1. COMPONENTS
FOR BIOMASS SYSTEMS

2. The Caleffi Biomass product series has been created specifically to be used in circuits of
systems with wood solid fuel generators, operating at high temperature with water or glycol
solutions as thermal medium. The materials of the components and their performance take
account of the specific system needs in terms of efficiency and safety of the generators and
systems.
BIOMASS
LOGS
Biomass is “the biodegradable fraction of products, waste and residues from biological
origin from agriculture (including vegetal and animal substances), forestry and related
industries (including fisheries and aquaculture), as well as the biodegradable fraction of
industrial and municipal waste”. Biomass can be in the form of a solid, liquid or gas.
This line of Caleffi products has been specifically designed for wood solid
biomass (solid fuel).
SOLID FUEL GENERATORS
PELLETS
Solid fuel generators can be classified in two macro-categories:
1) Boilers: generators “for solid fuels, hand and automatically stoked”, to be installed
in specific technical rooms. Heating takes place via a hydraulic connection to the
heating system.
2) Residential devices: “residential solid fuels burning appliances with boiler, not
exceeding a total nominal heat output of 35 kW”, installed directly inside the dwelling.
Hand or automatically stoked. Heating takes place via air and water circulation, with
a hydraulic connection to the heating system. Residential devices can be classified
in three types:
- Fireplace heating systems
- Thermostoves
- Thermocookers
WOODCHIPS
The generators are further divided according to their fuel stoking system:
Hand stoking, typically that of log-burning generators, requires an operator to put
the blocks of wood into the generator stoking compartment.
Automatic stoking refers to the last device conveying the fuel (for example pellets
or woodchips) from the storage tank to the combustion chamber.
Hand and automatically stoked boiler
Flue gas
Thermal exchange
Comburent air
M
Primary and
secondary air
M
M
Hand and automatically stoked residential device
M
2
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003

