ThermoMix boiler protection high-ow thermostatic mixing valve

280 series
ACCREDITED

CALEFFI
01223/13 NA
ISO 9001 No. 0003

ISO 9001 FM 21654

Replaces 01223/12 NA

Function
The ThermoMix boiler protection high-ow thermostatic mixing valve is used in hydronic heating systems with non-condensing boilers, including solid fuel, biomass, gas, LP or oil-red. It can be installed with steel, cast iron and copper tube style boilers, automatically controlling the return water temperature, preventing condensation of the water vapor contained in the ue gas. The 280 series ThermoMix valve mixes by-pass ow from the boiler with return ow from the system, sending a xed temperature ow to the boiler which protects against corrosion from condensation occurring when a minimum ue gas temperature is not otherwise maintained. Exchangeable thermostatic sensor cartridge changes valve temperature setting. The thermostatic sensor cartridge can easily be removed for maintenance or to change the valve set temperature, with out removing the valve body from the piping.

Product range
280 series ThermoMix boiler protection valve...............................................................................connections 1" and 1-1/4" NPT male or sweat union

Technical specications
Materials - body: - lower body plug: - shutter: - spring: - seal: - union seals: - thermostatic sensor: brass brass PSU stainless steel EPDM ber wax

Dimensions

Performance Suitable uids: water, glycol solutions Max. percentage of glycol: 50% Max. working pressure: 150 psi (10 bar) Working temperature range: 40212F (5100C) Thermostatic sensor cartridge: 130F (55C) Tset standard Optional cartridges Tset (eld replaceable): 115F (45C) 140F (60C) 160F (70C) Sensor cartridge accuracy: 4F (2C) By-pass closed temperature: Tset +18F (+10C) Fully open ow characteristic: 10 Cv (size 1") 14 Cv (size 1-1/4") Connections: - NPT male union: - sweat union: 1" and 1-1/4" 1" and 1-1/4" Code 280165A 280965A 280175A 280975A A 1" NPT 1" SWT 1 4" NPT
1

B 3 2"
1

C 7" 7" 7 8"

5

D 6" 6" 6 16"

13

E 1 8"
5

F 4 38" 4 38" 4 38" 4 38"

3 12" 3 16"
13

158" 1 16"
9

114" SWT

31316"

758"

61316"

1916"

Wood biomass and condensation build-up

Wood contains a variable moisture content depending on the type (logs, pellets, woodchips, etc.). Water vapor is released during the solid fuel drying phase inside the combustion chamber. The presence of cold surfacesCONDENSING in NONthe boiler or ue gas chimney can lower the temperature of BOILER the ue gas down to the dew point, causing condensation. Water vapor condenses on the boiler surfaces, together with soot and part of the unburnt hydrocarbons contained in the ue gas, producing tar deposits. These substances stick to the walls of the boiler, covering most of the inner surfaces. In addition to being dangerous due to its ammability, tar is damaging to the integrity of the boiler and limits the efciency of the ue gas-system waterexchanger. By keeping the boiler walls at the highest possible temperature, the boiler protection valve limits the formation of these substances thereby increasing combustion efciency, controlling emissions into the environment and prolonging boiler life.

Operating principle
The thermostatic sensor, completely immersed in the medium, controls NONthe CONDENSING movement of a shutter that regulates the by-pass ow from the BOILER boiler and toward the system. At boiler startup, the boiler protection NONthermostatic CONDENSING mixing valve recirculates the by-pass ow from the boiler BOILER to bring the boiler up to temperature as quickly as possible (g. 1). When the by-pass ow from the boiler Tf exceeds the setting of the boiler protection mixing valve Tset, the valves return from the system port starts opening to produce the water mixing Tmix: in this phase the system loading begins (g. 2). When the mixed ow to the boiler temperature Tmix is greater than the set point of the boiler protection mixing valve by approximately 18F (10C), the by-pass flow from the boiler port closes and water returns to the boiler at the same temperature as the return ow from the system (g. 3).
Tf Tset SYSTEM START UP by-pass open NONsystem return closed CONDENSING BOILER Tf Tset, Tmix=Tf 1

Flue gas and emission NONcontrol CONDENSING

BOILER

Tf > Tse by-pas system Tf > Tse

NONCONDENSING BOILER

NONCONDENSIN BOILER

Tf Tset SYSTEM START UP by-pass open Accumulation of ash system and return closed residues Tf Tset, Tmix=Tf Primary and secondary air Combustion efficiency
NONCONDENSING BOILER

BOILER PROTECTION VALVE Zone of condensation forming Tar deposits Corrosion Reduction in heat exchanger efficiency Flammability

Tf Tset SYSTEM START UP by-pass open system return closed Tf>Tset, Tset Tmix=Tf START OF SYSTEM LOADING Tf by-pass open system return open Tmix = Tset BY-PASS CLOSING Tf > Tset, Tr + < 18F Tset, Tmix=Tset by-pass closed system return open NONTf > Tmix Tset +18F , Tmix=Tr CONDENSING
BOILER NONCONDENSING BOILER NONCONDENSING BOILER

