castel product handbook eng

quality products for refrigeration and air conditioningproducts suitable for CFC, HCFC and HFC

2006 release www.castel.it

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Pessano - February 2006

Thermostatic • valve with interchangeable orifice assemblyexpansion • valve with fixed orifice assemblyvalves

Solenoid valves • valves for refrigerating systems• coils • permanent magnet• connectors• valves for different fluids

Safety devices • safety valves 3030 • safety valves 3060• ball shut-off valves• changeover devices• unions• fusible plugs

Check valves

Water regulating valves

Liquid indicatorsMoisture-liquid indicators

Dehydrators • dehydration of refrigerants • anti-acid solid core filter driers• filter driers with replaceable anti-acid solid core• mechanical filters with replaceable filtering block • strainers• disseccants

Oil separators

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

Threaded brass fittings

Solder copper fittings

Access fittings

Spare parts

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After forty five years in the industry of Refrigeration and Air

Conditioning components, Castel Quality Range of Products is

well known and highly appreciated

all over the world.

Quality is the main issue of our Company and it has

a special priority, in every step, all along the production cycle.

We produce on high tech machinery and updated automatic

production lines, operating in conformity with the safety and

environment standards currently enforced.

Castel offers to the Market and to Manufacturers fully tested

products suitable with CFC, HCFC and HFC Refrigerants

currently used in the Refrigeration &

Air Conditioning Industry.

UNI EN ISO 9001:2000 issued by ICIM certifies the Quality System

of the Factory. Moreover Castel Products count a number of

certifications in conformity with the EEC Directives and with

European and American Quality Approvals.

FROM QUALITY OUR NATURAL DEVELOPMENT

Application of Directive 97/23/EC of the European Parliamentand of the Council, of 29 may 1997, concerning pressureequipment towards Castel refrigeration products

phase as well as mixture thereof.

Pressure equipments referred to in Article 3 areclassified by categories in accordance withAnnex II, according to ascending level ofhazard, on the basis of: – State of the fluid– Danger classification of the fluid– Type of equipment– Dimensions and energetic potential:

V, DN, PS, PS x V, PS x DNand must satisfy the Essential SafetyRequirement set out in Annex I of PED.Pressure equipments below or equal to thelimits in Article 3, sections 1.1, 1.2 and 1.3 andsection 2, must not satisfy the Essential SafetyRequirement set out in Annex I. They must bedesigned and manufactured in accordance withthe sound engineering practice of a MemberState in order to ensure safe use (Article 3,Section 3).In the tables of general characteristics,collected in this Handbook, it’s showed the riskcategory in which every product is classified.

In Article 9 of PED the fluids are classified,according to their hazard, into two groups:– Group I comprises dangerous fluids. A

dangerous fluid is a substance orpreparation covered by the definitions inArticle 2 of Council Directive 67/548/EEC of27 June 1967 and following amendments,relating to the classification, packaging andlabeling of dangerous substance. Group Icomprises fluids defined as: explosive,extremely flammable, highly flammable,flammable, very toxic, toxic, oxidizing.

– Group II comprises all the others fluids notreferred to in group I.

Castel products are suitable for using withrefrigerant fluids proper to the Group II.These refrigerant fluids are listed andclassified L1 in Annex E of standard EN 378-1, plus fluids R30, R123 and R141b.Among the fluids listed in this standard, thereare the well known R12; R22; R134a; R404A;R407C; R401A; R502; R507.

The Directive 97/23/EC (PED) applies to the design, manufacture and conformityassessment of pressure equipment and assemblies with a maximum allowablepressure “PS” greater than 0,5 bar with the exception of the possibilities listed in Article 1, Section 3 of the same Directive.Since 30 May 2002 the Directive has become mandatory and, in the Member States of European Community,it has been possible to place on the market only pressure equipments CE marked according to PED.

For the purposes of the Directive see thefollowing definitions, used in this Handbook too:– Pressure equipment: vessels, piping, safety

accessories, and pressure accessories– Vessel: a housing designed and built to

contain fluids under pressure.– Piping: piping components intended for the

transport of fluids, when connected togetherfor integration into a pressure system.

– Safety accessories: devices designed toprotect pressure equipment against theallowable limits being exceeded.

– Pressure accessories: devices with anoperational function and having pressure-bearing housing. For example: solenoidvalves, valves, indicators.

– Assemblies: several pieces of pressureequipment assembled by a manufacturer toconstitute an integrated and functional whole.

– Maximum allowable pressure (PS):the maximum pressure for which theequipment is designed, as specified by themanufacturer.

– Maximum / minimum allowabletemperature (TS):the maximum/minimum temperatures forwhich the equipment is designed, asspecified by the manufacturer

– Volume (V): the internal volume of a chamber,including the volume of nozzles to the firstconnection or weld and excluding the volumeof permanent internal parts.

– Nominal size (DN): numerical designation ofsize, which is common to all components in apiping system.

– Fluids: gases, liquids and vapours in pure

All the products illustrated in this Handbook aresubmitted, one by one, to tightness testsbesides to functional tests.Allowable external leakage, measurable duringthe test, agrees to the definition given in theStandard DIN 3158-87 Par. 8.2:“During the test, no bubbles shall form over aperiod of one minute when the specimen isimmersed in water with low surface tension, …”.

EXTERNAL LEAKAGE

All the products illustrated in this Handbook, ifsubmitted to hydrostatic test, guarantee apressure strenght at least equal to 1,43 x PS incompliance with the Directive 97/23/EC.

All the products illustrated in this Handbook, ifsubmitted to burst test, guarantee a pressurestrength at least equal to 3 x PS according tothe Standard revision prEN 378-2 : 2000. Agreat number of products illustrated in theHandbook can guarantee an higher pressurestrength, equal to 5 x PS according to theStandard UL 207 : 2001. (for detailedinformation about these products pleasecontact Castel Technical Department).

The weights of the items listed in this Handbookinclude packaging and are not binding for theCompany.

WEIGHTS

PRESSURE CONTAINMENT

Application of Directive 2002/95/EC of the European Parliamentand of the Council, of 27 January 2003, on the restriction of the useof certain hazardous substances in electrical and electronicequipment

The restriction of use of these hazardoussubstances shall not apply to the applicationslisted in the Annex of the same Directive; amongthese applications the following exceptions areparticularly interesting in air conditioning /refrigerating systems:– Lead as an alloying element in steel containing

up to 0,35% lead by weight, aluminiumcontaining up to 0,4% lead by weight and as acopper alloy containing up to 4% lead byweight

– Hexavalent chromium as an anti-corrosion ofthe carbon steel cooling system in absorptionrefrigerators

The Member States of European Community hadto adopt the two Directives 2002/95/EC and2002/96/EC, with the next updating 2003/108/EC,before 13 August 2004, unless delays granted bythe European Parliament.For a long time Castel Company has started acareful inquiry, together with its suppliers, toidentify the presence or not of the above-mentioned hazardous substances, either in itsown products or in its own production processes,and to remove them progressively.At the end of this wide examination CastelCompany may declare that its products:– Do not contain mercury, cadmium,

polybrominated biphenyls (PBB),polybrominated diphenyl ethers (PBDE)

– Contain lead as an alloying element in steel,aluminium and copper alloys within theaccepted limits according to the Annex ofRoHS Directive

– Contain hexavalent chromium in very lowconcentration, not exceeding 0,003% byweight, used for the surface treatments (yellowzinc plating) of steel parts. Castel Company willremove the remaining yellow zinc platingtreatments from all its products, before the endof 2005, and will choose other surfacetreatments containing trivalent chromiuminstead of hexavalent chromium.

The purpose of Directive 2002/95/EC (RoHSDirective) is to prevent or restrict the use ofhazardous substances in electrical and electronicequipment and to contribute to theenvironmentally sound recovery and disposal ofwaste electrical and electronic equipment.RoHS Directive shall apply to electrical andelectronic equipment falling under the categories1, 2, 3, 4, 5, 6, 7 and 10 set out in Annex 1A toDirective 2002/96/EC (WEEE – Waste electricaland electronic equipment) and to electric lightbulbs and luminaries in households.The equipment proper to the first category,“Large household appliances”, and to the 10thcategory, “Automatic dispensers”, of Annex 1Ain WEEE Directive, are specified in Annex 1B inthe same Directive; this list of products shows:– Large cooling appliance– Refrigerators– Freezers– Other large appliances used for refrigeration,

conservation and storage of food– Air conditioner appliances– Other fanning, exhaust ventilation and

conditioning equipment– Automatic dispenser for hot or cold bottles

and cans

Article10 of WEEE Directive establishes that,from 13 August 2005, new electrical andelectronic equipment put on the market areappropriately identified as waste subject toseparate collection, by means of the propersymbol shown in Annex IV of the same Directive.

Article 4 of RoHS Directive establishes that, from1 July 2006, new electrical and electronicequipment put on the market does not containthe following substances:– Lead– Mercury– Cadmium– Hexavalent chromium– Polybrominated biphenyls (PBB)– Polybrominated diphenyl ethers (PBDE)

CONNECTIONS OF CASTEL PRODUCTS

Castel products can be supplied with differentconnections.

In particular Castel products are producedeither with threaded connections or solderconnections.Table 1 shows the equivalence between Castelcodes and dimensions in inches. These codesare commonly used in the international market.Table 2 shows the equivalence between Castelcodes and dimensions in millimetres.

CASTELCode

Dimension[in]

TABLE 1 - Equivalence between Castel code and dimension in inches

CASTELCode

Dimension[mm]

. …/M6

. …/M10

. …/M12

. …/M15

. …/M18

. …/M22

. …/M28

. …/M42

. …/M64

. …/M80

6

10

12

15

18

22

28

42

64

80

TABLE 2 - Equivalence between Castel code and dimension in millimeters

1/8"

1/4"

3/8"

1/2"

5/8"

3/4"

7/8"

1"

1" 1/8

1" 3/8

1" 5/8

2" 1/8

2" 5/8

3"

3" 1/8

3" 1/2

3" 5/8

4" 1/8

4" 1/4

. …/1

. …/2

. …/3

. …/4

. …/5

. …/6

. …/7

. …/8

. …/9

. …/11

. …/13

. …/17

. …/21

. …/24

. …/25

. …/28

. …/29

. …/33

. …/34

F.e. 1098/7 – solenoid valve with solder connection

with Ø = 7/8”.

F.e. 4411/M42A – filter drier with replaceable

anti-acid solid core with solder connection

with Ø = 42 mm.

Description of connections that are currentlyused for Castel products.

1) Threaded connections.They can be of three different types:

FLAREStraight threaded connection (according to SAEJ513-92; ASME B1.1-89) for junction to acopper pipe with a suitable flared end, using aright nut (see Table 3).

NPTTaper threaded connection (according to ASMEB1.20.1-92) to joint fittings, valves, safety valvesto vessel or steel pipes.

FPTStraight threaded connection (according to UNIISO 228/1) used in the hydraulic system to jointfittings or valves to vessel or steel pipes.F.e.: solenoid valves for water or air.

2) Solder connections.They can be of four different types and can fitpipes with diameter both in inches and inmillimetres:

ODS (or ODF)Female solder connection for copper tubes. The indicated size corresponds to the outerdiameter of the copper tube which to joint.F.e.: 1/2" ODS solder connection suitable to receive

inside a copper pipe with a 1/2" outer diameter.

ODMMale solder connection for copper tubes. The indicated size corresponds to the outerdiameter of the copper tube which to joint.F.e.: 16 ODM solder connection suitable to joint a copper

pipe with a 16 mm outer diameter, by means of an M16

female/female copper sleeve (in this case the type Castel

7700/M16).

IDSMale solder connection for copper tube. The indicated size corresponds to the innerdiameter of the copper tube which to joint.F.e.: 10 IDS solder connection suitable to receive outside

a copper pipe with an 10 mm inner diameter).

WSolder connection for steel pipes. The indicated size corresponds to the externaldiameter of the steel pipe which to joint.F.e.: 76,1 W solder connection suitable to connect a

steel pipe with a 76,1 mm external diameter, by means of

butt welding.

FLARE Suitable for Copper Tube Thread

1/4"

5/16"

3/8"

1/2"

5/8"

3/4"

7/8"

1"

Ø 1/4"

Ø 5/16"

Ø 3/8"

Ø 1/2"

Ø 5/8"

Ø 3/4"

Ø 7/8"

Ø 1"

7/16" - 20 UNF

1/2" - 20 UNF

5/8" - 18 UNF

3/4" - 16 UNF

7/8" - 14 UNF

1.1/16" - 14 UNS

1.1/4" - 12 UNF

1.3/8" - 12 UNF

TABLE 3 - Flare Connections

THE Kv FACTOR

«Table 1» shows refrigeration capacity valueswith unit Kv related to the nominal workingconditions specified in «Table 2».

Appropriate corrective coefficients may becalculated taking the values shown from Table 3to Table 8 as a basis; this will make it possibleto predict actual working conditions.

As a result:

– Liquid line:Q = Kv · Q1 · L1 · L2

– Suction lineQ = Kv · Q1 · S1 · S2

– Hot gas lineQ = Kv · Q1 · H1 · H2

since:

Q = required refrigeration capacity [kW];Kv = characteristic valve coefficient [m3/h];Q1 = reference refrigeration capacity [kW]

(Table 1).

L1 S1 H1 = are correction factors of therefrigeration capacity in the presence ofoperating temperatures different from referenceconditions.

L2 S2 H2 = are correction factors of therefrigeration capacity for pressure dropsdifferent from reference conditions.

The correct sizing of tubes and components ofa refrigerating system is of the utmostimportance for all kinds of plants; oversizingand undersizing are both to be avoided sincethey are equally hazardous for the correctoperation of the system.

The correct selection of a component is basedon the knowledge of the relationship betweencapacity and pressure drop through thatcomponent. For this purpose, EN 60534-1, EN60534-2-1 and EN 60534-2-3 standards require manufacturersto specify the Kv coefficient for every product.

The Kv factor is defined as the cold waterflow (volumic mass �� = 1000 kg/m3) in m3/hresulting in a 1 bar pressure drop with acompletely open valve.

This definition applies to all products describedin this handbook.

The merely physical meaning, this coefficientprecisely defines the fluid-dynamic andconstruction characteristics of the product, sothat, with the addition of other parameters moreclosely related to the nature and conditions ofthe fluid under consideration, thecapacity/pressure drop ratio may be preciselydetermined.

Castel provides appropriate tables for the mostcommonly used refrigerants in typical plantworking conditions in order to help engineers inthe correct selection of its products.

TABLE 1

Kvfactor[m3/h]

R134a

Liquid Vapour Hot gas

Refrigeration Capacity [kW]

1 16,85

R22

18,00

R404A

11,90

R407C

18,74

R410A

19,04

R507

11,80

R134a

2,16

R22

2,70

R404A

2,26

R407C

2,68

R410A

3,60

R507

2,15

R134a

8,50

R22

11,70

R404A

10,00

R407C

11,62

R410A

13,00

R507

7,77

+4

TABLE 2 - Nominal Working Conditions

–

+18

+38

0,15

1

Application Suction Temperature[°C]

Condensing Temperature[°C]

Pressure drop[bar]

LIQUIDO

VAPORE

GAS

CALDO

Evaporating Temperature[°C]

Liquid line

TABLE 3 - Correction Factors - L1 of the refrigeration capacity for operating temperatures different from nominal values.

LiquidTemperature

[°C] Refrigerant+ 10 + 5 0 – 5 – 10 – 15 – 20 – 25 – 30 – 35 – 40

Evaporating Temperature[°C]

0

+10

+20

+30

+40

+50

+60

R134a

R22

R404A

R407C

R410A

R507

R134a

R22

R404A

R407C

R410A

R507

R134a

R22

R404A

R407C

R410A

R507

R134a

R22

R404A

R407C

R410A

R507

R134a

R22

R404A

R407C

R410A

R507

R134a

R22

R404A

R407C

R410A

R507

R134a

R22

R404A

R407C

R410A

R507

1,23

1,19

1,28

1,23

1,19

1,33

1,12

1,08

1,13

1,12

1,08

1,17

1,00

0,99

0,99

0,99

1,00

1,00

0,88

0,89

0,85

0,85

0,85

0,80

0,76

0,79

0,68

0,71

0,70

0,58

1,21

1,17

1,26

1,22

1,17

1,30

1,10

1,07

1,12

1,10

1,07

1,15

0,98

0,98

0,97

0,97

0,99

0,97

0,86

0,88

0,83

0,84

0,84

0,78

0,74

0,78

0,66

0,70

0,69

0,56

1,19

1,16

1,25

1,20

1,16

1,28

1,08

1,06

1,09

1,08

1,06

1,13

0,96

0,97

0,95

0,96

0,96

0,95

0,84

0,87

0,81

0,82

0,81

0,76

0,72

0,77

0,64

0,68

0,67

0,54

1,17

1,16

1,22

1,18

1,16

1,26

1,06

1,05

1,07

1,06

1,05

1,10

0,94

0,96

0,93

0,94

0,95

0,93

0,82

0,86

0,79

0,80

0,80

0,74

0,70

0,76

0,62

0,66

0,66

0,52

1,15

1,15

1,20

1,16

1,15

1,23

1,04

1,04

1,05

1,04

1,04

1,08

0,92

0,95

0,92

0,92

0,94

0,90

0,80

0,85

0,77

0,79

0,79

0,71

0,68

0,75

0,60

0,65

0,65

0,50

1,13

1,13

1,17

1,15

1,13

1,20

1,02

1,03

1,04

1,03

1,03

1,05

0,90

0,93

0,89

0,90

0,93

0,87

0,78

0,84

0,75

0,77

0,78

0,68

0,66

0,74

0,58

0,63

0,63

0,47

1,34

1,32

1,40

1,35

1,32

1,52

1,23

1,22

1,27

1,23

1,22

1,35

1,11

1,11

1,16

1,13

1,11

1,17

1,00

1,02

1,02

1,00

1,02

1,02

0,88

0,92

0,87

0,89

0,92

0,85

0,76

0,82

0,73

0,75

0,76

0,66

0,64

0,72

0,56

0,61

0,61

0,45

1,32

1,31

1,38

1,33

1,31

1,49

1,21

1,21

1,25

1,21

1,21

1,32

1,09

1,10

1,13

1,11

1,10

1,14

0,98

1,01

0,99

0,99

1,01

0,99

0,86

0,90

0,85

0,87

0,91

0,82

0,74

0,81

0,71

0,73

0,74

0,63

0,62

0,71

0,54

0,60

0,60

0,42

1,30

1,29

1,36

1,31

1,29

1,46

1,18

1,19

1,23

1,19

1,19

1,29

1,07

1,08

1,11

1,09

1,08

1,12

0,96

0,99

0,97

0,97

0,99

0,96

0,84

0,89

0,83

0,85

0,90

0,79

0,72

0,80

0,69

0,72

0,73

0,60

0,60

0,70

0,52

0,58

0,58

0,40

1,28

1,27

1,33

1,29

1,27

1,42

1,16

1,17

1,20

1,18

1,18

1,26

1,05

1,07

1,08

1,07

1,07

1,08

0,94

0,98

0,95

0,95

0,98

0,93

0,82

0,87

0,80

0,83

0,87

0,76

0,70

0,78

0,67

0,70

0,72

0,57

0,58

0,68

0,50

0,56

0,57

0,36

1,26

1,25

1,31

1,25

1,25

1,38

1,14

1,16

1,18

1,16

1,16

1,22

1,03

1,05

1,06

1,06

1,05

1,04

0,91

0,96

0,93

0,94

0,96

0,89

0,80

0,86

0,78

0,82

0,86

0,72

0,68

0,77

0,65

0,69

0,71

0,54

0,56

0,67

0,48

0,55

0,56

0,33

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

Pressuredrop[bar]

0,01 0,03 0,05 0,10

L2 0,263 0,456 0,59 0,81 1,00 1,15 1,30 1,40 1,54 1,64 1,72 1,82 1,92 2,00

0,15 0,20 0,25 0,30 0,35 0,40 0,45 0,50 0,55 0,60

Suction line Hot gas line

Q = Kv · Q1 · S1 · S2 [kW]15 = Kv · 2,68 · 0,70 · 0,82

15Kv = ——— = 9,75 [m3/h]

1,538

The result involves the selection of a 1078/9 valvewith Kv = 10 [m3/h]

3) Hot gas line:Valve selection under the following conditions:

Refrigerant: R407CSet refrigeration capacity: 20 [kW]Condensation: + 40 [°C]Evaporation: 0 [°C]Set pressure drop: 0,5 [bar]

Q = Kv · Q1 · H1 · H2 [kW]20 = Kv · 11,62 · 0,94 · 0.7

20Kv = ——— = 2,61 [m3/h]

7,64

The result involves the selection of a 1078/5 valvewith Kv = 2.61 [m3/h]

1) Liquid line:Evaluation of pressure drop across the valve underthe following working conditions:

Castel 1078/5 valve: Kv = 2,61 [m3/h]Refrigerant: R407CSet refrigeration capacity: 35 [kW]Condensation: + 50 [°C]Evaporation: 0 [°C]

Q = Kv · Q1 · L1 · L2 [kW]35 = 2,61 · 18,74 · 0,82 · L2 [kW]

35L2 = ——— = 0,87

40,11

A pressure drop slightly above 0.11 barcorresponds to the L2 = 0.87 correction factor. Sucha pressure drop is compatible with the minimumdifferential pressure required by the valve.

2) Suction line:Valve selection under the following conditions:

Refrigerant: R407CSet refrigeration capacity: 15 [kW]Condensation: + 40 [°C]Evaporation: – 10 [°C]Set pressure drop: 0,1 [bar]

APPLICATION EXAMPLES

TABLE 5 - Correction Factors - S1 of the refrigeration capacityfor operating temperatures different from nominal values.

EvaporatingTemperature

[°C] + 60 + 55 + 50 + 45 + 40 + 35 + 30

Condensing Temperature [°C]

+10

0

–10

–20

–30

–40

0,87

0,67

0,51

0,35

0,36*

0,27*

0,92

0,73

0,55

0,39

0,38*

0,29*

0,98

0,78

0,59

0,43

0,41*

0,31*

1,04

0,83

0,64

0,50

0,35

0,43*

0,33*

1,11

0,85

0,70

0,53

0,37

0,46*

0,35*

1,17

0,96

0,76

0,57

0,39

0,48*

0,37*

1,23

1,01

0,80

0,60

0,45

0,50*

0,38*

TABLE 6 - Correction Factors - S2 of the refrigeration capacityfor pressure drops different from nominal values.

Pressuredrop[bar]

0,035 0,05 0,07 0,10 0,15 0,20 0,30 0,40 0,50 0,70

S2 0,47 0,57 0,68 0,82 1,00 1,15 1,40 1,64 1,82 2,15

TABLE 8 - Correction Factors - H2 of the refrigeration capacityfor pressure drops different from nominal values.

Pressuredrop[bar]

0,10 0,20 0,30 0,40 0,50 0,70 1,00 1,50 2,00 2,50

H2 0,32 0,45 0,54 0,65 0,70 0,83 1,00 1,17 1,30 1,44

TABLE 7 - Correction Factors - H1 of the refrigeration capacityfor operating temperatures different from nominal values.

EvaporatingTemperature

[°C] + 60 + 55 + 50 + 45 + 40 + 35 + 30

Condensing Temperature [°C]

+10

0

–10

–20

–30

–40

1,00

0,83

0,76

1,00

0,90

0,76

1,00

0,92

0,79

0,67

1,03

0,92

0,80

0,71

1,04

0,94

0,84

0,72

0,60

1,05

0,95

0,87

0,76

0,65

0,58

1,05

0,95

0,88

0,77

0,68

0,61

*Two-stages plants, two indipendent circuits, with intermediatetemperature -10 °C.

17

THERMOSTATIC EXPANSION VALVES

18

top of the valve’s diaphragm. The sensingbulb pressure is a function of thetemperature of the thermostatic charge thatis the substance within the bulb.The body is made from forged brass withconnection in angle configuration. Theinterchangeable orifice assembly can bereplaced through the inlet connection. Asteel rod, inside the body, transfers thediaphragm movement to the plug inside theorifice assembly. When the thermostaticcharge pressure increases, the diaphragmwill be deflected downward transferring thismotion to the plug, which lifts from seat andallows the liquid passing through orifice. Aspring opposes the force underneath thediaphragm and the side spindle can adjustits tension. Static superheat increases byturning the side spindle clockwise anddecreased by turning the spindle counterclockwise.The thermostatic element is hardlyconnected by brazing to the forged brassbody to avoid any leakage.The body assembly can be supplied withinternal or external equalizer; both typescan also be supplied either with flareconnections or with solder connections(outlet and external equalizer if present).

Castel thermostatic expansion valves series22 regulate the flow of refrigerant liquid intoevaporators; the liquid injection is controlledby the refrigerant superheat.The new Castel “22” series are designed towork with interchangeable orifice assembly,to provide flexibility in selection of capacities,and can be used in a wide range ofapplications as listed below:• Refrigeration systems (display cases in

supermarkets, freezers, ice cream and icemaker machines, transport refrigerationetc).

• Air conditioning systems• Heat pump systems• Liquid chillerswhich use refrigerant fluids proper to theGroup II (as defined in Article 9, Section2.2, of Directive 97/23/EC and referred to inDirective 67/548/EEC).

Castel thermostatic expansion valves actsas throttle device between the high pressureand the low pressure sides of refrigerationsystems and ensure that the rate ofrefrigerant flow into the evaporator exactlymatches the rate of evaporation of liquidrefrigerant in the evaporator. If the actualsuperheat is higher than the set point thevalve feeds the evaporator with more liquidrefrigerant, if the actual superheat is lowerthan the set point the valve decreases theflow of liquid refrigerant to the evaporator.Thus the evaporator is fully utilized and noliquid refrigerant may reach the compressor.

Castel thermostatic expansion valve series22 is made up of two parts that must worktogether: the first is the body, which is theactuator of the regulator, and the second isthe orifice, which contains the valve andattends the expansion of the refrigeratingfluid.

Body assembly: two parts make it up: thethermostatic (power) element and the bodywith its inner elements.The thermostatic element is the motor of thevalve; a sensing bulb is connected to thediaphragm assembly by a length of capillarytubing, which transmits bulb pressure to the

CONSTRUCTION

OPERATION

APPLICATION

THERMOSTATIC EXPANSION VALVES SERIES 22WITH INTERCHANGEABLE ORIFICE ASSEMBLY

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

externalequalizer

internalequalizer

Catalogue number

IN OUT Equal. OUT OUT Equal. min max

PS [bar]

SAE Flare ODS [mm] ODS [in]

Refri

gera

nt

Evap

orat

ing

Tem

pera

ture

Ran

ge[°C

]

Max

bul

b te

mpe

ratu

re [

°C]

MOP

TS [°C]Connections

–

2210/4E

2210/M12SE

2210/4SE

–

2211/4E

2211/M12SE

2211/4SE

–

2220/4E

2220/M12SE

2220/4SE

–

2221/4E

2221/M12SE

2221/4SE

–

2230/4E

2230/M12SE

2230/4SE

–

2231/4E

2231/M12SE

2231/4SE

–

2234/4E

2234/M12SE

2234/4SE

2210/4

2210/M12S

2210/4S

–

2211/4

2211/M12S

2211/4S

–

2220/4

2220/M12S

2220/4S

–

2221/4

2221/M12S

2221/4S

–

2230/4

2230/M12S

2230/4S

–

2231/4

2231/M12S

2231/4S

–

2234/4

2234/M12S

2234/4S

–

3/8"

3/8"

3/8"

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

–

–

–

1/4"

–

–

–

–

–

1/4"

–

–

–

–

–

1/4"

–

–

–

–

–

1/4"

–

–

–

–

–

1/4"

–

–

–

–

–

1/4"

–

–

–

–

–

1/4"

–

–

–

12

–

–

12

–

–

12

–

–

12

–

–

12

–

–

12

–

–

12

–

–

12

–

–

12

–

–

12

–

–

12

–

–

12

–

–

12

–

–

12

–

Equal.

–

–

–

–

6

–

–

–

–

–

6

–

–

–

–

–

6

–

–

–

–

–

6

–

–

–

–

–

6

–

–

–

–

–

6

–

–

–

–

–

6

–

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

1/2"

–

–

–

–

–

1/4"

–

–

–

–

–

1/4"

–

–

–

–

–

1/4"

–

–

–

–

–

1/4"

–

–

–

–

–

1/4"

–

–

–

–

–

1/4"

–

–

–

–

–

1/4"

R22

R407C

R134a

R404A

R507

- 40 ➝

+ 10

- 40 ➝

+ 10

- 40 ➝

+ 10

- 60 ➝

- 25

without

+ 15 °C

(95 psi)

without

+ 15 °C

(55 psi)

without

+ 15 °C

(120 psi)

- 20 °C

(30 psi)

100

(1)-60 +120 34

RiskCategoryaccording

to PED

Art. 3.3

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

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MOP (Maximum Operating Pressure): thisfunctionality limits the evaporator pressureto a maximum value to protect thecompressor from the overload condition(Motor Overload Protection). MOP is theevaporating pressure at which theexpansion valve will throttle liquid injectioninto the evaporator and thus prevent theevaporating pressure from rising. Expansionvalve operates as superheat control innormal working range and operates aspressure regulator within MOP range. TheMOP point will change if the factorysuperheat setting of the expansion valve ischanged. Superheat adjustments influencethe MOP point as following:• increase of superheat

decrease of MOP• decrease of superheat

increase of MOP

Superheat: this is the controlling parameterof the expansion valve. Superheat,measured at the evaporator outlet, isdefined as the difference between actualbulb temperature and the evaporatingtemperature at the saturation point. In orderto prevent liquid refrigerant from enteringthe compressor, a certain minimumsuperheat must be maintained. In expansionvalve operation the following terms areused:• Static superheat: it’s the superheat above

that the valve will begin to open. Castelthermo expansion valves are factorypreset for optimum static superheatsetting. This setting should be modifiedonly if absolutely necessary. Staticsuperheat for Castel valves without MOPis 5 °C and for Castel valves with MOP is4°C.

• Opening superheat: it’s the amount ofsuperheat above the static superheatrequired to produce a given valvecapacity

• Operating superheat: it’s the sum of staticand opening superheat

The nuts for flare connection type and theinlet-brazing adapter for solder connectiontype can be ordered separately.

The main part of body assembly are madewith the following materials:• stainless steel for bulb, capillary tubing,

diaphragm casing, diaphragm and rod• hot forged brass EN 12420 – CW 617N

for body• brass EN 12164 – CW 614N for

superheat setting spindle and springholder

• steel DIN 17223-1 for spring• copper tube EN 12735-1 – Cu DHP for

solder connection

Orifice assembly: interchangeable orificeassembly provide a wide range of capacityfrom 0,5 up to 15,5 kW (nominal capacitywith R22). The external cartridge containsthe following elements: housing, plug(metering device), seat, spring and strainer.The rigid design of orifice assembly and itsinternal components make sure that plugand seat will withstand all types of criticaloperations (liquid hammering, cavitation,sudden variation of pressure andtemperature contaminants). The springholds the plug firmly to the seat to ensurethe minimum leakage through the valve; forpositive shut-off, the installation of asolenoid valve is required. The strainer canbe cleaned or exchanged.

Liquid charge: the behaviour of valves withliquid charge is exclusively determined bytemperature changes at the bulb and notsubject to any cross-ambient interference.They feature a fast response time and thusreact quickly in the control circuit. Castelthermostatic expansion valves with liquidcharge cannot incorporate MOP functions.

Gas charge: the behaviour of valves withgas charge will be determined by the lowesttemperature at any part of the expansionvalve (thermostatic element, capillary tubeor bulb). If any parts other than the bulb aresubjected to the lowest temperature,malfunction of expansion valve may occur(charge migration). Castel thermostaticexpansion valves with gas charge alwaysfeature MOP functions and include ballastedbulb. Ballast in the bulb has a dampingeffect on the valve regulation and leads toslow opening and fast closure of the valve.

THERMOSTATIC CHARGES

21

To correctly select a thermo expansion valveon a refrigerating system, the followingdesign conditions must be available:Type of refrigerantEvaporator capacity, Qe

Evaporating temperature/pressure, Te / pe

Lowest possible condensing temperature/pressure, Tc / pc

Liquid refrigerant temperature, Tl

Pressure drop in the liquid line, distributorand evaporator, �p

The following procedure helps to select thecorrect valve for the system.

