CALEFFI FlowCal 121 Series User manual

F nction
The FlowCal™ automatic flow balancin valve maintains a
constant fixed flow rate within varyin system differential
pressure ran es. Operation is fully automatic requirin no
manual adjustment. The 121 series utilize an exclusive,
interchan eable flow cartrid e, made of anti-scale, low
noise polymer for use in coolin and heatin systems. The
FlowCal 121 series automatic flow balancin valves are
available with inte ral shut-off ball valve and optional
factory-installed pressure and temperature test ports.
Drain valves are also available as an accessory for
installin in the blowdown port connection.
Prod ct range
121 Series Automatic flow balancin valve with polymer cartrid e, ball valve, with and without
Pressure and Temperature Test ports;
sizes 1/2" - 3/4" - 1" - 1 1/4"
Technical characteristics
Material: Body:
FlowCal flow cartrid e:
Sprin :
Seals:
Ball:
Ball seat and stem seal:
Lever:
Pressure and temperature test port plu s:
Pressure and temperature test ports:
Drain port plu :
brass
anti-scale polymer
stainless steel
peroxide-cured EPDM
brass, chrome-plated
PTFE
zinc coated steel with vinyl rip
brass
body and cap- brass; core- nordel
b rass
Performance: Medium: water, lycol solutions
Max. percenta e of lycol: 50%
Max. workin pressure: 400 psi (400 WOG)
Workin temperature ran e: 32-212°F (0-100°C)
Connections: 1/2", 3/4", 1", 1-1/4" FNPT or Sweat with union x FNPT or Sweat
Pressure and temperature test ports connections: 1/4" FNPT
Blowdown port connection: 1/2" - 3/4": 1/4" FNPT
1" - 1 1/4": 1/2" FNPT
Flow rate: 27 flow rate settin s ran in from 0.5 - 21 GPM
Flow accuracy: ±10%
Differential Pressure Control Ran es: 2-14, 2-32, 4-34, 5-35, 3-32, 4-35
Identification: metal plate with ball chain statin ∆P ran e and fixed flow rate
CALEFFI
FlowCal™ Automatic flow balancing valve with polymer cartridge
121 Series
NA18055.02
www.caleffi.com
© Copyright 2018 Caleffi
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.

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.
CAUTION: All work must be performed by qualied 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 Teon®
pipe joint compounds. Teon®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 uids 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 followthese
instructions could result in property damage and/or personal injury.
WARNING: Clean the pipes of any debris, rust, incrustations, welding slag
and any other contaminants. For optimal operation, air in the system must
be removed.
Installation
Install the FlowCal TM automatic ow balancing valves on the circuit return pipe with ow
direction arrows indicating proper ow direction. It is important to allow easy access to the
FlowCal for inspection and maintenance.
The identication tag with the technical data must accompany the balancing valve after
installation. It is equipped with a special metal retaining ball chain especially useful when the
valve is enclosed with insulation.
Install a Y-strainer (series 120 on circuit supply pipe of the emitter coil to prevent clogging.
Strainers should be inspected and cleaned after start-up and twice per year thereafter.
FlowCal TM balancing valves may be installed in the pipe horizontally, vertically or at any angle.
For Sweat ttings: Union sweat tailpieces should be removed from the valve body for sweating to
the pipeline. Removethe
ow cartridg e (and adapter
for largersizes) and
FLOWCAL Version
pressure port plugs while
sweating the xed end into
RETURN
the pipeline. In addition,
wrap a wet cloth around the
EMITTER
ball valve portion of the
Y-Strainer Version
series 121 ow balancing
SUPPLY
valve (and the 120 Y-strainer)
when sweating in the integral
sweat body connection.
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.

FlowCal cartridge assembly and disassembly
The internal flow cartrid e can be removed easily from the valve body for inspection, cleanin or
replacement by unscrewin the cap as shown here.
Flow verification
The flow rate can not be field adjusted. To verify flow rate with pressure and temperature a es
or meter with sensor probes, use the factory-installed pressure and temperature test ports (or
install separately sourced PT test ports, also available from Caleffi). The PT test port accepts
either a 1/16" or 1/8" OD probe. Dirt or debris may be the cause for readin s outside the specified
flow rate.
Body
Cartridge
Retainer ring
Cap
B
1/2” - 3/4” from 0.5 to 10 gpm
Body
Cartridge
Retainer ring
Cap
Body
Adapter
Spring
Cartridge
Cap
1” - 1 1/4” from 2.5 to 21 gpm
from 2.5 to 10 gpm
from 11 to 21 gpm

CAUTION: If the FlowCalTM valve is not installed, commissioned
and maintained properly, accordin to the instructions contained in
this manual, it may not operate correctly and may endan er the user.
CAUTION: Make sure that all the connectin pipework is water ti ht.
Caleffi North America, Inc.
3883 West Milwaukee Road
Milwaukee, WI 53208
T: 414.238.2360 F: 414.238.2366
Press re and temperat re testing
The FlowCalTM body is fitted with
connections for the pressure and
temperature ports, which is useful when
checkin operation in the workin ran e.
In addition, drain valve (538202 FD
-1/4" NPT; 538402 FD-1/2" NPT) can
be connected for blowdown operations.
∆p (kPa)
7-23-18