AIR AND DIRT SEPARATORS. Flamco FLEXVENT. Air and dirt separators FLAMCOVENT FLAMCOVENT CLEAN FLEXAIR FLAMCO CLEAN FLAMCO A-S.

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1 AIR AND DIRT SEPARATORS 7 Flamco FLEXVENT FLAMCOVENT FLAMCOVENT CLEAN FLEXAIR FLAMCO CLEAN 2007 edition / UK FLAMCO A-S

2 Flexvent : reliable and easy to mount The Flexvent 3 /8 and 1 /2 are supplied together with a non return valve to facilitate mounting and removal. When the Flexvent is unscrewed from the non return valve, the valve will close automatically. It is now possible to remove the vent and clean the corrosion-resistant interior. This means that the installation does not have to be drained. Due to the compact dimensions of the Flexvent, it is possible to install a Flexvent in those places in any location where air collects. FLEXVENT 1 / 8 To set the Flexvent into operation, the red cap has to be loosened one revolution. Large distance between water and non return mechanism, reducing any chance of leakage. Flexvent are made of brass. The float floats on the water and keeps the air valve closed. When air is collected in the Flexvent, the water level will drop and the air valve is opened. The collected air will escape, allowing the water level to rise and the air valve to close. This process repeats when air is collected in the Flexvent during operation. The air gap in the upper part of each Flexvent protects the valve seat against contamination. As standard with a non return valve (not applicable on the 1 /8 model). YOUR INSTALLATION NEEDS A FLEX All Flexvents are tested by Flamco. The Flexvent H has a 1 /2 right-angled connection which means it can be mounted directly on one of the radiator sockets. This is your guarantee of quality. Compact design. Many different connection options. 7.2

3 FLEXVENT 3 / 8 FLEXVENT 1 / 2 FLEXVENT H 1 / 2 FLEXVENT SUPER 1 / 2 The cap of the Flexvent Super is conical in shape. The advantage of this construction is that the clearance between the water level and air valve is at its greatest. The air-escape duct can be opened or closed with an adjusting screw. The air valve forms an integral part of the cap, so that it is impossible to damage the air vent mechanism from outside. The amount of air that is allowed to escape through the Flexvent depends on the system pressure. The graph shows the relationship between the amount of air in litres/min at 15 C and 1 bar absolute pressure, and the system pressure FLEXVENT SUPER VENT l/min FLEXVENT Flexvent open (venting) Flexvent closed (sealed) bar Mounting of Flexvent and Flexvent Super. The Flexvent and the Flexvent Super have to be mounted in a vertical position. They must be mounted in places where air collects in the installation. 7.3

4 The best air separators for each situation The operation of the Flamcovent is based on a special method of separating gases from fluid (water). This method is based on a long-established and proven process from the processing industry. Originally the renowned Raschig ring was used, but this was replaced by the PALL ring. The operation of the Flexair is based on the principle of centrifugal force. BRASS FLAMCOVENT WITH THREADED CONNECTIONS OR COMPRESSION FITTINGS The Flamcovent micro-bubble air separators are based on the patented PALL ring process. A Flamcovent fitted in the correct place in the installation can remove all air which: is present in the water of the system in the form of small bubbles and micro-bubbles; is dissolved in the water of the central heating system. The air chamber of the Flamcovent is conical. The advantage of this design is that the distance (A) between the water level and the air valve is larger than in a straight chamber. This means that the chance of contamination is reduced to a minimum. See below. Air valve Air valve A A FLAMCOVENT ADVANTAGES: Even the smallest micro-bubbles attach themselves to the PALL rings and are thereby separated. The conical air chamber provides the greatest distance between the water level and the air valve. The air valve can be isolated using the adjusting screw. WATER LEVEL WATER LEVEL 7.4

5 STEEL FLAMCOVENT WITH WELDED CONNECTIONS STEEL FLAMCOVENT WITH FLANGED CONNECTIONS FLEXAIR WITH THREADED CONNECTIONS OR WELDED CONNECTIONS FLEXAIR FROM DN 65 WITH WELDED CONNECTIONS FLEXAIR FROM DN 65 WITH FLANGED CONNECTIONS Conical air chamber, reducing possible contamination of the valve. This is how efficient PALL rings are The design is such that all fluid comes into contact with the adhesion surface of the PALL rings. Microscopically small gas bubbles in the fluid will adhere to the contact surface of the PALL rings. The process of coalescence means that the microscopic Steel body. Drain valve for removal of floating debris on the water. Drain plug for removing debris which is heavier than water. bubbles will grow into larger bubbles. The larger gas bubbles will have sufficient floating power to be separated via an air chamber. The operation of the Flamcovent air separators is based on the term coalescence. A term that means that the smaller gas bubbles adhere to a surface and fuse together into a larger gas bubble which will rise in the air chamber. 7.5

