CALEFFI DIRTMAGCLEAN Use And Maintenance Manual

Calef S.p.A.
S.R. 229 no. 25 - 28010 Fontaneto d’Agogna - Italy
www.calef.com

DIRTMAGCLEAN

Self-cleaning magnetic dirt separator strainer

H0006359

© Copyright 2018 Caleffi

Code 579000

USE AND MAINTENANCE MANUAL

ORIGINAL

INSTRUCTIONS

DATE: 01/07/2018

REVISION: 00

TABLE OF CONTENTS

Contents

1 Introduction 3

1.1 Purpose of the manual 3

1.2 Requirements for use 3

1.3 Symbols 3

1.4 Denitions 4

2 General information 4
3 Characteristic components 5

3.1 Package composition 5

3.2 Technical features of the device and valves 5

3.3 Regulator and actuator technical features 5

3.4 Sizing 6
General description of the operation 6

4

4.1 Operating principle 6

4.2 Filtration 7

4.3 Filtering elements cleaning 7

4.4 Circuit lling and operating conditions reset 8
Overall dimensions 9

5
6 Adhesive labels location 9

6.1 Electrical connections label 10

7 Intended use 10
8

Packaging, handling and transport 11

8.1 Instructions for unpacking 11

8.2 Storage 11

8.3 Reception 11

8.4 Handling 12

8.5 Disposal of packaging 12

9 Installation 12

9.1 Hydraulic installation 13

9.2 Installation in by-pass 13

9.3 Device reset 15

9.4 Electrical installation 15

9.5 Cables wiring and positioning 15

9.6 Example of electrical connection for circulator management 16

9.7 Example of electrical connection with two parallel strainers 16

9.8 Battery installation 16

10 Regulator description and operation 17

10.1 Front panel 17

10.2 Display 17

10.3 Regulator operation 17

11 Commissioning 19

11.1 Filling and hydraulic test under pressure 19

11.2 First start-up 19

12 Maintenance 19
13 Important notice for correct disposal of the product 21
14 Malfunctions - troubleshooting 21
15 Spare parts 22
16

Risks, protections, warnings and cautions 22
Manufacturer's liability and warranty 23

17
18 Table of Interventions 24

2

1 Introduction

Dear Installer,
Thank you for choosing the self-cleaning magnetic dirt separator strainer, which we hope will always satisfy you; this product has been manufactured
in compliance with the most stringent safety regulations in force.
To ensure the safety of personnel, the self-cleaning magnetic dirt separator strainer referred to in this use and maintenance manual must be handled,
installed, used, maintained and dismantled/eliminated by carefully following the instructions provided in this use and maintenance manual in compliance
with the applicable law.
This manual is intended for operators and specialized personnel in order to allow correct use of the product. Please consider this information essential
as a practical guideline to installation, use and maintenance of the strainer.
This manual is an integral part of the self-cleaning magnetic dirt separator strainer and has been entirely prepared by the manufacturer in order to
provide the necessary information to all those who are authorized to interact with it.
This publication describes the status of the product at the time of publication and can in no way reect the future and non-standard product. The
contents of this manual have been checked for their correctness and compliance with the equipment described. However, it is not possible to
guarantee that there are no differences.

1.1 Purpose of the manual

The user manual is intended to provide all the information necessary for the installer to be able to manage the strainer in the most autonomous and
safe way possible:

• correct awareness of personnel to safety issues;

• dirt separator strainer, packaged and unpacked, handling in safety conditions;

• correct installation of the dirt separator strainer;

• in-depth knowledge of its operation and its limits;

• carry out maintenance operations correctly and safely;

This manual is to be considered as an integral part of the self-cleaning magnetic dirt separator strainer:

• it must be kept for the whole life of the strainer

• It must accompany the strainer in case of transfer to another owner.

To facilitate consultation and better detail the topics, the manual is divided into chapters.
Before carrying out any installation, use or maintenance operation, it is absolutely essential to read this manual carefully in all its parts.

The information not included, which concerns the assembly, disassembly, extraordinary maintenance, repair and installation of any safety accessories,
devices and equipment or electronic parts programming, can only be carried out by authorized personnel or by the authorized technical service, in
compliance with the recommendations provided by the manufacturer and the current health and safety regulations.
For any data not contained in this manual it is recommended to contact the manufacturer.

The dirt separator strainer is equipped with an electrical system that complies with the 2014/30/EU; 2014/35/EU directives.

A copy of the EU Declaration of Conformity is an integral part of the use and maintenance manual or on request to the manufacturer.

The construction complies with the provisions of the Machinery Directive 2006/42/EC.

