CALEFFI 548 Series User guide

Function
The hydraulic separator is a device which makes the primary
and secondary circuits connected to it independent, and can be
used on hot and chilled water systems. The separator is supplied
with an air vent and check valve assembly to provide automatic
discharge of the air in the circuits, and a drain valve for removing
impurities that collect at the bottom of the unit.
These items are designed for use in closed hydronic systems. Do not
use in plumbing applications. These items do not meet the low-lead
plumbing standards of U.S. and Canada.
Product range
548 series Hydraulic separator in steel with union connections, vent and drain.........................
connections 1", 1¼", 1½", 2" NPT female union
connections 1", 1¼", 1½", 2" sweat union
connections 1", 1¼", 1½", 2" press union
no tailpieces, separately source, field install 1" to 2"
548 series Hydraulic separator in steel with flanged connections, vent, drain and insulation............
connections 2", 2 1/2", 3", 4" ANSI
NA548 series Hydraulic separator in steel with flanged connections, vent, drain and insulation,
ASME and CRN................................................connections 2", 2 1/2", 3", 4" ANSI
NA548 series Hydraulic separator in steel with flanged connections, vent, drain and floor supports,
ASME and CRN............................................................connections 5" to 14" ANSI
(consult Caleffi for CRN status on size 14")
Hydro Separator
Installation, commissioning and servicing instructions
38505.06
1
© Copyright 2021 Caleffi 548, NA548 Series
www.caleffi.com
SAFETY INSTRUCTION
This safety alert symbol will be used in this manual to draw attention to safety
related instructions. When used, the safety alert symbol means.
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! FAILURE
TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN A SAFETY
HAZARD.
WARNING: This product can expose you to chemicals including lead, which
is known to the State of California to cause cancer and birth defects or other
reproductive harm. For more information go to www.P65Warnings.ca.gov.

Technical specications
Union connections
Materials - body: epoxy resin coated steel
- air vent body: . brass
- air vent hydraulic seal: peroxide-cured EPDM
- air vent float: . PP
- internal baffle: 300 series stainless steel
- shut off and drain valve body: brass
- union nuts: cast iron
- support bracket: polyester painted carbon steel
Performance
Suitable fluids: water and non-hazardous glycol solution up to 50%
Max. operating pressure: 150 psi (10 bar)
Working temperature range: without insulation 32–230°F (0–110°C)
with insulation 32–210°F (0–100°C)
(insulation shells are purchased separately for field installation)
Connections
Main connections: 1", 1¼", 1½", 2" NPT female with unions
1", 1¼", 1½", 2" sweat with unions
1", 1¼", 1½", 2" press with unions
1", 1¼", 1½", 2" body with no tailpieces for field installation of tailpieces purchased separately
Thermowell tap connection: ½" F straight thread
Lay length (press connection):
size 1 inch: 9"; size 1¼ inch: 9¾"; size 1½ inch: 11¼"; size 2 inch: 12¾"
Drain valve: ¾" garden hose thread
CAUTION: If the hydraulic separator is not installed, commissioned
and maintained properly, according to the instructions contained
in this manual, it may not operate correctly and may endanger the user.
CAUTION: Make sure that all the connecting pipework is water tight.
CAUTION: When making the water connections, make sure
that the connecting pipework is not mechanically over-stressed.
Over time this could cause breakages, with consequent water
losses which, in turn, could cause harm to property and/or people.
CAUTION: Water temperatures higher than 100°F (38°C) can be
dangerous. During the installation, commissioning and maintenance
of the hydraulic separator, take the necessary precautions
to ensure that such temperatures do not endanger people.
Leave this manual for the user
2
CAUTION: All work must be performed by qualified personnel
trained in the proper application, installation, and maintenance
of systems in accordance with all applicable codes and ordinances.