6 Choose between two air separator systems Flamcovent air separators contain PALL rings. They remove micro-bubbles from the system water. FLAMCOVENT BRASS Valve gear. Air chamber. Air valve. Adjusting screw. Operation of the Flamcovent The water flows over and past each PALL ring allowing gaseous water particles to adhere to the PALL ring surface. The flow rate of the water will diminish in proportion to the increase in diameter. In this way, air bubbles can rise to the air chamber. Float. Body (brass). Retaining plate. Float, float mechanism and air valve allow the air (separated from the water) out of the vent. PALL rings Air bubble size (μm) Flamcovent Air separator B Flamcovent air separators have been proved to be better! Tests carried out at the Delft Technical University have unequivocally proved that Flamcovent air separators remove all micro-bubbles from µm upwards. 7.6

7 for the best result! Flexair air separator The operation of the Flexair air separator relies on the principle of centrifugal force. Offset system connections rotate the water in the Flexair air separators. As a result, the heavier water is pushed against the walls, while the lighter air is removed by the air separator core. The float mechanism automatically removes the air from the air separator. On top of the Flexair air separators (DN 25 to DN 50) is a Flexvent. Larger Flexair air separators (from DN 65 upwards) are fitted with a Flexvent Super. FLAMCOVENT STEEL FLEXAIR Completelyprotected air chamber. The air collects at the top. The water is made to rotate (centrifugal vortex). Drain cock for removal of debris floating on the water. PALL rings. Drain plug for removal of debris particles which are heavier than water. Drain plug. Contaminants such as sand, welding residue etc., which are heavier than water, may collect in the bowl-shaped lower section of the air separator. The brass drain stop, centred at the bottom of the separator, serves as an outlet for such particles. With a Flamcovent you can achieve optimum and continuous air venting of your installation! 7.7

8 Insulation jackets, air and dirt separators and Correct insulation of a central-heating system to prevent heat loss is of the utmost importance. Considerations include the financial aspects of energy efficiency and environmental factors. Insulation means increased output, which in turn leads to a reduction in the use of fossil fuels and fewer CO 2 emissions. FLAMCOVENT ISOPLUS The Flamcovent ISOplus is suitable for Flamcovent air separators with welded or flanged connections. Aluminium ties with quickrelease tabs. 0.8 mm aluminium jacket. Insulation material made of 50 mm PUR hard foam. ADVANTAGES OF FLAMCOVENT ISOPLUS: Simple attachment. Fire-resistant to fire class B2 (DIN 4102-B2, flammable fluids other than highly-flammable). No CFCs (Chlorofluorocarbons). Low heat conductivity coefficient (). Maximum temperature 120 C. 7.8

9 air pots FLAMCO CLEAN FLAMCO A-S FLAMCOVENT CLEAN WITH WELDED CONNECTIONS FLAMCOVENT CLEAN WITH FLANGED CONNECTIONS The cleaned water flows to the installation via the exit connection. Water with dirt and silt particles flows into the reservoir. The water comes to a standstill and contamination sinks to the bottom. Dirt particles are kept at the bottom by the rounded flow profile. The dirt particles which have collected can be removed via the drain pipe. Powder coated finish to the reservoir. Flamco Clean Dirt particles in the water flow collide with the PALL rings in the Flamco Clean and sink to the bottom. The drain cock at the bottom of the unit provides a discharge point for the collected dirt particles. This means that the installation will no longer be subject to dips in output due to silt and containments. Flamcovent Clean This has been specially developed to remove air, but also dirt particles from the water. In the bottom part is an area which is free of turbulence. This gives the heavier particles the opportunity to sink to the bottom. The dirt particles cannot get back into the system. The sediment can escape through the drain cock on the bottom of the Flamcovent Clean. In terms of separation of air, the process is the same as that with the Flamcovent. The Flamco A-S dirt separator must be positioned in the return pipe of the heating installation. This prevents contamination of the (expensive) boiler installation. The Flamco A-S dirt separator can be used in sealed heating and cooling installations. The Flamco A-S offers particular advantages when used in old installations or when the installation is converted from an open system into a sealed one. 7.9

