Вы находитесь на странице: 1из 176

PRODUCT HANDBOOK

quality products for refrigeration and air conditioning products suitable for CFC, HCFC and HFC 2006 release www.castel.it

Pessano - February 2006

17

Thermostatic expansion valves Solenoid valves

SUMMARY

valve with interchangeable orifice assembly valve with fixed orifice assembly

valves for refrigerating systems coils permanent magnet connectors valves for different fluids safety valves 3030 safety valves 3060 ball shut-off valves changeover devices unions fusible plugs

Safety devices

Check valves Water regulating valves Liquid indicators Moisture-liquid indicators Dehydrators
dehydration of refrigerants anti-acid solid core filter driers filter driers with replaceable anti-acid solid core mechanical filters with replaceable filtering block strainers disseccants

85

Oil separators Valves


hermetic valves receiver valves stop valves diaphragm valves rotalock valves capped valves globe valves ball valves gauge mounting valves line piercing valve

117

Threaded brass fittings Solder copper fittings Access fittings Spare parts

FROM QUALITY OUR NATURAL DEVELOPMENT

After forty five years in the industry of Refrigeration and Air Conditioning components, Castel Quality Range of Products is well known and highly appreciated all over the world. Quality is the main issue of our Company and it has a special priority, in every step, all along the production cycle. We produce on high tech machinery and updated automatic production lines, operating in conformity with the safety and environment standards currently enforced. Castel offers to the Market and to Manufacturers fully tested products suitable with CFC, HCFC and HFC Refrigerants currently used in the Refrigeration & Air Conditioning Industry. UNI EN ISO 9001:2000 issued by ICIM certifies the Quality System of the Factory. Moreover Castel Products count a number of certifications in conformity with the EEC Directives and with European and American Quality Approvals.

Application of Directive 97/23/EC of the European Parliament and of the Council, of 29 may 1997, concerning pressure equipment towards Castel refrigeration products

The Directive 97/23/EC (PED) applies to the design, manufacture and conformity assessment of pressure equipment and assemblies with a maximum allowable pressure PS greater than 0,5 bar with the exception of the possibilities listed in Article 1, Section 3 of the same Directive. Since 30 May 2002 the Directive has become mandatory and, in the Member States of European Community, it has been possible to place on the market only pressure equipments CE marked according to PED. For the purposes of the Directive see the following definitions, used in this Handbook too: Pressure equipment: vessels, piping, safety accessories, and pressure accessories Vessel: a housing designed and built to contain fluids under pressure. Piping: piping components intended for the transport of fluids, when connected together for integration into a pressure system. Safety accessories: devices designed to protect pressure equipment against the allowable limits being exceeded. Pressure accessories: devices with an operational function and having pressurebearing housing. For example: solenoid valves, valves, indicators. Assemblies: several pieces of pressure equipment assembled by a manufacturer to constitute an integrated and functional whole. Maximum allowable pressure (PS): the maximum pressure for which the equipment is designed, as specified by the manufacturer. Maximum / minimum allowable temperature (TS): the maximum/minimum temperatures for which the equipment is designed, as specified by the manufacturer Volume (V): the internal volume of a chamber, including the volume of nozzles to the first connection or weld and excluding the volume of permanent internal parts. Nominal size (DN): numerical designation of size, which is common to all components in a piping system. Fluids: gases, liquids and vapours in pure

phase as well as mixture thereof. Pressure equipments referred to in Article 3 are classified by categories in accordance with Annex II, according to ascending level of hazard, on the basis of: State of the fluid Danger classification of the fluid Type of equipment Dimensions and energetic potential: V, DN, PS, PS x V, PS x DN and must satisfy the Essential Safety Requirement set out in Annex I of PED. Pressure equipments below or equal to the limits in Article 3, sections 1.1, 1.2 and 1.3 and section 2, must not satisfy the Essential Safety Requirement set out in Annex I. They must be designed and manufactured in accordance with the sound engineering practice of a Member State in order to ensure safe use (Article 3, Section 3). In the tables of general characteristics, collected in this Handbook, its showed the risk category in which every product is classified. In Article 9 of PED the fluids are classified, according to their hazard, into two groups: Group I comprises dangerous fluids. A dangerous fluid is a substance or preparation covered by the definitions in Article 2 of Council Directive 67/548/EEC of 27 June 1967 and following amendments, relating to the classification, packaging and labeling of dangerous substance. Group I comprises fluids defined as: explosive, extremely flammable, highly flammable, flammable, very toxic, toxic, oxidizing. Group II comprises all the others fluids not referred to in group I. Castel products are suitable for using with refrigerant fluids proper to the Group II. These refrigerant fluids are listed and classified L1 in Annex E of standard EN 378-1, plus fluids R30, R123 and R141b. Among the fluids listed in this standard, there are the well known R12; R22; R134a; R404A; R407C; R401A; R502; R507.

EXTERNAL LEAKAGE All the products illustrated in this Handbook are submitted, one by one, to tightness tests besides to functional tests. Allowable external leakage, measurable during the test, agrees to the definition given in the Standard DIN 3158-87 Par. 8.2: During the test, no bubbles shall form over a period of one minute when the specimen is immersed in water with low surface tension, .

PRESSURE CONTAINMENT All the products illustrated in this Handbook, if submitted to hydrostatic test, guarantee a pressure strenght at least equal to 1,43 x PS in compliance with the Directive 97/23/EC. All the products illustrated in this Handbook, if submitted to burst test, guarantee a pressure strength at least equal to 3 x PS according to the Standard revision prEN 378-2 : 2000. A great number of products illustrated in the Handbook can guarantee an higher pressure strength, equal to 5 x PS according to the Standard UL 207 : 2001. (for detailed information about these products please contact Castel Technical Department). WEIGHTS The weights of the items listed in this Handbook include packaging and are not binding for the Company.

Application of Directive 2002/95/EC of the European Parliament and of the Council, of 27 January 2003, on the restriction of the use of certain hazardous substances in electrical and electronic equipment

The purpose of Directive 2002/95/EC (RoHS Directive) is to prevent or restrict the use of hazardous substances in electrical and electronic equipment and to contribute to the environmentally sound recovery and disposal of waste electrical and electronic equipment. RoHS Directive shall apply to electrical and electronic equipment falling under the categories 1, 2, 3, 4, 5, 6, 7 and 10 set out in Annex 1A to Directive 2002/96/EC (WEEE Waste electrical and electronic equipment) and to electric light bulbs and luminaries in households. The equipment proper to the first category, Large household appliances, and to the 10th category, Automatic dispensers, of Annex 1A in WEEE Directive, are specified in Annex 1B in the same Directive; this list of products shows: Large cooling appliance Refrigerators Freezers Other large appliances used for refrigeration, conservation and storage of food Air conditioner appliances Other fanning, exhaust ventilation and conditioning equipment Automatic dispenser for hot or cold bottles and cans Article10 of WEEE Directive establishes that, from 13 August 2005, new electrical and electronic equipment put on the market are appropriately identified as waste subject to separate collection, by means of the proper symbol shown in Annex IV of the same Directive. Article 4 of RoHS Directive establishes that, from 1 July 2006, new electrical and electronic equipment put on the market does not contain the following substances: Lead Mercury Cadmium Hexavalent chromium Polybrominated biphenyls (PBB) Polybrominated diphenyl ethers (PBDE)

The restriction of use of these hazardous substances shall not apply to the applications listed in the Annex of the same Directive; among these applications the following exceptions are particularly interesting in air conditioning / refrigerating systems: Lead as an alloying element in steel containing up to 0,35% lead by weight, aluminium containing up to 0,4% lead by weight and as a copper alloy containing up to 4% lead by weight Hexavalent chromium as an anti-corrosion of the carbon steel cooling system in absorption refrigerators The Member States of European Community had to adopt the two Directives 2002/95/EC and 2002/96/EC, with the next updating 2003/108/EC, before 13 August 2004, unless delays granted by the European Parliament. For a long time Castel Company has started a careful inquiry, together with its suppliers, to identify the presence or not of the abovementioned hazardous substances, either in its own products or in its own production processes, and to remove them progressively. At the end of this wide examination Castel Company may declare that its products: Do not contain mercury, cadmium, polybrominated biphenyls (PBB), polybrominated diphenyl ethers (PBDE) Contain lead as an alloying element in steel, aluminium and copper alloys within the accepted limits according to the Annex of RoHS Directive Contain hexavalent chromium in very low concentration, not exceeding 0,003% by weight, used for the surface treatments (yellow zinc plating) of steel parts. Castel Company will remove the remaining yellow zinc plating treatments from all its products, before the end of 2005, and will choose other surface treatments containing trivalent chromium instead of hexavalent chromium.

CONNECTIONS OF CASTEL PRODUCTS


Castel products can be supplied with different connections.
TABLE 1 - Equivalence between Castel code and dimension in inches
CASTEL Code . /1 . /2 . /3 . /4 . /5 . /6 . /7 . /8 . /9 . /11 . /13 . /17 . /21 . /24 . /25 . /28 . /29 . /33 . /34 Dimension [in] 1/8" 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 1" 1" 1/8 1" 3/8 1" 5/8 2" 1/8 2" 5/8 3" 3" 1/8 3" 1/2 3" 5/8 4" 1/8 4" 1/4

In particular Castel products are produced either with threaded connections or solder connections. Table 1 shows the equivalence between Castel codes and dimensions in inches. These codes are commonly used in the international market. Table 2 shows the equivalence between Castel codes and dimensions in millimetres.

TABLE 2 - Equivalence between Castel code and dimension in millimeters


CASTEL Code . /M6 . /M10 . /M12 . /M15 . /M18 . /M22 . /M28 . /M42 . /M64 . /M80 Dimension [mm] 6 10 12 15 18 22 28 42 64 80

F.e. 1098/7 solenoid valve with solder connection with = 7/8.

F.e. 4411/M42A filter drier with replaceable anti-acid solid core with solder connection with = 42 mm.

Description of connections that are currently used for Castel products. 1) Threaded connections. They can be of three different types: FLARE Straight threaded connection (according to SAE J513-92; ASME B1.1-89) for junction to a copper pipe with a suitable flared end, using a right nut (see Table 3). NPT Taper threaded connection (according to ASME B1.20.1-92) to joint fittings, valves, safety valves to vessel or steel pipes. FPT Straight threaded connection (according to UNI ISO 228/1) used in the hydraulic system to joint fittings or valves to vessel or steel pipes.
F.e.: solenoid valves for water or air.

ODM Male solder connection for copper tubes. The indicated size corresponds to the outer diameter of the copper tube which to joint.
F.e.: 16 ODM solder connection suitable to joint a copper pipe with a 16 mm outer diameter, by means of an M16 female/female copper sleeve (in this case the type Castel 7700/M16).

IDS Male solder connection for copper tube. The indicated size corresponds to the inner diameter of the copper tube which to joint.
F.e.: 10 IDS solder connection suitable to receive outside a copper pipe with an 10 mm inner diameter).

W Solder connection for steel pipes. The indicated size corresponds to the external diameter of the steel pipe which to joint.
F.e.: 76,1 W solder connection suitable to connect a steel pipe with a 76,1 mm external diameter, by means of butt welding.

2) Solder connections. They can be of four different types and can fit pipes with diameter both in inches and in millimetres: ODS (or ODF) Female solder connection for copper tubes. The indicated size corresponds to the outer diameter of the copper tube which to joint.
F.e.: 1/2" ODS solder connection suitable to receive inside a copper pipe with a 1/2" outer diameter.

TABLE 3 - Flare Connections


FLARE 1/4" 5/16" 3/8" 1/2" 5/8" 3/4" 7/8" 1" Suitable for Copper Tube 1/4" 5/16" 3/8" 1/2" 5/8" 3/4" 7/8" 1" Thread 7/16" - 20 UNF 1/2" - 20 UNF 5/8" - 18 UNF 3/4" - 16 UNF 7/8" - 14 UNF 1.1/16" - 14 UNS 1.1/4" - 12 UNF 1.3/8" - 12 UNF

THE Kv FACTOR
The correct sizing of tubes and components of a refrigerating system is of the utmost importance for all kinds of plants; oversizing and undersizing are both to be avoided since they are equally hazardous for the correct operation of the system. The correct selection of a component is based on the knowledge of the relationship between capacity and pressure drop through that component. For this purpose, EN 60534-1, EN 60534-2-1 and EN 60534-2-3 standards require manufacturers to specify the Kv coefficient for every product. The Kv factor is defined as the cold water flow (volumic mass = 1000 kg/m3) in m3/h resulting in a 1 bar pressure drop with a completely open valve. This definition applies to all products described in this handbook. The merely physical meaning, this coefficient precisely defines the fluid-dynamic and construction characteristics of the product, so that, with the addition of other parameters more closely related to the nature and conditions of the fluid under consideration, the capacity/pressure drop ratio may be precisely determined. Castel provides appropriate tables for the most commonly used refrigerants in typical plant working conditions in order to help engineers in the correct selection of its products. Table 1 shows refrigeration capacity values with unit Kv related to the nominal working conditions specified in Table 2. Appropriate corrective coefficients may be calculated taking the values shown from Table 3 to Table 8 as a basis; this will make it possible to predict actual working conditions. As a result: Liquid line: Q = Kv Q1 L1 L2 Suction line Q = Kv Q1 S1 S2 Hot gas line Q = Kv Q1 H1 H2 since: Q = required refrigeration capacity [kW]; Kv = characteristic valve coefficient [m3/h]; Q1 = reference refrigeration capacity [kW] (Table 1). L1 S1 H1 = are correction factors of the refrigeration capacity in the presence of operating temperatures different from reference conditions. L2 S2 H2 = are correction factors of the refrigeration capacity for pressure drops different from reference conditions.

TABLE 1
Refrigeration Capacity [kW] Kv factor [m3/h] R134a R22 Liquid R404A R407C R410A R507 R134a R22 Vapour R404A R407C R410A R507 R134a R22 Hot gas R404A R407C R410A R507

16,85 18,00 11,90 18,74 19,04 11,80

2,16

2,70

2,26

2,68

3,60

2,15

8,50

11,70 10,00 11,62 13,00

7,77

TABLE 2 - Nominal Working Conditions


Application LIQUIDO VAPORE GAS CALDO +4 +18 Evaporating Temperature [C] Suction Temperature [C] +38 1 Condensing Temperature [C] Pressure drop [bar] 0,15

Liquid line
TABLE 3 - Correction Factors - L1 of the refrigeration capacity for operating temperatures different from nominal values.
Evaporating Temperature[C] Liquid Temperature [C] Refrigerant + 10 +5 0 5 10 15 20 25 30 35 40

R134a R22 0 R404A R407C R410A R507 R134a R22 +10 R404A R407C R410A R507 R134a R22 +20 R404A R407C R410A R507 R134a R22 +30 R404A R407C R410A R507 R134a R22 +40 R404A R407C R410A R507 R134a R22 +50 R404A R407C R410A R507 R134a R22 +60 R404A R407C R410A R507 1,23 1,19 1,28 1,23 1,19 1,33 1,12 1,08 1,13 1,12 1,08 1,17 1,00 0,99 0,99 0,99 1,00 1,00 0,88 0,89 0,85 0,85 0,85 0,80 0,76 0,79 0,68 0,71 0,70 0,58 1,21 1,17 1,26 1,22 1,17 1,30 1,10 1,07 1,12 1,10 1,07 1,15 0,98 0,98 0,97 0,97 0,99 0,97 0,86 0,88 0,83 0,84 0,84 0,78 0,74 0,78 0,66 0,70 0,69 0,56 1,19 1,16 1,25 1,20 1,16 1,28 1,08 1,06 1,09 1,08 1,06 1,13 0,96 0,97 0,95 0,96 0,96 0,95 0,84 0,87 0,81 0,82 0,81 0,76 0,72 0,77 0,64 0,68 0,67 0,54 1,17 1,16 1,22 1,18 1,16 1,26 1,06 1,05 1,07 1,06 1,05 1,10 0,94 0,96 0,93 0,94 0,95 0,93 0,82 0,86 0,79 0,80 0,80 0,74 0,70 0,76 0,62 0,66 0,66 0,52 1,15 1,15 1,20 1,16 1,15 1,23 1,04 1,04 1,05 1,04 1,04 1,08 0,92 0,95 0,92 0,92 0,94 0,90 0,80 0,85 0,77 0,79 0,79 0,71 0,68 0,75 0,60 0,65 0,65 0,50 1,13 1,13 1,17 1,15 1,13 1,20 1,02 1,03 1,04 1,03 1,03 1,05 0,90 0,93 0,89 0,90 0,93 0,87 0,78 0,84 0,75 0,77 0,78 0,68 0,66 0,74 0,58 0,63 0,63 0,47

1,34 1,32 1,40 1,35 1,32 1,52 1,23 1,22 1,27 1,23 1,22 1,35 1,11 1,11 1,16 1,13 1,11 1,17 1,00 1,02 1,02 1,00 1,02 1,02 0,88 0,92 0,87 0,89 0,92 0,85 0,76 0,82 0,73 0,75 0,76 0,66 0,64 0,72 0,56 0,61 0,61 0,45

1,32 1,31 1,38 1,33 1,31 1,49 1,21 1,21 1,25 1,21 1,21 1,32 1,09 1,10 1,13 1,11 1,10 1,14 0,98 1,01 0,99 0,99 1,01 0,99 0,86 0,90 0,85 0,87 0,91 0,82 0,74 0,81 0,71 0,73 0,74 0,63 0,62 0,71 0,54 0,60 0,60 0,42

1,30 1,29 1,36 1,31 1,29 1,46 1,18 1,19 1,23 1,19 1,19 1,29 1,07 1,08 1,11 1,09 1,08 1,12 0,96 0,99 0,97 0,97 0,99 0,96 0,84 0,89 0,83 0,85 0,90 0,79 0,72 0,80 0,69 0,72 0,73 0,60 0,60 0,70 0,52 0,58 0,58 0,40

1,28 1,27 1,33 1,29 1,27 1,42 1,16 1,17 1,20 1,18 1,18 1,26 1,05 1,07 1,08 1,07 1,07 1,08 0,94 0,98 0,95 0,95 0,98 0,93 0,82 0,87 0,80 0,83 0,87 0,76 0,70 0,78 0,67 0,70 0,72 0,57 0,58 0,68 0,50 0,56 0,57 0,36

1,26 1,25 1,31 1,25 1,25 1,38 1,14 1,16 1,18 1,16 1,16 1,22 1,03 1,05 1,06 1,06 1,05 1,04 0,91 0,96 0,93 0,94 0,96 0,89 0,80 0,86 0,78 0,82 0,86 0,72 0,68 0,77 0,65 0,69 0,71 0,54 0,56 0,67 0,48 0,55 0,56 0,33

TABLE 4 - Correction Factors - L2 of the refrigeration capacity for pressure drops different from nominal values.

Pressure drop [bar]

0,01

0,03

0,05

0,10

0,15

0,20

0,25

0,30

0,35

0,40

0,45

0,50

0,55

0,60

L2

0,263

0,456

0,59

0,81

1,00

1,15

1,30

1,40

1,54

1,64

1,72

1,82

1,92

2,00

Suction line
TABLE 5 - Correction Factors - S1 of the refrigeration capacity for operating temperatures different from nominal values.
Condensing Temperature [C] Evaporating Temperature [C]

Hot gas line


TABLE 7 - Correction Factors - H1 of the refrigeration capacity for operating temperatures different from nominal values.
Condensing Temperature [C] Evaporating Temperature [C]

+ 60

+ 55

+ 50

+ 45

+ 40

+ 35

+ 30

+ 60

+ 55

+ 50

+ 45

+ 40

+ 35

+ 30

+10 0 10 20 30 40

0,87 0,67 0,51 0,35

0,92 0,73 0,55 0,39

0,98 0,78 0,59 0,43

1,04 0,83 0,64 0,50 0,35

1,11 0,85 0,70 0,53 0,37 0,46* 0,35*

1,17 0,96 0,76 0,57 0,39 0,48* 0,37*

1,23 1,01 0,80 0,60 0,45 0,50* 0,38*

+10 0 10 20 30 40

1,00 0,83 0,76

1,00 0,90 0,76

1,00 0,92 0,79 0,67

1,03 0,92 0,80 0,71

1,04 0,94 0,84 0,72 0,60

1,05 0,95 0,87 0,76 0,65 0,58

1,05 0,95 0,88 0,77 0,68 0,61

0,36* 0,27*

0,38* 0,29*

0,41* 0,31*

0,43* 0,33*

*Two-stages plants, two indipendent circuits, with intermediate temperature -10 C.


TABLE 6 - Correction Factors - S2 of the refrigeration capacity for pressure drops different from nominal values. TABLE 8 - Correction Factors - H2 of the refrigeration capacity for pressure drops different from nominal values.

Pressure drop [bar]

0,035

0,05

0,07

0,10

0,15

0,20

0,30

0,40

0,50

0,70

Pressure drop [bar]

0,10

0,20

0,30

0,40

0,50

0,70

1,00

1,50

2,00

2,50

S2

0,47 0,57 0,68 0,82 1,00 1,15 1,40 1,64 1,82 2,15

H2

0,32 0,45 0,54 0,65 0,70 0,83 1,00 1,17 1,30 1,44

APPLICATION EXAMPLES 1) Liquid line: Evaluation of pressure drop across the valve under the following working conditions: Castel 1078/5 valve: Kv = 2,61 [m3/h] Refrigerant: R407C Set refrigeration capacity: 35 [kW] Condensation: + 50 [C] Evaporation: 0 [C] Q = Kv Q1 L1 L2 [kW] 35 = 2,61 18,74 0,82 L2 [kW] 35 L2 = = 0,87 40,11 A pressure drop slightly above 0.11 bar corresponds to the L2 = 0.87 correction factor. Such a pressure drop is compatible with the minimum differential pressure required by the valve. 2) Suction line: Valve selection under the following conditions: Refrigerant: R407C Set refrigeration capacity: 15 [kW] Condensation: + 40 [C] Evaporation: 10 [C] Set pressure drop: 0,1 [bar]

Q = Kv Q1 S1 S2 [kW] 15 = Kv 2,68 0,70 0,82 15 Kv = = 9,75 [m3/h] 1,538 The result involves the selection of a 1078/9 valve with Kv = 10 [m3/h] 3) Hot gas line: Valve selection under the following conditions: Refrigerant: R407C Set refrigeration capacity: 20 [kW] Condensation: + 40 [C] Evaporation: 0 [C] Set pressure drop: 0,5 [bar] Q = Kv Q1 H1 H2 [kW] 20 = Kv 11,62 0,94 0.7 20 Kv = = 2,61 [m3/h] 7,64 The result involves the selection of a 1078/5 valve with Kv = 2.61 [m3/h]

THERMOSTATIC EXPANSION VALVES

17

THERMOSTATIC EXPANSION VALVES SERIES 22 WITH INTERCHANGEABLE ORIFICE ASSEMBLY


APPLICATION Castel thermostatic expansion valves series 22 regulate the flow of refrigerant liquid into evaporators; the liquid injection is controlled by the refrigerant superheat. The new Castel 22 series are designed to work with interchangeable orifice assembly, to provide flexibility in selection of capacities, and can be used in a wide range of applications as listed below: Refrigeration systems (display cases in supermarkets, freezers, ice cream and ice maker machines, transport refrigeration etc). Air conditioning systems Heat pump systems Liquid chillers which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2, of Directive 97/23/EC and referred to in Directive 67/548/EEC). OPERATION Castel thermostatic expansion valves acts as throttle device between the high pressure and the low pressure sides of refrigeration systems and ensure that the rate of refrigerant flow into the evaporator exactly matches the rate of evaporation of liquid refrigerant in the evaporator. If the actual superheat is higher than the set point the valve feeds the evaporator with more liquid refrigerant, if the actual superheat is lower than the set point the valve decreases the flow of liquid refrigerant to the evaporator. Thus the evaporator is fully utilized and no liquid refrigerant may reach the compressor. CONSTRUCTION Castel thermostatic expansion valve series 22 is made up of two parts that must work together: the first is the body, which is the actuator of the regulator, and the second is the orifice, which contains the valve and attends the expansion of the refrigerating fluid. Body assembly: two parts make it up: the thermostatic (power) element and the body with its inner elements. The thermostatic element is the motor of the valve; a sensing bulb is connected to the diaphragm assembly by a length of capillary tubing, which transmits bulb pressure to the top of the valves diaphragm. The sensing bulb pressure is a function of the temperature of the thermostatic charge that is the substance within the bulb. The body is made from forged brass with connection in angle configuration. The interchangeable orifice assembly can be replaced through the inlet connection. A steel rod, inside the body, transfers the diaphragm movement to the plug inside the orifice assembly. When the thermostatic charge pressure increases, the diaphragm will be deflected downward transferring this motion to the plug, which lifts from seat and allows the liquid passing through orifice. A spring opposes the force underneath the diaphragm and the side spindle can adjust its tension. Static superheat increases by turning the side spindle clockwise and decreased by turning the spindle counter clockwise. The thermostatic element is hardly connected by brazing to the forged brass body to avoid any leakage. The body assembly can be supplied with internal or external equalizer; both types can also be supplied either with flare connections or with solder connections (outlet and external equalizer if present).

18

www.castel.it

THERMOSTATIC EXPANSION VALVES

Table 1: General Caracteristics of Body Assemblies of Thermostatic Expansion Valves


Max bulb temperature [C] Catalogue number SAE Flare internal equalizer 2210/4 2210/M12S 2210/4S 2210/4E 2210/M12SE 2210/4SE 2211/4 2211/M12S 2211/4S 2211/4E 2211/M12SE 2211/4SE 2220/4 2220/M12S 2220/4S 2220/4E 2220/M12SE 2220/4SE 2221/4 2221/M12S 2221/4S 2221/4E 2221/M12SE 2221/4SE 2230/4 2230/M12S 2230/4S 2230/4E 2230/M12SE 2230/4SE 2231/4 2231/M12S 2231/4S 2231/4E 2231/M12SE 2231/4SE 2234/4 2234/M12S 2234/4S 2234/4E 2234/M12SE 2234/4SE 3/8" 3/8" 3/8" external equalizer IN OUT 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" Equal. 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" Connections Refrigerant ODS [mm] OUT 12 12 12 12 12 12 12 12 12 12 12 12 12 12 Equal. 6 6 6 6 6 6 6 ODS [in] OUT 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" Equal. 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" - 60 - 20 C - 25 (30 psi) R404A R507 - 40 + 10 + 15 C (120 psi) without + 15 C (55 psi) 100 (1) -60 +120 34 Art. 3.3 R134a - 40 + 10 without + 15 C (95 psi) R22 R407C - 40 + 10 without Evaporating Temperature Range [C] TS [C] PS [bar] min max Risk Category according to PED

MOP

(1) when valve is installed. 60 C with element not mounted

www.castel.it

19

The nuts for flare connection type and the inlet-brazing adapter for solder connection type can be ordered separately. The main part of body assembly are made with the following materials: stainless steel for bulb, capillary tubing, diaphragm casing, diaphragm and rod hot forged brass EN 12420 CW 617N for body brass EN 12164 CW 614N for superheat setting spindle and spring holder steel DIN 17223-1 for spring copper tube EN 12735-1 Cu DHP for solder connection Orifice assembly: interchangeable orifice assembly provide a wide range of capacity from 0,5 up to 15,5 kW (nominal capacity with R22). The external cartridge contains the following elements: housing, plug (metering device), seat, spring and strainer. The rigid design of orifice assembly and its internal components make sure that plug and seat will withstand all types of critical operations (liquid hammering, cavitation, sudden variation of pressure and temperature contaminants). The spring holds the plug firmly to the seat to ensure the minimum leakage through the valve; for positive shut-off, the installation of a solenoid valve is required. The strainer can be cleaned or exchanged. THERMOSTATIC CHARGES Liquid charge: the behaviour of valves with liquid charge is exclusively determined by temperature changes at the bulb and not subject to any cross-ambient interference. They feature a fast response time and thus react quickly in the control circuit. Castel thermostatic expansion valves with liquid charge cannot incorporate MOP functions. Gas charge: the behaviour of valves with gas charge will be determined by the lowest temperature at any part of the expansion valve (thermostatic element, capillary tube or bulb). If any parts other than the bulb are subjected to the lowest temperature, malfunction of expansion valve may occur (charge migration). Castel thermostatic expansion valves with gas charge always feature MOP functions and include ballasted bulb. Ballast in the bulb has a damping effect on the valve regulation and leads to slow opening and fast closure of the valve.

MOP (Maximum Operating Pressure): this functionality limits the evaporator pressure to a maximum value to protect the compressor from the overload condition (Motor Overload Protection). MOP is the evaporating pressure at which the expansion valve will throttle liquid injection into the evaporator and thus prevent the evaporating pressure from rising. Expansion valve operates as superheat control in normal working range and operates as pressure regulator within MOP range. The MOP point will change if the factory superheat setting of the expansion valve is changed. Superheat adjustments influence the MOP point as following: increase of superheat decrease of MOP decrease of superheat increase of MOP Superheat: this is the controlling parameter of the expansion valve. Superheat, measured at the evaporator outlet, is defined as the difference between actual bulb temperature and the evaporating temperature at the saturation point. In order to prevent liquid refrigerant from entering the compressor, a certain minimum superheat must be maintained. In expansion valve operation the following terms are used: Static superheat: its the superheat above that the valve will begin to open. Castel thermo expansion valves are factory preset for optimum static superheat setting. This setting should be modified only if absolutely necessary. Static superheat for Castel valves without MOP is 5 C and for Castel valves with MOP is 4C. Opening superheat: its the amount of superheat above the static superheat required to produce a given valve capacity Operating superheat: its the sum of static and opening superheat

20

www.castel.it

Subcooling: its defined as the difference between the liquid refrigerant temperature and its saturation temperature. Subcooling generally increases the capacity of refrigeration system and may be accounted for when dimensioning an expansion valve. Depending on system design, subcooling may be necessary to prevent flash gas from forming in the liquid line. If flash gas forms in the liquid line, the capacity of expansion valve will be greatly reduced. All capacity tables, in this chapter, are calculated for a subcooling value of 4 C; if the actual subcooling is higher than 4 C the evaporator capacity must be divided by the appropriate correction factor shown is the tables below every capacity tables.

THERMOSTATIC EXPANSION VALVES

SELECTION To correctly select a thermo expansion valve on a refrigerating system, the following design conditions must be available: Type of refrigerant Evaporator capacity, Qe Evaporating temperature/pressure, Te / pe Lowest possible condensing temperature/ pressure, Tc / pc Liquid refrigerant temperature, Tl Pressure drop in the liquid line, distributor and evaporator, p The following procedure helps to select the correct valve for the system. Step 1 Determine the pressure drop across the valve. The pressure drop is calculated by the formula:

p tot = p c ( p e + p

41,5

39

66

35

43

29

40

42

42

39

66

35

43

34

40

54

www.castel.it

21

where: Pc = condensing pressure Pe = evaporating pressure p = sum of pressure drops in the liquid line, distributor and evaporator Step 2 Determine required valve capacity. Use the evaporating capacity Qe to select the required valve size at a given evaporating temperature. If necessary, correct the evaporator capacity for subcooling. Subcooling liquid refrigerant entering the evaporator increase the evaporator capacity, so that a smaller valve may be required. The subcooling is calculated by the formula:

Step 3 Determine required orifice size. Use the pressure drop across the valve, the evaporating temperature and the calculated evaporator capacity to select the corresponding orifice size from the capacity table corresponding to the chosen refrigerant. Step 4 Select a thermostatic charge. Chose the type of charge, liquid without MOP or gas with MOP, and the temperature range, normal temperature or low temperature. Step 5 Determine if external equalizer is required. External equalizer is always required if a distributor is used or if there is an appreciable difference in pressure from the valve outlet to the bulb location. Finally determine the type of connections and their sizes.

Tsub = Tc Tl
From the subcooling corrector factor table find the appropriate corrector factor Fsub corresponding to the Tsub calculated and determine the required valve capacity by the formula:

Q sub =

Qe

Fsub

Table 2: Orifice Assemblies - Rated Capacities in kW


Evaporating Temperature Range [C] Catalogue Number R22 R407C 220X 2200 2201 2202 2203 2204 2205 2206 0,5 1,0 2,5 3,5 5,2 8,0 10,5 15,5 - 40 + 10 R134a 0,4 0,9 1,8 2,6 4,6 6,7 8,6 10,5 R404A R507 0,38 0,7 1,6 2,1 4,2 6,0 7,7 9,1 -60 -25 R404A R507 0,38 0,7 1,6 2,1 3,5 4,9 6,0 6,6

Rated capacities, for temperature range - 40 + 10, are based on: Evaporating temperature Tevap = + 5 C Condensing temperature Tcond = + 32 C Refrigerant liquid temperature ahead of valve Tliq = + 28 C Rated capacities, for temperature range - 60 - 25, are based on: Evaporating temperature Tevap = - 30 C Condensing temperature Tcond = + 32 C Refrigerant liquid temperature ahead of valve Tliq = + 28 C

22

www.castel.it

Table 3: Solder adapters


ODS Connections Catalogue Number [in] 2271/M6S 2271/2S 2271/3S 2271/M10S 1/4" 3/8" [mm] 6 10

STEP 3 - Determine required orifice size Using the capacity table for R134a on page 25 with: pressure drop across the valve = 4,2 bar evaporating temperature = - 10 C calculated evaporator capacity = 5,55 kW select the corresponding orifice 2205 (N.B.: the expansion valve capacity must be equal or slightly more than the calculated evaporator capacity) MARKING

THERMOSTATIC EXPANSION VALVES

SIZING EXAMPLE Type of refrigerant R134a Evaporator capacity, Qe 6 kW Evaporating temperature/ pressure, Te - 10 C Lowest possible condensing + 30 C temperature/pressure, Tc Liquid refrigerant temperature, Tl + 20 C Pressure drop in the liquid line, distributor and evaporator, p 1,5 bar STEP 1 - Determine the pressure drop across the valve Condensing pressure at + 30 C - pc = 6,71 bar Evaporating pressure at - 10 C - pe = 1,01 bar

p tot = 6,71 ( 1,01 + 1,5 ) = 4,2 bar


STEP 2 - Determine required valve capacity

Main valve data are indicated on the upper side of the thermostatic element and on the cartridge surface of the orifice assembly. On the thermostatic element you may find the following data: The valve code number The refrigerant The evaporating temperature range The MOP value, if present The maximum allowable pressure PS The date of production On the cartridge of orifice assembly you may find the following data: The size of the orifice The date of production On the plastic cap of the orifice assembly package a label gives the orifice size. The cap can easily be fastened around the valve capillary tube to clearly identify the valve size.

