Hydraulic Separation Caleffi

8/6/2019 Hydraulic Separation Caleffi

1/20


2/20

A Techinal JournalfromCalef Hydronic Solutions

Printed:Milwaukee, Wisconsin USA

Copyright 2007Calef North America, Inc

CALEFFI NORTH AMERICA, INC9850 South 54th Street

Franklin, Wisconsin 53132 USA

TEL: 414.421.1000FAX: 414.421.2878

E-mail: [email protected]: www.calef.us

I n d e x3 Brie history o Cale f Italy and Cale f North America

7 Multiple benefts and ow possiblities

4 Hydraulic separation - Times have changed

8 Basic thermodynamics that govern all mixing situations

9 Formula used to calculate the mixed temperature

11 Hydro Separators sizing and applications

12 HydroLink - hydraulic separation plus mani old

15 Appendix o schematic symbols

16 Hydro Separator series 548 technical specifcations

18 HydroLink series 559 technical specifcations


3/20

3

Although Caleffi is a relatively new name in the NorthAmerican HVAC industry, it is a name recognized aroundthe world for quality hydronic products.

Caleffi S.p.A. was founded in 1961 in Gozzano,

Italy, by Francesco Caleffi. During the last 45 years,it has grown from a small machine shop into aworld wide company now serving markets in 50countries and generating over $300 million inannual sales. Each year, Caleffi processes over13,000 tons of brass as well as engineered polymersinto hundreds of specialized components, suchas valves, air separators, manifold systems andmodular heating distribution stations. The majorityof these products come from Caleffis ISO-certifiedand highly automated manufacturing facilities nearMilano, Italy.

A recognized world-class company, Caleffi nowserves the ever-expanding hydronic heating market inNorth America. From a main office/warehouse facilityin Milwaukee, Wisconsin, Caleffi North Americaprovides products with the same meticulous attentionto detail in design and manufacturing as it makesavailable to the rest of the world. These products aresold through a growing network of distributors andwholesalers across the U.S. and Canada.

Many Caleffi products are unique in the North

American market. These include hydraulic separators(the technical subject addressed in this issue of idronics) as well as Hydro Link distribution stations,auto-resetting valve actuators, pre-adjustable boilerfeed valves, and micrometric manifold systems.

However, unique and quality hardware alone doesntensure optimal system design and installation. To thisend, Caleffi North America is dedicated to continuouseducation in the area of hydronic technology. The bettertrained system designers are, the better they can applyCaleffi products as well as other hardware to produceefficient, reliable, and long-lasting hydronic comfortsystems. This high road approach ensures continuedgrowth of the hydronics market in North America, as wellas the rest of the world.

This idronics journal has been created specifically tosupport this commitment to continuous educationof North American hydronic professionals. Each issue

will provide detailed technical discussion of the bestpractices available for deploying hydronic technologyin the 21 st century. Youll find topics and technicaldepth not typically provided in newsletters and salesbrochures.

We hope you enjoy idronics and keep each issue handyfor future reference. A PDF file of each issue can be freelydownloaded from our web site www.caleffi.us located inthe Technical Library area. If you know of others who wouldenjoy reading idronics, please refer them to this web sitewhere they can download this PDF file.

Finally, if you have a particular topic you would liketo see addressed in a future issue, please feel freeto call or e-mail us at [email protected] with yoursuggestions.

A BRIEF HISTORY OF CALEFFI


4/20

4

An important benefit of hydronic heating is the abilityto provide several independently controlled zoneswithin a building. This is often done by supplying andreturning each zone circuit from a common headerset, as shown in Figure 1.

This piping arrangement is common in traditionalhydronic systems where a heat source with lowflow resistance is used (i.e., a cast iron boiler).Such boilers and the larger diameter header pipingconnecting them to the zone circuits create very littleflow resistance, and thus can accommodate relativelyhigh flow rates with minimal interference between thezone circuits. In short, the hydraulic characteristics of

these systems seldom create problems.

Times Have Changed: Today, many hydronicsystems use compact boilers as their heat source.These boilers have much higher flow resistancerelative to cast iron boilers. If such a boiler issimply substituted for the low flow resistance boilershown in Figure 1, problems are likely to develop,most notably interference between simultaneouslyoperating circulators. The schematic in Figure 2illustrates a situation to avoid.