3. P
T
Safety thermostat with
manual reset
TR
TR T
Adjustable thermostat with
automatic reset
Safety relief valve
Optical and acoustic
alarm
AL
To storage
Near the
Comburent air stop
device
AC
REFERENCE STANDARDS
PPM
Closed expansion
hand stocked
The standards classify systems according to the (only for and V > 300 l) system (open or closed vessel) and according to the system for stoking fuel into
expansion
generator
boilers
vessel
TC Control thermostat
Temperature gauge
the boiler, by hand (logs) or automatic (pellets, woodchips etc.).
Temperature relief
valve
RIARMO
SOLID
Generator
FUEL BOILER
Power rating
Product standard
Boiler
Up to 300 kW
EN 303-5 (2004)
Boiler
< 35 kW
Boiler
> 35 kW
Residential
Up to 35 kW
P
PLM
Safety pressure switch with
manual reset
System standard
Pressure gauge
542
1 1/2 X 1 1/2
542
EN 12828 (2003) for
Three way tap Europe
Minimum level protection
device
Temperature safety
relief valve
I.S.P.E.S.L. master
pressure gauge
EN 12828 (2003) Italy
PPM
Minimum pressure
protection device
I.S.P.E.S.L. test pocket
Temperature relief
valve with automatic
S
Collection R I.S.P.E.S.L. (1982-2005-2009*) Italy
filling
C
EN 13229 (2006)
EN 13240 (2006)
EN 12815 (2006)
EN 12828 (2003) Europe
UNI 10412-2 (2009) Italy
*In the phase of approval
Here we give some significant examples of open and closed vessel systems made in accordance with applicable standards
T
TR
TC
P
Comburent air stop
TR AC device PPM
T
P
Safety thermostat with
manual reset
Adjustable thermostat with
automatic reset
TR
TR T
AL Near Optical and acoustic
the
TR TL alarm P PPM PLM
P
generator
P
PPM
Control thermostat
To storage
(only for hand stocked
Closed expansion
boilers and V > 300 l)
To storage
To storage
(only for hand stocked
(only for hand stocked
boilers
ToboilersTemperature
storageand V > 300 l)
and V > 300 l)
(only for hand valve
stocked
boilers and V > 300 l)
SOLID
FUEL BOILER
Safety pressure switch
manual reset
T
vessel
Temperature gauge
Near the
Near
generator the
generator
withNear the
generator
Pressure
T
Safety relief valve
RIARMO
TR
relief
542
gauge
542
Three way tap for
I.S.P.E.S.L. master
pressure gauge
FUEL BOILER
PPM
Minimum pressure
protection device
TC
S
C
Temperature relief
valve with automatic
filling
Black devices: mandatory according to standards
Magenta or “framed” devices: optional or as an alternative
according to standards
AL
TL
RIARMO
542
1 1/2 X 1 1/2
542
RIARMO
542
1 1/2 X 1 1/2
542
S
C
S
C
T
S
TC
PPM
≤1 m
To storage
(only for hand stocked
boilers and V > 300 l)
Near the
generator
P
P PPM generatorC
T T
Near the
≤1 m
TL Near theP
PLM
To storage
(only for hand stocked
boilers and V > 300 l)
PLM
EN 303-5 (2004): Heating boilers for solid fuels, hand and
automatically stoked, nominal heat output of up to 300 kW.
Open vessel.
EN 303-5 (2004): Heating boilers for solid fuels, hand and
automatically stoked, nominal heat output of up to 300 kW.
Closed vessel.
TL
RIARMO
AL
C
Near the
generator
Near the
generator
SOLID FUEL
GENERATOR
SOLID FUEL
GENERATOR
SOLID FUEL
BOiLER
SOLID FUEL
BOiLER
PLM AC
S
generator
TC
P PPM T
SOLID
SOLID FUEL
FUEL BOILER
DOMESTIC
GENERATOR
DEVICE
To storage
(only for hand stocked
boilers
To storageand V > 300 l)
(only for hand stocked
boilers and V > 300 l)
Near the
generator
Near the
generator
SOLID FUEL
GENERATOR
542
I.S.P.E.S.L. test pocket
PLM
Near the
generator
SOLID FUEL
BOiLER
542
1 1/2 X 1 1/2
Temperature gaugetap for
Three way
I.S.P.E.S.L. master
Pressure gauge
pressure gauge
Pressure gauge
Three way tap forpocket
I.S.P.E.S.L. test
I.S.P.E.S.L. master
Three way tap for
pressure gauge
I.S.P.E.S.L. master
pressure gauge
I.S.P.E.S.L. test pocket
TR T
P
P PPM T TC
542
542
TR
SOLID FUEL
GENERATOR
TR TL
RIARMO
C
1 1/2 X 1 1/2
P PPM T TC
Temperature relief
Closed expansion
valve
vessel
Closed expansion
vessel
Temperature relief
Temperature safety
valve valve
relief
Temperature relief
valve
Temperature relief
valve with safety
Temperatureautomatic
filling
relief valve
Temperature safety
relief valve
Temperature relief
valve with automatic
Temperature relief
filling
valve with automatic
filling
EN 12828 (2003): Heating system in buildings - Design for
water-based heating systems.
Closed vessel.
RIARMO
PLM AC
P
Safety relief valve
Closed expansion
Safety relief valve
vessel
SOLID FUEL
Control thermostatlevel protection
Minimum
PLM GENERATOR
device
P Safety pressure switch with
manual reset
Safety pressure switch with
P
manual reset
P Minimum pressure
PLMPM Minimum level protection
protection device
device
PLM Minimum level protection
device
PPM Minimum pressure
protection device
PPM Minimum pressure
protection device
Temperature safety
relief valve
I.S.P.E.S.L. test pocket
TR TL
Safety relief valve
device
thermostat
TR Adjustablereset PPM with
Optical and acoustic
automatic
P
AL
T Safety thermostat with T TC AC Comburent air stop
alarm
device
manual reset
Comburent air stop
Safety thermostat with
AC
device
manual reset thermostat with
TC Adjustable thermostat
Control
Temperature gauge
TR automatic reset
Optical and acoustic
Near the AL
alarm
Adjustable thermostat with generator
Optical and acoustic
with
automatic resetpressure switchAL
P Safety
alarm Pressure gauge
manual reset
TC Control thermostat
Temperature gauge
1 1/2 X 1 1/2
SOLID FUEL
SOLID
BOiLER
FUEL BOILER
PLM Minimum level protection
device SOLID
AC Comburent air stop
Safety thermostat with
manual reset
T
TC
542
1 1/2 X 1 1/2
542
TL
RIARMO
TL
T
PLM AC
PLM AC
SOLID FUEL
GENERATOR
SOLID FUEL
GENERATOR
SOLID FUEL
GENERATOR
TC
AL
RIARMO
AL
TL
542
≤1 m
1 1/2 X 1 1/2
542
≤1 m
TC
T
T TR T L
TC P
PLM
≤1 m
542
S
1 1/2 X 1 1/2
542
≤1 m
≤1 m
≤1 m
S
DOMESTIC
DEVICE
≤1 m
C
Near the
generator
To storage
(only for hand stocked
boilers and V > 300 l)
S
C
S
C
SOLID FUEL
DOMESTIC
BOiLER
DEVICE
DOMESTIC
DEVICE
C
DOMESTIC
DEVICE
Collection R I.S.P.E.S.L. (2009): Applicatory technical
specifications of Title II of Italian Ministerial Decree DM 1.12.75
in accordance with art. 26 of the decree. (P>35 kW for Italy).
Hand and automatically stoked. Open vessel.
UNI 10412-2 (2009): Hot water heating systems - Safety
requirements.
Part 2: Requirements for systems with residential solid fuels
burning appliances with boiler, not exceeding a total nominal
heat output of 35 kW.
Automatically stoked. Closed vessel.
RIARMO
PLM AC
AL
542
1 1/2 X 1 1/2
542
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003
SOLID FUEL
GENERATOR
≤1 m
3

4. SAFETY DEVICES
542
543
tech. broch. 01001
Temperature relief valve, with fail-safe
action.
Manual reset for burner switch off or
alarm activation.
Working pressure: 0,3 ≤ P ≤ 10 bar.
Working temperature range: 5–100°C.
Setting temperature 98°C and 99°C
Qualified and calibrated to I.S.P.E.S.L.
Discharge rating:
1 1/2” x 1 1/4” - 136 kW.
1 1/2” x 1 1/2” - 419 kW.
Code
542870
542880
tech. broch. 01057
Temperature safety relief valve,
with double safety sensor, for solid
fuel generators.
Max. working pressure:
10 bar.
Working temperature
range: 5–110°C.
Setting temperature 95°C
Discharge flow rate with ∆p of
1 bar and T=110°C: 3000 l/h
Length of capillary: 1300 mm.
Certified to EN 14597 standard.
Setting
1 1/2” M x 1 1/4” F
1 1/2” M x 1 1/2” F
Code
98°C
99°C
543513
Setting
3/4” F
95°C
Function
Function
The temperature relief valve
discharges the system water on
reaching the setting temperature.
Equipped with positive action. It
can be used with non-pulverized
solid fuel generators with open or
closed vessel in accordance with
current regulations.
The temperature safety relief
valve
limits
the
water
temperature in solid fuel
generators equipped with a
built-in storage or emergency
exchanger (for immediate
cooling).
On reaching the setting
temperature, the valve opens
the flow of mains water
through
the
emergency
exchanger or built-in storage
unit, so as to draw off the
excess heat and thereby
lower the temperature of the
system water contained in the
boiler jacket.
I.S.P.E.S.L. reference standards
According to the provisions of
Collection R Ed. 2009, concerning
“central heating systems using hot
water with temperatures no greater
than 110°C and a maximum nominal
heat output greater than 35 kW”, the
use of the temperature relief valve is
contemplated in the following
cases:
Open vessel systems
- Systems with generators stoked
with non-pulverized solid fuel, in place of the consumption water
heater or emergency exchanger (chap. R.3.C., point 2.1, letter i2).
Closed vessel systems
- Thermal systems with generators stoked with non-pulverized solid
fuels up to a nominal heat output of 100 kW with partial cut-off in
place of the residual power dissipation device (chap. R.3.C., point 3.2).
Reference standards
Its use is contemplated in the I.S.P.E.S.L. standards, Collection R ed. 2009, chapter R.3.C., point 2.1, letter i2; point 3.1, letter i;
point 3.3. The valve complies with EN 14597, it can be combined
with solid fuel generators with a heat output of less than 100 kW,
used according to the system provisions of the standards
EN 12828, UNI 10412-2 and EN 303-5.
RIARMO
542
1 1/2 X 1 1/2
542
SOLID FUEL
GENERATOR
SOLID FUEL
GENERATOR
4
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003

