CALEFFI 523160A Guide

Low Lead High Flow Thermostatic Mixing Valves

5231 Series

NA10341.02

www.caleffi.com

ASSE 1017

Installation, commissioning and service instructions

Function

ASSE 1017 model 5231 series high ﬂow thermostatic mixing valves are

designed to be installed at the hot water heater (point of distribution) and

cannot be used for tempering water temperature at ﬁxtures as a point-of-use

valve. They are not designed to provide scald protection and should not

be used where ASSE 1070 devices are required. Series 5231 thermostatic

mixing valves can also be used for regulating the ﬂow temperature in radiant

panel heating systems, to which it assures a constant and accurate control

with ease of installation.

Product range

5231 series thermostatic mixing valve. Union thread NPT male and

union sweat connections, sizes 1", 1 ¼", 1 ½", 2". Inlet port check valve

assemblies available separately for ﬁeld installation.

Technical characteristics

Materials: - body: DZR low-lead brass

- shutter: brass

- springs: stainless steel

- seals: EPDM

- check valve extension (field installed): stainless steel

Suitable fluids: water

Max. percentage of glycol: 30% glycol solution

Setting range: see table on page 2

Temperature stability: ±3°F (±2°C)

Max. working pressure (static): 200 psi (14 bar)

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

Hot water inlet temperature range: 120–195°F (49–91°C)

Cold water inlet temperature range: 39–80°F (3.9–26.6°C)

Mixed temperature range: 95–150°F (32–66°C)

Max. inlet pressure ratio (H/C or C/H) for optimum performance: 2:1

Min. temperature difference between hot water

inlet and mixed water outlet for optimum performance: 20°F (11°C)

Max. water hardness: 10 grains

Certified to:

1. cUPC listed to ASSE 1017/CSA B125.3 Reduction of Lead in

Drinking Water Act Compliant: 0.25% Max. weighted average

lead content. Certifed by IAPMO R&T.

2. Meets requirements of ANSI/NSF 372 - 2011.

Code Description Flow

523160A 1" Union Thread NPT male 4.4 Cv

523168A 1" Union Sweat 4.4 Cv

523170A 1 ¼" Union Thread NPT male 4.4 Cv

523178A 1 ¼" Union Sweat 4.4 Cv

523177A 1 ¼” Union Sweat with outlet temp. gauge 4.4 Cv

523179A 1”, 1 ¼” Replacement body 4.4 Cv

523180A 1 ½” Union Thread NPT male 8.8 Cv

523188A 1 ½” Union Sweat 8.8 Cv

523190A 2” Union Thread NPT male 8.8 Cv

523198A 2” Union Sweat 8.8 Cv

523199A 1 ½”, 2” Replacement body 8.8 Cv

Replacement ﬁtting part numbers

Code Description Tailpiece

all ports (3)

Inlet Check

Valve

Assembly (2)**

Union

nuts (3)

Gaskets

(3)

523160A 1" Union Thread NPT male NA10009

NA10366

R31589 R50057

523168A 1" Union Sweat 31554 FD

523170A 1 1/4" Union Thread NPT male R41660

523178A 1 1/4" Union Sweat 41787 CST

523177A 1 1/4” Union Sweat with outlet temp. gauge* 41787 CST

(2 only)

R31589

(2 only -

177A)

R50057

(2 only -

177A)

523180A 1 1/2” Union Thread NPT male 41371A

NA10377 R51838 R50060

523188A 1 1/2” Union Sweat 41788 CST

523190A 2” Union Thread NPT male 41372A

523198A 2” Union Sweat 41789 CST

*Replacement outlet mixed temperature gauge adapter complete with outlet tailpiece, union nut and gasket, and

temperature gauge (30-210°F), code NA10315.

**Field installed only

Pos. Min 1234567Max

T (°F) 95 104 109 117 122 129 136 142 150

T (°C) 35 40 43 47 50 54 58 61 66

with: THOT = 155°F (68°C) · TCOLD = 55°F (13°C) · PINLETS = 43 psi (3 bar)

Setting the temperature

The temperature is set to the required value by means of the adjustment knob with the graduated

scale on the top of the valve

Principle of Operation

A thermostatic mixing valve mixes hot and cold water in such a way as to maintain a constant set

temperature of the mixed water at the outlet. A thermostatic element is fully immersed into the mixed

water. It then contracts or expands causing movement of the piston, closing either the hot or cold

inlets, regulating the ﬂow rates entering the valve.

If there are variations of temperature or pressure at the inlets, the internal element automatically reacts

attempting to restore the original temperature setting.

