quality products for refrigeration and air conditioningproducts suitable for CFC, HCFC and HFC
2006 release www.castel.it
PR
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Pessano - February 2006
Thermostatic • valve with interchangeable orifice assemblyexpansion • valve with fixed orifice assemblyvalves
Solenoid valves • valves for refrigerating systems• coils • permanent magnet• connectors• valves for different fluids
Safety devices • safety valves 3030 • safety valves 3060• ball shut-off valves• changeover devices• unions• fusible plugs
Check valves
Water regulating valves
Liquid indicatorsMoisture-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
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
Threaded brass fittings
Solder copper fittings
Access fittings
Spare parts
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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.
FROM QUALITY OUR NATURAL DEVELOPMENT
Application of Directive 97/23/EC of the European Parliamentand of the Council, of 29 may 1997, concerning pressureequipment towards Castel refrigeration products
phase as well as mixture thereof.
Pressure equipments referred to in Article 3 areclassified by categories in accordance withAnnex II, according to ascending level ofhazard, 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 DNand must satisfy the Essential SafetyRequirement set out in Annex I of PED.Pressure equipments below or equal to thelimits in Article 3, sections 1.1, 1.2 and 1.3 andsection 2, must not satisfy the Essential SafetyRequirement set out in Annex I. They must bedesigned and manufactured in accordance withthe sound engineering practice of a MemberState in order to ensure safe use (Article 3,Section 3).In the tables of general characteristics,collected in this Handbook, it’s showed the riskcategory 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 orpreparation covered by the definitions inArticle 2 of Council Directive 67/548/EEC of27 June 1967 and following amendments,relating to the classification, packaging andlabeling of dangerous substance. Group Icomprises fluids defined as: explosive,extremely flammable, highly flammable,flammable, very toxic, toxic, oxidizing.
– Group II comprises all the others fluids notreferred to in group I.
Castel products are suitable for using withrefrigerant fluids proper to the Group II.These refrigerant fluids are listed andclassified L1 in Annex E of standard EN 378-1, plus fluids R30, R123 and R141b.Among the fluids listed in this standard, thereare the well known R12; R22; R134a; R404A;R407C; R401A; R502; R507.
The Directive 97/23/EC (PED) applies to the design, manufacture and conformityassessment of pressure equipment and assemblies with a maximum allowablepressure “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 thefollowing 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 togetherfor integration into a pressure system.
– Safety accessories: devices designed toprotect pressure equipment against theallowable limits being exceeded.
– Pressure accessories: devices with anoperational function and having pressure-bearing housing. For example: solenoidvalves, valves, indicators.
– Assemblies: several pieces of pressureequipment assembled by a manufacturer toconstitute an integrated and functional whole.
– Maximum allowable pressure (PS):the maximum pressure for which theequipment is designed, as specified by themanufacturer.
– Maximum / minimum allowabletemperature (TS):the maximum/minimum temperatures forwhich the equipment is designed, asspecified by the manufacturer
– Volume (V): the internal volume of a chamber,including the volume of nozzles to the firstconnection or weld and excluding the volumeof permanent internal parts.
– Nominal size (DN): numerical designation ofsize, which is common to all components in apiping system.
– Fluids: gases, liquids and vapours in pure
All the products illustrated in this Handbook aresubmitted, one by one, to tightness testsbesides to functional tests.Allowable external leakage, measurable duringthe test, agrees to the definition given in theStandard DIN 3158-87 Par. 8.2:“During the test, no bubbles shall form over aperiod of one minute when the specimen isimmersed in water with low surface tension, …”.
EXTERNAL LEAKAGE
All the products illustrated in this Handbook, ifsubmitted to hydrostatic test, guarantee apressure strenght at least equal to 1,43 x PS incompliance with the Directive 97/23/EC.
All the products illustrated in this Handbook, ifsubmitted to burst test, guarantee a pressurestrength at least equal to 3 x PS according tothe Standard revision prEN 378-2 : 2000. Agreat number of products illustrated in theHandbook can guarantee an higher pressurestrength, equal to 5 x PS according to theStandard UL 207 : 2001. (for detailedinformation about these products pleasecontact Castel Technical Department).
The weights of the items listed in this Handbookinclude packaging and are not binding for theCompany.
WEIGHTS
PRESSURE CONTAINMENT
Application of Directive 2002/95/EC of the European Parliamentand of the Council, of 27 January 2003, on the restriction of the useof certain hazardous substances in electrical and electronicequipment
The restriction of use of these hazardoussubstances shall not apply to the applicationslisted in the Annex of the same Directive; amongthese applications the following exceptions areparticularly interesting in air conditioning /refrigerating systems:– Lead as an alloying element in steel containing
up to 0,35% lead by weight, aluminiumcontaining up to 0,4% lead by weight and as acopper alloy containing up to 4% lead byweight
– Hexavalent chromium as an anti-corrosion ofthe carbon steel cooling system in absorptionrefrigerators
The Member States of European Community hadto adopt the two Directives 2002/95/EC and2002/96/EC, with the next updating 2003/108/EC,before 13 August 2004, unless delays granted bythe European Parliament.For a long time Castel Company has started acareful inquiry, together with its suppliers, toidentify the presence or not of the above-mentioned hazardous substances, either in itsown products or in its own production processes,and to remove them progressively.At the end of this wide examination CastelCompany 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 theaccepted limits according to the Annex ofRoHS Directive
– Contain hexavalent chromium in very lowconcentration, not exceeding 0,003% byweight, used for the surface treatments (yellowzinc plating) of steel parts. Castel Company willremove the remaining yellow zinc platingtreatments from all its products, before the endof 2005, and will choose other surfacetreatments containing trivalent chromiuminstead of hexavalent chromium.
The purpose of Directive 2002/95/EC (RoHSDirective) is to prevent or restrict the use ofhazardous substances in electrical and electronicequipment and to contribute to theenvironmentally sound recovery and disposal ofwaste electrical and electronic equipment.RoHS Directive shall apply to electrical andelectronic equipment falling under the categories1, 2, 3, 4, 5, 6, 7 and 10 set out in Annex 1A toDirective 2002/96/EC (WEEE – Waste electricaland electronic equipment) and to electric lightbulbs and luminaries in households.The equipment proper to the first category,“Large household appliances”, and to the 10thcategory, “Automatic dispensers”, of Annex 1Ain WEEE Directive, are specified in Annex 1B inthe 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 andelectronic equipment put on the market areappropriately identified as waste subject toseparate collection, by means of the propersymbol shown in Annex IV of the same Directive.
Article 4 of RoHS Directive establishes that, from1 July 2006, new electrical and electronicequipment put on the market does not containthe following substances:– Lead– Mercury– Cadmium– Hexavalent chromium– Polybrominated biphenyls (PBB)– Polybrominated diphenyl ethers (PBDE)
CONNECTIONS OF CASTEL PRODUCTS
Castel products can be supplied with differentconnections.
In particular Castel products are producedeither with threaded connections or solderconnections.Table 1 shows the equivalence between Castelcodes and dimensions in inches. These codesare commonly used in the international market.Table 2 shows the equivalence between Castelcodes and dimensions in millimetres.
CASTELCode
Dimension[in]
TABLE 1 - Equivalence between Castel code and dimension in inches
CASTELCode
Dimension[mm]
. …/M6
. …/M10
. …/M12
. …/M15
. …/M18
. …/M22
. …/M28
. …/M42
. …/M64
. …/M80
6
10
12
15
18
22
28
42
64
80
TABLE 2 - Equivalence between Castel code and dimension in millimeters
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
. …/1
. …/2
. …/3
. …/4
. …/5
. …/6
. …/7
. …/8
. …/9
. …/11
. …/13
. …/17
. …/21
. …/24
. …/25
. …/28
. …/29
. …/33
. …/34
F.e. 1098/7 – solenoid valve with solder connection
with Ø = 7/8”.
F.e. 4411/M42A – filter drier with replaceable
anti-acid solid core with solder connection
with Ø = 42 mm.
Description of connections that are currentlyused for Castel products.
1) Threaded connections.They can be of three different types:
FLAREStraight threaded connection (according to SAEJ513-92; ASME B1.1-89) for junction to acopper pipe with a suitable flared end, using aright nut (see Table 3).
NPTTaper threaded connection (according to ASMEB1.20.1-92) to joint fittings, valves, safety valvesto vessel or steel pipes.
FPTStraight threaded connection (according to UNIISO 228/1) used in the hydraulic system to jointfittings or valves to vessel or steel pipes.F.e.: solenoid valves for water or air.
2) Solder connections.They can be of four different types and can fitpipes with diameter both in inches and inmillimetres:
ODS (or ODF)Female solder connection for copper tubes. The indicated size corresponds to the outerdiameter 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.
ODMMale solder connection for copper tubes. The indicated size corresponds to the outerdiameter 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).
IDSMale solder connection for copper tube. The indicated size corresponds to the innerdiameter 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).
WSolder connection for steel pipes. The indicated size corresponds to the externaldiameter 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.
FLARE Suitable for Copper Tube Thread
1/4"
5/16"
3/8"
1/2"
5/8"
3/4"
7/8"
1"
Ø 1/4"
Ø 5/16"
Ø 3/8"
Ø 1/2"
Ø 5/8"
Ø 3/4"
Ø 7/8"
Ø 1"
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
TABLE 3 - Flare Connections
THE Kv FACTOR
«Table 1» shows refrigeration capacity valueswith unit Kv related to the nominal workingconditions specified in «Table 2».
Appropriate corrective coefficients may becalculated taking the values shown from Table 3to Table 8 as a basis; this will make it possibleto predict actual working conditions.
As a result:
– Liquid line:Q = Kv · Q1 · L1 · L2
– Suction lineQ = Kv · Q1 · S1 · S2
– Hot gas lineQ = 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 therefrigeration capacity in the presence ofoperating temperatures different from referenceconditions.
L2 S2 H2 = are correction factors of therefrigeration capacity for pressure dropsdifferent from reference conditions.
The correct sizing of tubes and components ofa refrigerating system is of the utmostimportance for all kinds of plants; oversizingand undersizing are both to be avoided sincethey are equally hazardous for the correctoperation of the system.
The correct selection of a component is basedon the knowledge of the relationship betweencapacity and pressure drop through thatcomponent. For this purpose, EN 60534-1, EN60534-2-1 and EN 60534-2-3 standards require manufacturersto specify the Kv coefficient for every product.
The Kv factor is defined as the cold waterflow (volumic mass �� = 1000 kg/m3) in m3/hresulting in a 1 bar pressure drop with acompletely open valve.
This definition applies to all products describedin this handbook.
The merely physical meaning, this coefficientprecisely defines the fluid-dynamic andconstruction characteristics of the product, sothat, with the addition of other parameters moreclosely related to the nature and conditions ofthe fluid under consideration, thecapacity/pressure drop ratio may be preciselydetermined.
Castel provides appropriate tables for the mostcommonly used refrigerants in typical plantworking conditions in order to help engineers inthe correct selection of its products.
TABLE 1
Kvfactor[m3/h]
R134a
Liquid Vapour Hot gas
Refrigeration Capacity [kW]
1 16,85
R22
18,00
R404A
11,90
R407C
18,74
R410A
19,04
R507
11,80
R134a
2,16
R22
2,70
R404A
2,26
R407C
2,68
R410A
3,60
R507
2,15
R134a
8,50
R22
11,70
R404A
10,00
R407C
11,62
R410A
13,00
R507
7,77
+4
TABLE 2 - Nominal Working Conditions
–
+18
+38
0,15
1
Application Suction Temperature[°C]
Condensing Temperature[°C]
Pressure drop[bar]
LIQUIDO
VAPORE
GAS
CALDO
Evaporating Temperature[°C]
Liquid line
TABLE 3 - Correction Factors - L1 of the refrigeration capacity for operating temperatures different from nominal values.
LiquidTemperature
[°C] Refrigerant+ 10 + 5 0 – 5 – 10 – 15 – 20 – 25 – 30 – 35 – 40
Evaporating Temperature[°C]
0
+10
+20
+30
+40
+50
+60
R134a
R22
R404A
R407C
R410A
R507
R134a
R22
R404A
R407C
R410A
R507
R134a
R22
R404A
R407C
R410A
R507
R134a
R22
R404A
R407C
R410A
R507
R134a
R22
R404A
R407C
R410A
R507
R134a
R22
R404A
R407C
R410A
R507
R134a
R22
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.
Pressuredrop[bar]
0,01 0,03 0,05 0,10
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
0,15 0,20 0,25 0,30 0,35 0,40 0,45 0,50 0,55 0,60
Suction line Hot gas line
Q = Kv · Q1 · S1 · S2 [kW]15 = Kv · 2,68 · 0,70 · 0,82
15Kv = ——— = 9,75 [m3/h]
1,538
The result involves the selection of a 1078/9 valvewith Kv = 10 [m3/h]
3) Hot gas line:Valve selection under the following conditions:
Refrigerant: R407CSet 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
20Kv = ——— = 2,61 [m3/h]
7,64
The result involves the selection of a 1078/5 valvewith Kv = 2.61 [m3/h]
1) Liquid line:Evaluation of pressure drop across the valve underthe following working conditions:
Castel 1078/5 valve: Kv = 2,61 [m3/h]Refrigerant: R407CSet 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]
35L2 = ——— = 0,87
40,11
A pressure drop slightly above 0.11 barcorresponds to the L2 = 0.87 correction factor. Sucha pressure drop is compatible with the minimumdifferential pressure required by the valve.
2) Suction line:Valve selection under the following conditions:
Refrigerant: R407CSet refrigeration capacity: 15 [kW]Condensation: + 40 [°C]Evaporation: – 10 [°C]Set pressure drop: 0,1 [bar]
APPLICATION EXAMPLES
TABLE 5 - Correction Factors - S1 of the refrigeration capacityfor operating temperatures different from nominal values.
EvaporatingTemperature
[°C] + 60 + 55 + 50 + 45 + 40 + 35 + 30
Condensing Temperature [°C]
+10
0
–10
–20
–30
–40
0,87
0,67
0,51
0,35
0,36*
0,27*
0,92
0,73
0,55
0,39
0,38*
0,29*
0,98
0,78
0,59
0,43
0,41*
0,31*
1,04
0,83
0,64
0,50
0,35
0,43*
0,33*
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*
TABLE 6 - Correction Factors - S2 of the refrigeration capacityfor pressure drops different from nominal values.
Pressuredrop[bar]
0,035 0,05 0,07 0,10 0,15 0,20 0,30 0,40 0,50 0,70
S2 0,47 0,57 0,68 0,82 1,00 1,15 1,40 1,64 1,82 2,15
TABLE 8 - Correction Factors - H2 of the refrigeration capacityfor pressure drops different from nominal values.
Pressuredrop[bar]
0,10 0,20 0,30 0,40 0,50 0,70 1,00 1,50 2,00 2,50
H2 0,32 0,45 0,54 0,65 0,70 0,83 1,00 1,17 1,30 1,44
TABLE 7 - Correction Factors - H1 of the refrigeration capacityfor operating temperatures different from nominal values.
EvaporatingTemperature
[°C] + 60 + 55 + 50 + 45 + 40 + 35 + 30
Condensing Temperature [°C]
+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
*Two-stages plants, two indipendent circuits, with intermediatetemperature -10 °C.
17
THERMOSTATIC EXPANSION VALVES
18
top of the valve’s diaphragm. The sensingbulb pressure is a function of thetemperature of the thermostatic charge thatis the substance within the bulb.The body is made from forged brass withconnection in angle configuration. Theinterchangeable orifice assembly can bereplaced through the inlet connection. Asteel rod, inside the body, transfers thediaphragm movement to the plug inside theorifice assembly. When the thermostaticcharge pressure increases, the diaphragmwill be deflected downward transferring thismotion to the plug, which lifts from seat andallows the liquid passing through orifice. Aspring opposes the force underneath thediaphragm and the side spindle can adjustits tension. Static superheat increases byturning the side spindle clockwise anddecreased by turning the spindle counterclockwise.The thermostatic element is hardlyconnected by brazing to the forged brassbody to avoid any leakage.The body assembly can be supplied withinternal or external equalizer; both typescan also be supplied either with flareconnections or with solder connections(outlet and external equalizer if present).
Castel thermostatic expansion valves series22 regulate the flow of refrigerant liquid intoevaporators; the liquid injection is controlledby the refrigerant superheat.The new Castel “22” series are designed towork with interchangeable orifice assembly,to provide flexibility in selection of capacities,and can be used in a wide range ofapplications as listed below:• Refrigeration systems (display cases in
supermarkets, freezers, ice cream and icemaker machines, transport refrigerationetc).
• Air conditioning systems• Heat pump systems• Liquid chillerswhich use refrigerant fluids proper to theGroup II (as defined in Article 9, Section2.2, of Directive 97/23/EC and referred to inDirective 67/548/EEC).
Castel thermostatic expansion valves actsas throttle device between the high pressureand the low pressure sides of refrigerationsystems and ensure that the rate ofrefrigerant flow into the evaporator exactlymatches the rate of evaporation of liquidrefrigerant in the evaporator. If the actualsuperheat is higher than the set point thevalve feeds the evaporator with more liquidrefrigerant, if the actual superheat is lowerthan the set point the valve decreases theflow of liquid refrigerant to the evaporator.Thus the evaporator is fully utilized and noliquid refrigerant may reach the compressor.
Castel thermostatic expansion valve series22 is made up of two parts that must worktogether: the first is the body, which is theactuator of the regulator, and the second isthe orifice, which contains the valve andattends the expansion of the refrigeratingfluid.
Body assembly: two parts make it up: thethermostatic (power) element and the bodywith its inner elements.The thermostatic element is the motor of thevalve; a sensing bulb is connected to thediaphragm assembly by a length of capillarytubing, which transmits bulb pressure to the
CONSTRUCTION
OPERATION
APPLICATION
THERMOSTATIC EXPANSION VALVES SERIES 22WITH INTERCHANGEABLE ORIFICE ASSEMBLY
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Table 1: General Caracteristics of Body Assemblies of Thermostatic Expansion Valves
externalequalizer
internalequalizer
Catalogue number
IN OUT Equal. OUT OUT Equal. min max
PS [bar]
SAE Flare ODS [mm] ODS [in]
Refri
gera
nt
Evap
orat
ing
Tem
pera
ture
Ran
ge[°C
]
Max
bul
b te
mpe
ratu
re [
°C]
MOP
TS [°C]Connections
–
2210/4E
2210/M12SE
2210/4SE
–
2211/4E
2211/M12SE
2211/4SE
–
2220/4E
2220/M12SE
2220/4SE
–
2221/4E
2221/M12SE
2221/4SE
–
2230/4E
2230/M12SE
2230/4SE
–
2231/4E
2231/M12SE
2231/4SE
–
2234/4E
2234/M12SE
2234/4SE
2210/4
2210/M12S
2210/4S
–
2211/4
2211/M12S
2211/4S
–
2220/4
2220/M12S
2220/4S
–
2221/4
2221/M12S
2221/4S
–
2230/4
2230/M12S
2230/4S
–
2231/4
2231/M12S
2231/4S
–
2234/4
2234/M12S
2234/4S
–
3/8"
3/8"
3/8"
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"
–
–
–
–
–
1/4"
–
–
–
–
–
1/4"
–
–
–
–
–
1/4"
–
–
–
–
–
1/4"
–
–
–
–
–
1/4"
–
–
–
–
–
1/4"
–
–
–
–
–
1/4"
–
–
–
12
–
–
12
–
–
12
–
–
12
–
–
12
–
–
12
–
–
12
–
–
12
–
–
12
–
–
12
–
–
12
–
–
12
–
–
12
–
–
12
–
Equal.
–
–
–
–
6
–
–
–
–
–
6
–
–
–
–
–
6
–
–
–
–
–
6
–
–
–
–
–
6
–
–
–
–
–
6
–
–
–
–
–
6
–
–
–
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"
–
–
–
–
–
1/4"
–
–
–
–
–
1/4"
–
–
–
–
–
1/4"
–
–
–
–
–
1/4"
–
–
–
–
–
1/4"
–
–
–
–
–
1/4"
–
–
–
–
–
1/4"
R22
R407C
R134a
R404A
R507
- 40 ➝
+ 10
- 40 ➝
+ 10
- 40 ➝
+ 10
- 60 ➝
- 25
without
+ 15 °C
(95 psi)
without
+ 15 °C
(55 psi)
without
+ 15 °C
(120 psi)
- 20 °C
(30 psi)
100
(1)-60 +120 34
RiskCategoryaccording
to PED
Art. 3.3
(1) when valve is installed. 60 °C with element not mounted
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MOP (Maximum Operating Pressure): thisfunctionality limits the evaporator pressureto a maximum value to protect thecompressor from the overload condition(Motor Overload Protection). MOP is theevaporating pressure at which theexpansion valve will throttle liquid injectioninto the evaporator and thus prevent theevaporating pressure from rising. Expansionvalve operates as superheat control innormal working range and operates aspressure regulator within MOP range. TheMOP point will change if the factorysuperheat setting of the expansion valve ischanged. Superheat adjustments influencethe MOP point as following:• increase of superheat
decrease of MOP• decrease of superheat
increase of MOP
Superheat: this is the controlling parameterof the expansion valve. Superheat,measured at the evaporator outlet, isdefined as the difference between actualbulb temperature and the evaporatingtemperature at the saturation point. In orderto prevent liquid refrigerant from enteringthe compressor, a certain minimumsuperheat must be maintained. In expansionvalve operation the following terms areused:• Static superheat: it’s the superheat above
that the valve will begin to open. Castelthermo expansion valves are factorypreset for optimum static superheatsetting. This setting should be modifiedonly if absolutely necessary. Staticsuperheat for Castel valves without MOPis 5 °C and for Castel valves with MOP is4°C.
• Opening superheat: it’s the amount ofsuperheat above the static superheatrequired to produce a given valvecapacity
• Operating superheat: it’s the sum of staticand opening superheat
The nuts for flare connection type and theinlet-brazing adapter for solder connectiontype can be ordered separately.
The main part of body assembly are madewith 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 springholder
• steel DIN 17223-1 for spring• copper tube EN 12735-1 – Cu DHP for
solder connection
Orifice assembly: interchangeable orificeassembly provide a wide range of capacityfrom 0,5 up to 15,5 kW (nominal capacitywith R22). The external cartridge containsthe following elements: housing, plug(metering device), seat, spring and strainer.The rigid design of orifice assembly and itsinternal components make sure that plugand seat will withstand all types of criticaloperations (liquid hammering, cavitation,sudden variation of pressure andtemperature contaminants). The springholds the plug firmly to the seat to ensurethe minimum leakage through the valve; forpositive shut-off, the installation of asolenoid valve is required. The strainer canbe cleaned or exchanged.
Liquid charge: the behaviour of valves withliquid charge is exclusively determined bytemperature changes at the bulb and notsubject to any cross-ambient interference.They feature a fast response time and thusreact quickly in the control circuit. Castelthermostatic expansion valves with liquidcharge cannot incorporate MOP functions.
Gas charge: the behaviour of valves withgas charge will be determined by the lowesttemperature at any part of the expansionvalve (thermostatic element, capillary tubeor bulb). If any parts other than the bulb aresubjected to the lowest temperature,malfunction of expansion valve may occur(charge migration). Castel thermostaticexpansion valves with gas charge alwaysfeature MOP functions and include ballastedbulb. Ballast in the bulb has a dampingeffect on the valve regulation and leads toslow opening and fast closure of the valve.
THERMOSTATIC CHARGES
21
To correctly select a thermo expansion valveon a refrigerating system, the followingdesign conditions must be available:Type of refrigerantEvaporator capacity, Qe
Evaporating temperature/pressure, Te / pe
Lowest possible condensing temperature/pressure, Tc / pc
Liquid refrigerant temperature, Tl
Pressure drop in the liquid line, distributorand evaporator, �p
The following procedure helps to select thecorrect valve for the system.
Step 1Determine the pressure drop across thevalve. The pressure drop is calculated bythe formula:
( )pppp ectot ∆+−=∆
SELECTIONSubcooling: it’s defined as the differencebetween the liquid refrigerant temperatureand its saturation temperature. Subcoolinggenerally increases the capacity ofrefrigeration system and may be accountedfor when dimensioning an expansion valve.Depending on system design, subcoolingmay be necessary to prevent flash gas fromforming in the liquid line. If flash gas formsin the liquid line, the capacity of expansionvalve will be greatly reduced. All capacitytables, in this chapter, are calculated for asubcooling value of 4 °C; if the actualsubcooling is higher than 4 °C theevaporator capacity must be divided by theappropriate correction factor shown is thetables below every capacity tables.
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40
39
35
66
43
29
42
42
66
35
54
34
40
39
43
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Step 3Determine required orifice size. Use thepressure drop across the valve, theevaporating temperature and the calculatedevaporator capacity to select thecorresponding orifice size from the capacitytable corresponding to the chosenrefrigerant.
Step 4Select a thermostatic charge. Chose thetype of charge, liquid without MOP or gaswith MOP, and the temperature range,normal temperature or low temperature.
Step 5Determine if external equalizer is required.External equalizer is always required if adistributor is used or if there is anappreciable difference in pressure from thevalve outlet to the bulb location. Finallydetermine the type of connections and theirsizes.
where:Pc = condensing pressurePe = evaporating pressure�p = sum of pressure drops in the liquidline, distributor and evaporator
Step 2Determine required valve capacity. Use theevaporating capacity Qe to select therequired valve size at a given evaporatingtemperature. If necessary, correct theevaporator capacity for subcooling.Subcooling liquid refrigerant entering theevaporator increase the evaporatorcapacity, so that a smaller valve may berequired.
The subcooling is calculated by the formula:
From the subcooling corrector factor tablefind the appropriate corrector factor Fsub
corresponding to the �Tsub calculated anddetermine the required valve capacity by theformula:
sub
esub F
QQ =∆
lcsub TTT −=∆
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Table 2: Orifice Assemblies - Rated Capacities in kW
Catalogue Number
R22R407C R134a R404A
R507R404AR507
Evaporating Temperature Range [°C]
- 40 ➝ + 10 -60➝ -25
220X
2200
2201
2202
2203
2204
2205
2206
0,5
1,0
2,5
3,5
5,2
8,0
10,5
15,5
0,4
0,9
1,8
2,6
4,6
6,7
8,6
10,5
0,38
0,7
1,6
2,1
4,2
6,0
7,7
9,1
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
23
• Type of refrigerant R134a• Evaporator capacity, Qe 6 kW• Evaporating temperature/
pressure, Te - 10 °C• Lowest possible condensing
temperature/pressure, Tc + 30 °C• Liquid refrigerant temperature, Tl + 20 °C• Pressure drop in the liquid line, distributor
and evaporator, �p 1,5 bar
STEP 1 - Determine the pressure dropacross the valve• Condensing pressure at
+ 30 °C - pc = 6,71 bar• Evaporating pressure at
- 10 °C - pe = 1,01 bar
STEP 2 - Determine required valve capacity
From the subcooling corrector factor table5b, we find the appropriate corrector factorFsub equal to 1,08 for �Tsub = 10 °C. Requiredvalve capacity is:
kW5,551,086Q sub ⋅==∆
C102030Tsub °⋅=−=∆
( ) bar2,45,101,171,6p tot ⋅=+−=∆
SIZING EXAMPLE
STEP 3 - Determine required orifice sizeUsing the capacity table for R134a on page25 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 mustbe equal or slightly more than thecalculated evaporator capacity)
Main valve data are indicated on the upperside of the thermostatic element and on thecartridge surface of the orifice assembly.On the thermostatic element you may findthe 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 productionOn the cartridge of orifice assembly youmay find the following data:• The size of the orifice• The date of productionOn the plastic cap of the orifice assemblypackage a label gives the orifice size. Thecap can easily be fastened around the valvecapillary tube to clearly identify the valvesize.
