CALEFFI 116A Series Thermosetter Recirculation Thermal Balancing Valve Instructions

CALEFFI 116A Series Thermosetter Recirculation Thermal Balancing Valve

Product Information

• The ThermoSetterTM Recirculation thermal balancing valve is part of the 116A Series by Caleffi. It is designed for installation, commissioning, and servicing in various applications. The valve is compliant with NSF/ANSI/CAN 61 standards for safe water usage. It is available with a disinfection valve that can be controlled remotely by an automation system.
• The ThermoSetterTM 116A series can also be ordered pre-assembled with the Caleffi NA108 series low-lead brass full-port ball valve for isolation. This configuration includes two ball valves and low-lead close nipples.
• The valve is made of DZR low-lead brass body, adjustable cartridge, stainless steel springs, peroxide-cured EPDM hydraulic seals, and an adjustment knob. It has a maximum working pressure of 230 psi (16 bar) and a maximum differential pressure of 15 psi (1 bar). The adjustable temperature range, factory setting, disinfection temperature, closing temperature, and maximum inlet temperature are specified in the technical specifications.
• The product comes with safety instructions and warnings regarding potential hazards and exposure to lead. It is important to follow the installation, commissioning, and maintenance instructions provided in the manual to ensure proper operation and user safety.
• The ThermoSetterTM balancing valve should be installed with water-tight connecting pipework to prevent damages resulting from stress corrosion or misapplication.
• The valve is certified to comply with NSF/ANSI 372 low lead standards.

Product Usage Instructions

1. Ensure that all safety instructions and warnings are read and understood before proceeding with installation or usage of the ThermoSetterTM valve.
2. Install the valve according to the provided installation instructions in the manual.
3. Commission the valve as per the commissioning instructions in the manual to ensure proper operation.
4. Maintain the valve regularly to ensure continued performance and user safety.
5. If using the valve for thermostatic disinfection, follow the instructions provided in the manual for automatic thermostatic disinfection.
6. Ensure that the minimum flow rate specified in the manual is maintained for proper valve operation.
7. Refer to the installation tip provided in the manual for additional guidance during installation.

Installation, commissioning and servicing instructions

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 116A Series has an adjustment knob with connection size specific 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.

• The 1162xx and 1166xx Series are available with a “disinfection” bypass cartridge, for use in systems which are designed to perform thermal disinfection for control of Legionella. When the disinfection cartridge senses 160°F (70°C) -1162xx, or 140°F (60°C) -1166xx, water (2 available disinfection bypass temperature options), indicating disinfection control mode, it automatically opens a bypass flow path to allow sufficient flow for disinfection to occur. When the temperature drops back to normal range, the disinfection bypass 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 ThermoSetter 116A series is also available pre-assembled with the Caleffi NA108 series lowlead brass full-port ball valve for isolation. This can be ordered complete with two of these ball valves plus low-lead close nipples by adding a suffix “001” to the order code number.
• The valve complies with NSF/ANSI/CAN 61 (180°F/82°C Commercial Hot) as certified by ICC-ES, and complies with NSF/ANSI 372, low lead, and codes IPC, IRC, UPC and NPC for use in accordance with the US and Canadian plumbing codes, as certified by ICC-ES.

Product range

• 1161 series ThermoSetter w/o disinfection function, models w/ and w/o temperature gauge, w/ and w/o check valve……………connections ½”, ¾”, 1” & 1¼” NPT female
• 1162 series ThermoSetter w/ disinfection function bypass cartridge (160°F (70°C)), models w/ and w/o temperature gauge, w/ and w/o check valve…½”, ¾”, 1” & 1¼” NPT female
• 1163 series ThermoSetter w/ actuator disinfection function, models w/ and w/o temperature gauge, w/ and w/o check valve……½”, ¾”, 1” & 1¼” NPT female
• 1166 series ThermoSetter w/ disinfection function bypass cartridge (140°F (60°C)), models w/ and w/o temperature gauge, w/ and w/o check valve…½”, ¾”, 1” & 1¼” NPT female
• 116xxxA(C) 001 series Any ThermoSetter code number described above, with inlet and outlet ball valves…………….½”, ¾”, 1” & 1¼” NPT female

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.

• 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: 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.
• 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.
• CAUTION: Make sure that all the connecting pipework is water tight.
• Caleffishall not be liable for damages resulting from stress corrosion, misapplication or misuse of it products.

Technical specifications

Materials

• Body: DZR low-lead brass EN 12165 CW724R
  • Adjustable cartridge: PSU
• 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: sizes ½”& ¾” : 95–140°F (35 – 60°C)
• sizes 1” & 1¼”: 95 – 150°F (35 – 65°C)
  • Factory setting : 130°F (55°C)
• Disinfection temperature: 1162xx series-160°F (70°C) 1166xx series-140°F (60°C)*
  • Maximum temperature setting must be less than 140°F for 1” & 1 ¼” sizes when using the 140°F disinfection temperature bypass cartridge.
• Closing temperature: 1162xx series-170°F (75°C) 1166xx series-150°F (65°C)
  • Max. inlet temperature : 195°F (90°C) ½”& ¾” 1” & 1¼”
• Cv (Kv) max: 2.1 (1.8) 4.4 (3.8)
  • Cv (Kv) dis : 1.2 (1.0) 2.3 (2.0)
• Cv (Kv) min: 0.23 (0.2) 1.0 (0.9)
  • Cv (Kv) design: 0.52 (0.45) 1.9 (1.6)

Certifications

1. Complies with codes IPC, IRC, UPC and NPC and standard NSF/ANSI/CAN 61 (180°F/82°C Commercial Hot), as certified by ICC-ES, file PMG-1512.
2. Complies with NSF/ANSI 372, low lead, as certified by ICC-ES, file PMG-1360.