Thermal

Shutoff

The Calefﬁ 5231 series

mixing valves require a

minimum temperature

differential from hot inlet

to mixed water outlet of

20°F (11°C) to ensure

the correct operation,

and maximum pressure

difference between the

hot and cold inlet parts

no greater than 2:1 ratio.

Softened water use is

highly recommended as

the warranty is voided

if used on water with

hardness greater than

10 grains.

Recommended

ﬂowrates for

temperature stability:

Flow curves

0.1

0.2

0.3

0.5

p (psi)

0.1

0.2

0.3

0.5

(psi) (bar)

0.01

0.1

0.02

0.03

0.05

1.0

0.2

0.3

0.5

0.4 0.4

0.04

0.4

100

200

1 ¼"

1 ½"

4.4

8.8

Min.

Max.

(gpm) (gpm)

0.1

0.2

0.3

0.5

∆p(psi)

(l/min) (

gpm

)

0.1

0.2

0.3

0.5

(psi) (bar)

0.01

0.1

0.02

0.03

0.05

1.0

0.2

0.3

0.5

0.4 0.4

0.04

0.4

100

200

(l/min) (

gpm

)

1” 523060A

523068A

1/2” - 3/4”

1” 224

Min.

Max.

(gpm) (gpm)

1" 7

7.6

14.2

1-1/4”

1-1/2” 2”

HOT

MIXED

COLD

0.23

2.3

0.46

0.69

1.15

∆p (ft of head)

(l/s)(

gpm

)

4.6

6.9

11.5

0.1

0.2

0.3

0.5

(psi) (bar)

0.01

0.1

0.02

0.03

0.05

1.0

0.2

0.3

0.5

9.2

0.92 0.4

0.04

0.4

100

1.5

3.25

1” 1 1/2” 2”

1 1/4”

∆p



160

2.0

5.0

115

172

Flow should never exceed standards for pipe size and material.

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

proper application, installation, and maintenance of systems in accordance

with all applicable codes and ordinances.

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: If the thermostatic mixing 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.

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

valve 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

the installation, commissioning and maintenance of the thermostatic mixing

valve, 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 mixing valve, in accordance

with current legislation. Otherwise the mixing valve may be damaged and will

not operate correctly.

Leave this manual for the user

Use

Calefﬁ 5231 series thermostatic mixing valves are designed to be installed at the hot water

heater and cannot be used for tempering water temperature at ﬁxtures as a point-of-use

valve. They are not designed to provide scald protection or chill protection service and

should not be used where ASSE 1070 devices are required. Wherever a scald protection

feature is required, ASSE 1070 model mixing valves need to be installed. For safety reasons,

it is advisable to limit the maximum mixed water temperature to 120°F.

Instantaneous production of hot water

Calefﬁ 5231 series thermostatic mixing valves should not be used in conjunction with boilers giving

instantaneous production of domestic hot water. Their addition would compromise the correct

operation of the boiler itself.

Installation

Before installing a Calefﬁ 5231 series thermostatic mixing valve, the system must be inspected to

ensure that its operating conditions are within the range of the mixing valve, checking, for example,

the supply temperature, supply pressure, etc.

Systems where the Calefﬁ 5231 series thermostatic mixing valve is to be ﬁtted 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 affect performance and the manufacturer’s product

guarantee. Softened water use is highly recommended as the warranty is voided if used

on water with hardness greater than 10 grains.

The installation of ﬁlters of appropriate capacity at the inlet of the water from the mains

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.

Calefﬁ 5231 series thermostatic mixing valves must be installed in accordance with the diagrams

in this manual, taking into account all current applicable standards.

Calefﬁ 5231 series thermostatic mixing valves can be installed in any position, either vertical or

horizontal.

The following are shown on the mixing valve body:

- Hot water inlet, “H”.

- Cold water inlet, “C”.

- Mixed water outlet, unmarked.

In systems with thermostatic mixing valves, check valves must be installed to prevent undesirable

ﬂuid backﬂow. The 5231 series valves, codes listed in this instruction sheet, do not contain integral

check valves, so those must be sourced separately. Calefﬁ offers inlet port check valve assemblies

separately, for ﬁeld installation only to 5231 series valve.

It is essential that access to the valve is totally unobstructed for any maintenance which may be

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

the weight of the valve itself.

