CALEFFI TankMixer 520 Series Manual de usuario

Function

The Calefﬁ TankMixer™520_AX series kit combines a three-way

thermostatic mixing valve with a cold water tee and ﬂexible pipe for

easy installation directly on a typical gas-ﬁred water heater and other

water heaters that now comply with the National Appliance Energy

Conservation Act (NAECA). The TankMixer™maintains the desired

output temperature of the mixed water supplied at a constant set

value compensating for both temperature and pressure ﬂuctuations

of the incoming hot and cold water. The mixing valve also features a

thermal shut-off function that operates in the event of a cold water

supply failure at the inlet. Also available as body only, for a wide

variety of separately-sourced end connections, the angle style body

design offers improved ﬂuid dynamics for better performance and

reduces installation labor and materials, eliminating a piping elbow

in typical installations.

The valve has been speciﬁcally certiﬁed to ASSE 1017 and Low

Lead Plumbing Law by ICC-ES.

TankMixer™ water heater tank mixing valve

520 Series

NA10482

www.caleffi.com

Product range

52050_AX series kit: Adjustable three-way thermostatic mixing valve, angle body with cold water

tee and ﬂexible connector, connections ¾” NPT female to water heater; ¾” sweat,

press, and NPT male union mix outlet/cold water inlet.

52051_AX series kit: 52050_AX series kit with mixed outlet temperature gauge.

520051A: Adjustable three-way thermostatic mixing valve, angle style body only for ﬁeld installed

connection ﬁttings, source separately, connections 1” male union.

Technical specication

Materials

-Valve and cold water tee bodies:

DZR low-lead brass

-Shutter, seats and slide guides:

PSU

-Springs: stainless steel

-Seals: EPDM

-Adjustment knob: ABS

-Flexible pipe: stainless steel

-Recirc. port plug: low-lead brass

Performance

Suitable ﬂuids: water

Setting range: 5–150° F (35–65° C)

Tolerance: ±3° F (±2° C)

Max. working pressure (static): 145 psi (10 bar)

Max. working pressure (dynamic): 75 psi (5 bar)

Max. hot water inlet temperature: 195°F(90°C)

Max. inlet pressure ratio (H/C or C/H) for

optimal performance: 2:1

Min. temperature difference between hot

water inlet and mixed water outlet for optimal

performance: 27°F(15°C)

Min. ﬂow to ensure optimal performance:

0.5 gpm (2 L/min)

Certifications:

1. ASSE 1017/CSA B125.3, certiﬁed by ICC-ES,

ﬁle PMG-1357.

2. NSF/ANSI 372-2011, Drinking Water System

Components-Lead Content Reduction of Lead in

Drinking Water Act, California Health and Safety

Code 116875 S.3874, Reduction of Lead in Drinking

Water Act, certified by ICC-ES, file PMG-1360.

Leave this manual for the user.

CAUTION: If the thermostatic mixing 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.

CAUTION: When making the water connections, make sure that the pipework

connecting the TankMixer™thermostatic mixing valve is not mechanically

overstressed. Over time this could cause breakages, with consequent water

losses which, in turn, could cause harm to property and/or people.

CAUTION: Water temperatures higher than 100ºF (38ºC) can be

dangerous. During the installation, commissioning and maintenance of the

TankMixer™thermostatic mixing valve, take the necessary precautions to

ensure that such temperatures do not endanger people.

CAUTION: In the case of highly aggresive water, arrangements must

be made to treat the water before it enters the thermostatic mixing valve,

in accordance with current legislation. Otherwise the thermostatic mixing

valve may be damaged and will not operate correctly.

SAFETY INSTRUCTION

CAUTION: All work must be preformed by qualied personnel trained

in the proper application, installation, and maintenance of systems in

accordance with all applicable codes and ordinances.

This safety alert symbol will be used in this manual to draw attention to safety related

instructions. When used, the safety symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED! FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT

IN A SAFETY HAZARD.

Operating principle

The thermostatic mixing valve mixes the

hot and cold water at the inlets to maintain

constant mixed water at the desired set

temperature. The TankMixer™ 520 series

point of distribution mixing valve is an angled

conﬁguration combined with a ﬂexible hose

and cold water tee for easy installation to

most water heaters for direct mounting to

the universal ¾” male NPT threaded top

pipe connections with a variety of outlet

connection styles. This provides increased

usable hot water capacity on existing or new

high efficiency water heaters by allowing

water to be stored at a higher temperature

and safely delivered at lower adjustable

temperatures to all fixtures. In addition, it

can be used to reduce legionella growth

by allowing the water heater thermostat to

be set at 140°F. The flexible hose length

allows mounting to all water heater tank

sizes. The TankMixer™ 520_AX series comes

standard with a recirculation port that can be

plugged or used for connecting to a hot water

recirculation loop.