Step 1Determine the pressure drop across thevalve. The pressure drop is calculated bythe formula:

( )pppp ectot ∆+−=∆

SELECTIONSubcooling: it’s defined as the differencebetween the liquid refrigerant temperatureand its saturation temperature. Subcoolinggenerally increases the capacity ofrefrigeration system and may be accountedfor when dimensioning an expansion valve.Depending on system design, subcoolingmay be necessary to prevent flash gas fromforming in the liquid line. If flash gas formsin the liquid line, the capacity of expansionvalve will be greatly reduced. All capacitytables, in this chapter, are calculated for asubcooling value of 4 °C; if the actualsubcooling is higher than 4 °C theevaporator capacity must be divided by theappropriate correction factor shown is thetables below every capacity tables.

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40

39

35

66

43

29

42

42

66

35

54

34

40

39

43

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Step 3Determine required orifice size. Use thepressure drop across the valve, theevaporating temperature and the calculatedevaporator capacity to select thecorresponding orifice size from the capacitytable corresponding to the chosenrefrigerant.

Step 4Select a thermostatic charge. Chose thetype of charge, liquid without MOP or gaswith MOP, and the temperature range,normal temperature or low temperature.

Step 5Determine if external equalizer is required.External equalizer is always required if adistributor is used or if there is anappreciable difference in pressure from thevalve outlet to the bulb location. Finallydetermine the type of connections and theirsizes.

where:Pc = condensing pressurePe = evaporating pressure�p = sum of pressure drops in the liquidline, distributor and evaporator

Step 2Determine required valve capacity. Use theevaporating capacity Qe to select therequired valve size at a given evaporatingtemperature. If necessary, correct theevaporator capacity for subcooling.Subcooling liquid refrigerant entering theevaporator increase the evaporatorcapacity, so that a smaller valve may berequired.

The subcooling is calculated by the formula:

From the subcooling corrector factor tablefind the appropriate corrector factor Fsub

corresponding to the �Tsub calculated anddetermine the required valve capacity by theformula:

sub

esub F

QQ =∆

lcsub TTT −=∆

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Table 2: Orifice Assemblies - Rated Capacities in kW

Catalogue Number

R22R407C R134a R404A

R507R404AR507

Evaporating Temperature Range [°C]

- 40 ➝ + 10 -60➝ -25

220X

2200

2201

2202

2203

2204

2205

2206

0,5

1,0

2,5

3,5

5,2

8,0

10,5

15,5

0,4

0,9

1,8

2,6

4,6

6,7

8,6

10,5

0,38

0,7

1,6

2,1

4,2

6,0

7,7

9,1

0,38

0,7

1,6

2,1

3,5

4,9

6,0

6,6

Rated capacities, for temperature range - 40 ➝ + 10, are based on:– Evaporating temperature Tevap = + 5 °C– Condensing temperature Tcond = + 32 °C– Refrigerant liquid temperature ahead

of valve Tliq = + 28 °C

Rated capacities, for temperature range - 60 ➝ - 25, are based on:– Evaporating temperature Tevap = - 30 °C– Condensing temperature Tcond = + 32 °C– Refrigerant liquid temperature ahead


23

• Type of refrigerant R134a• Evaporator capacity, Qe 6 kW• Evaporating temperature/

pressure, Te - 10 °C• Lowest possible condensing

temperature/pressure, Tc + 30 °C• Liquid refrigerant temperature, Tl + 20 °C• Pressure drop in the liquid line, distributor

and evaporator, �p 1,5 bar

STEP 1 - Determine the pressure dropacross the valve• Condensing pressure at

+ 30 °C - pc = 6,71 bar• Evaporating pressure at

- 10 °C - pe = 1,01 bar

STEP 2 - Determine required valve capacity

From the subcooling corrector factor table5b, we find the appropriate corrector factorFsub equal to 1,08 for �Tsub = 10 °C. Requiredvalve capacity is:

kW5,551,086Q sub ⋅==∆

C102030Tsub °⋅=−=∆

( ) bar2,45,101,171,6p tot ⋅=+−=∆

SIZING EXAMPLE

STEP 3 - Determine required orifice sizeUsing the capacity table for R134a on page25 with:• pressure drop across the valve = 4,2 bar• evaporating temperature = - 10 °C• calculated evaporator capacity = 5,55 kW• select the corresponding orifice 2205

(N.B.: the expansion valve capacity mustbe equal or slightly more than thecalculated evaporator capacity)

Main valve data are indicated on the upperside of the thermostatic element and on thecartridge surface of the orifice assembly.On the thermostatic element you may findthe following data:• The valve code number• The refrigerant• The evaporating temperature range• The MOP value, if present• The maximum allowable pressure PS• The date of productionOn the cartridge of orifice assembly youmay find the following data:• The size of the orifice• The date of productionOn the plastic cap of the orifice assemblypackage a label gives the orifice size. Thecap can easily be fastened around the valvecapillary tube to clearly identify the valvesize.

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Table 3: Solder adapters

Catalogue NumberODS Connections

[in] [mm]

2271/M6S

2271/2S

2271/3S

2271/M10S

–

1/4"

3/8"

–

6

–

–

10

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Table 4a: Refrigerant R22/R407C - Capacities in kW for temperature range - 40°C ? +10°C

Orificecode

Orificecode

Pressure drop across valve [bar] Pressure drop across valve [bar]

2 4 6 8 10 12 14 16 2 4 6 8 10 12 14 16

Evaporating temperature = 0 °C

220X 0,37 0,48 0,55 0,59 0,63 0,65 0,66 0,66

2200 0,84 1,0 1,2 1,3 1,3 1,4 1,4 1,4

2201 1,9 2,4 2,7 3,0 3,1 3,2 3,3 3,3

2202 2,6 3,4 4,0 4,3 4,6 4,8 4,9 5,0

2203 4,6 6,1 7,1 7,8 8,2 8,5 8,7 8,8

2204 6,9 9,1 10,5 11,5 12,2 12,7 13,0 13,2

2205 8,8 11,6 13,3 14,6 15,5 16,1 16,4 16,6

2206 10,8 14,2 16,3 17,8 18,9 19,6 20,0 20,2

Evaporating temperature = -20 °C

220X 0,44 0,50 0,54 0,57 0,59 0,61 0,61

2200 0,88 1,0 1,1 1,1 1,2 1,2 1,2

2201 1,7 1,9 2,0 2,2 2,3 2,3 2,3

2202 2,4 2,7 2,9 3,1 3,2 3,3 3,3

2203 4,2 4,8 5,2 5,5 5,8 5,9 6,0

2204 6,2 7,1 7,7 8,2 8,5 8,7 8,8

2205 7,9 9,0 9,8 10,3 10,8 11,0 11,2

2206 9,6 11,0 11,9 12,6 13,1 13,5 13,7


220X 0,42 0,45 0,48 0,50 0,52 0,53

2200 0,8 0,86 0,92 0,95 0,98 0,99

2201 1,3 1,4 1,4 1,5 1,5 1,6

2202 1,7 1,9 2,0 2,0 2,1 2,1

2203 3,1 3,4 3,5 3,7 3,8 3,8

2204 4,6 4,9 5,2 5,4 5,6 5,7

2205 5,8 6,3 6,6 6,9 7,1 7,2

2206 7,1 7,7 8,1 8,4 8,7 8,8

Evaporating temperature = +10 °C

220X 0,37 0,48 0,55 0,60 0,63 0,65 0,65 0,67

2200 0,87 1,1 1,2 1,3 1,4 1,4 1,4 1,5

2201 2,2 2,8 3,2 3,4 3,6 3,7 3,8 3,8

2202 3,0 4,0 4,7 5,1 5,4 5,6 5,8 5,8

2203 5,4 7,2 8,3 9,1 9,7 10,0 10,2 10,3

2204 8,1 10,8 12,5 13,8 14,5 15,0 15,5 15,5

2205 10,2 13,6 15,7 17,2 18,3 18,9 19,3 19,5

2206 12,6 16,7 19,3 21,0 22,3 23,1 23,5 23,7


220X 0,37 0,47 0,53 0,57 0,60 0,63 0,64 0,64

2200 0,79 0,96 1,1 1,2 1,2 1,3 1,3 1,3

2201 1,6 2,0 2,3 2,5 2,6 2,7 2,8 2,8

2202 2,2 2,9 3,3 3,6 3,8 4,0 4,1 4,1

2203 3,9 5,1 5,9 6,4 6,8 7,1 7,3 7,3

2204 5,8 7,6 8,7 9,5 10,1 10,5 10,8 10,9

2205 7,4 9,6 11,0 12,0 12,8 13,3 13,6 13,8

2206 9,1 11,6 13,5 14,7 15,6 16,2 16,6 16,8


220X 0,40 0,45 0,49 0,52 0,55 0,56 0,57

2200 0,79 0,9 0,96 1,0 1,1 1,1 1,1

2201 1,4 1,5 1,7 1,8 1,8 1,9 1,9

2202 1,9 2,2 2,7 2,5 2,6 2,6 2,7

2203 3,4 3,9 4,2 4,4 4,6 4,7 4,8

2204 5,0 5,7 6,2 6,6 6,8 7,0 7,1

2205 6,4 7,2 7,8 8,3 8,6 8,8 9,0

2206 7,8 8,8 9,6 10,1 10,5 10,8 11,0

Table 4b: Refrigerant R22/R407C - Correction factor for subcooling �tsub > 4°C

�tsub [°C] 4 10 15 20 25 30 35 40 45 50

Fsub 1,00 1,06 1,11 1,15 1,20 1,25 1,30 1,35 1,39 1,44

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

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

Orificecode

Orificecode


2 4 6 8 10 2 4 6 8 10


220X 0,33 0,42 0,46 0,47 0,49

2200 0,65 0,78 0,86 0,89 0,91

2201 1,3 1,6 1,7 1,8 1,8

2202 1,7 2,2 2,4 2,6 2,6

2203 3,0 3,9 4,4 4,6 4,7

2204 4,5 5,7 6,4 6,8 7,0

2205 5,7 7,3 8,1 8,6 8,8

2206 7,0 8,9 1,0 10,5 10,8


220X 0,28 0,35 0,39 0,41 0,42

2200 0,53 0,62 0,69 0,72 0,73

2201 0,81 1,0 1,1 1,2 1,2

2202 1,1 1,4 1,5 1,6 1,7

2203 2,0 2,5 2,8 2,9 3,0

2204 2,9 3,6 4,0 4,3 4,4

2205 3,7 4,6 5,1 5,4 5,5

2206 4,5 5,6 6,2 6,6 6,8


220X 0,23 0,28 0,32 0,33 0,34

2200 0,44 0,50 0,54 0,56 0,57

2201 0,54 0,65 0,72 0,78 0,77

2202 0,7 0,9 1,0 1,0 1,0

2203 1,3 1,6 1,8 1,9 1,9

2204 1,9 2,3 2,6 2,7 2,7

2205 2,4 2,9 3,2 3,5 3,5

2206 3,0 3,6 4,0 4,2 4,3


220X 0,34 0,43 0,47 0,50 0,51

2200 0,71 0,86 0,93 0,97 0,98

2201 1,5 1,9 2,1 2,2 2,2

2202 2,0 2,6 3,0 3,1 3,2

2203 3,6 4,7 5,3 5,6 5,8

2204 5,4 7,0 7,8 8,3 8,6

2205 6,9 8,9 9,9 10,8 10,9

2206 8,4 10,8 12,1 12,8 13,2


220X 0,30 0,36 0,43 0,44 0,44

2200 0,59 0,70 0,77 0,81 0,82

2201 1,0 1,3 1,4 1,5 1,5

2202 1,4 1,8 2,0 2,1 2,1

2203 2,5 3,1 3,5 3,7 3,8

2204 3,6 4,6 5,1 5,4 5,6

2205 4,6 5,8 6,5 6,9 7,1

2206 5,7 7,1 8,0 8,4 8,6


220X 0,25 0,32 0,35 0,37 0,38

2200 0,48 0,55 0,61 0,64 0,64

2201 0,66 0,80 0,88 0,93 0,95

2202 0,9 1,1 1,2 1,3 1,3

2203 1,6 2,0 2,2 2,3 2,3

2204 2,3 2,9 3,2 3,3 3,4

2205 3,0 3,6 4,0 4,2 4,3

2206 3,6 4,4 4,9 5,2 5,3

Table 5b: Refrigerant R134a - Correction factor for subcooling �tsub > 4°C

�tsub [°C] 4 10 15 20 25 30 35 40 45 50

Fsub 1,00 1,08 1,13 1,19 1,25 1,31 1,37 1,42 1,48 1,54


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

Orificecode

Orificecode


2 4 6 8 10 12 14 16 2 4 6 8 10 12 14 16


220X 0,30 0,37 0,41 0,42 0,43 0,43 0,43 0,41

2200 0,68 0,80 0,87 0,90 0,92 0,93 0,91 0,87

2201 1,53 1,86 2,04 2,13 2,18 2,18 2,15 2,08

2202 2,06 2,64 2,95 3,13 3,22 3,25 3,21 3,11

2203 3,68 4,72 5,27 5,59 5,75 5,80 5,73 5,55

2204 5,49 7,15 7,86 8,33 8,58 8,64 8,53 8,27

2205 6,97 8,92 9,95 10,52 10,83 10,90 10,76 10,43

2206 8,57 10,93 12,16 12,85 13,21 13,30 13,12 12,72


220X 0,35 0,38 0,40 0,39 0,40 0,39 0,38

2200 0,70 0,75 0,77 0,79 0,79 0,79 0,76

2201 1,34 1,45 1,50 1,52 1,52 1,51 1,47

2202 1,85 2,04 2,14 2,17 2,18 2,16 2,09

2203 3,32 3,66 3,83 3,89 3,90 3,86 3,75

2204 4,88 5,40 5,64 5,75 5,77 5,71 5,56

2205 6,20 6,86 7,17 7,29 7,31 7,23 7,05

2206 7,60 8,39 8,75 8,91 8,93 8,84 8,61


220X 0,32 0,33 0,33 0,33 0,32 0,32

2200 0,60 0,61 0,62 0,61 0,60 0,59

2201 0,92 0,96 0,97 0,96 0,94 0,91

2202 1,27 1,32 1,33 1,31 1,28 1,24

2203 2,28 2,36 2,38 2,36 2,31 2,24

2204 3,34 3,47 3,50 3,48 3,42 3,33

2205 4,25 4,41 4,45 4,43 4,36 4,24

2206 5,19 5,39 5,45 5,42 5,33 5,19


220X 0,28 0,35 0,40 0,42 0,43 0,43 0,42 0,41

2200 0,67 0,82 0,90 0,94 0,96 0,96 0,93 0,90

2201 1,70 2,10 2,30 2,42 2,48 2,46 2,41 2,34

2202 2,32 3,00 3,39 3,61 3,73 3,74 3,68 3,59

2203 4,15 5,36 6,03 6,43 6,63 6,66 6,55 6,39

2204 6,24 8,06 9,06 9,66 9,95 9,98 9,81 9,57

2205 7,91 10,17 11,43 12,16 12,53 12,56 12,34 12,03

2206 9,71 12,47 13,98 14,86 15,29 15,31 15,05 14,66


220X 0,30 0,37 0,40 0,42 0,42 0,42 0,41 0,41

2200 0,65 0,76 0,82 0,84 0,87 0,87 0,85 0,83

2201 1,31 1,61 1,74 1,81 1,84 1,85 1,84 1,78

2202 1,76 2,24 2,50 2,62 2,69 2,71 2,68 2,60

2203 3,14 4,02 4,47 4,69 4,81 4,84 4,79 4,65

2204 4,66 5,97 6,61 6,95 7,13 7,18 7,11 6,91

2205 5,93 7,57 8,39 8,81 9,02 9,08 8,99 8,73

2206 7,28 9,27 10,26 10,76 11,00 11,08 10,97 10,65


220X 0,35 0,37 0,36 0,37 0,36 0,35

2200 0,67 0,70 0,70 0,70 0,69 0,67

2201 1,18 1,21 1,23 1,21 1,20 1,17

2202 1,63 1,69 1,71 1,70 1,68 1,64

2203 2,93 3,04 3,07 3,06 3,02 2,93

2204 4,28 4,47 4,52 4,51 4,46 4,35

2205 5,45 5,68 5,74 5,74 5,67 5,52

2206 6,66 6,94 7,02 7,01 6,93 6,75

Table 6b: Refrigerant R404A/R507 - Correction factor for subcooling �tsub > 4°C

�tsub [°C] 4 10 15 20 25 30 35 40 45 50

Fsub 1,00 1,10 1,20 1,29 1,37 1,46 1,54 1,63 1,70 1,78


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

Orificecode

Orificecode


2 4 6 8 10 12 14 16 2 4 6 8 10 12 14 16


2200 0,53 0,64 0,67 0,70 0,70 0,70 0,69 0,67

2201 0,88 1,07 1,18 1,21 1,23 1,21 1,20 1,17

2202 1,18 1,47 1,63 1,69 1,71 1,70 1,68 1,64

2203 2,12 2,65 2,93 3,04 3,07 3,05 3,02 2,93

2204 3,09 3,88 4,28 4,47 4,52 4,51 4,46 4,35

2205 3,94 4,94 5,45 5,68 5,74 5,74 5,67 5,52

2206 4,83 6,06 6,66 6,94 7,02 7,01 6,93 6,75


2200 0,49 0,53 0,54 0,54 0,53 0,52 0,50

2201 0,51 0,57 0,60 0,60 0,60 0,60 0,59

2202 0,91 0,99 1,02 1,02 1,01 0,98 0,95

2203 1,63 1,73 1,84 1,84 1,81 1,78 1,72

2204 2,36 2,60 2,69 2,71 2,68 2,63 2,56

2205 3,02 3,30 3,43 3,45 3,42 3,35 3,26

2206 3,69 4,04 4,20 4,22 4,18 4,12 4,00


2200 0,57 0,67 0,72 0,73 0,74 0,85 0,74 0,71

2201 0,98 1,20 1,31 1,36 1,37 1,37 1,35 1,31

2202 1,31 1,65 1,83 1,91 1,93 1,93 1,90 1,85

2203 2,35 2,97 3,28 3,42 3,47 3,46 3,42 3,32

2204 3,45 4,37 4,82 5,04 5,11 5,12 5,06 4,93

2205 4,40 5,56 6,14 6,40 6,49 6,49 6,42 6,26

2206 5,40 6,30 7,49 7,81 7,93 7,93 7,85 7,64


2200 0,56 0,60 0,61 0,62 0,61 0,60 0,59

2201 0,65 0,72 0,75 0,77 0,77 0,77 0,75

2202 1,17 1,27 1,32 1,33 1,31 1,28 1,24

2203 2,09 2,28 2,36 2,38 2,36 2,31 2,24

2204 3,03 3,34 3,47 3,50 3,48 3,42 3,33

2205 3,87 4,25 4,41 4,45 4,43 4,36 4,24

2206 4,73 5,19 5,39 5,45 5,47 5,33 5,19


2200 0,46 0,48 0,47 0,45 0,45 0,43

2201 0,58 0,60 0,60 0,58 0,56 0,54

2202 0,78 0,80 0,80 0,78 0,75 0,72

2203 1,40 1,44 1,43 1,40 1,36 1,30

2204 2,04 2,11 2,11 2,07 2,03 1,96

2205 2,59 2,69 2,66 2,65 2,59 2,50

2206 3,16 3,28 3,30 3,25 3,18 3,07


�tsub [°C] 4 10 15 20 25 30 35 40 45 50

Fsub 1,00 1,10 1,20 1,29 1,37 1,46 1,54 1,63 1,70 1,78


28

connection in angle configuration. The fixedorifice assembly is screwed into the bodythrough the inlet side. A steel rod, inside thebody, transfers the diaphragm movement tothe plug inside the orifice assembly. Whenthe thermostatic charge pressure increases,the diaphragm will be deflected downwardtransferring this motion to the plug, whichlifts from seat and allows the liquid passingthrough orifice. A spring opposes the forceunderneath the diaphragm and the sidespindle can adjust its tension. Staticsuperheat increases by turning the sidespindle clockwise and decreased by turningthe spindle counter clockwise.

Castel thermostatic expansion valves series23 regulate the flow of refrigerant liquid intoevaporators; the liquid injection is controlledby the refrigerant superheat.The new Castel “23” series are specificallydeveloped for soldering into hermeticrefrigeration systems; they are offered inrated capacities up to 15,5 kW (R22) andcan be used in a wide range of applicationsas listed below:• Refrigeration systems (display cases in

supermarkets, freezers, ice cream and icemaker machines, transport refrigerationetc).

• Air conditioning systems• Heat pump systems• Liquid chillerswhich use refrigerant fluids proper to theGroup II (as defined in Article 9, Section2.2, of Directive 97/23/EC and referred to inDirective 67/548/EEC).

Castel thermostatic expansion valves actsas throttle device between the high pressureand the low pressure sides of refrigerationsystems and ensure that the rate ofrefrigerant flow into the evaporator exactlymatches the rate of evaporation of liquidrefrigerant in the evaporator. If the actualsuperheat is higher than the set point thevalve feeds the evaporator with more liquidrefrigerant, if the actual superheat is lowerthan the set point the valve decreases theflow of liquid refrigerant to the evaporator.Thus the evaporator is fully utilized and noliquid refrigerant may reach the compressor.

Four parts make up the Castel thermoexpansion valve series 23: the thermostatic(power) element, the body with its innerelements, the orifice assembly and the inletconnection.The thermostatic element is the motor of thevalve; a sensing bulb is connected to thediaphragm assembly by a length of capillarytubing, which transmits bulb pressure to thetop of the valve’s diaphragm. The sensingbulb pressure is a function of thetemperature of the thermostatic charge thatis the substance within the bulb.The body is made from forged brass with

CONSTRUCTION

OPERATION

APPLICATION

HERMETIC THERMOSTATIC EXPANSION VALVES SERIES 23 WITH FIXED ORIFICE ASSEMBLY

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Table 1: General Characteristics of Thermostatic Expansion Valves

external equalizerinternal equalizer

Catalogue number

IN OUT Equal. IN OUT Equal. min max

PS [bar]

[in] [mm]

Refri

gera

nt

Evap

orat

ing

Tem

pera

ture

Ran

ge[°C

]

Max

bul

b te

mpe

ratu

re [

°C]

MOP

TS [°C]ODS Connections

–

2310/M6E 0X ➝ 06

2310/2E 0X ➝ 06

2310/3E 0X ➝ 06

2310/M10E 0X ➝ 06

–

2311/M6E 0X ➝ 06

2311/2E 0X ➝ 06

2311/3E 0X ➝ 06

2311/M10E 0X ➝ 06

–

2320/M6E 0X ➝ 06

2320/2E 0X ➝ 06

2320/3E 0X ➝ 06

2320/M10E 0X ➝ 06

–

2321/M6E 0X ➝ 06

2321/2E 0X ➝ 06

2321/3E 0X ➝ 06

2321/M10E 0X ➝ 06

–

2330/M6E 0X ➝ 06

2330/2E 0X ➝ 06

2330/3E 0X ➝ 06

2330/M10E 0X ➝ 06

–

2331/M6E 0X ➝ 06

2331/2E 0X ➝ 06

2331/3E 0X ➝ 06

2331/M10E 0X ➝ 06

–

2334/M6E 0X ➝ 06

2334/2E 0X ➝ 06

2334/3E 0X ➝ 06

2334/M10E 0X ➝ 06

2310/M6 0X➝06

2310/2 0X ➝ 06

2310/3 0X ➝ 06

2310/M10 0X ➝ 06

–

2311/M6 0X ➝ 06

2311/2 0X ➝ 06

2311/3 0X ➝ 06

2311/M10 0X ➝ 06

–

2320/M6 0X ➝ 06

2320/2 0X ➝ 06

2320/3 0X ➝ 06

2320/M10 0X ➝ 06

–

2321/M6 0X ➝ 06

2321/2 0X ➝ 06

2321/3 0X ➝ 06

2321/M10 0X ➝ 06

–

2330/M6 0X ➝ 06

2330/2 0X ➝ 06

2330/3 0X ➝ 06

2330/M10 0X ➝ 06

–

2331/M6 0X ➝ 06

2331/2 0X ➝ 06

2331/3 0X ➝ 06

2331/M10 0X ➝ 06

–

2334/M6 0X ➝ 06

2334/2 0X ➝ 06

2334/3 0X ➝ 06

2334/M10 0X ➝ 06

–

–

1/4"

3/8"

–

–

1/4"

3/8"

–

–

1/4"

3/8"

–

–

1/4"

3/8"

–

–

1/4"

3/8"

–

–

1/4"

3/8"

–

–

1/4"

3/8"

–

–

1/4"

3/8"

–

–

1/4"

3/8"

–

–

1/4"

3/8"

–

–

1/4"

3/8"

–

–

1/4"

3/8"

–

–

1/4"

3/8"

–

–

1/4"

3/8"

–

–

1/2"

1/2"

–

–

1/2"

1/2"

–

–

1/2"

1/2"

–

–

1/2"

1/2"

–

–

1/2"

1/2"

–

–

1/2"

1/2"

–

–

1/2"

1/2"

–

–

1/2"

1/2"

–

–

1/2"

1/2"

–

–

1/2"

1/2"

–

–

1/2"

1/2"

–

–

1/2"

1/2"

–

–

1/2"

1/2"

–

–

1/2"

1/2"

–

–

–

–

–

–

1/4"

1/4"

–

–

–

–

–

–

1/4"

1/4"

–

–

–

–

–

–

1/4"

1/4"

–

–

–

–

–

–

1/4"

1/4"

–

–

–

–

–

–

1/4"

1/4"

–

–

–

–

–

–

1/4"

1/4"

–

–

–

–

–

–

1/4"

1/4"

–

6

–

–

10

6

–

–

10

6

–

–

10

6

–

–

10

6

–

–

10

6

–

–

10

6

–

–

10

6

–

–

10

6

–

–

10

6

–

–

10

6

–

–

10

6

–

–

10

6

–

–

10

6

–

–

10

12

–

–

12

12

–

–

12

12

–

–

12

12

–

–

12

12

–

–

12

12

–

–

12

12

–

–

12

12

–

–

12

12

–

–

12

12

–

–

12

12

–

–

12

12

–

–

12

12

–

–

12

12

–

–

12

–

–

–

–

6

–

–

6

–

–

–

–

6

–

–

6

–

–

–

–

6

–

–

6

–

–

–

–

6

–

–

6

–

–

–

–

6

–

–

6

–

–

–

–

6

–

–

6

–

–

–

–

6

–

–

6

R22

R407C

R134a

R404A

R507

- 40 ➝

+ 10

- 40 ➝

+ 10

- 40 ➝

+ 10

- 60 ➝

- 25

without

+ 15 °C

(95 psi)

without

+ 15 °C

(55 psi)

without

+ 15 °C

(120 psi)

- 20 °C

(30 psi)

100

(1)-60 +120 34


to PED

Art. 3.3

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

30 www.castel.it

expansion valves with gas charge alwaysfeature MOP functions and include ballastedbulb. Ballast in the bulb has a dampingeffect on the valve regulation and leads toslow opening and fast closure of the valve.

MOP (Maximum Operating Pressure): thisfunctionality limits the evaporator pressureto a maximum value to protect thecompressor from the overload condition(Motor Overload Protection). MOP is theevaporating pressure at which theexpansion valve will throttle liquid injectioninto the evaporator and thus prevent theevaporating pressure from rising. Expansionvalve operates as superheat control innormal working range and operates aspressure regulator within MOP range. TheMOP point will change if the factorysuperheat setting of the expansion valve ischanged. Superheat adjustments influencethe MOP point as following:• increase of superheat

decrease of MOP• decrease of superheat

increase of MOP

Superheat: this is the controlling parameterof the expansion valve. Superheat,measured at the evaporator outlet, isdefined as the difference between actualbulb temperature and the evaporatingtemperature at the saturation point. In orderto prevent liquid refrigerant from enteringthe compressor, a certain minimumsuperheat must be maintained. In expansionvalve operation the following terms areused:• Static superheat: it’s the superheat

above that the valve will begin to open.Castel thermo expansion valves arefactory preset for optimum staticsuperheat setting. This setting should bemodified only if absolutely necessary.Static superheat for Castel valveswithout MOP is 5 °C and for Castelvalves with MOP is 4°C.

• Opening superheat: it’s the amount ofsuperheat above the static superheatrequired to produce a given valvecapacity

• Operating superheat: it’s the sum of staticand opening superheat

The fixed orifice assembly provide a widerange of capacity from 0,5 up to 15,5 kW(nominal capacity with R22). It contains thefollowing elements: housing, plug (meteringdevice), seat, spring and strainer. The rigiddesign of orifice assembly and its internalcomponents make sure that plug and seatwill withstand all types of critical operations(liquid hammering, cavitation, suddenvariation of pressure and temperaturecontaminants). The spring holds the plugfirmly to the seat to ensure the minimumleakage through the valve; for positive shut-off, the installation of a solenoid valve isrequired.The thermostatic element is hardlyconnected by brazing to the forged brassbody meanwhile the inlet connection iselectrical welded to the forged brass body.This construction makes the valve hermeticand avoids any leakage.The valve can be supplied with internal orexternal equalizer; both types are suppliedwith solder connections (inlet, outlet andexternal equalizer if present).The main part of valve are made with thefollowing materials:• stainless steel for bulb, capillary tubing,

diaphragm casing, diaphragm and rod• hot forged brass EN 12420 – CW 617N

for body• brass EN 12164 – CW 614N for

superheat setting spindle and springholder

• steel DIN 17223-1 for spring• copper tube EN 12735-1 – Cu DHP for

solder connection

Liquid charge: the behaviour of valves withliquid charge is exclusively determined bytemperature changes at the bulb and notsubject to any cross-ambient interference.They feature a fast response time and thusreact quickly in the control circuit. Castelthermostatic expansion valves with liquidcharge cannot incorporate MOP functions.

Gas charge: the behaviour of valves withgas charge will be determined by the lowesttemperature at any part of the expansionvalve (thermostatic element, capillary tubeor bulb). If any parts other than the bulb aresubjected to the lowest temperature,malfunction of expansion valve may occur(charge migration). Castel thermostatic

THERMOSTATIC CHARGES

31

Step 2Determine required valve capacity. Use theevaporating capacity Qe to select therequired valve size at a given evaporatingtemperature. If necessary, correct theevaporator capacity for subcooling.Subcooling liquid refrigerant entering theevaporator increase the evaporatorcapacity, so that a smaller valve may berequired. The subcooling is calculated bythe formula:

From the subcooling corrector factor tablefind the appropriate corrector factor Fsub

corresponding to the �Tsub calculated anddetermine the required valve capacity by theformula:

Step 3Determine required orifice size. Use thepressure drop across the valve, theevaporating temperature and the calculatedvalve capacity to select the correspondingorifice size from the capacity tablecorresponding to the chosen refrigerant.

sub

esub F

QQ =∆

Subcooling: it’s defined as the differencebetween the liquid refrigerant temperatureand its saturation temperature. Subcoolinggenerally increases the capacity ofrefrigeration system and may be accountedfor when dimensioning an expansion valve.Depending on system design, subcoolingmay be necessary to prevent flash gas fromforming in the liquid line. If flash gas formsin the liquid line, the capacity of expansionvalve will be greatly reduced. All capacitytables, in this chapter, are calculated for asubcooling value of 4 °C; if the actualsubcooling is higher than 4 °C theevaporator capacity must be divided by theappropriate correction factor shown is thetables below every capacity tables.

To correctly select a thermo expansion valveon a refrigerating system, the followingdesign conditions must be available:• Type of refrigerant• Evaporator capacity, Qe

• Evaporating temperature/pressure, Te / pe

• Lowest possible condensingtemperature/pressure, Tc / pc

• Liquid refrigerant temperature, Tl

• Pressure drop in the liquid line, distributorand evaporator, �p

The following procedure helps to select thecorrect valve for the system.