The designer of such a system might assume thateach zone circuit develops a flow based on the flowresistance of its piping and the circulator in thatcircuit. In essence, this thinking treats each zone

circuit as if it was a stand-alone circuit, unaffectedby its neighboring circuits.

This oversimplification ignores the fact that the totalflow of all zone circuits must pass through the high-resistance heat source. The latter will act as a flowbottleneck and significantly reduce the flow withineach zone circuit. The more zone circuits that operateat one time, the worse this bottlenecking effect is.The resulting drop in flow through individual zonecircuits may create under-heating, which will likelylead to complaints of inadequate heat delivery in

some zones.

Divide and Conquer: The solution to this problemis hydraulic separation. In short, its the concept ofpreventing flow in one circuit from interfering with flowin another circuit. When hydraulic separation betweencircuits is present, the designer can correctly think ofeach circuit as if it where a stand-alone entity anddesign it accordingly. This not only simplifies systemanalysis, it also prevents the previously describedflow interference problems.

New Hardware Provides MultipleFunctions And Simple Installation

HYDRAULIC SEPARATION

Figure 1

Figure 2


5/20

5

Although the term hydraulic separation is perhapsnew to many hydronic system designers in North

America, it is not a new discovery in hydronic heatingtechnology. The concept of primary/secondarypiping is perhaps the best-known form of hydraulicseparation now used in the North American hydronicsindustry. It is based on the use of two very closelyspaced tees, as shown in Figure 3.

Because the tees are very close together, the pressuredrop between them due to head loss is almost zero.Hence, the pressure at the side port of each tee isalmost exactly the same. Since there is no pressuredifferential between the tees, there is virtually notendency for flow to develop in the secondary circuit,even though flow is passing through the tees in theprimary circuit. The secondary circuit is thereforesaid to be hydraulically separated from the primarycircuit. Flow will develop in the secondary circuit onlywhen the secondary circulator is operating.

This concept can be extended to multiple secondarycircuits served by a common primary loop, as shownin Figure 4. Each secondary circuit, including thesecondary circuit through the boiler, is joined to theprimary circuit using a pair of closely spaced tees toprovide hydraulic separation.

Figure 3

Figure 4


6/20

6

The configuration shown in Figure 4 is more preciselycalled a series primary/secondary system. In thisapproach, all secondary circuits are arranged in asequence around the common primary loop.

Although hydraulic separation exists between allcircuits, so does an often-undesirable effect a dropin supply water temperature from one secondary circuitto the next whenever two or more of the secondarycircuits are operating simultaneously. Although thereare situations in which this temperature drop doesntpresent a problem, it does add complications thatprudent designers must assess and compensate for.

The piping configuration shown in Figure 5 is knownas a parallel primary/secondary system. Here, theprimary loop is divided into two or more crossoverbridges. Within each crossover bridge is a pair ofclosely spaced tees that provide hydraulic isolationbetween each secondary circuit, as well as theprimary loop.

Assuming that piping heat losses are minimal, aparallel primary/secondary system provides the samesupply water temperature to each secondary circuitregardless of which secondary circuits are operating.It eliminates the sequential temperature drop effectassociated with series primary/secondary circuits.

This benefit is achieved at the cost of more complicatedand costly piping. Notice that each crossover bridgecontains a flow-balancing valve. These valves areneeded to set the flow through each crossoverbridge in proportion to the thermal load served by thesecondary circuit supplied from that bridge. If thesevalves are not present and properly adjusted, theremay be problems, such as inadequate flows throughthe crossover bridges located farther away from theprimary circulator.

Another important consideration is that both seriesand parallel primary/secondary systems require aprimary circulator. This circulator obviously adds to theinstalled cost of the system. Even more importantly, itadds to the systems operating cost over its entire life.The latter may add up to hundreds, if not thousands,of dollars over a typical system life.

Wouldnt it be nice to achieve the benefits ofhydraulic separation and equal supply temperaturesto each load circuit without the costs associatedwith the primary circulator and the complexities of

building and adjusting a parallel primary/secondarysystem? This is possible through use of a specializedcomponent called a hydraulic separator.

