CALEFFI 551 Series DISCAL Air Separator Owner’s Manual
- June 15, 2024
- CALEFFI
Table of Contents
- 551 Series DISCAL Air Separator
- Function
- Technical specifications
- Dimensions
- Boiler micro-bubbles
- Cavitation and micro-bubbles
- Operating principles
- 551 and NA551 steel series
- Construction details
- Air separation efficiency
- Hydraulic characteristics
- Insulation shells
- Accessories
- Installation
- Application diagram
- SPECIFICATION SUMMARIES
- Documents / Resources
DISCAL® air separator
551 series
551 Series DISCAL Air Separator
Function
The DISCAL® air separator is used to continuously remove the air contained in
hydronic circuits of heating and cooling systems. The air discharge capacity
is very high. They automatically remove all the air present in the system down
to micro-bubble level with low head loss due to the special internal shape of
the separator body. Flow direction of the DISCAL air separator is
bidirectional; flow in either direction is permitted.
The
circulation of fully de-aerated water enables the equipment to operate under
optimum conditions, free from noise, corrosion, localized or mechanical
damage. Micro-bubbles, fusing with each other, increase in volume (get larger)
until they become large enough to rise to the top where they are automatically
released.
Product range
551 series……….. DISCAL air separator for horizontal pipes, in brass compact
with drain …………………connections ¾” integral sweat; ¾” NPT female
551 series …………….DISCAL air separator for horizontal pipes, in brass with
drain …………………………………connections ¾”, 1″, 1¼”, 1½” and 2″ NPT female
……………. 1″, 1¼”, 1½” and 2″ integral sweat
……………. 1″, 1¼”, 1½” and 2″ integral press
551 series ……………. DISCAL air separator for horizontal pipes, in steel with
flanged connections and drain ……………………………. connections 2″ to 6″ ANSI
551 series……………. DISCAL air separator for horizontal pipes, in steel with
threaded connections and drain …… connections 2″ and 2½” integral NPT male
NA551 series …………….DISCAL air separator for horizontal pipes, in steel with
flanged connections with drain, ASME and CRN …. connections 2″ to 12″ ANSI
5517 series……………. DISCAL air separator for horizontal or vertical pipes with
rotating collar, in brass with drain…………………….. connections ¾” and 1″ sweat
union, press union and NPT male union
Technical specifications
Brass air separator
Materials | – body: | brass |
---|---|---|
– internal element (compact & rotating collar versions): | 304 stainless steel | |
– internal element: | glass reinforced nylon PA66GF30 | |
– air vent float: | PP | |
– seal: | peroxide-cured EPDM | |
– air vent float linkages: | stainless steel | |
– air vent float guide pin: | stainless steel | |
Performance | water, glycol solution | |
Suitable fluids: | 50% | |
Max. percentage of glycol: | 150 psi (10 bar) | |
Max. working pressure: | 32–250°F (0–120°C) | |
Temperature range: | 100% removal to micro-bubble level | |
Air separation efficiency: | ||
Connections – main: | ||
compact series: | ¾” integral sweat; ¾” NPT female | |
horizontal: | ¾”, 1″, 1¼”, 1½” and 2″ NPT female |
1″, 1¼”, 1½” and 2″ integral sweat
1″, 1¼”, 1½” and 2″ integral press
rotating collar version, 5517 series:| ¾” and 1″ sweat, press and NPT male
union
– lay length (press connections):| see page 2
– drain:| ½” NPT female
5517 series:| ½” straight female
Steel air separator
Materials | – body: | epoxy resin coated steel |
---|---|---|
– internal element: | 304 stainless steel | |
– air vent float: | PP | |
– seal: | peroxide-cured EPDM | |
– air vent float linkages: | stainless steel | |
– air vent float guide pin: | stainless steel | |
– side drain shut-off valve: | brass | |
Performance | Suitable fluids: | water, glycol solution |
Max. percentage of glycol: | 50% | |
Max. working pressure: | sizes 2 – 6 inch: 150 psi (10 bar) |
sizes 8 – 12 inch: 200 psi (14 bar)
Temperature range (vessel):| 32–270°F (0–132°C)
Air separation efficiency:| 100% removal to microbubble level
Air separation efficiency:| 100% removal to microbubble level
Connections| – flanged:| 2″– 12″ ANSI B16.5 150 CLASS RF
– drain pipe:| sizes 2 – 6 inch: 1″ NPT male
sizes 8 – 12 inch: 2″ NPT male
– side drain shut-off valve:| ¾” GHT
– thermo well tap (8 – 12″ only):|
-inlet/outlet flanges:| ½” NPT female
-inlet/outlet flanges:| ½” NPT female
Agency Approval
NA551 series is designed and built in accordance with Section VIII, Division 1
of the ASME Boiler and Pressure Vessel Code and tagged and registered with the
National Board of Boiler and Pressure Vessel Inspectors, stamped for 150 psi
(10 bar) working pressure for 2 – 6 inch, 200 psi (14 bar) for 8 – 12 inch,
with ASME U stamp and CRN registered (CRN pending for 12 inch, consult
Caleffi).
