Caleffi Hydrolink Brochure

Hydronic separator-manifold HydroLink™

CALEFFI

series 559

cert. n° 0003

ISO 9001

01084/05 NA

Function The Hydrolink, a new device combining a hydronic separator and distribution manifold, is used in heating and air-conditioning systems to allow different heat adjustments of the various rooms when there is only one boiler or chiller. The various configurations are compact, and can be easily fitted in any kind of hydronic circuit, with the advantages of ease of installation and a saving of useful living space. Patent application No. MI2001A001270

Product range Code 559022A External 2+2 separator-manifold. Complete with support brackets and pre-formed insulation Code 559031A External 3+1 separator-manifold. Complete with support brackets and pre-formed insulation Cod e 559021A Bui l t-i n 2+ 1 se p a ra tor-ma ni fol d . Comp l e te wi th p re -for me d i nsul a ti on

Size 1 1/4”; branches 1” Size 1 1/4”; branc hes 1” Si z e 1”; b ra nc he s 1”

Technical characteristics Body

Insulation

Ma te ri a l : - Bod y :

Pa i nte d ste e l

Medium: Water and non-hazardous glycol solutions Ma x p e rc e nta g e of g l y c ol e : 50% Ma x. worki ng p re ssure : Te mp e ra ture ra ng e : Connections:

90 p si ( 6 b a r) 32 to 230°F ( 0 ÷ 110°C)

- main:

3+1 and 2+2: 2+1: - branches: 3+1 and 2+2: 2+1 (bottom): 2+1 (side): - air vent valve: 3+1, 2+2 and 2+1: - drain cock: 3+1, 2+2 and 2+1:

Center distances: - main: - branches:

3+1 and 2+2: 2+1: 3+1 and 2+2: 2+1:

1 1/4” F NPT 1” F NPT 1” M NPT 1” M NPT 1” F NPT 1/2” F straight 1/2” F straight 3 1/8” (80 mm) 2 3/8” (60 mm) 3 1/2” (90 mm) 3 1/2” (90 mm)

Ma te ri a l : Thi c kne ss: Density:

Cl ose d -c e l l e xp a nd e d PEX 3/4” ( 20 mm) - inner part: 2 lb/ft 3 (30 kg/m 3) - outer part: 3 lb/ft 3 (50 kg/m 3) Thermal conductivity: - at 32°F (0°C): 0.26 BTU/in (.038 W/mK) - at 100°F (40°C): 0.31 BTU/in (.045 W/mK) Vapor resistance coefficient (DIN 52615): > 1.300 Te mp e ra ture ra ng e : 32 to 212°F ( 0÷ 100°C) Fire resistance (DIN 4102): Class 1 (Class B2) Flow Characteristics Maximum recommended flow rates at connections: Branches 2+1 2+2 3+1

Primary 9 gpm (2.0 m 3/h) 11 gpm (2.5 m 3/h) 11 gpm (2.5 m 3/h)

Secondary (total) 22 gpm (5 m 3/h) 26 gpm (6 m 3/h) 26 gpm (6 m 3/h)

Dimensions

Operating principle When a single system contains a primary generating circuit, with its own pump, and a secondary user circuit, with one or more distribution pumps, operating conditions may arise in the system where the pumps interact, creating abnormal variations in flow rates and pressures in the circuits. In the HydroLink there is a low pressure loss zone, which enables the primary and secondary circuits connected to it to be hydraulically independent of each other; the flow in one circuit does not create a flow in the other if the pressure loss in the common section is negligible. In this case, the flow rates passing through the respective circuits depend exclusively on the flow characteristics of the pumps, preventing reciprocal influence due to connection in series. Downstream of the hydronic separation zone are the flow and return manifolds to which the various secondary distribution circuits can be connected.

A

C

I H

HydroLink™ Series 559 Pmax 90 psi - Tmax 230°F

A

38487

Patent Application No. MI2001A 001270

C D

Code

A

559022A 1 1/4”

B 1”

L

B E

C

F

G

D

E

F

G

H

I

L

1/2” 6 5/16” 3 9/16” 5 1/2” 20 7/8” 3 1/8” 9 7/8” 3 1/8”

C

Volume (gal)

29

1.8

G

Three possible hydronic balance situations are shown below as examples.

A

F

Weight (lb)

I H

HydroLink™ Series 559 Pmax 90 psi - Tmax 230°F 38503

A

Patent Application No. MI2001A 001270

secondary circuit C

B

D

Code

A

559031A 1 1/4”

B 1”

C

L D

E /F

M

E

G

H

I

L

M

1/2” 15 3/8” 3 9/16” 5 1/2” 3 1/8” 9 7/8” 29 15/16” 3 1/8”

Weight (lb)

Volume (gal)

39

2.6

C

A

H G

A

primary circuit HydroLink™ Series 559

A

Patent Application No. MI2001A 001270

A

38485

Pmax 90 psi - Tmax 230°F

B

C D

L E

Code

A

B

C

559021A

1”

1”

1/2”

GS1

F

D

I

E

F

H

I

L

6 1/8” 3 9/16” 20 1/2” 7 11/16” 3 9/16” 2 3/8”

GS2

GS3

Gp

Weight (lb)

Volume (gal)

16

1

GS1

GS2

GS3

Gp

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

GS1

GS2

GS3

Gp

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

GS4 Gprimary < Gsecondary (GS1+GS2+GS3+GS4)

Installation HydroLink units should be installed in accordance with the diagrams shown in this leaflet, ensuring the correct connection of the flow and return pipework and the main and branch connections. HydroLinks units can even be installed upside down, as long as the connection logic shown is adhered to. The 1/2” F connections must only be used for connecting an air vent valve and drain cock, and not for connecting branch circuits.