Connections

• Main connnections: ½”, ¾”, 1” & 1¼” 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)
• Thermostatic control, 1161xxA series
  • Thermostatic control with check valve, 1161xxAC series
• For 1166xx series with 140°F bypass temperature and 150°F closing temperature.
  • For 1162xx series with 160°F bypass temperature and 170°F closing temperature.

Function A – Temperature control
At the set temperature, the valve plug (1), controlled by the thermostatic balancing cartridge (2), gradually closes the outlet (3) 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.

1. Thermostatic control
2. Minimum flow rate

Function B – Automatic thermostatic disinfection

• The 1162xx and 1166xx 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 bypass passage begins to open to activate the second thermostatic cartridge (4) which controls the thermal disinfection process, allowing flow independent of the operation of the thermostatic balancing cartridge. This allows water flow through a special bypass port, opening the flow path up until the bypass temperature is attained shown in curve 3. If the temperature continues rising beyond this point, the flow is reduced through the bypass port to allow thermal balancing even during the disinfection process. When temperature reaches closing temperature, the disinfection bypass port (5) closes to protect the system fixtures from the effects of excessive temperatures, as shown in curve 4.
• 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 bypass 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.
• Electrically controlled disinfection

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.

Dimensions

ThermoSetter 116A series without check valves

**Code (1)| ****Code (2)| ****A| ****B| ****C| ****D| ****E| Wt w/o ball valves (lb/kg)| Wt with ball valves (lb/kg)
---|---|---|---|---|---|---|---|---
116 140A| 116 D40A| ½” NPT F| 4″| ¾”| 3″| —| 1.6 / (0.7)| —
116 140A 001| 116 D40A 001| ½” NPT F| —| ¾”| 3″| 11¼”| —| 2.6 (1.1)
116 141A| —| ½” NPT F| 4″| ¾”| 3″| —| 1.7 / (0.8)|
116 141A 001| —| ½” NPT F| —| ¾”| 3″| 11¼”| —| 2.7 (1.2)
116 150A| 116 D50A| ¾” NPT F| 4″| ¾”| 3″| —| 1.6/ (0.7)| —
116 150A 001| 116 D50A 001| ¾” NPT F| —| ¾”| 3″| 10 9/16“| —| 3.1 (1.4)
116 151A| —| ¾” NPT F| 4″| ¾”| 3″| —| 1.7 / (0.8)| —
116 151A 001| —| ¾” NPT F| —| ¾”| 3″| 10 9/16”| —| 3.2 (1.5)
116 160A| 116 D60A| 1″ NPT F| 4½”| 1″| 4 3/8“| —| 2.1 / (0.95)| —
116 160A 001| 116 D60A 001| 1″ NPT F| —| 1″| 4 3/8”| 12″| —| 4.1 (1.8)
116 161A| —| 1″ NPT F| 4½”| 1″| 4 3/8”| —| 2.2 / (1.00)| —
116 161A 001| —| 1″ NPT F| —| 1″| 4 3/8”| 12″| —| 4.2 (1.9)
116 170A| 116 D70A| 1¼” NPT F| 4½”| 1″| 4 3/8”| —| 2.1 / (0.95)| —
116 170A 001| 116 D70A 001| 1¼” NPT F| —| 1″| 4 3/8”| 13 7/8“| —| 5.6 (2.5)
116* 171A| —| 1¼” NPT F| 4½”| 1″| 4 3/8”| —| 2.2 / (1.00)| —
116 171A 001*| —| 1¼” NPT F| —| 1″| 4 3/8”| 13 7/8”| —| 5.7 (2.6)

• Codes with suffix ‘001’ come assembled with NA108 ball valves on the inlet and outlet.

1. Models without disinfection function with integral outlet temperature gauge.
2. Models with disinfection function

• D=2 for models with 160°F (70°C) disinfection temperature.
• D=6 for models with 140°F (60°C) disinfection temperature.
• D=3 for models with actuator disinfection function.
• NOTE: All models, in this column come complete with integral outlet temperature gauge.