Dimensions
Code | A | B | C | D | E | F | Wt (lb) |
---|---|---|---|---|---|---|---|
551 003A* | 3⁄4″ NPT | 31⁄16″ | 23⁄16″ | 53⁄8″ | 67⁄8″ | 1⁄2″ | 2.0 |
551 022A* | 3⁄4″ SWT | 31⁄16″ | 23⁄16″ | 53⁄8″ | 67⁄8″ | 1⁄2″ | 2.0 |
- Add suffix C to sweat and NPT code number when ordering the brass DISCAL to ship with expansion tank service check valve, code 561402A.
Code | A | B | C | D | E | F | Wt (lb) |
---|---|---|---|---|---|---|---|
5517 05A | 3⁄4″ NPT | 51⁄8″ | 23⁄16″ | 53⁄8″ | 91⁄4″ | 31⁄2″ | 4.9 |
5517 65A | 3⁄4″ press | 63⁄8″ | 23⁄16″ | 53⁄8″ | 93⁄4” | 31⁄2″ | 4.9 |
5517 95A | 3⁄4″ SWT | 6″ | 23⁄16″ | 53⁄8″ | 93⁄16” | 31⁄2″ | 4.9 |
5517 06A | 1″ NPT | 63⁄4″ | 23⁄16″ | 53⁄8″ | 93⁄4” | 31⁄2″ | 4.9 |
5517 66A | 1″ press | 63⁄4″ | 23⁄16″ | 53⁄8″ | 93⁄4” | 31⁄2″ | 4.9 |
5517 96A | 1″ SWT | 7″ | 23⁄16″ | 53⁄8″ | 93⁄4” | 31⁄2″ | 4.9 |
5517 16* | — | 33⁄4” | 23⁄16″ | 53⁄8″ | 91⁄4″ | 31⁄2″ | 4.4 |
- Body only, no end connection fittings. Source separately, see Calefficatalog for end connection code numbers.
Code | A | Lay length |
---|---|---|
5517 65A | 3⁄4″ press | 4 5⁄8″ |
5517 66A | 1″ press | 4 3⁄4″ |
Code | A | B | C | D | E | F | Wt (lb) |
---|---|---|---|---|---|---|---|
551 005A* | 3⁄4″ NPT | 45⁄16″ | 23⁄16″ | 53⁄4″ | 71⁄2″ | 1⁄2″ | 3.7 |
551 006A* | 1″ NPT | 45⁄16″ | 23⁄16″ | 53⁄4″ | 71⁄2″ | 1⁄2″ | 3.7 |
551 007A* | 11⁄4″ NPT | 47⁄8″ | 23⁄16″ | 69⁄16″ | 81⁄4″ | 1⁄2″ | 4.9 |
551 008A* | 11⁄2″ NPT | 47⁄8″ | 23⁄16″ | 69⁄16″ | 81⁄4″ | 1⁄2″ | 4.9 |
551 009A* | 2″ NPT | 51⁄8″ | 23⁄16″ | 69⁄16″ | 81⁄4″ | 1⁄2″ | 5.5 |
551 028A* | 1″ SWT | 51⁄16″ | 23⁄16″ | 53⁄4″ | 71⁄2″ | 1⁄2″ | 3.7 |
551 035A* | 11⁄4″ SWT | 53⁄16″ | 23⁄16″ | 65⁄16″ | 81⁄4″ | 1⁄2″ | 3.7 |
551 041A* | 11⁄2″ SWT | 53⁄4″ | 23⁄16″ | 69⁄16″ | 81⁄4″ | 1⁄2″ | 4.9 |
551 054A* | 2″ SWT | 61⁄8″ | 23⁄16″ | 69⁄16″ | 81⁄4″ | 1⁄2″ | 5.5 |
- Add suffix C to sweat, NPT and press (below) code numbers when ordering the brass DISCAL to ship with expansion tank service check valve, code 561402A.
