Idronics 2 Us 0

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271395_Idronics pg.1-36.indd 1 7/17/07 8:25:43 PM

Caleffi North America, Inc.
th
9850 South 54 Street
Franklin, WI 53132
T: 414.421.1000 F: 414.421.2878
Dear Hydronic Professional,
Welcome to the 2nd edition of idronics – Caleffi’s semi-annual design journal for
hydronic professionals.
The 1st edition of idronics was released in January 2007 and distributed to over
80,000 people in North America. It focused on the topic hydraulic separation. From
the feedback received, it’s evident we attained our goal of explaining the benefits
and proper application of this modern design technique for hydronic systems.
If you haven’t yet received a copy of idronics #1, you can do so by sending in the
attached reader response card, or by registering online at www.caleffi.us. The
publication will be mailed to you free of charge. You can also download the
complete journal as a PDF file from our Web site.
This second edition addresses air and dirt in hydronic systems. Though not a new
topic to our industry, the use of modern high-efficiency equipment demands a
thorough understanding of the harmful effects of air and dirt, as well as knowledge
on how to eliminate them. Doing so helps ensure the systems you design will
operate at peak efficiency and provide long trouble-free service.
We trust you will find this issue of idronics a useful educational tool and a handy
reference for your future hydronic system designs. We also encourage you to send
us feedback on this issue of idronics using the attached reader response card or by
e-mailing us at [email protected].
A Technical Journal
from Sincerely,
Caleffi Hydronic Solutions

Mark Olson
General Manager,
CALEFFI NORTH AMERICA, INC

9850 South 54th Street INDEX
Franklin, Wisconsin 53132 USA
4 As old as hydronics
5 Air-related problems
Tel: 414.421.1000
FAX: 414.421.2878 7 Forms of entrapped air
9 Air removal devices
E-mail: [email protected] 12 Placement of central air separators
Website: www.caleffi.us 13 Dirt separation
13 Dirt-related problems
14 Dirt separation methods
15 Efficiency of dirt separation
16 Placement of dirt separators
18 Combined air & dirt separators
18 Filling & purging hydronic systems
© Copyright 2007
23 Diagnosing and correcting air-related problems
25 Summary
26 Appendix
27 Air separation products technical specifications
Printed: 29 Dirt separation products technical specifications
Milwaukee, Wisconsin USA
31 Combination air/dirt separator products technical specifications

AIR & DIRT ELIMINATION IN HYDRONIC SYSTEMS
Welcome. heat emitters. These systems used large diameter piping

and operated at very low flow velocities. Air removal was
This issue of idronics discusses elimination of air and dirt mostly a matter of waiting for air pockets to form and then
releasing this air through manually operated valves that
from hydronic systems. Although both air and dirt can
were (hopefully) located where the air accumulated.
create similar problems, such as inadequate flow or poor
heat transfer, they both have unique characteristics that Most of these early systems were “open-loop” rather
are best examined individually at first. Then, total system than closed-loop systems. An expansion tank was often
solutions that address both air and dirt elimination will be located at the high point of the system and vented to the
atmosphere. Although air could leave this tank as the
shown. water in the system was heated and expanded, it could
also reenter the tank as the water cooled. This allowed
AS OLD AS HYDRONICS: a constant presence of dissolved oxygen molecules
Air control within hydronic heating systems has always within the water and provided a source of steady internal
corrosion. Occupants simply accepted the fact that
presented challenges. It began with the earliest hydronic
noises caused by entrapped air and the continuing need
systems that did not have circulators. Water flow was to “bleed” the system of air were just part of living with a
created by the buoyancy difference between hot water hot water heating system.
leaving the boiler and cooler water returning from the
During the 1940s, engineers began designing “closed-
loop” hydronic systems along with new hardware to help
water
Figure 1 to capture air and separate it from the circulating water.
system Although some of the devices developed at the time, such
as the boiler fitting shown in figure 1, are still in service
today, they do not represent state-of-the-art technology.
Even when closed-loop hydronic systems became

To boiler standard, industry veterans could attest that air elimination,
expansion fitting
tank especially during system commissioning, often remained
a challenge. Many frustrating hours went into ridding
systems of air, especially in large, complex piping systems.
Keeping the air out of those systems also required frequent
attention.
Part of the reason for this is that “closed-loop” hydronic

systems are not 100 percent sealed against air entry.
Although such systems appear to hold pressure
reasonably well for months, and seldom have visible
top of boiler water leaks, they are not perfectly sealed. Small amounts
water to system
of the gases that make up air can enter closed-loop

hydronic systems in a variety of ways, especially if the
system is poorly designed. Examples include air weepage
air bubbles at valve packings and circulator flange gaskets, as well
as molecular oxygen diffusion directly through the walls
dip of PEX or other types of polymer tubing. Air can even be
tube
boiler pulled into systems through devices intended to expel
water
it when improper design or maintenance allows internal
pressure to drop below atmospheric pressure.
271395_Feature pg.3_24.indd 3 7/13/07 3:20:43 PM

AIR-RELATED PROBLEMS: Inadequate Flow:
Figure 2 Circulator impellers transfer
Problems due to air in hydronic systems can be frustrating
to occupants as well as heating professionals. If these maximum mechanical
problems are not fully understood, the attempted solution energy to incompressible
often produces only temporary correction. Eventually fluids (e.g., liquids). A
those attempting to remedy chronic air problems may mixture of water and air
give up, thinking that the system is simply incapable is not an incompressible
of operating air-free. This is both unfortunate and fluid. Although most
unnecessary. Modern hydronic systems can be designed circulators can move water
with some entrained air,
to quickly and permanently eliminate air.
mechanical energy transfer
is not as efficient as with
Before discussing solutions, it’s important to understand
fully deaerated water. This
the problems that air can create in hydronic systems. decreases flow and reduces
They include: the rate of heat conveyance
by the system.
• Noises in piping and heat emitters that annoy
occupants Poor Heat Transfer: Air has much lower convective
• Inadequate flows due to a mixture of water and air heat transfer properties than water. When air displaces
in circulators water away from heat transfer surfaces within boilers
• Poor heat transfer by heat emitters when all heat or heat emitters, the rate of heat transfer can be
transfer surfaces are not wetted significantly reduced. In some cases, “cold spots” on
• Accelerated corrosion due to oxygen in contact radiators are indicative of entrapped air, as shown in
with ferrous metals figure 2.
• Improper lubrication of circulator bushings due to
air in flow Accelerated Corrosion: Air contains oxygen, and
• Improper performance of balancing valves oxygen in contact with ferrous metals causes corrosion.
• Complete loss of flow and heat output due to large Hydronic systems with chronic air problems are constantly
air pockets resupplying oxygen into the system, which allows
oxidation to occur at several times the rate experienced
Let’s examine each of these air-related problems in more in a properly deaerated system.
detail. The following chemical reactions can occur in hydronic
systems containing ferrous (iron-containing) components.
Noise: A key benefit provided by a properly designed The compound Fe3O4 is called magnetite, and appears
and installed hydronic system is silent conveyance as a dark gray sludge within the system, as shown in
comfort. Occupants should not hear flow as it travels figure 3. If oxygen continues to be present in the system,
through tubing and heat emitters. Properly deaerated magnetite will be converted to hematite (Fe2O3), which
can cause pitting corrosion throughout the system.
water traveling though piping at velocities of 4 feet per
second or less makes very little (essentially unnoticeable) Figure 3
sound. However, a mixture of water and air is much
more acoustically active. Entrapped air sounds tend to
be more noticeable when flow begins in a circuit due to
disturbance of stationary air pockets. Air-filled cavities
within piping and radiators act as acoustic amplifying
chambers, especially if the water level in the device is
below the level of the incoming water, in which case
a “water fall” effect is heard. Noise is also generated
when dissolved gases within water are released due
to a sudden drop in pressure. This is called gaseous
cavitation, and it often occurs in the orifice of valves.

Circulator Damage: Modern wet-rotor circulators Gaseous cavitation occurs within circulators when the
have ceramic bushings that depend on system water pressure at the eye of the impeller drops below the
for lubrication. Due to its lower density, air tends to saturation pressure of gases such as oxygen or nitrogen
accumulate near the pump shaft in the vicinity of the in solution with the water. The dissolved gas molecules
bushings. The presence of air bubbles or air pockets can instantly form bubbles that interfere with circulator
dislodge lubricating water and hence create premature performance, as depicted in figure 5.
bushing failure. The likely result is replacement of the
entire circulator.
Figure 5
Circulators installed in vertical piping with upward flow
and having spring-loaded check valves or flowchecks
near their discharge are especially susceptible to large
pockets of air (see figure 4). If a sufficient volume of air
enters the volute and displaces water in the impeller, the
circulator may be unable to clear itself and will quickly be
running without lubrication. Failure is almost certain.
Figure 4
spring-loaded
internal check
valve traps
rising air
in volute dissolved gases released from solution
create gaseous cavitation within circulator
Sediments formed by oxidation within the system can

be deposited on the impeller and volute of circulators,
lowering their performance or causing total blockage
(see figure 6).
Figure 6

Improper Performance of Balancing Valves: Hydronic FORMS OF ENTRAPPED AIR:
balancing valves are precision devices designed to Air exists in three distinct forms within hydronic systems:
perform within tight specification when conveying liquids.
• Stationary air pockets at high points
The presence of air in the water changes the pressure
• Entrained air bubbles
drop vs. flow rate characteristics of the valves, allowing
• Gases dissolved within water
flow rates to drift away from desired settings. This in turn
can lead to improper heat delivery in various portions of
Every hydronic system is completely filled with air prior to
the system. Highly throttled balancing valves can also
being commissioned. Stationary air pockets are typically
experience gaseous cavitation when water with a high
the remnants of air not expelled when the system is first
dissolved air content passes through them.
filled. In some systems, they may also exist due to an
improper design or installation detail that allows air to
Complete Loss of Flow: If a stationary air pocket is
reenter the system.
large enough, and the piping system is tall enough, the
system’s circulator cannot generate sufficient lift to force
Since air is lighter than water, it migrates toward high
water over the top of the system (see figure 7). Under
points in the system. Such points are not necessarily
such circumstances there will be complete loss of flow in
at the top of the system piping. Stationary air pockets
the circuit. Even if the circulator can establish some flow
can form at the top of heat emitters, even those located
over the top of the system, that flow may not be sufficient
at low elevations within a building. Air pockets can also
to entrain air and help dislodge the air pocket.
form in horizontal piping that eventually turns downward,
or piping that is routed above obstacles in its path, as
air shown in figure 8.
Figure 7
Figure 8 air pocket
circulator cannot lift water over top of circuit
As water enters the system, these locations can trap air,

especially if water approaches them from both directions.
Slow water movement during the filling process also
enhances air pocket formation.
Stationary air pockets can also reform as residual air bubbles
merge together and migrate toward high points. This is
especially likely in components with low flow velocities,
where slow-moving fluid is unable to push or drag the air
along. Examples of such components include large heat
emitters, large diameter piping, and storage tanks.

