CALEFFI 551006A, 551007A, 551008A, 551009A, 551028A Installation, Commissioning And Servicing Instructions

DISCAL® air separator

38456.11

www.caleffi.com

© Copyright 2018 Caleffi

551- 5517 - NA551 Series

Installation, commissioning and servicing instructions

Function

The DISCAL® air separator is 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.

This item is designed for use in closed hydronic systems. Do not use this item in plumbing applications. It does
not meet the low-lead plumbing standards of U.S. and Canada.

Product range

551 series DISCAL air separator for horizontal pipes, in brass compact with drain
Sizes ¾” integral 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” integral sweat
(A without service check valve, AC with service check)

551 series
Sizes

DISCAL air separator for horizontal pipes, in brass with drain

1” - 1 ¼” - 1 ½” - 2”

press (A without service check valve, AC with service check)

5517 series DISCAL air separator for horizontal or vertical pipes with rotating collar, in brass with
drain. Sizes

551 series DISCAL

¾” and 1” sweat union, press union and NPT male union

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

Scan to view

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, with ASME U-stamp. Sizes 2” – 12” ANSI.

Installation Tip

1

·

NA551 & 551 DISCAL

®

Technical specications

Brass air separator

Materials - body: brass

- internal element
(compact and rotating collar versions): 304 stainless steel

- internal element: glass reinforced nylon PA66GF30

- seal: peroxide-cured EPDM

- air vent float: PP

- 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"integral sweat
1” ,1-1/4 ”,1-1/ 2” and 2” integral press
rotating collar version, 5517 series: ¾” and 1” sweat, press and NPT male union

- lay length (press connection): see page 4 and 5

- drain: 1/2" NPT female
5517 series: 1/2” straight female

Steel air separator

Materials - body: epoxy resin painted steel

- internal element: 304 stainless steel

- seal: peroxide-cured EPDM

- air vent float: PP

- 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: sizes 2-6”: 150 psi (10 bar); sizes 8-12”: 200 psi (14 bar)
Temperature range: 32–270°F (0 –132°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 (12” pending, contact Caleffi).

2

Working Pressure & Temperature Limits

(Solder Type Limits Per ASTM Std. B16.18-1979)

FLOW-CONTROL

STYLE

SWEAT

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:

proper application, installation, and maintenance of systems in accordance
with all applicable codes and ordinances.

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.

TYPE OF
SOLDER

95-5

Tin-Antimony

50-50 tin-Lead 125 150

60-40 tin-Lead 75 250

All work must be performed by qualified personnel trained in the

MAXIMUM LIMITATIONS

PRESSURE PSI TEMPERATURE °F

150 250

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

3

C C

Dimensions

C

A

A

C

D

E

A

D

E

A

F F

B

Code A B C D E F Wt (lb)

551003A*3⁄4" NPT 31⁄16" 23⁄16" 53⁄8" 67⁄8"1⁄2" 2.0

551022A*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.

E

B

F

B

C

1/2

”

D

Code A B C D E F Wt (lb)

551705A3⁄4" NPT 51⁄8" 23⁄16" 53⁄8" 91⁄4" 31⁄2" 4.9

551765A3⁄4" press 63⁄8" 23⁄16" 53⁄8" 93⁄4” 31⁄2" 4.9

551795A3⁄4" SWT 6" 23⁄16" 53⁄8" 93⁄16” 31⁄2" 4.9

551706A 1" NPT 63⁄4" 23⁄16" 53⁄8" 93⁄4” 31⁄2" 4.9

551766A 1" press 63⁄4" 23⁄16" 53⁄8" 93⁄4” 31⁄2" 4.9

551796A 1" SWT 7" 23⁄16" 53⁄8" 93⁄4” 31⁄2" 4.9

551716* -- 33⁄4” 23⁄16" 53⁄8" 91⁄4" 31⁄2" 4.4

* Body only, no end connection fittings. Source separately, see Caleffi

catalog for end connection code numbers.

