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Caleffi North America, Inc.

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Franklin, WI 6HRBNMRHM
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T: 414.421.1000  
F: 414.421.2878

Dear Hydronic and Plumbing Professional,

Dear Hydronic Professional,
Twelve years after Caleffi North America was established, air issues, dirt issues and
Welcome
hydraulic to the 2ndissues
separation edition of idronics
continue to be – Caleffi’s
frequentsemi-annual
topics in the design journal
technical for
support
hydronic
calls professionals.
we receive. Some of these calls are from contractors trying to correct problems
in existing systems. Others are from designers looking for the best way to apply our
The 1stinedition
products a newof idronics
system. wascallers
Some released in January
simply ask: “Can2007 and
you distributed
explain to over
how this device
80,000 people in North America. It focused on the topic hydraulic separation. From
works?”
the feedback received, it’s evident we attained our goal of explaining the benefits
and proper application of this modern design technique for hydronic systems.
These calls confirm that an understanding of air & dirt separation, as well as hydraulic
A Technical Journal separation, is critically important to of
those who #1,design, install or by
maintain hydronic
If you haven’t yet received a copy idronics you can do so sending in the
from systems.
attachedThose whoresponse
reader comprehendcard,these
or by topics well are
registering more
online at capable of creating
www.caleffi.us. The and
maintaining the modern, energy-efficient systems today’s marketplace
publication will be mailed to you free of charge. You can also download the demands.
Caleffi Hydronic Solutions complete journal as a PDF file from our Web site.
This 15th edition of idronics combines the topics discussed in our 1st and 2nd issues
from 2007,
This and updates
second those topics
edition addresses airtoand
reflect
dirtseveral new products
in hydronic systems.now available
Though not afrom
new
CALEFFI NORTH AMERICA, INC topicSome
Caleffi. to ourofindustry,
these new the products
use of modern
combine high-efficiency
the functionsequipment
previouslydemands
performed a by
3883 W. Milwaukee Rd thorough
single understanding
components. of the the
Others expand harmful
rangeeffects of air and
of application fromdirt, as well as
residential knowledge
jobs through
Milwaukee, Wisconsin 53208 USA oncommercial
large how to eliminate
systems them.
thatDoing soheating
provide helps ensure the systems you design will
and cooling.
operate at peak efficiency and provide long trouble-free service.
Tel: 414-238-2360 From time to time, we receive photos showing installations of Caleffi products. We
We trust
sincerely you will find
appreciate thesethis issue of idronics
submittals. They helpa us useful
show educational
and explain tool
theand a handy
best way to
FAX: 414-238-2366 reference for your future hydronic system designs. We also encourage you to send
apply and install specific products. This issue includes several such photos. We sincerely
us feedback on this issue of idronics using the attached reader response card or by
thank all those who have sent us these photos and encourage you to continue sharing
E-mail: idronics@caleffi.com e-mailing us at idronics@caleffi.com.
them with us.
Website: www.caleffi.us
WeSincerely,
hope you enjoy this issue and encourage you to send us any feedback about idronics
To receive future idronics issues by e-mailing us at idronics@caleffi.com.
FREE, register online www.caleffi.us
For prior issues, please visit us at www.caleffi.us and click on the icon. There
© Copyright 2014 youMark
can Olson
download the PDF files. You can also register to receive hard copies of future
General Manager,
issues.
Caleffi North America, Inc. Caleffi North America, Inc.
Printed: Milwaukee, Wisconsin USA Mark Olson

General Manager & CEO

INDEX
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Disclaimer: Caleffi makes no warranty that the information presented in idronics meets the mechanical, electrical or other code requirements applicable within a Mixed Sources
given jurisdiction. The diagrams presented in idronics are conceptual, and do not represent complete schematics for any specific installation. Local codes may Products from well-managed
forests, controlled sources and
require differences in design, or safety devices relative to those shown in idronics. It is the responsibility of those adapting any information presented in idronics to
recycled wood or fiber.
verify that such adaptations meet or exceed local code requirements.
 Separation in Hydronic Systems
 (-31.#4"3(.-
 be captured and removed. The state-of-the-art dirt
To “separate” means to disconnect or segregate. The
word separate has several meanings in the context
of hydronic heating or cooling systems. This issue of
idronics examines three distinctly different forms of
separation within such systems. They are:
1. Air separation
2. Dirt separation
3. Hydraulic separation
All of these are desirable characteristics that exist in well-
planned hydronic systems.
(12$/ 1 3(.-
The ideal fluid in a hydronic heating or cooling system
is water without any impurities, air bubbles or dissolved
gases such as oxygen and nitrogen. However, every
hydronic system starts out with air in all of its components.
A well-planned system will quickly enable this air to be
gathered and removed from the system. It will also reduce
the dissolved air gases in the water to levels where they
are of no concern. The system should then maintain the
water at a very low level of dissolved air content over
its entire life. Any small amounts of air that may enter
the system during component maintenance should be
quickly captured and ejected.
#(132$/ 1 3(.-
A newly assembled hydronic system usually contains
dirt or remnants of oils used during manufacturing,
transportation or installation. It may also contain pieces
of joint sealing tape, rubber particles or ferrous metal
particles. The latter is common when cast iron or steel
components such as circulators, panel radiators or cast
iron sectional boilers are used in the system.
Dirt or metal particles are undesirable in hydronic systems.
Fine particles of dirt can interfere with the operation of
moving parts within valves or circulators. They can also
coat the internal surfaces of both heat sources and heat
emitters, decreasing rates of heat transfer. Metal particles
such as iron oxides can collect in circulators due to the
magnetic fields they create. All well-planned and properly
commissioned hydronic systems should contain very
little dirt. What dirt the system does contain should
separators discussed in this issue of idronics can remove
particles as small as 5 microns in diameter.
'8#1 4+("2$/ 1 3(.-
Many hydronic systems contain multiple circulators,
some of which need to operate at the same time. Ideally,
the operation of any one of these circulators will not
create any change in the flow or head produced by any
other circulator in the system that also happens to be
operating. When this is achieved, the circulators are said
to be hydraulically separated from each other.
There are several methods by which hydraulic separation
can be achieved. This issue of idronics discusses each of
them, along with their strengths and limitations.
For many applications, it makes sense to combine the
three fundamental forms of separation into a single
device. In other applications, or for retrofit situations, this
may not be possible or practical.
A thorough understanding of the principles involved in
each type of separation equips designers to select the
best products and installation locations for the system
at hand. This issue of idronics was written to provide this
understanding.
  (12$/ 1 3(.-
Air control within hydronic systems has always presented
challenges. It began with the earliest hydronic systems
that did not have circulators. Water flow was created by
the buoyancy difference between hot water in the boiler
and cooler water returning from the heat emitters. These
systems used large-diameter piping and operated at very
low flow velocities. Air removal was mostly a matter of
waiting for air pockets to form and then releasing this air
through manually operated valves located at high points
in the system where the air accumulated.
Most of these early systems were “open-loop” rather
than closed-loop systems. An expansion tank vented
to the atmosphere was located at the high point of the
3
 system—usually in the attic or upper floor, as seen in
Figure 2-1 Figure 2-1, which appeared in a heating design manual
"open" expansion tank at top of system
published in 1906.

Although air could leave this tank as the water in

the system was heated and expanded, it could also
reenter the tank as the water cooled. This allowed a
constant presence of dissolved oxygen molecules
within the water, which often sustained oxygen-
based corrosion within these systems constructed
of iron and steel piping.

Occupants in buildings got used to “bleeding” the air

from the system when its presence caused a drop in
heat output or an annoying noises in the system.

During the 1940s, engineers began designing closed-

loop hydronic systems. They created devices to help
capture air and separate it from the circulating water.
A system of this vintage typically used a standard
expansion tank that was supported above the boiler,
as shown in Figure 2-2.

Figure 2-2 water!

to!
system

To!
expansion!
tank
boiler!
Þtting

water to system

from!
boiler

air bubbles
dip tube

Courtesy of Bell & Gossett

4
Air bubbles rising from the boiler were captured by a Figure 2-3
special “boiler fitting,” and directed through a pipe to the
expansion tank. Another special “tank fitting” was used
to minimize the absorption of air within the expansion
tank into the system water. The overall process is best
described as air control rather than air elimination.
Although some of these systems are still in operation,
they do not represent modern technology. Very few
systems are now installed using this approach.

Even when closed-loop hydronic systems became

standard, industry veterans can attest that air elimination,
especially during system commissioning, often remained a
challenge. Significant time went into ridding systems of air,
especially in large, complex piping systems. Keeping the
air out of those systems also required frequent attention.

This is partially because closed-loop hydronic systems

are not 100% sealed against air entry. Although such
systems appear to hold pressure reasonably well for
months, and seldom have visible water leaks, they are
not perfectly sealed. Small amounts of the gases that
make up air can enter closed-loop hydronic systems
in a variety of ways, especially if those systems are
poorly designed. Examples include air weepage at
valve packings and circulator flange gaskets, as well as
molecular oxygen diffusion directly through the walls of
non-barrier PEX or other types of polymer tubing. Air can
even be sucked into hydronic circuits through devices
intended to expel it. This occurs when improper design,
improper component placement or maintenance allow
the pressure in the piping where the devices are located
to drop below atmospheric pressure.
(1 1$+ 3$#/1.!+$,2
Problems due to air in hydronic systems can be frustrating
to occupants as well as heating professionals. If these
problems are not fully understood, the attempted solution
often produces only temporary correction. Eventually,
those trying to remedy the situation may give up, thinking
that the system is incapable of operating air-free. This is
unfortunate and unnecessary, because every properly
designed modern hydronic system can quickly rid itself
of air and maintain itself essentially air-free for years.
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air pockets
-NHRDOne benefit provided by a properly designed and
installed hydronic system is the near-silent conveyance
of heat. Building occupants should not hear water as
it travels through tubing and heat emitters. Properly
deaerated water traveling through piping at velocities
of 4 feet per second or less produces sound levels that
are virtually undetectable by human ears. However, a
mixture of water and air is much more acoustically active.
Figure 2-4

The following problems can arise due to air in hydronic

systems:

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transfer surfaces are not wetted

5
Entrapped air sounds often become noticeable as flow
begins to disturb stationary air pockets. Air-filled cavities
within piping and radiators act as acoustic amplifying
chambers, especially if water enters a component which
has trapped a large pocket of air. Noise is also generated
when dissolved gases within water are released due
to a sudden drop in pressure. This is called gaseous
cavitation, and it often occurs at the orifice of valves or
the inlet of circulators.
(M@CDPT@SD %KNV Circulator impellers are designed to
transfer mechanical energy called “head” to incompressible
liquids. A mixture of water and air is not an incompressible
liquid. Although most circulators can maintain flow when
the liquid passing through contains some entrained air,
mechanical energy transfer is not as efficient as when
the liquid is fully deaerated. This decreases circulator
efficiency and reduces the rate of heat conveyance by the
system. Noise is also present as a mixture of liquid and air
bubbles pass through a circulator.
/NNQ 'D@S 3Q@MREDQ Air has much lower heat transfer
properties than water. A given volume of water can
absorb almost 3500 times more heat than the same
volume of air. When air displaces water away from heat
transfer surfaces within heat sources or heat emitters, the
rate of heat transfer can be significantly reduced. “Cool
spots” on radiators usually indicate entrapped air, as
shown in Figure 2-5.
Figure 2-5
BBDKDQ@SDC "NQQNRHNM Air is about 23% oxygen, and
oxygen in contact with ferrous metals such as steel and
cast iron causes corrosion. Many improperly deaerated
6
hydronic systems that experience chronic air problems
are constantly allowing air to enter the system. This
resupplies oxygen that furthers the corrosion reaction.
Poorly deaerated hydronic systems can fail prematurely
due to such corrosion. Corrosion of internal surfaces
can lead to leakage in thin steel components such as
panel radiators or expansion tank shells. Corrosion on
other surfaces can eventually break off as ferrous oxide
particles that can be carried throughout the system
and possibly become trapped in components such as
circulators or heat exchangers.
The following chemical reactions can occur in hydronic
systems containing ferrous (iron-containing) components.
O2 + Fe + 2H 2O
Fe(OH )2 + H 2
FERROUS

OXYGEN IRON IONS WATER HYDROGEN
HYDROXIDE
3Fe(OH )2
Fe
Fe3O4 + H 2 + H 2O
FERROUS

HYDROXIDE MAGNETITE
MA
MAGNETIT
TE HYDROGEN WATER
The compound Fe3O4 is called magnetite and appears
as a dark gray sludge within the system. Magnetite is
also attracted to magnetic fields created by circulators,
especially those containing powerful permanent magnets.
Circulator manufacturers have developed improved
methods of forestalling magnetite or other ferrous metal
particles from reaching the rotating inner parts of their
circulators, but the potential for some magnetite entry
into such parts still exists.
Figure 2-6
If oxygen continues to be present in the system, magnetite
will be converted to hematite (Fe2O3), which can cause
pitting corrosion throughout the system.
Figure 2-7 shows a pipe and circulator with accumulated
iron oxide sludge. Consider the effect such accumulation Figure 2-8
would have on flow rate.
Figure 2-7a

spring-loaded

internal check

valve traps

rising air

in volute

Courtesy of Tony Hillard

Figure 2-7b

Figure 2-9

Courtesy of Heatboy

"HQBTK@SNQ #@L@FD Modern wet-rotor circulators have

ceramic bushings that depend on system water for
lubrication. Due to its lower density, air tends to accumulate
near the pump shaft and these bushings. The presence of
air bubbles or air pockets can displace lubricating water
and hence create premature bushing failure. The likely
result is replacement of the entire circulator.

Circulators installed in vertical piping with upward dissolved gases released from solution

flow and having spring-loaded check valves near their create gaseous cavitation within circulator
discharge are especially susceptible to large pockets

7
of air. If a sufficient volume of air enters the volute and
displaces water in the impeller, the circulator may be Figure 2-10 air pocket
unable to clear itself and will quickly be running without
lubrication. Failure is almost certain.

Gaseous cavitation occurs within circulators when the

pressure at the eye of the impeller drops below the
saturation pressure of gases such as oxygen or nitrogen
in solution with the water. The dissolved gas molecules
instantly form bubbles that interfere with circulator
performance, as depicted in Figure 2-9.

Sediments formed by oxidation within the system can

be deposited on the impeller and volute of circulators,
lowering their performance or causing total blockage
(see Figure 2-6).

(LOQNODQ /DQENQL@MBD NE !@K@MBHMF 5@KUDR Hydronic

can form at the top of heat emitters, boiler sections,
balancing valves are precision devices designed to perform
unvented tanks, inverted diaphragm-type expansion
within tight specifications when conveying liquids. The
tanks or heat exchangers. Air pockets can also form
presence of air in the water changes the pressure drop
in horizontal piping that eventually turns downward or
versus flow rate characteristics of the valves, allowing
piping that is routed above obstacles in its path, as
flow rates to drift away from desired settings. This in turn
shown in Figure 2-10.
can lead to improper heat delivery in various portions
of the system. Highly throttled balancing valves can
As water enters the system, these locations can trap air,
also experience gaseous cavitation when water with a
especially if water approaches them from both directions.
high dissolved air content passes through them. Such
Slow water movement during the filling process also
cavitation can lead to annoying noises, especially in valves
enhances air pocket formation.
located within or near occupied spaces.
Stationary air pockets can also reform when air bubbles
"NLOKDSD +NRR NE %KNV If a stationary air pocket is
merge and migrate toward high points. This is especially
large enough, and the piping system is tall enough,
likely in components with low flow velocities, where
the system’s circulator cannot generate sufficient lift
slow-moving fluid is unable to push or drag the air along
to force water over the top of the system. Under such
with it. Examples of such components include large heat
circumstances, there will be complete loss of flow in the
emitters, large diameter piping and storage tanks.
circuit. Even if the circulator can establish some flow over
the top of the system, that flow may not be sufficient to
entrain air and help dislodge the air pocket.
$-31 (-$# (1!4!!+$2
A moving fluid may be able to carry air bubbles along
with the flow (e.g., entrain them). This is desirable from
%.1,2.%$-31 //$# (1 the standpoint of moving air bubbles from remote parts of
Air exists in three distinct forms within hydronic systems: the system back to a central air-separating device, where
they can be captured and expelled. However, if the fluid’s
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Every hydronic system is completely filled with air at the
start of its commissioning. As water enters the lower
portions of the system, air rises upward. However, some
components or improper piping configurations may not
allow all the air initially contained in the system to rise
to the top where an air venting device may be present.
This results in trapped air pockets. These pockets
The ability of a fluid to entrain air can be judged by its
ability to move bubbles vertically downward, against their
natural tendency to rise. If the fluid moves downward
faster than a bubble can rise, it will pull the bubble along.
A minimum flow velocity of 2 feet per second is needed
to entrain air bubbles within downward-flowing pipes.

8
,("1.!4!!+$2
Air can also exist in hydronic systems as microbubbles.
Individually, most microbubbles are too small to be
seen by the human eye. However, dense collections of
microbubbles can make otherwise clear water appear
cloudy. A common place to see temporary clouds of
microbubbles is in a drinking glass just filled with water
from a faucet having an aerator device. Figure 2-11 shows
a visually enhanced microscopic view of microbubbles.
Figure 2-11
#(22.+5$# (1
Molecules of the gases that make up air (nitrogen,
oxygen, carbon dioxide and some other compounds) can
exist “in solution” with water molecules. Since molecules
are too small to be seen, water that appears perfectly
clear and free of bubbles can still contain a significant
amount of dissolved gases that ultimately need to be
removed from the system.
The amount of dissolved gases that water can hold
depends on the water’s temperature and pressure. At
higher temperatures, the ability of water to contain
dissolved gases decreases, and vice versa. As the
pressure of the water increases, so does its ability to
hold dissolved gases in solution.

The contours in Figure 2-12 show the maximum amount

of dissolved air gases contained in water over a range of
temperatures and pressures (expressed as a percentage
of total volume). For example, at 15 psi gauge pressure
and a temperature of 65ºF, up to 3.6% of the molecules
in a container of water can be dissolved gases (oxygen,
nitrogen and other trace gases). However, if the water’s
temperature is raised to 170ºF while maintaining the
same pressure, its ability to hold dissolved gas is
reduced to 1.8% of its volume, half the previous level.
Such a change in temperature would be typical of
cold water heated within a boiler and illustrates the
“degassing” effect of increased temperature.

Source: www.urmc.rochester.edu
In hydronic systems, microbubbles form when water with Figure 2-12
dissolved gases such as oxygen and nitrogen is heated
in a boiler or other heat source. In chilled-water cooling Gauge pressure
Max amount in gallons of dissolved air per 100 gallons of water

systems, it is possible for microbubbles to form within 5.5

terminal units as the water absorbs heat under low water 30 psi 45 psi 60 psi 75 psi 90 psi 105 psi
5.0
pressure conditions. They can also form when water
passes through a component that creates a sudden and 4.5
significant pressure drop, such as a valve that is almost 4.0
closed. 15 psi
3.5

Microbubbles have extremely low rise velocities and are 3.0

easily entrained by moving fluids. This characteristic 2.5
makes them more difficult to capture compared to 0 psi
2.0
larger bubbles. Some hydronic systems, especially older
systems, have air-separating devices that do not provide 1.5
sufficiently low flow velocities or suitable internal detailing 1.0
to allow efficient microbubble separation. While larger
0.5
bubbles are more easily captured due to their greater rise
velocities, microbubbles are often swept through older 0
32 65 100 135 170 205 240 275 310 345
style air-separating devices without being captured. The
result can be a system that takes days, or sometimes Water temperature (

)
weeks, to reduce its air content to acceptable levels.