5. SAFETY DEVICES
544
529
tech. broch. 01058
Draught regulating valve,
with double safety.
Male threaded connection.
Adjustment range:
30–100°C.
Temperature relief valve, with positive
action, with automatic filling.
For solid fuel generators.
Max. working pressure: 6 bar.
Max. working temperature: 110°C
Working temperature range: 5–110°C.
Ambient temperature range: 1–50°C.
Setting temperature: 100°C (0/-5°C).
Discharge flow rate with ∆p of 1 bar
and T=110°C: 1600 l/h
Length of capillary: 1300 mm.
Code
Setting
544400
100°C
1/2” F
Code
529500
3/4”
Function
Function
On
reaching
the
setting
temperature, the temperature
relief valve discharges the water
of the system with a solid fuel
generator.
The device integrates in a single
group a temperature relief valve
with a positive safety remote
sensor and a filling valve. The
discharge of water enables
limiting the system water
temperature, while the filling inlet
enables the replacement of the
discharged flow rate.
The draught regulating valve, installed on the boiler with the
thermostatic element immersed in the medium, automatically
adjusts the flow rate of the comburent air to provide a more regular
and complete combustion.
Reference standards
Used when there is no
emergency exchanger and for
heat outputs < 35 kW (Italy).
S
C
RESIDENTIAL
DEVICE
5
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003

6. ANTI-CONDENSATION VALVE
280
Function
Anti-condensation valve
with thermostatic control
of the return temperature to
solid fuel generators.
Brass body.
The anti-condensation valve, used in heating systems with a solid
fuel generator, automatically regulates at the set value the
temperature of the water returning to the generator.
Keeping the boiler at a high temperature prevents condensation of
the water vapour contained in the flue gas.
Condensation produces tarry deposits that, accumulating on the
metal surfaces of the flue gas-system water exchanger, cause
corrosion, reduce the thermal efficiency of the flue gas-system
water exchanger and are a source of danger for the flues as they
are flammable.
The anti-condensation valve gives the generator a longer life and
ensures greater efficiency.
Flue gas and
emission control
Code
Connection
Kv (m3/h)
Settings
3/4”
1”
1 1/4”
3,2
9
12
45°C 55°C 60°C 70°C
45°C 55°C 60°C 70°C
45°C 55°C 60°C 70°C
28005
28006
28007
G
G
G
G
Code completion
Setting 45°C 55°C 60°C 70°C
G
4
5
6
7
Primary and
secondary air:
• Combustion
efficiency
Technical Specifications
Performance
Medium:
Maximum percentage of glycol:
Max. working pressure:
Working temperature range:
Setting temperature:
Accuracy:
By-pass complete closing temperature:
SR
ANTIAccumulation
of ash and residues CONDENSATION
water, glycol solutions
30%
16 bar
5–100°C
45°C, 55°C, 60°C, 70°C
±2°C
Tset + 10°C
Flow
by-pass
5
3/4” - 1” - 1 1/4” M with union
2
Thermostat replacement to modify setting
The adjustment sensor can
easily
be
removed
for
maintenance or to change the
set, with no need to remove the
valve body from the piping.
3
1
Installation in mixing mode (anti-condensation)
System
return
Installation
The valve can be fitted on both
sides of the generator in any
position, vertical or horizontal.
Installation is recommended
on the return to the generator
in mixing mode; it is also
allowed on the flow from the
generator in diverter mode according to the needs of system
control.
SOLID FUEL
GENERATOR
4
Characteristic components
1) Thermostatic sensor
2) Obturator
3) Spring
4) Plug
5) Valve body
Installation in diverter mode (system control)
SOLID FUEL
GENERATOR
6
M
Return
to generator
Connections:
SF
Zones of condensation
forming:
• Deposits and tar
• Corrosion
• Reduction in heat
exchanger efficiency
• Flammability
SOLID FUEL
GENERATOR
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003

