CALEFFI 548006US Hydro Separator User Manual
- June 3, 2024
- CALEFFI
Table of Contents
548006US Hydro Separator
User Manual
Installation, commissioning and
servicing instructions
Function
The hydraulic separator is a device which makes the primary and secondary circuits connected to it independent, and can be used on hot and chilled water systems. The separator is supplied with an air vent and check valve assembly to provide automatic discharge of the air in the circuits, and a drain valve for removing impurities that collect at the bottom of the unit. These items are designed for use in closed hydronic systems. Do not use in plumbing applications. These items do not meet the low-lead plumbing standards of U.S. and Canada.
Product range
548 series Hydraulic separator in steel with union connections, vent and
drain…..
connections 1″, 1¼”, 1½”, 2″ NPT female union
connections 1″, 1¼”, 1½”, 2″ sweat union
connections 1″, 1¼”, 1½”, 2″ press union
no tailpieces, separately source, field install 1″ to 2″
548 series Hydraulic separator in steel with flanged connections, vent, drain
and insulation………… connections 2″, 2 1/2″, 3″, 4″ ANSI
NA548 series Hydraulic separator in steel with flanged connections, vent,
drain and insulation,
ASME and CRN…………………………………………connections 2″, 2 1/2″, 3″, 4″ ANSI
NA548 series Hydraulic separator in steel with flanged connections, vent,
drain and floor supports,
ASME and CRN……………………………………………………connections 5″ to 14″ ANSI (consult Caleffi
for CRN status on size 14″)
SAFETY INSTRUCTION
**** This safety alert symbol will be used in this manual to draw attention
to safety related instructions. When used, the safety alert 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.
CAUTION: All work must be performed by qualified personnel trained in the
proper application, installation, and maintenance of systems in accordance
with all applicable codes and ordinances.
CAUTION: If the hydraulic separator 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 connecting
pipework is not mechanically over-stressed. 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 100°F (38°C) can be dangerous.
During the installation, commissioning and maintenance of the hydraulic
separator, take the necessary precautions to ensure that such temperatures do
not endanger people.
Leave this manual for the user
Technical specifications
Union connections
Materials
| – body: | epoxy resin coated steel. |
|---|---|
| – air vent body: | brass |
| – air vent hydraulic seal: | peroxide-cured EPDM. |
| – air vent float: | PP |
| – internal baffle: | 300 series stainless steel |
| – shut off and drain valve body: | brass |
| – union nuts: | cast iron |
| – support bracket: | polyester painted carbon steel |
Performance
Suitable fluids:
Max. operating pressure:
Working temperature range:| water and non-hazardous glycol solution up to 50%
150 psi (10 bar)
without insulation 32–230°F (0–110°C)
with insulation 32–210°F (0–100°C)
(insulation shells are purchased separately for field installation)
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Connections
Main connections:
Thermowell tap connection:
Lay length (press connection):
Drain valve:| 1″, 1¼”, 1½”, 2″ NPT female with unions
1″, 1¼”, 1½”, 2″ sweat with unions
1″, 1¼”, 1½”, 2″ press with unions
“, 1¼”, 1½”, 2″ body with no tailpieces for field installation of tailpieces
purchased separately
½” F straight thread
size 1 inch: 9″; size 1¼ inch: 9¾”; size 1½ inch: 11¼”; size 2 inch: 12¾” ¾”
garden hose thread
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Flanged connections
Materials| – body:
– air vent body:
– air vent hydraulic seal:
– air vent float:
– internal baffle:
– shut off and drain valve body:| epoxy resin coated steel.
brass
Viton.
Stainless steel
304 series stainless steel
brass
---|---|---
Performance
Suitable fluids:
Max. operating pressure:
Working temperature range:| water and non-hazardous glycol solution up to 50%
150 psi (10 bar)
with insulation 32–220°F (0–105°C)
without insulation (vessel) 32–270°F (0–132°C)
---|---
Connections
Main connections:
Thermowell tap connection (8-14″ only):
– front center:
– inlet/outlet flanges:
Drain valve: 2 –| 2″-14″ANSI B16.5 150 CLASS RF
. ¾” NPT female
½” NPT female
2 – 6″: 1¼” NPT female
8 – 14″: 2″ NPT female
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Technical specifications of insulation on union models (purchase separately, field install)
Material:
Thickness:
Density:
– inner part:
Conductivity (ISO 2581):
Coefficient of resistance to the diffusion of vapor:
Temperature range:
Fire resistance (DIN 4102):| closed-cell expanded PE-X
13/16′ (20 mm)
1.9 lb/ft3 (30 kg/m3)
3.1 IbM3 (50 kg/m3)
at 32°F (0°C): 9 BTU. in/hr.ft2.°F (0.038 W/(m.K)
at -40°F (-40°C); 11 BTU.in/hr.ft2.°F (0.045 W/(m.K)
1,300
32-210°F (0-100°C)
class B2
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Technical specifications of insulation, flanged versions to 4″ Internal part
Material:
Thickness:
Density:
Thermal conductivity:
Temperature range:
Outer part Materials:
Thickness:
Reaction to fire (DIN 4102):
Head covers Heat formed materials:| rigid closed cell expanded polyurethane
foam
2 3/8″(60 mm)
2.8113/ft3 (45 kg/m3) 6 BTU.in/hr.ft2.°F (0.023 W/(m.K))
32-220°F (0-105°C)
embossed aluminum
7.0-mil (0.7 mm)
class 1
PS
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Procedure for field installation of insulation on union models
- Remove the protective stip from the adhesive surface. Re-close the insulation shells.