Entrained Air Bubbles: The amount of dissolved gases that water can hold
A moving fluid may be able to carry air bubbles along depends on the water’s temperature and pressure.
(entrain them) through the system. This is desirable from At higher temperatures, the ability of water to contain
the standpoint of conveying air bubbles from remote parts dissolved gases decreases and vice versa.
of the system back to a central air-separating device
where they can be captured and expelled. However, if the The contours in figure 9 show the maximum amount of
fluid’s flow velocity through the air-separating device is too dissolved air gases contained in water over a range of
high, the entrained air cannot be efficiently separated and temperatures and pressures (expressed as a percentage
could end up making many passes through the system. of total volume). For example, at 30 psi absolute pressure
(about 15.3 psi gauge pressure) and a temperature of
The ability of a fluid to entrain air can be judged by its ability 65ºF, up to 3.6 percent of the molecules in a container
to move bubbles vertically downward, against their natural of water can be dissolved gases (oxygen, nitrogen, and
tendency to rise. If the fluid moves downward faster than other trace gases). However, if the water’s temperature
a bubble can rise, it will pull the bubble along. A minimum is raised to 170ºF while maintaining the same pressure,
flow velocity of 2 feet per second is recommended to its ability to hold dissolved gas is reduced to 1.8 percent
entrain air bubbles within downward-flowing pipes. of its volume, half the previous level. Such a change
in temperature would be typical of cold water heated
An especially challenging form of entrained air in hydronic within a boiler and illustrates the “degassing” effect of
systems is referred to as microbubbles. Individually, increased temperature.
microbubbles are too small to be seen by the human
eye. However, dense collections of microbubbles can Figure 9
make otherwise clear water appear cloudy. A common Absolute pressure
Max amount in gallons of dissolved air per 100 gallons of water

place to see temporary clouds of microbubbles is in a 5.5
45 psi 60 psi 75 psi 90 psi 105 psi 120 psi
drinking glass just filled with water from a faucet having 5.0
an aerator device.
4.5
In hydronic systems, microbubbles form when water with 4.0

30 psi
dissolved gases such as oxygen and nitrogen is heated in 3.5
a boiler. They can also form when water passes through
3.0
a component that creates a sudden and significant
pressure drop. An example of the latter is a throttling 2.5
15 psi
valve that is just slightly open. 2.0
1.5
Microbubbles have extremely low rise velocities and are
easily entrained by moving fluids. This characteristic 1.0
makes it more difficult to capture microbubbles. Later 0.5
sections describe how this is done.
0
32 65 100 135 170 205 240 275 310 345
Unfortunately, some hydronic systems, especially older Water temperature (°F)
systems, have air-separating devices that do not provide
sufficiently low flow velocities or internal details that
allow efficient microbubble separation. While larger The pressure at which water is maintained also
bubbles are captured due to their greater rise velocities, significantly affects its ability to contain dissolved air. At
microbubbles are often swept through the air-separating lower pressures, the ability of water to contain dissolved
device without being captured. The result can be a gases decreases and vice versa. Figure 9 shows that
system that takes days, or even weeks, to reduce its air reducing the pressure of 170ºF water from 30 to 15 psi
content to acceptable levels. absolute pressure (15.3 to about 0.3 psi gauge pressure)
reduces the amount of dissolved gas it can contain from
Dissolved Air: 1.8 percent to about 0.6 percent of its volume. This
Molecules of the gases that make up air can exist “in explains why air bubbles are more likely to form in the
solution” with water molecules. Since molecules are too upper portions of a multi-story hydronic system. Lower
small to be seen, water that appears perfectly clear and static pressure in the upper portions of the building makes
free of bubbles can still contain a significant amount of it easier for dissolved air to come out of solution. Higher
dissolved gases that ultimately need to be removed from static pressure near the bottom of the system tends to
the system. keep gases in solution.

Figure 10
float-type vents at top of riser piping
Water has the ability to repeatedly absorb and release AIR REMOVAL DEVICES:
gases as its temperature and/or pressure changes. This Most air removal devices used in hydronic systems
can affect hydronic systems in several ways — some can be classified as either high point vents or central
good and some not so good. For example, the ability air separators.
of water to absorb air as it cools helps reduce the
volume of stationary pockets in areas of the system High point vents release air from one or more high points
where flow is slow or non-existent. This absorbed air in the system where it tends to accumulate. Typical
can be carried back to the boiler where it will be forced locations for such vents are the top of each heat emitter,
out of solution by heating. An efficient air-separating the top of distribution risers (see figure 10), or wherever
device can be “waiting” downstream of the heat source piping turns downward following an upward or horizontal
to capture the resulting microbubbles and eject them run. High point vents are particularly useful for ejecting
from the system. On the negative side, the ability of air during or immediately after the system has been filled
water to absorb air can also cause a condition called with fluid (e.g., at startup or after servicing).
“water logging” in expansion tanks without diaphragms
or bladders. A central air separator is used to remove entrained air
from a flowing fluid, as well as to maintain the system at
It’s always desirable to minimize the dissolved air the lowest possible air content.
content of the system’s water. This is accomplished by
establishing conditions that encourage dissolved gases
to come out of solution (e.g., high temperatures and low
pressures). The sections that follow show how this is
best accomplished in hydronic systems.

Manual Air Vents: Hygroscopic Air Vents:
The simplest type of high point venting device is a Another type of small high point venting device is called
manual air vent. These components are essentially small a hygroscopic air vent. An example of such a device
valves that thread into 1/8-inch to 1/2-inch FPT tapings, is shown in figure 12. These devices contain a special
and are operated with a screwdriver or square head key. cellulose fiber disc that, when dry, allows air to pass
When opened, air moves up through the valve seat and through it and exit the vent. When water reaches the
exits through a small side opening. disc, it expands within a few seconds to stop further
flow from the device.
Manual air vents are commonly installed at the top of
each heat emitter. An example of a manual air vent Hygroscopic air vents can
installed at the top of a towel warmer radiator is shown Figure 12 be used in either automatic
in figure 11. Such vents are opened to release air that or manual mode. When the
rises to the high point as fluid enters lower in the system. knob is set one turn open,
When the fluid level reaches the manual air vent, a small they operate identical to a
stream of water will flow out the side of the vent. A small manual air vent. When the
piece of flexible tubing can be used to guide this stream knob is closed, they allow
into a can or pail. It’s important to capture this water air to pass but reseal as
and not allow it to stain carpets or otherwise damage soon as water contacts
surrounding materials. When a steady stream of water the internal fiber disc.
has been flowing from the vent for several seconds, it
should be closed. Minerals or sediment in the
system water can interfere
with the operation of the
Figure 11 internal hygroscopic disc. It
is generally recommended
that these discs be replaced every three years. Although
hygroscopic air vents are automatic, they can be manually
opened and are therefore not recommended in locations
where tampering is possible. A float-type air vent is a
preferred choice in such locations.
Float-type Air Vents:

A float-type air vent provides fully automatic air release
and instantaneous response to the presence of water. An
example of such a device is shown in figure 13.
It contains an air chamber,

Figure 13 a float assembly and an
air valve (see figure 13). As
air accumulates within the
chamber, the float descends.
A linkage attached to the
float eventually opens the
valve mechanism at the top
of the unit. As air is released,
water flows into the chamber
and lifts the float to close
the valve. Some Caleffi float-
type vents are equipped with
hygroscopic caps that seal
the vent from water leakage
in the event that the internal
valve mechanism did not
operate properly.

Figure 14
float-type air vent
vanes deflect bubbles

into upper chamber
microbubbles are
flow velocity not efficiently removed
not more than by air purgers
4 feet/second
microbubbles often remain

connection for entrained in water flow
expansion tank
Most float-type air vents are equipped with a cap that Central Air Separators:
protects the valve mechanism from debris. It’s important The ability to maintain very low air levels within a closed-
that this cap is loosened when the vent is put into service. loop hydronic system is vital to quiet, efficient and
If the cap is fully closed, the vent cannot operate. reliable operation. The key component in providing this
function is a central air separator. Such devices can
Float-type air vents are available in different sizes and be categorized as either air purgers or microbubble air
shapes that allow mounting of both horizontal and separators.
vertical orientations. Compact designs allow mounting
within the enclosures of heat emitters, such as fin-tube Air purgers are relatively simply devices that encourage
convectors or fan-coils. Larger “high-capacity” vents well-formed air bubbles to rise into a collection chamber
are available for use atop central air separators or other and pass out through a float-type air vent at the top
locations where high-volume air venting is needed. of that chamber. They rely heavily on the buoyancy of
well-formed bubbles as the means of separation. To
It’s important to remember that float-type air vents can achieve proper operation, the velocity of the flow
also allow air to enter the system if the system pressure stream entering the separator must be kept below
at their installed location drops below atmospheric 4 feet per second. Lower velocities increase the air
pressure. This can happen as a result of improper removal efficiency of these devices, albeit at the cost
placement of the expansion tank relative to the circulator. of larger and more expensive hardware. Air purgers are
It can also be caused by low static pressure in the not designed to capture microbubbles, and as such,
system. It’s good practice to design and commission cannot lower the dissolved air content of the system
all closed-loop hydronic systems so there is at least 5 as well as separators specifically designed for this
psi of positive static pressure at the top of the system. purpose. A cutaway illustration of a typical air purger
This ensures that float-type vents will always be able is shown in figure 14.
to expel any air that accumulates. Caleffi vents can be
equipped with “anti-siphon” caps that prevent airflow
into the vent if the pressure at the vent location drops
below atmospheric pressure.
10

