Products Handbook 2009

April 2009
Expansion valves Solenoid valves
thermostatic expansion valves with interchangeable orifice assembly PWM solenoid expansion valves with interchangeable orifice valves for refrigerating systems coils permanent magnet connectors valves for different fluids safety valves 3030 safety valves 3060 ball shut-off valves changeover devices unions fusible plugs
16 26 32 40 43 44 44 50 57 59 60 62 63 65 71
Safety devices
Check valves Water regulating valves Liquid indicators Moisture liquid indicators Dehydrators
dehydration of refrigerants anti-acid solid core filter driers solid core filter driers with sight glass solid core bi-flow filter driers filter driers with replaceable anti-acid solid core mechanical filters with replaceable filtering block strainers
77 83 85 94 97 100 105 110
Oi105 Valves
hermetic valves receiver valves stop valves diaphragm valves rotalock valves capped valves globe valves ball valves gauge mounting valves line piercing valve 112 114 116 118 120 122 124 126 129 130 131 141 153 159
Threaded brass fittings Solder copper fittings Access fittings Spare parts
Index
3
The techical data in this handbook are indicative. Castel reserves the right to modify the same at any time without any previous notice. The products listed in this handbook are protected according to the law
From quality our natural development

After more than forty 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 HCFC and HFC Refrigerants currently used in the Refrigeration & Air Conditioning Industry. UNI EN ISO 9001:2008 issued by ICIM certifies the Quality System of the Factory. Moreover Castel Products count a number of certifications in conformity with the EEC Directives and with European and American Quality Approvals.
Application of Directive 97/23/EC of the European Parliament and of the Council, of 29 May 1997, concerning pressure equipment towards Castel refrigeration products
The Directive 97/23/EC (PED) applies to the design, manufacture and conformity assessment of pressure equipment and assemblies with a maximum allowable pressure PS greater than 0,5 bar with the exception of the possibilities listed in Article 1, Section 3 of the same Directive. Since 30 May 2002 the Directive has become mandatory and, in the Member States of European Community, it has been possible to place on the market only pressure equipments CE marked according to PED. For the purposes of the Directive see the following definitions, used in this Handbook too: Pressure equipment: vessels, piping, safety accessories, and pressure accessories Vessel: a housing designed and built to contain fluids under pressure. Piping: piping components intended for the transport of fluids, when connected together for integration into a pressure system. Safety accessories: devices designed to protect pressure equipment against the allowable limits being exceeded. Pressure accessories: devices with an operational function and having pressurebearing housing. For example: solenoid valves, valves, indicators. Assemblies: several pieces of pressure equipment assembled by a manufacturer to constitute an integrated and functional whole. Maximum allowable pressure (PS): the maximum pressure for which the equipment is designed, as specified by the manufacturer.
Maximum / minimum allowable temperature (TS): the maximum/minimum temperatures for which the equipment is designed, as specified by the manufacturer Volume (V): the internal volume of a chamber, including the volume of nozzles to the first connection or weld and excluding the volume of permanent internal parts. Nominal size (DN): numerical designation of size, which is common to all components in a piping system. Fluids: gases, liquids and vapours in pure phase as well as mixture thereof. Pressure equipments referred to in Article 3 are classified by categories in accordance with Annex II, according to ascending level of hazard, on the basis of: State of the fluid Danger classification of the fluid Type of equipment Dimensions and energetic potential: V, DN, PS, PS x V, PS x DN and must satisfy the Essential Safety Requirement set out in Annex I of PED. Pressure equipments below or equal to the limits in Article 3, sections 1.1, 1.2 and 1.3 and section 2, must not satisfy the Essential Safety Requirement set out in Annex I. They must be designed and manufactured in accordance with the sound engineering practice of a Member State in order to ensure safe use (Article 3, Section 3). In the tables of general characteristics, collected in this Handbook, its showed the risk category in which every product is classified. In Article 9 of PED the fluids are classified, according to their hazard, into two groups:
Group I comprises dangerous fluids. A dangerous fluid is a substance or preparation covered by the definitions in Article 2 of Council Directive 67/548/EEC of 27 June 1967 and following amendments, relating to the classification, packaging and labeling of dangerous substance. Group I comprises fluids defined as: explosive, extremely flammable, highly flammable, flammable, very toxic, toxic, oxidizing. Group II comprises all the others fluids not referred to in group I. Castel products are suitable for using with refrigerant fluids proper to the Group II. These refrigerant fluids are listed and classified A1 in Annex E of standard EN 378-1:2008, plus fluids R30, R123, R141b and R245fa that are classified in other safety groups.
EXTERNAL LEAKAGE All the products illustrated in this Handbook are submitted, one by one, to tightness tests besides to functional tests. Allowable external leakage, measurable during the test, agrees to the definition given in the Standard EN 12284 : 2003, Par. 9.4: During the test, no bubbles shall form over a period of at least one minute when the specimen is immersed in water with low surface tension, . PRESSURE CONTAINMENT All the products illustrated in this Handbook, if submitted to hydrostatic test, guarantee a pressure strenght at least equal to 1,43 x PS in compliance with the Directive 97/23/EC. All the products illustrated in this Handbook, if submitted to burst test, guarantee a pressure strength at least equal to 3 x PS according to to the EN 378-2:2008 Standard. A great number of products illustrated in the Handbook can guarantee an higher pressure strength, equal to 5 x PS according to the Standard UL 207 : 2004. (for detailed information about these products please contact Castel Technical Department). WEIGHTS The weights of the items listed in this Handbook include packaging and are not binding for the Company.
Application of Directive 2002/95/EC of the European Parliament and of the Council, of 27 January 2003, on the restriction of the use of certain hazardous substances in electrical and electronic equipment
The purpose of Directive 2002/95/EC (RoHS Directive) is to prevent or restrict the use of hazardous substances in electrical and electronic equipment and to contribute to the environmentally sound recovery and disposal of waste electrical and electronic equipment. RoHS Directive shall apply to electrical and electronic equipment falling under the categories 1, 2, 3, 4, 5, 6, 7 and 10 set out in Annex 1A to Directive 2002/96/EC (WEEE Waste electrical and electronic equipment) and to electric light bulbs and luminaries in households. The equipment proper to the first category, Large household appliances, and to the 10th category, Automatic dispensers, of Annex 1A in WEEE Directive, are specified in Annex 1B in the same Directive; this list of products shows: Large cooling appliance Refrigerators Freezers Other large appliances used for refrigeration, conservation and storage of food Air conditioner appliances Other fanning, exhaust ventilation and conditioning equipment Automatic dispenser for hot or cold bottles and cans Article 10 of WEEE Directive establishes that, from 13 August 2005, new electrical and electronic equipment put on the market are appropriately identified as waste subject to separate collection, by means of the proper symbol shown in Annex IV of the same Directive. Article 4 of RoHS Directive establishes that, from 1 July 2006, new electrical and electronic equipment put on the market does not contain the following substances: Lead Mercury Cadmium Hexavalent chromium Polybrominated biphenyls (PBB) Polybrominated diphenyl ethers (PBDE) The restriction of use of these hazardous substances shall not apply to the applications
listed in the Annex of the same Directive; among these applications the following exceptions are particularly interesting in air conditioning / refrigerating systems: Lead as an alloying element in steel containing up to 0,35% lead by weight, aluminium containing up to 0,4% lead by weight and as a copper alloy containing up to 4% lead by weight Hexavalent chromium as an anti-corrosion of the carbon steel cooling system in absorption refrigerators The Member States of European Community had to adopt the two Directives 2002/95/EC and 2002/96/EC, with the next updating 2003/108/EC, before 13 August 2004, unless delays granted by the European Parliament. For a long time Castel Company has started a careful inquiry, together with its suppliers, to identify the presence or not of the abovementioned hazardous substances, either in its own products or in its own production processes, and to remove them progressively. At the end of this wide examination Castel Company may declare that its products: 1. Do not contain mercury, cadmium, polybrominated biphenyls (PBB), polybrominated diphenyl ethers (PBDE) 2. Do not contain hexavalent chromium, used for the surface treatments (yellow zinc plating) of steel parts. Castel Company has removed the yellow zinc plating treatments from all its products, before the end of 2005, and has chosen: other surface treatments containing trivalent chromium instead of hexavalent chromium. where possible, other materials which dont need surface treatments. 3. Contain lead as an alloying element in steel, aluminium and copper alloys within the accepted limits according to the Annex of RoHS Directive.
CONNECTIONS OF CASTEL PRODUCTS

Castel products can be supplied with different connections. In particular Castel products are produced either with threaded connections or solder connections. Table 1 shows the equivalence between Castel codes and dimensions in inches. These codes are commonly used in the international market. Table 2 shows the equivalence between Castel codes and dimensions in millimeters.
TABLE 1 - Equivalence between Castel code and dimension in inches

CASTEL code . /1 . /2 . /3 . /4 . /5 . /6 . /7 . /8 . /9 . /11 . /13 . /17 . /21 . /24 . /25 . /28 . /29 . /33 . /34 Dimension [in] 1/8" 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 1" 1" 1/8 1" 3/8 1" 5/8 2" 1/8 2" 5/8 3" 3" 1/8 3" 1/2 3" 5/8 4" 1/8 4" 1/4
TABLE 2: Equivalence between Castel code and dimension in millimeters

CASTEL code . /M6 . /M10 . /M12 . /M15 . /M18 . /M22 . /M28 . /M42 . /M64 . /M80 Dimension [mm] 6 10 12 15 18 22 28 42 64 80
F.e. 4411/M42A filter drier with replaceable anti-acid solid core with solder connection with = 42 mm.
F.e. 1098/7 solenoid valve with solder connection with = 7/8
Description of connections that are currently used for Castel products.

1) THREADED CONNECTIONS They can be of three different types: FLARE Straight threaded connection (according to SAE J513-92; ASME B1.1-89) for junction to a copper pipe with a suitable flared end, using a right nut (see Table 3). NPT Taper threaded connection (according to ASME B1.20.1-92) to joint fittings, valves, safety valves to vessel or steel pipes. FPT Straight threaded connection (according to UNI ISO 228/1) used in the hydraulic system to joint fittings or valves to vessel or steel pipes.
F.e.: solenoid valves for water or air.
ODM Male solder connection for copper tubes. The indicated size corresponds to the outer diameter of the copper tube which to joint.
F.e.: 16 ODM solder connection suitable to joint a copper pipe with a 16 mm outer diameter, by means of an M16 female/female copper sleeve (in this case the type Castel 7700/M16).
IDS Male solder connection for copper tube. The indicated size corresponds to the inner diameter of the copper tube which to joint.
F.e.: 10 IDS solder connection suitable to receive outside a copper pipe with an 10 mm inner diameter).
W Solder connection for steel pipes. The indicated size corresponds to the external diameter of the steel pipe which to joint.
F.e.: 76,1 W solder connection suitable to connect a steel pipe with a 76,1 mm external diameter, by means of butt welding.
2) SOLDER CONNECTIONS They can be of four different types and can fit pipes with diameter both in inches and in millimeters: ODS (or ODF) Female solder connection for copper tubes. The indicated size corresponds to the outer diameter of the copper tube which to joint.
F.e.: 1/2" ODS solder connection suitable to receive inside a copper pipe with a 1/2" outer diameter.
TABLE 3: Flare connections

FLARE 1/4" 5/16" 3/8" 1/2" 5/8" 3/4" 7/8" 1" Suitable for Copper tube 1/4" 5/16" 3/8" 1/2" 5/8" 3/4" 7/8" 1" thread 7/16" - 20 UNF 1/2" - 20 UNF 5/8" - 18 UNF 3/4" - 16 UNF 7/8" - 14 UNF 1.1/16" - 14 UNS 1.1/4" - 12 UNF 1.3/8" - 12 UNF
10
THE Kv FACTOR
The correct sizing of tubes and components of a refrigerating system is of the utmost importance for all kinds of plants; oversizing and undersizing are both to be avoided since they are equally hazardous for the correct operation of the system. The correct selection of a component is based on the knowledge of the relationship between capacity and pressure drop through that component. For this purpose, EN 60534-1, EN 60534-2-1 and EN 60534-2-3 standards require manufacturers to specify the Kv coefficient for every product. The Kv factor is defined as the cold water flow (volumic mass = 1000 kg/m3) in m3/h resulting in a 1 bar pressure drop with a completely open valve. This definition applies to all products described in this handbook. The merely physical meaning, this coefficient precisely defines the fluid-dynamic and construction characteristics of the product, so that, with the addition of other parameters more closely related to the nature and conditions of the fluid under consideration, the capacity/pressure drop ratio may be precisely determined. Castel provides appropriate tables for the most commonly used refrigerants in typical plant working conditions in order to help engineers in the correct selection of its products. Table 1 shows refrigeration capacity values with unit Kv related to the nominal working conditions specified in Table 2. Appropriate corrective coefficients may be calculated taking the values shown from Table 3 to Table 8 as a basis; this will make it possible to predict actual working conditions. As a result: Liquid line: Q = Kv Q1 L1 L2 Suction line Q = Kv Q1 S1 S2 Hot gas line Q = Kv Q1 H1 H2 since: Q = required refrigeration capacity [kW]; Kv = characteristic valve coefficient [m3/h]; Q1 = reference refrigeration capacity [kW] (Table 1). L1 S1 H1 = are correction factors of the refrigeration capacity in the presence of operating temperatures different from reference conditions. L2 S2 H2 = are correction factors of the refrigeration capacity for pressure drops different from reference conditions.
TABLE 1
Refrigeration Capacity [kW] Kv Factor [m3/h] R134a R22 Liquid R404A R407C R410A R507 R134a R22 Vapour R404A R407C R410A R507 R134a R22 Hot Gas R404A R407C R410A R507
16,85 18,00 11,90 18,74 19,04 11,80 2,16
2,70
2,26
2,68
3,60
2,15
8,50 11,70 10,00 11,62 13,00 7,77
TABLE 2 - Nominal Working Conditions

Application LIQUID VAPOUR +4 HOT +18 GAS 1 +38 0,15 Evaporating Temperature [C] Suction Temperature [C] Condensing Temperature [C] Pressure drop [bar]
11
Liquid line
TABLE 3 - Correction Factors L1 of the refrigeration capacity for operating temperatures different from nominal values
Evaporating Temperature [C] Liquid Temperature [C] Refrigerant + 10 +5 0 5 10 15 20 25 30 35 40
R134a R22 R404A 0 R407C R410A R507 R134a R22 R404A +10 R407C R410A R507 R134a R22 R404A +20 R407C R410A R507 R134a R22 R404A +30 R407C R410A R507 R134a R22 R404A +40 R407C R410A R507 R134a R22 R404A +50 R407C R410A R507 R134a R22 R404A +60 R407C R410A R507 0,71 0,70 0,58 0,70 0,69 0,56 0,68 0,67 0,54 0,66 0,66 0,52 0,65 0,65 0,50 0,63 0,63 0,47 0,85 0,85 0,80 0,76 0,79 0,68 0,84 0,84 0,78 0,74 0,78 0,66 0,82 0,81 0,76 0,72 0,77 0,64 0,80 0,80 0,74 0,70 0,76 0,62 0,79 0,79 0,71 0,68 0,75 0,60 0,77 0,78 0,68 0,66 0,74 0,58 0,99 1,00 1,00 0,88 0,89 0,85 0,97 0,99 0,97 0,86 0,88 0,83 0,96 0,96 0,95 0,84 0,87 0,81 0,94 0,95 0,93 0,82 0,86 0,79 0,92 0,94 0,90 0,80 0,85 0,77 0,90 0,93 0,87 0,78 0,84 0,75 1,12 1,08 1,17 1,00 0,99 0,99 1,10 1,07 1,15 0,98 0,98 0,97 1,08 1,06 1,13 0,96 0,97 0,95 1,06 1,05 1,10 0,94 0,96 0,93 1,04 1,04 1,08 0,92 0,95 0,92 1,03 1,03 1,05 0,90 0,93 0,89 1,23 1,19 1,33 1,12 1,08 1,13 1,22 1,17 1,30 1,10 1,07 1,12 1,20 1,16 1,28 1,08 1,06 1,09 1,18 1,16 1,26 1,06 1,05 1,07 1,16 1,15 1,23 1,04 1,04 1,05 1,15 1,13 1,20 1,02 1,03 1,04 1,23 1,19 1,28 1,21 1,17 1,26 1,19 1,16 1,25 1,17 1,16 1,22 1,15 1,15 1,20 1,13 1,13 1,17
1,34 1,32 1,40 1,35 1,32 1,52 1,23 1,22 1,27 1,23 1,22 1,35 1,11 1,11 1,16 1,13 1,11 1,17 1,00 1,02 1,02 1,00 1,02 1,02 0,88 0,92 0,87 0,89 0,92 0,85 0,76 0,82 0,73 0,75 0,76 0,66 0,64 0,72 0,56 0,61 0,61 0,45
1,32 1,31 1,38 1,33 1,31 1,49 1,21 1,21 1,25 1,21 1,21 1,32 1,09 1,10 1,13 1,11 1,10 1,14 0,98 1,01 0,99 0,99 1,01 0,99 0,86 0,90 0,85 0,87 0,91 0,82 0,74 0,81 0,71 0,73 0,74 0,63 0,62 0,71 0,54 0,60 0,60 0,42
1,30 1,29 1,36 1,31 1,29 1,46 1,18 1,19 1,23 1,19 1,19 1,29 1,07 1,08 1,11 1,09 1,08 1,12 0,96 0,99 0,97 0,97 0,99 0,96 0,84 0,89 0,83 0,85 0,90 0,79 0,72 0,80 0,69 0,72 0,73 0,60 0,60 0,70 0,52 0,58 0,58 0,40
1,28 1,27 1,33 1,29 1,27 1,42 1,16 1,17 1,20 1,18 1,18 1,26 1,05 1,07 1,08 1,07 1,07 1,08 0,94 0,98 0,95 0,95 0,98 0,93 0,82 0,87 0,80 0,83 0,87 0,76 0,70 0,78 0,67 0,70 0,72 0,57 0,58 0,68 0,50 0,56 0,57 0,36
1,26 1,25 1,31 1,25 1,25 1,38 1,14 1,16 1,18 1,16 1,16 1,22 1,03 1,05 1,06 1,06 1,05 1,04 0,91 0,96 0,93 0,94 0,96 0,89 0,80 0,86 0,78 0,82 0,86 0,72 0,68 0,77 0,65 0,69 0,71 0,54 0,56 0,67 0,48 0,55 0,56 0,33
TABLE 4 - Correction Factors L2 of the refrigeration capacity for pressure drops different from nominal values
Pressure drop [bar]
0,01
0,03
0,05
0,10
0,15
0,20
0,25
0,30
0,35
0,40
0,45
0,50
0,55
0,60
L2
0,263
0,456
0,59
0,81
1,00
1,15
1,30
1,40
1,54
1,64
1,72
1,82
1,92
2,00
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Suction line
TABLE 5 - Correction Factors - S1 of the refrigeration capacity for operating temperatures different fom nominal values
Condensing Temperature [C] Evaporating Temperature [C]
Hot gas line

TABLE 7 - Correction Factors - H1 of the refrigeration capacity for operating temperatures different from nominal values
Condensing Temperature [C]
+ 60
+ 55
+ 50
+ 45
+ 40
+ 35
+ 30
Evaporating Temperature [C]
+ 60
+ 55
+ 50
+ 45
+ 40
+ 35
+ 30
+10 0 10 20 30
0,87 0,67 0,51 0,35
0,92 0,73 0,55 0,39
0,98 0,78 0,59 0,43
1,04 0,83 0,64 0,50 0,35
1,11 0,85 0,70 0,53 0,37
1,17 0,96 0,76 0,57 0,39
1,23 1,01 0,80 0,60 0,45 +10 0 10 20 30 40 1,00 0,83 0,76 1,00 0,90 0,76 1,00 0,92 0,79 0,67 1,03 0,92 0,80 0,71 1,04 0,94 0,84 0,72 0,60 1,05 0,95 0,87 0,76 0,65 0,58 1,05 0,95 0,88 0,77 0,68 0,61
0,36* 0,38* 0,41* 0,43* 0,46* 0,48* 0,50* 40 0,27* 0,29* 0,31* 0,33* 0,35* 0,37* 0,38*
*Two-stages pants, two indipendent circuits, with intermediate temperature -10 C.

TABLE 6 - Correction Factors - S2 of the refrigeration capacity for pressure drops different from nominal values
Pressure drop [bar]
TABLE 8 - Correction Factors - H2 of the refrigeration capacity for pressure drops different from nominal values
Pressure drop [bar]
0,10 0,20 0,30 0,40 0,50 0,70 1,00 1,50 2,00 2,50
0,04 0,05 0,07 0,10 0,15 0,20 0,30 0,40 0,50 0,70 H2 0,32 0,45 0,54 0,65 0,70 0,83 1,00 1,17 1,30 1,44
S2
0,47 0,57 0,68 0,82 1,00 1,15 1,40 1,64 1,82 2,15
APPLICATION EXAMPLES 1) Liquid line: Evaluation of pressure drop across the valve under the following working conditions: Castel 1078/5 valve: Kv = 2,61 [m3/h] Refrigerant: R407C Set refrigeration capacity: 35 [kW] Condensation: + 50 [C] Evaporation: 0 [C] Q = Kv Q1 L1 L2 [kW] 35 = 2,61 18,74 0,82 L2 [kW] 35 L2 = = 0,87 40,11 A pressure drop slightly above 0.11 bar corresponds to the L2 = 0.87 correction factor. Such a pressure drop is compatible with the minimum differential pressure required by the valve. 2) Suction line: Valve selection under the following conditions: Refrigerant: R407C Set refrigeration capacity: 15 [kW] Condensation: + 40 [C] Evaporation: 10 [C] Set pressure drop: 0,1 [bar]
Q = Kv Q1 S1 S2 [kW] 15 = Kv 2,68 0,70 0,82 15 Kv = = 9,75 [m3/h] 1,538 The result involves the selection of a 1078/9 valve with Kv = 10 [m3/h] 3) Hot gas line: Valve selection under the following conditions: Refrigerant: R407C Set refrigeration capacity: 20 [kW] Condensation: + 40 [C] Evaporation: 0 [C] Set pressure drop: 0,5 [bar] Q = Kv Q1 H1 H2 [kW] 20 = Kv 11,62 0,94 0.7 20 Kv = = 2,61 [m3/h] 7,64 The result involves the selection of a 1078/5 valve with Kv = 2,61 [m3/h]
13
14
Expansion valves
THERMOSTATIC EXPANSION VALVES SERIES 22 WITH INTERCHANGEABLE ORIFICE ASSEMBLY

APPLICATION Castel thermostatic expansion valves series 22 regulate the flow of refrigerant liquid into evaporators; the liquid injection is controlled by the refrigerant superheat. The new Castel 22 series are designed to work with interchangeable orifice assembly, to provide flexibility in selection of capacities, and can be used in a wide range of applications as listed below: Refrigeration systems (display cases in supermarkets, freezers, ice cream and ice maker machines, transport refrigeration etc). Air conditioning systems Heat pump systems Liquid chillers which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2, of Directive 97/23/EC and referred to in Directive 67/548/EEC).
OPERATION Castel thermostatic expansion valves acts as throttle device between the high pressure and the low pressure sides of refrigeration systems and ensure that the rate of refrigerant flow into the evaporator exactly matches the rate of evaporation of liquid refrigerant in the evaporator. If the actual superheat is higher than the set point the valve feeds the evaporator with more liquid refrigerant, if the actual superheat is lower than the set point the valve decreases the flow of liquid refrigerant to the evaporator. Thus the evaporator is fully utilized and no liquid refrigerant may reach the compressor. diaphragm assembly by 1.5 meter length of capillary tubing, which transmits bulb pressure to the top of the valves diaphragm. The sensing bulb pressure is a function of the temperature of the thermostatic charge that is the substance within the bulb. The body is made from forged brass with connection in angle configuration. The interchangeable orifice assembly can be replaced through the inlet connection. A steel rod, inside the body, transfers the diaphragm movement to the plug inside the orifice assembly. When the thermostatic charge pressure increases, the diaphragm will be deflected downward transferring this motion to the plug, which lifts from seat and allows the liquid passing through orifice. A spring opposes the force underneath the diaphragm and the side spindle can adjust its tension. Static superheat increases by turning the side spindle clockwise and decreased by turning the spindle counter clockwise. The thermostatic element is hardly connected by brazing to the forged brass body to avoid any leakage. The body assembly can be supplied with internal or external equalizer; both types can also be supplied either with flare connections or with solder connections (outlet and external equalizer if present). The nuts for flare connection type and the inlet-
CONSTRUCTION Castel thermostatic expansion valve series 22 is made up of two parts that must work together: the first is the body, which is the actuator of the regulator, and the second is the orifice, which contains the valve and attends the expansion of the refrigerating fluid. Body assembly: two parts make it up: the thermostatic (power) element and the body with its inner elements. The thermostatic element is the motor of the valve; a sensing bulb is connected to the
16
TABLE 1a: General Characteristics of Body Assemblies of Liquid Charge Thermostatic Expansion Valves
Max bulb temperature [C] Connections Refrigerant SAE Flare internal equalizer 2210/4 2210/M12S 2210/4S 2210/4E 2210/M12SE 2210/4SE 2220/4 2220/M12S 2220/4S 3/8" 2220/4E 2220/M12SE 2220/4SE 2230/4 2230/M12S 2230/4S 2230/4E 2230/M12SE 2230/4SE 1/2" 1/2" 1/2" 1/4" 1/4" 12 12 12 6 6 1/2" 1/2" 1/2" 1/4" 1/4" R404A R507 external equalizer IN OUT 1/2" 1/2" 1/2" Equal. 1/4" ODS [mm] OUT 12 12 12 Equal. 6 ODS [in] OUT 1/2" 1/2" 1/2" Equal. 1/4" R134a + 10 - 40 without 100 -60 (1) +120 34 Art. 3.3 R22 R407C Evaporating Temperature Range [C] Catalogue number TS [C] PS [bar] min max Risk Category according to PED
MOP
(1) When valve is installed. 60 C with element not mounted

TABLE 1b: General Characteristics of Body Assemblies of MOP Charge Thermostatic Expansion Valves
Max bulb temperature [C] Evaporating temperature Range [C] Refrigerant Catalogue number SAE Flare internal equalizer 2211/4 2211/M12S 2211/4S 2211/4E 2211/M12SE 2211/4SE 2221/4 2221/M12S 2221/4S 2221/4E 2221/M12SE 2221/4SE 3/8" 2231/4 2231/M12S 2231/4S 2231/4E 2231/M12SE 2231/4SE 2234/4 2234/M12S 2234/4S 2234/4E 2234/M12SE 2234/4SE 1/2" 1/2" 1/2" 1/2" 1/4" 1/4" 12 12 12 12 6 6 1/2" 1/2" 1/2" 1/2" 1/4" 1/4" - 60 - 25 - 20 C (30 psi) R404A R507 + 15 C (120 psi) external equalizer IN OUT 1/2" 1/2" 1/2" 1/2" Equal. 1/4" 1/4" Connections ODS [mm] OUT 12 12 12 12 Equal. 6 6 ODS [in] OUT 1/2" 1/2" 1/2" 1/2" Equal. 1/4" R134a 1/4" 100 -60 (1) +120 34 Art. 3.3 (55 psi) - 40 + 10 + 15 C R22 R407C + 15 C (95 psi) MOP TS [C] PS [bar] min max Risk Category according to PED
(1) When valve is installed. 60 C with element not mounted
17
brazing adapter for solder connection type can be ordered separately. Every body assembly is supplied with a strap, code G9150/R61 that allows fixing the bulb to the pipe. This code can be ordered separately too, as repair kit. The main part of body assembly are made with the following materials: stainless steel for bulb, capillary tubing, diaphragm casing, diaphragm and rod hot forged brass EN 12420 CW 617N for body brass EN 12164 CW 614N for superheat setting spindle and spring holder steel DIN 17223-1 for spring copper tube EN 12735-1 Cu DHP for solder connection
charge cannot incorporate MOP functions.
Gas charge: the behaviour of valves with gas charge will be determined by the lowest temperature at any part of the expansion valve (thermostatic element, capillary tube or bulb). If any parts other than the bulb are subjected to the lowest temperature, malfunction of expansion valve may occur (charge migration). Castel thermostatic expansion valves with gas charge always feature MOP functions and include ballasted bulb. Ballast in the bulb has a damping effect on the valve regulation and leads to slow opening and fast closure of the valve. MOP (Maximum Operating Pressure): this functionality limits the evaporator pressure to a maximum value to protect the compressor from the overload condition (Motor Overload Protection). MOP is the evaporating pressure at which the expansion valve will throttle liquid injection into the evaporator and thus prevent the evaporating pressure from rising. Expansion valve operates as superheat control in normal working range and operates as pressure regulator within MOP range. The MOP point will change if the factory superheat setting of the expansion valve is changed. Superheat adjustments influence the MOP point as following: increase of superheat decrease of MOP decrease of superheat increase of MOP Superheat: this is the controlling parameter of the expansion valve. Superheat, measured at the evaporator outlet, is defined as the difference between actual bulb temperature and the evaporating temperature, deduce from evaporator pressure. In order to prevent liquid refrigerant from entering the compressor, a certain minimum superheat must be maintained. In expansion valve operation the following terms are used: Static superheat: its the superheat above that the valve will begin to open. Castel thermo expansion valves are factory preset at the following values: 5 C for Castel valves without MOP 4 C for Castel valves with MOP with nominal operating conditions (see table 2) Opening superheat: its the superheat above the static one required to produce a given valve capacity Operating superheat: its the sum of static and opening superheat
Orifice assembly: interchangeable orifice assembly provide a wide range of capacity from 0,5 up to 15,5 kW (nominal capacity with R22). The external cartridge contains the following elements: housing, plug (metering device), seat, spring and strainer. The rigid design of orifice assembly and its internal components make sure that plug and seat will withstand all types of critical operations (liquid hammering, cavitation, sudden variation of pressure and temperature contaminants). The spring holds the plug firmly to the seat to ensure the minimum leakage through the valve; for positive shut-off, the installation of a solenoid valve is required. Orifice assemblies are available in these two solutions: with conical flanged strainer, for valves with SAE Flare threaded connections. with flat flanged strainer, for valves with ODS solder connections, to use with adapter series 2271. Orifice assemblies strainers can be cleaned or exchanged, in this last case its possible to order separately the following two types of strainers. strainer 2290 for valves with SAE Flare threaded connections. strainer 2290/S for valves with ODS solder connections.
THERMOSTATIC CHARGES Liquid charge: the behaviour of valves with liquid charge is exclusively determined by temperature changes at the bulb and not subject to any cross-ambient interference. They feature a fast response time and thus react quickly in the control circuit. Castel thermostatic expansion valves with liquid
18
Subcooling: its defined as the difference between the condensing temperature (deduced from condensing pressure) and the actual temperature at inlet valve. Subcooling generally increases the capacity of refrigeration system and may be accounted for when dimensioning an expansion valve. Depending on system design, subcooling may be necessary to prevent flash gas from forming in the liquid line. If flash gas forms in the liquid line, the capacity of expansion valve will be greatly reduced. All capacity tables, in this chapter, are calculated for a subcooling value of 4 C; if the actual subcooling is higher than 4 C the valve capacity comes from evaporator capacity divided by the correction factor shown in the tables below every capacity table.
42
41,5
19
SELECTION To correctly select a thermo expansion valve on a refrigerating system, the following design conditions must be available: Type of refrigerant Evaporator capacity, Qe Evaporating temperature/pressure, Te / pe Lowest possible condensing temperature/ pressure, Tc / pc Liquid refrigerant temperature, Tl Pressure drop in the liquid line, distributor and evaporator, p The following procedure helps to select the correct valve for the system. Step 1 Determine the pressure drop across the valve. The pressure drop is calculated by the formula:
chosen refrigerant. Step 4 Select a thermostatic charge. Chose the type of charge, liquid without MOP or gas with MOP , and the temperature range, normal temperature or low temperature. Step 5 Determine if external equalizer is required. External equalizer is always required if a distributor is used or if there is an appreciable difference in pressure from the valve outlet to the bulb location. Finally determine the type of connections and their sizes. Step 6 Order the required components If SAE Flare connections you have to order the following two parts: - Body assembly (see tabs 1a/1b) - Orifice assembly, completed with strainer (see tab 2) If ODS connections you have to order the following three parts: - Body assembly (see tabs 1a/1b) - Orifice assembly, completed with strainer (see tab 2) - Solder adapter (see tab. 3)
p tot = p c ( p e + p
where: Pc = condensing pressure Pe = evaporating pressure p = sum of pressure drops in the liquid line, distributor and evaporator Step 2 Determine required valve capacity. Use the evaporating capacity Qe to select the required valve size at a given evaporating temperature. If necessary, correct the evaporator capacity for subcooling. Subcooling liquid refrigerant entering the evaporator increase the evaporator capacity, so that a smaller valve may be required. The subcooling is calculated by the formula:
TABLE 2: Orifice Assemblies - Rated Capacities in kW

