FlowCal Compact Dynamic 01166/14 NA Automatic Flow .
FlowCal compact dynamicautomatic flow balancing valve01166/14 NACALEFFI127 series01166/20 NAReplaces 01166/19 NA003FM 21654FunctionThe FlowCal compact dynamic automatic flow balancingvalve is pressure independent and maintains a fixed flow ratewithin varying system differential pressure ranges. It eliminatesthe need for onsite measurements and trial and error flowrate settings as required with manual calibration valves.The design incorporates an exclusive flow cartridge, made of ananti-scale, low noise polymer and a compact low-lead brass valve bodyfor use in hydronic and domestic water systems.The FlowCal balancing valve is available with NPT male, sweat, pressand PEX expansion union connections. The union nut makes installationand maintenance fast, easy and efficient for a variety of tailpiece options.Product range127 series FlowCal compact dynamic automatic flow balancing valve, with polymer cartridge .sizes 1/2”, 3/4”, 1" with NPT male, sweat, press, or PEX expansion union connectionsDimensionsTechnical specificationsMaterialsBody:Flow cartridge:Spring:Seals:DZR low-lead brass ( 0.25% Lead content)anti-scale polymerstainless steelperoxide-cured EPDMPerformanceMedium:water, glycol solutionsCACA50%232 psi (16 bar)Working temperature range:32-212 F (0-100 C)Connections:1/2”, 3/4”and 1” NPT male, sweat or press unionLay length (press connection):size ½ and ¾ inch: 3 5/8"size 1 inch: 4 1/16"Flow Rate:21 fixed flow rate settingsranging from 0.35 - 10 GPMFlow Accuracy: 10%Differential Pressure Control Ranges:2-14, 2-32, 4-34, 5-35 psidCertifications1. NSF/ANSI 372, Drinking Water SystemComponents-Lead Content Reduction of Leadin Drinking Water Act, California Health and SafetyCode 116875 S.3874, Reduction in Drinking WaterAct, Vermont Act 193 - The Lead in PlumbingSupplies Law and Maryland’s Lead Free Law HB.372,certified by ICC-ES, file PMG-1360.2. PEX expansion fittings certified to ASTM F 1960.US Patent: 7,246,635 B2.BBMax. percentage of glycol:Max. working pressure:AAnptsweatPEXexp.pressCodeAB127341AF.½" npt male5 13/16"C1.0127349AF.½" sweat4 ¼"0.8127346AF.½" press51/8"1.0127342AF.½" PEXexpansion63/8"1.0127351AF.¾" npt male5"1.0127359AF.¾" sweat4 13/16"0.8127356AF.¾" press5 5/8"127352AF.¾" PEXexpansion7 1/16"1.05/8"1.21 9/16"Weight (lb)PEXcrimp 1.0127361AF.1" npt male127369AF.1" sweat6"1.0127366AF.1" press5 13/16"1.3127362AF.1" PEXexpansion7 3/8"1.35
Circuit balancingModern heating and air-conditioning systems have to guarantee a high level of thermal comfort with a low energy consumption. This meanssupplying the system terminals with the correct design flow rates, to produce balanced hydraulic circuits.Unbalanced circuitsIn case of an unbalancedcircuit, the hydraulicimbalancebetweenemitters creates areaswith temperatures whichare not uniform, and, asa consequence, problemswith thermal comfort andhigh energy consumption.Flow rateFlowFlowraterate100 %50 100% %100 %140 %0 %180 100% %100 %FLOWCALFLOWCALFULL LOADPARTIAL LOADCircuits balanced with manual valvesTraditionally, hydrauliccircuits are balancedusing manual calibrationvalves. With these statictype devices, such circuitsare difficult to balanceperfectlyandhaveoperating limitations incase of partial closureby means of the controlvalves. The flow rate inthe open circuits doesnot remain constant atthe nominal value.Flow rateFlow rate100 %140 %Controlvalve(closed)100 %0 %100 %120 %Manual valveManual valveFULL LOADCircuits balanced with FlowCalFlowCalbalancesthe hydraulic circuitbyautomaticallycontrolling the designflow rate to eachemitter. Even with somecircuits partially closedby the control valves,the flow rates in theopen circuits remainconstantatthenominal value. Thesystem always providesthe greatest comfortand the highest energysavings.PARTIAL LOADFlow rateFlow rate100 %100 %Controlvalve(closed)100 %0 %100 %100 %FLOWCALFLOWCALFULL LOADPARTIAL LOAD