1.2 Requirements for use

All maintenance and operating cycle operations must be carried out by qualied, trained, authorized personnel in suitable psycho-physical conditions.
The maintenance technician must wear appropriate personal protective equipment: protective gloves for mechanical maintenance; gloves, clothing and
tools with a suitable degree of insulation for electrical maintenance.
Important! It is absolutely forbidden to remove or tamper with the accident prevention labels; if this is found, the manufacturer declines all responsibility
for any damage resulting from such removal.

1.3 Symbols

The symbols shown are used to draw the reader's attention to points of particular interest for the safety of the person or the strainer or to identify
particular operating conditions.

CAUTION, a general danger situation for
the safety of the person and/or for the
integrity of the machine

CAUTION, a general electrical danger
situation for the safety of the person and/
or for the integrity of the machine

Operating instructions

Read the instructions before use

Danger of re Mandatory safety footwear

Danger, hot surface Mandatory eye protection

Danger of ice formation Mandatory use of protective gloves

3

1.4 Denitions

DANGER ZONE

Any zone inside and/or near the self-cleaning magnetic dirt separator strainer, within which the presence of an exposed person constitutes a risk for
the safety and health of said person (Annex I, art. 1.1.1 Directive 2006/42/EC).

EXPOSED PERSON

Any person who is completely or partially in a danger zone (Annex I, art. 1.1.1 Directive 2006/42/EC).

INSTALLER / INTEGRATOR / MAINTAINANCE OPERATOR

Person in charge of installing and/or performing maintenance on the self-cleaning magnetic dirt separator strainer according to the intended use.

INSTALLER / INTEGRATOR / MAINTENANCE OPERATOR QUALIFICATION

Minimum level of skills that personnel must have.

SELF-CLEANING MAGNETIC DIRT SEPARATOR STRAINER

Purpose of this manual.

INTENDED USE

Use of the self-cleaning magnetic dirt separator strainer according to the information provided in this document.

RESIDUAL RISK

Danger that it was not possible to eliminate or sufciently reduce through the design, against which the protections are not (or are not totally) effective;
in this manual, information on its existence is given along with instructions and warnings to allow it to be overcome (see, respectively, 5.4 and 6.5.1 of
the European standards EN ISO 12100-1 and EN ISO 121000-2).

MANUFACTURER

Manufacturer of the self-cleaning magnetic dirt separator strainer.

EMPLOYER

The company including its chief executive ofcer, who is responsible for the installation of the self-cleaning magnetic dirt separator strainer that is
covered by this manual.

USER

Recipient to use the self-cleaning magnetic dirt separator strainer.

OPERATOR

Person in charge of installing, operating, regulating and cleaning the machine.

QUALIFIED TECHNICIAN

Specialized person, specially trained by Calef S.p.A. and authorized to carry out extraordinary maintenance or repairs requiring a particular knowledge
of the machine, of its operation, of the safety devices and their methods of intervention.

The operator and the qualied technician are obliged to read and understand the contents of this manual, which must be preserved intact and be an
integral part of the strainer.

2 General information

Manufacturer’s company name and address

CALEFFI S.p.A. S.R. 229, N. 25 – I – 28010 FONTANETO D’AGOGNA (NO)

General safety warnings

The dirt separator strainer has the exclusive function of ltering water and glycol solutions (max 50%). All liquids other than water and
glycol are excluded: therefore radioactive acids, explosives and contaminants are explicitly excluded. A different use excludes the
manufacturer from any responsibility for damage caused to the dirt separator strainer, property and persons. The designer, or installer,
is responsible to check the product compatibility with additives or substances dissolved in water.
Before carrying out the installation, check that the safety and operational standards of the strainer are complied with, in accordance
with the regulations in force.
Prior to the installation phase, check that the support surface is suitable to support the weight of the full strainer.
All operations described in this manual and in particular lifting, positioning, installation and connection to energy sources, within the
limits described and specied in this manual, must be performed by qualied and authorized personnel, in full compliance with the
instructions reported below and in compliance with the laws in force in the country of installation. Any operation not described in the
manual is to be considered prohibited and can not be carried out, except by authorized technical service personnel.

Tel. [phone] - info@calef.com - www.calef.com

Designation of the machine

DIRTMAGCLEAN

Art. 579000

ATTENTION: disconnect the strainer from the electrical mains using a suitable disconnector device, before any intervention.
Check the electric supply cables carefully and periodically; cables that are not intact or are worn out are a serious danger. Always be
vigilant and attentive, about the operation in progress if you decide to carry out an intervention on the strainer.

In case of incorrect operation, immediately interrupt the use and call the qualied technicians. If further information is required regarding
the points mentioned above, contact exclusively and in advance the Authorized Technical Service or the Manufacturer. It is forbidden
to tamper with the devices and circuits that govern its safety. It is forbidden to modify the strainer without the manufacturer’s written
authorization.