Catalogue number Valves with SAE Flare connections 220X 2200 2201 2202 2203 Valves with ODS connections 220X/S 2200/S 2201/S 2202/S 2203/S 2204/S 2205/S 2206/S Evaporating Temperature Range [C] - 40 + 10 R22 R407C 0,5 1,0 2,5 3,5 5,2 8,0 10,5 15,5 R134a 0,4 0,9 1,8 2,6 4,6 6,7 8,6 10,5 R404A R507 0,38 0,7 1,6 2,1 4,2 6,0 7,7 9,1 -60 -25 R404A R507 0,38 0,7 1,6 2,1 3,5 4,9 6,0 6,6
Tsub = Tc Tl
From the subcooling corrector factor table find the appropriate corrector factor Fsub corresponding to the Tsub calculated and determine the required valve capacity by the formula:
2204 2205 2206
Q sub =
Qe
Fsub
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
Step 3 Determine required orifice size. Use the pressure drop across the valve, the evaporating temperature and the calculated evaporator capacity to select the corresponding orifice size from the capacity table corresponding to the
20
TABLE 3: Solder adapters

ODS Connections Catalogue number [in] 2271/M6S 2271/2S 2271/3S 2271/M10S 1/4" 3/8" [mm] 6 10
pressure drop across the valve = 4,2 bar evaporating temperature = - 10 C calculated evaporator capacity = 5,55 kW select the corresponding orifice 2205 (N.B.: the expansion valve capacity must be equal or slightly more than the calculated evaporator capacity) MARKING
SIZING EXAMPLE Type of refrigerant R134a 6 kW Evaporator capacity, Qe Evaporating temperature/ pressure, Te - 10 C Lowest possible condensing temperature/pressure, Tc + 30 C + 20 C Liquid refrigerant temperature, Tl Pressure drop in the liquid line, distributor and evaporator, p 1,5 bar STEP 1 - Determine the pressure drop across the valve Condensing pressure at + 30 C - pc = 6,71 bar Evaporating pressure at - 10 C - pe = 1,01 bar
ptot = 6,71 ( 1,01 + 1,5 ) = 4,2 bar

STEP 2 - Determine required valve capacity
Main valve data are indicated on the upper side of the ther mostatic element and on the cartridge surface of the orifice assembly. On the thermostatic element you may find the following data: The valve code number The refrigerant The evaporating temperature range The MOP value, if present The maximum allowable pressure PS The date of production On the car tridge of orifice assembly you may find the following data: The size of the orifice The date of production On the plastic cap of the orifice assembly package the orifice size is marked. The cap can easily be fastened around the valve capillary tube to clearly identify the valve size.
Tsub = 30 20 = 10 C
From the subcooling corrector factor table 5b, we find the appropriate corrector factor Fsub equal to 1,08 for Tsub = 10 C Required valve capacity is:
Qsub = 6
/1,08 = 5,55 kW
STEP 3 - Determine required orifice size Using the capacity table for R134a on page 25 with:
21
TABLE 4a: Refrigerant R22/R407C - Capacities in kW for temperature range - 40 C

Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice code 2 4
+10 C
Pressure drop across valve [bar] 6 8 10 12 14 16
Evaporating temperature = +10 C 220X 2200 2201 2202 2203 2204 2205 2206 0,37 0,87 2,2 3,0 5,4 8,1 10,2 12,6 0,48 1,1 2,8 4,0 7,2 10,8 13,6 16,7 0,55 1,2 3,2 4,7 8,3 12,5 15,7 19,3 0,60 1,3 3,4 5,1 9,1 13,8 17,2 21,0 0,63 1,4 3,6 5,4 9,7 14,5 18,3 22,3 0,65 1,4 3,7 5,6 10,0 15,0 18,9 23,1 0,65 1,4 3,8 5,8 10,2 15,5 19,3 23,5 0,67 1,5 3,8 5,8 10,3 15,5 19,5 23,7
Evaporating temperature = 0 C 220X 2200 2201 2202 2203 2204 2205 2206 0,37 0,84 1,9 2,6 4,6 6,9 8,8 10,8 0,48 1,0 2,4 3,4 6,1 9,1 11,6 14,2 0,55 1,2 2,7 4,0 7,1 10,5 13,3 16,3 0,59 1,3 3,0 4,3 7,8 11,5 14,6 17,8 0,63 1,3 3,1 4,6 8,2 12,2 15,5 18,9 0,65 1,4 3,2 4,8 8,5 12,7 16,1 19,6 0,66 1,4 3,3 4,9 8,7 13,0 16,4 20,0 0,66 1,4 3,3 5,0 8,8 13,2 16,6 20,2
Evaporating temperature = -10 C 220X 2200 2201 2202 2203 2204 2205 2206 0,37 0,79 1,6 2,2 3,9 5,8 7,4 9,1 0,47 0,96 2,0 2,9 5,1 7,6 9,6 11,6 0,53 1,1 2,3 3,3 5,9 8,7 11,0 13,5 0,57 1,2 2,5 3,6 6,4 9,5 12,0 14,7 0,60 1,2 2,6 3,8 6,8 10,1 12,8 15,6 0,63 1,3 2,7 4,0 7,1 10,5 13,3 16,2 0,64 1,3 2,8 4,1 7,3 10,8 13,6 16,6 0,64 1,3 2,8 4,1 7,3 10,9 13,8 16,8
Evaporating temperature =-20 C 220X 2200 2201 2202 2203 2204 2205 2206 0,44 0,88 1,7 2,4 4,2 6,2 7,9 9,6 0,50 1,0 1,9 2,7 4,8 7,1 9,0 11,0 0,54 1,1 2,0 2,9 5,2 7,7 9,8 11,9 0,57 1,1 2,2 3,1 5,5 8,2 10,3 12,6 0,59 1,2 2,3 3,2 5,8 8,5 10,8 13,1 0,61 1,2 2,3 3,3 5,9 8,7 11,0 13,5 0,61 1,2 2,3 3,3 6,0 8,8 11,2 13,7
Evaporating temperature = -30 C 220X 2200 2201 2202 2203 2204 2205 2206 0,40 0,79 1,4 1,9 3,4 5,0 6,4 7,8 0,45 0,9 1,5 2,2 3,9 5,7 7,2 8,8 0,49 0,96 1,7 2,7 4,2 6,2 7,8 9,6 0,52 1,0 1,8 2,5 4,4 6,6 8,3 10,1 0,55 1,1 1,8 2,6 4,6 6,8 8,6 10,5 0,56 1,1 1,9 2,6 4,7 7,0 8,8 10,8 0,57 1,1 1,9 2,7 4,8 7,1 9,0 11,0
Evaporating temperature = -40 C 220X 2200 2201 2202 2203 2204 2205 2206 0,42 0,8 1,3 1,7 3,1 4,6 5,8 7,1 0,45 0,86 1,4 1,9 3,4 4,9 6,3 7,7 0,48 0,92 1,4 2,0 3,5 5,2 6,6 8,1 0,50 0,95 1,5 2,0 3,7 5,4 6,9 8,4 0,52 0,98 1,5 2,1 3,8 5,6 7,1 8,7 0,53 0,99 1,6 2,1 3,8 5,7 7,2 8,8
TABLE 4b: Refrigerant R22/R407C - Correction factor for subcooling tsub > 4 C
tsub [C] Fsub 4 1,00 10 1,06 15 1,11 20 1,15 25 1,20 30 1,25 35 1,30 40 1,35 45 1,39 50 1,44
When subcooling ahead of the expansion valve is over than 4 C, adjust the evaporator capacity by dividing by the appropriate correction factor found in table 4b
22
TABLE 5a: Refrigerant R134a Capacities in kW for temperature range - 40 C + 10 C

Orifice code 2 Pressure drop accross valve [bar] 4 6 8 10 Orifice code 2 Pressure drop accross valve [bar] 4 6 8 10
Evaporating temperature = +10 C 220X 2200 2201 2202 2203 2204 2205 2206 0,34 0,71 1,5 2,0 3,6 5,4 6,9 8,4 0,43 0,86 1,9 2,6 4,7 7,0 8,9 10,8 0,47 0,93 2,1 3,0 5,3 7,8 9,9 12,1 0,50 0,97 2,2 3,1 5,6 8,3 10,8 12,8 0,51 0,98 2,2 3,2 5,8 8,6 10,9 13,2
Evaporating temperature = 0 C 220X 2200 2201 2202 2203 2204 2205 2206 0,33 0,65 1,3 1,7 3,0 4,5 5,7 7,0 0,42 0,78 1,6 2,2 3,9 5,7 7,3 8,9 0,46 0,86 1,7 2,4 4,4 6,4 8,1 1,0 0,47 0,89 1,8 2,6 4,6 6,8 8,6 10,5 0,49 0,91 1,8 2,6 4,7 7,0 8,8 10,8
Evaporating temperature = -10 C 220X 2200 2201 2202 2203 2204 2205 2206 0,30 0,59 1,0 1,4 2,5 3,6 4,6 5,7 0,36 0,70 1,3 1,8 3,1 4,6 5,8 7,1 0,43 0,77 1,4 2,0 3,5 5,1 6,5 8,0 0,44 0,81 1,5 2,1 3,7 5,4 6,9 8,4 0,44 0,82 1,5 2,1 3,8 5,6 7,1 8,6
TABLE 5b: Refrigerant R134a - Correction factor for subcooling tsub > 4 C
tsub [C] Fsub 4 1,00 10 1,08 15 1,13 20 1,19 25 1,25 30 1,31 35 1,37 40 1,42 45 1,48 50 1,54
23
TABLE 6a: Refrigerant R404A/R507 Capacities in kW for temperature range - 40 C + 10 C

Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16
Evaporating temperature = +10 C 220X 2200 2201 2202 2203 2204 2205 2206 0,28 0,67 1,70 2,32 4,15 6,24 7,91 9,71 0,35 0,82 2,10 3,00 5,36 8,06 0,40 0,90 2,30 3,39 6,03 9,06 0,42 0,94 2,42 3,61 6,43 9,66 0,43 0,96 2,48 3,73 6,63 9,95 0,43 0,96 2,46 3,74 6,66 9,98 0,42 0,93 2,41 3,68 6,55 9,81 0,41 0,90 2,34 3,59 6,39 9,57
Evaporating temperature = 0 C 220X 2200 2201 2202 2203 2204 2205 2206 0,30 0,68 1,53 2,06 3,68 5,49 6,97 0,37 0,80 1,86 2,64 4,72 7,15 8,92 0,41 0,87 2,04 2,95 5,27 7,86 0,42 0,90 2,13 3,13 5,59 8,33 0,43 0,92 2,18 3,22 5,75 8,58 0,43 0,93 2,18 3,25 5,80 8,64 0,43 0,91 2,15 3,21 5,73 8,53 0,41 0,87 2,08 3,11 5,55 8,27
10,17 11,43 12,16 12,53 12,56 12,34 12,03 12,47 13,98 14,86 15,29 15,31 15,05 14,66
9,95 10,52 10,83 10,90 10,76 10,43
8,57 10,93 12,16 12,85 13,21 13,30 13,12 12,72
Evaporating temperature = -10 C 220X 2200 2201 2202 2203 2204 2205 2206 0,30 0,65 1,31 1,76 3,14 4,66 5,93 7,28 0,37 0,76 1,61 2,24 4,02 5,97 7,57 0,40 0,82 1,74 2,50 4,47 6,61 8,39 0,42 0,84 1,81 2,62 4,69 6,95 8,81 0,42 0,87 1,84 2,69 4,81 7,13 9,02 0,42 0,87 1,85 2,71 4,84 7,18 9,08 0,41 0,85 1,84 2,68 4,79 7,11 8,99 0,41 0,83 1,78 2,60 4,65 6,91 8,73
Evaporating temperature = -20 C 220X 2200 2201 2202 2203 2204 2205 2206 0,35 0,70 1,34 1,85 3,32 4,88 6,20 7,60 0,38 0,75 1,45 2,04 3,66 5,40 6,86 8,39 0,40 0,77 1,50 2,14 3,83 5,64 7,17 8,75 0,39 0,79 1,52 2,17 3,89 5,75 7,29 8,91 0,40 0,79 1,52 2,18 3,90 5,77 7,31 8,93 0,39 0,79 1,51 2,16 3,86 5,71 7,23 8,84 0,38 0,76 1,47 2,09 3,75 5,56 7,05 8,61
9,27 10,26 10,76 11,00 11,08 10,97 10,65
TABLE 6b: Refrigerant R404A/R507 - Correction factor for subcooling tsub > 4 C
tsub [C] Fsub 4 1,00 10 1,10 15 1,20 20 1,29 25 1,37 30 1,46 35 1,54 40 1,63 45 1,70 50 1,78
24
TABLE 7a: Refrigerant R404A/R507 Capacities in kW for temperature range - 60 C - 25 C

Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16
Evaporating temperature = -25 C 2200 2201 2202 2203 2204 2205 2206 0,57 0,98 1,31 2,35 3,45 4,40 5,40 0,67 1,20 1,65 2,97 4,37 5,56 6,30 0,72 1,31 1,83 3,28 4,82 6,14 7,49 0,73 1,36 1,91 3,42 5,04 6,40 7,81 0,74 1,37 1,93 3,47 5,11 6,49 7,93 0,85 1,37 1,93 3,46 5,12 6,49 7,93 0,74 1,35 1,90 3,42 5,06 6,42 7,85 0,71 1,31 1,85 3,32 4,93 6,26 7,64
Evaporating temperature = -30 C 2200 2201 2202 2203 2204 2205 2206 0,53 0,88 1,18 2,12 3,09 3,94 4,83 0,64 1,07 1,47 2,65 3,88 4,94 6,06 0,67 1,18 1,63 2,93 4,28 5,45 6,66 0,70 1,21 1,69 3,04 4,47 5,68 6,94 0,70 1,23 1,71 3,07 4,52 5,74 7,02 0,70 1,21 1,70 3,05 4,51 5,74 7,01 0,69 1,20 1,68 3,02 4,46 5,67 6,93 0,67 1,17 1,64 2,93 4,35 5,52 6,75
Evaporating temperature = -40 C 2200 2201 2202 2203 2204 2205 2206 0,56 0,65 1,17 2,09 3,03 3,87 4,73 0,60 0,72 1,27 2,28 3,34 4,25 5,19 0,61 0,75 1,32 2,36 3,47 4,41 5,39 0,62 0,77 1,33 2,38 3,50 4,45 5,45 0,61 0,77 1,31 2,36 3,48 4,43 5,47 0,60 0,77 1,28 2,31 3,42 4,36 5,33 0,59 0,75 1,24 2,24 3,33 4,24 5,19
Evaporating temperature = -50 C 2200 2201 2202 2203 2204 2205 2206 0,49 0,51 0,91 1,63 2,36 3,02 3,69 0,53 0,57 0,99 1,73 2,60 3,30 4,04 0,54 0,60 1,02 1,84 2,69 3,43 4,20 0,54 0,60 1,02 1,84 2,71 3,45 4,22 0,53 0,60 1,01 1,81 2,68 3,42 4,18 0,52 0,60 0,98 1,78 2,63 3,35 4,12 0,50 0,59 0,95 1,72 2,56 3,26 4,00
Evaporating temperature = -60 C 2200 2201 2202 2203 2204 2205 2206 0,46 0,58 0,78 1,40 2,04 2,59 3,16 0,48 0,60 0,80 1,44 2,11 2,69 3,28 0,47 0,60 0,80 1,43 2,11 2,66 3,30 0,45 0,58 0,78 1,40 2,07 2,65 3,25 0,45 0,56 0,75 1,36 2,03 2,59 3,18 0,43 0,54 0,72 1,30 1,96 2,50 3,07
TABLE 7b: Refrigerant R404A/R507 - Correction factor for subcooling tsub > 4 C
tsub [C] Fsub 4 1,00 10 1,10 15 1,20 20 1,29 25 1,37 30 1,46 35 1,54 40 1,63 45 1,70 50 1,78
25
PWM SOLENOID EXPANSION VALVE WITH INTERCHANGEABLE ORIFICE

APPLICATION Solenoid expansion valve Castel type 2028 regulates the refrigerant flow into the evaporator by modulating the opening time phase of the plug and so permitting a wide range of power. This valve must be used with a coil type HM4 (see table 2), controlled by an electronic regulator device (not supplied by Castel). This valve is most frequently used in refrigeration systems, in particular refrigerated cabinets in the supermarket, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/CE, and referred in Directive 67/548/CE). CONSTRUCTION Valve is supplied complete with its orifice; there are seven different orifices corresponding to seven different evaporator capacities , that increase passing from orifice 01 to orifice 07. The last two numbers in the code identify what size of orifice has been mounted on the valve into the factory; for example the code 2028/3S02 identifies a valve with 3/8 solder connections, size 02 orifice. The orifices are interchangeable and can be mounted even if the valve is soldered on the system; in this case use the corresponding spare parts kit, in according to table 3. The main parts of the valves are made with the following materials: Hot forged brass EN 12420 CW 617N for body and the housing pipe of the mobile plug Copper tube EN 12735-1 Cu-DHP for solder connections Austenitic stainless steel EN 10088-3 1.4301 for the filter Ferritic stainless steel EN 10088-3 1.4105 for mobile and fixed plugs Austenitic stainless steel EN 10088-3 1.4305 for orifices Chloroprene rubber (CR) for outlet seal gaskets .T.F.E. for seat gaskets P
OPERATION Valve type 2028 is a lamination device that receives liquid from the condenser and injects it into the evaporator, operating the necessary pressure drop across the expansion orifice. Its an ON/OFF valve that must be regulated with the Pulse Width Modulation (PWM) method and it can be actuated by a very simple electronic controller. In according to the PWM method, the evaporator refrigerant capacity QT, required in a fixed period T, is delivered by the valve in a time interval t, shorter than T. During the period t the valve opens and permits maximum flow (ON phase); in the remaining period T-t the valve closes with no flow (OFF phase). For an effective PWM regulation, the valve must be sized in such a way that in the hardest conditions of the system, the orifice of the valve is big enough to deliver the refrigerant requested; in these extreme conditions the valve will last opened for the entire period T. The use of an electronic regulator allows a more accurate metering of the refrigerant reaching a greater efficiency (and then a sensible decrement of the machinery management costs) and a faster response to the variations of the evaporation load.
COILS AND CONNECTORS Coils type HM4 must be mounted on these valves. Table 2 presents the most important characteristics of coils and corresponding connectors. For further technical characteristics about HM4 coils and their connectors see to the solenoid valve chapter.
SELECTION To correctly select a solenoid expansion valve on a refrigerating system, the following design conditions must be available: Type of refrigerant Evaporator capacity, Qe Evaporating temperature/pressure, Te / pe Lowest possible condensing temperature/pressure, Tc / pc Liquid refrigerant temperature, Tl Pressure drop in the liquid line, distributor and evaporator, p
26
TABLE 1: General Characteristics of PWM solenoid expansion valves

ODS Connections Catalogue number IN 2028/3S01 2028/M10S01 2028/3S02 2028/M10S02 2028/3S03 2028/M10S03 2028/3S04 2028/M10S04 2028/3S05 2028/M10S05 2028/3S06 2028/M10S06 2028/4S07 2028/M12S07 3/8 3/8 3/8 3/8 3/8 3/8 1/2 [in] OUT 1/2 1/2 1/2 1/2 1/2 1/2 5/8 IN 10 10 10 10 10 10 12 [mm] OUT 12 12 12 12 12 12 16 0,5 0,07 0,8 1,1 1,3 1,7 2,3 0,01 0,017 0,023 0,043 0,065 0,113 0,2 14 0 18 18 PWM (Pulse Width Modulating) Orifice Flow [mm] Kv Factor [m3/h] Opening pressure differential [bar] MOPD MinOPD AC/RAC DC Minimum working time [s] Operating principles TS [C] PS [bar] Risk Category according to PED
min
max
-40
100
45
Art. 3.3
TABLE 2: General Characteristic of coils

Consumption at 20C [mA] Coil type Catalogue number Voltage [V] Voltage tolerance [%] Frequency [Hz] 50 [Hz] 9160/RA2 HM4 9160/RA6 9160/RD1 9160/RD2 24 A.C. +6 / -10 220/230 A.C. 12 D.C. 24 D.C. +10 / -15 50 162 1350 650 1490 76 9150/R02 1350 650 9155/R01 Start D.C. Working 50 [Hz] 700 D.C. Connections Protection Degree IP65 Protection Degree IP65/IP68
TABLE 3: Orifice Nominal capacities in kW

Catalogue number Orifice size Orifice type [mm] 0,5 0,7 0,8 1,1 1,3 1,7 2,3 R22 1 1,9 2,5 3,9 6,7 9,2 14,7 R134a 0,9 1,7 2 3,2 5,6 7,7 12,2 Refrigerent R404A R507 9150/R63 9150/R64 9150/R65 9150/R66 9150/R67 9150/R68 9150/R69 01 02 03 04 05 06 07 0,8 1,6 1,9 2,9 5,1 7 11,3 1,1 2 2,4 3,8 6,7 9,1 15,3 1,3 2,4 3 4,8 8,4 11,4 18,2 R407C R410A
Nominal capacities are referred to: Evaporating temperature Tevap = +5C Condensating temperature Tcond = +32C inlet temperature of liquid Tliq = +28C
The following procedure helps to select the correct valve for the system. Step 1 Determine the pressure drop across the valve. The pressure drop is calculated by the formula:
where: Pc = condensing pressure Pe = evaporating pressure p = sum of pressure drops in the liquid line, distributor and evaporator Step 2 Subcooling correction. Use the evaporating capacity Qe to select the required valve size at a given evaporating temperature. If necessary,
p tot = p c ( p e + p
27
a given evaporating temperature. If necessary, correct the evaporator capacity for subcooling. Subcooling liquid refrigerant entering the evaporator increase the evaporator capacity, so that a smaller valve may be required. The subcooling is calculated by the formula:
SIZING EXAMPLE Type of refrigerant R404A Evaporator capacity, Qe 2,8 kW Evaporating temperature/pressure, Te - 5 C Lowest possible condensing temperature/pressure, Tc + 35 C + 20 C Liquid refrigerant temperature, Tl Pressure drop in the liquid line, 2 bar distributor and evaporator, !p Step 1 - Determine the pressure drop across the valve Condensing pressure at + 35 C - Pc = 16,9 bar Evaporating pressure at 5 C - Pe = 5,14 bar
Tsub = Tc Tl
From the subcooling corrector factor table find the appropriate corrector factor Fsub corresponding to the !Tsub calculated and determine the required valve capacity by the formula:
Qsub = Fsub . Qe
Step 3 Application correction . To obtain a correct regulation with this valve, is necessar y to oversize it so its closing period is between the 25% and the 50% of the total period T of the regulator. The correct choice of this closing period depends on the application, that can have peaks of load, and on the criterion used by the electronic regulator. Generally, anyway, this correcting factor Fev is strictly dependent by the evaporation temperature so it be assumed that Fev = 1.25 for Tev >= -15C and Fev = 1.50 for Tev<=-15C. These generic instructions must be verified on the real application. The capacity of the valve will have therefore to be at least equal to:
ptot = 16,9 ( 5,14 + 2 ) = 9,76 bar

Step 2 - Determine required valve capacity
Tsub = 35 20 = 15 C
From the subcooling corrector factor table 5b, we find the appropriate corrector factor Fsub equal to 0,83 for !Tsub = 15 C. Required valve capacity is:
Qsub = 0,83 . 2,8 = 2,324 kW

Step 3 - Determine application correction In according to the above criterion of sizing, Fev = 1,25:
Qev = 1,25 . 2,324 = 2,91 kW

Step 4 - Determine orifice size Using the capacity table for R404A on page 29 with: pressure drop across the valve = 9,76 bar evaporating temperature = - 5 C calculated evaporator capacity = 2,91 kW select the corresponding orifice 04 (N.B. : the expansion valve capacity must be equal or slightly more than the calculated evaporator capacity)
Qev = Fev . Qsub

Step 4 Determine required orifice size. Use the pressure drop across the valve, the evaporating temperature and the calculated evaporator capacity Qe to select the corresponding orifice size from the capacity table corresponding to the chosen refrigerant. Step 5 Liquid line sizing. Since the 2028 is an ON/OFF valve, during the opening phase of the valve, the flow rate can be too much higher than the mean flow rate. For this reason the designer must size the diameter of the pipes of the liquid line in according to the maximum flow rate across the orifice in the effective conditions of !Ptot and so avoiding the decrement of the valve capacity due to the pressure drop.
28
TABLE 4: Refrigerant R22 Capacities in kW

Orifice type 01 02 03 04 05 06 07 2 0,7 1,3 1,7 2,7 4,6 6,3 10,1 4 0,9 1,7 2,2 3,4 6,0 8,1 13,0 6 1,0 1,9 2,5 3,9 6,7 9,2 14,7 Pressure drop across valve [bar] 8 12 10 1,1 2,2 2,7 4,2 7,2 9,9 15,8 1,2 2,2 2,8 4,4 7,6 10,4 16,6 1,2 2,3 2,9 4,5 7,9 10,6 17,0 14 1,2 2,3 2,9 4,6 8,0 10,9 17,4 16 1,2 2,4 2,9 4,7 8,1 11,0 17,6 (1) 18 1,2 2,3 2,9 4,7 8,1 11,1 17,4 (2)
TABLE 5: Refrigerant R134a Capacities in kW

Orifice type 01 02 03 04 05 06 07 2 0,6 1,1 1,4 2,3 3,9 5,3 8,5 4 0,8 1,4 1,8 2,9 5,0 6,8 10,9 6 0,9 1,7 2,0 3,2 5,6 7,7 12,2 Pressure drop across valve [bar] 8 12 10 0,9 1,7 2,2 3,4 6,0 8,1 13,0 0,9 1,8 2,2 3,5 6,2 8,4 13,3 0,9 1,8 2,3 3,6 6,2 8,5 13,5 14 0,9 1,8 2,3 3,6 6,2 8,5 13,5 16 0,9 1,8 2,2 3,5 6,2 8,4 13,3 (1) 18 0,9 1,7 2,2 3,4 6,0 8,1 13 (2)
TABLE 6: Refrigerant R404A/R507 Capacities in kW

TABLE 7: Refrigerant R407C Capacities in kW

(1) Pressure differential not available with coils 9160/RD2 (2) Pressure differential not available with coils 9160/RD1 and 9160/RD2
29
TABLE 8: Refrigerant R410A Capacities in kW

(1) Pressure differential not available with coils 9160/RD2 (2) Pressure differential not available with coils 9160/RD1 and 9160/RD2
TABLE 9: Correction factor for subcooling tsub > 4C

Refrigerant R22 R134a R404A/R507 R407C R410A 4K 1 1 1 1 1 10K 0,94 093 0,91 0,93 0,95 15K 0,9 0,88 0,83 0,88 0,9 20K 0,87 0,84 0,78 0,83 0,85 25K 0,83 0,8 0,73 0,79 0,81 30K 0,8 0,76 0,68 0,75 0,77 35K 0,77 0,73 0,65 0,72 0,73 40K 0,74 0,7 0,61 0,69 0,7 45K 0,72 0,68 0,59 0,66 0,67 50K 0,69 0,65 0,56 0,64 0,64
When subcooling ahead of the expansion valve is over than 4 C, adjust the evaporator capacity by dividing by the appropriate correction factor found in table 8
The dimensions in brakets are referred to 2028/4S07 & 2028/M12S07 models
30
Solenoid valves
SOLENOID VALVES FOR REFRIGERATING SYSTEMS

cover; chloroprene rubber (CR) for outlet seal gaskets; .T.F.E. for seat gaskets. P INSTALLATION The valves can be installed in all sections of a refrigerating system, in compliance with the limits and capacities indicated in Tables 3 and 6. Tables 1 and 4 show the following functional characteristics of a solenoid valve: PS; TS; Kv factor; minimum Opening Pressure Differential (minOPD), that is the minimum pressure differential between inlet and outlet at which a solenoid valve, pilot operated, can open and stay opened; maximum Opening Pressure Differential (MOPD according to ARI STANDARD 760: 2001), that is the maximum pressure differential between inlet and outlet at which a solenoid valve, pilot operated, can open. Before connecting the valve to the pipe it is advisable to make sure that the refrigerating system is clean. In fact the valves with P .T.F.E. gaskets are particularly sensitive to dirt and debris. Furthermore check that the flow direction in the pipe corresponds to the arrow stamped on the body of the valve. All valves can be mounted in whatever position except with the coil pointing downwards. The brazing of valves with solder connections should be carried out with care, using a low melting point filler material. It is not necessary to disassemble the valves before brazing but its important to avoid direct contact between the torch flame and the valve body, which could be damaged and compromise the proper functioning of the valve. Before connecting a valve to the electrical system, be sure that the line voltage and frequency correspond to the values marked on the coil. The NO valves have been designed to work only with direct current coils. To use them in applications with 220/230 VAC suplly its necessary to mate the NO valve with the following components: Coil 9120/RD6 + Connector/ Rectifier 9150/R45
APPLICATIONS The solenoid valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). OPERATION The valves series 1020; 1028; 1050; 1058; 1059; 1064; 1068; 1070; 1078; 1079; 1090; 1098; 1099 are normally closed. NC = when the coil is de-energised the plunger stops the refrigerant flow. The valves series 1150; 1158; 1164; 1168; 1170; 1178;1190; 1198 are normally open. NO = when the coil is energised the plunger stops the refrigerant flow. The valves series 1020 and 1028 are direct acting, while the valves of all the other series are pilot operated, with diaphragm or piston. The NC valves are supplied either without coil (S type) or with coil (example: A6 type with coil HM2220 Vac). The NO valves are supplied only without coil (S type). N.B.: the NO valve visually differs from the corresponding NC model by means of the red ring installed below the yellow nut that fastens the coil. CONSTRUCTION The main parts of the valves are made with the following materials: hot forged brass EN 12420 CW 617N for body and cover; copper tube EN 12735-1 Cu-DHP for solder connections; austenitic stainless steel EN 10088-2 1.4303 for enclosure where the plunger moves; ferritic stainless steel EN 10088-3 1.4105 for plunger: austenitic stainless steel EN ISO 3506 A270 for tightening screws between body and
32
TABLE 1a: General Characteristics of NC valves (normally closed) with SAE Flare connections
Connections Catalogue number Seat size Nominal [mm] Kv Factor [m3/h] Operating Principles Opening Pressure Differential [bar] MOPD Coil type HM2 CM2 (AC) HM4 (AC) HM3 (DC) min. max. TS [C] PS [bar] Risk Category according to PED
SAE Flare 1/4" 3/8" 3/8"
min OPD
1020/2 1020/3 1064/3 1064/4 1070/4 1070/5 1050/5 1050/6 1090/5 1090/6
2,5 3 7
0,175 0,23 0,80 2,20
Direct Acting
0 19 +105 (1)
1/2" 1/2" 12,5 5/8" 5/8" 3/4" 16,5 5/8" 3/4" 3,80 4,80 2,61 3,80 4,80
Diaphragm Pilot Operated
25 0,05 21 (3) 18 35
45 +110
Art. 3.3
Piston Pilot Operated Diaphragm Pilot Operated
0,07 (2) 13 +105 0,05 21 (1)
(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 Departement.
TABLE 1b: General Characteristics of NC valves (normally closed) with ODS connections
Connections Catalogue number [in.] 1028/2 1028/2E 1028/3 1028/M10 1068/3 1068/M10 1068/M12 1068/4 1078/M12 1078/4 1078/5 1079/7 1058/5 1058/6 1058/7 1059/9 1098/5 1098/6 1098/7 1099/9 1078/9 1079/11 1098/9 1099/11 1078/11 1079/13 1079/M42 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" ODS [mm] 10 10 7 12 12 2,20 12,5 16 2,61 22 Piston Pilot Operated 16 22 5,70 16,5 16 22 5,70 25,5 35 35 35 42 27 16 Piston Pilot Operated 25 10 19 25 0,07 (3) (2) +110 10 3,80 4,80 Diaphragm Pilot Operated 21 +105 0,05 (1) 13 3,80 4,80 0,80 3 0,23 Seat size Nominal [mm] Kv Factor [m3/h] Operating Principles Opening Pressure Differential [bar] MOPD Coil type HM2 CM2 (AC) HM4 (AC) HM3 (DC) min. max. TS [C] PS [bar] Risk Category according to PED
min OPD
Direct Acting
2,2
0,15
19 Diaphragm Pilot Operated
+105 0,05 25 (3) 18 (1)
21 0,07
35
+110 (2)
45
Art. 3.3
(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 Departement.
33
TABLE 2: Dimensions and Weights of NC valves with 9100 coil (1)

Dimensions [mm] Catalogue number Weight [g] Q
H1
H2
H3
L1
L2
1020/2 1020/3 1028/2 75 1028/2E 1028/3 1028/M10 1064/3 1064/4 1068/3 82 1068/M10 1068/M12 1068/4 1070/4 1070/5 1078/M12 91 1078/4 1078/5 1079/7 1050/5 1050/6 1058/5 121 1058/6 1058/7 1059/9 1090/5 1090/6 1098/5 106 1098/6 1098/7 1099/9 1078/9 115 1079/11 1098/9 157 1099/11 1078/11 1079/13 1079/M42 175 141 113 127 99 96 72 78 50 93 65 75 47 69,5 40 62,5 34
58 65 125 125 125 125 68 72 111 111 127 127 100 106 127 45 127 175 190 120 124 175 175 180 216 57 120 124 175 175 180 216 250 80 292 235 68 277 50
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
278
80
2750 2750
(1) With coil type 9120 the dimension L2 is equal to 64 mm and the valves weights must be increased of 305 g.
34
Connectors are not included in the boxes and have to be ordered separately.
35
TABLE 3: Refrigerant Flow Capacity of NC valves

