F L O W I N G E X P E R T I S E

WATER TREATMENT IN
HEATING AND COOLING SYSTEMS
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in a HEATING AND COOLING SYSTEM,
at any stage of operation.
 AIR AND DIRT IN HEATING AND COOLING SYSTEMS

Problems linked to the presence of dirt Problems linked to the presence of air
The impurities contained in the water of the hydronic circuits can The problems caused by air contained in hydronic systems can be
cause a series of problems that should not be underestimated. serious and unpleasant both for the users and for the professionals
who service the system. If these problems are not analysed
Corrosion due to differential aeration thoroughly, they can often lead to solutions that are not decisive
This is due to the fact that, in the presence of water, a layer of scale in the long term.
on a metal surface leads to the formation of two zones (water/ Initially it is very important to identify the phenomena that the air in
impurities and impurities/metal) with a different oxygen content; for the system can provoke.
this reason, localised batteries are activated with current flows that
lead to corrosion of the metal surfaces. Noise in the pipes and in the terminals
The air contained in the system makes noise in the pipes and
Irregular operation of the valves the adjustment devices. This is much more evident during system
This is due to impurities, which can adhere stubbornly to the valve startup, i.e. when the flow begins to flow through the pipes.
seats and cause deformities in regulation and leaks, for example
in balancing valves. Insufficient flow rates, complete circulation blockages and
insufficient heat exchange between the emission terminals
Pumps blocking and seizing and the room
These problems may be suspended particles circulating through the Circulation can be partially or totally blocked by air bubbles present
pumps which can build up inside them, due to both the particular in some points in the system. This phenomenon is particularly
geometry of the pumps and to the effect of the magnetic fields serious for radiant panel systems, but can also cause thermal
generated by the pumps themselves. imbalances and lower radiator or fan coil efficiency.

Lower efficiency of the heat exchangers Corrosion of the system

Deposits and scale build-up can significantly reduce both the flow This is provoked by the oxygen present in the air and can lead
rates of the fluids and the heat exchanging surfaces. to the weakening but also the breakage of components such as
pipes, radiators and boiler heat exchangers.

Cavitation
This may compromise durability and operation, especially of the
pumps and regulating valves.

The products in this document have been categorised according to the solutions considered most suitable and effective for the system application
types described. However, this guide is not in any way intended to exclude the use of other Caleffi products with similar specifications in these
systems.
Caleffi S.p.A. declines any responsibility deriving from improper use of the data provided in this document. This document should not be considered
as a replacement for the technical heating design.

4
 Devices for separating impurities

Magnetic dirt separators

- brass 5463 series
- steel 5466 series

- technopolymer 5453 series

- technopolymer with double magnet 5457 series

Magnetic dirt separator filters

- under-boiler, chrome plated brass 5459 series
- under-boiler, technopolymer 5450 series
- multi-function device 5453 series

- self-cleaning, technopolymer 577 series

- self-cleaning, steel 5790 series

Air separation devices

Deaerators
- under-boiler, technopolymer 551 series
- with adjustable connections 551 series
- for horizontal pipes 551 series

Automatic air vents

- Standard 5020 - 5021 series
- High discharge pressure 5024 - 5025 - 5026 - 5027 series
- High discharge capacity 5022 - 501 - 551 series

Devices for separating air and impurities

Deaerators-dirt separators
- technopolymer with magnet 5464 series
- with magnet 5461 series
- standard 546 series

Domestic water treatment

- under-boiler polyphosphate dispenser 5459 series

Technical water treatment

- liquid chemical additives 5709 series

- pressurised chemical additives 5709 series
- automatic water treatment unit 580 series
- softening and demineralisation cartridges 580 series

5
 Magnetic dirt separators
Operating principle
Dirt separation is a physical treatment similar to filtration but more effective from the point of view of particle dimensions. By exploiting the principle
of precipitation by gravity, after just a few recirculations it is able to separate and deposit even particles with dimensions down to 0,005 mm (5 µm).
The impurity separating action of the magnetic dirt separator is based on the combined action of several phenomena.
The reduction in medium flow speed encourages the dirt particles to fall into the collection chamber as a result of gravity. The collection chamber
possesses the following features:
• it is located at the bottom of the device, at such a distance from the connections that the collected impurities are not affected by the swirling of
the flow through the mesh;
• it is large enough to increase the dirt storage capacity, which means emptying/draining procedures are required less often;
• it has a drain cock for draining the impurities collected in the lower part even while the system is running.

The internal element with mesh surfaces provides a low resistance to the passage of the medium while still guaranteeing separation, which takes
place due to the particles colliding with the mesh surfaces and then settling.
The magnet offers greater efficiency in the separation and collection of ferromagnetic impurities, which are captured in the dirt separator collection
chamber by the magnets in the device.

Pressure drops
Due to the conformation of these components (large cross section), their pressure drop is almost always
negligible over the range of optimal operating flow rates. The pressure drops are kept constant within the
operating time.

Sizing
Sizing a dirt separator mainly depends on the speed at which the medium flows through the device, since
an excessive speed would not allow correct separation of the impurities.
As is known, the medium flow speed depends on the flow rate and the cross section. Remaining within
the speed limits specified above therefore means not exceeding certain maximum permissible flow
rates for each size.

Magnetic dirt separator filters

Operating principle
The impurity separating action of the magnetic dirt separator filter is based on the combined action of several
components:
• an internal mesh element (1), which carries out dirt separation;
• magnets fitted directly in the flow path (2), which capture and retain ferrous impurities;
• a metal filter mesh (3), which separates off the impurities by means of mechanical selection.
The filter mesh is characterised by various parameters, one the most important being the mesh size (or filtering
capacity), which indicates the minimum dimensions of the particles that the filter is able to intercept. Another
concerns the filter mesh surface, with a larger surface area guaranteeing a lower degree of fouling.
The collection chamber at the bottom of these devices has the same special features as the chamber used in
1
dirt separators.

Pressure drops
Due to the passage through the filter mesh, a pressure drop is produced in the medium which increases as the
degree of clogging increases.
In combined devices such as dirt separator filters, the filter mesh is better
protected than that of a simple filter because some of the impurities fall into the
dirt separator. This means there is less fouling than in normal filters within the
same operating time.

It is important to preform regular maintenance of the dirt separator filter 2

with magnet; in some cases this process is made easier by automatic or
semi-automatic cleaning systems.

Sizing
The main parameter to assess when sizing a magnetic dirt separator filter
is its pressure drop. In fact, as the water passes through the filter mesh, it
creates a different pressure drop, depending on the filtration capacity. The
greater the filtration capacity, the greater the separation efficiency, but also
the pressure drop. 3

6
 HEAT PUMP SYSTEMS
TECHNOPOLYMER FILTER WITH MAGNET
SEMI-AUTOMATIC CLEANING MANUAL CLEANING

CALEFFI XF DIRTMAGPLUS®
577 5453
3/4” – 2” 3/4” – 1 1/4”
Ø22 - Ø28 Ø22 - Ø28

WALL-MOUNTED BOILER SYSTEMS

MAGNETIC FILTER TECHNOPOLYMER DIRT SEPARATOR WITH MAGNET AND FILTER

CALEFFI XS® DIRTMAGMINI®

5459 5450
3/4” M x 3/4” F captive nut 3/4” F captive nut x 3/4” M
Ø22 Ø22

WALL-MOUNTED BOILER SYSTEMS WITH TECHNICAL ROOM -

COOLING SYSTEMS
TECHNOPOLYMER DIRT TECHNOPOLYMER DIRT SEPARATOR TECHNOPOLYMER FILTER WITH
SEPARATOR WITH MAGNET WITH DOUBLE MAGNET MAGNET
STANDARD FLOW RATES HIGH FLOW RATES SEMI-AUTOMATIC CLEANING

DIRTMAG® DIRTMAGPRO® CALEFFI XF

5453 5457 577
3/4” – 1” 3/4” – 1 1/4” 3/4” – 1 1/4”
Ø22 - Ø28 Ø22 - Ø28 Ø22 - Ø28

MEDIUM/LARGE SYSTEMS
TECHNOPOLYMER FILTER WITH BRASS DIRT SEPARATOR WITH STEEL DIRT SEPARATOR WITH
MAGNET MAGNET MAGNET

CALEFFI XF DIRTMAG® DIRTMAG®

577 5463 5466
1 1/2” – 2” 3/4” – 2” DN 50–DN 65

LARGE SYSTEMS
STEEL DIRT SEPARATOR WITH MAGNET SELF-CLEANING MAGNETIC DIRT SEPARATOR FILTER
IN-LINE INSTALLATION BY-PASS INSTALLATION

DIRTMAG® DIRTMAGCLEAN®
5466 5790
DN 80–DN 300

7
 HEAT PUMP SYSTEMS

IMPURITIES IN HEAT PUMP SYSTEMS

The components of a heating and cooling system are exposed to degradation caused by the impurities that circulate in the thermal medium. If the
impurities are not removed as necessary, they may cause blockages and seizing of the pumps, lower efficiency of the heat exchangers, unreliable
valve operation and insufficient heat exchange.