FlowCal Compact Dynamic Automatic Flow Balancing ValvesFunctionThe FlowCal automatic flow balancing valve guarantees a constant flow rate when the upstream/downstream pressure differential varies.It is therefore necessary to refer to the Dp vs. flow rate diagram and to a basic diagram illustrating the operation methods and the relevant variableeffects.Operating principleThe FlowCal flow cartridge is composed of a cylinder, a spring-loaded piston, and a combination of fixed and variable geometric orifices through whichthe fluid flows. These variable orifice sizes increase or decrease by the piston movement, contingent on the system’s fluid thrust. A specially calibratedspring counteracts this movement to regulate the amount of fluid which may pass through the valve orifices, maintaining a balanced system. FlowCalvalves are high performance automatic flow balancing valves which control selected flow rates within a tight tolerance (approximately 10%) and offer awide range of operation.FLUIDTHRUSTFLUIDTHRUSTFLUIDTHRUSTBelow the differential pressure control range ( 2 psid)*In this case, the spring-loaded regulatingpiston remains in equilibrium withoutcompressing the spring and gives the fluidthe maximum free flow area. When belowthe differential pressure control range thepiston acts as a fixed orifice and thus theflow rate through the FlowCal depends onlyon the differential pressure.FLOW RATENominal2 psiDIFFERENTIALPRESSURE32 psiRange p 2–32 psiControl rangeFLOW RATENominalFinal pIf the differential pressure is within the controlrange, the spring-loaded piston is positionedto give the fluid a free flow area permitingregular flow at the nominal rate for which theFlowCal is set up.Initial pFLUIDTHRUSTFLUIDTHRUSTFLUIDTHRUSTWithin the differential pressure control range (2 - 32 psid)*2 psiDIFFERENTIALPRESSURE32 psiFLUIDTHRUSTFLUIDTHRUSTFLUIDTHRUSTAbove the differential pressure control range ( 32 psid)*In this case, the spring-loaded piston fullycompresses a spring and leaves only the fixedorifice for the fluid to pass through.The flow rate through the FlowCal dependsonly on the differential pressure.FLOW RATENominal2 psiDIFFERENTIALPRESSURE32 psiRange p 2–32 psi*These values are for this example. The same logic applies to the other Differential Pressure Control Ranges: 2 -14, 4 - 34, and 5 -35 psid.
Construction detailsPolymer flow cartridgeThe flow rate cartridge is made of an anti-scale polymer, speciallyengineered for use in cooling, heating and domestic watersystems, to prevent mineral buildup in a wide range of workingtemperatures. It features high resistance to the abrasion causedby continuous fluid flow, is insensitive to the deposit of scale andis fully compatible with glycols and additives used in circuits.Exclusive designWith its exclusive design, the flow cartridge is able to accuratelycontrol the flow rate in a wide range of operating pressures. Aspecial internal chamber acts as a damper for the vibrationstriggered by the fluid flow, allowing low noise operatingconditions to the device.For these reasons it can be used in systems on zone branchcircuits or directly at the terminals.BODYCARTRIDGECARTRIDGE LOCKING NUTPump Sizing using FlowCalSize the hydronic system with FlowCal automatic balancingvalves as follows:Control valve1. DPMAXCIRCUITDetermine the pressure head loss for the zone circuit withthe greatest pressure drop (flow resistance). This is true forany hydronic system with supply and return headers.As an example, this would be circuit #8 for the 2-pipe directreturn system with circuits having identical resistance,illustrated to the right, as it is farthest from the pump. If,however, all circuits are not identical, choose the circuit withthe greatest pressure drop.2. DPMINFlowCalAdd the minimum differential operating pressure(2, 4, or 5 psid) required for the FlowCal model selectedfor the circuit with the greatest pressure drop.12345678FlowCal3. PUMP HEAD DPMAXCIRCUIT DPMINFlowCalFlow rate tableCodeSize12734xAF 12735xAF 12736xAF 1/2”3/4”1”Flow rates (gpm)0.35; 0.50; 0.75; 1.00; 1.30; 1.50; 1.75; 2.00; 2.20; 2.50; 2.60; 3.00; 3.50; 4.00; 4.50; 5.00; 6.00; 7.00; 8.00; 9.00; 10.000.35; 0.50; 0.75; 1.00; 1.30; 1.50; 1.75; 2.00; 2.20; 2.50; 2.60; 3.00; 3.50; 4.00; 4.50; 5.00; 6.00; 7.00; 8.00; 9.00; 10.000.35; 0.50; 0.75; 1.00; 1.30; 1.50; 1.75; 2.00; 2.20; 2.50; 2.60; 3.00; 3.50; 4.00; 4.50; 5.00; 6.00; 7.00; 8.00; 9.00; 10.00Dp range (psid)2–142–324–345–35Minimum differential pressure requiredThis is equal to the minimum working Dp of the FlowCal cartridge: 2, 4 or 5 psi (13, 27 or 31 kPa).