Microbubble Air Separators:
Previous sections discussed gases dissolved in water as Figure 16
well as the characteristics of microbubbles. These forms
of air are more difficult to capture relative to well-formed
bubbles or large air pockets. Doing so requires surfaces
upon which microbubbles can cling and eventually merge
into larger bubbles. This process is called coalescence,
and it’s vitally important to attaining and maintaining
minimum air levels in hydronic systems.
As microbubbles coalesce together, they form larger
bubbles. Eventually the bubbles attain a volume
large enough that buoyancy forces overcome the
adhesion forces holding them to the coalescing
surface. The bubbles then rise along the coalescing
surfaces to a chamber above the main flow stream
where they can be collected and expelled through
a float-type air vent. The concept of coalescence coalescing media
inside such a separator is illustrated in figure 15.
PLACEMENT OF CENTRAL AIR SEPARATORS:

Central air separators work best when located where
the solubility of dissolved gases within the system
water is lowest. In heating systems, they should be
mounted near the outlet of the heat source (see figure
17). In cooling systems, they should be mounted on the
inlet side of the chiller (e.g., where water temperatures
are highest).
Notice how the air separator placement in figure 17 allows

flow through it during space heating as well as domestic
water heating operating modes. The greater the number
of times system water passes through the heat source
and central air separator, the better the latter device can
“scrub” dissolved gases from the water and expel them.
Fig
The ability of a microbubble air separator to lower the
water’s dissolved gas content allows that water to
absorb air back into solution as it cools. A common
example of this is water cooling within piping and heat
emitters during an off-cycle. Think of this cooling water
Figure 15
as a “sponge” that soaks up molecules of air gases with
which it comes in contact. Since these molecules are
pulled into and held in solution under these conditions,
The surface on which microbubbles coalesce is they will eventually be carried back to the heat source
called the “coalescing media.” Some microbubble when flow resumes. Upon heating, they will be released
air separators use metal meshes for this media, from solution as microbubbles and captured by the
while others use special polymers. In either case, the microbubble air separator. This process is ongoing and
coalescing media must provide high surface contact can eventually bring the dissolved air content of the
area, enhancement of vertical bubble movement and water to approximately 0.4 percent of system volume.
a relatively low pressure drop. Figure 16 shows the In this state, the water can provide efficient and virtually
coalescing media cartridges used in Caleffi Discal silent conveyance of heat, and its very low oxygen
microbubble air separators. content discourages corrosion.
11

Figure 17

microbubble
air separator
circulator
circulator
heating
DHW
to / from
space heating
system
VENT
Indirect domestic
water heater
DIRT SEPARATION: from reaming copper or iron piping often lodge inside
There are many ways dirt can enter a hydronic system. pipes during installation. Excess solder often forms
Perhaps the most common is through repeated handling small pellets inside piping. Welding slag grains are also
of piping and system components from manufacturing common in systems using steel pipe.
through transportation and eventually during installation.
Piping and components stored on-site can accumulate DIRT-RELATED PROBLEMS:
wind-blown dust or even larger dirt particles if dragged It goes without saying that the ideal hydronic heating or
over the ground or dirty floor surfaces. Insects can nest cooling system would be dirt-free. The presence of dirt
in piping stored in warehouses or on jobsites. can have serious consequences, including:
Sediments can also be present in hydronic systems, • Damage to rotating components in circulators,
especially older systems containing steel or iron piping especially impeller and bushing surfaces. An example
and cast iron radiators. This is especially true for of a circulator with a completely clogged impeller due
systems that originally operated with steam and are being to sediments in a system is shown in figure 18.
converted to hot water circulation. • Reduced heat transfer due to “fouled” surfaces
Even new cast iron boilers or radiators can contain in heat emitters, heat exchangers, and heat sources,
residue associated with their manufacturing. Metal chips especially those using compact heat exchangers.
12

Figure 18 Figure 20
Figure 19
• Similar fouling damage to heat transfer surfaces neck of a funnel. All system flow passes through the
within chillers. strainer and particles larger than the mesh size of the
• Erosion of internal piping surfaces, especially copper basket are trapped. Particles smaller than the mesh size
tubing (see figure 19). may pass through. On most Y-strainers, the basket must
• Discoloration of transparent wetted surfaces, such as be periodically removed to clear it of debris.
those on sightglasses or flow meters, as shown in
figure 20.
• Erosion and/or clogging of relief valves, balancing Figure 21
valves, check valves, venting valves, and thermostatic
radiator valves, as depicted in figure 21.
DIRT SEPARATION METHODS:

There are three common methods for capturing and
expelling dirt from hydronic systems:
1. Use of chemical “flocculants” to wash the inside of

the system.
2. Use of basket strainers.
3. Use of low-velocity-zone particle separators.
Chemical flocculants act as detergents within piping

systems. They provide the chemical reactions necessary
to dislodge certain types of accumulated sediments and
assist in bonding fine particles together so they can be
entrained in a flowing stream. A typical system cleaning
procedure involves adding the flocculants to the system,
then operating it at elevated temperatures for several
hours so that accumulated sediments or corrosion
residuals can be dislodged and carried along by the
flow. The system is then drained and flushed with clean
water to expel as much of the sediment as possible.
This procedure can be done when the system is first
commissioned or as a remedial measure for systems
in which sediments or corrosion scale have decreased
performance. Some flocculants also coat the inside of
piping and components with a residual film to protect
against corrosion.
Basket strainers, also known as Y-strainers, entrap dirt

within a “basket” made of stainless steel or brass mesh.
In essence, they work the same as a strainer inside the
13

As debris collects in a basket strainer, it impedes flow. A typical low-velocity-zone dirt separator only creates
This results in increased pressure drop and hence higher about 25 percent of the pressure drop of a comparable
head loss. If the strainer basket is not properly maintained, size basket strainer. It can also remain in service for
such head loss can be excessive. Flow reductions due relatively long periods between blowdowns due to its
to such head loss also reduce heat conveyance by the ability to collect or hold sediment away from the flow
system. When restricted strainers are present near the stream. Flow through the system does not need to stop
inlet of circulators, they can induce vapor cavitation due during the blowdown procedure.
to significant pressure drop. This can severely damage a
circulator if not corrected.
Figure 23
In some systems, the pressure drop across a basket
strainer is monitored to determine when cleaning is
necessary. Ball valves are installed to isolate the strainer
so its basket can be removed without significant fluid
loss, as shown in figure 22. Flow through the system
obviously needs to be stopped during this procedure.
Figure 22
P across strainer is

monitored to determine
when cleaning is necessary
basket strainer
ball valves isolate

strainer during cleaning
As with air separation, flow velocity through a low-
velocity-zone dirt separator affects performance. The
maximum preferred flow velocity through such a device
is 4 feet per second. Lower flow velocities reduce the
Low-velocity-zone dirt separators use a principle similar time required to separate the dirt and yield slightly lower
to that already discussed for separation of microbubbles. head loss. Operation at flow velocities up to 10 feet per
Water flows into the device along with entrained dirt second is possible, but higher flow velocities reduce
particles. Its flow velocity is greatly reduced by the wider separation efficiency.
cross-section of the separating chamber. The entering
dirt particles tend to move downward due to their density.
A specially designed media within the device provides
surfaces that assist in separating the dirt particles and
guiding them downward into a low velocity chamber where
they continue to settle to the bottom of the separator.
When a valve at the bottom of the chamber is opened, the
accumulated dirt is “blown down” (e.g., expelled) to a hose
or bucket. An example of a Caleffi Dirtcal low-velocity-
zone dirt separator is shown in figure 23.
14

EFFICIENCY OF DIRT SEPARATION:
No dirt separator can capture 100 percent of the dirt in a Testing has shown that Caleffi low-velocity-zone separators
stream of water during a single pass through the device. can remove nearly 100 percent of small sand particles
This is especially true of very small particles, which are in sizes greater than 100 micrometers (approximately
easily entrained with flow. The smaller the particles, the 0.004 inches) when operating with flow rates up to 4
greater the number of cycles needed to remove them. feet/second. Eventually these separators can remove
Figure 24 shows the results of a particle separation test particles as small as 5 micrometers (approximately 0.0002
performed on a Caleffi low-velocity-zone dirt separator. inch). This dimension is less than 1/10th the diameter of a
Results reflect particle size, flow velocity, and the number human hair, and much smaller than the particle size that
of passes (e.g., number of times the entire system volume can be captured by a typical Y-strainer.
has passed through the separator).
Efficiency (%)
Efficiency Efficiency
( Separated quantity
Initial quantity
.100%) 50 passages ( 2 f/s) 50 passages ( 4 f/s)
100
80
60
40
20
particle size
0
Micro
(μm)
1000
105
150
210
250
500
16
35
63
10
20
50
5
0
WORKING ZONE
DI RTCAL
CARTRIDGE FILTERS
SPECIAL STRAINERS
Y-STRAINERS
Figure 24
15

PLACEMENT OF DIRT SEPARATORS:
Because most dirt particles have a density greater than
water, they tend to migrate toward the lower portions of boiler
the system. Thus it makes sense to separate and capture
them in this area. It also makes sense to continually route
system flow through a dirt separator to increase the
number of passes the system volume makes through the
device in a given amount of time.
Dirt separators are commonly placed on the inlet side of
boilers and other heat sources, as shown in figure 25.
This is especially important in systems using boilers or
other heat sources with compact heat exchangers. It’s
also very important in systems where a new boiler is
installed in a system containing older piping and/or cast
iron radiators. Figure 26 shows such a situation. The dirt dirt
separator is placed on the return side of the distribution separator
system to capture particles that might otherwise flow
through the new boiler.
air
distribution separator
piping
system
dirt
separator
DHW
heating
VENT
Figure 27
Figure 25
Notice that purging valves have been located just
upstream of the dirt separator. This allows some of the
Figure 26 dirt in the system to be flushed out during initial filling
and purging (discussed later in the article). This in turn
old cast-iron decreases the amount of dirt the separator will eventually
radiator system have to capture.
air When possible, it’s also desirable to place the dirt

separator system
separator upstream of circulators. This helps extract dirt
circulator
prior to flow passing through the circulator. When doing
so, allow at least 12 pipe diameters of straight pipe
between the outlet of the air separator and inlet of the
boiler purge
circulator valve circulator.
VENT
Some systems use multiple circulators to push flow

dirt from different circuits into the boiler. In this case, the
separator
compromise is to place the dirt separator upstream of the
boiler, as shown in figure 27.
16