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Table 3: Solder adapters
Catalogue NumberODS Connections
[in] [mm]
2271/M6S
2271/2S
2271/3S
2271/M10S
–
1/4"
3/8"
–
6
–
–
10
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Table 4a: Refrigerant R22/R407C - Capacities in kW for temperature range - 40°C ? +10°C
Orificecode
Orificecode
Pressure drop across valve [bar] Pressure drop across valve [bar]
2 4 6 8 10 12 14 16 2 4 6 8 10 12 14 16
Evaporating temperature = 0 °C
220X 0,37 0,48 0,55 0,59 0,63 0,65 0,66 0,66
2200 0,84 1,0 1,2 1,3 1,3 1,4 1,4 1,4
2201 1,9 2,4 2,7 3,0 3,1 3,2 3,3 3,3
2202 2,6 3,4 4,0 4,3 4,6 4,8 4,9 5,0
2203 4,6 6,1 7,1 7,8 8,2 8,5 8,7 8,8
2204 6,9 9,1 10,5 11,5 12,2 12,7 13,0 13,2
2205 8,8 11,6 13,3 14,6 15,5 16,1 16,4 16,6
2206 10,8 14,2 16,3 17,8 18,9 19,6 20,0 20,2
Evaporating temperature = -20 °C
220X 0,44 0,50 0,54 0,57 0,59 0,61 0,61
2200 0,88 1,0 1,1 1,1 1,2 1,2 1,2
2201 1,7 1,9 2,0 2,2 2,3 2,3 2,3
2202 2,4 2,7 2,9 3,1 3,2 3,3 3,3
2203 4,2 4,8 5,2 5,5 5,8 5,9 6,0
2204 6,2 7,1 7,7 8,2 8,5 8,7 8,8
2205 7,9 9,0 9,8 10,3 10,8 11,0 11,2
2206 9,6 11,0 11,9 12,6 13,1 13,5 13,7
Evaporating temperature = -40 °C
220X 0,42 0,45 0,48 0,50 0,52 0,53
2200 0,8 0,86 0,92 0,95 0,98 0,99
2201 1,3 1,4 1,4 1,5 1,5 1,6
2202 1,7 1,9 2,0 2,0 2,1 2,1
2203 3,1 3,4 3,5 3,7 3,8 3,8
2204 4,6 4,9 5,2 5,4 5,6 5,7
2205 5,8 6,3 6,6 6,9 7,1 7,2
2206 7,1 7,7 8,1 8,4 8,7 8,8
Evaporating temperature = +10 °C
220X 0,37 0,48 0,55 0,60 0,63 0,65 0,65 0,67
2200 0,87 1,1 1,2 1,3 1,4 1,4 1,4 1,5
2201 2,2 2,8 3,2 3,4 3,6 3,7 3,8 3,8
2202 3,0 4,0 4,7 5,1 5,4 5,6 5,8 5,8
2203 5,4 7,2 8,3 9,1 9,7 10,0 10,2 10,3
2204 8,1 10,8 12,5 13,8 14,5 15,0 15,5 15,5
2205 10,2 13,6 15,7 17,2 18,3 18,9 19,3 19,5
2206 12,6 16,7 19,3 21,0 22,3 23,1 23,5 23,7
Evaporating temperature = -10 °C
220X 0,37 0,47 0,53 0,57 0,60 0,63 0,64 0,64
2200 0,79 0,96 1,1 1,2 1,2 1,3 1,3 1,3
2201 1,6 2,0 2,3 2,5 2,6 2,7 2,8 2,8
2202 2,2 2,9 3,3 3,6 3,8 4,0 4,1 4,1
2203 3,9 5,1 5,9 6,4 6,8 7,1 7,3 7,3
2204 5,8 7,6 8,7 9,5 10,1 10,5 10,8 10,9
2205 7,4 9,6 11,0 12,0 12,8 13,3 13,6 13,8
2206 9,1 11,6 13,5 14,7 15,6 16,2 16,6 16,8
Evaporating temperature = -30 °C
220X 0,40 0,45 0,49 0,52 0,55 0,56 0,57
2200 0,79 0,9 0,96 1,0 1,1 1,1 1,1
2201 1,4 1,5 1,7 1,8 1,8 1,9 1,9
2202 1,9 2,2 2,7 2,5 2,6 2,6 2,7
2203 3,4 3,9 4,2 4,4 4,6 4,7 4,8
2204 5,0 5,7 6,2 6,6 6,8 7,0 7,1
2205 6,4 7,2 7,8 8,3 8,6 8,8 9,0
2206 7,8 8,8 9,6 10,1 10,5 10,8 11,0
Table 4b: Refrigerant R22/R407C - Correction factor for subcooling �tsub > 4°C
�tsub [°C] 4 10 15 20 25 30 35 40 45 50
Fsub 1,00 1,06 1,11 1,15 1,20 1,25 1,30 1,35 1,39 1,44
When subcooling ahead of the expansion valve is other than 4 °C, adjust the evaporatore capacity by dividing bythe appropriate correction factor found in Table 4b
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Table 5a: Refrigerant R134a - Capacities in kW for temperature range - 40°C ➝➝ +10°C
Orificecode
Orificecode
Pressure drop across valve [bar] Pressure drop across valve [bar]
2 4 6 8 10 2 4 6 8 10
Evaporating temperature = 0 °C
220X 0,33 0,42 0,46 0,47 0,49
2200 0,65 0,78 0,86 0,89 0,91
2201 1,3 1,6 1,7 1,8 1,8
2202 1,7 2,2 2,4 2,6 2,6
2203 3,0 3,9 4,4 4,6 4,7
2204 4,5 5,7 6,4 6,8 7,0
2205 5,7 7,3 8,1 8,6 8,8
2206 7,0 8,9 1,0 10,5 10,8
Evaporating temperature = -20 °C
220X 0,28 0,35 0,39 0,41 0,42
2200 0,53 0,62 0,69 0,72 0,73
2201 0,81 1,0 1,1 1,2 1,2
2202 1,1 1,4 1,5 1,6 1,7
2203 2,0 2,5 2,8 2,9 3,0
2204 2,9 3,6 4,0 4,3 4,4
2205 3,7 4,6 5,1 5,4 5,5
2206 4,5 5,6 6,2 6,6 6,8
Evaporating temperature = -40 °C
220X 0,23 0,28 0,32 0,33 0,34
2200 0,44 0,50 0,54 0,56 0,57
2201 0,54 0,65 0,72 0,78 0,77
2202 0,7 0,9 1,0 1,0 1,0
2203 1,3 1,6 1,8 1,9 1,9
2204 1,9 2,3 2,6 2,7 2,7
2205 2,4 2,9 3,2 3,5 3,5
2206 3,0 3,6 4,0 4,2 4,3
Evaporating temperature = +10 °C
220X 0,34 0,43 0,47 0,50 0,51
2200 0,71 0,86 0,93 0,97 0,98
2201 1,5 1,9 2,1 2,2 2,2
2202 2,0 2,6 3,0 3,1 3,2
2203 3,6 4,7 5,3 5,6 5,8
2204 5,4 7,0 7,8 8,3 8,6
2205 6,9 8,9 9,9 10,8 10,9
2206 8,4 10,8 12,1 12,8 13,2
Evaporating temperature = -10 °C
220X 0,30 0,36 0,43 0,44 0,44
2200 0,59 0,70 0,77 0,81 0,82
2201 1,0 1,3 1,4 1,5 1,5
2202 1,4 1,8 2,0 2,1 2,1
2203 2,5 3,1 3,5 3,7 3,8
2204 3,6 4,6 5,1 5,4 5,6
2205 4,6 5,8 6,5 6,9 7,1
2206 5,7 7,1 8,0 8,4 8,6
Evaporating temperature = -30 °C
220X 0,25 0,32 0,35 0,37 0,38
2200 0,48 0,55 0,61 0,64 0,64
2201 0,66 0,80 0,88 0,93 0,95
2202 0,9 1,1 1,2 1,3 1,3
2203 1,6 2,0 2,2 2,3 2,3
2204 2,3 2,9 3,2 3,3 3,4
2205 3,0 3,6 4,0 4,2 4,3
2206 3,6 4,4 4,9 5,2 5,3
Table 5b: Refrigerant R134a - Correction factor for subcooling �tsub > 4°C
�tsub [°C] 4 10 15 20 25 30 35 40 45 50
Fsub 1,00 1,08 1,13 1,19 1,25 1,31 1,37 1,42 1,48 1,54
When subcooling ahead of the expansion valve is other than 4 °C, adjust the evaporatore capacity by dividing bythe appropriate correction factor found in Table 5b
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Table 6a: Refrigerant R404A/R507 - Capacities in kW for temperature range - 40°C ➝➝ +10°C
Orificecode
Orificecode
Pressure drop across valve [bar] Pressure drop across valve [bar]
2 4 6 8 10 12 14 16 2 4 6 8 10 12 14 16
Evaporating temperature = 0 °C
220X 0,30 0,37 0,41 0,42 0,43 0,43 0,43 0,41
2200 0,68 0,80 0,87 0,90 0,92 0,93 0,91 0,87
2201 1,53 1,86 2,04 2,13 2,18 2,18 2,15 2,08
2202 2,06 2,64 2,95 3,13 3,22 3,25 3,21 3,11
2203 3,68 4,72 5,27 5,59 5,75 5,80 5,73 5,55
2204 5,49 7,15 7,86 8,33 8,58 8,64 8,53 8,27
2205 6,97 8,92 9,95 10,52 10,83 10,90 10,76 10,43
2206 8,57 10,93 12,16 12,85 13,21 13,30 13,12 12,72
Evaporating temperature = -20 °C
220X 0,35 0,38 0,40 0,39 0,40 0,39 0,38
2200 0,70 0,75 0,77 0,79 0,79 0,79 0,76
2201 1,34 1,45 1,50 1,52 1,52 1,51 1,47
2202 1,85 2,04 2,14 2,17 2,18 2,16 2,09
2203 3,32 3,66 3,83 3,89 3,90 3,86 3,75
2204 4,88 5,40 5,64 5,75 5,77 5,71 5,56
2205 6,20 6,86 7,17 7,29 7,31 7,23 7,05
2206 7,60 8,39 8,75 8,91 8,93 8,84 8,61
Evaporating temperature = -40 °C
220X 0,32 0,33 0,33 0,33 0,32 0,32
2200 0,60 0,61 0,62 0,61 0,60 0,59
2201 0,92 0,96 0,97 0,96 0,94 0,91
2202 1,27 1,32 1,33 1,31 1,28 1,24
2203 2,28 2,36 2,38 2,36 2,31 2,24
2204 3,34 3,47 3,50 3,48 3,42 3,33
2205 4,25 4,41 4,45 4,43 4,36 4,24
2206 5,19 5,39 5,45 5,42 5,33 5,19
Evaporating temperature = +10 °C
220X 0,28 0,35 0,40 0,42 0,43 0,43 0,42 0,41
2200 0,67 0,82 0,90 0,94 0,96 0,96 0,93 0,90
2201 1,70 2,10 2,30 2,42 2,48 2,46 2,41 2,34
2202 2,32 3,00 3,39 3,61 3,73 3,74 3,68 3,59
2203 4,15 5,36 6,03 6,43 6,63 6,66 6,55 6,39
2204 6,24 8,06 9,06 9,66 9,95 9,98 9,81 9,57
2205 7,91 10,17 11,43 12,16 12,53 12,56 12,34 12,03
2206 9,71 12,47 13,98 14,86 15,29 15,31 15,05 14,66
Evaporating temperature = -10 °C
220X 0,30 0,37 0,40 0,42 0,42 0,42 0,41 0,41
2200 0,65 0,76 0,82 0,84 0,87 0,87 0,85 0,83
2201 1,31 1,61 1,74 1,81 1,84 1,85 1,84 1,78
2202 1,76 2,24 2,50 2,62 2,69 2,71 2,68 2,60
2203 3,14 4,02 4,47 4,69 4,81 4,84 4,79 4,65
2204 4,66 5,97 6,61 6,95 7,13 7,18 7,11 6,91
2205 5,93 7,57 8,39 8,81 9,02 9,08 8,99 8,73
2206 7,28 9,27 10,26 10,76 11,00 11,08 10,97 10,65
Evaporating temperature = -30 °C
220X 0,35 0,37 0,36 0,37 0,36 0,35
2200 0,67 0,70 0,70 0,70 0,69 0,67
2201 1,18 1,21 1,23 1,21 1,20 1,17
2202 1,63 1,69 1,71 1,70 1,68 1,64
2203 2,93 3,04 3,07 3,06 3,02 2,93
2204 4,28 4,47 4,52 4,51 4,46 4,35
2205 5,45 5,68 5,74 5,74 5,67 5,52
2206 6,66 6,94 7,02 7,01 6,93 6,75
Table 6b: Refrigerant R404A/R507 - Correction factor for subcooling �tsub > 4°C
�tsub [°C] 4 10 15 20 25 30 35 40 45 50
Fsub 1,00 1,10 1,20 1,29 1,37 1,46 1,54 1,63 1,70 1,78
When subcooling ahead of the expansion valve is other than 4 °C, adjust the evaporatore capacity by dividing bythe appropriate correction factor found in Table 6b
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Table 7a: Refrigerant R404A/R507 - Capacities in kW for temperature range - 60°C ➝➝ - 25°C
Orificecode
Orificecode
Pressure drop across valve [bar] Pressure drop across valve [bar]
2 4 6 8 10 12 14 16 2 4 6 8 10 12 14 16
Evaporating temperature = -30 °C
2200 0,53 0,64 0,67 0,70 0,70 0,70 0,69 0,67
2201 0,88 1,07 1,18 1,21 1,23 1,21 1,20 1,17
2202 1,18 1,47 1,63 1,69 1,71 1,70 1,68 1,64
2203 2,12 2,65 2,93 3,04 3,07 3,05 3,02 2,93
2204 3,09 3,88 4,28 4,47 4,52 4,51 4,46 4,35
2205 3,94 4,94 5,45 5,68 5,74 5,74 5,67 5,52
2206 4,83 6,06 6,66 6,94 7,02 7,01 6,93 6,75
Evaporating temperature = -50 °C
2200 0,49 0,53 0,54 0,54 0,53 0,52 0,50
2201 0,51 0,57 0,60 0,60 0,60 0,60 0,59
2202 0,91 0,99 1,02 1,02 1,01 0,98 0,95
2203 1,63 1,73 1,84 1,84 1,81 1,78 1,72
2204 2,36 2,60 2,69 2,71 2,68 2,63 2,56
2205 3,02 3,30 3,43 3,45 3,42 3,35 3,26
2206 3,69 4,04 4,20 4,22 4,18 4,12 4,00
Evaporating temperature = -25 °C
2200 0,57 0,67 0,72 0,73 0,74 0,85 0,74 0,71
2201 0,98 1,20 1,31 1,36 1,37 1,37 1,35 1,31
2202 1,31 1,65 1,83 1,91 1,93 1,93 1,90 1,85
2203 2,35 2,97 3,28 3,42 3,47 3,46 3,42 3,32
2204 3,45 4,37 4,82 5,04 5,11 5,12 5,06 4,93
2205 4,40 5,56 6,14 6,40 6,49 6,49 6,42 6,26
2206 5,40 6,30 7,49 7,81 7,93 7,93 7,85 7,64
Evaporating temperature = -40 °C
2200 0,56 0,60 0,61 0,62 0,61 0,60 0,59
2201 0,65 0,72 0,75 0,77 0,77 0,77 0,75
2202 1,17 1,27 1,32 1,33 1,31 1,28 1,24
2203 2,09 2,28 2,36 2,38 2,36 2,31 2,24
2204 3,03 3,34 3,47 3,50 3,48 3,42 3,33
2205 3,87 4,25 4,41 4,45 4,43 4,36 4,24
2206 4,73 5,19 5,39 5,45 5,47 5,33 5,19
Evaporating temperature = -60 °C
2200 0,46 0,48 0,47 0,45 0,45 0,43
2201 0,58 0,60 0,60 0,58 0,56 0,54
2202 0,78 0,80 0,80 0,78 0,75 0,72
2203 1,40 1,44 1,43 1,40 1,36 1,30
2204 2,04 2,11 2,11 2,07 2,03 1,96
2205 2,59 2,69 2,66 2,65 2,59 2,50
2206 3,16 3,28 3,30 3,25 3,18 3,07
Table 7b: Refrigerant R404A/R507 - Correction factor for subcooling �tsub > 4°C
�tsub [°C] 4 10 15 20 25 30 35 40 45 50
Fsub 1,00 1,10 1,20 1,29 1,37 1,46 1,54 1,63 1,70 1,78
When subcooling ahead of the expansion valve is other than 4 °C, adjust the evaporatore capacity by dividing bythe appropriate correction factor found in Table 7b
28
connection in angle configuration. The fixedorifice assembly is screwed into the bodythrough the inlet side. A steel rod, inside thebody, transfers the diaphragm movement tothe plug inside the orifice assembly. Whenthe thermostatic charge pressure increases,the diaphragm will be deflected downwardtransferring this motion to the plug, whichlifts from seat and allows the liquid passingthrough orifice. A spring opposes the forceunderneath the diaphragm and the sidespindle can adjust its tension. Staticsuperheat increases by turning the sidespindle clockwise and decreased by turningthe spindle counter clockwise.
Castel thermostatic expansion valves series23 regulate the flow of refrigerant liquid intoevaporators; the liquid injection is controlledby the refrigerant superheat.The new Castel “23” series are specificallydeveloped for soldering into hermeticrefrigeration systems; they are offered inrated capacities up to 15,5 kW (R22) andcan be used in a wide range of applicationsas listed below:• Refrigeration systems (display cases in
supermarkets, freezers, ice cream and icemaker machines, transport refrigerationetc).
• Air conditioning systems• Heat pump systems• Liquid chillerswhich use refrigerant fluids proper to theGroup II (as defined in Article 9, Section2.2, of Directive 97/23/EC and referred to inDirective 67/548/EEC).
Castel thermostatic expansion valves actsas throttle device between the high pressureand the low pressure sides of refrigerationsystems and ensure that the rate ofrefrigerant flow into the evaporator exactlymatches the rate of evaporation of liquidrefrigerant in the evaporator. If the actualsuperheat is higher than the set point thevalve feeds the evaporator with more liquidrefrigerant, if the actual superheat is lowerthan the set point the valve decreases theflow of liquid refrigerant to the evaporator.Thus the evaporator is fully utilized and noliquid refrigerant may reach the compressor.
Four parts make up the Castel thermoexpansion valve series 23: the thermostatic(power) element, the body with its innerelements, the orifice assembly and the inletconnection.The thermostatic element is the motor of thevalve; a sensing bulb is connected to thediaphragm assembly by a length of capillarytubing, which transmits bulb pressure to thetop of the valve’s diaphragm. The sensingbulb pressure is a function of thetemperature of the thermostatic charge thatis the substance within the bulb.The body is made from forged brass with
CONSTRUCTION
OPERATION
APPLICATION
HERMETIC THERMOSTATIC EXPANSION VALVES SERIES 23 WITH FIXED ORIFICE ASSEMBLY
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Table 1: General Characteristics of Thermostatic Expansion Valves
external equalizerinternal equalizer
Catalogue number
IN OUT Equal. IN OUT Equal. min max
PS [bar]
[in] [mm]
Refri
gera
nt
Evap
orat
ing
Tem
pera
ture
Ran
ge[°C
]
Max
bul
b te
mpe
ratu
re [
°C]
MOP
TS [°C]ODS Connections
–
2310/M6E 0X ➝ 06
2310/2E 0X ➝ 06
2310/3E 0X ➝ 06
2310/M10E 0X ➝ 06
–
2311/M6E 0X ➝ 06
2311/2E 0X ➝ 06
2311/3E 0X ➝ 06
2311/M10E 0X ➝ 06
–
2320/M6E 0X ➝ 06
2320/2E 0X ➝ 06
2320/3E 0X ➝ 06
2320/M10E 0X ➝ 06
–
2321/M6E 0X ➝ 06
2321/2E 0X ➝ 06
2321/3E 0X ➝ 06
2321/M10E 0X ➝ 06
–
2330/M6E 0X ➝ 06
2330/2E 0X ➝ 06
2330/3E 0X ➝ 06
2330/M10E 0X ➝ 06
–
2331/M6E 0X ➝ 06
2331/2E 0X ➝ 06
2331/3E 0X ➝ 06
2331/M10E 0X ➝ 06
–
2334/M6E 0X ➝ 06
2334/2E 0X ➝ 06
2334/3E 0X ➝ 06
2334/M10E 0X ➝ 06
2310/M6 0X➝06
2310/2 0X ➝ 06
2310/3 0X ➝ 06
2310/M10 0X ➝ 06
–
2311/M6 0X ➝ 06
2311/2 0X ➝ 06
2311/3 0X ➝ 06
2311/M10 0X ➝ 06
–
2320/M6 0X ➝ 06
2320/2 0X ➝ 06
2320/3 0X ➝ 06
2320/M10 0X ➝ 06
–
2321/M6 0X ➝ 06
2321/2 0X ➝ 06
2321/3 0X ➝ 06
2321/M10 0X ➝ 06
–
2330/M6 0X ➝ 06
2330/2 0X ➝ 06
2330/3 0X ➝ 06
2330/M10 0X ➝ 06
–
2331/M6 0X ➝ 06
2331/2 0X ➝ 06
2331/3 0X ➝ 06
2331/M10 0X ➝ 06
–
2334/M6 0X ➝ 06
2334/2 0X ➝ 06
2334/3 0X ➝ 06
2334/M10 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"
–
–
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"
–
–
–
–
–
–
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"
–
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
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
–
–
–
–
6
–
–
6
–
–
–
–
6
–
–
6
–
–
–
–
6
–
–
6
–
–
–
–
6
–
–
6
–
–
–
–
6
–
–
6
–
–
–
–
6
–
–
6
–
–
–
–
6
–
–
6
R22
R407C
R134a
R404A
R507
- 40 ➝
+ 10
- 40 ➝
+ 10
- 40 ➝
+ 10
- 60 ➝
- 25
without
+ 15 °C
(95 psi)
without
+ 15 °C
(55 psi)
without
+ 15 °C
(120 psi)
- 20 °C
(30 psi)
100
(1)-60 +120 34
RiskCategoryaccording
to PED
Art. 3.3
(1) when valve is installed. 60 °C with element not mounted
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expansion valves with gas charge alwaysfeature MOP functions and include ballastedbulb. Ballast in the bulb has a dampingeffect on the valve regulation and leads toslow opening and fast closure of the valve.
MOP (Maximum Operating Pressure): thisfunctionality limits the evaporator pressureto a maximum value to protect thecompressor from the overload condition(Motor Overload Protection). MOP is theevaporating pressure at which theexpansion valve will throttle liquid injectioninto the evaporator and thus prevent theevaporating pressure from rising. Expansionvalve operates as superheat control innormal working range and operates aspressure regulator within MOP range. TheMOP point will change if the factorysuperheat setting of the expansion valve ischanged. Superheat adjustments influencethe MOP point as following:• increase of superheat
decrease of MOP• decrease of superheat
increase of MOP
Superheat: this is the controlling parameterof the expansion valve. Superheat,measured at the evaporator outlet, isdefined as the difference between actualbulb temperature and the evaporatingtemperature at the saturation point. In orderto prevent liquid refrigerant from enteringthe compressor, a certain minimumsuperheat must be maintained. In expansionvalve operation the following terms areused:• Static superheat: it’s the superheat
above that the valve will begin to open.Castel thermo expansion valves arefactory preset for optimum staticsuperheat setting. This setting should bemodified only if absolutely necessary.Static superheat for Castel valveswithout MOP is 5 °C and for Castelvalves with MOP is 4°C.
• Opening superheat: it’s the amount ofsuperheat above the static superheatrequired to produce a given valvecapacity
• Operating superheat: it’s the sum of staticand opening superheat
The fixed orifice assembly provide a widerange of capacity from 0,5 up to 15,5 kW(nominal capacity with R22). It contains thefollowing elements: housing, plug (meteringdevice), seat, spring and strainer. The rigiddesign of orifice assembly and its internalcomponents make sure that plug and seatwill withstand all types of critical operations(liquid hammering, cavitation, suddenvariation of pressure and temperaturecontaminants). The spring holds the plugfirmly to the seat to ensure the minimumleakage through the valve; for positive shut-off, the installation of a solenoid valve isrequired.The thermostatic element is hardlyconnected by brazing to the forged brassbody meanwhile the inlet connection iselectrical welded to the forged brass body.This construction makes the valve hermeticand avoids any leakage.The valve can be supplied with internal orexternal equalizer; both types are suppliedwith solder connections (inlet, outlet andexternal equalizer if present).The main part of valve are made with thefollowing 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 springholder
• steel DIN 17223-1 for spring• copper tube EN 12735-1 – Cu DHP for
solder connection
Liquid charge: the behaviour of valves withliquid charge is exclusively determined bytemperature changes at the bulb and notsubject to any cross-ambient interference.They feature a fast response time and thusreact quickly in the control circuit. Castelthermostatic expansion valves with liquidcharge cannot incorporate MOP functions.
Gas charge: the behaviour of valves withgas charge will be determined by the lowesttemperature at any part of the expansionvalve (thermostatic element, capillary tubeor bulb). If any parts other than the bulb aresubjected to the lowest temperature,malfunction of expansion valve may occur(charge migration). Castel thermostatic
THERMOSTATIC CHARGES
31
Step 2Determine required valve capacity. Use theevaporating capacity Qe to select therequired valve size at a given evaporatingtemperature. If necessary, correct theevaporator capacity for subcooling.Subcooling liquid refrigerant entering theevaporator increase the evaporatorcapacity, so that a smaller valve may berequired. The subcooling is calculated bythe formula:
From the subcooling corrector factor tablefind the appropriate corrector factor Fsub
corresponding to the �Tsub calculated anddetermine the required valve capacity by theformula:
Step 3Determine required orifice size. Use thepressure drop across the valve, theevaporating temperature and the calculatedvalve capacity to select the correspondingorifice size from the capacity tablecorresponding to the chosen refrigerant.
sub
esub F
QQ =∆
Subcooling: it’s defined as the differencebetween the liquid refrigerant temperatureand its saturation temperature. Subcoolinggenerally increases the capacity ofrefrigeration system and may be accountedfor when dimensioning an expansion valve.Depending on system design, subcoolingmay be necessary to prevent flash gas fromforming in the liquid line. If flash gas formsin the liquid line, the capacity of expansionvalve will be greatly reduced. All capacitytables, in this chapter, are calculated for asubcooling value of 4 °C; if the actualsubcooling is higher than 4 °C theevaporator capacity must be divided by theappropriate correction factor shown is thetables below every capacity tables.
To correctly select a thermo expansion valveon a refrigerating system, the followingdesign conditions must be available:• Type of refrigerant• Evaporator capacity, Qe
• Evaporating temperature/pressure, Te / pe
• Lowest possible condensingtemperature/pressure, Tc / pc
• Liquid refrigerant temperature, Tl
• Pressure drop in the liquid line, distributorand evaporator, �p
The following procedure helps to select thecorrect valve for the system.
Step 1Determine the pressure drop across thevalve. The pressure drop is calculated bythe formula:
where:pc = condensing pressurepe = evaporating pressure�p = sum of pressure drops in the liquidline, distributor and evaporator
( )pppp ectot ∆+−=∆
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Table 2: Fixed orifices - Rated Capacities in kW
Orifice Size
R22R407C R134a R404A
R507R404AR507
Evaporating Temperature Range [°C]
- 40 ➝ + 10 -60➝ -25
23--/-0X
23--/-00
23--/-01
23--/-02
23--/-03
23--/-04
23--/-05
23--/-06
0,5
1,0
2,5
3,5
5,2
8,0
10,5
15,5
0,4
0,9
1,8
2,6
4,6
6,7
8,6
10,5
0,38
0,7
1,6
2,1
4,2
6,0
7,7
9,1
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
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STEP 1 - Determine the pressure dropacross the valve• Condensing pressure at
+ 38 °C - Pc = 13,6 bar• Evaporating pressure at
+ 5 °C - Pe = 4.8 bar
STEP 2 - Determine required valve capacity
From the subcooling corrector factor table3b we find the appropriate corrector factorFsub equal to 1,07 for �Tsub = 11 °C. Required valve capacity is:
STEP 3 - Determine required orifice sizeUsing the capacity table for R22 on page 33with:• 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 mustbe equal or slightly more than thecalculated evaporator capacity)
kW3,551,078,3Q sub ⋅==∆
C112738Tsub °⋅=−=∆
( ) bar3,85,08,46,13ptot ⋅=+−=∆
Step 4Select a thermostatic charge. Chose thetype of charge, liquid without MOP or gaswith MOP, and the temperature range,normal temperature or low temperature.
Step 5Determine if external equalizer is required.External equalizer is always required if adistributor is used or if there is anappreciable difference in pressure from thevalve outlet to the bulb location. Finallydetermine the type of connections and theirsizes.