9
As the pressure of the water is lowered, so is its ability For example, the ability of water to absorb air as it
to hold dissolved gases in solution. Figure 2-12 shows cools helps reduce the volume of stationary pockets in
that reducing the pressure of 170ºF water from 15 to 0 areas of the system where flow is slow. This absorbed
psi gauge pressure reduces the amount of dissolved air can be carried back to a high-efficiency separating
gas it can contain from 1.8% to about 0.6% of its device where it is then captured and ejected from the
volume. This explains why air bubbles are more likely system. The ability of water to absorb air can also cause
to form in the upper portions of a multi-story hydronic an undesirable condition called “water logging” in older
system. Lower static pressure in the upper portions of style expansion tanks without diaphragms or bladders.
the building makes it easier for dissolved air to come
out of solution. Higher static pressure near the bottom It’s always desirable to minimize the dissolved air
of the system tends to keep gases in solution. content of the system’s water. This is accomplished by
establishing conditions that encourage dissolved gases
Temperature also affects the solubility of dissolved gases to come out of solution (e.g., high temperatures and low
in water. Figure 2-13 shows a simple piping system with pressures), and placing an effective air separating device
representative temperatures and gauge pressures at four at a location where such conditions occur.
locations.
(11$,.5 +#$5("$2
The graph to the right of the piping schematic shows Most air removal devices used in hydronic systems can
the combination of temperature and gauge pressures be classified as either:
at these four locations. Notice that point A is the lowest
of the four points, and thus represents the lowest 1. High-point vents
solubility of air in water of the four locations. The lower 2. Central air separators
the solubility, the more likely microbubbles are present;
thus point A is the preferred location for the Caleffi High-point vents release air from one or more high points
Discal air separator. in the system where it tends to accumulate. Typical
locations for high-point vents are the top of each heat
Water can repeatedly absorb and release gases as its emitter, the top of distribution risers, the top of tanks or
temperature and/or pressure changes. This can affect hydraulic separators, or wherever piping turns downward
hydronic systems in several ways—some good and following an upward or horizontal run. Figure 2-14 shows
some not so good. some examples.

Figure 2-13 143ºF Gauge pressure

Max amount in gallons of dissolved air per 100 gallons of water

5.5
30 psi 45 psi 60 psi 75 psi 90 psi 105 psi

B C 18 psi 5.0
32 psi 169.9ºF
4.5
NOTE: pressures shown on

piping are gauge pressures 4.0
15 psi
ON
Discal air
3.5
separator
B
170ºF 3.0 D
2.5 C
20 psi 135ºF
2.0
0 psi
A
A
1.5
19.8 psi
D
VENT

1.0

0.5
low head loss boiler
0
32 65 100 135 170 205 240 275 310 345

location of lowest air Water temperature (

)

solubility in water

10
 Figure 2-14 

air vent 


manual air vent
air vent air vent
TRV

y
ra
ar
hydraulic

or
ct
separator

lle
co
r
la
manual air vent

so
TRV

piping risers 

air vent


manual

air vent air vent

manifold

buffer station
tank



Figure 2-15a
A central air separator is used to remove entrained air from a
flowing fluid, as well as to maintain the system at the lowest
possible air content.

, -4 + (15$-32
The simplest type of high-point venting device is a manual air vent.
These components are essentially small valves that thread into 1/8-
inch or 1/4-inch FPT tappings, and are operated with a screwdriver or
square head key. When opened, air moves through the valve seat and
exits through a small side opening.

Manual air vents are commonly installed at the top of each heat
emitter. An example of a manual air vent installed at the top of a panel
radiator is shown in Figure 2-15. Such vents are opened to release Figure 2-15b
air that rises to the high point as fluid enters lower in the system.
When the fluid level reaches the manual air vent, a small stream of
water will flow out the side of the vent. A small piece of flexible tubing
can be used to guide this stream into a can or pail. It’s important
to capture this water and not allow it to stain carpets or otherwise
damage surrounding materials. When a steady stream of water has
been flowing from the vent for several seconds, it should be closed.
After air has been removed from the system, be sure to check that the
system has adequate static water pressure.

Manual air vents can also be mounted on a special fitting called a

baseboard tee, an example of which is shown in Figure 2-16a. These

11
 fittings resemble a 90º elbow, but with
Figure 2-16a Figure 2-16b an extra port having either 1/8” or 1/4”
air vent FPT threads. They are typically installed
at high points where piping changes
baseboard tee
from vertical to horizontal. Their name
comes from a common application in
which they are mounted on the outlet of
a fin-tube element within a baseboard
convector, as seen in Figure 2-16b.

HyGROSCOpIC AIR veNTS:

Another type of small high-point venting
ßow device is called a hygroscopic air vent.
Þnned-tube An example of such a device is shown
baseboard element in Figure 2-17a. Figure 2-17b shows
this device installed at the top of a cast
iron radiator.

Figure 2-17a Figure 2-17b Hygroscopic air vents contain a special

cellulose fiber disc that, when dry,
allows air to pass through it and exit the
vent. When moisture reaches the disc,
it expands very quickly to stop further
flow from the device. The location and
thickness of the fiber disc is illustrated
in Figure 2-18.

Hygroscopic air vents can be used

in either automatic or manual mode.
When the knob is opened one turn
from its fully closed position, as shown
in Figure 2-19a, it operates the same
as a manual air vent. Any pressurized
air at the base of the vent exits through
a small hole at the side of the vent’s
brass body.
Figure 2-18
When the knob is fully closed, an internal O-ring seals off the side port.
However, if air is present at the vent, the fiber discs will dry and allow air
to pass through them. This air is discharged under the vent’s knob, as
internal shown in Figure 2-19b. Once the air has been vented and water reaches
hygroscopic!
air vent
disc the fiber discs, they swell very quickly to seal off any further discharge.
(DRY)

Minerals or sediment in the system water can interfere with the operation
of the internal hygroscopic disc. It is generally recommended that these
discs be replaced every three years. Caleffi hygroscopic air vents
contain an internal spring-loaded check valve that closes whenever the
upper portion of the vent body is removed, such as when changing the
fiber discs. This is illustrated in Figure 2-19c.
internal
disc
(WET)
Although hygroscopic air vents are automatic, they can be manually
opened and are therefore not recommended in locations where
tampering is possible. A float-type air vent is a preferred choice in such
locations.

12
 Figure 2-19a Figure 2-19b
%+. 3 38/$ (15$-32
A float-type air vent provides fully automatic air release
and instantaneous response to the presence of water. An
example of such a device is shown in Figure 2-20.
Figure 2-20a Figure 2-20b
cap, (sealed when closed)
air outlet ports
spring-loaded stem
valve seat & O-ring
linkage
air

water
inlet
It contains an air chamber, a float assembly and an air
valve. As air accumulates within the chamber, the float
descends. A linkage attached to the float eventually
opens the valve mechanism at the top of the unit. As air is
released, water flows into the chamber and lifts the float to
close the valve. Some Caleffi float-type vents are equipped
with hygroscopic caps that seal the vent from water
leakage, and thus provide secondary leak protection if the
vent’s internal valve mechanism does not operate properly.
Most float-type air vents are equipped with a cap that
protects the valve mechanism from debris. It’s important
Figure 2-19c
that this cap is loosened when the vent is put into
operation. If the cap is fully closed, the vent cannot
operate. Caleffi vents can be equipped with Caleffi-
specific “anti-siphon” caps that prevent airflow into the
vent if the pressure at the vent location drops below
atmospheric pressure.
Float-type air vents are available in different sizes and
shapes. Compact designs allow mounting within the
enclosures of heat emitters, such as fin-tube convectors
or fan-coils. Larger “high-capacity” vents are available for
use at the top of central air separators, storage tanks, or
other locations where high-volume air venting is needed.
It’s important to remember that some float-type air vents can
also allow air to enter the system if the system pressure at
their installed location drops below atmospheric pressure.
This can happen as a result of improper placement of the
expansion tank relative to the circulator. It can also be
caused by low static pressure in the system. Caleffi anti-
siphon vent caps are designed to prevent this intake of air.
It’s good practice to design and commission all closed-
loop hydronic systems so there is at least 5 psi of
positive static pressure at the top of the system. This
ensures that float-type vents will always be able to expel
any air that accumulates.
It’s also important to verify that the pressure rating of
float-type air vents is suitable for the conditions and
locations where they will be located in the system.
Hydronic systems that have piping installed over several
building stories can generate high static pressure in the
lower portions of the system, where such vents may be
located at the top of tanks, heat exchangers, hydraulic
separators, boilers or other devices.
13


Figure 2-21a Figure 2-21b 
 
 

 
  
 


 
  

  



 

  


 
 


  



 



    
  
  

  

  

 


 


"$-31 + (12$/ 1 3.12
The ability to maintain very low air levels within a closed-
loop hydronic system is vital to quiet, efficient and reliable
operation. The key component in providing this function is
a central air separator. Such devices can be categorized
as either air purgers or microbubble air separators.
the air removal efficiency of these devices, albeit at the cost
of larger and more expensive hardware. Air purgers are not
designed to capture microbubbles, and as such, cannot
lower the dissolved air content of the system as well as
separators specifically designed for this purpose. A cutaway
illustration of a typical air purger is shown in Figure 2-21b.

Figure 2-21a shows an example of a cast iron air purger.
These relatively simple devices encourage well-formed air
bubbles to rise into a collection chamber and then pass
out through a float-type air vent at the top of that chamber.
They rely heavily on the buoyancy of well-formed bubbles
as the means of separation. To achieve proper operation,
the velocity of the flow stream entering the separator must
be kept below 4 feet per second. Lower velocities increase
,("1.!4!!+$ (12$/ 1 3.12
Due to their small size and low buoyancy, microbubbles
are more difficult to capture relative to well-formed
bubbles or large air pockets. Doing so requires surfaces
upon which microbubbles can cling and eventually merge
into larger bubbles. This process is called coalescence
and is critically important to attaining and maintaining
minimum air levels in hydronic systems.

Figure 2-22a Figure 2-22b

cap
air discharge valve






 
 
  
 

  
 


 
  
 



14
 The surface on which microbubbles coalesce
Figure 2-23 is called the “coalescing media.” Some
microbubble air separators use metal meshes
for this media, while others use special
polymers. In either case, the coalescing media
must provide high surface contact area,
chiller enhancement of vertical bubble movement
and a relatively low pressure drop.


microbubble
/+ "$,$-3.%"$-31 + (1

air separator

microbubble
(vertical)
2$/ 1 3.12
air separator
Central air separators work best when
(horizontal)
located where the solubility of dissolved
gases within the system water is lowest. In
heating systems, they should be mounted
near the outlet of the heat source (see Figure
VENT VENT

2-23). In cooling systems, they should be

mounted on the inlet side of the chiller (e.g.,
where water temperatures are warmer).

In some situations, it is convenient to use

a central air separator that can mount in a
As microbubbles coalesce together, they form larger
vertical pipe. Figure 2-24 shows an example of such
bubbles. Eventually, the bubbles attain a volume large
an application. Notice how the air separator placement
enough that buoyancy forces overcome the adhesion
allows flow through it during space-heating as well as
forces holding them to the coalescing surface. The
domestic water-heating operating modes. The greater
bubbles then rise along the coalescing surfaces to a
the number of times system water passes through the
chamber above the main flow stream where they can
heat source and central air separator, the better the
be collected and expelled through a float-type air vent.
latter device can “scrub” dissolved gases from the water
The concept of coalescence inside such a separator is
and expel them.
illustrated in Figure 2-22b.
The ability of a microbubble air separator
boiler to lower the water’s dissolved gas content
Figure 2-24
allows that water to absorb air back into
solution as it cools. A common example of
this is water cooling within piping and heat
emitters during an off-cycle. Think of this
cooling water as a “sponge” that soaks
up molecules of air gases with which it

comes in contact. Since these molecules
microbubble

are pulled into and held in solution under
air separator

(vertical mount) these conditions, they will eventually be
carried back to the heat source when
flow resumes. Upon heating, they will be
circulator

circulator
heating

DHW

released from solution as microbubbles

and captured by the microbubble air
to / from separator. This process is ongoing and
space heating

system
can eventually bring the dissolved air
content of the water to approximately
VENT

0.4% of system volume. In this state, the

Indirect domestic

water can provide efficient and virtually
water heater
silent conveyance of heat, and its very low
oxygen content discourages corrosion.

15
 (1, - &$,$-3
There are some situations in which it is not desirable to eject
air from a closed-loop hydronic system. Instead, the air in
the system needs to be maintained in part of the system.
A closed-loop solar thermal system using drainback
freeze protection is one such situation. Consider the
closed-loop, drainback protection solar combisystem
shown in Figure 2-25.
For drainback freeze protection to work, there must be
air in the collectors and any exposed piping whenever
the collector circulator is off. Total air elimination, as
previously discussed, would defeat the purpose of
drainback freeze protection. However, the air in the
collectors and upper portion of the storage tank should
not be allowed to find its way into the distribution system
where it could potentially cause problems such as noise,
poor circulator performance or trapped air pockets.
Thus, the air in the system must be “managed.”
Figure 2-25
Starmax V
collectors
auxiliary boiler
air
pressure
adjust
air return tube
air space
sightglass
ThermoCon tank
16
Air management maintains the internal air volume in its
proper location within the system. In the system shown in
Figure 2-25, any air that is captured by the microbubble
air separator is returned to the air-filled portion of the
system rather than being ejected from the system. This
allows the pressurized closed-loop system to maintain
its initial pressurization, since air is not being expelled
from it. Likewise, when the collector circulator turns off,
air from the top of the tank moves back through the air
return tube, and then up into the collector array. At the
same time, water within the collector array and exposed
piping flows back down to the tank. No air is ejected
from the system.
Notice that there is no automatic makeup water assembly
on this system. Such an assembly, if present, would
eventually allow the system to fill with water should there
be an air leak at any point.
Also note that there is no expansion
tank in this system. The captive air
volume at the top of the storage
tank, if properly sized, provides the
volume needed to accommodate
the expansion volume of the
system’s water and serve as the
drainback space.
microbubble
air separator
to / from

distribution
Figure 3-1  #(132$/ 1 3(.-

There are many ways dirt can enter a hydronic system.

Perhaps the most common is through repeated handling of
piping and system components from manufacturing through
transportation and installation. Piping and components stored
on-site can accumulate wind-blown dust or even larger dirt
particles if dragged over the ground or dirty floor surfaces.
Insects can nest in piping stored in warehouses or on jobsites.

Sediment can also be present in hydronic systems, especially older

systems containing steel or iron piping and cast iron radiators. This
is especially true for systems that originally operated with steam
and are being converted to hot water circulation.
Figure 3-2
Even new cast iron boilers or radiators can contain residue
associated with their manufacturing. Metal chips from reaming
copper or iron piping often lodge inside pipes during installation.
Access solder often forms small pellets inside piping. Welding
slag grains are also common in systems using steel pipe.

#(13 1$+ 3$#/1.!+$,2

The ideal hydronic heating or cooling system would be dirt-free.
The presence of dirt can have serious consequences, including:

r
%BNBHF
UP
SPUBUJOH
DPNQPOFOUT
JO
DJSDVMBUPST
FTQFDJBMMZ

impeller and bushing surfaces. Figures 3-1 and 3-2 show two
examples of circulators with clogged impellers caused by
debris and iron oxides within hydronic systems.

r
3FEVDFE
IFBU
USBOTGFS
EVF
UP
iGPVMFEu
TVSGBDFT
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IFBU

sources, such as the cast iron boiler section seen in Figure
Figure 3-3 3-3. Fouling due to dirt accumulation is especially problematic
in boilers or other heat sources with compact heat exchangers.

Fouling due to dirt accumulation can also drastically affect the

thermal and hydraulic performance of heat exchangers. Figure
3-4 shows an example of a heavily fouled plate from a plate &
frame heat exchanger.
Figure 3-4

Photo courtesy of Ken Shockley

17
Similar fouling can occur with chillers and heat exchangers Figure 3-7
in chilled-water cooling systems.

Dirt in the flow stream can also exasperate internal

erosion of copper tubing, as shown in Figure 3-5. The
higher the flow velocity, the more aggressive the erosion.
Figure 3-5

Courtesy of Illinois State Water Survey Figure 3-8

Dirt in systems, especially very fine particles, can
eventually collect on transparent surfaces such as those
used in sightglasses, rotameter flow meters or flow
meters built into manifold stations. This can make
it difficult or impossible to read the flow level in the
sightglass or the flow rate through the meter. Figures 3-6
and 3-7 show two examples.
Figure 3-6

Figure 3-9

With sufficient accumulation, dirt buildup can cause the

moveable parts in the flow meter to jam, rendering the
meter useless.

Dirt can also cause erosion and/or clogging of relief

valves, balancing valves, check valves, venting valves
and thermostatic radiator valves, as depicted in Figures
3-8 and 3-9.

18
DIRT SepARATION meTHODS: Figure 3-11
There are three common methods for capturing and
expelling dirt from hydronic systems:

1. Use of chemical “flocculants” to wash the inside of the

system.
2. Use of basket strainers.
3. Use of low-velocity-zone particle separators.

Chemical flocculants act as detergents within piping

systems. They provide the chemical reactions necessary
to dislodge certain types of accumulated sediments and
assist in bonding fine particles together so that they
can be entrained in a flowing stream. A typical system
cleaning procedure involves adding the flocculants to the
system, then operating it at elevated temperatures for
several hours so that accumulated sediment or corrosion
residuals can be dislodged and carried along by the flow.
The system is then drained and flushed with clean water to As debris collects inside the strainer’s basket, it impedes
expel as much of the sediment as possible. This procedure flow. This results in increased pressure drop and hence higher
can be done when the system is first commissioned or head loss. If the strainer basket is not properly maintained,
as a remedial measure for systems in which sediment such head loss can be excessive. Figure 3-12 shows an
or corrosion scale has decreased performance. Some example of a heavily loaded basket from a Y-strainer.
flocculants also coat the inside of piping and components
with a residual film to protect against corrosion.
Figure 3-12
Basket strainers, also known as Y-strainers, entrap dirt
within a “basket” made of stainless steel or brass mesh.
The cross section of a typical Y-strainer is shown in
Figure 3-10.

Figure 3-10

Flow reductions due to dirt accumulation in Y-strainers will

Y-strainers work similarly to the strainer inside the neck
of a funnel. All system flow passes through the strainer
and particles larger than the mesh size of the basket are
trapped. Particles smaller than the mesh size may pass
through the basket, as shown in Figure 3-11.
reduce heat conveyance by the system. When restricted
strainers are present near the inlet of circulators, they can
induce vapor cavitation due to significant pressure drop.
This can severely damage a circulator if not corrected.
Experimental testing of Y-strainers in which 70% of the free
area of the basket screen is covered with debris have shown
a pressure drop 450% higher than the same Y-strainer with
a clean basket screen. Figure 3-13 compares the pressure

19
 Figure 3-13 Figure 3-15
6

5 1" Y-strainer

(70% plugged)
pressure drop (psi)

1" Y-strainer

2 (clean basket)

0
0 2 4 6 8 10 12 14 16

 


is reduced, often by a factor of 9 or more. The reduced

Figure 3-14
velocity makes it difficult for the flow stream to continue
P across strainer is

entraining the dirt particles. A specially designed media
monitored to determine
within the low-velocity-zone dirt separator further impedes
when cleaning is necessary dirt entrainment. The dirt particles drop out of the active
flow region of the separator and collect in the bowl at the
bottom of the separator. When a valve at the bottom of this
bowl is opened, the accumulated dirt is “blown down” (e.g.,
expelled) to a hose or bucket. An example of a Caleffi Dirtcal
low-velocity-zone dirt separator is shown in Figure 3-15.
basket strainer
A low-velocity-zone dirt separator has much lower head
loss and pressure drop compared to the same size
ball valves isolate

Y-strainer with a clean screen. Figure 3-16 compares the
strainer during cleaning
pressure drop of a 1” pipe size Caleffi Dirtcal separator to
that of a 1” pipe size Y-strainer with a clean basket, as well
drop of two 1” pipe size Y-strainers: one with a clean basket,
and the other with the basket 70% plugged with debris. Figure 3-16
In most systems, the pressure drop across a basket 6

strainer is monitored to determine when cleaning is

necessary. A pressure drop of 5% or more of the 5 1" Y-strainer

(70% plugged)
differential pressure across the circulator is a reasonable
pressure drop (psi)

4
indication that the strainer should be cleaned. Ball valves
are installed to isolate the strainer so its basket can be 3
removed without significant fluid loss, as shown in Figure
1" Y-strainer

3-14. Flow through the system must be stopped during 2 (clean basket)
this cleaning procedure.
1 1" Dirtcal

+.6 5$+."(38 9.-$#(132$/ 1 3.12
0
Low-velocity-zone dirt separators allow gravity and 0 2 4 6 8 10 12 14 16
deflection to separate dirt particles from the flow stream. 
 


