quality products for refrigeration and air conditioning products suitable for CFC, HCFC and HFC 2006 release PRODUCT HANDBOOK

Transcription

1 quality products for refrigeration and air conditioning products suitable for CFC, HCFC and HFC 2006 release PRODUCT HANDBOOK

2 Pessano - February 2006

3 17 Thermostatic expansion valves Solenoid valves valve with interchangeable orifice assembly valve with fixed orifice assembly valves for refrigerating systems coils permanent magnet connectors valves for different fluids SUMMARY Safety devices safety valves 3030 safety valves 3060 ball shut-off valves changeover devices unions fusible plugs Check valves Water regulating valves 85 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 Oil separators 117 Valves hermetic valves receiver valves stop valves diaphragm valves rotalock valves capped valves globe valves ball valves gauge mounting valves line piercing valve Threaded brass fittings Solder copper fittings Access fittings Spare parts

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

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6 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, it s 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, R3 and R141b. Among the fluids listed in this standard, there are the well known R; R; R134a; R404A; R407C; R401A; R502; R507.

7 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 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 : 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 : (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.

8 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,% 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.

9 CONNECTIONS OF CASTEL PRODUCTS Castel products can be supplied with different connections. TABLE 1 - Equivalence between Castel code and dimension in inches CASTEL Code. /1. /2. /3. /4. /5. /6. /7. /8. /9. /11. /13. /17. /21. /24. /25. /. /29. /33. /34 Dimension [in] 1/8" 3/4" 7/8" 1" 1" 1/8 1" 3/8 1" 5/8 2" 1/8 2" 5/8 3" 3" 1/8 3" 1/2 3" 5/8 4" 1/8 4" 1/4 F.e. 1098/7 solenoid valve with solder connection with = 7/8. In particular Castel products are produced either with threaded connections or solder connections. Table 1 shows the equivalence between Castel codes and dimensions in inches. These codes are commonly used in the international market. Table 2 shows the equivalence between Castel codes and dimensions in millimetres. TABLE 2 - Equivalence between Castel code and dimension in millimeters CASTEL Code. /M6. /M10. /M. /M15. /M18. /M. /M. /M. /M64. /M80 Dimension [mm] F.e. 4411/MA filter drier with replaceable anti-acid solid core with solder connection with = mm.

10 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 B ) to joint fittings, valves, safety valves to vessel or steel pipes. FPT Straight threaded connection (according to UNI ISO 8/1) 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.: ODM solder connection suitable to joint a copper pipe with a mm outer diameter, by means of an M female/female copper sleeve (in this case the type Castel 7700/M). 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.: ODS solder connection suitable to receive inside a copper pipe with a outer diameter. FLARE 5/" 3/4" 7/8" 1" TABLE 3 - Flare Connections Suitable for Copper Tube 5/" 3/4" 7/8" 1" Thread 7/" - 20 UNF - 20 UNF - 18 UNF 3/4" - UNF 7/8" - 14 UNF 1.1/" - 14 UNS 1. - UNF 1. - UNF

11 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 , EN and EN 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/m 3 ) in m 3 /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 Q 1 L 1 L 2 Suction line Q = Kv Q 1 S 1 S 2 Hot gas line Q = Kv Q 1 H 1 H 2 since: Q = required refrigeration capacity [kw]; Kv = characteristic valve coefficient [m 3 /h]; Q 1 = reference refrigeration capacity [kw] (Table 1). L 1 S 1 H 1 = are correction factors of the refrigeration capacity in the presence of operating temperatures different from reference conditions. L 2 S 2 H 2 = are correction factors of the refrigeration capacity for pressure drops different from reference conditions. TABLE 1 Refrigeration Capacity [kw] Kv factor [m 3 /h] R134a R Liquid Vapour Hot gas R404A R407C R410A R507 R134a R R404A R407C R410A R507 R134a R R404A R407C R410A R507 1,85 18,00 11,90 18,74 19,04 11,80 2, 2,70 2,26 2,68 3,60 2,15 8,50 11,70 10,00 11,62 13,00 7,77 Application Evaporating Temperature [ C] TABLE 2 - Nominal Working Conditions Suction Temperature [ C] Condensing Temperature [ C] Pressure drop [bar] LIQUIDO VAPORE GAS CALDO ,15 1

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

14 Suction line Hot gas line TABLE 5 - Correction Factors - S 1 of the refrigeration capacity for operating temperatures different from nominal values. TABLE 7 - Correction Factors - H 1 of the refrigeration capacity for operating temperatures different from nominal values. Evaporating Temperature [ C] Condensing Temperature [ C] Evaporating Temperature [ C] Condensing Temperature [ C] ,87 0,92 0,98 1,04 1,11 1,17 1, ,00 1,00 1,00 1,03 1,04 1,05 1,05 0 0,67 0,73 0,78 0,83 0,85 0,96 1,01 0 0,83 0,90 0,92 0,92 0,94 0,95 0, ,51 0,55 0,59 0,64 0,70 0,76 0, ,76 0,76 0,79 0,80 0,84 0,87 0, , 0,39 0,43 0,50 0,53 0,57 0, ,67 0,71 0,72 0,76 0, ,36* 0,38* 0,41* 0, 0,43* 0,37 0,46* 0,39 0,48* 0,45 0,50* ,60 0,65 0,58 0,68 0, ,27* 0,29* 0,31* 0,33* 0,* 0,37* 0,38* *Two-stages plants, two indipendent circuits, with intermediate temperature -10 C. TABLE 6 - Correction Factors - S 2 of the refrigeration capacity for pressure drops different from nominal values. TABLE 8 - Correction Factors - H 2 of the refrigeration capacity for pressure drops different from nominal values. Pressure drop [bar] 0,0 0,05 0,07 0,10 0,15 0,20 0,30 0,40 0,50 0,70 Pressure drop [bar] 0,10 0,20 0,30 0,40 0,50 0,70 1,00 1,50 2,00 2,50 S 2 0,47 0,57 0,68 0,82 1,00 1,15 1,40 1,64 1,82 2,15 H 2 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 [m 3 /h] Refrigerant: R407C Set refrigeration capacity: [kw] Condensation: + 50 [ C] Evaporation: 0 [ C] Q = Kv Q 1 L 1 L 2 [kw] = 2,61 18,74 0,82 L 2 [kw] L 2 = = 0,87 40,11 A pressure drop slightly above 0.11 bar corresponds to the L 2 = 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 Q 1 S 1 S 2 [kw] 15 = Kv 2,68 0,70 0,82 15 Kv = = 9,75 [m 3 /h] 1,538 The result involves the selection of a 1078/9 valve with Kv = 10 [m 3 /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 Q 1 H 1 H 2 [kw] 20 = Kv 11,62 0, Kv = = 2,61 [m 3 /h] 7,64 The result involves the selection of a 1078/5 valve with Kv = 2.61 [m 3 /h]

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17 THERMOSTATIC EXPANSION VALVES 17

18 THERMOSTATIC EXPANSION VALVES SERIES WITH INTERCHANGEABLE ORIFICE ASSEMBLY APPLICATION Castel thermostatic expansion valves series regulate the flow of refrigerant liquid into evaporators; the liquid injection is controlled by the refrigerant superheat. The new Castel series are designed to work with interchangeable orifice assembly, to provide flexibility in selection of capacities, and can be used in a wide range of applications as listed below: Refrigeration systems (display cases in supermarkets, freezers, ice cream and ice maker machines, transport refrigeration etc). Air conditioning systems Heat pump systems Liquid chillers which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2, of Directive 97/23/EC and referred to in Directive 67/548/EEC). OPERATION Castel thermostatic expansion valves acts as throttle device between the high pressure and the low pressure sides of refrigeration systems and ensure that the rate of refrigerant flow into the evaporator exactly matches the rate of evaporation of liquid refrigerant in the evaporator. If the actual superheat is higher than the set point the valve feeds the evaporator with more liquid refrigerant, if the actual superheat is lower than the set point the valve decreases the flow of liquid refrigerant to the evaporator. Thus the evaporator is fully utilized and no liquid refrigerant may reach the compressor. top of the valve s diaphragm. The sensing bulb pressure is a function of the temperature of the thermostatic charge that is the substance within the bulb. The body is made from forged brass with connection in angle configuration. The interchangeable orifice assembly can be replaced through the inlet connection. A steel rod, inside the body, transfers the diaphragm movement to the plug inside the orifice assembly. When the thermostatic charge pressure increases, the diaphragm will be deflected downward transferring this motion to the plug, which lifts from seat and allows the liquid passing through orifice. A spring opposes the force underneath the diaphragm and the side spindle can adjust its tension. Static superheat increases by turning the side spindle clockwise and decreased by turning the spindle counter clockwise. The thermostatic element is hardly connected by brazing to the forged brass body to avoid any leakage. The body assembly can be supplied with internal or external equalizer; both types can also be supplied either with flare connections or with solder connections (outlet and external equalizer if present). CONSTRUCTION Castel thermostatic expansion valve series is made up of two parts that must work together: the first is the body, which is the actuator of the regulator, and the second is the orifice, which contains the valve and attends the expansion of the refrigerating fluid. Body assembly: two parts make it up: the thermostatic (power) element and the body with its inner elements. The thermostatic element is the motor of the valve; a sensing bulb is connected to the diaphragm assembly by a length of capillary tubing, which transmits bulb pressure to the 18

19 Catalogue number internal equalizer 10/4 10/MS 10/4S 11/4 11/MS 11/4S 20/4 20/MS 20/4S external equalizer 10/4E 10/MSE 10/4SE 11/4E 11/MSE 11/4SE 20/4E Table 1: General Caracteristics of Body Assemblies of Thermostatic Expansion Valves Connections SAE Flare ODS [mm] ODS [in] IN OUT Equal. OUT Equal. OUT Equal. min max 6 6 Refrigerant Evaporating Temperature Range [ C] R - 40 R407C + 10 MOP without + 15 C (95 psi) without Max bulb temperature [ C] TS [ C] PS [bar] Risk Category according to PED THERMOSTATIC EXPANSION VALVES 20/MSE 6 21/4 20/4SE R134a /MS 21/4S 21/4E + 15 C (55 psi) 100 (1) Art /MSE 6 21/4SE 30/4 30/MS 30/4S 30/4E without 30/MSE 6 30/4SE 31/ /MS /4S 31/4E R404A R C (0 psi) 31/MSE 6 31/4SE 34/4 34/MS 34/4S C 34/4E - 25 (30 psi) 34/MSE 6 34/4SE (1) when valve is installed. 60 C with element not mounted 19

20 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 0 CW 617N for body brass EN 4 CW 614N for superheat setting spindle and spring holder steel DIN for spring copper tube EN 7-1 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 R). 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: it s 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 4 C. Opening superheat: it s the amount of superheat above the static superheat required to produce a given valve capacity Operating superheat: it s the sum of static and opening superheat 20

21 Subcooling: it s 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, Q e Evaporating temperature/pressure, T e / p e Lowest possible condensing temperature/ pressure, T c / p c Liquid refrigerant temperature, T l 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 + p ) e THERMOSTATIC EXPANSION VALVES 41,

22 where: P c = condensing pressure P e = evaporating pressure p = sum of pressure drops in the liquid line, distributor and evaporator Step 2 Determine required valve capacity. Use the evaporating capacity Q e 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: T sub = T From the subcooling corrector factor table find the appropriate corrector factor F sub corresponding to the T sub calculated and determine the required valve capacity by the formula: Q Q e sub = F c T l sub 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. Table 2: Orifice Assemblies - Rated Capacities in kw Evaporating Temperature Range [ C] Catalogue Number R R407C R134a R404A R507 R404A R507 0X 0,5 0,4 0,38 0, ,0 0,9 0,7 0,7 01 2,5 1,8 1,6 1,6 02 3,5 2,6 2,1 2,1 03 5,2 4,6 4,2 3,5 04 8,0 6,7 6,0 4, ,5 8,6 7,7 6, ,5 10,5 9,1 6,6 Rated capacities, for temperature range , are based on: Evaporating temperature Tevap = + 5 C Condensing temperature Tcond = + 32 C Refrigerant liquid temperature ahead of valve Tliq = + C Rated capacities, for temperature range , are based on: Evaporating temperature Tevap = - 30 C Condensing temperature Tcond = + 32 C Refrigerant liquid temperature ahead of valve Tliq = + C

23 Catalogue Number Type of refrigerant R134a Evaporator capacity, Q e 6 kw Evaporating temperature/ pressure, T e - 10 C Lowest possible condensing temperature/pressure, T c + 30 C Liquid refrigerant temperature, T l + 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 - p c = 6,71 bar Evaporating pressure at - 10 C - p e = 1,01 bar 71/M6S 71/2S 71/3S 71/M10S SIZING EXAMPLE p tot Table 3: Solder adapters = 6,71 [in] ODS Connections ( 1,01+ 1,5 ) = 4,2 bar STEP 2 - Determine required valve capacity T sub = = 10 C [mm] 6 10 From the subcooling corrector factor table 5b, we find the appropriate corrector factor F sub equal to 1,08 for T sub = 10 C. Required valve capacity is: 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 05 (N.B.: the expansion valve capacity must be equal or slightly more than the calculated evaporator capacity) MARKING 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. THERMOSTATIC EXPANSION VALVES Q sub = 6 1,08 = 5,55 kw 23

24 Table 4a: Refrigerant R/R407C - Capacities in kw for temperature range - 40 C? +10 C Orifice code Pressure drop across valve [bar] Orifice code Pressure drop across valve [bar] Evaporating temperature = +10 C 0X 0,37 0,48 0,55 0,60 0,63 0,65 0,65 0, ,87 1,1 1,2 1,3 1,4 1,4 1,4 1,5 01 2,2 2,8 3,2 3,4 3,6 3,7 3,8 3,8 02 3,0 4,0 4,7 5,1 5,4 5,6 5,8 5,8 03 5,4 7,2 8,3 9,1 9,7 10,0 10,2 10,3 04 8,1 10,8,5 13,8 14,5 15,0 15,5 15, ,2 13,6 15,7 17,2 18,3 18,9 19,3 19,5 06,6,7 19,3 21,0,3 23,1 23,5 23,7 Evaporating temperature = -10 C 0X 0,37 0,47 0,53 0,57 0,60 0,63 0,64 0, ,79 0,96 1,1 1,2 1,2 1,3 1,3 1,3 01 1,6 2,0 2,3 2,5 2,6 2,7 2,8 2,8 02 2,2 2,9 3,3 3,6 3,8 4,0 4,1 4,1 03 3,9 5,1 5,9 6,4 6,8 7,1 7,3 7,3 04 5,8 7,6 8,7 9,5 10,1 10,5 10,8 10,9 05 7,4 9,6 11,0,0,8 13,3 13,6 13,8 06 9,1 11,6 13,5 14,7 15,6,2,6,8 Evaporating temperature = -30 C 0X 0,40 0,45 0,49 0,52 0,55 0,56 0, ,79 0,9 0,96 1,0 1,1 1,1 1,1 01 1,4 1,5 1,7 1,8 1,8 1,9 1,9 02 1,9 2,2 2,7 2,5 2,6 2,6 2,7 03 3,4 3,9 4,2 4,4 4,6 4,7 4,8 04 5,0 5,7 6,2 6,6 6,8 7,0 7,1 05 6,4 7,2 7,8 8,3 8,6 8,8 9,0 06 7,8 8,8 9,6 10,1 10,5 10,8 11,0 Evaporating temperature = 0 C 0X 0,37 0,48 0,55 0,59 0,63 0,65 0,66 0, ,84 1,0 1,2 1,3 1,3 1,4 1,4 1,4 01 1,9 2,4 2,7 3,0 3,1 3,2 3,3 3,3 02 2,6 3,4 4,0 4,3 4,6 4,8 4,9 5,0 03 4,6 6,1 7,1 7,8 8,2 8,5 8,7 8,8 04 6,9 9,1 10,5 11,5,2,7 13,0 13,2 05 8,8 11,6 13,3 14,6 15,5,1,4, ,8 14,2,3 17,8 18,9 19,6 20,0 20,2 Evaporating temperature = -20 C 0X 0,44 0,50 0,54 0,57 0,59 0,61 0, ,88 1,0 1,1 1,1 1,2 1,2 1,2 01 1,7 1,9 2,0 2,2 2,3 2,3 2,3 02 2,4 2,7 2,9 3,1 3,2 3,3 3,3 03 4,2 4,8 5,2 5,5 5,8 5,9 6,0 04 6,2 7,1 7,7 8,2 8,5 8,7 8,8 05 7,9 9,0 9,8 10,3 10,8 11,0 11,2 06 9,6 11,0 11,9,6 13,1 13,5 13,7 Evaporating temperature = -40 C 0X 0, 0,45 0,48 0,50 0,52 0, ,8 0,86 0,92 0,95 0,98 0, ,3 1,4 1,4 1,5 1,5 1,6 02 1,7 1,9 2,0 2,0 2,1 2,1 03 3,1 3,4 3,5 3,7 3,8 3,8 04 4,6 4,9 5,2 5,4 5,6 5,7 05 5,8 6,3 6,6 6,9 7,1 7,2 06 7,1 7,7 8,1 8,4 8,7 8,8 Table 4b: Refrigerant R/R407C - Correction factor for subcooling tsub > 4 C tsub [ C] Fsub 1,00 1,06 1,11 1,15 1,20 1,25 1,30 1, 1,39 1,44 When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 4b 24