10 Correct mounting is your guarantee of effectiveness Here are some practical tips: when insulating air separators, the brass head must never be insulated! Before commissioning the installation, it must be properly flushed and cleaned. Excerpt from the Flamcovent Clean report drawn up by the Dutch TNO Institute for Environmental and Energy Technology. Available on CD for the full report. FLAMCOVENT CLEAN FLAMCO A-S The Flamco A-S dirt separator must be fitted in such a way that it is accessible at all times and can be maintained without any problem. The use of the Flamco A-S dirt separator reduces deposits of dirt in the boiler. Equally, removal of dirt and silt particles increases the service life of pumps, regulating equipment and other accessories. A pre-fabricated insulation package is available for the Flamco A-S (please order separately) containing a CFC-free insulation jacket. The standard version has 80 mm soft-foam insulation (easy-to-fit package). 7.10

11 min. 100 mm clearance When fitting in existing boiler houses where the supply pipe runs just below the ceiling, the clearance above must be at least 100 mm for the purposes of servicing. In terms of the position in the installation, there is no difference between the Flexair and the Flamcovent. The drawings show only the Flamcovent. FLEXAIR In order to correctly vent the installation, the Flexair or Flamcovent air separator must be mounted immediately after the boiler or mixing valve in the supply pipe. FLAMCOVENT RIGHT RIGHT WRONG Boiler Boiler Boiler Without mixing valve With mixing valve With mixing valve Work on a system (under pressure) must always be carried out by a competent engineer. The installer must inform the user of this and warn him of the dangers of improper and incorrect use. The entire central-heating installation must also be well maintained. Boiler in cellar Boiler in loft 7.11

12 Flexvent and Flexair Flexvent can be used in sealed cooling and heating systems up to a maximum temperature of 120 C and a maximum pressure of 10 bar. If no pressure is registered in the installation, e.g. when draining the installation, the Flexvent will also admit air. Flexair air separators are used in heating and cooling systems up to a maximum supply temperature of 110 C and a maximum pressure of 10 bar. The Flexair air separator is available in three different versions, one with threaded connections, one with welded connections and one with flanged connections. All connection pipes have ISO-standard dimensions. Flexair DN 65 air separators and larger are all CE approved. Models Flexvent Type Connection Material Shuf-off valve Code number Flexvent 1 /8 1 /8 male brass no FC VENT 18 Flexvent 3 /8 3 /8 male brass yes FC FLEXVENT Flexvent 1 /2 1 /2 male brass yes FC VENT 12 Flexvent Top 3 /8 white 3 /8 male brass yes FC VENT TOP W Flexvent Top 1 /2 1 /2 female brass no FC VENT TOP Flexvent H 1 /2 1 /2 male nickel-plated no FC VENT H Flexvent H 1 /2 white 1 /2 male nickel-plated no FC VENT HW Flexvent Super 1 /2 1 /2 female brass no FC VENTSUPER Models and dimensions Flexair Type Connection Ext. dia of pipe Dimensions mm Capacity Weight Code number mm A B Ø C Ø D Ø d E F liter kg Flexair threaded connections Flexair 1 G 1 female FCAS 25G Flexair 1 1 /4 G 1 1 /4 female / FCAS 32G Flexair 1 1 /2 G 1 1 /2 female / FCAS 40G Flexair 2 G 2 female FCAS 50G Flexair welded connections Flexair 25 S DN FCAS 25S Flexair 32 S DN FCAS 32S Flexair 40 S DN FCAS 40S Flexair 50 S DN FCAS 50S Flexair 65 S DN FCAS 65S Flexair 80 S DN FCAS 80S Flexair 100 S DN FCAS 100S Flexair 125 S DN FCAS 125S Flexair 150 S DN FCAS 150S Flexair 200 S DN FCAS 200S Flexair 250 S DN FCAS 250S Flexair 300 S DN FCAS 300S Flexair 350 S DN FCAS 350S Flexair 400 S DN FCAS 400S Flexair 500 S DN FCAS 500S Flexair 600 S DN FCAS 600S Flexair flanged connections PN 16 (DIN 2633) Flexair 65 F DN FCAS 65F Flexair 80 F DN FCAS 80F Flexair 100 F DN FCAS 100F Flexair 125 F DN FCAS 125F Flexair 150 F DN FCAS 150F Flexair 200 F DN FCAS 200F Flexair 250 F DN FCAS 250F Flexair 300 F DN FCAS 300F Flexair 350 F DN FCAS 350F Flexair 400 F DN FCAS 400F Flexair 500 F DN FCAS 500F Flexair 600 F DN FCAS 600F F A E Ø C B B ØdØDØD 7.12

