CALEFFI DIRTCAL 5462 Series User guide

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 the heat
exchangers, heating elements and pipes, resulting in
a lower thermal efficiency within the system. The dirt
separator separates off these dirt particles, 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 extremely limited head loss.
The DIRTMAG®magnetic dirt separator removes both
ferrous and non-ferrous impurities continuously, featuring
powerful removable magnets that remove up to 95%
of the ferrous impurities, including magnetite, that can
form in a hydronic system, 2 ½ times the removal
performance of a standard dirt separator.
Insulation shells are available separately for brass
models.
Product range
5462 Series DIRTCAL®dirt separator with NPT threaded connections, sizes 3/4”- 2”
5462 Series DIRTCAL
®
dirt separator with sweat connections, sizes 1”- 2”
5462 Seres DIRTCAL
®
dirt separator with press connections, sizes 1”- 1 ¼”
5463 Series DIRTMAG
®
magnetic dirt separator with NPT threaded connections, sizes 1”- 2”
5463 Series DIRTMAG
®
magnetic dirt separator with sweat connections, sizes 1”- 2”
5463 Seres DIRTMAG
®
dirt separator with press connections, sizes 1”- 1 ¼”
5465 Series Steel DIRTCAL
®
dirt separator with ANSI flanged connections,sizes 2"- 4"
5465M Series Steel DIRTMAG
®
magnetic dirt separator with ANSI flanged connections sizes 2" - 4"
NA5465 Series Steel DIRTCAL
®
dirt separator with ANSI flanged connections (ASME and CRN Registered),
sizes 2 - 6""
NA 5465M Series Steel DIRTMAG
®
magnetic dirt separator with ANSI flanged connections (ASME Registered)
sizes 2" - 6"
CBN5462 Series Insulation shells for DIRTCAL
®
series 5462 and DIRTMAG
®
series 5463, sizes 3/4"- 2".
DIRTCAL®- DIRTMAG® dirt separator
Installation, commissioning and servicing instructions
38643.07
1
© Copyright 2016 Caleffi 5462 - 5463 -5465 - 5465M - NA5465 - NA5465M Series
www.caleffi.com

Technical specifications
Brass body dirt separators and magnetic dirt separators
Connections: - Main: 3/4”, 1”, 1 1/4”, 1 1/2”, 2” NPT female
1”–1 1/4” - 1 1/2" - 2" sweat
- Top: 1/2” F (with plug)
- Drain: 3/4” garden hose connection
vertical: hose connection
- Lay length (press connections): size 1 inch: 4 ¾"
size 1 ¼inch: 5 1/8"
Materials: - Body, dirt collection chamber and top plug: brass
- Internal element: glass reinforced nylon PA66G30
- Hydraulic seal: EPDM
- Drain valve: brass
- Magnet (5463 series): neodymium rare-earth
Suitable fluids: water, glycol solution
Max percentage of glycol: 50%
Max working pressure: 150 psi (10 bar)
Temperature range: 32–250°F (0–120°C)
Particle separation capacity: to 5 μm (0.2 mil)
Ferrous impurities separation efficiency (magnetic models): up to 100% removal
CAUTION: If the DIRTCAL
®
and DIRTMAG
®
dirt 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
pipework connecting the DIRTCAL
®
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 DIRTCAL
®
or
DIRTMAG
®
dirt separator, take the necessary precautions to ensure that such
temperatures do not endanger people.
Leave this manual for the user
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.
32

Steel body dirt separators and magnetic dirt separators
Connections: - Main:
- NA5465, NA5465M 2", 2 1/2", 3", 4", 5”, 6" ANSI B16.5 150 CLASS RF
Flanged
- 5465, 5465M 2", 2 1/2", 3", 4" ANSI B16.5 150 CLASS RF Flanged
- Top: 3/4” M (with plug)
- Drain: 1” NPT
Materials: - Body: epoxy resin painted steel
- Int. element: stainless steel
(5465M, NA5465M) stainles steel and HDPE
- Hydraulic seal: non-asbestos fiber
- Drain valve: brass
- Magnet (M series): neodymium rare-earth
- Magnet probe drywell: brass
Suitable fluids: water, glycol solution
Max percentage of glycol: 50%
Max working pressure: 150 psi (10 bar)
Temperature range without insulation: 32–270°F (0–132°C)
Particle separation capacity: to 5 μm (0.2 mil)
Ferrous impurities efficiency(magnetic models): up to 100% removal
32
(kPa)
1" 1-1/4" 1-1/2" 2” 2-1/2” 3” 4” 3/4" 5” 6”
2”
0. 1
0.05
0.09
0.08
0.07
0.06
0.035
0.04
0.045
0.12
0.14
0.16
0.18
0.25
0. 3
0.35
0. 2
1
0.10
0.20
0. 5
0. 9
0. 8
0. 7
0. 6
0.12
0.14
0.16
0.18
0.25
0. 3
0.35
0. 4
0.45
1. 2
1. 4
1. 6
1. 8
2. 5
3
2
.
0
1
0. 5
0. 9
0. 8
0. 7
0. 6
0.45
0. 4
0.09
0.08
0.07
0.06
0.025
0.03
0. 02
(ft of hd)
∆p
(ft of hd)
100
2
10
5
20 50
1000
200 500
0.1
0.05
0.09
0.08
0.07
0.06
0.035
0.04
0.045
0.12
0.14
0.16
0.18
0.25
0. 3
0.35
0.2
1
0.5
0. 9
0. 8
0. 7
0. 6
0.45
0. 4
0.025
0.03
0. 02
6 7 8 9
12 14 16 18 25 30 35 40 45 60 70 80 90
120 140 160 180 250 400 450
300
350 600 700 800 900
3
3. 5
4
4. 5 2. 5
BRASS BODY
STEEL BODY
G(l/s) (gpm)
2
0. 5
10
1 5
0. 6 0. 7 0. 8 0. 9 1. 4 1. 6 2. 5
3
3. 5
4 6 7 8 9
12 14 16 18
20
35 25 30
40
50
60
0.25 0.40 0.45
0.20
0.30 0.35 0.15
0.125
Hydraulic characteristics
FLOW RATE (DIRTCAL®steel body)
Size 2" 2½" 3" 4" 5" 6"
4.0 f/s GPM 37 63 95 149 259 380
10.0 f/s GPM 89 150 227 355 816 904
Cv 88 176 211 328 520 842
FLOW RATE (Brass body)
Size ¾" 1" 1¼" 1½" 2"
4.0 f/s GPM 6 9 15 24 36
Cv 19 32 56 73 81
FLOW RATE (DIRTMAG® steel body)
Size 2" 2½" 3" 4" 5" 6"
4.0 f/s GPM 37 63 95 149 259 380
Cv 88 176 211 328 520 842

