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www.caleffi.com
DISCALDIRT® - DISCALDIRTMAG® air and dirt separator
38557.07
© Copyright 2018 Caleffi
546 - 5461 - NA546 - NA546_M Series
Installation, commissioning and servicing instructions
Function
Air and dirt separators are used to continuously remove
the air and debris contained in the hydronic circuits
of heating and cooling systems. The air discharge of these
devices is very high. They are capable of automatically
removing all of the air present in the system down to
the microbubble level. The DISCALDIRT® air and dirt
separator also removes any solid impurities in the system.
The impurities collect at the bottom of the device and can
be flushed through the integal drain shut-off valve. The
circulation of fully de-aerated and cleaned water enables
the equipment to operate under optimum conditions, free
from noise, corrosion, or mechanical damage.
The DISCALDIRTMAG® air and dirt separator with
added magnetic ring (brass and steel 5461 series) or
probe (steel 546 and NA546 series) removes both
ferrous and non-ferrous impurities continuously,
featuring powerful removable magnets that remove
up to 100% of the ferrous impurities, including magnetite, that can form in a hydronic system. The
DISCALDIRTMAG® has 2½ times the ferrous impurities removal performance of a standard air
and dirt separator. Insulation shells are available separately for field installation on the
brass DISCALDIRT® and DISCALDIRTMAG®.
These items are designed for use in closed hydronic systems. Do not use in plumbing applications. These items
do not meet the low-lead plumbing standards of U.S. and Canada.
Product range
54609 series DISCALDIRT® air and dirt separator in brass, connections 1" and 1-¼" sweat
546016A DISCALDIRT® air and dirt separator in brass, connection 1" NPT male
546 series DISCALDIRT® air and dirt separator in steel, connections 2"-6" ANSI flanged
5461 series DISCALDIRTMAG® air and dirt separator with magnet in brass,
connections 1", 1-¼" sweat, 1" NPT male
5461 series DISCALDIRTMAG® air and dirt separator with magnet in steel,
connections 1-½" and 2" press union, sweat union and NPT female union
NA546 series DISCALDIRT® air and dirt separator in steel, ASME & CRN,
connections 2½"-14" ANSI flanged
NA546050T DISCALDIRT® air and dirt separator in steel, ASME & CRN,
connections 2" NPT threaded
NA546_M series DISCALDIRTMAG® air and dirt separator with magnet in steel,
ASME & CRN, connections 2½"-14" ANSI flanged,
2" NPT threaded.
Scan to view
Installation Tip
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·
546,5461 & NA546 AIR & DIRT SEPARATOR
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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.
WARNING: This product can expose you to chemicals including lead, which
is known to the State of California to cause cancer and birth defects or other
reproductive harm. For more information go to www.P65Warnings.ca.gov.
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.
CAUTION: If the DISCALDIRT® and DISCALDIRTMAG® air and dirt separator 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 DISCALDIRT® and DISCALDIRTMAG® 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
DISCALDIRT® and DISCALDIRTMAG® air and dirt separator, take the necessary
precautions to ensure that such temperatures do not endanger people.
Leave this manual for the user
Technical specifications
Brass body air and dirt separators and magnetic air and dirt separators
Materials - body: brass
- dirt separation chamber: brass
- air vent body: brass
- internal element: glass reinforced nylon, PA66GF30
- air vent float: PP
- air vent float guide pin: stainless steel
- air vent float linkages: stainless steel
- spring: stainless steel
- seals: peroxide-cured EPDM
- bottom drain shut-off valve: brass
- magnet (5461 series): neodymium rare-earth
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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% removal to microbubble level
Particle separation capacity: to 5 µm (0.2 mil)
Ferrous impurities separation efficiency (5461 series): up to 100% removal
Connections - main: 1", 1-¼" sweat; 1" NPT male
- drain shut-off valve: ¾" garden hose connection
Steel body air and dirt separators and magnetic air and dirt separators
Materials - body: epoxy resin painted steel
- air vent body: brass
- internal element: (546, 5461, NA546) stainless steel
(NA546_M) stainless steel and HDPE
- air vent float: PP
- air vent float guide pin: stainless steel
- air vent float linkages: stainless steel
- spring: stainless steel
- seals: peroxide-cured EPDM
- bottom drain shut-off valve: brass
- side drain shut-off valve: brass
- magnet (5461 and M series): neodymium rare-earth
- magnet probe drywell (M series): brass
Performance
Suitable fluids: water, glycol solution
Max. percentage of glycol: 50%
Max. working pressure: 150 psi (10 bar)
Temperature range (vessel): -546, NA546, NA546_M series 32–270°F (0–132°C)
-5461 series 32–230°F (0–110°C)
Air separation efficiency: 100% removal to microbubble level
Particle separation capacity: to 5 µm (0.2 mil)
Ferrous impurities separation efficiency (5461 and M series): up to 100% removal
Connections - flanged (546 series): 2"–6" ANSI B16.5 150 CLASS RF
- flanged (NA546, NA546_M series): 2 ½"–14" ANSI B16.5 150 CLASS RF
- threaded (5461 series): 1 ½" and 2" NPT female union
- threaded (NA546, NA546_M series): 2" NPT male
- sweat union (5461 series): 1½" and 2"
- press union (5461 series): 1½" and 2"
- lay length (press connections): size 1 ½ inch: 11-1/8"
size 2 inch: 12 ½"
- bottom drain valve: 2"–6": 1" NPT female
8"–14": 2" NPT female
5461 series: 3/4" garden hose connection
Agency approval
-NA546, NA546_M series designed and built in accordance with Section VIII, Div. 1 of the ASME Boiler and
Pressure Vessel Code and tagged, registered with the National Board of Boiler and Pressure Vessel Inspectors,
stamped for 150 psi (10 bar) working pressure, with ASME U stamp.