In systems with a main mixing valve, it’s best to place dirt separators COMBINED AIR & DIRT
in the return line from the distribution system ahead of the SEPARATORS:
valve. This increases flow through the separator and also better Some designers prefer to combine
protects the mixing valve from dirt (see figure 28). the function of air separation and
dirt separation into a single device.
This approach saves space, especially
air
in t i g h t m e c h a n i c a l ro o m s . I t a l s o
separator
reduces cost relative to installing two
individual separators.
The p re f e r re d placement of a
combination air & dirt separator depends
on system piping. In systems where all
system flow passes through the boiler,
the best location is on the outlet of the
boiler where microbubbles are likely to
dirt occur. In systems using mixing valves,
separator
the preferred location is on the mixing
VENT
valve outlet where the water temperature
is still elevated (and thus microbubbles
are likely), and where system water flow
rate is highest (and thus the fluid makes
more passes through the device in a given
Figure 28 amount of time). The latter consideration
improves dirt separation efficiency. Both
situations are shown in figure 30.
With all installations, be sure to plan sufficient space to
connect a drain hose or place a bucket under the dirt
separator to capture the expelled fluid and dirt.
Low-velocity-zone dirt separators are also well-suited to air & dirt
protect the small fluid passageways within plate-type heat

separator Figure 30
exchangers from dirt accumulation. Separators should be
installed near the inlets of both the primary and secondary
sides of the heat exchanger, as shown in figure 29.
Figure 29 VENT
brazed
plate
heat dirt
air & dirt
separator
exchanger separator
dirt
separator VENT
17

FILLING & PURGING HYDRONIC SYSTEMS:
connection
This section discusses basic concepts and procedures optional ball valve (for filling large systems)
to system
for adding water to a system and purging it of air. These backflow preventer
techniques rely on the principles and air-elimination shutoff valve
hardware previously discussed.
Automatic Make-up Water Assemblies: VENT
NOTE: strainer assumed

Most hydronic systems experience very minor water to be present within
loss over their life due to weepage at valve stem backflow preventer.
packings, circulator flange gaskets, or “microleaks”
from threaded fittings. If this water is not replaced, automatic feed valve
expansion
system pressure eventually drops and operational tank
problems develop. The most common remedy for
water-based hydronic systems is to equip the system
with an automatic make-up water assembly. This
usually consists of a backflow preventer, automatic
feed valve, isolating valves, and possibly a strainer and
Figure 32
pressure gauge. A typical automatic make-up water
assembly is shown in figure 31.
The high flow bypass valve is installed in the straightest
automatic feed valve piping path leading to the system connection. This
connection minimizes pressure loss and provides the highest flow
backflow preventer to system
rate possible for filling and purging. Once the system is
shutoff valve filled and purged, the high flow bypass is turned off. Its
handle should then be removed to prevent accidental
operation, especially by those who don’t understand
VENT
its function. The automatic feed valve remains active

NOTE: strainer assumed
to be present within
to provide all necessary water inlet to make-up for
backflow preventer. expansion minor water losses.
tank
Some installers prefer to turn off the shutoff valve on the

automatic make-up water assembly once the system is
filled and purged. This prevents sustained water flow
Figure 31 into the system should it ever develop a leak. However,
if this is done, it’s important that someone periodically
Although individual components can be joined monitors system pressure and temporarily opens this
together with fittings to create this assembly, several valve when necessary to allow the automatic make-up
manufacturers offer pre-built assemblies to save time assembly to restore normal system pressure.
and reduce space requirements.
Purging:
In most residential systems, the automatic make-up The process of forcing air out of a hydronic system as
water assembly uses 1/2-inch pipe size components. water enters that system is called purging. Every hydronic
Large commercial systems often use 3/4-inch size system must be purged when it’s commissioned. In
components for higher water flow rates during the some cases air rises upward within the piping as water is
filling/purging process. A full-port ball valve can be
introduced lower in the system. In other cases air is forced
piped in parallel with an automatic feed valve to provide
along the piping by a rapidly moving water stream, and
higher filling rates in large commercial systems. This
eventually exits through an opened valve. Both forms of
concept is shown in figure 32.
purging are discussed in the following sections.
18

Rising Water Purging: Flow-through Purging:
Some of the air inside an empty hydronic system can The amount of air that can be rapidly expelled from
be expelled as water enters through the automatic a system during filling is significantly increased when
make-up water assembly. The concept is to introduce the entering fluid has sufficient velocity to entrain air
water low within the system, allowing it to displace air bubbles and carry them to an outlet valve. The greater
in the upward direction. High point venting devices the water pressure and flow volume available, the
such as those previously discussed allow rising air to faster flow-through purging can push air out of the
leave the system. The pressure supplied by the water system.
source must be sufficient to lift the water to the top of
the system. Circulators within the system are not used One method of flow-through purging is to add a boiler
to fill the system with water. drain valve and full-port ball valve (or a combination
purging valve) to the piping leading into the boiler, as
Air pockets often take several minutes to vent through shown in figure 33.
low capacity vents. This method of purging, although
simple in concept, is slow in execution, especially if Locating the circuit-purging valve near the inlet
high point vents are not properly located. It’s fair to connection of the boiler and upstream of the dirt
say that very few modern hydronic systems can be separator helps flush debris out of the system, rather
completely filled and purged using this procedure than into the boiler. It also reduces the amount of dirt
alone. that eventually collects within the dirt separator.
Flow-through purging begins

by opening the outlet valve
Figure 33 that connects to a drain hose.
air release
The automatic feed valve
is then manually opened to
allow rapid water flow into
the system. If a high flow
bypass valve is provided in
distribution parallel with the automatic
inline valve piping feed valve, it should also
closed system be opened to maximize the
dirt
during purging rate of water entry to the
separator
system.
boiler
off
Because the ball valve on the
boiler inlet pipe is closed, the
air & water
entering water begins filling
VENT
exit system
the boiler. Air within the boiler
through hose
is displaced as the water
outlet valve open enters. In some systems, this
during purging
air exits through a vent at the
top of the boiler; in others, it
5 gallon bucket migrates up to the central air
water enters through automatic
or drain separator and exits.
make-up assembly with automatic
feed valve in open position for purging
19

When the boiler is full, water flows out to the distribution is opened and the previous one is closed. This allows
system, displacing air ahead of it. This air is pushed along the maximum possible flow rate through each branch
by the rapid water flow and exits through the open hose circuit, one at a time, to dislodge and entrain as much
bib or side port of a combination purging valve near the air as possible. This technique is especially helpful on
boiler inlet. A hose leads this water to a collection pail or radiant panel systems or homerun distribution systems
directly to a floor drain. having several parallel circuits. Manifold valves can be
Purging continues until the discharge stream is free used to open and close each circuit as needed. After all
of visible air bubbles for at least 30 seconds. At this branches have been purged individually, open them all
point, most of the bulk air will have been purged from up at the same time and continue flow-through purging.
the system. The high flow bypass valve and purging The lowered resistance of the fully open distribution
outlet valve are closed and the fast fill function of the system maximizes flow rate and helps dislodge any
automatic feed valve is turned off. Caleffi Autofill valves
remaining air pockets in larger piping and components.
do the latter function automatically.
If the system has a differential pressure bypass valve,
it should be temporarily closed during purging. The
In systems with two or more branch circuits, the
concept and hardware placement for filling and purging
preferred approach is to purge through one branch at
a time. When the flow exiting the purge valve is free of systems with parallel branches is shown in figure 34.
air bubbles, the purging valve on the next branch circuit
Figure 34
Open one manifold valve at a time to

push maximum flow through each circuit
temporarily close differential pressure

bypass valve during purging
Panel radiators
on homerun
distribution system
other
heating
circuit
dirt
separator
combination purge valves shown

on each parallel branch circuit
boiler
off
air & water

VENT
exit system
through hose
5 gallon bucket
or drain
make-up assembly with automatic
feed valve in open position for purging
20

In a primary/secondary distribution system, it’s one at a time. This requires a separate purging valve for
important to include purging valves on each secondary each secondary circuit, as shown in figure 35.
circuit as well as the primary loop. When purging these
On systems using zone circulators or zone valves, it’s
systems, the preferred approach is to first isolate all
common to install a combination purging valve on the
secondary circuits, then purge the primary loop using return side of each zone circuit, as shown in figure 36.
the procedure described above. Once the primary loop This arrangement allows each circuit to be separately
is purged, proceed by purging each secondary circuit filled and purged during commissioning.
Figure 35
boiler
off
secondary circuits
boiler
circulator
combination purge valve

on each secondary circuit
dirt
separator closely spaced tees
series primary loop
primary STEPS 2,3,...

circulator
Purge secondary
circuits, one at a time
VENT
(including boiler circuit)
STEP 1:
Purge primary
loop
5 gallon bucket
or drain
21

Figure 36
manually open zone valve
to/from zone circuits while circuit is purged
temporarily close
differential pressure
bypass valve
during purging
boiler
off
VENT

make-up assembly with automatic 5 gallon bucket
feed valve in open position for purging or drain
parts of the system may drop below atmospheric