Step 1Determine the pressure drop across thevalve. The pressure drop is calculated bythe formula:

where:pc = condensing pressurepe = evaporating pressure�p = sum of pressure drops in the liquidline, distributor and evaporator

( )pppp ectot ∆+−=∆

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Table 2: Fixed orifices - Rated Capacities in kW

Orifice Size

R22R407C R134a R404A

R507R404AR507

Evaporating Temperature Range [°C]

- 40 ➝ + 10 -60➝ -25

23--/-0X

23--/-00

23--/-01

23--/-02

23--/-03

23--/-04

23--/-05

23--/-06

0,5

1,0

2,5

3,5

5,2

8,0

10,5

15,5

0,4

0,9

1,8

2,6

4,6

6,7

8,6

10,5

0,38

0,7

1,6

2,1

4,2

6,0

7,7

9,1

0,38

0,7

1,6

2,1

3,5

4,9

6,0

6,6

Rated capacities, for temperature range - 40 ➝ + 10, are based on:– Evaporating temperature Tevap = + 5 °C– Condensing temperature Tcond = + 32 °C– Refrigerant liquid temperature ahead


Rated capacities, for temperature range - 60 ➝ - 25, are based on:– Evaporating temperature Tevap = - 30 °C– Condensing temperature Tcond = + 32 °C– Refrigerant liquid temperature ahead


77

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108

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STEP 1 - Determine the pressure dropacross the valve• Condensing pressure at

+ 38 °C - Pc = 13,6 bar• Evaporating pressure at

+ 5 °C - Pe = 4.8 bar

STEP 2 - Determine required valve capacity

From the subcooling corrector factor table3b we find the appropriate corrector factorFsub equal to 1,07 for �Tsub = 11 °C. Required valve capacity is:

STEP 3 - Determine required orifice sizeUsing the capacity table for R22 on page 33with:• pressure drop across the valve = 8,3 bar• evaporating temperature = + 5 °C• calculated evaporator capacity = 3,55 kW• select the corresponding valve 23--/-02

(N.B.: the expansion valve capacity mustbe equal or slightly more than thecalculated evaporator capacity)

kW3,551,078,3Q sub ⋅==∆

C112738Tsub °⋅=−=∆

( ) bar3,85,08,46,13ptot ⋅=+−=∆

Step 4Select a thermostatic charge. Chose thetype of charge, liquid without MOP or gaswith MOP, and the temperature range,normal temperature or low temperature.

Step 5Determine if external equalizer is required.External equalizer is always required if adistributor is used or if there is anappreciable difference in pressure from thevalve outlet to the bulb location. Finallydetermine the type of connections and theirsizes.

• Type of refrigerant R22• Evaporator capacity, Qe 3,8 kW• Evaporating temperature/

pressure, Te + 5 °C• Lowest possible condensing

temperature/pressure, Tc + 38 °C• Liquid refrigerant temperature,Tl + 27 °C• Pressure drop in the liquid line, distributor

and evaporator, �p 0,5 bar

SIZING EXAMPLE

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

MARKING

Table 3a: Refrigerant R22/R407C - Capacities in kW for temperature range - 40°C ➝➝ + 10°C

Orificesize

Orificesize


2 4 6 8 10 12 14 16 2 4 6 8 10 12 14 16


23--/-0X 0,37 0,48 0,55 0,59 0,63 0,65 0,66 0,66

23--/-00 0,84 1,0 1,2 1,3 1,3 1,4 1,4 1,4

23--/-01 1,9 2,4 2,7 3,0 3,1 3,2 3,3 3,3

23--/-02 2,6 3,4 4,0 4,3 4,6 4,8 4,9 5,0

23--/-03 4,6 6,1 7,1 7,8 8,2 8,5 8,7 8,8

23--/-04 6,9 9,1 10,5 11,5 12,2 12,7 13,0 13,2

23--/-05 8,8 11,6 13,3 14,6 15,5 16,1 16,4 16,6

23--/-06 10,8 14,2 16,3 17,8 18,9 19,6 20,0 20,2


23--/-0X 0,44 0,50 0,54 0,57 0,59 0,61 0,61

23--/-00 0,88 1,0 1,1 1,1 1,2 1,2 1,2

23--/-01 1,7 1,9 2,0 2,2 2,3 2,3 2,3

23--/-02 2,4 2,7 2,9 3,1 3,2 3,3 3,3

23--/-03 4,2 4,8 5,2 5,5 5,8 5,9 6,0

23--/-04 6,2 7,1 7,7 8,2 8,5 8,7 8,8

23--/-05 7,9 9,0 9,8 10,3 10,8 11,0 11,2

23--/-06 9,6 11,0 11,9 12,6 13,1 13,5 13,7


23--/-0X 0,42 0,45 0,48 0,50 0,52 0,53

23--/-00 0,8 0,86 0,92 0,95 0,98 0,99

23--/-01 1,3 1,4 1,4 1,5 1,5 1,6

23--/-02 1,7 1,9 2,0 2,0 2,1 2,1

23--/-03 3,1 3,4 3,5 3,7 3,8 3,8

23--/-04 4,6 4,9 5,2 5,4 5,6 5,7

23--/-05 5,8 6,3 6,6 6,9 7,1 7,2

23--/-06 7,1 7,7 8,1 8,4 8,7 8,8


23--/-0X 0,37 0,48 0,55 0,60 0,63 0,65 0,65 0,67

23--/-00 0,87 1,1 1,2 1,3 1,4 1,4 1,4 1,5

23--/-01 2,2 2,8 3,2 3,4 3,6 3,7 3,8 3,8

23--/-02 3,0 4,0 4,7 5,1 5,4 5,6 5,8 5,8

23--/-03 5,4 7,2 8,3 9,1 9,7 10,0 10,2 10,3

23--/-04 8,1 10,8 12,5 13,8 14,5 15,0 15,5 15,5

23--/-05 10,2 13,6 15,7 17,2 18,3 18,9 19,3 19,5

23--/-06 12,6 16,7 19,3 21,0 22,3 23,1 23,5 23,7


23--/-0X 0,37 0,47 0,53 0,57 0,60 0,63 0,64 0,64

23--/-00 0,79 0,96 1,1 1,2 1,2 1,3 1,3 1,3

23--/-01 1,6 2,0 2,3 2,5 2,6 2,7 2,8 2,8

23--/-02 2,2 2,9 3,3 3,6 3,8 4,0 4,1 4,1

23--/-03 3,9 5,1 5,9 6,4 6,8 7,1 7,3 7,3

23--/-04 5,8 7,6 8,7 9,5 10,1 10,5 10,8 10,9

23--/-05 7,4 9,6 11,0 12,0 12,8 13,3 13,6 13,8

23--/-06 9,1 11,6 13,5 14,7 15,6 16,2 16,6 16,8


23--/-0X 0,40 0,45 0,49 0,52 0,55 0,56 0,57

23--/-00 0,79 0,9 0,96 1,0 1,1 1,1 1,1

23--/-01 1,4 1,5 1,7 1,8 1,8 1,9 1,9

23--/-02 1,9 2,2 2,7 2,5 2,6 2,6 2,7

23--/-03 3,4 3,9 4,2 4,4 4,6 4,7 4,8

23--/-04 5,0 5,7 6,2 6,6 6,8 7,0 7,1

23--/-05 6,4 7,2 7,8 8,3 8,6 8,8 9,0

23--/-06 7,8 8,8 9,6 10,1 10,5 10,8 11,0

Table 3b: Refrigerant R22/R407C - Correction factor for subcooling �tsub > 4°C

�tsub [°C] 4 10 15 20 25 30 35 40 45 50

Fsub 1,00 1,06 1,11 1,15 1,20 1,25 1,30 1,35 1,39 1,44


34 www.castel.it

Table 4a: Refrigerant R134a - Capacities in kW for temperature range - 40°C ➝➝ + 10°C

Orificesize

Orificesize


2 4 6 8 10 2 4 6 8 10


23--/-0X 0,33 0,42 0,46 0,47 0,49

23--/-00 0,65 0,78 0,86 0,89 0,91

23--/-01 1,3 1,6 1,7 1,8 1,8

23--/-02 1,7 2,2 2,4 2,6 2,6

23--/-03 3,0 3,9 4,4 4,6 4,7

23--/-04 4,5 5,7 6,4 6,8 7,0

23--/-05 5,7 7,3 8,1 8,6 8,8

23--/-06 7,0 8,9 1,0 10,5 10,8


23--/-0X 0,28 0,35 0,39 0,41 0,42

23--/-00 0,53 0,62 0,69 0,72 0,73

23--/-01 0,81 1,0 1,1 1,2 1,2

23--/-02 1,1 1,4 1,5 1,6 1,7

23--/-03 2,0 2,5 2,8 2,9 3,0

23--/-04 2,9 3,6 4,0 4,3 4,4

23--/-05 3,7 4,6 5,1 5,4 5,5

23--/-06 4,5 5,6 6,2 6,6 6,8


23--/-0X 0,23 0,28 0,32 0,33 0,34

23--/-00 0,44 0,50 0,54 0,56 0,57

23--/-01 0,54 0,65 0,72 0,78 0,77

23--/-02 0,7 0,9 1,0 1,0 1,0

23--/-03 1,3 1,6 1,8 1,9 1,9

23--/-04 1,9 2,3 2,6 2,7 2,7

23--/-05 2,4 2,9 3,2 3,5 3,5

23--/-06 3,0 3,6 4,0 4,2 4,3


23--/-0X 0,34 0,43 0,47 0,50 0,51

23--/-00 0,71 0,86 0,93 0,97 0,98

23--/-01 1,5 1,9 2,1 2,2 2,2

23--/-02 2,0 2,6 3,0 3,1 3,2

23--/-03 3,6 4,7 5,3 5,6 5,8

23--/-04 5,4 7,0 7,8 8,3 8,6

23--/-05 6,9 8,9 9,9 10,8 10,9

23--/-06 8,4 10,8 12,1 12,8 13,2


23--/-0X 0,30 0,36 0,43 0,44 0,44

23--/-00 0,59 0,70 0,77 0,81 0,82

23--/-01 1,0 1,3 1,4 1,5 1,5

23--/-02 1,4 1,8 2,0 2,1 2,1

23--/-03 2,5 3,1 3,5 3,7 3,8

23--/-04 3,6 4,6 5,1 5,4 5,6

23--/-05 4,6 5,8 6,5 6,9 7,1

23--/-06 5,7 7,1 8,0 8,4 8,6


23--/-0X 0,25 0,32 0,35 0,37 0,38

23--/-00 0,48 0,55 0,61 0,64 0,64

23--/-01 0,66 0,80 0,88 0,93 0,95

23--/-02 0,9 1,1 1,2 1,3 1,3

23--/-03 1,6 2,0 2,2 2,3 2,3

23--/-04 2,3 2,9 3,2 3,3 3,4

23--/-05 3,0 3,6 4,0 4,2 4,3

23--/-06 3,6 4,4 4,9 5,2 5,3

Table 4b: Refrigerant R134a - Correction factor for subcooling �tsub > 4°C

�tsub [°C] 4 10 15 20 25 30 35 40 45 50

Fsub 1,00 1,08 1,13 1,19 1,25 1,31 1,37 1,42 1,48 1,54


35

TH

ER

MO

STA

TIC

EX

PAN

SIO

N VA

LVE

S

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Table 5a: Refrigerant R404A/R507 - Capacities in kW for temperature range - 40°C ➝➝ + 10°C

Orificesize

Orificesize


2 4 6 8 10 12 14 16 2 4 6 8 10 12 14 16


23--/-0X 0,30 0,37 0,41 0,42 0,43 0,43 0,43 0,41

23--/-00 0,68 0,80 0,87 0,90 0,92 0,93 0,91 0,87

23--/-01 1,53 1,86 2,04 2,13 2,18 2,18 2,15 2,08

23--/-02 2,06 2,64 2,95 3,13 3,22 3,25 3,21 3,11

23--/-03 3,68 4,72 5,27 5,59 5,75 5,80 5,73 5,55

23--/-04 5,49 7,15 7,86 8,33 8,58 8,64 8,53 8,27

23--/-05 6,97 8,92 9,95 10,52 10,83 10,90 10,76 10,43

23--/-06 8,57 10,93 12,16 12,85 13,21 13,30 13,12 12,72


23--/-0X 0,35 0,38 0,40 0,39 0,40 0,39 0,38

23--/-00 0,70 0,75 0,77 0,79 0,79 0,79 0,76

23--/-01 1,34 1,45 1,50 1,52 1,52 1,51 1,47

23--/-02 1,85 2,04 2,14 2,17 2,18 2,16 2,09

23--/-03 3,32 3,66 3,83 3,89 3,90 3,86 3,75

23--/-04 4,88 5,40 5,64 5,75 5,77 5,71 5,56

23--/-05 6,20 6,86 7,17 7,29 7,31 7,23 7,05

23--/-06 7,60 8,39 8,75 8,91 8,93 8,84 8,61


23--/-0X 0,32 0,33 0,33 0,33 0,32 0,32

23--/-00 0,60 0,61 0,62 0,61 0,60 0,59

23--/-01 0,92 0,96 0,97 0,96 0,94 0,91

23--/-02 1,27 1,32 1,33 1,31 1,28 1,24

23--/-03 2,28 2,36 2,38 2,36 2,31 2,24

23--/-04 3,34 3,47 3,50 3,48 3,42 3,33

23--/-05 4,25 4,41 4,45 4,43 4,36 4,24

23--/-06 5,19 5,39 5,45 5,42 5,33 5,19


23--/-0X 0,28 0,35 0,40 0,42 0,43 0,43 0,42 0,41

23--/-00 0,67 0,82 0,90 0,94 0,96 0,96 0,93 0,90

23--/-01 1,70 2,10 2,30 2,42 2,48 2,46 2,41 2,34

23--/-02 2,32 3,00 3,39 3,61 3,73 3,74 3,68 3,59

23--/-03 4,15 5,36 6,03 6,43 6,63 6,66 6,55 6,39

23--/-04 6,24 8,06 9,06 9,66 9,95 9,98 9,81 9,57

23--/-05 7,91 10,17 11,43 12,16 12,53 12,56 12,34 12,03

23--/-06 9,71 12,47 13,98 14,86 15,29 15,31 15,05 14,66


23--/-0X 0,30 0,37 0,40 0,42 0,42 0,42 0,41 0,41

23--/-00 0,65 0,76 0,82 0,84 0,87 0,87 0,85 0,83

23--/-01 1,31 1,61 1,74 1,81 1,84 1,85 1,84 1,78

23--/-02 1,76 2,24 2,50 2,62 2,69 2,71 2,68 2,60

23--/-03 3,14 4,02 4,47 4,69 4,81 4,84 4,79 4,65

23--/-04 4,66 5,97 6,61 6,95 7,13 7,18 7,11 6,91

23--/-05 5,93 7,57 8,39 8,81 9,02 9,08 8,99 8,73

23--/-06 7,28 9,27 10,26 10,76 11,00 11,08 10,97 10,65


23--/-0X 0,35 0,37 0,36 0,37 0,36 0,35

23--/-00 0,67 0,70 0,70 0,70 0,69 0,67

23--/-01 1,18 1,21 1,23 1,21 1,20 1,17

23--/-02 1,63 1,69 1,71 1,70 1,68 1,64

23--/-03 2,93 3,04 3,07 3,06 3,02 2,93

23--/-04 4,28 4,47 4,52 4,51 4,46 4,35

23--/-05 5,45 5,68 5,74 5,74 5,67 5,52

23--/-06 6,66 6,94 7,02 7,01 6,93 6,75


�tsub [°C] 4 10 15 20 25 30 35 40 45 50

Fsub 1,00 1,10 1,20 1,29 1,37 1,46 1,54 1,63 1,70 1,78


36 www.castel.it

Table 6a: Refrigerant R404A/R507 - Capacities in kW for temperature range - 60°C ➝➝ - 25°C

Orificesize

Orificesize


2 4 6 8 10 12 14 16 2 4 6 8 10 12 14 16


23--/-00 0,53 0,64 0,67 0,70 0,70 0,70 0,69 0,67

23--/-01 0,88 1,07 1,18 1,21 1,23 1,21 1,20 1,17

23--/-02 1,18 1,47 1,63 1,69 1,71 1,70 1,68 1,64

23--/-03 2,12 2,65 2,93 3,04 3,07 3,05 3,02 2,93

23--/-04 3,09 3,88 4,28 4,47 4,52 4,51 4,46 4,35

23--/-05 3,94 4,94 5,45 5,68 5,74 5,74 5,67 5,52

23--/-06 4,83 6,06 6,66 6,94 7,02 7,01 6,93 6,75


23--/-00 0,49 0,53 0,54 0,54 0,53 0,52 0,50

23--/-01 0,51 0,57 0,60 0,60 0,60 0,60 0,59

23--/-02 0,91 0,99 1,02 1,02 1,01 0,98 0,95

23--/-03 1,63 1,73 1,84 1,84 1,81 1,78 1,72

23--/-04 2,36 2,60 2,69 2,71 2,68 2,63 2,56

23--/-05 3,02 3,30 3,43 3,45 3,42 3,35 3,26

23--/-06 3,69 4,04 4,20 4,22 4,18 4,12 4,00


23--/-00 0,57 0,67 0,72 0,73 0,74 0,85 0,74 0,71

23--/-01 0,98 1,20 1,31 1,36 1,37 1,37 1,35 1,31

23--/-02 1,31 1,65 1,83 1,91 1,93 1,93 1,90 1,85

23--/-03 2,35 2,97 3,28 3,42 3,47 3,46 3,42 3,32

23--/-04 3,45 4,37 4,82 5,04 5,11 5,12 5,06 4,93

23--/-05 4,40 5,56 6,14 6,40 6,49 6,49 6,42 6,26

23--/-06 5,40 6,30 7,49 7,81 7,93 7,93 7,85 7,64


23--/-00 0,56 0,60 0,61 0,62 0,61 0,60 0,59

23--/-01 0,65 0,72 0,75 0,77 0,77 0,77 0,75

23--/-02 1,17 1,27 1,32 1,33 1,31 1,28 1,24

23--/-03 2,09 2,28 2,36 2,38 2,36 2,31 2,24

23--/-04 3,03 3,34 3,47 3,50 3,48 3,42 3,33

23--/-05 3,87 4,25 4,41 4,45 4,43 4,36 4,24

23--/-06 4,73 5,19 5,39 5,45 5,47 5,33 5,19


23--/-00 0,46 0,48 0,47 0,45 0,45 0,43

23--/-01 0,58 0,60 0,60 0,58 0,56 0,54

23--/-02 0,78 0,80 0,80 0,78 0,75 0,72

23--/-03 1,40 1,44 1,43 1,40 1,36 1,30

23--/-04 2,04 2,11 2,11 2,07 2,03 1,96

23--/-05 2,59 2,69 2,66 2,65 2,59 2,50

23--/-06 3,16 3,28 3,30 3,25 3,18 3,07


�tsub [°C] 4 10 15 20 25 30 35 40 45 50

Fsub 1,00 1,10 1,20 1,29 1,37 1,46 1,54 1,63 1,70 1,78


37

SOLENOID VALVES

38 www.castel.it

– austenitic stainless steel EN ISO 3506 –A2-70 for tightening screws betweenbody and cover;

– chloroprene rubber (CR) for outlet sealgaskets;

– P.T.F.E. for seat gaskets.

The valves can be installed in all sections ofa refrigerating system, in compliance withthe limits and capacities indicated in Tables3 and 6. Tables 1 and 4 show the following functionalcharacteristics of a solenoid valve:– PS;– TS;– Kv factor;– minimum Opening Pressure Differential

(minOPD), that is the minimum pressuredifferential between inlet and outlet atwhich a solenoid valve, pilot operated,can open and stay opened;

– maximum Opening Pressure Differential(MOPD according to ARI STANDARD760: 2001), that is the maximum pressuredifferential between inlet and outlet atwhich a solenoid valve, pilot operated,can open.

Before connecting the valve to the pipe it isadvisable to make sure that the refrigeratingsystem is clean. In fact the valves withP.T.F.E. gaskets are particularly sensitive todirt and debris. Furthermore check that the flow direction inthe pipe corresponds to the arrow stampedon the body of the valve. All valves can be mounted in whateverposition except with the coil pointingdownwards. The brazing of valves with solderconnections should be carried out withcare, using a low melting point fillermaterial. It is not necessary to disassemblethe valves before brazing but it’s importantto avoid direct contact between the torchflame and the valve body, which could bedamaged and compromise the properfunctioning of the valve.Before connecting a valve to the electricalsystem, be sure that the line voltage andfrequency correspond to the values markedon the coil.

INSTALLATION

The solenoid valves, shown in this chapter,are classified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).

The valves series 1020; 1028; 1050; 1058;1059; 1064; 1068; 1070; 1078; 1079; 1090;1098; 1099 are normally closed. NC = when the coil is de-energised theplunger stops the refrigerant flow.The valves series 1150; 1158; 1164; 1168;1170; 1178;1190; 1198 are normally open. NO = when the coil is energised the plungerstops the refrigerant flow.The valves series 1020 and 1028 are directacting, while the valves of all the otherseries are pilot operated, with diaphragm orpiston.The NC valves are supplied either withoutcoil (S type) or with coil (example: A6 typewith coil HM2–220 Vac). The NO valves are supplied only without coil(S type).N.B.: the NO valve visually differs from thecorresponding NC model by means of thered ring installed below the yellow nut thatfastens the coil.

The main parts of the valves are made withthe following materials:– hot forged brass EN 12420 – CW 617N

for body and cover;– copper tube EN 12735-1 – Cu-DHP for

solder connections;– austenitic stainless steel EN 10088-2 –

1.4303 for enclosure where the plungermoves;

– ferritic stainless steel EN 10088-3 –1.4105 for plunger:

CONSTRUCTION

OPERATION

APPLICATIONS

SOLENOID VALVES FOR REFRIGERATING SYSTEMS

www.castel.it 39

– voltage 24 Vac:Coil 9120/RD2 + Connector 9150/R44;

– voltage 220 Vac:Coil 9120/RD6 + Connector 9150/R45.

The NO valves have been designed to workonly with direct current coils. To use them with an alternate current supplyit’s necessary to mate the NO valve with thefollowing components:

SO

LEN

OID

VALV

ES

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

CatalogueNumber SAE

Flare

1/4"

3/8"

–

–

–

–

3/8"

1/2"

–

–

–

–

1/2"

5/8"

–

–

–

–

5/8"

3/4"

–

–

–

–

5/8"

3/4"

–

–

–

–

–

–

–

–

–

–

–

–

–

1/4"

1/4"

3/8"

–

–

–

3/8"

–

–

1/2"

–

–

–

1/2"

5/8"

7/8"

–

–

5/8"

3/4"

7/8"

1.1/8"

–

–

5/8"

3/4"

7/8"

1.1/8"

1.1/8"

1.3/8"

1.1/8"

1.3/8"

1.3/8"

1.5/8"

–

–

–

–

–

–

10

–

–

–

10

12

–

–

–

12

–

16

22

–

–

16

–

22

–

–

–

16

–

22

–

–

35

–

35

35

–

42

2,5

3

2,2

3

7

12,5

16,5

25,5

25

27

0,175

0,23

0,15

0,23

0,80

2,20

2,61

2,20

2,61

3,80

4,80

3,80

4,80

5,70

3,80

4,80

3,80

4,80

5,70

10

10

16

0

0,05

0,07

0,05

0,07

25

(3)

21

25

(3)

19

18

13

19

– 35

+105

(1)

+110

(2)

+105

(1)

+110

(2)

45 Art. 3.3

Ø[in.]

Ø[mm]

ODS

Connections

Seat sizenominal Ø [mm]

Kv Factor[m3/h]

Ope

ratin

g Pr

inci

ples

minOPD

MOPDCoil type

Opening Pressure Differential [bar]

HM4(AC)

21

HM2CM2(AC)

HM3(DC)

min.

TS [°C]

max.

PS[bar]

Risk Categoryaccording

to PED

Dite

ct A

ctin

gD

iap

hrag

m P

ilot

Op

erat

ed

1020/2

1020/3

1028/2

1028/2E

1028/3

1028/M10

1064/3

1064/4

1068/3

1068/M10

1068/M12

1068/4

1070/4

1070/5

1078/M12

1078/4

1078/5

1079/7

1050/5

1050/6

1058/5

1058/6

1058/7

1059/9

1090/5

1090/6

1098/5

1098/6

1098/7

1099/9

1078/9

1079/11

1098/9

1099/11

1078/11

1079/13

1079/M42

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

Pis

ton

Pilo

t O

per

ated

Dia

phr

agm

Pilo

t O

per

ated

Pis

ton

Pilo

t O

per

ated

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

CatalogueNumber Weight [g]

H1 H2 H3 L1 L2 Q

75

82

91

121

106

115

157

172

62,5

69,5

75

93

78

96

127

138

34

40

47

65

50

72

99

110

58

65

125

125

125

125

68

72

111

111

127

127

100

106

127

127

175

190

120

124

175

175

180

216

120

124

175

175

180

216

250

292

235

277

278

50

–

–

45

57

80

68

68

340

355

350

350

365

365

400

415

400

395

420

420

710

755

690

680

775

765

1157

1487

1117

1307

1292

1347

1035

1365

995

1185

1170

1225

2565

2620

2050

2130

2710

2750

2750

Dimensions [mm]

1020/2

1020/3

1028/2

1028/2E

1028/3

1028/M10

1064/3

1064/4

1068/3

1068/M10

1068/M12

1068/4

1070/4

1070/5

1078/M12

1078/4

1078/5

1079/7

1050/5

1050/6

1058/5

1058/6

1058/7

1059/9

1090/5

1090/6

1098/5

1098/6

1098/7

1099/9

1078/9

1079/11

1098/9

1099/11

1078/11

1079/13

1079/M42

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

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L1

L2

H1 H

2

1064/31064/4

H3

L2

L1

H2

H1

1020/21020/3

H3

L1

L2

L2

L1

H1 H

2

H1 H

2

1028/21028/2E1028/31028/M10

1068/31068/41068/M101068/M12

H3

H3

1070/41070/5

H2

H1

L1

L2

Q

1050/51050/61090/51090/6

H3

L1

L2

H2

H1

Q

H3

1078/M121078/41078/51079/7

H3

L1

H1 H

2

Q

L2

1058/51058/61058/71059/9

1098/51098/61098/71099/9

L1

L2

H1 H

2Q

H3

H3

L1

H2

H1

1078/91079/11

L2

Q

H3

L1

H1

H2

Q

L2

1098/91099/111078/111079/131079/M42

41

SO

LEN

OID

VALV

ES

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

www.castel.it42


TABLE 3: Refrigerant Flow Capacity of NC valves

CatalogueNumber

R134a R22 R407C R404A R134a R22 R407C R404A R134a R22 R407C R404A

Liquid Vapour Hot Gas

Resa frigorifera [kW]

1020/2

1020/3

1028/2

1028/2E

1028/3

1028/M10

1064/3

1064/4

1068/3

1068/M10

1068/M12

1068/4

1070/4

1070/5

1078/M12

1078/4

1078/5

1079/7

1050/5

1050/6

1058/5

1058/6

1058/7

1059/9

1090/5

1090/6

1098/5

1098/6

1098/7

1099/9

1078/9

1079/11

1098/9

1099/11

1078/11

1079/13

1079/M42

2,95

3,88

2,53

3,88

13,5

37,1

44,0

37,1

44,0

64,0

80,9

64,0

80,9

96,0

64,0

80,9

64,0

80,9

96,0

168,5

168,5

269,6

3,15

4,14

2,70

4,14

14,4

39,6

47,0

39,6

47,0

68,4

86,4

68,4

86,4

102,6

68,4

86,4

68,4

86,4

102,6

180,0

180,0

288,0

3,28

4,31

2,81

4,31

15,0

41,2

48,9

41,2

48,9

71,2

90,0

71,2

90,0

106,8

71,2

90,0

71,2

90,0

106,8

187,4

187,4

299,8

2,08

2,74

1,79

2,74

9,5

26,2

31,1

26,2

31,1

45,2

57,1

45,2

57,1

67,8

45,2

57,1

45,2

57,1

67,8

119,0

119,0

190,4

R410A

3,33

4,38

2,86

4,38

15,2

41,9

49,7

41,9

49,7

72,4

91,4

7,4

91,4

108,5

72,4

91,4

72,4

91,4

108,5

190,4

190,4

304,6

–

1,73

4,75

5,64

4,75

5,64

8,2

10,4

8,2

10,4

12,3

8,2

10,4

8,2

10,4

12,3

21,6

21,6

34,6

–

2,16

5,94

7,05

5,94

7,05

10,3

13,0

10,3

13,0

15,4

10,3

13,0

10,3

13,0

15,4

27,0

27,0

43,2

–

2,14

5,90

6,99

5,90

6,99

10,2

12,9

10,2

12,9

15,3

10,2

12,9

10,2

12,9

15,3

26,8

26,8

42,9

–

1,81

4,97

5,90

4,97

5,90

8,6

10,8

8,6

10,8

12,9

8,6

10,8

8,6

10,8

12,9

22,6

22,6

36,2

R410A

–

2,88

7,92

9,40

7,92

9,40

13,7

17,3

13,7

17,3

20,5

13,7

17,3

13,7

17,3

20,5

36,0

36,0

57,6

1,49

1,96

1,28

1,96

6,8

18,7

22,2

18,7

22,2

32,3

40,8

32,3

40,8

48,5

32,3

40,8

32,3

40,8

48,5

85,0

85,0

136,0

2,05

2,69

1,76

2,69

9,4

25,7

30,5

25,7

30,5

44,5

56,2

44,5

56,2

66,7

44,5

56,2

44,5

56,2

66,7

117,0

117,0

187,2

2,03

2,67

1,74

2,67

9,3

25,6

30,3

25,6

30,3

44,2

55,8

44,2

55,8

66,2

44,2

55,8

44,2

55,8

66,2

116,2

116,2

185,9

1,75

2,30

1,50

2,30

8,0

22,0

26,1

22,0

26,1

38,0

48,0

38,0

48,0

57,0

38,0

48,0

38,0

48,0

57,0

100,0

100,0

160,0

R410A

2,28

2,99

1,95

2,99

10,4

28,6

33,9

28,6

33,9

49,4

62,4

49,4

62,4

74,1

49,9

62,4

49,4

62,4

74,1

130,0

130,0

208,0

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

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

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

Catalogue NumberSAEFlare

3/8"

–

–

1/2"

5/8"

–

–

–

5/8"

3/4"

–

–

–

5/8"

3/4"

–

–

–

–

–

–

–

3/8"

–

–

–

–

1/2"

5/8"

–

–

5/8"

3/4"

7/8"

–

–

5/8"

3/4"

7/8"

1.1/8"

1.1/8"

1.3/8"

–

–

10

–

–

12

–

16

–

–

16

–

22

–

–

16

–

22

–

–

35

7

12,5

16,5

25,5

25

27

0,80

2,20

2,61

2,20

2,61

3,80

4,80

3,80

4,80

5,70

3,80

4,80

3,80

4,80

5,70

10

10

16

0,05

0,07

0,05

0,07

21

19

– 35

+105

(1)

+110

(2)

+105

(1)

+110

(2)

32 Art. 3.3

Ø[in.]

Ø[mm]

ODS

Connections

Seat sizenominal Ø [mm]

Kv Factor[m3/h]

Operating Principles

MOPD

Opening PressureDifferential [bar]

minOPD

min.

TS [°C]

max.

PS[bar]


to PED

Coil T

ype

HM

3 (D

.C.)

1164/3

1168/3

1168/M10

1170/4

1170/5

1178/M12

1178/4

1178/5

1150/5

1150/6

1158/5

1158/6

1158/7

1190/5

1190/6

1198/5

1198/6

1198/7

1178/9

1198/9

1178/11 R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

R

(1) Temperature peaks of 120 °C are allowed during defrosting.

(2) Temperature peaks of 130 °C are allowed during defrosting.