In the specific case of heat pump systems, the use of

a magnetic dirt separator filter is recommended. The
impurities may actually put the already small inner
channels at risk of blockage, or prevent the internal
adjustment devices from working properly.
As the heat pump is a generator employing low
temperature differences, even small changes in flow
rate may adversely affect its performance.
The greater the filtering action of the magnetic dirt
separator filter, the longer the high efficiency of the
heat pump systems will be maintained.

8
 SIZING

DIRTMAGPLUS®
Sizing depends mainly* on the speed at which the medium flows through the device.
To guarantee optimal operation, the maximum speed on entering the device should be ≤ 1 m/s.
To remain within the speed limits specified above, the specific maximum permissible flow rate values for
each size must not be exceeded.

Max. flow rate Kv* ∆p* [kPa]

Code Connections
[l/h] [m3/h] (max. flow rate)
*In multifunction devices such as DIRTMAGPLUS®, the
filter mesh is more protected as some of the impurities 545375 3/4” 1,130 6.7 2.84
fall into the dirt separator. For this reason, sizing is mostly 545372 Ø 22 1130 6.7 2.84
determined by the maximum flow rate. 545376 1” 1130 6.7 2.84
545373 Ø 28 1130 6.7 2.84
545377 1 1/4” 1800 9.6 3.53

CALEFFI XF
Kv* [m3/h] Kv* [m3/h]
Code Connections
100 % filtration 50 % filtration
The main parameter to assess when sizing is the
pressure drop generated in the circuit. 577500 3/4” 10.3
577200 Ø 22 9
577600 1” 10.7
577300 Ø 28 10.5
577700 1 1/4” 10.7
577800 1 1/2” 23 40
577900 2” 23 40

HP nominal power
3 4 5 6 7 8 9 12 14 18 22 25 28 32 35
[kW]
Max. set flow rate
[l/h] (ΔT = 5 °C) 516 688 860 1032 1204 1376 1,548 2064 2408 3096 3784 4300 4816 5504 6020

Nominal pipe
3/4” 3/4” 1” 1” 1” 1” 1 1/4” 1 1/4” 1 1/4” 1 1/2” 1 1/2” 1 1/2” 2” 2” 2”
diameter**
DIRTMAGPLUS®

545372 545373
(Ø 22) (Ø 28)

∆p* [kPa] 0.59 1.05 1.65 2.37 3.23 -

DIRTMAGPLUS®

545375 545376 545377

(3/4”) (1”) (1 1/4”)

∆p* [kPa] 0.59 1.05 1.65 2.37 3.23 2.06 2.6 4.6 -

577200 577300
CALEFFI XF

(Ø 22) (Ø 28)

∆p* [kPa] 0.33 0.58 0.67 0.97 1.31 1.71 -

577500 577600 577700 577800 577900

CALEFFI XF

(3/4”) (1”) (1 1/4”) (1 1/2”) (2”)

∆p* [kPa] (100 %) 0.25 0.45 0.65 0.93 1.27 1.66 2.09 3.73 5.06 1.81 2.7 3.5 4.38 5.72 6.85
∆p* [kPa] (50 %) - 0.6 0.89 1.16 1.45 1.89 2.27

* With clean filter

** Pipe pressure drop r ~ 20-22 mm w.g./m (50 °C)

9
 WALL-MOUNTED BOILER SYSTEMS
ANGLED INSTALLATION
CALEFFI XS® DIRTMAGMINI®

System nominal power [kW] 8 9 10 12 14 16 18 21

System maximum flow rate [l/h]
(ΔT = 20 °C) 344 387 430 516 602 688 774 903
CALEFFI XS®

545900
(3/4” M x 3/4” F captive nut)

∆p* [kPa] 0.94 1.19 1.47 2.11 2.87 3.75 4.75 6.47
DIRTMAGMINI®

545000
(3/4” M x 3/4” F captive nut)

∆p* [kPa] 0.78 0.98 1.22 1.75 2.38 3.11 3.94 5.36
DIRTMAGMINI®

545022
(Ø 22)

∆p* [kPa] 0.78 0.98 1.22 1.75 2.38 3.11 3.94 5.36

SIZING
The main parameter to assess when sizing is the pressure drop generated in the circuit.

CALEFFI XS® DIRTMAGMINI®

Code Connections Kv* [m3/h]

545900 3/4” 3.55 Kv inst. Kv inst.
Code Connections in-line* angled*
[m3/h] [m3/h]

Code Connections Kv* [m3/h] 545000 3/4” 4.2 3.9

545910 3/4” 3.66 545022 Ø 22 4.2 3.9
545912 Ø 22 3.66

* With clean filter

10
 WALL-MOUNTED BOILER SYSTEMS
IN-LINE INSTALLATION
CALEFFI XS® DIRTMAGMINI®

System nominal power [kW] 8 9 10 12 14 16 18 21

System maximum flow rate [l/h]
(ΔT = 20 °C) 344 387 430 516 602 688 774 903
CALEFFI XS®

545910
(3/4” M x 3/4” F captive nut)

∆p* [kPa] 0.88 1.12 1.38 1.99 2.71 3.53 4.47 6.09
CALEFFI XS®

545912
(Ø 22)

∆p* [kPa] 0.88 1.12 1.38 1.99 2.71 3.53 4.47 6.09
DIRTMAGMINI®

545000
(3/4” M x 3/4” F captive nut)

∆p* [kPa] 0.67 0.85 1.05 1.51 2.05 2.68 3.4 4.62
DIRTMAGMINI®

545022
(Ø 22)

∆p* [kPa] 0.67 0.85 1.05 1.51 2.05 2.68 3.4 4.62

IMPURITIES IN WALL-MOUNTED BOILER SYSTEMS

Suspended particles and corrosion residues adhere to the inner surfaces of the heat
exchanger, generating a compact and strong layer which, by reducing the cross section, has
a twofold negative impact:
- blocking the passages, significantly reducing the medium flow rates;
- thermally insulating the heat exchanger, reducing its efficiency.
These scale build-ups can create zones with considerable temperature differences, leading to
localised overheating of the metal in the heat exchangers.
To compensate for this, the boiler regulation systems increase the power of the burner. This
results in:
- an increase in flue gas temperatures;
- greater heat loss (through the flue gases and boiler walls);
- reduced flue gas condensation.
All this lowers the boiler efficiency and increases energy costs.
In condensing boilers, this phenomenon is even more evident, especially at the onset of
scaling, when the deposits are still thin. In fact, increasing the flue gas temperature by just a
few degrees considerably reduces the condensation capacity of boilers, and therefore their
efficiency. Therefore, impurity deposits greatly affect the efficiency of condensing boilers.
* With clean filter

11
 WALL-MOUNTED BOILER SYSTEMS WITH TECHNICAL ROOM

hgiH
High ycneicffiE
Efficiency

hgiH
High ycneicffiE
Efficiency

COOLING SYSTEMS

SIZING
Sizing depends on the speed at which the medium flows through the device.
To guarantee optimal operation, the maximum speed on entering the device should be ≤ 1,2 m/s for DIRTMAG® and ≤ 1,6 m/s
for DIRTMAGPRO®. To remain within the speed limits specified above, the specific maximum permissible flow rate values for
each size must not be exceeded.