T sub = 30 20 = 10 C
From the subcooling corrector factor table 5b, we find the appropriate corrector factor Fsub equal to 1,08 for Tsub = 10 C. Required valve capacity is:

Q sub = 6

1,08

= 5,55 kW

www.castel.it

23

Table 4a: Refrigerant R22/R407C - Capacities in kW for temperature range - 40C ? +10C
Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16

Evaporating temperature = +10 C 220X 0,37 2200 2201 2202 2203 2204 2205 2206 0,87 2,2 3,0 5,4 8,1 10,2 12,6 0,48 1,1 2,8 4,0 7,2 10,8 13,6 16,7 0,55 1,2 3,2 4,7 8,3 12,5 15,7 19,3 0,60 1,3 3,4 5,1 9,1 13,8 17,2 21,0 0,63 1,4 3,6 5,4 9,7 14,5 18,3 22,3 0,65 1,4 3,7 5,6 10,0 15,0 18,9 23,1 0,65 1,4 3,8 5,8 10,2 15,5 19,3 23,5 0,67 1,5 3,8 5,8 10,3 15,5 19,5 23,7

Evaporating temperature = 0 C 220X 0,37 2200 2201 2202 2203 2204 2205 2206 0,84 1,9 2,6 4,6 6,9 8,8 10,8 0,48 1,0 2,4 3,4 6,1 9,1 11,6 14,2 0,55 1,2 2,7 4,0 7,1 10,5 13,3 16,3 0,59 1,3 3,0 4,3 7,8 11,5 14,6 17,8 0,63 1,3 3,1 4,6 8,2 12,2 15,5 18,9 0,65 1,4 3,2 4,8 8,5 12,7 16,1 19,6 0,66 1,4 3,3 4,9 8,7 13,0 16,4 20,0 0,66 1,4 3,3 5,0 8,8 13,2 16,6 20,2

Evaporating temperature = -10 C 220X 0,37 2200 2201 2202 2203 2204 2205 2206 0,79 1,6 2,2 3,9 5,8 7,4 9,1 0,47 0,96 2,0 2,9 5,1 7,6 9,6 11,6 0,53 1,1 2,3 3,3 5,9 8,7 11,0 13,5 0,57 1,2 2,5 3,6 6,4 9,5 12,0 14,7 0,60 1,2 2,6 3,8 6,8 10,1 12,8 15,6 0,63 1,3 2,7 4,0 7,1 10,5 13,3 16,2 0,64 1,3 2,8 4,1 7,3 10,8 13,6 16,6 0,64 1,3 2,8 4,1 7,3 10,9 13,8 16,8

Evaporating temperature = -20 C 220X 2200 2201 2202 2203 2204 2205 2206 0,44 0,88 1,7 2,4 4,2 6,2 7,9 9,6 0,50 1,0 1,9 2,7 4,8 7,1 9,0 11,0 0,54 1,1 2,0 2,9 5,2 7,7 9,8 11,9 0,57 1,1 2,2 3,1 5,5 8,2 10,3 12,6 0,59 1,2 2,3 3,2 5,8 8,5 10,8 13,1 0,61 1,2 2,3 3,3 5,9 8,7 11,0 13,5 0,61 1,2 2,3 3,3 6,0 8,8 11,2 13,7

Evaporating temperature = -30 C 220X 2200 2201 2202 2203 2204 2205 2206 0,40 0,79 1,4 1,9 3,4 5,0 6,4 7,8 0,45 0,9 1,5 2,2 3,9 5,7 7,2 8,8 0,49 0,96 1,7 2,7 4,2 6,2 7,8 9,6 0,52 1,0 1,8 2,5 4,4 6,6 8,3 10,1 0,55 1,1 1,8 2,6 4,6 6,8 8,6 10,5 0,56 1,1 1,9 2,6 4,7 7,0 8,8 10,8 0,57 1,1 1,9 2,7 4,8 7,1 9,0 11,0

Evaporating temperature = -40 C 220X 2200 2201 2202 2203 2204 2205 2206 0,42 0,8 1,3 1,7 3,1 4,6 5,8 7,1 0,45 0,86 1,4 1,9 3,4 4,9 6,3 7,7 0,48 0,92 1,4 2,0 3,5 5,2 6,6 8,1 0,50 0,95 1,5 2,0 3,7 5,4 6,9 8,4 0,52 0,98 1,5 2,1 3,8 5,6 7,1 8,7 0,53 0,99 1,6 2,1 3,8 5,7 7,2 8,8

Table 4b: Refrigerant R22/R407C - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,06 15 1,11 20 1,15 25 1,20 30 1,25 35 1,30 40 1,35 45 1,39 50 1,44

When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 4b

24

www.castel.it

Table 5a: Refrigerant R134a - Capacities in kW for temperature range - 40C


Orifice code 2 Pressure drop across valve [bar] 4 6 8 10 Orifice code 2

+10C

THERMOSTATIC EXPANSION VALVES

Pressure drop across valve [bar] 4 6 8 10

Evaporating temperature = +10 C 220X 2200 2201 2202 2203 2204 2205 2206 0,34 0,71 1,5 2,0 3,6 5,4 6,9 8,4 0,43 0,86 1,9 2,6 4,7 7,0 8,9 10,8 0,47 0,93 2,1 3,0 5,3 7,8 9,9 12,1 0,50 0,97 2,2 3,1 5,6 8,3 10,8 12,8 0,51 0,98 2,2 3,2 5,8 8,6 10,9 13,2

Evaporating temperature = 0 C 220X 2200 2201 2202 2203 2204 2205 2206 0,33 0,65 1,3 1,7 3,0 4,5 5,7 7,0 0,42 0,78 1,6 2,2 3,9 5,7 7,3 8,9 0,46 0,86 1,7 2,4 4,4 6,4 8,1 1,0 0,47 0,89 1,8 2,6 4,6 6,8 8,6 10,5 0,49 0,91 1,8 2,6 4,7 7,0 8,8 10,8

Evaporating temperature = -10 C 220X 2200 2201 2202 2203 2204 2205 2206 0,30 0,59 1,0 1,4 2,5 3,6 4,6 5,7 0,36 0,70 1,3 1,8 3,1 4,6 5,8 7,1 0,43 0,77 1,4 2,0 3,5 5,1 6,5 8,0 0,44 0,81 1,5 2,1 3,7 5,4 6,9 8,4 0,44 0,82 1,5 2,1 3,8 5,6 7,1 8,6

Evaporating temperature = -20 C 220X 2200 2201 2202 2203 2204 2205 2206 0,28 0,53 0,81 1,1 2,0 2,9 3,7 4,5 0,35 0,62 1,0 1,4 2,5 3,6 4,6 5,6 0,39 0,69 1,1 1,5 2,8 4,0 5,1 6,2 0,41 0,72 1,2 1,6 2,9 4,3 5,4 6,6 0,42 0,73 1,2 1,7 3,0 4,4 5,5 6,8

Evaporating temperature = -30 C 220X 2200 2201 2202 2203 2204 2205 2206 0,25 0,48 0,66 0,9 1,6 2,3 3,0 3,6 0,32 0,55 0,80 1,1 2,0 2,9 3,6 4,4 0,35 0,61 0,88 1,2 2,2 3,2 4,0 4,9 0,37 0,64 0,93 1,3 2,3 3,3 4,2 5,2 0,38 0,64 0,95 1,3 2,3 3,4 4,3 5,3

Evaporating temperature = -40 C 220X 2200 2201 2202 2203 2204 2205 2206 0,23 0,44 0,54 0,7 1,3 1,9 2,4 3,0 0,28 0,50 0,65 0,9 1,6 2,3 2,9 3,6 0,32 0,54 0,72 1,0 1,8 2,6 3,2 4,0 0,33 0,56 0,78 1,0 1,9 2,7 3,5 4,2 0,34 0,57 0,77 1,0 1,9 2,7 3,5 4,3

Table 5b: Refrigerant R134a - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,08 15 1,13 20 1,19 25 1,25 30 1,31 35 1,37 40 1,42 45 1,48 50 1,54

When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 5b

www.castel.it

25

Table 6a: Refrigerant R404A/R507 - Capacities in kW for temperature range - 40C +10C
Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16

Evaporating temperature = +10 C 220X 0,28 2200 2201 2202 2203 2204 2205 2206 0,67 1,70 2,32 4,15 6,24 0,35 0,82 2,10 3,00 5,36 8,06 0,40 0,90 2,30 3,39 6,03 9,06 0,42 0,94 2,42 3,61 6,43 9,66 0,43 0,96 2,48 3,73 6,63 9,95 0,43 0,96 2,46 3,74 6,66 9,98 0,42 0,93 2,41 3,68 6,55 9,81 0,41 0,90 2,34 3,59 6,39 9,57

Evaporating temperature = 0 C 220X 0,30 2200 2201 2202 2203 2204 2205 2206 0,68 1,53 2,06 3,68 5,49 6,97 0,37 0,80 1,86 2,64 4,72 7,15 8,92 0,41 0,87 2,04 2,95 5,27 7,86 0,42 0,90 2,13 3,13 5,59 8,33 0,43 0,92 2,18 3,22 5,75 8,58 0,43 0,93 2,18 3,25 5,80 8,64 0,43 0,91 2,15 3,21 5,73 8,53 0,41 0,87 2,08 3,11 5,55 8,27

7,91 10,17 11,43 12,16 12,53 12,56 12,34 12,03 9,71 12,47 13,98 14,86 15,29 15,31 15,05 14,66

9,95 10,52 10,83 10,90 10,76 10,43

8,57 10,93 12,16 12,85 13,21 13,30 13,12 12,72

Evaporating temperature = -10 C 220X 0,30 2200 2201 2202 2203 2204 2205 2206 0,65 1,31 1,76 3,14 4,66 5,93 7,28 0,37 0,76 1,61 2,24 4,02 5,97 7,57 0,40 0,82 1,74 2,50 4,47 6,61 8,39 0,42 0,84 1,81 2,62 4,69 6,95 8,81 0,42 0,87 1,84 2,69 4,81 7,13 9,02 0,42 0,87 1,85 2,71 4,84 7,18 9,08 0,41 0,85 1,84 2,68 4,79 7,11 8,99 0,41 0,83 1,78 2,60 4,65 6,91 8,73

Evaporating temperature = -20 C 220X 2200 2201 2202 2203 2204 2205 2206 0,35 0,70 1,34 1,85 3,32 4,88 6,20 7,60 0,38 0,75 1,45 2,04 3,66 5,40 6,86 8,39 0,40 0,77 1,50 2,14 3,83 5,64 7,17 8,75 0,39 0,79 1,52 2,17 3,89 5,75 7,29 8,91 0,40 0,79 1,52 2,18 3,90 5,77 7,31 8,93 0,39 0,79 1,51 2,16 3,86 5,71 7,23 8,84 0,38 0,76 1,47 2,09 3,75 5,56 7,05 8,61

9,27 10,26 10,76 11,00 11,08 10,97 10,65

Evaporating temperature = -30 C 220X 2200 2201 2202 2203 2204 2205 2206 0,35 0,67 1,18 1,63 2,93 4,28 5,45 6,66 0,37 0,70 1,21 1,69 3,04 4,47 5,68 6,94 0,36 0,70 1,23 1,71 3,07 4,52 5,74 7,02 0,37 0,70 1,21 1,70 3,06 4,51 5,74 7,01 0,36 0,69 1,20 1,68 3,02 4,46 5,67 6,93 0,35 0,67 1,17 1,64 2,93 4,35 5,52 6,75

Evaporating temperature = -40 C 220X 2200 2201 2202 2203 2204 2205 2206 0,32 0,60 0,92 1,27 2,28 3,34 4,25 5,19 0,33 0,61 0,96 1,32 2,36 3,47 4,41 5,39 0,33 0,62 0,97 1,33 2,38 3,50 4,45 5,45 0,33 0,61 0,96 1,31 2,36 3,48 4,43 5,42 0,32 0,60 0,94 1,28 2,31 3,42 4,36 5,33 0,32 0,59 0,91 1,24 2,24 3,33 4,24 5,19

Table 6b: Refrigerant R404A/R507 - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,10 15 1,20 20 1,29 25 1,37 30 1,46 35 1,54 40 1,63 45 1,70 50 1,78

When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 6b

26

www.castel.it

Table 7a: Refrigerant R404A/R507 - Capacities in kW for temperature range - 60C - 25C
Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16

THERMOSTATIC EXPANSION VALVES

Evaporating temperature = -25 C 2200 2201 2202 2203 2204 2205 2206 0,57 0,98 1,31 2,35 3,45 4,40 5,40 0,67 1,20 1,65 2,97 4,37 5,56 6,30 0,72 1,31 1,83 3,28 4,82 6,14 7,49 0,73 1,36 1,91 3,42 5,04 6,40 7,81 0,74 1,37 1,93 3,47 5,11 6,49 7,93 0,85 1,37 1,93 3,46 5,12 6,49 7,93 0,74 1,35 1,90 3,42 5,06 6,42 7,85 0,71 1,31 1,85 3,32 4,93 6,26 7,64

Evaporating temperature = -30 C 2200 2201 2202 2203 2204 2205 2206 0,53 0,88 1,18 2,12 3,09 3,94 4,83 0,64 1,07 1,47 2,65 3,88 4,94 6,06 0,67 1,18 1,63 2,93 4,28 5,45 6,66 0,70 1,21 1,69 3,04 4,47 5,68 6,94 0,70 1,23 1,71 3,07 4,52 5,74 7,02 0,70 1,21 1,70 3,05 4,51 5,74 7,01 0,69 1,20 1,68 3,02 4,46 5,67 6,93 0,67 1,17 1,64 2,93 4,35 5,52 6,75

Evaporating temperature = -40 C 2200 2201 2202 2203 2204 2205 2206 0,56 0,65 1,17 2,09 3,03 3,87 4,73 0,60 0,72 1,27 2,28 3,34 4,25 5,19 0,61 0,75 1,32 2,36 3,47 4,41 5,39 0,62 0,77 1,33 2,38 3,50 4,45 5,45 0,61 0,77 1,31 2,36 3,48 4,43 5,47 0,60 0,77 1,28 2,31 3,42 4,36 5,33 0,59 0,75 1,24 2,24 3,33 4,24 5,19

Evaporating temperature = -50 C 2200 2201 2202 2203 2204 2205 2206 0,49 0,51 0,91 1,63 2,36 3,02 3,69 0,53 0,57 0,99 1,73 2,60 3,30 4,04 0,54 0,60 1,02 1,84 2,69 3,43 4,20 0,54 0,60 1,02 1,84 2,71 3,45 4,22 0,53 0,60 1,01 1,81 2,68 3,42 4,18 0,52 0,60 0,98 1,78 2,63 3,35 4,12 0,50 0,59 0,95 1,72 2,56 3,26 4,00

Evaporating temperature = -60 C 2200 2201 2202 2203 2204 2205 2206 0,46 0,58 0,78 1,40 2,04 2,59 3,16 0,48 0,60 0,80 1,44 2,11 2,69 3,28 0,47 0,60 0,80 1,43 2,11 2,66 3,30 0,45 0,58 0,78 1,40 2,07 2,65 3,25 0,45 0,56 0,75 1,36 2,03 2,59 3,18 0,43 0,54 0,72 1,30 1,96 2,50 3,07

Table 7b: Refrigerant R404A/R507 - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,10 15 1,20 20 1,29 25 1,37 30 1,46 35 1,54 40 1,63 45 1,70 50 1,78

When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 7b

www.castel.it

27

HERMETIC THERMOSTATIC EXPANSION VALVES SERIES 23 WITH FIXED ORIFICE ASSEMBLY


APPLICATION Castel thermostatic expansion valves series 23 regulate the flow of refrigerant liquid into evaporators; the liquid injection is controlled by the refrigerant superheat. The new Castel 23 series are specifically developed for soldering into hermetic refrigeration systems; they are offered in rated capacities up to 15,5 kW (R22) and can be used in a wide range of applications as listed below: Refrigeration systems (display cases in supermarkets, freezers, ice cream and ice maker machines, transport refrigeration etc). Air conditioning systems Heat pump systems Liquid chillers which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2, of Directive 97/23/EC and referred to in Directive 67/548/EEC). OPERATION Castel thermostatic expansion valves acts as throttle device between the high pressure and the low pressure sides of refrigeration systems and ensure that the rate of refrigerant flow into the evaporator exactly matches the rate of evaporation of liquid refrigerant in the evaporator. If the actual superheat is higher than the set point the valve feeds the evaporator with more liquid refrigerant, if the actual superheat is lower than the set point the valve decreases the flow of liquid refrigerant to the evaporator. Thus the evaporator is fully utilized and no liquid refrigerant may reach the compressor. CONSTRUCTION Four parts make up the Castel thermo expansion valve series 23: the thermostatic (power) element, the body with its inner elements, the orifice assembly and the inlet connection. The thermostatic element is the motor of the valve; a sensing bulb is connected to the diaphragm assembly by a length of capillary tubing, which transmits bulb pressure to the top of the valves diaphragm. The sensing bulb pressure is a function of the temperature of the thermostatic charge that is the substance within the bulb. The body is made from forged brass with connection in angle configuration. The fixed orifice assembly is screwed into the body through the inlet side. A steel rod, inside the body, transfers the diaphragm movement to the plug inside the orifice assembly. When the thermostatic charge pressure increases, the diaphragm will be deflected downward transferring this motion to the plug, which lifts from seat and allows the liquid passing through orifice. A spring opposes the force underneath the diaphragm and the side spindle can adjust its tension. Static superheat increases by turning the side spindle clockwise and decreased by turning the spindle counter clockwise.

28

www.castel.it

THERMOSTATIC EXPANSION VALVES

Table 1: General Characteristics of Thermostatic Expansion Valves


Max bulb temperature [C] Catalogue number [in] internal equalizer external equalizer IN 2310/M6 0X06 2310/2 0X 06 2310/3 0X 06 2310/M10 0X 06 2310/M6E 0X 06 2310/2E 0X 06 2310/3E 0X 06 2310/M10E 0X 06 2311/M6 0X 06 2311/2 0X 06 2311/3 0X 06 2311/M10 0X 06 2311/M6E 0X 06 2311/2E 0X 06 2311/3E 0X 06 2311/M10E 0X 06 2320/M6 0X 06 2320/2 0X 06 2320/3 0X 06 2320/M10 0X 06 2320/M6E 0X 06 2320/2E 0X 06 2320/3E 0X 06 2320/M10E 0X 06 2321/M6 0X 06 2321/2 0X 06 2321/3 0X 06 2321/M10 0X 06 2321/M6E 0X 06 2321/2E 0X 06 2321/3E 0X 06 2321/M10E 0X 06 2330/M6 0X 06 2330/2 0X 06 2330/3 0X 06 2330/M10 0X 06 2330/M6E 0X 06 2330/2E 0X 06 2330/3E 0X 06 2330/M10E 0X 06 2331/M6 0X 06 2331/2 0X 06 2331/3 0X 06 2331/M10 0X 06 2331/M6E 0X 06 2331/2E 0X 06 2331/3E 0X 06 2331/M10E 0X 06 2334/M6 0X 06 2334/2 0X 06 2334/3 0X 06 2334/M10 0X 06 2334/M6E 0X 06 2334/2E 0X 06 2334/3E 0X 06 2334/M10E 0X 06 1/4" 3/8" 1/4" 3/8" 1/4" 3/8" 1/4" 3/8" 1/4" 3/8" 1/4" 3/8" 1/4" 3/8" 1/4" 3/8" 1/4" 3/8" 1/4" 3/8" 1/4" 3/8" 1/4" 3/8" 1/4" 3/8" 1/4" 3/8" OUT 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" Equal. 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" 1/4" IN 6 10 6 10 6 10 6 10 6 10 6 10 6 10 6 10 6 10 6 10 6 10 6 10 6 10 6 10 OUT 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 Equal. 6 6 6 6 6 6 6 6 6 6 6 6 6 6 - 60 - 20 C - 25 (30 psi) R404A R507 + 15 C (120 psi) - 40 + 10 without + 15 C (55 psi) 100 (1) -60 +120 34 Art. 3.3 R134a - 40 + 10 without + 15 C (95 psi) R22 R407C - 40 + 10 without ODS Connections Refrigerant [mm] Evaporating Temperature Range [C] TS [C] PS [bar] min max Risk Category according to PED

MOP

(1) when valve is installed. 60 C with element not mounted

www.castel.it

29

The fixed orifice assembly provide a wide range of capacity from 0,5 up to 15,5 kW (nominal capacity with R22). It contains the following elements: housing, plug (metering device), seat, spring and strainer. The rigid design of orifice assembly and its internal components make sure that plug and seat will withstand all types of critical operations (liquid hammering, cavitation, sudden variation of pressure and temperature contaminants). The spring holds the plug firmly to the seat to ensure the minimum leakage through the valve; for positive shutoff, the installation of a solenoid valve is required. The thermostatic element is hardly connected by brazing to the forged brass body meanwhile the inlet connection is electrical welded to the forged brass body. This construction makes the valve hermetic and avoids any leakage. The valve can be supplied with internal or external equalizer; both types are supplied with solder connections (inlet, outlet and external equalizer if present). The main part of valve are made with the following materials: stainless steel for bulb, capillary tubing, diaphragm casing, diaphragm and rod hot forged brass EN 12420 CW 617N for body brass EN 12164 CW 614N for superheat setting spindle and spring holder steel DIN 17223-1 for spring copper tube EN 12735-1 Cu DHP for solder connection THERMOSTATIC CHARGES Liquid charge: the behaviour of valves with liquid charge is exclusively determined by temperature changes at the bulb and not subject to any cross-ambient interference. They feature a fast response time and thus react quickly in the control circuit. Castel thermostatic expansion valves with liquid charge cannot incorporate MOP functions. Gas charge: the behaviour of valves with gas charge will be determined by the lowest temperature at any part of the expansion valve (thermostatic element, capillary tube or bulb). If any parts other than the bulb are subjected to the lowest temperature, malfunction of expansion valve may occur (charge migration). Castel thermostatic

expansion valves with gas charge always feature MOP functions and include ballasted bulb. Ballast in the bulb has a damping effect on the valve regulation and leads to slow opening and fast closure of the valve. MOP (Maximum Operating Pressure): this functionality limits the evaporator pressure to a maximum value to protect the compressor from the overload condition (Motor Overload Protection). MOP is the evaporating pressure at which the expansion valve will throttle liquid injection into the evaporator and thus prevent the evaporating pressure from rising. Expansion valve operates as superheat control in normal working range and operates as pressure regulator within MOP range. The MOP point will change if the factory superheat setting of the expansion valve is changed. Superheat adjustments influence the MOP point as following: increase of superheat decrease of MOP decrease of superheat increase of MOP Superheat: this is the controlling parameter of the expansion valve. Superheat, measured at the evaporator outlet, is defined as the difference between actual bulb temperature and the evaporating temperature at the saturation point. In order to prevent liquid refrigerant from entering the compressor, a certain minimum superheat must be maintained. In expansion valve operation the following terms are used: Static superheat: its the superheat above that the valve will begin to open. Castel thermo expansion valves are factory preset for optimum static superheat setting. This setting should be modified only if absolutely necessary. Static superheat for Castel valves without MOP is 5 C and for Castel valves with MOP is 4C. Opening superheat: its the amount of superheat above the static superheat required to produce a given valve capacity Operating superheat: its the sum of static and opening superheat

30

www.castel.it

Subcooling: its defined as the difference between the liquid refrigerant temperature and its saturation temperature. Subcooling generally increases the capacity of refrigeration system and may be accounted for when dimensioning an expansion valve. Depending on system design, subcooling may be necessary to prevent flash gas from forming in the liquid line. If flash gas forms in the liquid line, the capacity of expansion valve will be greatly reduced. All capacity tables, in this chapter, are calculated for a subcooling value of 4 C; if the actual subcooling is higher than 4 C the evaporator capacity must be divided by the appropriate correction factor shown is the tables below every capacity tables.

Step 2 Determine required valve capacity. Use the evaporating capacity Qe to select the required valve size at a given evaporating temperature. If necessary, correct the evaporator capacity for subcooling. Subcooling liquid refrigerant entering the evaporator increase the evaporator capacity, so that a smaller valve may be required. The subcooling is calculated by the formula:

THERMOSTATIC EXPANSION VALVES

Q sub =

Qe

Fsub

SELECTION To correctly select a thermo expansion valve on a refrigerating system, the following design conditions must be available: Type of refrigerant Evaporator capacity, Qe Evaporating temperature/pressure, Te / pe Lowest possible condensing temperature/pressure, Tc / pc Liquid refrigerant temperature, Tl Pressure drop in the liquid line, distributor and evaporator, p The following procedure helps to select the correct valve for the system.

From the subcooling corrector factor table find the appropriate corrector factor Fsub corresponding to the Tsub calculated and determine the required valve capacity by the formula: Step 3 Determine required orifice size. Use the pressure drop across the valve, the evaporating temperature and the calculated valve capacity to select the corresponding orifice size from the capacity table corresponding to the chosen refrigerant.

Table 2: Fixed orifices - Rated Capacities in kW

Step 1 Determine the pressure drop across the valve. The pressure drop is calculated by the formula:

Evaporating Temperature Range [C] Orifice Size R22 R407C 23--/-0X 23--/-00 23--/-01 0,5 1,0 2,5 3,5 5,2 8,0 10,5 15,5 - 40 + 10 R134a 0,4 0,9 1,8 2,6 4,6 6,7 8,6 10,5 R404A R507 0,38 0,7 1,6 2,1 4,2 6,0 7,7 9,1 -60 -25 R404A R507 0,38 0,7 1,6 2,1 3,5 4,9 6,0 6,6

p tot = p c ( p e + p

where: pc = condensing pressure pe = evaporating pressure p = sum of pressure drops in the liquid line, distributor and evaporator

23--/-02 23--/-03 23--/-04 23--/-05 23--/-06

Rated capacities, for temperature range - 40 + 10, are based on: Evaporating temperature Tevap = + 5 C Condensing temperature Tcond = + 32 C Refrigerant liquid temperature ahead of valve Tliq = + 28 C Rated capacities, for temperature range - 60 - 25, are based on: Evaporating temperature Tevap = - 30 C Condensing temperature Tcond = + 32 C Refrigerant liquid temperature ahead of valve Tliq = + 28 C

www.castel.it

31

Step 4 Select a thermostatic charge. Chose the type of charge, liquid without MOP or gas with MOP, and the temperature range, normal temperature or low temperature. Step 5 Determine if external equalizer is required. External equalizer is always required if a distributor is used or if there is an appreciable difference in pressure from the valve outlet to the bulb location. Finally determine the type of connections and their sizes. SIZING EXAMPLE Type of refrigerant R22 3,8 kW Evaporator capacity, Qe Evaporating temperature/ pressure, Te + 5 C Lowest possible condensing temperature/pressure, Tc + 38 C Liquid refrigerant temperature,Tl + 27 C Pressure drop in the liquid line, distributor and evaporator, p 0,5 bar

STEP 1 - Determine the pressure drop across the valve Condensing pressure at + 38 C - Pc = 13,6 bar Evaporating pressure at + 5 C - Pe = 4.8 bar

p tot = 13,6 ( 4,8 + 0,5

) = 8,3 bar

STEP 2 - Determine required valve capacity

Tsub = 38 27 = 11 C
From the subcooling corrector factor table 3b we find the appropriate corrector factor Fsub equal to 1,07 for Tsub = 11 C. Required valve capacity is:

Q sub = 3,8 1,07 = 3,55 kW


STEP 3 - Determine required orifice size Using the capacity table for R22 on page 33 with: pressure drop across the valve = 8,3 bar evaporating temperature = + 5 C calculated evaporator capacity = 3,55 kW select the corresponding valve 23--/-02 (N.B.: the expansion valve capacity must be equal or slightly more than the calculated evaporator capacity)

39

108

77

85

40

54

34

32

www.castel.it

THERMOSTATIC EXPANSION VALVES

MARKING The following data are indicated on the upper side of the thermostatic element of the valve: The valve code number The refrigerant The evaporating temperature range The MOP value, if present The maximum allowable pressure PS The date of production The size of the orifice

Table 3a: Refrigerant R22/R407C - Capacities in kW for temperature range - 40C + 10C
Orifice size 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice size 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16

Evaporating temperature = +10 C 23--/-0X 0,37 23--/-00 0,87 23--/-01 23--/-02 23--/-03 23--/-04 2,2 3,0 5,4 8,1 0,48 1,1 2,8 4,0 7,2 10,8 13,6 16,7 0,55 1,2 3,2 4,7 8,3 12,5 15,7 19,3 0,60 1,3 3,4 5,1 9,1 13,8 17,2 21,0 0,63 1,4 3,6 5,4 9,7 14,5 18,3 22,3 0,65 1,4 3,7 5,6 10,0 15,0 18,9 23,1 0,65 1,4 3,8 5,8 10,2 15,5 19,3 23,5 0,67 1,5 3,8 5,8 10,3 15,5 19,5 23,7

Evaporating temperature = 0 C 23--/-0X 0,37 23--/-00 0,84 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 1,9 2,6 4,6 6,9 8,8 0,48 1,0 2,4 3,4 6,1 9,1 11,6 14,2 0,55 1,2 2,7 4,0 7,1 10,5 13,3 16,3 0,59 1,3 3,0 4,3 7,8 11,5 14,6 17,8 0,63 1,3 3,1 4,6 8,2 12,2 15,5 18,9 0,65 1,4 3,2 4,8 8,5 12,7 16,1 19,6 0,66 1,4 3,3 4,9 8,7 13,0 16,4 20,0 0,66 1,4 3,3 5,0 8,8 13,2 16,6 20,2

23--/-05 10,2 23--/-06 12,6

23--/-06 10,8

Evaporating temperature = -10 C 23--/-0X 0,37 23--/-00 0,79 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 1,6 2,2 3,9 5,8 7,4 9,1 0,47 0,96 2,0 2,9 5,1 7,6 9,6 11,6 0,53 1,1 2,3 3,3 5,9 8,7 11,0 13,5 0,57 1,2 2,5 3,6 6,4 9,5 12,0 14,7 0,60 1,2 2,6 3,8 6,8 10,1 12,8 15,6 0,63 1,3 2,7 4,0 7,1 10,5 13,3 16,2 0,64 1,3 2,8 4,1 7,3 10,8 13,6 16,6 0,64 1,3 2,8 4,1 7,3 10,9 13,8 16,8

Evaporating temperature = -20 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,44 0,88 1,7 2,4 4,2 6,2 7,9 9,6 0,50 1,0 1,9 2,7 4,8 7,1 9,0 11,0 0,54 1,1 2,0 2,9 5,2 7,7 9,8 11,9 0,57 1,1 2,2 3,1 5,5 8,2 10,3 12,6 0,59 1,2 2,3 3,2 5,8 8,5 10,8 13,1 0,61 1,2 2,3 3,3 5,9 8,7 11,0 13,5 0,61 1,2 2,3 3,3 6,0 8,8 11,2 13,7

Evaporating temperature = -30 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,40 0,79 1,4 1,9 3,4 5,0 6,4 7,8 0,45 0,9 1,5 2,2 3,9 5,7 7,2 8,8 0,49 0,96 1,7 2,7 4,2 6,2 7,8 9,6 0,52 1,0 1,8 2,5 4,4 6,6 8,3 10,1 0,55 1,1 1,8 2,6 4,6 6,8 8,6 10,5 0,56 1,1 1,9 2,6 4,7 7,0 8,8 10,8 0,57 1,1 1,9 2,7 4,8 7,1 9,0 11,0

Evaporating temperature = -40 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,42 0,8 1,3 1,7 3,1 4,6 5,8 7,1 0,45 0,86 1,4 1,9 3,4 4,9 6,3 7,7 0,48 0,92 1,4 2,0 3,5 5,2 6,6 8,1 0,50 0,95 1,5 2,0 3,7 5,4 6,9 8,4 0,52 0,98 1,5 2,1 3,8 5,6 7,1 8,7 0,53 0,99 1,6 2,1 3,8 5,7 7,2 8,8

Table 3b: Refrigerant R22/R407C - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,06 15 1,11 20 1,15 25 1,20 30 1,25 35 1,30 40 1,35 45 1,39 50 1,44

When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 3b

www.castel.it

33

Table 4a: Refrigerant R134a - Capacities in kW for temperature range - 40C + 10C
Orifice size 2 Pressure drop across valve [bar] 4 6 8 10 Orifice size 2 Pressure drop across valve [bar] 4 6 8 10

Evaporating temperature = +10 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,34 0,71 1,5 2,0 3,6 5,4 6,9 8,4 0,43 0,86 1,9 2,6 4,7 7,0 8,9 10,8 0,47 0,93 2,1 3,0 5,3 7,8 9,9 12,1 0,50 0,97 2,2 3,1 5,6 8,3 10,8 12,8 0,51 0,98 2,2 3,2 5,8 8,6 10,9 13,2

Evaporating temperature = 0 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,33 0,65 1,3 1,7 3,0 4,5 5,7 7,0 0,42 0,78 1,6 2,2 3,9 5,7 7,3 8,9 0,46 0,86 1,7 2,4 4,4 6,4 8,1 1,0 0,47 0,89 1,8 2,6 4,6 6,8 8,6 10,5 0,49 0,91 1,8 2,6 4,7 7,0 8,8 10,8

Evaporating temperature = -10 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,30 0,59 1,0 1,4 2,5 3,6 4,6 5,7 0,36 0,70 1,3 1,8 3,1 4,6 5,8 7,1 0,43 0,77 1,4 2,0 3,5 5,1 6,5 8,0 0,44 0,81 1,5 2,1 3,7 5,4 6,9 8,4 0,44 0,82 1,5 2,1 3,8 5,6 7,1 8,6

Evaporating temperature = -20 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,28 0,53 0,81 1,1 2,0 2,9 3,7 4,5 0,35 0,62 1,0 1,4 2,5 3,6 4,6 5,6 0,39 0,69 1,1 1,5 2,8 4,0 5,1 6,2 0,41 0,72 1,2 1,6 2,9 4,3 5,4 6,6 0,42 0,73 1,2 1,7 3,0 4,4 5,5 6,8

Evaporating temperature = -30 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,25 0,48 0,66 0,9 1,6 2,3 3,0 3,6 0,32 0,55 0,80 1,1 2,0 2,9 3,6 4,4 0,35 0,61 0,88 1,2 2,2 3,2 4,0 4,9 0,37 0,64 0,93 1,3 2,3 3,3 4,2 5,2 0,38 0,64 0,95 1,3 2,3 3,4 4,3 5,3

Evaporating temperature = -40 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,23 0,44 0,54 0,7 1,3 1,9 2,4 3,0 0,28 0,50 0,65 0,9 1,6 2,3 2,9 3,6 0,32 0,54 0,72 1,0 1,8 2,6 3,2 4,0 0,33 0,56 0,78 1,0 1,9 2,7 3,5 4,2 0,34 0,57 0,77 1,0 1,9 2,7 3,5 4,3

Table 4b: Refrigerant R134a - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,08 15 1,13 20 1,19 25 1,25 30 1,31 35 1,37 40 1,42 45 1,48 50 1,54

When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 4b

34

www.castel.it

Table 5a: Refrigerant R404A/R507 - Capacities in kW for temperature range - 40C + 10C
Orifice size 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice size 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16

THERMOSTATIC EXPANSION VALVES

Evaporating temperature = +10 C 23--/-0X 0,28 23--/-00 0,67 23--/-01 1,70 23--/-02 2,32 23--/-03 4,15 23--/-04 6,24 0,35 0,82 2,10 3,00 5,36 8,06 0,40 0,90 2,30 3,39 6,03 9,06 0,42 0,94 2,42 3,61 6,43 9,66 0,43 0,96 2,48 3,73 6,63 9,95 0,43 0,96 2,46 3,74 6,66 9,98 0,42 0,93 2,41 3,68 6,55 9,81 0,41 0,90 2,34 3,59 6,39 9,57

Evaporating temperature = 0 C 23--/-0X 0,30 23--/-00 0,68 23--/-01 1,53 23--/-02 2,06 23--/-03 3,68 23--/-04 5,49 23--/-05 6,97 0,37 0,80 1,86 2,64 4,72 7,15 8,92 0,41 0,87 2,04 2,95 5,27 7,86 0,42 0,90 2,13 3,13 5,59 8,33 0,43 0,92 2,18 3,22 5,75 8,58 0,43 0,93 2,18 3,25 5,80 8,64 0,43 0,91 2,15 3,21 5,73 8,53 0,41 0,87 2,08 3,11 5,55 8,27

23--/-05 7,91 10,17 11,43 12,16 12,53 12,56 12,34 12,03 23--/-06 9,71 12,47 13,98 14,86 15,29 15,31 15,05 14,66 Evaporating temperature = -10 C 23--/-0X 0,30 23--/-00 0,65 23--/-01 1,31 23--/-02 1,76 23--/-03 3,14 23--/-04 4,66 23--/-05 5,93 23--/-06 7,28 0,37 0,76 1,61 2,24 4,02 5,97 7,57 0,40 0,82 1,74 2,50 4,47 6,61 8,39 0,42 0,84 1,81 2,62 4,69 6,95 8,81 0,42 0,87 1,84 2,69 4,81 7,13 9,02 0,42 0,87 1,85 2,71 4,84 7,18 9,08 0,41 0,85 1,84 2,68 4,79 7,11 8,99 0,41 0,83 1,78 2,60 4,65 6,91 8,73

9,95 10,52 10,83 10,90 10,76 10,43

23--/-06 8,57 10,93 12,16 12,85 13,21 13,30 13,12 12,72 Evaporating temperature = -20 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,35 0,70 1,34 1,85 3,32 4,88 6,20 7,60 0,38 0,75 1,45 2,04 3,66 5,40 6,86 8,39 0,40 0,77 1,50 2,14 3,83 5,64 7,17 8,75 0,39 0,79 1,52 2,17 3,89 5,75 7,29 8,91 0,40 0,79 1,52 2,18 3,90 5,77 7,31 8,93 0,39 0,79 1,51 2,16 3,86 5,71 7,23 8,84 0,38 0,76 1,47 2,09 3,75 5,56 7,05 8,61

9,27 10,26 10,76 11,00 11,08 10,97 10,65

Evaporating temperature = -30 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,35 0,67 1,18 1,63 2,93 4,28 5,45 6,66 0,37 0,70 1,21 1,69 3,04 4,47 5,68 6,94 0,36 0,70 1,23 1,71 3,07 4,52 5,74 7,02 0,37 0,70 1,21 1,70 3,06 4,51 5,74 7,01 0,36 0,69 1,20 1,68 3,02 4,46 5,67 6,93 0,35 0,67 1,17 1,64 2,93 4,35 5,52 6,75

Evaporating temperature = -40 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,32 0,60 0,92 1,27 2,28 3,34 4,25 5,19 0,33 0,61 0,96 1,32 2,36 3,47 4,41 5,39 0,33 0,62 0,97 1,33 2,38 3,50 4,45 5,45 0,33 0,61 0,96 1,31 2,36 3,48 4,43 5,42 0,32 0,60 0,94 1,28 2,31 3,42 4,36 5,33 0,32 0,59 0,91 1,24 2,24 3,33 4,24 5,19

Table 5b: Refrigerant R404A/R507 - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,10 15 1,20 20 1,29 25 1,37 30 1,46 35 1,54 40 1,63 45 1,70 50 1,78

When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 5b

www.castel.it

35

Table 6a: Refrigerant R404A/R507 - Capacities in kW for temperature range - 60C - 25C
Orifice size 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice size 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16

Evaporating temperature = -25 C 23--/-00 0,57 23--/-01 0,98 23--/-02 1,31 23--/-03 2,35 23--/-04 3,45 23--/-05 4,40 23--/-06 5,40 0,67 1,20 1,65 2,97 4,37 5,56 6,30 0,72 1,31 1,83 3,28 4,82 6,14 7,49 0,73 1,36 1,91 3,42 5,04 6,40 7,81 0,74 1,37 1,93 3,47 5,11 6,49 7,93 0,85 1,37 1,93 3,46 5,12 6,49 7,93 0,74 1,35 1,90 3,42 5,06 6,42 7,85 0,71 1,31 1,85 3,32 4,93 6,26 7,64

Evaporating temperature = -30 C 23--/-00 0,53 23--/-01 0,88 23--/-02 1,18 23--/-03 2,12 23--/-04 3,09 23--/-05 3,94 23--/-06 4,83 0,64 1,07 1,47 2,65 3,88 4,94 6,06 0,67 1,18 1,63 2,93 4,28 5,45 6,66 0,70 1,21 1,69 3,04 4,47 5,68 6,94 0,70 1,23 1,71 3,07 4,52 5,74 7,02 0,70 1,21 1,70 3,05 4,51 5,74 7,01 0,69 1,20 1,68 3,02 4,46 5,67 6,93 0,67 1,17 1,64 2,93 4,35 5,52 6,75

Evaporating temperature = -40 C 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,56 0,65 1,17 2,09 3,03 3,87 4,73 0,60 0,72 1,27 2,28 3,34 4,25 5,19 0,61 0,75 1,32 2,36 3,47 4,41 5,39 0,62 0,77 1,33 2,38 3,50 4,45 5,45 0,61 0,77 1,31 2,36 3,48 4,43 5,47 0,60 0,77 1,28 2,31 3,42 4,36 5,33 0,59 0,75 1,24 2,24 3,33 4,24 5,19

Evaporating temperature = -50 C 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,49 0,51 0,91 1,63 2,36 3,02 3,69 0,53 0,57 0,99 1,73 2,60 3,30 4,04 0,54 0,60 1,02 1,84 2,69 3,43 4,20 0,54 0,60 1,02 1,84 2,71 3,45 4,22 0,53 0,60 1,01 1,81 2,68 3,42 4,18 0,52 0,60 0,98 1,78 2,63 3,35 4,12 0,50 0,59 0,95 1,72 2,56 3,26 4,00

Evaporating temperature = -60 C 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,46 0,58 0,78 1,40 2,04 2,59 3,16 0,48 0,60 0,80 1,44 2,11 2,69 3,28 0,47 0,60 0,80 1,43 2,11 2,66 3,30 0,45 0,58 0,78 1,40 2,07 2,65 3,25 0,45 0,56 0,75 1,36 2,03 2,59 3,18 0,43 0,54 0,72 1,30 1,96 2,50 3,07

Table 6b: Refrigerant R404A/R507 - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,10 15 1,20 20 1,29 25 1,37 30 1,46 35 1,54 40 1,63 45 1,70 50 1,78

When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 6b

36

www.castel.it

SOLENOID VALVES

37

SOLENOID VALVES FOR REFRIGERATING SYSTEMS


APPLICATIONS The solenoid valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). OPERATION The valves series 1020; 1028; 1050; 1058; 1059; 1064; 1068; 1070; 1078; 1079; 1090; 1098; 1099 are normally closed. NC = when the coil is de-energised the plunger stops the refrigerant flow. The valves series 1150; 1158; 1164; 1168; 1170; 1178;1190; 1198 are normally open. NO = when the coil is energised the plunger stops the refrigerant flow. The valves series 1020 and 1028 are direct acting, while the valves of all the other series are pilot operated, with diaphragm or piston. The NC valves are supplied either without coil (S type) or with coil (example: A6 type with coil HM2220 Vac). The NO valves are supplied only without coil (S type). N.B.: the NO valve visually differs from the corresponding NC model by means of the red ring installed below the yellow nut that fastens the coil. CONSTRUCTION The main parts of the valves are made with the following materials: hot forged brass EN 12420 CW 617N for body and cover; copper tube EN 12735-1 Cu-DHP for solder connections; austenitic stainless steel EN 10088-2 1.4303 for enclosure where the plunger moves; ferritic stainless steel EN 10088-3 1.4105 for plunger: austenitic stainless steel EN ISO 3506 A2-70 for tightening screws between body and cover; chloroprene rubber (CR) for outlet seal gaskets; P.T.F.E. for seat gaskets. INSTALLATION The valves can be installed in all sections of a refrigerating system, in compliance with the limits and capacities indicated in Tables 3 and 6. Tables 1 and 4 show the following functional characteristics of a solenoid valve: PS; TS; Kv factor; minimum Opening Pressure Differential (minOPD), that is the minimum pressure differential between inlet and outlet at which a solenoid valve, pilot operated, can open and stay opened; maximum Opening Pressure Differential (MOPD according to ARI STANDARD 760: 2001), that is the maximum pressure differential between inlet and outlet at which a solenoid valve, pilot operated, can open. Before connecting the valve to the pipe it is advisable to make sure that the refrigerating system is clean. In fact the valves with P.T.F.E. gaskets are particularly sensitive to dirt and debris. Furthermore check that the flow direction in the pipe corresponds to the arrow stamped on the body of the valve. All valves can be mounted in whatever position except with the coil pointing downwards. The brazing of valves with solder connections should be carried out with care, using a low melting point filler material. It is not necessary to disassemble the valves before brazing but its important to avoid direct contact between the torch flame and the valve body, which could be damaged and compromise the proper functioning of the valve. Before connecting a valve to the electrical system, be sure that the line voltage and frequency correspond to the values marked on the coil.

