CALEFFI 5495 SEP4 User guide

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© Copyright 2018 Caleffi
Function
The Caleffi SEP4™ combination separator is a device that
incorporates four critical functions for hot or chilled water systems.
It combines high performance air and dirt (magnetic and non-
magnetic) removal into the hydraulic separation function which makes
the primary and secondary circuits connected to it hydraulically
independent. The SEP4™ features an internal coalescing element
that continuously and automatically eliminates 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 solid
impurities in the system without isolating the separator or shutting
down the system, the added powerful removable external magnet
belt (union) or probe(s) (flanged) in the lower body removes up to
100% of the ferrous impurities, including magnetite, that can form in a hydronic system. The SEP4™
has 2½ times the ferrous impurities removal performance of standard air and dirt separators.
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.
SAFETY INSTRUCTION
This safety alert symbol will be used in this manual to draw attention to safety related instructions.
When used, the safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED! FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD.
CAUTION: All work must be performed by qualified personnel trained in the
proper application, installation, and maintenance of systems in accordance
with all applicable codes and ordinances.
SEP4™ 4-in-1 hydraulic, air, dirt
and magnetic separator, ANSI flanged
38712.07
5495, NA549_AM Series
Installation, commissioning and servicing instructions
Product range
5495 series SEP4™ hydraulic, air, dirt and magnetic separator in steel
with flanged connections, drain and insulation connections 2” – 4” ANSI
NA549_M series SEP4™ hydraulic, air, dirt and magnetic separator in steel with flanged
connections and drain, ASME connections 2” – 14” ANSI
-pre-formed insulation shell included on 2” – 4” sizes.
-CRN approval for 2” – 8” sizes; consult factory for 12-14” sizes.
www.caleffi.com
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.

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CAUTION: If the SEP4™ 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.
Technical specifications
Materials
Separator body: epoxy resin coated steel body
Air vent body & shut-off and drain valve body: brass
Internal element: 300 series stainless steel
Air vent seal: VITON
Air vent float: stainless steel
Magnet: neodymium rare-earth
Magnet probe: brass
Performance
Suitable fluids: water and non-hazardous glycol solutions up to 50%
Max. operating pressure: 150 psi (10 bar)
Temperature range: - with insulation 32–220°F (0 – 105°C)
- without insulation 32–270°F (0 – 132°C)
Particle separation capacity: to 5 μm
Air separation efficiency: 100% removal to microbubble level
Ferrous impurities separation efficiency: up to 100% removal
Connections
Flanged: 2”–14” ANSI B16.5 150 CLASS RF
Drain valve: - connections 2”– 6”: 1¼” NPT female
- connection 8”– 14”: 2” NPT female
Thermo well tap (8 — 14” only):
- front center: ¾” NPT female
- inlet/outlet flanges: ½” NPT female
Agency Approval
Series NA549_M is designed and built in accordance with Section VIII, Division
1of the ASME Boiler and Pressure Vessel Code and tagged and registered with
the National Board of Boiler and Pressure Vessel Inspector, and CRN
registered, and stamped for 150 psi (10 bar) working pressure, with ASME U
stamp. 12”-14” is CRN pending, contact Caleffi.
CAUTION: Make sure that all the connecting pipework is water tight.
CAUTION: When making the water connections, make sure that the hydronic
separator connecting pipework is not mechanically 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 hydronic
separator, take the necessary precautions to ensure that such temperatures
do not endanger people.

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Installation
The installation of SEP4™ should only be done by qualified personnel in
accordance with current legislation. The SEP4™ is installed between the
primary and secondary circuits, always in a vertical position.
Hydraulic
characteristics
The SEP4™ should be sized according to the maximum flow rate of either
the primary circuit, or secondary circuit, whichever is largest.
Size 2" 21⁄2" 3" 4" 5” 6" 8" 10" 12" 14"
gpm 60 80 124 247 300 484 792 1330 1850 2500
m3/h 13.6 18.2 28.2 56 68 110 180 302 420 568
l/s 3.8 5.0 7.8 15.6 19 30.5 50 84 117 158
Gallons 4.0 4.0 8.0 8.0 23 23 95 175 255 450
liters 15.1 15.1 30 30 87 87 360 662 965 1703
Technical specifications of insulation
Inner 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
Material: Embossed aluminium
Thickness: 7-mil (0.70 mm)
Fire resistance (DIN 4102): Class 1
Head covers
Heat formed material: PS

Caleffi North America, Inc.
3883 W. Milwaukee Road
Milwaukee, WI 53208
T: 414.238.2360 F: 414.238.2366
10-19-18
·
Installation Tip
Scan to view
548, 549 & 5495
Service Instructions
There is no service required for the SEP4™ combination hydraulic, air, dirt, and magnetic separator.
CAUTION: Corrosion or leakage can cause 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.
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. For cooling applications, consider using a silicon caulk
or sealant by spreading a thin layer of sealant over
the shell mating surfaces.
5. Reassemble the two side sections, fitting the lower cap
into one of the two sections and then connecting the other.
6. Complete with the two black head covers.
7. Install the automatic air vent and the drain valve.
Isolating the air vent valve
The air vent (A), replacement part number 501502A, is isolated
manually, using a shut-off ball valve (B), replacement part number
NA39589.
Dirt removing element
The SEP4™ dirt removing element separates
and collects any impurities present in
thesystem.
Ferrous impurities removal element
The SEP4™ ferrous impurities removing ele-
ment is a flexible magnetic stack inside a
brass dry-well probe (three for the 8 to 14 inch
size SEP4™) just below the flow stream in the
lower body. The probe(s) attracts and holds
the magnetite in the lower body and is flushed
by unscrewing the magnetic probe(s) and slowly pulling it out of
the dry-well and purging through the open drain valve- aided by the
system pressure.
C
Leave this manual for the user.