The velocity of the flow stream entering such a separator

20
as the same Y-strainer with a basket that
is 70% plugged. Figure 3-17
Efficiency (%)
Lower head loss and pressure drop
Efficiency Efficiency
reduces the circulator power required
( Separated quantity
Initial quantity
.100%) 50 passages ( 2 f/s) 50 passages ( 4 f/s)
for a given flow rate. This reduces long-
100
term system operating cost.

Because sediment accumulates below 80

the flow stream, low-velocity-zone dirt

separators can operate for relatively 60

long periods between blowdowns.

Furthermore, flow through the system 40
does not need to stop during the
blowdown procedure. 20

As with air separation, flow velocity

particle size

0
through a low-velocity-zone dirt
Micro

(μm)

1000
105

150

210
250

500
16

35

63
10

20

50
separator affects performance. The 5
0

maximum flow velocity through such a

device is 4 feet per second. WORKING ZONE
DI RTCAL
$%%("($-"8.%#(132$/ 1 3(.-
No dirt separator or Y-strainer can CARTRIDGE FILTERS
capture 100% of the dirt in a flow stream
during a single pass through the device.
This is especially true of very small SPECIAL STRAINERS
particles, such as iron oxide, which are
easily entrained with flow. The smaller
Y-STRAINERS
the particles, the greater the number of
cycles required to remove them. Figure
3-17 shows the results of a particle
separation test performed on a Caleffi iron oxides are a common type of debris that could be
low-velocity-zone dirt separator. Results reflect particle present in many hydronic systems.
size, flow velocity and the number of passes (e.g.,
number of times the entire system volume has passed Iron oxide particles are attracted
through the separator). Figure 3-18
to magnetic fields. The most
common location of such
Testing has shown that Caleffi low-velocity-zone fields within hydronic systems
separators can remove nearly 100% of small sand particles is near a circulator’s motor.
in sizes greater than 100 micrometers (approximately Manufacturers of wet-rotor
0.004 inches) when operating with flow rates up to 4 circulators have continually
feet per second. Eventually these separators can remove improved the ability of their
particles as small as 5 micrometers (approximately 0.0002 circulators to isolate such
inch). This dimension is less than 1/10th the diameter of a particles from the fluid-filled
human hair, and much smaller than the particle size that space between the rotor and
can be captured by a typical Y-strainer. stator poles. Still, circulators
installed in systems with high
, &-$3("#(132$/ 1 3.12 iron oxide content are more
Many hydronic systems contain cast iron or steel likely to experience eventual
components. The presence of these ferrous metals accumulation of these particles
creates the opportunity for iron oxides to form. The within the rotor can. In severe
greater the presence of oxygen, and the more conductive cases, this accumulation
the water, the faster these oxides form. It follows that can jam the rotor within the

21
Figure 3-19 rotor can, preventing the
circulator from operating.
The high-efficiency wet-
rotor circulators that
are increasingly used in
hydronic systems contain
very strong rare earth
magnets within their
rotors, as demonstrated
in Figure 3-18. They may
also use closer spacing
between the rotor can and
rotor to improve magnetic
coupling between the
rotor and stator, which
improves motor efficiency.
Evidence suggests that
the long-term wire-to-
water efficiency of these circulators can decrease by
20% or more due to accumulation of iron-based particles
within the circulator, as seen in Figure 3-19. Although
the circulator may still operate, it does so at reduced
flow and head relative to when first installed. In other
cases, the circulator can be completely stalled by the
accumulation of such particles.
One way to help ensure that high-efficiency circulators
maintain good performance is to trap iron oxide particles,
as well as other debris, before they can accumulate
within the circulator. This is possible using magnetically
enhanced, low-velocity-zone dirt separators.
The ability of a low-velocity-zone dirt separator to
capture iron oxide particles is enhanced by installing
Figure 3-20
Figure 3-21
22
powerful rare-earth magnets on or within the separator.
Iron oxide particles are attracted to these magnets,
improving the capture efficiency of the separator. When
the magnetic portion of the separator is removed, the iron
oxide particles along with other debris can be flushed out
from the lower bowl of the separator.
Figures 3-20 and 3-21 show external and internal views
of a Caleffi DirtMag magnetic dirt separator. Notice the
black collar near the bottom of the separator’s bowl. This
collar contains powerful rare earth magnets that attract
ferrous metal particles and hold them against the side of
the brass body, which is nonmagnetic.
The permanent magnets used in this collar maintain
their full strength over time, allowing the separator to
constantly attract and capture ferrous particles as they
form in the system.
Figure 3-22 Figure 3-23
Figures 3-22 and 3-23 shows another variation on a
magnetic dirt separator. In this case, the separator’s
body is made of engineered polymer. The body connects
to a rotatable brass base fixture that allows the body to
remain vertical regardless of the orientation of the pipe
to which it is attached. This separator also contains a
media that helps separate dirt from the flow stream. The
magnetic collar can be seen at the lower end of the body.
Figure 3-24 shows a DirtMag separator being drained.
Notice that the magnetic collar has been removed during
the drainage process. This allows the captured ferrous
metal particles to drop into the lower bowl and be flushed
out with other debris.
Figure 3-25 shows how a magnet attracts iron containing
dirt particles that have been captured in the effluent
flushed from the DirtMag separator.
 Figure 3-24 Figure 3-26

distribution
piping
system
dirt
separator

VENT

Figure 3-27

Figure 3-25

old cast iron!

radiator system

air! system!
separator circulator

purge!
valve

magnetic!
dirt!
separator

as shown in Figure 3-26. This is especially important in

plACemeNT Of DIRT SepARATORS:
Because most dirt particles have a density greater than
water, they tend to migrate toward the lower portions of
the system. Thus, it makes sense to separate and capture
them in this area. It also makes sense to continually route
system flow through a dirt separator to increase the
number of passes the system volume makes through the
device in a given amount of time.
Dirt separators are commonly placed on the inlet side
of boilers, heat exchangers and other heat sources,
systems using boilers or other heat sources with compact
heat exchangers. It’s also very important in systems where
a new boiler is installed in a system containing older piping
and/or cast iron radiators, as shown in Figure 3-27.
The dirt separator is placed on the return side of
the distribution system to capture particles that might
otherwise flow through the new boiler. A magnetic dirt
separator is especially appropriate for such systems
given the higher potential of iron oxide particles in the
flow stream.

23
Notice that purging valves have been located just
Figure 3-29
upstream of the dirt separator. This allows some of the
dirt in the system to be flushed out during initial filling brazed

and purging. This, in turn, decreases the amount of dirt -plate

the separator will eventually have to capture. heat
dirt

exchanger separator
When possible, it’s also desirable to place the dirt
separator upstream of circulators. This helps extract dirt
before flow passes through the circulator. When doing so,
allow at least 12 pipe diameters of straight pipe between dirt

the outlet of the air separator and inlet of the circulator. separator
Some systems use multiple circulators to push flow
from different circuits into the boiler. In this case, the
compromise is to place the dirt separator upstream of the
boiler, as shown in Figure 3-28.
In systems with a main mixing valve, it’s best to place dirt
Figure 3-28 boiler separators in the return line from the distribution system
ahead of the valve. This increases flow through the
separator and better protects the mixing valve from dirt.

With all installations, be sure to plan sufficient space to

connect a drain hose or place a bucket under the dirt
separator to capture the expelled fluid and dirt.

Low-velocity-zone dirt separators are also well-suited

to protect the small fluid passageways within plate-type
heat exchangers from dirt accumulation. Separators
should be installed near the inlets of both the primary
DirtMag dirt
Discal air
and secondary sides of the heat exchanger, as shown in
separator separator Figure 3-29.

DHW DHW

heating heating

24
 Figure 4-1 Figure 4-2 Figure 4-3

combined
air & dirt VENT

separator

Combined air & dirt separators use the same

 ".,!(-$# (1#(132$/ 1 3(.-
Some designers prefer to combine the function of air
separation and dirt separation into a single device. This
approach saves space, especially in tight mechanical
rooms. It also reduces cost relative to installing two
individual separators.
principles of microbubble air separation in the
upper portion of the separator body, combined
with low-velocity-zone dirt separation in the lower
portion of the separator body. They have a float-type
automatic air vent at the top of the body and a drainage
valve at the bottom, as seen in Figure 4-1.
Caleffi also offers combined air & dirt separators with
magnetically enhanced separation of ferrous particles. A
cross section of one such separator is shown in Figure 4-2.

chilled-water

Figure 4-4 air handlers

air vent
Combined air &
dirt separator variable-speed

pressure-regulated

circulator



balancing

valves

temperature
air vent

sensor

chiller

ThermoCon buffer tank

25
/+ "$,$-3.%".,!(-$#
(1#(132$/ 1 3.12
The preferred placement of a combination air & dirt separator
depends on the application and system piping. In heating
systems, preference should be given to air separation. The
preferred placement of the combined air & dirt separator is
near the outlet of the heat source, as shown in Figure 4-3.
This creates conditions favorable to air separation (e.g.,
higher fluid temperature and lower pressure).
In cooling systems, the preferred placement of the air
& dirt separator is near the return to the chiller plant, as
shown in Figure 4-4. Water at this location has a slightly
higher temperature compared to water leaving the chiller.
This improves the conditions under which microbubbles
can form. It also places the dirt separating function on the
inlet to the chiller plant, which reduces the potential of dirt
accumulation within the chiller.
2(9(-& (1#(132$/ 1 3.12
The ability of an air separator, dirt separator or a
combined air & dirt separator to remove the undesired
materials from a stream of water depends on the flow
velocity of that stream. Slower flow velocities improve
separation efficiency. For optimum performance, the
pipe size for any of these separators should limit flow
velocity to 4 feet per second. Higher flow velocities of
up to 10 feet per second are possible but will decrease
the efficiency of air and dirt separation. Separation will
still occur, but over a longer time. Figure 4-5 lists the
nominal pipe size of separators along with the flow rates
corresponding to flow velocities of 4 feet per second and
10 feet per second.

Figure 4-5

BRASS STEEL

size 3/4" 1" 1.25" 2" 2.5" 3" 4" 5" 6" 8" 10" 12"

$"!

4 ft/sec 8.0 9.3 10.0 37.3 63 95 149 259 380 625 980 1410
GPM
$"!

10 ft/sec GPM 19.0 22.1 25.0 88.8 150 227 355 616 904 1570 2450 3530

26
 /1(-"(/+$2.%'8#1 4+("2$/ 1 3(.-
Figure 5-2









Many hydronic systems contain multiple independently circuit 1 head loss curve including

controlled circulators. These circulators can vary widely in common piping (circulator #1 on)
their flow and head characteristics. Some may operate at
fixed speeds, while others will operate at variable speeds.

When two or more circulators operate simultaneously in the

same system, they each attempt to establish differential
pressures based on their own pump curves. Ideally, each
circulator in a system will establish a differential pressure
and flow rate that is unaffected by the presence of another
operating circulator within the system. When this desirable pump curve

condition is achieved, the circulators are said to be (circulator #1)
GXCQ@TKHB@KKXRDO@Q@SDC from each other.

Conversely, the lack of GXCQ@TKHBRDO@Q@SHNM can create 0

0  

very undesirable operating conditions in which circulators



  


interfere with each other. The resulting flows and rates of  





heat transport within the system can be greatly affected circuit operating
by such interference, often to the detriment of proper
heat delivery.
Next, assume circulator 2 is turned on, while circulator
1 remains on. The flow rate through the common piping
Figure 5-1 Very little head loss occurs
increases, and so does the head loss across it. However,
in this portion of the circuits.
because of its spacious geometry, the increase in head loss
circulator 2
across the common piping is very small. The system head
circuit 2
loss curve that is now “seen” by circulator 1 will steepen,
but very slightly. It is shown as the green curve in Figure 5-3.
circuit 1

circulator 1
Figure 5-3
common piping
head (gain or loss) (feet of head)

circuit 1 head loss curve including

common piping (both circulators on)

circuit 1 head loss curve including

common piping (circulator #1 on)

The degree to which two or more operating circulators

interact with each other depends on the head loss within
the piping path they have in common. This piping path
is called the BNLLNMOHOHMF, since it is shared by both
circuits. The lower the head loss of the common piping,
the less the circulators will interfere with each other. pump curve

very small change in

head loss across

(circulator 1)
common piping

Consider the system shown in Figure 5-1. In this system, "

 

both circuits share common piping. The “spacious” are on
geometry of this common piping creates very low flow
0
velocity through it. As a result, very little head loss can 0  

occur across it.
VERY small decrease in

Assume that circulator 1 is operating, and circulator 2 is  

$"


off. The blue circuit head loss curve shown in Figure 5-2 "
 




applies to this situation. The point where the blue circuit $"


 

$"


 


"

 
"



#

head loss curve crosses the orange pump curve for are operating circuit operating
circulator 1 establishes the flow rate in circuit 1.

27
 Figure 5-4 circulator 2

Very little head loss occurs

in this portion of the circuits. circuit 2
circulator 2

circuit 2
common piping
circuit 1

circulator 1
common piping

circulator 1
common piping circuit 1

The operating point of circuit 1 has moved very slightly + "*.%'8#1 4+("2$/ 1 3(.-
to the left and slightly upward. This implies that the flow Having stressed that hydraulic separation is desirable, it
rate through circuit 1 has decreased very slightly. This very is worthwhile to consider a situation in which hydraulic
small change in flow rate is indicated in Figure 5-3. Such separation is NOT present and observe the consequences.
a small change in circuit flow rate will have virtually no
effect on the ability of circuit 1 to deliver heat. Thus, the Consider the horizontal piping system shown in Figure 5-5.
interference created when circulator 2 was turned on is of no The larger circulator is sized to move sufficient flow through
consequence. Therefore, this situation provides acceptable the higher flow-resistance circuit including the high-flow-
hydraulic separation between the two circulators. resistance heat source. When operating, the flow created by
the large circulator creates a pressure drop of 5 psi between
One could imagine a hypothetical situation in which the head the supply and return headers connected to the heat source.
loss across the common piping was zero, even with both
circuits operating. Because no head loss occurs across the
Figure 5-5
common piping, it would be impossible for either circulator
small circulator
to have any effect on the other circulator. Such a condition
P=22 psi
would represent “perfect” hydraulic separation and would large circulator
be ideal. Fortunately, perfect hydraulic separation is not P=17psi
required to ensure that the flow rates through independently heat source

operated circuits, each with their own circulator, and each with high
backseated

sharing the same low-head-loss common piping, remain 
   check valve
P= 10 psi

ON OFF
reasonably stable, and thus capable of delivering consistent
heat transfer. In animated terms, the two simultaneously

P = 5 psi
operating circulators cannot “sense” each other’s presence
within the system, and thus operate as if they were each in
an independent circuit. P=12 psi
P=13 psi
One can think of (and design) circuits that are known to P=16 psi
have a high degree of hydraulic separation, as if they
were completely independent of each other, as illustrated
in Figure 5-4.
P=17 psi
The required hydraulic performance of each circuit can be


determined as if it were a standalone circuit, unaffected

by the other circuits in the system. This is a very powerful
concept that simplifies design and troubleshooting.

28
 Figure 5-6 Figure 5-6 shows the pump curve for the
smaller circulator. Notice that the maximum
15
6 head added (feet) possible differential pressure this circulator
4 psi



 can create is 4 psi.
 D 

 144 

4 10

P = ( Head ) 

Because the reverse differential pressure of

5 psi is greater than the maximum forward
5 differential pressure of 4 psi, the circulator
2


cannot create flow, even though its impeller

 
   is spinning at normal speed. Its internal check
0 0 valve remains closed. Under this condition,
the circulator is said to be “deadheaded.” It
0 2 4 6 8 10 will dissipate its full input power as heat. This

 
 heat will be absorbed by the water in the
circulator’s volute, as well as be dissipated
by the circulator’s body. Although this is not a
The pressures shown in Figure 5-5 are those established condition that should be allowed by proper design, small
when the large circulator is operating and the small wet-rotor circulators can usually withstand such operation
circulator is off. Because there is no flow in the circuit for several hours. Such situations can be avoided by
containing the small circulator, the 17 psi pressure at the creating hydraulic separation between the circuits.
return end of this circuit is present around the circuit.
Hence, there is a 17 psi pressure at the discharge port
$5.+43(.-.%'8#1 4+("2$/ 1 3(.-
of the smaller circulator. This creates a reverse pressure
Although the term hydraulic separation is relatively new
differential of (17-12) = 5 psi across the small circulator,
to the North American hydronics industry, the principle
which forces its internal check valve closed.
of avoiding interaction between simultaneously operating
circulators in the same system is
not. During the 1950s, the concept
Figure 5-7
of primary/secondary piping was
introduced in North America. It
spring-loaded

check valve
was promoted as a way to provide
stable on/off flow control in multiple
secondary circuit independently controlled circuits, each
with its own circulator. It is based on the
secondary

use of two very closely spaced tees, as
circulator
purging
shown in Figure 5-7.
valve
Because the tees are very close
together, the pressure drop between
primary
closely
them due to head loss is almost zero.
circulator spaced
Hence, the pressure at the side port of
tees each tee is almost exactly the same.
another
primary loop secondary Since there is virtually no pressure
circuit differential between the tees, there is
very little tendency for flow to develop
heat source in the secondary circuit, even though
flow is passing through the tees in
the primary circuit. However, it is
still good practice to install a spring-
loaded check valve on the supply
side of every secondary circuit to
prevent buoyancy-driven flow from
developing. The intended flow rate in
the secondary circuit is achieved when

29
 whenever two or more of the
Figure 5-8 secondary circuits are operating
simultaneously. Although there
are situations in which this
temperature drop doesn’t
present a problem, it does add
complications that designers
must assess and compensate for.
vertical air separator
One way to overcome the
secondary circuits
series temperature drop effect
associated with series primary
loops is to create a parallel
primary loop, as shown in Figure
5-9.
boiler

circulator A parallel primary loop is divided
into two or more “crossover
bridges.” A pair of closely spaced
tees within each crossover bridge
VENT
provides hydraulic isolation
between each secondary circuit
closely closely closely closely and the parallel primary loop.
spaced primary
spaced spaced spaced
tees circulator tees tees tees
Unlike a system with a series
series primary loop
primary loop, a system with a
parallel primary loop provides
magnetic
essentially the same supply water
dirt separator temperature to each secondary
circuit, regardless of which
secondary circuits are operating.
This benefit is achieved through
the secondary circulator operates. Because the flow more complicated and costly
created by the primary circulator does not induce flow piping. Notice that each crossover bridge contains a
in the secondary circuit, nor does it have any significant flow-balancing valve. These valves are needed to set
effect on the flow in the secondary circuit when its the flow through each crossover bridge in proportion
secondary circulator is operating, these two circuits are to the thermal load served by the secondary circuit
hydraulically separated from each other. supplied from that bridge. If these valves are not present
and properly adjusted, there may be problems such as
This concept can be extended to multiple secondary inadequate flows through the crossover bridges located
circuits served by a common primary loop, as shown farther away from the primary circulator.
in Figure 5-8. Each secondary circuit, including the
secondary circuit through the boiler, is joined to the Another important consideration is that both series and
primary circuit using a pair of closely spaced tees to parallel primary/secondary systems require a primary
provide hydraulic separation. circulator. This circulator adds to the installed cost of
the system. More importantly, it adds to the system’s
The configuration shown in Figure 5-8 is more precisely operating cost over its entire life. Even one small primary
called a series primary/secondary system. With this loop circulator in a system can have operating costs that
approach, all secondary circuits are arranged in a total more than $1,000 over a typical 20-year design
sequence around the common primary loop. life. Larger primary loop circulators can have life-cycle
operating costs of several thousand dollars.
Although hydraulic separation exists between all circuits,
so does an often-undesirable effect—a drop in supply For example: Consider a primary loop circulator that must
water temperature from one secondary circuit to the next produce a flow rate of 50 gpm, with a corresponding

30
head of 15 feet (which is evidenced by a pressure gain
of 6.35 psi across the circulator). Assume the circulator
is a typical wet-rotor design and has a wire-to-water
efficiency of 25% at these operating conditions. The
estimated input power to operate this circulator is:
Furthermore, if the cost of electricity were to inflate at 4%
each year, the total operating cost of this circulator over a
20-year period would be:

This cost is only for operation of the primary loop

If this primary loop circulator were to operate for 3000
hours each year, and the local cost of electrical energy
was $0.10/kWhr, the annual operating cost would be:
circulator. It does not include purchase, installation or
maintenance of that circulator over time.
Imagine a situation in which the hydraulic separation
benefits of primary/secondary piping, as well as the equal
supply water temperatures provided by a parallel primary
loop, could be provided without having to construct a
primary loop or use a dedicated primary loop circulator.

