CALEFFI 252169A Guide

Function

The thermostatic mixer is used in solar thermalsystems

producing domestic hot water. 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 supply conditions

of the incoming hot and cold water. This particular series of

mixingvalves can function continuously at the high

temperatures of incoming hot water from the solar storage tank.

The valve has been specically certied to ASSE 1017.

Product range

Series 2521 thermostatic mixing valve. Union thread NPT male

connections, sizes 1/2”, 3/4”,1”; union solder connection, size

1/2”, 3/4”, 1”.

Technical Characteristics

· Materials: - Body: Low-lead brass

(<0.25% Lead content), chrome plated

- Shutter: PSU

- Springs: Stainless steel

- Seals: EPDM

· Setting range: 85–150°F (30–65°C)

· Accuracy: ±3°F (±2°C)

· Max working pressure (static): 200 psi (14 Bar)

· Max working pressure (dynamic): 75 psi (5 bar)

· Min working pressure (dynamic): 3 psi (0.2 bar)

· Max hot water inlet temperature: 212°F (100°C)

· Maximum inlet pressure ratio (H/C or C/H): 2:1

· Minimum temperature dierence between hot water inlet and

mixed water outlet for optimum performance: 30°F (15°C)

· Min. ow rate to ensure stable temperature: 1.3 gpm (5 lpm)

· Certied to: ASSE 1017

· Lead Plumbing Law Compliance: (0.25% Max. weighted

average lead content)

· Lead Plumbing Law Certied by ICC-ES, le MPG-1360.

Adjustable Thermostatic Mixing Valve for Solar Systems

2521 Series

28114.02

INSTALLATION AND COMMISSIONING MANUAL

ASSE 1017

www.cale.com

CALEFFI

Installation Tip

Scan to view

2521 Solar Mixing Valve

CAUTION: If the thermostatic mixer is not installed, commissioned and

maintained properly, according to theinstructions contained in this

manual, it may not operate correctly and may endanger the user.

CAUTION: Make sure that all the connecting pipework is water tight.

CAUTION: Installing in an ASSE 1017 application, check valves shall

be used.

CAUTION: When making the water connections, make sure that the mixer

connecting pipework is not mechanically over-stressed. Over time this

could cause breakages, with consequent water losses which, in turn,

could cause harm to property and/or people.

CAUTION: Water temperatures higher than 100°F can be dangerous.

During theinstallation, commissioning and maintenance of the

thermostatic mixer, take the necessary precautions to ensure that such

temperatures do not endanger people.

CAUTION: In the case of highly aggressive water, arrangements must be

made to treat the water before it enters the thermostatic mixer, in

accordance with current legislation. Otherwise the mixer may be damaged

and will not operate correctly.

Leave this manual for the user.

SAFETY INSTRUCTION

This safety alert symbol will be used in this manual to draw attention to safety related

instructions. When used, the safety alert symbol means ATTENTION! BECOME ALERT!

YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THESE INSTRUCTIONS MAY

RESULT IN A SAFETY HAZARD.

CAUTION: All work must be performed by qualied personnel trained in the

proper application, installation, and maintenance of systems in accordance

with all applicable codes and ordinances.

WARNING: This product can expose you to chemicals including lead, which is

known to the State of California to cause cancer and birth defects or other

reproductive harm. For more information go to www.P65Warnings.ca.gov.

O erating Princi le

The controlling element o the solar thermostatic

mixing valve is a temperature sensor that is ully

immersed in the mixed water outlet passage. As

it expands or contracts, the sensor continuously

establishes the correct proportion o hot and

cold water entering the valve. The low is

regulated by a piston sliding in a cylinder

between the hot and

cold water passages.

Even when there are

pressure drops due to

the drawing o o hot or

cold water or other uses

or variations in the

incoming temperature,

the mixer automatically

regulates the water low

to obtain the required

temperature.

Flow curves

Kv = 2.6

0.2

∆p(psi)

G(l/min) (

gpm

)

(psi) (bar)

0.5

001

002

003

05

Cv = 3.0

.04

0.4

.04

0.4

COLD

HOT

MIX

COLD HOT

Ex loded diagram

Reg lating knob

Head fixing screw

Reg lating spindle

“O” Ring seal

Upper sh tter seat

Thermostatic element

Inner sh tter

“O” Ring

O ter sh tter

“O” Ring

Spring cover

Spring

Valve body

Union n t

Gasket

Tail piece body

Installation

Before installingaCale 2521 series mixing valve, the system

must be inspected to ensure that its operating conditions are

within the range of the mixer, checking, for example, the supply

temperature, supply pressure, etc.

