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quality products for refrigeration and air conditioning products suitable for CFC, HCFC and HFC 2006 release www.castel.it
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SUMMARY
valve with interchangeable orifice assembly valve with fixed orifice assembly
valves for refrigerating systems coils permanent magnet connectors valves for different fluids safety valves 3030 safety valves 3060 ball shut-off valves changeover devices unions fusible plugs
Safety devices
Check valves Water regulating valves Liquid indicators Moisture-liquid indicators Dehydrators
dehydration of refrigerants anti-acid solid core filter driers filter driers with replaceable anti-acid solid core mechanical filters with replaceable filtering block strainers disseccants
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Threaded brass fittings Solder copper fittings Access fittings Spare parts
After forty five years in the industry of Refrigeration and Air Conditioning components, Castel Quality Range of Products is well known and highly appreciated all over the world. Quality is the main issue of our Company and it has a special priority, in every step, all along the production cycle. We produce on high tech machinery and updated automatic production lines, operating in conformity with the safety and environment standards currently enforced. Castel offers to the Market and to Manufacturers fully tested products suitable with CFC, HCFC and HFC Refrigerants currently used in the Refrigeration & Air Conditioning Industry. UNI EN ISO 9001:2000 issued by ICIM certifies the Quality System of the Factory. Moreover Castel Products count a number of certifications in conformity with the EEC Directives and with European and American Quality Approvals.
Application of Directive 97/23/EC of the European Parliament and of the Council, of 29 may 1997, concerning pressure equipment towards Castel refrigeration products
The Directive 97/23/EC (PED) applies to the design, manufacture and conformity assessment of pressure equipment and assemblies with a maximum allowable pressure PS greater than 0,5 bar with the exception of the possibilities listed in Article 1, Section 3 of the same Directive. Since 30 May 2002 the Directive has become mandatory and, in the Member States of European Community, it has been possible to place on the market only pressure equipments CE marked according to PED. For the purposes of the Directive see the following definitions, used in this Handbook too: Pressure equipment: vessels, piping, safety accessories, and pressure accessories Vessel: a housing designed and built to contain fluids under pressure. Piping: piping components intended for the transport of fluids, when connected together for integration into a pressure system. Safety accessories: devices designed to protect pressure equipment against the allowable limits being exceeded. Pressure accessories: devices with an operational function and having pressurebearing housing. For example: solenoid valves, valves, indicators. Assemblies: several pieces of pressure equipment assembled by a manufacturer to constitute an integrated and functional whole. Maximum allowable pressure (PS): the maximum pressure for which the equipment is designed, as specified by the manufacturer. Maximum / minimum allowable temperature (TS): the maximum/minimum temperatures for which the equipment is designed, as specified by the manufacturer Volume (V): the internal volume of a chamber, including the volume of nozzles to the first connection or weld and excluding the volume of permanent internal parts. Nominal size (DN): numerical designation of size, which is common to all components in a piping system. Fluids: gases, liquids and vapours in pure
phase as well as mixture thereof. Pressure equipments referred to in Article 3 are classified by categories in accordance with Annex II, according to ascending level of hazard, on the basis of: State of the fluid Danger classification of the fluid Type of equipment Dimensions and energetic potential: V, DN, PS, PS x V, PS x DN and must satisfy the Essential Safety Requirement set out in Annex I of PED. Pressure equipments below or equal to the limits in Article 3, sections 1.1, 1.2 and 1.3 and section 2, must not satisfy the Essential Safety Requirement set out in Annex I. They must be designed and manufactured in accordance with the sound engineering practice of a Member State in order to ensure safe use (Article 3, Section 3). In the tables of general characteristics, collected in this Handbook, its showed the risk category in which every product is classified. In Article 9 of PED the fluids are classified, according to their hazard, into two groups: Group I comprises dangerous fluids. A dangerous fluid is a substance or preparation covered by the definitions in Article 2 of Council Directive 67/548/EEC of 27 June 1967 and following amendments, relating to the classification, packaging and labeling of dangerous substance. Group I comprises fluids defined as: explosive, extremely flammable, highly flammable, flammable, very toxic, toxic, oxidizing. Group II comprises all the others fluids not referred to in group I. Castel products are suitable for using with refrigerant fluids proper to the Group II. These refrigerant fluids are listed and classified L1 in Annex E of standard EN 378-1, plus fluids R30, R123 and R141b. Among the fluids listed in this standard, there are the well known R12; R22; R134a; R404A; R407C; R401A; R502; R507.
EXTERNAL LEAKAGE All the products illustrated in this Handbook are submitted, one by one, to tightness tests besides to functional tests. Allowable external leakage, measurable during the test, agrees to the definition given in the Standard DIN 3158-87 Par. 8.2: During the test, no bubbles shall form over a period of one minute when the specimen is immersed in water with low surface tension, .
PRESSURE CONTAINMENT All the products illustrated in this Handbook, if submitted to hydrostatic test, guarantee a pressure strenght at least equal to 1,43 x PS in compliance with the Directive 97/23/EC. All the products illustrated in this Handbook, if submitted to burst test, guarantee a pressure strength at least equal to 3 x PS according to the Standard revision prEN 378-2 : 2000. A great number of products illustrated in the Handbook can guarantee an higher pressure strength, equal to 5 x PS according to the Standard UL 207 : 2001. (for detailed information about these products please contact Castel Technical Department). WEIGHTS The weights of the items listed in this Handbook include packaging and are not binding for the Company.
Application of Directive 2002/95/EC of the European Parliament and of the Council, of 27 January 2003, on the restriction of the use of certain hazardous substances in electrical and electronic equipment
The purpose of Directive 2002/95/EC (RoHS Directive) is to prevent or restrict the use of hazardous substances in electrical and electronic equipment and to contribute to the environmentally sound recovery and disposal of waste electrical and electronic equipment. RoHS Directive shall apply to electrical and electronic equipment falling under the categories 1, 2, 3, 4, 5, 6, 7 and 10 set out in Annex 1A to Directive 2002/96/EC (WEEE Waste electrical and electronic equipment) and to electric light bulbs and luminaries in households. The equipment proper to the first category, Large household appliances, and to the 10th category, Automatic dispensers, of Annex 1A in WEEE Directive, are specified in Annex 1B in the same Directive; this list of products shows: Large cooling appliance Refrigerators Freezers Other large appliances used for refrigeration, conservation and storage of food Air conditioner appliances Other fanning, exhaust ventilation and conditioning equipment Automatic dispenser for hot or cold bottles and cans Article10 of WEEE Directive establishes that, from 13 August 2005, new electrical and electronic equipment put on the market are appropriately identified as waste subject to separate collection, by means of the proper symbol shown in Annex IV of the same Directive. Article 4 of RoHS Directive establishes that, from 1 July 2006, new electrical and electronic equipment put on the market does not contain the following substances: Lead Mercury Cadmium Hexavalent chromium Polybrominated biphenyls (PBB) Polybrominated diphenyl ethers (PBDE)
The restriction of use of these hazardous substances shall not apply to the applications listed in the Annex of the same Directive; among these applications the following exceptions are particularly interesting in air conditioning / refrigerating systems: Lead as an alloying element in steel containing up to 0,35% lead by weight, aluminium containing up to 0,4% lead by weight and as a copper alloy containing up to 4% lead by weight Hexavalent chromium as an anti-corrosion of the carbon steel cooling system in absorption refrigerators The Member States of European Community had to adopt the two Directives 2002/95/EC and 2002/96/EC, with the next updating 2003/108/EC, before 13 August 2004, unless delays granted by the European Parliament. For a long time Castel Company has started a careful inquiry, together with its suppliers, to identify the presence or not of the abovementioned hazardous substances, either in its own products or in its own production processes, and to remove them progressively. At the end of this wide examination Castel Company may declare that its products: Do not contain mercury, cadmium, polybrominated biphenyls (PBB), polybrominated diphenyl ethers (PBDE) Contain lead as an alloying element in steel, aluminium and copper alloys within the accepted limits according to the Annex of RoHS Directive Contain hexavalent chromium in very low concentration, not exceeding 0,003% by weight, used for the surface treatments (yellow zinc plating) of steel parts. Castel Company will remove the remaining yellow zinc plating treatments from all its products, before the end of 2005, and will choose other surface treatments containing trivalent chromium instead of hexavalent chromium.
In particular Castel products are produced either with threaded connections or solder connections. Table 1 shows the equivalence between Castel codes and dimensions in inches. These codes are commonly used in the international market. Table 2 shows the equivalence between Castel codes and dimensions in millimetres.
F.e. 4411/M42A filter drier with replaceable anti-acid solid core with solder connection with = 42 mm.
Description of connections that are currently used for Castel products. 1) Threaded connections. They can be of three different types: FLARE Straight threaded connection (according to SAE J513-92; ASME B1.1-89) for junction to a copper pipe with a suitable flared end, using a right nut (see Table 3). NPT Taper threaded connection (according to ASME B1.20.1-92) to joint fittings, valves, safety valves to vessel or steel pipes. FPT Straight threaded connection (according to UNI ISO 228/1) used in the hydraulic system to joint fittings or valves to vessel or steel pipes.
F.e.: solenoid valves for water or air.
ODM Male solder connection for copper tubes. The indicated size corresponds to the outer diameter of the copper tube which to joint.
F.e.: 16 ODM solder connection suitable to joint a copper pipe with a 16 mm outer diameter, by means of an M16 female/female copper sleeve (in this case the type Castel 7700/M16).
IDS Male solder connection for copper tube. The indicated size corresponds to the inner diameter of the copper tube which to joint.
F.e.: 10 IDS solder connection suitable to receive outside a copper pipe with an 10 mm inner diameter).
W Solder connection for steel pipes. The indicated size corresponds to the external diameter of the steel pipe which to joint.
F.e.: 76,1 W solder connection suitable to connect a steel pipe with a 76,1 mm external diameter, by means of butt welding.
2) Solder connections. They can be of four different types and can fit pipes with diameter both in inches and in millimetres: ODS (or ODF) Female solder connection for copper tubes. The indicated size corresponds to the outer diameter of the copper tube which to joint.
F.e.: 1/2" ODS solder connection suitable to receive inside a copper pipe with a 1/2" outer diameter.
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
2,16
2,70
2,26
2,68
3,60
2,15
8,50
7,77
Liquid line
TABLE 3 - Correction Factors - L1 of the refrigeration capacity for operating temperatures different from nominal values.
Evaporating Temperature[C] Liquid Temperature [C] Refrigerant + 10 +5 0 5 10 15 20 25 30 35 40
R134a R22 0 R404A R407C R410A R507 R134a R22 +10 R404A R407C R410A R507 R134a R22 +20 R404A R407C R410A R507 R134a R22 +30 R404A R407C R410A R507 R134a R22 +40 R404A R407C R410A R507 R134a R22 +50 R404A R407C R410A R507 R134a R22 +60 R404A R407C R410A R507 1,23 1,19 1,28 1,23 1,19 1,33 1,12 1,08 1,13 1,12 1,08 1,17 1,00 0,99 0,99 0,99 1,00 1,00 0,88 0,89 0,85 0,85 0,85 0,80 0,76 0,79 0,68 0,71 0,70 0,58 1,21 1,17 1,26 1,22 1,17 1,30 1,10 1,07 1,12 1,10 1,07 1,15 0,98 0,98 0,97 0,97 0,99 0,97 0,86 0,88 0,83 0,84 0,84 0,78 0,74 0,78 0,66 0,70 0,69 0,56 1,19 1,16 1,25 1,20 1,16 1,28 1,08 1,06 1,09 1,08 1,06 1,13 0,96 0,97 0,95 0,96 0,96 0,95 0,84 0,87 0,81 0,82 0,81 0,76 0,72 0,77 0,64 0,68 0,67 0,54 1,17 1,16 1,22 1,18 1,16 1,26 1,06 1,05 1,07 1,06 1,05 1,10 0,94 0,96 0,93 0,94 0,95 0,93 0,82 0,86 0,79 0,80 0,80 0,74 0,70 0,76 0,62 0,66 0,66 0,52 1,15 1,15 1,20 1,16 1,15 1,23 1,04 1,04 1,05 1,04 1,04 1,08 0,92 0,95 0,92 0,92 0,94 0,90 0,80 0,85 0,77 0,79 0,79 0,71 0,68 0,75 0,60 0,65 0,65 0,50 1,13 1,13 1,17 1,15 1,13 1,20 1,02 1,03 1,04 1,03 1,03 1,05 0,90 0,93 0,89 0,90 0,93 0,87 0,78 0,84 0,75 0,77 0,78 0,68 0,66 0,74 0,58 0,63 0,63 0,47
1,34 1,32 1,40 1,35 1,32 1,52 1,23 1,22 1,27 1,23 1,22 1,35 1,11 1,11 1,16 1,13 1,11 1,17 1,00 1,02 1,02 1,00 1,02 1,02 0,88 0,92 0,87 0,89 0,92 0,85 0,76 0,82 0,73 0,75 0,76 0,66 0,64 0,72 0,56 0,61 0,61 0,45
1,32 1,31 1,38 1,33 1,31 1,49 1,21 1,21 1,25 1,21 1,21 1,32 1,09 1,10 1,13 1,11 1,10 1,14 0,98 1,01 0,99 0,99 1,01 0,99 0,86 0,90 0,85 0,87 0,91 0,82 0,74 0,81 0,71 0,73 0,74 0,63 0,62 0,71 0,54 0,60 0,60 0,42
1,30 1,29 1,36 1,31 1,29 1,46 1,18 1,19 1,23 1,19 1,19 1,29 1,07 1,08 1,11 1,09 1,08 1,12 0,96 0,99 0,97 0,97 0,99 0,96 0,84 0,89 0,83 0,85 0,90 0,79 0,72 0,80 0,69 0,72 0,73 0,60 0,60 0,70 0,52 0,58 0,58 0,40
1,28 1,27 1,33 1,29 1,27 1,42 1,16 1,17 1,20 1,18 1,18 1,26 1,05 1,07 1,08 1,07 1,07 1,08 0,94 0,98 0,95 0,95 0,98 0,93 0,82 0,87 0,80 0,83 0,87 0,76 0,70 0,78 0,67 0,70 0,72 0,57 0,58 0,68 0,50 0,56 0,57 0,36
1,26 1,25 1,31 1,25 1,25 1,38 1,14 1,16 1,18 1,16 1,16 1,22 1,03 1,05 1,06 1,06 1,05 1,04 0,91 0,96 0,93 0,94 0,96 0,89 0,80 0,86 0,78 0,82 0,86 0,72 0,68 0,77 0,65 0,69 0,71 0,54 0,56 0,67 0,48 0,55 0,56 0,33
TABLE 4 - Correction Factors - L2 of the refrigeration capacity for pressure drops different from nominal values.
0,01
0,03
0,05
0,10
0,15
0,20
0,25
0,30
0,35
0,40
0,45
0,50
0,55
0,60
L2
0,263
0,456
0,59
0,81
1,00
1,15
1,30
1,40
1,54
1,64
1,72
1,82
1,92
2,00
Suction line
TABLE 5 - Correction Factors - S1 of the refrigeration capacity for operating temperatures different from nominal values.
Condensing Temperature [C] Evaporating Temperature [C]
+ 60
+ 55
+ 50
+ 45
+ 40
+ 35
+ 30
+ 60
+ 55
+ 50
+ 45
+ 40
+ 35
+ 30
+10 0 10 20 30 40
+10 0 10 20 30 40
0,36* 0,27*
0,38* 0,29*
0,41* 0,31*
0,43* 0,33*
0,035
0,05
0,07
0,10
0,15
0,20
0,30
0,40
0,50
0,70
0,10
0,20
0,30
0,40
0,50
0,70
1,00
1,50
2,00
2,50
S2
0,47 0,57 0,68 0,82 1,00 1,15 1,40 1,64 1,82 2,15
H2
0,32 0,45 0,54 0,65 0,70 0,83 1,00 1,17 1,30 1,44
APPLICATION EXAMPLES 1) Liquid line: Evaluation of pressure drop across the valve under the following working conditions: Castel 1078/5 valve: Kv = 2,61 [m3/h] Refrigerant: R407C Set refrigeration capacity: 35 [kW] Condensation: + 50 [C] Evaporation: 0 [C] Q = Kv Q1 L1 L2 [kW] 35 = 2,61 18,74 0,82 L2 [kW] 35 L2 = = 0,87 40,11 A pressure drop slightly above 0.11 bar corresponds to the L2 = 0.87 correction factor. Such a pressure drop is compatible with the minimum differential pressure required by the valve. 2) Suction line: Valve selection under the following conditions: Refrigerant: R407C Set refrigeration capacity: 15 [kW] Condensation: + 40 [C] Evaporation: 10 [C] Set pressure drop: 0,1 [bar]
Q = Kv Q1 S1 S2 [kW] 15 = Kv 2,68 0,70 0,82 15 Kv = = 9,75 [m3/h] 1,538 The result involves the selection of a 1078/9 valve with Kv = 10 [m3/h] 3) Hot gas line: Valve selection under the following conditions: Refrigerant: R407C Set refrigeration capacity: 20 [kW] Condensation: + 40 [C] Evaporation: 0 [C] Set pressure drop: 0,5 [bar] Q = Kv Q1 H1 H2 [kW] 20 = Kv 11,62 0,94 0.7 20 Kv = = 2,61 [m3/h] 7,64 The result involves the selection of a 1078/5 valve with Kv = 2.61 [m3/h]
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MOP
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The nuts for flare connection type and the inlet-brazing adapter for solder connection type can be ordered separately. The main part of body assembly are made with the following materials: stainless steel for bulb, capillary tubing, diaphragm casing, diaphragm and rod hot forged brass EN 12420 CW 617N for body brass EN 12164 CW 614N for superheat setting spindle and spring holder steel DIN 17223-1 for spring copper tube EN 12735-1 Cu DHP for solder connection Orifice assembly: interchangeable orifice assembly provide a wide range of capacity from 0,5 up to 15,5 kW (nominal capacity with R22). The external cartridge contains the following elements: housing, plug (metering device), seat, spring and strainer. The rigid design of orifice assembly and its internal components make sure that plug and seat will withstand all types of critical operations (liquid hammering, cavitation, sudden variation of pressure and temperature contaminants). The spring holds the plug firmly to the seat to ensure the minimum leakage through the valve; for positive shut-off, the installation of a solenoid valve is required. The strainer can be cleaned or exchanged. THERMOSTATIC CHARGES Liquid charge: the behaviour of valves with liquid charge is exclusively determined by temperature changes at the bulb and not subject to any cross-ambient interference. They feature a fast response time and thus react quickly in the control circuit. Castel thermostatic expansion valves with liquid charge cannot incorporate MOP functions. Gas charge: the behaviour of valves with gas charge will be determined by the lowest temperature at any part of the expansion valve (thermostatic element, capillary tube or bulb). If any parts other than the bulb are subjected to the lowest temperature, malfunction of expansion valve may occur (charge migration). Castel thermostatic expansion valves with gas charge always feature MOP functions and include ballasted bulb. Ballast in the bulb has a damping effect on the valve regulation and leads to slow opening and fast closure of the valve.
MOP (Maximum Operating Pressure): this functionality limits the evaporator pressure to a maximum value to protect the compressor from the overload condition (Motor Overload Protection). MOP is the evaporating pressure at which the expansion valve will throttle liquid injection into the evaporator and thus prevent the evaporating pressure from rising. Expansion valve operates as superheat control in normal working range and operates as pressure regulator within MOP range. The MOP point will change if the factory superheat setting of the expansion valve is changed. Superheat adjustments influence the MOP point as following: increase of superheat decrease of MOP decrease of superheat increase of MOP Superheat: this is the controlling parameter of the expansion valve. Superheat, measured at the evaporator outlet, is defined as the difference between actual bulb temperature and the evaporating temperature at the saturation point. In order to prevent liquid refrigerant from entering the compressor, a certain minimum superheat must be maintained. In expansion valve operation the following terms are used: Static superheat: its the superheat above that the valve will begin to open. Castel thermo expansion valves are factory preset for optimum static superheat setting. This setting should be modified only if absolutely necessary. Static superheat for Castel valves without MOP is 5 C and for Castel valves with MOP is 4C. Opening superheat: its the amount of superheat above the static superheat required to produce a given valve capacity Operating superheat: its the sum of static and opening superheat
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Subcooling: its defined as the difference between the liquid refrigerant temperature and its saturation temperature. Subcooling generally increases the capacity of refrigeration system and may be accounted for when dimensioning an expansion valve. Depending on system design, subcooling may be necessary to prevent flash gas from forming in the liquid line. If flash gas forms in the liquid line, the capacity of expansion valve will be greatly reduced. All capacity tables, in this chapter, are calculated for a subcooling value of 4 C; if the actual subcooling is higher than 4 C the evaporator capacity must be divided by the appropriate correction factor shown is the tables below every capacity tables.