7. SOLID
SOLID FUEL FUEL
GENERATOR
GENERATOR
ANTI-CONDENSATION VALVE
SOLID FUEL FUEL
SOLID
GENERATOR
GENERATOR
Operating principle
The thermostat, completely immersed in the medium, controls the movement of an obturator that regulates the flows in by-pass and toward the
system. On starting up the generator, the anti-condensation valve recirculates the flow water so as to bring the generator up to temperature as
quickly as possible (1). When the flow temperature Tf exceeds the set of the anti-condensation valve Tset, the valve’s cold port starts opening
to produce the mixing Tmix: in this phase the system loading begins (2). When the generator return temperature Tmix is greater than the setting
of the anti-condensation valve by approximately 10°C, the by-pass port gets closed and water returns to the generator at the same temperature
of the system return (3 and 4).
Tf ≤ Tset SYSTEM START UP TRANSIENT
by-pass open
system return closed
Tf ≤ Tset, Tmix=Tf
Tf
Tf
Tmix Tmix
Tf
Tf
SOLID
SOLID FUEL FUEL
GENERATOR
GENERATOR
SOLID FUEL FUEL
SOLID
GENERATOR
GENERATOR
1
Tset
Tmix Tmix
Tf > Tset START OF SYSTEM LOADING
by-pass open
system return open
Tf > Tset, Tr < Tset, Tmix=Tset
Tf
Tr
Tr
SOLID FUEL FUEL
SOLID
GENERATOR
GENERATOR
Tset
Tr
Tf
Tmix Tmix
Tf
SOLID
SOLID FUEL FUEL
GENERATOR
GENERATOR
Tf
Tset
Tmix Tmix
Tr
Tset Tset
Tf
SOLID FUEL FUEL
SOLID
GENERATOR
GENERATOR
Tf
3
Tf
Tmix Tmix
Tf
Tset
Tmix Tmix
Tr
Tr
Tr
Tr
Tset
Tset Tset
Tmix = Tset + 10°C BY-PASS CLOSING
by-pass closed
system return open
Tf > Tmix = Tset +10°C, Tmix=Tr
SOLID
SOLID FUEL FUEL
GENERATOR
GENERATOR
2
Tmix > Tset + 10°C SYSTEM LOADED
by-pass closed
system return open
Tf > Tmix > Tset +10°C, Tmix=Tr
Tf
Tr
Tr
SOLID FUEL FUEL
SOLID
GENERATOR
GENERATOR
Tset
Tr
Tset Tset
Tf = Flow temperature
Tset = Anti-condensation set temperature
Tf
Tmix Tmix
Tf
SOLID
SOLID FUEL FUEL
GENERATOR
GENERATOR
Tf
Tset
Tmix Tmix
Tr
4
Tr
Tr
Tset
Tr
Tr
Tset Tset
Tmix = Mixed water temperature of generator return
Tr = System return temperature
Application diagram
System with inertial storage
Safety devices to choose according to
current regulations
M
M
SOLID FUEL
GENERATOR
7
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003

8. ANTI-CONDENSATION CIRCULATION UNIT
282
Function
Circulation unit
with anti-condensation valve,
with thermostatic control of the
return temperature to solid
fuel generators.
With insulation.
The anti-condensation circulation unit performs the function of
connecting the solid fuel generator to the distribution manifold,
controlling the return temperature to the generator, to avoid
condensation by means of the built-in thermostatic device. The unit
also enables connecting the generator to the inertial storage or
directly to the user system.
This unit has been specifically designed for the connection to the
separator/distribution manifold 559 series, both for the external use
and the recess mounting versions.
System
return
System
flow
4
Bottom-up flow, supply RH side
Top-down flow, supply LH side
Code
Connection
Settings
1”F
45°C 55°C 60°C 70°C
28260
G
1
Bottom-up flow, supply LH side
Top-down flow, supply RH side
Connection
Settings
1”F
Code
45°C 55°C 60°C 70°C
28261
G
7
G
Code completion
2
Setting 45°C 55°C 60°C 70°C
G
4
5
6
7
Technical Specifications
Performance
Medium:
Max. percentage of glycol:
Working temperature range:
Max. working pressure:
Max. recommended flow rate:
Temperature gauge scale:
Connections:
water, glycol solutions
30%
5–100°C
10 bar
2 m3/h
0–120°C
- system circuit:
- generator circuit:
- connection centre distance:
Anti-condensation valve
Working temperature range:
Set temperatures:
Accuracy:
By-pass complete closing temperature:
Pump
Three-speed pump:
5
3
1” F with union
1” F
90 mm
5–100°C
45°C, 55°C, 60°C, 70°C
±2°C
Tset +10°C
Generator
return
Generator
flow
Characteristic components
model UPS 25-60
Technical specifications of insulation
Material:
closed cell expanded PE-X
Thickness:
20 mm
Density:
internal part 30 kg/m3
external part 50 kg/m3
Thermal conductivity (DIN 52612):
at 0°C 0,038 W/(m·K)
at 40°C 0,045 W/(m·K)
Coefficient of resistance to the diffusion
of water vapour (DIN 52615):
> 1.300
Temperature range:
0–100°C
Reaction to fire (DIN 4102):
class B2
8
6
1) Anti-condensation valve
2) Three-speed pump
3) Shut-off valves
4) Check valve
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003
5) Flow temperature gauge
6) Return temperature gauge
7) Insulation

9. ANTI-CONDENSATION CIRCULATION UNIT
Application diagram
System with SEPCOLL, solid fuel generator combined with gas generator.
40
0
40
40
60
20
80
60
20
0
80
40
60
20
0
80
60
20
0
80
Configuration
with SEPCOLL
supplied from
right-hand side
Configuration
with SEPCOLL
supplied from
left-hand side
SOLID FUEL
GENERATOR
40
40
60
20
0
80
40
60
20
0
80
40
60
20
0
80
60
20
0
80
SOLID FUEL
GENERATOR
In the event of multiple presence of generators, apply
the current regulations
Construction details
Compact construction
The unit features all the functional components assembled in a kit and ready for installation. The centre distance has been specifically defined
for application to the SEPCOLL separator-manifold, 559 series.
Anti-condensation valve
This device incorporates a thermostatic sensor to control the temperature of the water returning to the generator so as to prevent condensation.
The sensor has been specifically realised to be removed from the valve body for maintenance or replacement if necessary.
Check valve
This device prevents reverse circulation of the medium. The check valve is useful when the circulation unit is used on its own for a direct
connection to the system or for the connection to a manifold not equipped with a hydraulic separator.
9
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003

