CALEFFI MixCal 521410A Guida

Materials: -Body: low-lead brass (<0.25% lead content)

-Shutter, seats and sliding guides: PPO

-Springs: stainless steel

-Seals: peroxide-cured EPDM

Suitable ﬂuids: water, 30% max glycol solution

Setting range (outlet temperature): 85–150°F (30–65°C)

Tolerance: ±3°F(±2°C)

Max. working pressure (static): 200 psi (14 bar)

Max. operating differential pressure (dynamic): 75 psi (5 bar)

Max. recommended differential pressure: 20 psi (1.5 bar)

Max. hot water inlet temperature: 200°F (93°C)

Max. inlet pressure ratio (H/C or C/H) for optimum performance: 2:1

Min. temperature difference between hot water inlet and mixed

water outlet for optimum performance: 27ºF (15ºC)

Min. ﬂow rate to ensure optimal performance: 1.0 GPM (3.8 L/min)

Lay length, hot to cold inlet: (½” & ¾” press connection) 3 5/8”

(1” press connection) 4 1/8”

Certiﬁed to:

Function

The Calefﬁ MixCal™ three-way thermostatic mixing valve is used in

systems producing domestic hot water or in hydronic and radiant

heating systems. With the unique mixing chamber design, MixCal

produces very stable mixed water temperture as inlet temperatures

and pressures vary. Scale formation is minimized with anti-scale

polymer sliding surfaces, preventing siezing or erratic mixed

temperatures. O-ring seals made from durable peroxide-cured EPDM

resist wear from common water treatment additives such as chlorine

and chloramines.

Product range

521A Series Three-way thermostatic mixing valve:

“C” models include inlet check valves. “419, 519, 619” models include

outlet gauge adapter. Connections: union thread NPT male, sizes ½”,

¾”, 1”; union sweat, sizes ½”, ¾”, 1”; union press, sizes ½” , ¾”, 1”;

union PEX crimp, sizes ½” , ¾”, 1”.

Technical Characteristics

MixCal™Adjustable three-way thermostatic mixing valve

521 series

38476.13

www.caleffi.com

INSTALLATION AND COMMISSIONING MANUAL

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

PMG-1357

2. Complies with 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,

as 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

pipwork connecting the MixCal 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 MixCal thermostatic mixing valve, take the necessary precautions to

ensure that such temperatures do not endanger people.

CAUTION: To prevent any damage which will cause the electronic mixing

valve to not operate correctly, treat highly aggressive water before entering

the thermostatic mixing valve. Be sure water hardness is less than 10 grains.

CAUTION: If installed in an ASSE 1017 application, check valves shall be

used.

SAFETY INSTRUCTION

CAUTION: All work must be preformed by qualiﬁed 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.

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.

ATTENTION: Lorsque vous effectuez les raccordements d'eau, assurez-

vous que la tuyauterie reliant le MixCal termostatico regolabile n'est pas

mécaniquement des overstressed. Au fil du temps, ceci pourrait causer des

ruptures, avec pour consequence des pertes en eau qui, à leur tour, peuvent

causer des dommages à la propriété et/ou les gens.

Ce symbole d'avertissement servira dans ce manuel à attirer l'attention sur la sécurité concernant

instructions. Lorsqu'il est utilisé, ce symbole signifie.

ATTENTION! DEVENEZ ALERTE ! VOTRE SÉCURITÉ EST EN JEU ! NE PAS SUIVRE CES

INSTRUCTIONS PEUT PROVOQUER UN RISQUE DE SECURITE.

ATTENTION: Tous les travaux doivent être effectués par du personnel qualifié

formé à la bonne application, installation et maintenance des systèmes

conformément aux codes et règlements locaux.

ATTENTION: Si le réducteur de pression, termostatico regolabile, n'est pas installé,

mis en service et entretenu correctement, selon les instructions contenues dans ce

manuel, il peut ne pas fonctionner correctement et peut mettre en danger l'utilisateur.

ATTENTION: S'assurer que tous les raccordements sont étanches.

ATTENTION: Les températures de l'eau supérieure à 100°F (38°C) peut

être dangereux. Au cours de l'installation, mise en service et l'entretien de

le réducteur de pression, le MixCal termostatico regolabile, prendre les

precautions nécessaires afin de s'assurer que de tells températures ne

compromettent pas les gens.

ATTENTION: Pour prévenir tout dommage qui provoque le mitigeur

électronique à ne pas fonctionner correctement, le traitement de l’eau très

agressive avant d’entrer dans le termostatico regolabile. Assurez-vous que la

dureté de l’eau est inférieure à 10 grains.

ATTENTION: S’il est installé dans un pays de ASSE1017 application, vériﬁez les

robinets doivent être utilisés.