SELECTION To correctly select a thermo expansion valve on a refrigerating system, the following design conditions must be available: Type of refrigerant Evaporator capacity, Qe Evaporating temperature/pressure, Te / pe Lowest possible condensing temperature/ pressure, Tc / pc Liquid refrigerant temperature, Tl Pressure drop in the liquid line, distributor and evaporator, p The following procedure helps to select the correct valve for the system. Step 1 Determine the pressure drop across the valve. The pressure drop is calculated by the formula:
p tot = p c ( p e + p
41,5
39
66
35
43
29
40
42
42
39
66
35
43
34
40
54
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where: Pc = condensing pressure Pe = evaporating pressure p = sum of pressure drops in the liquid line, distributor and evaporator Step 2 Determine required valve capacity. Use the evaporating capacity Qe to select the required valve size at a given evaporating temperature. If necessary, correct the evaporator capacity for subcooling. Subcooling liquid refrigerant entering the evaporator increase the evaporator capacity, so that a smaller valve may be required. The subcooling is calculated by the formula:
Step 3 Determine required orifice size. Use the pressure drop across the valve, the evaporating temperature and the calculated evaporator capacity to select the corresponding orifice size from the capacity table corresponding to the chosen refrigerant. Step 4 Select a thermostatic charge. Chose the type of charge, liquid without MOP or gas with MOP, and the temperature range, normal temperature or low temperature. Step 5 Determine if external equalizer is required. External equalizer is always required if a distributor is used or if there is an appreciable difference in pressure from the valve outlet to the bulb location. Finally determine the type of connections and their sizes.
Tsub = Tc Tl
From the subcooling corrector factor table find the appropriate corrector factor Fsub corresponding to the Tsub calculated and determine the required valve capacity by the formula:
Q sub =
Qe
Fsub
Rated capacities, for temperature range - 40 + 10, are based on: Evaporating temperature Tevap = + 5 C Condensing temperature Tcond = + 32 C Refrigerant liquid temperature ahead of valve Tliq = + 28 C Rated capacities, for temperature range - 60 - 25, are based on: Evaporating temperature Tevap = - 30 C Condensing temperature Tcond = + 32 C Refrigerant liquid temperature ahead of valve Tliq = + 28 C
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STEP 3 - Determine required orifice size Using the capacity table for R134a on page 25 with: pressure drop across the valve = 4,2 bar evaporating temperature = - 10 C calculated evaporator capacity = 5,55 kW select the corresponding orifice 2205 (N.B.: the expansion valve capacity must be equal or slightly more than the calculated evaporator capacity) MARKING
SIZING EXAMPLE Type of refrigerant R134a Evaporator capacity, Qe 6 kW Evaporating temperature/ pressure, Te - 10 C Lowest possible condensing + 30 C temperature/pressure, Tc Liquid refrigerant temperature, Tl + 20 C Pressure drop in the liquid line, distributor and evaporator, p 1,5 bar STEP 1 - Determine the pressure drop across the valve Condensing pressure at + 30 C - pc = 6,71 bar Evaporating pressure at - 10 C - pe = 1,01 bar
Main valve data are indicated on the upper side of the thermostatic element and on the cartridge surface of the orifice assembly. On the thermostatic element you may find the following data: The valve code number The refrigerant The evaporating temperature range The MOP value, if present The maximum allowable pressure PS The date of production On the cartridge of orifice assembly you may find the following data: The size of the orifice The date of production On the plastic cap of the orifice assembly package a label gives the orifice size. The cap can easily be fastened around the valve capillary tube to clearly identify the valve size.
T sub = 30 20 = 10 C
From the subcooling corrector factor table 5b, we find the appropriate corrector factor Fsub equal to 1,08 for Tsub = 10 C. Required valve capacity is:
Q sub = 6
1,08
= 5,55 kW
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Table 4a: Refrigerant R22/R407C - Capacities in kW for temperature range - 40C ? +10C
Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16
Evaporating temperature = +10 C 220X 0,37 2200 2201 2202 2203 2204 2205 2206 0,87 2,2 3,0 5,4 8,1 10,2 12,6 0,48 1,1 2,8 4,0 7,2 10,8 13,6 16,7 0,55 1,2 3,2 4,7 8,3 12,5 15,7 19,3 0,60 1,3 3,4 5,1 9,1 13,8 17,2 21,0 0,63 1,4 3,6 5,4 9,7 14,5 18,3 22,3 0,65 1,4 3,7 5,6 10,0 15,0 18,9 23,1 0,65 1,4 3,8 5,8 10,2 15,5 19,3 23,5 0,67 1,5 3,8 5,8 10,3 15,5 19,5 23,7
Evaporating temperature = 0 C 220X 0,37 2200 2201 2202 2203 2204 2205 2206 0,84 1,9 2,6 4,6 6,9 8,8 10,8 0,48 1,0 2,4 3,4 6,1 9,1 11,6 14,2 0,55 1,2 2,7 4,0 7,1 10,5 13,3 16,3 0,59 1,3 3,0 4,3 7,8 11,5 14,6 17,8 0,63 1,3 3,1 4,6 8,2 12,2 15,5 18,9 0,65 1,4 3,2 4,8 8,5 12,7 16,1 19,6 0,66 1,4 3,3 4,9 8,7 13,0 16,4 20,0 0,66 1,4 3,3 5,0 8,8 13,2 16,6 20,2
Evaporating temperature = -10 C 220X 0,37 2200 2201 2202 2203 2204 2205 2206 0,79 1,6 2,2 3,9 5,8 7,4 9,1 0,47 0,96 2,0 2,9 5,1 7,6 9,6 11,6 0,53 1,1 2,3 3,3 5,9 8,7 11,0 13,5 0,57 1,2 2,5 3,6 6,4 9,5 12,0 14,7 0,60 1,2 2,6 3,8 6,8 10,1 12,8 15,6 0,63 1,3 2,7 4,0 7,1 10,5 13,3 16,2 0,64 1,3 2,8 4,1 7,3 10,8 13,6 16,6 0,64 1,3 2,8 4,1 7,3 10,9 13,8 16,8
Evaporating temperature = -20 C 220X 2200 2201 2202 2203 2204 2205 2206 0,44 0,88 1,7 2,4 4,2 6,2 7,9 9,6 0,50 1,0 1,9 2,7 4,8 7,1 9,0 11,0 0,54 1,1 2,0 2,9 5,2 7,7 9,8 11,9 0,57 1,1 2,2 3,1 5,5 8,2 10,3 12,6 0,59 1,2 2,3 3,2 5,8 8,5 10,8 13,1 0,61 1,2 2,3 3,3 5,9 8,7 11,0 13,5 0,61 1,2 2,3 3,3 6,0 8,8 11,2 13,7
Evaporating temperature = -30 C 220X 2200 2201 2202 2203 2204 2205 2206 0,40 0,79 1,4 1,9 3,4 5,0 6,4 7,8 0,45 0,9 1,5 2,2 3,9 5,7 7,2 8,8 0,49 0,96 1,7 2,7 4,2 6,2 7,8 9,6 0,52 1,0 1,8 2,5 4,4 6,6 8,3 10,1 0,55 1,1 1,8 2,6 4,6 6,8 8,6 10,5 0,56 1,1 1,9 2,6 4,7 7,0 8,8 10,8 0,57 1,1 1,9 2,7 4,8 7,1 9,0 11,0
Evaporating temperature = -40 C 220X 2200 2201 2202 2203 2204 2205 2206 0,42 0,8 1,3 1,7 3,1 4,6 5,8 7,1 0,45 0,86 1,4 1,9 3,4 4,9 6,3 7,7 0,48 0,92 1,4 2,0 3,5 5,2 6,6 8,1 0,50 0,95 1,5 2,0 3,7 5,4 6,9 8,4 0,52 0,98 1,5 2,1 3,8 5,6 7,1 8,7 0,53 0,99 1,6 2,1 3,8 5,7 7,2 8,8
Table 4b: Refrigerant R22/R407C - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,06 15 1,11 20 1,15 25 1,20 30 1,25 35 1,30 40 1,35 45 1,39 50 1,44
When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 4b
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+10C
Evaporating temperature = +10 C 220X 2200 2201 2202 2203 2204 2205 2206 0,34 0,71 1,5 2,0 3,6 5,4 6,9 8,4 0,43 0,86 1,9 2,6 4,7 7,0 8,9 10,8 0,47 0,93 2,1 3,0 5,3 7,8 9,9 12,1 0,50 0,97 2,2 3,1 5,6 8,3 10,8 12,8 0,51 0,98 2,2 3,2 5,8 8,6 10,9 13,2
Evaporating temperature = 0 C 220X 2200 2201 2202 2203 2204 2205 2206 0,33 0,65 1,3 1,7 3,0 4,5 5,7 7,0 0,42 0,78 1,6 2,2 3,9 5,7 7,3 8,9 0,46 0,86 1,7 2,4 4,4 6,4 8,1 1,0 0,47 0,89 1,8 2,6 4,6 6,8 8,6 10,5 0,49 0,91 1,8 2,6 4,7 7,0 8,8 10,8
Evaporating temperature = -10 C 220X 2200 2201 2202 2203 2204 2205 2206 0,30 0,59 1,0 1,4 2,5 3,6 4,6 5,7 0,36 0,70 1,3 1,8 3,1 4,6 5,8 7,1 0,43 0,77 1,4 2,0 3,5 5,1 6,5 8,0 0,44 0,81 1,5 2,1 3,7 5,4 6,9 8,4 0,44 0,82 1,5 2,1 3,8 5,6 7,1 8,6
Evaporating temperature = -20 C 220X 2200 2201 2202 2203 2204 2205 2206 0,28 0,53 0,81 1,1 2,0 2,9 3,7 4,5 0,35 0,62 1,0 1,4 2,5 3,6 4,6 5,6 0,39 0,69 1,1 1,5 2,8 4,0 5,1 6,2 0,41 0,72 1,2 1,6 2,9 4,3 5,4 6,6 0,42 0,73 1,2 1,7 3,0 4,4 5,5 6,8
Evaporating temperature = -30 C 220X 2200 2201 2202 2203 2204 2205 2206 0,25 0,48 0,66 0,9 1,6 2,3 3,0 3,6 0,32 0,55 0,80 1,1 2,0 2,9 3,6 4,4 0,35 0,61 0,88 1,2 2,2 3,2 4,0 4,9 0,37 0,64 0,93 1,3 2,3 3,3 4,2 5,2 0,38 0,64 0,95 1,3 2,3 3,4 4,3 5,3
Evaporating temperature = -40 C 220X 2200 2201 2202 2203 2204 2205 2206 0,23 0,44 0,54 0,7 1,3 1,9 2,4 3,0 0,28 0,50 0,65 0,9 1,6 2,3 2,9 3,6 0,32 0,54 0,72 1,0 1,8 2,6 3,2 4,0 0,33 0,56 0,78 1,0 1,9 2,7 3,5 4,2 0,34 0,57 0,77 1,0 1,9 2,7 3,5 4,3
Table 5b: Refrigerant R134a - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,08 15 1,13 20 1,19 25 1,25 30 1,31 35 1,37 40 1,42 45 1,48 50 1,54
When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 5b
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Table 6a: Refrigerant R404A/R507 - Capacities in kW for temperature range - 40C +10C
Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16
Evaporating temperature = +10 C 220X 0,28 2200 2201 2202 2203 2204 2205 2206 0,67 1,70 2,32 4,15 6,24 0,35 0,82 2,10 3,00 5,36 8,06 0,40 0,90 2,30 3,39 6,03 9,06 0,42 0,94 2,42 3,61 6,43 9,66 0,43 0,96 2,48 3,73 6,63 9,95 0,43 0,96 2,46 3,74 6,66 9,98 0,42 0,93 2,41 3,68 6,55 9,81 0,41 0,90 2,34 3,59 6,39 9,57
Evaporating temperature = 0 C 220X 0,30 2200 2201 2202 2203 2204 2205 2206 0,68 1,53 2,06 3,68 5,49 6,97 0,37 0,80 1,86 2,64 4,72 7,15 8,92 0,41 0,87 2,04 2,95 5,27 7,86 0,42 0,90 2,13 3,13 5,59 8,33 0,43 0,92 2,18 3,22 5,75 8,58 0,43 0,93 2,18 3,25 5,80 8,64 0,43 0,91 2,15 3,21 5,73 8,53 0,41 0,87 2,08 3,11 5,55 8,27
7,91 10,17 11,43 12,16 12,53 12,56 12,34 12,03 9,71 12,47 13,98 14,86 15,29 15,31 15,05 14,66
Evaporating temperature = -10 C 220X 0,30 2200 2201 2202 2203 2204 2205 2206 0,65 1,31 1,76 3,14 4,66 5,93 7,28 0,37 0,76 1,61 2,24 4,02 5,97 7,57 0,40 0,82 1,74 2,50 4,47 6,61 8,39 0,42 0,84 1,81 2,62 4,69 6,95 8,81 0,42 0,87 1,84 2,69 4,81 7,13 9,02 0,42 0,87 1,85 2,71 4,84 7,18 9,08 0,41 0,85 1,84 2,68 4,79 7,11 8,99 0,41 0,83 1,78 2,60 4,65 6,91 8,73
Evaporating temperature = -20 C 220X 2200 2201 2202 2203 2204 2205 2206 0,35 0,70 1,34 1,85 3,32 4,88 6,20 7,60 0,38 0,75 1,45 2,04 3,66 5,40 6,86 8,39 0,40 0,77 1,50 2,14 3,83 5,64 7,17 8,75 0,39 0,79 1,52 2,17 3,89 5,75 7,29 8,91 0,40 0,79 1,52 2,18 3,90 5,77 7,31 8,93 0,39 0,79 1,51 2,16 3,86 5,71 7,23 8,84 0,38 0,76 1,47 2,09 3,75 5,56 7,05 8,61
Evaporating temperature = -30 C 220X 2200 2201 2202 2203 2204 2205 2206 0,35 0,67 1,18 1,63 2,93 4,28 5,45 6,66 0,37 0,70 1,21 1,69 3,04 4,47 5,68 6,94 0,36 0,70 1,23 1,71 3,07 4,52 5,74 7,02 0,37 0,70 1,21 1,70 3,06 4,51 5,74 7,01 0,36 0,69 1,20 1,68 3,02 4,46 5,67 6,93 0,35 0,67 1,17 1,64 2,93 4,35 5,52 6,75
Evaporating temperature = -40 C 220X 2200 2201 2202 2203 2204 2205 2206 0,32 0,60 0,92 1,27 2,28 3,34 4,25 5,19 0,33 0,61 0,96 1,32 2,36 3,47 4,41 5,39 0,33 0,62 0,97 1,33 2,38 3,50 4,45 5,45 0,33 0,61 0,96 1,31 2,36 3,48 4,43 5,42 0,32 0,60 0,94 1,28 2,31 3,42 4,36 5,33 0,32 0,59 0,91 1,24 2,24 3,33 4,24 5,19
Table 6b: Refrigerant R404A/R507 - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,10 15 1,20 20 1,29 25 1,37 30 1,46 35 1,54 40 1,63 45 1,70 50 1,78
When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 6b
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Table 7a: Refrigerant R404A/R507 - Capacities in kW for temperature range - 60C - 25C
Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice code 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16
Evaporating temperature = -25 C 2200 2201 2202 2203 2204 2205 2206 0,57 0,98 1,31 2,35 3,45 4,40 5,40 0,67 1,20 1,65 2,97 4,37 5,56 6,30 0,72 1,31 1,83 3,28 4,82 6,14 7,49 0,73 1,36 1,91 3,42 5,04 6,40 7,81 0,74 1,37 1,93 3,47 5,11 6,49 7,93 0,85 1,37 1,93 3,46 5,12 6,49 7,93 0,74 1,35 1,90 3,42 5,06 6,42 7,85 0,71 1,31 1,85 3,32 4,93 6,26 7,64
Evaporating temperature = -30 C 2200 2201 2202 2203 2204 2205 2206 0,53 0,88 1,18 2,12 3,09 3,94 4,83 0,64 1,07 1,47 2,65 3,88 4,94 6,06 0,67 1,18 1,63 2,93 4,28 5,45 6,66 0,70 1,21 1,69 3,04 4,47 5,68 6,94 0,70 1,23 1,71 3,07 4,52 5,74 7,02 0,70 1,21 1,70 3,05 4,51 5,74 7,01 0,69 1,20 1,68 3,02 4,46 5,67 6,93 0,67 1,17 1,64 2,93 4,35 5,52 6,75
Evaporating temperature = -40 C 2200 2201 2202 2203 2204 2205 2206 0,56 0,65 1,17 2,09 3,03 3,87 4,73 0,60 0,72 1,27 2,28 3,34 4,25 5,19 0,61 0,75 1,32 2,36 3,47 4,41 5,39 0,62 0,77 1,33 2,38 3,50 4,45 5,45 0,61 0,77 1,31 2,36 3,48 4,43 5,47 0,60 0,77 1,28 2,31 3,42 4,36 5,33 0,59 0,75 1,24 2,24 3,33 4,24 5,19
Evaporating temperature = -50 C 2200 2201 2202 2203 2204 2205 2206 0,49 0,51 0,91 1,63 2,36 3,02 3,69 0,53 0,57 0,99 1,73 2,60 3,30 4,04 0,54 0,60 1,02 1,84 2,69 3,43 4,20 0,54 0,60 1,02 1,84 2,71 3,45 4,22 0,53 0,60 1,01 1,81 2,68 3,42 4,18 0,52 0,60 0,98 1,78 2,63 3,35 4,12 0,50 0,59 0,95 1,72 2,56 3,26 4,00
Evaporating temperature = -60 C 2200 2201 2202 2203 2204 2205 2206 0,46 0,58 0,78 1,40 2,04 2,59 3,16 0,48 0,60 0,80 1,44 2,11 2,69 3,28 0,47 0,60 0,80 1,43 2,11 2,66 3,30 0,45 0,58 0,78 1,40 2,07 2,65 3,25 0,45 0,56 0,75 1,36 2,03 2,59 3,18 0,43 0,54 0,72 1,30 1,96 2,50 3,07
Table 7b: Refrigerant R404A/R507 - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,10 15 1,20 20 1,29 25 1,37 30 1,46 35 1,54 40 1,63 45 1,70 50 1,78
When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 7b
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MOP
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The fixed orifice assembly provide a wide range of capacity from 0,5 up to 15,5 kW (nominal capacity with R22). It contains the following elements: housing, plug (metering device), seat, spring and strainer. The rigid design of orifice assembly and its internal components make sure that plug and seat will withstand all types of critical operations (liquid hammering, cavitation, sudden variation of pressure and temperature contaminants). The spring holds the plug firmly to the seat to ensure the minimum leakage through the valve; for positive shutoff, the installation of a solenoid valve is required. The thermostatic element is hardly connected by brazing to the forged brass body meanwhile the inlet connection is electrical welded to the forged brass body. This construction makes the valve hermetic and avoids any leakage. The valve can be supplied with internal or external equalizer; both types are supplied with solder connections (inlet, outlet and external equalizer if present). The main part of valve are made with the following materials: stainless steel for bulb, capillary tubing, diaphragm casing, diaphragm and rod hot forged brass EN 12420 CW 617N for body brass EN 12164 CW 614N for superheat setting spindle and spring holder steel DIN 17223-1 for spring copper tube EN 12735-1 Cu DHP for solder connection THERMOSTATIC CHARGES Liquid charge: the behaviour of valves with liquid charge is exclusively determined by temperature changes at the bulb and not subject to any cross-ambient interference. They feature a fast response time and thus react quickly in the control circuit. Castel thermostatic expansion valves with liquid charge cannot incorporate MOP functions. Gas charge: the behaviour of valves with gas charge will be determined by the lowest temperature at any part of the expansion valve (thermostatic element, capillary tube or bulb). If any parts other than the bulb are subjected to the lowest temperature, malfunction of expansion valve may occur (charge migration). Castel thermostatic
expansion valves with gas charge always feature MOP functions and include ballasted bulb. Ballast in the bulb has a damping effect on the valve regulation and leads to slow opening and fast closure of the valve. MOP (Maximum Operating Pressure): this functionality limits the evaporator pressure to a maximum value to protect the compressor from the overload condition (Motor Overload Protection). MOP is the evaporating pressure at which the expansion valve will throttle liquid injection into the evaporator and thus prevent the evaporating pressure from rising. Expansion valve operates as superheat control in normal working range and operates as pressure regulator within MOP range. The MOP point will change if the factory superheat setting of the expansion valve is changed. Superheat adjustments influence the MOP point as following: increase of superheat decrease of MOP decrease of superheat increase of MOP Superheat: this is the controlling parameter of the expansion valve. Superheat, measured at the evaporator outlet, is defined as the difference between actual bulb temperature and the evaporating temperature at the saturation point. In order to prevent liquid refrigerant from entering the compressor, a certain minimum superheat must be maintained. In expansion valve operation the following terms are used: Static superheat: its the superheat above that the valve will begin to open. Castel thermo expansion valves are factory preset for optimum static superheat setting. This setting should be modified only if absolutely necessary. Static superheat for Castel valves without MOP is 5 C and for Castel valves with MOP is 4C. Opening superheat: its the amount of superheat above the static superheat required to produce a given valve capacity Operating superheat: its the sum of static and opening superheat
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Subcooling: its defined as the difference between the liquid refrigerant temperature and its saturation temperature. Subcooling generally increases the capacity of refrigeration system and may be accounted for when dimensioning an expansion valve. Depending on system design, subcooling may be necessary to prevent flash gas from forming in the liquid line. If flash gas forms in the liquid line, the capacity of expansion valve will be greatly reduced. All capacity tables, in this chapter, are calculated for a subcooling value of 4 C; if the actual subcooling is higher than 4 C the evaporator capacity must be divided by the appropriate correction factor shown is the tables below every capacity tables.