DIAGNOSING AND CORRECTING AIR-RELATED
pressure while the circulator is on. If float-type air vents
PROBLEMS:
are located in these locations, air will be sucked into
Properly designed and installed hydronic systems should
the piping. Air can also be sucked in through loose
operate for many years with virtually no detectable
valve packings if the pressure at the valve goes sub-
noise in occupied spaces. When noise does occur, it’s
atmospheric.
often symptomatic of improper air control. This section
Corrective action: This problem is resolved by relocating
describes some common noise complaints, provides
the expansion tank to the inlet side of the circulator. Two
possible causes, and gives suggested corrections. Keep in
acceptable options for expansion tank placement are
mind that some noises may be the result of a combination
shown in figure 37. This modification has been very
of these errors.
successful in many older systems, some of which had
chronic air problems for years.
Complaint #1: The system needs repeated “bleeding” to
remove entrapped air.
Possible Cause: The expansion tank is improperly
located on discharge side of circulator.
Description: If the expansion tank is located on the
discharge side of the circulator, the pressure in some
22

top of the system drops below atmospheric
pressure, air can be drawn in through vents
or valve packings. The automatic feed valve
should be set to maintain a minimum static
VENT VENT
pressure of 5 psi at the top of the system.
OK NEVER! distribution
piping A leak in the system can obviously lower
system pressure over time. Very minor leaks can be
hard to identify. Look for external scaling on
fittings, valves, or other locations where
piping joints are made. Such scaling is
a telltale sign of very slow but persistent
water leakage.
Corrective Actions: Make sure the feedwater W
VENT valve is adjusted to provide a minimum static e
pressure of 5 psi at the top of the system. s
Repair any leaks identified.
IDEAL a
Complaint #2: The system pressure is always low and air Complaint #3: The system is quiet when circulation
is heard in piping. begins, but flow noises begin as the water heats up.
Possible causes: Incorrect setting of the automatic Possible cause: Air gases going in and out of solution but
make-up water assembly, or a leak. not being captured and ejected from the system.
Description: Low system pressure is often caused by not Description: As described earlier, it’s possible for air
setting the automatic make-up water system properly or gases to go in and out of solution with water depending
disabling it. If, for example, the shutoff valve on the make- on temperatures and pressures. When water is heated, air
up water line is closed, pressure will eventually drop due to comes out of solution as microbubbles. If these are not
very minor water loss at valve packings, or as air is removed captured and ejected by a capable air separator, they will
by vents or the central air separator. If the pressure at the dissolve back into solution as soon as the system cools.
Figure 38 Figure 39
23

Figure 40
Complaint #4: Gurgling sounds are heard in piping.

Possible cause: Unentrained air bubbles.
Description: When persistent gurgling sounds are
present, especially in piping with downward flow, it’s
likely the flow velocity in that portion of the system is
too low to entrain the air and transport it to a central air SUMMARY:
separator. The ability of a hydronic system to provide efficient
Corrective action: All down-flowing piping should be and silent conveyance of heat depends strongly on the
sized to maintain a flow velocity of at least 2 feet/second condition of the fluid within the system. A well-designed
to effectively entrain air bubbles. If this is not possible, hydronic heating or cooling system should rid itself of
automatic high point vents must be installed at locations nearly all internal air shortly after commissioning. It should
where air can collect. then operate with highly deaerated water, and virtually no
noise will be detectable within occupied spaces.
Complaint #5: Water drains out of piping in upper parts
of the system every time the circulator turns off. Maintaining this high performance over the full design
Probable cause: Air vents or leaks at the top of open- life of the system requires that internal surfaces on heat
loop systems. sources, heat emitters and circulators remain as clean as
Description: This problem is often associated with possible. Sediments or other debris flowing through the
unpressurized thermal storage tanks or unpressurized system are obviously detrimental to this goal and should
outdoor wood-fired furnaces. In such systems, the pressure be collected and expelled.
above the water level in the tank or furnace drops below
atmospheric pressure when the circulator stops. Air will Caleffi offers system designers the highest quality air and
try to enter the piping at any such point. Air vents located dirt separation products available for these purposes in
above the water level are the most likely entry points. both large and small systems. The following photos show
However, valve packings, circulator flange gaskets, and typical installations.
even microleaks at threaded joints can admit air.
Corrective action: This type of system should not Figure 38 shows a small Caleffi Discal air separator being installed in a
have air vents, valves, circulators, or even threaded residential heating system.
fittings in any piping above the static water level in the Figure 39 shows a large Caleffi steel Discal air separator in service in a
tank or furnace. All piping should be designed for a Milwaukee school. Piping at the bottom provides additional sediment drain-
age capability.
flow rate of at least 2 ft./sec. to effectively entrain air
Figure 40 shows a small Caleffi Dirtcal dirt separator being installed in a
bubbles and bring them back to the tank where they residential system.
can be vented. Figure 41 shows a Caleffi combination air/dirt separator being installed in a
commercial cooling system.
24

GENERIC COMPONENTS CALEFFI COMPONENTS
3-way
thermostatic mixing
3-way motorized valve
circulator mixing valve
circulator w/ 4-way motorized

mixing valve DISCAL central
isolation flanges air separators
union
flow-check valve
circulator w/
internal check valve
& isolation flanges swing check valve
float -type
air vent
spring loaded
gate valve check valve
backflow preventer
VENT
globe valves purging valve W

ball valve
pressure
reducing
e
valve
pressure gauge
thermostatic
radiator valve zone valve
pressure (2 way)
relief
valve
thermostatic
radiator valve zone valve
pressure &
temperature (3 way)
relief valve
strainer
pressure
relief valve
primary/secondary metered
fitting balancing
valve differential
pressure
bypass valve
hose bib
drain valve
brazed
plate DIRTCAL
diverter tee heat dirt separator
exchanger
cap
diaphragm-type
expansion tank
Hydro air & dirt

Separator separator
conventional boiler
Hydrolink
(3 configurations)
manifold station with

balancing valves
indirect water heater (with trim) Modulating / condensing boiler
25

DISCAL air separator
series 551 CALEFFI
CALEFFI
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,
localised overheating or mechanical damage.
Product range
Se ri e s 551 D I SCA L a i r se p a ra tor i n b ra ss c omp a c t wi th d ra i n Si z e s 3/4” swe a t; 3/4” NPT fe ma l e
Series 551 DISCAL air separator in brass with drain Sizes 3/4” - 1” - 1 1/4” - 1 1/2” - 2” NPT female; 1” - 1 1/4” sweat
Se ri e s 551 D I SCA L a i r se p a ra tor i n ste e l wi th fl a ng e d c onne c ti ons Si z e s 2” ÷ 6” A NSI
Series NA551 DISCAL air separator in steel with flanged connections designed and built to ASME Sizes 2” ÷ 6” ANSI
Series NA551 DISCAL air separator in steel with threaded connections designed and built to ASME Sizes 2” ÷ 4” NPT
Cod. 561402A Service check valve in brass for easy replacement of expansion tank mounted to bottom drain Size 1/2” NPT x 1/2” NPT
NA prefix indicates 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.
Technical specification
Brass Discal Steel Discal

Ma te ri a l s: - Bod y : b ra ss Ma te ri a l s: - Bod y : e p oxy re si n p a i nte d ste e l
- Int. element (compact version): stainless steel - I nt. e l e me nt: sta i nl e ss ste e l
- I nt. e l e me nt: PA 66G F30 - D ra i n c oc k: c hrome p l a te d b ra ss
- Se a l : EPD M - Se a l : EPD M
Sui ta b l e fl ui d s: wa te r, g l y c ol sol uti on Sui ta b l e fl ui d s: wa te r, g l y c ol sol uti on
Ma x p e rc e nta g e of g l y c ol : 50 % Ma x p e rc e nta g e of g l y c ol : 50%
Ma x worki ng p re ssure : 150 p si ( 10 b a r ) Ma x worki ng p re ssure : 150 p si ( 10 b a r)
Te mp e ra ture ra ng e : 32÷ 250°F ( 0÷ 120°C ) Te mp e ra ture ra ng e : 32÷ 250°F ( 0÷ 120°C)
Connections: - Main: 3/4” sweat; 3/4” NPT female Connections: - Flanged: 2” ÷ 6” ANSI 150 CLASS
3/4” - 1” - 1 1/4” - 1 1/2” - 2” NPT female - Thre a d e d 2” ÷ 4”
1” - 1 1/4”” sweat - D ra i n: 1” NPT ma l e
- D ra i n: 1/2” NPT fe ma l e
26

Dimensions
C C F F
D
D
E
E
A
A
D
38466.01
38466.01
F F BI-DIRECTIONAL BI-DIRECTIONAL
E
Tmax 250°F Tmax 220°F Tmax 250°F Tmax 220°F
B B
Pmax 150 psi Pmax 150 psi Pmax 150 psi Pmax 150 psi
Code A B C D E F Weight (lb)

551022A 3/4” 3 1/16” 2 3/16” 5 5/8” 6 7/8” 1/2” 2.0
A
551003A 3/4” swt 3 1/16” 2 3/16” 5 5/8” 6 7/8” 1/2” 2.0
G G
B B
C
C
D
D
Code A B D E F G Weight (lb)
551050A 2” 13 3/4” 14 3/4” 19 15/16” 6 5/8” 1" 33.1
A
A
A
551060A 2 1/2” 13 3/4” 14 3/4” 19 15/16” 6 5/8” 1" 34.2

E E 551080A 3” 18 3/8” 17 1/8” 23 7/16” 8 5/8” 1" 61.7
B B 551100A 4” 18 1/2” 17 1/8” 23 7/16” 8 5/8” 1" 66.1
551120A 5” 25 21 7/16” 30 1/2” 12 3/4” 1" 105.8
Code A B - B’ C D E Weight (lb)
551150A 6” 25 21 7/16” 30 1/2” 12 3/4” 1" 116.8
551005A 3/4” 4 5/16” 5 3/4” 7 1/2” 1/2” 3.7
NA551050T 2” 10 1/4” 14 3/4” 19 15/16” 6 5/8” 1" 20.5
551006A 1” 4 5/16” 5 3/4” 7 1/2” 1/2” 3.7
NA551060T 2 1/2” 10 1/4” 14 3/4” 19 15/16” 6 5/8” 1" 21.0
551007A 1 1/4” 4 7/8” 6 9/16” 8 1/4” 1/2” 4.9
NA551080T 3” 14 5/8” 17 1/8” 23 7/16” 8 5/8” 1" 44.0
551008A 1 1/2” 4 7/8” 6 9/16” 8 1/4” 1/2” 4.9
NA551100T 4” 14 5/8” 17 1/8” 23 7/16” 8 5/8” 1" 46.3
551009A 2” 5 1/8” 6 9/16” 8 1/4” 1/2” 4.9
551028A 1” swt 5 1/16” 5 3/4” 7 1/2” 1/2” 3,7 Size 2” 2 1/2” 3” 4” 5” 6”
551035A 1 1/4” swt 5 3/16” 6 5/16” 8 1/4” 1/2” 3,7 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
The process of air formation Hydronic characteristics

