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 Size 1 1/4”; branches 1”
Code 559031A External 3+1 separator-manifold. Complete with support brackets and pre-formed insulation Size 1 1/4”; branc hes 1”
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 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 Ma te ri a l : Cl ose d -c e l l e xp a nd e d PEX
Medium: Water and non-hazardous glycol solutions Thi c kne ss: 3/4” ( 20 mm)
Ma x p e rc e nta g e of g l y c ol e : 50% Density: - inner part: 2 lb/ft 3 (30 kg/m 3)
- outer part: 3 lb/ft 3 (50 kg/m 3)
Ma x. worki ng p re ssure : 90 p si ( 6 b a r) Thermal conductivity: - at 32°F (0°C): 0.26 BTU/in (.038 W/mK)
Te mp e ra ture ra ng e : 32 to 230°F ( 0 ÷ 110°C) - at 100°F (40°C): 0.31 BTU/in (.045 W/mK)
Connections: - main: 3+1 and 2+2: 1 1/4” F NPT Vapor resistance coefficient (DIN 52615): > 1.300
2+1: 1” F NPT Te mp e ra ture ra ng e : 32 to 212°F ( 0÷ 100°C)
- branches: 3+1 and 2+2: 1” M NPT Fire resistance (DIN 4102): Class 1 (Class B2)
2+1 (bottom): 1” M NPT
2+1 (side): 1” F NPT
- air vent valve: 3+1, 2+2 and 2+1: 1/2” F straight Flow Characteristics
- drain cock: 3+1, 2+2 and 2+1: 1/2” F straight Maximum recommended flow rates at connections:
Center distances: - main: 3+1 and 2+2: 3 1/8” (80 mm)
2+1: 2 3/8” (60 mm) Branches Primary Secondary (total)
- branches: 3+1 and 2+2: 3 1/2” (90 mm) 2+1 9 gpm (2.0 m 3/h) 22 gpm (5 m 3/h)
2+1: 3 1/2” (90 mm)
2+2 11 gpm (2.5 m 3/h) 26 gpm (6 m 3/h)
3+1 11 gpm (2.5 m 3/h) 26 gpm (6 m 3/h)
Dimensions Operating principle
When a single system contains a primary generating circuit, with its
C 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
A

HydroLink™
rates and pressures in the circuits.
H
I

Series 559
Pmax 90 psi - Tmax 230°F

In the HydroLink there is a low pressure loss zone, which enables

Patent Application

38487
No. MI2001A 001270
A

the primary and secondary circuits connected to it to be

hydraulically independent of each other; the flow in one circuit
C B L does not create a flow in the other if the pressure loss in the
D E F common section is negligible.
G In this case, the flow rates passing through the respective circuits
depend exclusively on the flow characteristics of the pumps,
Weight Volume preventing reciprocal influence due to connection in series.
Code A B C D E F G H I L (lb) (gal)

559022A 1 1/4” 1” 1/2” 6 5/16” 3 9/16” 5 1/2” 20 7/8” 3 1/8” 9 7/8” 3 1/8” 29 1.8
Downstream of the hydronic separation zone are the flow and return
manifolds to which the various secondary distribution circuits can
be connected.

C F G Three possible hydronic balance situations are shown below as

examples.
A

HydroLink™
H
I

Series 559
Pmax 90 psi - Tmax 230°F
Patent Application
38503

No. MI2001A 001270

A

secondary circuit
C B M
D E
L

Weight Volume
Code A B C D E /F G H I L M (lb) (gal)

559031A 1 1/4” 1” 1/2” 15 3/8” 3 9/16” 5 1/2” 3 1/8” 9 7/8” 29 15/16” 3 1/8” 39 2.6

C
primary circuit
A

A
G

HydroLink™
H

Series 559
Pmax 90 psi - Tmax 230°F
38485

Patent Application
No. MI2001A 001270
A

C B L
D E I
F

Weight Volume
Code A B C D E F H I L (lb) (gal)