4

3 Characteristic components

10

11 6 7 4 2

15

13

1

14

9812 5

1. Filtering unit with magnets

2. Digital regulator

3. Single-phase electric motor (M1)

4. Solenoid valve (V2) with built-in check valve

5. Drain valve (V3)

6. Ball inlet valve (V1)

7. Automatic air vent valve with combined strainer

8. Insulation

9. Adjustable support feet

10. Clapet check valve

11. Vacuum breaker valve

12. Temperature and pressure probe S1

13. Temperature and pressure probe S2

14. Additive pouring cap

15. 1/2” connection with pressure gauge cap

16. 1/2” connection with cap for additional drain valve

3.1 Package content

• Filtering unit with magnets

• Installation and commissioning manual

• Programming manual

• Movement platform

• Packaging carton

3.2 Technical features of the device and
valves

Materials

Body-pipes and support feet: stainless steel AISI 10088-2
(AISI 304)
Internal filtering elements: polyester

Inlet and drain valves

Body: brass EN 12165 CW617N
Ball: brass EN 12165 CW617N, chrome plated
Ball seal: PTFE with EPDM O-Ring
Control stem seal: double EPDM O-Rings
Union seal: EPDM O-Ring

Loading and cleaning valve

Body: brass EN 12165 CW617N
Seals: EPDM

Circuit return valve with clapet retainer

Body: brass EN 12165 CW617N
Seals: EPDM

316

Performance

Medium: water, glycol solutions
Maximum percentage of glycol: 50%
Maximum working pressure: 10 bar
Working temperature range: 5–85°C
Hydraulic characteristics: Kv = 45 m3/h
Water content: 50 l
Strainer mesh size Ø: 30 µm
Particle separation rating: down to 2 μm
DHW inlet minimum dynamic pressure for 3 bar wash
Motor noise: < 60 dB
Volume of water drained during washing:
about 100 litres with p = 3 bar

Connections

- in circuit inlet: 2” M with captive nut

- in circuit outlet: 2” F

- filled for cleaning: 1” F

- drain: 1” M with captive nut

- additive pouring cap: 1” F

3.3 Technical features
regulator and actuators

Regulator

Material
Housing: PA6G30 anti-UV Grey RAL 7024
Electric supply: 230 V (ac) 50/60 Hz
Power consumption: 225 VA in cleaning phase and 5W in stand by
Insulation class: I
Protection class: IP 42
Ambient temperature: 5–50°C
Contact rating:

- IN1 relay: clean contact

- 3-point G.OUT control: Max 5 (2) A, 250 V

- ALARM relays: Max 1A, 48 V

- OUT1 relay: Max 1A, 48 V

Fuses: 2A (motor) and 315mA (actuators)
Battery: R2032 225 mAh - life approximately 1 year
(for only keeping date and time in the absence of network)

Inlet and drain valves

Synchronous motor
Electric supply: 230 V (ac)
Power consumption: 6 VA
Protection class: IP 65
Operating time: 60 s

Loading and cleaning valve

Solenoid type - normally closed (NC)
Electric supply: 230 V (ac)
Power consumption: 6 VA
Protection class: IP 65

Single-phase electric motor

Electric supply: 230 V (ac)
Power consumption: 0.18 kW
Protection class: IP 55

Ambient temperature range:

- Operation: 5 - 50°C EN 60721-3-3 Cl. 3K3 max. humidity 85%

- Transportation:

-30–70°C EN 60721-3-2 Cl. 2K3 max. humidity 95%

- Storage: -20–70°C EN 60721-3-1 Cl. 1K3 max. humidity 95%
Conforms to Directives: CE

Insulation

Material: EPP
Average thickness: 50 mm
Density: 45 kg/m3
Operating temperature range: 5–85°C
Thermal conductivity: 0.037 W/(m•K) at 10°C

5

3.4 Sizing

The sizing of the dirt separator strainer must be performed considering the following values:

Maximum recommended flow rate: 20 m3/h

Hydraulic characteristics

Δp(mm w.g.) Δp(kPa)

5000

50

2000

1000

500

200

100

50

0.5

2

3

1

5

10

20

30

50

20

10

5

2

1

0,5

100

G(m3/h)

Connections

Kv

(m3/h)

4 General description of the operation

The dirt separator strainer consists of a series of elements that make it possible to obtain a product capable of carrying out a constant and continuous
filtration of the system water and automatic cleaning.

2"

45

The device is used only in central heating systems to remove dirt and impurities from the circuit progressively and completely.
The device must not be used by persons (including children) with impaired physical, sensory or mental capabilities, or lack of experience
and knowledge, unless they are instructed.
Any use of the device other than its intended use is prohibited.

