CALEFFI ThermoBloc 281 Series Manuel utilisateur

www.caleffi.com

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

ThermoBloc™ boiler protection recirculation and distribution unit

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

0 1 2 3 4 5 6 7 8 9 10

(psi) (ft of head )

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)

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: 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.

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

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

Scan to view

281 ThermoBlocTM

Leave this manual for the user.

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