Code A Lay length

551765A3⁄4" press 4 5⁄8"

551766A 1" press 4 3⁄4"

4

D

B

E

A

A

A

D

B

E

A

G

F
B

F F

T

max

250F

P

max 150 psi

T

max

220F

P

max 150 psi

BI-DIRECTIONAL

38466.01

A

A

D

E

C

C

C

C C

C C

B

G

D

B

E

A

A

A

D

B

E

A

A

D

B

E

A

F

F F

A

D

B

E

F

A

T

max

250F

P

max 150 psi

A

A

D

E

C

C

C

C C

C C

B

G

D

E

A

A

D

E

A

A

F

B

F
B

Code A B C D E F Wt (lb)

551005A*3⁄4" NPT 45⁄16" 23⁄16" 53⁄4" 71⁄2"1⁄2" 3.7

551006A* 1" NPT 45⁄16" 23⁄16" 53⁄4" 71⁄2"1⁄2" 3.7

551007A* 11⁄4" NPT 47⁄8" 23⁄16" 69⁄16" 81⁄4"1⁄2" 4.9

551008A* 11⁄2" NPT 47⁄8" 23⁄16" 69⁄16" 81⁄4"1⁄2" 4.9

551009A* 2" NPT 51⁄8" 23⁄16" 69⁄16" 81⁄4"1⁄2" 5.5

551028A* 1" SWT 51⁄16" 23⁄16" 53⁄4" 71⁄2"1⁄2" 3.7

551035A* 11⁄4" SWT 53⁄16" 23⁄16" 65⁄16" 81⁄4"1⁄2" 3.7

551041A* 11⁄2" SWT 53⁄4" 23⁄16" 69⁄16" 81⁄4"1⁄2" 4.9

551054A* 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.

C

A

D

E

A

F

Code A B C D E F Wt (lb)

551066A* 1" press 6 3⁄16" 23⁄16" 53⁄4" 71⁄2"1⁄2" 3.8

551067A* 1¼" press 7 7⁄16" 23⁄16" 53⁄4" 71⁄2"1⁄2" 5.0

551068A* 11⁄2" press 8" 23⁄16" 69⁄16" 81⁄4"1⁄2" 5.1

551069A* 2" press 81⁄2" 23⁄16" 69⁄16" 81⁄4"1⁄2" 5.5

Code A Lay length

B

551066A* 1" press 4 1⁄2"

551067A* 1¼" press 5 1⁄8"

551068A* 11⁄2" press 5 1⁄4"

551069A* 2" press 5 1⁄2"

5

Dimensions

F J

G

38466.01

BI-DIRECTIONAL

max

max

T

250ϒF

T

220ϒF

max 150 psi

max 150 psi

P

P

E

WALL

D

H

A

C
B

F

Code A B C D E F G H J†Wt (lb)

**551050A 2" 133⁄4" 1" 143⁄4" 1915⁄16" 65⁄8" 213⁄16" 6" 65⁄16" 34

**551060A 21⁄2" 133⁄4" 1" 143⁄4" 1915⁄16" 65⁄8" 213⁄16" 7" 65⁄16" 35

**551080A 3" 183⁄8" 1" 171⁄8" 237⁄16" 85⁄8" 213⁄16" 71⁄2" 75⁄16" 62

**551100A 4" 181⁄2" 1" 171⁄8" 237⁄16" 85⁄8" 213⁄16" 9" 75⁄16" 67

NA551120A 5" 25" 1" 217⁄16" 301⁄2" 123⁄4" 213⁄16" 10" 93⁄8" 106

NA551150A 6" 25" 1" 217⁄16" 301⁄2" 123⁄4" 213⁄16" 10" 93⁄8" 117

Size 2" 2

1

⁄2" 3" 4" 5" 6"

Cap. (gal) 1.8 1.8 4.8 4.8 13.7 13.7

** 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.

6

2-13/16”

D

G

38783

T

110C

max

BI-DIRECTIONAL

max

P

10 bar

A

F

E

2”

B

Code A B D E

F

GCap.

NA551200A 8" 35 7/16" 20" 8 1/2" 20" 32 1/2" 56 335

NA551250A 10" 41 3/4" 26" 8 1/2" 22 5/8" 38 1/4" 110 617

NA551300A 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.

