a raised point (in red in the diagram) are for the positioning of the brackets for fixing manifolds with 50 mm spacing. The fasteners without a raised point are for the manifolds with 35 mm spacing.
Positioning of code 360001 bracket
Installation The box is supplied with a series of spacers to set the depth of the space available inside at between 80 mm and 100 mm. The spacer is supplied for a depth of 100 mm. (fig. 1). It can be cut or broken at the point indicated (fig. 2) to provide a depth of 80 mm. (fig. 3). The angle brackets for anchoring the box in the wall can be fixed at the bottom (fig. 4) or to the frame (fig. 5). They can also be set in a vertical or horizontal position. The particular way in which they are set will prevent them from moving while they are being cemented in.
10 0m m
80 mm
The box comes complete with guards to place on the sides where no piping passes to prevent mortar from falling on them and dirtying them when the casing is set into the mortar. Guards are provided for both the narrow and the broad side, to be fitted depending on whether the casing is positioned horizontally or vertically.
The guards are fitted with special fasteners to fix them to the bottom of the box and it is therefore best to fit them before placing the casing in the wall.
After the components have been positioned and tested for leaks, the guard (supplied with the casing) should be positioned before cement operations commence to prevent cement from entering the box and dirtying the contents.
The casing lends itself easily to methods normally employed on building sites for embedding. For example, once the distributor manifold has been installed with all the accessories and leak tests have been performed, the proper depth is measured and it is assembled from the two sides. It can all be then cemented in.
The shape of the frame and of the anchoring brackets (Fig. 10 and Fig. 10a) ensures reliable anchoring in the cement and will prevent cracks and breaks in the wall near the frame.
A grid (Fig. 11) over the whole of the back of the box ensures proper anchoring in the plaster.
The box comes with an anti-crush bar which must be removed after the cement has set.
10
11
12
10a
A special fastening system for the cover ensures rapid fitting and secure closing no matter how many times it is opened and closed. The screw can be turned with either a 5 mm. Allen wrench or a coin (fig. 13 fig. 13a). Turning the screw results in controlled deformation of the screw hole which ensures that it tightens and locks (fig. 13b).
13
13a
13b
The cover allows for a 30 mm depth tolerance for possible errors in the wall finish.
14
The ventilation holes in the cover are specially shaped so that air exits from the cover at a speed and in a direction which takes it immediately away from the cover. This prevents the formation of ugly marks on the wall.
15
Installation of 363 series wall port Another typical type of installation is where a recess is cut directly into the wall (fig. 16) and consequently only the series 363 inspection wall port is required. As in the case already described (fig. 5), the anchoring brackets are fixed directly to the inside of the frame.
16
30 mm
When installed vertically box code 362073 has a width of 360 mm, which is the same as the length of box code 362036 installed horizontally; this allows the two boxes to be positioned one above the other for particularly complex systems.
17
Application diagram for code 362073 + 362036 boxes
Manual valve Thermostatic valve Air vent valve Differential by-pass Zone valve
Series 362 Inspection plastic box with ventilation openings. Colour white RAL 9010. Internal dimensions ( h x b x d ). Code 362036 mm 360 x 270 x 100/80. Code 362056 mm 560 x 330 x 100/80. Code 362073 mm 730 x 360 x 100/80.
Series 363 Inspection plastic wall port with ventilation openings. Colour white RAL 9010. Internal dimensions ( h x b x d ). Code 363036 mm 360 x 270 x 100/80. Code 363056 mm 560 x 330 x 100/80. Code 363073 mm 730 x 360 x 100/80.
Code 360001 Mounting brackets for 1 distribution manifolds, 350 and 592 series; for 3/4 and 1 distribution manifolds, 351 and 598 series. In each package: two long and two short brackets.
Code 360002 Mounting brackets for 3/4 349, 350 and 592 series distribution manifold. In each package: two long and two short brackets.
Code 360001 Mounting brackets for single sided dual manifolds 356, 357 series and zone kit 640 series.
CALEFFI
High performance, anti-scald, thermostatic mixing valves

series 5213
cert. n 0003
CALEFFI
ISO 9001
01092/04 GB
Function In some domestic hot water distribution systems there is a need to protect the most vulnerable people against scalding caused by hot water, such as, for example, in hospitals, in nursing homes or in schools. This particular series of thermostatic mixing valves has been specially designed for these applications and installation at the point of use. These thermostatic mixing valves ensure enhanced thermal performance. They are able to accurately control the temperature of the mixed water supplied to the user in case of variations in the inlet supply pressure or temperature, or in the flow rate. They are designed with a special anti-scald function which immediately shuts off the flow of water discharging from the mixed water outlet in the event of a failure of cold supply. (The 5213 series thermostatic mixing valves are certified to UK specification NHS D 08, standard BS 7942: 2000 and standards EN 1111 and EN 1287).
Product Range Code 521303 Code 521315/322 Anti scald thermostatic mixing valve, complete with filters and check valves on the inlets Anti scald thermostatic mixing valve, complete with filters and check valves on the inlets Size 3/4 Sizes 15 and 22 mm for copper pipe
Technical specification Materials:- Body: Shutter: Springs: Seals: Cap: anti dezincification alloy EN 12165 CW602N, chrome plated PPO stainless steel EPDM ABS 30 50C 2C 10 bar 5 bar
Dimensions
C B B B
C B
Temperature setting range: Temperature stability: Max. working pressure (static): Max. working pressure (dynamic):
F A
A A
Max. inlet pressure: 85C Max. inlet pressure ratio (H/C or C/H): 6:1 Minimum temperature difference between the inlet hot water and the outlet mixed water to ensure anti scald performance: 10C Minimum flow rate for stable operation: 4 l/min
Code A B C D E F Weight (kg) 521303 3/4 66,5 133 130 81,5 48,5 0,75
B C D A E Code 521315 15 67,5 135 105 56 521322 22 75 150 106 57
F Weight (kg) 49 0,50 49 0,60
Connections: 3/4 M with union tail piece 15 and 22 mm with union tail piece and compression ends
Legionella vs 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 the 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 occur in approximately 30 seconds, while at 60C partial burning will occur in approximately 5 seconds. This 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 the storage and make it suitable for sanitary use; maintain the temperature constant while the incoming pressure and temperature conditions vary; have an anti scald safety function in case of failure of the cold water supply. Thermal disinfection The diagram opposite shows the behaviour of the bacteria Legionella as a Pneumophila function of changes in the temperature of the water in which it is contained. In order to ensure proper thermal disinfection, the temperature must not fall below 60C.
Temperature exposure time

C 75 70 65 60 55 50 45 Full thickness burns Partial thickness burns Safety conditions. Maximum exposure time at a given temperature.
0,1
10
100
1.000
10.000
Seconds
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
Exposure time to receive partial burns Temperature 70C Adults 1s 2s 5s 30 s 5 min Children 0-5 years -0,5 s 1s 10 s 2,5 min
Optimum temperature for growth of bacteria
65C 60C 55C 50C
Operating principle Code 521303 The thermostatic mixing valve mixes incoming hot and cold water in such a way as to maintain the temperature of the mixed water constant. A thermostatic element is fully immersed in the mixed water flow. As this expands or contracts it causes the internal shutter to move and thereby controls the flow of incoming hot and cold water. If the temperature or pressure of the incoming water changes, the internal element reacts immediately to restore the original water temperature at the outlet. Construction details Anti-scale materials The materials used in the construction of the mixer eliminate the problem of jamming caused by lime deposits. All the functional parts are made of a special anti-scale material, with a low friction coefficient, which guarantees high performance and long life. Anti scald safety function As a safety measure, in case of failure of the cold water supply, the valve immediately shuts off the flow of mixed water. This prevents dangerous burns. This performance is guaranteed if there is a minimum temperature difference between the inlet hot water and the outlet mixed water of 10C. In case of failure of the hot water supply, the valve shuts off the mixed water, to prevent dangerous thermal shocks (performance in compliance with UK standards NHS D 08 and BS 7942: 2000).
COLD
With compression ends
MIXED
HOT
Flow curves
P (bar)
1
0,9 0,8 0,7 0,6
Commissioning
15 mm 3/4 - 22 mm
P (m w.g.)
9 8 7 6
10
0,5
0,45 0,40 0,35 0,30 0,25
4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6
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 measuring equipment. Use of a digital thermometer is recommended for measuring the temperature of the mixed water. Temperature setting and locking The temperature is set at the desired value by turning the nut on the top of the valve using the socket set in the protective cap. Given the particular use of this type of mixing valve, the following table shows the recommended maximum outlet water temperatures to prevent scalding. Appliance Bidet Shower Wash basin Bath tub Max. Temp. 38C 41C 41C 44C
0,2
0,18 0,16 0,14 0,12 0,09 0,08 0,07 0,06
0,1
0,05
0,045 0,040 0,035 0,030 0,025
0,45 0,40 0,35 0,30
0,5
0,25 0,18 0,16 0,14 0,12
0,02
0,018 0,016 0,014 0,012
0,2
1,2
1,4
1,6
1,8
2,5
3,5
4,5
12
14
16
18
25
30
35
40
10
20
45
0,01
0,1
Code 521303 521315 521322
3/4 15 mm 22 mm
Kv (m3/h) 1,7 1,5 1,7
Q (l/min)
50
Once the temperature has been set it can then be locked at the desired value using a tamper-proof locking nut.
Use Given their flow characteristics, the Caleffi 5213 series thermostatic mixing valves are suitable for point of use applications or to supply a limited number of outlets. As a consequence, the flow rate through the mixing valve is generally the same as that at the final outlet. For best performance the mixing valve must have a minimum flow rate of 4 l/min. The domestic water system must be sized in accordance with the current legislation concerning the nominal flow rates of each outlet. Public buildings, hospitals, nursery schools The risk of scalding is very high in these types of applications due to the type of users: children, the elderly and the sick. In these installations, the two supply networks of hot water from a storage and cold water can have different origin and operate at different pressures. In the event of failure of the cold or hot water, the thermostatic mixing valve will immediately shut off the flow of mixed water to prevent possible scalding or thermal shocks. Selecting the correct size of the mixing valve Note the design flow rate, taking into account the possibility of simultaneous use of appliances, select the size of mixing valve by checking the loss of pressure that will be produced from the graph. In this case, check the available inlet pressure, the loss of pressure in the system downstream of the mixing valve and the residual pressure required by the appliances. Installation Before installing the mixing valve, the pipework must be flushed to ensure that no circulating impurities can compromise its operation. It is always advisable to install suitable filters at water connections with the mains. The 5213 series thermostatic mixing valves are fitted with strainers on the hot and cold water inlets. The 5213 series thermostatic mixing valves must be installed according to the diagrams and instructions contained in the instruction sheet or in this leaflet. The 5213 series mixing valves can be fitted in any position either vertically or horizontally. The following markings are provided on the body of the valve: the letter H on the hot water inlet the letter C on the cold water inlet the word MIX on the mixed water outlet. Check valves In order to prevent undesirable backsiphonage, check valves must be installed in systems with thermostatic mixing valves The 5213 series thermostatic mixing valves are supplied with built-in check valves at the hot and cold water inlets. Fitting temperature adjustment cap View of temperature adjustment
Temperature adjustment cap in place
Locking adjustment spindle with locking nut
Application diagrams Point of use installation Multiple use installation
COLD
Bathroom inlet installation
COLD
MIX
Code 521303 Anti-scald, thermostatic mixing valve. Certified to standards: NHS D08, BS 7942 - EN 1111 and EN 1287. 3/4 M connections. Body in anti dezincification alloy. Chrome plated. Shutter in PPO. Springs in stainless steel. Seals in EPDM. Cap in ABS. Maximum working temperature: 85 C. Temperature setting range: 30C to 50C. Temperature stability: 2C. Maximum working pressure (static): 10 bar. Maximum working pressure (dynamic): 5 bar. Maximum inlet pressure ratio (H/C or C/H): 6:1. With anti-scald safety function and complete with inlet strainers and check valves.
Series 5213 . . Anti-scald, thermostatic mixing valve. Certified to standards: NHS D08, BS 7942 - EN 1111 and EN 1287. 15 mm ( 22 mm) compression ends. Body in anti dezincification alloy. Chrome plated. Shutter in PPO. Springs in stainless steel. Seals in EPDM. Cap in ABS. Maximum working temperature: 85 C. Temperature setting range: 30C to 50C. Temperature stability: 2C. Maximum working pressure (static): 10 bar. Maximum working pressure (dynamic): 5 bar. Maximum inlet pressure ratio (H/C or C/H): 6:1. With anti-scald safety function and complete with inlet strainers and check valves.
CALEFFI
MIX
HOT HOT
Set point regulating unit for radiant panels

series 162
cert. n 0003
ISO 9001
01093/04 GB
Function The set point regulating unit is designed to maintain the flow temperature of fluid distributed in a low temperature underfloor radiant panel system constant at the set temperature. It is preassembled with distribution manifolds in a box to guarantee simple functioning, safety and easy installation.
Product range Code 16263 Code 16264 Code 162600 Code 162601 Set point regulating unit preassembed with distribution manifolds and box with pump UPS 25-60 Set point regulating unit preassembed with distribution manifolds and box with pump UPS 25-80 Set point regulating unit with pump UPS 25-60 Set point regulating unit with pump UPS 25-80
Technical specification - Piping materials: - Setting temperature range: - Max. primary inlet temperature: - Max. pressure: - Differential by-pass regulation: - Temperature gauge scale: - Pressure gauge scale: - Centre distance pump: - Pump connections: - Connections to manifold: - Connections to primary circuit: - Manifold outlet connections: Dimensions - brass EN 12165 CW617N, - polished copper 20 50C 100C 10 bar 10 60 kPa (1 6 m w.g.) 0 80C 0 6 bar 130 mm 1 1/2 with nut 1 1/4 with nut 1 with nut 3/4 M Safety thermostat - Factory setting: - Protection class: - Contacts rating: 55C 3C IP 55 10 A / 240 V
Safety thermostat
Electric wiring
L 230 V N
Room thermostat
Pump Three-speed pump: Materials: - Body: Electric supply: Max. ambient relative humidity: Max. ambient temperature: Protection class: Model UPS 25-60/UPS 25-80 GG 15/20 cast iron 230 V - 50 Hz 95% 80C IP 44
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
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
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
3 2 1
bar
4 5 1
3 2
bar
4 5 1
3 2
bar
4 5 1
3 2
bar
4 5
270-410
310
A 1626D3 4 640
50
1200
38
600
800
Code
with pump UPS 25-60 with pump UPS 25-80
45 50 55
45 50 55
45 50 55
45 50 55
A 1626F3 6 740 1626G3 7 790
A 1626H3 8 840 1626I3 1626I4 9 915
A 1626L3 1626L4 10 965 1626M3 1626M4 11 1015
27 150-190 1626O3 1626O4 13 1115
Outlet A
1626C3 3 590
1626E3 5 690
1626N3 1626N4 12 1065
Hydraulic diagram
Thermostatic valve
9 8
Balancing valve
BR
9
SR
System electric pump By-pass valve Shut-off valve
A
3 1 4 6 ST 10 7
ST
Check valve Flow sensor Safety sensor Safety thermostat Temperature gauge Pressure gauge
BF
SF
Pressure tapping points Air vent valve
Operating principle The principle by which the unit functions is to mix, at node A, the high temperature fluid of the primary boiler circuit with the low temperature return fluid of the secondary user circuit. It consists of the following components with their relative functions: 1 Pump, to distribute the low temperature fluid in the secondary user circuit. 2 Thermostatic valve, which maintains the temperature set for the flow to the secondary circuit constant by regulating the quantity of high temperature primary circuit fluid that can enter the secondary circuit. It is operated by a sensor immersed in the secondary fluid. The quantity of primary fluid that is let in, under average operating conditions, amounts to approximately 25% of the total secondary circuit flow. 3 Balancing valve, which balances the quantities of the two fluids that are mixed on the basis of nominal working temperature, of the desired power and of the flow rate of the secondary fluid. 4 Differential by-pass valve, which maintains the value set for the head on the secondary circuit constant as the number of open outlet circuits to panels varies. They can in fact be automatically shut-off if the valves are fitted with a thermoelectric and thermostat control to regulate the ambient thermal load. 5 Shut-off valve with built-in check valve Ballstop, which prevents undesired circulation in the circuit and allows circuits to be shut-off for maintenance if necessary. 6 Safety thermostat, which limits the maximum temperature of the fluid sent to the radiant panel circuit, whatever happens. If the sensor of the valve is damaged, it cuts out the supply to the circulator or the generator. 7 Temperature gauges , that monitor the flow and return temperatures of the radiant panel circuits to check the performance of the system and facilitate setting operations. 8 Manual air vent valve, for use when filling the system. 9 Suitable for connection to pressure tapping points , for measuring the working conditions of the circuit and of the circulator. The points can also be connected to a Flomet electronic differential pressure measurement device to speed system calibration operations. 10 Pressure gauge, to read pressures and check the pump head.
3
BOILER RETURN
40
7
45
20 0
60 80
SYSTEM RETURN
9 7
50 55
40 20 60 80
1
BOILER FLOW
3 2 1
bar
SYSTEM FLOW
4 5
6 10
The regulating unit is preassembled with: Return distribution manifold, serie 666, fitted with shut-off valves for individual circuits designed for use with thermoelectric controls. Flow distribution manifold, series 667, fitted with micrometric valves for calibrating individual circuits.
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
CALEFFI
Head units, series 5996, with automatic air vent valve and drain valve.
CALEFFI
For further details please refer to brochure 01044

p (m w.g.) p (kPa)
45 40 35 30 25 18 16 14 12 9 8 7 6 4 3,5 3 2,5 1,8 1,6 1,4 1,2
Regulation of the balancing valve The balancing valve (VB in diagram 1) must create differential pressure sufficient to force the injection of high temperature fluid through the thermostatic valve; given that the rspective sections of the circuit are in parallel, pV ~ pVB. BALANCING VALVE
p (m w.g.) p (kPa)
3
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 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
50
2 1 0,5
20 10
4 4,5
5 5,5 6 6,5 7 7,5 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
5 4,5
0,2 0,1
2 1
25
30
35 40 45
60
70
80
90
120
140 160
180
250
300
350 400 450
600
700
800
900
1000
20
50
100
200
500
0,2 0,1
200
500
1000
2000
G (l/h)
System sizing The nominal operating inlet flow rate from the boiler circuit is calculated with the following formula (see diagram 1): Gb = Gs (Tf-Tr) / (Tb-Tr) where: Gb Gs Tf Tr Tb = flow rate in the primary boiler circuit = flow rate in the secondary circuit = secondary circuit flow temperature = secondary circuit return temperature = primary boiler circuit temperature
The balancing valve is adjusted through eight full turns between the following conditions: fully closed, fully open. It is normally preset at 6.5 turns which satisfies the operating conditions of most systems. If adjustment is necessary to satisfy the actual requirements of a system, a practical method is described below with a reference table. Practical method Reference is made to the operating temperature of the boiler circuit and the heating system and the balancing valve is gradually closed until the temperature read on the flow temperature gauge of the unit reaches the operating temperature set for the thermostatic valve (-1K/-2K). The result is that the quantities of fluid which pass through the thermostatic valve and through the balancing valve are balanced to the nominal conditions. Reference table The table below may be used as a guide for setting the balancing valve. It takes into account the main parameters that interact when the system is operating under steady state conditions.
Tb (C) 70 70 70 70 70 70 70 70 Tf (C) 35 40 45 50 ( +0 - 2) 35 40 45 50 ( +0 - 2) Tr (C) 30 33 35 38 30 33 35 38 VB (turns) 7.5 6.5 5 4.5 7.5 6.5 5.5 5.5 Gs (l/h) 1900 1750 1200 1150 2700 2200 1550 1600
this value is used to determine the loss of pressure on the thermostatic valve using the graph given above. The value found must be added to the loss of pressure in the secondary circuit to determine the head necessary from the corresponding pump if there is zero head at the unit connections.
DIAGRAM 1
Gb pV H=0
Tb H VB
Tf
Gs
ps Tr
ps (kPa) 15 15 15 15 25 25 25 25
P max (kW) 10 13 14 16 15 17 18 20
5000
UPS 25-80
6
100
Kv (2K) = 0.82 Kv (1K) = 0.42
250
300
350 400 450
600
700
800
900
1200
1400 1600
1800
2500
3000
3500 4000 4500
120
140 160
180
G (l/h)
H (m w.g.)
6
H (m w.g.)
8
UPS 25-60
5
7 6
Example Tf = 40C Tr = 33C Tb = 70C Gs = 2000 l/h
4 3 2 1 0
5 4
2 1
0 0,5 1 1,5 2 2,5 3 3,5 4
3 2
Gb = 2000 (40-33) / (70-33) = 378 l/h The following is obtained from the graph: loss of pressure on the thermostatic valve pV ~ 25 kPa. The loss of pressure on the check valve is negligible. Given ps = 20 kPa the loss of pressure in the secondary circuit at the nominal flow rate Gs, the head is obtained H = pV + ps = 45 kPa
1 0 0 1 2 3 4 5 7 8
Q (m3/h)
Q (m3/h)
Speed
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (r.p.m.) 1800 1100 700
Speed
(A) 1,04 0,92 0,63
P (W) 245 210 140
n (r.p.m.) 2450 1500 1000
3 2 1
3 2 1
UPS 25-80 UPS 25-60 pump pump
With
With
Application diagram
Shut-off valve Thermostatic valve Manual valve Three-way zone valve
Mixed system with wall boiler and zone valve
RT
Electric pump
RT
Room thermostat Check valve Autoflow Filter

CALEFFI
40 20 0 60 80
RT
CALEFFI
Hydraulic separator
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 80
CALEFFI
CALEFFI
CALEFFI
45 50 55
C
3 2
bar
4 5
Dearator
1
Medium to large applications

CALEFFI
40 20 0 60 80
RT
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 80
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
40 20 0 60 80
CALEFFI
CALEFFI
45 50 55
C
3 2 1
bar
4 5
RT
CALEFFI
40 20 0 60 80
CALEFFI
45 50 55
C
CALEFFI
3 2 1
bar
4 5
Series 162
Set point regulating unit with brass and polished copper piping. 1 connections with union to primary circuit. Primary circuit maximum temperature: 100C, maximum pressure: 10 bar. Complete with: UPS 25-60 (UPS 25-80) pump, 130 mm between centres, 1 1/2 connections with union. Thermostatic valve with remote sensor, setting temperature range: 20-50C. Balancing valve. Differential by-pass valve, setting range: 10 60 kPa. Shut-off valve with built-in check valve. Safety thermostat, factory setting: 55C, protection class: IP 55. Temperature gauge scale: 0 80C. Pressure gauge scale 0 6 bar. Suitable for connection to pressure tapping points. Three-outlet (from 3 to 13) flow and return manifolds complete with built-in micrometric balancing valves, shut-off valves designed for thermoelectric controls and automatic air vent units. Supplied preassembled in painted sheet steel box with lock, depth adjustable from 150 to 190 mm, complete with floor supports, height adjustable from 270 to 410 mm.
C A L E F F I S . P. A . I 2 8 0 1 0 F O N TA N E T O D A G O G N A ( N O ) S . R . 2 2 9 , N . 2 5 T E L . + 3 9 0 3 2 2 8 4 9 1 FA X + 3 9 0 3 2 2 8 6 3 7 2 3
Http://www.calef fi.it E-mail: info@calef fi.it
Set point regulating unit with high temperature distribution kit

series 162
cert. n 0003
ISO 9001
01094/04 GB
Function The regulating unit with the high temperature distribution kit is designed for use with mixed systems consisting of radiant panels and radiators in combination with distribution manifolds for radiant panels. The function of the set point regulating unit is to maintain the flow temperature of the fluid distributed in a low temperature system for underfloor radiant panels constant at the set temperature. The function of the kit is to distribute part of the high temperature fluid from the primary boiler circuit to the heater units. It is supplied complete with a differential by-pass valve with a fixed calibration. This accessory is indispensable if the radiator circuits are controlled by thermostatic or thermo-electric valves.
Product range Code 16263 00 Code16264 00 Code 160002 Code 160003 Set point regulating unit preassembled with manifolds and box, high temperature distribution kit with UPS 25-60 pump Set point regulating unit preassembled with manifolds and box, high temperature distribution kit with UPS 25-80 pump High temperature distribution kit complete with 2-outlet manifolds and differential by-pass High temperature distribution kit complete with 3-outlet manifolds and differential by-pass
Technical specification for the set point regulating unit series 162 - Piping materials: - Setting temperature range: - Max. primary inlet temperature: - Max. pressure: - Differential by-pass regulation: - Temperature gauge scale: - Pressure gauge scale: - Centre distance pump: - Pump connections: - Connections to manifold: - Connections to primary circuit: - Manifold outlet connections: Safety thermostat - Factory setting: - Protection class: - Contacts rating: 55C 3C IP 55 10 A / 240 V
Safety thermostat
Technical specification for the high temperature distribution kit code 160002/3 - Materials: - Manifolds: brass EN 12165 CW617N brass EN 12164 CW614N - By-pass body: - Pipe gauged 18 with collar: copper - Hydraulic seals: EPDM Max. working pressure: Max. temperature: Differential by-pass setting: 10 bar 100C 20 kPa (2000 mm w.g.)
- brass EN 12165 CW617N, - polished copper 20 50C 100C 10 bar 10-60 kPa (1-6 m w.g.) 0 80C 0 6 bar 130 mm 1 1/2 with nut 1 1/4 with nut 1 with nut 3/4 M Wiring diagram
L 230 V N
- Manifold internal diameter: 30 mm - Manifold connections: - Inlet: 1 F - Outlet: 1 M - Branches: 1/2 F - Branch outlet centre distance: 50 mm
Dimensions Code Outlet A B C D E F 160002 2 1 1 1/2 205 164 50 160003 3 1 1 1/2 205 214 50
A B C D F E B
Room thermostat
Pump Three-speed pump: Materials: - Body: Electric supply: Max. ambient relative humidity: Max. ambient temperature: Protection class: Model UPS 25-60/UPS 25-80 GG 15/20 cast iron 230 V - 50 Hz 95% 80C IP 44
1000
2+3 outlets
2+7 outlets 3+6 outlets
CALEFFI
40 20 0 60 80
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
450 205
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
40 20 0 60
CALEFFI
80
CALEFFI
CALEFFI
80
CALEFFI
CALEFFI
80
CALEFFI
10 8 6 4 2 0
CALEFFI
3 2 1
bar
4 5
270410
310 A
50 A A
1200
38
800
2+11 outlets 3+10 outlets
Code
with UPS 25-60 UPS with UPS 25-80 pump
Radiator outlets Panel outlets A

Code
with UPS 25-60 pump with UPS 25-80 pump
1626C3 002 1626D3 002 1626E3 002 2 2 2 3 4 5 740 790 840
1626C3 003 1626D3 003 1626E3 003 3 3 3 3 4 5 790 840 890
45 50 55
27 150190
1626F3 002 1626G3 002 1626H3 002 2 2 2 6 7 8 890 940 990
1626I3 002 1626I4 002 2 9 1065
1626L3 002 1626M3 002 1626L4 002 1626M4 002 2 2 10 11 1115 1165
1626F3 003 1626G3 003 1626H3 003 3 3 3 6 7 8 940 990 1040
1626I3 003 1626I4 003 3 9 1115
1626L3 003 1626L4 003 3 10 1165
Hydraulic diagram
Thermostatic valve
11
9 8
Balancing vale
BR
9
SR
System electric pump By-pass valve
A
3 1 4 6 ST 10 7
ST
Shut-off valve Check valve Flow sensor Safety sensor Safety thermostat Temperature gauge
12
11
BF
SF
Pressure gauge Pressure tapping point Air vent valve
3
BOILER RETURN
40
7 2

45
20 0
60 80
SYSTEM RETURN
9 7
12 1
BOILER FLOW

55
40 20 0 60 80
50
C
SYSTEM FLOW
3 2 1
bar
4 5
6 10
Operating principle The principle by which the unit functions is to mix, at node A the high temperature fluid of the primary boiler circuit with the low temperature return fluid of the secondary user circuit. It consists of the following components with their relative functions: 1 Pump, to distribute the low temperature fluid in the secondary user circuit. 2 Thermostatic valve, which maintains the temperature set for the flow to the secondary circuit constant by regulating the quantity of high temperature primary circuit fluid that can enter the secondary circuit. It is operated by a sensor immersed in the secondary fluid. The quantity of primary fluid that is let in, under average operating conditions, amounts to approximately 25% of the total secondary circuit flow. 3 Balancing valve, which balances the quantities of the two fluids that are mixed on the basis of nominal working temperature, of the desired power and of the flow rate of the secondary fluid. 4 Differential by-pass valve, which maintains the value set for the head on the secondary circuit constant as the number of open outlet circuits to panels varies. They can in fact be automatically shut-off if the valves are fitted with a thermoelectric and thermostat control to regulate the ambient thermal load. 5 Shut-off with built-in check valve Ballstop, which prevents undesired circulation in the circuit and allows circuits to be shut-off for maintenance if necessary. 6 Safety thermostat, which limits the maximum temperature of the fluid sent to the radiant panel circuit, whatever happens. If the sensor of the valve is damaged, it cuts out the supply to the circulator or the generator. 7 Temperature gauges , that monitor the flow and return temperatures of the radiant panel circuits to check the performance of the system and facilitate setting operations. 8 Manual air vent valve, for use when filling the system. 9 Suitable for connection to pressure tapping points , for measuring the working conditions of the circuit and of the circulator. The points can also be connected to a Flomet electronic differential pressure measurement device to speed system calibration operations. 10 Pressure gauge, to read pressures and check the pump head. 11 Flow and return manifolds for high temperature distribution. 12 Fixed balancing differential by-pass to balance the pressure in the distributor manifold circuit as the flow rate varies.
The regulating unit is preassembled with:
Return distribution manifold, series 666, fitted with shut-off valves for individual circuits designed for use with thermoelectric controls. Flow distribution manifold, series 667, fitted with micrometric valves for calibrating individual circuits. Head units, series 5996, with automatic air vent valve and drain valve.
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
CALEFFI
CALEFFI
For further details please refer to brochure 01044

p (m w.g.)
Regulation of the balancing valve The balancing valve (VB IN DIAGRAM 1) must create differential pressure sufficient to force the injection of high temperature fluid through the thermostatic valve; given that the respective sections of the circuit are in parallel, pV ~ pVB. BALANCING VALVE
p (m w.g.) p (kPa)
3
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
p (kPa)
45 40 35 30 25 18 16 14 12 9 8 7 6 4 3,5 3 2,5 1,8 1,6 1,4 1,2
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
50
2 1 0,5
20 10
4 4,5
5 5,5 6 6,5 7 7,5 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
5 4,5
0,2 0,1
2 1
25
30 35 40 45
60
70 80 90
120 140 160 180
250
300 350 400 450
600
700 800 900
1000
20
50
100
200
500
0,2 0,1
200
500
1000
2000
G (l/h)
System sizing The nominal operating inlet flow rate from the boiler is calculated with the following equation (see diagram 1):
The balancing valve is adjusted through eight full turns between the following conditions: fully closed, fully open. It is normally preset at 6.5 turns which satisfies the operating conditions of most systems. If adjustment is necessary to satisfy the actual requirements of a system, a practical method is described below with a reference table. Practical method
Gb = Gs (Tf-Tr) / (Tb-Tr) where: Gb Gs Tf Tr Tb = flow rate in the primary boiler circuit = flow rate in the secondary circuit = secondary circuit flow temperature = secondary circuit return temperature = primary boiler circuit temperature Reference is made to the operating temperature of the boiler circuit and the heating system and the balancing valve is gradually closed until the temperature read on the flow temperature gauge of the unit reaches the operating temperature set for the thermostatic valve (-1K/-2K). The result is that the quantities of fluid which pass through the thermostatic valve and through the balancing valve are balanced to the nominal conditions. Reference table The table below may be used as a guide for setting the balancing valve. It takes into account the main parameters that interact when the system is operating under steady state conditions.
Tb (C) 70 70 70 70 70 70 70 70 Tm (C) 35 40 45 50 ( +0 - 2) 35 40 45 50 ( +0 - 2) Tr (C) 30 33 35 38 30 33 35 38 VB (turns) 7,5 6,5 5 4,5 7,5 6,5 5,5 5,5 Gs (l/h) 1900 1750 1200 1150 2700 2200 1550 1600
this value is used to determine the loss of pressure on the thermostatic valve using the graph given above. The value found must be added to the loss of pressure in the secondary circuit to determine the head necessary from the corresponding pump if there is zero head at the unit connections. DIAGRAM 1
Gb pV H=0
Tc
Tm
Gs
H VB Tr ps
ps (kPa) 15 15 15 15 25 25 25 25
P max (kW) 10 13 14 16 15 17 18 20
5000
UPS 25-80
6
100
Kv (2K) = 0,82 Kv (1K) = 0,42
250
300
350 400 450
600
700
800
900
1200
1400 1600
1800
2500
3000
3500 4000 4500
120
140 160
180
G (l/h)
H (m w.g.)
6
H (m w.g.)
8
UPS 25-60
5
7 6
Example Tf = 40C Tr = 33C Tb = 70C Gs = 2000 l/h
4 3 2 1 0
5 4
2 1
0 0,5 1 1,5 2 2,5 3 3,5 4
3 2 1 0 0 1 2
Gb = 2000 (40-33) / (70-33) = 378 l/h The following is obtained from the graph: loss of pressure on the thermostatic valve pV ~ 25 kPa. The loss of pressure on the check valve is negligible. Given ps = 20 kPa the loss of pressure in the secondary circuit at the nominal flow rate Gs, the head is obtained H = pV + ps = 45 kPa
UPS 25-80 UPS 25-60 pump pump

7 8
Q (m3/h)
With
With
Q (m3/h)
Speed
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (r.p.m.) 1800 1100 700
Speed
(A) 1,04 0,92 0,63
P (W) 245 210 140
n (r.p.m.) 2450 1500 1000
3 2 1
3 2 1
Hydraulic characteristics of the high temperature distribution kit Localised loss coefficient: - inlet: - branch outlet: 1.0 3.0
Hydraulic characteristics of the high temperature distribution kit by-pass

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 1200
20
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 boiler
Room thermostat Thermostatic valve Lockshield valve Manual valve
RT
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
40 20 0 60
CALEFFI
80
CALEFFI
10 8 6 4 2 0
CALEFFI
3 2 1
bar
4 5
RT
1000
100
200
500
50
900
CALEFFI
2-
6561 0
220 V - 3
45 50 55
Series 162 Set point regulating unit with brass and polished copper piping. 1 connections with union to primary circuit. Primary circuit maximum temperature: 100C, maximum pressure: 10 bar. Complete with: UPS 25-60 (UPS 25-80) pump, 130 mm between centres, 1 1/2 connections with union. Thermostatic valve with remote sensor, setting temperature range: 20-50C. Balancing valve. Differential by-pass valve, setting range: 10-60 kPa. Shut-off valve with built-in check valve. Safety thermostat, factory setting: 55C, protection class: IP 55. Temperature gauge scale: 0-80C. Pressure gauge scale 0-6 bar. Suitable for connection to pressure tapping points. Three-outlet (3 to 13) flow and return manifolds complete with built-in micrometric balancing valves, shut-off valves designed for thermoelectric controls and automatic air vent units. Supplied preassembled in painted sheet steel box with lock, depth adjustable from 150 to 190 mm, complete with floor supports, height adjustable from 270 to 410 mm.
Code 160002 2-outlet flow and return manifolds for primary distribution. Brass body. 1M X 1F main connections. 1/2F outlet connections. Supplied with 20 kPa set differential by-pass.
Code 160003 3-outlet flow and return manifolds for primary distribution. Brass body. 1M X 1F main connections. 1/2F outlet connections. Supplied with 20 kPa set differential by-pass.
C A L E F F I S . P. A . I 2 8 0 1 0 F O N TA N E T O D A G O G N A ( N O ) S . R . 2 2 9 , N . 2 5 T E L . + 3 9 0 3 2 2 8 4 9 1 FA X + 3 9 0 3 2 2 8 6 3 7 2 3
Http://www.calef fi.it E-mail: info@calef fi.it
Motorised temperature regulating unit
CALEFFI
series 161
cert. n 0003
ISO 9001
01095/04 GB
Function The temperature regulating unit is designed for use with a climatic or modulating temperature controller. The unit is compact to save space and facilitates installation in an embedded wall box. The unit is supplied complete with a three-way motorised valve, a three-speed pump, flow and return temperature gauges, a pressure gauge, a safety thermostat, an adjustable discharge valve, connecting piping and shut-off valves on the primary circuit. The unit is available in different configurations, both simple and preassembled in a box with distribution manifolds.
Product Range Code 1615 Motorised temperature regulating unit preassembled with distribution manifold and box Code 161600 Motorised temperature regulating unit preassembled
Technical specification Three -way valve Materials: - Body: brass EN 12165 CW617N, nickel plated - Ball: brass EN 12165 CW617N, chrome plated - Seals: EPDM Hydraulic unit: Materials: - Piping: polished copper - Fittings: brass EN 12164 CW614N - Shut-off valves: brass EN 12165 CW617N, nickel plated Temperature gauge scale: Pressure gauge scale: Connections to primary circuit: Connections to manifold: Manifold outlet connections: Actuator Three-point type: Electric supply: Operating time: Power consumption: Protection class: Max. ambient temperature: Protective cover: Cable length: Medium: Max. percentage of glycol: Working temperature range: Max. working pressure: 0 80C 0 6 bar 3/4 M 1 1/4 M union connection 3/4 M Safety thermostat: Setting temperature: Protection class: Contacts rating: Cable length: Pump Three-speed pump: Material: - Body: Max. ambient relative humidity: Max. ambient temperature: Protection class: Pump center distance: Pump connections: Cable length: Head available at regulating unit connections
H (m w.g.)
6
55C 3C IP 55 10 A - 240 V 0,55 m
UPS 25-60 GG 15/20 cast iron 95% 80C IP 44 130 mm 1 1/2 with union 1m
230V 50-60 Hz 95 s 4W IP 54 65C self extinguishing VO 0,9 m water, glycol solutions 30% 5 90C 10 bar
Power consumption
UPS 25-60
5 4 3 2 1 0
Speed
2 1
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (r.p.m.) 1800 1100 700
3 2 1
1,5 2 2,5 3
0,5
Q (m3/h)
Dimensions Code A B C D E F G H 161600 1 1 1/4 50 240 65 105 195 90
20 0
60 80
40
3 2 1
bar
4
20
40 60 80
A C
A D E
1000
6 outlets
10 outlets
13 outlets
40 20 0 60 80 20
40 60 80 20
40 60 80
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
450
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
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
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
10 8 6 4 2 0
CALEFFI
3 2 1
bar
4
20
3
40 60 80
2 1
bar
4
20
3
40 60 80
2 1
bar
4
20
40 60 80
5
5
5
3/4 270-410
240 315 A Code Outlets A 1615E0 5 635 1615F0 6 685
50 A 1615G0 7 735 1615H0 8 785 1615I0 9 865 A 1615L0 10 915 1615M0 11 965 1615N0 12 1015 110-150 1615O0 13 1065
10
40 20 0 60 80
SYSTEM RETURN
1 10 3
1 2 3 4 5 6 7 8 9 10
Three-way ball valve Three-point servomotor Three-speed pump: UPS 25-60 Adjustable discharge valve Safety thermostat Flow temperature gauge Return temperature gauge Pressure gauge Primary distribution shut-off valves Temperature sensor connection (option)
The regulating unit is preassembled with: Series 666 return distribution manifold, equipped with shut-off valves on individual circuit specially designed for thermoelectric control. Series 667 flow distribution manifold, equipped with micrometric valves for calibrating individual circuits.
10 8 6 4 2 0 10 8 6 4 2 0
CALEFFI
CALEFFI
9
2 1 0
3
bar
4
20
40 60 80
SYSTEM FLOW
5
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
5
BOILER FLOW
6
BOILER RETURN
Head units with automatic air vent, differential pressure control by-pass kit and drain valve.
1200
800
Hydraulic diagram
10
4
Temperature sensor (option)
SR
1
ST
Manual drain valve Temperature gauge

ST
5 8 6
10
Safety thermostat Shut-off ball valve Three-way motorised valve
SF
Pressure gauge Pump
BF
BR
Wiring diagram for connecting the regulating valve

Open
Close
Temperature sensor (option) The unit is fitted with 1/8 F fittings for secondary circuit flow and return immersion temperature sensors, available on request, code F69264.
Use of the safety thermostat The safety thermostat is fitted with a special easy-to-fit connector and is used to stop the boiler and protect the radiant panel circuits from dangerous overheating.
Temperature sensor technical specification
Type NTC Working temperature range: Time constant: Response: Beta value: Two-wire cable with connector Cable length:
-40 125C 2,5 s 10000 a 25C 25/85C 39771,5% 0,55 m
Application diagrams System with wall boiler and Sepcoll 2+1
Pump Variable speed pump Thermostatic valve
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
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
10 8 6 4 2 0
CALEFFI
3 2 1
bar
4
20
40 60 80
5
Mixed system with wall boiler and zone valves to the distribution manifolds
Pump Variable speed pump Thermostatic valve Lockshield valve

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
Shut-off valve Clock
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
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
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
3 2 1
bar
4
20
40 60 80
5
Series 1615. Motorised temperature regulating unit with piping in polished copper. 3/4 M connections to the primary distribution. 3/4 M manifold outlet connections. Working temperature range: 5 to 90C. Maximum working pressure: 10 bar. Supplied complete with: three-way ball valve; three-point actuator, electric supply 230 V, protection class: IP 54; three-speed pump UPS 25-60, adjustable drain valve; safety thermostat, working temperature range: 55C 3C, protection class: IP 55; temperature gauge scale: 0C to 80C; temperature gauge scale: 0 to 6 bar; primary distribution shut-off valve; fitted with connections for temperature sensors; 5-outlet (5 to 13) flow distribution manifold complete with micrometric preregulation valves and drain cock; 5-outlet (5 to 13) return distribution manifold complete with shut-off valves suitable for thermoelectric control and air vent valve. By-pass kit for panel system manifold, setting: 25 kPa (2500 mm w.g.). Supplied preassembled in coated steel sheet box with lock, adjustable depth from 110 and 140 mm, complete with adjustable height to 410 mm floor supports.
Code 161600 Motorised temperature regulating unit with piping in polished copper. 1 F connections to the primary distribution. 1 1/4 M with union connections to the secondary distribution. Working temperature range: 5 to 90C. Maximum working pressure: 10 bar. Supplied complete with: three-way ball valve; three-point actuator, power 230 V, protection class: IP 54; three-speed pump UPS 25-60, adjustable drain valve; safety thermostat, working temperature range: 55C 3C, protection class: IP 55; temperature gauge scale: 0C to 80C; pressure gauge scale: 0 to 6 bar; primary circuit shut-off valve; suitable for connecting to temperature sensors.
CALEFFI
Modulating temperature regulating unit for heating and cooling

with high temperature distribution kit
series 161
cert. n 0003
CALEFFI
ISO 9001
01096/04 GB
Function The modulating temperature regulating unit with high temperature distribution kit is designed for use with mixed type systems consisting of radiant panels and radiators or fan coils in combination with distribution manifolds for radiant panels. This unit, complete with digital temperature controller, controls the temperature of the fluid sent to radiant panels as a function of the actual thermal load. The unit is compact to save space and facilitates installation into an embedded wall box. The unit is supplied complete with digital temperature controller for both heating and cooling, a motorised three-way valve, components to limit relative humidity, a three-speed pump, flow and return sensors, a safety thermostat, flow and return temperature gauges, a pressure gauge, adjustable drain valve and shut-off valves on the primary circuit. The function of the kit is to distribute part of the primary fluid from the boiler or chiller unit to the heater and cooler units. It acts as a hydronic separator for underfloor heating circuits and is supplied complete with an adjustable differential by-pass for the primary circuit.
Product range Code 16152 003 Code 161503 Modulating temperature regulating unit with high temperature distribution kit, preassembled with manifolds and box High temperature distribution kit with 3-outlet manifold and differential by-pass
Technical specification Temperature controller Electric supply: Protection class: Three-way Materials: Actuator Three-point type: Electric supply: Operating time: Power consumption: Protection class: Max. ambient temperature: Protective cover: Medium: Max. percentage of glycol: Setting temperature range: Primary inlet temperature range: Max. working pressure: Panel manifold differential by-pass setting: Differential by-pass hydraulic characteristics
P (mm w.g.)
5000
4500 4000 3500 3000 2500 0,12 0,14 0,16 0,18 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
230 V - 50 Hz IP 40
valve Body: brass EN 12165 CW617N, nickel plated Ball: brass EN 12165 CW617N, chrome plated Hydraulic seals: EPDM
230 V - 50 Hz 95 s 4W IP 54 65C self extinguishing VO water, glycol solutions 30% 7 78C 5 90C 10 bar 25 kPa (2.500 mm w.g.)
Hydraulic unit Materials: - Piping: polished copper - Fittings: brass, EN 12164 CW614N - Shut-off valves: brass EN 12165 CW617N, nickel plated Temperature gauge scale: Pressure gauge scale: Connections to primary circuit: Connections to manifold: Manifold outlet connections: 0 80C 0 6 bar 3/4 M 1 1/4 M union connection 3/4 M
P (kPa)
50
45 40 35 30 25
2000
20
0,1
0,2
0,5
G (m3/h)
Flow/return temperature sensor NTC type Working temperature range: Time constant: Response: Beta value: Two-wire cable with 1/8 M connection Safety thermostat Setting temperature: Protection class: Contacts rating: Pump Three-speed pump: Material: - Body: Max. ambient relative humidity: Max. ambient temperature: Protection class: Pump centre distance: Pump connections:
High temperature distribution kit technical specification - code 161503 -10 125C 2,5 s 10.000 at 25C 25/85C 3977 1,5% Materials: - Manifold: - By-pass: - Hydraulic seals: Max. working pressure: Max. working temperature: Differential by-pass setting: brass EN 1982 CB753S brass EN 12165 CW617N EPDM 10 bar 100C 10 60 kPa (1 6 m w.g.)
55C 3C IP 55 10 A - 240 V
UPS 25-60 cast iron GG 15/20 95% 80C IP 44 130 mm 1 1/2 with union connection
Manifold internal diameter: 20 mm Manifold connections: - Inlet: 3/4 F nut - To the regulating unit: 1 M - Outlets: 23 p. 1,5 M - 18 mm - Outlet center distance: 50 mm Insulation Material: Thickness: Density: - inner part: - outer part: Thermal conductivity (DIN 52612):
closed cell PEX foam 15 mm 30 kg/m3 50 kg/m3 0C: 0,038 W/mK 40C: 0,045 W/mK Coefficient of resistance to the diffusion of vapour (DIN 52615): >1.300 Working temperature range: 0 100C Fire resistance (DIN 4102): B2 class

H (m w.g.)
6
Dimensions
UPS 25-60
5 4 3 2 1 0
Power consumption
D
I
Speed
2 1
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (r.p.m.) 1800 1100 700
CALEFFI
Mod. Dep.
0,5
1,5
2,5
G (m3/h)
1000
5 outlets
8 outlets
12 outlets
40 20 0 60 80
20
40 60 80 20
40 60 80
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
150052
Trasformatore
V DE
150051
AC 230V 50Hz 10,5VA T50
Convertitore
AC 24V 50Hz AC 230V 6(2)A T50
650
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
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
CALEFFI
CALEFFI
CALEFFI
CALEFFI
10 8 6 4 2 0
CALEFFI
3/4
3 2 1
bar
4
20
3
40 60 80
2 1
bar
4
20
3
40 60 80
2 1
bar
4
20
40 60 80
5
5
5
CALEFFI
Mod. Dep.
60
357
145
270410
440 A Code Radiator outlets Panels outlets A 1615E2 003 3 5 775 1615F2 003 3 6 825
50 A 1615G2 003 3 7 875 1615H2 003 3 8 925 1615I2 003 3 9 1015 A 1615L2 003 3 10 1055 1615M2 003 3 11 1105 110-150 1615N2 003 3 12 1155
1200
800
mH2O 6
1 2 3 4 5
3 2 1
357
Code 161503 A 3/4 B 23 p. 1.5 C 60 D 1 E 240 F 75 G 87 H 50
mH2O
1 2 3 4 5 6
Characteristic components 16 1 3 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Digital temperature controller Three-way ball valve Three-point actuator Three-speed pump: UPS 25-60 Flow temperature sensor Return temperature sensor Adjustable drain valve Safety thermostat Flow temperature gauge Return temperature gauge Pressure gauge Primary circuit shut-off valves High temperature distribution manifold Differential by-pass valve Max. RH% control sensor Max. RH% control components
40 20 0 60 80
CALEFFI
CALEFFI
150052
Trasformatore
V DE
150051
AC 230V 50Hz 10,5VA T50
SYSTEM RETURN
AC 24V 50Hz AC 230V 6(2)A T50
Convertitore
10 5
4 9 8 12 13
3 2
bar
4
20
40 60 80
SYSTEM FLOW
11
1
5 0 6
10 8 6 4 2 0 10 8 6 4 2 0
BOILER FLOW
CALEFFI
Mod. Dep.
CALEFFI
CALEFFI
BOILER RETURN
357
10 8 6 4 2 0
10 8 6 4 2 0
10 8 6 4 2 0
10 8 6 4 2 0
14
Hydraulic diagram
1 3 6 10 7
Temperature sensor Relative humidity sensor
TC
16
2
ST
8 11 9
12
13
BF
Pump
BR
12
14
mH2O 6
1 2 3 4 5
CALEFFI
CALEFFI
15
Digital temperature controller
SR
5 15
TC
Transformer/Converter Manual drain valve
SF
ST
Temperature gauge Safety thermostat Shut-off ball valve Three-way motorised valve Pressure gauge
Differential by-pass
High temperature distribution kit Operating The high temperature distribution kit distributes water to the heater or cooler units connected before the outlet to the secondary radiant panel circuit. It consists of a single sided dual manifold and a differential by-pass valve.
The differential by-pass valve is used to control the head to which the distribution circuit to the heater units is subjected; it facilitates circulation to the heater units and limits over pressure where there are thermostatic or electro-thermal valves.The differential valve is calibrated at the pressure loss value in the heater unit circuit.
High temperature distribution manifold The distributor manifold not only distributes the water in the heater unit circuits but also allows the hydronic separation between the primary and the secondary circuits. This separation improves the functioning of the secondary circuit to the panels and prevents changes in the flow rate in the primary circuit from affecting the secondary circuit. In this case, the flow rate in the respective circuits is an exclusive function of the pump flow rate and the reciprocal influence arising from coupling them in series is avoided. Two possible conditions of circuit equilibrium follow. A typical circuit design gives the following operating conditions: G primary = G secondary (inlet to the mixing valve) + G heating units G primary max. recommended: 1,5 m3/h
Manifold hydraulic characteristics Localised loss coefficient inlet (F+R): Localised loss coefficient outlets (F+R): 3,0 6,5
Gs
Secondary
Gp
Primary
mH2O
1 2 3 4 5 6
Differential by-pass technical specification

Setting positions
p (m w.g.)
8 7 6 5 4 3 2 1 0 0 0,5
(kPa)
80 70
Factory setting: 10 kPa (1 m w.g.)
6 5 4 3 2 1 1 1,5
Gs
60 50 40 30 20 10 2 0
G (m3/h)
Secondary
Gp
Primary
Operation The temperature controller receives the activation signal from the ambient thermostat to start the pump and operate the mixing valve. The controller operates the mixing valves according to two logic approaches depending on whether the return sensor is on or off. Set point regulation: return sensor off. Selector 6) OFF. In this case the flow temperature FT is held constant at the value set using the selector 5) both for heating and for cooling. The setting is shown on the display 1). Modulating regulation: return sensor on. Selector 6) ON. In this case the flow temperature FT is modified as a function of the temperature measured by the return sensor RT. This keeps the actual thermal output of the slab and as a consequence the ambient thermal load under control. The thermal response time of the system is thus reduced to a minimum. RTset = FTset - 35% (FTset - 20C) FTcalculated = FTset + (RTset - RT)
Example: FTset = 40C RTset = 40 - 0,35 (40 - 20) = 33C FTcalculated = 40 + (33 - RT)
10 11 12 9 6 5 The new FT value calculated is given on the display 1) with a small side bar showing.
The front panel contains the following functions: 1) Three-digit LCD display for: temperature measured or calculated and setting programmed delays in the system. Temperature range displayed: 0 99C with a 0,1C resolution. 2) Controller function selector On/Off. 3) Mixing valve on opening: Led on. 4) Mixing valve on closing: Led on. 5) Selector for setting flow temperature Temperature range: 7 78C Factory setting: - heating: max. 50C - cooling: min. 14C 6) Return sensor selector Sensor off: OFF Sensor on: ON Factory setting: ON 7) Pump running (ON): LED permanently on 8) S.T. led - safety temperature. Permanently on when the limit signalled by the thermostat or humidistat is reached. It also comes on permanently if the flow/return sensors malfunction (see paragraph flow/return sensor). 9) Switch for changing heating/ cooling function. 10) Adjuster for maximum duration of impulse on valve. Adjustable 0,2 6 s. Factory setting: 2,5 s. 11) Adjuster for time delay in reading return sensor. Adjustable 1 360 s. Factory setting: 20 s.
20 30
Each time the FT is calculated, the actual FT is displayed for 5 s, after which the new FT calculated is shown. Changes to FT stop when RT reaches RTset. The return sensor is switched off for the cooling function.
Curve correction with return sensor

FT; RT
(C)
50
Flow limit temperature
45 Design Flow Temperature FT Set
FT
ed lat lcu Ca
FT Flow temperature
40
35
ted ula alc C T

RT Set Design Return Temperature
25
12) Adjuster for valve-motor mechanical time delay. Adjustable 1 30 s. Factory setting: 13 s.
50%
100%
150%
Design Thermal Load %
Display The three-digit LCD display shows the following parameters: - flow temperature set using the selector 5). The flow temperature measured appears after 5 seconds. - the flow temperature measured with the return sensor off. - the flow temperature calculated with the return sensor on. - the maximum duration of the impulse to the valve, selected using the adjuster 10). Displayed for 5 seconds. - delay time for acquiring the return temperature, selected using the adjuster 11). Displayed for 5 seconds. - valve-motor mechanical delays, selected using the adjuster 12). Displayed for 5 seconds.
Heating safety thermostat If the safety thermostat signals a flow temperature greater than 55C the following state is set: pump OFF, mixing valve closed. The thermostat terminal is NC; if it is not connected, the temperature controller is set off.
Auxiliary micro-switch The controller is equipped with an auxiliary micro-switch which can be used to control other equipment. Example: For Heating: to switch the boiler on or off. Terminal NA- pump offambient thermostat OFF or safety thermostat ON (boiler off). Terminal NC-pump on-ambient thermostat ON (boiler on). For Cooling: to switch chiller unit on or off. Terminal NA-pump OFF-ambient thermostat OFF or RH% limit sensor on (chiller unit OFF). Terminal NC-pump ON-ambient thermostat ON (chiller unit ON). Contacts rating: 5 A (230 V).
Back panel
CALEFFI
M 230 V~ 5060 Hz ~ 5(2) A / 250 V~
1 L 2 N 3 4 5 6
230 V~ IN OUT
13 14 15 16 17 18 7 FS RS AT ST Open Close 8 9 10 11 12
Flow /return sensor The flow/return temperature sensors are of the NTC type. If the sensor detects electrical resistance that indicates a short circuit, the following operating state is set: pump OFF, mixing valve closed, LED 8) permanently on.
7 8 9 10 11 12
13 14 15
16 17 18
1 2 3
4 5 6

C -20 -15 -10 -5 0 5 97.060 72.940 55.319 42.324 32.654 25.396 C 10 15 20 25 30 35 19.903 15.714 12.493 10.000 8.056 6.530 C 40 45 50 55 60 65 5.327 4.370 3.603 2.986 2.488 2.083 C 70 75 80 85 90 95 1.752 1.480 1.255 1.070 915 787 C 100 105 110 115 120 125 680 592 517 450 390 340
The terminals for the various electrical components are located on the back panel. Electric supply 1 Supply 230 V~ live 2 Supply 230 V~ neutral 3 Earth Pump control 4 Earth 5 Pump control 230 V~ live 6 Pump control 230 V~ neutral Mixing valve control 7 Valve control on opening 8 Common C 9 Valve control on closing Auxiliary micro-switch 10 Auxiliary outlet NA 11 Common outlet C 12 Auxiliary outlet NC Flow/return sensor 13 Flow temperature sensor 14 Common C 15 Return temperature sensor Ambient thermostat/safety thermostat 16 Contact for ambient thermostat 17 Common C contact for ambient thermostat / common C contact for safety thermostat and humidity sensor converter 18 Contact for safety thermostat and humidity sensor converter
Flow temperature limit for heating or cooling Maximum heating and minimum cooling flow temperatures can be set with the controller. Dip switches are located on the back of the temperature control panel for this purpose. Different switch configurations give different limit temperatures. Factory setting: - heating: max 50C - cooling: min 14C.
Table of temperature limit dip switch positions Dip switch Maximum Minimum setting limit (C) limit (C) 0 0 0 0 50 14 0 0 1 0 54 13 0 1 0 0 58 12 0 1 1 0 62 11 1 0 0 0 66 10 1 0 1 0 70 9 1 1 0 0 74 8 1 1 1 0 78 7
ON
ON
Position 1 Position 0
1 2 1 2
Maximum cooling temperature limit Cooling flow temperature cannot be set greater than 25C.
Control of relative humidity When the temperature controller is used for cooling, the relative humidity sensor must be used. The function of this sensor is to detect the maximum relative humidity limit in order to prevent the formation of condensation in the cooling thermal slab. It is set at RH=80-85%. When this level is reached the following operating state is set: pump ON, mixing valve closed.
Testing the humidity sensor The functioning of the sensor must be checked at the start of each cooling season by placing a damp wad of cotton wool on the surface; this should cause the mixing valve to be switched off and switch on the red LED, 8), on the front of the control panel. Location of the humidity sensor The humidity sensor is located at the point where humidity is most likely to form which will depend on the system design. It is positioned with the carbon printed surface facing upwards as in the diagrams.
Connection of the humidity sensor The humidity sensor is connected to the temperature controller through a special transformer and converter.
ST
CALEFFI CALEFFI
Inferior side: placed on the cooling surface
150052
Transformer
V DE
150051
Converter
AC 230V 50Hz 10,5VA T50 AC 24V 50Hz AC 230V 6(2)A T50
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. Fix by inserting the two straps contained in the package through the holes in the sensor.
24V
24V~ 1 2 3 4 5 6
LN
~ ~
230 V
AT
13 14 15
1 L 2 N 3 4 5 6 FS
16 17 18
7 RS AT ST Open Close 8 9 10 11 12
Controller
The maximum heat energy that the panel can produce, in relation to the climate values recorded, can be reached by controlling the parameters below. - Minimum flow temperature can be set using the selector 5) on the front panel. - Maximum RH% limit, controlled through RH% sensor. - Room temperature controlled through room thermostat. - Room temperature and relative humidity controlled through a dedicated fan-coil or dehumidifier). N.B.: Through the RH% limit sensor, possible formation of condensation is anticipated. In areas with cooling, adequate air treatment must always be present.
13 14 15 16 17 18
230 V~ IN OUT
Accessories
738
Ambient chrono-thermostat, battery operated. With self-learning programme. Weekly programmable clock. Suitable for phone programmer. Three temperature levels. Minimum programming: 30 minutes.
Code
738107
120 x 90 x 20 mm
Application diagram
Pump Three-way valve Thermostatic valve

0 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

TU Thermostat/Humidistat
Lockshield valve
S/W
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
TU
40 20 0 60 80
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
150052
Trasformatore
V DE
150051
AC 50Hz 230V
Convertitore
AC 24V 50Hz AC 230V T50 6(2)A
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
3 2 1
bar
4
20
40 60 80
5
CALEFFI
Mod. Dep.
357
Code 1615.2 003 Modulating temperature regulating unit for heating and cooling with piping in polished copper. 34 M connections to primary circuit. 34 M distribution manifold outlets to radiant panels. 23 p.1,5 connections high temperature distribution manifold outlets. Primary inlet temperature range: 5 90C. Maximum working pressure: 10 bar. Complete with: three-way ball valve; three-point actuator, electric supply: 230 V, protection class: IP 54; radiant panel system temperature controller, electric supply 230 V, setting temperature range: 7 78C, complete with flow, return and relative humidity sensors; three-speed pump UPS 25-60, protection class: IP 44. Adjustable drain valve; safety thermostat, working temperature range: 55C3C, protection class: IP 55; Scale temperature gauge: 0 to 80C; scale pressure gauge: 0 to 6 bar; primary circuit shut-off valves; 5-outlet (5 to 12) flow manifold for panel systems complete with micrometric preregulation valves and drain cock; 5-outlet (5 to 12) return manifold for panel systems complete with shut-off valves suitable for thermoelectric controls and air vent valve; by-pass kit for panel system manifold, setting: 25 kPa (2500 mm w.g.); flow and return single sided dual manifold for high temperature circuit; by-pass valve for high temperature manifold, setting: 10 60 kPa; supplied preassembled in coated steel sheet box with lock, adjustable depth: 110 to 140 mm, complete with adjustable height 270 to 410 mm floor supports.
Code 161503 High temperature distribution kit for modulating temperature regulating unit consisting of: flow and return single sided dual manifold for high temperature circuit. 34 F with union connections to primary circuit; 23 p.1,5 outlet connections; by-pass valve for high temperature system manifold, setting: 10 - 60 kPa. Maximum working temperature: 100C. Maximum working pressure: 10 bar.
CALEFFI
mH2O
1 2 3 4 5 6
Modulating temperature regulating unit
CALEFFI
series 161
cert. n 0003
ISO 9001
01097/04 GB
Function The modulating temperature regulating unit is designed for use in underfloor heating systems in combination with distribution manifolds. This unit, complete with digital temperature controller, controls the temperature of the fluid sent to radiant panels as a function of the actual thermal load. The unit is compact to save space and facilitates installation into an embedded wall box. The unit is supplied complete with digital temperature controller, a motorised three-way valve, a three-speed pump, flow and return sensors, a safety thermostat, flow and return temperature gauges, a pressure gauge, an adjustable drain valve and shut-off valves on the primary circuit.
Product range Code 16151 Modulating temperature regulating unit preassembled with manifolds and box
P (mm w.g.)
5000
4500 4000 3500 3000 2500 0,12 0,14 0,16 0,18 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
230 V - 50 Hz IP 40
valve Body: brass EN 12165 CW617N, nickel plated Ball: brass EN 12165 CW617N, chrome plated Hydraulic seals: EPDM
230V - 50 Hz 95 s 4W IP 54 65C self extinguishing VO water, glycol solutions 30% 7 78C 5 90C 10 bar 25 kPa (2.500 mm w.g.)
P (kPa)
50
45 40 35 30 25
Hydraulic unit Materials: - Piping: polished copper - Fitting: brass EN 12164 CW614N - Shut-off valves: brass EN 12165 CW617N, nickel plated Temperature gauge scale: Pressure gauge scale: Connections to primary circuit: Connections to manifold: Manifold outlet connections: 0 80C 0 6 bar 3/4 M 1 1/4 M adjustable nut 3/4 M
2000
20
0,1
0,2
0,5
G (m3/h)
Head available at regulating unit connections -10 125C 2,5 s 10.000 at 25C 25/85C 3977 1.5%
H (m w.g.)
6
UPS 25-60
5 4 3
Power consumption
I
Speed
2 1
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (r.p.m.) 1800 1100 700
55C 3C IP 55 10 A / 240 V
2 1 0
3 2 1
1,5 2 2,5 3
0,5
G (m3/h)
UPS 25-60 GG 15/20 cast iron 95% 80C IP 44 130 mm 1 1/2 with union
Dimensions
1000
6 outlets
9 outlets
13 outlets
40 20 0 60 80
20
40 60 80 20
40 60 80
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
450
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
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
CALEFFI
CALEFFI
CALEFFI
CALEFFI
10 8 6 4 2 0
CALEFFI
3 2 1
bar
4
20
3
40 60 80
2 1
bar
4
20
3
40 60 80
2 1
bar
4
20
40 60 80
5
5
5
3/4
270-410
240 365 A
50
1200
800
110-150
Code Outlets A
1615E1 5 685
1615F1 6 735
1615G1 7 785
1615H1 8 835
1615I1 9 915
1615L1 10 965
1615M1 11 1015
1615N1 12 1065
1615O1 13 1115
6 7
SYSTEM RETURN
1 Digital temperature controller 2 Three-way ball valve 3 Three-point actuator 4 Three-speed pump: UPS 25-60 5 Flow temperature sensor 6 Return temperature sensor
40 20 0 60 80
7 Adjustable drain valve 8 Safety thermostat 9 Flow temperature gauge 10 Return temperature gauge 11 Pressure gauge 12 Primary circuit shut-off valves The regulating unit is preassembled with:
10 5
4 9 8
3 2
bar
SYSTEM FLOW
4
20 40 60 80
Series 666 return distribution manifold, equipped with shut-off valves on individual circuit specially designed for thermoelectric control. Series 667 flow distribution manifold, equipped with micrometric valves for calibrating individual circuits.
10 8 6 4 2 0 10 8 6 4 2 0
CALEFFI
CALEFFI
11
1
5 0 6
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
12
BOILER FLOW BOILER RETURN
Hydraulic diagram
1 3 6 10 7
Temperature sensor Manual air vent valve
SR
2
ST
Temperature gauge
ST
8 11 9
Safety thermostat Shut-off ball valve Three-way motorised valve Pressure gauge
SF
12
12
Pump
BF
BR

2 7 3 4 8 1
10
11
12
The front panel contains the following functions: 1) Three-digit LCD display for: temperature measured or calculated and setting programmed delays in the system. Temperature range displayed: 0 99C with a 0,1C resolution. 2) Controller function selector On/Off. 3) Mixing valve on opening: LED on. 4) Mixing valve on closing: LED on. 5) Selector for setting flow temperature Temperature range: 7 78C Factory setting: - heating: max 50C 6) Return sensor selector Sensor off: OFF Sensor on: ON Factory setting: ON 7) Pump running (ON): LED permanently on 8) S.T. LED - safety temperature. Permanently on when the limit signalled by the safety thermostat. It also comes on permanently if the flow/return sensors malfunction. 9) Switch for changing heating / cooling only with RH% control components.
35
The new FT value calculated is given on the display 1) with a small side bar showing.
Each time the FT is calculated, the actual FT is displayed for 5 s, after which the new FT calculated is shown. Changes to FT stop when RT reaches RTset.
Curve correction with return sensor
FT/RT (C)
50
Flow limit temperature
45 Design flow temperature FT Set 40
FT
ed lat lcu ca
FT flow temperature
FT
ed lat lcu ca
RT Set Design return temperature
10) Adjuster for maximum duration of impulse on valve. Adjustable 0.2 6 s. Factory setting: 2,5 s.
30
11) Adjuster for delay time in reading return sensor. Adjustable 1 360 s. Factory setting: 20 s.
25
12) Adjuster for valve-motor mechanical delays. Adjustable 1 30 s. Factory setting: 13 s.

20 50% 100% 150%
Design thermal load %
Display The three digit LCD display shows the following parameters: - flow temperature set using the selector 5). The flow temperature measured appears after 5 seconds. - the flow temperature measured with the return sensor off. - the flow temperature calculated with the return sensor on. - the maximum duration of the impulse to the valve, selected using the adjuster 10). Displayed for 5 seconds. - delay time for acquiring the return temperature, selected using the adjuster 11). Displayed for 5 seconds. - valve-motor mechanical delays, selected using the adjuster 12). Displayed for 5 seconds.
Heating safety thermostat If the safety thermostat signals a flow temperature greater than 55C the following state is set: pump OFF, mixing valve closed. The thermostat terminal is NC; if it is not connected, the temperature controller is set off. Auxiliary micro-switch The controller is equipped with an auxiliary micro-switch which can be used to control other equipment. Example: For Heating: to switch the boiler on or off. Terminal NA- pump off-ambient thermostat OFF or safety thermostat ON (boiler off). Terminal NC-pump on-ambient thermostat ON (boiler on). Contacts rating: 5 A (230 V) Flow/return sensor The flow/return temperature sensors are of the NTC type. If the sensor detects electrical resistance that indicates a short circuit, the following operating state is set: pump OFF, mixing valve closed, led 8) permanently on. Table of sensor resistance values
13 14 15 16 17 18
Back panel
CALEFFI
M 230 V~ 5060 Hz ~ 5(2) A / 250 V~
1 L 2 N 3 4 5 6
230 V~ IN OUT
1 2 3
4 5 6
7 8 9
10 11 12
C -20 -15 -10 -5 0 5
97.060 72.940 55.319 42.324 32.654 25.396
C 10 15 20 25 30 35
19.903 15.714 12.493 10.000 8.056 6.530
C 40 45 50 55 60 65
5.327 4.370 3.603 2.986 2.488 2.083
C 70 75 80 85 90 95
1.752 1.480 1.255 1.070 915 787
C 100 105 110 115 120 125
680 592 517 450 390 340
Flow temperature limit for heating Maximum heating can be set with the controller. Dip switches are located on the back of the temperature control panel for this purpose. Different switch configurations give different limit temperatures. Factory setting: - heating: max 50C
The terminals for the various electrical components are located on the back of the panel. Electrically powered 1 Supply 230 V~ live 2 Supply 230 V~ neutral 3 Earth Pump control 4 Earth 5 Pump control 230 V~ live 6 Pump control 230 V~ neutral Mixing valve control 7 Valve control on opening 8 Common C 9 Valve control on closing Auxiliary micro-switch 10 Auxiliary outlet NA 11 Common outlet C 12 Auxiliary outlet NC Flow/return sensor 13 Flow temperature sensor 14 Common C 15 Return temperature sensor Ambient thermostat/safety thermostat 16 Contact for ambient thermostat 17 Common C contact for ambient thermostat / Common C contact for safety thermostat 18 Contact for safety thermostat
Table of temperature limit dip switch positions Dip switch setting 0 0 0 0 1 0 1 0 0 1 1 0 0 0 0 0 1 0 1 0 0 1 1 0 Maximum limit (C) 50 54 58 62 66 70 74 78
0 0 0 0 1 1 1 1
ON
ON
1 2 1 2
Accessories
738
Chrono-thermostat, battery operated. With self-learning programme. Weekly programmable clock. Suitable for phone programmer. Three temperature levels. Minimum required programming: 30 minutes.
Code
738107
120 x 90 x 20 mm
Application diagram
Pump Variable speed pump Thermostatic valve Lockshield valve Shut-off valve Clock
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
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
CALEFFI
3 2 1
bar
4
20
40 60 80
5
Without hydronic separator, switch off the pump 161 unit using room thermostat contact, with boiler in sanitary hot water priority.
Pump Thermostatic valve Lockshield valve
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
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
10 8 6 4 2 0
CALEFFI
3 2 1
bar
4
20
40 60 80
5
Code 1615.1 Modulating temperature regulating unit for heating with piping in polished copper. 3 4 M connections to primary circuit. 3 4 M distribution manifold outlets to radiant panels. Primary inlet temperature range: 5 90C. Maximum working pressure: 10 bar. Complete with: three-way ball valve; three-point actuator, electric supply: 230 V, protection class: IP 54; radiant panel system temperature controller, electric supply 230 V, setting temperature range: 7 78C, complete with flow and return sensors; three-speed pump UPS 25-60, protection class: IP 44. Adjustable drain valve; safety thermostat, working temperature range: 55C3C, protection class: IP 55; temperature gauge scale: 0 to 80C; pressure gauge scale: 0 to 6 bar; primary circuit shut-off valves; 5-outlet (5 to 13) flow manifold for panel systems complete with micrometric preregulation valves and drain cock; 5-outlet (5 to 13) return manifold for panel systems complete with shut-off valves suitable for thermo-electric controls and air vent valve; by-pass kit for panel system manifold, setting: 25 kPa (2500 mm w.g.); supplied pre-assembled in coated steel sheet box with lock, adjustable depth: 110 to 140 mm, complete with adjustable height 270 to 410 mm floor supports.
CALEFFI
CALEFFI
series 161
cert. n 0003
ISO 9001
01098/04 GB
Function The modulating temperature regulating unit is designed for use in underfloor heating systems in combination with distribution manifolds. This unit, complete with digital temperature controller, controls the temperature of the fluid sent to radiant panels as a function of the actual thermal load. The unit is compact to save space and facilitates installation into an embedded wall box. The unit is supplied complete with digital temperature controller for both heating and cooling, a motorised three-way valve, components to limit relative humidity, a three-speed pump, flow and return sensors, a safety thermostat, flow and return temperature gauges, a pressure gauge, adjustable drain valve and shut-off valves on the primary circuit.
Product range Code 16152 Modulating temperature regulating unit preassembled with manifolds and box
P (mm w.g.)
5000
4500 4000 3500 3000 2500 0,12 0,14 0,16 0,18 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
230 V - 50 Hz IP 40
valve Body: brass EN 12165 CW617N, nickel plated Ball: brass EN 12165 CW617N chrome plated Hydraulic seals: EPDM
P (kPa)
50
45 40 35 30 25
Hydraulic unit Materials: - Piping: polished copper - Fittings: brass EN 12164 CW614N - Shut-off valves: brass EN 12165 CW617N, nickel plated Temperature gauge scale: Pressure gauge scale: Connections to primary circuit: Connections to manifold: Manifold outlet connections: 0 80C 0 6 bar 3/4 M 1 1/4 M union connection 3/4 M
2000
20
0,1
0,2
0,5
G (m3/h)
Head available at regulating unit connections -10 125C 2,5 s 10.000 at 25C 25/85C 3977 1,5%
H (m w.g.)
6
UPS 25-60
5 4 3
Power consumption
I
Speed
2 1
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (r.p.m.) 1800 1100 700
55C 3C IP 55 10 A / 240 V
2 1 0
3 2 1
1,5 2 2,5 3
0,5
G (m3/h)
UPS 25-60 cast iron GG 15/20 95% 80C IP 44 130 mm 1 1/2 with union
Dimensions
1000
800
5 outlets
8 outlets
12 outlets
40 20 0 60 80
20
40 60 80 20
40 60 80
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
450
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
150052
Trasformatore
V DE
150051
AC 230V 50Hz 10,5VA T50
Convertitore
AC 24V 50Hz AC 230V T50 6(2)A
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
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
10 8 6 4 2 0
CALEFFI
3 2 1
bar
4
20
3
40 60 80
2 1
bar
4
20
3
40 60 80
2 1
bar
4
20
40 60 80
5
5
5
3/4
270-410
240 A
50 A A 110-150
Code Outlets A
1615E2 5 775
1615F2 6 825
1615G2 7 875
1615H2 8 925
1615I2 9 1005
1615L2 10 1055
1615M2 11 1105
1200
1615N2 12 1155
Characteristic components 14 1 3 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Digital temperature controller Three-way ball valve Three-point actuator Three-speed pump: UPS 25-60 Flow temperature sensor Return temperature sensor Adjustable drain valve Safety thermostat Flow temperature gauge Return temperature gauge Pressure gauge Primary circuit shut-off valves Max. RH% control sensor Max. RH% control components
40 20 0 60 80
CALEFFI
CALEFFI
150052
Trasformatore
V DE
150051
AC 230V 50Hz 10,5VA T50
SYSTEM RETURN
AC 24V 50Hz AC 230V 6(2)A T50
Convertitore
10 5
4 9 8
3 2
bar
The regulating unit is preassembled with:

4
20 40 60 80
SYSTEM FLOW
11
1
5 0 6
12
13
Series 666 return distribution manifold, equipped with shut-off valves on individual circuit specially designed for thermoelectric control. Series 667 flow distribution manifold, equipped with micrometric valves for calibrating individual circuits.
10 8 6 4 2 0 10 8 6 4 2 0
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
CALEFFI
CALEFFI
Hydraulic diagram
1 3 6 10 7
Temperature sensor Relative humidity sensor
TC
14
SR
2
ST
TC
Transformer/Converter Manual drain valve
8 11 9
13
SF
ST
Temperature gauge Safety thermostat Shut-off ball valve Three-way motorised valve
12
12
Pressure gauge
BF
BR
Pump
Example: FTset = 40C RTset = 40 - 0.35 (40 - 20) = 33C FTcalculated = 40 + (33 - RT)
The front panel contains the following functions: 1) Three-digit LCD display for: temperature measured or calculated and setting programmed delays in the system. Temperature range displayed: 0 99C with a 0,1C resolution. 2) Controller function selector On/Off. 3) Mixing valve on opening: LED on. 4) Mixing valve on closing: LED on. 5) Selector for setting flow temperature Temperature range: 7 78C Factory setting: - heating: max. 50C - cooling: min. 14C 6) Return sensor selector Sensor off: OFF Sensor on: ON Factory setting: ON 7) Pump running (ON): LED permanently on 8) S.T. LED - safety temperature. Permanently on when the limit signalled by the thermostat or humidistat is reached. It also comes on permanently if the flow/return sensors malfunction. (see paragraph flow/return sensor). 9) Switch for changing heating/ cooling function. 10) Adjuster for maximum duration of impulse on valve. Adjustable 0,2 - 6 s. Factory setting: 2,5 s. 11) Adjuster for time delay in reading return sensor. Adjustable 1 360 s. Factory setting: 20 s. 12) Adjuster for valve-motor mechanical time delay. Adjustable 1 30 s. Factory setting: 13 s.
Each time the FT is calculated, the actual FT is displayed for 5 s, after which the new FT calculated is shown. Changes to FT stop when RT reaches RTset. The return sensor is switched off for the cooling function.
Curve correction with return sensor FT/RT (C)

50
Flow limit temperature FT Flow temperature
45 Design flow temperature FT Set
ed lat lcu a C FT
40
35
ed lat lcu a C FT
30
25
20 50% 100% 150%
Display The three-digit LCD display shows the following parameters: - flow temperature set using the selector 5). The flow temperature measured appears after 5 seconds. - the flow temperature measured with the return sensor off. - the flow temperature calculated with the return sensor on. - the maximum duration of the impulse to the valve, selected using the adjuster 10). Displayed for 5 seconds. - delay time for acquiring the return temperature, selected using the adjuster 11). Displayed for 5 seconds. - valve-motor mechanical delays, selected using the adjuster 12). Displayed for 5 seconds.
Auxiliary micro-switch The controller is equipped with an auxiliary micro-switch which can be used to control other equipment. Example: For Heating: to switch the boiler on or off. Terminal NA- pump offambient thermostat OFF or safety thermostat ON (boiler off). Terminal NC-pump on-ambient thermostat ON (boiler on). For Cooling: to switch chiller unit on or off. Terminal NA-pump OFF-ambient thermostat OFF or RH% limit sensor on (chiller unit OFF). Terminal NC-pump ON-ambient thermostat ON (chiller unit ON). Contacts rating: 5 A (230 V).
Back panel
CALEFFI
M 230 V~ 5060 Hz ~ 5(2) A / 250 V~
1 L 2 N 3 4 5 6
230 V~ IN OUT
Flow/return sensor The flow/return temperature sensors are of the NTC type. If the sensor detects electrical resistance that indicates a short circuit, the following operating state is set: pump OFF, mixing valve closed, LED 8) permanently on.
13 14 15
16 17 18

1 2 3 4 5 6 7 8 9 10 11 12 C -20 -15 -10 -5 0 5 97.060 72.940 55.319 42.324 32.654 25.396 C 10 15 20 25 30 35 19.903 15.714 12.493 10.000 8.056 6.530 C 40 45 50 55 60 65 5.327 4.370 3.603 2.986 2.488 2.083 C 70 75 80 85 90 95 1.752 1.480 1.255 1.070 915 787 C 100 105 110 115 120 125 680 592 517 450 390 340
The terminals for the various electrical components are located on the back panel. Electric supply 1 Supply 230 V~ live 2 Supply 230 V~ neutral 3 Earth Pump control 4 Earth 5 Pump control 230 V~ live 6 Pump control 230 V~ neutral Mixing valve control 7 Valve control on opening 8 Common C 9 Valve control on closing Auxiliary micro-switch 10 Auxiliary outlet NA 11 Common outlet C 12 Auxiliary outlet NC Flow/return sensor 13 Flow temperature sensor 14 Common C 15 Return temperature sensor Ambient thermostat/safety thermostat 16 Contact for ambient thermostat 17 Common C contact for ambient thermostat / Common C contact for safety thermostat and humidity sensor converter 18 Contact for safety thermostat converter and humidity sensor converter
Flow temperature limit for heating or cooling Maximum heating and minimum cooling flow temperatures can be set with the controller. Dip switches are located on the back of the temperature control panel for this purpose. Different switch configurations give different limit temperatures. Factory setting: - heating: max 50C - cooling: min 14C.
Table of temperature limit dip switch positions Dip switch Maximum Minimum setting limit (C) limit (C) 0 0 0 0 50 14 0 0 1 0 54 13 0 1 0 0 58 12 0 1 1 0 62 11 1 0 0 0 66 10 1 0 1 0 70 9 1 1 0 0 74 8 1 1 1 0 78 7
ON
ON
1 2 1 2
Control of relative humidity When the temperature controller is used for cooling, the relative humidity sensor must be used. The function of this sensor is to detect the maximum relative humidity limit in order to prevent the formation of condensation in the cooling thermal slab. It is set at RH=80-85%. When this level is reached the following operating state is set: pump ON, mixing valve closed.
Testing the humidity sensor The functioning of the sensor must be checked at the start of each cooling season by placing a damp wad of cotton wool on the surface; this should cause the mixing valve to be switched off and switch on the red LED, 8), on the front of the control panel. Location of the humidity sensor The humidity sensor is located at the point where humidity is most likely to form which will depend on the system design. It is positioned with the carbon printed surface facing upwards as in the diagrams.
Connection of the humidity sensor The humidity sensor is connected to the temperature controller through a special transformer and converter.
ST
Inferior side: placed on the cooling surface
CALEFFI CALEFFI
150052
Transformer
V DE
150051
Converter
AC 230V 50Hz 10,5VA T50 AC 24V 50Hz AC 230V 6(2)A T50
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. Fix by inserting the two straps contained in the package through the holes in the sensor.
24V
24V~ 1 2 3 4 5 6
LN
~ ~
230 V
AT
13 14 15
1 L 2 N 3 4 5 6 FS
16 17 18
7 RS AT ST Open Close 8 9 10 11 12
Controller
13 14 15 16 17 18
230 V~ IN OUT
The maximum heat energy that the panel can produce, in relation to the climate values recorded, can be reached by controlling the parameters below. - Minimum flow temperature can be set using the selector 5) on the front panel. Maximum RH% limit, controlled through RH% sensor. - Room temperature controlled through room thermostat. - Room temperature and relative humidity controlled through a dedicated fan-coil or dehumidifier). N.B.: Through the RH% limit sensor, possible formation of condensation is anticipated. In areas with cooling, adequate air treatment must always be present.
Accessories
738
Ambient chrono-thermostat, battery operated. With self-learning programme. Weekly programmable clock. Suitable for phone programmer. Three temperature levels. Minimum programming: 30 minutes.
Code
738107
120 x 90 x 20 mm
Application diagram
Pump Variable speed pump

0 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

TH Thermostat/Humidistat
Three-way valve Thermostatic valve
E/I
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
TH
40 20 0 60 80
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
150052
Trasformatore
V DE
150051
AC 50Hz 230V
Convertitore
AC 24V 50Hz AC 230V T50 6(2)A
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
3 2 1
bar
4
20
40 60 80
5
Without hydronic separator, switch off the pump of 161 unit using room thermostat contact, with boiler in sanitary hot water priority.
Pump Three-way 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

TH Thermostat/Humidistat
0 8 6 4 2 0
10 8 6 4 2 0
Thermostatic valve Lockshield valve
E/I
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
TH
40 20 0 60 80
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
150052
Trasformatore
V DE
150051
AC 50Hz 230V
Convertitore
AC 24V 50Hz AC 230V T50 6(2)A
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
3 2 1
bar
4
20
40 60 80
5
Code 1615.2 Modulating temperature regulating unit for heating and cooling with piping in polished copper. 3 4 M connections to primary circuit. 3 4 M distribution manifold outlets to radiant panels. Primary inlet temperature range: 5 90C. Maximum working pressure: 10 bar. Complete with: three-way ball valve; three-point actuator, electric supply: 230 V, protection class: IP 54; radiant panel system temperature controller, electric supply 230 V, setting temperature range: 7 78C, complete with flow, return and relative humidity sensors; three-speed pump UPS 25-60, protection class: IP 44. Adjustable drain valve; safety thermostat, working temperature range: 55C3C, protection class: IP 55; temperature gauges scale: 0 to 80C; pressure gauge scale: 0 to 6 bar; primary circuit shut-off valves; 5-outlet (5 to 12) flow manifold for panel systems complete with micrometric preregulation valves and drain cock; 5-outlet (5 to 12) return manifold for panel systems complete with shut-off valves suitable for thermo-electric controls and air vent valve; by-pass kit for panel system manifold, setting: 25 kPa (2500 mm w.g.); supplied pre-assembled in coated steel sheet box with lock, adjustable depth: 110 to 140 mm, complete with adjustable height 270 to 410 mm floor supports.
CALEFFI
Modulating temperature regulating unit with high temperature distribution kit

series 161
cert. n 0003
CALEFFI
01099/04 GB
ISO 9001
Function The modulating temperature regulating unit with high temperature distribution kit is designed for use with mixed type systems consisting of radiant panels and radiators or fan coils in combination with distribution manifolds for radiant panels. This unit, complete with digital temperature controller, controls the temperature of the fluid sent to radiant panels as a function of the actual thermal load. The unit is compact to save space and facilitates installation into an embedded wall box. The unit is supplied complete with digital temperature controller, a motorised three-way valve, a three-speed pump, flow and return sensors, a safety thermostat, flow and return temperature gauges, a pressure gauge, adjustable drain valve and shut-off valves on the primary circuit. The function of the kit is to distribute part of the primary fluid from the boiler to the heater units. It acts as a hydraulic separator for underfloor heating systems and is supplied complete with an adjustable differential by-pass for the primary circuit.
Product range Code 16151 003 Code 161503 Modulating temperature regulating unit with high temperature distribution kit, preassembled with manifolds and box High temperature distribution kit with 3-outlet manifold and differential by-pass
Technical specification Temperature controller Power consumption: Protection class: Three-way Materials: Servomotor Three-point type: Supply voltage: Operating time: Power consumption: Protection class: Max. ambient temperature: Protective cover: Medium: Max. percentage of glycol: Setting temperature range: Primary inlet temperature range: Max. working pressure: Panel manifold differential by-pass setting: Differential by-pass hydraulic characteristics
P (mm w.g.)
5000
4500 4000 3500 3000 2500 0,12 0,14 0,16 0,18 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
230 V - 50 Hz IP 40
valve Body: EN 12165 CW617N nickel plated brass Ball: EN 12165 CW617N chrome plated brass Hydraulic seals: EPDM
P (kPa)
50
45 40 35 30 25
Hydraulic unit Materials: - Piping: polished copper - Fittings: EN 12164 CW614N brass - Shut-off valves: EN 12165 CW617N nickel plated brass Temperature gauge scale: Pressure gauge scale: Connections to primary circuit: Connections to manifold: Manifold outlet connections: 0 80C 0 6 bar 3/4 M 1 1/4 M union connection 3/4 M
2000
20
0,1
0,2
0,5
G (m3/h)
High temperature distribution kit technical specification - code 161503 -10 125C 2,5 s 10.000 a 25C 25/85C 3977 1,5% Materials:- Manifold: - By-pass: - Hydraulic seals: Max. working pressure: Max. working temperature: Differential by-pass setting: brass EN 1982 CB753S brass EN 12165 CW617N EPDM 10 bar 100C 10 60 kPa (1 6 m w.g.)
55C 3C IP 55 10 A - 240 V
UPS 25-60 GG 15/20 cast iron 95% 80C IP 44 130 mm 1 1/2 with union
Manifold internal diameter: 20 mm Manifold connections: - Inlet: 3/4 F union - To the regulating unit: 1 M - Outlets: 23 p.1,5 M - 18 mm - Outlet center distance: 50 mm Insulation Material: Thickness: Density: - inner part: - outer part: Thermal conductivity (DIN 52612):
closed cell PEX foam 15 mm 30 kg/m3 50 kg/m3 0C: 0,038 W/mK 40C: 0,045 W/mK Coefficient of resistance to the diffusion of vapour (DIN 52615): >1300 Working temperature range: 0 100C Fire resistance (DIN 4102): B2 class

H (m w.g.)
6
Dimensions
UPS 25-60
5 4 3 2 1 0
Power consumption
D
Speed I
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (r.p.m.) 1800 1100 700
2 1
CALEFFI
Mod. Dep.
0,5
1,5
2,5
G (m3/h)
1000
5 outlets.
8 outlets
12 outlets
40 20 0 60 80
20
40 60 80 20
40 60 80
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
650
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
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
10 8 6 4 2 0
CALEFFI
3/4
3 2 1
bar
4
20
3
40 60 80
2 1
bar
4
20
3
40 60 80
2 1
bar
4
20
40 60 80
5
5
5
CALEFFI
Mod. Dep.
60
357
145
270-410
440 A Code Radiator outlets Panel outlets A 1615E1 003 3 5 765 1615F1 003 3 6 815
50 A 1615G1 003 3 7 865 1615H1 003 3 8 915 1615I1 003 3 9 995 A 1615L1 003 3 10 1045 1615M1 003 3 11 1095 110-150 1615N1 003 3 12 1145
1200
800
mH2O 6
1 2 3 4 5
3 2 1
357
Code 161503 A 3/4 B 23 p. 1,5 C 60 D 1 E 240 F 75 G 87 H 50
mH2O
1 2 3 4 5 6
Characteristic components 1 3 6 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Digital temperature controller Three-way ball valve Three-point servomotor Three-speed pump: UPS 25-60 Flow temperature sensor Return temperature sensor Adjustable discharge valve Safety thermostat Flow temperature gauge Return temperature gauge Pressure gauge Primary circuit shut-off valves High temperature distribution manifold Differential by-pass valve
40 20 0 60 80
SYSTEM RETURN
10 5
4 9 8 12 13
3 2
bar
4
20
40 60 80
SYSTEM FLOW
10 8 6 4 2 0 10 8 6 4 2 0
11
1
5 0 6
CALEFFI
CALEFFI
BOILER FLOW
CALEFFI
Mod. Dep.
BOILER RETURN
10 8 6 4 2 0
10 8 6 4 2 0
10 8 6 4 2 0
10 8 6 4 2 0
357
CALEFFI
CALEFFI
14
Hydraulic diagram
1 3 6 10 7
Temperature sensor Manual discharge valve
2
ST
8 11 9
12
13
BF BR
14
12
mH2O 6
1 2 3 4 5
SR
5
ST
Temperature gauge Safety thermostat Shut-off ball valve Three-way motorised valve Pressure gauge Pump Differential by-pass
SF
High temperature distribution kit Operation The high temperature distribution kit distributes water to the heater units connected before the outlet to the secondary radiant panel circuit. It consists of a single sided dual manifold and a differential by-pass valve.
The differential by-pass valve is used to control the head to which the distribution circuit to the heater units is subjected; it facilitates circulation to the heater units and limits over pressure where there are thermostatic or electro-thermal valves.The differential valve is calibrated at the value where pressure is lost in the heater unit circuit.
High temperature distribution manifold The distributor manifold not only distributes the water in the heater unit circuits but also allows the hydronic separation between the primary and the secondary circuits. This separation improves the functioning of the secondary circuit to the panels and prevents changes in the flow rate in the primary circuit from affecting the secondary circuit. In this case, the flow rate in the respective circuits is an exclusive function of the pump flow rate and the reciprocal influence arising from coupling them in series is avoided. Two possible conditions of circuit equilibrium follow. A typical circuit design gives the following operating conditions: G primary = G secondary (inlet to the mixing valve) + G heating units G primary max. recommended: 1,5 m3/h
Manifold hydraulic characteristics Localised loss coefficient inlet (F+R): Localised loss coefficient outlets (F+R): 3.0 6.5
Gs
Secondary
Gp
Primary
mH2O
1 2 3 4 5 6
Differential by-pass technical specification

Setting positions
p (m w.g.)
8 7 6 5 4 3 2 1 0 0 0,5
(kPa)
80 70
Factory setting: 10 kPa (1 m w.g.)
6 5 4 3 2 1 1 1,5
Gs
60 50 40 30 20 10 2 0
G (m3/h)
Secondary
Gp
Primary
Operation The temperature controller receives the activation signal from the ambient thermostat to start the pump and operate the mixing valve. The controller operates the mixing valves according to two logic approaches depending on whether the return sensor is on or off. Set point regulation: return sensor off. Selector 6) OFF. In this case the flow temperature FT is held constant at the value set using the selector 5) both for heating and for cooling. The setting is shown on the display 1). Modulating regulation: return sensor on. Selector 6) ON. In this case the flow temperature FT is modified as a function of the temperature measured by the return sensor RT. This keeps the actual thermal efficiency of the thermal mass and as a consequence the ambient thermal load under control. The thermal response time of the system is thus reduced to a minimum. RTset = FTset - 35% (FTset - 20C) FTcalculated = FTset + (RTset - RT)
The front panel contains the following functions: 1) Three-digit LCD display for: temperature measured or calculated and setting programmed delays in the system. Temperature range displayed: 0 99C with a 0,1C resolution. 2) Controller function selector On/Off. 3) Mixing valve on opening: LCD on. 4) Mixing valve on closing: LCD on. 5) Selector for setting flow temperature Temperature range: 7 78C Factory setting: - heating: max. 50C 6) Return sensor selector Sensor off: OFF Sensor on: ON Factory setting: ON 7) Pump running (ON): LED permanently on 8) S.T. LED - safety temperature. Permanently on when the limit signalled by the safety thermostat is reached. It also comes on permanently if the flow/return sensors malfunction. 9) Switch for changing heating / control components. cooling only with RH%
Each time the FT is calculated, the real FT is displayed for 5 s, after which the new FT calculated is shown. Changes to FT stop when RT reaches RTset.
Curve correction with return sensor FT/RT (C)

50
Limit flow temperature FT flow temperature
45 Design flow temperature FT Set
FT
ed lat lcu a c
40
35
FT
ed lat lcu a c
10) Adjuster for maximum duration of impulse on valve. Adjustable 0,2 6 s. Factory setting: 2,5 s. 11) Adjuster for delay time in reading return sensor. Adjustable 1 360 s. Factory setting: 20 s. 12) Adjuster for valve-motor mechanical delays. Adjustable 1 30 s. Factory setting: 13 s.
30
25
20 50% 100% 150%
Display The three digit lcd display shows the following parameters: - flow temperature set using the selector 5). The flow temperature measured appears after 5 seconds. - the flow temperature measured with the return sensor off. - the flow temperature calculated with the return sensor on. - the maximum duration of the impulse to the valve, selected using the adjuster 10). Displayed for 5 seconds. - delay time for acquiring the return temperature, selected using the adjuster 11). Displayed for 5 seconds. - valve-motor mechanical delays, selected using the adjuster 12). Displayed for 5 seconds.
Auxiliary micro-switch The controller is equipped with an auxiliary micro-switch which can be used to control other equipment. Example: For Heating: to switch the boiler on or off. Terminal NA- pump off-ambient thermostat OFF or safety thermostat ON (boiler off). Terminal NC-pump on-ambient thermostat ON (boiler on). Contacts rating: 5 A (230 V) Flow/return sensor The flow/return temperature sensors are of the NTC type. If the sensor detects electrical resistance that indicates a short circuit, the following operating state is set: pump OFF, mixing valve closed, led 8) permanently on.
Back panel
CALEFFI
M 230 V~ 5060 Hz ~ 5(2) A / 250 V~
1 L 2 N 3 4 5 6
230 V~ IN OUT
13 14 15
16 17 18

1 2 3 4 5 6 7 8 9 10 11 12 C -20 -15 -10 -5 0 5 97.060 72.940 55.319 42.324 32.654 25.396 C 10 15 20 25 30 35 19.903 15.714 12.493 10.000 8.056 6.530 C 40 45 50 55 60 65 5.327 4.370 3.603 2.986 2.488 2.083 C 70 75 80 85 90 95 1.752 1.480 1.255 1.070 915 787 C 100 105 110 115 120 125 680 592 517 450 390 340
The terminals for the various electrical components are located on the back panel. Electrically powered 1 Power 230 V~ live 2 Power 230 V~ neutral 3 Earth Pump control 4 Earth 5 Pump control 230 V~ live 6 Pump control 230 V~ neutral Mixing valve control 7 Valve control on opening 8 Common C 9 Valve control on closing Auxiliary micro-switch 10 Auxiliary outlet NA 11 Common outlet C 12 Auxiliary outlet NC Flow/return sensor 13 Flow temperature sensor 14 Common C 15 Return temperature sensor Ambient thermostat/safety thermostat 16 Contact for ambient thermostat 17 Common C contact for ambient thermostat/common C contact for safety thermostat 18 Contact for safety thermostat
Flow temperature limit for heating Maximum heating can be set with the controller. Dip switches are located on the back of the temperature control panel for this purpose. Different switch configurations give different limit temperatures. Factory setting: - heating: max 50C Table of temperature limit dip switch positions Dip switch setting 0 0 0 0 0 1 0 1 0 0 1 1 1 0 0 1 0 1 1 1 0 1 1 1 Maximum limit (C) 50 54 58 62 66 70 74 78
0 0 0 0 0 0 0 0
ON
ON
1 2 1 2
Accessories
738
Chrono-thermostat, battery operated. With self-learning programme. Weekly programmable clock. Suitable for phone programmer. Three temperature levels. Minimum required programming: 30 minutes.
Code
738107
120 x 90 x 20 mm
Application diagram
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
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
10 8 6 4 2 0
CALEFFI
3 2 1
bar
4
20
40 60 80
5
CALEFFI
Mod. Dep.
357
mH2O
1 2 3 4 5 6
Code 1615.1 003 Modulating temperature regulating unit for heating with piping in polished copper. 3 4 M connections to primary circuit. 34 M distribution manifold outlets to radiant panels. 23 p. 1,5 connections high temperature distribution manifold outlets. Primary inlet temperature range: 5 90C. Maximum working pressure: 10 bar. Complete with: three-way ball valve; three-point servomotor, electric supply: 230 V, protection level: IP 54; radiant panel system temperature controller, power consumption 230 V, setting temperature range: 7 78C, complete with flow and return sensors; three-speed pump UPS 25-60, protection class: IP 44. Adjustable discharge valve; safety thermostat, working temperature range: 55C3C, protection class: IP 55; temperature gauge scale: 0 to 80C; pressure gauge scale: 0 to 6 bar; primary circuit shut-off valves; 5-outlet (5 to 12) flow manifold for panel systems complete with micrometric preregulation valves and drain cock; 5-outlet (5 to 12) return manifold for panel systems complete with shut-off valves suitable for thermo-electric controls and air vent valve; by-pass kit for panel system manifold, setting: 25 kPa (2500 mm w.g.); supplied pre-assembled in coated steel sheet box with lock, adjustable depth: 110 to 140 mm, complete with adjustable height 270 to 410 mm floor supports.
Code 161503 High temperature distribution kit for modulating temperature regulating unit consisting of: flow and return single sided dual manifold high temperature circuit. 3 4 F with union connections to primary circuit; 23 p.1,5 outlet connections; by-pass valve for high temperature system manifold, setting: 10 60 kPa. Maximum working temperature: 100C. Maximum working pressure: 10 bar.
CALEFFI
CONTECA direct heat meter MID directive - M-bus transmission

7554 series
IS
TERE
BS EN ISO 9001:2008 Cert. n FM 21654
UNI EN ISO 9001:2000 Cert. n 0003
01111/09 GB
Function CONTECA is a direct heat energy meter especially suited to measuring thermal consumption in residential buildings. Thanks to its double memory register, it is able to keep a record of power in both heating and air-conditioning modes (option 755810). The device comprises an electronic calculator unit, a positive displacement flow rate gauge and two temperature probes. The CONTECA meter is very easy to install and hardly requires any maintenance. The CONTECA meter flow rate gauge is the turbine type. The turbine speed is measured by means of a high-resistance protected magnetic joint. As the mechanism is inside a vacuum there is no condensation. The mechanism block nut, made of non-magnetic material, prevents all attempted tampering. The electronic technology and the materials used offer precise and reliable measurements. The high-precision NTC temperature probes are easy to seal for greater protection against tampering. The cables connecting the flow and return probes to the calculator unit are 1,9 m long. The CONTECA meter is equipped with an 8-digit liquid crystal display that can be turned on with a button, as it is normally off in order to minimise battery usage. This display enables easy reading of consumption values as well as a range of technical data to allow appliance operating status evaluation and data logging. Heat meter size 1/2 2 with union DN 65 DN 200 flanged The CONTECA meter is able to acquire three additional pulse inputs and two additional alarm-status digital inputs, and is designed for centralised remote transmission (max. 250 modules) in M-Bus mode.
Product range 7554 series
Code 755010 Touch-Screen controller Code 755055/56 M-Bus interface - Remote transmission interface 7558 series Additional options
Technical specifications Electric supply: Data transmission: Anti-tamper protection Advanced control software Conformity: 24 V (ac) - 50 Hz - 1 W in accordance with M-Bus method
Standard installation
Anno di produzione
Numero di serie
Utente
directive 2004/22/CE EN1434
CALEFFI S.p.A.
Classe ambientale: Temp. amb. 545C, E1, M1 Riscaldamento: H :1090C H : 380 K Alimentazione: 24 V (ac) - 50 Hz - 1 W IP 54 Senso di flusso: ritorno K= l/imp.
M07 1259 DE-07-MI004-PTB024
RE
PUSH
Cod. 7554 DN IDB
755810
PN
CALEFFI
Technical data
Temperature probes Flow probe length Return probe length Probe type Temperature range limits Temperature difference limits Measurement sensitivity Positive displacement portion Dimensions/Connection Body Type of hydraulic connection Nominal pressure Maximum temperature of the medium Assembly Pulse output Permanent flow rate Minimum flow rate Maximum flow rate Microprocessor calculation unit Metrological specifications Centralised transmission Ambient temperature range limits Ambient classification Thermie/refrigeration measurement unit Electric supply Protection class Pulse inputs in compliance with EN 1434-1 - MID 2004/22/CE in M-Bus mode 545 MID 2004/22/CE E1-M1 8-digit display 24 V (ac) - 1 W - 50 Hz In accordance with DIN 40050: IP 54 class IB in accordance with EN 1434-2 1/22 Brass Male with union ISO 228 Threaded PN 10 DN 65DN 200 Steel FE510 Flanged PN 16 EN 1092-1 Flanged PN 16 m m C K C 1,9 1,9 NTC 1090 (THERMIE) - 225 (REFRIGERATION UNIT) 380 (THERMIE) - 320 (REFRIGERATION UNIT) 0,05
PN
bar C
Qp Qi Qs
l/h l/h l/h
90 normally horizontal class OA-OC in accordance with E1434-2 see table 1 and 2 see table 1 and 2 see table 1 and 2
C kWh
The CONTECA heat meter is supplied with accessories for installation, probe positioning and subsequent lead sealing. TAB. 1 Flow rate limits Connections from 1/2 to 2: 2 Y pockets (the flow pocket is fitted with filter mesh)
Code 755404 755405 755406 755407 755408 755409 Connect. Meas. type Single jet 1/2 Single jet 3/4 Multi jet 1 Multi jet 1 1/4 Multi jet 1 1/2 Multi jet 2 Q i (l/h) 30 50 70 120 200 3000 Q p (mc/h) 1,5 2,5 3,5 6 10 15,5 Qs (mc/h) 1,5 2,5 3,5 6 10 15,5
TAB. 2 - Flow rate limits (m3/h) - Connection from DN 65 to DN 200: 2 sleeves, 1/2, to be welded, with brass pocket and 1 lead sealing kit
Code 755410 755411 755412 755413 755414 755415 Connect. DN 65 DN 80 DN 100 DN 125 DN 150 DN 200 Meas. type Q i (mc/h) Woltmann 1,0 1,4 Woltmann 2,0 Woltmann 3,5 Woltmann 4,5 Woltmann 8,0 Woltmann Q p (mc/h) 25, 45, 70, 100, 150 250, Qs (mc/h) 50, 80, 120, 200, 300 500,
Dimensions
165 147
PUSH
40 E
M07 1259 DE-07-MI004-PTB024
CALEFFI S.p.A.
165 147
PUSH
40 E
120
Anno di produzione
Numero di serie
Anno di produzione
Numero di serie
Utente
Utente
1/2
88
B F
1/2 B
Code 755404 755405 755406 755407 755408 755409
A 1/2" 3/4" 1" 1 1/4" 1 1/2" 2"
B 110 130 260 260 300 300
C 18 18 43 43 46 57
D 108 108 159 159 185 199
E 80 80 102 102 136 166
F 190 226 358 378 438 458
H 44 51 60 73 80 90
G 59 69 87 99 109 126
Weight (Kg)
2,8 3,2 5,2 5,5 8,5 9,5
Code 755410 755411 755412 755413 755414 755415
A DN 65 DN 80 DN 100 DN 125 DN 150 DN 200
B 200 225 250 250 300 350
C 85 95 105 118 135 162
D 205 245 255 278 312 368
E 200 200 225 270 300 375
F 34 34 25 17 17 17
Weight (Kg)
12 16 20 23 38 55
M07 1259 07185865
CALEFFI S.p.A.
M07 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
120
755810
PN
Cod. 7554 DN IDB
755810
PN
Pre-installation guidelines It is good practice to provide shut-off valves upstream and downstream of the meter in order to facilitate installation and maintenance, if required. Upstream from the flow rate gauge, it is necessary to fit a filtering device in order to protect the gauge. From diameter 1/2 to diameter 2, this filter is already inside the flow temperature pocket. After installation, it is good practice to wash the pipes and carry out a pressure test. After washing and before installing the temperature probes, it is wise to check the mesh filter saturation level. After completing the hydraulic installation you can install the electric/electronic parts. When work has been completed, qualified technicians will lead seal the electronic module and the temperature probes.
Hydraulic installation diagrams Normally the flow rate gauge should be installed on the return pipe. The hydraulic diagrams given below show: a) Positioning the gauge The flow rate gauge should preferably be installed in a horizontal position with the turbine axis vertical, respecting the flow direction indicated by the arrow on the body, and so that it is in standby when there is no service. b) Positioning the probes The temperature probes (by means of the pocket or sleeve according to the DN) must be positioned on the corresponding flow/return pipes. The corresponding flow and return pipes are understood to be the ones involved with the same flow rate when the flow has started.
1) Diagram of system with metering on manifold with several stages.
PUSH
PUSH
PUSH
M07 1259 DE-07-MI004-PTB024
M07 1259 DE-07-MI004-PTB024
CALEFFI S.p.A.
CALEFFI S.p.A.
Anno di produzione
Numero di serie
Anno di produzione
Numero di serie
Anno di produzione
Numero di serie
Utente
Utente
Utente
CALEFFI S.p.A.
M07 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
Cod. 7554 DN IDB
755810
PN
Cod. 7554 DN IDB
755810
PN
M07 1259 07185865
2) Diagram of user circuit - adjustment with 3-way zone valves.
3) Diagram of user circuit in system with 4 pipes.
THERMIE
G
System
kWh
G
kWh
REFRIGERATION UNIT
Heating unit
R.U.
H.U.
Maintenance work Filter cleaning Sometimes it will be necessary to clean the filter installed in the flow circuit in a suitable position for the protection of the flow rate gauge. By observing the instantaneous flow rate and thermal gradient values (flow rate significantly reduced in relation to the nominal user value and thermal gradient significantly increased), it is easy to work out whether the filter is saturated and then clean it as necessary.
Metering variants (systems with 4 pipes) The CONTECA system is able, after the software has been activated (see refrigeration unit option code 755810), to keep separate records of the thermie and refrigeration units. The CONTECA system also makes it possible to keep a record of thermie and refrigeration units in a four-pipe distribution system. For a 7554 series complete meter with the addition of just 1 pulse positive displacement meter code 75591. of 2 pockets code 75590. and of 2 probes code 75593. it is possible to take two complete and separate thermie/refrigeration unit measurements.
Hydraulic characteristics Positive displacement meter + pockets for probe (if threaded connection)
DN 100 DN 125 DN 150 DN 200 1 1/4" 1 1/2" DN 65 DN 80
1/2"
3/4"
p (m w.g.)
5
4,5 4 3,5 3 2,5
p (kPa)
45 40 35 30 25 18 16 14 12 9 8 7 6
1"
2"
50
1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6
20 10 5
0,5
0,45 0,40 0,35 0,30 0,25
4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2