Available on request.R

Diaphragm Pilot

operated

Piston Pilot

Operated

Diaphragm Pilot

operated

Piston PilotOperated

L1

H2

H1

H3

L2

Q

1178/9

H2

L1

H1

H3

L2

Q

1170/41170/5

L1

H1 H

2

H3

L2

1164/3

H1

H2

L1

H3

L2

Q

1178/111198/9

H1 H

2

L1

H3

L2

Q

1178/M121178/41178/5

L1

H1 H

2

1168/31168/M10

H3

L2

H1

L2

L1

H2

H3Q

1150/51150/61190/51190/6

L

L2

H1 H

2

H3Q

1158/51158/61158/71198/51198/61198/7

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

45

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


H1 H2 H3 L1 L2 Q

87

96

126

111

120

162

177

74,5

80

98

83

101

132

143

40

47

70

50

72

99

110

68

111

111

100

106

127

127

175

120

124

175

175

180

120

124

175

175

180

250

235

278

64

–

45

57

80

68

68

705

705

700

1015

1060

995

985

1080

1462

1792

1422

1612

1597

1340

1670

1300

1490

1475

2870

2355

3015

Dimensions [mm]

1164/3

1168/3

1168/M10

1170/4

1170/5

1178/M12

1178/4

1178/5

1150/5

1150/6

1158/5

1158/6

1158/7

1190/5

1190/6

1198/5

1198/6

1198/7

1178/9

1198/9

1178/11

TABLE 6: Refrigerant Flow Capacity of NO valves

CatalogueNumber

R134a R22 R407C R404A R134a R22 R407C R404A R134a R22 R407C R404A


Refrigerant Flow Capacity [kW]

1164/3

1168/3

1168/M10

1170/4

1170/5

1178/M12

1178/4

1178/5

1150/5

1150/6

1158/5

1158/6

1158/7

1190/5

1190/6

1198/5

1198/6

1198/7

1178/9

1198/9

1178/11

13,5

37,1

44,0

37,1

44,0

64,0

80,9

64,0

80,9

96,0

64,0

80,9

64,0

80,9

96,0

168,5

168,5

269,6

14,4

39,6

47,0

39,6

47,0

68,4

86,4

68,4

86,4

102,6

68,4

86,4

68,4

86,4

102,6

180,0

180,0

288,0

15,0

41,2

48,9

41,2

48,9

71,2

90,0

71,2

90,0

106,8

71,2

90,0

71,2

90,0

106,8

187,4

187,4

299,8

9,5

26,2

31,1

26,2

31,1

45,2

57,1

45,2

57,1

67,8

45,2

57,1

45,2

57,1

67,8

119,0

119,0

190,4

1,73

4,75

5,64

4,75

5,64

8,2

10,4

8,2

10,4

12,3

8,2

10,4

8,2

10,4

12,3

21,6

21,6

34,6

2,16

5,94

7,05

5,94

7,05

10,3

13,0

10,3

13,0

15,4

10,3

13,0

10,3

13,0

15,4

27,0

27,0

43,2

2,14

5,90

6,99

5,90

6,99

10,2

12,9

10,2

12,9

15,3

10,2

12,9

10,2

12,9

15,3

26,8

26,8

42,9

1,81

4,97

5,90

4,97

5,90

8,6

10,8

8,6

10,8

12,9

8,6

10,8

8,6

10,8

12,9

22,6

22,6

36,2

6,8

18,7

22,2

18,7

22,2

32,3

40,8

32,3

40,8

48,5

32,3

40,8

32,3

40,8

48,5

85,0

85,0

136,0

9,4

25,7

30,5

25,7

30,5

44,5

56,2

44,5

56,2

66,7

44,5

56,2

44,5

56,2

66,7

117,0

117,0

187,2

9,3

25,6

30,3

25,6

30,3

44,2

55,8

44,2

55,8

66,2

44,2

55,8

44,2

55,8

66,2

116,2

116,2

185,9

8,0

22,0

26,1

22,0

26,1

38,0

48,0

38,0

48,0

57,0

38,0

48,0

38,0

48,0

57,0

100,0

100,0

160,0



46

(HM2, HM3) + connector, is IP65 accordingto EN 60529. Coils HM4 must be used withconnector type 9155/R01; protection degreeguaranteed by this other system, coil HM4 +connector 9155/R01, is IP65/IP68 accordingto EN 60529. Coils HM4 can be used withconnectors series 9150 and 9900 too;protection degree guaranteed by thissystem is IP65.Either the terminals of coils series HM2 andHM3 or the ones of coils series HM4 consistof two Faston line connections plus oneFaston earthing connection. Coil type CM2has a pre-assembled cable (length 1 meter).The coils are designed for continuous use.The solid construction of these coils issuitable for heavy-duty applications inrefrigerant systems. The maximum ambienttemperature for all coils is 50 °C.

HM2 (9100) and CM2 coils, 220/230V-50/60Hz and 240V-50/60Hz, are approvedby the German registration body VDE. All HM2 coils series 9105 are approved byUnderwriters Laboratories Inc of the UnitedStates. Moreover either coils types HM2, CM2 andHM4 (110 VAC, 220/230 VAC and 240 VAC)or coils type HM3 (220/230 VAC) aremanufactured according to Low VoltageDirectives EC 73/23, EC 93/68 and to EMC Directives EC 89/336, EC 92/31, EC 93/68.

ELECTRIC TYPE APPROVAL

For the normally closed solenoid valves,previously shown in this Handbook, Castelputs the following types of coils at disposalof its own customers:– coils series HM2, only for A.C.

(catalogue numbers 9100 - 9105).– coils series CM2, only for A.C.

(catalogue number 9110);– coils series HM3,either for A.C. or for D.C.

(catalogue number 9120).– coils series HM4, only for A.C.

(catalogue number 9160).

For the normally open solenoid valves,always shown in this Handbook, thecustomer’s selection must compulsorilyapply to the coils series HM3 – D.C.For applications of the NO solenoid valveswith a voltage supply of 220 VAC, Castelhas designed a specific coil at 220 V RAC(code 9120/RD6) that must be used solelywith the 220 VAC connector/rectifier circuit(code 9150/R45).For applications of the same NO valves witha voltage supply of 24 VAC, Castel suggeststo the user the 24 VDC coil (code 9120/RD2)with the 24 VAC connector/rectifier circuit(code 9150/R44).

Coils HM2 (9100), CM2, HM3 and HM4 areclass F in compliance with IEC 85 standardand their construction is in compliance withEN 60730-1 and EN 60730-2-8 standards.The windings are made with copper wire,insulation class H 180 °C, in compliancewith IEC 85 standard. The outer casing isprovided with dielectric and waterproofresins that assure a reinforced insulationmaking the coils suitable for all assemblies.Coils HM2 (9105) are class F, with ULapproved EIS (Electrical Insulation System),and their construction is in compliance withUL 429 Standards.Protection against electric contacts is class I.Therefore, for safety purposes, coils mustbe effectively connected to an earthingsystem. Rubber gaskets on the upper andlower ends of coil ensure moistureprotection of winding. Coils HM2 and HM3may be joined to all connectors producedby Castel except type 9155/R01; protectiondegree guaranteed by this system, coil

CONSTRUCTION

APPLICATION

COILS

www.castel.it

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TABLE 1: General Characteristics of coils

Coil Type

Degreeof

protectionConnectionsFrequecy

[Hz]Voltage

tollerance [%]Voltage

[V]CatalogueNumber

HM2

HM2

� Recognized

File number E243604

CM2

HM3

HM4

9100/RA2

9100/RA4

9100/RA6

9100/RA7

9100/RA8

9105/RA2

9105/RA4

9105/RA6

9105/RA7

9110/RA2

9110/RA4

9110/RA6

9110/RA7

9120/RA6

9120/RD1

9120/RD2

9120/RD4

9120/RD6

9160/RA2

9160/RA4

9160/RA6

9160/RA7

24 A.C.

110 A.C.

220/230 A.C.

240 A.C.

380 A.C.

24 A.C.

110/120 A.C.

220/230 A.C.

240 A.C.

24 A.C.

110 A.C.

220/230 A.C.

240 A.C.

220/230 A.C.

12 D.C.

24 D.C.

48 D.C.

220 RAC

24 A.C.

110 A.C.

220/230 A.C.

240 A.C.

+10 / -10

+6 / -10

+10 / -10

+10 / -10

+6 / -10

+10 / -10

+10 / -10

+6 / -10

+10 / -10

+6 / -10

+10 / -5

+10 / -10

+6 / -10

+10 / -10

50 / 60

60

50 / 60

50 / 60

–

50 / 60

Junction box

DIN 43650

Junction box

DIN 43650

Three wire

cable

Junction box

DIN 43650

Junction boxDIN 43650

or Connector

9155/R01 (1)

IP65

EN 60529

(with

junction box)

IP65 EN 60529

(with junction

box)

IP65

EN 60529

IP65

EN 60529

(with

junction box)

IP65 EN 60529(with junction box)

IP65/IP68EN 60529

(with connector)

L1

L2HH

L2

L1HM2 CM2

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

48 www.castel.it

TABLE 2: Coils Consumptions

CatalogueNumber

CoilType

50 [Hz]

Consumptions at 20 °C [mA]Dimensions

[mm]Weight

[g]

60 [Hz] D.C. 50 [Hz] 60 [Hz] D.C.

Start Working

9100/RA2

9100/RA4

9100/RA6

9100/RA7

9100/RA8

9105/RA2

9105/RA4

9105/RA6

9105/RA7

9110/RA2

9110/RA4

9110/RA6

9110/RA7

9120/RA6

9120/RD1

9120/RD2

9120/RD4

9120/RD6

9160/RA2

9160/RA4

9160/RA6

9160/RA7

HM2

HM2

�Recognized

CM2

HM3

HM4

920

230

120

100

58

–

920

230

120

100

190

–

1490

330

162

147

825

205

105

87

51

825

205

105

87

825

205

105

87

160

–

1320

300

142

130

_

–

–

–

1720

900

460

93

–

527

128

68

54

32

–

527

128

68

54

110

–

700

156

76

70

420

114

58

43

23

420

114

58

43

420

114

58

43

80

–

530

118

57

53

_

–

–

–

1720

900

460

93

–

L1 L2 H

57,5

57,5

66,5

82

63

34

34

34

61

41

35

35

35

35

35

165

165

230

470

220

L2

L1

H

L2H

L1HM4HM3

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This junction box, according to assemblyrequirements, allows choosing the sideposition of outer casing compared to innerterminal block; but it is not possible to pointthe cable upwards. The gland nut of casing issuitable to receive cables with an externaldiameter of 6 ÷ 9 mm and is provided with aself-locking device. Cables sized 3 x 0,75 mm2

are to be preferred for this junction box too.The junction box type 9155/R01 offers aprotection degree IP65/IP68 against dust andwater, according to EN 60529, when correctlyinstalled with the proper gaskets, which aresupplied as standard.The junction box 9150/R44 and 9150/R45 areequipped with a full-wave bridge rectifier plusVDR for protection. The VDR device, Voltagee-Dependent-Resistor, is a special type ofresistor, placed in parallel to the coil; itspurpose is to protect the diodes and the coilfrom any excessive voltage generated withinthe ac supply circuit.

The junction boxes 9150, DIN 43650standardized, represent an effective systemfor the connection of the coil to the supplycircuit, thus ensuring safety also in thepresence of moisture.These junction boxes, according to assemblyrequirements, allow choosing the position ofouter casing compared to inner terminal block.The clamping screw of casing may be PG9 orPG11, which are respectively suitable forcables with an external diameter of 6 ÷ 8 or 8 ÷ 10 mm. Cables sized 3 x 0,75 mm2 are tobe preferred.The junction box type 9900 is available withcabled core of different length. In this case, it is not possible to change the position ofcasing compared to terminal block.Both the two types offer a protection degreeIP65 against dust and water, according to EN 60529, when correctly installed with theproper gaskets, which are supplied asstandard.Castel has developed a specific junction box,type 9155/R01, suitable for use on thoserefrigerating systems working in heavy dutyenvironments, for example:– exposition to the atmospheric conditions;– rooms with high moisture degree;– cyclic condensing / evaporating on the

valve;– cyclic icing / defrosting on the valve.

CONNECTORS

TABLE 3: General Characteristics of connectors

CatalogueNumber

Nominal

Supply Voltage[V]

Maximum

PgCable length

[m]

Cable thickness

[mm2]Standard Degree

of protectionClass

of insulation

9150/R01

9150/R02

9150/R44

9150/R45

9155/R01

9900/X66

9900/X84

9900/X73

9900/X55

9900/X54

R

–

24 A.C.

220 A.C.

–

–

–

30 A.C.

250 A.C.

–

–

9

11

–

–

–

1

1,5

2

3

5

–

3 x 0,75

DIN

43650

–

DIN

43650

IP65

EN 60529

IP65/IP68

EN 60529

IP65

EN 60529

Group C

VDE 0110-1

/ 89

Available on request.R

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The solenoid valves, shown in this chapter,are classified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for the applicationsspecified in Table 1 where the different fluidsare indicated with the following symbols,according to an already established code:– W = Water;– L = Air;– B = Secondary coolants (solutions of

glycol and water);– O = Light oils (gas oil).In short these valves may be used:– with fluids in the gaseous state proper to

the Group II (as defined in Article 9,Section 2.2 of Directive 97/23/EC andreferred to in Directive 67/548/EEC);

– with fluids in the liquid state proper to theGroup I (as defined in Article 9, Section2.1 of Directive 97/23/EC and referred toin Directive 67/548/EEC).

APPLICATIONS

SOLENOID VALVES FOR DIFFERENT FLUIDS


50

Castel supplies to its customers thepermanent magnet code 9900/X91 for thenormally closed solenoid valves, shown in thischapter.This product can be used during brazing ofthe valve copper connections to the plantpipes; slipping it on the armature, instead ofthe coil, it allows the protective gas (nitrogen)flowing and avoids any damage to the plungergasket and to the diaphragm.

The main parts of the permanent magnet code9900/X91 are made with the followingmaterials:– three rings of anisotropic ferrite;– anodized aluminum for the body.

CONSTRUCTION

APPLICATION

PERMANET MAGNET

NC SOLENOID VALVE

PERMANENT MAGNET

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Table 1 shows the following functionalcharacteristics of a solenoid valve:– PS;– TS;– Kv factor;– minimum Opening Pressure Differential

(minOPD), that is the minimum pressuredifferential between inlet and outlet atwhich a solenoid valve, pilot operated,can open and stay opened;

– maximum Opening Pressure Differential(MOPD according to ARI STANDARD760: 2001), that is the maximum pressuredifferential between inlet and outlet atwhich a solenoid valve, pilot operated,can open.

Before connecting the valve it is advisableto make sure that the piping are clean andthat the flow direction in the pipecorresponds to the arrow stamped on thebody of the valve. All valves can be mounted in whateverposition except with the coil pointingdownwards. Before connecting a valve to the electricalsystem, be sure that the line voltage andfrequency correspond to the values markedon the coil.

INSTALLATION

All the valves for different fluids are normallyclosed. NC = when the coil is de-energisedthe plunger stops the refrigerant flow.The valves series 1512 and 1522 are directacting, while the valves series 1132 and1142 are pilot operated with diaphragm.


for body and cover;– austenitic stainless steel EN 10088-2 –

1.4303 for enclosure where the plungermoves;

– ferritic stainless steel EN 10088-3 –1.4105 for plunger;

– austenitic stainless steel EN ISO 3506 –A2-70 for tightening screws betweenbody and cover;

– fluorocarbon rubber (FPM) for outlet sealgaskets;

– fluorocarbon rubber (FPM) for seatgaskets;

– fluorocarbon rubber (FPM) fordiaphragms. Nitril rubber (NBR) for thevalves series 1142.

CONSTRUCTION

OPERATION

TABELLA 1: General Characteristics

CatalogueNumber

1,5

4,5

12,5

20

38

G 1/8"

G 1/4"

G 3/8"

G 1/2"

G 3/8"

G 1/2"

G 3/4"

G 1"

G 1.1/4"

G 1.1/2"

W.L.O.

W.O.

W.L.O.B.

0,070

0,40

2,10

2,20

5,50

6,00

19,00

21,00

0

0,1

0,15

0,3

30

4

17

12

11

-15

+105

+90

30

15

Art. 3.3

FPTConnectionsMain Use

Seat Sizenominal Ø [mm]

Kv Factor[m3/h]

Ope

ratin

g Pr

inci

ples

MOPD

Opening Pressure Differential

[bar]

minOPD

min.

TS [°C]

max.

PS[bar]


to PED

Coil T

ype

HM

2 (A

.C.)

- C

M2

(A.C

.) -

HM

3 (A

.C.;

D.C

.) -

HM

4 (A

.C.)

Dire

ct

Act

ing

Dia

phr

agm

Pilo

tO

per

ated

1512/01

1522/02

1522/03

1522/04

1132/03

1132/04

1132/06

1132/08

1142/010

1142/012

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The following ratio applies:

�pQ = Kv ��——

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

Table 2 provides the values of air capacityunder the following conditions:

• temperature at valve inlet = 20 °C;• discharge pressure (absolute) = 1 bar;• Kv of the valve under consideration = 1 m3/h.

The pressures upstream the valve specifiedin the table are absolute values.

Select the valve suitable for use withapproximately 200 m3/h of air, assuming anabsolute pressure of 8 bars at valve inlet ( = 7 bars of relative pressure + 1 bar) andan acceptable pressure drop across thevalve of 1,5 bars. In the column of pressures upstream thevalve, the value 8 is shown; where thiscolumn intersects the horizontal columnrelating to the pressure drop of 1,5, thevalue of 87 m3/h is shown. This is thecapacity value of a hypothetical valve withKv = 1 working under the above mentionedconditions.

200 / 87 = 2,29

This is the Kv value required in the caseunder consideration. In Table 1, select the valve with the Kv valuenearest to 2,29, rounding off the value andsubsequently checking that all thecharacteristics of the selected valve (max. opening pressure differential,temperature, connections, etc.) are suitable.

EXAMPLE

AIR CAPACITY

LIQUIDS CAPACITY

When the viscosity of the liquid is expressedas dynamic viscosity, i.e. cP, where:

1cP = 10-3 N sec/m2

the corresponding value of cinematicviscosity in cSt is obtained by the followingrelation:

�� = ——�

where:� = cinematic viscosity [cSt];� = dynamic viscosity [cP];� = volumic mass of the fluid at the

considered temperature [kg/dm3].

Moreover, the fluid viscosity may remarkablyvary according to changes in temperature.Therefore, if the temperature of the fluiddoes not ensure viscosity values compatiblewith the correct operation of the valve, thevalve may not open.

Viscosity cSt Reducing Factor

12

12 ÷ 30

30 ÷ 45

1

0,8

0,7

The values of maximum differential pressurespecified in Table 1 are suitable for fluids withmaximum cinematic viscosity of 12 cSt where:

1cSt = 10-6 m2/sec.

If the cinematic viscosity of the fluid underconsideration is more than 12 cSt it isnecessary to multiply the value of themaximum differential pressure by thefollowing reducing factors:

VISCOSITY

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TABLE 2 - Air Capacity (Kv = 1)

Pressuredrop[bar]

18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1,5 1,3 1,2 1,1 1,05 1,03 1,015

Capacity [m3/h] (1)

INLET PRESSURE (absolute) [bar]

0,0025

0,005

0,010

0,015

0,025

0,05

0,10

0,15

0,25

0,5 82,0 80,0 77,0 74,0 72,0 69,5 66,6 63,7 60,6 57,3 54,0

1 115,0 111,0 108,0 104,0 100,0 96,0 92,0 88,0 83,0 78,6 73,5

1,5 138,0 134,0 130,0 125,0 120,0 115,5 110,3 105,0 99,3 93,0 87,0

2 157,0 152,0 147,0 142,0 136,0 130,0 124,0 118,0 111,0 96,0 96,0

2,5 173,0 167,5 161,5 155,5 149,0 142,5 135,5 128,0 120,4 112,0 103,0

3 186,0 180,0 174,0 167,0 160,0 152,0 144,5 136,0 127,0 118,0 108,0

3,5 198,0 191,0 184,0 176,5 168,6 160,3 151,7 142,5 132,6 122,0 110,0

4 208,0 200,0 193,0 184,0 176,0 167,0 157,0 147,0 136,0 124,0 111,0

4,5 216,0 208,6 200,0 191,0 182,0 172,0 161,5 150,4 138,0 125,0

5 224,0 215,0 206,0 195,5 186,0 176,0 164,5 152,3 139,0

5,5 230,0 221,0 211,0 201,0 190,0 178,6 166,3 152,9

6 236,0 226,0 215,0 204,0 192,7 180,0 166,8

6,5 240,0 230,0 218,0 206,7 194,0 180,7

7 244,0 233,0 220,0 208,0 194,7

7,5 246,0 234,0 222,0 208,5

8 249,0 236,0 222,5

8,5 250,0 236,5

9 250,5

1,46 1,42 1,40 1,35

2,2 2,10 2,00 1,95 1,90

3,0 3,0 3,00 2,85 2,80 2,75

4,2 3,9 3,7 3,55 3,45 3,40 3,35

6,2 5,4 5,0 4,8 4,56 4,45 4,40

10,7 8,7 7,5 6,9 6,6 6,40 6,20

17,4 15,0 12,2 10,2 9,6 9,2 8,80

23,8 21,2 18,3 14,6 12,5 11,5 11,0

33,4 30,4 27,0 23,2 18,5 15,6 13,9

50,0 46,0 41,7 36,8 31,0 24,3 19,6

68,0 62,0 55,6 48,0 39,3 27,8

80,0 72,0 63,7 53,8 41,7

88,0 78,0 68,0 55,6

89,5 82,0 69,5

96,0 83,0

97,0

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

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

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


H1 H2 H3 L1 L2 Q

86

101

136

69

71

70

81

103

57

59

47

52

82

34

36

75

88

168

44

51

50

104

50

45

57

104

–

–

670

635

960

670

4100

4000

310

385

370

355

Dimensions [mm]

1132/03

1132/04

1132/06

1132/08

1142/010

1142/012

1512/01

1522/02

1522/03

1522/04


H2

H1

L1

L2

H3

H2

L1

H1

H3

L2

1132/031132/04

Q

L1

H2

H1

Q

H3

L2

1142/0101142/012

1132/061132/08

H2

H3H

1

L1

L2

H2

H3H

1

L1

L2

1512/011522/031522/04

1522/02

Q

55

SAFETY DEVICES

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with the atmosphere. For this reason, duringrelief, a gas leak occurs through this orifice.Utilized material: EN 12420-CW617N brass.

Disc: obtained through bar machining andequipped with gasket, it ensures therequired sealing degree on the valve seat.The gasket is made in P.T.F.E.(Polytetrafluorethylene), a material that,during valve estimated service life,maintains a good strength and does notcause the disc to stick on the seat. The discis properly guided in the body and the guideaction can never fail; there are no glands orretaining rings that hamper the movementthereof.Utilized material: EN 12164-CW614N brass.

Spring: it opposes the pressure and thefluid dynamic actions and always ensuresvalve re-closing after pressure relief. Thespring coils, when the disc has reached thelift corresponding to the state of relief at fullflow rate, are spaced apart by at least halfthe wire diameter and, in any case, by notless than 2 mm. The disc is equipped with amechanic lock and when it attains it, thespring set does not exceed 85% of the totalset.Utilized material: DIN 17223-1 steel for springs.

Setting system: hexagonal head, threadedring nut to be screwed inside the body topby compressing the spring below. Onsetting completion, the position attained bythe ring nut is maintained unchanged laying,in the threaded coupling, a bonding agentwith high mechanic strength and lowviscosity features to make penetrationthereof easier. The setting system isprotected against subsequent unauthorizedinterventions by means of a cap nut that isscrewed outside the body and is sealedwith lead to it.

Valves series 3030 are safety devicesaccording to the definition given in Article 1,Point 2.1.3, 2nd dash of 97/23/EC Directiveand are the subject of Article 3, Point 1.4 ofaforesaid Directive.The valves above mentioned are standardtype, unbalanced, direct-loaded safetyvalves. Valve opening is produced by thethrust the fluid under pressure exerts on thedisc, when said thrust exceeds, undersetting conditions, the opposing force of thespring acting on the disc.

Valves are identified by means of:– a model number formed of an

alphanumerical coding that includes:– in the first part the family identification

(e.g. 3030/44C);– in the second part the setting pressure,

expressed in bars, multiplied by 10(e.g. 140);

– a progressive serial number.

Body: squared, obtained through dieforging and subsequent machining. Ithouses the following elements:– the nozzle with flat sealing seat;– the disc guide;– the setting spring holder;– the threaded seat of the setting adjusting

ring nut.

In the body, above the disc guide, a smallpressure relief hole is provided throughwhich the spring holder is put into contact

CONSTRUCTION

GENERAL DESCRIPTION

SAFETY VALVES 3030

TABLE 1: General Characteristics of valves 3030

1/2" NPT

3/4" G

12

113

4,1

0,90

3/4" NPT

3/4" G

12

113

4,1

0,90

1" NPT

1.1/4" G

19,5

298

6,8

0,83

Catalogue Number 3030/44C 3030/66C 3030/88C

Connections

Flow Diameter [mm]

Flow Section [mm2]

Lift [mm]

Discharge Coefficient “Kd”

PS [bar]

TS [°C]

Set Pressure Range [bar]

Overpressure

Blowdown

Risk Category according to PED

55

- 50 / + 150

8 / 50

5% of set pressure

15% of set pressure

IV

Inlet male

Outlet male

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H3

H2

H1

L

� D

Ch

0062

3030

reasonably likely to be exceeded, shall befitted with suitable protection devices, forinstance safety devices such as safetyvalves. Such devices shall prevent pressurefrom permanently exceeding the maxallowable pressure PS of the equipmentthey protect. In any case, a short pressurepeak limited to 10% of admissiblemaximum pressure is permitted.As to the selection and sizing of the suitableprotection device, users shall refer to thespecific sector or product standards.EN 378-2: 2000 Standard “Refrigeratingsystems and heat pumps – safety andenvironmental requirements – Part 2:Design, construction, testing, marking anddocumentation”, harmonized with 97/23/ECDirective, provides a general outline of theprotection devices to be adopted inrefrigerating systems and their features (par7.4). It also indicates the criteria for theselection of the device suitable to the typeand sizes of the system component to beprotected (par. 7.4).EN 13136: 2001 Standard “Refrigeratingsystems and heat pumps – Pressure reliefdevices and their associated piping –Methods for calculation” highlights thepossible causes of overpressure in a systemand makes available to users theinstruments for pressure relief device sizing,among which the safety valves.

Use: protection against possibleoverpressures of the apparatuses listedbelow, with regard to the operatingconditions for which they have beendesigned:– refrigerating system and heat pump

components, for instance: condensers,liquid receivers, evaporators, liquidaccumulators, positive displacementcompressor discharge, heat exchangers,oil separators, piping(reference: EN 378-2: 2000);

– simple pressure vessels(reference: 87/404/ EEC Directive).

Fluids: the valves can be used with:– refrigerant fluids, in the physical state of

gas or vapour, belonging to Group IIaccording to the definitions of 97/23/ECDirective, Article 9, Point 2.2 (withreference to 67/548/EEC Directive of June27th, 1967);

– air and nitrogen (reference: 87/404/EECDirective).

In conformity with the provisions of Article15 of 97/23/EC Directive, the EC markingand the identification number of the notifiedbody involved in the production controlphase are reported on the valve body.Still on the body, the following information isindicated:– manufacturer’s mark, address and

manufacture country;– valve model;– flow section;– Kd discharge coefficient;– indication of flow direction;– max allowable pressure;– allowable temperature range;– set pressure;– production date;– serial number.

97/23/EC Directive requires that pressureequipment, in which permissible limits are

VALVE SELECTION

MARKING

SCOPE

TABLE 2: Dimensions and Weights of valves 3030


Ø D L Ch H1 H2 H3

38

38

50

38

38

56

28

28

40

44

44

58

115

115

158

159

159

216

780

780

1960

Dimensions [mm]

3030/44C

3030/66C

3030/88C

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for this calculation the value of k shall beas measured at 25 °C. (Section 7.2.3,Standard EN 13136: 2001).Values of k and calculated values of C forsome refrigerants are given in table A.1 ofthe aforesaid standard.

Following we show the values of k and C forthe more useful refrigerants.

SIZING OF SAFETY VALVES DESIGNED TO DISCHARGE GAS OR VAPOUR ATCRITICAL FLOW (Ref. EN 13136: 2001)

Critical flow occurs when the backpressurepb (the pressure existing immediately at theoutlet of a safety valve) is below or equal tothe critical pressure:

[bar abs]

with:– po = actual relieving pressure, upstream

the safety valve; it’s equal to the setpressure plus overpressure. That is apressure increase over set pressure atwhich the disc has its total lift. [bar abs];

– k = isentropic exponent of gas or vapour,based on the actual flowing conditions atthe safety valve inlet.

If k is unknown or anyway difficult toestablish it’s possible to suppose:

[bar abs]

A safety valve, which discharges toatmosphere, works in critical flow.

The safety valves designed to discharge gasor vapour at critical flow must be sized asfollow:

[mm2]

with:– Ac = minimum flow area of safety valve

[mm2];– Qmd = minimum required discharge

capacity, of refrigerant, of safety valve[kg/h];

– Kd = certified coefficient of discharge;– po = actual relieving pressure, upstream

the safety valve, see definition above [bar abs];

– vo = specific volume of gas or vapour atrelieving conditions po e To meaning withTo fluid temperature at valve inlet, settledby the user or by the designer [m3/kg];

– C = function of isentropic coefficient kcalculated from:

C kk

k

k= × ×

+

+( )−( )

3 9482

1

1

1,

AQ

C Kvpc

md

d

o

o

= ×× ×

×3 4690 9

,,

p pcritical o= ×0 5,

p pkb o

kk

≤+

−⎛⎝⎜

⎞⎠⎟2

1

1

Calculation of minimum required dischargecapacity of safety valve is closely linked tothe type of system where the valve isinstalled, with the causes that may arousethe opening of safety valve, i.e.:– external heat sources. The minimum

required discharge capacity shall bedetermined by the following:

[kg/h]

with:– � = density of heat flow rate, it’s

assumed to be 10 [kW/m2];– Asurf = external surface area of the

vessel [m2];– hvap = heat of vaporization of liquid at

po [kJ/kg];

– internal heat sources. The minimumrequired discharge capacity shall bedetermined by the following:

[kg/h]

withQh = rate of heat production [kW].

– Excessive pressure cased bycompressors. The minimum requireddischarge capacity shall be determinedby the following:

[kg/h]Q V nmd v= × × × ×60 10ρ η

QQ

hmdh

vap

=×3600

QA

hmdsurf

vap

=× ×3600 ϕ

RefrigerantIsentropiccoefficient

k

Functionof Isentropiccoefficient

C

R22

R134a

R404A

R407C

R410A

R507

1,17

1,12

1,12

1,14

1,17

1,10

2,54

2,50

2,50

2,51

2,54

2,48

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– ηv = volumetric efficiency estimated atsuction pressure and dischargepressure equivalent to the safety valvesetting.

with:– V = theoretical displacement of

compressor [m3]– n = rotational frequency of compressor

[min –1]– ρ10 = vapour density at refrigerant

saturation pressure / dew point at 10 °C [kg/m3]

Working conditions of compressorcorresponding to the relieving of safetyvalve:Condensing temperature:

+ 64 °C (27,25 bar abs)Evaporating temperature:

+ 10 °C (6,33 bar abs)

These conditions, settled in any case by thedesigner, are considered the mostunfavorable for the safety valve inconsequence of functional defects as:– move mistake;– non-working of automatic safety devices,

set to operate before safety valve.

It shall be excluded:– closeness the refrigerating system, the

presence of flammable substances in solarge quantities to be able to feed a fire.;

– inside the vessel, the presence of a heartsource.

Calculation of minimum dischargecapacityPrudentially leaving the vapour overheatingat the outlet of the liquid cooler out ofaccount, the volumetric efficiency ofcompressor is:

and so the minimum required dischargecapacity:

= 60x0,00224x1450x26,34x0,83=4260 [kg/h]

with ρ10 = 26,34 [kg/m3], vapour density ofR407C at saturation pressure / dew point at10 °C.

Q V nmd v= × × × × =60 10ρ η

ηvdisch e

suction

p

p= − = − =1 0 04 1 0 04

27 256 33

0 83, ,,

,,arg

System descriptionCompact refrigerating system designed tomake refrigerated water and consisting of:– open type reciprocating compressor;– water-cooled, shell-and-tube horizontally

condenser with lower section of shellused as receiver;

– shell-and-tube horizontally liquid coolerfed with a thermostatic valve;

– refrigerant fluid R407C.

Compressor data– Bore 82,5 mm– Stroke 69,8 mm– Cylinder number 6– Rotational frequency 1450 rpm– Clearance 4%The theoretical displacement of compressoris:

[m3]

Maximum allowable pressure of thecondenser, refrigerant side: PS = 25 bar.

Set pressure of the safety valve installed onthe upper shell section of condenser: pset = 25 bar

Actual relieving pressure of safety valve,choosing one valve type 3030 with anoverpressure of 5%:

[bar abs]p pset0 15

1001 27 25= × +⎛

⎝⎞⎠

+ = ,

V = × × × =π4

0 0825 0 0698 6 0 002242, , ,

EXAMPLE OF CALCULATION OF MINIMUM REQUIRED DISCHARGE CAPACITY Qmd ANDSIZING OF THE SAFETY VALVE FOR THE HIGH PRESSURE SIDE OF A REFRIGERATINGSYSTEM

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Sizing of minimum flow area of the safetyvalve

[mm2]

with:– C = 2,51, corresponding to isentropic

exponent k for R407C equal to 1,14,according to table A1 of standard EN13136:2001;

– Kd = 0,83, certified coefficient ofdischarge for safety valve 3030/88;

– vo = 0,0104 [m3/kg], specific volume ofoverheating vapour upstream the safetyvalve during relieving.This value is referred to the followingoperating conditions, upstream the safetyvalve:– pressure po = 27,25 [bar abs];– temperature To = 100 [°C]

(precautionary temperature, settled inany case by the designer).