There are now several modern

methods for achieving these
benefits without need of
Figure 5-9
constructing primary/secondary
piping systems. They are
discussed in the next section.

boiler

circulator

primary

circulator
VENT

closely
spaced closely
tees spaced
tees

balancing

valves

parallel primary loop

magnetic

dirt separator

31
 ,.#$1-,$3'.#2.%
'8#1 4+("2$/ 1 3(.-
Any component or combination of components with very
low head loss, and common to two or more hydronic
circuits, can provide hydraulic separation between those
circuits.
One way to create low head loss is to keep the flow path
through the common piping very short. Another way to
create low head loss is to significantly reduce the flow
velocity through the common piping.
Examples of devices that use these principles include:
1. A heat source that has very low head loss
2. A pair of closely spaced tees
3. A buffer tank with specific piping arrangement
4. A hydraulic separator
5. Specialty components such as a Caleffi HydroLink
Each of these methods can provide hydraulic separation
between simultaneously operating circulators, as well as
equal supply water temperature to each load circuit.
Nearly all cast iron sectional boilers have large chambers
through which water moves very slowly as it passes
from the boiler’s inlet to its outlet. These slow internal
velocities create very low head loss through the boiler,
even when all the zone circulators are operating. If this
type of boiler is combined with low-head-loss header
piping, as discussed in the previous section, the resulting
combination creates low-head-loss common piping for
the zone circuits. This, along with a very simple piping
arrangement, provides the necessary conditions for
hydraulic separation.
When modulating/condensing boilers were first introduced
to North America, many of them used compact internal
heat exchangers that created much higher head loss in
comparison to traditional cast iron boilers. Some of these
boilers were installed using the same piping arrangement
that was common practice with cast iron boilers, as
shown in Figure 6-2.
Figure 6-2
high-head-loss boiler

+.6 '$ # +.22'$ 32.41"$

Figure 6-1 shows an example of a system with a single
cast iron sectional boiler supplying 4 zone circulators.
Many North American hydronic systems were once piped
similar to this. Although the term hydraulic separation was
not used at that time to describe the inherent advantage of
this approach, these systems performed well with minimal
interference between simultaneously operating circulators.

Figure 6-1

VENT

low-head-loss

common piping

low-head-loss

headers
The high head loss of the mod/con boiler significantly
increased the overall head loss of the common piping and
largely negated the hydraulic separating characteristic
attained in systems using the older style, low-head-
VENT

loss boilers. This created many problem installations,

since installers and manufacturers did not immediately
low-head-loss boiler
recognize the source of the resulting flow problems.

Eventually, the source of the flow problems was traced

back to the high head loss of the new style boilers with

32
 their compact heat exchangers.
Figure 6-3 Piping methods were modified
to correct this problem. These
methods will be discussed shortly.

Today, there are modulating/

condensing boilers available with
low-head-loss characteristics. When
manifold station combined with low-temperature
serving
distribution systems, they provide
low-temperature
the benefit of high thermal efficiency,
heat emitters as well as the benefit of simple
gas
low-head-loss

burner common piping piping that provides excellent
hydraulic separation between the
circulators. Figure 6-3 shows an
example of such a system.

'8#1 4+("2$/ 1 3(.-

42(-&"+.2$+82/ "$#3$$2
Heat sources such as mod/con
boilers with compact internal heat
VENT exchangers or water-to-water heat
pumps tend to have high-head-
loss characteristics. Because of
modulating/condensing

this, they should not be part of a
heat source with low-

common piping assembly that is
head-loss characteristic
supposed to have low head loss.

One solution is to couple such heat

Figure 6-4 sources to a generously sized header
boiler with high- system using a pair of closely spaced
head-loss tees, as shown in Figure 6-4.
characteristic
Because they are positioned as
close to each other as possible,
there is virtually no head loss
between the tees. They form
the common piping between the
boiler circuit and the headers, and
thus provide hydraulic separation
between the boiler circulator and
any of the circulators on the supply
header. The headers have also
closely
been sized for low head loss.
spaced
As such, they provide hydraulic
VENT

tees
boiler low-head-loss
separation between any two or
circulator common piping more of the circulators connected
to the headers.

A suggested guideline is to size

headers for a flow velocity in the
range of 2 to 4 feet per second
when all the circulators supplied
by the header are operating. Low

33
Figure 6-5 flow velocity creates minimum head loss, while also allowing
Tube/pipe size Flow rate at Flow rate at for air bubble entrainment. The latter is useful when air bubbles
2 ft/sec 4 ft/sec need to be forced downward in a vertical header during
system commissioning.
1” M copper 5.5 gpm 10.9 gpm
Figure 6-5 lists the flow rates corresponding to flow velocities
1.25” M copper 8.2 gpm 16.3 gpm of 2 feet per second and 4 feet per second for type M copper
tubing in sizes from 1-inch to 5-inch, and in schedule 40
1.5” M copper 11.4 gpm 22.9 gpm steel for larger pipe sizes. For other piping materials or sizes,
the flow rate corresponding to a given flow velocity can be
2” M copper 19.8 gpm 39.6 gpm calculated using Formula 6-1.
2.5” M copper 30.5 gpm 61.1 gpm Formula 6-1:
3” M copper 43.6 gpm 87.1 gpm  d2 
f = v i 
 0.408 
4” M copper 75.9 gpm 152 gpm
Where:
5” M copper 118 gpm 236 gpm v = average flow velocity (ft/sec)
f = flow rate (gpm)
6” schd. 40 steel 180 gpm 361 gpm di = exact inside diameter of pipe (inches)

8” schd. 40 steel 312 gpm 624 gpm With proper hydraulic separation, such as shown in Figure 6-4,
it is possible to combine circulators with significantly different
10” schd. 40 steel 492 gpm 984 gpm pump curves on the same header system. It is also possible
to combine fixed-speed and variable-speed circulators on the
12” schd. 40 steel 699 gpm 1397 gpm
same low-head-loss headers.

'8#1 4+("2$/ 1 3(.-

Figure 6-6 42(-& !4%%$13 -*
boiler with high- Figure 6-6 shows a buffer tank
head-loss and generously sized headers
characteristic serving as the low-head-loss
common piping that provides
hydraulic separation between the
heat source circulator and each
of the distribution circulators.
This demonstrates that hydraulic
separation can sometimes be
accomplished as an ancillary
function to the main purpose of the
device (e.g., hydraulic separation
boiler
is not the main function of the
circulator
buffer tank).

buffer
Figure 6-7 shows an example

VENT

tank of a Caleffi ThermoCon tank

low-head-loss
serving as both a buffer tank
common piping and hydraulic separator between
a water-to-water geothermal heat
pump, a modulating/condensing
auxiliary boiler and the associated
distribution system.

34
Figure 6-7
Figure 6-9 shows the external appearance of several
Caleffi hydraulic separators. The front portion of the
insulation shell has been removed from the two smaller
separators. The large, self-supporting hydraulic separator
is awaiting site-installed insulation.

Hydraulic separators are sometimes also called KNV

Courtesy of Harvey Youker and Danny Gough
'8#1 4+("2$/ 1 3(.-42(-&
'8#1 4+("2$/ 1 3.1
Another method of providing hydraulic separation is
by installing a device appropriately called a hydraulic
separator. Although relatively new in North America,
hydraulic separators have been used in Europe for many
years. Figure 6-8 shows a hydraulic separator installed in
place of the buffer tank in Figure 6-6. Note the similarity
of the piping connections between the systems.
KNRR GD@CDQR or “CDBNTOKDQR ” They create a zone of
low flow velocity within their vertical body. The diameter
of the body is typically three times the diameter of the
connected piping. This causes the vertical flow velocity
in the vertical body to be approximately 1/9th that of the
connecting piping, as shown in Figure 6-10. Such low
velocity creates very little head loss and very little dynamic
pressure drop between the upper and lower connections.
Thus, a hydraulic separator provides hydraulic separation
in a manner similar to a buffer tank, only smaller.
The reduced flow velocity within a hydraulic separator
allows it to perform two additional functions. First,
air bubbles can easily
rise upward within
the vertical body and Figure 6-9
be captured in the
upper chamber. When

Figure 6-8
boiler with high-
head-loss
characteristic

boiler
circulator
VENT

low-head-loss common piping

hydraulic

separator

Installed separator photo courtesy of Rathe Associates

35
 sufficient air collects at the top of the
Figure 6-10 body, the float-type air vent allows it to be


ejected from the system. Thus, a hydraulic
separator can provide air separation.

diameter = 2"

 
 

 

 

 
 
" Second, the reduced flow velocity
area = A inside the hydraulic separator allows dirt
particles to drop into a collection chamber
at the bottom of the body. A valve at the
bottom can be periodically opened to
diameter = 6" flush out any accumulated dirt. Thus, the
"




area = 9A
"
 


 hydraulic separator also serves as a dirt

!




removal device.
"



 



"
 


 
The efficiency of both air and dirt separation
is enhanced through use of a coalescing
media in the active flow zones, which are

 


in line with the side ports of the separator.


 These are shown in Figure 6-11.

 
  High-performance hydraulic separators,

such as the Caleffi HydroCal, provide
three functions:

Figure 6-11 1. Hydraulic separation

HIGH 2. High-performance air
PERFORMANCE separation (equivalent to a
Caleffi Discal air separator)
hydraulic separator
3. High-performance dirt
"STANDARD"
(air & dirt removal separation (equivalent
to a Caleffi Dirtcal dirt
hydraulic
enhanced by separator)
separator coalescing media)

This multifunctional ability
allows a single high-
upper coalescing
media encourages

performance hydraulic
air bubbles to form separator to provide
hydraulic separation, as
air bubbles "ride" up
&
($&
, !&%
well as replace a high-
of the coalescing media performance air separator

"'&
"
&
&(
-")

zone
and high-performance dirt
separator, as illustrated in
Figure 6-12.
")$
"%!
coalescing media
media encourages

dirt particle to drop

"'&
"
&(
-")

zone

36
 Figure 6-12

 

HydroCal

distribution
boiler circuit heating

system
load(s)

air

separator
distribution
system
boiler
closely

circuit heating

spaced

load(s)
tees

dirt

separator

, &-$3(" ++8$-' -"$# Figure 6-13a Figure 6-13b

/ 13("+$2$/ 1 3(.-
The latest enhancement for high-performance hydraulic
separators is the addition of magnetic particle separation.
Figure 6-13 shows the Caleffi SEP4 separator, which
uses a collar containing strong rare earth magnets in
combination with a brass sediment bowl to add the fourth
function (e.g., magnetic particle separation) to the product.

The addition of magnetic particle separation makes

the SEP4 hydraulic separator especially useful for
applications in which an older distribution system—
one that may have some accumulated ferrous metal
sludge—is connected to a new heat source. Figure 6-14
shows a concept for how a SEP4 hydraulic separator
is used to interface the new boiler and high-efficiency
circulator to an older distribution system serving cast
iron radiators. Notice that each radiator has been
equipped with a thermostatic valve that allows for
individual heat output control.

37
 Figure 6-16
Figure 6-14
existing cast iron radiators
mod/con boiler
(converted from steam)
w/ compact heat exchanger
vent

ECM

pressure-
thermostatic

regulated
radiator

circulator valve

(each rad.)
Courtesy of Tweet / Garot Mechanical, Inc.,
supply temperature
Greenbay, Wisconsin
sensor (in well)
existing piping Given the surface area of their bodies,
hydraulic separators should always
be insulated to minimize heat loss to
VENT

their surroundings. This is especially

 #


hydraulic
true of larger hydraulic separators,
separator
which may have more surface area
than a modestly sized radiator, and
without insulation, would needlessly
overheat the mechanical room.
Figure 6-15 shows the insulation
shell supplied with a Caleffi SEP4
separator installed on the device.
Figure 6-15 shows another example of a SEP4 circulator
Figure 6-16 shows onsite fabricated insulation covering a
providing magnetically enhanced dirt separation in a system
large hydraulic separator in an industrial heating system.
using a high-efficiency permanent magnet circulator.
Figure 6-15 Figure 6-17 Hydraulic separators
should also be
properly supported.
Small units can
typically be supported
by channel strut, as
seen in Figure 6-17,
or by using clevis
hangers. Large
hydraulic separators
are designed to be
self-supported at
their base.

Hydraulic separators
are available in pipe
sizes from 1-inch to
over 12-inch. The
“size” of a hydraulic
Courtesy of Osborne Company Courtesy of Dan Schlicher

38
 Figure 6-18







 1" 1.25" 1.5" 2" 2.5" 3" 4" 5" 6" 8" 10" 12"


37(union)

11 18 26 80 124 247 300 484 792 1330 1850

  

separator refers to the nominal pipe size of the 4 side-

wall connections. Figure 6-19
air vent

Selecting an appropriate-size hydraulic separator is easy.

It is based on choosing a size that allows the maximum port 1
port 2

( supply from boiler) (supply to

anticipated flow rate into either side of the separator, distribution

without exceeding a preferred flow velocity of 4 feet per system)
second. Limiting the flow velocity to this value maintains
highly efficient air and dirt separation. The table in Figure
6-18 can be used as a reference.
port 3
port 4

(return to boiler) (return from

For example, if the maximum flow rate on the primary distribution

side of the hydraulic separator was 290 gpm, and system)
the maximum flow rate on the secondary side of the sediment
separator was 400 gpm, the higher flow rate would be drain
the limiting case. Figure 6-16 indicates that a 6” size
separator can handle flow rates up to 484 gpm, and thus
would be an appropriate selection for this situation.
Figure 6-20
MIXING AT THE POINT OF HYDRAULIC SEPARATION:
Mixing can occur within any component or group of
components that provides hydraulic separation. The
results of the mixing can be predicted by considering the
principles of: f1 f2
T1 T2
1. Conservation of mass
2. Conservation of thermal energy
NOTE: NOTE:
In essence, the first of these principles states that
the total flow rate of an incompressible fluid such as
f1 = f3 f2 = f 4
(always!) (always!)
water entering the separator has to equal the total flow
rate exiting the separator. The second principal implies
that, under steady-state operating conditions, the total
thermal energy entering the separator has to equal the f3 f4
total thermal energy leaving the separator. T3 T4

The temperatures at the two outlet ports of a hydraulic In this case only:

separator (e.g., ports 2 and 3 in Figure 6-19) depend on
the temperatures at the two inlet ports (e.g., ports 1 and 4
T1 = T2
in Figure 6-19), as well as the flow rates in both the boiler T3 = T4
circuit and distribution system.

39
There are three possible cases:
1. Flow in the distribution system is equal to flow in the
boiler circuit
2. Flow in the distribution system is greater than flow in
the boiler circuit
3. Flow in the distribution system is less than flow in the
boiler circuit
"@RD ū  #HRSQHATSHNM EKNV DPT@KR ANHKDQ EKNV This
situation tends to be the exception rather than the norm.
It is illustrated in Figure 6-20.
The flow and temperature leaving port 2 of the hydraulic
separator is the same as the temperature of the hot water
entering port 1. Very little internal mixing occurs because
the flows are balanced. Because of its buoyancy, the
hot water entering port 1 remains near the top of the
hydraulic separator. Most of the air bubbles carried into
port 1, or that form within the hydraulic separator, rise to
the top of the unit and are ejected through the air vent.
A similar situation exists at the lower ports of the separator.
Since the flows are balanced, the outlet temperature
Figure 6-21
returning to the heat source from port 3 equals the
temperature returning from the distribution system into
port 4. Again, very little mixing takes place within the
separator. Dirt particles carried into the separator at port
4 will settle to the bottom of its body, where they can be
periodically flushed out through the drain valve.
If a conventional boiler (e.g., one that is not intended to
operate with sustained flue gas condensation) is used, the
designer should verify that the water temperature on the
return side of the distribution system is high enough to
prevent sustained flue gas condensation within the boiler.
The use of a hydraulic separator in itself does not guarantee
that the water temperature entering the boiler will be high
enough to prevent sustained flue gas condensation.
"@RD ū  #HRSQHATSHNM RXRSDL EKNV HR FQD@SDQ SG@M
ANHKDQ EKNV Since the flow rates in the boiler circuit and
distribution system are not the same, mixing occurs within
the hydraulic separator. In this case, a portion of the cooler
water returning from the distribution system moves upward
through the separator and mixes with the hot water
entering from the boiler, as shown in Figure 6-21.
This mixing reduces the water temperature supplied to
the distribution system. This is not necessarily a bad
thing, but the designer needs to realize it can occur and
plan accordingly.

Formula 6-2 can be used to calculate the mixed

temperature (T2) supplied to the distribution system under
these conditions.
f1 f2 Formula 6-2
T1 T2  ( f
f ) T + ( f1 ) T1 
T2 =  4 1 4 
 f4
NOTE: NOTE:
Where:
f1 = f3 f2 = f 4 f4 = flow rate returning from distribution system (gpm)
(always!) (always!) f1 = flow rate entering from boiler (gpm)
T4 = temperature of fluid returning from distribution
system (ºF)
T1 = temperature of fluid entering from boiler (ºF)
f3 f4
T3 T4 Formula 1 is valid for both water and other system fluids,
provided all fluid entering and leaving the hydraulic
separator is the same. It can also be used with any
consistent set of units for flow and temperature.

Suppose, for example, that a distribution system containing

several operating circulators has 25 gallons per minute of
total flow. Water returns from the distribution system at
120ºF and enters port 4 of the hydraulic separator. At the

40
same time, the boiler flow rate is 10 gallons per minute,
and the water temperature supplied to port 1 is 160ºF.
Determine the mixed water temperature leaving port 3.
Also, what is the water temperature returning to the boiler?
The mixed water temperature is found using Formula 6-2:
 ( f
f ) T + ( f1 ) T1   ( 25
10 )120 + (10 )160 
T2 =  4 1 4  = 
 f4 25
Notice that the water temperature supplied to the
distribution system (136ºF) is substantially lower than the
water supplied from the boiler (160ºF). This is the result of
mixing within the hydraulic separator.
"@RD ū #HRSQHATSHNM RXRSDL EKNV HR KDRR SG@M ANHKDQ
EKNV Again, since the flow rates on opposite sides of the
hydraulic separator are not equal, mixing will occur inside
the separator. In this case, a portion of the hot water
entering from the boiler circuit moves downward through
the separator and mixes with cool water entering from the
distribution system, as shown in Figure 6-23.
 = 136º F
Figure 6-23

Since no mixing occurs in the bottom portion of the f1 f2

separator, the water temperature returning to the boiler T1 T2
is the same as that returning from the distribution system
(e.g., 120ºF).
NOTE: NOTE:
If the boiler firing rate is to be modulated based on the supply
temperature to the distribution system, the temperature f1 = f3 f2 = f 4
(always!) (always!)
sensor providing supply temperature information to the
modulating controller should be located within a sensor
well in the upper portion of the hydraulic separator, or
downstream of the distribution system outlet port (port f3 f4
2) of the hydraulic separator, as shown in Figure 6-22. If
the sensor is strapped to the outer surface of the pipe, it
T3 T4
should be firmly secured, then wrapped with insulation to
minimize error due to surrounding air temperature.

