News headlines about Legionnaires’ disease outbreaks are a stark reminder of a critical public health challenge that often originates within the very water systems of our commercial, institutional, and residential buildings.
Legionnaires’ disease, a severe form of pneumonia, is caused by Legionella bacteria, which thrive in specific conditions found in complex plumbing systems.
When cold water flow is minimal or stopped altogether, disinfectant levels evaporate, and temperatures gradually rise to the Legionella growth range (77–113°F, 25–42°C), leading to bacterial colonization and uneven free chlorine distribution throughout the system.
Understanding how these bacteria flourish in various parts of a building’s water infrastructure and how to prevent their growth proactively is crucial for safeguarding public health and ensuring compliance.
Understanding the Threat of Legionnaires’ Disease
Legionnaires’ disease is a severe lung infection contracted by inhaling small droplets of water (aerosols) contaminated with Legionella bacteria. Various building water systems, including showers and faucets, can generate these aerosols. It’s important to note that Legionnaires’ disease is not spread person-to-person.
Symptoms can range from mild to severe, including cough, shortness of breath, high fever, muscle aches, and headaches. While some individuals recover, Legionnaires’ disease can be fatal, particularly for those with weakened immune systems or chronic lung conditions. The severity and public impact of outbreaks underscore the critical need for effective and proactive prevention strategies.
The Critical Role of Balanced Recirculation
Recirculating cold water eliminates stagnation, which promotes harmful bacteria growth, and provides consistent distribution of residual chlorine throughout domestic cold-water systems:
Keeps water moving
Maintains water quality to reduce stagnation
Ensures residual chlorine is distributed throughout the cold-water system
Keeps water temperature in branches and risers evenly distributed, minimizing heat gain
How Thermostatic Technology Changes the Game
Implementing effective recirculation, particularly in large and complex plumbing systems, requires precision to ensure adequate flow to all branches without creating significant water waste or manual balancing. This is where self-actuating thermostatic valve technology comes into play.
How the CircuitSolver® CSU-CW Valve Works
The CircuitSolver® Union Cold Water valve, using innovative automatic thermal balancing technology, offers a robust solution for optimizing cold water recirculation loops, ensuring optimal conditions for Legionella control.
The CSU-CW valve utilizes the same reliable and precise thermal actuator technology as the original CircuitSolver®. It addresses critical issues related to Legionella mitigation in cold water recirculation systems by maintaining a stable temperature. It accomplishes this by continuously monitoring the water temperature and modulating flow to maintain a set temperature at the end of each branch or riser.
The valve operates over a 10°F temperature range. For example, a valve specified for a desired return temperature of 60°F will open at 70°F (10°F above the desired return temperature). At 60°F, the valve is in its closed position. A bypass in the design always allows water to flow back to the pump so that the pump is never dead-headed.
The CircuitSolver® Difference
Simplified Design & Operation
Unlike manual balancing valves that require extensive, often inexact, commissioning and re-balancing, automatic valves like CircuitSolver® provide continuous, dynamic balancing. This eliminates the need for manual adjustments, saving time and labor while ensuring optimal, ongoing system performance.
Enhanced Efficiency
By intelligently directing flow only where needed, CircuitSolver® thermostatic balancing valves maximize the effectiveness of the recirculation system, leading to both safety and cost savings.
Mitigate Legionella with Thermostatic Technology
By taking a proactive, comprehensive approach to Legionella control and utilizing advanced technology like CircuitSolver’s automatic thermal balancing valves, you can transform your building’s water system from a potential risk into a safe, reliable, and compliant resource, mitigating Legionella bacteria.
Find more information about our thermostatic balancing valves here.
Hot water distribution systems are critical to plumbing design, especially in large residential and commercial buildings. Maintaining consistent hot water temperatures across these systems can be challenging, but thermostatic balancing valves have emerged as an innovative solution.
What Are Thermostatic Balancing Valves?
A thermostatic balancing valve is a dynamic device that automatically adjusts water flow in response to temperature changes within a domestic hot water system (DHWS). Unlike manual balancing valves, which maintain a set position, thermostatic valves continuously adapt to real-time conditions, optimizing water flow without manual intervention. These valves rely solely on sensing temperature to maintain a set temperature in the water lines instead of using pressure or flow calculations. It is a temperature device solving a temperature problem.