0,6 0,7 0,8 0,9 250 300 350 400 450 120 140 160 180 1,2 1,4 1,6 1,8 2,5 3 3,5 4 4,5 25 30 35 40 45 12 14 16 18 60 70 80 90 6 7 8 9
0,25
0,18 0,16 0,14 0,12
2 1
0,1
0,5
100
200
Q (m3/h)
The dotted red line indicates the head loss (P=2 m. w.g.) for threaded connections and (p=2 m. w.g.) for flanged connections referring to the permanent flow rate (Qp).
500
50
10
20
system
system
CONTECA meter electrical connections
A
Mass meter Thermie/Refrigeration units
m3 m3 IMP
HW (domestic hot water) meter DCW (domestic cold water) meter Generic pulse meter: - gas - electric - technological or dual water Flow temperature probe RT Return temperature probe 2nd flow temperature probe (16 17) 2nd return temperature probe (15 16)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
FT RT FT2 RT2
A
Heat./Cond Polarised cable Rx
Flow temp. probe
24 V (a c)
When mounting in a box or directly on a wall, use the screws provided in the package, fixing them in the curved slots that in order to level the device correctly ( A ).
N
Zone valve status
Meter
m3
m3
PUL
Return
Return temp. probe
Tx
III Pulse
II Pulse
I Pulse
Flow
RT
Heating probes (for systems with 2 pipes)
FT
The CONTECA heat meter features various metering configurations referring to two-pipe or four-pipe and aggregated pulse acquisition systems that determine set connection positions. Two-pipe system 1) Thermie and/or refrigeration unit metering 6 7 Zone valve status* Four-pipe system 1) Thermie and/or refrigeration unit metering 6 - 7 Heating zone valve status* 7 - 8 Cooling zone valve status* 9 - 10 Heating mass meter 10 - 11 Cooling mass meter 19 - 20 Heating flow temperature probe (FT) 2) Pulse acquisition (Type OA-OC) 2.1) A single pulse meter 10 - 11 DHW or DCW 2.2) Two pulse meters 10 - 11 DHW 12 - 13 DCW 2.2) Three pulse meters 10 - 11 DHW 12 - 13 DCW 13 - 14 Generic (Ist pulse consumption) (Ist pulse consumption) 18 - 19 Heating return temperature probe (RT) 16 - 17 Cooling flow temperature probe (FT2) 15 - 16 Cooling return temperature probe (RT2) 2) Pulse acquisition 2.1) A single pulse meter 12 - 13 DHW or DCW 2.2) Two pulse meters (Ist pulse consumption) (IInd pulse consumption) 12 - 13 DHW 13 - 14 DCW (Ist pulse consumption) (Ist pulse consumption)
9 - 10 Mass meter 19 - 20 Flow temperature probe (FT) 18 - 19 Return temperature probe (RT)
(IInd pulse consumption)
(IIIrd pulse consumption)
(IInd pulse consumption)
*connection obligatory for certification
Data centralisation In the case of centralised data transmission via bus the following connection plan must necessarily be carried out: 1 - 2 3 - 5 Centralised power supply 24 V (ac) Polarised transmission bus 3 Tx (Transmission) 5 Rx (Reception) For the transmission bus, use an unshielded 2 x 1 mm2 FROR 450/750 2x1 CEI 20-2211 IMQ cable (our code 755855/N). Note: The transmission polarity must be fully observed. Energy pulse outputs, code 755881/755882 21 - 23 Remote thermie totaliser output (kWh) (Type OC) 21 - 22 Remote refrigeration unit totaliser output (kWh) (Type OC) These outputs can be connected to our code 755890 (remote energy totaliser) or a general supervisor. Output specifications: 1 IMP = 1 kWh - open collector contact Pulse duration: 120 ms Max. frequency = 1 Hz
User information cycle The heat meter is equipped with a liquid crystal display. The display is activated by pressing the button on the front . By repeatedly pressing the button briefly it is possible to scroll through the various information windows. In order to extend the battery life, the display is switched off 30 s after the probe button was last pressed.
PUSH
Heating - Energy (Thermie)
Cooling - Energy (Refrigeration units)
Carrier medium volume
1st pulse consumption
2nd pulse consumption
3rd pulse consumption
24 - 25 N/O 25 - 26 N/C Flow rate Digital inputs The digital inputs must have no potential (class IB) 6 - 7 Privileged to connect the ON/OFF status of the zone valve. For the ON times an internal register is increased by the hours of opening. General status and/or alarm input Power
7 - 8
Flow temperature
Notes: - If centralised data transmission is used, the 24 V (ac) electricity supply line should be used solely for that purpose and not directly controlled by the user. - Each 7554 series device is supplied with an anti-tamper lead sealing kit for the temperature probes and for the plastic electronics box. - Help the cables to pass through by breaking and shaping the plastic partition in the cable fairlead. The basic function of the partition is to protect the electronics card from dust and jets of water.
Return temperature
Thermal gradient
Bus network address
CKSUM
Segment test
- If the electricity mains is not connected, the following occurs: - display off but can be activated for 20 seconds each time the PUSH button is pressed.
- When the electricity mains is connected (24 V (ac)), the following occurs: - display always on - metering always enabled
Operating information The accumulated energy amounts are retrieved in a non-volatile memory device (EEPROM) each time the units of measurement are completed (1 kWh) and, at the same time, this increase causes the display to be updated (see User information cycle).
Tamper
Output relay code 755871 Relay 8 A - 230 V (ac) - 50 Hz
Test instructions The 7554 series calculator is equipped with a quick output test feature, located inside the plastic container. In order to access this, remove the seal and take out the fixing screws. The electronics card on the deepest level has a button on the very edge of the right-hand side (fig. 1) which can be used to select the technical menu. The pulse input can be simulated by connecting pins 9 - 10 (fig. 3). The maximum input frequency is 1 Hz.
(fig. 3)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
(fig. 1)
A
Heat./Cond
Return temp. probe Flow temp. probe
Polarised cable Rx
24 V (ac)
Meter
m3
Tx
III Pulse
II Pulse
I Pulse
m3
PUL
Return
Flow
RT
Heating probes (for systems with 2 pipes)
FT
The probes, which are absolutely inseparable from the electronics circuit, may be placed in a thermostatic bath, observing the temperature range 1090C and taking into account a T of between 380 K. Use the button (push) on the display front panel to scroll through the screens. The unit of measurement for the energy - test is Wh (fig. 2). The energy increases on the basis of the following equation: E =
(fig. 2) d - Date (DD.MM.YY)
= heat coefficient [kJ/m3K]
TV0,277769810-3 [Wh]
t - Time (hh.mm)
V = NP where N = number of pulses P = pulse value for each litre If the errors, after the metrological checking of the CONTECA meter in the 7554 series, are greater than the max. permitted value, the product should be sent to the Caleffi S.p.A. head office; 28010 Fontaneto dAgogna; S.R. 229 n 25; ITALY, for metrological requalification.
T = temperature variation [K] V = volume variation [ l ]
E1+ - Thermie - Test
E1- - Refrigeration units - Test
Operating specifications 1) The software used to control the metering process, in order to avoid unnecessary action or unwanted metering procedures, operates on the principle that consumption processing depends on a specific flow temperature value (FT). The thermie cycle is activated for a FT value >22C (factory set). The refrigeration unit cycle is activated for a FT value <15C (factory set). The set values may be modified by an authorised technician on request. 2) The software used to control the metering process also operates on the principle that consumption processing depends on the presence of a minimum temperature difference in order to further safeguard against unnecessary measurements or minimal unwanted metering deriving from natural dispersion. At the time of factory setting, a dead band of 0,4 K (factory set) is therefore defined. 3) The software used to control the metering process also works on the principle that the flow rate gauge is installed on the return pipe. Authorised technicians can, on request, adapt the configuration set so as to position the gauge on the flow pipe.
DATA CENTRALISATION
Architecture of centralisation - It is understood that every individual may have a specific idea relating to the complexity of the system and personal expectations. - It is also understood, for this very reason, that in general there is no divine law governing the drafting of a particular architecture. It is therefore true to say that an increase in the number of users, combined with the application of a centralised system, will necessarily increase the complexity of this system. In order to distinguish between a normal system and a complex system, you could argue that a centralised system with over 25 users could be a complex system which, for many obvious management-related reasons, practically requires continuous monitoring. Therefore, if the distinction made can, in principle, be perceived as correct, you can establish the following: WORKS for a NORMAL SYSTEM - Metering system - Laying down central power supply - Laying down transmission bus (code 755855/N) - Using FAST INTERFACE (code 755055) alternatively: - Using FAST/REMOTE INTERFACE (code 755056) - Using modem (code 755845 - 755846) WORKS for COMPLEX SYSTEMS (25 users or more) - Metering system - Laying down central power supply - Laying down transmission bus (code 755855/N) - Using CONTECA controller (code 755010) - Using GSM modem (code 755846) - Using data breakdown software (code 755830) and as an option - Individual user control (code 755871)
(A) Controller (max no. of 250 users)
PUSH
PUSH
DE-07-MI004-PTB024
CALEFFI S.p.A.
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
76072
Utente
Utente
76072
CALEFFI S.p.A.
DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
M08 1259
Cod. 7554 DN IDB
755810
PN
M08 1259
755010
755846
GSM
CALEFFI
230 V ~
PUSH PUSH
Controller
CALEFFI S.p.A.
DE-07-MI004-PTB024
Anno di produzione
2008
Numero di serie
CALEFFI S.p.A.
Anno di produzione
2008
Numero di serie
76072
Utente
Utente
76072
DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
M08 1259
Cod. 7554 DN IDB
755810
PN
M08 1259
Remote acquisition
(B) Interface Fast (max no. of 30 users)

Data centralisation Le soluzioni (A), (B) e (C) di centralizzazione solutions (A), (B) and dei datialternatives sono una in (C) are to alternativa alle altre. one another
PUSH
PUSH
DE-07-MI004-PTB024
CALEFFI S.p.A.
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
76072
Utente
Utente
76072
CALEFFI S.p.A.
DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
M08 1259
Cod. 7554 DN IDB
755810
PN
M08 1259
755055
FAST FAST-TELE AQUAPRO
Cod. 755055 Cod. 755056 Cod. 755060 Cod. 755500
24 V ~
230 V ~
Contatti Rel 4 x 8 A - 250 V Sonde temp. 0 90C
Alimentazione elettrica: 230 V (ac) - 50 Hz - 10 W
Togliere lalimentazione prima di aprire la scatola
76049
Tamb. : 545C
IP 54
Attenzione: Componenti in tensione
Fast Bus transmission line 2-way x 1 mm2 (755855/N) 24 V ~ centralised electric supply line
Local acquisition
N.B.: The transmission bus code 755855/N is a 2-way device (section 2 x 1 mm2). The controller allows a maximum of 250 users. The laying methods are in accordance with tree distribution (star). The maximum length of each individual section is 1200 m. It is possible to lay up to a maximum of 4 separate sections, using code 755005.
PUSH
PUSH
PUSH
DE-07-MI004-PTB024
DE-07-MI004-PTB024
CALEFFI S.p.A.
CALEFFI S.p.A.
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
76072
76072
LN
76072
Utente
Utente
Utente
CALEFFI S.p.A.
DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
M08 1259
Cod. 7554 DN IDB
755810
PN
M08 1259
Cod. 7554 DN IDB
755810
PN
M08 1259
7554..
PUSH PUSH
755810
PUSH
DE-07-MI004-PTB024
DE-07-MI004-PTB024
CALEFFI S.p.A.
CALEFFI S.p.A.
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
76072
76072
LB
L2
PUSH
PUSH
76072
Utente
Utente
Utente
PUSH
DE-07-MI004-PTB024
DE-07-MI004-PTB024
CALEFFI S.p.A.
CALEFFI S.p.A.
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
76072
76072
76072
Utente
Utente
Utente
CALEFFI S.p.A.
DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
M08 1259
Cod. 7554 DN IDB
755810
PN
M08 1259
Cod. 7554 DN IDB
755810
PN
M08 1259
CALEFFI S.p.A.
DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
M08 1259
Cod. 7554 DN IDB
PN
M08 1259
Cod. 7554 DN IDB
755810
PN
M08 1259
LA
1 Section
2 Section
3a Section
L1
LA + LB + ... + LN + L1 + L2 < 1.200 m
4a Section
Controller cod. 755010
ELECTRIC-ELECTRONIC OPTIONS
7550 CONTECA
controller
- Electric supply: 230 V (ac) 10% - 50 Hz - 60 W. - Ambient conditions 1035C with no dust. - Maximum number of users: 250. Includes: - 1 touch-screen CPU - 1 wall-mounting bracket The controller has the following feratures: - 1 touch-screen LCD monitor for viewing consumption and user data. - 1 RS232 port - 1 RS485 port - 2 USB ports - 1 LAN port
755871 OUT device

In centralised transmission and CONTECA controller mode (code 755010 ) the heating / cooling function can be activated / deactivated remotely via SMS for every individual user. Relay out specifications: 8 A - 230 V (ac) - cos = 1. MANAGER version - connection in SERIES Residences and hotels are particularly suitable types of users.
Terminal 25 - 26
PUSH
PUSH
M07 1259 DE-07-MI004-PTB024
CALEFFI S.p.A.
Anno di produzione
Numero di serie
Anno di produzione
Numero di serie
Utente
Utente
CALEFFI S.p.A.
M07 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
Cod. 7554 DN IDB
755810
PN
CALEFFI
SERIES 7554 . . 755871 739107
BUS line
The function of the controller is to acquire, via bus, all the totalised values of the individual users (thermie / refrigeration units / mass / hours of opening of the zone valve), consumer operating status (ON/OFF), totalised values from the additional pulse meters (domestic cold/hot water) and operational diagnostics. All the above-described totalised values are recorded on a daily basis in log files that are useful for consumption analysis and cost breakdown. The remote transmission and print software for consumption data is supplied with the product.
F N
~ 24V (ac)
123456
646002
755845
external 56 K analogue modem
USER version - connection in PARALLEL Holiday homes are a particularly suitable application.
External 56K analogue modem includes: - 230 V (ac) - 50 Hz - 10 W power supply unit - Telephone cable - Serial cable - Quick start guide for the installation of the drivers with CD-ROMs. - RS232C serial port interface / Standard V.92 Activating remote transmission via modem makes it possible to transfer the log files, over a telephone line, onto a remote personal computer.
Terminal 25 - 26
PUSH
PUSH
M07 1259 DE-07-MI004-PTB024
CALEFFI S.p.A.
Anno di produzione
Numero di serie
Anno di produzione
Numero di serie
Utente
Utente
CALEFFI S.p.A.
M07 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
Cod. 7554 DN IDB
755810
PN
CALEFFI
PARALLEL 7554 . . 755871 739107
755846
Digital GSM modem

F N
BUS line
The GSM modem is a dual-band GSM900/1800 device which is capable of managing AT Modem commands. It is an external device and includes: - Power supply unit with input 230 V (ac) 50 Hz - 3 VA / Output 8-30 V (dc) - Mini Sim card reader (Sim card NOT supplied) - FME-F antenna connector for antenna cable - Antenna cable: standard length 2 m - 9-pole sub-D female connector V.24/V.28 for RS 232C serial port output Operating specifications: - Dual-Band GSM900 and GSM1800 - GSM compatible phase 2/2+ Output power: - Class 4 (2W) GSM900 - Classe (1W) GSM1800 SMS specifications: - Point to Point Mobile Originated - Point to Point Mobile Terminated - SMS Cell Broadcast
~24V (ac)
The modem is supplied with an activation request module. It the customers responsibility to activate the SIM card. Activating remote transmission via modem makes it possible to transfer the log files, over a telephone line, onto a remote personal computer and to send activation / deactivation SMS messages.
123456
646002
In this regard, entering a database of enabled phone numbers for a specific user on the controller is the users security code. It is possible to add up to 3 enabled cellphone numbers.
ID 1 2 3 ....
TEL. 1
TEL. 2
TEL. 3
Any change in the enabled phone numbers can only be made by technical personnel authorised by the system manager (Administrator - Service - Certifier).
755830
Software for the breakdown of costs relating to heat consumption
75588.
Pulse output
The software can be used to transfer or manage log files containing consumption data; these log files are transferred as necessary onto an office PC to produce a printout of consumption and heating cost breakdown (thermie and refrigeration units), as well as any additional consumption (domestic water/electricity/gas). The reports are generated in Windows. N.B.: A comprehensive installation and user guide manual is an aid to performing the various operational steps.
The pulse output can be used to transfer the thermie and/or refrigeration unit energy values to a generic acquirer. The pulse weighs 1 kWh. The pulse output with no potential is an open collector with pulse period 120 ms - Vmax 24 V (dc).
Code
755881 Single pulse output - THERMIE 755882 Double pulse output - THERMIE/REFRIGERATION UNITS
PUSH
M07 1259 DE-07-MI004-PTB024
CALEFFI S.p.A.
Anno di produzione
Numero di serie
Anno di produzione
Numero di serie
Utente
Utente
755881
Consumption certification The natural difficulties in starting up a centralised system suggest it is wise to rely on a competent SERVICE, monitoring the first year of operation and then hopefully confirming this service for future years. Relying on a competent service means: - Having installed a centralized transmission system (controller code 755010 and modem, GSM code 755846). - Formally providing the service company with consent for the processing of your personal data. and therefore: - On request, Caleffi (via a regional service) offers FREE monitoring of consumption data for the first year of operation. - Caleffi sends monthly reports on the CERTIFIED consumption to the administration manager of the complex. At the end of the first year of operation, Caleffi, through its own regional services, offers product service and consumption certification contractors in times and manners to be defined.
755882 7554 . .
7554 . .
Monitoring acquisition sheet
755890
Remote energy totaliser
Electronic 8-digit LCD totaliser equipped with cover plate for three-slot recessed electric box. Lithium battery: duration 8 years - max. frequency 20 Hz Suitable for pulse outputs code 75588.. Cable length (2x1 mm2) not supplied by us: max. 150 m.
CALEFFI
3 4 0V
23 Thermie 22 Refrigeration
units
ENERGIA kWh
21
The CONTECA system offers many options: some are dictated by the plant engineering system (thermie/refrigeration units), others are suggested by the presence of a central transmission bus (pulse aggregation for other consumption data), others are for management (user status) with user enabling/disabling.
755825
Pulse input acquisition generic
755810
Refrigeration unit metering
The CONTECA meter, once the software module has been activated, is able to keep a record of the thermie and refrigeration units in separate registers through the evaluation of the thermal gradient inversion, both for current values and for log files.
The CONTECA module can, through the application of Hardware/Software code 755825, acquire an additional pulse input (as well as the 2 already dedicated to DHW and DCW). Sometimes, and normally when there is a controller (code 755010, it is beneficial to use the bus to transfer the user data in terms of consumption (gas meter / electricity meter). The generic pulse input must have no potential (no voltage, maximum frequency 1 Hz). Class IB. Residences and hotels are particularly suitable types of users.
CALEFFI S.p.A.
M07 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
Terminal 21 - 23 Thermie
Terminal 21 - 23 Thermie Terminal 21 - 22 Refr. units
PUSH
Cod. 7554 DN IDB
755810
PN
7554 series CONTECA direct heat meter conforming to directive 2004/22/CE (MID) for use in heating and air-conditioning systems, with the following characteristics: hot water positive displacement meter with magnetic joint (maximum temperature 90C), with pulse output, NTC temperature probe, 8-digit data display, temperature range 1090C, protection class IP 54, transmission via TWO-WAY bus in accordance with M-bus mode, electric supply 24 V (ac) 50 Hz - 1 W. Designed for remote activation of user services. Options: 3 additional pulse inputs - 2 voltage-free digital inputs for status/alarm - 1 relay output. Code 755010 Compact touch-screen CONTECA controller, equipped with RS232 - RS485, USB and LAN ports, with user monitoring function (max. 250) and daily logging of consumption data. Enabled for SMS message alarm and remote activation management, and for automatic transmission of data via email and FTP server. Electric supply 230 V (ac). Code 755055/755056 HW-SW interface for consumption data acquisition via digital transmission, in M-Bus mode. Electric supply 230 V (ac) 50 Hz - 5 VA. Includes software. Maximum number of users: 30. Code 755056 is designed for transmission via analogue/digital modem code 755845/755846. Ambient temperature range 1035C. Dimensions: width 160 mm x height 125 mm x depth 40 mm. 7940 series User domestic water cut-off for centralised system with user module featuring direct local reading meter, consisting of: 1/2 (3/4) direct reading positive displacement meter, BALLSTOP ball shut-off valve with incorporated check valve, ball shut-off valve with male terminal, fixing screws and collars. 7941 series User domestic water cut-off for centralised CONTECA system consisting of: 1/2 (3/4) positive displacement meter with pulse output (K=10), BALLSTOP ball shut-off valve with incorporated check valve, ball shut-off valve with male terminal, fixing screws and collars. 7930 - 7931 series User domestic water cut-off for centralised CONTECA system. 7930 series with direct local reading meter. 7931 series with positive displacement meter with pulse output (K=10). Consist of: pair of BALLSTOP ball shut-off valves with incorporated check valve, pair of 1/2 (3/4) positive displacement meters with/without pulse output, thermostatic mixing valve, fittings. Code 755810 Refrigeration unit metering. Upon activation of the software module, CONTECA is able to keep a record of the thermal units and refrigeration units, on the evaluation of the temperature difference reversal, in separate registers for both the current values and for the logged files. Code 75588. The single pulse output code 755881 or the double pulse output code 755882 can be used to transfer the thermie and/or refrigeration unit energy values to a generic acquirer. The pulse weighs 1 kWh. The pulse output with no potential is open collector with pulse time 120 ms - Vmax 24 V (dc). Code 755890 Electronic 8-digit LCD totaliser equipped with cover plate for three-slot recessed electric box. Lithium battery: duration 8 years - maximum frequency 20 Hz. Suitable for pulse outputs code 75588.. Cable length (2x1 mm2) not supplied by us: maximum 150 mm.
CERTIFICATION OF EVALUATION PROCEDURE FOR CONFORMITY TO DIRECTIVE 2004/22/EC (MID directive)
CONTECA 7554 series

With reference to CONTECA 7554 series heat meters, please note that the procedure for conformity to the requirements of directive 2004/22/EC, better known as the MID (Measuring Instruments Directive), has been completed. This directive has been made binding in Italy by means of Italian Law Decree N 22 dated 2nd February 2007, which makes it obligatory to use only meters that conform to the MID within the Italian market.
Typical examination certificate (in accordance with form B - MID directive)
Certificate of conformity for production process (in accordance with form D - MID directive)
CALEFFI
Motorised zone valves Z-one

series 642 - 643
cert. n 0003
CALEFFI
ISO 9001
01115/04 GB
Function The zone valves allow the automatic shut-off of circuits in heating and air conditioning systems. The series 642 (two-way) and 643 (three-way) zone valves are equipped with a spring return actuator with a synchronous motor and auxiliary microswitch. They are therefore extremely versatile and suitable for use in both heating and air conditioning systems. The actuator is fitted with a mechanism for rapidly clipping it onto the body of the valve which also makes it easy to remove.
Product range Series 642 Two-way motorised zone valve Series 643 Three-way motorised zone valve sizes: 1/2; 3/4 and 1 sizes: 1/2; 3/4 and 1
Technical specification Valve body Materials: - body: brass, EN 12165 CW617N - paddle stem: stainless steel - paddle: EPDM Medium: Max. percentage of glycol: Temperature range: Peak temperature of fluid: Max. working pressure: Connections: Actuator Materials: - base and cover: PC G10 Synchronous motor: Normally closed Supply: 230 V - 50 Hz Power consumption: 6,5 W; 7 VA Opening time: 70 75 s Closing time: 57 s Microswitch contacts rating: 0,8 A Protection class: IP 40 Max. ambient temperature: 40C Complies with Directives: 73/23/EC and 89/336/EC Length of power cable: 95 cm water, gycol solutions 30% 0 90C 110C 16 bar 1/2, 3/4, 1 F
Dimensions
( NC)
(NC) A
B (NA) AB
A B
Code
C 24 24 24
D 90 94 94
W eight (kg)
Code
Weight (kg)
642 042 1/2 78 642 052 3/4 78 642 062 1 88
0,97 0,98 1,10
643042 1/2 78 643052 3/4 78 643062 1 88
31,5 90,5 1,03 31,5 94,5 1,05 46,5 94,5 1,20
Operating principle With the electrical supply off, the actuator keeps the valve in the closed position. When an ambient temperature thermostat or other electrical device switches the supply on, the actuator moves the paddle into the open position. When the supply is turned off, the valve closes again due to the action of a return spring.
Construction details Auxiliary microswitch The actuator is fitted with a microswitch to operate devices such as, for example, a circulating pump. The microswitch comes on when the valve is 60% open. Manual opening The valve can be opened manually by moving the lever to lock open position. When the power is re s t o red the manual control is automatically overridden. Clip on actuator A rapid clip-on system makes it easy to remove it from the body of the valve for maintenance or replacement operations. Warning: the actuator can only be used with valve bodies 642 and 643 series. Operation The actuator is fitted with a special mechanism for gradual movement of the valve paddle which prevents judder and vibration due to the inertia of the gearmotor.
Valve operating states 2 way

With supply off Passage A closed
3 way
A closed B open AB open A open B closed AB open A open B open AB open
With supply on
Passage A open
Opened manually
Passage A open
642 series 2-way zone valve
Flow curves
P (mm w.g.)
4000
3000 30
1/2
3/4
1 P ( kPa)
40 20 10 5
2000 1800
1600 1400 1200 900 800 700 600
1000 500
NC) ( A
18 16 14 12 9 8 7 6
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
0,4 0,3
30
20 10
18 16 14 12
0,18 0,16 0,14 0,12
0,2 0,1
G (l/h) P (mm w.g.)

4000
1/2
3/4
1 P ( kPa)
40
30
643 series 3-way zone valve
3000
2000 1800
1600 1400 1200 900 800 700 600
A NC ) (
1000
B ( NA ) AB
18 16 14 12 9 8 7 6
20 10
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
20
18 16 14 12
0,18 0,16 0,14 0,12
0,2 0,1
10
G (l/h)
Connection
1/2 3/4 1
Kv (m /h) (2-way) (3-way) 2,5 2,5 4,5 4,5 6 6

3
Max. differential pressure (kPa) 210 150 100
AB
Installation - The valve can be fitted either vertically or horizontally, with the actuator in any position, except upside down.
360
Removal of the actuator 1. Set the lever on the side of the actuator to the open position (or to manual opening). 2. Press the open button on the side of the actuator and remove the actuator.
- When installed inside a casing it is important to ensure that there is adequate ventilation inside the casing itself. - The three-way valve cannot be transformed into a two-way valve and vice versa. - When zone valves are installed, the correct direction of flow must be observed as shown in the diagrams below. - Two-way zone valves can be installed on both the flow and return sides; the direction of flow indicated by the arrow on the body of the valve must be observed. Fitting of the actuator 1. Set the lever on the side of the actuator to the open position (or manual opening). 2. Check that the actuator is correctly positioned with respect to the valve as determined by the different dimensions of the operating stem and the locking pin. 3. P ress the open button fully down. Clip on the actuator and release the button.
(NC)
2-way (with the power off, passage A is closed)
2-way installed on the flow side
2
2-way installed on the return side
Electrical connections
3-way (with the power off, passage A is closed)
3-way installed on the flow side with diverter position and ON/OFF services
Thermostat
L N
230 V / 50 Hz
A AB
1 Brown 2 Blue 3 Grey 4 Orange 5 Yellow/Green
(NC)
A AB
B (NO)
M
3-way installed on the return side with mixer position and ON/OFF services
A AB
AB
Application diagrams diagram Application

Shut-off valve Manual valve Electric pump
RT
RT
Room thermostat Check valve Insulated manifold Differential by-pass Adjustable differential by-pass
Zone system
RT
RT
CHILLER
Two-pipe system
Series 642 Two-way motorised zone valve. Threaded connections 1/2 F (from 1/2 to 1). Brass body. Valve stem in EPDM. Cover in reinforced polycarbonate. Temperature range: 0 90C. Peak temperature of fluid: 110C. Maximum working pressure: 16 bar. Maximum differential pressure: 210 kPa (1/2: 210 kPa, 3/4: 150 kPa, 1: 100 kPa). Maximum percentage of glycol: 30%. Actuator: Voltage 230 V (ac). Power consumption: 6,5 W; 7 VA. Maximum ambient temperature: 40C. Opening time: 70 75 s. Closing time: 5 7 s. Fitted with auxiliary microswitch, contacts rating: 0,8 A. Protection class: IP 40. Series 643 Three-way motorised zone valve. Threaded connections: 1/2 F (from 1/2 to 1). Brass body. Valve stem in EPDM. Cover in reinforced polycarbonate. Temperature range: 0-90C. Peak temperature of fluid: 110C. Maximum working pressure: 16 bar. Maximum differential pressure: 210 kPa (1/2: 210 kPa, 3/4: 150 kPa, 1: 100 kPa). Maximum percentage of glycol: 30%. Actuator: Voltage 230 V (ac). Power consumption: 6,5 W; 7 VA. Maximum ambient temperature: 40C. Opening time: 70 75 s. Closing time: 5 7 s. Fitted with auxiliary microswitch, contacts rating: 0,8 A. Protection class: IP 40.
CALEFFI
CALEFFI S.P.A. I 28010 FONTANETO DAGOGNA (NO) S.R. 229, N.25 TEL. +39 0322 8491 FAX +39 0322 863723 H t t p : / / w w w. c a l e ffi.com E-mail: info@caleffi.it
Ice detection and control system
CALEFFI
series 605 01117/04 GB
Function The control unit detects the presence of ice and snow by a sensor that measures outside temperature and relative humidity. There are two types of sensor: - code 605010 and 605020 suitable for open spaces such as garages, parking places, steps, footpaths or loading ramps; - code 605030 used for gutters, flat roofs or dish antennas. Once the risk of ice formation has been detected, the unit is capable of switching on heating devices for the surfaces at risk.
Product range Code Code Code Code 605000 605010 605020 605030 Control unit for detecting ice/snow Temperature and relative humidity sensor for open outdoor areas with 6 metre cable Temperature and relative humidity sensor for open outdoor areas with 20 metre cable Temperature and relative humidity sensor for gutters, flat roofs and dish antenna with 6 metre cable
Technical specification Control unit Electric supply: Power consumption: Outlet terminal: Max. ambient temperature: Insulation test: Protection class: 230 V 6% - 50 Hz 10 VA 230 V - 6 A -- with zero voltage 50 C 4 kV II (after proper installation on the bar to DIN 43880 Sensors Working temperature range: Protection class: Cable length: -30 80C IP 68 - 605010: 6 m - 605020: 20 m - 605030: 6 m all extendable up to 50 m The cable used is oil sealed of the type SL-Y11Y to DIN VDE 0472/9.21 Abs. 8036.
Dimensions A
TEST
-15 -20 -25 -10 40 30
50 60
-1 -2 -3 5
3 4
2 1 5 + UMIDITA
TEMPERATURA
RISCALDAMENTO
RETE
CALEFFI
T50 6(2)A 230V 10VA 50 Hz
C B
-5
90
1 - Temperatura minima 2 - Durata attivazione
A B 88 C 60
C Code A 605010 68 605020 68
E B 5 5 C 31 31
G D E F 51 55 67 51 55 67 G 24 24
Code 605000
A 107
Weight (kg)
0,38
Code 605030
A 150
B 16
C 32
Control unit functions
Sensor functioning
1
-15 -20 -25 -10
3
50 40 30
10
The sensors measure ambient temperature and relative humidity. code 605010 and 605020 code 605030
60
-5
90
1 - Minimum temperature 2 - Operating time
TEST
CALEFFI
0 -1 -2 -3 5 1 2 3 4 1 5 + HUMIDITY 2 3 4
T50 6(2)A 230V 10VA 50 Hz
TEMPERATURE
HEATING
POWER
TFTFFF FF
SH L L N
Two heat sensors are located inside the sensor units completely embedded in protective polymer: - an NTC which measures temperature; - a hybrid PTC with a metallic electrode (more reliable than sensors that are normally used which can become dirty, corroded or short circuit) which measures relative humidity. The sensors function in combination with the control unit as follows: 1) the sensor detects a temperature lower than that set with selector 4; 2) the sensor itself heats to melt ice or snow that may be present; 3) after 4 minutes the sensor measures the relative humidity as a function of the change in the consumption of current; 4) if the relative humidity measured is higher than the value set by selector 5, the heating is switched on because two determining conditions are both met (low temperature and high relative humidity); 5) the heating remains on for the time set using selector 2. 6) the sensor repeats the following two checks of the environment 5 minutes before the heating is switched off: a) if the conditions are the same, the heating remains on for another cycle; b) if the temperature or the relative humidity have returned to normal levels the heating switches off at the end of the period set using selector 2.
1. Minimum working temperature The temperature setting range is from -5 to -25C. Recommended: -15C. The selector is for setting the temperature at which the unit stops functioning temporarily. 2. Heating time Setting range: from 30 to 90 minutes. The time set is the minimum that the heating will operate for (outlet SH on the terminal board). 3. Temperature The LED comes on if the sensor detects a temperature lower than that set with selector 4. If this occurs, the sensor is ready to measure the relative humidity as indicated in the paragraph Sensor Functioning. 4. Maximum working temperature The temperature setting range is from -3 to +5C. Recommended: +4C. The selector is for setting the temperature at which the unit stops functioning temporarily. 5. Sensitivity of relative humidity sensor Setting range: from 1 to 5. Recommended: 4. The sensitivity of the ice and snow detection system is lowest when set on 1. This means that the sensor must be very wet to detect the presence of humidity. On position 5, instead, it is very sensitive. 6. Humidity The LED flashes when the humidity is higher than the value set with selector 5; it only flashes if the LED 3 Temperature is on. 7. Heating The LED comes on when the heating is switched on. 8. Power The LED is green and comes on when power is supplied to the regulator. 9. Heating sensor The LED is red and comes on when the sensor for measuring the relative humidity is operating. 10. Test button The test button is used to switch the heating on regardless of the real ambient conditions (LED 7 on). If a yellow LED (No. 6) starts to flash during the test period, then a fault has occurred in the humidity sensor.
Table of control unit and heating operation Temperature outside the range 15C +4C within range 15C e +4C with low RH% within range 15C e +4C with high RH% Control unit state temporarily off on Heating state off
off
on
on
Wiring diagram of the detector system

-15 -20 -25 -10 40 30 50 60
-5
90
TEST
CALEFFI
0 -1 -2 -3 5 1 2 3 4 1 5 + HUMIDITY 2 3 4
T50 6(2)A 230V 10VA 50 Hz
TEMPERATURE
HEATING
POWER
TFTFFF FF
SH L L N
code 605010 605020
230 V heating control
code 605030
Installation Warning: a control unit can be connected to one sensor only. Instructions for the 605010 and 605020 code sensor installation. The cable enters the bottom part of the sensor. The sensor must be fitted in a special embedded brass housing supplied with it (see diagram) which allows easy fitting and replacement if necessary. It is recommended that the sensor is located where low temperatures and humidity are most probable such as in shaded places. The sensors must be installed as illustrated in figures 1 and 2 so that the surface of the sensor is flush with the surface of the ground. If the sensor is fitted on ramps or sloping surfaces they must be positioned horizontally so that snow or melted water is trapped by them.
Heating cable Sensor
Instructions for the 605030 code sensor installation Position the sensor at the centre of the gutter using the screws supplied (warning the thread of the screws must not be longer than 10 mm). The sensor must be fitted on the drilled metal support supplied which is clipped into the gutter or surface to be controlled, preferably close to the outlet of the gutter itself. If it is fitted on a dish antenna, it should be fitted horizontally on the lower flat part. The heating cable must be fitted on the back of the dish and fixed with the adhesive clip (607120 code). Warning: too much mechanical pressure on the surface of the sensor may damage it.
Adhesive clip Gutter sensor Clip Heating cable
1
Ramp heating using heating cable
Ramp heating using underfloor radiant panels
It is recommended that the sensor is positioned where the tyre treads pass
40 20 60 80 100 20 40 60 80 100
CALEFFI
100% 80%
19
18
17
16
15
25% 50%
55%
20
21
12
50
13
60
70 80 90 -25% +25%
40 30
WATCH
152 series Temperature regulating unit

-20 -25
14
22
-15 -10 40 30
50 60
24
23
12
11
10
163 series Thermostatic regulating unit

40
20 60 20
6
7
-50%
-5
90
TEST
559 series Sepcoll

-1
CALEFFI
0 -2 -3 1 2 3 4 5 1 5 + HUMIDITY 2 3 4
T50 6(2)A 230V 10VA 50 Hz
TEMPERATURE
HEATING
POWER
-15 -20 -25 -10 40 30
50 60
-5
90
TEST
CALEFFI
0 -1 -2 -3 5 1 2 3 4 1 5 + UMIDITA 2 3 4
T50 6(2)A 230V 10VA 50 Hz
TFTFFF FF
SH L L N
TEMPERATURA
RISCALDAMENTO
RETE
40
60
80
80
230 V
pump control
-15 -20 -25 -10 40 30
50 60
-5
90
TEST
CALEFFI
0 -1 -2 -3 5 1 2 3 4 1 5 + UMIDITA 2 3 4
T50 6(2)A 230V 10VA 50 Hz
TEMPERATURA
RISCALDAMENTO
RETE
Code 607100 Universal fitting for heating cable
-15
50 -10 40 30 60
Clips Gutter sensors Heating cable
-20 -25
-5
90
TEST
CALEFFI
0 -1 -2 -3 5 1 2 3 4 1 5 + HUMIDITY 2 3 4
T50 6(2)A 230V 10VA 50 Hz
TEMPERATURE
HEATING
POWER
TFTFFF FF
SH L L N
230 V
heating control
Code 605000 Control unit for detecting ice. Power: 230 V. Rated output: 10 VA. Maximum ambient temperature: 50C. Protection class II.
Code 605010 Sensor for outdoor areas. 6 metre cable extendable to 50 m. Protection class: IP 68. Working temperature range: -30C to 80C.
Code 605020 Sensor for outdoor areas. 20 metre cable extendable to 50 m. Protection class: IP 68. Working temperature range: -30 to 80C.
Code 605030 Sensor for gutters, roofs, and dish antennas. 6 metre cable extendable to 50 m. Protection class: IP 68. Working temperature range: -30 to 80C.
CALEFFI
Radio wave temperature control systems

740 series
cert. n 0003
CALEFFI
ISO 9001
01118/05 GB
Function Over the last decade, technology has entered our homes with increasingly more advanced audio/video systems and electrical appliances. The new frontier is represented by the evolution of technical systems owing to legitimate expectations of more comfortable, safer and more flexible household systems. Household automation via the development of the RADIO SYSTEM permits easily integrating household management and control products and services. Within this framework, the radio wave temperature control system is a significant application: easy to adjust temperature room by room straightforward installation modular integration full freedom with interior decoration
Product range 740 series Radio wave temperature control 740000 code Radio chrono-thermostat 740201 code Radio thermostat 740100 740101 740104 740202 code code code code Wall-mounting receiver Concealed receiver Wall-mounting receiver Wall-mounting receiver 1 channel 1 channel 2 channels 8 channels 740204 code Power bar 740206 code Power bar 740208 code Power bar 740102 code 740103 code 740112 code 740113 code Timer + wall-mounting receiver kit Timer + concealed receiver kit Timer + wall-mounting receiver + servomotor kit 646002 code Timer + concealed receiver + servomotor kit 646002 code 4 channels 6 channels 8 channels 1 channel 1 channel 1 channel 1 channel
Typical installations
230 V
1 2 3 4 5 6
t1 t2 t3
0 2 4 6 8 10 12 14 16 18 20 22
t1/t2/t
ON H2O
OFF
- t1 - t2
CALEFFI
1 2 3 4 5 6
t1 t2 t3
t1/t2/t
ON OFF H2O
- t1 - t2
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
ON
ON
ON
230 V
RESET
CALEFFI
RESET
CALEFFI
Mod. Dep.
356
Technical specifications Weekly digital chrono-thermostat with radio transmitter (740000 code) Power supply: 2 x 1,5 V alkaline penlight Operating time: 1 year Frequency: 868,35 MHz Maximum range in free air: 120 m Antenna: integrated Contact capacity: 5 (2) A / 250 V Installation: wall mounting Protection rating: IP 30 Insulation class: III Control input for telephone programmer code 739000 Temperature levels: 2 + antifreeze Reference standards: LVD EN 60 730-1 EMC EN 301 489-3 RADIO EN 300 220-3 Dimensions: 120 x 80 x 18 mm
1 2 3 4 5 6
t1 t2 t
0 2 4 6 8 10 12 14 16 18 20 22
t1/t2/t
ON OFF H2 O
- t1 - t2
CALEFFI
Programming: minimum 30 min Manual function - Temporary function - Receiver coupling test function - ON/OFF operation with adjustable differential from 0,2 to 0,7C.
Wall-mounting receiver: Power supply: Contact capacity: Output type: Reception frequency: Protection rating: Insulation class: Maximum range in free air: Reference standards:
1 channel (740100 code) 2 channels (740104 code) 230 V - 50-60 Hz 5 (2) A / 250 V free contact on switching 868,35 MHz IP 30 II 130 m LVD EN 60 730-1 EMC EN 301 489-3 RADIO EN 300 220-3
Dimensions: 132 x 90 x 25 mm
ON
CALEFFI
1
RESET
Recess-mounting receiver for plastic consumer box: Power supply: Contact capacity: Output type: Protection rating: Insulation class: Maximum range in free air:
1 channel (740101 code) 230 V - 50-60 Hz 5 (2) A / 250 V N/O free contact IP 30 II max 120 m
ON
RESET
Thermostat with radio transmitter (740201 code) Power supply: 2 x 1,5 V alkaline penlight Operating time: 1 year Frequency: 868,35 MHz Maximum range in free air: 130 m Operation: ON/OFF with differential that can be set from 0,3C to 0,6C Protection rating: IP 30
ON
CALEFFI
8-channel wall-mounting receiver (740202 code) Power supply: Input: Max bus length: Reception frequency: Signal range in free air: Protection rating: Insulation class: 18 V (via control bar) 1 VA 100 m (2 x 0,5 mm2) 868,35 MHz max 120 m IP 30 II
1 2 3 4 5 6 7 8
ON
CALEFFI
RESET
Power bar:
4 outputs + aux (740204 code) 6 outputs + aux (740206 code) 8 outputs + aux (740208 code)
Power supply: Input: Output type:
230 V - 50-60 Hz 5,5 VA maximum (8 outputs) relay with single-pole switchover contact - Polarized N/O-N/C - 8 (2) A / 250 V Auxiliary output type: relay with single-pole switchover contact potential-free N/O-N/C-COM - 8 (2) A / 250 V Maximum total load 8 outputs: 16 A Protection rating: IP 52 (with rubber cable clamps) Insulation class: II Reference standards: LVD EN 60 730-1 EMC EN 301 489-3 RADIO EN 300 220-3
1 - LED Power supply 230 V present 2 - LED Bus fault 3 - LED 18 Channel status 4 - LED Pump status
Operational/functional characteristics Relay output Each relay output of the power bar has a double switchover. Master function The MASTER function is the authority of a temperature control device to define periods of attenuation for itself and for the other devices (slaves) associated with it. The MASTER function can be performed only by the radio chrono-thermostat (740000 code). It is nevertheless possible to combine more than one master in a temperature control system. The decision to have a temperature control system with a number of master chrono-thermostats that interact with the 8-channel receiver may be made in order to have 2 or more entirely separate and independent zones as regards both time and temperature levels. After making this first distinction, the other temperature control devices can, in the self-learning phase, be associated with a specific master or remain completely independent. All the devices associated in the learning phase are independent in comfort operation as regards their temperature settings. The temperature setting can be selected on the thermostat knob. During attenuation, controlled by the master chrono-thermostat with its clock function, the crossed devices check that the attenuation setting selected on the master chrono-thermostat is observed. Lastly, all the devices (thermostats and chrono-thermostats too) that are not combined with a master device act independently according to their temperature settings. The association criterion must follow the proper path:
1 2 3 4 5 6 7 8
RESET
N L
It is therefore possible to pilot both a two-wire and a 3-wire generic valve. - PUMP CONTROL The pump control permits starting up the pump when there is an active channel (zone) and stopping the pump when all the channels are OFF. Since thermo-electric actuators, characterised by a starting lag (delay), are often installed, pump starting can be programmed in the receiver as: R - Delayed (120 s) or I - Instantaneous
FRONT PANEL OF 8-CHANNEL RECEIVER

ON
ON - Power on - 3-level bus signal indicator lights
Channel status LED Keys for manual channel overside Configuration RESET key Pump status LED
temperature control device receiver control bar valve servocontrol In this connection it is possible, on the front of the receiver, to pin the combined service channel by channel.
Radio systems - architecture

The modularity and ease of transmitter/receiver coupling make various operational architectures possible. The modular implementation makes it easy, even in the future, to add on new temperature control devices. All this is possible until the capacities of the receiver and differentiated outputs (power bar relay) are fully saturated. The following suggestions are by no means exhaustive.
1) Temperature control of a single zone (consumer plumbing boxes made of metal).
740000 code
740100 code
Receiver terminal board
2) Temperature controls of a single zone (consumer plumbing box made of plastic).
740000 code
1 2 3 4 5 6
t1 t2 t3
0 2 4 6 8 10 12 14 16 18 20 22
t1/t2/t
ON OFF H2O
- t1 - t2
230 V
CALEFFI
ON
740101 code
RESET
Mod. Dep.
CALEFFI
The distinction between wall-mounting receiver (740100 code) and concealed receiver (740101 code) depends on the type of material (metal - plastic) of the plumbing box. N.B. The metal boxes have the property of shielding the radio signals. Note: For both solutions it is possible to supply a complete pre-wired kit. 740102 code - Timer + wall-mounting receiver 740112 code - Timer + wall-mounting receiver + servomotor 646002 code 740103 code - Timer + concealed receiver 740113 code - Timer + concealed receiver + servomotor 646002 code
653
356 .peD .doM IFFELAC
3) Temperature control of two completely independent zones
With the same 2-channel wall-mounting receiver (740104 code) it is possible to have two setups. - Each zone is governed by its own chrono-thermostat with its own time settings and levels of comfort and attenuation settings.
740000 code
- The system pump is activated when required by a zone. - The system pump is stopped if no zone requires the temperature control service.
1 2 3 4 5 6
t1 t2 t3
t1/t2/t
ON OFF H2O
- t1 - t2
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
356
740104 code
ON
ON
CALEFFI
1 2
RESET
CALEFFI
Mod. Dep.
N L
230 V
NC NA C NC NA C
A B
740000 code
230 V
L N
1 2 3 4 5 6
t1 t2 t3
t1/t2/t
ON OFF H2O
- t1 - t2
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
4) Main zone temperature control with chrono-thermostat Secondary zone temperature control with thermostat
The type of system is identical to that of example 3. 740201 code
In this example, the chrono-thermostat 740000 code, according to its programming, determines the comfort and attenuation times for both zones. In periods of comfort zone 1 is temperature controlled according to the first temperature setting and zone (2) is governed according to the temperature setting selected on the radio thermostat (740201 code). In periods of attenuation zone 1 and zone 2 are temperature controlled according to the attenuation temperature setting of the chrono-thermostat.
15
ON
20
CALEFFI
25
30
10
ON
740104 code
CALEFFI
Mod. Dep.
356
SET 1 SET 2 SET ATTEN.
ON
CALEFFI
1 2
RESET
230 V
COMFORT 740000 code ATTENUAT.
COMFORT
t
1 2 3 4 5 6
t1 t2 t3 t1/t2/t
ON OFF H2O
- t1 - t2
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
5) Consumer temperature control with associated subzones
This setup, which provides room-by-room temperature control, is especially suited for panel heating systems where each loop is controlled by a thermo-electric actuator (6560 series). The control bar permits having electrical voltage all concentrated inside the consumer plumbing module.
1a Zone 740000 code
2a Zone 740201 code
3a Zone 740201 code
4a Zone 740201 code
5a Zone 740201 code
8-channel receiver (740202 code) The 8-channel receiver acquires the ON/OFF operating information from the single zone/subzone temperature control elements by radio and, via the 2-way bus, transfers operation to the corresponding output relays inside the control bar, turning the relevant electric valve(s) on/off. The control bar has three variants: 740204 code - 4 relays 740206 code - 6 relays 740208 code - 8 relays
30
30
30
1 2 3 4 5 6
t1 t2 t3
t1/t2/t
25
25
25
ON OFF H2O
- t1 - t2
15
ON
20
15
ON
20
15
ON
20
15
ON
20
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
T1
T2
T3
T4
T5
ON
ON
Day Ok
Reset
Prog
CALEFFI
1 2 3 4 5 6 7 8
RESET
740202 code
230 V
25
30
10
10
740208 code
10
10
Under the control of a single relay it is possible to associate one or more electrical valves (this is particularly suited to control a room served by 2 - 3 floor loops where there is a single thermostat or chrono-thermostat. The number of electric valves that can be associated is determined by the saturation of the intensity of the current 5 (2) A of the contacts of the single relay. In the case of thermo-electric actuator (series 6560), devices with a high input especially at start-up, the maximum number of controls that can be associated with the same relay (channel) is: 656102 code - 230 V - max 4 656104 code - 24 V - max 2
40 20 0 60 80
40 20 0 60 80
3 2 1
bar
4 5
Example of coupling - Chrono-thermostat defined as master of devices T2 - T3 - T4 - T5 - Chrono-thermostat associated with channel 1 / T2 channel 2 / T3 channel 3 / T4 channel 4 / T5 channel 5.
RICEIVER
CALEFFI
1 2 3 4
V1 and V2 valves associated with channel 1 2 V3 and V4 V5 valve associated with channel 3 V6 4 5 V7
45 50 55
CONTROL BAR 1Channel 2Channel 3Channel 4Channel 5Channel 1 2 3 4 5 6 C A N C A N C A N C A N C A N ... 8Channel Pump C A N L N
BUS
Power supply 18 V Power bar
V1 V2
V3 V4
V5
V6
V7
230 V Diagram 5
Alternative solutions Referring to diagram 5, which considers a single temperature control device as master and all the others as slaves, we can see how the user can reconfigure some devices either as masters of themselves or of other devices. It is thus possible to split a large zone (consumer) into several zones with or without associating the other temperature control devices. It is likewise possible to suspend the master function temporarily. The phase of personalization guided by audible and visual signals is characterised by the self-learning function and permits these modifications easily even by NON specialized personnel.
Tx-Rx SELF-LEARNING procedure The self-learning function is necessary in the phase of the first installation to couple each transmission device (chrono-thermostat/thermostat) with a specific channel of the receiver. - Press the TEST key on the thermostat or chrono-thermostat for at least 4 seconds. - By keeping the button pressed on the receiver for the channel where you want to save the transmitter (e.g. channel 1), coupling is performed. The channel LED blinks
MASTER setup This function is only active on the chrono-thermostat. Remember that this function is used to combine a set of devices that are already coupled (transmitter/receiver channel) with a main device (MASTER) that, for the entire set, will modulate the periods of comfort and attenuation. - Press the MASTER key on the chrono-thermostat until the display shows
MASTER
- When the MASTER radio signal reaches the receiver, the channel LEDs will show the current situation according to the following logic 1) LED blinking Channel under the domain of the active master
to confirm acquisition. - Turn off the TEST function on the thermostat or chrono-thermostat. And then proceed in the same way to couple the other devices. Note: When receiving a test signal the channel LED may be in the following three conditions: 1) LED on steady The channel is already occupied by another device 2) LED blinking Channel learned by the device at that time in the test phase 3) LED off The channel is free of devices
2) LED off Channel free and not in the domain of the active master Any outputs on which the transmitting device defined master has already been self-learned, it starts blinking since a self-learned chrono-thermostat is already master of itself.
Signal diagnostics During the self-learning procedure the receiver supplies the quality of the signal at visual and audible level by progressively illuminating the three LEDs accompanied by a beep. LED 1 + LED 2 + LED 3 on - high power LED 1 + LED 2 on - medium power LED 1 on - low power The visual-audible sequence is repeated cyclically every 3 seconds.
740000 code Digital chrono-thermostat, with weekly programming and radio transmitter (transmission frequency 868,35MHz) with max range 130 m in free air - 2 temperature levels + antifreeze - telephone control input - test function in couplings with the receiver.
740100 code Wall-mounting radio receiver - 1 channel - with indication of RF signal level.
740101 code Concealed radio receiver - 1 channel - with indication of RF signal level.
740104 code Wall-mounting radio receiver - 2 channels - with pump activation and indication of RF signal level.
740201 code Analog thermostat with radio transmitter (transmission frequency 868,35MHz) with max range 130 m in free air - test function in coupling with the receiver - summer winter control.
740202 code Wall-mounting radio receiver - 8 channels - with pump activation - equipped with control bus, reprogrammable non-volatile memory for coupling and assigning to master - manual forcing of channel output status - three-level test signal visual and audible indicator.
740204 code Power bar with 4 channels with pump activation, channel status indicator light, dialogue on 2-wire bus equipped with anchor slides on bottom of consumer plumbing box. Power supply 230 V.
CALEFFI
Heating cable with constant power consumption

6065 series
cert. n 0003
CALEFFI
ISO 9001
01119/06 GB
Function The heating system is generally composed of a heating cable and a thermostat connected to the normal electric mains. It is used for ice control and snow removal from ramps, steps, pedestrian crossings and ramps for otherwise-abled persons. The heating power released by the constant power consumption cable, on the contrary to the self-regulating type, is independent of the temperature. This feature ensures simple calculations for correct sizing, low costs and ease of installation; in addition, it can also be used to maintain temperature levels in rooms.
Product range Code Code Code Code Code Code 606523 606532 606545 606568 606596 606512 coil coil coil coil coil coil of of of of of of 122,9 131,9 145,4 168,1 196,4 120,1 m m m m m m
Technical specifications Materials: - conductor: - insulation: - protection sheathing: - outer coating: - earth conductor: double made of copper alloy XLPE (cross-linked polymer) aluminium PVC with high tensile strength and waterproofing copper
Performance Electric supply: 230 V (ac) Power consumption: 28 W/m Insulation resistance: >500 M Maximum adjustment temperature: 90C Maximum temperature tolerated by the cable: 160C Outside diameter: 7,5 mm Minimum bendings radius: 5 times the diameter of the cable
Operating principle The heating cable with constant power consumption is composed of a double copper alloy conductor with a earth conductor, XLPE (cross-linked polymer) insulation and PVC outer coating. The cable is the resistive type, where the live conductor generates heat by the Joule effect. The heating cable is supplied already terminated and ready for installation.
COLD CABLE
HOT CABLE
This is comprehensive of 10 metres of cold cable (that is the portion of non-resistive cable that ensures simple passage of current) with the possibility of reducing it by cutting off the excess. The section is identifiable thanks to asterisks marked on the outer coating. The joint between the hot cable and cold cable is marked with the word SPLICE, where the hot cable starts.
Sizing The heating cable is supplied in coils of a fixed length and cannot be shortened or joined to another heating cable. Depending on the location and pitch between the turns it is possible to determine the power per square metre to supply.
The following table gives the average operating powers according to the situation: Type of installation Plain only ice Plain ice plus snow Mountain (above 800 metres) only ice Mountain (above 800 metres) ice plus snow Necessary power 180 W/m2 200 W/m2 200 W/m2 240 W/m2
The second table gives the surface area it is possible to control with each section of heating cable according to the required parameters. The centre distance between the turns (pitch) depends on the power to install per square metre and can be obtained from the last row in the table. Code Length Power Nominal resistance 82,6 59,4 41,6 27,8 19,6 15,6 Input 180 W/m2 3,55 m2 4,94 m2 7,03 m2 10.55 m2 14,94 m2 18,60 m2 (pitch: 155 mm) Cover 200 W/m2 3.20 m2 4.46 m2 6.34 m2 9.52 m2 13.47 m2 16.77 m2 (pitch: 140 mm) 240 W/m2 2,66 m2 3,71 m2 5,28 m2 7,93 m2 11,23 m2 13,98 m2 (pitch: 115 mm)
606523 606532 606545 606568 606596 606512
22,9 m 31,9 m 45,4 m 68,1 m 96,4 m 120 m
640 W 890 W 1270 W 1900 W 2700 W 3400 W
2,91 A 4,04 A 5.78 A 8,63 A 12,27 A 15,45 A
Installation and laying The heating cables are normally laid in the concrete at a depth of approximately 50 mm from the surface. The cable is anchored on arc welded netting for reinforcement as normally used in the building trade. The cable is secured with clamps or ties, laying them out in a coil on the surface.
A 6(2) Hz 50
Control unit 230 V Relay
0 -1
5 60 D. MO
-2 A -3 UR AT ER MP TE
FI LEF CA
3 4 5
I F F LE CA
3 2 2 5 + 1 IDIT UM
0 10VA T50V 23
0 T5 TE RE Hz 50 A )A 0V TO m 23 6(2 EN 20 AM V= LD 24
1773
CA RIS
The hot portion of cable must always be completely sunk into the concrete and never installed in ducts or other construction components. To avoid overheating or malfunctioning, lay the cable avoiding abnormal overlapping or crossovers. It is essential to protect the heating cable from any deformation where there are crossovers of the expansion joints by using an omega section at the joint, without using ducting. It will be possible to lay the surface finish once the heating circuits have been made. Do not tread on the cable during the phase of laying and anyhow avoid causing any kind of damage when casting the concrete. Cast the concrete in the same direction in which the cable runs to avoid altering its layout. If asphalt is used, the temperature of the casting must not exceed 160C. Electrical tests It is necessary to check that the electrical magnitudes of continuity, insulation and input do not change when laying, so they will be checked before and after casting the concrete slab and marked on a specific card supplied in the package that will be kept in the junction box for future checks. Do not power up the heating cable until the concrete has completely dried, which is normally 6-8 weeks after laying. Although the cable can be used by connecting it directly to the electric mains via a switch, to avoid wasting power it is recommended to use a thermostat or an ice control unit that will automatically switch on only when operation is actually necessary.
ACCESSORIES
WATERTIGHT ELECTRICAL CONNECTOR code 607200
Function The fitting enables connecting the heating cable to the supply mains and its use is recommended if the cable crosses sections subject to high levels of humidity or immersed in water, thanks to the fittings high protection class.
Technical specifications Voltage: Max voltage: Max contact capacity: Protection class: 230 V (ac) 450 V (ac) 32 A IP 68
CONTROL UNIT FOR DETECTING ICE/SNOW code 605000
Function The control unit detects the presence of ice and snow by a sensor that measures outside temperature and relative humidity. There are two types of sensor: - code 605010 and 605020 suitable for open spaces such as entrances to garages, parking places, steps, footpaths or loading ramps; - code 605030 used for gutters, flat roofs or dish antennas. Once the risk of ice formation has been detected, the unit is capable of switching on heating devices for the surfaces at risk.
Technical specification Control unit Electric supply: Power consumption: Output terminal: Max ambient temperature: Insulation test: Protection class: 230 V 6% - 50 Hz 10 VA 230 V - 6 A -- with zero voltage 50C 4 kV II (after proper installation on the bar to DIN 43880) Sensors Working temperature range: Protection class: Cable length: -30 80C IP 68 - 605010: 6 m - 605020: 20 m - 605030: 6 m all can extendable up to 50 m (greater distances on request) The cable used is oil sealed of the type SL-Y11Y to DIN VDE 0472/9.21 Abs. 8036.
6065 series
Heating cable with constant power consumption to control ice and remove snow off ramps, steps and pedestrian crossings. Double copper alloy conductor, copper earth conductor. Nominal voltage 230 V (ac). Power consumption 28 W/m. Insulation resistance >500 M. Maximum temperature adjustment 90C. Maximum temperature tolerated 160C. Outside diameter 7,5 mm. Maximum installable length 120 m.
SIZING SHEET FOR RAMPS, STEPS AND PEDESTRIAN PASSAGEWAYS
NAME: SITE REF.: TELEPHONE: FAX:
DATE:
E-MAIL:
SURFACE TO HEAT TOTAL m2 m2

WHEEL BASE
................
m
................
HEATING TOTAL AREA WHEEL BASE ONLY
................
................
TYPE AND SIZE OF CONCRETE SLAB (GIVE DIMENSIONS IN SPACES PROVIDED) CONCRETE BED OF SAND WITH SELF-LOCKING ELEMENTS
CONCRETE
................ ................
OTHER
mm mm mm
SELF-LOCKING ELEMENTS SAND BED
mm
Reinforcement
Heating cable
................
................
mm
EARTH
................
Reinforcement
Heating cable EARTH
MINIMUM AMBIENT TEMPERATURE (MINIMUM VALUE -40C) REQUIRED TYPE OF PROTECTION ICE ONLY ICE PLUS SNOW PLACE PLAIN
MOUNTAIN (above 800 m)
Space for stating the surface area to heat with related distances:
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
Temperature regulating unit for heating and cooling

series 155
CALEFFI
01120/04 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 for either heating and cooling. The unit is delivered with all the required components for a regulating circuit. The unit is compact to save space and facilitates installation into an embedded wall box. It is supplied complete with: 4-way mixing valve, servomotor, electronically-regulated pump, flow temperature sensor, return temperature sensor, outside temperature sensor, limit control sensor for relative humidity, temperature controller, flow temperature gauge, unions for connecting to the manifolds and to the primary circuit. 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 supplied in a manifold box preassembled with manifolds.
The unit is factory set for use with underfloor heating systems.
Product range Code 1556 . 2 Code 151000 Temperature regulating unit for heating and cooling, in manifold box preassembled with manifolds Room thermostat and indoor sensor
Technical specification - Materials: - Body: - Hydraulic seals: - Mixing valve: Medium: Max. percentage of glycol: Temperature setting range: Max. working pressure: G-MS 58 brass EPDM 4-way water, glycol solutions 30% 5 60C 6 bar 0 60C 1 1/2 with union connection 1 F with union
Pump Electronic pump: Total consumption: Max. flow rate: Max. ambient relative humidity: Ambient temperature: Protection class: UPE 25-60 ~ 110 W 3.5 m3/h 95% 0 40C IP 42
- Temperature gauge scale: - Connections to the manifold: - Primary circuit connections:
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 G (m3/h)
Servomotor Electrically powered: Rating: Cycle time: Torque: 230 V - 50 Hz 1,3 VA 210 s 6 Nm
Factory setting: proportional head regulation.
Dimensions
1000
6 outlets
10 outlets
13 outlets
CALEFFI
26 24
19
18
17
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
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
28
CALEFFI
30 32 34
100% 80% 50% 25% 50%
CALEFFI
100% 80% 50% 25% 50%
20
12
22
15
14
CALEFFI
40 35 30 45 50 55 60 -25% +25%
13
CALEFFI50
40 30
CALEFFI
60
70 80 90 -25% +25%
CALEFFI50
40 30
CALEFFI
21
60
70 80 90 -25% +25%
CALEFFI
23
22
WATCH
10
20 30 20
24
10
60
20 0
40 60
20 0
40 60
450
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
2 6 4
Zu
2 6 4
Zu
2 6 4
Zu
CALEFFI
CALEFFI
CALEFFI
CALEFFI
CALEFFI
270-410
Code Outlets A
1 5
11
21
CALEFFI
26 26 24 24
19 19
18 18
17
16
20 20
22
23 23
9 9
24 24
1 1
7
SYSTEM RETURN
Zu
8
18
20 22 24
CALEFFI
16
BOILER FLOW
BOILER RETURN
Hydraulic diagram
SF
4-way mixing valve
M
SR
Servomotor 5996 series head units with automatic air vent and discharge valve.
CALEFFI
Variable speed pump
Automatic by-pass
BF
BR
Temperature gauge
6
7 7
6 6
5 5
2 2
6
7
-50%
-50%
-50%
CALEFFI
CALEFFI
320 A
50 150-190
1556E2 5 655
1556F2 6 705
1556G2 7 755
1556H2 8 805
1556I2 9 885
1556L2 10 935
1556M2 11 985
1556N2 12 1035
1200
800
12
11
10
1556O2 13 1085
28 28
30 30 32 32
34 34
12
22 22
15
14
50 40 40 35 30
60 45
70 50 80 55 90 60 -25% -25% +25% +25%
WATCH WATCH
10
20 30 20
10
60
-50% -50%
0 0
SYSTEM FLOW
10
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Temperature controller for heating and cooling Electronic pump UPE 25-60 Four-way mixing valve Servomotor Flow temperature sensor Return temperature sensor Outside temperature sensor Room thermostat and indoor sensor (optional) Limit control sensor for max. relative humidity RH% Flow temperature gauge Connection point for remote transmission
13
12
11 11
10
4 2 8 6
The regulating unit is preassembled with: 667 series flow distribution manifold, equipped with micrometric valves for calibrating individual circuits.
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
666 series return distribution manifold, equipped with shut-off valves on individual circuit specially designed for thermoelectric control.
CALEFFI
For more information see technical brochure 01044 GB
1 14 2 3 4 5 6 13 7
CALEFFI
26 24
19
18
17
16
10
28 30 32 34
20
21
12
22
15
14
23
40 35 30
45
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). 10) Start or stop cooling selector. If the outside temperature is higher than the set value, the cooling function is activated. Factory setting: 24C. 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.
22
50 55 60 -25% +25%
13
WATCH
11
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) 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. The LED is lit in the cooling function. The LED is lit in the heating function. Pump operating (ON): LED lit continuously. d)
2) 3) 4) 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). 6) 7) Mixing valve opening: LED lit. Sensor malfunction: LED lit.
8) Function selector, six different functions possible: a) b) c) d) 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 14). 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.
e)
TFLOW (C)
25%
f)
55 50 45 40 35 30 25 20 15 10 5 35 30 25 20 15
E (24;20) 80% 55%
50%
9)
6
7
8
-50% 0
12
b) c)
The characteristic curve has a straight line format. In the example shown below, it has been calculated using the factory set values. Example of calculation of characteristic curve 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
60
B (-10;45) D (4;40) C (11;33,75)
A (18;20)
10
-5
-10
-15
Preparatory phase Passive phase
TOUTSIDE (C)
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.
Printed circuit board The surface of the printed circuit board (PCB) identifies the following functions:
14 16 17
4(2)A 4(2)A
T 40 DIGITAL CONTROLLER t Typ 2125 N L LP PS MA MC C

4(2)A
OPEN CLOSE OPEN CLOSE
AMBIENT THERMOSTAT 2501
13
TA
N L
MXING PUMP INLET
230 V AC 4VA 230V AC 10A max
TA1 X SE SM SR
11 15 12
1 2 3 4 ON
PUMP N
-10 -5 30 -15 -20 -20 65 -10 18

6,25C
4(2)A
F KA KA A B
0 14
22
55 40 35
4,5
UR
4 10 3
DIP
4(2)A
20
65 1,5 6 max NZ 50
100
RF(%)
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.
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.

6,25C
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. If this temperature is lower, cooling will start following a preparatory phase, where Tflow equals the setTminY as at item 5 of the printed board circuit. Example: TO set on front panel=24C, TO set on PCB= 18C; TminY = 20C. Activation will take place: at TO = 22C (18+4) = preparatory phase at TO = 24C following the characteristic curve. 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
3)
13) Daily or weekly analogue clock, used to select the heating or cooling phases required with: the red indicators for heating comfort and set-back, the blue indicators to start and stop cooling, white indicator for heating and cooling with the same time programme. 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; to do this, turn the pointer clockwise until the innermost notch coincides with one of the outer notches. Reposition the outer ring, making sure that the reference day shown on it falls in the operating sector of the switching point.
7
24
1 2 3 4
1 2 3 4
ON
ON
12
23
22
d -7 21
Screed drying Free flow temperature 16C limited flow temperature
14C limited flow temperature 12C limited flow temperature 10C limited flow temperature
DIP
DIP
20
1 2 3 4
1 2 3 4
ON
ON
9
9
19
DIP
DIP
18
17
15
14
6
13
16
1 2 3 4
1 2 3 4
ON
ON
12
11
10
DIP
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.
6)
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 humidity 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.
7) NZ
8) RF(%) Return sensor regulation selector. Adjustable from 0% to 100%. Factory setting: 80%. This selector is used to optimise the system output accordign 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 0,3. Treturn Y = Tflow set Y - T Tcalculated flow = Tflow set Y + RF% (Treturn set Y - Treturn Y) Example with factory setting values: Flow temperature calculated on the characteristic curve: Tflow set Y = 40C (project conditions). TY = (40 - 20) = 20C T = 20 0,3 = 6C Treturn set Y = 40 - 6 = 34C. If the return temperature measured (Treturn Y) is Treturn set Y, the controller will modify the characteristic curve, moving it upwards or downwards, to restore the return temperature to that set. If Treturn Y = 30C Tcalculated flow = 40C + 0,8 (34-30) = 43,2C This continuous comparison prevents room overheating caused by gratuitous heat sources modifying the heating load. There is no effect on the cooling function. Thus:
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. Fix by inserting the two straps contained in the package through the suitable holes on the sensor.
CALEFFI
2426 2426
19 19
18 18
17
16
28 28
3032 3032
20 20
12
22 22
15
14
34 34
22
21
60
13
23
7080 7080
9 9
WATCH WATCH
24 24
4050 30 90 90 -25% -25% +25% +25%
10
20 30 20
12
1060
11
1 1
10
2 2
Curve with return temperature regulation

Treturn: 34C
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= 80 - 85%. When the calibrated value is reached, this will cause the following state: mixing valve closed, pump ON. 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.
The maximum heat energy that the panel can produce, in relation to the climate values recorded, can be reached by controlling the parameters below. - Minimum flow temperature on the characteristic curve, which can be selected through the microswitch (point 4 on the back panel). - Sensor controlled maximum RH% limit. - Room temperature controlled through room thermostat (code 151000). - Room temperature and relative humidity controlled through a dedicated fan-coil or dehumidifier). N.B.: When installing the RH% limit sensor according to the diagrams, as indicated, possible formation of condensation on the surface is anticipated. In areas where the max RH% limit sensor is installed, adequate ventilation must always be present.
8
7
6
6
5 5
-50% -50%
0 0
4 2 8 6
Zu
11) SE
Outside sensor wiring. Connect the outside sensor using 2-core cable (2x0,75) to the connector provided on the unit.
17) KA Chiller activation wiring. This activation takes place in the same way as in point 16.
Outside sensor LH side termial strip
Boiler circuit open
SE
Connecting wiring 12) SR Connector
C F KA KA
Chiller circuit open
Return sensor wiring. Factory fitted.

20 18 22 24
CALEFFI
16
13) TA1 Room thermostat wiring. Optional.

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
26 24
19
18
17
16
28
30 32 34
20
12
22
15
14
21
23
50 40 30
60
CALEFFI
70 80 90 -25% +25%
22
CALEFFI
13
WATCH
24
12
40 20
60
80 100
11
10
CALEFFI
14) PS
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.
2 6 4
Zu
CALEFFI
CALEFFI
Pump shut-down wiring User auxiliary contact RH side terminal strip

6 7 8
Table of sensor resistance values*

PS MA MC
Brown
Unit 155 pump
Pump shut-down variant
15) SM Flow sensor wiring. Factory fitted.
*excluding max RH% limit sensor
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 3 for at least half an hour. Ten minutes later, the regulating unit pump is activated.
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.
Safety thermostat code 150025 (optional) Temperature setting range: 55C 3C Protection level: IP 55 Contacts rating: 10 A - 240 V Cable length: 0,55 m
Use of safety thermostat The safety thermostat has a special snap on connector. It can be used to stop the boiler and protect the panel circuits from dangerous overheating.
It prevents hot water from entering the panel circuits directly when cooling in the absence of automatic summer-winter changeover as at point 16.
6
7
-50%
CALEFFI
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 and 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.
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
26 24
19
18
17
16
28
30 32 34
20
12
22
15
14
21
23
50 40 30
60
CALEFFI
70 80 90 -25% +25%
22
CALEFFI
13
WATCH
24
12
40 20
60
80 100
11
10
CALEFFI
2 6 4
Zu
CALEFFI
CALEFFI
Frost protection function When the selector (point 6 on the front panel) is positioned on , there are two types of intervention: or
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 Disconnect the wires on the back of the PCB on the right at the positions MA, marked No. 2 and 2 Zu 6 4 MC No. 3. 8
TFLOW (C)
n 2 n 3
MA MC
Press on the screw on the protective cover and turn it to the position desired. 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.
TA1 TA Room thermostat

20 18 22 24
TA 1
TA
CALEFFI
16
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.
6
7
-50%
CALEFFI

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
Room thermostat electrical connection Install the room thermostats and connect by sheathed 2-core cable (2 x 0,75) to the terminal strip of the regulator PCB, as shown in the diagram below.
Application diagram
Pump Variable speed pump Zone valve

0 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

TH
Thermostatic valve
Thermostat/humidistat
20 18 22 24
CALEFFI
TH
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
26 24
19
18
17
16
28
30 32 34
20
12
22
15
14
21
23
50 40 30
60
CALEFFI
70 80 90 -25% +25%
22
CALEFFI
13
WATCH
24
12
40 20
60
80 100
11
10
CALEFFI
2 6 4
Zu
CALEFFI
CALEFFI
Code 1556.2 Temperature regulating unit preassembled with manifold for radiant panels in box. Primary circuit connections: 1" F with union. Manifold outlets: 3/4 M. Brass body. EPDM hydraulic seals. Maximum working pressure: 6 bar. Ambient temperature: 0 to 40C. Setting temperature range: 5 to 60C (factory setting: 45C). Complete with: 4-way mixing valve; mixing valve servomotor, with the following specification: electrical 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: IP 42; temperature controller with with daily/weekly clock; flow temperature sensor; return temperature sensor; outside temperature sensor. Limit control sensor for relative humidity. Flow pocket temperature gauge, scale 0 60C; flow manifold, 5 outlets (5 to 13) complete with regulating valves; return manifold, 5 outlets (5 to 13) complete with shut-off valves suitable for thermoelectric heads; head unit with air vent valve and drain valve; box in sheet steel, RAL 9010 white colour, depth adjustable from 150 to 190 mm, complete with floor supports with height adjustable from 270 to 410 mm.
Code 151000 Room thermostat and indoor sensor for temperature regulating unit.
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
6
7
-50%
CALEFFI
Thermostatic regulating unit for underfloor radiant panels for 559 series Sepcoll
series 163
cert. n 0003
CALEFFI
01121/04 GB
ISO 9001
Function The thermostatic regulating unit is designed for maintaining the temperature set for the flow fluid constant in a low temperature circuit for underfloor radiant panels. This unit has been specially designed for use with both the external and wall embedded versions of the series 559 series separator/distribution manifolds. It comes supplied with a three-way thermostatic mixing valve with built-in temperature sensor, a three-speed pump, a safety thermostat, a differential by-pass valve, flow and return temperature gauges and secondary circuit shut-off valves. Supplied complete with preformed insulation shell.
Product range Code 163600 External thermostatic regulating unit for radiant panels for Sepcoll. Flow upwards, flow on right hand side Code 163610 External thermostatic regulating unit for radiant panels for Sepcoll. Flow upwards, flow on left hand side Size 1 Size 1
Technical specification Three-way thermostatic valve Materials: - Body: - Internal cartridge: - Springs: - Seals: By-pass Materials: Body: Springs: Obturator: Seals: brass EN 1982 CB753S stainless steel EPDM EPDM brass EN 1982 CB753S brass EN 12164 CW614N, chemically nickel plated stainless steel EPDM Safety thermostat Set temperature: Protection class: Contacts rating: 55C IP 55 10 A/ 240 V
Safety thermostat
Wiring diagrams
L 230 V N
Ambient thermostat
Pump Three-speed pump: Material: - Body: Electric supply: Max. relative humidity: Max. ambient temperature: Protection class: Pump centre distance: Pump connections: Head available at the regulating unit connections
H (m w.g.)
5
UPS 25-60
UPS 25/60 GG 15/20 cast iron 230 V - 50 Hz 95% 80C IP 44 130 mm 1 1/2 with union
Shut-off valves Materials: - Body: - Seals: Performance Medium: Max. percentage of glycol: Setting temperature range: Accuracy: Primary inlet max. temperature: By-pass setting range: water, glycol solutions 30% 25 55C 2C 85C 10-60 kPa (1- 6 m w.g.) 1 F with union 1 F 90 mm brass EN 12165 CW617N EPDM
Power consumption
Speed
3 2 1
4 3 2 1 0
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (r.p.m.) 1800 1100 700
3 2 1
Connections: - primary circuit: - secondary circuit: - connection centre distance:
0,5
1,5
2,5
G (m3/h)
Insulation technical specification Material: closed cell expanded PEX 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 vapour (DIN 52615): > 1.300 Temperature range: 0 100C Fire resistance (DIN 4102): B2 class
Dimensions
code 163600
code 163610
40
20 60 20
40
60 20
40
60 20
40
60
80
80
80
80
G
A B C A D D A C A B
A 1 1 B 95 95 C 90 90 D 77 77 E 460 460 F 320 320
Code 163600 163610
F
G 140 140
SYSTEM RETURN
SYSTEM FLOW
Hydraulic diagram 8
SR
SF
40
20
60 20
40
60
8
4
8 6 3 4
ST
80
80
5 2
2
BOILER RETURN BOILER FLOW
Characteristic components 1 2 3 4 5 6 7 8 Three-way thermostatic valve with built-in temperature sensor Three-speed UPS 25-60 pump Differential by-pass valve Safety thermostat Wiring box Flow temperature gauge Return temperature gauge Secondary circuit shut-off valves
BR
Shut-off valve Temperature gauge By-pass valve Safety probe
ST T
BF
Safety thermostat 3-way thermostatic valve System electric pump
Operating principle The regulating element of the three-way thermostatic valve is a temperature sensor, which is completely immersed in the outlet chamber of mixed water. It continuously regulates the correct proportions of hot water from the boiler and of return water from the panel circuit by expanding or contracting. It regulates these flows by means of a shutter which slides in a special cylinder located between the hot water and the water returning from the panel circuit passage seats. Even if the thermal load of the secondary circuit or the temperature of the water coming from the boiler changes, the mixing valve will automatically regulate the flow of water to provide water at the temperature that has been set.
Construction details Reduced pressure loss The three way mixing valve is fitted with a special shutter which operates in special seatings where the water passes. It therefore guarantees high flow rates with reduced obstruction, while maintaining accurate temperature regulation.
Replaceable cartridge The internal cartridge which contains all the regulation components is pre-assembled in a single unit and can be easily inspected for cleaning or replacement if required without the need to remove the valve body from the piping.
Anti-stick surfaces All the functional parts, such as the shutter, the seatings and guides have chemically nickel plated surfaces. This surface treatment reduces the wear of moving parts to a minimum and guarantees high performance and long life.
Low heat inertia thermostat sensor The element that is sensitive to temperature change, the engine of the three-way thermostatic valve, has low thermal inertia; it therefore reacts quickly to changes in the temperature and pressure of the inlet water which allows the valve to respond rapidly.
Temperature regulation and lock device The temperature can be set between minimum and maximum with one turn of the control knob (360). There is also a tamper-proof device for locking the temperature set.
Installation
Configuration with Sepcoll served from the right Thermostatic regulating unit code 163610
04
06 02 06
Configuration with Sepcoll served from the left

40 40
60 20 60 20 0 80 0 80
04
02
08
08
Thermostatic regulating unit code 163600
T T

04
06 02 06

04
02
40
20 60 20
40
60
08
08
80
80
Temperature setting The temperature is set to the desired temperature by using the graduated adjustment knob fitted on the three-way thermostatic valve. Position Temp. (C) Min
20
Cartridge replacement The internal cartridge containing all the regulation components can be inspected and replaced if necessary without the need to remove the valve from the piping. 1) Close the hot and cold inlet shut-off valves 2) Remove the internal cartridge for inspection or replacement by turning the nut as shown.
1
25
2
30
3
35
4
40
5
45
6
50
7
55
Max
58
Reference: Tboiler = 70C
Locking the setting Set the knob on the desired number, remove the screw on the top, pull the knob off and push it back on so that the groove on the inside fits over the ridge on the knob holder.
2 3
1 MIN
MA
Differential by-pass The differential by-pass valve is used to control the head in the secondary circuit. When the differential pressure set for the valve is reached, the valve opens and allows fluid to pass between the flow and return of the circuit, limiting the differential pressure at the value set. If the individual circuits to panels are shut-off by automatic two way on/off or modulating valves, the valve prevents excessive fluid velocities and the pump from overheating.
3) Replacement cartridges come complete with adjustment knobs.
By-pass flow curves
p (m w.g.)
8 7 6 5 4 3 2 1 0
Setting positions
(kPa)
80 70 60 50 40 30 20 10 0
6 5 4 3 2 1
4) Open the shut-off valves again and set the mixing valve at the temperature desired.
0,5
1,5
3
G (m /h)
Accessories
738107
Battery powered ambient chrono-thermostat. With self-learning programme, weekly clock programming, telephone input connection, Three temperature levels. Minimum programme periods of 30 minutes. Size: (w x h x d) 120 x 90 x 20 mm.
1 2 3 4 5 6
t1 t2 t 0 2 4 6 8 10 12 14 16 18 20 22 -t 1 -t 2 -t 3
ON OFF
C C
t 1 / t 2 / t 3
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
CALEFFI
CALEFFI
10 8 6 4 2 0
CALEFFI
CALEFFI
1 2 3 4 5 6
t1 t2 t 0 2 4 6 8 10 12 14 16 18 20 22 -t 1 -t 2 -t 3
ON OFF
C C
t 1 / t 2 / t 3
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
CALEFFI
CALEFFI
10 8 6 4 2 0
CALEFFI
CALEFFI
40
20 60 20
40
60 20
40
60 20
40
60
80
80
80
80
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
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
CALEFFI
CALEFFI
10 8 6 4 2 0
CALEFFI
40
20 60 20
40
60
80
80
Code 1636 . . Thermostatic regulating unit for underfloor radiant panels for the Sepcoll 559 series. Configuration with flow upwards and flow on the right hand side (or flow on left hand side). Connections to the primary circuit 1F union. Connections to the secondary circuit 1 F. Centre distance of connections to the primary and secondary circuits 90 mm. Setting temperature range: 25 55C. Accuracy: 2C. Primary inlet maximum temperature: 85C. Maximum working pressure: 10 bar. Complete with: three-way thermostatic valve with built-in sensor. Body and internal cartridge in brass with chemically nickel plated sliding surfaces. Springs in stainless steel. EPDM seals. Safety thermostat set at 55C, protection class: IP 55. Three-speed pump: UPS 25-60, power supply: 230 V-50 Hz, Maximum ambient temperature: 80C, protection class: IP 44. Temperature gauge scales: 0C to 80C. Differential by-pass valve, brass body, stainless steel spring, pressure range: 10 to 60 kPa. Shut-off valves on secondary circuit. Insulation in preformed closed cell expanded PEX.
CALEFFI
Modulating digital controller

for heating and cooling
161 series
IS
CALEFFI
TERE
UNI EN ISO 9001:2000 Cert. n 0003
01122/08 GB
Function The controller can be used with three-point motorized mixing valves with rotation times ranging between 30 and 240 seconds. It performs both set point and modulating regulation. In the modulating mode, the controller automatically varies the flow temperature depending on the actual value of the system return temperature. This is detected to indicate the instantaneous ambient load. This reduces system operating times and power overloads. The controller is equipped with flow and return temperature probes and a wiring box for an easy use when mounted on the wall. It can also be connected from the back by means of a standard recessed electrical box.
Product range Code 161000 Code 150050 Code 150051 Code 150052 Modulating digital controller for heating and cooling, with flow/return probes and contact probe holder Max. relative humidity probe Converter Transformer
Technical specifications Controller - Three point type - Electric supply: - Protection class: - Control temperature rage Flow/return temperature probes NTC type Control range: Time constant: Response: Beta value: Two-wire cable with connection: Cable length: Dimensions E D
Relative humidity control components (optional) Max. relative humidity probe - Electric supply: - RH% limit: Converter - Electric supply: - Microswitch contact rating: - Max. ambient temperature: - DIN bar clamps Transformer - Electric supply: - Power consumption: - Max. ambient temperature: - DIN bar clamps Dimensions
RE
230 V - 50 Hz IP 40 778C
24 V - 50 Hz 8085%
24 V - 50 Hz 6 / (2) A (230 V) 50C
-10125C 2,5 s 10.000 at 25C 25/85C 3977 1,5% 1/8 M 1m
230 V - 50 Hz 10,5 VA 50C
A
CALEFFI CALEFFI
150051
B
AC 24V 50Hz AC 230V 6(2)A T50
Convertitore
150052
Trasformatore
V DE
AC 50Hz
230V
24V~ 1 2 3 4 5 6
24V
LN
~ ~
1 A E 42
Weight (kg)
1 - when installing in a recessed junction box do not use the cable gland socket
A B 89
Weight (kg)
Code 161 000
A 133
B 129
C 90
D 35
0,31
Code 150051
A 54
0,12
Code 150052
A 54
B 89
Weight (kg)
0,38
Digital controller 2 7 3 4 8 1
Operating principle The controller receives the activation signal from the ambient thermostat to start the pump and operate the mixing valve. The controller operates the mixing valve according to two logic approaches, depending on whether the return probe is on or off. Set point regulation: return probe off. Selector 6) OFF. In this case the flow temperature FT is held constant at the value set using the selector 5) for both heating and cooling. The setting is shown on the display 1). Modulating regulation: return probe on. Selector 6) ON. In this case the flow temperature FT is modified as a function of the temperature measured by the return probe RT. This keeps under control the actual thermal efficiency of the slab and as a consequence the ambient thermal load. This thermal response time of the system is thus reduced to a minimum. RTset = FTset - 35% (FTset - 20C) FTcalculated = FTset + (RTset - RT)
10
11
12
The new FT value calculated is shown on the display 1) highlighted a side bar.
The front panel contains the following functions:
1) Three-digit LCD showing: measured or calculated temperature and settings of the delays programmed in the system. Temperature range displayed: 099C with 0,1C resolution. 2) Controller function selector ON/OFF. 3) Mixing valve on opening: LED on. 4) Mixing valve on closing: LED on. 5) Selector for setting flow temperature. Temperature range 778C Factory setting: - heating: max. 50C - cooling: min. 14C 6) Return probe switch. Probe off: OFF Probe on: ON Factory setting: ON 7) Pump operating (ON): LED permanently on. 8) S.T. LED safety temperature. Continuously ON when the limit indicated by the safety thermostat or safety humidostat is reached. Also continuously ON in case of flow/return probe malfunction (see flow/return probe paragraph). 9) Heating/cooling function exchange switch 10) Trimmer for maximum impulse duration on the valve. Adjustable 0,26 s. Factory setting: 2,5 s. Calculation of impulse value: Tpulse. (s) =
Each time the FT is calculated, the measured FT is displayed for 5 s, after which the new calculated FT is shown. Changes to FT stop when the RT reaches the RTset. The return probe is switched off during the cooling function. Curve correction with return probe
FT;RT (C)
50
Flow temperature limit
45
Design flow temperature
FT
u alc
lat
ed
FT Flow temperature
40
FT Set
lc Ca ula te d
35
FT
30
RT Set
Design return temperature
Rotation time of actuator (s) 40
25
20
Example:
Tactuator rotation = 120 s Tpulse = 120/40 = 3 s 11) Trimmer for time delay in reading return probe. Adjustable 1360 s. Factory setting: 20 s. 12) Trimmer of valve-motor mechanical delay recover. Adjustable 130 s. Factory setting: 5 s.
50%
100%
150%
Display The three-digit LCD display shows the following parameters: - Flow temperature set using the selector 5). The flow temperature measured appears after 5 s. - Measured flow temperature, with return probe off. - Calculated flow temperature, with return probe on. - Maximum duration of the impulse on the valve, selected using the trimmer 10). Displayed for 5 s. - Delay time for acquiring the return temperature, selected using the trimmer 11). Displayed for 5 s. - Valve-motor mechanical delay recover, selected using the trimmer 12). Displayed for 5 s.
Heating safety thermostat If the safety thermostat trips, on detecting a higher flow temperature than the setting, the following state comes into operation: pump OFF, mixing valve closed. The thermostat contact is N/C; if the connection is missing, the controller is off. Auxiliary microswitch The controller is equipped with an auxiliary microswitch which can be used to control other equipments. Example: For Heating, to switch the boiler on or off. N/O contact - Pump off - ambient thermostat OFF or safety thermostat on (boiler off). N/C contact - Pump on - ambient thermostat ON (boiler on). For Cooling, to switch the chiller unit on or off. N/O contact - Pump off - ambient thermostat OFF or RH% limit probe on (chiller unit off). N/C contact - Pump on - ambient thermostat ON (chiller unit on). Contact rating: 5 / (2) A (230 V). Flow/return probe The flow/return temperature probes are the NTC type. If the probes detect ohmic resistance indicating a short circuit, the following operating state is set: pump OFF, mixing valve closed, LED 8) permanently on.
Back panel
M 230 V~ 5060 Hz ~ 5(2) A / 250 V~
CALEFFI
13 14 15 16 17 18 1 L 2 N 3 4 5 6 SA SR TA TS Opens Closes 7 8 9 10 11 12
230 V~ IN OUT
*
13 14 15 16 17 18
Table of probe resistance values

1 2 3 4 5 6 7 8 9 10 11 12 C -20 -15 -10 -5 0 5 97.060 72.940 55.319 42.324 32.654 25.396 C 10 15 20 25 30 35 19.903 15.714 12.493 10.000 8.056 6.530 C 40 45 50 55 60 65 5.327 4.370 3.603 2.986 2.488 2.083 C 70 75 80 85 90 95 1.752 1.480 1.255 1.070 915 787 C 100 105 110 115 120 125 680 592 517 450 390 340
*When there is a safety thermostat, eliminate the jumper

The terminals for the various electrical connections are located on the back panel. Electric supply 1 Supply 230 V~ Live 2 Supply 230 V~ Neutral 3 Ground/Earth Pump control 4 Ground/Earth 5 Pump control 230 V~ Live 6 Pump control 230 V~ Neutral Mixing valve control (TRIAC: contact rating 1 A (230 V)) 7 Valve control on opening 8 Common C 9 Valve control on closing Auxiliary microswitch (contact rating relay 5 / (2) A) 10 Auxiliary outlet N/O 11 Auxiliary common outlet C 12 Auxiliary outlet N/C Flow/return probe 13 Flow temperature probe 14 Common C 15 Return temperature probe Ambient thermostat/safety thermostat 16 Ambient thermostat contact 17 Common C contact for ambient thermostat / common C contact for safety thermostat and humidity probe converter 18 Contact for safety thermostat and humidity probe converter.
Flow temperature limit for heating and cooling Maximum heating and minimum cooling flow temperatures can be set with the controller. Dip switches are located on the bottom of the controller in order to set different limit temperatures. Factory setting: - heating max. 50C - cooling min. 14C
Table of limit temperature-dip switch positions Dip switch Maximum Minimum setting Limit Limit 0 0 0 50 14 0 0 1 54 13 0 1 0 58 12 0 1 1 62 11 1 0 0 66 10 1 0 1 70 9 1 1 0 74 8 1 1 1 78 7
ON
1 2 3
Control of relative humidity When the controller is used for cooling, the relative humidity probe must be used. The function of this probe is to detect the maximum relative humidity limit in order to prevent the formation of condensation in the cooling slab. It is set for RH = 8085%. When this level is reached, the following operating state is set: pump ON, mixing valve closed. Connection of the humidity probe The humidity probe is connected to the controller through a special transformer and converter.
Testing the humidity probe The functioning of the probe must be checked at the start of each cooling season by placing a damp wad of cotton wool on the surface; this should cause the mixing valve to be switched off and switch on the red LED point 8 on the front of the control panel. Location of the humidity probe The humidity probe is located at the point where humidity is most likely to form which will depend on the system design. It is positioned with the carbon printed surface facing upwards as in the following diagrams.
E
Safety thermostat
CALEFFI CALEFFI
Upper side: carbon
ST
Lower side: placed on the cooling surface
AC 24V 50Hz AC 230V 6(2)A T50
150052
Trasformatore
V DE
150051
AC 230V 50Hz 10,5VA T50
Convertitore
24V
24V~ 1 2 3 4 5 6
LN
~ ~
230 V
Room thermostat Regulator cod. 161000
RT
Layouts for the correct positioning of the max RH% limit probe. The probe should be fixed to the manifold installed in the zone where the RH% relative humidity has not to exceed the safety limits. Fix the probe by inserting the two straps through the holes.
13 14 15
16 17 18
13 14 15 16 17 18 1 L 2 N 3 4 5 6 SA SR TA TS Opens Closes 7 8 9 10 11 12
230 V~ IN OUT
In order to control different zones that are at risk of condensation forming, the humidity probe should be connected to a special interface kit (transformer, converter and humidity probe). Up to 12 converters and probes can be connected to a single transformer. Example of connection with multiple sensors on different manifolds
TRANSFORMER
cod. 150052
10
CONVERTER cod. 150051
1 2 3 4 5 6
1 2 3 4 5 6
L N
230 V
Terminal board
24 V
RH% SENSOR cod. 150050
RH% SENSOR cod. 150050
17
The maximum thermal energy that the panel can produce can be reached by controlling the parameters below. - Minimum flow temperature can be set using the selector 5) on the front panel. - Maximum relative humidity RH% limit, controlled through the relative humidity probe. - Room temperature, controlled by the room thermostat - Room temperature and relative humidity, controlled by a fan coil or dehumidifier. N.B.: The RH% limit probe is used to forestall any formation of condensation. In areas with cooling, adequate air treatment must always be present.
ST
18
Example of connection to different zone valves

TRANSFORMER
cod. 150052
10
1 2 3 4 5 6
1 2 3 4 5 6
L N
230 V 24 V
Accessories
738
RH% SENSOR cod. 150050 RH% SENSOR cod. 150050
R1
R2
Rel NC
TA
R1
TA
Terminal board
R2
16 17 18
Code
Ambient digital chrono-thermostat, battery operated. With self-learning programme. Weekly programming. Suitable for phone programmer. Three temperature levels + antifreeze. Minimum programming: 30 minutes. Protection class. IP 30
ST
738107
124 x 90 x 21 mm
Mixing valves
610
Three-way butterfly mixing valve, threaded connections. Max. working pressure: 6 bar. Working temperature range: 2110C. Heavy series.
p (mm w.g.)
5000
1 11 /4 11 /2 2 -D N5 21 0 /2 DN 65 DN 80 DN 10 0
4500 4000 3500 3000 2500
p (kPa)
45 40 35 30 25
50
DN 12 5
3/ 4
2000 1800 1000 900 500

800 700 600 450 400 350 300 250 160 140 120 80 70 60 0,35 0,40 0,45 0,6 0,7 0,8 0,9 1,2 1,4 1,6 1,8 1600 1400 1200
18 16 14 12 9 8 7 6
20 10 5
4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2
Three-way butterfly mixing valve, flanged connections. Body PN 6. To be coupled with flat counterflange EN 1092-1. Max. working pressure: 6 bar. Working temperature range: 2110C. Heavy series.
200 180 10090 50
2 1
0,90 0,80 0,70 0,60 2,5 3,5 4 4,5
0,5
0,3
0,5
6 7 8 9
12 14 16 18
100
G (m3/h)
Kv (m3/h) Kv (m3/h) 3/4 7,5 DN 50 45 2 1/2 1 1 1/4 1 1/2 2 72 11,9 16,8 30 45 DN 65 DN 80 DN100 DN 125 72 140 183 340
611
Four-way butterfly mixing valve, threaded connections. Max. working pressure: 6 bar. Working temperature range: 2110C. Heavy series.
p (mm w.g.)
5000
2 -D N5 21 0 /2 DN 65 DN 80 DN 10 0
4500 4000 3500 3000 2500
p (kPa)
45 40 35 30 25
200
50
18 16 14 12 9 8 7 6
10
20
1000 900 500

800 700 600 450 400 350 300 250 160 140 120 80 70 60
1600 1400 1200
DN 12 5
120 140 160 180 120 140 160 180
3/ 4 1 11 /4 11 /2
2000 1800
30
50
120 140 160 180
25
35 40 45
60 70 80 90
20 10 5
4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2
Four-way butterfly mixing valve, flanged connections. Body PN 6. To be coupled with flat counterflange EN 1092-1. Max. working pressure: 6 bar. Working temperature range: 2110C. Heavy series.
200 180 10090 50
2 1
0,90 0,80 0,70 0,60 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
0,5
0,3
0,5
6 7 8 9
12 14 16 18
25
35 40 45
100
60 70 80 90
G (m3/h)
Kv (m3/h) Kv (m3/h) 3/4 7,8 DN 50 53 1 1 1/4 1 1/2 2 2 1/2 12,3 18,5 30 53 80 DN 65 DN 80 DN100 DN 125 80 140 230 410
612
Three-way sector mixing valve, threaded connections. Max. working pressure: 6 bar. Working temperature range: 2110C. Heavy series.
p (mm w.g.)
5000
11 /2 2 -D N5 21 0 /2 DN 65 DN 80 DN 10 0
4500 4000 3500 3000 2500
p (kPa)
45 40 35 30 25
200
50
18 16 14 12 9 8 7 6
10
20
1000 900 500

800 700 600 450 400 350 300 250 160 140 120 80 70 60
1600 1400 1200
DN 12 5
1 11 /4
3/ 4
2000 1800
30
50
20 10 5
4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2
Three-way sector mixing valve, flanged connections. Body PN 6. To be coupled with flat counterflange EN 1092-1. Max. working pressure: 6 bar. Working temperature range: 2110C. Heavy series.
200 180 10090 50
2 1
0,90 0,80 0,70 0,60 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
0,5
0,3
0,5
6 7 8 9
12 14 16 18
25
35 40 45
100
60 70 80 90
G (m3/h)
200
10
20
30
50
6370
Actuator for mixing valves 610-611-612 series from 3/4 to 1 1/2. With adapter. With auxiliary microswitch. Technical specifications Three point type Electric supply: Power consumption: Microswitch contact rating: Protection class: Operating time: Dynamic torque: 230 V (ac) or 24 V (ac) 3 VA 1 A (230 V) IP 42 60 s (90 rotation) 15 Nm Electric supply 1 = clockwise rotation (CW) 2 = counter clockwise rotation (CCW) 3 = common Auxiliary microswitch 4 = common 5 = N/C contact 6 = N/O contact
1 2 3 4 5 6
CW CCW CCW
L N
6370
Actuator for mixing valves 610-611-612 series from 2 to 5. With adapter. With auxiliary microswitch.
Electric supply 1 = clockwise rotation (CW) 2 = counter clockwise rotation (CCW) 3 = common Auxiliary microswitch
M
Technical specifications Three point type Electric supply: Power consumption: Microswitch contact rating: Protection class: Operating time: Dynamic torque: 230 V (ac) or 24 V (ac) 4,5 VA 1 A (230 V) IP 42 180 s (90 rotation) 35 Nm
4 = common 5 = N/C contact 6 = N/O contact

L N
1 2 3 4 5 6
CW CCW CCW
636
Three-way motorized piston valve, with manual opening. Full bore. With auxiliary microswitch. The valve can be transformed into a two-way valve by blanking off the central third way. Technical specifications Three point type Electric supply: 230 V (ac) or 24 V (ac) Max. working pressure: 16 bar Max. working temperature: 110C Auxiliary microswitch contact rating: 3 A (230 V) Protection class: IP 44 Operating time: 90 s p max: 1 1/4, 1,2 bar; 1 1/2, 1 bar; 2, 0,9 bar
Hydraulic characteristics p (mm w.g.)

5.000 3.000
2.000
p (kPa)
50
1 1/ 1 4 1/ 2 2
30 20 10 5 3 2 1
1.000 500 300 200 100
0,5
10
20
Kv (m3/h)
1 1/4 14
1 1/2 19
2 25
G (m3/h)
6371
Three-way motorized ball valve, with manual opening. T drilling, reduced bore. With auxiliary microswitch. Technical specifications Three point type Electric supply: 230 V (ac) or 24 V (ac) Max. working pressure: 40 bar p max: 6 bar Working temperature range: -10100C Max. ambient temperature: 55C Power consumption: 3/4 and 1: 3 VA 1 1/42: 5 VA Auxiliary microswitch contact rating: 1 A (230) Protection class: IP 65 Operating time: 60 s (90 rotation) Dynamic torque: - 3/4 and 1: 15 Nm - 1 1/4 2: 20 Nm
Hydraulic characteristics p (mm w.g.)

5.000 3.000
2.000
p (kPa)
50
/4
11 / 2 2
50
30 20 10 5 3 2 1
1.000 500 300 200 100
0,5
11
3/
10
20
G (m3/h)
Kv (m3/h) 3/4 6,5 1 9,8 1 1/4 17,7 1 1/2 30 2 39,2
50
Application diagram
Shut-off valve
1 2 3 4
L/MIN
Pump Temperature probe Pressure gauge

CALEFFI
CALEFFI
CAMERA
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
Temperature gauge
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
ST
Safety thermostat Differential by-pass valve

1 2 3 4
L/MIN
CALEFFI
CAMERA
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CALEFFI
CALEFFI
CALEFFI
150052
Trasformatore
V DE
150051
AC 50Hz 230V
Convertitore
AC 24V 50Hz AC 230V 6(2)A T50
150051
Convertitore
AC 24V 50Hz AC 230V 6(2)A T50
24V
24V~ 1 2 3 4 5 6
24V~ 1 2 3 4 5 6
LN
~ ~
ST
S/W
220 - 240 V 50 Hz
Code 161000 Modulating digital controller for heating and cooling. Complete with flow/return probes and contact probe holder. Three point type. Electric supply 230 V - 50 Hz. Protection class IP 40. Control temperature range 778C. Complete with NTC flow/return probes. Working temperature range -10125C. Time constant 2,5 s. Response 10.000 at 25C. Beta value 25/85C 3977 1,5%. Two-wire cable with 1/8 M connection, length 1 m. Code 150050 Maximum relative humidity probe. Electric supply 24 V 50 Hz. RH% limit: 8085%. Code 150051 Converter. Electric supply: 24 V - 50 Hz. Microswitch contact rating (TRIAC) 1 A (230 V). Maximum ambient temperature 50C. DIN bar clamps. Code 150052 Transformer. Electric supply 230 V - 50 Hz. Power consumption 10,5 VA. Maximum ambient temperature 50C. DIN bar clamps. 610 series Three-way butterfly mixing valve with manual control. Heavy series. Threaded 3/4 F connections (3/42 1/2). Cast iron body and rotor. Aluminium cover and handle. NBR seals. Working temperature range 2110C. Maximum working pressure 6 bar. Can be motorized. 610 series Three-way butterfly mixing valve with manual control. Heavy series. Flanged DN 50 connections (from DN 50 to DN 125). To be coupled with counterflange EN 1092-1. Cast iron body and rotor. Aluminium cover and handle. NBR seals. Working temperature range 2110C. Maximum working pressure 6 bar. Can be motorized. 611 series Four-way butterfly mixing valve with manual control. Heavy series. Threaded 3/4 F connections (3/42 1/2). Cast iron body and rotor. Aluminium cover and handle. NBR seals. Working temperature range 2110C. Maximum working pressure 6 bar. Can be motorized. 611 series Four-way butterfly mixing valve with manual control. Heavy series. Flanged DN 50 connections (DN 50DN 125). To be coupled with counterflange EN 1092-1. Cast iron body and rotor. Aluminium cover and handle. NBR seals. Working temperature range 2110C. Maximum working pressure 6 bar. Can be motorized. 612 series Three-way sector mixing valve with manual control. Heavy series. Threaded 3/4 F connections (3/42 1/2). Cast iron body and rotor. Aluminium cover and handle. NBR seals. Working temperature range 2110C. Maximum working pressure 6 bar. Can be motorized. 612 series Three-way sector mixing valve with manual control. Heavy series. Flanged DN 50 connections (from DN 50 to DN 125). To be coupled with counterflange EN 1092-1. Cast iron body and rotor. Aluminium cover and handle. NBR seals. Working temperature range 2110C. Maximum working pressure 6 bar. Can be motorized. 636 series Three-way motorized piston valve. Three-way with manual opening. Full bore. 1 1/4 F connections (from 1 1/4 to 2). Brass body. Stainless steel stem. Self-extinguishing ABS motor cover. Maximum working pressure 16 bar. Maximum working temperature 110C. Three point type actuator. Electric supply 230 V (ac) or 24 V (ac). Power consumption 3,7 VA. Operating time 90 seconds. Protection class IP 44. Maximum ambient temperature 50C. Auxiliary microswitch contact rating 3 A (230 V). 637 series Three-way motorized zone ball valve with manual opening and T drilling. Threaded 3/4 F connections (from 3/4 to 2). Nickled brass body and ball. PTFE seals. Working temperature range -10100 C. Maximum working pressure 40 bar. Maximum differential pressure 6 bar. Actuator: Electric supply 230 V (ac) or 24 V (ac). Power consumption 3 VA (3/41); 5 VA (1 1/42). Dynamic torque 15 Nm (3/4 and 1: 15 Nm - 1 1/42: 20 Nm). Operating time 60 seconds (rotation 90). Protection class IP 65. Maximum ambient temperature 55C. Auxiliary microswitch contact rating 1 A. 6370 series Actuator for mixing valves from 3/4 (from 3/4 to 5). Three point type regulation. Electric supply 230 V (ac) or 24 V (ac). Power consumption 3 VA (3/41 1/2); 4,5 VA (25). Dynamic torque 15 Nm (3/41 1/2: 15 Nm - 25: 35 Nm). Operating time 60 seconds (3/41 1/2: 60 s, 25: 180 s). Protection class IP 42. Maximum ambient temperature 50C. Auxiliary microswitch contact rating 1 A.
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
DISCALDIRT deaerator-dirt separator
CALEFFI
546 series
ACCREDITED
01123/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003
Function Deaerators-dirt separators are used to continuously eliminate the air and dirt 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. At the same time they separate dirt and impurities contained in the water within the circuit and collect them in the lower part of the valve body, from which they may be expelled. The circulation of fully deaerated water enables the equipment to operate under optimum conditions, free from any noise, corrosion, localised overheating or mechanical damage. Flanged and weld-end deaerators-dirt separators are supplied complete with hot pre-formed shell insulation to ensure perfect thermal insulation when used in both hot and chilled water systems. Patented. Reference documentation: - Tech. broch. 01060 DISCAL deaerator 551 series - Tech. broch. 01137 DIRTCAL dirt separator 5462 series
Product range 546 546 546 546 series series series series DISCALDIRT DISCALDIRT DISCALDIRT DISCALDIRT deaerator-dirt deaerator-dirt deaerator-dirt deaerator-dirt separator separator separator separator with with with with olive connections threaded connections flanged connections and pre-formed insulation weld ends and pre-formed insulation size 22 with nuts for copper pipe sizes 3/4 and 1 sizes DN 50DN 150 sizes DN 50DN 150
Technical specifications series Materials Body: Dirt separation chamber: Automatic air vent body: Internal element: Float: Float guide: Stem: Float lever: Spring: Hydraulic seals: Drain cock: Drain valve: Performance Medium: Max. percentage of glycol: Max. working pressure: Working temperature range: Particle separation rating: Connections Main: 546 threaded brass EN 12165 CW617N brass EN 12165 CW617N brass EN 12165 CW617N PA66G30 PP brass EN 12164 CW614N brass EN 12164 CW614N stainless steel stainless steel EPDM brass EN 12165 CW617N 546 flanged and weld ends epoxy resin coated steel brass EN 12165 CW617N stainless steel PP brass EN 12164 CW614N brass EN 12164 CW614N stainless steel stainless steel EPDM brass EN 12165 CW617N
water, non-hazardous glycol solutions excluded from the guidelines of directive 67/548/EC 50% 10 bar 0110C up to 5 m
water, non-hazardous glycol solutions excluded from the guidelines of directive 67/548/EC 50% 10 bar 0110C up to 5 m
with compression ends for 22 mm copper pipe; 3/4, 1 F
Drain:
hose connection
DN 50DN 150 flanged PN 16 to be coupled with counterflanges EN 1092-1 DN 50DN 150 weld ends 1 F
Technical specifications of insulation Inner part Material: Thickness: closed cell expanded PE-X DN 50DN 100; 60 mm DN 125DN 150; 50 mm Density: - inner part: 30 kg/m3 - outer part: 80 kg/m3 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 Material: Thickness: Reaction to fire (DIN 4102): embossed unfinished aluminium 0,7 mm class 1
Dimensions
B C F C E F C
38552
38552
D 1 G B
Code A B C D E
Code
F Mass (kg) 3,0
546002 22 127 55 128 141 325
B C 1 E G B A F
Code
D 374 374 436 436
E 775 775 912 912
G Mass (kg) 18 19 33 35 82 85
G Mass (kg) 13 13 25 25 70 70
546052 DN 50 350 55 546062 DN 65 350 55 546082 DN 80 466 55 546102 DN 100 470 55 546122 DN 125 635 55 546152 DN 150 635 55 Code A B C D E F Mass (kg) 2,9 2,9 546005 3/ 4 105 55 128 141 325 546006 1 105 55 128 141 325
169 300 169 300 219 370 219 370
546053 DN 50 260 55 374 775 546063 DN 65 260 55 374 775 546083 DN 80 366 55 436 912 546103 DN 100 366 55 436 912
169 300 169 300 219 370 219 370
541 1245 324 480 541 1245 324 480
546123 DN 125 525 55 541 1245 324 480 546153 DN 150 525 55 541 1245 324 480
Dimensions Volume (l)
DN 50 13,6
DN 65 13,8
DN 80 28,6
DN 100 29,6
DN 125 85
DN 150 87
Operating principle The deaerator-dirt separator 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. The impurities in the water, colliding with the metal surfaces of the internal element, are separated out and fall to the bottom of the valve body.
Construction details The particular construction of the DISCALDIRT allows it to be maintained and cleaned without removing the device from the system. Note the following: The moving parts that control the air venting are accessed simply by removing the upper cover (1). The deaerator-dirt separator automatic air vent, located at the top of the device, is equipped with a long chamber for float movement (2). This feature prevents any impurities in the water from reaching the seal seat. Simply unscrew the top part of the casing (3) to clean the entire air venting system. Flanged and weld-end deaerators-dirt separetors are equipped with a cock (4) 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.
1 1 1 1 1 1
2 2 3 2 3 3
2 2 3 3 4 4 1 4 1 2 3
5 5 6 6
When checking the internal element of threaded deaerators-dirt separators, simply unscrew the large dirt collection chamber (5) to 2 2 which the internal element is fixed, so that it can be removed for 3 5 3 cleaning. Threaded versions of DISCALDIRT have a collection chamber equipped with a shut-off cock and hose attachment with plug (6), while flanged and weld-end versions have a ball shut-off valve (7). 4 This 6 means impurities can even be expelled while the system is in operation.
6 7 7 Insulation Flanged and weld-end DISCALDIRT 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. 7
22 - 3/4 DN 100 DN 125 DN 150 DN 50 DN 65 DN 80
p (mm w.g.)
400
350 300 250
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
DN 22-3/4 Kv (m3/h) 16,2 DN Kv (m3/h) DN 80 180
1 28,1
DN 50 75
DN 65 150 DN 150 720
200
180 160 140 120
DN 100 DN 125 280 450
100
90 80 70 60
50
45 40 35 30 25
0,5
The maximum recommended speed of the medium to the device connections is 1,2 m/s. The following table shows the maximum flow rates in order to meet this requirement. DN l/min m3/h DN l/min m3/h 1 22-3/4 35,18 22,7 2,11 1,36 DN 80 361,5 21,69 DN 50 141,20 8,47 DN 65 238,72 14,32 DN 150 1436,6 86,2
20
18 16 14 12
0,2
120
140 160
100
G (m3/h)
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.
Boiler micro-bubbles Micro-bubbles are formed continuously on the surface separating the water from the combustion chamber due to the fluid temperature. Combustion chamber This air, carried Flame temperature 1000C wall by the water, collects in the Boundary layer critical points of FLAME WATER the circuit from where it must be Micro-bubbles removed. Some Wall temperature Boundary layer of this air is 160C temperature 156C reabsorbed in Average water the presence of temperature 70C colder surfaces.
Cavitation and 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 Implosions Seat-obturator air and vapour distance Cavitation micro-bubbles, micro-bubbles the formation which is of Pressure Velocity enhanced in the case of non de-aerated Fluid vapour pressure may water, subsequently implode due to the cavitation phenomenon.
Pressure Velocity
Graph: Solubility of air in water

Absolute pressure Max amount in litres of dissolved air per m3 of water (l/m3)
Water temperature C
200
0,5
10
20
50
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
60
30
70 80 90
10
0,1
DN 100 DN 125 980 564,8 58,8 33,69
7 8 9
Separation efficiency The capacity for separating the impurities in the medium circulating in the closed circuits of the systems basically depends on three parameters: 1) It increases as the size and mass of the particle increase. The larger and heavier particles drop before the lighter ones. 2) It increases as the speed decreases. If the speed decreases, there is a calm zone inside the dirt separator and the particles separate more easily. 3) It increases as the number of recirculations increases. The medium in the circuit, flowing through the dirt separator a number of times during operation, is subjected to a progressive action of separation, until the impurities are completely removed. The Caleffi DISCALDIRT deareator-dirt separator, thanks to the special design of its internal element, is able to completely separate the impurities in the circuit down to a minimum particle size of 5 m. The graph alongside, summarising the tests carried out in a specialised laboratory (TNO - Science and Industry), illustrates how it is able to quickly separate nearly all the impurities. After only 50 recirculations, approximately one day of operation, up to 100% is effectively removed from the circuit for particles of diameter greater than 100 m and on average up to 80% taking account of the smallest particles. The continual passing of the medium during normal operation of the system gradually leads to complete dirt removal. Reduced head losses A normal Y strainer performs its function via a metal mesh selected for the size of the largest particle. The medium therefore has a consequent initial loss of head that increases as the degree of clogging increases. Whereas, the dirt separator carries out its action by the particles striking the internal element and subsequently dropping into the collection chamber. The consequent head losses are greatly reduced and are not affected by the amount of impurities collected. The graph alongside shows a comparison of the differences in head loss between the two types of device.
Particle separation rating - Deaerator-dirt separator efficiency
Efficiency (%)
Separated quantity Initial quantity
.100%)
Efficiency 50 passages (0,5 m/s)
Efficiency 50 passages (1 m/s)
100
80
60
40
20
Particle dimensions (m)
WORKING ZONE
DIRTCAL DIR TCAL

CARTRIDGE FILTERS
SPECIAL STRAINERS
Tests in a specialized laboratory TNO - Science and Industry (NL)

Y-STRAINERS
Comparison of head losses: deaerator-dirt separator Y-STRAINERS p (kPa) p (mm w.g.)