Systems where the Cale 2521 series mixing valve is to be

tted must be drained and cleaned out to remove any dirt or

debris which may have accumulated during installation.

Failure to remove dirt or debris may aect performance

and the manufacturer's product guarantee.

The installation olters of appropriate capacity at the inlet

of the water from main supply is always advisable.

In areas which are subject to highly aggressive water,

arrangements must be made to treat the water before it

enters the valve.

Cale 2521 series mixing valve must be installed in accordance

with the diagrams in this manual, taking into account all current

applicable standards.

Cale 2521 series mixing valve can be installed in any position,

either vertical or horizontal.

The following are shown on the valve body:

- Hot water inlet, color red and marked “HOT”.

- Cold water inlet, color blue and marked “COLD”.

- Mixed water outlet, marked “MIX”.

It is essential that access to the valve is totally unobstructed for

any maintenance which may be required to thevalve or

connections. The pipework from/to the valve must not be used to

support the weight of the valve itself.

Use

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 end user.

Because of their ow characteristics, the valves can be installed

to control the temperature for both single point of use and for point

of distribution. In order to guarantee the delivery of mixed water at

the set temperature, the 2521 series thermostatic mixing valves

must haveaminimum ow rate of 1.3 gpm.

Application Diagrams

COLD/BLUEHOT/RED

MIX

Key to symbols

Safety relief valve

Isolation and check valve

Isolation valve

Expansion vessel

Filter

HOT

COLD

MIX

MIN

HOT

COLD

CALEFFI

MIN

Normally closed

valve

Commissioning

A ter installation, the valve must be tested and commissioned in

accordance with the instructions given below, taking into account

current applicable standards.

1) Ensure that the system is clean and ree rom any dirt or debris

be ore commissioning the thermostatic mixer.

2) It is recommended that the temperature is set using a suitable

calibrated digital thermometer. The valve must be

commissioned by measuring the temperature o the mixed

water emerging at the point o use.

3) The maximum outlet temperature rom the valve must be set

taking account o the luctuations due to simultaneous use.

It is essential or these conditions to be stabilised be ore

commissioning.

4) Adjust the temperature using the adjusting knob on the valve.

For sa ety reasons, it is advisable to limit the maximum mixed

water temperature to 120°F in domestic hot water systems.

Setting the tem erature

The temperature is set to the required value by means o the

adjusting knob with the graduated scale on the top o the valve.

Preset locking

Position the handle to the number required. Unscrew the head

screw, pull o the handle and reposition it so that the handle its

into the internal slot o the knob. Tighten the head screw.

Maintenance

In service tests should be carried out regularly to monitor the

mixer per ormance, as deterioration o per ormance could

indicate that the valve and/or the system require maintenance. I ,

during these tests, the temperature o the mixed water has

changed signi icantly in comparison with the previous test, the

details given in the installation and commissioning sections

should be checked and maintenance carried out.

The ollowing aspects should be checked regularly to ensure that

the optimum per ormance levels o the valve are maintained.

Every 12 months at least, or more o ten i necessary.

1) Check and clean the system ilters.

2) Veri y that any check valves positioned upstream o the Cale i

valve are operating correctly, without problems caused by

impurities.

3) The Cale i valve should not be dismantled. Limescale can be

removed rom internal components by immersion in a suitable

de-scaling luid.

4) When the components which can be maintained have been

checked, commissioning should be carried out again.

Min 1 2 3 4 5 6 7 Max

81 90 100 111 120 127 136 145 152

Pos.

27 32 38 44 49 53 58 63 67

Troubleshooting

Under normal operating conditions the Cale 2521 series mixing valve will provideavery

high level of performance. However, in some circumstances, where our maintenance plan is

not followed, the following problems may arise.

Symptom

Fluctuating mixed water

temperature

Erratic ow of water from

thevalve

No ow of water from the

valve

Cause

a) Erratic supply temperatures

at the inletsofthevalve.

b) Starvationofthewater

supplies at the inlets

of the valve.

c) Incorrectcommissioning

of the valve.

a) Insucient water supplies.

b) Fluctuationsinsupply

pressures/temperatures.

c) Adverse eect created

by otherdraw o points

on thesystem.

a) In-line lters blocked.

Insucient supply pressures.

c) Debris obstructing valve

operation.

Corrective action

·Restore inlet conditions

within thelimits of the

valve.

·Stabilizeinlet supply

conditions.

·Clean lters.

·Restore inlet supplies.

·Clean debris or scale

from valve.

Caleffi North America, Inc.

3883 West Milwaukee Road

Milwaukee, WI 53208

T: 414.238.2360 F: 414.238.2366

Leave this manual for the user.

6-6-18

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