Order Code Numbering for FlowCal 127 tion127341AF.½" npt male127351AF.¾" npt male127361AF.1" npt male127342AF.½" PEX exp.127352AF.¾" PEX exp.127352AF.1" PEX exp.127346AF.½" press127356AF.¾" press127366AF.1" press127349AF.½" sweat127359AF.¾" sweat127369AF.1" sweatAll fittings are union style.Flow rate (GPM)Last 3 digits*(AF ) P controlranges 8G02.502G59.009G010.0010GFlow rate (GPM)Last 3 digits*(AF )2.602G63.003G03.503G54.004G02 - 142 - 321.0 GPM P 2 - 32 PSID1.0 GPM P 2 - 32 PSID1.0 GPM P 2 - 32 PSIDApplication DiagramTo balance hydronic fan coil circuits. P controlranges (psid)2 - 324 - 345 - 35
Hot water recirculationUnbalanced exampleBalanced example.5 GPM1.0 GPM 2 - 32 PSID.5 GPM1.0 GPM 2 - 32 PSID1.0 GPM 2 - 32 PSID1.0 GPM 2 - 32 PSID.5 GPM1 GPMcoldwatersupply.5 GPMtricklerecirculationpumpcheckvalveBalancing made fast, easy, and accurate with the Caleffi FlowCal 127 series balancing valveHot water recirculation systems are designed to minimize wait time for hot water to arrive when a fixture is opened. Systems left unbalanced or improperlybalanced result in wasted water down the drain, a costly and environmentally unfriendly situation - not to mention the undesired annoyance placed onbuilding occupants. Multiple hot and cold water risers are supplied from common hot and cold water mains. The number and type of fixtures served byeach set of risers will often be different. A recirculation riser accompanies each set of hot and cold risers. A single circulator provides recirculation flowthrough the entire system. This type of piping network is similar to a 2-pipe direct return distribution system for hydronic heating. Because of differencesin the lengths or sizes of both the main piping and riser piping, the recirculation flow through each set of risers is likely to be different. This can lead todifferent temperature drops between the beginning of a given hot water riser and the end of its associated return riser. This may cause the hot watertemperature arriving at a distant fixture to be insufficient for the intended usage. This situation can be corrected by “balancing” the recirculation flowbetween the various sets of risers. The goal of such balancing is to establish recirculation flow rates that create equal temperature drop between thestart of each hot water riser and the end of its associated return (recirculation) riser.Balancing is enabled with the FlowCal pressure independent low-lead balancing valve, with fixed flow rate, presuming riser flow rates have been computedin advance. These valves will control to the design flowrate without the worry of pressure differentials. For added convenience to properly install this system asdepicted, Caleffi offers a union with temperature gauge, code NA102 series, to be installed on each riser, and an in-line flow check valve, code NA510 series,to be installed ahead of each FlowCal balancing valve on the return line, pictured in the "balanced" diagram above.SPECIFICATION SUMMARY127 seriesCompact dynamic automatic pressure independent flow balancing valve with polymer flow cartridge FlowCal . Connections ½”,¾”, 1” NPT male, sweat, press and PEX expansion union. PEX expansion fittings must comply with ASTM F 1960. DZR low-leadbrass body ( 0.25% lead content) certified by ICC-ES file PMG-1360. Anti-scale polymer cartridge. Stainless steel spring. Peroxidecured EPDM seals. Water and up to 50% maximum glycol solutions. Maximum working pressure 232 psi (16 bar). Workingtemperature range 32 to 212 degrees F (0 to 100 degrees C). Dp range 2–35 psi. Range of available flow rates for all connectionsizes 0.35 - 10.00 gpm. Accuracy 10%.We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.Caleffi North America, Inc.3883 W. Milwaukee RoadMilwaukee, WI 53208Tel: 414-238-2360 · Fax: 414-238-2366sales@caleffi.com · www.caleffi.com Copyright 2020 Caleffi North America, Inc.
Control valve (closed) A RA A A A 100 % 100 % 100 % Flow rate 140 0 % 120 % Flow rate 100 % 100 % 100 % Flow rate 100 % 0 % 100 % Flow rate: Unbalanced circuits: In case of an unbalanced circuit, the hydraulic : imbalance between emitters creat
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