Refrigerant Flow Capacity [kW] Catalogue number R134a 1020/2 1020/3 1028/2 1028/2E 1028/3 1028/M10 1064/3 1064/4 1068/3 13,5 1068/M10 1068/M12 1068/4 1070/4 1070/5 1078/M12 37,1 1078/4 1078/5 44,0 1079/7 1050/5 1050/6 1058/5 1058/6 1058/7 96,0 1059/9 1090/5 1090/6 1098/5 1098/6 1098/7 96,0 1099/9 1078/9 168,5 1079/11 1098/9 168,5 1099/11 1078/11 1079/13 1079/M42 269,6 288,0 299,8 190,4 304,6 34,6 43,2 42,9 36,2 57,6 136,0 187,2 185,9 160,0 208,0 180,0 187,4 119,0 190,4 21,6 27,0 26,8 22,6 36,0 85,0 117,0 116,2 100,0 130,0 180,0 187,4 119,0 190,4 21,6 27,0 26,8 22,6 36,0 85,0 117,0 116,2 100,0 130,0 102,6 106,8 67,8 108,5 12,3 15,4 15,3 12,9 20,5 48,5 66,7 66,2 57,0 74,1 64,0 80,9 64,0 80,9 68,4 86,4 68,4 86,4 71,2 90,0 71,2 90,0 45,2 57,1 45,2 57,1 72,4 91,4 72,4 91,4 8,2 10,4 8,2 10,4 10,3 13,0 10,3 13,0 10,2 12,9 10,2 12,9 8,6 10,8 8,6 10,8 13,7 17,3 13,7 17,3 32,3 40,8 32,3 40,8 44,5 56,2 44,5 56,2 44,2 55,8 44,2 55,8 38,0 48,0 38,0 48,0 49,4 62,4 49,4 62,4 102,6 106,8 67,8 108,5 12,3 15,4 15,3 12,9 20,5 48,5 66,7 66,2 57,0 74,1 64,0 80,9 64,0 80,9 68,4 86,4 68,4 86,4 71,2 90,0 71,2 90,0 45,2 57,1 45,2 57,1 72,4 91,4 72,4 91,4 8,2 10,4 8,2 10,4 10,3 13,0 10,3 13,0 10,2 12,9 10,2 12,9 8,6 10,8 8,6 10,8 13,7 17,3 13,7 17,3 32,3 40,8 32,3 40,8 44,5 56,2 44,5 56,2 44,2 55,8 44,2 55,8 38,0 48,0 38,0 48,0 49,4 62,4 49,4 62,4 47,0 48,9 31,1 49,7 5,64 7,05 6,99 5,90 9,40 22,2 30,5 30,3 26,1 33,9 39,6 41,2 26,2 41,9 4,75 5,94 5,90 4,97 7,92 18,7 25,7 25,6 22,0 28,6 37,1 44,0 39,6 47,0 41,2 48,9 26,2 31,1 41,9 49,7 4,75 5,64 5,94 7,05 5,90 6,99 4,97 5,90 7,92 9,40 18,7 22,2 25,7 30,5 25,6 30,3 22,0 26,1 28,6 33,9 14,4 15,0 9,5 15,2 1,73 2,16 2,14 1,81 2,88 6,8 9,4 9,3 8,0 10,4 3,88 4,14 4,31 2,74 4,38 1,96 2,69 2,67 2,30 2,99 2,95 3,88 2,53 R22 3,15 4,14 2,70 Liquid R407C 3,28 4,31 2,81 R404A 2,08 2,74 1,79 R410A 3,33 4,38 2,86 R134a R22 Vapour R407C R404A R410A R134a 1,49 1,96 1,28 R22 2,05 2,69 1,76 Hot Gas R407C 2,03 2,67 1,74 R404A 1,75 2,30 1,50 R410A 2,28 2,99 1,95
Refrigerant flow capacity referred to the following operating conditions: Evaporating temperatre: +4 C Condensing temperature: +38 C Pressure drop: 0,15 bar
Particularly for hot gas: Suction temperature: +18 C Pressure drop: 1 bar
36
TABLE 4a: General Characteristics of NO valves (normally open) with SAE Flare connections
Connections Catalogue number Coil type Seat size nominal [mm] Kv Factor [m3/h] Operating Principles Opening Pressure Differential [bar] min OPD 0,80 2,20 12,5 5/8" 5/8" 3/4" 16,5 1190/5 1190/6
R R
TS [C] PS [bar] min. max. Risk Category according to PED
SAE Flare 3/8" 1/2"
MOPD
1164/3 1170/4 1170/5 1150/5 1150/6
R R
HM3 (D.C.)
R R R
2,61 3,80 4,80 3,80 4,80
Diaphragm pilot operated Piston Pilot Operated Diaphragm pilot operated
0,05
21
+105 (1)
0,07 19
35
+110 (2) +105
32
Art. 3.3
5/8" 3/4
0,05
(1)
(1) Temperature peaks of 120 C are allowed during defrosting. (2) Temperature peaks of 130 C are allowed during defrosting.
R
Available on request.
TABLE 4b: General Characteristics of NO valves (normally open) with ODS connections
Connections Catalogue number Coil type [in.] ODS [mm] 7 0,80 Diaphragm Pilot Operated 0,05 21 +105 (1) 10 12 2,20 16 16 22 16,5 16 22 35 25,5 25 27 12,5 2,61 3,80 4,80 5,70 3,80 4,80 5,70 10 10 16 Piston Pilot Operated +110 0,07 (2) Diaphragm Pilot Operated 19 +105 0,05 (1) Piston Pilot Operated +110 0,07 35 (2) 32 Art. 3.3 Seat size nominal [mm] Kv Factor [m3/h] Operating Principles Opening Pressure Differential [bar] min OPD TS [C] PS [bar] min. MOPD max. Risk Category according to PED
1168/3 1168/M10 1178/M12 1178/4 1178/5 1158/5 1158/6 1158/7 1198/5 1198/6 1198/7 1178/9 1198/9 1178/11
R R R R R
3/8" 1/2" 5/8" HM3 (D.C.) 5/8" 3/4" 7/8" 5/8" 3/4" 7/8" 1.1/8" 1.1/8" 1.3/8"
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.
R
37

1164/3 1168/3 1168/M10
1170/4 1170/5
1178/M12 1178/4 1178/5
1150/5 1150/6 1190/5 1190/6
1158/5 1158/6 1158/7 1198/5 1198/6 1198/7
1198/9 1178/11 1178/9
Connectors and coils are not included in the boxes and have to be ordered separately.
38
TABLE 5: Dimensions and Weights of NO valves with 9120 coil

H1
H2
H3
L1
L2
1164/3 1168/3 1168/M10 1170/4 1170/5 1178/M12 1178/4 1178/5 1150/5 1150/6 1158/5 1158/6 1158/7 1190/5 1190/6 1198/5 1198/6 1198/7 1178/9 1198/9 1178/11 120 162 177 101 132 143 72 99 110 111 83 50 126 98 70 96 80 47 87 74,5 40
68 111 111 100 106 127 127 175 120 124 175 175 180 57 120 124 175 175 180 250 235 278 80 68 68 64 45
705 705 700 1015 1060 995 985 1080 1462 1792 1422 1612 1597 1340 1670 1300 1490 1475 2870 2355 3015
TABLE 6: Refrigerant Flow Capacity of NO valves

Refrigerant Flow Capacity [kW] Catalogue number R134a 1164/3 1168/3 1168/M10 1170/4 1170/5 1178/M12 37,1 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 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 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 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 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 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 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 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 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 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 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 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 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 39,6 41,2 26,2 4,75 5,94 5,90 4,97 18,7 25,7 25,6 22,0 37,1 44,0 39,6 47,0 41,2 48,9 26,2 31,1 4,75 5,64 5,94 7,05 5,90 6,99 4,97 5,90 18,7 22,2 25,7 30,5 25,6 30,3 22,0 26,1 13,5 14,4 15,0 9,5 1,73 2,16 2,14 1,81 6,8 9,4 9,3 8,0 R22 Liquid R407C R404A R134a R22 Vapour R407C R404A R134a R22 Hot Gas R407C R404A
Refrigerant flow capacity referred to the following operating conditions: Evaporating temperatre: +4 C Condensing temperature: +38 C Pressure drop: 0,15 bar
Particularly for hot gas: Suction temperature: +18 C Pressure drop: 1 bar
39
COILS
Protection against electric contacts is class I for all the coils. Therefore, for safety purposes, coils must be effectively connected to an earthing system. Rubber gaskets on the upper and lower ends of coil ensure moisture protection of winding. Coils HM2 and HM3 may be joined to all connectors produced by Castel except type 9155/R01; protection degree guaranteed by this system, coil (HM2, HM3) + connector, is IP65 according to EN 60529. Coils HM4 must be preferably used with connector type 9155/R01; protection degree guaranteed by this other system, coil HM4 + connector 9155/R01, is IP65/IP68 according to EN 60529. Coils HM4 can be used with connectors series 9150 and 9900 too; protection degree guaranteed by this system is IP65. Either the terminals of coils series HM2 and HM3 or the ones of coils series HM4 consist of two Faston line connections plus one Faston earthing connection. Coil type CM2 has a preassembled cable (length 1 meter). The coils are designed for continuous use. The solid construction of these coils is suitable for heavy-duty applications in refrigerant systems. The maximum ambient temperature for all coils is 50 C. ELECRIC TYPE APPROVAL Coils series 9100, 220/230 VAC and 240 VAC supply, are approved by the german registration body VDE. Coils series 9105 are approved by Underwriters laboratories Inc. of the United States. Coils series 9100, 9110 and 9160, 110 VAC, 220/230 Vac and 240 VAC supply, and coils series 9120, 220/230 VAC supply, are manufactured according to low Voltage (LV) Directive 2006/95/EC. Coils series 9100, 9110, 9120 and 9160 are manufactured according to Electromagnetic Compatibility (EMC) Directive 2004/108/EC.
APPLICATION For the normally closed solenoid valves, previously shown in this Handbook, Castel puts the following types of coils at disposal of its own customers: coils series HM2, only for A.C. (catalogue numbers 9100 - 9105). coils series CM2, only for A.C. (catalogue number 9110); coils series HM3,either for A.C. or for D.C. (catalogue number 9120). coils series HM4, only for A.C. (catalogue number 9160). For the normally open solenoid valves, always shown in this Handbook, the customers selection must compulsorily apply to the coils series HM3 D.C. For applications of the NO solenoid valves with a voltage supply of 220 VAC, Castel has designed a specific coil at 220 V RAC (code 9120/RD6) that must be used solely with the 220 VAC connector/rectifier circuit (code 9150/R45).
CONSTRUCTION Coils HM2 (9100) are class H, whereas coils CM2, HM3 and HM4 are class F, in compliance with IEC 85 standard and their construction is in compliance with EN 60730-1 and EN 607302-8 standards. The windings are made with copper wire, insulation class H 180 C, in compliance with IEC 85 standard. The outer casing is provided with dielectric and waterproof resins that assure a reinforced insulation making the coils suitable for all assemblies. Coils HM2 (9105) are class F, with UL approved EIS (Electrical Insulation System), and their construction is in compliance with UL 429 Standards.
40
TABLE 1: General Characteristics of coils
Coil Type
Catalogue number
Voltage [V]
Voltage tollerance [%]
Frequency [Hz]
Connections
Degree of protection
9100/RA2 9100/RA4 HM2 9100/RA6 9100/RA7 9100/RA8 9105/RA2 HM2
24 A.C. +10 / -10 110 A.C. Junction box 220/230 A.C. 240 A.C. +10 / -10 380 A.C. 24 A.C. 110/120 A.C. +6 / -10 60 DIN 43650 +10 / -10 +10 / -10 (with junction box) 220/230 A.C. 240 A.C. 24 A.C. 110 A.C. 50 / 60 Three wire cable EN 60529 220/230 A.C. 240 A.C. 220/230 A.C. 12 D.C. Junction box EN 60529 (With junction box) 24 D.C. +10 / -5 DIN 43650 48 D.C. 220 RAC 24 A.C. +10 / -10 110 A.C. 50 / 60 220/230 A.C. 240 A.C. +6 / -10 +10 / -10 Junction box DIN 43650 or Connector 9155/R01 (1) IP65 EN 60529 (with junction box) IP65/IP68 EN 60529 (with connector) +6 / -10 +10 / -10 +6 / -10 50 / 60 IP65 IP65 +10 / -10 junction box IP65 EN 60529 junction box) +6 / -10 50 / 60 DIN 43650 (with EN 60529 IP65
Recognized
File number E243604
9105/RA4 9105/RA6 9105/RA7 9110/RA2 9110/RA4
CM2 9110/RA6 9110/RA7 9120/RA6 9120/RD1 HM3 9120/RD2 9120/RD4 9120/RD6 9160/RA2 9160/RA4 HM4 9160/RA6 9160/RA7
(1) Coil HM4 can also be coupled to connectors series 9150 and 9900, achieving a degree of protection IP65, the versatile degree of protection ( IP65/IP68) is achieved coupling coil HM4 with four screws connector 9155/R01
HM2
CM2
41
TABLE 2: Coils consumptions

Consumptions at 20 C [mA] Coil Type Catalogue number 50 [Hz] 9100/RA2 9100/RA4 HM2 9100/RA6 9100/RA7 9100/RA8 HM2 9105/RA2 9105/RA4 9105/RA6 9105/RA7 9110/RA2 9110/RA4 CM2 9110/RA6 9110/RA7 9120/RA6 9120/RD1 HM3 9120/RD2 9120/RD4 9120/RD6 9160/RA2 9160/RA4 HM4 9160/RA6 9160/RA7 162 147 142 130 1490 330 1320 300 76 70 57 53 460 93 700 156 530 118 63 41 35 220 120 100 190 105 87 160 1720 900 460 93 920 230 105 87 825 205 68 54 110 58 43 80 1720 900 82 61 35 470 527 128 920 230 140 100 58 Start 60 [Hz] 825 205 128 87 51 825 205 58 43 420 114 66,5 34 35 230 _ D.C. 50 [Hz] 527 128 68 54 32 Working 60 [Hz] 420 114 58 43 23 420 114 57,5 34 35 165 _ 57,5 34 35 165 D.C. L1 Dimensions [mm]
Weight [g] H
L2
Recognized
HM3
HM4
42
CONNECTORS
The junction boxes 9150, DIN 43650 standardized, represent an effective system for the connection of the coil to the supply circuit, thus ensuring safety also in the presence of moisture. These junction boxes, according to assembly requirements, allow choosing the position of outer casing compared to inner terminal block. The clamping screw of casing may be PG9 or PG11, which are respectively suitable for cables with an external diameter of 6 8 or 8 10 mm. Cables sized 3 x 0,75 mm2 are to be preferred. The junction box type 9900 is available with cabled core of different length. In this case, it is not possible to change the position of casing compared to terminal block. Both the two types offer a protection degree IP65 against dust and water, according to EN 60529, when correctly installed with the proper gaskets, which are supplied as standard. Castel has developed a specific junction box, type 9155/R01, suitable for use on those refrigerating systems working in heavy duty environments, for example: exposition to the atmospheric conditions; rooms with high moisture degree; cyclic condensing / evaporating on the valve; cyclic icing / defrosting on the valve. This junction box, according to assembly requirements, allows choosing the side position of outer casing compared to inner terminal block; but it is not possible to point the cable upwards. The gland nut of casing is suitable to receive cables with an external diameter of 6 9 mm and is provided with a self-locking device. Cables sized 3 x 0,75 mm2 are to be preferred for this junction box too. The junction box type 9155/R01 offers a protection degree IP65/IP68 against dust and water, according to EN 60529, when correctly installed with the proper gaskets, which are supplied as standard. The junction box 9150/R45 is equipped with a full-wave bridge rectifier plus VDR for protection. The VDR device, Voltage e-Dependent-Resistor, is a special type of resistor, placed in parallel to the coil; its purpose is to protect the diodes and the coil from any excessive voltage generated within the ac supply circuit. WARNING: the junction box 9150/R45 must be solely used with coils 9120/RD6 (220 VRAC). The wrong use of these junction boxes with other types of Castel coils takes quickly to the destruction of the coil.
TABLE 3: General Characteristics of connectors

Supply Voltage [V] Pg Nominal 9150/R01 9150/R02 11 9150/R45 9155/R01 9900/X66 9900/X84 R 9900/X73 9900/X55 9900/X54 220 A.C. 250 A.C. IP65/IP68 1 1,5 DIN 2 3 5 3 x 0,75 43650 EN 60529 IP65 EN 60529 Group C VDE 0110-1 / 89 43650 EN 60529 Maximum 9 DIN IP65
Catalogue number
Cable length [m]
Cable thickness [mm2]
Standard
Degree of protection
Class of insulation
43
PERMANENT MAGNET
APPLICATION Castel supplies to its customers the permanent magnet code 9900/X91 for the normally closed solenoid valves, shown in this chapter. This product can be used during brazing of the valve copper connections to the plant pipes; slipping it on the armature, instead of the coil, it allows the protective gas (nitrogen) flowing and avoids any damage to the plunger gasket and to the diaphragm. CONSTRUCTION The main parts of the permanent magnet code 9900/X91 are made with the following materials: three rings of anisotropic ferrite; anodized aluminum for the body.
SOLENOID VALVES FOR DIFFERENT FLUIDS

APPLICATIONS The solenoid valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for the applications specified in Table 1 where the different fluids are indicated with the following symbols, according to an already established code: W = Water; L = Air; B = Secondary coolants (solutions of glycol and water); O = Light oils (gas oil). In short these valves may be used: with fluids in the gaseous state proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC); with fluids in the liquid state proper to the Group I (as defined in Article 9, Section 2.1 of Directive 97/23/EC and referred to in Directive 67/548/EEC).
44
TABLE 1: General Characteristics

Seat Size nominal [mm] Operating Principles Opening Pressure Differrential [bar] min OPD min. MOPD 30 Acting Direct 0 4 30 G 1/2" +105 G 3/8" 12,5 G 1/2" W.L.O.B. G 3/4" 20 G 1" G 1.1/4" 38 1142/012 G 1.1/2" 21,00 6,00 19,00 2,20 5,50 2,10 Diaphragm Pilot Operated 0,1 17 -15 Art. 3.3 TS [C] PS [bar] max. Risk Category according to PED
Catalogue number
Coil Type
Main Use
FPT Connections
Kv Factor [m3/h]
1512/01 HM2 (A.C.) - CM2 (A.C.) HM3 (A.C.; D.C.) - HM4 (A.C.) 1522/02 1522/03 1522/04 1132/03 1132/04 1132/06 1132/08 1142/010
W.L.O.
G 1/8" G 1/4"
1,5
0,070
W.O.
G 3/8"
4,5
0,40
0,15
12 15
0,3
11
+90
OPERATION All the valves for different fluids are normally closed. NC = when the coil is de-energised the plunger stops the refrigerant flow. The valves series 1512 and 1522 are direct acting, while the valves series 1132 and 1142 are pilot operated with diaphragm. CONSTRUCTION The main parts of the valves are made with the following materials: hot forged brass EN 12420 CW 617N for body and cover; austenitic stainless steel EN 10088-2 1.4303 for enclosure where the plunger moves; ferritic stainless steel EN 10088-3 1.4105 for plunger; austenitic stainless steel EN ISO 3506 A270 for tightening screws between body and cover; fluorocarbon rubber (FPM) for outlet seal gaskets; fluorocarbon rubber (FPM) for seat gaskets; fluorocarbon rubber (FPM) for diaphragms. Nitril rubber (NBR) for the valves series 1142.
INSTALLATION Table 1 shows the following functional characteristics of a solenoid valve: PS; TS; Kv factor; minimum Opening Pressure Differential (minOPD), that is the minimum pressure differential between inlet and outlet at which a solenoid valve, pilot operated, can open and stay opened; maximum Opening Pressure Differential (MOPD according to ARI STANDARD 760: 2001), that is the maximum pressure differential between inlet and outlet at which a solenoid valve, pilot operated, can open. Before connecting the valve it is advisable to make sure that the piping are clean and that the flow direction in the pipe corresponds to the arrow stamped on the body of the valve. All valves can be mounted in whatever position except with the coil pointing downwards. Before connecting a valve to the electrical system, be sure that the line voltage and frequency correspond to the values marked on the coil.
45
VISCOSITY The values of maximum differential pressure specified in Table 1 are suitable for fluids with maximum cinematic viscosity of 12 cSt where: 1cSt = 10-6 m2/sec. If the cinematic viscosity of the fluid under consideration is more than 12 cSt it is necessary to multiply the value of the maximum differential pressure by the following reducing factors:
AIR CAPACITY Table 2 provides the values of air capacity under the following conditions: temperature at valve inlet = 20 C; discharge pressure (absolute) = 1 bar; Kv of the valve under consideration = 1 m3/h. The pressures upstream the valve specified in the table are absolute values.
EXAMPLE
Cinematic Viscosity cSt 12 12 30 30 45 Reducing factor 1 0,8 0,7
When the viscosity of the liquid is expressed as , where: dynamic viscosity, i.e. cP 1cP = 10-3 N sec/m2 the corresponding value of cinematic viscosity in cSt is obtained by the following relation: = where: = cinematic viscosity [cSt]; = dynamic viscosity [cP]; = volumic mass of the fluid at the considered temperature [kg/dm3]. Moreover, the fluid viscosity may remarkably vary according to changes in temperature. Therefore, if the temperature of the fluid does not ensure viscosity values compatible with the correct operation of the valve, the valve may not open. LIQUIDS CAPACITY The following ratio applies: Q = Kv x p
Select the valve suitable for use with approximately 200 m3/h of air, assuming an absolute pressure of 8 bars at valve inlet ( = 7 bars of relative pressure + 1 bar) and an acceptable pressure drop across the valve of 1,5 bars. In the column of pressures upstream the valve, the value 8 is shown; where this column intersects the horizontal column relating to the pressure drop of 1,5, the value of 87 m3/h is shown. This is the capacity value of a hypothetical valve with Kv = 1 working under the above mentioned conditions. 200 / 87 = 2,29 This is the Kv value required in the case under consideration. In Table 1, select the valve with the Kv value nearest to 2,29, rounding off the value and subsequently checking that all the characteristics of the selected valve (max. opening pressure differential, temperature, connections, etc.) are suitable.
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].
46
TABLE 2 - Air Capacity (Kv = 1)

Capacity [m3/h] (1) Pressure drop [bar] 18 0,0025 0,005 0,010 0,015 0,025 0,05 0,1 0,15 0,25 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7 7,5 8 8,5 9 10,7 6,2 8,7 4,2 5,4 7,5 3,0 3,9 5,0 6,9 9,6 17 16 15 14 13 12 11 10 9 Inlet pressure (absolute) [bar] 8 7 6 5 4 3 2 1,5 1,3 1,2 1,1 1,05 1,03 1,015 1,46 2,2 2,10 3,0 3,00 3,7 3,55 4,8 4,56 6,6 6,40 9,2 8,8 1,42 1,40 1,35 2,00 1,95 1,90 2,85 2,80 2,75 3,45 3,40 3,35 4,45 4,40 6,20
17,4 15,0 12,2 10,2
23,8 21,2 18,3 14,6 12,5 11,5 11,0 33,4 30,4 27,0 23,2 18,5 15,6 13,9 82,0 80,0 77,0 74,0 72,0 69,5 66,6 63,7 60,6 57,3 54,0 50,0 46,0 41,7 36,8 31,0 24,3 19,6 115,0 111,0 108,0 104,0 100,0 96,0 92,0 88,0 83,0 78,6 73,5 68,0 62,0 55,6 48,0 39,3 27,8 138,0 134,0 130,0 125,0 120,0 115,5 110,3 105,0 99,3 93,0 87,0 80,0 72,0 63,7 53,8 41,7 157,0 152,0 147,0 142,0 136,0 130,0 124,0 118,0 111,0 96,0 96,0 88,0 78,0 68,0 55,6 173,0 167,5 161,5 155,5 149,0 142,5 135,5 128,0 120,4 112,0 103,0 89,5 82,0 69,5 186,0 180,0 174,0 167,0 160,0 152,0 144,5 136,0 127,0 118,0 108,0 96,0 83,0 198,0 191,0 184,0 176,5 168,6 160,3 151,7 142,5 132,6 122,0 110,0 97,0 208,0 200,0 193,0 184,0 176,0 167,0 157,0 147,0 136,0 124,0 111,0 216,0 208,6 200,0 191,0 182,0 172,0 161,5 150,4 138,0 125,0 224,0 215,0 206,0 195,5 186,0 176,0 164,5 152,3 139,0 230,0 221,0 211,0 201,0 190,0 178,6 166,3 152,9 236,0 226,0 215,0 204,0 192,7 180,0 166,8 240,0 230,0 218,0 206,7 194,0 180,7 244,0 233,0 220,0 208,0 194,7 246,0 234,0 222,0 208,5 249,0 236,0 222,5 250,0 236,5 250,5
(1) The table provides air capacity values in m3/h under the following conditions: temperature at value inlet: + 20 C pressure at outlet (absolute): 1 bar Kv of the solenoid valve: 1 m3/h
47
TABLE 3 - Dimensions and Weights (valves with coils 9100)

H1
H2
H3
L1
L2
1132/03 91 1132/04 50 1132/06 101 1132/08 1142/010 136 1142/012 1512/01 1522/02 50 1522/03 1522/04 71 59 36 51 69 57 34 44 103 82 168 104 104 81 52 88 57 75 47 75 45
664 641 1004 944 4100 4000 310 385 370 355
With coils 9120 the dimension L2 is equal to 64 mm and the weight must be increased of 305 g.
L2
L2 L2
H2
H1 H2
H1 H2
H1
H3
1512/01 L1 L1
1522/02 1522/03 1522/04
H3
L1
1132/03 1132/04
L2 L2 Q
H2
H2
H1
H3
H1
L1
1132/06 1132/08 L1
1142/010 1142/012
Connectors are not included in the boxes and have to be ordered separately
48
H3
H3
Safety devices
SAFETY VALVES 3030

atmosphere. For this reason, during relief, a gas leak occurs through this orifice. Utilized material: EN 12420-CW617N brass. Disc: obtained through bar machining and equipped with gasket, it ensures the required sealing degree on the valve seat. The gasket is made in P .T.F.E. (Polytetrafluorethylene), a material that, during valve estimated service life, maintains a good strength and does not cause the disc to stick on the seat. The disc is properly guided in the body and the guide action can never fail; there are no glands or retaining rings that hamper the movement thereof. Utilized material: EN 12164-CW614N brass. Spring: it opposes the pressure and the fluid dynamic actions and always ensures valve reclosing after pressure relief. The spring coils, when the disc has reached the lift corresponding to the state of relief at full flow rate, are spaced apart by at least half the wire diameter and, in any case, by not less than 2 mm. The disc is equipped with a mechanic lock and when it attains it, the spring set does not exceed 85% of the total set. Utilized material: DIN 17223-1 steel for springs. Setting system: hexagonal head, threaded ring nut to be screwed inside the body top by compressing the spring below. On setting completion, the position attained by the ring nut is maintained unchanged laying, in the threaded coupling, a bonding agent with high mechanic strength and low viscosity features to make penetration thereof easier. The setting system is protected against subsequent unauthorized interventions by means of a cap nut that is screwed outside the body and is sealed with Castel lead to it.
GENERAL DESCRIPTION Valves series 3030 are safety devices according to the definition given in Article 1, Point 2.1.3, 2nd dash of 97/23/EC Directive and are the subject of Article 3, Point 1.4 of aforesaid Directive. The valves above mentioned are standard type, unbalanced, direct-loaded safety valves. Valve opening is produced by the thrust the fluid under pressure exerts on the disc, when said thrust exceeds, under setting conditions, the opposing force of the spring acting on the disc. Valves are identified by means of: a model number formed of an alphanumerical coding that includes: in the first part the family identification (e.g. 3030/44C); in the second part the setting pressure, expressed in bars, multiplied by 10 (e.g. 140); an alphanumerical serial number. CONSTRUCTION Body: squared, obtained through die forging and subsequent machining. It houses the following elements: the nozzle with flat sealing seat; the disc guide; the setting spring holder; the threaded seat of the setting adjusting ring nut. In the body, above the disc guide, a small pressure relief hole is provided through which the spring holder is put into contact with the
TABLE 1: General Characteristics of valves 3030
Catalogue number Inlet male Connections Outlet male 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 3/4" G 12 113 4,1 0,90 3/4" G 12 113 4,1 0,90 55 - 50 / + 150 8 / 50 5% of set pressure 15% of set pressure IV 1.1/4" G 19,5 298 6,8 0,83 3030/44C 3030/66C 3030/88C 1" NPT
1/2" NPT 3/4" NPT
50
TABLE 2: Dimensions and Weights of valves 3030

Catalogue number 3030/44C 3030/66C 3030/88C Dimensions [mm] D 38 38 50 L 38 38 56 Ch 28 28 40 H1 44 44 58 H2 115 115 158 H3 159 159 216 Weight [g] 780 780 1960
SCOPE Use: protection against possible overpressures of the apparatuses listed below, with regard to the operating conditions for which they have been designed: refrigerating system and heat pump components, for instance: condensers, liquid receivers, evaporators, liquid accumulators, positive displacement compressor discharge, heat exchangers, oil separators, piping (reference: EN 378-2: 2008); simple pressure vessels (reference: 87/404/ EEC Directive). Fluids: the valves can be used with: refrigerant fluids, in the physical state of gas or vapour, belonging to Group II according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27th, 1967); air and nitrogen (reference: 87/404/EEC Directive). MARKING In conformity with the provisions of Article 15 of 97/23/EC Directive, the EC marking and the identification number of the notified body involved in the production control phase are reported on the valve body. Still on the body, the following information is indicated: manufacturers mark, address and manufacture country; valve model; flow section; Kd discharge coefficient; indication of flow direction; max allowable pressure; allowable temperature range; set pressure; production date; serial number. VALVE SELECTION 97/23/EC Directive requires that pressure equipment, in which permissible limits are reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance
D
3030
H2
L
safety devices such as safety valves. Such devices shall prevent pressure from permanently exceeding the max allowable pressure PS of the equipment they protect. In any case, a short pressure peak limited to 10% of admissible maximum pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific sector or product standards. EN 378-2: 2008 Standard Refrigerating systems and heat pumps safety and environmental requirements Part 2: Design, construction, testing, marking and documentation, harmonized with 97/23/EC Directive, provides a general outline of the protection devices to be adopted in refrigerating systems and their features (par 6.2.5). It also indicates the criteria for the selection of the device suitable to the type and sizes of the system component to be protected (par. 6.2.6). EN 13136: 2001/A1: 2005 Standard Refrigerating systems and heat pumps Pressure relief devices and their associated piping Methods for calculation highlights the possible causes of overpressure in a system and makes available to users the instruments for pressure relief device sizing, among which the safety valves.
H1
51
Ch
H3
SIZING OF SAFETY VALVES DESIGNED TO DISCHARGE GAS OR VAPOUR AT CRITICAL FLOW (Ref. EN 13136: 2001/A1: 2005)
Critical flow occurs when the backpressure pb (the pressure existing immediately at the outlet of a safety valve) is below or equal to the critical pressure:
2 k 1 pb p o k +1
[bar abs]
for this calculation the value of k shall be as measured at 25 C. (Section 7.2.3, Standard EN 13136: 2001/A1:2005). Values of k and calculated values of C for some refrigerants are given in table A.1 of the aforesaid standard. Following we show the values of k and C for the more useful refrigerants.
Isentropic coefficient k 1,17 1,12 1,12 1,14 1,17 1,10 Function of Isentropic coefficient C 2,54 2,50 2,50 2,51 2,54 2,48
with: po = actual relieving pressure, upstream the safety valve; its equal to the set pressure plus overpressure. That is a pressure increase over set pressure at which the disc has its total lift. [bar abs]; k = isentropic exponent of gas or vapour, based on the actual flowing conditions at the safety valve inlet. If k is unknown or anyway difficult to establish its possible to suppose:
Refrigerant
R22 R134a R404A R407C R410A R507
p critical = 0, 5 po
[bar abs]
A safety valve, which discharges to atmosphere, works in critical flow. The safety valves designed to discharge gas or vapour at critical flow must be sized as follow:
Calculation of minimum required discharge capacity of safety valve is closely linked to the type of system where the valve is installed, with the causes that may arouse the opening of safety valve, i.e.: external heat sources. The minimum required discharge capacity shall be determined by the following:
Qmd =
A c = 3, 469
Qmd vo C 0, 9 K d po
3600 A surf hvap
[kg/h]
[mm2] with: = density of heat flow rate, its assumed to be 10 [kW/m2]; Asurf = external surface area of the vessel [m2]; hvap = heat of vaporization of liquid at po [kJ/kg]; internal heat sources. The minimum required discharge capacity shall be determined by the following:
with: Ac = minimum flow area of safety valve [mm2]; Qmd = minimum required discharge capacity, of refrigerant, of safety valve [kg/h]; Kd = certified coefficient of discharge; po = actual relieving pressure, upstream the safety valve, see definition above [bar abs]; vo = specific volume of gas or vapour at relieving conditions po e To meaning with To fluid temperature at valve inlet, settled by the user or by the designer [m3/kg]; C = function of isentropic coefficient k calculated from:
Qmd =
3600 Qh hvap
[kg/h]
with Qh = rate of heat production [kW]. Excessive pressure caused by compressors. The minimum required discharge capacity shall be determined by the following:
C = 3, 948 k
2 k +1
( k +1) ( k 1)
Qmd = 60 V n 10 v
[kg/h]
52
with: V = theoretical displacement of compressor [m3] n = rotational frequency of compressor [min 1] 10 = vapour density at refrigerant saturation pressure / dew point at 10 C [kg/m3]
v = volumetric efficiency estimated at suction pressure and discharge pressure equivalent to the safety valve setting.
EXAMPLE OF CALCULATION OF MINIMUM REQUIRED DISCHARGE CAPACITY Qmd AND SIZING OF THE SAFETY VALVE FOR THE HIGH PRESSURE SIDE OF A REFRIGERATING SYSTEM
System description Compact refrigerating system designed to make refrigerated water and consisting of: open type reciprocating compressor; water-cooled, shell-and-tube horizontally condenser with lower section of shell used as receiver; shell-and-tube horizontally liquid cooler fed with a thermostatic valve; refrigerant fluid R407C. Compressor data Bore 82,5 mm Stroke 69,8 mm Cylinder number 6 Rotational frequency 1450 rpm Clearance 4% The theoretical displacement of compressor is:
These conditions, settled in any case by the designer, are considered the most unfavorable for the safety valve in consequence of functional defects as: move mistake; non-working of automatic safety devices, set to operate before safety valve. It shall be excluded: closeness the refrigerating system, the presence of flammable substances in so large quantities to be able to feed a fire.; inside the vessel, the presence of a heart source. Calculation of minimum discharge capacity Prudentially leaving the vapour overheating at the outlet of the liquid cooler out of account, the volumetric efficiency of compressor is:
V=
0, 08252 0, 0698 6 = 0, 00224 4
[m3]
Maximum allowable pressure of the condenser, refrigerant side: PS = 25 bar. Set pressure of the safety valve installed on the upper shell section of condenser: pset = 25 bar Actual relieving pressure of safety valve, choosing one valve type 3030 with an overpressure of 5%:
v = 1 0, 04
p disch arg e psuction
= 1 0, 04
27, 25 = 0, 83 6, 33
and so the minimum required discharge capacity:
Qmd = 60 V n 10 v =
= 60x0,00224x1450x26,34x0,83 = 4260 [kg/h] with 10 = 26,34 [kg/m3], vapour density of R407C at saturation pressure / dew point at 10 C.
5 p0 = pset 1 + + 1 = 27, 25 [bar abs] 100