38

www.castel.it

The NO valves have been designed to work only with direct current coils. To use them with an alternate current supply its necessary to mate the NO valve with the following components:

voltage 24 Vac: Coil 9120/RD2 + Connector 9150/R44; voltage 220 Vac: Coil 9120/RD6 + Connector 9150/R45.

SOLENOID VALVES

TABLE 1: General Characteristics of NC valves (normally closed)


Connections Catalogue Number ODS SAE Flare 1/4" 3/8" 3/8" 1/2" 1/2" 5/8" 5/8" 3/4" 5/8" 3/4" [in.] 1/4" 1/4" 3/8" 3/8" 1/2" 1/2" 5/8" 7/8" 5/8" 3/4" 7/8" 1.1/8" 5/8" 3/4" 7/8" 1.1/8" 1.1/8" 1.3/8" 1.1/8" 1.3/8" 1.3/8" 1.5/8" [mm] 10 7 0,80 Diaphragm Pilot Operated 10 12 12 16 22 16 22 16 22 35 35 35 42 27 16 25,5 16,5 12,5 2,20 2,61 2,20 +105 (1) 3 0,23 2,5 3 2,2 0,175 Ditect Acting 0,23 0,15 Seat size nominal [mm] Operating Principles Kv Factor [m3/h] Opening Pressure Differential [bar] MOPD Coil type HM2 CM2 (AC) HM4 (AC) HM3 (DC) min. max. TS [C] PS [bar] Risk Category according to PED

min OPD

1020/2 1020/3 1028/2 1028/2E 1028/3 1028/M10 1064/3 1064/4 1068/3 1068/M10 1068/M12 1068/4 1070/4 1070/5 1078/M12 1078/4 1078/5 1079/7 1050/5 1050/6 1058/5 1058/6 1058/7 1059/9 1090/5 1090/6 1098/5 1098/6 1098/7 1099/9 1078/9 1079/11 1098/9 1099/11 1078/11 1079/13 1079/M42

19

0,05

25 (3)

18

2,61 3,80 Piston Pilot Operated 4,80 3,80 4,80 5,70 3,80 4,80 3,80 4,80 5,70 13 Diaphragm Pilot Operated 21 35 45 Art. 3.3

0,07

+110 (2)

0,05

21

+105 (1)

10

Piston Pilot Operated

25

10

0,07

25 (3)

19 +110 (2)

(1) Temperature peaks of 120 C are allowed during defrosting. (2) Temperature peaks of 130 C are allowed during defrosting. (3) For information about higher MOPD, please contact Castel Technical Department.

www.castel.it

39

SOLENOID VALVES FOR REFRIGERATING SYSTEMS

TABLE 2: Dimensions and Weights of NC valves with 9100 coil (1)


Dimensions [mm] Catalogue Number Weight [g] H1 H2 H3 L1 L2 Q

1020/2 1020/3 1028/2 1028/2E 1028/3 1028/M10 1064/3 1064/4 1068/3 1068/M10 1068/M12 1068/4 1070/4 1070/5 1078/M12 1078/4 1078/5 1079/7 1050/5 1050/6 1058/5 1058/6 1058/7 1059/9 1090/5 1090/6 1098/5 1098/6 1098/7 1099/9 1078/9 1079/11 1098/9 1099/11 1078/11 1079/13 1079/M42 172 138 110 115 96 72 106 78 50 121 93 65 91 75 47 82 69,5 40 75 62,5 34

58 65 125 125 125 125 68 72 111 111 127 127 100 106 127 127 175 190 120 124 175 175 180 216 120 124 175 175 180 216 250 292 235 277 80 57 50 45

340 355 350 350 365 365 400 415 400 395 420 420 710 755 690 680 775 765 1157 1487 1117 1307 1292 1347 1035 1365 995 1185 1170 1225 2565 2620 2050 2130 2710

157

127

99

68

278

68

2750 2750

(1) With coil type 9120 the dimension L2 is equal to 64 mm and the valves weights must be increased of 305 g.

40

www.castel.it

SOLENOID VALVES

L2 L2

H2

H1

H2

H1

H3

L1 L2

1020/2 1020/3

L1

L2

H2

H1

H3

H1

H2

L1 L2

1064/3 1064/4

L1 L2

H2

H1

H1

H2

H3

L1

1070/4 1070/5

L1

L2

L2

H2

H1

H3

H1

H3 1058/5 1058/6 1058/7 1059/9 L2

H2

H3 1078/M12 1078/4 1078/5 1079/7

H3 1068/3 1068/4 1068/M10 1068/M12

H3 1028/2 1028/2E 1028/3 1028/M10

L1

1050/5 1050/6 1090/5 1090/6 L2

L1

1098/5 1098/6 1098/7 1099/9

H2

H1

H2

H1

L1 L1 1078/9 1079/11 1098/9 1099/11 1078/11 1079/13 1079/M42

Connectors are not included in the boxes and have to be ordered separately.

H3

H3

www.castel.it

41

SOLENOID VALVES FOR REFRIGERATING SYSTEMS

TABLE 3: Refrigerant Flow Capacity of NC valves


Resa frigorifera [kW] Catalogue Number R134a 1020/2 1020/3 1028/2 1028/2E 1028/3 1028/M10 1064/3 1064/4 1068/3 1068/M10 1068/M12 1068/4 1070/4 1070/5 1078/M12 1078/4 1078/5 1079/7 1050/5 1050/6 1058/5 1058/6 1058/7 1059/9 1090/5 1090/6 1098/5 1098/6 1098/7 1099/9 1078/9 1079/11 1098/9 1099/11 1078/11 1079/13 1079/M42 269,6 288,0 299,8 190,4 304,6 34,6 43,2 42,9 36,2 57,6 136,0 187,2 185,9 160,0 208,0 37,1 44,0 37,1 39,6 47,0 39,6 41,2 48,9 41,2 26,2 31,1 26,2 41,9 49,7 41,9 4,75 5,64 4,75 5,94 7,05 5,94 5,90 6,99 5,90 4,97 5,90 4,97 7,92 9,40 7,92 18,7 22,2 18,7 25,7 30,5 25,7 25,6 30,3 25,6 22,0 26,1 22,0 28,6 33,9 28,6 13,5 14,4 15,0 9,5 15,2 1,73 2,16 2,14 1,81 2,88 6,8 9,4 9,3 8,0 10,4 3,88 4,14 4,31 2,74 4,38 2,95 3,88 2,53 R22 3,15 4,14 2,70 Liquid R407C 3,28 4,31 2,81 R404A 2,08 2,74 1,79 R410A 3,33 4,38 2,86 R134a R22 Vapour R407C R404A R410A R134a 1,49 1,96 1,28 R22 2,05 2,69 1,76 Hot Gas R407C 2,03 2,67 1,74 R404A 1,75 2,30 1,50 R410A 2,28 2,99 1,95

1,96

2,69

2,67

2,30

2,99

44,0 64,0 80,9 64,0 80,9 96,0 64,0 80,9 64,0 80,9 96,0

47,0 68,4 86,4 68,4 86,4 102,6 68,4 86,4 68,4 86,4 102,6

48,9 71,2 90,0 71,2 90,0 106,8 71,2 90,0 71,2 90,0 106,8

31,1 45,2 57,1 45,2 57,1 67,8 45,2 57,1 45,2 57,1 67,8

49,7 72,4 91,4 7,4 91,4 108,5 72,4 91,4 72,4 91,4 108,5

5,64 8,2 10,4 8,2 10,4 12,3 8,2 10,4 8,2 10,4 12,3

7,05 10,3 13,0 10,3 13,0 15,4 10,3 13,0 10,3 13,0 15,4

6,99 10,2 12,9 10,2 12,9 15,3 10,2 12,9 10,2 12,9 15,3

5,90 8,6 10,8 8,6 10,8 12,9 8,6 10,8 8,6 10,8 12,9

9,40 13,7 17,3 13,7 17,3 20,5 13,7 17,3 13,7 17,3 20,5

22,2 32,3 40,8 32,3 40,8 48,5 32,3 40,8 32,3 40,8 48,5

30,5 44,5 56,2 44,5 56,2 66,7 44,5 56,2 44,5 56,2 66,7

30,3 44,2 55,8 44,2 55,8 66,2 44,2 55,8 44,2 55,8 66,2

26,1 38,0 48,0 38,0 48,0 57,0 38,0 48,0 38,0 48,0 57,0

33,9 49,4 62,4 49,4 62,4 74,1 49,9 62,4 49,4 62,4 74,1

168,5

180,0

187,4

119,0

190,4

21,6

27,0

26,8

22,6

36,0

85,0

117,0

116,2

100,0

130,0

168,5

180,0

187,4

119,0

190,4

21,6

27,0

26,8

22,6

36,0

85,0

117,0

116,2

100,0

130,0

Refrigerant flow capacity referred to the following operating conditions: Evaporating temperature: + 4 C Condensing temperature: + 38 C Pressure drop: 0,15 bar

Particularly for hot gas: Suction temperature: + 18 C Pressure drop: 1 bar

42

www.castel.it

SOLENOID VALVES

TABLE 4: General Characteristics of NO valves (normally open)


Connections Coil Type Catalogue Number ODS SAE Flare 3/8" 1/2" 5/8" 5/8" HM3 (D.C.) 3/4" 5/8" 3/4" [in.] 3/8" 1/2" 5/8" 5/8" 3/4" 7/8" 5/8" 3/4" 7/8" 1.1/8" 1.1/8" 1.3/8" [mm] 10 12 16 16 22 16 22 35 25,5 25 27 16,5 12,5 2,20 2,61 2,20 2,61 3,80 4,80 3,80 4,80 5,70 3,80 4,80 3,80 4,80 5,70 10 10 16 Piston Pilot Operated 0,07 +110 (2) Diaphragm Pilot operated 0,05 +105 (1) Piston Pilot Operated +110 (2) Diaphragm Pilot operated 0,05 21 +105 (1) 7 0,80 Seat size Kv Factor nominal [m3/h] [mm] Operating Principles Opening Pressure Differential [bar] min OPD TS [C] PS [bar] min. MOPD max. Risk Category according to PED

1164/3 1168/3 1168/M10 1170/4 1170/5 1178/M12 1178/4 1178/5 1150/5 1150/6 1158/5 1158/6 1158/7 1190/5 1190/6 1198/5 1198/6 1198/7 1178/9 1198/9 1178/11

R R R R R R R R R R R R R R R R R R R R R

0,07 19

35

32

Art. 3.3

(1) Temperature peaks of 120 C are allowed during defrosting. (2) Temperature peaks of 130 C are allowed during defrosting.
R

Available on request.

www.castel.it

43

SOLENOID VALVES FOR REFRIGERATING SYSTEMS

L2

L2

H2

H1

H3

H1

H2

L1

1164/3

L1

1168/3 1168/M10

L2

L2

H2

H1

H1

H2

H3

L1

1170/4 1170/5

L1

L2

L2

H3

1150/5 1150/6 1190/5 1190/6

H2

H3 1178/M12 1178/4 1178/5

H3

L1

L L2 L2

H2

H3

1158/5 1158/6 1158/7 1198/5 1198/6 1198/7

H2

H1

H1

H1

H2

H1

L1 L1 1178/9 1198/9 1178/11


Connectors and coils are not included in the boxes and have to be ordered separately.

44

H3

www.castel.it

H3

SOLENOID VALVES

TABLE 5: Dimensions and Weights of NO valves with 9120 coil


Dimensions [mm] Catalogue Number Weight [g] H1 H2 H3 L1 L2 Q

1164/3 1168/3 1168/M10 1170/4 1170/5 1178/M12 1178/4 1178/5 1150/5 1150/6 1158/5 1158/6 1158/7 1190/5 1190/6 1198/5 1198/6 1198/7 1178/9 1198/9 1178/11 120 162 177 101 132 143 72 99 110 111 83 50 126 98 70 96 80 47 87 74,5 40

68 111 111 100 106 127 127 175 120 124 175 175 180 120 124 175 175 180 250 235 278 80 68 68 57 64 45

705 705 700 1015 1060 995 985 1080 1462 1792 1422 1612 1597 1340 1670 1300 1490 1475 2870 2355 3015

TABLE 6: Refrigerant Flow Capacity of NO valves


Refrigerant Flow Capacity [kW] Catalogue Number R134a 1164/3 1168/3 1168/M10 1170/4 1170/5 1178/M12 1178/4 1178/5 1150/5 1150/6 1158/5 1158/6 1158/7 1190/5 1190/6 1198/5 1198/6 1198/7 1178/9 1198/9 1178/11 37,1 44,0 37,1 44,0 64,0 80,9 64,0 80,9 96,0 64,0 80,9 64,0 80,9 96,0 168,5 168,5 269,6 39,6 47,0 39,6 47,0 68,4 86,4 68,4 86,4 102,6 68,4 86,4 68,4 86,4 102,6 180,0 180,0 288,0 41,2 48,9 41,2 48,9 71,2 90,0 71,2 90,0 106,8 71,2 90,0 71,2 90,0 106,8 187,4 187,4 299,8 26,2 31,1 26,2 31,1 45,2 57,1 45,2 57,1 67,8 45,2 57,1 45,2 57,1 67,8 119,0 119,0 190,4 4,75 5,64 4,75 5,64 8,2 10,4 8,2 10,4 12,3 8,2 10,4 8,2 10,4 12,3 21,6 21,6 34,6 5,94 7,05 5,94 7,05 10,3 13,0 10,3 13,0 15,4 10,3 13,0 10,3 13,0 15,4 27,0 27,0 43,2 5,90 6,99 5,90 6,99 10,2 12,9 10,2 12,9 15,3 10,2 12,9 10,2 12,9 15,3 26,8 26,8 42,9 4,97 5,90 4,97 5,90 8,6 10,8 8,6 10,8 12,9 8,6 10,8 8,6 10,8 12,9 22,6 22,6 36,2 18,7 22,2 18,7 22,2 32,3 40,8 32,3 40,8 48,5 32,3 40,8 32,3 40,8 48,5 85,0 85,0 136,0 25,7 30,5 25,7 30,5 44,5 56,2 44,5 56,2 66,7 44,5 56,2 44,5 56,2 66,7 117,0 117,0 187,2 25,6 30,3 25,6 30,3 44,2 55,8 44,2 55,8 66,2 44,2 55,8 44,2 55,8 66,2 116,2 116,2 185,9 22,0 26,1 22,0 26,1 38,0 48,0 38,0 48,0 57,0 38,0 48,0 38,0 48,0 57,0 100,0 100,0 160,0 13,5 14,4 15,0 9,5 1,73 2,16 2,14 1,81 6,8 9,4 9,3 8,0 R22 Liquid R407C R404A R134a R22 Vapour R407C R404A R134a R22 Hot Gas R407C R404A

Refrigerant flow capacity referred to the following operating conditions: Evaporating temperature: + 4 C Condensing temperature: + 38 C Pressure drop: 0,15 bar

Particularly for hot gas: Suction temperature: + 18 C Pressure drop: 1 bar

www.castel.it

45

COILS
APPLICATION For the normally closed solenoid valves, previously shown in this Handbook, Castel puts the following types of coils at disposal of its own customers: coils series HM2, only for A.C. (catalogue numbers 9100 - 9105). coils series CM2, only for A.C. (catalogue number 9110); coils series HM3,either for A.C. or for D.C. (catalogue number 9120). coils series HM4, only for A.C. (catalogue number 9160). For the normally open solenoid valves, always shown in this Handbook, the customers selection must compulsorily apply to the coils series HM3 D.C. For applications of the NO solenoid valves with a voltage supply of 220 VAC, Castel has designed a specific coil at 220 V RAC (code 9120/RD6) that must be used solely with the 220 VAC connector/rectifier circuit (code 9150/R45). For applications of the same NO valves with a voltage supply of 24 VAC, Castel suggests to the user the 24 VDC coil (code 9120/RD2) with the 24 VAC connector/rectifier circuit (code 9150/R44). CONSTRUCTION Coils HM2 (9100), CM2, HM3 and HM4 are class F in compliance with IEC 85 standard and their construction is in compliance with EN 60730-1 and EN 60730-2-8 standards. The windings are made with copper wire, insulation class H 180 C, in compliance with IEC 85 standard. The outer casing is provided with dielectric and waterproof resins that assure a reinforced insulation making the coils suitable for all assemblies. Coils HM2 (9105) are class F, with UL approved EIS (Electrical Insulation System), and their construction is in compliance with UL 429 Standards. Protection against electric contacts is class I. Therefore, for safety purposes, coils must be effectively connected to an earthing system. Rubber gaskets on the upper and lower ends of coil ensure moisture protection of winding. Coils HM2 and HM3 may be joined to all connectors produced by Castel except type 9155/R01; protection degree guaranteed by this system, coil (HM2, HM3) + connector, is IP65 according to EN 60529. Coils HM4 must be used with connector type 9155/R01; protection degree guaranteed by this other system, coil HM4 + connector 9155/R01, is IP65/IP68 according to EN 60529. Coils HM4 can be used with connectors series 9150 and 9900 too; protection degree guaranteed by this system is IP65. Either the terminals of coils series HM2 and HM3 or the ones of coils series HM4 consist of two Faston line connections plus one Faston earthing connection. Coil type CM2 has a pre-assembled cable (length 1 meter). The coils are designed for continuous use. The solid construction of these coils is suitable for heavy-duty applications in refrigerant systems. The maximum ambient temperature for all coils is 50 C. ELECTRIC TYPE APPROVAL HM2 (9100) and CM2 coils, 220/230V50/60Hz and 240V-50/60Hz, are approved by the German registration body VDE. All HM2 coils series 9105 are approved by Underwriters Laboratories Inc of the United States. Moreover either coils types HM2, CM2 and HM4 (110 VAC, 220/230 VAC and 240 VAC) or coils type HM3 (220/230 VAC) are manufactured according to Low Voltage Directives EC 73/23, EC 93/68 and to EMC Directives EC 89/336, EC 92/31, EC 93/68.

46

www.castel.it

SOLENOID VALVES

TABLE 1: General Characteristics of coils

Coil Type

Catalogue Number

Voltage [V]

Voltage tollerance [%]

Frequecy [Hz]

Connections

Degree of protection

9100/RA2 9100/RA4 HM2 9100/RA6 9100/RA7 9100/RA8 HM2 Recognized File number E243604 9105/RA2 9105/RA4 9105/RA6 9105/RA7 9110/RA2 CM2 9110/RA4 9110/RA6 9110/RA7 9120/RA6 9120/RD1 HM3 9120/RD2 9120/RD4 9120/RD6 9160/RA2 HM4 9160/RA4 9160/RA6 9160/RA7

24 A.C. 110 A.C. 220/230 A.C. 240 A.C. 380 A.C. 24 A.C. 110/120 A.C. 220/230 A.C. 240 A.C. 24 A.C. 110 A.C. 220/230 A.C. 240 A.C. 220/230 A.C. 12 D.C. 24 D.C. 48 D.C. 220 RAC 24 A.C. 110 A.C. 220/230 A.C. 240 A.C.

+10 / -10 +6 / -10 +10 / -10 +10 / -10 +6 / -10 +10 / -10 +10 / -10 +6 / -10 +10 / -10 +6 / -10 50 / 60 Junction box +10 / -5 DIN 43650 50 / 60 60 Junction box DIN 43650 50 / 60 Junction box DIN 43650

IP65 EN 60529 (with junction box)

IP65 EN 60529 (with junction box)

Three wire cable

IP65 EN 60529

IP65 EN 60529 (with junction box) Junction box DIN 43650 or Connector 9155/R01 (1) IP65 EN 60529 (with junction box) IP65/IP68 EN 60529 (with connector)

+10 / -10 +6 / -10 +10 / -10 50 / 60

(1) Coil HM4 can also be coupled to connectors series 9150 and 990, achieving a degree of protection IP65, the versatile degree of protection (IP65/IP68) is achieved coupling coil H4 with four screws connector 9155/RO1.

L2

HM2

L1

CM2

L1

L2

www.castel.it

47

TABLE 2: Coils Consumptions


Consumptions at 20 C [mA] Coil Type Catalogue Number 50 [Hz] 9100/RA2 9100/RA4 HM2 9100/RA6 9100/RA7 9100/RA8 HM2 9105/RA2 9105/RA4 Recognized 9105/RA6 9105/RA7 9110/RA2 CM2 9110/RA4 9110/RA6 9110/RA7 9120/RA6 9120/RD1 HM3 9120/RD2 9120/RD4 9120/RD6 9160/RA2 HM4 9160/RA4 9160/RA6 9160/RA7 1490 330 162 147 1320 300 142 130 920 230 120 100 190 920 230 120 100 58 Start 60 [Hz] 825 205 105 87 51 825 205 105 87 825 205 105 87 160 1720 900 460 93 700 156 76 70 530 118 57 53 63 41 35 220 527 128 68 54 110 _ D.C. 50 [Hz] 527 128 68 54 32 Working 60 [Hz] 420 114 58 43 23 420 114 58 43 420 114 58 43 80 1720 900 460 93 82 61 35 470 66,5 34 35 230 57,5 34 35 165 _ 57,5 34 35 165 D.C. L1 Dimensions [mm]

Weight [g] H

L2

L2

HM3 L1

HM4

L1

48

www.castel.it

L2

CONNECTORS
The junction boxes 9150, DIN 43650 standardized, represent an effective system for the connection of the coil to the supply circuit, thus ensuring safety also in the presence of moisture. These junction boxes, according to assembly requirements, allow choosing the position of outer casing compared to inner terminal block. The clamping screw of casing may be PG9 or PG11, which are respectively suitable for cables with an external diameter of 6 8 or 8 10 mm. Cables sized 3 x 0,75 mm2 are to be preferred. The junction box type 9900 is available with cabled core of different length. In this case, it is not possible to change the position of casing compared to terminal block. Both the two types offer a protection degree IP65 against dust and water, according to EN 60529, when correctly installed with the proper gaskets, which are supplied as standard. Castel has developed a specific junction box, type 9155/R01, suitable for use on those refrigerating systems working in heavy duty environments, for example: exposition to the atmospheric conditions; rooms with high moisture degree; cyclic condensing / evaporating on the valve; cyclic icing / defrosting on the valve. This junction box, according to assembly requirements, allows choosing the side position of outer casing compared to inner terminal block; but it is not possible to point the cable upwards. The gland nut of casing is suitable to receive cables with an external diameter of 6 9 mm and is provided with a self-locking device. Cables sized 3 x 0,75 mm2 are to be preferred for this junction box too. The junction box type 9155/R01 offers a protection degree IP65/IP68 against dust and water, according to EN 60529, when correctly installed with the proper gaskets, which are supplied as standard. The junction box 9150/R44 and 9150/R45 are equipped with a full-wave bridge rectifier plus VDR for protection. The VDR device, Voltage e-Dependent-Resistor, is a special type of resistor, placed in parallel to the coil; its purpose is to protect the diodes and the coil from any excessive voltage generated within the ac supply circuit.

SOLENOID VALVES

TABLE 3: General Characteristics of connectors


Supply Voltage [V] Pg Nominal 9150/R01 9150/R02 9150/R44 9150/R45 9155/R01 9900/X66 9900/X84 R 9900/X73 9900/X55 9900/X54 Maximum 9 DIN 11 43650 IP65 EN 60529

Catalogue Number

Cable length [m]

Cable thickness [mm2]

Standard

Degree of protection

Class of insulation

24 A.C. 220 A.C.

30 A.C. 250 A.C.

1 1,5 2 3 5 3 x 0,75

IP65/IP68 EN 60529

Group C VDE 0110-1 / 89

DIN 43650

IP65 EN 60529

Available on request.

www.castel.it

49

PERMANET MAGNET
APPLICATION Castel supplies to its customers the permanent magnet code 9900/X91 for the normally closed solenoid valves, shown in this chapter. This product can be used during brazing of the valve copper connections to the plant pipes; slipping it on the armature, instead of the coil, it allows the protective gas (nitrogen) flowing and avoids any damage to the plunger gasket and to the diaphragm. CONSTRUCTION The main parts of the permanent magnet code 9900/X91 are made with the following materials: three rings of anisotropic ferrite; anodized aluminum for the body.

PERMANENT MAGNET

NC SOLENOID VALVE

SOLENOID VALVES FOR DIFFERENT FLUIDS


APPLICATIONS The solenoid valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for the applications specified in Table 1 where the different fluids are indicated with the following symbols, according to an already established code: W = Water; L = Air; B = Secondary coolants (solutions of glycol and water); O = Light oils (gas oil). In short these valves may be used: with fluids in the gaseous state proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC); with fluids in the liquid state proper to the Group I (as defined in Article 9, Section 2.1 of Directive 97/23/EC and referred to in Directive 67/548/EEC).

Connectors are not included in the boxes and have to be ordered separately.

50

www.castel.it

SOLENOID VALVES

TABELLA 1: General Characteristics


Operating Principles Coil Type Opening Pressure Differential [bar] min OPD MOPD 30 Direct Acting 0 TS [C] PS [bar] min. max. Risk Category according to PED

Catalogue Number

Main Use

FPT Connections

Seat Size nominal [mm]

Kv Factor [m3/h]

1512/01 1522/02 1522/03 1522/04 1132/03 1132/04 1132/06 1132/08 1142/010 1142/012 HM2 (A.C.) - CM2 (A.C.) HM3 (A.C.; D.C.) - HM4 (A.C.)

W.L.O.

G 1/8" G 1/4"

1,5

0,070

W.O.

G 3/8" G 1/2" G 3/8" G 1/2"

4,5

0,40

4 +105

30

2,20 5,50 6,00 19,00 21,00

W.L.O.B.

G 3/4" G 1" G 1.1/4" G 1.1/2"

20

Diaphragm Pilot Operated

12,5

2,10

0,1

17

-15

Art. 3.3

0,15

12 15

38

0,3

11

+90

OPERATION All the valves for different fluids are normally closed. NC = when the coil is de-energised the plunger stops the refrigerant flow. The valves series 1512 and 1522 are direct acting, while the valves series 1132 and 1142 are pilot operated with diaphragm. CONSTRUCTION The main parts of the valves are made with the following materials: hot forged brass EN 12420 CW 617N for body and cover; austenitic stainless steel EN 10088-2 1.4303 for enclosure where the plunger moves; ferritic stainless steel EN 10088-3 1.4105 for plunger; austenitic stainless steel EN ISO 3506 A2-70 for tightening screws between body and cover; fluorocarbon rubber (FPM) for outlet seal gaskets; fluorocarbon rubber (FPM) for seat gaskets; fluorocarbon rubber (FPM) for diaphragms. Nitril rubber (NBR) for the valves series 1142.

INSTALLATION Table 1 shows the following functional characteristics of a solenoid valve: PS; TS; Kv factor; minimum Opening Pressure Differential (minOPD), that is the minimum pressure differential between inlet and outlet at which a solenoid valve, pilot operated, can open and stay opened; maximum Opening Pressure Differential (MOPD according to ARI STANDARD 760: 2001), that is the maximum pressure differential between inlet and outlet at which a solenoid valve, pilot operated, can open. Before connecting the valve it is advisable to make sure that the piping are clean and that the flow direction in the pipe corresponds to the arrow stamped on the body of the valve. All valves can be mounted in whatever position except with the coil pointing downwards. Before connecting a valve to the electrical system, be sure that the line voltage and frequency correspond to the values marked on the coil.

www.castel.it

51

VISCOSITY The values of maximum differential pressure specified in Table 1 are suitable for fluids with maximum cinematic viscosity of 12 cSt where: 1cSt = 10-6 m2/sec. If the cinematic viscosity of the fluid under consideration is more than 12 cSt it is necessary to multiply the value of the maximum differential pressure by the following reducing factors:

LIQUIDS CAPACITY The following ratio applies: p

Q = Kv

where: Kv = Kv factor of the valve [m3/h]; Q = capacity [m3/h]; p = pressure drop through the valve [bar]; = volumic mass of the liquid [kg/dm3]. AIR CAPACITY

Viscosity cSt 12 12 30 30 45

Reducing Factor 1 0,8 0,7

Table 2 provides the values of air capacity under the following conditions: temperature at valve inlet = 20 C; discharge pressure (absolute) = 1 bar; Kv of the valve under consideration = 1 m3/h. The pressures upstream the valve specified in the table are absolute values. EXAMPLE Select the valve suitable for use with approximately 200 m3/h of air, assuming an absolute pressure of 8 bars at valve inlet ( = 7 bars of relative pressure + 1 bar) and an acceptable pressure drop across the valve of 1,5 bars. In the column of pressures upstream the valve, the value 8 is shown; where this column intersects the horizontal column relating to the pressure drop of 1,5, the value of 87 m3/h is shown. This is the capacity value of a hypothetical valve with Kv = 1 working under the above mentioned conditions. 200 / 87 = 2,29 This is the Kv value required in the case under consideration. In Table 1, select the valve with the Kv value nearest to 2,29, rounding off the value and subsequently checking that all the characteristics of the selected valve (max. opening pressure differential, temperature, connections, etc.) are suitable.

When the viscosity of the liquid is expressed as dynamic viscosity, i.e. cP, where: 1cP = 10-3 N sec/m2 the corresponding value of cinematic viscosity in cSt is obtained by the following relation: = where: = cinematic viscosity [cSt]; = dynamic viscosity [cP]; = volumic mass of the fluid at the considered temperature [kg/dm3]. Moreover, the fluid viscosity may remarkably vary according to changes in temperature. Therefore, if the temperature of the fluid does not ensure viscosity values compatible with the correct operation of the valve, the valve may not open.

52

www.castel.it

SOLENOID VALVES

TABLE 2 - Air Capacity (Kv = 1)


Capacity [m3/h] (1) Pressure drop [bar] 18 0,0025 0,005 0,010 0,015 0,025 0,05 0,10 0,15 0,25 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7 7,5 8 8,5 9 10,7 6,2 8,7 4,2 5,4 7,5 3,0 3,9 5,0 6,9 9,6 17 16 15 14 13 12 11 10 INLET PRESSURE (absolute) [bar] 9 8 7 6 5 4 3 2 1,5 1,3 1,2 1,1 1,05 1,03 1,015

1,46 1,42 1,40 1,35 2,2 2,10 2,00 1,95 1,90 3,0 3,00 2,85 2,80 2,75 3,7 3,55 3,45 3,40 3,35 4,8 4,56 4,45 4,40 6,6 6,40 6,20 9,2 8,80

17,4 15,0 12,2 10,2

23,8 21,2 18,3 14,6 12,5 11,5 11,0 33,4 30,4 27,0 23,2 18,5 15,6 13,9 82,0 80,0 77,0 74,0 72,0 69,5 66,6 63,7 60,6 57,3 54,0 50,0 46,0 41,7 36,8 31,0 24,3 19,6 115,0 111,0 108,0 104,0 100,0 96,0 92,0 88,0 83,0 78,6 73,5 68,0 62,0 55,6 48,0 39,3 27,8 138,0 134,0 130,0 125,0 120,0 115,5 110,3 105,0 99,3 93,0 87,0 80,0 72,0 63,7 53,8 41,7 157,0 152,0 147,0 142,0 136,0 130,0 124,0 118,0 111,0 96,0 96,0 88,0 78,0 68,0 55,6 173,0 167,5 161,5 155,5 149,0 142,5 135,5 128,0 120,4 112,0 103,0 89,5 82,0 69,5 186,0 180,0 174,0 167,0 160,0 152,0 144,5 136,0 127,0 118,0 108,0 96,0 83,0 198,0 191,0 184,0 176,5 168,6 160,3 151,7 142,5 132,6 122,0 110,0 97,0 208,0 200,0 193,0 184,0 176,0 167,0 157,0 147,0 136,0 124,0 111,0 216,0 208,6 200,0 191,0 182,0 172,0 161,5 150,4 138,0 125,0 224,0 215,0 206,0 195,5 186,0 176,0 164,5 152,3 139,0 230,0 221,0 211,0 201,0 190,0 178,6 166,3 152,9 236,0 226,0 215,0 204,0 192,7 180,0 166,8 240,0 230,0 218,0 206,7 194,0 180,7 244,0 233,0 220,0 208,0 194,7 246,0 234,0 222,0 208,5 249,0 236,0 222,5 250,0 236,5 250,5

(1) The table provides air capacity values in m3/h under the following conditions: temperature at value inlet: + 20C pressure at outlet (absolute): 1 bar Kv of the solenoid valve: 1 m3/h

www.castel.it

53

TABLE 3 - Dimensions and Weight (Valves with coils 9100)


Dimensions [mm] Catalogue Number Weight [g] H1 H2 H3 L1 L2 Q

1132/03 1132/04 1132/06 1132/08 1142/010 1142/012 1512/01 1522/02 1522/03 1522/04

86

70

47

75 50

45

670 635 960 670 4100 4000 310 385

101

81

52

88

57

136 69

103 57

82 34

168 44

104

104

71

59

36

51

50

370 355

With coils 9120 the dimension L2 is equal to 64 mm and the weight must be increased of 305 g.