- If the hydraulic separator is used with chilled water spread a thin layer of sealant on the edge of the insulation and wait until the solvent evaporates (approximarly 10 minutes) and close it again. Note that once the sealant dries it may be difficult to remove the insulation shell in the future without destroying portions of the insulation.
- Reassemble the two side sections.
Procedure for installation of insulation for 2″ to 4″ flanged models
- Remove the two black head covers at the ends.
- Open the two side sections and the lower cap
- Install the separator in the system.
- Spread a thin layer of sealant over surfaces A and B. Wait for the solvent to evaporate (approxi-mately 10 minutes).
- Reassemble the two side sections, fitting the lower cap into one of the two sections and then connecting the other.
- Finish the assembly with the adhesive tape provided in the box.
- Complete with the two black head covers.
- Install the automatic air vent and the drain valve.
Hydraulic characteristics
The hydraulic separator should be sized according to the maximum flow rate
value at the inlet.The selected design value must be the greatest required
flow rate of either the primary circuit or the secondary circuit.
| Union| Flanged
---|---|---
Size| 1″| 11/4″| 11/2″| 2″| 2″| 21/2″| 3″| 4″| 5″| 6″| 8″| 10″| 12″| 14″
gpm| 11| 18| 26| 37| 60| 80| 124| 247| 300| 484| 792| 1330| 1850| 2500
Us| 0.7| 1.| 2.| 2.| 4.| 5.0| 8.| 16| 19| 30| 50| 84| 117| 158
gallons| 0.5| 0.7| 1.| 4.| 4.0| 4.0| 8.0| 8.0| 23.| 23| 95| 175| 255| 450
liters| 2.| 3.| 5.| 13.| 15.| 15.| 30.| 30.| 85.| 87.0| 360| 662| 965| 1703
Accessories
Replacement support bracket for field installation with 548 series union connection Hydro separators.
Insulation jacket for field installation on 548 series union connection Hydro
separators.
NA10778 …fits 1” and 1¼” union 548 series
NA10796 …………….fits 1½” union 548 series
NA10797 ……………….fits 2” union 548 series
NA10805 ……………..fits 1” union 548 series
NA10806 …………….fits 1¼” union 548 series
NA10807 …………….fits 1½” union 548 series
NA10808 ……………..fits 2” union 548 series
Replacement drain valve for 548 series union connection Hydro separators.
Max. working pressure:
Max. working temperature:
Connection:| 150 psi
250°F
¾” garden hose thread
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538402 FD ………………….½” NPT x ¾” GHT
Temperature pocket well fits 548 series union connection Hydro separators.
1 ¾” pocket length. Inside thread: 20 x 1.0 mm.
694045 ………………………½” straight thread
R20011…………………………..sealing washer
NA10426……………sensor holding grommet
NA10425………kit containing above 3 items
Installation
The hydralic separator should be installed only by qualified personnel in accordance with current local codes and legislation. The hydraulic separator is installed between the primary and secondary circuits, always in a vertical position.
CAUTION: Corrosion or leakage can cause damage or injury. Periodically
inspect for signs of corrosion or leakage. If corrosion or leakage is noted,
the vent must be replaced. Failure to follow these instructions could result
in property damage and/or personal injury.
Service instructions
There is no service required for the 548 and NA548 series hydraulic separator.
Leave this manual at the service of users for their use
http://bit.ly/IS_548-549-5495-Hydraulic-Separators
6-30-21
Caleffi North America, Inc.
3883 W. Milwaukee Road
Milwaukee, WI 53208
T: 414.238.2360 F: 414.238.2366
Documents / Resources
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CALEFFI 548006US Hydro
Separator
[pdf] User Manual
548006US Hydro Separator, 548006US, Hydro Separator, Separator
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