Figure 6-22
boiler

This condition occurs when the boiler heat output rate is

(temporarily) higher than the current system load. Under
this condition, heat is being injected into the system
faster than the load is removing heat. This produces
supply
a relatively fast increase in boiler return temperature.
temperature
If a modulating boiler is being used, this will lead to a
sensor relatively fast decrease in firing rate, which usually will
strapped
result in a reduction in boiler-side flow rate.
to pipe

(& insulated)
Under this scenario, the temperature returning to the
boiler (T3) can be calculated using Formula 6-3:
hydraulic

separator Formula 6-3

supply
 ( f
f ) T + ( f4 ) T4 
temperature
T3 =  1 2 1 
sensor in well  f1

41
Where:
T3 = temperature of fluid returned to the boiler(s) (ºF)
f1 = flow rate entering from boiler(s) (gpm)
f2, f4 = flow rate of the distribution system (gpm)
T1 = temperature of fluid entering from boiler(s) (ºF)
T4 = temperature of fluid returning from distribution
system (ºF)
Assume the boiler supply temperature is 170ºF, and that
boiler flow rate into port 1 of the hydraulic separator is
15 gallons per minute. Water returns from the distribution
system and enters port 4 of the hydraulic separator at
100ºF and 10 gallons per minute flow rate. What is the
water temperature returned to the boiler?
Substituting these operating conditions into Formula
6-2 yields:
 ( f
f ) T + ( f4 ) T4   (15
10 )170 + (10 )100 
T3 =  1 2 1  = 
 f1 15
Notice that the boiler inlet temperature is about 23ºF
higher than the return temperature of the distribution
system. This is caused by mixing within the hydraulic
separator.
If the system uses a conventional (non-condensing) boiler,
one might consider the boost in boiler return temperature
beneficial because it moves the boiler operating condition
away from potential flue gas condensation. However, this
temperature boost effect can quickly diminish if flow through
the distribution system increases (i.e., more load circuits
turn on), or if the return temperature of the distribution
system drops. Use of a hydraulic separator alone does not
prevent flue gas condensation under all circumstances.
$7/ -2(.-3 -*/+ "$,$-31$+ 3(5$
3.3'$'8#1 4+("2$/ 1 3.1
Because there is very little head loss across a hydraulic
separator, vertically or horizontally, the system’s expansion
tank can be teed into the piping near any of the separator’s
4 main ports. The lower ports are preferred because they
expose the expansion tank to lower temperature fluids
compared to the upper ports. Figure 6-24 shows both of
 = 123.3º F
these options.
The system’s expansion tank should not be connected to
the bottom of the hydraulic separator. This would allow
dirt to migrate from the bottom of the separator into the
expansion tank, where it will accumulate on top of the
tank’s diaphragm.

Figure 6-24

boiler OK boiler OK boiler NOT OK

hydraulic
hydraulic
hydraulic

separator separator separator

makeup

makeup

VENT VENT

makeup
VENT
water

water
water
subsystem
subsystem subsystem
expansion

expansion
expansion

tank
tank tank

42
 outdoor
'8#1 4+("2$/ 1 3(.-6(3'
Figure 6-25 temperature
,4+3(/+$!.(+$12.1"'(++$12
sensor Hydraulic separators are ideal for use with multiple boiler
boiler systems. Figure 6-25 shows an example.
multiple
system
boiler
controller
system The headers supplying the boilers should be sized
for minimal head loss. A suggested sizing criteria is a
flow velocity of 2 to 4 feet per second when all boiler
circulators are operating.
to loads
The hydraulic separator allows the boiler side flow rate
to be significantly different from the distribution side flow

Figure 6-26

hydraulic

separator

VENT

Courtesy of Coffey Plumbing & Heating

Figure 6-27
rejected heat rejected heat

VFD
chiller #2 chiller #1
HydroCal with

insulation shell
FlowCal valve

motorized

to / from
ball valve purging
chilled-water
valves cooling system

All chilled-water piping must

be insulated and vapor-sealed
VENT

43
rate. It also allows for efficient air and dirt separation
within the system. Figure 6-26 shows an example of this
type of system.
Each boiler has its own circulator and check valve. This
makes it possible to stop flow through boilers that are not
operating, and thus stop unnecessary heat loss. It also
allows for partial heat delivery to the hydraulic separator
if one of the boilers, or one of the boiler circulators, is not
responding.
This piping arrangement is also suitable for multiple
chillers in chilled-water cooling systems, as shown in
Figure 6-27.
Notice that the chilled water from the chillers flows into
the lower side connection of the hydraulic separator.
The somewhat warmer “chilled” water returning from the
distribution system flows into the upper side connection.
This arrangement creates more favorable conditions for
air separation at the top of the hydraulic separator and
minimizes the potential for dirt being carried into the
chillers.
This piping arrangement uses a motorized ball valve on
each chiller that opens only when that chiller is active.
The variable frequency drive (VFD) operates the chiller
circulator as necessary to maintain a nearly constant
differential pressure across the headers serving the
chillers. This reduces the input power to the chiller
circulator under partial load conditions.
Caleffi FlowCal balancing valves are used to maintain the
present flow rate through each chiller when it is active.
44
/1.#4"326(3'(-3$&1 3$#
'8#1 4+("2$/ 1 3(.-
The principle of hydraulic separation combined with
uniform supply water temperature to distribution circuits
is desirable in both large and small hydronic systems.
Caleffi Hydro Separators are ideal for medium to large
systems. Currently available models range from 1-inch to
12-inch pipe size connections.
For smaller systems, Caleffi offers products that integrate
the principle of hydraulic separation with the functionality
of distribution headers. One example is the Caleffi
HydroLink, shown in Figure 7-1.
Figure 7-1
The HydroLink provides a chamber to hydraulically
separate the boiler circuit from the distribution circuits.
It also provides a self-contained manifold station that
supplies up to four independently controlled load
circuits with the same supply temperature. These
features and their equivalent piping are shown in
Figure 7-2.
A critical detail within the HydroLink is the hydraulic
separation chamber on the left side of the unit. This
chamber is separated from the manifold chambers
by a baffle plate with two closely spaced openings.
Given their size and placement, these openings act
similarly to a pair of closely spaced tees, eliminating
any significant pressure differential between the upper
and lower manifold chambers. This prevents flow
in the boiler circuit from inducing flow in any of
the distribution circuits connected to the manifold
chamber.
The HydroLink is available in several models with differing
numbers and placement of the manifold connections.
Figure 7-4 shows some of the combinations.
 Figure 7-2

opening


closely

opening spaced

tees

s
lace
rep

hydraulic

separation

chamber
THIS
vent
s
lace
rep

HYDROLINK

closely

spaced

tees

drain

Figure 7-3 Figure 7-4

A typical configuration for the HydroLink has the heat
source connected to the “primary” chamber piping
on the left side of the unit, along with several load
circuits connected to the other “secondary” connections
that connect into the manifold chamber. Two additional
tapped connections are provided in the top and bottom
of the primary chamber for mounting an air vent and drain
valve/makeup water assembly, as shown in Figure 7-5.
The HydroLink product is supplied with a form-fitting
insulation shell to minimize heat loss.

45
 Figure 7-5 Figure 7-7
boiler

vent
circulators w/

check valves
HydroLink

purge

drain
VENT

valves
circulator

mixing

valve

hydraulic separation tube

Figure 7-6

Caleffi also offers distribution manifold stations with

integrated hydraulic separation details, an example
of which is shown in Figure 7-7.

The small tube that connects the supply and

return piping just above the isolation ball valves
provides hydraulic separation between the
circulator supplying flow from the heat source to
the distribution manifold station and the circulator
integrated into the distribution manifold station.
This allows two or more distribution manifold
stations to be piped as shown in Figure 7-8.

Each manifold station is supplied from a common

header system. A zone valve opens whenever its
associated distribution manifold station requires
heat. The Caleffi FlowCal pressure-independent
valves maintain the desired flow rate to each manifold

46
 Figure 7-8
distribution
manifold station distribution manifold station

variable-speed

pressure-regulated
FloCal FloCal
circulator
zone valve zone valve

purging valve

station. The “crossover” tubes just above the isolation
ball valves on each manifold station allow hydraulic
separation between the built-in manifold station circulator
and the variable-speed pressure-regulated circulator that
supplies flow in the headers. This arrangement also allows
the option of continuous flow through the distribution
circuits connected to the manifold stations. The mixing
valve within each distribution manifold station allows the
possibility of high-temperature supply water from the
header system. This, in combination with the relatively
low return water temperature that is typical of many
radiant panel systems, allows a low flow rate between the
headers and manifold station, which minimizes pipe size
and circulator power requirements.

47
 the SEP4 separator and flowing onward to the space-
$7 ,/+$2823$,2
heating zones. This allows the boiler to respond to
any variations in the water temperature supplied to the
This section shows several examples of how air, dirt and
distribution system. The secondary circulator operates in
hydraulic separation can be applied in modern hydronic
a constant differential pressure mode and automatically
heating and cooling systems.
changes speed as required depending on the number
of active space-heating zones. Each zone circuit is
$7 ,/+$2823$,ū equipped with a Caleffi FlowCal balancing valve to assure
The system shown in Figure 8-1 uses a modulating/
properly proportioned flow.
condensing boiler to supply two zones of low-temperature
radiant panel heating, as well as an indirect domestic
Upon a call for domestic water heating, the ZVR103
water heater.
operates the boiler in setpoint mode to create a higher
supply water temperature, which allows for full boiler
The limited zoning in this system provides a good match
output to be transferred to the heat exchanger coil inside
between the modulating output of the boiler and the
the indirect water heater. The ZVR103 also turns off the
space-heating loads. Thus, the system is able to operate
system circulator, temporarily stopping any heat transfer
without a buffer tank.
to the space-heating zones.
Upon a demand for heating from either zone thermostat,
The SEP4 provides hydraulic separation between the
the Caleffi ZVR103 relay center powers on the associated
fixed-speed system circulator and the variable-speed
zone valve and turns on the variable-speed pressure-
secondary circulator. It also provides high-efficiency air
regulated secondary circulator, as well as the system
and dirt separation, including magnetically enhanced dirt
circulator. The boiler operates based on outdoor reset
separation. The latter is desirable because of the high-
control and monitors the temperature of the water exiting
efficiency circulator used in the system.

Figure 8-1

mod/con
ZVR103
boiler

outdoor

temperature

sensor
Quicksetter

balancing
valves

DHW

CW

secondary

SEP4 circulator

system

circulator

priority

circulator
indirect water heater

48
$7 ,/+$2823$,ū
The system shown in Figure 8-2 uses a single modulating/
condensing boiler to supply space heating and domestic
hot water.
Space heating is supplied by several panel radiators,
each of which is equipped with a thermostatic radiator
valve allowing it to operate independently of the other
panels. Because of the extensive zoning, a small buffer
tank is used to prevent boiler short cycling. This buffer
tank, when piped as shown, also provides hydraulic
separation between the boiler circulator and the variable-
speed pressure-regulated distribution circulator.
A vertical Discal air separator is mounted just below the
boiler’s outlet port, where the water is hottest and near it
lowest pressure. This encourages microbubble formation,
capture and elimination from the system.
A float-type air separator is mounted at the top of the
buffer tank to prevent air entrapment.
Manual air vents are located in the upper left corner of
each panel radiator to expedite air removal at system
commissioning.
Figure 8-2
mod/con boiler
Discal
DHW
DirtMag
temperature

sensor

(in well)
pressure-regulated

distribution circulator
temperature

sensor

(in well)
indirect water heater ThermoCon

buffer tank
A DirtMag separator with an integral magnetic collar is
mounted on the piping leading into the boiler and boiler
circulator. Its use helps ensure that the high-efficiency
variable-speed circulator, as well as the small heat
exchanger passages inside the boiler, remain clear of
ferrous metal particles and other debris.
Domestic hot water is heated by an indirect water heater
that is controlled as a priority load by the boiler’s internal
control circuitry.
$7 ,/+$2823$,ū
Hydraulic separators can be well-applied in modern
geothermal heat pump systems. One example is shown
in Figure 8-3.
The HydroCal separator shown in Figure 8-3 provides
hydraulic separation between the earth loop circulator
and the variable-speed pressure-regulated circulator
that provides flow to the heat pumps. This allows for a
different flow rate in the earth loop compared to those
to the heat pump array. The flow rate to the heat pump
array is controlled by the variable-speed pressure-
regulated circulator, which responds to the opening and
TRV TRV
thermostatic

radiator valves

(TRV) on each

radiator
TRV TRV
variable-speed

TRV
VENT
49
 closing of zone valves or motorized
Figure 8-3 ball valves on each heat pump.
The earth loop circulator could

 



also vary its speed in response to

 



some control criteria, such as the


 
temperature drop or rise across
the earth loop connections to the
hydraulic separator. This allows the

  

power required by the earth loop
circulator to be reduced as the
TXV number of operating heat pumps
decreases.

 



 


 
!

The HydroCal separator also



provides high-performance air and
  dirt removal from the earth loop
and heat pump array portions of
the system. The latter function is
  


especially useful given the likelihood

of dirt and debris entering the earth
TXV
loop piping during construction.
 




$7 ,/+$2823$,ū
The system shown in Figure 8-4


 
uses a Caleffi HydroLink as the
“hub” of a multi-temperature/multi-
load system.
  


The conventional boiler supplies

  heat to the hydraulic separation
TXV

  
chamber in the HydroLink. This

 
 hydraulically separates the
boiler circulator from the other
  

 

circulators. The water temperature
  supplied to the boiler is regulated
by a Caleffi 3-way ThermoMix
 
boiler protection valve. This


 
  ensures the boiler does not operate
with low inlet water temperatures
! 
that could cause sustained flue
   gas condensation.

Two of the loads attached to the

" 


HydroLink are supplied through


   Caleffi HydroMixers. These modules
  

  include a mixing valve, circulator
 

 and differential pressure bypass
valve. The mixing valve reduces the
water temperature to that required
by the low-temperature radiant
panel circuits. The differential
#

pressure bypass valve modulates
 
to maintain a reasonably steady
differential pressure across

50
 Figure 8-4
to/from zones to/from zones

manifold valve
actuators on
each circuit

low supply water
medium supply water

temperature circuits temperature circuits

integral P bypass valve

HydroMixers
vertical Discal

air separator future

load

HydroLink

3-way
thermostatic
mixing valve

VENT

air handler

indirect water heater conventional boiler

vertical DirtCal separator

the manifold station as the manifold valve actuators
open and close in response to zone thermostats. The
supply water temperature from each HydroMixer can be
independently adjusted. The mixing can be done with
either a thermostatic valve or motorized 3-way valve.
The HydroLink also supplies hot water directly to the coil
of an air handler, which operates as a separate zone.
The indirect water heater is operated as a priority load.
It is not connected through the HydroLink. This reduces
the amount of piping and water that must be heated
during a call for domestic water heating. It also allows
the domestic water heating mode to operate with a
single circulator.
To minimize thermal migration, spring-loaded check valves
are provided in the piping returning to the boiler from both
the indirect water heater and from the HydroLink.
A vertical Discal air separator provides high performance
air separation whenever heated water is flowing from the
boiler. Likewise, a vertical Dirtcal separator provides dirt
separation for all flow about to pass into the boiler.

51
 boiler #1 boiler #2
Figure 8-5
mixing mixing
VENT
expansion boiler #4
tank
$7 ,/+$2823$,ū
The heating loads in large buildings are often supplied from
a multiple boiler system. The water temperature required for
space heating is determined by the type and size of heat
emitters used in the distribution system. When convectors
or air handlers are selected as the heat emitters, the water
temperature required under design load conditions is
relatively high, often in the range of 170º to 190ºF. However,
under partial load conditions, the supply water temperature
can be reduced using outdoor reset control.
When the water temperature returning from the
distribution system is approximately 130ºF or lower,
some condensation forms on the combustion side of the
boiler heat exchangers. This is beneficial if a modulating/
condensing boiler is supplying heat, but must be avoided
if a conventional boiler is supplying heat. Thus, when
the system is operating at part load with low to medium
supply water temperature, it is beneficial to supply the
required heat using a modulating/condensing boiler.
However, as outdoor temperature drops, the required supply
water temperature increases along with the increasing
52
low-head-
loss headers
system

circulator
boiler #3 HydroCal
load. If modulating/condensing boilers are operating, they
will eventually stop condensing and provide almost the
same thermal efficiency as conventional boilers.
This situation can be well served by a “hybrid” multiple
boiler system that includes both modulating/condensing
boilers and conventional boilers. An example of such a
system is shown in Figure 8-5.
Under low to medium load conditions, mod/con boilers
#1 and #2 provide heat to the system. During this time,
the system water temperatures are low enough to
allow these boilers to operate with sustained flue gas
condensation, and thus high thermal efficiency. As the
load and required supply water temperature increases,
boiler #3 and eventually boiler #4 are brought online.
Boilers #1 and #2 continue to operate, but not in a
condensing mode. As such, they contribute heat to the
load at approximately the same thermal efficiency as the
conventional boilers. This approach reduces overall boiler
plant cost because it uses less expensive conventional
boilers with efficiency comparable to that of a mod/con
boiler operating in non-condensing mode.
Figure 8-5 shows how a larger Caleffi HydroCal separator Figure 8-7
can be used in combination with low-head-loss headers
to combine these boilers. The HydroCal unit provides
hydraulic separation between the boiler circulators and
the system circulator. It also provides high-efficiency air
and dirt separation for the system. The low-head-loss
headers in combination with the HydroCal separator
provide hydraulic separation between the individual boiler
circulators.

Note that boilers #3 and #4 include a high-flow-capacity

3-way thermostatic mixing valve. This ensures that the
inlet water temperature to these boilers remains above
the dewpoint of their exhaust gases, and thus the boilers
will operate without sustained flue gas condensation.

The firing order of boilers #1 and #2 can be rotated to

allow each boiler to accumulate approximately the same
number of run hours over the course of a heating season.
This can also be done for boilers #3 and #4.

Figure 8-6 shows an example of a hybrid multiple boiler

system using two modulating/condensing boilers as the
“lead stages,” and three conventional boilers as stages
3, 4 and 5. The insulating piping above the boiler leads to
the hydraulic separator seen wrapped with insulation at
the far left of the photo.
Figure 8-6
Courtesy of GOES Heating Systems

If the hydraulic separator is used for a chilled-water

cooling system, or as part of a geothermal earth loop
system, the insulation should include a vapor barrier to
prevent condensation on the surface of the separator.

24,, 18
For optimal performance, modern hydronic systems
require several types of separating devices. These
include air separation, dirt separation, and in many
cases, hydraulic separation. The latter eliminates
undesirable interaction of simultaneously operating
Courtesy of GOES Heating Systems circulators. This issue of idronics has discussed the best
available technology for providing these functions. When
properly implemented, these functions allow the system
Figure 8-7 shows another example of a large (8” pipe size)
to operate without the detrimental effects of entrapped
Caleffi hydraulic separator that has been fully insulated.
air, accumulating debris and inconsistent flow.
Large hydraulic separators have several square feet of
surface area. Without insulation, this surface area would
create a high rate of heat loss and needlessly overheat
the mechanical room.

53
 //$-#(7 /(/(-&28,!.++$&$-#

GENERIC COMPONENTS CALEFFI COMPONENTS

 "
#

circulator !
  
 


  

circulator w/
 "
#

 
$ 

!
  inline check valve
manifold station with
balancing valves
union
$ "
 "


circulator w/

  
!