**Code (1)| ****Code (2)| ****A| ****B| ****C| ****D| ****E| Wt w/o ball valves (lb/kg)| Wt with ball valves (lb/kg)
---|---|---|---|---|---|---|---|---
116 140AC| 116 D40AC| ½” NPT F| 5 7/16“| ¾”| 3″| —| 1.8 / 0.8| —
116 140AC 001| 116 D40AC 001| ½” NPT F| —| ¾”| 3″| 12 15/16“| —| 2.8 (1.3)
116 141AC| —| ½” NPT F| 5 7/16”| ¾”| 3″| —| 1.9 / 0.9|
116 141AC 001| —| ½” NPT F| —| ¾”| 3″| 12 15/16“| —| 2.9 (1.3)
116 150AC| 116 D50AC| ¾” NPT F| 5 5/8“| ¾”| 3″| —| 1.8/ 0.8| —
116 150AC 001| 116 D50AC 001| ¾” NPT F| —| ¾”| 3″| 13 1/8“| —| 3.1 (1.4)
116 151AC| —| ¾” NPT F| 5 5/8”| ¾”| 3″| —| 1.9 / 0.9| —
116 151AC 001| —| ¾” NPT F| —| ¾”| 3″| 13 1/8“| —| 3.2 (1.5)
116 160AC| 116 D60AC| 1″ NPT F| 9 ½”| 1″| 4 3/8“| —| 2.3 / 1.00| —
116 160AC 001| 116 D60AC 001| 1″ NPT F| —| 1″| 4 3/8“| 15 ¾”| —| 4.3 (1.9)
116 161AC| —| 1″ NPT F| 9 ½”| 1″| 4 3/8“| —| 2.4 / 1.1| —
116 161AC 001| —| 1″ NPT F| —| 1″| 4 3/8“| 15 ¾”| —| 4.4 (2.0)
116 170AC| 116 D70AC| 1¼” NPT F| 9 ¾”| 1″| 4 3/8“| —| 2.3 / 1.00| —
116 170AC 001| 116 D70AC 001| 1¼” NPT F| —| 1″| 4 3/8“| 17 3/8“| —| 4.1 (1.8)
116* 171AC| —| 1¼” NPT F| 9 ¾”| 1″| 4 3/8“| —| 2.4 / 1.1| —
116 171AC 001*| —| 1¼” NPT F| —| 1″| 4 3/8“| 17 3/8“| —| 4.2 (1.9)

Codes with suffix ‘001’ come assembled with NA108 ball valves on the inlet and outlet.

1. Models without disinfection function with integral outlet temperature gauge.
2. Models with disinfection function

• D=2 for models with 160°F (70°C) disinfection temperature.
• D=6 for models with 140°F (60°C) disinfection temperature.
• D=3 for models with actuator disinfection function.
• NOTE: All models, in this column come complete with integral outlet temperature gauge.

Flow characteristics

• 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 = 0.23 for ½” & ¾”; 1.0 for 1″ & 1¼”) 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 graphs 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.
• The “bypass mode” curve in the chart above shows the head loss of the valve when it is in bypass thermal disinfection mode for Legionella control.
• The “bypass mode” curve in the chart above shows the head loss of the valve when it is in bypass thermal disinfection mode for Legionella control.

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 (A), 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 regulating screw (B).
• NOTE: for 1″ and 1¼” sizes only stop at 1 1/8” as shown. Replace the knob and reposition it to the maximum value (140º ½” & ¾”), (150º 1″ & 1¼”) . 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.

Insulation shell

• The ThermoSetter insulation shell, code CBN116140 (sizes ½” & ¾”), CBN116160 (sizes 1″ & 1¼”) can be purchased separately to minimize heat loss.

Replacement parts

Isolation ball valves

• The NA108 series low-lead brass full-port ball valves are designed for isolating ThermoSetter 116A series thermal balancingi valves with the 1/2″ through 1- 1/4″ FNPT connections. The isolation valve easily installs in the inlet and outlet sides of the valve body using a low-lead close nipple. Some products are available pre-assembled with the NA108 series isolation valve.
• For example, the Caleffi 116A series ThermoSetter can be ordered complete with two of these ball valves plus low-lead close nipples by adding a suffix “001” to the order code number, see page 9 through 11.
• The NA108 series have an extended stem which allows operation if the valve body gets insulated.
• There is no need to purchase an expensive separate stem extension which then has to be field-installed between the valve body and handle.
• The valve features a blowout proof stem, PTFE seats, double o-ring stem seals, lead free brass ball and stem, and polyamide thermal plastic T handle.
• The following codes can be ordered separately for field installation with separately sourced low-lead close nipples.

Code Description

• NA10824 ½” FNPT
• NA10825 ¾” FNPT
• NA10826 1″ FNPT
• NA10827 1¼” FNPT

Application diagrams

Hot water recirculation with thermal balancing valves

Hot water recirculation with actuator controlled disinfection

• Caleffi North America, Inc. 3883 W. Milwaukee Road Milwaukee, WI 53208 T: 414.238.2360 F: 414.238.2366
• www.caleffi.com

Documents / Resources

| CALEFFI 116A Series Thermosetter Recirculation Thermal Balancing Valve [pdf] Instructions
116A Series Thermosetter Recirculation Thermal Balancing Valve, 116A Series, Thermosetter Recirculation Thermal Balancing Valve, Thermal Balancing Valve, Balancing Valve
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References

• Caleffi Hydronic Solutions | Caleffi S.p.a.
• P65Warnings.ca.gov

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