Flow curve

Kv = 1.7

0.1

0.023

0.23

0.046

0.069

0.02

0.05

0.2

0.5

0.115

2.3

0.46

0.69

1.15

∆p

(ft of head)

G (l/min) (

gpm

)

4.6

6.9

11.5

0.01

0.1

0.02

0.03

0.05

0.2

0.3

0.5

(psi) (bar)

0.1

0.2

0.5

0.05

0.001

0.01

0.002

0.003

0.005

0.1

0.02

0.03

0.05

1.0

0.2

0.3

0.5

Cv = 2.0

9.2

0.092

0.92

0.04

0.4

0.004

0.04

0.4

115

161

2.0

5.0

190

100

140

Use

Calefﬁ TankMixer™520 series thermostatic mixing valves are designed to be installed at

the hot water heater. The 520 series valve cannot be used for tempering water temperature at ﬁxtures

as a point-of-use valve. They are not designed to provide scald protection or chill protection service.

They should not be used where ASSE 1070 devices are required. Wherever a scald protection

feature is required, Calefﬁ 5213 series high performance mixing valves need to be installed. For safety

reasons, it is advisable to limit the maximum mixed water temperature to 120°F when anti-scald

devices are not used at each ﬁxture.

Construction details

Thermal shut-off

In the event of accidental cold water supply failure, the shutter seals off the hot water passage,

thus preventing the delivery of mixed temperature water. This is only guaranteed when there

is a minimum temperature difference between the inlet hot water and the mixed temperature

water delivery of 27°F.

Water heater

As a result of the NAECA, many water heaters now have more insulation making them

physically larger, for the same water capacity, than the older models. So units with less

capacity are installed requiring higher temperature settings to provide the capacity users were

previously accustomed, requiring mixing valves to temper the water to safe levels.

Calefﬁ TankMixer™520_AX series thermostatic mixing valves with cold water tee assembly

and ﬂexible connector will conveniently ﬁt a typical gas-ﬁred water heater and a wide variety

of other water heaters. A recirculation return can be connected at the side port of the cold

water tee.

Installation

Before installing a Calefﬁ TankMixer™520 series three-way thermostatic mixing valve,

the system must be inspected to ensure that its operating conditions are within the range of the

mixing valve, checking, for example, the supply temperature, supply pressure, etc.

Systems where the 520 series thermostatic mixing valve will be installed must be drained and

cleaned out to remove any dirt or debris which may have accumulated during installation.

The installation of appropriately sized ﬁlters at the inlet from the main water supply is always

advisable.

Calefﬁ TankMixer™520 series thermostatic mixing valves must be installed by qualiﬁed

personnel in accordance with the diagrams in this brochure, taking into account all current

applicable standards.

Calefﬁ TankMixer™520 series thermostatic mixing valves can be installed in any position,

either vertical or horizontal, or upside down.

The following are shown on the thermostatic mixing valve body:

- Hot water inlet, color red and marked “HOT”.

- Cold water inlet, color blue and marked “COLD”.

- Mixed water outlet, marked “MIX”.

Locking the setting

Position the handle to the number required with

respect to the index point. Unscrew the head screw,

pull off the handle and reposition it so that the handle

fits into the internal slot of the knob. Tighten the

headscrew.

Check valve

In systems with thermostatic mixing valves, check valves should be installed to prevent

undesired backﬂow. The TankMixer™ 520_AX series mixing valves are supplied complete

with a check valve on the cold water tee outlet port to the mixing valve. As a convenience for

easier installations, the TankMixer™ 520051A body only can be ﬁeld-installed with separately

purchased union tailpieces for ½”, ¾” or 1” npt female or male, press, PEX barb or sweat with

or without check valves (for the hot and cold inlet ports).

Index Point

Pos. Min. 1 2 3 4 5 6 7 Max.

T (°F) 95 105 115 120 125 132 140 145 150

T (°C) 35 40 45 48 52 56 60 63 65

with: T

HOT = 158°F (70°C), with: T

cold = 59°F (15°C), P = 43 psi (3 bar)

Temperature setting and locking

The control knob permits temperature setting between minimum and maximum in one

turn (360°). It also has a tamper-proof system to lock the temperature at the set value. The

temperature is set to the required value by means of the knob with the graduated scale, on

the top of the valve.

Commissioning

The Calefﬁ TankMixer™520 series thermostatic mixing valve must be commissioned in

accordance with current standards by qualiﬁed personnel using temperature measuring

equipment. Calefﬁ 520510AX, 520516AX and 5210519AX with integral outlet port temperature

gauge provide a time-saving temperature setting process to get close to the desired

temperature. Use of a digital thermometer is recommended for conﬁrming the ﬁnal setting of

the mixed water temperature. Note: For models purchased without the outlet temperature

gauge, the temperature gauge adapter with temperature gauge can be separately purchased

and ﬁeld installed, code NA10056 for 3/4" models.