1000
900 800 700 600 450 400 350 300 250 180 160 140 120 90 80 70 60 45 40 35 30 25 18 16 14 12 9 8 7 6
10 5
500
Y-strainer curve 3/4 - Kv=8
4.5 4 3,5 3 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6
200 100 50
2 1 0,5
0,45 0,4 0,35 0,3 0,25
20 10
DISCALDIRT curve 3/4 - Kv=16,2

250 300 350 400 450 600 700 800 900 1200 1400 1600 1800 2500 3000 3500 4000 4500
0,18 0,16 0,14 0,12
0,2 0,1
200
500
1000
2000
Installation DISCALDIRT devices may be used in both heating and cooling circuits, to guarantee progressive elimination of impurities and air which form continuously. They should preferably be installed after the boiler, on the pump suction side, as this is where most of the micro-bubbles form. DISCALDIRT deaerators-dirt separators must be installed in a vertical position. It is recommended that the air vent cap is replaced with a Caleffi 5620 series hygroscopic safety cap if the device is installed in a location that cannot be inspected.
CHILLER
5000
G (l/h)
1000
105
150
210 250
500
16
35
63
10
20
50
Application diagram
P T
F
A
Shut-off valve Ball valve BALLSTOP

T
Pump AUTOFLOW Flow meter Temperature probe Safety thermostat
Pressure switch Control pocket Gas filter Gas regulator
Sensor pocket Safety valve Backflow preventer
Temperature gauge Differential by-pass valve
Automatic filling unit Y-strainer
Regulator
F
Flow switch Expansion vessel Zone valve 3-way valve
Fuel shut-off valve Anti-vibration joint
DISCALDIRT 546 series Deaerator-dirt separator. Connections with compression ends for 22 mm copper pipe and 3/4 connections (and 1) F. Brass dirt separation chamber and body. Brass automatic air vent body. PA66G30 internal element. PP float. Brass float guide and stem. Stainless steel float lever and spring. EPDM hydraulic seals. Brass drain cock. Medium water and non-dangerous 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. Particle separation rating down to 5 m. Drain: with hose connection.
DISCALDIRT 546 series Deaerator-dirt separator. 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 valve 1 F. Epoxy resin coated steel body. Brass automatic air vent body. Stainless steel internal element. PP float. Brass float guide and stem. Stainless steel float lever and spring. EPDM hydraulic seals. Brass drain valve. Medium: water and non-dangerous 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. Particle separation rating down to 5 m. Closed cell expanded PE-X shell insulation and embossed unfinished aluminium external cover. Working temperature range 0100C.
CALEFFI
CALEFFI S.p.A. S.R.229, N.25 28010 Fontaneto dAgogna (NO) Italia Tel. +39 0322 8491 Fax +39 0322 863305 www.caleffi.it info@caleffi.it
DISCALAIR high-performance automatic air vent

551 series
cert. n 0003
CALEFFI
ISO 9001
01124/06 GB
Function DISCALAIR devices are able to release large quantities of air that has formed in the hydraulic circuits of heating and air conditioning systems, even against substantial pressure values. This venting capacity is due to the particular geometry of the venting mechanism, identical to that of the DISCAL deaerators 551 series. This prevents the appearance of negative phenomena that might prejudice the working life and performance of the heating system, such as: - corrosive processes caused by oxygen; - air pockets in the heating elements; - cavitation in the circulating pumps.
Product range Code 551004 High-performance automatic air vent size 1/2 F
Technical specifications Materials: - body: - cover: - float: - float guide: - obturator stem: - float lever: - spring: - hydraulic seals: Medium: Max. percentage of glycol: Max. working pressure: Max. discharge pressure: Temperature range: Connections: brass EN 12165 CW617N brass EN 12165 CW617N PP brass EN 12164 CW614N brass EN 12164 CW614N stainless steel stainless steel EPDM water, glycol solutions 50% 10 bar 10 bar 0110C 1/2 F
Dimensions
Code 551004
A 1/2"
B 115
C 35
C
D 55
Weight (kg) 0,62
Operating principle The accumulation of air bubbles in the valve body causes the float to drop so that the obturator opens. This action, and therefore correct valve operation, is ensured as long as the water pressure remains under the maximum discharge pressure.
Installation DISCALAIR automatic air vent 551 series must be installed in a vertical position. We recommend installing a shut-off valve upstream of the DISCALAIR device to simplify any maintenance operations. During operation the upper cap must be loosened in the normal version, whereas it must be completely tightened in the hygroscopic version. The installation of the valve in places subject to freezing is not recommended; if this is the case, the atuomatic deaerator Caleffi MAXCAL 501 series should be used. It is recommended that the venting valve cap be replaced by the Caleffi AQUASTOP hygroscopic safety cap code R59681 in all cases where inspection is not possible.
Construction details High discharge pressure The valve is able to release large quantities of air up to a pressure of 10 bar, thanks to the particular internal geometry used in its design. Operating chamber The valve body is made in such a way as to have a long chamber for movement of the float controlling the obturator. This characteristic prevents impurities in the water from reaching the seal housing. Hydraulic characteristics Discharge capacity in the phase of filling the system
Nl/s
1,5 1,4 1,3 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2
0,1 0
The operating principle is based on the properties of the cellulose fibre disks forming the retaining cartridge. These disks increase their volume by 50% when they come into contact with water, thus closing the valve. This avoids any damage in the event of water leakage.
Maintenance The DISCALAIR automatic air vent is designed to enable the inspection of the internal mechanism. Access to the moving parts that control the air outlet is obtained by simply removing the upper cover. The body moreover can be separated from the lower part connected to the pipe.
0,5
1,5
2,5
3,5
4,5
5,5
6,5
7,5
8,5
10 bar (air)
9,5
SPECIFICATION SUMMARIES DISCALAIR 551 series High-performance automatic air vent. 1/2 F connections. Brass body and cover. PP float. Brass float guide. Stainless steel float lever and spring. Brass obturator stem. EPDM hydraulic seals. Medium water and glycol solutions; maximum percentage of glycol 50%. Temperature range 0110C. Maximum working pressure 10 bar. Maximum discharge pressure 10 bar. Code R59681 Hygroscopic safety cap. Brass body. EPDM hydraulic seals. Cellulose fibre disks seal cartridge; fibre volume increase on contact with water 50%. Maximum working pressure 10 bar. Maximum working temperature 110C.
CALEFFI
Pre-adjustable automatic filling unit assemblies for high flow rates

series 554 - 574
CALEFFI
01125/05 GB
Function The automatic filling unit is a device consisting of a pressure reducing valve with compensating seat, an inlet strainer, an upstream shut-off valve with built-in check valve and a downstream shut-off 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. 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. A pre-assembled version is also available, complete with upstream backflow preventer and shut-off valve.
Reference documentation - Tech. broch. 01085 Pressure reducing valves, series 5350 - Tech. broch. 01022 Backflow preventer, series 574 - Tech. broch. 01021 Ballstop ball valve with built-in check valve
Product range Code 554040 Pre-adjustable automatic filling unit assembly for high flow rates, with pressure gauge connection and setting indicator Size 1/2 Code 5541 . 0 Pre-adjustable automatic filling unit assembly for high flow rates, with pressure gauge and setting indicator Sizes 1/2, 3/4 Code 574001 Charging unit with pressure gauge, complete with BA type backflow preventer, series 574, strainer and shut-off valve Size 3/4
Technical specification 554040 - 5541 . 0 Materials (554040 - 5541.0 codes only) Body: Cover: Control spindle: Moving parts: Seals: Filter: Shut-off valves: Performance Max. pressure upstream: Pressure setting range: Factory setting: Max. working temperature: Pressure gauge scale: Filter mesh size : Medium: Connections Inlet: Outlet: Pressure gauge: dezincification resistant alloy EN 12165 CW602N PA 66 G 30 stainless steel dezincification resistant alloy EN 12164 CW602N NBR stainless steel brass EN 12165 CW617N, chrome-plated 16 bar 1 6 bar 3 bar 60C 0 10 bar 0,51 mm water 1/2, 3/4 F 1/2, 3/4 F 1/4 F 574001 dezincification resistant alloy EN 12165 CW602N stainless steel dezincification resistant alloy EN 12164 CW602N NBR stainless steel brass EN 12165 CW617N 10 bar 1 6 bar 3 bar 60C 0 10 bar 0,40 mm water 3/4 F 3/4 F -
Dimensions
CALEFFI
CALEFFI
CALEFFI
E D
Code 554040/140 554150
A 1/2 3/4
B 112 112
C 204 232
Weight (kg) 1,72 1,9
Code 574001
A 3/4
B 112
C 30
D 505
Weight (kg) 6,1
Construction details 554 series The 554 series filling unit assembly consists of: - Pressure reducing valve, series 5350 - Ball valve with built-in check valve, series 3230 - Shut-off ball valve Pre-adjustment 554 series filling unit assemblies are provided with an adjustment knob and a calibration pressure indicator which is visible from both sides. This pressure indicator has an incremental movement, so that the pressure can be adjusted continuously, with the value being displayed at 0,5 bar increments. The system pressure can thus be pre-set to the required value even before the reducer is installed.
Non-stick materials The central support 1 containing the moving parts, is made of a plastic material with a low adhesion coefficient. This solution minimises the possibility of limescale formation, the main cause of eventual malfunctions.
2 1
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 antiextrusion rings 2 on the compensanting piston, the valve can be used in continuous service with upstream pressures of up to 25 bar.
Removable self-contained cartridge The cartridge, which includes the diaphragm, filter, seat, obturator and compensating piston, is pre-assembled as a self-contained unit with the cover, and can easily be removed for inspection and maintenance purposes.
4 6 2 8 0 10 bar
CALEFFI
CALE FFI
Code 574001 The filling unit is a device placed between the heating system and the public mains or the internal water supply system. In order to prevent potentially polluted water, (which may be hazardous to human health), from flowing back from the heating system, it is always advisable to install a pre-assembled kit with backflow preventer. 574001 code filling unit assembly consists of: - Controllable, reduced pressure zone backflow preventer, BA type, series 574 - Pre-adjustable pressure reducing valve, series 5350 - Shut-off ball valves - Y-strainer, series 577
Installation 1. Filling unit can be installed in either vertical or horizontal pipework. However, the unit must not be installed upside down.
CALEFF I
CALEFF I
2. The special method of mechanical pre-adjustment with pressure setting indicator makes it possible to set the unit to the required value in the system before the beginning of the filling phase. 3. When the system is being commissioned, the unit is normally calibrated at a pressure no lower than the hydrostatic pressure plus 0,3 bar. 4. During filling, the internal mechanism will automatically regulate the pressure until it reaches the required value, without the need to oversee the filling operation itself. 5. Given the pre-calibrating function, the presence of the downstream pressure gauge is not essential. 6. 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.
Maintenance For inspection, cleaning or replacement of the complete regulating cartridge: 1) Isolate the reducer. 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) Carry out the essential operations of checking and cleaning the filter. 5)The whole self-contained cartridge can be refitted or replaced with a spare. When the cartridge is screwed back into the valve body the pressure indication windows will return to the original position. 6) Reopen the shut-off valves. The pressure will return to the original set valve.
Series 574
BA type controllable reduced pressure zone backflow preventer series 574, designed in compliance with the EN 12729 European standard - Devices to prevent pollution by backflow of potable
water. Controllable backflow preventer with reduced pressure zone. Family B - Type A.
BA type backflow preventer can be installed to prevent pollution from types of water classified up to the category 4 in accordance with the EN 1717 standardProtection 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 4 Fluid that presents a significant health hazard due to concentrations of toxic substances.
CALEFF I
Application diagram
F
A
IFFELAC
IFFELAC
IFFELAC
AC IFFEL
Shut-off valve Ball valve Check valve Temperature gauge

Differential by-pass valve F Flow switch Zone valve
T
T
Pump Autoflow
P
3-way valve
Fuel shut-off valve Anti-vibration joint
Pressure switch Sensor pocket Control pocket Safety valve Gas filter
Flow meter
Temperature probe
Safety thermostat
Gas regulator Controller Expansion vessel Air separator
Series 554 Pre-adjustable automatic filling unit assembly. 1/2F (1/2 and 3/4) threaded connections. Body and moving parts in dezincification resistant alloy. Maximum working temperature 60C. Maximum inlet pressure 16 bar. Pressure setting range 1 - 6 bar. Consisting of: pressure reducing valve with compensating seat, cover in PA 66 G 30, filter in stainless steel, siliding surfaces in anti-scaling material, diaphragm and seals in NBR, removable for maintenance operations, pressure setting indicator for the device pre-adjustment, pressure gauge scale 0 - 10 bar (version with pressure gauge), 1/4F pressure gauge connection (version with pressure gauge connection); upstream shut-off ball valve with built-in check valve, chrome plated; downstream shut-off ball valve, chrome plated.
Code 574001 Charging unit with backflow preventer. 3/4 F connections. Maximum working temperature 60C. Maximum working pressure 10 bar. Consisting of: pressure reducing valve with compensating seat, body and moving parts in dezincification resistant alloy, cover in PA 66 G 30, seals in NBR, pressure setting range 1 - 6 bar, complete with strainer; downstream pressure gauge scale 0 - 10 bar; BA type controllable reduced pressure zone backflow preventer, complying with EN 12729, body in dezincification resistant alloy, diaphragm and seals in NBR, discharge tundish with fixing collar for the discharge piping; shut-off ball valve in brass; backflow preventer Y-strainer.
CALEFFI
Manifolds in composite specifically designed for radiant panel systems

670 series
cert. n 0003
CALEFFI
ISO 9001
01126/05 GB
Function Manifolds in composite are used to control and distribute the fluid in the circuits of floor radiant panel systems. This particular series of manifolds, made in a specific composite material for use in air-conditioning systems, is composed of: flow manifold, with flow meters and built-in balancing valves; return manifold, with shut-off valves fitted for thermo-electric actuator; end fittings with automatic air vent valves and filler/drain cocks; ball shut-off valves; liquid crystal digital thermometers, on the flow and return manifolds. They are supplied pre-assembled in a special box with reduced depth and height-adjustable supports to facilitate installation and plumbing connections.
Reference documents Tech. Broch. 01042 Thermo-electric actuator
Product range 670 series Manifolds in composite specifically designed for radiant panel systems, pre-assembled in box Size 1
Technical specifications Materials: Flow manifold - body: Flow-rate balancing valve - obturator: - flow meter body: - spring: - hydraulic seals: - balancing unit cover: Return manifold - body: Shut-off valve - obturator: - obturator stem: - spring: - hydraulic seals: - control knob: End fittings - body: - air vent valve body: - filler/drain cock body: - air vent valve seal: - hydraulic seals:
PA66GF brass EN 12164 CW614N PSU stainless steel EPDM ABS PA66GF EPDM stainless steel stainless steel EPDM ABS PA66GF PA66GF brass EN 12165 CW617N silicone rubber EPDM
Ball shut-off valves - valve body: - union seals: - control lever:
brass EN 12165 CW617N EPDM PA66GF
Performance Medium: Max. percentage of glycol: Max. working pressure: Max. cold hydraulic test pressure: Max. air vent valve discharge pressure: Temperature range: Flow meter scale: Accuracy: Liquid crystal digital thermometer scale Manifold connections - main: - outlets: water, glycol solutions 30% 4 bar 6 bar 6 bar 5-60C 1-4 l/min 10% 24-48C
1 F 3/4 x coupling with adapter code 675850
Dimensions
30
6
195 70
C
C. MATRIM. ENTRATA PRANZO CAMERA CUCINA BAGNO
1 2 3 4
L/MIN
550 255
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
C
91 65 43
270-410
48
110 A B
50
80-120
Code Nr. outlets A B (Wall box width) Weight (kg)
6706C1 3 300 600 14,8
6706D1 4 350 600 15,0
6706E1 5 400 600 15,2
6706F1 6 450 600 15,4
6706G1 7 500 800 19,4
6706H1 8 550 800 19,6
6706I1 9 600 800 19,8
6706L1 10 650 800 20,0
12 2
8 3
C
4
C
50 50 40 30 20 10
9 11
1 2 3 4
L/MIN
10
1 2 3 4
L/MIN
5
1 2 3 4
L/MIN
6
1 2 3 4
L/MIN
40 30 20 10
7 13
1 2 3 4
L/MIN
1 2 3 4
L/MIN
C
Pre-assembled unit complete with: 1) Flow manifold with flow meters and built-in flow rate balancing valves 2) Return manifold with built-in shut-off valves fitted for thermo-electric actuator 3) End fittings with automatic air vent with hygroscopic cap, discharge valve and filler/drain cock 4) Pair of ball shut-off valves 5) Liquid crystal digital thermometers on the flow and return manifolds 6) Adhesive labels indicating the rooms 7) Pair of brackets fastening to the box 8) Box with adjustable height and depth 9) Coupling adapter with clip 675850 code 10) Template for cutting pipe 675002 code Accessories 11) 680 series single and multi-layer plastic pipe fitting with self-adjustable diameter 12) 656 series thermo-electric actuator 13) Push-fit thermometer for panel circuit 675900 code
Construction details Specific plastic material The manifolds are made with a specifically selected polymer for heating and cooling system applications. The basic characteristics for this use are: high strain resistance while maintaining good ultimate elongation good resistance to crack propagation very low moisture absorption, for constant mechanical behaviour high abrasion resistance due to medium constant flow performance stability to temperature changes compatibility with the glycols and additives used in the circuits
These basic material characteristics, combined with the appropriate shaping of the most highly stressed areas, enable a comparison with the metals typically used in the construction of distribution manifolds.
Return manifold The return manifold is equipped with built-in shut-off valves. Using the shut-off valve with a manual knob, the flow rate to the single circuits can be reduced so much as to shut off the circuit completely. The valve is equipped with a stainless steel control stem in a single piece, with a double O-ring seal. The rubber obturator is specially shaped to minimize the losses of head and the noise produced by the flow of the medium, preventing the seal seat from possibly sticking. The valves are fitted to accommodate thermo-electric actuator in order to automate their action upon receiving a signal from an ambient thermostat.
Flow manifold The flow manifold is equipped with flow meters and built-in flow rate balancing valves. Using the balancing valve with the special tapered obturator, the flow rate to the single circuits can be adjusted accurately as required, with the setting being read off the single flow meter with a scale of 1-4 l/min. This simplifies and speeds up the operation of calibrating the circuit, with no need for reference graphs. After balancing, the valve can be locked in position by means of its tamper-proof cover. This valve makes it possible to seal off the single circuit should this be necessary.
Modular manifolds The manifolds and end fittings are modular thanks to the threaded connections with O-ring seals and lock clips preventing unscrewing. With this connection system, the operation of assembling the various components is simplified and the hydraulic seal is fully assured. End fitting The end fitting is equipped with an automatic air vent with hygroscopic safety cap, discharge valve and filler/drain ball cock. The automatic air vent is equipped with a removal mechanism air with a silicone rubber obturator. The vent mechanism is connected to the valve body by a fixing clip, making any inspection and maintenance work easier. The hygroscopic safety plug anyhow prevents water leaking to protect the installation. The manual discharge valve speeds up the operation of filling the circuit, done by using the drain/filler ball cock.
Replaceable components The headworks of the balancing valve with flow meter and of the shut-off valve can be removed and replaced with spare parts.
Panel circuit outlets The outlet connections of the single panel circuits are designed to use a special coupling adapter that can be removed with a fixing clip. The brass adapter has a double O-ring seal and a hexagon on its surface. The pipe fitting is connected straight onto the threaded side. With this particular connection system, the fitting with the adapter can be tightened onto the piping outside the box and then coupled on the manifold body later, making the plumbing installation simpler and more practical.
Digital thermometers A liquid crystal digital thermometer is fitted on the flow and return manifold body, on both sides, with a temperature range of 24-48C. The liquid crystals automatically light up green at the measured temperature, making it easy to read even when there is poor lighting. This thermometer is calibrated to display the actual temperature of the medium, which is essential to evaluate the systems thermal load and operating conditions.
Room identification On the manifold body, at the outlet of each panel circuit, there is a special surface for affixing an adhesive label identifying the corresponding room.
Thermometers for loop piping As an accessory, a special spirit thermometer with a scale of 5-50C is available, equipped with a push-fit plastic body, for the single loop piping, with an outside diameter from 15 to 18 mm. This thermometer, installed on the return line, measures the actual temperature of the medium returning from the circuit making it possible to check the state of the single panels heat transfer accurately.
Shut-off valves The ball shut-off valves on the flow and return of the circuits are the union-type with a flat-seat seal made of EPDM.
Box The manifolds are supplied bracketed in a recess-mounting plate box with an adjustable depth from 80 to 120 mm. The box, specifically designed to be used with radiant panel systems, is equipped with floor supports that are adjustable in height from 270 to 410 mm, the height being chosen according to the thickness of the slab. With these supports, the pipe passageway is clear of obstruction; a double curtain wall then enables the plastering to be done directly and the correct fitting of frame and cover. The back wall of the box has grooves and holes to secure the manifold brackets; the side and top walls have holes for the main pipes to pass through. The cover is opened and closed using a special handle with a push-fit clamp, without using any keys or tools.
Bracketing The manifolds have holes to secure them on brackets to allow housing them in boxes. The manifolds are reversible, in that they can be positioned with the entry from the right or left. The return manifold, located at the top, is installed at an angle on purpose in order to make it easier for the panel circuit pipes to pass through, up to 20 mm in diameter. The manifolds can thus be bracketed in a box just 80 mm deep, allowing for installation in thin walls.
The box is also customizable for connecting the main pipes coming in from the top.
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 radiant panel 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.
PBall V
PR Man.
PSV
C
1 2 3 4
L/MIN
PTot.
PBV
PLoop
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
C
C. MATRIM.
GTot.
GLoop
ENTRATA
PRANZO
CAMERA
CUCINA
PBall V
PF Man.
BAGNO
PTot.
PTot. PBV PLoop PSV
= Total loss at the ends of the manifold (Flow + Return + Loop) = Localized loss at loop balancing valve (loop flow rate)
PBV
PLoop = Loop loss (loop flow rate)

PBall V PF. Man. GLoop PR Man. PBall V
PSV
= Localized loss at panel circuit shut-off valve (loop flow rate)
PF. Man. = Distributed loss of the flow manifold (total flow rate)
GTot. GTot.
PR. Man. = Distributed loss of the return manifold (total flow rate) PBall V. = Ball valve loss (total flow rate)
PTot. = PBV +PLoop + PSV + PF Man. + PR Man. + PBall V x 2
(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

250 300 350 400 120 140 160 180 450 25 30 35 40 45 60 70 80 90
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

1200 1400 1600 1800 2500 3000 3500 600 700 800 900
0,5
20
18 16 14 12
0,2
20
18 16 14 12
0,2
10
20
0,1
500
10
500
0,1
4000
1000
2000
100
200
50
G (l/h)
G (l/h)
Flow rate balancing valve fully open Shut-off valve

Kv 1,00 2,40
Kv0,01 100 240
Flow or return manifold 36 outlets Flow or return manifold 710 outlets Ball valve
* Average value
Kv 16,0* 12,0* 16,5*
Kv0,01 1600* 1200* 1650*
Example of calculation of total loss of head Supposing we need to calculate the loss of head of a manifold with three outlets with the following characteristics: Total manifold flow rate: 350 l/h The pipes of the three loops have the following characteristics of flow rate and loss of head: Circuit 1 P1 = 10 kPa G1 = 120 l/h Circuit 2 P2 = 15 kPa G2 = 150 l/h Circuit 3 P3 = 7 kPa G3 = 80 l/h
(1.2)
We calculate each term of the formula (1.1), using the relationship: P = G2/Kv0.012 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 loop of the panel piping. In the case we are examining, the relevant circuit is No. 2. It follows that: PBV PLoop PSV PF Man. PR Man. PBall V = = = = = = 1502/1002 = 2,25 kPa 15 kPa 1502/2402 = 0,39 kPa 3502/16002 = 0,05 kPa 3502/16002 = 0,05 kPa 3502/16502 = 0,04 kPa
} Values obtained by disregarding variations due to flow rate to each branch circuit
By means of (1.1) adding up all the calculated terms, we have: PTot.= 2,25 + 15 + 0,39 + 0,05 + 0,05 + 0,04 = 17,64 kPa Note: Because of the low head losses for the ball valves and the manifolds, the three terms relating to them can be neglected. In general, the total head loss is reasonably approximate to that of the branched circuit of the panel.
Using balancing valves with flow meter The balancing valves in the flow manifold make it possible to balance each single circuit of the panels to obtain the actual design flow rates. Considering the following data: - flow rate of medium that must flow through each circuit - head loss that for this flow rate is generated in each circuit: PCircuit = PLoop + PSV (PShut-off valve) - available head on the panel circuit or predetermined head: HPredetermined PCircuit + = PBV + PLoop + PSV
disadvantaged
SV PCircuit PTot. HPredetermined PCircuit +

disadvantaged
Referring to the diagram alongside, the balancing valve must, for the loop flow rate, provide an additional head loss equal to the difference PBV (PBalancing valve).
BV
PBV
Flow rate adjustment and reading Raise the block cover with the aid of a screwdriver and turn it over onto the flow meter. Adjust the flow rate of the single panels by turning the flow meter body that acts on the built-in balancing valve. The flow rate must be read off the graduated scale, expressed in l/min, printed on the flow meter. After making all the adjustments, reposition all the knobs and hook them in their seat to prevent tampering.
670 series Manifold in composite specifically designed for radiant panel systems with 3 (from 3 to 10) outlets. Body of PA66GF. Seals of EPDM. Head connections: 1 F threaded. Outlet connections: 3/4 M. Media: water and glycol solutions. Maximum percentage of glycol 30%. Maximum working pressure 4 bar. Temperature range 5-60C. Maximum automatic air vent discharge pressure 6 bar. Complete with: - Flow manifold with flow-rate balancing valves and flow meter with graduated scale 1-4 l/min. Accuracy 10%. - Return manifold with shut-off valves fitted for thermo-electric actuator. - Pair of end fittings with automatic air vent with hygroscopic cap, discharge valve, filler/drain cock. - Pair of ball shut-off valves, brass body. Union seals made of EPDM. - Liquid crystal digital thermometers on the flow and return manifolds. Scale 24-48C. - Adhesive labels indicating the rooms. - Pair of fixing brackets. - Box made of painted sheet steel with clamp; adjustable depth of from 80 to 120 mm; with floor supports that are adjustable from 270 to 410 mm. - Coupling adapter with clip 675850 code for manifold outlet and pipe fitting connection 680 series. - Template for pipe cutting 675002 code.
Accessories
675
Coupling adapter with clip code 675850 for manifold outlet 670 series and pipe fitting connection 680 series. Size: 3/4 M - 18-clip coupling.
Technical and construction specifications Materials: - body: - seal: - clip: Medium: Max. percentage of glycol: Max. working pressure: Temperature range: Connection: brass EN 12164 CW614N double O-ring of EPDM stainless steel water, glycol solutions 30% 10 bar 0-100C 5-60C (coupled in the manifold 670) 3/4 M - 18-clip coupling
680
Single and multi-layer plastic pipe fitting with self-adjustable diameter. Size 3/4.
Technical and construction specifications Materials: adapter: nut: pipe clenching ring: seals: dielectric seal ring: brass EN 12164 CW614N brass EN 12164 CW614N PA66GF EPDM EPDM water, glycol solutions 30% 10 bar 5-80C (PEX) 5-50C (Multi-layer) 3/4
1 2 3 4
Medium: Max percentage of glycol: Max working pressure: Temperature range: Connection:
Construction details Pipe-fitting coupling flexibility This fitting has been specifically designed in order to adjust to several pipe diameters. The great variety of plastic pipes, single and multi-layer, on the market and the breadth of permissible tolerances have made it necessary to design a specific fitting. Keeping the nominal dimensions of the fittings currently on the market, the new construction solution makes it possible to use the same fitting for pipes with differences on their outside diameter of up to 2 mm and on their inside diameter of up to 0,5 mm. Pull-out resistance This fitting opposes high resistance to pipe pull-out. Its special tightening system makes it suitable for all applications, ensuring a perfect hydraulic seal. Low head losses The internal profile of the adapter (1) is shaped to obtain a Venturi effect as the medium flows. It permits having a head loss 20% lower than that corresponding to passages of the same diameter. Dielectric seal ring The fitting is equipped with a rubber insulating element (2) to prevent contact between the aluminium in the multi-layer pipe and the brass of the fitting. This prevents any galvanic corrosion generated by two different metals. Double O-ring seal On the adapter there are two O-ring seals (3) (4) made of EPDM in order to avoid potential leaks even at high working pressures.
Code
Piping (mm) inside outside
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
7,5- 8 8,5- 9 9,5- 9,5 1 9,5-10 1 9,5-10 10,5-11 10,5-11 11,5-12 11,5-12 12,5-13 12,5-13 13,5-14 13,5-14 14,5-15 15,5-16 17
12-14 12-14 14-16 12-14 14-16 14-16 16-18 14-16 16-18 16-18 18-20 16-18 18-20 18-20 18-20 22,50
6561
Code
Tech. brosch. 01042
Technical and constructional specifications Materials: - protective shell - colour self-extinguishing polycarbonate RAL 9010 white version with micro: RAL 9002 grey 230 V
(ac)
Thermo-electric actuator. Normally closed.

Voltage (V)
656102 656104
230 224
Thermo-electric actuator. Normally closed. With auxiliary microswitch.

Code Voltage (V)
656112 656114
230 224
- 24 V (dc) 1A 230 V (ac) = 13 mA 24 V (ac) - 24 V (dc) = 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 Approval:
(ac)
- 24 V
675
Push-fit thermometer for panel piping, code 675900.
695
System test pump code 695000. Comprehensive of pressure gauge and hose for connecting to the system.
Technical and constructional specifications Material: - body: PA6GF alcohol 5-50C 60C from 15 to 18 mm Thermometer fluid: Thermometer scale: Max. working temperature: Range of use of pipe outside (e) diam.: Conducting paste supplied in package
Technical and constructional specifications Materials: - body: - piston: - control lever: Max. working pressure: Water content: Pressure gauge scale: Hose connection: Hose length: bronze brass galvanized steel 50 bar 12 l 0-60 bar 1/2 1,5 m
680 series Self-adjustable diameter fitting for single and multi-layer plastic pipes with internal profile having a Venturi effect to limit head losses. Size 3/4 F. Nut and adapter made of brass, seals of EPDM, dielectric seal ring of EPDM, pipe clenching ring of PA66GF. Media: water and glycol solutions. Maximum percentage of glycol 30%. Maximum working pressure 10 bar. Temperature range 5-80C (PEX); 5-50C (Multi-layer). 675 series Push-fit thermometer for panel piping. Range of use of pipe outside diameter: from 15 to 18 mm. Body of PA6GF. Thermometer fluid: alcohol. Thermometer scale 5-50C. Maximum working temperature 60C. 6561 series Thermo-electric actuator. Normally closed (Normally closed with auxiliary microswitch). 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. 695 series System test pump with 0-60 bar pressure gauge and 1,5 m hose. Hose connection of 1/2. Maximum working pressure: 50 bar. Water content: 12 l.
Application diagram
1 2 3 4 5 6
t1 t2 td 0 2 4 6 8 10 12 14 16 18 20 22 -t 1 -t 2 -t 3
ON OFF
C C
t 1 / t 2 / t 3
CALEFFI
C
C
50 40 30 20 10 50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
C
1 2 3 4 5 6
t1 t2 td 0 2 4 6 8 10 12 14 16 18 20 22 -t 1 -t 2 -t 3
ON OFF
C C
t 1 / t 2 / t 3
CALEFFI
C
C
50 40 30 20 10 50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
C
40
20 60 20
40
60 20
40
60 20
40
60
80
80
80
80
6 8 01
4 2 0 8
4 2
01
40
20 60 20
40
60 20
40
60 20
40
60
80
80
80
80
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 thermostatic mixing valve for solar systems

2521 series
cert. n 0003
CALEFFI
01127/06 GB
ISO 9001
Function The thermostatic mixing valve is used in systems for the production of domestic hot water. It is designed to maintain the set temperature of the mixed water supplied to the user when there are variations in the temperature and pressure conditions of the incoming hot and cold water or in the flow rate. This particular series of mixing valves can function continuously at the high temperatures of the incoming hot water from the solar storage tank.
Product range Code 252140/50 Adjustable thermostatic mixing valve for solar systems Code 252153 Adjustable thermostatic mixing valve with inlet check valves for solar systems sizes 1/2, 3/4 size 3/4
Technical specifications - Materials: - body: dezincification resistant alloy EN 12165 CW602N, chrome plated - shutter: PSU - springs: stainless steel - seal components: EPDM 3065C 2C 14 bar 5 bar 0,2 bar Max. inlet temperature: Max. inlet pressures ratio (H/C o C/H): Min. temperature difference between hot water at inlet and mixed water at outlet for optimum performance: Min. flow rate to ensure stable temperature: 100C 2:1 15C 5 l/min
Setting range: Accuracy: Max. working pressure (static): Max. working pressure (dynamic): Min. working pressure (dynamic):
Connections: - standard version: - 1/2 and 3/4 M with union - with check valves version: - 3/4 M with union
Dimensions C B B B C B
MIN
MAX 7
MIN
MAX 7
COLD
COLD
HOT
HOT
MIX
MIX
A Code 252140 252150 A 1/2 3/4 B 67 67 C 134 134 D 152 152 E 86,5 86,5 F 65,5 65,5
A
Weight (kg)
1,11 1,12
Code 252153
A 3/4
B 71,5
C 143
D 156,5
E 91
F 65,5
A
Weight (kg)
1,21
Solar systems - high temperatures In solar systems with natural circulation in the primary circuit and storage tank with heating jacket, the temperature of the water in the storage tank can vary considerably depending on the degree of solar radiation and can reach very high temperatures over long periods. In summer, and if there is little water usage, the hot water at the storage tank outlet can actually reach temperatures around 98C before the pressure and temperature safety valves are actuated. At these temperatures, the hot water cannot be used directly, because of the danger of scalding. Water temperatures over 50C can cause burns very quickly. For example, at 55C, partial burn occurs in about 30 seconds, whereas at 60C partial burn occurs in about 5 seconds. Consequently, the thermostatic mixing valve installed must be able to: reduce the temperature of the water supplied through the hot water system to a lower value than to the storage tank, i.e. a value usable by the user. For reasons of safety, we advise adjusting the temperature of the mixed water supplied to the user to a value not higher than 50C maintain a constant temperature in the mixed water when there are variations in the inlet temperatures and pressures. maintain function and efficiency over time, without being affected by the continuous high temperature of the hot water at the inlet. ensure that water is stored at high temperature for longer periods, and supplied to the water system at a lower temperature.
Operating principe The controlling element of the thermostatic mixing valve is a temperature sensor fully immersed in the mixed water outlet passage 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 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 set temperature. Construction details High heat resistance The internal flow regulation components are designed to maintain performance of the mixing valve with inlet hot water temperatures up to 100C, in continuous operation. Anti-scale materials The materials used in the construction of the mixing valve 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.
Versions with check valves
MIXED
COLD
HOT
p (bar)
1,5 1,0
p (m w.g.)
15 10
Check vales In systems with thermostatic mixing valves, check valves should be installed to prevent undesirable fluid backflow. The thermostatic mixing valves are also available in versions with incorporated check valves at the hot and cold 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.
0,5 0,3 0,2
5 3 2
0,1
Kv = 2,6 (m3/h) Use 2521 series thermostatic mixing valves are typically installed at the outlet of hot water storage tanks in solar systems, to ensure constant temperature of the mixed water supplied to the user. 2521 series thermostatic mixing valves, because of their flow characteristics, can be installed to control the temperature for both single consumers (e.g., washbasin, bidet, shower) and for multiple consumers. In order to guarantee the delivery of mixed water at the set temperature, the thermostatic mixing valves must have a minimum flow rate of 5 l/min. Installation Before installing mixing valve, the pipework must be flushed out to ensure that there are no circulating impurities to harm the system. We recommend always installing filters of sufficient capacity at the inlet of the water system. 2521 series thermostatic mixing valves must be installed according to the installation diagrams shown on the instructions sheet or this leaflet. 2521 series thermostatic mixing valves can be installed in any position, horizontally or vertically. The following are indicated on the body of the mixing valve: hot water inlet, indicated with the colour red and the word HOT cold water inlet, indicated with the colour blue and the word COLD mixed water outlet with the word MIX. Temperature adjustment table Position T (C) Min. 27 1 32 2 38 3 44 4 49 5 53 6 58 7 63 Max. 67
0,05 0,2 0,5 1 2 5
0,5
10
20
50
Temperature adjustment The temperature is set at the desired value by means of the knob with the graduated scale, on the top of the valve.
Locking the setting After setting the temperature, the setting can be locked at the desired value using the control knob. In order to do this, unscrew the lock screw on the upper part of the control knob, remove the knob and put it back on so that the internal reference couples with the protrusion on the knob carrier ring nut.
2 3
1 MI N
MA
Application diagrams - System with thermal integration Shut-off valve

T
Pressure reducing valve Tundish Check valve T/P safety valve

HOT
2 1
COLD
CALEFFI
Temperature gauge Expansion vessel

T
MIN MAX 7
Automatic diverting valve

T
Thermostat Pump Safety valve
System with thermal integration and recirculation
HOT
2 1
Code 2521.0 Adjustable thermostatic mixing valve, for solar systems. 1/2 (or 3/4) M connections with union. Dezincification resistant alloy body. Chrome plated. Shutter, regulator seats and slide surfaces made of plastic, scale-resistant material with high heat resistance. EPDM seals. Stainless steel springs. Maximum inlet temperature: 100C. Setting range from 30C to 65C. Maximum working pressure: 14 bar. Accuracy: 2C. Provided with tamper-proof setting lock. Code 252153 Adjustable thermostatic mixing valve, for solar systems. Complete with check valves at the inlets. 3/4 M connections with union. Dezincification resistant alloy body. Chrome plated. Shutter, regulator seats and slide surfaces made of plastic, scale-resistant material with high heat resistance. EPDM seals. Stainless steel springs. Maximum inlet temperature: 100C. Setting range from 30C to 65C. Maximum working pressure: 14 bar. Accuracy 2C. Provided with tamper-proof setting lock.
CALEFFI
COLD
CALEFFI
MIN MAX 7
Direct supply unit for Sepcoll 559 series
CALEFFI
163 series
cert. n 0003
ISO 9001
01128/05 GB
Function The direct supply unit supplies the circuits of the high-temperature heating system or air-conditioning system directly from the outlets of a hydraulic separator/manifold. This unit has been specifically designed for use with both the external and concealed versions of the separator/distribution manifolds 559 series. The unit is supplied complete with pre-formed insulation shells, three-speed pump, differential by-pass valve, flow and return temperature gauges on secondary circuit and pressure gauge on the primary inlet, shut-off valves on secondary circuit.
Product range 163620 code Direct supply unit for Sepcoll. Upward flow, right side flow 163630 code Direct supply unit for Sepcoll. Upward flow, left side flow Size 1 Size 1
Technical specifications By-pass Materials: body: spring: obturator: seals: brass EN 1982 CB753S stainless steel EPDM EPDM Wiring diagram
L 230 V N
Ambient thermostat
Shut-off valves Materials: - body: - seals: Connecting pipes Materials: - body: - seals: Performance Medium: Max. percentage of glycol: Max. inlet temperature on primary: Max. working pressure: By-pass setting range: Temperature gauge scale: Pressure gauge scale: Connections: - primary circuit: - secondary circuit: - connection centre distance: water, glycol solutions 30% 100C 10 bar 10-60 kPa (1-6 m w.g.) 0-80C 10 bar 1 F with union 1 F 90 mm brass EN 12165 CW617N non-asbestos fibre brass EN 12165 CW617N EPDM Pump Three-speed pump: Material: - body: Electric supply: Max. ambient humidity: Max. ambient temperature: Protection class: Pump centre distance: Pump connections: Head available at the unit connections
H (m w.g.)
6 5 4 3 2 1 0 0 0,5
model UPS 25/60 cast iron GG 15/20 230 V - 50 Hz 95% 80C IP 44 130 mm 1 1/2 with union
Power consumption
UPS 25-60 3
Speed
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (r.p.m.) 1800 1100 700
3
2 1
1 1,5 2 2,5 3 3,5 4
2 1
Q (m3/h)
Insulation technical specifications Material: closed cell expanded PEX 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 vapour (DIN 52615): > 1.300 Temperature range: 0-100C Reaction to fire (DIN 4102): B2 class
Dimensions
Code 163620
Code 163630
40
20 60 20
40
60 20
40
60 20
40
60
80
80
80
80
G
A B C A D D A C A B
A 1 1 B 95 95 C 90 90 D 77 77 E 460 460 F 320 320 G 140 140
Weight (kg)
Code 163620 163630
SYSTEM RETURN
SYSTEM FLOW
Hydraulic diagram 6
SR
40
20 60 20
SF
40
60
80
80
6 5 2
6 4
3 1
1
Characteristic components 1 2 3 4 5 6 7 8 Three-speed pump UPS 25-60 Differential by-pass valve Wiring box Secondary flow temperature gauge Secondary return temperature gauge Secondary circuit shut-off valves Pressure gauge Insulation
BR
Shut-off valve Temperature gauge Pressure gauge
BF
By-pass valve System electric pump
F
7,5 7,5
Differential by-pass The differential by-pass valve is used to control the total head in the secondary supply circuit. When the set differential pressure value is reached, the obturator opens and allows fluid to pass from the flow to the return circuit, keeping the pressure differential at the set value. If the individual circuits are shut off by automatic two-way on/off modulating or thermostatic valves, the valve prevents overheating of the pump and excessive velocity of the fluid.
By-pass hydraulic characteristics
p (m w.g.)
8 7 6 5 4 3 2 1 0 0 0,5
Set positions
(kPa)
80 70
6 5 4 3 2 1
60 50 40 30 20 10 1 1,5 2 0
G (m3/h)
Installation
Configuration with Sepcoll supplied from the right Direct supply unit 163630 code
20 0
Configuration with Sepcoll supplied from the left

40
20 60 20
40
60
Direct supply unit 163620 code

40
20 60 20
40
60 20
80
40
80 60 20
40
80 60
80
80
T T

40
60 20
40
60
80
80
80
Application diagram
1 2 3 4 5 6
t1 t2 t -t 1 -t 2 -t 3
ON OFF
C C
t 1 / t 2 / t 3
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
C
C
50 40 30 20 10 50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
C
40
20 60 20
40
60 20
40
60 20
40
60
80
80
80
80
6 8 01
4 2 0 8
4 2
01
40
20 60 20
40
60 20
40
60 20
40
60
80
80
80
80
Pump Thermostatic valve Lockshield
163620 / 163630 codes Direct supply unit for Sepcoll 559 series. Configuration with upward flow and right side flow (or left side flow). 1 F union connections on primary circuit. 1 F connections on secondary circuit. Centre distance between primary and secondary circuit connections: 90 mm. Maximum temperature at inlet of primary circuit: 100C. Maximum working pressure: 10 bar. Complete with: UPS 25-60 three-speed pump, 230 V - 50 Hz power supply, maximum ambient temperature: 80C, protection class: IP 44; temperature gauge scale: 0-80C; pressure gauge: 0-10 bar; differential by-pass valve, brass body, stainless steel spring, setting range: 10-60 kPa; shut-off valves on secondary circuit. With pre-formed insulation shells in closed cell expanded PEX.
CALEFFI
CALEFFI S.P.A. S.R.229, N.25 28010 FONTANETO DAGOGNA (NO) TEL. 0322 8491 FAX 0322 863305 Http://www.caleffi.it E-mail: info@caleffi.it
Thermostatic mixing valve with interchangeable cartridge for solar systems

2523 series
CALEFFI
01129/05 GB
Function The thermostatic mixing valve is used in systems for the production of domestic hot water. It is designed to maintain the set temperature of the mixed water supplied to the user when there are variations in the temperature and pressure conditions of the incoming hot and cold water or in the flow rate. This particular series of mixing valves has been designed specifically for systems requiring high flow rates and can function continuously at the high temperatures of the incoming hot water from the solar storage tank.
Product range 2523 series Thermostatic mixing valve with interchangeable cartridge for solar systems Sizes 1/2 - 3/4
Technical specifications Materials:- body: brass EN 12165 CW617N, chrome-plated - cartridge and shutter: brass EN 12164 CW614N, electroless nickel plated - springs: stainless steel - seal components: EPDM Setting range: Accuracy: Max working pressure (static): Max working pressure (dynamic): Min working pressure (dynamic): Max inlet temperature: Max inlet pressures ratio (H/C or C/H): Min flow rate to ensure stable temperature: Connections: 30-65C 2C 14 bar 5 bar 0,2 bar 110C 2:1 1/2: 6,7 l/min 3/4: 8,4 l/min
Dimensions
C B B
MIN
MAX 7
CALEFFI
1/2 and 3/4 M with union
Code 252340 252350
A 1/2 3/4
B 85 85
C 170 170
D 169 169
E 95 95
F 74 74
Weight (kg)
1,65 1,68
Solar systems - high temperatures In solar systems with natural circulation in the primary circuit and storage tank with heating jacket, the temperature of the water in the storage tank can vary considerably depending on the degree of solar radiation, and can reach very high temperatures over long periods. In summer, and if there is little water usage, the hot water at the storage tank outlet can actually reach temperatures around 98C before the pressure and temperature safety valves are actuated. At these temperatures, the hot water cannot be used directly, because of the danger of scalding. Water temperatures over 50C can cause burns very quickly. For example, at 55C, partial burn occurs in about 30 seconds, whereas at 60C partial burn occurs in about 5 seconds. Consequently, the thermostatic mixing valve installed must be able to: reduce the temperature of the water supplied through the hot water system to a lower value than to the storage tank, i.e. a value usable by the consumer. For reasons of safety, we advise adjusting the temperature of the mixed water supplied to the user to a value not higher than 50C. maintain a constant temperature in the mixed water when there are variations in the inlet temperatures and pressures. maintain function and efficiency over time, without being affected by continuous high temperature of the hot water at the inlet. ensure that water is stored at high temperature for longer periods, and supplied to the water system at a lower temperature.
Operating principle The controlling element of the thermostatic mixing valve is a temperature sensor fully immersed in the mixed water outlet passage 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 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. Construction details High heat resistance The internal flow regulation components are designed to maintain performance of the mixing valve with inlet hot water temperatures up to 110C, in continuous operation.
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 pipework. Wearproof coating All functional parts, such as the shutter, valve seats and guides, are electroless nickel plated. This wearproof coating minimizes the risk of scale forming and ensures performance is maintained over time. Low-inertia thermostat The most temperature-sensitive element, the engine of the thermostatic mixer, 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 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.
MIXED
COLD
HOT
p (bar) 1,5 1,0
1/2 3/4
Temperature adjustment table

p (m w.g.) 15 10
Position T (C)
Min 25
1 29
2 33
3 39
4 43
5 48
6 52
7 58
Max 65
0,5 0,3 0,2
Locking the setting

3 2
0,1
Turn the knob onto the required number, undo the locking screw, remove the knob and put it back on so that the internal reference couples with the protrusion on the knob carrier ring nut.
2 3
1 MIN
MA
0,05
0,5 1 2
5
0,5
10
20
50
Recommended FLOW RATES to ensure stable operation and an accuracy of 2C Kv (m3/h) 4,0 4,5 Minimum (l/min) 6,7 8,4 Maximum* (l/min) 82,0 92,0
Replacing 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 pipework. 1) Close the shut-off valves on the hot and cold inlets. Set the knob to the maximum value. 2) Remove the temperature adjustment knob after unscrewing the lock screw on the top. Remove the plastic knob carrier ring nut. 3) Remove the internal cartridge for inspection or replacement with a new one, using a suitably sized spanner. 4) Fit the knob carrier ring nut back on so that the position indicator is visible. 5) The spare cartridge is supplied preset on the highest value. Then put the control knob back on so that the word MAX align with the position indicator. By turning the knob clockwise it must be possible to make the adjustment from the maximum to the minimum value. Secure the knob with the lock screw. 6) Reopen the shut-off valves and adjust the mixing value onto the required temperature.
1/2 3/4
1/2 3/4
* P = 1,5 bar Use 2523 series thermostatic mixing valves are typically installed at the outlet of hot water storage tanks in solar systems, to ensure constant temperature of the mixed water supplied to the user. 2523 series thermostatic mixing valves, because of their flow characteristics, can be installed in centralised systems with many different user fittings or for controlling groups of fittings, such as shower units, washbasin units, etc. In order to guarantee the delivery of mixed water at the set temperature, the thermostatic mixing valves must have a minimum flow rate of 6,7 l/min (1/2) and 8,4 l/min (3/4). Installation Before installing the mixing valve, pipes should be flushed to remove any impurities that could impair performance. We recommend always installing filters of sufficient capacity at the inlet of the water system. 2523 series thermostatic mixing valves must be installed as shown in the installation diagrams in this leaflet, taking account of the current applicable regulations. 2523 series thermostatic mixing valves can be installed in any position, horizontally or vertically. The following are indicated on the body of the mixing valve: hot water inlet, indicated with the colour red. cold water inlet, indicated with the colour blue. Check valves
3a
3b In systems with thermostatic mixing valves, check valves should be installed to prevent undesired back flows. 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 adjustment The temperature is set at the desired value by means of the knob with the graduated scale, on the top of the valve.
Application diagrams - System with thermal integration

Shut-off valve
T
Pressure reducing valve Tundish Check valve T/P safety valve

T
Temperature gauge
2 1
CALEFFI CALEFFI
Expansion vessel Automatic diverting valve

T
MIN M AX 7
Thermostat Pump
Safety valve
System with thermal integration and recirculation
2 1
CALEFFI CALEFFI
MIN MAX 7
2523 Series Adjustable thermostatic mixing valve with interchangeable cartridge for solar systems. 1/2 (1/2 or 3/4) M connections with union. Brass body. Chrome-plated. Electroless nickel plated brass shutter and cartridge. Stainless steel springs. Seals of EPDM. Maximum inlet temperature 110C. Adjustment range from 30C to 65C. Maximum working pressure (static) 14 bar. Maximum working pressure (dynamic) 5 bar. Accuracy 2C. Provided with tamper-proof setting lock.
CALEFFI
Temperature and pressure relief valve

309 series
cert. n 0003
CALEFFI
ISO 9001
01130/05 GB
General information The temperature and pressure relief valves (TP) 309 series are made by Caleffi S.p.A 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 harmonisation of Member States with regard to pressurised equipment. Function The TP relief valve controls and limits the temperature and pressure of the hot water contained in a domestic storage heater and prevents it from being able to reach temperatures of over 100C, with the formation of steam. On reaching the settings, the valve discharges a sufficient amount of water into the atmosphere so that the temperature and pressure return within the systems operating limits. This particular series of valves is certified as conforming to the performance requirements of the European standard EN 1490 (for settings of 4 - 7 - 10 bar).
Product range 309 series Temperature and pressure relief valve Sizes 1/2 x 15 mm, 3/4 x 15 mm and 3/4 x 22 mm
Technical specifications Materials: - body: dezincification-resistant alloy EN 12165 CW602N - stem: brass EN 12164 CW614N - obturator and diaphragm: EPDM - spring: steel EN 10270-1 SH - control knob: PA6GF PN 10 - 1/2 and 3/4 15; - 3/4 22; 10 kW 25 kW water IV 90C 3 - 4 - 6 - 7 - 10 bar
Dimensions
111 5
B D A F B 15 15 22 C
Nominal pressure: Discharge rating: Medium: PED category: Settings: - temperature: - pressure:
Connections: 1/2 M x 15 mm with compression fitting for copper pipe 3/4 M x 15 mm with compression fitting for copper pipe 3/4 M x 22 mm with compression fitting for copper pipe Code completion ( . . ) Code 3094.. 30 3 bar 40 4 bar 60 6 bar 70 7 bar 00 10 bar Code 3094 . . 309542 3095 . . A 1/2 3/4 3/4
Code 309542 Code 3095.. 42 4 bar 30 3 bar 60 6 bar 70 7 bar 00 10 bar
C 40 43 43
D 102 99 99
E 88 91 91
F 39 39 39
Weight (kg) 0,253 0,261 0,310
Operating principle The valve opens the outlet on reaching the settings for: - temperature: the thermostat compound inside the temperature sensor 1) submerged in the hot water storage heater, expands as the temperature increases. This expansion causes a thrust pin to move and act on the obturator 2) opening the valve. The valve is set to open at temperatures of over 90C. - pressure: the obturator, opposed by a set spring, raises on reaching the pressure setting and opens the outlet completely. The pressure setting is chosen according to the maximum permissible pressure in the system. As the temperature and pressure decrease, the opposite action occurs with the valve subsequently reclosing within the set tolerances. Certification CE mark 309 series TP relief valves comply with the essential safety requirements of Directive 97/23/EC concerning pressure equipment (also called P.E.D.). They are therefore classified as category IV and are equipped with the CE mark. Product certification in accordance with European Standard EN 1490 European Standard EN 1490: 2000, entitled Building valves - Combined temperature and pressure relief valves Tests and requirements, describes the constructional and performance specifications that TP relief valves must have. Caleffi 309 series TP relief valves are certified by Buildcert (UK) to comply with the requirements of the European Standard EN 1490 (for settings 4 7 10 bar).
Installation Before installing a TP relief valve it is necessary for the sizing to be performed correctly by specialized technical personnel in accordance with the current regulations for the specific applications. Any use other than the intended use is prohibited. The TP relief valves must be installed by qualified technical personnel in accordance with current regulations. The TP relief valve must be installed observing the direction of flow indicated by the arrow on the valve body.
Assembly Plumbing system TP relief valves must be installed on the top of the hot water storage heater, making sure that the temperature sensor is correctly submerged in the tank. Make sure that there are no shut-off devices between the valve and the storage heater. TP relief valves can be fitted vertically or horizontally, but not overturned. This prevents debris from impairing operation.
Correct installations
Correct installation
HOT WATER STORAGE HEATER
SOLAR STORAGE
SOLAR STORAGE
309 series Temperature and pressure relief valve. Equipped with the CE mark in accordance with directive 97/23/EC. Threaded 1/2 M connections on the inlet and 15 mm (3/4x 15 mm and 3/4x 22 mm) with compression fitting for copper pipe on the outlet. Temperature setting 90C. Pressure setting 3 bar (available settings: 3-4-6-7-10 bar for 1/2, 4 bar for 3/4 x 15 mm, 3-6-7-10 bar for 3/4 x 22 mm). Valves with 4-7-10 bar setting certified to EN 1490 standard. Discharge rating: 1/2 x 15 mm: 10 kW, 3/4 x 15 mm: 10 kW, 3/4 x 22 mm: 25 kW. Medium: water. Nominal pressure: PN 10. Dezincification-resistant alloy body. Brass stem. Obturator and diaphragm in EPDM. Steel spring. Control knob in glass-fiber re-inforced nylon.
CALEFFI
Motorised ball zone valves with 3-contact control

6442 - 6443 - 6444 series
cert. n 0003
CALEFFI
ISO 9001
01131/06 GB
Function The motorised zone valves permit automatically shutting off the medium in air-conditioning and plumbing systems. The high level of hydraulic performance of this particular series of valves combined with reduced dimensions and practical installation make it especially suited to zone heating systems. The motorised ball valves are used in the above-mentioned systems mainly thanks to the following features: - No seepage - Short operating times (opening - closing valve) - Operational capacity with high pressure differentials - Low head losses - Combination with any type of 3-contact control in order to have complete control when opening and closing, due to the electrical construction features. Patent application No. MI 2005 A 001282
European directive conformity CE mark directives 89/336 EC and 73/23 EC.
Product range 6442 Series Motorised two-way ball zone valve with 3-contact control Code 6443.. 3BY Motorised three-way ball zone valve, by-pass version, with 3-contact control 6444 Series Motorised three-way ball zone valve, with telescopic by-pass tee, with 3-contact control sizes 1/2, 3/4,1 M with union sizes 1/2, 3/4,1 M with union sizes 1/2, 3/4,1 M with union
Technical specifications Valve body Materials: body brass EN 12165 CW617N ball brass EN 12164 CW614N, chrome plated ball seal PTFE with O-Ring in EPDM control stem seal double O-Ring in EPDM union seal O-Ring in EPDM water, glycol solutions 50% 10 bar -5110C 10 bar 1/21 M with union Actuator Materials: - protective shell: - colour: Synchronous motor Electric supply: self-extinguishing polycarbonate grey RAL 9002
Medium: Max. percentage of glycol: Max. working pressure: Temperature range: Max. pressure differential: Connections:
230 V ( 10%) - 5060 Hz 24 V ( 10%) - 5060 Hz Power consumption: 4 VA Auxiliary microswitch contacts rating: 0,8 A (230 V) Protection class: IP 44 (vertical control stem) IP 40 (horizontal control stem) Operating time (angle of rotation 90): 40 s Ambient temperature range: 055C Dynamic starting torque: 8 Nm Length of supply cable: 100 cm
Dimensions - Code completion ( . )
2 230 V 4 24 V 6442 series 2-way
E D G
F A
B C
Code A 64424 . 1/2 64425 . 3/4 64426 . 1
B 60 60 60
C 117 117 126
D 60 60 60
E 95 95 95
F 88 88 88
H Weight (kg) G 55 Es. 37 0,97 55 Es. 37 0,97 55 Es. 38 1,00 6443.. 3BY code 3-way by-pass version
E D G
CALEFFI
A B C
D Code A B C 64434 . 3BY 1/2 60 117 60 64435. 3BY 3/4 60 117 60 64436. 3BY 1 60 126 60 E 95 95 95 F 88 88 88
H G I 55 Es. 37 59 55 Es. 37 59 55 Es. 37 63
Weight (kg)
1,1 1,1 1,3 6444 series 3-way with telescopic by-pass
E D G
CALEFFI
B C
D Code A B C 64444 . 1/2 60 117 60 64445 . 3/4 60 117 60 64446 . 1 60 126 60 E 95 95 95 F 88 88 88
H G I Weight (kg) 55 Es. 37 4963 1,40 55 Es. 37 4963 1,40 55 Es. 38 4963 1,57
63
49
Construction details Seals The valves are equipped with unions with a flat seat with EPDM O-Ring seal.
Directions of flow and position indicator Removing the actuator reveals the slot on the top of the control stem on which acts the pin of the actuator: - it permits opening/closing the valve manually with a screwdriver. - its position shows the direction of flow according to the position of the ball, which is especially helpful when testing or checking the system. Here are three diagrams, one for each type of valve; the position of the slot shows the direction of flow.
Actuator Two-way valve 6442 series ON/OFF mode The valves can be used in ON/OFF mode with a single electrical enabling signal for opening or closing given by the three-contact thermostat/timer-thermostat or an ordinary switch. Modulating mode The electrical construction features of the actuator allow it to be combined with any type of three-point regulator. Drive transmission Thanks to the tapered coupling between the stem of the valve (A) and the shaft of the gearmotor (B), there is a constant mesh of the two components. This permits automatic compensation of the mechanical slack thanks to the force (C) on the stem applied by the pressure of the medium. Valve actuator coupling By means of a steel clip (D), the coupling between the valve and actuator is fast and easy with a straightforward coupling operation with automatic locking. Cam and limit microswitches The cam (A) that works the limit microswitches (B) can move vertically and is supported by a tapered spring (C). In this way the contact with the microswitches is kept constant compensating for wear of the parts over time.
D A C
Three-way valve with by-pass 6443.. 3BY code
CALEFFI
CALEFFI
Three-way valve with by-pass tee 6444 series
Auxiliary microswitch The actuator is equipped with an auxiliary microswitch to be used, for instance, to stop the pump on closing the valve and vice versa. It turns on for an average valve opening value of 80%.
CALEFFI CALEFFI
Telescopic three-way valve and tee with calibrated nozzle The telescopic three-way valve with by-pass tee 6444 series permits coupling with manifolds with a main centre distance of between 49 and 63 mm. The by-pass tee is equipped with a calibrated nozzle U6 (A) in order to create losses of head equivalent to those of the user circuit. This system permits keeping the system flow rate constant and therefore the head of the pump, both when the valve is open and on by-pass.
All the valves are supplied with the slot/indicator in the horizontal position.
Hydraulic characteristics Two-way zone valve 6442 series, sizes 1/2, 3/4 and 1
p (mm w.g.)
4000
3000 30
p (kPa)
40 20 10 5
p (mm w.g.)
4000
3000
Three-way zone valve with by-pass tee 6444 series on open operation, sizes 1/2, 3/4, 1
p (kPa)
40
30
2000 1000 500
1800 1600 1400 1200 900 800 700 600
18 16 14 12 9 8 7 6
2000 1000 500
1800 1600 1400 1200 900 800 700 600
18 16 14 12 9 8 7 6
20 10 5
CALEFFI
400 300
4 3
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
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
40 30
0,4 0,3
20 10
18 16 14 12
0,18 0,16 0,14 0,12
0,2 0,1
20 10
18 16 14 12
0,18 0,16 0,14 0,12
0,2 0,1
6000
7000
8000
9000
6000
7000
8000
1200
1400
1600
1800
2500
3000
3500
4000
4500
1200
1400
1600
1800
2500
3000
3500
4000
500
300
10000
300
500
4500
9000
40 45
600
700
800
900
40 45
600
700
800
900
350
350
Kv (m3/h) = 11,1
G (l/h)
Kv (m3/h) = 10,3
G (l/h)
p (mm w.g.)
4000
3000
Three-way zone valve with by-pass code 6443.. 3BY on open operation, sizes 1/2, 3/4, 1
p (kPa)
40
30
Three-way zone valve 6444 series on by-pass operation equipped with nozzle U6, sizes 1/2, 3/4, 1
p (mm w.g.)
5000
4000
p (kPa)
50
40 30
2000 1000 500
1800 1600 1400 1200 900 800 700 600
18 16 14 12 9 8 7 6
20 10 5
3000
CALEFFI
2000 1800
1600 1400 1200
10000
16 18 14 12 9 8 7 6
1000
2000
5000
1000
2000
5000
CALEFFI
20
1000
400 300
4 3
900 800 700 600
10
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
500
400 300 4 3
200 0,5
40 30
0,4 0,3
180 160 140 120 90 80 70 60

1200 1400 1600 1800 120 140 160 180 250 300 350 400 450 600 700 800 900
1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6

60 70 80 90
100 0,2 0,1 50
20 10
18 16 14 12
0,18 0,16 0,14 0,12
0,5
6000
7000
8000
1200
1400
1600
1800
2500
3000
3500
4000
4500
9000
40 45
600
700
800
900
350
10000
1000
2000
5000
Kv (m3/h) = 10,3
G (l/h)
Kv (m3/h) = 1,2
G (l/h)
Three-way zone valve with by-pass code 6443.. 3BY on by-pass operation, sizes 1/2, 3/4, 1
p (mm w.g.)
5000
4000 3000
CALEFFI
p (kPa)
50
40 30
2000 1800
1600 1400 1200
16 18 14 12 9 8 7 6
20
1000
900 800 700 600
10
500
400 300 4 3
200
180 160 140 120 90 80 70 60

60 70 80 90 120 140 160 180 250 300 350 400 450 600 700 800 900 1200 1400 1600 1800
1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6
100
50
0,5
Kv (m3/h) = 1,8
G (l/h)
2000
1000
100
200
500
50
2000
1000
100
200
300
500
500
50
Installation 1. The two-way valve can be installed either on the flow pipe or on the return pipe. 1. Connection diagram for room thermostat (RT) and electric supply. The illustrated connection permits opening and closing the valve according to the ambient thermostat signal.
USER
ACTUATOR
2. The three-way valves with by-pass and with by-pass tee must be installed on the flow pipe.
M
CLOSE
Max 0,8 A
USER
3. The valve must be installed with the control stem in the horizontal or vertical position, never overturned.
Horizontal stem Vertical stem
3b. In installations with chilled water, with the risk of condensation, the actuator must be installed with the control stem vertical.
2. Pump disconnection diagram when no zone is in operation. This diagram, using the auxiliary microswitch, permits turning off the pump when the zone valve is closed. If the pump has an input current greater than 0,8 A (170 VA) it is necessary to use an intermediate contactor.
C A L E F F I
C A L E F F I
4. The actuator can be fitted on the valve body in the two positions shown. Fastening is with a stainless steel clip.
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
OPEN
RT
CLOSE
5. In the box installation leave a gap of at least 30 mm between the actuator and frame for replacement, if necessary, or maintenance.
min. 30 mm
N L
CALEFFI
min. 30 mm
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
Microswitches The motor is equipped with limit microswitches that cut off the electricity supply on reaching the valve open/closed positions. The auxiliary microswitch turns on for an average valve opening value of 80%.
6. To prevent reaching high temperatures, where the zone valve is installed there should be constant ventilation.
C
I I
Wiring diagrams
OPEN
Max 0,8 A
L E F F
L E F F
L E F F
L E F F
C A L E F F I C A L E F F I
C A L E F F I
356
356
C A L E F F I
C A L E F F I
ACTUATOR
Max 0,8 A
RT
356
C A L E F F I
C C C
CLOSE
OPEN
Application diagrams In systems with zone control, action is taken to automatically cut off the circuits serving the heat exchanger terminal emitters, according to the temperature reached in the room. This circuit closing can however cause changes in pressure and flow rate throughout the system so it is essential to make sure these changes are kept under control within acceptable limits.
System with 6442 series two-way zone valves, differential by-pass valve and Autoflow The system works with variable flow rate and it is necessary to keep the pressure differential generated by the zone valves closing under control. This increase, which can reach unacceptable limits for the system to work properly, translates into an increase in the flow rate to the circuits still open, with problems for the pumps and the boiler. It is therefore necessary to keep the pressure differentials under control by means of differential by-pass valves or variable speed pumps. Installing the Autoflow however always limits the flow rate to the open circuits to the nominal value.
Shut-off valve Thermostatic valve Manual valve Electric pump Autoflow
RT
RT
Room thermostat Differential by-pass Air vent valve Differential by-pass valve
System with code 6443.. 3BY three-way zone valve with by-pass
RT
CALEFFI
RT
CALEFFI
System with 6444 series three-way zone valves with by-pass tee and Autoflow
RT
Autonomous system with 6444 series three-way zone valves with by-pass tee and Autoflow
CALEFFI
RT
CALEFFI
RT
CALEFFI
6442 series Motorised two-way ball zone valve with three-contact control. 1/2 M (from 1/2 to 1) connections with union. Brass body. Chrome plated brass ball. Ball seal made of PTFE with O-Ring in EPDM. Control stem seal with double O-Ring in EPDM. Union seals with O-Ring in EPDM. Medium water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 10 bar. Temperature range -5110 C. Maximum working differential pressure 10 bar. Self-extinguishing polycarbonate actuator; grey RAL 9002; synchronous three-contact motor with auxiliary microswitch; electric supply 230 V (or 24 V); power consumption 4 VA; dynamic starting torque 8 Nm. Auxiliary microswitch contacts rating 0,8 A. Protection class IP 44 with control stem in vertical position, IP 40 with control stem in horizontal position. Operating time (angle of rotation 90C) 40 s; ambient temperature range 055C.
Code 6443.. 3BY Motorised three-way ball zone valve, by-pass version, with three-contact control. 1/2 M (from 1/2 to 1) connections with union. Brass body. Chrome plated brass ball. Ball seal made of PTFE with O-Ring in EPDM. Control stem seal with double O-Ring in EPDM. Union seals with O-Ring in EPDM. Medium water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 10 bar. Temperature range -5110 C. Maximum working differential pressure 10 bar. Self-extinguishing polycarbonate actuator; grey RAL 9002; synchronous three-contact motor with auxiliary microswitch; electric supply 230 V (or 24 V); power consumption 4 VA; dynamic starting torque 8 Nm. Auxiliary microswitch contacts rating 0,8 A. Protection class IP 44 with control stem in vertical position, IP 40 with control stem in horizontal position. Operating time (angle of rotation 90C) 40 s; ambient temperature range 055C. 6444 series Motorised three-way ball zone valve with telescopic by-pass tee with three-contact control. 1/2 M (from 1/2 to 1) connections with union. Brass body. Chrome plated brass ball. Ball seal made of PTFE with O-Ring in EPDM. Control stem seal with double O-Ring in EPDM. Union seals with O-Ring in EPDM. Medium water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 10 bar. Equipped with a calibrated nozzle (U6) on the third way, to balance the system. Temperature range -5110 C. Maximum working differential pressure 10 bar. Centre distance between the connections adjustable from 49 to 63 mm. Self-extinguishing polycarbonate actuator; grey RAL 9002; synchronous three-contact motor with auxiliary microswitch; electric supply 230 V (or 24 V); power consumption 4 VA; dynamic take-off torque 8 Nm. Auxiliary microswitch contacts capacity 0,8 A. Protection class IP 44 with control stem in vertical position, IP 40 with control stem in horizontal position. Operating time (angle of rotation 90C) 40 s; ambient temperature range 055C.
CALEFFI
Motorised ball diverter valve with 3-contact control

6443 series
ACCREDITED
CALEFFI
01132/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003
Function The motorised diverter valves can be used to automatically divert the medium in air-conditioning and hydraulic/domestic water systems. The exceptional hydraulic performance level of this particular series of valves combined with reduced dimensions and practical installation make the products especially suited to heating systems and domestic hot water production systems. The motorised ball valves are used in the above-mentioned systems predominantly thanks to the following features: - no seepage - short operating times (valve opening - closing); available in versions with operating times of 10 seconds and 40 seconds - operation at high differential pressures - low head losses - compatibility with any type of 3-contact control for complete control during the opening and closing phases, thanks to the electrical construction features. Patent application No. MI2005A001282 European directive conformity CE mark directives 89/336 EC and 73/23 EC.
Product range 6443 series Motorised three-way ball diverter valve with 3-contact control sizes 1/2, 3/4 and 1
Technical specifications Materials Valve body Body: Ball: Ball seal: Control stem seal: Union seal: Actuator Protective shell: Colour: Performance Valve body Medium: Max. percentage of glycol: Maximum working pressure: Working temperature range: Maximum differential pressure: Connections: Actuator Synchronous motor Electric supply:
Dimensions
brass EN 12165 CW617N brass EN 12164 CW614N, chrome plated PTFE with EPDM O-ring two EPDM O-rings EPDM O-ring self-extinguishing polycarbonate grey RAL 9002
I F
A AB
water, glycol solutions 50% 10 bar -5110C 10 bar 1/21 M with union
Code 644342 644344 644346 644352 644354 644356 644353 644355 644357 644362 644364 644366 A 1/2" 1/2" 1/2" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 1" 1" 1" B 60 60 60 60 60 60 78 78 78 78 78 78 C 117 117 117 117 117 117 149 149 149 159 159 159
A B C
230 V (10%) - 5060 Hz 24 V (10%) - 5060 Hz Power consumption: 4 VA (644346, 644356, 644357, 644366) 8 VA Auxiliary microswitch contact rating: 0,8 A (230 V) Protection class: IP 44 (vertical control stem) IP 40 (horizontal control stem) Operating time (angle of rotation 90): 40 s (644346, 644356, 644357, 644366) 10 s Ambient temperature range: 055C Dynamic torque: 8 Nm Length of supply cable: 100 cm
D 60 60 60 60 60 60 60 60 60 60 60 60
E 95 95 95 95 95 95 95 95 95 95 95 95
F 88 88 88 88 88 88 91 91 91 91 91 91
G 55 55 55 55 55 55 55 55 55 55 55 55
H Ex.37 Ex.37 Ex.37 Ex.37 Ex.37 Ex.37 Ex.37 Ex.37 Ex.37 Ex.47 Ex.47 Ex.47
I El. Supply Op. Time (s) 58,5 230 V 40 58,5 24 V 40 58,5 230 V 10 58,5 230 V 40 58,5 24 V 40 58,5 230 V 10 73 230 V 40 73 24 V 40 73 230 V 10 78 230 V 40 78 24 V 40 78 230 V 10
Mass (kg)
1,1 1,1 1,1 1,1 1,1 1,1 1,4 1,4 1,4 1,7 1,7 1,7
6443 series, 3-way diverter version
Cam and limit microswitches The cam (4) that controls the limit microswitches (5) can move vertically and is supported by a tapered spring (6). In this way, the contact with the microswitches is kept constant, compensating for wear of the parts over time.
Auxiliary microswitch The actuator is equipped with an auxiliary microswitch to be used, for instance, to stop the pump on closing the valve and vice versa. It shuts off for an average valve opening value of 80%.
Operating times The actuator is available in two versions, with an operating time of 10 seconds or 40 seconds (with angle of rotation 90).
Directions of flow and position indicator
AB
Construction details Seals The valves are equipped with unions which have a flat seat with an O-Ring seal made of EPDM.
Removing the actuator reveals a slot in the top of the control stem on which the actuator pin acts: - this slot allows the valve to be opened and closed manually with a screwdriver; - its position indicates the position of the ball and therefore the direction of flow. This is extremely useful in system testing and checking procedures. The following diagram illustrates the direction of flow, in accordance with the position of the slot. 6443 series three-way diverter valve Flow diversion can be choked thanks to the electrical features of the three-contact actuator.
Actuator ON/OFF mode The valves may be used in ON/OFF mode, with a single electrical enabling signal for opening or closing provided by the three-contact thermostat/timer-thermostat or an ordinary switch. Modulating mode The electrical construction features of the actuator allow it to be combined with any type of three-point temperature controller. Drive transmission The taper coupling between the valve control stem (1) and the gearmotor shaft (2) allows constant connection between the two components. This provides automatic compensation for mechanical slack via the thrust (S) exerted on the control stem by the pressure of the medium.
T DRILLING ON/OFF operation via three-wire or modulating thermostat controlled by a three-point controller Rotation of 90
2 1
3
A
A AB B
A AB
Valve actuator coupling By means of a steel clip (3), the valve and actuator are connected quickly and easily, simply by pushing the two parts together until they click into place.
AB
AB
All the valves are supplied with the slot/indicator in the horizontal position.
p (mm w.g.)
5000
4000 3000 40 30
Wiring diagrams
1/2 - 3/4 3/4 1
p (kPa)
50
1. Connection diagram for room thermostat (RT) and electric supply. The illustrated connection makes it possible to open and close the valve according to the signal provided by the 3-contact room thermostat.
ACTUATOR
2000 1000 500
1800 1600 1400 1200 900 800 700 600
A AB
A AB
18 16 14 12 9 8 7 6
20 10
M
5
CLOSE OPEN
Max 0,8 A
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
20 10
18 16 14 12
0,18 0,16 0,14 0,12
0,2 0,1
N L
RT
120
140
160
180
250
300
350
400
450
600
700
800
900
1200
1400
1600
1800
2500
3000
3500
4000
500
1000
2000
4500
5000
100
200
G (l/h)
2. Connection diagram - with on-off switch device The illustrated connection makes it possible to open and close the valve when the switch allows, using an intermediate relay device.
ACTUATOR
CLOSE
1. The three-way diverter valves may be used as zone valves as indicated: a. on the flow in the diverter position (common inlet AB and outlets A or B) and ON/OFF mode A A B
USER
b. on the return in the mixing valve position (i.e. inlets A and B and common outlet AB) and ON/OFF mode
N L
N.C. relay 230 V
ON-OFF SWITCH DEVICE
A A
USER
3. Pump disconnection diagram when no zone is in operation. This diagram, using the auxiliary microswitch, allows the pump to be deactivated when the diverter valve used as a zone valve is closed. If the pump has a power consumption level over 0,8 A (170 VA), an intermediate contactor must be used.
ACTUATOR
AB
A AB
CLOSE
2b. In installations with chilled water, at risk of condensation, the actuator must be installed with the control stem in a vertical position.
A AB
3. The actuator can be fitted onto the valve body in the two positions indicated. It is secured using a flexible stainless steel clip.
N L
A AB B A AB B
Microswitches The motor is equipped with limit microswitches that cut off the electricity supply on reaching the valve open/closed positions. The auxiliary microswitch shuts off at an average valve opening value of 80%.
OPEN
Horizontal stem
Vertical stem
AB
2. The valve must be installed with the control stem in a horizontal or vertical position, never turned upside down.
RT
OPEN
Code 644342/44/46 644352/54/56 644353/55/57 644362/64/66
Connection Kv (m3/h) 1/2 3,9 3/4 3,9 3/4 8,6 1 9,0
Max 0,8 A
Max. 0,8 A
Shut-off valve Pump Mixing valve
T
Solar thermal system with three-way diverter valve (10 s) If the water from the storage tank is at a lower temperature than required (and set on the thermostat) the diverter valve sends the water to the boiler. Otherwise, the valve sends the water directly to the mixing valve.
Temperature safety valve Safety valve Expansion vessel Deaerator Dirt separator Manual valve Temperature gauge BALLSTOP Temperature/Pressure safety relief valve
T T
Diverter on the secondary circuit for domestic hot water

B BA A
Thermostat Pressure reducing valve Check valve Y-filter
Heating/domestic hot water system with diverter valve (10 s)
Integrated system of solid-liquid/gas heat generators When the solid fuel generator energy supply is not sufficient to keep the temperature of the medium at the desired value, the diverter valve steps in to send the water into the circuit of the fluid/gas-fuelled boiler.
T
BA
AB B
Diverter on the heating circuit
6443 series Motorised three-way ball diverter valve with three-contact control. 1/2 M (from 1/2 to 1) connections with union. Brass body. Chrome plated brass ball. PTFE ball seal with EPDM O-Ring. Control stem seal with double EPDM O-Ring. Union seals with EPDM O-Ring. Medium water and glycol solutions; maximum percentage of glycol 50%. Maximum working pressure 10 bar. Temperature range -5110C. Maximum working differential pressure 10 bar. Self-extinguishing polycarbonate actuator. Grey RAL 9002. Three-contact synchronous motor with auxiliary microswitch. Electric supply 230 V (or 24 V 10%) 5060 Hz. Power consumption 4 VA (8 VA for 10 s version). Dynamic torque 8 Nm. Auxiliary microswitch contact rating 0,8 A. Protection class IP 44 with control stem vertical, IP 40 with control stem horizontal. Operating time (angle of rotation 90) 40 s (10 s). Ambient temperature range 055C.
CALEFFI
Automatic air vent and shut-off valve for solar heating systems
250 series
cert. n 0003
CALEFFI
ISO 9001
01133/07 GB
Function Automatic air vents are used in the closed circuits of solar heating systems to allow air contained in the fluid to be released automatically by means of a valve operated by a float in contact with fluid in the system. The shut-off valves are on the contrary typically used in combination with the automatic air vent valves to be able to cut them off after filling the circuit of solar heating systems. These particular series of products have been specially made to work at high temperature with a glycol medium.
Product range Code 250031 Automatic air vent for solar systems Code R29284 Shut-off valve for automatic air vent size 3/8 M sizes 3/8 M x 3/8 F
Technical specifications of 250 series valve Materials: body: brass EN 12165 CW617N, chrome plated cover: brass EN 12165 CW617N, chrome plated control spindle: alloy UNI EN 12164 CW602N float and conveyor: high resistance polymer seals: high resistance elastomer water, glycol solutions 50% -30180C 10 bar 5 bar 3/8 M
Technical specifications of valve code R29284 Materials: - body: - ball: - seals: brass EN 12165 CW 617N, chrome plated brass EN 12164 CW 614N, chrome plated high resistance elastomer water, glycol solutions 50% -30200C 10 bar 3/8 F x 3/8 M
Medium: Max. percentage of glycol: Working temperature range: Max. working pressure: Connections:
Medium: Max. percentage of glycol: Working temperature range: Max. working pressure: Max. discharge pressure: Connections:
Dimensions
Dimensions
C A
Tmax = 180C / 360F Pmax = 10 bar / 150 psi
B C
Code 250031
A 3/8
B 97
C 55
D 11
Weight (kg)
0,32
Code R29284
A 3/8
B 46
C 8,5
D 35
Weight (kg)
0,90
Operating principe 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.
Maintenance 250 series automatic air vent is made to allow checking of the internal mechanism. Access to the moving parts that govern the air vent is attained by simply taking off the top cover. A shut-off valve must be installed before the 250 series device in order to simplify any maintenance work and for shutting off after the phase of filling.
Construction details Resistance to temperature The high performance level of this series of automatic air vent valves, required moreover in solar heating systems, is ensured by using materials that are highly resistant to temperature. They allow maintaining the functional features of the valve with glycol water temperatures up to 180C. Hydraulic characteristics Discharge capacity when the system is being filled
Nl/s
1,2 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
Application diagram
7 bar (air)
Installation 250 series automatic air vents must be installed in vertical position, typically on the top of the solar heating system panels and at points in the circuit where air bubbles gather that need to be discharged. They must always be installed in combination with a shut-off valve. This is necessary since the vent valves must be shut off after use to remove the air in the phase of filling and starting up the system.
Tmax = 180C / 360F Pmax = 10 bar / 150 psi Tmax = 180C / 360F Pmax = 10 bar / 150 psi Tmax = 180C / 360F Pmax = 10 bar / 150 psi Tmax = 180C / 360F Pmax = 10 bar / 150 psi
250 series Automatic air vent for solar heating systems. 3/8 M threaded connections. Brass body and cover. Chrome plated. Float in high resistance polymer. Seals in high resistance elastomer. Medium: water and glycol solutions. Maximum percentage of glycol: 50%. Working temperature range: -30180C. Maximum working pressure: 10 bar. Maximum discharge pressure: 5 bar. Code R29284 Shut-off valve for automatic air vent for solar heating systems. 3/8 F x 3/8 M threaded connections. Chrome plated brass body and ball. Seals in high resistance elastomer. Medium: water and glycol solutions. Maximum percentage of glycol: 50%. Working temperature range: -30200C. Maximum working pressure: 10 bar.
CALEFFI
Deaerators for solar thermal systems DISCAL

251 series
ACCREDITED
CALEFFI
01134/10 GB
ISO 9001 No. 0003
ISO 9001
FM 21654
Function Deaerators are used to discharge continuously air from the hydraulic circuits of air-conditioning or solar thermal systems. The air vent capacity of these devices is extremely high. They are able to automatically remove all the air from the circuits, down to micro-bubble level. The circulation of fully deaerated water allows the systems to work under optimal conditions without any trouble of noise, corrosion, local overheating and mechanical damage. They are available in versions for installation to horizontal or vertical pipes. This particular series of deaerators has been specifically designed to work at high temperature with glycol solutions, typical condition of solar thermal systems.
Product range 251 series DISCAL Deaerator for horizontal pipes, for solar thermal systems. With drain 251 series DISCAL Deaerator for horizontal pipes, for solar thermal systems. Compact version 251 series DISCAL Deaerator for vertical pipes, for solar thermal systems. Compact version sizes 1 and 1 1/4 size 3/4 sizes 3/4 and 1
Technical specifications Materials Body: Cover: Float: Internal element: Float guide: Obturator stem: Float lever: Spring: Hydraulic seals: Dimensions
C C C
brass EN 12165 CW617N, chrome plated brass EN 12165 CW617N, chrome plated high resistance polymer stainless steel brass EN 12164 CW614N dezincification resistant alloy EN 12164 CW602N stainless steel stainless steel high-resistance elastomer
Performance Medium: Max. percentage of glycol: Working temperature range: Max. working pressure: Max. discharge pressure: Connections: - main
water, glycol solutions 50% -30160C 10 bar 10 bar
for horizontal pipes 3/4, 1 and 1 1/4 F for vertical pipes 3/4 and 1 F (version 1 and 1 1/4) 1/2 F (with plug)
- drain
D E
F B
B A B E Code 251905 251906 Mass (kg) 2,05 2,05 Mass (kg) 1,80 2,36 Code A B C D E Mass (kg) 251003 3/4" 78 55 143 162 0,91
Code 251006 251007
The process of air formation The quantity of air that can remain dissolved in solution in the water depends on the pressure and temperature. This relationship is known as Henrys law, whose graph below permits quantifying the physical phenomenon of releasing the air contained in the medium. By way of example: at the constant absolute pressure of 2 bar, heating the water from 20C to 80C, the quantity of air released by the solution is equal to 18 l per m3 of water. In accordance with this law it may be noted how there is a greater release of air from the solution as the temperature increases and the pressure decreases. This air is in the form of micro-bubbles with diameters in the order of tenths of a millimetre. The micro-bubbles form continuously in the water of the solar thermal systems on the top of the panels, that is at the points in the circuit where the highest temperatures are reached. This air is partly reabsorbed as the medium reaches the parts of the circuit at a lower temperature, partly remaining in the medium and therefore must be extracted. Graph of solubility of air in water
Absolute pressure Max amount in litres of dissolved air per m3 of water (l/m3)
System operation In solar panel thermal systems with forced circulation it is necessary to expel all the air in the medium during the phases of starting up and operating the system. The deaerator permits separating and expelling this air from the medium continuously and safely. This means that the circuit stays completely deaerated automatically; any decrease in pressure due to the release of air is compensated by a suitable filling unit.
automatic filling
Water temperature C
Operating principle The deaerator utilises the combined action of several physical principles. The active part is composed of a set of metal screen surfaces arranged like spokes (1). These elements create such swirling motion as to facilitate the release of micro-bubbles and their adhesion to the surfaces. The bubbles, joining together, increase in volume until the hydrostatic thrust is such as to overcome the force of adhesion to the structure. They then rise towards the top of the device from where they are released by a float-operated automatic air vent valve (2).
1 2
Construction details Resistance to heat and high discharge pressure The high performance of this series of deaerators, moreover required in solar thermal systems, is guaranteed by the use of particularly heat resistant materials. They allow maintaining the functional features of the deaerator with glycol water temperatures up to 160C. The internal geometry of the deaerator has been designed to be able to discharge the air up to a pressure of 10 bar. Facilitated maintenance operations DISCAL devices are built so that maintenance and cleaning procedures can be performed without having to remove the valve body from the pipe. Access to the moving parts controlling the air vent is attained simply by removing the top cover.
Air separation efficiency 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 50 40 30 20
1 bar 2 bar 3 bar
10
Tmax = 160C - 320F Pmax = 10 bar - 150 psi
0
1000 1100 1200 Tme (s) 25 No. of recirc. 100 200 300 400 500 600 700 800 900
V = 1 m/s - T = constant
10
Vertical version
Installation The deaerator must always be installed vertically and preferably: - upstream of the pump where, due to the high speed of the medium and the ensuing drop in pressure, the air micro-bubbles develop more easily; - on the return and in the bottom part of the solar thermal circuit, with no formation of steam. The flow direction of the medium is not important in DISCAL devices.
3/4" - 1"
400
350 300 250
1 1/4"
3/4"
1"
p (mm w.g.)
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
0,6
0,7
0,8
0,9
1,2
1,4
1,6
1,8
2,5
3,5
4,5
10
0,1
0,5
(m3/h)
Size Kv (m3/h)
3/4 10
3/4 - 1
Vertical version
1 28,1
1 1/4 48,8
17
The maximum recommended speed of the medium inside the pipe is 1,2 m/s. The following table shows the maximum flow rates in order to meet this requirement.
Size l/min Kv (m3/h) 3/4 22,7 1,36 3/4 - 1
Vertical version
10
1 35,18 2,11
1 1/4 57,85 3,47
22,7 1,36
15
20
Application diagram Solar thermal system with thermal integration, with boiler and hot water storage
Shut-off valve Pump Thermostatic mixing valve Air vent

T
Cold water - Water mains Hot tap water Mixed tap water Solar thermal circuit
Thermostat Expansion vessel Temperature gauge BALLSTOP Regulator Safety valve
automatic filling
DISCAL 251 series Deaerator for solar thermal systems. Connections 1 (and 1 1/4) F for horizontal pipes, version with drain; 3/4 F, compact version. Brass body, chrome plated. High-resistance polymer float. Stainless steel internal element, float lever and spring. Brass float guide. Dezincification resistant alloy obturator stem. High-resistance elastomer hydraulic seals. Medium water and glycol solutions; maximum percentage of glycol 50%. Working temperature range -30160C. Maximum working pressure 10 bar. Maximum discharge pressure 10 bar. DISCAL 251 series Deaerator for solar thermal systems. Connections 3/4 (and 1) F for vertical pipes, compact version. Brass body, chrome plated. High-resistance polymer float. Stainless steel internal element, float lever and spring. Brass float guide. Dezincification resistant alloy obturator stem. High-resistance elastomer hydraulic seals. Medium water and glycol solutions; maximum percentage of glycol 50%. Working temperature range -30160C. Maximum working pressure 10 bar. Maximum discharge pressure 10 bar.
CALEFFI
High-performance automatic air vent valves for solar heating systems DISCALAIR SOLAR
251 series
cert. n 0003
CALEFFI
ISO 9001
01135/07 GB
Function DISCALAIR devices are used in air-conditioning systems or in the phase of filling and starting solar heating systems to discharge even large quantities of air that has formed in the circuits. This function is performed even when there is considerable pressure thanks to the special geometry of the discharge mechanism, which is identical to the one on DISCAL 551 series deaerators. This particular series of automatic air vent valves has been specifically designed to work at high temperature with a glycol medium, which is typical of solar heating systems.
Product range Code 251004 High-performance automatic air vent valve for solar heating systems size 1/2 F
Technical specifications - Materials: body brass EN 12165 CW617N, chrome plated cover: brass EN 12165 CW617N, chrome plated float: high resistance polymer float guide: brass EN 12164 CW614N obturator stem: dezincification resistant alloy EN 12164 CW602N - float lever: stainless steel - spring: stainless steel - hydraulic seals: high resistance elastomer water, glycol solutions 50% -30160C 10 bar 10 bar 1/2 F
Dimensions
Medium: Max percentage of glycol: Temperature range: Max working pressure: Max discharge pressure: Connections:
Code 251004
A 1/2"
B 114,5
C 35
C D 55
Weight (kg) 0,62
Operating principle The accumulation of air bubbles in the valve body causes the float to drop so that the obturator opens. This action, and therefore correct valve operation, is ensured as long as the water pressure remains under the maximum discharge pressure.
Maintenance The DISCALAIR automatic air vent valve is built to permit inspecting the internal mechanism. Access to the moving parts that govern the air vent is attained by simply taking off the top cover. The body moreover can be separated from the bottom portion connected to the pipe. A shut-off valve must be installed before the DISCALAIR device in order to simplify any maintenance work and for shutting off after the phase of filling.
Construction details Resistance to heat and high discharge pressure The high performance of this series of automatic air vent valves, moreover required in solar heating systems, is ensured by the use of particularly heat resistant materials. They allow maintaining the functional features of the valve with glycol water temperatures up to 160C. The internal geometry of the valve has been designed to be able to discharge the air up to a pressure of 10 bar.
Application diagram
Hydraulic characteristics Discharge capacity in the phase of filling the system

Nl/s
1,5 1,4 1,3 1,2 1,1 1,0 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
7,5
8,5
10 bar (air)
9,5
Installation DISCALAIR series 251 automatic air vent valves must be installed vertically, typically on the top of solar heating system panels and at points in the circuit where bubbles of air that must be discharged gather. They must always be installed in combination with a shut-off valve. This is necessary since the vent valves must be shut off after use, to remove the air in the phase of filling and starting up the system.
Tmax = 160C / 320F Pmax = 10 bar / 150 psi Tmax = 160C / 320F Pmax = 10 bar / 150 psi Tmax = 160C / 320F Pmax = 10 bar / 150 psi Tmax = 160C / 320F Pmax = 10 bar / 150 psi
DISCALAIR SOLAR 251 series High-performance automatic air vent valve for solar heating systems. Connections 1/2 F. Brass body, chrome plated. High resistance polymer float. Stainless steel float lever and spring. Brass float guide. Dezincification resistant alloy obturator stem. High resistance elastomer hydraulic seals. Medium water and glycol solutions; maximum percentage of glycol 50%. Temperature range -30160C. Maximum working pressure 10 bar. Maximum discharge pressure 10 bar.
CALEFFI
Circulation units for solar heating systems

255 - 256 series
cert. n 0003
CALEFFI
ISO 9001
01136/07 GB
Function Circulation units are used on the primary circuit of solar heating systems to control the temperature of the hot water storage. The pump inside the units is activated by the signal from the differential temperature regulator. The units contain the functional and safety devices for an optimal circuit control. Available with flow and return connection and with return connection only.
Product range Code 255056 Code 255156 Code 255166 Code 256056 Circulation unit for solar heating systems, flow and return connection, flow meter scale: 113 l/min Circulation unit for solar heating systems, flow and return connection, flow meter scale: 830 l/min Circulation unit for solar heating systems, flow and return connection, flow meter scale: 540 l/min with Grundfos Solar 25-120 pump Circulation unit for solar heating systems, return connection, flow meter scale: 113 l/min size 3/4 size 3/4 size 1 size 3/4
Technical specifications Materials: Body: Temperature gauge: Seals: O-Rings: Gaskets: Insulating shell:
brass EN 12165 CW617N steel / aluminium PTFE / EPDM EPDM / Viton AFM 34, asbestos free EPP, thermal conductivity = 0,041 W/(mK)
Grundfos pump Code 255056, 255156 and 256056 Code 255166 Body: Power supply: Max. pressure: Max. temperature: Protection class:
solar model 15-60 solar model 25-120 cast iron GG 15/20 230 V - 50 Hz 10 bar 110C IP 42
Performance: Medium: Max. percentage of glycol:
water, glycol solutions 50%
Grundfos pump Solar 15-60 and Solar 25-120 hydraulic characteristics

H (m w.g.)
12 11 10 9 8 7 6 5 4 3 2 1 0 0 0,5 1 1,5 2 2,5 3 0 3,5 60 40 20
Max. working temperature: 180C Max. working pressure: 10 bar Safety relief valve temperature range: -30160C Safety relief valve factory setting: 6 bar (for other factory settings, see 253 series) Min. opening pressure for shut-off and check valve: p: 2 kPa (200 mm w.g.) Adjustment range of flow meter: 113 l/min (code 255056 - 256056) 830 l/min (code 255156) 540 l/min (code 256166) Max flow meter temperature: 120C Pressure gauge scale: 06 bar Temperature gauge scale: 0160C Connections: Hose connection: Filling/drain connections: 3/4 F 3/4 M with 13 mm hose connection
(kPa)
120 100 80
UPS SOLAR 25-120
UPS SOLAR 15-60
Q (m3/h)
Dimensions
B A A
2 8
2 1 0 6 3 4 5
2 8 12
2 1 0 6 3 4 5
4 7
80 80 100 120 140 0 160 40 60 100 120 140 0 160 60
4 3 11
10
80 60 40 100 120 140 0 160 20
3 10 9
40
20
20
9
2 1 0 6 3 4 5
1
80 60 40 100 120 140 0 160 40 60 80 100 120 140 0 160 20 20
1 6 5 3
5 4 3 2 1 0
3 5
5 4 3 2 1 0
5 4 3 2 1 0
A E
F E D C Code A B 255056 3/4 90 130 405 245 520 255156 3/4 90 130 405 245 520 255166 1 90 130 405 245 520
Weight (kg)
7,00 7,25 9,50
1 2 3 4 5 6 7 8 9 10 11 12
Grundfos-Solar circulation pump Safety relief valve for solar heating systems, 253 series Filling/drain cock Fitting connector with pressure gauge Flow meter Air vent Flow temperature gauge Return temperature gauge Pre formed insulation shell Shut-off and check valve (on the back side of the temperature gauge) Connection kit for expansion vessel (optional) 3/4 plug (to be used if no expansion vessel is installed)
B A Construction details Shut-off and check valve

2 1 0 6 3 4 5
The shut-off and check valves are built into the ball cocks of the temperature gauge connectors. To allow the medium to flow in both directions it is necessary to open the respective ball cocks (B) to 45 with a 14 mm fixed spanner. The check valve is opened by the ball, see figure (A). In normal system operation the ball cocks must be fully open.
80 60 40 100 120 140 0 160
20
5 4 3 2 1 0
A
A E
14
B
Code A B 256056 3/4 130 C 405 D 555 E 200
Weight (kg)
5,00
Flow meter The flow meter has a built-in adjustable flow limiter. The meter is available with three different ranges of 113 l/min, 830 l/min and 540 l/min depending on the version. The flow meter must be fitted in a vertical position only.
Air separator The solar circulation unit, version with flow and return connection, is equipped with an air vent separator on the flow line. The gases, separated from the thermal carrier medium, are collected at the top of the deaerator. The collected gases must be evacuated from time to time (every day after putting into operation and afterwards, depending on the quantity of air, once a week or once a month) using the manual air vent with a suitably sized screwdriver. To maintain optimal efficiency of the solar heating system, afterwards, it is necessary to vent the system every six months by using the deaerator.
Adjustable nut
Flow rate adjustment Fitting 1/2 F
Graduation Fitting 3/4 F
Accessories
259
Welded expansion vessel for solar heating systems. Diaphragm certified DIN 4807-3 standard. Compatible with glycol solutions. Max. working pressure: 10 bar. Max. diaphragm temperature: 100C. System temperature range: -10120C.
Code Litres Connections Precharge (bar)
257
broch. 01143
Differential temperature regulator for solar heating systems, with relay output. Complete with box, contact probe and immersion probe with pocket. Box protection class: IP 65. Electric supply: 230 V 6% - 50 Hz. Power consumption: 1,45 VA. Contacts rating on switch-over: 6 A (230 V). T adjustment range: 220 K. Hysteresis: 2 K ( 1 K).
Code
259012 259018 259025 259035 259050
12 18 25 35 50
3/4 3/4 3/4 3/4 3/4
2,5 2,5 2,5 2,5 2,5
257020
257
broch. 01143
255
Expansion vessel connection kit. Consisting of: stainless steel hose, automatic shut-off cock, wall bracket. Max. working pressure: 10 bar. Max. cock working temperature: 110C. Hose length: 500 mm. Used on a bracket for expansion vessels with a maximum capacity of 24 l.
Code
Thermostat for solar heating systems, with relay output. For thermal integration control and diverter valves. Complete with box, contact probe. Box protection class: IP 65. Electric supply: 230 V 6% - 50 Hz. Power consumption: 1,45 VA. Contacts rating: 6 A (230 V). Adjustment temperature range: 2090C. Hysteresis: 1 K.
257030
Code Connections
255001
3/4
257 255
System filling pump for circulation units 255 and 256 series.
broch. 01143
Regulator and thermostat for solar heating systems, with relay output. Complete with box, 1 contact probe and 2 immersion probes with pocket. Box protection class: IP 65. Characteristics as codes 257020 and 257030.
Code
Code
Connections
255010
3/4
257040
2544
Male fitting, mechanical o-ring seal for solar heating systems. For soft (annealed) copper an hard copper, brass, mild and stainless steel pipes. Max. working pressure: 16 bar. Temperature range: -30160C. Black nickel plated nut.
255-256
Fastening bracket supporting boxes containing regulator and thermostat, 257 series
Code
Connections
254458 254452
3/4 M x 18 mm 3/4 M x 22 mm
Code
255002 256002
for circulation unit 255 series for circulation unit 256 series
Shut-off valve Pump Air vent valve Expansion vessel Temperature gauge Safety relief valve
Circulation unit with differential temperature regulator
2 1 0
4 5 6
80 60 40 100 120 140 0 160 40 60
80 100 120 140 0 160
20
20
5 4 3 2 1 0
Circulation unit with differential temperature regulator and thermostat
2 1 0
4 5 6
80 60 40 100 120 140 0 160 40 60
80 100 120 140 0 160
20
20
5 4 3 2 1 0
Double circulation unit with double differential temperature regulator and solar panels with different orientation
2 1 0
4 5 6 1
4 5
80 60 40 100 120 140 0 160 40 60
80 100 120 140 0 160
20
20
5 4 3 2 1 0
5 4 3 2 1 0
SPECIFICATION SUMMARIES Code 255056 Circulation unit for solar heating systems. Connections 3/4 F. Flow and return connection. Brass body. Steel and aluminium temperature gauge. PTFE and EPDM seals. EPDM and Viton O-Rings. AFM 34 gaskets, asbestos free. EPP insulating shell. Medium water and glycol solutions. Maximum percentage of glycol 50%. Maximum working temperature 180C. Maximum working pressure 10 bar. Safety relief valve temperature range -30160C. Safety relief valve factory set at 6 bar. p minimum opening shut-off and check valve 2 kPa. Flow meter scale 113 l/min. Maximum flow meter temperature 120C. Pressure gauge scale 06 bar. Temperature gauge scale 0160C. Filling/drain connections with 13 mm hose connection. Grundfos Solar 15-60 pump. Cast iron body GG 15/20. Electric supply 230 V 50 Hz. Maximum pressure 10 bar. Maximum temperature 110C. Protection class IP 42.
Code 255156 Circulation unit for solar heating systems. Connections 3/4 F. Flow and return connection. Brass body. Steel and aluminium temperature gauge. PTFE and EPDM seals. EPDM and Viton O-Rings. AFM 34 gaskets, asbestos free. EPP insulating shell. Medium water and glycol solutions. Maximum percentage of glycol 50%. Maximum working temperature 180C. Maximum working pressure 10 bar. Safety relief valve temperature range -30160C. Safety relief valve factory set at 6 bar. p minimum opening shut-off and check valve 2 kPa. Flow meter scale 830 l/min. Maximum flow meter temperature 120C. Pressure gauge scale 06 bar. Temperature gauge scale 0160C. Filling/drain connections with 13 mm hose connection. Grundfos Solar 15-60 pump. Cast iron body GG 15/20. Electric supply 230 V 50 Hz. Maximum pressure 10 bar. Maximum temperature 110C. Protection class IP 42.
Code 255166 Circulation unit for solar heating systems. Connections 1 F. Flow and return connection. Brass body. Steel and aluminium temperature gauge. PTFE and EPDM seals. EPDM and Viton O-Rings. AFM 34 gaskets, asbestos free. EPP insulating shell. Medium water and glycol solutions. Maximum percentage of glycol 50%. Maximum working temperature 180C. Maximum working pressure 10 bar. Safety relief valve temperature range -30160C. Safety relief valve factory set at 6 bar. p minimum opening shut-off and check valve 2 kPa. Flow meter scale 540 l/min. Maximum flow meter temperature 120C. Pressure gauge scale 06 bar. Temperature gauge scale 0160C. Filling/drain connections with 13 mm hose connection. Grundfos Solar 25-120 pump. Cast iron body GG 15/20. Electric supply 230 V 50 Hz. Maximum pressure 10 bar. Maximum temperature 110C. Protection class IP 42.
Code 256056 Circulation unit for solar heating systems. Connections 3/4 F. Flow and return connection. Brass body. Steel and aluminium temperature gauge. PTFE and EPDM seals. EPDM and Viton O-Rings. AFM 34 gaskets, asbestos free. EPP insulating shell. Medium water and glycol solutions. Maximum percentage of glycol 50%. Maximum working temperature 180C. Maximum working pressure 10 bar. Safety relief valve temperature range -30160C. Safety relief valve factory set at 6 bar. p minimum opening shut-off and check valve 2 kPa. Flow meter scale 113 l/min. Maximum flow meter temperature 120C. Pressure gauge scale 06 bar. Temperature gauge scale 0160C. Filling/drain connections with 13 mm hose connection. Grundfos Solar 15-60 pump. Cast iron body GG 15/20. Electric supply 230 V 50 Hz. Maximum pressure 10 bar. Maximum temperature 110C. Protection class IP 42.
CALEFFI
Dirt separators DIRTCAL

