CALEFFI DISCAL 551 Series User guide

Function
Air separators are used to continuously remove the air contained
in the hydronic circuits of heating and cooling systems. The air
discharge capacity of these devices is very high. They are capable
of removing automatically all the air present in the system down to
micro-bubble level.
The circulation of fully de-aerated water enables the equipment to
operate under optimum conditions, free from any noise, corrosion,
localized overheating 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
Sizes ¾” sweat; ¾” NPT female (A without service check valve, AC with service check)
551 series DISCAL®air separator for horizontal pipes, in brass with drain
Sizes ¾” - 1” - 1 ¼” - 1 ½” - 2” NPT female; 1” - 1 ¼” - 1 ½” - 2” sweat
(A without service check valve, AC with service check)
551 series DISCAL® air separator for horizontal pipes, in brass with drain
Sizes 1” - 1 ¼” press (A without service check valve, AC with service check)
551 series DISCAL® air separator for horizontal pipes, in steel with flanged connections with drain
Sizes 2” – 6” ANSI
NA551 series DISCAL®air separator for horizontal pipes, in steel with flanged connections with drain
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
Sizes 2” – 12” ANSI
NA5519 series DISCAL®air separator for vertical pipes, in brass compact with drain
Sizes ¾” and 1” sweat
Installation, commissioning and servicing instructions
38456.08
www.caleffi.com
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551- NA551 - NA519 Series
© Copyright 2016 Caleffi
DISCAL®air separator

2
Technical specifications
Brass air separator
Materials - body: brass
- internal element
(compact & vertical versions): 304 stainless steel
- internal element: glass reinforced nylon PA66GF30
- seal: EPDM
- air vent float linkages: stainless steel
- air vent float guide pin: stainless steel
Performance
Suitable fluids: water, glycol solution
Max. percentage of glycol: 50%
Max. working pressure: 150 psi (10 bar)
Temperature range: 32–250°F (0–120°C)
Air separation efficiency: 100% to micro-bubble level
Connections - main:
compact series: 3/4" sweat; 3/4" NPT female
horizontal: 3/4", 1", 1-1/4", 1-1/2" and 2" NPT female
1", 1-1/4", 1-1/2" and 2" sweat
- lay length (press connection): size 1 inch: 4 ¾”
size 1 ¼ inch: 5 1/8”
vertical: 3/4" and 1" sweat
- drain valve: 1/2" NPT female
Steel air separator
Materials - body: epoxy resin painted steel
- internal element: 304 stainless steel
- seal: EPDM
- air vent float linkages: stainless steel
- air vent float guide pin: stainless steel
Performance
Suitable fluids: water, glycol solution
Max. percentage of glycol: 50%
Max. working pressure: 150 psi (10 bar)
Temperature range: 32–250°F (0–120°C)
Air separation efficiency: 100% to micro-bubble 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
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 Inspector, and CRN registered.