Figure 6 shows an illustration of a hydraulic separator.

Figure 5

Figure 6


7/20

7

Figure 7 shows where the device is installed in a

typical hydronic heating system.

The geometric proportions of a hydraulic separatorare important to proper operation. Many hydraulicseparators use a 1:3 ratio between the pipingconnection size and the diameter of the verticalcylinder. This provides proper mixing within thehydraulic separator (when flow in the boiler circuit isdifferent from flow in the distribution circuit). Theseproportions also ensure a relatively low flow velocitywithin the vertical cylinder that minimizes pressuredrop, allowing air bubbles to rise to the top and dirt

particles to settle to the bottom.

A specially designed baffle located near the top ofthe vertical cylinder in some hydraulic separatorsalso assists with air removal. The perforatedsurface of this baffle allows air bubbles to coalesceand rise above the flow stream area. The bubblesare then captured in the upper chamber of theseparator and ejected through a float-type vent atthe top of the unit.

Multiple Benefits: As its name implies, a hydraulic

separator provides hydraulic separation. It does sousing the same physical principles at work in theclosely spaced tees of a primary/secondary pipingsystem.

Its also important to recognize that some hydraulicseparators provide additional functions, namely airseparation and sediment separation. In systemsusing closely spaced tees for hydraulic separation,these functions require additional components. Suchcomponents usually cost more to purchase and install

relative to a multi-functional hydraulic separator thatprovides all three functions in one device, as shownin Figure 8. Separate components also require morespace for installation and increase system heatloss relative to a single hydraulic separator with aninsulated jacket.

Flow Possibilities: The temperatures at the twooutlet ports of a hydraulic separator (e.g., ports 2and 3 in Figure 6) depend on the temperatures atthe two inlet ports (e.g., ports 1 and 4 in Figure 6) aswell as the flow rates in both the boiler circuit anddistribution system.

There are three possible cases:

1. Flow in the distribution system is equal to flow inthe boiler circuit.

2. Flow in the distribution system is greater than flowin the boiler circuit.3. Flow in the distribution system is less than flow inthe boiler circuit.

Figure 7

Figure 8


8/20

8

Well examine each case using the basicthermodynamics that govern all mixing situations.

Case #1. Distribution flow equals boiler flow: In thiscase, which is typically the exception rather than thenorm, the flow and temperature leaving the distributionsystem outlet port (port 2) of the hydraulic separatoris essentially the same as the temperature of the hotwater entering the boiler inlet port (port 1), as shownin Figure 9. Very little mixing occurs because the flowsare balanced. The hot water entering port 1 remainsnear the top of the hydraulic separator because of itsbuoyancy. Most of the air bubbles carried into port 1,or that form within the hydraulic separator, rise to thetop of the unit and are ejected through the vent.

A similar situation exists at the lower ports of theseparator. Since the flows are balanced, the outlettemperature returned to the boiler from port 3 equalsthe temperature returning from the distribution systeminto port 4. Again, very little mixing takes place withinthe separator. Dirt particles carried into the separatorfrom port 4 will tend to settle to the bottom of theseparator where they can be periodically flushed outthrough the drain valve.

If a conventional (non-condensing) boiler is used inthe system, the designer should verify that the watertemperature on the return side of the distributionsystem is high enough to prevent sustained flue gascondensation within the boiler.

Case #2. Distribution system flow is greater than boiler flow: Since the flow rates in the boiler circuit anddistribution system are not the same, mixing occurswithin the hydraulic separator. In this case, a portionof the cooler water returning from the distributionsystem moves upward through the separator andmixes with the hot water entering from the boiler, asshown in Figure 10.

This mixing reduces the water temperature suppliedto the distribution system. This is not necessarily abad thing, but the designer does need to realize itcan occur.

Formula 1 can be used to calculate the mixedtemperature (T 2 ) supplied to the distribution systemunder these conditions.