L2

L2 L2

H2

H1 H2

H1 H2

H1

H3

1512/01 L1 L1

1522/02 1522/03 1522/04

H3

L1

1132/03 1132/04

L2 L2 Q H2

H2

H1

H3

H1

L1

1132/06 1132/08 L1

1142/010 1142/012

Connectors are not included in the boxes and have to be ordered separately.

54

www.castel.it

H3

H3

SAFETY DEVICES

55

SAFETY VALVES 3030


GENERAL DESCRIPTION Valves series 3030 are safety devices according to the definition given in Article 1, Point 2.1.3, 2nd dash of 97/23/EC Directive and are the subject of Article 3, Point 1.4 of aforesaid Directive. The valves above mentioned are standard type, unbalanced, direct-loaded safety valves. Valve opening is produced by the thrust the fluid under pressure exerts on the disc, when said thrust exceeds, under setting conditions, the opposing force of the spring acting on the disc. Valves are identified by means of: a model number formed of an alphanumerical coding that includes: in the first part the family identification (e.g. 3030/44C); in the second part the setting pressure, expressed in bars, multiplied by 10 (e.g. 140); a progressive serial number. CONSTRUCTION Body: squared, obtained through die forging and subsequent machining. It houses the following elements: the nozzle with flat sealing seat; the disc guide; the setting spring holder; the threaded seat of the setting adjusting ring nut. In the body, above the disc guide, a small pressure relief hole is provided through which the spring holder is put into contact
TABLE 1: General Characteristics of valves 3030
Catalogue Number Inlet male Outlet male 3030/44C 1/2" NPT 3/4" G 12 113 4,1 0,90 3030/66C 3/4" NPT 3/4" G 12 113 4,1 0,90 55 - 50 / + 150 8 / 50 5% of set pressure 15% of set pressure IV 3030/88C 1" NPT 1.1/4" G 19,5 298 6,8 0,83

with the atmosphere. For this reason, during relief, a gas leak occurs through this orifice. Utilized material: EN 12420-CW617N brass. Disc: obtained through bar machining and equipped with gasket, it ensures the required sealing degree on the valve seat. The gasket is made in P.T.F.E. (Polytetrafluorethylene), a material that, during valve estimated service life, maintains a good strength and does not cause the disc to stick on the seat. The disc is properly guided in the body and the guide action can never fail; there are no glands or retaining rings that hamper the movement thereof. Utilized material: EN 12164-CW614N brass. Spring: it opposes the pressure and the fluid dynamic actions and always ensures valve re-closing after pressure relief. The spring coils, when the disc has reached the lift corresponding to the state of relief at full flow rate, are spaced apart by at least half the wire diameter and, in any case, by not less than 2 mm. The disc is equipped with a mechanic lock and when it attains it, the spring set does not exceed 85% of the total set. Utilized material: DIN 17223-1 steel for springs. Setting system: hexagonal head, threaded ring nut to be screwed inside the body top by compressing the spring below. On setting completion, the position attained by the ring nut is maintained unchanged laying, in the threaded coupling, a bonding agent with high mechanic strength and low viscosity features to make penetration thereof easier. The setting system is protected against subsequent unauthorized interventions by means of a cap nut that is screwed outside the body and is sealed with lead to it.

Connections

Flow Diameter [mm] Flow Section [mm ] Lift [mm] Discharge Coefficient Kd PS [bar] TS [C] Set Pressure Range [bar] Overpressure Blowdown Risk Category according to PED
2

56

www.castel.it

SAFETY DEVICES

TABLE 2: Dimensions and Weights of valves 3030


Catalogue Number 3030/44C 3030/66C 3030/88C Dimensions [mm] Weight [g] D 38 38 50 L 38 38 56 Ch 28 28 40 H1 44 44 58 H2 115 115 158 H3 159 159 216 780 780 1960
D H2 0062 L H1 3030 H3 Ch

SCOPE Use: protection against possible overpressures of the apparatuses listed below, with regard to the operating conditions for which they have been designed: refrigerating system and heat pump components, for instance: condensers, liquid receivers, evaporators, liquid accumulators, positive displacement compressor discharge, heat exchangers, oil separators, piping (reference: EN 378-2: 2000); simple pressure vessels (reference: 87/404/ EEC Directive). Fluids: the valves can be used with: refrigerant fluids, in the physical state of gas or vapour, belonging to Group II according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27th, 1967); air and nitrogen (reference: 87/404/EEC Directive). MARKING In conformity with the provisions of Article 15 of 97/23/EC Directive, the EC marking and the identification number of the notified body involved in the production control phase are reported on the valve body. Still on the body, the following information is indicated: manufacturers mark, address and manufacture country; valve model; flow section; Kd discharge coefficient; indication of flow direction; max allowable pressure; allowable temperature range; set pressure; production date; serial number. VALVE SELECTION 97/23/EC Directive requires that pressure equipment, in which permissible limits are

reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance safety devices such as safety valves. Such devices shall prevent pressure from permanently exceeding the max allowable pressure PS of the equipment they protect. In any case, a short pressure peak limited to 10% of admissible maximum pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific sector or product standards. EN 378-2: 2000 Standard Refrigerating systems and heat pumps safety and environmental requirements Part 2: Design, construction, testing, marking and documentation, harmonized with 97/23/EC Directive, provides a general outline of the protection devices to be adopted in refrigerating systems and their features (par 7.4). It also indicates the criteria for the selection of the device suitable to the type and sizes of the system component to be protected (par. 7.4). EN 13136: 2001 Standard Refrigerating systems and heat pumps Pressure relief devices and their associated piping Methods for calculation highlights the possible causes of overpressure in a system and makes available to users the instruments for pressure relief device sizing, among which the safety valves.

www.castel.it

57

SIZING OF SAFETY VALVES DESIGNED TO DISCHARGE GAS OR VAPOUR AT CRITICAL FLOW (Ref. EN 13136: 2001) Critical flow occurs when the backpressure pb (the pressure existing immediately at the outlet of a safety valve) is below or equal to the critical pressure: for this calculation the value of k shall be as measured at 25 C. (Section 7.2.3, Standard EN 13136: 2001). Values of k and calculated values of C for some refrigerants are given in table A.1 of the aforesaid standard. Following we show the values of k and C for the more useful refrigerants.

2 k 1 pb p o k +1

[bar abs]

with: po = actual relieving pressure, upstream the safety valve; its equal to the set pressure plus overpressure. That is a pressure increase over set pressure at which the disc has its total lift. [bar abs]; k = isentropic exponent of gas or vapour, based on the actual flowing conditions at the safety valve inlet. If k is unknown or anyway difficult to establish its possible to suppose:

Refrigerant

Isentropic coefficient k 1,17 1,12 1,12 1,14 1,17 1,10

Function of Isentropic coefficient C 2,54 2,50 2,50 2,51 2,54 2,48

R22 R134a R404A R407C R410A R507

p critical = 0, 5 po

[bar abs]

A safety valve, which discharges to atmosphere, works in critical flow. The safety valves designed to discharge gas or vapour at critical flow must be sized as follow:

Calculation of minimum required discharge capacity of safety valve is closely linked to the type of system where the valve is installed, with the causes that may arouse the opening of safety valve, i.e.: external heat sources. The minimum required discharge capacity shall be determined by the following:

Qmd =

Qmd vo A c = 3, 469 C 0, 9 K d po

3600 A surf hvap

[kg/h]

[mm2] with: = density of heat flow rate, its assumed to be 10 [kW/m2]; Asurf = external surface area of the vessel [m2]; hvap = heat of vaporization of liquid at po [kJ/kg]; internal heat sources. The minimum required discharge capacity shall be determined by the following:

with: Ac = minimum flow area of safety valve [mm2]; Qmd = minimum required discharge capacity, of refrigerant, of safety valve [kg/h]; Kd = certified coefficient of discharge; po = actual relieving pressure, upstream the safety valve, see definition above [bar abs]; vo = specific volume of gas or vapour at relieving conditions po e To meaning with To fluid temperature at valve inlet, settled by the user or by the designer [m3/kg]; C = function of isentropic coefficient k calculated from:

Qmd =

3600 Qh hvap

[kg/h]

with Qh = rate of heat production [kW]. Excessive pressure cased by compressors. The minimum required discharge capacity shall be determined by the following:

2 (k 1) C = 3, 948 k k +1

( k +1)

Qmd = 60 V n 10 v

[kg/h]

58

www.castel.it

with: V = theoretical displacement of compressor [m3] n = rotational frequency of compressor [min 1] 10 = vapour density at refrigerant saturation pressure / dew point at 10 C [kg/m3]

v = volumetric efficiency estimated at suction pressure and discharge pressure equivalent to the safety valve setting.

SAFETY DEVICES

EXAMPLE OF CALCULATION OF MINIMUM REQUIRED DISCHARGE CAPACITY Qmd AND SIZING OF THE SAFETY VALVE FOR THE HIGH PRESSURE SIDE OF A REFRIGERATING SYSTEM System description Compact refrigerating system designed to make refrigerated water and consisting of: open type reciprocating compressor; water-cooled, shell-and-tube horizontally condenser with lower section of shell used as receiver; shell-and-tube horizontally liquid cooler fed with a thermostatic valve; refrigerant fluid R407C. Compressor data Bore 82,5 mm Stroke 69,8 mm Cylinder number 6 Rotational frequency 1450 rpm Clearance 4% The theoretical displacement of compressor is: Working conditions of compressor corresponding to the relieving of safety valve: Condensing temperature: + 64 C (27,25 bar abs) Evaporating temperature: + 10 C (6,33 bar abs) These conditions, settled in any case by the designer, are considered the most unfavorable for the safety valve in consequence of functional defects as: move mistake; non-working of automatic safety devices, set to operate before safety valve. It shall be excluded: closeness the refrigerating system, the presence of flammable substances in so large quantities to be able to feed a fire.; inside the vessel, the presence of a heart source. Calculation of minimum discharge capacity Prudentially leaving the vapour overheating at the outlet of the liquid cooler out of account, the volumetric efficiency of compressor is:

V=

0, 08252 0, 0698 6 = 0, 00224 [m3] 4

Maximum allowable pressure of the condenser, refrigerant side: PS = 25 bar. Set pressure of the safety valve installed on the upper shell section of condenser: pset = 25 bar Actual relieving pressure of safety valve, choosing one valve type 3030 with an overpressure of 5%:

v = 1 0, 04

p disch arg e psuction

= 1 0, 04

27, 25 = 0, 83 6, 33

p0 = pset

5 1+ + 1 = 27, 25 [bar abs] 100

and so the minimum required discharge capacity:

Qmd = 60 V n 10 v =
= 60x0,00224x1450x26,34x0,83=4260 [kg/h] with 10 = 26,34 [kg/m3], vapour density of R407C at saturation pressure / dew point at 10 C.

www.castel.it

59

Sizing of minimum flow area of the safety valve

A c = 3, 469 = 3, 469

Qmd v o = C 0, 9 K d po

4260 0, 0104 = 154 [mm2] 2, 51 0, 9 0, 83 27, 25

with: C = 2,51, corresponding to isentropic exponent k for R407C equal to 1,14, according to table A1 of standard EN 13136:2001; Kd = 0,83, certified coefficient of discharge for safety valve 3030/88; vo = 0,0104 [m3/kg], specific volume of overheating vapour upstream the safety valve during relieving. This value is referred to the following operating conditions, upstream the safety valve: pressure po = 27,25 [bar abs]; temperature To = 100 [C] (precautionary temperature, settled in any case by the designer). Conclusion: the selected safety valve is the model 3030/88 with the following characteristics: certified coefficient of discharge, Kd = 0,83; flow section, Ac = 298 [mm2]; set pressure, pset = 25 bar. In case of single-screw compressor with injection of pressurized oil, the theoretical displacement is:

Vc =

D2 L 4

[m3]

with: D = rotor diameter [m]; L = rotor length [m].

60

www.castel.it

VALVE INSTALLATION As far as the installation of safety relief valves is concerned, the fundamental points listed below shall be taken into account: safety valves shall be installed near an area of the system where vapours or gases are present and there is no fluid turbulence; the position shall be as upright as possible, with the inlet connector turned downwards; vessels, joined together with piping rightly selected by the manufacturer and without any stop valve between them, may be considered as only one vessel for the installation of a safety valve; the union between the valve and the equipment to be protected shall be as short as possible. Furthermore, its passage section shall not be narrower than the valve inlet section. In any case, EN 13136: 2001 standard states that the pressure loss between protected vessel and safety valve, at discharge capacity, shall not exceed 3% of the setting value, including any accessory mounted on the upstream line; in selecting the safety valve location, it shall be taken into account that valve operation involves the discharge of the refrigerant fluid under pressure, sometimes even at high temperature. Where the risk exists to cause direct injuries to the persons nearby, an exhaust conveying piping shall be provided, which shall be sized in such a way as not to compromise valve operation. EN 13136: 2001 standard states that this piping shall not generate, at discharge capacity, a back pressure exceeding 10% of pressure po, for standard type valves, unbalanced. To calculate the pressure loss either in the upstream line (between vessel and safety valve) or in the downstream line (between safety valve and atmosphere) refer to EN 13136: 2001 standard, Chapter 7.4. Pressure loss in the upstream line Calculation of pressure loss is given by:

with: A = flow area of safety valve [mm2]; Ain = inside area of inlet tube to valve [mm2]; Kdr = Kd x 0,9, derated coefficient of discharge; C = function of isentropic coefficient k; = addition of pressure loss coefficients n of any component and piping; The coefficients n are relevant to: pipe elements loss, as connections and bends; valves loss; loss along the pipe and are listed in EN 13136:2001 standard, Table A.4. Example: assume to install, on the condenser of the previous example, a safety valve type 3030/88, set to 25 bar, using a steel union with the following characteristics: din = 28 [mm], inside diameter; Ain = 616 [mm2], inside area; L = 60 [mm], length; flush connection to the shell of condenser, with a broken edge. From table A.4 its possible to have these data: 1 (inlet) = 0,25 2 (length) = x L/ din = 0,02 x 60/28 = 0,043 with = 0,02 for steel tube T = 1 + 2 = 0,25 + 0,043 = 0,293 Between safety valve and union its installed a shut-off valve type 3033/88 (see page 46). The main characteristics of this valve are: dR = 20 [mm], inside diameter; AR = 314 [mm2], inside area; kv = 20 [m3/h], kv factor. Pressure loss coefficient R of shut-off valve is given by:

SAFETY DEVICES

314 R = 2, 592 103 = 0, 64 20


The total pressure loss coefficient is: T + R = 0,933 We remember the main characteristics of safety valve 3030/88 and of refrigerant fluid R407C: A = 298 [mm2] Kdr = 0,83 x 0,9 =0,747 C = 2,51 Pressure loss in the upstream line is:

A pin = 0, 032 C K dr po A in

pin 298 = 0, 032 2, 51 0, 747 0, 933 = 0, 0245 po 616

www.castel.it

61

The obtained value is admissible because lower than the value of 0,03 forecast in EN 13136:2001. standard. Pressure loss in the downstream line Calculation of pressure loss is given by:
2 A 2 C K dr po 0, 064 A out = po 1

pout po

Example: assume to install a discharge pipe on safety valve type 3030/88 of the previous example, using a steel tube nominal size 2 with the following characteristics: dout = 53 [mm], inside diameter; Aout = 2206 [mm2], inside area; L = 3000 [mm], ength; pipe bend 90 with bending radius R equal to three times external diameter of tube. From table A.4 its possible to have these data: 1 (bend) = 0,25; 2 (length) = x L/ din = 0,02 x 3000/53 = 1,13 with = 0,02 for steel tube; T = 1 + 2 = 0,25 + 1,13 = 1,38. Pressure loss in the downstream line is:
2 298 2 2, 51 0, 747 27, 25 0, 064 1, 38 2206 = 27, 25 1

with: A = flow area of safety valve [mm2] Aout = inside area of outlet tube to valve [mm2] Kdr = Kd x 0,9, derated coefficient of discharge C = function of isentropic coefficient k = addition of pressure loss coefficients n of piping The coefficients n are relevant to: pipe elements loss, bends; loss along the pipe and are listed in EN 13136:2001 standard, Table A.4.

pout = 0, 075 po

The obtained value is admissible because lower than the value of 0,10 forecast in EN 13136:2001. standard.

62

www.castel.it

SAFETY VALVES 3060


In the body, above the disc guide, a small pressure relief duct is provided through which the spring holder is put into contact with the output connection. For this reason, during relief, no gas leak occurs into the atmosphere. Utilized material: EN 12420-CW617N brass. Disc: obtained through bar machining and equipped with gasket, it ensures the required sealing degree on the valve seat. The gasket is made in P.T.F.E. (Polytetrafluorethylene), a material that, during valve estimated service life, maintains a good strength and does not cause the disc to stick on the seat. The disc is properly guided in the body and the guide action can never fail; there are no glands or retaining rings that hamper the movement thereof. Utilized material: EN 12164-CW614N brass. Spring: it opposes the pressure and the fluid dynamic actions and always ensures valve re-closing after pressure relief. Utilized material: DIN 17223-1 steel for springs. Setting system: hexagonal head, threaded ring nut to be screwed inside the body top by compressing the spring below. On setting completion, the position attained by the ring nut is maintained unchanged laying, in the threaded coupling, a bonding agent with high mechanic strength and low viscosity features to make penetration thereof easier. The setting system is protected against subsequent unauthorized interventions by means of a cap nut that is screwed outside the body and is sealed to it with a punched copper rivet.

SAFETY DEVICES

GENERAL DESCRIPTION Valves series 3060 are safety devices according to the definition given in Article 1, Point 2.1.3, 2nd dash of 97/23/EC Directive and are the subject of Article 3, Point 1.4 of aforesaid Directive. The valves above mentioned are standard type, unbalanced, direct-loaded safety valves. Valve opening is produced by the thrust the fluid under pressure exerts on the disc, when said thrust exceeds, under setting conditions, the opposing force of the spring acting on the disc. Valves are identified by means of: a model number formed of an alphanumerical coding that includes: in the first part the family identification (e.g. 3060/45C); in the second part the setting pressure, expressed in bars, multiplied by 10 (e.g. 140); a progressive serial number. CONSTRUCTION Body: squared, obtained through die forging and subsequent machining. It houses the following elements: the nozzle with flat sealing seat; the disc guide; the setting spring holder; the threaded seat of the setting adjusting ring nut.

www.castel.it

63

TABLE 3: General Characteristics of valves 3060


Catalogue Number Inlet male Outlet male 3060/23C 1/4" NPT 3/8" SAE 3060/24C 1/4" NPT 1/2" SAE 7 38,5 0,63 0,69 0,63 0,69 55 - 50 / + 150 9 / 50 10% of set pressure IV 3060/33C 3/8" NPT 3/8" SAE 3060/34C 3/8" NPT 1/2" SAE 3060/45C 1/2" NPT 5/8" SAE 9,5 70,9 0,45 0,92 3060/36C 3/8" NPT 3/4" G 10,0 78,5 0,93 3060/46C 1/2" NPT 3/4" G

Connections

Flow Diameter [mm] Flow Section [mm2] Discharge Coefficient Kd PS [bar] TS [C] Set Pressure Range [bar] Overpressure Risk Category according to PED

SCOPE Use: protection against possible overpressures of the apparatuses listed below, with regard to the operating conditions for which they have been designed: refrigerating system and heat pump components, for instance: condensers, liquid receivers, evaporators, liquid accumulators, positive displacement compressor discharge, heat exchangers, oil separators, piping. (reference: EN 378-2: 2000); simple pressure vessels (reference: 87/404/ EEC Directive). Fluids: the valves can be used with: refrigerant fluids, in the physical state of gas or vapour, belonging to Group II according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27th, 1967); Air and nitrogen (reference: 87/404/EEC Directive). MARKING In conformity with the provisions of Article 15 of 97/23/EC Directive the following information are reported on the valve body: manufacturers mark, address and manufacture country; indication of flow direction; max allowable pressure; set pressure;

allowable temperature range; production date; serial number. The following data are stamped on the cap: EC marking and the identification number of the notified body involved in the production control phase; valve model; flow section; Kd discharge coefficient. VALVE SELECTION 97/23/EC Directive requires that pressure equipment, in which permissible limits are reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance safety devices such as safety valves. Such devices shall prevent pressure from permanently exceeding the max allowable pressure PS of the equipment they protect. In any case, a short pressure peak limited to 10% of admissible maximum pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific sector or product standards. EN 378-2: 2000 Standard Refrigerating systems and heat pumps safety and environmental requirements Part 2: Design, construction, testing, marking and documentation, harmonized with 97/23/EC Directive, provides a general outline of the protection devices to be adopted in refrigerating systems and their features (par 7.4). It also indicates the criteria for the

64

www.castel.it

selection of the device suitable to the type and sizes of the system component to be protected (par. 7.4). EN 13136: 2001 Standard Refrigerating systems and heat pumps Pressure relief devices and their associated piping Methods for calculation highlights the possible causes of overpressure in a system and makes available to users the instruments for pressure relief device sizing, among which the safety valves. For sizing and installation of safety valves series 3060 see the previous chapter of safety valves series 3030.
3060

SAFETY DEVICES

H2 Ch H1 L

TABLE 4: Dimensions and Weights of valves 3060


Dimensions [mm] Catalogue Number D L Ch Weight [g] H1 H2 H3

3060/23C 3060/24C 3060/33C 3060/34C 3060/45C 3060/36C 3060/46C

45 45 45 45 45 48 48

35 35 35 35 40,5 40 40

20 20 20 20 23 27 27

33,5 33,5 33,5 33,5 36,5 37 40

48,5 48,5 48,5 48,5 54,5 62,5 62,5

82 82 82 82 91 99,5 102,5

H3

200 215 215 215 290 380 390

BALL SHUT-OFF VALVES FOR SAFETY VALVES


APPLICATIONS We would like to remember to our customer that the running of pressure equipments and pressure assemblies is excluded by the scope of Directive 97/23/EC but its regulated in compliance with national regulations of Member States of European Communities. We think that these regulations, actually on updating with the Competent Bodies of all the states to avoid conflicts with the ESR of PED, could provide for periodical checks on the pressure equipments and assemblies. Any intervention for periodic checking or replacement of an installed safety valve becomes very difficult if the protected vessel is not equipped with a shut-off valve. The shut-off valves series 3033 and 3063, installed between vessel and safety valve, allow to remove the valve for periodic checking or replacement without blowing off all the refrigerant from a section of the system. These valves can be used with the same fluids foreseen for safety valves series 3030 and 3060, in particularly: refrigerant fluids, in the physical state of gas or vapour, belonging to Group II according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27th, 1967); air and nitrogen (reference: 87/404/EEC Directive).

www.castel.it

65

CONSTRUCTION Castel supplies to its customers the valves series 3033 and 3063 in open position and the ball spindle is protected by means of a cap screwed to the body and sealed with lead to it. Any closing intervention on the valve forcedly causes the tampering of the seal and then these interventions shall be performed exclusively by: staff authorized to work on the system; public servant of a Competent Body. These persons will be responsible for the next valve reopening and the new cap sealing with their own lead. The main parts of these valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; hot forged brass EN 12420 CW 617N, chromium plated, for ball; steel, with proper surface protection, for the spindle; P.T.F.E. for seat ball gaskets; chloroprene rubber (CR) for outlet seal gaskets; glass reinforced PBT for cap that covers the spindle.

SEAL

VALVE 3030/..

H3

BALL VALVE 3033/.. SEAL

H2 H1

D A L C

TABLE 5: General Characteristics, Dimensions and Weights of valves 3033, 3063


TS [C] Catalogue Number Designed for valve Kv Factor [m3/h] PS [bar] min max D A C L H1 H2 H3 Dimensions [mm] Weight [g] Risk Category according to PED

3063/44

3060/45C 3060/46C 3030/44C

10

1/2" NPT

78

58

35

82,5

162

350

3033/44

10

-50

+150

55

13

101

73

59

100

178

710

Art. 3.3

3033/88

3030/88C

20

20

1" NPT

107

77

72

123

323

1070

CHANGEOVER DEVICES FOR SAFETY VALVES


APPLICATIONS The changeover device type 3032 is a service valve for dual pressure relief valves that allows using one valve while isolating the other from the system. This device allows the user to work on the isolated valve, for periodic checking or replacement, while the system is completely operative and the other valve is in service. N.B.: each safety valve placed on a changeover device must have sufficient capacity to protect the vessel alone. Valve type 3032/44 is supplied with: two female threaded connections 1/2 NPT with swivel nut, code Castel 3039/4; two O-Ring. These components ensure the perfect alignment of two safety valves 3060/45.

66

www.castel.it

The valves series 3032 can be used with the same fluids foreseen for safety valves series 3030 and 3060, in particularly: refrigerant fluids, in the physical state of gas or vapour, belonging to Group II according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27th, 1967); air and nitrogen (reference: 87/404/EEC Directive). CONSTRUCTION The valve 3032 is designed so that it is never possible to close off both ports at the same time, excluding all the two safety valves. Under working conditions, the shutter must be clamped against one of the two seats of the valve, front port or back port, in order to ensure always full discharge to the corresponding safety valve. Intermediate positions of the shutter are not

acceptable in order not to affect the operation of both safety valves. The valve ensures a pressure drop perfectly compatible with the safety valve operation under conditions of discharge of saturated vapour as well as overheated vapour. The main parts of these valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; chloroprene rubber (CR) for outlet seal gaskets; glass reinforced PBT for cap that covers the spindle.

SAFETY DEVICES

TABLE 6: General Characteristics, Dimensions and Weights of valves 3032


TS [C] Catalogue Number Designed for valve Kv Factor [m3/h] PS [bar] min max D A B H1 H2 L1 L2 L3 Dimensions [mm] Weight [g] Risk Category according to PED

3032/44

3060/45C 3060/46C 3030/44C

3,3

13

1/2" 1/2" NPT NPT 3/4" 1/2" NPT NPT 3/4" 3/4" NPT NPT 1 1/4" 1

117

45

31

91

48

775

3032/64

9,0 -50 +150 55

17,5

95

52

48

133

80

1750 Art. 3.3

3032/66

3030/66C

9,0

17,5

95

52

48

133

80

1750

3032/108 3030/88C

18

30

NPT NPT

123

74

66

185

110

3200

L3

B 3039/4

B L3

GASKET 3032/44 B H1
B A

3032/64 3032/66 3032/108 A


B
CHIUSO-CLOSED

CHIUSO-CLOSED

H1

H2

H2

D A L1 L1

D A L2

www.castel.it

67

SAFETY VALVES UNIONS


Unions series 3035 allow assembling safety valves series 3030 and 3060 or shut-off valves series 3032, 3033 and 3063 close to the pressure equipments to protect, set up in a refrigerating system. These unions are designed for installations according to the following two ways: Make a copper tube jointing the pressure equipment to the union, fit the end of this tube into the solder connection of the union and then make a capillary brazing. Drill the inner/outer pipe close to the pressure equipment (if possible make a collar on the pipe), put the end of the union into this drill and then make a braze welding. The unions series 3035 are machined by brass bar EN 12164-CW614N.

3060

3035

Copper pipe

TABLE 7: General Characteristics, Dimensions and Weights of unions 3035


Connections Catalogue Number NPT PS [bar] ODS [mm] 12 18 22 28 35 55 D L Ch Dimensions [mm] Weight [g]

Ch. L

3035/2 3035/3

1/4 3/8 1/2 3/4 1

18 22 28 35 42

33 36,5 44 51 72

21 27 32 40 45

58 90,5 165 255 364

3035/4 3035/6 3035/8

68

www.castel.it

FUSIBLE PLUGS
GENERAL DESCRIPTION Fusible plugs series 3080/.C and 3082/.C are safety devices according to the definition given in Article 1, Point 2.1.3, 2nd dash of 97/23/EC Directive and are the subject of Article 3, Point 1.4 of aforesaid Directive. According to the definition given in Point 3.6.4 of EN 378-1 : 2000 Standard, fusible plug is a device containing material that melts at a predetermined temperature and thereby relieving the pressure. Castel has resolved to classify fusible plugs series 3080/.C and 3082/.C in the Category of Risk I therefore fixing their use, as protection devices, on specific pressure equipments, proper to the same Category of Risk I, in compliance with Annex II, Point 2, of 97/23/EC Directive. In consequence of this choice, fusible plugs series 3080/.C and 3082/.C cannot be used, as sole protection devices, on pressure equipments proper to Categories of Risk higher than first. CONSTRUCTION The body of the fusible plug is an NPT plug drilled with a taper hole. A predetermined quantity of fusible alloy, with checked melting point, is poured inside this hole. The parts of the fusible plugs are made with the following materials: Brass EN 12164 CW 614N, hot tinned, for the plug. Eutectic alloy with several components, cadmium and lead free, for the fusible material. SCOPE Use: the fusible plugs are basically used to protect the components in a refrigerating system or heat pump against possible overpressures, with regard to the operating conditions for which they have been designed, in case of an excessive external heat source, such as fire. Fluids: the fusible plugs can be used with refrigerant fluids belonging to Group 2 according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27th, 1967). MARKING In conformity with the provisions of Article 15 of 97/23/EC Directive and of Point 7.3.3 of EN 378-2 : 2000 Standard the following data are reported on the hexagonal nut: EC marking; Manufacturer's logo; Max allowable pressure PS; Melting point. INSTALLATION If a fusible plug is mounted on a pressure vessel or any other part which it protect it shall be placed in a section where superheated refrigerant would not affect its correct function. Fusible plug shall not be covered by thermal insulation. Discharge from fusible plugs shall take place so that persons and property are not endangered by the released refrigerant. EN 378-2 : 2000 Standard, harmonized with the 97/23/EC Directive, establishes that a fusible plug shall not be used as the sole pressure relief device between a refrigerant containing component and the atmosphere for systems with a refrigerant charge larger than: 2,5 kg of group L1 refrigerant (ex. R22; R134a; R404A; R407C; R410A; R507). 1,5 kg of group L2 refrigerant. 1,0 kg of group L3 refrigerant. FUSIBLE PLUG SELECTION 97/23/EC Directive requires that pressure equipment, in which permissible limits are reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance safety devices such as fusible plugs. Such devices shall prevent pressure from permanently exceeding the max allowable pressure PS of the equipment they protect. In any case, a short pressure peak limited to 10% of admissible maximum pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific sector or product standards. EN 378-2 : 2000 Standard Refrigerating systems and heat pumps safety and environmental requirements Part 2: Design, construction, testing, marking and

www.castel.it

69

SAFETY DEVICES

documentation provides a general outline of the protection devices to be adopted in refrigerating systems and their features (par 7.4). It also indicates the criteria for the selection of the device suitable to the type and sizes of the system component to be protected (par. 7.4). EN 13136 : 2001 Standard Refrigerating systems and heat pumps Pressure relief devices and their associated piping Methods for calculation, harmonized with 97/23/EC Directive, highlights the possible causes of overpressure in a system and makes available to users the instruments for pressure relief device sizing, among which the fusible plugs. SIZING OF FUSIBLE PLUGS (REF. EN 13136 : 2001) As the fusible plugs discharge to atmosphere, they always work in critical flow (to know the definition of critical flow, see the chapter of safety valves series 3030). The fusible plugs must be sized as follow:

C = function of isentropic coefficient k (as measured at 25 C , see Section 7.2.3 , EN 13136 : 2001 Standard) calculated from:

C = 3, 948 k

( k+1) 2 ( k1)

k +1

To find the values of k and C for the more useful refrigerants, see the chapter of safety valves series 3030 Calculation of minimum required discharge capacity of fusible plug is closely linked to the main cause that may arouse the opening of fusible plug, which is the external heat sources. The minimum required discharge capacity shall be determined by the following:

Q md =

3600 Asurf hvap

[kg/h]

Ac = 3, 469

Q md v o [mm2] C K dr po

with = density of heat flow rate, its assumed to be 10 [kW/m2] Asurf = external surface area of the vessel [m2] hvap = heat of vaporization of liquid at po [kJ/kg] EN 13136 : 2001 Standard also establishes that the following values for Kdr shall be the maximum used depending on how the pipe between the vessel and the fusible plug is mounted on the vessel: flush or flared connection: Kdr = 0,70 inserted connection: Kdr = 0,55

with: Ac = minimum flow area of fusible plug [mm2] Qmd = minimum required discharge capacity, of refrigerant, of fusible plug [kg/h] Kdr =derated coefficient of discharge of fusible plug, equal to 0,9 x Kd po = pressure upstream the fusible plug, inside the equipment to be protected [bar abs] vo = specific volume of gas or vapour at relieving conditions po e To , [m3/kg] (To is the fluid temperature at plug inlet, settled by the user or by the designer)

70

www.castel.it

SAFETY DEVICES

TABLE 8: General Characteristics, Dimensions and Weights of fusible plugs 3080 and 3082
Hexagonal Key Wrench Torque min/max [Nm] Risk Category Weight according to [g] PED

Catalogue Number

NPT Flow Diameter Flow Section Connections [mm] [mm2]

Kd

PS [bar]

Melting Point [C]

3080/2C 3080/3C 3080/4C 3082/2C 3082/3C 3082/4C

1/4" 3/8" 1/2" 1/4" 3/8" 1/2"

5,7 8,5 9,3 5,7 8,5 9,3

25,5 56,7 67,9 25,5 56,7 67,9 0,91 30 138 42 79

17 22 17 22

10 / 15 14 / 20 21 / 30 10 / 15 14 / 20 21 / 30

23 39 76 23 39 76 I

www.castel.it

71

CHECK VALVES

73

CHECK VALVES
APPLICATIONS The check valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). For heavy duty, about the operation temperature, for example installation on the discharge line close to the compressor, Castel has developed three new series of valves, types 3122, 3142 and 3182, equipped with special gasket for high temperature, between the body and its cover. MATERIALS The main parts of the valves are made with the following materials: hot forged brass EN 12420 CW 617N for body and cover; copper tube EN 12735-1 Cu-DHP for solder connections; austenitic stainless steel AISI 302 for the spring; chloroprene rubber (CR) for outlet seal gaskets. Metal-rubber laminated gaskets for the valves series 3122, 3142 and 3182; P.T.F.E. for seat gasket. INSTALLATION The valves can be installed in any section of a refrigerating system, where it is necessary to avoid an inversion of the refrigerating flow, in compliance with the limits and capacities indicated in table 3. Table 1 shows the following functional characteristics of a check valve: PS; TS; Kv factor; minimum opening pressure differential, that is the minimum pressure differential between inlet and outlet at which a check valve can open and stay opened. Before connecting the valve to the pipe it is advisable to make sure that the refrigerating system is clean. In fact the valves with P.T.F.E. gaskets are particularly sensitive to dirt and debris. Furthermore check that the flow direction in the pipe corresponds to the arrow stamped on the body of the valve. The allowed operating positions are: types 3122 and 3142 with horizontal axis and valve cover facing upward; types 3182 with inlet facing down and the valve cover facing upward; types 3110, 3130 and 3131, preferably with vertical axis and arrow upward. Sloping axis, up to horizontal position, are tolerable. The brazing of valves with solder connections should be carried out with care, using a low melting point filler material. Before starting to braze, its necessary to disassemble the valves series 3122, while this operation is not necessary with solder connection valves. In any case, its important to avoid direct contact between the torch flame and the valve body, which could be damaged and compromise the proper functioning of the valve.