25 Orifice code Table 5a: Refrigerant R134a - Capacities in kw for temperature range - 40 C +10 C Pressure drop across valve [bar] Orifice code Pressure drop across valve [bar] Evaporating temperature = +10 C 0X 0,34 0,43 0,47 0,50 0, ,71 0,86 0,93 0,97 0, ,5 1,9 2,1 2,2 2,2 02 2,0 2,6 3,0 3,1 3,2 03 3,6 4,7 5,3 5,6 5,8 04 5,4 7,0 7,8 8,3 8,6 05 6,9 8,9 9,9 10,8 10,9 06 8,4 10,8,1,8 13,2 Evaporating temperature = -10 C 0X 0,30 0,36 0,43 0,44 0, ,59 0,70 0,77 0,81 0, ,0 1,3 1,4 1,5 1,5 02 1,4 1,8 2,0 2,1 2,1 03 2,5 3,1 3,5 3,7 3,8 04 3,6 4,6 5,1 5,4 5,6 05 4,6 5,8 6,5 6,9 7,1 06 5,7 7,1 8,0 8,4 8,6 Evaporating temperature = -30 C 0X 0,25 0,32 0, 0,37 0, ,48 0,55 0,61 0,64 0, ,66 0,80 0,88 0,93 0, ,9 1,1 1,2 1,3 1,3 03 1,6 2,0 2,2 2,3 2,3 04 2,3 2,9 3,2 3,3 3,4 05 3,0 3,6 4,0 4,2 4,3 06 3,6 4,4 4,9 5,2 5,3 Evaporating temperature = 0 C 0X 0,33 0, 0,46 0,47 0, ,65 0,78 0,86 0,89 0, ,3 1,6 1,7 1,8 1,8 02 1,7 2,2 2,4 2,6 2,6 03 3,0 3,9 4,4 4,6 4,7 04 4,5 5,7 6,4 6,8 7,0 05 5,7 7,3 8,1 8,6 8,8 06 7,0 8,9 1,0 10,5 10,8 Evaporating temperature = -20 C 0X 0, 0, 0,39 0,41 0, 00 0,53 0,62 0,69 0,72 0, ,81 1,0 1,1 1,2 1,2 02 1,1 1,4 1,5 1,6 1,7 03 2,0 2,5 2,8 2,9 3,0 04 2,9 3,6 4,0 4,3 4,4 05 3,7 4,6 5,1 5,4 5,5 06 4,5 5,6 6,2 6,6 6,8 Evaporating temperature = -40 C 0X 0,23 0, 0,32 0,33 0, ,44 0,50 0,54 0,56 0, ,54 0,65 0,72 0,78 0, ,7 0,9 1,0 1,0 1,0 03 1,3 1,6 1,8 1,9 1,9 04 1,9 2,3 2,6 2,7 2,7 05 2,4 2,9 3,2 3,5 3,5 06 3,0 3,6 4,0 4,2 4,3 THERMOSTATIC EXPANSION VALVES Table 5b: Refrigerant R134a - Correction factor for subcooling tsub > 4 C tsub [ C] Fsub 1,00 1,08 1,13 1,19 1,25 1,31 1,37 1, 1,48 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 25

26 Table 6a: Refrigerant R404A/R507 - Capacities in kw for temperature range - 40 C +10 C Orifice code Pressure drop across valve [bar] Orifice code Pressure drop across valve [bar] Evaporating temperature = +10 C 0X 0, 0, 0,40 0, 0,43 0,43 0, 0, ,67 0,82 0,90 0,94 0,96 0,96 0,93 0, ,70 2,10 2,30 2, 2,48 2,46 2,41 2, ,32 3,00 3,39 3,61 3,73 3,74 3,68 3, ,15 5,36 6,03 6,43 6,63 6,66 6,55 6, ,24 8,06 9,06 9,66 9,95 9,98 9,81 9, ,91 10,17 11,43,,53,56,34, ,71,47 13,98 14,86 15,29 15,31 15,05 14,66 Evaporating temperature = -10 C 0X 0,30 0,37 0,40 0, 0, 0, 0,41 0, ,65 0,76 0,82 0,84 0,87 0,87 0,85 0, ,31 1,61 1,74 1,81 1,84 1,85 1,84 1, ,76 2,24 2,50 2,62 2,69 2,71 2,68 2, ,14 4,02 4,47 4,69 4,81 4,84 4,79 4, ,66 5,97 6,61 6,95 7,13 7,18 7,11 6, ,93 7,57 8,39 8,81 9,02 9,08 8,99 8, , 9,27 10,26 10,76 11,00 11,08 10,97 10,65 Evaporating temperature = -30 C 0X 0, 0,37 0,36 0,37 0,36 0, 00 0,67 0,70 0,70 0,70 0,69 0, ,18 1,21 1,23 1,21 1,20 1, ,63 1,69 1,71 1,70 1,68 1, ,93 3,04 3,07 3,06 3,02 2, , 4,47 4,52 4,51 4,46 4, 05 5,45 5,68 5,74 5,74 5,67 5, ,66 6,94 7,02 7,01 6,93 6,75 Evaporating temperature = 0 C 0X 0,30 0,37 0,41 0, 0,43 0,43 0,43 0, ,68 0,80 0,87 0,90 0,92 0,93 0,91 0, ,53 1,86 2,04 2,13 2,18 2,18 2,15 2, ,06 2,64 2,95 3,13 3, 3,25 3,21 3, ,68 4,72 5,27 5,59 5,75 5,80 5,73 5, ,49 7,15 7,86 8,33 8,58 8,64 8,53 8, ,97 8,92 9,95 10,52 10,83 10,90 10,76 10, ,57 10,93,,85 13,21 13,30 13,,72 Evaporating temperature = -20 C 0X 0, 0,38 0,40 0,39 0,40 0,39 0, ,70 0,75 0,77 0,79 0,79 0,79 0, ,34 1,45 1,50 1,52 1,52 1,51 1, ,85 2,04 2,14 2,17 2,18 2, 2, ,32 3,66 3,83 3,89 3,90 3,86 3, ,88 5,40 5,64 5,75 5,77 5,71 5, ,20 6,86 7,17 7,29 7,31 7,23 7, ,60 8,39 8,75 8,91 8,93 8,84 8,61 Evaporating temperature = -40 C 0X 0,32 0,33 0,33 0,33 0,32 0, ,60 0,61 0,62 0,61 0,60 0, ,92 0,96 0,97 0,96 0,94 0, ,27 1,32 1,33 1,31 1, 1, , 2,36 2,38 2,36 2,31 2, ,34 3,47 3,50 3,48 3, 3, ,25 4,41 4,45 4,43 4,36 4, ,19 5,39 5,45 5, 5,33 5,19 Table 6b: Refrigerant R404A/R507 - Correction factor for subcooling tsub > 4 C tsub [ C] Fsub 1,00 1,10 1,20 1,29 1,37 1,46 1,54 1,63 1,70 1,78 When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 6b 26

27 Orifice code Table 7a: Refrigerant R404A/R507 - Capacities in kw for temperature range - 60 C - 25 C Pressure drop across valve [bar] Orifice code Pressure drop across valve [bar] Evaporating temperature = -25 C 00 0,57 0,67 0,72 0,73 0,74 0,85 0,74 0, ,98 1,20 1,31 1,36 1,37 1,37 1, 1, ,31 1,65 1,83 1,91 1,93 1,93 1,90 1, , 2,97 3, 3, 3,47 3,46 3, 3, ,45 4,37 4,82 5,04 5,11 5, 5,06 4, ,40 5,56 6,14 6,40 6,49 6,49 6, 6, ,40 6,30 7,49 7,81 7,93 7,93 7,85 7,64 Evaporating temperature = -40 C 00 0,56 0,60 0,61 0,62 0,61 0,60 0, ,65 0,72 0,75 0,77 0,77 0,77 0, ,17 1,27 1,32 1,33 1,31 1, 1, ,09 2, 2,36 2,38 2,36 2,31 2, ,03 3,34 3,47 3,50 3,48 3, 3, ,87 4,25 4,41 4,45 4,43 4,36 4, ,73 5,19 5,39 5,45 5,47 5,33 5,19 Evaporating temperature = -60 C 00 0,46 0,48 0,47 0,45 0,45 0, ,58 0,60 0,60 0,58 0,56 0, ,78 0,80 0,80 0,78 0,75 0, ,40 1,44 1,43 1,40 1,36 1, ,04 2,11 2,11 2,07 2,03 1, ,59 2,69 2,66 2,65 2,59 2, , 3, 3,30 3,25 3,18 3,07 Evaporating temperature = -30 C 00 0,53 0,64 0,67 0,70 0,70 0,70 0,69 0, ,88 1,07 1,18 1,21 1,23 1,21 1,20 1, ,18 1,47 1,63 1,69 1,71 1,70 1,68 1, , 2,65 2,93 3,04 3,07 3,05 3,02 2, ,09 3,88 4, 4,47 4,52 4,51 4,46 4, 05 3,94 4,94 5,45 5,68 5,74 5,74 5,67 5, ,83 6,06 6,66 6,94 7,02 7,01 6,93 6,75 Evaporating temperature = -50 C 00 0,49 0,53 0,54 0,54 0,53 0,52 0, ,51 0,57 0,60 0,60 0,60 0,60 0, ,91 0,99 1,02 1,02 1,01 0,98 0, ,63 1,73 1,84 1,84 1,81 1,78 1, ,36 2,60 2,69 2,71 2,68 2,63 2, ,02 3,30 3,43 3,45 3, 3, 3, ,69 4,04 4,20 4, 4,18 4, 4,00 THERMOSTATIC EXPANSION VALVES Table 7b: Refrigerant R404A/R507 - Correction factor for subcooling tsub > 4 C tsub [ C] Fsub 1,00 1,10 1,20 1,29 1,37 1,46 1,54 1,63 1,70 1,78 When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 7b 27

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

29 Catalogue number internal equalizer external equalizer 2310/M6 0X /2 0X /3 0X /M10 0X /M6E 0X /2E 0X /3E 0X /M10E 0X /M6 0X /2 0X /3 0X /M10 0X /M6E 0X /2E 0X /3E 0X /M10E 0X /M6 0X /2 0X /3 0X /M10 0X /M6E 0X /2E 0X /3E 0X /M10E 0X /M6 0X /2 0X /3 0X /M10 0X /M6E 0X /2E 0X /3E 0X /M10E 0X /M6 0X /2 0X /3 0X /M10 0X /M6E 0X /2E 0X /3E 0X /M10E 0X /M6 0X /2 0X /3 0X /M10 0X /M6E 0X /2E 0X /3E 0X /M10E 0X /M6 0X /2 0X /3 0X /M10 0X /M6E 0X /2E 0X /3E 0X /M10E 0X 06 Table 1: General Characteristics of Thermostatic Expansion Valves [in] ODS Connections [mm] IN OUT Equal. IN OUT Equal. min max Refrigerant R134a R404A R507 Evaporating Temperature Range [ C] R - 40 R407C MOP without + 15 C (95 psi) without + 15 C (55 psi) without + 15 C (0 psi) C - 25 (30 psi) Max bulb temperature [ C] 100 (1) TS [ C] PS [bar] Risk Category according to PED Art. 3.3 THERMOSTATIC EXPANSION VALVES (1) when valve is installed. 60 C with element not mounted 29

30 The fixed orifice assembly provide a wide range of capacity from 0,5 up to 15,5 kw (nominal capacity with R). 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 0 CW 617N for body brass EN 4 CW 614N for superheat setting spindle and spring holder steel DIN for spring copper tube EN 7-1 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: it s 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 4 C. Opening superheat: it s the amount of superheat above the static superheat required to produce a given valve capacity Operating superheat: it s the sum of static and opening superheat 30

31 Subcooling: it s 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, Q e Evaporating temperature/pressure, T e / p e Lowest possible condensing temperature/pressure, T c / p c Liquid refrigerant temperature, T l 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 + p ) where: p c = condensing pressure p e = evaporating pressure p = sum of pressure drops in the liquid line, distributor and evaporator e Step 2 Determine required valve capacity. Use the evaporating capacity Q e 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 Q = sub sub From the subcooling corrector factor table find the appropriate corrector factor F sub corresponding to the T sub calculated and determine the required valve capacity by the formula: Step 3 Determine required orifice size. Use the pressure drop across the valve, the evaporating temperature and the calculated valve capacity to select the corresponding orifice size from the capacity table corresponding to the chosen refrigerant. Table 2: Fixed orifices - Rated Capacities in kw Orifice Size 23--/-0X 23--/ / / / / / /-06 R R407C e F Evaporating Temperature Range [ C] 0,5 1,0 2,5 3,5 5,2 8,0 10,5 15, 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 R404A R507 0,38 0,7 1,6 2,1 3,5 4,9 6,0 6,6 THERMOSTATIC EXPANSION VALVES Rated capacities, for temperature range , are based on: Evaporating temperature Tevap = + 5 C Condensing temperature Tcond = + 32 C Refrigerant liquid temperature ahead of valve Tliq = + C Rated capacities, for temperature range , are based on: Evaporating temperature Tevap = - 30 C Condensing temperature Tcond = + 32 C Refrigerant liquid temperature ahead of valve Tliq = + C 31

32 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 R Evaporator capacity, Q e 3,8 kw Evaporating temperature/ pressure, T e + 5 C Lowest possible condensing temperature/pressure, T c + 38 C Liquid refrigerant temperature,t l + 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 - P c = 13,6 bar Evaporating pressure at + 5 C - P e = 4.8 bar p tot = 13,6 STEP 2 - Determine required valve capacity From the subcooling corrector factor table 3b we find the appropriate corrector factor F sub equal to 1,07 for T sub = 11 C. Required valve capacity is: T sub = = 11 C Q sub ( 4,8 + 0,5 ) = 8,3 bar = 3,8 1,07 = 3,55 kw STEP 3 - Determine required orifice size Using the capacity table for R on page 33 with: pressure drop across the valve = 8,3 bar evaporating temperature = + 5 C calculated evaporator capacity = 3,55 kw select the corresponding valve 23--/-02 (N.B.: the expansion valve capacity must be equal or slightly more than the calculated evaporator capacity)

33 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 R/R407C - Capacities in kw for temperature range - 40 C + 10 C THERMOSTATIC EXPANSION VALVES Orifice size Pressure drop across valve [bar] Orifice size Pressure drop across valve [bar] Evaporating temperature = +10 C 23--/-0X 0,37 0,48 0,55 0,60 0,63 0,65 0,65 0, /-00 0,87 1,1 1,2 1,3 1,4 1,4 1,4 1,5 23--/-01 2,2 2,8 3,2 3,4 3,6 3,7 3,8 3,8 23--/-02 3,0 4,0 4,7 5,1 5,4 5,6 5,8 5,8 23--/-03 5,4 7,2 8,3 9,1 9,7 10,0 10,2 10,3 23--/-04 8,1 10,8,5 13,8 14,5 15,0 15,5 15,5 23--/-05 10,2 13,6 15,7 17,2 18,3 18,9 19,3 19,5 23--/-06,6,7 19,3 21,0,3 23,1 23,5 23,7 Evaporating temperature = -10 C 23--/-0X 0,37 0,47 0,53 0,57 0,60 0,63 0,64 0, /-00 0,79 0,96 1,1 1,2 1,2 1,3 1,3 1,3 23--/-01 1,6 2,0 2,3 2,5 2,6 2,7 2,8 2,8 23--/-02 2,2 2,9 3,3 3,6 3,8 4,0 4,1 4,1 23--/-03 3,9 5,1 5,9 6,4 6,8 7,1 7,3 7,3 23--/-04 5,8 7,6 8,7 9,5 10,1 10,5 10,8 10,9 23--/-05 7,4 9,6 11,0,0,8 13,3 13,6 13,8 23--/-06 9,1 11,6 13,5 14,7 15,6,2,6,8 Evaporating temperature = -30 C 23--/-0X 0,40 0,45 0,49 0,52 0,55 0,56 0, /-00 0,79 0,9 0,96 1,0 1,1 1,1 1,1 23--/-01 1,4 1,5 1,7 1,8 1,8 1,9 1,9 23--/-02 1,9 2,2 2,7 2,5 2,6 2,6 2,7 23--/-03 3,4 3,9 4,2 4,4 4,6 4,7 4,8 23--/-04 5,0 5,7 6,2 6,6 6,8 7,0 7,1 23--/-05 6,4 7,2 7,8 8,3 8,6 8,8 9,0 23--/-06 7,8 8,8 9,6 10,1 10,5 10,8 11,0 Evaporating temperature = 0 C 23--/-0X 0,37 0,48 0,55 0,59 0,63 0,65 0,66 0, /-00 0,84 1,0 1,2 1,3 1,3 1,4 1,4 1,4 23--/-01 1,9 2,4 2,7 3,0 3,1 3,2 3,3 3,3 23--/-02 2,6 3,4 4,0 4,3 4,6 4,8 4,9 5,0 23--/-03 4,6 6,1 7,1 7,8 8,2 8,5 8,7 8,8 23--/-04 6,9 9,1 10,5 11,5,2,7 13,0 13,2 23--/-05 8,8 11,6 13,3 14,6 15,5,1,4,6 23--/-06 10,8 14,2,3 17,8 18,9 19,6 20,0 20,2 Evaporating temperature = -20 C 23--/-0X 0,44 0,50 0,54 0,57 0,59 0,61 0, /-00 0,88 1,0 1,1 1,1 1,2 1,2 1,2 23--/-01 1,7 1,9 2,0 2,2 2,3 2,3 2,3 23--/-02 2,4 2,7 2,9 3,1 3,2 3,3 3,3 23--/-03 4,2 4,8 5,2 5,5 5,8 5,9 6,0 23--/-04 6,2 7,1 7,7 8,2 8,5 8,7 8,8 23--/-05 7,9 9,0 9,8 10,3 10,8 11,0 11,2 23--/-06 9,6 11,0 11,9,6 13,1 13,5 13,7 Evaporating temperature = -40 C 23--/-0X 0, 0,45 0,48 0,50 0,52 0, /-00 0,8 0,86 0,92 0,95 0,98 0, /-01 1,3 1,4 1,4 1,5 1,5 1,6 23--/-02 1,7 1,9 2,0 2,0 2,1 2,1 23--/-03 3,1 3,4 3,5 3,7 3,8 3,8 23--/-04 4,6 4,9 5,2 5,4 5,6 5,7 23--/-05 5,8 6,3 6,6 6,9 7,1 7,2 23--/-06 7,1 7,7 8,1 8,4 8,7 8,8 Table 3b: Refrigerant R/R407C - Correction factor for subcooling tsub > 4 C tsub [ C] Fsub 1,00 1,06 1,11 1,15 1,20 1,25 1,30 1, 1,39 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 33