Insulation

CALEFFI

CALEFFI

100

2,25 2,0

1,75

80

1,0

2,0

1,75

80 1,5

16

-15

20

0,5

20

1,0

23

1,75 2,0

24

9

2,25

0,75 0,5

3

WATCH

10

1,25

5

0

-5

-10

-15

-20

0,25

1,5 1,75 2,0 2,25

1

2

10

10

9

3

6

8

4

7

5

6

3 4 5

20

40

0,25

15

11

1

21

1,5

11

2

16

12

0,25

60

0,75

17

20

12

6

18

12

-20

22

-10

6

22

-5

13

13

23

0

7

5

8

1,0 0,75 0,5

3

WATCH

10

1,25

14

14

24

1,0

19

40

20 15

15

15

21

0,5 0,25

20

9

1,25

60

0,75

17

9

18

12

The Hydrolink is supplied with heat-preformed shell insulation. This system ensures not only perfect heat insulation but also the tightness required to prevent atmospheric water vapour from entering the unit. For this reason, this type of insulation may also be used in cooling water circuits, as it prevents condensation from forming on the surface of the valve body.

100

2,25

1,5 1,25

19

20

20

Support brackets The HydroLink external versions 2+2 and 3+1 are supplied complete with suitable wall-mounting brackets, which make it possible to adjust the front-to-back positioning.

Application diagrams RT

35 40 45 50 55 60

40 20

60 80

0

CALEFFI

CALEFFI

°C

CALEFFI

10 8 6 4 2 0

40 20

10 8 6 4 2 0

10 8 6 4 2 0

60

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

10 8 6 4 2 0

CALEFFI

80

0

°C

RT

35 40 45

20

50 55 60

40 20

60 80

0

CALEFFI

CALEFFI

°C

CALEFFI

CALEFFI

30 25

CALEFFI

20

CALEFFI

30 25

CALEFFI

System with wall-mounted boiler and built-in HydroLink 2+1

10 8 6 4 2 0

40 20

60 80

0

°C

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

M S

-

+ 20

System with floor standing boiler and HydroLink 3+1

18

CALEFFI

22

16

24

CALEFFI

CALEFFI

CALEFFI

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

CALEFFI

M S

-

+ 20

18

CALEFFI

10 8 6 4 2 0

10 8 6 4 2 0

10 8 6 4 2 0

CALEFFI

2,25

100 2,0 1,75 1,5

80

CALEFFI

2,25

1,0

0,5

5

0

-5

-10

-15

-20

CALEFFI

100

1,5

1,0

80

60

0,75 40

0,5

0,25 10

1,25

10 8 6 4 2 0

1,25 60

0,75

15

1,0

10 8 6 4 2 0

2,0 1,75

1,25

20

0,75 0,5 0,25

22 24

CALEFFI

CALEFFI

10 8 6 4 2 0

CALEFFI

16

CALEFFI

CALEFFI

40

0,25 20

20

1,5

15

1,0 1,75

0,75

2,0

0,5

2,25

0,25

10

1,25

5

0

-5

-10

-15

-20

20

1,5 1,75 2,0 2,25

9

8 20

20

SPECIFICATION SUMMARIES Code 559022A External hydraulic separator-manifold, branches 2+2, for heating and air-conditioning systems. Painted steel body. Connections to generator 1 1/4” F, centre distance 3 1/8” (80 mm). Branch connections 1” M, centre distance 3 1/2” (90 mm) . 1/2” F connections for air vent valve and drain cock. Max. working pressure 90 psi (6 bar) . Temperature range 32 to 230°F (0÷110°C) . Complete with support brackets. Code 559031A External hydraulic separator-manifold, branches 3+1, for heating and air-conditioning systems. Painted steel body. Connections to generator 1 1/4” F, centre distance 3 1/8” (80 mm) . Branch connections 1” M, centre distance 3 1/2” (90 mm) . 1/2” F connections for air vent valve and drain cock. Max. working pressure 90 psi (6 bar) . Temperature range 32 to 230°F (0÷110°C) . Complete with support brackets. Code 559021A Built-in hydraulic separator-manifold, branches 2+1, for heating and air-conditioning systems. Painted steel body. Connections to generator 1” F, centre distance 2 3/8” (60 mm) . Side branch connections 1” M, centre distance 3 1/2” (90 mm) . Head branch connections 1” F, centre distance 2 3/8” (60 mm) . 1/2” F connections for air vent valve and drain cock. Max. working pressure 90 psi (6 bar) . Temperature range 32 to 230°F (0÷110°C) .

We reserve the right to change our products and their relevant technical data, contained in this publication, at any time and without prior notice.

CALEFFI Caleffi North America, Inc.

9850 South 54th Street / Milwaukee, WI 53132 Tel: 414.421.1000 / Fax: 414.421.2878 / www.caleffi.us © Copyright 2005 Caleffi North America, Inc.