7

(gal)

Wt
(lb)

Hydraulic characteristics

0.56

(l/s) (gpm

0.27

0.14

Δ

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

678

3.5

3.0

2.7

4.3

4.0

2.2

0.33

0.39

0.25

0.22

0.19

0.17

ft of water x .433 = psi

4.0 f/s

R: 5517 series rotating collar version.
C: Compact version.

2”

3035

1.9

2.2

1 1/4”

4045607080

50

2.5

3.3

3.9

2.8

4.4

2” Steel

5.0

8”

12”

3”

4”

2 1/2”

0
9

120

140

100

6.9

8.3

5.6

5”

160180

250

400

350

300

200

11

12

171922

25

9.7

14

10”

6”

(

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

0
45

600

700

800

900

500

333944

50

56

28

1200

1000

698397

2

)

1600

1800

1400

2000

111

125

G

0.44

3/4” C

9

10520

0.50

3/4" - 1"

Rotatting Collar

121416

0.83

0.69

0.97

3/4”

1”

18

25

1.1

1.7

1.25

1.4

Flow capacity — brass

Size

¾"

¾" 1" R 1" 1¼" 1½" 2"

C/R

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

(kPa)

)

6

5

4.5
4

3.5
3

2.5

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

.

1

0

0.09

0.08

0.07

0.06

4.0 f/s

10.0 f/s

Flow capacity — steel

Size 2" 2 ½" 3" 4" 5" 6" 8" 10" 12"

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

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

8

Installation

T

max

250F

P

max 150 psi

T

max

220F

P

max 150 psi

BI-DIRECTIONAL

38466.01

T

max

250F

P

max 150 psi

T

max

220F

P

max 150 psi

BI-DIRECTIONAL

38466.01

T

max

250F

P

max 150 psi

T

max

220F

P

max 150 psi

BI-DIRECTIONAL

38466.01

T

max

250F

P

max 150 psi

T

max

220F

P

max 150 psi

BI-DIRECTIONAL

38466.01

T

max

250F

P

max 150 psi

T

max

220F

P

max 150 psi

BI-DIRECTIONAL

38466.01

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. The standard replacement cap
code is 59119.

CHILLER

38466.01

BI-DIRECTIONAL

max

max

T

250F

T

220F

P

P

max 150 psi

max 150 psi

38466.01

220F

max
max 150 psi

T
P

BI-DIRECTIONAL

250F

max 150 psi
max

P

T

max 150 psi

max 150 psi

P

P

T

250F

T

220F

max

max

BI-DIRECTIONAL

38466.01

T

P

max

max 150 psi

250F

BI-DIRECTIONAL

P

T

max 150 psi

max

220F

38466.01

9

Construction details

6

5

4

DISCAL air separators are designed to allow
maintenance and cleaning without having to
remove the valve body from the piping. 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)
prevents the float
from sticking due
to accumulating
residue in the
flowing fluids,

59756

59829

even when the DISCAL air separator is not
installed perfectly vertical.

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 (4). Replacement cap and float
assembly for all versions of the brass DISCAL
551 and 5517series is code F39807.

When cleaning, simply unscrew the portion

of the body containing the
automatic air vent (5). For the
rotating collar and compact
models, the element can be
removed by removing the
upper cover(4). There is no
need to remove the air vent
body for these models.

F39807

4

5

3

3

10

5

4

3

5

4

4

4

11

Accessories

Item Code Description

561402A

R59681

562100

5 9119

Check valve for expansion tanks.
1/2" NPT connections.

Hydroscopic safety vent cap.

Small anti-vacuum vent cap.

Replacement DISCAL air ventcap.

Insulation shells for brass DISCAL series for
horizontal pipes. These are not designed for the
compact or 517 series rotating collar DISCAL.

Code Size

CBN551005

CBN551007

CBN551009

For ¾" and 1"

For 1¼" and 1½"

For 2"

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).

12

Caleffi North America, Inc.
3883 West Milwaukee Road
Milwaukee, WI 53208
T: 414.238.2360 F: 414.238.2366

10-12-18