34 Table 4a: Refrigerant R134a - Capacities in kw for temperature range - 40 C + 10 C Orifice size Pressure drop across valve [bar] Orifice size Pressure drop across valve [bar] Evaporating temperature = +10 C 23--/-0X 0,34 0,43 0,47 0,50 0, /-00 0,71 0,86 0,93 0,97 0, /-01 1,5 1,9 2,1 2,2 2,2 23--/-02 2,0 2,6 3,0 3,1 3,2 23--/-03 3,6 4,7 5,3 5,6 5,8 23--/-04 5,4 7,0 7,8 8,3 8,6 23--/-05 6,9 8,9 9,9 10,8 10,9 23--/-06 8,4 10,8,1,8 13,2 Evaporating temperature = -10 C 23--/-0X 0,30 0,36 0,43 0,44 0, /-00 0,59 0,70 0,77 0,81 0, /-01 1,0 1,3 1,4 1,5 1,5 23--/-02 1,4 1,8 2,0 2,1 2,1 23--/-03 2,5 3,1 3,5 3,7 3,8 23--/-04 3,6 4,6 5,1 5,4 5,6 23--/-05 4,6 5,8 6,5 6,9 7,1 23--/-06 5,7 7,1 8,0 8,4 8,6 Evaporating temperature = -30 C 23--/-0X 0,25 0,32 0, 0,37 0, /-00 0,48 0,55 0,61 0,64 0, /-01 0,66 0,80 0,88 0,93 0, /-02 0,9 1,1 1,2 1,3 1,3 23--/-03 1,6 2,0 2,2 2,3 2,3 23--/-04 2,3 2,9 3,2 3,3 3,4 23--/-05 3,0 3,6 4,0 4,2 4,3 23--/-06 3,6 4,4 4,9 5,2 5,3 Evaporating temperature = 0 C 23--/-0X 0,33 0, 0,46 0,47 0, /-00 0,65 0,78 0,86 0,89 0, /-01 1,3 1,6 1,7 1,8 1,8 23--/-02 1,7 2,2 2,4 2,6 2,6 23--/-03 3,0 3,9 4,4 4,6 4,7 23--/-04 4,5 5,7 6,4 6,8 7,0 23--/-05 5,7 7,3 8,1 8,6 8,8 23--/-06 7,0 8,9 1,0 10,5 10,8 Evaporating temperature = -20 C 23--/-0X 0, 0, 0,39 0,41 0, 23--/-00 0,53 0,62 0,69 0,72 0, /-01 0,81 1,0 1,1 1,2 1,2 23--/-02 1,1 1,4 1,5 1,6 1,7 23--/-03 2,0 2,5 2,8 2,9 3,0 23--/-04 2,9 3,6 4,0 4,3 4,4 23--/-05 3,7 4,6 5,1 5,4 5,5 23--/-06 4,5 5,6 6,2 6,6 6,8 Evaporating temperature = -40 C 23--/-0X 0,23 0, 0,32 0,33 0, /-00 0,44 0,50 0,54 0,56 0, /-01 0,54 0,65 0,72 0,78 0, /-02 0,7 0,9 1,0 1,0 1,0 23--/-03 1,3 1,6 1,8 1,9 1,9 23--/-04 1,9 2,3 2,6 2,7 2,7 23--/-05 2,4 2,9 3,2 3,5 3,5 23--/-06 3,0 3,6 4,0 4,2 4,3 Table 4b: Refrigerant R134a - Correction factor for subcooling tsub > 4 C tsub [ C] Fsub 1,00 1,08 1,13 1,19 1,25 1,31 1,37 1, 1,48 1,54 When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 4b 34

35 Orifice size Table 5a: Refrigerant R404A/R507 - Capacities in kw for temperature range - 40 C + 10 C Pressure drop across valve [bar] Orifice size Pressure drop across valve [bar] Evaporating temperature = +10 C 23--/-0X 0, 0, 0,40 0, 0,43 0,43 0, 0, /-00 0,67 0,82 0,90 0,94 0,96 0,96 0,93 0, /-01 1,70 2,10 2,30 2, 2,48 2,46 2,41 2, /-02 2,32 3,00 3,39 3,61 3,73 3,74 3,68 3, /-03 4,15 5,36 6,03 6,43 6,63 6,66 6,55 6, /-04 6,24 8,06 9,06 9,66 9,95 9,98 9,81 9, /-05 7,91 10,17 11,43,,53,56,34, /-06 9,71,47 13,98 14,86 15,29 15,31 15,05 14,66 Evaporating temperature = -10 C 23--/-0X 0,30 0,37 0,40 0, 0, 0, 0,41 0, /-00 0,65 0,76 0,82 0,84 0,87 0,87 0,85 0, /-01 1,31 1,61 1,74 1,81 1,84 1,85 1,84 1, /-02 1,76 2,24 2,50 2,62 2,69 2,71 2,68 2, /-03 3,14 4,02 4,47 4,69 4,81 4,84 4,79 4, /-04 4,66 5,97 6,61 6,95 7,13 7,18 7,11 6, /-05 5,93 7,57 8,39 8,81 9,02 9,08 8,99 8, /-06 7, 9,27 10,26 10,76 11,00 11,08 10,97 10,65 Evaporating temperature = -30 C 23--/-0X 0, 0,37 0,36 0,37 0,36 0, 23--/-00 0,67 0,70 0,70 0,70 0,69 0, /-01 1,18 1,21 1,23 1,21 1,20 1, /-02 1,63 1,69 1,71 1,70 1,68 1, /-03 2,93 3,04 3,07 3,06 3,02 2, /-04 4, 4,47 4,52 4,51 4,46 4, 23--/-05 5,45 5,68 5,74 5,74 5,67 5, /-06 6,66 6,94 7,02 7,01 6,93 6,75 Evaporating temperature = 0 C 23--/-0X 0,30 0,37 0,41 0, 0,43 0,43 0,43 0, /-00 0,68 0,80 0,87 0,90 0,92 0,93 0,91 0, /-01 1,53 1,86 2,04 2,13 2,18 2,18 2,15 2, /-02 2,06 2,64 2,95 3,13 3, 3,25 3,21 3, /-03 3,68 4,72 5,27 5,59 5,75 5,80 5,73 5, /-04 5,49 7,15 7,86 8,33 8,58 8,64 8,53 8, /-05 6,97 8,92 9,95 10,52 10,83 10,90 10,76 10, /-06 8,57 10,93,,85 13,21 13,30 13,,72 Evaporating temperature = -20 C 23--/-0X 0, 0,38 0,40 0,39 0,40 0,39 0, /-00 0,70 0,75 0,77 0,79 0,79 0,79 0, /-01 1,34 1,45 1,50 1,52 1,52 1,51 1, /-02 1,85 2,04 2,14 2,17 2,18 2, 2, /-03 3,32 3,66 3,83 3,89 3,90 3,86 3, /-04 4,88 5,40 5,64 5,75 5,77 5,71 5, /-05 6,20 6,86 7,17 7,29 7,31 7,23 7, /-06 7,60 8,39 8,75 8,91 8,93 8,84 8,61 Evaporating temperature = -40 C 23--/-0X 0,32 0,33 0,33 0,33 0,32 0, /-00 0,60 0,61 0,62 0,61 0,60 0, /-01 0,92 0,96 0,97 0,96 0,94 0, /-02 1,27 1,32 1,33 1,31 1, 1, /-03 2, 2,36 2,38 2,36 2,31 2, /-04 3,34 3,47 3,50 3,48 3, 3, /-05 4,25 4,41 4,45 4,43 4,36 4, /-06 5,19 5,39 5,45 5, 5,33 5,19 THERMOSTATIC EXPANSION VALVES Table 5b: Refrigerant R404A/R507 - Correction factor for subcooling tsub > 4 C tsub [ C] Fsub 1,00 1,10 1,20 1,29 1,37 1,46 1,54 1,63 1,70 1,78 When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 5b

36 Table 6a: Refrigerant R404A/R507 - Capacities in kw for temperature range - 60 C - 25 C Orifice size Pressure drop across valve [bar] Orifice size Pressure drop across valve [bar] Evaporating temperature = -25 C 23--/-00 0,57 0,67 0,72 0,73 0,74 0,85 0,74 0, /-01 0,98 1,20 1,31 1,36 1,37 1,37 1, 1, /-02 1,31 1,65 1,83 1,91 1,93 1,93 1,90 1, /-03 2, 2,97 3, 3, 3,47 3,46 3, 3, /-04 3,45 4,37 4,82 5,04 5,11 5, 5,06 4, /-05 4,40 5,56 6,14 6,40 6,49 6,49 6, 6, /-06 5,40 6,30 7,49 7,81 7,93 7,93 7,85 7,64 Evaporating temperature = -40 C 23--/-00 0,56 0,60 0,61 0,62 0,61 0,60 0, /-01 0,65 0,72 0,75 0,77 0,77 0,77 0, /-02 1,17 1,27 1,32 1,33 1,31 1, 1, /-03 2,09 2, 2,36 2,38 2,36 2,31 2, /-04 3,03 3,34 3,47 3,50 3,48 3, 3, /-05 3,87 4,25 4,41 4,45 4,43 4,36 4, /-06 4,73 5,19 5,39 5,45 5,47 5,33 5,19 Evaporating temperature = -60 C 23--/-00 0,46 0,48 0,47 0,45 0,45 0, /-01 0,58 0,60 0,60 0,58 0,56 0, /-02 0,78 0,80 0,80 0,78 0,75 0, /-03 1,40 1,44 1,43 1,40 1,36 1, /-04 2,04 2,11 2,11 2,07 2,03 1, /-05 2,59 2,69 2,66 2,65 2,59 2, /-06 3, 3, 3,30 3,25 3,18 3,07 Evaporating temperature = -30 C 23--/-00 0,53 0,64 0,67 0,70 0,70 0,70 0,69 0, /-01 0,88 1,07 1,18 1,21 1,23 1,21 1,20 1, /-02 1,18 1,47 1,63 1,69 1,71 1,70 1,68 1, /-03 2, 2,65 2,93 3,04 3,07 3,05 3,02 2, /-04 3,09 3,88 4, 4,47 4,52 4,51 4,46 4, 23--/-05 3,94 4,94 5,45 5,68 5,74 5,74 5,67 5, /-06 4,83 6,06 6,66 6,94 7,02 7,01 6,93 6,75 Evaporating temperature = -50 C 23--/-00 0,49 0,53 0,54 0,54 0,53 0,52 0, /-01 0,51 0,57 0,60 0,60 0,60 0,60 0, /-02 0,91 0,99 1,02 1,02 1,01 0,98 0, /-03 1,63 1,73 1,84 1,84 1,81 1,78 1, /-04 2,36 2,60 2,69 2,71 2,68 2,63 2, /-05 3,02 3,30 3,43 3,45 3, 3, 3, /-06 3,69 4,04 4,20 4, 4,18 4, 4,00 Table 6b: Refrigerant R404A/R507 - Correction factor for subcooling tsub > 4 C tsub [ C] Fsub 1,00 1,10 1,20 1,29 1,37 1,46 1,54 1,63 1,70 1,78 When subcooling ahead of the expansion valve is other than 4 C, adjust the evaporatore capacity by dividing by the appropriate correction factor found in Table 6b 36

37 SOLENOID VALVES 37

38 SOLENOID VALVES FOR REFRIGERATING SYSTEMS APPLICATIONS The solenoid valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). OPERATION The valves series 1020; 10; 1050; 1058; 1059; 1064; 1068; 1070; 1078; 1079; 1090; 1098; 1099 are normally closed. NC = when the coil is de-energised the plunger stops the refrigerant flow. The valves series 1150; 1158; 14; 18; 1170; 1178;1190; 1198 are normally open. NO = when the coil is energised the plunger stops the refrigerant flow. The valves series 1020 and 10 are direct acting, while the valves of all the other series are pilot operated, with diaphragm or piston. The NC valves are supplied either without coil (S type) or with coil (example: A6 type with coil HM20 Vac). The NO valves are supplied only without coil (S type). N.B.: the NO valve visually differs from the corresponding NC model by means of the red ring installed below the yellow nut that fastens the coil. CONSTRUCTION The main parts of the valves are made with the following materials: hot forged brass EN 0 CW 617N for body and cover; copper tube EN 7-1 Cu-DHP for solder connections; austenitic stainless steel EN for enclosure where the plunger moves; ferritic stainless steel EN for plunger: austenitic stainless steel EN ISO 06 A2-70 for tightening screws between body and cover; chloroprene rubber (CR) for outlet seal gaskets; P.T.F.E. for seat gaskets. INSTALLATION The valves can be installed in all sections of a refrigerating system, in compliance with the limits and capacities indicated in Tables 3 and 6. Tables 1 and 4 show the following functional characteristics of a solenoid valve: PS; TS; Kv factor; minimum Opening Pressure Differential (minopd), that is the minimum pressure differential between inlet and outlet at which a solenoid valve, pilot operated, can open and stay opened; maximum Opening Pressure Differential (MOPD according to ARI STANDARD 760: 2001), that is the maximum pressure differential between inlet and outlet at which a solenoid valve, pilot operated, can open. Before connecting the valve to the pipe it is advisable to make sure that the refrigerating system is clean. In fact the valves with P.T.F.E. gaskets are particularly sensitive to dirt and debris. Furthermore check that the flow direction in the pipe corresponds to the arrow stamped on the body of the valve. All valves can be mounted in whatever position except with the coil pointing downwards. The brazing of valves with solder connections should be carried out with care, using a low melting point filler material. It is not necessary to disassemble the valves before brazing but it s important to avoid direct contact between the torch flame and the valve body, which could be damaged and compromise the proper functioning of the valve. Before connecting a valve to the electrical system, be sure that the line voltage and frequency correspond to the values marked on the coil. 38

39 The NO valves have been designed to work only with direct current coils. To use them with an alternate current supply it s necessary to mate the NO valve with the following components: Catalogue Number 1020/2 1020/3 10/2 10/2E 10/3 10/M /3 1064/4 1068/3 1068/M /M 1068/4 1070/4 1070/5 1078/M 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/ /9 1099/ / / /M SAE Flare 3/4" 3/4" Connections [in.] 7/8" 3/4" 7/8" 1.1/8" 3/4" 7/8" 1.1/8" 1.1/8" /8" ODS [mm] voltage 24 Vac: Coil 90/RD2 + Connector 9150/R44; voltage 0 Vac: Coil 90/RD6 + Connector 9150/R45. TABLE 1: General Characteristics of NC valves (normally closed) Seat size nominal [mm] 2,5 3 2,2 3 7,5,5 25, Kv Factor [m 3 /h] 0,175 0,23 0,15 0,23 0,80 2,20 2,61 2,20 2,61 3,80 4,80 3,80 4,80 5,70 3,80 4,80 3,80 4,80 5, Operating Principles Ditect Acting Diaphragm Pilot Operated Piston Pilot Operated Diaphragm Pilot Operated Piston Pilot Operated Opening Pressure Differential [bar] min OPD 0 0,05 0,07 0,05 0,07 HM2 CM2 (AC) 21 MOPD Coil type HM4 (AC) 25 (3) (3) HM3 (DC) min. TS [ C] max (1) +110 (2) +105 (1) +110 (2) PS [bar] Risk Category according to PED 45 Art. 3.3 SOLENOID VALVES (1) Temperature peaks of 0 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. 39

40 SOLENOID VALVES FOR REFRIGERATING SYSTEMS TABLE 2: Dimensions and Weights of NC valves with 9100 coil (1) Dimensions [mm] Catalogue Number H 1 H 2 H 3 L 1 L 2 Q Weight [g] 1020/ / /2 10/2E 75 62, / /M / / /3 1068/M , /M / / / /M 1078/ / / / / /5 1058/ / /9 1090/ / /5 1098/ / / /9 1079/ /9 1099/ / / /M 2750 (1) With coil type 90 the dimension L 2 is equal to 64 mm and the valves weights must be increased of 305 g. 40

41 H1 H2 H1 H2 L1 L2 L2 H3 1020/2 1020/3 H3 H1 H2 H1 H2 L1 L2 L2 H3 H3 10/2 10/2E 10/3 10/M10 SOLENOID VALVES L1 L2 1064/3 1064/4 L1 L2 1068/3 1068/4 1068/M /M H1 H2 Q H3 H1 H2 Q H3 L1 L2 1070/4 1070/5 L1 L2 1078/M 1078/4 1078/5 1079/7 H1 H2 Q H3 H1 H2 Q H3 L1 L2 1050/5 1050/6 1090/5 1090/6 L1 L2 1058/5 1058/6 1058/7 1059/9 1098/5 1098/6 1098/7 1099/9 H2 H1 H2 Q H3 H1 Q H3 L1 1078/9 1079/11 Connectors are not included in the boxes and have to be ordered separately. L1 1098/9 1099/ / / /M 41

42 SOLENOID VALVES FOR REFRIGERATING SYSTEMS TABLE 3: Refrigerant Flow Capacity of NC valves Resa frigorifera [kw] Catalogue Number Liquid Vapour Hot Gas R134a R R407C R404A R410A R134a R R407C R404A R410A R134a R R407C R404A R410A 1020/2 2,95 3,15 3, 2,08 3,33 1,49 2,05 2,03 1,75 2, 1020/3 3,88 4,14 4,31 2,74 4,38 1,96 2,69 2,67 2,30 2,99 10/2 10/2E 2,53 2,70 2,81 1,79 2,86 1, 1,76 1,74 1,50 1,95 10/3 3,88 4,14 4,31 2,74 4,38 1,96 2,69 2,67 2,30 2,99 10/M /3 1064/4 1068/3 1068/M10 13,5 14,4 15,0 9,5 15,2 1,73 2, 2,14 1,81 2,88 6,8 9,4 9,3 8,0 10,4 1068/M 1068/4 1070/4 37,1 39,6 41,2 26,2 41,9 4,75 5,94 5,90 4,97 7,92 18,7 25,7 25,6,0,6 1070/5 44,0 47,0 48,9 31,1 49,7 5,64 7,05 6,99 5,90 9,40,2 30,5 30,3 26,1 33,9 1078/M 1078/4 37,1 39,6 41,2 26,2 41,9 4,75 5,94 5,90 4,97 7,92 18,7 25,7 25,6,0,6 1078/5 1079/7 44,0 47,0 48,9 31,1 49,7 5,64 7,05 6,99 5,90 9,40,2 30,5 30,3 26,1 33,9 1050/5 64,0 68,4 71,2 45,2 72,4 8,2 10,3 10,2 8,6 13,7 32,3 44,5 44,2 38,0 49,4 1050/6 80,9 86,4 90,0 57,1 91,4 10,4 13,0,9 10,8 17,3 40,8 56,2 55,8 48,0 62,4 1058/5 64,0 68,4 71,2 45,2 7,4 8,2 10,3 10,2 8,6 13,7 32,3 44,5 44,2 38,0 49,4 1058/6 80,9 86,4 90,0 57,1 91,4 10,4 13,0,9 10,8 17,3 40,8 56,2 55,8 48,0 62,4 1058/7 1059/9 96,0 102,6 106,8 67,8 108,5,3 15,4 15,3,9 20,5 48,5 66,7 66,2 57,0 74,1 1090/5 64,0 68,4 71,2 45,2 72,4 8,2 10,3 10,2 8,6 13,7 32,3 44,5 44,2 38,0 49,9 1090/6 80,9 86,4 90,0 57,1 91,4 10,4 13,0,9 10,8 17,3 40,8 56,2 55,8 48,0 62,4 1098/5 64,0 68,4 71,2 45,2 72,4 8,2 10,3 10,2 8,6 13,7 32,3 44,5 44,2 38,0 49,4 1098/6 80,9 86,4 90,0 57,1 91,4 10,4 13,0,9 10,8 17,3 40,8 56,2 55,8 48,0 62,4 1098/7 1099/9 96,0 102,6 106,8 67,8 108,5,3 15,4 15,3,9 20,5 48,5 66,7 66,2 57,0 74,1 1078/9 1079/11 8,5 180,0 187,4 119,0 190,4 21,6 27,0 26,8,6 36,0 85,0 117,0 1,2 100,0 130,0 1098/9 1099/11 8,5 180,0 187,4 119,0 190,4 21,6 27,0 26,8,6 36,0 85,0 117,0 1,2 100,0 130,0 1078/ /13 269,6 8,0 299,8 190,4 304,6 34,6 43,2,9 36,2 57,6 136,0 187,2 185,9 0,0 208,0 1079/M Refrigerant flow capacity referred to the following operating conditions: Evaporating temperature: + 4 C Condensing temperature: + 38 C Pressure drop: 0,15 bar Particularly for hot gas: Suction temperature: + 18 C Pressure drop: 1 bar