74

www.castel.it

CHECK VALVES

TABLE 1: General Characteristics


Connections Catalogue Number ODS SAE Flare 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 5/8" 7/8" 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" 2.5/8" 3.1/8" 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" 22 28 35 42 54 10 12 16 18 22 10 12 16 22 22 28 35 42 54 22 28 35 42 54 8,5 9,5 19,0 37,0 45,4 Art. 3.3 40,0 0,1 35 +160 1,6 1,8 3,3 6,6 8,8 15,2 25,0 I 0,3 3,3 40 +105 45 Art. 3.3 1.1/8" 1.3/8" 1.3/8" 1.5/8" 2" 2" 28 35 35 [in.] [mm] [in.] ODM [mm] 0,4 1,6 Kv Factor [m3/h] Minimum Opening Pressure Differential [bar] TS [C] PS [bar] min. max. Risk Category according toPED

3110/2 3110/3 3110/4 3110/5 3110/6 3122/M22 3122/7 3122/M28 3122/9 3122/11 3122/13 3122/M42 3122/17 3130/2 3130/3 3130/M10 3130/M12 3130/4 3130/5 3130/M18 3130/6 3130/7 3131/M10 3131/M12 3131/5 3131/7 3142/7 3142/M28 3142/9 3142/11 3142/13 3142/M42 3142/17 3142/21 3142/25 3182/7 3182/M28 3182/9 3182/11 3182/13 3182/M42 3182/17

40

+105

3,3 Art. 3.3 6,6

8,8 15,2 25,0 40,0 0,5 1,6 0,1 35 +160

1,8

www.castel.it

75

TABLE 2: Dimensions and Weights


Dimensions [mm] Catalogue Number H Weight [g] H1 L L1 Q D Ch

3110/2 3110/3 3110/4 3110/5 3110/6 3122/M22 3122/7 3122/M28 3122/9 3122/11 3122/13 3122/M42 3122/17 3130/2 3130/3 3130/M10 3130/M12 3130/4 3130/5 3130/M18 3130/6 3130/7 3131/M10 3131/M12 3131/5 3131/7 3142/7 3142/M28 3142/9 3142/11 3142/13 3142/M42 3142/17 3142/21 3142/25 3182/7 3182/M28 3182/9 3182/11 3182/13 3182/M42 3182/17

84 84,5 83 109 108 37 27 23 20

150 155 165 440 460 1180

84,5

28,5

100

60 1090

101,5 125,5 142 144

34 37 42,5

118 141 173

68 88 104

1625 2955 4225 170

148

23

20

185

183

37

28

450

198 148 183 198 170 84,5 28,5 201 232 256 60 1320 23 20 185

37

28

450

101,5 125,5

34 37

68 88

1885 3315

142

42,5

285 329

104

4875 5690 1280

151

95

130,5

100,5

60

1295 1855 3255 4780

177

109,5

150

116

68

221

123,5

195,5

143,5

104

76

www.castel.it

CHECK VALVES

Ch H H H1 M10 20 3110 D 3122 L 3130 3131 D L L1 Q Q H H H1 M10 20 L 3182 3142

H1

www.castel.it

77

TABLE 3: Refrigerant Flow Capacity


Refrigerant Flow Capacity [kW] Catalogue Number R134a 3110/2 3110/3 3110/4 3110/5 3110/6 3122/M22 3122/7 3122/M28 3122/9 3122/11 3122/13 3122/M42 3122/17 3130/2 3130/3 3130/M10 3130/M12 3130/4 3130/5 3130/M18 3130/6 3130/7 3131/M10 3131/M12 3131/5 3131/7 3142/7 3142/M28 3142/9 3142/11 3142/13 3142/M42 3142/17 3142/21 3142/25 3182/7 3182/M28 3182/9 3182/11 3182/13 3182/M42 3182/17 143,2 160,1 320,2 623,5 765,0 153,0 171,0 342,0 666,0 817,2 159,3 178,0 356,1 693,4 850,8 101,2 113,1 226,1 440,3 540,3 161,8 180,9 361,8 704,5 864,4 18,4 20,5 41,0 79,9 98,1 23,0 25,7 51,3 99,9 122,6 22,8 25,5 50,9 99,2 121,7 19,2 21,5 42,9 83,6 102,6 30,6 34,2 68,4 133,2 163,4 72,3 80,8 161,5 314,5 385,9 99,5 111,2 222,3 432,9 531,2 98,8 110,4 220,8 429,9 527,5 85,0 95,0 190,0 370,0 454,0 110,5 123,5 247,0 481,0 590,2 674,0 720,0 749,6 476,0 761,6 86,4 108,0 107,2 90,4 144,0 340,0 468,0 464,8 400,0 520,0 27,0 30,3 55,6 111,2 148,3 256,1 421,3 28,8 32,4 59,4 118,8 158,4 273,6 450,0 30,0 33,7 61,8 123,7 164,9 284,8 468,5 19,0 21,4 39,3 78,5 104,7 180,9 297,5 30,5 34,3 62,8 125,7 167,6 289,4 476,0 3,5 3,9 7,1 14,3 19,0 32,8 54,0 4,3 4,9 8,9 17,8 23,8 41,0 67,5 4,3 4,8 8,8 17,7 23,6 40,7 67,0 3,6 4,1 7,5 14,9 19,9 34,4 56,5 5,8 6,5 11,9 23,8 31,7 54,7 90,0 13,6 15,3 28,1 56,1 74,8 129,2 212,5 18,7 21,1 38,6 77,2 103,0 177,8 292,5 18,6 20,9 38,3 76,7 102,3 176,6 290,5 16,0 18,0 33,0 66,0 88,0 152,0 250,0 20,8 23,4 42,9 85,8 114,4 197,6 325,0 55,6 59,4 61,8 39,3 62,8 7,1 8,9 8,8 7,5 11,9 28,1 38,6 38,3 33,0 42,9 6,7 27,0 30,3 55,6 R22 7,2 28,8 32,4 59,4 Liquid R407C 7,5 30,0 33,7 61,8 R404A 4,8 19,0 21,4 39,3 R410A 7,6 30,5 34,3 62,8 R134a 0,9 3,5 3,9 7,1 R22 1,1 4,3 4,9 8,9 Vapour R407C 1,1 4,3 4,8 8,8 R404A 0,9 3,6 4,1 7,5 R410A 1,4 5,8 6,5 11,9 R134a 3,4 13,6 15,3 28,1 R22 4,7 18,7 21,1 38,6 Hot Gas R407C 4,6 18,6 20,9 38,3 R404A 4,0 16,0 18,0 33,0 R410A 5,2 20,8 23,4 42,9

111,2

118,8

123,7

78,5

125,7

14,3

17,8

17,7

14,9

23,8

56,1

77,2

76,7

66,0

85,8

148,3 256,1 421,3 674,0 8,4 27,0

158,4 273,6 450,0 720,0 9,0 28,8

164,9 284,8 468,5 749,6 9,4 30,0

104,7 180,9 297,5 476,0 6,0 19,0

167,6 289,4 476,0 761,6 9,5 30,5

19,0 32,8 54,0 86,4 1,1 3,5

23,8 41,0 67,5 108,0 1,4 4,3

23,6 40,7 67,0 107,2 1,3 4,3

19,9 34,4 56,5 90,4 1,1 3,6

31,7 54,7 90,0 144,0 1,8 5,8

74,8 129,2 212,5 340,0 4,3 13,6

103,0 177,8 292,5 468,0 5,9 18,7

102,3 176,6 290,5 464,8 5,8 18,6

88,0 152,0 250,0 400,0 5,0 16,0

114,4 197,6 325,0 520,0 6,5 20,8

30,3

32,4

33,7

21,4

34,3

3,9

4,9

4,8

4,1

6,5

15,3

21,1

20,9

18,0

23,4

Refrigerant flow capacity referred to the following operating conditions: Evaporating temperature: + 4 C Condensing temperature: + 38 C Pressure drop: 0,15 bar

Particularly for hot gas: Suction temperature: + 18 C Pressure drop: 1 bar

78

www.castel.it

WATER REGULATING VALVES

79

WATER REGULATING VALVES


OPERATIONS The moving elements of the valve are a metal bellows and a shutter. The thrust of the refrigerant condensation pressure outside the bellows favours the opening of the valve and the thrust of the adjustment spring on the shutter acts in the opposite sense. Given a specific setting of the spring, the valve progressively opens in line with the increasing condensation pressure, and closes when this pressure decreases. When the compressor stops, the valve closes: water is no longer fed into the condenser, this being a notable operating economy. Valve setting is performed in the works at a pressure of 7,5 bars. Setting is modified by turning the control screw. Three reference notches, marked with letters A, B, and C, are present on the spring cover. Each notch is equivalent to a different spring setting. The notches are referred to the following condensation pressures: letter A equivalent to about 7.5 bar (valid for R12 and R134a at a temperature of condensation of 30 C); letter B equivalent to about 14 bar (valid for R404A, R407C and R507 at a temperature of condensation of 30 C); letter C equivalent to about 18 bar (top limit of working pressure).

APPLICATIONS The water regulating valve, employed with condenser fed with either main or well water, keeps the condensation pressure constant at the previously set value by adjusting the water flow so as to ensure a balanced heat exchange under all conditions. At plant start-up, this adjustment is designed to allow the thermostatic valve to rapidly reach normal operating conditions and subsequently, during operations, to avoid excessive pressure increases or decreases under different flow conditions. An excessive rise of high pressure affects the refrigerating capacity of the system. On the other side, pressure lowering leads to insufficient refrigerant feeding of the evaporator with a consequent increased gas overheating and parallel reduction of gas pressure at compressor suction. Castel valves are appropriate for refrigerant fluids CFC, HCFC and HFC and only for main and well water.

1/4"

A
CAT.
RANGE 5-18 bar MAX WATER PRESS. 10 bar MAX WATER TEMP. 80 |BC MEDIUM R134a-R404A-R12-R22-R502

B C

48 Ch
A02

L 87 1/4"Flare

80

www.castel.it

99

MADE IN ITALY

WATER REGULATING VALVES

TABLE 1 - General Characteristics


Connections Catalogue Number UNI ISO 228/1 Working pressure [bar] Maximum water pressure [bar] Maximum water Temperature [C] Refrigerant Kv max Factor working [m3/h] pressure [bar] 2 518 10 80 3 4,7 20

Ch

Weight [g]

3210/03 3210/04 3210/06

G 3/8" G 1/2" G 3/4"

27 32

70 74

1015 985 1010

MATERIALS The materials used for the main parts are: hot-forged brass EN 12420-CW617N for main body; austenitic stainless steel AISI 303 for the seat; nitril rubber (NBR) for seat gasket; NBR coated-fabric for diaphragms. INSTALLATION The valve will be mounted on the water outlet side of the condenser, preferably vertically, with the bellows downward. The high pressure connection to the bellow must show no deflection. The arrow on the valve body shows water flow direction. EXAMPLE OF VALVE SELECTION A refrigerating system including a hermetic compressor and a condenser fed with mains water. Mains water pressure: 3 bar Water temperature at the condenser inlet: 14 C.

Expected thermal difference: Dt = 10 C. Condensation temperature expected on the basis of the water/refrigerant heat exchange in the condenser: approximately 6 C above the water temperature at the outlet, equivalent to 30 C (with a corresponding saturation pressure) (fig. 1). Refrigeration yield at the level of the evaporator: 18,6 kW under the following operating conditions, condensation temperature: + 30 C; evaporation temperature: 15 C. Thermal power to be disposed of at the level of the condenser (Table 2): 18,6 x 1,325 = 24,65 [kW] Water flow rate: 24,65 x 860 = 2120 l/h = 2,12 [m3/h] 10

Condensing Temperature

Water

Te m p e

rature

Heat exchange surface


Fig. 1 Heat exchange pattern in the condenser

www.castel.it

81

The pressure drop corresponding to the water flow rate specified above in the condenser/piping circuit, with the exclusion of the water regulating valve, is about 2.5 bar. The water regulating valve has this pressure differential at its disposal: p = 3 2,5 = 0,5 bar At p = 0,5 bar the 3210/04 valve, completly opened, ensures the required flow rate (fig. 2).

When the point of intersection of pressure differential through the valve and flow range is within the area between the curves of two valves, select the valve with larger diameter. When the valve is completely closed, the pressure must be the same as the refrigerant saturation pressure at the air temperature of the place where the condenser is installed. When the valve begins to open, the pressure is about 0.2 bar above the pressure when the valve is totally closed.

Q [m /h]

7 6,5 6 5,5 5 4,5 4 3,5 3 2,5 2 1,5 1 0,5 0 0,375 0,625 0,875 2,375 2,625 26 27 1,375 1,625 1,875 0,25 0,75 2,25 0,125 1,125 2,125 2,75 28 1,25 1,75 0,5 2,5 25 1,5 0 1 2 3210/03 3210/04 3210/06

p [bar]
11 20 22 23 24 0 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 21

p [H2O]

Fig. 2 Characteristic curves when the valves are completely open

82

www.castel.it

WATER REGULATING VALVES

TABLE 2 - Thermal factor for hermetic refrigeration compressors. Relationship between the total heat to be disposed of at the level of the condenser and refrigeration capacity at the level of the evaporator
Evaporating Temperature [C] Condensing Temperature [C]

35

30

25

20

15

10

+5

+10

+30 +35 +40 +45 +50 +55 +60

1,524 1,553 1,578

1,473 1,503 1,531

1,421 1,453 1,484 1,521

1,371 1,403 1,435 1,475

1,325 1,355 1,387 1,425 1,468 1,520

1,281 1,310 1,340 1,377 1,420 1,465 1,526

1,238 1,268 1,295 1,330 1,369 1,412 1,457

1,200 1,228 1,254 1,285 1,320 1,363 1,398

1,163 1,188 1,210 1,240 1,270 1,304 1,338

1,133 1,155 1,175 1,200 1,227 1,255 1,285

TABLE 3 - Thermal factor for open compressors (direct or belt driven). Relationship between the total heat to be disposed of at the level of the condenser and refrigeration capacity at the level of the evaporator
Evaporating Temperature [C] Condensing Temperature [C]

35

30

25

20

15

10

+5

+10

+30 +35 +40 +45 +50 +55 +60

1,460 1,495 1,537

1,417 1,450 1,487 1,530

1,371 1,405 1,441 1,485

1,330 1,367 1,396 1,437 1,482

1,291 1,320 1,350 1,390 1,431

1,243 1,279 1,306 1,342 1,381 1,426 1,474

1,213 1,240 1,265 1,295 1,334 1,369 1,410

1,178 1,202 1,224 1,252 1,288 1,320 1,355

1,143 1,168 1,185 1,211 1,241 1,274 1,330

1,114 1,133 1,152 1,175 1,200 1,228 1,255

www.castel.it

83

LIQUID INDICATORS & MOISTURE-LIQUID INDICATORS

85

LIQUID INDICATORS & MOISTURE-LIQUID INDICATORS


APPLICATIONS The indicators, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. The indicators series 3780 are excluded from the scope of Directive 97/23/EC, as specified in the Guidelines 1/8 and 1/9, because they are piping components. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). Liquid indicators and moisture liquid indicators ensure a fast and safe inspection of the conditions of the refrigerant fluid in the circuit concerning regular flow and moisture. Liquid indicators also ensure inspection of the regular return of oil to the compressor crankcase. OPERATION The moisture/liquid indicators consist of a sensitive element as a ring, which changes color passing from green to yellow according to the percentage of moisture in the system. The data of moisture content, shown in table 1 with the green color, can be considered admissible for the proper working of the system. When the sensitive element from green fade to yellow, green Chartreuse, working conditions of the system could become difficult. When the sensitive element becomes yellow, its time to substitute the dehydrator filter. If the charge and working condition are normal, the refrigerant fluid appears perfectly liquid underneath the lens of the indicator. The presence of bubbles indicates that the refrigerant fluid is partial evaporating along the liquid line.

TABLE 1: Moisture contained in the fluid [p.p.m.]


Refrigerant fluid Colour R22 R134a R404A R407C R410A R507

Green Green Chartreuse Yellow

<60 60 >60

<75 75 >75

<30 30 >30

<30 30 >30

<30 30 >30

<30 30 >30

CONSTRUCTION Castel liquid indicators and liquid/moisture indicators are manufactured with the glass lens which has been fused onto the metallic ring. This construction permits the total elimination of sealing gasket between the glass disc and the metallic structure with the consequent elimination of possible refrigerant leaks. The main parts of the indicators are made with the following materials: hot forged brass EN 12420 CW 617N for body; copper tube EN 12735-1 Cu-DHP for solder connections; steel, with proper surface protection, for the ring; chloroprene rubber (CR) for outlet seal gaskets; elastomer polyester for cap that covers the ring.

86

www.castel.it

LIQUID INDICATORS & MOISTURE-LIQUID INDICATORS

TABLE 2: General Characteristics


Catalogue Number Liquid Indicators 3610/22 3610/33 3610/44 3610/55 3610/66 Moisture Liquid Indicators 3710/22 3710/33 3710/44 3710/55 3710/66 male male ODS Type SAE Flare 1/4" 3/8" 1/2" 5/8" 3/4" soldering 1/4" male female 3/8" 1/2" 5/8" 3/4" [in.] 5/8" 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 1.1/8" 1.3/8" 2.1/8" [mm] 12 16 18 22 10 12 16 18 22 35 42 [in.] 1.3/8" 1.5/8" Connections TS [C] ODM [mm] 28 35 42 5/8" 7/8" 1.1/8" 1.3/8" saddle type 16 18 22 28 35 Excluded 35 I Art. 3.3 I 30 +110 45 Art. 3.3 [in.] for pipe [mm] Foro [mm] min. max. Risk Category PS [bar] according to PED

3620/M12 3720/M12 3620/5 3720/5

3620/M18 3720/M18 3620/M22 3720/M22 3640/2 3640/3 3740/2 3740/3

3640/M10 3740/M10 3640/M12 3740/M12 3640/4 3640/5 3740/4 3740/5

3640/M18 3740/M18 3640/6 3640/7 3640/9 3650/22 3650/33 3650/44 3650/55 3650/66 3740/6 3740/7 3740/9 3750/22 3750/33 3750/44 3750/55 3750/66 3770/M28 3770/11 3770/13 3770/M42 soldering 3771/11 3771/M42 3771/17 3780/5 3780/M18 3780/7 3780/9 3780/11 3781/M28 level glass

28

www.castel.it

87

INSTALLATION At the start-up the color of the sensitive element may be yellow, due to exposure to air humidity and to moisture in the circuit. When the moisture of the refrigerant is brought back to acceptable levels with the dehydrator, the indicator color is once again green. This is evidence that equilibrium has been re-stablished. In case of persisting yellow, measures have to be taken to eliminate moisture. Only when the sensitive element comes back to green, there is evidence that adopted measures were effective. About 12 hours of system operation are required to achieve equilibrium. However, the moisture

indication is given normally when the plant is in function and the fluid is flowing The brazing of indicators with solder connections should be carried out with care, using a low melting point filler material. Before starting to braze, its necessary to disassemble the ring of indicators series 3620, 3720, 3780 and 3781, while this operation is not necessary with solder connection indicators. In any case, avoid direct contact between the torch flame and the indicator body or ring, which could be damaged and compromise the proper functioning of the indicator.

34,5 Ch H1

34.5 Ch H1 H
H H1

34,5

L 3610 3710 3620 3720

L
3640 3740

34,5 34,5 Ch 32 Ch H2 H H1 Ch 32

34,5

L 3650 3750

L 3770 3771

34,5 Ch 32 33,5 H1 4,5

34,5

tubo

28 3780 3781

88

www.castel.it

H1

LIQUID INDICATORS & MOISTURE-LIQUID INDICATORS

TABLE 3: Dimensions and Weights


Catalogue Number Moisture Liquid Indicators 3710/22 3710/33 3710/44 3710/55 3710/66 3720/M12 3720/5 3720/M18 3720/M22 3740/2 3740/3 3740/M10 3740/M12 3740/4 3740/5 3740/M18 3740/6 3740/7 3740/9 3750/22 3750/33 3750/44 3750/55 3750/66 3770/M28 3770/11 3770/13 3770/M42 3771/11 3771/M42 3771/17 3780/5 3780/M18 3780/7 3780/9 3780/11 40 46 53,5 31,5 36 38,5 46 53,5 27,5 31,5 36 22,5 24,5 26 31,5 36 38 41,5 45 41,5 45 30 31 33 36 39,5 90 131 38,5 26 117 Dimensions [mm] Weight [g] H H1 L Ch

Liquid Indicators 3610/22 3610/33 3610/44 3610/55 3610/66 3620/M12 3620/5 3620/M18 3620/M22 3640/2 3640/3 3640/M10 3640/M12 3640/4 3640/5 3640/M18 3640/6 3640/7 3640/9 3650/22 3650/33 3650/44 3650/55 3650/66

28,5 31,5 36 38,5 46 28,5 38,5 40 46 28,5

22 22,5 24,5 26 31,5 22 26 27,5 31,5 22

71,5 77,5 81,5 89,5 93

12 17 22 24 28

130 165 210 255 315 100

49

110 110

61 133

160 135 195

200

210 215

151 186 68 74 77 84 92 150 160 170 160 170 12 17 22 24 28

295 580 165 205 235 300 525 250 300 480 300 480 550

www.castel.it

89

DEHYDRATORS AND FILTERS

91

DEHYDRATION OF REFRIGERANTS
Among contaminating agents causing serious damages to refrigerating systems, moisture plays a major role. Its presence, even possible in the refrigerating system, is due to many factors: inadequate or insufficiently prolonged vacuum before refrigerant charging; oil used for topping up remained exposed to air humidity; refrigerant used for subsequent additions contained in non dried vessels; sealing defects especially in systems not designed for operation at low temperatures. High temperatures combined with humidity give rise to complex phenomena enhancing acid formation both in lubricating oil and refrigerant. Oil organic acids react with metal and favor the formation of sludge, which are viscous clots consisting of insoluble metal salts and large molecules of polymerized oil. Sludge affects the lubrication of the moving elements of the compressor, can clog valves and filters and cause serious damages. Acids, especially hydrofluoric acid, produced by the hydrolysis of the fluorinated refrigerant (in compressors iron and aluminum act as catalysts) are particularly corrosive. Acids etch metal surfaces with the consequent formation of crystal salts, which stick to surfaces and affect the total heat exchange coefficient in the condenser and in the evaporator. In the sealed and semi-sealed groups, these salts damage the windings of electric motors as in these groups cold gas cools windings through direct contact. On the other hand, water solubility in refrigerants in a liquid phase, is quite reduced, especially at low temperatures. As a consequence, when in the system water exceeds the very low limits of solubility admitted at low temperature, excess water turns into ice, and blocks expansion valves and capillaries either partially or totally. Consequently, refrigerating plants must be equipped with a filter drier on the liquid line and types available on the market are essentially two: molecular sieve driers and solid core driers. In molecular sieve driers, with a charge constituted by non-agglomerated products, the dehydrating mass is pressed in between two fine steel mesh disks, or two filtering disks of various material, kept in place by a spring. In solid core driers, dehydrating and deacidifying products with binders constitute the block. Water adsorption combines with the neutralization of acids that may be present in the refrigerant, and with a strong filtering action. Castel have planned either its production lines of hermetic driers on this second solution that avoid any risk of abrasion of the charge and consequently the making of powder and permit to put the filter in any position inside the refrigerating system. It is always advisable to install a moisture indicator downstream the filter, which will show the refrigerant moisture and, consequently, the degree of efficiency of the filter. The dehydrating capacity of Castel drier is relative to the charge of refrigerant and not to the refrigeration potential of the plant. As a matter of fact, for the same refrigerant potential and for the same type of refrigerant fluid, there can be different refrigerant charges according to the type, design and working conditions of the plant as well as to the shutter degree. The data shown in the following tables are deduced from the test results of the present Castel production. It is important to note in the case of a high oil level in the circuit (> 5%) the data shown in the tables will be reduced considerably.

92

www.castel.it

ANTI-ACID SOLID CORE FILTER DRIERS WITH MOLECULAR SIEVES AND ACTIVATED ALUMINA SERIES 42
Approved by Underwriters Laboratories Inc.

DEHYDRATORS AND FILTERS

SOLID CORE FILTER DRIERS WITH 100% MOLECULAR SIEVES SERIES 43


Approved by Underwriters Laboratories Inc. APPLICATIONS The filters, shown in this chapter, are classified Pressure vessels in the sense of the Pressure Equipment Directive 94/23/EC, Article 1, Section 2.1.1 and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). Filters series 42 and series 43 have been developed for specific installations on refrigerating systems using HFC refrigerant fluids, particularly R134a, R404A, R407C, R410A ed R507 mixed with polyolester lubricants. In spite of this, the new block may be successfully used also in refrigerating systems using the old CFC or HCFC refrigerant fluids, mixed with mineral lubricants The blocks in the filters series 42 are molded from a blend of dehydrating charge, 80% of 3 molecular sieves and 20 % of activated alumina, and a special binding agent in appropriate proportions. The choice of blend, molecular sieves activated alumina, gives to the block a very high capacity of acid adsorption also maintaining very good dehydrating characteristics. The presence of a controlled and defined percentage of activated alumina, lower than the maximum value recommended by ASERCOM, keeps unchanged the original concentration of additives in the polyolester lubricant.

CONSTRUCTION The filter is completely manufactured in steel, either with nickel-plated Flare threaded connections. The product range also includes types with copper plated solder connections, offering the possibility to solder the copper pipe inside the connections (ODS) or outside the connections, using a copper sleeve (ODM). On specific customers request, Castel is also able the supply them filters series 42 and 43 with: solder connections made of copper tube EN 12735-1 Cu-DHP ORFS (O-Ring Face Seal) threaded connections according to SAE J 1453 Standard.

www.castel.it

93

The blocks in the filters series 43 are molded from a blend of dehydrating charge, totally made of 3 molecular sieves, and a special binding agent in appropriate proportions. The choice of the 3 molecular sieves, as sole dehydrating material, gives to the block a superlative capacity of water adsorption also maintaining quite good deacidifying characteristics. The manufacturing process gives a considerable compacted ness and stoutness to both the products so that they are resistant to shocks and abrasions. The shape of the block is designed in order to offer the maximum possible surface area to the incoming fluid. The internal cavity is also positioned in such a way as to have a uniform wall thickness. As a result, the fluid encounters a constant strength at all points, flows linearly through the block, and ensures efficient dehydration and minimum charge loss. The block is chemically inert, not deliquescent, does not react with refrigerating fluids, and is capable of blocking oil by-products dragged into the circuit. Impurities accumulate in the ring between the metal shell and the block; this prevents filter clogging.

EXAMPLE OF SELECTION System data: Refrigerant: R407C Condensing temperature: + 50 [C] Weight of refrigerant: 34 [kg] According to DIN 8949:2000, the adsorption capacity of the drier is given by: (1.050 50) x 34 / 1.000 = 34 g of H2O where: 1.050 ppm. = moisture in the refrigerant entering the filter according to DIN 8949:2000 50 ppm. = moisture in the refrigerant flowing out the filter according to DIN 8949:2000 Comparing the absorption capacity required with the values shown in table 2, drier mod.4032 should be selected, with a water absorption capacity of 47,5 g at 50 C. If the dehydrating capacity of products is expressed in water drops, it must be remembered that: 1g H2O = 20 water drops In this case and when a molecular sieve drier is selected, the following result is obtained: 34 x 20 = 680 water drops. If moisture exceeds the values specified in DIN 8949:2000, a drier with a higher adsorption capacity shall be selected.

Solid core dehydrator 1 Spring 2 Stainless steel mesh 3 Block 4 Felt

94

flow direction

www.castel.it

DEHYDRATORS AND FILTERS

TABLE 1: General Characteristics


Catalogue Number High water capacity core (1) Threaded Connections 4303/2 4303/2F (2) 4303/3 4305/2 4305/2F (2) 4305/3 4308/2 4308/2F (2) 4308/3 4308/3F (2) 4308/4 4316/2 4316/3 4316/3F (2) 4316/4 4316/5 4330/3 4330/4 4330/5 4332/4 4332/5 4341/5 4341/6 Solder Connections 4303/2S 4305/2S 4305/3S 4305/M10S 4308/2S 4308/3S 4308/M10S 4308/M12S 4308/4S 4316/3S 4316/M10S 4316/M12S 4316/4S 4316/5S 4330/3S 4330/4S 4330/5S 4332/4S 4332/5S 4341/5S 4341/6S 4341/7S 4375/4S 4375/5S 4375/6S 4375/7S 4375/9S Connections Block Nominal International Filtering Volume Reference Surface [cm3] [cm2] ODS SAE Flare [in.] 1/4" 1/4" 3/8" 1/4" 3/8" 1/2" 3/8" 1/2" 5/8" 3/8" 1/2" 5/8" 1/2" 5/8" 5/8" 3/4" 7/8" 1/2" 5/8" 3/4" 7/8" 1.1/8" [mm] 10 10 12 10 12 16 16 16 16 16 [in.] 3/8" 3/8" 1/2" 3/8" 1/2" 5/8" 1/2" 5/8" 3/4" 1/2" 5/8" 3/4" 5/8" 3/4" 3/4" 7/8" 1.1/8" 5/8" 3/4" 7/8" 1.1/8" 1.3/8" ODM [mm] 12 12 14 16 12 14 16 16 16 16 35 40 +80 42 (3) Art. 3.3 min. max. TS [C] PS [bar] Risk Category according to PED

032 032S 033 052 052S 053 053S 082 082S 083 083S 084 084S 162 163 163S 164 164S 165 165S 303 303S 304 304S 305 305S 304 304S 305 305S 415 415S 416 416S 417S 754S 755S 756S 757S 759S 660 1340 330 670 255 500 310 500 155 250 103 130 70 80 47 50

1/4" 1/4" 3/8" 1/4" 1/4" 3/8" 1/4" 1/4" 3/8" 3/8" 1/2" 1/4" 3/8" 3/8" 1/2" 5/8" 3/8" 1/2" 5/8" 1/2" 5/8" 5/8" 3/4"

(1) 100% molecular sieves; (2) Male-female connections (Inlet female) (3) PS = 400 psig in compliance with the UL approval

www.castel.it

95

TABLE 2: General Characteristics


Catalogue Number Anti-acid core (1) Threaded Connections 4203/2 4203/3 4205/2 4205/3 4208/2 4208/3 4208/4 4216/2 4216/3 4216/4 4216/5 4230/3 4230/4 4230/5 4232/4 4232/5 4241/5 4241/6 Solder Connections 4203/2S 4205/2S 4205/3S 4208/2S 4208/3S 4208/4S 4216/3S 4216/4S 4216/5S 4230/3S 4230/4S 4230/5S 4232/4S 4232/5S 4241/5S 4241/6S 4241/7S 4275/4S 4275/5S 4275/6S 4275/7S 4275/9S Connections Block Nominal International Filtering Volume Reference Surface [cm3] [cm2] ODS SAE Flare [in.] 1/4" 1/4" 3/8" 1/4" 3/8" 1/2" 3/8" 1/2" 5/8" 3/8" 1/2" 5/8" 1/2" 5/8" 5/8" 3/4" 7/8" 1/2" 5/8" 3/4" 7/8" 1.1/8" [mm] 16 16 16 16 16 [in.] 3/8" 3/8" 1/2" 3/8" 1/2" 5/8" 1/2" 5/8" 3/4" 1/2" 5/8" 3/4" 5/8" 3/4" 3/4" 7/8" 1.1/8" 5/8" 3/4" 7/8" 1.1/8" 1.3/8" ODM [mm] 16 16 16 16 16 35 40 +80 42 (2) Art. 3.3 min. max. TS [C] PS [bar] Risk Category according to PED

032 032S 033 052 052S 053 053S 082 082S 083 083S 084 084S 162 163 163S 164 164S 165 165S 303 303S 304 304S 305 305S 304 304S 305 305S 415 415S 416 416S 417S 754S 755S 756S 757S 759S 660 1340 330 670 255 500 310 500 155 250 103 130 70 80 47 50

1/4" 3/8" 1/4" 3/8" 1/4" 3/8" 1/2" 1/4" 3/8" 1/2" 5/8" 3/8" 1/2" 5/8" 1/2" 5/8" 5/8" 3/4"

(1) 80% molecular sieves + 20% activated alumina (2) PS = 400 psig in compliance with the UL approval

96

www.castel.it

DEHYDRATORS AND FILTERS

TABLE 3: Refrigerant Flow Capacity and Water Capacity


Refrigerant Flow Capacity, pressure drop 0,07 bar (1) [kW] R407C R410A R404A R507 R134a R134a R22 Water Capacity at + 25 C (2) [g H2O] R407C R404A R507 R410A R134a R22 Dehydratable Charge at + 25 C [kg refrigerant] R407C R404A R507 R410A R134a R22 Water Capacity at + 50 C (2) [g H2O] R407C R410A R404A R507 R134a R22 Dehydratable Charge at + 50 C [kg refrigerant] R407C 2,9 5,2 R404A R507 R410A 3,2 5,6 9,8 R22 3,2 5,7

Catalogue Number

4303/2 4303/2F 4303/2S 4303/3 4305/2 4305/2F 4305/2S 4305/3 4305/3S 4305/M10S 4308/2 4308/2F 4308/2S 4308/3 4308/3F 4308/3S 4308/M10S 4308/M12S 4308/4 4308/4S 4316/2 4316/3 4316/3F 4316/3S 4316/M10S 4316/M12S 4316/4 4316/4S 4316/5 4316/5S 4330/3 4330/3S 4330/4 4330/4S 4330/5 4330/5S 4332/4 4332/4S 4332/5 4332/5S 4341/5 4341/5S 4341/6 4341/6S 4341/7S 4375/4S 4375/5S 4375/6S 4375/7S 4375/9S

6,5 8,0

7,0 8,6

4,6 5,6

6,9 8,5

7,0 8,6 4,1 3,8 4,2 3,4 3,7 4,4 4,0 4,5 3,6 3,9 3,5 3,0 3,9 2,7 2,9 3,8 4,2

14,9 16,1 10,5 16,0 16,2 6,7 8,2 7,2 8,9 4,7 5,8 7,1 8,8 7,2 9,0

15,4 16,6 10,8 16,5 16,7 19,4 21,0 13,7 20,8 21,2

7,3

6,7

7,4

6,0

6,5

7,8

7,2

8,0

6,4

7,0

6,3

5,3

6,9

4,8

5,2

6,8

7,4

6,9 8,5

7,5 9,2

4,9 6,0

7,4 9,1

7,5 9,3

18,0 19,5 12,7 19,3 19,6 12,7 11,6 13,0 10,4 11,3 13,7 12,5 13,9 11,2 12,2 10,9 9,3 12,0 8,4 22,8 24,7 16,1 24,5 24,8 29,0 31,3 20,4 31,0 31,4 24,0 25,9 16,9 25,7 26,0 29,0 31,3 20,4 31,0 31,4 6,9 7,5 4,9 7,4 7,5 9,1 11,8 10,0 13,0 9,0

19,7 21,3 13,9 21,1 21,4

24,6 26,6 17,3 26,4 26,7 34,1 36,9 24,0 36,6 37,0 28,2 30,5 19,9 30,3 30,6 34,1 36,9 24,0 36,6 37,0 37,6 40,6 26,4 40,3 40,8 45,0 48,7 31,7 48,3 48,9 21,7 23,4 15,3 23,2 23,5 27,1 29,3 19,0 29,0 29,4 30,9 33,4 21,8 33,2 33,5 37,3 40,4 26,3 40,0 40,5 38,8 41,9 27,3 41,6 41,9 46,6 50,4 32,8 50,0 50,6 33,6 36,3 23,6 36,0 36,4 40,5 43,8 28,5 43,4 44,0 39,9 43,1 28,1 42,8 43,0 48,2 52,1 33,9 51,7 52,3 40,9 44,2 28,8 43,8 44,4 49,5 53,5 34,8 53,1 53,7 67,2 72,6 47,3 72,0 73,0 74,2 80,2 52,2 79,6 80,5 53,4 57,7 37,5 57,3 57,9 54,5 58,9 38,3 58,4 59,1 80,6 87,1 56,8 86,4 87,6 122,8 112,2 125,6 100,6 109,4 132,0 120,6 135,1 108,2 117,6 106,0 90,0 116,6 81,0 88,2 114,0 96,8 125,4 87,1 94,8 92,8 100,3 65,3 99,5 100,6 96,5 104,3 67,9 103,5 104,7 61,4 56,1 62,8 50,3 54,7 66,0 60,3 67,5 54,1 58,8 53,0 45,0 58,3 40,5 44,1 57,0 48,4 62,7 43,5 47,4 45,4 41,4 46,4 37,2 40,5 48,8 44,5 49,9 40,0 43,5 39,1 33,2 43,1 29,9 32,6 42,0 35,7 46,3 32,2 35,1 50,2 45,8 51,2 41,0 44,6 54,0 49,2 55,1 44,1 48,0 43,2 36,8 47,6 33,0 36,0 46,5 39,6 51,2 35,5 38,7 25,1 22,9 25,6 20,5 22,3 27,0 24,6 27,5 22,0 24,0 21,6 18,4 23,8 16,5 18,0 23,2 19,8 25,6 17,7 19,4

(1) (2) See caption on page 98.

www.castel.it

97

TABLE 4: Refrigerant Flow Capacity and Water Capacity


Refrigerant Flow Capacity, pressure drop 0,07 bar (1) [kW] R407C R410A R404A R507 R134a R134a R22 Water Capacity at + 25 C (2) [g H2O] R407C R404A R507 R410A R134a R22 Dehydratable Charge at + 25 C [kg refrigerant] R407C R404A R507 R410A R134a R22 Water Capacity at + 50 C (2) [g H2O] R407C R410A R404A R507 R134a R22 Dehydratable Charge at + 50 C [kg refrigerant] R407C 2,5 4,4 R404A R507 R410A 2,7 4,8 8,3 R22 2,8 4,9

Catalogue Number

4203/2 4203/2S 4203/3 4205/2 4205/2S 4205/3 4205/3S 4208/2 4208/2S 4208/3 4208/3S 4208/4 4208/4S 4216/2 4216/3 4216/3S 4216/4 4216/4S 4216/5 4216/5S 4230/3 4230/3S 4230/4 4230/4S 4230/5 4230/5S 4232/4 4232/4S 4232/5 4232/5S 4241/5 4241/5S 4241/6 4241/6S 4241/7S 4275/4S 4275/5S 4275/6S 4275/7S 4275/9S

6,5 8,0

7,0 8,6

4,6 5,6

6,9 8,5

7,0 8,6 3,5 3,2 3,6 2,9 3,1 3,8 3,4 3,9 3,1 3,4 3,0 2,6 3,3 2,3 2,5 3,3 3,6

14,9 16,1 10,5 16,0 16,2 6,7 8,2 7,2 8,9 4,7 5,8 7,1 8,8 7,2 9,0 6,2 5,7 6,3 5,1 5,5 6,7 6,1 6,8 5,5 6,0 5,4 4,5 5,9 4,1 4,5 5,8 6,3

15,4 16,6 10,8 16,5 16,7 19,4 21,0 13,7 20,8 21,2 6,9 8,5 7,5 9,2 4,9 6,0 7,4 9,1 7,5 9,3

18,0 19,5 12,7 19,3 19,6 22,8 24,7 16,1 24,5 24,8 24,0 25,9 16,9 25,7 26,0 29,0 31,3 20,4 31,0 31,4 6,9 7,5 4,9 7,4 7,5