• Type of refrigerant R22• Evaporator capacity, Qe 3,8 kW• 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
SIZING EXAMPLE
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The following data are indicated on theupper side of the thermostatic element ofthe 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
MARKING
Table 3a: Refrigerant R22/R407C - Capacities in kW for temperature range - 40°C ➝➝ + 10°C
Orificesize
Orificesize
Pressure drop across valve [bar] Pressure drop across valve [bar]
2 4 6 8 10 12 14 16 2 4 6 8 10 12 14 16
Evaporating temperature = 0 °C
23--/-0X 0,37 0,48 0,55 0,59 0,63 0,65 0,66 0,66
23--/-00 0,84 1,0 1,2 1,3 1,3 1,4 1,4 1,4
23--/-01 1,9 2,4 2,7 3,0 3,1 3,2 3,3 3,3
23--/-02 2,6 3,4 4,0 4,3 4,6 4,8 4,9 5,0
23--/-03 4,6 6,1 7,1 7,8 8,2 8,5 8,7 8,8
23--/-04 6,9 9,1 10,5 11,5 12,2 12,7 13,0 13,2
23--/-05 8,8 11,6 13,3 14,6 15,5 16,1 16,4 16,6
23--/-06 10,8 14,2 16,3 17,8 18,9 19,6 20,0 20,2
Evaporating temperature = -20 °C
23--/-0X 0,44 0,50 0,54 0,57 0,59 0,61 0,61
23--/-00 0,88 1,0 1,1 1,1 1,2 1,2 1,2
23--/-01 1,7 1,9 2,0 2,2 2,3 2,3 2,3
23--/-02 2,4 2,7 2,9 3,1 3,2 3,3 3,3
23--/-03 4,2 4,8 5,2 5,5 5,8 5,9 6,0
23--/-04 6,2 7,1 7,7 8,2 8,5 8,7 8,8
23--/-05 7,9 9,0 9,8 10,3 10,8 11,0 11,2
23--/-06 9,6 11,0 11,9 12,6 13,1 13,5 13,7
Evaporating temperature = -40 °C
23--/-0X 0,42 0,45 0,48 0,50 0,52 0,53
23--/-00 0,8 0,86 0,92 0,95 0,98 0,99
23--/-01 1,3 1,4 1,4 1,5 1,5 1,6
23--/-02 1,7 1,9 2,0 2,0 2,1 2,1
23--/-03 3,1 3,4 3,5 3,7 3,8 3,8
23--/-04 4,6 4,9 5,2 5,4 5,6 5,7
23--/-05 5,8 6,3 6,6 6,9 7,1 7,2
23--/-06 7,1 7,7 8,1 8,4 8,7 8,8
Evaporating temperature = +10 °C
23--/-0X 0,37 0,48 0,55 0,60 0,63 0,65 0,65 0,67
23--/-00 0,87 1,1 1,2 1,3 1,4 1,4 1,4 1,5
23--/-01 2,2 2,8 3,2 3,4 3,6 3,7 3,8 3,8
23--/-02 3,0 4,0 4,7 5,1 5,4 5,6 5,8 5,8
23--/-03 5,4 7,2 8,3 9,1 9,7 10,0 10,2 10,3
23--/-04 8,1 10,8 12,5 13,8 14,5 15,0 15,5 15,5
23--/-05 10,2 13,6 15,7 17,2 18,3 18,9 19,3 19,5
23--/-06 12,6 16,7 19,3 21,0 22,3 23,1 23,5 23,7
Evaporating temperature = -10 °C
23--/-0X 0,37 0,47 0,53 0,57 0,60 0,63 0,64 0,64
23--/-00 0,79 0,96 1,1 1,2 1,2 1,3 1,3 1,3
23--/-01 1,6 2,0 2,3 2,5 2,6 2,7 2,8 2,8
23--/-02 2,2 2,9 3,3 3,6 3,8 4,0 4,1 4,1
23--/-03 3,9 5,1 5,9 6,4 6,8 7,1 7,3 7,3
23--/-04 5,8 7,6 8,7 9,5 10,1 10,5 10,8 10,9
23--/-05 7,4 9,6 11,0 12,0 12,8 13,3 13,6 13,8
23--/-06 9,1 11,6 13,5 14,7 15,6 16,2 16,6 16,8
Evaporating temperature = -30 °C
23--/-0X 0,40 0,45 0,49 0,52 0,55 0,56 0,57
23--/-00 0,79 0,9 0,96 1,0 1,1 1,1 1,1
23--/-01 1,4 1,5 1,7 1,8 1,8 1,9 1,9
23--/-02 1,9 2,2 2,7 2,5 2,6 2,6 2,7
23--/-03 3,4 3,9 4,2 4,4 4,6 4,7 4,8
23--/-04 5,0 5,7 6,2 6,6 6,8 7,0 7,1
23--/-05 6,4 7,2 7,8 8,3 8,6 8,8 9,0
23--/-06 7,8 8,8 9,6 10,1 10,5 10,8 11,0
Table 3b: Refrigerant R22/R407C - Correction factor for subcooling �tsub > 4°C
�tsub [°C] 4 10 15 20 25 30 35 40 45 50
Fsub 1,00 1,06 1,11 1,15 1,20 1,25 1,30 1,35 1,39 1,44
When subcooling ahead of the expansion valve is other than 4 °C, adjust the evaporatore capacity by dividing bythe appropriate correction factor found in Table 3b
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Table 4a: Refrigerant R134a - Capacities in kW for temperature range - 40°C ➝➝ + 10°C
Orificesize
Orificesize
Pressure drop across valve [bar] Pressure drop across valve [bar]
2 4 6 8 10 2 4 6 8 10
Evaporating temperature = 0 °C
23--/-0X 0,33 0,42 0,46 0,47 0,49
23--/-00 0,65 0,78 0,86 0,89 0,91
23--/-01 1,3 1,6 1,7 1,8 1,8
23--/-02 1,7 2,2 2,4 2,6 2,6
23--/-03 3,0 3,9 4,4 4,6 4,7
23--/-04 4,5 5,7 6,4 6,8 7,0
23--/-05 5,7 7,3 8,1 8,6 8,8
23--/-06 7,0 8,9 1,0 10,5 10,8
Evaporating temperature = -20 °C
23--/-0X 0,28 0,35 0,39 0,41 0,42
23--/-00 0,53 0,62 0,69 0,72 0,73
23--/-01 0,81 1,0 1,1 1,2 1,2
23--/-02 1,1 1,4 1,5 1,6 1,7
23--/-03 2,0 2,5 2,8 2,9 3,0
23--/-04 2,9 3,6 4,0 4,3 4,4
23--/-05 3,7 4,6 5,1 5,4 5,5
23--/-06 4,5 5,6 6,2 6,6 6,8
Evaporating temperature = -40 °C
23--/-0X 0,23 0,28 0,32 0,33 0,34
23--/-00 0,44 0,50 0,54 0,56 0,57
23--/-01 0,54 0,65 0,72 0,78 0,77
23--/-02 0,7 0,9 1,0 1,0 1,0
23--/-03 1,3 1,6 1,8 1,9 1,9
23--/-04 1,9 2,3 2,6 2,7 2,7
23--/-05 2,4 2,9 3,2 3,5 3,5
23--/-06 3,0 3,6 4,0 4,2 4,3
Evaporating temperature = +10 °C
23--/-0X 0,34 0,43 0,47 0,50 0,51
23--/-00 0,71 0,86 0,93 0,97 0,98
23--/-01 1,5 1,9 2,1 2,2 2,2
23--/-02 2,0 2,6 3,0 3,1 3,2
23--/-03 3,6 4,7 5,3 5,6 5,8
23--/-04 5,4 7,0 7,8 8,3 8,6
23--/-05 6,9 8,9 9,9 10,8 10,9
23--/-06 8,4 10,8 12,1 12,8 13,2
Evaporating temperature = -10 °C
23--/-0X 0,30 0,36 0,43 0,44 0,44
23--/-00 0,59 0,70 0,77 0,81 0,82
23--/-01 1,0 1,3 1,4 1,5 1,5
23--/-02 1,4 1,8 2,0 2,1 2,1
23--/-03 2,5 3,1 3,5 3,7 3,8
23--/-04 3,6 4,6 5,1 5,4 5,6
23--/-05 4,6 5,8 6,5 6,9 7,1
23--/-06 5,7 7,1 8,0 8,4 8,6
Evaporating temperature = -30 °C
23--/-0X 0,25 0,32 0,35 0,37 0,38
23--/-00 0,48 0,55 0,61 0,64 0,64
23--/-01 0,66 0,80 0,88 0,93 0,95
23--/-02 0,9 1,1 1,2 1,3 1,3
23--/-03 1,6 2,0 2,2 2,3 2,3
23--/-04 2,3 2,9 3,2 3,3 3,4
23--/-05 3,0 3,6 4,0 4,2 4,3
23--/-06 3,6 4,4 4,9 5,2 5,3
Table 4b: Refrigerant R134a - Correction factor for subcooling �tsub > 4°C
�tsub [°C] 4 10 15 20 25 30 35 40 45 50
Fsub 1,00 1,08 1,13 1,19 1,25 1,31 1,37 1,42 1,48 1,54
When subcooling ahead of the expansion valve is other than 4 °C, adjust the evaporatore capacity by dividing bythe appropriate correction factor found in Table 4b
35
TH
ER
MO
STA
TIC
EX
PAN
SIO
N VA
LVE
S
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Table 5a: Refrigerant R404A/R507 - Capacities in kW for temperature range - 40°C ➝➝ + 10°C
Orificesize
Orificesize
Pressure drop across valve [bar] Pressure drop across valve [bar]
2 4 6 8 10 12 14 16 2 4 6 8 10 12 14 16
Evaporating temperature = 0 °C
23--/-0X 0,30 0,37 0,41 0,42 0,43 0,43 0,43 0,41
23--/-00 0,68 0,80 0,87 0,90 0,92 0,93 0,91 0,87
23--/-01 1,53 1,86 2,04 2,13 2,18 2,18 2,15 2,08
23--/-02 2,06 2,64 2,95 3,13 3,22 3,25 3,21 3,11
23--/-03 3,68 4,72 5,27 5,59 5,75 5,80 5,73 5,55
23--/-04 5,49 7,15 7,86 8,33 8,58 8,64 8,53 8,27
23--/-05 6,97 8,92 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 0,35 0,38 0,40 0,39 0,40 0,39 0,38
23--/-00 0,70 0,75 0,77 0,79 0,79 0,79 0,76
23--/-01 1,34 1,45 1,50 1,52 1,52 1,51 1,47
23--/-02 1,85 2,04 2,14 2,17 2,18 2,16 2,09
23--/-03 3,32 3,66 3,83 3,89 3,90 3,86 3,75
23--/-04 4,88 5,40 5,64 5,75 5,77 5,71 5,56
23--/-05 6,20 6,86 7,17 7,29 7,31 7,23 7,05
23--/-06 7,60 8,39 8,75 8,91 8,93 8,84 8,61
Evaporating temperature = -40 °C
23--/-0X 0,32 0,33 0,33 0,33 0,32 0,32
23--/-00 0,60 0,61 0,62 0,61 0,60 0,59
23--/-01 0,92 0,96 0,97 0,96 0,94 0,91
23--/-02 1,27 1,32 1,33 1,31 1,28 1,24
23--/-03 2,28 2,36 2,38 2,36 2,31 2,24
23--/-04 3,34 3,47 3,50 3,48 3,42 3,33
23--/-05 4,25 4,41 4,45 4,43 4,36 4,24
23--/-06 5,19 5,39 5,45 5,42 5,33 5,19
Evaporating temperature = +10 °C
23--/-0X 0,28 0,35 0,40 0,42 0,43 0,43 0,42 0,41
23--/-00 0,67 0,82 0,90 0,94 0,96 0,96 0,93 0,90
23--/-01 1,70 2,10 2,30 2,42 2,48 2,46 2,41 2,34
23--/-02 2,32 3,00 3,39 3,61 3,73 3,74 3,68 3,59
23--/-03 4,15 5,36 6,03 6,43 6,63 6,66 6,55 6,39
23--/-04 6,24 8,06 9,06 9,66 9,95 9,98 9,81 9,57
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 0,37 0,40 0,42 0,42 0,42 0,41 0,41
23--/-00 0,65 0,76 0,82 0,84 0,87 0,87 0,85 0,83
23--/-01 1,31 1,61 1,74 1,81 1,84 1,85 1,84 1,78
23--/-02 1,76 2,24 2,50 2,62 2,69 2,71 2,68 2,60
23--/-03 3,14 4,02 4,47 4,69 4,81 4,84 4,79 4,65
23--/-04 4,66 5,97 6,61 6,95 7,13 7,18 7,11 6,91
23--/-05 5,93 7,57 8,39 8,81 9,02 9,08 8,99 8,73
23--/-06 7,28 9,27 10,26 10,76 11,00 11,08 10,97 10,65
Evaporating temperature = -30 °C
23--/-0X 0,35 0,37 0,36 0,37 0,36 0,35
23--/-00 0,67 0,70 0,70 0,70 0,69 0,67
23--/-01 1,18 1,21 1,23 1,21 1,20 1,17
23--/-02 1,63 1,69 1,71 1,70 1,68 1,64
23--/-03 2,93 3,04 3,07 3,06 3,02 2,93
23--/-04 4,28 4,47 4,52 4,51 4,46 4,35
23--/-05 5,45 5,68 5,74 5,74 5,67 5,52
23--/-06 6,66 6,94 7,02 7,01 6,93 6,75
Table 5b: Refrigerant R404A/R507 - Correction factor for subcooling �tsub > 4°C
�tsub [°C] 4 10 15 20 25 30 35 40 45 50
Fsub 1,00 1,10 1,20 1,29 1,37 1,46 1,54 1,63 1,70 1,78
When subcooling ahead of the expansion valve is other than 4 °C, adjust the evaporatore capacity by dividing bythe appropriate correction factor found in Table 5b
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Table 6a: Refrigerant R404A/R507 - Capacities in kW for temperature range - 60°C ➝➝ - 25°C
Orificesize
Orificesize
Pressure drop across valve [bar] Pressure drop across valve [bar]
2 4 6 8 10 12 14 16 2 4 6 8 10 12 14 16
Evaporating temperature = -30 °C
23--/-00 0,53 0,64 0,67 0,70 0,70 0,70 0,69 0,67
23--/-01 0,88 1,07 1,18 1,21 1,23 1,21 1,20 1,17
23--/-02 1,18 1,47 1,63 1,69 1,71 1,70 1,68 1,64
23--/-03 2,12 2,65 2,93 3,04 3,07 3,05 3,02 2,93
23--/-04 3,09 3,88 4,28 4,47 4,52 4,51 4,46 4,35
23--/-05 3,94 4,94 5,45 5,68 5,74 5,74 5,67 5,52
23--/-06 4,83 6,06 6,66 6,94 7,02 7,01 6,93 6,75
Evaporating temperature = -50 °C
23--/-00 0,49 0,53 0,54 0,54 0,53 0,52 0,50
23--/-01 0,51 0,57 0,60 0,60 0,60 0,60 0,59
23--/-02 0,91 0,99 1,02 1,02 1,01 0,98 0,95
23--/-03 1,63 1,73 1,84 1,84 1,81 1,78 1,72
23--/-04 2,36 2,60 2,69 2,71 2,68 2,63 2,56
23--/-05 3,02 3,30 3,43 3,45 3,42 3,35 3,26
23--/-06 3,69 4,04 4,20 4,22 4,18 4,12 4,00
Evaporating temperature = -25 °C
23--/-00 0,57 0,67 0,72 0,73 0,74 0,85 0,74 0,71
23--/-01 0,98 1,20 1,31 1,36 1,37 1,37 1,35 1,31
23--/-02 1,31 1,65 1,83 1,91 1,93 1,93 1,90 1,85
23--/-03 2,35 2,97 3,28 3,42 3,47 3,46 3,42 3,32
23--/-04 3,45 4,37 4,82 5,04 5,11 5,12 5,06 4,93
23--/-05 4,40 5,56 6,14 6,40 6,49 6,49 6,42 6,26
23--/-06 5,40 6,30 7,49 7,81 7,93 7,93 7,85 7,64
Evaporating temperature = -40 °C
23--/-00 0,56 0,60 0,61 0,62 0,61 0,60 0,59
23--/-01 0,65 0,72 0,75 0,77 0,77 0,77 0,75
23--/-02 1,17 1,27 1,32 1,33 1,31 1,28 1,24
23--/-03 2,09 2,28 2,36 2,38 2,36 2,31 2,24
23--/-04 3,03 3,34 3,47 3,50 3,48 3,42 3,33
23--/-05 3,87 4,25 4,41 4,45 4,43 4,36 4,24
23--/-06 4,73 5,19 5,39 5,45 5,47 5,33 5,19
Evaporating temperature = -60 °C
23--/-00 0,46 0,48 0,47 0,45 0,45 0,43
23--/-01 0,58 0,60 0,60 0,58 0,56 0,54
23--/-02 0,78 0,80 0,80 0,78 0,75 0,72
23--/-03 1,40 1,44 1,43 1,40 1,36 1,30
23--/-04 2,04 2,11 2,11 2,07 2,03 1,96
23--/-05 2,59 2,69 2,66 2,65 2,59 2,50
23--/-06 3,16 3,28 3,30 3,25 3,18 3,07
Table 6b: Refrigerant R404A/R507 - Correction factor for subcooling �tsub > 4°C
�tsub [°C] 4 10 15 20 25 30 35 40 45 50
Fsub 1,00 1,10 1,20 1,29 1,37 1,46 1,54 1,63 1,70 1,78
When subcooling ahead of the expansion valve is other than 4 °C, adjust the evaporatore capacity by dividing bythe appropriate correction factor found in Table 6b
37
SOLENOID VALVES
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– austenitic stainless steel EN ISO 3506 –A2-70 for tightening screws betweenbody and cover;
– chloroprene rubber (CR) for outlet sealgaskets;
– P.T.F.E. for seat gaskets.
The valves can be installed in all sections ofa refrigerating system, in compliance withthe limits and capacities indicated in Tables3 and 6. Tables 1 and 4 show the following functionalcharacteristics of a solenoid valve:– PS;– TS;– Kv factor;– minimum Opening Pressure Differential
(minOPD), that is the minimum pressuredifferential between inlet and outlet atwhich a solenoid valve, pilot operated,can open and stay opened;
– maximum Opening Pressure Differential(MOPD according to ARI STANDARD760: 2001), that is the maximum pressuredifferential between inlet and outlet atwhich a solenoid valve, pilot operated,can open.
Before connecting the valve to the pipe it isadvisable to make sure that the refrigeratingsystem is clean. In fact the valves withP.T.F.E. gaskets are particularly sensitive todirt and debris. Furthermore check that the flow direction inthe pipe corresponds to the arrow stampedon the body of the valve. All valves can be mounted in whateverposition except with the coil pointingdownwards. The brazing of valves with solderconnections should be carried out withcare, using a low melting point fillermaterial. It is not necessary to disassemblethe valves before brazing but it’s importantto avoid direct contact between the torchflame and the valve body, which could bedamaged and compromise the properfunctioning of the valve.Before connecting a valve to the electricalsystem, be sure that the line voltage andfrequency correspond to the values markedon the coil.
INSTALLATION
The solenoid valves, shown in this chapter,are classified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).
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 theplunger 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 plungerstops the refrigerant flow.The valves series 1020 and 1028 are directacting, while the valves of all the otherseries are pilot operated, with diaphragm orpiston.The NC valves are supplied either withoutcoil (S type) or with coil (example: A6 typewith coil HM2–220 Vac). The NO valves are supplied only without coil(S type).N.B.: the NO valve visually differs from thecorresponding NC model by means of thered ring installed below the yellow nut thatfastens the coil.
The main parts of the valves are made withthe 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 plungermoves;
– ferritic stainless steel EN 10088-3 –1.4105 for plunger:
CONSTRUCTION
OPERATION
APPLICATIONS
SOLENOID VALVES FOR REFRIGERATING SYSTEMS
www.castel.it 39
– voltage 24 Vac:Coil 9120/RD2 + Connector 9150/R44;
– voltage 220 Vac:Coil 9120/RD6 + Connector 9150/R45.
The NO valves have been designed to workonly with direct current coils. To use them with an alternate current supplyit’s necessary to mate the NO valve with thefollowing components:
SO
LEN
OID
VALV
ES
TABLE 1: General Characteristics of NC valves (normally closed)
CatalogueNumber SAE
Flare
1/4"
3/8"
–
–
–
–
3/8"
1/2"
–
–
–
–
1/2"
5/8"
–
–
–
–
5/8"
3/4"
–
–
–
–
5/8"
3/4"
–
–
–
–
–
–
–
–
–
–
–
–
–
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"
–
–
–
–
–
–
10
–
–
–
10
12
–
–
–
12
–
16
22
–
–
16
–
22
–
–
–
16
–
22
–
–
35
–
35
35
–
42
2,5
3
2,2
3
7
12,5
16,5
25,5
25
27
0,175
0,23
0,15
0,23
0,80
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
0
0,05
0,07
0,05
0,07
25
(3)
21
25
(3)
19
18
13
19
– 35
+105
(1)
+110
(2)
+105
(1)
+110
(2)
45 Art. 3.3
Ø[in.]
Ø[mm]
ODS
Connections
Seat sizenominal Ø [mm]
Kv Factor[m3/h]
Ope
ratin
g Pr
inci
ples
minOPD
MOPDCoil type
Opening Pressure Differential [bar]
HM4(AC)
21
HM2CM2(AC)
HM3(DC)
min.
TS [°C]
max.
PS[bar]
Risk Categoryaccording
to PED
Dite
ct A
ctin
gD
iap
hrag
m P
ilot
Op
erat
ed
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
(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.
Pis
ton
Pilo
t O
per
ated
Dia
phr
agm
Pilo
t O
per
ated
Pis
ton
Pilo
t O
per
ated
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SOLENOID VALVES FOR REFRIGERATING SYSTEMS
TABLE 2: Dimensions and Weights of NC valves with 9100 coil (1)
CatalogueNumber Weight [g]
H1 H2 H3 L1 L2 Q
75
82
91
121
106
115
157
172
62,5
69,5
75
93
78
96
127
138
34
40
47
65
50
72
99
110
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
278
50
–
–
45
57
80
68
68
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
2750
2750
Dimensions [mm]
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
(1) With coil type 9120 the dimension L2 is equal to 64 mm and the valves weights must be increased of 305 g.
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L1
L2
H1 H
2
1064/31064/4
H3
L2
L1
H2
H1
1020/21020/3
H3
L1
L2
L2
L1
H1 H
2
H1 H
2
1028/21028/2E1028/31028/M10
1068/31068/41068/M101068/M12
H3
H3
1070/41070/5
H2
H1
L1
L2
Q
1050/51050/61090/51090/6
H3
L1
L2
H2
H1
Q
H3
1078/M121078/41078/51079/7
H3
L1
H1 H
2
Q
L2
1058/51058/61058/71059/9
1098/51098/61098/71099/9
L1
L2
H1 H
2Q
H3
H3
L1
H2
H1
1078/91079/11
L2
Q
H3
L1
H1
H2
Q
L2
1098/91099/111078/111079/131079/M42
41
SO
LEN
OID
VALV
ES
Connectors are not included in the boxes and have to be ordered separately.
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SOLENOID VALVES FOR REFRIGERATING SYSTEMS
TABLE 3: Refrigerant Flow Capacity of NC valves
CatalogueNumber
R134a R22 R407C R404A R134a R22 R407C R404A R134a R22 R407C R404A
Liquid Vapour Hot Gas
Resa frigorifera [kW]
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
2,95
3,88
2,53
3,88
13,5
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
3,15
4,14
2,70
4,14
14,4
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
3,28
4,31
2,81
4,31
15,0
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
2,08
2,74
1,79
2,74
9,5
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
R410A
3,33
4,38
2,86
4,38
15,2
41,9
49,7
41,9
49,7
72,4
91,4
7,4
91,4
108,5
72,4
91,4
72,4
91,4
108,5
190,4
190,4
304,6
–
1,73
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
–
2,16
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
–
2,14
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
–
1,81
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
R410A
–
2,88
7,92
9,40
7,92
9,40
13,7
17,3
13,7
17,3
20,5
13,7
17,3
13,7
17,3
20,5
36,0
36,0
57,6
1,49
1,96
1,28
1,96
6,8
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
2,05
2,69
1,76
2,69
9,4
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
2,03
2,67
1,74
2,67
9,3
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
1,75
2,30
1,50
2,30
8,0
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
R410A
2,28
2,99
1,95
2,99
10,4
28,6
33,9
28,6
33,9
49,4
62,4
49,4
62,4
74,1
49,9
62,4
49,4
62,4
74,1
130,0
130,0
208,0
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
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VALV
ES
TABLE 4: General Characteristics of NO valves (normally open)
Catalogue NumberSAEFlare
3/8"
–
–
1/2"
5/8"
–
–
–
5/8"
3/4"
–
–
–
5/8"
3/4"
–
–
–
–
–
–
–
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"
–
–
10
–
–
12
–
16
–
–
16
–
22
–
–
16
–
22
–
–
35
7
12,5
16,5
25,5
25
27
0,80
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
0,05
0,07
0,05
0,07
21
19
– 35
+105
(1)
+110
(2)
+105
(1)
+110
(2)
32 Art. 3.3
Ø[in.]
Ø[mm]
ODS
Connections
Seat sizenominal Ø [mm]
Kv Factor[m3/h]
Operating Principles
MOPD
Opening PressureDifferential [bar]
minOPD
min.
TS [°C]
max.
PS[bar]
Risk Categoryaccording
to PED
Coil T
ype
HM
3 (D
.C.)
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
(1) Temperature peaks of 120 °C are allowed during defrosting.
(2) Temperature peaks of 130 °C are allowed during defrosting.
Available on request.R
Diaphragm Pilot
operated
Piston Pilot
Operated
Diaphragm Pilot
operated
Piston PilotOperated
L1
H2
H1
H3
L2
Q
1178/9
H2
L1
H1
H3
L2
Q
1170/41170/5
L1
H1 H
2
H3
L2
1164/3
H1
H2
L1
H3
L2
Q
1178/111198/9
H1 H
2
L1
H3
L2
Q
1178/M121178/41178/5
L1
H1 H
2
1168/31168/M10
H3
L2
H1
L2
L1
H2
H3Q
1150/51150/61190/51190/6
L
L2
H1 H
2
H3Q
1158/51158/61158/71198/51198/61198/7
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SOLENOID VALVES FOR REFRIGERATING SYSTEMS
Connectors and coils are not included in the boxes and have to be ordered separately.
45
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VALV
ES
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TABLE 5: Dimensions and Weights of NO valves with 9120 coil
CatalogueNumber Weight [g]
H1 H2 H3 L1 L2 Q
87
96
126
111
120
162
177
74,5
80
98
83
101
132
143
40
47
70
50
72
99
110
68
111
111
100
106
127
127
175
120
124
175
175
180
120
124
175
175
180
250
235
278
64
–
45
57
80
68
68
705
705
700
1015
1060
995
985
1080
1462
1792
1422
1612
1597
1340
1670
1300
1490
1475
2870
2355
3015
Dimensions [mm]
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
TABLE 6: Refrigerant Flow Capacity of NO valves
CatalogueNumber
R134a R22 R407C R404A R134a R22 R407C R404A R134a R22 R407C R404A
Liquid Vapour Hot Gas
Refrigerant Flow Capacity [kW]
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
13,5
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
14,4
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
15,0
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
9,5
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
1,73
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
2,16
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
2,14
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
1,81
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
6,8
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
9,4
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
9,3
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
8,0
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
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
46
(HM2, HM3) + connector, is IP65 accordingto EN 60529. Coils HM4 must be used withconnector type 9155/R01; protection degreeguaranteed by this other system, coil HM4 +connector 9155/R01, is IP65/IP68 accordingto EN 60529. Coils HM4 can be used withconnectors series 9150 and 9900 too;protection degree guaranteed by thissystem is IP65.Either the terminals of coils series HM2 andHM3 or the ones of coils series HM4 consistof two Faston line connections plus oneFaston earthing connection. Coil type CM2has a pre-assembled cable (length 1 meter).The coils are designed for continuous use.The solid construction of these coils issuitable for heavy-duty applications inrefrigerant systems. The maximum ambienttemperature for all coils is 50 °C.
HM2 (9100) and CM2 coils, 220/230V-50/60Hz and 240V-50/60Hz, are approvedby the German registration body VDE. All HM2 coils series 9105 are approved byUnderwriters Laboratories Inc of the UnitedStates. Moreover either coils types HM2, CM2 andHM4 (110 VAC, 220/230 VAC and 240 VAC)or coils type HM3 (220/230 VAC) aremanufactured according to Low VoltageDirectives EC 73/23, EC 93/68 and to EMC Directives EC 89/336, EC 92/31, EC 93/68.
ELECTRIC TYPE APPROVAL
For the normally closed solenoid valves,previously shown in this Handbook, Castelputs the following types of coils at disposalof 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, thecustomer’s selection must compulsorilyapply to the coils series HM3 – D.C.For applications of the NO solenoid valveswith a voltage supply of 220 VAC, Castelhas designed a specific coil at 220 V RAC(code 9120/RD6) that must be used solelywith the 220 VAC connector/rectifier circuit(code 9150/R45).For applications of the same NO valves witha voltage supply of 24 VAC, Castel suggeststo the user the 24 VDC coil (code 9120/RD2)with the 24 VAC connector/rectifier circuit(code 9150/R44).
Coils HM2 (9100), CM2, HM3 and HM4 areclass F in compliance with IEC 85 standardand their construction is in compliance withEN 60730-1 and EN 60730-2-8 standards.The windings are made with copper wire,insulation class H 180 °C, in compliancewith IEC 85 standard. The outer casing isprovided with dielectric and waterproofresins that assure a reinforced insulationmaking the coils suitable for all assemblies.Coils HM2 (9105) are class F, with ULapproved EIS (Electrical Insulation System),and their construction is in compliance withUL 429 Standards.Protection against electric contacts is class I.Therefore, for safety purposes, coils mustbe effectively connected to an earthingsystem. Rubber gaskets on the upper andlower ends of coil ensure moistureprotection of winding. Coils HM2 and HM3may be joined to all connectors producedby Castel except type 9155/R01; protectiondegree guaranteed by this system, coil
CONSTRUCTION
APPLICATION
COILS
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www.castel.it 47
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VALV
ES
TABLE 1: General Characteristics of coils
Coil Type
Degreeof
protectionConnectionsFrequecy
[Hz]Voltage
tollerance [%]Voltage
[V]CatalogueNumber
HM2
HM2
� Recognized
File number E243604
CM2
HM3
HM4
9100/RA2
9100/RA4
9100/RA6
9100/RA7
9100/RA8
9105/RA2
9105/RA4
9105/RA6
9105/RA7
9110/RA2
9110/RA4
9110/RA6
9110/RA7
9120/RA6
9120/RD1
9120/RD2
9120/RD4
9120/RD6
9160/RA2
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
+10 / -5
+10 / -10
+6 / -10
+10 / -10
50 / 60
60
50 / 60
50 / 60
–
50 / 60
Junction box
DIN 43650
Junction box
DIN 43650
Three wire
cable
Junction box
DIN 43650
Junction boxDIN 43650
or Connector
9155/R01 (1)
IP65
EN 60529
(with
junction box)
IP65 EN 60529
(with junction
box)
IP65
EN 60529
IP65
EN 60529
(with
junction box)
IP65 EN 60529(with junction box)
IP65/IP68EN 60529
(with connector)
L1
L2HH
L2
L1HM2 CM2
(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.
48 www.castel.it
TABLE 2: Coils Consumptions
CatalogueNumber
CoilType
50 [Hz]
Consumptions at 20 °C [mA]Dimensions
[mm]Weight
[g]
60 [Hz] D.C. 50 [Hz] 60 [Hz] D.C.
Start Working
9100/RA2
9100/RA4
9100/RA6
9100/RA7
9100/RA8
9105/RA2
9105/RA4
9105/RA6
9105/RA7
9110/RA2
9110/RA4
9110/RA6
9110/RA7
9120/RA6
9120/RD1
9120/RD2
9120/RD4
9120/RD6
9160/RA2
9160/RA4
9160/RA6
9160/RA7
HM2
HM2
�Recognized
CM2
HM3
HM4
920
230
120
100
58
–
920
230
120
100
190
–
1490
330
162
147
825
205
105
87
51
825
205
105
87
825
205
105
87
160
–
1320
300
142
130
_
–
–
–
1720
900
460
93
–
527
128
68
54
32
–
527
128
68
54
110
–
700
156
76
70
420
114
58
43
23
420
114
58
43
420
114
58
43
80
–
530
118
57
53
_
–
–
–
1720
900
460
93
–
L1 L2 H
57,5
57,5
66,5
82
63
34
34
34
61
41
35
35
35
35
35
165
165
230
470
220
L2
L1
H
L2H
L1HM4HM3
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ES
This junction box, according to assemblyrequirements, allows choosing the sideposition of outer casing compared to innerterminal block; but it is not possible to pointthe cable upwards. The gland nut of casing issuitable to receive cables with an externaldiameter of 6 ÷ 9 mm and is provided with aself-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 aprotection degree IP65/IP68 against dust andwater, according to EN 60529, when correctlyinstalled with the proper gaskets, which aresupplied as standard.The junction box 9150/R44 and 9150/R45 areequipped with a full-wave bridge rectifier plusVDR for protection. The VDR device, Voltagee-Dependent-Resistor, is a special type ofresistor, placed in parallel to the coil; itspurpose is to protect the diodes and the coilfrom any excessive voltage generated withinthe ac supply circuit.
The junction boxes 9150, DIN 43650standardized, represent an effective systemfor the connection of the coil to the supplycircuit, thus ensuring safety also in thepresence of moisture.These junction boxes, according to assemblyrequirements, allow choosing the position ofouter casing compared to inner terminal block.The clamping screw of casing may be PG9 orPG11, which are respectively suitable forcables with an external diameter of 6 ÷ 8 or 8 ÷ 10 mm. Cables sized 3 x 0,75 mm2 are tobe preferred.The junction box type 9900 is available withcabled core of different length. In this case, it is not possible to change the position ofcasing compared to terminal block.Both the two types offer a protection degreeIP65 against dust and water, according to EN 60529, when correctly installed with theproper gaskets, which are supplied asstandard.Castel has developed a specific junction box,type 9155/R01, suitable for use on thoserefrigerating systems working in heavy dutyenvironments, for example:– exposition to the atmospheric conditions;– rooms with high moisture degree;– cyclic condensing / evaporating on the
valve;– cyclic icing / defrosting on the valve.
CONNECTORS
TABLE 3: General Characteristics of connectors
CatalogueNumber
Nominal
Supply Voltage[V]
Maximum
PgCable length
[m]
Cable thickness
[mm2]Standard Degree
of protectionClass
of insulation
9150/R01
9150/R02
9150/R44
9150/R45
9155/R01
9900/X66
9900/X84
9900/X73
9900/X55
9900/X54
R
–
24 A.C.
220 A.C.
–
–
–
30 A.C.
250 A.C.
–
–
9
11
–
–
–
1
1,5
2
3
5
–
3 x 0,75
DIN
43650
–
DIN
43650
IP65
EN 60529
IP65/IP68
EN 60529
IP65
EN 60529
Group C
VDE 0110-1
/ 89
Available on request.R
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The solenoid valves, shown in this chapter,are classified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for the applicationsspecified in Table 1 where the different fluidsare 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 andreferred to in Directive 67/548/EEC);
– with fluids in the liquid state proper to theGroup I (as defined in Article 9, Section2.1 of Directive 97/23/EC and referred toin Directive 67/548/EEC).
APPLICATIONS
SOLENOID VALVES FOR DIFFERENT FLUIDS
Connectors are not included in the boxes and have to be ordered separately.
50
Castel supplies to its customers thepermanent magnet code 9900/X91 for thenormally closed solenoid valves, shown in thischapter.This product can be used during brazing ofthe valve copper connections to the plantpipes; slipping it on the armature, instead ofthe coil, it allows the protective gas (nitrogen)flowing and avoids any damage to the plungergasket and to the diaphragm.
The main parts of the permanent magnet code9900/X91 are made with the followingmaterials:– three rings of anisotropic ferrite;– anodized aluminum for the body.
CONSTRUCTION
APPLICATION
PERMANET MAGNET
NC SOLENOID VALVE
PERMANENT MAGNET
51
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Table 1 shows the following functionalcharacteristics of a solenoid valve:– PS;– TS;– Kv factor;– minimum Opening Pressure Differential
(minOPD), that is the minimum pressuredifferential between inlet and outlet atwhich a solenoid valve, pilot operated,can open and stay opened;
– maximum Opening Pressure Differential(MOPD according to ARI STANDARD760: 2001), that is the maximum pressuredifferential between inlet and outlet atwhich a solenoid valve, pilot operated,can open.
Before connecting the valve it is advisableto make sure that the piping are clean andthat the flow direction in the pipecorresponds to the arrow stamped on thebody of the valve. All valves can be mounted in whateverposition except with the coil pointingdownwards. Before connecting a valve to the electricalsystem, be sure that the line voltage andfrequency correspond to the values markedon the coil.
INSTALLATION
All the valves for different fluids are normallyclosed. NC = when the coil is de-energisedthe plunger stops the refrigerant flow.The valves series 1512 and 1522 are directacting, while the valves series 1132 and1142 are pilot operated with diaphragm.
The main parts of the valves are made withthe 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 plungermoves;
– ferritic stainless steel EN 10088-3 –1.4105 for plunger;
– austenitic stainless steel EN ISO 3506 –A2-70 for tightening screws betweenbody and cover;
– fluorocarbon rubber (FPM) for outlet sealgaskets;
– fluorocarbon rubber (FPM) for seatgaskets;
– fluorocarbon rubber (FPM) fordiaphragms. Nitril rubber (NBR) for thevalves series 1142.