 

 
 

 
$ 

swing check valve

! "):-4

spring-loaded

VENT
preventer
gate valve check valve
pressure-
reducing
distribution

globe valves purging valve valve station

ball valve pressure-

reducing
Starmax V


  valve solar collector
(3/4")
primary/secondary

911(,&
pressure
relief zone valve

(2 way) geothermal

valve
manifold

hose bib
station
drain valve pressure &
temperature
relief valve zone valve

(3 way) thermostatic

diverter tee
radiator valve

cap metered
thermoelectric
ThermoCon

balancing thermostatic

zone valve
buffer

valve radiator valve
(2 way) tanks (4 sizes)

dual isolation

  "

valve for

brazed-

! 
  panel radiators
plate

heat
differential

exchanger pressure

bypass valve

DIRTCAL

 
  
dirt


 

 
  separators

Comp.
DIRTMAG

dirt

separators Hydro
SEP4
Separator
heating mode

reversible
HydroCal
water-to-water
Separator
heat pump

DISCALDIRT
DISCALDIRTMAG

reversing
conventional boiler HydroCal
valve air & dirt
air & dirt

Separator
separator separator
evaporator

condenser

FLOCAL
DISCALDIRT

balancing
air & dirt
mixing units

TXV valve separator 
"-,9&2/ 1(-,0

QuickSetter

balancing
solar

valve w/
circulation

:-4+$1$/ station

motorized

ball valve

(2 way)
Modulating / condensing boiler

motorized
6#/-*(,)

"-,9&2/ 1(-,0

ball valve

(3 way)
high-temperature

high-temperature
solar 3-way thermostatic

solar DISCAL
mixing valve
air separators

isolar

differential

high-temperature
temperature

solar pressure

  controller
relief valve

high-temperature
high-
solar air vent temperature

ThermoBloc™
solar

high-temperature
expansion

shut-off valve for
tank
4--#9/$#
!-(*$/ solar air vent
indirect water heater (with trim)

54
FlowCal™ Y-strainer

120 series CALEFFI

3DBGQDE

Function
The FlowCal™ 120 series Y-strainers include a combination Y-strainer
with integral brass ball valve. Inspection, cleaning and replacing the
strainer cartridge can be done easily without removing the body from
the pipeline. All configurations are available with optional factory-
installed pressure and temperature test ports. Drain valves are also
available as an accessory for installing in the drain port connection.

Product range
120 series FlowCal™ Y-strainer with connections............... 1/2", 3/4", 1", 1-1/4" NPT female union x NPT female union; sweat union x sweat
538202 FD Drain valve for field installation in 1/2", 3/4" 120 series drain port...........................................................connection 1/4" NPT male
538402 FD Drain vlave for field installation in 1", 1-1/4" 120 series drain port...........................................................connection 1/2" NPT male
NA10233 Fast-plug pressure/temperature test port for 120 series Y-strainer, standard length 1-1/2".....................connection 1/4" NPT male
NA10235 Fast-plug pressure/temperature test port for 120 series Y-strainer, extended length 2-1/4".....................connection 1/4" NPT male

Technical specifications Dimensions

E
Connections - main: 1/2", 3/4", 1", 1-1/4" NPT female union x
NPT female
D

1/2", 3/4", 1", 1-1/4" sweat union x sweat

- drain port: 1/2", 3/4" 120 series 1/4" NPTF
A

A
FFI
LE
CA

1", 1-1/4" 120 series 1/2" NPTF

C

- PT test ports: 1/4" NPTF

F

Materials - body: brass

B
- strainer cartridge: stainless steel
- seals: EPDM Code A B D E F
C Weight (lb)
- ball: brass, chrome-plated 12014 ... 1/2" 6 3/16” 1 15/16” 1 15/16” 3 15/16” 1/4" 3.00
- ball and control stem seal: PTFE 12015 ... 3/4" 6 1/4” 1 15/16” 1 15/16” 3 15/16” 1/4" 3.00
- lever: special zinc-plated steel 12016 ... 1" 8 5/8” 3 3/4” 2 5/8” 4 3/4” 1/2" 6.00
Performance 12017 ... 1 1/4" 8 11/16” 3 3/4” 2 5/8” 4 3/4” 1/2" 6.00
Suitable fluids: water and non-hazardous glycol solution up to 50%
Max. working pressure: 400 psi (400 WOG)
Working temperature range: 32–212°F
Strainer mesh diameter: 0.87 mm (20 mesh)
Cv: 1/2": 8.0; 3/4" : 8.4; 1" : 19; 1-1/4": 20
Identification: metal plate with ball chain stating mesh size

55
 ®
dirt separator

mm- RDQHDR CALEFFI

3DBGQDE
Function
In heating and air conditioning control systems, the circulation of
water containing impurities may result in rapid wear and damage
to components such as pumps and control valves. It also causes
blockages in heat exchangers, heating elements and pipes, resulting in
lower thermal efficiency within the system.
The dirt separator separates off these dirt particles which are mainly
made up of particles of sand and rust, collecting them in a large
collection chamber, from which they can be removed even while the
system is in operation. This device is capable of efficiently removing even
the smallest particles, with very low head loss.
Insulation shells are available separately for field installation on 5462 series
horizontal brass DIRTCAL®.

Product range
5462 series DIRTCAL® dirt separator for horizontal pipes, in brass.....................................connections 3⁄4" to 2" NPT female and 1" to 2" sweat
5465 series DIRTCAL® dirt separator for horizontal pipes, in steel..................................................................connections 2" to 4" ANSI flanged
NA5465 series DIRTCAL® dirt separator for horizontal pipes, in steel, ASME & CRN...........................................connections 2" to 6" ANSI flanged

Technical specifications
Brass DIRTCAL®
,@SDQH@KR - body, dirt collection chamber and top plug:
 - internal element:
- seal:
 - drain valve:
/DQENQL@MBD
Suitable fluids:
Max. percentage of glycol:
Max. working pressure:
Temperature range:
Particle separation efficiency:
"NMMDBSHNMR - main:
 - top:
 - drain:
 - vertical:
Steel DIRTCAL®
brass ,@SDQH@KR- body: epoxy resin painted steel
glass reinforced nylon PA66G30 - internal element: stainless steel
EPDM  - hydraulic seal: fiber
brass  - drain valve: brass
/DQENQL@MBD
Suitable fluids: water, glycol solution
water, glycol solution Max. percentage of glycol: 50%
50% Max. working pressure: 150 psi (10 bar)
150 psi Temperature range without insulation: 32—250°F (0—120°C)
32–250°F Particle separation capacity: to 5 μm (0.2 mil)
to 5 μm "NMMDBSHNMR - flanged: 2"– 6" ANSI B16.5 150 CLASS RF
3/4", 1", 1-1/4", 1-1/2" and 2" NPT female  - top: 3/4" M (with plug)
1", 1-1/4", 1-1/2" and 2" sweat  - drain: 1" NPT
1/2" F (with plug)
3/4" garden hose connection FDMBX@OOQNU@K - NA5465 series designed and built in accordance
hose connection with Section VIII, Division 1 of the AMSE Boiler and Pressure Vessel
Code and tagged and registered with the National Board of Boiler and
Pressure Vessel Inspectors, CRN Registered.

56
Operating principle
The dirt separator operating principle
is based on the combined action of a
number of physical phenomena. The
internal element (1) is composed of a
set of concentric diamond pattern mesh
surfaces. The dirt in the water strikes
these surfaces, separates and drops
into the bottom of the body (2) where
they collect. In addition, the large internal
volume of DIRTCAL® slows down the
velocity of the medium and with the
help of gravity, separates the contained
particles.
The collected dirt can then be
discharged, even with the system
running, by opening the drain valve (3)
with the handle (4).
Dimensions
NPT
B Sweat
Separation efficiency
The capacity for separating the dirt in the medium circulating in the
closed circuits of the hydronic systems depends on three factors:
1
1. It increases as the size and mass of the dirt particle increases.
The larger and heavier dirt particles drop before the lighter ones.
2. It increases as the fluid velocity decreases. If the velocity decreases,
there is a low-velocity-zone inside the dirt separator and the dirt
particles separate more easily.
2 3. It increases as the number of recirculations increases. The medium
in the circuit, flowing through the dirt separator a number of times
3 during operation, is subjected to a continuous separation, until the
dirt particles are completely removed.
4 The special design of the internal mesh element in the Caleffi DIRTCAL®
dirt separator, is able to completely separate the dirt particles in
the circuit down to a minimum particle size of 5 μm (0.2 mil). The
 adjacent graph illustrates how DIRTCAL® quickly separates nearly all
the dirt particles. After only 50 recirculations, approximately one day
of operation, up to 100% is effectively removed from the circuit for
particles of diameter greater than 100 μm (3.9 mil) and on average up
to 80% taking account of the smallest particles. The continual passing
of the medium during normal operation of the system gradually leads to
complete dirt removal.
B

Particle separation capacity — dirt separator efficiency

2”

2”
A
A

Efficiency (%)
Efficiency Efficiency
( Separated quantity
Initial quantity
.100%) 50 passages (1.6 f/s) 50 passages (3.2 f/s)
C

100

80
1¼”

1¼”

60

40

"NCD ! C 6S KA
20
05A ⁄4" NPT
3
45⁄16" 5" 4.2
0
06A 1" NPT 45⁄16" 5" 4.2
particle
Micro

(Δm)

1000
105

150

210
250

500
16

35

63
10

20

50
5
0

07A 11⁄4" NPT 47⁄8" 6" 5.3

WORKING ZONE
08A 1 ⁄2" NPT
1
4 ⁄8"
7
6" 6.2
DIRTCAL
09A 2" NPT 51⁄8" 6" 6.2 CARTRIDGE FILTER

28A 1" SWT 51⁄16" 5" 4.2

SPECIAL FILTER
35A 11⁄4" SWT 53⁄16" 6" 4.2
Y-STRAINERS
41A 11⁄2" SWT 53⁄4" 6" 4.9
54A 2" SWT 61⁄8" 6" 5.5

B "@O 
G "NCD ! C # $ % & ' J* * 6S KA
F@K
50A 2" 133⁄4" 1" 143⁄4" 247⁄16" 6 5⁄8" ⁄4"
3
6" 6 5⁄16" 12" 1.8 29
60A 2 ⁄2"
1
13 ⁄4"
3
1" 14 ⁄4" 24 ⁄16" 6 ⁄8"
3 7 5
⁄4"
3
7" 6 ⁄16"
5
12" 1.8 32
80A 3" 183⁄8" 1" 171⁄8" 291⁄8" 8 5⁄8" ⁄4"
3
71⁄2" 7 5⁄16" 13 3⁄8" 4.8 51
H

BI-DIRECTIONAL

Tmax 110 C Tmax 105 C

Pmax 10 bar Pmax 10 bar

10A 4" 181⁄2" 1" 171⁄8" 291⁄8" 8 5⁄8" ⁄4"

3
9" 7 5⁄16" 13 3⁄8" 4.8 54
E

- 50A 2" 13 ⁄4"

3
1" 16 ⁄16" 23 ⁄8"
5 7
6 ⁄8"
5
⁄4"
3
6" 6 5⁄16" 12" 1.8 38
K

- 60A 21⁄2" 133⁄4" 1" 16 5⁄16" 237⁄8" 6 5⁄8" ⁄4"

3
7" 6 5⁄16" 12" 1.8 38
D

- 80A 3" 18 ⁄8"

3
1" 20 ⁄16" 30 ⁄8"
11 5
8 ⁄8"
5
⁄4"
3
7 ⁄2"1
7 ⁄16" 13 ⁄8"
5 3
4.8 55
- 10A 4" 183⁄8" 1" 2011⁄16" 30 5⁄8" 8 5⁄8" ⁄4"
3
9" 7 5⁄16" 13 3⁄8" 4.8 55
- 12A 5" 25" 1" 23 ⁄16" 34 ⁄16" 12 ⁄4"
3 15 3
⁄4"
3
10" 9 ⁄8" 17 ⁄16"
3 3
13.7 138
C
F - 15A 6" 25" 1" 23 3⁄16" 3415⁄16" 12 3⁄4" ⁄4"
3
10" 9 3⁄8" 17 3⁄16" 13.7 148
*This dimension allows for a minimum of 3" wall clearance to accommodate insulation if used.

57
 ®
DISCAL
air and dirt separator
m- RDQHDR CALEFFI
3DBGQDE

Function
Air and dirt separators are used to continuously remove the air and debris
contained in the hydronic circuits of heating and cooling systems. The air
discharge of these devices is very high. They are capable of automatically
removing all of the air present in the system down to the micro-bubble
®
level. The DISCALDIRT air and dirt separator also separates any solid
impurities in the system. The impurities collect at the bottom of the device
and can be removed through the drain pipe for the steel versions, to which
a separately sourced drain valve can be mounted, or drain shut-off valve
for the brass version. The circulation of fully de-aerated and cleaned water
enables the equipment to operate under optimum conditions, free from
noise, corrosion, localized or mechanical damage.
Insulation shells are available separately for field installation for the brass
®
DISCALDIRT air and dirt separators.

Product range
®
5460 series DISCALDIRT air and dirt separator in brass..........................................................connections 3/4", 1", 1-1/4" sweat & 1" NPT male
®
546 series DISCALDIRT air and dirt separator in steel with flanged connections..........................................................connections 2"–6" ANSI
®
NA546 series DISCALDIRT air and dirt separator in steel with flanged connections...................................................connections 2-1/2"–12" ANSI
*Prefix NA are designed and built in accordance with Section VIII, Division 1 of the ASME Boiler and Pressure Vessel Code and
tagged and registered with the National Board of Boiler and Pressure Vessel Inspector; CRN registered

Technical specifications
Brass DISCALDIRT® Steel DISCALDIRT®
,@SDQH@KR - body: brass ,@SDQH@KR - body: epoxy resin painted steel
- dirt separation chamber: brass - air vent body: brass
- air vent body: brass - internal element: 304 stainless steel
- internal element: glass reinforced nylon, PA66GF30 - air vent float: PP
- air vent float: PP - air vent float guide pin: stainless steel
- air vent float guide pin: stainless steel - air vent float linkages: stainless steel
- air vent float linkages: stainless steel - spring: stainless steel
- spring: stainless steel - seals: EPDM
- seals: EPDM - side drain shut-off valve: brass
- drain shut-off valve: brass /DQENQL@MBD
Suitable fluids: water, glycol solution
/DQENQL@MBD Max. percentage of glycol: 50%
Suitable fluids: water, glycol solution Max. working pressure: 150 psi
Max. percentage of glycol: 50% Temperature range: 32–250°F
Max. working pressure: 150 psi Particle separation efficiency: to 5 μm (0.2 mil)
Temperature range: 32–250°F "NMMDBSHNMR - flanged (ASME & CRN registered):
Particle separation efficiency: to 5 μm (0.2 mil) 2"–12" ANSI B16.5 150 CLASS RF
- flanged: 2"–6" ANSI B16.5 150 CLASS RF
"NMMDBSHNMR - main: 3/4", 1", 1-1/4" sweat; 1" NPT male - drain pipe: 2"–6": 1" NPT male
- drain shut-off valve: hose connection 8"–12": 2" NPT male

58
Dimensions
F
C
B
C 3 1/8”

D
E

38552
A

E
F

A
D

H
G
B

"@O  6S KA
"NCD ! C # $ % & ' F@K
050A 2" 13 ⁄4"
3
2 ⁄16"
3
14 ⁄16"
9
28 ⁄4"
1
6 ⁄8"
5
1" 13 ⁄16"
11
3.6 39.7
060A 2 1⁄2" 13 3⁄4" 2 3⁄16" 149⁄16" 281⁄4" 6 5⁄8" 1" 1311⁄16" 3.6 41.9
6S 
"NCD "NMMDBSHNMR ! C # $ % 080A 3" 18 3⁄8" 2 3⁄16" 17" 341⁄2" 8 5⁄8" 1" 17 1⁄2" 7.6 72.7
KA
95A Sweat 3
⁄4" 7 3⁄8" 2 1⁄8" 5" 51⁄2" 12 3⁄4" 8.3 100A 4" 18 1⁄2" 2 3⁄16" 17" 341⁄2" 8 5⁄8" 1" 17 1⁄2" 7.8 77.1

96A Sweat 1" 7 ⁄8"

3
2 ⁄8"
1
5" 5 ⁄2"
1
12 ⁄4"
3
8.3 120A 5" 25" 2 3⁄16" 211⁄16" 4611⁄16" 12 3⁄4" 1" 25 5⁄8" 22.4 180.7

16A NPT male 1" 7 3⁄8" 2 1⁄8" 5" 51⁄2" 12 3⁄4" 8.3 150A 6" 25" 2 3⁄16" 211⁄16" 4611⁄16" 12 3⁄4" 1" 25 5⁄8" 23.0 187.3
*Add prefix NA to flanged code number when ordering ASME tagged and registered with the
97A Sweat 11⁄4" 6 3⁄16" 2 1⁄8" 5" 51⁄2" 12 3⁄4" 8.3
National Board of Boiler and Pressure Vessel Inspector and CRN registered.

F Operating principle
3 1/8”

C ,HBQNATAAKD@HQRDO@Q@SHNM
3 1/8” The air and dirt separator uses the
combined action of several physical
principles. The active part is the
D

internal element (1) and consists of a

38552

glass-reinforced nylon mesh for the

brass DISCALDIRT ®, or an assembly
E

of concentric metal mesh ( 304

A

stainless steel) surfaces for the steel

DISCALDIRT ®. These elements create
the whirling movement required to
facilitate the release of micro-bubbles
and their adhesion to these surfaces.
H

The bubbles, fusing with each other, increase in volume until the
hydrostatic thrust is such as to overcome the adhesion force to the
structure. They rise towards the top of the unit from which they are
released through a float-operated automatic air vent valve.
,HBQNO@QSHBKDCHQSRDO@Q@SHNM
®
G The DISCALDIRT dirt removing element
separates and collects any impurities present
B
in the system. Impurities in the fluid upon
striking the surfaces of the DISCALDIRT ® 1

"@O  6S  inter nal element (1), get separated and

"NCD ! C # $ % & ' J F@K KA
- 200A 8" 35 7⁄16" 2 3⁄16" 35 3⁄16" 75 3⁄8" 20" 2" 43 3⁄16" 92 3⁄4" 95 355 drop to the bottom of the body in the dirt
- 250A 10" 413⁄4" 2 3⁄16" 38 9⁄16" 8613⁄16" 26" 2" 481⁄4" 1011⁄16" 175 555 collection chamber (2) where they collect.In
- 300A 12" 46 7⁄16" 2 3⁄16" 411⁄8" 93 11⁄16" 30" 2" 52 9⁄16" 107 5⁄16" 255 825 addition, the large internal volume of slows
*Add prefix NA to flanged code number when ordering ASME tagged and registered with the down the velocity of the fluid thus helping, by 2

National Board of Boiler and Pressure Vessel Inspector and CRN registered. gravity, to separate the particles it contains.
-.3$ Drawings may not reflect the actual size of the separators. The collected impurities are discharged, by 3

opening the drain valve (3), even with the

system operating.
!Q@RR#(2" +#(13 ®

59
Automatic air vent
for heating systems and radiators
      RDQHDR CALEFFI
3DBGQDE
Function
Automatic air vents are designed to remove trapped air that
accumulates in heating and air conditioning systems automatically.
Air removal enhances performance and life of a system by reducing
the affects of:
- corrosion due to the oxygen;
- pockets of air trapped in the heating emitters;
- cavitation in the circulation pumps.
- service check valve allows an easy replacement of air vent without
purging the system (except 5080).

Series 501
Extra high capacity float type automatic air vent designed for use on
large pipes where large quantity of air is required to be released from
the system.
Series 5022 - 5023
High capacity float type automatic air vent designed for use on
manifolds or pipes in sealed heating systems.

Series 5020 - 5021 - 5026 - 5027

Float type automatic air vent designed to vent air that is released from
the water while being heated.