DIRTMAG® DIRTMAGPRO®

Max. flow rate Kv ∆p [kPa] Max. flow rate Kv ∆p [kPa]

Code Connections Code Connections
[l/h] [m3/h] (max. flow rate) [l/h] [m3/h] (max. flow rate)
545305 3/4” 1300 10.3 1.57 545705 3/4” 1600 9.5 2.84
545345 3/4” 1300 7.5 3.04 545702 Ø 22 1600 8.5 3.53
545302 Ø 22 1300 9.5 1.86 545706 1” 1800 10 3.23
545306 1” 1300 10.5 1.57 545703 Ø 28 1800 9.5 3.63
545346 1” 1300 7.5 3.04 545707 1 1/4” 2600 10.5 6.08
545303 Ø 28 1300 10.6 1.47
545307 1 1/4” 2100 10.5 4.00
545347 1 1/4” 2100 9.9 4.51

12
 System nominal power
8 12 14 16 18 22 25 30
(heating) [kW]
System maximum flow rate [l/h]
(∆T = 15 °C) 459 688 803 917 1032 1261 1433 1720

Nominal pipe diameter*** 3/4” 3/4” 1” 1” 1” 1” 1 1/4” 1 1/4”

545305 - 545302 545306 - 545303 545307

DIRTMAG®

(3/4” - Ø 22) (1” - Ø 28) (1 1/4”)

∆p [kPa] 0.21 0.48 0.58 0.76 0.96 1.43 1.86 2.68

545345 545346 545347

DIRTMAG®

(3/4”) (1”) (1 1/4”)

∆p [kPa] 0.37 0.84 1.15 1.49 1.89 2.83 2.1 3

DIRTMAGPRO®

545705 - 545702 545706 - 545703 545707

(3/4” - Ø 22) (1” - Ø 28) (1 1/4”)

∆p [kPa] 0.26 0.59 0.59 0.89 1.12 1.68 1.86 2.68

CALEFFI XF **

577500 - 577200 577600 - 577300 577700

(3/4” - Ø 22) (1” - Ø 28) (1 1/4”)

∆p* [kPa] 0.23 0.52 0.55 0.74 0.95 1.4 1.79 2.58

System nominal power

2 3 5 7 9 11 13 15
(cooling) [kW]
System maximum flow rate [l/h]
(∆T = 5 °C) 344 516 860 1204 1548 1892 2236 2580

Nominal pipe diameter*** 3/4” 3/4” 1” 1” 1 1/4” 1 1/4” 1 1/4” 1 1/4”

545305 - 545302 545306 - 545303 545307

DIRTMAG®

(3/4” - Ø 22) (1” - Ø 28) (1 1/4”)

∆p [kPa] 0.12 0.27 0.67 1.30 2.19 3.24 -

545345 545346 545347

DIRTMAG®

(3/4”) (1”) (1 1/4”)

∆p [kPa] 0.21 0.47 1.31 2.58 4.26 6.36 -

DIRTMAGPRO®

545705 - 545702 545706 - 545703 545707

(3/4” - Ø 22) (1” - Ø 28) (1 1/4”)

∆p [kPa] 0.15 0.33 0.78 1.53 2.17 3.24 4.54 6.04

CALEFFI XF **

577500 - 577200 577600 - 577300 577700

(3/4” - Ø 22) (1” - Ø 28) (1 1/4”)

∆p* [kPa] 0.12 0.28 0.66 1.29 2.1 3.13 4.37 5.81

* With clean filter

**Sizing CALEFFI XF page 9
***Pipe pressure drop r ~ 20-22 mm w.g./m (50 °C)

13
 MEDIUM/LARGE SYSTEMS - HEATING

MEDIUM/LARGE SYSTEMS - COOLING

SIZING
Sizing depends on the speed at which the medium flows through the device.
To guarantee optimal operation, the maximum speed on entering the device should be ≤ 1,2 m/s.
To remain within the speed limits specified above, the specific maximum permissible flow rate values for each size must not be
exceeded.

DIRTMAG®
DIRTMAG®

Max. flow rate Kv ∆p [kPa]

Code Size
[l/h] [m3/h] (max. flow rate)
Max. flow rate Kv ∆p [kPa]
Code Connections
[l/h] [m3/h] (max. flow rate) 546650 DN 50 8470 60.5 1.96
546315 3/4” 1360 16.2 0.7 546660 DN 65 14320 110 1.69
546316 1” 2110 28.1 0.56 546680 DN 80 21690 160 1.86
546317 1 1/4” 3470 48.8 0.51 546610 DN 100 33890 216 2.45
546318 1 1/2” 5420 63.2 0.74 546612 DN 125 58800 365 2.6
546319 2” 8200 70 1.37 546615 DN 150 86200 535 2.6

14
System nominal power
35 40 45 55 65 75 85 100
(heating) [kW]
System maximum flow rate [l/h]
(∆T = 15 °C) 2007 2293 2580 3153 3727 4300 4873 5733

2” 2”
Nominal pipe diameter*** 1 1/4” 1 1/4” 1 1/4” 1 1/2” 1 1/2” 1 1/2”
DN 50 DN 50

577800 577900
CALEFFI XF **

(1 1/2”) (2”)

∆p* [kPa] (100 %) 0.76 0.99 1.26 1.88 2.63 3.5 4.49 6.21
∆p* [kPa] (50 %) 0.25 0.33 0.42 0.62 0.87 1.16 1.48 2.05

546317 546318 546319

DIRTMAG®

(1 1/4”) (1 1/2”) (2”)

∆p [kPa] 0.17 0.22 0.28 0.25 0.35 0.46 0.48 0.67

546650
DIRTMAG®

(DN 50)

∆p [kPa] - 0.65 0.9

System nominal power

20 25 30 35 40 50 60 70
(cooling) [kW]
System maximum flow rate
[l/h] (∆T = 5 °C) 3440 4300 5160 6020 6880 8600 10320 12040

2” 2” 2”
Nominal pipe diameter*** 1 1/2” 1 1/2” DN 65 DN 65 DN 65
DN 50 DN 50 DN 50

577800 577900
CALEFFI XF **

(1 1/2”) (2”)

∆p* [kPa] (100 %) 2.24 3.5 5 6.85 8.95 -

∆p* [kPa] (50 %) 0.74 1.16 1.66 2.27 2.96 -

546318 546319
DIRTMAG®

(1 1/2”) (2”)

∆p [kPa] 0.3 0.46 0.54 0.74 0.97 -

546650 546660
DIRTMAG®

(DN 50) (DN 65)

∆p [kPa] - 0.73 0.99 1.29 2.02 2.91 3.96

* With clean filter

**Sizing CALEFFI XF page 9
***Pipe pressure drop r ~ 20-22 mm w.g./m (50 °C)

15
 LARGE SYSTEMS -
HEATING/COOLING - IN-LINE INSTALLATION

H0001039

H0001039

H0001039

H0001039
SIZING
DIRTMAG®
Max. flow rate Kv ∆p [kPa]
Code Size
Sizing depends on the speed at which the medium [l/h] [m3/h] (max. flow rate)
flows through the device. 546650 DN 50 8470 60.5 1.96
To guarantee optimal operation, the maximum
546660 DN 65 14320 110 1.66
speed on entering the device should be ≤ 1,2 m/s.
To remain within the speed limits specified above, 546680 DN 80 21690 160 1.86
the specific maximum permissible flow rate 546610 DN 100 33890 216 2.45
values for each size must not be exceeded.
546612 DN 125 58800 365 2.55
546615 DN 150 86200 535 2.55
546620 DN 200 146000 900 2.63
546625 DN 250 232000 1200 3.74
546630 DN 300 325000 1500 4.7

System nominal power

(heating) [kW]
300 500 1000 1300 1800 2200 2500 3000 3500
System maximum flow rate [l/h]
(∆T = 15 °C) 17200 28667 57333 74533 103200 126133 143333 172000 200667

Nominal pipe diameter* DN 80 DN 100 DN 125 DN 150 DN 200 DN 200 DN 200 DN 250 DN 250

546680 546610 546612 546615 546620 546625

DIRTMAG®

(DN 80) (DN 100) (DN 125) (DN 150) (DN 200) (DN 250)

∆p [kPa] 1.16 1.76 2.47 1.94 1.31 1.96 2.53 2.05 2.8

System nominal power

(cooling) [kW]
100 150 300 400 800 1000 1200 1400 1600
System maximum flow rate [l/h]
(∆T = 5 °C) 17200 25800 51600 68800 137600 172000 206400 240800 275200