Figure 9

Figure 10


9/20

9

Formula 1

Where:f4 = flow rate returning from distribution system (gpm)f1 = flow rate entering from boiler(s) (gpm)T4 = temperature of fluid returning from distributionsystem (F)T1 = temperature of fluid entering from boiler (F)

Formula 1 is valid for both water and other systemfluids, provided all fluid entering and leaving thehydraulic separator is the same. It can also beused with any consistent set of units for flow andtemperature.

Heres an example of how to use Formula 1:Suppose a distribution system containing severalsimultaneously operating circulators is running at 25gallons per minute of total flow. Water returns fromthe distribution system at 120F and enters port 4 ofthe hydraulic separator. At the same time, the boilerflow rate is 10 gallons per minute, and the watertemperature supplied to port 1 is 160F. What is themixed water temperature leaving port 3 headed forthe supply side of the distribution system? Also, whatis the water temperature returning to the boiler?

The mixed water temperature is found usingFormula 1:

Notice that the water temperature supplied to thedistribution system (136F) is substantially lower thanthe water supplied from the boiler (160F). This is theresult of mixing within the hydraulic separator.

Since no mixing occurs in the bottom portion ofthe separator, the water temperature returning tothe boiler is the same as that returning from thedistribution system: 120F.

If the boiler firing rate is to be modulated based onthe supply temperature to the distribution system,its imperative that the temperature sensor providing

supply temperature information to the modulatingcontroller is located downstream of the distributionsystem outlet port (port 2) of the hydraulic separator.

Case #3: Distribution system flow is less than boiler flow: Again, since the flow rates on opposite sidesof the hydraulic separator are not equal, mixing willoccur inside the separator. In this case, a portion ofthe hot water entering from the boiler circuit movesdownward through the separator and mixes with coolwater entering from the distribution system, as shownin Figure 11.

This condition occurs when the boiler heat output rateis (temporarily) higher than the current system load.Simply put, heat is being injected into the systemfaster than the load is removing heat. This producesa relatively fast increase in boiler return temperature.If a modulating boiler is being used, this will lead toa relatively fast decrease in firing rate as the systemattempts to achieve thermal equilibrium.

Under this scenario, the temperature returning to theboiler (T 3 ) can be calculated using Formula 2:

Formula 2

Figure 11


10/20

10

Where:

T3 = temperature of fluid returned to the boiler(s)(F)f1 = flow rate entering from boiler(s) (gpm)f2, f

4= flow rate of the distribution system (gpm)

T1 = temperature of fluid entering from boiler(s) (F)T4 = temperature of fluid returning from distributionsystem (F)

Heres an example: Assume the boiler supplytemperature is 170F, and that boiler flow rate intoport 1 of the hydraulic separator is 15 gallons perminute. Water returns from the distribution systemand enters port 4 of the hydraulic separator at 100Fand 10 gallons per minute flow rate. What is thewater temperature returned to the boiler?

Substituting these operating conditions into Formula2 yields:

Notice that the boiler inlet temperature is about 23Fhigher than the return temperature of the distributionsystem. This again is due to mixing within the hydraulicseparator.

If the system uses a conventional (non-condensing) boiler,one might consider the boost in boiler return temperaturebeneficial because it moves the boiler operating conditionaway from potential flue gas condensation. However, thistemperature boost effect can quickly diminish if flowthrough the distribution system increases (i.e., moreload circuits turn on), or if the return temperature of thedistribution system drops. Use of a hydraulic separator

alone does not prevent flue gas condensation under allcircumstances. The only way to ensure such protectionis to install automatic mixing devices on the load circuitsthat monitor boiler return temperature and reducehot water flow when necessary to prevent the boilerfrom dropping below a predetermined minimum returntemperature. This concept is shown in Figure 12. Here,a variable speed injection pump is the mixing device thatmonitors boiler inlet temperature and reduces hot waterflow into the low temperature distribution system whennecessary to prevent flue gas condensation within theboiler. Notice that the variable speed injection pump ispiped in parallel with the fixed speed circulator servingthe higher temperature load circuit. This is possiblebecause of the very low pressure drop through theHydro Separator, as well as a low pressure drop alongthe headers on the right side of the Hydro Separator.The mixing needed to boost boiler return temperatureoccurs within the Hydro Separator rather than thedownstream tee in a primary/secondary system. Theinjection pump and fixed speed circulator both requirea check valve to prevent reverse flow.