CONSTRUCTION
OPERATION
TABELLA 1: General Characteristics
CatalogueNumber
1,5
4,5
12,5
20
38
G 1/8"
G 1/4"
G 3/8"
G 1/2"
G 3/8"
G 1/2"
G 3/4"
G 1"
G 1.1/4"
G 1.1/2"
W.L.O.
W.O.
W.L.O.B.
0,070
0,40
2,10
2,20
5,50
6,00
19,00
21,00
0
0,1
0,15
0,3
30
4
17
12
11
-15
+105
+90
30
15
Art. 3.3
FPTConnectionsMain Use
Seat Sizenominal Ø [mm]
Kv Factor[m3/h]
Ope
ratin
g Pr
inci
ples
MOPD
Opening Pressure Differential
[bar]
minOPD
min.
TS [°C]
max.
PS[bar]
Risk Categoryaccording
to PED
Coil T
ype
HM
2 (A
.C.)
- C
M2
(A.C
.) -
HM
3 (A
.C.;
D.C
.) -
HM
4 (A
.C.)
Dire
ct
Act
ing
Dia
phr
agm
Pilo
tO
per
ated
1512/01
1522/02
1522/03
1522/04
1132/03
1132/04
1132/06
1132/08
1142/010
1142/012
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The following ratio applies:
�pQ = 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].
Table 2 provides the values of air capacityunder 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 specifiedin the table are absolute values.
Select the valve suitable for use withapproximately 200 m3/h of air, assuming anabsolute pressure of 8 bars at valve inlet ( = 7 bars of relative pressure + 1 bar) andan acceptable pressure drop across thevalve of 1,5 bars. In the column of pressures upstream thevalve, the value 8 is shown; where thiscolumn intersects the horizontal columnrelating to the pressure drop of 1,5, thevalue of 87 m3/h is shown. This is thecapacity value of a hypothetical valve withKv = 1 working under the above mentionedconditions.
200 / 87 = 2,29
This is the Kv value required in the caseunder consideration. In Table 1, select the valve with the Kv valuenearest to 2,29, rounding off the value andsubsequently checking that all thecharacteristics of the selected valve (max. opening pressure differential,temperature, connections, etc.) are suitable.
EXAMPLE
AIR CAPACITY
LIQUIDS CAPACITY
When the viscosity of the liquid is expressedas dynamic viscosity, i.e. cP, where:
1cP = 10-3 N sec/m2
the corresponding value of cinematicviscosity in cSt is obtained by the followingrelation:
�� = ——�
where:� = cinematic viscosity [cSt];� = dynamic viscosity [cP];� = volumic mass of the fluid at the
considered temperature [kg/dm3].
Moreover, the fluid viscosity may remarkablyvary according to changes in temperature.Therefore, if the temperature of the fluiddoes not ensure viscosity values compatiblewith the correct operation of the valve, thevalve may not open.
Viscosity cSt Reducing Factor
12
12 ÷ 30
30 ÷ 45
1
0,8
0,7
The values of maximum differential pressurespecified in Table 1 are suitable for fluids withmaximum cinematic viscosity of 12 cSt where:
1cSt = 10-6 m2/sec.
If the cinematic viscosity of the fluid underconsideration is more than 12 cSt it isnecessary to multiply the value of themaximum differential pressure by thefollowing reducing factors:
VISCOSITY
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TABLE 2 - Air Capacity (Kv = 1)
Pressuredrop[bar]
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1,5 1,3 1,2 1,1 1,05 1,03 1,015
Capacity [m3/h] (1)
INLET PRESSURE (absolute) [bar]
0,0025
0,005
0,010
0,015
0,025
0,05
0,10
0,15
0,25
0,5 82,0 80,0 77,0 74,0 72,0 69,5 66,6 63,7 60,6 57,3 54,0
1 115,0 111,0 108,0 104,0 100,0 96,0 92,0 88,0 83,0 78,6 73,5
1,5 138,0 134,0 130,0 125,0 120,0 115,5 110,3 105,0 99,3 93,0 87,0
2 157,0 152,0 147,0 142,0 136,0 130,0 124,0 118,0 111,0 96,0 96,0
2,5 173,0 167,5 161,5 155,5 149,0 142,5 135,5 128,0 120,4 112,0 103,0
3 186,0 180,0 174,0 167,0 160,0 152,0 144,5 136,0 127,0 118,0 108,0
3,5 198,0 191,0 184,0 176,5 168,6 160,3 151,7 142,5 132,6 122,0 110,0
4 208,0 200,0 193,0 184,0 176,0 167,0 157,0 147,0 136,0 124,0 111,0
4,5 216,0 208,6 200,0 191,0 182,0 172,0 161,5 150,4 138,0 125,0
5 224,0 215,0 206,0 195,5 186,0 176,0 164,5 152,3 139,0
5,5 230,0 221,0 211,0 201,0 190,0 178,6 166,3 152,9
6 236,0 226,0 215,0 204,0 192,7 180,0 166,8
6,5 240,0 230,0 218,0 206,7 194,0 180,7
7 244,0 233,0 220,0 208,0 194,7
7,5 246,0 234,0 222,0 208,5
8 249,0 236,0 222,5
8,5 250,0 236,5
9 250,5
1,46 1,42 1,40 1,35
2,2 2,10 2,00 1,95 1,90
3,0 3,0 3,00 2,85 2,80 2,75
4,2 3,9 3,7 3,55 3,45 3,40 3,35
6,2 5,4 5,0 4,8 4,56 4,45 4,40
10,7 8,7 7,5 6,9 6,6 6,40 6,20
17,4 15,0 12,2 10,2 9,6 9,2 8,80
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
50,0 46,0 41,7 36,8 31,0 24,3 19,6
68,0 62,0 55,6 48,0 39,3 27,8
80,0 72,0 63,7 53,8 41,7
88,0 78,0 68,0 55,6
89,5 82,0 69,5
96,0 83,0
97,0
(1) The table provides air capacity values in m3/h under the following conditions:– temperature at value inlet: + 20°C– pressure at outlet (absolute): 1 bar– Kv of the solenoid valve: 1 m3/h
54 www.castel.it
With coils 9120 the dimension L2 is equal to 64 mm and the weight must be increased of 305 g.
TABLE 3 - Dimensions and Weight (Valves with coils 9100)
CatalogueNumber Weight [g]
H1 H2 H3 L1 L2 Q
86
101
136
69
71
70
81
103
57
59
47
52
82
34
36
75
88
168
44
51
50
104
50
45
57
104
–
–
670
635
960
670
4100
4000
310
385
370
355
Dimensions [mm]
1132/03
1132/04
1132/06
1132/08
1142/010
1142/012
1512/01
1522/02
1522/03
1522/04
Connectors are not included in the boxes and have to be ordered separately.
H2
H1
L1
L2
H3
H2
L1
H1
H3
L2
1132/031132/04
Q
L1
H2
H1
Q
H3
L2
1142/0101142/012
1132/061132/08
H2
H3H
1
L1
L2
H2
H3H
1
L1
L2
1512/011522/031522/04
1522/02
Q
55
SAFETY DEVICES
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with the atmosphere. For this reason, duringrelief, a gas leak occurs through this orifice.Utilized material: EN 12420-CW617N brass.
Disc: obtained through bar machining andequipped with gasket, it ensures therequired 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 notcause the disc to stick on the seat. The discis properly guided in the body and the guideaction can never fail; there are no glands orretaining rings that hamper the movementthereof.Utilized material: EN 12164-CW614N brass.
Spring: it opposes the pressure and thefluid dynamic actions and always ensuresvalve re-closing after pressure relief. Thespring coils, when the disc has reached thelift corresponding to the state of relief at fullflow rate, are spaced apart by at least halfthe wire diameter and, in any case, by notless than 2 mm. The disc is equipped with amechanic lock and when it attains it, thespring set does not exceed 85% of the totalset.Utilized material: DIN 17223-1 steel for springs.
Setting system: hexagonal head, threadedring nut to be screwed inside the body topby compressing the spring below. Onsetting completion, the position attained bythe ring nut is maintained unchanged laying,in the threaded coupling, a bonding agentwith high mechanic strength and lowviscosity features to make penetrationthereof easier. The setting system isprotected against subsequent unauthorizedinterventions by means of a cap nut that isscrewed outside the body and is sealedwith lead to it.
Valves series 3030 are safety devicesaccording to the definition given in Article 1,Point 2.1.3, 2nd dash of 97/23/EC Directiveand are the subject of Article 3, Point 1.4 ofaforesaid Directive.The valves above mentioned are standardtype, unbalanced, direct-loaded safetyvalves. Valve opening is produced by thethrust the fluid under pressure exerts on thedisc, when said thrust exceeds, undersetting conditions, the opposing force of thespring 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.
Body: squared, obtained through dieforging and subsequent machining. Ithouses 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 smallpressure relief hole is provided throughwhich the spring holder is put into contact
CONSTRUCTION
GENERAL DESCRIPTION
SAFETY VALVES 3030
TABLE 1: General Characteristics of valves 3030
1/2" NPT
3/4" G
12
113
4,1
0,90
3/4" NPT
3/4" G
12
113
4,1
0,90
1" NPT
1.1/4" G
19,5
298
6,8
0,83
Catalogue Number 3030/44C 3030/66C 3030/88C
Connections
Flow Diameter [mm]
Flow Section [mm2]
Lift [mm]
Discharge Coefficient “Kd”
PS [bar]
TS [°C]
Set Pressure Range [bar]
Overpressure
Blowdown
Risk Category according to PED
55
- 50 / + 150
8 / 50
5% of set pressure
15% of set pressure
IV
Inlet male
Outlet male
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H3
H2
H1
L
� D
Ch
0062
3030
reasonably likely to be exceeded, shall befitted with suitable protection devices, forinstance safety devices such as safetyvalves. Such devices shall prevent pressurefrom permanently exceeding the maxallowable pressure PS of the equipmentthey protect. In any case, a short pressurepeak limited to 10% of admissiblemaximum pressure is permitted.As to the selection and sizing of the suitableprotection device, users shall refer to thespecific sector or product standards.EN 378-2: 2000 Standard “Refrigeratingsystems and heat pumps – safety andenvironmental requirements – Part 2:Design, construction, testing, marking anddocumentation”, harmonized with 97/23/ECDirective, provides a general outline of theprotection devices to be adopted inrefrigerating systems and their features (par7.4). It also indicates the criteria for theselection of the device suitable to the typeand sizes of the system component to beprotected (par. 7.4).EN 13136: 2001 Standard “Refrigeratingsystems and heat pumps – Pressure reliefdevices and their associated piping –Methods for calculation” highlights thepossible causes of overpressure in a systemand makes available to users theinstruments for pressure relief device sizing,among which the safety valves.
Use: protection against possibleoverpressures of the apparatuses listedbelow, with regard to the operatingconditions for which they have beendesigned:– refrigerating system and heat pump
components, for instance: condensers,liquid receivers, evaporators, liquidaccumulators, positive displacementcompressor 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 IIaccording to the definitions of 97/23/ECDirective, Article 9, Point 2.2 (withreference to 67/548/EEC Directive of June27th, 1967);
– air and nitrogen (reference: 87/404/EECDirective).
In conformity with the provisions of Article15 of 97/23/EC Directive, the EC markingand the identification number of the notifiedbody involved in the production controlphase are reported on the valve body.Still on the body, the following information isindicated:– manufacturer’s 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.
97/23/EC Directive requires that pressureequipment, in which permissible limits are
VALVE SELECTION
MARKING
SCOPE
TABLE 2: Dimensions and Weights of valves 3030
CatalogueNumber Weight [g]
Ø D L Ch H1 H2 H3
38
38
50
38
38
56
28
28
40
44
44
58
115
115
158
159
159
216
780
780
1960
Dimensions [mm]
3030/44C
3030/66C
3030/88C
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for this calculation the value of k shall beas measured at 25 °C. (Section 7.2.3,Standard EN 13136: 2001).Values of k and calculated values of C forsome refrigerants are given in table A.1 ofthe aforesaid standard.
Following we show the values of k and C forthe more useful refrigerants.
SIZING OF SAFETY VALVES DESIGNED TO DISCHARGE GAS OR VAPOUR ATCRITICAL FLOW (Ref. EN 13136: 2001)
Critical flow occurs when the backpressurepb (the pressure existing immediately at theoutlet of a safety valve) is below or equal tothe critical pressure:
[bar abs]
with:– po = actual relieving pressure, upstream
the safety valve; it’s equal to the setpressure plus overpressure. That is apressure increase over set pressure atwhich the disc has its total lift. [bar abs];
– k = isentropic exponent of gas or vapour,based on the actual flowing conditions atthe safety valve inlet.
If k is unknown or anyway difficult toestablish it’s possible to suppose:
[bar abs]
A safety valve, which discharges toatmosphere, works in critical flow.
The safety valves designed to discharge gasor vapour at critical flow must be sized asfollow:
[mm2]
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 atrelieving conditions po e To meaning withTo fluid temperature at valve inlet, settledby the user or by the designer [m3/kg];
– C = function of isentropic coefficient kcalculated from:
C kk
k
k= × ×
+
+( )−( )
3 9482
1
1
1,
AQ
C Kvpc
md
d
o
o
= ×× ×
×3 4690 9
,,
p pcritical o= ×0 5,
p pkb o
kk
≤+
−⎛⎝⎜
⎞⎠⎟2
1
1
Calculation of minimum required dischargecapacity of safety valve is closely linked tothe type of system where the valve isinstalled, with the causes that may arousethe opening of safety valve, i.e.:– external heat sources. The minimum
required discharge capacity shall bedetermined by the following:
[kg/h]
with:– � = density of heat flow rate, it’s
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 minimumrequired discharge capacity shall bedetermined by the following:
[kg/h]
withQh = rate of heat production [kW].
– Excessive pressure cased bycompressors. The minimum requireddischarge capacity shall be determinedby the following:
[kg/h]Q V nmd v= × × × ×60 10ρ η
hmdh
vap
=×3600
QA
hmdsurf
vap
=× ×3600 ϕ
RefrigerantIsentropiccoefficient
k
Functionof Isentropiccoefficient
C
R22
R134a
R404A
R407C
R410A
R507
1,17
1,12
1,12
1,14
1,17
1,10
2,54
2,50
2,50
2,51
2,54
2,48
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– ηv = volumetric efficiency estimated atsuction pressure and dischargepressure equivalent to the safety valvesetting.
with:– V = theoretical displacement of
compressor [m3]– n = rotational frequency of compressor
[min –1]– ρ10 = vapour density at refrigerant
saturation pressure / dew point at 10 °C [kg/m3]
Working conditions of compressorcorresponding to the relieving of safetyvalve:Condensing temperature:
+ 64 °C (27,25 bar abs)Evaporating temperature:
+ 10 °C (6,33 bar abs)
These conditions, settled in any case by thedesigner, are considered the mostunfavorable for the safety valve inconsequence 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 solarge quantities to be able to feed a fire.;
– inside the vessel, the presence of a heartsource.
Calculation of minimum dischargecapacityPrudentially leaving the vapour overheatingat the outlet of the liquid cooler out ofaccount, the volumetric efficiency ofcompressor is:
and so the minimum required dischargecapacity:
= 60x0,00224x1450x26,34x0,83=4260 [kg/h]
with ρ10 = 26,34 [kg/m3], vapour density ofR407C at saturation pressure / dew point at10 °C.
Q V nmd v= × × × × =60 10ρ η
ηvdisch e
suction
p
p= − = − =1 0 04 1 0 04
27 256 33
0 83, ,,
,,arg
System descriptionCompact refrigerating system designed tomake refrigerated water and consisting of:– open type reciprocating compressor;– water-cooled, shell-and-tube horizontally
condenser with lower section of shellused as receiver;
– shell-and-tube horizontally liquid coolerfed 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 compressoris:
[m3]
Maximum allowable pressure of thecondenser, refrigerant side: PS = 25 bar.
Set pressure of the safety valve installed onthe upper shell section of condenser: pset = 25 bar
Actual relieving pressure of safety valve,choosing one valve type 3030 with anoverpressure of 5%:
[bar abs]p pset0 15
1001 27 25= × +⎛
⎝⎞⎠
+ = ,
V = × × × =π4
0 0825 0 0698 6 0 002242, , ,
EXAMPLE OF CALCULATION OF MINIMUM REQUIRED DISCHARGE CAPACITY Qmd ANDSIZING OF THE SAFETY VALVE FOR THE HIGH PRESSURE SIDE OF A REFRIGERATINGSYSTEM
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Sizing of minimum flow area of the safetyvalve
[mm2]
with:– C = 2,51, corresponding to isentropic
exponent k for R407C equal to 1,14,according to table A1 of standard EN13136:2001;
– Kd = 0,83, certified coefficient ofdischarge for safety valve 3030/88;
– vo = 0,0104 [m3/kg], specific volume ofoverheating vapour upstream the safetyvalve during relieving.This value is referred to the followingoperating conditions, upstream the safetyvalve:– pressure po = 27,25 [bar abs];– temperature To = 100 [°C]
(precautionary temperature, settled inany case by the designer).
Conclusion: the selected safety valve is themodel 3030/88 with the followingcharacteristics:– certified coefficient of discharge, Kd = 0,83;– flow section, Ac = 298 [mm2];– set pressure, pset = 25 bar.
In case of single-screw compressor withinjection of pressurized oil, the theoreticaldisplacement is:
[m3]
with:– D = rotor diameter [m];– L = rotor length [m].
VD
Lc =×
×π 2
4
= ×× ×
× =3 4694260
2 51 0 9 0 830 010427 25
154,, , ,
,,
AQ
C Kvpc
md
d
o
o
= ×× ×
× =3 4690 9
,,
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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;– ξ = addition of pressure loss coefficients
ξn of any component and piping;The coefficients ξn 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 thecondenser of the previous example, a safetyvalve type 3030/88, set to 25 bar, using asteel union with the followingcharacteristics:– 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 it’s possible to have thesedata:– ξ1 (inlet) = 0,25– ξ2 (length) = λ x L/ din = 0,02 x 60/28 = 0,043
with λ = 0,02 for steel tube– ξT = ξ1 + ξ2 = 0,25 + 0,043 = 0,293Between safety valve and union it’s installeda 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 ξR of shut-off valveis given by:
The total pressure loss coefficient is: ξT + ξR
= 0,933
We remember the main characteristics ofsafety valve 3030/88 and of refrigerant fluidR407C:– A = 298 [mm2]– Kdr = 0,83 x 0,9 =0,747– C = 2,51
Pressure loss in the upstream line is:
∆pp
in
o
= × × ×⎡⎣⎢
⎤⎦⎥
× =0 032298616
2 51 0 747 0 933 0 02452
, , , , ,
ζR = × ⎡⎣⎢
⎤⎦⎥
× =−2 59231420
10 0 642
3, ,
VALVE INSTALLATIONAs far as the installation of safety reliefvalves is concerned, the fundamental pointslisted below shall be taken into account:• safety valves shall be installed near an
area of the system where vapours orgases are present and there is no fluidturbulence; the position shall be asupright as possible, with the inletconnector turned downwards;
• vessels, joined together with pipingrightly selected by the manufacturer andwithout any stop valve between them,may be considered as only one vessel forthe installation of a safety valve;
• the union between the valve and theequipment to be protected shall be asshort as possible. Furthermore, itspassage section shall not be narrowerthan the valve inlet section. In any case,EN 13136: 2001 standard states that thepressure loss between protected vesseland safety valve, at discharge capacity,shall not exceed 3% of the setting value,including any accessory mounted on theupstream line;
• in selecting the safety valve location, itshall be taken into account that valveoperation involves the discharge of therefrigerant fluid under pressure,sometimes even at high temperature.Where the risk exists to cause directinjuries to the persons nearby, an exhaustconveying piping shall be provided, whichshall be sized in such a way as not tocompromise valve operation. EN 13136: 2001 standard states that thispiping shall not generate, at dischargecapacity, a back pressure exceeding 10%of pressure po, for standard type valves,unbalanced.
To calculate the pressure loss either in theupstream line (between vessel and safetyvalve) or in the downstream line (betweensafety valve and atmosphere) refer to EN 13136: 2001 standard, Chapter 7.4.
Pressure loss in the upstream lineCalculation of pressure loss is given by:
∆pp
AA
C Kin
o indr= × × ×
⎡
⎣⎢
⎤
⎦⎥ ×0 032
2
, ζ
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Example: assume to install a discharge pipeon safety valve type 3030/88 of the previousexample, 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 oftube.
From table A.4 it’s possible to have thesedata:– ξ1 (bend) = 0,25;– ξ2 (length) = λ x L/ din = 0,02 x 3000/53 = 1,13
with λ = 0,02 for steel tube;– ξT = ξ1 + ξ2 = 0,25 + 1,13 = 1,38.
Pressure loss in the downstream line is:
The obtained value is admissible becauselower than the value of 0,10 forecast in EN 13136:2001. standard.
= =∆pp
out
o
0 075,
0 064 1 38298
22062 51 0 747 27 25
27 25
212
, , , , ,
,
× × × × ×⎛⎝
⎞⎠
⎡
⎣⎢
⎤
⎦⎥
=
The obtained value is admissible becauselower than the value of 0,03 forecast in EN 13136:2001. standard.
Pressure loss in the downstream lineCalculation of pressure loss is given by:
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– ξ = addition of pressure loss coefficients ξn
of pipingThe coefficients ξn are relevant to:– pipe elements loss, bends;– loss along the pipe and are listed in EN 13136:2001 standard,Table A.4.
∆pp
AA
C K p
pout
o
outdr o
o
=
× × × × ×⎛
⎝⎜
⎞
⎠⎟
⎡
⎣⎢⎢
⎤
⎦⎥⎥
0 0642
12
, ζ
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Valves series 3060 are safety devicesaccording to the definition given in Article 1,Point 2.1.3, 2nd dash of 97/23/EC Directiveand are the subject of Article 3, Point 1.4 ofaforesaid Directive.The valves above mentioned are standardtype, unbalanced, direct-loaded safetyvalves. Valve opening is produced by thethrust the fluid under pressure exerts on thedisc, when said thrust exceeds, undersetting conditions, the opposing force of thespring 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.
Body: squared, obtained through dieforging and subsequent machining. Ithouses 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.
CONSTRUCTION
GENERAL DESCRIPTION
In the body, above the disc guide, a smallpressure relief duct is provided throughwhich the spring holder is put into contactwith the output connection. For this reason,during relief, no gas leak occurs into theatmosphere.Utilized material: EN 12420-CW617N brass.
Disc: obtained through bar machining andequipped with gasket, it ensures therequired 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 notcause the disc to stick on the seat. The discis properly guided in the body and the guideaction can never fail; there are no glands orretaining rings that hamper the movementthereof.Utilized material: EN 12164-CW614N brass.
Spring: it opposes the pressure and thefluid dynamic actions and always ensuresvalve re-closing after pressure relief.Utilized material: DIN 17223-1 steel for springs.
Setting system: hexagonal head, threadedring nut to be screwed inside the body topby compressing the spring below. Onsetting completion, the position attained bythe ring nut is maintained unchanged laying,in the threaded coupling, a bonding agentwith high mechanic strength and lowviscosity features to make penetrationthereof easier. The setting system isprotected against subsequent unauthorizedinterventions by means of a cap nut that isscrewed outside the body and is sealed to itwith a punched copper rivet.
SAFETY VALVES 3060
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• 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 theproduction control phase;
• valve model;• flow section;• Kd discharge coefficient.
97/23/EC Directive requires that pressureequipment, in which permissible limits arereasonably likely to be exceeded, shall befitted with suitable protection devices, forinstance safety devices such as safetyvalves. Such devices shall prevent pressurefrom permanently exceeding the maxallowable pressure PS of the equipmentthey protect. In any case, a short pressurepeak limited to 10% of admissiblemaximum pressure is permitted.As to the selection and sizing of the suitableprotection device, users shall refer to thespecific sector or product standards.EN 378-2: 2000 Standard “Refrigeratingsystems and heat pumps – safety andenvironmental requirements – Part 2:Design, construction, testing, marking anddocumentation”, harmonized with 97/23/ECDirective, provides a general outline of theprotection devices to be adopted inrefrigerating systems and their features (par7.4). It also indicates the criteria for the
VALVE SELECTION
TABLE 3: General Characteristics of valves 3060
1/4" NPT
3/8" SAE
0,63
7
38,5
10,0
78,5
1/4" NPT
1/2" SAE
0,69
3/8" NPT
3/8" SAE
0,63
3/8" NPT
1/2" SAE
0,69
1/2" NPT
5/8" SAE
9,5
70,9
0,45
3/8" NPT
3/4" G
0,92
1/2" NPT
3/4" G
0,93
Catalogue Number 3060/23C 3060/24C 3060/33C 3060/34C 3060/45C 3060/36C 3060/46C
Connections
Flow Diameter [mm]
Flow Section [mm2]
Discharge Coefficient “Kd”
PS [bar]
TS [°C]
Set Pressure Range [bar]
Overpressure
Risk Category according to PED
55
- 50 / + 150
9 / 50
10% of set pressure
IV
Inlet male
Outlet male
Use: protection against possibleoverpressures of the apparatuses listedbelow, with regard to the operatingconditions for which they have beendesigned:– refrigerating system and heat pump
components, for instance: condensers,liquid receivers, evaporators, liquidaccumulators, positive displacementcompressor 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 IIaccording to the definitions of 97/23/ECDirective, Article 9, Point 2.2 (withreference to 67/548/EEC Directive of June27th, 1967);
• Air and nitrogen(reference: 87/404/EEC Directive).
In conformity with the provisions of Article15 of 97/23/EC Directive the followinginformation are reported on the valve body:• manufacturer’s mark, address and
manufacture country;• indication of flow direction;• max allowable pressure;• set pressure;
MARKING
SCOPE
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� D
L
H1
H2
H3
Ch
3060
selection of the device suitable to the typeand sizes of the system component to beprotected (par. 7.4).EN 13136: 2001 Standard “Refrigeratingsystems and heat pumps – Pressure reliefdevices and their associated piping –Methods for calculation” highlights thepossible causes of overpressure in a systemand makes available to users theinstruments for pressure relief device sizing,among which the safety valves.For sizing and installation of safety valvesseries 3060 see the previous chapter ofsafety valves series 3030.
TABLE 4: Dimensions and Weights of valves 3060
CatalogueNumber Weight [g]
Ø D L Ch H1 H2 H3
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
200
215
215
215
290
380
390
Dimensions [mm]
3060/23C
3060/24C
3060/33C
3060/34C
3060/45C
3060/36C
3060/46C
BALL SHUT-OFF VALVES FOR SAFETY VALVES
allow to remove the valve for periodicchecking or replacement without blowing offall the refrigerant from a section of thesystem. These valves can be used with thesame fluids foreseen for safety valves series3030 and 3060, in particularly:– refrigerant fluids, in the physical state of
gas or vapour, belonging to Group IIaccording to the definitions of 97/23/ECDirective, Article 9, Point 2.2 (withreference to 67/548/EEC Directive of June27th, 1967);
– air and nitrogen(reference: 87/404/EEC Directive).
We would like to remember to our customerthat the running of pressure equipments andpressure assemblies is excluded by thescope of Directive 97/23/EC but it’sregulated in compliance with nationalregulations of Member States of EuropeanCommunities.We think that these regulations, actually onupdating with the Competent Bodies of allthe states to avoid conflicts with the ESR ofPED, could provide for periodical checks onthe pressure equipments and assemblies.Any intervention for periodic checking orreplacement of an installed safety valvebecomes very difficult if the protectedvessel is not equipped with a shut-off valve.The shut-off valves series 3033 and 3063,installed between vessel and safety valve,
APPLICATIONS
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A
A
C
H2
H1
H3
L
� D
SEAL
BALL VALVE 3033/..
VALVE 3030/..
SEAL
TABLE 5: General Characteristics, Dimensions and Weights of valves 3033, 3063
CatalogueNumber
Designed for valve
Kv Factor[m3/h]
Risk Categoryaccording
to PED
Weight [g]min max
PS [bar]Ø D A C L H1 H2 H3
Art. 3.3
Dimensions [mm]TS [°C]
3063/44
3033/44
3033/88
3060/45C
3060/46C
3030/44C
3030/88C
5
10
20
-50 +150 55
10
13
20
1/2"
NPT
1"
NPT
78
101
107
58
73
77
35
59
72
82,5
100
123
162
178
323
350
710
1070
Castel supplies to its customers the valvesseries 3033 and 3063 in open position andthe ball spindle is protected by means of acap screwed to the body and sealed withlead to it. Any closing intervention on thevalve forcedly causes the tampering of theseal and then these interventions shall beperformed exclusively by:– staff authorized to work on the system;– public servant of a Competent Body.These persons will be responsible for thenext valve reopening and the new capsealing with their own lead.
The main parts of these valves are madewith 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.
CONSTRUCTION
N.B.: each safety valve placed on achangeover device must have sufficientcapacity 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 perfectalignment of two safety valves 3060/45.
The changeover device type 3032 is a servicevalve for dual pressure relief valves thatallows using one valve while isolating theother from the system. This device allows theuser to work on the isolated valve, forperiodic checking or replacement, while thesystem is completely operative and the othervalve is in service.
APPLICATIONS
CHANGEOVER DEVICES FOR SAFETY VALVES
L3
L2
H1
H1A
CHIUSO-CLOSED
H2
L1
BB A
L1
H2
L3
B
D
A
B
D
A
AB
B
CHIUSO-CLOSED
AB
A
3039/4
GASKET
3032/44
3032/663032/108
3032/64
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acceptable in order not to affect theoperation of both safety valves. The valveensures a pressure drop perfectlycompatible with the safety valve operationunder conditions of discharge of saturatedvapour as well as overheated vapour.The main parts of these valves are madewith 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.
The valves series 3032 can be used with thesame fluids foreseen for safety valves series3030 and 3060, in particularly:– refrigerant fluids, in the physical state of
gas or vapour, belonging to Group IIaccording to the definitions of 97/23/ECDirective, Article 9, Point 2.2 (withreference to 67/548/EEC Directive of June27th, 1967);
– air and nitrogen(reference: 87/404/EEC Directive).
The valve 3032 is designed so that it isnever possible to close off both ports at thesame time, excluding all the two safetyvalves. Under working conditions, theshutter must be clamped against one of thetwo seats of the valve, front port or backport, in order to ensure always full dischargeto the corresponding safety valve.Intermediate positions of the shutter are not
CONSTRUCTION
TABLE 6: General Characteristics, Dimensions and Weights of valves 3032
CatalogueNumber
Designed for valve
Kv Factor[m3/h]
Risk Categoryaccording
to PED
Weight [g]min max
PS [bar]L3L2L1H2H1
Art. 3.3
Dimensions [mm]TS [°C]
3032/44
3032/64
3032/66
3032/108
3060/45C
3060/46C
3030/44C
3030/66C
3030/88C
3,3
9,0
9,0
18
-50 +150 55
117
95
95
123
45
52
52
74
31
48
48
66
91
133
133
185
48
80
80
110
775
1750
1750
3200
B
1/2"
NPT
1/2"
NPT
3/4"
NPT
1
NPT
A
1/2"
NPT
3/4"
NPT
3/4"
NPT
1 1/4"
NPT
D
13
17,5
17,5
30
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Unions series 3035 allow assembling safetyvalves series 3030 and 3060 or shut-offvalves series 3032, 3033 and 3063 close tothe pressure equipments to protect, set upin a refrigerating system.These unions are designed for installationsaccording to the following two ways:– Make a copper tube jointing the pressure
equipment to the union, fit the end of thistube into the solder connection of theunion and then make a capillary brazing.