10. 2
ANTI-CONDENSATION RECIRCULATION AND DISTRIBUTION UNIT
281
Function
Anti-condensation
recirculation and
distribution unit,
with thermostatic control
of the return temperature
to solid fuel generators.
Brass body.
With insulation.
The anti-condensation recirculation and distribution unit enables the
connection of the solid fuel generator to the user system (direct or
with inertial storage). It controls the return temperature to the
generator to avoid condensation, by means of the built-in
thermostatic device.
5
4
Flow
by-pass
Ritorno
al generatore
4
5
3
1
2
5
Connection
28106
28107
G
G
G
Settings
1” F
1 1/4” F
Code
45°C 55°C 60°C 70°C
45°C 55°C 60°C 70°C
5
4
4
Generator
return
Code completion
Setting 45°C 55°C 60°C 70°C
G
4
5
6
7
System
return
3
Characteristic components
Technical Specifications
Performance
Medium:
Max. percentage of glycol:
Working temperature range:
Max. working pressure:
Maximum recommended flow rate:
Temperature gauge scale:
Connections:
water, glycol solutions
30%
5–100°C
10 bar
1,5 m3/h
0–120°C
1” F and 1 1/4” F with union
Anti-condensation valve
Working temperature range:
Setting temperature:
Accuracy:
By-pass complete closing temperature:
Pump
Three-speed pump:
Technical specifications of insulation
Material:
Mean thickness:
Density:
Working temperature range:
Thermal conductivity:
Reaction to fire (UL94):
5–100°C
45°C, 55°C, 60°C, 70°C
±2°C
Tset +10°C
RS 4-3
EPP
30 mm
45 kg/m3
-5–120°C
0,037 W/(m·K) at 10°C
class HBF
1) Anti-condensation thermostatic device
2) Three-speed pump
3) Valve for natural circulation
4) Union with built-in ball valve
5) Temperature gauge housing
Construction details
Single casting and reversibility
The compact brass single casting, that houses the pump and
functional components, enables immediate installation of the
device, either on the right or left of the solid fuel generator,
respecting the flow directions as shown. The temperature gauges
can be extracted from the housings and re-inserted in the same
position on the back side of the unit.
Anti-condensation valve
This device incorporates a thermostatic sensor to control the
temperature of the water returning to the solid fuel generator so as
to prevent condensation. The sensor has been specifically realised
to be removed from the valve body for maintenance or replacement
if necessary.
Natural circulation valve
The function of this clapet device is to ensure
natural circulation of the medium in the event of
pump stop due to an electric power failure.
When the pump is active, the thrust of medium
keeps the valve closed, forcing the water to flow
through the anti-condensation thermostatic
valve. If the event of pump stop, when the water
within the boiler is at high temperature, a natural
circulation of the water begins, by-passing the anti-condensation
valve, thus preventing the temperature in the generator from
reaching dangerous high levels.
Dirt separator
In order to carry out continuous dirt separation
in the system it is available the 5462 series
DIRTCAL® dirt separator as accessory.
10
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003

11. ANTI-CONDENSATION RECIRCULATION AND DISTRIBUTION UNIT
Operating principle
The thermostat, completely immersed in the medium, controls the movement of an obturator that regulates the flows in by-pass and toward the
system. On starting up the generator, the recirculation unit recirculates the flow water so as to bring the generator up to temperature as quickly
as possible (1). When the flow temperature Tf exceeds the set of the anti-condensation valve Tset, the unit’s cold port starts opening to produce
the mixing Tmix: in this phase the system loading begins (2). When the generator return temperature Tmix is greater than the set of the
anti-condensation valve by approximately 10°C, the by-pass port gets closed and water returns to the generator atTf same temperature of the
the
Tf Tf
Tf
system return (3).
Tf ≤ Tset SYSTEM START UP TRANSIENT
by-pass open
Tf
system return closed
Tf ≤ Tset, Tmix=Tf
Tf
Tmix
Tmix
Tmix
Tf > Tset START OF SYSTEM LOADING
by-pass open
Tf
Tf
system return open
Tf > Tset, Tr < Tset, Tmix=Tset
1
Tmix
Tmix
Tr Tr
TsetTset
Tmix
Tset
Tmix > Tset + 10°C SYSTEM LOADED
by-pass closed
system return open
Tf > Tmix > Tset +10°C, Tmix=Tr
Tr
Tmix
Tr
Tmix
Tr Tr
TsetTset
Tset
Tset
PUMP OFF
Natural circulation valve open
M
M
Natural circulation of the medium
3
Tf Tf
Tf
2
Tr
Tr
Tset
4
Tf
SOLID FUEL
GENERATOR
Tmix
Tmix
Tmix
Tmix
Tf = Flow temperature
Tset = Anti-condensation set temperature
Tr Tr
TsetTset
Tr
Tr
Tmix = Mixed water temperature of generator return
Tr = System return temperature
Application diagram
Tset
Tset
System with inertial storage
Safety devices to choose according
to current regulations
M
M
SOLID FUEL
GENERATOR
11
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003

