CALEFFI GEO 110 Series Guide

1
Distribution manifold for geothermal systems
156.01
www.caleffi.com
110 series
INSTALLATION AND COMMISSIONING MANUAL
© Copyright 2011 Caleffi
CONTENTS
Warnings
Product range
Technical s ecifications
Characteristic com onents
Package content
Pre-assembled manifold
Right-side version installation
Mounting brackets - manifold
Shut-off valves installation
Branch circuits connection
Closing and o ening
shut-off and regulating valves
Left-side version installation
Modular manifold
Filling the circuit
2
3
4
5
6
7
8-9
10
Hydraulic test
Commissioning and circuit balancing 11
Shut-off valve fitted for flow rate measuring sensor
with Vortex effect - 111 series 12
Balancing valve 112 series 13
Float flow meter 113 series
Installation in external ocket 14
Accessories 15-16
Function
The CALEFFI GEO®110 series manifolds are used for the
control and distribution of medium in closed circuit
geothermal plants.
In circuits with geothermal heat pump the thermal medium
is generally a mixture of water and anti-freeze fluid since
the temperatures can be extremely low. The components
are made with high-performance materials for this type of
application.
They are supplied pre-assembled, complete with end
fittings and temperature gauges, or in ready-to-assemble
modules.

2
WARNINGS
These instructions must be read and understood before installing and maintaining the device.
CAUTION! FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN A SAFETY HAZARD!
CAUTION!
YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN INJURY
THE PRODUCT SUPPLIED WITH THIS INSTRUCTION SHEET IS REFERRED TO BELOW AS ‘DEVICE’
The device must be installed, commissioned and maintained by qualified technical personnel in accordance with national
regulations and/or relevant local requirements.
If the device is not installed, commissioned and maintained correctly in accordance with the instructions provided in this manual, then it may
not work properly and may endanger the user.
Clean the pipes of any debris, rust, incrustations, limescale, welding slag and any other contaminants. The hydraulic circuit must be clean.
Make sure that all connecting pipework is watertight.
When connecting water pipes, make sure that threaded connections are not overstressed mechanically. Over time this may result in breakage,
causing water damage and/or personal injury.
Water temperatures higher than 50°C may cause severe burns. When installing, commissioning and servicing the device, take the necessary
precautions so that these temperatures will not be hazardous for people.
In the case of particularly hard or impure water, there must be suitable provision for filtering and treating the water before it enters the device,
in accordance with current legislation. Otherwise the device may be damaged and will not work properly.
For optimal operation, any air in the medium must be removed. For reasons of safety, due to the high compression capacity of air, testing the
entire system, and especially the valves, for watertightness using compressed air is not recommended.
Any use of the device other than its intended use is prohibited.
Any coupling of the device with other system components must be made while taking the operational characteristics of both units into
consideration. An incorrect coupling could compromise the operation of the device and/or system.
The unit must be installed in an environment where any leakage would not cause personal injury or property damage.
Leave this manual as a reference guide for the user. Dispose of the product in compliance with current legislation
Product range
110 series Pre-assembled geothermal manifold DN 50
111 series Ball shut-off valve fitted for integrated flow rate measuring sensor Ø 25, Ø 32, Ø 40
112 series Balancing valve with flow meter Ø 25, Ø 32, Ø 40
113 series Float flow meter Ø 25, Ø 32
130 series Flow rate electronic measuring station for connecting sensor with Vortex effect
Technical specifications
Manifold
Materials
Flow manifold
Body: polymer PA66G30
Return manifold
Body: polymer PA66G30
End fitting
Air vent
Obturator stem: brass EN 12164 CW614N
Spring: stainless steel
Seals: EPDM
Float: PP
Drain/fill cock
Body: brass EN 12165 CW617N
Performance
Medium: water, glycol solutions, salt solutions
Max. percentage of glycol: 50%
Max. working pressure: 6 bar
System test pressure: 10 bar
Working temperature range: -10–60°C
Ambient temperature range: -20–60°C
Main connections: 1 1/4”
Outlets: 42 p. 2.5 TR
Centre distance: 100 mm
Technical specifications
Shut-off and balancing devices
Materials
Shut-off valve
Body: brass EN 12165 CW617N
Polymer cap: PA66G30
Seal ring: stainless steel
Balancing valve
Body: brass EN 12165 CW617N
Ball: brass EN 12164 CW614N
Ball control stem: brass EN 12164 CW614N
Ball seal seat: PTFE
Flow meter
Body: brass EN 12165 CW617N
Headwork: brass EN 12164 CW614N
Obturator stem: brass EN 12164 CW614N
Springs: stainless steel
Seals: EPDM
Flow meter float: PSU
Indicator cover: PSU
Float flow meter
Body: brass EN 12165 CW617N
Ball: brass EN 12164 CW614N
Ball control stem: brass EN 12164 CW614N
Ball seal seat: PTFE
Float: brass EN 12165 CW614N
Seals: EPDM
Graduated scale support: PSU
Accuracy: 10%
Outlet connections with mechanical seal for 111 series shut-off
valves, 112 series balancing valves and 113 series flow meters.