5462 - 5465 - 5469 series
ACCREDITED
CALEFFI
01137/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003
Function In heating and air conditioning systems, the circulation of water containing impurities may result in rapid wear and damage of components such as pumps and control valves. It also causes blockages in heat exchangers, heating elements and pipes, resulting in a lower thermal efficiency of the system. The dirt separator separates off these impurities, which are mainly made up of sand and rust particles. These are collected in a large collection chamber that requires low frequency cleaning procedures, 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. The threaded connection product is available in versions for installation on horizontal or vertical pipes. Flanged DIRTCAL dirt separators are supplied complete with hot pre-formed shell insulation to ensure perfect thermal insulation when used with both hot and chilled water.
Reference documentation - Tech. Broch. 01054 Automatic air vent MINICAL-VALCAL 5020 - 5021 - 5022 series - Tech. Broch. 01031 Automatic air vent MAXCAL for heating, air-conditioning and cooling systems. 501 series Product range 5462 5465 5469 5469 series series series series DIRTCAL DIRTCAL DIRTCAL DIRTCAL dirt dirt dirt dirt separator separator separator separator for for for for horizontal pipes with threaded connections sizes 3/4-2 horizontal pipes with flanged connections and pre-formed insulation sizes DN 50-DN 150 vertical pipes with olive connections size 22 with nuts for copper pipe vertical pipes with threaded connections sizes 3/4, 1
Technical specifications series Materials: Body: Dirt collection chamber: Top plug: Internal element: Hydraulic seals: Drain cock: Performance: Medium: Max. percentage of glycol: Max. working pressure: Working temperature range: Particle separation rating: Connections: Main: 5462 - 5469 threaded 5465 flanged
brass EN 1982 CB753S brass EN 12165 CW617N brass EN 12164 CW617N PA66G30 (stainless steel, 5469 series) EPDM brass EN 12165 CW617N
epoxy resin coated steel brass EN 12165 CW617N stainless steel non-asbestos fibre (top plug) brass EN 12165 CW617N, chrome plated
water, non-hazardous glycol solutions excluded from the guidelines of directive 67/548/EC 50% 10 bar 0110C down to 5 m
water, non-hazardous glycol solutions excluded from the guidelines of directive 67/548/EC 50% 10 bar 0110C down to 5 m
3/4, 1, 1 1/4, 1 1/2, 2 F 22 mm with compression ends for copper pipe 1/2 F (with plug) hose connection
Top: Drain:
DN 50 - 65 - 80 - 100 - 125 - 150 flanged PN 16 to be coupled with counterflange EN 1092-1 3/4 M (with plug) 1 F
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) 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 specifications of insulation for flanged versions DN 125 and DN 150 Internal 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
B G B
BI-DIRECTIONAL
A C Code 546905 546906

Mass (kg)
1,95 1,95
C F
Code 546902
Mass (kg)
1,95
Code A B 546205 3/4 110 546206 1 110 546207 1 1/4 124 546208 1 1/2 124 546209 2 127
C 56 56 56 56 56
D 131,5 131,5 151,5 151,5 145,5
E 49 49 49 49 55
Mass (kg) F 236,5 1,87 236,5 1,87 256,5 2,22 256,5 2,22 256,5 2,36
A Code 546550 DN 50 546560 DN 65 546580 DN 80 546510 DN 100 546512 DN 125 546515 DN 150
Volume (l) 7
B 350 350 466 470 635 635
C 1 1 1 1 1 1
D 425 425 500 500 600 600

18
E 620 620 740 740 900 900
F G Mass (kg) 169 3/4" 13 169 3/4" 15 219 3/4" 23 219 3/4" 25 324 3/4" 52 324 3/4" 54
52 52
Dimensions DN 50 DN 65 DN 80 DN 100 DN 125 DN 150 7 18
Operating principle The dirt separator operating principle is based on the combined action of a number of physical phenomena. The internal element (1) is composed of a set of radial reticular surfaces. The impurities in the water, on striking these surfaces, get separated, dropping into the bottom of the body (2) where they are collected. In addition, the large internal volume of DIRTCAL slows down the flow speed of the medium thus helping, by gravity, to separate the particles it contains. The collected impurities are discharged, even with the system running, by opening the drain cock (3); this procedure can even be performed while the system is in operation. The dirt separator is designed in such a way that the direction in which the medium is flowing inside it makes no difference.
3
3
Construction details Low head losses and performance maintained over time The separating action of the dirt separator is based on using the internal element with reticular surfaces in place of the ordinary strainer. The screen, by its nature, offers little resistance to the flow of the medium while ensuring separation. This occurs due to the particles colliding with the reticular surfaces and then settling, not by filtration, an action by which the strainer, over time, gets instead progressively clogged by the sludge it removes. The internal shape of the body was also designed to offer minimum resistance to the passage of the medium. All this is to the benefit of performance, i.e. the high capacity to separate impurities and the low head losses that remain unaltered over time.
Geometric structure and large dirt collection chamber The geometrical structure of DIRTCAL is such that, the flow speed inside it is slowed down to help separate the particles of impurities. The dirt collection chamber has the following features: - It is located at the bottom of the device, at such a distance from the connections that the collected impurities are not affected by the swirling of the flow through the screen. - It is large enough to offer an increased amount of collected dirt, which means emptying/ discharging procedures are required less often (in contrast to strainers, which need to be cleaned frequently). - It is easy to inspect, by unscrewing it from the valve body for any servicing of the internal element required in the event of obstruction by fibres or large particles of dirt.
Top connection The connection on the top of the dirt separator can be used to install an automatic air vent, code 502040 MINICAL for the threaded version (A), code 501500 MAXCAL for the flanged version (B).
Draining off with the system running The dirt separator collection chamber is equipped with a shut-off ball cock with special lever in the threaded version (C), and with a shut-off ball valve with butterfly handle in the flanged version (D). These valves can be used to drain off the impurities which have collected at the bottom of the dirt separator, even with the system in operation.
B C D
BI-DIRECTIONAL
Maintenance To carry out maintenance operation (in threaded models for horizontal pipes) (E), simply use a 26 mm hex wrench (1) to unscrew the dirt collection chamber to which the internal element is fixed, in order to extract it for cleaning purposes. For vertical pipe models (F), only the dirt collection chamber may be unscrewed for cleaning procedures, without the whole internal element being removed.
Insulation Flanged DIRTCAL devices are supplied complete with hot preformed shell insulation. This system ensures not only perfect thermal insulation, but also the tightness required to prevent water vapour entering the device from the ambient. For this reason, this type of insulation may also be used in chilled water circuits as it prevents condensation from forming on the surface of the valve body.
3/4" 22 - 3/4" - 1 Vertical version
Sizes
DN 100 DN 125 DN 150 1 1/4" 1 1/2" 2 DN 50 DN 65 DN 80
3/4" 16,2 DN 50 75,0
22 - 3/4 - 1
Vertical version
1" 28,1
1 1/4" 1 1/2" 48,8 63,2
2" 70,0
p (mm w.g.) 400

350 300 250
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
1"
Kv (m3/h) Sizes
17 DN 65 150,0 DN 80 180,0
DN 100 DN 125 DN 150 280,0 450,0 720,0
200
180 160 140 120
Kv (m3/h)
100
90 80 70 60
50
45 40 35 30 25
0,5
The maximum recommended speed of the medium inside the pipe is 1,2 m/s. The following table shows the maximum flow rates in order to meet this requirement.
Sizes 22-3/4"-1 l/min m3/h Sizes l/min m3/h 22,7 1,36 DN 50 141,20 8,47 1" 35,18 2,11 DN 65 238,72 14,32 1 1/4" 57,85 3,47 1 1/2" 90,36 5,42 2" 136,6 8,2
20
18 16 14 12
0,2
0,6
0,7 0,8 0,9
1,2
1,4 1,6
1,8
2,5
3,5 4 4,5
30
35 40 45
60
12
14 16
18
25
70 80 90
120
140 160
100
200
10
20
0,5
50
180
10
0,1
DN 80 DN 100 DN 125 DN 150 361,5 21,69 564,8 33,89 980,0 58,8 1436,6 86,2
7 8 9
G (m3/h)
Separation efficiency The capacity for separating the impurities in the medium circulating in the closed circuits of the systems basically depends on three parameters: 1) It increases as the size and mass of the particle increase. The larger and heavier particles drop before the lighter ones. 2) It increases as the speed decreases. If the speed decreases, there is a calm zone inside the dirt separator and the particles separate more easily. 3) It increases as the number of recirculations increases. The medium in the circuit, flowing through the dirt separator a number of times during operation, is subjected to a progressive action of separation, until the impurities are completely removed. The Caleffi DIRTCAL dirt separator, thanks to the special design of its internal element, is able to completely separate the impurities in the circuit down to a minimum particle size of 5 m. The graph alongside, summarising the tests carried out in a specialised laboratory (TNO - Science and Industry), illustrates how it is able to quickly separate nearly all the impurities. After only 50 recirculations, approximately one day of operation, up to 100% is effectively removed from the circuit for particles of diameter greater than 100 m and on average up to 80% taking account of the smallest particles. The continual passing of the medium during normal operation of the system gradually leads to complete dirt removal.
Particle separation rating - Dirt separator efficiency

Efficiency (%) Efficiency 50 passages (0,5 m/s)
Separated quantity Initial quantity
.100%)
Efficiency 50 passages (1 m/s)
100
80
60
40
20
Particle dimensions (m)
WORKING ZONE
DIRTCAL
CARTRIDGE FILTERS
SPECIAL STRAINERS
Tests in a specialized laboratory TNO - Science and Industry (NL)

Y-STRAINERS
Comparison of head losses: DIRT SEPARATOR - Y-STRAINERS

1000
p (mm w.g.)
900 800 700 600 450 400 350 300 250 180 160 140 120 90 80 70 60 45 40 35 30 25 18 16 14 12
p (kPa)
9 8 7 6
10 5
Reduced head losses A normal Y strainer performs its function via a metal mesh selected for the size of the largest particle. The medium therefore has a consequent initial loss of head that increases as the degree of clogging increases. Whereas, the dirt separator carries out its action by the particles striking the internal element and subsequently dropping into the collection chamber. The consequent head losses are greatly reduced and are not affected by the amount of impurities collected. The graph alongside shows a comparison of the differences in head loss between the two types of device.
500
Y-strainer curve 3/4 - Kv=8
4.5 4 3,5 3 2,5 1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6
200 100 50
DIRTCAL curve 3/4 - Kv=16,2
0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12
20 10
1200
1400
1600
1800
2500
3000
3500
4000
4500
250
300
350
400
450
600
700
800
900
200
500
1000
2000
Installation The dirt separator should preferably be installed on the return circuit upstream of the boiler. This enables it to intercept any impurities already present in the circuit, particularly when it is first started, before they reach the boiler. The dirt separator should always be installed vertically and ideally upstream of the pump. Use the specific versions designed for installation on horizontal or vertical pipes. The flow direction of the medium is not important in dirt separators.
CHILLER
5000
G (l/h)
1000
105
150
210 250
500
16
35
63
10
20
50
2 1 0,5
0,2 0,1
Application diagram
P T
F
A
BI-DIRECTIONAL
Shut-off valve Ball valve BALLSTOP
Safety thermostat
Control pocket Gas filter
Anti-vibration joint Pocket Safety valve
Regulator Pump Expansion vessel AUTOFLOW Y strainer Flow rate metering device Temperature sensor
T
P
Gas regulator
Temperature gauge Differential by-pass valve
Backflow preventer 3 way tap

A
Fuel shut-off valve
Automatic filling unit
Pressure switch
5462 series DIRTCAL Dirt separator. Connections for horizontal pipes 3/4 F (from 3/4 to 2). Top connection 1/2 F (with plug). Drain with hose connection. Brass dirt collection chamber and body. PA66G30 internal element. EPDM hydraulic seals. Brass drain cock. 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. Particle separation rating down to 5m. Patented. 5465 series DIRTCAL Dirt separator. Flanged connections DN 50 (from DN 50 to DN 150), PN 16; can be coupled with counterflanges EN 1092-1. Top connection 3/4 (with plug). Drain 1 F. Epoxy resin coated steel body. Stainless steel internal element. Hydraulic seals in non-asbestos fibre. 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. Particle separation rating down to 5m. Complete with: - chrome plated brass drain valve - 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 (0100C for DN 125 and DN 150). Patented. 5469 series DIRTCAL Dirt separator. Connections 22 with compression ends for copper pipe and 3/4 (and 1) F connections. Brass dirt collection chamber and body. Steel internal element. EPDM hydraulic seals. Brass drain cock. Medium water and nonhazardous 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. Particle separation rating down to 5m.
CALEFFI
Automatic flow regulator with adjustable cartridge

118 series
cert. n 0003
CALEFFI
ISO 9001
01138/06 GB
Function Flow regulators maintain a constant flow rate as the upstream/downstream pressure difference varies. They automatically balance the hydronic circuit and ensure the design flow rate. This particular series of devices is equipped with a special cartridge that can be adjusted from the outside, with which the flow rate can be set on the desired value directly, with no need to shut off the valve.
Product range Series 118 Automatic flow regulator with adjustable cartridge Code 118000 Cartridge adjustment key sizes 1/2 - 3/4 - 1 - 1 1/4
Technical specifications Materials: body: pressure port plugs: adjustable cartridge: hydraulic seals: brass EN 12165 CW617N brass EN 12164 CW614N polymer with HNBR diaphragm EPDM
Dimensions
2
5 4 3 2 1
Medium: Max percentage of glycol: Max working pressure: Temperature range: p Range: Flow rates: Accuracy:
D A
17210 kPa; 17400 kPa; 30400 kPa; 35400 kPa 0,105,00 m3/h 5% 1/21 1/4 F 1/4 F
B A Code 118141 1/2 118151 3/4" 1" 118161 118171 1 1/4 B 83 94 128 128 C 31 31 47 47 D 80 80 100 100
Weight(kg) 0,66 0,62 1,90 1,70
Connections: Pressure port connections:
Operating principle With reference to the drawing shown, p1 and p3 are the pressures in the circuit. p = (p1-p3) is the total pressure difference between upstream and downstream of the valve. Pressure p2 is determined by the diaphragm in reaction to the pressure p1 that acts on the upper chamber of the diaphragm. Interacting with the spring, the difference (p1-p2) remains constant, keeping a constant pA through the orifice (A). The outcome is a constant flow rate through the valve irrespective of changes in the upstream/downstream pressure difference.
Flow rate adjustment By using the special key (code 118000) you act on the adjustment mechanism and read off the desired position on the graduated reference scale. A double gauge, with a scale from 1 to 5 and decimal division from 1 to 9, permits making exact flow rate adjustments. Its colour identifies the pressure range. Depending on the range of flow rate, the cartridges are available in various colours to permit easy identification. The same colours are on the outside, on the adjuster screw and on the protection cover.
A
p2
p1
p1
p3
pawl
cartridge
G Flow rate
GNom
Working range (Range p) p start p end DIFFERENTIAL PRESSURE
Method of coding for 118 series flow regulator

For correct identification of the device, fill in the form giving series N, size, flow rate and Full code:
SERIES SIZE
SIZE
RANGE OF FLOW RATE AND RANGE p

SIZE DIGIT 1/2 4 3/4 5 1 6 1 1/4 7
The last three digits indicate the available ranges of flow rate and the Range p, with the corresponding cartridges. Each cartridge is marked by a specific colour.
p range (kPa)
Body size
Cartridge size
Flow rate range (m3/h)
Cartridge colour
Cartridge code digit
1/2 - 3/4
DN DN DN DN DN
20 20 20 20 20
17-210 17-210 35-400 35-400 30-400 17-400
0,10-0,40 0,15-0,60 0,14-0,60 0,24-0,90 0,40-1,30 1,05-5,00
Black Green Black Green Red Black
1YB 1YG 1GB 1GG 1YR 2YB
1 - 1 1/4
DN 40
Flow-rate adjustment tables

Flow rate - codes 1YB and 1YG - white pawl DN 15 (1/2) and DN 20 (3/4) 17210 kPa l/h Black Min (p) (kPa)
17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 17 18 18 18 18 18 18 18 18 18 19 19 19 19
Flow rate - codes 1GB and 1GG - grey pawl DN 15 (1/2) and DN 20 (3/4) 35400 kPa l/h Black Min (p) (kPa)
32 32 33 33 33 33 33 33 33 33 34 34 34 34 34 34 35 35 35 35 35 36 36 36 36 37 37 37 37 38 38 38 38 39 39 39 40 40 40 41 41
Flow rate - code 1YR - white pawl DN 15 (1/2) and DN 20 (3/4) 30400 kPa l/h Adjustment position
Flow rate - code 2YB - white pawl DN 25 (1) and DN 32 (1 1/4)
Adjustment position Green Min (p) Rotation (kPa)

15 15 15 15 15 15 15 15 15 15 15 15 15 15 15 16 16 16 16 16 16 17 17 17 17 17 18 18 18 18 18 19 19 19 20 20 20 20 21 21 21 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0 3,1 3,2 3,3 3,4 3,5 3,6 3,7 3,8 3,9 4,0 4,1 4,2 4,3 4,4 4,5 4,6 4,7 4,8 4,9 5,0
Adjustment position Green Min (p) Rotation (kPa)

32 32 32 32 32 32 32 32 32 32 32 32 32 33 33 33 33 34 34 34 35 35 35 36 36 37 37 38 38 39 39 40 40 41 41 42 42 43 44 44 45 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0 3,1 3,2 3,3 3,4 3,5 3,6 3,7 3,8 3,9 4,0 4,1 4,2 4,3 4,4 4,5 4,6 4,7 4,8 4,9 5,0
17400 kPa l/h
Adjustment position
l/h
l/h
Red Min (p) Rotation (kPa)

29 30 30 31 31 32 32 33 34 34 35 35 36 37 38 38 39 40 41 42 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 58 59 60 61 62 64 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0 3,1 3,2 3,3 3,4 3,5 3,6 3,7 3,8 3,9 4,0 4,1 4,2 4,3 4,4 4,5 4,6 4,7 4,8 4,9 5,0
Black Min (p) Rotation (kPa)

17 17 17 17 17 18 18 18 18 18 18 18 18 18 18 19 19 19 19 19 19 19 19 19 19 19 19 19 20 20 20 20 20 20 20 20 20 20 20 20 20 1,0 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9 2,0 2,1 2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0 3,1 3,2 3,3 3,4 3,5 3,6 3,7 3,8 3,9 4,0 4,1 4,2 4,3 4,4 4,5 4,6 4,7 4,8 4,9 5,0
100,0 107,8 115,6 124,4 131,2 139,0 146,8 154,6 162,4 170,2 178,0 185,8 193,6 201,4 209,2 217,0 224,8 232,6 240,4 248,2 256,0 263,8 271,6 279,4 287,2 295,0 302,8 310,6 318,4 326,2 334,0 341,8 349,6 357,4 365,2 373,0 380,8 388,6 396,4 404,2 412,0
157,0 168,3 179,6 190,9 202,2 213,5 224,8 236,1 247,4 258,7 270,0 281,3 292,6 303,9 315,2 326,5 337,8 349,1 360,4 371,7 383,0 394,3 405,6 416,9 428,2 439,5 450,8 462,1 473,4 484,7 496,0 507,3 518,6 529,9 541,2 552,5 563,8 575,1 586,4 597,7 609,0
137,9 149,8 161,8 173,7 185,6 197,6 209,5 221,4 233,3 245,3 257,2 269,1 281,1 293,0 304,9 316,9 328,8 340,7 352,6 364,6 376,5 388,4 400,4 412,3 424,2 436,2 448,1 460,0 471,9 483,9 495,8 507,7 519,7 531,6 543,5 555,5 567,4 579,3 591,2 603,2 615,1
237,6 254,1 270,5 287,0 303,5 319,9 336,4 352,8 369,3 385,8 402,2 418,7 435,1 451,6 468,1 484,5 501,0 517,4 533,9 550,4 566,8 583,3 599,8 616,2 632,7 649,1 665,6 682,1 698,5 715,0 731,4 747,9 764,4 780,8 797,3 813,7 830,2 846,7 863,1 879,6 896,1
405,9 527,4 448,9 470,4 491,9 513,4 534,9 556,4 577,9 599,4 620,9 642,4 663,9 685,4 706,9 728,4 749,9 771,4 792,9 814,4 835,9 857,4 878,9 900,4 921,9 943,4 964,9 986,5 1008,0 1029,0 1051,0 1072,0 1094,0 1115,0 1137,0 1158,0 1180,0 1201,0 1223,0 1244,0 1266,0
1048,0 1203,4 1355,9 1505,6 1652,4 1796,3 1937,3 2075,4 2210,7 2343,0 2472,5 2599,1 2722,8 2843,6 2961,6 3076,6 3188,8 3298,1 3404,5 3508,0 3608,7 3706,4 3801,3 3893,3 3982,4 4068,6 4152,0 4232,4 4310,0 4384,7 4456,5 4525,4 4591,5 4654,6 4714,9 4772,3 4826,8 4878,4 4927,2 4973,0 5016,0
Minimum differential pressure required To correctly size the pump, you need to add, to the fixed head losses of the most disadvantaged circuit, the minimum pressure difference required by the device. This value corresponds to the minimum p of the start of the working range, indicated in the tables.
Accessories 100
Code
tech. broch 01041
130 FLOMET
Electronic flow rate and pressure differential measuring station. Supplied complete with shut-off valves and connection fittings. It can be used to check operation in the working range of Autoflow devices. It can also be used to measure the flow rate of balancing valves series 131, 135 and of the metering devices series 683. Transducer range: 0,05200 kPa. Max differential pressure: 200 kPa.
Pair of fast-plug pressure/temperature test port. Max working pressure: 30 bar. Working temperature range: -5130C. 1/4
100000
100
Pair of fittings with fast coupling syringe for connection of the pressure ports to the measuring instruments. Female 1/4 threaded connection. Max working pressure: 10 bar. Max working temperature: 110C. 1/4
Code
Code
100010
130000 130001
Supply 230 V (ac) Battery operated
Application diagrams In heating and air-conditioning systems, the regulators are preferably installed on the circuit return pipe. Some typical installation examples are given below.
To serve a number of heat emitters in line: radiators, convectors, fan coils, air heaters, strips, etc...
To ensure the design flow rates (with both valve open and valve closed) to the various zones of a system.
118 series Automatic flow regulator with adjustable cartridge. 1/2 F connections (from 1/2 to 1 1/4), 1/4 F pressure port. Brass pressure port plugs and body. Polymer adjustable cartridge with HNBR diaphragm. EPDM hydraulic seals. Medium: water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 25 bar. Temperature range 0100C. p range 17210 kPa (17400 kPa, 30400 kPa, 35400 kPa). Range of flow rate from 0,10 to 5,00 m3/h. Accuracy 5%.
CALEFFI
1 2 3 4 5
1 2 3 4 1 2 1 2 1 2 1 2
4 5
T.A.
To regulate the flow in each riser or secondary branch of a system.
1 2 3 4 5
1 2 3 4
1 2 3 4
1 2 3 4
2
5 4 3
4
2
5
2
5 4 3 2 1 1 2 3
2
5 4 3 2 1
2
5 4
2 1
2 1
T.A.
2
5 4 3 2 1 1 2 1 3 2 1 4 3 2
2
5
2
5 4 3
2
5 4
2
5 4 3 2 1
T.A.
2
5 4 3 2 1 1 2 3
2
5 4 3 2 1
2
5 4 3 2 1
2
5 4
2
5
2
5 4 3 2 1 1 2 3
2
5 4 3 2 1
2
5 4
2
2 1
4 3
5 4 3 2 1
To ensure the design flow rate at each terminal emitter in very large networks.
Thermostatic regulator for domestic hot water recirculation circuits

116 series
cert. n 0003
CALEFFI
01139/06 GB
ISO 9001
Function The thermostatic regulator is used for automatic balancing of recirculation circuits in domestic hot water distribution systems, so as to ensure that all parts of the network reach the required temperature. It is also equipped with a by-pass mechanism, either manual or automatic with thermoelectric actuator, to be used in the event of thermal disinfection against Legionella.
Product range 116 series Code 116002 Code 116004 Thermostatic regulator for recirculation circuit Thermoelectric actuator for 116 series Thermoelectric actuator for 116 series size 1/2- 3/4 230 V (ac) 24 V (ac)
Technical specifications Materials: body: adjustable cartridge: springs: hydraulic seals: brass EN 12165 CW617N PPS stainless steel EPDM
Dimensions
Performance: Medium: Temperature setting range: Factory set: Accuracy: Max. working temperature: Max. working pressure: Max. pressure differential: Connections: Pressure port connections:
water 3565C 55C 2C 100C 10 bar 1 bar 1/23/4 F 1/4 F with plug A
Normally closed-ON/OFF Electric supply: Power consumption: Insulation: Protection class: Ambient temperature range: Operating time: Length of supply cable:
230 V (ac) 24 V (ac) 1,8 W class II IP 54 060C 150200 s 1m
Code 116040 116050
A 1/2 3/4
B 80 80
C D 132 132
Thermoelectric actuator
D C 31 31 D 97 97 Weight (kg) 0,61 0,56
Operating principle On reaching the set temperature, the obturator, governed by an internal thermostat, modulates the closure of the hot water orifice, thereby aiding circulation towards the other connected circuits. If the temperature decreases there is the opposite action and the orifice reopens. Thanks to the special design of the preassembled cartridge, the thermostat is not directly in contact with the hot water in circulation. This limits potential trouble with blockage due to limescale. The regulator is equipped with a mechanism that allows circulation regardless of the thermostat action, used to carry out thermal disinfection of the circuit.
Graph for head loss

P (kPa)
18 16 14 12 9 8 7 6
P (mm w.g.) 2000

1800 1600 1400 1200
20
10
Thermostatic operation 5K
1000
By-pass operation
900 800 700 600
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
500
450 400 350 300 250
200
180 160 140 120
100
90 80 70 60
0,5
250 300 350 400 120 140 160 180 450 12 14 16 18 25 30 35 40 45 60 70 80 90
50
100
200
1,4 1,2 1 Kv - (m3/h) 0,8 0,6 0,4 0,2 0 20 25 30 Water temperature (C) 35 40 45 50 55 60 65 70
35 40 45 50 55 60
Set temperature (C)
To correctly size the recirculation pump head, add the loss of head of the valve to the loss of head of the most disadvantaged circuit.
Example Recirculation circuit calculated for an average heat loss of 12 W/m and a temperature difference of 2K between the starting point and the most unfavourable delivery point, at the top of a riser 20 m. in height. Thermostatic regulator located at the base of the riser. Flow rate for the riser, which therefore passes through the thermostatic regulator: G = 12 20 0,860/2= 103 l/h Thermostatic regulator set temperature: Treg = 55C. The graph shows the loss of head of the valve, in thermostatic operation: preg = 6 kPa. From calculations made based on the nominal flow rates, the loss of head from the pipes in the circuit and from the circuit components such as boiler, mixer, valves of the most disadvantaged circuit can be found. Let us suppose that this value is known: pcircuit = 14 kPa Pump head at nominal flow rate: H = pcircuit+preg = 14 + 6 = 20 kPa.
65
System sizing The thermostatic regulators are used for automatic balancing of the various branches of domestic hot water recirculation circuits, so as to ensure the required temperature in each section, to prevent the growth of Legionella and limit heat losses. The recirculation circuits are generally sized according to the flow rate required for each branch, based on the allowed heat loss and the corresponding decrease in temperature along the pipe. Generally speaking, the maximum allowed temperature drop between the point of departure from the heating plant and the point of return to the latter is 5C. According to the flow rate, determined using the various calculation methods, it is possible to calculate the loss of head caused by passage through the thermostatic regulator, using the graphs provided below. The curves for the loss of head are shown with: - valve in thermostatic operating mode. In this case, reference is made to an average aperture corresponding to 5K, between the valve set temperature and the incoming water temperature, bearing in mind the losses along the pipe. This value allows the head required for the recirculation pump to be limited. It is also always necessary to take care to ensure the minimum flow rate required by the mixers in the heating plant. - valve in by-pass operating mode. In this case, the valve obturator is fully open and the minimum loss of head is produced during thermal disinfection against Legionella.
20m
500
10
20
50
G (l/h)
Installation Before fitting the thermostatic regulator, the pipes must be flushed to ensure that none of the impurities in circulation will affect its performance. We recommend always installing filters of sufficient capacity at the inlet of the water system. The thermostatic regulator can be fitted in any position, vertical or horizontal, provided it complies with the direction of flow indicated by the arrow on the valve body.
By-pass The by-pass mechanism operates manually, simply by removing the black protective cover. By installing the thermoelectric actuator it is possible to govern the mechanism automatically. To ensure that the valve is in the open position while the system is being put into service, the actuator is supplied in a normally open (NO) position, and remains in this position until it is powered up electrically for the first time.
Temperature setting The regulator is supplied with a factory temperature setting of 55C. The temperature is set at the desired value by turning the upper screw with the control key. The graded scale shows the temperatures to which the indicator can be set. After adjustment, screw the black protective cover all the way down to activate thermostatic operation.
Maintenance The preassembled cartridge containing the control components can be removed from the valve body for checking, cleaning or replacement.
Checking temperature The valve body is fitted with threaded connectors, which can be used for pressure/temperature ports to check the temperature reached and the loss of head.
116 series Thermostatic regulator for domestic hot water recirculation circuits. Connections 1/2 and 3/4 F. Pressure port connections 1/4 F with plug. Brass body. Adjustable PPS cartridge. Stainless steel springs. EPDM hydraulic seals. Regulation temperature range 3565C. Factory setting 55C. Precision 2C. Maximum working temperature 100C.
Code 116002 Thermoelectric actuator for 116 series, normally closed-ON/OFF. Power supply 230 V (ac). Power consumption 1,8 W. Insulation class II. Protection class IP 54. Ambient temperature range 060C. Operating time 150200 s. Power cable length 1 m.
Code 116004 Thermoelectric actuator for 116 series, normally closed-ON/OFF. Power supply 24 V (ac). Power consumption 1,8 W. Insulation class II. Protection class IP 54. Ambient temperature range 060C. Operating time 150200 s. Power cable length 1 m.
nu n do all e iid etu ot em ttte me etn mrreta tn ed p ep o ed
nu n do all e iid etu ot em ttte me etn mrreta tn ed p ep o ed
CALEFFI
High-Style valves for designer heating systems

Convertible radiator valves and lockshields 400 series. Thermostatic control heads 200 series
cert. n 0003
CALEFFI
01140/07 GB
ISO 9001
Function Convertible radiator valves and lockshields are typically used to shut off and balance the flow rate of medium on the terminal emitters of heating and air-conditioning systems. Whereas thermostatic control head are used in automatically regulating the ambient temperature on the set value: for this purpose convertible radiator valves can be converted from manual to thermostatic by simply replacing the control knob with the thermostatic control. The chrome-plating and special design of this series of products make them particularly suited to the styling requirements of designer heating systems.
Product range VALVES 4001 Series 4003 Series Convertible radiator valve and square lockshield, HIGH-STYLE, for designer heating systems Convertible radiator valve with double right square and double left square lockshield, HIGH-STYLE, for designer heating systems 4004 Series Convertible radiator valve with double left square and double right square lockshield, HIGH-STYLE, for designer heating systems Code 387127 Multipurpose wrench for unions *Connectable with mechanical fittings series 437 - 447 - 681 - 679 THERMOSTATIC CONTROL HEAD Code 200015 - Thermostatic control with built-in sensor with liquid-filled element, HIGH-STYLE, for designer heating systems. Scale of adjustment 05 corresponding to 028C - Tamperproof antitheft cap for use in public places - Wrench for tightening tamperproof antitheft cap Size 1/2 radiator x 23 p.1,5 piping* Size 1/2 radiator x 23 p.1,5 piping* Size 1/2 radiator x 23 p.1,5 piping* from 3/8 to 1
Technical specifications of valves and lockshields Materials: Body: brass EN 12165 CW617N, high chrome finish Control device upper port: brass EN 12164 CW614N Obturator control stem: stainless steel Spring: stainless steel Lockshield obturator control stem: brass EN 12164 CW614N - Hydraulic seals: EPDM - Control knob: ABS, high chrome finish - Knob cap: PA, high chrome finish - Lockshield knob: brass EN 12164 CW614N, high chrome finish - Pipe-cover shell: ABS, high chrome finish - 1/2 x 23 p.1,5 water, glycol solutions 30% 10 bar 1 bar 5100C
Control adjustment range scale, 200 series
0
0C
7C
1
12C
234
16C 20C 24C
5
28C
Technical specifications of control heads 200 series Adjustment range: Adjustment temperature range: Antifreeze trigger: Max ambient temperature: 05 028C ~ 7C 50C
Valve or lockshield connections: Medium: Max percentage of glycol: Max working pressure: Max differential pressure with control fitted: Temperature range:
Dimensions
31
31
31
58 A
A 58
A 58 31
C F
D F
31 E
31 E
A 58
A 58
Code A B C
D
F
C F
C F
58 A
400100 23 p.1,5 1/2 32,5 5580 44 59 48,5
Weight (kg)
0,86
400300 23 p.1,5 1/2 31 5580 46,5 61 47
Code
Weight (kg)
0,86
400400 23 p.1,5 1/2 31 5580 46,5 61 47
Code
Weight (kg)
0,86
48
RH version
48
LH version
48
58 A
A 58
A 58
Code A
C C F F
D F
B 1/2 E 106,5 F 48,5
C 32,5
Weight (kg)
Code
A 23 p.1,5 5580 D E 109
B 1/2 F 47
C 31
Weight (kg)
Code
A 12 5580 D E 109
B 1/2 F 47
C 31
Weight (kg)
400100 + 20001.
Code
23 p.1,5 D
400300 +20001.
Code
400400+20001.
Code
400100 + 20001. 5580
0,55
400300 +20001.
0,55
400412+20001.
0,55
A
Code A B 80 C 48 D 52,5 E 35
E
F 36
Weight (kg)
20001. 30 p.1,5
0,21
Operating principle of thermostatic control head The control device of the thermostatic valve is a proportional temperature regulator, composed of a bellows containing a specific thermostatic medium. As the temperature increases, the medium increases in volume and causes the bellows to dilate. As the temperature decreases there is the opposite process; the bellows contracts due to the thrust of the counter spring. The axial movements of the sensitive element are transmitted to the valve actuator by means of the connecting stem, thereby adjusting the flow of medium in the heating body.
Valve shut
Tailpiece with rubber seal The coupling union to the radiator connection thread has a specially shaped rubber ring (1). This system guarantees the hydraulic seal with no need for further sealing materials, such as PTFE tapes etc. A perfect hydraulic seal with the valve body is on the other hand ensured by the double O-Ring (2).
Valve and lockshield coupling with designer heating system The coupling between valve/lockshield and designer heating system must be made using the specific tailpiece with sealing (1a), to be screwed onto the radiator using the code 387127 Caleffi union wrench. On completing the coupling, lock the valve to the tailpiece by screwing the socket head screw into the hole shown.
1a
Valve open
Construction details Valve The stainless steel control stem (1) has an EPDM double seal O-Ring (2) - (3). In this way the upper portion of the control device upper port (4) can be replaced even with the system running. The obturator (5) is shaped so as to optimize 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.
Telescopic pipe-cover shell A chrome-plated pipe-cover shell is supplied in the package for the aesthetic requirement of covering the entire connection between the valve/lockshield and piping. The coupling between the shell and valve body is telescopic in order to adjust the distances between the valves/lockshields and the walling from where the piping comes. The shell is lastly secured to the valve with its specific screw.
Lockshield The hydraulic seal of the lockshield is ensured by using the EPDM O-Rings on the control device upper port (1) and on the control stem of the lockshield (2) while the O-Ring on the obturator (3) enables shutting off 2 1 3 the radiator completely.
Interchangeable lockshield and valve control device upper ports
With the system already installed there could be the drawback of having swapped over the delivery and return, causing malfunctioning and noise. To get round this problem it is possible, with the system empty, to swap over the two control device upper ports (A) B and (B) of the valves.
Hydraulic characteristics Convertible radiator valves with square connections, high-style, with manual adjustment, code 400100.
p (mm w.g.)
5000 2000 1000 500 200 100 50 20 10
Convertible radiator valves with double square connections, high-style, with manual adjustment, code 400300/400400.
p (kPa)
50 20 10 5 2 1 0,5 0,2 0,1
p (mm w.g.) 5000 2000 1000 500 200 100 50 20 10
p (kPa) 50 20 10 5 2 1 0,5 0,2 0,1
1000
2000
100
200
500
20
50
10
20
50
100
200
500
1000
Kv0,01 = 200 l/h
G (l/h)
Kv0,01 = 127 l/h
G (l/h)
Convertible radiator valves with square connections, high-style, with thermostatic adjustment, proportional band 2K, code 400100 + 20010..
p (mm w.g.)
3000 2000
Convertible radiator valves with double square connections, high-style, with thermostatic adjustment, proportional band 2K, code 400300 + 20010. , 400400 + 20010..
p (mm w.g.) 3000 2000 1000 500 200 100 50 20 10 p (kPa) 30 20
p (kPa)
30 20
1000 500 200 100 50 20 10
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)
1000
2000
100
200
500
10
20
50
10
20
50
100
200
500
1000
Kv0,01 = 56 l/h
P differential max = 1 bar
G (l/h)
Kv0 01 = 60 l/h
P differential max = 1 bar
High-style lockshields, square connections, code 400100.

p (mm w.g.)
5000 2000 1000 500 200 100 50 20 10
1 2 3
High-style lockshields, double square connections, code 400300, 400400.

p (mm w.g.)
5000 2000 1000 500 200 100 50 20 10
1000 2000 100 200 500 10 20 50
1 2 3
p (kPa) 50
20 10 5
4
2000
p (kPa) 50
20 10 5 2
op en
to ta lly
lly ta to
en op
2 1 0,5 0,2 0,1
1 0,5 0,2 0,1
1000
2000
100
200
500
10
20
50
Reg. pos.
Kv0,01 (l/h) 21 37 84 151 192
G (l/h)
Reg. pos.
Kv0,01 (l/h) 21 34 90 130 137
G (l/h)
1 turn 2 turns 3 turns 4 turns F.O.
1 turn 2 turns 3 turns 4 turns F.O.
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).
Valve conversion from manual to thermostatic
Before installing the thermostatic control turn the knob into the fully-open position (Pos. 5).
Operations to carry out before fitting the tamperproof cap Temperature restriction
Turn the knob the new to maximum open position required (e.g. Pos.3). Turn the ring anti-clockwise up to the stop.
2.
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.
Tamperproof and antitheft cap The tamperproof and antitheft version of the thermostatic control is obtained by fitting the cap on the knob as shown hereunder. It is secured with two screws equipped with a special head that can only be tightened by using the appropriate wrench.
SPECIFICATION SUMMARIES 4001 Series Square convertible radiator valve and lockshield HIGH-STYLE for designer heating systems, high chrome finish; valve fitted for thermostatic and electro-thermal controls. Connections for piping 23 p.1,5. Connection to the radiator 1/2 M with EPDM pre-seal nipples supplied. Brass body. ABS valve knob and PA cap, chrome-plated. Brass lockshield knob, chrome-plated. Stainless steel obturator control stem and stainless steel valve spring. Brass lockshield obturator control stem, chrome-plated. Valve with double seal on the control stem with EPDM O-Ring. Brass control device upper port, chrome-plated ABS pipe-cover shells, chrome-plated. Allen wrench for tightening valve. Medium: water and glycol solutions; Maximum percentage of glycol 30%. Maximum working pressure 10 bar. Max differential pressure with control fitted 1 bar. Temperature range 5100C. 4003 Series Right double square convertible radiator valves valve and left double square lockshield HIGH-STYLE for designer heating systems, high chrome finish; valve fitted for thermostatic and electro-thermal controls. Connections for piping 23 p.1,5. Connection to the radiator 1/2 M with EPDM pre-seal nipples supplied. Brass body. ABS valve knob and PA cap, chrome-plated. Brass lockshield knob, chrome-plated. Stainless steel obturator control stem and stainless steel valve spring. Brass lockshield obturator control stem, chrome-plated. Valve with double seal on the control stem with EPDM O-Ring. Brass control device upper port, chrome-plated ABS pipe-cover shells, chrome-plated. Allen wrench for tightening valve. Medium: water and glycol solutions; Maximum percentage of glycol 30%. Maximum working pressure 10 bar. Max differential pressure with control fitted 1 bar. Temperature range 5100C. 4004 Series Left double square convertible radiator valves valve and right double square lockshield HIGH-STYLE for designer heating systems, high chrome finish; valve fitted for thermostatic and electro-thermal controls. Connections for piping 23 p.1,5. Connection to the radiator 1/2 M with EPDM pre-seal nipples supplied. Brass body. ABS valve knob and PA cap, chrome-plated. Brass lockshield knob, chrome-plated. Stainless steel obturator control stem and stainless steel valve spring. Brass lockshield obturator control stem, chrome-plated. Valve with double seal on the control stem with EPDM O-Ring. Brass control device upper port, chrome-plated ABS pipe-cover shells, chrome-plated. Allen wrench for tightening valve. Medium: water and glycol solutions; Maximum percentage of glycol 30%. Maximum working pressure 10 bar. Max differential pressure with control fitted 1 bar. Temperature range 5100C. Code 200015 -Thermostatic control for HIGH-STYLE convertible radiator valves or thermostatic radiator valves for designer heating systems. Sensor incorporated with liquid-sensitive element. High chrome finish. Maximum working pressure 10 bar. Max differential pressure with control fitted 1 bar. Temperature range 5100C. Max 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. Antifreeze trigger ~7C. - Tamperproof antitheft cap for thermostatic control head, for use in public places, high chrome finish. - Special wrench for tightening tamperproof antitheft cap, code 209004. Code 387127 Multipurpose wrench. Can be used for unions from 3/8 to 1.
CALEFFI
Automatic flow regulator with high-resistance polymer cartridge

121 - 126 series
cert. n 0003
CALEFFI
ISO 9001
01141/06 GB
Function The Autoflow devices are automatic flow regulators capable of maintaining a constant flow rate of the medium as the operating conditions of the hydronic circuit change. They automatically balance the hydronic circuit and ensure the design flow rate at each terminal emitter. In this particular series, the devices are equipped with an innovative and exclusive regulator element made of high-resistance polymer, selected for use in air-conditioning and plumbing systems. With this new regulator, the devices provide silent operation, accuracy in control, insensitivity to scale and a long service life. The devices are available in both the version as a flow regulator and in the version completed with a shut-off ball valve. Patent application No. MI2004A001549
Product range 121 series Automatic flow regulator with high-resistance polymer cartridge and ball valve 126 series Automatic flow regulator with high-resistance polymer cartridge sizes 1/2 - 3/4 - 1 - 1 1/4 sizes 1/2 - 3/4 - 1 - 1 1/4
Technical specifications series Materials Body: Autoflow cartridge: Spring: Seals: Ball: Ball seat: Control stem seal: Lever: Pressure port plugs: Performance Medium: Maximum percentage of glycol: Maximum working pressure: Working temperature range: p Range: Flow rates: Accuracy: Connections Pressure ports connections Dimensions E D D 121 brass EN 12165 CW617N high-resistance polymer stainless steel EPDM brass EN 12165 CW614N, chrome-plated PTFE PTFE special zinc-plated steel POM water, glycol solutions 50% 16 bar 0100C 15200 kPa 0,122,0 m3/h 10% 1/21 1/4 F with union x F 1/4 F 126 brass EN 12165 CW617N high-resistance polymer stainless steel EPDM special zinc-plated steel POM water, glycol solutions 50% 16 bar 0100C 15200 kPa 0,122,0 m3/h 10% 1/21 1/4 F 1/4 F
FFI LE CA
FI LEF CA
A
C 50 50 96 96 F 1/4" 1/4" 1/2" 1/2"
B
Code 121141 ... 121151 ... 121161 ... 121171 ... A 1/2" 3/4" 1" 1 1/4" B 156,5 159,5 218,5 220,5 C 50 50 96 96 D 50 50 66 66 E 100 100 120 120 F 1/4" 1/4" 1/2" 1/2"
Weight (kg)
B
Code 126141 ... 126151 ... 126161 ... 126171 ... A 1/2" 3/4" 1" 1 1/4" B 101 106 140 148
Weight (kg)
1,00 1,00 1,85 1,87
C
F
0,45 0,48 1,36 1,24
Circuit balancing
DYNAMIC CIRCUIT BALANCING
Modern heating and air-conditioning systems have to guarantee a high level of thermal comfort with a low consumption of energy. This means supplying the system terminal emitters with the correct design flow rates, to produce balanced hydraulic circuits.
Unbalanced circuits
If a circuit is not balanced, the hydraulic imbalance between emitters creates areas with temperatures which are not unifor m, problems with thermal comfort, and higher energy consumption.
Flow rate
50 %
17
140 %
22 24
180 %

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 the case of partial closure by means of the regulating valves. The flow rate in the open circuits does not remain c o n stant at the nominal value.
FULL LOAD
Flow rate
Flow rate
100 %
140 %
100 %
Regulating valve
0%
100 %
Manual valve PARTIAL LOAD
120 %

Autoflow balances the hydraulic circuit a u t o m a t i c a l l y, ensuring that each ter minal emitter receives 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 c o n stant 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
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 a basic diagram illustrating the methods of operation and the effects of the relevant variables. Principle of operation The regulating element of these devices is a piston and a cylinder that has side apertures, of fixed and variable geometry, through which the medium flows. These apertures are governed by the movement of the piston on which the thrust of the medium acts. A specially calibrated spring counteracts this movement. Autoflows are high performance automatic regulators. They regulate the flow rates selected within a very tight tolerance (approx. 10%) and offer a wide range of operation.

In this case, the regulating piston remains in equilibrium 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
0,15 bar/15 kPa DIFFERENTIAL 2,0 bar/200 kPa PRESSURE Kv0,01 = 0,258 G0 Range p 15200 kPa

If the differential pressure is contained within the control range, the piston compresses the spring and gives the medium a free flow area to permit regular flow at the nominal rate for which the AUTOFLOW is set up.
FLOW RATE
Control range Initial p Final p
G0
0,15 bar/15 kPa DIFFERENTIAL 2,0 bar/200 kPa PRESSURE

In this case, the piston compresses the spring fully and only leaves the fixed geometry aperture for the medium to pass through. 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
0,15 bar/15 kPa DIFFERENTIAL 2,0 bar/200 kPa PRESSURE Kv0,01 = 0,070 G0 Range p 15200 kPa
Construction details New polymer regulator The flow-rate regulator element is made entirely of high-resistance polymer, specially chosen for use in air-conditioning and plumbing systems. Its mechanical behaviour is excellent in a wide range of working temperatures, it features high resistance to abrasion due to the medium flowing continuously, it is insensitive to the deposit of scale and is fully compatible with the glycols and additives used in circuits. Exclusive design The new regulator, thanks to its exclusive design, is able to accurately regulate the flow rate in a wide range of operating pressures. A special internal chamber acts as a damper for the beating and vibration triggered by the flow of the medium, making sure the device works quietly. For these reasons it can be used in system circuits on both zone outlets and directly at the terminal emitters. Ball valve The control stem of the ball valve has a blowout-proof stem 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 self contained cartridge so as to permit easy removal from the body for inspection or replacement. It is equipped with a special automatic fixing system with wire and an operating ring for fast and safe positioning without using tools.
Connecting the device The body of the Autoflow device is fitted with connections for the pressure ports, which is useful when checking operation in the working range. In addition, the cartridge plug contains a connection to be able to use a circuit drain valve.
p (kPa)
Sizing the circuit with Autoflow

Sizing the circuit containing Autoflow is particularly easy to accomplish. As illustrated by the diagrams, shown alongside by way of example, the calculation of the loss of head for choosing the pump is made by referring to the hydraulically most unfavourable circuit and 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 Caleffi Handbooks and the technical report 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
FI LEF CA
I LEFF CA
d. co
18 150
Q =
ge
Ran
= p
FI LEF CA
m a kP
/h
I LEFF CA
d. co
18 150
Q =
ge
Ran
= p
m a kP
/h
1
Autoflow
p circuit (flow + return) extra p absorbed by Autoflow at 50% load minimum p requested by Autoflow p branch circuit at nominal flow rate
H pump
p absorbed by Autoflow at 100% load
4 Terminal
Flow-rate tables
p Range
(kPa)
Code
kv0,01 (l/h)

Flow rates (m3/h)
121141 121151 121161 121171
1.690 1.773 1.800 1.850
15 15 15 15
15200 15200 15200 15200
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 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 0,5; 0,6; 0,7; 0,8; 0,9; 1,0; 1,2; 1,4; 1,6; 1,8; 2,0 0,5; 0,6; 0,7; 0,8; 0,9; 1,0; 1,2; 1,4; 1,6; 1,8; 2,0
Code
kv0,01 (l/h)

p Range
(kPa)
Flow rates (m3/h)
126141 126151 126161 126171
1.669 1.758 1.400 1.450
15 15 15 15
15200 15200 15200 15200
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 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 0,5; 0,6; 0,7; 0,8; 0,9; 1,0; 1,2; 1,4; 1,6; 1,8; 2,0 0,5; 0,6; 0,7; 0,8; 0,9; 1,0; 1,2; 1,4; 1,6; 1,8; 2,0
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 Autoflow 126 series dimension 1 with flow rate G0 = 1200 l/h and p Range 15200 kPa: prequired = pAutoflow + pbody = 15 + (G0 /kv0,01)2 = 15 + (1200 /1400)2 = 15,7 kPa Pump head H = pcircuit + prequired
Method of coding for Autoflow series 121 - 126

For correct identification of the device, fill in the form giving series No., size, flow rate and p. 1st Complete code 2nd 3rd 4th 5th 6th 7th 8th 9th
{
SERIES
{
SIZE
FLOW RATE - p RANGE
SERIES
1st
2nd
3rd
SIZE
5th
{
121 126 Size Digit 4 digit M40 M50 M60 m3/h 0,70 0,80 0,90
Autoflow regulator and ball valve Autoflow regulator
1/2"
3/4" 5
1" 6
1 1/4" 7
7th
8th
9th
The last three digits indicate the flow rates available.
with p Range 15200 kPa

m3/h 0,12 0,15 0,20 digit M12 M15 M20 m3/h 0,25 0,30 0,35 digit M25 M30 M35 m3/h 0,40 0,50 0,60 digit M70 M80 M90 m3/h 1,00 1,20 1,40 digit 1M0 1M2 1M4 m3/h 1,60 1,80 2,00 digit 1M6 1M8 2M0
Installation of Autoflow
In air-conditioning systems, AUTOFLOW devices must preferably be installed on the circuit return pipe. Some typical installation examples are given below.
To regulate the flow rate in each riser or secondary branch of a system.
T.A.
T.A.
T.A.
To guarantee the design flow rate (with valves open or closed) to the various zones of a system.
To balance circuits used in air conditioning units.
To create heat exchanger flow balancing by-passes To balance circuits for hot water distribution
To control the amount of water delivered and balance the various circuits in irrigation systems.
To limit the flow rate of hot water which can be delivered in systems with instantaneous production or limited capacity
For further details, consult Applications Sheets Nos. 04301, 04302, 04303 and the technical report "Dynamic Balancing of Hydronic Systems".
Accessories 120 FILTER Version

Combination of filter and ball valve.
tech. broch. 01041
125 FILTER Version

Y-filter.
tech. broch. 01041
Brass body. Stainless steel filter cartridge. Maximum working pressure: 25 bar Temperature range: 0110C Filter mesh : 1/2-1 1/4: 0,87 mm Fitted for connecting pressure ports and drain valve.
Code kv0.01 (l/h)
Brass body. Stainless steel filter cartridge. Maximum working pressure: Temperature range: Filter mesh :
25 bar -20110C 1/2-1 1/4: 0,87 mm
Fitted for connecting pressure ports and drain valve.

Code kv0.01 (l/h)
120141 120151 120161 120171
000 000 000 000
1/2 3/4 1 1 1/4
1.687 1.725 1.665 1.723
125141 125151 125161 125171
000 000 000 000
1/2 3/4 1 1 1/4
0,688 0,705 1.410 1.494
Head losses
- The stated values of kv0,01 refer to the body of the device with filter.
Head losses
- The stated values of kv0,01 refer to the body of the device with filter.
130 FLOMET
Electronic flow rate and differential pressure measuring station. Supplied complete with hoses 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.
100
tech. broch. 01041
Fast-plug pressure/temperature test ports for automatic flow regulators. Their special construction permits making rapid and accurate measurements while ensuring leaktightness. Can be used for: - checking the operation of Autoflow device; - checking the degree of strainers clogging; - checking the heat output of the emitter terminals. Cap cover facing available in: - Red for upstream pressure - Green for downstream pressure. Brass body. EPDM seals. Working temperature range: -5130C Max. working pressure: 30 bar.
Code
Code
130000 130001
supply 230 V battery operated 100000 1/4
117
Dual-purpose ball valve 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 and you want to keep it even after subsequently closing and reopening the valve.
100
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
100010
Code Use
1/4
117000 117001
120, 121 series 1/2, 3/4 120, 121 series 1, 1 1/4
538
Drain cock with hose connection.
Code
538201 538401
1/4 1/2
121 series Automatic flow regulator and ball valve, Autoflow. Brass body. High-resistance polymer cartridge. Stainless steel spring. EPDM seals. Chrome-plated brass ball. PTFE ball seat and stem seal. Zinc-plated steel lever. POM pressure port plugs. Medium: water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 16 bar. Temperature range 0100C. Accuracy 10%. p Range 15200 kPa. Range of available flow rates: 0,122,0 m3/h. Connections 1/2 (3/4, 1 and 1 1/4) F with union x F. 126 series Automatic flow regulator, Autoflow. Brass body. High-resistance polymer cartridge. Stainless steel spring. EPDM seals. POM pressure port plugs. Medium: water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 16 bar. Temperature range 0100C. Accuracy 10%. p Range 15200 kPa. Range of available flow rates: 0,122,0 m3/h. Connections 1/2 (3/4, 1 and 1 1/4) F x F.
CALEFFI
Thermo-electric actuator with manual opening and position indicator

6563 series
cert. n 0003
CALEFFI
01142/06 GB
ISO 9001
Function The thermo-electric actuator, coupled with zone valves and distribution manifolds for radiant panel systems and radiators, performs the function of making the medium shut-off automatic with control by the room thermostat or another electrical switch. 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. Patent application No. MI 2005 A 000742.
European directive conformity CE mark in accordance with directives 89/336 EC and 73/23 EC.
Reference documentation Tech. broch. Tech. broch. Tech. broch. Tech. broch. 01072 Zone valve 676 series 01044 Distribution manifolds for radiant panel systems 668 series 01065 Distribution manifolds for radiator systems 663 series 01126 Manifolds in composite specifically designed for radiant panel systems 670 series
Product range Code 656302 Thermo-electric actuator with manual opening and position indicator Code 656304 Thermo-electric actuator with manual opening and position indicator Code 656312 Thermo-electric actuator with manual opening, position indicator and auxiliary microswitch Code 656314 Thermo-electric actuator with manual opening, position indicator and auxiliary microswitch electric supply 230 V (ac) electric supply 24 V (ac) or 24 V (dc) electric supply 230 V (ac) electric supply 24 V (ac) or 24 V (dc)
Dimensions
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 656312/14): 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 Code 6563..
A M 30 x 1,5
B 76
C 42
Weight (kg) 0,18
Principle of operation With no power, the device (actuator + valve), is normally closed. With power, the valve opens thanks to the action of a wax thermostatic expansion element governed directly by a PTC resistor.
Using the thermo-electric actuator 1. Normal operation of the control in automatic mode. In automatic mode, the thermo-electric actuatorl opens the valve when it is supplied with electricity. The opening is displayed by the central disc raising on the top of the knob and by the green circular indicator too.
Construction details The thermo-electric actuator 6563 series is equipped with an automatic valve opening position indicator, a knob for opening the valve manually and a mechanism for returning to automatic mode if 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. 2. Using the knob to open the valve manually: Turn the knob on the top of the control anticlockwise until its limit stop trips and the arrow symbols and overlap. To close the valve manually and restore automatic operation of the device, turn the knob clockwise onto AUTO. Note: On the series equipped with an auxiliary microswitch, in the manual opening position the micro contact is closed.
ON
OFF
3. Automatic return from the manual position to the automatic one. When the control in the manual position is powered, an internal mechanism enables automatic release from this position and a return to normal operation. A few seconds after powering up, the knob will automatically return to the AUTO position and the opening indicator will stay on the open position.
ON
Valve in by-pass position
Electrical connections Electrical connections for codes 656302, 656304.
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.
N L
1 0
RT
- 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 should 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.
BROWN BLUE
Electrical connections for codes 656312 and 656314 Wiring diagram with pump disconnection. The auxiliary microswitch can be used to disconnect the pump when the services do not need any heat and the valves are 1 shut. 0 If the pump input exceeds N the capacity of the contacts equal to 0,8 A, an L intermediate contactor should be used.
- In assemblies with zone valves or manifold 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
RT
CALEFFI
The auxiliary microswitch turns on for an average opening value of the thermo-electric actuator of 80%.
40 20 0 60 80
CALEFFI
CALEFFI
CALEFFI
CALEFFI
BLACK BLACK BROWN BLUE
40
20 0
60 80
CALEFFI
Coupling table
656302 656304 656312 656314

676 677 678
Recommendations for use When thermo-electric actuators are to be installed on devices wich automatically shut off the heating elements, it is always advisable to use a differential by-pass to control over-pressure of the system during the partial or total closure of the circuits: For pre-assembled manifolds 668 series a differential by-pass with a fixed calibration setting of 2500 mm w.g. is available, code 668000; whereas for pre-assembled manifolds 663 series a differential by-pass with a fixed calibration setting of 2000 mm w. g. is available, code 663000.
663
666-668
670
CALEFFI
CALEFFI
code 668000
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
Hydraulic characteristics Table of hydraulic characteristics of control 6563 + valve body 656302, 656304, 656312, 656314 + Zone valve (straight/by-pass) Series 676 677 678 663 666 668 670 DN kv0,01 (l/h)
(m w.g.) 12 12 12 25 25 25 25 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., 519 series.
mH2O
pmax *
CALEFFI
CALEFFI
10 8 6 4 2 0
CALEFFI
370 1/21 370/100 370/100 1 1/4 1 1/4 1 1/4 1 287 287 287 240
1 2 3 4 5 6
Manifold for radiant panel systems and radiators
* Maximum pressure differential assured by the servo control for regular operation
Applications The thermo-electric actuators with manual opening and position indicator can be installed in the various types of systems listed below: In zone systems, requiring reduced overall dimensions and a limited coefficient of the flow rate to the automatic regulating valve. In systems with fan coils, if you want to fit them with valves to shut off the medium automatically.
40 20 0 60 80
RT
CALEFFI
CALEFFI
CALEFFI
40 20 0 60 80
CALEFFI
CALEFFI
CALEFFI
RT
CALEFFI Mod.
357
In plumbing systems to adjust the temperature in water storage heaters. In radiant panel systems and radiators, if you want to: - adjust the temperature in the single ambients heated by the circuits branching out from the manifold. - shut off each circuit directly from the manifold, with less work and expense to make the electrical connections.
CALEFFI
CALEFFI
RT
C
C
50 40 30 20 10 50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
C
Codes 656302/04 Thermo-electric actuator with manual opening and position indicator. Normally closed. Self-extinguishing polycarbonate protective shell. RAL 9010 white colour. Supply voltage: 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 40. Made with double insulation. Maximum ambient temperature: 50C. Operating time opening/closing from 120 to 180 s. Length of supply cable: 80 cm. Codes 656312/14 Thermo-electric actuator with manual opening and position indicator. Normally closed with auxiliary microswitch. Self-extinguishing polycarbonate protective shell. RAL 9002 grey colour. Supply voltage: 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. Auxiliary microswitch contacts rating 0,8 A (230 V). Protection class: IP 40. Made with double insulation. Maximum ambient temperature: 50C. Operating time opening/closing from 120 to 180 s. Length of supply cable: 80 cm.
CALEFFI
Differential temperature regulators and thermostats

257 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
01143/07 GB
Function The differential regulator acquires the temperature signals from the probes installed at the panel outlet and in the boiler, calculates the difference between the two temperatures and, by comparison with the set value, commands the primary solar circuit circulation pump. The thermostat controls the storage temperature and activates thermal integration from alternative sources to solar energy (water heaters, electricity, etc.). In addition, it can control the diverter valves in solar panels with natural circulation in order to utilize the albeit minimal available energy.
Product range Code 257020 Code 257030 Code 257040 Code 257010 Differential temperature regulator for solar heating systems, with relay output. Complete with box, contact probe and immersion probe with pocket. Thermostat for solar heating systems, with relay output. For thermal integration control and diverter valves. Complete with box and contact probe. Regulator and thermostat for solar heating systems, with relay output. Complete with box, 1 contact probe and 2 immersion probes with pocket. Differential temperature regulator for solar heating systems with relay output. Complete with contact probe and immersion probe with pocket.
Technical specifications Differential temperature regulator Electric supply: Power consumption: Contacts rating on switch-over: T adjustment range: Hysteresis: Max ambient temperature: Insulation test: Dimensions: Thermostat Electric supply: Power consumption: Contacts rating on switch-over: Adjustable temperature range: Hysteresis: Max ambient temperature: Alarm output contact: Insulation test: Dimensions: 230 V 6% - 50 Hz 1,45 VA 6 A (230 V) 220 K 2 K ( 1 K) 50C 4 kV 3 DIN 230 V 6% - 50 Hz 1,45 VA 6 (2) A (230 V) 2090C 1K 50C 24 V / 20 mA 4 kV 3 DIN
Boxes Dimensions:
- Code 257001: - Code 257003: Protection class: Temperature probes NTC type Working range: Two-wire cable Length of cable:
Probe resistance values table

C -20 -18 -16 -14 -12 -10 -8 -6 -4 -2 14616 13211 11958 10839 9838 8941 8132 7405 6752 6164 C 0 2 4 6 8 10 12 14 16 18 C 5634 20 5155 22 4721 24 4329 26 3974 28 3652 30 3360 32 3094 34 2852 36 2632 38 2431 2247 2079 1925 1785 1657 1539 1430 1331 1239 C 40 44 46 48 50 52 54 56 58 60 1154 1004 938 876 819 767 718 673 631 592 C 62 64 66 68 70 72 74 76 78 80 556 522 491 462 434 409 386 364 343 324 C 82 84 86 88 90 92 94 96 98 100 306 290 274 260 246 233 221 210 199 189
RE
4 DIN 6 DIN IP 65
-20100C 2 m (can be extended to 200 m in case of a cable with 0,5 mm2 cross-section)
Dimensions
C B
C B
A Code A 257 020 122 B 47
D C D Weight (Kg) 200 112 1,2 Code A 257 030 122
A B 47
D C D Weight(Kg) 200 112 1,4 Code A 257 040 160
C B
A B 47
D D Weight(Kg) C 200 112 1,83
Operation
50 40 30 20 C
60 70 80 90
-00
CALEFFI
Sonda
ON
AC 24V 50Hz AC 230V T50 6(2)A
2 1 0
4 5 6
80 60 40 100 120 140 0 160 40 60
80 100 120 140 0 160
20
20
2
5 4 3 2 1 0
Differential temperature regulator
-00
CALEFFI
Probe
Diff. Temp.
2
C
FROM / TO BOILER
ON
AC 24V 50Hz AC 230V 6(2)A T50
N L
SH
TF 1
TF 2
Differential temperature regulator The differential temperature regulator, using the two probes, measures the difference in temperature between probe (1) in the solar panel and probe (2) in the boiler. The differential temperature value can be read on the two digit display. If the T detected value exceeds the set value, the output contact is activated and may, for example, trigger the pump in the solar system circulation unit. It is recommended to set the T value between 5C and 8C, since this value optimises operation while taking into account the heat loss occurring within the solar system pipes. It also allow to activate the circulator only when the available thermal energy is higher than the consumed electricity. Thermostat The thermostat, using the probe, measures the temperature of the natural or forced circulation solar storage, according to the type of application; should it be below the set value, the thermostat will activate a contact powering the device connected to it. On solar regulator systems, a value equal to or greater than 55C is set. It is recommended to carry out periodic heat treatment to the hot water storage to prevent any possible growth of Legionella. Assembly The regulator and the thermostat are set up for assembly on a DIN bar, in a box or in a wiring cabinet.
1
Thermostat
50 40 30 20 C
60 70 80 90
N L
SH
TF
1) Display indicating differential temperature or temperatures of single probes 2) Selector for setting the differential temperature trigger value 3) Button to select the display of operating parameter 4) Connection to temperature probes 5) Electric supply 6) Actuating relay output 7) Selector for setting thermostat actuation temperature 8) Thermostat operation indicator LED 9) Probe fault alarm output
Components and accessories
257
Differential temperature regulator for solar heating systems, with relay output. Complete with contact probe and immersion probe with 1/4 pocket. Characteristics as for code 257020.
Code
257
Box complete with DIN bar, for 257 series regulator or thermostat. Protection class: IP 65.
257001
Code
257010
257 257
Differential temperature regulator for solar heating systems, with relay output. Characteristics as for code 257020.
Code
Double box complete with DIN bar, for 257 series regulator and thermostat. Protection class: IP 65.
Code
257003
257000
257
Thermostat for solar heating systems, with relay output. For thermal integration control and diverter valves. Characteristics as for code 257030.
Code Code
150
Contact probe for 257 series regulator or thermostat and for 1520 series regulator (flow or return) Length of cable: 2 m. 150009
257002
150
Pocket for immersion probe code 150006.
Code
150
Immersion probe for series 257 regulator or thermostat and for series 1520 regulator. Length of cable: 2 m. 150006
150029
1/4 M
Application diagrams Example of connection between thermostat and natural circulation solar heating system. The device controls the diverter valve according to the temperature detected in the solar water storage. If the temperature is not sufficient, the domestic water is passed through the hot water storage controlled by the boiler.
Shut-off valve Pressure reducing valve Tundish Check valve T/P safety relief valve
HOT
2 1
CALEFFI
MIN
50 40 30 20 C
60 70
MAX 7
90
Diverter on the secondary circuit
COLD
80
Temperature gauge Expansion vessel

T
Automatic diverter valve Pump Safety relief valve
Example of combined connection of thermostat and regulator to a forced circulation solar heating system. The regulator controls the circulation unit pump according to the temperature detected on the solar panel and in the lower part of the water storage. If the temperature detected in the upper part of the storage is insufficient, the thermostat integrates it by starting the pump.
Shut-off valve Pump Air vent Expansion vessel Safety relief valve
2 1 0
4 5 6
80 60 40 100 120 140 0 160 40 60
80 100 120 140 0 160
20
20
5 4 3 2 1 0
Code 257020 Differential temperature regulator for solar heating systems, complete with box, contact probe and immersion probe with pocket. Electrical supply 230 V 6% - 50 Hz. Nominal power consumption 1,45 VA. Contact rating 6 A (230 V). T adjustment range 220 K. Hysteresis 2 K ( 1 K). Maximum ambient temperature 50C. Insulation test 4 kV. Dimensions 3 DIN. Box: Dimensions 4 DIN. Dimensions (w x h x d) 122 x 200 x 112 mm. Protection class IP 65.
Code 257030 Thermostat for solar heating systems. Complete with box and contact probe. Electrical supply 230 V 6% - 50 Hz. Nominal power consumption 1,45 VA. Contacts rating on switch-over 6 (2) A (230 V). Adjustable temperature range 2090C. Hysteresis 1 K. Maximum ambient temperature 50C. Alarm output contact 24 V, 20 mA. Insulation test 4 kV. Dimensions 3 DIN. Box: dimensions 4 DIN. Dimensions (w x h x d) 122 x 200 x 112 mm. Protection class IP 65.
Code 257040 Regulator and thermostat for solar heating systems. Complete with box, 1 contact probe and 2 immersion probes with pocket. Regulator: electrical supply 230 V 6% - 50 Hz. Nominal power consumption 1,45 VA. Contacts rating on switch-over 6 A (230 V). T adjustment range 220 K. Hysteresis 2 K ( 1 K). Maximum ambient temperature 50C. Insulation test 4 kV. Dimensions 3 DIN. Thermostat: electrical supply 230 V 6% - 50 Hz. Nominal power consumption 1,45 VA. Contacts rating on switch-over 6 (2) A (230 V). Adjustable temperature range 2090C. Hysteresis 1 K. Maximum ambient temperature 50C. Alarm output contact 24 V / 20 mA. Insulation test 4 kV. Dimensions 3 DIN. Box: dimensions 6 DIN. Dimensions (w x h x d) 160 x 200 x 112 mm. Protection class IP 65.
CALEFFI
Pre-assembled distribution manifolds for radiant panel systems

668...S1 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
01144/07 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. They are offered in a pre-assembled version comprehensive of: flow meters to regulate and check the flow rate on the flow manifold; manual shut-off valves designed for thermo-electric actuator on the return manifold; end fittings comprehensive of automatic air vent and multi-position valves to fill/drain the system; differential by-pass kit to keep the head balanced as the flow rate varies; pair of ball shut-off valves and brackets for box or wall mounting.
Reference Documentation - Tech. Brochure 01041 Automatic flow regulator with stainless steel cartridge 120 - 125 - 103 series - Tech. Brochure 01042 Thermo-electric actuator 6561 series - Tech. Brochure 01142 Thermo-electric actuator with manual opening and position indicator 6563 series - Tech. Brochure 01054 Automatic air vent 5020 series
Product range 6686...S1 series Pre-assembled distribution manifold for radiant panel systems 6687...S1 series Pre-assembled distribution manifold for radiant panel systems Size 1 Size 1 1/4
Technical specifications Materials Flow manifold Body: Flow rate regulating valve Headwork: Obturator: Flow meter body: Spring: Hydraulic seals: Regulating unit cover: Return manifold Body: Shut-off valve Headwork: Obturator stem: Obturator: Springs: Seals: Control knob: Ball shut-off valves Body: Ball: Control knob: brass EN 1982 CB753S brass EN 12164 CW614N brass EN 12164 CW614N PSU stainless steel EPDM ABS brass EN 1982 CB753S PA66GF stainless steel EPDM stainless steel EPDM ABS brass EN 12165 CW617N brass EN 12164 CW614N, chrome plated aluminium EN AB 46100
End fitting Body: Automatic air vent Obturator stem: Spring: Seals: Float: Multi-position valve Ball: Control lever: Hose connection: Performance Medium: Max. percentage of glycol: Max. working pressure: End fitting max. discharge pressure: Temperature range: Flow meter scale: Accuracy: Main connections: Centre distance: Outlets: Centre distance:
RE
brass EN 12165 CW617N brass EN 12164 CW614N stainless steel EPDM PP brass EN 12165 CW617N PA66GF brass EN 12164 CW614N
water, glycol solutions 30% 10 bar 2,5 bar 080C 15 l/min 15% 1, 1 1/4 F 195 mm 3/4 M 18 50 mm
Dimensions
108
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 o 1 1/4
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
195
1 o 1 1/4
CALEFF
SOGGIORNO
CALEFFI
59
25
3/4 L TOTAL
50
27
Code (1) Code (1 1/4) N outlets
L TOTAL
Weight (kg)
6686C5S1 6686D5S1 6686E5S1 6686F5S1 6686G5S1 6686H5S1 6687C5S1 6687D5S1 6687E5S1 6687F5S1 6687G5S1 6687H5S1 3 4 5 6 7 8 380 430 480 530 580 630 7,2 7,8 8,3 9,4 10,1 10,6
6686I5S1 6687I5S1 9 700 11,4
6686L5S1 6686M5S1 6686N5S1 6686O5S1 6687L5S1 6687M5S1 6687N5S1 6687O5S1 10 11 12 13 750 800 850 900 12,2 13,0 13,7 14,5
Characteristic components 1 Flow manifold complete with flow meters and built-in flow rate regulating valves 2 Return manifold with built-in shut-off valves suitable for thermo-electric actuator 3 Flow end fitting with two-position ball valve, automatic air vent and fill/drain hose connection
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
CALEFFI
CAMERA
HOBBY
SOGGIORNO
WC
CALEFFI
4 Return end fitting with three-position ball valve, by-pass connection and fill/drain hose connection 5 Off-centre by-pass kit with fixed setting comprehensive of manifold connecting pipe 6 Ball shut-off valves 7 Brackets for box or wall mounting
CALEFFI
CAMERA
HOBBY
SOGGIORNO
WC
CALEFFI
Construction details Flow manifold The flow manifold is equipped with flow meters and built-in flow rate balancing valves. Acting on the regulating valve with the special cone-shaped obturator (1), the flow rate to the single circuits can be accurately adjusted to the required value, just by reading the value on the single flow meter with a scale of 15 l/min (2). This simplifies and speeds up the operation of circuit calibration, with no need for reference graphs. After adjustment, the valve can be locked open by means of its tamper-proof cover (3), which also acts as a knob for adjusting the flow rate. This valve makes it possible to seal off the single circuit, should this be necessary.
ALEFFI
Return manifold The return manifold is equipped with manual shut-off valves (1), in order to cut off the flow to the individual circuits. They can also be fitted with a thermo-electric actuator (2) that, when used with a room thermostat, maintains the ambient temperature at the set values despite any thermal load variation. The obturator stem (3) is made of ground stainless steel in order to minimize friction and prevent dangerous encrustation. The headwork (4) has a double EPDM O-Ring seal (5)-(6) on the sliding stem. The EPDM obturator (7) is shaped to optimize the hydraulic characteristics of the valve, preventing any sticking in the sealing seat after the circuit has been shut off. It minimizes the noise caused by the medium flow, also during the progressive action of opening or closing when operating with thermo-electric actuator.
1 5 6 7 4 3 2
ALEFFI
Modular manifolds The manifolds are modular thanks to the threaded connections with an O-ring seal. The special machining of the thread on these connections enables perfect alignment between the two coupled parts once they are fully screwed in.
Replaceable components The headwork of the regulating valve with flow meter can be removed and replaced with spare parts.
End fitting Automatic air vent The automatic air vent performs the function of automatically expelling the air accumulating in the circuits of the air-conditioning system. It is equipped with a hygroscopic safety plug (1) that prevents water getting out to protect the installation.
Room identification On the manifold body, at the outlet of the single panel circuit, there is a special seat to place an adhesive label identifying the corresponding room.
Thermometers for circuit piping As an accessory, there is a special spirit thermometer with a scale of 550C, equipped with a push-fit plastic body, for the single circuit piping, with an outside diameter between 15 to 18 mm. This thermometer, installed on the return pipework, measures the actual temperature of the medium returning from the circuit making it possible to check the proper heat exchange of each single panel.
Manifold reversibility The manifolds are reversible, so they can be positioned with the entry from the right or left.
External shape of the manifolds and brackets The casting process makes it possible to shape the manifold outer geometry as needed. In this way, recesses (1) have been made in correspondence with the pipe passage coming down from the upper manifold, to allow it to be partially housed, for the benefit of depth. This particular outer shaping does not affect the head loss values, 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 controls (setting lockshield and shut-off valves) obstruct the medium flow.
The partial pipe housing in the manifold shaping is moreover helped by the brackets, mounted with a precise slope in order to obtain a 25 mm shift between the upper and lower manifolds. As shown in the figure, at the time of installation, this offset makes a perfect automatic match between the pipe position and the manifold shape.
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
b c
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
25 mm
End fittings with multi-position valves The ball valves in the end fittings can be positioned to perform different functions.
Fill/drain Filling the circuits. Filling via the flow manifold and draining via the return manifold: both valves are in the open position.
Closing Closing the connection to the filling and draining valves. Both valves are in the closed position. The automatic air vent on the flow manifold is always connected and cannot be shut-off.
Operation with by-pass Normal operation. The valve of the return manifold is in the position of connection with the by-pass and the valve of the flow manifold is in the open position.
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 fluid as it passes through the devices forming the manifold assembly and the radiant panel 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.
PBall v.
1 2 3 4
L/MIN
PF Man.
1 2 3 4
L/MIN
PBV
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
GTot.
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
PTot.
PSV PLoop
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
GLoop
PBall v.
PR Man.
PBV
PLoop
PTot.
PTot.
PSV
PBV
= Total loss at the ends of the manifold (Flow + Return + Loop) = Localized loss at loop balancing valve (loop flow rate)
PBall V.
PF Man.
GLoop
PR Man.
PBall .V.
PSV
PLoop = Loop loss (Loop flow rate)
GTot.
GTot.
PF Man. = Distributed loss of the flow manifold (total flow rate)
= Localized loss at panel circuit shut-off valve (loop flow rate)
PR Man. = Distributed loss of the return manifold (total flow rate) PBall V. = Ball valve loss (total flow rate)
PTot. = PBV + PLoop + PSV + PF Man. + PR Man. + PBall V. x 2
(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)
Flow-rate regulating valve fully open (BV) Panel circuit shut-off valve (SV)
Kv 1,85 2,50
Kv0,01 185 250
Flow or return manifold 37 outlets Flow or return manifold 813 outlets Ball valve
* Average value
Kv 21,0* 15,0* 47,5
Kv0,01 2100* 1500* 4750
Example of calculation of total head loss Supposing we need to calculate the head loss of a manifold with three circuits (loops) with the following characteristics: Total manifold flow rate: 450 l/h The flow rate and head loss of the three loops are as follows: Circuit 1 P1= 10 kPa G1= 120 l/h P=G2/Kv0,012 Circuit 2 P2= 20 kPa G2= 250 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:
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, corresponding to a head loss of 1 kPa It should be highlighted that the PTot. must be calculated taking into account the circuit with the greatest head losses, distributed along the entire piping loop of the panel. In our example, the relevant circuit is Nr. 2. It follows that: PBV PLoop PSV PF Man. PR Man. PBall V. = = = = = = 2502/1852 = 1,82 kPa 20 kPa 2502/2502 = 1 kPa 4502/21002 = 0,04 kPa 4502/21002 = 0,04 kPa 4502/47502 = 0,01 kPa
} Values obtained by neglecting the changes due to the flow rate dispersed to each branch circuit
PTot.= 1,82 + 20 + 1 + 0,04 + 0,04 + 0,01 x 2 = 22,82 kPa
Using formula (1.1), adding up all the calculated terms, we obtain:
Note: We can ignore the three terms for the head losses associated with the ball valves and manifolds because of their low values. In general, the total head loss is fairly close to the branched circuit of the panel head loss.
4000
100
200
500
500
20
50
Using the balancing valves with flow meter The balancing valves in the flow manifold make it possible to adjust each individual circuit in the panels to obtain the design flow rates in each loop.
Considering the following data: - medium flow rate across each circuit - head loss generated in each circuit by this flow rate: PCircuit = PLoop + PSV (PShut-off valve) - available head on the panel circuit or predefined head: HPredefined PCircuit + = PBV + PLoop + PSV
disadvantaged
BV
PBV
PTot.
Referring to the diagram alongside, for the loop flow rate the balancing valve must provide an additional head loss equal to the difference PBV (PBalancing valve).
PCircuit HPredefined PCircuit SV
+ disadvantaged
Flow rate adjustment and reading Raise the block cover with the aid of a screwdriver and turn it over onto the flow meter. Adjust the flow rate of the single panels by turning the flow meter body acting on the built-in balancing valve. The flow rate must be read off the graduated scale, expressed in l/min, printed on the flow meter. After making all the adjustments, reposition and lock all the knobs in their seat to prevent tampering.
668S1 series Pre-assembled distribution manifold for radiant panel systems with 3 (from 3 to 13) outlets. Brass body. EPDM hydraulic seals. Main connections 1 (and 1 1/4) threaded F, centre distance 195 mm. Outlet connections 3/4 M 18, outlet centre distance 50 mm. Medium: water and glycol solutions; maximum percentage of glycol 30%. Maximum working pressure 10 bar. Temperature range 080C. Maximum automatic air vent discharge pressure 2,5 bar. Consisting of: - Flow manifold with flow rate balancig valves and flow meter with graduated scale 15 l/min. Accuracy 15%. - Return manifold, with shut-off valves suitable for thermo-electric actuator. - Pair of end fittings comprehensive of automatic air vent with hygroscopic plug, fill/drain hose connection, multi-position ball valves for coupling with the off-centre by-pass kit with fixed setting supplied in the package. - Off-centre by-pass kit with fixed setting. Threaded connections 1 M x 3/4 M. Brass body and nuts. Copper gauged pipe. PA obturator, stainless steel spring, EPDM seals, asbestos-free fibre gaskets. Differential pressure fixed setting 25 kPa. - Adhesive labels indicating the rooms. - Pair of ball shut-off valves, brass body. Union seals made of EPDM. - Pair of fixing brackets.

17 10 9 13 8 14 1 2 7 12 15 11 16 4 6 3 5
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
CALEFFI
CAMERA
CALEFFI
CAMERA
HOBBY
SOGGIORNO
WC
CALEFFI
CALEFFI
CAMERA
CALEFFI
CAMERA
HOBBY
SOGGIORNO
WC
CALEFFI
C
50 40 30 20 10 50 40 30 20 10
1. Flow manifold with flow meters and flow rate balancing valves, 667...S1 series 2. Return manifold with built-in shut-off valves suitable for thermo-electric actuator, 666...S1 series 3. Flow end fitting with two-position ball valve, automatic air vent and fill/drain hose connection, code 599674 4. Return end fitting with three-position ball valve, by-pass connection and fill/drain hose connection, code 599675 5. Off-centre by-pass kit with fixed setting comprehensive of manifold connecting pipe, code 668000S1 6. Automatic air vent, code 502043 7. Ball shut-off valve, 391...S1 series
Brackets for mounting in a box or on a wall, code 658100 Strainer, 120 series Autoflow, 120 series Push-fit temperature gauge for panel piping, code 675900 Fitting for plastic or multilayer panel pipe, 680 series Reduction, 3642..S1 series Blind cap, code 386500 Thermo-electric actuator, 6561 series Thermo-electric actuator with manual opening and position indicator, 6563 series 17. Box, 659 and 661 series
8. 9. 10. 11. 12. 13. 14. 15. 16.
Off-centre by-pass kit with fixed setting, code 668000S1 Function In radiant panel systems, the medium distribution circuits can be totally or partially shut off by closing the thermo-electric valves in the manifolds. 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 performs the function of keeping the flow and return pressure of the manifold circuit balanced when the flow rate varies. This valve is suitable for quick coupling with the 668...S1 series manifolds, reducing the overall dimensions to a minimum. Product range Code 668000S1 Off-centre by-pass kit with fixed setting Technical specifications Materials Nuts: Gauged pipe 18 with folder: Check valve obturator: Spring: Seals: Gaskets: Performance Medium: Max. percentage of glycol: Max. working pressure: Temperature range: Differential pressure fixed setting: Connections: water, glycol solutions 30% 10 bar 0100C 25 kPa (2500 mm w.g.) 1 x 3/4 F with captive nut C Code 668000S1 A 3/4" B 1" C 25 Weight (kg) 0,160 B brass EN 12165 CW617N copper PA stainless steel EPDM asbestos free fibre Dimensions A Sizes 1 x 3/4
143
Operating principle The by-pass valve contains a non-return obturator integral with a counter spring. When the fixed setting differential pressure value is reached, the valve obturator opens gradually. In this way the flow is recirculated and, being proportional to the closure of the electrothermal valves, keeps the differential pressure constant in the manifold circuit. Construction details The off-centre by-pass kit has a fixed setting that cannot be changed since it has no accessible adjustment. The small, compact size and offset connections make this device particularly easy to mount after installing thermo-electric valves on the manifold. In addition, its installation does not require any wider or deeper zone boxes than the required ones for normal manifolds. Hydraulic characteristics By-pass differential pressure: 25 kPa (2500 mm w.g.)
p (mm w.g.)
5000
4500 4000 3500 3000 2500
p (kPa)
50
45 40 35 30 25
Off-centre by-pass kit installation on manifolds 668S1 series To fit the differential by-pass on the manifolds, 668S1 series, it is necessary to carry out the following operations: 1) Close the multi-position valves (A and B) of both end fittings (flow and return). 2) Remove the hose attachment (C) from the multi-position valve of the upper manifold. 3) Remove the plastic plug (D) from the end fitting of the lower manifold. 4) Install the off-centre by-pass kit (E) code 668000S1 and move the multi-position valve levers back into by-pass operation position as shown in figure 2.
1
1 2 3 4
L/MIN
2
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2
1 2 3 4
L/MIN
1 2
1 2 3 4
L/MIN
A
CALEFFI
3 4
L/MIN
A
CALEFFI
O
3 4
L/MIN
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
SOGGIORNO
WC
SOGGIORNO
WC
CALEFFI
D B
CALEFF
B
BAGNO
SOGGIORNO
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
WC
CALEFFI
BAGNO
SOGGIORNO
WC
CALEFFI
Code 668000S1 Off-centre by-pass kit with fixed setting. Threaded female connections 1 x 3/4 with captive nut. Brass nuts. Copper gauged 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 0100C. Differential pressure fixed setting 25 kPa.
0,2
0,5
0,1
10
20
2000
20
Single and multi-layer plastic pipe fitting with self-adjusting diameter 680 series
Function The self-adjusting fitting for single and multi-layer plastic pipes is a mechanical device that allows a safe and easy connection of the radiant panel system pipes to the related manifolds. Due to the specific requirements of this type of system, it has been designed to meet the need of having a versatile connector, being adjustable for different pipe diameters. Patented Product range 6805 series . . Self-adjusting fitting for single and multi-layer plastic pipes Size 3/4
Technical specifications Materials Nut: Adapter: Seals: Electric insulating ring: Twin cone: Performance Medium: Max. percentage of glycol: water, glycol solutions 30% brass EN 12164 CW614N brass EN 12164 CW614N EPDM EPDM PA 66 G50
Characteristic components 1) Adapter 2) Clenching ring 3) Nut
Code
inside
outside
Max. working pressure: 10 bar Temperature range: 580C (PE-X) 575C (Multi layer marked 95C).
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
7,518,0 8,519, 9, 9,5 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 Pipe-fitting coupling flexibility This fitting has been specifically designed in order to adjust to several pipe diameters. The great variety of plastic pipes, single and multi-layer, on the market and the breadth of permissible tolerances have made it necessary to design a specific fitting. Keeping the nominal dimensions of the fittings currently on the market, the new construction solution makes it possible to use the same fitting for pipes with differences on their outside diameter up to 2 mm and on their inside diameter up to 0,5 mm. Pull-out resistance This fitting opposes high resistance to pipe pull-out. Its special tightening system makes it suitable for all applications, ensuring a perfect hydraulic seal. Low head losses The internal profile of the adapter (4) is shaped to obtain a Venturi effect as the medium flows. It permits reducing the head losses about 20% less than the loss corrisponding to the passages of the same diameter.
4 5 6 7
Dielectric seal ring The fitting is equipped with a rubber insulating element (5) to prevent contact between the aluminium in the multi layer pipe and the brass of the fitting. This prevents any galvanic corrosion generated by two different metals. Double O-Ring seal On the adapter there are two O-Ring seals (6) (7) made of EPDM in order to avoid potential leaks even at high working pressures.
680 series Self-adjusting diameter fitting for single and multi layer plastic pipes with internal profile having a Venturi effect to limit head losses. Size 3/4 F. Brass cap and adapter, EPDM seals, EPDM dielectric ring, PA clenching ring. Medium: water and glycol solutions. Maximum percentage of glycol 30%. Maximum working pressure 10 bar. Temperature range 580C (PE-X); 575C (Multi layer marked 95C).
Standard thermo-electric actuators
6561
broch. 01042
Technical specifications Materials Protective shell: Colour: self-extinguishing polycarbonate (code 656102/04) white RAL 9010 (code 656112/14) grey RAL 9002
Thermo-electric actuator for manifolds. Normally closed.

Code Voltage (V)
656102 656104
230 224
Performance Normally closed Electric supply: Starting current: Working current:

broch. 01042
6561
Thermo-electric actuator for manifolds. Normally closed. With auxiliary microswitch.

Code Voltage (V)
656112 656114
230 224
Power consumption: 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.
230 V (ac) - 24 V (ac) - 24 V (dc) 1A 230 V (ac) = 13 mA 24 V (ac) - 24 V (dc) = 140 mA 3W
Thermo-electric actuators with manual opening and position indicator
6563
broch. 01142
Technical specifications Materials Protective shell: Colour: self-extinguishing polycarbonate (code 656302/04) white RAL 9010 (code 656312/14) grey RAL 9002
Thermo-electric actuator for manifolds. Normally closed.

Code Voltage (V)
656302 656304
230 224
Performance Normally closed Electric supply: Starting current: Working current:

broch. 01142
6563
Thermo-electric actuator for manifolds. Normally closed. With auxiliary microswitch.

Code Voltage (V)
656312 656314
230 224
Power consumption: Auxiliary microswitch contacts rating (code 656312/14): 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
The 6563 series thermo-electric actuator 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 the automatic operation when the system is electrically put into operation. Normal valve operation in automatic mode Using the knob to open the valve manually Automatic return from the manual position to the automatic one
Automatic flow rate regulators
broch. 01041
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 specifications With thermometer scale 080C, 40 mm Max. working pressure: 25 bar Max. working temperature: 110C Range p: 14220 kPa Accuracy: 5%
Code
Flow rate m3/h
Code
Flow rate m3/h
120961 120961 120961 120961 120961 120961 120961
1L2 1L4 1L6 1L8 2L0 2L2 2L5
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
1,20 1,40 1,60 1,80 2,00 2,25 2,50
They
are available on request with other flow rates
120 STRAINER Version
broch. 01041
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 specifications With thermometer scale 080C, 40 mm Max. working pressure: 25 bar Maximum working temperature: 110C Filter mesh : 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...S1
Return manifold, with built-in shut-off valves suitable for thermo-electric actuator.
Technical specifications Materials Return manifold Body: Shut-off valve Headwork: Obturator stem: Obturator: Springs: Seals: Control knob: Flow manifold Body: brass EN 1982 CB753S PA66GF stainless steel EPDM stainless steel EPDM ABS brass EN 1982 CB753S
Code
Connection No. outlet
Outlets
666735S1 666745S1 666755S1 666765S1 666775S1 666785S1
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
667...S1
Flow manifold, with flow meters and built-in flow rate regulating valves.
Flow rate regulating valve Headwork: brass EN 12164 CW614N Obturator: brass EN 12164 CW614N Flow meter body: PSU Spring: stainless steel Hydraulic seals: EPDM Regulating unit cover: ABS Performance
Code
Connection No. outlet
Outlets
667735S1 667745S1 667755S1 667765S1 667775S1 667785S1
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
Medium: water, glycol solutions Max. percentage of glycol: 30% Max. working pressure: 10 bar Temperature range: 080C Flow meter scale: 15 l/min Accuracy: 15% Main connections: 1 1/4 F Outlets: 3/4 M 18 Centre distance: 50 mm
Shut-off valves
391...S1
Pair of ball valves. Female-male connections with union with O-Ring seal. With thermometer scale 080C, 40 mm. Max working pressure: 10 bar. Temperature range: 0100C.
Code Connections
391...S1
Pair of ball valves. Female-male connections with union with O-Ring seal. With thermometer connection. Max working pressure: 10 bar. Temperature range: 0100C.
Code Connections
391167S1 391177S1
1 x 1 1/4 1 1/4 x 1 1/4
391067S1 391077S1
1 x 1 1/4 1 1/4 x 1 1/4
End fittings
5996
Flow end fitting complete with double radial end fitting with two-position ball valve, automatic air vent and fill/drain hose connection. Max. working pressure: 10 bar. Max. discharge pressure: 2,5 bar. Temperature range: 0100C.
5996
Return end fitting complete with double radial end fitting with three-position ball valve, by-pass connection with plug and fill/drain hose connection. Max. working pressure: 10 bar. Temperature range: 0100C.
Code
Code
599674
1 1/4
599675
1 1/4
Automatic air vent
Brackets
5020
Automatc air vent with hygroscopic plug. In hot stamped brass. For manifolds end fittings 668...S1 series. Max. working pressure: 10 bar. Max. discharge pressure: 2,5 bar. Max. working temperature: 110C.
658
Pair of brackets for use with boxes, 659 series or directly on the wall. With screws and plugs.
Code
Code
502043
1/2 M
658100
Plug disc
Reduction
386
Code
3642..S1
Reduction fitting.
Code
386500
3/4
364276S1
1 F x 1 1/4 M
Temperature gauge
System test pump
675
Push-fit thermometer for panel piping. Code 675900.
695
System test pump code 695000. Comprehensive of pressure gauge and hose for connecting to the system.
Technical specifications Material Body: Thermometer fluid: Temperature gauge scale: Max. working temperature: Range of use outside diam. (e) pipes: Conducting paste supplied in package PA6GF alcohol 550C 60C from 15 to 18 mm
Technical specifications Materials Body: Piston: Control lever: Max. working pressure: Water content: Pressure gauge scale: Hose connection: Length of hose:
Code
bronze brass galvanized steel 50 bar 12 l 060 bar 1/2 1,5 m
Code
675900
695000
Boxes
659
Box for manifolds 668 and 668...S1 series. Wall or floor installation (with series 660). Closure with a push-fit clamp. Made of painted steel. Adjustable depth from 110 to 140 mm.
Code (h x w x d)
661
Box for manifolds. 668...S1 series. Closure with a push-fit clamp. Made of painted steel. Adjustable depth from 110 to 150 mm. With supports for installation on floor. Adjustable height from 270 to 410 mm.
659043 659063 659083 659103 659123
500 500 500 500 500
x x x x x
1400 1600 1800 1000 1200
x x x x x
110140 110140 110140 110140 110140
Code
(h x w x d)
660
Floor installation kit for box 659 series. Consisting of: - 2 supports height cm. 20, - 2 side panels, - 1 pipe-bending bar.
Code
661043 661063 661083 661103 661123
500 500 500 500 500
x x x x x
1400 1600 1800 1000 1200
x x x x x
110 150 110 150 110 150 110 150 110 150
660040 660060 660080 660100 660120
for for for for for
659043 659063 659083 659103 659123
Choice of box size, 659 or 661 series according to the number of outlets.
For max outlets no. 17+17 With Autoflow for max outlets no. 15+15
For max outlets no. 14+14 With Autoflow for max outlets no. 11+11 For max outlets no. 10+10 With Autoflow for max outlets no. 7+7 For max outlets no. 6+6 With Autoflow for max outlets no. 4+4
1000
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
/MIN
1 2 3 4
L/MIN
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
GIORNO
WC
CALEFFI
GIORNO
WC
CALEFFI
GIORNO
WC
CALEFFI
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
SOGGIORNO
WC
CALEFFI
SOGGIORNO
WC
CALEFFI
SOGGIORNO
WC
CALEFFI
1200
CALEFFI
600
800
Thermostatic mixing valve, adjustable with knob and with anti-scald function
5217 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
01145/07 GB
Function In some hot water distribution systems there is a need to protect the most vulnerable people against scalding caused by hot water, such as, for example, in hospitals, in nursing homes or in schools. This particular series of thermostatic mixing valves has been specially designed for these applications and installation upstream the point of use. These thermostatic mixing valves ensure high thermal performance. They are able to accurately control the temperature of the mixed water supplied to the user in case of variations in the inlet supply pressure or temperature, or in the flow rate. They are designed with a special anti-scald function which immediately shuts off the flow of water discharging from the mixed water outlet in the event of a failure of cold supply. (Certified under standard NF 079 doc. 8 - Device of class 12 (1/2) and class 20 (3/4), RU type, regulated by user).
Product range Code 521714 Code 521713 Thermostatic mixing valve, adjustable with knob and with anti-scald function, complete with strainers and check valves at the inlet Thermostatic mixing valve, adjustable with knob and with anti-scald function, complete with strainers and check valves at the inlet
RE
Size 1/2 Size 3/4
Technical specifications Materials Body: dezincification resistant alloy EN 12165 CW602N, chrome plated PSU stainless steel EPDM ABS
Dimensions
C B B
Shutter: Springs: Sealing elements: Knob: Performance Temperature adjustment range: Accuracy: Max. working pressure (static): Max. working pressure (dynamic):
F D E A
3050C 2C 10 bar 5 bar
Max. inlet temperature: 85C Inlet temperature recommended for optimum system performance, avoiding the build-up of limescale (according to NF079 doc. 8) 65C Max. inlet pressures ratio (H/C or C/H): 2:1 Min. temperature difference between hot water inlet and mixed outlet, to ensure anti-scald function: 15C Min. flow rate for stable temperature: Acoustic group: Connections: 4 l/min (1/2) 6 l/min (3/4) I 1/2 and 3/4 M with union Code 521714 521713 A 1/2 3/4 B 62,5 67 C 125 134
D E 126,5 81,5 127 82
F 45 45
Weight
(Kg) 0,58 0,81
Legionella vs scalding risk In systems producing 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 60 C. 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 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. This time may be reduced by 50% for children and elderly people. In view of the above, it is necessary to use a thermostatic mixing valve which can: reduce the temperature at the point of use to a value lower than that of the storage and make it suitable for sanitary use. maintain the temperature constant while while the incoming pressure and temperature conditions vary. prevent the water temperature at the outlet from reaching values above 50C. have an anti-scald safety function in case of failure of the cold water supply.

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
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.
70 60 50 40 30 20 10 0 Surviving bacteria inactive Optimum temperature for growth of bacteria Instant death of bacteria Death of 90% of bacteria in 2 minutes Death of 90% of bacteria in 2 hours
Exposure time required to cause partial burns Temperature 70C 65C 60C 55C 50C Adults 1s 2s 5s 30 s 5 min Children 0-5 years 0.5 s 1s 10 s 2,5 min
Operating principle The thermostatic mixing valve mixes the hot and cold water at the inlet so as to maintain the mixed water at a constant set temperature at the outlet. A thermostatic element is fully immersed in the mixed water pipe. It contracts or expands, thus moving an obturator which controls the hot or cold water passage at the inlet. If there are changes in inlet temperature or pressure, the internal element reacts automatically to restore the set temperature at the outlet. Construction details Anti-scale materials The materials used in constructing the mixing valve were selected to eliminate seizing due to limescale deposits. All functional parts have been made using a special material with low friction coefficient, which ensures over time performance. Anti-scald safety function As a safety measure, in case of failure of the cold water supply, the valve immediately shuts off the flow of mixed water. This prevents dangerous burns. This performance is guaranteed if there is a minimum temperature difference between the inlet hot water and the outlet mixed water of 15C (performance in compliance with French standards NF 079 Doc. 8). In case of failure of the hot water supply, the valve shuts off the mixed water to prevent dangerous thermal shocks.
Code 521713
COLD
Code 521714
COLD
MIXED
HOT
HOT
p (bar) 1,5 1,0
521714 521713
Thermal transient
p (m w.g.) 15 10
During transient, following rapid changes in pressure, temperature or flow rate, the temperature increases with respect to the initial set point and this increase must be of limited duration to guarantee safety.
T(C) 60C 55C 2K Starting temperature 2K
0,5 0,3 0,2
5 3 2
< 0,5 s - max
< 3 s - max
0,1
0,05
0,5
Temperature rise
Stabilisation period
Stable conditions Time (s)
0,2
0,5
10
20
Code 521714 521713
1/2 3/4
Kv (m3/h) 1,5 1,85 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 equipped. Use of a digital thermometer is recommended for measuring the temperature of the mixed water. Temperature setting The temperature is set at the desired value using the regulator knob. Given the particular use of this type of mixing valve, the following table shows the recommended maximum outlet water temperatures to prevent scalding.
Use According to its flow characteristics, the Caleffi 5217 series thermostatic mixing valves can be used for application at the point of use or for a limited number of users, for example a bathroom. For this reason, the flow passing through the valve is generally the same as through the final user, for example the tap of a basin, shower, bidet, etc. To ensure a stable operation, a minimum flow rate of 4 l/min (1/2) and 6 l/min (3/4) must be guarantee to the mixing valve. The system must always be sized taking into account the current legislation on the nominal flow rate to each user. Public buildings, hospitals, nursery schools In this type of application the risk of scalding is extremly high because of the nature of the hot water users, who include children, old people, sick people. In these installations, the two supply networks providing hot water from the boiler and cold water may have different origins and operate at different pressures. In case of failure of the cold water supply, the mixing valve is able to shut off the supply of mixed water to prevent possible scalding. Selecting the correct size mixing valve If the design flow rate is known, taking into account simultaneous use of the sanitary appliances, the dimensions of the mixing valve are chosen by checking the graph provided to find the loss of head produced. In this case, it is necessary to check the available pressure, the loss of head in the system downstream of the mixer and the residual pressure to be guaranteed to user appliances. Installation Before installing the mixing valve, the connecting pipes should be washed to remove any impurities that could impair performance. We always recommend installing strainers of sufficient capacity at the inlet from the public water network. The 5217 series mixing valves are equipped with strainers on the hot and cold water inlets. The 5217 series thermostatic mixing valves must be installed as shown in the installation diagrams on the instruction sheet or in this leaflet. The 5217 series thermostatic mixing can be installed in any position, horizontally or vertically. The following marks are indicated on the mixing valve body: hot water inlet, indicated by the letter H (Hot) cold water inlet, indicated by the letter C (Cold) mixed water outlet, indicated by the word MIX. Check valves In systems with thermostatic mixing valves, check valves should be installed to prevent undesired flow return. 5217 series mixing valves are equipped with check valves at the hot and cold water inlets.
50
Appliance Bidet Shower Wash basin Bath tub
Tmax. 38C 41C 41C 44C
Application diagrams Point of use installation Multiple use installation with distribution unit
Bathroom installation
5217 series Thermostatic mixing valve adjustable with knob and with anti-scald function. Certified under standard NF 079 doc. 8. 1/2 and 3/4 M connections. Dezincification resistant alloy body. Chrome plated. Shutter in PSU. Stainless steel springs. EPDM seal elements. ABS knob. Maximum working temperature 85C. Adjustment range 3050C. Accuracy 2C. Maximum working pressure (static) 10 bar. Maximum working pressure (dynamic) 5 bar. Maximum inlet pressures ratio (H/C or C/H) 2:1. Complete with strainers and check valves at the inlets.
CALEFFI
CALEFFI S.P.A. I 28010 FONTANETODAGOGNA (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.
Direct heat meter Conteca Solar - M-bus Transmission

75525 series
IS
TERE
UNI EN ISO 9001:2000 Cert. n 0003
01146/08 GB
Function Conteca Solar is a direct heat energy meter especially suited for measuring heat energy recovered from a solar source used for an alternative management of the allocation of energy expenditures. The device comprises an electronic calculator unit, a flow rate volume meter and two temperature probes. The Conteca Solar meter is extremely simple to install and needs no special maintenance. The Conteca Solar flow rate meter is the turbine type. The turbine speed is measured by means of a high-resistance protected magnetic joint. Thanks to the mechanism being in a vacuum there is no condensation. The mechanism block cap, made of non-magnetic material, prevents all attempted tampering. The electronic technology and the materials used enable precise and reliable measurements. The temperature probes are high-precision Pt 100 that are easy to seal for greater protection against tampering. The cables connecting the flow and return probes to the calculator unit are 1,9 m long. The Conteca Solar meter is equipped with an 8-digit liquid crystal display that can be turned on with a button as it is normally off in order to save battery charge. This display enables easy reading of consumption and a range of technical data to permit evaluation of the operating status of the device and log the data. The Conteca Solar meter is fitted for centralised teletransmission (max 250 modules) in M-Bus mode.
Product range 75525 series Code 755000 Code 755055/56 7558 series Heat meter Controller M-Bus interface - Teletransmission interface Additional options Size 1/2 - 3/4 - 1 with union
Technical specifications Performance: Electric supply: Long life storage battery: Data transmission: Antitamper protection Conformity to standards: Max. percentage of glycol:
24 V (ac) - 50 Hz - 1 W 5 years using M Bus protocol EN 1434 EN 1434 50%
RE
Technical data
Temperature probes Flow probe length Return probe length Probe type Temperature range limits Temperature difference limits Measurement sensitivity Volumetric part Dimensions/Connection Body Type of hydraulic connection Nominal flow rate Lower measurement range Upper measurement range Nominal pressure Max. medium temperature Installation Pulse output Microprocessor calculator unit Metrological specifications Centralised transmission Ambient temperature range limits Ambient classification Heat consumption indicator Electric supply: - (without centralisation) - (with centralisation) Protection class Pulse inputs
m m T C K C
1,9 1,9 Pt 100 5120 0115 0,05
Qp Qi Qmax PN
l/h l/h l/h bar C
1/21 brass male with union ISO 228 see table 1 see table 1 see table 1 threaded PN 10 120 normally horizontal class OA-OC according to EN 1434-2
C kWh
in conformity with EN 1434-1 in M-Bus mode 545 MID 2004/22/CE E1 - M1 8 digit display Incorporated battery, 5 year life 24V (ac) - 1W - 50 Hz according to DIN 40050: IP 54 class IB according to EN 1434-2
Dimensions TAB. 1 - Flow rate range (m3/h) - Connections from 1/2 to 1:

40
165 147
Code 755254 755255 755256
Meas. type Single jet Single jet Multi jet
Qi 0,12 0,20 0,35
Qp 1,5 2,5 3,5
Qmax 1,5 2,5 3,5
120
F G
B B1
Code 755254 755255 755256
A 1/2" 3/4" 1"
B 110 130 260
B1 190 230 378
C 18 21 45
D 96 96 185
E 80 80 102
F 44 51 60
G 59 69 82
The Conteca Solar heat meter is supplied complete with accessories for installation, positioning of the probes and subsequent sealing. Each Conteca Solar meter has n. 2 Y pockets (the flow pocket is fitted with a mesh strainer).
M07 1259 07185865
H 59 69 87
Guidelines for first installation It is a good rule to have straight sections of piping immediately upstream and downstream from the meter. Length upstream 4 diameters. Length downstream 2 diameters. It is a good rule to have shut-off valves upstream and downstream from the meter in order to facilitate installation and maintenance, if required. In order to protect the meter, a strainer is fitted inside the temperature flow pocket. After installation, it is a good rule to wash the pipes and carry out a pressure test. After flushing and before securing the temperature probe, it is a good rule to check the state of clogging of the mesh strainer. After installing the hydraulic part you can install the electric/electronic parts. The default percentage of glycol set is 30%. If the percentage to be used is not 30%, the actual percentage must be notified when ordering. Application diagram Normally the hydraulic installation of the flow-rate meter is to be done on the return pipe. - The hydraulic diagrams given below show: a) the positioning of the meter so that it is at rest when there is no service. The flow-rate meter must preferably be installed in a horizontal position with the turbine axis vertical and respecting the direction of flow indicated by the arrow on the body. b) the positioning of the probes The temperature probes (by means of the pocket) must be positioned on the corresponding flow/return pipes. The corresponding flow and return pipes are the ones involved with the same flow rate when the flow has started.
SYSTEM FLOW
M07 1259 07185865
SYSTEM RETURN
M07 1259 07185865
Hydraulic characteristics Volume meter + pockets for probe p (m w.g.)