The amount of air which can remain dissolved in a water solution is
2” Steel
3/4" C
1 1/4"
1 1/2"
2 1/2”
3/4"
a function of pressure and temperature. ΔP (ft of water)

1"
2”
3”
4”
5”
6”
(ft of water) (kPa)
This relationship is governed by Henry’s Law and the graph below 1 1 3
0.9 0.9
demonstrates the physical phenomenon of the air release from water. 0.8 0.8 2.5
0.7 0.7
As an example, at a constant absolute pressure of 30 psi (2 bar), if 0.6 0.6
2
1.8
the water is heated from 65°F (18°C) to 170°F (75°C), the amount 0.5 0.5
1.6
1.4
0.45 0.45
of air released by the solution is equal to 1.8 gallons of air per 100 0.4 0.4 1.2
0.35 0.35
gallons of water. 0.3 0.3
1
0.9
According to this law it can be seen that the amount of air released 0.25 0.25
0.8
0.7
increases with temperature rise and pressure reduction. The air 0.2
0.18
0.2
0.18
0.6
comes in the form of micro-bubbles of diameters in the order of 0.16 0.16 0.5
0.14 0.14 0.45
0.4
tenths of a millimetre. 0.12 0.12
0.35
In heating and cooling systems there are specific points where this 0.1 0.1 0.3
0.09 0.09
0.08 0.08
process of formation of micro-bubbles takes place continuously: in the 0.07 0.07
0.25
0.2
boiler and in any device which operates under conditions of cavitation. 0.06 0.06 0.18
0.16
0.05 0.05 0.14
0.045 0.045
0.04 0.04 0.12
0.035 0.035
Absolute pressure 0.03 0.03
0.1
0.09
0.08
0.025 0.025
5.5 0.07
Max amount in gallons of dissolved air per 100 gallons of water
45 psi 60 psi 75 psi 90 psi 105 psi 120 psi 0.02 0.02 0.06
2
10
20
50
100
200
500
1000
2.5
3
3.5
4
4.5
6
7
8
9
12
14
16
18
25
30
35
40
45
60
70
80
90
120
140
160
180
250
350
400
450
600
700
800
900
300
5.0
G (m3/h) (gpm)
4.5
0,6
0,7
0,8
0,9
1,2
1,4
1,6
1,8
2,5
3
3,5
4
4,5
6
7
8
9
12
14
16
18
25
30
35
40
45
60
70
80
90
120
140
160
180
0,5
10
20
50
100
200
4.0
30 psi
3.5 The fluid velocity at connections for Discal 551 series air separators is
3.0
recommended to not exceed 10.0 f/s. Above this speed, heavy internal
turbolance and noise can occur and air elimination efficiency begins to fall
2.5 measurably. Optimal air elimination performance occurs at fluid velocities of
15 psi
4.2 f/s or less. See the flow capacity chart.
2.0
FLOW CAPACITY
1.5 BRA SS STEEL
1.0 Size 3/4” C 3/4” 1” 1 1/4” 1 1/2” 2” 2” 2 1/2” 3” 4” 5” 6”
Optimal GPM 6.0 8.0 9.3 15.3 23.9 36.1 37.3 63.0 95 149 259 380
0.5 (≤4,2 f/s) m3/h 1.4 1.8 2.1 3.5 5.4 8.2 8.5 14.3 21.7 33.9 58.8 86.2
0 Max. GPM 14.3 19.0 22.1 36.4 56.8 86.0 88.8 150.1 227.4 355.3 616.4 903.6
32 65 100 135 170 205 240 275 310 345 (10.0 f/s) m3/h 3.2 4.3 5.0 8.3 12.9 19.5 20.2 34.1 51.6 80.7 140.0 205.2
Water temperature ( °F ) Cv 14 19 21 43 51 78 86 179 211 345 520 809
27

Dirt separator DIRTCAL
5462 series CALEFFI
CALEFFI
Function
In heating and air conditioning control systems, the circulation of

water containing impurities may result in rapid wear and damage to
components such as pumps and control valves. It also causes
blockages in the heat exchangers, heating elements and pipes,
resulting in a lower thermal efficiency within the system.
The dirt separator separates off these impurities, which are mainly
made up of particles of sand and rust, collecting them in a large
collection chamber, from which they can be removed even while
the system is in operation.
This device is capable of efficiently removing even the smallest
particles, with extremely limited head loss.
Patented.
Product range
5462 Series D I RTCA L d i r t se p a ra tor wi th NPT threaded connections si z e s 3/4”–1 1/2”
5462 Series DIRTCAL dirt separator with sweat connections sizes 1” - 1 1/4”
Technical specifications Dimensions
Materials: - body: brass

- dirt collection chamber: brass NPT Sweat
- top plug: brass B B
- i nte r na l e l e me nt: PA 66G 30
- hy d ra ul i c se a l s: EPD M
E
E
- drain cock: brass
A
Medium: water, glycol solution

Ma x p e rc e nta g e of g l y c ol : 50%
Ma x worki ng p re ssure : 150 psi (10 bar)
Te mp e ra ture ra ng e : 32 – 250º F (0 –110°C)
D
Pa r ti c l e se p a ra ti on c a p a c i ty : to 5 μm
Connections: - main: 3/4”, 1”, 1 1/4”, 1 1/2” NPT
1” & 1 1/4” sweat
- top : 1/2” F wi th p l ug
C
- d ra i n: 3/4” garden hose
Code A B C D E Weight (lb)

546205A 3/4” NPT 4 5/16” 1” 5” 2” 4.2
546206A 1” NPT 4 5/16” 1” 5” 2” 4.2
546207A 1 1/4” NPT 4 7/8” 1” 6” 2” 5.3
546208A 1 1/2” NPT 4 7/8” 1” 6” 2” 5.3
546228A 1” Sweat 5 1/16” 1” 5” 2” 4.2
546235A 1 1/4” Sweat 5 3/16” 1” 5” 2” 4.2
28

Hydronic characteristics
1 1/4"
1 1/2"
3/4"
ΔP (ft of water)
1"
(ft of water) (kPa)
1 1 3
0.9 0.9
0.8 0.8 2.5
0.7 0.7
2
0.6 0.6 1.8
1.6
The maximum fluid velocity recommended at the unit connections is
0.5 0.5 1.4 ~ 4.2 f/s. The following table shows the recommended flow rates to comply with
0.45 0.45
0.4 0.4 1.2
0.35 0.35 this condition.
0.3 0.3
1
0.9
0.8
0.25 0.25
0.7
0.2 0.2 0.6
Size 3/4" 1" 1 1/4" 1 1/2"
0.18 0.18
0.16 0.16 0.5
0.14 0.14 0.45
0.4
Gpm 6 9.3 15.3 23.9
0.12 0.12
0.1 0.1
0.35 m 3/h 1.36 2.11 3.47 5.42
0.3
0.09 0.09
0.08 0.08 0.25
Cv 18.8 32.6 56.6 73.3
0.07 0.07
0.06 0.06
0.2
0.18
0.16
0.05 0.05 0.14
0.045 0.045
0.04 0.04 0.12
0.035 0.035
0.03 0.03
0.1
2
10
20
50
100
2.5
3
3.5
4
4.5
6
7
8
9
12
14
16
18
25
30
35
40
45
60
70
80
90
G (m /h) (gpm)
3
0,6
0,7
0,8
0,9
1,2
1,4
1,6
1,8
2,5
3
3,5
4
4,5
6
7
8
9
12
14
16
18
25
0,5
10
20
Separation efficiency
The capacity for separating the impurities in the
medium circulating in the closed circuits of the systems Efficiency (%)
Efficiency Efficiency
basically depends on three parameters:
1) It increases as the size and mass of the particle ( Separated quantity
Initial quantity
.100%) 50 passages ( 2 f/s) 50 passages ( 4 f/s)
increase. The larger and heavier particles drop 100
before the lighter ones.
2) It increases as the speed decreases. If the speed 80

decreases, there is a calm zone inside the dirt
separator and the particles separate more easily.
60
3) It increases as the number of recirculations
increases. The medium in the circuit, flowing through
the dirt separator a number of times during 40
operation, is subjected to a progressive action of
separation , until the impurities are completely
removed. 20
The Caleffi DIRTCAL dirt separator, thanks to the

special design of its internal element, is able to
particle size
0
completely separate the impurities in the circuit down
Micro
(μm)
1000
105
150
210
250
500
to a minimum particle size of 5 μm.
16
35
63
10
20
50
5
0
The graph alongside, summarising the tests carried out

in a specialised laboratory (TNO - Science and
Industry), illustrates how it is able to quickly separate WORKING ZONE
nearly all the impurities. After only 50 recirculations, DI RTCAL
approximately one day of operation, up to 100% is
effectively removed from the circuit for particles of
diameter greater than 100 μm and on average up to CARTRIDGE FILTERS
80% taking account of the smallest particles. The
continual passing of the medium during normal
operation of the system gradually leads to complete
dirt removal. SPECIAL STRAINERS
Reduced head losses

A normal Y strainer performs its function via a metal Y-STRAINERS
mesh selected for the size of the largest particle. The
medium therefore has a consequent initial loss of head
that increases as the degree of clogging increases.
Whereas, the dirt separator carries out its action by the
particles striking the internal element and subsequently
dropping into the collection chamber. The consequent
head losses are greatly reduced and are not affected
by the amount of impurities collected.
29

