Caleffi Hydro Separator, 549, NA549, HYDROCAL User Manual

www.caleffi.com

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