Step 2 Determine required valve capacity. Use the evaporating capacity Qe to select the required valve size at a given evaporating temperature. If necessary, correct the evaporator capacity for subcooling. Subcooling liquid refrigerant entering the evaporator increase the evaporator capacity, so that a smaller valve may be required. The subcooling is calculated by the formula:
Q sub =
Qe
Fsub
SELECTION To correctly select a thermo expansion valve on a refrigerating system, the following design conditions must be available: Type of refrigerant Evaporator capacity, Qe Evaporating temperature/pressure, Te / pe Lowest possible condensing temperature/pressure, Tc / pc Liquid refrigerant temperature, Tl Pressure drop in the liquid line, distributor and evaporator, p The following procedure helps to select the correct valve for the system.
From the subcooling corrector factor table find the appropriate corrector factor Fsub corresponding to the Tsub calculated and determine the required valve capacity by the formula: Step 3 Determine required orifice size. Use the pressure drop across the valve, the evaporating temperature and the calculated valve capacity to select the corresponding orifice size from the capacity table corresponding to the chosen refrigerant.
Step 1 Determine the pressure drop across the valve. The pressure drop is calculated by the formula:
Evaporating Temperature Range [C] Orifice Size R22 R407C 23--/-0X 23--/-00 23--/-01 0,5 1,0 2,5 3,5 5,2 8,0 10,5 15,5 - 40 + 10 R134a 0,4 0,9 1,8 2,6 4,6 6,7 8,6 10,5 R404A R507 0,38 0,7 1,6 2,1 4,2 6,0 7,7 9,1 -60 -25 R404A R507 0,38 0,7 1,6 2,1 3,5 4,9 6,0 6,6
p tot = p c ( p e + p
where: pc = condensing pressure pe = evaporating pressure p = sum of pressure drops in the liquid line, distributor and evaporator
Rated capacities, for temperature range - 40 + 10, are based on: Evaporating temperature Tevap = + 5 C Condensing temperature Tcond = + 32 C Refrigerant liquid temperature ahead of valve Tliq = + 28 C Rated capacities, for temperature range - 60 - 25, are based on: Evaporating temperature Tevap = - 30 C Condensing temperature Tcond = + 32 C Refrigerant liquid temperature ahead of valve Tliq = + 28 C
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Step 4 Select a thermostatic charge. Chose the type of charge, liquid without MOP or gas with MOP, and the temperature range, normal temperature or low temperature. Step 5 Determine if external equalizer is required. External equalizer is always required if a distributor is used or if there is an appreciable difference in pressure from the valve outlet to the bulb location. Finally determine the type of connections and their sizes. SIZING EXAMPLE Type of refrigerant R22 3,8 kW Evaporator capacity, Qe Evaporating temperature/ pressure, Te + 5 C Lowest possible condensing temperature/pressure, Tc + 38 C Liquid refrigerant temperature,Tl + 27 C Pressure drop in the liquid line, distributor and evaporator, p 0,5 bar
STEP 1 - Determine the pressure drop across the valve Condensing pressure at + 38 C - Pc = 13,6 bar Evaporating pressure at + 5 C - Pe = 4.8 bar
) = 8,3 bar
Tsub = 38 27 = 11 C
From the subcooling corrector factor table 3b we find the appropriate corrector factor Fsub equal to 1,07 for Tsub = 11 C. Required valve capacity is:
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85
40
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MARKING The following data are indicated on the upper side of the thermostatic element of the valve: The valve code number The refrigerant The evaporating temperature range The MOP value, if present The maximum allowable pressure PS The date of production The size of the orifice
Table 3a: Refrigerant R22/R407C - Capacities in kW for temperature range - 40C + 10C
Orifice size 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice size 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16
Evaporating temperature = +10 C 23--/-0X 0,37 23--/-00 0,87 23--/-01 23--/-02 23--/-03 23--/-04 2,2 3,0 5,4 8,1 0,48 1,1 2,8 4,0 7,2 10,8 13,6 16,7 0,55 1,2 3,2 4,7 8,3 12,5 15,7 19,3 0,60 1,3 3,4 5,1 9,1 13,8 17,2 21,0 0,63 1,4 3,6 5,4 9,7 14,5 18,3 22,3 0,65 1,4 3,7 5,6 10,0 15,0 18,9 23,1 0,65 1,4 3,8 5,8 10,2 15,5 19,3 23,5 0,67 1,5 3,8 5,8 10,3 15,5 19,5 23,7
Evaporating temperature = 0 C 23--/-0X 0,37 23--/-00 0,84 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 1,9 2,6 4,6 6,9 8,8 0,48 1,0 2,4 3,4 6,1 9,1 11,6 14,2 0,55 1,2 2,7 4,0 7,1 10,5 13,3 16,3 0,59 1,3 3,0 4,3 7,8 11,5 14,6 17,8 0,63 1,3 3,1 4,6 8,2 12,2 15,5 18,9 0,65 1,4 3,2 4,8 8,5 12,7 16,1 19,6 0,66 1,4 3,3 4,9 8,7 13,0 16,4 20,0 0,66 1,4 3,3 5,0 8,8 13,2 16,6 20,2
23--/-06 10,8
Evaporating temperature = -10 C 23--/-0X 0,37 23--/-00 0,79 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 1,6 2,2 3,9 5,8 7,4 9,1 0,47 0,96 2,0 2,9 5,1 7,6 9,6 11,6 0,53 1,1 2,3 3,3 5,9 8,7 11,0 13,5 0,57 1,2 2,5 3,6 6,4 9,5 12,0 14,7 0,60 1,2 2,6 3,8 6,8 10,1 12,8 15,6 0,63 1,3 2,7 4,0 7,1 10,5 13,3 16,2 0,64 1,3 2,8 4,1 7,3 10,8 13,6 16,6 0,64 1,3 2,8 4,1 7,3 10,9 13,8 16,8
Evaporating temperature = -20 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,44 0,88 1,7 2,4 4,2 6,2 7,9 9,6 0,50 1,0 1,9 2,7 4,8 7,1 9,0 11,0 0,54 1,1 2,0 2,9 5,2 7,7 9,8 11,9 0,57 1,1 2,2 3,1 5,5 8,2 10,3 12,6 0,59 1,2 2,3 3,2 5,8 8,5 10,8 13,1 0,61 1,2 2,3 3,3 5,9 8,7 11,0 13,5 0,61 1,2 2,3 3,3 6,0 8,8 11,2 13,7
Evaporating temperature = -30 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,40 0,79 1,4 1,9 3,4 5,0 6,4 7,8 0,45 0,9 1,5 2,2 3,9 5,7 7,2 8,8 0,49 0,96 1,7 2,7 4,2 6,2 7,8 9,6 0,52 1,0 1,8 2,5 4,4 6,6 8,3 10,1 0,55 1,1 1,8 2,6 4,6 6,8 8,6 10,5 0,56 1,1 1,9 2,6 4,7 7,0 8,8 10,8 0,57 1,1 1,9 2,7 4,8 7,1 9,0 11,0
Evaporating temperature = -40 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,42 0,8 1,3 1,7 3,1 4,6 5,8 7,1 0,45 0,86 1,4 1,9 3,4 4,9 6,3 7,7 0,48 0,92 1,4 2,0 3,5 5,2 6,6 8,1 0,50 0,95 1,5 2,0 3,7 5,4 6,9 8,4 0,52 0,98 1,5 2,1 3,8 5,6 7,1 8,7 0,53 0,99 1,6 2,1 3,8 5,7 7,2 8,8
Table 3b: Refrigerant R22/R407C - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,06 15 1,11 20 1,15 25 1,20 30 1,25 35 1,30 40 1,35 45 1,39 50 1,44
When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 3b
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Table 4a: Refrigerant R134a - Capacities in kW for temperature range - 40C + 10C
Orifice size 2 Pressure drop across valve [bar] 4 6 8 10 Orifice size 2 Pressure drop across valve [bar] 4 6 8 10
Evaporating temperature = +10 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,34 0,71 1,5 2,0 3,6 5,4 6,9 8,4 0,43 0,86 1,9 2,6 4,7 7,0 8,9 10,8 0,47 0,93 2,1 3,0 5,3 7,8 9,9 12,1 0,50 0,97 2,2 3,1 5,6 8,3 10,8 12,8 0,51 0,98 2,2 3,2 5,8 8,6 10,9 13,2
Evaporating temperature = 0 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,33 0,65 1,3 1,7 3,0 4,5 5,7 7,0 0,42 0,78 1,6 2,2 3,9 5,7 7,3 8,9 0,46 0,86 1,7 2,4 4,4 6,4 8,1 1,0 0,47 0,89 1,8 2,6 4,6 6,8 8,6 10,5 0,49 0,91 1,8 2,6 4,7 7,0 8,8 10,8
Evaporating temperature = -10 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,30 0,59 1,0 1,4 2,5 3,6 4,6 5,7 0,36 0,70 1,3 1,8 3,1 4,6 5,8 7,1 0,43 0,77 1,4 2,0 3,5 5,1 6,5 8,0 0,44 0,81 1,5 2,1 3,7 5,4 6,9 8,4 0,44 0,82 1,5 2,1 3,8 5,6 7,1 8,6
Evaporating temperature = -20 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,28 0,53 0,81 1,1 2,0 2,9 3,7 4,5 0,35 0,62 1,0 1,4 2,5 3,6 4,6 5,6 0,39 0,69 1,1 1,5 2,8 4,0 5,1 6,2 0,41 0,72 1,2 1,6 2,9 4,3 5,4 6,6 0,42 0,73 1,2 1,7 3,0 4,4 5,5 6,8
Evaporating temperature = -30 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,25 0,48 0,66 0,9 1,6 2,3 3,0 3,6 0,32 0,55 0,80 1,1 2,0 2,9 3,6 4,4 0,35 0,61 0,88 1,2 2,2 3,2 4,0 4,9 0,37 0,64 0,93 1,3 2,3 3,3 4,2 5,2 0,38 0,64 0,95 1,3 2,3 3,4 4,3 5,3
Evaporating temperature = -40 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,23 0,44 0,54 0,7 1,3 1,9 2,4 3,0 0,28 0,50 0,65 0,9 1,6 2,3 2,9 3,6 0,32 0,54 0,72 1,0 1,8 2,6 3,2 4,0 0,33 0,56 0,78 1,0 1,9 2,7 3,5 4,2 0,34 0,57 0,77 1,0 1,9 2,7 3,5 4,3
Table 4b: Refrigerant R134a - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,08 15 1,13 20 1,19 25 1,25 30 1,31 35 1,37 40 1,42 45 1,48 50 1,54
When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 4b
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Table 5a: Refrigerant R404A/R507 - Capacities in kW for temperature range - 40C + 10C
Orifice size 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice size 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16
Evaporating temperature = +10 C 23--/-0X 0,28 23--/-00 0,67 23--/-01 1,70 23--/-02 2,32 23--/-03 4,15 23--/-04 6,24 0,35 0,82 2,10 3,00 5,36 8,06 0,40 0,90 2,30 3,39 6,03 9,06 0,42 0,94 2,42 3,61 6,43 9,66 0,43 0,96 2,48 3,73 6,63 9,95 0,43 0,96 2,46 3,74 6,66 9,98 0,42 0,93 2,41 3,68 6,55 9,81 0,41 0,90 2,34 3,59 6,39 9,57
Evaporating temperature = 0 C 23--/-0X 0,30 23--/-00 0,68 23--/-01 1,53 23--/-02 2,06 23--/-03 3,68 23--/-04 5,49 23--/-05 6,97 0,37 0,80 1,86 2,64 4,72 7,15 8,92 0,41 0,87 2,04 2,95 5,27 7,86 0,42 0,90 2,13 3,13 5,59 8,33 0,43 0,92 2,18 3,22 5,75 8,58 0,43 0,93 2,18 3,25 5,80 8,64 0,43 0,91 2,15 3,21 5,73 8,53 0,41 0,87 2,08 3,11 5,55 8,27
23--/-05 7,91 10,17 11,43 12,16 12,53 12,56 12,34 12,03 23--/-06 9,71 12,47 13,98 14,86 15,29 15,31 15,05 14,66 Evaporating temperature = -10 C 23--/-0X 0,30 23--/-00 0,65 23--/-01 1,31 23--/-02 1,76 23--/-03 3,14 23--/-04 4,66 23--/-05 5,93 23--/-06 7,28 0,37 0,76 1,61 2,24 4,02 5,97 7,57 0,40 0,82 1,74 2,50 4,47 6,61 8,39 0,42 0,84 1,81 2,62 4,69 6,95 8,81 0,42 0,87 1,84 2,69 4,81 7,13 9,02 0,42 0,87 1,85 2,71 4,84 7,18 9,08 0,41 0,85 1,84 2,68 4,79 7,11 8,99 0,41 0,83 1,78 2,60 4,65 6,91 8,73
23--/-06 8,57 10,93 12,16 12,85 13,21 13,30 13,12 12,72 Evaporating temperature = -20 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,35 0,70 1,34 1,85 3,32 4,88 6,20 7,60 0,38 0,75 1,45 2,04 3,66 5,40 6,86 8,39 0,40 0,77 1,50 2,14 3,83 5,64 7,17 8,75 0,39 0,79 1,52 2,17 3,89 5,75 7,29 8,91 0,40 0,79 1,52 2,18 3,90 5,77 7,31 8,93 0,39 0,79 1,51 2,16 3,86 5,71 7,23 8,84 0,38 0,76 1,47 2,09 3,75 5,56 7,05 8,61
Evaporating temperature = -30 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,35 0,67 1,18 1,63 2,93 4,28 5,45 6,66 0,37 0,70 1,21 1,69 3,04 4,47 5,68 6,94 0,36 0,70 1,23 1,71 3,07 4,52 5,74 7,02 0,37 0,70 1,21 1,70 3,06 4,51 5,74 7,01 0,36 0,69 1,20 1,68 3,02 4,46 5,67 6,93 0,35 0,67 1,17 1,64 2,93 4,35 5,52 6,75
Evaporating temperature = -40 C 23--/-0X 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,32 0,60 0,92 1,27 2,28 3,34 4,25 5,19 0,33 0,61 0,96 1,32 2,36 3,47 4,41 5,39 0,33 0,62 0,97 1,33 2,38 3,50 4,45 5,45 0,33 0,61 0,96 1,31 2,36 3,48 4,43 5,42 0,32 0,60 0,94 1,28 2,31 3,42 4,36 5,33 0,32 0,59 0,91 1,24 2,24 3,33 4,24 5,19
Table 5b: Refrigerant R404A/R507 - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,10 15 1,20 20 1,29 25 1,37 30 1,46 35 1,54 40 1,63 45 1,70 50 1,78
When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 5b
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35
Table 6a: Refrigerant R404A/R507 - Capacities in kW for temperature range - 60C - 25C
Orifice size 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16 Orifice size 2 4 Pressure drop across valve [bar] 6 8 10 12 14 16
Evaporating temperature = -25 C 23--/-00 0,57 23--/-01 0,98 23--/-02 1,31 23--/-03 2,35 23--/-04 3,45 23--/-05 4,40 23--/-06 5,40 0,67 1,20 1,65 2,97 4,37 5,56 6,30 0,72 1,31 1,83 3,28 4,82 6,14 7,49 0,73 1,36 1,91 3,42 5,04 6,40 7,81 0,74 1,37 1,93 3,47 5,11 6,49 7,93 0,85 1,37 1,93 3,46 5,12 6,49 7,93 0,74 1,35 1,90 3,42 5,06 6,42 7,85 0,71 1,31 1,85 3,32 4,93 6,26 7,64
Evaporating temperature = -30 C 23--/-00 0,53 23--/-01 0,88 23--/-02 1,18 23--/-03 2,12 23--/-04 3,09 23--/-05 3,94 23--/-06 4,83 0,64 1,07 1,47 2,65 3,88 4,94 6,06 0,67 1,18 1,63 2,93 4,28 5,45 6,66 0,70 1,21 1,69 3,04 4,47 5,68 6,94 0,70 1,23 1,71 3,07 4,52 5,74 7,02 0,70 1,21 1,70 3,05 4,51 5,74 7,01 0,69 1,20 1,68 3,02 4,46 5,67 6,93 0,67 1,17 1,64 2,93 4,35 5,52 6,75
Evaporating temperature = -40 C 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,56 0,65 1,17 2,09 3,03 3,87 4,73 0,60 0,72 1,27 2,28 3,34 4,25 5,19 0,61 0,75 1,32 2,36 3,47 4,41 5,39 0,62 0,77 1,33 2,38 3,50 4,45 5,45 0,61 0,77 1,31 2,36 3,48 4,43 5,47 0,60 0,77 1,28 2,31 3,42 4,36 5,33 0,59 0,75 1,24 2,24 3,33 4,24 5,19
Evaporating temperature = -50 C 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,49 0,51 0,91 1,63 2,36 3,02 3,69 0,53 0,57 0,99 1,73 2,60 3,30 4,04 0,54 0,60 1,02 1,84 2,69 3,43 4,20 0,54 0,60 1,02 1,84 2,71 3,45 4,22 0,53 0,60 1,01 1,81 2,68 3,42 4,18 0,52 0,60 0,98 1,78 2,63 3,35 4,12 0,50 0,59 0,95 1,72 2,56 3,26 4,00
Evaporating temperature = -60 C 23--/-00 23--/-01 23--/-02 23--/-03 23--/-04 23--/-05 23--/-06 0,46 0,58 0,78 1,40 2,04 2,59 3,16 0,48 0,60 0,80 1,44 2,11 2,69 3,28 0,47 0,60 0,80 1,43 2,11 2,66 3,30 0,45 0,58 0,78 1,40 2,07 2,65 3,25 0,45 0,56 0,75 1,36 2,03 2,59 3,18 0,43 0,54 0,72 1,30 1,96 2,50 3,07
Table 6b: Refrigerant R404A/R507 - Correction factor for subcooling tsub > 4C
tsub [C] Fsub 4 1,00 10 1,10 15 1,20 20 1,29 25 1,37 30 1,46 35 1,54 40 1,63 45 1,70 50 1,78
When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 6b
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SOLENOID VALVES
37
38
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The NO valves have been designed to work only with direct current coils. To use them with an alternate current supply its necessary to mate the NO valve with the following components:
voltage 24 Vac: Coil 9120/RD2 + Connector 9150/R44; voltage 220 Vac: Coil 9120/RD6 + Connector 9150/R45.