Working conditions of compressor corresponding to the relieving of safety valve: Condensing temperature: + 64 C (27,25 bar abs) Evaporating temperature: + 10 C (6,33 bar abs)
53
Sizing of minimum flow area of the safety valve
A c = 3, 469 = 3, 469
Qmd v o = C 0, 9 K d po
4260 0, 0104 = 154 [mm2] 2, 51 0, 9 0, 83 27, 25
with: C = 2,51, corresponding to isentropic exponent k for R407C equal to 1,14, according to table A1 of standard EN 13136:2001/A1:2005; Kd = 0,83, certified coefficient of discharge for safety valve 3030/88; vo = 0,0104 [m3/kg], specific volume of overheating vapour upstream the safety valve during relieving. This value is referred to the following operating conditions, upstream the safety valve: pressure po = 27,25 [bar abs]; temperature To = 100 [C] (precautionary temperature, settled in any case by the designer). Conclusion: the selected safety valve is the model 3030/88 with the following characteristics: certified coefficient of discharge, Kd = 0,83; flow section, Ac = 298 [mm2]; set pressure, pset = 25 bar. In case of single-screw compressor with injection of pressurized oil, the theoretical displacement is:
Vc =
D2 L 4
[m3]
with: D = rotor diameter [m] L = rotor length [m]
54
VALVE INSTALLATION As far as the installation of safety relief valves is concerned, the fundamental points listed below shall be taken into account: safety valves shall be installed near an area of the system where vapours or gases are present and there is no fluid turbulence; the position shall be as upright as possible, with the inlet connector turned downwards; vessels, joined together with piping rightly selected by the manufacturer and without any stop valve between them, may be considered as only one vessel for the installation of a safety valve; the union between the valve and the equipment to be protected shall be as short as possible. Furthermore, its passage section shall not be narrower than the valve inlet section. In any case, EN 13136: 2001/A1:2005 Standard states that the pressure loss between protected vessel and safety valve, at discharge capacity, shall not exceed 3% of the setting value, including any accessory mounted on the upstream line; in selecting the safety valve location, it shall be taken into account that valve operation involves the discharge of the refrigerant fluid under pressure, sometimes even at high temperature. Where the risk exists to cause direct injuries to the persons nearby, an exhaust conveying piping shall be provided, which shall be sized in such a way as not to compromise valve operation. EN 13136: 2001/A1:2005 Standard states that this piping shall not generate, at discharge capacity, a back pressure exceeding 10% of pressure po, for standard type valves, unbalanced. To calculate the pressure loss either in the upstream line (between vessel and safety valve) or in the downstream line (between safety valve and atmosphere) refer to EN 13136: 2001/A1:2005 Standard, Chapter 7.4. Pressure loss in the upstream line Calculation of pressure loss is given by:
with: A = flow area of safety valve [mm2]; Ain = inside area of inlet tube to valve [mm2]; Kdr = Kd x 0,9, derated coefficient of discharge; C = function of isentropic coefficient k; = addition of pressure loss coefficients n of any component and piping; The coefficients n are relevant to: pipe elements loss, as connections and bends; valves loss; loss along the pipe and are listed in EN 13136:2001/A1:2005 Standard, Table A.4. Example: assume to install, on the condenser of the previous example, a safety valve type 3030/88, set to 25 bar, using a steel union with the following characteristics: din = 28 [mm], inside diameter; Ain = 616 [mm2], inside area; L = 60 [mm], length; flush connection to the shell of condenser, with a broken edge. From table A.4 its possible to have these data: 1 (inlet) = 0,25 2 (length) = x L/ din = 0,02 x 60/28 = 0,043 with = 0,02 for steel tube T = 1 + 2 = 0,25 + 0,043 = 0,293 Between safety valve and union its installed a shut-off valve type 3033/88 (see page 59). The main characteristics of this valve are: dR = 20 [mm], inside diameter; AR = 314 [mm2], inside area; kv = 20 [m3/h], kv factor. Pressure loss coefficient R of shut-off valve is given by:
2
314 R = 2, 592 103 = 0, 64 20

The total pressure loss coefficient is: T + R = 0,933 We remember the main characteristics of safety valve 3030/88 and of refrigerant fluid R407C: A = 298 [mm2] Kdr = 0,83 x 0,9 =0,747 C = 2,51 Pressure loss in the upstream line is:
2
A pin = 0, 032 C K dr po A in
pin 298 = 0, 032 2, 51 0, 747 0, 933 = 0, 0245 po 616
55
The obtained value is admissible because lower than the value of 0,03 forecast in EN 13136:2001/A1:2005 Standard. Pressure loss in the downstream line Calculation of pressure loss is given by:
Example: assume to install a discharge pipe on safety valve type 3030/88 of the previous example, using a steel tube nominal size 2 with the following characteristics: - dout = 53 [mm] , inside diameter - Aout = 2206 [mm2] , inside area - L = 3000 [mm] , length - pipe bend 90 with bending radius R equal to three times external diameter of tube From table A.4 its possible to have these data: - 1 (bend) = 0,25 - 2 (length) = x L/ din = 0,02 3000/53 = 1,13 with = 0,02 for steel tube - T = 1 + 2 = 0,25 + 1,13 = 1,38 Pressure loss in the downstream line is: [bar]
with: - P1 = inlet pressure to downstream line [bar ass] - P2 = outlet pressure to downstream line, equal to atmospheric pressure [bar ass] - 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 - Po = actual relieving pressure, upstream the valve [bar abs] - = addition of pressure loss coefficients n of piping The coefficients n are relevant to: - pipe elements loss, bends - loss along the pipe and are listed in EN 13136:2001//A1:2005 Standard, Table A.4.
The obtained value is admissible because lower than the value of 0,10 forecast in EN 13136:2001/A1:2005 Standard.
56
SAFETY VALVES 3060

pressure relief duct is provided through which the spring holder is put into contact with the output connection. Utilized material: EN 12420-CW617N brass. Disc: obtained through bar machining and equipped with gasket, it ensures the required sealing degree on the valve seat. The gasket is made in P .T.F.E. (Polytetrafluorethylene), a material that, during valve estimated service life, maintains a good strength and does not cause the disc to stick on the seat. The disc is properly guided in the body and the guide action can never fail; there are no glands or retaining rings that hamper the movement thereof. Utilized material: EN 12164-CW614N brass. Spring: it opposes the pressure and the fluid dynamic actions and always ensures valve reclosing after pressure relief. Utilized material: DIN 17223-1 steel for springs. Setting system: hexagonal head, threaded ring nut to be screwed inside the body top by compressing the spring below. On setting completion, the position attained by the ring nut is maintained unchanged laying, in the threaded coupling, a bonding agent with high mechanic strength and low viscosity features to make penetration thereof easier. The setting system is protected against subsequent unauthorized interventions by means of a cap nut that is housed into the brass body and is fixed in this seat with an edge calking operation.
GENERAL DESCRIPTION Valves series 3060 are safety devices according to the definition given in Article 1, Point 2.1.3, 2nd dash of 97/23/EC Directive and are the subject of Article 3, Point 1.4 of aforesaid Directive. The valves above mentioned are standard type, unbalanced, direct-loaded safety valves. Valve opening is produced by the thrust the fluid under pressure exerts on the disc, when said thrust exceeds, under setting conditions, the opposing force of the spring acting on the disc. Valves are identified by means of: a model number formed of an alphanumerical coding that includes: in the first part the family identification (e.g. 3060/45C); in the second part the setting pressure, expressed in bars, multiplied by 10 (e.g. 140); an alphanumerical serial number. CONSTRUCTION Body: squared, obtained through die forging and subsequent machining. It houses the following elements: the nozzle with flat sealing seat; the disc guide; the setting spring holder; the threaded seat of the setting adjusting ring nut. In the body, above the disc guide, a small
57
TABLE 3: General Characteristics valves 3060

Catalogue number inlet male Connections outlet male Flow Diameter [mm] Flow Section [mm2] Discharge Coefficient Kd PS [bar] TS [C] St Pressure Range [bar] Overpressure Risk Category according to PED 0,63 0,69 3/8" SAE 1/2" SAE 7,0 38,5 0,63 0,69 55 - 50 / + 150 9 / 50 10% of set pressure IV 3/8" SAE 1/2" SAE 5/8" SAE 9,5 70,9 0,45 0,92 3/4" G 10,0 78,5 0,93 3/4" G 3060/23C 1/4" NPT 3060/24C 1/4" NPT 3060/33C 3/8" NPT 3060/34C 3/8" NPT 3060/45C 1/2" NPT 3060/36C 3/8" NPT 3060/46C 1/2" NPT
SCOPE Use: protection against possible overpressures of the apparatuses listed below, with regard to the operating conditions for which they have been designed: refrigerating system and heat pump components, for instance: condensers, liquid receivers, evaporators, liquid accumulators, positive displacement compressor discharge, heat exchangers, oil separators, piping. (reference: EN 378-2: 2008); simple pressure vessels (reference: 87/404/ EEC Directive). Fluids: the valves can be used with: refrigerant fluids, in the physical state of gas or vapour, belonging to Group II according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27th, 1967); Air and nitrogen (reference: 87/404/EEC Directive). MARKING In conformity with the provisions of Article 15 of 97/23/EC Directive the following information are reported on the valve body: manufacturers mark, address and manufacture country indication of flow direction max allowable pressure set pressure allowable temperature range production date serial number The following data are stamped on the cap:
EC marking and the identification number of the notified body involved in the production control phase valve model flow section Kd discharge coefficient VALVE SELECTION 97/23/EC Directive requires that pressure equipment, in which permissible limits are reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance safety devices such as safety valves. Such devices shall prevent pressure from permanently exceeding the max allowable pressure PS of the equipment they protect. In any case, a short pressure peak limited to 10% of admissible maximum pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific sector or product standards. EN 378-2: 2008 Standard Refrigerating systems and heat pumps safety and environmental requirements Part 2: Design, construction, testing, marking and documentation, harmonized with 97/23/EC Directive, provides a general outline of the protection devices to be adopted in refrigerating systems and their features (par 6.2.5). It also indicates the criteria for the selection of the device suitable to the type and sizes of the system component to be protected (par. 6.2.6). EN 13136: 2001/A1:2005 Standard Refrigerating systems and heat pumps Pressure relief devices and their associated piping Methods
58
TABLE 4: Dimensions and Weights of valves 3060

Dimensions [mm] Catalogue number D L Ch Weight [g]
H1
H2
H3
3060/23C 3060/24C 3060/33C 3060/34C 3060/45C 3060/36C 3060/46C
21,5 21,5 21,5 21,5 24,5 30 30
35 35 35 35 39,0 40 40
20 20 20 20 23 27 27
33,5 33,5 33,5 33,5 37 37 40
46,5 46,5 46,5 46,5 52,5 59,5 59,5
80 80 80 80 89 96,5 99,5
H1
Ch
H3
180 195 195 195 240 360 380
for calculation highlights the possible causes of overpressure in a system and makes available to users the instruments for pressure relief device sizing, among which the safety valves. For sizing and installation of safety valves series 3060 see the previous chapter of safety valves series 3030.
3060
BALL SHUT-OFF VALVES FOR SAFETY VALVES

APPLICATIONS We would like to remember to our customer that the running of pressure equipments and pressure assemblies is excluded by the scope of Directive 97/23/EC but its regulated in compliance with national regulations of Member States of European Communities. We think that these regulations, actually on updating with the Competent Bodies of all the states to avoid conflicts with the ESR of PED, could provide for periodical checks on the pressure equipments and assemblies. Any intervention for periodic checking or replacement of an installed safety valve becomes very difficult if the protected vessel is not equipped with a shut-off valve. The shut-off valves series 3033 and 3063, installed between vessel and safety valve, allow to remove the valve for periodic checking or replacement without blowing off all the refrigerant from a section of the system. These valves can be used with the same fluids foreseen for safety valves series 3030 and 3060, in particularly: refrigerant fluids, in the physical state of gas or vapour, belonging to Group II according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27th, 1967); air and nitrogen (reference: 87/404/EEC Directive). CONSTRUCTION Castel supplies to its customers the valves series 3033 and 3063 in open position and the ball spindle is protected by means of a cap screwed to the body and sealed with lead to it. Any closing intervention on the valve forcedly causes the tampering of the seal and then these interventions shall be performed exclusively by:
H2
59
staff authorized to work on the system; public servant of a Competent Body. These persons will be responsible for the next valve reopening and the new cap sealing with their own lead. The main parts of these valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; hot forged brass EN 12420 CW 617N, chromium plated, for ball; steel, with proper surface protection, for the spindle; P .T.F.E. for seat ball gaskets; chloroprene rubber (CR) for outlet seal gaskets; glass reinforced PBT for cap that covers the spindle.
SEAL
VALVE 3030/..
BALL VALVE 3033/.. SEAL
TABLE 5: General Characteristics, dimensions and Weights of valves 3033, 3063

TS [C] Catalogue number Designed for valve Kv Factor [m3/h] PS [bar] min max D A C L H1 H2 H3 Dimensions [mm] Weight [g] Risk Category according to PED
3060/45C 3063/44 3060/46C 3033/44 3030/44C 10 -50 +150 55 13 1" 3033/88 3030/88C 20 20 NPT 107 77 72 123 323 1070 5 10 1/2" NPT 101 73 59 100 245 710 Art. 3.3 78 58 44,5 84,5 162 350
CHANGEOVER DEVICES FOR SAFETY VALVES

APPLICATIONS The changeover device type 3032 is a service valve for dual pressure relief valves that allows using one valve while isolating the other from the system. This device allows the user to work on the isolated valve, for periodic checking or replacement, while the system is completely operative and the other valve is in service. N.B.: each safety valve placed on a changeover device must have sufficient capacity to protect the vessel alone. Valve type 3032/44 is supplied with: two female threaded connections 1/2 NPT with swivel nut, code Castel 3039/4; two O-Ring. These components ensure the perfect alignment of two safety valves 3060/45. The valves series 3032 can be used with the same fluids foreseen for safety valves series 3030 and 3060, in particularly: refrigerant fluids, in the physical state of gas
60
or vapour, belonging to Group II according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27th, 1967); air and nitrogen (reference: 87/404/EEC Directive). CONSTRUCTION The valve 3032 is designed so that it is never possible to close off both ports at the same time, excluding all the two safety valves. Under working conditions, the shutter must be clamped against one of the two seats of the valve, front port or back port, in order to ensure always full discharge to the corresponding safety valve. Intermediate positions of the shutter are not acceptable in order not to affect the operation of both safety valves. The valve ensures a pressure drop perfectly compatible with the safety valve operation under conditions
of discharge of saturated vapour as well as overheated vapour. The main parts of these valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; chloroprene rubber (CR) for outlet seal gaskets; glass reinforced PBT for cap that covers the spindle.
TABLE 6: General Characteristics, Dimensions and Weights of valves 3032

TS [C] Catalogue number Designed for valve Kv Factor [m3/h] PS [bar] min max D A B H1 H2 L1 L2 L3 Dimensions [mm] Weight [g] Risk Category according to PED
3060/45C 3032/44 3060/46C 3032/64 3030/44C 9,0 -50 3032/66 3030/66C 9,0 +150 55 17,5 3,3 13
1/2" NPT 3/4" NPT 3/4" 17,5 NPT 1
1/2" 117 NPT 1/2" 95 NPT 3/4" 95 NPT 1 NPT 1 NPT 123 74 66 185 110 3200 120 71 66 185 110 3200 52 48 133 80 1750 Art. 3.3 52 48 133 80 1750 45 33 91 50 775
3032/88 3030/88C 3032/108
14,5
22,0 NPT 1 1/4" NPT
20,0
31,0
GASKET
61
SAFETY VALVES UNIONS

Unions series 3035 allow assembling safety valves series 3030 and 3060 or shut-off valves series 3032, 3033 and 3063 close to the pressure equipments to protect, set up in a refrigerating system. These unions are designed for installations according to the following two ways: Make a copper tube jointing the pressure equipment to the union, fit the end of this tube into the solder connection of the union and then make a capillary brazing. Drill the inner/outer pipe close to the pressure equipment (if possible make a collar on the pipe), put the end of the union into this drill and then make a braze welding. The unions series 3035 are machined by brass bar EN 12164-CW614N.
3060
3035
copper tube Tubo di rame
Copper tube
TABLE 7: General Characteristics, Dimensions and Weights of unions 3035

Connections Catalogue number NPT PS [bar] D L Ch Dimensions [mm] Weight [g]
ODS [mm] 12 18 22 28 36 42
3035/2 3035/3 3035/4 3035/6 3035/8 3035/10
1/4 3/8 1/2 3/4 1 1.1/4"
18 22 55 28 35 42 54
33 36,5 44 51 62 67
21 26 32 40 45 55
58 90,5 165 255 364 613
62
FUSIBLE PLUGS
GENERAL DESCRIPTION Fusible plugs series 3080/.C and 3082/.C are safety devices according to the definition given in Article 1, Point 2.1.3, 2nd dash of 97/23/EC Directive and are the subject of Article 3, Point 1.4 of aforesaid Directive. According to the definition given in Point 3.6.4 of EN 378-1:2008 Standard, fusible plug is a device containing material that melts at a predetermined temperature and thereby relieving the pressure. Castel has resolved to classify fusible plugs series 3080/.C and 3082/.C in the Category of Risk I therefore fixing their use, as protection devices, on specific pressure equipments, proper to the same Category of Risk I, in compliance with Annex II, Point 2, of 97/23/EC Directive. In consequence of this choice, fusible plugs series 3080/.C and 3082/.C cannot be used, as sole protection devices, on pressure equipments proper to Categories of Risk higher than first. CONSTRUCTION The body of the fusible plug is an NPT plug drilled with a taper hole. A predetermined quantity of fusible alloy, with checked melting point, is poured inside this hole. The parts of the fusible plugs are made with the following materials: Brass EN 12164 CW 614N, hot tinned, for the plug. Eutectic alloy with several components, cadmium and lead free, for the fusible material. SCOPE Use: the fusible plugs are basically used to protect the components in a refrigerating system or heat pump against possible overpressures, with regard to the operating conditions for which they have been designed, in case of an excessive external heat source, such as fire. Fluids: the fusible plugs can be used with refrigerant fluids belonging to Group 2 according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27th, 1967).
MARKING In conformity with the provisions of Article 15 of 97/23/EC Directive and of Point 7.3.3 of EN 378-2:2008 Standard the following data are reported on the hexagonal nut: EC marking; Manufacturer's logo; Max allowable pressure PS; Melting point. INSTALLATION If a fusible plug is mounted on a pressure vessel or any other part which it protect it shall be placed in a section where superheated refrigerant would not affect its correct function. Fusible plug shall not be covered by thermal insulation. Discharge from fusible plugs shall take place so that persons and property are not endangered by the released refrigerant. EN 378-2:2008 Standard, harmonized with the 97/23/EC Directive, establishes that a fusible plug shall not be used as pressure relief device on vessels containing refrigerants proper to A2, B1, B2, A3 e B3 groups. The same Standard establishes that a fusible plug shall not be used as the sole pressure relief device between a refrigerant containing component and the atmosphere for systems with a refrigerant charge larger than 2,5 kg of group A1 refrigerant (ex. R22; R134a; R404A; R407C; R410A; R507). FUSIBLE PLUG SELECTION 97/23/EC Directive requires that pressure equipment, in which permissible limits are reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance safety devices such as fusible plugs. Such devices shall prevent pressure from permanently exceeding the max allowable pressure PS of the equipment they protect. In any case, a short pressure peak limited to 10% of admissible maximum pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific sector or product standards. EN 378-2 : 2008 Standard Refrigerating systems and heat pumps safety and environmental requirements Part 2:Design, construction, testing, marking and documentation provides a general outline of the protection devices to be adopted in
63
refrigerating systems and their features (par 6.2.5). It also indicates the criteria for the selection of the device suitable to the type and sizes of the system component to be protected (par.6.2.6). EN 13136 : 2001/A1:2005 Standard Refrigerating systems and heat pumps Pressure relief devices and their associated piping Methods for calculation, harmonized with 97/23/EC Directive, highlights the possible causes of overpressure in a system and makes available to users the instruments for pressure relief device sizing, among which the fusible plugs. SIZING OF FUSIBLE PLUG (REF. EN 13136: 2001/A1:2005) As the fusible plugs discharge to atmosphere, they always work in critical flow (to know the definition of critical flow, see the chapter of safety valves series 3030). The fusible plugs must be sized as follow:
( k+1)
2 ( k1) C = 3, 948 k k +1
To find the values of k and C for the more useful refrigerants, see the chapter of safety valves series 3030 Calculation of minimum required discharge capacity of fusible plug is closely linked to the main cause that may arouse the opening of fusible plug, which is the external heat source. The minimum required discharge capacity shall be determined by the following:
Q md =
3600 Asurf hvap
[kg/h]
Ac = 3, 469
Q md v o [mm2] C K dr po
with = density of heat flow rate, its assumed to be 10 [kW/m2] Asurf = external surface area of the vessel [m2] hvap = heat of vaporization of liquid at po [kJ/kg] EN 13136 : 2001/A1:2005 Standard also establishes that the following values for Kdr shall be the maximum used depending on how the pipe between the vessel and the fusible plug is mounted on the vessel: flush or flared connection: Kdr = 0,70 inserted connection: Kdr = 0,55.
with: Ac = minimum flow area of fusible plug [mm2] Qmd = minimum required discharge capacity, of refrigerant, of fusible plug [kg/h] Kdr =derated coefficient of discharge of fusible plug, equal to 0,9 x Kd po = pressure upstream the fusible plug, inside the equipment to be protected [bar abs] vo = specific volume of gas or vapour at relieving conditions po e To , [m3/kg] (To is the fluid temperature at plug inlet, settled by the user or by the designer) C = function of isentropic coefficient k (as measured at 25 C , see Section 7.2.3 , EN 13136 : 2001/A1:2005 Standard) calculated from:
TABLE 8: General Characteristics, Dimensions and Weights of fusible plugs 3080 e 3082
Hexagonal Key Wrench Torque min/max [Nm] Risk Category according to PED
Catalogue number
Connections NPT
Flow Diameter [mm]
Flow Section [mm2]
Kd
PS [bar]
Melting point [C]
Weight [g]
3080/1C 3080/2C 3080/3C 3080/4C 3082/1C 3082/2C 3082/3C 3082/4C
1/8" 1/4" 3/8" 1/2" 1/8" 1/4" 3/8" 1/2"
4,9 5,7 8,5 9,3 4,9 5,7 8,5 9,3
18,8 25,5 42 56,7 67,9 0,91 18,8 25,5 30 56,7 67,9 138 79
12 17
7 / 10 10 / 15 14 / 20
11 23 39 76 I 11 23 39 76
12 12 17
21 / 30 7 / 10 10 / 15 14 / 20
22
21 / 30
64
Check valves
CHECK VALVES
APPLICATIONS The check valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). For heavy duty, about the operation temperature, for example installation on the discharge line close to the compressor, Castel has developed three new series of valves, types 3122, 3142 and 3182, equipped with special gasket for high temperature, between the body and its cover. MATERIALS The main parts of the valves are made with the following materials: hot forged brass EN 12420 CW 617N for body and cover; copper tube EN 12735-1 Cu-DHP for solder connections; austenitic stainless steel AISI 302 for the spring; chloroprene rubber (CR) for outlet seal gaskets. Metal-rubber laminated gaskets for the valves series 3122, 3142 and 3182; P .T.F.E. for seat gasket.
INSTALLATION The valves can be installed in any section of a refrigerating system, where it is necessary to avoid an inversion of the refrigerating flow, in compliance with the limits and capacities indicated in table 3. Table 1 shows the following functional characteristics of a check valve: PS; TS; Kv factor; minimum opening pressure differential, that is the minimum pressure differential between inlet and outlet at which a check valve can open and stay opened. Before connecting the valve to the pipe it is advisable to make sure that the refrigerating .T.F.E. system is clean. In fact the valves with P gaskets are particularly sensitive to dirt and debris. Furthermore check that the flow direction in the pipe corresponds to the arrow stamped on the body of the valve. The allowed operating positions are: types 3122 and 3142 with horizontal axis and valve cover facing upward; types 3182 with inlet facing down and the valve cover facing upward; types 3112, 3132 and 3133, preferably with vertical axis and arrow upward. Sloping axis, up to horizontal position, are tolerable. The brazing of valves with solder connections should be carried out with care, using a low melting point filler material. Before starting to braze, its necessary to disassemble the valves series 3122, while this operation is not necessary with solder connection valves. In any case, its important to avoid direct contact between the torch flame and the valve body, which could be damaged and compromise the proper functioning of the valve.
66

Connections Catalogue Number SAE Flare ODS [in.] [mm] ODM [in.] [mm] Kv Factor [m3/h] Minimum Opening Pressure Differential [bar] TS [C] PS [bar] min. max. Risk Category according to PED
3112/2 3112/3 3112/4 3112/5 3112/6 3122/M22 3122/7 3122/M28 3122/9 3122/11 3122/13 3122/M42 3122/17 3132/2 3132/3 3132/M10 3132/M12 3132/4 3132/5 3132/M18 3132/6 3132/7 3133/M10 3133/M12 3133/5 3133/7 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 1.1/8 1.3/8 1.3/8 1.5/8 2 28
0,5 1,5 1,8 3,3 5,0 Art. 3.3 6,6 35 8,8 35 35 15,2 25,0 2 40,0 0,5 1,5 10 12 1,8 16 18 22 10 12 16 22 22 28 35 25,0 42 54 22 28 9,5 35 37,0 42 54 45,4 I 19,0 Art. 3.3 8,5 40,0 0,1 35 +160 I 15,2 8,8 1,4 1,7 0,3 3,3 5,0 6,6 5,0 45 Art. 3.3 3,3 40 +105 0,1 I +160 40 +105
67
TABLE 2: Dimensions and Weights

Dimensions [mm] Catalogue number H H1 L L1 Q D Ch Weight [g]
3112/2 3112/3 3112/4 3112/5 3112/6 3122/M22
56 68 73 85 98
16 20 22 27 33
14 18 20 24 30
70 110 140 220 350 1180
3122/7 84,5 3122/M28 3122/9 3122/11 3122/13 125,5 3122/M42 3122/17 3132/2 3132/3 107 3132/M10 3132/M12 132 3132/4 3132/5 3132/M18 3132/6 3132/7 3133/M10 3133/M12 3133/5 3133/7 3142/7 3142/M28 3142/9 3142/11 3142/13 125,5 3142/M42 4875 3142/17 285 3142/21 3142/25 3182/7 1295 3182/M28 3182/9 3182/11 3182/13 3182/M42 3182/17 221 123,5 195,5 143,5 104 4780 177 109,5 150 116 68 3255 151 95 130,5 100,5 60 1855 142 42,5 329 104 5690 1280 37 256 88 101,5 34 232 68 3315 84,5 28,5 201 1885 107 132 139 165 170 60 20 22 27 33 110 145 210 310 1320 165 33 310 139 27 210 22 145 20 110 142 92 42,5 173 104 16 4225 95 37 141 88 2955 101,5 34 118 68 1625 1090 28,5 100 60
68
Ch
Ch
3112
3132 3133
D
3132 3133
3122
D
3132 3133
3112
3112
3142
3182
69
TABLE 3: Refrigerant Flow Capacity

Refrigerant Flow Capacity [kW] Catalogue Number R134a R22 Liquid R404A R407C R410A R134a R22 Vapour R404A R407C R410A R134a R22 Hot Gas R404A R407C R410A
3112/2 3112/3 3112/4 3112/5 3112/6 3122/M22
8,4 25,3 30,3 55,6 84,3 111,2
9,0 27,0 32,4 59,4 90,0 118,8
6,0 17,9 21,4 39,3 59,5 78,5
9,4 28,1 33,7 61,8 93,7 123,7
9,5 28,6 34,3 62,8 95,2 125,7
1,1 3,2 3,9 7,1 10,8 14,3
1,4 4,1 4,9 8,9 13,5 17,8
1,1 3,4 4,1 7,5 11,3 14,9
1,3 4,0 4,8 8,8 13,4 17,7
1,8 5,4 6,5 11,9 18,0 23,8
4,3 12,8 15,3 28,1 42,5 56,1
5,9 17,6 21,1 38,6 58,5 77,2
5,0 15,0 18,0 33,0 50,0 66,0
5,8 17,4 20,9 38,3 58,1 76,7
6,5 19,5 23,4 42,9 65,0 85,8
3122/7 3122/M28 148,3 3122/9 3122/11 3122/13 421,3 3122/M42 3122/17 3132/2 3132/3 25,3 3132/M10 3132/M12 30,3 3132/4 3132/5 3132/M18 3132/6 3132/7 3133/M10 3133/M12 3133/5 3133/7 3142/7 3142/M28 148,3 3142/9 3142/11 3142/13 421,3 3142/M42 3142/17 3142/21 3142/25 3182/7 3182/M28 160,1 3182/9 3182/11 3182/13 623,5 3182/M42 3182/17 765,0 817,2 540,3 850,8 864,4 98,1 122,6 102,6 121,7 163,4 385,9 531,2 454,0 527,5 590,2 666,0 440,3 693,4 704,5 79,9 99,9 83,6 99,2 133,2 314,5 432,9 370,0 429,9 481,0 320,2 342,0 226,1 356,1 361,8 41,0 51,3 42,9 50,9 68,4 161,5 222,3 190,0 220,8 247,0 171,0 113,1 178,0 180,9 20,5 25,7 21,5 25,5 34,2 80,8 111,2 95,0 110,4 123,5 143,2 153,0 101,2 159,3 161,8 18,4 23,0 19,2 22,8 30,6 72,3 99,5 85,0 98,8 110,5 674,0 720,0 476,0 749,6 761,6 86,4 108,0 90,4 107,2 144,0 340,0 468,0 400,0 464,8 520,0 450,0 297,5 468,5 476,0 54,0 67,5 56,5 67,0 90,0 212,5 292,5 250,0 290,5 325,0 256,1 273,6 180,9 284,8 289,4 32,8 41,0 34,4 40,7 54,7 129,2 177,8 152,0 176,6 197,6 158,4 104,7 164,9 167,6 19,0 23,8 19,9 23,6 31,7 74,8 103,0 88,0 102,3 114,4 25,3 30,3 55,6 84,3 111,2 27,0 32,4 59,4 90,0 118,8 17,9 21,4 39,3 59,5 78,5 28,1 33,7 61,8 93,7 123,7 28,6 34,3 62,8 95,2 125,7 3,2 3,9 7,1 10,8 14,3 4,1 4,9 8,9 13,5 17,8 3,4 4,1 7,5 11,3 14,9 4,0 4,8 8,8 13,4 17,7 5,4 6,5 11,9 18,0 23,8 12,8 15,3 28,1 42,5 56,1 17,6 21,1 38,6 58,5 77,2 15,0 18,0 33,0 50,0 66,0 17,4 20,9 38,3 58,1 76,7 19,5 23,4 42,9 65,0 85,8 84,3 90,0 59,5 93,7 95,2 10,8 13,5 11,3 13,4 18,0 42,5 58,5 50,0 58,1 65,0 55,6 59,4 39,3 61,8 62,8 7,1 8,9 7,5 8,8 11,9 28,1 38,6 33,0 38,3 42,9 32,4 21,4 33,7 34,3 3,9 4,9 4,1 4,8 6,5 15,3 21,1 18,0 20,9 23,4 27,0 17,9 28,1 28,6 3,2 4,1 3,4 4,0 5,4 12,8 17,6 15,0 17,4 19,5 674,0 8,4 720,0 9,0 476,0 6,0 749,6 9,4 761,6 9,5 86,4 1,1 108,0 1,4 90,4 1,1 107,2 1,3 144,0 1,8 340,0 4,3 468,0 5,9 400,0 5,0 464,8 5,8 520,0 6,5 450,0 297,5 468,5 476,0 54,0 67,5 56,5 67,0 90,0 212,5 292,5 250,0 290,5 325,0 256,1 273,6 180,9 284,8 289,4 32,8 41,0 34,4 40,7 54,7 129,2 177,8 152,0 176,6 197,6 158,4 104,7 164,9 167,6 19,0 23,8 19,9 23,6 31,7 74,8 103,0 88,0 102,3 114,4
Refrigerant ow 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
70
Water regulating valves
WATER REGULATING VALVES

pressure outside the bellows favours the opening of the valve and the thrust of the adjustment spring on the shutter acts in the opposite sense. Given a specific setting of the spring, the valve progressively opens in line with the increasing condensation pressure, and closes when this pressure decreases. When the compressor stops, the valve closes: water is no longer fed into the condenser, this being a notable operating economy. Valve setting is performed in the works at a pressure of 7,5 bars. Setting is modified by turning the control screw. Three reference notches, marked with letters A, B, and C, are present on the spring cover. Each notch is equivalent to a different spring setting. The notches are referred to the following condensation pressures: letter A equivalent to about 7.5 bar (valid for R134a at a temperature of condensation of 30 C); letter B equivalent to about 14 bar (valid for R404A, R407C and R507 at a temperature of condensation of 30 C); letter C equivalent to about 18 bar (top limit of working pressure) APPLICATIONS The water regulating valve, employed with condenser fed with either main or well water, keeps the condensation pressure constant at the previously set value by adjusting the water flow so as to ensure a balanced heat exchange under all conditions. At plant start-up, this adjustment is designed to allow the thermostatic valve rapidly reaches normal operating conditions and subsequently, during operations, to avoid excessive pressure increases or decreases under different flow conditions. An excessive rise of high pressure affects the refrigerating capacity of the system. On the other side, pressure lowering leads to insufficient refrigerant feeding of the evaporator with a consequent increased gas overheating and parallel reduction of gas pressure at compressor suction. Castel valves are appropriate for refrigerant fluids HCFC and HFC and only for main and well water.
1/4"
A
CAT.
RANGE 5-18 bar MAX WATER PRESS. 10 bar MAX WATER TEMP. 80 |BC MEDIUM R134a-R404A-R12-R22-R502
B C
48 Ch
A02
L
87
OPERATIONS The moving elements of the valve are a metal bellows and a shutter. The thrust of the refrigerant condensation
1/4"Flare
72
99
MADE IN ITALY