10,8 9,9 11,0 8,8

9,6 11,6 10,6 11,9 9,5 10,3 9,3

7,9 10,2 7,1

7,7 10,0 8,5 11,0 7,7

19,7 21,3 13,9 21,1 21,4 24,6 26,6 17,3 26,4 26,7 28,2 30,5 19,9 30,3 30,6 21,3 19,5 21,8 17,4 19,0 22,9 20,9 23,4 18,7 20,4 18,4 15,6 20,2 14,0 15,3 19,7 16,8 21,8 15,1 16,5 34,1 36,9 24,0 36,6 37,0 37,6 40,6 26,4 40,3 40,8 45,0 48,7 31,7 48,3 48,9 21,7 23,4 15,3 23,2 23,5 27,1 29,3 19,0 29,0 29,4 30,9 33,4 21,8 33,2 33,5 37,3 40,4 26,3 40,0 40,5 38,8 41,9 27,3 41,6 41,9 46,6 50,4 32,8 50,0 50,6 33,6 36,3 23,6 36,0 36,4 40,5 43,8 28,5 43,4 44,0 39,9 43,1 28,1 42,8 43,0 48,2 52,1 33,9 51,7 52,3 40,9 44,2 28,8 43,8 44,4 49,5 53,5 34,8 53,1 53,7 67,2 72,6 47,3 72,0 73,0 74,2 80,2 52,2 79,6 80,5 53,4 57,7 37,5 57,3 57,9 54,5 58,9 38,3 58,4 59,1 80,6 87,1 56,8 86,4 87,6 104,4 95,4 106,8 85,5 93,0 112,2 102,5 114,8 91,9 100,0 90,1 76,5 99,1 68,9 75,0 96,9 82,3 106,6 74,0 80,6 92,8 100,3 65,3 99,5 100,6 96,5 104,3 67,9 103,5 104,7 52,2 47,7 53,4 42,8 46,5 56,1 51,3 57,4 46,0 50,0 45,1 38,3 49,6 34,4 37,5 48,4 41,1 53,3 37,0 40,3 38,6 35,2 39,4 31,6 34,4 41,5 37,8 42,4 34,0 37,0 33,2 28,2 36,6 25,4 27,7 35,7 30,3 39,4 27,3 29,8 42,7 38,9 43,5 34,9 37,9 45,9 41,9 46,8 37,5 40,8 36,7 31,3 40,5 28,1 30,6 39,5 33,6 43,5 30,2 32,9

(1) Maximum values of the refrigerant flow capacity at which the drier can be used when fluid dehydration is not the a major problem, provided that the original moisture is limited before the installation of the drier. The maximum refrigerant flow capacities are referred to a total pressure drop of 0,07 bar, inlet and outlet connections included, (according to ARI STANDARD 710:86 - with condensing temperature at +30 C and evaporating temperature at -15 C) (2) Water capacity values with R22 are referred to the following conditions, fixed in ARI STANDARD 710:86: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 60 ppm Water capacity values with the other refrigerant fluids are referred to the following conditions, fixed in DIN 8949:2000 Standard: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 50 ppm

98

www.castel.it

TABLE 5: Dimensions and Weights


Connections Catalogue Number ODS SAE Flare 1/4" 1/4" 3/8" 1/4" 1/4" 3/8" 1/4" 1/4" 3/8" 3/8" 1/2" 1/4" 3/8" 3/8" 1/2" 5/8" 3/8" 1/2" 5/8" 1/2" 5/8" 5/8" 3/4" [in.] 1/4" 1/4" 3/8" 1/4" 3/8" 1/2" 3/8" 1/2" 5/8" 3/8" 1/2" 5/8" 1/2" 5/8" 5/8" 3/4" 7/8" 1/2" 5/8" 3/4" 7/8" 1.1/8" [mm] 10 10 12 10 12 16 16 16 16 16 91 73 52 D L 103 92 94 111 119 109 110 127 112 146 135 137 154 142 139 146 162 146 158 166 154 151 158 174 158 183 166 245 230 253 237 262 245 187 173 196 179 231 214 232 219 332 332 332 338 338 240 230 Dimensions [mm]

Weight [g]

4303/2 4303/2F 4303/2S 4303/3 4305/2 4305/2F 4305/2S 4305/3 4305/3S 4305/M10S 4308/2 4308/2F 4308/2S 4308/3 4308/3F 4308/3S 4308/M10S 4308/M12S 4308/4 4308/4S 4316/2 4316/3 4316/3F 4316/3S 4316/M10S 4316/M12S 4316/4 4316/4S 4316/5 4316/5S 4330/3 4330/3S 4330/4 4330/4S 4330/5 4330/5S 4332/4 4332/4S 4332/5 4332/5S 4341/5 4341/5S 4341/6 4341/6S 4341/7S 4375/4S 4375/5S 4375/6S 4375/7S 4375/9S

4203/2 4203/2S 4203/3 4205/2 4205/2S 4205/3 4205/3S 4208/2 4208/2S 4208/3 4208/3S 4208/4 4208/4S 4216/2 4216/3 4216/3S 4216/4 4216/4S 4216/5 4216/5S 4230/3 4230/3S 4230/4 4230/4S 4230/5 4230/5S 4232/4 4232/4S 4232/5 4232/5S 4241/5 4241/5S 4241/6 4241/6S 4241/7S 4275/4S 4275/5S 4275/6S 4275/7S 4275/9S

235 275 260 295 260

380 345 395 380 345 380 430 380 635 690 680 620 630 640 680 640 740 640 1380 1240 1360 1280 1480 1370 1300 1200 1320 1250 1580 1470 1640 1560 1600 2540 2640 2820 2900 3050

220

D male connections

D male - female connections (female - in)

D solder connections

www.castel.it

99

FILTER DRIERS WITH REPLACEABLE ANTI-ACID SOLID CORE


Approved by Underwriters Laboratories Inc. Except filters 4423/17A, /21A, /25A and 4424/25A, /33A APPLICATIONS The filters, shown in this chapter, are classified Pressure vessels in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.1 and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). OPERATION In the case of filters with more than one block, the passage of the fluid takes place in parallel; as a result, the pressure drop does not increase proportionately to the number of blocks. A large ring between the block and the inner surface of the filter permits the accumulation of solid particles, and prevents clogging. Before leaving the filter, the refrigerant fluid must pass through the mesh sieve on which blocks are mounted. The danger that small particles of dehydrating material being introduced into the system is thus avoided. Furthermore, at filter outlet, a plastic cup, the edge of which closely adheres to the inner surface of the filter, prevents dirt from reaching the outlet connection during normal operation and block change. CONSTRUCTION The filters type 4410 are manufactured in steel, with the exception of the connections which are made of EN 12735-1 Cu-DHP copper tube. The filters type 4420 are completely manufactured in steel and solder connection, are machined with a steel bar EN 10025 S355JR. The blocks series 4490 and 4491 has been developed for specific installations on refrigerating systems using HFC refrigerant fluids, particularly R134a, R404A, R407C, R410A ed R507 mixed with polyolester lubricants. In spite of this, the new block may be successfully used also in refrigerating systems using the old CFC or HCFC refrigerant fluids, mixed with mineral lubricants. The blocks 4490, type A and type B, and the block 4491, type A, are molded from a blend of dehydrating charge, totally made of 3 molecular sieves, and a special binding agent in appropriate proportions. The choice of the 3 molecular sieves, as sole dehydrating material, gives to the block a superlative capacity of water adsorption also maintaining quite good deacidifying characteristics. The blocks 4490, type AA and type AB, and the block 4491, type AA, are molded from a blend of dehydrating charge, 80% of 3 molecular sieves and 20 % of activated alumina, and a special binding agent in appropriate proportions. The choice of blend, molecular sieves activated alumina, gives to the block a very high capacity of acid adsorption also maintaining very good dehydrating characteristics. The presence of a controlled and defined percentage of activated alumina, lower than the maximum value recommended by ASERCOM, keeps unchanged the original concentration of additives in the polyolester lubricant.

100

www.castel.it

DEHYDRATORS AND FILTERS

TABLE 1: General Characteristics


Nominal Volume [in.] 5/8" 7/8" 1.1/8" 1 420 48 800 1.3/8" 1.5/8" 2.1/8" 4490/A 4490/B 4490/AA 4490/AB 2 840 96 1600 7/8" 1.1/8" 1.3/8" 2.1/8" 1.3/8" 3 1260 144 2400 1.5/8" 1.5/8" 4 1680 192 3200 2.1/8" 2.1/8" 4491/A 4491/AA 4 2520 400 6400 3 1890 300 4800 2.5/8" 3.1/8" 3.1/8" 4.1/8" Connections TS [C] ODS [cu.in] 4411/5A 4411/7A 4411/9A 4411/11A 4411/13A 4411/M42A 4411/17A 4412/7A 4412/9A 4412/11A 4412/M42A 4412/17A 4413/11A 4413/13A 4413/M42A 4414/13A 4414/M42A 4414/17A 4423/17A 4423/21A 4423/25A 4424/25A 4424/33A [cm3] [mm] 16 22 35 42 54 22 35 42 54 35 42 42 54 54 80 80 60,3 76,1 88,9 88,9 114,3 32 II 35 (1) 45 (1) I ODM [mm] min. max. PS [bar] Risk Category according to PED

Catalogue Number

Core Cat. Number

Number of Cores

Core Filtering Surface [cm2]

40

+80

(1) PS = 470 psig in compliance with the UL approval

The manufacturing process of blocks series 4490 and 4491 gives a considerable compacted ness and stoutness to both the products so that they are resistant to shocks and abrasions. The blocks series 4490 have a volume of 48 cu.in., equivalent to approx. 800 cm3, and it is used with type 4411, 4412, 4413 and 4414 filters. The block series 4491 has a volume of 100 cu.in., equivalent to approx. 1600 cm3. and it is used with type 4421, 4423 and 4424 filters. The two blocks are shaped as a hollow cylinder and their overall dimensions correspond to those of other international brands. Consequently they are interchangeable. The hollow cylinder shape offers a large surface area to the inflowing fluid, which crosses the block in radial sense. As a result, dehydration is highly efficient with a minimum loss of charge. Filters may be supplied also with an access fitting kit G9150/R05, to be ordered separately.

5 3 4

inlet

outlet

Sketch of filter with 2 blocks 1 Block 2 Mesh sieve serving as block support 3 Spring 4 Retainer cup 5 Access fitting 1/4 SAE flare (to order separately)

www.castel.it

101

TABLE 2A: Refrigerant Flow Capacity and Water Capacity (filters)


Refrigerant Flow Capacity, pressure drop 0,07 bar (1) [kW] R407C R404A R410A R134a R134a R22 Water Capacity at + 25 C (2) [g H2O] R407C R404A R410A R134a R22 Dehydratable Charge at + 25 C [kg refrigerant] R407C R404A R410A R134a R22 Water Capacity at + 50 C (2) [g H2O] R407C R404A R410A R134a R22 Dehydratable Charge at + 50 C [kg refrigerant] R407C 60 R407C 60 51 R404A R410A 65 65 55 R410A R22 66 66 R22

Catalogue Number

4411/5A 4411/7A 4411/9A 4411/11A 4411/13A 4411/M42A 4411/17A 4412/7A 4412/9A 4412/11A 4412/M42A 4412/17A 4413/11A 4413/13A 4413/M42A 4414/13A 4414/M42A 4414/17A 4423/17A 4423/21A 4423/25A 4424/25A 4424/33A

83

90

59

89

90

146 158 103 156 159 200 216 141 214 217 233 252 164 250 253 84 77 86 69 75 90 83 92 74 81 72 61 80 56 60 77 86

250 270 176 268 271

146 158 103 156 159 226 244 159 242 245 306 331 215 328 332 168 154 172 138 150 181 166 185 148 161 144 122 160 112 120 155 131 172 120 129 333 361 234 357 362 327 354 230 351 355 361 391 254 387 393 252 231 258 207 225 271 248 277 223 242 216 183 240 168 180 232 197 258 181 194

426 460 300 456 462 336 308 344 276 300 361 331 370 297 323 288 244 320 224 240 310 262 344 241 258

447 483 315 479 485 492 532 346 527 534 504 462 516 414 450 542 497 555 445 484 432 366 480 336 360 465 394 516 361 387 670 725 472 719 728 737 797 519 791 800 1180 1276 830 1265 1281 672 616 688 552 600 723 662 740 594 645 576 488 640 448 480 619 525 688 482 516

TABLE 2B: Refrigerant Flow Capacity and Water Capacity (single block)
Refrigerant Flow Capacity, pressure drop 0,07 bar (1) [kW] R407C R404A R410A R134a R134a R22 Water Capacity at + 25 C (2) [g H2O] R407C R404A R410A R134a R22 Dehydratable Charge at + 25 C [kg refrigerant] R407C R404A R410A R134a R22 Water Capacity at + 50 C (2) [g H2O] R407C R404A R410A R134a R22 Dehydratable Charge at + 50 C [kg refrigerant] R404A 86 12 73

Catalogue Number

4490/A - 4490/B 4491/A 4490/AA - 4490/AB 4491/AA

84

77

86

69

75

90

83

92

74

81

72

61

80

56

60

77

168 154 172 138 150 181 166 185 148 161 144 122 160 112 120 155 131 71 65 73 59 64 77 70 79 63 69 61 52 68 48 95 51 66 56

120 129

(3)

143 131 146 117 128 154 141 157 126 137 122 104 136

102 132 112 146 102 110

(1) Maximum values of the refrigerant flow capacity at which the drier can be used when fluid dehydration is not the a major problem, provided that the original moisture is limited before the installation of the drier. The maximum refrigerant flow capacities are referred to a total pressure drop of 0,07 bar, inlet and outlet connections included, (according to ARI STANDARD 710:86 - with condensing temperature at + 30 C and evaporating temperature at -15 C) (2) Water capacity values with R22 are referred to the following conditions, fixed in ARI STANDARD 710:86: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 60 ppm Water capacity values with the other refrigerant fluids are referred to the following conditions, fixed in DIN 8949:2000 Standard: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 50 ppm (3) Maximum values of the refrigerant flow capacity (according to ARI STANDARD 710:86) at which filter driers: - series 4411, 4412, 4413, and 4414 can be used with blocks type 4490/AA and 4490/AB - series 4423 and 4424 can be used with blocks type 4491/AA when fluid dehydration is not the a major problem, are the same achieved with block type 4490/A, 4490/B and 4491/A.

102

www.castel.it

DEHYDRATORS AND FILTERS

TABLE 3: Dimensions and Weights


Connections Catalogue Number [in.] 4411/5A 4411/7A 4411/9A 4411/11A 4411/13A 4411/M42A 4411/17A 4412/7A 4412/9A 4412/11A 4412/M42A 4412/17A 4413/11A 4413/13A 4413/M42A 4414/13A 4414/M42A 4414/17A 4423/17A 4423/21A 4423/25A 4424/25A 4424/33A 5/8" 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" 7/8" 1.1/8" 1.3/8" 2.1/8" 1.3/8" 1.5/8" 1.5/8" 2.1/8" 2.1/8" 2.5/8" 3.1/8" 3.1/8" 4.1/8" ODS [mm] 16 22 35 42 54 22 35 42 54 35 42 42 54 54 80 80 60,3 76,1 88,9 88,9 114,3 163 200 121 149 W [mm] D1 D2 H1 148 154 159 171 162 296 300 312 303 442 454 H2 235 241 246 258 249 383 387 399 390 529 541 113 595 586 520 525 693 682 673 641 646 814 760 148 103 143 324 185 H3 P 90 96 101 113 103 96 101 113 103 101 5360 5405 5395 5464 5435 5410 5585 6880 7015 6985 7136 8510 8470 8445 9940 10010 18000 18200 18400 21600 22000 Dimensions [mm]

Weight [g]

600

H3 20

H2 H1

D2

D1

www.castel.it

103

BLOCKS REPLACEMENT
Blocks must be ordered separately from the filter. They are supplied in individual packages, which are hermetically sealed in suitable wrappings (type 4490), and in special bags (type 4491) for safe storage over long periods of time. Every cartridge is equipped of two seals in synthetic material to use like seal between the two cartridges and between the cartridge and its covers. If the filter is installed in a system without any by-pass, the block replacement has to be done following these instructions: 1 Close the valve on the departing line. 2 Start the compressor and its auxiliaries in order to transfer the refrigerant charge into the high pressure side of the plant (liquid receiver). 3 Stop the compressor at a suction pressure sufficiently higher than the atmospheric pressure. 4 Shutt off the service valve at the suction side of the compressor. NOTE: if during the transfer of the refrigerant to the high-pressure side of the plant, the discharge pressures reach too high values (the condenser is flooded due to insufficient capacity of the liquid receiver), shut off the valve on the compressor suction side and stop immediately the compressor. 5 Replace quickly the filter block. During the preparation of the new block, close the filter with a clean cloth. The slight over-pressure inside the filter and the ability of the technician will prevent air from getting into the plant. 6 The internal cleanliness of the body is guaranteed by the cleaning effect of the cup which is characteristic of Castel filters. if air is supposed to have entered the plant during filter block replacement, produce a vacuum in the low-pressure side of the plant, and always in the sector of the circuit involved. 7 Open the valve on the departure of liquid line 8 Slowly open the suction valve of the compressor and start the compressor and its auxiliaries. 9 Top the charge up, if necessary.

D1 D2 4490

TABLE 4: General Characteristics, Dimensions and Weights


Nominal Volume Dimensions [mm]

Catalogue Number

Core Filtering Surface [cm2]

Weight [g] H

[cu.in] 4490/A 4490/B (1) 4490/AA 4490/AB (1) 4491/A 4491/AA 630 100 420 48

[cm3]

D1

D2

800

47

96

140

670

D1
1600 53 122 165 1350

D2 4491

(1) Supplied without cover gasket as spare part

104

www.castel.it

MECHANICAL FILTERS WITH REPLACEABLE FILTERING BLOCK


Approved by Underwriters Laboratories Inc. Except filters 4421/21C, /25C, /M80C, /33C APPLICATIONS The filters, shown in this chapter, are classified Pressure vessels in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.1 and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). OPERATION Good filtering of the refrigerant on the lowpressure side of the system is a guarantee of protection for the compressor. System cleanliness is ensured by micro filtering cores, which filter out impurities derived from manufacture and assembly of the refrigerating system. CONSTRUCTION The filters type 4410 are manufactured in steel, with the exception of the connections which are made of EN 12735-1 Cu-DHP copper tube. The filters type 4420 are completely manufactured in steel and solder connection, are machined with a steel bar EN 10025 S355JR. Zinc plated wire cloths and a filtering baffle form the block, which features a large surface, with controlled porosity. The block can stop solid particles up to 20 micron. At the two ends, soft felt gaskets ensure perfect sealing with the plastic cups. Filters are supplied with an access fitting kit G9150/R05. SUCTION LINE SELECTION CRITERION With clean systems, refrigerant flow capacity and pressure drops of table 2 are reported to a gas speed of 20 m/s for pipes adequate to the filter connections. For refrigerant flow capacities different from the table values, under the other same conditions, gas speeds and relative pressure drops through the filter can be gained for simple proportionality. EXAMPLE System data: Refrigerant: R407C Refrigerant flow capacity: 130 [kW] Evaporating temperature: + 5 [C] Suction pipe: 2.1/8 Filter: 4411/17C In table 2, corresponding to filter type 4411/17C refrigerant and evaporating temperature, the following data is given: refrigerant flow capacity = 141,7 [kW]; pressure drop = 0,21 [bar]. The gas speed in the suction line will be:

DEHYDRATORS AND FILTERS

20

130 2 = 16,8 [m/s] 141,7 2

Pressure drop through the filter:

0, 21

130 2 = 0,177 [bar] 141,7 2

Remember that the dimensioning of the suction line in a refrigerating system requires great attention. In fact the relative pressure loss, included filter, which implies a reduction of flow capacity sucked by the compressor, influences directly the refrigerating capacity of the plant. This line is normally sized to have a total pressure loss lower then a variation of the saturation temperature of 1 C. For example diagram 1, referred to R22, allows to estimate the aforesaid variation in function of pressure loss and evaporating temperature.

www.castel.it

105

After all its always important to remember that the refrigerant flow capacity of a compressor, under the other same conditions, can reduce considerably because of the decrease of the saturation temperature, consequent to the pressure loss in the suction line.

To such purpose diagram 2 illustrates the existing relation between saturation temperature, in the suction line, and variation of the refrigerant flow capacity of a compressor.

TABLE 1: General Characteristics


Connections Catalogue Number Core Cat. Number Number of Cores Core Filtering Surface [cm2] [in.] 4411/7C 4411/9C 4411/11C 4411/13C 4411/M42C 4411/17C 4411/21C 4421/21C 4421/25C 4421/33C 4496/C 1850 1 4495/C 820 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" 2.5/8" 2.5/8" 3.1/8" 4.1/8" TS [C] ODS [mm] 22 35 42 54 80 76,1 88,9 114,3 32 40 +80 I 45 (1) W [mm] min. max. PS [bar] Risk Category according to PED

(1) PS = 470 psig in compliance with the UL approval

3 2

inlet

outlet
Sketch of filter with mechanical block 1 Block 2 Retainer cup 3 Spring

106

www.castel.it

DIAGRAM 1

DEHYDRATORS AND FILTERS

6 5

-45

-40

-35 -30 -25

Equivalent variation of the saturation temperature

ra tu re

te m

pe

-20 -15 -10 -5 0 +10

2 1 0 0 5

ev ap
10

or at io

15

20

25

30

35

Pressure loss (kPa)

DIAGRAM 2

1,5

0,5

0 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10

Saturation temperature at the suction (C)

Correction factor of refrigerant flow capacity

www.castel.it

107

TABLE 2: Refrigerant Flow Capacity and Pressure Drop


Evaporating Temperature [C] Catalogue Number Refrigerant [kW] R134a R22 4411/7C R404A R407C R410A R134a R22 4411/9C R404A R407C R410A R134a R22 4411/11C R404A R407C R410A R134a 4411/13C 4411/M42C R22 R404A R407C R410A R134a R22 4411/17C R404A R407C R410A R134a R22 4411/21C R404A R407C R410A R134a R22 4421/21C R404A R407C R410A R134a R22 4421/25C R404A R407C R410A R134a R22 4421/33C R404A R407C R410A 17,0 26,0 23,7 22,2 38,4 28,7 43,0 40,0 37,6 63,5 43,5 65,0 60,7 57,0 96,0 62,0 93,0 86,8 81,4 137,0 108,3 162,0 151,3 141,7 239,0 167,0 249,0 232,7 218,0 368,0 167,0 249,0 232,7 218,0 368,0 238,0 356,0 332,0 312,0 526,0 416,0 623,0 581,0 547,0 921,0 +5 [bar] 0,084 0,120 0,150 0,100 0,230 0,091 0,130 0,160 0,110 0,250 0,092 0,130 0,160 0,110 0,250 0,110 0,150 0,200 0,136 0,300 0,170 0,230 0,310 0,210 0,440 0,300 0,420 0,550 0,380 0,810 0,120 0,170 0,220 0,160 0,340 0,210 0,300 0,390 0,270 0,600 0,630 0,900 1,170 0,790 1,800 [kW] 13,7 21,5 20,0 19,0 31,7 23,0 36,4 34,0 32,1 53,7 35,0 55,0 51,4 48,6 81,0 50,0 79,0 73,5 69,5 116,0 87,0 137,0 128,0 121,1 202,0 133,5 211,0 197,0 186,4 311,0 133,5 211,0 197,0 186,4 311,0 191,0 302,0 281,0 266,0 446,0 334,0 528,0 491,0 468,0 780,0 0 [bar] 0,070 0,100 0,130 0,090 0,200 0,074 0,110 0,140 0,100 0,210 0,075 0,110 0,140 0,100 0,210 0,090 0,130 0,170 0,120 0,250 0,140 0,190 0,270 0,180 0,370 0,250 0,360 0,480 0,330 0,700 0,100 0,150 0,200 0,140 0,300 0,180 0,260 0,340 0,230 0,500 0,540 0,770 1,000 0,690 1,400 [kW] 9,0 15,6 14,0 12,8 23,0 15,0 26,0 24,0 21,3 38,0 23,0 39,0 36,2 33,2 57,0 33,0 56,0 51,7 47,5 82,0 57,2 97,0 90,0 82,6 143,0 87,5 149,0 138,6 127,0 220,0 87,5 149,0 138,6 127,0 220,0 125,0 213,0 198,0 182,0 315,0 218,0 372,0 346,0 320,0 550,0 -10 [bar] 0,048 0,074 0,090 0,060 0,140 0,051 0,080 0,100 0,066 0,150 0,052 0,080 0,100 0,068 0,150 0,062 0,090 0,120 0,080 0,180 0,100 0,150 0,190 0,125 0,290 0,180 0,270 0,330 0,210 0,520 0,070 0,110 0,130 0,090 0,200 0,120 0,190 0,220 0,150 0,370 0,360 0,570 0,660 0,440 1,200 [kW] 6,0 10,8 9,0 8,4 16,0 10,0 18,0 15,0 14,2 26,0 15,0 27,0 22,7 21,9 40,0 21,4 39,0 32,4 31,3 57,0 37,3 66,4 56,5 54,4 98,0 57,0 102,0 87,0 83,7 150,0 57,0 102,0 87,0 83,7 150,0 81,5 146,0 124,0 119,7 215,0 142,0 255,0 217,0 210,0 377,0 -20 [bar] 0,033 0,052 0,060 0,043 0,100 0,035 0,056 0,070 0,047 0,110 0,036 0,056 0,070 0,047 0,110 0,043 0,064 0,080 0,056 0,120 0,070 0,100 0,130 0,087 0,250 0,120 0,180 0,230 0,150 0,350 0,050 0,074 0,100 0,060 0,150 0,090 0,130 0,170 0,100 0,250 0,270 0,390 0,500 0,300 0,800 [kW] 3,5 7,2 6,0 5,1 10,6 6,0 12,0 10,0 8,7 17,7 9,0 18,0 14,5 13,4 26,0 13,0 26,0 20,7 19,2 38,0 22,4 44,0 36,0 33,4 65,0 34,3 68,0 55,5 51,4 100,0 34,3 68,0 55,5 51,4 100,0 49,0 97,0 79,3 73,5 143,0 85,0 170,0 138,7 129,0 251,0 -30 [bar] 0,021 0,037 0,040 0,028 0,100 0,022 0,040 0,050 0,031 0,110 0,023 0,040 0,050 0,031 0,110 0,027 0,046 0,060 0,037 0,100 0,040 0,070 0,100 0,057 0,200 0,070 0,120 0,170 0,100 0,240 0,030 0,050 0,070 0,040 0,100 0,050 0,090 0,120 0,070 0,200 0,150 0,270 0,360 0,200 0,530

Refrigerant flow capacities and pressure drops are referred to the following working conditions: Liquid temperature ahead expansion valve: + 35 C Overheating of suction gas: 6 C

108

www.castel.it

DEHYDRATORS AND FILTERS

TABLE 3: Dimensions and Weights


Connections Catalogue Number [in.] 4411/7C 4411/9C 4411/11C 4411/13C 4411/M42C 4411/17C 4411/21C 4421/21C 4421/25C 4421/33C 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" 2.5/8" 2.5/8" 3.1/8" 4.1/8" ODS [mm] 22 35 42 54 80 76,1 88,9 114,3 163 200 121 149 W [mm] D1 D2 H1 H2 H3 P 5450 5375 5435 5410 5585 6030 12000 12200 12500 Dimensions [mm]

Weight [g]

154 159 171 162 186 187 192

241 246 258 249 273 308 313 200 185

96 101 113 103 128 143 148

D1

D2

D2

D1

TABLE 4: General Characteristics Dimensions and Weights


Filtering Surface Dimensions [mm]

P
Weight [g]

Catalogue Number

[sq.in]

[cm2]

D1

D2

4495/C

127

820

60

87

138

480

4496/C

287

1850

80

113

168

750

H1

H2

4495 - 4496

20

H3

www.castel.it

109

STRAINERS
APPLICATIONS The filters, shown in this chapter, are classified Pressure vessels in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.1 and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION The filter is completely manufactured in steel, either with nickel-plated Flare threaded connections. The product range also includes types with copper plated solder connections, offering the possibility to solder the copper pipe inside the connections (ODS) or outside the connections, using a copper sleeve (ODM). Inside the filters there is a screen basket, with wide filtering surface, made of austenitic stainless steel AISI 304. These filters may not be cleaned.

TABLE 1: General Characteristics


Connections Catalogue Number Filtering Surface [cm2] Useful Passage Surface [%] Mesh Opening [mm] ODS SAE Flare 3/8" 1/2" 36,6 0,166 142 [in.] 3/8" 1/2" 5/8" [mm] 10 12 16 18 [in.] 1/2" 5/8" 3/4" ODM [mm] 12 14 16 22 8,0 3,4 2,4 3,2 2,4 40 +80 42 Art. 3.3 Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED

4510/3 4510/4 4520/3 4520/M10 4520/M12 4520/4 4520/5 4520/M18

58 142

58

TABLE 2: Dimensions and Weights


Dimensions [mm]

Catalogue Number

Weight [g] L

D 4510/3 4510/4 4520/3 4520/M10 4520/M12 4520/4 4520/5 4520/M18 76 52 52 76

110 174 109 113 122 126 170

195 515 195 205 215 245 495

D D 4510 4520

DESSICCANTS
For using on refrigerating systems, Castel puts the following desiccants at disposal of its own customers: Activated alumina Code No 4901/AA Molecular sieve Code No 4901/MS Silicagel Code No 4901/SG hermetically sealed in steel cans with a weight of about 0,750 kg and supplied in multiply package of 15 cans.

110

www.castel.it

OIL SEPARATORS

111

OIL SEPARATORS
APPLICATIONS The oil separators, shown in this chapter, are classified Pressure vessels in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.1 and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). The advantages of the oil separator on the discharge line of a compressor in a refrigeration system are confirmed by many years of experience. The oil separator intercepts the oil mixed with compressed gas and returns it to the crankcase of the compressor thus assuring an efficient lubrication of its moving parts. Furthermore, the oil separator maintains a high coefficient of condenser and evaporator performance by almost completely removing oil deposits from their exchange surfaces. When a very high temperature at the end of the compression stage leads to the formation of oil vapours, a separator with a capacity exceeding the values shown in the table should be used. Moreover, the oil separator, damping the valves pulsations, reduces system noise with an open or semi-hermetic compressor. Finally, the use of an oil separator leads to: a longer life of the compressor; a better performance of the whole system with consequent energy saving; a quieter operation by reducing pulsations. Table 1 and 3 show the technical data relating to the working conditions of oil separators. CONSTRUCTION Castel manufactures two types of oil separators: separators series 5520 can be overhauled for maintenance and can be replaced from the system. They are equipped with threaded connections, which can mate to the connections type 5590 (to be ordered separately) separators series 5540 are closed type and they cannot be dismantled from the system, except cutting the piping. The body is manufactured from steel pipe of adequate thickness. Flanges and cover are also made of steel. Either threaded connections of separators series 5520 or solder connections of separators series 5540 are manufactured, machining, with steel bar EN 10277-3 11S Mn Pb 37 + C. The internal device is simple in order to assure a trouble-free long operation. Appropriate metallic screens, placed on the inlet and outlet, rapidly reduce gas speed, and create the conditions required for the separation of the oil from the refrigerant. A float operated needle valve, set on the bottom of the vessel, return the oil to the crankcase of compressor. The bottom also includes a chamber that collects all metallic debris. A permanent magnet holds these impurities to avoid they stop or damage the operation of needle, moved by floating.

112

www.castel.it

SELECTING THE SIZE OF AN OIL SEPARATOR The selecting of an oil separator should be done comparing the characteristics of the installed compressor, establishing: inlet connection must agree with the discharge diameter of the compressor refrigerant flow capacity with fixed working conditions (saturated discharge temperature saturated suction temperature, eventually liquid subcooling, sucked vapour overheating). This is necessary to define the gas speed referred to the cross section of oil separator, assigned an end compression temperature. It is advisable the above-mentioned speed doesnt exceed 0,5 m/s, to avoid great swirl phenomena. Table 3 has being written following this principle. Generally, fixed the following data: refrigerating capacity of compressor, type of refrigerant and working conditions, the volumetric capacity Q, of compressed gas, is given by:

Check of gas speed, referred to the cross section of oil separator, is given by:

OIL SEPARATORS

v = QS

[m/s]

with:

S = gross cross section of shell separator [m2] INSTALLATION The oil separators type 5520 and 5540 should be installed in the discharge line between the compressor and the condenser mounted securely in a vertical position and reasonably close to the compressor. To prevent the return of refrigerant from condenser, during the off cycle of the system, its advisable to install a check valve between the condenser and oil separator outlet connection. Oil separator performs best when operating at or near the compressor discharge temperature. In location the oil separator, choose a position to avoid, as far as possible, chilling of the shell, which may result in condensing of liquid within the separator. If this is not possible, it is advisable to supply the separator with the better solutions (insulation, strap heater, others) to prevent the refrigerant in the system from condensing in the shell. Before the oil separator is installed, either one 5520 or one 5540, an initial charge of oil should be added to it. Refer to general characteristics of oil separators or to instruction sheet for the proper amount of oil. Oil pre-charge is very important, failure to pre-charge separator sump may result in damage to the oil return float mechanism. Use the same type of oil that is in the compressor crankcase. Acting as the lay out of refrigerating system, the return line may be run from the oil fitting to: the compressor crankcase; the suction line upstream the compressor or upstream the receiver, if present; the oil reservoir if oil control system is being used. A sight glass may be installed in the oil line, in a position that oil is flowing through the tube, to check the correct working of the oil separator.

Q=

P vg H

[m3/s]

with:

P = refrigerant flow capacity kW] H = heat content differential, see diagram (fig. 1). [kJ/kg] vg = specific volume of compressed gas, separator inlet (fig. 1). [m3/kg].

Fig. 1

www.castel.it

113

IN IN OUT

OUT

outlet screen cylinder

outlet screen cylinder

inlet screen cylinder

steel plate

inlet screen cylinder

steel plate

stainless steel ball

oil return tube

stainless steel ball

oil return tube

stainless steel needle

permanent magnet

stainless steel needle

permanent magnet

5540
TABLE 1: General Characteristics
Solder Connections Catalogue Number [in.] 5540/4 5540/5 5540/7 5540/9 5540/11 5540/13 5540/M42 5540/17 5520/C 1/2" 5/8" 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" ODS [mm] 16 35 42 54 [in.] 5/8" 3/4" 1" 1.3/8" 1.5/8" ODM [mm] 16 35 5590/5 5590/7 5590/9 5590/11 5590/13 5590/M42 5/8" 7/8" 1.1/8" 1.3/8" 1.5/8" 16 35 42 1/4" 0,4 / 0,5 3/8" 0,6 / 0,7 21 1/4" 0,4 / 0,5 Catalogue Number Couple of solder connections IN / OUT ODS (1) [in.] [mm] Oil connection [SAE Flare] Oil addition [kg]

5520

TS [C] Max. differential pressure [bar] PS [bar] min. max. Risk Category according to PED

10

+ 130

32

II

5520/D

5520/E

(1) The dimensions of the separator's connections must agree with the discharge diameter of the compressor

114

www.castel.it

OIL SEPARATORS

TABLE 2: Dimensions and Weights


Catalogue Number Solder Connections ODS Separator Connections [in.] 1/2" 5/8" 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" 5590/5 5590/7 5590/9 5590/11 5590/13 5590/M42 5/8" 7/8" 1.1/8" 1.3/8" 1.5/8" [mm] 16 35 42 54 16 35 42 121 149 391 92 483 7680 163,5 17,5 123 D1 D2 H1 H2 H3 H4 Dimensions [mm] Weight [g]

5540/4 5540/5 5540/7 5540/9 5540/11 5540/13 5540/M42 5540/17 5520/C

280 367

4200 4960 5030 5835 5800 10000 10460 6980

428

471 481 336 61 397

5520/D

67

458

7760

5520/E

5590/..

Gasket

H3

D2

H4

H1

H2

H1

H4

M10
5520

M10
5540

D1

D1

www.castel.it

115

TABLE 3: Refrigerant Flow Capacity


Refrigerant Capacity (1) [kW] Catalogue Number Catalogue Number of solder connections 20 5540/4 5540/5 5540/7 5540/9 5540/11 5540/13 5540/M42 5540/17 5520/C 5590/5 5590/7 5590/9 5590/11 5590/13 5590/M42 5,3 16,4 18,6 21,2 23,9 33,1 42,5 16,4 18,6 21,2 23,9 26,5 R134a R22 R404A R407C

Evaporating Temperature [C] +5 6,1 18,9 21,3 24,3 27,4 38,0 48,8 18,9 21,3 24,3 27,4 30,4 40 6,4 19,7 22,2 25,4 28,6 39,6 50,9 19,7 22,2 25,4 28,6 31,8 +5 7,9 24,5 27,7 31,5 35,6 49,3 63,4 24,5 27,7 31,5 35,6 39,5 40 6,4 19,9 22,5 25,7 28,9 40,1 51,5 19,9 22,5 25,7 28,9 32,1 +5 8,8 27,3 30,8 35,2 39,6 54,9 70,6 27,3 30,8 35,2 39,6 44,0 40 6,0 18,6 21,0 24,6 27,0 37,6 48,3 18,6 21,0 24,6 27,0 30,0 +5 8,0 24,6 27,8 31,8 35,8 49,6 63,7 24,6 27,8 31,8 35,8 40,0

5520/D

5520/E

(1) Refrigerant flow capacity with a condensing temperature of + 40C and normal overheating values of vapour sucked by compressor. No liquid subcooling. Maximum pressure drop of 0,15 bar

116

www.castel.it

VALVES

117

HERMETIC VALVES
APPLICATIONS The hermetic valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION These valves are available in the following two types: two-ways shut-off valves types 6010/2 and 6012/22; three-ways valves; two main connections plus a third one for charging or manometer connection, types: 6060 with right access connection; 6070 with left access connection. On both types, the access connection may be shut off by the back-seating of the spindle. The main parts of the hermetic valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle.