12. CONNECTION AND ENERGY MANAGEMENT UNIT
(heating only version)
2851
Connection and
energy management
unit, heating only
version.
Code
28515
Function
The connection and energy management unit preassembled in the
box enables combining solid fuel generators with another type of
generator, which may already be present in the heating system.
Main functional features:
- connection of new solid fuel generators (both boilers and
residential devices, with maximum heat output of 35 kW, both
with open or closed vessel) with other closed vessel generators
- possibility of not adding the power outputs of the two
generators as described in I.S.P.E.S.L. (Italy).
- automatic system management with a specific digital regulator
with synoptic diagram: generators, mixed heating circuits, solar
water storage
- built-in anti-condensation system (optional) for solid fuel generator
- easy access to components for maintenance
- practical installation thanks to the arrangement in a box.
7
5
45°C 55°C 60°C 70°C
G
G
Code completion
Setting 45°C 55°C 60°C 70°C
G
4
5
6
7
G
3
4
Settings
= 0 Without anti-condensation valve
2
1
Technical specifications
Performance
6
8
Connections:
Regulator
Three-point type
Power supply:
Pumps
Three-speed pump:
Three-speed pump:
Diverter valve with spring return
Max. working pressure:
∆p max:
Diverter valve actuator with spring return
Synchronous motor
Normally closed
Power supply:
Opening time:
Closing time:
12
3/4” M
230 V - 50 Hz
model UPS 25-60
model UPS 15-60
10 bar
1 bar
1) Grundfos UPS 25-60 pump on primary side for solid fuel
generator
2) Grundfos UPS 15-60 pump on secondary side (system)
3) Brazed plate heat exchanger
4) Anti-condensation valve (optional)
5) Three-way diverter valve with spring return
6) Dirt separator
7) Digital regulator
8) Shut-off ball valves
9) Box for exposed mounting
ACCREDITED
FM 21654
SYSTEM
FLOW
Characteristic components
230 V - 50 Hz
70–75 s
5–7 s
ISO 9001
SYSTEM
RETURN
SOLID FUEL
GENERATOR
FLOW
Anti-condensation set temperature (optional):
45°C, 55°C, 60°C, 70°C
Accuracy:
±2°C
By-pass complete closing temperature:
Tset + 10°C
BOILER
RETURN
9
BOILER
FLOW
solutions
30%
5–100°C
10 bar
35 kW
2,0 m3/h
2,0 m3/h
SOLID FUEL
GENERATOR
RETURN
Medium:
water, glycol
Max. percentage of glycol:
Working temperature range:
Max. working pressure:
Max. heat exchanger net output:
Max. recommended primary circuit flow rate:
Max. recommended secondary circuit flow rate (system):
ISO 9001 No. 0003

13. CONNECTION AND ENERGY MANAGEMENT UNIT
(heating only version)
Operating conditions
The digital regulator automatically manages the unit’s operation, receiving the signal from the probes and activating the pumps, the motorized
valve and the generators. The heating circuit is managed according to need.
Heating with solid fuel generator
K
S1
SOLID FUEL
GENERATOR
RT
Open vessel
D
V1
P1
K
Heating system
T
S1
P2
SOLID FUEL
GENERATOR
SYSTEM
FLOW
BOILER
RETURN
BOILER
FLOW
BOILER
RETURN
SYSTEM
RETURN
SOLID FUEL
GENERATOR
RETURN
HEATING
BOILER
BOILER
FLOW
Closed vessel
SOLID FUEL
GENERATOR
FLOW
C
Phase 1: solid fuel generator active
- Coloured components = active, grey components = not active
- Pumps P1 and P2 ON
- Boiler OFF
- Valve V1 connects the system to the solid fuel generator via the heat exchanger
Heating with boiler
K
S1
SOLID FUEL
GENERATOR
RT
Open vessel
D
V1
P1
K
Heating system
T
P2
S1
Closed vessel
SYSTEM
FLOW
SYSTEM
RETURN
SOLID FUEL
GENERATOR
FLOW
C
SOLID FUEL
GENERATOR
RETURN
SOLID FUEL
GENERATOR
HEATING
BOILER
Phase 2: solid fuel generator off or not at temperature
- Coloured components = active, grey components = not active
- Pumps P1 and P2 OFF
- Boiler active
- Valve V1 connects the system to the boiler
13
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003

14. CONNECTION AND ENERGY MANAGEMENT UNIT
(heating and domestic hot water with storage version)
2853
Connection and
energy management
unit, heating and
domestic hot water
with storage version.
Code
28535
Function
The connection and energy management unit preassembled in the
box enables combining solid fuel generators with another type of
generator, which may already be present in the heating system.
The unit is fitted for the production of domestic hot water with a
connection to a storage.
Main functional features:
- connection of new solid fuel generators (both boilers and
residential devices, with maximum heat output of 35 kW, both
with open or closed vessel) with other closed vessel generators
- possibility of not adding the power outputs of the two
generators as described in I.S.P.E.S.L. (Italy)
- automatic system management with a specific digital regulator
with synoptic diagram: generators, mixed heating circuits, solar
water storage, domestic water storage
- built-in anti-condensation system (optional) for solid fuel
generator
- easy access to components for maintenance
- practical installation thanks to the arrangement in a box.
Settings
45°C 55°C 60°C 70°C
G
G
7
Code completion
3
Setting 45°C 55°C 60°C 70°C
G
4
5
6
7
G
4
= 0 Without anti-condensation valve
10
Technical specifications
5
Performance
Medium:
water, glycol
Max. percentage of glycol:
Working temperature range:
Max. working pressure:
Max. heat exchanger net output:
Max. recommended primary circuit flow rate:
Max. recommended secondary circuit flow rate (system):
solutions
30%
5–100°C
10 bar
35 kW
2,0 m3/h
2,0 m3/h
2
1
6
8
9
DHW STORAGE
FLOW
SYSTEM
FLOW
SYSTEM
RETURN
BOILER
RETURN
Characteristic components
Diverter valves with spring return
See 2851 series
14
BOILER
FLOW
230 V - 50 Hz
Pumps
See 2851 series
Diverter valve actuator with spring return
Synchronous motor
Normally closed
Power supply:
Opening time:
Closing time:
DHW STORAGE
RETURN
Regulator
Three-point type
Power supply:
3/4” M
SOLID FUEL
GENERATOR
RETURN
Connections:
SOLID FUEL
GENERATOR
FLOW
Anti-condensation set temperatures (optional):
45°C, 55°C, 60°C, 70°C
Accuracy:
±2°C
By-pass complete closing temperature:
Tset + 10°C
230 V - 50 Hz
70–75 s
5–7 s
1) Grundfos UPS 25-60 pump on primary side for solid fuel
generator
2) Grundfos UPS 15-60 pump on secondary side (system)
3) Brazed plate heat exchanger
4) Anti-condensation valve (optional)
5) Three-way diverter valve with spring return
6) Dirt separator
7) Digital regulator
8) Shut-off ball valves
9) Box for exposed mounting
10) Three-way diverter valve with spring return for priority on
domestic water with storage
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003