Code | A | B | C | D | E | F | Wt (lb) |
---|---|---|---|---|---|---|---|
551 066A* | 1″ press | 6 3⁄16″ | 23⁄16″ | 53⁄4″ | 71⁄2″ | 1⁄2″ | 3.8 |
551 067A* | 1¼” press | 7 7⁄16″ | 23⁄16″ | 53⁄4″ | 71⁄2″ | 1⁄2″ | 5.0 |
551 068A* | 11⁄2″ press | 8″ | 23⁄16″ | 69⁄16″ | 81⁄4″ | 1⁄2″ | 5.1 |
551 069A* | 2″ press | 81⁄2″ | 23⁄16″ | 69⁄16″ | 81⁄4″ | 1⁄2″ | 5.5 |
Code | A | Lay length | |||||
--- | --- | --- | |||||
551 066A* | 1″ press | 4 1⁄2″ | |||||
551 067A* | 1¼” press | 5 1⁄8″ | |||||
551 068A* | 11⁄2″ press | 5 1⁄4″ | |||||
551 069A* | 2″ press | 5 1⁄2″ |
Dimensions
Code| A| B| C| D| E| F| G| H|
J †| Wt (lb)
---|---|---|---|---|---|---|---|---|---|---
**551 050A| 2″| 133⁄4″| 1″| 143⁄4″| 1915⁄16″| 65⁄8″| 213⁄16″| 6″| 65⁄16″|
34
**551 060A| 21⁄2″| 133⁄4″| 1″| 143⁄4″| 1915⁄16″| 65⁄8″| 213⁄16″| 7″|
65⁄16″| 35
**551 080A| 3″| 183⁄8″| 1″| 171⁄8″| 237⁄16″| 85⁄8″| 213⁄16″| 71⁄2″|
75⁄16″| 62
**551 100A| 4″| 181⁄2″| 1″| 171⁄8″| 237⁄16″| 85⁄8″| 213⁄16″| 9″| 75⁄16″|
67
NA551 120A| 5″| 25″| 1″| 217⁄16″| 301⁄2″| 123⁄4″| 213⁄16″| 10″| 93⁄8″|
106
NA551 150A| 6″| 25″| 1″| 217⁄16″| 301⁄2″| 123⁄4″| 213⁄16″| 10″| 93⁄8″|
117
** Add prefix NA to flanged code number when ordering ASME tagged and
registered with the National Board of boiler and Pressure Vessel Inspector and
CRN registered.
This dimension allows for a minimum of 3″ wall clearance to accommodate
insulation if used.
Code| A| B| D| E| F| __G|
Cap. (gal)| Wt (lb)
---|---|---|---|---|---|---|---|---
NA551 200A| 8″| 35 7/16″| 20″| 8 1/2″| 20″| 32 1/2″| 56| 335
NA551 250A| 10″| 41 3/4″| 26″| 8 1/2″| 22 5/8″| 38 1/4″| 110| 617
NA551 300A| 12″| 46 1/2″| 30″| 8 1/2″| 25 3/8″| 43 3/8″| 169| 871
These models are ASME tagged and registered with the National Board of Boiler
and Pressure Vessel Inspector and CRN registered (12″ pending, consult
Caleffi).
NOTE: Drawings may not reflect the actual size of the separators.