-NA546 and NA546_M series 2"-10" series is also CRN registered, sizes 12" - 14" CRN pending, consult Caleffi.
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Operating principle
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2 2
3
1
2
3
3
1
1
2
3
3
Microbubble air separation
The air and dirt separator uses the combined action of several physical principles. The active part is
the internal element (1) and consists of a glass-reinforced nylon mesh for the bras s DI SC AL DI RT®
and DISCALDIRTMAG®, or for the steel DISCALDIRT® and DISCALDIRTMAG® an assembly
of concentric metal mesh (stainless steel) surfaces. These elements create the whirling movement
required to facilitate the release of micro-bubbles and their adhesion to these surfaces.
The bubbles, fusing with each other, increase in volume until the hydrostatic thrust is such as to
overcome the adhesion force to the structure. They rise towards the top of the unit from which they
are released through a float-operated automatic air vent valve.
Brass DISCALDIRT
(546 series)
®
Brass DISCALDIRTMAG
(5461 series)
Steel DISCALDIRT® Steel DISCALDIRTMAG
®
®
(546, NA546 series) (NA546_M series)
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Microparticle dirt separation
The DISCALDIRT® and DISCALDIRTMAG® dirt removing element separates and collects any
impurities present in thesystem.
Impurities in the fluid upon striking the surfaces of the DISCALDIRT® and DISCALDIRTMAG®’s
internal element (1), get separated and drop to the bottom of the body in the dirt collection
chamber (2) where they collect.
In addition, the large internal volume slows down the velocity of the fluid thus helping, by
gravity, to separate the particles it contains.
The collected impurities are discharged, by opening the drain valve (3), even with the system
operating.
1
2
3
A
Ferrous impurities separation
Non-ferrous and ferrous impurities, including magnetite, in
hydronic systems can deposit onto heat exchanger surfaces
and accumulate in pump cavities causing reduced thermal
efficie ncy and premature wear. The small and often microscopic
magnetic particles, called magnetite, form when iron or steel corrodes.
Highly abrasive, the extremely fine particles are difficult to remove
by traditional means. DISCALDIRTMAG® separators offer highly
efficient separation of typical dirt as well as magnetite. The versatile
DISCALDIRTMAG
both ferrous and non-ferrous impurities continuously. In addition
to removing typical dirt particles with an internal element in a
low-velocity-zone chamber, the DISCALDIRTMAG® features
a powerful removable magnet below the flow line for fast and
effective capture of ferrous impurities.The magnet removes up to 100% of the ferrous impurities,
including magnetite, that can form in a hydronic system.
For the brass and steel 5461 series DISCALDIRTMAG
by a strong neodymium rare-earth magnetic field created by a powerful removable magnet around
the body below the flow line.
For the steel 546 and NA546 series DISCALDIRTMAG
by a concentrated magnetic field created by a stack of neodymium rare-earth magnets positioned
inside a brass dry-well below the flow stream.
®
magnetic air and dirt separator removes
B
C
D
®
(A, B, D), the ferrous impurities are captured
®
(C), the ferrous impurities are captured
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Hydraulic characteristics
0.56
G (l/s) (gpm)
(kPa)
Δ
0.27
P
(ft of water)
2
1.8
1.6
1.4
1.2
1
0.9
0.8
0.7
0.6
0.5
0.45
0.4
0.35
0.3
0.25
0.2
0.18
0.16
0.14
0.12
0.1
0.09
0.08
0.07
0.06
0.05
0.045
0.04
0.035
0.03
0.025
0.
0
2
2.2
0.17
4.3
3.5
3.0
2.7
4.0
0.22
0.19
0.25
5
0.33
678
0.39
0.44
0.50
9
1214161825
10
0.83
0.69
0.97
20
1.1
1.25
Flow capacity
1”
1.4
1 1/4”
3035
1.9
1.7
5461
1 1/2”
2”
404560708090
50
2.2
2.5
3.3
3.9
2.8
4.4
546
2”
NA546
5.0
5.6
2 1/2”
120
100
6.9
(
ft of water)
8”
3”
4”
5”
14
250
171922
0
400
45
350
300
500
33
25
28
140
160
180
200
11
12
8.3
9.7
10”
6”
600
39
12”
14”
6
2
1.8
5
1.6
4.5
1.4
4
1.2
3.5
1
3
0.9
2.5
0.8
0.7
2
0.6
1.8
1.6
0.5
1.4
0.45
0.4
1.2
0.35
1
0.3
0.9
0.8
0.25
0.7
0.6
0.2
0.18
0.16
0
.
