Caleffi 548 User Manual
Hydro Separator
series 548
CALEFFI
Function
This device consists of several different functional components,
each of which meets specific requirements, typical of the circuits
used in heating and air-conditioning systems.
· Hydronic separator
To keep connected hydronic circuits totally independent from
each other.
· Dirt remover
To permit the separation and collection of any impurities present
in the circuits. Provided with a valved connection with discharge
piping.
· Automatic air vent valve
For automatic venting of any air contained in the circuits.
Provided with a valved connection for maintenance purposes.
Product range
Series 548 NPT F hydronic separator with insulation sizes 1”, 1
1/4
”, 1
1/2
” and 2” NPT F union
sizes 2”, 2
1/2
”, 3“ and 4” ANSI Flangenoitalusni htiw rotarapes cinordyh degnalF 845 seireS
Technical specification
R
E
G
I
S
T
E
R
E
D
BSI EN ISO 9001:2000
Cert. n° FM 21654
UNI EN ISO 9001:2000
Cert. n° 0003
01076/08 NA
Replaces 01076/06 NA
sizes 1” and 1
Series NA548 Flanged hydronic separator without insulation sizes 5”, 6”, 8”, 10” and 12” ASME ANSI Flange
*NA prefix indicates ASME tagged and registered with the National Board of Boiler and Pressure Vessel Inspectors
1/4
” sweat unionSeries 548 Sweat hydronic separator with insulation
Threaded and sweat union connections
Materials: - Body: epoxy resin painted steel
- Drain and shut-off valve: brass
- Air vent body: brass
Suitable fluids: water, glycol solution
Max percentage of glycol: 50%
Max working pressure: 150 psi (10 bar)
Temperature range: - with insulation: 32÷210°F (0÷100°C)
- without insulation: 32÷250°F (0÷120°C)
Connections: - Main: 1” & 1 1/4“ sweat & NPT and 1 1/2” & 2” NPT union
- Drain: 3/4“ hose
- thermometer pocket: 1/2“
Flanged connections
Materials: - Body: epoxy resin painted steel
- Drain and shut-off valve brass
- Air vent body brass
Suitable fluids: water, glycol solution
Max percentage of glycol: 50%
Max working pressure: 150 psi (10 bar)
Temperature range: - with insulation: 32÷220°F (0÷105°C)
- without insulation: 32÷250°F (0÷120°C)
Connections: - Flanged: 2” ÷ 12” ANSI 150 CLASS
- Drain: 1 1/4” & 2” NPT F
Technical specifcation of insulation for union connection versions
- Material: double density closed cell expanded PEX
- Thickness: 3/4” (20 mm)
- Density: - internal part: 2 lb/ft (30 kg/m3)
- external part: 3 lb/ft (50 kg/m3)
- Thermal conductivity: 32ºF (0°C): 9 BTU/in (0.038 W/m·K)
-40ºF (-40°C): 11 BTU/in (0.045 W/m·K)
- Coefficient of resistance to the diffusion of vapor: > 1.300
- Temperature range: 32-210ºF (0 -100ºC)
- Reaction to fire (DIN 4102) : class B 2
Technical specifcation of insulation for fanged versions up to 4”
Internal part
- Material: rigid closed cell expanded polyurethane foam
- Thickness: 2 3/8” (60 mm)
- Density: 3 lb/ft (45 kg/m3)
- Thermal conductivity: 6 BTU/in (0.023 W/m·K)
- Temperature range: 32-220 º F (0 – 105°C)
External cover
- Material: embossed aluminium
- Thickness: 7.0-mil (0.7 mm)
- Reaction to fire: class 1
Head covers
- Heat moulded material: PS
Dimensions
AA
HYDRO-SEPARATOR
Serie 548
max
max
T
250°F
T
220°F
max
max
P
150 psi
P
D EC
150 psi
A
A
C D E
B
C
A
2”
2 1/2”
3”
4”
5”
6”
1 1/4"
1 1/4"
1 1/4"
1 1/4"
1 1/4"
1 1/4"
B
13”
13”
15”
15”
15”
15”
Code
548006A/96A
548007A/97A
548008A
1 1/4”
1 1/2”
548009A 2"
Code
548052A
B
8 3/4”
9 3/8”
10 7/8”
C
6 1/4”
7 3/8”
7 3/4”
10 1/8”
8 5/8”
9 1/2”
10 1/4”
11 7/8”
8”
8 3/8”
8 3/4”
9 1/2”
7.5
8.3
12.5
26.012”
(gal)
0.5
11
18
0.7
26
1.3
3.5
37
A
1"
Volume
Flow (gpm)
Weight (lb)
E
D
548062A
548082A
548102A
NA548120A*
NA548
NA548150A*
* without insulation
NA prefix indicates ASME tagged and registered with the National
Board of Boiler and Pressure Vessel Inspectors.
Add NA prefix to 2” to 4” flanged connection for ASME approved.
For larger ASME sizes consult with factory.
Operating principle
When a single system contains a primary production circuit, with its own
pump, and a secondary user circuit, with one or more distributions pumps,
operating conditions may arise in the system whereby the pumps interact,
creating abnormal variations in circuit flow rates and pressures.
The hydronic separator creates a zone with a low pressure loss, which
enables the primary and secondary circuits c on ne ct ed t o it t o be
hydraulically independent of each other;
the flow in one circuit does
not create a flow in the other if the pressure loss in the common
section is negligible.
HYDRO-SEPARATOR
Serie 548
T
250°F
T
220°F
max
max
P
150 psi
P
150 psi
max
max
HYDRO-SEPARATOR
Serie 548
T
250°F P
max
max
150 psi
C ED
AA
B
F
13”
13”
18”
18”
22”
22”
Weight (lb)
E
D
F
14”
14”
18”
18”
25”
25”
73
79
108
117
220
231
15”
15”
17”
17”
19”
19”
Flow (gpm)
40
80
124
247
300
484
Volume
4.0
4.0
8.0
8.0
22.5
23.2
(gal)
B
F
A
B
C
D
E
Code
NA548
NA548
NA548
200A
250A
300A
8”
2”
39
3/8
”
33
10”
2”
12”
2”
7/8
43
5/16
”
35
7/8
47
1/4
”
37
7/8
F
”
27
”
30”
”
31
Weight
1/2
”
35
1/2
”
41
3/4
”
1/2
”
47
3/4
”
1,100
When the secondary pump is off, there is no circulation in the secondary
circuit; the whole flow rate produced by the primary pump is by-passed
through the separator.
With the hydronic separator, it is thus possible to have a primary production
circuit with a constant flow rate and a secondary distribution circuit with
a variable flow rate; these operating conditions are typical of modern
heating and cooling systems.
Gp Gs
550
725
Flow
792
1,330
1,850
Volume
(gpm)(lb)
(gal)
95
175
255
In this case, the flow rate in the respective circuits depends exclusively
on the flow rate characteristics of the pumps, preventing reciprocal
influence caused by connection in series.
Therefore, using a device with these characteristics means that the flow
in the secondary circuit only circulates when the relevant pump is on,
permitting the system to meet the specific load requirements at that time.
Primary Secondary
G
primary
= G
secondary
sGpG
Primary Secondary
Gp Gs
G
primary
primary secondary
Three possible hydronic balance situations are shown below.
Primary Secondary
Gp Gs
> G
secondary
G
primary
< G
secondary
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