The process of air formation
The amount of air which can remain dissolved in a water solution is a function
of pressure and temperature. This relationship is governed by Henry’s Law and
the graph below demonstrates the physical phenomenon of the air release from
water. As an example, at a constant absolute pressure of 30 psi (2 bar), if
the water is heated from 65ºF (18ºC) to 170ºF (75ºC), the amount of air
released by the solution is equal to 1.8 gallons of air per 100 gallons of
water. According to this law it can be seen that the amount of air released
increases with temperature rise and pressure reduction. The air comes in the
form of micro-bubbles of diameters in the order of tenths of a millimeter.
In heating and cooling systems there are specific points where this process of
formation of micro-bubbles takes place continuously: in the boiler and in any
device which operates under conditions of cavitation.
Boiler micro-bubbles
Micro-bubbles are formed continuously on the surface separating the water from the combustion chamber due to the fluid temperature. This air, carried by the water, collects in the critical points of the circuit from where it must be removed.Some of this air is reabsorbed in the presence of colder surfaces.
Cavitation and micro-bubbles
Micro-bubbles develop where the fluid velocity is very high with the
corresponding reduction in pressure. These points are typically the pump
impeller and the valve port.
These air and vapor micro-bubbles,
the formation of which is enhanced in the case of non de-aerated water, may
subsequently implode due to the cavitation phenomenon.
Operating principles
The DISCAL air separator is used to continuously remove the air contained in
hydronic circuits of heating and cooling systems.
The air discharge capacity is very high. They are capable of removing
automatically all the air present in the system down to micro-bubble level
with low head loss due the special internal shape of the separator body.
Flow direction of the DISCAL air separator is bidirectional; flow in either
direction is permitted.The air separator uses the combined action of several
physical principles. The active part consists of an assembly of concentric
mesh surfaces (1). These elements create the whirling movement required to
facilitate the release of microbubbles and their adhesion to these surfaces.
The
bubbles, fusing with each other, increase in size until the hydrostatic thrust
overcomes the adhesion force to the mesh. They rise towards the top of the
unit from which they are released through a float-operated (2) automatic air
vent, with stainless steel float guide pin (3) and stainless steel float
linkages (4).
551 and NA551 steel series
Steel models
Steel flanged models come standard with a side drain valve (A) to drain large
amounts of air when filling the circuit and to remove any debris present above
the water level.
A 1″ drain valve (code NA39753) can be connected (B) at the bottom of the 2″ –
6″ steel flanged DISCAL to drain collected dirt particles.
A replacement air vent assembly for the DISCAL brass 551 series (except
rotating collar and compact versions) is code 59829; for the DISCAL steel 551
and NA551 series is code 59756.The moving parts that control air venting are accessed
simply by removing the upper cover (5). Replacement cap and float assembly for
all versions of the brass DISCAL 551 and 5517 series is code F39807.
Construction details
DISCAL air separators are designed to allow maintenance and cleaning without
having to remove the valve body from the pipework. All DISCAL air separators
come standard with a bottom connection for installing a drain valve. All
internal air release control components are fully accessible in all the
models.
The automatic air vent, located at the top of the units, has a long chamber
for the movement of the float. This feature prevents any debris present in the
water from reaching the sealing seat. A stainless steel float guide pin (3),
along with a stainless steel float linkage (4) prevents the float from
sticking due to accumulating residue in the flowing fluids, even when the
DISCAL air separator is not installed perfectly vertical.When
cleaning, simply unscrew the portion of the body containing the automatic air
vent (6). For rotating collar and compact models the air vent body is not
removable so the internal mesh element can be pullled out by removing the
upper cover (5).
DISCAL air separators with flanged end connections have an integral side
drain port with brass shutoff drain valve, code 538402 FD (A), which has two
functions:
- Air removal while filling the system during system commissioning.
- Debris removal that float within the air separator.
Air separation efficiency
DISCAL air separators continuously remove entrained air in hydronic systems with very high separation efficiency. The amount of air removed from a system varies depending on fluid velocity and temperature. As illustrated on the graph, at the 4.0 feet per second fluid velocity, all the air artificially introduced into the system is gradually eliminated during normal system operation by the DISCAL air separator. In conditions where the fluid velocity is slower or the temperature of the fluid is higher, the amount of air separated is even faster.
