Four-way valve - knowledge compendium (construction, diagram, connection, control, types, settings, operating mechanism)

What is a four-way valve?

✅ A four-way valve is a specialized device used in heating and cooling systems that enables precise management of media flow between different circuits. Its main function is to regulate the temperature of the heating medium, which affects the overall efficiency of the system. The four-way valve is particularly useful in installations where simultaneous management of two circuits is required—for instance, in central heating boilers, where it mixes supply water with return water to maintain optimal boiler operating conditions and minimize the risk of corrosion.

Thanks to its construction, the four-way valve increases the energy efficiency of the system and improves thermal comfort within a building. It’s worth mentioning that the four-way valve is sometimes also referred to as a four-way mixer or mixing valve, terms that refer to its function of blending two streams of water with different temperatures to maintain the desired temperature throughout the heating installation.

What is a four-way valve used for?

The four-way valve is a key component in heating installations that require precise temperature control of the medium. Installing a four-way valve is often used in central heating (CH) systems with solid fuel boilers, where it is essential to protect the boiler from excessively low return medium temperatures, which can lead to corrosion and shorten its lifespan. A CH installation with a four-way valve allows for mixing hot supply water with cooler return water, stabilizing the water temperature in the boiler and protecting it from overheating.

The four-way valve is also used in systems with heat pumps, where it enables optimal management of the heating and cooling circuits, as well as in installations with solar collectors, where it allows for efficient use of solar heat. This results in a more efficient heating system, which translates to lower energy consumption and higher thermal comfort in the building.

Four-way valve – construction diagram

Now, let’s look at how a four-way valve is constructed. The construction diagram includes several key elements that enable its proper operation. The construction of the four-way valve is based on a body, typically made of brass, stainless steel, or cast iron, which ensures durability and resistance to high temperatures and pressure. Inside the body is a rotating partition, also called a rotor or mixing element, which controls the flow of the medium between four ports: the supply, return, and two output ports.

An important component in the four-way valve’s construction is the stem, which connects the partition to the actuator (in the case of a four-way valve with an actuator), allowing precise control of its position. Seals located in the ports and around the stem ensure the tightness of the entire construction, preventing leaks. Additionally, the valve can be equipped with adjustment elements that enable manual or automatic control of the medium flow.

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Four-way ball valve – operating principle

✅ How does a four-way ball valve work?

The operating principle of this device is based on the controlled mixing or separation of two streams of medium, allowing for stable operating conditions in heating or cooling systems. Inside the valve, there is a rotating partition, controlled by a stem connected to an actuator or manual adjustment mechanism. This partition directs the medium flow between four ports: one supply, one return, and two output ports.

When the partition changes its position, the 4-way ball valve can simultaneously mix hot water with cold water or direct the medium in a chosen direction, depending on the system's needs. For example, in a heating system, it can mix return water with supply water to achieve the desired temperature in the circuit. Therefore, the operating principle of the four-way valve plays a crucial role in precise temperature and flow direction control, directly impacting the efficiency and reliability of the entire system.

Where is a four-way valve with an actuator best applied?

A four-way valve with an actuator is widely used in advanced heating and cooling systems where precise flow management of the medium is essential. With an integrated actuator, such a valve enables automatic regulation, significantly enhancing the efficiency and convenience of system operation. A four-way valve with an actuator is especially recommended in situations that require dynamic adjustment of temperature and flow direction in response to changing system conditions. The ability to integrate with building automation systems makes four-way valves with actuators ideal for modern installations. Choosing the right application for a 4-way valve with an actuator allows for optimal system performance.

Examples of applications:

• Central heating systems with solid fuel boilers: The four-way valve with an actuator regulates the return water temperature, protecting the boiler from corrosion and improving its efficiency.
• Heat pump systems: The 4-way valve with an actuator manages the distribution of the medium between the heating and cooling circuits, adjusting the system to the current needs of the building.
• Cascade installations with multiple heat sources: The four-way valve with an actuator allows for flow management between different heat sources, such as a boiler and a heat pump, enabling efficient use of both sources depending on the current energy requirements of the system.

In summary, the four-way valve with an actuator is a key component in installations that require precise control and automation. Its application contributes to improved efficiency and longevity of the heating or cooling system.

Four-way valve – or maybe a three-way valve?

The four-way valve is an alternative to the three-way valve, which is more commonly heard of and frequently used in CH (central heating) and DHW (domestic hot water) systems. Most heating systems that require mixing could operate with either a four-way or a three-way valve. However, they cannot be freely substituted for each other, as this requires a completely different design. The three-way valve has a simpler structure, with only three paths, as its name suggests, making it somewhat less versatile than its four-way counterpart.

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4-way valve – how to set it for optimal performance?

✅☑️ To ensure optimal performance of a four-way valve, it is necessary to adjust its settings according to the specific characteristics of the installation and the requirements of the heating or cooling system. Proper four-way valve settings enhance energy efficiency and thermal comfort in the building. Below are the steps to achieve optimal valve operation:

1. Determine the set temperature: The first step is to establish the optimal set temperature for the 4-way valve based on the specific system. For example, in heating installations with solid fuel boilers, the return temperature should be at least 55°C to prevent condensation and corrosion of the boiler. For heat pumps, the temperature can be lower but should still be precisely selected to meet system requirements.
   
   
2. Initial valve positioning: Set the valve in a starting position that allows mixing of the return water with the supply water in proportions suited to the system’s operating conditions. It is usually recommended to set the valve so that the return water is sufficiently heated before it goes back to the heat source, enhancing system efficiency.
   
   
3. Actuator calibration: If the valve is equipped with an actuator, it needs to be calibrated to respond accurately to control signals from the automation system. Calibration involves setting the valve’s end positions and verifying that the actuator correctly responds to changing input signals.
   
   
4. Testing valve operation: Perform tests under various system operating conditions, adjusting supply and return temperatures and thermal loads. Observe how the four-way valve responds to these changes and whether it maintains the set temperature in the circuit. Adjust the settings as needed.

Proper settings for the 4-way valve are essential for the optimal operation of the heating or cooling system. They ensure energy efficiency and equipment longevity. Regular monitoring and adjustment of settings help maintain the high performance of the entire installation.

Four-way valve – connection diagram

Connecting a four-way valve requires precision and proper planning to ensure optimal system operation. Where should the four-way valve be installed? The valve should be installed between the heat source (e.g., boiler) and the heat distribution system, such as radiators or underfloor heating. It is typically placed on the return pipe, where it can mix the return medium with the supply medium, stabilizing the return temperature to the boiler.

How to connect a four-way valve? First, connect the supply pipes to the appropriate valve ports: hot water from the boiler to one port and returning water from the heating system to another. Then, connect the valve’s outlets to the heat distribution system—one outlet directs hot water to the heating circuit, and the other directs cooled water back to the boiler. Finally, ensure all connections are sealed and the valve is properly calibrated to ensure effective system operation.

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