5
4,5 4 3,5 3 2,5
p (kPa)
45 40 35 30 25 18 16 14 12 9 8 7 6
1/2"
3/4"
1"
50
Qp
20 10 5
1,8 1,6 1,4 1,2 0,9 0,8 0,7 0,6
0,5
0,45 0,40 0,35 0,30 0,25
4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2
0,25
0,18 0,16 0,14 0,12
2 1
0,6
0,7
0,8
0,9
1,2
1,4
1,6
1,8
2,5
3,5
4,5
0,1 0,5
Q (m3/h) 1/2 Kv 2,5 3/4 4,2 1 5,9
Conteca Solar meter electrical connections
M07 1259 07185865
Cooling/Heating mass meter Flow temperature probe Return temperature probe
FT RT
1 2 3 4 5 6 7 8
9 10 11 12
21 22 23 24 25 26
A
Return Temp. probe Flow Temp. probe
For mounting in a box or directly on a wall, use the screws provided in the package, fixing them in the curved slots that enable levelling the device correctly ( A )
Volume meter
24 V (a c)
Rx
Tx
Flow
Return
FT
M07 1259 07185865
RT
Data centralisation In the case of centralised data transmission via bus, the following connection plan must necessarily be carried out: 1 - 2 3 - 5 Centralised power supply 24 V (ac) Transmission bus 3 Tx (Transmission) 5 Rx (Reception)
User information cycle The heat meter is equipped with a liquid crystal display. The display is activated by pressing the button on the front . By repeatedly pressing the button briefly it is possible to scroll through the various information windows. In order to have a longer battery life, the display is switched off 30 s after last pressing the sensor button.
PUSH
For the transmission bus, use shieldless cable 2 x 1 mm2 type FROR 450/750 2x1 CEI 20-22 I I IMQ (our code 755855/N).
Cooling - Energy (Refrigeration units) (Not active) Energy pulse outputs, code. 755881 21 - 23 Remote thermie totalizer output (kWh) (Type OC) These outputs can be connected to our code 755890 (remote energy totalizer) or a general supervisor. Output specifications: 1 IMP = 1 kWh - open collector contact Pulse duration: 120 msec Medium volume
Notes: - The heat meter is equipped with a storage battery (life 5 years). - With centralised transmission it is necessary and essential to have a power supply of 24 V (ac) - 50 Hz - 1 W. To prevent tampering on the device, this line must be centralised and not under the direct control of the user. - Each 75525 series device is supplied with a kit of lead seals and wire to allow sealing of both the temperature probes and the plastic box containing the electronic components. - Help the cables to pass through by breaking and shaping the plastic partition in the cable fairlead. The basic function of the partition is to protect the electronic card from dust and from any spray of water.
Number of openings in the ABS shell (Antitamper system) Check Sum
Segment test
ELECTRONIC OPTIONS
755881
Pulse output
755890
Remote energy totalizer
The pulse output allows energy data to be transferred to a generic data acquisition device. The pulse weighs 1 kWh. The pulse output with no potential is open collector with pulse time 120 ms - Vmax 24 V (ac).
Code
Electronic 8 digit LCD totalizer equipped with cover plate for three-slot wall-mounting electric box. Lithium battery: life 8 years - max frequency 20 Hz Suitable for pulse outputs code 755881. Cable length (2x1 mm2) not supplied by us: max 150 m.
755881
Single pulse output - THERMIE
CALEFFI
3 4 0V
23 Thermie 21
Terminal 21 - 23 Thermie
ENERGIA kWh
755881 75525
Acquisition card (supervisor)
Bus network address
Temperature difference
Return temperature
Flow temperature
Power
Flow rate
1st supplementary consumption
75525 series CONTECA SOLAR direct dynamic heat meter for use in solar heating systems with the following characteristics: volume meter for hot water with magnetic joint (Maximum temperature 120C) with pulse output; Pt100 temperature probe; data visualised on 8 digit display; temperature range 5120C; protection class IP 54; transmission via TWO-WAY bus according to M-bus mode; conformity to EN 1434; electric supply by battery 24 V (ac) in M-bus transmission mode.
CALEFFI
Temperature and pressure relief valve for solar systems

309 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
01147/07 GB
General information The temperature and pressure relief valves (TP) 309 series for solar systems are made by Caleffi S.p.A 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 harmonisation of Member States with regard to pressurised equipment. Function The TP relief valve controls and limits the temperature and pressure of the hot water contained in a solar domestic water storage heater and prevents it from being able to reach temperatures of over 100C, with the formation of steam. On reaching the settings, the valve discharges a sufficient amount of water into the atmosphere so that the temperature and pressure return within the systems operating limits. This particular series of valves is certified as conforming to the performance requirements of the European standard EN 1490 (for settings of 7 - 10 bar).
Product range 309 series Temperature and pressure relief valve for solar systems Sizes 1/2 x 15 mm, 3/4 x 22 mm
Technical specifications Materials: Body: Stem: Obturator and diaphragm: Spring: Control knob: Performance Nominal pressure: Discharge rating: Medium: PED category: Settings: Connections: - temperature: - pressure: - 1/2 15; - 3/4 22;
Dimensions
PN 10 10 kW 25 kW water IV 90C 6 - 7 - 10 bar A F
1/2 M x 15 mm with compression fitting for copper pipe 3/4 M x 22 mm with compression fitting for copper pipe
Code completion ( . . ) Code 3094.. 61 6 bar 71 7 bar 01 10 bar Code 3095.. 61 6 bar 71 7 bar 01 10 bar Code 3094 . . 3095 . . A 1/2 3/4 B 15 22 C 40 43
D 102 99
E 88 91
C F 39 39
dezincification-resistant alloy EN 12165 CW602N chrome plated brass EN 12164 CW614N EPDM steel EN 10270-1 SH PA6GF
111 5
RE
Weight (kg) 0,253 0,310
Operating principle The valve opens the outlet on reaching the settings for: - temperature: the thermostat compound inside the temperature sensor 1), submerged in the hot water storage heater, expands as the temperature increases. This expansion causes a thrust pin to move and act on the obturator 2) opening the valve. The valve is set to open at temperatures of over 90C. - pressure: the obturator, opposed by a set spring, raises on reaching the pressure setting and opens the outlet completely. The pressure setting is chosen according to the maximum permissible pressure in the system. As the temperature and pressure decrease, the opposite action occurs with the valve subsequently reclosing within the set tolerances. Certification CE mark 309 series TP relief valves for solar systems comply with the essential safety requirements of Directive 97/23/EC concerning pressure equipment (also called P.E.D.). They are therefore classified as category IV and are equipped with the CE mark. Product certification in accordance with European Standard EN 1490 European Standard EN 1490: 2000, entitled Building valves - Combined temperature and pressure relief valves Tests and requirements, describes the constructional and performance specifications that TP relief valves must have. Caleffi 309 series TP relief valves for solar systems are certified by Buildcert (UK) to comply with the requirements of the European Standard EN 1490 (for settings 7 10 bar).
Installation Before installing a TP relief valve it is necessary for the sizing to be performed correctly by specialized technical personnel in accordance with the current regulations for the specific applications. Any use other than the intended use is prohibited. The TP relief valves must be installed by qualified technical personnel in accordance with current regulations. The TP relief valves must be installed observing the direction of flow indicated by the arrow on the valve body.
Assembly Plumbing system TP relief valves must be installed on the top of the solar hot water storage heater, making sure that the temperature sensor is correctly submerged in the tank. Make sure that there are no shut-off devices between the valve and the storage heater. TP relief valves can be fitted vertically or horizontally, but not overturned. This prevents debris from impairing operation.
SOLAR HOT WATER STORAGE
SOLAR STORAGE
SOLAR STORAGE
309 series Temperature and pressure relief valve for solar systems. Equipped with the CE mark in accordance with directive 97/23/EC. Dezincification-resistant alloy body. Brass stem. Obturator and diaphragm in EPDM. Steel spring. Control knob in glass-fiber re-inforced nylon. Threaded 1/2 M connections on the inlet and 15 mm (and 3/4 M x 22 mm) with compression fitting for copper pipe on the outlet. Temperature setting 90C. Pressure setting 6 bar (available settings: 6-7-10 bar). Valves with 7-10 bar setting certified to EN 1490 standard. Discharge rating: 1/2 x 15 mm: 10 kW, 3/4 x 22 mm: 25 kW. Medium: water. Category PED IV. Nominal pressure: PN 10.
CALEFFI
Balancing valve with flow meter for solar thermal systems

258 series
IS
CALEFFI
BSI EN ISO 9001:2000 Cert. n FM 21654 UNI EN ISO 9001:2000 Cert. n 0003
TERE
01148/08 GB
Function The balancing valve is an hydraulic device that accurately regulates the flow rate of heating medium supplied to the various circuits of solar thermal systems. This particular series of valves is equipped with a flow meter for a direct reading of the regulated flow rate. The flow meter, housed in a by-pass circuit on the valve body and that can be shut off during normal functioning, allows a fast and easy balancing of circuits without the need of differential pressure gauges or diagrams. The balancing valve is equipped with a hot preformed shell insulation to ensure a perfect thermal performance. This particular series of valves has been specifically designed to work with glycol solutions at high temperatures, typical conditions of solar thermal systems. Patent application No. MI2007A000703. Product range 258 series Balancing valves with flow meter for solar thermal systems size 3/4 and 1
Technical specifications Materials Valve Body: Ball: Ball control stem: Ball seal seat: Control stem guide: Seals: Flow meter Body: Headwork: Obturator stem: Springs: Seals: Flow meter float: Indicator cover:
Flow rate ranges Code 258503

3/4 27
RE
258523
3/4 728
258603
1 1040
brass EN 12165 CW617N, chrome plated brass EN 12164 CW614N brass EN 12164 CW614N, chrome plated high resistance polymer high resistance polymer high resistance elastomer brass EN 12165 CW617N, chrome plated brass EN 12164 CW614N brass EN 12164 CW614N, chrome plated stainless steel high resistance elastomer high resistance polymer high resistance polymer water, glycol solutions 50% 10 bar -30130C l/min 10% 90 9 mm 3/4 and 1 F
Size Flow rates (l/min) Dimensions
Performance Medium: Max. percentage of glycol: Max. working pressure: Working temperature range: Flow rate scale unit of measurement: Accuracy: Control stem angle of rotation: Operating wrench: Threaded connections:
CALEFFI
bar
7 6 5 4 3 2
7 6 5 4 3 2
Insulation Material: closed cell expanded PE-X Thickness: 10 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 water vapour (DIN 52615): > 1.300 Working temperature range: 0100C Reaction to fire (DIN 4102): class B2
Code 258503 258523 258603
A 3/4 3/4 1
B 83,5 83,5 85
C 45,5 45,5 47
D 145 145 158
Weight (kg) 0,74 0,74 0,96
Benefits of balancing solar thermal circuits When a solar thermal circuit is properly balanced, it is ensured the correct flow rate circulating through the system, depending on the panel size.
Operating principle The balancing valve is an hydraulic device that allows to regulate the medium flow rate passing through. The regulating action is made by a ball obturator (1), operated by a control stem (2). The flow rate is controlled by means of a flow meter (3) housed in a by-pass circuit, on the valve body, that can be shut off during normal functioning. The flow rate value is indicated by a metal sphere (4), sliding within a transparent guide (5), marked alongside by a graduated scale (6).
1
3
3
7 6 5
2 3
5 6 4
4 3 2
5 4
Automatic filling
Construction details Temperature In solar thermal systems, the primary circuit thermal medium is a glycol solution operating at high temperature; for taking into account these particular working conditions, the seals and the inner plastic components of the valve are made of highly temperature resistant materials. Flow meter The flow rate value is displayed directly by a flow meter housed in a by-pass circuit on the valve body, automatically shut-off during normal functioning. The use of a flow meter greatly simplifies the process of system balancing, since the flow rate can be measured and controlled at any time and there is no need for differential pressure gauges or reference charts. Flow meter obturator The obturator (1) opens and shuts the circuit between the flow meter and the valve. The obturator can be easily opened by pulling the ring (2), and is closed automatically, 1 after completion of the procedure, by the internal spring (3). The spring and the EPDM 4 3 2 seal (4) guarantee over time a perfect circuit closure during normal functioning. The operating ring (2) is made of a material with low thermal conductivity to avoid burns if the flow meter is opened while hot medium is passing through the valve. Ball and magnet indicator The ball (4) that indicates the flow rate value is not in direct contact with the thermal medium passing through the flow meter. Thanks to an effective and innovative measuring system, the ball slides up and down in a cylinder (5) that is actually separate from the body of the flow meter. The ball is moved by a magnet (6) fixed to a float (7). This means that the flow rate indication system remains perfectly clean and provides reliable readings over time.
The provision of a flow meter also means that it is not anymore necessary to calculate valve settings at the system design stage. The advantages of this solution can be explained as significant time and cost saving, because the traditional balancing device presetting, performed by qualified technicians, is a long and difficult procedure.
5 7 6 4
Complete closing and opening of the valve The valve can be completely closed and opened. A slot on the obturator stem indicates the status of the valve. When the control stem is turned fully clockwise and the slot lies perpendicular to the Completely closed Completely open axis of the valve, the valve is fully closed (A). When the control stem is turned fully anti-clockwise and the slot lies parallel to the axis of the valve, the valve is fully open (B). A B
Insulation The 258 series balancing valve is supplied complete with hot pre-formed insulation. This system ensures total thermal insulation, which is especially helpful in limiting heat losses in outdoor installations, typical of solar thermal systems.
p (mm w.g.)
15.000 10.000
Flow rate adjustment

p (kPa)
150 100
3/4 3/4 1
The flow rate is adjusted by carrying out the following operations:
5.000
50
2.000 1.000
20 10
A. With the aid of the indicator (1), mark the reference flow rate at which the valve has to be set.
B. Use the ring (2) to open the obturator that shuts off the flow of medium in the flow meter (3) under normal operating conditions.
500
200
100 50
100
250
500
1.000
2.500
5.000
10.000
3 2
G (l/h)
Code Size Flow rates

(l/min)
3
258503 258523 258603

3/4 27 0,9 3/4 7 28 5,4 1 10 40 7,2
Kv (m /h)
Kv valves fully open
Correction for media with different density For fluids with a viscosity 3E, e.g. water/glycol solutions with density different with respect to the water at 20C ( = 1 kg/dm3), to which the upper diagram refers, it should be considered that: - pressure drop (for sizing the pump) is determined by: pactual = preference x glycol solution; - variation in flow rate measurement remains within the specified accuracy (10%) for glycol percentages up to 50%. Installation Install the balancing valve in such a way to ensure free access to the flow meter obturator, control stem and flow rate indicator. We recommend to install straight sections of pipe as shown in the illustration below to ensure accurate flow measurement. 258 series 258 series Pump
C.Keeping the obturator open, apply a wrench on the control stem of the valve (4) to adjust the flow rate. It is indicated by a metal ball (5) that runs inside a transparent guide (6) marked by a graduated scale in l/min.
5 6
5D
10D
The valve can be installed in any position by respecting the flow direction shown on the valve body. The valve can be installed either horizontally or vertically.
D.After completing the balancing, release the ring of the flow meter obturator that, thanks to an internal spring, will automatically go back into the closed position.
6 5 4 3 2 4 5 6 7 2 3
3 4 5 6
Application diagrams - Flow rate adjustment an a single solar circuit
Shut-off valve Pump Deaerator Air vent Expansion vessel Temperature gauge Ballstop Controller Safety relief valve
2
Automatic filling
Flow rate adjustment in two or more solar circuits
2
Automatic filling
258 series Balancing valve with flow meter for solar thermal systems. Threaded connections 3/4 (and 1) F x F. Brass body, chrome plated. Brass ball. Brass control stem ball, chrome plated. High resistance elastomer seals. High resistance polymer control stem guide. Brass flow meter body, chrome plated. Brass flow meter headwork. Brass flow meter obturator stem, chrome plated. Stainless steel flow meter spring. High resistance polymer flow meter float. High resistance polymer flow indicator cover. High resistance elastomer seals. Expanded closed cell PE-X pre-formed shell insulation. Medium water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 10 bar. Working temperature range -30130C. Flow rate scale unit of measurement l/min. Accuracy 10%. Control stem angle of rotation 90.
CALEFFI
Balancing valve with flow meter

132 series
IS
CALEFFI
TERE
UNI EN ISO 9001:2000 Cert. n 0003
01149/08 GB
Function The balancing valve is an hydraulic device that accurately regulates the flow rate of heating medium supplied to system terminals. A correct balancing of hydraulic systems is essential to guarantee the system operation according to its design specifications, high thermal confort and low energy consumption. This particular series of valves is equipped with a flow meter for a direct reading of the regulated flow rate. The flow meter, housed in a by-pass circuit on the valve body and that can be shut off during normal functioning, allows a fast and easy balancing of circuits without the need for differential pressure gauges or diagrams. The balancing valve is equipped with a hot pre-formed shell insulation to ensure a perfect thermal performance in case of use both with hot and chilled water. Patent application No. MI2007A000703. Product range 132 series Balancing valve with flow meter sizes 1/2, 3/4, 1, 1 1/4, 1 1/2 and 2
Technical specifications Materials Valve Body: Ball: Ball control stem: Ball seal seat: Control stem guide: Seals: Flow meter Body: Headwork: Obturator stem: Springs: Seals: Flow meter float: Indicator cover:
Flow rate ranges Code 132402 132512 132522 132602 132702 132802 132902
brass EN 12165 CW617N brass EN 12164 CW614N brass EN 12164 CW614N, chrome plated PTFE PSU EPDM brass EN 12165 CW617N brass EN 12164 CW614N brass EN 12164 CW614N, chrome plated stainless steel EPDM PSU PSU water, glycol solutions 50% 10 bar -10110C l/min 10% 90 1/21 1/4: 9 mm 1 1/2 and 2: 12 mm 1/22 F
Size Flow rates
(l/min)
Dimensions A C
RE
1/2 27
3/4 513
3/4 728
1 1040
1 1/4 2070
1 1/2 30120
2 50200
Performance Medium: Max. percentage of glycol: Max. working pressure: Working temperature range: Flow rate range unit of measurement: Accuracy: Control stem angle of rotation: Operating wrench: Threaded connections:
CALEFFI
15 bar
7 6 5 4 3 2
A Code 132402 132512 132522 132602 132702 132802 132902 A 1/2 3/4 3/4 1 1 1/4 1 1/2 2 B 83,5 83,5 83,5 85 88 91 96,5
B C 45,5 45,5 45,5 47 50 56,5 62 D 145 145 145 158 163,5 171 177 Weight (kg) 0,80 0,74 0,74 0,96 1,19 1,47 2,00
Insulation Material: closed cell expanded PE-X Thickness: 10 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 water vapour (DIN 52615): > 1.300 Working temperature range: 0100C Reaction to fire (DIN 4102): class B2
Advantages of balanced circuits Balanced circuits have the following principal benefits: 1. The system terminals operate correctly in heating, cooling and dehumidification without waste of energy and provide a better comfort. 2. The pumps run in their zone of highest efficiency, thus reducing the risk of overheating and excessive wear. 3. Too high medium speeds, which can result in noise and abrasion, are avoided. 4. The differential pressures acting on the regulation valves are limited in value, thus preventing faulty operation.
Operating principle The balancing valve is an hydraulic device that allows to regulate the medium flow rate passing through. The regulating action is made by a ball obturator (1), operated by a control stem (2). The flow rate is controlled by means of a flow meter (3) housed in a by-pass circuit, on the valve body, that can be shut off during normal functioning. The flow rate value is indicated by a metal sphere (4), sliding within a transparent guide (5), marked alongside by a graduated scale (6).
1
15 1
3
7 6 5
2
3 7 6 5 4 2
5 6 4
4 3 2
5
3 7 6 5 4 2
4
3 2 4
Construction details Flow meter The flow rate value is displayed directly by a flow meter housed in a by-pass circuit on the valve body, automatically shut-off during normal functioning. The use of a flow meter greatly simplifies the process of system balancing, since the flow rate can be measured and controlled at any time and there is no need for differential pressure gauges or reference charts. The provision of a flow meter also means that it is not anymore necessary to calculate valve settings at the system design stage. The advantages of this solution can be explained as significant time and cost saving, because the traditional balancing device presetting, performed by qualified technicians, is a long and difficult procedure.
5 6 7
Flow meter obturator The obturator (1) opens and shuts the circuit between the flow meter and the valve. The obturator can be easily opened by pulling the ring (2), and is closed automatically, after completion of the procedure, by theinternal spring (3). The spring and the EPDM seal (4) guarantee over time a perfect circuit closure during normal functioning.
The operating ring (2) is made of a material with low thermal conductivity to avoid burns if the flow meter is opened while hot medium is passing through the valve.
Ball/magnet indicator The ball (4) that indicates the flow rate value is not in direct contact with the thermal medium passing through the flow meter. Thanks to an effective and innovative measuring system, the ball slides up and down in a cylinder (5) that is actually separate from the body of the flow meter. The ball is moved by a magnet (6) fixed to a float (7). This means that the flow rate indication system remains perfectly clean and provides reliable readings over time.
5 7 6 4
Complete closing and opening of the valve The valve can be completely closed and opened. A slot on the obturator stem indicates the status of the valve. When the control stem is turned fully clockwise Completely closed Completely open and the slot lies perpendicular to the axis of the valve, the valve is fully closed (A). When the control stem is turned fully anti-clockwise and the A B slot lies parallel to the axis of the valve, the valve is fully open (B). Hydraulic characteristics
p (mm w.g.)
15.000 10.000
Insulation The 132 series balancing valve is supplied complete with hot pre-formed insulation. This system ensures not only perfect thermal insulation, but also tightness to water vapour from the environment towards the inside. For these reasons, this type of insulation can also be used in chilled water circuits as it prevents condensation forming on the surface of the valve body.
Flow rate adjustment

p (kPa)
150 100
1 1/4 1 1/2 3/4 3/4 1 2
1/2
The flow rate is adjusted by carrying out the following operations: A. With the aid of the indicator (1), mark the reference flow rate at which the valve has to be set. B. Use the ring (2) to open the obturator that shuts off the flow of medium in the flow meter (3) under normal operating conditions.
5.000
50
2.000 1.000
20 10
500
200
100 50
100
250
500
1.000
2.500
5.000
10.000
1 25.000 50.000
3 2
G (l/h)
Code Size Flow rates

(l/min)
132402 132512 132522 132602 132702 132802 132902

1/2 27 0,9 3/4 513 2,5 3/4 728 5,4 1 1040 7,2 1 1/4 2070 13,1 1 1/2 2
30120 50200 27,8 46,4
Kv (m3/h)
Kv valves fully open
Correction for liquids with different densities For fluids with a viscosity 3E, e.g. water/glycol solutions with density different with respect to the water at 20C ( = 1 kg/dm3), to which the upper diagram refers, it should be considered that: - pressure drop (for sizing the pump) is determined by: pactual = preference x glycol solution; - variation in flow rate measurement remains within the specified accuracy (10%) for glycol percentages up to 50%. Installation Install the balancing valve in such a way to ensure free access to the flow meter obturator, control stem and flow rate indicator. We recommend to install straight sections of pipe as shown in the illustration below to ensure accurate flow measurement. 132 series 132 series Pump
C.Keeping the obturator open, apply a wrench on the control stem of the valve (4) to adjust the flow rate. It is indicated by a metal ball (5) that runs inside a transparent guide (6) marked by a graduated scale in l/min.
5 6
5D
10D
The valve can be installed in any position by respecting the flow direction shown on the valve body. The valve can be installed either horizontally or vertically.
D.After completing the balancing, release the ring of the flow meter obturator that, thanks to an internal spring, will automatically go back into the closed position.
6 5 4 3 2 4 5 6 7 2 3
3 4 5 6
Application diagrams The balancing valve with the flow meter should preferably be installed on the circuit return pipe.
To adjust the flow rate to each riser
To balance circuits serving air conditioning units
To adjust the flow rate to each terminal
To balance the by-pass branch of outside compensated control circuits
To balance zone branches in circuits with three-way valves
To balance sanitary water distribution circuits
132 series Balancing valve with flow meter. Threaded connections 1/2 (from 1/2 to 2) F x F. Brass body. Brass ball. Brass ball control stem, chrome plated. PTFE ball seal seat. PSU control stem guide. Brass flow meter body and headwork. Brass flow meter obturator control stem, chrome plated. Stainless steel flow meter springs. PSU flow meter float and indicator cover. EPDM seals. With pre-formed shell insulation in expanded closed cell PE-X. Medium water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 10 bar. Working temperature range -10110C. Flow rate range unit of measurement l/min. Accuracy 10%. Control stem angle of rotation 90.
CALEFFI
Manifolds for industrial radiant panel systems

6509 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
01150/08 GB
Function This series of stainless steel manifolds is provided for control and distribution of the heating fluid in radiant panel systems that require particularly high flow rates. For this reason they are mainly indicated for industrial type applications, such as warehouses, factories, large workshops, etc. They are supplied in a pre-assembled version with 3 to 16 outlets complete with: shut-off valves on the outlets giving the possibility of cutting off the heating to different areas, pockets for temperature gauges (supplied in the package) for controlling the radiant panel heat exchange and cocks with hose connection for filling/draining the circuit. The use of stainless steel allows the manifolds to be used with drinking water or aggressive fluids.
Product range 6509 series Manifolds for industrial radiant panel systems size 2
Technical specifications Materials
Dimensions
105
Manifold Body: Shut-off valves Body: Control lever:
stainless steel brass EN 12165 CW617N, chrome plated aluminium
Performance Medium: Max. percentage of glycol: Max. working pressure: Temperature range: Temperature gauge scale: Main connections: Manifold inner diameter: Main connection centre distance: Outlets: Outlet centre distance: Fill/drain cock: water, glycol solutions 50%
2
350
RE
40
10 bar -10110C 080C 2 M x 2 M 54 mm 350 mm 3/4 F 80 mm hose connection
CALEFFI
CALEFFI
CALEFFI
105
3/4
80 L
60
Inlet localized head loss coefficient : Outlet localized head loss coefficient : Kv (m3/h) shut-off ball valves:
1,0 3,0 17
Code outlets 650903 3 650904 4 650905 5 650906 6 650907 7 650908 8 650909 9
L 285 365 445 525 605 685 765
Weight (kg)
08,4 09,7 11,0 15,0 15,3 16,6 18,6
Codice 650910 650911 650912 650913 650914 650915 650916
deriv.
10 11 12 13 14 15 16
L 845 925 1005 1085 1165 1245 1325
Weight (kg)
19,8 21,0 22,2 23,4 24,6 25,8 27,0
CALEFFI
CALEFFI
CALEFFI
8 9 1
CALEFFI
CALEFFI
CALEFFI
Pre-assembled unit complete with: 1) Flow manifold complete with ball shut-off valves 2) Return manifold complete with ball shut-off valves 3) Pair of brackets, complete with insulating clamps 4) Fill/drain cocks with hose connection 5) Pair of temperature gauges 6) End fitting caps
Accessories: 7) Three-piece 2 F x M union fitting, code 588091 8) 942 series sleeve 9) Fitting with self-adjusting diameter for plastic pipes, DARCAL 681 series
Construction details Ease of installation The manifold is supplied pre-assembled with fixing brackets, ready for mounting directly on the wall. Temperature gauges and fill/drain cocks The manifold is supplied complete with pockets for temperature gauges (1), included in the package, for the control and measurement of the flow and 2 return heating fluid and the control of the radiant panel heat exchange. 1 To make circuit filling and draining easier, the cocks (2) are built-in to the manifolds, positioned centrally at the top side. Reversibility of connections The manifold is reversible: the main connections can be positioned with entry from the right or left by unscrewing and moving the end fitting caps. Low head losses The underfloor systems for industrial applications usually are based on higher heating fluid flow rates than those intended for civil use. For this reason, the 6509 series manifold has been designed with inner diameter an outlets that allow maximum flow through them with reduced head losses.
Stainless steel body The stainless steel, the manifold is constructed with, gives a greater compactness to the unit, not only with regard to the installation but also in relation to its intended use (in industrial environments). The stainless steel alloy brings further benefits since the manifold can be used also with drinking water and aggressive fluids.
Underfloor radiant panels and work environment Comfort The increased worker comfort makes it possible to reduce waste and margins of error and provides a general incentive to achieving optimum, professional work standards. The heating, based prevalently on the propagation of heat by irradiation (1a), avoids conditions of thermal stratification thanks to the lack of the upward motion of the air, typical of ventilation systems (1b). This makes the temperature profile more adaptable to the room height (2a) and the needs of the human body, with a greater presence of oxygen in the environment and the optimum relative humidity of the air. Workers health Radiant panel heating systems avoid the formation of air currents generated by ventilation systems (1b). These currents cause the movement of particles, dust and ultra-fine substances (e.g. sawdust in carpentry workshops) that can create problems, especially with regard to workers health (2b). Energy Saving The prevalent amount of heat yielded by radiant panel systems is from irradiation (1a). This makes it possible to keep the air at a lower temperature whilst maintaining the same comfort level, thus reducing the flow temperature of the heating fluid. In an industrial context, if the heating fluid temperatures are low then the heat generated by production processes can be re-used, thus reducing costs. Maintenance As there are no parts subject to wear in radiant panel systems, routine and non-routine maintenance costs (3b) are drastically reduced. The system is tamper-proof and guaranteed free of possible breaks caused by moving loads (3a). In ventilation systems, the micro-particles transported by the air currents and the excessive thermal gradients caused by the currents can also cause problems for precision machining equipments (4b) and products (e.g. in the medical/pharmaceutical or food industries). Zone control In radiant panel systems, cutting the heating off to different areas is easy, thanks to the shut-off valves on the manifold (4a).
Accessories
681
Self-adjusting diameter fitting for plastic pipes. Max. working pressure: 10 bar. Temperature range: 580C. Chrome plated.
Code
588
Three-piece straight union fitting. Chrome plated.
588091
Code inside outside
2 F x M with union
681687 681605
1 1
17,5 19,5
25 25
942
Sleeve. Chrome plated.
Code
681
Fitting with self-adjusting diameter for single and multilayer plastic pipes. Max. working pressure: 10 bar. Temperature range: 580C (PE-X) 575C (Multi-layer marked 95C). Chrome plated. Patented.
942551 942561
3/4 M x 3/4 3/4 M x 1
695
System test pump. With pressure gauge and hose for connecting to the system.
Code
inside
outside
681502 681500 681501 681506 681515 681517 681524 681526 681535 681537 681546 681555 681556 681564
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
7,5 8 1 9 9,5 9,5 10 19,5 10 10,5 11 10,5 11 11,5 12 11,5 12 12,5 13 12,5 13 13,5 14 14,5 15 15 15,5 15,5 16
12 14 12 14 14 16 14 16 16 18 18 18 18 18
14 16 14 16 16 18 16 18 18 20 20 20 20 20
Technical specifications Materials: Body: Piston: Control lever: Performance: Max. working pressure: Water content: Pressure gauge scale: Hose connection: Length of hose:
Code
bronze brass galvanized steel 50 bar 12 l 060 bar 1/2 1,5 m
695000
1/2
6509 series Manifolds for industrial radiant panel systems with 3 (from 3 to 16) outlets. Stainless steel body. Shut-off valves with chrome plated brass body, aluminium control levers. Main connections 2 M. Outlet connections 3/4 F, centre distance 80 mm. Mediums: water and glycol solutions; maximum percentage of glycol 50%. Maximum working pressure 10 bar. Temperature range -10110C. Complete with: - Flow and return manifolds complete with ball shut-off valves, fill/drain cocks with hose connection and pockets for temperature gauges. - Pair of brackets, complete with insulating clamps. - Blind end plugs. - Pair of temperature gauges.
CALEFFI
Modulating temperature regulating unit
CALEFFI
171 series
IS
TERE
UNI EN ISO 9001:2000 Cert. n 0003
01151/07 GB
Function The temperature regulating unit is made to be used in radiant panel systems in combination with distribution manifolds. The modulating temperature regulating unit, comprehensive of digital temperature regulator, controls the temperature of the medium sent to the panels according to the actual thermal load. In this particular series, the temperature is regulated by a dedicated hydraulic unit equipped with a specific motorised three-way valve. It is supplied with a removable differential by-pass kit for the primary circuit. This accessory is essential when there is a primary circuit circulation pump and the radiator circuits or fan coils are controlled by thermostatic or thermo-electric valves. In case of connection with a Sepcoll or an hydraulic separator without primary pump, the kit can be removed and the hydraulic unit is connected directly. Patent application No. MI2006A 001935. Reference Documentation - Tech. brochure 01144 Pre-assembled distribution manifolds for radiant panel systems 668...S1 series
Product range Code 1715.1 Code 1715.3 Modulating regulating unit, with UPS 25-60 pump Modulating regulating unit, with UPS 25-80 pump
Technical specifications Materials Regulating unit with motorised three-way valve Body: brass EN 1982 CB753S Headwork: brass EN 12164 CW614N Obturator: stainless steel Seals: EPDM Flow adapter unit Body: Primary circuit by-pass kit Body: By-pass valve: Spring: Shut-off valves Body: Ball: brass EN 1982 CB753S brass EN 1982 CB753S POM stainless steel
Performance Medium: Max. percentage of glycol: Control temperature range: Primary inlet temperature range: Max. working pressure: Panel manifolds differential by-pass setting: Primary circuit differential by-pass setting: Temperature gauge scale: Pressure gauge scale: Connections: primary circuit: to regulating unit: panel circuit outlets: outlet centre distance: water, glycol solutions 30% 2078C 5100C 10 bar 25 kPa (2.500 mm w.g.) 10 kPa (1.000 mm w.g.) 080C 010 bar 3/4 M 1 F with nut 3/4 M - 18 mm 50 mm
brass EN 12165 CW617N brass EN 12164 CW614N, chrome plated
Panel circuit differential by-pass graph p (mm w.g.)

5000
4500 4000 3500 3000 2500
0,2
0,1
0,5
10
20
2000
RE
p (kPa)
50
45 40 35 30 25
20
Digital controller Three-point type Electric supply: Power consumption: Protection class: Actuator Three-point type Electric supply: Operating time: Power consumption: Auxiliary micro contact rating: Protection class: Max. ambient temperature: Protective cover: Flow/return temperature probes NTC type Working range: Time constant: Response: Two-wire cable with 1/8 M connection Safety thermostat Factory set: Protection class: Contacts rating: Pump Three-speed pump: Material: Body: Electric supply: Maximum ambient humidity: Max. ambient temperature: Protection class: Pump centre distance: Pump connections: model UPS 25-60/UPS 25-80 cast iron GG 15/20 230 V - 50 Hz 95% 80C IP 44 130 mm 1 1/2 with nut 55C 3C IP 55 10 A / 240 V -10125C 2,5 s 10.000 at 25C 230 V - 50 Hz 50 s (rotation 120) 8 VA 0,8 A IP 44 55C self-extinguishing VO 230 V - 50 Hz 3 VA IP 40
Head available at the regulating unit connections

H (m w.g.)
6
(kPa)
60
H (m w.g.)
8 7 6
(kPa)
80
UPS 25-60
5 4 3 2 1 0 50 40
UPS 25-80
70 60
5 4 3 2
3 2 1
2 1
50 40 30 20 10
30 20 10 0
1 0 0 0,5 1 1,5 2 2,5 3 3,5 4
0,5
1,5
2,5
G (m3/h)
G (m3/h)
Power consumption
Speed I
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (rpm) 1800 1100 700
Speed
(A) 1,04 0,92 0,63
P (W) 245 210 140
n (rpm) 2450 1500 700
3 2 1
3 2 1
Insulation Material: Thickness: Density: - inner part: - outer part: Thermal conductivity (DIN 52612): Coefficient of resistance to the diffusion of water vapour (DIN 52615): Working temperature range: Reaction to fire (DIN 4102): closed cell expanded PE-X 15 mm 30 kg/m3 50 kg/m3 0C: 0,038 W/(mK) 40C: 0,045 W/(mK) >1300 0100C Class B2
Dimensions
1000
5 outlets
9 outlets
13 outlets
3 2 1 0
co n fo r
1 2
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
bar
4 5 6
2.5 CL
3 4
L/MIN
m e n or m e ISP E
SL
30 20 10 0
40
50 60 70
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
80
700
CALEFF
SOGGIORNO
CALEFFI
CALEFF
CAMERA
CALEFFI
CALEFF
CAMERA
CALEFFI
30 20 10 0
40
50 60 70
80
270410
115
3/4
60 345 A 50 A A 110150
with ups 25-60 pump with ups 25-80 pump
code
Panel outlets A
1200
800
1
3
10
2 1 0
c on
8 4 6 2
bar
4 5 6
CL
5
SYSTEM FLOW
Flow manifold equipped with flow meters and balancing valves

1 2 3 4
L/MIN
f or m
e n o r m e I SP
ES L
1 2 3 4
L/MIN
1 2 3 4
L/MIN
2.5
30 20 10 0
40
50 60 70
80
9 7
CALEFFI
CAMERA
SOGGIORNO
WC
CALEFFI
Return manifold equipped with shut-off valves.
30 20 10 0
40
50 60 70
SYSTEM RETURN
CALEFFI
CAMERA
SOGGIORNO
WC
CALEFFI
80
11
12
BOILER BOILER FLOW RETURN
End fittings with multi-position ball valves, automatic air vent, differential by-pass kit and fill/drain hose connection.
1 2 3 4
Digital controller for heating Three-way mixing valve Three-point actuator Three-speed circulation pump UPS 25-60 Three-speed circulation pump UPS 25-80 5 Flow temperature probe 6 Return temperature probe
7 8 9 10 11 12
Adjustable drain cock Safety thermostat Flow and return temperature gauges with pocket Pressure gauge Primary circuit shut-off valves Primary circuit differential by-pass kit
Hydraulic diagram
Digital controller
SF
10 5 9 7 8
Adjustable drain cock Temperature gauge Temperature probe
RT
ST
9 4 6 3
RT ST
Room thermostat Safety thermostat Ball shut-off valve
SR
2
Motorised three-way valve Pressure gauge Pump
12 11 11
BF
BR
Operating principle The medium temperature is regulated by a three-way mixing valve with a sector obturator comprehensive of an actuator managed by a specific digital controller. The controller receives the signal from two probes, flow probe on the mixing valve outlet and probe from the panel circuit return, and it controls the movement of the valve. The flow in the valve is regulated by a shaped obturator (1) that, by turning, closes or opens the hot water flow port (2) and the water returning port from the circuit (3) to adjust the desired flow temperature. Even if the secondary circuit thermal load or the inlet temperature from the boiler change, the mixing valve automatically adjusts the flow rates until it obtains the optimal flow temperature.
SECONDARY FLOW
3
SECONDARY RETURN
2
PRIMARY INLET PRIMARY RETURN
Construction details Regulating unit body The valve body, containing the thermal regulating device, is made out of a single casting with connections to the primary and secondary circuits. A specific internal channel carries the system return medium to the regulating valve, making it possible for the unit to be smaller in size and easy to connect. Reduced head losses The three-way mixing valve is equipped with a special obturator acting on calibrated water orifices. This ensures a high flow rate and a reduced size, while maintaining accurate temperature control, with no swinging due to sudden changes in thermal load. Electrical connections The actuator is electrically connected through an external plug-socket system with a protective rubber cap. This system does not require opening the lid to connect the cables. In this way, replacing the actuator (should this ever be necessary) is particularly easy to do. Manual opening By removing the actuator, the valve can be opened-closed manually by using a screwdriver. Regulating way - primary inlet Fully closed Fully open Flow unit The flow unit is made out of a single casting with the necessary ports to connect with the functional components such as the safety thermostat, temperature gauge, pressure gauge, drain valve and flow temperature probe.
30 20 10 0
40
50 60 70
80
op
open
se
clo
se
en
clo
Differential by-pass kit for primary circuit Operation The differential by-pass kit for the primary circuit enables controlling the flow supplied to the heating elements connected before the outlet to the panel circuit regulating unit.
Removable kit In case of an hydraulic circuit connected to a Sepcoll or to an hydraulic separator without primary pump, the kit can be removed and the hydraulic unit is connected directly. The circuit shut-off valves, equipped with nut connection, can be removed easily and used directly on the unit.
Connection without hydraulic separator or SEPCOLL
Differential valve The differential valve is used to control the head in the primary distribution circuit. It aids the flow circulation towards the heating elements and limits overpressure if there are thermostatic or thermo-electric valves. The differential valve has a fixed setting that cannot be changed. It is preset to 10 kPa, mean value for the loss of head in the primary circuit.
p (mm w.g.)
2000
1800 1600 1400 1200
p (kPa)
18 16 14 12
20
1000
900 800 700 600
9 8 7 6
10
Direct connection to hydraulic separator or SEPCOLL

10 20 2 5
Primary circuit by-pass kit The by-pass kit permits hydraulic separation between the primary and secondary circuits. This hydraulic separation optimizes the operation of the secondary circuit at the panels thus preventing the influence on the secondary circuit by any primary circuit flow rate variation. In this case, the flow rate through the respective circuits depends solely on the pump flow rate characteristics, preventing reciprocal influence due to their coupling in series. Two possible conditions of hydraulic balance are described here. The component is typically sized in order to have the following working rate: G primary = G
secondary
Secondary
Gs
Secondary
Gs
(inlet to the mixing valve) + G heating elements
Gp Primary
Gp Primary
G primary maximum recommended: 1,5 m3/h
0,2
0,5
0,1
500
Digital regulator 2 7 3 4 8 1
Operation The regulator receives the signal from the room thermostat to switch the pump on and to control the mixing valve. The regulator acts on the mixing valve following two operating logics, depending on the state of activation of the return sensor. Set point regulation: return probe off. Selector 6) OFF. In this case the flow temperature TM is kept constant at the value set with the selector 5) in both heating and cooling. This setting is shown on the display 1). Modulating regulation: return probe on. Selector 6) ON. In this case the flow temperature TM is changed according to the temperature measured by the return probe TR. In this way the actual thermal efficiency of the slab is kept under control and, as a result, the rooms thermal load as well. This minimizes the systems thermal response times. TRset = TMset - 35% (TMset - 20C) TMcalculated = TMset + (TRset - TR)
Example: TMset = 40C TRset = 40 - 0,35 (40 - 20) = 33C TMcalculated = 40 + (33 - TR)
The new value of TM calculated is shown on the display 1) with a side bar. 10 11 12 9 6 5 At each update of the TM calculated, the TM measured is displayed for 5 s, thereafter the new TM calculated is shown again.
The front panel identifies the following functions: 1) Three-digit LCD indicating: the measured or calculated temperature and the settings of the delays programmed in the system. Temperature range displayed: 099C with resolution 0,1C. TM modification stops when TR reaches TRset. 2) Regulator On/Off function selector. 3) Mixing on opening: LED on. Curve correction graph with return probe 4) Mixing on closing: LED on. 5) Selector for setting the flow temperature. Temperature range 778C Factory configuration: - heating: max 50C TM;TR (C)
50 Flow temperature limit
6) Return probe selector. Probe off: OFF Probe on: ON Factory configuration: ON 7) Pump working (ON): LED on steady. 8) T.S. LED safety temperature. Continuously ON when the limit signalled by the safety thermostat is reached. Continuously ON even if the flow/return probe malfunction (see flow/return sensor paragraph). 9) Heating/cooling function switch, only with RH% control components
45
Designed flow temperature
TM
Ca
la lcu
te
40
TM Set
Ca lcu lat ed
35
TM
TR Set
30
Return temperature designed
25
20
10) Trimmer for maximum pulse duration on the valve. Adjustable 0,26 s. Factory configuration: 2,5 s. Pulse value calculation: Display Tpulse (s) =
50%
100%
150%
Actuator rotation time (s) 40
The three-digit LCD displays the following parameters: - flow temperature set with selector 5). After 5 s the measured flow temperature appears. - measured flow temperature, with return sensor off. - calculated flow temperature, with return sensor on. - maximum duration of pulse on the valve, selectable via trimmer 10). Displayed for 5 s. - return temperature acquisition delay time, selectable via trimmer 11). Displayed for 5 s. - valve-motor mechanical delay recovery, selectable via trimmer 12). Displayed for 5 s
Example:
Tactuator rotation = 120 s Tpulse = 120/40 = 3 s 11) Return probe reading delay time trimmer. Adjustable 1360 s. Factory configuration: 20 s. 12) Valve-motor mechanical delay recovery trimmer. Adjustable 130 s. Factory configuration: 13 s.
TM
Flow temperature
Designed thermal load %
Back panel
M 230 V~ 5060 Hz ~ 5(2) A / 250 V~
CALEFFI
13 14 15 16 17 18 1 L 2 N 3 4 5 6 SA SR TA TS Open Close 7 8 9 10 11 12
Heating safety thermostat If the safety thermostat trips, on detecting a higher flow temperature than the setting, the following state comes into operation: pump OFF, mixing valve closed. The thermostat contact is N/C; if the connection fails, the regulator is not on. Auxiliary microswitch The regulator is equipped with an auxiliary microswitch that can be used to control other devices.
230 V~ IN OUT
13 14 15
16 17 18
1 2 3
4 5 6
7 8 9
10 11 12
Example: When Heating, to turn the water heater on/off. N/O contact - Pump stationary - ambient thermostat OFF or safety thermostat on (water heater off). N/C contact - Pump on - ambient thermostat ON (water heater on). Contact capacity: 5 A (230 V). Flow/return probe The flow/return temperature probes are the NTC type. If the probes detect an ohmic resistance corresponding to short circuiting, the following operating state comes into operation: pump OFF, mixing valve closed, LED 8) on steady. Sensor resistance values table
C -20 -15 -10 -5 0 5 97.060 72.940 55.319 42.324 32.654 25.396 C 10 15 20 25 30 35 19.903 15.714 12.493 10.000 8.056 6.530 C 40 45 50 55 60 65 5.327 4.370 3.603 2.986 2.488 2.083 C 70 75 80 85 90 95 1.752 1.480 1.255 1.070 915 787 C 100 105 110 115 120 125 680 592 517 450 390 340
On the back panel there are terminals for the electrical connections of the various components. Electric supply 1 Electric supply 230 V~ Live 2 Electric supply 230 V~ Neutral 3 Ground/Earth Pump command 4 Ground/Earth 5 Pump command 230 V~ Live 6 Pump command 230 V~ Neutral Mixer command 7 Valve command for opening 8 Common C 9 Valve command for closing Auxiliary microswitch 10 Auxiliary output N/O 11 Auxiliary output common C 12 Auxiliary output N/C Flow/return probe 13 Flow temperature probe 14 Common C 15 Return temperature probe Ambient thermostat/safety thermostat 16 Contact for ambient thermostat 17 Contact for common C ambient thermostat / Contact for common C safety thermostat 18 Contact for safety thermostat.
Flow temperature limit for heating The regulator enables selecting the maximum flow temperature for heating. For this purpose, the regulator base contains specific dipswitches that enable setting different temperature limits.
Factory configuration:
- heating max 50C.
Dipswitch position-temperature limit table Setting Limit Dipswitch maximum 0 0 0 50 0 0 1 54 0 1 0 58 0 1 1 62 1 0 0 66 1 0 1 70 1 1 0 74 1 1 1 78
ON
1 2 3
Accessories
738
Chrono-thermostat for ambient, battery operated. With self-learning program. Weekly programmable clock. With phone programmer. 3 temperature levels + antifreeze. 30 minutes minimum programme.
Code
738107
124 x 90 x 21 mm
Pump Variable speed pump Three-way valve Thermostatic valve
1 2 3 4 5 6
t1 t2 t - t1 - t2 - t3
ON OFF
C C
t1/t2/t3
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
RT
Lockshield Shut-off valve
co
n fo
rm e no rme IS PE S
Clock
RT
Room thermostat Manual valve
1 2 3 4 5 6
t1 t2 t
ON OFF
C C - t1 - t2 - t3
t1/t2/t3
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
RT
co
n fo
rm e no rme IS PE S
Code 1715.. Modulating temperature regulating unit. Connections to the primary circuit 3/4 M. Connections to the regulating unit 1 F with nut. Panel circuit outlet connections 3/4 M - 18 mm. Primary circuit manifold outlet connections 3/4 M - 18 mm. Medium: water and glycol solutions; Maximum percentage of glycol 30%. Control temperature range 2078C. Temperature range at primary circuit inlet 5100C. Maximum working pressure 10 bar. Panel manifolds differential by-pass setting 25 kPa. Primary circuit differential by-pass setting 10 kPa. Temperature gauge scale 080C. Pressure gauge scale 010 bar. Complete with: flow manifold for panel system with 5 outlets (from 5 to 13) with brass body, flow rate regulating valve with flow meter with a scale of 15 l/min; return manifold for panel system with 5 outlets (from 5 to 13) with brass body, shut-off valve. Regulating unit with motorised three-way valve, three-point actuator, electric supply 230 V - 50 Hz, protection class IP 44. Digital controller, electric supply 230 V - 50 Hz, comprehensive of probes measuring temperature of flow and return. Flow adapter unit with brass body. By-pass kit with brass body, POM differential by-pass valve and stainless steel spring. Shut-off valves with brass body and chrome plated brass ball. Safety thermostat: factory setting 55C 3C, protection class IP 55, contact rating 10 A / 240 V. Three-speed circulation pump UPS 25-60 (and UPS 25-80), protection class IP 44. Pre-formed PE-X shell insulation for primary circuit. Supplied preassembled in a painted plate box with lock, depth adjustable from 110 to 150 mm, including floor supports adjustable in height from 270 to 410 mm.
CALEFFI

171 series
IS
CALEFFI
TERE
UNI EN ISO 9001:2000 Cert. n 0003
01152/07 GB
Function The temperature regulating unit is made to be used in radiant panel systems in combination with distribution manifolds. The modulating temperature regulating unit, comprehensive of digital temperature regulator, controls the temperature of the medium sent to the panels according to the actual thermal load. In this particular series, the temperature is regulated by a dedicated hydraulic unit equipped with a specific motorised three-way valve. It is supplied with removable differential by-pass kit for the primary circuit. This accessory is essential when there is a primary circuit circulation pump and the radiator circuits or fan coils are controlled by thermostatic or thermo-electric valves. In case of connection with a Sepcoll or an hydraulic separator without primary pump, the kit can be removed and the hydraulic unit is connected directly. Patent application No. MI2006A 001935. Reference Documentation - Tech. brochure 01144 Pre-assembled distribution manifolds for radiant panel systems 668...S1 series
Product range Code 1715.2 Code 1715.4 Modulating regulating unit for heating and cooling with UPS 25-60 pump Modulating regulating unit for heating and cooling with UPS 25-80 pump
Performance Medium: Max. percentage of glycol: Control temperature range: Primary inlet temperature range: Max. working pressure: Panel manifolds differential by-pass setting: Primary circuit differential by-pass setting: Temperature gauge scale: Pressure gauge scale: Connections: primary circuit: to regulating unit: panel circuit outlets: outlet centre distance: water, glycol solutions 30% 778C 5100C 10 bar 25 kPa (2.500 mm w.g.) 10 kPa (1.000 mm w.g.) 080C 010 bar 3/4 M 1 F with nut 3/4 M - 18 mm 50 mm

5000
4500 4000 3500 3000 2500
0,2
0,1
0,5
10
20
2000
RE
p (kPa)
50
45 40 35 30 25
20

H (m w.g.)
6
(kPa)
60
H (m w.g.)
8 7 6
(kPa)
80
UPS 25-60
5 4 3 2 1 0 50 40
UPS 25-80
70 60
5 4 3 2
3 2 1
2 1
50 40 30 20 10
30 20 10 0
1 0 0 0,5 1 1,5 2 2,5 3 3,5 4
0,5
1,5
2,5
G (m3/h)
G (m3/h)
Power consumption
Speed I
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (rpm) 1800 1100 700
Speed
(A) 1,04 0,92 0,63
P (W) 245 210 140
n (rpm) 2450 1500 700
3 2 1
3 2 1
Dimensions
1000
5 outlets
8 outlets
12 outlets
3 2 1 0
co n fo r
1 2
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
bar
4 5 6
2.5 CL
3 4
L/MIN
m e n or m e ISP E
SL
CALEFFI
CALEFFI
150052
Trasformatore
V DE
150051
AC 50Hz 230V
30 20 10
AC 24V 50Hz AC 230V 6(2)A T50
40
50 60 70
CALEFFI
Convertitore
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
80
700
CALEFF
SOGGIORNO
CALEFFI
CALEFF
CAMERA
CALEFFI
CALEFF
CAMERA
CALEFFI
30 20 10 0
40
50 60 70
80
270410
115
3/4
60 415 A 50 A A 110150
code
Panel outlets A
1200
800
1 8
1 0
c on
10
3 2
bar
4 5 6
CL
5
SYSTEM FLOW

1 2 3 4
L/MIN
f or m
e n o r m e I SP
ES L
1 2 3 4
L/MIN
1 2 3 4
L/MIN
2.5
4 14 6 2 3
CALEFFI
CALEFFI
30 20 10 0
40
50 60 70
150052
Trasformatore
V DE
150051
AC 50Hz 230V
80
Convertitore
AC 24V 50Hz AC 230V T50 6(2)A
9 7 13
CALEFFI
CAMERA
SOGGIORNO
WC
CALEFFI
30 20 10 0
40
50 60 70
SYSTEM RETURN
CALEFFI
CAMERA
SOGGIORNO
WC
CALEFFI
80
11
12
BOILER BOILER FLOW RETURN
1 2 3 4 5 6 7
Digital controller for heating and cooling Three-way mixing valve Three-point actuator Three-speed circulation pump UPS 25-60 Three-speed circulation pump UPS 25-80 Flow temperature probe Return temperature probe Adjustable drain cock
8 9 10 11 12 13 14
Safety thermostat Flow and return temperature gauges with pocket Pressure gauge Primary circuit shut-off valves Primary circuit differential by-pass kit Max. RH% control probe Max. RH% control components
Hydraulic diagram
SF
10 5 9 7 13
Digital controller
RT
T C
Transformer/Convertor Adjustable drain cock Temperature gauge Temperature probe
14
T C
ST
9 4 6 3
RT
Humidity % probe Room thermostat Safety thermostat Ball shut-off valve Motorised three-way valve Pressure gauge
SR
2
ST
12 11 11
Pump
BF
BR
Operating principle The medium temperature is regulated by a three-way mixing valve with a sector obturator comprehensive of an actuator managed by a specific digital controller. The controller receives the signal from two probes, flow probe on the mixing valve outlet and probe from the panel circuit return, and it controls the movement of the valve. The flow in the valve is regulated by a shaped obturator (1) that, by turning, closes or opens the hot water flow port (2) and the water returning port from the circuit (3) to adjust the desired flow temperature. Even if the secondary circuit thermal load or the inlet temperature from the boiler change, the mixing valve automatically adjusts the flow rates until it obtains the optimal flow temperature.
SECONDARY FLOW
3
SECONDARY RETURN
2
30 20 10 0
40
50 60 70
80
op
open
se
clo
se
en
clo
Differential valve The differential valve is used to control the head in the primary distribution circuit. It aids the flow circulation towards the heating or cooling elements and limits overpressure if there are thermostatic or thermo-electric valves. The differential valve has a fixed setting that cannot be changed. It is preset to 10 kPa, mean value for the loss of head in the primary circuit.
p (mm w.g.)
2000
1800 1600 1400 1200
p (kPa)
18 16 14 12
20
1000
900 800 700 600
9 8 7 6
10

10 20 2 5
Kit di by-pass circuito primario The by-pass kit permits hydraulic separation between the primary and secondary circuits. This hydraulic separation optimizes the operation of the secondary circuit at the panels thus preventing the influence on the secondary circuit by any primary circuit flow rate variation. In this case, the flow rate through the respective circuits depends solely on the pump flow rate characteristics, preventing reciprocal influence due to their coupling in series. Two possible conditions of hydraulic balance are described here. The component is typically sized in order to have the following working rate: G primary = G
secondary
Secondary
Gs
Secondary
Gs
Gp Primary
Gp Primary
0,2
0,5
0,1
500
The front panel identifies the following functions: 1) Three-digit LCD indicating: the measured or calculated temperature and the settings of the delays programmed in the system. Temperature range displayed: 099C with resolution 0,1C. TM modification stops when TR reaches TRset. 2) Regulator On/Off function selector. 3) Mixing on opening: LED on. Curve correction graph with return probe 4) Mixing on closing: LED on. 5) Selector for setting the flow temperature. Temperature range 778C Factory configuration: - heating: max 50C - cooling: min 14C 6) Return probe selector. Probe off: OFF Probe on: ON Factory configuration: ON 7) Pump working (ON): LED on steady. 8) T.S. LED safety temperature. Continuously ON when the limit signalled by the safety thermostat or by the safety humidostat is reached. Continuously ON even if the flow/return probe malfunction (see flow/return sensor paragraph). 9) Heating/cooling function switch 10) Trimmer for maximum pulse duration on the valve. Adjustable 0,26 s. Factory configuration: 2,5 s. Pulse value calculation: Tpulse (s) =
20 50% 100% 150%
The return probe is not active in the cooling function.
TM;TR (C)
50
45
TM
Ca
la lcu
te
40
TM Set
Ca lcu lat ed
35
TM
TR Set
30
25
Display The three-digit LCD displays the following parameters: - flow temperature set with selector 5). After 5 s the measured flow temperature appears. - measured flow temperature, with return sensor off. - calculated flow temperature, with return sensor on. - maximum duration of pulse on the valve, selectable via trimmer 10). Displayed for 5 s. - return temperature acquisition delay time, selectable via trimmer 11). Displayed for 5 s. - valve-motor mechanical delay recovery, selectable via trimmer 12). Displayed for 5 s
Example:
TM
Flow temperature
Back panel
M 230 V~ 5060 Hz ~ 5(2) A / 250 V~
CALEFFI
Flow temperature limit for heating and cooling The regulator enables selecting the maximum flow temperature for heating and the minimum flow temperature for cooling. For this purpose, the regulator base contains specific dipswitches that enable setting different temperature limits.
230 V~ IN OUT
- heating max. 50C - cooling: min. 14C.
13 14 15
16 17 18
Dipswitch position-temperature limit table Setting Limit Limit Dipswitch maximum minimum 0 0 0 50 14 0 0 1 54 13 0 1 0 58 12 0 1 1 62 11 1 0 0 66 10 1 0 1 70 9 1 1 0 74 8 1 1 1 78 7
1 2 3
4 5 6
7 8 9
10 11 12
ON
On the back panel there are terminals for the electrical connections of the various components. Electric supply 1 Electric supply 230 V~ Live 2 Electric supply 230 V~ Neutral 3 Ground/Earth Pump command 4 Ground/Earth 5 Pump command 230 V~ Live 6 Pump command 230 V~ Neutral Mixer command 7 Valve command for opening 8 Common C 9 Valve command for closing Auxiliary microswitch 10 Auxiliary output N/O 11 Auxiliary output common C 12 Auxiliary output N/C Flow/return probe 13 Flow temperature probe 14 Common C 15 Return temperature probe Ambient thermostat/safety thermostat 16 Contact for ambient thermostat 17 Contact for common C ambient thermostat / Contact for common C safety thermostat and humidity probe convertor 18 Contact for safety thermostat and humidity probe convertor. Heating safety thermostat If the safety thermostat trips, on detecting a higher flow temperature than the setting, the following state comes into operation: pump OFF, mixing valve closed. The thermostat contact is N/C; if the connection fails, the regulator is not on. Auxiliary microswitch The regulator is equipped with an auxiliary microswitch that can be used to control other devices. Example: When Heating, to turn the water heater on/off. N/O contact - Pump stationary - ambient thermostat OFF or safety thermostat on (water heater off). N/C contact - Pump on - ambient thermostat ON (water heater on). When Cooling, to turn the refrigerating unit on/off. N/O contact - Pump stationary - ambient thermostat OFF or RH% limit probe on (refrigerating unit off). N/C contact - Pump on - ambient thermostat ON (refrigerating unit on). Contact capacity: 5 A (230 V). Flow/return probe The flow/return temperature probes are the NTC type. If the probes detect an ohmic resistance corresponding to short circuiting, the following operating state comes into operation: pump OFF, mixing valve closed, LED 8) on steady. Sensor resistance values table
C -20 -15 -10 -5 0 5 97.060 72.940 55.319 42.324 32.654 25.396 C 10 15 20 25 30 35 19.903 15.714 12.493 10.000 8.056 6.530 C 40 45 50 55 60 65 5.327 4.370 3.603 2.986 2.488 2.083 C 70 75 80 85 90 95 1.752 1.480 1.255 1.070 915 787 C 100 105 110 115 120 125 680 592 517 450 390 340
1 2 3
Maximum temperature limit for cooling When cooling, the flow temperature can be selected no higher than 25C. Relative humidity control When using the cooling regulator, it is necessary to use the specific relative humidity probe. This probe has the task of measuring the limit of relative humidity so as to prevent condensation in the cooling slab. It is set for RH=80 85%. On reaching the setting, it triggers the following operating state: pump ON, mixer closed. Humidity probe control At the start of each cooling season, the operating state of the probe must be checked by placing a moist wad of cotton wool on its surface; this will cause the mixer to close and the red LED point 8 on the panel front to light up. Positioning the humidity probe Depending on the system characteristics, the humidity probe is located where there is the greatest risk of condensation. It is placed with the carbon portion upwards, as shown in the following diagrams.
Top side: carbon
Bottom side: housed on the cooling surface
Steps for correctly positioning the max RH% limit probe. The probe is secured to the manifold installed in the zone where you want to check that the relative humidity RH% cannot exceed the safety values. It is secured by means of the two clamps, using the specific holes. By controlling the following parameters it is possible to reach the maximum heating power delivered by the panel. - Minimum flow temperature, selectable via selector (5) on front panel. - Relative humidity RH% limit point, checked with relative humidity probe. - Ambient temperature, checked via ambient thermostat - Temperature and relative humidity of the ambient air, checked via fan coil or dehumidifier. Caution: The RH% limit probe is used to prevent any condensation from forming. In rooms where there is cooling, there must always be suitable air treatment.
Humidity probe connection

Safety thermostat
CALEFFI CALEFFI
150052
Transformer
V DE
150051
Converter
AC 50Hz 230V AC 24V 50Hz AC 230V 6(2)A T50
ST
4 5 6
The humidity probe is connected to the regulator by installing the transformer and convertor in between. If you want to monitor various zones at risk of condensation, the humidity probe must be connected to a suitable interface kit (transformer, convertor and humidity probe). Up to 12 convertors plus probes can be connected to a single transformer.
24V
24V~ 1 2 3
LN
~ ~
230 V Room thermostat
Accessories
RT
13 14 15 16 17 18
738
Chrono-thermostat for ambient, battery operated. With self-learning program. Weekly programmable clock. With phone programmer. 3 temperature levels + anti-freeze. 30-minute minimum programme.
Code
13 14 15 16 17 18 1 2 3 4 5 6
L N
IN OUT 230 V~
7 8 9 10 11 12 SA SR TA TS
Open Close
738107
124 x 90 x 21 mm
Application diagram
Pump Variable speed pump Three-way valve Thermostatic valve Lockshield Shut-off valve Clock
TH Thermostat/Humidostat
S/W
1 2 3 4 5 6
t1 t2 t
ON OFF
C C - t1 - t2 - t3
t1/t2/t3
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
TH
co
nf o rme
P ES no r me I S
Code 1715.. Modulating temperature regulating unit for heating and cooling. Connections to the primary circuit 3/4 M. Connections to the regulating unit 1 F with nut. Panel circuit outlet connections 3/4 M - 18 mm. Medium: water and glycol solutions; Maximum percentage of glycol 30%. Control temperature range 778C. Temperature range at primary circuit inlet 5100C. Maximum working pressure 10 bar. Panel manifolds differential by-pass setting 25 kPa. Primary circuit differential by-pass setting 10 kPa. Temperature gauge scale 080C. Pressure gauge scale 010 bar. Complete with: flow manifold for panel system with 5 outlets (from 5 to 12) with brass body, flow rate regulating valve with flow meter with a scale of 15 l/min; return manifold for panel system with 5 outlets (from 5 to 12) with brass body, shut-off valve. Regulating unit with motorised three-way valve, three-point actuator, electric supply 230 V - 50 Hz, protection class IP 44. Digital controller, electric supply 230 V - 50 Hz, comprehensive of probes measuring temperature of flow, return and relative humidity. Flow adapter unit with brass body. By-pass kit with brass body, POM differential by-pass valve and stainless steel spring. Shut-off valves with brass body and chrome plated brass ball. Safety thermostat: factory setting 55C 3C, protection class IP 55, contact rating 10 A / 240 V. Three-speed circulation pump UPS 25-60 (and UPS 25-80), protection class IP 44. Pre-formed PE-X shell insulation for primary circuit. Supplied preassembled in a painted plate box with lock, depth adjustable from 110 to 150 mm, including floor supports adjustable in height from 270 to 410 mm.
CALEFFI
Modulating temperature regulating unit with distribution kit for primary circuit
171 series
IS
CALEFFI
TERE
UNI EN ISO 9001:2000 Cert. n 0003
01153/07 GB
Function The temperature regulating unit with the distribution kit for the primary circuit is made to be used in mixed systems: radiant panels and radiators or fan coils, in combination with distribution manifolds for radiant panels. The modulating temperature regulating unit, comprehensive of digital temperature regulator, controls the temperature of the medium sent to the panels according to the actual thermal load. In this particular series, the temperature is regulated by a dedicated hydraulic unit equipped with a specific motorised three-way valve. The function of the kit is to distribute a portion of the medium flowing from the primary boiler circuit to the heating elements. It is supplied with manifolds with built-in shut-off and balacing valves and a differential by-pass kit for the primary circuit. This accessory is essential when there is a primary circuit circulation pump and the radiator circuits or fan coils are controlled by thermostatic or thermo-electric valves. Patent application No. MI2006A 001935. Reference Documentation - Tech. brochure 01144 Pre-assembled distribution manifolds for radiant panel systems 668...S1 series
Product range Code 1715.1 003 Code 1715.3 003 Modulating regulating unit with distribution kit for primary circuit, with UPS 25-60 pump Modulating regulating unit with distribution kit for primary circuit, with UPS 25-80 pump
Performance Medium: Max. percentage of glycol: Control temperature range: Primary inlet temperature range: Max. working pressure: Panel manifolds differential by-pass setting: Primary circuit differential by-pass setting: Primary circuit manifold inside diameter: Temperature gauge scale: Pressure gauge scale: Connections: primary circuit: to regulating unit: panel circuit outlets: outlet centre distance: water, glycol solutions 30% 2078C 5100C 10 bar 25 kPa (2.500 mm w.g.) 10 kPa (1.000 mm w.g.) 27 mm 080C 010 bar 3/4 M 1 F with nut 3/4 M - 18 mm 50 mm
RE
Primary circuit distribution manifolds Flow manifold Body: Flow rate regulating valve Obturator: Hydraulic seals: Return manifold Body: Shut-off valve Stem: Obturator and seals: Springs: Control knob: brass EN 1982 CB753S brass EN 12164 CW614N EPDM brass EN 1982 CB753S stainless steel EPDM stainless steel ABS p (mm w.g.)
5000
4500 4000 3500 3000 2500
- primary circuit manifold outlets: 3/4 M - 18 mm - outlet centre distance: 50 mm Panel circuit differential by-pass graph p (kPa)
50
45 40 35 30 25
0,2
0,1
0,5
10
20
2000
20

H (m w.g.)
6
(kPa)
60
H (m w.g.)
8 7 6
(kPa)
80
UPS 25-60
5 4 3 2 1 0 50 40
UPS 25-80
70 60
5 4 3 2
3 2 1
2 1
50 40 30 20 10
30 20 10 0
1 0 0 0,5 1 1,5 2 2,5 3 3,5 4
0,5
1,5
2,5
G (m3/h)
G (m3/h)
Power consumption
Speed I
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (rpm) 1800 1100 700
Speed
(A) 1,04 0,92 0,63
P (W) 245 210 140
n (rpm) 2450 1500 700
3 2 1
3 2 1
Dimensions
1000 5 outlets 8 outlets 12 outlets 1200
110150
800
3 2 1 0
co n fo r
1 2
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
bar
4 5 6
2.5 CL
3 4
L/MIN
m e n or m e ISP E
SL
30 20 10 0
40
50 60 70
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
80
700
CALEFF
SOGGIORNO
CALEFFI
CALEFF
CAMERA
CALEFFI
CALEFF
CAMERA
CALEFFI
3/4
30 20 10 0
40
50 60 70
80
270410
129 105
415 A
50 A A
code
1
3 2
bar
10
4 5 0
c on

1 2 3 4
L/MIN
8 4 6 2 3 11
BOILER RETURN
1 6
f or m
e n o r m e I SP
CL 2.5
ES L
30 20 10 0
40
50 60 70
80
SYSTEM FLOW
5
CALEFFI
1 2 3 4
L/MIN
1 2 3 4
L/MIN
CAMERA
SOGGIORNO
WC
CALEFFI
9 7
30 20 10 0 C 40 50 60 70 80
SYSTEM RETURN
CALEFFI
CAMERA
SOGGIORNO
WC
CALEFFI
9 12 13
BOILER FLOW
1 2 3 4
Digital controller for heating Three-way mixing valve Three-point actuator Three-speed circulation pump UPS 25-60 Three-speed circulation pump UPS 25-80 5 Flow temperature probe 6 Return temperature probe
7 8 9 10 11 12 13
Adjustable drain cock Safety thermostat Flow and return temperature gauges with pocket Pressure gauge Primary circuit shut-off valves Distribution manifolds with built-in valves for primary circuit Primary circuit differential by-pass kit
Hydraulic diagram
Digital controller
SF
10 5 9 7 8
Adjustable drain cock Temperature gauge Temperature probe
RT
ST
9 4 6
RT ST
11
12
SR
2
BF
12 13
11
BR
Operating principle The medium temperature is regulated by a three-way mixing valve with a sector obturator comprehensive of an actuator managed by a specific digital controller. The controller receives the signal from two probes, flow probe on the mixing valve outlet and probe from the panel circuit return, and it controls the movement of the valve. The flow in the valve is regulated by a shaped obturator (1) that, by turning, closes or opens the hot water flow ports (2) and the water returning ports from the circuit (3) to adjust the desired flow temperature. Even if the secondary circuit thermal load or the inlet temperature from the boiler change, the mixing valve automatically adjusts the flow rates until it obtains the optimal flow temperature.
SECONDARY FLOW
3
SECONDARY RETURN
2
30 20 10 0
40
50 60 70
80
op
open
se
clo
se
en
clo
Distribution and differential by-pass kit for primary circuit Operation The distribution and differential by-pass kit for the primary circuit enables controlling the flow supplied to the heating elements connected before the outlet to the panel circuit regulating unit. It is composed of distribution manifolds with built-in regulating and shut-off valves, and the differential by-pass kit for the primary circuit.
Primary circuit distribution manifolds The distribution manifolds are equipped with: - flow rate regulating valves built into the flow manifold. In this way it is possible to set the right flow rate and balance the various connected circuits. - shut-off valves built into the return manifold. The same circuits can be automatically shut off by using the thermo-electric controls. p (mm w.g.)
500 450
400 350 300 250 180 160 140 120 80 70 60 45 40 35 30 25 16 14 12 800 700 600
Hydraulic characteristics of flow rate regulating valve Adjustment position 2 turns 3 turns 4 turns 5 turns F.O. Kv (m3/h) Kv0,01 (l/h) 0,22 1,30 3,20 4,70 5,40 22 130 320 470 540 5 mm
1000 900
p (kPa)
9 8 7 6
10 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
2 1 0,5
10090 50
0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12
Differential valve The differential valve is used to control the head in the primary distribution circuit. It aids the flow circulation towards the heating elements and limits overpressure if there are thermostatic or thermoelectric valves. The differential valve has a fixed setting that cannot be changed. It is preset to 10 kPa, mean value for the loss of head in the primary circuit. p (mm w.g.)
2000
1800 1600 1400 1200
2018 10 0,2 0,1 0,5 1
0,2 0,1
p (kPa)
18 16 14 12
20
10
20
1000
900 800 700 600
9 8 7 6
10
Primary circuit by-pass kit The by-pass kit permits hydraulic separation between the primary and secondary circuits. This hydraulic separation optimizes the operation of the secondary circuit at the panels thus preventing the influence on the secondary circuit by any primary circuit flow rate variation. In this case, the flow rate through the respective circuits depends solely on the pump flow rate characteristics, preventing reciprocal influence due to their coupling in series. Two possible conditions of hydraulic balance are described here. The component is typically sized in order to have the following working rate: G primary = G secondary (inlet to the mixing valve) + G heating elements G primary maximum recommended: 1,5 m3/h
Secondary
Gs
Secondary
Gs
Gp
Gp
Primary
Primary
0,5
0,2
Flow rate regulating valve fully open Shut-off valve
Kv 5,40 4,10
Kv0,01 540 410
0,1
10
20
500
The front panel identifies the following functions: 1) Three-digit LCD indicating: the measured or calculated temperature and the settings of the delays programmed in the system. Temperature range displayed: 099C with resolution 0,1C. TM modification stops when TR reaches TRset. 2) Regulator On/Off function selector. 3) Mixing on opening: LED on. Curve correction graph with return probe 4) Mixing on closing: LED on. 5) Selector for setting the flow temperature. Temperature range 778C Factory configuration: - heating: max 50C TM;TR (C)
50 Flow temperature limit
6) Return probe selector. Probe off: OFF Probe on: ON Factory configuration: ON 7) Pump working (ON): LED on steady. 8) T.S. LED safety temperature. Continuously ON when the limit signalled by the safety thermostat is reached. Continuously ON even if the flow/return probe malfunction (see flow/return probe paragraph). 9) Heating/cooling function switch, only with RH% control components
45
TM
Ca
la lcu
te
40
TM Set
Ca lcu lat ed
35
TM
TR Set
30
25
20
10) Trimmer for maximum pulse duration on the valve. Adjustable 0,26 s. Factory configuration: 2,5 s. Pulse value calculation: Display Tpulse (s) =
50%
100%
150%
The three-digit LCD displays the following parameters: - flow temperature set with selector 5). After 5 s the measured flow temperature appears. - measured flow temperature, with return sensor off. - calculated flow temperature, with return sensor on. - maximum duration of pulse on the valve, selectable via trimmer 10). Displayed for 5 s. - return temperature acquisition delay time, selectable via trimmer 11). Displayed for 5 s. - valve-motor mechanical delay recovery, selectable via trimmer 12). Displayed for 5 s
Example:
TM
Flow temperature
Back panel
M 230 V~ 5060 Hz ~ 5(2) A / 250 V~
CALEFFI
Heating safety thermostat If the safety thermostat trips, on detecting a higher flow temperature than the setting, the following state comes into operation: pump OFF, mixing valve closed. The thermostat contact is N/C; if the connection fails, the regulator is not on. Auxiliary microswitch The regulator is equipped with an auxiliary microswitch that can be used to control other devices.
230 V~ IN OUT
13 14 15
16 17 18
1 2 3
4 5 6
7 8 9
10 11 12
Example: When Heating, to turn the water heater on/off. N/O contact - Pump stationary - ambient thermostat OFF or safety thermostat on (water heater off). N/C contact - Pump on - ambient thermostat ON (water heater on). Contact capacity: 5 A (230 V). Flow/return probe The flow/return temperature probes are the NTC type. If the probes detect an ohmic resistance corresponding to short circuiting, the following operating state comes into operation: pump OFF, mixing valve closed, LED 8) on steady. Sensor resistance values table
C -20 -15 -10 -5 0 5 97.060 72.940 55.319 42.324 32.654 25.396 C 10 15 20 25 30 35 19.903 15.714 12.493 10.000 8.056 6.530 C 40 45 50 55 60 65 5.327 4.370 3.603 2.986 2.488 2.083 C 70 75 80 85 90 95 1.752 1.480 1.255 1.070 915 787 C 100 105 110 115 120 125 680 592 517 450 390 340
On the back panel there are terminals for the electrical connections of the various components. Electric supply 1 Electric supply 230 V~ Live 2 Electric supply 230 V~ Neutral 3 Ground/Earth Pump command 4 Ground/Earth 5 Pump command 230 V~ Live 6 Pump command 230 V~ Neutral Mixer command 7 Valve command for opening 8 Common C 9 Valve command for closing Auxiliary microswitch 10 Auxiliary output N/O 11 Auxiliary output common C 12 Auxiliary output N/C Flow/return probe 13 Flow temperature probe 14 Common C 15 Return temperature probe Ambient thermostat/safety thermostat 16 Contact for ambient thermostat 17 Contact for common C ambient thermostat / Contact for common C safety thermostat 18 Contact for safety thermostat.
Flow temperature limit for heating The regulator enables selecting the maximum flow temperature for heating. For this purpose, the regulator base contains specific dipswitches that enable setting different temperature limits.
- heating max 50C.
Dipswitch position-temperature limit table Setting Limit Dipswitch maximum 0 0 0 50 0 0 1 54 0 1 0 58 0 1 1 62 1 0 0 66 1 0 1 70 1 1 0 74 1 1 1 78
ON
1 2 3
Accessories
738
Chrono-thermostat for ambient, battery operated. With self-learning program. Weekly programmable clock. With phone programmer. 3 temperature levels + anti-freeze. 30-minute minimum programme.
Code
738107
124 x 90 x 21 mm
Application diagram
Pump Thermostatic valve Manual valve
RT
Lockshield Shut-off valve Clock
Room thermostat
1 2 3 4 5 6
t1 t2 t
ON OFF
C C - t1 - t2 - t3
t1/t2/t3
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
RT
3 2 1 0
co
1 2
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
bar
4 5 6
2.5 CL
3 4
L/MIN
nf o
rm e n or me I S PES
30 20 10 0
40
50 60 70
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
80
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
30 20 10 0
40
50 60 70
80
Code 1715.. 003 Modulating temperature regulating unit with distribution kit for primary circuit. Connections to the primary circuit 3/4 M. Connections to the regulating unit 1 F with nut. Panel circuit outlet connections 3/4 M- 18 mm. Primary circuit manifold outlet connections 3/4 M - 18 mm. Medium: water and glycol solutions; maximum percentage of glycol 30%. Control temperature range 2078C. Temperature range at primary circuit inlet 5100C. Maximum working pressure 10 bar. Panel manifolds differential by-pass setting 25 kPa. Primary circuit differential by-pass setting 10 kPa. Temperature gauge scale 080C. Pressure gauge scale 010 bar. Complete with: flow manifold for panel system with 5 outlets (from 5 to 12) with brass body, flow rate regulating valve with flow meter with a scale of 15 l/min; return manifold for panel system with 5 outlets (from 5 to 12) with brass body, shut-off valve. Regulating unit with motorised three-way valve, three-point actuator, electric supply 230 V - 50 Hz, protection class IP 40. Digital controller, electric supply 230 V - 50 Hz, comprehensive of probes measuring temperature of flow and return. Flow adapter unit with brass body. Primary circuit distribution manifolds with 3 outlets, brass body, flow rate regulating and shut-off valves. By-pass kit with brass body, POM differential by-pass valve and stainless steel spring. Shut-off valves with brass body and chrome plated brass ball. Safety thermostat: factory setting 55C 3C, protection class IP 55, contact rating 10 A / 240 V. Three-speed circulation pump UPS 25-60 (and UPS 25-80), protection class IP 44. Pre-formed PE-X shell insulation for primary circuit. Supplied preassembled in a painted plate box with lock, depth adjustable from 110 to 150 mm, including floor supports adjustable in height from 270 to 410 mm.
CALEFFI

with distribution kit for primary circuit
171 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
01154/07 GB
Function The temperature regulating unit with the distribution kit for the primary circuit is made to be used in mixed systems: radiant panels and radiators or fan coils, in combination with distribution manifolds for radiant panels. The modulating temperature regulating unit, comprehensive of digital temperature regulator, controls the temperature of the medium sent to the panels according to the actual thermal load. In this particular series, the temperature is regulated by a dedicated hydraulic unit equipped with a specific motorised three-way valve. The function of the kit is to distribute a portion of the medium flowing from the primary boiler circuit to the heating or cooling elements. It is supplied with manifolds with built-in shut-off and balacing valves and a differential by-pass kit for the primary circuit. This accessory is essential when there is a primary circuit circulation pump and the radiator circuits or fan coils are controlled by thermostatic or thermo-electric valves. Patent application No. MI2006A 001935. Reference Documentation - Tech. brochure 01144 Pre-assembled distribution manifolds for radiant panel systems 668...S1 series Product range Code 1715.2 003 Code 1715.4 003 Modulating regulating unit for heating and cooling with distribution kit for primary circuit, with UPS 25-60 pump Modulating regulating unit for heating and cooling with distribution kit for primary circuit, with UPS 25-80 pump
Performance Medium: Max. percentage of glycol: Control temperature range: Primary inlet temperature range: Max. working pressure: Panel manifolds differential by-pass setting: Primary circuit differential by-pass setting: Primary circuit manifold inside diameter: Temperature gauge scale: Pressure gauge scale: Connections: primary circuit: to regulating unit: panel circuit outlets: outlet centre distance: water, glycol solutions 30% 778C 5100C 10 bar 25 kPa (2.500 mm w.g.) 10 kPa (1.000 mm w.g.) 27 mm 080C 010 bar 3/4 M 1 F with nut 3/4 M - 18 mm 50 mm
RE
Primary circuit distribution manifolds Flow manifold Body: Flow rate regulating valve Obturator: Hydraulic seals: Return manifold Body: Shut-off valve Stem: Obturator and seals: Springs: Control knob: brass EN 1982 CB753S brass EN 12164 CW614N EPDM brass EN 1982 CB753S stainless steel EPDM stainless steel ABS p (mm w.g.)
5000
4500 4000 3500 3000 2500
50
45 40 35 30 25
0,5
0,1
0,2
10
20
2000
20

H (m w.g.)
6
(kPa)
60
H (m w.g.)
8 7 6
(kPa)
80
UPS 25-60
5 4 3 2 1 0 50 40
UPS 25-80
70 60
5 4 3 2
3 2 1
2 1
50 40 30 20 10
30 20 10 0
1 0 0 0,5 1 1,5 2 2,5 3 3,5 4
0,5
1,5
2,5
G (m3/h)
G (m3/h)
Power consumption
Speed I
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (rpm) 1800 1100 700
Speed
(A) 1,04 0,92 0,63
P (W) 245 210 140
n (rpm) 2450 1500 700
3 2 1
3 2 1
Dimensions
800
1000
5 outlets
8 outlets
12 outlets
3 2 1 0
co n fo r
1 2
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
bar
4 5 6
2.5 CL
3 4
L/MIN
m e n or m e ISP E
SL
CALEFFI
CALEFFI
30 20 10 0
40
50 60 70
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
150052
Trasformatore
V DE
150051
AC 50Hz 230V
80
Convertitore
AC 24V 50Hz AC 230V 6(2)A T50
700
CALEFF
SOGGIORNO
CALEFFI
CALEFF
CAMERA
CALEFFI
CALEFF
CAMERA
CALEFFI
3/4
30 20 10 0
40
50 60 70
80
270410
129 105
415 A
50 A A
1200
110150
1715E2 003 3 5 765
1715F2 003 3 6 815
1715G2 003 3 7 865
1715H2 003 3 8 915
1715I2 003 3 9 985
1715L2 003 1715L4 003 3 10 1035
1715M2 003 1715M4 003 3 11 1085
1715N2 003 1715N4 003 3 12 1135
code
Characteristic components Flow manifold equipped with flow meters and balacing valves
1 2 3 4
L/MIN
1 8
1 0
c on
10
3 2
bar
4 5 6
CL
5
SYSTEM FLOW
f or m
e n o r m e I SP
ES L
1 2 3 4
L/MIN
1 2 3 4
L/MIN
2.5
4 15 6 2 3
CALEFFI
CALEFFI
30 20 10 0
40
50 60 70
150052
Trasformatore
V DE
150051
AC 50Hz 230V
80
Convertitore
AC 24V 50Hz AC 230V 6(2)A T50
9 7 14
CALEFFI
CAMERA
SOGGIORNO
WC
CALEFFI
30 20 10 0
40
50 60 70
SYSTEM RETURN
CALEFFI
CAMERA
SOGGIORNO
WC
CALEFFI
80
9
BOILER FLOW
12 13
11
BOILER RETURN
1 2 3 4 5 6 7
Digital controller for heating and cooling Three-way mixing valve Three-point actuator Three-speed circulation pump UPS 25-60 Three-speed circulation pump UPS 25-80 Flow temperature probe Return temperature probe Adjustable drain cock
8 9 10 11 12 13 14 15
Safety thermostat Flow and return temperature gauges with pocket Pressure gauge Primary circuit shut-off valves Distribution manifolds with built-in valves for primary circuit Primary circuit differential by-pass kit Max. RH% control probe Max. RH% control components
Hydraulic diagram
SF
10 5 9 7 14
Digital controller
RT
T C
Transformer/Convertor Adjustable drain cock Temperature gauge Temperature probe
15
T C
ST
9 4 6
RT
Humidity % probe Room thermostat Safety thermostat Ball shut-off valve Motorised three-way valve
11
12
SR
2
ST
BF
12 13
11
Pressure gauge Pump Differential by-pass
BR
Operating principle The medium temperature is regulated by a three-way mixing valve with a sector obturator comprehensive of an actuator managed by a specific digital controller. The controller receives the signal from two probes, flow probe on the mixing valve outlet and probe from the panel circuit return, and it controls the movement of the valve. The flow in the valve is regulated by a shaped obturator (1) that, by turning, closes or opens the hot water flow ports (2) and the water returning ports from the circuit (3) to adjust the desired flow temperature. Even if the secondary circuit thermal load or the inlet temperature from the boiler change, the mixing valve automatically adjusts the flow rates until it obtains the optimal flow temperature.
SECONDARY FLOW
3
SECONDARY RETURN
2
30 20 10 0
40
50 60 70
80
op
open
se
clo
se
en
clo
Distribution and differential by-pass kit for primary circuit Operation The distribution and differential by-pass kit for the primary circuit enables controlling the flow supplied to the heating or cooling elements connected before the outlet to the panel circuit regulating unit. It is composed of distribution manifolds with built-in regulating and shut-off valves, and the differential by-pass kit for the primary circuit.
Primary circuit distribution manifolds The distribution manifolds are equipped with: - flow rate regulating valves built into the flow manifold. In this way it is possible to set the right flow rate and balance the various connected circuits. - shut-off valves built into the return manifold. The same circuits can be automatically shut off by using the thermo-electric controls. p (mm w.g.)
500 450
400 350 300 250 180 160 140 120 80 70 60 45 40 35 30 25 16 14 12 800 700 600
1000 900
p (kPa)
9 8 7 6
10 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
2 1 0,5
10090 50
0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12
Differential valve The differential valve is used to control the head in the primary distribution circuit. It aids the flow circulation towards the heating or cooling elements and limits overpressure if there are thermostatic or thermo-electric valves. The differential valve has a fixed setting that cannot be changed. It is preset to 10 kPa, mean value for the loss of head in the primary circuit. p (mm w.g.)
2000
1800 1600 1400 1200
2018 10 0,2 0,5 0,1 1
0,2 0,1
p (kPa)
18 16 14 12
20
10
20
1000
900 800 700 600
9 8 7 6
10
10
Secondary
Gs
Secondary
Gs
Gp
Gp
Primary
Primary
20
0,2
0,1
0,5
Kv 5,40 4,10
Kv0,01 540 410
500
The front panel identifies the following functions: 1) Three-digit LCD indicating: the measured or calculated temperature and the settings of the delays programmed in the system. Temperature range displayed: 099C with resolution 0,1C. TM modification stops when TR reaches TRset. 2) Regulator On/Off function selector. 3) Mixer on opening: LED on. Curve correction graph with return probe 4) Mixer on closing: LED on. 5) Selector for setting the flow temperature. Temperature range 778C Factory configuration: - heating: max 50C - cooling: min 14C 6) Return probe selector. Probe off: OFF Probe on: ON Factory configuration: ON 7) Pump working (ON): LED on steady. 8) T.S. LED safety temperature. Continuously ON when the limit signalled by the safety thermostat or by the safety humidostat is reached. Continuously ON even if the flow/return sensors malfunction (see flow/return sensor paragraph). 9) Heating/cooling function switch 10) Trimmer for maximum pulse duration on the valve. Adjustable 0,26 s. Factory configuration: 2,5 s. Pulse value calculation: Tpulse (s) =
20 50% 100% 150%
The return probe is not active in the cooling function.
TM;TR (C)
50
45
TM
Ca
la lcu
te
40
TM Set
Ca lcu lat ed
35
TM
TR Set
30
25
Display The three-digit LCD displays the following parameters: - flow temperature set with selector 5). After 5 s the measured flow temperature appears. - measured flow temperature, with return sensor off. - calculated flow temperature, with return sensor on. - maximum duration of pulse on the valve, selectable via trimmer 10). Displayed for 5 s. - return temperature acquisition delay time, selectable via trimmer 11). Displayed for 5 s. - valve-motor mechanical delay recovery, selectable via trimmer 12). Displayed for 5 s
Example:
TM Flow temperature
Back panel
M 230 V~ 5060 Hz ~ 5(2) A / 250 V~
CALEFFI
13 14 15 16 17 18 1 L 2 N 3 4 5 6 SA SR TA TS Apre Chiude 7 8 9 10 11 12
Flow temperature limit for heating and cooling The regulator enables selecting the maximum flow temperature for heating and the minimum flow temperature for cooling. For this purpose, the regulator base contains specific dipswitches that enable setting different temperature limits.
230 V~ IN OUT
- heating max 50C - cooling: min 14C.
13 14 15
16 17 18
Dipswitch position-temperature limit table Setting Limit Limit Dipswitch maximum minimum 0 0 0 50 14 0 0 1 54 13 0 1 0 58 12 0 1 1 62 11 1 0 0 66 10 1 0 1 70 9 1 1 0 74 8 1 1 1 78 7
1 2 3
4 5 6
7 8 9
10 11 12
ON
On the back panel there are terminals for the electrical connections of the various components. Electric supply 1 Electric supply 230 V~ Live 2 Electric supply 230 V~ Neutral 3 Ground/Earth Pump command 4 Ground/Earth 5 Pump command 230 V~ Live 6 Pump command 230 V~ Neutral Mixer command 7 Valve command for opening 8 Common C 9 Valve command for closing Auxiliary microswitch 10 Auxiliary output N/O 11 Auxiliary output common C 12 Auxiliary output N/C Flow/return probe 13 Flow temperature probe 14 Common C 15 Return temperature probe Ambient thermostat/safety thermostat 16 Contact for ambient thermostat 17 Contact for common C ambient thermostat / Contact for common C safety thermostat and humidity probe convertor 18 Contact for safety thermostat and humidity probe convertor. Heating safety thermostat If the safety thermostat trips, on detecting a higher flow temperature than the setting, the following state comes into operation: pump OFF, mixing valve closed. The thermostat contact is N/C; if the connection fails, the regulator is not on. Auxiliary microswitch The regulator is equipped with an auxiliary microswitch that can be used to control other devices. Example: When Heating, to turn the water heater on/off. N/O contact - Pump stationary - ambient thermostat OFF or safety thermostat on (water heater off). N/C contact - Pump on - ambient thermostat ON (water heater on). When Cooling, to turn the refrigerating unit on/off. N/O contact - Pump stationary - ambient thermostat OFF or RH% limit probe on (refrigerating unit off). N/C contact - Pump on - ambient thermostat ON (refrigerating unit on). Contact capacity: 5 A (230 V). Flow/return probe The flow/return temperature probes are the NTC type. If the probes detect an ohmic resistance corresponding to short circuiting, the following operating state comes into operation: pump OFF, mixing valve closed, LED 8) on steady.
1 2 3
Maximum temperature limit for cooling When cooling, the flow temperature can be selected no higher than 25C. Relative humidity control When using the cooling regulator, it is necessary to use the specific relative humidity probe. This probe has the task of measuring the limit of relative humidity so as to prevent condensation in the cooling slab. It is set for RH=80 85%. On reaching the setting, it triggers the following operating state: pump ON, mixer closed. Humidity probe control At the start of each cooling season, the operating state of the probe must be checked by placing a moist wad of cotton wool on its surface; this will cause the mixer to close and the red LED point 8 on the panel front to light up. Positioning the humidity probe Depending on the system characteristics, the humidity probe is located where there is the greatest risk of condensation. It is placed with the carbon portion upwards, as shown in the following diagrams.
Top side: carbon
Sensor resistance values table

C -20 -15 -10 -5 0 5 97.060 72.940 55.319 42.324 32.654 25.396 C 10 15 20 25 30 35 19.903 15.714 12.493 10.000 8.056 6.530 C 40 45 50 55 60 65 5.327 4.370 3.603 2.986 2.488 2.083 C 70 75 80 85 90 95 1.752 1.480 1.255 1.070 915 787 C 100 105 110 115 120 125 680 592 517 450 390 340
Steps for correctly positioning the max RH% limit probe. The probe is secured to the manifold installed in the zone where you want to check that the relative humidity RH% cannot exceed the safety values. It is secured by means of the two clamps, using the specific holes. By controlling the following parameters it is possible to reach the maximum heating power delivered by the panel. - Minimum flow temperature, selectable via selector (5) on front panel. - Relative humidity RH% limit point, checked with relative humidity probe. - Ambient temperature, checked via ambient thermostat - Temperature and relative humidity of the ambient air, checked via fan coil or dehumidifier. Caution: The RH% limit probe is used to prevent any condensation from forming. In rooms where there is cooling, there must always be suitable air treatment.
Humidity probe connection

Safety thermostat
CALEFFI CALEFFI
150052
Trasformatore
V DE
150051
AC 50Hz 230V
ST
AC 24V 50Hz AC 230V 6(2)A T50
Convertitore
The humidity probe is connected to the regulator by installing the transformer and convertor in between. If you want to monitor various zones at risk of condensation, the humidity probe must be connected to a suitable interface kit (transformer, convertor and humidity probe). Up to 12 convertors plus probes can be connected to a single transformer.
24V
24V~ 1 2 3 4 5 6
LN
~ ~
230 V Room thermostat
Accessories
RT
13 14 15 16 17 18
738
Chrono-thermostat for ambient, battery operated. With self-learning program. Weekly programmable clock. With phone programmer. 3 temperature levels + antifreeze. 30 minutes minimum program.
Code
13 14 15 16 17 18 1 2 3 4 5 6
L N
IN OUT 230 V~
7 8 9 10 11 12 SA SR TA TS
Open Close
738107
124 x 90 x 21 mm
Application diagram
Pump Three-way valve
1 2 3 4
MIN
Lockshield Shut-off valve Clock

1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
Thermostatic valve Manual valve
BBY
BAGNO
SOGGIORNO
WC
E/I
1 2 3 4 5 6
t1 t2 t
ON OFF
C C - t1 - t2 - t3
t1/t2/t3
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
TH
TA
3 2 1 0
co
1 2
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
bar
4 5 6
2.5 CL
3 4
L/MIN
nf o
rm e n or me I S PES
CALEFFI
CALEFFI
20 10
30
40
50 60 70
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
150052
Trasformatore
V DE
150051
AC 50Hz 230V
Convertitore
AC 24V 50Hz AC 230V T50 6(2)A
80
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
30 20 10 0
40
50 60 70
80
Code 1715.. 003
Modulating temperature regulating unit for heating and cooling with distribution kit for primary circuit. Connections to the primary circuit 3/4 M. Connections to the regulating unit 1 F with nut. Panel circuit outlet connections 3/4 M - 18 mm. Primary circuit manifold outlet connections 3/4 M - 18 mm. Medium: water and glycol solutions; Maximum percentage of glycol 30%. Control temperature range 778C. Maximum temperature at primary circuit inlet 100C. Maximum working pressure 10 bar. Panel manifolds differential by-pass setting 25 kPa. Primary circuit differential by-pass setting 10 kPa. Temperature gauge scale 080C. Pressure gauge scale 010 bar. Complete with: flow manifold for panel system with 5 outlets (from 5 to 12) with brass body, flow rate regulating valve with flow meter with a scale of 15 l/min; return manifold for panel system with 5 outlets (from 5 to 12) with brass body, shut-off valve. Regulating unit with motorised three-way valve, three-point actuator, electric supply 230 V - 50 Hz, protection class IP 44. Digital controller, electric supply 230 V - 50 Hz, comprehensive of probes measuring temperature of flow, return and relative humidity. Flow adapter unit with brass body. Primary circuit distribution manifolds with 3 outlets, brass body, flow rate regulating and shut-off valves. By-pass kit with brass body, POM differential by-pass valve and stainless steel spring. Shut-off valves with brass body and chrome plated brass ball. Safety thermostat: factory setting 55C 3C, protection class IP 55, contact rating 10 A / 240 V. Three-speed circulation pump UPS 25-60 (and UPS 25-80), protection class IP 44. Pre-formed PE-X shell insulation for primary circuit. Supplied preassembled in a painted plate box with lock, depth adjustable from 110 to 150 mm, including floor supports adjustable in height from 270 to 410 mm.
CALEFFI
Set point temperature regulating unit
CALEFFI
172 series
IS
TERE
UNI EN ISO 9001:2000 Cert. n 0003
01155/07 GB
Function The temperature regulating unit is made to be used in radiant panel systems, in combination with distribution manifolds. The set point regulating unit performs the function of keeping the flow temperature constant, at the set value, for the medium distributed in a low temperature system for floor radiant panels. In this particular series, the temperature is regulated by a specific hydraulic unit equipped with a thermostatic three-way valve with a built-in sensor. It is supplied with a removable differential by-pass kit for the primary circuit. This accessory is essential when there is a primary circuit circulation pump and the radiator circuits are controlled by thermostatic or thermo-electric valves. In case of connection with a Sepcoll or an hydraulic separator without primary pump, the kit can be removed and the hydraulic unit is connected directly. Patent application No. MI2006A 001935. Reference Documentation - Tech. brochure 01144 Pre-assembled distribution manifolds for radiant panel systems 668...S1 series
Product range Code 1725.1 Code 1725.3 Pre-assembled set point regulating unit with manifolds and box, with UPS 25-60 pump Pre-assembled set point regulating unit with manifolds and box, with UPS 25-80 pump
Technical specifications Materials Regulating unit with thermostatic three-way valve Body: brass EN 1982 CB753S Headwork: brass EN 12164 CW614N Obturator: PSU Seals: EPDM Flow adapter unit Body: Primary circuit by-pass kit Body: By-pass valve: Spring: Shut-off valves Body: Ball: brass EN 1982 CB753S brass EN 1982 CB753S POM stainless steel
Performance Medium: Max. percentage of glycol: Control temperature range: Accuracy: Primary inlet max. temperature: Max. working pressure: Panel manifold differential by-pass setting: Primary circuit differential by-pass setting: Temperature gauge scale: Pressure gauge scale: Connections: primary circuit: to regulating unit: panel circuit outlets: outlet centre distance: water, glycol solutions 30% 2555C 2C 90C 10 bar 25 kPa (2.500 mm w.g.) 10 kPa (1.000 mm w.g.) 080C 010 bar 3/4 M 1 F with nut 3/4 M - 18 mm 50 mm

5000
4500 4000 3500 3000 2500
0,1
0,2
0,5
10
20
2000
RE
p (kPa)
50
45 40 35 30 25
20
Safety thermostat Factory set: Protection class: Contact rating: Electrical connection diagram 55C 3C IP 55 10 A / 240 V

H (m w.g.)
6
(kPa)
60
H (m w.g.)
8 7 6
(kPa)
80
UPS 25-60
5 4 3 2 50 40
UPS 25-80
70 60
5 4 3 2
3 2 1
30 20 10 0
2 1
50 40 30 20 10
Unit pump
Room thermostat
1 0
1 0 0 0,5 1 1,5 2 2,5 3 3,5 4
User side
RT
L
0,5
1,5
2,5
G (m3/h)
G (m3/h)
Power consumption
Speed I
ST
Safety thermostat
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (rpm) 1800 1100 700
Speed
(A) 1,04 0,92 0,63
P (W) 245 210 140
n (rpm) 2450 1500 700
3 2 1
3 2 1
Pump Three-speed pump: Material: Body: Electric supply: Max. ambient humidity: Max. ambient temperature: Protection class: Pump centre distance: Pump connections: model UPS 25-60/UPS 25-80 cast iron GG 15/20 230 V - 50 Hz 95% 80C IP 44 130 mm 1 1/2 with nut
Insulation Material: Thickness: Density: - inner part: - outer part: Thermal conductivity (DIN 52612): closed cell expanded PE-X 15 mm 30 kg/m3 50 kg/m3 0C: 0,038 W/(mK) 40C: 0,045 W/(mK) >1300 0100C Class B2
Coefficient of resistance to the diffusion of water vapour (DIN 52615): Working temperature range: Reaction to fire (DIN 4102):
Dimensions
4 outlets
7 outlets
11 outlets
13 outlets
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
co
nf o rm
e n o r me IS P
ES L
BAGNO
SOGGIORNO
WC
CALEFFI
BAGNO
SOGGIORNO
WC
CALEFFI
BAGNO
SOGGIORNO
WC
CALEFFI
BAGNO
SOGGIORNO
WC
CALEFFI
BAGNO
SOGGIORNO
WC
CALEFFI
BAGNO
SOGGIORNO
WC
CALEFFI
code
Panel outlets A
9 3 4
c on
for m
ES L e no r m e I S P
6
SYSTEM FLOW

1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
5
CALEFFI
CAMERA
SOGGIORNO
WC
CALEFFI
2 1
SYSTEM RETURN
5
CALEFFI
CAMERA
SOGGIORNO
WC
CALEFFI
BOILER FLOW
BOILER RETURN
1 Thermostatic three-way mixing valve with built-in sensor 2 Three-speed circulation pump UPS 25-60 Three-speed circulation pump UPS 25-80. 3 Adjustable drain cock 4 Safety thermostat 5 Flow and return temperature gauges with pocket
6 7 8 9
Pressure gauge Primary circuit shut-off valves Primary circuit differential by-pass kit Electrical wiring case
Hydraulic diagram
RT
6 9 5 3 4
SF
Manual drain cock Temperature gauge

RT
ST
ST
2 1 5
T
Thermostatic three-way valve Pressure gauge Pump Differential by-pass
SR
8 7 7
BF
BR
Operating principle The regulator element inside the thermostatic three-way valve consists of a temperature sensor (1) fully immersed in the mixed water outlet chamber. By expanding and contracting, it continuously ensures a correct proportioning of hot water, coming from the boiler, and water returning from the panel circuit. The water intake is regulated by a shaped obturator (2) that slides inside a special cylinder placed between the hot water flow (3) and the water returning from the circuit (4). Even if the thermal load of the secondary circuit or the inlet temperature from the boiler change, the mixing valve automatically adjusts the flow rates until it obtains the set temperature.
SECONDARY FLOW
4
SECONDARY RETURN
2
3
Regulating unit body The valve body, containing the temperature regulating device, is made out of a single casting with connections to the primary and secondary circuits. A specific internal channel carries the system return medium to the regulating valve, making it possible for the unit to be smaller in size and easy to connect.
Reduced head losses The three-way mixing valve is equipped with a special obturator that acts on calibrated water orifices. This ensures a high flow rate and a reduced size, while maintaining accurate temperature control.
Flow unit The flow unit is made out of a single casting with the necessary ports to connect with the functional components such as the safety thermostat, temperature gauge, pressure gauge and drain valve.
Non-sticking materials The materials used for the mixing valve construction eliminate potential sticking due to scale. All functional parts, such as the obturator, valve seats and guides, have been made using a special material with low friction coefficient, which ensures performance over time.
30 20 40 50 60 70 0 C 80
Low inertia thermostat sensor The temperature-sensitive element, the engine of the thermostatic three-way 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 as the thermal load changes.
10
Temperature adjustment and locking The control knob is used to adjust temperature in a full turn (360) between min. and max. It also has tamper protection for locking the temperature at the set value. Adjustment locking 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 carrier ring nut.
35 40
30
25
MI N
MA
p (mm w.g.)
2000
1800 1600 1400 1200
p (kPa)
18 16 14 12
20
1000
900 800 700 600
9 8 7 6
10

10 20 2 5
secondary
Secondary
Gs
Secondary
Gs
Gp Primary
Gp Primary
0,2
0,5
0,1
500
Pump Variable speed pump Three-way valve Thermostatic valve
1 2 3 4 5 6
t1 t2 t - t1 - t2 - t3
ON OFF
C C
t1/t2/t3
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
RT
Lockshield Shut-off valve
co n f
o rme
ES norm e IS P
Clock RT Room thermostat Manual valve
1 2 3 4 5 6
t1 t2 t
ON OFF
C C - t1 - t2 - t3
t1/t2/t3
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
RT
co n f
o r me
ES norm e IS P
Code 1725.1 Set point temperature regulating unit. Connections to the primary circuit 3/4 M. Connections to the regulating unit 1 F with nut. Panel circuit outlet connections 3/4 M - 18 mm. Medium: water and glycol solutions; maximum percentage of glycol 30%. Adjustment temperature range 2555C. Maximum temperature at primary circuit inlet 90C. Maximum working pressure 10 bar. Panel manifolds differential by-pass setting 25 kPa. Primary circuit differential by-pass setting 10 kPa. Temperature gauge scale 080C. Pressure gauge scale 010 bar. Complete with: flow manifold for panel system with 3 outlets (from 3 to 13) with brass body, flow rate regulating valve with flow meter with a scale of 15 l/min; return manifold for panel system with 3 outlets (from 3 to 13) with brass body, shut-off valve. Regulating unit with thermostatic three-way valve with brass body and headwork, PSU obturator and EPDM seals. Flow adapter unit with brass body. By-pass kit with brass body, POM differential by-pass valve and stainless steel spring. Shut-off valves with brass body and chrome plated brass ball. Electric supply 230 V - 50 Hz. Safety thermostat: factory setting 55C 3C, protection class IP 55, contact rating 10 A / 240 V. Three-speed circulation pump UPS 25-60 (and UPS 25-80), protection class IP 44. Pre-formed PE-X shell insulation for primary circuit. Supplied preassembled in a painted steel box with lock, depth adjustable from 110 to 150 mm, including floor supports adjustable in height from 270 to 410 mm.
CALEFFI
Set point temperature regulating unit

172 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
01156/07 GB
Function The temperature regulating unit with the distribution kit for the primary circuit is made to be used in mixed systems: radiant panels and radiators, in combination with distribution manifolds for radiant panels. The set point regulating unit performs the function of keeping the flow temperature constant, at the set value, for the medium distributed in a low temperature system for floor radiant panels. In this particular series, the temperature is regulated by a specific hydraulic unit equipped with a thermostatic three-way valve with a built-in sensor. The function of the kit is to distribute a portion of the medium flowing from the primary boiler circuit to the heating emitters. It is supplied with manifolds with built-in shut-off and balancing valves and a differential by-pass kit for the primary circuit. This accessory is essential when there is a primary circuit circulation pump and the radiator circuits are controlled by thermostatic or thermo-electric valves. Patent application No. MI2006A 001935. Reference Documentation - Tech. brochure 01144 Pre-assembled distribution manifolds for radiant panel systems 668...S1 series
Product range Code 1725.1 003 Pre-assembled set point regulating unit with manifolds and box, distribution kit for primary circuit, with UPS 25-60 pump Code 1725.3 003 Pre-assembled set point regulating unit with manifolds and box, distribution kit for primary circuit, with UPS 25-80 pump
Technical specifications Materials Regulating unit with thermostatic three-way valve Body: brass EN 1982 CB753S Headwork: brass EN 12164 CW614N Obturator: PSU Seals: EPDM Flow adapter unit Body: Primary circuit by-pass kit Body: By-pass valve: Spring: Shut-off valves Body: Ball: brass EN 1982 CB753S brass EN 1982 CB753S POM stainless steel
Performance Medium: Max. percentage of glycol: Control temperature range: Accuracy: Primary inlet max. temperature: Max. working pressure: Panel manifold differential by-pass setting: Primary circuit differential by-pass setting: Primary circuit manifold inner diameter: Temperature gauge scale: Pressure gauge scale: Connections: primary circuit: to regulating unit: panel circuit outlets: outlet centre distance: water, glycol solutions 30% 2555C 2C 90C 10 bar 25 kPa (2.500 mm w.g.) 10 kPa (1.000 mm w.g.) 27 mm 080C 010 bar 3/4 M 1 F with nut 3/4 M - 18 mm 50 mm
RE
Primary circuit distribution manifolds Flow manifold Body: brass EN 1982 CB753S Flow rate regulating valve Obturator: brass EN 12164 CW614N Hydraulic seals: EPDM Return manifold Body: Shut-off valve Stem: Obturator and seals: Springs: Control knob: brass EN 1982 CB753S stainless steel EPDM stainless steel ABS
- primary circuit manifold outlets: 3/4 M - 18 mm - outlet centre distance: 50 mm Panel circuit differential by-pass graph p (mm w.g.)
5000
4500 4000 3500 3000 2500
p (kPa)
50
45 40 35 30 25
0,5
0,1
0,2
10
20
2000
20
Safety thermostat Factory set: Protection class: Contacts rating: Electrical connections diagram 55C 3C IP 55 10 A / 240 V

H (m w.g.)
6
(kPa)
60
H (m w.g.)
8 7 6
(kPa)
80
UPS 25-60
5 4 3 2 50 40
UPS 25-80
70 60
5 4 3 2
3 2 1
30 20 10 0
2 1
50 40 30 20 10
Unit pump
Room thermostat
1 0
1 0 0 0,5 1 1,5 2 2,5 3 3,5 4
User side
RT
L
0,5
1,5
2,5
G (m3/h)
G (m3/h)
Power consumption
Speed I
ST
Safety thermostat
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (rpm) 1800 1100 700
Speed
(A) 1,04 0,92 0,63
P (W) 245 210 140
n (rpm) 2450 1500 700
3 2 1
3 2 1
Pump Three-speed pump: Material: Body: Electric supply: Max. ambient humidity: Max. ambient temperature: Protection class: Pump centre distance: Pump connections: model UPS 25-60/UPS 25-80 cast iron GG 15/20 230 V - 50 Hz 95% 80C IP 44 130 mm 1 1/2 with nut
Insulation Material: Thickness: Density: - inner part: - outer part: Thermal conductivity (DIN 52612): closed cells expanded PE-X 15 mm 30 kg/m3 50 kg/m3 0C: 0,038 W/(mK) 40C: 0,045 W/(mK) >1300 0100C Class B2
Coefficient of resistance to the diffusion of water vapour (DIN 52615): Working temperature range: Reaction to fire (DIN 4102):
Dimensions
800
1000
5 outlets.
8 outlets.
12 outlets.
3 2 1 0
co
nf o rm
e n o r me IS P
bar
4 5 6
ES L
CL 2.5
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
30 20 10 0
40
50 60 70
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
80
700
CALEFFI
SOGGIORNO
CALEFFI
CALEFF
CAMERA
SOGGIORNO
CALEFFI
3/4
MAX 7
CALEFF
CAMERA
SOGGIORNO
CALEFFI
30 20 10 0
40
50 60 70
MIN
270410
129 105
80
405 A
50 A A
1200
110150
with ups 25-60 pump 1725C1003 1725D1003 1725E1003 1725F1003 1725G1003 1725H1003 1725I1003 1725L1003 1725M1003 1725N1003 with ups 25-80 pump 1725L3003 1725M3003 1725N3003 Radiator outlets 3 3 3 3 3 3 3 3 3 3
code
Panel outlets A
3 655
4 705
5 755
6 805
7 855
8 905
9 975
10 1025
11 1075
12 1125
Characteristic components Flow manifold equipped with flow meters and balancing valves
1 2 3 4
L/MIN
3 2 1
bar
4 5
10 3 4
0
c on
6
f orm
e no r m e I SP
6
SYSTEM FLOW
E SL
CL 2.5
30 20 10 0
40
50 60 70
1 2 3 4
L/MIN
1 2 3 4
L/MIN
80
CALEFFI
CAMERA
SOGGIORNO
WC
CALEFFI
5 2
30 20 10 0
40
50 60 70
MIN
SYSTEM RETURN
MAX 7
80
5
BOILER FLOW
CALEFFI
CAMERA
SOGGIORNO
WC
CALEFFI
7
BOILER RETURN
8 9
1. Thermostatic three-way mixing valve with built-in sensor 2. Three-speed circulation pump UPS 25-60 Three-speed circulation pump UPS 25-80. 3. Adjustable drain cock 4. Safety thermostat 5. Flow and return temperature gauges with pocket
6. 7. 8. 9. 10.
Pressure gauge Primary circuit shut-off valves Primary circuit distribution manifolds with built-in valves Primary circuit differential by-pass kit Electrical wiring case
Plumbing diagram
RT
6 10 5 3
SF
Manual drain valve Temperature gauge

RT
ST
ST
2 1 5
T
Thermostatic three-way valve Pressure gauge Pump Differential by-pass
SR
BF
8 9
BR
SECONDARY FLOW
4
SECONDARY RETURN
2
3
Regulating unit body The valve body containing the temperature regulating device is made out of a single casting with connections to the primary and secondary circuits. A specific internal channel carries the system return medium to the regulating valve, making it possible for the unit to be smaller in size and easy to connect.
Flow unit The flow unit is made out of a single casting with the necessary ports to connect with the functional components such as the safety thermostat, temperature gauge, pressure gauge and drain valve.
Non-sticking materials The materials used for the mixing valve construction eliminate potential sticking due to scale. All functional parts, such as the obturator, valve seats and guides, have been made using a special material with low friction coefficient, which ensures performance over time.
30 20 40 50 60 70 0 C 80
Low-inertia thermostat sensor The temperature-sensitive element, the engine of the thermostatic three-way 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 as the thermal load changes.
10
Temperature adjustment and locking The control knob is used to adjust temperature in a full turn (360) between min. and max. It also has tamper protection for locking the temperature at the set value. Adjustment locking 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 carrier ring nut.
35 40
30
25
MI N
MA
Distribution and differential by-pass kit for primary circuit Operation The distribution and differential by-pass kit for the primary circuit enables controlling the flow to the heating elements connected before the outlet to the regulating unit for the panel circuit. It is composed of distribution manifolds with regulating and shut-off valves and the differential by-pass kit for the primary circuit.
1000 900 500 450

400 350 300 250 180 160 140 120 80 70 60 800 700 600
p (mm w.g.)
Primary circuit distribution manifolds The distribution manifolds are equipped with: - flow regulating valves built into the flow manifold. In this way it is possible to set the right flow rate and balance the various connected circuits. - shut-off valves built into the return manifold. The same circuits can be automatically shut off by using the thermo-electric actuators.
10 5
p (kPa)
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
200
2 1 0,5
10090 50
45 40 35 30 25 16 14 12
0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12
p (mm w.g.)
2000
1800 1600 1400 1200
2018 10 0,1 0,2 0,5 1
0,2 0,1
p (kPa)
18 16 14 12
20
10
20
1000
900 800 700 600
9 8 7 6
10
- 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
Secondary
Gs
Secondary
Gs
Gp
Gp
Primary
Primary
0,2
0,1
0,5
Kv 5,40 4,10
Kv0,01 540 410
10
20
500
Application diagram
Pump Thermostatic valve Manual valve Lockshield Shut-off valve Clock
RT Room thermostat
1 2 3 4 5 6
t1 t2 t
ON OFF
C C - t1 - t2 - t3
t1/t2/t3
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
RT
3 2 1 0
co n fo
1 2
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
bar
4 5 6
2.5 CL
3 4
L/MIN
SL rm e no r m e I S P E
30 20 10 0
40
50 60 70
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
80
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
MAX 7
30
40
50 60 70
MIN
20 10 0 C
80
Code 1725.. 003 Set point temperature regulating unit with distribution kit for primary circuit. Connections to the primary circuit 3/4 M. Connections to the regulating unit 1 F with nut. Panel circuit outlet connections 3/4 M - 18 mm. Primary circuit manifold outlet connections 3/4 M - 18 mm. Medium: water and glycol solutions; maximum percentage of glycol 30%. Adjustment temperature range 2555C. Maximum temperature at primary circuit inlet 90C. Maximum working pressure 10 bar. Panel manifolds differential by-pass setting 25 kPa. Primary circuit differential by-pass setting 10 kPa. Temperature gauge scale 080C. Pressure gauge scale 010 bar. Complete with: flow manifold for panel system with 3 outlets (from 3 to 12) with brass body, flow rate regulating valve with flow meter with a scale of 15 l/min; return manifold for panel system with 3 outlets (from 3 to 12) with brass body, shut-off valve. Regulating unit with thermostatic three-way valve with brass body and headwork, PSU obturator and EPDM seals. Flow adapter unit with brass body. Primary circuit distribution manifolds with 3 outlets, brass body, flow rate regulating and shut-off valves. By-pass kit with brass body, POM differential by-pass valve and stainless steel spring. Shut-off valves with brass body and chrome plated brass ball. Electric supply 230 V - 50 Hz. Safety thermostat: factory setting 55C 3C, protection class IP 55, contacts rating 10 A / 240 V. Three-speed circulation pump UPS 25-60 (and UPS 25-80), protection class IP 44. Pre-formed PE-X shell insulation for primary circuit. Supplied preassembled in a painted steel box with lock, depth adjustable from 110 to 150 mm, including floor supports adjustable in height from 270 to 410 mm.
CALEFFI
Outside compensated temperature regulating unit

174 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
01157/08 GB
Function The temperature regulating unit is made to be used in radiant panel systems in combination with distribution manifolds. The outside compensated temperature regulating unit, complete with temperature digital regulator, controls the temperature of the medium sent to the panels, with a compensation depending on the outside and inside temperature and the actual thermal load. In this particular series, the temperature is regulated by a dedicated hydraulic unit equipped with a specific motorised three-way valve. It is supplied with a removable differential by-pass kit for the primary circuit. This accessory is essential when there is a primary circuit circulation pump and the radiator circuits or fan coils are controlled by thermostatic or thermo-electric valves. In case of connection with a Sepcoll or an hydraulic separator without primary pump, the kit can be removed and the hydraulic unit is connected directly. Patent application No. MI2006A001935. Reference Documentation - Tech. brochure 01144 Pre-assembled distribution manifolds for radiant panel systems 668...S1 series
Product range Code 1745.1 Outside compensated temperature regulating unit, with UPS 25-60 pump Code 1745.3 Outside compensated temperature regulating unit, with UPS 25-80 pump
Performance Medium: Max. percentage of glycol: Control temperature range: Primary inlet temperature range: Max. working pressure: Panel manifold differential by-pass setting: Primary circuit differential by-pass setting: Temperature gauge scale: Pressure gauge scale: Connections: primary circuit: to regulating unit: panel circuit outlets: outlet centre distance: water, glycol solutions 30% 2090C 5100C 10 bar 25 kPa (2.500 mm w.g.) 10 kPa (1.000 mm w.g.) 080C 010 bar 3/4 M 1 F with nut 3/4 M - 18 mm 50 mm
brass EN 12165 CW617N brass EN 12164 CW614N, chrome plated Panel circuit differential by-pass graph p (mm w.g.)
5000
4500 4000 3500 3000 2500
0,1
0,2
0,5
10
20
2000
RE
p (kPa)
50
45 40 35 30 25
20
Digital controller Three-point type Electric supply: Power consumption: Protection class: Actuator Three-point type Electric supply: Operating time: Power consumption: Auxiliary microswitch contact rating: Protection class: Max. ambient temperature: Protective cover: Flow/return temperature probes NTC type Working range: Two-wire cable Safety thermostat Factory set: Protection class: Contact rating: Pump Three-speed pump: Material: Body: Electric supply: Max. ambient humidity: Max. ambient temperature: Protection class: Pump centre distance: Pump connections: model UPS 25-60/UPS 25-80 cast iron GG 15/20 230 V - 50 Hz 95% 80C IP 44 130 mm 1 1/2 with nut 55C 3C IP 55 10 A / 240 V -20100C 230 V - 50 Hz 50 s (rotation 120) 8 VA 0,8 A IP 44 55C self-extinguishing VO 230 V - 50 Hz 5,5 VA IP 40

H (m w.g.)
6
(kPa)
60
H (m w.g.)
8 7 6
(kPa)
80
UPS 25-60
5 4 3 2 1 0 50 40
UPS 25-80
70 60
5 4 3 2
3 2 1
2 1
50 40 30 20 10
30 20 10 0
1 0 0 0,5 1 1,5 2 2,5 3 3,5 4
0,5
1,5
2,5
G (m3/h)
G (m3/h)
Power consumption
Speed I
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (rpm) 1800 1100 700
Speed
(A) 1,04 0,92 0,63
P (W) 245 210 140
n (rpm) 2450 1500 1000
3 2 1
3 2 1
Insulation Material: Thickness: Density: - inner part: - outer part: Thermal conductivity (DIN 52612): Coefficient of resistance to the diffusion of water vapour (DIN 52615): Working temperature range: Reaction to fire (DIN 4102): closed cell expanded PE-X 15 mm 30 kg/m3 50 kg/m3 0C: 0,038 W/(mK) 40C: 0,045 W/(mK) >1300 0100C class B2
Dimensions
1000
Optimiser
5 Outlets
9 Outlets
13 Outlets
Optimiser
Optimiser
CALEFFI
3 2 1 0
co n fo r
1 2
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
bar
4 5 6
2.5 CL
3 4
L/MIN
m e n or m e ISP E
SL
30 20 10 0
40
50 60 70
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
80
700
CALEFF
SOGGIORNO
CALEFFI
CALEFF
CAMERA
CALEFFI
CALEFF
CAMERA
CALEFFI
30 20 10 0
40
50 60 70
80
270410
115
3/4
60 345 A 50 A A 110150
with pump ups 25-60 with pump ups 25-80
code
4 4
4 4
4 4
1200
800
4 4
Panel outlets A
1 10 4 6 15 2
CALEFFI
Optimiser
11
Optimiser
Flow manifold equipped with flow meters and balancing valves.