5
0.45
0.14
0.4
0.12
0.35
0.1
0.3
0.09
0.08
0.25
0.07
0
.
2
0.06
0.18
0.16
0.05
0.14
0.045
0.04
0.12
0.035
.
1
0
0.03
0.09
0.08
0.025
0.07
0.06
0.
0
1600
2
1800
2000
111
125
001400
700
800
900
12
1000
698397
44
50
56
FLOW RATE (brass body)
Size 1" 1¼"
4.0 f/s GPM 9 10
Cv 32 40
FLOW RATE (DISCALDIRT® & MAG® steel body)
Size 2" 2½" 3" 4" 5" 6" 8" 10" 12" 14"
GPM 37 63 95 149 259 380 625 980 1,410 1,910
4.0 f/s
10.0 f/s
GPM 89 150 227 355 816 904 1,570 2,450 3,530 4,800
Cv 87 174 208 324 520 832 1,109 1,387 1,664 1,967
FLOW RATE (DISCALDIRTMAG® steel body)
Size 1½" 2" Union 2" Flg 2½" 3" 4" 5" 6"
4.0 f/s GPM 15 25 37 63 95 149 259 380
Cv 50 79 87 174 208 324 520 832
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Installation
CHILLER
CHILLER
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4
1
DISCALDIRT® and DISCALDIRTMAG® units may be used in both heating and cooling systems, to
ensure continuous air and dirt elimination. The units should be installed after the boiler and on the
pump suction side, as these are the points where the formation of micro-bubbles is greatest.
DISCALDIRT
®
and DISCALDIRTMAG® air and dirt separators must be installed vertically. In
installation conditions where inspection is not possible, it is recommended that the venting valve
cap is replaced by a Caleffi part number R59681 hygroscopic safety vent. The standard replacement
cap code number is 59199.
Maintenance
The DISCALDIRT® and DISCALDIRTMAG® air
and dirt separator is designed to be maintained
and cleaned without removing it from systempiping. The automatic air vent, located at the top of the
device, has a long chamber for float movement (2). This prevents any impurities in the water from
reaching the seal seat. The corrosion resistant stainless steel pinned linkage and PP float can be
accessed by removing the upper cover (1). The stainless steel float guide pin (4) prevents the float
from jamming against the inside housing, sticking due to accumulating residue in the flowing fluids, in
non-vertical installations or from boiler or chiller residue buildup. Unscrew the top part of the casing
(3) to clean the entire air ventingsystem. The air venting system in the brass DISCALDIRT®
and DISCALDIRTMAG® and steel
DISCALDIRT® and DISCALDIRTMAG®
air and dirt separators features a pinned
float. Steel DISCALDIRT® 546
1
a n d NA546 series and DISCALDIRTMAG®
NA546_M series air and dirt s e p a r a t o r s
with flanged and threaded connections
have an integral side drain port with shut-
2
3
off valve, code 538402 FD (5), which has
two functions:
1. Air removal while filling the system
during system commissioning.
2. Debris removal that float within the air
separator.
4
CHILLER
1
2
3
4
5
7
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The drain valve (code NA39753 - 1 inch or code NA59600 - 2 inch) installed on the drain pipe at the
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1
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4
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1
2
4
6
3
1
2
4
7
5
2
1
3
4
5
2
1
3
4
base of the steel DISCALDIRT® and DISCALDIRTMAG® air and dirt separator (8) can be used to
remove any debris that has settled at the bottom of the separator, even while the system is in operation.
To inspect the internal element of brass DISCALDIRT® and DISCALDIRTMAG® air and dirt separators,
unscrew the large dirt separation chamber (6) with a
26 mm hexagon wrench. The internal element can be
removed for cleaning. Additionally, the brass and steel
5461 series air and dirt separators have a lever operated
6
shut-off drain valve code 538402 FD, and ¾" garden
hose attachment with plug (7), to drain accumulated
debris as needed.
7
8
Draining off dirt and ferrous impurities
The dirt separator collection chamber has a drain valve. Using the handle provided it is possible to
drain off the accumulated dirt particles even with the system in operation.
For the brass and steel 5461 series DISCALDIRTMAG®, captured ferrous impurities are easily flushed
by unclamping the magnetic
collar and purging.
To purge the ferrous impurities in the steel 546 and
NA546 series DISCALDIRTMAG®, the flexible magnetic
stack is removed from the brass dry-well and, with the
system still running, the drain valve is opened. Aided
by the system pressure, the dirt and ferrous impurities,
including magnetite, flushes out quickly and effectively.
Leave this manual at the service of users for their use
Caleffi North America, Inc.
3883 W. Milwaukee Road
Milwaukee, WI 53208
T: 414.238.2360 F: 414.238.2366
8
9-10-18
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