CONSIGNE DE SÉCURITÉ

LAISSEZ CE MANUEL AVEC L’UTILISATEUR

AVERTISSEMENT:

Ce produit peut vous exposer à des produits chimiques comme le

plomb, qui est connu dans l’État de Californie pour causer le cancer, dommages à la

naissance ou autre. Pour plus d’informations rendez-vous www.P65Warnings.ca.gov.

COLD

HOT

MIX

COLD

HOT

MIX

Operating principle

The controlling element of the three-way

thermostatic mixing valve is a thermostatic

sensor fully immersed in the mixed water

outlet tube which, as it expands or contracts,

continuously establishes the correct proportion

of hot and cold water entering the valve. The

regulation of these ﬂows is by means of a

piston sliding in a cylinder between the hot

and cold water passages. Even when there

are pressure drops due to the drawing off of

hot or cold water for other uses, or variations

in the incoming temperature, the thermostatic

mixing valve automatically regulates the water

ﬂow to obtain the required temperature.

COLD

HOT

MIX

Inlet port check valve detail for 521 “AC” models

Flow curve

Flow should never exceed standards for pipe size and materials.

Kv = 2.6

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)

(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)

0.2

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 = 3.0

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 MixCal series 521 thermostatic mixing valves are designed to be installed at the hot water

heater. The Calefﬁ Mix Cal series 521 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 anti-chill service.

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

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

reasons, it is advisable to limit the maximum mixed water temperature to 120ºF.

Instantaneous production of hot water

Caleffi MixCal 521 series thermostatic mixing valves may be used with boilers or heaters providing

instantaneous hot water as long as the heater is the type which is capable of modulating its output

to handle low demand. A small amount of storage or piping length between the heat exchanger

and mixing valve will improve stability of water delivery temperature.

Installation

NOTE TO INSTALLER: The Caleffi MixCal series 521 thermostatic mixing valve should be installed

by qualified personnel, in accordance with local codes and ordinances. It is the responsibility of the

installer to properly select, install and adjust this thermostatic mixing valve as specified in these

instructions. Before installing a Caleffi MixCal series 521 thermostatic mixing valve, the system

must be inspected to ensure that it’s operating conditions are within the range of the thermostatic

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

Systems where the Calefﬁ MixCal series 521 thermostatic mixing valve is to be installed must

be drained and cleaned out to remove any dirt or debris which may have accumulated during

installation. Failure to remove dirt or debris may affect performance and the manufacturer’s product

guarantee. The installation of ﬁlters of appropriate capacity at the inlet of the water from the mains

supply is always advisable. In area which are subject to highly aggressive water, arrangements must

be made to treat the water before it enters the valve.

Calefﬁ MixCal series 521 thermostatic mixing valves must be installed in accordance with the

diagrams in this manual, taking into account all current applicable standards.

Calefﬁ Mix Cal series 521 thermostatic mixing valves can be installed in any position, either vertical

or horizontal.

The following are shown on the mixer body:

– Hot water inlet, color red and marker “HOT”.

– Cold water inlet, color blue and marker “COLD”.

– Mixed water outlet, marker “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. Index

Point

Check valves

In order to prevent undersirable backsiphonage, separate check valves should be installed in systems

with code “521 A” model thermostatic mixing valves (these models do not contain integral check valves

in the hot and cold inlet ports). As a convenience for easier installations, the Calefﬁ code “521 AC”

model series thermostatic mixing valves include integral check valves in the hot and cold inlet ports.

NOTE TO INSTALLER: DO NOT TEST FIT OR INSTALL CHECK VALVES BEFORE SOLDERING. IF

INSTALLED, REMOVAL WILL REQUIRE DAMAGING THE CHECK VALVE AND IT WILL NO LONGER

BE USABLE.

The diagram below shows the order in which everything goes together. Note that the check valves

are installed on the hot and cold inlets, the mixed outlet does not require a check valve. Note that the

O-ring is installed on to the groove of the check valve.

After soldering the tailpieces into place, slide in the check valve into the tailpiece with o-ring going in

ﬁrst. It will click into place and then the screen will ﬁt into the groove of the tailpiece with the domed

end facing the mixing valve. Once the check valve and screen is installed, use the sealing washer

between the tailpiece and mixing valve body to create a seal and tighten down the union nut.

Commissioning

The special purpose of the thermostatic mixing valve must be commissioned in accordance with

current standards by qualiﬁed personnel using temperature measuring equipment. Calefﬁ codes

521419A, 521519A, and 521619A with integral outlet port temperature gauges provide a time-saving

temperature setting process to get close to the desired temperture. Use of a digital thermometer is

recommended for determining the ﬁnal setting of the mixed water temperature.