15. CONNECTION AND ENERGY MANAGEMENT UNIT
(heating and domestic hot water with storage version)
Operating conditions
The digital regulator automatically manages the unit’s operation, receiving the signal from the probes and activating the pumps, the motorized
valves and the generators. The heating circuit and the preparation of domestic hot water with storage are managed according to need.
NOTE: for heating operation, please refer to the diagrams in “Connection and energy management unit, heating only
version” 2851 series
Domestic hot water production with solid fuel generator
DHW
Domestic water
system
K
S2
S1
DCW
RT
SOLID FUEL
GENERATOR
TA
Open vessel
D V2
D
V1
P1
S1
DHW STORAGE
FLOW
DHW STORAGE
RETURN
SYSTEM
FLOW
SYSTEM
RETURN
Phase 1: solid fuel generator active
HEATING
- Coloured components = active,
BOILER
grey components = not active
- Pumps P1 and P2 ON
- Boiler OFF
- Valve V1 connects the system to the solid fuel generator via the heat exchanger
- Valve V2 diverts the flow of system water towards the domestic water storage
BOILER
RETURN
C
Closed vessel
BOILER
FLOW
Heating
system
P2
SOLID FUEL
GENERATOR
RETURN
T
SOLID FUEL
GENERATOR
SOLID FUEL
GENERATOR
FLOW
K
Domestic hot water production with boiler
DHW
Domestic
water system
K
S2
S1
DCW
SOLID FUEL
GENERATOR
RT
TA
Open vessel
K
D V2
D
V1
P1
S1
DHW STORAGE
FLOW
SYSTEM
FLOW
SYSTEM
RETURN
15
ACCREDITED
ISO 9001
DHW STORAGE
RETURN
Phase 2: solid fuel generator off or
not at temperature
HEATING
- Coloured components = active,
BOILER
grey components = not active
- Pumps P1 and P2 OFF
- Boiler active
- Valve V1 connects the system to the boiler
- Valve V2 diverts the flow of system water towards the domestic water storage
BOILER
RETURN
C
Closed vessel
BOILER
FLOW
Heating
system
P2
SOLID FUEL
GENERATOR
RETURN
T
SOLID FUEL
GENERATOR
FLOW
SOLID FUEL
GENERATOR
FM 21654
ISO 9001 No. 0003

16. CONNECTION AND ENERGY MANAGEMENT UNIT
(heating and instantaneous domestic hot water version)
2855
Connection and
energy management
unit, heating and
instantaneous
domestic hot water
version.
The connection and energy management unit preassembled in the
box enables combining solid fuel generators with another type of
generator, which may already be present in the heating system.
The unit is fitted for the production of instantaneous domestic hot
water with a heat exchanger.
Main functional features:
- connection of new solid fuel generators (both boilers and
residential devices, with maximum heat output of 35 kW, both
with open or closed vessel) with other closed vessel generators
- possibility of not adding the power outputs of the two
generators as described in I.S.P.E.S.L. (Italy)
- automatic system management with a specific digital regulator
with synoptic diagram: generators, mixed heating circuits, solar
water storage, instantaneous production of domestic hot water
- built-in anti-condensation system (optional) for solid fuel
generator
- easy access to components for maintenance
- practical installation thanks to the arrangement in a box.
Settings
Code
28555
Function
45°C 55°C 60°C 70°C
G
G
Code completion
10
Setting 45°C 55°C 60°C 70°C
G
4
5
6
7
G
7
11
= 0 Without anti-condensation valve
4
3
Technical specifications
Performance
1
Medium:
water, glycol
Max. percentage of glycol:
Working temperature range:
Max. working pressure:
Max. heat exchanger net output:
Max. recommended primary circuit flow rate:
Max. recommended secondary circuit flow rate (system):
Max. domestic hot water heat exchanger net output:
Max. domestic hot water flow rate delivery:
solutions
30%
5–100°C
10 bar
35 kW
2,0 m3/h
2,0 m3/h
35 kW
1,1 m3/h
Anti-condensation set temperatures (optional):
45°C, 55°C, 60°C, 70°C
Accuracy:
±2°C
By-pass complete closing temperature:
Tset + 10°C
SYSTEM
FLOW
SYSTEM
RETURN
BOILER
RETURN
BOILER
FLOW
SOLID FUEL
GENERATOR
RETURN
SOLID FUEL
GENERATOR
FLOW
Characteristic components
156 l/h
108 l/h
Diverter valve actuator with spring return
See 2851 series
10 bar
10 bar
1) Grundfos UPS 25-60 pump on primary side for solid fuel
generator
2) Grundfos UPS 15-60 pump on secondary side (system)
3) Brazed plate heat exchanger for heating
4) Anti-condensation valve (optional)
5) Three-way diverter valve with spring return
6) Dirt separator
7) Digital regulator
8) Shut-off ball valves
9) Box for exposed mounting
10) Three-way three point diverter ball valve for DHW priority
11) Brazed plate heat exchanger for DHW
12) Flow switch
Diverter ball valve actuator for DHW priority
Synchronous motor
Electric supply:
230 V (± 10%) - 50–60 Hz
Operating time (angle of rotation 90°):
10 s
16
8
12
230 V - 50 Hz
Diverter valve with spring return
See 2851 series
Diverter ball valve for DHW priority
Max. working pressure:
∆p max:
9
3/4” M
Pumps
See 2851 series
Flow switch
Contacts normally open (NO)
Contacts close with increasing flow at:
Contacts open with decreasing flow at:
2
DCW INLET
Regulator
Three-point type
Power supply:
6
DHW OUTLET
Connections:
5
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003