13 Flamcovent The Flamcovent air separators are suitable for sealed systems up to a maximum temperature of 120 C and a maximum pressure of 10 bar. Flamcovent air separators in brass have threaded connections. Flamcovent air separators in steel have electrostatically applied powder coating, which creates a smooth and even red finish. The Flamcovent has welded or flanged connections. Flamcovent DN 50 air separators and larger are all CE approved. Models and dimensions Flamcovent Type Connection Ext. dia of pipe Dimensions mm Weight Code number mm A B Ø C Ø D Ø d E F G kg Flamcovent (brass) Flamcovent 3 /4 3 /4 female / FCDA 075 Flamcovent 1 1 female FCDA 100 Flamcovent 1 1 /4 1 1 /4 female / FCDA 125 Flamcovent 1 1 /2 1 1 /2 female / FCDA 150 Flamcovent (steel) welded connections Flamcovent 50 S DN FCDA S 50 Flamcovent 65 S DN FCDA S 65 Flamcovent 80 S DN FCDA S 80 Flamcovent 100 S DN FCDA S100 Flamcovent 125 S DN FCDA S125 Flamcovent 150 S DN FCDA S150 Flamcovent 200 S DN FCDA S200 Flamcovent 250 S DN FCDA S250 Flamcovent 300 S DN FCDA S300 Flamcovent 350 S DN FCDA S350 Flamcovent 400 S DN FCDA S400 Flamcovent 500 S DN FCDA S500 Flamcovent 600 S DN FCDA S600 Flamcovent (steel) flanged connections PN 16 (DIN 2633) Flamcovent 50 F DN FCDA F 50 Flamcovent 65 F DN FCDA F 65 Flamcovent 80 F DN FCDA F 80 Flamcovent 100 F DN FCDA F100 Flamcovent 125 F DN FCDA F125 Flamcovent 150 F DN FCDA F150 Flamcovent 200 F DN FCDA F200 Flamcovent 250 F DN FCDA F250 Flamcovent 300 F DN FCDA F300 Flamcovent 350 F DN FCDA F350 Flamcovent 400 F DN FCDA F400 Flamcovent 500 F DN FCDA F500 Flamcovent 600 F DN FCDA F600 Models and dimensions Flamcovent Vertical Type Connection Dimensions in mm Weight Code number A B C D kg Flamcovent V mm FCDA V22 Flamcovent V 3 /4 3 /4 F / FCDA V075 A E A E Ø C B Ø C B G Ød F ØdØDØD 7.13