1 2 3 4
L/MIN
3 2 1 0
c on
f or m
bar
4 5 6
CL
5
SYSTEM FLOW
1 2 3 4
L/MIN
1 2 3 4
L/MIN
e n o r m e I SP
ES L
2.5
30 20 10 0
40
50 60 70
80
8 9
CALEFFI
CAMERA
SOGGIORNO
WC
CALEFFI
30 20 10 0
40
50 60 70
SYSTEM RETURN
CALEFFI
80
CAMERA
SOGGIORNO
WC
CALEFFI
3 14
Optimiser
12
+
13
1 2 3 4 5 6 7 8
Digital temperature controller Optimiser Three-way mixing valve Three-point actuator Three-speed circulation pump UPS 25-60 Three-speed circulation pump UPS 25-80 Flow temperature probe Return temperature probe Outside temperature probe Flow and return temperature gauges with pocket
9 10 11 12 13 14 15
Adjustable drain cock Safety thermostat Pressure gauge Primary circuit shut-off valves Primary circuit differential by-pass kit Remote control and room probe thermostat Interface wire connection
Hydraulic diagram
14
15
SF
11 5 8 9 10
Digital controller Optimiser Adjustable drain cock Temperature gauge Temperature probe
RPT
RPT
ST
8 4
Room probe thermostat Safety thermostat Ball shut-off valve
ST
7 3 2
SR
Motorised three-way valve Pressure gauge Pump Differential by-pass
13 12 12
Interface wire connection Outside temperature probe
BF
BR
Operating principle The medium temperature is regulated by a three-way mixing valve with a sector obturator comprehensive of an actuator managed by a specific digital controller. The controller receives the signal from four probes, flow probe on the mixing valve outlet, probe on the panel circuit return, outside probe and room probe. It controls the valve movement. The flow in the valve is regulated by a shaped obturator (1) that, by turning, closes or opens the hot water flow ports (2) and the water returning ports from the circuit (3) to adjust the desired flow temperature. Even if the secondary circuit thermal load or the inlet temperature from the boiler change, the mixing valve automatically adjusts the flow rates until it obtains the optimal flow temperature.
SECONDARY FLOW
3
SECONDARY RETURN
2
Construction details Regulating unit body The valve body, containing the thermal regulating device, is made out of a single casting with connections to the primary and secondary circuits. A specific internal channel carries the system return medium to the regulating valve, making it possible for the unit to be smaller in size and easy to connect. Reduced head losses The three-way mixing valve is equipped with a special obturator acting on calibrated water orifices. This ensures a high flow rate and a reduced size, while maintaining accurate temperature control, with no swinging due to sudden changes in thermal load.
clo
se
Manual opening By removing the actuator, the valve can be opened-closed manually by using a screwdriver. Regulating way - primary inlet Fully closed Fully open
op
open
Electrical connections The actuator is electrically connected through an external plug-socket system with a protective rubber cap. This system does not require opening the lid to connect the cables. In this way, replacing the actuator (should this ever be necessary) is particularly easy to do. Auxiliary microswitch The actuator is equipped with an auxiliary microswitch that can be used to switch on the generator. Mixing valve fully closed: contact OFF. Start opening mixing valve: contact ON.
Flow unit The flow unit is made out of a single casting with the necessary ports to connect with the functional components such as the safety thermostat, temperature gauge, pressure gauge, drain cock and flow temperature probe.
ACTUATOR
CLOSES OPENS
M
2
COMMON
MAX 0,8 A
6
30 20 10 0 C 40 50 60 70 80
230 V
clo
se
en
p (mm w.g.)
2000
1800 1600 1400 1200
p (kPa)
18 16 14 12
20
1000
900 800 700 600
9 8 7 6
10

10 20 2 5
secondary
Secondary
Gs
Secondary
Gs
Gp Primary
Gp Primary
0,2
0,5
0,1
500
Remote control and room probe thermostat
Description of controls 1. The LED gives information on the status by means of a multicoloured diode; the statuses it indicates are as follows: - flashing green: controller initialisation - fixed green: controller operating - flashing green/red: controller operating with probe error - flashing red: controller verification loop - prolonged red: controller error 2. The mini-DIN connector, on the front of the panel, makes it possible to view all the parameters managed by the control. A Sub D 9-pole mini-DIN data transmission cable is used for the connection to a PC. The cable and specific transmission program are available as optionals.
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3. The display shows the text in a clear way, giving all the information and menu points. All the values displayed are continuously refreshed. The monitor light switches on automatically when a function is selected. If no other commands are given in 4 minutes, the monitor goes back to the standard page and the light switches off. 4. The Select knob can be turned to the right (+) or left (-) to go to the different menu, function or value editing fields. Press the knob to select any of the menu points. Room temperature management The remote control can be used to change the room temperature, either increasing it or decreasing it in relation to a standard reference value. The change ( 5 K) is shown in the lines on the display, with increments of 0,5 K in relation to the reference values: comfort 20C; set-back correction 18C. The actual room temperature is shown on the fourth line on the display. 5. Function keys: Esc Info Set Changes the display of the selected menu point and goes back to the previous menu level. The changed data are not accepted and not recorded. Displays brief information about the current menu point. The change that has been made is recorded. Interface wiring box Transmission interface
Remote control base with room probe
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CALEFFI
Installation of the control on board the controller The control front panel can also be installed on board the controller. In this case, the wiring box and the base containing the room probe are no longer needed; the controller is no longer able to manage the room probe.
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CALEFFI
Immediate comfort function This makes it possible to change the comfort without changing the controller set parameters. The second line of the display shows the standard correction value - 0 of the characteristic curve. This value can be increased to + 5 or reduced to - 5 by turning the knob to the right or to the left respectively. Each single change corresponds to a 5% shift in the characteristic curve. Example, referred to factory configuration: flow temperature-heating start-up T = 20C and flow T at outside min. temp. = 40C corresponds to a temperature range T of 20 K (100%). The adjustment of the correction is +1; this means that the temperature of the mixing valve circuit 1 is raised by 1 K (5% of T), thus the flow temperature will be 41C.
Terminal board Electrical connections L Live N Neutral La Mixing valve relay contact a1 Mixing valve opening contact a2 Mixing valve closing contact N Neutral output for mixing valve and pump b0 Pump relay contact b1 Pump contact Probe connections Terminal board X X1 Outside probe X2 Common outside and room probes X3 Room probe X4 Flow probe X5 Common flow and return probes X6 Return probe Activating the internal battery The protective tab must be removed from the battery before setting the operating data. Probe resistance table C -20 -18 -16 -14 -12 -10 -8 -6 -4 14616 13211 11958 10839 9838 8941 8132 7405 6752 C -2 0 +2 +4 +6 +8 +10 +12 +14 6164 5634 5155 4721 4329 3974 3652 3360 3094 C +16 +18 +20 +22 +24 +26 +28 +30 +32 2852 2632 2431 2247 2079 1925 1785 1657 1539 C +34 +36 +38 +40 +42 +44 +46 +48 +50 1430 1331 1239 1154 1076 1004 938 876 819 C +52 +54 +56 +58 +60 +62 +64 +66 +68 767 718 673 631 592 556 522 491 462 C +70 +72 +74 +76 +78 +80 +82 +84 +86 434 409 386 364 343 324 306 290 274 C +88 +90 +92 +94 +96 +98 +100 260 246 233 221 210 199 189
L N
La a1 a2 N
b0 b1
X1 X2 X3 X4 X5 X6 X7 X8
Room probe thermostat resistance table C 18 19 20 15720 15260 14800 C 21 22 23 14370 13940 13520
The remote control base must be positioned horizontally, following the usual installation instructions for a normal room probe thermostat. If this is not possible, the room probe thermostat function must be disabled by positioning a jumper on terminal board X, contact x2=x3. The controller automatically positions on the immediate comfort function. Controller - remote control connection
Optimiser
230V~
( (
The cables must be connected in the same order as the polarisation
Optimiser
Optimiser
CALEFFI
Space for colour matching of cables between interface and remote control
Probe connection Dedicated raceway must be used for the connection of the flow, return and outside probes, the room probe thermostat and controller. If the connection cable shares the raceway with other power cables, shielded and earthed cable must be used. Any alteration to the wiring of the controller could result in electrical disturbance. A reset must be done (i.e. switching the controller's power supply off for a few seconds) whenever work is done on the wiring. Maximum distance between remote control and controller: 100 m, with 4-pole cable of 0.5 mm2 section.
A B C D
A B C D
Commissioning - immediate start The controller is ready to start operating immediately using the factory configurations, for radiant panel systems. Max. flow T corresponding to outside min. temp.
-25
Factory setting: characteristic curve for mixing valve circuit Characteristic Set-back correction curve curve
50
50
Min. flow T heating start
Setting range
40
40
30
25 % correction
30
20
20
30
25
20
15
10
-5
-10
-15
Setting range Max outside T, end of heating Main factory configurations OT - average = not active Compensation RT = Off (0%) Structure gradient = 100 Characteristic curve =1 Mixing valve rotation time = 240 s IP correction value = 20 K max. blocking FT = 55C
Setting range Min outside T corresponding to max flow
mOT constant Optimisation Slab drying Set-back correction curve Rotation correction Neutral zone
= = = = = =
100 not active not active -25% 290 s 2K
Operating information
Meaning Meaning
Setting range
-20
Automatic T max Off Stand by Comfort Set-back correction
.
> >> #
x
Off Line choise Selected value Edited value Probe resistance above working range Probe resistance below working range Value not available
Meaning Mixing valve opens/ or scroll menu up Mixing valve stopped Mixing valve closes/ or scroll menu down Mixing valve fully open position Mixing valve fully closed position Measured value Calculated nominal value
On
Details of functions Adjustment of flow temperature in relation to the outside temperature The calculated flow temperature depends on the quantities read by the probes: outside, flow, return probe, room probe thermostat and set curve. Mixing valve and pump blocking safety system Long shutdown periods, such as in the summer, could lead to mixing valve malfunctions or pump blocking. To avoid this, the mixing valve and pump are operated automatically for 60 seconds every day. Frost protection function - double control level First level: the pump is switched on if the outside temperature is less than 4C or the room temperature less than 5C (room probe present). It is switched off when the outside temperature exceeds 6C or the room temperature exceeds 7C. Second level: if the flow or return temperature is less than 7C, the mixing valve is opened and the pump switched on. When this temperature in the circuit is over 20C, the pump switches off and the mixing valve is closed. Probe control Outside temperature probe error When the measured temperature range is less than -25C or greater than +40C, the following state automatically comes into operation: pump off, mixing valve closed and the display will show the message < OT probe malfunction > and the red LED will flash. The frost protection function, flow sensor and summer blocking safety system, however, remain enabled. Flow temperature probe error When the measured temperature range is less than 0C or greater than 110C, the following state automatically comes into operation: pump off, mixing valve closed. The display will show the message < FT probe malfunction > and the red LED will flash. Optional probe recognition If there are no optional probes (room t. and return t.), the controller will signal their absence with -X- . When the probes are connected, the system recognises them automatically. As these are corrective probes, no alarm state is signalled in the event of a malfunction. Slab drying (for floors, wall and ceiling heating systems) The new low-temperature systems have to be heated gradually, after a period of natural drying. The automatic initial heating-drying program can be used for this. This program must be activated in Standby function. The overall duration is seven days. In the first three days, the flow temperature will be maintained at 25C. In the remaining four days, the flow temperature will be at the value set at the max. blocking temperature menu point (menu structure level 4). At the end of this procedure, the slab drying function must be switched off, otherwise the controller repeats the operation automatically. If there is a break in the electricity during the drying, the program will restart automatically from the point when the break occurred. Procedure: Level 0
Select Select Select Select Set
> Configuration > Desired mixing valve circuit > Operativity > Slab drying
CAUTION: when this procedure is set, check whether the max. blocking FT needs to be adjusted; the factory set is 55C Comfort and set-back correction optimisation (manual or with self-learning) Comfort optimisation and set-back correction (manual or with self-learning) The room probe thermostat must be present for this operation. The optimisation makes it possible to bring forward the activation of the change from set-back correction to comfort (in this function the FT is set at the max. design specification), so as to reduce to a minimum the actual time necessary to reach the desired comfort level. This function can operate in three ways: = off; = active; A = self-learning.
Active: Since the time of the bringing forward depends on a number of different system parameters (power, outside and room temperatures, heat exchange, type of structure, etc.), a structure gradient reference coefficient must be set. Some reference values are given below. Structure gradient reference values - Building with low heat loss: 400 - Factory configuration: 100 - Building with very high heat loss: 50 Self-learning : In this case the bringing forward of the activation depends on the controller. The maximum suggested self-learning period is 10 days; before the end of the 10 days it is necessary to go from operating state A = self-learning to the = active operating state. The resulting structure gradient coefficient will be entered automatically at the < constant > operating state menu point. Average outside temperature This function can be enabled when necessary. If enabled, the average outside temperature, known as OT ref., is calculated automatically and recorded every hour. It is used to determine the flow temperature value. The calculation of the average OT ref. makes it possible to attenuate the effect of sudden changes of outside temperature.
Effect of return temperature If the return temperature probe is connected, the controller uses this value as an approximate parameter of the required actual thermal load. The controller calculates the difference between the design return temperature (with an influence between 0 and 50%. Factory configuration: 0%) and the actual measured value. This difference is used to change the flow temperature. For example, if the thermal load is less than the design value, there will be a final T between flow and return that is lower than the design value. In this case the characteristic curve will be lowered. If the actual thermal load is greater, then the characteristic curve will be raised. Effect of room probe thermostat If a room probe thermostat (code 151000) is connected, the actual room temperature will be read. The user can set the desired comfort room temperature on the thermostat. In the set-back correction function, this value is automatically reduced by 2 K. During the Manual forcing to Tmax function, the effect of the room probe thermostat on the controller is not active. Depending on the temperature difference between the actual measured value and the set value, the characteristic curve is moved to the right or left.
Work states
Standby In this state, the controller remains inactive, keeping the mixing valve closed and the pump off. The mixing valve and pump frost protection and anti-blocking function remains active. Comfort During the comfort function, the flow temperature is adjusted according to the measured outside temperature, following the set characteristic curve. This curve is automatically corrected if a room probe thermostat or a return probe are present. Set-back correction During the set-back correction function, the nominal flow temperature is lowered, by means of a parallel downward shifting of the characteristic curve. This shifting is settable with a parameter of between 0 and -50%. Maximum temperature This function guarantees heating to the maximum set temperature. This value, Tmax, can be set from 25C to 90C. Standard indication and change of nominal value On the display there is: day of week, date, time, curve correction, work state, room temperature or outside temperature. Example: Remote control Control on controller
Fri 23. Apr Corr. Room Comfort T- room
22:41 +0.0K +23.9C
Fri 23. Apr 22:41 Corr. comf. +0 Frost protection OT +5.3C
Operation with programming of time bands 10 programs are available, with a total of 13 configurable setting points (SP). Factory configuration: program 1 (2 setting points); program 2 (5 setting points). All programs are editable. Factory configuration program 1: Setting points identical every day SP point 1 2 Factory configuration, program 2: 5 setting points with different options each day. SP point 1 2 3 4 5 Time 05:00 07:00 09:00 22:00 23:30 Action Set-back correction Comfort Comfort Set-back correction Standby Active on Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun Time 06:00 22:00 Action Comfort Set-back correction Active on Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun
For a detailed description of the different functions, refer to the commissioning manual
Pump Variable speed pump Tree-way valve Thermostatic valve Lockshield valve Shut-off valve
Optimiser
RT
RT
Clock Room thermostat Manual valve
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CALEFFI
Outside temperature probe

c on
f or me
PE nor me I S
SL
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RT
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PE nor me I S
SL
Code 1745.. Outside compensated temperature regulating unit. Connections to primary circuit 3/4" M. Connections to regulating unit 1" F with nut. Panel circuit outlet connections 3/4" M - 18 mm. Medium: water and glycol solutions; maximum percentage of glycol 30%. Control temperature range 2090C. Primary inlet temperature range 5-100C. Maximum working pressure 10 bar. Panel manifold differential by-pass setting 25 kPa. Primary circuit differential by-pass setting 10 kPa. Temperature gauge scale 080C. Pressure gauge scale 010 bar. Complete with: flow manifold for panel system with 5 outlets (from 5 to 13) with brass body, flow rate regulating valve with flow meter with a scale of 15 l/min; return manifold for panel system with 5 outlets (from 5 to 13) with brass body, shut-off valve. Regulating unit with motorised three-way valve, three-point actuator, electric supply 230 V - 50 Hz, protection class IP 44. Digital controller, electric supply 230 V - 50 Hz, complete with probes for measuring outside, room, flow and return temperature. Management of controller and room temperature with remote control. Flow adapter unit with brass body. By-pass kit with brass body, POM differential by-pass valve and stainless steel spring. Shut-off valves with brass body and chrome plated brass ball. Safety thermostat: factory setting 55C 3C, protection class IP 55, contact rating 10 A/240 V. Three-speed circulation pump UPS 25-60 (and UPS 25-80), protection class IP 44. Pre-formed PE-X shell insulation for primary circuit. Supplied preassembled in painted steel box. Closure with a push-fit clamp. Depth adjustable from 110 to 150 mm, including floor supports adjustable in height from 270 to 410 mm.
CALEFFI
Outside compensated temperature regulating unit with distribution kit for primary circuit
174 series
IS
CALEFFI
01158/08 GB
TERE
UNI EN ISO 9001:2000 Cert. n 0003
Function The temperature regulating unit with the distribution kit for the primary circuit is made to be used in mixed systems: radiant panels and radiators or fancoils, in combination with distribution manifolds for radiant panels. The outside compensated temperature regulating unit, complete with temperature digital regulator, operates on the medium temperature, supplied to the panels, with a compensation depending on the outside and inside temperature and the actual thermal load. In this particular series, the temperature is regulated by a specific hydraulic unit equipped with a motorised three-way valve. The function of the kit is to distribute a portion of the medium flowing from the primary boiler circuit to the heating elements. It is supplied with manifolds with built-in shut-off and balancing valves and a differential by-pass kit for the primary circuit. This accessory is essential when there is a primary circuit circulation pump and the radiator circuits are controlled by thermostatic or thermo-electric valves. Patent application No. MI2006A001935. Reference Documentation - Tech. brochure 01144 Pre-assembled distribution manifolds for radiant panel systems 668...S1 series Product range Code 1745.1 003 Outside compensated temperature regulating unit with distribution kit for primary circuit, with UPS 25-60 pump Code 1745.3 003 Outside compensated temperature regulating unit with distribution kit for primary circuit, with UPS 25-80 pump
Performance Medium: Max. percentage of glycol: Control temperature range: Primary inlet temperature range: Max. working pressure: Panel manifold differential by-pass setting: Primary circuit differential by-pass setting: Primary circuit manifold inner diameter: Temperature gauge scale: Pressure gauge scale: Connections: primary circuit: to regulating unit: panel circuit outlets: outlet centre distance: water, glycol solutions 30% 2090C 5100C 10 bar 25 kPa (2.500 mm w.g.) 10 kPa (1.000 mm w.g.) 27 mm 080C 010 bar 3/4 M 1 F with nut 3/4 M - 18 mm 50 mm
brass EN 12165 CW617N brass EN 12164 CW614N, chrome plated p (mm w.g.)
5000
4500 4000 3500 3000 2500
RE
50
45 40 35 30 25
Primary circuit distribution manifolds Flow manifold Body: Flow rate regulating valve Obturator: Hydraulic seals: Return manifold Body: Shut-off valve Obturator stem: Obturator and seals: Springs: Control knob: brass EN 1982 CB753S brass EN 12164 CW614N EPDM brass EN 1982 CB753S stainless steel EPDM stainless steel ABS
0,1
0,2
0,5
10
20
2000
20
Digital controller Three-point type Electric supply: Power consumption: Protection class: Actuator Three-point type Electric supply: Operating time: Power consumption: Auxiliary microswitch contact rating: Protection class: Max. ambient temperature: Protective cover: Flow/return temperature probes NTC type Working range: Two-wire cable Safety thermostat Factory set: Protection class: Contact rating: Pump Three-speed pump: Material: Body: Electric supply: Max. ambient humidity: Max. ambient temperature: Protection class: Pump centre distance: Pump connections: model UPS 25-60/UPS 25-80 cast iron GG 15/20 230 V - 50 Hz 95% 80C IP 44 130 mm 1 1/2 with nut 55C 3C IP 55 10 A / 240 V -20100C 230 V - 50 Hz 50 s (rotation 120) 8 VA 0,8 A IP 44 55C self-extinguishing VO 230 V - 50 Hz 5,5 VA IP 40

H (m w.g.)
6
(kPa)
60
H (m w.g.)
8 7 6
(kPa)
80
UPS 25-60
5 4 3 2 1 0 50 40
UPS 25-80
70 60
5 4 3 2
3 2 1
2 1
50 40 30 20 10
30 20 10 0
1 0 0 0,5 1 1,5 2 2,5 3 3,5 4
0,5
1,5
2,5
G (m3/h)
G (m3/h)
Power consumption
Speed I
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (rpm) 1800 1100 700
Speed
(A) 1,04 0,92 0,63
P (W) 245 210 140
n (rpm) 2450 1500 1000
3 2 1
3 2 1
Insulation Material: Thickness: Density: - inner part: - outer part: Thermal conductivity (DIN 52612): Coefficient of resistance to the diffusion of water vapour (DIN 52615): Working temperature range: Reaction to fire (DIN 4102): closed cell expanded PE-X 15 mm 30 kg/m3 50 kg/m3 0C: 0,038 W/(mK) 40C: 0,045 W/(mK) >1300 0100C class B2
Dimensions
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outlets
+
outlets
outlets
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CALEFFI
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
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fo r m E SL e n or me IS P
HOBBY
BAGNO
SOGGIORNO
WC
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CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
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CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
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with pump ups 25-60 with pump ups 25-80
code
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co
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m e n or m e IS PE
SL
SYSTEM FLOW

SYSTEM RETURN
BOILER FLOW
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End fittings with multi-position ball valves, automatic air vent, differential pressure control by-pass kit and fill/drain hose connection.
BOILER RETURN
1 2 3 4 5 6 7 8
Digital temperature controller Optimiser Three-way mixing valve Three-point actuator Three-speed circulation pump UPS 25-60 Three-speed circulation pump UPS 25-80 Flow temperature probe Return temperature probe Outside temperature probe Flow and return temperature gauges with pocket
9 10 11 12 13 14 15 16
Adjustable drain cock Safety thermostat Pressure gauge Primary circuit shut-off valves Distribution manifolds with built-in valves for primary circuit Primary circuit differential by-pass kit Remote control and room probe thermostat Interface wire connection
Hydraulic diagram Digital controller Optimiser
15 RPT
16
SF
11 5 8 9 10
RPT
Adjustable drain cock Temperature gauge Temperature probe Room probe thermostat Safety thermostat Ball shut-off valve Motorised three-way valve
ST
ST
8 4 7 13 3 2 6
SR
Pressure gauge Pump Differential by-pass
12
BF
13 14
12
BR
Outside temperature probe Interface wire connection
Operating principle The medium temperature is regulated by a three-way mixing valve with a sector obturator comprehensive of an actuator managed by a specific digital controller. The controller receives the signal from four probes, flow probe on the mixing valve outlet, probe on the panel circuit return, outside probe and room probe. It controls the valve movement. The flow in the valve is regulated by a shaped obturator (1) that, by turning, closes or opens the hot water flow ports (2) and the water returning ports from the circuit (3) to adjust the desired flow temperature. Even if the secondary circuit thermal load or the inlet temperature from the boiler change, the mixing valve automatically adjusts the flow rates until it obtains the optimal flow temperature.
SECONDARY FLOW
3
SECONDARY RETURN
2
Construction details Regulating unit body The valve body, containing the thermal regulating device, is made out of a single casting with connections to the primary and secondary circuits. A specific internal channel carries the system return medium to the regulating valve, making it possible for the unit to be smaller in size and easy to connect. Reduced head losses The three-way mixing valve is equipped with a special obturator acting on calibrated water orifices. This ensures a high flow rate and a reduced size, while maintaining accurate temperature control, with no variations due to sudden changes in thermal load.
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Manual opening By removing the actuator, the valve can be opened-closed manually by using a screwdriver. Regulating way - primary inlet Fully closed Fully open
op
open
Electrical connections The actuator is electrically connected through an external plug-socket system with a protective rubber cap. This system does not require opening the lid to connect the cables. In this way, replacing the actuator (should this ever be necessary) is particularly easy to do. Auxiliary microswitch The actuator is equipped with an auxiliary microswitch that can be used to switch on the generator. Mixing valve fully closed: contact OFF. Start opening mixing valve: contact ON.
ACTUATOR
CLOSES OPENS
M
2
COMMON
MAX 0,8 A
6
30 20 10 0 C 40 50 60 70 80
230 V
clo
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Distribution and differential by-pass kit for primary circuit Operation The distribution and differential by-pass kit for the primary circuit enables controlling the flow supplied to the heating elements connected before the outlet to the panel circuit regulating unit. It is composed of distribution manifolds with built-in regulating and shut-off valves and the differential by-pass kit for the primary circuit.
Primary circuit distribution manifolds The distribution manifolds are equipped with: - flow rate regulating valves built into the flow manifold. In this way it is possible to set the right flow rate and balance the various connected circuits. - shut-off valves built into the return manifold. The same circuits can be automatically shut off by using the thermo-electric actuators. p (mm w.g.)
500 450
400 350 300 250 180 160 140 120 80 70 60 45 40 35 30 25 16 14 12 800 700 600
1000 900
p (kPa)
9 8 7 6
10 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
2 1 0,5
10090 50
0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12
Differential valve The differential valve is used to control the head in the primary distribution circuit. It aids the flow circulation towards the heating elements and limits overpressure if there are thermostatic or thermo-electric valves. The differential valve has a fixed setting that cannot be changed. It is preset to 10 kPa, mean value for the loss of head in the primary circuit. p (mm w.g.)
2000
1800 1600 1400 1200
2018 10 0,2 0,1 0,5 1
0,2 0,1
p (kPa)
18 16 14 12
20
10
20
1000
900 800 700 600
9 8 7 6
10
10
Secondary
Gs
Secondary
Gs
Gp
Gp
Primary
Primary
20
0,2
0,1
0,5
Kv 5,40 4,10
Kv0,01 540 410
500
Description of controls 1. The LED gives information on the status by means of a multicoloured diode; the statuses it indicates are as follows: - flashing green: controller initialisation - fixed green: controller operating - flashing green/red: controller operating with probe error - flashing red: controller verification loop - prolonged red: controller error 2. The mini-DIN connector, on the front of the panel, makes it possible to view all the parameters managed by the control. A Sub D 9-pole mini-DIN data transmission cable is used for the connection to a PC. The cable and specific transmission program are available as optionals.
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3. The display shows the text in a clear way, giving all the information and menu points. All the values displayed are continuously refreshed. The monitor light switches on automatically when a function is selected. If no other commands are given in 4 minutes, the monitor goes back to the standard page and the light switches off. 4. The Select knob can be turned to the right (+) or left (-) to go to the different menu, function or value editing fields. Press the knob to select any of the menu points. Room temperature management The remote control can be used to change the room temperature, either increasing it or decreasing it in relation to a standard reference value. The change ( 5 K) is shown in the lines on the display, with increments of 0,5 K in relation to the reference values: comfort 20C; set-back correction 18C. The actual room temperature is shown on the fourth line on the display. 5. Function keys: Esc Info Set Changes the display of the selected menu point and goes back to the previous menu level. The changed data are not accepted and not recorded. Displays brief information about the current menu point. The change that has been made is recorded. Interface wiring box Transmission interface
Optimiser
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CALEFFI
Installation of the control on board the controller The control front panel can also be installed on board the controller. In this case, the wiring box and the base containing the room probe are no longer needed; the controller is no longer able to manage the room probe.
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CALEFFI
Immediate comfort function This makes it possible to change the comfort without changing the controller set parameters. The second line of the display shows the standard correction value - 0 of the characteristic curve. This value can be increased to + 5 or reduced to - 5 by turning the knob to the right or to the left respectively. Each single change corresponds to a 5% shift in the characteristic curve. Example, referred to factory configuration: flow temperature-heating start-up T = 20C and flow T at outside min. temp. = 40C corresponds to a temperature range T of 20 K (100%). The adjustment of the correction is +1; this means that the temperature of the mixing valve circuit 1 is raised by 1 K (5% of T), thus the flow temperature will be 41C.
Terminal board Electrical connections L Live N Neutral La Mixing valve relay contact a1 Mixing valve opening contact a2 Mixing valve closing contact N Neutral output for mixing valve and pump b0 Pump relay contact b1 Pump contact Probe connections Terminal board X X1 Outside probe X2 Common outside and room probes X3 Room probe X4 Flow probe X5 Common flow and return probes X6 Return probe Activating the internal battery The protective tab must be removed from the battery before setting the operating data. Probe resistance table C -20 -18 -16 -14 -12 -10 -8 -6 -4 14616 13211 11958 10839 9838 8941 8132 7405 6752 C -2 0 +2 +4 +6 +8 +10 +12 +14 6164 5634 5155 4721 4329 3974 3652 3360 3094 C +16 +18 +20 +22 +24 +26 +28 +30 +32 2852 2632 2431 2247 2079 1925 1785 1657 1539 C +34 +36 +38 +40 +42 +44 +46 +48 +50 1430 1331 1239 1154 1076 1004 938 876 819 C +52 +54 +56 +58 +60 +62 +64 +66 +68 767 718 673 631 592 556 522 491 462 C +70 +72 +74 +76 +78 +80 +82 +84 +86 434 409 386 364 343 324 306 290 274 C +88 +90 +92 +94 +96 +98 +100 260 246 233 221 210 199 189
L N
La a1 a2 N
b0 b1
X1 X2 X3 X4 X5 X6 X7 X8
The remote control base must be positioned horizontally, following the usual installation instructions for a normal room thermostat. If this is not possible, the room thermostat function must be disabled by positioning a jumper on terminal board X, contact x2=x3. The controller automatically positions on the immediate comfort function. Controller - remote control connection
Optimiser
230V~
( (
The cables must be connected in the same order as the polarisation
Optimiser
Optimiser
CALEFFI
Probe connection Dedicated raceway must be used for the connection of the flow, return and outside probes, the room thermostat and controller. If the connection cable shares the raceway with other power cables, shielded and earthed cable must be used. Any alteration to the wiring of the controller could result in electrical disturbance. A reset must be done (i.e. switching the controller's power supply off for a few seconds) whenever work is done on the wiring. Maximum distance between remote control and controller: 100 m, with 4-pole cable of 0.5 mm2 section.
A B C D
A B C D
Commissioning - immediate start The controller is ready to start operating immediately using the factory configurations, for radiant panel systems. Max. flow T corresponding to outside min. temp.
-25
Factory setting: characteristic curve for mixing valve circuit Characteristic Set-back correction curve curve
50
50
Setting range
40
40
30
25 % correction
30
20
20
30
25
20
15
10
-5
-10
-15
Setting range Max outside T, end of heating Main factory configurations OT - average = not active Compensation RT = Off (0%) Structure gradient = 100 Characteristic curve =1 Mixing valve rotation time = 240 s IP correction value = 20 K max. blocking FT = 55C
Setting range Min outside T corresponding to max flow
mOT constant Optimisation Slab drying Set-back correction curve Rotation correction Neutral zone
= = = = = =
100 not active not active -25% 290 s 2K
Operating information
Meaning Meaning
Setting range
-20
Automatic T max Off Stand by Comfort Set-back correction
.
> >> #
x
Meaning Mixing valve opens/ or scroll menu up Mixing valve stopped Mixing valve closes/ or scroll menu down Mixing valve fully open position Mixing valve fully closed position Measured value Calculated nominal value
On
Details of functions Adjustment of flow temperature in relation to the outside temperature The calculated flow temperature depends on the quantities read by the probes: outside, flow, return probe, room thermostat and set curve. Mixing valve and pump blocking safety system Long shutdown periods, such as in the summer, could lead to mixing valve malfunctions or pump blocking. To avoid this, the mixing valve and pump are operated automatically for 60 seconds every day. Frost protection function - double control level First level: the pump is switched on if the outside temperature is less than 4C or the room temperature less than 5C (room probe present). It is switched off when the outside temperature exceeds 6C or the room temperature exceeds 7C. Second level: if the flow or return temperature is less than 7C, the mixing valve is opened and the pump switched on. When this temperature in the circuit is over 20C, the pump switches off and the mixing valve is closed. Probe control Outside temperature probe error When the measured temperature range is less than -25C or greater than +40C, the following state automatically comes into operation: pump off, mixing valve closed and the display will show the message < OT probe malfunction > and the red LED will flash. The frost protection function, flow sensor and summer blocking safety system, however, remain enabled. Flow temperature probe error When the measured temperature range is less than 0C or greater than 110C, the following state automatically comes into operation: pump off, mixing valve closed. The display will show the message < FT probe malfunction > and the red LED will flash. Optional probe recognition If there are no optional probes (room t. and return t.), the controller will signal their absence with -X- . When the probes are connected, the system recognises them automatically. As these are corrective probes, no alarm state is signalled in the event of a malfunction. Slab drying (for floors, wall and ceiling heating systems) The new low-temperature systems have to be heated gradually, after a period of natural drying. The automatic initial heating-drying program can be used for this. This program must be activated in Standby function. The overall duration is seven days. In the first three days, the flow temperature will be maintained at 25C. In the remaining four days, the flow temperature will be at the value set at the max. blocking temperature menu point (menu structure level 4). At the end of this procedure, the slab drying function must be switched off, otherwise the controller repeats the operation automatically. If there is a break in the electricity during the drying, the program will restart automatically from the point when the break occurred. Procedure: Level 0
CAUTION: when this procedure is set, check whether the max. blocking FT needs to be adjusted; the factory set is 55C Comfort and set-back correction optimisation (manual or with self-learning) Comfort optimisation and set-back correction (manual or with self-learning) The room probe thermostat must be present for this operation. The optimisation makes it possible to bring forward the activation of the change from set-back correction to comfort (in this function the FT is set at the max. design specification), so as to reduce to a minimum the actual time necessary to reach the desired comfort level. This function can operate in three ways: = off; = active; A = self-learning.
Active: Since the time of the bringing forward depends on a number of different system parameters (power, outside and room temperatures, heat exchange, type of structure, etc.), a structure gradient reference coefficient must be set. Some reference values are given below. Structure gradient reference values - Building with low heat loss: 400 - Factory configuration: 100 - Building with very high heat loss: 50 Self-learning : In this case the bringing forward of the activation depends on the controller. The maximum suggested self-learning period is 10 days; before the end of the 10 days it is necessary to go from operating state A = self-learning to the = active operating state. The resulting structure gradient coefficient will be entered automatically at the < constant > operating state menu point. Average outside temperature This function can be enabled when necessary. If enabled, the average outside temperature, known as OT ref., is calculated automatically and recorded every hour. It is used to determine the flow temperature value. The calculation of the average OT ref. makes it possible to attenuate the effect of sudden changes of outside temperature.
Effect of return temperature If the return temperature probe is connected, the controller uses this value as an approximate parameter of the required actual thermal load. The controller calculates the difference between the design return temperature (with an influence between 0 and 50%. Factory configuration: 0%) and the actual measured value. This difference is used to change the flow temperature. For example, if the thermal load is less than the design value, there will be a final T between flow and return that is lower than the design value. In this case the characteristic curve will be lowered. If the actual thermal load is greater, then the characteristic curve will be raised. Effect of room probe thermostat If a room probe thermostat (code 151000) is connected, the actual room temperature will be read. The user can set the desired comfort room temperature on the thermostat. In the set-back correction function, this value is automatically reduced by 2 K. During the Manual forcing to Tmax function, the effect of the room probe thermostat on the controller is not active. Depending on the temperature difference between the actual measured value and the set value, the characteristic curve is moved to the right or left.
Work states
Standby In this state, the controller remains inactive, keeping the mixing valve closed and the pump off. The mixing valve and pump frost protection and anti-blocking function remains active. Comfort During the comfort function, the flow temperature is adjusted according to the measured outside temperature, following the set characteristic curve. This curve is automatically corrected if a room probe thermostat or a return probe are present. Set-back correction During the set-back correction function, the nominal flow temperature is lowered, by means of a parallel downward shifting of the characteristic curve. This shifting is settable with a parameter of between 0 and -50%. Maximum temperature This function guarantees heating to the maximum set temperature. This value, Tmax, can be set from 25C to 90C. Standard indication and change of nominal value On the display there is: day of week, date, time, curve correction, work state, room temperature or outside temperature. Example: Remote control Control on controller
22:41 +0.0K +23.9C
Fri 23. Apr 22:41 Corr. comf. +0 Frost protection OT +5.3C
Operation with programming of time bands 10 programs are available, with a total of 13 configurable setting points (SP). Factory configuration: program 1 (2 setting points); program 2 (5 setting points). All programs are editable. Factory configuration program 1: Setting points identical every day SP point 1 2 Factory configuration, program 2: 5 setting points with different options each day. SP point 1 2 3 4 5 Time 05:00 07:00 09:00 22:00 23:30 Action Set-back correction Comfort Comfort Set-back correction Standby Active on Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun Time 06:00 22:00 Action Comfort Set-back correction Active on Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun
For a detailed description of the different functions, refer to the commissioning manual
Application diagram
Pump Thermostatic valve Manual valve

RT
Lockshield Shut-off valve Clock Outside temperature probe
Room thermostat
Optimiser
RT
Optimiser
Optimiser
CALEFFI
1
3 2
bar
1 2
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
4 5
3 4
L/MIN
0
co
6
2.5
nf o
SL rm e n o r me IS PE
CL
30 20 10 0
40
50 60 70
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
80
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
30 20 10 0
40
50 60 70
80
Code 1745.. 003 Outside compensated temperature regulating unit with distribution kit for primary circuit. Connections to primary circuit 3/4" M. Connections to regulating unit 1" F with nut. Panel circuit outlet connections 3/4" M - 18 mm. Primary circuit manifold outlet connections 3/4" M - 18 mm. Medium: water and glycol solutions; maximum percentage of glycol 30%. Control temperature range 2090C. Primary inlet temperature range 5-100C. Maximum working pressure 10 bar. Panel manifold differential by-pass setting 25 kPa. Primary circuit differential by-pass setting 10 kPa. Temperature gauge scale 080C. Pressure gauge scale 010 bar. Complete with: flow manifold for panel system with 5 outlets (from 5 to 12) with brass body, flow rate regulating valve with flow meter with a scale of 15 l/min; return manifold for panel system with 5 outlets (from 5 to 12) with brass body, shut-off valve. Regulating unit with motorised three-way valve, three-point actuator, electric supply 230 V - 50 Hz, protection class IP 44. Digital controller, electric supply 230 V - 50 Hz, complete with probes for measuring outside, room, flow and return temperature. Management of controller and room temperature with remote control. Flow adapter unit with brass body. Primary circuit distribution manifolds with 3 outlets, brass body, flow rate regulating and shut-off valves. By-pass kit with brass body, POM differential by-pass valve and stainless steel spring. Shut-off valves with brass body and chrome plated brass ball. Safety thermostat: factory setting 55C 3C, protection class IP 55, contact rating 10 A/240 V. Three-speed circulation pump UPS 25-60 (and UPS 25-80), protection class IP 44. Pre-formed PE-X shell insulation for primary circuit. Supplied preassembled in painted steel box. Closure with a push-fit clamp. Depth adjustable from 110 to 150 mm, including floor supports adjustable in height from 270 to 410 mm.
CALEFFI
Motorised temperature regulating unit for Sepcoll 559 series

164 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
01159/07 GB
Function The motorised temperature regulating unit is configured for being combined with an outside compensated or modulating temperature regulator to control the flow temperature in heating and air-conditioning systems. This unit is specially made for connection to the Sepcoll 559 series separator/manifold, either in the exposed or concealed versions. Supplied complete with motorised three-way mixing valve, three-speed pump, safety thermostat, differential by-pass valve, flow and return temperature gauges, secondary circuit shut-off valves. Supplied complete with pre-formed insulation shell, suitable for heating and cooling.
Product range Code 164600 Motorised temperature regulating unit for Sepcoll. Flow upwards, supply on right hand side Code 164610 Motorised temperature regulating unit for Sepcoll. Flow upwards, supply on left hand side Size 1 Size 1
Technical specifications Materials Regulating unit with motorised three-way valve Body: Headwork: Obturator: Seals: By-pass valve Body: Spring: Obturator: Seals: Shut-off valves Body: Ball: Seals: Actuator Three-point type With auxiliary microswitch Electric supply: Operating time: Power consumption: Microswitch contact rating: Protection class: Max. ambient temperature: Protective cover: brass EN 12165 CW617N, nickel plated brass EN 12164 CW614N, chrome plated EPDM brass EN 1982 CB753S stainless steel EPDM EPDM brass EN 1982 CB753S brass EN 12164 CW614N stainless steel EPDM Safety thermostat Factory set: Protection class: Contacts rating: Performance Medium: Max. percentage of glycol: Primary inlet temperature range: Max. working pressure: By-pass setting range: Temperature gauges scale: Connections: - primary circuit: - secondary circuit: - connections centre distance: water, glycol solutions 30% 5100C 10 bar 1060 kPa (16 m w.g.) 080C 1 F with union 1 F 90 mm 55C 3C IP 55 10 A / 240 V
230 V - 50 Hz 50 s (120 rotation) 8 VA 0,8 A (230 V) IP 44 55C self-extinguishing VO
RE
Pump Three-speed pump: Material: - Body: Electric supply: Max. ambient humidity: Max. ambient temperature: Protection class: Pump centre distance: Pump connections: Head available at the unit connections
H (m w.g.)
6 5 4 3 2 1 0 0 0,5
Dimensions Model UPS 25-60 Cast iron GG 15/20 230 V-50 Hz 95% 80C IP 44 130 mm 1 1/2 with nut Code 164600 Code 164610
40
20 60 20
40
60 20
40
60 20
40
60
80
80
80
80
H (kPa)
60
Power consumption
Speed I
G
A B C A D D A C A B
A 1 1 B 95 95 C 90 90 D 77 77 E 460 460 F 320 320 G 140 140
UPS 25-60 3 2 1
50 40 30 20 10
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (rpm) 1800 1100 700
3 2 1
1,5
Q (m3/h)
Insulation expanded PE-X with closed cells 20 mm - internal part 30 kg/m3 - external part 50 kg/m3 Heat 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 Material: Thickness: Density:
Code 164600 164610
F
Weight (kg)
SYSTEM RETURN
SYSTEM FLOW
Hydraulic diagram
SR
2
20 0
SF
40
60 20
40
60
4
80
6 5 2
6 4
ST
80
3 1
9
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C
ELECTRICAL CONNECTIONS
OPEN
ACTUATOR
M
2
COMMON
CLOSE
MAX 0,8 A
EXTERNAL PLUG-IN SOCKET
230 V
1
Characteristic components 1 2 3 4 5 6 7 8 9 Three-speed pump UPS 25-60 Differential by-pass valve Electrical wiring box Secondary flow temperature gauge Secondary return temperature gauge Shut-off valves on secondary circuit Three-way mixing valve Three-point actuator Insulation
BR
Shut-off valve Temperature gauge Pressure gauge By-pass valve
ST
BF
Safety thermostat System pump Three-way mixing valve
Actuator
E
9,0 9,0
Construction details Mixing valve The mixing valve is a three-way type with a sector obturator. The internal regulating element is made entirely of stainless steel so as to minimize wear on the moving parts and ensure performance is maintained over time. The obturator and the valve body are sized so as to ensure a high flow rate with reduced overall dimensions while permitting accurate regulation of the water flows. Thus providing the best conditions for precise adjustment of the temperature of the mixed water sent to the system.
Manual opening By removing the actuator, the valve can be opened-closed manually by using a screwdriver. 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.
Regulating way - primary inlet Fully closed Fully open
op
open
se
Using the safety thermostat The safety thermostat, equipped with a special quick-coupling connector, can be used to shut down the boiler and protect the panel circuit from dangerously high temperatures.
clo
se
Actuator electrical connection diagram
ACTUATOR
CLOSE OPEN
M
2
COMMON
MAX 0,8 A
COMMON
230 V
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C
ACTUATOR
MAX 0,8 A
Actuator The actuator is a three-point type so it can easily be combined with the most widely used temperature regulators, both outside conpensated and modulating. The actuator is moreover equipped with an auxiliary microswitch that can be used to shut down the boiler or the chiller unit when the valve is closed. The microswitch contacts are closed when the valve is approximately 20% open. The actuator can be fitted on the valve body in the two shown positions. Fastening is done with a stainless steel clip.
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C

OPEN
ACTUATOR
M
2
COMMON
CLOSE
MAX 0,8 A
230 V
230 V
COMMON CLOSE OPEN
en
clo
Accessories
161
broch. 01122
Digital controller for heating and cooling complete with f/r probes. Control temperature range: 778C. Electric supply: 230 V - 50 Hz. Protection class: IP 40. Sensor connection: 1/8 M. Length of probe cable: 0,55 m.
1520
Outside compensated temperature controller complete with flow probe and outside probe. Setting range: 2090C. Electric supply: 230 V - 50 Hz. Protection class: IP 40.
Installation - Exposed Sepcoll
Configuration with sepcoll supplied from right-hand side
Configuration with sepcoll supplied from left-hand side
code 164610
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C
OPEN
code 164610
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C
OPEN
code 164600
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C
OPEN
code 164600
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C
OPEN
ACTUATOR
CLOSE
ACTUATOR
CLOSE
ACTUATOR
CLOSE
ACTUATOR
M
2
COMMON
M
2
COMMON
M
2
COMMON
M
2
COMMON
CLOSE
MAX 0,8 A
MAX 0,8 A
MAX 0,8 A
MAX 0,8 A
230 V
230 V
230 V
code 164600
code 164600
code 164610
Concealed Sepcoll Code 163630 Code 164610
Differential by-pass The differential by-pass valve is used to control the total head of water in the secondary supply circuit. When the set differential pressure value is reached, the obturator opens and allows fluid to pass from the supply to the return circuit, keeping the pressure differential at the set value. If the individual circuits are shut off by automatic two-way on/off, modulating or thermostatic valves, the valve prevents pump over-heating and excessive fluid velocity.
6 8 01
4
L N
2 0
40
20 60 20
40
60
80
80
By-pass hydraulic characteristics
p (m w.g.)
8 7 6 5 4 3 2 1 0 0,5
Setting positions
6 5 4 3 2 1
1,5
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C
230 V

1
ACTUATOR
MAX 0,8 A
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C

1
ACTUATOR
MAX 0,8 A
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C
ACTUATOR
MAX 0,8 A
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C

1
ACTUATOR
MAX 0,8 A
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C

1
ACTUATOR
MAX 0,8 A
L N
COMMON CLOSE OPEN
230 V
6
230 V
230 V
230 V
COMMON CLOSE OPEN CLOSE
COMMON OPEN CLOSE
COMMON OPEN
code 164610
230 V
COMMON CLOSE OPEN
(kPa)
80 70 60 50 40 30 20 10 2 0
G (m3/h)
RT
C
C
50 40 30 20 10 50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
C
RT
C
C
50 40 30 20 10 50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10 50 40 30 20 10
C
50 40 30 20 10
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
C
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C

OPEN
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C

OPEN
ACTUATOR
CLOSE
ACTUATOR
M
2
COMMON
M
2
COMMON
CLOSE
MAX 0,8 A
MAX 0,8 A
230 V
6 8 01
4 2 0 8
4 2
01
40
20 60 20
40
60 20
40
60 20
40
60
80
80
80
80
RT Room thermostat
230 V
RT
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
CALEFFI
CALEFFI
10 8 6 4 2 0
CALEFFI
6 8 01
4
N
2 0
40
20 60 20
40
60
80
80
Pump Variable speed pump Thermostatic valve Lockshield valve
RT
Room thermostat Shut-off valve Clock
164 series Motorised temperature regulating unit for SEPCOLL 559 series. Configuration with bottom-up flow and supply right side (or supply left side). 1 F union connection to primary circuit. 1 F connection to secondary circuit. Centre distance between primary and secondary circuit connections 90 mm. Maximum temperature at inlet of primary circuit 100C. Maximum working pressure 10 bar. Complete with: Three-way mixing valve, brass body, stainless steel obturator; Three-point actuator, electric supply 230 V - 50 Hz, protection class IP 44; Three-speed pump UPS 25-60, electric supply 230 V - 50 Hz, maximum ambient temperature 55C, protection class IP 44; Temperature gauge scale 080C; Differential by-pass valve, brass body, stainless steel spring, setting range 1060 kPa; Shut-off valves on secondary circuit. With pre-formed shell insulation in expanded closed cell PE-X.
CALEFFI
230 V ~ 10% 5060 Hz - 8 VA IP 44 - Tamb. 055C

1
ACTUATOR
MAX 0,8 A
L
COMMON CLOSE OPEN
230 V
6
Multi-function compact unit

for temperature control, thermal disinfection and distribution for sanitary water system 6005 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
01160/08 GB
Function The multi-function unit is used in sanitary water systems to control the hot and cold water delivered to user taps, serving a bathroom or a dwelling. A high-performance adjustable thermostatic mixing valve keeps the hot water temperature at the desired level and protects the user from the danger of scalding. A flushing valve is used for the circuit thermal disinfection all the way to the tap, in compliance with anti-Legionella regulations. Patent application No. MI2007A000936
Product range Cod. Cod. Cod. Cod. 600500 600530 600540 600550 Unit Unit Unit Unit with with with with cold water circuit outlet kit manifolds and box with 3 cold and 2 hot outlets manifolds and box with 4 cold and 3 hot outlets manifolds and box with 5 cold and 4 hot outlets size 3/4 size 3/4 - outlets 23 p. 1,5 size 3/4 - outlets 23 p. 1,5 size 3/4 - outlets 23 p. 1,5
Technical specifications Materials Mixing valve Body: Obturator: Springs: Sealing elements: Cap: Flushing valve Control stem: Obturators: Control stem seal: Manual control knob: dezincification-resistant alloy EN 1982 CB752S, chrome plated PSU stainless steel EPDM ABS stainless steel EPDM EPDM ABS Performance Multi-function unit Medium: drinking water Setting range: 3050C Factory set: 43C Accuracy: 2C Max. working pressure (static): 10 bar Max. working pressure (dynamic): 5 bar Max. inlet temperature: 85C Max. inlet pressure ratio (H/C or C/H): 2:1 Min. temperature difference between inlet hot water and outlet mixed water to ensure anti-scald performance: 15C Min. flow rate for stable operation: 6 l/min Performances to standards: NF 079 doc.8, EN 1111, EN 1287 Connections: inlet 3/4 M, outlet 3/4 M with union
Cold water circuit outlet kit Body: brass EN 1982 CB753S, chrome plated Shut-off valves with strainer and check valve Body: brass EN 12165 CW617N, chrome-plated Check valve: POM Check valve spring: stainless steel Strainer: stainless steel Strainer seal: EPDM Control lever: PA Thermo-electric actuator Protective shell: Colour: Distribution manifolds Body: Obturator stem: Headwork: Hydraulic seals: Control knob: Brackets: Box Material: Colour: Useful dimensions: self-extinguishing polycarbonate white RAL 9010
brass EN 12165 CW617N, chrome-plated brass EN 12165 CW614N brass EN 12164 CW614N EPDM PA6GF stainless steel impact-resistant PS - anti UV white RAL 9010 560 x 330 mm, depth 80 mm
Thermo-electric actuator Normally closed Electric supply: Starting current: Working current: Working power consumption: Protection class: Double insulation construction: Max. ambient temperature: Operating time for start of flushing: Length of supply cable: Distribution manifolds Medium: Max. working pressure: Temperature range: Main connections: Outlet connections: Outlet centre distance:
RE
230 V (ac) 1A 13 mA 3W IP 44 (in vertical position) CE 50C 210 s 80 cm
drinking water 10 bar 5100C 3/4 F x M 23 p. 1,5 18 35 mm
Dimensions Code 600500

90
MIX
3/4
330
CALEFFI COLD HOT
MIX CALEFFI
COLD
HOT
COLD
COLD
HOT
111
COLD
HOT
3/4
3/4 50 198 86 17 L
16 35 560
23 p.1,5
COLD
3/4 50
3/4
Code No. outlets L Weight (kg)
600500 2,3
600530 2+3 325 4,6
600540 3+4 360 4,8
600550 4+5 395 5,0
Legionella-danger of scalding In systems producing hot water with storage, in order to avoid the growth of the dangerous bacterium known as Legionella, the hot water must be stored at a temperature of at least 60 C. At this temperature it is certain that the bacterium growth will be totally eliminated. At this temperature, however, the water cannot be used directly. As shown in the diagram provided, temperatures of more than 50C can cause scalds 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. On average, these times can be halved for children and elderly people. Therefore, it is necessary to use a thermostatic mixing valve able to: - reduce the temperature at the point of use to a value lower than that of the storage and make it suitable for sanitary use. - maintain the temperature constant despite any variation of the incoming pressure and temperature. - prevent the water temperature at the outlet from reaching values above 50C. - have an anti-scald safety function in case of failure of the cold water supply.

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
Exposure time required to cause partial burns Thermal disinfection
Temperature
To be more certain that there is no growth of Legionella, all sections of the network must be subjected to thermal disinfection. Even in the section downstream of the mixing valve, as far as the user tap, it must be possible to flush the system at temperatures exceeding 60C. This means by-passing the thermostatic mixing valve, which is set at lower values, and activating another valve that allows the taps to be fed directly with the hot water arriving from the distribution network. Reference documents With regard to the prevention and control of Legionella, see the National Regulations and applicable Code of Practice. Applications The temperature control and thermal disinfection unit is typically used in systems serving hospitals, nursing homes, sports and shopping centres, hotels, campsites and colleges. In these structures with their collective use, it is more than ever necessary to control and prevent legionnaires disease in a programmed manner, allowing thermal disinfection to be carried out right up to the user tap if necessary. 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.
Adults 1s 2s 5s 30 s 5 min
Children 0-5 years 0,5 s 1s 10 s 2,5 min
70C 65C 60C 55C 50C
70 60 50 40 30 20 10 0
Hydraulic diagram Operation with mixing
10
12
Flushing valve closed Cold water valve open
OFF
MIX CALEFFI COLD HOT
COLD
HOT
COLD
9
Operation with thermal disinfection Flushing valve open Cold water valve closed
1) Anti-scald thermostatic mixing valve, adjustable with tamper-proof block for the temperature setting 2) Automatic flushing valve for thermal disinfection, for mixing valve by-pass and simultaneous cold water inlet shut-off 3) Ball shut-off valves with built-in strainers and check valves at the hot and cold water inlets 4) Cold water circuit outlet kit 5) Distribution manifold with built-in shut-off valves with control knob for hot water circuit 6) Distribution manifold with built-in shut-off valves with control knob for cold water circuit 7) Stainless steel brackets 8) Water hammer arrester 525 series (optional) 9) Ventilated plastic box 10) Timer with programmable key, code 600200 ( optional)
ON
T
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. According to 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 After turning the flushing valve control switch on (approx. 210 s), the user taps must be opened to carry out thermal disinfection using the hot water from the distribution network. The tap opening times and their disinfection frequency will depend on how the system is run and on applicable regulations.
HOT
During thermal disinfection flushing, the high temperature hot water heats the monoblock body of the multifunction unit completely. In this way, even the body of the mixing valve itself is entirely disinfected, making sure that there are no areas that remain at lower temperatures, where there would be a risk of Legionella formation.
MIX CALEFFI COLD HOT
MIX
COLD
HOT COLD
In a traditional system, comprising a mixing valve and a flushing valve connected by pipes, this risk may still exist. Part of the mixing valve, as it is always in contact with the cold water, remains at a temperature that does not give the certainty of complete disinfection of all its parts.
COLD
Operating principle Mixing valve The thermostatic mixing valve mixes the hot and cold water at the inlet so as to maintain the mixed water at a constant set temperature at the outlet. A thermostatic element (1) is fully immersed in the mixed water pipe. It contracts or expands, moving an obturator which controls the passage of hot or cold water at the inlet. If there are changes in inlet temperature or pressure, the internal element reacts automatically to restore the set temperature at the outlet. Flushing valve The flushing valve, which can be activated manually or automatically using a thermo-electric actuator, allows the hot water to pass directly to the unit outlet. Using the control stem with double obturator (2), it opens the by-pass on the hot water inlet to the mixing valve and, at the same time, shuts the cold water inlet off. This prevents any mixing of hot and cold water during the flushing operation, with the taps open, as this would reduce the temperature of the water sent to perform thermal disinfection.
3 1
MIXED
Construction details Monoblock unit The valve body, containing the thermal regulating and by-pass components, is made out of a single casting with connections to the hot water inlet, the cold water inlet and the mixed water outlet. A specific internal channel carries the hot water to the mixing valve inlet and to the flushing valve, making it possible for the unit to be smaller in size and easily connectable. Anti-scale materials The materials used in constructing the mixing valve eliminate seizing due to limescale deposits. All functional parts were made using a special anti-scale material with low friction coefficient, which ensures performances over time. Anti-scald safety function As a safety measure, in case of failure of cold water supply, the valve immediately shuts off the flow of hot water. This prevents dangerous burns. This performance is guaranteed if there is a minimum temperature difference between the inlet hot water and the outlet mixed water of 15C (performance in compliance with French standard NF 079 Doc. 8). In case of failure of hot water supply as well, the valve shuts off the cold water passage and therefore mixed water to prevent dangerous thermal shocks. Control stem The flushing valve control stem (3) is made of stainless steel with a double O-ring seal in EPDM. In this way the upper portion of the headwork can be replaced even with the system running. Shut-off valves The hot and cold water inlet shut-off valves are fitted with stainless steel strainers (4) with EPDM seals and check valves (5).
COLD
4 5
COLD
HOT
p (bar)
1,5 1,0
MIX
BY-PASS
p (m w.g.)
15
Kv MIX (m3/h) : 1,75 Kv BY-PASS (m3/h) : 1,80
10
0,5
0,3 0,2
3 2
0,1
0,05 0,2 0,5 1 2
0,5 5 50
10
20
Use According to its flow characteristics, the unit with thermostatic mixing valve can be used for application with a limited number of users, for example a bathroom. For this reason, the flow rate passing through the valve is generally the same as through the final user, for example the tap of a basin, shower, bidet, etc. To ensure stable operation, a minimum flow rate of 6 l/min must be guaranteed to the mixing valve. The system must always be dimensioned taking into account the current legislation on the nominal flow rate to each user. Public buildings, hospitals, kindergartens In this type of application, the risk of scalding is extremly high because of the nature of the hot water users, who include children, old people, sick people. In these installations, the two supply networks providing hot water from the storage and cold water may have different origins and operate at different pressures. In case of failure of cold water supply, the mixing valve is able to shut off the supply of mixed water to prevent possible burns. Head loss check in the mixing valve If the design flow rate is known, taking into account simultaneous use of the sanitary appliances, the head loss produced by the mixing valve is checked using the graph provided. It is necessary to verify the available pressure, the head loss in the system downstream of the mixing valve and the residual pressure to be guaranteed to user appliances. Installation Before installing the unit with the mixing valve, the pipes must be washed out to ensure that no impurities in circulation will impair its performance. We recommend always installing suitable strainers at the inlet of the water system. The mixing valve unit is fitted with shut-off valves with strainers at the hot and cold water inlets. The mixing valve unit must be installed according to the diagram provided within the instruction sheet or in this brochure. The unit can be installed in any position, vertical or horizontal. The following marks are indicated on the unit body: hot water inlet, indicated by the word Hot cold water inlet, indicated by the word Cold mixed water outlet, indicated by the word MIX. Check valves In systems with thermostatic mixing valves, check valves shall be installed to prevent undesired backflows. The mixing valve unit is fitted with check valves, incorporated in the shut-off valves at the hot and cold water inlets.
Thermal transient During transient, due to rapid changes in pressure, temperature or flow rate, the temperature increases with respect to the initial set point and this increase must be of limited duration to guarantee safety.
T(C) 60C 55C 2K Initial temperature Temperature rise Stabilisation period Stable conditions Time (s) 2K
< 0,5 s - max
< 3 s - max
Commissioning According to the special purpose of the thermostatic mixing valve, it must be commissioned in accordance to the current regulations by qualified personnel using appropriate temperature measurement equipment. We recommend using a digital thermometer for measuring the temperature of the mixed water.
Recommended temperatures Given the specific use of this type of mixing valve, the following table summarizes the maximum water temperatures at the tap to avoid scalding. Appliance Bidet Shower/Washbasin Bath Tmax 38C 41C 44C
Temperature setting The temperature is set at the desired value using the regulator screw. Temperature adjustment can then be locked by means of the tamper-proof locking nut. 1. Using the cover for temperature adjustment. 2. Temperature setting. 3. Adjustment locking using the locking nut.
1.
2.
3.
Manual opening The flushing valve can be activated manually by means of the knob provided. Thermo-electric actuator The operating knob can be removed, by unscrewing the locking nut, and replaced by a thermo-electric actuator. This allows automatic operation of the valve, controlled by a suitable switch or timer.
Distribution manifolds The hot and cold water distribution manifolds are fitted with shut-off valves with operating knobs for each circuit and identification labels for each of the appliances served. This creates balanced distribution of water to the various user outlets, enabling the circuit supplying each individual appliance to be shut off in order to carry out any maintenance.
Hydraulic characteristics of outlet

p (bar)
1,0
p (m w.g.)
10
Kv (m /h): 3
0,5 0,3 0,2 5 3 2
0,1
0,05 0,03 0,02 0,2 0,5 1 2
0,5 0,3 Flow rate (l/min) (m3/h) 0,2 5 50
10
Manifold inner diameter: 20 mm
Box The box is supplied with guards to be positioned on the sides where no pipes pass, to ensure that no mortar falls inside the box itself when it is fitted, dirtying the components. This guard is supplied so that it can be fitted both on the shorter and on the longer side, according to the position in which the box is fitted, horizontal or vertical. The cover allows recovery of 30 mm depth, caused by possible errors in wall finishing.
The particular shape of the ventilation holes in the cover give the air flowing out a speed and direction that ensure it will flow away from the cover itself quickly. This prevents the formation of unaesthetic stains on the wall.
20
12
12
MIX CALEFFI COLD HOT CALEFFI COLD
MIX
HOT
COLD
HOT
COLD
1 12
COLD
HOT
COLD
1 12
MIX CALEFFI COLD HOT CALEFFI COLD
MIX
HOT
COLD
HOT
COLD
1 12
COLD
HOT
COLD
1 12
COLD HOT COLD HOT

COLD COLD
12
COLD
COLD
COLD HOT COLD HOT
COLD
COLD
CALEFFI MIX CALEFFI MIX
CALEFFI MIX
HOT COLD HOT
HOT COLD HOT CALEFFI
12
MIX
Accessories
6002
525 ANTISHOCK
broch. 01020
3641
Blind end plug. Chrome plated.
Code
Water hammer arrester. Brass body. Chrome plated. Max. working pressure: 10 bar. Max. working temperature: 90C. PTFE seal on thread.
364151
3/4 M
5991
Code
End fitting. Chrome plated. 1/2

Code
525040 Timer with programmable key, settings from 1 to 12 minutes. To operate the valves used to carry out thermal disinfection of circuit sections, up to the outlet taps. Electric supply: 230 V (ac).
Code Code
599155
3/4 F x 1/2 F
3642
End fitting. Chrome plated.
Code
5993
Blind end plug. Chrome plated.
600200
364255
3/4 M x 1/2 F
599351
3/4 M
Series 6005 Multi-function compact unit for temperature control, thermal disinfection (cod. 600500). Multi-function compact unit for temperature control, thermal disinfection and distribution for sanitary water system, pre-assembled in box (cod. 600530 - 600540 - 600550). Complete with: Multi-function monoblock unit with anti-scald thermostatic mixing valve and flushing valve for thermal disinfection of the circuit. Complete with shut-off valves, inspectable strainers and check valves at the hot and cold water inlets. Ready for direct connection to the distribution manifolds. With cold water circuit outlet kit. Connections: inlet 3/4 M, outlet 3/4 M with union. Dezincification-resistant alloy body. Chrome plated. Medium: drinking water. Anti-scald thermostatic mixing valve, with performance in compliance with standard NF 079 doc.08, EN 1111 and EN 1287. With tamper-proof block for the temperature setting. Obturator in PSU. Stainless steel springs. EPDM seal elements. ABS cap. Maximum inlet temp. 85C. Adjustment range 30-50C. Accuracy 2C. Maximum working pressure (static) 10 bar. Maximum working pressure (dynamic) 5 bar. Maximum inlet pressure ratio (H/C or C/H) 2:1. Flushing valve for mixing valve control by-pass and simultaneous cold water inlet shut-off, manual or automatic with thermo-electric actuator. Stainless steel control stem with double obturator in EPDM. Control stem seal with double O-Ring in EPDM. Manual control knob in ABS. Shut-off valves and outlet kit with chrome plated brass body. Inspectable stainless steel strainers with EPDM seal. Check valves with POM body and obturator and stainless steel spring. Thermo-electric actuator. Normally closed. Electric supply 230 V (ac). Working power consumption 3 W. Starting current 1 A. Working current 13 mA. Protection class IP 44 (in vertical position). Maximum ambient temperature 50C. Operating time for start of flushing 210 seconds. Length of supply cable 80 cm. Hot and cold water distribution manifolds fitted with shut-off valves with operating knobs for each circuit and identification labels for each of the appliances served. With 2+3 hot and cold water outlets (or 3+4 or 4+5). Main connections 3/4 F, outlet connections 23 p. 1,5 mm. Centre distance: 35 mm. Brass manifold body, chrome plated. Brass stem and headwork. EPDM hydraulic seals. Maximum working pressure: 10 bar. Temperature range: 5100C. PA6GF knob. Stainless steel brackets. Ventilated box. Colour white RAL 9010. Useful dimensions 560 x 330 mm, depth 80 mm. Code. 525040 Water hammer arrester. Threaded connections 1/2 M. Brass body. Chrome plated. Very high resistance polymer piston. Carbon steel spring. EPDM seals with anti-extrusion rings. Maximum working temperature 90C. Maximum working pressure 10 bar. Maximum water hammer pressure 50 bar. Code. 600200 Timer with programmable key, settings from 1 to 12 minutes. To operate the valves used to carry out thermal disinfection. Power supply 230 V (ac).
CALEFFI
Compact automatic charging unit assembly with BA type backflow preventer

574 series
IS
CALEFFI
01161/08 GB
TERE
UNI EN ISO 9001:2000 Cert. n 0003
Function The charging unit assembly is composed of a shut-off valve with an inspectable strainer, a BA type controllable reduced pressure zone backflow preventer and a pre-adjustable filling unit. 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, providing automatically a re-fill of the missing water. This product has the peculiarity of being pre-adjustable. That means it can be adjusted at a desired pressure value before the system filling stage. The backflow preventer is inserted to prevent the contaminated water of the closed heating circuit from flowing back into the domestic water supply network, in compliance with EN 1717 standard prescriptions. The device is proposed complete with pre-formed shell insulation and with a compact dimension design to make its hydraulic installation easier.
Reference Documentation - Tech. brochure 01022. Controllable reduced pressure zone backflow preventer (BA type). 574-575-570 series.
Product range Code 574011 Compact automatic charging unit assembly with BA type backflow preventer size 1/2
Technical specifications Materials Backflow preventer Body and cover: Check valves: Springs: Diaphragm and seals: Filling unit Body: Cover: Obturator stem and moving parts: Strainer: Diaphragm and seals: dezincification-resistant alloy EN 12165 CW602N PSU-POM stainless steel EPDM brass EN 12165 CW617N PA66G30 brass EN 12164 CW614N stainless steel NBR
Backflow preventer Designation: Certification: Pressure ports: Upstream filter mesh : Filling unit Set pressure range: Factory set: Indicator accuracy: Pressure gauge range: Internal filter mesh : Connections: Dimensions
RE
Family B, Type A EN 12729 upstream, intermediate, downstream 0,4 mm 0,24 bar 1,5 bar 0,15 bar 04 bar 0,28 mm 1/2 M with union
Insulation Material: Density: Performance Medium: Maximum working pressure: Maximum working temperature: Acoustic group:
0
CALEFFI
EPS 33 kg/m3
E
drinking water 10 bar 65C II
Code A 574011 1/2
B 101,5
C 50
D E F Weight (kg) 182 40-60 250 1,6
Shut-off ball valve Body: dezincification-resistant alloy EN 12165 CW602N Ball: brass EN 12164 CW614N Seals: EPDM Lever handle: PA66G30
Characteristic components The charging unit assembly 574 series is complete with: 1) Inspectable strainer 2) Ball shut-off valve 3) BA type controllable backflow preventer with reduced pressure zones 4) Pre-adjustable filling unit with pressure gauge 5) Shut-off cock 6) Pre-formed shell insulation
Automatic filling unit Pre-adjustment This model is provided with a pressure regulation indicator, which facilitates setting operations. The system charging pressure may be set, turning the regulating 2 screw, even before the 30 20 system charging phase begins.
1
40
Manual/automatic opening and pressure gauge The assembly is provided with a manual shut-off cock (5) in the lower part that offers the possibility of closing the water supply to the system after the filling is completed. The pressure in the system 2 can be checked using the gauge 3 1 supplied in order to re-open the cock 4 whenever necessary to restore the 0 automatic charging, which will gradually bring the pressure up to the set value. 5
CALEFFI
10
50
CALEFFI
Anti-stick materials The components inside the assembly are made of plastic having a low adherence coefficient. This solution reduces to a minimum the chance of scale forming, the major cause of any malfunctions.
Removable cartridge and filter The cartridge containing the operation mechanisms, protected by a strainer having a large surface area, is removable. This peculiarity makes it possible to perform inspections, internal cleaning operations and, if necessary, cartridge replacement in an extremely simple and functional manner.
psi bar
Shut-off valve and inspectable strainer upstream The shut-off valve upstream (2) of the assembly, together with the cock (5), makes it possible to shut off the backflow preventer for cleaning, checking and, if necessary, replacing internal components. The purpose of the inspectable strainer (1) located upstream is to protect the backflow preventer from any impurities of the supply network that could 1 2 jeopardize its operation.
Insulation The assembly is supplied complete with insulation, sized to limit thermal losses and to prevent condensation forming on the surface.
Compact assembly The assembly is designed compact and with reduced overall dimensions in order to make hydraulic installation easier, above all if space is limited. This condition is typical of small and medium-size systems this product is designed for.
BA type controllable backflow preventer with reduced pressure zones Corrosion-proof materials The materials used to manufacture the backflow preventers must be insensitive to corrosion caused by the contact with drinking water. This is why they are made using dezincification-resistant alloy and stainless steel, as they are a guarantee to keep best performance over time. Simplified maintenance When needed, any disassembly and maintenance work is easier to perform thanks to the use of components easy to verify and replace without having to disassemble the valve body from the pipe.
p (bar)
5,0 4,5 4,0 3,5 3,0 2,5 2,0 1,5 1,0 0,5
0,25 0,50 0,75 1,25 0 1
p (m w.g.)
50 45 40 35 30 25 20 15
5
1,50
Charging flow rate 2,65 m3/h p 1,5 bar Ref. EN 1567 Installation
1. The backflow prevention valve unit must be installed horizontally, respecting the direction of flow shown with an arrow on the valve body. The discharge tundish to EN1717 standard must be connected to the piping leading to the sewerage system.
3
CALEFFI
0
CALEFFI
2. The special mechanical preregulation system with pressure indicator allows the assembly to be set to the desired system value before the charging stage starts. 3. The valve is normally set to a pressure no lower than the value obtained by adding the hydrostatic pressure and 0,3 bar. 4. During the charging stage, the internal mechanism will automatically adjust the pressure by closing the supply when the set value is reached, without having to watch the lengthy filling operation. 5. In view of the preregulation function, a pressure gauge downstream of the equipment is not crucial. 6. Once the system is filled, the shut-off valve of the assembly can be closed. To reinstate the automatic charging conditions, the valve just has to be re-opened. The system pressure value will gradually go back to the set value. Use of backflow preventer according to European standards To avoid backflows of water from the heating system, which is potentially polluted and dangerous for human health, it is indispensable to install a preassembled charging unit with a backflow preventer. The correct use of hydraulic backflow preventers is governed by the European reference standard EN 1717: 2000 Protection
Inspection and maintenance Charging unit assembly For the periodical cleaning, control or replacement of the whole cartridge you must: 1) Shut off the valve with the valve upstream and by using a valve downstream. 2) Open the bottom handle. 3) Fully undo the setting screw. 4) Remove the upper cap. 5) Take out the cartridge with some pliers. 6) After inspection and eventual cleaning of the body, the whole unit can be reassembled or replaced by a spare cartridge. 7) Reset the unit.
against pollution of potable water in water installation and general requirements of devices to prevent pollution by backflow.
The controllable backflow preventer with reduced pressure zones is a BA type, certified according to European standard EN 12729 -
Devices to prevent pollution by backflow of potable water. Controllable backflow preventer with reduced pressure zones. Family B - Type A. It may be used to protect against the risk of
contamination by waters classified up to Category 4 (heating systems with reference to European standard EN 1717): Fluid
that presents a significant health hazard due to the presence of one or more toxic or highly toxic substances or one or more radioactive, mutagenic or carcinogenic substances.
Flow rate (m3/h)
10
CALEFFI
Application diagram
P T
F
2 1 3
0
CALEFFI
Shut-off valve Ball valve Ballstop Temperature gauge Differential by-pass valve
F
T
T
Pump Autoflow
P
3-way cock Pressure switch Inspection pocket Gas strainer Gas controller Deaerator
Fuel shut-off valve Anti-vibration joint Pocket Safety relief valve
Flow metering device Temperature probe Safety thermostat Controller Expansion vessel
Code 574011 Compact automatic charging unit assembly with BA type backflow preventer. Connections 1/2 M with union. Maximum working temperature 65C. Maximum working pressure 10 bar. Medium water. Complete with: - Controllable backflow preventer with reduced pressure zones, BA type, compliant with EN 12729. Dezincification-resistant alloy body, EPDM diaphragm and seals. Stainless steel spring. Complete with discharge tundish with collar for fixing to the drain pipe; - Pre-adjustable filling unit. Brass body, control stem and moving parts. Glass nylon cover. NBR seals. Adjustment range 0,24 bar. Complete with cock, stainless steel strainer with mesh size 0,28 mm and check valve. Pressure gauge with 04 bar scale; - Dezincification-resistant alloy shut-off ball valve. Brass ball. EPDM seals. Glass nylon handle; - Strainer upstream with mesh size 0,4 mm; - EPS insulation, density 33 kg/m3.
CALEFFI
Anti-scald thermostatic mixing valve for wash-hand basins

601-602 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
01162/08 GB
Function In certain sanitary hot water distribution systems, for example hospitals, nursing homes, schools, sport centres etc., it is necessary to protect vulnerable people from a risk of scalding with hot water. This particular series of thermostatic mixing valves has been specifically designed for this type of application, for installation just upstream of the basin tap. The mixing valves automatically maintain the mixed water temperature constant, despite any variation in inlet pressure or temperature or the actual flow rate drawn at the tap. A special by-pass mechanism is used on the 602 series unit to thermally disinfect the circuit all the way to the tap, in compliance with anti-Legionella regulations.
Product range 601 series Anti-scald thermostatic mixing valve for wash-hand basins 602 series Anti-scald thermostatic mixing valve with by-pass, for wash-hand basins sizes 3/8 and 1/2 sizes 3/8 and 1/2
Technical specifications Materials Body: Obturator: Spring: Sealing elements: Cover:
Max. inlet temperature: Max. inlet pressure ratio (H/C or C/H): Min. temperature difference between hot water inlet and mixed outlet to guarantee the anti-scald function: Min. flow rate for a stable operation: Connections: Hot
3/8 F (captive nut) 3/8 F (captive nut)
RE
90C 5:1 10C 4,5 l/min Cold and mixed

3/8 - 10 olive 3/8 - 12 olive 3/8 M (flat seat) 1/2 - 15 olive 1/2 M (flat seat)
brass EN 12165 CW617N, chrome plated brass EN 12164 CW614N stainless steel EPDM ABS
Performance Medium: Adjustment range: Factory set: Accuracy: Max. working pressure (static): Max. working pressure (dynamic):
water 2550C 41C 2C 10 bar 5 bar
3/8 F (captive nut) 1/2 - 15 olive 1/2 M (flat seat)
Dimensions
B B A G A F C F B D A
601
602
601
602
Code A B C D E E F G Weight (kg) 601310/602310 3/8" 10 40 62 28 55 51 46 0,60/0,69 601312/602312 3/8" 12 40 62 28 55 51 46 0,60/0,69
Code A B 601415/602415 15 40
C 62
D 28
D 55
E 47
F 47
Weight (kg)
0,60/0,69
B G
A F
601
602
601
602
Code A B C D E E F G Weight (kg) 601333/602333 3/8" 3/8" 40 62 28 55 51 38 0,60/0,69
Code A B 601444/602444 1/2 40
C 62
D 28
D 55
E 51
Legionella - scalding risk In 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 will be totally inhibited. At this temperature, however, the water cannot be used directly. As shown in the diagram opposite, temperatures of more than 50C can cause burns very quickly. For example, at 55C, partial burn will occur in approximately 30 seconds, while at 60C partial burn will occur in approximately 5 seconds. This time may be reduced by 50% for children and elderly people. In view of the above, it is necessary to use a thermostatic mixing valve which can: - reduce the temperature at the point of use to a value lower than that of the storage and make it suitable for sanitary use. - maintain the temperature constant while the incoming pressure and temperature conditions vary. - prevent the water temperature at the outlet from reaching values above 50C. - have an anti-scald safety function in case of failure of the cold water supply. 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.

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
F Weight (kg) 38 0,60/0,69
Seconds
Exposure time required to cause partial burns

70 60 50 40 30 20 10 0
Temperature 70C 65C 60C
Adults 1s 2s 5s 30 s 5 min
Children 0-5 years 0,5 s 1s 10 s 2,5 min
55C 50C
Operating principle The thermostatic mixing valve mixes the hot and cold water at the inlet so as to maintain constant the adjusted mixed water temperature at the outlet. A thermostatic element is fully immersed in the mixed water port. It contracts or expands, moving an obturator which controls the passage of the hot or cold water at the inlet. If there are changes in inlet temperature or pressure, the internal element reacts automatically to restore the adjusted temperature at the outlet.
COLD
MIXED
Thermal disinfection - By-pass function 602 series mixing valves are equipped with a by-pass device which allows to reach the delivery tap with the thermal disinfection, as required by established legislation. The by-pass provides total disinfection of the system and the mixing valve itself, without the need for disassembly.
HOT
HOT
COLD
MIXED
HOT
Anti-scald safety function In case of hot or cold water supply failure at the inlet, the obturator closes the water port, thus shutting off the mixed water outlet. This function is only guaranteed if there is a minimum temperature difference of 10C between the hot water at the inlet and the mixed water at the outlet.
HOT
p (bar) 1,5 1,0 p (m w.g.) 15 10
Installation Before installing the mixing valve, the connecting pipes should be flushed to remove any impurities that could impair the performance. We recommend to install always strainers of adequate performance at the water inlet from the hydraulic network. 601-602 series mixing valves are equipped with strainers at the hot and cold water inlets. 601-602 series thermostatic mixing valves can be installed in any position, horizontally or vertically. The hot and cold water supplies must be connected as shown on the valve body (red dot for hot water - blue dot for cold water - the mixed water output is not marked).
0,5 0,3 0,2
5 3 2
0,1
0,05 0,1 0,2 0,5 1
0,5 Flow rate (l/min) (m3/h) 2 20
Kv (m3/h) = 0,8 Use 601-602 series thermostatic mixing valves are designed for installation underneath the wash-hand basin. For correct operation, the minimum flow rate must be 4,5 l/min. The system must always be sized to take into account current legislation about the nominal flow rate to each user. Check valves In systems with thermostatic mixing valves, check valves should be installed to prevent undesired back flows. 601-602 series thermostatic mixing valves are equipped with check valves at the hot and cold water inlets.
10
Temperature adjustment The temperature of the mixed water can be set to the desired value by turning the adjustment screw. Applying the cover, equipped with screws, prevents unauthorised persons tampering with the setting.
By-pass function
Cold water
Hot water
The 602 series thermostatic mixing valve is equipped with a special by-pass mechanism to provide thermal disinfection of each individual tap. After removing the protective cover, turn the screw fully anti-clockwise. In this way, only the incoming hot water will circulate, independently of the thermostat action.
By-pass closed
By-pass open
Application diagram
601 series Anti-scald thermostatic mixing valve for wash-hand basins. Threaded connections 3/8 (and 1/2). Chrome plated brass body. Brass obturator. Stainless steel spring. EPDM seal elements. ABS cover. Medium water. Adjustment range 2550C. Factory set 41C. Accuracy 2C. Maximum working pressure (static) 10 bar; maximum working pressure (dynamic) 5 bar. Maximum inlet temperature 90C. Maximum inlet pressure ratio (H/C or C/H) 5:1. Minimum temperature difference between the inlet hot water and the outlet mixed water to ensure anti-scald performance 10C. Minimum flow rate for a stable operation 4,5 l/min.
602 series Thermostatic mixing valve with by-pass, for wash-hand basins. Threaded connections 3/8 (and 1/2). Chrome plated brass body. Brass obturator. Stainless steel spring. EPDM seal elements. ABS cover. Medium: water. Adjustment range 2550C. Factory set 41C. Accuracy 2C. Maximum working pressure (static) 10 bar; maximum working pressure (dynamic) 5 bar. Maximum inlet temperature 90C. Maximum inlet pressure ratio (H/C or C/H) 5:1. Minimum temperature difference between the inlet hot water and the outlet mixed water to ensure anti-scald performance 10C. Minimum flow rate for a stable operation 4,5 l/min.
CALEFFI
Solar storage-to-boiler connection kit
CALEFFI
264 - 265 series
IS
TERE
UNI EN ISO 9001:2000 Cert. n 0003
01163/08 GB
Function The solar storage-to-boiler connection kits automatically control and optimize the thermal energy contained in a solar water storage, ensuring that domestic hot water is distributed throughout the system at a controlled optimum temperature. The kits come complete with anti-scald thermostatic mixing valve, motorised diverter valve and thermostat with temperature probe for the solar water storage. They ensure that users always receive hot water at the set temperature and switch the boiler on if the temperature of the water coming from the solar storage falls below the set point. The kits are available in two versions, for use with either modulating or non-modulating boilers. These compact kits are designed for quick and easy installation in both new and existing systems. They come complete with a pre-formed shell protective cover. Patent application No. MI2007A000936.
Product range Code 264352 SOLARNOCAL Solar storage-to-boiler connection kit without thermal integration Code 265352 SOLARINCAL Solar storage-to-boiler connection kit with thermal integration size 3/4 size 3/4
Technical specifications Materials Mixing valve Body: Obturator: Springs: Seals: Control knob: Diverter valve Body: Ball: Ball seal: Control stem seal: Union seals: Actuator Protective shell: Colour: Protective cover: Material: Thickness: Density: Working temperature range: Reaction to fire (EN 13501-1): Connections:
dezincification resistant alloy EN 12165 CW602N, chrome plated PSU stainless steel EPDM ABS
Mixing valve Max. working pressure: 10 bar (static); 5 bar (dynamic) Adjustment temperature range: 3555C Factory set: 43C Accuracy: 2C Max. inlet temperature: 100C Max. inlet pressure ratio (H/C or C/H): 2:1 Minimum temperature difference between the inlet hot water and the outlet mixed water to ensure anti-scald performance: 10C Min. flow rate for stable operation: 4 l/min Actuator Three-contact type Electric supply: 230 V (ac) Power consumption: 8 VA Auxiliary microswitch contact rating: 0,8 A (230 V) Protection class: IP 44 (control stem in vertical position) IP 40 (control stem in horizontal position) Operating time: 10 s Ambient temperature range: 055C Dynamic torque: 6 Nm Length of supply cable: 1m Thermostat Electric supply: Power consumption: Adjustable temperature range: Factory set: Box protection class:
brass EN 12165 CW617N, chrome plated brass EN 12164 CW614N, chrome plated PTFE with EPDM O-Ring two EPDM O-Rings non-asbestos fibre
self-extinguishing polycarbonate grey RAL 9002
PVC 7 mm 1,29 kg/dm3 -5110C class B2
RE
230 V (ac) 10 (2+8) VA 3550C 45C IP 65
- inlet and outlet: 3/4 M with union - boiler connection (265 series): 3/4 M
Performance Diverter valve Max. working pressure: Max. differential pressure: Working temperature range:
10 bar 10 bar -5110C
Temperature probe Working range: -25110C Time constant: 1 min Response: 100 k at 25C Two wire cable with 4,5 mm probe L=2m Maximum distance: 10 m with 2 x 0,25 mm2 cable 100 m with 2 x 0,5 mm2 cable
Dimensions
230 V - 5 VA - IP 65
E A G A
230 V - 5 VA - IP 65
A D B
A C D
A B C
Code 264352
A 3/4"
B 90
C 87,5
D 45
E 131
Weight (kg)
2,3
Code A B C D 265352 3/4" 108,5 87,5 66,5
E 50
F 81
G Weight (kg) 45 2,3
High temperature and solar systems In solar thermal systems with natural circulation in the primary circuit and a water storage with heating jacket, the temperature of the domestic water in the storage can vary considerably depending on the degree of solar radiation and can reach very high temperatures over long periods. In summer, and if there is little water usage, the hot water at the storage outlet can actually reach temperatures around 98C before the temperature and pressure safety relief valves are actuated. At these temperatures, the hot water cannot be used directly, because of the danger of scalding for users. Water temperatures over 50C can cause burns very quickly. For example, at 55C, partial burn occurs in about 30 seconds, whereas at 60C partial burn occurs in about 5 seconds. It is therefore necessary to use a thermostatic mixing valve able to: - reduce the temperature of the water distributed throughout the domestic water system to a value lower than that in the storage and suitable for the end user. For reasons of safety, it is recommended to set the temperature of the mixed water distributed to the users to values no higher than 50C; - keep mixed water temperature constant despite variations in inlet temperature and pressure; - continue functioning over time without any loss in performance and without problems due to the continuously high temperature of the incoming water; - enable the high temperature water in the storage to last longer, by distributing it to the user circuit at a reduced temperature; - have an anti-scald safety function in case of failure of the cold water supply.
Exposure time to cause partial burns Temperature 70C 65C 60C 55C 50C Adults 1s 2s 5s 30 s 5 min Children 0-5 years -0,5 s 1s 10 s 2,5 min
Integration with boiler Solar domestic water storages are normally installed in conjunction with boilers or water heaters. In this way, boilers or water heaters can be switched on to produce domestic hot water when solar radiation is insufficient, therefore the thermal energy available within the storage is low. The following actions are necessary to control this type of system automatically and ensure the correct distribution of domestic hot water: - install a motorised diverter valve between the solar water circuit and the boiler or water heater; - install a thermostat with a temperature probe positioned in the solar water circuit, to operate the diverter valve depending on the water temperature; - switch the boiler or water heater on if the temperature of the solar hot water is insufficient; - connect the solar hot water circuit to the boiler or water heater according to the functioning mode of the boiler or water heater, which can be instant modulating, non modulating, or equipped with its own storage.
USER
MODULATING BOILER
NON MODULATING BOILER
264 series SOLARNOCAL

Characteristic components 1) Diverter valve 2) Diverter valve actuator 3) Thermostatic mixing valve 4) Diverter valve control thermostat 5) Solar water storage temperature probe Operating principle A thermostatic anti-scald mixing valve, at the kit inlet, controls the temperature of the water coming from the solar water storage. The thermostat, by means of the probe positioned on the hot water flow from the solar water storage, controls the diverter valve at the kit outlet. Depending on the temperature set, the valve diverts the water towards the user circuit or activates the boiler circuit, without thermal integration. Hydraulic diagram
3
Cold water inlet
1
Inlet from boiler
BOILER
BOILER
COLD
COLD
MIXED
SOLAR
USER OUTLET
SOLAR
USER OUTLET
Inlet from solar storage
User outlet
TSOLAR > 45C
TSOLAR < 45C
265 series SOLARINCAL

Characteristic components 1) Diverter valve 2) Diverter valve actuator 3) Thermostatic mixing valve 4) Diverter valve control thermostat 5) Solar storage temperature probe Operating principle The thermostat, by means of the probe positioned on the hot water flow from the solar water storage, controls the diverter valve at the kit inlet. Depending on the temperature set, the valve diverts the water towards the user circuit or activates the boiler circuit, with thermal integration. A thermostatic anti-scald mixing valve, at the kit outlet, constantly controls the temperature of the water sent to the user.
Hydraulic diagram
Inlet from boiler Outlet to boiler
BOILER
BOILER
2
M M D COLD D COLD
Cold water inlet
MIXED
SOLAR
MIXED
SOLAR
Mixed water outlet
TSOLAR > 45C
TSOLAR < 45C
Construction details Mixing valve High resistance to temperature Internal control components are designed to maintain constant the mixing valve performance with inlet hot water temperatures up to 100C, in continuous operation. Anti-scale materials The materials used in constructing the mixing valve were selected to eliminate seizing due to limescale deposits. All functional parts have been made using a special anti-scale material with low friction coefficient, which ensures over time performance. Anti-scald safety function As a safety measure, in case of failure of the cold water supply, the valve immediately shuts off the flow of the hot water. This prevents dangerous burns. This performance is guaranteed if there is a minimum temperature difference between the inlet hot water and the outlet mixed water of 10C. Also in case of failure of the hot water supply, the valve shuts off the cold water port and thus the outlet mixed water to prevent dangerous thermal shocks.
Actuator Drive transmission A taper coupling allows a constant connection between the valve control stem (A) and the output shaft of the gear actuator (B). This provides automatic compensation for the mechanical slack thanks to the thrust (C) of the fluid pressure on the control stem. Valve-actuator coupling An elastic steel fastener (D) allows the valve to be coupled to the actuator quickly and easily, by a simple clutch operation with automatic locking.
Diverter valve Directions of flow and position indicator Removing the actuator reveals a slot at the top of the control stem on which the shaft of the actuator acts: - this slot allows the valve to be opened and closed manually with a screwdriver; - the slot position allows to understand the flow direction depending on the ball position. This is extremely useful for system commissioning and checking. Two diagrams follow here regarding the two valves types. As visible, the slot position shows the flow direction. 264 series

C A D B B B C
Cam and stop limit microswitches A cam (A) operates the stop limit microswitches (B). This cam, which can move vertically, is supported by a tapered spring (C). This keeps the cam in constant contact with the microswitches and compensates for wear over time.
265 series Auxiliary microswitch The auxiliary microswitch closes at an average valve aperture of 80%.
OPEN CLOSE
Max 0,8 A
Valves are initially delivered with the slot vertical.
Diverter-mixing valve coupling The diverter-mixing valve coupling on the Solarnocal and Solarincal solar storage-to-boiler connection kits allows the mixing valve to rotate through 360 to satisfy all the possible installation needs. The kit comes complete with a special pre-formed protective cover.
Application Solar storage-to-boiler connection kits are generally installed near the boiler, at the outlet from the solar hot water storage, to ensure a constant temperature of the mixed water supplied to the user. Given their flow characteristics, thermostatic mixing valves can be installed to control water temperature both for single user points (e.g. washbasins, bidets, showers) and for multiple users. To ensure that the mixed water is supplied at the set temperature, a minimum flow rate of 4 l/min must be ensured to the mixing valves. Checking the head loss in the kit If the design flow rate is known and taking into account the simultaneous use of sanitary appliances, the head loss produced by the kit can be checked using the diagram. It is necessary to check the available pressure, the head loss in the system downstream of the kit and the residual pressure to be guaranteed to user devices. Installation Before installing the kits, the pipework must be flushed to ensure that no circulating impurities can compromise their operation. It is recommended to install always strainers of adequate performance at the water inlet from the hydraulic network. The kits must be fitted according to the installation diagram provided in the instruction manual or in this brochure. The kits can be installed in any position, vertically or horizontally. They cannot, however, be installed with the actuator of the diverter valve upside down.
Hydraulic characteristics of the 264 series

p (bar) 1,5
Kv (m /h)
3
p (m w.g.) 15 1,1 10
1,0
0,5
7,1
0,3 0,2
3 2
Check valves In systems with thermostatic mixing valves, check valves should be installed to prevent undesired backflow. The kit with mixing valve incorporates check valves on the hot and cold water inlets. Commissioning In view of the special applications for which the thermostatic mixing valve is used, it must be commissioned according to current regulations, by qualified technicians equipped with suitable temperature measurement instruments. We recommend using a digital thermometer for measuring the mixed water temperature. Temperature adjustment The temperature is set to the desired value by means of the control knob on the thermostatic mixing valve.
0,1

p (bar) 1,5
Kv (m3/h)
100
p (m w.g.) 15 1,40 10
1,0
0,5 0,3 0,2
1,55
5 3 2
0,05 0,2 0,5 1 2 5
0,5 10
10
20
50
Valve position indicator The thermostat is equipped with a LED indicating the diverter valve position, showing whether it is connected to the solar circuit or the boiler. The LED is a two colour type: Green: solar circuit active Red: boiler circuit active
0,1
0,05 0,2 0,5 1 2
0,5
10
20
50
Set temperature adjustment / Electrical connections The thermostat is adjusted in the factory to operate at a temperature of 45C, thus diverting the water to the boiler if the temperature falls below this set value. If necessary, the thermostat trip value can be adjusted between 35 and 50C, by turning the trimmer to suit the needs of the system and boiler. In 264 series kit its possible to set the temperature to a value between 50 and 70C, above which the valve is again deviated to the solar water circuit. In this way, the diverter valve only operates when the solar water storage is full of enough thermal energy, avoiding excessive variations in the temperature of the distributed hot water caused by the action of the diverter valve.
264 series Solarnocal

FUS
5x20 315 mA T
28086
FUS
5x20 315 mA T
35
ON
Com.
50
50
OFF
70
ON
35
50
OFF
Com.
Probe
L N L N
Probe
230 V (ac)
Diverter valve
230 V (ac)
Diverter valve
Factory set:
ON: 45C OFF: 60C
Factory set:
ON: 45C OFF: 45C
Application diagrams 264 series Solarnocal
NON MODULATING BOILER
COLD WATER INLET
COLD USER
265 series Solarincal
MODULATING BOILER
MIXED COLD
COLD WATER INLET
28087
TSET (C)
265 series Solarincal

TSET (C)
264 series Solar storage-to-boiler connection kit without thermal integration. Inlet and outlet threaded connections 3/4 M with unions. Medium drinking water. Consisting of: - Mixing valve: dezincification resistant alloy body, chrome plated; PSU obturator; stainless steel springs; EPDM seals; ABS control knob. Maximum working pressure 10 bar (static), 5 bar (dynamic); adjustment temperature range 3555C; factory set 43C; accuracy 2C; maximum inlet temperature 100C; maximum inlet pressures ratio (H/C or C/H) 2:1; minimum temperature difference between the inlet hot water and the outlet mixed water to ensure anti-scald performance 10C; minimum flow rate for a stable operation 4 l/min. - Diverter valve: brass body, chrome plated; brass ball, chrome plated; PTFE ball seal with EPDM O-Ring; double EPDM O-Ring control stem seal; non-asbestos fibre union seal. Maximum working pressure 10 bar; maximum differential pressure 10 bar; working temperature range -5110C. - Actuator with protective shell in self-extinguishing polycarbonate; colour grey RAL 9002. - Three-contact actuator with auxiliary microswitch; electric supply 230 V (ac); power consumption 8 VA; auxiliary microswitch contact rating 0,8 A (230 V); protection class IP 44 with control stem in vertical position, IP 40 with control stem in horizontal position; operating time 10 s; ambient temperature range 055C; dynamic torque 6 Nm; length of electric supply cable 1 m. - PVC pre-formed shell protective cover. Temperature range -5110C. - Thermostat: electric supply 230 V (ac); power consumption 10 (2+8) VA; adjustable temperature range 3550C; factory set 45C; box protection class IP 65. - Temperature probe: working range 0100C; time constant 1 min; response 100 k at 25C; two wire cable with 4,5 mm probe, L = 2 m. 265 series Solar storage-to-boiler connection kit with thermal integration. Inlet and outlet threaded connections 3/4 M with unions, boiler connection 3/4 M. Medium drinking water. Consisting of: - Mixing valve: dezincification resistant alloy body, chrome plated; PSU obturator; stainless steel springs; EPDM seals; ABS control knob. Maximum working pressure 10 bar (static), 5 bar (dynamic); adjustment temperature range 3555C; factory set 43C; accuracy 2C; maximum inlet temperature 100C; maximum inlet pressures ratio (H/C or C/H) 2:1; minimum temperature difference between the inlet hot water and the outlet mixed water to ensure anti-scald performance 10C; minimum flow rate for a stable operation 4 l/min. - Diverter valve: brass body, chrome plated; brass ball, chrome plated; PTFE ball seal with EPDM O-Ring; double EPDM O-Ring control stem seal; non-asbestos fibre union seals. Maximum working pressure 10 bar; maximum differential pressure 10 bar; working temperature range -5110C. - Actuator with protective shell in self-extinguishing polycarbonate; colour grey RAL 9002. - Three-contact actuator with auxiliary microswitch; electric supply 230 V (ac); power consumption 8 VA; auxiliary microswitch contact rating 0,8 A (230 V); protection class IP 44 with control stem in vertical position, IP 40 with control stem in horizontal position; operating time 10 s; ambient temperature range 0-55C; dynamic torque 6 Nm; length of electric supply cable 1 m. - PVC pre-formed shell protective cover. Temperature range -5110C. - Thermostat: electric supply 230 V (ac); power consumption 10 (2+8) VA; adjustable temperature range 3550C; factory set 45C; box protection class IP 65. - Temperature probe: working range 0-100C; time constant 1 min; response 100 k at 25C; two wire cable with 4,5 mm probe, L = 2 m.
CALEFFI
Solar storage-to-boiler thermostatic connection kit