Connections Catalogue number UNI ISO 228/1 Working pressure [bar] Maximum water pressure [bar] Maximum water Temperature [C] Kv Factor [m3/h] Refrigerant max. working pressure [bar]
Ch
Weight [g]
3210/03 3210/04 3210/06
G 3/8" G 1/2" G 3/4" 5 - 18 10 80
2 27 3 4,7 20 32 74 70
1015 985 1010
MATERIALS The materials used for the main parts are: ST-UNI-EN 12165 - CW617N hot-forged brass for the main body; austenitic stainless steel AISI 303 for the seat; nitril rubber (NBR) for seat gasket; NBR coated-fabric for diaphragms. INSTALLATION The valve will be mounted on the water outlet side of the condenser, preferably vertically, with the bellows downward. The high pressure connection to the bellow must show no deflection. The arrow on the valve body shows water flow direction.
Water temperature at the condenser inlet: 14 C. Expected thermal difference: Dt = 10 C. Condensation temperature expected on the basis of the water/refrigerant heat exchange in the condenser: approximately 6 C above the water temperature at the outlet, equivalent to 30 C (with a corresponding saturation pressure) (fig. 1). Refrigeration yield at the level of the evaporator: 18,6 kW under the following operating conditions, condensation temperature: + 30 C; evaporation temperature: 15 C. Thermal power to be disposed of at the level of the condenser (Table 2): 18,6 x 1,325 = 24,65 [kW]
EXAMPLE OF VALVE SELECTION Water flow rate: A refrigerating system including a hermetic compressor and a condenser fed with mains water. Mains water pressure: 3 bar 24,65 x 860 = 2120 l/h = 2,12 [m3/h] 10
Fig. 1 Heat exchange pattern in the condenser.
73
The pressure drop corresponding to the water flow rate specified above in the condenser/piping circuit, with the exclusion of the water regulating valve, is about 2,5 bar. The water regulating valve has this pressure differential at its disposal: p = 3 2,5 = 0,5 bar At p = 0,5 bar the 3210/04 valve, completly opened, ensures the required flow rate (fig. 2).
When the point of intersection of pressure differential through the valve and flow range is within the area between the curves of two valves, select the valve with larger diameter. When the valve is completely closed, the pressure must be the same as the refrigerant saturation pressure at the air temperature of the place where the condenser is installed. When the valve begins to open, the pressure is about 0,2 bar above the pressure when the valve is totally closed.
Q [m /h]
7 6,5 6 5,5 5 4,5 4 3,5 3 2,5 2 1,5 1 0,5 0 3210/03 3210/04 3210/06
0,375
0,625
0,875
2,375
2,625 26 27
0,25
0,75
1,375
1,625
1,875
2,25
0,125
1,125
2,125
p [bar]
11 20 22 23 24 25 28 0 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 21
p [H2O]
Fig. 2 Characteritics curves when the valves are completely open
74
2,75
1,75
0,5
1,25
2,5
1,5
TABLE 2: Thermal factor for hermetic refrigeration compressors. Relationship between the total heat to be disposed of at the level of the condenser and refrigeration capacity at the level of the evaporator
Evaporating Temperature [C] Condensing Temperature [C]
35
30
25
20
15
10
+5
+10
+30 +35 +40 +45 +50 +55 +60
1,524 1,553 1,578
1,473 1,503 1,531
1,421 1,453 1,484 1,521
1,371 1,403 1,435 1,475
1,325 1,355 1,387 1,425 1,468 1,520
1,281 1,310 1,340 1,377 1,420 1,465 1,526
1,238 1,268 1,295 1,330 1,369 1,412 1,457
1,200 1,228 1,254 1,285 1,320 1,363 1,398
1,163 1,188 1,210 1,240 1,270 1,304 1,338
1,133 1,155 1,175 1,200 1,227 1,255 1,285
TABLE 3: Thermal factor for open compressors (direct or belt driven). Relationship between the total heat to be disposed of at the level of the condenser and the refrigeration capacity at the level of the evaporator
Evaporating Temperature [C] Condensing Temperature [C]
35
30
25
20
15
10
+5
+10
+30 +35 +40 +45 +50 +55 +60
1,460 1,495 1,537
1,417 1,450 1,530
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 1,120 1,228 1,255
75
Liquid Indicators & Moisture-Liquid Indicators
LIQUID INDICATORS & MOISTURE-LIQUID INDICATORS

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

Refrigerant fluid Colour R22 R134a R404A R407C R410A R507
Green Green
<60 60
<75 75 >75
<30 30 >30
<30 30 >30
<30 30 >30
<30 30 >30
Chartreuse Yellow >60
CONSTRUCTION New liquid indicators, series 38, and new liquid/moisture indicators, series 39, are manufactured in a total hermetic construction to avoid any possible refigerant leaks. The glass lens, with its proper gasket, is housed into the brass body and is fixed in this seat with an edge calking operation. The main parts of the indicators are made with the following materials: hot forged brass EN 12420 CW 617N for body; copper tube EN 12735-1 Cu-DHP for solder connections; Glass for lens; PTFE for outlet seal gaskets; Liquid/moisture indicators series 3770, 3771, 3780 and 3781 are manufactured with the glass lens directly fused onto a steel metallic ring, with proper surface protection.
78
TABLE 2: General Characteristics of liquid indicators

Connections TS [C] Catalogue number Type ODS SAE Flare 1/4" 3/8" male3810/44 male 3810/55 3810/66 3840/2 3840/3 3840/M10 3840/M12 3840/4 3840/5 3840/M18 3840/6 3840/7 3840/9 3850/22 3850/33 male3850/44 female 3850/55 3850/66 5/8" 3/4 1/2" soldering 5/8" 3/4" 1/4" 3/8" 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 1.1/8" 10 12 16 18 22 30 +110 45 Art. 3.3 1/2" [in.] [mm] min. max. PS [bar] RIsk Category according to PED
3810/22 3810/33
INSTALLATION At the start-up the color of the sensitive element may be yellow, due to exposure to air humidity and to moisture in the circuit. When the moisture of the refrigerant is brought back to acceptable levels with the dehydrator, the indicator color is once again green. This is evidence that equilibrium has been reestablished. In case of persisting yellow, measures have to be taken to eliminate moisture. Only when the sensitive element comes back to green, there is evidence that adopted measures were effective. About 12 hours of system operation are required to
achieve equilibrium. However, the moisture indication is given normally when the plant is in function and the fluid is flowing. The brazing of indicators with solder connections should be carried out with care, using a low melting point filler material. In any case, avoid direct contact between the torch flame and the indicator body or glass, wich could be damaged and compromise the proper functioning of the indicator. With indicators series 3780 and 3781 its necessary to disassemble the ring before starting to braze.
79
TABLE 3: General Characteristics of liquid / moisture indicators

Connections TS [C] Catalogue number Type ODS SAE Flare 1/4" 3/8" male3910/44 male 3910/55 3910/66 3940/2 3940/3 3940/M10 3940/M12 3940/4 3940/5 3940/M18 3940/6 3940/7 3940/9 3950/22 3950/33 male3950/44 female 3950/55 3950/66 3770/M28 3770/11 3770/13 soldering 3770/M42 3771/11 3771/M42 3771/17 3780/5 3780/M18 3780/7 3780/9 3780/11 3781/M28 level glass saddle type 1.1/8" 1.3/8" 28 35 28 1.3/8" 2.1/8" 35 42 42 5/8" 7/8" 16 18 Excluded 22 35 I Art. 3.3 5/8" 3/4" 1.3/8" 1.5/8" 28 35 I 1/2" soldering 5/8" 3/4" 1/4" 3/8" 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 1.1/8" 10 12 16 18 22 45 30 +110 Art. 3.3 1/2" [in.] [mm] [in.] ODM [mm] [in.] for pipe [mm] hole [mm] min. max. PS [bar] Risk Category according to PED
3910/22 3910/33
3810 3910
3840 3940
3850 3950
80

Catalogue number Moisture Liquid Indicators 3910/22 3910/33 3910/44 3910/55 3910/66 3940/2 3940/3 190 3840/M10 3840/M12 3840/4 3840/5 3840/M18 3840/6 3840/7 3840/9 3850/22 3850/33 3850/44 3850/55 3850/66 3940/M10 3940/M12 3940/4 3940/5 195 3940/M18 34 3940/6 3940/7 3940/9 3950/22 3950/33 3950/44 3950/55 3950/66 3770/M28 3770/11 3770/13 45 3770/M42 3771/11 3771/M42 3771/17 3780/5 3780/M18 3780/7 3780/9 3780/11 30 31 33 36 39,5 90 45 170 550 41,5 160 300 480 170 480 37,5 43,5 26,5 30 34 37,5 43,5 23,5 26 17,5 18,5 21,5 23,5 26 38 41,5 151 186 68 74 77 82 92 150 160 17 22 24 28 35 21,5 215 310 540 140 190 240 300 525 250 300 131 34 21,5 225 117 Dimensions [mm] Weight [g] H H1 L Ch
Liquid Indicators 3810/22 3810/33 3810/44 3810/55 3810/66 3840/2 3840/3
22 26,5 30 34 37,5 22
16,5 17,5 18,5 21,5 23,5 15,5
71,5 77,5 81,5 89,5 90 133
12 17 22 24 28
115 150 210 195 315 120
3770
3771
3780
3781
81
Dehydrators and Filters
DEHYDRATION OF REFRIGERANTS
Among contaminating agents causing serious damages to refrigerating systems, moisture plays a major role. Its presence, even possible in the refrigerating system, is due to many factors: inadequate or insufficiently prolonged vacuum before refrigerant charging; oil used for topping up remained exposed to air humidity; refrigerant used for subsequent additions contained in non dried vessels; sealing defects especially in systems not designed for operation at low temperatures. High temperatures combined with humidity give rise to complex phenomena enhancing acid formation both in lubricating oil and refrigerant. Oil organic acids react with metal and favor the formation of sludge, which are viscous clots consisting of insoluble metal salts and large molecules of polymerized oil. Sludge affects the lubrication of the moving elements of the compressor, can clog valves and filters and cause serious damages. Acids, especially hydrofluoric acid, produced by the hydrolysis of the fluorinated refrigerant (in compressors iron and aluminum act as catalysts) are particularly corrosive. Acids etch metal surfaces with the consequent formation of crystal salts, which stick to surfaces and affect the total heat exchange coefficient in the condenser and in the evaporator. In the sealed and semi-sealed groups, these salts damage the windings of electric motors as in these groups cold gas cools windings through direct contact. On the other hand, water solubility in refrigerants in a liquid phase, is quite reduced, especially at low temperatures. As a consequence, when in the system water exceeds the very low limits of solubility admitted at low temperature, excess water turns into ice, and blocks expansion valves and capillaries either partially or totally. Consequently, refrigerating plants must be equipped with a filter drier on the liquid line and types available on the market are essentially two: molecular sieve driers and solid core driers. In molecular sieve driers, with a charge constituted by non-agglomerated products, the dehydrating mass is pressed in between two fine steel mesh disks, or two filtering disks of various material, kept in place by a spring. In solid core driers, dehydrating and deacidifying products with binders constitute the block. Water adsorption combines with the neutralization of acids that may be present in the refrigerant, and with a strong filtering action. Castel have planned either its production lines of hermetic driers on this second solution that avoid any risk of abrasion of the charge and consequently the making of powder and permit to put the filter in any position inside the refrigerating system. It is always advisable to install a moisture indicator downstream the filter, which will show the refrigerant moisture and, consequently, the degree of efficiency of the filter. The dehydrating capacity of Castel drier is relative to the charge of refrigerant and not to the refrigeration potential of the plant. As a matter of fact, for the same refrigerant potential and for the same type of refrigerant fluid, there can be different refrigerant charges according to the type, design and working conditions of the plant as well as to the shutter degree. The data shown in the following tables are deduced from the test results of the present Castel production. It is important to note in the case of a high oil level in the circuit (> 5%) the data shown in the tables will be reduced considerably.
84
ANTI-ACID SOLID CORE FILTER DRIERS WITH MOLECULAR SIEVES AND ACTIVATED ALUMINA SERIES 42 Approved by Underwriters Laboratories Inc. SOLID CORE FILTER DRIERS WITH 100% MOLECULAR SIEVES SERIES 43 Approved by Underwriters Laboratories Inc.
APPLICATIONS The filters, shown in this chapter, are classified Pressure vessels in the sense of the Pressure Equipment Directive 94/23/EC, Article 1, Section 2.1.1 and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). Filters series 42 and series 43 have been developed for specific installations on refrigerating systems using HFC refrigerant fluids, particularly R134a, R404A, R407C, R410A and R507 mixed with polyolester lubricants. In spite of this, the new block may be successfully used also in refrigerating systems using the old CFC or HCFC refrigerant fluids, mixed with mineral lubricants. CONSTRUCTION The filter is completely manufactured in steel, either with nickel-plated Flare threaded connections. The product range also includes types with copper plated solder connections, offering the possibility to solder the copper pipe inside the connections (ODS) or outside the connections, using a copper sleeve (ODM). On specific customers request, Castel is also able the supply them filters series 42 and 43 with: solder connections made of copper tube EN 12735-1 Cu-DHP ORFS (O-Ring Face Seal) threaded connections according to SAE J 1453 Standard. The blocks in the filters series 42 are molded from a blend of dehydrating charge, 80% of 3 molecular sieves and 20 % of activated alumina, and a special binding agent in appropriate proportions. The choice of blend, molecular sieves activated alumina, gives to the block a very high capacity of acid adsorption also maintaining very good dehydrating characteristics. The presence of a controlled and defined percentage of activated alumina, lower than the maximum value recommended by ASERCOM, keeps unchanged the original concentration of additives in the polyolester lubricant. The blocks in the filters series 43 are molded from a blend of dehydrating charge, totally made of 3 molecular sieves, and a special binding agent in appropriate proportions. The choice of the 3 molecular sieves, as sole dehydrating material, gives to the block a superlative capacity of water adsorption also
85
maintaining quite good deacidifying characteristics. The manufacturing process gives a considerable compacted ness and stoutness to both the products so that they are resistant to shocks and abrasions. The shape of the block is designed in order to offer the maximum possible surface area to the incoming fluid. The internal cavity is also positioned in such a way as to have a uniform wall thickness. As a result, the fluid encounters a constant strength at all points, flows linearly through the block, and ensures efficient dehydration and minimum charge loss. The block is chemically inert, not deliquescent, does not react with refrigerating fluids, and is capable of blocking oil by-products dragged into the circuit. Impurities accumulate in the ring between the metal shell and the block; this prevents filter clogging.
EXAMPLE OF SELECTION System data: Refrigerant: R407C Condensing temperature: + 50 [C] Weight of refrigerant: 34 [kg] According to DIN 8949:2000, the adsorption capacity of the drier is given by: (1.050 50) x 34 / 1.000 = 34 g of H2O where: 1.050 ppm. = moisture in the refrigerant entering the filter according to DIN 8949:2000 50 ppm. = moisture in the refrigerant flowing out the filter according to DIN 8949:2000 Comparing the absorption capacity required with the values shown in table 3, drier mod.4341 should be selected, with a water absorption capacity of 40,5 g at 50 C. If the dehydrating capacity of products is expressed in water drops, it must be remembered that: 1g H2O = 20 water drops In this case and when a molecular sieve drier is selected, the following result is obtained: 34 x 20 = 680 water drops. If moisture exceeds the values specified in DIN 8949:2000, a drier with a higher adsorption capacity shall be selected.
Solid core dehydrator 1 Spring 2 Block 3 Felt 4 Stainless steel mesh
86
flow direction
TABLE 1a: General Characteristics of filters with high water capacity core (1). SAE flare connections
Catalogue number International Reference Block Filtering Surface [cm2] Nominal Volume [cm3] TS [C] min. 1/4" 47 50 1/4" 3/8" 1/4" 70 80 1/4" 3/8" 1/4" 1/4" 103 130 3/8" 3/8" 1/2" 1/4" 3/8" 155 250 3/8" 1/2" 5/8" 3/8" 310 4330/5 4332/4 4332/5 4341/5 4341/6 305 304 305 255 415 416 330 670 500 500 1/2" 5/8" 1/2" 5/8" 5/8" 3/4" 45 40 +80 Art. 3.3 (3) max. PS [bar] Risk Category according to PED
Connections
4303/2 4303/2F (2) 4303/3 4305/2 4305/2F (2) 4305/3 4308/2 4308/2F (2) 4308/3 4308/3F (2) 4308/4 4316/2 4316/3 4316/3F (2) 4316/4 4316/5 4330/3 4330/4
032 033 052 053 082 083 084 162 163 164 165 303 304
(1) 100% molecular sieves; (2) Male-female connections (Inlet female) (3) PS = 400 psig in compliance with the UL approval
87
TABLE 1b: General Characteristics of filters with high water capacity core (1). Solder connections
Connections Catalogue number International Reference Block Filtering Surface [cm2] Nominal Volume [cm3] [in.] 50 1/4" 1/4" 70 80 3/8" 1/4" 3/8" 103 130 1/2" 3/8" 155 250 1/2" 5/8" 3/8" 310 500 1/2" 5/8" 255 500 1/2" 5/8" 5/8" 330 670 3/4" 7/8" 1/2" 5/8" 660 1340 3/4" 7/8" 1.1/8" ODS [mm] 10 10 12 10 12 16 16 16 16 16 [in.] 3/8" 3/8" 1/2" 3/8" 1/2" 5/8" 1/2" 5/8" 3/4" 1/2" 5/8" 3/4" 5/8" 3/4" 3/4" 7/8" 1.1/8" 5/8" 3/4" 7/8" 1.1/8" 1.3/8" ODM [mm] 12 12 14 16 12 Art. 3.3 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 164S 165S 303S 304S 305S 304S 305S 415S 416S 417S 754S 755S 756S 757S 759S 14 16 16 16 16 35 I 40 +80 45 (2) min. max. TS [C] PS [bar] Risk Category according to PED
4303/2S 4305/2S 4305/3S 4305/M10S 4308/2S 4308/3S 4308/M10S 4308/M12S 4308/4S 4316/3S 4316/M10S
032S 052S 053S 082S 083S 084S 163S
47
(1) 100% molecular sieves; (2) PS = 400 psig in compliance with the UL approval
88
TABLE 2a: General Characteristics of filters with antiacid core (1). SAE Flare connections
Block Filtering Surface [cm2] 47 Nominal Volume [cm3] TS [C] Connections min. max. PS [bar] Risk Category according to PED
Catalogue number
International Reference
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
032 033 052 053 082 083 084 162 163
50
1/4" 3/8"
70
80
1/4" 3/8" 1/4"
103
130
3/8" 1/2" 1/4" 3/8" 45 Art. 3.3 1/2" 5/8" 3/8" 40 +80 (2)
155 164 165 303 304 305 304 255 305 415 330 416 310
250
500
1/2" 5/8" 1/2"
500 5/8" 5/8" 670 3/4"
(1) 80% molecular sieves + 20% activated alumina; (2) PS = 400 psig in compliance with the UL approval
89
TABLE 2b: General Characteristics of filters with antiacid core (1). Solder connections
Connections Catalogue number International reference Block Filtering Surface [cm2] Nominal Volume [cm3] [in.] 50 1/4" 1/4" 70 80 3/8" 1/4" 3/8" 103 130 1/2" 3/8" 155 250 _ 1/2" 5/8" 3/8" 310 500 1/2" 5/8" 1/2 255 4232/5S 4241/5S 4241/6S 4241/7S 4275/4S 4275/5S 4275/6S 4275/7S 4275/9S 305S 415S 416S 417S 754S 755S 756S 757S 759S 660 1340 330 67 500 5/8" 5/8" 3/4" 7/8" 1/2" 5/8" 3/4" 7/8" 1.1/8" 16 16 16 3/4" 3/4" 7/8" 1.1/8" 5/8" 3/4" 7/8" 1.1/8" 1.3/8" 16 35 I ODS [mm] 10 10 12 10 12 16 16 [in.] 3/8" 3/8" 1/2" 3/8" 1/2" 5/8" 1/2" 5/8" 3/4" 1/2" 5/8" 3/4" 5/8" ODM [mm] 12 12 14 16 12 14 16 16 16 45 40 +80 (2) Art. 3.3 min. max. TS [C] PS [bar] Risk Category according to PED
4203/2S 4205/2S 4205/3S 4205/M10S 4208/2S 4208/3S 4208/M10S 4208/M12S 4208/4S 4216/3S 4216/M10S 4216/M12S 4216/4S 4216/5S 4230/3S 4230/4S 4230/5S 4232/4S
032S 052S 053S 082S 083S 084S 163S 164S 165S 303S 304S 305S 304S
47
(1) 80% molecular sieves + 20% activated alumina; (2) PS = 400 psig in compliance with the UL approval
90
TABLE 3: Refrigerant Flow Capacity and Water Capacity

Refrigerant Flow Capacity, Pressure drop 0,07 bar (1) [kW] R407C R404A R507 R410A R134a R134a R22 Water capacity at + 25 C (2) [g H2O] R407C R404A R507 R410A R134a R22 Dehydratable Charge at + 25 C [kg refrigerant] R407C R404A R507 R410A R134a R22 Water capacity at + 50 C (2) [g H2O] R407C R404A R507 R410A R134a R22 Dehydratable Charge at + 50 C [kg refrigerant] R407C 2,9 5,2 R404A R507 R410A 3,2 5,6 9,8 R22 3,2 5,7
Catalogue number
4303/2 6,5 4303/2F 4,1 4303/2S 4303/3 4305/2 6,7 4305/2F 4305/2S 4305/3 4305/3S 19,4 21,0 13,7 20,8 21,2 4305/M10S 4308/2 6,9 4308/2F 4308/2S 4308/3 18,0 19,5 12,7 19,3 19,6 4308/3F 12,7 11,6 13,0 10,4 11,3 13,7 12,5 13,9 11,2 12,2 10,9 9,3 12,0 8,4 4308/3S 22,8 24,7 16,1 24,5 24,8 4308/M10S 4308/M12S 4308/4 4308/4S 4316/2 4316/3 19,7 21,3 13,9 21,1 21,4 4316/3F 4316/3S 24,6 26,6 17,3 26,4 26,7 4316/M10S 25,1 22,9 25,6 20,5 22,3 27,0 24,6 27,5 22,0 24,0 21,6 18,4 23,8 16,5 18,0 23,2 19,8 25,6 17,7 19,4 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 67,2 72,6 47,3 72,0 73,0 4341/6S 4341/7S 4375/4S 4375/5S 4375/6S 4375/7S 4375/9S 74,2 80,2 52,2 79,6 80,5 53,4 57,7 37,5 57,3 57,9 54,5 58,9 38,3 58,4 59,1 80,6 87,1 56,8 86,4 87,6 122,8 112,2 125,6 100,6 109,4 132,0 120,6 135,1 108,2 117,6 106,0 90,0 116,6 81,0 88,2 114,0 96,8 125,4 87,1 94,8 92,8 100,3 65,3 99,5 100,6 96,5 104,3 67,9 103,5 104,7 34,1 36,9 24,0 36,6 37,0 28,2 30,5 19,9 30,3 30,6 34,1 36,9 24,0 36,6 37,0 37,6 40,6 26,4 40,3 40,8 45,0 48,7 31,7 48,3 48,9 21,7 23,4 15,3 23,2 23,5 27,1 29,3 19,0 29,0 29,4 30,9 33,4 21,8 33,2 33,5 50,2 45,8 51,2 41,0 44,6 54,0 49,2 55,1 44,1 48,0 43,2 36,8 47,6 33,0 36,0 46,5 39,6 51,2 35,5 38,7 37,3 40,4 26,3 40,0 40,5 38,8 41,9 27,3 41,6 41,9 46,6 50,4 32,8 50,0 50,6 33,6 36,3 23,6 36,0 36,4 40,5 43,8 28,5 43,4 44,0 45,4 41,4 46,4 37,2 40,5 48,8 44,5 49,9 40,0 43,5 39,1 33,2 43,1 29,9 32,6 42,0 35,7 46,3 32,2 35,1 39,9 43,1 28,1 42,8 43,0 48,2 52,1 33,9 51,7 52,3 40,9 44,2 28,8 43,8 44,4 49,5 53,5 34,8 53,1 53,7 61,4 56,1 62,8 50,3 54,7 66,0 60,3 67,5 54,1 58,8 53,0 45,0 58,3 40,5 44,1 57,0 48,4 62,7 43,5 47,4 29,0 31,3 20,4 31,0 31,4 24,0 25,9 16,9 25,7 26,0 29,0 31,3 20,4 31,0 31,4 6,9 7,5 4,9 7,4 7,5 9,1 11,8 10,0 13,0 9,0 8,5 9,2 6,0 9,1 9,3 7,5 4,9 7,4 7,5 8,2 8,9 5,8 8,8 9,0 7,3 15,4 16,6 10,8 16,5 16,7 6,7 7,4 6,0 6,5 7,8 7,2 8,0 6,4 7,0 6,3 5,3 6,9 4,8 5,2 6,8 7,4 7,2 4,7 7,1 7,2 8,0 8,6 5,6 8,5 8,6 14,9 16,1 10,5 16,0 16,2 3,8 4,2 3,4 3,7 4,4 4,0 4,5 3,6 3,9 3,5 3,0 3,9 2,7 2,9 3,8 4,2 7,0 4,6 6,9 7,0
(1) (2) See caption on page 92.
91

Water capacity, Pressure drop 0,07 bar (1) [kW] R407C R404A R507 R410A R134a R134a R22 Water capacity at + 25 C (2) [g H2O] R407C R404A R507 R410A R134a R22 Dehydratable Charge at + 25 C [kg refrigerant] R407C R404A R507 R410A R134a R22 Water capacity at + 50 C (2) [g H2O] R407C R404A R507 R410A R134a R22 Dehydratable Charge at + 50 C [kg refrigerant] R407C 2,5 2,7 4,4 4,8 8,3 R404A R507 3,6 6,3 R22
Catalogue number
4203/2 4203/2S 4203/3 4205/2 4205/2S 4205/3 4205/3S 4208/2 4208/2S 4208/3 4208/3S 4208/4 4208/4S 4216/2 4216/3 4216/3S 4216/4 4216/4S 4216/5 4216/5S 4230/3 4230/3S 4230/4 4230/4S 4230/5 4230/5S 4232/4 4232/4S 4232/5 4232/5S 4241/5 4241/5S 4241/6
6,5 8,0
7,0 8,6
4,6 5,6
6,9 8,5
7,0 8,6 3,5 3,2 3,6 2,9 3,1 3,8 3,4 3,9 3,1 3,4 3,0 2,6 3,3 2,3 2,5 3,3 2,8
14,9 16,1 10,5 16,0 16,2 6,7 8,2 7,2 8,9 4,7 5,8 7,1 8,8 7,2 9,0 6,2 15,4 16,6 10,8 16,5 16,7 19,4 21,0 13,7 20,8 21,2 6,9 8,5 7,5 9,2 4,9 6,0 7,4 9,1 7,5 9,3 10,8 9,9 11,0 8,8 22,8 24,7 16,1 24,5 24,8 24,0 25,9 16,9 25,7 26,0 29,0 31,3 20,4 31,0 31,4 6,9 7,5 4,9 7,4 7,5 9,6 11,6 10,6 11,9 9,5 10,3 9,3 7,9 10,2 7,1 7,7 10,0 8,5 11,0 7,7 5,7 6,3 5,1 5,5 6,7 6,1 6,8 5,5 6,0 5,4 4,5 5,9 4,1 4,5 5,8 4,9
18,0 19,5 12,7 19,3 19,6
19,7 21,3 13,9 21,1 21,4 24,6 26,6 17,3 26,4 26,7 28,2 30,5 19,9 30,3 30,6 21,3 19,5 21,8 17,4 19,0 22,9 20,9 23,4 18,7 20,4 18,4 15,6 20,2 14,0 15,3 19,7 16,8 21,8 15,1 16,5 34,1 36,9 24,0 36,6 37,0 37,6 40,6 26,4 40,3 40,8 45,0 48,7 31,7 48,3 48,9 21,7 23,4 15,3 23,2 23,5 27,1 29,3 19,0 29,0 29,4 30,9 33,4 21,8 33,2 33,5 42,7 38,9 43,5 34,9 37,9 45,9 41,9 46,8 37,5 40,8 36,7 31,3 40,5 28,1 30,6 39,5 33,6 43,5 30,2 32,9 37,3 40,4 26,3 40,0 40,5 38,8 41,9 27,3 41,6 41,9 46,6 50,4 32,8 50,0 50,6 33,6 36,3 23,6 36,0 36,4 40,5 43,8 28,5 43,4 44,0 38,6 35,2 39,4 31,6 34,4 41,5 37,8 42,4 34,0 37,0 33,2 28,2 36,6 25,4 27,7 35,7 30,3 39,4 27,3 29,8 39,9 43,1 28,1 42,8 43,0 48,2 52,1 33,9 51,7 52,3 40,9 44,2 28,8 43,8 44,4 49,5 53,5 34,8 53,1 53,7 52,2 47,7 53,4 42,8 46,5 56,1 51,3 57,4 46,0 50,0 45,1 38,3 49,6 34,4 37,5 48,4 41,1 53,3 37,0 40,3 67,2 72,6 47,3 72,0 73,0
4241/6S 4241/7S 4275/4S 4275/5S 4275/6S 4275/7S 4275/9S 74,2 80,2 52,2 79,6 80,5 53,4 57,7 37,5 57,3 57,9 54,5 58,9 38,3 58,4 59,1 80,6 87,1 56,8 86,4 87,6 104,4 95,4 106,8 85,5 93,0 112,2 102,5 114,8 91,9 100,0 90,1 76,5 99,1 68,9 75,0 96,9 82,3 106,6 74,0 80,6 92,8 100,3 65,3 99,5 100,6 96,5 104,3 67,9 103,5 104,7
(1) Maximum values of the refrigerant flow capacity at which the drier can be used when fluid dehydration is not the a major problem, provided that the original moisture is limited before the installation of the drier. The maximum refrigerant flow capacities are referred to a total pressure drop of 0,07 bar, inlet and outlet connections included, (according to ARI STANDARD 710:86 - with condensing temperature at +30 C and evaporating temperature at -15 C) (2) Water capacity values with R22 are referred to the following conditions, fixed in ARI STANDARD 710:86: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 60 ppm Water capacity values with the other refrigerant fluids are referred to the following conditions, fixed in DIN 8949:2000 Standard: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 50 ppm
92

Connections Catalogue number ODS SAE Flare 1/4" 1/4" 3/8" 1/4" 1/4" 3/8" 1/4" 1/4" 3/8" 3/8" 1/2" 1/4" 3/8" 3/8" 1/2" 5/8" 3/8" 1/2" 5/8" 1/2" 5/8" 5/8" 3/4" [in.] 1/4" 1/4" 3/8" 1/4" 3/8" 1/2" 3/8" 1/2" 5/8" 3/8" 1/2" 5/8" 1/2" 5/8" 5/8" 3/4" 7/8" 1/2" 5/8" 3/4" 7/8" 1.1/8" [mm] 112 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 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 10 52 139 10 12 151 10 12 73 16 16 16 16 91 219 16 367 373 378 378 378 1600 2540 2640 2820 2900 3050 1560 183 166 245 230 253 237 262 245 187 173 196 179 231 214 232 740 640 1380 1240 1360 1280 1480 1370 1300 1200 1320 1250 1580 1470 1640 158 174 158 630 640 680 640 146 162 146 158 166 154 380 430 380 635 690 680 620 345 135 137 154 142 345 395 380 146 380 260 D L 103 92 94 111 119 275 4305/2F 4305/2S 4305/3 4305/3S 4205/2S 4205/3 4205/3S 109 110 127 260 295 240 230 220 235 Dimensions [mm]
Weight [g]
4303/2 4303/2F 4303/2S 4303/3 4305/2
4203/2 4203/2S 4203/3 4205/2
solder connections
male - female connections (female - in)
male connections
93
SOLID CORE FILTER DRIERS WITH SIGHT GLASS SERIES 41
CONSTRUCTION
The lter series 41 is a liquid line lter drier with a sight glass directly brazed on its outlet side. This group reduces the amount of eld brazing required and the potential risk for leaks. Moisture/liquid indicators ensure a fast and safe inspection of the conditions of the refrigerant uid in the circuit concerning regular ow and moisture The lter is completely manufactured in steel, either with nickel-plated Flare threaded connections or with copper plated solder connections. Liquid/moisture indicator is manufactured with the glass lens directly fused onto a steel metallic ring, with proper surface protection. The block is molded from a blend of dehydrating charge, totally made of 3 molecular sieves, and a special binding agent in appropriate proportions. The choice of the 3 molecular sieves, as sole dehydrating material, gives to the block a superlative capacity of water adsorption also maintaining quite good deacidifying characteristics. The manufacturing process gives a considerable compactness and stoutness to both the products so that they are resistant to shocks and abrasions. OPERATION
APPLICATIONS
The lters, shown in this chapter, are classied Pressure vessels in the sense of the Pressure Equipment Directive 94/23/EC, Article 1, Section 2.1.1 and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant uids proper to the Group II (as dened in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). Filters series 41 have been developed for specic installations on refrigerating systems using HFC refrigerant uids, particularly R134a , R404A , R407C , R410A and R507 mixed with polyolester lubricants. In spite of this, the new block may be successfully used also in refrigerating systems using the old CFC or HCFC refrigerant uids, mixed with mineral lubricants
The moisture/liquid indicators consist of a sensitive element as a ring, which changes color passing from green to yellow according to the percentage of moisture in the system. The data of moisture content, shown in table 1 with the green colour, can be considered admissible for the proper working of the system. When the sensitive element from green fade to yellow, green Chartreuse, working conditions of the system could become difcult. When the sensitive element becomes yellow, its time to substitute the dehydrator lter. If the charge and working condition are normal, the refrigerant uid appears perfectly liquid underneath the lens of the indicator. The presence of bubbles indicates that the refrigerant uid is partial evaporating along the liquid line. INSTALLATION
At the start-up the color of the sensitive element may be yellow, due to exposure to air humidity and to moisture in the circuit. When the moisture of the refrigerant is brought back to acceptable levels with the dehydrator, the indicator color is once again green. This is evidence that equilibrium has been re-established. In case of persisting yellow, measures have to be taken to eliminate moisture. Only when the sensitive
94
TABLE 1: Moisture contained in the uid [p.p.m.]