SOLENOID VALVES
min OPD
1020/2 1020/3 1028/2 1028/2E 1028/3 1028/M10 1064/3 1064/4 1068/3 1068/M10 1068/M12 1068/4 1070/4 1070/5 1078/M12 1078/4 1078/5 1079/7 1050/5 1050/6 1058/5 1058/6 1058/7 1059/9 1090/5 1090/6 1098/5 1098/6 1098/7 1099/9 1078/9 1079/11 1098/9 1099/11 1078/11 1079/13 1079/M42
19
0,05
25 (3)
18
2,61 3,80 Piston Pilot Operated 4,80 3,80 4,80 5,70 3,80 4,80 3,80 4,80 5,70 13 Diaphragm Pilot Operated 21 35 45 Art. 3.3
0,07
+110 (2)
0,05
21
+105 (1)
10
25
10
0,07
25 (3)
19 +110 (2)
(1) Temperature peaks of 120 C are allowed during defrosting. (2) Temperature peaks of 130 C are allowed during defrosting. (3) For information about higher MOPD, please contact Castel Technical Department.
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1020/2 1020/3 1028/2 1028/2E 1028/3 1028/M10 1064/3 1064/4 1068/3 1068/M10 1068/M12 1068/4 1070/4 1070/5 1078/M12 1078/4 1078/5 1079/7 1050/5 1050/6 1058/5 1058/6 1058/7 1059/9 1090/5 1090/6 1098/5 1098/6 1098/7 1099/9 1078/9 1079/11 1098/9 1099/11 1078/11 1079/13 1079/M42 172 138 110 115 96 72 106 78 50 121 93 65 91 75 47 82 69,5 40 75 62,5 34
58 65 125 125 125 125 68 72 111 111 127 127 100 106 127 127 175 190 120 124 175 175 180 216 120 124 175 175 180 216 250 292 235 277 80 57 50 45
340 355 350 350 365 365 400 415 400 395 420 420 710 755 690 680 775 765 1157 1487 1117 1307 1292 1347 1035 1365 995 1185 1170 1225 2565 2620 2050 2130 2710
157
127
99
68
278
68
2750 2750
(1) With coil type 9120 the dimension L2 is equal to 64 mm and the valves weights must be increased of 305 g.
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SOLENOID VALVES
L2 L2
H2
H1
H2
H1
H3
L1 L2
1020/2 1020/3
L1
L2
H2
H1
H3
H1
H2
L1 L2
1064/3 1064/4
L1 L2
H2
H1
H1
H2
H3
L1
1070/4 1070/5
L1
L2
L2
H2
H1
H3
H1
H2
L1
L1
H2
H1
H2
H1
Connectors are not included in the boxes and have to be ordered separately.
H3
H3
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1,96
2,69
2,67
2,30
2,99
44,0 64,0 80,9 64,0 80,9 96,0 64,0 80,9 64,0 80,9 96,0
47,0 68,4 86,4 68,4 86,4 102,6 68,4 86,4 68,4 86,4 102,6
48,9 71,2 90,0 71,2 90,0 106,8 71,2 90,0 71,2 90,0 106,8
31,1 45,2 57,1 45,2 57,1 67,8 45,2 57,1 45,2 57,1 67,8
49,7 72,4 91,4 7,4 91,4 108,5 72,4 91,4 72,4 91,4 108,5
5,64 8,2 10,4 8,2 10,4 12,3 8,2 10,4 8,2 10,4 12,3
7,05 10,3 13,0 10,3 13,0 15,4 10,3 13,0 10,3 13,0 15,4
6,99 10,2 12,9 10,2 12,9 15,3 10,2 12,9 10,2 12,9 15,3
5,90 8,6 10,8 8,6 10,8 12,9 8,6 10,8 8,6 10,8 12,9
9,40 13,7 17,3 13,7 17,3 20,5 13,7 17,3 13,7 17,3 20,5
22,2 32,3 40,8 32,3 40,8 48,5 32,3 40,8 32,3 40,8 48,5
30,5 44,5 56,2 44,5 56,2 66,7 44,5 56,2 44,5 56,2 66,7
30,3 44,2 55,8 44,2 55,8 66,2 44,2 55,8 44,2 55,8 66,2
26,1 38,0 48,0 38,0 48,0 57,0 38,0 48,0 38,0 48,0 57,0
33,9 49,4 62,4 49,4 62,4 74,1 49,9 62,4 49,4 62,4 74,1
168,5
180,0
187,4
119,0
190,4
21,6
27,0
26,8
22,6
36,0
85,0
117,0
116,2
100,0
130,0
168,5
180,0
187,4
119,0
190,4
21,6
27,0
26,8
22,6
36,0
85,0
117,0
116,2
100,0
130,0
Refrigerant flow capacity referred to the following operating conditions: Evaporating temperature: + 4 C Condensing temperature: + 38 C Pressure drop: 0,15 bar
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SOLENOID VALVES
1164/3 1168/3 1168/M10 1170/4 1170/5 1178/M12 1178/4 1178/5 1150/5 1150/6 1158/5 1158/6 1158/7 1190/5 1190/6 1198/5 1198/6 1198/7 1178/9 1198/9 1178/11
R R R R R R R R R R R R R R R R R R R R R
0,07 19
35
32
Art. 3.3
(1) Temperature peaks of 120 C are allowed during defrosting. (2) Temperature peaks of 130 C are allowed during defrosting.
R
Available on request.
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L2
L2
H2
H1
H3
H1
H2
L1
1164/3
L1
1168/3 1168/M10
L2
L2
H2
H1
H1
H2
H3
L1
1170/4 1170/5
L1
L2
L2
H3
H2
H3
L1
L L2 L2
H2
H3
H2
H1
H1
H1
H2
H1
44
H3
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H3
SOLENOID VALVES
1164/3 1168/3 1168/M10 1170/4 1170/5 1178/M12 1178/4 1178/5 1150/5 1150/6 1158/5 1158/6 1158/7 1190/5 1190/6 1198/5 1198/6 1198/7 1178/9 1198/9 1178/11 120 162 177 101 132 143 72 99 110 111 83 50 126 98 70 96 80 47 87 74,5 40
68 111 111 100 106 127 127 175 120 124 175 175 180 120 124 175 175 180 250 235 278 80 68 68 57 64 45
705 705 700 1015 1060 995 985 1080 1462 1792 1422 1612 1597 1340 1670 1300 1490 1475 2870 2355 3015
Refrigerant flow capacity referred to the following operating conditions: Evaporating temperature: + 4 C Condensing temperature: + 38 C Pressure drop: 0,15 bar
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45
COILS
APPLICATION For the normally closed solenoid valves, previously shown in this Handbook, Castel puts the following types of coils at disposal of its own customers: coils series HM2, only for A.C. (catalogue numbers 9100 - 9105). coils series CM2, only for A.C. (catalogue number 9110); coils series HM3,either for A.C. or for D.C. (catalogue number 9120). coils series HM4, only for A.C. (catalogue number 9160). For the normally open solenoid valves, always shown in this Handbook, the customers selection must compulsorily apply to the coils series HM3 D.C. For applications of the NO solenoid valves with a voltage supply of 220 VAC, Castel has designed a specific coil at 220 V RAC (code 9120/RD6) that must be used solely with the 220 VAC connector/rectifier circuit (code 9150/R45). For applications of the same NO valves with a voltage supply of 24 VAC, Castel suggests to the user the 24 VDC coil (code 9120/RD2) with the 24 VAC connector/rectifier circuit (code 9150/R44). CONSTRUCTION Coils HM2 (9100), CM2, HM3 and HM4 are class F in compliance with IEC 85 standard and their construction is in compliance with EN 60730-1 and EN 60730-2-8 standards. The windings are made with copper wire, insulation class H 180 C, in compliance with IEC 85 standard. The outer casing is provided with dielectric and waterproof resins that assure a reinforced insulation making the coils suitable for all assemblies. Coils HM2 (9105) are class F, with UL approved EIS (Electrical Insulation System), and their construction is in compliance with UL 429 Standards. Protection against electric contacts is class I. Therefore, for safety purposes, coils must be effectively connected to an earthing system. Rubber gaskets on the upper and lower ends of coil ensure moisture protection of winding. Coils HM2 and HM3 may be joined to all connectors produced by Castel except type 9155/R01; protection degree guaranteed by this system, coil (HM2, HM3) + connector, is IP65 according to EN 60529. Coils HM4 must be used with connector type 9155/R01; protection degree guaranteed by this other system, coil HM4 + connector 9155/R01, is IP65/IP68 according to EN 60529. Coils HM4 can be used with connectors series 9150 and 9900 too; protection degree guaranteed by this system is IP65. Either the terminals of coils series HM2 and HM3 or the ones of coils series HM4 consist of two Faston line connections plus one Faston earthing connection. Coil type CM2 has a pre-assembled cable (length 1 meter). The coils are designed for continuous use. The solid construction of these coils is suitable for heavy-duty applications in refrigerant systems. The maximum ambient temperature for all coils is 50 C. ELECTRIC TYPE APPROVAL HM2 (9100) and CM2 coils, 220/230V50/60Hz and 240V-50/60Hz, are approved by the German registration body VDE. All HM2 coils series 9105 are approved by Underwriters Laboratories Inc of the United States. Moreover either coils types HM2, CM2 and HM4 (110 VAC, 220/230 VAC and 240 VAC) or coils type HM3 (220/230 VAC) are manufactured according to Low Voltage Directives EC 73/23, EC 93/68 and to EMC Directives EC 89/336, EC 92/31, EC 93/68.
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SOLENOID VALVES
Coil Type
Catalogue Number
Voltage [V]
Frequecy [Hz]
Connections
Degree of protection
9100/RA2 9100/RA4 HM2 9100/RA6 9100/RA7 9100/RA8 HM2 Recognized File number E243604 9105/RA2 9105/RA4 9105/RA6 9105/RA7 9110/RA2 CM2 9110/RA4 9110/RA6 9110/RA7 9120/RA6 9120/RD1 HM3 9120/RD2 9120/RD4 9120/RD6 9160/RA2 HM4 9160/RA4 9160/RA6 9160/RA7
24 A.C. 110 A.C. 220/230 A.C. 240 A.C. 380 A.C. 24 A.C. 110/120 A.C. 220/230 A.C. 240 A.C. 24 A.C. 110 A.C. 220/230 A.C. 240 A.C. 220/230 A.C. 12 D.C. 24 D.C. 48 D.C. 220 RAC 24 A.C. 110 A.C. 220/230 A.C. 240 A.C.
+10 / -10 +6 / -10 +10 / -10 +10 / -10 +6 / -10 +10 / -10 +10 / -10 +6 / -10 +10 / -10 +6 / -10 50 / 60 Junction box +10 / -5 DIN 43650 50 / 60 60 Junction box DIN 43650 50 / 60 Junction box DIN 43650
IP65 EN 60529
IP65 EN 60529 (with junction box) Junction box DIN 43650 or Connector 9155/R01 (1) IP65 EN 60529 (with junction box) IP65/IP68 EN 60529 (with connector)
(1) Coil HM4 can also be coupled to connectors series 9150 and 990, achieving a degree of protection IP65, the versatile degree of protection (IP65/IP68) is achieved coupling coil H4 with four screws connector 9155/RO1.
L2
HM2
L1
CM2
L1
L2
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Weight [g] H
L2
L2
HM3 L1
HM4
L1
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L2
CONNECTORS
The junction boxes 9150, DIN 43650 standardized, represent an effective system for the connection of the coil to the supply circuit, thus ensuring safety also in the presence of moisture. These junction boxes, according to assembly requirements, allow choosing the position of outer casing compared to inner terminal block. The clamping screw of casing may be PG9 or PG11, which are respectively suitable for cables with an external diameter of 6 8 or 8 10 mm. Cables sized 3 x 0,75 mm2 are to be preferred. The junction box type 9900 is available with cabled core of different length. In this case, it is not possible to change the position of casing compared to terminal block. Both the two types offer a protection degree IP65 against dust and water, according to EN 60529, when correctly installed with the proper gaskets, which are supplied as standard. Castel has developed a specific junction box, type 9155/R01, suitable for use on those refrigerating systems working in heavy duty environments, for example: exposition to the atmospheric conditions; rooms with high moisture degree; cyclic condensing / evaporating on the valve; cyclic icing / defrosting on the valve. This junction box, according to assembly requirements, allows choosing the side position of outer casing compared to inner terminal block; but it is not possible to point the cable upwards. The gland nut of casing is suitable to receive cables with an external diameter of 6 9 mm and is provided with a self-locking device. Cables sized 3 x 0,75 mm2 are to be preferred for this junction box too. The junction box type 9155/R01 offers a protection degree IP65/IP68 against dust and water, according to EN 60529, when correctly installed with the proper gaskets, which are supplied as standard. The junction box 9150/R44 and 9150/R45 are equipped with a full-wave bridge rectifier plus VDR for protection. The VDR device, Voltage e-Dependent-Resistor, is a special type of resistor, placed in parallel to the coil; its purpose is to protect the diodes and the coil from any excessive voltage generated within the ac supply circuit.
SOLENOID VALVES
Catalogue Number
Standard
Degree of protection
Class of insulation
1 1,5 2 3 5 3 x 0,75
IP65/IP68 EN 60529
DIN 43650
IP65 EN 60529
Available on request.
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49
PERMANET MAGNET
APPLICATION Castel supplies to its customers the permanent magnet code 9900/X91 for the normally closed solenoid valves, shown in this chapter. This product can be used during brazing of the valve copper connections to the plant pipes; slipping it on the armature, instead of the coil, it allows the protective gas (nitrogen) flowing and avoids any damage to the plunger gasket and to the diaphragm. CONSTRUCTION The main parts of the permanent magnet code 9900/X91 are made with the following materials: three rings of anisotropic ferrite; anodized aluminum for the body.
PERMANENT MAGNET
NC SOLENOID VALVE
Connectors are not included in the boxes and have to be ordered separately.
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SOLENOID VALVES
Catalogue Number
Main Use
FPT Connections
Kv Factor [m3/h]
1512/01 1522/02 1522/03 1522/04 1132/03 1132/04 1132/06 1132/08 1142/010 1142/012 HM2 (A.C.) - CM2 (A.C.) HM3 (A.C.; D.C.) - HM4 (A.C.)
W.L.O.
G 1/8" G 1/4"
1,5
0,070
W.O.
4,5
0,40
4 +105
30
W.L.O.B.
20
12,5
2,10
0,1
17
-15
Art. 3.3
0,15
12 15
38
0,3
11
+90
OPERATION All the valves for different fluids are normally closed. NC = when the coil is de-energised the plunger stops the refrigerant flow. The valves series 1512 and 1522 are direct acting, while the valves series 1132 and 1142 are pilot operated with diaphragm. CONSTRUCTION The main parts of the valves are made with the following materials: hot forged brass EN 12420 CW 617N for body and cover; austenitic stainless steel EN 10088-2 1.4303 for enclosure where the plunger moves; ferritic stainless steel EN 10088-3 1.4105 for plunger; austenitic stainless steel EN ISO 3506 A2-70 for tightening screws between body and cover; fluorocarbon rubber (FPM) for outlet seal gaskets; fluorocarbon rubber (FPM) for seat gaskets; fluorocarbon rubber (FPM) for diaphragms. Nitril rubber (NBR) for the valves series 1142.
INSTALLATION Table 1 shows the following functional characteristics of a solenoid valve: PS; TS; Kv factor; minimum Opening Pressure Differential (minOPD), that is the minimum pressure differential between inlet and outlet at which a solenoid valve, pilot operated, can open and stay opened; maximum Opening Pressure Differential (MOPD according to ARI STANDARD 760: 2001), that is the maximum pressure differential between inlet and outlet at which a solenoid valve, pilot operated, can open. Before connecting the valve it is advisable to make sure that the piping are clean and that the flow direction in the pipe corresponds to the arrow stamped on the body of the valve. All valves can be mounted in whatever position except with the coil pointing downwards. Before connecting a valve to the electrical system, be sure that the line voltage and frequency correspond to the values marked on the coil.
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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:
Q = Kv
where: Kv = Kv factor of the valve [m3/h]; Q = capacity [m3/h]; p = pressure drop through the valve [bar]; = volumic mass of the liquid [kg/dm3]. AIR CAPACITY
Viscosity cSt 12 12 30 30 45
Table 2 provides the values of air capacity under the following conditions: temperature at valve inlet = 20 C; discharge pressure (absolute) = 1 bar; Kv of the valve under consideration = 1 m3/h. The pressures upstream the valve specified in the table are absolute values. EXAMPLE Select the valve suitable for use with approximately 200 m3/h of air, assuming an absolute pressure of 8 bars at valve inlet ( = 7 bars of relative pressure + 1 bar) and an acceptable pressure drop across the valve of 1,5 bars. In the column of pressures upstream the valve, the value 8 is shown; where this column intersects the horizontal column relating to the pressure drop of 1,5, the value of 87 m3/h is shown. This is the capacity value of a hypothetical valve with Kv = 1 working under the above mentioned conditions. 200 / 87 = 2,29 This is the Kv value required in the case under consideration. In Table 1, select the valve with the Kv value nearest to 2,29, rounding off the value and subsequently checking that all the characteristics of the selected valve (max. opening pressure differential, temperature, connections, etc.) are suitable.
When the viscosity of the liquid is expressed as dynamic viscosity, i.e. cP, where: 1cP = 10-3 N sec/m2 the corresponding value of cinematic viscosity in cSt is obtained by the following relation: = where: = cinematic viscosity [cSt]; = dynamic viscosity [cP]; = volumic mass of the fluid at the considered temperature [kg/dm3]. Moreover, the fluid viscosity may remarkably vary according to changes in temperature. Therefore, if the temperature of the fluid does not ensure viscosity values compatible with the correct operation of the valve, the valve may not open.
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SOLENOID VALVES
1,46 1,42 1,40 1,35 2,2 2,10 2,00 1,95 1,90 3,0 3,00 2,85 2,80 2,75 3,7 3,55 3,45 3,40 3,35 4,8 4,56 4,45 4,40 6,6 6,40 6,20 9,2 8,80
23,8 21,2 18,3 14,6 12,5 11,5 11,0 33,4 30,4 27,0 23,2 18,5 15,6 13,9 82,0 80,0 77,0 74,0 72,0 69,5 66,6 63,7 60,6 57,3 54,0 50,0 46,0 41,7 36,8 31,0 24,3 19,6 115,0 111,0 108,0 104,0 100,0 96,0 92,0 88,0 83,0 78,6 73,5 68,0 62,0 55,6 48,0 39,3 27,8 138,0 134,0 130,0 125,0 120,0 115,5 110,3 105,0 99,3 93,0 87,0 80,0 72,0 63,7 53,8 41,7 157,0 152,0 147,0 142,0 136,0 130,0 124,0 118,0 111,0 96,0 96,0 88,0 78,0 68,0 55,6 173,0 167,5 161,5 155,5 149,0 142,5 135,5 128,0 120,4 112,0 103,0 89,5 82,0 69,5 186,0 180,0 174,0 167,0 160,0 152,0 144,5 136,0 127,0 118,0 108,0 96,0 83,0 198,0 191,0 184,0 176,5 168,6 160,3 151,7 142,5 132,6 122,0 110,0 97,0 208,0 200,0 193,0 184,0 176,0 167,0 157,0 147,0 136,0 124,0 111,0 216,0 208,6 200,0 191,0 182,0 172,0 161,5 150,4 138,0 125,0 224,0 215,0 206,0 195,5 186,0 176,0 164,5 152,3 139,0 230,0 221,0 211,0 201,0 190,0 178,6 166,3 152,9 236,0 226,0 215,0 204,0 192,7 180,0 166,8 240,0 230,0 218,0 206,7 194,0 180,7 244,0 233,0 220,0 208,0 194,7 246,0 234,0 222,0 208,5 249,0 236,0 222,5 250,0 236,5 250,5
(1) The table provides air capacity values in m3/h under the following conditions: temperature at value inlet: + 20C pressure at outlet (absolute): 1 bar Kv of the solenoid valve: 1 m3/h
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1132/03 1132/04 1132/06 1132/08 1142/010 1142/012 1512/01 1522/02 1522/03 1522/04
86
70
47
75 50
45
101
81
52
88
57
136 69
103 57
82 34
168 44
104
104
71
59
36
51
50
370 355
With coils 9120 the dimension L2 is equal to 64 mm and the weight must be increased of 305 g.
L2
L2 L2
H2
H1 H2
H1 H2
H1
H3
1512/01 L1 L1
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.