262 - 263 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
BS EN ISO 9001:2000 Cert. n FM 21654
01164/09 GB
Function The solar storage-to-boiler connection kits automatically control and optimise the thermal energy contained in the solar water storage, ensuring that domestic hot water is distributed throughout the system at a controlled optimum temperature. They ensure that users always receive hot water at the set temperature and switch the boiler on if the temperature of the water coming from the solar storage falls below the set point. The kits are available in two versions, to be coupled with various boiler kinds, with storage or istantaneous. Depending on the version, they are supplied complete with thermostatic diverter valve, special thermostatic control device designed to prevent boiler hunting and anti-scald thermostatic mixing valve. These compact kits are designed for quick and easy installation in both new and existing systems. They come complete with a pre-formed shell protective cover. Patent application No. MI2008A001813.
Product range Code 262350 SOLARINCAL-T. Solar thermostatic connection kit to boilers with storage Code 263350 SOLARINCAL-T PLUS. Solar thermostatic connection kit to instantaneous boilers size 3/4 size 3/4
Technical specifications Materials Thermostatic mixing valve Body: - 262 series: - 263 series: Obturator: Springs: Seals: Knob: Performance Thermostatic mixing valve Medium: Max. working pressure:
dezincification resistant alloy EN 12165 CW602N, chrome plated dezincification resistant alloy EN 1982 CB752S, chrome plated PSU stainless steel EPDM ABS
Diverter valve and thermostatic control device Body: - 262 series: brass EN 12165 CW617N, chrome plated - 263 series: dezincification resistant alloy EN 1982 CB752S, chrome plated Obturator: PSU Springs: stainless steel Seals: EPDM Cover: ABS Union seals: non-asbestos fibre Protective cover 262 series Material: Thickness: Density: Working temperature range: Reaction to fire (EN 13501-1): 263 series Material: Thickness: Thermal conductivity: Density: Working temperature range: Reaction to fire (UL 94): Connections: - inlet and outlet: - boiler: PVC 7 mm 1,29 kg/dm3 -5110C class B EPP 15 mm 0,037 W/(mK) at 10C 0,045 kg/dm3 -5120C class HBF 3/4 M with union 3/4 M
drinking water 10 bar (static); 5 bar (dynamic) Max. inlet temperature: 100C Adjustment temperature range: 3555C Factory set: 43C Accuracy: 2C Max. inlet pressure ratio (H/C or C/H): 2:1 Min. temperature difference between inlet hot water and the outlet mixed water to ensure anti-scald performance: 10C Min. flow rate for stable operation: 4 l/min Performance to standards: NF 079 doc. 8, EN 15092, EN 1111, EN 1287 Thermostatic diverter valve Max. working pressure: Max. differential pressure: Max. inlet temperature: Factory set: Accuracy: Thermostatic control device Max. inlet temperature: Factory set: Accuracy:
RE
10 bar 5 bar 100C 45C 2C
85C 30C 2C
Dimensions
A F A F A E A A B C A D A A B A A C A D
Code 262350
A 3/4"
B 66,5
C 108,5
D 40
E 81
F Weight (kg) 42,5 1,75
Code 263350
A 3/4"
B 60
C 60
D 78
E 88,5
F Weight (kg) 45,5 1,85
High temperature and solar systems In solar thermal systems with natural circulation in the primary circuit and a water storage with heating jacket, the temperature of the domestic water in the storage can vary considerably depending on the degree of solar radiation and can reach very high temperatures over long periods. In summer, and if there is little water usage, the hot water at the storage outlet can actually reach temperatures around 98C before the temperature and pressure safety relief valves are actuated. At these temperatures, the hot water cannot be used directly, because of the danger of scalding for users. Water temperatures over 50C can cause burns very quickly. For example, at 55C, partial burn occurs in about 30 seconds, whereas at 60C partial burn occurs in about 5 seconds. It is therefore necessary to use a thermostatic mixing valve able to: - reduce the temperature of the water distributed throughout the domestic water system to a value lower than that in the storage and suitable for the end user. For reasons of safety, it is recommended to set the temperature of the mixed water distributed to the users to values no higher than 50C; - keep mixed water temperature constant despite variations in inlet temperature and pressure; - continue functioning over time without any loss in performance and without problems due to the continuously high temperature of the incoming water; - enable the high temperature water in the storage to last longer, by distributing it to the user circuit at a reduced temperature; - have an anti-scald safety function in case of failure of the cold water supply.
Exposure time to cause partial burns Temperature 70C 65C 60C 55C 50C Adults 1s 2s 5s 30 s 5 min Children 0-5 years 0,5 s 1s 10 s 2,5 min
Integration with boiler Solar domestic water storages are normally installed in conjunction with boilers or water heaters. In this way, boilers or water heaters can be switched on to produce domestic hot water when solar radiation is insufficient, therefore the thermal energy available within the storage is low. The following actions are necessary to control this type of system automatically and ensure the correct distribution of domestic hot water: - install a suitable thermostatic diverter valve between the solar circuit and the boiler or water heater, to divert hot water automatically in accordance with its temperature; - switch the boiler or water heater on if the temperature of the solar hot water is insufficient; - connect the solar hot water circuit to the boiler or water heater according to the functioning mode of the boiler or water heater, which can be instant modulating or equipped with its own storage.
USER
MODULATING BOILER
262 series SOLARINCAL-T

Characteristic components 1) Thermostatic diverter valve 2) Anti-scald thermostatic mixing valve Inlet from boiler Operating principle A thermostatic diverter valve, at the kit inlet, receives hot water coming from the solar water storage. Depending on the temperature set (factory set: 45C), the valve diverts the water automatically and in a proportional manner towards the user circuit or the boiler with storage circuit, with thermal integration. The valve modulates the flow rates to optimise the energy contained in the solar storage and reduce boiler operation times to a minimum. A thermostatic anti-scald mixing valve, at the kit outlet, constantly controls the water temperature sent to the user.
Outlet to boiler
Cold water inlet
Hydraulic diagram
BOILER
BOILER
Mixed water outlet

COLD
D COLD
MIXED
SOLAR
MIXED
SOLAR
TSOLAR > 45C
TSOLAR < 45C
263 series SOLARINCAL-T P L U S

Characteristic components 1) Thermostatic diverter valve 2) Thermostatic control device 3) Anti-scald thermostatic mixing valve Operating principle A thermostatic diverter valve, at the kit inlet, receives hot water coming from the solar water storage. Depending on the temperature set (factory set: 45C), the valve diverts the water automatically and proportionally towards the user circuit or the instantaneous boiler circuit, with thermal integration. The valve modulates the flow rates to optimise the energy contained in the solar storage and reduce boiler operation times to a minimum. A specific thermostatic control device limits the boiler inlet temperature to prevent it being switched on and off too often, which leads to hunting and irregular operation. An anti-scald thermostatic mixing valve, at the kit outlet, constantly controls the water temperature sent to the user.
Outlet to boiler
Inlet from boiler
Cold water inlet
2
Mixed water outlet Inlet from solar storage
Hydraulic diagram
BOILER BOILER
M COLD
D COLD
MIXED
SOLAR
MIXED
SOLAR
TSOLAR > 45C
TSOLAR < 45C
Construction details Operational flexibility The kits are made using a single casting, so as to minimise their overall size and make installation easier. They are supplied complete with components used for control and operation, designed for direct connection to the circuit without sections of piping having to be fitted between the various devices. High resistance to temperature The internal control components of the diverter valve and the mixing valve are designed to maintain constant performance with inlet hot water temperatures up to 100C, in continuous operation. Anti-scale materials The materials used when constructing the kit were selected to eliminate seizing due to limescale deposits. All functional parts have been made using a special anti-scale material with low friction coefficient, which ensures over time performance. Diverter valve The thermostatic diverter valve at the kit inlet features a built-in sensor, which is immersed directly in the flow of hot water coming from the solar storage. Through the action of the thermostat controlling obturator movement, the flow rate is adjusted proportionally and automatically, without the need for external energy sources. This means there is no need for other temperature probes in the circuit and electrical wiring procedures. T > 45C
Diverter valve
Mixing valve
T < 45C
Control device
Anti-scald safety function As a safety measure, in case of failure of the cold water supply, the valve immediately shuts off the flow of the hot water. This prevents dangerous burns. This performance is guaranteed if there is a minimum temperature difference between the inlet hot water and the outlet mixed water of 10C. Also in case of failure of the hot water supply, the valve shuts off the cold water port and thus the outlet mixed water to prevent dangerous thermal shocks.
Thermostatic control device If used in conjunction with instantaneous boilers, the water temperature at the boiler inlet may reach certain values (T>35C) which prevent the boiler from modulating enough the thermal power transferred to the medium. Low flow rates may lead to the boiler being switched on and off too often, with consequent hunting that prevents the boiler from operating efficiently. The thermostatic control device in the 263 series limits the occurrence of this phenomenon, as it keeps the water temperature at the boiler inlet at a constant low value (T=30C) by mixing the solar hot water coming from the diverter valve with the cold water at the inlet. This means the boiler always operates with a suitable thermaldifference between the inlet and the outlet, resulting in optimal management of the energy produced. Thermostatic mixing valve A special anti-scald thermostatic mixing valve offering high thermal performance is positioned at the kit outlet in order to control the temperature and protect the user. The mixing valve keeps the temperature of the hot water at the kit outlet, supplied to the user, at a constant level, even in the event of variations in temperature and pressure at the inlet or flow rate requested.
Thermal transient During transient, following rapid changes in pressure, temperature or flow rate, the outlet mixed water temperature increases with respect to the initial set point and this increase must be of limited duration to guarantee safety. The anti-scald mixing valve always ensures that these conditions are respected.
T(C) 60C 55C
< 0,5 s - max
< 3 s - max
2K Initial temperature Temperature rise Stabilisation period Stable conditions Time (s) 2K
Diverter-mixing valve coupling The diverter-mixing valve coupling on the Solarincal T storage-toboiler thermostatic connection kit allows the mixing valve to rotate through 360 to satisfy all the possible installation needs. The kit comes complete with a special pre-formed protective cover.
Application Solar storage-to-boiler connection kits are generally installed near the boiler, on the pipe of the hot water coming from the solar storage, to ensure a constant temperature of the mixed water supplied to the user. Given their flow rate characteristics, thermostatic kits can be installed to control water temperature both for single user points (e.g. washbasins, bidets, showers) and for multiple users. To ensure that the mixed water is supplied at the set temperature, a minimum flow rate of 4 l/min must be ensured to the kits with thermostatic mixing valves. Checking the head loss in the kit If the design flow rate is known and taking into account the simultaneous use of sanitary appliances, the head loss produced by the kit can be checked using the diagram. It is necessary to check the available pressure, the head loss in the system downstream of the kit and the residual pressure to be guaranteed to user devices. Installation Before installing the kits, the pipework must be flushed to ensure that no circulating impurities can compromise their operation. It is recommended to install always strainers of adequate performance at the water inlet from the hydraulic network. The kits must be fitted according to the installation diagram provided in the instruction manual or in this brochure. The kits can be installed in any position, vertically or horizontally.

p (bar) 1,5 1,0 with Tsol > 45C = 1,3 with Tsol < 45C = 1,2
Kv (m3/h)
Tsol > 45C
Tsol < 45C
p (m w.g.) 15 10
0,5
0,3 0,2
3 2
0,1
0,05 0,2 0,5 1 2
0,5 5
Bracketing The 263 series connection kit is supplied complete with a special wallmounting bracket. This simplifies the installation process and makes connection easier while ensuring a secure support.
10
20
50

p (bar) 1,5 1,0 with Tsol > 45C = 1,2 with Tsol < 45C = 1,1
Kv (m3/h)
Check valves In systems with thermostatic mixing valves, check valves shall be installed to prevent undesired backflow. The kit with mixing valve incorporates check valves on the hot and cold water inlets. Commissioning In view of the special applications for which the thermostatic mixing valve is used, it must be commissioned according to current regulations, by qualified technicians equipped with suitable temperature measurement instruments. We recommend using a digital thermometer for measuring the mixed water temperature. Temperature adjustment The temperature of the mixed water is set to the desired value by means of the control knob on the thermostatic mixing valve.
Tsol > 45C
Tsol < 45C
p (m w.g.) 15 10
0,5
0,3 0,2
3 2
0,1
0,05 0,2 0,5 1 2
0,5
10
20
50
Temperature setpoint adjustment The diverter valve is factory adjusted to operate at a temperature of 45C, diverting water to the boiler if the temperature falls below this setpoint value. The set temperature value is fixed using a locking ring. The 263 series thermostatic control device is factory set and fixed to keep constantly at 30C the temperature of the water at the boiler inlet.
Factory configurations Diverter valve: 45C Thermostatic control device: 30C
Application diagrams 262 series Thermostatic Solarincal - natural circulation solar system Shut-off valve Pressure reducing valve Discharge tundish Check valve T/P safety relief valve Temperature gauge Expansion vessel
T
Thermostat Pump
MIXED COLD
COLD WATER INLET
Safety relief valve
262 series Thermostatic Solarincal - forced circulation solar system
MIXED COLD
COLD WATER INLET
263 series Thermostatic Solarincal-T Plus - natural circulation solar system
MODULATING BOILER
MIXED COLD
COLD WATER INLET
262 series Solar thermostatic connection kit to boilers with storage. Inlet and outlet connections 3/4 M with union. Boiler connections 3/4 M. Medium drinking water. Complete with: - Diverter valve with chrome plated brass body. PSU obturator; stainless steel springs; EPDM seals; ABS cover. Union seals in non-asbestos fibre. Maximum working pressure 10 bar; maximum differential pressure 5 bar; maximum inlet temperature 100C; factory set 45C; accuracy 2C. - Anti-scald thermostatic mixing valve with dezincification resistant alloy body, chrome plated; PSU obturator; stainless steel springs; EPDM seals; ABS control knob. Maximum working pressure (static) 10 bar, 5 bar (dynamic); temperature adjustment range 35-55C; factory set 43C; accuracy 2C. Maximum inlet temperature 100C; maximum ratio between inlet pressures (H/C or C/H) 2:1; minimum temperature differential between hot water inlet and mixed water outlet to ensure anti-scald performance 10C; minimum flow rate for stable operation 4 l/min. Performance to standards: NF 079 doc. 8, EN 15092, EN 1111, EN 1287. Complete with a PVC pre-formed shell protective cover. 263 series Solar thermostatic connection kit to instantaneous boilers. Inlet and outlet connections 3/4 M with union. Boiler connections 3/4 M. Medium drinking water. Complete with: - Diverter valve with dezincification resistant alloy body, chrome plated. PSU obturator; stainless steel springs; EPDM seals; ABS cover. Union seals in non-asbestos fibre. Maximum working pressure 10 bar; maximum differential pressure 5 bar; maximum inlet temperature 100C; factory set 45C. Accuracy 2%. - Thermostatic control device with dezincification resistant alloy body, chrome plated. PSU obturator; stainless steel springs; EPDM seals; ABS cover. Union seals in non-asbestos fibre. Maximum inlet temperature 85C; factory set 30C; accuracy 2C. - Anti-scald thermostatic mixing valve with dezincification-resistant alloy body, chrome plated; PSU obturator; stainless steel springs; EPDM seals; ABS control knob. Maximum working pressure (static) 10 bar, 5 bar (dynamic); temperature adjustment range 35-55C; factory set 43C; accuracy 2C. Maximum inlet temperature 100C; maximum ratio between inlet pressures (H/C or C/H) 2:1; minimum temperature differential between hot water inlet and mixed water outlet to ensure anti-scald performance 10C; minimum flow rate for stable operation 4 l/min. Performance to standards: NF 079 doc. 8, EN 15092, EN 1111, EN 1287. Complete with a EPP pre-formed shell protective cover.
CALEFFI
Adjustable anti-scald thermostatic mixing valve for solar thermal systems

2527 series
IS
CALEFFI
01165/09 GB
TERE
BS EN ISO 9001:2000 Cert. n FM 21654
UNI EN ISO 9001:2000 Cert. n 0003
Function The thermostatic mixing valve is used in solar thermal systems for the production of domestic hot water. It is designed to maintain the set temperature of the mixed water supplied to the user when there are variations in the temperature and pressure conditions of the incoming hot and cold water or in the flow rate. It is also fitted with an anti-scald safety function, which immediately shuts off the hot water flow in case of a failure in the cold water supply at the inlet. This particular series of mixing valves can function continuously at the high temperatures of the incoming hot water from the solar storage tank.
Product range 2527 series Adjustable anti-scald thermostatic mixing valve for solar thermal systems. Complete with strainers and check valves at the inlets
RE
sizes 1/2 and 3/4
Technical specifications Materials Body: Obturator: Springs: Seal components: Control knob:
Dimensions
C B B
dezincification resistant alloy EN 12165 CW602N, chrome plated PSU stainless steel EPDM ABS
D
F A
Performance Adjustment range: 3555C Accuracy: 2C Max. working pressure (static): 10 bar Max. working pressure (dynamic): 5 bar Max. inlet temperature: 100C Max. inlet pressure ratio (H/C or C/H): 2:1 Minimum temperature difference between the inlet hot water and the outlet mixed water to ensure anti-scald performance: 10C Min. flow rate for stable operation: 4 l/min Performance to standards: NF 079 doc. 8, EN 15092 EN 1111, EN 1287 Connections: 1/2 and 3/4 M with union
Code 252714 252713
A 1/2 3/4
B 62,5 67
C 125 134
D E 126,5 81,5 127 82
F Weight (kg) 45 0,58 45 0,81
High temperature solar systems In solar thermal systems with natural circulation in the primary circuit and a water storage with heating jacket, the temperature of the domestic water in the storage can vary considerably depending on the degree of solar radiation and can reach very high temperatures over long periods. In summer, and if there is little water usage, the hot water at the storage outlet can actually reach temperatures around 98C before the temperature and pressure safety relief valves are actuated. At these temperatures, the hot water cannot be used directly, because of the danger of scalding for users. Water temperatures over 50C can cause burns very quickly. For example, at 55C, partial burn occurs in about 30 seconds, whereas at 60C partial burn occurs in about 5 seconds. It is therefore necessary to use a thermostatic mixing valve able to: reduce the temperature of the water distributed throughout the domestic water system to a value lower than that in the storage and suitable for the end user. For reasons of safety, it is recommended to set the temperature of the mixed water distributed to the users to values no higher than 50C; keep mixed water temperature constant despite variations in inlet temperature and pressure. continue functioning over time without any loss in performance and without problems due to the continuously high temperature of the incoming water; enable the high temperature water in the tank to last longer, by distributing it to the user circuit at a reduced temperature. have an anti-scald safety function in case of failure of the cold water supply. Exposure time to cause partial burns Temperature 70C 65C 60C 55C 50C Adults 1s 2s 5s 30 s 5 min Children 0-5 years -0,5 s 1s 10 s 2,5 min
Operating principle The thermostatic mixing valve mixes the hot and cold water at the inlet so as to maintain the mixed water at a constant set temperature at the outlet. A thermostatic element is fully immersed in the mixed water outlet passage. It contracts or expands, moving an obturator which controls the passage of hot or cold water at the inlet. If there are changes in the inlet temperature or pressure, the internal element automatically reacts to restore the set temperature at the outlet.
Code 252713
Construction details High resistance to temperature Internal control components are designed to maintain constant the mixing valve performance with inlet hot water temperatures up to 100C, in continuous operation. Anti-scale materials The materials used in constructing the mixing valve were selected to eliminate seizing due to limescale deposits. All functional parts have been made using a special anti-scale material with low friction coefficient, which ensures over time performance. Anti-scald safety function As a safety measure, in case of failure of the cold water supply, the valve immediately shuts off the flow of the hot water. This prevents dangerous burns. This performance is guaranteed if there is a minimum temperature difference between the inlet hot water and the outlet mixed water of 10C. Also in case of failure of the hot water supply, the valve shuts off the cold water port and thus the outlet mixed water to prevent dangerous thermal shocks.
COLD
Code 252714
MIXED
HOT
p (bar) 1,5 1,0
252714 252713
Commissioning
p (m w.g.) 15 10
0,5 0,3 0,2
5 3
In view of the special applications for which the thermostatic mixing valve is used, it must be commissioned according to current regulations, by qualified technicians equipped with suitable temperature measurement instruments. We recommend using a digital thermometer for measuring the mixed water temperature.
Temperature adjustment
2
0,1
The temperature of the mixed water sent to the user is set at the desired value using the control knob with the graduated scale on the valve.
Code 252714 252713
1/2 3/4
Kv (m3/h) 1,5 1,7
Use In view of their flow characteristics, the 2527 series thermostatic mixing valves can be installed to control the temperature for individual user fittings (for example wash basin, bidet, shower) or multiple user fittings. To ensure stable operation, the mixing valve must be guaranteed a minimum flow rate of 4 l/min. The system must always be sized in accordance with current legislation regarding the nominal flow rate to each user fitting.
Selecting the mixing valve size If the design flow rate is known, taking into account simultaneous use of the sanitary appliances, the size of the mixing valve is chosen by checking on the graph provided the head loss produced. In this case, it is necessary to check the available pressure, the head loss in the system downstream of the mixing valve and the residual pressure to be guaranteed to the user appliances. Thermal transient During transient, following rapid changes in pressure, temperature or flow rate, the outlet mixed water temperature increases with respect to the initial set point and this increase must be of limited duration to guarantee safety. The anti-scald mixing valve always ensures that these conditions are respected.
Installation Before installing the mixing valve, the pipework must be flushed to ensure that no circulating impurities can compromise its operation. It is recommended to install always strainers of adequate performance at the water inlet from the hydraulic network. The 2527 series mixing valve is equipped with strainers at the cold and hot water inlets. The 2527 series thermostatic mixing valve must be fitted according to the installation diagram provided in the instruction manual or in this brochure. The 2527 series thermostatic mixing valve can be installed in any position, vertically or horizontally. The following marks are indicated on the valve body: hot water inlet by the letter H (Hot) cold water inlet by the letter C (Cold) mixed water outlet by the word MIX
Starting temperature Temperature rise Stabilisation period Stable conditions Time (s)
0,05
0,5
0,2
0,5
10
20
50
< 0,5 s - max
< 3 s - max
2K 2K
Check valves In systems with thermostatic mixing valves, check valves should be installed to prevent undesired backflow. The 2527 series thermostatic mixing valve incorporates check valves on the hot and cold water inlets, specific for solar hot water high temperatures.
Application diagrams - System with thermal integration Shut-off valve

T
Pressure reducing valve Discharge tundish Check valve T/P safety relief valve Temperature gauge Expansion vessel
T
Automatic diverter valve

T
Thermostat Pump
Normally closed valve System with thermal integration and recirculation
Safety relief valve
2527 series Adjustable anti-scald thermostatic mixing valve for solar thermal systems. Connections 1/2 (and 3/4) M with union. Dezincification resistant alloy body. Chrome plated. Obturator in PSU. Stainless steel springs. EPDM seal elements. ABS control knob. Maximum inlet temperature 100C. Adjustment range 3555C. Accuracy 2C. Maximum working pressure (static) 10 bar. Maximum working pressure (dynamic) 5 bar. Maximum inlet pressures ratio (H/C or C/H) 2:1. Complete with strainers and check valves at the inlets. Minimum temperature difference between the inlet hot water and the outlet mixed water to ensure anti-scald performance 10C. Minimum flow rate for stable operation 4 l/min. Performance to standards NF 079 doc. 8, EN 15092, EN 1111, EN 1287.
CALEFFI
Compact automatic flow rate regulator with polymer cartridge

127 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
BS EN ISO 9001:2000 Cert. n FM 21654
01166/09 GB
Function The AUTOFLOW devices are automatic flow rate stabilizers capable of maintaining a constant flow rate of the medium as the operating conditions of the hydraulic system change. They are used to automatically balance the hydraulic system, guaranteeing the design flow rate to each terminal. This series of devices is fitted with an interchangeable flow rate regulator, made of high resistance, scale resistant and low noise polymer, for specific use in air-conditioning, hydraulic and domestic water systems. This special AUTOFLOW series is also supplied with a compact, reduced size valve body for easy installation on individual terminals or system zones. Patent application no. MI2004A001549
Product range 127 series Compact automatic flow rate regulator, with polymer cartridge sizes 1/2 and 3/4
Technical specifications Materials Body: Autoflow cartridge: Spring: Seals: Performance Medium: Max. percentage of glycol: Max. working pressure: Working temperature range: p range: Flow rates: Accuracy: Connections:
Dimensions
brass EN 12164 CW614N high resistance polymer stainless steel EPDM
RE
water, glycol solutions 50% 16 bar 0100C 15200 kPa 0,121,6 m3/h 10% 1/2 and 3/4 F Code 127141 127151 A 1/2" 3/4" B 74 74
A C
B C 41 41
Weight (kg) 0,24 0,25
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 terminals 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 comfort and higher energy consumption.
Flow rate
50 %
17
140 %
22 24
180 %

Traditionally, hydraulic circuits are balanced using manual calibration valves. With these static-type devices, such circuits are difficult to balance perfectly 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.
FULL LOAD
Flow rate
Flow rate
100 %
140 %
100 %
Regulating valve
0%
100 %
Manual valve PARTIAL LOAD
120 %

Autoflow balances the hydraulic circuit automatically, by ensuring to each terminal emitter the design flow rate. Even in 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 %
100 %
100%
Regulating valve
0%
100%
100 %
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 side fixed and variable geometry orifices, through which the fluid flows. These orifices are governed by the piston movement, pushed by the medium thrust. A specially calibrated spring counteracts this movement. Autoflows are high performance automatic regulators. They regulate selected flow rates within a very tight tolerance (approx. 10%) and offer a wide range of operation.

In this case, the regulating piston remains in equilibrium without compressing the spring and gives the fluid the maximum free flow area. In practice, the piston acts as a fixed regulator and thus the flow rate through the AUTOFLOW depends solely on the differential pressure.
FLOW RATE
G0
0,15 bar/15 kPa DIFFERENTIAL 2,0 bar/200 kPa PRESSURE Kv0,01 = 0,258 G0 range p 15200 kPa where G0 = nominal flow rate

If the differential pressure is contained within the control range, the piston compresses the spring and gives the medium a free flow area to permit regular flow at the nominal rate for which the AUTOFLOW is set up.
FLOW RATE
Control range Initial p Final p where G0 = nominal flow rate
G0
0,15 bar/15 kPa DIFFERENTIAL 2,0 bar/200 kPa PRESSURE

In this case, the piston fully compresses the spring and leaves only the fixed geometry aperture for the medium to pass through. 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
0,15 bar/15 kPa DIFFERENTIAL 2,0 bar/200 kPa PRESSURE Kv0,01 = 0,070 G0 range p 15200 kPa
Construction details New polymer regulator The flow rate regulator is made entirely of high resistance polymer, specially chosen for use in air-conditioning and hydraulic systems. Its mechanical behaviour is excellent in a wide range of working temperatures, it features high resistance to the abrasion caused by continuous medium flow, it is insensitive to the deposit of scale and is fully compatible with glycols and additives used in circuits. Exclusive design With its exclusive design, the new regulator is able to accurately regulate the flow rate in a wide range of operating pressures. A special internal chamber acts as a damper for beating and vibrations triggered by the medium flow, allowing low noise operating conditions to the device. For these reasons it can be used in systems both on zone branch circuits and directly at the terminals. Cartridge removal The device is easy to remove for inspection or manual replacement of the regulator, by unscrewing the cartridge locking nut from the valve body. Compact valve body with reduced dimensions This special series of devices is also supplied with a compact, simplified valve body for easy fitting on pipes and more costefficient installations.
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 Caleffi Handbooks and the technical report 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
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
Flow rate table

Code Size Minimum working p (kPa) p range (kPa) Flow rates (m3/h)
127141 G G G 127151 G G G
1/2 3/4
15 15
15200 15200
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 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
Minimum differential pressure required Equal to the minimum working p of the AUTOFLOW cartridge (15 kPa). Example AUTOFLOW 127 series size 3/4 with flow rate G0 = 1,200 l/h and p range 15200 kPa: prequired = pAUTOFLOW = 15 kPa Pump head H = pcircuit + prequired
Method of coding for AUTOFLOW 127 series

For proper identification of the device, fill in the form indicating: size, flow rate and p range. 1th Complete code: 2th 3th 4th 5th 6th 7th 8th 9th
1 2 7 1
{
SERIES
{
SIZE
FLOW RATE AND p RANGE 127 AUTOFLOW regulators
SERIES
1th
2th
3th
SIZE
5th
{
Size Digit m3/h 0,35 0,40 0,50 0,60 0,70 digit M35 M40 M50 M60 M70
1/2" 4
3/4" 5
FLOW RATE AND p RANGE 7th
The last three digits indicate the available flow rate values.
8th
9th
m3/h 0,12 0,15 0,20 0,25 0,30
with p range 15200 kPa

digit M12 M15 M20 M25 M30 m3/h 0,80 0,90 1,00 1,20 1,40 digit M80 M90 1M0 1M2 1M4 m3/h 1,60
digit 1M6
Applications of AUTOFLOW (
Installation of AUTOFLOW
In air-conditioning systems, AUTOFLOW devices should preferably be installed on the circuit return pipe. Some typical installation examples are given below.
T.A.
T.A.
T.A.
To guarantee the design flow rates (with open or closed valve) to the various zones of a system.
Applications of AUTOFLOW (
To balance sanitary water distribution circuits.
To create heat exchanger flow balancing by-passes
To control the amount of delivered water and balance the various circuits in irrigation systems.
To limit the hot water flow rate delivered in systems with instantaneous production or limited capacity.
For further details, consult Applications Sheets Nr. 04301, 04302, 04303 and the technical report "Dynamic Balancing of Hydronic Systems".
127 series Compact automatic flow rate regulator, AUTOFLOW. Connections 1/2 (3/4) F x F. Brass body. High resistance polymer cartridge. Stainless steel spring. EPDM seals. Medium water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 16 bar. Working temperature range 0100C. p range 15200 kPa. Range of available flow rates 0,121,6 m3/h. Accuracy 10%.
CALEFFI
Outside compensated temperature regulating unit for heating and cooling

174 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
BS EN ISO 9001:2000 Cert. n FM 21654
01167/09 GB
Function The temperature regulating unit is made for use in radiant panel systems in combination with distribution manifolds. The outside compensated temperature regulating unit, complete with temperature digital regulator for heating and cooling, controls the temperature of the medium sent to the panels, with a compensation depending on the outside and inside temperature and the actual thermal load. In this particular series, the temperature is regulated by a dedicated hydraulic unit equipped with a specific motorised three-way valve. It is supplied with a removable differential by-pass kit for the primary circuit. This accessory is essential when there is a primary circuit circulation pump and the radiator circuits or fan coils are controlled by thermostatic or thermo-electric valves. In case of connection with a SEPCOLL or an hydraulic separator without primary pump, the kit can be removed and the hydraulic unit is connected directly. Patent application No. MI2006A001935. Reference Documentation - Tech. Brochure 01144 Preassembled distribution manifolds for radiant panel systems 668...S1 series
Product range Code 1745.2 Outside compensated temperature regulating unit for heating and cooling, with pump UPS 25-60 Code 1745.4 Outside compensated temperature regulating unit for heating and cooling, with pump UPS 25-80
Technical specifications Materials Regulating unit with motorised three-way valve Body: brass EN 1982 CB753S Headwork: brass EN 12164 CW614N Obturator: stainless steel Seals: EPDM Flow adapter unit Body: Primary circuit by-pass kit Body: By-pass valve: Spring: Shut-off valves Body: Ball: brass EN 1982 CB753S
Performance Medium: Max. percentage of glycol: Control temperature range: Primary inlet temperature range: Max. working pressure: Panel manifold differential by-pass setting: Primary circuit differential by-pass setting: Temperature gauge scale: Pressure gauge scale: brass EN 1982 CB753S POM stainless steel Connections: - primary circuit: - to regulating unit: - panel circuit outlets: - outlet centre distance: water, glycol solutions 30% 290C 5100C 10 bar 25 kPa (2.500 mm w.g.) 10 kPa (1.000 mm w.g.) 080C 010 bar 3/4 M 1 F with nut 3/4 M - 18 mm 50 mm
brass EN 12165 CW617N brass EN 12164 CW614N, chrome plated Panel circuit differential by-pass graph p (mm w.g.)
5000
4500 4000 3500 3000 2500
0,2
0,5
0,1
10
20
2000
RE
p (kPa)
50
45 40 35 30 25
20
Digital controller Three-point type Electric supply: Power consumption: Protection class: Actuator Three-point type Electric supply: Operating time: Power consumption: Auxiliary microswitch contact rating: Protection class: Max. ambient temperature: Protective cover: Flow/return temperature probes NTC type Control range: Two-wire cable Safety thermostat Factory set: Protection class: Contact rating: Pump Three-speed pump: Material: Body: Electric supply: Max. ambient humidity: Max. ambient temperature: Protection class: Pump centre distance: Pump connections: model UPS 25-60/UPS 25-80 cast iron GG 15/20 230 V - 50 Hz 95% 80C IP 44 130 mm 1 1/2 with nut 55C 3C IP 55 10 A/240 V -20100C 230 V - 50 Hz 50 s (rotation 120) 8 VA 0,8 A IP 44 55C self-extinguishing VO 230 V - 50 Hz 5,5 VA IP 40

H (m w.g.)
6
(kPa)
60
H (m w.g.)
8 7 6
(kPa)
80
UPS 25-60
5 4 3 2 1 0 50 40
UPS 25-80
70 60
5 4 3 2
3 2 1
2 1
50 40 30 20 10
30 20 10 0
1 0 0 0,5 1 1,5 2 2,5 3 3,5 4
0,5
1,5
2,5
G (m3/h)
G (m3/h)
Power consumption
Speed I
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (rpm) 1800 1100 700
Speed
(A) 1,04 0,92 0,63
P (W) 245 210 140
n (rpm) 2450 1500 1000
3 2 1
3 2 1
Insulation Material: Thickness: Density: - inner part: - outer part: Thermal conductivity (DIN 52612): closed cells expanded PE-X 15 mm 30 kg/m3 50 kg/m3 0C: 0.038 W/(mK) 40C: 0.045 W/(mK) Coefficient of resistance to the diffusion of water vapour (DIN 52615): >1300 Working temperature range: 0100C Reaction to fire (DIN 4102): class B2
Dimensions
1000
Optimiser
5 outlets
+
9 outlets
13 outlets
Optimiser
Optimiser
CALEFFI
1 2 1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
3 2 1 0
c on
bar
4 5 6
2.5 CL
3 4
L/MIN
30 20 10 0
40
50 60 70
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
80
700
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
30 20 10 0
40
50 60 70
80
115
3/4
270410
60 345 A
50 A A
1200
800
110150
code
Panel outlets A
1745E2 5 695
1745F2 6 745
1745G2 7 795
1745H2 8 845
1745I2 9 915
1745L2 1745L4 10 965
1745M2 1745M4 11 1015
1745N2 1745N4 12 1065
1745O2 1745O4 13 1115
1 7
CALEFFI
Optimiser
11
Optimiser
Flow manifold equipped with flow meters and balacing valves

1 2 3 4
L/MIN
3 2 1 0
c on
f or m
10 4 6 16 2
bar
4 5 6
CL
5
SYSTEM FLOW
CALEFFI
1 2 3 4
L/MIN
1 2 3 4
L/MIN
e n o r m e I SP
ES L
2.5
30 20 10 0
40
50 60 70
CAMERA
SOGGIORNO
WC
80
8 9 15
CALEFFI
30 20 10 0
40
50 60 70
SYSTEM RETURN
CALEFFI
CAMERA
SOGGIORNO
WC
CALEFFI
80
3 14
Optimiser
13
+
12
1 2 3 4 5 6 7 8
Heating and cooling controller Optimiser Three-way mixing valve Three-point actuator Three-speed circulation pump UPS 25-60 Three-speed circulation pump UPS 25-80 Flow temperature probe Return temperature probe Outside temperature probe Flow and return temperature gauges with pockets
9 10 11 12 13 14 15 16
Adjustable drain cock Safety thermostat Pressure gauge Primary circuit shut-off valves Primary circuit differential by-pass kit Remote control and room probe thermostat Max. RH% control probe Interface wire connection
Hydraulic diagram
14
16
SF
11 8 9 10 5 15
Digital controller Optimiser Adjustable drain cock Temperature gauge Temperature probe Humidity % probe
RPT
ST
8 4
RPT ST
Room probe thermostat Safety thermostat Ball shut-off valve Motorised three-way valve Pressure gauge
7 3 2
SR
13
Pump
12
12
Differential by-pass Outside temperature probe Interface wire connection
BF
BR
Operating principle The medium temperature is regulated by a three-way mixing valve with a sector obturator comprehensive of an actuator managed by a specific digital controller. The controller receives the signal from four probes, flow probe on the mixing valve outlet, probe on the panel circuit return, outside probe and room probe. It controls the valve movement. The flow in the valve is regulated by a shaped obturator (1) that, by turning, closes or opens the hot water flow ports (2) and the water returning ports from the circuit (3) to adjust the desired flow temperature. Even if the secondary circuit thermal load or the inlet temperature from the boiler change, the mixing valve automatically adjusts the flow rates until it obtains the optimal flow temperature. SECONDARY FLOW
3
SECONDARY RETURN
2
Construction details Regulating unit body The valve body, containing the thermal regulating device, is made out of a single casting with connections to the primary and secondary circuits. A specific internal channel carries the system return medium to the regulating valve, making it possible for the unit to be smaller in size and easily to connect.
Manual opening By removing the actuator, the valve can be opened-closed manually by using a screwdriver.
Fully closed
Fully open
op
Reduced head losses The three-way mixing valve is equipped with a special obturator acting on calibrated water orifices. This ensures a high flow rate and a reduced size, while maintaining accurate temperature control, with no swinging due to sudden changes in thermal load.
open
se
Electrical connections The actuator is electrically connected through an external plug-socket system with a protective rubber cap. This system does not require opening the lid to connect the cables. In this way, replacing the actuator (should this ever be necessary) is particularly easy to do.
COMMON
Auxiliary microswitch The actuator is equipped with an auxiliary microswitch that can be used to switch on the generator. Mixing valve fully closed: contact OFF. Start opening mixing valve: contact ON.
30 20
40
50 60 70
ACTUATOR
10 0 C
M
2
CLOSE
OPEN
MAX 0,8 A
80
230 V
clo
se
en
clo
Primary circuit differential by-pass kit Operation The differential by-pass kit for the primary circuit enables controlling the flow supplied to the heating or cooling elements connected before the outlet to the panel circuit regulating unit.
p (mm w.g.)
2000
1800 1600 1400 1200
p (kPa)
18 16 14 12
20
1000
900 800 700 600
9 8 7 6
10

2
Primary circuit by-pass kit The by-pass kit permits hydraulic separation between the primary and secondary circuits. This hydraulic separation optimises the operation of the secondary circuit at the panels thus preventing the influence on the secondary circuit by any primary circuit flow rate variation. In this case, the flow rate through the respective circuits depends solely on the pump flow rate characteristics, preventing reciprocal influence due to their coupling in series. Two possible conditions of hydraulic balance are described here. The component is typically sized in order to have the following working rate: G primary = G
secondary
Secondary
Gs
Secondary
Gs
Gp Primary
Gp Primary
0,2
0,5
0,1
10
20
500
Description of controls 1. The LED gives information on the status by means of a multicoloured diode: - flashing green: controller initialisation - fixed green: controller operating - flashing green/red: controller operating with probe error - flashing red: controller verification loop - prolonged red: controller error. 2. The mini-DIN connector, on the front of the panel, makes it possible to view all the parameters managed by the control. A Sub D 9-pole mini-DIN data transmission cable is used for connection to a PC. The cable and specific transmission program are available as optional extras.
Optimiser
CALEFFI
3. The display shows the text in a clear way, giving all the information and menu points. All the values displayed are continuously refreshed. The monitor light switches on automatically when a function is selected. If no other commands are given in 4 minutes, the monitor goes back to the standard page and the light switches off. 4. The Select knob can be turned to the right (+) or left (-) to go to the different menu, function or value editing fields. Press the knob to select any of the menu points. Room temperature management The remote control can be used to change the room temperature, either increasing it or decreasing it in relation to a standard reference value. The change (5 K) is shown in the lines on the display, with increments of 0.5 K in relation to the reference values: comfort heating 20C; set-back correction 18C. Comfort cooling 22C or off. The actual room temperature is shown on the fourth line on the display.
Optimiser
5. Function keys: Esc Info Set Changes the display of the selected menu point and goes back to the previous menu level. + The changed data are not accepted and not recorded. Displays brief information relating to the current menu point. The change that has been made is recorded.
Optimiser
Optimiser
Interface wiring box
Transmission interface
Optimiser
Optimiser
Optimiser
Optimiser
CALEFFI
Optimiser
CALEFFI
Optimiser
Installation of the control on board the controller The control front panel can also be installed on board the controller. In this case, the wiring box and the base containing the room probe are no longer needed; the controller is no longer able to manage this probe.
2
Optimiser
1 3
CALEFFI
Immediate comfort function This makes it possible to change the comfort without changing the controller set parameters. The second line of the display shows the standard correction value - 0 of the characteristic curve. This value can be increased to + 5 or reduced to - 5 by turning the knob to the right or to the left respectively. Each single change corresponds to a 5% shift in the characteristic curve. Example: - flow temperature-heating start-up T = 20C - flow T at outside min. temp. = 40C corresponds to a temperature range T of 20 K (100%). - the adjustment of the correction is +1; this means that the flow temperature is raised by 1 K (5% of T), thus the flow temperature will be 41C. Immediate heating/cooling comfort function The value can be modified by 0,5 K steps instead of 1K. The curve is therefore modified by 2,5% instead of 5%.
Optimiser
Heating terminal board

Electrical connections L Line N Neutral La Mixing valve relay contact a1 Mixing valve opening contact a2 Mixing valve closing contact N Neutral output for mixing valve and pump b0 Pump relay contact b1 Pump contact Probe connections Terminal board X X1 Outside probe X2 Common outside and room probes X3 Room probe X4 Flow probe X5 Common flow and return probes X6 Return probe
L N
La a1 a2 N
b0 b1
230 V~
( (
X1 X2 X3 X4 X5 X6 X7 X8
Heating / cooling terminal board

Electrical connections L Live N Neutral La Mixing valve relay contact a1 Mixing valve opening contact a2 Mixing valve closing contact N Neutral output for mixing valve and pump b0 Pump relay contact b1 Pump contact Lc Heating/cooling circuit relay contact c1 Heating control c2 Cooling control N Heating/cooling circuit neutral output d0 No-potential contact on Chiller activation outlet d1 No-potential contact on Chiller activation inlet
La a1 a2 N b0 b1 Lc c1 c2 N
d0 d1
Probes connection Terminal board Y y1 RH% probe y2 RH% probe y9 Summer-winter function connection for thermostats cod.151003 Terminal board X x1 Outside probe x2 Common outside probe and optional room probe code 151000 x3 Room probe thermostat, optional, code 151000 x4 Flow probe x5 Common flow and return probe x6 Return probe 1 x9 Summer-winter function connection for thermostats cod.151003
230 V~
y1 y2 y3 y4 y5 y6 y7 y8 y9
x1 x2 x3 x4 x5 x6 x7 x8 x9
Probe resistance table C -20 -18 -16 -14 -12 -10 -8 -6 -4 14616 13211 11958 10839 9838 8941 8132 7405 6752 C -2 0 +2 +4 +6 +8 +10 +12 +14 6164 5634 5155 4721 4329 3974 3652 3360 3094 C +16 +18 +20 +22 +24 +26 +28 +30 +32 2852 2632 2431 2247 2079 1925 1785 1657 1539 C +34 +36 +38 +40 +42 +44 +46 +48 +50 1430 1331 1239 1154 1076 1004 938 876 819 C +52 +54 +56 +58 +60 +62 +64 +66 +68 767 718 673 631 592 556 522 491 462 C +70 +72 +74 +76 +78 +80 +82 +84 +86 434 409 386 364 343 324 306 290 274 C +88 +90 +92 +94 +96 +98 +100 260 246 233 221 210 199 189
The remote control base must be positioned horizontally, following the usual installation instructions for a normal room probe thermostat. If this is not possible, the room probe thermostat function must be disabled by positioning a jumper on terminal board X, contact x2=x3. The controller automatically positions on the immediate comfort function.
Controller - remote control connection

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The wires must be connected in the same order as the polarisation.
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Probes connection Dedicated raceway must be used for the connection of the flow, return and outside probes, the room probe thermostat and controller. If the connection cable shares the raceway with other power cables, shielded and earthed cable must be used. Any alteration to the wiring of the controller could result in electrical disturbance. A reset must be done (i.e. switching the controller's power supply off for a few seconds) whenever work is done on the wiring. Maximum distance between remote control and controller: 100 m, with 4-pole cable of 0,5 mm2 section.
A B C D
Relative humidity probe
Relative humidity control When using the cooling regulator, it is necessary to use the specific relative humidity probe. This probe has the task of measuring the limit of relative humidity so as to prevent condensation in the cooling slab. It is set for RH = 8085%. On reaching the setting, it triggers the following operating state: pump ON, mixer closed. Humidity probe control At the start of each cooling season, the operating state of the probe must be checked by placing a moist wad of cotton wool on its surface; this will cause the mixer to close and the red LED point 8 on the panel front to light up. Positioning the humidity probe Depending on the system characteristics, the humidity probe is located where there is the greatest risk of condensation. It is placed with the carbon portion upwards, as shown in the following diagrams.
Top side: carbon
A B C D
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Steps for correctly positioning the max RH% limit probe. The probe is + secured to the manifold installed in the zone where you want to check that the relative humidity RH% cannot exceed the safety values. It is secured by means of the two clamps, using the specific holes. By controlling the following parameters it is possible to reach the maximum heating power delivered by the panel. - Minimum flow temperature, selectable via selector (5) on front panel. - Relative humidity RH% limit point, checked with relative humidity probe. - Ambient temperature, checked via ambient thermostat. - Temperature and relative humidity of the ambient air, checked via fan coil or dehumidifier. Caution: The RH% limit probe is used to prevent any condensation from forming. In rooms where there is cooling, there must always be suitable air treatment.
Commissioning - immediate start

The controller is ready to start operating immediately using the factory configurations, for radiant panel systems
Max. flow T corresponding to outside min. temp.
-25
Heating curve
50
Characteristic Set-back correction curve curve
50
40
40
30
25 % corrective
30
20
20
30
25
20
15
10
-5
-10
-15
-20
Main factory configurations: OT - average = active Compensation RT = 25% Structure gradient = 100 Characteristic curve =1 Mixing valve rotation time = 50 s IP correction value = 20 K max. blocking FT = 55C mOT constant = 100 Slab Drying = not active Set-back correction curve = -25% Rotation correction = 60 s Neutral zone =2K Time programming = see page 14 of the manual Main factory configurations: OT - average = active Compensation RT = off Structure gradient = 100 Characteristic curve = Heat 1 Characteristic curve = Heat/Cool 1-2 Mixing valve rotation time = 50 s IP correction value = 20 K max. blocking FT = Heat 55C max. blocking FT = Heat/Cool 14C mOT constant = 100 Slab drying = not active Set-back correction curve = -25% Rotation correction = 60 s Neutral zone =2K Time programming = see page 14 of the manual
Setting range
Setting range Min. outside T, end of heating
Setting range Min. outside T corresponding to max. flow
Cooling curve
30
Setting range
20
A
10
Passive time band
0 40 30 30 25
A. Factory set Tmin. outside 25C Tmax. outside 35C Tmax. flow 18C 20 Tmin. flow 14C
B. Example Tmin. outside 25C Tmax. outside 40C Tmax. flow 20C Tmin. flow 14C
Setting range
Operating information given on the display

Meaning Meaning
Setting range
Automatic Tmax Off Stand by Comfort Set-back correction
.
> >> #
Meaning Mixing valve opens / or scroll menu up Mixing valve stopped Mixing valve closes / or scroll menu down Mixing valve fully open position Mixing valve fully closed position Measured value Calculated nominal value
On
CAUTION: when this procedure is set, check whether the max. blocking FT needs to be adjusted; the factory set is 55C
Comfort optimisation and set-back correction (manual or with self-learning) The room probe thermostat must be present for this operation. The optimisation makes it possible to bring forward the activation of the change from set-back correction to comfort (in this function the FT is set at the max. design specification), so as to reduce to a minimum the actual time necessary to reach the desired comfort level. This function can operate in three ways: = off; = active; A = self-learning.
Active: Since the time of the bringing forward depends on a number of different system parameters (power, outside and room temperatures, heat exchange, type of structure, etc.), a structure gradient reference coefficient must be set. Some reference values are given below. This funcion is not active in cooling mode Structure gradient reference values - Building with low heat loss: 400 - Factory configuration: 100 - Building with very high heat loss: 50 This funcion is not active in cooling mode. Self-learning: In this case the bringing forward of the activation depends on the controller. The maximum suggested self-learning period is 10 days; before the end of the 10 days it is necessary to go from operating state A = self-learning to the = active operating state. The resulting structure gradient coefficient will be entered automatically at the < constant > operating state menu point. Average outside temperature This function can be enabled when necessary. If enabled, the average outside temperature, known as OT ref., is calculated automatically and recorded every hour. It is used to determine the flow temperature value. The calculation of the average OT ref. makes it possible to attenuate the effect of sudden changes of outside temperature.
Effect of return temperature If the return temperature probe is connected, the controller uses this value as an approximate parameter of the required actual thermal load. The controller calculates the difference between the design return temperature (with an influence between 0 and 50%. Factory configuration: 0%) and the actual measured value. This difference is used to change the flow temperature. For example, if the thermal load is less than the design value, there will be a final T between flow and return that is lower than the design value. In this case the characteristic curve will be lowered. If the actual thermal load is greater, then the characteristic curve will be raised. This funcion is not active in cooling mode. Effect of room probe thermostat If a room probe thermostat is connected, the actual room temperature will be read. The user can set the desired comfort room temperature on the thermostat. In the set-back correction function, this value is automatically reduced by 2 K. During the Manual forcing to Tmax function, the effect of the room probe thermostat on the controller is not active. Depending on the temperature difference between the actual measured value and the set value, the characteristic curve is moved to the right or left.
Work states
Standby In this state, the controller remains inactive, keeping the mixing valve closed and the pump off. The mixing valve and pump frost protection and anti-blocking function remain active. Comfort During the comfort function, the flow temperature is adjusted according to the measured outside temperature, following the set characteristic curve. This curve is automatically corrected if a room probe thermostat or a return probe are present. Set-back correction During the set-back correction function, the nominal flow temperature is lowered, by means of a parallel downward shifting of the characteristic curve. This shifting is settable with a parameter of between 0 and -50%. This funcion is not active in cooling mode. Maximum temperature This function guarantees heating to the maximum set temperature. This value, Tmax, can be set from 25C to 90C.
Standard indication and change of nominal value On the display there is: day of week, date, time, curve correction, work state, room temperature. Example: Remote control
22:41 +0.0K +23.9C
Fri 23. Apr 22:41 Corr. comf. +0 Frost protection T. room -x-C
Control on controller
Operation with programming of time bands 4 programs are available, with a total of 12 configurable setting points (SP). Factory configuration: program 1 (2 setting points); program 2 (5 setting points). All programs are editable. Factory configuration program 1: Setting points identical every day SP point 1 2 Time 06:00 22:00 Action Comfort Set-back correction Active on Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun
Factory configuration, program 2: 5 setting points with different options each day. SP point 1 2 3 4 5 Time 05:00 07:00 09:00 22:00 23:30 Action Set-back correction Comfort Comfort Set-back correction Standby Active on Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun
For a detailed description of the different functions, refer to the commissioning manual.
Application diagram
Pump Variable speed pump Three-way valve Thermostatic valve Lockshield valve
TH
Shut-off valve Clock Thermostat/Humidostat Outside probe

S/W Summer/Winter
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S/W
Optimiser
Optimiser
TH
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1 2 1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
3 2 1
bar
4 5
CL
4
L/MIN
c on
SL fo r m e no r me I SP E
6
2.5
30 20 10 0
40
50 60 70
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
80
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
30 20 10 0
40
50 60 70
80
Code 1745.. Outside compensated temperature regulating unit for heating and cooling. Connections to primary circuit 3/4 M. Connections to regulating unit 1 F with nut. Panel circuit outlet connections 3/4M - 18 mm. Medium: water and glycol solutions; maximum percentage of glycol 30%. Control temperature range 290C. Primary inlet temperature range 5100C. Maximum working pressure 10 bar. Panel manifold differential by-pass setting 25 kPa. Primary circuit differential by-pass setting 10 kPa. Temperature gauge scale 080C. Pressure gauge scale 010 bar. Complete with: flow manifold for panel system with 5 outlets (from 5 to 13) with brass body, flow rate regulating valve with flow meter with a scale of 15 l/min; return manifold for panel system with 5 outlets (from 5 to 13) with brass body, shut-off valve. Regulating unit with motorised three-way valve, three-point actuator, electric supply 230 V - 50 Hz, protection class IP 44. Digital controller, electric supply 230 V - 50 Hz, complete with probes for measuring outside, room, flow and return temperature and relative humidity. Management of controller and room temperature with remote control. Flow adapter unit with brass body. By-pass kit with brass body, POM differential by-pass valve and stainless steel spring. Shut-off valves with brass body and chrome plated brass ball. Safety thermostat: factory setting 55C 3C, protection class IP 55, contact rating 10A/240 V. Three-speed circulation pump UPS 25-60 (and UPS 25-80), protection class IP 44. Pre-formed PE-X shell insulation for primary circuit. Supplied preassembled in painted steel box. Closure with a push-fit clamp. Depth adjustable from 110 to 150 mm, including floor supports adjustable in height from 270 to 410 mm.
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Outside compensated temperature regulating unit for heating and cooling, with distribution kit for primary circuit
174 series
IS
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UNI EN ISO 9001:2000 Cert. n 0003
TERE
BS EN ISO 9001:2000 Cert. n FM 21654
01168/09 GB
Function The temperature regulating unit with the distribution kit for the primary circuit is made to be used in mixed systems: radiant panels and radiators or fancoils, in combination with distribution manifolds for radiant panels. The outside compensated temperature regulating unit, complete with temperature digital regulator for heating and cooling, operates on the temperature of the medium, supplied to the panels, with a compensation depending on the outside and indoor temperature and the actual thermal load. In this particular series, the temperature is regulated by a specific hydraulic unit equipped with a motorised three-way valve. The function of the kit is to distribute a portion of the medium flowing from the primary boiler/chiller circuit to the heating or cooling elements. It is supplied with manifolds with built-in shut-off and balancing valves and a differential by-pass kit for the primary circuit. This accessory is essential when there is a primary circuit circulation pump and the radiator or fan coil circuits are controlled by thermostatic or thermo-electric valves. Patent application No. MI2006A001935. Reference Documentation - Tech. Brochure 01144 Pre-assembled distribution manifolds for radiant panel systems 668...S1 series Product range Code 1745.2 003 Outside compensated temperature regulating unit for heating and cooling with distribution kit for primary circuit, with UPS 25-60 pump Code 1745.4 003 Outside compensated temperature regulating unit for heating and cooling with distribution kit for primary circuit, with UPS 25-80 pump
Performance Medium: Max. percentage of glycol: Control temperature range: Primary inlet temperature range: Max. working pressure: Panel manifold differential by-pass setting: Primary circuit differential by-pass setting: Primary circuit manifold inner diameter: Temperature gauge scale: Pressure gauge scale: Connections: - primary circuit: - to regulating unit: - panel circuit outlets: - outlet centre distance: - primary circuit manifold outlets: - outlet centre distance: brass EN 1982 CB753S brass EN 12164 CW614N EPDM brass EN 1982 CB753S stainless steel EPDM stainless steel ABS Panel circuit differential by-pass graph p (mm w.g.)
5000
4500 4000 3500 3000 2500
RE
water, glycol solutions 30% 290C 5100C 10 bar 25 kPa (2.500 mm w.g.) 10 kPa (1.000 mm w.g.) 27 mm 080C 010 bar 3/4 M 1 F with nut 3/4 M - 18 mm 50 mm 3/4 M - 18 mm 50 mm p (kPa)
50
45 40 35 30 25
Primary circuit distribution manifolds Flow manifold Body: Flow rate regulating valve Obturator: Hydraulic seals: Return manifold Body: Shut-off valve Obturator stem: Obturator and seals: Springs: Control knob:
0,2
0,5
0,1
10
20
2000
20
Digital controller Three-point type Electric supply: Power consumption: Protection class: Actuator Three-point type Electric supply: Operating time: Power consumption: Auxiliary microswitch contact rating: Protection class: Max. ambient temperature: Protective cover: Flow/return temperature probes NTC type Control range: Two-wire cable Safety thermostat Factory set: Protection class: Contact rating: Pump Three-speed pump: Material: Body: Electric supply: Max. ambient humidity: Max. ambient temperature: Protection class: Pump centre distance: Pump connections: model UPS 25-60/UPS 25-80 cast iron GG 15/20 230 V - 50 Hz 95% 80C IP 44 130 mm 1 1/2 with nut 55C 3C IP 55 10 A/240 V -20100C 230 V - 50 Hz 50 s (rotation 120) 8 VA 0,8 A IP 44 55C self-extinguishing VO 230 V - 50 Hz 5,5 VA IP 40

H (m w.g.)
6
(kPa)
60
H (m w.g.)
8 7 6
(kPa)
80
UPS 25-60
5 4 3 2 1 0 50 40
UPS 25-80
70 60
5 4 3 2
3 2 1
2 1
50 40 30 20 10
30 20 10 0
1 0 0 0,5 1 1,5 2 2,5 3 3,5 4
0,5
1,5
2,5
G (m3/h)
G (m3/h)
Power consumption
Speed I
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (rpm) 1800 1100 700
Speed
(A) 1,04 0,92 0,63
P (W) 245 210 140
n (rpm) 2450 1500 1000
3 2 1
3 2 1
Insulation Material: Thickness: Density: - inner part: - outer part: Thermal conductivity (DIN 52612): closed cells expanded PE-X 15 mm 30 kg/m3 50 kg/m3 0C: 0,038 W/(mK) 40C: 0,045 W/(mK) Coefficient of resistance to the diffusion of water vapour (DIN 52615): >1300 Working temperature range: 0100C Reaction to fire (DIN 4102): class B2
Dimensions
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5 outlets
+
8 outlets
12 outlets
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1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
c on
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
code
2 4
2 4
2 4
Radiators outlet Panel outlets A
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Flow manifold equipped with flow meters and balacing valves

1 2
co
n fo r
1 2 3 4
L/MIN
1 2 3 4
L/MIN
m e n or m e IS PE
SL
3 4
L/MIN
SYSTEM FLOW
CALEFFI
CAMERA
SOGGIORNO
WC
CALEFFI
15 16
SYSTEM RETURN
CALEFFI
CAMERA
SOGGIORNO
CALEFFI
WC
14
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BOILER FLOW
17 13
BOILER RETURN
1 2 3 4 5 6 7 8
Heating and cooling controller Optimiser Three-way mixing valve Three-point actuator Three-speed circulation pump UPS 25-60 Three-speed circulation pump UPS 25-80 Flow temperature probe Return temperature probe Outside temperature probe Flow and return temperature gauges with pockets
9 10 11 12 13 14 15 16 17
Adjustable drain cock Safety thermostat Pressure gauge Primary circuit shut-off valves Primary circuit differential by-pass kit Remote control and room probe thermostat Max. RH% control probe Interface wire connection Distribution manifolds with built-in valves for primary circuit
Hydraulic diagram Digital controller Optimiser
14 RPT
SF
11 8 9 10 5 15
Adjustable drain cock Temperature gauge Temperature probe Humidity % probe

RPT
ST
Room probe thermostat Safety thermostat Ball shut-off valve
8 4 7 17 3 2 6
ST
SR
12
BF
17 13
12
Differential by-pass Outside temperature probe Interface wire connection
BR
Operating principle The medium temperature is regulated by a three-way mixing valve with a sector obturator comprehensive of an actuator managed by a specific digital controller. The controller receives the signal from four probes, flow probe on the mixing valve outlet, probe on the panel circuit return, outside probe and room probe. It controls the valve movement. The flow in the valve is regulated by a shaped obturator (1) that, by turning, closes or opens the hot water flow ports (2) and the water returning ports from the circuit (3) to adjust the desired flow temperature. Even if the secondary circuit thermal load or the inlet temperature from the boiler change, the mixing valve automatically adjusts the flow rates until it obtains the optimal flow temperature. SECONDARY FLOW
3
SECONDARY RETURN
2
Construction details Regulating unit body The valve body, containing the thermal regulating device, is made out of a single casting with connections to the primary and secondary circuits. A specific internal channel carries the system return medium to the regulating valve, making it possible for the unit to be smaller in size and easily to connect.
Manual opening By removing the actuator, the valve can be opened-closed manually by using a screwdriver.
Fully closed
Fully open
op
Reduced head losses The three-way mixing valve is equipped with a special obturator acting on calibrated water orifices. This ensures a high flow rate and a reduced size, while maintaining accurate temperature control, with no swinging due to sudden changes in thermal load.
open
se
Electrical connections The actuator is electrically connected through an external plug-socket system with a protective rubber cap. This system does not require opening the lid to connect the cables. In this way, replacing the actuator (should this ever be necessary) is particularly easy to do.
COMMON
Auxiliary microswitch The actuator is equipped with an auxiliary microswitch that can be used to switch on the generator. Mixing valve fully closed: contact OFF. Start opening mixing valve: contact ON.
30
40
50 60 70
ACTUATOR
CLOSE OPEN
20 10 0 C
M
2
MAX 0,8 A
80
230 V
clo
se
en
clo
Distribution and differential by-pass kit for primary circuit Operation The distribution and differential by-pass kit for the primary circuit enables controlling the flow supplied to the heating or cooling elements connected before the outlet to the panel circuit regulating unit. It is composed of distribution manifolds with built-in regulating and shut-off valves and the differential by-pass kit for the primary circuit.
500 450
400 350 300 250 180 160 140 120 80 70 60 45 40 35 30 25 16 14 12 800 700 600
Hydraulic characteristics of the flow rate regulating valve Adjustment position 2 turns 3 turns 4 turns 5 turns F.O. Kv (m3/h) Kv0,01 (l/h) 0,22 1,30 3,20 4,70 5,40 22 130 320 470 540 5 mm
1000 900
p (kPa)
9 8 7 6
10 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
2 1 0,5
10090 50
0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12
p (mm w.g.)
2000
1800 1600 1400 1200
2018 10 0,2 0,5 0,1 1
0,2 0,1
p (kPa)
18 16 14 12
20
10
20
1000
900 800 700 600
9 8 7 6
10
- 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
Secondary
Gs
Secondary
Gs
Gp
Gp
Primary
Primary
0,2
0,5
0,1
Kv 5,40 4,10
Kv0,01 540 410
10
20
500
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Description of controls 1. The LED gives information on the status by means of a multicoloured diode: - flashing green: controller initialisation - fixed green: controller operating - flashing green/red: controller operating with probe error - flashing red: controller verification loop - prolonged red: controller error. 2. The mini-DIN connector, on the front of the panel, makes it possible to view all the parameters managed by the control. A Sub D 9-pole mini-DIN data transmission cable is used for connection to a PC. The cable and specific transmission program are available as optional extras.
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3. The display shows the text in a clear way, giving all the information and menu points. All the values displayed are continuously refreshed. The monitor light switches on automatically when a function is selected. If no other commands are given in 4 minutes, the monitor goes back to the standard page and the light switches off. 4. The Select knob can be turned to the right (+) or left (-) to go to the different menu, function or value editing fields. Press the knob to select any of the menu points. Room temperature management The remote control can be used to change the room temperature, either increasing it or decreasing it in relation to a standard reference value. The change (5 K) is shown in the lines on the display, with increments of 0.5 K in relation to the reference values: comfort heating 20C; set-back correction 18C. Comfort cooling 22C or off. The actual room temperature is shown on the fourth line on the display.
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5. Function keys: Esc Info Set Changes the display of the selected menu point and goes back to the previous menu level. + The changed data are not accepted and not recorded. Displays brief information relating to the current menu point. The change that has been made is recorded.
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Interface wiring box
Transmission interface
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Installation of the control on board the controller The control front panel can also be installed on board the controller. In this case, the wiring box and the base containing the room probe are no longer needed; the controller is no longer able to manage this probe.
2
Optimiser
1 3
CALEFFI
Immediate comfort function This makes it possible to change the comfort without changing the controller set parameters. The second line of the display shows the standard correction value - 0 of the characteristic curve. This value can be increased to + 5 or reduced to - 5 by turning the knob to the right or to the left respectively. Each single change corresponds to a 5% shift in the characteristic curve. Example: - flow temperature-heating start-up T = 20C - flow T at outside min. temp. = 40C corresponds to a temperature range T of 20 K (100%). - the adjustment of the correction is +1; this means that the flow temperature is raised by 1 K (5% of T), thus the flow temperature will be 41C. Immediate heating/cooling comfort function The value can be modified by 0,5 K steps instead of 1K. The curve is therefore modified by 2,5% instead of 5%.
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Heating terminal board

Electrical connections L Live N Neutral La Mixing valve relay contact a1 Mixing valve opening contact a2 Mixing valve closing contact N Neutral output for mixing valve and pump b0 Pump relay contact b1 Pump contact Probe connections Terminal board X X1 Outside probe X2 Common outside and room probes X3 Room probe X4 Flow probe X5 Common flow and return probes X6 Return probe
L N
La a1 a2 N
b0 b1
230 V~
( (
X1 X2 X3 X4 X5 X6 X7 X8
Heating / cooling terminal board

Electrical connections L Live N Neutral La Mixing valve relay contact a1 Mixing valve opening contact a2 Mixing valve closing contact N Neutral output for mixing valve and pump b0 Pump relay contact b1 Pump contact Lc Heating/cooling circuit relay contact c1 Heating control c2 Cooling control N Heating/cooling circuit neutral output d0 No-potential contact on Chiller activation outlet d1 No-potential contact on Chiller activation inlet
La a1 a2 N b0 b1 Lc c1 c2 N
d0 d1
Probes connection Terminal board Y y1 RH% probe y2 RH% probe y9 Summer-winter function connection for thermostats code 151003 Terminal board X x1 Outside probe x2 Common outside probe and optional room probe code 151000 x3 Room probe thermostat, optional, code 151000 x4 Flow probe x5 Common flow and return probe x6 Return probe 1 x9 Summer-winter function connection for thermostats cod.151003
230 V~
y1 y2 y3 y4 y5 y6 y7 y8 y9
x1 x2 x3 x4 x5 x6 x7 x8 x9
Probe resistance table C -20 -18 -16 -14 -12 -10 -8 -6 -4 14616 13211 11958 10839 9838 8941 8132 7405 6752
C -2 0 +2 +4 +6 +8 +10 +12 +14
6164 5634 5155 4721 4329 3974 3652 3360 3094
C +16 +18 +20 +22 +24 +26 +28 +30 +32
2852 2632 2431 2247 2079 1925 1785 1657 1539
C +34 +36 +38 +40 +42 +44 +46 +48 +50
1430 1331 1239 1154 1076 1004 938 876 819
C +52 +54 +56 +58 +60 +62 +64 +66 +68
767 718 673 631 592 556 522 491 462
C +70 +72 +74 +76 +78 +80 +82 +84 +86
434 409 386 364 343 324 306 290 274
C +88 +90 +92 +94 +96 +98 +100
260 246 233 221 210 199 189
The remote control base must be positioned horizontally, following the usual installation instructions for a normal room probe thermostat. If this is not possible, the room probe thermostat function must be disabled by positioning a jumper on terminal board X, contact x2=x3. The controller automatically positions on the immediate comfort function.
Controller - remote control connection

Optimiser
The wires must be connected in the same order as the polarisation.
Optimiser
Optimiser
CALEFFI
Probes connection Dedicated raceway must be used for the connection of the flow, return and outside probes, the room probe thermostat and controller. If the connection cable shares the raceway with other power cables, shielded and earthed cable must be used. Any alteration to the wiring of the controller could result in electrical disturbance. A reset must be done (i.e. switching the controller's power supply off for a few seconds) whenever work is done on the wiring. Maximum distance between remote control and controller: 100 m, with 4-pole cable of 0,5 mm2 section.
A B C D
Relative humidity probe
Relative humidity control When using the cooling regulator, it is necessary to use the specific relative humidity probe. This probe has the task of measuring the limit of relative humidity so as to prevent condensation in the cooling slab. It is set for RH = 8085%. On reaching the setting, it triggers the following operating state: pump ON, mixer closed. Humidity probe control At the start of each cooling season, the operating state of the probe must be checked by placing a moist wad of cotton wool on its surface; this will cause the mixer to close and the red LED point 8 on the panel front to light up. Positioning the humidity probe Depending on the system characteristics, the humidity probe is located where there is the greatest risk of condensation. It is placed with the carbon portion upwards, as shown in the following diagrams.
Top side: carbon
A B C D
Optimiser
Steps for correctly positioning the max RH% limit probe. The probe is + secured to the manifold installed in the zone where you want to check that the relative humidity RH% cannot exceed the safety values. It is secured by means of the two clamps, using the specific holes. By controlling the following parameters it is possible to reach the maximum heating power delivered by the panel. - Minimum flow temperature, selectable via selector (5) on front panel. - Relative humidity RH% limit point, checked with relative humidity probe. - Ambient temperature, checked via ambient thermostat. - Temperature and relative humidity of the ambient air, checked via fan coil or dehumidifier. Caution: The RH% limit probe is used to prevent any condensation from forming. In rooms where there is cooling, there must always be suitable air treatment.
Commissioning - Immediate start

The controller is ready to start operating immediately using the factory configurations, for radiant panel systems
Max. flow T corresponding to outside min. temp.
-25
Heating curve
50
Characteristic Set-back correction curve curve
50
40
40
30
25 % corrective
30
20
20
30
25
20
15
10
-5
-10
-15
-20
Main factory configurations: OT - average = active Compensation RT = 25% Structure gradient = 100 Characteristic curve =1 Mixing valve rotation time = 50 s IP correction value = 20 K max. blocking FT = 55C mOT constant = 100 Slab Drying = not active Set-back correction curve = -25% Rotation correction = 60 s Neutral zone =2K Time programming = see page 14 of the manual Main factory configurations: OT - average = active Compensation RT = off Structure gradient = 100 Characteristic curve = Heat 1 Characteristic curve = Heat/Cool 1-2 Mixing valve rotation time = 50 s IP correction value = 20 K max. blocking FT = Heat 55C max. blocking FT = Heat/Cool 14C mOT constant = 100 Slab drying = not active Set-back correction curve = -25% Rotation correction = 60 s Neutral zone =2K Time programming = see page 14 of the manual
Setting range
Setting range Min. outside T, end of heating
Setting range Min. outside T corresponding to max. flow
Cooling curve
30
Setting range
20
A
10
Passive time band
0 40 30 30 25 20
A. Factory set Tmin. outside 25C Tmax. outside 35C Tmax. flow 18C Tmin. flow 14C
B. Example Tmin. outside 25C Tmax. outside 40C Tmax. flow 20C Tmin. flow 14C
Setting range
Operating information shown on the display
Meaning Automatic Tmax Off Standby Comfort Set-back
Selected value Edited value Probe resistance above working range Probe resistance below working range Value not available
On
> >> #
x
Meaning Off Line choise
Setting range
Meaning Mixing valve opens / or scroll menu up Mixing valve stopped Mixing valve closes/or scroll menu down Mixing valve fully open position Mixing valve fully closed position Measured value Calculated nominal value
CAUTION: when this procedure is set, check whether the max. blocking FT needs to be adjusted; the factory set is 55C
Comfort optimisation and set-back correction (manual or with self-learning) The room probe thermostat must be present for this operation. The optimisation makes it possible to bring forward the activation of the change from set-back correction to comfort (in this function the FT is set at the max. design specification), so as to reduce to a minimum the actual time necessary to reach the desired comfort level. This function can operate in three ways: = off; = active; A = self-learning.
Active: Since the time of the bringing forward depends on a number of different system parameters (power, outside and room temperatures, heat exchange, type of structure, etc.), a structure gradient reference coefficient must be set. Some reference values are given below.
Structure gradient reference values - Building with low heat loss: 400 - Factory configuration: 100 - Building with very high heat loss: 50 This funcion is not active in cooling mode. Self-learning: In this case the bringing forward of the activation depends on the controller. The maximum suggested self-learning period is 10 days; before the end of the 10 days it is necessary to go from operating state A = self-learning to the = active operating state. The resulting structure gradient coefficient will be entered automatically at the < constant > operating state menu point. Average outside temperature This function can be enabled when necessary. If enabled, the average outside temperature, known as OT ref., is calculated automatically and recorded every hour. It is used to determine the flow temperature value. The calculation of the average OT ref. makes it possible to attenuate the effect of sudden changes of outside temperature.
Effect of return temperature If the return temperature probe is connected, the controller uses this value as an approximate parameter of the required actual thermal load. The controller calculates the difference between the design return temperature (with an influence between 0 and 50%. Factory configuration: 0%) and the actual measured value. This difference is used to change the flow temperature. For example, if the thermal load is less than the design value, there will be a final T between flow and return that is lower than the design value. In this case the characteristic curve will be lowered. If the actual thermal load is greater, then the characteristic curve will be raised. This funcion is not active in cooling mode. Effect of room probe thermostat If a room probe thermostat is connected, the actual room temperature will be read. The user can set the desired comfort room temperature on the thermostat. In the set-back correction function, this value is automatically reduced by 2 K. During the Manual forcing to Tmax function, the effect of the room probe thermostat on the controller is not active. Depending on the temperature difference between the actual measured value and the set value, the characteristic curve is moved to the right or left.
Work states
Standby In this state, the controller remains inactive, keeping the mixing valve closed and the pump off. The mixing valve and pump frost protection and anti-blocking function remain active. Comfort During the comfort function, the flow temperature is adjusted according to the measured outside temperature, following the set characteristic curve. This curve is automatically corrected if a room probe thermostat or a return probe are present. Set-back correction During the set-back correction function, the nominal flow temperature is lowered, by means of a parallel downward shifting of the characteristic curve. This shifting is settable with a parameter of between 0 and -50%. This funcion is not active in cooling mode. Maximum temperature This function guarantees heating to the maximum set temperature. This value, Tmax, can be set from 25C to 90C. Standard indication and change of nominal value On the display there is: day of week, date, time, curve correction, work state, room temperature. Example:
Remote control
+23.9C
22:41 +0.0K
Fri 23. Apr 22:41 Corr. comf. +0 Frost protection T. room -x-C
Control on controller
Operation with programming of time bands 4 programs are available, with a total of 12 configurable set points (SP). Factory configuration: program 1 (2 set points); program 2 (5 set points). All programs are editable. Factory configuration program 1: Set points identical every day SP point 1 2 Time 06:00 22:00 Action Comfort Set-back Active on Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun
Factory configuration, program 2: 5 set points with different options each day. SP point 1 2 3 4 5 Time 05:00 07:00 09:00 22:00 23:30 Action Set-back Comfort Comfort Set-back Standby Active on Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun Mon Tues Wed Thurs Fri Sat Sun
For a detailed description of the different functions, please refer to the commissioning manual.
Application diagram
Pump Three-way valve Thermostatic valve

1 2 3 4
L/MIN

1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
Outside probe
RT Room thermostat S/W Summer/Winter
Manual valve
HOBBY BAGNO
SOGGIORNO
WC
Lockshield valve
Optimiser
S/W
Optimiser
Optimiser
TH
RT
CALEFFI
1
3 2
bar
1 2
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
4 5
3 4
L/MIN
0
co
6
2.5
nf o
SL rm e n o r me IS PE
CL
30 20 10 0
40
50 60 70
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
80
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
30 20 10 0
40
50 60 70
80
Code 1745.. 003 Outside compensated temperature regulating unit for heating and cooling, with distribution kit for primary circuit. Connections to primary circuit 3/4 M. Connections to regulating unit 1 F with nut. Panel circuit outlet connections 3/4 M - 18 mm. Primary circuit manifold outlet connections 3/4 M - 18 mm. Medium water and glycol solutions; maximum percentage of glycol 30%. Control temperature range 290C. Primary inlet temperature range 5100C. Maximum working pressure 10 bar. Panel manifold differential by-pass setting 25 kPa. Primary circuit differential by-pass setting 10 kPa. Temperature gauge scale 080C. Pressure gauge scale 010 bar. Complete with: flow manifold for panel system with 5 outlets (from 5 to 12) with brass body, flow rate regulating valve with flow meter with scale of 15 l/min; return manifold for panel system with 5 outlets (from 5 to 12) with brass body, shut-off valve. Regulating unit with motorised three-way valve, three-point actuator, electric supply 230 V - 50 Hz, protection class IP 44. Digital controller, electric supply 230 V - 50 Hz, complete with probes measuring outside, flow and return temperature and relative humidity. Management of controller and room temperature with remote control. Flow adapter unit with brass body. Flow adapter unit with brass primary circuit distribution manifolds with 3 outlets, brass body and flow rate regulating and shut-off valves. By-pass kit with brass body, POM differential by-pass valve and stainless steel spring. Shut-off valves with brass body and chrome-plated brass ball. Safety thermostat: factory setting 55C 3C, protection class IP 55, contact rating 10 A / 240 V. Three-speed circulation pump UPS 25-60 (and UPS 25-80), protection class IP 44. Pre-formed PE-X shell insulation for primary circuit. Supplied preassembled in painted steel panel box. Closure with a push-fit clamp. Depth adjustable from 110 to 150 mm, including floor supports adjustable in height from 270 to 410 mm.
CALEFFI
Mixing valves and actuators
CALEFFI
610 - 611 - 612 - 6370 series
IS
TERE
BS EN ISO 9001:2008 Cert. n FM 21654
UNI EN ISO 9001:2000 Cert. n 0003
01169/09 GB
Function The mixing valves are used in central heating system regulation, by mixing the water flowing out of the boiler with the water returning from the system, in order to obtain the desired flow temperature of the water supplied to the user. They may be motorised and used in conjunction with outside compensated regulators in order to supply hot water to the user depending on the actual thermal load required, thereby adhering to recent energy saving regulations. Reference Documentation - Tech. broch. 01122 - Ins. sheet 18057 - Ins. sheet 18075 Modulating digital controller for heating and cooling - 161 series. Optimiser digital outside compensated regulator for heating - 1520 series. Optimiser digital outside compensated regulator for heating and heating/cooling 1520 series.
Product range 610 610 611 611 612 612 series series series series series series Three-way threaded butterfly mixing valve with manual control Three-way flanged butterfly mixing valve with manual control Four-way threaded butterfly mixing valve with manual control Four-way flanged butterfly mixing valve with manual control Three-way threaded segment mixing valve with manual control Three-way flanged segment mixing valve with manual control sizes 3/42 1/2 F sizes DN 50DN 125 sizes 3/42 1/2 F sizes DN 50DN 125 sizes 3/42 1/2 F sizes DN 50 - DN 125 electric supply 230 V (ac) or 24 V (ac) electric supply 230 V (ac) or 24 V (ac)
Code 63700. Actuator for mixing valves from 3/4 to 1 1/2, with auxiliary microswitch Code 63701. Actuator for mixing valves from 2 to 5, with auxiliary microswitch
Technical specifications Materials Body: Rotor: Cover: Bushing: Lever: Seals: Performance Medium: Max. percentage of glycol: Max. working pressure: Working temperature range: Rotor angle of rotation: Threaded connections: Flanged connections:
cast iron EN 1561/98 EN-GJL-200 cast iron EN 1561/98 EN-GJL-200 aluminium aluminium PA66GF30 EPDM
Actuator 3-contact type Electric supply: - code 637002, 637012: - code 637004, 637014: Power consumption: - code 637002, 637004: - code 637012, 637014: Auxiliary microswitch contact rating: - code 637002, 637004: - code 637012, 637014: Protection class: Operating time: - code 637002, 637004: - code 637012, 637014: Dynamic torque: - code 637002, 637004: - code 637012, 637014: Maximum ambient temperature: Complete with adapter
RE
230 V - 50 Hz 24 V - 50 Hz 3 VA 4,5 VA 10 (2) A - 250 V (ac) 16 (4) A - 250 V (ac) IP 42 60 s 180 s 15 Nm 35 Nm 55C
water, glycol solutions 30% 6 bar 2110C 90
3/42 1/2 F DN 50DN 125, PN 6 to be coupled with counterflanges EN 1092-1
Dimensions
D E E F G E D E F G
C A
Code A 610005 3/4" 610006 1" 610007 1 1/4" 610008 1 1/2" 610009 2" 610020 2 1/2"
B 52 52 52 52 52 66
C 65 65 70 78 75 100
D 130 130 140 156 150 200
E 65 65 70 78 75 100
F 40 40 40 40 40 56
G Weight (kg) 2,8 128 2,8 128 3,1 128 3,6 128 4,6 128 128 8,8
Code A 610050 DN 50 610060 DN 65 610080 DN 80 610100 DN 100 610120 DN 125
C 90 100 115 130 145 D
D 180 200 230 260 290
E 90 100 115 130 145
F 140 160 190 210 240
G 190 210 240 260 290 G F
Weight (kg)
7,1 9,8 13,1 20,2 32
D E E F
Code 611005 611006 611007 611008 611009 611020
B A 65 3/4" 65 1" 1 1/4" 70 1 1/2" 78 75 2" 2 1/2" 100
C 65 65 70 78 75 100
D 130 130 140 156 150 200
E 65 65 70 78 75 100
F 40 40 40 40 40 56
G Weight (kg) 128 2,9 128 3 128 3,3 128 4 128 5,1 158 9,7
Code A 611050 DN 50 611060 DN 65 611080 DN 80 611100 DN 100 611120 DN 125
B 90 100 115 130 145
C 90 100 115 130 145
D 180 200 230 260 290
E 90 100 115 130 145
F 140 160 190 210 240
G 190 210 240 260 290
Weight (kg) 8,3 11,6 16,4 21 28
E D Code A 612005 3/4" 612006 1" 612007 1 1/4" 612008 1 1/2" 612009 2" 612020 2 1/2" B 65 65 70 78 75 100
F G E D E F G D 180 200 230 260 290 E 90 100 115 130 145 F 140 160 190 210 240 B G 190 210 240 260 290
Weight (kg)
D 130 130 140 156 150 200
E 65 65 70 78 75 100
F 40 40 40 40 40 56
G Weight (kg) 128 2,8 128 2,8 128 3,1 128 3,6 128 4,6 158 8,8
Code
B 90 100 115 130 145
612050 DN 50 612060 DN 65 612080 DN 80 612100 DN 100 612120 DN 125 A
8 9,6 13,2 20,3 26
C B
D E B 100 C 125 D 90 E 112 F 61

Weight (kg)
D Code 63701. A 79 B 130 C 83
C D 44 E 162
Weight (kg)
Code 63700.
A 25
0,72
1,3
Operating principle Caleffi 610 and 612 series valves, butterfly and segment type respectively, are three-way devices while Caleffi 611 series are four-way butterfly devices. 610 and 612 series valves may be used as mixing or as diverter valves, while 611 series valves may only be used for mixing purposes. The three-way mixing valve simultaneously controls the medium in the primary circuit and the system return medium. In particular, the two mediums are mixed directly inside the valve. The four-way mixing valve also simultaneously controls the medium in the primary circuit and the system return medium. The two mediums are mixed directly inside the valve body, so as to enable double circulation on both the primary and secondary circuits. In this application, the mixing valve also carries out hydraulic separation between the primary and secondary circuits.
Modifying the inlet position: customised installation 610, 611 and 612 series valves may be used with customised ports: 1) for 610 and 611 series devices, the inlet port for the hot water supplied by the boiler (identified with the label A ) may be swapped with the system return cold water inlet, positioned in line. The mixed water outlet remains the same in both configurations, i.e. positioned at 90 underneath the graduated plate. 2) for 612 series devices, the inlet port for the hot water supplied by the boiler (identified with the label A ) may be swapped with the outlet of the mixed water supplied to the system, positioned in line. The system return cold water inlet remains the same in both configurations, i.e. positioned at 90 on the part opposite the graduated plate. Only in the 612 series is it necessary to access the inside of the valve body, by loosening the four hexagonal screws, and rotate the rotor shaped bushing by 180. Please refer to the instruction sheet for detailed information. When customising the ports, we suggest the A label is removed and the ports identified in accordance with the new scheme, in order to make any future component maintenance procedures easier.
Legend: Boiler flow System flow Boiler return System return A Boiler inlet (mixing valve function) Mixing function Diverter function
Legend: Boiler flow Boiler return

A
System flow System return Customed
Boiler inlet (mixing valve function) Standard
610 series Mixing function
610 series
610 series
610 series
A A
611 series Mixing function

A
611 series Diverter function

A A
611 series
612 series
612 series
612 series
612 series
Installation example: 610 series 3-way butterfly valve - mixing function
Installation example: 612 series 3-way segment valve - mixing function
Hydraulic characteristics 610 series

5000
Construction details p (kPa)

1 11 /4 11 /2 2 -D N5 21 0 /2 DN 65 DN 8 DN 0 10 0
45 40 35 30 25
p (mm w.g.)
4500 4000 3500 3000 2500
50
Operation at high temperatures The materials used for the body and internal parts and the EPDM seals ensure the Caleffi 610, 611 and 612 series mixing valves are suitable for use in heating systems with temperatures of up to 110C. Anti-friction system Inside the valves, between the mixing devices and the body, there is a sleeve in anti-friction material, which absorbs any variations in volume caused by heat-related expansion of the valve parts; it also ensures smooth rotation in all working temperature ranges. Linear characteristics Thanks to the shape of the ports allowing the medium to pass through the sleeve, the system regulation is of linear type. This is the optimal condition for guaranteeing the best possible control of variable thermal loads on the system. Motor-driven option Caleffi 610, 611 and 612 series mixing valves are supplied as manually-controlled devices, but can be motorised through the application of Caleffi actuators 6370 series.
DN 12 5
3/ 4
2000 1800 1000 900 500

800 700 600 450 400 350 300 250 160 140 120 80 70 60 0,35 0,40 0,45 0,6 0,7 0,8 0,9 1,2 1,4 1,6 1,8 1600 1400 1200
18 16 14 12 9 8 7 6
20 10 5
4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2
200 180 10090 50
2 1
0,90 0,80 0,70 0,60 2,5 3,5 4 4,5
0,5
0,3
0,5
6 7 8 9
12 14 16 18
100
G (m3/h)
Kv (m3/h) Kv (m3/h) 3/4 7,5 DN 50 45 2 1/2 1 1 1/4 1 1/2 2 72 11,9 16,8 30 45 DN 65 DN 80 DN100 DN 125 72 140 183 340
200
10
20
30
50
120 140 160 180
25
35 40 45
60 70 80 90
Sizing method To find the most suitable size of Caleffi 610, 611 and 612 series mixing valve, it is necessary to know two parameters: - the flow rate of the medium passing through the mixing valve - the head loss that can be attributed to the valve. Generally, the valve is given a loss value of 515% of the head loss of the user circuit. Example Required flow rate: System piping: Head loss in the user circuit:
611 series
5000
p (mm w.g.)
DN 21 50 /2 DN 65 DN 80 DN 10 0
4500 4000 3500 3000 2500
p (kPa)
45 40 35 30 25
50
DN 12 5
3/ 4 1 11 /4 11 /2
2000 1800 1000 900 500

800 700 600 450 400 350 300 250 160 140 120 80 70 60 0,35 0,40 0,45 0,6 0,7 0,8 0,9 1,2 1,4 1,6 1,8 2,5 1600 1400 1200
2 -
18 16 14 12 8 7 6
20
10 9 5
G = 5 m3/h 2 p = 3000 mm w.g. = 30 kPa 611 series
4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2
200 180 10090 50
2 1
0,90 0,80 0,70 0,60 3,5 4 4,5
The head loss of the mixing valve pV should be between 5% (pVA, point A) and 15% (pVB, point B) of the head loss of the user circuit: pVA = p 0,05 = 150 mm w.g. = 1,5 kPa (point A) pVB = p 0,15 = 450 mm w.g. = 4,5 kPa (point B)
Mixing valve chosen:
0,5
0,3
0,5
6 7 8 9
12 14 16 18
100
G (m3/h)
200
10
20
30
50
120 140 160 180
25
35 40 45
60 70 80 90
Using the hydraulic characteristic diagram for the 611 series valve, we enter an x-coordinate with a value of 5 m3/h and move upwards until points A and B have been identified (at the intersection with the respective head loss values). The line joining points A and B intersects the head loss curve for the 4-way 1 1/2 valve in the 611 series, which should therefore be installed in the system.
In the majority of cases, correct sizing leads to the selection of a valve with a smaller diameter than that of the piping onto which it is installed. Installation Valve installation The 610, 611 and 612 series mixing valves installed with the rotor axis horizontal may be oriented in any position, although avoiding to place the cable guiding slit towards the top. If, on the other hand, they are installed with the rotor axis vertical, the actuator must be positioned above the valve.
612 series
5000
p (mm w.g.)
11 /2 2 -D N5 21 0 /2 DN 65 DN 80 DN 10 0
4500 4000 3500 3000 2500
p (kPa)
45 40 35 30 25
50
DN 12 5
1 11 /4
3/ 4
2000 1800 1000 900 500

800 700 600 450 400 350 300 250 160 140 120 80 70 60 0,35 0,40 0,45 0,6 0,7 0,8 0,9 1,2 1,4 1,6 1,8 1600 1400 1200
18 16 14 12 9 8 7 6
20 10 5
4,5 4 3,5 3 2,5 1,8 1,6 1,4 1,2
200 180 10090 50
2 1
0,90 0,80 0,70 0,60 2,5 3,5 4 4,5
0,5
0,3
0,5
6 7 8 9
12 14 16 18
100
200
10
20
30
50
120 140 160 180
25
35 40 45
60 70 80 90
G (m3/h)
Motorising the valve When fitting 6730 series actuators to the valve, please refer to the instruction sheet for detailed information.
Wiring diagrams Actuator code 637002-637004 (SM50) Actuator code 637012-637014 (SM100) Actuator 1- clockwise rotation (CW) 2- anti-clockwise rotation (ACW) 3- common Auxiliary microswitch (graphical representation at the end of indicated rotation) CW 4- normally open N/O 5- normally closed N/C L 6- common
N
Actuator 1- anti-clockwise rotation (ACW) 2- clockwise rotation (CW) 3- common Auxiliary microswitch (graphical representation at the end of indicated rotation) 4- common 5- normally closed N/C 6- normally open N/O
1 2 3 4 5 6
ACW
L
N
1 2 3 4 5 6
ACW ACW
CW
ACW
Coupling with digital regulators Actuator code 637002 (SM50) with modulating digital regulator for heating and cooling code 161000 Actuator code 637012 (SM100) with modulating digital regulator for heating and cooling code 161000
1 2 3 4 5 6
ACW CW ACW
1 2 3 4 5 6
7 8 9
CW ACW ACW
13 14 15 16 17 18 1 L 2 N 3 4 5 6 SA SR TA TS 7 8 9 10 11 12 1 L Open Close 2 N 3 4 5 6
13 14 15 16 17 18 7 SA SR TA TS 8 9 10 11 12
230 V~ IN OUT
230 V~ IN OUT
Open Close
* When there is a safety thermostat eliminate the jumper

N.B: Check the direction in which the actuator rotates. If necessary, switch actuator terminals 1 and 2.
Actuator code 637002 (SM50) with Optimiser digital outside compensated regulator code 152001
Actuator code 637012 (SM100) with Optimiser digital outside compensated regulator code 152001
230 V~
Electrical connections 1 2 3 4 5 6 L Phase N Neutral ACW ACW CW La Mixing valve relay contact a1 a2 N a1 Mixing valve opening contact a2 Mixing valve closing contact N Neutral output for mixing valve and pump b0 Pump relay contact b1 Pump contact L N La a1 a2 N b0 b1
230 V~
( (
Electrical connections L Phase N Neutral La Mixing valve relay contact a1 Mixing valve opening contact a2 Mixing valve closing contact N Neutral output for mixing valve and pump L N b0 Pump relay contact b1 Pump contact
1 2 3 4 5 6
CW ACW ACW
a1 a2 N
La a1 a2 N b0 b1
( (
X1 X2 X3 X4 X5 X6 X7 X8
X1 X2 X3 X4 X5 X6 X7 X8
N.B: Check the direction in which the actuator rotates. If necessary, switch actuator terminals 1 and 2.
161
Digital regulator for heating and cooling, complete with f/r probes and contact probe holder. Adjustment temperature range: 778C. Electric supply: 230 V - 50 Hz. Protection class: IP 40. Probe connection: 1/8 M. Length of probe cable: 1 m.
Code
1520
Outside compensated regulator complete with flow contact probe and outside probe. Adjustment range: 2090C. Electric supply: 230 V - 50 Hz. Protection class: IP 40.
Code
161000
152001 152002 152003
1 channel 2 channels 3 channels
1520
Digital outside compensated regulator for heating and cooling. Complete with flow probe, outside probe and relative humidity limit probe. Electric supply: 230 V - 50 Hz. Power consumption: 5,5 VA. Protection class: IP 40.
Code
N.B. It is recommended to set the actuator operating time within the regulator parameters (see actuator technical data).
152021
1 channel
Shut-off valve Pump Temperature probe Pressure gauge Temperature gauge
220 - 240 V 50 Hz
230V L N
220 - 240 V 50 Hz
220 - 240 V 50 Hz
Shut-off valve Pump

1 2 3 4
L/MIN
Temperature probe Pressure gauge

1 2 3 4
L/MIN
CALEFFI
CAMERA
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
Temperature gauge
S/W
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
Summer/Winter selector
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
ST
Safety thermostat
1 2 3 4
L/MIN
CALEFFI
CAMERA
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
CALEFFI
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CALEFF
CAMERA
HOBBY
BAGNO
SOGGIORNO
WC
CALEFFI
CALEFFI
CALEFFI
CALEFFI
150052
Trasformatore
V DE
150051
AC 50Hz 230V
Convertitore
AC 24V 50Hz AC 230V 6(2)A T50
150051
Convertitore
AC 24V 50Hz AC 230V 6(2)A T50
24V
24V~ 1 2 3 4 5 6
24V~ 1 2 3 4 5 6
LN
~ ~
ST
S/W
220 - 240 V 50 Hz
610 series Three-way butterfly mixing valve with manual control. Heavy series. Threaded connections 3/4 F (3/42 1/2). Flanged connections DN 50 (DN 50DN 125). Coupling with counterflange EN 1092-1. Cast iron body and rotor. Aluminium cover. PA66GF30 lever. EPDM seals. Medium water, glycol solutions. Maximum percentage of glycol 30%. Working temperature range 2110C. Maximum working pressure 6 bar. Can be motorised. 611 series Four-way butterfly mixing valve with manual control. Heavy series. Threaded connections 3/4 F (3/42 1/2). Flanged connections DN 50 (DN 50DN 125). Coupling with counterflange EN 1092-1. Cast iron body and rotor. Aluminium cover. PA66GF30 lever. EPDM seals. Medium water, glycol solutions. Maximum percentage of glycol 30%. Working temperature range 2110C. Maximum working pressure 6 bar. Can be motorised. 612 series Three-way segment mixing valve with manual control. Heavy series. Threaded connections 3/4 F (3/42 1/2). Flanged connections DN 50 (DN 50DN 125). Coupling with counterflange EN 1092-1. Cast iron body and rotor. Aluminium cover. PA66GF30 lever. EPDM seals. Medium water, glycol solutions. Maximum percentage of glycol 30%. Working temperature range 2110C. Maximum working pressure 6 bar. Can be motorised. 6370 series Actuator for 3/4 (3/45) mixing valves. Three point type regulation. Electric supply 230 V (ac) or 24 V (ac). Power consumption 3 VA (3/41 1/2), 4,5 VA (25). Dynamic torque 15 Nm (3/41 1/2), 35 Nm (25). Operating time 60 s (3/41 1/2), 180 s (25). Protection class IP 42. Maximum ambient temperature 55C. Equipped wth auxiliary microswitch, contact rating 10 (2) A - 250 V (ac) (3/41 1/2), 16 (4) A - 250 V (ac) (25). Code 161000 Modulating digital regulator for heating and cooling. Complete with flow/return probes and contact probe holder. Three-point type. Electric supply 230 V - 50 Hz. Protection class IP 40. Adjustment temperature range 778C. With NTC flow/return probes. Working temperature range -10125C. Time constant 2,5 s. Response 10.000 at 25C. Two-wire cable with 1/8 M connection, length 1 m. 1520 series OPTIMISER digital outside compensated regulator. Electric supply 230 V (ac) 10%, 5060 Hz. Power consumption 5,5 VA. Output signals: 3 relay contacts for code 152001, 6 relay contacts for code 152002, 10 relay contacts for code 152003. Contact rating 250 V (ac), 8(2) A (maximum 9 A in total). Protection class II. Protection class IP 40. Working ambient temperature range 040C. Storage temperature range -2070C. Maximum permissible humidity Class F, in accordance with DIN 40040. Mixing valve rotation time can be set between 10 and 900 s. Data retention with no power supply in indelible EEPROM. RS 232 remote reading system. Clock operating life with no power supply 24 hours. Minimum sp function changeover time 10 minutes. Dimensions: 180 x 130 x 60 mm. Code 152021 OPTIMISER digital outside compensated regulator for heating and heating/cooling. Electric supply 230 V (ac), 10%; 50-60 Hz. Power consumption 5,5 VA. Output signals: 3 relay contacts for heating, 6 relay contacts for heat./cool. Contact rating 250 V (ac), 8(2) A (maximum 9 A in total). Protection class II. Protection class IP 40. Working ambient temperature range 040C. Storage temperature range -2070C. Maximum permissible humidity Class F, in accordance with DIN 40040. Mixing valve rotation time can be set between 10 and 900 s. Data retention with no power supply in indelible EEPROM. Remote reading via RS 232 mini DIN connection. Clock operating life with no power supply 24 hours. Minimum sp function changeover time 10 minutes. Dimensions: 180 x 130 x 60 mm. Code 150050 Relative humidity limit probe. Electric supply 24 V - 50 Hz. RH% limit 8085%. Code 150051 Converter. Electric supply 24 V - 50 Hz. Microswitch contact rating (TRIAC) 1 A (230 V). Maximum ambient temperature 50C. DIN bar clamps. Code 150052 Transformer. Electric supply 230 V - 50 Hz. Power consumption 10,5 VA. Maximum ambient temperature 50C. DIN bar clamps.
CALEFFI
Distribution manifold for heating systems

662 series
D
RE
IS
CALEFFI
T E RE
BS EN ISO 9001:2008 Cert. n FM 21654
UNI EN ISO 9001:2000 Cert. n 0003
01180/09 GB
Function The distribution manifold is used for the control and distribution of thermal medium in heating systems. It features accuracy in controlling the flow rate to the individual circuits, shutting them off, and a reduced size. Furthermore, the reduced head losses allow it to be used as a distribution manifold for several zones, when installed directly in a central heating system. This manifold is supplied complete with special mounting brackets which, during installation, allow the centre distance of the main flow and return connections to be adjusted easily.
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. 01054 Automatic air vent valves 5020 series - Tech. broch. 01141 Automatic flow regulator with highresistance polymer cartridge - Tech. broch. 01041 Automatic flow rate regulator with stainless steel cartridge Product range 662 series Distribution manifold for heating systems size 1
Technical specifications Materials Flow manifold Body: Lockshield valve Headwork: Lockshield stem: Seals: Cap:
Performance Medium: Max. percentage of glycol: brass EN 1982 CB753S brass EN 12164 CW614N brass EN 12164 CW614N EPDM self-extinguishing polycarbonate Max. working pressure: Working temperature range:
Main connections: 1 F Centre distances available for main connections: 196 mm, 175 mm 154 mm, 133 mm and 112 mm Outlets: Centre distance: 3/4 M - 18 50 mm
Lockshield adjustment with 5 mm allen key Return manifold Body: Shut-off valve Headwork: Obturator stem: Obturator: Spring: Seals: Knob: End fitting Air vent: Plug: Brackets and supports: Body: brass EN 1982 CB753S PSU stainless steel EPDM stainless steel EPDM ABS POM brass EN 12165 CW617N
PA6G30
Dimensions
51 196 - 175 - 154 - 133 - 112 29 1 1
3/4
50 A
Code N of outlets Total L (A) Weight (kg)
6626B5 2 165 2
6626C5 3 215 2,4
6626D5 4 265 2,8
6626E5 5 315 3,4
6626F5 6 365 3,8
6626G5 7 425 4,1
6626H5 8 475 4,8
6626I5 9 525 5,5
6626L5 10 575 6
6626M5 11 625 6,9
6626N5 12 675 7,2
6626O5 13 735 7,7
3
1 Flow manifold complete with lockshield valves for flow rate pre-adjustment 2 Return manifold complete with shut-off valves fitted for thermo-electric actuator 3 End fittings complete with manual air vent, double radial end fitting and plugs 4 Pair of mounting brackets for box or wall installation 5 Upper and lower manifold supports for brackets; may be assembled using the quick push-fit system
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 of the lockshield (2), while the O-Ring on the obturator (3) permits full closure of the outlet circuit, if necessary.
Adjustable manifold centre distances
1 2
Each bracket has a series of slots so that the manifold supports can be attached manually. This means that the entire unit can be mounted quickly and that the main centre distances of the manifold (A-A) can be adjusted depending on installation needs.
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.
Low head losses The manifold outlet sections have been specifically designed to generate low head loss. This means the manifold can be used (as illustrated in the diagram) as a distribution device for 2, 3 or 4 independent zones, when installed directly in a central heating system.
2 1 4 5 3 6
A simple numeric example can be used to demonstrate the device efficiency performing this function. Imagine we are using the 662 series manifold with 2 outlets to distribute the medium to other two zone manifolds with 5 outlets each. If we consider an average flow rate value per manifold of 700 l/h, the calculation gives us an average value of around 6 kPa for the zone manifold/valve and lockshield head loss. The calculated value is in line with the head losses for the zone valves used in this type of application.
Thermo-electric actuators can be used to make the various zones operate independently in response to the chrono-thermostats controlling them.
RT
CALEFFI
Modular manifolds The manifolds are modular thanks to the threaded connections with O-Ring seal (1). The threading is designed to create a perfect hydraulic seal and to align the relevant respective outlets correctly when the components are screwed on and fully tightened.
RT
CALEFFI
CALEFFI
Bracket and manifold mounting The manifolds are easily mounted onto the brackets (1) using the modular supports (2) supplied, without the aid of mounting accessories (nuts and wrenches).
2 1
Managing the medium directly in the central heating system simplifies the electrical connection process of the thermo-electric actuators fitted to the manifold for zone control purposes.
Hydraulic characteristics In order to determine the hydraulic characteristics of the circuit, it is necessary to calculate the total head loss suffered by the flow of medium as it passes through the devices forming the manifold assembly and the radiator circuits. From a hydraulic point of view, the system consisting 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/R = Pipe/Radiator
PRet. man.
PSV
PTot.
P PP/ T/V R
PLV
GTot.
GP/ R
PFlow man.
PLV
PTot.
PTot.
PSV
PP/ R
PLV PP/R
PRM
= Total loss at the ends of the manifold (Flow + Return + Pipe/Radiator) = Localised loss of circuit setting lockshield valve (P/R circuit flow rate) = Pipe/Radiator loss (P/R circuit flow rate) = Localised loss P/R circuit shut-off valve (P/R circuit flow rate) = Distributed loss of the flow manifold (total flow rate) = Distributed loss of the return manifold (total flow rate)
PFM
GP/ R
PSV PFM
GTot. GP/ R
GTot.
PRM
GP/ R
PTot. = PLV +PP/R + PSV + PFM + PRM

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 head losses for each specific component of the system, as indicated with the formula (1.1).
(1.1)
1000 900 500 450

400 350 300 250 180 160 140 120 80 70 60 800 700 600
p (mm w.g.)
SV
LV p (kPa)
9 8 7 6
10 5
1000 900 500 450

400 350 300 250 180 160 140 120 80 70 60 800 700 600
p (mm w.g.)
813 outlets
27 outlets
p (kPa)
9 8 7 6
10 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
2 1 0,5
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
2 1 0,5
10090 50
10090 50
45 40 35 30 25 16 14 12
0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12
2018 10 0,2 0,5 0,1 1
0,2 0,1
45 40 35 30 25 16 14 12
0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12
2018 10 0,2 0,5 1 2
0,2 0,1
Lockshield (LV) fully open Shut-off valve (SV)
Kv 5,40 4,10
Kv0,01 540 410
Flow/return manifold 27 outlets Flow/return manifold 813 outlets

* Average value
Kv 16,70* 10,40*
Kv0,01 1670* 1040*
- Kv = flow rate in m3/h for a head loss of 1 bar - Kv0,01 = flow rate in l/h for a head loss of 1 kPa
Example of total head loss calculation Supposing we need to calculate the head loss of a manifold with three outlets with the following characteristics: Total manifold flow rate: 410 l/h The pipes and radiators of the three circuits have the following flow rate and head loss characteristics: Circuit 1 G1 = 80 l/h PRadiator 1 = 1,3 kPa PPipe 1 = 1,7 kPa PP/R1 = 1,7 + 1,3 = 3 kPa P=G2/Kv0,012 G=flow rate in l/h P = head loss 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 highlighted 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 consisting of pipe + radiator. In the case we are examining, the relevant circuit is No. 3. It follows that: PLV3 PP/R3 PSV3 PFM PRM = 2002/5402 = 0,14 kPa = 12,5 kPa = 2002/4102 = 0,24 kPa = 4102/16702 = 0,06 kPa = 4102/16702 = 0,06 kPa Circuit 2 G2 = 130 l/h PRadiator 2 = 3 kPa PPipe 2 = 6,8 kPa PP/R2 = 6,8 + 3 = 9,8 kPa Circuit 3 G3 = 200 l/h PRadiator 3 = 5,3 kPa PPipe 3 = 7,2 kPa PP/R3 = 7,2 + 5,3 = 12,5 kPa
(1.2)
Each segment of the formula (1.1) is calculated using the following relationship:
} Values obtained by neglecting the changes due to tapping off flow rate to the single branched circuits.
PTot.= 0,14 +12,5 + 0,24 + 0,06 + 0,06 13 kPa
Using formula (1.1), adding up all the calculated terms, we obtain:
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 consisting of the pipe, radiator and lockshield valve fully open.
10
20
10
20
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 (design data). the head loss that, for this flow rate, is generated in each circuit: PCircuit = PP/R + PSV the head loss of the most disadvantaged circuit: PCircuit = PLV + PP/R + PSV
+ disadvantaged
(1.3)
(1.4)
In all the circuits the lockshield, for the flow rate GCircuit, must provide an additional head loss 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 head losses open to 80%. Once the data PLV and GCircuit has been established for each circuit, we need to refer to the graph displaying the hydraulic characteristics of the lockshield and choose the optimum adjustment curve to which the valve adjustment position corresponds.
SYSTEM FLOW SV PCircuit
PTot.
most disadvantaged circuit
LV SYSTEM RETURN
PLV
Example of adjustment Suppose we need to balance three circuits with the head loss and flow rate characteristics for the pipe/radiator assembly shown in the example (1.2): Since circuit No. 3 is the most disadvantaged one, because it has the greatest head loss for the pipe/radiator assembly, we need to adjust the remaining circuits: Circuit 3 PP/R3 = 12,5 kPa G3 = 200 l/h PLV3 = 2002/5402 = 0,14 kPa PSV3 = 2002/4102 = 0,24 kPa With the relationship (1.4): Pcircuit 3 = 0,14 + 12,5 + 0,24 13 kPa
most disadvantaged
Circuit 1 PP/R1 = 3 kPa G1 = 80 l/h PSV1 = 802/4102 = 0,04 kPa with the relationship (1.3): PCircuit 1 = 3,0 + 0,04 3 kPa
Circuit 2 PP/R2 = 9,8 kPa G2 = 130 l/h PSV2 = 1302/4102 = 0,1 kPa with the relationship (1.3): PCircuit 2 = 9,8 + 0,1 = 9,9 kPa
P 1 P most P LV1 P 2 P LV2 P 3
disadvantaged circuit
pcircuit
To adjust circuits 1 and 2, the data we need for each one to go and read the lockshield valve adjustment position will be as follows: Circuit 1 PLV1 = 13 - 3 = 10 kPa G1 = 80 l/h No. of adjustment turns = 2 Circuit 2 PLV2 = 13 - 9,9 = 3,1 kPa G2 = 130 l/h No. of adjustment turns 2,5* Circuit 3 Adjustment position fully open * Approximation to the nearest curve on the adjustment graph, due to excess or fault
most disadvantaged
p (mm w.g.)
5000
4500 4000 3500 3000 2500
13 kPa
p (kPa)
45 40
50
5 mm
35 30 25
2000
1800 1600 1400 1200
18 16 14 12 9 8 7
20
1000
900 800 700 600
10
2,5
3,5
FO
6 4,5 4,0 3,5 3,0 2,5
500
450 400 350 300 250
200
180 160 140 120
1,8 1,6 1,4 1,2
100
0,020
10
0,5
20
2,0 Flow rate (l/min) (m3/h)
0,05
0,025
0,030
0,035
0,040
0,045
0,1
0,2
0,5
0,30
1,0
0,08
0,06
0,07
0,09
0,12
0,14
0,16
0,18
0,25
0,35
0,40
0,45
0,6
0,7
0,8
0,9
1,2
1,4
1,6
1,8
Hydraulic characteristics of lockshield valve
p (mm w.g.)
5000
4500 4000 3500 3000 2500
p (kPa)
45 40
50
5 mm
35 30 25
2000
1800 1600 1400 1200
18 16 14 12 9 8 7
20
1000
900 800 700 600
10
2,5
3,5
TA
6 4,5 4,0 3,5 3,0 2,5
500
450 400 350 300 250
200
180 160 140 120
1,8 1,6 1,4 1,2
100
0,020
10
0,5