TABLE 1: General Characteristics


Connections Catalogue Number (1) 6010/2 6012/22 6020/222 6020/233 6020/244 6020/255 6060/22M6 6060/23M10 6070/22M6 6070/23M8 6070/23M10 6070/24M12 6070/25M16 1/4" SAE Flare (2) 1/4" 1/4" 1/4" 3/8" 1/2" 5/8" 1/4" 3/8" 1/4" 3/8" 3/8" 1/2" 5/8" (3) 1/4" 1/4" 3/8" 1/2" 5/8" 6 10 6 8 10 12 16 [in.] 1/4" ODS (4) [mm] 0,27 0,39 1,20 2,20 2,80 0,46 1,38 0,46 1,29 1,38 2,55 3,40 -60 +110 45 Art. 3.3 Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED

+4,5+130

6010/2 4.5

H2

H1

L2

118

www.castel.it

VALVES

TABLE 2: Dimensions and Weights


Dimensions [mm] Catalogue Number Weight [g]

H1

H2

H3

H4

H5

L1

L2

L3

P1

6010/2 6012/22 6020/222 6020/233 6020/244 6020/255 6060/22M6 6060/23M10 6070/22M6 6070/23M8 6070/23M10 6070/24M12 6070/25M16

14

66

36

29 62 67 77 79 24

58 55,5

160 145 360 370 520 530

25

51

61

115

26,5

52 31 33

68,5 56,5 58,5 56,5 59 68 69

127

34 37 34 37

92 91 92 90 30,5

205 200 205 210 220 32,5 310 320

27 24

25,5

31 33 38,5 39,5

27

29,5

28

43,5

102

6012/22 4.5 H2 4 2 H1 L1 L2 L2 6060 6020 I 2 P1

H2

1 2 H4

H3

H1

H5

3 H3 1 H2 H1 M10 L1

L1 L3 6070 2

M8 11

P1

L2

H2 H3

H5

1 M8 11

H1

L1 L3

www.castel.it

119

RECEIVER VALVES
APPLICATIONS The receiver valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION These valves are available in the following two types: two-ways valves, 90 angle connections, types 6110 and 6120; three-ways valves; two main connections (90 angle) plus a third one for charging, type 6132. The access connection may be shut off by the back-seating of the spindle; two-ways valves, 120 angle connections, type 6140. The main parts of the receiver valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle.

TABLE 1: General Characteristics


Connections Catalogue Number (1) 6110/21 6110/22 6110/X15 6110/23 6110/32 6110/33 6110/X13 6110/43 6110/44 6110/54 6110/66 6120/22 6120/23 6120/33 6120/43 6120/44 6120/54 6120/66 6132/22 6132/33 6132/44 6132/54 6140/22 6140/23 1/4" 3/8" f SAE Flare (2) 1/4" 1/4" 1/4" 1/4" 3/8" 3/8" 3/8" 1/2" 1/2" 5/8" 3/4" 1/4" 1/4" 3/8" 1/2" 1/2" 5/8" 3/4" 1/4" 3/8" 1/2" 5/8" 1/4" 1/4" NPT (3) 1/8" 1/4" 3/8" 1/4" 3/8" 3/8" 1/2" 1/2" 3/4" 1/4" 3/8" 3/8" 3/8" 1/2" 1/2" 3/4" 1/4" 3/8" 1/2" 1/2" 1/4" 3/8" 2,40 3,40 6,00 0,44 0,45 1,35 2,40 3,40 6,00 0,45 1,20 2,20 3,85 0,36 +130 +110 -60 45 Art. 3.3 +130 1,35 0,45 0,44 Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED

1/4" f

120

www.castel.it

VALVES

TABLE 2: Dimensions and Weights


Dimensions [mm] Catalogue Number Weight [g]

6110

H1

H2

L1

L2

6110/22 6110/X15 6110/23 6110/32 6110/33 6110/X13 6110/43 6110/44 6110/54 6110/66 6120/22 6120/23 6120/33 6120/43 6120/44 6120/54 6120/66 6132/22 6132/33 6132/44 6132/54 6140/22 6140/23

72 83

48

27,5

110 130

29 77 50

135 130

31

140 175 220

87 88 92 128 27,5 55,5 34,5

NPT 3 L1

235 245

88

42,5 72 77 48 50

675 110 130 140 225 55,5 305 245

6120 2

30 33 40 56 29

80 93 94 130 94 97 112 115 69

64

240 250 375 365 115 125

H1

88

670

3 L1

NPT L2

63,5

36

75

57

46

1 6132 2 H1

H2

6110/X13 6110/X15

NPT L2 L1

H2

2 H1 2

6140

NPT 3 1 L1 L1 L2

H1

H1

H2

6110/21

70,5

100

www.castel.it

121

STOP VALVES
APPLICATIONS The stop valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION The very compact design of these brass valves allows minimum dimensional sizes and the fixing flange complies with current market requirements. Valves 6170 and 6175 must be completed with the following devices, to be ordered separately: valve code 8394/A or code 8394/B; cap with gasket code 8392/A. The main parts of the stop valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; brass EN 12164 CW 614N for spindle and protection cap; chloroprene rubber (CR) for outlet seal gaskets for series 6165 and 6175; chloroprene rubber (CR) and aramidic fibers for gland seal, only for series 6170.

TABLE 1: General Characteristics


Connections Catalogue Number Way Nr. (1) 6165/22 6165/33 6175/33 6175/44 6175/55 6170/66 6170/77 3 1/4" SAE Flare (2) 1/4" 3/8" 3/8" 1/2" 5/8" 3/4" 7/8" [in.] 1/4" 3/8" 3/8" 1/2" 5/8" 3/4" 7/8" 16 ODS (3) [mm] 0,68 1,70 1,70 3,40 4,60 9,00 10,80 -20 +110 45 Art. 3.3 Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED

122

www.castel.it

VALVES

TABLE 2: Dimensions and Weights


Dimensions [mm] Catalogue Number Weight [g] I

H1

H2

H3

L1

L2

L3

6165/22 6165/33 6175/33 6175/44 6175/55 6170/66 6170/77 20 65 17 52 8

9,5 12,7 15,9 19 12 22,2 28,6

29 30,5

29 31

59,5 67 38

113 120 135 225 235 50 655 670

36

28,5

104

47

36

83

6170 6165 6175

2 H2 H2

H1

H3

D L1 L1 L3 6.5 6.5 I

H3

H1

3 D L2

www.castel.it

123

DIAPHRAGM VALVES
APPLICATIONS The diaphragm valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION Diaphragm valves dont have gland seal. The external sealing is ensured by some thin metal discs (diaphragms), which hermetically divide the spindle chamber from the fluid flow area. The main parts of the hermetic valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; brass EN 12164 CW 614N for spindle; harmonic steel for spring; nylon for seat sealing gaskets.

TABLE 1: General Characteristics


Connections Catalogue Number ODS (2) SAE Flare (1) 1/4" 3/8" 1/2" 5/8" 3/4" 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 16 [in.] [mm] 0,28 1,00 1,30 1,80 3,65 0,28 1,00 1,30 1,80 3,65 -35 +90 28 Art. 3.3 Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED

6210/2 6210/3 6210/4 6210/5 6210/6 6220/2 6220/3 6220/4 6220/5 6220/6 6220/7

124

www.castel.it

VALVES

TABLE 2: Dimensions and Weights


Dimensioni [mm] Catalogue Number H1 H2 L1 d I D Weight [g]

6210/2 6210/3 6210/4 6210/5 6210/6 6220/2 6220/3 6220/4 6220/5 6220/6 6220/7

68 53,5

58 74 78 62,5 98 53 53,5 61 70 71 4,5 6,2 4,5

36 52

200 325 335 340

72

38

86 68

50 36

60

655 195

72

38

52

300 305 580 645

86

62,5

92 94

6,2

50

60

6210 D

6220 D

H2

H2

H1

1 A94

H1

A94

L1 d

L1 d

www.castel.it

125

ROTALOCK VALVES
APPLICATIONS The rotalock valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION Rotalock valves, mounted with 7910 fittings and 7990 gaskets, assure fast installation and safe sealing. Before tightening it is possible to turn the valve in every direction. All Rotalock valves have an additional charging connection, which can be excluded by the back sealing of the spindle. Fittings 7910 and gaskets 7990 have to be ordered separately. The main parts of the hermetic valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle; steel bar EN 10277-3 11 S Mn Pb 37 for 7910 fittings; P.T.F.E. for 7990 gaskets.

Valves 6310 6320

Gasket 7990

Coupling 7910

TABLE 1: General Characteristics


Connections Catalogue Number (1) 6310/2 6310/3 6310/4 6320/3 6320/4 6320/5 6320/6 1/4" SAE Flare (2) 1/4" 3/8" 1/2" 3/8" 1/2" 5/8" 3/4" 1" UNS Swivel nut (3) 0,46 1,35 1,40 3,10 3,4 -60 +110 45 Art. 3.3 Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED

3/4" UNF

126

www.castel.it

VALVES

TABLE 2: Dimensions and Weights


Dimensions [mm] Catalogue Number Weight [g]

H1

H2

L1

L2

6310/2 6310/3 6310/4 6320/3 6320/4 6320/5 6320/6 72 36,5 69,5 34,5 68,5 33,5

94 64

290 300 330

97

114,5 117,5 77,5

400 415 425

6310 6320

1 2

H1 H2

3 L1

L2

www.castel.it

127

CAPPED VALVES
APPLICATIONS The capped valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION The main parts of the capped valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle. INSTALLATION The brazing of capped valves with solder connections, type 6420, should be carried out with care, using a low melting point filler material. Its necessary to remove the spindle assembly, with gland too, before brazing the body. Its important to avoid direct contact between the torch flame and the valve body, which could be damaged and compromise the proper functioning of the valve.

TABLE 1: General Characteristics


Connections Catalogue Number (1) 6410/2 6410/3 6410/4 6410/5 6410/6 6420/2 6420/3 6420/M10 6420/M12 6420/4 6420/5 6420/M18 6420/6 6420/M22 6420/7 6460/22A
E E

TS [C] ODS (3) Kv Factor [m3/h] [mm] 0,40 1,00 1,45 1,70 3,50 PS [bar] min. max. Risk Category according to PED

SAE Flare (2) [in.]

1/4" 3/8" 1/2" 5/8" 3/4" 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 1/4" 1/4" 10 12 16 18 22

0,40 1,00 -60 1,45 1,70 +110 45 Art. 3.3

3,50

0,35

Until exhaustion of the stock

128

www.castel.it

VALVES

TABLE 2: Dimensions and Weights


Dimensions [mm] Catalogue Number Weight [g] d I

H1

H2

L1

L2

L3

P1

6410/2 6410/3 6410/4 6410/5 6410/6 6420/2 6420/3 6420/M10 6420/M12 6420/4 6420/5 6420/M18 6420/6 6420/M22 6420/7 6460/22A 85,5 67 113 89,5 85,5 67 113 89,5 85,5 67

68 74 78 98 57 61 6,2 50 4,5 38

305 325 330 695 300

4,5

38

70 71 92 6,2 94 97 34 51 35 4,5 38 50

305

700 685 690 395

6410

6420

6460/22A

H2

H2

H1

H1

3 A94

A94

L1

L1

H1

H2

L2

L3

45

I
I I

A P1 1 1 C L1 2

N.B. When the valve 6460/22A is closed, connections A-B are open and C is stopped; when opened, all connections are open.

www.castel.it

129

GLOBE VALVES
APPLICATIONS The globe valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION These valves are available in the following two types: 6512 with straight solder connections; 6532 with solder angle connections; The main parts of the globe valves are made with the following materials: hot forged brass EN 12420 CW 617N for body, cover and cap that covers the spindle; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; metal-rubber laminated for outlet seal gaskets P.T.F.E. for seat gaskets.

TABLE 1: General Characteristics


Connections Catalogue Number [in.] 6512/M22 6512/7 6512/M28 6512/9 6512/11 6512/13 6512/M42 6512/17 6532/M22 6532/7 6532/M28 6532/9 6532/11 6532/13 6532/M42 6532/17 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" ODS [mm] 22 28 35 42 54 22 28 35 42 54 [in.] 1.1/8" 1.3/8" 1.3/8" 1.5/8" 2" 2" 1.1/8" 1.3/8" 1.3/8" 1.5/8" 2" 2" ODM [mm] 28 35 35 28 35 35 7,1 Art. 3.3 Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED

8,4 15,0 25,0 40,00 8,2

I -35 +160 45

9,1 18,7 38,0 48,5

Art. 3.3

130

www.castel.it

VALVES

TABLE 2: Dimensions and Weights


Dimensions [mm] Catalogue Number H Weight [g] Q A

H1

L1

6512/M22 6512/7 6512/M28 6512/9 6512/11 6512/13 6512/M42 6512/17 6532/M22 6532/7 6532/M28 6532/9 6532/11 6532/13 6532/M42 6532/17 238 65 139 86,5 104 138 165 52,5 93 59 68 126 147 44,5 80 50 60 94 166 199 215 34 37 42,5 118 141 173 136 28,5 100 60 94

1415

1310 68 88 104 126 2020 3500 5050 1350

138

1290 1910 4920 4765

6512

Q H H1

M10

6532

Q H

L1 L

www.castel.it

131

H1

BALL VALVES
APPLICATIONS The ball valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION The specific design of Castel ball valves: ensures the internal equilibrium of pressures when the valve is closed; permits the bi-directional flow of the refrigerant and, consequently, the assembly on the plant without taking into account the direction of the refrigerant; prevents any risk of ejection or explosion of the spindle. The opening and closing of the valve is realized by turning the spindle one fourth of a turn. A standstill in turning realizes either a full opening or a full closing, moreover the arrow printed on the spindle head shows the flow direction. The electric welding of the bodies and the seal gaskets, assembled on the spindle, prevent any leaks. Ball valves are available in the following two types: type 6590 (full port) and type 6591 (reduced port) without access fitting. type 6590/A (full port) and type 6591/A (reduced port) with access fitting. These ball valves are equipped with valve core 8394/A and cap 8392/A. The main parts of the valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; hot forged brass EN 12420 CW 617N, chromium plated, for ball; copper tube EN 12735-1 Cu-DHP for solder connections; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) for outlet seal gaskets; P.T.F.E. for seat ball gaskets; glass reinforced PBT for cap that covers the spindle. Hot forged brass EN 12420 CW 617N for caps on sizes from 6590/M64A up to 6591/34A. INSTALLATION The brazing of ball valves should be carried out with care, using a low melting point filler material. It is important to avoid direct contact between the torch flame and the valve body, which could be damaged and compromise the proper functioning of the valve.

6590

132

www.castel.it

VALVES

TABLE 1: General Characteristics


Catalogue Number without access fitting 6590/M6 6590/2 6590/3 6590/M10 6590/M12 6590/4 6591/5 6590/M15 6590/5 6590/M18 6590/6 6591/7 6590/7 6591/M28 6591/9 6590/M28 6590/9 6591/11 6590/11 6591/13 6591/M42 6590/13 6590/M42 6591/17 6590/17 6591/M64 6591/21 Connections ODS with access fitting [in.] 1/4" 3/8" 1/2" 5/8" 5/8" 3/4" 7/8" 7/8" 1.1/8" 1.1/8" 1.3/8" 1.3/8" 1.5/8" 1.5/8" 2.1/8" 2.1/8" 2.5/8" 2.5/8" 3" 3.1/8" 3.1/8" 3.1/2" 3.5/8" 4.1/8" 4.1/4" 80 89 105 108 80 430 42 [mm] 6 10 12 16 15 16 18 22 22 28 28 35 35 42 42 54 54 64 64 65 293,0 I 50 178,0 38 100,0 32 68,0 25 40,0 -40 +150 45 19 24,0 15 14,5 Art. 3.3 5,0 10 0,8 Ball Port [mm] Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED

6590/3A 6590/M10A 6590/M12A 6590/4A 6590/M15A 6590/5A 6590/M18A 6590/6A 6590/7A 6590/M28A 6590/9A 6590/11A 6590/13A 6590/M42A 6590/17A 6591/M64A 6591/21A 6590/M64A 6590/21A 6591/24A 6591/25A

3,0

6590/25A 6591/28A 6591/29A 6591/33A 6591/34A

www.castel.it

133

TABLE 2: Dimensions and Weights


Dimensions [mm] Catalogue Number H Weight [g] I d

H1

H2

L1

L2

6590/M6 6590/2 6590/3 6590/M10 6590/M12 6590/4 6591/5 6590/M15 6590/5 6590/M18 6590/6 6591/7 6590/7 6591/M28 6591/9 6590/M28 6590/9 6591/11 6590/11 6591/13 6591/M42 6590/13 6590/M42 6591/17 6590/17 6591/M64 6591/21

6590/3A 6590/M10A 6590/M12A 6590/4A 6590/M15A 6590/5A 6590/M18A 6590/6A 6590/7A 6591/M28 6590/M28A 6590/9A 6590/11A 6590/13A 6590/M42A 6590/17A 6591/M64A 6591/21A 6590/M64A 6590/21A 6591/24A 6591/25A 172,5 62 150 55 130 45 117 38 101,5 30 95,5 27,5 80 24 73 20

260

33

121

65

24

300

138

73,5

18 M5

290

36

141

74

32

410

38

177 175 206

92 93 108,5

33

450 760 800

41 45

206 248

109 130

43 49

1050

247

129

2050 30 M6 3320 3240 5450

48

262 292

136 151

49

53

303

162

58

5500 8120 8090 8310 8350 75 M10 12400 12450

330 64 350

175

58

185

68

6590/25A 6591/28A 6591/29A 6591/33A 6591/34A 196,5 75 70 400 209 86 380 199 76

12500

L2

H2

H L1 L I 6590/..A H1

134

www.castel.it

GAUGE MOUNTING VALVES


APPLICATIONS The valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). They are used for mounting and intercepting the gauges on control panels. CONSTRUCTION The valves are equipped with: a little flange for fixing the valve to the control panel; a SAE-Flare connection for joining it to the copper tube; an NPT (type 8320) or a swivel SAE FLare (8321) connection for mounting the gauge. The main parts of this valve are made with the following materials: Hot forged brass EN 12420 CW 617N for body; Steel, with proper surface protection, for the spindle; Chloroprene rubber (CR) and aramidic fibers for gland seal; Glass reinforced PBT for cap that covers the spindle.

VALVES

TABLE 1: General Characteristics, Dimensions and Weight


Connections Catalogue Number Dimensions [mm] Peso [g] min. max. TS [C] PS [bar] Risk Category according to PED

SAE Flare 1/4" 1/4" 1/4"

NPT

SAE Flare 1/4" f

H1

L1

L2

L3

8320/21 8320/22 8321/22

1/8" 1/4"

19 37 40 83 35 17

140 186 -60 +130 45 Art. 3.3

8321 8320

Ch.19

L3 L2 L1 34

H1

L3 L2 L1 34

www.castel.it

135

H1

6.5

6.5

LINE PIERCING VALVE


APPLICATIONS The valve, shown in this chapter, is classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. It is designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). The piercing valve is a fast and cheap means of providing a loading, outlet or inlet point in the refrigerating system. It can be applied on copper tube with a 6 mm to 10 mm diameter, and can be installed in any position on the system. CONSTRUCTION The main parts of the piercing valve are made with the following materials: Hot forged brass EN 12420 CW 617N for body; Hardened steel for the needle; Chloroprene rubber (CR) for the outlet seal gaskets. INSTALLATION The threaded fork must be installed astride of the copper tube, the valve is fastened to the pipe by tightening the lower nut and screwing it the needle pierces the pipe. The hole, pierced by the needle, connects the pipe inlet with the SAE-Flare connection as shown in figures 1 and 2.

TABLE 1: General Characteristics, Dimensions and Weight


Connections Catalogue Number Pipe diameter [mm] 6 - 10 Dimensions [mm] Weight [g] min. max. TS [C] PS [bar] Risk Category according to PED

SAE Flare 1/4"

H1

L1

L2

L3

8330/A

72

25,5

29

36

104

-10

+70

25

Art. 3.3

L2

Fig. 1 - The valve is installed with the threaded fork astride of the copper pipe to be pierced.

1/4"SAE flare H1 opened valve H2

L1
Fig 2 - Tightening of lower screw nut.

136

www.castel.it

THREADED BRASS FITTINGS

137

THREADED BRASS FITTINGS


APPLICATIONS All the fittings, shown in this chapter, are excluded from the scope of Directive 97/23/EC, as specified in the Guidelines 1/8 and 1/9, because they are piping components. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). OPERATION The sealing system between the end of a male connection and a nut series 7010, 7020 and 7030 requires a special flaring of the end of copper tube, the so-called flared connection. The sealing system between the end of a male connection and a Flare-ODS adapter allows avoiding the flaring process on copper tube end (national laws of some European countries dont accept this operation) because the tube end is brazed into the solder connection of the adapter. We wish to remember to our customers that they may assure no leakage of the male connection/adapter system only interposing the copper gasket 7580, supplied with the same adapter. Flange joints 7630 consist of two brass bushes for brazing to the copper tubes. When the four flange screws are tightened, a gasket, put between the two bushes, assures the seal of flanged joints.

CONSTRUCTION All nuts, from series 7010 to series 7050, and all the elbows, TEE and cross fittings, from series 7210 to series 7410, are manufactured with hot forged brass EN 12420 CW 617N. All straight fittings, from series 7110 to series 7170, and all the plug, from series 7510 to series 7520, are machined by brass bar EN 12164 CW 614N. Seal caps series 7560 and gaskets series 7580 are made with copper Cu ETP UNI 5649. The main parts of the flanges joints are made with the following materials: hot forged brass EN 12420 CW 617N for bushes and flanges; aramidic fibers for seal gasket of the flanges.

138

www.castel.it

THREADED BRASS FITTINGS

TABLE 1: General Characteristics


Copper pipe Catalogue Number International Reference SAE Flare PS [bar] D L Ch Dimensions [mm] Wrench torque min / max [Nm] Weight [g]

[in]

[mm]

SAE Flare nuts (inch tubing)


L
7010/22 7010/33 7010/44 7010/55 NS44 NS46 NS48 NS410 NS412 NS414 NS416 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 1" 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 1" 6 16 22 45 6,5 9,7 13 16,2 19,4 22,5 25,6 15,5 19,5 22,5 25 29,5 36,5 36,5 17 22 25 28 33 41 11 / 14 20 / 25 34 / 47 54 / 75 68 / 71 90 /120 120 / 150 19 38 49 64 97 186 153

7010/66 7010/77

Ch

7010/88

SAE Flare cap nuts


L
7020/20 N54 CAP NUT 1/4" cieco N5-5 7020/X01 5/16" cieco 45 16 19 14 / 20 25 15,5 17 11 / 14 20

Ch

CAP NUT

SAE Flare reducing nuts (inch tubing)


L
7020/32 7020/43 7020/54 NRS464 NRS486 NRS4108 NRS41210 NRS41614 3/8" 1/2" 5/8" 3/4" 1" 1/4" 3/8" 1/2" 5/8" 7/8" 6 16 22 45 6,5 9,7 13 16,2 22,5 19,5 22,5 25 29,5 36,5 22 25 28 33 41 11 / 14 20 / 25 34 / 47 54 / 75 90 /120 38 53 69 104 160

7020/65

Ch

7020/87

SAE Flare nuts (metric tubing)


L
7030/3M8 7030/3M10 7030/4M10 7030/4M12 1/2" 5/8" 3/8" 8 10 10 12 14 12 14 14 18 45 8,3 10,3 10,3 12,3 14,3 12,3 14,3 14,3 18,3 25 28 54 / 75 22,5 25 34 / 47 19,5 22 20 / 25 37 36 53 50 47 70 68 106 98

D
Ch

7030/4M14 7030/5M12 7030/5M14 7030/6M14 7030/6M18

3/4"

29,5

33

68 / 71

SAE Flare twin nuts


L
7050/2 7050/3 7050/4 US44 US46 US48 US410 1/4" 3/8" 1/2" 5/8" 45 46 51 25 28 34 / 47 54 / 75 105 140 32 40 17 22 11 / 14 20 / 25 39 78

Ch

7050/5

www.castel.it

139

TABLE 2: General Characteristics


Connections Catalogue Number International Reference SAE Flare NPT PS [bar] L Ch Dimensions [mm] Weight [g]

SAE Flare unions


7110/2 U24 U26 U28 U210 U212
E

1/4" 3/8" 1/2" 5/8" 3/4" 1" 45

38 44 50 58 63 72

12 17 20 23 27 36

23 46 73 113 164 304

7110/3 7110/4 7110/5

Ch

7110/6 7110/8

U216

Reducing SAE Flare unions


7120/23 UR264 UR284
R R

1/4" x 3/8" 1/4" x 1/2" 3/8" x 1/2" 3/8" x 5/8" 1/2" x 5/8" 5/8" x 3/4" 45

42 45 48 52 54 61,5

17

38 58

7120/24 7120/34 7120/35

UR286 UR2-106 UR2108

20 23 23 27

66 89 98 170

Ch

7120/45 7120/56
R

UR2-1210

SAE Flare / NPT unions


7130/2 U14B U16C U18D U112F U116H 1/4" 3/8" 1/2" 3/4" 1" 1/4" 3/8" 1/2" 3/4" 1" 45 38,1 41,2 49,8 57,6 68 14 17 22 27 36 32 48 92 152 277

L
7130/3 7130/4

Ch

7130/6 7130/8

SAE Flare / NPT reducing unions


L
7140/21 7140/32 7140/43 U14A U16B U18C U110D 1/4" 3/8" 1/2" 5/8" 1/8" 1/4" 45 3/8" 1/2" 45,2 53,8 20 23 64 102 32,9 41,1 12 17 20 39

Ch
7140/54

R E

Available on request Until exhaustion of the stock

140

www.castel.it

THREADED BRASS FITTINGS

TABLE 3: General Characteristics


Connections Catalogue Number International Reference SAE Flare NPT m f GAS [in.] ODS [mm] PS [bar] L Ch Dimensions [mm] Weight [g]

Male/female reducing unions (reduced female)


L
7150/21 7150/32 7150/43 7150/54 U34A UR346 UR368 UR3810 UR3812 UR31012 1/4" 3/8" 1/2" 5/8" 5/8" 3/4" 1/4" 3/8" 1/2" 1/2" 5/8" 45 1/8" f 29 33 38 45 46,5 49,5 14 17 22 25 27 30 21 38 66 99 132 157

Ch

7150/64 7150/65

Male/female reducing unions (reduced male)


L
7150/23 7150/24 7150/34 7150/45 7150/46 UR364 UR384 UR386 UR3108 UR3128 UR31210 1/4" 1/4" 3/8" 1/2" 1/2" 5/8" 3/8" 1/2" 1/2" 5/8" 3/4" 3/4" 45 33 36 39 44 45 49 22 25 30 34 49 66 74 127 140 150

Ch

7150/56

Cylinder adaptors
L
7154/2 7156/2 1/4" W 21,8 14 filetti dx. femmina 1/4" 20 14 filetti sx. femmina 45 29 27 52 25 46

Ch

Male/female unions
L
7160/2 1/4" 1/4" 30,5 17 31

7160/3

3/8"

3/8"

45

36

22

57

Ch

7160/4

1/2"

1/2"

41

25

84

Unions SAE Flare to BSP


L
7164/2 7166/2 1/4" 1/4" G1/4" G1/4" f 45 32 17 25 32,5 20 45

Ch

Male SAE Flare/solder unions


7170/22 US344 US366 US388 US31010

7170/2M8 7170/33 7170/3M10

1/4"

1/4" 3/8" 1/2" 5/8"

8 10 12 16 18 45

26,5

12

17

3/8"

33

17

39

Ch

7170/44 7170/4M12 7170/55 7170/6M18

1/2" 5/8" 3/4"

35 42 45,5

20 23 27

55 82 123

Available on request

www.castel.it

141

TABLE 3: General Characteristics


Connections Item Position Catalogue Number ODS SAE Flare [in.] [mm] PS [bar] Dimensions [mm] Wrench torque Weight min/max [g] [Nm]

L1

L2

L3

L4

Ch

Flare / ODS adapters


1 2 3 1 2 3 1 2 9900/X58 9900/X62 7580/2 9900/X58 9900/X70 7580/2 9900/X59 9900/X63 7580/3 9900/X59 9900/X71 7580/3 9900/X60 9900/X64 7580/4 9900/X60 9900/X72 7580/4 9900/X61 9900/X65 7580/5 9900/X68 9900/X69 7580/6 9900/X68 9900/X77 7580/6 3/4" 18 30 5 3/4" 3/4" 30 5 5/8" 5/8" 16 27,5 5 1/2" 12 1/2" 1/2" 45 26 26 4,5 4,5 3/8" 10 23,5 4 3/8" 3/8" 23,5 4 1/4" 6 21 3,5 1/4" 1/4" 21 3,5 16 16 18,5 18,5 21 21 22,5 25 25 20 36 20 36 18 30 17 17 27 27 14,7 22 14,7 22 12,5 17 12,5 17 11/14 11/14 20/25 20/25 34/47 34/47 54/75 68/71 68/71 455 404 271 226 207 130 114 83 67

L4 L3

3 1 2 3 1

L1

L2

2 3 1 2

POS.3

3 1 2 3 1 2 3 1 2 3

Flare/ODS fitting

Nut

Connection

Copper seal

Copper pipe

SAE/Flare connection

142

www.castel.it

THREADED BRASS FITTINGS

TABLE 5: General Characteristics


Connections Catalogue Number International Reference SAE Flare NPT m f PS [bar] H L Dimensions [mm] Weight [g]

SAE Flare elbows


7210/2 7210/3 E24 E26 E28 E210 E212 1/4" 3/8" 1/2" 5/8" 3/4" 45 26 29,5 32,5 36 42,5 26 29,5 32,5 36 42,5 29 49 83 116 192

7210/4 7210/5

7210/6

SAE Flare / NPT elbows


7220/2 7220/3 E14B E16C E18D E112F 1/4" 3/8" 7220/4 1/2" 3/4" 1/2" 3/4" 1/4" 3/8" 45 32,5 42,5 32 39,5 91 183 26 29,5 24 28,5 33 54

7220/6

SAE Flare / reduced NPT elbows


7230/21 7230/32 E14A E16B E18C E110D 1/4" 3/8" 7230/43 1/2" 5/8" 3/8" 1/2" 1/8" 1/4" 45 32,5 36 31 35 75 114 26 29,5 21 29,5 30 46

7230/54

Male/female SAE Flare elbows


7240/2 1/4" 1/4" 28,5 28 56

7240/3

3/8"

3/8"

45

32

31

84

7240/4

1/2"

1/2"

39,5

38

198

www.castel.it

143

TABLE 6: General Characteristics


Connections Catalogue Number International Reference (1) SAE Flare (2) (3) (4) NPT (3) PS [bar] H L Dimensions [mm] Weight [g]

SAE Flare TEE


7310/2 7310/3 7310/4
L H

T24 T26 T28 T210 T212

1/4" 3/8" 1/2" 5/8" 3/4"

1/4" 3/8" 1/2" 5/8" 3/4"

1/4" 3/8" 1/2" 5/8" 3/4" 45

23,5 29 31,5 36 41,5

47 58 63 72 83

32 69 97 153 235

7310/5 7310/6

SAE Flare reducing TEE (reduced side connections)


7320/223
H

TR246 TR268 TR2810 TR21012

1/4" 3/8" 1/2" 5/8"

1/4" 3/8" 1/2" 5/8"

3/8" 1/2" 45 5/8" 3/4"

29 32,5 38 41,5

56 63 72 83

77 95 153 228

7320/334 7320/445

7320/556

SAE Flare reducing TEE (reduced central connection)


7320/332
H

TR264 TR286 TR2108 TR21210

3/8" 1/2" 5/8" 3/4"

3/8" 1/2" 5/8" 3/4"

1/4" 3/8" 45 1/2" 5/8"

28 32,5 38 41,5

58 63 72 83

77 101 158 220

7320/443 7320/554
L

7320/665

SAE Flare / NPT TEE (taper central connection)


H

7330/221

T14A

1/4"

1/4"

1/8" 45 1/4"

28,5

28

56

7330/222

T14B

1/4"

1/4"

39,5

38

198

Male/female SAE Flare TEE (female central connection)


H

7340/222
L

T64

1/4"

1/4"

1/4"

45

27,5

56

78

SAE Flare cross

7410/2
L

C14

1/4"

1/4"

1/4"

1/4"

45

52

52

55

144

www.castel.it

THREADED BRASS FITTINGS

TABLE 7: General Characteristics


Connections Catalogue Number International Reference ODS SAE Flare NPT [in.] [mm] PS [bar] H L Ch Dimensions [mm] Wrench torque min / max [Nm] Weight [g]

SAE Flare plugs


L
7510/2 P24 1/4" 23 12 11 / 14 19

7510/3

P26

3/8"

45

26

17

20 / 25

40

Ch

7510/4

P28

1/2"

30

20

34 / 47

67

NPT plugs
7520/1 121B02 121B04 121B06 7520/4 7520/6 121B08 121B12 121B16 1/2" 3/4" 1" 1/8" 1/4" 3/8" 45 29,8 32,1 39 22 27 34 25 / 35 30 / 40 60 / 80 87 149 279 15,9 23,1 23,2 12 14 17 10 / 13 15 / 20 17 / 22 12 27 43

L
7520/2 7520/3

Ch

7520/8

Copper seal caps


7560/2 7560/3 7560/4 7560/5 7560/6 7560/7 B14 B16 B18 B110 B112 B114 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 45 0,5 1 1,5 2 4 10

Copper gaskets
7580/2 7580/3 7580/4 7580/5 7580/6 B24 B26 B28 B210 B212 1/4" 3/8" 1/2" 5/8" 3/4" 45 0,5 0,5 1 1,5 3

Flange joints
H H
7630/7 7630/9 7630/11 7630/13 7630/M42 1.5/8" 2.1/8" 42 54 24 25 67 71 68 / 80 7/8" 1.1/8" 1.3/8" 35 45 42 / 50 1340 1940 23 63 20 / 24 315 490 1045

7630/17

www.castel.it

145

COPPER BRAZE-JOINT PRESSURE FITTINGS

147

COPPER BRAZE-JOINT PRESSURE FITTINGS


APPLICATIONS All the fittings, shown in this chapter, are excluded from the scope of Directive 97/23/EC, as specified in the Guidelines 1/8 and 1/9, because they are piping components. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, made of seamless copper tube specified in EN 12735-1 : 2001 Standard, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). PRODUCTS RANGE Series 77 show the following selection of copper braze-joint fittings, with ODS / IDS millimeters connections, practically in all diameter dimensions: 7700 Female to female couplings 7702 Female to female reducing couplings 7703 Male to female reducing couplings 7708 90 female to female elbows short radius 7709 90 male to female elbows short radius 7716 45 female to female elbows 7717 45 male to female elbows 7718 90 female to female elbows long radius 7719 90 male to female elbows long radius 7732 Tees and reducing tees Series 78 show a the following selection of copper braze-joint fittings, with ODS / IDS inch connections, limited to few diameter dimensions: 7832 Tees and reducing tees Reinforced series 79 show the following selection of copper braze-joint fittings, with ODS / IDS millimeters connections, limited to some dimensions: 7900 Female to female couplings 7902 Female to female reducing couplings 7903 Male to female reducing couplings 7916 45 female to female elbows 7917 45 male to female elbows 7918 90 female to female elbows long radius 7919 90 male to female elbows long radius 7932 Tees and reducing tees CONSTRUCTION Dimensions and tolerances of the ODS / IDS connections ends in copper braze-joint fittings series 77, 78 and 79 are in compliance with the EN 1254-1 : 1998 Standard. All copper braze-joint fittings series 77, 78 and 79 are made of seamless copper tube EN 12735-2 CW024A, soft annealed. Technical characteristics of copper fittings series 77 and 78, depending on tube nominal diameters, are given in table 1, while technical characteristics of copper fittings series 79, always depending on nominal diameters, are given in table 2. Copper braze-joint fittings series 77, 78 and 79, if submitted to ambient-temperature burst test, guarantee a pressure strength at least equal to 3 x PS (30 C rated workingpressure as shown in tables 1 and 2) according to ASME B16.50 : 2001 Standard.