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H3
H3
SAFETY DEVICES
55
with the atmosphere. For this reason, during relief, a gas leak occurs through this orifice. Utilized material: EN 12420-CW617N brass. Disc: obtained through bar machining and equipped with gasket, it ensures the required sealing degree on the valve seat. The gasket is made in P.T.F.E. (Polytetrafluorethylene), a material that, during valve estimated service life, maintains a good strength and does not cause the disc to stick on the seat. The disc is properly guided in the body and the guide action can never fail; there are no glands or retaining rings that hamper the movement thereof. Utilized material: EN 12164-CW614N brass. Spring: it opposes the pressure and the fluid dynamic actions and always ensures valve re-closing after pressure relief. The spring coils, when the disc has reached the lift corresponding to the state of relief at full flow rate, are spaced apart by at least half the wire diameter and, in any case, by not less than 2 mm. The disc is equipped with a mechanic lock and when it attains it, the spring set does not exceed 85% of the total set. Utilized material: DIN 17223-1 steel for springs. Setting system: hexagonal head, threaded ring nut to be screwed inside the body top by compressing the spring below. On setting completion, the position attained by the ring nut is maintained unchanged laying, in the threaded coupling, a bonding agent with high mechanic strength and low viscosity features to make penetration thereof easier. The setting system is protected against subsequent unauthorized interventions by means of a cap nut that is screwed outside the body and is sealed with lead to it.
Connections
Flow Diameter [mm] Flow Section [mm ] Lift [mm] Discharge Coefficient Kd PS [bar] TS [C] Set Pressure Range [bar] Overpressure Blowdown Risk Category according to PED
2
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SAFETY DEVICES
SCOPE Use: protection against possible overpressures of the apparatuses listed below, with regard to the operating conditions for which they have been designed: refrigerating system and heat pump components, for instance: condensers, liquid receivers, evaporators, liquid accumulators, positive displacement compressor discharge, heat exchangers, oil separators, piping (reference: EN 378-2: 2000); simple pressure vessels (reference: 87/404/ EEC Directive). Fluids: the valves can be used with: refrigerant fluids, in the physical state of gas or vapour, belonging to Group II according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27th, 1967); air and nitrogen (reference: 87/404/EEC Directive). MARKING In conformity with the provisions of Article 15 of 97/23/EC Directive, the EC marking and the identification number of the notified body involved in the production control phase are reported on the valve body. Still on the body, the following information is indicated: manufacturers mark, address and manufacture country; valve model; flow section; Kd discharge coefficient; indication of flow direction; max allowable pressure; allowable temperature range; set pressure; production date; serial number. VALVE SELECTION 97/23/EC Directive requires that pressure equipment, in which permissible limits are
reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance safety devices such as safety valves. Such devices shall prevent pressure from permanently exceeding the max allowable pressure PS of the equipment they protect. In any case, a short pressure peak limited to 10% of admissible maximum pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific sector or product standards. EN 378-2: 2000 Standard Refrigerating systems and heat pumps safety and environmental requirements Part 2: Design, construction, testing, marking and documentation, harmonized with 97/23/EC Directive, provides a general outline of the protection devices to be adopted in refrigerating systems and their features (par 7.4). It also indicates the criteria for the selection of the device suitable to the type and sizes of the system component to be protected (par. 7.4). EN 13136: 2001 Standard Refrigerating systems and heat pumps Pressure relief devices and their associated piping Methods for calculation highlights the possible causes of overpressure in a system and makes available to users the instruments for pressure relief device sizing, among which the safety valves.
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SIZING OF SAFETY VALVES DESIGNED TO DISCHARGE GAS OR VAPOUR AT CRITICAL FLOW (Ref. EN 13136: 2001) Critical flow occurs when the backpressure pb (the pressure existing immediately at the outlet of a safety valve) is below or equal to the critical pressure: for this calculation the value of k shall be as measured at 25 C. (Section 7.2.3, Standard EN 13136: 2001). Values of k and calculated values of C for some refrigerants are given in table A.1 of the aforesaid standard. Following we show the values of k and C for the more useful refrigerants.
2 k 1 pb p o k +1
[bar abs]
with: po = actual relieving pressure, upstream the safety valve; its equal to the set pressure plus overpressure. That is a pressure increase over set pressure at which the disc has its total lift. [bar abs]; k = isentropic exponent of gas or vapour, based on the actual flowing conditions at the safety valve inlet. If k is unknown or anyway difficult to establish its possible to suppose:
Refrigerant
p critical = 0, 5 po
[bar abs]
A safety valve, which discharges to atmosphere, works in critical flow. The safety valves designed to discharge gas or vapour at critical flow must be sized as follow:
Calculation of minimum required discharge capacity of safety valve is closely linked to the type of system where the valve is installed, with the causes that may arouse the opening of safety valve, i.e.: external heat sources. The minimum required discharge capacity shall be determined by the following:
Qmd =
Qmd vo A c = 3, 469 C 0, 9 K d po
[kg/h]
[mm2] with: = density of heat flow rate, its assumed to be 10 [kW/m2]; Asurf = external surface area of the vessel [m2]; hvap = heat of vaporization of liquid at po [kJ/kg]; internal heat sources. The minimum required discharge capacity shall be determined by the following:
with: Ac = minimum flow area of safety valve [mm2]; Qmd = minimum required discharge capacity, of refrigerant, of safety valve [kg/h]; Kd = certified coefficient of discharge; po = actual relieving pressure, upstream the safety valve, see definition above [bar abs]; vo = specific volume of gas or vapour at relieving conditions po e To meaning with To fluid temperature at valve inlet, settled by the user or by the designer [m3/kg]; C = function of isentropic coefficient k calculated from:
Qmd =
3600 Qh hvap
[kg/h]
with Qh = rate of heat production [kW]. Excessive pressure cased by compressors. The minimum required discharge capacity shall be determined by the following:
2 (k 1) C = 3, 948 k k +1
( k +1)
Qmd = 60 V n 10 v
[kg/h]
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with: V = theoretical displacement of compressor [m3] n = rotational frequency of compressor [min 1] 10 = vapour density at refrigerant saturation pressure / dew point at 10 C [kg/m3]
v = volumetric efficiency estimated at suction pressure and discharge pressure equivalent to the safety valve setting.
SAFETY DEVICES
EXAMPLE OF CALCULATION OF MINIMUM REQUIRED DISCHARGE CAPACITY Qmd AND SIZING OF THE SAFETY VALVE FOR THE HIGH PRESSURE SIDE OF A REFRIGERATING SYSTEM System description Compact refrigerating system designed to make refrigerated water and consisting of: open type reciprocating compressor; water-cooled, shell-and-tube horizontally condenser with lower section of shell used as receiver; shell-and-tube horizontally liquid cooler fed with a thermostatic valve; refrigerant fluid R407C. Compressor data Bore 82,5 mm Stroke 69,8 mm Cylinder number 6 Rotational frequency 1450 rpm Clearance 4% The theoretical displacement of compressor is: Working conditions of compressor corresponding to the relieving of safety valve: Condensing temperature: + 64 C (27,25 bar abs) Evaporating temperature: + 10 C (6,33 bar abs) These conditions, settled in any case by the designer, are considered the most unfavorable for the safety valve in consequence of functional defects as: move mistake; non-working of automatic safety devices, set to operate before safety valve. It shall be excluded: closeness the refrigerating system, the presence of flammable substances in so large quantities to be able to feed a fire.; inside the vessel, the presence of a heart source. Calculation of minimum discharge capacity Prudentially leaving the vapour overheating at the outlet of the liquid cooler out of account, the volumetric efficiency of compressor is:
V=
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
= 1 0, 04
27, 25 = 0, 83 6, 33
p0 = pset
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.
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A c = 3, 469 = 3, 469
Qmd v o = C 0, 9 K d po
with: C = 2,51, corresponding to isentropic exponent k for R407C equal to 1,14, according to table A1 of standard EN 13136:2001; Kd = 0,83, certified coefficient of discharge for safety valve 3030/88; vo = 0,0104 [m3/kg], specific volume of overheating vapour upstream the safety valve during relieving. This value is referred to the following operating conditions, upstream the safety valve: pressure po = 27,25 [bar abs]; temperature To = 100 [C] (precautionary temperature, settled in any case by the designer). Conclusion: the selected safety valve is the model 3030/88 with the following characteristics: certified coefficient of discharge, Kd = 0,83; flow section, Ac = 298 [mm2]; set pressure, pset = 25 bar. In case of single-screw compressor with injection of pressurized oil, the theoretical displacement is:
Vc =
D2 L 4
[m3]
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VALVE INSTALLATION As far as the installation of safety relief valves is concerned, the fundamental points listed below shall be taken into account: safety valves shall be installed near an area of the system where vapours or gases are present and there is no fluid turbulence; the position shall be as upright as possible, with the inlet connector turned downwards; vessels, joined together with piping rightly selected by the manufacturer and without any stop valve between them, may be considered as only one vessel for the installation of a safety valve; the union between the valve and the equipment to be protected shall be as short as possible. Furthermore, its passage section shall not be narrower than the valve inlet section. In any case, EN 13136: 2001 standard states that the pressure loss between protected vessel and safety valve, at discharge capacity, shall not exceed 3% of the setting value, including any accessory mounted on the upstream line; in selecting the safety valve location, it shall be taken into account that valve operation involves the discharge of the refrigerant fluid under pressure, sometimes even at high temperature. Where the risk exists to cause direct injuries to the persons nearby, an exhaust conveying piping shall be provided, which shall be sized in such a way as not to compromise valve operation. EN 13136: 2001 standard states that this piping shall not generate, at discharge capacity, a back pressure exceeding 10% of pressure po, for standard type valves, unbalanced. To calculate the pressure loss either in the upstream line (between vessel and safety valve) or in the downstream line (between safety valve and atmosphere) refer to EN 13136: 2001 standard, Chapter 7.4. Pressure loss in the upstream line Calculation of pressure loss is given by:
with: A = flow area of safety valve [mm2]; Ain = inside area of inlet tube to valve [mm2]; Kdr = Kd x 0,9, derated coefficient of discharge; C = function of isentropic coefficient k; = addition of pressure loss coefficients n of any component and piping; The coefficients n are relevant to: pipe elements loss, as connections and bends; valves loss; loss along the pipe and are listed in EN 13136:2001 standard, Table A.4. Example: assume to install, on the condenser of the previous example, a safety valve type 3030/88, set to 25 bar, using a steel union with the following characteristics: din = 28 [mm], inside diameter; Ain = 616 [mm2], inside area; L = 60 [mm], length; flush connection to the shell of condenser, with a broken edge. From table A.4 its possible to have these data: 1 (inlet) = 0,25 2 (length) = x L/ din = 0,02 x 60/28 = 0,043 with = 0,02 for steel tube T = 1 + 2 = 0,25 + 0,043 = 0,293 Between safety valve and union its installed a shut-off valve type 3033/88 (see page 46). The main characteristics of this valve are: dR = 20 [mm], inside diameter; AR = 314 [mm2], inside area; kv = 20 [m3/h], kv factor. Pressure loss coefficient R of shut-off valve is given by:
SAFETY DEVICES
A pin = 0, 032 C K dr po A in
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The obtained value is admissible because lower than the value of 0,03 forecast in EN 13136:2001. standard. Pressure loss in the downstream line Calculation of pressure loss is given by:
2 A 2 C K dr po 0, 064 A out = po 1
pout po
Example: assume to install a discharge pipe on safety valve type 3030/88 of the previous example, using a steel tube nominal size 2 with the following characteristics: dout = 53 [mm], inside diameter; Aout = 2206 [mm2], inside area; L = 3000 [mm], ength; pipe bend 90 with bending radius R equal to three times external diameter of tube. From table A.4 its possible to have these data: 1 (bend) = 0,25; 2 (length) = x L/ din = 0,02 x 3000/53 = 1,13 with = 0,02 for steel tube; T = 1 + 2 = 0,25 + 1,13 = 1,38. Pressure loss in the downstream line is:
2 298 2 2, 51 0, 747 27, 25 0, 064 1, 38 2206 = 27, 25 1
with: A = flow area of safety valve [mm2] Aout = inside area of outlet tube to valve [mm2] Kdr = Kd x 0,9, derated coefficient of discharge C = function of isentropic coefficient k = addition of pressure loss coefficients n of piping The coefficients n are relevant to: pipe elements loss, bends; loss along the pipe and are listed in EN 13136:2001 standard, Table A.4.
pout = 0, 075 po
The obtained value is admissible because lower than the value of 0,10 forecast in EN 13136:2001. standard.
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SAFETY DEVICES
GENERAL DESCRIPTION Valves series 3060 are safety devices according to the definition given in Article 1, Point 2.1.3, 2nd dash of 97/23/EC Directive and are the subject of Article 3, Point 1.4 of aforesaid Directive. The valves above mentioned are standard type, unbalanced, direct-loaded safety valves. Valve opening is produced by the thrust the fluid under pressure exerts on the disc, when said thrust exceeds, under setting conditions, the opposing force of the spring acting on the disc. Valves are identified by means of: a model number formed of an alphanumerical coding that includes: in the first part the family identification (e.g. 3060/45C); in the second part the setting pressure, expressed in bars, multiplied by 10 (e.g. 140); a progressive serial number. CONSTRUCTION Body: squared, obtained through die forging and subsequent machining. It houses the following elements: the nozzle with flat sealing seat; the disc guide; the setting spring holder; the threaded seat of the setting adjusting ring nut.
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Connections
Flow Diameter [mm] Flow Section [mm2] Discharge Coefficient Kd PS [bar] TS [C] Set Pressure Range [bar] Overpressure Risk Category according to PED
SCOPE Use: protection against possible overpressures of the apparatuses listed below, with regard to the operating conditions for which they have been designed: refrigerating system and heat pump components, for instance: condensers, liquid receivers, evaporators, liquid accumulators, positive displacement compressor discharge, heat exchangers, oil separators, piping. (reference: EN 378-2: 2000); simple pressure vessels (reference: 87/404/ EEC Directive). Fluids: the valves can be used with: refrigerant fluids, in the physical state of gas or vapour, belonging to Group II according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27th, 1967); Air and nitrogen (reference: 87/404/EEC Directive). MARKING In conformity with the provisions of Article 15 of 97/23/EC Directive the following information are reported on the valve body: manufacturers mark, address and manufacture country; indication of flow direction; max allowable pressure; set pressure;
allowable temperature range; production date; serial number. The following data are stamped on the cap: EC marking and the identification number of the notified body involved in the production control phase; valve model; flow section; Kd discharge coefficient. VALVE SELECTION 97/23/EC Directive requires that pressure equipment, in which permissible limits are reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance safety devices such as safety valves. Such devices shall prevent pressure from permanently exceeding the max allowable pressure PS of the equipment they protect. In any case, a short pressure peak limited to 10% of admissible maximum pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific sector or product standards. EN 378-2: 2000 Standard Refrigerating systems and heat pumps safety and environmental requirements Part 2: Design, construction, testing, marking and documentation, harmonized with 97/23/EC Directive, provides a general outline of the protection devices to be adopted in refrigerating systems and their features (par 7.4). It also indicates the criteria for the
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selection of the device suitable to the type and sizes of the system component to be protected (par. 7.4). EN 13136: 2001 Standard Refrigerating systems and heat pumps Pressure relief devices and their associated piping Methods for calculation highlights the possible causes of overpressure in a system and makes available to users the instruments for pressure relief device sizing, among which the safety valves. For sizing and installation of safety valves series 3060 see the previous chapter of safety valves series 3030.
3060
SAFETY DEVICES
H2 Ch H1 L
45 45 45 45 45 48 48
35 35 35 35 40,5 40 40
20 20 20 20 23 27 27
82 82 82 82 91 99,5 102,5
H3
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CONSTRUCTION Castel supplies to its customers the valves series 3033 and 3063 in open position and the ball spindle is protected by means of a cap screwed to the body and sealed with lead to it. Any closing intervention on the valve forcedly causes the tampering of the seal and then these interventions shall be performed exclusively by: staff authorized to work on the system; public servant of a Competent Body. These persons will be responsible for the next valve reopening and the new cap sealing with their own lead. The main parts of these valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; hot forged brass EN 12420 CW 617N, chromium plated, for ball; steel, with proper surface protection, for the spindle; P.T.F.E. for seat ball gaskets; chloroprene rubber (CR) for outlet seal gaskets; glass reinforced PBT for cap that covers the spindle.
SEAL
VALVE 3030/..
H3
H2 H1
D A L C
3063/44
10
1/2" NPT
78
58
35
82,5
162
350
3033/44
10
-50
+150
55
13
101
73
59
100
178
710
Art. 3.3
3033/88
3030/88C
20
20
1" NPT
107
77
72
123
323
1070
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The valves series 3032 can be used with the same fluids foreseen for safety valves series 3030 and 3060, in particularly: refrigerant fluids, in the physical state of gas or vapour, belonging to Group II according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27th, 1967); air and nitrogen (reference: 87/404/EEC Directive). CONSTRUCTION The valve 3032 is designed so that it is never possible to close off both ports at the same time, excluding all the two safety valves. Under working conditions, the shutter must be clamped against one of the two seats of the valve, front port or back port, in order to ensure always full discharge to the corresponding safety valve. Intermediate positions of the shutter are not
acceptable in order not to affect the operation of both safety valves. The valve ensures a pressure drop perfectly compatible with the safety valve operation under conditions of discharge of saturated vapour as well as overheated vapour. The main parts of these valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; chloroprene rubber (CR) for outlet seal gaskets; glass reinforced PBT for cap that covers the spindle.