By ensuring hot water is distributed evenly throughout the system, thermostatic balancing valves improve energy efficiency, minimize water waste, reduce maintenance needs, and provide hot water on demand.
Why is Balancing a DHWS Necessary?
In any hot water recirculation system, water naturally flows through the path of least resistance. This often leads to uneven distribution, where branches or risers located farther from the hot water source experience reduced flow and significant heat loss.
Balancing valves counteract these issues by normalizing water flow throughout the system. Installed at the end of the branch or the top of each riser, these valves ensure sufficient flow and temperature in every branch or riser to offset the heat loss.
Typically, the branches/risers closest to the water source require the least flow, and the ones further away require more.
Types of Balancing Valves Used Today
Several balancing valves are available today, each with its advantages and disadvantages.
Manual Balancing Valves
Manual balancing valves have traditionally been used in DHWS. They are an adjustable ball valve type with pressure ports used to determine the flow. While functional and inexpensive, they require iterative adjustment to balance DHWS because they are pressure-dependent flow devices. Every time a manual balancing valve is adjusted, it impacts the setting of all the other valves in the system. This process can be time-consuming and expensive, especially in larger systems, and often requires a journeyman or certified plumber to balance the system.
Fixed Flow Balancing Valves
Also known as pressure-independent or automatic balancing valves, these devices have a constant flow rate based on a customer-selected cartridge. They utilize replaceable, flow-regulating cartridges, each with a set operating flow rate and differential pressure ranges, eliminating labor associated with manual balancing. Fixed flow valves have static flow settings and are not dynamic, meaning they do not adjust the flow as conditions change within a system.
Due to their small orifices and tight clearances, they are also prone to clogging in high mineral-content environments.
Electric Balancing Valves
Electric valves offer temperature sensing, motorized control, and integration with a building management system (BMS). While they provide advanced control and data monitoring, these valves are complex, expensive, and less reliable due to their intricate components. The use of these valves in DHWS has been minimal.
Thermostatic Balancing Valves
Thermostatic valves dynamically adjust flow based on real-time temperature changes. By sensing the water temperature, they automatically modulate flow to maintain a set temperature in the branch or riser, eliminating the need for manual calculations and adjustments. This technology ensures quick and accurate system balancing.
How Thermal Balancing Valves Operate
Thermostatic balancing valves are gaining attention due to their ability to automatically regulate water temperatures in domestic hot water systems – eliminating manual balancing and callbacks.
Thermal balancing valves use paraffin wax actuators to modulate flow based on fluid temperature. A temperature increase changes the wax state from solid to liquid, creating a maximum change in volume. The wax pushes on the diaphragm and extends a piston to adjust the amount of flow through the valve. As the temperature cools, the wax returns to a solid, and the piston retracts, allowing for more flow. This simple, reliable mechanism enables precise temperature control.
Key Advantages Include:
No manual intervention: The valves adjust automatically as system conditions change.
Energy efficiency: Consistent temperature control reduces heat loss and water waste.
Reliable operation: The wax-based actuator has no shelf life and ensures long-term durability.
Pump protection: Valves never fully close, ensuring adequate flow to prevent pump overheating.
Fixed vs. Adjustable Thermostatic Valves
Fixed Thermostatic Valves
Fixed thermostatic balancing valves are factory-calibrated for a specific temperature and cannot be adjusted in the field. A replacement kit can quickly change the actuator’s temperature set point, but they are set for a given return temperature. This tamper-proof design eliminates the risk of adjustment by non-qualified personnel and ensures consistent performance.
Fixed thermostatic balancing valves have a higher Cv than adjustable valves at 5°F below their set point because they go from fully extended to retracted over a 10°F lifespan vs. 50°F for the adjustable thermostatic balancing valves. With a broader stroke range and higher Cv, fixed thermostatic balancing valves minimize pressure drops and simplify installation.
Adjustable Thermostatic Valves
Adjustable thermostatic balancing valves have an actuator cartridge design that allows users to set the desired temperature by adjusting the position of the actuator. The temperature range is typically over a 50°F span. They have low Cv at 5°F below the desired return temperature, resulting in higher pressure drops than fixed valves (>4:1).