Conclusion: the selected safety valve is themodel 3030/88 with the followingcharacteristics:– certified coefficient of discharge, Kd = 0,83;– flow section, Ac = 298 [mm2];– set pressure, pset = 25 bar.

In case of single-screw compressor withinjection of pressurized oil, the theoreticaldisplacement is:

[m3]

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

VD

Lc =×

×π 2

4

= ×× ×

× =3 4694260

2 51 0 9 0 830 010427 25

154,, , ,

,,

AQ

C Kvpc

md

d

o

o

= ×× ×

× =3 4690 9

,,

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with:– A = flow area of safety valve [mm2];– Ain = inside area of inlet tube to valve

[mm2];– Kdr = Kd x 0,9, derated coefficient of

discharge;– C = function of isentropic coefficient k;– ξ = addition of pressure loss coefficients

ξn of any component and piping;The coefficients ξn are relevant to:– pipe elements loss, as connections

and bends;– valves loss;– loss along the pipe and are listed in EN 13136:2001 standard,Table A.4.

Example: assume to install, on thecondenser of the previous example, a safetyvalve type 3030/88, set to 25 bar, using asteel union with the followingcharacteristics:– din = 28 [mm], inside diameter;– Ain = 616 [mm2], inside area;– L = 60 [mm], length;– flush connection to the shell of

condenser, with a broken edge.From table A.4 it’s possible to have thesedata:– ξ1 (inlet) = 0,25– ξ2 (length) = λ x L/ din = 0,02 x 60/28 = 0,043

with λ = 0,02 for steel tube– ξT = ξ1 + ξ2 = 0,25 + 0,043 = 0,293Between safety valve and union it’s installeda shut-off valve type 3033/88 (see page 46).The main characteristics of this valve are:– dR = 20 [mm], inside diameter;– AR = 314 [mm2], inside area;– kv = 20 [m3/h], kv factor.Pressure loss coefficient ξR of shut-off valveis given by:

The total pressure loss coefficient is: ξT + ξR

= 0,933

We remember the main characteristics ofsafety valve 3030/88 and of refrigerant fluidR407C:– A = 298 [mm2]– Kdr = 0,83 x 0,9 =0,747– C = 2,51

Pressure loss in the upstream line is:

∆pp

in

o

= × × ×⎡⎣⎢

⎤⎦⎥

× =0 032298616

2 51 0 747 0 933 0 02452

, , , , ,

ζR = × ⎡⎣⎢

⎤⎦⎥

× =−2 59231420

10 0 642

3, ,

VALVE INSTALLATIONAs far as the installation of safety reliefvalves is concerned, the fundamental pointslisted below shall be taken into account:• safety valves shall be installed near an

area of the system where vapours orgases are present and there is no fluidturbulence; the position shall be asupright as possible, with the inletconnector turned downwards;

• vessels, joined together with pipingrightly selected by the manufacturer andwithout any stop valve between them,may be considered as only one vessel forthe installation of a safety valve;

• the union between the valve and theequipment to be protected shall be asshort as possible. Furthermore, itspassage section shall not be narrowerthan the valve inlet section. In any case,EN 13136: 2001 standard states that thepressure loss between protected vesseland safety valve, at discharge capacity,shall not exceed 3% of the setting value,including any accessory mounted on theupstream line;

• in selecting the safety valve location, itshall be taken into account that valveoperation involves the discharge of therefrigerant fluid under pressure,sometimes even at high temperature.Where the risk exists to cause directinjuries to the persons nearby, an exhaustconveying piping shall be provided, whichshall be sized in such a way as not tocompromise valve operation. EN 13136: 2001 standard states that thispiping shall not generate, at dischargecapacity, a back pressure exceeding 10%of pressure po, for standard type valves,unbalanced.

To calculate the pressure loss either in theupstream line (between vessel and safetyvalve) or in the downstream line (betweensafety valve and atmosphere) refer to EN 13136: 2001 standard, Chapter 7.4.

Pressure loss in the upstream lineCalculation of pressure loss is given by:

∆pp

AA

C Kin

o indr= × × ×

⎡

⎣⎢

⎤

⎦⎥ ×0 032

2

, ζ

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Example: assume to install a discharge pipeon safety valve type 3030/88 of the previousexample, using a steel tube nominal size 2”with the following characteristics:– dout = 53 [mm], inside diameter;– Aout = 2206 [mm2], inside area;– L = 3000 [mm], ength;– pipe bend 90° with bending radius R

equal to three times external diameter oftube.

From table A.4 it’s possible to have thesedata:– ξ1 (bend) = 0,25;– ξ2 (length) = λ x L/ din = 0,02 x 3000/53 = 1,13

with λ = 0,02 for steel tube;– ξT = ξ1 + ξ2 = 0,25 + 1,13 = 1,38.

Pressure loss in the downstream line is:

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

= =∆pp

out

o

0 075,

0 064 1 38298

22062 51 0 747 27 25

27 25

212

, , , , ,

,

× × × × ×⎛⎝

⎞⎠

⎡

⎣⎢

⎤

⎦⎥

=

The obtained value is admissible becauselower than the value of 0,03 forecast in EN 13136:2001. standard.

Pressure loss in the downstream lineCalculation of pressure loss is given by:

with:– A = flow area of safety valve [mm2]– Aout = inside area of outlet tube to valve

[mm2]– Kdr = Kd x 0,9, derated coefficient of

discharge– C = function of isentropic coefficient k– ξ = addition of pressure loss coefficients ξn

of pipingThe coefficients ξn are relevant to:– pipe elements loss, bends;– loss along the pipe and are listed in EN 13136:2001 standard,Table A.4.

∆pp

AA

C K p

pout

o

outdr o

o

=

× × × × ×⎛

⎝⎜

⎞

⎠⎟

⎡

⎣⎢⎢

⎤

⎦⎥⎥

0 0642

12

, ζ

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Valves series 3060 are safety devicesaccording to the definition given in Article 1,Point 2.1.3, 2nd dash of 97/23/EC Directiveand are the subject of Article 3, Point 1.4 ofaforesaid Directive.The valves above mentioned are standardtype, unbalanced, direct-loaded safetyvalves. Valve opening is produced by thethrust the fluid under pressure exerts on thedisc, when said thrust exceeds, undersetting conditions, the opposing force of thespring acting on the disc.

Valves are identified by means of:– a model number formed of an

alphanumerical coding that includes:– in the first part the family identification

(e.g. 3060/45C);– in the second part the setting pressure,

expressed in bars, multiplied by 10(e.g. 140);

– a progressive serial number.

Body: squared, obtained through dieforging and subsequent machining. Ithouses the following elements:– the nozzle with flat sealing seat;– the disc guide;– the setting spring holder;– the threaded seat of the setting adjusting

ring nut.

CONSTRUCTION

GENERAL DESCRIPTION

In the body, above the disc guide, a smallpressure relief duct is provided throughwhich the spring holder is put into contactwith the output connection. For this reason,during relief, no gas leak occurs into theatmosphere.Utilized material: EN 12420-CW617N brass.

Disc: obtained through bar machining andequipped with gasket, it ensures therequired sealing degree on the valve seat.The gasket is made in P.T.F.E.(Polytetrafluorethylene), a material that,during valve estimated service life,maintains a good strength and does notcause the disc to stick on the seat. The discis properly guided in the body and the guideaction can never fail; there are no glands orretaining rings that hamper the movementthereof.Utilized material: EN 12164-CW614N brass.

Spring: it opposes the pressure and thefluid dynamic actions and always ensuresvalve re-closing after pressure relief.Utilized material: DIN 17223-1 steel for springs.

Setting system: hexagonal head, threadedring nut to be screwed inside the body topby compressing the spring below. Onsetting completion, the position attained bythe ring nut is maintained unchanged laying,in the threaded coupling, a bonding agentwith high mechanic strength and lowviscosity features to make penetrationthereof easier. The setting system isprotected against subsequent unauthorizedinterventions by means of a cap nut that isscrewed outside the body and is sealed to itwith a punched copper rivet.

SAFETY VALVES 3060

64 www.castel.it

• allowable temperature range;• production date;• serial number.

The following data are stamped on the cap:• EC marking and the identification number

of the notified body involved in theproduction control phase;

• valve model;• flow section;• Kd discharge coefficient.

97/23/EC Directive requires that pressureequipment, in which permissible limits arereasonably likely to be exceeded, shall befitted with suitable protection devices, forinstance safety devices such as safetyvalves. Such devices shall prevent pressurefrom permanently exceeding the maxallowable pressure PS of the equipmentthey protect. In any case, a short pressurepeak limited to 10% of admissiblemaximum pressure is permitted.As to the selection and sizing of the suitableprotection device, users shall refer to thespecific sector or product standards.EN 378-2: 2000 Standard “Refrigeratingsystems and heat pumps – safety andenvironmental requirements – Part 2:Design, construction, testing, marking anddocumentation”, harmonized with 97/23/ECDirective, provides a general outline of theprotection devices to be adopted inrefrigerating systems and their features (par7.4). It also indicates the criteria for the

VALVE SELECTION

TABLE 3: General Characteristics of valves 3060

1/4" NPT

3/8" SAE

0,63

7

38,5

10,0

78,5

1/4" NPT

1/2" SAE

0,69

3/8" NPT

3/8" SAE

0,63

3/8" NPT

1/2" SAE

0,69

1/2" NPT

5/8" SAE

9,5

70,9

0,45

3/8" NPT

3/4" G

0,92

1/2" NPT

3/4" G

0,93

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

Connections

Flow Diameter [mm]

Flow Section [mm2]

Discharge Coefficient “Kd”

PS [bar]

TS [°C]

Set Pressure Range [bar]

Overpressure

Risk Category according to PED

55

- 50 / + 150

9 / 50

10% of set pressure

IV

Inlet male

Outlet male

Use: protection against possibleoverpressures of the apparatuses listedbelow, with regard to the operatingconditions for which they have beendesigned:– refrigerating system and heat pump

components, for instance: condensers,liquid receivers, evaporators, liquidaccumulators, positive displacementcompressor discharge, heat exchangers,oil separators, piping.(reference: EN 378-2: 2000);

– simple pressure vessels(reference: 87/404/ EEC Directive).

Fluids: the valves can be used with:• refrigerant fluids, in the physical state of


• Air and nitrogen(reference: 87/404/EEC Directive).

In conformity with the provisions of Article15 of 97/23/EC Directive the followinginformation are reported on the valve body:• manufacturer’s mark, address and

manufacture country;• indication of flow direction;• max allowable pressure;• set pressure;

MARKING

SCOPE

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H1

H2

H3

Ch

3060

selection of the device suitable to the typeand sizes of the system component to beprotected (par. 7.4).EN 13136: 2001 Standard “Refrigeratingsystems and heat pumps – Pressure reliefdevices and their associated piping –Methods for calculation” highlights thepossible causes of overpressure in a systemand makes available to users theinstruments for pressure relief device sizing,among which the safety valves.For sizing and installation of safety valvesseries 3060 see the previous chapter ofsafety valves series 3030.

TABLE 4: Dimensions and Weights of valves 3060


Ø D L Ch H1 H2 H3

45

45

45

45

45

48

48

35

35

35

35

40,5

40

40

20

20

20

20

23

27

27

33,5

33,5

33,5

33,5

36,5

37

40

48,5

48,5

48,5

48,5

54,5

62,5

62,5

82

82

82

82

91

99,5

102,5

200

215

215

215

290

380

390

Dimensions [mm]

3060/23C

3060/24C

3060/33C

3060/34C

3060/45C

3060/36C

3060/46C

BALL SHUT-OFF VALVES FOR SAFETY VALVES

allow to remove the valve for periodicchecking or replacement without blowing offall the refrigerant from a section of thesystem. These valves can be used with thesame fluids foreseen for safety valves series3030 and 3060, in particularly:– refrigerant fluids, in the physical state of


– air and nitrogen(reference: 87/404/EEC Directive).

We would like to remember to our customerthat the running of pressure equipments andpressure assemblies is excluded by thescope of Directive 97/23/EC but it’sregulated in compliance with nationalregulations of Member States of EuropeanCommunities.We think that these regulations, actually onupdating with the Competent Bodies of allthe states to avoid conflicts with the ESR ofPED, could provide for periodical checks onthe pressure equipments and assemblies.Any intervention for periodic checking orreplacement of an installed safety valvebecomes very difficult if the protectedvessel is not equipped with a shut-off valve.The shut-off valves series 3033 and 3063,installed between vessel and safety valve,

APPLICATIONS

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A

A

C

H2

H1

H3

L

� D

SEAL

BALL VALVE 3033/..

VALVE 3030/..

SEAL

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

CatalogueNumber

Designed for valve

Kv Factor[m3/h]


to PED

Weight [g]min max

PS [bar]Ø D A C L H1 H2 H3

Art. 3.3

Dimensions [mm]TS [°C]

3063/44

3033/44

3033/88

3060/45C

3060/46C

3030/44C

3030/88C

5

10

20

-50 +150 55

10

13

20

1/2"

NPT

1"

NPT

78

101

107

58

73

77

35

59

72

82,5

100

123

162

178

323

350

710

1070

Castel supplies to its customers the valvesseries 3033 and 3063 in open position andthe ball spindle is protected by means of acap screwed to the body and sealed withlead to it. Any closing intervention on thevalve forcedly causes the tampering of theseal and then these interventions shall beperformed exclusively by:– staff authorized to work on the system;– public servant of a Competent Body.These persons will be responsible for thenext valve reopening and the new capsealing with their own lead.

The main parts of these valves are madewith the following materials:– hot forged brass EN 12420 – CW 617N

for body;– hot forged brass EN 12420 – CW 617N,

chromium plated, for ball;– steel, with proper surface protection, for

the spindle;– P.T.F.E. for seat ball gaskets;– chloroprene rubber (CR) for outlet seal

gaskets;– glass reinforced PBT for cap that covers

the spindle.

CONSTRUCTION

N.B.: each safety valve placed on achangeover device must have sufficientcapacity to protect the vessel alone.Valve type 3032/44 is supplied with:– two female threaded connections 1/2” NPT

with swivel nut, code Castel 3039/4;– two O-Ring.These components ensure the perfectalignment of two safety valves 3060/45.

The changeover device type 3032 is a servicevalve for dual pressure relief valves thatallows using one valve while isolating theother from the system. This device allows theuser to work on the isolated valve, forperiodic checking or replacement, while thesystem is completely operative and the othervalve is in service.

APPLICATIONS

CHANGEOVER DEVICES FOR SAFETY VALVES

L3

L2

H1

H1A

CHIUSO-CLOSED

H2

L1

BB A

L1

H2

L3

B

D

A

B

D

A

AB

B

CHIUSO-CLOSED

AB

A

3039/4

GASKET

3032/44

3032/663032/108

3032/64

67www.castel.it

acceptable in order not to affect theoperation of both safety valves. The valveensures a pressure drop perfectlycompatible with the safety valve operationunder conditions of discharge of saturatedvapour as well as overheated vapour.The main parts of these valves are madewith the following materials:– hot forged brass EN 12420 – CW 617N

for body;– steel, with proper surface protection, for

the spindle;– chloroprene rubber (CR) and aramidic

fibers for gland seal;– chloroprene rubber (CR) for outlet seal

gaskets;– glass reinforced PBT for cap that covers

the spindle.

The valves series 3032 can be used with thesame fluids foreseen for safety valves series3030 and 3060, in particularly:– refrigerant fluids, in the physical state of


– air and nitrogen(reference: 87/404/EEC Directive).

The valve 3032 is designed so that it isnever possible to close off both ports at thesame time, excluding all the two safetyvalves. Under working conditions, theshutter must be clamped against one of thetwo seats of the valve, front port or backport, in order to ensure always full dischargeto the corresponding safety valve.Intermediate positions of the shutter are not

CONSTRUCTION

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

CatalogueNumber

Designed for valve

Kv Factor[m3/h]


to PED

Weight [g]min max

PS [bar]L3L2L1H2H1

Art. 3.3

Dimensions [mm]TS [°C]

3032/44

3032/64

3032/66

3032/108

3060/45C

3060/46C

3030/44C

3030/66C

3030/88C

3,3

9,0

9,0

18

-50 +150 55

117

95

95

123

45

52

52

74

31

48

48

66

91

133

133

185

48

80

80

110

775

1750

1750

3200

B

1/2"

NPT

1/2"

NPT

3/4"

NPT

1

NPT

A

1/2"

NPT

3/4"

NPT

3/4"

NPT

1 1/4"

NPT

D

13

17,5

17,5

30

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Unions series 3035 allow assembling safetyvalves series 3030 and 3060 or shut-offvalves series 3032, 3033 and 3063 close tothe pressure equipments to protect, set upin a refrigerating system.These unions are designed for installationsaccording to the following two ways:– Make a copper tube jointing the pressure

equipment to the union, fit the end of thistube into the solder connection of theunion and then make a capillary brazing.

– Drill the inner/outer pipe close to thepressure equipment (if possible make acollar on the pipe), put the end of theunion into this drill and then make a brazewelding.

The unions series 3035 are machined bybrass bar EN 12164-CW614N.

SAFETY VALVES UNIONS

Copper pipe

3060

3035

Ø D

L

Ch.

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

Catalogue Number ODS

Ø [mm]

PS [bar]D L Ch

Weight[g]

NPT

Connections Dimensions [mm]

3035/2

3035/3

3035/4

3035/6

3035/8

1/4”

3/8”

1/2”

3/4”

1”

12

18

22

28

35

55

18

22

28

35

42

33

36,5

44

51

72

21

27

32

40

45

58

90,5

165

255

364

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In conformity with the provisions of Article15 of 97/23/EC Directive and of Point 7.3.3of EN 378-2 : 2000 Standard the followingdata are reported on the hexagonal nut:• EC marking;• Manufacturer's logo;• Max allowable pressure PS;• Melting point.

If a fusible plug is mounted on a pressurevessel or any other part which it protect itshall be placed in a section wheresuperheated refrigerant would not affect itscorrect function. Fusible plug shall not becovered by thermal insulation. Dischargefrom fusible plugs shall take place so thatpersons and property are not endangeredby the released refrigerant.EN 378-2 : 2000 Standard, harmonized withthe 97/23/EC Directive, establishes that afusible plug shall not be used as the solepressure relief device between a refrigerantcontaining component and the atmospherefor systems with a refrigerant charge largerthan:• 2,5 kg of group L1 refrigerant (ex. R22;

R134a; R404A; R407C; R410A; R507).• 1,5 kg of group L2 refrigerant.• 1,0 kg of group L3 refrigerant.

97/23/EC Directive requires that pressureequipment, in which permissible limits arereasonably likely to be exceeded, shall befitted with suitable protection devices, forinstance safety devices such as fusibleplugs. Such devices shall prevent pressurefrom permanently exceeding the maxallowable pressure PS of the equipmentthey protect. In any case, a short pressurepeak limited to 10% of admissiblemaximum pressure is permitted.As to the selection and sizing of the suitableprotection device, users shall refer to thespecific sector or product standards.EN 378-2 : 2000 Standard “Refrigeratingsystems and heat pumps – safety andenvironmental requirements – Part 2:Design, construction, testing, marking and

FUSIBLE PLUG SELECTION

INSTALLATION

MARKING

Fusible plugs series 3080/.C and 3082/.Care safety devices according to thedefinition given in Article 1, Point 2.1.3, 2nd

dash of 97/23/EC Directive and are thesubject of Article 3, Point 1.4 of aforesaidDirective.According to the definition given in Point3.6.4 of EN 378-1 : 2000 Standard, fusibleplug is a device containing material thatmelts at a predetermined temperature andthereby relieving the pressure.Castel has resolved to classify fusible plugsseries 3080/.C and 3082/.C in the Categoryof Risk I therefore fixing their use, asprotection devices, on specific pressureequipments, proper to the same Category ofRisk I, in compliance with Annex II, Point 2,of 97/23/EC Directive.In consequence of this choice, fusible plugsseries 3080/.C and 3082/.C cannot beused, as sole protection devices, onpressure equipments proper to Categoriesof Risk higher than first.

The body of the fusible plug is an NPT plugdrilled with a taper hole. A predeterminedquantity of fusible alloy, with checkedmelting point, is poured inside this hole.The parts of the fusible plugs are made withthe following materials:• Brass EN 12164 – CW 614N, hot tinned,

for the plug.• Eutectic alloy with several components,

cadmium and lead free, for the fusiblematerial.

Use: the fusible plugs are basically used toprotect the components in a refrigeratingsystem or heat pump against possibleoverpressures, with regard to the operatingconditions for which they have beendesigned, in case of an excessive externalheat source, such as fire.Fluids: the fusible plugs can be used withrefrigerant fluids belonging to Group 2according to the definitions of 97/23/ECDirective, Article 9, Point 2.2 (with referenceto 67/548/EEC Directive of June 27th, 1967).

SCOPE

CONSTRUCTION

GENERAL DESCRIPTION

FUSIBLE PLUGS

70 www.castel.it

– C = function of isentropic coefficient k (asmeasured at 25 °C , see Section 7.2.3 ,EN 13136 : 2001 Standard) calculatedfrom:

To find the values of k and C for the moreuseful refrigerants, see the chapter of safetyvalves series 3030Calculation of minimum required dischargecapacity of fusible plug is closely linked tothe main cause that may arouse the openingof fusible plug, which is the external heatsources.The minimum required discharge capacityshall be determined by the following:

[kg/h]

with– ϕ = density of heat flow rate, it’s assumed

to be 10 [kW/m2]– Asurf = external surface area of the vessel

[m2]– hvap = heat of vaporization of liquid at po

[kJ/kg]

EN 13136 : 2001 Standard also establishesthat the following values for Kdr shall be themaximum used depending on how the pipebetween the vessel and the fusible plug ismounted on the vessel:• flush or flared connection: Kdr = 0,70• inserted connection: Kdr = 0,55

Q

Ahmd

surf

vap

=× ×3600 ϕ

C k

k

k

k= × ×

+

+( )−( )

3 9482

1

1

1,

documentation” provides a general outlineof the protection devices to be adopted inrefrigerating systems and their features (par7.4). It also indicates the criteria for theselection of the device suitable to the typeand sizes of the system component to beprotected (par. 7.4).EN 13136 : 2001 Standard “ Refrigeratingsystems and heat pumps – Pressure reliefdevices and their associated piping –Methods for calculation”, harmonized with97/23/EC Directive, highlights the possiblecauses of overpressure in a system andmakes available to users the instruments forpressure relief device sizing, among whichthe fusible plugs.

As the fusible plugs discharge toatmosphere, they always work in criticalflow (to know the definition of critical flow,see the chapter of safety valves series3030).The fusible plugs must be sized as follow:

[mm2]

with:– Ac = minimum flow area of fusible plug

[mm2]– Qmd = minimum required discharge

capacity, of refrigerant, of fusible plug[kg/h]

– Kdr =derated coefficient of discharge offusible plug, equal to 0,9 x Kd

– po = pressure upstream the fusible plug,inside the equipment to be protected [barabs]

– vo = specific volume of gas or vapour atrelieving conditions po e To , [m3/kg] (To isthe fluid temperature at plug inlet, settledby the user or by the designer)

A

QC K

vpc

md

dr

o

o

= ××

×3 469,

SIZING OF FUSIBLE PLUGS (REF. EN 13136 : 2001)

71www.castel.it

TABLE 8: General Characteristics, Dimensions and Weights of fusible plugs 3080 and 3082

CatalogueNumber

NPTConnections

Flow Diameter[mm]

Flow Section[mm2] Kd PS

[bar]Melting Point

[°C]

Hexa

gona

l Key

Wrench Torque

min/max [Nm]

Weight[g]

Risk Categoryaccording to

PED

3080/2C

3080/3C

3080/4C

3082/2C

3082/3C

3082/4C

1/4"

3/8"

1/2"

1/4"

3/8"

1/2"

5,7

8,5

9,3

5,7

8,5

9,3

25,5

56,7

67,9

25,5

56,7

67,9

0,91

42

30

79

138

17

22

17

22

10 / 15

14 / 20

21 / 30

10 / 15

14 / 20

21 / 30

23

39

76

23

39

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CHECK VALVES

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Before connecting the valve to the pipe it isadvisable to make sure that the refrigeratingsystem is clean. In fact the valves withP.T.F.E. gaskets are particularly sensitive todirt and debris. Furthermore check that theflow direction in the pipe corresponds to thearrow stamped on the body of the valve.

The allowed operating positions are:– types 3122 and 3142 with horizontal axis

and valve cover facing upward;– types 3182 with inlet facing down and the

valve cover facing upward;– types 3110, 3130 and 3131, preferably

with vertical axis and arrow upward.Sloping axis, up to horizontal position,are tolerable.

The brazing of valves with solderconnections should be carried out withcare, using a low melting point fillermaterial. Before starting to braze, it’snecessary to disassemble the valves series3122, while this operation is not necessarywith solder connection valves. In any case,it’s important to avoid direct contactbetween the torch flame and the valve body,which could be damaged and compromisethe proper functioning of the valve.

The check valves, shown in this chapter, areclassified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).For heavy duty, about the operationtemperature, for example installation on thedischarge line close to the compressor,Castel has developed three new series ofvalves, types 3122, 3142 and 3182,equipped with special gasket for hightemperature, between the body and itscover.


for body and cover;– copper tube EN 12735-1 – Cu-DHP for

solder connections;– austenitic stainless steel AISI 302 for the

spring;– chloroprene rubber (CR) for outlet seal

gaskets. Metal-rubber laminated gasketsfor the valves series 3122, 3142 and 3182;

– P.T.F.E. for seat gasket.

The valves can be installed in any section ofa refrigerating system, where it is necessaryto avoid an inversion of the refrigeratingflow, in compliance with the limits andcapacities indicated in table 3. Table 1 shows the following functionalcharacteristics of a check valve:– PS;– TS;– Kv factor;– minimum opening pressure differential,

that is the minimum pressure differentialbetween inlet and outlet at which a checkvalve can open and stay opened.

INSTALLATION

MATERIALS

APPLICATIONS

CHECK VALVES

75www.castel.it

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EC

K VA

LVE

STABLE 1: General Characteristics

CatalogueNumber SAE

Flare Ø[in.]

Ø[mm]

Ø[in.]

Ø[mm]

ODS ODM

Connections

KvFactor[m3/h]

MinimumOpeningPressure

Differential[bar] min.

TS [°C]

max.

PS[bar]


toPED

3110/2

3110/3

3110/4

3110/5

3110/6

3122/M22

3122/7

3122/M28

3122/9

3122/11

3122/13

3122/M42

3122/17

3130/2

3130/3

3130/M10

3130/M12

3130/4

3130/5

3130/M18

3130/6

3130/7

3131/M10

3131/M12

3131/5

3131/7

3142/7

3142/M28

3142/9

3142/11

3142/13

3142/M42

3142/17

3142/21

3142/25

3182/7

3182/M28

3182/9

3182/11

3182/13

3182/M42

3182/17

1/4"

3/8"

1/2"

5/8"

3/4"

–

–

–

7/8"

–

1.1/8"

1.3/8"

1.5/8"

–

2.1/8"

1/4"

3/8"

–

–

1/2"

5/8"

–

3/4"

7/8"

–

–

5/8"

7/8"

7/8"

–

1.1/8"

1.3/8"

1.5/8"

–

2.1/8"

2.5/8"

3.1/8"

7/8"

–

1.1/8"

1.3/8"

1.5/8"

–

2.1/8"

–

22

–

28

–

35

–

42

54

–

–

10

12

–

16

18

–

22

10

12

16

22

22

28

–

35

–

42

54

–

–

22

28

–

35

–

42

54

–

–

1.1/8"

1.3/8"

1.3/8"

1.5/8"

2"

2"

–

–

28

–

35

35

–

0,4

1,6

3,3

6,6

8,8

15,2

25,0

40,0

0,5

1,6

1,8

3,3

1,6

1,8

3,3

6,6

8,8

15,2

25,0

40,0

8,5

9,5

19,0

37,0

45,4

0,1

0,3

0,1

– 40

– 35

– 40

– 35

+105

+160

+105

+160

45

Art. 3.3

I

Art. 3.3

I

Art. 3.3

I

76 www.castel.it

TABLE 2: Dimensions and Weights


H H1 L L1 Q Ø D Ch

84

84,5

83

109

108

84,5

101,5

125,5

142

144

148

183

198

148

183

198

84,5

101,5

125,5

142

151

177

221

–

28,5

34

37

42,5

–

28,5

34

37

42,5

95

109,5

123,5

–

100

118

141

173

–

170

201

232

256

285

329

130,5

150

195,5

–

100,5

116

143,5

–

60

68

88

104

–

60

68

88

104

60

68

104

23

37

–

23

37

23

37

–

20

27

–

20

28

20

28

–

150

155

165

440

460

1180

1090

1625

2955

4225

170

185

450

185

450

1320

1885

3315

4875

5690

1280

1295

1855

3255

4780

Dimensions [mm]

3110/2

3110/3

3110/4

3110/5

3110/6

3122/M22

3122/7

3122/M28

3122/9

3122/11

3122/13

3122/M42

3122/17

3130/2

3130/3

3130/M10

3130/M12

3130/4

3130/5

3130/M18

3130/6

3130/7

3131/M10

3131/M12

3131/5

3131/7

3142/7

3142/M28

3142/9

3142/11

3142/13

3142/M42

3142/17

3142/21

3142/25

3182/7

3182/M28

3182/9

3182/11

3182/13

3182/M42

3182/17

77www.castel.it

H

H1

L

Q

� 20M10

3122

L

H1

H

� 20M10

Q

3142

H

� D31303131

L1

H

H1

L

3182

Q

H

� D3110

Ch

CH

EC

K VA

LVE

S

78 www.castel.it

TABLE 3: Refrigerant Flow Capacity

CatalogueNumber

R134a R22 R407C R404A R410A R22 R407C R404A R410A R22 R407C R404A R410A


Refrigerant Flow Capacity [kW]

3110/2

3110/3

3110/4

3110/5

3110/6

3122/M22

3122/7

3122/M28

3122/9

3122/11

3122/13

3122/M42

3122/17

3130/2

3130/3

3130/M10

3130/M12

3130/4

3130/5

3130/M18

3130/6

3130/7

3131/M10

3131/M12

3131/5

3131/7

3142/7

3142/M28

3142/9

3142/11

3142/13

3142/M42

3142/17

3142/21

3142/25

3182/7

3182/M28

3182/9

3182/11

3182/13

3182/M42

3182/17

6,7

27,0

30,3

55,6

111,2

148,3

256,1

421,3

674,0

8,4

27,0

30,3

55,6

27,0

30,3

55,6

111,2

148,3

256,1

421,3

674,0

143,2

160,1

320,2

623,5

765,0

7,2

28,8

32,4

59,4

118,8

158,4

273,6

450,0

720,0

9,0

28,8

32,4

59,4

28,8

32,4

59,4

118,8

158,4

273,6

450,0

720,0

153,0

171,0

342,0

666,0

817,2

7,5

30,0

33,7

61,8

123,7

164,9

284,8

468,5

749,6

9,4

30,0

33,7

61,8

30,0

33,7

61,8

123,7

164,9

284,8

468,5

749,6

159,3

178,0

356,1

693,4

850,8

4,8

19,0

21,4

39,3

78,5

104,7

180,9

297,5

476,0

6,0

19,0

21,4

39,3

19,0

21,4

39,3

78,5

104,7

180,9

297,5

476,0

101,2

113,1

226,1

440,3

540,3

7,6

30,5

34,3

62,8

125,7

167,6

289,4

476,0

761,6

9,5

30,5

34,3

62,8

30,5

34,3

62,8

125,7

167,6

289,4

476,0

761,6

161,8

180,9

361,8

704,5

864,4

R134a

0,9

3,5

3,9

7,1

14,3

19,0

32,8

54,0

86,4

1,1

3,5

3,9

7,1

3,5

3,9

7,1

14,3

19,0

32,8

54,0

86,4

18,4

20,5

41,0

79,9

98,1

1,1

4,3

4,9

8,9

17,8

23,8

41,0

67,5

108,0

1,4

4,3

4,9

8,9

4,3

4,9

8,9

17,8

23,8

41,0

67,5

108,0

23,0

25,7

51,3

99,9

122,6

1,1

4,3

4,8

8,8

17,7

23,6

40,7

67,0

107,2

1,3

4,3

4,8

8,8

4,3

4,8

8,8

17,7

23,6

40,7

67,0

107,2

22,8

25,5

50,9

99,2

121,7

0,9

3,6

4,1

7,5

14,9

19,9

34,4

56,5

90,4

1,1

3,6

4,1

7,5

3,6

4,1

7,5

14,9

19,9

34,4

56,5

90,4

19,2

21,5

42,9

83,6

102,6

1,4

5,8

6,5

11,9

23,8

31,7

54,7

90,0

144,0

1,8

5,8

6,5

11,9

5,8

6,5

11,9

23,8

31,7

54,7

90,0

144,0

30,6

34,2

68,4

133,2

163,4

R134a

3,4

13,6

15,3

28,1

56,1

74,8

129,2

212,5

340,0

4,3

13,6

15,3

28,1

13,6

15,3

28,1

56,1

74,8

129,2

212,5

340,0

72,3

80,8

161,5

314,5

385,9

4,7

18,7

21,1

38,6

77,2

103,0

177,8

292,5

468,0

5,9

18,7

21,1

38,6

18,7

21,1

38,6

77,2

103,0

177,8

292,5

468,0

99,5

111,2

222,3

432,9

531,2

4,6

18,6

20,9

38,3

76,7

102,3

176,6

290,5

464,8

5,8

18,6

20,9

38,3

18,6

20,9

38,3

76,7

102,3

176,6

290,5

464,8

98,8

110,4

220,8

429,9

527,5

4,0

16,0

18,0

33,0

66,0

88,0

152,0

250,0

400,0

5,0

16,0

18,0

33,0

16,0

18,0

33,0

66,0

88,0

152,0

250,0

400,0

85,0

95,0

190,0

370,0

454,0

5,2

20,8

23,4

42,9

85,8

114,4

197,6

325,0

520,0

6,5

20,8

23,4

42,9

20,8

23,4

42,9

85,8

114,4

197,6

325,0

520,0

110,5

123,5

247,0

481,0

590,2



79

WATER REGULATING VALVES

80 www.castel.it

The water regulating valve, employed withcondenser fed with either main or wellwater, keeps the condensation pressureconstant at the previously set value byadjusting the water flow so as to ensure abalanced heat exchange under allconditions. At plant start-up, this adjustment isdesigned to allow the thermostatic valve torapidly reach normal operating conditionsand subsequently, during operations, toavoid excessive pressure increases ordecreases under different flow conditions.An excessive rise of high pressure affectsthe refrigerating capacity of the system. On the other side, pressure lowering leadsto insufficient refrigerant feeding of theevaporator with a consequent increased gasoverheating and parallel reduction of gaspressure at compressor suction. Castel valves are appropriate for refrigerantfluids CFC, HCFC and HFC and only formain and well water.