Hydraulic characteristics
| Flow capacity — brass
---|---
| Size| ¾” C/R| ¾”| 1″R| 1″| 1¼”| 1½”|
2″
4.0 f/s| GPM| 6| 6| 10| 10| 15| 22| 39
l/s| 0.4| 0.4| 0.6| 0.6| 1.0| 1.4| 2.5
| Cv| 12/14| 19| 14| 32| 56| 73| 81
R : 5517 series rotating collar version.
C: Compact version.
| Flow capacity — steel
---|---
| Size| 2″| 2 ½”| 3″| 4″| 5″| 6″| 8″|
10″| 12″
4.0 f/s| GPM| 39| 60| 90| 160| 245| 355| 625| 980| 1,410
l/s| 2.5| 3.8| 5.7| 10| 15.5| 22.4| 40.0| 62.0| 89.0
10.0 f/s| GPM| 100| 155| 220| 400| 615| 880| 1,570| 2,450| 3,530
l/s| 6.3| 9.8| 14| 25.2| 38.8| 55.5| 99.0| 154.5| 222.7
| Cv| 87| 174| 208| 324| 520| 832| 1,109| 1,387| 1,664
Insulation shells
Insulation shells for brass DISCAL series for horizontal pipes. These are not designed for the compact or 517 series rotating collar DISCAL.
Code | Size |
---|---|
CBN551 005 | For ¾” and 1″ |
CBN551 007 | For 1¼” and 1½” |
CBN551 009 | For 2″ |
Insulation
Material: | closed cell expanded PE-X |
---|---|
Thickness: | 25/64″ (10 mm) |
Density – inner part: | 1.9 lb/ft3 (30 kg/m 3) |
– outer part: | 3.1 lb/ft (50 kg/m ) |
Thermal conductivity (DIN 52612) | |
– at 32ºF (0ºC): | 0.263 BTU·in/hr·ft 2 ·ºF (0.038 W/(m·K) |
– at 104ºF (40ºC): | 0.312 BTU·in/hr·ft 2 ·ºF (0.045 W/(m·K) |
Coefficient of resistance to water vapor (DIN 52615): | >1,300 |
Working temperature range: | 32–212ºF (0–100ºC) |
Accessories
Item
| Code|
Description
---|---|---
| 561402A| Check valve for expansion tanks. 1/2″ NPT connections.
| R59681| Hydroscopic safety vent cap.
| 562100| Small anti-vacuum vent cap.
| 59119| Replacement DISCAL air vent cap.
Optional drain valves, separator sizes 2″ – 6″, code NA39753 (1″ NPT female with T handle); separator sizes 8″ -12″, code NA59600 (2″ NPT female with lever).
Installation
DISCAL units may be used in heating or cooling systems to ensure the
progressive removal of air which is continuously formed. The units should
preferably be installed after the boiler and on the pump suction side, as
these are the points where the formation of micro-bubbles is greatest. DISCAL
air separators for horizontal pipes must be installed vertically. Flow
direction of the DISCAL air separator is bidirectional (flow in either
direction is permitted), except for the 5517 series rotating collar version.
For the 5517 series, the correct flow direction is shown by an arrow on the
T-fitting. Turn the T-fitting by hand to correctly orient it to install in
either horizontal or vertical piping. In installation conditions where
inspection is not possible, it is recommended that the venting
valve cap is replaced by a Caleffi Code R59681 hygroscopic safety vent.
Application diagram
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SPECIFICATION SUMMARIES
DISCAL ® 551 series – Compact
Air separator in brass complete with brass automatic air vent containing
pinned float. Connections for horizontal pipes, 3/4″ NPT female threads or
3/4″ sweat. Brass body. Peroxide-cured EPDM seals. 304 stainless steel
internal mesh element. PP float. tainless steel float linkages. Stainless
steel float guide pin. Bottom 1/2″ NPT female thread for drain. Models
available with pre-installed service check valve. Maximum working pressure 150
psi (10 bar), Temperature range 32 to 250°F (0 to 120°C). Glycol maximum 50%.
Air separation efficiency: 100% removal to micro-bubble level.