Refrigerant uid Colour R22 Green Green Chartreuse Yellow <60 R134a <75 R404A <30 R407C <30 R410A <30 R507 <30
60
75
30
30
30
30
>60
>75
>30
>30
>30
>30
element comes back to green, there is evidence that adopted measures were effective. About 12 hours of system operation are required to achieve equilibrium. However, the moisture indication is given normally when the plant is in function and the uid is owing The brazing of lter/indicator with solder connections should be carried out with care, using a low melting point ller material. In any case, avoid direct contact between the torch ame and the indicator body or glass, which could be damaged and compromise the proper functioning of the indicator.
TABLE 2: General Characteristics of lters with sight glass

International Reference Catalogue Number Nominal Volume [cm3] Block Filtering Surface [cm2] Connections ODS SAE Flare 1/4 3/8 103 4108/4 4116/3 4116/4 4116/5 4108/3S 4108/4S 4116/3S 4116/4S 4116/5S 083S 084 084S 163 163S 164 155 164S 165 165S 250 5/8 1/2 5/8 16 3/4 5/8 16 130 1/2 3/8 1/2 3/8 1/2 3/8 1/2 5/8 16 40 80 45 Art. 3.3 1/2 1/4 4108/3 083 3/8 [in.] [mm] ODM [in.] [mm] min. TS [C] PS [bar] max. Risk Category according to PED
SAE Flare 4108/2
ODS 4108/2S
082 082S
95

Refrigerant Flow Capacity, pressure drop 0,07 bar (1) [kW] R407C R134A R404A R507 R410A R134A R22 Water Capacity at + 25 C (2) [g H2O] R407C R404A R507 R410A R134a R22 Dehydratable Charge at + 25 C [kg refrigerant] R407C R404A R507 R410A R134A R22 Water Capacity at + 50 C (2) [g H2O] R407C R404A R507 R410A R134A R22 Dehydratable Charge at + 50 C [kg refrigerant] R407C R404A R507 R410A 9,8 R22 538 510 553 515 593 595 795 780 835 805 895 870
Catalogue Number
4108/2
6,9
7,5
4,9
7,4
7,5
4108/2S 8,5
9,2
6,0
9,1
9,3
4108/3 18,0 19,5 12,7 19,3 19,6 12,7 11,6 13,0 10,4 11,3 13,7 12,5 13,9 11,2 12,2 11,0 9,3 12,1 8,4 4108/3S 22,8 24,7 16,1 24,5 24,8 9,1 11,8 10,0 13,0 9,0
4108/4 24,0 25,9 16,9 25,7 26,0
4108/4S 29,0 31,3 20,4 31,0 31,4
4116/3 19,7 21,3 13,9 21,1 21,4
4116/3S 24,6 26,6 17,3 26,4 26,7
4116/4 28,2 30,5 19,9 30,3 30,6 25,1 22,9 25,6 20,5 22,3 27,0 24,6 27,5 22,0 24,0 21,6 18,4 23,8 16,5 18,0 23,2 19,8 25,6 17,7 19,4 4116/4S 34,1 36,9 24,0 36,6 37,0
4116/5 37,6 40,6 26,4 40,3 40,8
4116/5S 45,0 48,7 31,7 48,3 48,9 (1) : Maximum values of the refrigerant ow capacity at which the drier can be used when uid dehydration is not the a major problem, provided that the original moisture is limited before the installation of the drier. The maximum refrigerant ow capacities are referred to a total pressure drop of 0,07 bar, inlet and outlet connections included, (according to ARI STANDARD 710:86 - with condensing temperature at + 30 C and evaporating temperature at - 15 C ) (2) : Water capacity values with R22 are referred to the following conditions, xed in ARI STANDARD 710:86: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 60 ppm Water capacity values with the other refrigerant uids are referred to the following conditions, xed in DIN 8949:2000 Standard: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 50 ppm

Connections Catalogue Number SAE Flare [in.] 4108/2 4108/2S 4108/3 4108/3S 4108/4 4108/4S 4116/3 4116/3S 4116/4 4116/4S 4116/5 4116/5S 1/4" 3/8" 1/2" 3/8" 1/2" 5/8" 1/4" 3/8" 1/2" 3/8" 1/2" 5/8" [mm] 52 73 16 212 219 221 193 198 200 202 204 210 D L 182 190 191 ODS Dimensions [mm]
Weight [g]
96
SOLID CORE BI-FLOW FILTER DRIERS SERIES 46
APPLICATIONS
CONSTRUCTION
The lters, shown in this chapter, are classied Pressure vessels in the sense of the Pressure Equipment Directive 94/23/EC, Article 1, Section 2.1.1 and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation in liquid lines on conditioning plants with reverse-cycle, on heat pumps and on refrigerating systems which use refrigerant uids proper to the Group II (as dened in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/ EEC). Filters series 46 have been developed for specic installations on refrigerating systems using HFC refrigerant uids, particularly R134a , R404A , R407C , R410A and R507 mixed with polyolester lubricants. In spite of this, the new block may be successfully used also in refrigerating systems using the old CFC or HCFC refrigerant uids, mixed with mineral lubricants
The lter is completely manufactured in steel, either with copper plated solder connections, offering the possibility to solder the copper pipe inside the connections (ODS) or outside the connections, using a copper sleeve (ODM). By-ow lter driers have two built-in check valves, one on both sides, which ensure that the refrigerant liquid always ows through the drier from the outer side of the solid core towards the center, regardless of the ow direction. Thus all dirt particles are retained irrespective of ow direction. The blocks are molded from a blend of dehydrating charge, totally made of 3 molecular sieves, and a special binding agent in appropriate proportions. The choice of the 3 molecular sieves, as sole dehydrating material, gives to the block a superlative capacity of water adsorption also maintaining quite good deacidifying characteristics. The manufacturing process gives a considerable compactness and stoutness to both the products so that they are resistant to shocks and abrasions. The blocks are symmetrical and are designed to offer the maximum possible surface area to the incoming uid, while the internal hole guaranties a uniform wall thickness. As a result, the uid encounters a constant strength at all points, ows linearly through the block, and ensures efcient dehydration and minimum charge loss. The block is chemically inert, not deliquescent, does not react with refrigerating uids, and is capable of blocking oil by-products dragged into the circuit. When building heat pump systems or conditioning plants with reverse-cycle, the use of by-ow lter driers eliminates the need for external check valves and reduces external piping and brazing.
97
TABLE 1: General Characteristics of by-ow lter driers

Connections Catalogue Number International Reference Block Filtering Surface [cm2] Nominal Volume [cm3] [in.] 4608/3S 4608/4S 4616/3S 4616/4S 4616/5S 083S 70 084S 163S 164S 165S 105 150 95 1/2" 3/8" 1/2" 5/8" 16 5/8" 1/2" 5/8" 3/4" 16 16 40 +80 45 Art. 3,3 3/8" TS [C] ODS [mm] [in.] 1/2" ODM [mm] min. max. PS [bar] Risk Category according to PED
Catalogue Number
Refrigerant Flow Capacity, pressure drop 0,07 bar (1) [kW]
Water Capacity at + 25 C (2) [g H2O]
Dehydratable Charge at + 25 C [kg refrigerant]
Water Capacity at + 50 C (2) [g H2O]
Dehydratable Charge at + 50 C [kg refrigerant]
R407C
R407C
R407C
R407C
R407C
R134A
R404A R507
R410A
R134A
R404A R507
R410A
R134A
R404A R507
R410A
R134A
R404A R507
R410A
R134A
R404A R507
4608/3S 11,5 12,5 8,1 12,4 12,6
14,0 12,7 14,3 11,4 12,4 15,1 13,7 15,4 12,3 13,3 12,1 10,2 13,3 9,2 10,0 13,0 11,0 14,3 9,9 10,8
4608/4S 16,0 17,3 11,3 17,2 17,4
4616/3S 16,8 18,2 11,9 18,1 18,3
4616/4S 28,1 30,4 19,8 30,2 30,5 27,6 25,2 28,2 22,5 24,5 29,7 27,1 30,3 24,2 26,3 23,7 20,2 26,2 18,1 19,8 25,5 21,7 28,2 19,5 21,3
4616/5S 36,6 39,6 25,8 39,3 39,8
(1) : Maximum values of the refrigerant ow capacity at which the drier can be used when uid dehydration is not the a major problem, provided that the original moisture is limited before the installation of the drier. The maximum refrigerant ow capacities are referred to a total pressure drop of 0,07 bar, inlet and outlet connections included, (according to ARI STANDARD 710:86 - with condensing temperature at + 30 C and evaporating temperature at - 15 C )
(2) : Water capacity values with R22 are referred to the following conditions, xed in ARI STANDARD 710:86: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 60 ppm Water capacity values with the other refrigerant uids are referred to the following conditions, xed in DIN 8949:2000 Standard: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 50 ppm
98
R410A
R22
R22
R22
R22
R22
Catalogue Number [in.] 4608/3S 4608/4S 4616/3S 4616/4S 4616/5S 3/8 1/2 3/8 1/2 5/8
ODS connections [mm] 60 16 83 D
L
Dimensions [mm] L 140 146 149 156 164 345 380 620 640 640 Weight [g]
99
FILTER DRIERS WITH REPLACEABLE ANTI-ACID SOLID CORE

Approved by Underwriters Laboratories Inc. Except filters 4423/17A, /21A, /25A and 4424/25A, /33A APPLICATIONS The filters, shown in this chapter, are classified Pressure vessels in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.1 and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). OPERATIONS In the case of filters with more than one block, the passage of the fluid takes place in parallel; as a result, the pressure drop does not increase proportionately to the number of blocks. A large ring between the block and the inner surface of the filter permits the accumulation of solid particles, and prevents clogging. Before leaving the filter, the refrigerant fluid must pass through the mesh sieve on which blocks are mounted. The danger that small particles of dehydrating material being introduced into the system is thus avoided. Furthermore, at filter outlet, a plastic cup, the edge of which closely adheres to the inner surface of the filter, prevents dirt from reaching the outlet connection during normal operation and block change. CONSTRUCTION The filters type 4410 are manufactured in steel, with the exception of the connections which are made of EN 12735-1 Cu-DHP copper tube. The filters type 4420 are completely manufactured in steel and solder connection, are machined with a steel bar EN 10025 S355JR. The blocks series 4490 and 4491 has been developed for specific installations on refrigerating systems using HFC refrigerant fluids, particularly R134a, R404A, R407C, R410A ed R507 mixed with polyolester lubricants. In spite of this, the new block may be successfully used also in refrigerating systems
using the old CFC or HCFC refrigerant fluids, mixed with mineral lubricants. The blocks 4490, type A and type B, and the block 4491, type A, are molded from a blend of dehydrating charge, totally made of 3 molecular sieves, and a special binding agent in appropriate proportions. The choice of the 3 molecular sieves, as sole dehydrating material, gives to the block a superlative capacity of water adsorption also maintaining quite good deacidifying characteristics. The blocks 4490, type AA and type AB, and the block 4491, type AA, are molded from a blend of dehydrating charge, 80% of 3 molecular sieves and 20 % of activated alumina, and a special binding agent in appropriate proportions. The choice of blend, molecular sieves activated alumina, gives to the block a very high capacity of acid adsorption also maintaining very good dehydrating characteristics. The presence of a controlled and defined percentage of activated alumina, lower than the maximum value recommended by ASERCOM, keeps unchanged the original concentration of additives in the polyolester lubricant.
The manufacturing process of blocks series 4490 and 4491 gives a considerable compacted ness and stoutness to both the products so that they are resistant to shocks and abrasions. The blocks series 4490 have a volume of 48 cu.in., equivalent to approx. 800 cm3, and it is used with
100

Core Filtering Surface [cm2] Nominal Volume [in.] 5/8" 7/8" 1.1/8" 1 420 48 800 1.3/8" 1.5/8" 2.1/8" 4490/A 4490/B 4490/AA 4490/AB 2 840 96 1600 7/8" 1.1/8" 1.3/8" 2.1/8" 1.3/8" 3 1260 144 2400 1.5/8" 1.5/8" 4 1680 192 3200 2.1/8" 2.1/8" 3 4491/A 4423/25A 4491/AA 4424/25A 4 4424/33A 2520 400 6400 114,3 88,9 88,9 32 II 1890 300 4800 2.5/8" Connections TS [C] ODS [cu.in] 4411/5A 4411/7A 4411/9A 4411/11A 4411/13A 4411/M42A 4411/17A 4412/7A 4412/9A 4412/11A 4412/M42A 4412/17A 4413/11A 4413/13A 4413/M42A 4414/13A 4414/M42A 4414/17A 4423/17A 4423/21A [cm3] [mm] 16 22 35 42 54 22 45 (2) 35 42 40 54 35 42 42 54 54 60,3 76,1 35 (2) +80 I W [mm] min. max. PS [bar] Risk Category according to PED
Catalogue number (1)
Core Cat. number
Number of Core
"(1) : filters series 4411 , 4412 , 4413 and 4414 with A suffix, as shown in table, are equipped with 1/4"" NPT threaded cover filters series 4411 , 4412 , 4413 and 4414 with B suffix, not shown in table, are equipped with blind cover" (2) PS = 470 psig in compliance with UL approval
type 4411, 4412, 4413 and 4414 filters. The block series 4491 has a volume of 96 cu.in., equivalent to approx. 1600 cm3. and it is used with type 4421, 4423 and 4424 filters. The two blocks are shaped as a hollow cylinder and their overall dimensions correspond to those of other international brands. Consequently they are interchangeable. The hollow cylinder shape offers a large surface area to the inflowing fluid, which crosses the block in radial sense. As a result, dehydration is highly efficient with a minimum loss of charge. Liquid line filter driers series 4411, 4412, 4413 and 4414 are supplied in these two solutions: - Codes with A suffix (listed in table 1), equipped with 1/4 NPT threaded cover for mounting an access fitting with valve core (for example G9150/R05) - Codes with B suffix (listed in table 1), equipped with blind cover Liquid line filter driers series 4423 e 4424 are supplied solely in codes with A suffix (not listed in table 1), equipped with 1/4 NPT threaded cover for mounting an access fitting with valve core (for example G9150/R05).
inlet
outlet
Sketch of filter with 2 blocks 1 Block 2 Mesh sieve serving as block support 3 Spring 4 Cover 5 Bottom
101
TABLE 2a: Refrigerant Flow Capacity and Water Capacity (filters)

Refrigerant Flow Capacity, Pressure drop 0,07 bar (1) [kW] R407C R404A R410A R134a R134a R22 Water Capacity at + 25 C (2) [g H2O] R407C R404A R410A R134a R22 Dehydratable Charge at + 25 C [kg refrigerant] R407C R404A R410A R134a R22 Water Capacity at + 50 C (2) [g H2O] R407C R404A R410A R134a R22 Dehydratable Charge at + 50 C [kg refrigerant] R407C 60 R407C 60 51 R404A R410A 65 65 55 R410A R22 66 66 R22 56
Catalogue number
4411/5A 4411/7A 4411/9A 4411/11A 4411/13A 4411/M42A 4411/17A 4412/7A 4412/9A 4412/11A 4412/M42A
83
90
59
89
90
146 158 103 156 159 200 216 141 214 217 233 252 164 250 253 84 77 86 69 75 90 83 92 74 81 72 61 80 56 60 77 86
250 270 176 268 271
146 158 103 156 159 226 244 159 242 245 306 331 215 328 332 168 154 172 138 150 181 166 185 148 161 144 122 160 112 120 155 131 172 120 129 333 361 234 357 362
4412/17A 4413/11A 4413/13A 361 391 254 387 393 4413/M42A 4414/13A 4414/M42A 4414/17A 4423/17A 4423/21A 4423/25A 4424/25A 4424/33A 447 483 315 479 485 492 532 346 527 534 504 462 516 414 450 542 497 555 445 484 432 366 480 336 360 465 394 516 361 387 670 725 472 719 728 737 797 519 791 800 672 616 688 552 600 723 662 740 594 645 576 488 640 448 480 619 525 688 482 516 1180 1276 830 1265 1281 426 460 300 456 462 336 308 344 276 300 361 331 370 297 323 288 244 320 224 240 310 262 344 241 258 327 354 230 351 355 252 231 258 207 225 271 248 277 223 242 216 183 240 168 180 232 197 258 181 194
TABLE 2b: Refrigerant Flow Capacity and Water Capacity (single block)
Refrigerant Flow Capacity, Pressure drop 0,07 bar (1) [kW] R407C R410A R404A R134a R134a R22 Water Capacity at + 25 C (2) [g H2O] R407C R404A R410A R134a R22 Dehydratable Charge at + 25 C [kg refrigerant] R407C R404A R410A R134a R22 Water Capacity at + 50 C (2) [g H2O] R407C R404A R410A R134a R22 Dehydratable Charge at + 50 C [kg refrigerant] R404A 86 73
Catalogue number
4490/A - 4490/B 4491/A 4490/AA - 4490/AB (3) 4491/AA
84
77
86
69
75
90
83
92
74
81
72
61
80
56
60
77
168 154 172 138 150 181 166 185 148 161 144 122 160 112 120 155 131 12 120 129 71 65 73 59 64 77 70 79 63 69 61 52 68 48 51 66
143 131 146 117 128 154 141 157 126 137 122 104 136 95 102 132 112 146 102 110
(1) Maximum values of the refrigerant flow capacity at which the drier can be used when fluid dehydration is not the a major problem, provided that the original moisture is limited before the installation of the drier. The maximum refrigerant flow capacities are referred to a total pressure drop of 0,07 bar, inlet and outlet connections included, (according to ARI STANDARD 710:86 - with condensing temperature at + 30 C and evaporating temperature at -15 C) (2) Water capacity values with R22 are referred to the following conditions, fixed in ARI STANDARD 710:86: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 60 ppm Water capacity values with the other refrigerant fluids are referred to the following conditions, fixed in DIN 8949:2000 Standard: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 50 ppm (3) Maximum values of the refrigerant flow capacity (according to ARI STANDARD 710:86) at which filter driers: - series 4411, 4412, 4413, and 4414 can be used with blocks type 4490/AA and 4490/AB - series 4423 and 4424 can be used with blocks type 4491/AA when fluid dehydration is not the a major problem, are the same achieved with block type 4490/A, 4490/B and 4491/A.
102

Connections Catalogue number [in.] 4411/5A 4411/7A 4411/9A 4411/11A 4411/13A 4411/M42A 4411/17A 4412/7A 4412/9A 4412/11A 4412/M42A 4412/17A 4413/11A 4413/13A 4413/M42A 4414/13A 4414/M42A 4414/17A 4423/17A 4423/21A 4423/25A 4424/25A 4424/33A 5/8" 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" 7/8" 1.1/8" 1.3/8" 2.1/8" 1.3/8" 1.5/8" 1.5/8" 2.1/8" 2.1/8" 2.5/8" ODS [mm] 16 22 154 35 171 42 54 22 296 35 42 54 35 454 42 113 595 42 10010 54 54 60,3 518 76,1 88,9 88,9 114,3 163 200 538 705 715 661 162 829 760 839 172 22000 21600 641 600 142 18200 18400 586 673 103 18000 682 9940 541 8445 121 149 300 312 303 442 387 399 390 529 324 101 113 103 101 7015 6985 7136 8510 8470 383 96 6880 162 249 103 258 113 5410 5585 159 246 185 101 241 96 5395 5464 5435 W [mm] D1 D2 H1 148 H2 235 H3 P 90 5360 5405 Dimensions [mm]
Weight [g]
103
BLOCKS REPLACEMENT
Blocks must be ordered separately from the filter. They are supplied in individual packages, which are hermetically sealed in suitable wrappings (type 4490), and in special bags (type 4491) for safe storage over long periods of time. Every cartridge is equipped of two seals in synthetic material to use like seal between the two cartridges and between the cartridge and its covers. If the filter is installed in a system without any by-pass, the block replacement has to be done following these instructions: 1 Close the valve on the departing line. 2 Start the compressor and its auxiliaries in order to transfer the refrigerant charge into the high pressure side of the plant (liquid receiver). 3 Stop the compressor at a suction pressure sufficiently higher than the atmospheric pressure. 4 Shutt off the service valve at the suction side of the compressor. NOTE: if during the transfer of the refrigerant to the high-pressure side of the plant, the discharge pressures reach too high values (the condenser is flooded due to insufficient capacity of the liquid receiver), shut off the valve on the compressor suction side and stop immediately the compressor. 5 Replace quickly the filter block. During the preparation of the new block, close the filter with a clean cloth. The slight over-pressure inside the filter and the ability of the technician will prevent air from getting into the plant.
4490
4491
TABLE 4: General Characteristics, dimensions and Weights

Core Filtering Surface [cm2] Nominal Volume Dimensions [mm]
Catalogue number
Weight [g] H
[cu.in] 4490/A 4490/B (1) 420 4490/AA 4490/AB (1) 4491/A 630 4491/AA 100 48
[cm3]
D1
D2
6 The internal cleanliness of the body is guaranteed by the cleaning effect of the cup which is characteristic of Castel filters. if air is supposed to have entered the plant during filter block replacement, produce a vacuum in the low-pressure side of the plant, and always in the sector of the circuit involved. 7 Open the valve on the departure of liquid line 8 Slowly open the suction valve of the compressor and start the compressor and its auxiliaries. 9 Top the charge up, if necessary.
800
47
96
140
670
1600
53
122
165
1350
(1) Supplied without cover gasket as spare part
104
MECHANICAL FILTERS WITH REPLACEABLE FILTERING BLOCK

Approved by Underwriters Laboratories Inc. Except filters 4421/21C, /25C, /33C APPLICATIONS The filters, shown in this chapter, are classified Pressure vessels in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.1 and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). OPERATION Good filtering of the refrigerant on the lowpressure side of the system is a guarantee of protection for the compressor. System cleanliness is ensured by micro filtering cores, which filter out impurities derived from manufacture and assembly of the refrigerating system. CONSTRUCTION The filters type 4410 are manufactured in steel, with the exception of the connections which are made of EN 12735-1 Cu-DHP copper tube. The filters type 4420 are completely manufactured in steel and solder connection, are machined with a steel bar EN 10025 S355JR. Zinc plated wire cloths and a filtering baffle form the block, which features a large surface, with controlled porosity. The block can stop solid particles up to 20 micron. At the two ends, soft felt gaskets ensure perfect sealing with the plastic cups. Filters are supplied with an access fitting kit G9150/R05. SUCTION LINE: SELECTION CRITERION With clean systems, refrigerant flow capacity and pressure drops of table 2 are reported to a gas speed of 20 m/s for pipes adequate to the filter connections. For refrigerant flow capacities different from the table values, under the other same conditions, gas speeds and relative pressure drops through the filter can be gained for simple proportionality. EXAMPLE
System data: Refrigerant: R407C Refrigerant flow capacity: 130 [kW] Evaporating temperature: + 5 [C] Suction pipe: 2.1/8 Filter: 4411/17C
In table 2, corresponding to filter type 4411/17C refrigerant and evaporating temperature, the following data is given: refrigerant flow capacity = 141,7 [kW]; pressure drop = 0,21 [bar]. The gas speed in the suction line will be:
20
130 2 = 16,8 [m/s] 141,7 2
Pressure drop through the filter:
0, 21
130 2 = 0,177 [bar] 141,7 2
Remember that the dimensioning of the suction line in a refrigerating system requires great attention. In fact the relative pressure loss, included filter, which implies a reduction of flow capacity sucked by the compressor, influences directly the refrigerating capacity of the plant. This line is normally sized to have a total pressure loss lower then a variation of the saturation temperature of 1 C.
105
For example diagram 1, referred to R22, allows to estimate the aforesaid variation in function of pressure loss and evaporating temperature. After all its always important to remember that the refrigerant flow capacity of a compressor, under the other same conditions, can reduce considerably because of the decrease of the saturation temperature, consequent to the
pressure loss in the suction line. To such purpose diagram 2 illustrates the existing relation between saturation temperature, in the suction line, and variation of the refrigerant flow capacity of a compressor.

Connections Catalogue Number Core Cat. Number Number of Core Core Filtering Surface [cm2] TS [C] ODS [in.] 7/8" 1.1/8" 1.3/8" 4495/C 820 1.5/8" 1 2.1/8" 2.5/8" 2.5/8" 4496/C 1850 [mm] 22 35 42 54 76,1 88,9 114,3 32 40 +80 I 45 (1) W [mm] min. max. PS [bar] Risk Category according to PED
4411/7C 4411/9C 4411/11C 4411/13C 4411/M42C 4411/17C 4411/21C 4421/21C 4421/25C 4421/33C
(1) PS = 470 psig in compliance with the UL approval
inlet
outlet
Sketch of filter with mechanical block 1 Block 2 Cover 3 Botton 4 Spring
106
DIAGRAM 1
6 5
-40
-35 -30 -25
Equivalent variation of the saturation temperature
4 3 2 1 0 0 5 10
ap ev
a or
tio
m te
pe
ur at
-20 -15 -10 -5 0 +10
15
20
25
30
35
Pressure loss (kPa)
DIAGRAM 2
1,5
0,5
0 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10
Saturation temperature at the suction (C)
Correction factor of refrigerant flow capacity
107
TABLE 2: Refrigerant Flow Capacity and Pressure drop

Evaporating Temperature [C] Catalogue number Refrigerant [kW] R134a R22 4411/7C R404A R407C R410A R134a R22 4411/9C R404A R407C R410A R134a R22 4411/11C R404A R407C R410A R134a R22 4411/13C R404A 4411/M42C R407C R410A R134a R22 4411/17C R404A R407C R410A R134a R22 4411/21C R404A R407C R410A R134a R22 4421/21C R404A R407C R410A R134a R22 4421/25C R404A R407C R410A R134a R22 4421/33C R404A R407C R410A 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 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 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 0,120 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 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 0,080 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 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 0,056 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 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 0,037 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 86,8 0,200 73,5 0,170 51,7 0,120 32,4 0,080 20,7 0,060 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 +5 [bar] 0,084 0,120 0,150 0,100 0,230 0,091 0,130 0,160 0,110 0,250 0,092 0,130 0,160 0,110 0,250 0,110 0,150 [kW] 13,7 21,5 20,0 19,0 31,7 23,0 36,4 34,0 32,1 53,7 35,0 55,0 51,4 48,6 81,0 50,0 79,0 0 [bar] 0,070 0,100 0,130 0,090 0,200 0,074 0,110 0,140 0,100 0,210 0,075 0,110 0,140 0,100 0,210 0,090 0,130 [kW] 9,0 15,6 14,0 12,8 23,0 15,0 26,0 24,0 21,3 38,0 23,0 39,0 36,2 33,2 57,0 33,0 56,0 -10 [bar] 0,048 0,074 0,090 0,060 0,140 0,051 0,080 0,100 0,066 0,150 0,052 0,080 0,100 0,068 0,150 0,062 0,090 [kW] 6,0 10,8 9,0 8,4 16,0 10,0 18,0 15,0 14,2 26,0 15,0 27,0 22,7 21,9 40,0 21,4 39,0 -20 [bar] 0,033 0,052 0,060 0,043 0,100 0,035 0,056 0,070 0,047 0,110 0,036 0,056 0,070 0,047 0,110 0,043 0,064 [kW] 3,5 7,2 6,0 5,1 10,6 6,0 12,0 10,0 8,7 17,7 9,0 18,0 14,5 13,4 26,0 13,0 26,0 -30 [bar] 0,021 0,037 0,040 0,028 0,100 0,022 0,040 0,050 0,031 0,110 0,023 0,040 0,050 0,031 0,110 0,027 0,046
Refrigerant flow capacities and pressure drops are referred to the following working conditions: Liquid temperature ahead expansion valve: + 35 C Overheating of suction gas: 6 C
108

Connections Catalogue Number [in.] 4411/7C 4411/9C 4411/11C 4411/13C 4411/M42C 4411/17C 4411/21C 4421/21C 4421/25C 4421/33C 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" 2.5/8" 2.5/8" ODS [mm] 22 154 35 42 54 76,1 88,9 114,3 163 200 162 186 187 205 215 249 273 308 328 338 200 103 128 142 162 172 5585 6030 12000 12200 12500 121 149 171 258 159 246 185 113 5410 101 241 96 5375 5435 W [mm] D1 D2 H1 H2 H3 P 5450 Dimensions [mm]
Weight [g]
4495 4496
TABLE 4: General Characteristics, dimensions and Weights

Filtering Surface Dimensions [mm]
Catalogue number
Weight [g] H
[sq.in]
[cm2]
D1
D2
4495/C
127
820
60
87
138
480
4496/C
287
1850
80
113
168
750
109
STRAINERS
APPLICATIONS The filters, shown in this chapter, are classified Pressure vessels in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.1 and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC).
CONSTRUCTION The filter is completely manufactured in steel, either with nickel-plated Flare threaded connections. The product range also includes types with copper plated solder connections, offering the possibility to solder the copper pipe inside the connections (ODS) or outside the connections, using a copper sleeve (ODM). Inside the filters there is a screen basket, with wide filtering surface, made of austenitic stainless steel AISI 304. These filters may not be cleaned.