– Drill the inner/outer pipe close to thepressure equipment (if possible make acollar on the pipe), put the end of theunion into this drill and then make a brazewelding.
The unions series 3035 are machined bybrass bar EN 12164-CW614N.
SAFETY VALVES UNIONS
Copper pipe
3060
3035
Ø D
L
Ch.
TABLE 7: General Characteristics, Dimensions and Weights of unions 3035
Catalogue Number ODS
Ø [mm]
PS [bar]D L Ch
Weight[g]
NPT
Connections Dimensions [mm]
3035/2
3035/3
3035/4
3035/6
3035/8
1/4”
3/8”
1/2”
3/4”
1”
12
18
22
28
35
55
18
22
28
35
42
33
36,5
44
51
72
21
27
32
40
45
58
90,5
165
255
364
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In conformity with the provisions of Article15 of 97/23/EC Directive and of Point 7.3.3of EN 378-2 : 2000 Standard the followingdata are reported on the hexagonal nut:• EC marking;• Manufacturer's logo;• Max allowable pressure PS;• Melting point.
If a fusible plug is mounted on a pressurevessel or any other part which it protect itshall be placed in a section wheresuperheated refrigerant would not affect itscorrect function. Fusible plug shall not becovered by thermal insulation. Dischargefrom fusible plugs shall take place so thatpersons and property are not endangeredby the released refrigerant.EN 378-2 : 2000 Standard, harmonized withthe 97/23/EC Directive, establishes that afusible plug shall not be used as the solepressure relief device between a refrigerantcontaining component and the atmospherefor systems with a refrigerant charge largerthan:• 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.
97/23/EC Directive requires that pressureequipment, in which permissible limits arereasonably likely to be exceeded, shall befitted with suitable protection devices, forinstance safety devices such as fusibleplugs. Such devices shall prevent pressurefrom permanently exceeding the maxallowable pressure PS of the equipmentthey protect. In any case, a short pressurepeak limited to 10% of admissiblemaximum pressure is permitted.As to the selection and sizing of the suitableprotection device, users shall refer to thespecific sector or product standards.EN 378-2 : 2000 Standard “Refrigeratingsystems and heat pumps – safety andenvironmental requirements – Part 2:Design, construction, testing, marking and
FUSIBLE PLUG SELECTION
INSTALLATION
MARKING
Fusible plugs series 3080/.C and 3082/.Care safety devices according to thedefinition given in Article 1, Point 2.1.3, 2nd
dash of 97/23/EC Directive and are thesubject of Article 3, Point 1.4 of aforesaidDirective.According to the definition given in Point3.6.4 of EN 378-1 : 2000 Standard, fusibleplug is a device containing material thatmelts at a predetermined temperature andthereby relieving the pressure.Castel has resolved to classify fusible plugsseries 3080/.C and 3082/.C in the Categoryof Risk I therefore fixing their use, asprotection devices, on specific pressureequipments, proper to the same Category ofRisk I, in compliance with Annex II, Point 2,of 97/23/EC Directive.In consequence of this choice, fusible plugsseries 3080/.C and 3082/.C cannot beused, as sole protection devices, onpressure equipments proper to Categoriesof Risk higher than first.
The body of the fusible plug is an NPT plugdrilled with a taper hole. A predeterminedquantity of fusible alloy, with checkedmelting point, is poured inside this hole.The parts of the fusible plugs are made withthe following materials:• Brass EN 12164 – CW 614N, hot tinned,
for the plug.• Eutectic alloy with several components,
cadmium and lead free, for the fusiblematerial.
Use: the fusible plugs are basically used toprotect the components in a refrigeratingsystem or heat pump against possibleoverpressures, with regard to the operatingconditions for which they have beendesigned, in case of an excessive externalheat source, such as fire.Fluids: the fusible plugs can be used withrefrigerant fluids belonging to Group 2according to the definitions of 97/23/ECDirective, Article 9, Point 2.2 (with referenceto 67/548/EEC Directive of June 27th, 1967).
SCOPE
CONSTRUCTION
GENERAL DESCRIPTION
FUSIBLE PLUGS
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– C = function of isentropic coefficient k (asmeasured at 25 °C , see Section 7.2.3 ,EN 13136 : 2001 Standard) calculatedfrom:
To find the values of k and C for the moreuseful refrigerants, see the chapter of safetyvalves series 3030Calculation of minimum required dischargecapacity of fusible plug is closely linked tothe main cause that may arouse the openingof fusible plug, which is the external heatsources.The minimum required discharge capacityshall be determined by the following:
[kg/h]
with– ϕ = density of heat flow rate, it’s 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 establishesthat the following values for Kdr shall be themaximum used depending on how the pipebetween the vessel and the fusible plug ismounted on the vessel:• flush or flared connection: Kdr = 0,70• inserted connection: Kdr = 0,55
Q
Ahmd
surf
vap
=× ×3600 ϕ
C k
k
k
k= × ×
+
+( )−( )
3 9482
1
1
1,
documentation” provides a general outlineof the protection devices to be adopted inrefrigerating systems and their features (par7.4). It also indicates the criteria for theselection of the device suitable to the typeand sizes of the system component to beprotected (par. 7.4).EN 13136 : 2001 Standard “ Refrigeratingsystems and heat pumps – Pressure reliefdevices and their associated piping –Methods for calculation”, harmonized with97/23/EC Directive, highlights the possiblecauses of overpressure in a system andmakes available to users the instruments forpressure relief device sizing, among whichthe fusible plugs.
As the fusible plugs discharge toatmosphere, they always work in criticalflow (to know the definition of critical flow,see the chapter of safety valves series3030).The fusible plugs must be sized as follow:
[mm2]
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 offusible plug, equal to 0,9 x Kd
– po = pressure upstream the fusible plug,inside the equipment to be protected [barabs]
– vo = specific volume of gas or vapour atrelieving conditions po e To , [m3/kg] (To isthe fluid temperature at plug inlet, settledby the user or by the designer)
A
QC K
vpc
md
dr
o
o
= ××
×3 469,
SIZING OF FUSIBLE PLUGS (REF. EN 13136 : 2001)
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TABLE 8: General Characteristics, Dimensions and Weights of fusible plugs 3080 and 3082
CatalogueNumber
NPTConnections
Flow Diameter[mm]
Flow Section[mm2] Kd PS
[bar]Melting Point
[°C]
Hexa
gona
l Key
Wrench Torque
min/max [Nm]
Weight[g]
Risk Categoryaccording to
PED
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
42
30
79
138
17
22
17
22
10 / 15
14 / 20
21 / 30
10 / 15
14 / 20
21 / 30
23
39
76
23
39
76
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Before connecting the valve to the pipe it isadvisable to make sure that the refrigeratingsystem is clean. In fact the valves withP.T.F.E. gaskets are particularly sensitive todirt and debris. Furthermore check that theflow direction in the pipe corresponds to thearrow 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 solderconnections should be carried out withcare, using a low melting point fillermaterial. Before starting to braze, it’snecessary to disassemble the valves series3122, while this operation is not necessarywith solder connection valves. In any case,it’s important to avoid direct contactbetween the torch flame and the valve body,which could be damaged and compromisethe proper functioning of the valve.
The check valves, shown in this chapter, areclassified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).For heavy duty, about the operationtemperature, for example installation on thedischarge line close to the compressor,Castel has developed three new series ofvalves, types 3122, 3142 and 3182,equipped with special gasket for hightemperature, between the body and itscover.
The main parts of the valves are made withthe 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 gasketsfor the valves series 3122, 3142 and 3182;
– P.T.F.E. for seat gasket.
The valves can be installed in any section ofa refrigerating system, where it is necessaryto avoid an inversion of the refrigeratingflow, in compliance with the limits andcapacities indicated in table 3. Table 1 shows the following functionalcharacteristics of a check valve:– PS;– TS;– Kv factor;– minimum opening pressure differential,
that is the minimum pressure differentialbetween inlet and outlet at which a checkvalve can open and stay opened.
INSTALLATION
MATERIALS
APPLICATIONS
CHECK VALVES
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CH
EC
K VA
LVE
STABLE 1: General Characteristics
CatalogueNumber SAE
Flare Ø[in.]
Ø[mm]
Ø[in.]
Ø[mm]
ODS ODM
Connections
KvFactor[m3/h]
MinimumOpeningPressure
Differential[bar] min.
TS [°C]
max.
PS[bar]
RiskCategoryaccording
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
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
–
–
1.1/8"
1.3/8"
1.3/8"
1.5/8"
2"
2"
–
–
28
–
35
35
–
0,4
1,6
3,3
6,6
8,8
15,2
25,0
40,0
0,5
1,6
1,8
3,3
1,6
1,8
3,3
6,6
8,8
15,2
25,0
40,0
8,5
9,5
19,0
37,0
45,4
0,1
0,3
0,1
– 40
– 35
– 40
– 35
+105
+160
+105
+160
45
Art. 3.3
I
Art. 3.3
I
Art. 3.3
I
76 www.castel.it
TABLE 2: Dimensions and Weights
CatalogueNumber Weight [g]
H H1 L L1 Q Ø D Ch
84
84,5
83
109
108
84,5
101,5
125,5
142
144
148
183
198
148
183
198
84,5
101,5
125,5
142
151
177
221
–
28,5
34
37
42,5
–
28,5
34
37
42,5
95
109,5
123,5
–
100
118
141
173
–
170
201
232
256
285
329
130,5
150
195,5
–
100,5
116
143,5
–
60
68
88
104
–
60
68
88
104
60
68
104
23
37
–
23
37
23
37
–
20
27
–
20
28
20
28
–
150
155
165
440
460
1180
1090
1625
2955
4225
170
185
450
185
450
1320
1885
3315
4875
5690
1280
1295
1855
3255
4780
Dimensions [mm]
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
77www.castel.it
H
H1
L
Q
� 20M10
3122
L
H1
H
� 20M10
Q
3142
H
� D31303131
L1
H
H1
L
3182
Q
H
� D3110
Ch
CH
EC
K VA
LVE
S
78 www.castel.it
TABLE 3: Refrigerant Flow Capacity
CatalogueNumber
R134a R22 R407C R404A R410A R22 R407C R404A R410A R22 R407C R404A R410A
Liquid Vapour Hot Gas
Refrigerant Flow Capacity [kW]
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
6,7
27,0
30,3
55,6
111,2
148,3
256,1
421,3
674,0
8,4
27,0
30,3
55,6
27,0
30,3
55,6
111,2
148,3
256,1
421,3
674,0
143,2
160,1
320,2
623,5
765,0
7,2
28,8
32,4
59,4
118,8
158,4
273,6
450,0
720,0
9,0
28,8
32,4
59,4
28,8
32,4
59,4
118,8
158,4
273,6
450,0
720,0
153,0
171,0
342,0
666,0
817,2
7,5
30,0
33,7
61,8
123,7
164,9
284,8
468,5
749,6
9,4
30,0
33,7
61,8
30,0
33,7
61,8
123,7
164,9
284,8
468,5
749,6
159,3
178,0
356,1
693,4
850,8
4,8
19,0
21,4
39,3
78,5
104,7
180,9
297,5
476,0
6,0
19,0
21,4
39,3
19,0
21,4
39,3
78,5
104,7
180,9
297,5
476,0
101,2
113,1
226,1
440,3
540,3
7,6
30,5
34,3
62,8
125,7
167,6
289,4
476,0
761,6
9,5
30,5
34,3
62,8
30,5
34,3
62,8
125,7
167,6
289,4
476,0
761,6
161,8
180,9
361,8
704,5
864,4
R134a
0,9
3,5
3,9
7,1
14,3
19,0
32,8
54,0
86,4
1,1
3,5
3,9
7,1
3,5
3,9
7,1
14,3
19,0
32,8
54,0
86,4
18,4
20,5
41,0
79,9
98,1
1,1
4,3
4,9
8,9
17,8
23,8
41,0
67,5
108,0
1,4
4,3
4,9
8,9
4,3
4,9
8,9
17,8
23,8
41,0
67,5
108,0
23,0
25,7
51,3
99,9
122,6
1,1
4,3
4,8
8,8
17,7
23,6
40,7
67,0
107,2
1,3
4,3
4,8
8,8
4,3
4,8
8,8
17,7
23,6
40,7
67,0
107,2
22,8
25,5
50,9
99,2
121,7
0,9
3,6
4,1
7,5
14,9
19,9
34,4
56,5
90,4
1,1
3,6
4,1
7,5
3,6
4,1
7,5
14,9
19,9
34,4
56,5
90,4
19,2
21,5
42,9
83,6
102,6
1,4
5,8
6,5
11,9
23,8
31,7
54,7
90,0
144,0
1,8
5,8
6,5
11,9
5,8
6,5
11,9
23,8
31,7
54,7
90,0
144,0
30,6
34,2
68,4
133,2
163,4
R134a
3,4
13,6
15,3
28,1
56,1
74,8
129,2
212,5
340,0
4,3
13,6
15,3
28,1
13,6
15,3
28,1
56,1
74,8
129,2
212,5
340,0
72,3
80,8
161,5
314,5
385,9
4,7
18,7
21,1
38,6
77,2
103,0
177,8
292,5
468,0
5,9
18,7
21,1
38,6
18,7
21,1
38,6
77,2
103,0
177,8
292,5
468,0
99,5
111,2
222,3
432,9
531,2
4,6
18,6
20,9
38,3
76,7
102,3
176,6
290,5
464,8
5,8
18,6
20,9
38,3
18,6
20,9
38,3
76,7
102,3
176,6
290,5
464,8
98,8
110,4
220,8
429,9
527,5
4,0
16,0
18,0
33,0
66,0
88,0
152,0
250,0
400,0
5,0
16,0
18,0
33,0
16,0
18,0
33,0
66,0
88,0
152,0
250,0
400,0
85,0
95,0
190,0
370,0
454,0
5,2
20,8
23,4
42,9
85,8
114,4
197,6
325,0
520,0
6,5
20,8
23,4
42,9
20,8
23,4
42,9
85,8
114,4
197,6
325,0
520,0
110,5
123,5
247,0
481,0
590,2
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
79
WATER REGULATING VALVES
80 www.castel.it
The water regulating valve, employed withcondenser fed with either main or wellwater, keeps the condensation pressureconstant at the previously set value byadjusting the water flow so as to ensure abalanced heat exchange under allconditions. At plant start-up, this adjustment isdesigned to allow the thermostatic valve torapidly reach normal operating conditionsand subsequently, during operations, toavoid excessive pressure increases ordecreases under different flow conditions.An excessive rise of high pressure affectsthe refrigerating capacity of the system. On the other side, pressure lowering leadsto insufficient refrigerant feeding of theevaporator with a consequent increased gasoverheating and parallel reduction of gaspressure at compressor suction. Castel valves are appropriate for refrigerantfluids CFC, HCFC and HFC and only formain and well water.
APPLICATIONS
WATER REGULATING VALVES
1/4"
48
Ch
1/4"Flare
8799
L
A02
MAD
E IN ITALY
RANGE 5-18 bar
MEDIUM R134a-R404A-R12-R22-R502MAX WATER TEMP. 80 |BCMAX WATER PRESS. 10 bar
CAT. BC
A
The moving elements of the valve are ametal bellows and a shutter. The thrust of the refrigerant condensationpressure outside the bellows favours theopening of the valve and the thrust of theadjustment spring on the shutter acts in theopposite sense. Given a specific setting ofthe spring, the valve progressively opens inline with the increasing condensationpressure, and closes when this pressuredecreases. When the compressor stops, the valvecloses: water is no longer fed into thecondenser, this being a notable operatingeconomy.Valve setting is performed in the works at apressure of 7,5 bars. Setting is modified byturning the control screw.Three reference notches, marked withletters A, B, and C, are present on thespring cover. Each notch is equivalent to adifferent spring setting.The notches are referred to the followingcondensation pressures:• letter A equivalent to about 7.5 bar
(valid for R12 and R134a at a temperatureof condensation of 30 °C);
• letter B equivalent to about 14 bar (valid for R404A, R407C and R507 at atemperature of condensation of 30 °C);
• letter C equivalent to about 18 bar (top limit of working pressure).
OPERATIONS
81www.castel.it
• Expected thermal difference: Dt = 10 °C.• Condensation temperature expected on
the basis of the water/refrigerant heatexchange in the condenser:approximately 6 °C above the watertemperature at the outlet, equivalent to30 °C (with a corresponding saturationpressure) (fig. 1).
• Refrigeration yield at the level of theevaporator: 18,6 kW under the following operatingconditions,condensation temperature: + 30 °C;evaporation temperature: –15 °C.
Thermal power to be disposed of at thelevel 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
WA
TE
R R
EG
ULA
TIN
G VA
LVE
S
Fig. 1 – Heat exchange pattern in the condenser
TABLE 1 - General Characteristics
CatalogueNumber Weight [g]
Connections
UNI ISO228/1
Workingpressure
[bar]
Maximumwater
pressure[bar]
Maximumwater
Temperature[°C]
KvFactor
[m3/h]
Refrigerantmax
workingpressure
[bar]
Ch L
3210/03
3210/04
3210/06
G 3/8"
G 1/2"
G 3/4"
5÷18 10 80
2
3
4,7
2027
32
70
74
1015
985
1010
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.
The valve will be mounted on the wateroutlet side of the condenser, preferablyvertically, with the bellows downward.The high pressure connection to the bellowmust show no deflection.The arrow on the valve body shows waterflow direction.
A refrigerating system including a hermeticcompressor and a condenser fed withmains water.• Mains water pressure: 3 bar• Water temperature at the condenser inlet:
14 °C.
EXAMPLE OF VALVE SELECTION
INSTALLATION
MATERIALS
Heat exchange surface
Condensing Temperature
W a t e r Te m p e r a t u r e
82 www.castel.it
When the point of intersection of pressuredifferential through the valve and flow rangeis within the area between the curves of twovalves, select the valve with larger diameter.
When the valve is completely closed, thepressure must be the same as therefrigerant saturation pressure at the airtemperature of the place where thecondenser is installed.When the valve begins to open, thepressure is about 0.2 bar above thepressure when the valve is totally closed.
The pressure drop corresponding to thewater flow rate specified above in thecondenser/piping circuit, with the exclusionof the water regulating valve, is about 2.5 bar.
The water regulating valve has this pressuredifferential at its disposal:
�p = 3 – 2,5 = 0,5 bar
At �p = 0,5 bar the 3210/04 valve, completlyopened, ensures the required flow rate (fig. 2).
0
0,5
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
∆p [H2O]
1
1,5
2
2,5
3
3,5
4
4,5
5
5,5
6
6,5
7
0
0,12
5
0,25
0,37
5
0,5
0,62
5
0,75
0,87
5 1
1,12
5
1,25
1,37
5
1,5
1,62
5
1,75
1,87
5 2
2,12
5
2,25
2,37
5
2,5
2,62
5
2,75
∆p [bar]
Q [m3/h]
3210/04
3210/06
3210/03
Fig. 2 – Characteristic curves when the valves are completely open
83
WA
TE
R R
EG
ULA
TIN
G VA
LVE
S
www.castel.it
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
CondensingTemperature
[°C]
Evaporating Temperature [°C]
–35 –30 –25 –20 –15 –10 –5 0 +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
CondensingTemperature
[°C]
Evaporating Temperature [°C]
–35 –30 –25 –20 –15 –10 –5 0 +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
85
LIQUID INDICATORS & MOISTURE-LIQUID INDICATORS
The data of moisture content, shown intable 1 with the “green” color, can beconsidered admissible for the properworking of the system. When the sensitiveelement from green fade to yellow, “greenChartreuse”, working conditions of thesystem could become difficult. When thesensitive element becomes “yellow”, it’stime to substitute the dehydrator filter.If the charge and working condition arenormal, the refrigerant fluid appearsperfectly liquid underneath the “lens” of theindicator. The presence of bubbles indicatesthat the refrigerant fluid is partialevaporating along the liquid line.
Castel liquid indicators and liquid/moistureindicators are manufactured with the glass“lens” which has been fused onto themetallic ring. This construction permits thetotal elimination of sealing gasket betweenthe glass disc and the metallic structurewith the consequent elimination of possiblerefrigerant leaks.
The main parts of the indicators are madewith 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.
CONSTRUCTION
The indicators, shown in this chapter, areclassified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.The indicators series 3780 are excluded fromthe scope of Directive 97/23/EC, as specifiedin the Guidelines 1/8 and 1/9, because theyare piping components.They are designed for installation oncommercial refrigerating systems and on civiland industrial conditioning plants, which userefrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 ofDirective 97/23/EC and referred to inDirective 67/548/EEC).Liquid indicators and moisture liquidindicators ensure a fast and safe inspectionof the conditions of the refrigerant fluid in thecircuit concerning regular flow and moisture.Liquid indicators also ensure inspection ofthe regular return of oil to the compressorcrankcase.
The moisture/liquid indicators consist of asensitive element as a ring, which changescolor passing from green to yellowaccording to the percentage of moisture inthe system.
OPERATION
APPLICATIONS
LIQUID INDICATORS & MOISTURE-LIQUID INDICATORS
TABLE 1: Moisture contained in the fluid [p.p.m.]
ColourR22 R134a R404A R407C R410A
Refrigerant fluid
Green
Green
“Chartreuse”
Yellow
<60
60
>60
<75
75
>75
<30
30
>30
<30
30
>30
<30
30
>30
R507
<30
30
>30
86 www.castel.it
87www.castel.it
LIQU
ID IN
DIC
AT
OR
S &
M
OIS
TU
RE
-LIQU
ID IN
DIC
AT
OR
STABLE 2: General Characteristics
MoistureLiquid
Indicators
LiquidIndicators
Catalogue Number
Type SAE Flare
Risk Categoryaccording
to PED
PS [bar]ODS ODM for pipeTS [°C]
Ø [mm]
Ø [mm]
Ø [mm]
Ø Foro[mm] max.Ø
[in.]Ø
[in.]Ø
[in.] min.
Art. 3.3
I
Art. 3.3
I
Excluded
Connections
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
3781/M28
male
male
soldering
male
female
soldering
saddle
type
level glass
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
–
1/4"
3/8"
1/2"
5/8"
3/4"
–
–
–
–
–
–
–
–
–
–
–
–
–
–
1/4"
3/8"
1/2"
5/8"
3/4"
–
–
–
–
–
–
–
–
–
–
–
–
–
–
5/8"
–
–
1/4"
3/8"
–
–
1/2"
5/8"
–
3/4"
7/8"
1.1/8"
–
–
–
–
–
–
–
–
–
1.3/8"
–
2.1/8"
–
–
–
–
–
–
12
16
18
22
–
–
10
12
–
16
18
–
22
–
–
–
–
–
–
–
–
–
–
35
42
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
1.3/8"
1.5/8"
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
28
35
–
42
–
–
–
–
–
5/8"
–
7/8"
1.1/8"
1.3/8"
–
–
16
18
22
28
35
–
–
28
– 30 +110
45
35
88 www.castel.it
L
H1
HH1
H H1
L
Ø 34,5Ø 34,5
Ø 34,5
tubo
Ø
Ø 34,5
33,5 4,5
Ø 28
36403740
36103710
3780 3781
Ch 32
Ø 34,5
L
H H1
36503750
Ch
Ch
L
H1
Ø 34,5
3771
Ch 32
L
H2
Ø 34,5
3770
Ch 32
Ø 34.5
L
H1
H
37203620
Ch
indication is given normally when the plantis in function and the fluid is flowingThe brazing of indicators with solderconnections should be carried out withcare, using a low melting point fillermaterial. Before starting to braze, it’snecessary to disassemble the ring ofindicators series 3620, 3720, 3780 and3781, while this operation is not necessarywith solder connection indicators. In anycase, avoid direct contact between thetorch flame and the indicator body or ring,which could be damaged and compromisethe proper functioning of the indicator.
At the start-up the color of the sensitiveelement may be yellow, due to exposure toair humidity and to moisture in the circuit.When the moisture of the refrigerant isbrought back to acceptable levels with thedehydrator, the indicator color is once againgreen. This is evidence that equilibrium hasbeen re-stablished. In case of persistingyellow, measures have to be taken toeliminate moisture. Only when the sensitiveelement comes back to green, there isevidence that adopted measures wereeffective. About 12 hours of systemoperation are required to achieveequilibrium. However, the moisture
INSTALLATION
89www.castel.it
LIQU
ID IN
DIC
AT
OR
S &
M
OIS
TU
RE
-LIQU
ID IN
DIC
AT
OR
S
Moisture Liquid
IndicatorsH H1 L Ch
28,5
31,5
36
38,5
46
28,5
38,5
40
46
28,5
38,5
40
46
53,5
31,5
36
38,5
46
53,5
–
71,5
77,5
81,5
89,5
93
49
61
133
117
131
151
186
68
74
77
84
92
150
160
170
160
170
–
12
17
22
24
28
–
12
17
22
24
28
–
Catalogue Number
TABLE 3: Dimensions and Weights
LiquidIndicators
Weight [g]
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
Dimensions [mm]
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
–
130
165
210
255
315
100
110
110
160
135
195
200
210
215
295
580
165
205
235
300
525
250
300
480
300
480
550
90
22
22,5
24,5
26
31,5
22
26
27,5
31,5
22
26
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
91
DEHYDRATORS AND FILTERS
92 www.castel.it
In molecular sieve driers, with a chargeconstituted by non-agglomeratedproducts, the dehydrating mass is pressedin between two fine steel mesh disks, ortwo filtering disks of various material, keptin place by a spring.In solid core driers, dehydrating anddeacidifying products with bindersconstitute the block. Water adsorptioncombines with the neutralization of acidsthat may be present in the refrigerant, andwith a strong filtering action.Castel have planned either its productionlines of hermetic driers on this secondsolution that avoid any risk of abrasion ofthe charge and consequently the makingof powder and permit to put the filter inany position inside the refrigeratingsystem.It is always advisable to install a moistureindicator downstream the filter, which willshow the refrigerant moisture and,consequently, the degree of efficiency ofthe filter.The dehydrating capacity of Castel drier isrelative to the charge of refrigerant and notto the refrigeration potential of the plant.As a matter of fact, for the samerefrigerant potential and for the same typeof refrigerant fluid, there can be differentrefrigerant charges according to the type,design and working conditions of the plantas well as to the shutter degree.The data shown in the following tables arededuced from the test results of thepresent Castel production.It is important to note in the case of a highoil level in the circuit (> 5%) the datashown in the tables will be reducedconsiderably.
Among contaminating agents causingserious 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 driedvessels;
• sealing defects especially in systemsnot designed for operation at lowtemperatures.
High temperatures combined withhumidity give rise to complex phenomenaenhancing acid formation both inlubricating oil and refrigerant.Oil organic acids react with metal andfavor the formation of sludge, which areviscous clots consisting of insoluble metalsalts and large molecules of polymerizedoil.Sludge affects the lubrication of themoving elements of the compressor, canclog valves and filters and cause seriousdamages.Acids, especially hydrofluoric acid,produced by the hydrolysis of thefluorinated refrigerant (in compressors ironand aluminum act as catalysts) areparticularly corrosive.Acids etch metal surfaces with theconsequent formation of crystal salts,which stick to surfaces and affect the totalheat exchange coefficient in thecondenser and in the evaporator.In the sealed and semi-sealed groups,these salts damage the windings ofelectric motors as in these groups coldgas cools windings through direct contact.On the other hand, water solubility inrefrigerants in a liquid phase, is quitereduced, especially at low temperatures.As a consequence, when in the systemwater exceeds the very low limits ofsolubility admitted at low temperature,excess water turns into ice, and blocksexpansion valves and capillaries eitherpartially or totally.Consequently, refrigerating plants must beequipped with a filter drier on the liquidline and types available on the market areessentially two: molecular sieve driers andsolid core driers.
DEHYDRATION OF REFRIGERANTS
DE
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93www.castel.it
The blocks in the filters series 42 aremolded from a blend of dehydratingcharge, 80% of 3 Å molecular sievesand 20 % of activated alumina, and aspecial binding agent in appropriateproportions. The choice of blend,molecular sieves – activated alumina,gives to the block a very high capacityof acid adsorption also maintaining verygood dehydrating characteristics. Thepresence of a controlled and definedpercentage of activated alumina, lowerthan the maximum value recommendedby ASERCOM, keeps unchanged theoriginal concentration of additives in thepolyolester lubricant.
The filters, shown in this chapter, areclassified “Pressure vessels” in thesense of the Pressure EquipmentDirective 94/23/EC, Article 1, Section2.1.1 and are subject of Article 3,Section 1.1 of the same Directive.They are designed for installation oncommercial refrigerating systems andon civil and industrial conditioningplants, which use refrigerant fluidsproper to the Group II (as defined inArticle 9, Section 2.2 of Directive97/23/EC and referred to in Directive67/548/EEC).Filters series 42 and series 43 havebeen developed for specific installationson refrigerating systems using HFCrefrigerant fluids, particularly R134a,R404A, R407C, R410A ed R507 mixedwith polyolester lubricants. In spite ofthis, the new block may be successfullyused also in refrigerating systems usingthe old CFC or HCFC refrigerant fluids,mixed with mineral lubricants
The filter is completely manufactured insteel, either with nickel-plated Flarethreaded connections. The productrange also includes types with copperplated solder connections, offering thepossibility to solder the copper pipeinside the connections (ODS) or outsidethe connections, using a copper sleeve(ODM).On specific customers’ request, Castelis also able the supply them filtersseries 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 1453Standard.
CONSTRUCTION
APPLICATIONS
ANTI-ACID SOLID CORE FILTER DRIERS WITHMOLECULAR SIEVES AND ACTIVATED ALUMINA –SERIES 42Approved by Underwriters Laboratories Inc. �
SOLID CORE FILTER DRIERS WITH 100% MOLECULAR SIEVES – SERIES 43Approved by Underwriters Laboratories Inc. �
94 www.castel.it
The blocks in the filters series 43 aremolded from a blend of dehydratingcharge, totally made of 3 Å molecularsieves, and a special binding agent inappropriate proportions. The choice ofthe 3 Å molecular sieves, as soledehydrating material, gives to the blocka superlative capacity of wateradsorption also maintaining quite gooddeacidifying characteristics.The manufacturing process gives aconsiderable compacted ness andstoutness to both the products so thatthey are resistant to shocks andabrasions.The shape of the block is designed in
order to offer the maximum possiblesurface area to the incoming fluid. Theinternal cavity is also positioned in sucha way as to have a uniform wallthickness. As a result, the fluidencounters a constant strength at allpoints, flows linearly through the block,and ensures efficient dehydration andminimum charge loss.The block is chemically inert, notdeliquescent, does not react withrefrigerating fluids, and is capable ofblocking oil by-products dragged intothe circuit. Impurities accumulate in thering between the metal shell and theblock; this prevents filter clogging.
System data:Refrigerant: R407CCondensing temperature: + 50 [°C]Weight of refrigerant: 34 [kg]
According to DIN 8949:2000, the adsorptioncapacity of the drier is given by:
(1.050 – 50) x 34 / 1.000 = 34 g of H2O
where:
1.050 ppm. = moisture in the refrigerantentering the filter according to DIN8949:200050 ppm. = moisture in the refrigerant flowingout the filter according to DIN 8949:2000
Comparing the absorption capacity requiredwith the values shown in table 2, driermod.4032 should be selected, with a waterabsorption capacity of 47,5 g at 50 °C.If the dehydrating capacity of products isexpressed in water drops, it must beremembered that:
1g H2O = 20 water drops
In this case and when a molecular sievedrier is selected, the following result isobtained:34 x 20 = 680 water drops.
If moisture exceeds the values specified inDIN 8949:2000, a drier with a higheradsorption capacity shall be selected.