3
Characteristic components
1
6
7
8
3
2
4
5
Pre-assembled unit complete with:
1) Polymer manifold complete with sealing gasket
2) Brass end fitting
3) Air vent
4) Temperature gauge with pocket
5) Fill/drain cock
6) Closure plate
7) Pair of stainless steel brackets
) Stainless steel rods including screws and bolts for seal and clamping
Package content
The package contains:
- modules for flow and return manifold
- stainless steel rods including screws and bolts for clamping seal
- end fitting and closure plates with corresponding insulation
- 2 automatic air vents
- 2 fill/drain cocks
- 2 temperature gauges with pockets
- pair of stainless steel brackets with corresponding wall anchors for wall fixing
- assembly instructions
- set of labels for direction of flow and circuit identification
Maintenance
DO NOT USE CHEMICALS
TO CLEAN THE MANIFOLD

4
Right-side version installation
1) Install the temperature gauge and the air vent. The end fitting is
supplied with only the fill/drain cock already mounted. Unfasten
the insulation by means of the tear-off closure (a1) and make a
hole through the embossed signs on the inner side (b1).
2) Unscrew the cap from the front connection and screw down the
pocket for the temperature gauge, tightening it to the end stop.
3) Close the insulation and fit the air vent in the upper connection.
2) Thread the furnished nuts onto the steel bars extending from the
end cap. Do not tighten them to the end stop since they are
used as locks to connect the manifold to the brackets.
3) Connect the manifolds to the brackets using the quick coupling,
before mounting the brackets on the wall. If necessary the
manifolds can be connected without the insulation inserted on
the end fitting, so that the screws for connecting the manifold to
the brackets remain visible.
PRE-ASSEMBLED MANIFOLD
The pre-assembled manifold is supplied in the right-side version
but can be fitted with the main connections on the left side
depending on the heat pump position compared to the probes.
Mounting brackets - manifold
1) Hand thread the furnished screws several turns into the rear
threads on the end fitting: do not tighten them to the end stop
since they are the anchor point between the manifold and the
brackets.
right-side version
left-side version
a1 a2
b1 B2