4
Installation
The dirt separator must always be installed in a vertical position, preferably on the return circuit
upstream of the boiler (or chiller). This enables it to intercept dirt particles already present in the
circuit, particularly when it is first started, before they reach the boiler (or chiller).
Flow direction for the DIRTCAL®and DIRTMAG®dirt separators is bi-directional; flow in either
direction is permitted.
CHILLER
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
CHILLER
5

4
WARNING: The symbol shown on the removable ring (A)
indicates the presence of magnets that generate a strong
magnetic field. This could cause damages to electronic devices
kept in its proximity.
1.Remove the ring (A) containing the two magnets, that
during the dirt separation phase retained the ferrous impru-
rities.
2. Carry out the dirt drain of operation by opening the
ball shut-off valve (B).
Procedure for removing insulation in the DIRTMAG 5463
series; and draining dirt particles in the DIRTMAG 5463 series
and 5465M series
Draining off dirt and ferrous impurities
The dirt separator collection chamber has a drain
valve. Using the handle provided it is possible to
drain off the accumulated dirt particles even with the
system in operation.
For the brass DIRTMAG®, captured impurities are
easily flushed by unclamping the magnetic collar and
purging.
For the brass DIRTMAG®, the ferrous impurities
are captured by a strong neodymium rare-
earth magnetic field created by a powerful
removable magnet around the body below
the flow line.
1
1
Tmax 110°C
Pmax 10 bar
Tmax 105°C
Pmax 10 bar
BI-DIRECTIONAL
Maintenance
To perform maintenance, simply use a 26
mm hexagon wrench (1) to unscrew the dirt
collection chamber, of the brass DIRTCAL®and
DIRTMAG®, to which the inner mesh element is
connected for removal and cleaning.
To purge the ferrous impurities in the steel
DIRTMAG®, the flexible magnetic stack is removed
from the brass dry-well and, with the system still
running, the drain valve is opened. Aided by the
system pressure, the dirt and ferrous impurities,
including magnetite flushes out quickly and
effectively.
5
A
B

Caleffi North America, Inc.
3883 W. Milwaukee Road
Milwaukee, WI 53208
T: 414.238.2360 F: 414.238.2366
CALEFFI
6
Use of top connector
The connector on top of the dirt separator can be used for optional
installation of an automatic air vent valve, Caleffi code 502243A
for the threaded or sweat versions- 5462 and 5463 Series (A),
replacing the standard 1/2" NPT Male plug (pn NA10044).
Use Caleffi code 501502A for the flanged version 5465 and 5465M
Series (C) -replacing the standard 3/4" NPT End Cap (pn 41525).
Use bottom connector
The dirt separators come
complete with drain valves
installed on the bottom port:
Caleffi code 538402 FD for
horizontal threaded or sweat
versions- 5462 and 5463
series (A), code NA39753 for
the flanged version - 5465,
5465M,NA5465, and NA5465M
series (C).
1
1
Tmax 110°C
Pmax 10 bar
Tmax 105°C
Pmax 10 bar
BI-DIRECTIONAL
1
1
Tmax 110°C
Pmax 10 bar
Tmax 105°C
Pmax 10 bar
BI-DIRECTIONAL
A
C
1
1
Tmax 110°C
Pmax 10 bar
Tmax 105°C
Pmax 10 bar
BI-DIRECTIONAL
B
Safety
The dirt separator must be installed by a licensed plumber in accordance with national
regulations and/or relevant local requirements.
Make sure that all connecting joints are water tight.
Leave this manual at the service of users for their use
1
1
Tmax110°C
Pmax10bar
Tmax105°C
Pmax10bar
BI-DIRECTIONAL
03-10-16
When making pipe connections take care not to damage the thread in the body of the valve by over
tightening. Take care not to apply too much force to the body of the valve when making pipe connections.
Water temperatures greater than 120°F may cause serious burns. When installing, using and
maintaining dirt separators take appropriate measure to ensure that these temperatures do not cause
harm to persons.