CAUTION: If the DISCAL
®
valve is not installed, commissioned and
maintained properly, according to the instructions contained in this
manual, it may not operate correctly and may endanger the user.
CAUTION: Make sure that all the connecting pipework is water tight.
CAUTION: When making the water connections, make sure that the
pipework connecting the DISCAL
®
is not mechanically over-stressed. Over
time this could cause breakages, with consequent water losses which, in turn,
could cause harm to property and/or people.
CAUTION: Water temperatures higher than 100°F (38°C) can be dangerous.
During the installation, commissioning and maintenance of the DISCAL
®
valve, take the necessary precautions to ensure that such temperatures do
not endanger people.
Leave this manual for the user
SAFETY INSTRUCTION
This safety alert symbol will be used in this manual to draw attention to safety related
instructions. When used, the safety alert symbol means.
ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD.
CAUTION: All work must be performed by qualified personnel trained in the
proper application, installation, and maintenance of systems in accordance
with all applicable codes and ordinances.
FLOW-CONTROL
STYLE
TYPE OF
SOLDER
MAXIMUM LIMITATIONS
PRESSURE PSI TEMPERATURE °F
SWEAT
95-5
Tin-Antimony 150 250
50-50 tin-Lead 125 150
60-40 tin-Lead 75 250
Working Pressure & Temperature Limits
(Solder Type Limits Per ASTM Std. B16.18-1979)
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Hydraulic characteristics
4
0.56
G(l/s) (gpm)
(kPa)
2.8
1.4
0.33 0.39
0.44 0.50 0.69
0.83 0.97
1.1
1.25
1.7
1.9 2.2 2.5 3.3
3.9
4.4 5.0 6.9
11 12
5.6
8.3 9.7
14
2”
2 1/2”
28
17 19 22 25
3” 4”
33 39
44 50
56
5” 6”
0.2
0.11
0.16
0.3
0.8
0.5
1
0
. 1
0
. 2
0
. 5
0.9
0.8
0.7
0.6
0.12
0.14
0.16
0.18
0.25
0.3
0.35
0.4
0.45
1.2
1.4
1.6
1.8
2.5
3
2
2.3
1.1
1.6
0.09
0.08
0.07
0.06
0.07
0. 0 5
(ft of water) Δ P (psi)
100
10
5
20 50
1000
200 500
0.1
0.05
0.09
0.08
0.07
0.06
0.035
0.04
0.045
0.12
0.14
0.16
0.18
0.25
0.3
0.35
0.2
1
0.5
0.9
0.8
0.7
0.6
0.45
0.4
0.025
0.03
0. 0 2
6
7
8
9
12 14 16 18 25 30 35
40 45 60
70
80 90
120 140 160
180
250 400 450
300
350 600 700 800 900
3.3
4.6
6
4.5
1.2
1.4
1.6
1.8
2
69 83 97
111 125
2000
1200
1400 1600 1800
4
3.5
5
12”
10”
8”
4.3
4.0
3.5 3.0 2.7
2.2
0.27
0.25
0.22 0.19 0.17
0.14
1”
3/4” C
1 1/4” 1 1/2”
2”
FLG
3/4” 3/4-1”
Flow capacity — brass
Fluid
Velocity Size 3⁄4"C 3⁄4"3⁄4"-1"1"11⁄4"11⁄2"2"
4.0 f/s
GPM 6 8 9 9 15 24 36
l/s 0.4 0.5 0.57 0.6 1.0 1.5 2.3
10.0 f/s
GPM 14 19 20 22 36 57 66
l/s 0.9 1.2 1.26 1.4 2.3 3.6 4.1
Cv 12 19 19 32 56 73 81
Flow capacity — steel
Fluid
Velocity Size 2"21⁄2"3"4"5"6"8”10”12”
4.0 f/s GPM 37 63 96 149 259 380 625 980 1410
l/s 2.4 4.0 6.0 9.4 16.3 24.0 39.4 61.8 89.0
10.0 f/s GPM 89 150 227 355 816 904 1,570 2,450 3,530
l/s 5.6 9.5 14.3 22.4 51.0 57.0 99.0 155.0 223.0
Cv 87 174 208 324 520 832 1,109 1,387 1,664

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. 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. The standard replacement cap code is 59119.
CHILLER
5

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 (except vertical
versions) 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)
prevents the float
from sticking due
to accumulating
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4
3
6
5
5
3
4
4
4
3
6
5
5
3
4
4
59829
residue in the flowing fluids, even when the
DISCAL
®
air separator is not installed perfectly
vertical.
A replacement air vent assembly for the
DISCAL
®
brass 551 series (except vertical
and compact) 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
(4). Replacement cap and float assembly for all
versions of the brass DISCAL
®
551 and NA551
series is code F39807.
When cleaning, simply
unscrew the portion of the
body containing the automatic
air vent (5). For the vertical
and compact models without
a drain, the element can be
removed by removing the
upper cover(4). There is no
need to remove the air vent
body for these models.
4
3
6
5
5
3
4
4
F39807
59756

4
3
6
5
5
3
4
4
4
3
6
5
5
3
4
4
4
3
6
5
5
3
4
4
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Caleffi North America, Inc.
3883 West Milwaukee Road
Milwaukee, WI 53208
T: 414.238.2360 F: 414.238.2366
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.
5 9119 Replacement DISCAL
®
air ventcap.
03-10-16