5
Shut-off valves installation
1) Uncouple the return manifold (the one with medium flowing from
the heat pump to the geothermal probes) and connect the
shut-off valve. Position the seal and thread the nut fully onto the
manifold outlet.
) After having attached the manifold to the brackets, fully tighten
the nuts on the end cap and closure plate. If necessary this
operation can be carried out without the insulation inserted on
the end fitting.
4) Position the manifold and mark the wall anchor holes on the wall.
Install the wall anchors and attach the brackets to the wall using
the mounting slots. If more convenient, the brackets can be
installed on the wall first, then connect the manifold to the
brackets.
2) Uncouple the flow manifold (the one with medium flowing from
the geothermal probes to the heat pump) and connect the
regulating valves. The manifold is fitted for use with three
different circuit balancing systems.
6) Determine the manifolds flow direction and attach the labels
supplied with the manifold. This will help with the installation of
the circuits and the respective regulating valves. The
recommended flow direction is shown in the following figure:
111 series
Ball shut-off valve, with
insulation
112 series
Balancing valve with flow
meter, with insulation
113 series
Float flow meter, with
insulation

6
Branch circuits connection
1) With the manifold mounted on the brackets, prepare the pipe for
the outlets and cut it to size for connecting to the fitting. Both the
shut-off and balancing valves are equipped with DECA fitting for
attaching to the geothermal pipe.
Helpful suggestions for installation
Pipe preparation.
Pipe connection
Cut pipe square Do not cut at an
angle
Remove burrs from
the outer surface
Loosen the locking
nut of the DECA
fitting without taking it
Insert the pipe to the
end stop
Snugly tighten the
locking nut
Do not disassemble the fitting
and then put the elements on the
pipe.
3) In all three situations, simply position the seal and fully tighten
the nut on the manifold outlet.
2) To make it easier to insert the pipe into the DECA fitting,
uncouple the shut-off/balancing valve from the manifold, couple
the pipe to the fitting and then reconnect the valve to the
manifold, ensuring that the sealing gasket is correctly
positioned.
3) Stick the circuit label beside the appropriate outlet. This can be
very useful for system maintenance or leakages.
4) Repeat the above steps for all the pipes, paying attention to the
bending of the pipes in the area under the manifolds.

7
Closing and opening shut-off valves
The control lever opens
and closes the ball
valve. The lever must be
positioned parallel with
the bevelled edges of
the closure cap, aligned
with the slots so as to
correctly guide the cap.
Closing and opening regulating valves
On the float flow meter (113 series) and balancing valve
(112 series) there is a slot for the complete opening or closing of
the valve. A slot on the obturator stem indicates the status of the
valve. When the control stem is turned clockwise 90° and the slot is
perpendicular to the valve axis, this indicates that the valve isfully
closed (A); when the stem is turned 90° anti-clockwise to the end
stop and the slot is parallel with the valve axis, this indicates that
the valve isfully open (B).
When the control lever is in the vertical position, the ball is open and
the medium is flowing (A). When the lever is in the horizontal
position the ball is closed: the seats ensure a tight seal and impede
the flow of medium (B).
) Connect main pipes.
It is advisable to insert a ball valve between the manifold and the
main pipe so that the geothermal circuits can be excluded
easily.
6) When the manifold is fully installed, check that the insulations
are closed and insert the temperature gauges into the pockets
mounted previously. Tighten the screw on the pockets to keep
the temperature gauge in position.
AB
A B
A B

8
1) Remove the insulation from the manifold.
2) Undo the four nuts and take out the closure plate and the seal.
3) Extract the modules from the threaded bars.
4) Undo the drain and the closure cap.
Left-side version installation
The standard right-side version of the manifold can be installed in
the left-side version by proceeding as follows:
) Turn the end fitting with
steel rods upside down
1 0°.
6) Rotate the end fitting 1 0°
lengthwise so that the front
connection is positioned as
shown in the following
figure.
NOTE: With a higher number of outlets it may be necessary to
repeat the tightening sequence several times.
To mount the manifold on the brackets follow the instructions under
“Mounting brackets – manifold”.
7) Install the drain fully into the lower connection and the pocket
for the temperature gauge into the front connection.
8) Reassemble the manifold by alternately inserting a seal and a
module, using the studs as a reference: the studs on each
module should be aligned with the end cap.
9) After having inserted the same number of modules to match the
number of outlets, assemble the manifold with seal, closure
plate with grooves facing the inside, and the tightening nuts.
10) To tighten the nuts, follow
the adjustment diagram
shown opposite with the
following procedure:
- tighten with torque wrench
to 5 N·m.
- retighten with torque wrench
to 5 N·m.

