CALEFFI ThermoSetter 116 Series User guide

Function

The ThermoSetter™adjustable thermal balancing valve is used

for automatic balancing of recirculation loops in domestic hot

water systems, to speed hot water delivery, reduce water waste

and save energy. The internal thermostatic balancing cartridge

automatically modulates flow to ensure a constant temperature

in the recirculation piping system. The 116 Series has an

adjustment knob with 95°F to 140°F (35°C to 60°C) temperature

scale indication. An integral dry-well holds a slide-in temperature

gauge for local indication, or a sensor for remote temperature

sensing. The optional check valve protects against circuit thermo-

syphoning.

ThermoSetter™ Recirculation Thermal balancing valve

H0001890.03

116 Series

Installation, commissioning and servicing instructions

Product range

1161 series

ThermoSetter w/o disinfection function, models w/ and w/o temperature

gauge, w/ and w/o check valve.........................connections ½” and ¾” NPT female

1162 series

ThermoSetter w/ disinfection function, models w/ and w/o temperature

gauge, w/ and w/o check valve.........................connections ½” and ¾” NPT female

1163 series

ThermoSetter w/ actuator disinfection function, models w/ and w/o

temperature gauge, w/ and w/o check valve..........................................................

connections ½” and ¾” NPT female

www.caleffi.com

The 1162xx Series is available with a “disinfection” by-pass cartridge, for use in systems which

are designed to perform thermal disinfection for prevention of Legionella. When the disinfection

cartridge senses 160°F (70°C) water, indicating disinfection control mode, it automatically opens

a by-pass flow path to allow sufficient flow for disinfection to occur. When the temperature drops

back to normal range, the disinfection by-pass cartridge closes to return flow control to the

balancing cartridge.

The 1163xx Series is also available with a “disinfection” valve that is controlled by a 24V spring

return normally-closed thermo-electric actuator, rather than thermostatically, thus allowing

thermal disinfection mode to be controlled remotely by an automation system.

The valve is ICC-ES certified to NSF/ANSI 61 (180°F/82°C Commercial Hot) and NSF/ANSI 372, low

lead laws. It meets codes IPC, IRC, UPC and NPC for use in accordance with the US and Canadian

plumbing codes.

NSF 61

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.

LEAVE THIS MANUAL FOR THE USER.

Caleffi shall not be liable for damages resulting from stress corrosion, misapplication or misuse of it products.

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.

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

pipe joint compounds. Teflon®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 fluids 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.

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

CAUTION: If the series ThermoSetter balancing 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.

CONSIGNE DE SÉCURITÉ

Ce symbole d'avertissement servira dans ce manuel à attirer l'attention sur la sécurité concernant

instructions. Lorsqu'il est utilisé, ce symbole signifie. ATTENTION! DEVENEZ ALERTE ! VOTRE

SÉCURITÉ EST EN JEU ! NE PAS SUIVRE CES INSTRUCTIONS PEUT PROVOQUER UN

ATTENTION: Tous les travaux doivent être effectués par du personnel

qualifié formé à la bonne application, installation et maintenance des systèmes

conformément aux codes et règlements locaux.

ATTENTION: Un serrage excessif et la rupture peut se produire avec

l’utilisation de composés à joint de tuyau en Téflon®. Pouvoir lubrifiant Teflon®

permet de sorte qu’il faut prendre soin de ne pas trop serrer les articulations.

Le non-respect de ces instructions peut entraîner des dommages matériels

et/ou des blessures.

AVERTISSEMENT: Les liquides du système sont sous pression ou de la

température peuvent être dangereux. Être sûr que la pression a été réduite

à zéro et la température du système est inférieure à 100°F (38°C). Le non-

respect de ces instructions peut entraîner des dommages matériels et/ou des

blessures.Le non-respect de ces instructions peut entraîner des dommages

matériels et/ou des blessures.

ATTENTION: Si le vanne d’équilibrage, Série ThermoSetter, n'est pas installé,

mis en service et entretenu correctement, selon les instructions contenues dans ce

manuel, il peut ne pas fonctionner correctement et peut mettre en danger l'utilisateur.

ATTENTION: S'assurer que tous les raccordements sont étanches.

Calefﬁ ne pourra être tenue responsable des dommages résultant de la corrosion, d’une mauvaise

utilisation ou une mauvaise utilisation des produits.