Nominal pipe diameter* DN 80 DN 100 DN 125 DN 150 DN 200 DN 250 DN 250 DN 300 DN 300

546680 546610 546612 546615 546620 546625 546630

DIRTMAG®

(DN 80) (DN 100) (DN 125) (DN 150) (DN 200) (DN 250) (DN 300)

∆p [kPa] 1.16 1.43 2 1.65 2.34 2.05 2.96 2.58 3.37

*Water maximum speed v ~ 1,2 m/s

16
 LARGE SYSTEMS -
HEATING/COOLING - BY-PASS INSTALLATION

SIZING
DIRTMAGCLEAN®
With this type of by-pass connection, the flow
Kv* Max. flow rate ∆p* [kPa]
rate through the device G2 is only a fraction of Code Connections
[m3/h] [l/h] (max. flow rate)
the total system flow rate G1.
The flow rate that needs to be treated by the 579000 2” 45 20000 19.8
device G2 varies from 15 to 80 % of the total 579001 2” 45 20000 19.8
flow rate G1.
By-pass connection can be performed in two Device connected
Device connected in parallel in parallel Device connected
Device connected in parallel in parallel
ways: with a dedicated
with a dedicated pump pump with a balancing
with a balancing valve valve

- device connected in parallel with a dedicated G1 G1 G1 G1

pump; G2 G2
G2 G2

- device connected in parallel with a balancing

valve.

System nominal power

(heating) [kW]
500 550 600 650 700 800 1000 1500 2000
System maximum flow rate [l/h]
(∆T = 15 °C) 28667 31533 34400 37267 40133 45867 57333 86000 114667

Max. flow rate in by-pass [l/h] 20000 20000 20000 20000 20000 20000 20000 20000 20000
DIRTMAGCLEAN®

579000 | 579001

System nominal power

(cooling) [kW]
250 300 350 400 450 500 600 700 800
System maximum flow rate [l/h]
(∆T = 5 °C) 43000 51600 60200 68800 77400 86000 103200 120400 137600

Max. flow rate in by-pass [l/h] 20000 20000 20000 20000 20000 20000 20000 20000 20000
DIRTMAGCLEAN®

579000 | 579001

* With clean filter

17
 Deaerators
Operating principle
The deaerator utilises the combined action of several physics principles. The active part consists of a set of concentric mesh surfaces. These elements
create the swirling motion required to facilitate the release of micro-bubbles and their adhesion to the surfaces. The bubbles, fusing with each other,
increase in volume until the hydrostatic thrust is sufficient to overcome the force of adhesion to the structure. They then rise towards the top of the
device and are expelled through a float-operated automatic air vent valve.

Air separation efficiency

The amount of air that can be removed from a circuit increases as the
circulation speed and the pressure decrease.
The enlargement of the device cross-section (A2 > A1) allows a decrease
in speed (V2 < V1). This feature, combined with the swirling movements
created by a concentric mesh surface, allows an efficient air separation
and the release of micro-bubbles.
(%)
100
After just 25 recirculations at the maximum recommended speed, almost all
the air introduced into the circuit is eliminated by the DISCAL® deaerator, with 90
1 bar
variable percentages according to the pressure within the circuit. 80
2 bar
3 bar
The small amount which remains is then gradually eliminated during normal
system operation. In conditions where the speed is slower or the temperature 70
of the medium is higher, the amount of air separated is even greater. 60

50
Systems with glycol solutions 40
It is also useful to use deaerators in systems with antifreeze mixtures 30 of
water and glycol.
Water- g lyco l mixt ure s a re h i gh l y vi sc ou s a nd t h e re f o re 20 Air introduced (%)
have a strong tendency to trap both air bubbles and micro-bubbles, preventing 10 Air removed (%)
their elimination.
0

T ime
100

200

300

400

500

600

700

800

900

1000

1100

1200

(s)
0

No. of
recirc.
V = 1 m/s - T = constant

20

25
10

15
Sizing
Sizing a deaerator mainly depends on the speed at which the medium flows through the device, since an excessive speed would not allow correct
air separation and releasing of the micro-bubbles.
As is known, the medium flow speed depends on the flow rate and the cross section. Remaining within the speed limits specified above therefore
means not exceeding certain maximum permissible flow rates for each size.

18
 WALL-MOUNTED BOILER SYSTEMS
TECHNOPOLYMER DEAERATOR

DISCALSLIM®
551
3/4” – 1”
Ø18 - Ø22

WALL-MOUNTED BOILER SYSTEMS WITH TECHNICAL ROOM

BRASS DEAERATOR WITH ADJUSTABLE CONNECTIONS

DISCAL®
551
3/4” – 1”
Ø22 - Ø28

MEDIUM/LARGE SYSTEMS
BRASS DEAERATOR STEEL DEAERATOR

DISCAL® DISCAL®
551 551
3/4” – 2” DN 50–DN 65

LARGE SYSTEMS
STEEL DEAERATOR

DISCAL®
551
DN 80–DN 300

19
 WALL-MOUNTED BOILER SYSTEMS

System nominal power [kW] 8 9 10 12 14 16 18 21

System maximum flow rate [l/h]

(ΔT = 20 °C) 344 387 430 516 602 688 774 903
DISCALSLIM®

551805 551806
(3/4” F) (1” F)

∆p [kPa] 0.07 0.09 0.11 0.16 0.21 0.28 0.35 0.48

DISCALSLIM®

551801 551802
(Ø 18) (Ø 22)

∆p [kPa] 0.15 0.18 0.23 0.33 0.21 0.28 0.35 0.48

SIZING
DISCALSLIM®

Sizing depends on the speed at which the Max. flow rate Kv ∆p [kPa]
medium flows through the device. Code Connections
[l/h] [m3/h] (max. flow rate)
To guarantee optimal operation, the maximum
551801 Ø 18 1300 9 2.1
speed on entering the device should be ≤
1,2 m/s. 551805 3/4” 1300 13 1
To remain within the speed limits specified 551802 Ø 22 1300 13 1
above, the specific maximum permissible 551806 1” 1300 13 1
flow rate values for each size must not be
exceeded.

FORMATION OF AIR MICRO-BUBBLES IN THE BOILER

Micro-bubbles form continuously on the surfaces separating the water from the
Temperature of the
combustion chamber due to the high temperature of the medium. The phenomenon flame 1000 °C
is similar to the one we can observe on the walls of a pan when we are heating water. Combustion chamber wall
This air, carried by the water, collects at critical points of the circuit, from which it must
be removed. Some of it is reabsorbed where it meets colder surfaces. Boundary layer

FLAME WATER
Micro-bubbles

Temperature of the Temperature of the

wall 160 °C boundary layer 156 °C

Average temperature
of the water 70 °C

20
 WALL-MOUNTED BOILER SYSTEMS WITH TECHNICAL ROOM

hgiH
High ycneicffiE
Efficiency

System nominal power [kW] 10 12 14 16 18 22 25 30

System maximum flow rate [l/h]

573 688 803 917 1032 1261 1433 1720
(∆T = 15 °C)

Nominal pipe diameter* 3/4” 3/4” 1” 1” 1” 1” 1 1/4” 1 1/4”

551702 551703
DISCAL®

(Ø 22) (Ø 28)

∆p [kPa] 0.23 0.33 0.45 0.58 0.74 1.10 1.43 2.05

551705 551706
DISCAL®

(3/4” F) (1” F)

∆p [kPa] 0.23 0.33 0.45 0.58 0.74 1.10 1.43 2.05

551716
DISCAL®

(1” M)

∆p [kPa] - 0.45 0.58 0.74 1.10 1.43 2.05

* Pressure drop r ~ 20-22 mm w.g./m (50 °C)

SIZING

DISCAL®

Sizing depends on the speed at which the Max. flow rate Kv ∆p [kPa]
medium flows through the device. Code Connections
[l/h] [m3/h] (max. flow rate)
To guarantee optimal operation, the maximum
551705 3/4” F 1360 12 1.28
speed on entering the device should be ≤
1,2 m/s. 551702 Ø 22 1360 12 1.28
To remain within the speed limits specified 551706 1” F 2110 12 3.1
above, the specific maximum permissible 551716 1” M 2110 12 3.1
flow rate values for each size must not be
exceeded. 551703 Ø 28 2110 12 3.1

21
MEDIUM/LARGE SYSTEMS -
HEATING

MEDIUM/LARGE SYSTEMS -
COOLING

22
 SIZING
Sizing depends on the speed at which the medium flows through the device.
To guarantee optimal operation, the maximum speed on entering the device should be ≤ 1,2 m/s.
To remain within the speed limits specified above, the specific maximum permissible flow rate values for each size must not be
exceeded.

