Ask Caleffi

Ever feel like you’re just punching a clock while the industry evolves without you? In this episode, we ditch the product specs to discuss the mindset required to build a meaningful, lifelong career in the plumbing and hydronics trades. Success in the field is about more than just turning a wrench; it’s about humility, constant curiosity, and knowing when to ask for help. We explore how to balance technical mastery with mental well-being to ensure you stay as sharp as your tools. In this episode, you’ll learn: Craft vs. Job: How shifting your perspective from "clocking in" to "mastering a craft" changes your career trajectory. The Eternal Student: Leveraging webinars, certifications, and manufacturer resources to stay ahead of the curve. Checking the Ego: Why asking questions early and staying teachable is the fastest way to gain respect. Full-Circle Techs: Why understanding the "rough-in" makes you a powerhouse at service and troubleshooting. Code & Compliance: Navigating the standards and approvals that keep your installs professional and legal. Beyond the Tool Belt: The importance of protecting your mental health and building a support system for when life gets heavy. Don't forget to subscribe and leave a review wherever you listen.

Ever been haunted by "ghost flows" or a radiator that won't stop clicking? In this episode, the team breaks down separation—the art of managing air, dirt, and pressure to ensure your system actually behaves. Hydronic systems fail when air bubbles block heat transfer and magnetite turns ECM pumps into debris magnets. We dive into the "gotchas" of piping placement and why the right hardware is the only way to protect your boiler's efficiency and your sanity. In this episode, you’ll learn: The Air War: Why air is the enemy of heat transfer and when to ditch the scoop for a high-performance separator. Hydraulic Peace of Mind: How to prevent pump conflict so your circulators don’t fight each other. The 4-in-1 Advantage: Why the SEP4™ style device simplifies piping and speeds up installs. Direction Matters: How backward piping drives unwanted mixing and kills efficiency by boosting return temps. Magnetite & Modern Pumps: Why magnetic separation is now essential survival gear for ECM circulators. Water Chemistry: Why separators need a wingman in the form of high-quality inhibitors. Don't forget to subscribe and leave a review wherever you listen.

Legionella isn’t a “rare edge case” problem—it’s a predictable outcome of physics and biology. When water sits warm and stagnant, it becomes an incubator for bacteria that grows in the biofilm of the piping. In this episode, we step inside the lab to demystify Legionnaires’ disease and the plumbing conditions that allow it to thrive. From the mechanics of aerosolization in showers and misters to the high-stakes environments of hospitals and hotels, we’re breaking down the "why" and "how" of waterborne pathogens. More importantly, we’re getting practical about the engineering and design strategies that actually mitigate risk. What’s on the Menu: The Big Triggers: Understanding stagnation, dead legs, and the "danger zone" temperature ranges where Legionella is most aggressive. Design for Mitigation: How hot water recirculation and flow balancing prevent the "warm and still" conditions that lead to outbreaks. The Thermal Disinfection Strategy: Why programming a high-temp spike while the building sleeps is a powerful tool—and the hardware required to do it safely. Safety vs. Sterilization: The critical role of ASSE 1070 point-of-use mixing and ASSE 1017 master valves in protecting users from scalding during disinfection cycles. If you work in plumbing, hydronics, facilities management, or healthcare design, this episode provides a clear, no-nonsense framework for reducing risk in both commercial and residential systems.

We’re diving deep into the practical mechanics of thermostatic and digital mixing valves, featuring the Caleffi 521 Series and the 520 AngleMix™. Moving beyond the spec sheet, we break down how these valves actually behave in the field, and why sizing design flow rather than pipe size is critical for performance. What we cover in this session: The Standards Playbook: Why distinguishing between ASSE 1017 (point-of-distribution) and ASSE 1070 (point-of-use) is the only way to ensure true anti-scald protection. The 1017-before-1070 Rule: How to avoid the 120°F hard-stop trap. The Oversizing Epidemic: Why sizing by pipe diameter instead of Cv leads to "hunting", and how to use ultrasonic flow meters to get the math right. Digital vs. Thermostatic: Navigating minimum flow requirements and the tighter temperature bands of electronic controls. The Real-World Fix: Why you should adjust your settings based on the farthest fixture’s thermometer, not the valve’s dial. Don't forget to subscribe and leave a review wherever you listen.