EXAMPLE OF SELECTION
flow
dire
ctio
n
Solid core dehydrator1 – Spring2 – Stainless steel mesh3 – Block4 – Felt
DE
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95www.castel.it
TABLE 1: General CharacteristicsCatalogueNumber
InternationalReference
BlockFilteringSurface
[cm2]
NominalVolume[cm3]
ThreadedConnections
SolderConnections
SAEFlare
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"
–
–
–
–
–
–
–
–
–
1/4"
–
–
–
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"
–
–
–
–
–
–
–
–
–
10
–
–
–
–
–
–
10
12
–
–
–
–
–
–
10
12
–
–
–
16
–
–
–
–
–
16
–
–
–
16
–
16
–
–
–
–
16
–
–
–
–
–
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"
–
–
–
–
–
–
–
–
–
12
–
–
–
–
–
–
12
14
–
16
–
–
–
–
12
14
–
16
–
–
–
–
–
16
–
–
–
16
–
–
–
–
–
–
–
16
–
–
–
35
– 40 +8042
(3)Art. 3.3
Ø[in.]
Ø[mm]
Ø[in.]
Ø[mm]
ODS ODM
Connections
min.
TS [°C]
max.
PS[bar]
RiskCategoryaccording
to PED
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
–
–
–
–
–
–
–
–
–
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
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
47
70
103
155
310
255
330
660
50
80
130
250
500
500
670
1340
(1) 100% molecular sieves; (2) Male-female connections (Inlet female)(3) PS = 400 psig in compliance with the UL approval
High water capacity core (1)
96 www.castel.it
TABLE 2: General Characteristics
ThreadedConnections
CatalogueNumber
InternationalReference
BlockFilteringSurface
[cm2]
NominalVolume[cm3]
SolderConnections
SAEFlare
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"
–
–
–
–
–
–
–
–
1/4"
–
–
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"
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
16
–
–
–
–
–
16
–
–
–
16
–
16
–
–
–
–
16
–
–
–
–
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"
–
–
–
–
–
–
–
–
–
–
–
–
16
–
–
–
–
16
–
–
–
–
–
16
–
–
–
16
–
–
–
–
–
–
–
16
–
–
–
35
– 40 +8042
(2)Art. 3.3
Ø[in.]
Ø[mm]
Ø[in.]
Ø[mm]
ODS ODM
Connections
min.
TS [°C]
max.
PS[bar]
RiskCategoryaccording
to PED
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
–
–
–
–
–
–
–
–
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
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
47
70
103
155
310
255
330
660
50
80
130
250
500
500
670
1340
(1) 80% molecular sieves + 20% activated alumina(2) PS = 400 psig in compliance with the UL approval
Anti-acid core (1)
DE
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97www.castel.it
(1) (2) See caption on page 98.
TABLE 3: Refrigerant Flow Capacity and Water Capacity
CatalogueNumber
Refrigerant Flow Capacity, pressure drop
0,07 bar (1) [kW]
R134
a
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
14,9
6,7
8,2
15,4
19,4
6,9
8,5
18,0
22,8
29,0
24,0
29,0
6,9
19,7
24,6
34,1
28,2
34,1
37,6
45,0
21,7
27,1
30,9
37,3
38,8
46,6
33,6
40,5
39,9
48,2
40,9
49,5
67,2
74,2
53,4
54,5
80,6
92,8
96,5
R22
7,0
8,6
16,1
7,2
8,9
16,6
21,0
7,5
9,2
19,5
24,7
31,3
25,9
31,3
7,5
21,3
26,6
36,9
30,5
36,9
40,6
48,7
23,4
29,3
33,4
40,4
41,9
50,4
36,3
43,8
43,1
52,1
44,2
53,5
72,6
80,2
57,7
58,9
87,1
100,3
104,3
R404
AR5
074,6
5,6
10,5
4,7
5,8
10,8
13,7
4,9
6,0
12,7
16,1
20,4
16,9
20,4
4,9
13,9
17,3
24,0
19,9
24,0
26,4
31,7
15,3
19,0
21,8
26,3
27,3
32,8
23,6
28,5
28,1
33,9
28,8
34,8
47,3
52,2
37,5
38,3
56,8
65,3
67,9
R407
C
6,9
8,5
16,0
7,1
8,8
16,5
20,8
7,4
9,1
19,3
24,5
31,0
25,7
31,0
7,4
21,1
26,4
36,6
30,3
36,6
40,3
48,3
23,2
29,0
33,2
40,0
41,6
50,0
36,0
43,4
42,8
51,7
43,8
53,1
72,0
79,6
57,3
58,4
86,4
99,5
103,5
R410
A
7,0
8,6
16,2
7,2
9,0
16,7
21,2
7,5
9,3
19,6
24,8
31,4
26,0
31,4
7,5
21,4
26,7
37,0
30,6
37,0
40,8
48,9
23,5
29,4
33,5
40,5
41,9
50,6
36,4
44,0
43,0
52,3
44,4
53,7
73,0
80,5
57,9
59,1
87,6
100,6
104,7
Water Capacityat + 25 °C (2) [g H2O]
R134
a
4,1
7,3
12,7
25,1
50,2
45,4
61,4
122,8
R22
3,8
6,7
11,6
22,9
45,8
41,4
56,1
112,2
R404
AR5
07
4,2
7,4
13,0
25,6
51,2
46,4
62,8
125,6
R407
C
3,4
6,0
10,4
20,5
41,0
37,2
50,3
100,6
R410
A
3,7
6,5
11,3
22,3
44,6
40,5
54,7
109,4
Dehydratable Chargeat + 25 °C
[kg refrigerant]
R134
a
4,4
7,8
13,7
27,0
54,0
48,8
66,0
132,0
R22
4,0
7,2
12,5
24,6
49,2
44,5
60,3
120,6
R404
AR5
07
4,5
8,0
13,9
27,5
55,1
49,9
67,5
135,1
R407
C
3,6
6,4
11,2
22,0
44,1
40,0
54,1
108,2
R410
A
3,9
7,0
12,2
24,0
48,0
43,5
58,8
117,6
Water Capacityat + 50 °C (2) [g H2O]
R134
a
3,5
6,3
10,9
21,6
43,2
39,1
53,0
106,0
R22
3,0
5,3
9,3
18,4
36,8
33,2
45,0
90,0
R404
AR5
07
3,9
6,9
12,0
23,8
47,6
43,1
58,3
116,6
R407
C
2,7
4,8
8,4
16,5
33,0
29,9
40,5
81,0
R410
A
2,9
5,2
9,1
18,0
36,0
32,6
44,1
88,2
Dehydratable Chargeat + 50 °C
[kg refrigerant]
R134
a
3,8
6,8
11,8
23,2
46,5
42,0
57,0
114,0
R22
3,2
5,7
10,0
19,8
39,6
35,7
48,4
96,8
R404
AR5
07
4,2
7,4
13,0
25,6
51,2
46,3
62,7
125,4
R407
C
2,9
5,2
9,0
17,7
35,5
32,2
43,5
87,1
R410
A
3,2
5,6
9,8
19,4
38,7
35,1
47,4
94,8
98 www.castel.it
TABLE 4: Refrigerant Flow Capacity and Water Capacity
CatalogueNumber
Refrigerant Flow Capacity, pressure drop
0,07 bar (1) [kW]
R134
a
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
14,9
6,7
8,2
15,4
19,4
6,9
8,5
18,0
22,8
24,0
29,0
6,9
19,7
24,6
28,2
34,1
37,6
45,0
21,7
27,1
30,9
37,3
38,8
46,6
33,6
40,5
39,9
48,2
40,9
49,5
67,2
74,2
53,4
54,5
80,6
92,8
96,5
R22
7,0
8,6
16,1
7,2
8,9
16,6
21,0
7,5
9,2
19,5
24,7
25,9
31,3
7,5
21,3
26,6
30,5
36,9
40,6
48,7
23,4
29,3
33,4
40,4
41,9
50,4
36,3
43,8
43,1
52,1
44,2
53,5
72,6
80,2
57,7
58,9
87,1
100,3
104,3
R404
AR5
07
4,6
5,6
10,5
4,7
5,8
10,8
13,7
4,9
6,0
12,7
16,1
16,9
20,4
4,9
13,9
17,3
19,9
24,0
26,4
31,7
15,3
19,0
21,8
26,3
27,3
32,8
23,6
28,5
28,1
33,9
28,8
34,8
47,3
52,2
37,5
38,3
56,8
65,3
67,9
R407
C
6,9
8,5
16,0
7,1
8,8
16,5
20,8
7,4
9,1
19,3
24,5
25,7
31,0
7,4
21,1
26,4
30,3
36,6
40,3
48,3
23,2
29,0
33,2
40,0
41,6
50,0
36,0
43,4
42,8
51,7
43,8
53,1
72,0
79,6
57,3
58,4
86,4
99,5
103,5
R410
A
7,0
8,6
16,2
7,2
9,0
16,7
21,2
7,5
9,3
19,6
24,8
26,0
31,4
7,5
21,4
26,7
30,6
37,0
40,8
48,9
23,5
29,4
33,5
40,5
41,9
50,6
36,4
44,0
43,0
52,3
44,4
53,7
73,0
80,5
57,9
59,1
87,6
100,6
104,7
(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 referredto a total pressure drop of 0,07 bar, inlet and outlet connections included, (according to ARI STANDARD 710:86 - with condensingtemperature 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 ppmWater 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
Water Capacityat + 25 °C (2) [g H2O]
R134
a
3,5
6,2
10,8
21,3
42,7
38,6
52,2
104,4
R22
3,2
5,7
9,9
19,5
38,9
35,2
47,7
95,4
R404
AR5
07
3,6
6,3
11,0
21,8
43,5
39,4
53,4
106,8
R407
C
2,9
5,1
8,8
17,4
34,9
31,6
42,8
85,5
R410
A
3,1
5,5
9,6
19,0
37,9
34,4
46,5
93,0
Dehydratable Chargeat + 25 °C
[kg refrigerant]
R134
a
3,8
6,7
11,6
22,9
45,9
41,5
56,1
112,2
R22
3,4
6,1
10,6
20,9
41,9
37,8
51,3
102,5
R404
AR5
07
3,9
6,8
11,9
23,4
46,8
42,4
57,4
114,8
R407
C
3,1
5,5
9,5
18,7
37,5
34,0
46,0
91,9
R410
A
3,4
6,0
10,3
20,4
40,8
37,0
50,0
100,0
Water Capacityat + 50 °C (2) [g H2O]
R134
a
3,0
5,4
9,3
18,4
36,7
33,2
45,1
90,1
R22
2,6
4,5
7,9
15,6
31,3
28,2
38,3
76,5
R404
AR5
07
3,3
5,9
10,2
20,2
40,5
36,6
49,6
99,1
R407
C
2,3
4,1
7,1
14,0
28,1
25,4
34,4
68,9
R410
A
2,5
4,5
7,7
15,3
30,6
27,7
37,5
75,0
Dehydratable Chargeat + 50 °C
[kg refrigerant]
R134
a
3,3
5,8
10,0
19,7
39,5
35,7
48,4
96,9
R22
2,8
4,9
8,5
16,8
33,6
30,3
41,1
82,3
R404
AR5
07
3,6
6,3
11,0
21,8
43,5
39,4
53,3
106,6
R407
C
2,5
4,4
7,7
15,1
30,2
27,3
37,0
74,0
2,7
4,8
8,3
16,5
32,9
29,8
40,3
80,6
R410
A
L
� D
solder connections
TABLE 5: Dimensions and Weights
CatalogueNumber
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
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"
–
–
–
–
–
–
–
–
–
1/4"
–
–
–
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"
–
–
–
–
–
–
–
–
–
10
–
–
–
–
–
–
10
12
–
–
–
–
–
–
10
12
–
–
–
16
–
–
–
–
–
16
–
–
–
16
–
16
–
–
–
–
16
–
–
–
52
73
91
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
220
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
SAEFlare Ø
[in.]Ø
[mm] Ø D L
ODS
Connections Dimensions [mm]
Weight [g]
L
� D
male connections
L
� D
male - female connections (female - in)
99www.castel.it
100 www.castel.it
filter, the refrigerant fluid must pass throughthe mesh sieve on which blocks aremounted. The danger that small particles ofdehydrating material being introduced intothe system is thus avoided. Furthermore, atfilter outlet, a plastic cup, the edge of whichclosely adheres to the inner surface of thefilter, prevents dirt from reaching the outletconnection during normal operation andblock change.
The filters type 4410 are manufactured insteel, with the exception of the connectionswhich are made of EN 12735-1 – Cu-DHPcopper tube.The filters type 4420 are completelymanufactured in steel and solderconnection, are machined with a steel barEN 10025 S355JR.The blocks series 4490 and 4491 has beendeveloped for specific installations onrefrigerating systems using HFC refrigerantfluids, particularly R134a, R404A, R407C,R410A ed R507 mixed with polyolesterlubricants. In spite of this, the new blockmay be successfully used also inrefrigerating systems using the old CFC orHCFC refrigerant fluids, mixed with minerallubricants.The blocks 4490, type A and type B, and theblock 4491, type A, are molded from a blendof dehydrating charge, totally made of 3 Åmolecular sieves, and a special bindingagent in appropriate proportions. The choiceof the 3 Å molecular sieves, as soledehydrating material, gives to the block asuperlative capacity of water adsorption alsomaintaining quite good deacidifyingcharacteristics.The blocks 4490, type AA and type AB, andthe block 4491, type AA, are molded from ablend of dehydrating charge, 80% of 3 Åmolecular sieves and 20 % of activatedalumina, and a special binding agent inappropriate proportions. The choice ofblend, molecular sieves – activated alumina,gives to the block a very high capacity ofacid adsorption also maintaining very gooddehydrating characteristics. The presence of a controlled and definedpercentage of activated alumina, lower thanthe maximum value recommended byASERCOM, keeps unchanged the originalconcentration of additives in the polyolesterlubricant.
CONSTRUCTION
FILTER DRIERS WITH REPLACEABLE ANTI-ACID SOLID COREApproved by Underwriters LaboratoriesInc. �Except filters 4423/17A, /21A, /25A and4424/25A, /33A
The filters, shown in this chapter, areclassified “Pressure vessels” in the sense ofthe Pressure Equipment Directive 97/23/EC,Article 1, Section 2.1.1 and are subject ofArticle 3, Section 1.1 of the same Directive.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).
In the case of filters with more than oneblock, the passage of the fluid takes placein parallel; as a result, the pressure dropdoes not increase proportionately to thenumber of blocks. A large ring between theblock and the inner surface of the filterpermits the accumulation of solid particles,and prevents clogging. Before leaving the
OPERATION
APPLICATIONS
DE
HY
DR
AT
OR
S A
ND
FILTE
RS
101www.castel.it
The manufacturing process of blocks series4490 and 4491 gives a considerablecompacted ness and stoutness to both theproducts so that they are resistant toshocks and abrasions.The blocks series 4490 have a volume of 48cu.in., equivalent to approx. 800 cm3, and itis used with type 4411, 4412, 4413 and4414 filters.The block series 4491 has a volume of 100cu.in., equivalent to approx. 1600 cm3. andit is used with type 4421, 4423 and 4424filters.The two blocks are shaped as a hollowcylinder and their overall dimensionscorrespond to those of other internationalbrands. Consequently they areinterchangeable. The hollow cylinder shapeoffers a large surface area to the inflowingfluid, which crosses the block in radialsense. As a result, dehydration is highlyefficient with a minimum loss of charge.Filters may be supplied also with an accessfitting kit G9150/R05, to be orderedseparately.
TABLE 1: General Characteristics
CatalogueNumber
Core FilteringSurface
[cm2]
Number of Cores
Core Cat.Number
Nominal Volume
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"
800
1600
2400
3200
4800
6400
48
96
144
192
300
400
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
– 40 +80
45 (1)
35 (1)
32
I
II
Ø[in.][cm3][cu.in] Ø
[mm]Ø
[mm]
ODS ODM
Connections
min.
TS [°C]
max.
PS[bar]
RiskCategoryaccording
to PED
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
4490/A -
4490/B -
4490/AA
4490/AB
4491/A
4491/AA
1
2
3
4
3
4
420
840
1260
1680
1890
2520
(1) PS = 470 psig in compliance with the UL approval
5
3
1
2
4
4
outlet
inlet
Sketch of filter with 2 blocks1 – Block2 – Mesh sieve serving as block support3 – Spring4 – Retainer cup5 – Access fitting 1/4” SAE flare (to order separately)
102 www.castel.it
TABLE 2A: Refrigerant Flow Capacity and Water Capacity (filters)
CatalogueNumber
Refrigerant Flow Capacity, pressure drop
0,07 bar (1) [kW]
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
146
200
233
250
146
226
306
333
327
361
426
447
492
670
737
1180
90
158
216
252
270
158
244
331
361
354
391
460
483
532
725
797
1276
59
103
141
164
176
103
159
215
234
230
254
300
315
346
472
519
830
89
156
214
250
268
156
242
328
357
351
387
456
479
527
719
791
1265
90
159
217
253
271
159
245
332
362
355
393
462
485
534
728
800
1281
R134
a
R22
R404
A
R407
C
R410
A
84
168
252
336
504
672
77
154
231
308
462
616
86
172
258
344
516
688
69
138
207
276
414
552
75
150
225
300
450
600
R134
a
R22
R404
A
R407
C
R410
A
90
181
271
361
542
723
83
166
248
331
497
662
92
185
277
370
555
740
74
148
223
297
445
594
81
161
242
323
484
645
R134
a
R22
R404
A
R407
C
R410
A
72
144
216
288
432
576
61
122
183
244
366
488
80
160
240
320
480
640
56
112
168
224
336
448
60
120
180
240
360
480
R134
a
R22
R404
A
R407
C
R410
A
77
155
232
310
465
619
66
131
197
262
394
525
86
172
258
344
516
688
60
120
181
241
361
482
65
129
194
258
387
516
R134
a
R22
R404
A
R407
C
R410
A
Water Capacityat + 25 °C (2) [g H2O]
Dehydratable Chargeat + 25 °C
[kg refrigerant]
Water Capacityat + 50 °C (2) [g H2O]
Dehydratable Chargeat + 50 °C
[kg refrigerant]
(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 referredto a total pressure drop of 0,07 bar, inlet and outlet connections included, (according to ARI STANDARD 710:86 - with condensingtemperature 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 ppmWater 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/AAwhen fluid dehydration is not the a major problem, are the same achieved with block type 4490/A, 4490/B and 4491/A.
TABLE 2B: Refrigerant Flow Capacity and Water Capacity (single block)
CatalogueNumber
Refrigerant Flow Capacity, pressure drop
0,07 bar (1) [kW]
R134
a
4490/A - 4490/B
4491/A
4490/AA - 4490/AB
4491/AA
–
(3)
84
168
71
143
77
154
65
131
86
172
73
146
69
138
59
117
90
181
77
154
83
166
70
141
92
185
79
157
74
148
63
126
72
144
61
122
61
122
52
104
80
160
68
136
56
112
48
95
77
155
66
132
66
131
56
112
86
12
73
146
60
120
51
102
75
150
64
128
81
161
69
137
60
120
51
102
65
129
55
110
R22
R404
A
R407
C
R410
A
R134
a
R22
R404
A
R407
C
R410
A
R134
a
R22
R404
A
R407
C
R410
A
R134
a
R22
R404
A
R407
C
R410
A
R134
a
R22
R404
A
R407
C
R410
A
Water Capacityat + 25 °C (2) [g H2O]
Dehydratable Chargeat + 25 °C
[kg refrigerant]
Water Capacityat + 50 °C (2) [g H2O]
Dehydratable Chargeat + 50 °C
[kg refrigerant]
H3
20H1
H2
P
ØD1
ØD2
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TABLE 3: Dimensions and Weights
CatalogueNumber
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"
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
121
163
149
200
148
154
159
171
162
296
300
312
303
442
454
595
586
520
525
693
235
241
246
258
249
383
387
399
390
529
541
682
673
641
646
814
185
324
600
760
90
96
101
113
103
96
101
113
103
101
113
103
143
148
5360
5405
5395
5464
5435
5410
5585
6880
7015
6985
7136
8510
8470
8445
9940
10010
18000
18200
18400
21600
22000
Ø[in.]
Ø[mm]
Ø[mm]
Ø D1 Ø D2 H1 H2 H3 P
ODS W
Connections Dimensions [mm]
Weight [g]
104 www.castel.it
Blocks must be ordered separately from thefilter. They are supplied in individualpackages, which are hermetically sealed insuitable wrappings (type 4490), and inspecial bags (type 4491) for safe storageover long periods of time.Every cartridge is equipped of two seals insynthetic material to use like seal betweenthe two cartridges and between thecartridge and its covers.If the filter is installed in a system withoutany by-pass, the block replacement has tobe 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 chargeinto the high pressure side of the plant(liquid receiver).
3 Stop the compressor at a suctionpressure sufficiently higher than theatmospheric pressure.
4 Shutt off the service valve at the suctionside of the compressor.NOTE: if during the transfer of therefrigerant to the high-pressure side ofthe plant, the discharge pressures reachtoo high values (the condenser is floodeddue to insufficient capacity of the liquidreceiver), shut off the valve on thecompressor suction side and stopimmediately the compressor.
5 Replace quickly the filter block. Duringthe preparation of the new block, closethe filter with a clean cloth. The slightover-pressure inside the filter and theability of the technician will prevent airfrom getting into the plant.
BLOCKS REPLACEMENT
� D1
� D2
H
4491
H
� D2
� D1
4490
TABLE 4: General Characteristics, Dimensions and Weights
CatalogueNumber
Core FilteringSurface
[cm2]
4490/A
4490/B (1)
4490/AA
4490/AB (1)
4491/A
4491/AA
420
630
48
100
800
1600
47
53
96
122
140
165
670
1350
[cu.in] [cm3] Ø D1 Ø D2 H
Weight [g]
Nominal Volume
Dimensions [mm]
(1) Supplied without cover gasket as spare part
6 The internal cleanliness of the body isguaranteed by the cleaning effect of thecup which is characteristic of Castelfilters.if air is supposed to have entered theplant during filter block replacement,produce a vacuum in the low-pressureside of the plant, and always in the sectorof the circuit involved.
7 Open the valve on the departure of liquidline
8 Slowly open the suction valve of thecompressor and start the compressorand its auxiliaries.
9 Top the charge up, if necessary.
With clean systems, refrigerant flowcapacity and pressure drops of table 2 arereported to a gas speed of 20 m/s for pipesadequate to the filter connections. For refrigerant flow capacities different fromthe table values, under the other sameconditions, gas speeds and relativepressure drops through the filter can begained for simple proportionality.
System data:Refrigerant: R407CRefrigerant flow capacity: 130 [kW]Evaporating temperature: + 5 [°C]Suction pipe: Ø 2.1/8”Filter: 4411/17C
In table 2, corresponding to filter type4411/17C refrigerant and evaporatingtemperature, 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:
[m/s]
Pressure drop through the filter:
[bar]
Remember that the dimensioning of thesuction line in a refrigerating systemrequires great attention. In fact the relative pressure loss, included filter, which implies a reduction offlow capacity sucked by the compressor,influences directly the refrigerating capacityof the plant.This line is normally sized to have a totalpressure loss lower then a variation of thesaturation temperature of 1° C. For example diagram 1, referred to R22,allows to estimate the aforesaid variation infunction of pressure loss and evaporatingtemperature.
€
0,21130
141,70,177
2
2× =
20130
141,716,8
2
2× =
EXAMPLE
SELECTION CRITERION
SUCTION LINEApproved by Underwriters LaboratoriesInc. �Except filters 4421/21C, /25C, /M80C, /33C
The filters, shown in this chapter, areclassified “Pressure vessels” in the sense ofthe Pressure Equipment Directive 97/23/EC,Article 1, Section 2.1.1 and are subject ofArticle 3, Section 1.1 of the same Directive.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).
Good filtering of the refrigerant on the low-pressure side of the system is a guaranteeof protection for the compressor. Systemcleanliness is ensured by micro filteringcores, which filter out impurities derivedfrom manufacture and assembly of therefrigerating system.
The filters type 4410 are manufactured insteel, with the exception of the connectionswhich are made of EN 12735-1 – Cu-DHPcopper tube.The filters type 4420 are completelymanufactured in steel and solderconnection, are machined with a steel barEN 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 suppliedwith an access fitting kit G9150/R05.
CONSTRUCTION
OPERATION
APPLICATIONS
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MECHANICAL FILTERS WITH REPLACEABLE FILTERINGBLOCK
106 www.castel.it
To such purpose diagram 2 illustrates theexisting relation between saturationtemperature, in the suction line, andvariation of the refrigerant flow capacity of acompressor.
After all it’s always important to rememberthat the refrigerant flow capacity of acompressor, under the other sameconditions, can reduce considerablybecause of the decrease of the saturationtemperature, consequent to the pressureloss in the suction line.
TABLE 1: General Characteristics
CatalogueNumber
Core FilteringSurface
[cm2]
Number of Cores
Core Cat.Number
45 (1)
32
I
Ø[in.]
Ø[mm]
Ø[mm]
ODS W
Connections
min.
TS [°C]
max.
PS[bar]
RiskCategoryaccording
to PED
4411/7C
4411/9C
4411/11C
4411/13C
4411/M42C
4411/17C
4411/21C
4421/21C
4421/25C
4421/33C
4495/C
4496/C
1
820
1850
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"
22
–
35
–
42
54
–
–
80
–
–
76,1
88,9
114,3
– 40 +80
(1) PS = 470 psig in compliance with the UL approval
outlet
inlet
3
1
2
2
Sketch of filter with mechanical block1 – Block2 – Retainer cup3 – Spring
DIAGRAM 1
DIAGRAM 2
0 5 10 15 20 25 30 350
1
2
3
4
5
6-45 -40 -35
-30
-25
-20
-15
-10-50
+10
evap
orat
ion te
mpe
ratu
re
Pressure loss (kPa)
Equ
ival
ent v
aria
tion
of th
e sa
tura
tion
tem
pera
ture
0
0,5
1
1,5
2
-40 -35 -30 -25 -20 -15 -10 -5 0 5 10
Cor
rect
ion
fact
or o
f ref
riger
ant
flow
cap
acity
Saturation temperature at the suction (°C)
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TABLE 2: Refrigerant Flow Capacity and Pressure Drop
CatalogueNumber Refrigerant
Evaporating Temperature [°C]
[bar][kW][bar][kW][bar][kW][bar][kW][bar][kW]
-30-20-100+5
4411/7C
4411/9C
4411/11C
4411/13C
4411/M42C
4411/17C
4411/21C
4421/21C
4421/25C
4421/33C
R134a
R22
R404A
R407C
R410A
R134a
R22
R404A
R407C
R410A
R134a
R22
R404A
R407C
R410A
R134a
R22
R404A
R407C
R410A
R134a
R22
R404A
R407C
R410A
R134a
R22
R404A
R407C
R410A
R134a
R22
R404A
R407C
R410A
R134a
R22
R404A
R407C
R410A
R134a
R22
R404A
R407C
R410A
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
0,070
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
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
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
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
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
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
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
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
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
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
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H3
H2
H1
P
20
ØD2
ØD1
H
� D1
� D2
4495 - 4496
TABLE 4: General Characteristics Dimensions and Weights
CatalogueNumber
4495/C
4496/C
127
287
820
1850
60
80
87
113
138
168
480
750
[sq.in] [cm2] Ø D1 Ø D2 H
Filtering Surface
Dimensions [mm]
Weight [g]
TABLE 3: Dimensions and Weights
CatalogueNumber
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"
22
–
35
–
42
54
–
–
80
–
–
76,1
88,9
114,3
121
163
149
200
154
159
171
162
186
187
192
241
246
258
249
273
308
313
185
200
96
101
113
103
128
143
148
5450
5375
5435
5410
5585
6030
12000
12200
12500
Ø[in.]
Ø[mm]
Ø[mm]
Ø D1 Ø D2 H1 H2 H3 P
ODS W
Connections Dimensions [mm]
Weight [g]
110 www.castel.it
L
� D
4520
L
� D
4510
The filter is completely manufactured insteel, either with nickel-plated Flarethreaded connections. The product rangealso includes types with copper platedsolder connections, offering the possibilityto solder the copper pipe inside theconnections (ODS) or outside theconnections, using a copper sleeve (ODM).Inside the filters there is a screen basket,with wide filtering surface, made ofaustenitic stainless steel AISI 304.These filters may not be cleaned.
CONSTRUCTION
The filters, shown in this chapter, areclassified “Pressure vessels” in the sense ofthe Pressure Equipment Directive 97/23/EC,Article 1, Section 2.1.1 and are subject ofArticle 3, Section 1.1 of the same Directive.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).
APPLICATIONS
For using on refrigerating systems, Castelputs the following desiccants at disposal ofits 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 aweight of about 0,750 kg and supplied inmultiply package of 15 cans.
STRAINERS
DESSICCANTS
TABLE 1: General Characteristics
CatalogueNumber
UsefulPassageSurface
[%]
MeshOpening
[mm]
Kv Factor[m3/h]
Filtering Surface
[cm2] SAEFlare
3/8"
1/2"
–
–
–
–
–
–
–
–
3/8"
–
–
1/2"
5/8"
–
–
–
–
10
12
–
16
18
–
–
1/2"
–
–
5/8"
3/4"
–
–
–
–
12
14
16
–
22
– 40 +80 42 Art. 3.3
Ø[in.]
Ø[mm]
Ø[in.]
Ø[mm]
ODS ODM
Connections
min.
TS [°C]
max.
PS[bar]
RiskCategoryaccording
to PED
4510/3
4510/4
4520/3
4520/M10
4520/M12
4520/4
4520/5
4520/M18
58
142
58
142
36,6 0,166
2,4
3,2
2,4
3,4
8,0
TABLE 2: Dimensions and Weights
CatalogueNumber
4510/3
4510/4
4520/3
4520/M10
4520/M12
4520/4
4520/5
4520/M18
52
76
52
76
110
174
109
113
122
126
170
195
515
195
205
215
245
495
Ø D L
Dimensions [mm]
Weight [g]
111
OIL SEPARATORS
112 www.castel.it
– separators series 5540 are closed typeand they cannot be dismantled from thesystem, except cutting the piping.
The body is manufactured from steel pipe ofadequate thickness. Flanges and cover arealso made of steel. Either threaded connections of separators series 5520 or solderconnections of separators series 5540 aremanufactured, machining, with steel bar EN 10277-3 11S Mn Pb 37 + C.
The internal device is simple in order toassure a trouble-free long operation.Appropriate metallic screens, placed on theinlet and outlet, rapidly reduce gas speed,and create the conditions required for theseparation of the oil from the refrigerant. A float operated needle valve, set on thebottom of the vessel, return the oil to thecrankcase of compressor. The bottom alsoincludes a chamber that collects all metallicdebris. A permanent magnet holds theseimpurities to avoid they stop or damage theoperation of needle, moved by floating.
The oil separators, shown in this chapter,are classified “Pressure vessels” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.1 and aresubject of Article 3, Section 1.1 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).The advantages of the oil separator on thedischarge line of a compressor in arefrigeration system are confirmed by manyyears of experience. The oil separatorintercepts the oil mixed with compressedgas and returns it to the crankcase of thecompressor thus assuring an efficientlubrication of its moving parts. Furthermore,the oil separator maintains a high coefficientof condenser and evaporator performanceby almost completely removing oil depositsfrom their exchange surfaces. When a veryhigh temperature at the end of thecompression stage leads to the formation ofoil vapours, a separator with a capacityexceeding the values shown in the tableshould be used. Moreover, the oil separator,damping the valves pulsations, reducessystem noise with an open or semi-hermeticcompressor.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 datarelating to the working conditions of oilseparators.