43 Catalogue Number 14/3 R 18/3 R 18/M10 R 1170/4 R 1170/5 R 1178/M R 1178/4 R Coil Type SAE Flare TABLE 4: General Characteristics of NO valves (normally open) Connections [in.] ODS [mm] 10 Seat size nominal [mm] 7,5 Kv Factor [m 3 /h] 0,80 2,20 2,61 2,20 Operating Principles Diaphragm Pilot operated Opening Pressure Differential [bar] min OPD 0,05 MOPD 21 min. TS [ C] max (1) PS [bar] Risk Category according to PED SOLENOID VALVES 1178/5 R 2, /5 R 3, /6 1158/5 1158/6 1158/7 1190/5 R R R R R HM3 (D.C.) 3/4" 3/4" 7/8",5 4,80 3,80 4,80 5,70 3,80 Piston Pilot Operated 0, (2) 32 Art /6 R 3/4" 4, /5 1198/6 R R 3/4" 3,80 4,80 Diaphragm Pilot operated 0, (1) 1198/7 R 7/8" 5, /9 R 1.1/8" 25, /9 R 1178/11 R 1.1/8" Piston Pilot Operated 0, (2) (1) Temperature peaks of 0 C are allowed during defrosting. (2) Temperature peaks of 130 C are allowed during defrosting. R Available on request. 43

44 SOLENOID VALVES FOR REFRIGERATING SYSTEMS L2 L2 H1 H2 H3 H3 H1 H2 L1 14/3 L2 Q H1 H2 H3 L1 1170/4 1170/5 L2 L2 H2 H1 H3 H1 H2 L1 18/3 18/M10 L2 Q L1 1178/M 1178/4 1178/5 L2 L2 H1 H2 Q L1 H3 1150/5 1150/6 1190/5 1190/6 H1 H2 Q L H3 1158/5 1158/6 1158/7 1198/5 1198/6 1198/7 H2 Q H3 H1 Q H3 L1 1178/9 L1 1198/9 1178/11 Connectors and coils are not included in the boxes and have to be ordered separately. 44

45 Catalogue Number 14/3 18/3 18/M /4 1170/5 1178/M TABLE 5: Dimensions and Weights of NO valves with 90 coil Dimensions [mm] H 1 H 2 H 3 L 1 L 2 Q , Weight [g] SOLENOID VALVES 1178/ / / / / / /7 1190/ / / / / / / / TABLE 6: Refrigerant Flow Capacity of NO valves Refrigerant Flow Capacity [kw] Catalogue Number Liquid Vapour Hot Gas R134a R R407C R404A R134a R R407C R404A R134a R R407C R404A 14/3 18/3 13,5 14,4 15,0 9,5 1,73 2, 2,14 1,81 6,8 9,4 9,3 8,0 18/M /4 37,1 39,6 41,2 26,2 4,75 5,94 5,90 4,97 18,7 25,7 25,6,0 1170/5 44,0 47,0 48,9 31,1 5,64 7,05 6,99 5,90,2 30,5 30,3 26,1 1178/M 1178/4 37,1 39,6 41,2 26,2 4,75 5,94 5,90 4,97 18,7 25,7 25,6,0 1178/5 44,0 47,0 48,9 31,1 5,64 7,05 6,99 5,90,2 30,5 30,3 26,1 1150/5 64,0 68,4 71,2 45,2 8,2 10,3 10,2 8,6 32,3 44,5 44,2 38,0 1150/6 80,9 86,4 90,0 57,1 10,4 13,0,9 10,8 40,8 56,2 55,8 48,0 1158/5 64,0 68,4 71,2 45,2 8,2 10,3 10,2 8,6 32,3 44,5 44,2 38,0 1158/6 80,9 86,4 90,0 57,1 10,4 13,0,9 10,8 40,8 56,2 55,8 48,0 1158/7 96,0 102,6 106,8 67,8,3 15,4 15,3,9 48,5 66,7 66,2 57,0 1190/5 64,0 68,4 71,2 45,2 8,2 10,3 10,2 8,6 32,3 44,5 44,2 38,0 1190/6 80,9 86,4 90,0 57,1 10,4 13,0,9 10,8 40,8 56,2 55,8 48,0 1198/5 64,0 68,4 71,2 45,2 8,2 10,3 10,2 8,6 32,3 44,5 44,2 38,0 1198/6 80,9 86,4 90,0 57,1 10,4 13,0,9 10,8 40,8 56,2 55,8 48,0 1198/7 96,0 102,6 106,8 67,8,3 15,4 15,3,9 48,5 66,7 66,2 57,0 1178/9 8,5 180,0 187,4 119,0 21,6 27,0 26,8,6 85,0 117,0 1,2 100,0 1198/9 8,5 180,0 187,4 119,0 21,6 27,0 26,8,6 85,0 117,0 1,2 100,0 1178/11 269,6 8,0 299,8 190,4 34,6 43,2,9 36,2 136,0 187,2 185,9 0,0 Refrigerant flow capacity referred to the following operating conditions: Evaporating temperature: + 4 C Condensing temperature: + 38 C Pressure drop: 0,15 bar Particularly for hot gas: Suction temperature: + 18 C Pressure drop: 1 bar 45

46 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 ). coils series CM2, only for A.C. (catalogue number 9110); coils series HM3,either for A.C. or for D.C. (catalogue number 90). coils series HM4, only for A.C. (catalogue number 90). For the normally open solenoid valves, always shown in this Handbook, the customer s selection must compulsorily apply to the coils series HM3 D.C. For applications of the NO solenoid valves with a voltage supply of 0 VAC, Castel has designed a specific coil at 0 V RAC (code 90/RD6) that must be used solely with the 0 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 90/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 and EN 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 9 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 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 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, 0/230V- 50/60Hz 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, 0/230 VAC and 240 VAC) or coils type HM3 (0/230 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/

47 Coil Type HM2 HM2 Recognized File number E Catalogue Number 9100/RA2 9100/RA4 9100/RA6 9100/RA7 9100/RA8 9105/RA2 9105/RA4 9105/RA6 9105/RA7 TABLE 1: General Characteristics of coils Voltage [V] 24 A.C. 110 A.C. 0/230 A.C. 240 A.C. 380 A.C. 24 A.C. 110/0 A.C. 0/230 A.C. 240 A.C. Voltage tollerance [%] +10 / / / / / / -10 Frequecy [Hz] 50 / Connections Junction box DIN Junction box DIN Degree of protection IP65 EN (with junction box) IP65 EN (with junction box) SOLENOID VALVES CM2 9110/RA2 9110/RA4 9110/RA6 24 A.C. 110 A.C. 0/230 A.C. +10 / / / 60 Three wire cable IP65 EN /RA7 240 A.C. +10 / -10 HM3 90/RA6 90/RD1 90/RD2 90/RD4 90/RD6 0/230 A.C. D.C. 24 D.C. 48 D.C. 0 RAC +6 / / / 60 Junction box DIN IP65 EN (with junction box) HM4 90/RA2 90/RA4 90/RA6 90/RA7 24 A.C. 110 A.C. 0/230 A.C. 240 A.C. +10 / / / / 60 Junction box DIN or Connector 9155/R01 (1) IP65 EN (with junction box) IP65/IP68 EN (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 H L2 H HM2 L1 CM2 L1 47

48 TABLE 2: Coils Consumptions Coil Type Catalogue Number Start Consumptions at 20 C [ma] Working Dimensions [mm] Weight [g] 50 [Hz] 60 [Hz] D.C. 50 [Hz] 60 [Hz] D.C. L 1 L 2 H 9100/RA /RA HM2 9100/RA _ _ 57, /RA /RA HM2 9105/RA Recognized 9105/RA4 9105/RA , /RA /RA CM2 9110/RA4 9110/RA , /RA /RA /RD HM3 90/RD2 90/RD /RD /RA HM4 90/RA4 90/RA /RA L2 L2 H H HM3 L1 HM4 L1 48

49 CONNECTORS The junction boxes 9150, DIN 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 mm 2 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 mm 2 are to be preferred for this junction box too. The junction box type 9155/R01 offers a protection degree IP65/IP68 against dust and water, according to EN 60529, when correctly installed with the proper gaskets, which are supplied as standard. The junction box 9150/R44 and 9150/R45 are equipped with a full-wave bridge rectifier plus VDR for protection. The VDR device, Voltage e-dependent-resistor, is a special type of resistor, placed in parallel to the coil; its purpose is to protect the diodes and the coil from any excessive voltage generated within the ac supply circuit. SOLENOID VALVES TABLE 3: General Characteristics of connectors Catalogue Number Nominal Supply Voltage [V] Maximum Pg Cable length [m] Cable thickness [mm 2 ] Standard Degree of protection Class of insulation 9150/R /R02 9 DIN IP /R /R45 24 A.C. 0 A.C. 30 A.C. 250 A.C EN /R01 IP65/IP68 EN Group C VDE /X66 1 / /X /X /X55 R 1, x 0,75 DIN IP65 EN /X54 5 R Available on request. 49

50 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. PERMANENT MAGNET NC SOLENOID VALVE CONSTRUCTION The main parts of the permanent magnet code 9900/X91 are made with the following materials: three rings of anisotropic ferrite; anodized aluminum for the body. SOLENOID VALVES FOR DIFFERENT FLUIDS APPLICATIONS Connectors are not included in the boxes and have to be ordered separately. The solenoid valves, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section and are subject of Article 3, Section 1.3 of the same Directive. They are designed for the applications specified in Table 1 where the different fluids are indicated with the following symbols, according to an already established code: W = Water; L = Air; B = Secondary coolants (solutions of glycol and water); O = Light oils (gas oil). In short these valves may be used: with fluids in the gaseous state proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC); with fluids in the liquid state proper to the Group I (as defined in Article 9, Section 2.1 of Directive 97/23/EC and referred to in Directive 67/548/EEC). 50

51 Catalogue Number 15/01 15/02 15/03 15/ / / / /08 11/010 11/0 Coil Type HM2 (A.C.) - CM2 (A.C.) - HM3 (A.C.; D.C.) - HM4 (A.C.) Main Use W.L.O. W.O. W.L.O.B. FPT Connections G 1/8" G G G G G G 3/4" G 1" G 1. G 1. TABELLA 1: General Characteristics Seat Size nominal [mm] 1,5 4,5, Kv Factor [m 3 /h] 0,070 0,40 2,10 2,20 5,50 6,00 19,00 21,00 Operating Principles Direct Acting Diaphragm Pilot Operated Opening Pressure Differential [bar] min OPD 0 0,1 0,15 0,3 MOPD TS [ C] min. max PS [bar] Risk Category according to PED Art. 3.3 SOLENOID VALVES 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 15 and 15 are direct acting, while the valves series 1132 and 11 are pilot operated with diaphragm. CONSTRUCTION The main parts of the valves are made with the following materials: hot forged brass EN 0 CW 617N for body and cover; austenitic stainless steel EN for enclosure where the plunger moves; ferritic stainless steel EN for plunger; austenitic stainless steel EN ISO 06 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 11. 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. 51

52 VISCOSITY The values of maximum differential pressure specified in Table 1 are suitable for fluids with maximum cinematic viscosity of cst where: 1cSt = 10-6 m 2 /sec. If the cinematic viscosity of the fluid under consideration is more than cst it is necessary to multiply the value of the maximum differential pressure by the following reducing factors: Viscosity cst When the viscosity of the liquid is expressed as dynamic viscosity, i.e. cp, where: 1cP = 10-3 N sec/m 2 Reducing Factor 1 0,8 0,7 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/dm 3 ]. Moreover, the fluid viscosity may remarkably vary according to changes in temperature. Therefore, if the temperature of the fluid does not ensure viscosity values compatible with the correct operation of the valve, the valve may not open. LIQUIDS CAPACITY The following ratio applies: p Q = Kv where: Kv = Kv factor of the valve [m 3 /h]; Q = capacity [m 3 /h]; p = pressure drop through the valve [bar]; = volumic mass of the liquid [kg/dm 3 ]. AIR CAPACITY Table 2 provides the values of air capacity under the following conditions: temperature at valve inlet = 20 C; discharge pressure (absolute) = 1 bar; Kv of the valve under consideration = 1 m 3 /h. The pressures upstream the valve specified in the table are absolute values. EXAMPLE Select the valve suitable for use with approximately 200 m 3 /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 m 3 /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. 52

53 Pressure drop [bar] TABLE 2 - Air Capacity (Kv = 1) Capacity [m 3 /h] (1) INLET PRESSURE (absolute) [bar] ,5 1,3 1,2 1,1 1,05 1,03 1,015 0,0025 0,005 0,010 0,015 0,025 0,05 0,10 0,15 0,25 0,5 82,0 80,0 77,0 74,0 72,0 69,5 66,6 63,7 60,6 57,3 54, ,0 111,0 108,0 104,0 100,0 96,0 92,0 88,0 83,0 78,6 73,5 1,5 138,0 134,0 130,0 5,0 0,0 115,5 110,3 105,0 99,3 93,0 87, ,0 152,0 147,0 1,0 136,0 130,0 4,0 118,0 111,0 96,0 96,0 2,5 173,0 7,5 1,5 155,5 149,0 1,5 1,5 8,0 0,4 1,0 103, ,0 180,0 174,0 7,0 0,0 152,0 144,5 136,0 7,0 118,0 108,0 3,5 198,0 191,0 184,0 176,5 8,6 0,3 151,7 1,5 132,6 2,0 110, ,0 200,0 193,0 184,0 176,0 7,0 157,0 147,0 136,0 4,0 111,0 4,5 2,0 208,6 200,0 191,0 182,0 172,0 1,5 150,4 138,0 5,0 5 4,0 215,0 206,0 195,5 186,0 176,0 4,5 152,3 139,0 5,5 230,0 1,0 211,0 201,0 190,0 178,6 6,3 152, ,0 6,0 215,0 204,0 192,7 180,0 6,8 6,5 240,0 230,0 218,0 206,7 194,0 180, ,0 233,0 0,0 208,0 194,7 7,5 246,0 234,0 2,0 208, ,0 236,0 2,5 8,5 250,0 236, ,5 1,46 1, 1,40 1, 2,2 2,10 2,00 1,95 1,90 3,0 3,0 3,00 2,85 2,80 2,75 4,2 3,9 3,7 3,55 3,45 3,40 3, 6,2 5,4 5,0 4,8 4,56 4,45 4,40 10,7 8,7 7,5 6,9 6,6 6,40 6,20 17,4 15,0,2 10,2 9,6 9,2 8,80 23,8 21,2 18,3 14,6,5 11,5 11,0 33,4 30,4 27,0 23,2 18,5 15,6 13,9 50,0 46,0 41,7 36,8 31,0 24,3 19,6 68,0 62,0 55,6 48,0 39,3 27,8 80,0 72,0 63,7 53,8 41,7 88,0 78,0 68,0 55,6 89,5 82,0 69,5 96,0 83,0 97,0 SOLENOID VALVES (1) The table provides air capacity values in m 3 /h under the following conditions: temperature at value inlet: + 20 C pressure at outlet (absolute): 1 bar Kv of the solenoid valve: 1 m 3 /h 53

54 Catalogue Number TABLE 3 - Dimensions and Weight (Valves with coils 9100) Dimensions [mm] H 1 H 2 H 3 L 1 L 2 Q Weight [g] 1132/ / / / /010 11/ / /02 15/ /04 5 With coils 90 the dimension L 2 is equal to 64 mm and the weight must be increased of 305 g. L2 L2 L2 H1 H2 H3 H1 H2 H3 H1 H2 Q H3 L1 15/01 L1 15/02 15/03 15/04 L1 1132/ /04 L2 L2 Q H1 H2 H2 Q H3 H1 H3 L1 1132/ /08 11/010 11/0 L1 Connectors are not included in the boxes and have to be ordered separately. 54

55 SAFETY DEVICES 55

56 SAFETY VALVES 3030 GENERAL DESCRIPTION Valves series 3030 are safety devices according to the definition given in Article 1, Point 2.1.3, 2nd dash of 97/23/EC Directive and are the subject of Article 3, Point 1.4 of aforesaid Directive. The valves above mentioned are standard type, unbalanced, direct-loaded safety valves. Valve opening is produced by the thrust the fluid under pressure exerts on the disc, when said thrust exceeds, under setting conditions, the opposing force of the spring acting on the disc. Valves are identified by means of: a model number formed of an alphanumerical coding that includes: in the first part the family identification (e.g. 3030/44C); in the second part the setting pressure, expressed in bars, multiplied by 10 (e.g. 140); a progressive serial number. CONSTRUCTION Body: squared, obtained through die forging and subsequent machining. It houses the following elements: the nozzle with flat sealing seat; the disc guide; the setting spring holder; the threaded seat of the setting adjusting ring nut. In the body, above the disc guide, a small pressure relief hole is provided through which the spring holder is put into contact TABLE 1: General Characteristics of valves 3030 Catalogue Number 3030/44C 3030/66C 3030/88C Inlet male Connections Outlet male Flow Diameter [mm] Flow Section [mm 2 ] Lift [mm] Discharge Coefficient Kd PS [bar] TS [ C] Set Pressure Range [bar] Overpressure Blowdown Risk Category according to PED NPT 3/4" G 113 4,1 3/4" NPT 3/4" G 113 4,1 1" NPT 1. G 19, ,8 0,90 0,90 0, / / 50 5% of set pressure 15% of set pressure IV with the atmosphere. For this reason, during relief, a gas leak occurs through this orifice. Utilized material: EN 0-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 4-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 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. 56

57 TABLE 2: Dimensions and Weights of valves 3030 Dimensions [mm] Catalogue Number Weight [g] D L Ch H 1 H 2 H /44C 3030/66C 3030/88C 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: manufacturer s mark, address and manufacture country; valve model; flow section; Kd discharge coefficient; indication of flow direction; max allowable pressure; allowable temperature range; set pressure; production date; serial number. VALVE SELECTION D Ch 0062 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. L H2 H1 H3 SAFETY DEVICES 97/23/EC Directive requires that pressure equipment, in which permissible limits are 57