14 Flamcovent ISOplus, Flamcovent Clean and Flamco Clean The Flamco Clean can be used for both heating and cooling installations. It is a compact design dirt separator, available in four different connection sizes. Use of the Flamco Clean prevents deposits of dirt and silt from forming in the system, which means that the efficiency of the installation remains at its peak. The Flamco Clean dirt separator is placed in the return pipe to the boiler or chiller. Flamcovent Clean DN 50 air separators and larger are all CE approved. Models and dimensions Flamcovent ISOplus Type Suitable for Dimensions mm Aluminium jacket A Ø B mm Number of ties Code number Flamcovent ISOplus 50 Flamcovent 50 S/F Flamcovent ISOplus 65 Flamcovent 65 S/F Flamcovent ISOplus 80 Flamcovent 80 S/F Flamcovent ISOplus 100 Flamcovent 100 S/F Flamcovent ISOplus 125 Flamcovent 125 S/F Flamcovent ISOplus 150 Flamcovent 150 S/F Flamcovent ISOplus 200 Flamcovent 200 S/F A Models and dimensions Flamcovent Clean Type Connection Ext. dia of pipe Dimensions mm Capacity Weight Code number mm A B Ø C Ø D Ø d E litres kg Flamcovent Clean welded connections Flamcovent Clean 50 S DN FC DAC 50S Flamcovent Clean 65 S DN FC DAC 65S Flamcovent Clean 80 S DN FC DAC 80S Flamcovent Clean 100 S DN FC DAC 100S Flamcovent Clean 125 S DN FC DAC 125S Flamcovent Clean 150 S DN FC DAC 150S Flamcovent Clean 200 S DN FC DAC 200S Flamcovent Clean 250 S DN FC DAC 250S Flamcovent Clean 300 S DN FC DAC 300S Flamcovent Clean 350 S DN FC DAC 350S Flamcovent Clean 400 S DN FC DAC 400S Flamcovent Clean 500 S DN FC DAC 500S Flamcovent Clean 600 S DN FC DAC 600S Flamcovent Clean flanged connections PN 16 (DIN 2633) Flamcovent Clean 50 F DN FC DAC 50F Flamcovent Clean 65 F DN FC DAC 65F Flamcovent Clean 80 F DN FC DAC 80F Flamcovent Clean 100 F DN FC DAC 100F Flamcovent Clean 125 F DN FC DAC 125F Flamcovent Clean 150 F DN FC DAC 150F Flamcovent Clean 200 F DN FC DAC 200F Flamcovent Clean 250 F DN FC DAC 250F Flamcovent Clean 300 F DN FC DAC 300F Flamcovent Clean 350 F DN FC DAC 350F Flamcovent Clean 400 F DN FC DAC 400F Flamcovent Clean 500 F DN FC DAC 500F Flamcovent Clean 600 F DN FC DAC 600F A E A B C Ø B Ø C B B E Ød F ØdØD ØD Models and dimensions Flamco Clean Type Connection Dimensions mm Code number A B C Ø d E F Flamco Clean 3 /4 3 /4 female / FC DAC 075 Flamco Clean 1 1 female FC DAC 100 Flamco Clean 1 1 /4 1 1 /4 female / FC DAC 125 Flamco Clean 1 1 /2 1 1 /2 female / FC DAC 150 Flamco Clean V22 22 mm FC DAC 22MM V Flamco Clean V 3 /4 3 /4 female / FC DAC 75MM V A F Ød Ød E 7.14

15 Flamco A-S The Flamco A-S dirt separator should be installed with isolation valves in both the in and out flow streams for ease of maintenance. A bypass with shut-off valve should also be fitted. Therefore the installation can remain in operation while it is being serviced. The resistance of all models is 12 mbar, the connection for the drain valve is 1 female thread. The air bleed connection is 1 /2 female thread. The maximum supply temperature is 120 C. CE-compliant pursuant to directive 97/23/EC. Models Flamco A-S Type Capacity Capacity Max. Weight Code number output kg liter m 3 /h t = 20 ºC 6 bar 10 bar 6 bar 10 bar Flamco A-S kw FC AS 080 FC AS B Flamco A-S kw FC AS 110 FC AS B Flamco A-S kw FC AS 180 FC AS B Flamco A-S kw FC AS 300 FC AS B Flamco A-S kw FC AS 400 FC AS B Flamco A-S kw FC AS 600 FC AS B Flamco A-S kw FC AS 800 FC AS B Flamco A-S kw FC AS 1000 FC AS B Flexvent Super optional. Insulation available on request. Dimensions Flamco A-S Type Flanged connections Dimensions mm DN..PN 16 Ø D H H1 H2 Ø d Flamco A-S Flamco A-S Flamco A-S Flamco A-S Flamco A-S Flamco A-S Flamco A-S Flamco A-S H H2 H1 Ø d Ø D 7.15

16 FLEXVENT AIR AND DIRT SEPARATORS FLAMCOVENT CONTENTS PAGE FLAMCOVENT CLEAN Flexvent 7.2/7.3 Flamco air separators a wide range 7.4/7.5 Flamco air separators the best technology 7.6/7.7 and insulation jackets 7.8/7.9 Flamco UK Limited Unit 4, St. Michael s Road Lea Green Industrial Estate St. Helens, Merseyside WA9 4WZ Tel.: +44 (0) Fax: +44 (0) info@flamco.co.uk Mounting in the installation 7.10/7.11 Technical data 7.12/7.15 FLEXAIR On the Flamco CD is more information about the function and construction of air separators, resistance graphs, practical instructions, and fitting and operating instructions. FLAMCO CLEAN Copyright Flamco UK Limited. No part of this publication may be reproduced or published in any way without explicit mention of the source. The data listed are solely applicable to Flamco products. Flamco UK Limited shall accept no liability whatsoever for incorrect use, application or interpretation of the technical information. Flamco UK Limited reserves the right to make technical alterations. Flamco UK Limited conditions of sale apply. FLAMCO A-S