APPLICATIONS

WATER REGULATING VALVES

1/4"

48

Ch

1/4"Flare

8799

L

A02

MAD

E IN ITALY

RANGE 5-18 bar

MEDIUM R134a-R404A-R12-R22-R502MAX WATER TEMP. 80 |BCMAX WATER PRESS. 10 bar

CAT. BC

A

The moving elements of the valve are ametal bellows and a shutter. The thrust of the refrigerant condensationpressure outside the bellows favours theopening of the valve and the thrust of theadjustment spring on the shutter acts in theopposite sense. Given a specific setting ofthe spring, the valve progressively opens inline with the increasing condensationpressure, and closes when this pressuredecreases. When the compressor stops, the valvecloses: water is no longer fed into thecondenser, this being a notable operatingeconomy.Valve setting is performed in the works at apressure of 7,5 bars. Setting is modified byturning the control screw.Three reference notches, marked withletters A, B, and C, are present on thespring cover. Each notch is equivalent to adifferent spring setting.The notches are referred to the followingcondensation pressures:• letter A equivalent to about 7.5 bar

(valid for R12 and R134a at a temperatureof condensation of 30 °C);

• letter B equivalent to about 14 bar (valid for R404A, R407C and R507 at atemperature of condensation of 30 °C);

• letter C equivalent to about 18 bar (top limit of working pressure).

OPERATIONS

81www.castel.it

• Expected thermal difference: Dt = 10 °C.• Condensation temperature expected on

the basis of the water/refrigerant heatexchange in the condenser:approximately 6 °C above the watertemperature at the outlet, equivalent to30 °C (with a corresponding saturationpressure) (fig. 1).

• Refrigeration yield at the level of theevaporator: 18,6 kW under the following operatingconditions,condensation temperature: + 30 °C;evaporation temperature: –15 °C.

Thermal power to be disposed of at thelevel of the condenser (Table 2):

18,6 x 1,325 = 24,65 [kW]

Water flow rate:

24,65 x 860––––––––––– = 2120 l/h = 2,12 [m3/h]

10

WA

TE

R R

EG

ULA

TIN

G VA

LVE

S

Fig. 1 – Heat exchange pattern in the condenser

TABLE 1 - General Characteristics


Connections

UNI ISO228/1

Workingpressure

[bar]

Maximumwater

pressure[bar]

Maximumwater

Temperature[°C]

KvFactor

[m3/h]

Refrigerantmax

workingpressure

[bar]

Ch L

3210/03

3210/04

3210/06

G 3/8"

G 1/2"

G 3/4"

5÷18 10 80

2

3

4,7

2027

32

70

74

1015

985

1010

The materials used for the main parts are:• hot-forged brass EN 12420-CW617N for

main body;• austenitic stainless steel – AISI 303 for

the seat;• nitril rubber (NBR) for seat gasket;• NBR coated-fabric for diaphragms.

The valve will be mounted on the wateroutlet side of the condenser, preferablyvertically, with the bellows downward.The high pressure connection to the bellowmust show no deflection.The arrow on the valve body shows waterflow direction.

A refrigerating system including a hermeticcompressor and a condenser fed withmains water.• Mains water pressure: 3 bar• Water temperature at the condenser inlet:

14 °C.

EXAMPLE OF VALVE SELECTION

INSTALLATION

MATERIALS

Heat exchange surface

Condensing Temperature

W a t e r Te m p e r a t u r e

82 www.castel.it

When the point of intersection of pressuredifferential through the valve and flow rangeis within the area between the curves of twovalves, select the valve with larger diameter.

When the valve is completely closed, thepressure must be the same as therefrigerant saturation pressure at the airtemperature of the place where thecondenser is installed.When the valve begins to open, thepressure is about 0.2 bar above thepressure when the valve is totally closed.

The pressure drop corresponding to thewater flow rate specified above in thecondenser/piping circuit, with the exclusionof the water regulating valve, is about 2.5 bar.

The water regulating valve has this pressuredifferential at its disposal:

�p = 3 – 2,5 = 0,5 bar

At �p = 0,5 bar the 3210/04 valve, completlyopened, ensures the required flow rate (fig. 2).

0

0,5

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

∆p [H2O]

1

1,5

2

2,5

3

3,5

4

4,5

5

5,5

6

6,5

7

0

0,12

5

0,25

0,37

5

0,5

0,62

5

0,75

0,87

5 1

1,12

5

1,25

1,37

5

1,5

1,62

5

1,75

1,87

5 2

2,12

5

2,25

2,37

5

2,5

2,62

5

2,75

∆p [bar]

Q [m3/h]

3210/04

3210/06

3210/03

Fig. 2 – Characteristic curves when the valves are completely open

83

WA

TE

R R

EG

ULA

TIN

G VA

LVE

S

www.castel.it

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

CondensingTemperature

[°C]

Evaporating Temperature [°C]

–35 –30 –25 –20 –15 –10 –5 0 +5 +10

+30

+35

+40

+45

+50

+55

+60

1,524

1,553

1,578

–

–

–

–

1,473

1,503

1,531

–

–

–

–

1,421

1,453

1,484

1,521

–

–

–

1,371

1,403

1,435

1,475

–

–

–

1,325

1,355

1,387

1,425

1,468

1,520

–

1,281

1,310

1,340

1,377

1,420

1,465

1,526

1,238

1,268

1,295

1,330

1,369

1,412

1,457

1,200

1,228

1,254

1,285

1,320

1,363

1,398

1,163

1,188

1,210

1,240

1,270

1,304

1,338

1,133

1,155

1,175

1,200

1,227

1,255

1,285

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

CondensingTemperature

[°C]


–35 –30 –25 –20 –15 –10 –5 0 +5 +10

+30

+35

+40

+45

+50

+55

+60

1,460

1,495

1,537

–

–

–

–

1,417

1,450

1,487

1,530

–

–

–

1,371

1,405

1,441

1,485

–

–

–

1,330

1,367

1,396

1,437

1,482

–

–

1,291

1,320

1,350

1,390

1,431

–

–

1,243

1,279

1,306

1,342

1,381

1,426

1,474

1,213

1,240

1,265

1,295

1,334

1,369

1,410

1,178

1,202

1,224

1,252

1,288

1,320

1,355

1,143

1,168

1,185

1,211

1,241

1,274

1,330

1,114

1,133

1,152

1,175

1,200

1,228

1,255

85

LIQUID INDICATORS & MOISTURE-LIQUID INDICATORS

The data of moisture content, shown intable 1 with the “green” color, can beconsidered admissible for the properworking of the system. When the sensitiveelement from green fade to yellow, “greenChartreuse”, working conditions of thesystem could become difficult. When thesensitive element becomes “yellow”, it’stime to substitute the dehydrator filter.If the charge and working condition arenormal, the refrigerant fluid appearsperfectly liquid underneath the “lens” of theindicator. The presence of bubbles indicatesthat the refrigerant fluid is partialevaporating along the liquid line.

Castel liquid indicators and liquid/moistureindicators are manufactured with the glass“lens” which has been fused onto themetallic ring. This construction permits thetotal elimination of sealing gasket betweenthe glass disc and the metallic structurewith the consequent elimination of possiblerefrigerant leaks.

The main parts of the indicators are madewith the following materials:– hot forged brass EN 12420 – CW 617N

for body;– copper tube EN 12735-1 – Cu-DHP for

solder connections;– steel, with proper surface protection, for

the ring;– chloroprene rubber (CR) for outlet seal

gaskets;– elastomer polyester for cap that covers

the ring.

CONSTRUCTION

The indicators, shown in this chapter, areclassified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.The indicators series 3780 are excluded fromthe scope of Directive 97/23/EC, as specifiedin the Guidelines 1/8 and 1/9, because theyare piping components.They are designed for installation oncommercial refrigerating systems and on civiland industrial conditioning plants, which userefrigerant fluids proper to the Group II (as defined in Article 9, Section 2.2 ofDirective 97/23/EC and referred to inDirective 67/548/EEC).Liquid indicators and moisture liquidindicators ensure a fast and safe inspectionof the conditions of the refrigerant fluid in thecircuit concerning regular flow and moisture.Liquid indicators also ensure inspection ofthe regular return of oil to the compressorcrankcase.

The moisture/liquid indicators consist of asensitive element as a ring, which changescolor passing from green to yellowaccording to the percentage of moisture inthe system.

OPERATION

APPLICATIONS

LIQUID INDICATORS & MOISTURE-LIQUID INDICATORS

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

ColourR22 R134a R404A R407C R410A

Refrigerant fluid

Green

Green

“Chartreuse”

Yellow

<60

60

>60

<75

75

>75

<30

30

>30

<30

30

>30

<30

30

>30

R507

<30

30

>30

86 www.castel.it

87www.castel.it

LIQU

ID IN

DIC

AT

OR

S &

M

OIS

TU

RE

-LIQU

ID IN

DIC

AT

OR

STABLE 2: General Characteristics

MoistureLiquid

Indicators

LiquidIndicators

Catalogue Number

Type SAE Flare


to PED

PS [bar]ODS ODM for pipeTS [°C]

Ø [mm]

Ø [mm]

Ø [mm]

Ø Foro[mm] max.Ø

[in.]Ø

[in.]Ø

[in.] min.

Art. 3.3

I

Art. 3.3

I

Excluded

Connections

3710/22

3710/33

3710/44

3710/55

3710/66

3720/M12

3720/5

3720/M18

3720/M22

3740/2

3740/3

3740/M10

3740/M12

3740/4

3740/5

3740/M18

3740/6

3740/7

3740/9

3750/22

3750/33

3750/44

3750/55

3750/66

3770/M28

3770/11

3770/13

3770/M42

3771/11

3771/M42

3771/17

3780/5

3780/M18

3780/7

3780/9

3780/11

3781/M28

male

male

soldering

male

female

soldering

saddle

type

level glass

3610/22

3610/33

3610/44

3610/55

3610/66

3620/M12

3620/5

3620/M18

3620/M22

3640/2

3640/3

3640/M10

3640/M12

3640/4

3640/5

3640/M18

3640/6

3640/7

3640/9

3650/22

3650/33

3650/44

3650/55

3650/66

–

1/4"

3/8"

1/2"

5/8"

3/4"

–

–

–

–

–

–

–

–

–

–

–

–

–

–

1/4"

3/8"

1/2"

5/8"

3/4"

–

–

–

–

–

–

–

–

–

–

–

–

–

–

5/8"

–

–

1/4"

3/8"

–

–

1/2"

5/8"

–

3/4"

7/8"

1.1/8"

–

–

–

–

–

–

–

–

–

1.3/8"

–

2.1/8"

–

–

–

–

–

–

12

16

18

22

–

–

10

12

–

16

18

–

22

–

–

–

–

–

–

–

–

–

–

35

42

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

1.3/8"

1.5/8"

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

28

35

–

42

–

–

–

–

–

5/8"

–

7/8"

1.1/8"

1.3/8"

–

–

16

18

22

28

35

–

–

28

– 30 +110

45

35

88 www.castel.it

L

H1

HH1

H H1

L

Ø 34,5Ø 34,5

Ø 34,5

tubo

Ø

Ø 34,5

33,5 4,5

Ø 28

36403740

36103710

3780 3781

Ch 32

Ø 34,5

L

H H1

36503750

Ch

Ch

L

H1

Ø 34,5

3771

Ch 32

L

H2

Ø 34,5

3770

Ch 32

Ø 34.5

L

H1

H

37203620

Ch

indication is given normally when the plantis in function and the fluid is flowingThe brazing of indicators with solderconnections should be carried out withcare, using a low melting point fillermaterial. Before starting to braze, it’snecessary to disassemble the ring ofindicators series 3620, 3720, 3780 and3781, while this operation is not necessarywith solder connection indicators. In anycase, avoid direct contact between thetorch flame and the indicator body or ring,which could be damaged and compromisethe proper functioning of the indicator.

At the start-up the color of the sensitiveelement may be yellow, due to exposure toair humidity and to moisture in the circuit.When the moisture of the refrigerant isbrought back to acceptable levels with thedehydrator, the indicator color is once againgreen. This is evidence that equilibrium hasbeen re-stablished. In case of persistingyellow, measures have to be taken toeliminate moisture. Only when the sensitiveelement comes back to green, there isevidence that adopted measures wereeffective. About 12 hours of systemoperation are required to achieveequilibrium. However, the moisture

INSTALLATION

89www.castel.it

LIQU

ID IN

DIC

AT

OR

S &

M

OIS

TU

RE

-LIQU

ID IN

DIC

AT

OR

S

Moisture Liquid

IndicatorsH H1 L Ch

28,5

31,5

36

38,5

46

28,5

38,5

40

46

28,5

38,5

40

46

53,5

31,5

36

38,5

46

53,5

–

71,5

77,5

81,5

89,5

93

49

61

133

117

131

151

186

68

74

77

84

92

150

160

170

160

170

–

12

17

22

24

28

–

12

17

22

24

28

–

Catalogue Number


LiquidIndicators

Weight [g]

3710/22

3710/33

3710/44

3710/55

3710/66

3720/M12

3720/5

3720/M18

3720/M22

3740/2

3740/3

3740/M10

3740/M12

3740/4

3740/5

3740/M18

3740/6

3740/7

3740/9

3750/22

3750/33

3750/44

3750/55

3750/66

3770/M28

3770/11

3770/13

3770/M42

3771/11

3771/M42

3771/17

3780/5

3780/M18

3780/7

3780/9

3780/11

Dimensions [mm]

3610/22

3610/33

3610/44

3610/55

3610/66

3620/M12

3620/5

3620/M18

3620/M22

3640/2

3640/3

3640/M10

3640/M12

3640/4

3640/5

3640/M18

3640/6

3640/7

3640/9

3650/22

3650/33

3650/44

3650/55

3650/66

–

130

165

210

255

315

100

110

110

160

135

195

200

210

215

295

580

165

205

235

300

525

250

300

480

300

480

550

90

22

22,5

24,5

26

31,5

22

26

27,5

31,5

22

26

27,5

31,5

36

22,5

24,5

26

31,5

36

38

41,5

45

41,5

45

30

31

33

36

39,5

91

DEHYDRATORS AND FILTERS

92 www.castel.it

In molecular sieve driers, with a chargeconstituted by non-agglomeratedproducts, the dehydrating mass is pressedin between two fine steel mesh disks, ortwo filtering disks of various material, keptin place by a spring.In solid core driers, dehydrating anddeacidifying products with bindersconstitute the block. Water adsorptioncombines with the neutralization of acidsthat may be present in the refrigerant, andwith a strong filtering action.Castel have planned either its productionlines of hermetic driers on this secondsolution that avoid any risk of abrasion ofthe charge and consequently the makingof powder and permit to put the filter inany position inside the refrigeratingsystem.It is always advisable to install a moistureindicator downstream the filter, which willshow the refrigerant moisture and,consequently, the degree of efficiency ofthe filter.The dehydrating capacity of Castel drier isrelative to the charge of refrigerant and notto the refrigeration potential of the plant.As a matter of fact, for the samerefrigerant potential and for the same typeof refrigerant fluid, there can be differentrefrigerant charges according to the type,design and working conditions of the plantas well as to the shutter degree.The data shown in the following tables arededuced from the test results of thepresent Castel production.It is important to note in the case of a highoil level in the circuit (> 5%) the datashown in the tables will be reducedconsiderably.

Among contaminating agents causingserious damages to refrigerating systems,moisture plays a major role. Its presence,even possible in the refrigerating system,is due to many factors:• inadequate or insufficiently prolonged

vacuum before refrigerant charging;• oil used for topping up remained

exposed to air humidity;• refrigerant used for subsequent

additions contained in non driedvessels;

• sealing defects especially in systemsnot designed for operation at lowtemperatures.

High temperatures combined withhumidity give rise to complex phenomenaenhancing acid formation both inlubricating oil and refrigerant.Oil organic acids react with metal andfavor the formation of sludge, which areviscous clots consisting of insoluble metalsalts and large molecules of polymerizedoil.Sludge affects the lubrication of themoving elements of the compressor, canclog valves and filters and cause seriousdamages.Acids, especially hydrofluoric acid,produced by the hydrolysis of thefluorinated refrigerant (in compressors ironand aluminum act as catalysts) areparticularly corrosive.Acids etch metal surfaces with theconsequent formation of crystal salts,which stick to surfaces and affect the totalheat exchange coefficient in thecondenser and in the evaporator.In the sealed and semi-sealed groups,these salts damage the windings ofelectric motors as in these groups coldgas cools windings through direct contact.On the other hand, water solubility inrefrigerants in a liquid phase, is quitereduced, especially at low temperatures.As a consequence, when in the systemwater exceeds the very low limits ofsolubility admitted at low temperature,excess water turns into ice, and blocksexpansion valves and capillaries eitherpartially or totally.Consequently, refrigerating plants must beequipped with a filter drier on the liquidline and types available on the market areessentially two: molecular sieve driers andsolid core driers.

DEHYDRATION OF REFRIGERANTS

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The blocks in the filters series 42 aremolded from a blend of dehydratingcharge, 80% of 3 Å molecular sievesand 20 % of activated alumina, and aspecial binding agent in appropriateproportions. The choice of blend,molecular sieves – activated alumina,gives to the block a very high capacityof acid adsorption also maintaining verygood dehydrating characteristics. Thepresence of a controlled and definedpercentage of activated alumina, lowerthan the maximum value recommendedby ASERCOM, keeps unchanged theoriginal concentration of additives in thepolyolester lubricant.

The filters, shown in this chapter, areclassified “Pressure vessels” in thesense of the Pressure EquipmentDirective 94/23/EC, Article 1, Section2.1.1 and are subject of Article 3,Section 1.1 of the same Directive.They are designed for installation oncommercial refrigerating systems andon civil and industrial conditioningplants, which use refrigerant fluidsproper to the Group II (as defined inArticle 9, Section 2.2 of Directive97/23/EC and referred to in Directive67/548/EEC).Filters series 42 and series 43 havebeen developed for specific installationson refrigerating systems using HFCrefrigerant fluids, particularly R134a,R404A, R407C, R410A ed R507 mixedwith polyolester lubricants. In spite ofthis, the new block may be successfullyused also in refrigerating systems usingthe old CFC or HCFC refrigerant fluids,mixed with mineral lubricants

The filter is completely manufactured insteel, either with nickel-plated Flarethreaded connections. The productrange also includes types with copperplated solder connections, offering thepossibility to solder the copper pipeinside the connections (ODS) or outsidethe connections, using a copper sleeve(ODM).On specific customers’ request, Castelis also able the supply them filtersseries 42 and 43 with:• solder connections made of copper

tube EN 12735-1 – Cu-DHP• ORFS (O-Ring Face Seal) threaded

connections according to SAE J 1453Standard.

CONSTRUCTION

APPLICATIONS

ANTI-ACID SOLID CORE FILTER DRIERS WITHMOLECULAR SIEVES AND ACTIVATED ALUMINA –SERIES 42Approved by Underwriters Laboratories Inc. �

SOLID CORE FILTER DRIERS WITH 100% MOLECULAR SIEVES – SERIES 43Approved by Underwriters Laboratories Inc. �

94 www.castel.it

The blocks in the filters series 43 aremolded from a blend of dehydratingcharge, totally made of 3 Å molecularsieves, and a special binding agent inappropriate proportions. The choice ofthe 3 Å molecular sieves, as soledehydrating material, gives to the blocka superlative capacity of wateradsorption also maintaining quite gooddeacidifying characteristics.The manufacturing process gives aconsiderable compacted ness andstoutness to both the products so thatthey are resistant to shocks andabrasions.The shape of the block is designed in

order to offer the maximum possiblesurface area to the incoming fluid. Theinternal cavity is also positioned in sucha way as to have a uniform wallthickness. As a result, the fluidencounters a constant strength at allpoints, flows linearly through the block,and ensures efficient dehydration andminimum charge loss.The block is chemically inert, notdeliquescent, does not react withrefrigerating fluids, and is capable ofblocking oil by-products dragged intothe circuit. Impurities accumulate in thering between the metal shell and theblock; this prevents filter clogging.

System data:Refrigerant: R407CCondensing temperature: + 50 [°C]Weight of refrigerant: 34 [kg]

According to DIN 8949:2000, the adsorptioncapacity of the drier is given by:

(1.050 – 50) x 34 / 1.000 = 34 g of H2O

where:

1.050 ppm. = moisture in the refrigerantentering the filter according to DIN8949:200050 ppm. = moisture in the refrigerant flowingout the filter according to DIN 8949:2000

Comparing the absorption capacity requiredwith the values shown in table 2, driermod.4032 should be selected, with a waterabsorption capacity of 47,5 g at 50 °C.If the dehydrating capacity of products isexpressed in water drops, it must beremembered that:

1g H2O = 20 water drops

In this case and when a molecular sievedrier is selected, the following result isobtained:34 x 20 = 680 water drops.

If moisture exceeds the values specified inDIN 8949:2000, a drier with a higheradsorption capacity shall be selected.

EXAMPLE OF SELECTION

flow

dire

ctio

n

Solid core dehydrator1 – Spring2 – Stainless steel mesh3 – Block4 – Felt

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TABLE 1: General CharacteristicsCatalogueNumber

InternationalReference

BlockFilteringSurface

[cm2]

NominalVolume[cm3]

ThreadedConnections

SolderConnections

SAEFlare

1/4"

1/4"

–

3/8"

1/4"

1/4"

–

3/8"

–

–

1/4"

1/4"

–

3/8"

3/8"

–

–

–

1/2"

–

1/4"

3/8"

3/8"

–

–

–

1/2"

–

5/8"

–

3/8"

–

1/2"

–

5/8"

–

1/2"

–

5/8"

–

5/8"

–

3/4"

–

–

–

–

–

–

–

–

–

1/4"

–

–

–

1/4"

–

3/8"

–

–

–

1/4"

–

–

3/8"

–

–

–

1/2"

–

–

–

3/8"

–

–

–

1/2"

–

5/8"

–

3/8"

–

1/2"

–

5/8"

–

1/2"

–

5/8"

–

5/8"

–

3/4"

7/8"

1/2"

5/8"

3/4"

7/8"

1.1/8"

–

–

–

–

–

–

–

–

–

10

–

–

–

–

–

–

10

12

–

–

–

–

–

–

10

12

–

–

–

16

–

–

–

–

–

16

–

–

–

16

–

16

–

–

–

–

16

–

–

–

–

–

3/8"

–

–

–

3/8"

–

1/2"

–

–

–

3/8"

–

–

1/2"

–

–

–

5/8"

–

–

–

1/2"

–

–

–

5/8"

–

3/4"

–

1/2"

–

5/8"

–

3/4"

–

5/8"

–

3/4"

–

3/4"

–

7/8"

1.1/8"

5/8"

3/4"

7/8"

1.1/8"

1.3/8"

–

–

–

–

–

–

–

–

–

12

–

–

–

–

–

–

12

14

–

16

–

–

–

–

12

14

–

16

–

–

–

–

–

16

–

–

–

16

–

–

–

–

–

–

–

16

–

–

–

35

– 40 +8042

(3)Art. 3.3

Ø[in.]

Ø[mm]

Ø[in.]

Ø[mm]

ODS ODM

Connections

min.

TS [°C]

max.

PS[bar]


to PED

4303/2

4303/2F (2)

–

4303/3

4305/2

4305/2F (2)

–

4305/3

–

–

4308/2

4308/2F (2)

–

4308/3

4308/3F (2)

–

–

–

4308/4

–

4316/2

4316/3

4316/3F (2)

–

–

–

4316/4

–

4316/5

–

4330/3

–

4330/4

–

4330/5

–

4332/4

–

4332/5

–

4341/5

–

4341/6

–

–

–

–

–

–

–

–

–

4303/2S

–

–

–

4305/2S

–

4305/3S

4305/M10S

–

–

4308/2S

–

–

4308/3S

4308/M10S

4308/M12S

–

4308/4S

–

–

–

4316/3S

4316/M10S

4316/M12S

–

4316/4S

–

4316/5S

–

4330/3S

–

4330/4S

–

4330/5S

–

4332/4S

–

4332/5S

–

4341/5S

–

4341/6S

4341/7S

4375/4S

4375/5S

4375/6S

4375/7S

4375/9S

032

–

032S

033

052

–

052S

053

053S

–

082

–

082S

083

–

083S

–

–

084

084S

162

163

–

163S

–

–

164

164S

165

165S

303

303S

304

304S

305

305S

304

304S

305

305S

415

415S

416

416S

417S

754S

755S

756S

757S

759S

47

70

103

155

310

255

330

660

50

80

130

250

500

500

670

1340

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

High water capacity core (1)

96 www.castel.it

TABLE 2: General Characteristics

ThreadedConnections

CatalogueNumber


BlockFilteringSurface

[cm2]

NominalVolume[cm3]

SolderConnections

SAEFlare

1/4"

–

3/8"

1/4"

–

3/8"

–

1/4"

–

3/8"

–

1/2"

–

1/4"

3/8"

–

1/2"

–

5/8"

–

3/8"

–

1/2"

–

5/8"

–

1/2"

–

5/8"

–

5/8"

–

3/4"

–

–

–

–

–

–

–

–

1/4"

–

–

1/4"

–

3/8"

–

1/4"

–

3/8"

–

1/2"

–

–

3/8"

–

1/2"

–

5/8"

–

3/8"

–

1/2"

–

5/8"

–

1/2"

–

5/8"

–

5/8"

–

3/4"

7/8"

1/2"

5/8"

3/4"

7/8"

1.1/8"

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

–

16

–

–

–

–

–

16

–

–

–

16

–

16

–

–

–

–

16

–

–

–

–

3/8"

–

–

3/8"

–

1/2"

–

3/8"

–

1/2"

–

5/8"

–

–

1/2"

–

5/8"

–

3/4"

–

1/2"

–

5/8"

–

3/4"

–

5/8"

–

3/4"

–

3/4"

–

7/8"

1.1/8"

5/8"

3/4"

7/8"

1.1/8"

1.3/8"

–

–

–

–

–

–

–

–

–

–

–

–

16

–

–

–

–

16

–

–

–

–

–

16

–

–

–

16

–

–

–

–

–

–

–

16

–

–

–

35

– 40 +8042

(2)Art. 3.3

Ø[in.]

Ø[mm]

Ø[in.]

Ø[mm]

ODS ODM

Connections

min.

TS [°C]

max.