After installation, the valve must be tested and commisioned in accordance with instructions

given below, taking into account current applicable standards.

1) Ensure that the system is clean and free from dirt or debris before commissioning the

thermostatic mixer.

2) It is recommended that the temperature is set using a suitable calibrated digital thermometer.

The valve must be commissioned by measuring the temperature of the mixed water emerging

at the point of use.

3) The maximum outlet temperature from the valve must be set accounting for ﬂuctuations due

to simultaneous use. It is essential for these conditions to be stabilized before commissioning.

4) Adjust the temperature using the adjusting knob on the valve. For safety reasons. it is

advisable to limit the maximum mixed water temperature to 120ºF in domestic hot water

systems.

5) The temperature may be adjusted using the control knob.

a) Adjust the temperature of the mixed water to the desired value.

b) Measure and record the temperature at the cold and hot water inlets.

c) Measure and record the temperature of the water delivered from the tap at the lowest

and highest ﬂow rates.

d) Run a test of the thermal shut-off function. Close the cold water inlet shut-off valve and

check the mixed water delivery. The delivery ﬂow rate should quickly drop to zero.

e) Measure and record the maximum mixed water temperature. The temperature may not

exceed the values permitted in any applicable legislation or code of practice.

f) Restore the cold water inlet supply and measure the water delivery temperature after it

has stabilized. The ﬁnal temperature measured in this test may not exceed the permitted

values by ±3°F (±2°C).

In case of change to temperature setting, repeat tests in accordance with points d, e, f.

All the above information should be recorded in the commissioning report and updated in the

maintenance report whenever the valve is worked on.

Application diagrams

MAIN WATER SUPPLY

SYSTEM WITH RECIRCULATION

HOT WATER

STORAGE

MAIN WATER SUPPLY

SYSTEM WITHOUT RECIRCULATION

HOT WATER

STORAGE

Ball valve

Ball valve with

check valve

Temperature gauge

Pump

Expansion vessel

Thermostat

Temperature/pressure

safety relief valve

Safety relief valve

Pressure reducing

valve

Y-strainer

MAIN WATER SUPPLY

Caleffi North America, Inc.

3883 West Milwaukee Road

Milwaukee, WI 53208

T: 414.238.2360 F: 414.238.2366

4-21-17

Troubleshooting

Under normal operating conditions the Calefﬁ TankMixer™520 series thermostatic mixing

valve will provide a very high level of performance. However, in some circumstances, where the

following maintenance schedule is not followed problems may arise.

Recommended maintenance schedule:

Tests should be conducted regularly to monitor the thermostatic mixing valve performance,

as deterioration of performance could indicate that the valve and/or the system require

maintenance. If, during these tests, the temperature of the mixed water has changed

signiﬁcantly in comparison with the previous test, the details given in the installation and

commissioning sections should be checked and maintenance conducted.

The following should be checked regularly to ensure that the optimum performance levels of

the valve are maintained. Check every 12 months at least, or more often if necessary.

1) Check and clean the system ﬁlters.

2) Check that any check valves positioned upstream of the Calefﬁ thermostatic mixing valve are

operating correctly, without problems caused by impuritites.

3) Limescale can be removed from internal components of the thermostatic mixing valve by

immersion in a suitable de-scaling ﬂuid.

4) When the components which can be maintained have been checked, commission the valve.

Symptoms Cause Corrective action

Hot water at the cold taps a) Operation of check valve is

hindered; Check valve is not

sealing correctly.

b) Check valves not ﬁtted.

- Replace faulty check valve

Fluctuating mixed water

temperature

a) Erratic supply temperatures at

the inlet of the valve.

b) Starvation of the water

supplies at the inlets of the valve.

c) Incorrect commissioning of the

valve.

- Restore inlet conditions within

the limits of the valve.

Erratic ﬂow of water from

the valve

a) Insufﬁcient water supplies

b) Fluctuations in the supply

pressures/temperatures.

c) Adverse effect created by other

draw off points on the system

- Stabilize inlet supply condi-

tions.

No ﬂow of water from the

valve

a) In-line ﬁlers blocked.

b) Insufﬁcient supply pressures.

c) Debris obstructing valve

operation.

- Clean ﬁlters

- Resore inlet supplies

- Clean debris or scale from

the valve.

Valve shut-off function not

performed when tested

a) Installation not compliant with

instructions.

b) Minimum temperature differ-

ence not reached.

c) Valve mechanism blocked

by dirt.

- Follow installation instructions.

- Increase hot water

temperature.

- Remove dirt/limescale from

the valve.

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