DISCAL®
DISCAL®
Max. flow rate Kv ∆p [kPa]
Code Size
[l/h] [m3/h] (max. flow rate)
Max. flow rate Kv ∆p [kPa]
Code Connections
[l/h] [m3/h] (max. flow rate) 551052 DN 50 8470 75 1.28
551005 3/4” 1360 16.2 0.7 551062 DN 65 14320 150 0.91
551006 1” 2110 28.1 0.56 551082 DN 80 21690 180 1.45
551007 1 1/4” 3470 48.8 0.51 551102 DN 100 33890 280 1.46
551008 1 1/2” 5420 63.2 0.74 551122 DN 125 58800 450 1.71
551009 2” 8200 70 1.37 551152 DN 150 86200 720 1.43

System nominal power

35 40 45 55 65 75 85 100
(heating) [kW]
System maximum flow rate [l/h]
(∆T = 15 °C) 2007 2293 2580 3153 3727 4300 4873 5733

2” 2”
Nominal pipe diameter* 1 1/4” 1 1/4” 1 1/4” 1 1/2” 1 1/2” 1 1/2”
DN 50 DN 50

551007 551008 551009

DISCAL®

(1 1/4” F) (1 1/2” F) (2” F)

∆p [kPa] 0.17 0.22 0.28 0.25 0.35 0.46 0.48 0.67

551052
DISCAL®

(DN 50)

∆p [kPa] - 0.42 0.58

System nominal power

20 25 30 35 40 50 60 70
(cooling) [kW]
System maximum flow rate [l/h]
(∆T = 5 °C) 3440 4300 5160 6020 6880 8600 10320 12040

2” 2” 2”
Nominal pipe diameter* 1 1/2” 1 1/2” DN 65 DN 65 DN 65
DN 50 DN 50 DN 50

551008 551009
DISCAL®

(1 1/2” F) (2” F)

∆p [kPa] 0.3 0.46 0.54 0.74 0.97 -

551052 551062
DISCAL®

(DN 50) (DN 65)

∆p [kPa] - 0.47 0.64 0.84 0.33 0.47 0.64

* Pressure drop r ~ 20-22 mm w.g./m (50 °C)

23
LARGE SYSTEMS -
HEATING

LARGE SYSTEMS -
COOLING

24
 SIZING
DISCAL®
Max. flow rate Kv ∆p [kPa]
Code Size
Sizing depends on the speed at which the medium [l/h] [m3/h] (max. flow rate)
flows through the device. 551052 DN 50 8470 75 1.28
To guarantee optimal operation, the maximum
551062 DN 65 14320 150 0.91
speed on entering the device should be ≤ 1,2 m/s.
To remain within the speed limits specified above, 551082 DN 80 21690 180 1.45
the specific maximum permissible flow rate 551102 DN 100 33890 280 1.46
values for each size must not be exceeded.
551122 DN 125 58800 450 1.71
551152 DN 150 86200 720 1.43
551200 DN 200 146000 900 2.63
551250 DN 250 232000 1200 3.74
551300 DN 300 325000 1500 4.7

System nominal power

(heating) [kW]
300 500 1000 1300 1800 2200 2500 3000 3500
System max. flow rate [l/h]
(∆T = 15 °C) 17200 28667 57333 74533 103200 126133 143333 172000 200667

Nominal pipe diameter* DN 80 DN 100 DN 125 DN 150 DN 200 DN 200 DN 200 DN 250 DN 250

551082 551102 551122 551152 551200 551250

DISCAL®

(DN 80) (DN 100) (DN 125) (DN 150) (DN 200) (DN 250)

∆p [kPa] 0.91 1.05 1.62 1.07 1.31 1.96 2.53 2.05 2.8

System nominal power

(cooling) [kW]
100 150 300 400 800 1000 1200 1400 1600
System max. flow rate [l/h]
(∆T = 5 °C) 17200 25800 51600 68800 137600 172000 206400 240800 275200

Nominal pipe diameter* DN 80 DN 100 DN 125 DN 150 DN 200 DN 250 DN 250 DN 300 DN 300

551082 551102 551122 551152 551200 551250 551300

DISCAL®

(DN 80) (DN 100) (DN 125) (DN 150) (DN 200) (DN 250) (DN 300)

∆p [kPa] 0.91 0.85 1.31 0.91 2.34 2.05 2.96 2.58 3.37

*Water maximum speed v ~ 1,2 m/s

25
 Automatic air vents
Standard automatic air vents

Code 502030/40 502031/41 502050/60 502051/61 502130/40 502131/41 502132/42 502133

MINICAL®

Material brass chrome plated brass brass chrome plated brass brass chrome plated brass chrome plated brass brass
Maximum discharge
2.5 bar
pressure

Maximum working
10 bar
pressure

Maximum working
120 °C 110 °C
temperature

Automatic shut-off optional - ✔

Hygroscopic cap optional ✔ optional ✔ -

Anti-suction valve optional optional optional optional ✔

Connections 3/8” - 1/2” 3/8” - 1/2” 3/4” - 1” 3/4” - 1” 3/8” - 1/2” 3/8” - 1/2” 3/8” - 1/2” 3/8”

Automatic air vents Hygroscopic cap

with high discharge pressure The discs increase in volume by 50 % when they come into
Code 502420/30 502530/33/43 502630/40/41 502730
contact with water. This leads to valve closure, in order to
avoid potential leaks of water.
ROBOCAL®
s

Material brass brass chrome plated brass brass

Maximum discharge
4 bar 6 bar
pressure Dry disk
Maximum working
10 bar
pressure

Maximum working s+50 %

115 °C 110 °C 115 °C 110 °C
temperature

Automatic shut-off optional ✔ optional ✔

Hygroscopic cap - - - -

Anti-suction valve - - optional optional

Wet disk
Connections 1/4” - 3/8” 3/8” - 1/2” 3/8” - 1/2” 3/8”

Automatic air vents

with high discharge capacity Automatic shut-off cock
This facilitates maintenance
Code 501500 551004 502221/31/41
operations by inhibiting the flow of
MAXCAL® DISCALAIR® VALCAL® water when the valve is deactivated,
and makes it easier to make sure
the air vent device is working.

Material brass brass chrome plated brass Anti-suction valve

Maximum discharge Installed on the air vent line, it functions as a check valve: it
6 bar 10 bar 4 bar only allows air to be released.
pressure
In a situation where the system experiences negative
Maximum working
16 bar 10 bar 10 bar pressure, the internal element closes off the outlet channel to
pressure
prevent unwanted air from entering.
Maximum working
120 °C 110 °C 120 °C
temperature

Automatic shut-off - - optional

Hygroscopic cap - optional optional

Anti-suction valve - optional optional

Connections 3/4” 1/2” 1/4”- 3/8”- 1/2”

26
 Deaerators-Dirt separators
These are made by assembling, in a single product, a deaerator and a dirt separator. A single product can therefore be used both to separate air and
to separate the impurities present in the system water.

Operating principle

The device makes use of the combined action of the deaerator and the dirt separator. The internal element
creates swirling movements that facilitate the release of micro-bubbles and the subsequent creation of bubbles
that then rise to the top of the device, from which they are evacuated by means of an automatic air vent with
float. Moreover, the impurities in the water, striking against the surfaces of the internal element, are separated
and fall to the bottom of the valve body.
Deaerators-dirt separators fitted with a magnet offer greater efficiency in the separation and collection of ferrous
impurities. The impurities are captured inside the dirt separator body by the strong magnetic field created by the
magnets inserted in the special outer ring.
With respect to the solutions that call for the installation of separate deaerators and dirt separators, the
deaerators-dirt separators present the following advantages: they take up less space and require a smaller
number of connections, and are therefore ideal for systems where it is not possible to install the two separate
components. Nevertheless, two separate devices will always guarantee a higher performance level.