9
1) Fully tighten the drain cock on the lower thread of the end cap
and the pocket for the temperature gauge on the front thread.
2) Tighten the steel rods to the end stop.
6) Hand thread the furnished screws several turns into the rear
threads: do not tighten them to the end stop since they are the
anchor point between the manifold and the brackets.
3) Insert a seal and a manifold body on the rods, using the studs
as a reference: the studs on each module should be aligned
with the end cap.
4) After having inserted the same number of modules to match the
number of outlets, assemble the manifold with seal, closure
plate with grooves facing the inside, and the tightening nuts.
MODULAR MANIFOLD
The distribution manifold has been designed so that it is easy to
mount on a bench.
Since the manifold is reversible, it can be mounted with the main
connections on the right or left depending on the heat pump
position.
The following instructions refer to the manifold with right-side
connections, although it is also possible to mount the left-side
version following the same procedure.
7) Close the insulation and fit the air vent snugly into the upper
connection.
NOTE: With a higher number of outlets it may be necessary to
repeat the tightening sequence several times.
) To tighten the nuts follow the
adjustment diagram shown
opposite with the following
procedure:
- tighten with torque wrench
to 5 N·m.
- retighten with torque wrench
to 5 N·m.
right-side version left-side version

10
Filling the circuits
1) Close all the outlets to the geothermal circuits using the shut-off
and regulating valves.
2) Open the fill and drain cocks using the specific cap and make
sure that the shut-off valves are closed.
) When filling is complete, close the valves in the first circuit and
repeat the same sequence of operations for all the other
circuits.
3) Connect the system testing pump to the fill cock on the flow
manifold and a drain pipe to the cock on the return manifold.
Direct the drain pipe into a container if the medium in the
system contains glycol.
4) Fill the first circuit by opening the corresponding valves,
making sure that all the air in the circuit is removed. Check that
the cap on the air vent is open.

11
Hydraulic test
1) When all circuits have been filled the system seal test can be
carried out.
2) Disconnect the drain
pipe and close the
corresponding drain
cock. Leave the
system testing pump
connected.
3) Open all the circuit shut-off valves.
Commissioning and circuit balancing
1) Open all the circuit shut-off valves and the ball valves on the
main pipes, if any.
2) Let the medium circulate so as to completely eliminate the air in
the system.
3) Balance the circuits by operating the regulating valves or shut-
off valves based on the configuration of the manifold.
4) Bring the circuit up to pressure, to a maximum of 10 bar, for the
set period of time.
During the test, the
pressure must not
exceed 10 bar

12
In the case of horizontal installations, before inserting the sensor
(A) drain the liquid contained in the ball using the rear cock (B).
The presence of liquid may impede the correct positioning of the
sensor in the valve body.
Ensure that the sensor is correctly inserted without exerting force
on the lower tabs (C).
Shut-off valve fitted for flow rate measuring sensor with
Vortex effect – 111 series
Correct installation of the sensor
The sensor is positioned in place of the end cap of the shut-off valve
on the flow manifold when the valve is in the closed position.
To swap the cap with the sensor you need to:
4) Remove the seal ring.3) Remove the knob and the
ring stop.
) Take out the cap and insert the measuring sensor, making sure
that it is correctly positioned by means of the holder tabs. The
tabs, when seated, must slide underneath the sealing profile
when the sensor rotates.
8) Insert the spacer so as to
ensure the correct position
of the ring and turn the
control knob to the closed
position.
7) Insert the measuring
sensor and retain it with the
seal ring.
9) Open the ball using the specific knob. These operations must
also be repeated carefully when replacing the sensor with the
closure cap after the balancing operations are complete.
For balancing remove the knob and insert the plug of the flow
rate meter.
1) Turn the control knob to the
open position.
2) Close the valve.
Flow rate regulation is performed by using the special knob to
control the shut-off valve on the return manifold in correspondence
with the same circuit, until the instrument indicates the design
setting. This operation must be repeated on the following branches
to obtain the desired flow rate.
A
B
C