Series 5080
Radiator air vent valve designed to remove automaticall any air
trapped inside the heat emitters both during the filling of the system
and in normal operation.
Product range

501 series Extra high capacity automatic air vent..................................................................................................connections 3/4" NPT female
5020 series `MINICAL® automatic air vent..................................................................................................................connections 1/8" NPT male
5021 series MINICAL® automatic air vent with service check valve............................................................................connections 1/8" NPT male
5022 series High capacity automatic air vent............................................................................................................connections 1/2" NPT male
5023 series High capacity automatic air vent with service check valve.......................................................................connections 1/2" NPT male
5026 series Automatic air vent .......................................................................................................................connections 1/8" - 1/4" NPT male
5027 series Automatic air vent with service check valve...................................................................................connections 1/8" - 1/4" NPT male
5080 series Automatic hygroscopic air vent for radiators...........................................................................................connections 1/8" NPT male

Series 501 MINICAL® 5020-5021 5022 - 5023 5026 - 5027 5080

Materials
Body: brass brass brass brass chrome plated brass
Float: stainless steel polypropylene PP PP -
Mechanism stem: stainless steel brass brass - -
Mechanism seal: viton - EPDM silicon rubber -
Seals: EPDM EPDM EPDM EPDM EPDM
Performance
Max working pressure: 230 psi 150 psi 150 psi 150 psi 150 psi
Max venting pressure: 90 psi 40 psi 60 psi 90 psi -
Max working 502015A 250°F
250°F 250°F 240°F 212°F
temperature: 502115A 230°F

60
 C
C

F
A

E
B

E
B
C

E
D
A

B
B’
E’
A

B’
E’

D
D
A
A

D
Code A B C D E F
502015A 1/8” NPT 3 1/8” 17/8” 3/8” 2 3/4 ” A
B
C Code A B C D E’
Code A B C D E
D 502115A 1/8”NPT 3 11/16” 17/8” 3/8” 3 5/16”
502610A 1/8” 3 1/16 ” 1 9/16 ” 7/16 ” 2 5/8 ”
Code A B C D E 502620A 1/4” 3 1/16 ” 1 9/16 ” 1/2” 2 5/8 ”
502243A 1/2”NPT 4” 2 3/16” 1/2” 2 1/2 ”
Code A B’ C D E’
Code A B C D E F Code A B’ C D E’ 502710A 1/8” 4” 1 9/16 ” 1/2” 3 3/8 ” Code A B C D E F
501502A 3/8” 3/4” 1 9/16 ” 3 13/16” 6 1/4” 5 5/16 ” 502343A 1/2”NPT 4 3/4 ” 2 3/16 ” 1/2” 3 1/4” 502720A 1/4” 4” 1 9/16 ” 1/2” 3 3/8 ” 508013A 1/8” 1 1/4 ” 11/16 ” 7/16 ” 13/16 ” 9/16 ”

Operation
Air flow
The accumulation of air bubbles in the valve
body causes the float to drop so that the air
Flow rate
vent valve opens when the water pressure is
(Nl/s) 5020 - 5021 5022 - 5023 5026 - 5027 (SCFM) (Nl/s)
below the maximum venting pressure rating.
1.2 2.5 1.2
Construction details 1.1 1.1
2.25
1 1
2
,NCDKRVHSGRDQUHBDBGDBJU@KUD 0.9 0.9
The service check valve seals off the vent 0.8 1.75 0.8
body with an EPDM O-ring, allowing easy 0.7 1.5 0.7
maintenance by shutting off the water flow 0.6 1.25 0.6
when the vent is removed. This feature also 0.5 1 0.5
allows for easy inspection of the air vent. 0.4 0.4
,(-(" +® 0.3
0.75
0.3
RDQHDR 0.5
'XFQNRBNOHBB@ONOSHNM@K 0.2 0.2
All MINICAL® models can be equipped with the optional hygroscopic 0.1 0.25 0.1
safety cap, part number R59681. This special cap contains cellulose 0 0 0
fiber discs that form a seal by increasing their volume 50% when

(bar) (psi)
10

20

30

40

50

60

70

80

90
0

they become wet. This prevents potential damage in case of

leakage.
1.5

2.5

3.5

4.5

5.5

6.5
0.5

1.5

2.5

3.5

4.5

5.5
0

RDQHDR Flow rate

The components used for the
elimination of air such as the SCFM 501 (SCFM) (Nl/s)
float, sliding guide zones, spring 5
10 10
and mechanism stem are made 4.5
9 9
of stainless steel. This minimizes 4
8 8
the friction and ensures maximum 3.5
7 7
reliability. 3
6 6
5 5 2.5
The venting air is passed through
2
a forced passage and a filter with 4 4
1.5
a thin mesh strainer. This prevents 3 3
2 2 1
leakage due to debris, that can be 0.5
1 1
deposited between the seat and
0 0 0
the mechanism.
(bar) (psi)
10

20

30

40

50

60

70

80

90


0

The size of this air vent makes it

suitable for applications on large
1.5

2.5

3.5

4.5

5.5

6.5
0.5

1.5

2.5

3.5

4.5

5.5

pipes, particularly on horizontal

0

sections (distribution manifolds in central boilers applications) or

wherever it is required to release large quantities of air from the
system.

61
DISCAL® air separator

551 series CALEFFI

3DBGQDE

Function
Air separators are used to continuously remove the air contained
in the hydronic circuits of heating and cooling systems. The air
discharge capacity of these devices is very high. They are capable of
removing automatically all the air present in the system down to the
micro-bubble level.
The circulation of fully de-aerated water enables the equipment to
operate under optimum conditions, free from noise, corrosion, localized
or mechanical damage. Micro-bubbles, fusing with each other, increase
in volume (get larger) until they become large enough to rise to the top
where they are automatically released.

Product range
551 series DISCAL® air separator for horizontal pipes, in brass with drain.............................................connections 3/4", 1", 1-1/4", 1-1/2" and 2"
551 series DISCAL® air separator for horizontal pipes, in steel with flanged connections and drain......................................connections 2" to 6"
NA551 series DISCAL® air separator for horizontal pipes, in steel with flanged connections with drain, ASME and CRN..........connections 2" to 6"
NA5519 series DISCAL® air separator for vertical pipes, in brass......................................................................connections 3/4" and 1" integral sweat

Technical specifications
Brass air separator Max. working pressure: 150 psi
,@SDQH@KR - body: brass Temperature range: 32–250°F
- internal element "NMMDBSHNMR - flanged: 2"– 6" ANSI B16.5 150 CLASS RF
 - drain pipe: 1" NPT male
(compact & vertical versions): 304 stainless steel
- internal element: glass reinforced nylon PA66GF30 FDMBX OOQNU@K - NA551 series is designed and built in accordance
- seal: EPDM with Section VIII, Division 1 of the ASME Boiler
- air vent float guide pin: stainless steel and Pressure Vessel Code and tagged and
registered with the National Board of Boiler and
/DQENQL@MBD
Pressure Vessel Inspector, and CRN registered.
Suitable fluids: water, glycol solution
Max. percentage of glycol: 50% Dimensions
Max. working pressure: 150 psi
Temperature range: 32–250°F
"NMMDBSHNMR C C C
A
D

D
D

- main:
E

compact series: 3/4" sweat; 3/4" NPT female

A
A

A
B

horizontal: 3/4", 1", 1-1/4", 1-1/2" and 2" NPT female

1", 1-1/4", 1-1/2" and 2" sweat F F
vertical: 3/4" and 1" sweat B A B
- drain valve: 1/2" NPT female G
Steel air separator
,@SDQH@KR - body: epoxy resin painted steel "NCD ! C # $ % 6SKA
- internal element: 304 stainless steel 003A* ⁄4"
3
31⁄16" 2 3⁄16" 5 3⁄8" 6 7⁄8" 1
⁄2" 2.0
- seal: EPDM
- air vent float guide pin: stainless steel 022A* ⁄4" SWT 31⁄16"
3
2 3⁄16" 5 3⁄8" 6 7⁄8" 1
⁄2" 2.0

/DQENQL@MBD - 995 ⁄4"

3
5 ⁄16"
1
2 ⁄16"
3
NA 9 ⁄16"
3 1
⁄2" 4.5
Suitable fluids: water, glycol solution - 996 1" 61⁄16" 2 3⁄16" NA 9 9⁄16" 1
⁄2" 4.5
Max. percentage of glycol: 50%
*Add suffix C to sweat and NPT code number when ordering the brass
DISCAL® to ship with expansion tank service check valve, code 561402A.

62
Dimensions

"NCD ! C # $ % & ' J† 6SKA

F J
**050A 2" 13 ⁄4"
3
1" 14 ⁄4"
3
19 ⁄16"
15
6 ⁄8"
5
2 ⁄16"
13
6" 6 ⁄16"
5
34
G
**060A 21⁄2" 13 3⁄4" 1" 14 3⁄4" 1915⁄16" 6 5⁄8" 213⁄16" 7" 6 5⁄16" 35
**080A 3" 18 ⁄8"
3
1" 17 ⁄8"
1
23 ⁄16"7
8 ⁄8"
5
2 ⁄16"
13
7 ⁄2"
1
7 ⁄16"
5
62

D
**100A 4" 181⁄2" 1" 171⁄8" 23 7⁄16" 8 5⁄8" 213⁄16" 9" 75⁄16" 67
38466.01

WALL
BI-DIRECTIONAL

E
- 120A 5" 25" 1" 21 ⁄16"
7
30 ⁄2" 1
12 ⁄4"
3
2 ⁄16"
13
10" 9 ⁄8" 3
106
Tmax 250ϒF Tmax 220ϒF
Pmax 150 psi Pmax 150 psi

- 150A 6" 25" 1" 217⁄16" 301⁄2" 12 3⁄4" 213⁄16" 10" 9 3⁄8" 117
H

2HYD Ū aŪ Ū Ū Ū Ū
"@O &@K 1.8 1.8 4.8 4.8 13.7 13.7
C **Add prefix NA to flanged code number when ordering ASME tagged and registered with the
B F
National Board of boiler and Pressure Vessel Inspector and CRN registered.
†This dimension allows for a minimum of 3" wall clearance to accommodate insulation if used.

The air separator uses the

C C combined action of several physical
D

principles. The active part consists

E

of an assembly of concentric mesh

A

A
A

surfaces (1). These elements create

A

3 2
the whirling movement required
F F to facilitate the release of micro-
B B
bubbles and their adhesion to these 1
surfaces.
"NCD ! C # $ % 6SKA The bubbles, fusing with each other,
005A* ⁄4"
3
4 ⁄16"
5
2 ⁄16"
3
5 ⁄4"
3
7 ⁄2"
1
⁄2"
1
3.7 increase in size until the hydrostatic
thrust overcomes the adhesion force
006A* 1" 4 5⁄16" 2 3⁄16" 53⁄4" 71⁄2" ⁄2"
1
3.7
to the mesh. They rise towards the
007A* 1 ⁄4"
1
4 ⁄8"
7
2 ⁄16"
3
6 ⁄16"
9
8 ⁄4"
1
⁄2"
1
4.9 top of the unit from which they are
008A* 11⁄2" 47⁄8" 2 3⁄16" 6 9⁄16" 81⁄4" ⁄2"
1
4.9 released through a float-operated
automatic air vent, with stainless
009A* 2" 51⁄8" 2 3⁄16" 6 9⁄16" 81⁄4" ⁄2"
1
5.5 steel float guide pin (3). AQ@RRRDQHDR
028A* 1" SWT 5 ⁄16"
1
2 ⁄16"
3
5 ⁄4"
3
7 ⁄2"
1
⁄2"
1
3.7
Air separation efficiency
035A* 11⁄4" SWT 5 3⁄16" 2 3⁄16" 6 5⁄16" 81⁄4" ⁄2"
1
3.7
DISCAL® air separators continuously remove entrapped air in hydronic
041A* 11⁄2" SWT 5 3⁄4" 2 3⁄16" 6 9⁄16" 81⁄4" ⁄2"
1
4.9
systems with very high efficiency. The amount of air removed from a
054A* 2" SWT 61⁄8" 2 3⁄16" 6 9⁄16" 81⁄4" ⁄2"
1
5.5 system varies depending on fluid velocity and system pressures. As
*Add suffix C to sweat and NPT code number when ordering the brass illustrated on the graph, after just 25 recirculations at the 3.2 feet per
DISCAL® to ship with expansion tank service check valve, code 561402A. second fluid velocity, almost all the air artificially introduced into the
circuit is eliminated by the DISCAL® air separator, with percent removed
varying based on system pressure and fluid temperature.
The small amount which remains is then gradually eliminated during
normal system operation. In conditions where the fluid velocity is slower
Operating principles or the temperature of the medium is higher, the amount of air separated
The DISCAL® air separator is even greater.
is used to continuously Air introduced - Air removed - (%)
remove the air contained in 100

hydronic circuits of heating 90

14.5 psi
and cooling systems. The air 80
29 psi
43.5 psi
discharge capacity is very 70
high. They are capable of 60
removing automatically all 50
the air present in the system
40
down to micro-bubble level
30
with low head loss due the
20
special internal shape of
10
the separator body. Flow
0
direction of the DISCAL® air
100

200

600

700

800

900
300

400

500

1000

1100

1200

(sec)
Tme
0

separator is bidirectional; flow

in either direction is permitted.

63
Hydro separator

548 and NA548 series CALEFFI

Tech ref: 01076

Function
The Caleffi 548 and NA548 series hydraulic separator creates a zone
with a low pressure loss, which enables primary and secondary circuits
connected to it to be hydraulically independent of each other;SGDlNV
HMNMDBHQBTHSCNDRMNS@EEDBSSGDlNVHMSGDNSGDQ 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.
p'XCQ@TKHBRDO@Q@SNQ - To keep connected hydronic circuits totally
independent from each other.
p #HQS QDLNUDQ - To permit the separation and collection of any
impurities present in the circuits. Provided with a valved connection
with discharge piping.
p TSNL@SHB @HQ UDMS U@KUD - For automatic venting of any air
contained in the circuits. Provided with a valved connection for
maintenance purposes.

Product range
548 series Hydro separator in steel with union connections, drain and insulation..........................................................connections 1" to 2"
548 series Hydro separator in steel with flanged connections, drain and insulation.............................................connections 2" to 4" ANSI
NA548 series Hydro separator in steel with flanged connections, drain and insulation ASME and CRN....................connections 2" to 4" ANSI
NA548 series Hydro separator in steel with flanged connections and drain, ASME and CRN...............................connections 5" to 12" ANSI*
*Larger sizes available, consult factory

Technical specifications
Threaded and sweat connections Flanged connections
"NMMDBSHNMR - main: 1", 1¼", 1½", 2" NPT female union "NMMDBSHNMR - main: 2"-12"ANSI B16.5 150 CLASS RF
1", 1¼", 1½", 2" sweat union - drain valve: 2 — 6": 1¼" NPT female
- drain valve: ¾" garden hose thread 8 — 12": 2" NPT female
- thermo well trap: ½" straight thread female - thermo well trap (8 — 12" only):
,@SDQH@KR - separator body: epoxy resin painted steel - front center: ¾" NPT female
- air vent body: brass - inlet/outlet flanges: ½" NPT female
- shut off and drain valve body: brass ,@SDQH@KR - separator body: epoxy resin painted steel
/DQENQL@MBD - air vent body: brass
Suitable fluids: water and non-hazardous glycol solution up to 50% - shut off and drain valve body: brass
Max. operating pressure: 150 psi - internal baffle: stainless steel
Working temperature range with insulation: 32–210°F /DQENQL@MBD
Working temperature range without insulation: 32–250°F Suitable fluids: water and non-hazardous glycol solution up to 50%
Max. operating pressure: 150 psi
3DBGMHB@KRODBHkB@SHNMRNEHMRTK@SHNM Working temperature range with insulation: 32–210°F
Materials: double density closed cell expanded PEX Working temperature range without insulation (vessel): 32–270°F
Thickness: 3/4"
Density: - internal part: 2 lb/ft 3DBGMHB@KRODBHkB@SHNMRNEHMRTK@SHNMENQl@MFDCUDQRHNMRTOSNŪ
- external part: 3 lb/ft (MSDQM@KHMRTK@SHNM
Thermal conductivity: 32°F: 9 BTU/in Materials: rigid closed cell expanded polyurethane foam
-40°F: 11 BTU/in Thickness: 2 3/8"
Coefficient of resistance to the diffusion of vapor: >1,300 Density: 3 lb/ft
Temperature range: 32–210°F Thermal conductivity: 6 BTU/in
Reaction to fire (DIN4102): class B 2 Temperature range: 32–220°F
.TSDQRJHM
Materials: embossed aluminum
Thickness: 7.0-mil
Reaction to fire (DIN 4102): class 1
'D@CBNUDQR
Heat formed materials: PS

64
 Dimensions

E
E

A
A

A
HYDRO SEPARATOR
Serie 548

HYDRO SEPARATOR

Tmax 120¯C
Pmax 10 bar
Tmax 105¯C
Pmax 10 bar
HYDRO-SEPARATOR
Serie 548

38...
D

Tmax 120¯C Tmax 105¯C

Pmax 10 bar Pmax 10 bar

Tmax 110¯C Pmax 10 bar

C
A
A

A
C

B
F
B

D
Code A B C D E E Weight (lb) Flow (gpm) Vol. (gal)
548052A 2” 1 1/4” 13” 13” 15” 14” 75 40 4.0
548062A 2 1/4” 1 1/4” 13” 13” 15” 14” 82 80 4.0
548082A 3” 1 1/4” 15” 18” 17” 18” 112 124 8.0
548102A 4” 1 1/4” 15” 18” 17” 18” 117 247 8.0 B
NA548120A* 5” 1 1/4” 15” 22” 19” 25” 220 300 22.5 F
Code A B C D D Weight (lb) Flow (gpm) Vol. (gal)
NA548150A* 6” 1 1/4” 15” 22” 19” 25” 231 484 23.2

548006A/96A 1” 8 3/4” 6 1/4” 8 5/8” 8” 13 11 0.5 * without insulation Code A B C D E D Weight (lb) Flow (gpm) Vol. (gal)
NA prefix indicates ASME tagged and registered with the National Board of Boiler NA548200A 8” 520 792 95
548007A/97A 1 1/4” 9 3/8” 7 3/8” 9 1/2” 8 3/8” 17 18 0.7 2” 39 3/8” 33 7/8” 27 1/2” 35 1/2”
and Pressure Vessel Inspectors.
548008A/98A 1 1/2” 10 7/8” 7 3/4” 10 1/4” 8 3/4” 25 26 1.3 NA548250A 10” 2” 43 5/16” 35 7/8” 30” 41 3/4” 725 1,330 175
Add NA prefix to 2” to 4” flanged connection for ASME approved.
548009A/99A 2” 12” 10 1/8” 11 7/8” 9 1/2” 27 34 3.5 NA548300A 12” 2” 47 1/4” 37 7/8” 31 1/2” 47 3/4” 1,100 1,850 255
For larger ASME sizes consult with factory.

Operating principle

When a single system contains a primary production circuit, with its When the secondary pump is off, there is no circulation in the secondary
own pump, and a secondary user circuit, with one or more distributions circuit; the whole flow rate produced by the primary pump is by-passed
pumps, operating conditions may arise in the system whereby the pumps through the separator.
interact, creating abnormal variations in circuit flow rates and pressures.
With the hydraulic separator, it is therefore possible to have a primary
The hydraulic separator creates a zone with a low pressure loss, which production circuit with a constant flow rate and a secondary distribution
enables the primary and secondary circuits connected to it to be circuit with a variable flow rate; these operating conditions are typical of
hydraulically independent of each other; VJGƀQYKPQPGEKTEWKVFQGU modern heating and cooling systems.
PQVCHHGEVVJGƀQYKPVJGQVJGT
Gp Gs
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 primary secondary
in the secondary circuit only circulates when the relevant pump is on,
permitting the system to meet the specific load requirements at that time.

3GQDDONRRHAKDGXCQ@TKHBA@K@MBDRHST@SHNMR@QDRGNVMADKNV

Primary Secondary Primary Secondary Primary Secondary

Gp Gs Gp Gs Gp Gs

Gprimary = Gsecondary Gprimary > Gsecondary Gprimary < Gsecondary

65
HydroCal™ combination hydraulic,
air and dirt separator
549 and NA549 series CALEFFI
Tech ref: 01178

Function
The Caleffi HydroCal™ combination hydraulic, air and dirt separator
is a device that combines high performance air and dirt removal with
hydraulic separation. Primary and secondary circuits connected to it
become hydraulically decoupled thus eliminating pump conflict.
A proven, time tested stainless steel internal coalescing element
continuously and automatically eliminates all entrained air, including
microbubbles, in the system. Air discharge capacity is very high. Over
time, dirt particles as tiny as 5 microns are captured and collected
away from the flow stream.
The 3-in-1 high performance functionality of the HydroCal ™ saves
system installation and maintenance cost as there is no need to include
separate air and dirt separators. It can be used on either hot or chilled
water systems.