Sizing
Sizing a deaerator-dirt separator mainly depends on the speed at which the medium flows through the device,
since an excessive speed would not allow correct separation of air and impurities.
As is known, the medium flow speed depends on the flow rate and the cross section. Remaining within the
speed limits therefore means not exceeding certain maximum permissible flow rates for each size.

HEAT PUMP SYSTEMS

TECHNOPOLYMER MAGNETIC DEAERATOR-DIRT SEPARATOR

DISCALDIRTMAG®
5464
3/4” – 1”
Ø22 - Ø28

WALL-MOUNTED BOILER SYSTEMS WITH TECHNICAL ROOM -

COOLING SYSTEMS
BRASS MAGNETIC DEAERATOR-DIRT SEPARATOR

DISCALDIRTMAG®
5461
3/4” – 1”

MEDIUM/LARGE SYSTEMS
STEEL MAGNETIC DEAERATOR-DIRT STEEL DEAERATOR-DIRT
SEPARATOR SEPARATOR

DISCALDIRTMAG® DISCALDIRT®
5461 546
1 1/2” – 2” DN 50–DN 65

LARGE SYSTEMS
STEEL DEAERATOR-DIRT SEPARATOR

DISCALDIRT®
546
DN 80–DN 300

27
 HEAT PUMP SYSTEMS

SIZING
DISCALDIRTMAG®

Sizing depends on the speed at which the Max. flow rate Kv ∆p [kPa]
medium flows through the device. Code Connections
[l/h] [m3/h] (max. flow rate)
To guarantee optimal operation, the maximum
546405 3/4” 1300 10.5 1.53
speed on entering the device should be ≤
1,2 m/s. 546402 Ø 22 1300 10.5 1.53
To remain within the speed limits specified 546406 1” 1300 10.5 1.53
above, the specific maximum permissible 546407 1 1/4” 2100 10.5 4.00
flow rate values for each size must not be
exceeded. 546403 Ø 28 1300 10.5 1.53

HP nominal power
[kW]
3 4 5 6 7 8 9 12 14 18 22 25 28 32 35
Max. set flow rate
[l/h] (ΔT = 5 °C) 516 688 860 1032 1204 1376 1,548 2064 2408 3096 3784 4300 4816 5504 6020

Nominal pipe
3/4” 3/4” 1” 1” 1” 1” 1 1/4” 1 1/4” 1 1/4” 1 1/2” 1 1/2” 1 1/2” 2” 2” 2”
diameter*
DISCALDIRTMAG®

546402 546403
(Ø 22) (Ø 28)

∆p [kPa] 0.24 0.43 0.67 0.97 1.31 1.72 -

DISCALDIRTMAG®

546405 546406 546407

(3/4”) (1”) (1 1/4”)

∆p [kPa] 0.24 0.43 0.67 0.97 1.31 1.72 2.17 3.86

* Pressure drop r ~ 20-22 mm w.g./m (50 °C)

28
 WALL-MOUNTED BOILER SYSTEMS WITH TECHNICAL ROOM -
COOLING SYSTEMS

hgiH
High ycneicffiE
Efficiency

SIZING
DISCALDIRTMAG®

Sizing depends on the speed at which the Max. flow rate Kv ∆p [kPa]
medium flows through the device. Code Connections
[l/h] [m3/h] (max. flow rate)
To guarantee optimal operation, the maximum
546105 3/4” 1360 16.2 0.7
speed on entering the device should be ≤
1,2 m/s. 546106 1” 2110 28.1 0.56
To remain within the speed limits specified 546107 1 1/4” 3470 46.7 0.55
above, the specific maximum permissible
flow rate values for each size must not be
exceeded.

System nominal power (heating)

[kW]
10 12 14 16 18 22 25 30
System maximum flow rate [l/h]
(∆T = 15 °C) 573 688 803 917 1032 1261 1433 1720

Nominal pipe diameter* 3/4” 3/4” 1” 1” 1” 1” 1 1/4” 1 1/4”

546105 546106 546107

DISCALDIRT-
MAG®

(3/4”) (1”) (1 1/4”)

∆p [kPa] 0.12 0.18 0.03 0.11 0.13 0.2 0.09 0.14

System nominal power (cooling)

[kW]
2 3 5 7 9 11 13 15
System maximum flow rate [l/h]
(∆T = 5 °C) 344 516 860 1204 1548 1892 2236 2580

Nominal pipe diameter* 3/4” 3/4” 1” 1” 1 1/4” 1 1/4” 1 1/4” 1 1/4”

546105 546106 546107

DISCALDIRT-
MAG®

(3/4”) (1”) (1 1/4”)

∆p [kPa] 0.04 0.1 0.09 0.18 0.11 0.16 0.23 0.30

* Pressure drop r ~ 20-22 mm w.g./m (50 °C)

29
MEDIUM/LARGE SYSTEMS -
HEATING

H0002025
H0002025

MEDIUM/LARGE SYSTEMS -
COOLING

30
 SIZING
Sizing depends on the speed at which the medium flows through the device.
To guarantee optimal operation, the maximum speed on entering the device should be ≤ 1,2 m/s.
To remain within the speed limits specified above, the specific maximum permissible flow rate values for each size must not be
exceeded.

DISCALDIRTMAG® DISCALDIRT®

Max. flow rate Kv ∆p [kPa] Max. flow rate Kv ∆p [kPa]

Code Connections Code Size
[l/h] [m3/h] (max. flow rate) [l/h] [m3/h] (max. flow rate)
546118 1 1/2” 3410 43.2 0.62 546052 DN 50 8470 75 1.28
546119 2” 5680 68.3 0.69 546062 DN 65 14320 150 0.91
546082 DN 80 21690 180 1.45
546102 DN 100 33890 280 1.46
546122 DN 125 58800 450 1.71
546152 DN 150 86200 720 1.43

System nominal power

(heating) [kW]
35 40 45 55 65 75 85 100

System max. flow rate [l/h]

(∆T = 15 °C) 2007 2293 2580 3153 3727 4300 4873 5733

2” 2”
Nominal pipe diameter* 1 1/4” 1 1/4” 1 1/4” 1 1/2” 1 1/2” 1 1/2”
DN 50 DN 50
DISCALDIRTMAG®

546118 546119
(1 1/2”) (2”)

∆p [kPa] 0.22 0.28 0.36 0.53 0.29 0.4 0.51 0.7

DISCALDIRT®

546052
(DN 50)

∆p [kPa] - 0.42 0.58

System nominal power

(cooling) [kW]
20 25 30 35 40 50 60 70

System max. flow rate [l/h]

(∆T = 5 °C) 3440 4300 5160 6020 6880 8600 10320 12040

2” 2” 2”
Nominal pipe diameter* 1 1/2” 1 1/2” DN 65 DN 65 DN 65
DN 50 DN 50 DN 50
DISCALDIRTMAG®

546119
(2”)

∆p [kPa] 0.25 0.4 0.57 -

DISCALDIRT®

546052 546062
(DN 50) (DN 65)

∆p [kPa] - 0.47 0.64 0.84 0.33 0.47 0.64

* Pressure drop r ~ 20-22 mm w.g./m (50 °C)

31
LARGE SYSTEMS -
HEATING

LARGE SYSTEMS -
COOLING

32
 SIZING
DISCALDIRT®
Max. flow rate Kv ∆p [kPa]
Sizing depends on the speed at which the medium Code Size
[l/h] [m3/h] (max. flow rate)
flows through the device. 546052 DN 50 8470 75 1.28
To guarantee optimal operation, the maximum
speed on entering the device should be ≤ 1,2 m/s. 546062 DN 65 14320 150 0.91
To remain within the speed limits specified above, 546082 DN 80 21690 180 1.45
the specific maximum permissible flow rate 546102 DN 100 33890 280 1.46
values for each size must not be exceeded.
546122 DN 125 58800 450 1.71
546152 DN 150 86200 720 1.43
546200 DN 200 146000 900 2.63
546250 DN 250 232000 1200 3.74
546300 DN 300 325000 1500 4.7

System nominal power

(heating) [kW]
300 500 1000 1300 1800 2200 2500 3000 3500
System max. flow rate [l/h]
(∆T = 15 °C) 17200 28667 57333 74533 103200 126133 143333 172000 200667