SAFETY DEVICES
3032/44
3,3
13
1/2" 1/2" NPT NPT 3/4" 1/2" NPT NPT 3/4" 3/4" NPT NPT 1 1/4" 1
117
45
31
91
48
775
3032/64
17,5
95
52
48
133
80
3032/66
3030/66C
9,0
17,5
95
52
48
133
80
1750
3032/108 3030/88C
18
30
NPT NPT
123
74
66
185
110
3200
L3
B 3039/4
B L3
GASKET 3032/44 B H1
B A
CHIUSO-CLOSED
H1
H2
H2
D A L1 L1
D A L2
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3060
3035
Copper pipe
Ch. L
3035/2 3035/3
18 22 28 35 42
33 36,5 44 51 72
21 27 32 40 45
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FUSIBLE PLUGS
GENERAL DESCRIPTION Fusible plugs series 3080/.C and 3082/.C are safety devices according to the definition given in Article 1, Point 2.1.3, 2nd dash of 97/23/EC Directive and are the subject of Article 3, Point 1.4 of aforesaid Directive. According to the definition given in Point 3.6.4 of EN 378-1 : 2000 Standard, fusible plug is a device containing material that melts at a predetermined temperature and thereby relieving the pressure. Castel has resolved to classify fusible plugs series 3080/.C and 3082/.C in the Category of Risk I therefore fixing their use, as protection devices, on specific pressure equipments, proper to the same Category of Risk I, in compliance with Annex II, Point 2, of 97/23/EC Directive. In consequence of this choice, fusible plugs series 3080/.C and 3082/.C cannot be used, as sole protection devices, on pressure equipments proper to Categories of Risk higher than first. CONSTRUCTION The body of the fusible plug is an NPT plug drilled with a taper hole. A predetermined quantity of fusible alloy, with checked melting point, is poured inside this hole. The parts of the fusible plugs are made with the following materials: Brass EN 12164 CW 614N, hot tinned, for the plug. Eutectic alloy with several components, cadmium and lead free, for the fusible material. SCOPE Use: the fusible plugs are basically used to protect the components in a refrigerating system or heat pump against possible overpressures, with regard to the operating conditions for which they have been designed, in case of an excessive external heat source, such as fire. Fluids: the fusible plugs can be used with refrigerant fluids belonging to Group 2 according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27th, 1967). MARKING In conformity with the provisions of Article 15 of 97/23/EC Directive and of Point 7.3.3 of EN 378-2 : 2000 Standard the following data are reported on the hexagonal nut: EC marking; Manufacturer's logo; Max allowable pressure PS; Melting point. INSTALLATION If a fusible plug is mounted on a pressure vessel or any other part which it protect it shall be placed in a section where superheated refrigerant would not affect its correct function. Fusible plug shall not be covered by thermal insulation. Discharge from fusible plugs shall take place so that persons and property are not endangered by the released refrigerant. EN 378-2 : 2000 Standard, harmonized with the 97/23/EC Directive, establishes that a fusible plug shall not be used as the sole pressure relief device between a refrigerant containing component and the atmosphere for systems with a refrigerant charge larger than: 2,5 kg of group L1 refrigerant (ex. R22; R134a; R404A; R407C; R410A; R507). 1,5 kg of group L2 refrigerant. 1,0 kg of group L3 refrigerant. FUSIBLE PLUG SELECTION 97/23/EC Directive requires that pressure equipment, in which permissible limits are reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance safety devices such as fusible plugs. Such devices shall prevent pressure from permanently exceeding the max allowable pressure PS of the equipment they protect. In any case, a short pressure peak limited to 10% of admissible maximum pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific sector or product standards. EN 378-2 : 2000 Standard Refrigerating systems and heat pumps safety and environmental requirements Part 2: Design, construction, testing, marking and
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SAFETY DEVICES
documentation provides a general outline of the protection devices to be adopted in refrigerating systems and their features (par 7.4). It also indicates the criteria for the selection of the device suitable to the type and sizes of the system component to be protected (par. 7.4). EN 13136 : 2001 Standard Refrigerating systems and heat pumps Pressure relief devices and their associated piping Methods for calculation, harmonized with 97/23/EC Directive, highlights the possible causes of overpressure in a system and makes available to users the instruments for pressure relief device sizing, among which the fusible plugs. SIZING OF FUSIBLE PLUGS (REF. EN 13136 : 2001) As the fusible plugs discharge to atmosphere, they always work in critical flow (to know the definition of critical flow, see the chapter of safety valves series 3030). The fusible plugs must be sized as follow:
C = function of isentropic coefficient k (as measured at 25 C , see Section 7.2.3 , EN 13136 : 2001 Standard) calculated from:
C = 3, 948 k
( k+1) 2 ( k1)
k +1
To find the values of k and C for the more useful refrigerants, see the chapter of safety valves series 3030 Calculation of minimum required discharge capacity of fusible plug is closely linked to the main cause that may arouse the opening of fusible plug, which is the external heat sources. The minimum required discharge capacity shall be determined by the following:
Q md =
[kg/h]
Ac = 3, 469
Q md v o [mm2] C K dr po
with = density of heat flow rate, its assumed to be 10 [kW/m2] Asurf = external surface area of the vessel [m2] hvap = heat of vaporization of liquid at po [kJ/kg] EN 13136 : 2001 Standard also establishes that the following values for Kdr shall be the maximum used depending on how the pipe between the vessel and the fusible plug is mounted on the vessel: flush or flared connection: Kdr = 0,70 inserted connection: Kdr = 0,55
with: Ac = minimum flow area of fusible plug [mm2] Qmd = minimum required discharge capacity, of refrigerant, of fusible plug [kg/h] Kdr =derated coefficient of discharge of fusible plug, equal to 0,9 x Kd po = pressure upstream the fusible plug, inside the equipment to be protected [bar abs] vo = specific volume of gas or vapour at relieving conditions po e To , [m3/kg] (To is the fluid temperature at plug inlet, settled by the user or by the designer)
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SAFETY DEVICES
TABLE 8: General Characteristics, Dimensions and Weights of fusible plugs 3080 and 3082
Hexagonal Key Wrench Torque min/max [Nm] Risk Category Weight according to [g] PED
Catalogue Number
Kd
PS [bar]
17 22 17 22
10 / 15 14 / 20 21 / 30 10 / 15 14 / 20 21 / 30
23 39 76 23 39 76 I
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CHECK VALVES
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CHECK VALVES
APPLICATIONS The check valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). For heavy duty, about the operation temperature, for example installation on the discharge line close to the compressor, Castel has developed three new series of valves, types 3122, 3142 and 3182, equipped with special gasket for high temperature, between the body and its cover. MATERIALS The main parts of the valves are made with the following materials: hot forged brass EN 12420 CW 617N for body and cover; copper tube EN 12735-1 Cu-DHP for solder connections; austenitic stainless steel AISI 302 for the spring; chloroprene rubber (CR) for outlet seal gaskets. Metal-rubber laminated gaskets for the valves series 3122, 3142 and 3182; P.T.F.E. for seat gasket. INSTALLATION The valves can be installed in any section of a refrigerating system, where it is necessary to avoid an inversion of the refrigerating flow, in compliance with the limits and capacities indicated in table 3. Table 1 shows the following functional characteristics of a check valve: PS; TS; Kv factor; minimum opening pressure differential, that is the minimum pressure differential between inlet and outlet at which a check valve can open and stay opened. Before connecting the valve to the pipe it is advisable to make sure that the refrigerating system is clean. In fact the valves with P.T.F.E. gaskets are particularly sensitive to dirt and debris. Furthermore check that the flow direction in the pipe corresponds to the arrow stamped on the body of the valve. The allowed operating positions are: types 3122 and 3142 with horizontal axis and valve cover facing upward; types 3182 with inlet facing down and the valve cover facing upward; types 3110, 3130 and 3131, preferably with vertical axis and arrow upward. Sloping axis, up to horizontal position, are tolerable. The brazing of valves with solder connections should be carried out with care, using a low melting point filler material. Before starting to braze, its necessary to disassemble the valves series 3122, while this operation is not necessary with solder connection valves. In any case, its important to avoid direct contact between the torch flame and the valve body, which could be damaged and compromise the proper functioning of the valve.
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CHECK VALVES
3110/2 3110/3 3110/4 3110/5 3110/6 3122/M22 3122/7 3122/M28 3122/9 3122/11 3122/13 3122/M42 3122/17 3130/2 3130/3 3130/M10 3130/M12 3130/4 3130/5 3130/M18 3130/6 3130/7 3131/M10 3131/M12 3131/5 3131/7 3142/7 3142/M28 3142/9 3142/11 3142/13 3142/M42 3142/17 3142/21 3142/25 3182/7 3182/M28 3182/9 3182/11 3182/13 3182/M42 3182/17
40
+105
1,8
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3110/2 3110/3 3110/4 3110/5 3110/6 3122/M22 3122/7 3122/M28 3122/9 3122/11 3122/13 3122/M42 3122/17 3130/2 3130/3 3130/M10 3130/M12 3130/4 3130/5 3130/M18 3130/6 3130/7 3131/M10 3131/M12 3131/5 3131/7 3142/7 3142/M28 3142/9 3142/11 3142/13 3142/M42 3142/17 3142/21 3142/25 3182/7 3182/M28 3182/9 3182/11 3182/13 3182/M42 3182/17
84,5
28,5
100
60 1090
34 37 42,5
68 88 104
148
23
20
185
183
37
28
450
198 148 183 198 170 84,5 28,5 201 232 256 60 1320 23 20 185
37
28
450
101,5 125,5
34 37
68 88
1885 3315
142
42,5
285 329
104
151
95
130,5
100,5
60
177
109,5
150
116
68
221
123,5
195,5
143,5
104
76
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CHECK VALVES
H1
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77
111,2
118,8
123,7
78,5
125,7
14,3
17,8
17,7
14,9
23,8
56,1
77,2
76,7
66,0
85,8
30,3
32,4
33,7
21,4
34,3
3,9
4,9
4,8
4,1
6,5
15,3
21,1
20,9
18,0
23,4
Refrigerant flow capacity referred to the following operating conditions: Evaporating temperature: + 4 C Condensing temperature: + 38 C Pressure drop: 0,15 bar
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APPLICATIONS The water regulating valve, employed with condenser fed with either main or well water, keeps the condensation pressure constant at the previously set value by adjusting the water flow so as to ensure a balanced heat exchange under all conditions. At plant start-up, this adjustment is designed to allow the thermostatic valve to rapidly reach normal operating conditions and subsequently, during operations, to avoid excessive pressure increases or decreases under different flow conditions. An excessive rise of high pressure affects the refrigerating capacity of the system. On the other side, pressure lowering leads to insufficient refrigerant feeding of the evaporator with a consequent increased gas overheating and parallel reduction of gas pressure at compressor suction. Castel valves are appropriate for refrigerant fluids CFC, HCFC and HFC and only for main and well water.
1/4"
A
CAT.
RANGE 5-18 bar MAX WATER PRESS. 10 bar MAX WATER TEMP. 80 |BC MEDIUM R134a-R404A-R12-R22-R502
B C
48 Ch
A02
L 87 1/4"Flare
80
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MADE IN ITALY
Ch
Weight [g]
27 32
70 74
MATERIALS The materials used for the main parts are: hot-forged brass EN 12420-CW617N for main body; austenitic stainless steel AISI 303 for the seat; nitril rubber (NBR) for seat gasket; NBR coated-fabric for diaphragms. INSTALLATION The valve will be mounted on the water outlet side of the condenser, preferably vertically, with the bellows downward. The high pressure connection to the bellow must show no deflection. The arrow on the valve body shows water flow direction. EXAMPLE OF VALVE SELECTION A refrigerating system including a hermetic compressor and a condenser fed with mains water. Mains water pressure: 3 bar Water temperature at the condenser inlet: 14 C.
Expected thermal difference: Dt = 10 C. Condensation temperature expected on the basis of the water/refrigerant heat exchange in the condenser: approximately 6 C above the water temperature at the outlet, equivalent to 30 C (with a corresponding saturation pressure) (fig. 1). Refrigeration yield at the level of the evaporator: 18,6 kW under the following operating conditions, condensation temperature: + 30 C; evaporation temperature: 15 C. Thermal power to be disposed of at the level of the condenser (Table 2): 18,6 x 1,325 = 24,65 [kW] Water flow rate: 24,65 x 860 = 2120 l/h = 2,12 [m3/h] 10
Condensing Temperature
Water
Te m p e
rature
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The pressure drop corresponding to the water flow rate specified above in the condenser/piping circuit, with the exclusion of the water regulating valve, is about 2.5 bar. The water regulating valve has this pressure differential at its disposal: p = 3 2,5 = 0,5 bar At p = 0,5 bar the 3210/04 valve, completly opened, ensures the required flow rate (fig. 2).
When the point of intersection of pressure differential through the valve and flow range is within the area between the curves of two valves, select the valve with larger diameter. When the valve is completely closed, the pressure must be the same as the refrigerant saturation pressure at the air temperature of the place where the condenser is installed. When the valve begins to open, the pressure is about 0.2 bar above the pressure when the valve is totally closed.
Q [m /h]
7 6,5 6 5,5 5 4,5 4 3,5 3 2,5 2 1,5 1 0,5 0 0,375 0,625 0,875 2,375 2,625 26 27 1,375 1,625 1,875 0,25 0,75 2,25 0,125 1,125 2,125 2,75 28 1,25 1,75 0,5 2,5 25 1,5 0 1 2 3210/03 3210/04 3210/06
p [bar]
11 20 22 23 24 0 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 21
p [H2O]
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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
TABLE 3 - Thermal factor for open compressors (direct or belt driven). Relationship between the total heat to be disposed of at the level of the condenser and refrigeration capacity at the level of the evaporator
Evaporating Temperature [C] Condensing Temperature [C]
35
30
25
20
15
10
+5
+10
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83
85
<60 60 >60
<75 75 >75
<30 30 >30
<30 30 >30
<30 30 >30
<30 30 >30
CONSTRUCTION Castel liquid indicators and liquid/moisture indicators are manufactured with the glass lens which has been fused onto the metallic ring. This construction permits the total elimination of sealing gasket between the glass disc and the metallic structure with the consequent elimination of possible refrigerant leaks. The main parts of the indicators are made with the following materials: hot forged brass EN 12420 CW 617N for body; copper tube EN 12735-1 Cu-DHP for solder connections; steel, with proper surface protection, for the ring; chloroprene rubber (CR) for outlet seal gaskets; elastomer polyester for cap that covers the ring.
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3640/M18 3740/M18 3640/6 3640/7 3640/9 3650/22 3650/33 3650/44 3650/55 3650/66 3740/6 3740/7 3740/9 3750/22 3750/33 3750/44 3750/55 3750/66 3770/M28 3770/11 3770/13 3770/M42 soldering 3771/11 3771/M42 3771/17 3780/5 3780/M18 3780/7 3780/9 3780/11 3781/M28 level glass
28
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INSTALLATION At the start-up the color of the sensitive element may be yellow, due to exposure to air humidity and to moisture in the circuit. When the moisture of the refrigerant is brought back to acceptable levels with the dehydrator, the indicator color is once again green. This is evidence that equilibrium has been re-stablished. In case of persisting yellow, measures have to be taken to eliminate moisture. Only when the sensitive element comes back to green, there is evidence that adopted measures were effective. About 12 hours of system operation are required to achieve equilibrium. However, the moisture
indication is given normally when the plant is in function and the fluid is flowing The brazing of indicators with solder connections should be carried out with care, using a low melting point filler material. Before starting to braze, its necessary to disassemble the ring of indicators series 3620, 3720, 3780 and 3781, while this operation is not necessary with solder connection indicators. In any case, avoid direct contact between the torch flame and the indicator body or ring, which could be damaged and compromise the proper functioning of the indicator.
34,5 Ch H1
34.5 Ch H1 H
H H1
34,5
L
3640 3740
34,5 34,5 Ch 32 Ch H2 H H1 Ch 32
34,5
L 3650 3750
L 3770 3771
34,5
tubo
28 3780 3781
88
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H1
Liquid Indicators 3610/22 3610/33 3610/44 3610/55 3610/66 3620/M12 3620/5 3620/M18 3620/M22 3640/2 3640/3 3640/M10 3640/M12 3640/4 3640/5 3640/M18 3640/6 3640/7 3640/9 3650/22 3650/33 3650/44 3650/55 3650/66
12 17 22 24 28
49
110 110
61 133
200
210 215
295 580 165 205 235 300 525 250 300 480 300 480 550
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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.
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ANTI-ACID SOLID CORE FILTER DRIERS WITH MOLECULAR SIEVES AND ACTIVATED ALUMINA SERIES 42
Approved by Underwriters Laboratories Inc.
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.
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The blocks in the filters series 43 are molded from a blend of dehydrating charge, totally made of 3 molecular sieves, and a special binding agent in appropriate proportions. The choice of the 3 molecular sieves, as sole dehydrating material, gives to the block a superlative capacity of water adsorption also maintaining quite good deacidifying characteristics. The manufacturing process gives a considerable compacted ness and stoutness to both the products so that they are resistant to shocks and abrasions. The shape of the block is designed in order to offer the maximum possible surface area to the incoming fluid. The internal cavity is also positioned in such a way as to have a uniform wall thickness. As a result, the fluid encounters a constant strength at all points, flows linearly through the block, and ensures efficient dehydration and minimum charge loss. The block is chemically inert, not deliquescent, does not react with refrigerating fluids, and is capable of blocking oil by-products dragged into the circuit. Impurities accumulate in the ring between the metal shell and the block; this prevents filter clogging.
EXAMPLE OF SELECTION System data: Refrigerant: R407C Condensing temperature: + 50 [C] Weight of refrigerant: 34 [kg] According to DIN 8949:2000, the adsorption capacity of the drier is given by: (1.050 50) x 34 / 1.000 = 34 g of H2O where: 1.050 ppm. = moisture in the refrigerant entering the filter according to DIN 8949:2000 50 ppm. = moisture in the refrigerant flowing out the filter according to DIN 8949:2000 Comparing the absorption capacity required with the values shown in table 2, drier mod.4032 should be selected, with a water absorption capacity of 47,5 g at 50 C. If the dehydrating capacity of products is expressed in water drops, it must be remembered that: 1g H2O = 20 water drops In this case and when a molecular sieve drier is selected, the following result is obtained: 34 x 20 = 680 water drops. If moisture exceeds the values specified in DIN 8949:2000, a drier with a higher adsorption capacity shall be selected.