PS[bar]


to PED

4203/2

–

4203/3

4205/2

–

4205/3

–

4208/2

–

4208/3

–

4208/4

–

4216/2

4216/3

–

4216/4

–

4216/5

–

4230/3

–

4230/4

–

4230/5

–

4232/4

–

4232/5

–

4241/5

–

4241/6

–

–

–

–

–

–

–

–

4203/2S

–

–

4205/2S

–

4205/3S

–

4208/2S

–

4208/3S

–

4208/4S

–

–

4216/3S

–

4216/4S

–

4216/5S

–

4230/3S

–

4230/4S

–

4230/5S

–

4232/4S

–

4232/5S

–

4241/5S

–

4241/6S

4241/7S

4275/4S

4275/5S

4275/6S

4275/7S

4275/9S

032

032S

033

052

052S

053

053S

082

082S

083

083S

084

084S

162

163

163S

164

164S

165

165S

303

303S

304

304S

305

305S

304

304S

305

305S

415

415S

416

416S

417S

754S

755S

756S

757S

759S

47

70

103

155

310

255

330

660

50

80

130

250

500

500

670

1340

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

Anti-acid core (1)

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

TABLE 3: Refrigerant Flow Capacity and Water Capacity

CatalogueNumber

Refrigerant Flow Capacity, pressure drop

0,07 bar (1) [kW]

R134

a

4303/2

4303/2F

4303/2S

4303/3

4305/2

4305/2F

4305/2S

4305/3

4305/3S

4305/M10S

4308/2

4308/2F

4308/2S

4308/3

4308/3F

4308/3S

4308/M10S

4308/M12S

4308/4

4308/4S

4316/2

4316/3

4316/3F

4316/3S

4316/M10S

4316/M12S

4316/4

4316/4S

4316/5

4316/5S

4330/3

4330/3S

4330/4

4330/4S

4330/5

4330/5S

4332/4

4332/4S

4332/5

4332/5S

4341/5

4341/5S

4341/6

4341/6S

4341/7S

4375/4S

4375/5S

4375/6S

4375/7S

4375/9S

6,5

8,0

14,9

6,7

8,2

15,4

19,4

6,9

8,5

18,0

22,8

29,0

24,0

29,0

6,9

19,7

24,6

34,1

28,2

34,1

37,6

45,0

21,7

27,1

30,9

37,3

38,8

46,6

33,6

40,5

39,9

48,2

40,9

49,5

67,2

74,2

53,4

54,5

80,6

92,8

96,5

R22

7,0

8,6

16,1

7,2

8,9

16,6

21,0

7,5

9,2

19,5

24,7

31,3

25,9

31,3

7,5

21,3

26,6

36,9

30,5

36,9

40,6

48,7

23,4

29,3

33,4

40,4

41,9

50,4

36,3

43,8

43,1

52,1

44,2

53,5

72,6

80,2

57,7

58,9

87,1

100,3

104,3

R404

AR5

074,6

5,6

10,5

4,7

5,8

10,8

13,7

4,9

6,0

12,7

16,1

20,4

16,9

20,4

4,9

13,9

17,3

24,0

19,9

24,0

26,4

31,7

15,3

19,0

21,8

26,3

27,3

32,8

23,6

28,5

28,1

33,9

28,8

34,8

47,3

52,2

37,5

38,3

56,8

65,3

67,9

R407

C

6,9

8,5

16,0

7,1

8,8

16,5

20,8

7,4

9,1

19,3

24,5

31,0

25,7

31,0

7,4

21,1

26,4

36,6

30,3

36,6

40,3

48,3

23,2

29,0

33,2

40,0

41,6

50,0

36,0

43,4

42,8

51,7

43,8

53,1

72,0

79,6

57,3

58,4

86,4

99,5

103,5

R410

A

7,0

8,6

16,2

7,2

9,0

16,7

21,2

7,5

9,3

19,6

24,8

31,4

26,0

31,4

7,5

21,4

26,7

37,0

30,6

37,0

40,8

48,9

23,5

29,4

33,5

40,5

41,9

50,6

36,4

44,0

43,0

52,3

44,4

53,7

73,0

80,5

57,9

59,1

87,6

100,6

104,7

Water Capacityat + 25 °C (2) [g H2O]

R134

a

4,1

7,3

12,7

25,1

50,2

45,4

61,4

122,8

R22

3,8

6,7

11,6

22,9

45,8

41,4

56,1

112,2

R404

AR5

07

4,2

7,4

13,0

25,6

51,2

46,4

62,8

125,6

R407

C

3,4

6,0

10,4

20,5

41,0

37,2

50,3

100,6

R410

A

3,7

6,5

11,3

22,3

44,6

40,5

54,7

109,4

Dehydratable Chargeat + 25 °C

[kg refrigerant]

R134

a

4,4

7,8

13,7

27,0

54,0

48,8

66,0

132,0

R22

4,0

7,2

12,5

24,6

49,2

44,5

60,3

120,6

R404

AR5

07

4,5

8,0

13,9

27,5

55,1

49,9

67,5

135,1

R407

C

3,6

6,4

11,2

22,0

44,1

40,0

54,1

108,2

R410

A

3,9

7,0

12,2

24,0

48,0

43,5

58,8

117,6


R134

a

3,5

6,3

10,9

21,6

43,2

39,1

53,0

106,0

R22

3,0

5,3

9,3

18,4

36,8

33,2

45,0

90,0

R404

AR5

07

3,9

6,9

12,0

23,8

47,6

43,1

58,3

116,6

R407

C

2,7

4,8

8,4

16,5

33,0

29,9

40,5

81,0

R410

A

2,9

5,2

9,1

18,0

36,0

32,6

44,1

88,2


[kg refrigerant]

R134

a

3,8

6,8

11,8

23,2

46,5

42,0

57,0

114,0

R22

3,2

5,7

10,0

19,8

39,6

35,7

48,4

96,8

R404

AR5

07

4,2

7,4

13,0

25,6

51,2

46,3

62,7

125,4

R407

C

2,9

5,2

9,0

17,7

35,5

32,2

43,5

87,1

R410

A

3,2

5,6

9,8

19,4

38,7

35,1

47,4

94,8

98 www.castel.it

TABLE 4: Refrigerant Flow Capacity and Water Capacity

CatalogueNumber


0,07 bar (1) [kW]

R134

a

4203/2

4203/2S

4203/3

4205/2

4205/2S

4205/3

4205/3S

4208/2

4208/2S

4208/3

4208/3S

4208/4

4208/4S

4216/2

4216/3

4216/3S

4216/4

4216/4S

4216/5

4216/5S

4230/3

4230/3S

4230/4

4230/4S

4230/5

4230/5S

4232/4

4232/4S

4232/5

4232/5S

4241/5

4241/5S

4241/6

4241/6S

4241/7S

4275/4S

4275/5S

4275/6S

4275/7S

4275/9S

6,5

8,0

14,9

6,7

8,2

15,4

19,4

6,9

8,5

18,0

22,8

24,0

29,0

6,9

19,7

24,6

28,2

34,1

37,6

45,0

21,7

27,1

30,9

37,3

38,8

46,6

33,6

40,5

39,9

48,2

40,9

49,5

67,2

74,2

53,4

54,5

80,6

92,8

96,5

R22

7,0

8,6

16,1

7,2

8,9

16,6

21,0

7,5

9,2

19,5

24,7

25,9

31,3

7,5

21,3

26,6

30,5

36,9

40,6

48,7

23,4

29,3

33,4

40,4

41,9

50,4

36,3

43,8

43,1

52,1

44,2

53,5

72,6

80,2

57,7

58,9

87,1

100,3

104,3

R404

AR5

07

4,6

5,6

10,5

4,7

5,8

10,8

13,7

4,9

6,0

12,7

16,1

16,9

20,4

4,9

13,9

17,3

19,9

24,0

26,4

31,7

15,3

19,0

21,8

26,3

27,3

32,8

23,6

28,5

28,1

33,9

28,8

34,8

47,3

52,2

37,5

38,3

56,8

65,3

67,9

R407

C

6,9

8,5

16,0

7,1

8,8

16,5

20,8

7,4

9,1

19,3

24,5

25,7

31,0

7,4

21,1

26,4

30,3

36,6

40,3

48,3

23,2

29,0

33,2

40,0

41,6

50,0

36,0

43,4

42,8

51,7

43,8

53,1

72,0

79,6

57,3

58,4

86,4

99,5

103,5

R410

A

7,0

8,6

16,2

7,2

9,0

16,7

21,2

7,5

9,3

19,6

24,8

26,0

31,4

7,5

21,4

26,7

30,6

37,0

40,8

48,9

23,5

29,4

33,5

40,5

41,9

50,6

36,4

44,0

43,0

52,3

44,4

53,7

73,0

80,5

57,9

59,1

87,6

100,6

104,7

(1) Maximum values of the refrigerant flow capacity at which the drier can be used when fluid dehydration is not the a major problem,provided that the original moisture is limited before the installation of the drier. The maximum refrigerant flow capacities are referredto a total pressure drop of 0,07 bar, inlet and outlet connections included, (according to ARI STANDARD 710:86 - with condensingtemperature at +30 °C and evaporating temperature at -15 °C)

(2) Water capacity values with R22 are referred to the following conditions, fixed in ARI STANDARD 710:86:- Liquid temperatures: 25 °C and 50 °C- Equilibrium point dryness, EPD: 60 ppmWater capacity values with the other refrigerant fluids are referred to the following conditions, fixed in DIN 8949:2000 Standard:- Liquid temperatures: 25 °C and 50 °C- Equilibrium point dryness, EPD: 50 ppm


R134

a

3,5

6,2

10,8

21,3

42,7

38,6

52,2

104,4

R22

3,2

5,7

9,9

19,5

38,9

35,2

47,7

95,4

R404

AR5

07

3,6

6,3

11,0

21,8

43,5

39,4

53,4

106,8

R407

C

2,9

5,1

8,8

17,4

34,9

31,6

42,8

85,5

R410

A

3,1

5,5

9,6

19,0

37,9

34,4

46,5

93,0


[kg refrigerant]

R134

a

3,8

6,7

11,6

22,9

45,9

41,5

56,1

112,2

R22

3,4

6,1

10,6

20,9

41,9

37,8

51,3

102,5

R404

AR5

07

3,9

6,8

11,9

23,4

46,8

42,4

57,4

114,8

R407

C

3,1

5,5

9,5

18,7

37,5

34,0

46,0

91,9

R410

A

3,4

6,0

10,3

20,4

40,8

37,0

50,0

100,0


R134

a

3,0

5,4

9,3

18,4

36,7

33,2

45,1

90,1

R22

2,6

4,5

7,9

15,6

31,3

28,2

38,3

76,5

R404

AR5

07

3,3

5,9

10,2

20,2

40,5

36,6

49,6

99,1

R407

C

2,3

4,1

7,1

14,0

28,1

25,4

34,4

68,9

R410

A

2,5

4,5

7,7

15,3

30,6

27,7

37,5

75,0


[kg refrigerant]

R134

a

3,3

5,8

10,0

19,7

39,5

35,7

48,4

96,9

R22

2,8

4,9

8,5

16,8

33,6

30,3

41,1

82,3

R404

AR5

07

3,6

6,3

11,0

21,8

43,5

39,4

53,3

106,6

R407

C

2,5

4,4

7,7

15,1

30,2

27,3

37,0

74,0

2,7

4,8

8,3

16,5

32,9

29,8

40,3

80,6

R410

A

L

� D

solder connections


CatalogueNumber

4303/2

4303/2F

4303/2S

4303/3

4305/2

4305/2F

4305/2S

4305/3

4305/3S

4305/M10S

4308/2

4308/2F

4308/2S

4308/3

4308/3F

4308/3S

4308/M10S

4308/M12S

4308/4

4308/4S

4316/2

4316/3

4316/3F

4316/3S

4316/M10S

4316/M12S

4316/4

4316/4S

4316/5

4316/5S

4330/3

4330/3S

4330/4

4330/4S

4330/5

4330/5S

4332/4

4332/4S

4332/5

4332/5S

4341/5

4341/5S

4341/6

4341/6S

4341/7S

4375/4S

4375/5S

4375/6S

4375/7S

4375/9S

4203/2

–

4203/2S

4203/3

4205/2

–

4205/2S

4205/3

4205/3S

–

4208/2

–

4208/2S

4208/3

–

4208/3S

–

–

4208/4

4208/4S

4216/2

4216/3

–

4216/3S

–

–

4216/4

4216/4S

4216/5

4216/5S

4230/3

4230/3S

4230/4

4230/4S

4230/5

4230/5S

4232/4

4232/4S

4232/5

4232/5S

4241/5

4241/5S

4241/6

4241/6S

4241/7S

4275/4S

4275/5S

4275/6S

4275/7S

4275/9S

1/4"

1/4"

–

3/8"

1/4"

1/4"

–

3/8"

–

–

1/4"

1/4"

–

3/8"

3/8"

–

–

–

1/2"

–

1/4"

3/8"

3/8"

–

–

–

1/2"

–

5/8"

–

3/8"

–

1/2"

–

5/8"

–

1/2"

–

5/8"

–

5/8"

–

3/4"

–

–

–

–

–

–

–

–

–

1/4"

–

–

–

1/4"

–

3/8"

–

–

–

1/4"

–

–

3/8"

–

–

–

1/2"

–

–

–

3/8"

–

–

–

1/2"

–

5/8"

–

3/8"

–

1/2"

–

5/8"

–

1/2"

–

5/8"

–

5/8"

–

3/4"

7/8"

1/2"

5/8"

3/4"

7/8"

1.1/8"

–

–

–

–

–

–

–

–

–

10

–

–

–

–

–

–

10

12

–

–

–

–

–

–

10

12

–

–

–

16

–

–

–

–

–

16

–

–

–

16

–

16

–

–

–

–

16

–

–

–

52

73

91

103

92

94

111

119

109

110

127

112

146

135

137

154

142

139

146

162

146

158

166

154

151

158

174

158

183

166

245

230

253

237

262

245

187

173

196

179

231

214

232

219

332

332

332

338

338

240

230

220

235

275

260

295

260

380

345

395

380

345

380

430

380

635

690

680

620

630

640

680

640

740

640

1380

1240

1360

1280

1480

1370

1300

1200

1320

1250

1580

1470

1640

1560

1600

2540

2640

2820

2900

3050

SAEFlare Ø

[in.]Ø

[mm] Ø D L

ODS


Weight [g]

L

� D

male connections

L

� D

male - female connections (female - in)

99www.castel.it

100 www.castel.it

filter, the refrigerant fluid must pass throughthe mesh sieve on which blocks aremounted. The danger that small particles ofdehydrating material being introduced intothe system is thus avoided. Furthermore, atfilter outlet, a plastic cup, the edge of whichclosely adheres to the inner surface of thefilter, prevents dirt from reaching the outletconnection during normal operation andblock change.

The filters type 4410 are manufactured insteel, with the exception of the connectionswhich are made of EN 12735-1 – Cu-DHPcopper tube.The filters type 4420 are completelymanufactured in steel and solderconnection, are machined with a steel barEN 10025 S355JR.The blocks series 4490 and 4491 has beendeveloped for specific installations onrefrigerating systems using HFC refrigerantfluids, particularly R134a, R404A, R407C,R410A ed R507 mixed with polyolesterlubricants. In spite of this, the new blockmay be successfully used also inrefrigerating systems using the old CFC orHCFC refrigerant fluids, mixed with minerallubricants.The blocks 4490, type A and type B, and theblock 4491, type A, are molded from a blendof dehydrating charge, totally made of 3 Åmolecular sieves, and a special bindingagent in appropriate proportions. The choiceof the 3 Å molecular sieves, as soledehydrating material, gives to the block asuperlative capacity of water adsorption alsomaintaining quite good deacidifyingcharacteristics.The blocks 4490, type AA and type AB, andthe block 4491, type AA, are molded from ablend of dehydrating charge, 80% of 3 Åmolecular sieves and 20 % of activatedalumina, and a special binding agent inappropriate proportions. The choice ofblend, molecular sieves – activated alumina,gives to the block a very high capacity ofacid adsorption also maintaining very gooddehydrating characteristics. The presence of a controlled and definedpercentage of activated alumina, lower thanthe maximum value recommended byASERCOM, keeps unchanged the originalconcentration of additives in the polyolesterlubricant.

CONSTRUCTION

FILTER DRIERS WITH REPLACEABLE ANTI-ACID SOLID COREApproved by Underwriters LaboratoriesInc. �Except filters 4423/17A, /21A, /25A and4424/25A, /33A

The filters, shown in this chapter, areclassified “Pressure vessels” in the sense ofthe Pressure Equipment Directive 97/23/EC,Article 1, Section 2.1.1 and are subject ofArticle 3, Section 1.1 of the same Directive.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).

In the case of filters with more than oneblock, the passage of the fluid takes placein parallel; as a result, the pressure dropdoes not increase proportionately to thenumber of blocks. A large ring between theblock and the inner surface of the filterpermits the accumulation of solid particles,and prevents clogging. Before leaving the

OPERATION

APPLICATIONS

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101www.castel.it

The manufacturing process of blocks series4490 and 4491 gives a considerablecompacted ness and stoutness to both theproducts so that they are resistant toshocks and abrasions.The blocks series 4490 have a volume of 48cu.in., equivalent to approx. 800 cm3, and itis used with type 4411, 4412, 4413 and4414 filters.The block series 4491 has a volume of 100cu.in., equivalent to approx. 1600 cm3. andit is used with type 4421, 4423 and 4424filters.The two blocks are shaped as a hollowcylinder and their overall dimensionscorrespond to those of other internationalbrands. Consequently they areinterchangeable. The hollow cylinder shapeoffers a large surface area to the inflowingfluid, which crosses the block in radialsense. As a result, dehydration is highlyefficient with a minimum loss of charge.Filters may be supplied also with an accessfitting kit G9150/R05, to be orderedseparately.


CatalogueNumber

Core FilteringSurface

[cm2]

Number of Cores

Core Cat.Number

Nominal Volume

5/8"

7/8"

1.1/8"

1.3/8"

1.5/8"

–

2.1/8"

7/8"

1.1/8"

1.3/8"

–

2.1/8"

1.3/8"

1.5/8"

–

1.5/8"

–

2.1/8"

2.1/8"

2.5/8"

3.1/8"

3.1/8"

4.1/8"

800

1600

2400

3200

4800

6400

48

96

144

192

300

400

16

22

–

35

–

42

54

22

–

35

42

54

35

–

42

–

42

54

54

–

80

80

–

–

60,3

76,1

88,9

88,9

114,3

– 40 +80

45 (1)

35 (1)

32

I

II

Ø[in.][cm3][cu.in] Ø

[mm]Ø

[mm]

ODS ODM

Connections

min.

TS [°C]

max.

PS[bar]


to PED

4411/5A

4411/7A

4411/9A

4411/11A

4411/13A

4411/M42A

4411/17A

4412/7A

4412/9A

4412/11A

4412/M42A

4412/17A

4413/11A

4413/13A

4413/M42A

4414/13A

4414/M42A

4414/17A

4423/17A

4423/21A

4423/25A

4424/25A

4424/33A

4490/A -

4490/B -

4490/AA

4490/AB

4491/A

4491/AA

1

2

3

4

3

4

420

840

1260

1680

1890

2520

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

5

3

1

2

4

4

outlet

inlet

Sketch of filter with 2 blocks1 – Block2 – Mesh sieve serving as block support3 – Spring4 – Retainer cup5 – Access fitting 1/4” SAE flare (to order separately)

102 www.castel.it

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

CatalogueNumber


0,07 bar (1) [kW]

4411/5A

4411/7A

4411/9A

4411/11A

4411/13A

4411/M42A

4411/17A

4412/7A

4412/9A

4412/11A

4412/M42A

4412/17A

4413/11A

4413/13A

4413/M42A

4414/13A

4414/M42A

4414/17A

4423/17A

4423/21A

4423/25A

4424/25A

4424/33A

83

146

200

233

250

146

226

306

333

327

361

426

447

492

670

737

1180

90

158

216

252

270

158

244

331

361

354

391

460

483

532

725

797

1276

59

103

141

164

176

103

159

215

234

230

254

300

315

346

472

519

830

89

156

214

250

268

156

242

328

357

351

387

456

479

527

719

791

1265

90

159

217

253

271

159

245

332

362

355

393

462

485

534

728

800

1281

R134

a

R22

R404

A

R407

C

R410

A

84

168

252

336

504

672

77

154

231

308

462

616

86

172

258

344

516

688

69

138

207

276

414

552

75

150

225

300

450

600

R134

a

R22

R404

A

R407

C

R410

A

90

181

271

361

542

723

83

166

248

331

497

662

92

185

277

370

555

740

74

148

223

297

445

594

81

161

242

323

484

645

R134

a

R22

R404

A

R407

C

R410

A

72

144

216

288

432

576

61

122

183

244

366

488

80

160

240

320

480

640

56

112

168

224

336

448

60

120

180

240

360

480

R134

a

R22

R404

A

R407

C

R410

A

77

155

232

310

465

619

66

131

197

262

394

525

86

172

258

344

516

688

60

120

181

241

361

482

65

129

194

258

387

516

R134

a

R22

R404

A

R407

C

R410

A



[kg refrigerant]



[kg refrigerant]

(1) Maximum values of the refrigerant flow capacity at which the drier can be used when fluid dehydration is not the a major problem,provided that the original moisture is limited before the installation of the drier. The maximum refrigerant flow capacities are referredto a total pressure drop of 0,07 bar, inlet and outlet connections included, (according to ARI STANDARD 710:86 - with condensingtemperature at + 30 °C and evaporating temperature at -15 °C)

(2) Water capacity values with R22 are referred to the following conditions, fixed in ARI STANDARD 710:86:- Liquid temperatures: 25 °C and 50 °C- Equilibrium point dryness, EPD: 60 ppmWater capacity values with the other refrigerant fluids are referred to the following conditions, fixed in DIN 8949:2000 Standard:- Liquid temperatures: 25 °C and 50 °C- Equilibrium point dryness, EPD: 50 ppm

(3) Maximum values of the refrigerant flow capacity (according to ARI STANDARD 710:86) at which filter driers:- series 4411, 4412, 4413, and 4414 can be used with blocks type 4490/AA and 4490/AB- series 4423 and 4424 can be used with blocks type 4491/AAwhen fluid dehydration is not the a major problem, are the same achieved with block type 4490/A, 4490/B and 4491/A.

TABLE 2B: Refrigerant Flow Capacity and Water Capacity (single block)

CatalogueNumber


0,07 bar (1) [kW]

R134

a

4490/A - 4490/B

4491/A

4490/AA - 4490/AB

4491/AA

–

(3)

84

168

71

143

77

154

65

131

86

172

73

146

69

138

59

117

90

181

77

154

83

166

70

141

92

185

79

157

74

148

63

126

72

144

61

122

61

122

52

104

80

160

68

136

56

112

48

95

77

155

66

132

66

131

56

112

86

12

73

146

60

120

51

102

75

150

64

128

81

161

69

137

60

120

51

102

65

129

55

110

R22

R404

A

R407

C

R410

A

R134

a

R22

R404

A

R407

C

R410

A

R134

a

R22

R404

A

R407

C

R410

A

R134

a

R22

R404

A

R407

C

R410

A

R134

a

R22

R404

A

R407

C

R410

A



[kg refrigerant]



[kg refrigerant]

H3

20H1

H2

P

ØD1

ØD2

DE

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CatalogueNumber

4411/5A

4411/7A

4411/9A

4411/11A

4411/13A

4411/M42A

4411/17A

4412/7A

4412/9A

4412/11A

4412/M42A

4412/17A

4413/11A

4413/13A

4413/M42A

4414/13A

4414/M42A

4414/17A

4423/17A

4423/21A

4423/25A

4424/25A

4424/33A

5/8"

7/8"

1.1/8"

1.3/8"

1.5/8"

–

2.1/8"

7/8"

1.1/8"

1.3/8"

–

2.1/8"

1.3/8"

1.5/8"

–

1.5/8"

–

2.1/8"

2.1/8"

2.5/8"

3.1/8"

3.1/8"

4.1/8"

16

22

–

35

–

42

54

22

–

35

42

54

35

–

42

–

42

54

54

–

80

80

–

–

60,3

76,1

88,9

88,9

114,3

121

163

149

200

148

154

159

171

162

296

300

312

303

442

454

595

586

520

525

693

235

241

246

258

249

383

387

399

390

529

541

682

673

641

646

814

185

324

600

760

90

96

101

113

103

96

101

113

103

101

113

103

143

148

5360

5405

5395

5464

5435

5410

5585

6880

7015

6985

7136

8510

8470

8445

9940

10010

18000

18200

18400

21600

22000

Ø[in.]

Ø[mm]

Ø[mm]

Ø D1 Ø D2 H1 H2 H3 P

ODS W


Weight [g]

104 www.castel.it

Blocks must be ordered separately from thefilter. They are supplied in individualpackages, which are hermetically sealed insuitable wrappings (type 4490), and inspecial bags (type 4491) for safe storageover long periods of time.Every cartridge is equipped of two seals insynthetic material to use like seal betweenthe two cartridges and between thecartridge and its covers.If the filter is installed in a system withoutany by-pass, the block replacement has tobe done following these instructions:

1 Close the valve on the departing line.2 Start the compressor and its auxiliaries in

order to transfer the refrigerant chargeinto the high pressure side of the plant(liquid receiver).

3 Stop the compressor at a suctionpressure sufficiently higher than theatmospheric pressure.

4 Shutt off the service valve at the suctionside of the compressor.NOTE: if during the transfer of therefrigerant to the high-pressure side ofthe plant, the discharge pressures reachtoo high values (the condenser is floodeddue to insufficient capacity of the liquidreceiver), shut off the valve on thecompressor suction side and stopimmediately the compressor.

5 Replace quickly the filter block. Duringthe preparation of the new block, closethe filter with a clean cloth. The slightover-pressure inside the filter and theability of the technician will prevent airfrom getting into the plant.

BLOCKS REPLACEMENT

� D1

� D2

H

4491

H

� D2

� D1

4490

TABLE 4: General Characteristics, Dimensions and Weights

CatalogueNumber


[cm2]

4490/A

4490/B (1)

4490/AA

4490/AB (1)

4491/A

4491/AA

420

630

48

100

800

1600

47

53

96

122

140

165

670

1350

[cu.in] [cm3] Ø D1 Ø D2 H

Weight [g]

Nominal Volume

Dimensions [mm]

(1) Supplied without cover gasket as spare part

6 The internal cleanliness of the body isguaranteed by the cleaning effect of thecup which is characteristic of Castelfilters.if air is supposed to have entered theplant during filter block replacement,produce a vacuum in the low-pressureside of the plant, and always in the sectorof the circuit involved.

7 Open the valve on the departure of liquidline

8 Slowly open the suction valve of thecompressor and start the compressorand its auxiliaries.

9 Top the charge up, if necessary.

With clean systems, refrigerant flowcapacity and pressure drops of table 2 arereported to a gas speed of 20 m/s for pipesadequate to the filter connections. For refrigerant flow capacities different fromthe table values, under the other sameconditions, gas speeds and relativepressure drops through the filter can begained for simple proportionality.

System data:Refrigerant: R407CRefrigerant flow capacity: 130 [kW]Evaporating temperature: + 5 [°C]Suction pipe: Ø 2.1/8”Filter: 4411/17C

In table 2, corresponding to filter type4411/17C refrigerant and evaporatingtemperature, the following data is given:

– refrigerant flow capacity = 141,7 [kW];– pressure drop = 0,21 [bar].

The gas speed in the suction line will be:

[m/s]

Pressure drop through the filter:

[bar]

Remember that the dimensioning of thesuction line in a refrigerating systemrequires great attention. In fact the relative pressure loss, included filter, which implies a reduction offlow capacity sucked by the compressor,influences directly the refrigerating capacityof the plant.This line is normally sized to have a totalpressure loss lower then a variation of thesaturation temperature of 1° C. For example diagram 1, referred to R22,allows to estimate the aforesaid variation infunction of pressure loss and evaporatingtemperature.

€

0,21130

141,70,177

2

2× =

20130

141,716,8

2

2× =

EXAMPLE

SELECTION CRITERION

SUCTION LINEApproved by Underwriters LaboratoriesInc. �Except filters 4421/21C, /25C, /M80C, /33C


Good filtering of the refrigerant on the low-pressure side of the system is a guaranteeof protection for the compressor. Systemcleanliness is ensured by micro filteringcores, which filter out impurities derivedfrom manufacture and assembly of therefrigerating system.

The filters type 4410 are manufactured insteel, with the exception of the connectionswhich are made of EN 12735-1 – Cu-DHPcopper tube.The filters type 4420 are completelymanufactured in steel and solderconnection, are machined with a steel barEN 10025 S355JR.Zinc plated wire cloths and a filtering baffle form the block, which features a large surface, with controlled porosity. The block can stop solid particles up to 20 micron. At the two ends, soft felt gaskets ensure perfect sealing with the plastic cups. Filters are suppliedwith an access fitting kit G9150/R05.

CONSTRUCTION

OPERATION

APPLICATIONS

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MECHANICAL FILTERS WITH REPLACEABLE FILTERINGBLOCK

106 www.castel.it

To such purpose diagram 2 illustrates theexisting relation between saturationtemperature, in the suction line, andvariation of the refrigerant flow capacity of acompressor.

After all it’s always important to rememberthat the refrigerant flow capacity of acompressor, under the other sameconditions, can reduce considerablybecause of the decrease of the saturationtemperature, consequent to the pressureloss in the suction line.


CatalogueNumber


[cm2]

Number of Cores

Core Cat.Number

45 (1)

32

I

Ø[in.]

Ø[mm]

Ø[mm]

ODS W

Connections

min.

TS [°C]

max.

PS[bar]


to PED

4411/7C

4411/9C

4411/11C

4411/13C

4411/M42C

4411/17C

4411/21C

4421/21C

4421/25C

4421/33C

4495/C

4496/C

1

820

1850

7/8"

1.1/8"

1.3/8"

1.5/8"

–

2.1/8"

2.5/8"

2.5/8"

3.1/8"

4.1/8"

22

–

35

–

42

54

–

–

80

–

–

76,1

88,9

114,3

– 40 +80

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

outlet

inlet

3

1

2

2

Sketch of filter with mechanical block1 – Block2 – Retainer cup3 – Spring

DIAGRAM 1

DIAGRAM 2

0 5 10 15 20 25 30 350

1

2

3

4

5

6-45 -40 -35

-30

-25

-20

-15

-10-50

+10

evap

orat

ion te

mpe

ratu

re

Pressure loss (kPa)

Equ

ival

ent v

aria

tion

of th

e sa

tura

tion

tem

pera

ture

0

0,5

1

1,5

2

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

Cor

rect

ion

fact

or o

f ref

riger

ant

flow

cap

acity

Saturation temperature at the suction (°C)

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108 www.castel.it

TABLE 2: Refrigerant Flow Capacity and Pressure Drop

CatalogueNumber Refrigerant


[bar][kW][bar][kW][bar][kW][bar][kW][bar][kW]

-30-20-100+5

4411/7C

4411/9C

4411/11C

4411/13C

4411/M42C

4411/17C

4411/21C

4421/21C

4421/25C

4421/33C

R134a

R22

R404A

R407C

R410A

R134a

R22

R404A

R407C

R410A

R134a

R22

R404A

R407C

R410A

R134a

R22

R404A

R407C

R410A

R134a

R22

R404A

R407C

R410A

R134a

R22

R404A

R407C

R410A

R134a

R22

R404A

R407C

R410A

R134a

R22

R404A

R407C

R410A

R134a

R22

R404A

R407C

R410A

13,7

21,5

20,0

19,0

31,7

23,0

36,4

34,0

32,1

53,7

35,0

55,0

51,4

48,6

81,0

50,0

79,0

73,5

69,5

116,0

87,0

137,0

128,0

121,1

202,0

133,5

211,0

197,0

186,4

311,0

133,5

211,0

197,0

186,4

311,0

191,0

302,0

281,0

266,0

446,0

334,0

528,0

491,0

468,0

780,0

0,070

0,100

0,130

0,090

0,200

0,074

0,110

0,140

0,100

0,210

0,075

0,110

0,140

0,100

0,210

0,090

0,130

0,170

0,120

0,250

0,140

0,190

0,270

0,180

0,370

0,250

0,360

0,480

0,330

0,700

0,100

0,150

0,200

0,140

0,300

0,180

0,260

0,340

0,230

0,500

0,540

0,770

1,000

0,690

1,400

9,0

15,6

14,0

12,8

23,0

15,0

26,0

24,0

21,3

38,0

23,0

39,0

36,2

33,2

57,0

33,0

56,0

51,7

47,5

82,0

57,2

97,0

90,0

82,6

143,0

87,5

149,0

138,6

127,0

220,0

87,5

149,0

138,6

127,0

220,0

125,0

213,0

198,0

182,0

315,0

218,0

372,0

346,0

320,0

550,0

0,048

0,074

0,090

0,060

0,140

0,051

0,080

0,100

0,066

0,150

0,052

0,080

0,100

0,068

0,150

0,062

0,090

0,120

0,080

0,180

0,100

0,150

0,190

0,125

0,290

0,180

0,270

0,330

0,210

0,520

0,070

0,110

0,130

0,090

0,200

0,120

0,190

0,220

0,150

0,370

0,360

0,570

0,660

0,440

1,200

6,0

10,8

9,0

8,4

16,0

10,0

18,0

15,0

14,2

26,0

15,0

27,0

22,7

21,9

40,0

21,4

39,0

32,4

31,3

57,0

37,3

66,4

56,5

54,4

98,0

57,0

102,0

87,0

83,7

150,0

57,0

102,0

87,0

83,7

150,0

81,5

146,0

124,0

119,7

215,0

142,0

255,0

217,0

210,0

377,0

0,033

0,052

0,060

0,043

0,100

0,035

0,056

0,070

0,047

0,110

0,036

0,056

0,070

0,047

0,110

0,043

0,064

0,080

0,056

0,120

0,070

0,100

0,130

0,087

0,250

0,120

0,180

0,230

0,150

0,350

0,050

0,074

0,100

0,060

0,150

0,090

0,130

0,170

0,100

0,250

0,270

0,390

0,500

0,300

0,800

3,5

7,2

6,0

5,1

10,6

6,0

12,0

10,0

8,7

17,7

9,0

18,0

14,5

13,4

26,0

13,0

26,0

20,7

19,2

38,0

22,4

44,0

36,0

33,4

65,0

34,3

68,0

55,5

51,4

100,0

34,3

68,0

55,5

51,4

100,0

49,0

97,0

79,3

73,5

143,0

85,0

170,0

138,7

129,0

251,0

0,021

0,037

0,040

0,028

0,100

0,022

0,040

0,050

0,031

0,110

0,023

0,040

0,050

0,031

0,110

0,027

0,046

0,060

0,037

0,100

0,040

0,070

0,100

0,057

0,200

0,070

0,120

0,170

0,100

0,240

0,030

0,050

0,070

0,040

0,100

0,050

0,090

0,120

0,070

0,200

0,150

0,270

0,360

0,200

0,530

0,084

0,120

0,150

0,100

0,230

0,091

0,130

0,160

0,110

0,250

0,092

0,130

0,160

0,110

0,250

0,110

0,150

0,200

0,136

0,300

0,170

0,230

0,310

0,210

0,440

0,300

0,420

0,550

0,380

0,810

0,120

0,170

0,220

0,160

0,340

0,210

0,300

0,390

0,270

0,600

0,630

0,900

1,170

0,790

1,800

17,0

26,0

23,7

22,2

38,4

28,7

43,0

40,0

37,6

63,5

43,5

65,0

60,7

57,0

96,0

62,0

93,0

86,8

81,4

137,0

108,3

162,0

151,3

141,7

239,0

167,0

249,0

232,7

218,0

368,0

167,0

249,0

232,7

218,0

368,0

238,0

356,0

332,0

312,0

526,0

416,0

623,0

581,0

547,0

921,0

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

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109www.castel.it

H3

H2

H1

P

20

ØD2

ØD1

H

� D1

� D2

4495 - 4496

TABLE 4: General Characteristics Dimensions and Weights

CatalogueNumber

4495/C

4496/C

127

287

820

1850

60

80

87

113

138

168

480

750

[sq.in] [cm2] Ø D1 Ø D2 H

Filtering Surface

Dimensions [mm]

Weight [g]


CatalogueNumber

4411/7C

4411/9C

4411/11C

4411/13C

4411/M42C

4411/17C

4411/21C

4421/21C

4421/25C

4421/33C

7/8"

1.1/8"

1.3/8"

1.5/8"

–

2.1/8"

2.5/8"

2.5/8"

3.1/8"

4.1/8"

22

–

35

–

42

54

–

–

80

–

–

76,1

88,9

114,3

121

163

149

200

154

159

171

162

186

187

192

241

246

258

249

273

308

313

185

200

96

101

113

103

128

143

148

5450

5375

5435

5410

5585

6030

12000

12200

12500

Ø[in.]