4.1 Operating principle

This device flushes the system circuit medium by direct action through the direct action of passing through the specific filtering elements appropriately
arranged inside the body. The specific filtering mesh allows the removal of impurities that are deposited on the external surface of the strainers.
The very selective mesh filters particles with a diameter of 30 μm at the first passage and separates dirt particles up to 2 μm. At the same time, ferrous
particles are separated out by the magnets on the surface of the filter element.

Automatic cleaning of the filtering elements takes place mechanically by means of washing with pressurised mains water while the filtering elements
rotate.
In all its functional phases - operation, cleaning,filling and draining - the device is controlled by a special digital regulator, which can also be managed
remotely using a BMS system running MODBUS-RTU protocol.

This device operates according to different operating steps:

- filtration/ normal operation

- filtering elements cleaning

- circuit filling and operating conditions reset

The digital regulator manages the opening status of the inlet and load/drain valves, together with the strainers rotation motor during the cleaning. The
cleaning phase is automatically activated according to a preset pressure drop value or in a programmed way.
Depending on the type of system, the device can be combined with others for parallel operation.

6

4.2 Filtration

During normal operation, the medium coming from the system enters in the strainer body through the motorised ball valve V1. The medium is forced
to pass through the filtration discs, then it is conveyed into the central part until it comes out of the device through the clapet check valve.

Inlet from the system

H0004833

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Cale S.p.A.

S.R. 229 no. 25

28010 Fontaneto d’Agogna

Italy

System return

Clapet check valve

V1

Supply: 230V (ac) ±10%

IP 42

P

MAX: 10 bar (1 MPa)

579 series

Power: xxx VA

T

MAX: 90°C

MIN: 5°C

T

T

ROOM: 5-50 °C

4.3 Filtering elements cleaning

It can be activated manually, by time or automatically by controlling the medium pressure drop between internal pressure and pressure detected after
the filtering elements. The choice of the type of operation is carried out by the regulator. During the first cleaning phase (emptying) the inlet ball valve V1
closes while the clapet check valve prevents the system backflow. Once the inlet valve V1 is completely closed, the drain valve V3 is opened, located
in the lower part of the device. When the vacuum breaker valve, present in the upper part of the strainer body, is opened it allows the progressive
draining of the tank, causing part of the dirt to come out.

Vacuum breaker valve

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Cale S.p.A.

S.R. 229 no. 25

28010 Fontaneto d’Agogna

Italy

Clapet check valve

V1

Supply: 230V (ac) ±10%

IP 42

579 series

Power: xxx VA

P

MAX

: 10 bar (1 MPa)

: 90°C

MAX

T
T

MIN: 5°C

ROOM: 5-50 °C

T

V3

7

During the second cleaning phase (mechanical cleaning with water injection), the two-way solenoid valve V2 (equipped with check valve) is opened
injecting water from the water mains. In order to perform an effective cleaning, a minimum dynamic pressure of 3 bar must be guaranteed during
washing and the installation of an anti-backflow system is mandatory to protect the aqueduct network (apply according to local regulations in force).
At the same time the shaft on which the filtering discs are clamped is rotated by means of the motor M1, in order to allow the fixed brushes to clean
their surface and to clean the magnets.

Air vent valve

V1

V3

V2

Supply: 230V (ac) ±10%

P

MAX: 10 bar (1 MPa)

IP 42

H0004833

579 series

Power: xxx VA

MAX: 90°C

T
T

MIN: 5°C

ROOM: 5-50 °C

T

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Italy

M1

4.4 Circuit filling and operating conditions restoring

At the end of the cleaning phase the initial conditions are restored, in order to continue with the normal filtration. The drain valve V3 is closed and
the rotation of the motor M1 is stopped. The strainer can be filled in two ways: with mains water through the solenoid valve V2 or using the system
circuit through the valve V1. This second option is preferable when the water in the heating circuit is treated and contains additives. The filling action
is gradual until the pressure detected in the system is reached. During this phase the air vent valve starts to expel the air in the tank and allows
optimal filling.

V1

V2

Supply: 230V (ac) ±10%

IP 42

H0004833

579 series

Power: xxx VA

P

MAX: 10 bar (1 MPa)

MAX: 90°C

T
T

MIN: 5°C

ROOM: 5-50 °C

T

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Cale S.p.A.

S.R. 229 no. 25

28010 Fontaneto d’Agogna

Italy

V1

V2

Supply: 230V (ac) ±10%

IP 42

P

MAX: 10 bar (1 MPa)

579 series

Power: xxx VA

MAX: 90°C

T
T

MIN: 5°C

ROOM: 5-50 °C

T

M1

H0004833

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Italy

M1

V3

V3

Filling with system waterFilling with mains water

87