AVERTISSEMENT:

Ce produit peut vous exposer à des produits chimiques comme

le plomb, qui est connu dans l’État de Californie pour causer le cancer, dommages à la

naissance ou autre. Pour plus d’informations rendez-vous www.P65Warnings.ca.gov.

LAISSEZ CE MANUEL AVEC L’UTILISATEUR

Thermostatic control,

1161xxA series

Thermostatic control with check valve,

1161xxAC series

Technical specifications

Materials

Body: DZR low-lead brass EN 12165 CW724R

Adjustable cartridge: Stainless steel & copper

Springs: Stainless steel EN 10270-3 (AISI 302)

Hydraulic seals: peroxide-cured EPDM

Adjustment knob: ABS

Performance

Suitable fluid: water

Max. working pressure: 230 psi (16 bar)

Max. differential pressure: 15 psi (1 bar)

Adjustable temperature range: 95–140°F (35 – 60°C)

Factory setting: 130°F (55°C)

Disinfection temperature: 160°F (70°C)

Closing temperature: 170°F (75°C)

Max. inlet temperature: 195°F (90°C)

Cv (Kv) max: 2.1 (1.8)

Cv (Kv) dis: 1.2 (1.0)

Cv (Kv) min: 0.23 (0.2)

Cv (Kv) design: 0.52 (0.45)

Certifications

1. Complies with codes IPC, IRC, UPC and NPC.

2. ICC-ES certified to NSF/ANSI 61 (180°F/82°C Commercial Hot), file PMG-1512.

3. NSF/ANSI 372, low lead certified by ICC-ES, file PMG-1360.

Connections

Main connnections: ½” NPT female

¾” NPT female

Temperature gauge/probe pocket: Ø 10 mm metric

Temperature gauge code 116010

Scale: 30 - 180°F (0–80°C)

Diameter: 1½” (40 mm)

Stem diameter: 0.35” (9 mm)

Function A - Temperature control

At the set temperature, the valve plug, controlled by the thermostatic balancing cartridge,

gradually closes the outlet to the minimum. The outlet never fully closes to always allow a

minimum flow for temperature sensing and to prevent recirculation pump dead-heading. If the

temperature decreases, the outlet increases, causing flow and thus temperature to increase

back to the set temperature as shown in curve 1. If temperature exceeds the set-point, the

plug stays in the minimum closed position as shown in curve 2. The balancing cartridge has a

throttling range of 60°F, from full open to minimum position.

max

T (°F)

G (gpm)

dis

min

Automatic disinfection

Thermal disinfection

Temperature control

100

140

150

160

190

170

180

185

set

(2.1)

(1.2)

(0.23)

design

(0.52)

Function B - Automatic thermostatic disinfection

The 1162xx series operating characteristic curves for operating mode B are curves 1,

2, 3 and 4. When a temperature higher than about 155°F (68°C) is reached, a by-pass

passage begins to open to activate the second thermostatic cartridge which controls the

thermal disinfection process, allowing flow independent of the operation of the thermostatic

balancing cartridge. This allows water flow through a special by-pass port, opening the flow

path up until the temperature of 160°F (70°C) is attained shown in curve 3. If the temperature

continues rising beyond this point, the flow is reduced through the by-pass port to allow

thermal balancing even during the disinfection process. When temperature reaches about

170°F (75°C), the closes the disinfection by-pass port to protect the system fixtures from the

effects of excessive temperatures, as shown in curve 4.

Thermostatic control Minimum flow rate

Thermostatic disinfection Thermal shut-off

Function C - Actuator-controlled disinfection

The 1163xx series operating characteristic curves for operating mode C are curves 1, 2 and

5. When the disinfection operating temperature setting of the electronic disinfection system is

reached, the thermo-electric actuator 656 series (which is controlled by a dedicated electronic

control system), is energized to operate the by-pass valve to control the disinfection process,

allowing flow independent of the operation of the thermostatic balancing cartridge shown

in curve 5. In this case, the minimum head loss is produced during this thermal disinfection

process.

Installation

Before installing the ThermoSetter, flush the pipes to make sure that impurities in system

will not interfere with valve performance. Strainers of sufficient capacity at the inlet from the

water main are highly recommended. The ThermoSetter can be installed in any position,

vertical or horizontal, following the flow direction indicated by the arrow on the valve body.

The ThermoSetter must be installed according to the diagrams given in this manual. It must

be installed to allow free access to for checking on operation and maintenance procedures.