NOTE: Gauge adapters with 2” diameter, 20-210ºF scale, code NA10328 (1/2” sweat), NA10056

(3/4” sweat) or NA10058 (1” sweat) can be separately purchased and ﬁeld installed to the Calefﬁ

MixCal series 521 models sold without the integral gauge adapters.

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 taking account of the ﬂuctuations

due to simultaneous use. It is essential for these conditions to be stabilised 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.

41 3

VALVE BODY

UNION NUT, Quantity 3 per valve

UNION WASHER, Quantity 3 per valve

INLET PORT MALE TAILPIECE

WITH INTEGRAL CHECK VALVE

Quantity 2 per valve

INLET PORT CONIC FILTER,

Quantity 2 per valve

7OUTLET PORT TAILPIECE,

Quantity 1 per valve

5CHECK VALVE O-RING

2 3 6

(SWEAT TAILPIECE)

MIX

SUPPLY

HOTCOLD

MIX

BOILER

SUPPLY

MIX

Safety relief valve

Check valve

Isolation valve

Expansion vessel

Filter

Pump

WATER

HEATER

WATER

HEATER

CALEFFI

Radiant panels heating system

MIX

SUPPLY

HOTCOLD

MIX

BOILER

SUPPLY

MIX

Safety relief valve

Check valve

Isolation valve

Expansion vessel

Filter

Pump

WATER

HEATER

WATER

HEATER

CALEFFI

*MixCal series 521 thermostatic mixing valves with inlet check valves, “AC” models, can be used

instead of separately installed check valves.

**Refer to principle of operation on page 8.

SUPPLY

MIX

WATER

HEATER

Safety relief valve

Check valve

Isolation valve

Expansion vessel

Filter

Pump

Globe valve

Domestic hot water system

without recirculation

Domestic hot water system

with recirculation**

CALEFFI

COLD

HOT

HOT/RED COLD/BLUE

MIX

SUPPLY

HOTCOLD

MIX

BOILER

SUPPLY

MIX

Safety relief valve

Check valve

Isolation valve

Expansion vessel

Filter

Pump

WATER

HEATER

WATER

HEATER

CALEFFI

Application Diagrams

Temperature adjustment

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

top of the valve.

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

T (°F) 81 90 100 111 120 127 136 145 152

T (°C) 27 32 38 44 49 53 58 63 67

with: T

HOT = 155°F (68°C), with: T

cold = 55°F (13°C), P = 43 psi (13 bar)

Recirculation with point-of-distribution thermostatic mixing valves

For domestic recirculating water systems, , that include a single ASSE 1017 point-

of-distribution thermostatic mixing valve, such as the Caleffi MixCal 521 series, the

piping installation in the application drawing on page 7 is recommended.

In any recirculating hot water distribution system there will be times when the circulator is

operating, but no hot water is being drawn at the ﬁxtures. Under this condition, heat continually

dissipates from the piping forming the recirculation loop. If the loop is relatively short, and well

insulated, the rate of heat loss should be very small. If the loop is long, and uninsulated, the

rate of heat loss could be substantially greater.

To maintain the recirculating water at the desired delivery temperature the heat lost from the

loop must be replaced. This requires some water ﬂow between the loop and the hot water

source. Ideally, this ﬂow is adjusted so that the rate of heat transfer from the hot water source

to the loop exactly balances the rate of heat loss from the loop’s piping.

The ﬁgure (below) shows a “bypass valve” (1), and “return valve” (2), which regulate how

much warm water from the return side of the recirculating loop ﬂows back to the storage tank.

When there is no demand for hot water at the ﬁxtures, the ﬂow of return water to the tank

will equal the rate of hot water ﬂow from the tank to the inlet port of the mixing valve. Ideally,

this ﬂow should be adjusted so that the rate of heat transfer from the tank to the recirculating

loop exactly balances the rate of heat loss from the recirculating loop. This allows the water

temperature leaving themixing valve to remain stable.

The bypass valve (1) and possibly the return valve (2) must be adjusted when there is no

domestic water draw on the recirculating loop (when all the ﬁxtures are off). Begin with the

bypass valve (1) fully closed, and the return valve (2) fully open. Turn on the recirculating

circulator and let it run for several minutes. The supply water temperature leaving the mixing

valve will likely be lower than the setting of the valve, since there is no return ﬂow to the tank

thus, no hot water to the hot port of the mixing valve.

Slowly open the bypass valve (1) and monitor the temperature leaving the mixing valve. It will

likely begin rising as some water returns to the tank, and an equal ﬂow of hot water moves

from the tank to the hot port of the mixing valve. When the temperature leaving the mixing valve

remains stable, and is at or very close to the temperature set on the mixing valve, the bypass

valve is correctly set.