1 2 3

Tf > Tse by-pas system Tf > Tse

Tmix > T by-pas system NONTfCONDENSI > Tmix

BOILER

NONCONDENSIN BOILER

Characteristic components
By-pass from boiler

Tmix = Tset + 18F BY-PASS CLOSING Temp gauge pocket by-pass closed wells (4) system Valve bodyreturn open Tf > Tmix Tset +18F , Tmix=Tr
Spring Thermostatic sensor
NONCONDENSING BOILER

Tmix = Tset + 18F BY-PASS CLOSING by-pass closed system return open Tmix > Tset + 18F SYSTEM LOADED Tf > Tmix Tset +18F , Tmix=Tr by-pass closed system return open Tf > Tmix > Tset +18F , Tmix=Tr
NONCONDENSING BOILER

3 4

Tmix > T by-pas system Tf > Tmix

Shutter

NONCONDENSI BOILER

Plug

System return

Return from system

NONCONDENSING BOILER

Mixed to boiler

Construction details
Brass body The brass body prevents the formation of ferrous residues in the system, prolonging boiler operating life. Thermostatic sensor replacement to modify the setting The thermostatic sensor can be easily replaced for maintenance or set pointchange without removing. Code F29633 F29634 F29635 F29636 Description 115F 130F 140F 160F

Sizing method/set point selection

Knowing the BTU output and thermal head on the boiler, the boiler ow rate can be calculated. Use the hydraulic characteristics graph to identify the pressure drop of the valve. The valve size can then be selected from the pressure drop value with the available head of the system pump. The thermostatic set point (F) must be selected to control a mixed return to the boiler temperature that is high enough to prevent condensation, also using the information or instructions supplied by the manufacturers of solid fuel boilers.

Installation
The valve can be installed on both sides of the boiler in any position, vertical or horizontal. Installation is recommended on the return to the boiler in mixing mode. It can also be installed on the ow from the boiler in diverting mode. Installation in mixing mode (boiler protection)

Temperature gauge pocketwells The boiler protection mixing valve body features temperature gauge pocket wells on front and rear sides, allowing installation of a temperature gauge (codeF29571) for monitoring the working temperatures: by-pass from boiler, return from system, and mixed toboiler.

Hydraulic characteristics
p kPa 150 100

NONCONDENSING NONBOILER CONDENSING BOILER

1"

1-1/4"

p ft of hd (psi) 48 33 (21) (14.5)

50 30 20

16 10 7

(7) (4.3) (3)

Installation in diverting mode (system control)

10

3.5

(1.5)

5 (22) (44) (2) (4) (9)

1.6 5.5 (88) Flow rate l/s (gpm)

(0.7)
NONCONDENSING NONBOILER CONDENSING BOILER

.16

.33

.83

1.6

Cv:

size 1", 10 size 1-1/4", 14

Application diagrams
Non-condensing boiler, direct supply to the system Use safety devices according to local regulations
Tf Tset SYSTEM START UP Tfby-pass Tset SYSTEM START UP open by-passreturn open closed system return closed Tf system Tset, Tmix=Tf Tf Tset, Tmix=Tf
Air separator Dirt separator Pump Shut-off valve Expansion vessel Check valve
NONCONDENSING NONBOILER CONDENSING BOILER

3.3

1 1

Tf > Ts Tf > Ts by-pa by-pa syste Tfsyste > Tse Tf > Tse

Motorized mixing valve Pressure reducing valve Filling unit

NON CONDENS NON BOILE CONDENS BOILE

NONCONDENSING BOILER

Backflow preventer Safety relief valve

*
*Air purge recommended for boiler loop

Dirt separator for vertical pipes Air separator for vertical pipes Hydraulic separator

Tmix = Tset + 18F BY-PASS CLOSING Tmix = Tset + 18F BY-PASS CLOSING by-pass closed by-passreturn closed system open return Tf system > Tmix Tset open +18F , Tmix=Tr Tf > Tmix Tset +18F , Tmix=Tr

Y-strainer

3 3

Tmix > Tmix > by-pa by-pa system Tfsystem > Tm Tf > Tm

System with buffer tank storage Use safety devices according to local regulations

NONCONDENSING BOILER

NONCONDENSING BOILER

*Air purge recommended for boiler loop

Non-condensing boiler, connection to buffer tank storage in parallel Use safety devices according to local regulations

NONCONDENSING BOILER

SOLID FUEL BOILER

*
*Air purge recommended for boiler loop

SPECIFICATION SUMMARIES
ThermoMix 280 series Boiler protection thermostatic mixing valve. Connections 1" to 1-1/4" NPT male or sweat with union. Brass body. Brass lower body plug. PSU shutter. Stainless steel spring. EPDM seal. Wax thermostatic sensor. Suitable for water and glycol solutions. Maximum percentage of glycol 50%. Maximum working pressure 150 psi (10 bar). Working temperature range 40212F (5100C). Set point temperature 130F (55C) standard; 115F(45C); 140F(60C); and160F (70C) optional. Sensor cartridge accuracy 4F (2C). Hot inlet from boiler complete closed temperature Tset +18F (10C).

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice. Caleffi North America, Inc. 3883 W. Milwaukee Road Milwaukee, WI 53208 Tel: 414-238-2360 Fax: 414-238-2366 sales@caleffi.com www.caleffi.us
Copyright 2013 Caleffi North America, Inc.