Technical specications
Flanged connections
Materials - body: epoxy resin coated steel
- air vent body: . brass
- air vent hydraulic seal: Viton
- air vent float: . Stainless steel
- internal baffle: 304 series stainless steel
- shut off and drain valve body: brass
Performance
Suitable fluids: water and non-hazardous glycol solution up to 50%
Max. operating pressure: 150 psi (10 bar)
Working temperature range: with insulation 32–220°F (0–105°C)
without insulation (vessel) 32–270°F (0–132°C)
Connections
Main connections: 2"-14"ANSI B16.5 150 CLASS RF
Thermowell tap connection (8-14" only):
- front center: . ¾" NPT female
- inlet/outlet flanges: ½" NPT female
Drain valve: 2 - 6": 1¼" NPT female
8 - 14": 2" NPT female
3

Technical specications of insulation on union models
(purchase separately, eld install)
Material: closed-cell expanded PE-X
Thickness: 13/16"(20 mm)
Density: - inner part: 1.9 lb/ft3(30 kg/m3)
- outer part: 3.1 lb/ft3(50 kg/m3)
Conductivity (ISO 2581): at 32°F (0°C): 9 BTU.in/hr.ft2.°F (0.038 W/(m.K)
at -40°F (-40°C); 11 BTU.in/hr.ft2.°F (0.045 W/(m·K)
Coefficient of resistance to the diffusion of vapor: > 1,300
Temperature range: 32–210°F (0–100°C)
Fire resistance (DIN 4102): class B2
Technical specications of insulation, anged versions to 4"
Internal part
Material: rigid closed cell expanded polyurethane foam
Thickness: 2 3/8" (60 mm)
Density: 2.8 lb/ft3 (45 kg/m3)
Thermal conductivity: 6 BTU.in/hr.ft2.°F (0.023 W/(m.K))
Temperature range: 32–220°F (0–105°C)
Outer part
Materials: embossed aluminum
Thickness: 7.0-mil (0.7 mm)
Reaction to fire (DIN 4102): class 1
Head covers
Heat formed materials: PS
4

5
Procedure for eld installation of insulation
on union models
1. Remove the protective stip from the adhesive
surface. Re-close the insulation shells.
2. If the hydraulic separator is used with chilled
water spread a thin layer of sealant on the edge of
the insulation and wait until the solvent evaporates
(approximarly 10 minutes) and close it again. Note
that once the sealant dries it may be difficult to
remove the insulation shell in the future without
destroying portions of the insulation.
3. Reassemble the two side sections.
Service Instructions
There is no service required for the hydraulic separator.
CAUTION:
Corrosionorleakage cancause damage or injury.
Periodically inspect for signs of corrosion or leakage. If corrosion or
leakage is note,the vent must be replaced. Failure to follow these
instructions could result in property damage and/or personal injury.
B
Procedure for installation and insulation assembly
(only for 2” to 4” sizes)
1. Remove the two black head covers at the ends.
2. Open the two side sections and the lower cap.
3. Install the separator in the system.
4. Spreadathin layer of sealant over surfacesAand B.
Wait for the solvent to evaporate (approx. 10 minutes).
5. Reassemble the two side sections, tting the lower cap into
one of the two sections and then connecting the other.
6. Finish the assembly with the adhesive tape provided in the box.
7. Complete with the two black head covers.
8. Fit the automatic air vent and the drain valve.
Procedure for installation and insulation
assembly on union models
1. Remove the protective strip from the adhesive
surface. Re-close the insulation shells.
2. If the hydraulic separator is used with chilled
water spreadathin layer of sealant on the edge
of the insulationandwait until the solvent
evaporates (10 minutes approx
) and the close
it again.
A
Caleffi North America, Inc.
3883 West Milwaukee Road
Milwaukee, WI 53208
T: 414.238.2360 F: 414.238.2366
-18
Service Instructions
There is no service required for the hydraulic separator.
CAUTION:
Corrosionorleakage cancause damage or injury.
Periodically inspect for signs of corrosion or leakage. If corrosion or
leakage is note,the vent must be replaced. Failure to follow these
instructions could result in property damage and/or personal injury.
B
Procedure for installation and insulation assembly
(only for 2” to 4” sizes)
1. Remove the two black head covers at the ends.
2. Open the two side sections and the lower cap.
3. Install the separator in the system.
4. Spreadathin layer of sealant over surfacesAand B.
Wait for the solvent to evaporate (approx. 10 minutes).
5. Reassemble the two side sections, tting the lower cap into
one of the two sections and then connecting the other.
6. Finish the assembly with the adhesive tape provided in the box.
7. Complete with the two black head covers.
8. Fit the automatic air vent and the drain valve.
Procedure for installation and insulation
assembly on union models
1. Remove the protective strip from the adhesive
surface. Re-close the insulation shells.
2. If the hydraulic separator is used with chilled
water spreadathin layer of sealant on the edge
of the insulationandwait until the solvent
evaporates (10 minutes approx
) and the close
it again.
A
Caleffi North America, Inc.
3883 West Milwaukee Road
Milwaukee, WI 53208
T: 414.238.2360 F: 414.238.2366
-18
Procedure for installation of insulation for
2" to 4" anged models
1. Remove the two black head covers at the ends.
2. Open the two side sections and the lower cap.
3. Install the separator in the system.
4. Spread a thin layer of sealant over surfaces A
and B. Wait for the solvent to evaporate (approxi-
mately 10 minutes).
5. Reassemble the two side sections, fitting the
lower cap into one of the two sections and then
connecting the other.
6. Finish the assembly with the adhesive tape
provided in the box.
7. Complete with the two black head covers.
8. Install the automatic air vent and the drain valve.