4) After completing the balancing, release the ring (2) of the flow
meter obturator which, thanks to an internal spring, will
automatically go backinto the closed position.
) After balancing the system
insert the insulation and
ensure that it is correctly
closed.
13
Balancing valve – 112 series
Flow rate regulation is carried out as follows:
3) Keeping the obturator open, use a 9 mm fixed hex spanner on
the valve’s control stem (4) to regulate the flow rate. The flow
rate is indicated by a metal ball (5) running inside a transparent
guide (6) alonga graduated scale in m3/min.
1) With the aid of the indicator
(1), mark the reference flow
rate on which thevalve is to
be set.
2) Use the ring (2) to open the
obturator that shuts off the
flow of medium in the flow
meter (3) under normal
operating conditions.
After balancing, disconnect the electronic meter and put the
shut-off valves back into their standard operating condition as
follows:
10) Close the valve using the specific knob and take out the sensor
by removing the ring stop and the seal ring.
Repeat the operations for all the circuits.
The sensors, the electronic meter and the control lever are only
used for start-up. The installer requires a single kit to operate all
systems of this type: this notably reduces costs and prevents
needless system head loss caused by the presence of an obstacle
in the flow.
11) Fit the cap back in and
secure it with the seal ring
and the stop.
12) Reopen the valve with the
knob.
13) After balancing the system
insert the insulation and
ensure that it is correctly
closed.

14
When the manifold is coupled
with the 113 series flow meter,
horizontal installation is not
possible due to the gravity
operation of the flow meter.
For horizontal installation, simply install the air vent in the central
position.
Installation in external pocket
The manifold, if coupled with the 111 series shut-off valve or 112 series
balancing valve, can also be installed in external pocket in the
horizontal position.
1) Take the cap out of the
central connection of the
end cap.
2) Fully insert the cap into the
upper connection.
3) Close the insulation, making
holes where necessary.
4) Fully install the air vent in
the central connection.
Float flow meter – 113 series
1) Adjust the flow rate by
using a 9 mm fixed hex
spanner on the ball valve.
2) The flow rate can be read
on the graduated scale in
correspondence with the
upper edge of the float.
3) Carry out the balancing operations on all circuits.
To obtain the actual flow rate when using glycol solutions at low
temperature it is necessary to multiply the reading of the float flow
meter by a correction factor of:
-0.9 for concentrations of 20-30%
-0. for concentrations of 40-50%.
4) After balancing the system
insert the insulation and
ensure that it is correctly
closed.