Figure 12


11/20

11

Sizing & Application: Hydraulic separators mustbe properly sized to provide proper hydraulic, air,and dirt separation. Excessively high flow rates willimpede these functions.

Sizing is straightforward. First, determine themaximum flow rate that will exist in both the boilercircuit and distribution system, then note the greater

of these values. Next, look up the pipe connectionsize of the hydraulic separator needed to handle thismaximum flow rate in the table below.

The header piping connecting to the distribution sideof the Hydro Separator should be sized for a flowvelocity of 4 feet per second or less under maximumflow rate conditions. All header piping should also bekept as short as possible to minimize pressure drop.

Be sure that all load circuits having individualcirculators include an appropriate check valve. This

is necessary to prevent reverse flow as well asbuoyancy-induced heat migration through that circuitwhen its circulator is off. The internal spring-loadedcheck valves included with some circulators areacceptable, as are flow-check or spring-loadedcheck valves mounted on the discharge side of thecirculators. A standard swing check valve does notprovide protection against forward heat migrationand is not an acceptable device for this service.

Hydraulic separators are an ideal way to interface newboilers, especially those with high flow resistance heat

Figure 13

1 1.25 1.5 2 2.5 3 4 6

11 18 26 40 80 124 247 485

Pipe size ofhydraulic separator

Max ow rate(GPM)


12/20

12

exchangers, to existing distribution systems. Theyeliminate the potential of flow bottlenecks that mayarise in systems where the full flow of the distributionsystem would otherwise be routed through the boiler.Their ability to collect and dispose of sediment alsomakes them ideal for older systems where sedimentis more common. This is especially true in systemsthat once operated with steam and have since beenconverted to hot water.

HydroLink: The principle of hydraulic separationcombined with uniform supply water temperatureto distribution circuits is desirable in both large andsmall hydronic systems.

As already discussed, the Caleffi Hydro Separator isideal for medium to large systems. Currently availablemodels can handle flow rates up to 485 gpm withpiping sizes ranging from 1 to 6 inches.

For smaller systems, Caleffi also offers the HydroLink,as shown in Figure 14.

This product provides a chamber to hydraulicallyseparate the boiler circuit from the distribution circuits.It also provides a self-contained manifold station thatsupplies up to four independently controlled load

circuits with the same supply temperature. Thesefeatures and their equivalent piping are shown inFigure 15.

Figure 14

Figure 15


13/20

13

Figure 16

A critical detail within the HydroLink is the hydraulicseparation chamber on the left side of the unit. Thischamber is separated from the manifold chambersby a baffle plate with two closely spaced openings.Given their size and placement, these openings actsimilarly to a pair of closely spaced tees, eliminatingany significant pressure differential between the upperand lower manifold chambers. This prevents flow in theboiler circuit from inducing flow in any of the distributioncircuits connected to the manifold chamber.

Figure 16 illustrates the functional similarities betweenthe Hydro Separator in a larger system with site-builtheaders and the HydroLink in a smaller system.

Caleffi Hydraulic Separators and HydroLinks arecurrently being installed in residential and commercialhydronic systems across North America.

Figure 17 shows a small (1-inch pipe size) Hydro Separatorinstalled in a residential heating system. The body of theseparator is enclosed in a form-fitting insulation shell tominimize heat loss to the mechanical room. This Hydro


14/20

14

Separator is installed between a modulating boilerand the space-heating distribution system containingseveral zone circulators.

Figure 18 shows a 4-inch Hydro Separator installedin a larger commercial system where it provides thelink between a multiple boiler system and severalindependently controlled distribution circuits.

Figure 19 shows a four-circuit HydroLink installed in aresidential heating system. Like the Hydro Separatorin Figure 17, this HydroLink is fitted with a form-fitting insulation jacket to minimize heat loss. In thissystem, it provides hydraulic separation between the high-performance boiler and several independently controlledheating distribution zones, each with its own circulator.