The return valve (2) can remain fully open unless a situation occurs where the bypass valve (1)

is fully open, but the temperature leaving the mixing valve is still too low. If this occurs, partially

close the return valve (2) to add ﬂow resistance. This forces more ﬂow through the bypass valve

(1). Repeat the previously described procedure of slowly opening the bypass valve (1) until the

water temperature leaving the mixing valve is stable.

Replacement ttings

Complete kit Valve size Connection Union Nut Tailpiece Washer

NA20640

½ inch

NPT male

F61008

R31981

F50055

NA20640C 59893A

NA20649 Sweat NA10002

NA20649C 59904A

NA20646 Press incl. w/ tailpc NA16264

NA20647 PEX crimp F61008 F0000492

NA20647A NA10484

NA20650

¾ inch

NPT male

F61008

31901A

F50055

NA20650C 59840A

NA20659 Sweat NA10003

NA20659C 59905A

NA20656 Press incl. w/ tailpc NA16264

NA20656A F0000698 NA10419

NA20657 PEX crimp F61008 F0000520

NA20657A NA10485

NA20660

1 inch

NPT male

incl. w/ tailpc

59817A

F50055

NA20660C 59894A

NA20669 Sweat 59834A

NA20669C 59906A

NA20666 Press NA16266

NA20667 PEX crimp F61008 F0000521

NA20667A NA10486

Replacement parts

Replacement body.

Complies to

requirements of NSF/

ANSI 372-2016, low

lead, as certified by

ICC-ES, file

PMG-1360. Certified

to ASSE 1017/CSA

B125.3 by ICC-ES,

file PMG-1357.

ASSE 1017

521101A.........................1" male union thread

Point of distribution

mixed temperature

gauge adaptor fits

MixCal 521 series

mixing valves. Threaded

union mounting

replaces existing mixed

outlet with ¾" or 1"

sweat pipe connection.

NA10328.........................½" sweat with gauge

NA10056.........................¾" sweat with gauge

NA10058..........................1" sweat with gauge

NA10358 ...............1" union thread with gauge

688003A...Replacement gauge w/ pocket well

R39591............................ Replacement gauge

Removable gauge ﬁts into temperature well.

Gauge dial is 2” diameter and scale from

30—210º F.

HOT

COLD

MIX

MIN

B B

HOT

COLD

MIX

MIN

B B

MIX

110130

150

170

190

210

ϒF

MIX

110130

150

170

190

210

ϒF

Dimensions

NPT male & Press connections

Laylength (press)

size ½ & ¾ inch: 3 5/8"

size 1 inch: 4 1/8"

Code A B C D* E F

NPT Threaded connections

521400A 1⁄2" 25⁄8" 51⁄4" 6" 33⁄8" 25⁄8"

521400AC 1⁄2" 25⁄8" 51⁄4" 6" 33⁄8" 25⁄8"

521410A** 1⁄2" 25⁄8" 51⁄4" 73⁄8" 4¾" 25⁄8"

521410AC** 1⁄2" 25⁄8" 51⁄4" 73⁄8" 4¾" 25⁄8"

521500A 3⁄4" 25⁄8" 51⁄4" 6" 33⁄8" 25⁄8"

521500AC 3⁄4" 3" 6" 6" 33⁄8" 25⁄8"

521510A** 3⁄4" 25⁄8" 51⁄4" 8" 53⁄8" 25⁄8"

521510AC** 3⁄4" 3" 6" 8" 53⁄8" 25⁄8"

521600A 1" 27⁄8" 53⁄4" 61⁄4" 3¾" 25⁄8"

521600AC 1" 31⁄16" 61⁄8" 61⁄4" 3¾" 25⁄8"

521610A** 1" 27⁄8" 53⁄4" 75⁄8" 51⁄8" 25⁄8"

521610AC** 1" 31⁄16" 61⁄8" 75⁄8" 51⁄8" 25⁄8"

Press connections

521406A ½" 29⁄16" 51⁄8" 6" 33⁄8" 25⁄8"

521416A** ½" 29⁄16" 51⁄8" 81⁄4" 55⁄8" 25⁄8"

521506A ¾" 213⁄16" 55⁄8" 8½" 57⁄8" 25⁄8"

521506AC ¾" 43⁄16" 83⁄8" 61⁄4" 35⁄8" 25⁄8"

521516A** ¾" 213⁄16" 55⁄8" 8½" 57⁄8" 25⁄8"

521516AC** ¾" 43⁄16" 83⁄8" 8½" 57⁄8" 25⁄8"

521606A 1" 215⁄16" 57⁄8" 65⁄16" 311⁄16" 25⁄8"

521616A** 1" 215⁄16" 57⁄8" 85⁄8" 6" 25⁄8"

Troubleshooting

Under normal operating conditions the Calefﬁ 521 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.

*At minimum temperature position

on adjusting knob.

**Model with integral outlet

temperature gauge.

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