Nominal pipe diameter* DN 80 DN 100 DN 125 DN 150 DN 200 DN 200 DN 200 DN 250 DN 250
DISCALDIRT®

546082 546102 546122 546152 546200 546250

(DN 80) (DN 100) (DN 125) (DN 150) (DN 200) (DN 250)

∆p [kPa] 0.91 1.05 1.62 1.07 1.31 1.96 2.53 2.05 2.8

System nominal power

(cooling) [kW]
100 150 300 400 800 1000 1200 1400 1600
System max. flow rate [l/h]
(∆T = 5 °C) 17200 25800 51600 68800 137600 172000 206400 240800 275200

Nominal pipe diameter* DN 80 DN 100 DN 125 DN 150 DN 200 DN 250 DN 250 DN 300 DN 300
DISCALDIRT®

546082 546102 546122 546152 546200 546250 546300

(DN 80) (DN 100) (DN 125) (DN 150) (DN 200) (DN 250) (DN 300)

∆p [kPa] 0.91 0.85 1.31 0.91 2.34 2.05 2.96 2.58 3.37

*Water maximum speed v ~ 1,2 m/s

33
 Domestic water treatment - Polyphosphate dispenser
Operating principle

Scaling is the result of calcium and magnesium (the salts that determine water hardness) becoming deposited on the pipe walls, heat exchanger
surfaces and control and regulation components. The amount of deposit depends on:
• the water temperature
• the water hardness
• the volume of water used.
Unlike other salts, calcium and magnesium salts become less soluble as temperature increases. For this reason, all systems in which water is heated,
especially those used for domestic hot water production, are at risk of scaling.
The parameter to monitor is the total hardness, the sum of the concentration of calcium and magnesium ions responsible for scaling. Calcium
and magnesium bicarbonates are chemically balanced with the calcium and magnesium carbonates, water and carbon dioxide. As temperature
increases, the soluble bicarbonates become insoluble carbonates, forming limescale and releasing carbon dioxide.

Sodium and potassium polyphosphates (food polyphosphates) inside the container combine with calcium and magnesium ions (in the water) to form
a chemical compound similar to limescale but which cannot adhere to pipe surfaces.
A shielding is then formed which prevents the precipitation of calcium and magnesium and the consequent formation of limescale deposits.
The polyphosphates, moreover, get deposited on the surface of the pipes, forming a protective film to protect them from scaling.

Construction details

Double Venturi proportional dosage

To keep the polyphosphate dosage efficient, dispensing must take place
continuously and in a controlled manner, both with the minimum flow rate
at the tap and with a variable water flow rate. This dosage maintains the
protective film on the pipes and combats the precipitation of salts.
The Caleffi double Venturi proportional dispensing system features full
mechanical operation and does not require an electric supply. Part of the
inlet water flow passes through the first Venturi and only a minimal part
passes through the second Venturi.
This innovative double Venturi proportional dispensing system allows a
very precise dosing of polyphosphates, just underneath the average value
of 5 mg/l (expressed as P2O5).

Check valve
The dispenser has two check valves: one at the inlet, upstream of the
shut-off ball, to ensure the non-return of the water treated in the system
and one downstream, to limit excessive dispersion of salts inside the pipes
in the case of prolonged inactivity.

Air vent
The air vent makes it possible to eliminate air from the container and to
lower the pressure inside the device before refilling takes place.

Design
The special white and chrome-plated finish means that the dispenser
easily adapts to the domestic environment. Its very small dimensions
make it suitable for installation on most wall-mounted boilers, regardless of
whether they are installed in new or renovated systems. It can be installed
underneath the boiler, next to the 5459 series magnetic filter.

Equipment for domestic use, for the treatment of potable water.

When using the polyphosphate crystal treatment, check current national regulations.
Italy: the use of polyphosphates is classed as a chemical conditioning treatment (as expressed in UNI 8065) which is based on the dispensing of
salts in proportion to the amount of cold water passing through the device, without changing the water hardness.

Caleffi XP - 5459 series

Crystal refill duration
Average value: 35–40 m3 domestic hot water. Data refers to water with an average hardness of 12 °f, pH 7, temperature 20
°C and average domestic hot water usage. The polyphosphate fill status can be monitored easily through the clear windows,
which can be used to check the level of the dark-coloured pellets.

We do not recommend heating domestic hot water to over 70 °C, to avoid compromising the properties of the polyphosphates.

34
 WALL-MOUNTED BOILER SYSTEMS
CALEFFI XP POLYPHOSPHATE DISPENSER (5459 series)

WALL-MOUNTED BOILER SYSTEMS

CALEFFI XS® (5459 series) + CALEFFI XP (5459 series)

35
 The chemical treatment of “technical” water

The purely chemical treatment of water is considered an internal treatment and requires the addition of specific products able to perform different
functions.

Cleaning the system

This category includes all products dedicated to removing dirt and deposits, metal oxides, greases, oils and residues from work in new and existing
systems. Depending on their formulation they can be more or less "aggressive" in order to remove dirt and sludge even in totally compromised
systems.

System protection
This category is very wide but among the most known and used products there are corrosion and encrustation inhibitors for radiator or radiant panel
systems, biocides and products with antifreeze function.

Maintaining system efficiency

This category includes all the products that perform targeted actions such as sealants (to eliminate small water leaks from the system), noise reducers
and pH regulators.

Products for cleaning the system Corrosion and encrustation inhibitors

CLEANER INHIBITOR
On the market there are three macro categories of products for the They are the most popular products among those dedicated to
systems cleaning and flushing: system protection.
• acids, weak or strong. They allow circuit functionality to be Corrosion and encrustation inhibitors can act by:
restored in a short time but are not recommended in the • power consumption. A chemical-physical interaction is
presence of circuits with galvanised or metal components in created between the product and the metal.
general because the risk of corrosion is high. • precipitation. Also called “filming” because they create a
• sequestrants. They bind to the substances present in the water protective film on pipes and component surfaces within the
with more or less stable bonds but are still able to remove the system to prevent the materials from being deposited.
particles from the water solution and prevent them from aggregating.
They are not aggressive products and do not affect metals. Often these products also contain chemicals that can regulate the
Since they act at ion (molecular particle) level, the “sequestered” water pH.
particles cannot, however, be captured by conventional filtration As heating and cooling systems are made of many different
systems because of their very small size. Therefore, when using materials, the corrosion inhibitor must be compatible with all metal
sequestrants, it is necessary to completely drain the system materials, plastics, rubber, diaphragms and seals.
after flushing. It is preferable to add the inhibitors after having carried out
• dispersants. These adhere to any substance in the water, an accurate cleaning and flushing of the system with specific
inducing an electrical charge that prevents the particles from products, in order to eliminate most of the impurities present in
aggregating and creating a sort of repulsion between them. the circuit.
Since they act on the particles, it is possible to capture Once a year it is useful to check the concentration of the product
and eliminate them using common filtration systems. inside the system in order to keep it always within the optimal
They also have a corrosion-proof effect and are kept stable working limits.
with temperature. It is therefore not necessary to drain these
products after cleaning the system. However, it is advisable to
drain the impurities retained by the filtration systems during
the cleaning process.

System flushing and water treatment

Stop the circulator, close the Add C3 CLEANER, using the dirt Let the product circulate within Close the ball shut-off valves and
ball shut-off valves and drain the separator as a convenient point the circuit. add C1 INHIBITOR via the dirt
water out of the dirt separator. of access to the circuit. separator.

Stop the circulator and drain the

circuit until clean water comes out.

36
 CHEMICAL ADDITIVES 5709 SERIES
Dispensing of C3 CLEANER / C3 FAST CLEANER
The entire contents of a bottle or a canister is enough to treat 150 litres of water in the system (approximately 15
radiators or 120 m2 of radiant panels). No problems have been recorded in the event of overdosage. The water
temperature affects the duration of treatment.
Circulate for:
• minimum 1 hour with high temperature water (T ≥ 50 °C)
• minimum 4 hours with low temperature water (30 °C < T < 50 °C)
• up to 1 week with cold water (T ≤ 30 °C).

Dispensing of C1 INHIBITOR / C1 FAST INHIBITOR

The entire contents of a bottle or a canister is enough to treat 150 litres of water in the system (approximately
15 radiators or 120 m2 of radiant panels). No problems have been recorded in the event of overdosage. It is
nevertheless preferable to overdose rather than underdose, given that in the event of underdosing the treatment
is no longer effective.
Use a double dose for systems filled with softened water.

