CALEFFI ThermoSetter 116 Series User manual

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© Copyright 2020 Caleffi
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
H0001890.04
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” & ¾” NPT female
1162 series ThermoSetter w/ disinfection function by-pass cartridge ( 160°F (70°C)), models w/
and w/o temperature gauge, w/ and w/o check valve...connections ½” & 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” & ¾” NPT female
1166 series ThermoSetter w/ disinfection function by-pass cartridge ( 140°F (60°)), models w/
and w/o temperature gauge, w/ and w/o check valve...connections ½” & ¾” NPT female
www.caleffi.com
The 1162xx and 1166xx 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) -1162xx, or 140°F (60°C)-1166xx, water (2 available
temperature options), 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

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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.

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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

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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: 1162xx series-160°F (70°C)
1166xx series-140°F (60°C)
Closing temperature: 1162xx series-170°F (75°C)
1166xx series-150°F (65°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)

5
2
5
31
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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.
Cvmax
T (°F)
G (gpm)
Cvdis
Cvmin
Automatic disinfection
C
Thermal disinfection
Temperature control
100 140 150 160 190 170 180 185
Tset
(2.1)
(1.2)
(0.23)
Cvdesign
(0.52)
1
1
Thermostatic control Minimum flow rate
For 1162xx series with 160°F by-pass temperature
and 170°F closing temperature.

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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
by-pass 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 by-pass port,
opening the flow path up until the by-pass temperature 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
closing temperature, the disinfection by-pass port (5) closes to protect the system fixtures
from the effects of excessive temperatures, as shown in curve 4.
Thermostatic disinfection Thermal shut-off
2
5
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4
Cvmax
T (°F)
G (gpm)
Cvdis
Cvmin
Automatic disinfection
C
Thermal disinfection
Temperature control
100
120 130 140 180 150 160 170
Tset
(2.1)
(1.2)
(0.23)
Cvdesign
(0.52)
For 1166xx series with 140°F by-pass temperature
and 150°F closing temperature.

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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
TM

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Dimensions
A
Code B C DMass (kg)
DN
A
Code B C D
1/2" 100
Mass (kg)
3/4 100
18,5
18,5
74,5
74,5
116140
116150
0,650
0,600
DN
15
20
1/2" 100
3/4 100
18,5
18,5
74,5
74,5
116240
116250
0,750
0,700
15
20
A
Code B C DMass (kg)
DN
1/2" 100
3/4 100
18,5
18,5
74,5
74,5
116240
116250
0,750
0,700
15
20
B
B’
B
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
B’
116(2/6)xx
1163xx
Code A B B* C D Wt (lb/kg)
116D40A(C)** ½" NPT F 4" 5 7/16" ¾" 3" 1.7 / 0.75
116D50A(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
*
*Models with check valve tail-piece (C) end-to-end dimension is B'.
**D=2 for models with 160°F (70°C) disinfection temperature;
D=6 for models with 140°F (60°C) disinfection temperature.

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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
4
5
6
7.25
10
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
11
13
20
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

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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.

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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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Caleffi North America, Inc.
3883 W. Milwaukee Road
Milwaukee, WI 53208
T: 414.238.2360 F: 414.238.2366
4-10-2020
Application diagram
130°F
130°F
130°F
140°F
120°F
NOTE: Do not set at temperatures >120ºF if anti-scald valves are not installed at the fixtures.
Hot water recirculation with thermal balancing valves
230 V 50 Hz
THERMAL DISINFECTION
CONTROL UNIT/
B.A.S. INTERFACE
Master mixing valve for
disinfection not shown.
Hot water recirculation with actuator controlled disinfection