Electrically controlled disinfection

Installation Tip

Scan to view

116 ThermoSetter

Dimensions

Code B C DMass (kg)

Code B C D

1/2" 100

Mass (kg)

3/4 100

18,5

74,5

116140

116150

0,650

0,600

1/2" 100

3/4 100

18,5

74,5

116240

116250

0,750

0,700

Code B C DMass (kg)

1/2" 100

3/4 100

18,5

74,5

116240

116250

0,750

0,700

B’

Code A B B'* C D Wt (lb/kg)

116140A(C) ½" NPT F 4"5 7/16" ¾" 3" 1.7 / 0.75

116141A(C)** ½" NPT F 4"5 7/16" ¾" 3" 1.7 / 0.75

116150A(C) ¾" NPT F 4"5 5/8" ¾" 3" 1.5 / 0.70

116151A(C)** ¾" NPT F 4"5 5/8" ¾" 3" 1.5 / 0.70

*Models with check valve tail-piece (C) end-to-end dimension is B'.

**with integral outlet temperature gauge.

B’

1162xx

1163xx

Code A B B'* C D Wt (lb/kg)

116240A(C) ½" NPT F 4" 5 7/16" ¾" 3" 1.7 / 0.75

116250A(C) ¾" NPT F 4" 5 5/8" ¾" 3" 1.5 / 0.70

116340A(C) ½" NPT F 4"5 7/16" ¾" 3" 1.7 / 0.75

116350A(C) ¾" NPT F 4"5 5/8" ¾" 3" 1.5 / 0.70

The ThermoSetter thermostatic balancing valve is designed to balance

individual branches of domestic hot water recirculation systems, based

on the temperature at the valve. It automatically modulates flow to

maintain hot water availability to all fixtures in the branch circuit.

The valve is at minimum flow (Cv = .23) when the incoming water

temperature is equal to the set-point position of the adjustment

dial. The valve opens as incoming water temperature drops.

For pressure loss calculations in the recirculation system, follow

traditional pipe sizing and head loss practices. For pressure loss

calculations across the ThermoSetter valve, use the design curve

shown in the graph below. This line represents a typical valve position

under normal working conditions (∆T= 10°F). Determine the pressure

drop across the valve by selecting the branch design GPM on the

graph X-axis, draw a vertical line up to the “design” curve, then

go across to the Y-axis to find the design pressure drop. Include

that pressure drop in your head loss calculations for the circuit.

2. 5 3

4.5 6 7 8.810 1213.2

0.01

0.02

0.03

0.05

0.07

0.10

0.15

0.20

0.30

0.50

0.70

1.00

1.50

2.00

3.00

7.25

14.5

0.70

2.00

Flow rate

(/m) (gpm)

0.40

0.30

0.12

0.10

0.08

1.40

1.80

0.90

0.60

0.30

1.20

0.16

0.20

0.50

0.60

0.90

1.00

1.80

0.36

0.48

2.40

3.00

3.60

4.20

4.80

5.40

6.00

7.80

∆p (psi) ∆p (kPa)

0.1

0.2

0.3

0.5

0.7

1.0

1.4

2.0

3.5

7.0

10˚F ∆T

inlet to setpoint

Operation in

by-pass mode

0.23 Cv

minimum

1.2 Cv

by-pass

2.1 Cv

full open

0.52 Cv

design

The “by-pass mode” curve in the chart above shows the head loss of

the valve when it is in by-pass thermal disinfection mode for Legionella

control.

Flow characteristics

Temperature adjustment

Set the desired recirculation system temperature by turning the adjustment knob. The graduated

scale shows the temperatures at which the indicator can be set. A valve temperature setting at about

10°F (5°C) higher than the water temperature at the valve inlet is recommended, accounting for heat

losses along the line, to limit the head required at the recirculation pump. Be sure this is the minimum

flow rate at the mixing valves in the central heating system.

Adjustment locking

After adjusting the temperature, the setting can be locked at the desired value using the adjustment

knob. Unscrew the locking screw at the top of the adjustment knob, remove the knob and then

put it back on so that the internal groove couples with the protrusion on the knob holder nut. When

this block is used, the reference of the indication of the temperature values on the knob is lost. To

restore it, completely unscrew the lcoking screw. Reposition the knob on MAX value. Tighten the

locking screw.

Maintenance

Both the balancing adjustment cartridge and the disinfection control cartridge can be removed from

the valve body for periodic inspection, cleaning or replacement.

Innsulation shell

The ThermoSetter thermal balancing valve can be supplied with an optional insulation shell, code

CBN116140 purchased separately, to minimize heat loss.

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