148

www.castel.it

COPPER BRAZE-JOINT PRESSURE FITTINGS

INSTALLATION The internal working pressure-temperature rating for a copper fitting, is dependent upon, not only fitting strength, but also the adopted joining process and the used filler metal. The working pressure-temperature values given in tables 1 and 2 are referred to a brazing process, performed in accordance with the sound engineering practice. We wish to remember the definition of brazing process, given in EN 13133 : 2000 Standard. The process of joining generally applied to the joining of materials by a heating process during which the parent materials do not melt and the filler metal is drawn into the joint by capillary action. It is generally applicable to joining systems where the filler metal melts at 450 C or above. In actual practice brazing is done at temperatures ranging from 630 to 820 C and there are two general types of brazing filler metals, normally used for joining copper tube: Copper Phosphorus alloys (the so called B-CuP), proper to CP Class of EN 1044 : 1999 Standard, that are normally used without fluxes; Silver alloys (the so called B-Ag), proper to AG Class of EN 1044 : 1999, that must be used with their specific fluxes.
Tube Nominal Diameter

TABLE 1
Working Pressure PS [bar], depending on temperature

[mm] 6 8 10 12 14 15 16 18 22 28 35 42 54 64 67 76 80 89 106

[in.] 1/4" 3/8" 1/2" 5/8" 7/8" 1" 1.1/8" 1.3/8" 1.5/8" 2.1/8" 2.5/8" 3.1/8" 3.1/2"

-40 / 30 C 90 90 70 60 60 50 50 45 45 45 40 40 35 30 30 30 25 25 20 20 20 20 18 18 18 18 15

95 C 72 72 56 48 48 40 40 36 36 36 32 32 28 24 24 24 20 20 16 16 16 16 14 14 14 12 12

150 C 63 63 49 42 42 35 35 32 32 32 28 28 24 21 21 21 18 18 14 14 14 14 13 13 13 11 11

Note: working pressures shown in this table are in comparison with rated working pressures established in ASME B16.50 : 2001 Standard.

TABLE 2
Working Pressure PS [bar], depending on temperature Tube Nominal Diameter -40 / 30 C [in.] 7/8 1 3/4 1.1/8 1.3/8 1.5/8 3/4 2.1/8 (1) 60 55 50 50 50 40 40 35 (2) 80 73 67 67 67 53 53 47 (1) 50 45 40 40 40 35 35 30 150 C (2) 67 60 53 53 53 47 47 40 (1) 45 41 37 37 37 30 30 26 95 C (2) 60 55 49 49 49 40 40 35

[mm] 22 3/4 28 3/4 35 3/4 42 54

(1) PS values listed in this column are referred to a safety coefficient 4, according to ASME B16.50 : 2001 Standard (2) PS values listed in this column are referred to a safety coefficient 3, minimum value warranted by Castel for all its products

www.castel.it

149

TABLE 3: General Characteristics


Connections Catalog Number International Code IDS [mm] ODS [mm] Weight [g] Note

Female to female couplings (metric tubing)


7700/M6 7700/M8 7700/M10 7700/M12 7700/M14 7700/M16 7700/M18 7700/M22 7700/M28 7700/M35 7700/M42 7700/M54 7700/M76 7700/M89 5270/6 5270/8 5270/10 5270/12 5270/14 5270/16 5270/18 5270/22 5270/28 5270/35 5270/42 5270/54 5270/76 5270/89 6 8 10 12 14 16 18 22 28 35 42 54 76 89 6 8 10 12 14 16 18 22 28 35 42 54 76 89 2 3 4 5 8 8 13 20 39 71 89 138 220 350

Female to female reducing couplings (metric tubing)


7702/M10.6 7702/M10.8 7702/M12.8 7702/M12.10 7702/M14.10 7702/M14.12 7702/M16.10 7702/M16.12 7702/M16.14 7702/M18.12 7702/M18.16 7702/M22.12 7702/M22.14 7702/M22.16 7702/M22.18 7702/M28.12 7702/M28.18 7702/M28.22 7702/M35.22 7702/M35.28 7702/M42.28 7702/M42.35 7702/M54.35 7702/M54.42 7702/M67.54 7702/M76.54 5240/10.6 5240/10.8 5240/12.8 5240/12.10 5240/14.10 5240/14.12 5240/16.10 5240/16.12 5240/16.14 5240/18.12 5240/18.16 5240/22.12 5240/22.14 5240/22.16 5240/22.18 5240/28.12 5240/28.18 5240/28.22 5240/35.22 5240/35.28 5240/42.28 5240/42.35 5240/54.35 5240/54.42 5240/67.54 5240/76.54 10 10 12 12 14 14 16 16 16 18 18 22 22 22 22 28 28 28 35 35 42 42 54 54 67 76 6 8 8 10 10 12 10 12 14 12 16 12 14 16 18 12 18 22 22 28 28 35 35 42 54 54 3 6 6 8 9 9 12 9 11 12 13 22 19 23 23 34 29 33 56 56 66 88 166 160 246 314

150

www.castel.it

COPPER BRAZE-JOINT PRESSURE FITTINGS

TABLE 4: General Characteristics


Connections Catalog Number International Code IDS [mm] ODS [mm] Weight [g] Note

Male to female reducing couplings (metric tubing)


7703/M8.6 7703/M10.6 7703/M10.8 7703/M12.6 7703/M12.8 7703/M12.10 7703/M14.10 7703/M14.12 7703/M16.10 7703/M16.12 7703/M16.14 7703/M18.10 7703/M18.12 7703/M18.14 7703/M18.16 7703/M22.12 7703/M22.14 7703/M22.16 7703/M22.18 7703/M28.12 7703/M28.14 7703/M28.16 7703/M28.18 7703/M28.22 7703/M35.18 7703/M35.22 7703/M35.28 7703/M42.22 7703/M42.28 7703/M42.35 7703/M54.28 7703/M54.42 7703/M67.42 7703/M67.54 7703/M76.42 7703/M80.42 7703/M106.54 5243/8.6 5243/10.6 5243/10.8 5243/12.6 5243/12.8 5243/12.10 5243/14.10 5243/14.12 5243/16.10 5243/16.12 5243/16.14 5243/18.10 5243/18.12 5243/18.14 5243/18.16 5243/22.12 5243/22.14 5243/22.16 5243/22.18 5243/28.12 5243/28.14 5243/28.16 5243/28.18 5243/28.22 5243/35.18 5243/35.22 5243/35.28 5243/42.22 5243/42.28 5243/42.35 5243/54.28 5243/54.42 5243/67.42 5243/67.54 5243/76.42 5243/80.42 5243/106.54 8 10 10 12 12 12 14 14 16 16 16 18 18 18 18 22 22 22 22 28 28 28 28 28 35 35 35 42 42 42 54 54 67 67 76 80 106 6 6 8 6 8 10 10 12 10 12 14 10 12 14 16 12 14 16 18 12 14 16 18 22 18 22 28 22 28 35 28 42 42 54 42 42 54 2 3 3 3 6 4 8 5 9 9 8 12 9 11 8 23 20 20 21 32 31 33 29 32 50 65 50 90 102 93 125 146 197 246 270 306 784 = 7700/M8 = 7702/M10.6 = 7702/M10.8 = 7700/M10 = 7702/M12.10 = 7700/M12 = 7702/M14.10 = 7702/M14.12 = 7700/M14 = 7702/M16.10 = 7702/M16.12 = 7702/M16.14 = 7700/M16 = 7700/M6

www.castel.it

151

TABLE 5: General Characteristics


Connections Catalog Number International Code IDS [mm] ODS [mm] Weight [g] Note

90 female to female elbows - short radius (metric tubing)


7708/M6 7708/M8 7708/M14 7708/M16 7708/M18 7708/M22 7708/M28 7708/M35 7708/M42 7708/M54 5090/6 5090/8 5090/14 5090/16 5090/18 5090/22 5090/28 5090/35 5090/42 5090/54 6 8 14 16 18 22 28 35 42 54 6 8 14 16 18 22 28 35 42 54 4 5 12 13 22 34 56 119 163 298

90 male to female elbows - short radius (metric tubing)


7709/M16 7709/M18 7709/M22 7709/M28 7709/M35 7709/M42 7709/M54 5092/16 5092/18 5092/22 5092/28 5092/35 5092/42 5092/54 16 18 22 28 35 42 54 16 18 22 28 35 42 54 18 26 34 67 114 184 304

45 female to female elbows (metric tubing)


7716/M16 7716/M18 7716/M22 7716/M28 7716/M35 7716/M54 7716/M80 5041/16 5041/18 5041/22 5041/28 5041/35 5041/54 5041/80 16 18 22 28 35 54 80 16 18 22 28 35 54 80 16 21 35 61 119 231 740

45 male to female elbows (metric tubing)


7717/M22 7717/M28 7717/M35 7717/M42 7717/M54 7717/M80 5040/22 5040/28 5040/35 5040/42 5040/54 5040/80 22 28 35 42 54 80 42 54 80 167 288 800 22 28 35 33 57 124

152

www.castel.it

COPPER BRAZE-JOINT PRESSURE FITTINGS

TABLE 6: General Characteristics


Connections Catalog Number International Code IDS [mm] ODS [mm] Weight [g] Note

90 female to female elbows - long radius (metric tubing)


7718/M10 7718/M12 7718/M14 7718/M16 7718/M18 7718/M22 7718/M28 7718/M35 7718/M42 7718/M54 7718/M64 7718/M67 7718/M76 7718/M80 7718/M89 5002/10 5002/12 5002/14 5002/16 5002/18 5002/22 5002/28 5002/35 5002/42 5002/54 5002/64 5002/67 5002/76 5002/80 5002/89 10 12 14 16 18 22 28 35 42 54 64 67 76 80 89 10 12 14 16 18 22 28 35 42 54 64 67 76 80 89 7 11 15 20 29 46 79 146 216 353 420 505 880 1340 1670

90 male to female elbows - long radius (metric tubing)


7719/M12 7719/M14 7719/M16 7719/M18 7719/M22 7719/M28 7719/M35 7719/M42 7719/M54 7719/M64 7719/M67 7719/M76 7719/M80 5001/12 5001/14 5001/16 5001/18 5001/22 5001/28 5001/35 5001/42 5001/54 5001/64 5001/67 5001/76 5001/80 12 14 16 18 22 28 35 42 54 64 67 76 80 12 14 16 18 22 28 35 42 54 64 67 76 80 11 16 20 30 47 86 144 210 390 470 550 915 1006

www.castel.it

153

TABLE 7: General Characteristics


Connections Catalog Number International Code IDS [mm] ODS [mm] Weight [g] Note

Tees (metric tubing)


7732/M6 7732/M8 7732/M10 7732/M12 7732/M14 7732/M16 7732/M18 7732/M22 7732/M28 7732/M35 7732/M42 7732/M54 7732/M64 7732/M67 7732/M80 5130/6 5130/8 5130/10 5130/12 5130/14 5130/16 5130/18 5130/22 5130/28 5130/35 5130/42 5130/54 5130/64 5130/67 5130/80 6 8 10 12 14 16 18 22 28 35 42 54 64 67 80 6 8 10 12 14 16 18 22 28 35 42 54 64 67 80 6 8 10 12 14 16 18 22 28 35 42 54 64 67 80 5 7 17 14 22 25 36 59 101 185 269 465 510 658 1084

Reducing tees (metric tubing)


7732/M8.6.8 7732/M8.10.8 7732/M10.6.10 7732/M10.8.8 7732/M10.8.10 7732/M10.12.10 7732/M12.8.12 7732/M12.10.12 7732/M12.14.12 7732/M12.16.12 7732/M14.12.14 7732/M14.22.14 7732/M16.12.16 7732/M16.14.16 7732/M16.16.12 7732/M16.22.16 7732/M18.12.18 7732/M18.16.18 7732/M18.22.18 7732/M22.12.22 7732/M22.16.22 7732/M22.18.22 7732/M22.28.22 7732/M28.22.28 7732/M35.28.35 7732/M42.22.42 7732/M42.28.42 7732/M54.42.54 5130/8.6.8 5130/8.10.8 5130/10.6.10 5130/10.8.8 5130/10.8.10 5130/10.12.10 5130/12.8.12 5130/12.10.12 5130/12.14.12 5130/12.16.12 5130/14.12.14 5130/14.22.14 5130/16.12.16 5130/16.14.16 5130/16.16.12 5130/16.22.16 5130/18.12.18 5130/18.16.18 5130/18.22.18 5130/22.12.22 5130/22.16.22 5130/22.18.22 5130/22.28.22 5130/28.22.28 5130/35.28.35 5130/42.22.42 5130/42.28.42 5130/54.42.54 8 8 10 10 10 10 12 12 12 12 14 14 16 16 16 16 18 18 18 22 22 22 22 28 35 42 42 54 6 10 6 8 8 12 8 10 14 16 12 22 12 14 16 22 12 16 22 12 16 15 18 22 28 22 28 42 8 8 10 8 10 10 12 12 12 12 14 14 16 16 12 16 18 18 18 22 22 22 22 28 35 42 42 54 7 12 10 13 10 17 12 13 17 22 34 57 22 20 30 58 27 28 45 37 45 43 93 75 110 154 170 354

154

www.castel.it

COPPER BRAZE-JOINT PRESSURE FITTINGS

TABLE 8: General Characteristics


Connections Catalog Number International Code IDS [mm] ODS [mm] Weight [g] Note

Tees (inch tubing)

7832/222

5130/222

1/4"

1/4"

1/4"

7832/333

7832/333

3/8

3/8

3/8

Reducing tees (inch tubing)

7832/232

5130/232

1/4"

3/8"

1/4"

11

7832/323

7832/323

3/8

1/4"

3/8

14

www.castel.it

155

TABLE 9: General Characteristics


Connections Catalog Number International Code IDS [mm] ODS [mm] Note

Female to female couplings, reinforced series (metric tubing)


7900/M22 7900/M28 7900/M35 7900/M42 7900/M54 22 28 35 42 54 22 28 35 42 54

Female to female reducing couplings, reinforced series (metric tubing)


7902/M28.22 7902/M35.22 7902/M35.28 7902/M42.28 7902/M42.35 7902/M54.35 7902/M54.42 28 35 35 42 42 54 54 22 22 28 28 35 35 42

Male to female reducing couplings, reinforced series (metric tubing)


7903/M28.22 7903/M35.22 7903/M35.28 7903/M42.28 7903/M42.35 7903/M54.35 7903/M54.42 28 35 42 42 42 54 54 22 22 28 28 35 35 42

45 female to female elbows, reinforced series (metric tubing)


7916/M22 22 22

7916/M28

28

28

7916/M35

35

35

7916/M42

42

42

7916/M54

54

54

45 male to female elbows, reinforced series (metric tubing)


7917/M22 22 22

7917/M28

28

28

7917/M35

35

35

7917/M42

42

42

7917/M54

54

54

156

www.castel.it

COPPER BRAZE-JOINT PRESSURE FITTINGS

TABLE 10: General Characteristics


Connections Catalog Number International Code IDS [mm] ODS [mm] Note

90 female to female elbows - long radius, reinforced series (metric tubing)


7918/M22 22 22

7918/M28

28

28

7918/M35

35

35

7918/M42

42

42

7918/M54

54

54

90 male to female elbows - long radius, reinforced series (metric tubing)


7919/M22 22 22

7919/M28

28

28

7919/M35

35

35

7919/M42

42

42

7919/M54

54

54

Tees, reinforced series (metric tubing)


7932/M22 22 22 22

7932/M28

28

28

28

7932/M35

35

35

35

7932/M42

42

42

42

7932/M54

54

54

54

www.castel.it

157

ACCESS FITTINGS & VALVE CORES

159

ACCESS FITTINGS & VALVE CORES


APPLICATIONS All the access fittings and valve cores, shown in this chapter, are excluded from the scope of Directive 97/23/EC, as specified in the Guidelines 1/8 and 1/9, because they are piping components. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). The access fittings allow to create a loading or draining point rapidly and with a minimum expense. After completion of the loading or draining operations, the cap with gasket (cod. 8392/A) prevents any leakage. For particular customers requirements, the 7020/20 flare blind nut with combined 8580/2 copper flare gasket may replace the 8392/A cap. This solution requires to screw the nut with a torque wrench at 8,5 11,5 Nm. For system using R410A refrigerant, Castel has developed three specific access fittings with 5/16 SAE-Flare connection (codes 8350/X09 , 8351/X05 and 8351/X07) that have to be used with the following parts: valve core, code 8395/A; flare blind nut, code 7020/X01; copper gaskets, code 8580/2. Also this solution requires to screw the nut with a torque wrench at 8,5 11,5 Nm. OPERATION The valve consists of a body that can have different shapes and sizes, according to the different requirements of the customers. Inside the valve, the valve core seat is manufactured according to the ARI STANDARD 720:1997. When the internal valve core has been inserted through the fitting, by the mounting tool (code 8390/A), the fluid flows just acting on the valve needle.
Fitting

CONSTRUCTION The straight fittings are machined by hexagonal brass bar EN 12164 CW 614N. The TEE and cross fittings are manufactured with hot forged brass EN 12420 CW 617N. The main parts of the valve cores are made with the following materials: brass EN 12164 CW 614N for body; chloroprene rubber (CR) for seat gasket; chloroprene rubber (CR) for outlet seal gasket for types 8394/A and 8395/A; PTFE for outlet seal gasket for type 8394/B.

Nut

Gasket

Valve core

Access fitting with inserted valve core

160

www.castel.it

ACCESS FITTINGS & VALVE CORES

TABLE 1: General Characteristics


Connections Catalogue Number SAE Flare NPT m f [in.] ODS [mm] [in.] IDS [mm] PS [bar] L Ch D H Dimensions [mm]

Straight access fittings L


8350/22 1/4" 1/4" 26 11

Ch L
8350/X01 1/4" 6 3/8" 20 11

Ch L
8350/X03 1/4" 6 130 90 11

Ch
L H

8350/X11

8350/X09

5/16"

1/4"

27 14 9,4 2,1

Ch D

8351/2 1/4" 8351/X04 8351/X05

8-10 6 7 45

30 11 26 27 14

Ch L

5/16" 8351/X07

3/8" 6

1/4" 8351/X02 1/4" 5 3/8" 8 26 11

Ch L
8352/22 1/4" 31 11

Ch L
8354/21 8354/22 8354/23 1/4" 1/8" 1/4" 3/8" 28 11 33 14 38 17

Ch L

8362/22

1/4"

1/4"

35 17

Ch

www.castel.it

161

TABLE 2: General Characteristics


Connections Catalogue Number SAE Flare NPT m f [in.] IDS [mm] PS [bar] L Ch D H Dimensions [mm] Note

TEE access fittings

8380/X01

1/4"

43

24

L
45
The valve core may be installed on each of the two 1/4" SAE Flare connections.

8380/122

1/4"

1/8"

45

24

TEE access fittings with swivel nuts


With valve-core opening device on female connection. The valve core may be installed on each of the two 1/4" SAE Flare connections.

8380/X06

50

1/4"

1/4"

35

30

L
8380/X08 49
The valve core may be installed on each of the two 1/4" SAE Flare connections.

162

www.castel.it

ACCESS FITTINGS & VALVE CORES

TABLE 3: General Characteristics


Connections Catalogue Number SAE Flare NPT m f [in.] IDS [mm] PS [bar] L Ch D H Dimensions [mm] Note

Cross access fittings

8382/1222 1/4"

1/8"

48

50

8382/X02

1/4"

1/4"

45

48

50 three 1/4" SAE Flare


connections.

The valve core may be installed on each of the

8382/X03

1/4"

48

44

Cross access fittings with swivel nuts

8382/X04

1/4"

1/4"

35

50

46

With valve-core opening device on female connection. The valve core may be installed on each of the three 1/4" SAE Flare connections.

www.castel.it

163

TABLE 4: General Characteristics


Connections Catalogue Number SAE Flare NPT m f [in.] IDS [mm] PS [bar] L Ch D H Dimensions [mm] Note

Core remover (for all types)


8390/A 75

Caps with gasket


D

8392/A

13

L
1/4 35 13

8392/B

22

The key needs to remove the valve core.

Spare valve cores


Outside spring. Torque wrench 0,25 / 0,30 Nm. (1) Static pressure: 40 [bar] (1) Working pressure: 28 [bar]

8394/A

(1)

8394/B

(2)

Inside spring. Torque wrench 0,20 / 0,35 Nm. (2) Static pressure: 40 [bar] (2) Working pressure: 28 [bar]

8395/A

(3)

Outside spring. Torque wrench 0,4 / 0,8 Nm. (3) Static pressure: 68 [bar] (3) Working pressure: 48 [bar]

Copper gasket with neck

8580/2

1/4"

45

2,8

5,2

Manifolds with access fittings

H
9900/X47

175

30 Four ways

L
1/4" 35

H
9900/X87

162

30 Three ways

164

www.castel.it

ACCESSORIES AND SPARE PARTS

165

KIT N

ITEMS CODE

DESCRIPTION

SUITABLE FOR PRODUCTS

NOTE

ACCESSORIES AND SPARE PARTS FOR SOLENOID VALVES


008217 008218 008229 004238 9900/X94 G9150/R06 200193 Yellow nut for fixing coil Black screw for fixing coil O Ring for yellow nut O Ring under coil Enclosure Bracket All the solenoid valves All the solenoid valves All the solenoid valves All the solenoid valves All the N.C. solenoid valves N.C.and N.O. solenoid valves type: 1020/..; 1028/..; 1064/..; 1068/..; 1070/4 - /5; 1078/4 - /5 - /M12; 1079/7; 009060 Screw 1164/..; 1168/..; 1170/4 - /5; 1178/4 - /5 - /M12; 1512/..; 1522/..; 1132/03 - /04 9150/R07 008323 200292 004254 9150/R08 008323 200292 200646 004259 9150/R09 008323 200292 009003 004257 004298 9150/R10 008323 004571 200431 004266 004299 9150/R48 008323 004571 009262 004251 004625 9150/R50 008323 004571 009278 009277 004251 004625 9150/R11 008323 200292 004118 004253 004256 004254 004692 9150/R43 008387 008415 008393 004251 008966 004256 004692 Plunger Plunger spring Nut/body O Ring Plunger Plunger spring Diaphragm Nut/body O Ring Plunger Plunger spring Diaphragm Cover/body O Ring Cover/body screws Plunger Plunger spring Diaphragm Cover/body O Ring Cover/body screws Plunger Plunger spring Diaphragm Cover/body O Ring Cover/body screws Plunger Plunger spring Piston Piston ring Cover/body O Ring Cover/body screws Plunger Plunger spring Diaphragm Cover/body O Ring Pilot O Ring Nut/cover O Ring Cover/body screws Piston Piston ring Piston spring Cover/body O Ring New pilot O Ring Old pilot O Ring Cover/body screws N.C.and N.O. solenoid valves type: 1098/9; 1099/11 1198/9 Main piston pilot operated spare parts N.C. solenoid valves type: 1078/9; 1079/11 N.C. solenoid valves type: 1050/5 - /6; 1058/5 - /6 - /7; 1059/9 N.C. solenoid valves type: 1090/5 - /6; 1098/5 - /6 - /7; 1099/9 N.C. solenoid valves type: 1070/6; 1078/6 - /7; 1079/9 Valves out of stock N.C. solenoid valves type: 1064/..; 1068/.. 1098/9; 1099/11 1078/11; 1079/13 - /M42 N.C. solenoid valves type: 1070/4 - /5; 1078/4 - /5 - /M12; 1079/7 Diaphragm pilot operated spare parts for: 1098/9; 1099/11; 1078/11; 1079/13 - /M42 N.C. solenoid valves type: 1020/..; 1028/..

166

www.castel.it

KIT N

ITEMS CODE

DESCRIPTION

SUITABLE FOR PRODUCTS

NOTE

RICAMBI PER VALVOLE SOLENOIDI


9150/R39 008387 008415 008393 004691 008966 004256 004692 9150/R35 N.D. 200646 004259 004238 9150/R34 008757 009003 004257 004254 004238 004298 9150/R49 008757 009262 004251 004254 004238 004625 9150/R51 008757 009278 009277 004251 004254 004238 004625 9150/R42 008757 004118 004253 004256 004254 004238 004692 9150/R15 200581 200292 004242 9150/R12 200581 200292 200520 004244 004298 9150/R13 200581 200292 004617 004625 9150/R14 200581 200292 200552 004246 004242 004309 Piston Piston ring Piston spring Cover/body O Ring New pilot O Ring Old pilot O Ring Cover/body screws Pre-assembled armature with nuts Diaphragm Nut/body O Ring O Ring under coil N.O. armature group Diaphragm Cover/body O Ring Nut/cover O Ring O Ring under coil Cover/body screws N.O. armature group Diaphragm Cover/body O Ring Nut/cover O Ring O Ring under coil Cover/body screws N.O. armature group Piston Piston ring Cover/body O Ring Nut/cover O Ring O Ring under coil Cover/body screws N.O. armature group Diaphragm Cover/body O Ring Pilot O Ring Nut/cover O Ring O Ring under coil Cover/body screws Plunger Plunger spring Nut/body O Ring Plunger Plunger spring Diaphragm Cover/body O Ring Cover/body screws Plunger Plunger spring Diaphragm Cover/body screws Plunger Plunger spring Diaphragm No 2 pilot O Rings Nut/cover O Ring Cover/body screws Solenoid valves for different fluids type: 1142/010 - /012 Solenoid valves for different fluids type: 1132/06 - /08 Solenoid valves for different fluids type: 1512/.. 1522/.. Solenoid valves for different fluids type: 1132/03 - /04 N.O. solenoid valves type: 1178/9 N.O. solenoid valves type: 1150/5 - /6; 1158/5 - /6 - /7 N.O. solenoid valves type: 1190/5 - /6; 1198/5 - /6 - /7 N.O. solenoid valves type: 1164/..; 1168/.. 1198/9 1178/11 N.O. solenoid valves type: 1170/4- /5; 1178/4 - /5 - /M12 Diaphragm pilot operated spare parts for: 1198/9 1178/11 N.C.and N.O. solenoid valves type: 1078/11; 1079/13 - /M42 1178/11 Main piston pilot operated spare parts

www.castel.it

167

KIT N

ITEMS CODE

DESCRIPTION

SUITABLE FOR PRODUCTS

NOTE

ACCESSORIES AND SPARE PARTS FOR CHECK VALVES


9150/R16 003558 001869 004251 004299 9150/R17 003559 000728 004691 004692 9150/R18 003854 000728 008002 004302 9150/R19 003855 001857 004261 004302 9150/R52 003558 001869 008863 004299 9150/R53 003559 000728 009174 004692 9150/R54 003854 000728 009175 004302 9150/R55 003855 001857 009176 004302 Piston Spring Cover/body O Ring Cover/body screws Piston Spring Cover/body O Ring Cover/body screws Piston Spring Cover/body O Ring Cover/body screws Piston Spring Cover/body O Ring Cover/body screws Piston Spring Cover/body gasket Cover/body screws Piston Spring Cover/body gasket Cover/body screws Piston Spring Cover/body gasket Cover/body screws Piston Spring Cover/body gasket Cover/body screws Check valves type: 3122/17 3142/17 - /21 - /25 3182/13 - /M42 - /17 Check valves type: 3120/17 3140/17 - /21 - /25 3160/17; 3180/13 - /M42 - /17 Check valves type: 3122/7 - /9 - /M22 - /M28 3142/7 - /9 - /M28 3182/7 - /9 - /M28 Check valves type: 3122/11 3142/11 3182/11 Check valves type: 3122/13 - /M42 3142/13 - /M42 Valves out of stock Check valves type: 3120/7 - /9 - /M22 - /M28 3140/7 - /9 - /M28 3180/7 - /9 - /M28 Check valves type: 3120/11 3140/11 3180/11 Check valves type: 3120/13 - /M42 3140/13 - /M42 Valves out of stock Valves out of stock Valves out of stock

ACCESSORIES AND SPARE PARTS FOR INDICATORS


9150/R20 003575 007779 004259 9150/R21 004270 007780 004259 Nut Protection cap Nut/body O Ring Pre-assembled nut Protection cap Nut/body O Ring Moisture - liquid indicators type: 3710/..; 3720/..; 3740/..; 3750/..; 3770/..; 3771/..; 3780/..; 3781/.. Liqud indicators type: 3610/..; 3620/..; 3640/..; 3650/..

168

www.castel.it

KIT N

ITEMS CODE

DESCRIPTION

SUITABLE FOR PRODUCTS

NOTE

ACCESSORIES AND SPARE PARTS FOR FILTERS


G9150/R05 8354/22 8392/A 8394/B 003319 003322 Access fitting Cap with gasket Valve core Spring Flange gasket Filters with replaceable block type: 4411/..; 4412/..; 4413/..; 4414/.. 4421/..; 4423/..; 4424/.. All the filters series 44 Filters with replaceable block type: 4411/..; 4412/..; 4413/..; 4414/.. 009406 003324 007677 9150/R57 005535 004592 008336 Dehydrating block cover Dehydrating block bottom Filtering tube Mechanical block cover Mechanical block bottom Flange gasket Filters with replaceable block type: 4411/..C Filters with replaceable block type: 4421/..; 4423/..; 4424/.. 008304 008305 008307 008403 008345 008344 9150/R58 008303 008306 Dehydrating block cover Dehydrating block bottom Screw for filtering tube Filtering tube Filtering tube Filtering tube Mechanical block cover Mechanical block bottom Filters with replac. block type: 4421/..A Filters with replac. block type: 4423/..A Filters with replac. block type: 4424/..A Filters with replac. block type: 4421/..C Filters with replaceable block type: 4421/..A; 4423/..A; 4424/..A Filters with replaceable block type: 4411/..A; 4412/..A; 4413/..A; 4414/..A

ACCESSORIES AND SPARE PARTS FOR OIL SEPARATORS


5590/5 5590/7 003879 5590/9 5590/11 003870 5590/13 5590/M42 003965 003322 Pair of connections 5/8" ODS Pair of connections 7/8" ODS Connection gasket Pair of connections 1.1/8" ODS Pair of connections 1.3/8" ODS Connection gasket Pair of connections 1.5/8" ODS Pair of connections M42 ODS Connection gasket Flange gasket Oil separators type 5520/. Oil separators type 5520/E To be ordered separately Oil separators type 5520/D To be ordered separately Oil separators type 5520/C To be ordered separately

www.castel.it

169

KIT N

ITEMS CODE

DESCRIPTION

SUITABLE FOR PRODUCTS

NOTE

ACCESSORIES AND SPARE PARTS FOR CHANGEOVER VALVES


9150/R24 004297 004329 004330 004348 9150/R25 000529 000534 000535 001039 3039/4 004260 009036 008281 Gland Gland seal gaskets Gland seal gaskets Washer Gland Gland seal gaskets Gland seal gaskets Washer Pair of connections 1/2"NPT female Connection/body O Ring Cap Cap Changeover valve 3032/64 - /66 Changeover valve 3032/44 Changeover valve type 3032/108 All the changeover devices type 3032/44 - /64 - /66

ACCESSORIES AND SPARE PARTS FOR BALL SHUT-OFF VALVES


009035 009256 Cap Cap Ball shut-off valves 3033/.. Ball shut-off valves 3063/44

RICAMBI PER RUBINETTI PER SISTEMI FRIGORIFERI ERMETICI


9150/R23 003664 000384 000957 000382 007486 000913 Gland Gland seal gaskets Gland seal gaskets Washer Cap Spindle Hermetic valves type 6010/2; 6012/22 G9150/R33 004307 004326 Screw Spring washer Hermetic valves type 6020/.. All the hermetic valves type: 6010/..; 6012/..; 6020/..; 6060/..; 6070/..

ACCESSORIES AND SPARE PARTS FOR HERMETIC VALVES


9150/R23 003664 000384 000957 000382 007486 000913 Gland Gland seal gaskets Gland seal gaskets Washer Cap Spindle Receiver valves type: 6110/21 - /22 - /23 - /32 - /33 6120/22 - /23 - /33 6132/.. 6140/22 - /23 Receiver valves type: 6110/21 - /22; 6120/22; 6140/22 - /23 001641 Spindle Receiver valves type: 6110/23 - /32 - /33; 6120/23 - /33 9150/R24 004297 004329 004330 004348 009036 001647 9150/R25 000529 000534 000535 001039 008282 001038 Gland Gland seal gaskets Gland seal gaskets Washer Cap Spindle Gland Gland seal gaskets Gland seal gaskets Washer Cap Spindle Receiver valves type: 6110/66 6120/66 Receiver valves type: 6110/43 - /44 - /54 6120/43 - /44 - /54

170

www.castel.it

KIT N

ITEMS CODE

DESCRIPTION

SUITABLE FOR PRODUCTS

NOTE

ACCESSORIES AND SPARE PARTS FOR STOP VALVES


9150/R26 000822 000823 000824 007476 Gland Gland seal gaskets Gland seal gaskets Washer Stop valves type: 6170/66 - /77

ACCESSORIES AND SPARE PARTS FOR ROTALOCK VALVES


9150/R23 003664 000384 000957 000382 7910/6 Gland Gland seal gaskets Gland seal gaskets Washer Steel solder connection 3/4" UNF-16 7990/6 7910/8 PTFE gasket for 7910/6 Steel solder connection 1" UNS-16 7990/8 PTFE gasket for 7910/8 To be ordered separately Rotalock valves types: 6310/.. 6320/..

ACCESSORIES AND SPARE PARTS FOR CAPPED VALVES


9150/R23 003664 000384 000957 000382 007486 002337 Gland Gland seal gaskets Gland seal gaskets Washer Cap Spindle Capped valves type: 6410/2 - /3 - /4 - /5 005174 Nipple/body O Ring 6420/2 - /3 - /M10 - /M12 - /4 - /5 6460/22A. 007619 Spindle Capped valves type: 6410/6 007676 Nipple/body O Ring 6420/M18 - /6 - /M22 - /7 Capped valves type: 6410/..; 6420/..; 6460/..

www.castel.it

171

KIT N

ITEMS CODE

DESCRIPTION

SUITABLE FOR PRODUCTS

NOTE

ACCESSORIES AND SPARE PARTS FOR GLOBE VALVES


9150/R24 004297 004329 004330 004348 001635 004296 9150/R27 007637 Gland Gland seal gaskets Gland seal gaskets Washer Cap Cap gasket Spindle/plate group Globe valves type: (1) 6510/M22 - /7 - /M28 - /9 - /11 6512/M22 - /7 - /M28 - /9 - /11 (1) 6520/7 - /9 - /11 (1) 6530/M22 - /7 - /M28 - /9 - /11 6532/M22 - /7 - /M28 - /9 - /11 Globe valves type: (1) 6510/M22 - /7 - /M28 - /9 6512/M22 - /7 - /M28 - /9 004299 Cover/body screws (1) 6520/7 - /9 (1) 6530/M22 - /7 - /M28 - /9 6532/M22 - /7 - /M28 - /9 004251 Cover/body O Ring Globe valves type: (1) 6510/M22 - /7 - /M28 - /9 (1) 6520/7 - /9 (1) 6530/M22 - /7 - /M28 - /9 008863 Cover/body gasket Globe valves type: 6512/M22 - /7 - /M28 - /9 6532/M22 - /7 - /M28 - /9 9150/R28 007638 Spindle/plate group Globe valves type: (1) 6510/11; 004692 004291 Cover/body screws Cover/body O Ring (1) 6520/11; 6512/11 (1) 6530/11; 6532/11 (1) valves out of stock

Globe valves type: (1) 6510/11; (1) 6520/11; (1) 6530/11

009174

Cover/body gasket

Globe valves type: 6512/11; 6532/11

9150/R26

000822 000823 000824 007476 001228 000830 004302

Gland Gland seal gaskets Gland seal gaskets Washer Cap Cap gasket Cover/body screws Spindle/plate group

Globe valves type: (1) 6510/13 - /M42 - /17 6512/13 - /M42 - /17 (1) 6520/13 - /M42 - /17 (1) 6530/13 - /M42 - /17 6532/13 - /M42 - /17

9150/R29

007639

Globe valves type: (1) 6510/13 - /M42 6512/13 - /M42 (1) 6520/13 - /M42

008002

Cover/body O Ring

Globe valves type: (1) 6510/13 - /M42 (1) 6520/13 - /M42

009175

Cover/body gasket

Globe valves type: 6512/13 - /M42

9150/R30

007640

Spindle/plate group

Globe valves type: (1) 6510/17; 6512/17

(1) 6520/17; (1) 6530/13 - /M42 - /17 6532/13 - /M42 - /17 004261 Cover/body O Ring Globe valves type: (1) 6510/17; (1) 6520/17 (1) 6530/13 - /M42 - /17 009176 Cover/body gasket Globe valves type: 6512/17 6532/13 - /M42 - /17

172

www.castel.it

KIT N

ITEMS CODE

DESCRIPTION

SUITABLE FOR PRODUCTS

NOTE

ACCESSORIES AND SPARE PARTS FOR BALL VALVES


009055 Cap Ball valves type: 6590/M6 - /2 - /3 - /3A - /M10 - /M10A - /M12 - /M12A - /4 - /4A 6591/5 6590/M15 - M15A - /5 - /5A - /M18 - /M18A - /6 - /6A 6591/7 009036 Cap Ball valves type: 6590/7 - /7A 6591/M28 - /9 6590/M28 - /M28A - /9 - /9A 6591/11 009037 Cap Ball valves type: 6590/11 - /11A 6591/13 - /M42 6590/13 - /13A - /M42 - /M42A 6591/17 009038 Cap Ball valves type: 6590/17 - /17A 6591/21 - /21A 009207 Cap Ball valves type: 6590/M64A - /21A G9150/R46 009208 8394/A 8392/A Gasket Valve core Cap with gasket 6591/24A - /25A Ball valves with access fitting

ACCESSORIES AND SPARE PARTS FOR COMPRESSOR VALVES


9150/R23 003664 000384 000957 000382 Gland Gland seal gaskets Gland seal gaskets Washer Compressor valves type 6640

ACCESSORIES AND SPARE PARTS FOR GAUGE MOUNTING VALVES


9150/R23 003664 000384 000957 000382 Gland Gland seal gaskets Gland seal gaskets Washer Gauge mounting valves 8320/21 - /22

www.castel.it

173

Note

Progetto grafico: Giorgio DAndrea

Impaginazione e fotolito: Ruta - Milano

Stampa: B.S.Z. srl - Mazzo di Rho (Mi)