D
DISCAL air and dirt separators
series 546 CALEFFI
CALEFFI
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 capacity of these devices is
very high. They are capable of automatically removing all of the air
present in the system down to the micro-bubble level. The Discal
air/dirt separates any solid impurities in the system. The impurities
collect at the bottom of the device and can be removed through
the ball valve.
The circulation of fully de-aerated and cleaned water enables

the equipment to operate under optimum conditions, free from any
noise, corrosion, localized overheating or mechanical damage.
Product range
Se ri e s 546 D I SCA LD I RT a i r a nd d i rt se p a ra tor wi th A NSI fl a ng e d c onne c ti ons si z e s 2” - 6” A
Se ri e s 546 D I SCA LD I RT a i r a nd d i rt se p a ra tor wi th thre a d e d c onne c ti ons si z e s 2” - 4” B
Series NA546 DISCALDIRT air and separator with ANSI flanged connections designed and built to ASME sizes 2” - 6”
Series NA546 DISCALDIRT air and separator with threaded connections designed and built to ASME sizes 2” - 4”
NA prefix indicates 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.
Technical specification Dimensions
A Model T Model
Materials: F
- Bod y : e p oxy re si n p a i nte d ste e l F
- I nt. e l e me nt: sta i nl e ss ste e l

- D ra i n v a l v e : c hrome p l a te d b ra ss
- Re l e a se v a l v e : b ra ss
D
D
- Se a l : EPD M
38552
38552
Sui ta b l e fl ui d s: wa te r, g l y c ol sol uti on

E
E
A
Ma x p e rc e nta g e of g l y c ol : 50%
Ma x worki ng p re ssure : 150 p si ( 10 b a r)

Te mp e ra ture ra ng e : 32-250°F (0 - 121°C)
Connections: - Flanged: 2” - 6” ANSI 150 CLASS 1”

1”
B
- Thre a d e d : 2” - 4” B
- Drain: 1” NPT female
Code A B D E F Cap. (gal) Weight (lb)
546 050A 2” 13 3/4 ” 14 3/4” 30 1/2” 6 5/8” 3.6 39.7

546 060A 2 1/2” 13 3/4 ” 14 3/4” 30 1/2” 6 5/8” 3.7 41.9
546 080A 3” 18 3/8 ” 17 1/8” 35 7/8” 8 5/8” 7.6 72.7
546 100A 4” 18 3/8 ” 17 1/8” 35 7/8” 8 5/8” 7.8 77.2
546 120A 5” 25” 21 5/16” 49” 12 3/4” 22.5 180.1
546 150A 6” 25” 21 5/16” 49” 12 3/4” 23 187.4
NA546050T 2” 10 1/4” 14 3/4” 30 1/2” 6 5/8” 3.6 28.6
NA546060T 2 1/2” 10 1/4” 14 3/4” 30 1/2” 6 5/8” 3.7 28.8
NA546080T 3” 14 5/8” 17 1/8” 35 7/8” 8 5/8” 7.6 55.1
NA546100T 4” 14 5/8” 17 1/8” 35 7/8” 8 5/8” 7.8 55.5
Add prefix NA to flanged code number for tagged and registered with the National
Board of Boiler and Pressure Vessel Inspectors.
30

Dimensions Construction details
A Model T Model
F
F
The air and dirt separator have an integral
release point (A), which has two functions:
1.To aid the removal of air while filling the
D
system during the
D
38552
A 2.To aid the removal of any debris that
38552
may float within the air
E
E
A
A
1”
B 1”
B
Code A B D E F Cap. (gal) Weight (lb)
546 050A 2” 13 3/4 ” 14 3/4” 30 1/2” 6 5/8” 3.6 39.7

546 060A 2 1/2” 13 3/4 ” 14 3/4” 30 1/2” 6 5/8” 3.7 41.9
546 080A 3” 18 3/8 ” 17 1/8” 35 7/8” 8 5/8” 7.6 72.7
546 100A 4” 18 3/8 ” 17 1/8” 35 7/8” 8 5/8” 7.8 77.2
A drain valve fitted to the base of the
546 120A 5” 25” 21 5/16” 49” 12 3/4” 22.5 180.1 device (B) provides the capability to
546 150A 6” 25” 21 5/16” 49” 12 3/4” 23 187.4 remove any debris that has settled at
NA546050T 2” 10 1/4” 14 3/4” 30 1/2” 6 5/8” 3.6 28.6 the bottom of the air eliminator.
NA546060T 2 1/2” 10 1/4” 14 3/4” 30 1/2” 6 5/8” 3.7 28.8
B
NA546080T 3” 14 5/8” 17 1/8” 35 7/8” 8 5/8” 7.6 55.1
NA546100T 4” 14 5/8” 17 1/8” 35 7/8” 8 5/8” 7.8 55.5
Add prefix NA to flanged code number for tagged and registered with the National
Board of Boiler and Pressure Vessel Inspectors.
Boiler micro-bubbles Hydronic characteristics
2 1/2”
Micro-bubbles are
Δ (ft of water)
2”
3”
4”
5”
6”
formed continuously on Flame temperature (ft of water) (kPa)
1800°F (1000 °C) Combustion chamber wall 1 1
the surface separating 0.9 0.9
3
0.8 0.8 2.5

the water from the Boundary layer 0.7 0.7
2
combustion chamber 0.6 0.6 1.8
FLAME WATER 0.5 0.5
1.6
due to the fluid 0.45 0.45
1.4
temperature. Micro-bubbles 0.4

0.35
0.4
0.35
1.2
1
This air, carried by the Wall temperature Boundary layer
0.3 0.3 0.9
0.8
water, collects in the 320°F (160 °C) temperature 313 °F (156 °C) 0.25 0.25
0.7
critical points of the 0.2 0.2 0.6

0.18 0.18
0.16 0.16 0.5
circuit from where it Average water
temperature 160 °F (70 °C)
0.14 0.14 0.45
0.4
must be removed. 0.12 0.12
0.35
Some of this air is 0.1 0.1 0.3

0.09 0.09
0.08 0.08 0.25
reabsorbed in the 0.07 0.07
0.2
presence of colder surfaces. 0.06 0.06 0.18
0.16
0.05 0.05 0.14
0.045 0.045
0.04 0.04 0.12
Cavitation and micro-bubbles 0.035
0.03
0.035
0.03
0.1
0.09
Micro-bubbles develop where the fluid velocity is very high with 0.025 0.025
0.08
0.07
the corresponding reduction in pressure.These points are typically 0.02 0.02 0.06
5
10
20
50
100
200
500
1000
6
7
8
9
12
14
16
18
25
30
35
40
45
60
70
80
90
120
140
160
180
250
350
400
450
600
700
800
900
300
the pump impeller and

(m3/h) (gpm)
the regulating valve

seating. These air and
1,2
1,4
1,6
1,8
2,5
3
3,5
4
4,5
6
7
8
9
12
14
16
18
25
30
35
40
45
60
70
80
90
120
140
160
180
2
10
20
50
100
200
vapor micro-bubbles,
the formation of which The fluid velocity at connections for Discal 546 series air separators is
Implosions recommended to not exceed 10.0 f/s. Above this speed,heavy internal
is enhanced in the Seat-obturator
distance turbolance and noise can occur and air elimination efficiency begins to fall
case of non Cavitation
micro-bubbles
measurably. Optimal air elimination performance occurs at fluid velocities of
de-aerated water, 4.2 f/s or less. See the flow capacity chart.
Velocity
Pressure
Pressure Velocity
may subsequently FLOW CAPACITY
implode due to the Size 2” 2 1/2” 3” 4” 5” 6”
cavitation Fluid vapour Optimal GPM 37.3 63.0 95 149 259 380
pressure ( ≤4,2 f/s) m3/h 8.5 14.3 21.7 33.9 58.8 86.2
phenomenon.
Max. GPM 88.8 150.1 227.4 355.3 616.4 903.6
(10.0 f/s) m3/h 20.2 34.1 51.6 80.7 140.0 205.2
Cv 86 179 211 345 520 809
31

Automatic air vent
for heating systems and radiators
series 501 - 5022 - 5026 - 5027 - 5080 CALEFFI
CALEFFI
Function
Series 501
Extra high capacity float type automatic air vent designed for use
on large pipes where large quantity of air is required to be released
from the system.
Series 5022 - 5023

High capacity float type automatic air vent designed for use on
manifolds or pipes in sealed heating systems. Check valve on 5023
series allows an easy replacement of air vent without purging the
system.
Series 5026 - 5027

Float type automatic air vent designed to vent air that is released from
the water while being heated. Check valve on 5027 series allows an
easy replacement of air vent without purging the system.
Series 5080
Radiator air vent valve designed to remove automatically any air
trapped inside the heat emitters both during the filling of the system
and in normal operation.
Product range
Series 501 Extra high capacity automatic air vent Size 3/4”
Series 5022 High capacity automatic air vent Size 1/2”
Se ri e s 5023 Hi g h c a p a c i ty a utoma ti c a i r v e nt wi th c he c k v a l v e Si z e 1/2”
Series 5026 Automatic air vent Sizes 1/8” - 1/4”
Series 5027 Automatic air vent with check valve Sizes 1/8” - 1/4”
Series 5080 Automatic hygroscopic air vent for radiators Size 1/8”
series 501 5022 - 5023 5026 - 5027 5080
Materials
Bod y : b ra ss b ra ss b ra ss c hrome p l a te d b ra ss
Fl oa t: sta i nl e ss ste e l PP PP -
Me c ha ni sm ste m: sta i nl e ss ste e l b ra ss - -
Me c ha ni sm se a l : Vi ton EPD M Si l i c on rub b e r -
Se a l s: EPD M EPD M EPD M EPD M
Performance
Max working pressure: 230 psi (16 bar) 150 psi (10 bar) 150 psi (10 bar) 150 psi (10 bar)
Ma x v e nti ng p re ssure : 90 p si ( 6 b a r) 60 p s i ( 4 b a r ) 90 p si ( 6 b a r) -
Max working temperature: -4÷250°F (-20÷120°C) 250°F (120°C) 240°F (115°C) 212°F (100°C)
Connections: inlet 3/4” NPT female 1/2” NPT male 1/8” and 1/4” NPT male 1/8” NPT male
exhaust 3/8” female straight
32