While versatile, these valves require calibration during installation, which introduces potential errors if some valves are set incorrectly in the system, making troubleshooting difficult.
For over a decade, CircuitSolver® thermostatic balancing valves have transformed domestic hot water recirculating system balancing. By automatically and continuously adjusting to maintain the specified water temperature, CircuitSolver® eliminates the labor-intensive process of manual balancing. It is a temperature device solving a temperature problem—not a flow device trying to solve a temperature problem.
Key Benefits Include:
Reliable performance: CircuitSolver® addresses temperature problems directly, ensuring even hot water distribution.
Ease of installation: Ideal for both new construction and retrofits, these valves simplify system balancing without requiring balancing.
Reduced callbacks: Automatically balancing the system resolves common hot water issues, eliminating the need to have a professional balance the system.
With thousands of successful installations, CircuitSolver® thermostatic hot water recirculation valves are a trusted solution for plumbing engineers and contractors seeking efficiency and reliability.
Ready to optimize your next plumbing project? Contact CircuitSolver® to learn more about our thermostatic balancing valves and how they can simplify your DHWS design.
Watch the video to learn more about thermostatic balancing valves.
For nearly a decade, CircuitSolver® has exceeded the standard for balancing domestic hot water systems. The thermostatic self-actuating balancing valve controls temperature and ensures hot water is delivered consistently to all fixtures without the need for manual balancing. The simple design combined with the unique technology of the valve has transformed the future of domestic hot water balancing.
To date, there are thousands of CircuitSolver® installed in buildings across the country with more being spec’d into projects every day. More and more contractors are realizing the convenience the valve creates by eliminating the need for time-consuming and expensive manual balancing labor and equipment.
ThermOmegaTech® interviewed a few contractors to hear about their experiences using CircuitSolver®. Below are the responses from three plumbing contractors: E.M. Duggan Inc, Pan-Pacific Mechanical, and Production Plus Plumbing Inc.
E.M. Duggan Inc. – Boston, Massachusetts
Project Overview
Founded in 1891, E.M. Duggan Inc. is a full mechanical contractor specializing in commercial plumbing, HVAC and sprinkler systems in and around Boston, Massachusetts. Stephen Thompson, who has been working for E.M. Duggan for 30+ years, talks about the recently completed Avalon North Station high-rise apartments, right next to the home of the Boston Celtics, and the installation of CircuitSolver®.
Installation
This newly constructed 38-story luxury apartment building with 537 units used CircuitSolver® to balance its domestic hot water system. The system was broken into three zones of water — low, medium, and high — and required roughly 100 Circuit Solvers.
Results
The contractor was pleased with how quickly the system was balanced. It usually takes two to three days to balance a system manually, but by using CircuitSolver®, this process was done instantly. This translated into huge savings in terms of time and effort that is usually devoted to the balancing process. There was no scaling or gumming up of the system either, which is sometimes an issue when using manual valves. They experienced no problems or call backs.
When asked how CircuitSolver® compares to other balancing valves, Thompson says, “It’s hard to compare to since there really isn’t anything else like it on the market.”
Pan-Pacific Mechanical – Los Angeles, California
Project Overview
For 60+ years, Pan-Pacific Mechanical has been a family-owned mechanical contractor in California. Richard Parker talks about the USC Village project at University Park Campus Los Angeles, and his experience with installing CircuitSolver®.
Installation
This construction project consisted of five buildings — five stories, at 750,000 square feet a piece. Each building required 110 Circuit Solvers totaling 600 valves for the whole project.
Results
Normally it takes a long time to balance a system. A project this size would take three or four plumbers per building at least two weeks to get the system perfectly balanced. With CircuitSolver®, the contractor was able to start up the system, and it was balanced automatically.
This saved them both time and money, plus made the whole process easier. They have had to make zero adjustments and haven’t had any clogging issues that can be a problem when using other valves. Since CircuitSolver® automatically adjusts to the changing water temperatures, the system doesn’t becomes unbalanced and hot water will be at the branch when you need it, so there won’t be any long wait times.
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Pan-Pacific Mechanical – Los Angeles, California