Hydraulic characteristics
The hydraulic separator should be sized according to the maximum flow rate value at the inlet.The
selected design value must be the greatest required flow rate of either the primary circuit or the
secondary circuit.
Union Flanged
Size 1" 1¼" 11/2" 2" 2" 21/2" 3" 4" 5" 6" 8" 10" 12 " 14"
gpm 11 18 26 37 60 80 124 247 300 484 792 1330 1850 2500
l/s 0.7 1.1 1.6 2.3 3.8 5.0 7.8 16 19 30 50 84 117 158
gallons 0.5 0.7 1.3 3.5 4.0 4.0 8.0 8.0 22.5 23 95 175 255 450
liters 1.9 2.6 4.9 13.2 15.1 15.1 30.3 30.3 85.2 87.0 360 662 965 1703
6

7
Accessories
Insulation jacket for
field installation on
548 series union
connection Hydro
separators.
NA10805 .................fits 1” union 548 series
NA10806 ................fits 1¼” union 548 series
NA10807 ................fits 1½” union 548 series
NA10808 .................fits 2” union 548 series
Replacement
support bracket for
field installation with
548 series union
connection Hydro
separators.
NA10778 ...fits 1” and 1¼” union 548 series
NA10796 ................fits 1½” union 548 series
NA10797 ...................fits 2” union 548 series
Replacement drain
valve for 548 series
union connection
Hydro separators.
538402 FD ......................½" NPT x ¾" GHT
Max. working pressure: 150 psi
Max. working temperature: 250°F
Connection: ¾" garden hose thread
Temperature pocket
well fits 548 series
union connection
Hydro separators.
694045 ...........................½" straight thread
R20011................................sealing washer
NA10426...............sensor holding grommet
NA10425.........kit containing above 3 items
1 ¾" pocket length.
Inside thread: 20 x 1.0 mm.

8
Installation
The hydralic separator should be installed only by qualified personnel in accordance with current
local codes and legislation. The hydraulic separator is installed between the primary and secondary
circuits, always in a vertical position.
CAUTION: Corrosion or leakage can cause damage or injury. Periodically
inspect for signs of corrosion or leakage. If corrosion or leakage is noted,
the vent must be replaced. Failure to follow these instructions could result in
property damage and/or personal injury.
Service instructions
There is no service required for the 548 and NA548 series hydraulic separator.
Leave this manual at the service of users for their use
6-30-21
·
Installation Tip
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548, 549 & 5495
Caleffi North America, Inc.
3883 W. Milwaukee Road
Milwaukee, WI 53208
T: 414.238.2360 F: 414.238.2366