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CALEFFI
HYDROCAL™ Air, Dirt, and Hydro Separator
38712.01
© Cop yri g ht 20 1 0 C ale f fi
549 Series
Installation, commissioning and servicing instructions
Function
The Caleffi HYDROCAL™ combination air, dirt and hydro
separator is a device that, incorporates high performance air and
dirt removal functionality into the hydro separation function which
makes the primary and secondary circuits connected to it
hydraulically independent, and can be used on hot or chilled
water systems. The HYDROCAL features a proven stainless steel
internal element that combines to continuously and automatically
eliminate air micro-bubbles with the simultaneous removal of dirt
particles as tiny as 5 microns. The air discharge capacity is very
high, with the capability of automatically removing all the air
present in the system down to the micro-bubble level. The 3 in 1
high performance functionality of the HYDROCAL saves system
installation and maintenance costs as there is no need to include
separate air and dirt separators.
Product range
Series 549 HYDROCAL 2”–4” flanged ANSI 150 CLASS
Series NA549 HYDROCAL 2”–6” flanged (ANSI 150 CLASS ASME registered)
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.
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 HYDROCAL 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
hydronic separator connecting pipework is not mechanically overstressed. 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
hydronic separator, take the necessary precautions to ensure that such
temperatures do not endanger people.
Leave this manual for the user.
Technical specifications
Separator: 2”–4” ANSI 150 CLASS
2”–6” ANSI 150 CLASS (ASME)
Connections: - Air vent relief: 3/8” Female
- Drain valve: 1 1/4” NPT Female
Materials: - Separator body: Epoxy resin painted steel
- Air vent body: Brass
- Shut-off and drain valve body: Brass
- Int. element: Stainless steel
- Air vent seal: VITON
- Air vent float: Stainless steel
Medium: Water and non-hazardous glycol solutions up to 50%
Max operating pressure: 150 psi (10 bar)
Temperature range: 32–250°F (0–120°C)
Particle separation capacity: to 5 µm
Technical
specifications
of insulation
Inner part
Material: rigid closed cell expanded polyurethane foam
Thickness: 2 3/8” (60 mm)
Density: 3 lb/ft
3
(45 kg/m3)
Conductivity (ISO 2581): 0.16 BTU/in (0.023 W/(m·K)
Temperature range: 32–220°F (0–105°C)
Outer part
Material: Embossed aluminium
Thickness: 7-mil (0.70 mm)
Fire resistance (DIN 4102): Class 1
Head covers
Heat formed material: PS
Hydraulic
characteristics
The HYDROCAL should be sized according to the maximum flow rate
value foreseen at the inlet. The selected value must be either that of the
primary circuit or of the secondary, whichever is the greatest.
Installation
Size
2” 2 1/2” 3” 4” 6”
gpm 37 62 94 148 376
3
m
/h 8.47 18 14.32 21.69 86.2
The installation of HYDROCAL should only be carried out by qualified
personnel in accordance with current legislation.
The HYDROCAL is installed between the primary and secondary circuits,
always in a vertical position.
Procedure for installation and insulation assembly
CALEFFI
(only for 2” to 4” sizes)
1. Remove the two black head covers at the ends.
2. Open the two side sections and the lower cap.
3. Install the separator in the system.
4. Spread a thin layer of sealant over surfaces A and B.
Wait for the solvent to evaporate (approx. 10 minutes).
5. 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.
6.
7. Complete with the two black head covers.
8. Fit the automatic air vent and the drain valve.
A
B
CAUTION:
Periodically inspect for signs of corrosion or leakage. If corrosion or
leakage is note, 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 HYDROCAL Air, Dirt, and Hydro Separator.
Corrosion or leakage can cause damage or injury.
Caleffi North America, Inc.
3883 West Milwaukee Road
Milwaukee, WI 53208
T: 414.238.2360 F: 414.238.2366
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