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flow direction
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032 032S 033 052 052S 053 053S 082 082S 083 083S 084 084S 162 163 163S 164 164S 165 165S 303 303S 304 304S 305 305S 304 304S 305 305S 415 415S 416 416S 417S 754S 755S 756S 757S 759S 660 1340 330 670 255 500 310 500 155 250 103 130 70 80 47 50
1/4" 1/4" 3/8" 1/4" 1/4" 3/8" 1/4" 1/4" 3/8" 3/8" 1/2" 1/4" 3/8" 3/8" 1/2" 5/8" 3/8" 1/2" 5/8" 1/2" 5/8" 5/8" 3/4"
(1) 100% molecular sieves; (2) Male-female connections (Inlet female) (3) PS = 400 psig in compliance with the UL approval
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032 032S 033 052 052S 053 053S 082 082S 083 083S 084 084S 162 163 163S 164 164S 165 165S 303 303S 304 304S 305 305S 304 304S 305 305S 415 415S 416 416S 417S 754S 755S 756S 757S 759S 660 1340 330 670 255 500 310 500 155 250 103 130 70 80 47 50
1/4" 3/8" 1/4" 3/8" 1/4" 3/8" 1/2" 1/4" 3/8" 1/2" 5/8" 3/8" 1/2" 5/8" 1/2" 5/8" 5/8" 3/4"
(1) 80% molecular sieves + 20% activated alumina (2) PS = 400 psig in compliance with the UL approval
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Catalogue Number
4303/2 4303/2F 4303/2S 4303/3 4305/2 4305/2F 4305/2S 4305/3 4305/3S 4305/M10S 4308/2 4308/2F 4308/2S 4308/3 4308/3F 4308/3S 4308/M10S 4308/M12S 4308/4 4308/4S 4316/2 4316/3 4316/3F 4316/3S 4316/M10S 4316/M12S 4316/4 4316/4S 4316/5 4316/5S 4330/3 4330/3S 4330/4 4330/4S 4330/5 4330/5S 4332/4 4332/4S 4332/5 4332/5S 4341/5 4341/5S 4341/6 4341/6S 4341/7S 4375/4S 4375/5S 4375/6S 4375/7S 4375/9S
6,5 8,0
7,0 8,6
4,6 5,6
6,9 8,5
7,0 8,6 4,1 3,8 4,2 3,4 3,7 4,4 4,0 4,5 3,6 3,9 3,5 3,0 3,9 2,7 2,9 3,8 4,2
14,9 16,1 10,5 16,0 16,2 6,7 8,2 7,2 8,9 4,7 5,8 7,1 8,8 7,2 9,0
15,4 16,6 10,8 16,5 16,7 19,4 21,0 13,7 20,8 21,2
7,3
6,7
7,4
6,0
6,5
7,8
7,2
8,0
6,4
7,0
6,3
5,3
6,9
4,8
5,2
6,8
7,4
6,9 8,5
7,5 9,2
4,9 6,0
7,4 9,1
7,5 9,3
18,0 19,5 12,7 19,3 19,6 12,7 11,6 13,0 10,4 11,3 13,7 12,5 13,9 11,2 12,2 10,9 9,3 12,0 8,4 22,8 24,7 16,1 24,5 24,8 29,0 31,3 20,4 31,0 31,4 24,0 25,9 16,9 25,7 26,0 29,0 31,3 20,4 31,0 31,4 6,9 7,5 4,9 7,4 7,5 9,1 11,8 10,0 13,0 9,0
24,6 26,6 17,3 26,4 26,7 34,1 36,9 24,0 36,6 37,0 28,2 30,5 19,9 30,3 30,6 34,1 36,9 24,0 36,6 37,0 37,6 40,6 26,4 40,3 40,8 45,0 48,7 31,7 48,3 48,9 21,7 23,4 15,3 23,2 23,5 27,1 29,3 19,0 29,0 29,4 30,9 33,4 21,8 33,2 33,5 37,3 40,4 26,3 40,0 40,5 38,8 41,9 27,3 41,6 41,9 46,6 50,4 32,8 50,0 50,6 33,6 36,3 23,6 36,0 36,4 40,5 43,8 28,5 43,4 44,0 39,9 43,1 28,1 42,8 43,0 48,2 52,1 33,9 51,7 52,3 40,9 44,2 28,8 43,8 44,4 49,5 53,5 34,8 53,1 53,7 67,2 72,6 47,3 72,0 73,0 74,2 80,2 52,2 79,6 80,5 53,4 57,7 37,5 57,3 57,9 54,5 58,9 38,3 58,4 59,1 80,6 87,1 56,8 86,4 87,6 122,8 112,2 125,6 100,6 109,4 132,0 120,6 135,1 108,2 117,6 106,0 90,0 116,6 81,0 88,2 114,0 96,8 125,4 87,1 94,8 92,8 100,3 65,3 99,5 100,6 96,5 104,3 67,9 103,5 104,7 61,4 56,1 62,8 50,3 54,7 66,0 60,3 67,5 54,1 58,8 53,0 45,0 58,3 40,5 44,1 57,0 48,4 62,7 43,5 47,4 45,4 41,4 46,4 37,2 40,5 48,8 44,5 49,9 40,0 43,5 39,1 33,2 43,1 29,9 32,6 42,0 35,7 46,3 32,2 35,1 50,2 45,8 51,2 41,0 44,6 54,0 49,2 55,1 44,1 48,0 43,2 36,8 47,6 33,0 36,0 46,5 39,6 51,2 35,5 38,7 25,1 22,9 25,6 20,5 22,3 27,0 24,6 27,5 22,0 24,0 21,6 18,4 23,8 16,5 18,0 23,2 19,8 25,6 17,7 19,4
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97
Catalogue Number
4203/2 4203/2S 4203/3 4205/2 4205/2S 4205/3 4205/3S 4208/2 4208/2S 4208/3 4208/3S 4208/4 4208/4S 4216/2 4216/3 4216/3S 4216/4 4216/4S 4216/5 4216/5S 4230/3 4230/3S 4230/4 4230/4S 4230/5 4230/5S 4232/4 4232/4S 4232/5 4232/5S 4241/5 4241/5S 4241/6 4241/6S 4241/7S 4275/4S 4275/5S 4275/6S 4275/7S 4275/9S
6,5 8,0
7,0 8,6
4,6 5,6
6,9 8,5
7,0 8,6 3,5 3,2 3,6 2,9 3,1 3,8 3,4 3,9 3,1 3,4 3,0 2,6 3,3 2,3 2,5 3,3 3,6
14,9 16,1 10,5 16,0 16,2 6,7 8,2 7,2 8,9 4,7 5,8 7,1 8,8 7,2 9,0 6,2 5,7 6,3 5,1 5,5 6,7 6,1 6,8 5,5 6,0 5,4 4,5 5,9 4,1 4,5 5,8 6,3
15,4 16,6 10,8 16,5 16,7 19,4 21,0 13,7 20,8 21,2 6,9 8,5 7,5 9,2 4,9 6,0 7,4 9,1 7,5 9,3
18,0 19,5 12,7 19,3 19,6 22,8 24,7 16,1 24,5 24,8 24,0 25,9 16,9 25,7 26,0 29,0 31,3 20,4 31,0 31,4 6,9 7,5 4,9 7,4 7,5
19,7 21,3 13,9 21,1 21,4 24,6 26,6 17,3 26,4 26,7 28,2 30,5 19,9 30,3 30,6 21,3 19,5 21,8 17,4 19,0 22,9 20,9 23,4 18,7 20,4 18,4 15,6 20,2 14,0 15,3 19,7 16,8 21,8 15,1 16,5 34,1 36,9 24,0 36,6 37,0 37,6 40,6 26,4 40,3 40,8 45,0 48,7 31,7 48,3 48,9 21,7 23,4 15,3 23,2 23,5 27,1 29,3 19,0 29,0 29,4 30,9 33,4 21,8 33,2 33,5 37,3 40,4 26,3 40,0 40,5 38,8 41,9 27,3 41,6 41,9 46,6 50,4 32,8 50,0 50,6 33,6 36,3 23,6 36,0 36,4 40,5 43,8 28,5 43,4 44,0 39,9 43,1 28,1 42,8 43,0 48,2 52,1 33,9 51,7 52,3 40,9 44,2 28,8 43,8 44,4 49,5 53,5 34,8 53,1 53,7 67,2 72,6 47,3 72,0 73,0 74,2 80,2 52,2 79,6 80,5 53,4 57,7 37,5 57,3 57,9 54,5 58,9 38,3 58,4 59,1 80,6 87,1 56,8 86,4 87,6 104,4 95,4 106,8 85,5 93,0 112,2 102,5 114,8 91,9 100,0 90,1 76,5 99,1 68,9 75,0 96,9 82,3 106,6 74,0 80,6 92,8 100,3 65,3 99,5 100,6 96,5 104,3 67,9 103,5 104,7 52,2 47,7 53,4 42,8 46,5 56,1 51,3 57,4 46,0 50,0 45,1 38,3 49,6 34,4 37,5 48,4 41,1 53,3 37,0 40,3 38,6 35,2 39,4 31,6 34,4 41,5 37,8 42,4 34,0 37,0 33,2 28,2 36,6 25,4 27,7 35,7 30,3 39,4 27,3 29,8 42,7 38,9 43,5 34,9 37,9 45,9 41,9 46,8 37,5 40,8 36,7 31,3 40,5 28,1 30,6 39,5 33,6 43,5 30,2 32,9
(1) Maximum values of the refrigerant flow capacity at which the drier can be used when fluid dehydration is not the a major problem, provided that the original moisture is limited before the installation of the drier. The maximum refrigerant flow capacities are referred to a total pressure drop of 0,07 bar, inlet and outlet connections included, (according to ARI STANDARD 710:86 - with condensing temperature at +30 C and evaporating temperature at -15 C) (2) Water capacity values with R22 are referred to the following conditions, fixed in ARI STANDARD 710:86: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 60 ppm Water capacity values with the other refrigerant fluids are referred to the following conditions, fixed in DIN 8949:2000 Standard: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 50 ppm
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Weight [g]
4303/2 4303/2F 4303/2S 4303/3 4305/2 4305/2F 4305/2S 4305/3 4305/3S 4305/M10S 4308/2 4308/2F 4308/2S 4308/3 4308/3F 4308/3S 4308/M10S 4308/M12S 4308/4 4308/4S 4316/2 4316/3 4316/3F 4316/3S 4316/M10S 4316/M12S 4316/4 4316/4S 4316/5 4316/5S 4330/3 4330/3S 4330/4 4330/4S 4330/5 4330/5S 4332/4 4332/4S 4332/5 4332/5S 4341/5 4341/5S 4341/6 4341/6S 4341/7S 4375/4S 4375/5S 4375/6S 4375/7S 4375/9S
4203/2 4203/2S 4203/3 4205/2 4205/2S 4205/3 4205/3S 4208/2 4208/2S 4208/3 4208/3S 4208/4 4208/4S 4216/2 4216/3 4216/3S 4216/4 4216/4S 4216/5 4216/5S 4230/3 4230/3S 4230/4 4230/4S 4230/5 4230/5S 4232/4 4232/4S 4232/5 4232/5S 4241/5 4241/5S 4241/6 4241/6S 4241/7S 4275/4S 4275/5S 4275/6S 4275/7S 4275/9S
380 345 395 380 345 380 430 380 635 690 680 620 630 640 680 640 740 640 1380 1240 1360 1280 1480 1370 1300 1200 1320 1250 1580 1470 1640 1560 1600 2540 2640 2820 2900 3050
220
D male connections
D solder connections
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99
100
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Catalogue Number
Number of Cores
40
+80
The manufacturing process of blocks series 4490 and 4491 gives a considerable compacted ness and stoutness to both the products so that they are resistant to shocks and abrasions. The blocks series 4490 have a volume of 48 cu.in., equivalent to approx. 800 cm3, and it is used with type 4411, 4412, 4413 and 4414 filters. The block series 4491 has a volume of 100 cu.in., equivalent to approx. 1600 cm3. and it is used with type 4421, 4423 and 4424 filters. The two blocks are shaped as a hollow cylinder and their overall dimensions correspond to those of other international brands. Consequently they are interchangeable. The hollow cylinder shape offers a large surface area to the inflowing fluid, which crosses the block in radial sense. As a result, dehydration is highly efficient with a minimum loss of charge. Filters may be supplied also with an access fitting kit G9150/R05, to be ordered separately.
5 3 4
inlet
outlet
Sketch of filter with 2 blocks 1 Block 2 Mesh sieve serving as block support 3 Spring 4 Retainer cup 5 Access fitting 1/4 SAE flare (to order separately)
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Catalogue Number
4411/5A 4411/7A 4411/9A 4411/11A 4411/13A 4411/M42A 4411/17A 4412/7A 4412/9A 4412/11A 4412/M42A 4412/17A 4413/11A 4413/13A 4413/M42A 4414/13A 4414/M42A 4414/17A 4423/17A 4423/21A 4423/25A 4424/25A 4424/33A
83
90
59
89
90
146 158 103 156 159 200 216 141 214 217 233 252 164 250 253 84 77 86 69 75 90 83 92 74 81 72 61 80 56 60 77 86
146 158 103 156 159 226 244 159 242 245 306 331 215 328 332 168 154 172 138 150 181 166 185 148 161 144 122 160 112 120 155 131 172 120 129 333 361 234 357 362 327 354 230 351 355 361 391 254 387 393 252 231 258 207 225 271 248 277 223 242 216 183 240 168 180 232 197 258 181 194
426 460 300 456 462 336 308 344 276 300 361 331 370 297 323 288 244 320 224 240 310 262 344 241 258
447 483 315 479 485 492 532 346 527 534 504 462 516 414 450 542 497 555 445 484 432 366 480 336 360 465 394 516 361 387 670 725 472 719 728 737 797 519 791 800 1180 1276 830 1265 1281 672 616 688 552 600 723 662 740 594 645 576 488 640 448 480 619 525 688 482 516
TABLE 2B: Refrigerant Flow Capacity and Water Capacity (single block)
Refrigerant Flow Capacity, pressure drop 0,07 bar (1) [kW] R407C R404A R410A R134a R134a R22 Water Capacity at + 25 C (2) [g H2O] R407C R404A R410A R134a R22 Dehydratable Charge at + 25 C [kg refrigerant] R407C R404A R410A R134a R22 Water Capacity at + 50 C (2) [g H2O] R407C R404A R410A R134a R22 Dehydratable Charge at + 50 C [kg refrigerant] R404A 86 12 73
Catalogue Number
84
77
86
69
75
90
83
92
74
81
72
61
80
56
60
77
168 154 172 138 150 181 166 185 148 161 144 122 160 112 120 155 131 71 65 73 59 64 77 70 79 63 69 61 52 68 48 95 51 66 56
120 129
(3)
143 131 146 117 128 154 141 157 126 137 122 104 136
(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
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Weight [g]
600
H3 20
H2 H1
D2
D1
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103
BLOCKS REPLACEMENT
Blocks must be ordered separately from the filter. They are supplied in individual packages, which are hermetically sealed in suitable wrappings (type 4490), and in special bags (type 4491) for safe storage over long periods of time. Every cartridge is equipped of two seals in synthetic material to use like seal between the two cartridges and between the cartridge and its covers. If the filter is installed in a system without any by-pass, the block replacement has to be done following these instructions: 1 Close the valve on the departing line. 2 Start the compressor and its auxiliaries in order to transfer the refrigerant charge into the high pressure side of the plant (liquid receiver). 3 Stop the compressor at a suction pressure sufficiently higher than the atmospheric pressure. 4 Shutt off the service valve at the suction side of the compressor. NOTE: if during the transfer of the refrigerant to the high-pressure side of the plant, the discharge pressures reach too high values (the condenser is flooded due to insufficient capacity of the liquid receiver), shut off the valve on the compressor suction side and stop immediately the compressor. 5 Replace quickly the filter block. During the preparation of the new block, close the filter with a clean cloth. The slight over-pressure inside the filter and the ability of the technician will prevent air from getting into the plant. 6 The internal cleanliness of the body is guaranteed by the cleaning effect of the cup which is characteristic of Castel filters. if air is supposed to have entered the plant during filter block replacement, produce a vacuum in the low-pressure side of the plant, and always in the sector of the circuit involved. 7 Open the valve on the departure of liquid line 8 Slowly open the suction valve of the compressor and start the compressor and its auxiliaries. 9 Top the charge up, if necessary.
D1 D2 4490
Catalogue Number
Weight [g] H
[cu.in] 4490/A 4490/B (1) 4490/AA 4490/AB (1) 4491/A 4491/AA 630 100 420 48
[cm3]
D1
D2
800
47
96
140
670
D1
1600 53 122 165 1350
D2 4491
104
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20
0, 21
Remember that the dimensioning of the suction line in a refrigerating system requires great attention. In fact the relative pressure loss, included filter, which implies a reduction of flow capacity sucked by the compressor, influences directly the refrigerating capacity of the plant. This line is normally sized to have a total pressure loss lower then a variation of the saturation temperature of 1 C. For example diagram 1, referred to R22, allows to estimate the aforesaid variation in function of pressure loss and evaporating temperature.
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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.
3 2
inlet
outlet
Sketch of filter with mechanical block 1 Block 2 Retainer cup 3 Spring
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DIAGRAM 1
6 5
-45
-40
ra tu re
te m
pe
2 1 0 0 5
ev ap
10
or at io
15
20
25
30
35
DIAGRAM 2
1,5
0,5
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107
Refrigerant flow capacities and pressure drops are referred to the following working conditions: Liquid temperature ahead expansion valve: + 35 C Overheating of suction gas: 6 C
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Weight [g]
D1
D2
D2
D1
P
Weight [g]
Catalogue Number
[sq.in]
[cm2]
D1
D2
4495/C
127
820
60
87
138
480
4496/C
287
1850
80
113
168
750
H1
H2
4495 - 4496
20
H3
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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.
58 142
58
Catalogue Number
Weight [g] L
D D 4510 4520
DESSICCANTS
For using on refrigerating systems, Castel puts the following desiccants at disposal of its own customers: Activated alumina Code No 4901/AA Molecular sieve Code No 4901/MS Silicagel Code No 4901/SG hermetically sealed in steel cans with a weight of about 0,750 kg and supplied in multiply package of 15 cans.
110
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OIL SEPARATORS
111
OIL SEPARATORS
APPLICATIONS The oil separators, shown in this chapter, are classified Pressure vessels in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.1 and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). The advantages of the oil separator on the discharge line of a compressor in a refrigeration system are confirmed by many years of experience. The oil separator intercepts the oil mixed with compressed gas and returns it to the crankcase of the compressor thus assuring an efficient lubrication of its moving parts. Furthermore, the oil separator maintains a high coefficient of condenser and evaporator performance by almost completely removing oil deposits from their exchange surfaces. When a very high temperature at the end of the compression stage leads to the formation of oil vapours, a separator with a capacity exceeding the values shown in the table should be used. Moreover, the oil separator, damping the valves pulsations, reduces system noise with an open or semi-hermetic compressor. Finally, the use of an oil separator leads to: a longer life of the compressor; a better performance of the whole system with consequent energy saving; a quieter operation by reducing pulsations. Table 1 and 3 show the technical data relating to the working conditions of oil separators. CONSTRUCTION Castel manufactures two types of oil separators: separators series 5520 can be overhauled for maintenance and can be replaced from the system. They are equipped with threaded connections, which can mate to the connections type 5590 (to be ordered separately) separators series 5540 are closed type and they cannot be dismantled from the system, except cutting the piping. The body is manufactured from steel pipe of adequate thickness. Flanges and cover are also made of steel. Either threaded connections of separators series 5520 or solder connections of separators series 5540 are manufactured, machining, with steel bar EN 10277-3 11S Mn Pb 37 + C. The internal device is simple in order to assure a trouble-free long operation. Appropriate metallic screens, placed on the inlet and outlet, rapidly reduce gas speed, and create the conditions required for the separation of the oil from the refrigerant. A float operated needle valve, set on the bottom of the vessel, return the oil to the crankcase of compressor. The bottom also includes a chamber that collects all metallic debris. A permanent magnet holds these impurities to avoid they stop or damage the operation of needle, moved by floating.
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SELECTING THE SIZE OF AN OIL SEPARATOR The selecting of an oil separator should be done comparing the characteristics of the installed compressor, establishing: inlet connection must agree with the discharge diameter of the compressor refrigerant flow capacity with fixed working conditions (saturated discharge temperature saturated suction temperature, eventually liquid subcooling, sucked vapour overheating). This is necessary to define the gas speed referred to the cross section of oil separator, assigned an end compression temperature. It is advisable the above-mentioned speed doesnt exceed 0,5 m/s, to avoid great swirl phenomena. Table 3 has being written following this principle. Generally, fixed the following data: refrigerating capacity of compressor, type of refrigerant and working conditions, the volumetric capacity Q, of compressed gas, is given by:
Check of gas speed, referred to the cross section of oil separator, is given by:
OIL SEPARATORS
v = QS
[m/s]
with:
S = gross cross section of shell separator [m2] INSTALLATION The oil separators type 5520 and 5540 should be installed in the discharge line between the compressor and the condenser mounted securely in a vertical position and reasonably close to the compressor. To prevent the return of refrigerant from condenser, during the off cycle of the system, its advisable to install a check valve between the condenser and oil separator outlet connection. Oil separator performs best when operating at or near the compressor discharge temperature. In location the oil separator, choose a position to avoid, as far as possible, chilling of the shell, which may result in condensing of liquid within the separator. If this is not possible, it is advisable to supply the separator with the better solutions (insulation, strap heater, others) to prevent the refrigerant in the system from condensing in the shell. Before the oil separator is installed, either one 5520 or one 5540, an initial charge of oil should be added to it. Refer to general characteristics of oil separators or to instruction sheet for the proper amount of oil. Oil pre-charge is very important, failure to pre-charge separator sump may result in damage to the oil return float mechanism. Use the same type of oil that is in the compressor crankcase. Acting as the lay out of refrigerating system, the return line may be run from the oil fitting to: the compressor crankcase; the suction line upstream the compressor or upstream the receiver, if present; the oil reservoir if oil control system is being used. A sight glass may be installed in the oil line, in a position that oil is flowing through the tube, to check the correct working of the oil separator.
Q=
P vg H
[m3/s]
with:
P = refrigerant flow capacity kW] H = heat content differential, see diagram (fig. 1). [kJ/kg] vg = specific volume of compressed gas, separator inlet (fig. 1). [m3/kg].
Fig. 1
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113
IN IN OUT
OUT
steel plate
steel plate
permanent magnet
permanent magnet
5540
TABLE 1: General Characteristics
Solder Connections Catalogue Number [in.] 5540/4 5540/5 5540/7 5540/9 5540/11 5540/13 5540/M42 5540/17 5520/C 1/2" 5/8" 7/8" 1.1/8" 1.3/8" 1.5/8" 2.1/8" ODS [mm] 16 35 42 54 [in.] 5/8" 3/4" 1" 1.3/8" 1.5/8" ODM [mm] 16 35 5590/5 5590/7 5590/9 5590/11 5590/13 5590/M42 5/8" 7/8" 1.1/8" 1.3/8" 1.5/8" 16 35 42 1/4" 0,4 / 0,5 3/8" 0,6 / 0,7 21 1/4" 0,4 / 0,5 Catalogue Number Couple of solder connections IN / OUT ODS (1) [in.] [mm] Oil connection [SAE Flare] Oil addition [kg]
5520
TS [C] Max. differential pressure [bar] PS [bar] min. max. Risk Category according to PED
10
+ 130
32
II
5520/D
5520/E
(1) The dimensions of the separator's connections must agree with the discharge diameter of the compressor
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OIL SEPARATORS
280 367
428
5520/D
67
458
7760
5520/E
5590/..
Gasket
H3
D2
H4
H1
H2
H1
H4
M10
5520
M10
5540
D1
D1
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Evaporating Temperature [C] +5 6,1 18,9 21,3 24,3 27,4 38,0 48,8 18,9 21,3 24,3 27,4 30,4 40 6,4 19,7 22,2 25,4 28,6 39,6 50,9 19,7 22,2 25,4 28,6 31,8 +5 7,9 24,5 27,7 31,5 35,6 49,3 63,4 24,5 27,7 31,5 35,6 39,5 40 6,4 19,9 22,5 25,7 28,9 40,1 51,5 19,9 22,5 25,7 28,9 32,1 +5 8,8 27,3 30,8 35,2 39,6 54,9 70,6 27,3 30,8 35,2 39,6 44,0 40 6,0 18,6 21,0 24,6 27,0 37,6 48,3 18,6 21,0 24,6 27,0 30,0 +5 8,0 24,6 27,8 31,8 35,8 49,6 63,7 24,6 27,8 31,8 35,8 40,0
5520/D
5520/E
(1) Refrigerant flow capacity with a condensing temperature of + 40C and normal overheating values of vapour sucked by compressor. No liquid subcooling. Maximum pressure drop of 0,15 bar
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VALVES
117
HERMETIC VALVES
APPLICATIONS The hermetic valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION These valves are available in the following two types: two-ways shut-off valves types 6010/2 and 6012/22; three-ways valves; two main connections plus a third one for charging or manometer connection, types: 6060 with right access connection; 6070 with left access connection. On both types, the access connection may be shut off by the back-seating of the spindle. The main parts of the hermetic valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle.
+4,5+130
6010/2 4.5
H2
H1
L2
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VALVES
H1
H2
H3
H4
H5
L1
L2
L3
P1
6010/2 6012/22 6020/222 6020/233 6020/244 6020/255 6060/22M6 6060/23M10 6070/22M6 6070/23M8 6070/23M10 6070/24M12 6070/25M16
14
66
36
29 62 67 77 79 24
58 55,5
25
51
61
115
26,5
52 31 33
127
34 37 34 37
92 91 92 90 30,5
27 24
25,5
31 33 38,5 39,5
27
29,5
28
43,5
102
H2
1 2 H4
H3
H1
H5
3 H3 1 H2 H1 M10 L1
L1 L3 6070 2
M8 11
P1
L2
H2 H3
H5
1 M8 11
H1
L1 L3
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119
RECEIVER VALVES
APPLICATIONS The receiver valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION These valves are available in the following two types: two-ways valves, 90 angle connections, types 6110 and 6120; three-ways valves; two main connections (90 angle) plus a third one for charging, type 6132. The access connection may be shut off by the back-seating of the spindle; two-ways valves, 120 angle connections, type 6140. The main parts of the receiver valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle.