Castel manufactures two types of oilseparators:– separators series 5520 can be overhauled
for maintenance and can be replacedfrom the system. They are equipped withthreaded connections, which can mate tothe connections type 5590 (to be orderedseparately)
CONSTRUCTION
APPLICATIONS
OIL SEPARATORS
113www.castel.it
Check of gas speed, referred to the crosssection of oil separator, is given by:
[m/s] with:
– S = gross cross section of shell separator [m2]
The oil separators type 5520 and 5540should be installed in the discharge linebetween the compressor and thecondenser mounted securely in a verticalposition and reasonably close to thecompressor.To prevent the return of refrigerant fromcondenser, during the off cycle of thesystem, it’s advisable to install a checkvalve between the condenser and oilseparator outlet connection.Oil separator performs best when operatingat or near the compressor dischargetemperature. In location the oil separator,choose a position to avoid, as far aspossible, chilling of the shell, which mayresult in condensing of liquid within theseparator. If this is not possible, it isadvisable to supply the separator with thebetter solutions (insulation, strap heater,others) to prevent the refrigerant in thesystem from condensing in the shell. Before the oil separator is installed, eitherone 5520 or one 5540, an initial charge ofoil should be added to it. Refer to generalcharacteristics of oil separators or toinstruction sheet for the proper amount ofoil. Oil pre-charge is very important, failureto pre-charge separator sump may result indamage to the oil return float mechanism.Use the same type of oil that is in thecompressor crankcase.Acting as the lay out of refrigeratingsystem, the return line may be run from theoil 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 thetube, to check the correct working of the oilseparator.
INSTALLATION
v QS=The selecting of an oil separator should be
done comparing the characteristics of theinstalled compressor, establishing:– inlet connection must agree with the
discharge diameter of the compressor– refrigerant flow capacity with fixed
working conditions (saturated dischargetemperature saturated suctiontemperature, eventually liquid subcooling,sucked vapour overheating).
This is necessary to define the gas speedreferred to the cross section of oil separator,assigned an end compression temperature.It is advisable the above-mentioned speeddoesn’t exceed 0,5 m/s, to avoid great swirlphenomena.Table 3 has being written following thisprinciple.Generally, fixed the following data:refrigerating capacity of compressor, type ofrefrigerant and working conditions, thevolumetric capacity Q, of compressed gas,is given by:
[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].
QPH
vg= ×∆
SELECTING THE SIZE OF AN OIL SEPARATOR
OIL S
EPA
RA
TO
RS
Fig. 1
5540
IN OUT
5520
IN OUT
stainlesssteel needle
screen cylinderinlet
stainless steel ball
magnetpermanent
outletscreen cylinder
steel plate
oil return tube
screen cylinderinlet
stainless steel ball
stainlesssteel needle
outletscreen cylinder
steel plate
oil return tube
magnetpermanent
114 www.castel.it
TABLE 1: General Characteristics
CatalogueNumber Catalogue
Number
Max.differentialpressure
[bar]
Oil addition
[kg]
Oil connection[SAE Flare]
1/2"
5/8"
7/8"
1.1/8"
1.3/8"
1.5/8"
–
2.1/8"
–
16
–
–
35
–
42
54
5/8"
3/4"
1"
1.3/8"
1.5/8"
–
–
–
16
–
–
35
–
–
–
–
–
16
–
–
35
–
42
1/4"
3/8"
1/4"
0,4 / 0,5
0,6 / 0,7
0,4 / 0,5
21
–
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"
–
– 10 + 130 32
I
II
I
Ø[in.]
Ø[mm]
Ø[in.]
Ø[mm]
Ø[in.]
Ø[mm]
ODS ODM ODS (1)
Solder Connections Couple of solder connectionsIN / OUT
min.
TS [°C]
max.
PS[bar]
Risk Categoryaccording
to PED
5540/4
5540/5
5540/7
5540/9
5540/11
5540/13
5540/M42
5540/17
5520/C
5520/D
5520/E
(1) The dimensions of the separator's connections must agree with the discharge diameter of the compressor
–
–
–
115www.castel.it
OIL S
EPA
RA
TO
RS
TABLE 2: Dimensions and Weights
Separator
Catalogue Number
Connections
5540/4
5540/5
5540/7
5540/9
5540/11
5540/13
5540/M42
5540/17
5520/C
5520/D
5520/E
–
5590/5
5590/7
5590/9
5590/11
5590/13
5590/M42
1/2"
5/8"
7/8"
1.1/8"
1.3/8"
1.5/8"
–
2.1/8"
5/8"
7/8"
1.1/8"
1.3/8"
1.5/8"
–
–
16
–
–
35
–
42
54
16
–
–
35
–
42
–
149
17,5
–
336
391
–
61
67
92
280
367
428
471
481
397
458
483
123
163,5
121
4200
4960
5030
5835
5800
10000
10460
6980
7760
7680
Ø[in.]
Ø[mm]
Ø D1 Ø D2 H1 H2 H3 H4
ODS
Solder Connections Dimensions [mm]
Weight[g]
H2
H4
H4
H1
H1
H3
� D2
� D1
M10
� D1
M10
5520 5540
Gasket
5590/..
116 www.castel.it
TABLE 3: Refrigerant Flow Capacity
CatalogueNumber
CatalogueNumberof solder
connections
Refrigerant Capacity (1) [kW]
–20 + 5 –40 + 5 –40 + 5 –40 + 5
R134a
Evaporating Temperature [°C]
R22 R404A R407C
5540/4
5540/5
5540/7
5540/9
5540/11
5540/13
5540/M42
5540/17
5520/C
5520/D
5520/E
–
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
6,1
18,9
21,3
24,3
27,4
38,0
48,8
18,9
21,3
24,3
27,4
30,4
6,4
19,7
22,2
25,4
28,6
39,6
50,9
19,7
22,2
25,4
28,6
31,8
7,9
24,5
27,7
31,5
35,6
49,3
63,4
24,5
27,7
31,5
35,6
39,5
6,4
19,9
22,5
25,7
28,9
40,1
51,5
19,9
22,5
25,7
28,9
32,1
8,8
27,3
30,8
35,2
39,6
54,9
70,6
27,3
30,8
35,2
39,6
44,0
6,0
18,6
21,0
24,6
27,0
37,6
48,3
18,6
21,0
24,6
27,0
30,0
8,0
24,6
27,8
31,8
35,8
49,6
63,7
24,6
27,8
31,8
35,8
40,0
(1) Refrigerant flow capacity with a condensing temperature of + 40°C and normal overheating values of vapoursucked by compressor. No liquid subcooling.
Maximum pressure drop of 0,15 bar
117
VALVES
H1
L2
H2
6010/2
32
I
� 4
.5
118 www.castel.it
– three-ways valves; two main connectionsplus a third one for charging or manometerconnection, types:– 6060 with right access connection;– 6070 with left access connection.
On both types, the access connection maybe shut off by the back-seating of thespindle.
The main parts of the hermetic valves aremade 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.
The hermetic valves, shown in this chapter,are classified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).
These valves are available in the followingtwo types:– two-ways shut-off valves types 6010/2
and 6012/22;
CONSTRUCTION
APPLICATIONS
HERMETIC VALVES
TABLE 1: General Characteristics
CatalogueNumber
Kv Factor[m3/h]
–
1/4"
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"
1/4"
–
1/4"
3/8"
1/2"
5/8"
–
–
1/4"
–
–
6
10
6
8
10
12
16
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
+4,5+130
+110
45 Art. 3.3
(1) (2) (3) Ø[in.]
Ø[mm]
SAE Flare ODS (4)
Connections
min.
TS [°C]
max.
PS[bar]
Risk Categoryaccording
to PED
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
L1
H4
H2H
3
I
H1
� 4
.5
M106070
L3
L1
L2
SSS
H2
H1
L2
L1
6012/22
4 2
12
3
L2
L3
L1
P1
H1
H3
H2
H5
M8
11
6060
D
2
1
P1
H1
H3
H2
H5
11
M8
2
1
6020
4
4
VALV
ES
119www.castel.it
TABLE 2: Dimensions and Weights
CatalogueNumber
H1 H2 H3 H4 H5 I L1 L2 L3 P1
Dimensions [mm]
Weight [g]
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
25
26,5
25,5
29,5
66
51
52
31
33
31
33
38,5
39,5
–
61
68,5
56,5
58,5
56,5
59
68
69
–
115
127
–
–
1
36
–
–
29
62
67
77
79
24
27
24
27
28
58
55,5
–
34
37
34
37
43,5
–
92
91
92
90
102
–
30,5
32,5
160
145
360
370
520
530
205
200
205
210
220
310
320
120 www.castel.it
These valves are available in the followingtwo 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 maybe shut off by the back-seating of thespindle;
– two-ways valves, 120° angle connections,type 6140.
The main parts of the receiver valves aremade with the following materials:
– hot forged brass EN 12420 – CW 617Nfor body;
– steel, with proper surface protection, forthe spindle;
– chloroprene rubber (CR) and aramidicfibers for gland seal;
– glass reinforced PBT for cap that coversthe spindle.
CONSTRUCTION
The receiver valves, shown in this chapter,are classified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2 of Directive 97/23/EC andreferred to in Directive 67/548/EEC).
APPLICATIONS
RECEIVER VALVES
TABLE 1: General Characteristics
CatalogueNumber
Kv Factor[m3/h]
–
1/4" f
–
3/8" f
–
1/4"
–
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"
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"
0,44
0,45
1,35
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
-60
+130
+110
+130
45 Art. 3.3
(1) (2) (3)
SAE Flare NPT
Connections
min.
TS [°C]
max.
PS[bar]
Risk Categoryaccording
to PED
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
H1
H2
L1
2
3
6110
L1
L2
H1
NPT
2
3
6120
H1
L2
L1
NPT
3
2
6140
L2L1
H1
H2
1
2
3 NPT
6132
NPT
H2
H1
L1
6110/X136110/X15
1
2
VALV
ES
121www.castel.it
TABLE 2: Dimensions and Weights
CatalogueNumber
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
70,5
72
83
77
87
88
92
128
27,5
30
33
40
56
63,5
57
48
50
55,5
88
–
29
36
–
27,5
29
31
34,5
42,5
72
77
80
93
94
130
94
97
112
115
69
–
48
50
55,5
88
64
75
46
100
110
130
135
130
140
175
220
235
245
675
110
130
140
225
305
245
670
240
250
375
365
115
125
H1 H2 L1 L2
Dimensions [mm]
Weight [g]
122 www.castel.it
The main parts of the stop valves are madewith 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.
The stop valves, shown in this chapter, areclassified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).
The very compact design of these brassvalves allows minimum dimensional sizesand the fixing flange complies with currentmarket requirements.Valves 6170 and 6175 must be completedwith the following devices, to be orderedseparately:– valve code 8394/A or code 8394/B;– cap with gasket code 8392/A.
CONSTRUCTION
APPLICATIONS
STOP VALVES
TABLE 1: General Characteristics
CatalogueNumber
Kv Factor[m3/h]
2
3
–
1/4"
1/4"
3/8"
3/8"
1/2"
5/8"
3/4"
7/8"
1/4"
3/8"
3/8"
1/2"
5/8"
3/4"
7/8"
–
16
–
0,68
1,70
1,70
3,40
4,60
9,00
10,80
-20 +110 45 Art. 3.3
Way Nr.
(1) (2) Ø[in.]
Ø[mm]
SAE Flare ODS (3)
Connections
min.
TS [°C]
max.
PS[bar]
Risk Categoryaccording
to PED
6165/22
6165/33
6175/33
6175/44
6175/55
6170/66
6170/77
VALV
ES
123www.castel.it
TABLE 2: Dimensions and Weights
CatalogueNumber
H1 H2 H3 Ø D L1 L2 L3 I
Dimensions [mm]
Weight [g]
6165/22
6165/33
6175/33
6175/44
6175/55
6170/66
6170/77
17
20
28,5
52
65
104
8
12
9,5
12,7
15,9
19
22,2
28,6
29
30,5
36
47
–
29
31
36
–
59,5
67
83
38
50
113
120
135
225
235
655
670
I I
L2
L3
H3
L1
H1
H2
L1
H3
H1
H2
�D�D
6170
6165 6175
� 6
.5
� 6
.5
2 2
3 3
1
124 www.castel.it
Diaphragm valves don’t have gland seal.The external sealing is ensured by somethin metal discs (diaphragms), whichhermetically divide the spindle chamberfrom the fluid flow area.
The main parts of the hermetic valves aremade 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.
CONSTRUCTION
The diaphragm valves, shown in thischapter, are classified “Pressureaccessories” in the sense of the PressureEquipment 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 oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).
APPLICATIONS
DIAPHRAGM VALVES
TABLE 1: General Characteristics
CatalogueNumber
Kv Factor[m3/h]
1/4"
3/8"
1/2"
5/8"
3/4"
–
–
–
1/4"
3/8"
1/2"
5/8"
3/4"
7/8"
–
16
–
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
Ø[in.]
Ø[mm]
SAE Flare(1)
ODS (2)
Connections
min.
TS [°C]
max.
PS[bar]
Risk Categoryaccording
to PED
6210/2
6210/3
6210/4
6210/5
6210/6
6220/2
6220/3
6220/4
6220/5
6220/6
6220/7
VALV
ES
125www.castel.it
TABLE 2: Dimensions and Weights
Catalogue Number
6210/2
6210/3
6210/4
6210/5
6210/6
6220/2
6220/3
6220/4
6220/5
6220/6
6220/7
68
72
86
68
72
86
53,5
62,5
53,5
62,5
58
74
78
98
53
61
70
71
92
94
4,5
6,2
4,5
6,2
36
38
50
36
38
50
52
60
52
60
200
325
335
340
655
195
300
305
580
645
H1 H2 L1 d I D
Dimensioni [mm]
Weight [g]
D
L1
d
H1
H2
I
D
H2
H1
d
L1
I
A94 A94
2 2
6210 6220
1 1
6310
Valves
6320
7990
Gasket
7910
Coupling
126 www.castel.it
The main parts of the hermetic valves aremade 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.
The rotalock valves, shown in this chapter,are classified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).
Rotalock valves, mounted with 7910 fittingsand 7990 gaskets, assure fast installationand safe sealing.Before tightening it is possible to turn thevalve in every direction.All Rotalock valves have an additionalcharging connection, which can beexcluded by the back sealing of the spindle.Fittings 7910 and gaskets 7990 have to beordered separately.
CONSTRUCTION
APPLICATIONS
ROTALOCK VALVES
TABLE 1: General Characteristics
CatalogueNumber
Kv Factor[m3/h]
1/4"
1/4"
3/8"
1/2"
3/8"
1/2"
5/8"
3/4"
3/4"
UNF
1"
UNS
0,46
1,35
1,40
3,10
3,4
-60 +110 45 Art. 3.3
(1) (2) (3)
SAE Flare Swivel nut
Connections
min.
TS [°C]
max.
PS[bar]
Risk Categoryaccording
to PED
6310/2
6310/3
6310/4
6320/3
6320/4
6320/5
6320/6
L2
L1
H1
H2
6310 6320
12
3
VALV
ES
127www.castel.it
TABLE 2: Dimensions and Weights
CatalogueNumber
6310/2
6310/3
6310/4
6320/3
6320/4
6320/5
6320/6
68,5
69,5
72
33,5
34,5
36,5
94
97
114,5
117,5
64
77,5
290
300
330
400
415
425
H1 H2 L1 L2
Dimensions [mm]
Weight [g]
128 www.castel.it
The brazing of capped valves with solderconnections, type 6420, should be carriedout with care, using a low melting point fillermaterial. It‘s necessary to remove thespindle assembly, with gland too, beforebrazing the body. It’s important to avoiddirect contact between the torch flame andthe valve body, which could be damagedand compromise the proper functioning ofthe valve.
INSTALLATION
The capped valves, shown in this chapter,are classified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).
The main parts of the capped valves aremade 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.
CONSTRUCTION
APPLICATIONS
CAPPED VALVES
TABLE 1: General Characteristics
CatalogueNumber
Kv Factor[m3/h]
1/4"
3/8"
1/2"
5/8"
3/4"
–
1/4"
–
1/4"
–
1/4"
3/8"
–
1/2"
5/8"
–
3/4"
–
7/8"
–
–
10
12
–
16
18
–
22
–
0,40
1,00
1,45
1,70
3,50
0,40
1,00
1,45
1,70
3,50
0,35
-60 +110 45 Art. 3.3
Ø[in.]
Ø[mm]
SAE Flare
(2)(1)
ODS (3)
Connections
min.
TS [°C]
max.
PS[bar]
Risk Categoryaccording
to PED
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
Until exhaustion of the stockE
L1
d
L1
H2
H1
I
d
IH
1H
2
A94 A94
L3
L1
45°
d
L2
I
P1
H1
H2
A
C
B
1 1
1
1
2
3 3
6410 6420 6460/22A
VALV
ES
129www.castel.it
TABLE 2: Dimensions and Weights
CatalogueNumber
H1 H2 L1 L2 L3 P1 d I
Dimensions [mm]
Weight [g]
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
113
85,5
113
85,5
67
89,5
67
89,5
67
68
74
78
98
57
61
70
71
92
94
97
–
34
–
51
–
35
4,5
6,2
4,5
6,2
4,5
38
50
38
50
38
305
325
330
695
300
305
700
685
690
395
N.B. When the valve 6460/22A is closed, connections A-B are open and C is stopped; when opened, all connections are open.
These valves are available in the followingtwo types:– 6512 with straight solder connections;– 6532 with solder angle connections;The main parts of the globe valves aremade with the following materials:– hot forged brass EN 12420 – CW 617N
for body, cover and cap that covers thespindle;
– steel, with proper surface protection, forthe spindle;
– chloroprene rubber (CR) and aramidicfibers for gland seal;
– metal-rubber laminated for outlet sealgaskets
– P.T.F.E. for seat gaskets.
CONSTRUCTION
The globe valves, shown in this chapter,are classified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of thesame Directive.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section2.2 of Directive 97/23/EC and referred to inDirective 67/548/EEC).
APPLICATIONS
GLOBE VALVES
TABLE 1: General Characteristics
CatalogueNumber
Kv Factor[m3/h]
–
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"
22
–
28
–
35
–
42
54
22
–
28
–
35
–
42
54
–
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"
–
28
–
35
35
–
–
–
–
28
–
35
35
–
–
–
–
7,1
8,4
15,0
25,0
40,00
8,2
9,1
18,7
38,0
48,5
-35 +160 45
Art. 3.3
I
Art. 3.3
I
Ø[in.]
Ø[mm]
ODS
Ø[mm]
Ø[in.]
ODM
Connections
min.
TS [°C]
max.
PS[bar]
Risk Categoryaccording
to PED
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
130 www.castel.it
H1
L1
L
H
A
Q
6532
H1
H
L
M10
A
Q
6512
TABLE 2: Dimensions and Weights
CatalogueNumber
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
136
166
199
215
147
165
238
28,5
34
37
42,5
44,5
52,5
65
100
118
141
173
80
93
139
–
50
59
86,5
60
68
88
104
60
68
104
94
126
138
94
126
138
1415
1310
2020
3500
5050
1350
1290
1910
4920
4765
H H1 L L1 Q A
Dimensions [mm]
Weight [g]
VALV
ES
131www.castel.it
132 www.castel.it
BALL VALVES
6590
The ball valves, shown in this chapter, areclassified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and on civiland industrial conditioning plants, which userefrigerant fluids proper to the Group II (asdefined in Article 9, Section 2.2 of Directive97/23/EC and referred to in Directive67/548/EEC).
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, theassembly on the plant without taking intoaccount the direction of the refrigerant;
– prevents any risk of ejection or explosionof the spindle.
The opening and closing of the valve isrealized by turning the spindle one fourth of aturn. A standstill in turning realizes either afull opening or a full closing, moreover thearrow printed on the spindle head shows theflow direction.The electric welding of the bodies and theseal gaskets, assembled on the spindle,
CONSTRUCTION
APPLICATIONS prevent any leaks.Ball valves are available in the following twotypes:– 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 valvecore 8394/A and cap 8392/A.
The main parts of the valves are made withthe 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 from6590/M64A up to 6591/34A.
The brazing of ball valves should be carriedout with care, using a low melting point fillermaterial. It is important to avoid direct contactbetween the torch flame and the valve body,which could be damaged and compromisethe proper functioning of the valve.
INSTALLATION
VALV
ES
133www.castel.it
TABLE 1: General Characteristics
withoutaccessfitting
withaccess fitting
Catalogue Number
Kv Factor[m3/h]
–
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"
6
–
–
10
12
–
16
15
16
18
–
22
22
28
–
28
–
35
35
–
42
–
42
54
54
64
–
64
–
80
89
–
105
108
10
15
19
25
32
38
50
65
80
0,8
3,0
5,0
14,5
24,0
40,0
68,0
100,0
178,0
293,0
430
-40 +150
45
42
Art. 3.3
I
Ø[in.]
Ø[mm]
Ball PortØ [mm]
ODS
Connections
min.
TS [°C]
max.
PS[bar]
Risk Categoryaccording
to PED
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
–
6590/M28A
6590/9A
–
6590/11A
–
6590/13A
6590/M42A
–
6590/17A
6591/M64A
6591/21A
6590/M64A
6590/21A
6591/24A
6591/25A
6590/25A
6591/28A
6591/29A
6591/33A
6591/34A
134 www.castel.it
L2
H2
L1
L
d
I
H1
H
6590/..A
TABLE 2: Dimensions and Weights
CatalogueNumber
H H1 H2 L L1 L2 I d
Dimensions [mm]
Weight [g]
–
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
6590/25A
6591/28A
6591/29A
6591/33A
6591/34A
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
–
73
80
95,5
101,5
117
130
150
172,5
196,5
20
24
27,5
–
30
38
45
55
62
75
–
33
–
36
–
38
–
41
–
45
–
48
–
53
64
70
121
138
141
177
175
206
206
248
247
262
292
303
330
350
380
400
65
73,5
74
92
93
108,5
109
130
129
136
151
162
175
185
199
209
–
24
–
32
–
33
–
43
–
49
–
49
–
58
58
68
76
86
18
30
75
M5
M6
M10
260
300
290
410
450
760
800
1050
2050
3320
3240
5450
5500
8120
8090
8310
8350
12400
12450
12500
8320
Ch.19
8321
H1
34
Ø 6.5
L1
L3
L2
H1Ø 6.5
L3
L2
L1
34
VALV
ES
135www.castel.it
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 thegauge.
The main parts of this valve are made withthe 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.
CONSTRUCTION
GAUGE MOUNTING VALVES
TABLE 1: General Characteristics, Dimensions and Weight
CatalogueNumber
1/4"
1/4"
1/4"
1/8"
1/4"
–
19
37
40
-60 +130 45 Art. 3.3
H1SAEFlare NPT
–
–
1/4" f
SAEFlare
Connections Dimensions [mm]
min.
TS [°C]
max.
PS[bar]
Risk Categoryaccording
to PED
8320/21
8320/22
8321/22
83
L1
35
L2
17
L3
140
186
Peso[g]
The valves, shown in this chapter, areclassified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC). They are used formounting and intercepting the gauges oncontrol panels.
APPLICATIONS
136 www.castel.it
The main parts of the piercing valve aremade 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.
The threaded fork must be installed astrideof the copper tube, the valve is fastened tothe pipe by tightening the lower nut andscrewing it the needle pierces the pipe. Thehole, pierced by the needle, connects thepipe inlet with the SAE-Flare connection asshown in figures 1 and 2.
INSTALLATION
CONSTRUCTION
The valve, shown in this chapter, is classified“Pressure accessories” in the sense of thePressure Equipment Directive 97/23/EC,Article 1, Section 2.1.4 and are subject ofArticle 3, Section 1.3 of the same Directive.It is designed for installation on commercialrefrigerating systems and on civil andindustrial conditioning plants, which userefrigerant fluids proper to the Group II (asdefined in Article 9, Section 2.2 of Directive97/23/EC and referred to in Directive67/548/EEC).The piercing valve is a fast and cheap meansof providing a loading, outlet or inlet point inthe refrigerating system. It can be applied oncopper tube with a 6 mm to 10 mm diameter,and can be installed in any position on thesystem.
APPLICATIONS
LINE PIERCING VALVE
TABLE 1: General Characteristics, Dimensions and Weight
CatalogueNumber
1/4" 6 - 10 72 -10 +70 25 Art. 3.3
H1SAEFlare
Pipe diameter
[mm]
Connections Dimensions [mm]
min.
TS [°C]
max.
PS[bar]
Risk Categoryaccording
to PED
8330/A 25,5
L1
29
L2
36
L3
104
Weight[g]
L2
L1
H2
H1
open
ed v
alve
1/4"SAE flareFig. 1 - The valve is installed with the threaded forkastride of the copper pipe to be pierced.
Fig 2 - Tightening of lower screw nut.
137
THREADED BRASS FITTINGS
138 www.castel.it
connection/adapter system only interposingthe copper gasket 7580, supplied with thesame adapter.Flange joints 7630 consist of two brassbushes 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.
All nuts, from series 7010 to series 7050,and all the elbows, TEE and cross fittings,from series 7210 to series 7410, aremanufactured with hot forged brass EN 12420 – CW 617N.All straight fittings, from series 7110 toseries 7170, and all the plug, from series7510 to series 7520, are machined by brassbar 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 aremade with the following materials:– hot forged brass EN 12420 – CW 617N
for bushes and flanges;– aramidic fibers for seal gasket of the
flanges.
CONSTRUCTION
All the fittings, shown in this chapter, areexcluded from the scope of Directive97/23/EC, as specified in the Guidelines 1/8and 1/9, because they are pipingcomponents.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).
The sealing system between the end of amale connection and a nut series 7010,7020 and 7030 requires a special flaring ofthe end of copper tube, the so-called flaredconnection.The sealing system between the end of amale connection and a Flare-ODS adapterallows avoiding the flaring process oncopper tube end (national laws of someEuropean countries don’t accept thisoperation) because the tube end is brazedinto the solder connection of the adapter. We wish to remember to our customers thatthey may assure no leakage of the male
OPERATION
APPLICATIONS
THREADED BRASS FITTINGS
L
� D
Ch
TH
RE
AD
ED
BR
AS
S FIT
TIN
GS
139www.castel.it
TABLE 1: General Characteristics
CatalogueNumber
InternationalReference
SAE Flare Ø
[in]Ø
[mm]
PS [bar]
Ø D L Ch
Copper pipe Dimensions [mm]Wrenchtorque
min / max[Nm]
Weight[g]
7010/22
7010/33
7010/44
7010/55
7010/66
7010/77
7010/88
NS4–4
NS4–6
NS4–8
NS4–10
NS4–12
NS4–14
NS4–16
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
SAE Flare nuts (inch tubing)
L
Ch
7020/20
7020/X01
N5–4
CAP NUT
N5-5
CAP NUT
1/4"
5/16"
cieco cieco 45 –
15,5
16
17
19
11 / 14
14 / 20
20
25
SAE Flare cap nuts
L
� D
Ch
7020/32
7020/43
7020/54
7020/65
7020/87
NRS4–64
NRS4–86
NRS4–108
NRS4–1210
NRS4–1614
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
SAE Flare reducing nuts (inch tubing)
L
� D
Ch
7030/3M8
7030/3M10
7030/4M10
7030/4M12
7030/4M14
7030/5M12
7030/5M14
7030/6M14
7030/6M18
–
3/8"
1/2"
5/8"
3/4"
–
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
19,5
22,5
25
29,5
22
25
28
33
20 / 25
34 / 47
54 / 75
68 / 71
37
36
53
50
47
70
68
106
98
SAE Flare nuts (metric tubing)
L
Ch
7050/2
7050/3
7050/4
7050/5
US4–4
US4–6
US4–8
US4–10
1/4"
3/8"
1/2"
5/8"
45 –
32
40
46
51
17
22
25
28
11 / 14
20 / 25
34 / 47
54 / 75
39
78
105
140
SAE Flare twin nuts
– –
140 www.castel.it
L
Ch
TABLE 2: General Characteristics
CatalogueNumber
InternationalReference
SAE Flare NPT
PS [bar]
L Ch
Connections Dimensions [mm]
Weight[g]
7110/2
7110/3
7110/4
7110/5
7110/6
7110/8
U2–4
U2–6
U2–8
U2–10
U2–12
U2–16
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
SAE Flare unions
L
Ch
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
20
23
23
27
38
58
66
89
98
170
Reducing SAE Flare unions
L
Ch
7130/2
7130/3
7130/4
7130/6
7130/8
U1–4B
U1–6C
U1–8D
U1–12F
U1–16H
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
SAE Flare / NPT unions
L
Ch
7140/21
7140/32
7140/43
7140/54
U1–4A
U1–6B
U1–8C
U1–10D
1/4"
3/8"
1/2"
5/8"
1/8"
1/4"
3/8"
1/2"
45
32,9
41,1
45,2
53,8
12
17
20
23
20
39
64
102
SAE Flare / NPT reducing unions
Available on request
Until exhaustion of the stockE
R
7120/23
7120/24
7120/34
7120/35
7120/45
7120/56
UR2–64
UR2–84
UR2–86
UR2-106
UR2–108
UR2-1210
E
R
R
R
TH
RE
AD
ED
BR
AS
S FIT
TIN
GS
141www.castel.it
L
L
L
L
L
L
Ch
Ch
Ch
Ch
Ch
Ch
TABLE 3: General Characteristics
CatalogueNumber
InternationalReference SAE Flare ODS
m fNPT GAS
Ø[in.]
Ø[mm]
PS [bar]
L Ch
Connections Dimensions [mm]
Weight[g]
7150/21
7150/32
7150/43
7150/54
7150/64
7150/65
U3–4A
UR3–46
UR3–68
UR3–810
UR3–812
UR3–1012
1/4"
3/8"
1/2"
5/8"
5/8"
3/4"
–
1/4"
3/8"
1/2"
1/2"
5/8"
1/8" f
–– – – 45
29
33
38
45
46,5
49,5
14
17
22
25
27
30
21
38
66
99
132
157
Male/female reducing unions (reduced female)
7150/23
7150/24
7150/34
7150/45
7150/46
7150/56
UR3–64
UR3–84
UR3–86
UR3–108
UR3–128
UR3–1210
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
Male/female reducing unions (reduced male)
7154/2
7156/2
–
1/4"
1/4"
20 – 14 filetti sx. femmina
W 21,8 – 14 filetti dx. femmina
45 29
25
27
46
52
Cylinder adaptors
7160/2
7160/3
7160/4
R –
1/4"
3/8"
1/2"
1/4"
3/8"
1/2"
– – – – 45
30,5
36
41
17
22
25
31
57
84
Male/female unions
7164/2
7166/2
–
1/4"
–
–
1/4"
–
G1/4"
f
G1/4"
m
– – 45
32,5
32
20
17
45
25
Unions SAE Flare to BSP
7170/22
7170/2M8
7170/33
7170/3M10
7170/44
7170/4M12
7170/55
7170/6M18
US3–44
–
US3–66
–
US3–88
–
US3–1010
–
1/4"
3/8"
1/2"
5/8"
3/4"
– – –
1/4"
–
3/8"
–
1/2"
–
5/8"
–
–
8
–
10
–
12
16
18
45
26,5
33
35
42
45,5
12
17
20
23
27
17
39
55
82
123
Male SAE Flare/solder unions
Available on requestR
Copper seal
Copper pipe
Flare/ODS fitting
Nut Connection
SAE/Flare connection
L1L4 L3
L2
POS.3
142 www.castel.it
TABLE 3: General Characteristics
Item
Po
sitio
n
CatalogueNumber SAE
Flare
ODS
Ø[in.]
