CALEFFI 519 Series User manual

Function

The differential pressure by-pass valve is used in systems with a

ﬁxed speed circulating pump supplying several zones controlled

by two way zone valves. This valve ensures that the head pressure

of the pump is proportional to the number of two way valves being

closed. It will bypass the differential pressure created by the pump

as the zone valves close, thus eliminating water hammer noise.

Product range

Code 519502A By-pass with ﬂow up to9gpm. Size 3/4" MNPT

union inlet x 3/4" MNPT union outlet

Code 519599A By-pass with ﬂow up to9gpm. Size 3/4" Sweat

union inlet x 3/4" Sweat union outlet

Code 519600A By-pass with ﬂow up to 40 gpm Size 1" FNPT

inlet x 1" MNPT union outlet

Code 519609A By-pass with ﬂow up to 40 gpm Size 1” Female

NPT x 1” sweat outlet

Code 519700A By-pass with ﬂow up to 45 gpm Size11/4" FNPT

inlet x 1 1/4" MNPT union outlet

Code 519709A By-pass with ﬂow up to 45 gpm Size11/4" FNPT

inlet x 1 1/4" Sweat union outlet

Technical characteristics

Materials

Body: brass

Valve plug: brass

Valve plug gasket: peroxide-cured EPDM

O-Ring seals: peroxide-cured EPDM

Union seals: asbestos free NBR

Control knob: ABS

Spring: stainless steel

Performance

Suitable ﬂuids: water, glycol solutions

Max percentage of glycol: 30%

Temperature range: 32–230°F (0–110°C)

Maximum working pressure: 150 psi (10 bar)

Flow rates: 3/4” ﬂow up to9gpm

1” ﬂow up to 40 gpm

1 1/4” ﬂow up to 45 gpm

Setting range: 1 - 6mw.g. (2-10 psi)

CALEFFI

Adjustable differential pressure by-pass valve with graduated scale

519 Series

38482.05

www.cale.com

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 INASAFETY HAZARD.

These items are designed for use in closed hydronic systems. Do not use in plumbing

applications. These items do not meet the low-lead plumbing standards of U.S. and

Canada.

Code 519566A By-pass with ﬂow up to9gpm. Size 3/4" press

union inlet x 3/4" press union outlet

Operating principle When the spring (1) compression is adjusted using the control

knob (2), the force balance acting on the valve plug (3) changes,

thus modifying the threshold pressure value

of the valve. The valve

plug opens, activating the by-pass circuit, only when it is subjected

to a di rential pressure su t to generate a thrust greater than

the thrust exerted by the spring. This allows the w discharge

through the outlet (4), limiting the di rence in pressure between

the two points in the system where the valve is

System operation

O = open

C = close

The job of the di erential pressure 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 ow rate in the circuit decreases due to partial closure of the two-

way zone valves, the head loss in the circuit increases, point B.

The by-pass valve, set to the nominal head value of the pump,

limits the increase in pressure, by-passing the w rate ∆G. This

behavior is guaranteed at any closing condition of the system two-

way zone valves. In fact, once the position of the valve control

knob has been established, the threshold pressure value is more

or less constant as the discharge w rate varies (see hydraulic

characteristic diagrams).

A proper valve sizing must guarantee a su cient w rate by-pass to

keep the pump at its nominal operating point in all system operating

conditions, for example when the rst zone valves are closed.

Flow rate G

∆p

∆pNOMINAL

Pump curve

∆p constant

on the circuit

Circuit resistance curve

with two-way valves

partially open

Circuit resistance curve with

two-way valves fully open

∆G

50% 100%

Two-way

TOTAL LOAD

mH2O

PARTIAL LOAD

mH2O

CAUTION: All work must be performed by d personnel trained in the

proper application, installation, and maintenance of systems in accordance

with all applicable codes and ordinances.

CAUTION: Over-tightening and breakage can occur with the use of T ®

pipe joint compounds. T ®provides lubricity so that care must be

exercised not to over-tighten joints. Failure to follow these instructions

could result in property damage and /or personal injury.

WARNING: System s are under pressure or temperature can be

hazardous. Be sure the pressure has been reduced to zero and the

system temperature is below 100°F (38°C). Failure to follow these

instructions could result in property damage and/or personal injury.

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.

The dierential pressure by-pass valve can be tted in any position,

respecting the owdirectionindicated by the arrow on thevalve body.

In systems with a traditional boiler it is normally tted between the

system ow and return ends, which allows thecontrol of the pressure

and the passage of a minimum ow through the heatgenerator.

In systems withacondensation boiler, it is preferable to t the

by-pass directlybetween theupstream and downstream sections of

the pump,asthis allows a higher ∆T in the circuit, with lower return

temperatures and therefore better operation of the system.

In the event of highby-passow rate levels, it is recommended to t

the valve between the ow and return ends of each column, rather

thanttinganumber of valves in parallel at the central boiler.

mH2O

Installation

To regulate the valve, turn the knob to the required value on the

graduated scale:the values correspond to the dierential pressure in

psi or meters w.g. to open the by-pass.

For a quick setup adjustment of the dierential pressure by-pass

valve, use the following manual method. As an example, a hydronic

system with several zone valves: the system must be operating, the

zone valves must be fully open and theby-pass valve must be set to

the maximum value (a) (clockwise). Graduallyopen the dierential

pressure by-pass valve using the control knob (counterclockwise).

Useathermometer, or simply your hand,tocheck that the hot water

is owing into the by-pass circuit (b). As soon as a rise in the

temperature is noted, turn control knob (clockwise) one halfturn

closed so hot water stopsowing into the by-pass (c). Lock the knob

in this position (d) with the locking screw.

Adjustment

mH2O

6mH2O

a) b)

mH2O

6mH2O

c) d)

Hydraulic

characteristics

code 519502A, 519566A

519599A (3/4”)

∆p

(psi)

0.5

1.5

G(m3/h) (gpm)

∆p

(psi) (m w.g.)

Setting positions

Service Instructions

There is no service required for the dierential by-pass valves.

CAUTION: If the by-pass valve is not installed, commissioned and

maintained properly, according to the instructions 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.

Leave this manual for the user.

Caleffi North America, Inc.

3883 West Milwaukee Road

Milwaukee, WI 53208

T: 414.238.2360 F: 414.238.2366

∆p

(m w.g.)

/h) (gpm)

∆p

(m w.g.) (psi)

code 519700A -

519709A (1 1/4”)

Setting positions

∆p

(m w.g.)

G(m

/h) (gpm)

∆p

(m w.g.) (psi)

code 519600A -

519609A (1”)

Setting positions

7-19-18

Installation Tip

Scan to view

519 DPBV

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