58 SIZING OF SAFETY VALVES DESIGNED TO DISCHARGE GAS OR VAPOUR AT CRITICAL FLOW (Ref. EN 13136: 2001) Critical flow occurs when the backpressure p b (the pressure existing immediately at the outlet of a safety valve) is below or equal to the critical pressure: p [bar abs] with: p o = actual relieving pressure, upstream the safety valve; it s 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 it s possible to suppose: p [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: A b critical c 2 po k + 1 = 05, k k 1 p Qmd = 3, 469 C 09, K [mm 2 ] with: A c = minimum flow area of safety valve [mm 2 ]; Q md = minimum required discharge capacity, of refrigerant, of safety valve [kg/h]; K d = certified coefficient of discharge; p o = actual relieving pressure, upstream the safety valve, see definition above [bar abs]; v o = specific volume of gas or vapour at relieving conditions p o e T o meaning with T o fluid temperature at valve inlet, settled by the user or by the designer [m 3 /kg]; C = function of isentropic coefficient k calculated from: 2 C = 3, 948 k k + 1 o d ( k + 1) ( k 1) v p o o 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. Refrigerant R R134a R404A R407C R410A R507 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: 3600 ϕ Asurf Qmd = [kg/h] h with: = density of heat flow rate, it s assumed to be 10 [kw/m 2 ]; A surf = external surface area of the vessel [m 2 ]; h vap = heat of vaporization of liquid at p o [kj/kg]; internal heat sources. The minimum required discharge capacity shall be determined by the following: 3600 Qh Q [kg/h] md = h vap vap Isentropic coefficient k 1,17 1, 1, 1,14 1,17 1,10 with Q h = rate of heat production [kw]. Function of Isentropic coefficient C 2,54 2,50 2,50 2,51 2,54 2,48 Excessive pressure cased by compressors. The minimum required discharge capacity shall be determined by the following: Qmd = 60 V n ρ10 ηv [kg/h] 58

59 with: V = theoretical displacement of compressor [m 3 ] n = rotational frequency of compressor [min 1 ] ρ 10 = vapour density at refrigerant saturation pressure / dew point at 10 C [kg/m 3 ] η 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 Q md 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: π 2 V = 0, , = 0, Maximum allowable pressure of the condenser, refrigerant side: PS = 25 bar. [m 3 ] Set pressure of the safety valve installed on the upper shell section of condenser: p set = 25 bar Actual relieving pressure of safety valve, choosing one valve type 3030 with an overpressure of 5%: p 5 = =, 0 p set 1 [bar abs] 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: pdischarge 27, 25 η v = 1 0, 04 = 1 0, 04 = 083, p 633, and so the minimum required discharge capacity: Q = V n ρ η = md suction = 60x0,004x1450x26,34x0,83=60 [kg/h] v with ρ 10 = 26,34 [kg/m 3 ], vapour density of R407C at saturation pressure / dew point at 10 C. 59

60 Sizing of minimum flow area of the safety valve A c Qmd = 3, 469 C 09, K 60 0, 0104 = 3, 469 = , 09, 083, 27, 25 d vo = p o [mm 2 ] with: C = 2,51, corresponding to isentropic exponent k for R407C equal to 1,14, according to table A1 of standard EN 13136:2001; K d = 0,83, certified coefficient of discharge for safety valve 3030/88; v o = 0,0104 [m 3 /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 p o = 27,25 [bar abs]; temperature T o = 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, A c = 298 [mm 2 ]; set pressure, p set = 25 bar. In case of single-screw compressor with injection of pressurized oil, the theoretical displacement is: V c = π D 4 2 L [m 3 ] with: D = rotor diameter [m]; L = rotor length [m]. 60

61 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 p o, 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: p p o in 2 A = 0, 032 C Kdr A ζ in with: A = flow area of safety valve [mm 2 ]; A in = inside area of inlet tube to valve [mm 2 ]; K dr = K d x 0,9, derated coefficient of discharge; C = function of isentropic coefficient k; ξ = addition of pressure loss coefficients ξ n of any component and piping; The coefficients ξ 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: d in = [mm], inside diameter; A in = 6 [mm 2 ], inside area; L = 60 [mm], length; flush connection to the shell of condenser, with a broken edge. From table A.4 it s possible to have these data: ξ 1 (inlet) = 0,25 ξ 2 (length) = λ x L/ d in = 0,02 x 60/ = 0,043 with λ = 0,02 for steel tube ξ T = ξ 1 + ξ 2 = 0,25 + 0,043 = 0,293 Between safety valve and union it s installed a shut-off valve type 3033/88 (see page 46). The main characteristics of this valve are: d R = 20 [mm], inside diameter; A R = 314 [mm 2 ], inside area; kv = 20 [m 3 /h], kv factor. Pressure loss coefficient ξ R of shut-off valve is given by: ζ R = , = 0, 64 The total pressure loss coefficient is: ξ T + ξ R = 0,933 We remember the main characteristics of safety valve 3030/88 and of refrigerant fluid R407C: A = 298 [mm 2 ] K dr = 0,83 x 0,9 =0,747 C = 2,51 Pressure loss in the upstream line is: 2 pin = p , 2, 51 0, , 933 = 0, 0245 o 2 SAFETY DEVICES 61

62 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: p p out o 2 A 0, 064 ζ C Kdr po Aout = p with: A = flow area of safety valve [mm 2 ] A out = inside area of outlet tube to valve [mm 2 ] K dr = K d x 0,9, derated coefficient of discharge C = function of isentropic coefficient k ξ = addition of pressure loss coefficients ξ n of piping The coefficients ξ n are relevant to: pipe elements loss, bends; loss along the pipe and are listed in EN 13136:2001 standard, Table A.4. o 1 2 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: d out = 53 [mm], inside diameter; A out = 06 [mm 2 ], 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 it s possible to have these data: ξ 1 (bend) = 0,25; ξ 2 (length) = λ x L/ d in = 0,02 x 3000/53 = 1,13 with λ = 0,02 for steel tube; ξ T = ξ 1 + ξ 2 = 0,25 + 1,13 = 1,38. Pressure loss in the downstream line is: , 064 1, 38 2, 51 0, , , 25 pout = = p o 0, = The obtained value is admissible because lower than the value of 0,10 forecast in EN 13136:2001. standard. 62

63 SAFETY VALVES 3060 In the body, above the disc guide, a small pressure relief duct is provided through which the spring holder is put into contact with the output connection. For this reason, during relief, no gas leak occurs into the atmosphere. Utilized material: EN 0-CW617N brass. 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. 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 4-CW614N brass. Spring: it opposes the pressure and the fluid dynamic actions and always ensures valve re-closing after pressure relief. Utilized material: DIN steel for springs. Setting system: hexagonal head, threaded ring nut to be screwed inside the body top by compressing the spring below. On setting completion, the position attained by the ring nut is maintained unchanged laying, in the threaded coupling, a bonding agent with high mechanic strength and low viscosity features to make penetration thereof easier. The setting system is protected against subsequent unauthorized interventions by means of a cap nut that is screwed outside the body and is sealed to it with a punched copper rivet. 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. 63

64 TABLE 3: General Characteristics of valves 3060 Catalogue Number 3060/23C 3060/24C 3060/33C 3060/34C 3060/45C 3060/36C 3060/46C Connections Inlet male Outlet male NPT SAE NPT SAE NPT SAE NPT SAE NPT SAE NPT 3/4" G NPT 3/4" G Flow Diameter [mm] 7 9,5 10,0 Flow Section [mm 2 ] 38,5 70,9 78,5 Discharge Coefficient Kd 0,63 0,69 0,63 0,69 0,45 0,92 0,93 PS [bar] 55 TS [ C] - 50 / Set Pressure Range [bar] 9 / 50 Overpressure 10% of set pressure Risk Category according to PED IV 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 27 th, 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: manufacturer s mark, address and manufacture country; indication of flow direction; max allowable pressure; set pressure; allowable temperature range; production date; serial number. The following data are stamped on the cap: EC marking and the identification number of the notified body involved in the production control phase; valve model; flow section; Kd discharge coefficient. VALVE SELECTION 97/23/EC Directive requires that pressure equipment, in which permissible limits are reasonably likely to be exceeded, shall be fitted with suitable protection devices, for instance safety devices such as safety valves. Such devices shall prevent pressure from permanently exceeding the max allowable pressure PS of the equipment they protect. In any case, a short pressure peak limited to 10% of admissible maximum pressure is permitted. As to the selection and sizing of the suitable protection device, users shall refer to the specific sector or product standards. EN 378-2: 2000 Standard Refrigerating systems and heat pumps safety and environmental requirements Part 2: Design, construction, testing, marking and documentation, harmonized with 97/23/EC Directive, provides a general outline of the protection devices to be adopted in refrigerating systems and their features (par 7.4). It also indicates the criteria for the 64

65 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 Ch D L H1 H2 H3 SAFETY DEVICES Catalogue Number TABLE 4: Dimensions and Weights of valves 3060 Dimensions [mm] D L Ch H 1 H 2 H 3 Weight [g] 3060/23C ,5 48, /24C ,5 48, /33C ,5 48, /34C ,5 48, /45C 45 40, ,5 54, /36C ,5 99, /46C ,5 102,5 390 BALL SHUT-OFF VALVES FOR SAFETY VALVES APPLICATIONS We would like to remember to our customer that the running of pressure equipments and pressure assemblies is excluded by the scope of Directive 97/23/EC but it s regulated in compliance with national regulations of Member States of European Communities. We think that these regulations, actually on updating with the Competent Bodies of all the states to avoid conflicts with the ESR of PED, could provide for periodical checks on the pressure equipments and assemblies. Any intervention for periodic checking or replacement of an installed safety valve becomes very difficult if the protected vessel is not equipped with a shut-off valve. The shut-off valves series 3033 and 3063, installed between vessel and safety valve, allow to remove the valve for periodic checking or replacement without blowing off all the refrigerant from a section of the system. These valves can be used with the same fluids foreseen for safety valves series 3030 and 3060, in particularly: refrigerant fluids, in the physical state of gas or vapour, belonging to Group II according to the definitions of 97/23/EC Directive, Article 9, Point 2.2 (with reference to 67/548/EEC Directive of June 27 th, 1967); air and nitrogen (reference: 87/404/EEC Directive). 65

66 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. H3 A SEAL VALVE 3030/.. BALL VALVE 3033/.. The main parts of these valves are made with the following materials: hot forged brass EN 0 CW 617N for body; hot forged brass EN 0 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. H2 H1 A SEAL D L C TABLE 5: General Characteristics, Dimensions and Weights of valves 3033, 3063 Catalogue Number Designed for valve Kv Factor [m 3 /h] min TS [ C] max PS [bar] Dimensions [mm] D A C L H 1 H 2 H 3 Weight [g] Risk Category according to PED 3063/ /45C 3060/46C , / /44C NPT Art / /88C " NPT CHANGEOVER DEVICES FOR SAFETY VALVES APPLICATIONS The changeover device type 3032 is a service valve for dual pressure relief valves that allows using one valve while isolating the other from the system. This device allows the user to work on the isolated valve, for periodic checking or replacement, while the system is completely operative and the other valve is in service. N.B.: each safety valve placed on a changeover device must have sufficient capacity to protect the vessel alone. Valve type 3032/44 is supplied with: two female threaded connections 1/2 NPT with swivel nut, code Castel 3039/4; two O-Ring. These components ensure the perfect alignment of two safety valves 3060/

67 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 27 th, 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 0 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; chloroprene rubber (CR) for outlet seal gaskets; glass reinforced PBT for cap that covers the spindle. SAFETY DEVICES TABLE 6: General Characteristics, Dimensions and Weights of valves 3032 Catalogue Number Designed for valve Kv Factor [m 3 /h] min TS [ C] max PS [bar] D A B Dimensions [mm] H 1 H 2 L 1 L 2 L 3 Weight [g] Risk Category according to PED 3032/ /45C 3060/46C 3,3 13 NPT NPT / / /44C 3030/66C 9,0 9, ,5 17,5 3/4" NPT 3/4" NPT NPT 3/4" NPT Art / /88C NPT NPT L3 B 3039/4 B L3 GASKET 3032/ / / /44 B A H1 B A B A CHIUSO-CLOSED H1 B CHIUSO-CLOSED A H2 H2 L1 D A L1 D A L2 67

68 SAFETY VALVES UNIONS Unions series 30 allow assembling safety valves series 3030 and 3060 or shut-off valves series 3032, 3033 and 3063 close to the pressure equipments to protect, set up in a refrigerating system. These unions are designed for installations according to the following two ways: Make a copper tube jointing the pressure equipment to the union, fit the end of this tube into the solder connection of the union and then make a capillary brazing. Drill the inner/outer pipe close to the pressure equipment (if possible make a collar on the pipe), put the end of the union into this drill and then make a braze welding. The unions series 30 are machined by brass bar EN 4-CW614N. 30 Copper pipe 3060 TABLE 7: General Characteristics, Dimensions and Weights of unions 30 Connections Dimensions [mm] Ch. Catalogue Number NPT ODS [mm] PS [bar] D L Ch Weight [g] L 30/2 1/ D 30/3 30/4 3/8 1/ , ,5 5 30/6 3/ /

69 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, 2 nd 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 of EN : 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 4 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 27 th, 1967). MARKING In conformity with the provisions of Article 15 of 97/23/EC Directive and of Point of EN : 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 : 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. R; 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 : 2000 Standard Refrigerating systems and heat pumps safety and environmental requirements Part 2: Design, construction, testing, marking and SAFETY DEVICES 69

70 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 : 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 : 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: A c Q md = 3, 469 C K [mm 2 ] with: A c = minimum flow area of fusible plug [mm 2 ] Q md = minimum required discharge capacity, of refrigerant, of fusible plug [kg/h] K dr =derated coefficient of discharge of fusible plug, equal to 0,9 x K d p o = pressure upstream the fusible plug, inside the equipment to be protected [bar abs] v o = specific volume of gas or vapour at relieving conditions p o e T o, [m 3 /kg] (T o is the fluid temperature at plug inlet, settled by the user or by the designer) dr v p o o C = function of isentropic coefficient k (as measured at 25 C, see Section 7.2.3, EN : 2001 Standard) calculated from: ( k+ 1) 2 ( k 1) C = 3, 948 k k + 1 To find the values of k and C for the more useful refrigerants, see the chapter of safety valves series 3030 Calculation of minimum required discharge capacity of fusible plug is closely linked to the main cause that may arouse the opening of fusible plug, which is the external heat sources. The minimum required discharge capacity shall be determined by the following: Q md 3600 ϕ A = h vap surf [kg/h] with ϕ = density of heat flow rate, it s assumed to be 10 [kw/m 2 ] A surf = external surface area of the vessel [m 2 ] h vap = heat of vaporization of liquid at p o [kj/kg] EN : 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: K dr = 0,70 inserted connection: K dr = 0,

71 TABLE 8: General Characteristics, Dimensions and Weights of fusible plugs 3080 and 3082 Catalogue Number 3080/2C 3080/3C 3080/4C 3082/2C 3082/3C 3082/4C NPT Connections Flow Diameter [mm] 5,7 8,5 9,3 5,7 8,5 9,3 Flow Section [mm 2 ] 25,5 56,7 67,9 25,5 56,7 67,9 Kd 0,91 PS [bar] 30 Melting Point [ C] Hexagonal Key Wrench Torque min/max [Nm] 10 / / / / / / 30 Weight [g] Risk Category according to PED I SAFETY DEVICES 71

72

73 CHECK VALVES 73

74 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 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 32, 31 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 0 CW 617N for body and cover; copper tube EN 7-1 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 32, 31 and 3182; P.T.F.E. for seat gasket. 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 32 and 31 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, it s necessary to disassemble the valves series 32, while this operation is not necessary with solder connection valves. In any case, it s 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. 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. 74

75 75 CHECK VALVES TABLE 1: General Characteristics Catalogue Number SAE Flare [in.] [mm] [in.] [mm] ODS ODM Connections Kv Factor [m 3 /h] Minimum Opening Pressure Differential [bar] min. TS [ C] max. PS [bar] Risk Category according toped 3110/2 3110/3 3110/4 3110/5 3110/6 32/M 32/7 32/M 32/9 32/11 32/13 32/M 32/ /2 3130/3 3130/M /M 3130/4 3130/5 3130/M /6 3130/7 3131/M /M 3131/5 3131/7 31/7 31/M 31/9 31/11 31/13 31/M 31/17 31/21 31/ /7 3182/M 3182/9 3182/ / /M 3182/17 3/4" 7/8" 1.1/8" /8" 3/4" 7/8" 7/8" 7/8" 1.1/8" /8" /8" 7/8" 1.1/8" /8" /8" " 2" 0,4 1,6 3,3 6,6 8,8 15,2 25,0 40,0 0,5 1,6 1,8 3,3 1,6 1,8 3,3 6,6 8,8 15,2 25,0 40,0 8,5 9,5 19,0 37,0 45,4 0,1 0,3 0, Art. 3.3 I Art. 3.3 I Art. 3.3 I

76 Catalogue Number TABLE 2: Dimensions and Weights Dimensions [mm] H H 1 L L 1 Q D Ch Weight [g] 3110/ /3 84, / /5 3110/ /M 32/7 32/M 32/9 32/11 84,5 101,5, /13 32/M 5, /17 1, / /3 3130/M /M /4 3130/5 3130/M / / /M /M /5 3131/ / /M 31/9 84,5, /11 101, /13 31/M 5, /17 31/21 31/25 1, / /M 3182/ ,5 100, / , / /M 1 3,5 195,5 143, /