Product range
549 series HydroCal™ hydraulic, air and dirt separator in steel with flanged connections insulation.......................................connections 2–4" ANSI
NA549 series HydroCal™ hydraulic, air and dirt separator in steel with flanged connections, insulation, ASME and CRN......... connections 2–4" ANSI
NA549 series HydroCal™ hydraulic, air and dirt separator in steel with flanged connections ASME and CRN.........................connections 6–12" ANSI*
*Larger sizes are available, consult factory

Technical specifications Dimensions

"NMMDBSHNMR - flanged: 2–12" ANSI B16.5 150 CLASS RF
- drain valve: 2–6": 1-1/4" NPT female
8–12": 2" NPT female
- thermometer pockets (8–12" only):
front center: 3/4" NPT female
inlet/outlet flanges: 1/2" NPT female
E

,@SDQH@KR - separator body: epoxy resin painted steel body

- air vent body brass HYDRO
A

- shut-off and drain valve body: brass

38711

- internal element: stainless steel

D

- air vent seal: VITON BI-DIRECTIONAL

Tmax 250ϒF
Pmax 150 psi
Tmax 220ϒF
Pmax 150 psi

- air vent float: stainless steel

A

/DQENQL@MBD
Suitable fluids: water and non-hazardous glycol solutions up to 50%
C

Max. operating pressure: 150 psi

Working temperature range with insulation: 32–220°F
Working temperature range without insulation (vessel): 32–270°F B
Particle separation capacity: to 5 μm F

FDMBX@OOQNU@K 2–6”
Series NA549 is designed and built in accordance with Section VIII,
Division 1 of the ASME Boiler and Pressure Vessel Code and tagged
and registered with the National Board of Boiler and Pressure Vessel 8–12”
Inspector, and CRN registered.
6S  %KNV 5NK
Technical specifications of insulation up to 4" "NCD A B C D E F KAR  FOL F@K 
(MMDQHMRTK@SHNM 549052A 2" 1 ⁄4" 1
13" 13" 15" 14" 73 37.3 4.0
Material: rigid closed cell expanded polyurethane foam 549062A 21⁄2" 11⁄4" 13" 13" 15" 14" 79 63 4.0
Thickness: 2-3/8" 549082A 3" 11⁄4" 15" 17 3⁄4" 17" 18" 108 95.5 8.0
Density: 3 lb/ft3 549102A 4" 11⁄4" 15" 17 3⁄4" 17" 18" 117 149 8.0
Conductivity (ISO 2581): 0.16 BTU·in/hr·ft2·°F (0.023 W/(m·K) NA549150A* 6" 11⁄4" 15" 22" 19" 25" 231 380 23.2
Temperature range: 32–220°F NA549200A* 8" 2" 33 7⁄8" 39 3⁄8" 271⁄2" 351⁄2" 520 625 95.0
.TSDQRJHM NA549250A* 10" 2" 33 7⁄8" 43 5⁄16" 30" 413⁄4" 725 1,030 175
Material: embossed aluminium NA549300A* 12" 2" 33 7⁄8" 47 1⁄4" 311⁄2" 47 3⁄4" 1100 1,650 255
Thickness: 7-mil (0.70 mm) *Without insulation
Fire resistance (DIN 4102): class 1 NA prefix indicates ASME tagged and registered with the National Board of Boiler and Pressure
'D@CBNUDQR Vessel Inspectors and CRN registered.
Heat formed material: PS Add NA prefix to 2" to 4" flanged connection for ASME approved, CRN registered.

66
Operating principle
'XCQ@TKHBRDO@Q@SHNM
When a single system contains a primary production circuit, with its through the separator. With the hydraulic separator, it is therefore
own pump, and a secondary user circuit, with one or more distribution possible to have a primary production circuit with a constant flow rate
pumps, operating conditions may arise in the system whereby the and a secondary distribution circuit with a variable flow rate; these
pumps interact, creating abnormal variations in circuit flow rates and operating conditions are typical of modern heating and cooling systems.
pressures. The hydraulic separator creates a zone with a low pressure
loss, which enables the primary and secondary circuits connected to it
to be hydraulically independent of each other; SGDlNVHMNMDBHQBTHS Three possible hydraulic balance situations are shown below.
CNDRMNS@EEDBSlNVHMSGDNSGDQ
In this case, the flow rate in the respective circuits depends exclusively Primary Secondary Primary Secondary Primary Secondary
on the flow rate characteristics of the circuit pumps, preventing
Gp Gs Gp Gs Gp Gs
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.
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 &Orimary = &Recondary &Orimary > &Recondary &Orimary < &Recondary

Construction details
,HBQNATAAKD@HQRDO@Q@SHNM
T h e H y d r o C a l ’s i n t e r n a l
element (1) creates the whirling
movement required to facilitate
the release of microbubbles and
their adhesion to the internal !
element surfaces. The bubbles,
fusing with each other, increase
in size until the hydrostatic thrust
overcomes the adhesion force
to the mesh. They rise towards
the top of the unit from which
they are released through a float-
operated automatic air vent.

,HBQNO@QSHBKDCHQSRDO@Q@SHNM
Impurities in the fluid upon
striking the surfaces of the
HydroCal’s internal element (1),
get separated and drop to the
bottom of the body (2) where
they collect.
C
In addition, the large internal
volume of HydroCal ™ slows
down the flow speed of the (RNK@SHMFSGD@HQUDMSU@KUD
fluid thus helping, by gravity, to
The air vent (A), replacement part number 501502A, is isolated
separate the particles it contains.
manually, using a shut-off ball valve (B), replacement part number
The collected impurities are NA39589.
discharged, by opening the drain
valve (3) with the handle (4), even 1 #HQSQDLNUHMFDKDLDMS
with the system operating. The HydroCal ™ dirt removing
element separates and collects
any impurities present in
the system.
These impurities are removed by
the drain valve (C) replacement
part number NA39588 for
2
connection sizes 2–6"; NA59600
for connection size 8–12", which
3
can be connected to a discharge
4 pipe, a t t h e b o t t o m o f t h e
separator.

67
SEP ™ combination hydraulic, air,
dirt and magnetic separator
5495 series CALEFFI
3DBGQDE

%TMBSHNM
The SEP4™ combination hydraulic, air, dirt and magnetic separator
is a device that, incorporates high performance air and magnetic and
non-magnetic dirt removal functionality into the hydraulic 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 SEP4 ™ features an HDPE 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 4-in-1 high performance functionality of the SEP4™ saves system
installation and maintenance costs as there is no need to include separate
air and dirt separators. In addition to removing sand and rust impurities,
the added powerful removable external magnetic ring around the lower
body removes up to 95% of the ferrous oxide particles that can form in a
hydronic system.

Product range
Code ttA SEP4™ hydraulic, air, dirt and magnetic separator connections .............................................1", 1¼", 1½", 2" NPT female union
Code ttA SEP4™ hydraulic, air, dirt and magnetic separator connections .................................................... 1", 1¼", 1½", 2" sweat union

Technical specifications Dimensions

,@SDQH@KR - body: epoxy resin coated steel
- union nuts: NPTF tailpiece, galvanized metal
sweat tailpiece, brass
- air vent body: brass EN 12165 CW617N
E

- air vent hydraulic seal: EPDM

- air vent float: PP
- air vent float link & guide pin: stainless steel
A

- int. element: HDPE

- drain valve body: brass EN 12165 CW617N
- magnet: neodymium rare-earth
D

/DQENQL@MBD
Suitable fluids: water, glycol solution
Max. percentage of glycol: 50%
A

Max. working pressure: 150 psi

Working temperature range: without insulation 32 – 230°F
with insulation 32 – 210°F
Particle separation capacity: to 5 μm (0.2 mil)
C

Magnetic particle separation efficiency: up to 95% removal

Main connections: 1", 1¼", 1½", 2" NPT F brass unions
1", 1¼", 1½", 2" sweat brass unions
Thermowell tap connection: ½" F straight thread
Drain valve: ¾" hose B
(MRTK@SHNM
Material: closed-cell expanded PE-X
6S  %KNV 5NK
Thickness: 13/16" "NCD ! C # $ KAR  FOL F@K 
Density: - inner insulation: 1.9 lb/ft 3 06A/96A 1" 8 3⁄4" 6 5⁄8" 8 5⁄8" 6" 15 11 0.5
- outer skin: 5.0 lb/ft 3 07A/97A 11⁄4" 9 3⁄4" 6 5⁄ 8" 9 1⁄2" 5 7⁄8" 19 18 0.7
Conductivity (ISO 2581): at 32°F; .16 BTU/in 08A/98A 11⁄2" 11" 6 5⁄ 8" 10 1⁄4" 6 7⁄8" 27 26 1.3
at 105°F; .26 BTU/in 09A/99A 2" 12 3⁄8" 6 3⁄ 8" 117⁄ 8" 6 5⁄ 8" 29 37 3.5
Water vapor resistance coefficient (DIN 52615): > 1,300 tA: NPT female union connections. tA: sweat union connections.
Temperature range: 32–212°F
Fire resistance (DIN 4102): class B2

68
Operating principle
through the separator. With the hydraulic separator, it is therefore
'XCQ@TKHBRDO@Q@SHNM
possible to have a primary production circuit with a constant flow rate
When a single system contains a primary production circuit, with its and a secondary distribution circuit with a variable flow rate; these
own pump, and a secondary user circuit, with one or more distribution operating conditions are typical of modern heating and cooling systems.
pumps, operating conditions may arise in the system whereby the pumps
Three possible hydraulic balance situations are shown below.
interact, creating abnormal variations in circuit flow rates and pressures.
The hydraulic separator creates a flow path with a low pressure loss,
which enables the primary and secondary circuits connected to it to be
hydraulically independent of each other; SGDlNVHMNMDBHQBTHSCNDR Gp Gs
MNS@EEDBSlNVHMSGDNSGDQ In this case, the flow rate in the respective
circuits depends exclusively on the flow rate characteristics of the circuit
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, primary secondary
permitting the system to meet the specific load requirements at that
time.
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

Primary Secondary Primary Secondary Primary Secondary

Gp Gs Gp Gs Gp Gs

&Orimary = &Recondary &Orimary > &Recondary &Orimary < &Recondary

,HBQN ATAAKD@HQRDO@Q@SHNM ,@FMDSHBO@QSHBKDRDO@Q@SHNM

The SEP4’s internal air separation element (1) creates the whirling
movement required to facilitate the release of micro-bubbles and their
adhesion to the internal element surfaces. The bubbles, fusing with
each other, increase in size until the hydrostatic thrust overcomes the
adhesion force to the mesh. They rise towards the top of the unit from
which they are released through a float-operated automatic air vent.
The SEP4™ incorporates a fourth separation function by removing both
magnetic and non-magnetic particles continuously. The SEP4™ features
a powerful removable external rare-earth magnet around the body below
the flow line for fast and effective capture of ferrous particles. The SEP4™
magnetic particle separation function causes no added system pressure
drop since the magnet is positioned externally and not inside the flow path.

 HM GHFGODQENQL@MBDETMBSHNM@KHSX
,HBQN O@QSHBKDCHQSRDO@Q@SHNM
Impurities in the fluid upon striking Hydraulic separation Air separation
the surfaces of the SEP4’s internal 
dirt separation element (2), get
separated and drop to the bottom
of the body (3) where they collect.
In addition, the large internal
volume of SEP4™ slows down the
flow speed of the fluid thus helping, 
by gravity, to separate the particles
it contains. Dirt separation Magnetic removal of ferrous particles
The collected impurities are
discharged, by opening the drain
valve (4) with the handle (5), even
with the system operating. 3

 

69
 ® ™
and DISCAL
magnetic dirt separator
  - RDQHDR CALEFFI
3DBGQDE  
Function
Air, dirt and magnetic separators are used to continuously remove the
air and debris contained in the hydronic circuits of heating and cooling
systems. Caleffi offers several versions of air, dirt and hydraulic separators
that also feature magnetic particle removal.
The DIRTMAG ® magnetic dirt separator and DISCALDIRTMAG ™
magnetic air and dirt separator removes both magnetic and non-
magnetic particles, featuring a powerful removable external magnet
around the body that removes up to 95% of the ferrous oxide particles
that can form in a hydronic system. The 5461 series and the 5463 series
brass versions are available with NPT threaded or sweat connections in
versions for horizontal pipes only. Insulation shells are available separately
for field installation.
The body of the patent pending NA5453 series separator is made
of glass reinforced nylon specifically designed for use in heating and
cooling systems. It also is especially versatile as it can be installed on
either horizontal or vertical piping with the rotating brass base mount. It
is available with conventional NPT and sweat union connections. Also
available for size ¾”, the Presscon™ copper tailpiece with union nut
makes installation and maintenance fast, easy and efficient. Special slots
in the EPDM O-ring allows fluid to leak during system testing if unpressed
and provide a perfect leak proof seal when completely pressed.

/QNCTBSQ@MFD

NA54530 series DIRTMAG® dirt separator with magnet for horizontal and vertical pipes...............................connections ¾” & 1” NPT male union
NA54539 series DIRTMAG® dirt separator with magnet for horizontal and vertical pipes.....................................connections ¾” & 1” sweat union
NA54536 series DIRTMAG® dirt separator with magnet for horizontal and vertical pipes.......................................................connections ¾” press
54611 series DISCALDIRTMAG™ air and dirt separator with magnet in brass...............................................................connections 1" NPT male
54619 series DISCALDIRTMAG™ air and dirt separator with magnet in brass..................................................connections 3/4", 1", 1-1/4" sweat
5463 series DIRTMAG® magnetic dirt separator for horizontal pipes, in brass..........................................................connections 1" to 2" sweat

Technical specifications 

Brass DIRTMAG®, DISCALDIRTMAG™ DIRTMAG® (NA5453 series)

,@SDQH@KR - body: brass ,@SDQH@KR
- dirt separation chamber: brass Body: glass reinforced nylon PA66G30
- top plug(5463): brass Dirt separator cover: glass reinforced nylon PA66G30
- air vent body (5461): brass Top plug: brass EN 12164 CW614N
- internal element: glass reinforced nylon, PA66GF30 Drain screw: brass EN 12164 CW614N
Tee pipe fitting: brass EN 1982 CB 753S
- air vent float (5461): PP
Locking nut for tee pipe fitting: brass EN 12420 CW617N
- air vent float guide pin (5461): stainless steel
Internal element: HDPE
- air vent float linkages (5461): stainless steel
Hydraulic seals: EPDM
- spring (5461): stainless steel
Drain valve: brass EN 12165 CW617N
- seals: EPDM
- drain shut-off valve: brass /DQENQL@MBD
- magnet: neodymium rare-earth Suitable Fluids: water, glycol solutions
/DQENQL@MBD Max. percentage of glycol: 30%
Suitable fluids: water, glycol solution Max. working pressure: 45 psi
Max. percentage of glycol: 50% Working temperature range: 32–195°F
Max. working pressure: 150 psi Magnets: neodymium rare earth
Temperature range: 32–250°F Magnetic particle separation efficiency: up to 95% removal
Particle separation efficiency: to 5 μm (0.2 mil)
Magnetic particle separation efficiency: up to 95% removal "NMMDBSHNMR
Main connections: 3/4” and 1” NPT male union
"NMMDBSHNMR - main(5461): 3/4", 1", 1-1/4" sweat; 1" NPT male
3/4” and 1” sweat union
- main(5463): 1", 1-1/4";1-1/2"; 2" sweat and NPTF 3/4” press
- drain shut-off valve: hose connection Lay length (press connection): 5 7/16”
Drain valve: hose connection

70
Dimensions

B 15/8"
NPT B Sweat B
31/2"

2”
2”

A
A

C
5½”
C
C

B
A
1¼”
1¼”

7"
C
"NCD ! C 6S KA
06A 1" NPT 4 5⁄16" 5" 4.2

2¼”
28A 1" SWT 51⁄16" 5" 4.2
07A 11⁄4" NPT 47⁄8" 6" 5.3 "NCD ! C 6S KA
35A 11⁄4" SWT 5 3⁄16" 6" 4.2 "NCD ! C 6S KA NA545305 ¾” NPT 6 7/8” 3 7/16” 4.5
08A 11⁄2" NPT 47⁄ 8" 6" 6.2 95A 3⁄4"SWT 7 3⁄8" 5" 8.5 NA545395 ¾” SWT 6 5/8” 3 5/16” 4.5
41A 11⁄2" SWT 5 3⁄4" 6" 4.9 96A 1" SWT 7 3⁄8" 5" 8.5 NA545365 ¾” press 7 1/4” 3 5/8” 4.5
09A 2" NPT 51⁄8" 6" 6.2 16A 1" NPT M 7 3⁄8" 5" 8.5 NA545306 1” NPT 7 1/2” 3 3/4” 4.5
54A 2" SWT 61⁄8" 6" 5.5 97A 1¼" SWT 7 3⁄8" 5" 8.5 NA545396 1” SWT 7 5/8” 3 7/8” 4.5

Operating principle Locknut

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1 Engineered

The DISCALDIRTMAG™ air, dirt, and Polymer Body

magnetic separator uses the combined 1

action of several physical principles. 2

The active part is the internal element
(1) and consists of a glass-reinforced 2
3
nylon mesh. These elements create the Brass Tee
Pipe Fitting
3
whirling movement required to facilitate 4

the release of micro-bubbles and their

adhesion to these surfaces.
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The bubbles, fusing with each other,  -  
increase in volume until the hydrostatic
thrust is such as to overcome the
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adhesion force to the structure. They
The DIRTMAG® and DISCALDIRTMAG™ dirt
rise towards the top of the unit from
removing element separates and collects any
which they are released through a float-
impurities present in the system. 1
operated automatic air vent valve.
,@FMDSHBO@QSHBKDRDO@Q@SHNM Impurities in the fluid upon striking the surfaces
of the DIRTMAG® and DISCALDIRTMAG ™ ’s
The DIRTMAG® and DISCALDIRTMAG ™
internal element (1), get separated and drop
removes both magnetic and non-magnetic
to the bottom of the body in the dirt collection
particles continuously. The DIRTMAG ®
chamber (2) where they collect. 2
and DISCALDIRTMAG ™ feature a powerful
removable external rare-earth magnet around In addition, the large internal volume of slows
the body below the flow line for fast and effective down the velocity of the fluid thus helping, by
gravity, to separate the particles it contains. 3
capture of ferrous particles. The DIRTMAG®
and DISCALDIRTMAG ™ magnetic particle The collected impurities are discharged, by
separation function causes no added system opening the drain valve (3), even with the system
pressure drop since the magnet is positioned operating.
externally and not inside the flow path.
The special design of the internal mesh element in the Caleffi DIRTMAG®
Ferrous oxide forms in hydronic systems when iron or steel corrodes. and DISCALDIRTMAG™, is able to completely separate the dirt particles
The abrasive, extremely fine sediment is difficult to remove and can in the circuit down to a minimum particle size of 5 μm (0.2 mil). After
deposit onto heat exchange surfaces and accumulate in pump cavities only 50 recirculations, approximately one day of operation, up to 100%
causing reduced efficiency and premature wear. The DIRTMAG® and is effectively removed from the circuit for particles of diameter greater
DISCALDIRTMAG™ accomplish 2 1/2 times the ferrous oxide removal than 100 μm (3.9 mil) and on average up to 80% taking account of the
performance of standard dirt separation function, delivering up to smallest particles. The continual passing of the medium during normal
95% elimination efficiency. Captured impurities are easily flushed by operation of the system gradually leads to complete dirt removal.
unclamping the collar and purging - even with the system still operating.

71
 Magnetic Separation
Removes 95% of ferrous impurities
Ferrous oxide forms in hydronic systems when iron or steel corrodes.
This abrasive, extremely fine sediment is difficult to remove; it can
deposit onto heat exchanger surfaces and accumulate in pump
cavities causing reduced efficiency and premature wear. Caleffi
magnetic dirt separators accomplish 2½ times the ferrous oxide
removal performance of standard dirt separators, delivering up to
95% elimination efficiency.

Components for today's modern hydronic systems

Heating & Cooling

www.caleffi.us - Milwaukee, WI USA