15
Accessories
113621
113631
Ø 25
Ø 32
0,3–1,2
0,3–1,2
Connection Scale (m3/h)
113
Float flow meter.
Direct reading of flow rate.
Ball valve for flow rate adjustment.
Brass body.
Female connections with captive nut.
Complete with fitting for polyethylene pipe.
Max. working pressure: 10 bar.
Working temperature range: -10–110°C
Ambient temperature range: -20–60°C.
Medium: water, glycol solutions, saline solutions.
Max. percentage of glycol: 50%.
Accuracy: ±10%.
Connection to manifold: 42 p.2,5 TR.
113001
113
Insulation for float flow meter.
Material: closed cell expanded PE-X.
Thickness: 10 mm.
Density: int. part 30 kg/m3, ext. part: 0 kg/m3.
Thermal conductivity (DIN 52612):
at 0°C: 0,03 W/(m·K) at 40°C: 0,045 W/(m·K).
Coefficient of resistance to steam (DIN 52615): > 1.300.
Working temperature range: 0–100°C.
Reaction to fire (DIN 4102): class B2.
Code
Code
112621
112631
112641
Ø 25
Ø 32
Ø 40
0,3–1,2
0,3–1,2
0,3–1,2
Connection Scale (m3/h)
112
Balancing valve with flow meter.
Direct reading of flow rate.
Ball valve for flow rate adjustment.
Graduated scale flow meter with magnetic
movement flow rate indicator.
Brass valve body and flow meter.
Female connections with captive nut.
Complete with fitting for polyethylene pipe.
Max. working pressure: 10 bar.
Working temperature range: -10–110°C
Ambient temperature range: -20–60°C.
Medium: water, glycol solutions, saline solutions.
Max. percentage of glycol: 50%.
Accuracy: ±10%.
Connection to manifold: 42 p.2,5 TR.
112
Insulation for balancing valves.
Material: closed cell expanded PE-X.
Thickness: 10 mm.
Density: int. part 30 kg/m3, ext. part: 0 kg/m3.
Thermal conductivity (DIN 52612):
at 0°C: 0.03 W/(m·K) at 40°C: 0.045 W/(m·K).
Coefficient of resistance to steam (DIN 52615): > 1.300
Working temperature range: 0–100°C.
Reaction to fire (DIN 4102): class B2.
Ø25-Ø32
Ø 40
Application
112001
112003
Code
Code
Ø 25 - Ø 32
Application
111620
111630
111640
Ø 25
Ø 32
Ø 40
Connection
Ø25-Ø32
Ø 40
Application
111
Ball shut-off valve fitted
for integrated flow rate measuring sensor.
Brass body. Polymer top cap.
Female connections with captive nut.
Complete with fitting for polyethylene pipe.
Max. working pressure: 6 bar.
Max. system test pressure: 10 bar.
Working temperature range: -10–60°C.
Ambient temperature range: -20–60°C.
Medium: water, glycol solutions, saline solutions.
Max. percentage of glycol: 50%.
Connection to manifold: 42 p.2,5 TR.
Patent application No. MI2010A000 76.
111010
111
Integrated flow rate measuring sensor
with Vortex effect.
Accuracy of flow rate reading: ±10%.
111002
111
Control lever for shut-off valves.
Polymer body.
111001
111003
111
Insulation for shut-off valves.
Material: closed cell expanded PE-X.
Thickness: 10 mm.
Density: int. part 30 kg/m3, ext. part 0 kg/m3.
Thermal conductivity (DIN 52612):
at 0°C: 0,03 W/(m·K) at 40°C: 0,045 W/(m·K).
Coefficient of resistance to steam (DIN 52615): > 1.300
Working temperature range: 0–100°C.
Reaction to fire (DIN 4102): class B2.
130010
130
Flow rate electronic measuring station
for connecting sensor with Vortex
effect. Complete with:
- box;
- power supply;
- control lever;
- measuring sensor with Vortex effect;
- connecting cable;
- sensor seal ring;
9 V-NiMH rechargeable battery.
Complete with power supply for battery charger.
Flow rate measurement scale: l/h - l/min - GPM.
Flow rate: 300–1400 l/h.
Accuracy of flow rate reading with Vortex sensor:
±10%.
Protection class: IP 44.
Code
Code
Code
Code
Code

16
115700 1 1/4”
115
Instrument and accessories holder for heat pumps
complete with steel anchoring base.
Connections: 1 1/4” F.
Max. working pressure: 2,5 bar.
Working temperature range: -20–90°C (temperature
gauges 50°C).
Ambient temperature range: -10–55°C.
Medium: water, glycol solutions, saline solutions.
Max. percentage of glycol: 50%.
A saline solution can be used as the medium,
changing the provided pressure gauge with the
stainless steel version, code 557596.
Code
1150 0 900 x 60 x 175
Dimensions (h x b x d)
115
Box for coupling with instrument holder anchoring
base 115 series.
Made of painted steel.
Composed of outer casing and door.
Code