DISCAL® 551 series
Air separator in brass complete with brass automatic air vent containing
pinned float. Connections for horizontal pipes, 3/4″ to 2″ NPT female threads,
1″ to 2″ sweat and 1”, 1-¼” integral press. Brass body. Peroxide-cured EPDM
seals. Glass reinforced nylon PA66G30 internal mesh element. PP float.
Stainless steel float linkages. Stainless steel float guide pin. Bottom 1/2″
NPT female thread for drain. Models available with pre-installed service check
valve. Maximum working pressure 150 psi (10 bar), Temperature range 32 to
250°F (0 to 120°C). Glycol maximum 50%. Air separation efficiency: 100%
removal to micro-bubble level. Provide with insulation shell, code CBN551
series.
DISCAL® 5517 series – Rotating collar
Air separator in brass complete with brass automatic air vent containing
pinned float. Connections for horizontal and vertical pipes, 3/4″ to 1″ sweat,
press and NPT male thread with union nuts. Brass body. Peroxide-cured EPDM
seals. 304 stainless steel internal mesh element. PP float. Stainless steel
float linkages. Stainless steel float guide pin. Bottom 1/2″ straight female
thread for drain. Maximum working pressure 150 psi (10 bar). Temperature range
32 to 250°F (0 to 120°C). Glycol maximum 50%. Air separation efficiency: 100%
removal to micro-bubble level.
DISCAL® 551 series – Flanged
Air separator in steel with brass side drain valve and automatic air vent with
pinned float. Flanged ANSI B16.5 CLASS 150 RF connections from 2″ to 6″ for
horizontal pipes. Epoxy resin coated steel body. Peroxide-cured EPDM seal. 304
Stainless steel internal mesh element. PP float. Stainless steel float
linkages. Stainless steel float guide pin. Bottom 1″ NPT male thread for drain
and side drain port supplied with integral brass shutoff valve, code 538402
FD, and ¾” garden hose connection. Provide with separately purchased brass
drain ball valve, 1” NPT female with T handle, code NA39753. Maximum working
pressure 150 psi (10 bar). Vessel working temperature range 32 to 270°F (0 to
132°C). Glycol maximum 50%. Air separation efficiency: 100% removal to micro-
bubble level.
DISCAL® 551 series – Flanged, ASME & CRN
Air separator in steel with brass side drain valve and automatic air vent with
pinned float. Flanged ANSI B16.5 CLASS 150 RF connections from 2″ to 12″ for
horizontal pipes. Epoxy resin coated steel body. Peroxide-cured EPDM seal. 304
Stainless steel internal mesh element. PP float. Stainless steel float
linkages. Stainless steel float guide pin. Bottom 1″ NPT male thread for
drain, 2” to 6” separators, 2” NPT male thread for drain, 8” to 12”
separators, and side drain port supplied with integral brass shutoff valve,
code 538402 FD, and ¾” garden hose connection. For separator size 8” to 12”
only thermometer pocket well on inlet/outlet flanges ½” NPT female. Provide
with separately purchased brass drain ball valve, for 2” to 6” size separators
1” NPT female with T handle, code NA39753. For 8” to 12” size separators 2”
NPT female with lever handle, code NA59600, is supplied but not attached.
Maximum working pressure for 2″ to 6″ separators 150 psi (10 bar), for 8″ to
12″ separators 200 psi (14 bar). Vessel working temperature range 32 to 270°F
(0 to 132°C). Glycol maximum 50%. Air separation efficiency: 100% removal to
micro-bubble level. Designed and built in accordance with Section VIII,
Division 1 of the ASME Boiler and Pressure Vessel Code and tagged and
registered with the National Board of Boiler and Pressure Vessel Inspector,
and CRN registered (pending for 12”), and stamped for 150 psi (10 bar) working
pressure, with ASME U stamp.
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 North America, Inc.
3883 W. Milwaukee Road
Milwaukee, WI 53208
Tel:414-238-2360 · Fax:
414-238-2366
sales@caleffi.com
www.caleffi.com
©Copyright 2022 Caleffi North America, Inc.
Documents / Resources
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CALEFFI 551 Series DISCAL Air
Separator
[pdf] Owner's Manual
551 Series DISCAL Air Separator, 551 Series, DISCAL Air Separator, Air
Separator, Separator
---|---
References
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