Summary: Hydraulic separation, when properly executed,allows multiple, independently controlled circulators tocoexist in a system without interference. When accomplishedin the form of a Hydro Separator or HydroLink, theadditional benefits of uniform supply temperature, airseparation and dirt separation are also achieved. Thesedevices eliminate the need for a primary loop circulator,which reduces system installation and operating cost.With suitable vapor-retardant insulation shells, the HydroSeparator or HydroLink devices can also provide thesebenefits in chilled water as well as hot water systems. Theyare truly a modern way of achieving a synergy of functionand simplicity of installation.

Figure 17

Figure 18

Figure 19


15/20

15

circulator

circulator w/ isolation anges

circulator w/ internal check valve& isolation anges

centralair separator

gate valve

globe valves

ball valve

backow preventer

pressurereducingvalve

thermostaticradiator valve

thermostaticradiator valve

strainer

primary/secondarytting

zone valve(2 way)

zone valve(3 way)

cap

hose bibdrain valve

diverter tee

oat -typeair vent

union

pressure gauge

diaphragm-typee x pansion tank

3-waythermostatic mi x ingvalve3-way motorizedmix ing valve

4-way motorizedmix ing valve

ow-check valve

swing check valve

spring loadedcheck valve

purging valve

differentialpressurebypass valve

meteredbalancingvalve

pressurereliefvalve

brazedplateheatexchanger

VENT

HydroSeparator

Hydrolink

manifold station withbalancing valves

Modulating / condensing boiler

conventional boiler

indirect water heater (with trim)

GENERIC COMPONENTS CALEFFI COMPONENTS

pressurerelief valve

pressure &temperaturerelief valve

APPENDIX of Schematic Symbols


16/20

Hydro Separator

series 548 CALEFFI

Function

This device consists of several different functional components,each of which meets specic requirements, typical of the circuitsused in heating and air-conditioning systems.

Hydronic separatorTo keep connected hydronic circuits totally independent romeach other.

Dirt remover To permit the separation and collection of any impurities presentin the circuits. Provided with a valved connection with dischargepiping.

Automatic air vent valveFor automatic venting o any air contained in the circuits.Provided with a valved connection or maintenance purposes.

Product range

Series 548 NPT F hydronic separator with insulation sizes 1, 1 1/4 and 1 1/2 NPT F unionsizes 2, 2 1/2, 3, 4, 5 & 6 ANSI FlangenoitalusnihtiwrotarapescinordyhdegnalF845seireS

series >> degnalf845548 sweat and threaded

MaterialsleetsdetniapniseryxopEleetsdetniapniseryxopE:ydobrotarapeS

ssarBssarB:ydobtnevri Adetalpemorhc,ssarBssarB:ydobevlavniarddnaf f o-tuhSNO TI VMDPE:laestnevri A

Air vent oat: leetssselniatSPP

Performance )rab01(isp051 )rab01(isp051:erusserpgnitarepo.xaM

Te )C0110(F032-23 )C0110(F032-23:egnarerutarepmMedium: Water, non hazardous glycol solutions Water, non hazardous glycol solutions

%05%05:locylgegatnecrep.xaM

Connections1 & 1 1/4 sweat & NPT and 1 1/2 NPT union:rotarapeS 2", 2 1/2", 3",4", 5 & 6 with anged ANSI 150 CLASS

-F2 / 1: )tekcopretemomreht(tnorF Air vent relief: 8 / 3- F

F4 / 11rotcennocesoh:evlavniarD

Technical specification

sizes 1 and 1 1/4 sweat unionSeries 548 Sweat hydronic separator with insulation

16


17/20

When the secondar y pump is off, there is no circulation in thesecondary circuit; the whole ow rate produced by the primarypump is by-passed through the separator.

With the hydraulic separator, it is thus possible to have a productioncircuit with a constant ow rate and a distribution circuit with

a variable ow ra te ; these opera ting conditions are typical of modern heating anda i r - c o n d i t i o n i n gsystems.

Operating principle

When a single system contains a primary production circuit, with itsown pump, and a secondary user circuit, with one or moredistribution pumps, operating conditions may arise in the systemwhereby the pumps interact, creating abnormal variations in circuitow rates and pressures.

The hydraulic separator creates a zone with a low pressure loss,which enables the primary and secondary circuits connected to it tobe hydraulically independent of each other; the ow in one circuitdoes not create a ow in the other if the pressure loss in thecommon section is negligible.