- Kv = flow rate in m3/h for a head loss of 1 bar
2 0,22 22
2,5 0,60 60
3 1,30 130
3,5 3,20 320
4 4,70 470
20
- Kv0.01 = flow rate in l/h for a head loss of 1 kPa
662 series Distribution manifold for heating systems with 2 (from 2 to 13) outlets. Brass body. EPDM seals. Main threaded connections 1 F. Centre distances available for main connections: 196 mm, 175 mm, 154 mm and 112 mm. Outlet threaded connections 3/4 M - 18, centre distance 50 mm. Medium water and glycol solutions. Maximum percentage of glycol 30%. Maximum working pressure 10 bar. Working temperature range 5100C. Consisting of: - Flow manifold complete with lockshield valves with 5 full pre-adjustment turns. - Return manifold complete with shut-off valves fitted for thermo-electric actuator. - End fittings consisting of double radial connection, manual air vent and plug. - Pair of mounting brackets for box or wall installation. - Upper and lower manifold supports for brackets; may be assembled using the quick push-fit system.
2,0 Flow rate (l/min) (m3/h)

F.O. 5,40 540
0,05
0,025
0,030
0,035
0,040
0,045
0,1
0,2
0,5
0,30
1,0
0,08
0,06
0,07
0,09
0,12
0,14
0,16
0,18
0,25
0,35
0,40
0,45
0,6
0,7
0,8
0,9
1,2
1,4
1,6
1,8
10
15
System return
CALEFFI
16
System flow
14
11
12
13
17
18
1) Flow manifold complete with lockshield valves for flow rate pre-adjustment, 6621 series 2) Return manifold complete with shut-off valves fitted for thermo-electric actuator, 6620 series 3) End fittings complete with manual air vent, double radial end fitting and plug, 5996 series 4) Pair of mounting brackets for box or wall installation, code 658400 5) Upper and lower manifold supports for brackets; may be assembled using the quick push-fit system
6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18)
AUTOFLOW, 121 series Filter, 120 series Thermo-electric actuator, 6561 series Thermo-electric actuator with manual opening and position indicator, 6563 series Drain cock, code 337231 DARCAL fitting, code 6805 . . DARCAL fitting, code 6795 . . Mechanical fitting, code 3475 . . Screw plug, code 386500 Automatic air vent, code 502033 Flexible by-pass kit with fixed setting, code 662000 Drain cock, code 538400 Box, code 659..4 and code 661..5
Fixed set differential by-pass kit with flexible hose, code 662000
Function In heating systems, the medium distribution circuits can be totally or partially shut off by closing the thermo-electric 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 which may generate noise problems, a high medium speed, mechanical erosion and hydraulic unbalancing of the system itself. The differential by-pass kit for 662 series manifolds performs the function of keeping the flow and return pressure in the manifold circuit balanced as the flow rate changes. This special by-pass kit consists of a flexible hose which makes installation easier and allows the manifold to be adapted to suit the brackets, according to the actual positions of the system flow and return piping. Product range Code 662000 Fixed set differential by-pass kit with flexible hose size 3/4 x 3/4 F captive nut
Technical specifications Materials Flexible hose: stainless steel Nuts: brass EN 12165 CW617N, chrome plated Check valve support body:brass EN 12165 CW617N, chrome plated Check valve obturator: POM Spring: stainless steel Hydraulic seals: EPDM Performance Medium: Max. percentage of glycol: Max. working pressure: Working temperature range: Fixed set differential pressure: Hose connections: Check valve support connections: Operating principle The by-pass valve contains a non-return obturator integral with a counter acting spring. When the fixed set pressure value is reached, the valve obturator gradually opens. In this way the flow is recirculated and, being proportional to the closure of the thermo-electric valves, keeps the differential pressure constant in the manifold circuit. Construction details The differential by-pass kit has a fixed set that cannot be changed since it has no accessible adjustment devices. As it is made using woven stainless steel, it remains flexible and is easily fitted to the manifold. The flexibility of the hose also offers the advantage of being able to adjust the position of the flow and return manifolds on the brackets, according to the actual centre distance between the system flow and return piping. water, glycol solutions 30% 10 bar 0100C 20 kPa (2000 mm w.g.) 3/4 x 1/2 F captive nut 1/2 M x 3/4 F
Dimensions
A
CALEFFI
A
Code 662000 A 3/4" B 1/2 C 420 Weight (kg) 0,24

p (mm w.g.) 5000
4500 4000 3500 3000 2500
20 kPa (2000 mm w.g.)

p (kPa)
45 40 35 30 25
50
2000
1800 1600 1400 1200
18 16 14 12
20
120
140 160
180
250
300
350 400 450
600
700
800 900
60
70
80
90
1000
10
Code 662000 Fixed set differential by-pass kit with flexible hose. Connections 3/4 x 3/4 F captive nut. Brass nuts, chrome plated. Stainless steel flexible hose. Brass check valve support body. Stainless steel spring. EPDM hydraulic seals. Medium water and glycol solutions. Maximum percentage of glycol 30%. Maximum working pressure 10 bar. Working temperature range 0100C. Differential pressure fixed set 20 kPa.
G (l/h)
1000
100
200
500
50
By-pass installation To fit the differential by-pass kit on the 662 series manifolds, it is necessary to carry out the following steps: 1) When the system is empty, remove the plugs (A) from the flow and return manifold end fittings. 2) Screw the check valve support (B) (supplied) onto the return manifold end fitting and create a seal using hemp, PTFE tape or another suitable sealant. 3) Fit the flexible hose (C) to the two manifold end fittings using the captive nuts, once the seals (D) (supplied) have been positioned correctly.
CALEFFI
CALEFFI
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Automatic flow rate regulators
121 AUTOFLOW
Combination of automatic flow rate regulator and ball valve. Brass body. AUTOFLOW high-resistance polymer cartridge. Max. working pressure: Temperature range: Max. percentage of glycol: p range: Flow rates: Accuracy: Designed for pressure test port and drain valve connection. Patent application No. MI2004A001549.
Code Kv (m3/h)

broch. 01141
16 bar 0100C 50% 15200 kPa 0,124,5 m3/h 10%
Minimum working p range ? p (kPa) (kPa)
121141 121151 121161 121171
1/2 3/4 1 1 1/4
16,90 17,73 18,00 18,50
15 15 15 15
15200 15200 15200 15200
120 FILTER
Combination of filter and ball valve. Brass body. Stainless steel filter cartridge. Max. working pressure: Temperature range: Max. percentage of glycol: Filter mesh :
broch. 01041
25 bar 0110C 50% 1/21 1/4: 0,87 mm; 1 1/2 and 2: 0,73 mm
Designed for pressure test port and drain valve connection. If there are any insulated pipes, the reversible lever can be replaced with the extended lever.
Code Kv (m3/h)
120141 120151 120161 120171 120181 120191
000 000 000 000 000 000
1/2 3/4 1 1 1/4 1 1/2 2
16,87 17,25 16,65 17,23 39,13 39,69
6561
Thermo-electric actuator. For 662 series manifolds. Normally closed.
Code Voltage (V)
broch. 01042
Technical specifications Materials Protective shell: Colour:
self-extinguishing polycarbonate (code 656102/04) white RAL 9010 (code 656112/14) grey RAL 9002
656102 656104
230 224
6561
Thermo-electric actuator. For 662 series manifolds. Normally closed. With auxiliary microswitch.
Code Voltage (V)
broch. 01042
Power consumption: Auxiliary microswitch contact 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
656112 656114
230 224
Thermo-electric actuators with manual opening and position indicator
6563
Thermo-electric actuator. For 662 series manifolds. Normally closed.
Code Voltage (V)
broch. 01142
Technical specifications Materials Protective shell: Colour:
self-extinguishing polycarbonate (code 656302/04) white RAL 9010 (code 656312/14) grey RAL 9002
656302 656304
230 224
6563
Thermo-electric actuator. For 662 series manifolds. Normally closed. With auxiliary microswitch.
Code Voltage (V)
broch. 01142
Power consumption: Auxiliary microswitch contact rating (code 656312/14): 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 Patent application No. MI2005A000742.
656312 656314
230 224
The 6563 series thermo-electric actuator 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 electric 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 necessarily having to connect and power up the controls. - the knob is left in the manual position at the end of the tests. In this case the control automatically reverts to automatic operation when the system is electrically put into operation.
Manifolds
662
Pair of manifolds complete with shut-off and lockshield valves for flow rate pre-adjustment. Max. working pressure: 10 bar. Temperature range: 5100C. Outlet centre distance: 50 mm.
6621
Flow manifold complete with lockshield valves for flow rate pre-adjustment. Max. working pressure: 10 bar. Temperature range: 5100C. Outlet centre distance: 50 mm.
Code Connection No. of outlets Outlets
Code
No. of Connection outlets
Outlets
662625 662635 662645 662655 662665
1 1 1 1 1
x x x x x
2 3 4 5 6
3/4 3/4 3/4 3/4 3/4
M M M M M
662125 662135 662145 662155 662165
1 1 1 1 1
x x x x x
2 3 4 5 6
3/4 3/4 3/4 3/4 3/4
M M M M M
6620
Return manifold complete with shut-off valves, fitted for thermo-electric actuator. Max. working pressure: 10 bar. Temperature range: 5100C. Outlet centre distance: 50 mm.
Materials Flow manifold Body: Lockshield valve Headwork: Lockshield stem: Seals: Cap:
brass EN 1982 CB753S brass EN 12164 CW614N brass EN 12164 CW614N EPDM self-extinguishing polycarbonate
Lockshield adjustment with 5 mm allen key Return manifold Body: Shut-off valve Headwork: Obturator stem: Obturator: Spring: Seals: Knob: Performance Max. working pressure: Working temperature range: Main connections: Outlets: Centre distance: brass EN 1982 CB753S PSU stainless steel EPDM stainless steel EPDM ABS 10 bar 5100C 1 F 3/4 M - 18 50 mm
Code
No. of Connection outlets
Outlets
662025 662035 662045 662055 662065
1 1 1 1 1
x x x x x
2 3 4 5 6
3/4 3/4 3/4 3/4 3/4
M M M M M
Drain cock
Air vents
5020 538
Drain cock with hose connection and cap. Max. working pressure: 10 bar. Max. working temperature: 110C. Automatic air vent in stamped brass. With hygroscopic safety cap. Max. working pressure: 10 bar. Max. drain pressure: 2,5 bar. Max. working temperature: 120C.
Code
Code
538400 Brackets
1/2 M
502033
3/8 M
658
Polymer mounting brackets with adjustable centre distance, for 662 series manifolds. With screws and fixings. For use with boxes 659..4 series or direct wall mounting.
Code Code
337
Drain cock with metal seal. Adjustable outlet. PTFE seal on thread. Max. working pressure: 10 bar. Max. working temperature: 100C.
658400
337231
3/8 M
End fitting
386
3/4 3/8
5996
End fitting with manual air vent, and plug. Max. working pressure: 10 bar. Temperature range: 5100C. Main connection: 1 F. Lower connection: 3/4 M. Upper air vent connection: 3/8 F. Lower cap connection: 1/2 F. Double radial end fitting.
1
Code
386500
3/4
679
Fitting for multilayer plastic pipes for continuous high temperature use. Max. working pressure: 10 bar. Temperature range: 095C. Chrome plated. For a correct use calibrate the multi layer pipe before installation using the Caleffi 679 series calibrator.
Code
1/2 3/4
Code
599662 Fittings
1 F
680
Fitting with self-adjustable diameter for single and multilayer plastic pipes. Max. working pressure: 10 bar. Temperature range: 580C (PE-X) 575C (Multilayer marked 95C). Patented.
Code inside outside
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
Calibrator and handle to calibrate multilayer pipes before use with fittings 679 series fittings.
680507 680502 680503 680500 680501 680506 680515 680517 680524 680526 680535 680537 680544 680546 680555 680556 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 3/4 3/4
17,518,0 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 15,515,5 15,516 17
10,512 12,514 12,514 14,516 12,514 14,516 14,516 16,518 14,516 16,518 16,518 18,520 16,518 18,520 18,520 18,520 18,520 22,50
Code
679001 679002 679003 679004 679006 679007 679008 679009
Calibrator 14x2 Calibrator 16x2 Calibrator 16x2,25 Calibrator 18x2 Calibrator 20x2 Calibrator 20x2,25 Calibrator 20x2,5 Burnished effect handle for calibrator
Calibration of the multi-layer pipe and assembly of the fitting components, 679 series
347
Compression fitting for annealed copper, hard copper, brass, mild steel and stainless steel pipes. With O-Ring seal. Max. working pressure: 10 bar. Temperature range: -25120C.
Pipe Pipe clamp Nut Hose connection
Code
Valve or manifold connection
347510 347512 347514 347515 347516 347518
3/4 3/4 3/4 3/4 3/4 3/4
10 12 14 15 16 18
Choice of box size, 659 and 661 series, according to the number of outlets
L total
218,5
Code 6626B5 6626C5 No. of outlets 2 3 Length (total) of manifold (mm) 190 240 Length of box (mm) 400 400 Box code, 659 series 659044 659044 Box code, 661 series 661045 661045 Boxes
6626D5 4 290 400 659044 661045
6626E5 5 340 600 659064 661065
6626F5 6 390 600 659064 661065
6626G5 7 450 600 659064 661065
6626H5 8 500 600 659064 661065
6626I5 9 550 800 659084 661085
6626L5 10 600 800 659084 661085
6626M5 11 650 800 659084 661085
6626N5 12 700 800 659084 661085
6626O5 13 760 1000 659104 661105
659
Box for manifolds. Wall or floor installation (with 660 series). Closure with a push-fit clamp. Made of painted steel. Adjustable depth from 110 to 140 mm.
Code (h x w x d) Code (h x w x d)
659
Box for manifolds. Closure with a push-fit clamp. Made of painted steel. Adjustable depth from 80 to 120 mm.
659044 659064 659084 659104 659124
500 500 500 500 500
x x x x x
1400 1600 1800 1000 1200
x x x x x
110140 110140 110140 110140 110140
659045 659065 659085 659105 659125
500 500 500 500 500
x x x x x
1400 1600 1800 1000 1200
x x x x x
80120 80120 80120 80120 80120
660
Floor installation KIT for box, for 659..4 series. Consists of: - 2 supports - height 20 cm, - 2 side panels, - 1 pipe-bending bar.
661
Box for manifolds. Closure with a push-fit clamp. Made of painted steel. Adjustable depth from 110 to 150 mm. Complete with floor installation supports. Adjustable height from 270 to 410 mm.
Code (h x w x d)
Code
660040 660060 660080 660100 660120
for for for for for
659044 659064 659084 659104 659124
661045 661065 661085 661105 661125
500 500 500 500 500
x x x x x
1400 1600 1800 1000 1200
x x x x x
110150 110150 110150 110150 110150
Application diagrams Independent radiator system with wall-mounted boiler and direct distribution
Shut-off valve Ball shut-off valve Manual valve Pump

RT
Room thermostat Differential by-pass valve Zone valve Thermostatic valve
RT
CALEFFI
RT
AUTOFLOW
Zone heating system and differential by-pass valve
RT
CALEFFI
RT
CALEFFI
CALEFFI
Anti-freeze safety device Garden tap, ball-type, with anti-freeze safety device
603 series
IS
CALEFFI
T E RE
BS EN ISO 9001:2008 Cert. n FM 21654
UNI EN ISO 9001:2000 Cert. n 0003
01181/09 GB
Function The anti-freeze safety device prevents ice build-up in domestic water circuits, avoiding possible damage to water storages and pipes in hydraulic, solar and irrigation systems. When the minimum ambient operating temperature is reached, it automatically opens so that a minimum quantity of water may flow toward the drain, enabling a small continuous inflow of water; this prevents water from freezing inside the pipe. When the ambient temperature increases or in the event of contact with warmer water, the opposite action occurs, causing the device to shut off and circuit normal operating conditions to be restored. A particular product has been developed by combining the freeze protection device with a garden tap, ball-type, specifically constructed for these installations. Patent application No. MI2009U000006
Product range Code 603041 Anti-freeze safety device Code 603450 Garden tap, ball-type, with anti-freeze safety device 1/2 F nut 1/2 M x 3/4 M with hose connection
Technical specifications Materials Garden tap Body: Ball: Ball control stem: Seal elements: Control lever: Lever fixing nut: Anti-freeze device Body: Obturator stem: Seal seat: Springs: Seal elements: Strainers: Performance Medium: water Max. working pressure: 10 bar Ambient temperature range: -3090C Opening temperature: 3C Closing temperature: 4C Accuracy: 1C Connections: - anti-freeze device (603041): 1/2 F with nut - garden tap (603450): 1/2 M x 3/4 M with hose connection for 15 mm pipe brass EN 12165 CW617N, chrome plated brass EN 12164 CW614N, chrome plated brass EN 12164 CW614N, chrome plated EPDM stainless steel stainless steel
Dimensions
C
brass EN 12165 CW617N, chrome plated brass UNI EN 12164 CW614N stainless steel stainless steel NBR stainless steel
Code A 603450 1/2
RE
Code 603041
A 1/2
D
B 52,5
C 26
E
Weight (kg)
0,120
B 63
C 47
D 66
E 100
F 3/4
Weight (kg)
0,450
Operating principle A thermostatic element (1) in contact with the ambient air controls a shut-off obturator fitted to a passage seat in contact with the water contained in the pipe (2). When the ambient temperature drops to the minimum intervention value, the thermostat contracts. This causes the obturator to move and open a tiny passage so that water can drain out, allowing a small amount of water to flow in continuously; this prevents water from freezing inside the pipe. Water from the supply network, which is usually warmer than the air temperature up to the intervention value, laps the thermostat and causes the opposite action: the channel closes again and normal circuit operating conditions are restored. For optimal system operation without the risk of freezing, it is recommended that the part of the circuit in which the safety device is installed is connected to the water supply network and a suitable pressure level maintained.
ANTI-FREEZE SAFETY DEVICE CLOSED
ANTI-FREEZE SAFETY DEVICE OPEN
Volume of water drained While the anti-freeze device is in operation, the drain outlet will drip as a result of the cyclical opening and closing phases taking place correctly. The amount of water drained out varies in accordance with the outdoor temperature, the temperature of the water in the pipe and the length of piping exposed to the air. As a general guide, in the worst case conditions, the amount of water drained out is less than 500 cm3/h.
Construction details The valve is fitted with a ball featuring blow-out proof design, double O-ring seal and packing gland; the control lever and fixing nut are made of stainless steel, for total resistance against corrosion in different climatic conditions. The tap is fitted with a special hooking system so that a bucket or water container can be hung easily on it while being filled.
The anti-freeze safety device drain seat is made using stainless steel, so as to guarantee a perfect water tightness without any corrosion problems caused by contact with drained water. The drain zone is also protected by a metal mesh outside the body, to prevent dirt from entering and causing the device to malfunction.
The outlet thread on the tap is designed to allow direct coupling with hose connections and the normal accessories used in conjunction with garden hoses, for easier and more straightforward operation.
Installation Before installing the device, make sure that the system has been flushed and cleaned to remove any traces of dirt that may have accumulated during installation. The device must only be installed in vertical position, as shown in the diagram, so as to permit a free and unrestricted downward flow of the water as it drains out. The device must be installed in the points of the circuit at risk of freezing so that the water may flow freely and in order to prevent pipes, storages or components located upstream of the device from freezing. Pipes downstream of the device must be protected from frost if, due to the intervention of the device, the water contained in them remains stagnant without flowing. In the case of exposed outdoor pipes, the installation of a suitable heating cable will provide effective protection.
Backflow prevention device When installing the device on a drinking water system, the garden tap must be installed in accordance with current regulations relating to anti-pollution protection, as specified by standard EN 1717. The tap may be connected to a garden hose and the water contained within the hose may come into contact with hazardous substances. A suitable backflow preventer, double check valve or vacuum breaker valve should be selected and fitted in accordance with type of use and the corresponding hazard level.
Application diagrams Application of code 603450 Application of code 603041 on domestic water circuit
Installation with heating cable on pipe downstream of the device
code 603041 Anti-freeze safety device. Connection 1/2 F with nut. Brass body, chrome plated. Brass obturator stem. Stainless steel seal seat. NBR seal elements. Medium water. Working temperature range from -30C to 90C. Maximum working pressure 10 bar. Opening temperature 3C. Closing temperature 4C. Accuracy 1C. code 603450 Ball-type garden tap, with anti-freeze safety device. Connection 1/2 M x 3/4 M with hose connection for 15 mm pipe. Brass body. Chrome plated. Brass ball and control stem, chrome plated. EPDM seal elements. Stainless steel control lever and fixing nut. Medium water. Working temperature range from -30C to 90C. Maximum working pressure 10 bar. Complete with: anti-freeze safety device. Brass body, chrome plated. Brass obturator stem. Stainless steel seal seat. NBR seal elements. Medium water. Working temperature range from -30C to 90C. Maximum working pressure 10 bar. Opening temperature 3C. Closing temperature 4C. Accuracy 1C.
CALEFFI
Pressure reducing valve
CALEFFI
576 series
IS
TERE
BS EN ISO 9001:2008 Cert. n FM 21654
UNI EN ISO 9001:2000 Cert. n 0003
01183/09 GB
Function The pressure reducing valve is a device which, installed on the water mains, reduces and regulates the pressure entering from the public network, irrespective of upstream pressure variations. In case of necessity, this series of pressure reducing valves is easy to inspect and maintain since it can be completely disassembled from the top and therefore it is not necessary to remove the appliance from the pipe. The reducing valve can be used in water distribution networks, drinking water supply systems and irrigation systems.
Product range 576 series Pressure reducing valve
RE
sizes DN 80-DN 150 (DN 200 on request)
Technical specifications Materials Body and cover: Diaphragm: Obturator: Obturator seat: cast iron EN-GJS-450-10 cloth covered elastomer - CR PUR stainless steel
Dimensions
Corrosion-resistant epoxy coating suitable for contact with drinking water. Performance Max. upstream pressure: Downstream pressure setting range: Max. working temperature: Pressure gauge scale: Connections Flanged connections:
2 1 3 1 2 3
16 bar 1,56 bar on request 612 bar 65C 016 bar
CALEFFI
bar
CALEFFI
bar
A D Code 576080 576100 576120 576150 576200 A DN 80 DN 100 DN 125 DN 150 DN 200 B 108 112 141 145 174 C 466 466 576 576 686 D 310 350 400 480 600 B
DN 80DN 150 (DN 200 on request) DN 80DN 150, PN 16; DN 200, PN 10
Coupling with counterflange EN 1092-1
Face-to-face gage according to ISO 5752 series 1
C Weight (kg) 34 37 84 87 115
Operating principle The operating principle of the pressure reducing valve is based on the balance between two opposing forces: the thrust exerted by the downstream pressure on the lower part of the mobile valve is counteracted by the adjustable compression force of the spring. Since the active surface of the diaphragm is equivalent to the active surface of the mobile valve, the thrust which the upstream pressure exerts on the lower part of the diaphragm is compensated by the thrust exerted on the upper part of the mobile valve, thus rendering the appliance insensitive to changes in upstream pressure. When the pressure downstream of the reducing valve becomes lower than the regulating pressure, the force exerted by the spring becomes predominant and the obturator opens, increasing the degree of opening to increase the flow rate and restore the pressure (Fig. 1). However when the downstream pressure increases, the obturator closes, reducing the degree of opening to limit the flow rate. The downstream pressure therefore remains constant.
Characteristic components 11 12 13 14 15 16 17 18 19 10 11 12 Body Stem Seat Cover Lower cylinder Obturator holder Obturator stop Flange Mounting plate Guide cylinder Guide beat Adjustment spring 13 14 15 16 17 18 19 20 21 22 23 Diaphragm Mobile valve Guide ring Lower cylinder O-ring Non-removable nut Nut Cover fixing nut Setting screw Adjustment key Pressure gauge Pressure gauge cock
21 20 18
2 1 3 1
2 3
4 9 12 22
2 2 3 1 3 1 0
2 17 8 15 13 7 14
CALEFFI
bar 4 0
CALEFFI
bar
CALEFFI
bar
CALEFFI
bar
10 23 19 16 5 3 1
UPSTREAM
DOWNSTREAM
Fig.1
11
Hydraulic characteristics The following cavitation diagram can be used to check the operating conditions of the pressure reducing valve: Zone 1 : normal operating conditions Zone 2 : cavitation zone (use not recommended) Zone 3 : impossible
Sizing Upstream pressure (bar) The diameter of the appliance must be chosen based on the maximum flow rate and the conditions of use and not according the diameter of the pipe. The maximum flow rate is calculated considering an average velocity in the inflow section of 1,5 m/s.
Downstream pressure (bar)
Installation 1. Before the installation, open all distribution taps to clean out the system and to expel air remaining in the pipes. 2. Install the shut-off valves upstream and downstream to facilitate future maintenance. 3. The reducing valve can be installed in any position.
Maintenance When performing maintenance it is not necessary to remove the appliance from the pipe. 1. Isolate the appliance by closing the shut-off valves. 2. Unscrew the setting screw (20) in an anticlockwise direction until it is completely removed, diagram A. 3. Unscrew the nuts and remove the cover (4). Extract the mounting plate (9) and the spring (12). 4. Disengage the diaphragm (13) from the pins. With the adjustment key (21) positioned as indicated in diagram B unscrew the nut (18) with a plate wrench. 5. Remove the flange (8), the diaphragm (13), the obturator stop (7) and the lower cylinder (5). 6. To unscrew the seat (3) use the up-side down turned cover as shown in diagram C. 7. After having removed the seat, extract the obturator holder (6) and the gasket (20) using the stem (2). NOTE: If necessary, the obturator gasket can be changed without removing the seat. Check that it is correctly refitted.
2 1 3 1
2 3
CALEFFI
bar
CALEFFI
bar
CALEFFI
1 0
4 bar
20 9
12
3
CALEFFI
1 0
4 bar
2 1 3 1
2 3
CALEFFI
bar
13 8 5
CALEFFI
bar
4. Close the downstream shut-off valve. 5. Calibrate the device using the special key, turning it clockwise to increase the value and anticlockwise to decrease it. 6. Read the desired value on the downstream pressure gauge.
Installation recommendations Water hammer is one of the major causes of breakage in pressure reducing valves. Consequently during installation in high-risk systems, it is advisable to fit suitable devices to absorb water hammer. Functional faults The reducing valve does not maintain the set value In the majority of cases, this problem is due to impurities depositing on the seat seal and causing seepage and creeping, thereby increasing downstream pressure. The solution is to install a filter downstream of the valve and to ensure that maintenance is properly carried out (see maintenance section).
2 1 3 1 2 3
0 1
CALEFFI
2
bar
4 3
0 1
CALEFFI
2
bar 4 3
A
2
2 1 3 2
18 5 21
CALEFFI
bar
CALEFFI
bar
CALEFFI
bar
CALEFFI
bar
20 2 6
576 series
Pressure reducing valve with compensated seat. Flanged connections DN 80 (from DN 80 to DN 150, PN 16; DN 200 PN 10). Cast iron body. Stainless steel seat. Diaphragm in cloth covered elastomer - CR, obturator in PUR. Maximum working temperature 65C. Maximum upstream pressure 16 bar. Downstream pressure setting range from 1,5 to 6 bar, on request from 6 to 12 bar. Supplied with double pressure gauge 016 bar upstream and downstream. Corrosion-resistant epoxy coating for contact with drinking water. Diaphragm, seat and obturator removable for maintenance purposes.
CALEFFI
Ball valve for solar thermal systems
CALEFFI
240 series
ACCREDITED
01185/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003
Function The 240 series ball valve is used to shut off the medium contained within solar thermal systems. The control lever, supplied with an anti-scald knob, is equipped with a device which can be used to lock the valve in open or closed position. The body, ball, control stem and lever are made of stainless steel to guarantee optimal resistance in terms of contact with the medium as well as the wear caused by external agents. This particular series of ball valves has been specifically designed to work at high temperature with a glycol solution, typical condition of solar thermal systems.
Product range 240 series Ball valve for solar thermal systems sizes 1/2, 3/4 and 1
Technical specifications Materials Body: Ball: Control stem: Lever: Knob: Ball seal seat: AISI AISI AISI AISI 316 stainless steel 316 stainless steel 316 stainless steel 304 stainless steel expanded PUR PTFE + graphite Performance Medium: Max. percentage of glycol: Nominal pressure: Working temperature range: Connections: water, glycol solutions 50% PN 63 -30200C 1/2, 3/4, 1 F
Dimensions
1/2"
400
350 300 250
1"
3/4"
p (mm w.g.)
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
0,6 0,7 0,8 0,9 1,2 1,4 1,6 1,8 2,5 3,5 4,5 12 14 16 18
0,2
10
0,1
0,5
10
Code 240400 240500 240600
A 1/2" 3/4" 1
B 58 65 76
C 70 75 90
D 115 115 170
Mass (kg)
0,305 0,390 0,645
Code 240400 240500 240600 Size 1/2 3/4 1 Kv (m3/h) 15 32 57
G (m3/h)
20
Construction details Locking device The control lever can be locked in position for greater safety. Once the valve has been opened or shut off, slide the shaped clamp (1) downwards, inserting it into the relevant protruding slot (2) on the valve body. The hole (3) on the control lever may be used to fit a tamper-proof safety seal or a padlock (not supplied) which locks the clamp (1) in position. Control lever knob The knob (4) covering the control lever is made of plastic material with low thermal conductivity. Specifically designed to withstand high temperatures, it prevents burns during operation and is resistant to the wear normally experienced by plastic materials when installed outdoors.
Stainless steel components In outdoor installations, the deterioration of product components occurs more quickly due to the action of climatic agents, resulting in a shortened period of normal operation. Using stainless steel to make the components of the 240 series valve ensures the device remains reliable and functional for long time. It also ensures the device is suitable for contact with the high-temperature glycol solution. Installation The valve can be fitted on either vertical or horizontal pipes. Make sure that it is easy to move the control lever in order to open or shut off the valve once it has been installed.

Use of the ball valve in solar panel circuit with inverse return connection Keep the valve in its open position with a tamper-proof seal or padlock (not supplied)
Application diagrams Use of the ball valve in a system with circulation unit
Use of the ball valve in solar panel circuit with balancing via AUTOFLOW Keep the valve in its open position with a tamper-proof seal or padlock (not supplied)
AUTOFLOW
Automatic filling
AUTOFLOW
240 series Ball valve for solar thermal systems. Threaded connections 1/2 x 1/2 (from 1/2 to 1) F. Stainless steel body, lever, control stem and ball. PTFE and graphite ball seal seat. Expanded PUR knob. Medium water and glycol solutions; maximum percentage of glycol 50%. Nominal pressure PN 63. Working temperature range -30200C.
CALEFFI
Pressure reducing valve
CALEFFI
539 series
ACCREDITED
01188/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003
Function In most cases the delivery pressure from the public water network is very high, thus it needs to be reduced to provide the user with: - greater comfort through a reduction in noise emission levels (vibration, whistles), - water save by avoiding excessive levels of consumption, - a secure internal water circuit, limiting the risk of leakage and mechanical wear on devices. Compliant with NF 079 doc.4 - EN 1567
Product range Code 539250 Pressure reducing valve size 3/4 F
Technical specifications Materials
Dimensions C
Body: Nipples: Cover: Obturator: Moving parts: Spring: Seat: Diaphragm: Hydraulic seals: Performance
dezincification resistant alloy dezincification resistant alloy
CB752S CW602N PA66G38 dezincification resistant alloy CW602N brass CW614N steel EN 10270-1 DH (C98) stainless steel AISI 303 NBR NBR
E A
Medium: Max. upstream pressure: Downstream pressure setting range: Factory setting: Max. working temperature:
water 25 bar 16 bar 3 bar 80C A F
C B F A F F A G E 75,5 F 1/2 G Mass(kg) 25,5 0,880
Connections: - main: refer to table of dimensions - pressure gauge connection: 1/4 F
Code A 539250 3/4
B 77
C 75
D 31,5
Cut-away
3
Head losses in bar
1 0
1,5
2,5
500
1000
1500
2000
2500
3000
3500
4000
Flow rate in l/h The black curve satisfies the requirements of standard NF. The red curve represents the performance capabilities of pressure reducing valve code 539250.
Installation and adjustment 1 Before installing the valve, open all taps to flush the entire system and to purge air from the pipes. 2 Install upstream and downstream shut-off valves to facilitate future maintenance operations. 3 Install the reducing valve in vertical or horizontal position, but never upside-down.
Installation advice Installing pressure reducing valves below ground is not recommended, most of all for two reasons: - it is difficult to read the pressure gauge, if not actually impossible; - impurities could enter the device through the ports, used to discharge the pressure, which are located on the cover. Water hammer is one the main causes of failure of pressure reducing valves. It is suggested a device to absorb the water hammer (ANTISHOCK 525 series). To prevent impurities from impairing the operation of the pressure reducing valve, we advise the installation of a dirt separator upstream of the reducing valve (DIRTCAL 5462 series).
4 Close the downstream shut-off valve. 5 Adjust the setting using the spring pressing screw, located on the cover, using a 10 mm hexagonal wrench, turning clockwise to increase the setting and anti-clockwise to reduce it. 6 Read off the value on the pressure gauge. (Caleffi pressure reducing valves are factory set to 3 bar).
Series 539250 Pressure reducing valve. Threaded connections 3/4 F. Dezincification resistant alloy body and obturator. Brass moving parts. Stainless steel seat. Steel spring. NBR seals. NBR diaphragm. Medium water. Maximum working temperature 80C. Maximum upstream pressure 25 bar. Downstream pressure setting range 16. Factory setting 3 bar. Compliant with NF standard.
CALEFFI
Set point thermostatic regulating unit
CALEFFI
182 series
IS
TERE
BS EN ISO 9001:2000 Cert. n FM 21654
UNI EN ISO 9001:2000 Cert. n 0003
01190/09 GB
Function The temperature regulating unit is made to be used in radiant panel systems, in combination with distribution manifolds. The set point regulating unit performs the function of keeping the flow temperature constant, at the set value, for the medium distributed in a low temperature system for floor radiant panels. In this particular series, the temperature is regulated by a specific hydraulic unit equipped with a thermostatic three-way valve with a built-in sensor. Patent application No. MI2006A001935.
Reference documentation - Tech. broch. 01126 Manifolds in composite specifically designed for radiant panel systems 670 series.
Product range Code 1825.1 Pre-assembled set point thermostatic regulating unit with manifolds and box, with UPS 25-60 pump
Technical specifications Materials Regulating unit with thermostatic three-way valve Body: brass EN 1982 CB753S Headwork: brass EN 12164 CW614N Obturator: PSU Seals: EPDM Flow adapter unit Body: brass EN 1982 CB753S
Performance Medium: Max. percentage of glycol: Control temperature range: Accuracy: Primary inlet max. temperature: Max. working pressure: Panel manifold differential by-pass setting (code 182000, optional): Liquid crystal digital thermometer scale: Pressure gauge scale: Connections: - to regulating unit: - panel circuit outlets: water, glycol solutions 30% 2555C 2C 90C 4 bar 25 kPa (2.500 mm w.g.) 2448C 010 bar

5000
4500 4000 3500 3000 2500
10
20
1,5
0,1
0,2
0,5
RE
3/4 M with union 3/4 for coupling with adapter code 675850 - outlet centre distance: 50 mm - centre distance between primary circuit connections: 60 mm
50
45 40 35 30 25
p (kPa)
2000
20

H (m w.g.) 6 (kPa) 60
UPS 25-60
5 4 50 40
Unit pump
L N
3 2 1
30 20 10 0
230 V
User side
2 1 0
ST
Safety thermostat
RT
Room thermostat
0,5
1,5
2,5
G (m3/h)
Power consumption
I
Speed
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (rpm) 1800 1100 700
Pump Three-speed pump: Material: - body: Electric supply: Max. ambient humidity: Max. ambient temperature: Protection class: Pump centre distance: Pump connections: model UPS 25-60 cast iron GG 15/20 230 V - 50 Hz 95% 80C IP 44 130 mm 1 1/2 with nut
3 2 1
Dimensions
5 outlets
9 outlets
13 outlets
ENTRATA
CUCINA
BAGNO
ENTRATA
CUCINA
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
L/MIN
ENTRATA
CUCINA
BAGNO
ENTRATA
CUCINA
co
n fo
SL r m e n or me IS P E
3/4
3/4
Code Panel outlets A
BAGNO
BAGNO
1 2 3 4
1
3
SYSTEM RETURN
C
CALEFFI
ENTRATA
CUCINA
BAGNO
2 4
SYSTEM FLOW

1 2 3 4
L/MIN
Flexible kit for differential by-pass setting (optional, code 182000)
1 2 3 4
L/MIN
1 2 3 4
L/MIN
Serie 182
Pmax 10 bar Tset 2060C Alimentazione 24 V
C
ENTRATA CUCINA BAGNO
4
bar
6 8
2 0
co n
fo r m
10
ES L e no r me I SP
CL 2.5
5
End fittings with automatic air vent and fill/drain cock.
1. Thermostatic three-way mixing valve with built-in sensor 2. Three-speed circulation pump UPS 25-60 3. Provision for adjustable drain valve
4. Safety thermostat 5. Pressure gauge 6. Electrical wiring case
Hydraulic diagram
C Digital thermometer T
1
RT
Room thermostat Safety thermostat Thermostatic three-way valve Pressure gauge
BF
C
ST
T
BR
3
SR
RT
6 2 4
Pump Provision for adjustable drain valve
ST C
5
SF
4 2 1
PRIMARY INLET
Construction details Regulating unit body The valve body, containing the temperature regulating device, is made out of a single casting with connections to the primary and secondary circuits. A specific internal channel carries the system return medium to the regulating valve, making it possible for the unit to be smaller in size and easy to connect. Reduced head losses The three-way mixing valve is equipped with a special obturator that acts on calibrated water orifices. This ensures a high flow rate and a reduced size, while maintaining accurate temperature control. Non-sticking materials The materials used for the mixing valve construction eliminate potential sticking due to scale. All functional parts, such as the obturator, valve seats and guides, have been made using a special material with low friction coefficient, which ensures performance over time. Low-inertia thermostatic sensor The temperature-sensitive element, the engine of the thermostatic three-way 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 as the thermal load changes. Temperature adjustment and locking The control knob is used to adjust temperature in a full turn (360) between min. and max. It also has tamper protection for locking the temperature at the set value.
3
SECONDARY RETURN SECONDARY FLOW
Serie 182
PRIMARY RETURN
Flow unit The flow unit is made out of a single casting with the necessary ports to connect with the functional components such as the safety thermostat and the pressure gauge.
Adjustment locking 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 carrier ring nut.
4
bar
6 8
2 0
co n
fo r m
10
ES L e no r me I SP
CL 2.5
Safety thermostat We recommend the safety thermostat is connected to the heat generator so that the electric supply is cut off when the triggering temperature is reached. To do so, connect the two safety thermostat wires directly to the generator and create an electrical jumper between the two contacts on the terminal board for unit 182, previously connected to the safety thermostat.
Pump Variable speed pump Three-way valve Thermostatic valve Lockshield
t1/t2/t3
1 2 3 4 5 6
t1 t2 t
ON OFF
C C - t1 - t2 - t3
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
RT

RT
Room thermostat Differential by-pass valve
co L n fo r m e no rme IS PES
1 2 3 4 5 6
t1 t2 t
ON OFF
C C - t1 - t2 - t3
t1/t2/t3
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
RT
co L n fo r m e no rme IS PES
182 series Set point thermostatic regulating unit. Connections to the regulating unit 3/4 M with union. Panel circuit outlet connections 3/4 for coupling with adapter code 675850. Medium water and glycol solutions; maximum percentage of glycol 30%. Adjustment temperature range 2555C. Maximum temperature at primary circuit inlet 90C. Maximum working pressure 4 bar. Panel manifold differential by-pass setting (optional, code 182000) 25 kPa. Liquid crystal thermometer scale 2448C. Pressure gauge scale 0-10 bar. Complete with: flow manifold for panel system with 3 outlets (from 3 to 13) with PA66GF body, flow rate regulating valve with flow meter with a scale of 14 l/min; return manifold for panel system with 3 outlets (from 3 to 13) with PA66GF body, shut-off valve. Regulating unit with thermostatic three-way valve with brass body and headwork, PSU obturator and EPDM seals. Flow adapter unit with brass body. Electric supply 230 V - 50 Hz. Safety thermostat: factory set 55C 3C, protection class IP 55, contact rating 10 A / 240 V. Three-speed UPS 25-60 pump, protection class IP 44. Supplied preassembled in painted steel box. Closure with a push-fit clamp. Depth adjustable from 110 to 150 mm, including floor supports adjustable in height from 270 to 410 mm.
CALEFFI

182 series
IS
CALEFFI
UNI EN ISO 9001:2000 Cert. n 0003
TERE
BS EN ISO 9001:2000 Cert. n FM 21654
01191/09 GB
Function The temperature regulating unit with the distribution kit for the primary circuit is made to be used in mixed systems: radiant panels and radiators, in combination with distribution manifolds for radiant panels. The set point regulating unit performs the function of keeping the flow temperature constant, at the set value, for the medium distributed in a low temperature system for floor radiant panels. In this particular series, the temperature is regulated by a specific hydraulic unit equipped with a thermostatic three-way valve with a built-in sensor. The function of the kit is to distribute a portion of the medium flowing from the primary boiler circuit to the heating elements. It is supplied complete with manifold and a differential by-pass kit for primary circuit. This accessory is essential when there is a primary circuit circulation pump and the radiator circuits are controlled by thermostatic or thermo-electric valves. Patent application No. MI2006A001935. Reference documentation - Tech. broch. 01126 Manifolds in composite specifically designed for radiant panel systems 670 series. Product range Code 1825.1 002 Pre-assembled set point thermostatic regulating unit with manifolds and box, distribution kit for primary circuit, with UPS 25-60 pump
Technical specifications Materials Regulating unit with thermostatic three-way valve Body: brass EN 1982 CB753S Headwork: brass EN 12164 CW614N Obturator: PSU Seals: EPDM Flow adapter unit Body: Primary circuit by-pass kit Body: By-pass valve: Spring: Primary circuit distribution manifold Body: brass EN 1982 CB753S brass EN 1982 CB753S POM stainless steel brass EN 1982 CB753S
Performance Medium: Max. percentage of glycol: Adjustment temperature range: Accuracy: Primary inlet max. temperature: Max. working pressure: Panel manifold differential by-pass setting (code 182000, optional): Primary circuit differential by-pass setting: Liquid crystal digital thermometer scale: Pressure gauge scale: Connections: - primary circuit: - to regulating unit: - panel circuit outlets: water, glycol solutions 30% 2555C 2C 90C 4 bar 25 kPa (2.500 mm w.g.) 10 kPa (1.000 mm w.g.) 20 mm 2448C 010 bar
Primary circuit manifold average inner diameter:

5000
4500 4000 3500 3000 2500
10
20
1,5
0,1
0,2
0,5
RE
3/4 F 1 F with nut 3/4 for coupling with adapter code 675850 - outlet centre distance: 50 mm - primary circuit manifold connection centre distance: - primary circuit manifold outlets: - outlet centre distance: 60 mm 1/2 F 40 mm p (kPa)
50
45 40 35 30 25
2000
20

H (m w.g.) 6 (kPa) 60
UPS 25-60
5 4 50 40
Unit pump
L N
3 2 1
30 20 10 0
230 V
User side
2 1 0
ST
Safety thermostat
RT
Room thermostat
0,5
1,5
2,5
G (m3/h)
Power consumption
I
Speed
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (rpm) 1800 1100 700
Pump Three-speed pump: Material: Body: Electric supply: Max. ambient humidity: Max. ambient temperature: Protection class: Pump centre distance: Pump connections: model UPS 25-60 cast iron GG 15/20 230 V - 50 Hz 95% 80C IP 44 130 mm 1 1/2 with nut
3 2 1
Dimensions
5 outlets
9 outlets
13 outlets
ENTRATA
ENTRATA
CUCINA
CUCINA
BAGNO
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
L/MIN
ENTRATA
ENTRATA
CUCINA
CUCINA
BAGNO
co
n fo
SL r m e n or me IS P E
3/4
3/4
Code Radiator outlets Panel outlets A
BAGNO
BAGNO
1 2 3 4
6
CALEFFI Mod. Dep.
1 3
SYSTEM RETURN
C
CALEFFI
ENTRATA
CUCINA
BAGNO
2 4
SYSTEM FLOW

1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
Serie 182
C
ENTRATA CUCINA BAGNO
4
bar
6 8
2 0
co n
fo r m
10
ES L e no r me I SP
CL 2.5
5
1. 2. 3. 4.
Thermostatic three-way mixing valve with built-in sensor Three-speed circulation pump UPS 25-60 Provision for adjustable drain valve Safety thermostat
5. 6. 7. 8.
Pressure gauge Primary circuit distribution manifold Primary circuit differential by-pass kit Electrical wiring case
Hydraulic diagram
1
RT
BF
6
ST
BR
7 3 8 2 4
SR
Pump Differential by-pass Provision for adjustable drain valve
RT
ST C
5
SF
4 2 1
PRIMARY INLET
Construction details Regulating unit body The valve body, containing the temperature regulating device, is made out of a single casting with connections to the primary and secondary circuits. A specific internal channel carries the system return medium to the regulating valve, making it possible for the unit to be smaller in size and easy to connect. Reduced head losses The three-way mixing valve is equipped with a special obturator that acts on calibrated water orifices. This ensures a high flow rate and a reduced size, while maintaining accurate temperature control. Non-sticking materials The materials used for the mixing valve construction eliminate potential sticking due to scale. All functional parts, such as the obturator, valve seats and guides, have been made using a special material with low friction coefficient, which ensures performance over time. Low-inertia thermostatic sensor The temperature-sensitive element, the engine of the thermostatic three-way 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 as the thermal load changes. Temperature adjustment and locking The control knob is used to adjust temperature in a full turn (360) between min. and max.. It also has tamper protection for locking the temperature at the set value.
3
SECONDARY RETURN SECONDARY FLOW
Flow unit The flow unit is made out of a single casting with the necessary ports to connect with the functional components such as the safety thermostat and the pressure gauge.
Serie 182
PRIMARY RETURN
4
bar
6 8
2 0
co n
fo r m
10
ES L e no r me I SP
CL 2.5
Distribution and differential by-pass kit for primary circuit Operating principle The distribution and differential by-pass kit for the primary circuit enables controlling the flow to the heating elements connected before the outlet to the regulating unit for the panel circuit. It is composed of a distribution manifold and a differential by-pass kit for the primary circuit.
Primary circuit distribution manifold Single casting The primary circuit distribution manifold is created using a single casting, without any connections between the internal tubes. This eliminates potential leakage caused by coupling with metals with different expansion coefficients. The connections of the side outlets are positioned tangentially to the main tubes, to make fitting mounting easier. Hydraulic characteristics Coefficient of localized head loss at the inlet (F+R): 3,0 Coefficient of localized head loss at the outlet (F+R): 6,5 Differential valve The differential valve is used to control the head in the primary distribution circuit. It aids flow circulation towards the heating elements and limits overpressure if there are thermostatic or thermo-electric valves. The differential valve has a fixed setting that cannot be changed. It is preset to 10 kPa, the mean value for the loss of head in the primary circuit.
p (mm w.g.)
2000
1800 1600 1400 1200
p (kPa)
18 16 14 12
20
Example: Let us calculate the head loss of the primary circuit manifold.
vtot = Gtot / Atot = 960 10 -3 / [( 0,02 2 / 4) 3600] = 0,849 m/s speed of water entering the primary circuit manifold ?pcp=?1 ? vtot2 / 2 = 1081,2 Pa = 1,08 kPa localized manifold inlet head loss (with ? = 1000 kg/m3 water density)
Gs = 700 l/h flow rate to secondary circuit Grad = 130 l/h flow rate to individual radiator Gtot = 2 Grad + Gs = 960 l/h total flow rate
vrad = Grad / A = 130 10 -3 / [( 0,015 2 / 4) 3600] = 0,205 m/s ?prad = ?2 ? vrad2 / 2= 136,58 Pa = 0,136 kPa localized head loss at the outlet. Given the limited length of the primary circuit manifold, the corresponding distributed head losses are negligible. The total loss is as follows: ?p = ?pcp + ?prad = 1,08 + 0,136 1,2 kPa
Primary
Gp
CALEFFI Mod. Dep.
Secondary
Gs
Primary
Gp
CALEFFI Mod. Dep.
Secondary
Gs
357
357
Flow rate (l/min) (m 3/h)
Primary circuit manifold outlets: D = 15 mm average diameter ?2 = 6,5 coefficient of localized head loss (F+R)
Primary circuit manifold main connections: D = 20 mm average diameter ?1 = 3 coefficient of localized head loss (F+R)
1000
900 800 700 600
9 8 7 6
10
500 1 0,2 0,5 0,1
10
20
Application diagram
1 2 3 4 5 6
t1 t2 t
ON OFF
C C - t1 - t2 - t3
t1/t2/t3
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
CALEFFI
Mod. Dep.
357
C. MATRIM. CAMERA
C
C. MATRIM. PRANZO
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
Serie 182
C
C. MATRIM. C. MATRIM. PRANZO CAMERA
3 2 1 0
co
bar
4 5 6
CL 2.5
nfo SL r m e n o r me IS P E
182 series Set point thermostatic regulating unit with distribution kit for primary circuit. Connections to primary circuit 3/4 F. Connections to regulating unit 1 F with nut. Panel circuit outlet connections 3/4 for coupling with adapter code 675850. Primary circuit manifold outlet connections 1/2 F. Medium water and glycol solutions; maximum percentage of glycol 30%. Adjustment temperature range 2555C. Maximum temperature at primary circuit inlet 90C. Maximum working pressure 4 bar. Panel manifold differential by-pass (optional, code 182000) setting 25 kPa. Primary circuit differential by-pass setting 10 kPa. Liquid crystal thermometer scale 2448C. Pressure gauge scale 010 bar. Complete with: flow manifold for panel system with 3 outlets (from 3 to 13) with PA66GF body, flow rate regulating valve with flow meter with a scale of 14 l/min; return manifold for panel system with 3 outlets (from 3 to 13) with PA66GF body, shut-off valve. Regulating unit with thermostatic three-way valve with brass body and headwork, PSU obturator and EPDM seals. Flow adapter unit with brass body. Primary circuit distribution manifold with 2 outlets and brass body. By-pass kit with brass body, POM differential by-pass valve and stainless steel spring. Electric supply 230 V - 50 Hz. Safety thermostat: factory set 55C 3C, protection class IP 55, contact rating 10 A / 240 V. Three-speed pump UPS 25-60, protection class IP 44. Supplied pre-assembled in painted steel box. Closure with a push-fit clamp. Depth adjustable from 110 to 150 mm, including floor supports adjustable in height from 270 to 410 mm.
CALEFFI

182 series
ACCREDITED
CALEFFI
01192/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003
replaces dp 01191/09GB
Function The temperature regulating unit with the distribution kit for the primary circuit is made to be used in mixed systems: radiant panels and radiators, in combination with distribution manifolds for radiant panels. The set point regulating unit performs the function of keeping the flow temperature constant, at the set value, for the medium distributed in a low temperature system for floor radiant panels. In this particular series, the temperature is regulated by a specific hydraulic unit equipped with a thermostatic three-way valve with a built-in sensor. The function of the kit is to distribute a portion of the medium flowing from the primary boiler circuit to the heating elements. It is supplied complete with manifolds with built-in shut-off and regulating valves and an adjustable differential by-pass kit for the primary circuit. The latter accessory is essential when there is a primary circuit circulation pump and the radiator circuits are controlled by thermostatic or thermo-electric valves. Patent application No. MI2006A001935. Reference documentation - Tech. broch. 01126 Manifolds in composite specifically designed for radiant panel systems 670 series.
Product range Code 1826.1 002 Pre-assembled set point thermostatic regulating unit with manifolds and box, distribution kit for primary circuit, with UPS 25-60 pump
Technical specifications Materials Regulating unit with thermostatic three-way valve Body: brass EN 1982 CB753S Headwork: brass EN 12164 CW614N Obturator: PSU Seals: EPDM Flow adapter unit Body: Primary circuit by-pass kit Body: By-pass valve: Spring: Primary circuit distribution manifolds Flow manifold Body: Flow rate regulating valve Obturator: Hydraulic seals: Return manifold Body: Shut-off valve Obturator stem: Obturator and seals: Springs: Knob: brass EN 1982 CB753S brass EN 12164 CW614N EPDM brass EN 1982 CB753S stainless steel EPDM stainless steel ABS brass EN 1982 CB753S brass EN 1982 CB753S PA6G30 stainless steel
Performance Medium: Max. percentage of glycol: Adjustment temperature range: Accuracy: Primary inlet max. temperature: Max. working pressure: water, glycol solutions 30% 2555C 2C 90C 4 bar
Panel manifold differential by-pass setting (code 182000, optional): 25 kPa (2.500 mm w.g.) Primary circuit differential by-pass setting range: 230 kPa (0,23 m w.g.) Primary circuit manifold average inner diameter: Liquid crystal digital thermometer scale: Pressure gauge scale: Connections: - primary circuit: - to regulating unit: - panel circuit outlets: 20 mm 2448C 010 bar
1 F 1 F with nut 3/4 for coupling with adapter code 675850 - outlet centre distance: 50 mm - primary circuit manifold outlets: 3/4 M - 18 mm - outlet centre distance: 50 mm

5000
4500 4000 3500 3000 2500
p (kPa)
50
45 40 35 30 25
0,1
0,2
0,5
10
20
1,5
2000
20
Safety thermostat Factory set: Protection class: Contact rating: Electrical connection diagram 55C 3C IP 55 10 A/240 V

H (m w.g.) 6 (kPa) 60
UPS 25-60
5 4 50 40
Unit pump
L N
3 2 1
30 20 10 0
230 V
User side
2 1 0
ST
Safety thermostat
RT
Room thermostat
0,5
1,5
2,5
3
G (m /h)
Power consumption
Speed I
(A) 0,40 0,30 0,20
P (W) 90 65 45
n (rpm) 1800 1100 700
Pump Three-speed pump: Material: Body: Electric supply: Max. ambient humidity: Max. ambient temperature: Protection class: Pump centre distance: Pump connections: model UPS 25-60 cast iron GG 15/20 230 V - 50 Hz 95% 80C IP 44 130 mm 1 1/2 with nut
3 2 1
Dimensions
6 outlets
10 outlets
13 outlets
CUCINA
CUCINA
BAGNO
500
3/4 50
330
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
L/MIN
CUCINA
CUCINA
BAGNO
co n
fo rm
PE e no r me IS
SL
Code Radiator outlets Panel outlets A
BAGNO
BAGNO
1 2 3 4
565
615
665
715
765
815
865
915
965
1015
1065
6
BOILER FLOW
7 1 3
C
CALEFFI
ENTRATA
CUCINA
BOILER RETURN
SYSTEM RETURN
BAGNO
2 4

1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
Serie 182
SYSTEM FLOW
ENTRATA
CUCINA
4
bar
6 8
0
co n
fo r m
10
ES L e no r m e I SP
CL 2.5
1 2 3 4
Thermostatic three-way mixing valve with built-in sensor Three-speed circulation pump UPS 25-60 Provision for adjustable drain valve Safety thermostat
5 6 7 8
Pressure gauge Primary circuit distribution manifolds Primary circuit differential by-pass kit Electrical wiring case
Hydraulic diagram
1
RT
BAGNO
BF
6
ST
BR
7 3 8 2 4
SR
Pump Differential by-pass Provision for adjustable drain valve
RT
ST C
5
SF
4 2 1
PRIMARY INLET
Construction details Regulating unit body The valve body, containing the temperature regulating device, is made out of a single casting with connections to the primary and secondary circuits. A specific internal channel carries the system return medium to the regulating valve, making it possible for the unit to be smaller in size and easy to connect.
3
SECONDARY RETURN SECONDARY FLOW Flow unit The flow unit is made out of a single casting with the necessary ports to connect with the functional components such as the safety thermostat and the pressure gauge.
Serie 182
PRIMARY RETURN
Non-sticking materials The materials used for the mixing valve construction eliminate potential sticking due to scale. All functional parts, such as the obturator, valve seats and guides, have been made using a special material with low friction coefficient, which ensures product performance over time.
Low-inertia thermostatic sensor The temperature-sensitive element, the engine of the thermostatic three-way 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 as the thermal load changes.
Temperature adjustment and locking The control knob is used to adjust temperature in a full turn (360) between min. and max. It also has tamper protection for locking the temperature at the set value.
4
bar
6 8
2 0
co n
fo r m
10
ES L e no r me I SP
CL 2.5
Distribution and differential by-pass kit for primary circuit Operating principle The distribution and differential by-pass kit for the primary circuit enables controlling the flow to the heating elements connected before the outlet to the regulating unit for the panel circuit. It is composed of distribution manifolds with built-in regulating and shut-off valves and the adjustable differential by-pass kit for the primary circuit.
1000 900 500 450
400 350 300 250 180 160 140 120 80 70 60 45 40 35 30 25 16 14 12 800 700 600
Hydraulic characteristics of the flow rate regulating valve Adjustment position 2 turns 3 turns 4 turns 5 turns F.O. Kv (m3/h) Kv0,01 (l/h) 0,22 1,30 3,20 4,70 5,40 22 130 320 470 540 5 mm
p (kPa)
9 8 7 6
10 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
2 1 0,5
10090 50
0,45 0,4 0,35 0,3 0,25 0,18 0,16 0,14 0,12
Differential valve The differential valve is used to control the head in the primary distribution circuit. It aids flow circulation towards the heating elements and limits overpressure if there are thermostatic or thermo-electric valves. The differential valve setting can be adjusted. It is preset to 5 kPa, the mean value for the loss of head in the primary circuit. If necessary, the intervention value can be adjusted within the range 230 kPa (0,23 m w.g.), using the corresponding knob with graduated scale.
p (m w.g.) 5
4 3 3 2,5 2 2 1,5 1 1 0,5 0,2 0,25 0,75 10 20 30
2018 10 0,2 1 0,5 0,1
0,2 0,1
(kPa) 50
40

Kv 5,40 4,10
Kv0,01 540 410
10
20
Primary
Gp
Primary Secondary
Gs Gp
Secondary
Gs
0,5
10
15
Application diagram
Pump Thermostatic valve Lockshield valve Shut-off valve Clock
t1
- t1 - t2 - t3
t2 t3
0 2 4 6 8 10 12 14 16 18 20 22
CALEFFI
TA
C
C. MATRIM. C. MATRIM.
1 2 3 4
L/MIN
1 2 3 4
L/MIN
1 2 3 4
L/MIN
L/MIN
Serie 182
C
C. MATRIM. C. MATRIM. PRANZO CAMERA
3 2 1 0
bar
4 5 6
5 CL
on f ES L o rm e n or me IS P
182 series Set point thermostatic regulating unit with distribution kit for primary circuit. Connections to primary circuit 1 F. Connections to regulating unit 1 F with nut. Panel circuit outlet connections 3/4 for coupling with adapter code 675850. Primary circuit manifold outlet connections 3/4 M - 18 mm. Medium water and glycol solutions; maximum percentage of glycol 30%. Adjustment temperature range 25 55C. Maximum temperature at primary circuit inlet 90C. Maximum working pressure 4 bar. Panel manifold differential by-pass (optional, code 182000) setting 25 kPa (2500 mm w.g.). Primary circuit differential by-pass setting range 230 kPa (0,23 m w.g.). Liquid crystal thermometer scale 2448C. Pressure gauge scale 010 bar. Complete with: flow manifold for panel system with 3 outlets (from 3 to 13) with PA66GF body, flow rate regulating valve with flow meter with a scale of 14 l/min; return manifold for panel system with 3 outlets (from 3 to 13) with PA66GF body, shut-off valve. Regulating unit with thermostatic three-way valve with brass body and headwork, PSU obturator and EPDM seals. Flow adapter unit with brass body. Primary circuit distribution manifolds with 2 outlets, brass body and flow rate regulating and shut-off valves. By-pass kit with brass body, PA6G30 differential by-pass valve and stainless steel spring. Electric supply 230 V - 50 Hz. Safety thermostat: factory set 55C 3C, protection class IP 55, contact rating 10 A/240 V. Three-speed pump UPS 25-60, protection class IP 44. Supplied preassembled in painted steel box. Closure with a push-fit clamp. Depth adjustable from 110 to 150 mm, including floor supports adjustable in height from 270 to 410 mm.
CALEFFI
PRANZO
1 2 3 4
CAMERA
Hot and cold domestic water consumption multiple acquirer

AQUAPRO 7556 series
ACCREDITED
CALEFFI
01201/10 GB
ISO 9001 FM 21654 ISO 9001 No. 0003
Specifications AQUAPRO is an electronic hot and cold domestic water consumption data acquisition module. This compact appliance comprises a calculator unit, to which up to 8 water jet meters can be connected. AQUAPRO is equipped with an 8-digit liquid crystal display for easy reading of consumption values as well as a range of other technical data. AQUAPRO is designed for centralised remote transmission (max. 250 modules, max. 2000 measuring points).
Displays
1st domestic water consumption
Typical installation
755600
PUSH
2nd domestic water consumption
3rd domestic water consumption
Cod. 755600
Tfluido : 595C
Utente 1 Utente 2
IDB
IP 54
Tamb. : 545C
Utente 3

Utente 4
Utente 5
Utente 6
Utente 7
Utente 8
7941 - 7942 - 7943 8

8th domestic water consumption
24 V ~ Bus line 1
Bus network address
76050
Segment test
Operational fault diagnosis Product range Code 755600 Domestic water consumption acquisition module Code 755060 AQUAPRO interface for connection with 755600 Code 755061 AQUAPRO-REMOTE interface for connection between 755600 and modem
Technical specifications Performance Electric supply: 24 V (ac) - 50 Hz - 1 W Maximum number of connectable water jet meters: 8 Long life battery: 5 years Ambient operating temperature: 545C (with no humidity or dust) Data transmission: Antitamper protection using RS485/M-bus protocol EN 1434
Dimensions
B A
PUSH
Cod. 755600
Tfluido : 595C
Utente 1 Utente 2
IDB
IP 54
Tamb. : 545C
Utente 3

Utente 4
Utente 5
Utente 6
Utente 7
Utente 8
Each AQUAPRO module admits max 8 pulse inputs. Each user can be associated with max 2 pulse inputs.
Series 755600
A 147
B 165
76050
C 120
D 40
Weight (Kg) 0,45
Hydraulic options
Dimensions
7941
Domestic water function
D C
A A
Consumer domestic water cut-off composed of: - BALLSTOP ball shut-off valve with check valve. - water jet meter, conforms to Directive 2004/22/EC (MID 001), with pulse output; - ball shut-off valve with male terminal.
B
Code Qnom m3/h K pulse
794140 794141 794150 794151
cold domestic water 1/2 hot domestic water 1/2 cold domestic water 3/4 hot domestic water 3/4
1.6 1.6 2.5 2.5
10 10 10 10
7942
Domestic water jet meter
Domestic water water jet meter in conformity with Directive 2004/22/EC (MID 001) for hot/cold domestic water with pulse output. Complete with fittings. Tmax: 90C. Note: Can be installed in 7556 series box only sizes less than 1.
Code 794140 794141 794150 794151 794160 794161
A 1/2 1/2 3/4 3/4 1 1
B 280 280 330 330 460 460
C 75 75 75 75 75 75
D 110 110 130 130 260 260
Weight (Kg) 1,10 1,10 1,50 1,50 3.50 5,50
794204 794205 794206 794207 794208 794209
1/2 3/4 1 1 1/4 1 1/2 2
1.6 2.5 3.5 6 10 15
10 10 10 100 100 100
B C Code 794204 794205 794206 794207 794208 794209 A 1/2 3/4 1 1 1/4 1 1/2 2 B 110 130 260 260 300 300 C 190 226 358 378 438 458 D 16 19 34 34 45 45 E 68 68 159 159 185 199 F Weight (Kg) 70 0,95 70 1,20 100 3,50 100 4,30 110 7,50 125 10,00
7943
Domestic water function Consumer domestic water cut-off composed of: - BALLSTOP ball shut-off valve with check valve; - water jet meter, in conformity with Directive 2004/22/EC (MID 001) with pulse output; - 90 elbow at the outlet.
Code Qnom m3/h K pulse
794340 794341 794350 794351
cold domestic water 1/2 hot domestic water 1/2 cold domestic water 3/4 hot domestic water 3/4
1.6 1.6 2.5 2.5
10 10 10 10
Code
Size
Qnom m3/h K pulse
Domestic water water jet meter Conforms to Directive 2004/22/EC (MID 001) Size Single jet meter Permanent flow rate Q3 Overload flow rate Q4 Working temperature range Horizontal installation (H) Minimum flow rate Q1 Transition flow rate Q2 Vertical installation (V) Minimum flow rate Q1 Transition flow rate Q2 COLD WATER HOT WATER 1/2 3/4 1/2 3/4 PN 16 1,600 l/h 2,500 l/h 1,600 l/h 2,500 l/h 2,000 l/h 3,125 l/h 2,000 l/h 3,125 l/h 0.1-30C 30-90C 32 l/h 128 l/h 64 l/h 160 l/h 50 l/h 200 l/h 100 l/h 250 l/h 32 l/h 128 l/h 64 l/h 160 l/h 50 l/h 200 l/h 100 l/h 250 l/h
Code 794340/41 794350/51
75 75
Max error % for Q2 Q Q4 for Q1 Q Q2
2% 5%
3% 5%
Weight (Kg) 1,10 1,10
Wall box for AQUAPRO system
AQUAPRO interface 755060 series
7556
Wall box made of painted sheet metal for interiors (RAL 9010), fitted for installation of domestic water function.
Code
Code
no. of functions
Useful dim. (h x w x d)
755060 755061
AQUAPRO interface AQUAPRO REMOTE interface
755604 755608
max 4 max 8
400 x 0650 x 110-140 600 x 1100 x 110 -140
Specifications With the AQUAPRO interface it is possible to have central M-Bus transmission equipped with a single data collection point, with the possibility of remote data transmission via GSM modem (code 755846) or analogue modem (code 755845). Using a portable PC and complementary software, the operator can transfer and print out the consumption data by connecting this interface locally to the portable PC, or by connecting from a remote PC.
755604
Fitted with 4 guides
Technical specifications Electric supply: Dimensions: 230 V (ac) - 50 Hz 10 VA 160 x 125 x 40 mm
The supply includes: - Serial cable for PC connection - Acquisition software provided on USB FLASH PEN - Instruction manual - USB/RS232 converter
Typical installation
755608
755600
755600
PUSH PUSH
Fitted with 8 guides

Cod. 755600
Tfluido : 595C
Utente 1 Utente 2
PUSH
IDB
IP 54
Utente 1
Cod. 755600
Tfluido : 595C
Utente 2
IDB
IP 54
Cod. 755600
Tfluido : 595C
Utente 1 Utente 2
IDB
IP 54
Tamb. : 545C
Utente 3
Tamb. : 545C
Utente 3
76050

Utente 3 Utente 4
Utente 5
Utente 6
Utente 7
Utente 8
7941 - 7942 - 7943 8
Utente 5
Utente 6
Utente 7
Utente 8
Utente 5
Utente 6
Utente 7
Utente 8
24 V ~
Utente 1 Utente 5
76050
PUSH
PUSH
Cod. 755600
Tfluido : 595C
Utente 2
IDB
IP 54
Cod. 755600
Tfluido : 595C
Utente 1 Utente 2
IDB
IP 54
Tamb. : 545C
Utente 3
Tamb. : 545C
Utente 3

Utente 4

Utente 4
76050
Utente 6
Utente 7
Utente 8
Utente 5
Utente 6
Utente 7
Utente 8
Bus line
1
PUSH PUSH
Cod. 755600
IDB
IP 54
Cod. 755600
Tfluido : 595C
Utente 1 Utente 2
IDB
IP 54
755845 755846 (GSM)
Tfluido : 595C
Utente 1 Utente 2
Tamb. : 545C
Utente 3
Tamb. : 545C
Utente 3

Utente 4

Utente 4
76050
Utente 5
Utente 6
Utente 7
Utente 8
Utente 5
Utente 6
Utente 7
Utente 8
755061 AQUAPRO TELE

Cod. 755055 Cod. 755056 Cod. 755060 Cod. 755500
Contatti Rel 4 x 8 A - 250 V Sonde temp. 0 90C Alimentazione elettrica: 230 V (ac) - 50 Hz - 10 W
Local service
Modem
PWR CD RD SD
56K FAXMODEM
76049
Tamb. : 545C
IP 54
230 V ~
bus
24 V ~
Cod. 755055 Cod. 755056 Cod. 755060 Cod. 755500

76049
Tamb. : 545C
IP 54
Local service
230 V ~
755060 AQUAPRO
Options
Code
755832 755845 755846 755855/N
water metering and cost allocation software analogue modem GSM digital modem bus cable (FROR 450/750 - 2x1 mm2) - 100 m reel
76050
76050
76050
Tamb. : 545C

Utente 4

Utente 4
AQUAPRO acquirer electrical connections 1 - 2 Power supply 24 V (ac) 3 - 5 Bus line data transmission 10 - 11 2nd Pulse 12 - 13 3rd Pulse 13 - 14 4th Pulse 15 - 16 5th Pulse
Rx Polarised cable
9 - 10 1st Pulse
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
BUS data transmission line
VIII Pulse
VII Pulse
IV Pulse
VI Pulse
16 - 17 6th Pulse 18 - 19 7th Pulse 19 - 20 8th Pulse
III Pulse
24 V (a c)
For mounting in a box or directly on a wall, use the screws provided in the package, fixing them in the curved slots which enable the device to be levelled correctly. Sample screenshots of the AQUAPRO cost allocation system
Tx
Code 755600 ACQUAPRO module for acquisition of domestic water consumption data supplied with 24 V (ac), with maximum 8 inputs and LCD display for local readings, can be connected via BUS cable code 755855/N to controller for centralised display. Data transmission in BUS mode. Ambient operating temperature with no humidity or dust: 5-45C. Code 755060 AQUAPRO interface, for acquisition of consumption data via digital transmission in Bus mode. Power supply 230 V (ac) 50 Hz - 10 VA. Includes software. Maximum number of connectable AQUAPRO devices: 250. Code 755061 AQUAPRO interface, for acquisition of consumption data via digital transmission in Bus mode. Power supply 230 V (ac) 50 Hz - 10 VA. Includes software. Maximum number of connectable AQUAPRO devices: 250. Fitted for transmission via analogue/digital modem 755845/755846. 7941 series Consumer domestic water cut-off for CONTECA centralised system consisting of: water jet meter (MID 001) with pulse output, sizes 1/2 and 3/4 (K=10); BALLSTOP ball shut-off valve with check valve. With male terminal. 7942 series Water jet meter (MID 001) for consumer hot/cold domestic water with direct local display and pulse output k=10 (100). Connections 1/22 M. Maximum temperature 90C. Complete with fittings. 7943 series Water jet meter (MID 001) for consumer hot/cold domestic water with direct local display and pulse output k=10. Connections 1/23/4. BALLSTOP ball shut-off valve with check valve. With 90 elbow terminal at the outlet. 7556 series Box made of painted sheet metal for interiors (RAL 9010). Fitted with connections for installing 7941 and 7943 series domestic water functions.
CALEFFI
V Pulse
II Pulse
I Pulse
Universal user module, PLURIMOD

Centralised domestic water CONTECA heat metering 7000 series
IS
CALEFFI
TERE
BS EN ISO 9001:2008 Cert. n FM 21654
UNI EN ISO 9001:2000 Cert. n 0003
01203/09 GB
Specifications Current regulations and provisions regarding the design of centralised domestic water/heating systems require the application of user modules. The user module (independent flame-free mini-boiler) offers independent heating control and therefore keeps a record of direct consumption data, both in terms of thermie/refrigeration units and domestic hot/cold water. The user module incorporates multiple hydraulic solutions which can be actuated directly on-site. Three-way zone valve, equipped with by-pass setting. Two-way zone valve (by-pass in closed position). Vertical or horizontal positioning with left side ot right side connection. AUTOFLOW arrangement. Possibility for aggregation of 3 domestic water outlets.
Standard functions
to other users
PUSH
On/off zone regulation Heat metering in conformity with directive 2004/22/EC (MID) with arrangement for centralised transmission. Insulation.
CALEFFI S.p.A.
Anno di produzione Numero di serie
M07 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
Optional functions
567
8 90
PN
123456
12
3
CALDA
5 67
8 90
123456
12
CALDA
5 67
TECNICA
8 90
123456
12
TECNICA
5 67
FREDDA
8 90
123456
12
FREDDA
da C.H.P
domestic hot water production
Technical specifications Materials Components: Connecting pipes: brass EN 12165 CW617N; CW614N; CW602N copper 10 bar 390C water, glycol solutions 30% 3/4 M
Performance Max. working pressure: Temperature range: Medium: Maximum percentage of glycol: Connections: Insulation Material: Temperature range: Reaction to fire (DIN 4102):
semi-rigid expanded polyurethane 090C class B2
6 45 7
89 0
90
67
67
6 45 7
89 0
90
6 45 7
89 0
90
67
6 45 7
2 34
Utente
89 0
90
Possibility for aggregation of 3 domestic water outlets (DHW, DCW and any dual water). AUTOFLOW automatic flow rate regulator. Mix function with mechanical thermostatic mixing valve 5217 series.
Characteristic components - 520x520 galvanised plate box adjustable depth between 110 and 150 mm - door made of painted plate for interiors (RAL 9010) - actuator, 6440 series - one-piece zone valve - bracket template with 2 pairs of ball shut-off valves and flushing pipes - CONTECA heat meter, 7554 series - template for positioning of triple-function domestic water outlet, 700050/700051 series - meter template connection point.
RE
45
12
67
2 34 2 34 2 34
45
12 12 12
3 3 3
45
1 1
45
Template - for PLURIMOD module - code 700005

Dimensions
68,5 383 68,5 33
520
The template box code 700005 is supplied complete with: - 2 pairs of 3/4 M ball valves - 2 flushing pipes for initial washing of the system - adhesive label showing the flow direction (to be applied) - cardboard to protect against any rubble created during the finishing stages of the construction work - the template box has guides for positioning the water meters, code 700050/700051
80
80
Recessed box with galvanised base and painted door for interiors (RAL 9010); equipped with finishing frame, adjustable from 110 to 150 mm in depth.
100
80
130
50
142
236 520
142
110150
Positioning the template box The special shape of the template box allows it to be applied in several positions, making it a universal product. 1) Horizontal (left-hand connection) 2) Vertical (top connection)
From C.H.P.
FLOW FLOW FLOW FLOW
3) Horizontal (right-hand connection)
From C.H.P.
dual water
DHW
DCW
FOLW
DHW dual water DCW user
DHW dual water DCW
1) Horizontal with MIX function (left-hand connection)
2) Vertical with MIX function (top connection)

From C.H.P.
3) Horizontal with MIX function (right-hand connection)
FLOW FLOW
FLOW FLOW
From C.H.P.
DHW
DCW
FLOW
DHW MIX
DHW MIX
MIX
DCW user
DCW
Note: Any domestic water functions should be positioned in accordance with the above instructions. The central position is assigned to the dual water or technical function. Other positioning schemes do not allow for the installation of the MIX function code 700055.
From C.H.P.
user
user
From C.H.P.
user
user
80
FLOW FLOW
PLURIMOD hydraulic module - code 700015-700016

Fig. 1
3 1
6 4
Bracketing the electronic metering panel The PLURIMOD hydraulic module code 700015/16 is supplied for hydraulic installation as shown in Fig. 1 (LHS riser). If installation on the RHS riser is required, the following steps will be necessary: 1. Remove the CONTECA electronic panel (5) by turning it anticlockwise and remove the metal plate (B) by loosening the fixing screws.
BOILER FLOW
Cod. 7554 DN IDB
755810
PUSH
Anno di produzione
Numero di serie
A
The hydraulic module includes:
Utente
CALEFFI S.p.A.
M07 1259 DE-07-MI004-PTB024
3. Disconnect the module from the ball valves. 4. Turn the module by 180 in relation to the zone valve axis. Remove the closure disc (C).
700015 - hydraulic module DN 3/4, actuator 230 V 700016 - hydraulic module DN 3/4, actuator 24 V
C
Note: By adjusting the by-pass knob (A), the module can be changed from a two-way module (by-pass closed) to CALEFFI three-way module with adjustable by-pass. The hydraulic module can be connected via the left-hand connection or the right-hand connection, provided that the direction of flow is respected. Actuator specifications 3-contact actuator. Auxiliary microswitch. Power consumption: 4 VA. Ambient temperature range: 055C. Protection class: IP 44 (vertical control stem), IP 40 (horizontal control stem). Operating time: 40 s (90 rotation).
CALEFFI
5. Turn the flow water by 180, observing the flow direction.
5 67
8 90
123456
12
3
CALEFFI
123456
12
3
ACTUATOR
M
CLOSE OPEN
Max 0,8 A
6. Replace the insulation and the closure disc. 7. Fix the locking plate in place.
PUSH
Anno di produzione
Numero di serie
Utente
CALEFFI
N L
TA
CALEFFI
123456
67
543
CALEFFI S.p.A.
M07 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
21
32 1
45 7 6
2 34
09 8
Note: For further details, please see
broch. 01131
8. Reconnect the module to the ball valves. 9. Reattach the electronic panel and connect the pulse cable for the flow meter. 10.Close the CONTECA electronic panel again.
67
6 45 7
2 34
5 67
89 0
90
6 45 7
89 0
90
8 90
67
6 45 7
2 34
1) 2) 3) 4) 5) 6)
zone valve assembly complete with temperature probe pockets volume meter 3/4, 7554 series actuator, 6440 series template for AUTOFLOW, code 700075 CONTECA electronic panel, 7554 series insulation
567
89 0
90
67
2 34
67
6 45 7
2 34
BOILER RETURN
CALEFFI S.p.A.
Anno di produzione Numero di serie
M07 1259 DE-07-MI004-PTB024
PN
567
8 90
123456
12
3
2. Open the electronic panel and disconnect the pulse cable of the flow rate gauge (terminal 9/10). Remove the insulation (6).
45
Utente
89 0
90
12
PUSH
5 B
Cod. 7554 DN IDB
755810
PN
CALEFFI
8 90
123456
12
12
3
45
45
12
45
12
765
09
09
A) Hydraulic module with open zone valve

p (bar)
1 0,5 0,3 0,2 0,1 0,05 0,03 0,02
B) Hydraulic module with closed zone valve

p (mm w.g.)
10000 5000 3000 2000 1000 500 300 200
p (bar)
1 0,5 0,3 0,2 0,1 0,05 0,03 0,02 0,01
p (mm w.g.)
10000 5000 3000 2000 1000 500 300 200 100
Kv = 3,46
500
0,01
100
1000
2000
5000
G (l/h)
200
1000
2000
5000
Operating range (noise) To protect users from noise which may be generated inside the plumbing unit it is necessary to ensure a flow rate value which is below the noise threshold relating to differential pressures. The following values are provided as an indication. Noise limits - p (mm w.g.)
1 By-pass open by 1 turn; Kv = 0,72 2 By-pass open by 2 turns; Kv = 1,47 3 By-pass completely open; Kv = 1,77
700075... Compact automatic flow rate regulator
p1800 Noise unlikely 1800 < p < 2200 Noise likely p 2200 Noise very likely The dotted red line in diagram A indicates the max. limit of the operating flow rate G=3,46 0,18 = 1460 l/h which corresponds to a velocity, reached by the medium, of approximately 1,2 m/sec. By removing the template sleeve ((4) in Fig. 1), it is possible to connect the flow rate regulator code 700075... ... To complete the code, please consult the table below:
Inspecting the strainer Loosen cap A (with 24 mm wrench) to access the filter easily for regular inspection and maintenance.
m3/h digit 0,12 M12 0,15 M15 0,20 M20
with range p 15200 kPa

m3/h digit 0,25 M25 0,30 M30 0,35 M35
m3/h digit 0,40 M40 0,50 M50 0,60 M60
m3/h digit 0,70 M70 0,80 M80 0,90 M90
G (l/h)
200
500
m3/h digit 1,00 1M0 1,20 1M2 1,40 1M4
Example: maximum flow rate required 600 l/h, code 700075 M60
HYDRAULIC OPTIONS
700050 - 700051 Domestic water function
700050 DHW / DCW function with local reading 3/4 M x 3/4 M 700051 DHW / DCW function with pulse output 3/4 M x 3/4 M Characteristic components: - BALLSTOP valve with built-in check valve 3/4 M - Template connection point - Shut-off ball valve 3/4 M with male terminal - Domestic water meter (supplied) 2004/22/EC certification Technical data domestic water function In conformity with directive 2004/22/CE (MID 001) Dimensions Single jet meter Permanent flow rate Q3 Overload flow rate Q4 Working temperature range Horizontal installation (H) Minimum flow rate Q1 Transitional flow rate Q2 Vertical installation (V) Minimum flow rate Q1 Transitional flow rate Q2 COLD WATER HOT WATER 1/2 3/4 1/2 3/4 PN 16 1.600 l/h 2.500 l/h 1.600 l/h 2.500 l/h 2.000 l/h 3.125 l/h 2.000 l/h 3.125 l/h 0,130C 3090C 32 l/h 128 l/h 64 l/h 160 l/h 50 l/h 200 l/h 100 l/h 250 l/h 32 l/h 128 l/h 64 l/h 160 l/h 50 l/h 200 l/h 100 l/h 250 l/h
Notes:
before bracketing the domestic hot water function onto the template supports, check the flow direction indicated on the BALLSTOP body valve. before bracketing the water meter, check the flow direction marked on the meter body itself.
To prevent dripping caused by condensation, it is wise to position the domestic cold water (DCW) or dual water (DW) gauge on the lower part of the template supports. Note: the DHW/DCW functions are supplied separately. The template connection point allows the hydraulic water network to be flushed before installation takes place. The positive displacement meter is supplied, for subsequent hydraulic bracketing and any necessary electrical wiring on the electronic panel.
Max % error per Q2 Q Q4 per Q1 Q Q2
2% 5%
3% 5%
CALEFFI
DE-07-MI0 M0
CALEFFI S.p.A
(ac)
567
567
8 90
123456
12
CALDA
567
8 90
123456
12
FREDDA
Components: Mixing valve 5217 series with anti-scald safety function, certified to NF 079 standard with temperature adjustment 3050C Copper pipes and fittings: Max. working pressure: Max. inlet temperature: User connections 1/2 M with union 10 bar 85C
Note: The mix function requires the presence of two domestic water functions (DHW - DCW) code 700050/700051 and excludes the option of a third domestic water function. Note: for further details, please see
broch. 01092
6 45 7
89 0
90
80
3
67
6 45 7
89 0
90
67
6 45 7
2 34
700055 Mix function
sso: ritorno
e
K=
Numero di serie
l/imp.
8 90
12
89 0
90
67
6 45 7
2 34
89 0
DCW
567
FREDDA
8 90
123456
12
FREDDA
90
67
6 45 7
2 34
dual water
TECNICA
567
8 90
123456
12
TECNICA
89 0
90
67
6 45 7
2 34
89 0
90
DHW
CALDA
567
8 90
123456
12
12 12 12
3 3 3
CALDA
45
1 1 1
45 45
45
1
12
3
67
2 34 2 34
45
12
Mixed water
45
12
CONTECA heat meter, 7554 series Conforms to directive 2004/22/EC/MID Accuracy class: 3 according to EN 1434
Technical specifications Temperature probe Type: Temperature difference limit: Measurement sensitivity: Water meter Nominal pressure: Maximum temperature of the medium: Lowest flow rate Q i : Nominal flow rate Q p : Installation: Calculation unit Metrological specifications: NTC 380 K 0,05C
PN10 90C 50 l/h 2500 l/h horizontal / vertical
Terminal board - electric cables and signals
conformity to EN 1434-1 2004/22/EC MID Centralised transmission: in M-Bus mode Ambient classification: MID 2004/22/EC E1-M1 Supply: 24 V (ac) - 1 W - 50 Hz Protection class in accordance with DIN 40050: IP 54
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Zone valve status
Meter

RT FT
Heating probes (for system with 2 pipes)
Cooling - Energy (Refrigeration units) The CONTECA heat meter features various metering configurations referring to two-pipe and aggregated pulse acquisition systems that determine set connection positions. Two-pipe system 1) Thermie and/or refrigeration unit metering 6 7 Zone valve status* 2nd pulse consumption 1st pulse consumption
Carrier medium volume
9 - 10 Mass meter 19 - 20 Flow probe (TA)
3rd pulse consumption 2) Pulse acquisition (Type OA-OC) 2.1) One single pulse meter 10 - 11 DHW or DCW 2.2) Two pulse meters Flow temperature (1st pulse consumption) Power Flow rate
12 - 13 DCW 2.2) Three pulse meters 10 - 11 DHW 12 - 13 DCW 13 - 14 Generic/Dual
(2nd pulse consumption) Return temperature (1st pulse consumption) (2nd pulse consumption) (3rd pulse consumption) Note: for further details, please see
broch. 01111
*Compulsory connection for consumption certification
10 - 11 DHW
(1st pulse consumption)
18 - 19 Return probe (RT)
m3
m3
PUL Return
Return temp. probe Flow temp. probe
Polarized cable Rx
Heat-A/C
User information cycle The heat meter is equipped with a liquid crystal display. The display is activated by pressing the button on the front PUSH . By repeatedly pressing the button briefly it is possible to scroll through the various information windows. In order to extend the battery life, the display is switched off 30 s after the sensor button was last pressed.
24 V (ac)
Tx
III Pulse
II Pulse
I Pulse
Flow
755890
Remote energy totaliser

Electronic 8-digit LCD totaliser equipped with cover plate for three-slot recessed electric box, for remote monitoring of thermie or refrigeration unit consumption. Lithium battery: duration 8 years - max. frequency 20 Hz. Cable section (2x1 mm2), max. length 150 m.
755810
Refrigeration unit metering
The CONTECA meter, via software, is able to keep a record of the thermie and refrigeration units in separate registers through the evaluation of the thermal gradient inversion.
75588.
22 Refrigeration units 23 Thermie 0V 21
Pulse output
3 4
The pulse output can be used to transfer the thermie and/or refrigeration unit energy values to a generic acquirer. The pulse weighs 1 kWh. The pulse output with no potential is an open collector with pulse period 120 ms - Vmax 24 V (dc).
Code
755881 755882
Single pulse output - THERMIE Double pulse output - THERMIE/REFRIGERATION UNITS
DATA CENTRALISATION
(A) CONTROLLER Remote acquisition 755010
Controller
PUSH PUSH
M07 1259 DE-07-MI004-PTB024
CALEFFI S.p.A.
Anno di produzione Numero di serie Anno di produzione Numero di serie Utente Utente
CALEFFI S.p.A.
M07 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
Cod. 7554 DN IDB
755810
PN
(B) INTERFACE FAST-TELE
Remote acquisition
PUSH PUSH
M07 1259 DE-07-MI004-PTB024
CALEFFI S.p.A.
Anno di produzione
Numero di serie
Anno di produzione
Numero di serie
Utente
Utente
CALEFFI S.p.A.
M07 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
Cod. 7554 DN IDB
755810
PN
Modem 7558545 7558546

analogic digital
Data centralisation solutions (A), (B) and (C) are alternatives to one another
PUSH PUSH
FAST-TELE
(C) FAST INTERFACE
M07 1259 DE-07-MI004-PTB024
CALEFFI S.p.A.
Anno di produzione
Numero di serie
Anno di produzione
Numero di serie
Utente
Utente
CALEFFI S.p.A.
M07 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
Cod. 7554 DN IDB
755810
PN
FAST
Local acquisition
N.B.: The transmission bus code 755855/N is a two-way device (section 2 x 1 mm2). The controller allows a maximum of 250 users. The laying methods are in accordance with the tree distribution (star). The maximum length of each individual section is 1200 m. It is possible to lay up to a maximum of 4 separate sections.
Note: for further details, please see
broch. 01111
Code 700005 Template for PLURIMOD universal positioning user module, consisting of: - Box made of painted plate for interiors (RAL 9010) with universal closure door. (w = 520 - h = 520 - d = 110150 mm). - Two pairs of ball shut-off valves 3/4 M. - Flushing pipes for checking water tightness and washing the system. - Triple domestic water function positioning flaps (DHW - DCW - Dual water or technical function). Code 700015/16 PLURIMOD universal positioning hydraulic module with adjustable configuration from two-way to three-way, with adjustable by-pass. Equipped with: - Hydraulic unit with ball zone valve and pockets for temperature gauges. - Actuator, 6440 series, supply 230 V for code 700015 or 24 V (ac) for code 700016. - CONTECA heat meter - EC 2004/22 certification (MID). - Template for AUTOFLOW. - Insulation. Code 700050/51 Domestic cold water (DCW) function, domestic hot water (DHW) function and dual water (DW) or technical function equipped with: - BALLSTOP shut-off ball valve with built-in check valve. - Water meter without pulse output (K 10) 3/4 code 700050; with pulse output code 700051. - Shut-off ball valve with male terminal. - Template connection point for water meter. Code 700055 Domestic water MIX function consisting of: - Thermostatic mixing valve, 5217 series, 3/4 certified to standard NF 079 doc. 8. - Copper pipes and quick push-fit connections. Code 700075... Compact automatic flow rate regulator, AUTOFLOW. Quick push-fit connections. Brass body. High resistance polymer cartridge. Stainless steel spring. EPDM seals. Medium water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 16 bar. Working temperature range 0100C. Range p 15200 kPa. Range of available flow rates 0,121,4 m3/h. Accuracy 10%. Code 700010 Compact touch-screen CONTECA controller, with RS232 - RS485, USB and LAN ports, user monitoring function (maximum 250) and daily logging of consumption data. Enabled for SMS message alarm and remote activation management, and for automatic transmission of data via FTP server. Supply 230 V (ac).
CALEFFI
Recess-mounting two-way user satellite for instant domestic water production

SAT22 series
ACCREDITED
CALEFFI
01206/10 GB
ISO 9001
FM 21654
ISO 9001 No. 0003
Specifications The SAT22 satellite unit regulates the plumbing units heat requirement and instantly generates domestic hot water through the same medium, making the general supply network as simple as possible (two pipes only). The SAT22 user satellite is therefore the most complete simplification for individual plumbing units in central systems. The SAT22 user satellite, a two-way system with modulating control of the heating medium, is particularly suitable for centralised systems with condensing boilers, and for centralised systems served by remote heating. - Basic functions - ON/OFF heating regulation with medium modulation through p control valve - instant hot domestic water production wit exchanger/sensor/DHW pre-adjustment valve system and control of primary return temperature - thermostatic domestic water mixing with anti-scald device - heat metering in conformity with Directive 2004/22/EC (MI004) with arrangement for centralised transmission - Optional functions - cold domestic water meter code 794204 in conformity with Directive 2004/22/EC (MI001) - centralised data transmission code 755010
0000000
MI 2 1 MA 7
PUSH
Cod. 7554 DN IDB
755810
PN
M07 1259 DE-07-MI004-PTB024
Anno di produzione
Numero di serie
Utente
CALEFFI S.p.A.
Notes: The positioning of the wall box is the first essential and necessary step for installation of the SAT22 user satellite, which can only be installed indoors. Wall box code 794972 is only used for user satellite code SAT22.
Technical specifications Materials Ball valves:
Characteristic components - insulated brazed exchanger: Pnom 50 kW
- body: brass EN 12165 CW617N - valve with non-return (domestic water inlet): non-return EN 13959 type approved Fe360 plate thickness 15/10 mm epoxy polyester powder coating RAL 9010 copper 10 bar 090C water/glycol solutions, max 30% 3/4 M
Box:
Connection pipes: Performance Max. working pressure: Working temperature range: Medium: Connections:
- thermostatic mixing valve with adjustable anti-scald function: 3050C 2C - two-way ball zone valve and actuator: 230 V (ac) - 6 W - 7554 series CONTECA heat meter: 24 V (ac) - 50 Hz - 1 W fitted for RS485/M-bus - differential pressure regulator with fixed setting: 15 kPa - 127 series AUTOFLOW
SAT22 Two-way user satellite
LEGEND 1) 2) AUTOFLOW compact automatic flow rate regulator (600-1200 l/h) Flow temperature probe pocket (equipped with filter) Ball zone valve (6442 series) Differential pressure regulator with fixed setting 15 kPa Brazed exchanger (Pnom 50 Kw) DHW pre-adjustment valve with primary return max. temperature control for systems with condensing boilers and remote heating sub-central units Anti-scald mixing valve DCW positive displacement meter (optional) code 794204 In conformity with Directive 2004/22/EC (MI001) Size Single jet meter Permanent flow rate Q3 Overload flow rate Q4 Working temperature range Vertical installation (V) Minimum flow rate Q1 Transition flow rate Q2 Max error percentage COLD WATER 1/2 PN 16 1,600 l/h 2,000 l/h 0,130C
7 6 5
MA 7
3) 4)
10
PUSH
5) 6)
MI
Anno di produzione
Numero di serie
11 9 8
Utente
CALEFFI S.p.A.
M07 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
4 3 2 1
0000000
7) 8)
12
Heating
Heating
DHW
DCW
DCW
C.H.
C.H.
64 l/h 160 l/h 2% for Q2 Q Q4 5% for Q1 Q Q2
9-10)CONTECA heat meter in conformity with Directive 2004/22/EC (MI004) 11) 12) Dimensions of wall box code 794972 Return probe pocket Recess-mounting wall box for interiors
Operating principle
PIPING CENTRE DISTANCE PLANE
The heating medium main supply is equipped with an AUTOFLOW compact automatic flow rate regulator (1) (flow rate 900 l/h, on request 6001200 l/h). Heating function The ball zone valve (3) equipped with 230 V (ac) (24 V (ac) optional) actuator controls the plumbing unit heat flow and the differential pressure regulator (4) maintains a constant pressure difference throughout the entire heating circuit. DHW function The brazed exchanger (5), equipped with built-in temperature probe, together with pre-adjustment valve (6) and mixing valve (7) with anti-scald function, is responsible for DHW production. The DCW inlet can be fitted with an additional meter (8).
MIXED WATER OUTLET
COLD WATER INLET
COLD WATER OUTLET
HEATING RETURN
HEATING FLOW
BOILER RETURN
BOILER FLOW
212300 mm
750 mm
35
58 75
75
75
75
75
90
57
Heat metering The 7554 series CONTECA heat meter (10) determines the total user energy requirement through the pair of probes and the flow rate meter (9). Wallbox code 794972 is supplied with a recess-mounting wall box made of painted sheet metal for interiors (RAL 9010) with door, ball shut-off valves and check valves.
580 mm
140 mm
A) Heating function (differential regulator fully open). Without AUTOFLOW

p (bar)
0,5 0,3 0,2 0,1 0,05 0,03 0,02 0,01 0,005
p (mm w.g.)
5000 3000 2000 1000 500 300 200 100 50
The red lines in the diagrams and in the charts, positioned at the p value of 0.25 bar, indicate the precautionary operating limits for preventing noise generation. Gwork = kv 0,25
0000000
MI
MA 7
PUSH
Anno di produzione
Numero di serie
Utente
Kv = 2,3 m3/h
2000 1000 5000 100 200 500
HEATING RETURN
HEATING FLOW
BOILER RETURN
MIXED WATER OUTLET
COLD WATER OUTLET
B) Exchanger primary hot domestic water function (exchanger regulating valve fully open). Without AUTOFLOW
p (bar)
0,5 0,3 0,2 0,1 0,05 0,03 0,02 0,01 0,005
p (mm w.g.)
5000 3000 2000 1000 500 300 200
0000000
2 1 MI MA 7
Anno di produzione
Numero di serie
Utente
Kv = 1,6 m3/h
100 200 500 1000 2000 5000
100 50
G (l/h)
HEATING RETURN HEATING FLOW BOILER RETURN MIXED WATER OUTLET COLD WATER OUTLET BOILER FLOW
PUSH
Anno di produzione Numero di serie Utente
C) Heating and hot domestic water function (differential regulator and exchanger regulating valve fully open). Without AUTOFLOW
p (bar)
0,5 0,3 0,2 0,1 0,05 0,03 0,02 0,01 0,005
p (mm w.g.)
5000
MA 7
3000 2000 1000 500 300 200 100
MI
COLD WATER INLET
Kv = 2,7 m3/h
2000 1000 5000 100 200 500
0000 000
50
G (l/h)
HEATING RETURN HEATING FLOW BOILER RETURN MIXED WATER OUTLET COLD WATER OUTLET BOILER FLOW COLD WATER INLET
CALEFFI S.p.A.
M07 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
CALEFFI S.p.A.
M07 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
BOILER FLOW
PUSH
755810
COLD WATER INLET
G (l/h)
PN
CALEFFI S.p.A.
M07 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
DHW production Operating principle The performance of the exchanger depends on the primary medium flow rate and on the temperature of the medium. The thermostatic valve US (A) modulates the primary outlet flow rate IP based on the sensor (B) which is immersed in the exchanger.
0 1 2 3
SET temperature fluctuation (48C) in response to changes in DHW requirement Fig. 3

Domestic water mix temperature (C) EO Transients with primary temperature of 70C
50 49 48 47 46 45 44 43 42 41 40
B
IS
A
UP
100
200
300 Time (s)
400
500
600
Transients with primary temperature of 70C

0 1 2 3
Thermostatic valve The thermostatic valve is equipped with a control knob which allows preadjustment of the plumbing unit DHW.
Domestic water flow rate (l/h) EO
1200 1000 800 600 400 200 0
The pre-adjustment values are purely 42C indicative since they depend on the 45C primary flow rate and temperature 48C and the domestic water inlet 52C temperature (factory pre-adjustment 3). An anti-scald mixing valve is installed on the DHW outlet which enables the DHW temperature to be precisely regulated, above all levelling off possible temperature increases due to sudden downward variations of the domestic water flow rate (see fig. 3). This mixing valve incorporates a definable anti-scald function.
0 1 2 3 4
100
200
300 Time (s)
400
500
600
DHW function DHW temperature compared to required flow rate parameterised with boiler flow temperature and AUTOFLOW 600 l/h. Fig. 4
50,00 49,00 48,00 47,00 46,00 45,00 44,00 43,00 42,00 41,00 40,00 39,00 38,00 37,00 36,00 35,00 200
Heating and DHW function DHW temperature compared to required flow rate parameterised with boiler flow temperature and AUTOFLOW 900 l/h.
50,00 49,00 48,00 47,00 46,00 45,00 44,00 43,00 42,00 41,00 40,00 39,00 38,00 37,00 36,00 35,00 200
COMPLIANT ZONE
Domestic water temperature (C)
Flow. Temp. Centr. 50C Flow. Temp. Centr. 55C Flow. Temp. Centr. 60C Flow. Temp. Centr. 65C Flow. Temp. Centr. 70C Flow. Temp. Centr. 75C
Domestic water temperature (C)
Flow. Temp. Centr. 50C Flow. Temp. Centr. 55C Flow. Temp. Centr. 60C Flow. Temp. Centr. 65C Flow. Temp. Centr. 70C Flow. Temp. Centr. 75C
300
400
500
600
700
800
900
1000
300
400
500
600
700
800
900
1000
Flow rate (l/h) DHW function Flow medium (l/h) (IP) 600 700 800 900 520 580 720 720 DHW l/h kW Primary temperature C (IP) 50 19 21 26 27 1000 T inlet DCW = 14C T outlet DHW = 47C (+0 / -2C) 760 760 940 55 27 28 34 36 950 920 1000 60 34 35 36 65 1000 1000 36 38 Heating Flow medium (l/h) (IP) (l/h) (US) 600 700 800 900 1200 350 400 500 600 720 250 300 400 500
Flow rate (l/h) Heating - DHW function Primary temperature C (IP) 50 9 11 14 18 55 14 17 20 24 60 320 380 470 550 650 480 540 640 780 12 17 19 23 28 65 440 550 670 750 880 16 20 24 27 32 70 500 600 740 860 1000 18 22 27 31 36 75 570 670 800 940 1050 21 24 29 34 40
COMPLIANT ZONE
127 series Compact automatic flow rate regulator
Heating function: The ball zone valve (2) equipped with 230/24 V (ac) actuator controls the plumbing unit heat flow and the differential pressure regulator (3) maintains a constant pressure difference throughout the entire heating circuit. 140 series Differential pressure regulator (3) Regulation curve
p (kPa)
The heating medium main supply is equipped with an AUTOFLOW compact automatic flow rate regulator (1) (available flow rate ranges 6001200 l/h). Unless specified otherwise, the M90 cartridge with flow rate 900 l/h must be installed. ... To complete the code refer to the following table:
30 25 20 15 10 5 0 100 200 300 400 500 600 700 800 900 1000
with p range 15200 kPa

m3/h digit
0,60 M60
0,70 M70
0,80 M80
0,90 M90
1,00 1M0
1,20 1M2
Flow rate (l/h)
Central transmission electrical diagram
A
2 1 MI MA 7
PUSH
B
Cod. 7554 IDB DN
755810
User satellite installed in shared parts (outside of plumbing unit)
PN
M07 1259 DE-07-MI004-PTB024
Anno di produzione
Numero di serie
Utente
PUSH
PUSH
CALEFFI S.p.A.
User satellite installed inside the plumbing unit
PUSH
PUSH
Cod. 7554 IDB DN
755810
PN
DE-07-MI004-PTB024 M08 1259
Cod. 7554 IDB DN
755810
PN
DE-07-MI004-PTB024 M08 1259
Cod. 7554 IDB DN
755810
PN
M08 1259 DE-07-MI004-PTB024
Cod. 7554 IDB DN
755810
PN
DE-07-MI004-PTB024 M08 1259
CALEFFI S.p.A.
CALEFFI S.p.A.
CALEFFI S.p.A.
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
76072
76072
76072
PUSH
PUSH
PUSH
76072
Utente
Utente
0000 000
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
Utente
Utente
PUSH
M08 1259 DE-07-MI004-PTB024
DE-07-MI004-PTB024
CALEFFI S.p.A.
CALEFFI S.p.A.
CALEFFI S.p.A.
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
76072
76072
Utente
Utente
76072
Utente
Utente
SAT22
PUSH PUSH PUSH PUSH
Cod. 7554 DN IDB
755810
PN
DE-07-MI004-PTB024 M08 1259
Cod. 7554 DN IDB
755810
PN
DE-07-MI004-PTB024 M08 1259
Cod. 7554 DN IDB
755810
PN
M08 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
M08 1259 DE-07-MI004-PTB024
CALEFFI S.p.A.
CALEFFI S.p.A.
CALEFFI S.p.A.
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
76072
76072
Utente
Utente
76072
Utente
Utente
755010
Hydronic Solutions
CALEFFI
PUSH
PUSH
PUSH
76072
PUSH
M08 1259 DE-07-MI004-PTB024
DE-07-MI004-PTB024
CALEFFI S.p.A.
CALEFFI S.p.A.
CALEFFI S.p.A.
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
Anno di produzione
2008
Numero di serie
76072
76072
76072
Utente
Utente
Utente
Utente
Cod. 755010 - Serial
BUS Line
Controller
BUS Line
755855 LSC
Cod. 755055 Cod. 755056 Cod. 755060 Cod. 755500
755855 LSC
~ 230 V (ac)
Alimentazione elettrica: 230 V
(ac) -
50 Hz - 10 W
Guidelines for hydraulic - electrical installation - Normally wall box code 794972 is supplied separately in order to ensure correct laying of the system-plumbing unit connection pipes. - Before installing the SAT22 satellite unit it is advisable to flush the system using a U-connection pipe, if applicable. The satellite includes a positive displacement meter, exchanger and probe pocket with inlet filter, components which may fail or become clogged. Electric supply: 230 V (ac) line placed under plumbing unit control on activation of thermostat or timer-thermostat 24 V (ac) centralised line for CONTECA heat meter. Centralised transmission line via BUS cable code 755855 LSC (2x1 mm2 cable inserted in dedicated raceway).
76049
amb.:
545C
IP 54
755055 (alternative to 755010)
76072
CALEFFI S.p.A.
Classe ambientale: Temp. amb. 545C, E1, M1 H :1090C H : 380 K Riscaldamento: Alimentazione: 24 V (ac) - 50 Hz - 1 W IP 54 Senso di flusso: ritorno K= l/imp.
DE-07-MI004-PTB024
M08 1259
M08 1259
M08 1259 DE-07-MI004-PTB024
Cod. 7554 IDB DN
755810
PN
Cod. 7554 IDB DN
755810
PN
Cod. 7554 IDB DN
755810
PN
Cod. 7554 IDB DN
755810
PN
CALEFFI S.p.A.
76072
CALEFFI S.p.A.
DE-07-MI004-PTB024
M08 1259 DE-07-MI004-PTB024
Cod. 7554 DN IDB
755810
PN
M08 1259
Cod. 7554 DN IDB
755810
PN
M08 1259
Cod. 7554 DN IDB
755810
PN
Cod. 7554 DN IDB
755810
PN
CALEFFI S.p.A.
755010
CONTECA TOUCH controller
755055
FAST interface
The controller is able to acquire, via bus, all the totalised values of the individual users (heating units / refrigeration units / mass / opening times of the zone valve), user operating status (ON/OFF), totalised values from the supplementary pulse meters (hot/cold domestic water) and operational diagnostics. All the above-described totalised values are recorded on a daily basis in log files that are useful for analysing consumption and allocating costs. Maximum number of plumbing units: 250. Comprises: - 1 CPU touch screen - 1 rack for wall mounting The controller has the following features: - 1 touch screen LCD monitor for display of consumption and user data - 1 RS232 port - 1 RS485 port - 2 USB ports - 1 LAN port - GSM modem Electric supply: 230 V (ac) 10% - 50 Hz - 60 W. Ambient conditions: 1035C with no dust.
As an alternative to controller code 755010 it is possible to have RS485/M-bus central transmission via FAST interface. Using a portable PC with Windows environment and complementary software, the operator can transfer the consumption data of the individual units by connecting this interface locally to the portable PC. Maximum number of plumbing units: 30. Comprises: - Data acquisition software. - Instruction manual. Specifications: Electric supply: 230 V (ac) - 50 Hz - 5 VA. RS232-C interface. Dimensions 165 x 120 x 40 mm.
MAINTENANCE AND FUNCTIONAL DIAGNOSTICS To ensure correct operation and maximum efficiency of the user satellite, it is necessary to perform the following maintenance operations and functional checks, including during first start-up: a) Inspect and clean the filter mesh in the pocket on the flow pipe (see diagram on page 2) b) Check the clogging of the heat exchanger (5) c) Check the operation of the zone valve (3) by switching the room timer-thermostat. d) Visually check for water leakage from the fittings or shut-off valves NOTE: it is advisable at the end of the winter heating period to close the plumbing unit distribution valves (second and third ball valve from the right).
So that the order can be processed, details regarding the plumbing units must be sent to Caleffi.
794204
Pulse domestic water function
If the building has a controller code 755010 and therefore a central transmission line, it is advisable to use the pulse-type cold domestic water meter. The plumbing unit CONTECA module, suitably connected to the rotary meter, acquires the pulses and makes them available for transmission over the bus, facilitating compression and logging of all plumbing unit consumption. Nominal flow rate: Qnom 1.6 m3/h.
Code SAT22 Recess-mounting two-way user satellite for heating and instant hot domestic water production equipped with CONTECA heat meter for local display and arranged for RS485/M-bus transmission. Conforms to Directive 2004/22/EC (MID). Fitted for cold domestic water pulse litre counter code 794204. The SAT22 satellite unit comprises: two-way ball zone valve, with 6440 series actuator (230 V (ac)); brazed exchanger with pre-adjustment valve (Pnom 50 kW). Adjustable thermostatic mixing valve 3050 2C, differential pressure valve. Code 794972 Wall box for SAT22 user satellite including: - Recess-mounting wall box for interiors (l=580 mm - h=7501050 mm - d=140 mm) painted with epoxy polyester powder coating RAL 9010. - Inlet connections from central hearing plant at the bottom 3/4 M. - Outlet connections to plumbing unit at the bottom 3/4 M. Code 794204 Positive displacement meter for plumbing unit cold domestic water with 2004/22/CE (MI001) certification, with direct local display and pulse output k=10. Connection 1/2 M; Qnom 1.6 m3/h. Maximum temperature 30C.
CALEFFI

Catalog Tehnic Complet - GB

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Catalog Tehnic Complet - GB

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

F C 45 53 D 115 131 E 158 183

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

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

- heat capacity P without top-up reset:

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

3041 3045 3046 3047 3048 3049

Class A Check valve

2.5 3 3.5 4 4.5

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

CODE 304740 304750 304760 DN A B

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

CODE 304840 304850 DN

1/2 1/2 71 25,5

3/4 3/4 78 27,5

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

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

Class A flanged check valves

.5 .5 1.5 2.5 3.5 4.5

* Average speed on an entry section

FAX +39 0322 863723

Anti-pollution check valves

Code 304540 304550 304560 304570 304580 304590

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

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

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

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

Weight (kg) 0,16

Code 304640 304650 304660 304670 304680

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

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

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

Weight (kg) 0,40

*Internal check valve DN

4.5 4 3.5 3 2.5

* single check valve

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

Shut-off valve upstream Controllable check valve Inspection points

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

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

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

DP UNIT FLOW UNIT TEMP UNIT POWER UNIT

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

131 series construction details

flow rate readout error %