Ø[mm]
PS [bar]
L1 L2 L3 L4 Ch
Connections Dimensions [mm]
Weight [g]
Wrenchtorque
min/max[Nm]
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
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
1/4"
1/4"
3/8"
3/8"
1/2"
1/2"
5/8"
3/4"
3/4"
1/4"
–
3/8"
–
1/2"
–
5/8"
3/4"
–
–
6
–
10
–
12
16
–
18
45
–
21
–
21
–
23,5
–
23,5
–
26
–
–
26
–
27,5
–
30
–
30
–
3,5
–
3,5
–
4
–
4
–
4,5
–
–
4,5
–
5
–
5
–
5
16
–
–
16
–
–
18,5
–
–
18,5
–
–
21
–
–
21
–
–
22,5
–
–
25
–
–
25
–
–
12,5
–
12,5
–
14,7
–
14,7
–
17
–
–
17
–
18
–
20
–
20
–
17
–
17
–
22
–
22
–
27
–
–
27
–
30
–
36
–
36
–
67
83
114
130
207
226
271
404
455
11/14
–
11/14
–
20/25
–
20/25
–
34/47
–
34/47
–
54/75
–
68/71
–
68/71
–
Flare / ODS adapters
TH
RE
AD
ED
BR
AS
S FIT
TIN
GS
143www.castel.it
H
L
TABLE 5: General Characteristics
CatalogueNumber
InternationalReference SAE Flare
m fNPT
PS [bar]
H L
Connections Dimensions [mm]
Weight[g]
7210/2
7210/3
7210/4
7210/5
7210/6
E2–4
E2–6
E2–8
E2–10
E2–12
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
SAE Flare elbows
L
H
7220/2
7220/3
7220/4
7220/6
E1–4B
E1–6C
E1–8D
E1–12F
1/4"
3/8"
1/2"
3/4"
–
1/4"
3/8"
1/2"
3/4"
45
26
29,5
32,5
42,5
24
28,5
32
39,5
33
54
91
183
SAE Flare / NPT elbows
L
H
7230/21
7230/32
7230/43
7230/54
E1–4A
E1–6B
E1–8C
E1–10D
1/4"
3/8"
1/2"
5/8"
–
1/8"
1/4"
3/8"
1/2"
45
26
29,5
32,5
36
21
29,5
31
35
30
46
75
114
SAE Flare / reduced NPT elbows
H
L
7240/2
7240/3
7240/4
–
1/4"
3/8"
1/2"
1/4"
3/8"
1/2"
– 45
28,5
32
39,5
28
31
38
56
84
198
Male/female SAE Flare elbows
144 www.castel.it
TABLE 6: General Characteristics
CatalogueNumber
InternationalReference SAE Flare
(1) (2) (3) (4)
NPT(3)
PS [bar]
H L
Connections Dimensions [mm]
Weight[g]
H
L
7310/2
7310/3
7310/4
7310/5
7310/6
T2–4
T2–6
T2–8
T2–10
T2–12
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
SAE Flare TEE
H
L
7320/223
7320/334
7320/445
7320/556
TR2–46
TR2–68
TR2–810
TR2–1012
1/4"
3/8"
1/2"
5/8"
1/4"
3/8"
1/2"
5/8"
3/8"
1/2"
5/8"
3/4"
– – 45
29
32,5
38
41,5
56
63
72
83
77
95
153
228
SAE Flare reducing TEE (reduced side connections)
H
L
7320/332
7320/443
7320/554
7320/665
TR2–64
TR2–86
TR2–108
TR2–1210
3/8"
1/2"
5/8"
3/4"
3/8"
1/2"
5/8"
3/4"
1/4"
3/8"
1/2"
5/8"
– – 45
28
32,5
38
41,5
58
63
72
83
77
101
158
220
SAE Flare reducing TEE (reduced central connection)
H
L
7330/221
7330/222
T1–4A
T1–4B
1/4"
1/4"
1/4"
1/4"
– –
1/8"
1/4"
45
28,5
39,5
28
38
56
198
SAE Flare / NPT TEE (taper central connection)
H
L
7340/222 T6–4 1/4" 1/4" 1/4" – – 45 27,5 56 78
Male/female SAE Flare TEE (female central connection)
H
L
7410/2 C1–4 1/4" 1/4" 1/4" 1/4" – 45 52 52 55
SAE Flare cross
TABLE 7: General Characteristics
CatalogueNumber
InternationalReference SAE
Flare NPTODS
Ø[in.]
Ø[mm]
PS [bar]
H L Ch
Connections Dimensions [mm]Wrenchtorque
min / max[Nm]
Weight[g]
L
Ch
7520/1
7520/2
7520/3
7520/4
7520/6
7520/8
121–B–02
121–B–04
121–B–06
121–B–08
121–B–12
121–B–16
–
1/8"
1/4"
3/8"
1/2"
3/4"
1"
– – 45 –
15,9
23,1
23,2
29,8
32,1
39
12
14
17
22
27
34
10 / 13
15 / 20
17 / 22
25 / 35
30 / 40
60 / 80
12
27
43
87
149
279
NPT plugs
L
Ch
7510/2
7510/3
7510/4
P2–4
P2–6
P2–8
1/4"
3/8"
1/2"
– – – 45 –
23
26
30
12
17
20
11 / 14
20 / 25
34 / 47
19
40
67
SAE Flare plugs
7560/2
7560/3
7560/4
7560/5
7560/6
7560/7
B1–4
B1–6
B1–8
B1–10
B1–12
B1–14
1/4"
3/8"
1/2"
5/8"
3/4"
7/8"
– – – 45 – – – –
0,5
1
1,5
2
4
10
Copper seal caps
7580/2
7580/3
7580/4
7580/5
7580/6
B2–4
B2–6
B2–8
B2–10
B2–12
1/4"
3/8"
1/2"
5/8"
3/4"
– – – 45 – – – –
0,5
0,5
1
1,5
3
Copper gaskets
L
H H 7630/7
7630/9
7630/11
7630/13
7630/M42
7630/17
– – –
7/8"
1.1/8"
1.3/8"
1.5/8"
–
2.1/8"
–
–
35
–
42
54
45
23
24
25
63
67
71
–
20 / 24
42 / 50
68 / 80
315
490
1045
1340
1940
Flange joints
TH
RE
AD
ED
BR
AS
S FIT
TIN
GS
145www.castel.it
147
COPPER BRAZE-JOINT PRESSURE FITTINGS
148 www.castel.it
Reinforced series 79 show the followingselection of copper braze-joint fittings, withODS / IDS millimeters connections, limitedto 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
Dimensions and tolerances of the ODS / IDSconnections ends in copper braze-jointfittings series 77, 78 and 79 are incompliance with the EN 1254-1 : 1998Standard.All copper braze-joint fittings series 77, 78and 79 are made of seamless copper tubeEN 12735-2 – CW024A, soft annealed.Technical characteristics of copper fittingsseries 77 and 78, depending on tubenominal diameters, are given in table 1,while technical characteristics of copperfittings series 79, always depending onnominal diameters, are given in table 2.Copper braze-joint fittings series 77, 78 and79, if submitted to ambient-temperatureburst test, guarantee a pressure strength atleast equal to 3 x PS (30 °C rated working-pressure as shown in tables 1 and 2)according to ASME B16.50 : 2001 Standard.
CONSTRUCTION
All the fittings, shown in this chapter, areexcluded from the scope of Directive97/23/EC, as specified in the Guidelines 1/8and 1/9, because they are pipingcomponents.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,made of seamless copper tube specified inEN 12735-1 : 2001 Standard, which userefrigerant fluids proper to the Group II (asdefined in Article 9, Section 2.2 of Directive97/23/EC and referred to in Directive67/548/EEC).
Series 77 show the following selection ofcopper braze-joint fittings, with ODS / IDSmillimeters connections, practically in alldiameter 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 ofcopper braze-joint fittings, with ODS / IDSinch connections, limited to few diameterdimensions:– 7832 Tees and reducing tees
PRODUCTS RANGE
APPLICATIONS
COPPER BRAZE-JOINT PRESSURE FITTINGS
CO
PP
ER
BR
AZ
E-JO
INT
PR
ES
SU
RE
FITT
ING
S
149www.castel.it
The internal working pressure-temperaturerating for a copper fitting, is dependentupon, not only fitting strength, but also theadopted joining process and the used fillermetal. The working pressure-temperaturevalues given in tables 1 and 2 are referred toa brazing process, performed in accordancewith the sound engineering practice.We wish to remember the definition ofbrazing process, given in EN 13133 : 2000Standard.“The process of joining generally applied tothe joining of materials by a heating processduring which the parent materials do notmelt and the filler metal is drawn into thejoint by capillary action. It is generallyapplicable to joining systems where the fillermetal melts at 450 °C or above”.In actual practice brazing is done attemperatures ranging from 630 to 820 °Cand there are two general types of brazingfiller metals, normally used for joiningcopper tube:– Copper – Phosphorus alloys (the so
called B-CuP), proper to CP Class of EN1044 : 1999 Standard, that are normallyused without fluxes;
– Silver alloys (the so called B-Ag), properto AG Class of EN 1044 : 1999, that mustbe used with their specific fluxes.
INSTALLATION TABLE 1
Tube Nominal Diameter
6
–
8
–
10
12
–
14
15
16
18
22
–
28
–
35
–
42
54
64
–
67
76
–
80
89
106
–
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"
–
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
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
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
[mm] [in.] -40 / 30 °C 95 °C 150 °C
Working Pressure PS [bar],depending on temperature
TABLE 2
Tube Nominal Diameter
22
3/4
28
3/4
35
3/4
42
54
7/8”
1”
3/4
1.1/8”
1.3/8”
1.5/8”
3/4
2.1/8”
60
55
50
50
50
40
40
35
80
73
67
67
67
53
53
47
50
45
40
40
40
35
35
30
[mm] [in.] (1) (2) (1)
67
60
53
53
53
47
47
40
45
41
37
37
37
30
30
26
60
55
49
49
49
40
40
35
(2) (1)
-40 / 30 °C 150 °C 95 °C
(2)
Working Pressure PS [bar], depending on temperature
(1) PS values listed in this column are referred to a safetycoefficient 4, according to ASME B16.50 : 2001 Standard
(2) PS values listed in this column are referred to a safetycoefficient 3, minimum value warranted by Castel for all itsproducts
Note: working pressures shown in this table are in comparison with rated working pressures established in ASME B16.50 : 2001 Standard.
150 www.castel.it
TABLE 3: General Characteristics
International Code
Catalog Number IDS
Ø[mm]
ODSØ
[mm]
Weight [g] Note
Connections
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 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
Female to female reducing couplings (metric tubing)
CO
PP
ER
BR
AZ
E-JO
INT
PR
ES
SU
RE
FITT
ING
S
151www.castel.it
TABLE 4: General Characteristics
International Code
Catalog Number IDS
Ø[mm]
ODSØ
[mm]
Weight [g] Note
Connections
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/M6
= 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
Male to female reducing couplings (metric tubing)
152 www.castel.it
TABLE 5: General Characteristics
International Code
Catalog Number IDS
Ø[mm]
ODSØ
[mm]
Weight [g] Note
Connections
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° female 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
90° male to female elbows - short radius (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° female 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
– –
22
28
35
42
54
80
33
57
124
167
288
800
45° male to female elbows (metric tubing)
CO
PP
ER
BR
AZ
E-JO
INT
PR
ES
SU
RE
FITT
ING
S
153www.castel.it
TABLE 6: General Characteristics
International Code
Catalog Number IDS
Ø[mm]
ODSØ
[mm]
Weight [g] Note
Connections
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° female 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
90° male to female elbows - long radius (metric tubing)
154 www.castel.it
TABLE 7: General Characteristics
International Code
Catalog Number IDS
Ø[mm]
ODSØ
[mm]
Weight [g] Note
Connections
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
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
Reducing tees (metric tubing)
CO
PP
ER
BR
AZ
E-JO
INT
PR
ES
SU
RE
FITT
ING
S
155www.castel.it
TABLE 8: General Characteristics
International Code
Catalog Number IDS
Ø[mm]
ODSØ
[mm]
Weight [g] Note
Connections
7832/222
7832/333
5130/222
7832/333
–
1/4"
3/8
1/4"
3/8
1/4"
3/8
8
8
Tees (inch tubing)
7832/232
7832/323
5130/232
7832/323
–
1/4"
3/8
3/8"
1/4"
1/4"
3/8
11
14
Reducing tees (inch tubing)
156 www.castel.it
TABLE 9: General Characteristics
International Code
Catalog Number IDS
Ø[mm]
ODSØ
[mm]
Note
Connections
7900/M22
7900/M28
7900/M35
7900/M42
7900/M54
– – –
22
28
35
42
54
22
28
35
42
54
Female to female couplings, reinforced series (metric tubing)
7916/M22
7916/M28
7916/M35
7916/M42
7916/M54
– – –
22
28
35
42
54
22
28
35
42
54
45° female to female elbows, reinforced series (metric tubing)
7917/M22
7917/M28
7917/M35
7917/M42
7917/M54
–
22
28
35
42
54
– –
22
28
35
42
54
45° male to female elbows, 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
Female 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
Male to female reducing couplings, reinforced series (metric tubing)
CO
PP
ER
BR
AZ
E-JO
INT
PR
ES
SU
RE
FITT
ING
S
157www.castel.it
TABLE 10: General Characteristics
International Code
Catalog Number IDS
Ø[mm]
ODSØ
[mm]
Note
Connections
7918/M22
7918/M28
7918/M35
7918/M42
7918/M54
– – –
22
28
35
42
54
22
28
35
42
54
90° female to female elbows - long radius, reinforced series (metric tubing)
7919/M22
7919/M28
7919/M35
7919/M42
7919/M54
– – –
22
28
35
42
54
22
28
35
42
54
90° male to female elbows - long radius, reinforced series (metric tubing)
7932/M22
7932/M28
7932/M35
7932/M42
7932/M54
– –
22
28
35
42
54
22
28
35
42
54
22
28
35
42
54
Tees, reinforced series (metric tubing)
159
ACCESS FITTINGS & VALVE CORES
160 www.castel.it
The straight fittings are machined byhexagonal brass bar EN 12164 – CW 614N.The TEE and cross fittings are manufacturedwith hot forged brass EN 12420 – CW 617N.The main parts of the valve cores are madewith 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.
CONSTRUCTION
All the access fittings and valve cores,shown in this chapter, are excluded from thescope of Directive 97/23/EC, as specified inthe Guidelines 1/8 and 1/9, because theyare piping components.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).The access fittings allow to create a loadingor draining point rapidly and with aminimum expense.After completion of the loading or drainingoperations, the cap with gasket (cod. 8392/A) prevents any leakage.For particular customer’s requirements, the 7020/20 flare blind nut with combined8580/2 copper flare gasket may replace the 8392/A cap.This solution requires to screw the nut witha torque wrench at 8,5 ÷ 11,5 Nm.For system using R410A refrigerant, Castelhas developed three specific access fittingswith 5/16” SAE-Flare connection (codes8350/X09 , 8351/X05 and 8351/X07) thathave 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 nutwith a torque wrench at 8,5 ÷ 11,5 Nm.
The valve consists of a body that can havedifferent shapes and sizes, according to thedifferent requirements of the customers.Inside the valve, the valve core seat ismanufactured according to the ARI STANDARD 720:1997.When the internal valve core has beeninserted through the fitting, by the mountingtool (code 8390/A), the fluid flows justacting on the valve needle.
OPERATION
APPLICATIONS
ACCESS FITTINGS & VALVE CORES
Nut
Gasket
Valve core
Fitting
Access fitting with inserted valve core
L
Ch
L
Ch
L
Ch
L
Ch
L
Ch
Ch
L
L
Ch
L
Ch
AC
CE
SS
FITT
ING
S &
VALV
E C
OR
ES
161www.castel.it
TABLE 1: General Characteristics
CatalogueNumber SAE Flare ODS IDS
m fNPT
Ø[in.]
Ø[in.]
Ø[mm]
Ø[mm]
PS [bar]
L Ch D H
Connections Dimensions [mm]
8350/22 1/4" –
–
–
–
–
–
–
–
–
–
–
–
1/4" – – – 26 11 – –
Straight access fittings
8350/X01 1/4" – 6 3/8" – 20 11 – –
1/4" – – – 6
90
130
11 – –
L
H
D
Ch8350/X09 5/16" 1/4" – – – 27 14 9,4 2,1
8351/2
8351/X04
8351/X05
8351/X07
1/4"
5/16"
–
6
–
–
–
3/8"
8-10
6
7
6
30
26
27
11
14
– –
8351/X02 1/4" – 5
1/4"
–
3/8"
8 26 11 – –
8352/22 1/4" – – – – – – 31 11 – –
1/4" –
1/8"
1/4"
3/8"
– – – –
28
33
38
11
14
17
– –
1/4" 1/4" – – – – – 35 17 – –
8354/21
8354/22
8354/23
8362/22
8350/X03
8350/X11
45
162 www.castel.it
TABLE 2: General Characteristics
CatalogueNumber SAE Flare IDS
m fNPT
Ø[in.]
Ø[mm]
PS [bar]
L Ch D H
Connections Dimensions [mm]
Note
H
L
L
H
1/4" – – – 6
45
43 – – 24
The valve core may be installed on each of the two 1/4" SAE Flareconnections.
8380/122 1/4" – 1/8" – – 45 – – 24
TEE access fittings
8380/X01
H
L
1/4" 1/4" – – – 35
50
49
– – 30
With valve-core openingdevice on femaleconnection.The valve core may beinstalled on each of thetwo 1/4" SAE Flareconnections.
The valve core may beinstalled on each of thetwo 1/4" SAE Flareconnections.
TEE access fittings with swivel nuts
8380/X06
8380/X08
AC
CE
SS
FITT
ING
S &
VALV
E C
OR
ES
163www.castel.it
TABLE 3: General Characteristics
CatalogueNumber SAE Flare IDS
m fNPT
Ø[in.]
Ø[mm]
PS [bar]
L Ch D H
Connections Dimensions [mm]
Note
L
H
L
H
L
H
1/4" – 1/8" – –
45
48 – – 50
The valve core may beinstalled on each of thethree 1/4" SAE Flareconnections.
1/4" – 1/4" – – 48 – – 50
Cross access fittings
1/4" – – – 6 48 – – 44
8382/1222
L
H
1/4" 1/4" – – – 35 50 – – 46
With valve-core openingdevice on femaleconnection.The valve core may beinstalled on each of thethree 1/4" SAE Flareconnections.
Cross access fittings with swivel nuts
8382/X04
8382/X02
8382/X03
164 www.castel.it
TABLE 4: General Characteristics
CatalogueNumber SAE Flare IDS
m fNPT
Ø[in.]
Ø[mm]
PS [bar]
L Ch D H
Connections Dimensions [mm]
Note
L
� D
L– – – – – – 75 – – –8390/A
L
� D
– 1/4” – – – 35
13
– 13 –
Caps with gasket
8392/A
22 The key needs to remove the valve core.8392/B
– – – – –
(1)
(2)
(3)
– – – –
Outside spring.Torque wrench 0,25 / 0,30 Nm.(1) Static pressure: 40 [bar](1) Working pressure: 28 [bar]
8394/A
Inside spring. Torque wrench 0,20 / 0,35 Nm.(2) Static pressure: 40 [bar](2) Working pressure: 28 [bar]
Outside spring.Torque wrench 0,4 / 0,8 Nm.(3) Static pressure: 68 [bar](3) Working pressure: 48 [bar]
8394/B
8395/A
Core remover (for all types)
1/4" – – – – 45 2,8 – 5,2 –8580/2
Copper gasket with neck
L
H
1/4" – – – – 35
175
– –
30 Four ways
L
H
162 30 Three ways9900/X87
Manifolds with access fittings
Spare valve cores
9900/X47
165
ACCESSORIES AND SPARE PARTS
KIT Nº ITEMS CODE DESCRIPTION SUITABLE FOR PRODUCTS NOTE
166 www.castel.it
ACCESSORIES AND SPARE PARTS FOR SOLENOID VALVES
9900/X94
G9150/R06
9150/R07
9150/R08
9150/R09
9150/R10
9150/R48
9150/R50
9150/R11
9150/R43
008217
008218
008229
004238
200193
009060
008323
200292
004254
008323
200292
200646
004259
008323
200292
009003
004257
004298
008323
004571
200431
004266
004299
008323
004571
009262
004251
004625
008323
004571
009278
009277
004251
004625
008323
200292
004118
004253
004256
004254
004692
008387
008415
008393
004251
008966
004256
004692
Yellow nut for fixing coil
Black screw for fixing coil
O Ring for yellow nut
O Ring under coil
Enclosure
Bracket
Screw
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
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;
1164/..; 1168/..;
1170/4 - /5; 1178/4 - /5 - /M12;
1512/..; 1522/..; 1132/03 - /04
N.C. solenoid valves type:
1020/..; 1028/..
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
N.C. solenoid valves type:
1070/6; 1078/6 - /7; 1079/9
N.C. solenoid valves type:
1090/5 - /6; 1098/5 - /6 - /7; 1099/9
N.C. solenoid valves type:
1050/5 - /6; 1058/5 - /6 - /7; 1059/9
N.C. solenoid valves type:
1078/9; 1079/11
N.C.and N.O. solenoid valves type:
1098/9; 1099/11
1198/9
Diaphragm pilot
operated spare parts for:
1098/9; 1099/11;
1078/11; 1079/13 - /M42
Valves out of stock
Main piston pilot
operated spare parts
KIT Nº ITEMS CODE DESCRIPTION SUITABLE FOR PRODUCTS NOTE
167www.castel.it
RICAMBI PER VALVOLE SOLENOIDI
9150/R39
9150/R35
9150/R34
9150/R49
9150/R51
9150/R42
9150/R15
9150/R12
9150/R13
9150/R14
008387
008415
008393
004691
008966
004256
004692
N.D.
200646
004259
004238
008757
009003
004257
004254
004238
004298
008757
009262
004251
004254
004238
004625
008757
009278
009277
004251
004254
004238
004625
008757
004118
004253
004256
004254
004238
004692
200581
200292
004242
200581
200292
200520
004244
004298
200581
200292
004617
004625
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
N.C.and N.O. solenoid valves type:
1078/11; 1079/13 - /M42
1178/11
N.O. solenoid valves type:
1164/..; 1168/..
1198/9
1178/11
N.O. solenoid valves type:
1170/4- /5; 1178/4 - /5 - /M12
N.O. solenoid valves type:
1190/5 - /6; 1198/5 - /6 - /7
N.O. solenoid valves type:
1150/5 - /6; 1158/5 - /6 - /7
N.O. solenoid valves type:
1178/9
Solenoid valves for different fluids type:
1512/..
1522/..
Solenoid valves for different fluids type:
1132/03 - /04
Solenoid valves for different fluids type:
1132/06 - /08
Solenoid valves for different fluids type:
1142/010 - /012
Main piston pilot
operated spare parts
Diaphragm pilot
operated spare parts for:
1198/9
1178/11
KIT Nº ITEMS CODE DESCRIPTION SUITABLE FOR PRODUCTS NOTE
168 www.castel.it
ACCESSORIES AND SPARE PARTS FOR CHECK VALVES
9150/R16
9150/R17
9150/R18
9150/R19
9150/R52
9150/R53
9150/R54
9150/R55
003558
001869
004251
004299
003559
000728
004691
004692
003854
000728
008002
004302
003855
001857
004261
004302
003558
001869
008863
004299
003559
000728
009174
004692
003854
000728
009175
004302
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:
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
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
Check valves type:
3122/17
3142/17 - /21 - /25
3182/13 - /M42 - /17
Valves out of stock
Valves out of stock
Valves out of stock
Valves out of stock
ACCESSORIES AND SPARE PARTS FOR INDICATORS
9150/R20
9150/R21
003575
007779
004259
004270
007780
004259
Nut
Protection cap
Nut/body O Ring
Pre-assembled nut
Protection cap
Nut/body O Ring
Liqud indicators type:
3610/..; 3620/..; 3640/..; 3650/..
Moisture - liquid indicators type:
3710/..; 3720/..; 3740/..; 3750/..;
3770/..; 3771/..; 3780/..; 3781/..
KIT Nº ITEMS CODE DESCRIPTION SUITABLE FOR PRODUCTS NOTE
169www.castel.it
ACCESSORIES AND SPARE PARTS FOR FILTERS
G9150/R05
9150/R57
9150/R58
8354/22
8392/A
8394/B
003319
003322
009406
003324
007677
005535
004592
008336
008304
008305
008307
008403
008345
008344
008303
008306
Access fitting
Cap with gasket
Valve core
Spring
Flange gasket
Dehydrating block cover
Dehydrating block bottom
Filtering tube
Mechanical block cover
Mechanical block bottom
Flange gasket
Dehydrating block cover
Dehydrating block bottom
Screw for filtering tube
Filtering tube
Filtering tube
Filtering tube
Mechanical block cover
Mechanical block bottom
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/..
Filters with replaceable block type:
4411/..A; 4412/..A; 4413/..A; 4414/..A
Filters with replaceable block type:
4411/..C
Filters with replaceable block type:
4421/..; 4423/..; 4424/..
Filters with replaceable block type:
4421/..A; 4423/..A; 4424/..A
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
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/C
Oil separators type 5520/D
Oil separators type 5520/E
Oil separators type 5520/.
To be ordered separately
To be ordered separately
To be ordered separately
KIT Nº ITEMS CODE DESCRIPTION SUITABLE FOR PRODUCTS NOTE
170 www.castel.it
ACCESSORIES AND SPARE PARTS FOR CHANGEOVER VALVES
9150/R24
9150/R25
004297
004329
004330
004348
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
All the changeover devices type
3032/44 - /64 - /66
Changeover valve type
3032/108
Changeover valve 3032/44
Changeover valve 3032/64 - /66
RICAMBI PER RUBINETTI PER SISTEMI FRIGORIFERI ERMETICI
9150/R23
G9150/R33
003664
000384
000957
000382
007486
000913
004307
004326
Gland
Gland seal gaskets
Gland seal gaskets
Washer
Cap
Spindle
Screw
Spring washer
All the hermetic valves type:
6010/..; 6012/..; 6020/..; 6060/..;
6070/..
Hermetic valves type 6010/2;
6012/22
Hermetic valves type 6020/..
ACCESSORIES AND SPARE PARTS FOR HERMETIC VALVES
9150/R23
9150/R24
9150/R25
003664
000384
000957
000382
007486
000913
001641
004297
004329
004330
004348
009036
001647
000529
000534
000535
001039
008282
001038
Gland
Gland seal gaskets
Gland seal gaskets
Washer
Cap
Spindle
Spindle
Gland
Gland seal gaskets
Gland seal gaskets
Washer
Cap
Spindle
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
Receiver valves type:
6110/23 - /32 - /33; 6120/23 - /33
Receiver valves type:
6110/43 - /44 - /54
6120/43 - /44 - /54
Receiver valves type:
6110/66
6120/66
ACCESSORIES AND SPARE PARTS FOR BALL SHUT-OFF VALVES
009035
009256
Cap
Cap
Ball shut-off valves 3033/..
Ball shut-off valves 3063/44
KIT Nº ITEMS CODE DESCRIPTION SUITABLE FOR PRODUCTS NOTE
171www.castel.it
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
7990/6
7910/8
7990/8
Gland
Gland seal gaskets
Gland seal gaskets
Washer
Steel solder connection
3/4" UNF-16
PTFE gasket for 7910/6
Steel solder connection
1" UNS-16
PTFE gasket for 7910/8
Rotalock valves types:
6310/..
6320/..
To be ordered
separately
ACCESSORIES AND SPARE PARTS FOR CAPPED VALVES
9150/R23 003664
000384
000957
000382
007486
002337
005174
007619
007676
Gland
Gland seal gaskets
Gland seal gaskets
Washer
Cap
Spindle
Nipple/body O Ring
Spindle
Nipple/body O Ring
Capped valves type:
6410/..; 6420/..; 6460/..
Capped valves type:
6410/2 - /3 - /4 - /5
6420/2 - /3 - /M10 - /M12 - /4 - /5
6460/22A.
Capped valves type:
6410/6
6420/M18 - /6 - /M22 - /7
KIT Nº ITEMS CODE DESCRIPTION SUITABLE FOR PRODUCTS NOTE
172 www.castel.it
ACCESSORIES AND SPARE PARTS FOR GLOBE VALVES
9150/R24
9150/R27
9150/R28
9150/R26
9150/R29
9150/R30
004297
004329
004330
004348
001635
004296
007637
004299
004251
008863
007638
004692
004291
009174
000822
000823
000824
007476
001228
000830
004302
007639
008002
009175
007640
004261
009176
Gland
Gland seal gaskets
Gland seal gaskets
Washer
Cap
Cap gasket
Spindle/plate group
Cover/body screws
Cover/body O Ring
Cover/body gasket
Spindle/plate group
Cover/body screws
Cover/body O Ring
Cover/body gasket
Gland
Gland seal gaskets
Gland seal gaskets
Washer
Cap
Cap gasket
Cover/body screws
Spindle/plate group
Cover/body O Ring
Cover/body gasket
Spindle/plate group
Cover/body O Ring
Cover/body gasket
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
(1) 6520/7 - /9
(1) 6530/M22 - /7 - /M28 - /9
6532/M22 - /7 - /M28 - /9
Globe valves type:
(1) 6510/M22 - /7 - /M28 - /9
(1) 6520/7 - /9
(1) 6530/M22 - /7 - /M28 - /9
Globe valves type:
6512/M22 - /7 - /M28 - /9
6532/M22 - /7 - /M28 - /9
Globe valves type:
(1) 6510/11; 6512/11
(1) 6520/11; (1) 6530/11; 6532/11
Globe valves type:
(1) 6510/11; (1) 6520/11; (1) 6530/11
Globe valves type:
6512/11; 6532/11
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
Globe valves type:
(1) 6510/13 - /M42
6512/13 - /M42
(1) 6520/13 - /M42
Globe valves type:
(1) 6510/13 - /M42
(1) 6520/13 - /M42
Globe valves type:
6512/13 - /M42
Globe valves type:
(1) 6510/17; 6512/17
(1) 6520/17; (1) 6530/13 - /M42 - /17
6532/13 - /M42 - /17
Globe valves type:
(1) 6510/17; (1) 6520/17
(1) 6530/13 - /M42 - /17
Globe valves type:
6512/17
6532/13 - /M42 - /17
(1) valves out of stock
KIT Nº ITEMS CODE DESCRIPTION SUITABLE FOR PRODUCTS NOTE
173www.castel.it
ACCESSORIES AND SPARE PARTS FOR BALL VALVES
G9150/R46
009055
009036
009037
009038
009207
009208
8394/A
8392/A
Cap
Cap
Cap
Cap
Cap
Gasket
Valve core
Cap with gasket
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
Ball valves type:
6590/7 - /7A
6591/M28 - /9
6590/M28 - /M28A - /9 - /9A
6591/11
Ball valves type:
6590/11 - /11A
6591/13 - /M42
6590/13 - /13A - /M42 - /M42A
6591/17
Ball valves type:
6590/17 - /17A
6591/21 - /21A
Ball valves type:
6590/M64A - /21A
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
Note
Progetto grafico: Giorgio D’Andrea Impaginazione e fotolito: Ruta - Milano Stampa: B.S.Z. srl - Mazzo di Rho (Mi)