77 CHECK VALVES Q Ch H1 H 32 L M10 20 H1 H H H 3110 D D L L1 Q Q H H1 L M

78 TABLE 3: Refrigerant Flow Capacity Refrigerant Flow Capacity [kw] Catalogue Number Liquid Vapour Hot Gas R134a R R407C R404A R410A R134a R R407C R404A R410A R134a R R407C R404A R410A 3110/2 6,7 7,2 7,5 4,8 7,6 0,9 1,1 1,1 0,9 1,4 3,4 4,7 4,6 4,0 5,2 3110/3 27,0,8 30,0 19,0 30,5 3,5 4,3 4,3 3,6 5,8 13,6 18,7 18,6,0 20,8 3110/4 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 3110/5 3110/6 55,6 59,4 61,8 39,3 62,8 7,1 8,9 8,8 7,5 11,9,1 38,6 38,3 33,0,9 32/M 32/7 111,2 118,8 3,7 78,5 5,7 14,3 17,8 17,7 14,9 23,8 56,1 77,2 76,7 66,0 85,8 32/M 32/9 148,3 158,4 4,9 104,7 7,6 19,0 23,8 23,6 19,9 31,7 74,8 103,0 102,3 88,0 114,4 32/11 256,1 273,6 4,8 180,9 9,4 32,8 41,0 40,7 34,4 54,7 9,2 177,8 176,6 152,0 197,6 32/13 32/M 1,3 450,0 468,5 297,5 476,0 54,0 67,5 67,0 56,5 90,0 2,5 292,5 290,5 250,0 325,0 32/17 674,0 720,0 749,6 476,0 761,6 86,4 108,0 107,2 90,4 144,0 340,0 468,0 464,8 400,0 520,0 3130/2 8,4 9,0 9,4 6,0 9,5 1,1 1,4 1,3 1,1 1,8 4,3 5,9 5,8 5,0 6,5 3130/3 3130/M10 27,0,8 30,0 19,0 30,5 3,5 4,3 4,3 3,6 5,8 13,6 18,7 18,6,0 20,8 3130/M 3130/4 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 3130/5 3130/M /6 55,6 59,4 61,8 39,3 62,8 7,1 8,9 8,8 7,5 11,9,1 38,6 38,3 33,0,9 3130/7 3131/M10 27,0,8 30,0 19,0 30,5 3,5 4,3 4,3 3,6 5,8 13,6 18,7 18,6,0 20,8 3131/M 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 3131/5 3131/7 55,6 59,4 61,8 39,3 62,8 7,1 8,9 8,8 7,5 11,9,1 38,6 38,3 33,0,9 31/7 111,2 118,8 3,7 78,5 5,7 14,3 17,8 17,7 14,9 23,8 56,1 77,2 76,7 66,0 85,8 31/M 31/9 148,3 158,4 4,9 104,7 7,6 19,0 23,8 23,6 19,9 31,7 74,8 103,0 102,3 88,0 114,4 31/11 256,1 273,6 4,8 180,9 9,4 32,8 41,0 40,7 34,4 54,7 9,2 177,8 176,6 152,0 197,6 31/13 31/M 1,3 450,0 468,5 297,5 476,0 54,0 67,5 67,0 56,5 90,0 2,5 292,5 290,5 250,0 325,0 31/17 31/21 674,0 720,0 749,6 476,0 761,6 86,4 108,0 107,2 90,4 144,0 340,0 468,0 464,8 400,0 520,0 31/ /7 143,2 153,0 159,3 101,2 1,8 18,4 23,0,8 19,2 30,6 72,3 99,5 98,8 85,0 110,5 3182/M 3182/9 0,1 171,0 178,0 113,1 180,9 20,5 25,7 25,5 21,5 34,2 80,8 111,2 110,4 95,0 3,5 3182/11 320,2 3,0 6,1 6,1 361,8 41,0 51,3 50,9,9 68,4 1,5 2,3 0,8 190,0 247,0 3182/ /M 623,5 666,0 693,4 440,3 704,5 79,9 99,9 99,2 83,6 133,2 314,5 432,9 9,9 370,0 481,0 3182/17 765,0 817,2 850,8 540,3 864,4 98,1 2,6 1,7 102,6 3,4 385,9 531,2 527,5 454,0 590,2 Refrigerant flow capacity referred to the following operating conditions: Evaporating temperature: + 4 C Condensing temperature: + 38 C Pressure drop: 0,15 bar Particularly for hot gas: Suction temperature: + 18 C Pressure drop: 1 bar 78

79 WATER REGULATING VALVES 79

80 WATER REGULATING VALVES OPERATIONS 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. The moving elements of the valve are a metal bellows and a shutter. The thrust of the refrigerant condensation pressure outside the bellows favours the opening of the valve and the thrust of the adjustment spring on the shutter acts in the opposite sense. Given a specific setting of the spring, the valve progressively opens in line with the increasing condensation pressure, and closes when this pressure decreases. When the compressor stops, the valve closes: water is no longer fed into the condenser, this being a notable operating economy. Valve setting is performed in the works at a pressure of 7,5 bars. Setting is modified by turning the control screw. Three reference notches, marked with letters A, B, and C, are present on the spring cover. Each notch is equivalent to a different spring setting. The notches are referred to the following condensation pressures: letter A equivalent to about 7.5 bar (valid for R and R134a at a temperature of condensation of 30 C); letter B equivalent to about 14 bar (valid for R404A, R407C and R507 at a temperature of condensation of 30 C); letter C equivalent to about 18 bar (top limit of working pressure). Ch L 48 CAT. RANGE 5-18 bar MAX WATER PRESS. 10 bar MAX WATER TEMP. 80 BC MEDIUM R134a-R404A-R-R-R502 A02 MADE IN ITALY A B C Flare 80

81 Catalogue Number 3210/ / /06 MATERIALS Connections UNI ISO 8/1 G G G 3/4" Working pressure [bar] TABLE 1 - General Characteristics Maximum water pressure [bar] Maximum water Temperature [ C] The materials used for the main parts are: hot-forged brass EN 0-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. Kv Factor [m 3 /h] Refrigerant max working pressure [bar] 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] 2 3 4,7 20 Ch L Weight [g] WATER REGULATING VALVES 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. Water flow rate: 24,65 x 860 = 20 l/h = 2, [m 3 /h] 10 Condensing Temperature W a t e r Te m p e r a t u r e Heat exchange surface Fig. 1 Heat exchange pattern in the condenser 81

82 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 3 /h] 7 6,5 6 5, /06 4,5 4 3,5 3210/04 3 2,5 3210/03 2 1,5 1 0, ,5 0,25 0,375 0,5 0,625 0,75 0, ,5 1,25 1,375 1,5 1,625 1,75 1, ,5 2,25 2,375 2,5 2,625 2,75 p [bar] p [H 2 O] Fig. 2 Characteristic curves when the valves are completely open 82

83 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 Condensing Temperature [ C] Evaporating Temperature [ C] ,524 1,553 1,578 1,473 1,503 1,531 1,1 1,453 1,484 1,521 1,371 1,403 1,4 1,475 1,325 1,5 1,387 1,5 1,468 1,520 1,1 1,310 1,340 1,377 1,0 1,465 1,526 1,238 1,268 1,295 1,330 1,369 1,4 1,457 1,200 1,8 1,254 1,5 1,320 1,363 1,398 1,3 1,188 1,210 1,240 1,270 1,304 1,338 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 1,133 1,155 1,175 1,200 1,7 1,255 1,5 WATER REGULATING VALVES Condensing Temperature [ C] Evaporating Temperature [ C] ,460 1,417 1,371 1,330 1,291 1,243 1,213 1,178 1,143 1, ,495 1,450 1,405 1,367 1,320 1,279 1,240 1,202 1,8 1, ,537 1,487 1,441 1,396 1,0 1,306 1,265 1,4 1,185 1, ,530 1,485 1,437 1,390 1,3 1,295 1,252 1,211 1, ,482 1,431 1,381 1,334 1,8 1,241 1, ,6 1,369 1,320 1,274 1, ,474 1,410 1,5 1,330 1,

84

85 LIQUID INDICATORS & MOISTURE-LIQUID INDICATORS 85

86 LIQUID INDICATORS & MOISTURE-LIQUID INDICATORS APPLICATIONS The indicators, shown in this chapter, are classified Pressure accessories in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section and are subject of Article 3, Section 1.3 of the same Directive. The indicators series 3780 are excluded from the scope of Directive 97/23/EC, as specified in the Guidelines 1/8 and 1/9, because they are piping components. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). Liquid indicators and moisture liquid indicators ensure a fast and safe inspection of the conditions of the refrigerant fluid in the circuit concerning regular flow and moisture. Liquid indicators also ensure inspection of the regular return of oil to the compressor crankcase. OPERATION The moisture/liquid indicators consist of a sensitive element as a ring, which changes color passing from green to yellow according to the percentage of moisture in the system. The data of moisture content, shown in table 1 with the green color, can be considered admissible for the proper working of the system. When the sensitive element from green fade to yellow, green Chartreuse, working conditions of the system could become difficult. When the sensitive element becomes yellow, it s time to substitute the dehydrator filter. If the charge and working condition are normal, the refrigerant fluid appears perfectly liquid underneath the lens of the indicator. The presence of bubbles indicates that the refrigerant fluid is partial evaporating along the liquid line. TABLE 1: Moisture contained in the fluid [p.p.m.] Colour Green Green Chartreuse Yellow CONSTRUCTION Refrigerant fluid R R134a R404A R407C R410A <60 60 >60 <75 75 >75 <30 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 0 CW 617N for body; copper tube EN 7-1 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. 30 >30 <30 30 >30 <30 30 >30 R507 <30 30 >

87 87 LIQUID INDICATORS & MOISTURE-LIQUID INDICATORS TABLE 2: General Characteristics Moisture Liquid Indicators Liquid Indicators Catalogue Number Type SAE Flare Risk Category according to PED PS [bar] ODS ODM for pipe TS [ C] [mm] [mm] [mm] Foro [mm] max. [in.] [in.] [in.] min. Art. 3.3 I Art. 3.3 I Excluded Connections 3710/ 3710/ / / / /M 3720/5 3720/M /M 3740/2 3740/3 3740/M /M 3740/4 3740/5 3740/M /6 3740/7 3740/9 3750/ 3750/ / / / /M 3770/ / /M 3771/ /M 3771/ /5 3780/M /7 3780/9 3780/ /M male male soldering male female soldering saddle type level glass 3610/ 3610/ / / / /M 3620/5 3620/M /M 3640/2 3640/3 3640/M /M 3640/4 3640/5 3640/M /6 3640/7 3640/9 3650/ 3650/ / / /66 3/4" 3/4" 3/4" 7/8" 1.1/8" /8" /8" 1.1/8"

88 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 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, it s 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 Ch H H1 H H1 L L ,5 Ch 32 34,5 Ch L 34,5 34,5 Ch 32 tubo H H1 H2 H1 H H1 L Ch 32 34,5 H1 L L ,5 4,

89 89 LIQUID INDICATORS & MOISTURE-LIQUID INDICATORS Moisture Liquid Indicators H H 1 L Ch,5 31, ,5 46,5 38, ,5 38, ,5 31, , ,5 71,5 77,5 81,5 89, Catalogue Number TABLE 3: Dimensions and Weights Liquid Indicators Weight [g] 3710/ 3710/ / / / /M 3720/5 3720/M /M 3740/2 3740/3 3740/M /M 3740/4 3740/5 3740/M /6 3740/7 3740/9 3750/ 3750/ / / / /M 3770/ / /M 3771/ /M 3771/ /5 3780/M /7 3780/9 3780/11 Dimensions [mm] 3610/ 3610/ / / / /M 3620/5 3620/M /M 3640/2 3640/3 3640/M /M 3640/4 3640/5 3640/M /6 3640/7 3640/9 3650/ 3650/ / / / ,5 24, , ,5 31, ,5 31,5 36,5 24, , , , ,5

90

91 DEHYDRATORS AND FILTERS 91

92 DEHYDRATION OF REFRIGERANTS Among contaminating agents causing serious damages to refrigerating systems, moisture plays a major role. Its presence, even possible in the refrigerating system, is due to many factors: inadequate or insufficiently prolonged vacuum before refrigerant charging; oil used for topping up remained exposed to air humidity; refrigerant used for subsequent additions contained in non dried vessels; sealing defects especially in systems not designed for operation at low temperatures. High temperatures combined with humidity give rise to complex phenomena enhancing acid formation both in lubricating oil and refrigerant. Oil organic acids react with metal and favor the formation of sludge, which are viscous clots consisting of insoluble metal salts and large molecules of polymerized oil. Sludge affects the lubrication of the moving elements of the compressor, can clog valves and filters and cause serious damages. Acids, especially hydrofluoric acid, produced by the hydrolysis of the fluorinated refrigerant (in compressors iron and aluminum act as catalysts) are particularly corrosive. Acids etch metal surfaces with the consequent formation of crystal salts, which stick to surfaces and affect the total heat exchange coefficient in the condenser and in the evaporator. In the sealed and semi-sealed groups, these salts damage the windings of electric motors as in these groups cold gas cools windings through direct contact. On the other hand, water solubility in refrigerants in a liquid phase, is quite reduced, especially at low temperatures. As a consequence, when in the system water exceeds the very low limits of solubility admitted at low temperature, excess water turns into ice, and blocks expansion valves and capillaries either partially or totally. Consequently, refrigerating plants must be equipped with a filter drier on the liquid line and types available on the market are essentially two: molecular sieve driers and solid core driers. In molecular sieve driers, with a charge constituted by non-agglomerated products, the dehydrating mass is pressed in between two fine steel mesh disks, or two filtering disks of various material, kept in place by a spring. In solid core driers, dehydrating and deacidifying products with binders constitute the block. Water adsorption combines with the neutralization of acids that may be present in the refrigerant, and with a strong filtering action. Castel have planned either its production lines of hermetic driers on this second solution that avoid any risk of abrasion of the charge and consequently the making of powder and permit to put the filter in any position inside the refrigerating system. It is always advisable to install a moisture indicator downstream the filter, which will show the refrigerant moisture and, consequently, the degree of efficiency of the filter. The dehydrating capacity of Castel drier is relative to the charge of refrigerant and not to the refrigeration potential of the plant. As a matter of fact, for the same refrigerant potential and for the same type of refrigerant fluid, there can be different refrigerant charges according to the type, design and working conditions of the plant as well as to the shutter degree. The data shown in the following tables are deduced from the test results of the present Castel production. It is important to note in the case of a high oil level in the circuit (> 5%) the data shown in the tables will be reduced considerably. 92

93 ANTI-ACID SOLID CORE FILTER DRIERS WITH MOLECULAR SIEVES AND ACTIVATED ALUMINA SERIES Approved by Underwriters Laboratories Inc. SOLID CORE FILTER DRIERS WITH 100% MOLECULAR SIEVES SERIES 43 Approved by Underwriters Laboratories Inc. APPLICATIONS The filters, shown in this chapter, are classified Pressure vessels in the sense of the Pressure Equipment Directive 94/23/EC, Article 1, Section and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). Filters series and series 43 have been developed for specific installations on refrigerating systems using HFC refrigerant fluids, particularly R134a, R404A, R407C, R410A ed R507 mixed with polyolester lubricants. In spite of this, the new block may be successfully used also in refrigerating systems using the old CFC or HCFC refrigerant fluids, mixed with mineral lubricants The blocks in the filters series are molded from a blend of dehydrating charge, 80% of 3 Å molecular sieves and 20 % of activated alumina, and a special binding agent in appropriate proportions. The choice of blend, molecular sieves activated alumina, gives to the block a very high capacity of acid adsorption also maintaining very good dehydrating characteristics. The presence of a controlled and defined percentage of activated alumina, lower than the maximum value recommended by ASERCOM, keeps unchanged the original concentration of additives in the polyolester lubricant. DEHYDRATORS AND FILTERS 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 and 43 with: solder connections made of copper tube EN 7-1 Cu-DHP ORFS (O-Ring Face Seal) threaded connections according to SAE J 1453 Standard. 93

94 The blocks in the filters series 43 are molded from a blend of dehydrating charge, totally made of 3 Å molecular sieves, and a special binding agent in appropriate proportions. The choice of the 3 Å 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: ( ) x 34 / = 34 g of H 2 O where: ppm. = moisture in the refrigerant entering the filter according to DIN 8949: 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 H 2 O = 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. flow direction Solid core dehydrator 1 Spring 2 Stainless steel mesh 3 Block 4 Felt 94

95 DEHYDRATORS AND FILTERS 95 TABLE 1: General Characteristics Catalogue Number International Reference Block Filtering Surface [cm 2 ] Nominal Volume [cm 3 ] Threaded Connections Solder Connections SAE Flare 3/4" 3/4" 7/8" 3/4" 7/8" 1.1/8" /4" 3/4" 3/4" 3/4" 7/8" 1.1/8" 3/4" 7/8" 1.1/8" (3) Art. 3.3 [in.] [mm] [in.] [mm] ODS ODM Connections min. TS [ C] max. PS [bar] Risk Category according to PED 4303/2 4303/2F (2) 4303/3 4305/2 4305/2F (2) 4305/3 4308/2 4308/2F (2) 4308/3 4308/3F (2) 4308/4 43/2 43/3 43/3F (2) 43/4 43/5 4330/3 4330/4 4330/5 4332/4 4332/5 4341/5 4341/6 4303/2S 4305/2S 4305/3S 4305/M10S 4308/2S 4308/3S 4308/M10S 4308/MS 4308/4S 43/3S 43/M10S 43/MS 43/4S 43/5S 4330/3S 4330/4S 4330/5S 4332/4S 4332/5S 4341/5S 4341/6S 4341/7S 4375/4S 4375/5S 4375/6S 4375/7S 4375/9S S S S S S S 2 3 3S 4 4S 5 5S S S S S S S 4 4S 417S 754S 755S 756S 757S 759S (1) 100% molecular sieves; (2) Male-female connections (Inlet female) (3) PS = 400 psig in compliance with the UL approval High water capacity core (1)

96 96 TABLE 2: General Characteristics Threaded Connections Catalogue Number International Reference Block Filtering Surface [cm 2 ] Nominal Volume [cm 3 ] Solder Connections SAE Flare 3/4" 3/4" 7/8" 3/4" 7/8" 1.1/8" 3/4" 3/4" 3/4" 3/4" 7/8" 1.1/8" 3/4" 7/8" 1.1/8" (2) Art. 3.3 [in.] [mm] [in.] [mm] ODS ODM Connections min. TS [ C] max. PS [bar] Risk Category according to PED 03/2 03/3 05/2 05/3 08/2 08/3 08/4 /2 /3 /4 /5 30/3 30/4 30/5 32/4 32/5 41/5 41/6 03/2S 05/2S 05/3S 08/2S 08/3S 08/4S /3S /4S /5S 30/3S 30/4S 30/5S 32/4S 32/5S 41/5S 41/6S 41/7S 75/4S 75/5S 75/6S 75/7S 75/9S S S S S S S 2 3 3S 4 4S 5 5S S S S S S S 4 4S 417S 754S 755S 756S 757S 759S (1) 80% molecular sieves + 20% activated alumina (2) PS = 400 psig in compliance with the UL approval Anti-acid core (1)