Connections Catalogue number Filtering Surface [cm2] Usefull Passage Surface [%] Mesh Opening [mm] ODS SAE Flare 3/8" 1/2" 36,6 4520/M12 4520/4 4520/5 4520/M18 142 58 0,166 1/2" 5/8" 12 16 18 5/8" 3/4" 14 16 22 8,0 3,4 [in.] 3/8" [mm] 10 [in.] 1/2" ODM [mm] 2,4 4520/M10 12 40 +80 45 Art. 3.3 Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED
4510/3 4510/4 4520/3
58 142
2,4 3,2
4510
4520

Dimensions [mm]
Catalogue number D 4510/3 4510/4 4520/3 52 76
Weight [g] L 110 174 109 195 515 195 205 215 245 495
4520/M10 4520/M12 4520/4 4520/5 4520/M18 76 52 113 122 126 170
110
Valves
HERMETIC VALVES
a third one for charging or manometer connection, types: 6065 with right access connection; 6075 with left access connection. N.B. : the third way must be equiped with a valve core (for example type 8394/A or other similar ones) to be ordered separately. The main parts of the hermetic valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, or brass for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle.
APPLICATIONS The hermetic valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION These valves are available in the following two types: two-ways shut-off valves types 6010/2 and 6012/22; three-ways valves; two main connections plus

Connections Catalogue number (1) 6010/2 6012/22 6020/222 6020/233 6020/244 6020/255 6065/22M6 6065/23M10 6075/22M6 6075/23M8 6075/23M10 6075/24M12 6075/25M16 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" 3/8" 1/2" 5/8" 6 10 6 8 10 12 16 1/4" 0,39 1,20 2,20 2,80 0,46 1,38 0,46 1,29 1,38 2,55 3,40 -40 +110 45 Art. 3.3 SAE Flare (2) 1/4" (3) 1/4" [in.] 0,27 +130 ODS (4) [mm] Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED
6010/2
112
TABLE 2: Dimensions and Weight

Dimensions [mm] Catalogue number Weight [g]
H1
H2
H3
H4
H5
L1
L2
L3
P1
6010/2 14 6012/22 6020/222 25 6020/233 6020/244 26,5 6020/255 6065/22M6 6065/23M10 6075/22M6 6075/23M8 33 6075/23M10 6075/24M12 29,5 6075/25M16 39,5 69 38,5 68 58,5 25,5 31 33 31 56,5 58,5 56,5 1 52 68,5 127 51 61 115 66 36
29 62
58 55,5
160 145 360 370
67 77 79
520 530 205 200 72 30,5 205 210 220 310 84 32 320
25
25
6012/22
6020
6065
6075
113
RECEIVER VALVES
APPLICATIONS The receiver valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC).
CONSTRUCTION These valves are available in the following two types: two-ways valves, 90 angle connections, types 6110 and 6120; three-ways valves; two main connections (90 angle) plus a third one for charging, type 6132. The access connection may be shut off by the back-seating of the spindle; two-ways valves, 120 angle connections, type 6140. The main parts of the receiver valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle.

Connections Catalogue number (1) 6110/21 6110/22 6110/X15 6110/23 6110/32 6110/33 6110/X13 6110/43 6110/44 6110/54 6110/66 6120/22 6120/23 6120/33 6120/43 6120/44 6120/54 6120/66 6132/22 6132/33 1/4" 6132/44 6132/54 6140/22 6140/23 1/4" 3/8" 1/2" 5/8" 1/4" 1/2" 1/2" 1/4" 0,36 +130 2,20 3,85 3/8" f 1/4" f 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" 1/4" 3/8" 1/4" 3/8" 3/8" 1/2" 3,40 1/2" 3/4" 1/4" 3/8" 3/8" 3/8" 1/2" 3,40 1/2" 3/4" 1/4" 3/8" 6,00 0,45 1,20 +110 6,00 0,44 -60 0,45 1,35 2,40 45 Art. 3.3 +130 2,40 1,35 0,45 0,44 SAE Flare (2) 1/4" NPT (3) 1/8" Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED
114

6110
L2
H1
H2
L1
6110/21 6110/22 6110/X15 6110/23 6110/32 6110/33 6110/X13 6110/43 6110/44
70,5 72 83 29 77 50 31 87 88 55,5 92 34,5 48 27,5
100 110 130 135 130 140 175 220 235 245
6110/54 6110/66 6120/22 6120/23 6120/33 6120/43 6120/44 33 6120/54 6120/66 6132/22 56 6132/33 6132/44 63,5 6132/54 6140/22 57 6140/23 69 46 36 115 29 97 112 75 40 94 130 94 64 88 30 93 55,5 128 27,5 88 42,5 72 77 50 80 48
NPT 3 L1
675 110 130 140 225 305 245 670 240 250 375 365 115 125
6120 2
H1
3 L1
NPT L2
1 6132 2
H1
H2
6110/X13 6110/X15
NPT L2 L1
H2
2
H1
6140 2
H1
NPT 3
1 L1
L2 L1
115
H1
H2
STOP VALVES
APPLICATIONS The stop valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC).
The main parts of the stop valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; brass EN 12164 CW 614N for spindle and protection cap; chloroprene rubber (CR) for outlet seal gaskets for series 6165 and 6175; chloroprene rubber (CR) and aramidic fibers for gland seal, only for series 6170.
CONSTRUCTION The very compact design of these brass valves allows minimum dimensional sizes and the fixing flange complies with current market requirements. Valves 6170 and 6175 must be completed with the following devices, to be ordered separately: valve code 8394/A or code 8394/B; cap with gasket code 8392/A.

Connections Catalogue number Way Nr. (1) 6165/22 2 6165/33 6175/33 6175/44 6175/55 6170/66 6170/77 3 1/4" 3/8" 3/8" 1/2" 5/8" 3/4" 7/8" 3/8" 3/8" 1/2" 5/8" 3/4" 7/8" 10,80 16 1,70 3,40 4,60 9,00 -20 +110 45 Art. 3.3 1,70 SAE Flare (2) 1/4" [in.] 1/4" ODS (3) [mm] 0,68 Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED
116

Dimensions [mm] Catalogue number Weight [g] I
H1
H2
H3
L1
L2
L3
6165/22 6165/33 6175/33 6175/44 20 6175/55 6170/66 28,5 6170/77 104 12 65 17 52
9,5 12,7 8 15,9
29 30,5 29 36 31 59,5 67 38
113 120 135 225 235 655
19 22,2 47 28,6 36 83 50
670
6170 6165 6175
H2
H1
H2
3 D L1 L1 L3
H1
H3
H3
3 D L2
6.5
6.5
117
DIAPHRAGM VALVES
APPLICATIONS The diaphragm valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC).
CONSTRUCTION Diaphragm valves dont have gland seal. The external sealing is ensured by some thin metal discs (diaphragms), which hermetically divide the spindle chamber from the fluid flow area. The main parts of the hermetic valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; brass EN 12164 CW 614N for spindle; harmonic steel for spring; nylon for seat sealing gaskets.

Connections Catalogue number ODS (2) SAE Flare (1) 1/4" 3/8" 1/2" 5/8" 6210/6 6220/2 6220/3 6220/4 6220/5 6220/6 6220/7 5/8" 3/4" 7/8" 3,65 16 1,80 3/4" 1/4" 3/8" 1/2" 3,65 0,28 1,00 1,30 -35 +90 28 Art. 3.3 [in.] [mm] 0,28 1,00 1,30 1,80 Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED
6210/2 6210/3 6210/4 6210/5
118

Dimensions [mm] Catalogue number Weight [g] d I D
H1
H2
L1
6210/2 6210/3
68 53,5
58 74 4,5
36 52 38
200 325 335 340
6210/4 6210/5 6210/6 6220/2 6220/3
72 78 86 68 53,5 62,5 98 53 61 4,5 70 71 92 86 62,5 94 6,2 6,2
50 36
60
655 195 300
52 38 305
6220/4 6220/5 6220/6 6220/7
72
580 50 60 645
6210 D
6220 D
6260
H2
H2
H1
H1
1 A94
A94
L1
L1
H1
A 1
119
H2
ROTALOCK VALVES
The main parts of the hermetic valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle; steel bar EN 10277-3 11 S Mn Pb 37 for 7910 fittings; P .T.F.E. for 7990 gaskets.
APPLICATIONS The rotalock valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC).
CONSTRUCTION Rotalock valves, mounted with 7910 fittings and 7990 gaskets, assure fast installation and safe sealing. Before tightening it is possible to turn the valve in every direction. All Rotalock valves have an additional charging connection, which can be excluded by the back sealing of the spindle. Fittings 7910 and gaskets 7990 have to be ordered separately.
Valves 6310 6320
Gasket
7990
Coupling
7910

Connections Catalogue number (1) 6310/2 6310/3 6310/4 6320/3 6320/4 6320/5 6320/6 1/4" SAE Flare (2) 1/4" 3/4" 3/8" UNF 1/2" 3/8" 1/2" 5/8" 3/4" 1" UNS 3,4 1,40 3,10 -60 +110 45 Art. 3.3 1,35 Swivel nut (3) 0,46 Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED
120
Guarnizione
TABLE 2: Dimensions and Weight 7990
H1
H2
L1
L2
Raccordo 7910
290
6310/2 6310/3 6310/4 6320/3 6320/4 6320/5 6320/6 72 36,5 69,5 34,5 68,5 33,5
94 64 97
300 330
114,5 77,5 117,5
400 415 425
6310 6320
1 2
H1 H2
3 L1
L2
121
CAPPED VALVES
APPLICATIONS The capped valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION The main parts of the capped valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle.
INSTALLATION The brazing of capped valves with solder connections, type 6420, should be carried out with care, using a low melting point filler material. Its necessary to remove the spindle assembly, with gland too, before brazing the body. Its important to avoid direct contact between the torch flame and the valve body, which could be damaged and compromise the proper functioning of the valve.

Connections Catalogue number (1) 6410/2 6410/3 6410/4 6410/ 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
TS [C] ODS (3) Kv Factor [m3/h] [mm] 0,40 1,00 1,45 1,70 3,50 PS [bar] min. max. Risk Category according to PED
SAE Flare (2) [in.]
1/4" 3/8" 1/2" 5/8" 3/4" 1/4" 3/8"
0,40 1,00
10 -60 12 1,45 1/2" 5/8" 3/4" 7/8" 16 18 3,50 22 1,70 +110 45 Art. 3.3
1/4"
1/4"
0,35
Until exhaustion of the stock
122

Dimensions [mm] Catalogue number Weight [g] d I
H1
H2
L1
L2
L3
P1
6410/2 6410/3 85,5 6410/4 6410/5 6410/6 6420/2 6420/3 113 89,5 67
68 74 4,5 78 98 57 61 6,2 50 38
305 325 330 695 300
6420/M10 85,5 6420/M12 70 6420/4 6420/5 6420/M18 92 6420/6 113 6420/M22 94 6420/7 6460/22A 85,5 67 97 89,5 71 67
4,5 38 305
700 685 6,2 50 690 34 51 35 4,5 38 395
6410
6420
6460/22A
N.B. When the valve 6460/22A is closed, connections A-B are open and C is stopped; when opened, all connections are open.
123
GLOBE VALVES
APPLICATIONS The globe valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC).
CONSTRUCTION These valves are available in the following two types: 6512 with straight solder connections; 6532 with solder angle connections; The main parts of the globe valves are made with the following materials: hot forged brass EN 12420 CW 617N for body, cover and cap that covers the spindle; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; metal-rubber laminated for outlet seal gaskets P .T.F.E. for seat gaskets.

Connections Catalogue number [in.] 6512/M22 6512/7 6512/M28 6512/9 6512/11 6512/13 6512/M42 6512/17 6532/M22 6532/7 6532/M28 6532/9 6532/11 6532/13 6532/M42 6532/17 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" ODS [mm] 22 28 35 42 54 22 28 35 42 54 [in.] 1.1/8" 1.3/8" 1.3/8" 1.5/8" 2" 2" 1.1/8" 1.3/8" 1.3/8" 1.5/8" 2" 2" ODM [mm] 28 7,1 35 8,4 35 25,0 28 8,2 35 9,1 35 38,0 48,5 I 18,7 Art. 3.3 40,0 -35 +160 45 I 15,0 Art. 3.3 Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED
124

Dimensions [mm] Catalogue number H Weight [g] Q A
H1
L1
6512/M22 1415 6512/7 136 6512/M28 1310 6512/9 6512/11 6512/13 199 6512/M42 6512/17 6532/M22 1350 6532/7 147 6532/M28 1290 6532/9 6532/11 6532/13 4920 6532/M42 6532/17 238 65 139 86,5 104 138 4765 165 52,5 93 59 68 126 1910 44,5 80 50 60 94 215 42,5 173 104 37 141 88 138 5050 3500 166 34 118 68 126 2020 28,5 100 60 94
6532 6512
125
BALL VALVES
Ball valves are available in the following two types: type 6590 (full port) and type 6591 (reduced port) without access fitting. type 6590/A (full port) and type 6591/A (reduced port) with access fitting. These ball valves are equipped with valve core 8394/A and cap 8392/A. The main parts of the valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; hot forged brass EN 12420 CW 617N, chromium plated, for ball; copper tube EN 12735-1 Cu-DHP for solder connections; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) for outlet seal gaskets; P .T.F.E. for seat ball gaskets; glass reinforced PBT for cap that covers the spindle. Hot forged brass EN 12420 CW 617N for caps on sizes from 6590/M64A up to 6591/34A. INSTALLATION The brazing of ball valves should be carried out with care, using a low melting point filler material. It is important to avoid direct contact between the torch flame and the valve body, which could be damaged and compromise the proper functioning of the valve.
APPLICATIONS The ball valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION The specific design of Castel ball valves: ensures the internal equilibrium of pressures when the valve is closed; permits the bi-directional flow of the refrigerant and, consequently, the assembly on the plant without taking into account the direction of the refrigerant; prevents any risk of ejection or explosion of the spindle. The opening and closing of the valve is realized by turning the spindle one fourth of a turn. A standstill in turning realizes either a full opening or a full closing, moreover the arrow printed on the spindle head shows the flow direction. The electric welding of the bodies and the seal gaskets, assembled on the spindle, prevent any leaks.
6590
126

Catalogue number Without access fitting 6590/M6 6590/2 6590/3 6590/M10 6590/M12 6590/4 6591/5 6590/M15 6590/5 6590/M18 6590/6 6591/7 6590/7 6591/M28 6591/9 6590/M28 6590/9 6591/11 6590/11 6591/13 6591/M42 6590/13 6590/M42 6591/17 6590/17 6591/M64 6591/21 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 1.5/8" 2.1/8" 2.1/8" 2.5/8" 2.5/8" 65 3" 3.1/8" 3.1/8" 3.1/2" 3.5/8" 4.1/8" 4.1/4" 80 89 105 108 80 430 42 293 42 42 54 54 64 64 I 50 178 38 100 6590/M28A 6590/9A 6590/11A 1.1/8" 1.1/8" 1.3/8" 1.3/8" 1.5/8" 28 35 -40 35 32 68 +150 25 40 45 6590/3A 6590/M10A 6590/M12A 6590/4A 6590/M15A 6590/5A 6590/M18A 6590/6A 6590/7A 1/4" 3/8" 1/2" 5/8" 5/8" 3/4" 7/8" 7/8" 3 10 12 16 15 16 18 22 22 28 19 24 15 14,5 Art. 3.3 5 10 With access fitting Connections ODS [in.] [mm] 6 0,8 Ball Port [mm] Kv Factor [m3/h] TS [C] PS [bar] min. max. Risk Category according to PED
127

Dimensions [mm] Catalogue number H Weight [g] I d
H1
H2
L1
L2
6590/M6 6590/2 6590/3 6590/M10 6590/M12 6590/4 6591/5 6590/M15 6590/5 6590/M18 6590/6 6591/7 6590/7 6591/M28 6591/9 6590/M28 6590/9 6591/11 6590/11 6591/13 6591/M42 6590/13 6590/M42 6591/17 6590/17 6591/M64 6591/21 6590/13A 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 400 209 86 12500 196,5 75 70 380 199 76 75 M10 12450 172,5 62 64 350 185 68 330 175 58 148 54 53 275 149 58 4400 8120 8090 8310 8350 12400 127 44 45 239 253 126 133 48 2470 2520 4360 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 117 37 101,5 30 41 45 210 112 30 M6 206 248 109 130 43 43 1518 1050 95,5 206 108,5 800 27,5 38 177 175 92 93 33 450 760 80 24 36 141 74 32 410 138 73,5 18 M5 290 73 20 33 121 65 24 300 260
6590/..A
128
GAUGE MOUNTING VALVES
APPLICATIONS The valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). They are used for mounting and intercepting the gauges on control panels.
CONSTRUCTION The valves are equipped with: a little flange for fixing the valve to the control panel; a SAE-Flare connection for joining it to the copper tube; an NPT (type 8320) or a swivel SAE FLare (8321) connection for mounting the gauge. The main parts of this valve are made with the following materials: Hot forged brass EN 12420 CW 617N for body; Steel, with proper surface protection, for the spindle; Chloroprene rubber (CR) and aramidic fibers for gland seal; Glass reinforced PBT for cap that covers the spindle.

Connections Catalogue number Dimensions [mm] Weight [g] min. max. TS [C] PS [bar] Risk Category according to PED
SAE Flare 1/4" 1/4" 1/4"
NPT
SAE Flare 1/4" f
H1
L1
L2
L3
8320/21 8320/22 8321/22
1/8" 1/4"
19 37 40 83 35 17
140 -60 186 +130 45 Art. 3.3
8320
8321
129
LINE PIERCING VALVE
APPLICATIONS The valve, shown in this chapter, is classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and is subject of Article 3, Section 1.3 of the same Directive. It is designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). The piercing valve is a fast and cheap means of providing a loading, outlet or inlet point in the refrigerating system. It can be applied on copper tube with a 6 mm to 10 mm diameter, and can be installed in any position on the system.
CONSTRUCTION The main parts of the piercing valve are made with the following materials: Hot forged brass EN 12420 CW 617N for body; Hardened steel for the needle; Chloroprene rubber (CR) for the outlet seal gaskets. INSTALLATION The threaded fork must be installed astride of the copper tube, the valve is fastened to the pipe by tightening the lower nut and screwing it the needle pierces the pipe. The hole, pierced by the needle, connects the pipe inlet with the SAE-Flare connection as shown in figures 1 and 2.
TABLE 1: General characteristics, dimensions and weight

Connections Catalogue number Pipe diameter [mm] 6 - 10 Dimensions [mm] Weight [g] min. max. TS [C] PS [bar] Risk Category according to PED
SAE Flare 1/4"
H1
L1
L2
L3
8330/A
72
25,5
29
36
104
-10
+70
25
Art. 3.3
130
opened valve
Threaded brass fittings
THREADED BRASS FITTINGS

All straight fittings, from series 7110 to series 7170, and all the plug, from series 7510 to series 7520, are machined by brass bar EN 12164 CW 614N. Seal caps series 7560 and gaskets series 7580 are made with copper Cu ETP UNI 5649. The main parts of the flanges joints are made with the following materials: hot forged brass EN 12420 CW 617N for bushes and flanges; aramidic fibers for seal gasket of the flanges.
APPLICATIONS All the fittings, shown in this chapter, are excluded from the scope of Directive 97/23/EC, as specified in the Guidelines 1/8 and 1/9, because they are piping components. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). OPERATION The sealing system between the end of a male connection and a nut series 7010, 7020 and 7030 requires a special flaring of the end of copper tube, the so-called flared connection. The sealing system between the end of a male connection and a Flare-ODS adapter allows avoiding the flaring process on copper tube end (national laws of some European countries dont accept this operation) because the tube end is brazed into the solder connection of the adapter. We wish to remember to our customers that they may assure no leakage of the male connection/adapter system only interposing the copper gasket 7580, supplied with the same adapter. Flange joints 7630 consist of two brass bushes for brazing to the copper tubes. When the four flange screws are tightened, a gasket, put between the two bushes, assures the seal of flanged joints. CONSTRUCTION All nuts, from series 7010 to series 7050, and all the elbows, TEE and cross fittings, from series 7210 to series 7410, are manufactured with hot forged brass EN 12420 CW 617N.
132

Copper pipe Catalogue number International Reference SAE Flare PS [bar] D L Ch Dimensions [mm] Wrench torque min / max [Nm] Weight [g]
[in]
[mm]
SAE Flare nuts (inch tubing)

7010/22 7010/33 7010/44 7010/55 7010/66 7010/77 7010/88 NS44 NS46 NS48 NS410 NS412 NS414 NS416 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 1" 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 1" 6 16 22 45 6,5 9,7 13 16,2 19,4 22,5 25,6 15,5 19,5 22,5 25 29,5 36,5 41 36,5 120 / 150 153 17 22 25 28 33 11 / 14 20 / 25 34 / 47 54 / 75 68 / 71 90 /120 19 38 49 64 97 186
SAE Flare cap nuts

N54 7020/20 CAP NUT 1/4" blind N5-5 7020/X02 CAP NUT 5/16" 15 15 8,5 / 11,5 14 blind 45 15,5 17 11 / 14 20
SAE Flare reducing nuts (inch tubing)

7020/32 7020/43 7020/54 7020/65 7020/87 NRS464 NRS486 NRS4108 NRS41210 NRS41614 3/8" 1/2" 5/8" 3/4" 1" 1/4" 3/8" 1/2" 5/8" 7/8" 6 16 22 45 6,5 9,7 13 16,2 22,5 19,5 22,5 25 29,5 36,5 22 25 28 33 41 20 / 25 34 / 47 54 / 75 68 / 71 120 / 150 38 53 69 104 160
SAE Flare nuts (metric tubing)

7030/3M8 3/8" 7030/3M10 7030/4M10 7030/4M12 7030/4M14 7030/5M12 5/8" 7030/5M14 7030/6M14 3/4" 7030/6M18 18 18,3 14 14 14,3 14,3 29,5 33 68 / 71 98 1/2" 10 10 12 14 12 45 10,3 10,3 12,3 14,3 12,3 25 28 54 / 75 68 106 22,5 25 34 / 47 8 8,3 19,5 22 20 / 25 36 53 50 47 70 37
SAE Flare twin nuts

7050/2 7050/3 7050/4 7050/5 US44 US46 US48 US410 1/4" 3/8" 1/2" 5/8" 45 46 51 25 28 34 / 47 54 / 75 105 140 32 40 17 22 11 / 14 20 / 25 39 78
133

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

7110/2 7110/3 7110/4 7110/5 7110/6 7110/8
E
U24 U26 U28 U210 U212 U216
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
Reducing SAE Flare unions

7120/23 7120/24 7120/34 7120/35 7120/45 7120/56
R R R
UR264 UR284 UR286 UR2-106 UR2108 UR2-1210
1/4" x 3/8" 1/4" x 1/2" 3/8" x 1/2" 3/8" x 5/8" 1/2" x 5/8" 5/8" x 3/4" 45
42 45 48 52 54 61,5
17
38 58
20 23 23 27
66 89 98 170
SAE Flare / NPT unions

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

7140/21 7140/32 7140/43 7140/54 U14A U16B U18C U110D 1/4" 3/8" 1/2" 5/8" 1/8" 1/4" 45 3/8" 1/2" 45,2 53,8 20 23 64 102 32,9 41,1 12 17 20 39
R E
Available on request Until exhaustion of the stock
134

Connections Catalogue number International Reference SAE Flare NPT m f GAS [in.] ODS [mm] PS [bar] L Ch Dimensions [mm] Weight [g]
Male / female reducing unions (reduced female)

7150/21 7150/32 7150/43 7150/54 7150/64 7150/65 U34A UR346 UR368 UR3810 UR3812 UR31012 1/4" 3/8" 1/2" 5/8" 3/4" 3/4" 1/4" 3/8" 1/2" 1/2" 5/8" 45 45 46,5 49,5 25 27 30 99 132 157 1/8" f 29 33 38 14 17 22 21 38 66
Male / female reducing unions (reduced male)

7150/23 7150/24 7150/34 7150/45 7150/46 7150/56 UR364 UR384 UR386 UR3108 UR3128 UR31210 1/4" 1/4" 3/8" 1/2" 1/2" 5/8" 3/8" 1/2" 1/2" 5/8" 3/4" 3/4" 45 44 45 34 49 150 30 127 140 33 36 25 39 74 22 49 66
Cylinder adaptors
7154/2 7156/2 1/4" W 21,8 14 right thread, female 1/4" 20 14 left thread, female 45 29 27 52 25 46
Male / female unions

7160/2 1/4" 1/4" 30,5 17 31
7160/3
3/8"
3/8"
45
36
22
57
7160/4
1/2"
1/2"
41
25
84
Unions SAE Flare to BSP

7164/2 7166/2 1/4" 1/4" G1/4" m 32 17 25 G1/4" f 45 32,5 20 45
Male SAE Flare / solder unions

7170/22 7170/2M8 7170/33 7170/3M10 7170/44 7170/4M12 7170/55 7170/6M18 US344 1/4" US366 3/8" US388 1/2" US31010 5/8" 3/4" 5/8" 12 16 18 42 45,5 23 27 82 123 1/2" 35 20 55 10 45 3/8" 8 33 17 39 1/4" 26,5 12 17
Available on request
135

Item position Connections Catalogue number ODS SAE Flare [in.] [mm] PS [bar] Dimensions [mm] Wrench torque Weight min/max [g] [Nm]
L1
L2
L3
L4
Ch
Flare - ODS adapters

1 2 3 9900/X58 9900/X62 7580/2 9900/X58 9900/X70 7580/2 9900/X59 9900/X63 7580/3 9900/X59 9900/X71 7580/3 9900/X60 9900/X64 7580/4 9900/X60 9900/X72 7580/4 9900/X61 9900/X65 7580/5 9900/X68 9900/X69 7580/6 9900/X68 9900/X77 7580/6 3/4" 18 30 5 3/4" 3/4" 30 5 5/8" 5/8" 16 27,5 5 1/2" 12 1/2" 1/2" 45 26 26 4,5 4,5 3/8" 10 23,5 4 3/8" 3/8" 23,5 4 1/4" 6 21 3,5 1/4" 1/4" 21 3,5 16 16 18,5 18,5 21 21 22,5 25 25 20 36 3 68/71 455 20 36 3 1 2 68/71 404 18 30 3 1 2 54/75 271 17 17 27 3 1 27 3 1 2 34/47 226 34/47 207 14,7 22 3 1 2 20/25 130 14,7 22 3 20/25 114 12,5 17 3 1 2 11/14 83 12,5 17 11/14 67
POS. 1
1 2
POS. 2
1 2
POS. 3
Flare/ODS fitting
Nut
Connection
Copper seal
Copper pipe
SAE/Flare connection
136

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

7210/2 7210/3 7210/4 7210/5 7210/6 E24 E26 E28 E210 E212 1/4" 3/8" 1/2" 5/8" 3/4" 45 24,5 29,5 32,5 36 42,5 24,5 29,5 32,5 36 42,5 26 49 83 116 192
SAE Flare / NPT elbows

7220/2 7220/3 7220/4 7220/6 E14B E16C E18D E112F 1/4" 3/8" 1/2" 3/4" 1/2" 3/4" 1/4" 3/8" 45 32,5 42,5 32 39,5 91 183 26 29,5 24 28,5 33 54
SAE Flare / reduced NPT elbows

7230/21 7230/32 7230/43 7230/54 E14A E16B E18C E110D 1/4" 3/8" 1/2" 5/8" 3/8" 1/2" 1/8" 1/4" 45 32,5 36 31 35 75 114 24,5 29,5 23,5 29,5 25 46
Male / female SAE Flare elbows

7240/2 1/4" 1/4" 28,5 28 56
7240/3
3/8"
3/8"
45
32
31
84
7240/4
1/2"
1/2"
39,5
38
198
137

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

7310/2 7310/3 7310/4 7310/5 7310/6 T24 T26 T28 T210 T212 1/4" 3/8" 1/2" 5/8" 3/4" 1/4" 3/8" 1/2" 5/8" 3/4" 1/4" 3/8" 1/2" 5/8" 3/4" 45 23,5 29 31,5 36 41,5 47 58 63 72 83 32 69 97 153 235
SAE Flare reducing TEE (reduced side connections)

7320/223 7320/334 7320/445 7320/556 TR246 TR268 TR2810 TR21012 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 38 41,5 72 83 153 228 29 32,5 56 63 77 95
SAE Flare reducing TEE (reduced central connection)

7320/332
H
TR264 TR286 TR2108 TR21210
3/8" 1/2" 5/8" 3/4"
3/8" 1/2" 5/8" 3/4"
1/4" 3/8" 45 1/2" 5/8"
28 32,5 38 41,5
58 63 72 83
77 101 158 220
7320/443 7320/554
7330/221 L
7320/665
SAE Flare / NPT TEE (taper central connection)

7330/221 T14A 1/4" 1/4" 7330/222
H
7340/222
1/8" 1/4" 45
21
47
56
T14B
1/4"
1/4"
24
51
198
Male / female SAE Flare (female central connection)

L
7340/222
T64
1/4"
1/4"
1/4"
45
27,5
56
78
SAE Flare cross

7410/2
7410/2
C14
1/4"
1/4"
1/4"
1/4"
45
52
52
55
138

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

7510/2 P24 1/4" 23 12 11 / 14 19
7510/3
P26
3/8"
45
26
17
20 / 25
40
7510/4
P28
1/2"
30
20
34 / 47
67
NPT plugs
7520/1 7520/2 7520/3 7520/4 7520/6 7520/8 121B02 121B04 121B06 121B08 121B12 121B16 1/2" 3/4" 1" 1/8" 1/4" 3/8" 45 29,8 32,1 39 22 27 34 25 / 35 30 / 40 60 / 80 87 149 279 15,9 23,1 23,2 12 14 17 10 / 13 15 / 20 17 / 22 12 27 43
Copper seal caps

7560/2 7560/3 7560/4 7560/5 7560/6 7560/7 B14 B16 B18 B110 B112 B114 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 45 0,5 1 1,5 2 4 10
Ch
Copper gasket
7580/2 7580/3 7580/4 7580/5 B24 B26 B28 B210 B212 1/4" 3/8" 1/2" 5/8" 3/4" 45 0,5 0,5 1 1,5 3
Ch
7580/6
Flange joints
7630/7 7630/9 7630/11 7630/13 7630/M42 1.5/8" 2.1/8" 42 54 24 25 67 71 68 / 80 7/8" 1.1/8" 1.3/8" 35 42 42 / 50 1340 1940 22 20 / 24 23 63 490 1045 315
7630/17
139
Copper braze - joint pressure fittings
COPPER BRAZE-JOINT PRESSURE FITTINGS

dimensions: 7832 Tees and reducing tees Reinforced series 79 show the following selection of copper braze-joint fittings, with ODS / IDS millimeters connections, limited to some dimensions: 7900 Female to female couplings 7902 Female to female reducing couplings 7903 Male to female reducing couplings 7916 45 female to female elbows 7917 45 male to female elbows 7918 90 female to female elbows long radius 7919 90 male to female elbows long radius 7932 Tees and reducing tees CONSTRUCTION Dimensions and tolerances of the ODS / IDS connections ends in copper braze-joint fittings series 77, 78 and 79 are in compliance with the EN 1254-1 : 1998 Standard. All copper braze-joint fittings series 77, 78 and 79 are made of seamless copper tube EN 12735-2 CW024A, soft annealed. Technical characteristics of copper fittings series 77 and 78, depending on tube nominal diameters, are given in table 1, while technical characteristics of copper fittings series 79, always depending on nominal diameters, are given in table 2. Copper braze-joint fittings series 77, 78 and 79, if submitted to ambient-temperature burst test, guarantee a pressure strength at least equal to 3 x PS (30 C rated working-pressure as shown in tables 1 and 2) according to ASME B16.50 : 2001 Standard.
APPLICATIONS All the fittings, shown in this chapter, are excluded from the scope of Directive 97/23/EC, as specified in the Guidelines 1/8 and 1/9, because they are piping components. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, made of seamless copper tube specified in EN 12735-1 : 2001 Standard, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). PRODUCTS RANGE Series 77 show the following selection of copper braze-joint fittings, with ODS / IDS millimeters connections, practically in all diameter dimensions: 7700 Female to female couplings 7702 Female to female reducing couplings 7703 Male to female reducing couplings 7708 90 female to female elbows short radius 7709 90 male to female elbows short radius 7716 45 female to female elbows 7717 45 male to female elbows 7718 90 female to female elbows long radius 7719 90 male to female elbows long radius 7732 Tees and reducing tees Series 78 show the following selection of copper braze-joint fittings, with ODS / IDS inch connections, limited to few diameter
142
INSTALLATION
Tube Nominal Diameter
TABLE 1
Working Pressure PS [bar], depending on temperature
The internal working pressure-temperature rating for a copper fitting, is dependent upon, not only fitting strength, but also the adopted joining process and the used filler metal. The working pressure-temperature values given in tables 1 and 2 are referred to a brazing process, performed in accordance with the sound engineering practice. We wish to remember the definition of brazing process, given in EN 13133 : 2000 Standard. The process of joining generally applied to the joining of materials by a heating process during which the parent materials do not melt and the filler metal is drawn into the joint by capillary action. It is generally applicable to joining systems where the filler metal melts at 450 C or above. In actual practice brazing is done at temperatures ranging from 630 to 820 C and there are two general types of brazing filler metals, normally used for joining copper tube: Copper Phosphorus alloys (the so called BCuP), proper to CP Class of EN 1044 : 1999 Standard, that are normally used without fluxes; Silver alloys (the so called B-Ag), proper to AG Class of EN 1044 : 1999, that must be used with their specific fluxes.
[mm] 6 8 10 12 14 15 16 18 22 28 35 42 54 64 67 76 80 89 106
[in.] 1/4" 3/8" 1/2" 5/8" 7/8" 1" 1.1/8" 1.3/8" 1.5/8" 2.1/8" 2.5/8" 3.1/8" 3.1/2"
-40 / +30 C 90 90 70 60 60 50 50 45 45 45 40 40 35 30 30 30 25 25 20 20 20 20 18 18 18 18 15
+95 C 72 72 56 48 48 40 40 36 36 36 32 32 28 24 24 24 20 20 16 16 16 16 14 14 14 12 12
+150 C 63 63 49 42 42 35 35 32 32 32 28 28 24 21 21 21 18 18 14 14 14 14 13 13 13 11 11
Note: working pressure shown in this table are in comparison with rated working pressures established in ASME B16.50 : 2001 Standard.
TABLE 2
Working Pressure PS [bar], depending on temperature Tube Nominal Diameter -40 /+ 30 C [in.] 7/8 1 1.1/8 1.3/8 1.5/8 2.1/8 (1) 60 55 50 50 50 40 40 35 (2) 80 73 67 67 67 53 53 47 (1) 50 45 40 40 40 35 35 30 +95 C (2) 67 60 53 53 53 47 47 40 (1) 45 41 37 37 37 30 30 26 +150 C (2) 60 55 49 49 49 40 40 35
[mm] 22 28 35 42 54
(1) PS values listed in this column are referred to a safety coefficient 4, according to ASME B16.50 : 2001 Standard (2) PS values listed in this column are referred to a safety cefficient 3, minimum value warranted by Castel for all its products
143