In this case, the ow rate in the respective circuits dependsexclusively on the ow rate characteristics of the pumps, preventingreciprocal inuence caused by connection in series.

Therefore, using a device with these characteristics means that theow in the secondary circuit only circulates when the relevant pumpis on, permitting the system to meet the specic load requirementsat that time. Three possible hydraulic balance situations are shown below.

Dimensions

G primary = G secondary G primary > G secondary G primary < G secondary

Primary Secondary

sGpG

Primary Secondary

sGpG

Primary Secondary

sGpG

Gp Gs

primary secondary

623.2

A 2

2 1/2 3456

B1 1/4 "1 1/4 "1 1/4 "1 1/4 "1 1/4 "1 1/4 "

D131318182222

C131315151515

E151517171919

F141418182525

FB

C

D

E

A

A 1"

1 1/4 1 1/2

B8 7/8 9 3/4 11 1/8

C789

D6 5/8 9 1/2 10 1/4

E899

Code548052A548062A548082A548102A548120A*548150A*

Code548006A/96A548007A/97A548008A

SEPARATOREIDRAULICOSerie548

Tmax 120 CPmax 10 bar


Size Volume(gal)

10.5

1 1/4 0.7

1 1/2 1.3

24

2 1/2 4

38

48

A

D

E

C

B

A

A



522.5

* without insulation

Weight (lb)

7.58.312.5

Weight (lb)

7379

108117220231

Technical specification of insulation for threaded and sweat versions

- Material: double density closed cell expanded PEX: 3/4 (20 mm)ssenkcih T-

: 2 lb/ft (30 kg/m )traplanretni-:ytisneD- 3

: 3 lb/ft (50 kg/m )traplanretxe- 3

- Thermal conductivity (ISO 2581):32F (0C): 9 BTU/in (0.038 W/mK)-40F (-40C): 11 BTU/in (0.045 W/mK)

- Coefcient of resistance to the diffusion of vapour (DIN 52615): > 1.300: 32-212F (0-100C)egnarerutarepme T-

2Bssalc: )2014NID(erif otnoitcaeR-

Technical specification of insulation for flanged

Internal part- Material: rigid closed cell expanded polyurethane foam

: 2 3/8 (60 mm)ssenkcih T-: 3 lb/ft (45 kg/m )ytisneD- 3

- Thermal conductivity (ISO 2581): 6 BTU/in (0.023 W/mK)C)501(0: 32-220 Fegnarerutarepme T-

External cover- Material: embossed aluminium

m)m7.(0: 7.0-milssenkcih T-1ssalc: )2014NID(erif otnoitcaeR-

Head coversSP:lairetamdedluomtaeH-

17


18/20

Hydronic separator-manifoldHydrseries 559

Function

The Hydrolink, a new device combining a hydronic separator anddistribution manifold, is used in heating and air-conditioningsystems to allow different heat adjustments of the various roomswhen there is only one boiler or chiller.

The various congurations are compact, and can be easily tted inany kind of hydronic circuit, with the advantages of ease of installation and a saving of useful living space.

Patent application No. MI2001A001270

CALEFFI

Product range

Code 559022A External 2+2 separator-manifold. Complete with support bracketsand pre-formed insulation Size 1 1/4; branches 1Code 559031A External 3+1 separator-manifold. Complete with support brackets and pre-formed insulation Size 1 1/4; branc hes 1

1sehcnarb;1eziSnoitalusnidemrof -erphtiwetelpmoC.dlof inam-rotarapes1+2ni-tliuB A120955edoC

Technical characteristics

Body

leetsdetniaP:ydoB-:lairetaM

Medium: Water and non-hazardous glycol solutions%05:elocylgf oegatnecrepxaM

)rab6(isp09:erusserpgnikrow.xaM Te )C0110(F032ot23:egnarerutarepm

Connections: - main: 3+1 and 2+2: 1 1/4 F NPT2+1: 1 F NPT

- branches: 3+1 and 2+2: 1 M NPT2+1 (bottom): 1 M NPT2+1 (side): 1 F NPT

- air vent valve: 3+1, 2+2 and 2+1: 1/2 F straight- drain cock: 3+1, 2+2 and 2+1: 1/2 F straight