Application diagrams

Key to symbols

Safetyrelief valve

Check valve

Isolation valve

Expansion vessel

Filter

Pump

Domestic water system with recirculation

MIN

Globe Valve

STORAGE

HOT WATER

HEATER

Key to symbols

Safetyrelief valve

Check valve

Isolation valve

Expansion vessel

Filter

Pump

Radiant panels heating system application

HOTCOLD

MIX

Radiant panel loop

MIN

Domestic water system with recirculation

ASSE 1017 model application

MIN

STORAGE

HOT WATER

HEATER

COLD

BLUE

HOT

RED

MIX

MIN

RETURN

SUPPLY

CALEFFI

Key to symbols

Safetyrelief valve

Check valve

Isolation valve

Expansion vessel

Filter

Pump

Radiant panels heating system application

HOTCOLD

MIX

Radiant panel loop

MIN

Domestic water system with recirculation

ASSE 1017 model application

MIN

STORAGE

HOT WATER

HEATER

COLD

BLUE

HOT

RED

MIX

MIN

RETURN

SUPPLY

CALEFFI

Commissioning

After 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 free from any dirt or debris before commissioning the

thermostatic mixing valve. Be sure water hardness is less than 10 grains.

2) It is recommended that the temperature is set using a suitable calibrated digital thermometer.

The valve must be commissioned by measuring the temperature of the mixed water at the outlet.

3) The maximum outlet temperature from the valve must be set taking account of the ﬂuctuations

due to simultaneous use. It is essential for these conditions to be stabilized before commissioning.

4) Adjust the temperature using the adjusting knob on the valve. For safety reasons, it is advisable

to limit the maximum mixed water temperature to 120°F in domestic hot water systems.

Preset locking

Position the handle to the number required. Unscrew the head screw, pull off the handle and

reposition it so that the handle ﬁts into the internal slot of the knob. Tighten the head screw.

Maintenance

Service tests should be carried out regularly to monitor the mixing valve performance, as deterioration

of performance could indicate that the valve and/or the system require maintenance. If, during

these tests, the temperature of the mixed water has changed signiﬁcantly in comparison with the

previous test, the details given in the installation and commissioning sections should be checked

and maintenance carried out.

The following aspects should be checked regularly to ensure that the optimum performance levels

of the valve are maintained. Every 12 months at least, or more often if necessary.

1) Check and clean the system ﬁlters.

2) Check that any non-return valves positioned upstream of the Calefﬁ valve are operating correctly,

without problems caused by impurities.

3) Limescale can be removed from internal components by immersion in a suitable de-scaling

ﬂuid.

4) When the components which can be maintained have been checked, commissioning should

be carried out again.

Replacement parts

Point of distribution mixed temperature

gauge adaptor ﬁts High Flow 5231

series mixing valves. Threaded union

mounting replaces existing mixed

outlet with 1¼" sweat pipe connection.

Removable gauge ﬁts into temperature

well. Gauge dial is 2" diameter and

scale from 30—210ºF.

Low-lead brass body.

Code Description Lbs

NA10315 1 ¼" sweat with gauge 0.5

688003A Replacement gauge 0.2

Inlet check valve assembly for mounting

on inlet union tail pieces of 5231 mixing

valves.Stainless steel body, acetal plastic

check valve insert with NBR o-ring.

Code Description Open Pressure Lbs

NA10366 Check valve assembly 1' and 1 ¼" 0.23 psi 1.0

NA10367 Check valve assembly 1 ½" & 2" 0.20 psi 1.5

Replacement body.

Meets requirements of ANSI/NSF

372-2011.

Certiﬁed to: cUPC listed to ASSE

1017/CSA B125.3, Low lead.

ASSE 1017

5231

High Flow Body

Code Description Min. Flow (gpm) Cv Lbs

523179A 1 ½" union thread 4.4 7.6 5.0

523199A 2 ½" union thread 8.8 14.2 15.0

Caleffi North America, Inc.

3883 West Milwaukee Road

Milwaukee, WI 53208

T: 414.238.2360 F: 414.238.2366

Troubleshooting

Under normal operating conditions the Calefﬁ 5231 series thermostatic mixing valve will provide a

very high level of performance. However, in some circumstances, where our maintenance plan is not

followed, the following problems may arise.

Symptom Cause Corrective action

Hot water at the cold taps a) Operation of check valve

is hindered; check valve is

not sealing correctly

b) Check valves not fitted

• Replace faulty check valves

Fluctuating mixer water

temperature

a) Erratic supply

temperatures at the inlets

of the valve

b) Starvation of the water

supplies at the inlets of

thevalve

c) Incorrect commissioning

ofthe valve

• Restore inlet conditions

within the limits of the valve

Erratic flow of water from

thevalve

a) Insufficient water supplies

b) Fluctuations in supply

pressures/temperatures

c) Adverse effect created by

other draw off points on

the system

• Stabilize inlet supply

conditions

No flow of water from

thevalve

a) In-line filters blocked

b) Insufficient supply

pressures

c) Debris obstructing

valveoperation

• Clean filters

• Restore inlet supplies

• Clean debris or scale

fromvalve

04-30-15

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