17. CONNECTION AND ENERGY MANAGEMENT UNIT
(heating and instantaneous domestic hot water version)
Operating conditions
The digital regulator automatically manages the unit’s operation, receiving the signal from the probes and activating the pumps, the motorized
valves and the generators. The heating circuit and the instantaneous preparation of domestic hot water are managed according to need.
NOTE: for heating operation, please refer to the diagrams in “Connection and energy management unit, heating only
version” 2851 series
Domestic hot water production with solid fuel generator
RT
S3
K
SOLARINCAL
T
D
S1
M
F
SOLID FUEL
GENERATOR
Domestic
water system
D
V3
P1
Open vessel
D
V1
K
T
S1
A
Heating
system
P2
SOLID FUEL
GENERATOR
SYSTEM
FLOW
SYSTEM
RETURN
BOILER
FLOW
BOILER
RETURN
SOLID FUEL
GENERATOR
RETURN
DHW
DCW INLET
HEATING
BOILER
SOLID FUEL
GENERATOR
FLOW
Closed vessel
DHW OUTLET
C
Phase 1: solid fuel generator active
- Coloured components = active, grey components = not active
- Pumps P1 ON, P2 OFF
- Boiler OFF
- Valve V1 connects the system to the solid fuel generator via the heat exchanger
- Valve V3, activated by the flow switch F, diverts the flow of the solid fuel generator towards the DHW heat exchanger
Domestic hot water production with boiler
RT
S3
K
SOLARINCAL
TA
D
S1
M
F
SOLID FUEL
GENERATOR
Domestic water
system
D
V3
P1
Open vessel
D
V1
K
S1
T
Heating
system
P2
DHW
SYSTEM
FLOW
SYSTEM
RETURN
BOILER
RETURN
BOILER
FLOW
SOLID FUEL
GENERATOR
RETURN
HEATING
BOILER
DCW INLET
Closed vessel
SOLID FUEL
GENERATOR
FLOW
C
DHW OUTLET
SOLID FUEL
GENERATOR
Phase 2: solid fuel generator OFF or not at temperature
- Coloured components = active, grey components = not active
- Pumps P1 and P2 OFF
- Valve V1 connects the system to the boiler
- Boiler active for the production of DHW by means of thermal integration via the kit SOLARINCAL 265 series type
17
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003

18. DIGITAL REGULATOR FOR SYSTEMS
WITH SOLID FUEL GENERATOR
1522
Function
Digital regulator for
systems with solid fuel
generator.
The digital regulator enables controlling and managing heating
systems containing a solid fuel generator, which may be combined
with another type of generator.
The regulator has the following functions:
- management of the solid fuel generator combined with another
type of generator.
- regulation of two secondary circuits by means of the activation of
the booster pumps and mixing valves for flow temperature
adjustment.
- regulation and management of the domestic hot water circuit with
storage and recirculation circuit.
Code
The regulator has 6 pre-set programs that can be adapted by the
user to many system situations.
152200
Technical specifications
Electric supply:
230 V (ac); ±10%, 50-60 Hz
Adjustment range:
20–90°C
Protection class:
II
Protection class:
IP 40
Number of probes to choose according to the type of system
1
3
Description of controls
1.
2.
3.
4.
5.
Functional status indicator LED.
Mini DIN connector on front of panel for PC connection.
Display: menu display.
Select knob: selection of menu, functions and parameter editing.
Function keys.
2
4
5
Program diagrams
The regulator enables outside compensated
temperature regulation of the mixed circuits, loading the
domestic hot water storage unit and managing the
energy arriving from the buffer storage. If this is not
sufficiently loaded, the regulator activates the boiler
integration.
T
T
M
T
T
M
M
T
T
SOLID FUEL
GENERATOR
Diagram of system management with direct
connection to the buffer storage, mixed circuits and
domestic hot water with dedicated storage.
T
T
T
M
T
T
T
M
T
SOLID FUEL
GENERATOR
Diagram of system management with direct
connection to the buffer storage, mixed circuits,
domestic hot water with dedicated storage and
integration boiler.
18
M
T
T
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003
T

19. TYPES OF APPLICATION DIAGRAMS OF BIOMASS SYSTEMS
Solid fuel generator, direct connection to buffer storage.
Safety devices to choose according
to current regulations
M
M
D
M
SOLARINCAL
SOLID FUEL
GENERATOR
T
Solid fuel generator, parallel connection to buffer storage.
Safety devices to choose according
to current regulations
M
M
SOLID FUEL
GENERATOR
T
Solid fuel generator, direct supply to the system.
Safety devices to choose according
to current regulations
M
M
DOMESTIC
DEVICE
T
We reserve the right to modify our products, make technical improvements and develop them further.
None of the illustrations, numerical data, etc., are binding.
19
ACCREDITED
ISO 9001
FM 21654
ISO 9001 No. 0003

20. 0318111GB
Caleffi S.p.A. S.R. 229 n. 25 28010 Fontaneto D’Agogna (NO) Italy Tel. +39 0322 8491 Fax +39 0322 863723
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