97 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/MS 4308/4 4308/4S 43/2 43/3 43/3F 43/3S 43/M10S 43/MS 43/4 43/4S 43/5 43/5S 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 R134a 6,5 8,0 Refrigerant Flow Capacity, pressure drop 0,07 bar (1) [kw] 14,9,1 10,5,0,2 6,7 19,4 21,0 13,7 20,8 21,2 6,9 8,5 R 7,0 8,6 7,2 7,5 9,2 R404A R507 4,6 5,6 4,7 4,9 6,0 R407C 6,9 8,5 7,1 7,4 9,1 R410A 7,0 8,6 7,2 7,5 9,3 29,0 31,3 20,4 31,0 31,4 24,0 25,9,9 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 TABLE 3: Refrigerant Flow Capacity and Water Capacity R134a 4,1 8,2 8,9 5,8 8,8 9,0 7,3 15,4,6 10,8,5,7 Water Capacity at + 25 C (2) [g H 2 O] R 3,8 6,7 R404A R507 4,2 7,4 R407C 3,4 6,0 R410A 3,7 6,5 R134a 4,4 7,8 Dehydratable Charge at + 25 C [kg refrigerant] R 4,0 7,2 R404A R507 4,5 8,0 24,6 26,6 17,3 26,4 26,7 25,1,9 25,6 20,5,3 27,0 24,6 27,5,0 24,0 21,6 18,4 23,8,5 18,0 23,2 19,8 25,6 17,7 19,4 34,1 36,9 24,0 36,6 37,0,2 30,5 19,9 30,3 30,6 34,1 36,9 24,0 36,6 37,0 37,6 40,6 26,4 40,3 40,8 45,0 48,7 31,7 48,3 48,9 21,7 23,4 15,3 23,2 23,5 27,1 29,3 19,0 29,0 29,4 30,9 33,4 21,8 33,2 33,5 50,2 45,8 51,2 41,0 44,6 54,0 49,2 55,1 44,1 48,0 43,2 36,8 47,6 33,0 36,0 46,5 39,6 51,2,5 38,7 37,3 40,4 26,3 40,0 40,5 38,8 41,9 27,3 41,6 41,9 46,6 50,4 32,8 50,0 50,6 33,6 36,3 23,6 36,0 36,4 40,5 43,8,5 43,4 44,0 45,4 41,4 46,4 37,2 40,5 48,8 44,5 49,9 40,0 43,5 39,1 33,2 43,1 29,9 32,6,0,7 46,3 32,2,1 39,9 43,1,1,8 43,0 48,2 52,1 33,9 51,7 52,3 40,9 44,2,8 43,8 44,4 49,5 53,5 34,8 53,1 53,7 61,4 56,1 62,8 50,3 54,7 66,0 60,3 67,5 54,1 58,8 53,0 45,0 58,3 40,5 44,1 57,0 48,4 62,7 43,5 47,4 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 2,81,25,6100,6109,4132,00,61,1108,2117,6106,0 90,0 1,6 81,0 88,2 114,0 96,8 5,4 87,1 94,8 92,8 100,3 65,3 99,5 100,6 96,5 104,3 67,9 103,5104,7 R407C 3,6 6,4 R410A 3,9 7,0 R134a 3,5 6,3 Water Capacity at + 50 C (2) [g H 2 O] R 3,0 5,3 R404A R507 18,0 19,5,7 19,3 19,6,7 11,6 13,0 10,4 11,3 13,7,5 13,9 11,2,2 10,9 9,3,0 8,4,8 24,7,1 24,5 24,8 3,9 6,9 R407C 2,7 4,8 R410A 2,9 5,2 R134a 3,8 6,8 Dehydratable Charge at + 50 C [kg refrigerant] R 3,2 5,7 R404A R507 4,2 7,4 R407C 2,9 5,2 9,1 11,8 10,0 13,0 9,0 R410A 3,2 5,6 9,8 DEHYDRATORS AND FILTERS (1) (2) See caption on page

98 TABLE 4: Refrigerant Flow Capacity and Water Capacity Catalogue Number Refrigerant Flow Capacity, pressure drop 0,07 bar (1) [kw] Water Capacity at + 25 C (2) [g H 2 O] Dehydratable Charge at + 25 C [kg refrigerant] Water Capacity at + 50 C (2) [g H 2 O] Dehydratable Charge at + 50 C [kg refrigerant] R134a R R404A R507 R407C R410A R134a R R404A R507 R407C R410A R134a R R404A R507 R407C R410A R134a R R404A R507 R407C R410A R134a R R404A R507 R407C R410A 03/2 03/2S 03/3 05/2 05/2S 05/3 05/3S 08/2 08/2S 08/3 08/3S 08/4 08/4S /2 /3 /3S /4 /4S /5 /5S 30/3 30/3S 30/4 30/4S 30/5 30/5S 32/4 32/4S 32/5 32/5S 41/5 41/5S 41/6 41/6S 41/7S 75/4S 75/5S 75/6S 75/7S 75/9S 6,5 7,0 4,6 6,9 7,0 8,0 8,6 5,6 8,5 8,6 3,5 3,2 3,6 2,9 3,1 3,8 3,4 3,9 3,1 3,4 3,0 2,6 3,3 2,3 2,5 3,3 2,8 3,6 2,5 2,7 14,9,1 10,5,0,2 6,7 7,2 4,7 7,1 7,2 8,2 8,9 5,8 8,8 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 4,9 6,3 4,4 4,8 15,4,6 10,8,5,7 19,4 21,0 13,7 20,8 21,2 6,9 7,5 4,9 7,4 7,5 8,5 9,2 6,0 9,1 9,3 18,0 19,5,7 19,3 19,6 10,8 9,9 11,0 8,8 9,6 11,6 10,6 11,9 9,5 10,3 9,3 7,9 10,2 7,1 7,7 10,0 8,5 11,0 7,7 8,3,8 24,7,1 24,5 24,8 24,0 25,9,9 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 26,7,2 30,5 19,9 30,3 30,6 21,3 19,5 21,8 17,4 19,0,9 20,9 23,4 18,7 20,4 18,4 15,6 20,2 14,0 15,3 19,7,8 21,8 15,1,5 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 33,5,7 38,9 43,5 34,9 37,9 45,9 41,9 46,8 37,5 40,8 36,7 31,3 40,5,1 30,6 39,5 33,6 43,5 30,2 32,9 37,3 40,4 26,3 40,0 40,5 38,8 41,9 27,3 41,6 41,9 46,6 50,4 32,8 50,0 50,6 33,6 36,3 23,6 36,0 36,4 40,5 43,8,5 43,4 44,0 38,6,2 39,4 31,6 34,4 41,5 37,8,4 34,0 37,0 33,2,2 36,6 25,4 27,7,7 30,3 39,4 27,3 29,8 39,9 43,1,1,8 43,0 48,2 52,1 33,9 51,7 52,3 40,9 44,2,8 43,8 44,4 49,5 53,5 34,8 53,1 53,7 52,2 47,7 53,4,8 46,5 56,1 51,3 57,4 46,0 50,0 45,1 38,3 49,6 34,4 37,5 48,4 41,1 53,3 37,0 40,3 67,2 72,6 47,3 72,0 73,0 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 1,2102,5114,8 91,9 100,0 90,1 76,5 99,1 68,9 75,0 96,9 82,3 106,6 74,0 80,6 92,8 100,3 65,3 99,5 100,6 96,5 104,3 67,9 103,5 104,7 (1) Maximum values of the refrigerant flow capacity at which the drier can be used when fluid dehydration is not the a major problem, provided that the original moisture is limited before the installation of the drier. The maximum refrigerant flow capacities are referred to a total pressure drop of 0,07 bar, inlet and outlet connections included, (according to ARI STANDARD 710:86 - with condensing temperature at +30 C and evaporating temperature at -15 C) (2) Water capacity values with R are referred to the following conditions, fixed in ARI STANDARD 710:86: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 60 ppm Water capacity values with the other refrigerant fluids are referred to the following conditions, fixed in DIN 8949:2000 Standard: - Liquid temperatures: 25 C and 50 C - Equilibrium point dryness, EPD: 50 ppm 98

99 L D solder connections TABLE 5: Dimensions and Weights 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/MS 4308/4 4308/4S 43/2 43/3 43/3F 43/3S 43/M10S 43/MS 43/4 43/4S 43/5 43/5S 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 03/2 03/2S 03/3 05/2 05/2S 05/3 05/3S 08/2 08/2S 08/3 08/3S 08/4 08/4S /2 /3 /3S /4 /4S /5 /5S 30/3 30/3S 30/4 30/4S 30/5 30/5S 32/4 32/4S 32/5 32/5S 41/5 41/5S 41/6 41/6S 41/7S 75/4S 75/5S 75/6S 75/7S 75/9S 3/4" 3/4" 7/8" 3/4" 7/8" 1.1/8" SAE Flare [in.] [mm] D L ODS Connections Dimensions [mm] Weight [g] L D male connections L D male - female connections (female - in) 99

100 FILTER DRIERS WITH REPLACEABLE ANTI-ACID SOLID CORE Approved by Underwriters Laboratories Inc. Except filters 43/17A, /21A, /25A and 44/25A, /33A APPLICATIONS The filters, shown in this chapter, are classified Pressure vessels in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). OPERATION In the case of filters with more than one block, the passage of the fluid takes place in parallel; as a result, the pressure drop does not increase proportionately to the number of blocks. A large ring between the block and the inner surface of the filter permits the accumulation of solid particles, and prevents clogging. Before leaving the filter, the refrigerant fluid must pass through the mesh sieve on which blocks are mounted. The danger that small particles of dehydrating material being introduced into the system is thus avoided. Furthermore, at filter outlet, a plastic cup, the edge of which closely adheres to the inner surface of the filter, prevents dirt from reaching the outlet connection during normal operation and block change. CONSTRUCTION The filters type 4410 are manufactured in steel, with the exception of the connections which are made of EN 7-1 Cu-DHP copper tube. The filters type 40 are completely manufactured in steel and solder connection, are machined with a steel bar EN S5JR. The blocks series 4490 and 4491 has been developed for specific installations on refrigerating systems using HFC refrigerant fluids, particularly R134a, R404A, R407C, R410A ed R507 mixed with polyolester lubricants. In spite of this, the new block may be successfully used also in refrigerating systems using the old CFC or HCFC refrigerant fluids, mixed with mineral lubricants. The blocks 4490, type A and type B, and the block 4491, type A, are molded from a blend of dehydrating charge, totally made of 3 Å molecular sieves, and a special binding agent in appropriate proportions. The choice of the 3 Å molecular sieves, as sole dehydrating material, gives to the block a superlative capacity of water adsorption also maintaining quite good deacidifying characteristics. The blocks 4490, type AA and type AB, and the block 4491, type AA, are molded from a blend of dehydrating charge, 80% of 3 Å molecular sieves and 20 % of activated alumina, and a special binding agent in appropriate proportions. The choice of blend, molecular sieves activated alumina, gives to the block a very high capacity of acid adsorption also maintaining very good dehydrating characteristics. The presence of a controlled and defined percentage of activated alumina, lower than the maximum value recommended by ASERCOM, keeps unchanged the original concentration of additives in the polyolester lubricant

101 Catalogue Number 4411/5A 4411/7A 4411/9A 4411/11A 4411/13A 4411/MA 4411/17A 44/7A 44/9A 44/11A 44/MA 44/17A Core Cat. Number 4490/A /B /AA 4490/AB Number of Cores 1 2 Core Filtering Surface [cm 2 ] TABLE 1: General Characteristics [cu.in] Nominal Volume [cm 3 ] [in.] 7/8" 1.1/8" /8" 7/8" 1.1/8" /8" Connections ODS [mm] ODM [mm] TS [ C] min. max PS [bar] 45 (1) Risk Category according to PED I DEHYDRATORS AND FILTERS 4413/11A /13A /MA 4414/13A /MA (1) 4414/17A 2.1/8" 54 43/17A 2.1/8" 54 60,3 43/21A 43/25A 44/25A 44/33A 4491/A 4491/AA /8" 3.1/8" 4.1/8" ,1 88,9 88,9 114,3 32 II (1) PS = 470 psig in compliance with the UL approval The manufacturing process of blocks series 4490 and 4491 gives a considerable compacted ness and stoutness to both the products so that they are resistant to shocks and abrasions. The blocks series 4490 have a volume of 48 cu.in., equivalent to approx. 800 cm 3, and it is used with type 4411, 44, 4413 and 4414 filters. The block series 4491 has a volume of 100 cu.in., equivalent to approx. 00 cm 3. and it is used with type 41, 43 and 44 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. 4 outlet 5 3 inlet 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)

102 TABLE 2A: Refrigerant Flow Capacity and Water Capacity (filters) Catalogue Number Refrigerant Flow Capacity, pressure drop 0,07 bar (1) [kw] Water Capacity at + 25 C (2) [g H 2 O] Dehydratable Charge at + 25 C [kg refrigerant] Water Capacity at + 50 C (2) [g H 2 O] Dehydratable Charge at + 50 C [kg refrigerant] R134a R R404A R407C R410A R134a R R404A R407C R410A R134a R R404A R407C R410A R134a R R404A R407C R410A R134a R R404A R407C R410A 4411/5A /7A /9A /11A /13A 4411/MA /17A 44/7A /9A /11A /MA 44/17A /11A /13A 4413/MA /13A 4414/MA /17A 43/17A /21A /25A /25A 44/33A TABLE 2B: Refrigerant Flow Capacity and Water Capacity (single block) Catalogue Number Refrigerant Flow Capacity, pressure drop 0,07 bar (1) [kw] Water Capacity at + 25 C (2) [g H 2 O] Dehydratable Charge at + 25 C [kg refrigerant] Water Capacity at + 50 C (2) [g H 2 O] Dehydratable Charge at + 50 C [kg refrigerant] R134a R R404A R407C R410A R134a R R404A R407C R410A R134a R R404A R407C R410A R134a R R404A R407C R410A R134a R R404A R407C R410A 4490/A /B 4491/A /AA /AB 4491/AA (3) (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 R 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, 44, 4413, and 4414 can be used with blocks type 4490/AA and 4490/AB - series 43 and 44 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

103 Catalogue Number 4411/5A 4411/7A 4411/9A 4411/11A 4411/13A 4411/MA 4411/17A 44/7A 44/9A 44/11A 44/MA 44/17A [in.] 7/8" 1.1/8" /8" 7/8" 1.1/8" /8" Connections ODS [mm] TABLE 3: Dimensions and Weights W [mm] Dimensions [mm] D 1 D 2 H 1 H 2 H 3 P Weight [g] DEHYDRATORS AND FILTERS 4413/11A /13A 4413/MA 4414/13A 4414/MA 4414/17A /8" /17A 43/21A 2.1/8" ,3 76, /25A 3.1/8" 80 88, /25A 44/33A 3.1/8" 4.1/8" 80 88,9 114, H3 H2 20 H1 D2 D1 P 103

104 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. H D1 D TABLE 4: General Characteristics, Dimensions and Weights Catalogue Number Core Filtering Surface [cm 2 ] Nominal Volume Dimensions [mm] [cu.in] [cm 3 ] D 1 D 2 H Weight [g] H 4490/A 4490/B (1) 4490/AA /AB (1) 4491/A 4491/AA D1 D2 (1) Supplied without cover gasket as spare part

105 MECHANICAL FILTERS WITH REPLACEABLE FILTERING BLOCK Approved by Underwriters Laboratories Inc. Except filters 41/21C, /25C, /M80C, /33C APPLICATIONS The filters, shown in this chapter, are classified Pressure vessels in the sense of the Pressure Equipment Directive 97/23/EC, Article 1, Section and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). OPERATION Good filtering of the refrigerant on the lowpressure side of the system is a guarantee of protection for the compressor. System cleanliness is ensured by micro filtering cores, which filter out impurities derived from manufacture and assembly of the refrigerating system. CONSTRUCTION The filters type 4410 are manufactured in steel, with the exception of the connections which are made of EN 7-1 Cu-DHP copper tube. The filters type 40 are completely manufactured in steel and solder connection, are machined with a steel bar EN S5JR. Zinc plated wire cloths and a filtering baffle form the block, which features a large surface, with controlled porosity. The block can stop solid particles up to 20 micron. At the two ends, soft felt gaskets ensure perfect sealing with the plastic cups. Filters are supplied with an access fitting kit G9150/R05. SUCTION LINE SELECTION CRITERION With clean systems, refrigerant flow capacity and pressure drops of table 2 are reported to a gas speed of 20 m/s for pipes adequate to the filter connections. For refrigerant flow capacities different from the table values, under the other same conditions, gas speeds and relative pressure drops through the filter can be gained for simple proportionality. EXAMPLE System data: Refrigerant: R407C Refrigerant flow capacity: 130 [kw] Evaporating temperature: + 5 [ C] Suction pipe: 2.1/8 Filter: 4411/17C In table 2, corresponding to filter type 4411/17C refrigerant and evaporating temperature, the following data is given: refrigerant flow capacity = 141,7 [kw]; pressure drop = 0,21 [bar]. The gas speed in the suction line will be: =, ,7 [m/s] Pressure drop through the filter: , 21 = 0, ,7 [bar] 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 R, allows to estimate the aforesaid variation in function of pressure loss and evaporating temperature. DEHYDRATORS AND FILTERS 105

106 After all it s always important to remember that the refrigerant flow capacity of a compressor, under the other same conditions, can reduce considerably because of the decrease of the saturation temperature, consequent to the pressure loss in the suction line. To such purpose diagram 2 illustrates the existing relation between saturation temperature, in the suction line, and variation of the refrigerant flow capacity of a compressor. TABLE 1: General Characteristics Catalogue Number Core Cat. Number Number of Cores Core Filtering Surface [cm 2 ] [in.] ODS Connections [mm] W [mm] min. TS [ C] max. PS [bar] Risk Category according to PED 4411/7C 7/8" 4411/9C 1.1/8" 4411/11C /13C 4495/C (1) 4411/MC 4411/17C 1 2.1/8" I 4411/21C 2. 41/21C 2. 76,1 41/25C 41/33C 4496/C /8" 4.1/8" 80 88,9 114,3 32 (1) PS = 470 psig in compliance with the UL approval 2 3 inlet 1 2 outlet Sketch of filter with mechanical block 1 Block 2 Retainer cup 3 Spring 106

107 DIAGRAM 1 Equivalent variation of the saturation temperature evaporation temperature DEHYDRATORS AND FILTERS Pressure loss (kpa) DIAGRAM 2 2 1,5 1 0,5 Correction factor of refrigerant flow capacity Saturation temperature at the suction ( C) 107