Ever stayed in a hotel where you have to turn the shower on, go grab breakfast, and come back just to find "warm" water? In this episode of Ask Caleffi , the team dives deep into the "why" and "how" of domestic hot water (DHW) balancing. Water is inherently lazy, it takes the path of least resistance. In a DHW system can mean that the furthest risers in a building can be cold while the closest ones hog all the heat. The crew breaks down the symptoms of an unbalanced system and compares the most popular solutions on the market today. From the old-school struggle of manual balancing valves to the modern efficiency of thermostatic balancing, we cover it all to help you save water, energy, and your sanity. In this episode, you’ll learn: The Ball Valve Myth: Why using a ball valve for balancing is a recipe for failure. Manual vs. Automatic: The pros and cons of fixed-flow cartridges versus the "hand grenade" (the 132 QuickSetter). Thermostatic Balancing: How to "zone" your DHW system by temperature rather than just flow. Legionella Management: A look at thermal disinfection and how to automate it using Building Automation Systems (BAS). Pump Protection: Why pairing balancing valves with ECM pumps in Delta P mode is critical to prevent pipe erosion. Don't forget to subscribe and leave a review wherever you listen.

Which pressure reducing valve is right for your plumbing system? Sometimes PRVs require two valves in series. Hear how the guys get the pressure right in all sorts of applications, from sea to shining sea.

Steady plumbing system pressure is the goal, what do you need to check if the pressure is creeping up? The team discusses the different types of municipal and private systems that bring pressurized water to buildings. Each water service is unique and PRVs can smooth out the delivery. Also, hear what type of debris the guys have found in the inlet screens in the field.

There are always rabbit holes in hydronic startups. Find out how the team deals with the tricky task of keeping a hydronic system in good shape. Fluid quality and high-performance separators are key. Over the years, the guys have built 1,000 machines that will help in the process, tune in to hear what they are.

Zoning options can be overwhelming, because there are so many choices and no two projects are the same. The team walks through the different zone valve and zone relay technologies you will run across in the field. Hear how you can set yourself up for simple installation and service.

The team is in the lab to talk about the best way to fill a hydronic system. They break these fill valves down and share stories from the field. Find out what questions you should ask your customer to determine if you should leave the AutoFill on or off.

What happens in the field when you need to loosen a union to service a valve? Do you always need to replace the sealing elements? How can the Posi-Stop™ embedded O-ring union system help? Which products are shipping now with Posi-Stop? Former service plumber and current Caleffi tech. support ace Matt DeLuca joins the guys today to talk about Posi-Stop as a first-time guest on the podcast. There are many tips and tricks that plumbers use in the field to get fittings to seal. No need for creativity or guesswork with Posi-Stop. An EPDM O-ring seal compresses to a controlled value by way of a positive metal-to-metal stop. Want to hear YOUR QUESTION on Ask Caleffi, take this quick 4 question survey for your chance to hear your question in a future episode. Survey: https://forms.gle/fRfnU8Px3B1Lq7K69

In this episode, Greg and Dan talk to "the man, the myth, the legend" of zone valves, Mike Schreiner, Caleffi CTO. Mike has been working with zone valves for his entire career and is pleased to share his wealth of knowledge to help our Ask Caleffi audience learn: What's important when considering a zone valve? How do you properly size? What is the flow coefficient (a.k.a. Cv or differential pressure) and why is it important? BTW: there is a BIG difference between close-off pressure and system pressure! Zone valves and actuators... say what? In which application is a 2-way valve best used? A 3-way? How are end switches applied? What's the difference between a micro-switch and a Reed switch? Normally Opened. Normally closed. Why Z-one? (one valve for ALL!) Valve versatility with union connections. How about relay boards? (you CAN'T wire a zone valve wrong with a relay board!) All this and MORE when you Get in the Zone with Mike!

What drives the adoption of solar hot water systems? Are there specific factors that signal the beginning or end of a spike in system installations? Which applications are always a good fit? What qualifications do you need to work on these systems? How do you evaluate a site to know if the location is good for solar? In this episode, Greg and Dan are joined by Carlson-Holohan Industry Award of Excellence winning Caleffi Training Manager Bob Rohr. Over his career, Bob has been all over North America to help install, commission and educate about solar thermal systems. The team will talk about when and where financial incentives have helped offset the cost of these systems. They also discuss resources to help evaluate potential sites for solar. For rebates specific to you zip code, check https://www.dsireusa.org/ Want to hear YOUR QUESTION on Ask Caleffi, take this quick 4 question survey for your chance to hear your question in a future episode. Survey: https://forms.gle/fRfnU8Px3B1Lq7K69

Why should installers care about BIM (building information models)? Could BIM help you avoid working around other trades in a crowded chase? What efficiency gains are there with prefabrication? Can the files detect errors, before the product is even purchased? What is a digital twin? In this episode, the guys are talking to Woody Dickinson. Woody knows Caleffi's technical details like the back of his hand. With BIM, he is able to take a career's worth of engineering knowledge and integrate it into three-dimensional construction files. While BIM is often only used to make sure everything will fit into a room, there is so much more. Hear how this technology is solving problems on drafting tables and in actual mechanical rooms. Want to hear YOUR QUESTION on Ask Caleffi, take this quick 4-question survey for your chance to hear your question in a future episode. Survey: https://forms.gle/fRfnU8Px3B1Lq7K69