Dispensing of C7 BIOCIDE
The entire contents of a bottle or a canister is enough to treat 150 litres of water in the system (approximately 15 radiators or
120 m2 of radiant panels). No problems have been recorded in the event of overdosage. It is nevertheless preferable to overdose
rather than underdose, given that in the event of underdosing the treatment is no longer effective. For protective usage, leave the
product in the system together with C1 INHIBITOR or C1 FAST INHIBITOR. For washing or sanitising usage, leave the product in
the system together with C3 CLEANER or C3 FAST CLEANER. Repeat the application once a year.

Dispensing of C4 LEAK SEALER

The entire contents of a bottle or a canister is enough to treat 150 litres of water in the system (approximately 15 radiators or
120 m2 of radiant panels). No problems have been recorded in the event of overdosage. It is nevertheless preferable to overdose
rather than underdose, given that in the event of underdosing the treatment is no longer effective. Shake before use; use the whole
contents. Use preferably in combination with C1 INHIBITOR or C1 FAST INHIBITOR.

When using the chemical additive treatment, check current national regulations.

The dirt separator or under-boiler The dirt separator or under-boiler

magnetic filter can be used as an magnetic filter can be used as an
access point to inject the circuit access point to inject the circuit
with liquid chemical additives with pressurised liquid chemical
designed to wash and protect the additives designed to wash and
system. protect the system.

Treatment summary

Protection against
Washing and Protection against Repair of micro-
System cleaning corrosion and
sanitising bacterial growth fissures
limescale

C3 CLEANER

C3 FAST CLEANER

C1 INHIBITOR

C1 FAST INHIBITOR

C7 BIOCIDE

C4 LEAK SEALER

Cleaning and washing treatments: pour into the Protective treatments: use in the system and Treatment “as needed”
system and leave to circulate for the required check once a year. for minor leaks. Leave in
time. Then drain the system to eliminate the the system.
impurities collected in the dirt separator.

37
 Devices for the demineralisation and softening of “technical water”
Problems such as corrosion and encrustations in the circuit of the heating/cooling system are due to the poor
quality of the water circulating within the system. The systems are filled with water from the potable water mains,
calcium and which guarantees its supply with controlled parameters: there are a large amount of salts including calcium and
magnesium magnesium (hardness minerals), sodium and many others (chlorine, bicarbonate, sulphate).
other
salts Limescale deposits
Limescale deposits are more or less coherent formations (hard and compact) due to the hardness of the water,
that is to its content of calcium and magnesium salts.
The limescale formation process can be summarized as follows:
1. In the water the calcium and magnesium bicarbonates (soluble substances) are in equilibrium with calcium carbonates
and magnesium and with carbon dioxide.
2. An increase in the water temperature releases part of the carbon dioxide and upsets the previous equilibrium.

3. To restore the equilibrium and produce new carbon dioxide, the calcium and
magnesium carbonates are transformed into calcium and magnesium carbonates.

4. Carbonates are poorly soluble substances that precipitate to form the encrustation known as “limescale”.

Untreated water Corrosion

As mentioned with regard to the presence of impurities in the system, corrosion is an electrochemical phenomenon,
favoured by the presence of oxygen and other causes that contribute to its evolution to a varying extent.
Corrosion generally affects the system as a whole and not just individual parts of it. The appearance of corrosion
in one point may therefore be symptomatic of general corrosion of the entire system.
The causes of corrosion are many but they are generally favoured by the concomitant presence of deposits on metal surfaces.
The onset of corrosion is particularly fast in hot water systems, because the oxygen/metal reaction speed is directly proportional to temperature.
To avoid these problems it is advisable to check the parameters of the feed water used for filling and to adopt a suitable water treatment. Some
parameters to keep under control in a thermal system are:

HARDNESS ELECTRICAL CONDUCTIVITY

The hardness refers mainly to the content of calcium and The electrical conductivity supplies an indirect measurement of
magnesium salts. the concentration of the substances dissolved in the water and is
The more the content of these minerals increases, the harder the therefore suitable for giving an indication of the purity and salinity
water. of the water.
UNIT OF MEASUREMENT: French degree (°f) which corresponds UNIT OF MEASUREMENT: μS/cm.
to 10 mg of calcium carbonate per litre of water.
1 °f = 10 mg/l = 10 ppm The salts dissolved in the water are "broken" into two parts (ions):
cations having positive electric charge and anions having negative
electric charge.
Hardness The water is consequently an electrical conductor. Its conductivity
Classification Concentration depends on the concentration of ions present, that is on the
(°F) concentration of salts.
Very soft 0–80 0–8
Soft 80–150 8–15
Slightly hard 150–200 15–20
Medium hardness 200–320 20–32
Hard 320–500 32–50
Very hard >500 > 50

AUTOMATIC WATER TREATMENT UNIT

Function
The automatic water treatment unit, installed on the inlet pipe, is used to treat
water in the closed circuits of heating and cooling systems.
It comes complete with a by-pass regulator for adjusting the hardness level of the
outlet water in the softening treatment.

Electronic controller
Parameters and data relating to a specific treatment can be set directly from the
front panel of the controller.
The software will automatically calculate the parameters for correct operation,
such as conductivity and litres, to be aware of when the softening cartridge will
need to be replaced.

38
 SOFTENING DEMINERALISATION
The most common and most widely-known treatment is softening, A more efficient treatment is demineralisation, applicable only on the
which eliminates encrustations but leaves the full salinity and and pH closed circuits of heating systems, but extremely effective in eliminating
completely unchanged, meaning the risk of corrosion is not reduced. salts and electrical conductivity.

The treatment, using a

single type of resin, replaces The treatment, through two
sodium calcium and magnesium types of resins, completely
(minerals responsible for the eliminates the salts present
other hardness of the water and in the water releasing pure
salts poorly soluble) with sodium water.
(more soluble).

Does not alter the water Eliminates water salinity.

salinity.
Does not reduce the risk of Reduces the risk of corrosion.
corrosion.
Prevents the formation of Prevents the formation of
limescale deposits. limescale deposits.
Softened water Demineralised water

Specific additives need to be added to the heating circuit in order to The result is a water with a high degree of purity, an extremely low
neutralise water aggressivity and prevent potential corrosion. electrical conductivity and a balanced pH which stabilizes in a short time
on values between 7 and 8.

SOFTENING CARTRIDGES DEMINERALISATION CARTRIDGES

580 series 580 series

Sizing coeff. Sizing coeff. Sizing coeff. Sizing coeff.

(hardness °f) (hardness °dH) (residual cond. (residual cond.
Code < 10 μS/cm) < 50 μS/cm) (*)
Code
580902 26 14
580900 140 220
580903 43 24
580901 180 280
Softening cartridge sizing
The volume of treatable water depends on the hardness of the (*) If a full demineralisation treatment is not required (residual
filling water and must be calculated as follows: conductivity < 10 μS/cm), it is preferable to use the sizing coefficient
Sizing coeff. for residual conductivity < 50 μS/cm.
Volume of treatable water (m3) =
hardness IN - hardness OUT Demineralisation cartridge sizing
hardness IN = untreated water hardness (°f/°dH) The volume of treatable water depends on the electrical
hardness OUT = treated water hardness target (°f/°dH) conductivity of the filling water and must be calculated as follows:
Sizing coefficient
Volume of treatable water (m3) =
When using the softening or demineralisation treatment Electrical conductivity (μS/cm)
cartridges, check current national regulations.

Connection fitting
(code F0001298)

Automatic water treatment unit

(code 580020)

22
131 131

400 004

Compact automatic filling unit

bar
aabb
rrbar

(code 580011)

SOFT.
DEMIN.
Softening cartridges
(code 580902-580903)

Cartridges for
demineralisation
(code 580900-580901)

We reserve the right to make changes and improvements to our products and the related technical data in this publication, at any time and
without prior notice.
The website www.caleffi.com always has the most up-to-date version of the document, which should be used for technical verifications.

39
CALEFFI S.p.A. · S.R.229, N.25 · 28010 Fontaneto d’Agogna (NO) · Italy
Tel. +39 0322 8491 · [email protected] www.caleffi.com

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