559021A 1” 1” 1/2” 6 1/8” 3 9/16” 20 1/2” 7 11/16” 3 9/16” 2 3/8” 16 1

GS1 GS2 GS3 GS1 GS2 GS3 GS1 GS2 GS3

Gp Gp Gp

GS4 GS4 GS4

Gprimary = Gsecondary (GS1+GS2+GS3+GS4) Gprimary > Gsecondary (GS1+GS2+GS3+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
The Hydrolink is supplied with heat-preformed shell insulation. This
CALEFFI
100

CALEFFI
100
system ensures not only perfect heat insulation but also the
tightness required to prevent atmospheric water vapour from
2,25 2,25
2,0 2,0

1,75 1,75
80 80
1,5 1,5

1,25 1,25

60 60
1,0 1,0

18 0,75
18 0,75

19 17 40 19 17 40
16 0,5
16 0,5

20 20
12 0,25
12 0,25
21

21
15

20
15

20
20 15 10 5 0 -5 -10 -15 -20 20 15 10 5 0 -5 -10 -15 -20
14

14
22

1,25
22

1,25
1,0 1,5 1,0 1,5

0,75 1,75 0,75 1,75

23

13

23

13

0,5 2,0 0,5 2,0

9 3 9 3
24

12

24

12

WATCH WATCH

0,25 2,25 0,25 2,25

11

11
1

1
10

10
2

3 9 9
6
3
6

entering the unit. For this reason, this type of insulation may also be
4 8 4 8
5 6 7 5 6 7

20 20

used in cooling water circuits, as it prevents condensation from

forming on the surface of the valve body.

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
System with
wall-mounted 30
35 40 45
50

boiler and built-in

25 55
20 60

40
20 60

0 80 CALEFFI
CALEFFI

°C

CALEFFI

HydroLink 2+1
CALEFFI

CALEFFI

10 10 10 10 10 10
8 8 8 8 8 8
6 6 6 6 6 6
4 4 4 4 4 4
2 2 2 2 2 2
0 0 0 0 0 0

40
20 60
CALEFFI
80 CALEFFI
0

°C

RT

35 40 45
30 50
25 55
20 60

40
20 60

0 80 CALEFFI
CALEFFI

°C

CALEFFI
CALEFFI

CALEFFI

10 10 10 10 10 10
8 8 8 8 8 8
6 6 6 6 6 6
4 4 4 4 4 4
2 2 2 2 2 2
0 0 0 0 0 0

40
20 60
CALEFFI
80 CALEFFI
0

°C
 M S - +
20

System with floor

18 22

CALEFFI 16 24

CALEFFI
CALEFFI

standing boiler and

CALEFFI

CALEFFI
HydroLink 3+1
10 10 10 10 10 10
8 8 8 8 8 8
6 6 6 6 6 6
4 4 4 4 4 4
2 2 2 2 2 2
0 0 0 0 0 0

CALEFFI
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M S - +
20

18 22

CALEFFI 16 24

CALEFFI
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CALEFFI

CALEFFI
10 10 10 10 10 10
8 8 8 8 8 8
6 6 6 6 6 6
4 4 4 4 4 4
2 2 2 2 2 2
0 0 0 0 0 0

CALEFFI
CALEFFI

CALEFFI CALEFFI
100 100
2,25 2,25
2,0 2,0

1,75 1,75
80 80
1,5 1,5

1,25 1,25
60 60
1,0 1,0

0,75 0,75
40 40
0,5 0,5
0,25 0,25

20 20
20 15 10 5 0 -5 -10 -15 -20 20 15 10 5 0 -5 -10 -15 -20

1,25 1,25
1,0 1,5 1,0 1,5

0,75 1,75 0,75 1,75

0,5 2,0 0,5 2,0

0,25 2,25 0,25 2,25

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.