Center distances: - main: 3+1 and 2+2: 3 1/8 (80 mm)2+1: 2 3/8 (60 mm)

- branches: 3+1 and 2+2: 3 1/2 (90 mm)2+1: 3 1/2 (90 mm)

Insulation

XEPdednapxellec-desolC:lairetaM )mm02(4 / 3:ssenkcih T

Density: - inner part: 2 lb/ft 3 (30 kg/m 3 )- outer part: 3 lb/ft 3 (50 kg/m 3 )

Thermal conductivity: - at 32F (0C): 0.26 BTU/in (.038 W/mK)- at 100F (40C): 0.31 BTU/in (.045 W/mK)

Vapor resistance coefcient (DIN 52615): > 1.300 Te )C0010(F212ot23:egnarerutarepmFire resistance (DIN 4102): Class 1 (Class B2)

Flow Characteristics

Maximum recommended ow rates at connections:

Branches Primary Secondary (total)2+1 9 gpm (2.0 m 3 /h) 22 gpm (5 m 3 /h)2+2 11 gpm (2.5 m 3 /h) 26 gpm (6 m 3 /h)3+1 11 gpm (2.5 m 3 /h) 26 gpm (6 m 3 /h)

18


19/20

Dimensions

A

C

BC

H I

L D E

F G

A

M

A

A

C

BCE

H I

GD F

L

A

C

BCE

G H

FD

A

L

A

A

I

3 8 4 8 7Patent Applic ation

No.MI2001A001270

Series559HydroLink

Pmax9 0 p si - T max230 F

PatentApplicationNo.MI2001A001270 3 8

5 0 3

Series559HydroLink

Pmax9 0 ps i - Tmax230 F

3 8 4 8 5

PatentApplicationNo.MI2001A001270

Series559HydroLink

Pmax9 0 p si - T max230 F

A 1 1/4

B1

D15 3/8

E / F3 9/16

G5 1/2

C1/2

Code559031A

H3 1/8

I9 7/8

L 29 15/16

M3 1/8

Weight (lb)

39

Volume(gal)

2,6

A 1

B1

D6 1/8

E3 9/16

F20 1/2

C1/2

Code559021A

H7 11/16

I3 9/16

L 2 3/8

Weight (lb)

16

Volume(gal)

1

A 1 1/4

B1

D6 5/16

E3 9/16

F5 1/2

C1/2

Code559022A

G20 7/8

H3 1/8

I9 7/8

L 3 1/8

Weight (lb)

29

Volume(gal)

1,8

Operating principleWhen a single system contains a primary generating circuit, with itsown pump, and a secondary user circuit, with one or moredistribution pumps, operating conditions may arise in the systemwhere the pumps interact, creating abnormal variations in owrates and pressures in the circuits.In the HydroLink there is a low pressure loss zone, which enablesthe primary and secondary circuits connected to it to behydraulically independent of each other; the flow in one circuitdoes not create a flow in the other if the pressure loss in thecommon section is negligible.In this case, the ow rates passing through the respective circuitsdepend exclusively on the ow characteristics of the pumps,preventing reciprocal inuence due to connection in series.Downstream of the hydronic separation zone are the ow and returnmanifolds to which the various secondary distribution circuits canbe connected.

Three possible hydronic balance situations are shown below asexamples.

primary circuit

secondary circuit

Gp

GS1 GS2 GS3

GS4

Gp

GS1 GS2 GS3

GS4

GS1 GS2 GS3

Gp

GS4

Gprimary =Gsecondary (GS1+GS2+GS3+GS4) Gprimary >Gsecondary (GS1+GS2+GS3+GS4) Gprimary


20/20

www.calef.usCale f North America, Inc.9850 South 54th Street / Milwaukee, WI 53132Tel: 414.421.1000 / Fax: 414.421.2878idronics@cale f.com / www.cale f.us

CALEFFI S.p.A. Corporate Headquarters - ITALY CALEFFI North America Inc. - Milwaukee WI

CALEFFI IN THE WORLD

Documents

Hydraulic Separation Caleffi