Dimensions
C C
F
A
E
B
E
C
E
D
E
B
A
B’
E’
D
A
B’
E’
A
D
F
D A
B
C
A Code A B C D E
D 502610A 1/8” 3 1/16” 1 9/16” 7/16” 2 5/8”
Code A B C D E 502620A 1/4” 3 1/16” 1 9/16” 1/2” 2 5/8”
502243A 1/2” 4” 2 3/16” 1/2” 2 1/2”
Code A B’ C D E’
Code A B C D E F Code A B’ C D E’ 502710A 1/8” 4” 1 9/16” 1/2” 3 3/8” Code A B C D E F
501502A 3/8” 3/4” 1 9/16” 3 13/16” 6 1/4” 5 5/16” 502343A 1/2” 4 3/4” 2 3/16” 1/2” 3 1/4” 502720A 1/4” 4” 1 9/16” 1/2” 3 3/8” 508013A 1/8” 1 1/4” 11/16” 7/16” 13/16” 9/16”
Valve code 5080 can be used manually or

automatically.
The automatic discharge is based on the
property of the cellulose fibre discs forming
the seal cartridge.
Flow rate
SCFM 5022 - 5023 5026 - 5027 (SCFM) (Nl/s)
1,2 2.5 1.2
1,1 1.1
2.25
1 1
2
0,9 0.9
0,8 1.75 0.8
0,7 1.5 0.7
0,6 1.25 0.6
0,5 1 0.5
0,4 0.4
0.75
0,3 0.3
0,2 0.5 0.2
0,1 0.25 0.1
0 0 0
(psi)
10
20
30
40
50
60
70
80
90
0
(bar)
0.5
1.5
1.5
2.5
2.5
3.5
3.5
4.5
4.5
5.5
5.5
6.5
0
502 Flow rate

SCFM (SCFM) (Nl/s)
5
10 10
4.5
9 9
4
8 8
3.5
7 7
3
6 6
5 5 2.5
2
4 4
1.5
3 3
2 2 1
1 1 0.5
0 0 0
(psi)
10
20
30
40
50
60
70
80
90
0
(bar)
0.5
1.5
1.5
2.5
2.5
3.5
3.5
4.5
4.5
5.5
5.5
6.5
0
33

Pre-adjustable filling units
& backflow preventer
series 553 - 573 CALEFFI
CALEFFI
Function
The automatic filling unit is a device consisting of a pressure

reducing valve with compensating seat, an inlet filter, a shut-off
valve and a check valve.
It is installed on the water inlet piping in sealed heating systems,
and its main function is to maintain the pressure of the system
stable at a set value, automatically filling up with water as required.
This product has the characteristic of being pre-adjustable,
which means that it can be adjusted at the required pressure
value before the system charging phase.
After installation, during the filling or topping-off phase, the water
feed will stop when the set pressure is reached.
A pre-assembled version is also available, complete with upstream
backflow preventer.
C US
Product range
Cod e 553542A Fi l l i ng uni t wi th p re ssure g a ug e a nd p re ssure se tti ng i nd i c a tor Si z e 1/2”

Se ri e s 573 Ba c kfl ow p re v e nte r wi th i nte r me d i a te a tmosp he ri c v e nt wi th thre a d e d c onne c ti ons Si z e 1/2” - 3/4”
Se ri e s 573 Ba c kfl ow p re v e nte r wi th i nte r me d i a te a tmosp he ri c v e nt wi th swe a t c onne c ti ons Si z e 1/2”
Cod e 573002A Cha rg i ng uni t c omp l e te wi th b a c kfl ow p re v e nte r 573 se ri e s wi th thre a d e d c onne c ti ons Si z e 1/2”
Cod e 573009A Cha rg i ng uni t c omp l e te wi th b a c kfl ow p re v e nte r 573 se ri e s wi th swe a t c onne c ti ons Si z e 1/2”
Filling unit Backflow preventer

Ma te ri a l : Bod y : b ra ss Ma te ri a l : Bod y : b ra ss
Cov e r: PA 66 G F 30 Che c k v a l v e : PSU
Se a l s: N BR Check valve stem: brass
Ma xi mum Worki ng Pre ssure : 230 p si ( 16 b a r) D i a p hra g m: EPD M
Pre ssure se tti ng ra ng e : 3÷ 60 p si ( 0.2÷ 4 b a r) Se a l s: EPD M
Fa c tor y se tti ng : 15 p si ( 1.035 b a r) Ma xi mum worki ng p re ssure : 175 p si ( 12 b a r)
I nd i c a tor a c c ura c y : ± 2 p si ( ± 0.15 b a r) Ma xi mum worki ng te mp e ra ture : 210°F ( 99°C)
Maximum Working Temperature: 150°F (65°C) Medium: water
Connection: Inlet: 1/2” NPT Male with union tailpiece Ce r ti fi e d to: CSA B64.3 a nd A SSE 1012
O utl e t: 1/2” NPT Fe ma l e
Conne c ti ons: 1/2”-3/4” NPT fe ma l e wi th uni on
1/2” sweat with union
34

Dimensions
BACKFLOW PREVE
Sizes: 1/2” - 3/4”
Series: 573
S/N
A’
A
E
D
D
VENT
BACKFLOW PREVE
Sizes: 1/2” - 3/4”

Series: 573
A’
S/N
A
B
A
D
C VENT
C
B
Code A A’ B C D C
B 573403A 1/2” 1/2” 1/2” 4 1/2“ 1 3/8“
573503A 3/4” 3/4” 1/2” 4 1/2“ 1 3/8“ Code A A’ B C D E
Code A B C D 573409A 1/2” SWT 1/2” SWT 1/2” 4 7/16“ 1 3/8“ 573002A 1/2" 1/2" 1/2” 9” 1 3/8“ 4”
553542A 1/2" 413/16“ 115/16“ 4” 573493A 1/2” SWT 1/2” NPT 1/2” 4 7/16“ 1 3/8“ 573009A 1/2” SWT 1/2” NPT 1/2” 8 15/16“ 1 3/8“ 4”
Construction details Backflow preventer
Pre-calibration The backflow preventer with atmospheric vent is designed to

protect drinking water systems from the return, caused by
This model is equipped with a backsiphonage or backpressure, of contaminated fluids.
pressure setting indicator for
the commissioning operation. The Caleffi 573 series has been specifically certified to standards
The system charge pressure CSA B64.3 and ASSE 1012.
can be input by
means of the 2
30
adjusting screw, 20
1
before the start

40
3
10
of the system
50
charging phase. bar0

0 psi 4
CALEFFI
VENT
Backflow preventer flow rate graph
Δp (psi) (psi) (bar)

20 20
10 10
0.5
5 5
G (l/min) (gpm)
0.3
0.5
15
10
1
5
2
10
20
50
Cv = 0.7
Code 573002A - 573009A

Charging unit consists of:
- Backflow preventer 573 series with atmospheric vent,
- Filling unit, 553 series
35

Discal - Air Separator and Air & Dirt Separator www.caleffi.us
• Non-corrosive element efficiently removes corrosive, oxygen rich micro-bubbles
• Continuously removes the air and dirt in heating and chilled water systems
• Wide product range including sweat, threaded and flanged connections
• Built to ASME Boiler and Pressure Vessel Code, Registered with National Board
Caleffi North America Inc. - Milwaukee, WI - Tel 414.421.1000 - sales@caleffi.com
CALEFFI SOLUTIONS MADE IN ITALY

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1

271395_Idronics pg.1-36.indd 1 7/17/07 8:25:43 PM

Dear Hydronic Professional,

Caleffi Hydronic Solutions

CALEFFI NORTH AMERICA, INC

271395_Idronics pg.1-36.indd 2 7/17/07 8:25:47 PM

Welcome. heat emitters. These systems used large diameter piping

Even when closed-loop hydronic systems became

Part of the reason for this is that “closed-loop” hydronic

of the gases that make up air can enter closed-loop

271395_Feature pg.3_24.indd 3 7/13/07 3:20:43 PM

271395_Feature pg.3_24.indd 4 7/13/07 3:20:43 PM

Sediments formed by oxidation within the system can

271395_Feature pg.3_24.indd 5 7/13/07 3:20:45 PM

As water enters the system, these locations can trap air,

271395_Feature pg.3_24.indd 6 7/13/07 3:20:46 PM

Max amount in gallons of dissolved air per 100 gallons of water

In hydronic systems, microbubbles form when water with 4.0

271395_Feature pg.3_24.indd 7 7/13/07 3:20:47 PM

271395_Feature pg.3_24.indd 8 7/13/07 3:20:47 PM

Float-type Air Vents:

It contains an air chamber,

271395_Feature pg.3_24.indd 9 7/13/07 3:20:48 PM

vanes deflect bubbles

microbubbles often remain

271395_Feature pg.3_24.indd 10 7/13/07 3:20:50 PM

PLACEMENT OF CENTRAL AIR SEPARATORS:

Notice how the air separator placement in figure 17 allows

271395_Feature pg.3_24.indd 11 7/13/07 3:20:51 PM

271395_Feature pg.3_24.indd 12 7/13/07 3:20:55 PM

DIRT SEPARATION METHODS:

1. Use of chemical “flocculants” to wash the inside of

Chemical flocculants act as detergents within piping

Basket strainers, also known as Y-strainers, entrap dirt

271395_Feature pg.3_24.indd 13 7/13/07 3:20:55 PM

P across strainer is

ball valves isolate

271395_Feature pg.3_24.indd 14 7/13/07 3:21:04 PM

271395_Feature pg.3_24.indd 15 7/13/07 3:21:07 PM

air When possible, it’s also desirable to place the dirt

Some systems use multiple circulators to push flow

271395_Feature pg.3_24.indd 16 7/13/07 3:21:07 PM

Low-velocity-zone dirt separators are also well-suited to air & dirt

protect the small fluid passageways within plate-type heat

271395_Feature pg.3_24.indd 17 7/13/07 3:21:09 PM

Automatic Make-up Water Assemblies: VENT

NOTE: strainer assumed

its function. The automatic feed valve remains active

Some installers prefer to turn off the shutoff valve on the

271395_Feature pg.3_24.indd 18 7/13/07 3:21:11 PM

Flow-through purging begins

271395_Feature pg.3_24.indd 19 7/13/07 3:21:11 PM

Open one manifold valve at a time to

temporarily close differential pressure

combination purge valves shown

air & water

271395_Feature pg.3_24.indd 20 7/13/07 3:21:12 PM

combination purge valve

series primary loop