108 108 TABLE 2: Refrigerant Flow Capacity and Pressure Drop Catalogue Number Refrigerant Evaporating Temperature [ C] [bar] [kw] [bar] [kw] [bar] [kw] [bar] [kw] [bar] [kw] /7C 4411/9C 4411/11C 4411/13C 4411/MC 4411/17C 4411/21C 41/21C 41/25C 41/33C R134a R R404A R407C R410A R134a R R404A R407C R410A R134a R R404A R407C R410A R134a R R404A R407C R410A R134a R R404A R407C R410A R134a R R404A R407C R410A R134a R R404A R407C R410A R134a R R404A R407C R410A R134a R R404A R407C R410A 13,7 21,5 20,0 19,0 31,7 23,0 36,4 34,0 32,1 53,7,0 55,0 51,4 48,6 81,0 50,0 79,0 73,5 69,5 1,0 87,0 137,0 8,0 1,1 202,0 133,5 211,0 197,0 186,4 311,0 133,5 211,0 197,0 186,4 311,0 191,0 302,0 1,0 266,0 446,0 334,0 5,0 491,0 468,0 780,0 0,070 0,100 0,130 0,090 0,200 0,074 0,110 0,140 0,100 0,210 0,075 0,110 0,140 0,100 0,210 0,090 0,130 0,170 0,0 0,250 0,140 0,190 0,270 0,180 0,370 0,250 0,360 0,480 0,330 0,700 0,100 0,150 0,200 0,140 0,300 0,180 0,260 0,340 0,230 0,500 0,540 0,770 1,000 0,690 1,400 9,0 15,6 14,0,8 23,0 15,0 26,0 24,0 21,3 38,0 23,0 39,0 36,2 33,2 57,0 33,0 56,0 51,7 47,5 82,0 57,2 97,0 90,0 82,6 143,0 87,5 149,0 138,6 7,0 0,0 87,5 149,0 138,6 7,0 0,0 5,0 213,0 198,0 182,0 315,0 218,0 372,0 346,0 320,0 550,0 0,048 0,074 0,090 0,060 0,140 0,051 0,080 0,100 0,066 0,150 0,052 0,080 0,100 0,068 0,150 0,062 0,090 0,0 0,080 0,180 0,100 0,150 0,190 0,5 0,290 0,180 0,270 0,330 0,210 0,520 0,070 0,110 0,130 0,090 0,200 0,0 0,190 0,0 0,150 0,370 0,360 0,570 0,660 0,440 1,200 6,0 10,8 9,0 8,4,0 10,0 18,0 15,0 14,2 26,0 15,0 27,0,7 21,9 40,0 21,4 39,0 32,4 31,3 57,0 37,3 66,4 56,5 54,4 98,0 57,0 102,0 87,0 83,7 150,0 57,0 102,0 87,0 83,7 150,0 81,5 146,0 4,0 119,7 215,0 1,0 255,0 217,0 210,0 377,0 0,033 0,052 0,060 0,043 0,100 0,0 0,056 0,070 0,047 0,110 0,036 0,056 0,070 0,047 0,110 0,043 0,064 0,080 0,056 0,0 0,070 0,100 0,130 0,087 0,250 0,0 0,180 0,230 0,150 0,0 0,050 0,074 0,100 0,060 0,150 0,090 0,130 0,170 0,100 0,250 0,270 0,390 0,500 0,300 0,800 3,5 7,2 6,0 5,1 10,6 6,0,0 10,0 8,7 17,7 9,0 18,0 14,5 13,4 26,0 13,0 26,0 20,7 19,2 38,0,4 44,0 36,0 33,4 65,0 34,3 68,0 55,5 51,4 100,0 34,3 68,0 55,5 51,4 100,0 49,0 97,0 79,3 73,5 143,0 85,0 170,0 138,7 9,0 251,0 0,021 0,037 0,040 0,0 0,100 0,0 0,040 0,050 0,031 0,110 0,023 0,040 0,050 0,031 0,110 0,027 0,046 0,060 0,037 0,100 0,040 0,070 0,100 0,057 0,200 0,070 0,0 0,170 0,100 0,240 0,030 0,050 0,070 0,040 0,100 0,050 0,090 0,0 0,070 0,200 0,150 0,270 0,360 0,200 0,530 0,084 0,0 0,150 0,100 0,230 0,091 0,130 0,0 0,110 0,250 0,092 0,130 0,0 0,110 0,250 0,110 0,150 0,200 0,136 0,300 0,170 0,230 0,310 0,210 0,440 0,300 0,0 0,550 0,380 0,810 0,0 0,170 0,0 0,0 0,340 0,210 0,300 0,390 0,270 0,600 0,630 0,900 1,170 0,790 1,800 17,0 26,0 23,7,2 38,4,7 43,0 40,0 37,6 63,5 43,5 65,0 60,7 57,0 96,0 62,0 93,0 86,8 81,4 137,0 108,3 2,0 151,3 141,7 239,0 7,0 249,0 232,7 218,0 368,0 7,0 249,0 232,7 218,0 368,0 238,0 6,0 332,0 3,0 526,0 4,0 623,0 581,0 547,0 921,0 Refrigerant flow capacities and pressure drops are referred to the following working conditions: Liquid temperature ahead expansion valve: + C Overheating of suction gas: 6 C

109 Catalogue Number 4411/7C 4411/9C 4411/11C 4411/13C 4411/MC 4411/17C 4411/21C 41/21C 41/25C 41/33C [in.] 7/8" 1.1/8" /8" /8" 4.1/8" Connections ODS [mm] TABLE 3: Dimensions and Weights W [mm] 76,1 88,9 114, Dimensions [mm] D 1 D 2 H 1 H 2 H 3 P Weight [g] DEHYDRATORS AND FILTERS D1 H H3 D2 20 D H2 D1 H1 TABLE 4: General Characteristics Dimensions and Weights P Catalogue Number Filtering Surface Dimensions [mm] [sq.in] [cm 2 ] D 1 D 2 H Weight [g] 4495/C /C

110 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 and are subject of Article 3, Section 1.1 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). CONSTRUCTION The filter is completely manufactured in steel, either with nickel-plated Flare threaded connections. The product range also includes types with copper plated solder connections, offering the possibility to solder the copper pipe inside the connections (ODS) or outside the connections, using a copper sleeve (ODM). Inside the filters there is a screen basket, with wide filtering surface, made of austenitic stainless steel AISI 304. These filters may not be cleaned. TABLE 1: General Characteristics Catalogue Number Filtering Surface [cm 2 ] Useful Passage Surface [%] Mesh Opening [mm] SAE Flare [in.] Connections ODS [mm] [in.] ODM [mm] Kv Factor [m 3 /h] min. TS [ C] max. PS [bar] Risk Category according to PED 4510/3 58 2,4 4510/4 1 3,2 4520/3 4520/M /M 58 36,6 0, , Art /4 3,4 4520/5 3/4" 4520/M ,0 TABLE 2: Dimensions and Weights Catalogue Number D Dimensions [mm] L Weight [g] 4510/ L L 4510/ /3 4520/M /M / /5 4520/M D D 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

111 OIL SEPARATORS 111

112 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 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. 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 S 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. 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) 1

113 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 doesn t 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: Q = P [m 3 /s] with: H v g P = refrigerant flow capacity kw] H = heat content differential, see diagram (fig. 1). [kj/kg] v g = specific volume of compressed gas, separator inlet (fig. 1). [m 3 /kg]. Fig. 1 Check of gas speed, referred to the cross section of oil separator, is given by: v = Q S [m/s] with: S = gross cross section of shell separator [m 2 ] 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, it s 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. OIL SEPARATORS 113

114 IN OUT IN OUT outlet screen cylinder outlet screen cylinder inlet screen cylinder steel plate inlet screen cylinder steel plate stainless steel ball oil return tube stainless steel ball oil return tube stainless steel needle permanent magnet stainless steel needle permanent magnet TABLE 1: General Characteristics Catalogue Number [in.] Solder Connections ODS ODM ODS (1) Catalogue Number [mm] [in.] [mm] Couple of solder connections IN / OUT [in.] [mm] Oil connection [SAE Flare] Oil addition [kg] Max. differential pressure [bar] min. TS [ C] max. PS [bar] Risk Category according to PED 5540/4 5540/5 3/4" 5540/7 7/8" 1" 0,4 / 0,5 I 5540/9 5540/11 1.1/8" / /M 5540/17 2.1/8" 54 0,6 / 0, II 5520/C 5590/5 5590/7 7/8" 5520/D 5590/9 5590/11 1.1/8" 1. 0,4 / 0,5 I 5520/E 5590/ /M 1. (1) The dimensions of the separator's connections must agree with the discharge diameter of the compressor 114

115 Separator 5540/4 5540/5 5540/7 5540/9 5540/11 Catalogue Number Connections Solder Connections [in.] 7/8" 1.1/8" 1. ODS [mm] TABLE 2: Dimensions and Weights 3 Dimensions [mm] D 1 D 2 H 1 H 2 H 3 H Weight [g] OIL SEPARATORS 5540/ /M 5540/ /8" 54 3,5 17, /C 5590/5 5590/7 7/8" /D 5520/E 5590/9 5590/ / /M 1.1/8" /.. Gasket H1 H1 H2 H4 H4 H3 D2 M10 M D D

116 Catalogue Number Catalogue Number of solder connections TABLE 3: Refrigerant Flow Capacity Refrigerant Capacity (1) [kw] R134a R R404A R407C Evaporating Temperature [ C] /4 5,3 6,1 6,4 7,9 6,4 8,8 6,0 8,0 5540/5,4 18,9 19,7 24,5 19,9 27,3 18,6 24,6 5540/7 18,6 21,3,2 27,7,5 30,8 21,0 27,8 5540/9 5540/11 21,2 23,9 24,3 27,4 25,4,6 31,5,6 25,7,9,2 39,6 24,6 27,0 31,8,8 5540/ /M 33,1 38,0 39,6 49,3 40,1 54,9 37,6 49,6 5540/17,5 48,8 50,9 63,4 51,5 70,6 48,3 63,7 5520/C 5590/5 5590/7,4 18,6 18,9 21,3 19,7,2 24,5 27,7 19,9,5 27,3 30,8 18,6 21,0 24,6 27,8 5520/D 5590/9 5590/11 21,2 23,9 24,3 27,4 25,4,6 31,5,6 25,7,9,2 39,6 24,6 27,0 31,8,8 5520/E 5590/ /M 26,5 30,4 31,8 39,5 32,1 44,0 30,0 40,0 (1) Refrigerant flow capacity with a condensing temperature of + 40 C and normal overheating values of vapour sucked by compressor. No liquid subcooling. Maximum pressure drop of 0,15 bar 1

117 VALVES 117

118 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 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 60/; 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 0 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle. TABLE 1: General Characteristics Catalogue Number Connections SAE Flare ODS (4) (1) (2) (3) [in.] [mm] Kv Factor [m 3 /h] min. TS [ C] max. PS [bar] Risk Category according to PED 6010/2 60/ 0,27 +4, /2 0, /233 1, /244 2, /255 2, /M6 6 0, Art /23M , /M6 6 0, /23M8 8 1, /23M , /24M 2, /25M 3, /2 H1 H2 2 3 I 4.5 L

119 Catalogue Number TABLE 2: Dimensions and Weights Dimensions [mm] H 1 H 2 H 3 H 4 H 5 I L 1 L 2 L 3 P 1 Weight [g] VALVES 6010/2 60/ , /2 6020/ / / , , /M , /23M , /M6 25, , , /23M8 6070/23M /24M 6070/25M 29,5 38,5 39, , , / I H H1 L1 L L P1 H2 1 2 D 4 H3 H4 L3 L1 H1 H5 M H3 H1 3 H2 P L2 L1 M10 H3 H2 4 S 1 H5 H1 M8 11 L1 L

120 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 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 60; three-ways valves; two main connections (90 angle) plus a third one for charging, type The access connection may be shut off by the back-seating of the spindle; two-ways valves, 0 angle connections, type The main parts of the receiver valves are made with the following materials: hot forged brass EN 0 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle. TABLE 1: General Characteristics Catalogue Number Connections SAE Flare NPT (1) (2) (3) Kv Factor [m 3 /h] min. TS [ C] max. PS [bar] Risk Category according to PED 6110/ / 1/8" 0, /X15 f 6110/23 0, / /33 1, 6110/X13 f 6110/43 2, / /54 3, /66 3/4" 3/4" 6,00 60/ 60/23 0,44 0, Art /33 1, 60/43 2,40 60/44 60/54 3,40 60/66 3/4" 3/4" 6, / 0, / /44 1,20 2, /54 3, / 6140/23 0,

121 H1 H2 L L1 L2 H1 NPT H1 L2 L1 NPT L2 L1 H1 H NPT 6132 NPT H2 H1 L1 6110/X /X VALVES 1 TABLE 2: Dimensions and Weights Catalogue Number 6110/ / 6110/X / / / /X / / / /66 60/ 60/23 60/33 60/43 60/44 60/54 60/ / 6132/ / / / 6140/23 70, , , , , ,5, , H 1 H 2 L 1 L 2 Dimensions [mm] Weight [g]

122 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 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). The main parts of the stop valves are made with the following materials: hot forged brass EN 0 CW 617N for body; brass EN 4 CW 614N for spindle and protection cap; chloroprene rubber (CR) for outlet seal gaskets for series 65 and 6175; chloroprene rubber (CR) and aramidic fibers for gland seal, only for series 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. TABLE 1: General Characteristics Catalogue Number Way Nr. (1) (2) Connections SAE Flare ODS (3) [in.] [mm] Kv Factor [m 3 /h] min. TS [ C] max. PS [bar] Risk Category according to PED 65/ 65/ /33 2 0,68 1,70 1, /44 3, Art /55 3 4, / /77 3/4" 7/8" 3/4" 7/8" 9,00 10,80 2

123 Catalogue Number TABLE 2: Dimensions and Weights Dimensions [mm] H 1 H 2 H 3 D L 1 L 2 L 3 I Weight [g] VALVES 65/ 65/ / ,5, , , / / , / /77,5 104,2, H1 H3 D L1 L2 L3 I I H2 H2 L1 D H3 H

124 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 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 don t 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 0 CW 617N for body; brass EN 4 CW 614N for spindle; harmonic steel for spring; nylon for seat sealing gaskets. TABLE 1: General Characteristics Catalogue Number SAE Flare (1) Connections [in.] ODS (2) [mm] Kv Factor [m 3 /h] min. TS [ C] max. PS [bar] Risk Category according to PED 6210/2 0, 6210/3 1, /4 1, /5 6210/6 3/4" 1,80 3,65 60/2 0, Art /3 1,00 60/4 60/5 1,30 1,80 60/6 60/7 3/4" 7/8" 3,65 4

125 Catalogue Number TABLE 2: Dimensions and Weights Dimensioni [mm] H 1 H 2 L 1 d I D Weight [g] VALVES 6210/ /3 6210/4 6210/ , , / ,5 98 6, / /3 60/4 60/ , , /6 60/ , , D D H1 H2 1 1 H1 H2 2 2 A94 A94 L1 L1 d I d I 5

126 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 and are subject of Article 3, Section 1.3 of the same Directive. They are designed for installation on commercial refrigerating systems and on civil and industrial conditioning plants, which use refrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 of Directive 97/23/EC and referred to in Directive 67/548/EEC). The main parts of the hermetic valves are made with the following materials: hot forged brass EN 0 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 S Mn Pb 37 for 7910 fittings; P.T.F.E. for 7990 gaskets. CONSTRUCTION Rotalock valves, mounted with 7910 fittings and 7990 gaskets, assure fast installation and safe sealing. Before tightening it is possible to turn the valve in every direction. All Rotalock valves have an additional charging connection, which can be excluded by the back sealing of the spindle. Fittings 7910 and gaskets 7990 have to be ordered separately. Valves Gasket 7990 Coupling 7910 TABLE 1: General Characteristics Catalogue Number Connections SAE Flare Swivel nut (1) (2) (3) Kv Factor [m 3 /h] min. TS [ C] max. PS [bar] Risk Category according to PED 6310/2 6310/3 6310/4 3/4" UNF 0,46 1, 6320/3 1, Art /4 1" 3, /5 6320/6 3/4" UNS 3,4 6

127 Catalogue Number TABLE 2: Dimensions and Weights Dimensions [mm] H 1 H 2 L 1 L 2 Weight [g] VALVES 6310/ /3 6310/4 68,5 33, /3 69,5 34, /4 114, /5 6320/ ,5 117,5 77, H2 H1 3 L2 L1 7

128 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 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). INSTALLATION The brazing of capped valves with solder connections, type 60, should be carried out with care, using a low melting point filler material. It s necessary to remove the spindle assembly, with gland too, before brazing the body. It s 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. CONSTRUCTION The main parts of the capped valves are made with the following materials: hot forged brass EN 0 CW 617N for body; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; glass reinforced PBT for cap that covers the spindle. TABLE 1: General Characteristics Catalogue Number (1) SAE Flare (2) Connections [in.] ODS (3) [mm] Kv Factor [m 3 /h] min. TS [ C] max. PS [bar] Risk Category according to PED 6410/2 0, /3 1, /4 1, /5 1, /6 3/4" 3,50 60/2 0,40 60/3 60/M10 60/M 60/4 60/5 10 1,00 1,45 1, Art /M /6 60/M 3/4" 3,50 60/7 6460/A E 7/8" 0, E Until exhaustion of the stock 8

129 Catalogue Number TABLE 2: Dimensions and Weights Dimensions [mm] H 1 H 2 L 1 L 2 L 3 P 1 d I Weight [g] VALVES 6410/ /3 6410/4 6410/5 85, , / ,5 98 6, / /3 60/M10 60/M 60/4 85, , / /M18 60/6 60/M 60/ , , /A 85, , /A L1 L1 I d H1 I d H2 H2 H2 1 1 H1 3 3 H1 A94 A94 L2 L3 d I 45 A B P C L1 N.B. When the valve 6460/A is closed, connections A-B are open and C is stopped; when opened, all connections are open. 9

130 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 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: 65 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 0 CW 617N for body, cover and cap that covers the spindle; steel, with proper surface protection, for the spindle; chloroprene rubber (CR) and aramidic fibers for gland seal; metal-rubber laminated for outlet seal gaskets P.T.F.E. for seat gaskets. TABLE 1: General Characteristics Catalogue Number [in.] ODS [mm] Connections [in.] ODM [mm] Kv Factor [m 3 /h] min. TS [ C] max. PS [bar] Risk Category according to PED 65/M 65/7 7/8" 1.1/8" 7,1 65/M 65/9 1.1/8" ,4 Art / ,0 65/13 65/M 1. 2" 2" 25,0 I 65/ /M 6532/7 2.1/8" 7/8" /8" 40,00 8, /M 6532/9 1.1/8" ,1 Art / ,7 6532/ /M 1. 2" 2" 38,0 I 6532/17 2.1/8" 54 48,

131 Catalogue Number TABLE 2: Dimensions and Weights Dimensions [mm] H H 1 L L 1 Q A Weight [g] VALVES 65/M 65/7 65/M 65/9 65/ , /13 65/M /17 215, /M 6532/7 6532/M 6532/9 6532/ / /M ,5 52, , A 6532/ Q 6532 A Q H1 H H1 H M10 L L L

132 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 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 0 CW 617N for body; hot forged brass EN 0 CW 617N, chromium plated, for ball; copper tube EN 7-1 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 0 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

133 VALVES TABLE 1: General Characteristics without access fitting with access fitting Catalogue Number Kv Factor [m 3 /h] 3/4" 7/8" 7/8" 1.1/8" 1.1/8" /8" 2.1/8" " 3.1/8" 3.1/8" /8" ,8 3,0 5,0 14,5 24,0 40,0 68,0 100,0 178,0 293, Art. 3.3 I [in.] [mm] Ball Port [mm] ODS Connections min. TS [ C] max. PS [bar] Risk Category according to PED 6590/M6 6590/2 6590/3 6590/M /M 6590/4 6591/5 6590/M /5 6590/M /6 6591/7 6590/7 6591/M 6591/9 6590/M 6590/9 6591/ / / /M 6590/ /M 6591/ / /M / /3A 6590/M10A 6590/MA 6590/4A 6590/M15A 6590/5A 6590/M18A 6590/6A 6590/7A 6590/MA 6590/9A 6590/11A 6590/13A 6590/MA 6590/17A 6591/M64A 6591/21A 6590/M64A 6590/21A 6591/24A 6591/25A 6590/25A 6591/A 6591/29A 6591/33A 6591/34A