1/4" f
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VALVES
6110
H1
H2
L1
L2
6110/22 6110/X15 6110/23 6110/32 6110/33 6110/X13 6110/43 6110/44 6110/54 6110/66 6120/22 6120/23 6120/33 6120/43 6120/44 6120/54 6120/66 6132/22 6132/33 6132/44 6132/54 6140/22 6140/23
72 83
48
27,5
110 130
29 77 50
135 130
31
NPT 3 L1
235 245
88
42,5 72 77 48 50
6120 2
30 33 40 56 29
64
H1
88
670
3 L1
NPT L2
63,5
36
75
57
46
1 6132 2 H1
H2
6110/X13 6110/X15
NPT L2 L1
H2
2 H1 2
6140
NPT 3 1 L1 L1 L2
H1
H1
H2
6110/21
70,5
100
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121
STOP VALVES
APPLICATIONS The stop valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION The very compact design of these brass valves allows minimum dimensional sizes and the fixing flange complies with current market requirements. Valves 6170 and 6175 must be completed with the following devices, to be ordered separately: valve code 8394/A or code 8394/B; cap with gasket code 8392/A. The main parts of the stop valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; brass EN 12164 CW 614N for spindle and protection cap; chloroprene rubber (CR) for outlet seal gaskets for series 6165 and 6175; chloroprene rubber (CR) and aramidic fibers for gland seal, only for series 6170.
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VALVES
H1
H2
H3
L1
L2
L3
29 30,5
29 31
59,5 67 38
36
28,5
104
47
36
83
2 H2 H2
H1
H3
D L1 L1 L3 6.5 6.5 I
H3
H1
3 D L2
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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.
6210/2 6210/3 6210/4 6210/5 6210/6 6220/2 6220/3 6220/4 6220/5 6220/6 6220/7
124
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VALVES
6210/2 6210/3 6210/4 6210/5 6210/6 6220/2 6220/3 6220/4 6220/5 6220/6 6220/7
68 53,5
36 52
72
38
86 68
50 36
60
655 195
72
38
52
86
62,5
92 94
6,2
50
60
6210 D
6220 D
H2
H2
H1
1 A94
H1
A94
L1 d
L1 d
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125
ROTALOCK VALVES
APPLICATIONS The rotalock valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION Rotalock valves, mounted with 7910 fittings and 7990 gaskets, assure fast installation and safe sealing. Before tightening it is possible to turn the valve in every direction. All Rotalock valves have an additional charging connection, which can be excluded by the back sealing of the spindle. Fittings 7910 and gaskets 7990 have to be ordered separately. The main parts of the hermetic valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle; steel bar EN 10277-3 11 S Mn Pb 37 for 7910 fittings; P.T.F.E. for 7990 gaskets.
Gasket 7990
Coupling 7910
3/4" UNF
126
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VALVES
H1
H2
L1
L2
6310/2 6310/3 6310/4 6320/3 6320/4 6320/5 6320/6 72 36,5 69,5 34,5 68,5 33,5
94 64
97
6310 6320
1 2
H1 H2
3 L1
L2
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127
CAPPED VALVES
APPLICATIONS The capped valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION The main parts of the capped valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle. INSTALLATION The brazing of capped valves with solder connections, type 6420, should be carried out with care, using a low melting point filler material. Its necessary to remove the spindle assembly, with gland too, before brazing the body. Its important to avoid direct contact between the torch flame and the valve body, which could be damaged and compromise the proper functioning of the valve.
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
1/4" 3/8" 1/2" 5/8" 3/4" 1/4" 3/8" 1/2" 5/8" 3/4" 7/8" 1/4" 1/4" 10 12 16 18 22
3,50
0,35
128
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VALVES
H1
H2
L1
L2
L3
P1
6410/2 6410/3 6410/4 6410/5 6410/6 6420/2 6420/3 6420/M10 6420/M12 6420/4 6420/5 6420/M18 6420/6 6420/M22 6420/7 6460/22A 85,5 67 113 89,5 85,5 67 113 89,5 85,5 67
68 74 78 98 57 61 6,2 50 4,5 38
4,5
38
70 71 92 6,2 94 97 34 51 35 4,5 38 50
305
6410
6420
6460/22A
H2
H2
H1
H1
3 A94
A94
L1
L1
H1
H2
L2
L3
45
I
I I
A P1 1 1 C L1 2
N.B. When the valve 6460/22A is closed, connections A-B are open and C is stopped; when opened, all connections are open.
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129
GLOBE VALVES
APPLICATIONS The globe valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION These valves are available in the following two types: 6512 with straight solder connections; 6532 with solder angle connections; The main parts of the globe valves are made with the following materials: hot forged brass EN 12420 CW 617N for body, cover and cap that covers the spindle; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; metal-rubber laminated for outlet seal gaskets P.T.F.E. for seat gaskets.
I -35 +160 45
Art. 3.3
130
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VALVES
H1
L1
6512/M22 6512/7 6512/M28 6512/9 6512/11 6512/13 6512/M42 6512/17 6532/M22 6532/7 6532/M28 6532/9 6532/11 6532/13 6532/M42 6532/17 238 65 139 86,5 104 138 165 52,5 93 59 68 126 147 44,5 80 50 60 94 166 199 215 34 37 42,5 118 141 173 136 28,5 100 60 94
1415
138
6512
Q H H1
M10
6532
Q H
L1 L
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H1
BALL VALVES
APPLICATIONS The ball valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section 2.1.4 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION The specific design of Castel ball valves: ensures the internal equilibrium of pressures when the valve is closed; permits the bi-directional flow of the refrigerant and, consequently, the assembly on the plant without taking into account the direction of the refrigerant; prevents any risk of ejection or explosion of the spindle. The opening and closing of the valve is realized by turning the spindle one fourth of a turn. A standstill in turning realizes either a full opening or a full closing, moreover the arrow printed on the spindle head shows the flow direction. The electric welding of the bodies and the seal gaskets, assembled on the spindle, prevent any leaks. Ball valves are available in the following two types: type 6590 (full port) and type 6591 (reduced port) without access fitting. type 6590/A (full port) and type 6591/A (reduced port) with access fitting. These ball valves are equipped with valve core 8394/A and cap 8392/A. The main parts of the valves are made with the following materials: hot forged brass EN 12420 CW 617N for body; hot forged brass EN 12420 CW 617N, chromium plated, for ball; copper tube EN 12735-1 Cu-DHP for solder connections; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) for outlet seal gaskets; P.T.F.E. for seat ball gaskets; glass reinforced PBT for cap that covers the spindle. Hot forged brass EN 12420 CW 617N for caps on sizes from 6590/M64A up to 6591/34A. INSTALLATION The brazing of ball valves should be carried out with care, using a low melting point filler material. It is important to avoid direct contact between the torch flame and the valve body, which could be damaged and compromise the proper functioning of the valve.
6590
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VALVES
6590/3A 6590/M10A 6590/M12A 6590/4A 6590/M15A 6590/5A 6590/M18A 6590/6A 6590/7A 6590/M28A 6590/9A 6590/11A 6590/13A 6590/M42A 6590/17A 6591/M64A 6591/21A 6590/M64A 6590/21A 6591/24A 6591/25A
3,0
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H1
H2
L1
L2
6590/M6 6590/2 6590/3 6590/M10 6590/M12 6590/4 6591/5 6590/M15 6590/5 6590/M18 6590/6 6591/7 6590/7 6591/M28 6591/9 6590/M28 6590/9 6591/11 6590/11 6591/13 6591/M42 6590/13 6590/M42 6591/17 6590/17 6591/M64 6591/21
6590/3A 6590/M10A 6590/M12A 6590/4A 6590/M15A 6590/5A 6590/M18A 6590/6A 6590/7A 6591/M28 6590/M28A 6590/9A 6590/11A 6590/13A 6590/M42A 6590/17A 6591/M64A 6591/21A 6590/M64A 6590/21A 6591/24A 6591/25A 172,5 62 150 55 130 45 117 38 101,5 30 95,5 27,5 80 24 73 20
260
33
121
65
24
300
138
73,5
18 M5
290
36
141
74
32
410
38
92 93 108,5
33
41 45
206 248
109 130
43 49
1050
247
129
48
262 292
136 151
49
53
303
162
58
330 64 350
175
58
185
68
6590/25A 6591/28A 6591/29A 6591/33A 6591/34A 196,5 75 70 400 209 86 380 199 76
12500
L2
H2
H L1 L I 6590/..A H1
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VALVES
NPT
H1
L1
L2
L3
1/8" 1/4"
19 37 40 83 35 17
8321 8320
Ch.19
L3 L2 L1 34
H1
L3 L2 L1 34
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135
H1
6.5
6.5
H1
L1
L2
L3
8330/A
72
25,5
29
36
104
-10
+70
25
Art. 3.3
L2
Fig. 1 - The valve is installed with the threaded fork astride of the copper pipe to be pierced.
L1
Fig 2 - Tightening of lower screw nut.
136
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137
CONSTRUCTION All nuts, from series 7010 to series 7050, and all the elbows, TEE and cross fittings, from series 7210 to series 7410, are manufactured with hot forged brass EN 12420 CW 617N. All straight fittings, from series 7110 to series 7170, and all the plug, from series 7510 to series 7520, are machined by brass bar EN 12164 CW 614N. Seal caps series 7560 and gaskets series 7580 are made with copper Cu ETP UNI 5649. The main parts of the flanges joints are made with the following materials: hot forged brass EN 12420 CW 617N for bushes and flanges; aramidic fibers for seal gasket of the flanges.
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[in]
[mm]
7010/66 7010/77
Ch
7010/88
Ch
CAP NUT
7020/65
Ch
7020/87
D
Ch
3/4"
29,5
33
68 / 71
Ch
7050/5
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139
38 44 50 58 63 72
12 17 20 23 27 36
Ch
7110/6 7110/8
U216
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
Ch
7120/45 7120/56
R
UR2-1210
L
7130/3 7130/4
Ch
7130/6 7130/8
Ch
7140/54
R E
140
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Ch
7150/64 7150/65
Ch
7150/56
Cylinder adaptors
L
7154/2 7156/2 1/4" W 21,8 14 filetti dx. femmina 1/4" 20 14 filetti sx. femmina 45 29 27 52 25 46
Ch
Male/female unions
L
7160/2 1/4" 1/4" 30,5 17 31
7160/3
3/8"
3/8"
45
36
22
57
Ch
7160/4
1/2"
1/2"
41
25
84
Ch
1/4"
8 10 12 16 18 45
26,5
12
17
3/8"
33
17
39
Ch
35 42 45,5
20 23 27
55 82 123
Available on request
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141
L1
L2
L3
L4
Ch
L4 L3
3 1 2 3 1
L1
L2
2 3 1 2
POS.3
3 1 2 3 1 2 3 1 2 3
Flare/ODS fitting
Nut
Connection
Copper seal
Copper pipe
SAE/Flare connection
142
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7210/4 7210/5
7210/6
7220/6
7230/54
7240/3
3/8"
3/8"
45
32
31
84
7240/4
1/2"
1/2"
39,5
38
198
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143
47 58 63 72 83
32 69 97 153 235
7310/5 7310/6
29 32,5 38 41,5
56 63 72 83
77 95 153 228
7320/334 7320/445
7320/556
28 32,5 38 41,5
58 63 72 83
7320/443 7320/554
L
7320/665
7330/221
T14A
1/4"
1/4"
1/8" 45 1/4"
28,5
28
56
7330/222
T14B
1/4"
1/4"
39,5
38
198
7340/222
L
T64
1/4"
1/4"
1/4"
45
27,5
56
78
7410/2
L
C14
1/4"
1/4"
1/4"
1/4"
45
52
52
55
144
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7510/3
P26
3/8"
45
26
17
20 / 25
40
Ch
7510/4
P28
1/2"
30
20
34 / 47
67
NPT plugs
7520/1 121B02 121B04 121B06 7520/4 7520/6 121B08 121B12 121B16 1/2" 3/4" 1" 1/8" 1/4" 3/8" 45 29,8 32,1 39 22 27 34 25 / 35 30 / 40 60 / 80 87 149 279 15,9 23,1 23,2 12 14 17 10 / 13 15 / 20 17 / 22 12 27 43
L
7520/2 7520/3
Ch
7520/8
Copper gaskets
7580/2 7580/3 7580/4 7580/5 7580/6 B24 B26 B28 B210 B212 1/4" 3/8" 1/2" 5/8" 3/4" 45 0,5 0,5 1 1,5 3
Flange joints
H H
7630/7 7630/9 7630/11 7630/13 7630/M42 1.5/8" 2.1/8" 42 54 24 25 67 71 68 / 80 7/8" 1.1/8" 1.3/8" 35 45 42 / 50 1340 1940 23 63 20 / 24 315 490 1045
7630/17
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145
147
148
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INSTALLATION The internal working pressure-temperature rating for a copper fitting, is dependent upon, not only fitting strength, but also the adopted joining process and the used filler metal. The working pressure-temperature values given in tables 1 and 2 are referred to a brazing process, performed in accordance with the sound engineering practice. We wish to remember the definition of brazing process, given in EN 13133 : 2000 Standard. The process of joining generally applied to the joining of materials by a heating process during which the parent materials do not melt and the filler metal is drawn into the joint by capillary action. It is generally applicable to joining systems where the filler metal melts at 450 C or above. In actual practice brazing is done at temperatures ranging from 630 to 820 C and there are two general types of brazing filler metals, normally used for joining copper tube: Copper Phosphorus alloys (the so called B-CuP), proper to CP Class of EN 1044 : 1999 Standard, that are normally used without fluxes; Silver alloys (the so called B-Ag), proper to AG Class of EN 1044 : 1999, that must be used with their specific fluxes.
Tube Nominal Diameter
TABLE 1
Working Pressure PS [bar], depending on temperature
[mm] 6 8 10 12 14 15 16 18 22 28 35 42 54 64 67 76 80 89 106
[in.] 1/4" 3/8" 1/2" 5/8" 7/8" 1" 1.1/8" 1.3/8" 1.5/8" 2.1/8" 2.5/8" 3.1/8" 3.1/2"
-40 / 30 C 90 90 70 60 60 50 50 45 45 45 40 40 35 30 30 30 25 25 20 20 20 20 18 18 18 18 15
95 C 72 72 56 48 48 40 40 36 36 36 32 32 28 24 24 24 20 20 16 16 16 16 14 14 14 12 12
150 C 63 63 49 42 42 35 35 32 32 32 28 28 24 21 21 21 18 18 14 14 14 14 13 13 13 11 11
Note: working pressures shown in this table are in comparison with rated working pressures established in ASME B16.50 : 2001 Standard.
TABLE 2
Working Pressure PS [bar], depending on temperature Tube Nominal Diameter -40 / 30 C [in.] 7/8 1 3/4 1.1/8 1.3/8 1.5/8 3/4 2.1/8 (1) 60 55 50 50 50 40 40 35 (2) 80 73 67 67 67 53 53 47 (1) 50 45 40 40 40 35 35 30 150 C (2) 67 60 53 53 53 47 47 40 (1) 45 41 37 37 37 30 30 26 95 C (2) 60 55 49 49 49 40 40 35
(1) PS values listed in this column are referred to a safety coefficient 4, according to ASME B16.50 : 2001 Standard (2) PS values listed in this column are referred to a safety coefficient 3, minimum value warranted by Castel for all its products
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149
150
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151
152
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153
154
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7832/222
5130/222
1/4"
1/4"
1/4"
7832/333
7832/333
3/8
3/8
3/8
7832/232
5130/232
1/4"
3/8"
1/4"
11
7832/323
7832/323
3/8
1/4"
3/8
14
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155
7916/M28
28
28
7916/M35
35
35
7916/M42
42
42
7916/M54
54
54
7917/M28
28
28
7917/M35
35
35
7917/M42
42
42
7917/M54
54
54
156
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7918/M28
28
28
7918/M35
35
35
7918/M42
42
42
7918/M54
54
54
7919/M28
28
28
7919/M35
35
35
7919/M42
42
42
7919/M54
54
54
7932/M28
28
28
28
7932/M35
35
35
35
7932/M42
42
42
42
7932/M54
54
54
54
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157
159
CONSTRUCTION The straight fittings are machined by hexagonal brass bar EN 12164 CW 614N. The TEE and cross fittings are manufactured with hot forged brass EN 12420 CW 617N. The main parts of the valve cores are made with the following materials: brass EN 12164 CW 614N for body; chloroprene rubber (CR) for seat gasket; chloroprene rubber (CR) for outlet seal gasket for types 8394/A and 8395/A; PTFE for outlet seal gasket for type 8394/B.
Nut
Gasket
Valve core
160
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Ch L
8350/X01 1/4" 6 3/8" 20 11
Ch L
8350/X03 1/4" 6 130 90 11
Ch
L H
8350/X11
8350/X09
5/16"
1/4"
27 14 9,4 2,1
Ch D
8-10 6 7 45
30 11 26 27 14
Ch L
5/16" 8351/X07
3/8" 6
Ch L
8352/22 1/4" 31 11
Ch L
8354/21 8354/22 8354/23 1/4" 1/8" 1/4" 3/8" 28 11 33 14 38 17
Ch L
8362/22
1/4"
1/4"
35 17
Ch
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161
8380/X01
1/4"
43
24
L
45
The valve core may be installed on each of the two 1/4" SAE Flare connections.
8380/122
1/4"
1/8"
45
24
8380/X06
50
1/4"
1/4"
35
30
L
8380/X08 49
The valve core may be installed on each of the two 1/4" SAE Flare connections.
162
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8382/1222 1/4"
1/8"
48
50
8382/X02
1/4"
1/4"
45
48
8382/X03
1/4"
48
44
8382/X04
1/4"
1/4"
35
50
46
With valve-core opening device on female connection. The valve core may be installed on each of the three 1/4" SAE Flare connections.
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163
8392/A
13
L
1/4 35 13
8392/B
22
8394/A
(1)
8394/B
(2)
Inside spring. Torque wrench 0,20 / 0,35 Nm. (2) Static pressure: 40 [bar] (2) Working pressure: 28 [bar]
8395/A
(3)
Outside spring. Torque wrench 0,4 / 0,8 Nm. (3) Static pressure: 68 [bar] (3) Working pressure: 48 [bar]
8580/2
1/4"
45
2,8
5,2
H
9900/X47
175
30 Four ways
L
1/4" 35
H
9900/X87
162
30 Three ways
164
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165
KIT N
ITEMS CODE
DESCRIPTION
NOTE
166
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KIT N
ITEMS CODE
DESCRIPTION
NOTE
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167
KIT N
ITEMS CODE
DESCRIPTION
NOTE
168
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KIT N
ITEMS CODE
DESCRIPTION
NOTE
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169
KIT N
ITEMS CODE
DESCRIPTION
NOTE
170
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KIT N
ITEMS CODE
DESCRIPTION
NOTE
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171
KIT N
ITEMS CODE
DESCRIPTION
NOTE
009174
Cover/body gasket
9150/R26
Gland Gland seal gaskets Gland seal gaskets Washer Cap Cap gasket Cover/body screws Spindle/plate group
Globe valves type: (1) 6510/13 - /M42 - /17 6512/13 - /M42 - /17 (1) 6520/13 - /M42 - /17 (1) 6530/13 - /M42 - /17 6532/13 - /M42 - /17
9150/R29
007639
Globe valves type: (1) 6510/13 - /M42 6512/13 - /M42 (1) 6520/13 - /M42
008002
Cover/body O Ring
009175
Cover/body gasket
9150/R30
007640
Spindle/plate group
(1) 6520/17; (1) 6530/13 - /M42 - /17 6532/13 - /M42 - /17 004261 Cover/body O Ring Globe valves type: (1) 6510/17; (1) 6520/17 (1) 6530/13 - /M42 - /17 009176 Cover/body gasket Globe valves type: 6512/17 6532/13 - /M42 - /17
172
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KIT N
ITEMS CODE
DESCRIPTION
NOTE
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173
Note