CALEFFI ThermoBloc 281 Series Bedienungsanleitung
www.caleffi.com
1
NA10294.03
Function
The ThermoBloc™ boiler protection recirculation and distribution unit
is used in hydronic heating systems with non-condensing boilers,
including solid fuel, biomass, gas LP or oil-fired. It can be installed
with steel, cast iron and copper tube style boilers, automatically
controlling the return water temperature, protection against corrosion
from condensation occurring when a minimum flue gas temperature
is not otherwise maintained. The ThermoBloc™ unit is compact for
easy installation, reducing required space and fittings. It combines
the functionality of a boiler protection valve with a circulation pump
and a unique flapper check valve allowing for thermosyphon flow
between the boiler and distribution system during a power outage. The
ThermoBloc™ includes three temperature gauges and is encased in
an insulation shell.
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.
Product range
281 series boiler protection recirculation and distribution unit. NPT
male or sweat, sizes 1”, 1-1/4”.
Technical Characteristics
· Materials: - Body: brass
- Shutter: PSU
- Spring: stainless steel
- Flapper check valve: PPS
- Seal: peroxide-cured EPDM
- Thermostatic sensor: wax
· Suitable fluids: water, up to 50% glycol solutions
· Max working pressure: 150 psi (10 bar)
· Working temperature range: 40-210°F (5-100°C)
· Termperature gauge scale: 30-250°F (0-120°C)
· Thermostatic sensor cartridge: 130°F (55°C) standard
115°F (45°C), 140°F (60°C),
160°F (70°C) optional cartridges
· Sensor cartridge accuracy: ±3.6°F (±2°C)
· Bypass from boiler complete closing
temperature: Tset +18°F (10°C)
· Connections: - NPT male union: 1” and 1-1/4”
- sweat union: 1” and 1-1/4”
281 Series
Installation, commissioning and servicing instructions
© Copyright 2018 Caleffi
ThermoBloc™ boiler protection recirculation and distribution unit
2
Pump
Three speed pump: Wilo Star S-16 U15
Body: cast iron
Power supply: 115 V - 60 Hz
Max. pressure: 85 psi (6 bar)
Max. temperature: 230°F (110°C)
Agency approval: cULus
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: If the boiler protection unit 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.
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.
Pump characteristics
Insulation
Material: EPP
Mean thickness: 30 mm
Density: 45 kg/m3
Working temperature range: 40-210°F (5-100°C)
Thermal conductivity: 0.037 W/(m.K) at 10°C
Reaction to fire (UL94): class HBF
4
5
6
7
8
9
0
1
2
3
0 1 2 3 4 5 6 7 8 9 10
11
16
14
12
10
8
6
4
2
20
(psi) (ft of head )
0
18
0.05
0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70
(gpm)
(lps)
1
2
3
0
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.
3
CAUTION: When making the water connections, make sure that the boiler
protection unit connecting pipework is not mechanically over-stressed. 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 100°F can be dangerous. During
the installation, commissioning and maintenance of the boiler protection unit,
take the necessary precautions to ensure that such temperatures do not
endanger people.
CAUTION: In the case of highly aggressive water, arrangements must be made
to treat the water before it enters the boiler protection valve, in accordance
with current legislation. Otherwise the boiler protection unit may be damaged
and will not operate correctly.
Operation/Use
The thermostatic sensor, completely immersed in the medium, controls the movement of a
shutter that regulates the bypass flow from the boiler and toward the system. At boiler startup,
the boiler protection recirculation and distribution unit recirculates the bypass flow from the
boiler to bring the boiler up to temperature as quickly as possible. When the bypass flow from
the boiler exceeds the setting of the fixed thermostatic sensor, the unit’s return from the
system port starts opening to produce the water mixing temperature: in this phase the
system loading begins.
When the mixed flow to the boiler temperature is greater than the set point of the boiler
protection recirculation and distribution unit by approximately 18°F (10°C), the bypass flow
from the boiler port closes and water returns to the boiler at the same temperature as the
return flow from the system.