Connections Catalogue number International Reference IDS [mm] ODS [mm] Weight [g] Note
Female to female couplings (metric tubing)

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

7702/M10.6 7702/M10.8 7702/M12.8 7702/M12.10 7702/M14.10 7702/M14.12 7702/M16.10 7702/M16.12 7702/M16.14 7702/M18.12 7702/M18.16 7702/M22.12 7702/M22.14 7702/M22.16 7702/M22.18 7702/M28.12 7702/M28.18 7702/M28.22 7702/M35.22 7702/M35.28 7702/M42.28 7702/M42.35 7702/M54.35 7702/M54.42 7702/M67.54 7702/M76.54 5240/10.6 5240/10.8 5240/12.8 5240/12.10 5240/14.10 5240/14.12 5240/16.10 5240/16.12 5240/16.14 5240/18.12 5240/18.16 5240/22.12 5240/22.14 5240/22.16 5240/22.18 5240/28.12 5240/28.18 5240/28.22 5240/35.22 5240/35.28 5240/42.28 5240/42.35 5240/54.35 5240/54.42 5240/67.54 5240/76.54 22 22 28 28 28 35 35 42 42 54 54 67 76 16 18 12 18 22 22 28 28 35 35 42 54 54 23 23 34 29 33 56 56 66 88 166 160 246 314 10 10 12 12 14 14 16 16 16 18 18 22 22 6 8 8 10 10 12 10 12 14 12 16 12 14 3 6 6 8 9 9 12 9 11 12 13 22 19
144

Male to female reducing couplings (metric tubing)

7703/M8.6 7703/M10.6 7703/M10.8 7703/M12.6 7703/M12.8 7703/M12.10 7703/M14.10 7703/M14.12 7703/M16.10 7703/M16.12 7703/M16.14 7703/M18.10 7703/M18.12 7703/M18.14 7703/M18.16 7703/M22.12 7703/M22.14 7703/M22.16 7703/M22.18 7703/M28.12 7703/M28.14 7703/M28.16 7703/M28.18 7703/M28.22 7703/M35.18 7703/M35.22 7703/M35.28 7703/M42.22 7703/M42.28 7703/M42.35 7703/M54.28 7703/M54.42 7703/M67.42 7703/M67.54 7703/M76.42 7703/M80.42 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 8 10 10 12 12 12 14 14 16 16 16 18 18 18 18 22 22 22 22 28 28 28 28 28 35 35 35 42 42 42 54 54 67 67 76 80 106 6 6 8 6 8 10 10 12 10 12 14 10 12 14 16 12 14 16 18 12 14 16 18 22 18 22 28 22 28 35 28 42 42 54 42 42 54 2 3 3 3 6 4 8 5 9 9 8 12 9 11 8 23 20 20 21 32 31 33 29 32 50 65 50 90 102 93 125 146 197 246 270 306 784 = 7700/M8 = 7702/M10.6 = 7702/M10.8 = 7700/M10 = 7702/M12.10 = 7700/M12 = 7702/M14.10 = 7702/M14.12 = 7700/M14 = 7702/M16.10 = 7702/M16.12 = 7702/M16.14 = 7700/M16 = 7700/M6
7703/M106.54 5243/106.54
145

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

7708/M6 7708/M8 7708/M14 7708/M16 7708/M18 7708/M22 7708/M28 7708/M35 7708/M42 7708/M54 5090/6 5090/8 5090/14 5090/16 5090/18 5090/22 5090/28 5090/35 5090/42 5090/54 22 28 35 42 54 22 28 35 42 54 34 56 119 163 298 6 8 14 16 18 6 8 14 16 18 4 5 12 13 22
90 male to female elbows - short radius (metric tubing)

7709/M16 7709/M18 7709/M22 7709/M28 7709/M35 7709/M42 7709/M54 5092/16 5092/18 5092/22 5092/28 5092/35 5092/42 5092/54 16 18 22 28 35 42 54 16 18 22 28 35 42 54 18 26 34 67 114 184 304
45 female to female elbows (metric tubing)

7716/M16 7716/M18 7716/M22 7716/M28 7716/M35 7716/M54 7716/M80 5041/16 5041/18 5041/22 5041/28 5041/35 5041/54 5041/80 16 18 22 28 35 54 80 16 18 22 28 35 54 80 16 21 35 61 119 231 740
45 male to female elbows (metric tubing)

7717/M22 7717/M28 7717/M35 7717/M42 7717/M54 7717/M80 5040/22 5040/28 5040/35 5040/42 5040/54 5040/80 22 28 35 42 54 80 42 54 80 167 288 800 22 28 35 33 57 124
146

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

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

7719/M12 7719/M14 7719/M16 7719/M18 7719/M22 7719/M28 7719/M35 7719/M42 7719/M54 7719/M64 7719/M67 7719/M76 7719/M80 5001/12 5001/14 5001/16 5001/18 5001/22 5001/28 5001/35 5001/42 5001/54 5001/64 5001/67 5001/76 5001/80 12 14 16 18 22 28 35 42 54 64 67 76 80 12 14 16 18 22 28 35 42 54 64 67 76 80 11 16 20 30 47 86 144 210 390 470 550 915 1006
147

Tees (metric tubing)

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

7732/M8.6.8 7732/M8.10.8 7732/M10.6.10 7732/M10.8.8 7732/M10.8.10 7732/M10.12.10 7732/M12.8.12 7732/M12.10.12 7732/M12.14.12 7732/M12.16.12 7732/M14.12.14 7732/M14.22.14 7732/M16.12.16 7732/M16.14.16 7732/M16.16.12 7732/M16.22.16 7732/M18.12.18 7732/M18.16.18 7732/M18.22.18 7732/M22.12.22 7732/M22.16.22 7732/M22.18.22 7732/M22.28.22 7732/M28.22.28 7732/M35.28.35 7732/M42.22.42 7732/M42.28.42 7732/M54.42.54 5130/8.6.8 5130/8.10.8 5130/10.6.10 5130/10.8.8 5130/10.8.10 5130/10.12.10 5130/12.8.12 5130/12.10.12 5130/12.14.12 5130/12.16.12 5130/14.12.14 5130/14.22.14 5130/16.12.16 5130/16.14.16 5130/16.16.12 5130/16.22.16 5130/18.12.18 5130/18.16.18 5130/18.22.18 5130/22.12.22 5130/22.16.22 5130/22.18.22 5130/22.28.22 5130/28.22.28 5130/35.28.35 5130/42.22.42 5130/42.28.42 5130/54.42.54 8 8 10 10 10 10 12 12 12 12 14 14 16 16 16 16 18 18 18 22 22 22 22 28 35 42 42 54 6 10 6 8 8 12 8 10 14 16 12 22 12 14 16 22 12 16 22 12 16 18 28 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
148

Tees (inch tubing)
7832/222
5130/222
1/4"
1/4"
1/4"
7832/333
5130/333
3/8
3/8
3/8
Reducing tees (inch tubing)
7832/323
5130/323
3/8
1/4"
3/8
14
149

Connections Catalogue number International Reference IDS [mm] ODS [mm] Note
Female to female couplings, reinforced series (metric tubing)

7900/M22 7900/M28 7900/M35 7900/M42 7900/M54 22 28 35 42 54 22 28 35 42 54
Female to female reducing couplings, reinforced series (metric tubing)

7902/M28.22 7902/M35.22 7902/M35.28 7902/M42.28 7902/M42.35 7902/M54.35 7902/M54.42 28 35 35 42 42 54 54 22 22 28 28 35 35 42
Male to female reducing couplings, reinforced series (metric tubing)

7903/M28.22 7903/M35.22 7903/M35.28 7903/M42.28 7903/M42.35 7903/M54.35 7903/M54.42 28 35 35 42 42 54 54 22 22 28 28 35 35 42
45 female to female elbows, reinforced series (metric tubing)

7916/M22 22 22
7916/M28
28
28
7916/M35
35
35
7916/M42
42
42
7916/M54
54
54
45 male to female elbows, reinforced series (metric tubing)

7917/M22 22 22
7917/M28
28
28
7917/M35
35
35
7917/M42
42
42
7917/M54
54
54
150

Connections Catalogue number International Reference IDS [mm] ODS [mm] Note
90 female to female elbows - long radius, reinforced series (metric tubing)

7918/M22 22 22
7918/M28
28
28
7918/M35
35
35
7918/M42
42
42
7918/M54
54
54
90 male to female elbows - long radius, reinforced series (metric tubing)

7919/M22 22 22
7919/M28
28
28
7919/M35
35
35
7919/M42
42
42
7919/M54
54
54
Tees, reinforced series (metric tubing)

7932/M22 22 22 22
7932/M28
28
28
28
7932/M35
35
35
35
7932/M42
42
42
42
7932/M54
54
54
54
151
Access fittings & valve cores
ACCESS FITTINGS & VALVE CORES
APPLICATIONS All the access fittings and valve cores, shown in this chapter, are excluded from the scope of Directive 97/23/EC, as specified in the Guidelines 1/8 and 1/9, because they are piping components. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). The access fittings allow to create a loading or draining point rapidly and with a minimum expense. After completion of the loading or draining operations, the cap with gasket (cod. 8392/A) prevents any leakage. For particular customers requirements, the 7020/20 flare blind nut with combined 8580/2 copper flare gasket may replace the 8392/A cap. This solution requires to screw the nut with a torque wrench at 8,5 11,5 Nm. For system using R410A refrigerant, Castel has developed three specific access fittings with 5/16 SAE-Flare connection (codes 8350/X09, 8351/X05 and 8351/X07) that have to be used with the following parts: valve core, code 8395/A1; flare blind nut, code 7020/X02; Also this solution requires to screw the nut with a torque wrench at 8,5 11,5 Nm.
CONSTRUCTION The straight fittings are machined by hexagonal brass bar EN 12164 CW 614N. The TEE and cross fittings are manufactured with hot forged brass EN 12420 CW 617N. The main parts of the valve cores are made with the following materials: brass EN 12164 CW 614N for body; chloroprene rubber (CR) for seat gasket; chloroprene rubber (CR) for outlet seal gasket for types 8394/A and 8395/A; PTFE for outlet seal gasket for type 8394/B.
OPERATION
The valve consists of a body that can have different shapes and sizes, according to the different requirements of the customers. Inside the valve, the valve core seat is manufactured according to the ARI STANDARD 720:1997. When the internal valve core has been inserted through the fitting, by the mounting tool (code 8390/A), the fluid flows just acting on the valve needle.
Access fitting with inserted valve core
154

Connections Catalogue number SAE Flare NPT m f [in.] ODS [mm] [in.] IDS [mm] PS [bar] L Ch D H Dimensions [mm]
Straight access fittings
8350/22
1/4"
1/4"
26 11
8350/X01
1/4"
3/8"
20 11
8350/X03
1/4"
90 11
8350/X09
5/16"
1/4"
27 14 9,4 2,1
8351/2 1/4" 8351/X04 8351/X05 5/16" 8351/X07
8-10 6 7 45
30 11 26
3/8" 6
27 14
1/4" 8351/X02 1/4" 5 3/8" 8 26 11
8352/22
1/4"
31 11
8354/21 8354/22 8354/23 1/4"
1/8" 1/4" 3/8"
28 11 33 14 38 17
8362/22
1/4"
1/4"
35 17
155

Connections Catalogue number SAE Flare NPT m f [in.] IDS [mm] PS [bar] L Ch D H Dimensions [mm] Note
TEE access fittings
8380/X01
1/4"
43
24
45
The valve core may be installed on each of the two 1/4 SAE Flare connections.
8380/122 1/4"
1/8"
45
24
TEE access fittings with swivel nuts

With valve-core opening device on female connection. The valve core may be installed on each of the two 1/4 SAE Flare connections
8380/X06
50
1/4"
1/4"
45
24
8380/X08
49
The valve core may be installed on each of the two 1/4 SAE Flare connections
156

Connections Catalogue number SAE Flare NPT m f [in.] IDS [mm] PS [bar] L Ch D H Dimensions [mm] Note
Cross access fittings
8382/1222 1/4"
1/8"
48
50
8382/X02
1/4"
1/4"
45
48
50 three 1/4 SAE Flare

connections
The valve core may be installed on each of the
8382/X03
1/4"
48
44
Cross access fittings with swivel nuts
8382/X04
1/4"
1/4"
45
50
With valve-core opening device on female connection. 46 The valve core may be installed on each of the three 1/4 SAE Flare connections
157

Connections Catalogue number SAE Flare NPT m f [in.] IDS [mm] PS [bar] min max L Ch D H TS [C] Dimensions [mm] Note
Core remover (for all types)

8390/A 75
Caps with gasket
8392/A
13
1/4
35
13
8392/B
22
The key needs to remove the valve core.
Spare valve cores

Outside spring. Torque wrench 0,4 / 0,8 Nm. (1) - Static pressure: 40 [bar] (1) - working pressure: 28 [bar] Outside spring. Torque wrench 0,30 / 0,35 Nm. (2) - Static pressure: 40 [bar] (2) - working pressure: 28 [bar] Outside spring. Torque wrench 0,4 / 0,5 Nm. (4) - Static pressure: 140 [bar] (4) -working pressure: 60 [bar]
8394/A
(1)
-40 +100
8394/B
(2)
-30
+90
8395/A1
(4)
-40
+100
Copper gasket with neck

8580/2 1/4" 45 2,8 5,2
Manifolds with access fittings
9900/X47
175
30 Four ways
1/4" 9900/X87
45
162
30 Three ways
158
Accessories and spare parts
KIT N
ITEM CODE
DESCRIPTION
SUITABLE FOR PRODUCTS
NOTE
ACCESSORIES AND SPARE PARTS FOR SOLENOID VALVES

008217 008218 008229 004238 G9150/R06 200193 Yellow nut for fixing coil Black screw for fixing coil O Ring for yellow nut O Ring under coil Bracket All the solenoid valves All the solenoid valves All the solenoid valves All the solenoid valves N.C. and N.O. solenoid valves type: 1020/..; 1028/..; 1064/..; 1068/..; 1070/4 - /5; 1078/4 - /5 - /M12; 1079/7; 009060 Screw 1164/..; 1168/..; 1170/4 - /5; 1178/4 - /5 - /M12; 1512/..; 1522/..; 1132/03 - /04 9150/R07 008323 200292 004254 9150/R08 008323 200292 200646 004259 9150/R09 008323 200292 009003 004257 004298 9150/R10 008323 004571 200431 004266 004299 9151/R04 008323 004571 009894 004251 004625 9150/R50 008323 004571 009278 009277 004251 004625 9150/R11 008323 200292 004118 004253 004256 004254 004692 9150/R43 008387 008415 008393 004251 008966 004256 004692 Plunger Plunger spring Nut/body O Ring Plunger Plunger spring Diaphragm Nut/body O Ring Plunger Plunger spring Diaphragm Cover/body O Ring Cover/body screws Plunger Plunger spring Diaphragm Cover/body O Ring Cover/body screws Plunger Plunger spring Diaphragm Cover/body O Ring Cover/body screws Plunger Plunger spring Piston Piston ring Cover/body O Ring Cover/body screws Plunger Plunger spring Diaphragm Cover/body O Ring Pilot O Ring Nut/cover O Ring Cover/body screws Piston Piston ring Piston spring Cover/body O Ring New Pilot O Ring Old Pilot O Ring Cover/body screws N.C. and N.O. solenoid valves type: 1098/9; 1099/11 1198/9 Main piston pilot operated spare parts N.C. solenoid valves type: 1078/9; 1079/11 N.C. solenoid valves type: 1050/5 - /6; 1058/5 - /6 - /7; 1059/9 N.C. solenoid valves type: 1090/5 - /6; 1098/5 - /6 - /7; 1099/9 N.C. solenoid valves type: 1070/6; 1078/6 - /7; 1079/9 Valves out of stock N.C. solenoid valves type: 1064/..; 1068/.. 1098/9; 1099/11 1078/11; 1079/13 - /M42 N.C. solenoid valves type: 1070/4 - /5; 1078/4 - /5 - /M12; 1079/7 Diaphragm pilot operated spare parts for: 1098/9; 1099/11; 1078/11; 1079/13 - /M42 N.C. solenoid valves type: 1020/..; 1028/..
160
KIT N
ITEM CODE
DESCRIPTION
NOTE
ACCESSORIES AND SPARE PARTS FOR SOLENOID VALVES

9150/R39 008387 008415 008393 004691 008966 004256 004692 9150/R35 N.D. 200646 004259 004238 9150/R34 008757 009003 004257 004254 004238 004298 200286 9151/R05 008757 009894 004251 004254 004238 004625 200286 9150/R51 008757 009278 009277 004251 004254 004238 004625 200286 9150/R42 008757 004118 004253 004256 004254 004238 004692 200286 200581 9150/R15 200292 004242 200581 9150/R12 200292 200520 004244 004298 200581 9150/R13 200292 004617 004625 200581 9150/R14 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/body O Ring O Ring under coil Cover/body screws Nut N.O. armature group Diaphragm Cover/body O Ring Nut/cover O Ring O Ring under coil Cover/body screws Nut N.O. armature group Piston Piston ring Cover/body O Ring Nut/cover O Ring O Ring under coil Cover/body screws Nut N.O. armature group. Diaphragm Cover/body O Ring Pilot O Ring Nut/cover O Ring O Ring under coil Cover/body screws Nut Punger 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 Ring Nut/cover O Ring Cover/body screws Solenoid valves for different fluids type: 1142/010 - /012 Solenoid valves for different fluids type: 1132/06 - /08 Solenoid valves for different fluids type: 1132/03 - /04 Solenoid valves for different fluids type: 1512/.. N.O. solenoid valves type: 1178/9 N.O. solenoid valves type: 1150/5 - /6; 1158/5 - /6 - /7 N.O. solenoid valves type: 1190/5 - /6; 1198/5 - /6 - /7 N.O. solenoid valves type: 1164/..; 1168/.. 1198/9 1178/11 N.O. solenoid valves type: 1170/4- /5; 1178/4 - /5 - /M12 Diaphragm pilot operated spare parts for: 1198/9 1178/11 N.C. and N.O. solenoid valves type: 1078/11; 1079/13 - /M42 1178/11 Main piston pilot operated spare parts
161
KIT N
ITEM CODE
DESCRIPTION
NOTE
ACCESSORIES AND SPARE PARTS FOR CHECK VALVES

9150/R16 003558 001869 004251 004299 9150/R17 003559 000728 004691 004692 9150/R18 003854 000728 008002 004302 9150/R19 003855 001857 004261 004302 9150/R52 003558 001869 008863 004299 9150/R53 003559 000728 009174 004692 9150/R54 003854 000728 009175 004302 9150/R55 003855 001857 009176 004302 Piston Spring Cover/body O Ring Cover/body screws Piston Spring Cover/body O Ring Cover/body screws Piston Spring Cover/body O Ring Cover/body screws Piston Spring Cover/body O Ring Cover/body screws Piston Spring Cover/body gasket Cover/body screws Piston Spring Cover/body gasket Cover/body screws Piston Spring Cover/body gasket Cover/body screws Piston Spring Cover/body gasket Cover/body screws Check valves type: 3122/17 3142/17 - /21 - /25 3182/13 - /M42 - /17 Check valves type: 3120/17 3140/17 - /21 - /25 3160/17; 3180/13 - /M42 - /17 Check valves type: 3122/7 - /9 - /M22 - /M28 3142/7 - /9 - /M28 3182/7 - /9 - /M28 Check valves type: 3122/11 3142/11 3182/11 Check valves type: 3122/13 - /M42 3142/13 - /M42 Valves out of stock Check valves type: 3120/7 - /9 - /M22 - /M28 3140/7 - /9 - /M28 3180/7 - /9 - /M28 Check valves type: 3120/11 3140/11 3180/11 Check valves type: 3120/13 - /M42 3140/13 - /M42 Valves out of stock Valves out of stock Valves out of stock
162
KIT N
ITEM CODE
DESCRIPTION
NOTE
ACCESSORIES AND SPARE PARTS FOR INDICATORS

9150/R20 003575 007779 004259 9150/R21 004270 007780 004259 Nut Protection cap Nut/body O Ring Pre-assembled nut Protection cap Nut/body O Ring Moisture - liquid indicators type: 3710/..; 3720/..; 3740/..; 3750/..; 3770/..; 3771/..; 3780/..; 3781/.. 3710/..; 3740/..; 3750/..; out of stock Liquid indicators type: 3610/..; 3620/..; 3640/..; 3650/.. 3610/; 3640/..; 3650/.. out of stock
ACCESSORIES AND SPARE PARTS FOR FILTERS

G9150/R05 8354/22 8392/A 8394/B 003319 003322 Access fitting Cap with gasket valve core Spring Flange gasket Filters with replaceable block type: 4411/..; 4412/..; 4413/..; 4414/.. 4421/..; 4423/..; 4424/.. All the filters series 44 Filters with replaceable block type: 4411/..; 4412/..; 4413/..; 4414/.. 009406 003324 007677 9150/R57 005535 004592 008336 Dehydrating block cover Dehydrating block bottom Filtering tube for one block Mechanical block cover Mechanical block bottom Flange gasket Filters with replaceable block type: 4411/..A-B; 4412/..A-B; 4413/..A-B; 4414/..A-B Filters with replaceable block type: 4411/..C Filters with replaceable block type: 4421/..; 4423/..; 4424/.. 008304 008305 008307 008403 008345 008344 9150/R58 008303 008306 Dehydrating block cover Dehydrating block bottom Screw for filtering tube Filtering tube Filtering tube Filtering tube Mechanical block cover Mechanical block bottom Filters with replac. block type: 4421/..A Filters with replac. block type: 4423/..A Filters with replac. block type: 4424/..A Filters with replaceable block type: tipo:4421/..C Filters with replaceable block type: 4421/..A; 4423/..A; 4424/..A
163
KIT N
ITEM CODE
DESCRIPTION
NOTE
CHANGEOVER VALVES
9150/R24 004297 004329 004330 004348 9150/R25 000529 000534 000535 001039 3039/44 004260 009036 008281 Gland Gland seal gaskets Gland seal gaskets Washer Gland Gland seal gaskets Gland seal gaskets Washer Pair of connetions 1/2"NPT female Connection/body O Ring Cap Cap Changeover valve 3032/64 - /66 Changeover valve 3032/44 Changeover valve 3032/108 Changeover devices 3032/44 - /64 - /66
BALL SHUT-OFF VALVES

009035 009256 Cap Cap Ball shut-off valves 3033/.. Ball shut-off valves 3063/44
HERMETIC VALVES
9150/R23 003664 000384 000957 000382 007486 000913 Gland Gland seal gaskets Gland seal gaskets Washer Cap Spindle Hermetic valves type: 6010/2; 6012/22 G9150/R33 004307 004326 Screw Spring washer Hermetic valves type: 6020/.. All the hermetic valves type: 6010/..; 6012/..; 6020/..; 6060/..; 6070/.. 6060/..; 6070/.. out of stock
RECEIVER VALVES
9150/R23 003664 000384 000957 000382 007486 000913 Gland Gland seal gaskets Gland seal gaskets Washer Cap Spindle Receiver valves type: 6110/21 - /22 - /23 - /32 - /33 6120/22 - /23 - /33 6132/.. 6140/22 - /23 Receiver valves type: 6110/21 - /22; 6120/22; 6140/22 001641 Spindle Receiver valves type: 6110/23 - /32 - /33; 6120/23 - /33 9150/R24 004297 004329 004330 004348 009036 001647 9150/R25 000529 000534 000535 001039 008282 001038 Gland Gland seal gaskets Gland seal gaskets Washer Cap Spindle Gland Gland seal gaskets Gland seal gaskets Washer Cap Spindle Receiver valves type: 6110/66 6120/66 Receiver valves type: 6110/43 - /44 - /54 6120/43 - /44 - /54
164
KIT N
ITEM CODE
DESCRIPTION
NOTE
STOP VALVES
9150/R26 000822 000823 000824 007476 Gland Gland seal gasket Gland seal gasket Washer Stop valves type: 6170/66 - /77
ROTALOCK VALVES
9150/R23 003664 000384 000957 000382 7910/6 Gland Gland seal gasket Gland seal gasket Washer Steel solder connection 3/4" UNF-16 7990/6 7910/8 PTFE gasket for 7910/6 Steel solder connection 1" UNS-16 7990/8 PTFE gasket for 7910/8 To be ordered separately Rotalock valves type: 6310/.. 6320/..
CAPPED VALVES
9150/R23 003664 000384 000957 000382 007486 002337 Gland Gland seal gasket Gland seal gasket Washer Cap Spindle Capped valves type: 6410/2 - /3 - /4 - /5 005174 Nipple/body O Ring 6420/2 - /3 - /M10 - /M12 - /4 - /5 6460/22A. 007619 Spindle Capped valves type: 6410/6 007676 Nipple/body O Ring 6420/M18 - /6 - /M22 - /7 Capped valves type: 6410/..; 6420/..; 6460/..
165
KIT N
ITEM CODE
DESCRIPTION
NOTE
GLOBE VALVES
9150/R24 004297 004329 004330 004348 001635 004296 9150/R27 007637 Gland Gland seal gaskets Gland seal gaskets Washer Cap Cap gasket Spindle/plate group Globe valves type: (1) 6510/M22 - /7 - /M28 - /9 - /11 6512/M22 - /7 - /M28 - /9 - /11 (1) 6520/7 - /9 - /11 (1) 6530/M22 - /7 - /M28 - /9 - /11 6532/M22 - /7 - /M28 - /9 - /11 Globe valves type: (1) 6510/M22 - /7 - /M28 - /9 6512/M22 - /7 - /M28 - /9 004299 Cover/body screws (1) 6520/7 - /9 (1) 6530/M22 - /7 - /M28 - /9 6532/M22 - /7 - /M28 - /9 004251 Cover/body O Ring Globe valves type: (1) 6510/M22 - /7 - /M28 - /9 (1) 6520/7 - /9 (1) 6530/M22 - /7 - /M28 - /9 008863 Cover/body gasket Globe valves type: 6512/M22 - /7 - /M28 - /9 6532/M22 - /7 - /M28 - /9 9150/R28 007638 Spindle/plate group Globe valves type: (1) 6510/11; 004692 Cover/body screws (1) 6520/11; 6532/11 004691 Cover/body O Ring Globe valves type: (1) 6510/11; (1) 6520/11; (1) 6530/11 009174 Cover/body gasket Globe valves type: 6512/11; 9150/R26 000822 000823 000824 007476 001228 000830 004302 9150/R29 007639 Gland Gland seal gaskets Gland seal gaskets Washer Cap Cap gasket Cover/body screws Spindle/plate group Globe valves type: (1) 6510/13 - /M42 6512/13 - /M42 (1) 6520/13 - /M42 008002 Cover/body O Ring Globe valves type: (1) 6510/13 - /M42 (1) 6520/13 - /M42 009175 Cover/body gasket Globe valves type: 6512/13 - /M42 9150/R30 007640 Spindle/plate group Globe valves type: (1) 6510/17; 6512/17 6532/11 6512/11 (1) 6530/11; (1) Valves out of stock
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
(1) 6520/17; (1) 6530/13 - /M42 - /17 6532/13 - /M42 - /17 004261 Cover/body O Ring Globe valves type: (1) 6510/17; (1) 6520/17 (1) 6530/13 - /M42 - /17 009176 Cover/body gasket Globe valves type: 6512/17 6532/13 - /M42 - /17
166
KIT N
ITEM CODE
DESCRIPTION
NOTE
BALL VALVES
009055 Plastic cap Ball valves type: 6590/M6 - /2 - /3 - /3A - /M10 009750 Brass cap /M10A - /M12 - /M12A - /4 - /4A 6591/5 003752 Brass cap gasket 6590/M15 - M15A - /5 - /5A - /M18 - /M18A - /6 - /6A 6591/7 009036 Plastic cap Ball valves type: 6590/7 - /7A 009751 Brass cap 6591/M28 - /9 6590/M28 - /M28A - /9 - /9A 004296 Brass cap gasket 6591/11
009037 009752
Plastic cap Brass cap
Ball valves type: 6590/11 - /11A 6591/13 - /M42
000530
Brass cap gasket
6590/13 - /13A - /M42 - /M42A 6591/17
009038 009753 009754
Plastic cap Brass cap Brass cap gasket
Ball valves type: 6590/17 - /17A 6591/21 - /21A 6591/M64 - /M64A
009207
Brass cap
Ball valves type: 6590/M64A - /21A
009208
Brass cap gasket
6591/24A - /25A 6590/25A 6591/28A - /29A - /33A - /34A
9150/R46
8394/A 8392/A
Valve core Cap with gasket
Ball valves with access fitting
COMPRESSOR VALVES
9150/R23 003664 000384 000957 000382 Gland Gland seal gasket Gland seal gasket Washer Compressor valves type: 6640 Valves out of stock
GAUGE MOUNTING VALVES

9150/R23 003664 000384 000957 000382 Gland Gland seal gasket Gland seal gasket Washer Gauge mounting valves: 8320/21 - /22
167
NOTE
168

Products Handbook 2009

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Products Handbook 2009

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April 2009

Expansion valves Solenoid valves

77 83 85 94 97 100 105 110

From quality our natural development

CONNECTIONS OF CASTEL PRODUCTS

TABLE 1 - Equivalence between Castel code and dimension in inches

TABLE 2: Equivalence between Castel code and dimension in millimeters

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

Description of connections that are currently used for Castel products.

TABLE 3: Flare connections

16,85 18,00 11,90 18,74 19,04 11,80 2,16

8,50 11,70 10,00 11,62 13,00 7,77

TABLE 2 - Nominal Working Conditions

Hot gas line

Evaporating Temperature [C]

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

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

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

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

1,11 0,85 0,70 0,53 0,37

1,17 0,96 0,76 0,57 0,39

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

THERMOSTATIC EXPANSION VALVES SERIES 22 WITH INTERCHANGEABLE ORIFICE ASSEMBLY

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

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

charge cannot incorporate MOP functions.

TABLE 2: Orifice Assemblies - Rated Capacities in kW

2204 2205 2206

TABLE 3: Solder adapters

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

TABLE 4a: Refrigerant R22/R407C - Capacities in kW for temperature range - 40 C

Pressure drop across valve [bar] 6 8 10 12 14 16

TABLE 5a: Refrigerant R134a Capacities in kW for temperature range - 40 C + 10 C

TABLE 6a: Refrigerant R404A/R507 Capacities in kW for temperature range - 40 C + 10 C

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

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

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

TABLE 7a: Refrigerant R404A/R507 Capacities in kW for temperature range - 60 C - 25 C

PWM SOLENOID EXPANSION VALVE WITH INTERCHANGEABLE ORIFICE

TABLE 1: General Characteristics of PWM solenoid expansion valves

TABLE 2: General Characteristic of coils

TABLE 3: Orifice Nominal capacities in kW

ptot = 16,9 ( 5,14 + 2 ) = 9,76 bar

Qsub = 0,83 . 2,8 = 2,324 kW

Qev = 1,25 . 2,324 = 2,91 kW

Qev = Fev . Qsub

TABLE 4: Refrigerant R22 Capacities in kW

TABLE 5: Refrigerant R134a Capacities in kW

TABLE 6: Refrigerant R404A/R507 Capacities in kW

TABLE 7: Refrigerant R407C Capacities in kW

TABLE 8: Refrigerant R410A Capacities in kW

TABLE 9: Correction factor for subcooling tsub > 4C

The dimensions in brakets are referred to 2028/4S07 & 2028/M12S07 models

SOLENOID VALVES FOR REFRIGERATING SYSTEMS

SAE Flare 1/4" 3/8" 3/8"

0,175 0,23 0,80 2,20

Diaphragm Pilot Operated

Piston Pilot Operated Diaphragm Pilot Operated

0,07 (2) 13 +105 0,05 21 (1)

19 Diaphragm Pilot Operated

+105 0,05 25 (3) 18 (1)

SOLENOID VALVES FOR REFRIGERATING SYSTEMS

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