Do I leave the air vent cap open or close it? Do you leave the AutoFill(TM) open or closed? Where should you put the expansion tank? Do you pump into the boiler or pump out of it? Hydro separator or closely spaced tees? Where should you put the air separator? In this episode, the guys have put together a few of the trickiest topics that come up often on the tech. support lines. The questions are simple, the answers are more complex. Dan and Greg will help put the questions into context, so you can understand yes, no or maybe for each project you work with. Listen in to see where they agree or disagree. Will this episode ruin a longstanding friendship or can the guys keep it professional? Want to hear YOUR QUESTION on Ask Caleffi, take this quick 4 question survey for your chance to hear your question in a future episode. Survey: https://forms.gle/fRfnU8Px3B1Lq7K69

What has Steve Steve learned about the plumbing and heating industry since 1990? What happens at the MCE Mostra Convengo trade show in Italy? What part of the Caleffi factory reminded Steve of Raiders of the Lost Ark? How do you, "automate for the best?" What was Steve's favorite meal? Why has nobody interviewed this guy before? In this episode, Dan and Greg sit with Steve Smith to hear more about his recent trip to Italy to visit the Caleffi factory and visit Mostra. He details some of the most memorable sections of the tour, on the topics of manufacturing, company culture, and even coffee culture. Find out how manufacturers and contractors can learn from each other and find the right information at the right time. Want to hear YOUR QUESTION on Ask Caleffi, take this quick 4-question survey for your chance to hear your question in a future episode. Survey: https://forms.gle/fRfnU8Px3B1Lq7K69

How does Caleffi support a rapidly growing plumbing product offering? What makes a great troubleshooter? How do you train an apprentice in the first place? Where is the best place to work if you are a Brewers fan and also a journeyman plumber? In this episode, the guys introduce the newest member of the Ask Caleffi team. Straight from the field, Matt DeLuca is a Journeyman plumber and expert troubleshooter. He talks to Dan and Greg about his background in the trades, starting in 2008. He also shares the topic that has come up the most on the tech support lines in his first few weeks on the phones. Want to hear YOUR QUESTION on Ask Caleffi, take this quick 4 question survey for your chance to hear your question in a future episode. Survey: https://forms.gle/fRfnU8Px3B1Lq7K69

Where does the water come from? How do you know what pressure you need in a building? Are you over 80PSI? Are mountain states the only ones who have big fluxuations in municipal water supply pressures? What is a "noisy little guy?" In this episode, the guys are throwing paper airplanes and talking about pressure reducing valves. Our PresCal is sold all over the world, so we have seen some crazy applications. Dan, Greg, and Cody discuss what pressures you should shoot for when adjusting a PRV. They also explain why two pressure reducing valves in series may be a great way to go. If your PRV pressure is creeping up, there is one quick thing you can do to get it back in service, without running to the wholesaler. Want to hear YOUR QUESTION on Ask Caleffi, take this quick 4 question survey for your chance to hear your question in a future episode. Survey: https://forms.gle/fRfnU8Px3B1Lq7K69

How do you fill a radiant system with the least amount of headache, in order to get the air out? Should you flush through the boiler side? What takes the least amount of time? When is a fill cart helpful? Is street pressure water enough to properly purge? In this episode, the guys share their field experience filling manifolds. Just like toppings on a hot dog, there is no one specific way to do it that everyone will agree on. Dan and Greg go over the hows and whys for the different approaches. They mention the specifics for the various styles of Caleffi manifolds, including when to use the H-fitting on the 172 series products. Want to hear YOUR QUESTION on Ask Caleffi, take this quick 4 question survey for your chance to hear your question in a future episode. Survey: https://forms.gle/fRfnU8Px3B1Lq7K69

DHW recirculation systems can cause a lot of headaches, if not operating properly. Quick troubleshooting is essential, especially in the multi-family sector. How do you know what needs to be fixed? What questions do you need to ask occupants and building managers? Are all shower valves the same? Do you need x-ray vision? In this two-part episode , the guys interview Mark Eatheton. Mark is a licensed Master Plumber in Colorado and an ICC licensed Master Mechanical Contractor. He has worked on a variety of troublesome, multi-family DHW recirculation projects over the years and offers his advice to avoid pulling your hair out. Mark and the team at Advanced Hydronics have worked with Energy Outreach Colorado to reduce energy usage and water waste in many projects across the state. Starting with occupant surveys, they determine what bothers the residents. After that, Mark describes the symptoms to look for throughout the building. To finish, he describes the best path forward with specific control components. Thanks for joining us today. Want to hear YOUR QUESTION on Ask Caleffi? Take this quick 4 question survey for your chance to hear your question in a future episode. Survey: https://forms.gle/fRfnU8Px3B1Lq7K69