When power is out and the circulation pump stops running, the flapper check valve, which is
closed during normal operation, opens with a slight pressure differential resulting from the
effects of heated water in the boiler and cooler water in the distribution system, a natural
thermosyphon flow. This prevents a excessive heat buildup which eventually would cause the
pressure relief valve to open.
The compact brass body casting houses the pump and all functioning components, offering
easy installation, either on the right or left side of the boiler. The temperature gauges can be
easily removed and re-inserted on the back side of the unit.
The brass body prevents the formation of ferrous residues in the system, prolonging boiler
operating life.
The unit features a thermostatic sensor to control the temperature of water returning to the
boiler to prevent condensation. The sensor can be easily replaced for maintenance or set
point change.
CAUTION: Make sure that all the connecting pipework is water tight.
4
Installation
The ThermoBloc™ boiler protection recirculation and distribution unit can be installed on both
sides of the boiler following the flow directions indicated on the body. Installation is recommended
on the return to the boiler in mixing mode, in vertical postion (axis of the pump horizontal and
the axis of the thermostatic sensor vertical). This allows for the proper functionality of the natural
circulation flapper check valve. Separately purchased ball valves (Caleffi code NA39753- 1” FNPT
or NA39588- 1–1/4”
FNPT) installed on
each inlet and the
mixed flow outlet are
highly recommended
for isolation and
maintenance.
Natural circulation flapper check valve
The flapper check valve allows the natural thermosyphon circulation
of the system heat transfer fluid when the pump stops running
due to power failure. When the pump is running under normal
conditions the thrust of the flowing medium keeps the flapper
closed, forcing flow past the thermostatic sensor. When the pump
stops running and the fluid in the boiler is at high temperature,
natural circulation begins, by-passing the thermostatic sensor,
preventing over heating in the boiler.
Flapper check valve – lock
Before installation, remove the screw that
keeps the flapper check valve closed.
This screw is factory-installed to prevent
breakage during shipment. Removing the
protective screw ensures full functionality
of the flapper check valve as a natural
circulation device. To do this, unscrew the
union located on the mixed water outlet
port (to boiler) and access the screw
inside the valve body, unscrewing it using
a phillips head screwdriver.
BO IL ER
BO IL ER
5
Replacement parts and accessories
Maintenance/Temperature setting field change out
To remove the thermostatic sensor for maintenance or field change
out of thermostatic sensor cartridge, proceed as follows, paying
attention to the position of each component:
1) Remove the insulation and the temperature gauges, shut off
the three separately-purchased ball valves and remove the
unit body from the pipes.
2) Using a 17 mm hex key, unscrew and extract the shutter
locking nut, entering through the upper by-pass from boiler
port on the unit (fig. 1).
3) Extract the spring: attached to it are the shutter and the
thermostatic sensor (fig. 2).
4) Conduct appropriate maintenance or replace the
thermostatic sensor with a new cartridge, separately
purchased. The sensor can be fully inserted into the seat
with a slight interference fit.
5) Reassemble the shutter unit following the procedure in
reverse order.
Replacement thermostatic sensor cartridges. Easy replacement to change
the ThermoBloc™ boiler protection recirculation and distribution unit set
temperature:
F29633 115°F (45°C)
F29634 130°F (55°C)- standard factory-supplied setting
F29635 140°F (60°C)
F29636 160°F (70°C)
Dual scale temperature gauge for ThermoBloc™ boiler protection recirculation
and distribution unit:
F29571 32 - 250°F (0 - 120°C)
Replacement pump. Easy replacement by removing 2 bolts and inserting
the head in the 281 assembly.
F19379 115 VAC / .8 A. 16 feet head
R50057 Replacement 1-1/2” union washer.
Cale North America, Inc.
3883 W. Milwaukee Road
Milwaukee, WI 53208
T:414.238.2360 F:414.238.2366
7-24-18
·
Installation Tip
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281 ThermoBlocTM
Leave this manual for the user.
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