Ø[mm]

Ø[mm]

Ø D1 Ø D2 H1 H2 H3 P

ODS W


Weight [g]

110 www.castel.it

L

� D

4520

L

� D

4510

The filter is completely manufactured insteel, either with nickel-plated Flarethreaded connections. The product rangealso includes types with copper platedsolder connections, offering the possibilityto solder the copper pipe inside theconnections (ODS) or outside theconnections, using a copper sleeve (ODM).Inside the filters there is a screen basket,with wide filtering surface, made ofaustenitic stainless steel AISI 304.These filters may not be cleaned.

CONSTRUCTION


APPLICATIONS

For using on refrigerating systems, Castelputs the following desiccants at disposal ofits own customers:• Activated alumina Code No 4901/AA• Molecular sieve Code No 4901/MS• Silicagel Code No 4901/SG

hermetically sealed in steel cans with aweight of about 0,750 kg and supplied inmultiply package of 15 cans.

STRAINERS

DESSICCANTS


CatalogueNumber

UsefulPassageSurface

[%]

MeshOpening

[mm]

Kv Factor[m3/h]

Filtering Surface

[cm2] SAEFlare

3/8"

1/2"

–

–

–

–

–

–

–

–

3/8"

–

–

1/2"

5/8"

–

–

–

–

10

12

–

16

18

–

–

1/2"

–

–

5/8"

3/4"

–

–

–

–

12

14

16

–

22

– 40 +80 42 Art. 3.3

Ø[in.]

Ø[mm]

Ø[in.]

Ø[mm]

ODS ODM

Connections

min.

TS [°C]

max.

PS[bar]


to PED

4510/3

4510/4

4520/3

4520/M10

4520/M12

4520/4

4520/5

4520/M18

58

142

58

142

36,6 0,166

2,4

3,2

2,4

3,4

8,0


CatalogueNumber

4510/3

4510/4

4520/3

4520/M10

4520/M12

4520/4

4520/5

4520/M18

52

76

52

76

110

174

109

113

122

126

170

195

515

195

205

215

245

495

Ø D L

Dimensions [mm]

Weight [g]

111

OIL SEPARATORS

112 www.castel.it

– separators series 5540 are closed typeand they cannot be dismantled from thesystem, except cutting the piping.

The body is manufactured from steel pipe ofadequate thickness. Flanges and cover arealso made of steel. Either threaded connections of separators series 5520 or solderconnections of separators series 5540 aremanufactured, machining, with steel bar EN 10277-3 11S Mn Pb 37 + C.

The internal device is simple in order toassure a trouble-free long operation.Appropriate metallic screens, placed on theinlet and outlet, rapidly reduce gas speed,and create the conditions required for theseparation of the oil from the refrigerant. A float operated needle valve, set on thebottom of the vessel, return the oil to thecrankcase of compressor. The bottom alsoincludes a chamber that collects all metallicdebris. A permanent magnet holds theseimpurities to avoid they stop or damage theoperation of needle, moved by floating.

The oil separators, shown in this chapter,are classified “Pressure vessels” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.1 and aresubject of Article 3, Section 1.1 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).The advantages of the oil separator on thedischarge line of a compressor in arefrigeration system are confirmed by manyyears of experience. The oil separatorintercepts the oil mixed with compressedgas and returns it to the crankcase of thecompressor thus assuring an efficientlubrication of its moving parts. Furthermore,the oil separator maintains a high coefficientof condenser and evaporator performanceby almost completely removing oil depositsfrom their exchange surfaces. When a veryhigh temperature at the end of thecompression stage leads to the formation ofoil vapours, a separator with a capacityexceeding the values shown in the tableshould be used. Moreover, the oil separator,damping the valves pulsations, reducessystem noise with an open or semi-hermeticcompressor.Finally, the use of an oil separator leads to:– a longer life of the compressor;– a better performance of the whole system

with consequent energy saving;– a quieter operation by reducing

pulsations.Table 1 and 3 show the technical datarelating to the working conditions of oilseparators.

Castel manufactures two types of oilseparators:– separators series 5520 can be overhauled

for maintenance and can be replacedfrom the system. They are equipped withthreaded connections, which can mate tothe connections type 5590 (to be orderedseparately)

CONSTRUCTION

APPLICATIONS

OIL SEPARATORS

113www.castel.it

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

[m/s] with:

– S = gross cross section of shell separator [m2]

The oil separators type 5520 and 5540should be installed in the discharge linebetween the compressor and thecondenser mounted securely in a verticalposition and reasonably close to thecompressor.To prevent the return of refrigerant fromcondenser, during the off cycle of thesystem, it’s advisable to install a checkvalve between the condenser and oilseparator outlet connection.Oil separator performs best when operatingat or near the compressor dischargetemperature. In location the oil separator,choose a position to avoid, as far aspossible, chilling of the shell, which mayresult in condensing of liquid within theseparator. If this is not possible, it isadvisable to supply the separator with thebetter solutions (insulation, strap heater,others) to prevent the refrigerant in thesystem from condensing in the shell. Before the oil separator is installed, eitherone 5520 or one 5540, an initial charge ofoil should be added to it. Refer to generalcharacteristics of oil separators or toinstruction sheet for the proper amount ofoil. Oil pre-charge is very important, failureto pre-charge separator sump may result indamage to the oil return float mechanism.Use the same type of oil that is in thecompressor crankcase.Acting as the lay out of refrigeratingsystem, the return line may be run from theoil fitting to:– the compressor crankcase;– the suction line upstream the compressor

or upstream the receiver, if present;– the oil reservoir if oil control system is

being used.

A sight glass may be installed in the oil line,in a position that oil is flowing through thetube, to check the correct working of the oilseparator.

INSTALLATION

v QS=The selecting of an oil separator should be

done comparing the characteristics of theinstalled compressor, establishing:– inlet connection must agree with the

discharge diameter of the compressor– refrigerant flow capacity with fixed

working conditions (saturated dischargetemperature saturated suctiontemperature, eventually liquid subcooling,sucked vapour overheating).

This is necessary to define the gas speedreferred to the cross section of oil separator,assigned an end compression temperature.It is advisable the above-mentioned speeddoesn’t exceed 0,5 m/s, to avoid great swirlphenomena.Table 3 has being written following thisprinciple.Generally, fixed the following data:refrigerating capacity of compressor, type ofrefrigerant and working conditions, thevolumetric capacity Q, of compressed gas,is given by:

[m3/s] with:

– P = refrigerant flow capacity kW]– ∆H = heat content differential, see

diagram (fig. 1). [kJ/kg]– vg = specific volume of compressed gas,

separator inlet (fig. 1). [m3/kg].

QPH

vg= ×∆

SELECTING THE SIZE OF AN OIL SEPARATOR

OIL S

EPA

RA

TO

RS

Fig. 1

5540

IN OUT

5520

IN OUT

stainlesssteel needle

screen cylinderinlet

stainless steel ball

magnetpermanent

outletscreen cylinder

steel plate

oil return tube

screen cylinderinlet

stainless steel ball

stainlesssteel needle

outletscreen cylinder

steel plate

oil return tube

magnetpermanent

114 www.castel.it


CatalogueNumber Catalogue

Number

Max.differentialpressure

[bar]

Oil addition

[kg]

Oil connection[SAE Flare]

1/2"

5/8"

7/8"

1.1/8"

1.3/8"

1.5/8"

–

2.1/8"

–

16

–

–

35

–

42

54

5/8"

3/4"

1"

1.3/8"

1.5/8"

–

–

–

16

–

–

35

–

–

–

–

–

16

–

–

35

–

42

1/4"

3/8"

1/4"

0,4 / 0,5

0,6 / 0,7

0,4 / 0,5

21

–

5590/5

5590/7

5590/9

5590/11

5590/13

5590/M42

–

5/8"

7/8"

1.1/8"

1.3/8"

1.5/8"

–

– 10 + 130 32

I

II

I

Ø[in.]

Ø[mm]

Ø[in.]

Ø[mm]

Ø[in.]

Ø[mm]

ODS ODM ODS (1)

Solder Connections Couple of solder connectionsIN / OUT

min.

TS [°C]

max.

PS[bar]


to PED

5540/4

5540/5

5540/7

5540/9

5540/11

5540/13

5540/M42

5540/17

5520/C

5520/D

5520/E

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

–

–

–

115www.castel.it

OIL S

EPA

RA

TO

RS


Separator

Catalogue Number

Connections

5540/4

5540/5

5540/7

5540/9

5540/11

5540/13

5540/M42

5540/17

5520/C

5520/D

5520/E

–

5590/5

5590/7

5590/9

5590/11

5590/13

5590/M42

1/2"

5/8"

7/8"

1.1/8"

1.3/8"

1.5/8"

–

2.1/8"

5/8"

7/8"

1.1/8"

1.3/8"

1.5/8"

–

–

16

–

–

35

–

42

54

16

–

–

35

–

42

–

149

17,5

–

336

391

–

61

67

92

280

367

428

471

481

397

458

483

123

163,5

121

4200

4960

5030

5835

5800

10000

10460

6980

7760

7680

Ø[in.]

Ø[mm]

Ø D1 Ø D2 H1 H2 H3 H4

ODS

Solder Connections Dimensions [mm]

Weight[g]

H2

H4

H4

H1

H1

H3

� D2

� D1

M10

� D1

M10

5520 5540

Gasket

5590/..

116 www.castel.it

TABLE 3: Refrigerant Flow Capacity

CatalogueNumber

CatalogueNumberof solder

connections

Refrigerant Capacity (1) [kW]

–20 + 5 –40 + 5 –40 + 5 –40 + 5

R134a


R22 R404A R407C

5540/4

5540/5

5540/7

5540/9

5540/11

5540/13

5540/M42

5540/17

5520/C

5520/D

5520/E

–

5590/5

5590/7

5590/9

5590/11

5590/13

5590/M42

5,3

16,4

18,6

21,2

23,9

33,1

42,5

16,4

18,6

21,2

23,9

26,5

6,1

18,9

21,3

24,3

27,4

38,0

48,8

18,9

21,3

24,3

27,4

30,4

6,4

19,7

22,2

25,4

28,6

39,6

50,9

19,7

22,2

25,4

28,6

31,8

7,9

24,5

27,7

31,5

35,6

49,3

63,4

24,5

27,7

31,5

35,6

39,5

6,4

19,9

22,5

25,7

28,9

40,1

51,5

19,9

22,5

25,7

28,9

32,1

8,8

27,3

30,8

35,2

39,6

54,9

70,6

27,3

30,8

35,2

39,6

44,0

6,0

18,6

21,0

24,6

27,0

37,6

48,3

18,6

21,0

24,6

27,0

30,0

8,0

24,6

27,8

31,8

35,8

49,6

63,7

24,6

27,8

31,8

35,8

40,0

(1) Refrigerant flow capacity with a condensing temperature of + 40°C and normal overheating values of vapoursucked by compressor. No liquid subcooling.

Maximum pressure drop of 0,15 bar

117

VALVES

H1

L2

H2

6010/2

32

I

� 4

.5

118 www.castel.it

– three-ways valves; two main connectionsplus a third one for charging or manometerconnection, types:– 6060 with right access connection;– 6070 with left access connection.

On both types, the access connection maybe shut off by the back-seating of thespindle.

The main parts of the hermetic valves aremade with the following materials:– hot forged brass EN 12420 – CW 617N



fibers for gland seal;– glass reinforced PBT for cap that covers

the spindle.

The hermetic valves, shown in this chapter,are classified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).

These valves are available in the followingtwo types:– two-ways shut-off valves types 6010/2

and 6012/22;

CONSTRUCTION

APPLICATIONS

HERMETIC VALVES


CatalogueNumber

Kv Factor[m3/h]

–

1/4"

1/4"

1/4"

1/4"

3/8"

1/2"

5/8"

1/4"

3/8"

1/4"

3/8"

3/8"

1/2"

5/8"

1/4"

–

1/4"

3/8"

1/2"

5/8"

–

–

1/4"

–

–

6

10

6

8

10

12

16

0,27

0,39

1,20

2,20

2,80

0,46

1,38

0,46

1,29

1,38

2,55

3,40

-60

+4,5+130

+110

45 Art. 3.3

(1) (2) (3) Ø[in.]

Ø[mm]

SAE Flare ODS (4)

Connections

min.

TS [°C]

max.

PS[bar]


to PED

6010/2

6012/22

6020/222

6020/233

6020/244

6020/255

6060/22M6

6060/23M10

6070/22M6

6070/23M8

6070/23M10

6070/24M12

6070/25M16

L1

H4

H2H

3

I

H1

� 4

.5

M106070

L3

L1

L2

SSS

H2

H1

L2

L1

6012/22

4 2

12

3

L2

L3

L1

P1

H1

H3

H2

H5

M8

11

6060

D

2

1

P1

H1

H3

H2

H5

11

M8

2

1

6020

4

4

VALV

ES

119www.castel.it


CatalogueNumber

H1 H2 H3 H4 H5 I L1 L2 L3 P1

Dimensions [mm]

Weight [g]

6010/2

6012/22

6020/222

6020/233

6020/244

6020/255

6060/22M6

6060/23M10

6070/22M6

6070/23M8

6070/23M10

6070/24M12

6070/25M16

14

25

26,5

25,5

29,5

66

51

52

31

33

31

33

38,5

39,5

–

61

68,5

56,5

58,5

56,5

59

68

69

–

115

127

–

–

1

36

–

–

29

62

67

77

79

24

27

24

27

28

58

55,5

–

34

37

34

37

43,5

–

92

91

92

90

102

–

30,5

32,5

160

145

360

370

520

530

205

200

205

210

220

310

320

120 www.castel.it

These valves are available in the followingtwo types:– two-ways valves, 90° angle connections,

types 6110 and 6120;– three-ways valves; two main connections

(90° angle) plus a third one for charging,type 6132. The access connection maybe shut off by the back-seating of thespindle;

– two-ways valves, 120° angle connections,type 6140.

The main parts of the receiver valves aremade with the following materials:

– hot forged brass EN 12420 – CW 617Nfor body;

– steel, with proper surface protection, forthe spindle;

– chloroprene rubber (CR) and aramidicfibers for gland seal;

– glass reinforced PBT for cap that coversthe spindle.

CONSTRUCTION

The receiver valves, shown in this chapter,are classified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2 of Directive 97/23/EC andreferred to in Directive 67/548/EEC).

APPLICATIONS

RECEIVER VALVES


CatalogueNumber

Kv Factor[m3/h]

–

1/4" f

–

3/8" f

–

1/4"

–

1/4"

1/4"

1/4"

1/4"

3/8"

3/8"

3/8"

1/2"

1/2"

5/8"

3/4"

1/4"

1/4"

3/8"

1/2"

1/2"

5/8"

3/4"

1/4"

3/8"

1/2"

5/8"

1/4"

1/4"

1/8"

1/4"

–

3/8"

1/4"

3/8"

–

3/8"

1/2"

1/2"

3/4"

1/4"

3/8"

3/8"

3/8"

1/2"

1/2"

3/4"

1/4"

3/8"

1/2"

1/2"

1/4"

3/8"

0,44

0,45

1,35

2,40

3,40

6,00

0,44

0,45

1,35

2,40

3,40

6,00

0,45

1,20

2,20

3,85

0,36

-60

+130

+110

+130

45 Art. 3.3

(1) (2) (3)

SAE Flare NPT

Connections

min.

TS [°C]

max.

PS[bar]


to PED

6110/21

6110/22

6110/X15

6110/23

6110/32

6110/33

6110/X13

6110/43

6110/44

6110/54

6110/66

6120/22

6120/23

6120/33

6120/43

6120/44

6120/54

6120/66

6132/22

6132/33

6132/44

6132/54

6140/22

6140/23

H1

H2

L1

2

3

6110

L1

L2

H1

NPT

2

3

6120

H1

L2

L1

NPT

3

2

6140

L2L1

H1

H2

1

2

3 NPT

6132

NPT

H2

H1

L1

6110/X136110/X15

1

2

VALV

ES

121www.castel.it


CatalogueNumber

6110/21

6110/22

6110/X15

6110/23

6110/32

6110/33

6110/X13

6110/43

6110/44

6110/54

6110/66

6120/22

6120/23

6120/33

6120/43

6120/44

6120/54

6120/66

6132/22

6132/33

6132/44

6132/54

6140/22

6140/23

70,5

72

83

77

87

88

92

128

27,5

30

33

40

56

63,5

57

48

50

55,5

88

–

29

36

–

27,5

29

31

34,5

42,5

72

77

80

93

94

130

94

97

112

115

69

–

48

50

55,5

88

64

75

46

100

110

130

135

130

140

175

220

235

245

675

110

130

140

225

305

245

670

240

250

375

365

115

125

H1 H2 L1 L2

Dimensions [mm]

Weight [g]

122 www.castel.it

The main parts of the stop valves are madewith the following materials:– hot forged brass EN 12420 – CW 617N

for body;– brass EN 12164 – CW 614N for spindle

and protection cap;– chloroprene rubber (CR) for outlet seal

gaskets for series 6165 and 6175;– chloroprene rubber (CR) and aramidic

fibers for gland seal, only for series 6170.

The stop valves, shown in this chapter, areclassified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).

The very compact design of these brassvalves allows minimum dimensional sizesand the fixing flange complies with currentmarket requirements.Valves 6170 and 6175 must be completedwith the following devices, to be orderedseparately:– valve code 8394/A or code 8394/B;– cap with gasket code 8392/A.

CONSTRUCTION

APPLICATIONS

STOP VALVES


CatalogueNumber

Kv Factor[m3/h]

2

3

–

1/4"

1/4"

3/8"

3/8"

1/2"

5/8"

3/4"

7/8"

1/4"

3/8"

3/8"

1/2"

5/8"

3/4"

7/8"

–

16

–

0,68

1,70

1,70

3,40

4,60

9,00

10,80

-20 +110 45 Art. 3.3

Way Nr.

(1) (2) Ø[in.]

Ø[mm]

SAE Flare ODS (3)

Connections

min.

TS [°C]

max.

PS[bar]


to PED

6165/22

6165/33

6175/33

6175/44

6175/55

6170/66

6170/77

VALV

ES

123www.castel.it


CatalogueNumber

H1 H2 H3 Ø D L1 L2 L3 I

Dimensions [mm]

Weight [g]

6165/22

6165/33

6175/33

6175/44

6175/55

6170/66

6170/77

17

20

28,5

52

65

104

8

12

9,5

12,7

15,9

19

22,2

28,6

29

30,5

36

47

–

29

31

36

–

59,5

67

83

38

50

113

120

135

225

235

655

670

I I

L2

L3

H3

L1

H1

H2

L1

H3

H1

H2

�D�D

6170

6165 6175

� 6

.5

� 6

.5

2 2

3 3

1

124 www.castel.it

Diaphragm valves don’t have gland seal.The external sealing is ensured by somethin metal discs (diaphragms), whichhermetically divide the spindle chamberfrom the fluid flow area.


for body;– brass EN 12164 – CW 614N for spindle;– harmonic steel for spring;– nylon for seat sealing gaskets.

CONSTRUCTION

The diaphragm valves, shown in thischapter, are classified “Pressureaccessories” in the sense of the PressureEquipment Directive 97/23/EC, Article 1,Section 2.1.4 and are subject of Article 3,Section 1.3 of the same Directive.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).

APPLICATIONS

DIAPHRAGM VALVES


CatalogueNumber

Kv Factor[m3/h]

1/4"

3/8"

1/2"

5/8"

3/4"

–

–

–

1/4"

3/8"

1/2"

5/8"

3/4"

7/8"

–

16

–

0,28

1,00

1,30

1,80

3,65

0,28

1,00

1,30

1,80

3,65

-35 +90 28 Art. 3.3

Ø[in.]

Ø[mm]

SAE Flare(1)

ODS (2)

Connections

min.

TS [°C]

max.

PS[bar]


to PED

6210/2

6210/3

6210/4

6210/5

6210/6

6220/2

6220/3

6220/4

6220/5

6220/6

6220/7

VALV

ES

125www.castel.it


Catalogue Number

6210/2

6210/3

6210/4

6210/5

6210/6

6220/2

6220/3

6220/4

6220/5

6220/6

6220/7

68

72

86

68

72

86

53,5

62,5

53,5

62,5

58

74

78

98

53

61

70

71

92

94

4,5

6,2

4,5

6,2

36

38

50

36

38

50

52

60

52

60

200

325

335

340

655

195

300

305

580

645

H1 H2 L1 d I D

Dimensioni [mm]

Weight [g]

D

L1

d

H1

H2

I

D

H2

H1

d

L1

I

A94 A94

2 2

6210 6220

1 1

6310

Valves

6320

7990

Gasket

7910

Coupling

126 www.castel.it





the spindle;– steel bar EN 10277-3 11 S Mn Pb 37 for

7910 fittings;– P.T.F.E. for 7990 gaskets.

The rotalock valves, shown in this chapter,are classified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).

Rotalock valves, mounted with 7910 fittingsand 7990 gaskets, assure fast installationand safe sealing.Before tightening it is possible to turn thevalve in every direction.All Rotalock valves have an additionalcharging connection, which can beexcluded by the back sealing of the spindle.Fittings 7910 and gaskets 7990 have to beordered separately.

CONSTRUCTION

APPLICATIONS

ROTALOCK VALVES


CatalogueNumber

Kv Factor[m3/h]

1/4"

1/4"

3/8"

1/2"

3/8"

1/2"

5/8"

3/4"

3/4"

UNF

1"

UNS

0,46

1,35

1,40

3,10

3,4

-60 +110 45 Art. 3.3

(1) (2) (3)

SAE Flare Swivel nut

Connections

min.

TS [°C]

max.

PS[bar]


to PED

6310/2

6310/3

6310/4

6320/3

6320/4

6320/5

6320/6

L2

L1

H1

H2

6310 6320

12

3

VALV

ES

127www.castel.it


CatalogueNumber

6310/2

6310/3

6310/4

6320/3

6320/4

6320/5

6320/6

68,5

69,5

72

33,5

34,5

36,5

94

97

114,5

117,5

64

77,5

290

300

330

400

415

425

H1 H2 L1 L2

Dimensions [mm]

Weight [g]

128 www.castel.it

The brazing of capped valves with solderconnections, type 6420, should be carriedout with care, using a low melting point fillermaterial. It‘s necessary to remove thespindle assembly, with gland too, beforebrazing the body. It’s important to avoiddirect contact between the torch flame andthe valve body, which could be damagedand compromise the proper functioning ofthe valve.

INSTALLATION

The capped valves, shown in this chapter,are classified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).

The main parts of the capped valves aremade with the following materials:– hot forged brass EN 12420 – CW 617N




the spindle.

CONSTRUCTION

APPLICATIONS

CAPPED VALVES


CatalogueNumber

Kv Factor[m3/h]

1/4"

3/8"

1/2"

5/8"

3/4"

–

1/4"

–

1/4"

–

1/4"

3/8"

–

1/2"

5/8"

–

3/4"

–

7/8"

–

–

10

12

–

16

18

–

22

–

0,40

1,00

1,45

1,70

3,50

0,40

1,00

1,45

1,70

3,50

0,35

-60 +110 45 Art. 3.3

Ø[in.]

Ø[mm]

SAE Flare

(2)(1)

ODS (3)

Connections

min.

TS [°C]

max.

PS[bar]


to PED

6410/2

6410/3

6410/4

6410/5

6410/6

6420/2

6420/3

6420/M10

6420/M12

6420/4

6420/5

6420/M18

6420/6

6420/M22

6420/7

6460/22A E

Until exhaustion of the stockE

L1

d

L1

H2

H1

I

d

IH

1H

2

A94 A94

L3

L1

45°

d

L2

I

P1

H1

H2

A

C

B

1 1

1

1

2

3 3

6410 6420 6460/22A

VALV

ES

129www.castel.it


CatalogueNumber

H1 H2 L1 L2 L3 P1 d I

Dimensions [mm]

Weight [g]

6410/2

6410/3

6410/4

6410/5

6410/6

6420/2

6420/3

6420/M10

6420/M12

6420/4

6420/5

6420/M18

6420/6

6420/M22

6420/7

6460/22A

85,5

113

85,5

113

85,5

67

89,5

67

89,5

67

68

74

78

98

57

61

70

71

92

94

97

–

34

–

51

–

35

4,5

6,2

4,5

6,2

4,5

38

50

38

50

38

305

325

330

695

300

305

700

685

690

395

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

These valves are available in the followingtwo types:– 6512 with straight solder connections;– 6532 with solder angle connections;The main parts of the globe valves aremade with the following materials:– hot forged brass EN 12420 – CW 617N

for body, cover and cap that covers thespindle;

– steel, with proper surface protection, forthe spindle;

– chloroprene rubber (CR) and aramidicfibers for gland seal;

– metal-rubber laminated for outlet sealgaskets

– P.T.F.E. for seat gaskets.

CONSTRUCTION

The globe valves, shown in this chapter,are classified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of thesame Directive.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section2.2 of Directive 97/23/EC and referred to inDirective 67/548/EEC).

APPLICATIONS

GLOBE VALVES


CatalogueNumber

Kv Factor[m3/h]

–

7/8"

–

1.1/8"

1.3/8"

1.5/8"

–

2.1/8"

–

7/8"

–

1.1/8"

1.3/8"

1.5/8"

–

2.1/8"

22

–

28

–

35

–

42

54

22

–

28

–

35

–

42

54

–

1.1/8"

1.3/8"

1.3/8"

1.5/8"

2"

2"

–

–

1.1/8"

1.3/8"

1.3/8"

1.5/8"

2"

2"

–

28

–

35

35

–

–

–

–

28

–

35

35

–

–

–

–

7,1

8,4

15,0

25,0

40,00

8,2

9,1

18,7

38,0

48,5

-35 +160 45

Art. 3.3

I

Art. 3.3

I

Ø[in.]

Ø[mm]

ODS

Ø[mm]

Ø[in.]

ODM

Connections

min.

TS [°C]

max.

PS[bar]


to PED

6512/M22

6512/7

6512/M28

6512/9

6512/11

6512/13

6512/M42

6512/17

6532/M22

6532/7

6532/M28

6532/9

6532/11

6532/13

6532/M42

6532/17

130 www.castel.it

H1

L1

L

H

A

Q

6532

H1

H

L

M10

A

Q

6512


CatalogueNumber

6512/M22

6512/7

6512/M28

6512/9

6512/11

6512/13

6512/M42

6512/17

6532/M22

6532/7

6532/M28

6532/9

6532/11

6532/13

6532/M42

6532/17

136

166

199

215

147

165

238

28,5

34

37

42,5

44,5

52,5

65

100

118

141

173

80

93

139

–

50

59

86,5

60

68

88

104

60

68

104

94

126

138

94

126

138

1415

1310

2020

3500

5050

1350

1290

1910

4920

4765

H H1 L L1 Q A

Dimensions [mm]

Weight [g]

VALV

ES

131www.castel.it

132 www.castel.it

BALL VALVES

6590

The ball valves, shown in this chapter, areclassified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and on civiland industrial conditioning plants, which userefrigerant fluids proper to the Group II (asdefined in Article 9, Section 2.2 of Directive97/23/EC and referred to in Directive67/548/EEC).

The specific design of Castel ball valves:– ensures the internal equilibrium of

pressures when the valve is closed;– permits the bi-directional flow of the

refrigerant and, consequently, theassembly on the plant without taking intoaccount the direction of the refrigerant;

– prevents any risk of ejection or explosionof the spindle.

The opening and closing of the valve isrealized by turning the spindle one fourth of aturn. A standstill in turning realizes either afull opening or a full closing, moreover thearrow printed on the spindle head shows theflow direction.The electric welding of the bodies and theseal gaskets, assembled on the spindle,

CONSTRUCTION

APPLICATIONS prevent any leaks.Ball valves are available in the following twotypes:– type 6590 (full port) and type 6591

(reduced port) without access fitting.– type 6590/A (full port) and type 6591/A

(reduced port) with access fitting. These ball valves are equipped with valvecore 8394/A and cap 8392/A.


for body;– hot forged brass EN 12420 – CW 617N,

chromium plated, for ball;– copper tube EN 12735-1 – Cu-DHP for

solder connections;– steel, with proper surface protection, for

the spindle;– chloroprene rubber (CR) for outlet seal

gaskets;– P.T.F.E. for seat ball gaskets;– glass reinforced PBT for cap that covers

the spindle. Hot forged brass EN 12420 –CW 617N for caps on sizes from6590/M64A up to 6591/34A.

The brazing of ball valves should be carriedout with care, using a low melting point fillermaterial. It is important to avoid direct contactbetween the torch flame and the valve body,which could be damaged and compromisethe proper functioning of the valve.

INSTALLATION

VALV

ES

133www.castel.it


withoutaccessfitting

withaccess fitting

Catalogue Number

Kv Factor[m3/h]

–

1/4"

3/8"

–

–

1/2"

5/8"

–

5/8"

–

3/4"

7/8"

7/8"

–

1.1/8"

–

1.1/8"

1.3/8"

1.3/8"

1.5/8"

–

1.5/8"

–

2.1/8"

2.1/8"

–

2.5/8"

–

2.5/8"

3"

3.1/8"

3.1/8"

3.1/2"

3.5/8"

4.1/8"

4.1/4"

6

–

–

10

12

–

16

15

16

18

–

22

22

28

–

28

–

35

35

–

42

–

42

54

54

64

–

64

–

80

89

–

105

108

10

15

19

25

32

38

50

65

80

0,8

3,0

5,0

14,5

24,0

40,0

68,0

100,0

178,0

293,0

430

-40 +150

45

42

Art. 3.3

I

Ø[in.]

Ø[mm]

Ball PortØ [mm]

ODS

Connections

min.

TS [°C]

max.

PS[bar]


to PED

6590/M6

6590/2

6590/3

6590/M10

6590/M12

6590/4

6591/5

6590/M15

6590/5

6590/M18

6590/6

6591/7

6590/7

6591/M28

6591/9

6590/M28

6590/9

6591/11

6590/11

6591/13

6591/M42

6590/13

6590/M42

6591/17

6590/17

6591/M64

6591/21

–

–

6590/3A

6590/M10A

6590/M12A

6590/4A

–

6590/M15A

6590/5A

6590/M18A

6590/6A

–

6590/7A

–

6590/M28A

6590/9A

–

6590/11A

–

6590/13A

6590/M42A

–

6590/17A

6591/M64A

6591/21A

6590/M64A

6590/21A

6591/24A

6591/25A

6590/25A

6591/28A

6591/29A

6591/33A

6591/34A

134 www.castel.it

L2

H2

L1

L

d

I

H1

H

6590/..A


CatalogueNumber

H H1 H2 L L1 L2 I d

Dimensions [mm]

Weight [g]

–

6590/3A

6590/M10A

6590/M12A

6590/4A

–

6590/M15A

6590/5A

6590/M18A

6590/6A

–

6590/7A

6591/M28

–

6590/M28A

6590/9A

–

6590/11A

–

6590/13A

6590/M42A

–

6590/17A

6591/M64A

6591/21A

6590/M64A

6590/21A

6591/24A

6591/25A

6590/25A

6591/28A

6591/29A

6591/33A

6591/34A

6590/M6

6590/2

6590/3

6590/M10

6590/M12

6590/4

6591/5

6590/M15

6590/5

6590/M18

6590/6

6591/7

6590/7

6591/M28

6591/9

6590/M28

6590/9

6591/11

6590/11

6591/13

6591/M42

6590/13

6590/M42

6591/17

6590/17

6591/M64

6591/21

–

73

80

95,5

101,5

117

130

150

172,5

196,5

20

24

27,5

–

30

38

45

55

62

75

–

33

–

36

–

38

–

41

–

45

–

48

–

53

64

70

121

138

141

177

175

206

206

248

247

262

292

303

330

350

380

400

65

73,5

74

92

93

108,5

109

130

129

136

151

162

175

185

199

209

–

24

–

32

–

33

–

43

–

49

–

49

–

58

58

68

76

86

18

30

75

M5

M6

M10

260

300

290

410

450

760

800

1050

2050

3320

3240

5450

5500

8120

8090

8310

8350

12400

12450

12500

8320

Ch.19

8321

H1

34

Ø 6.5

L1

L3

L2

H1Ø 6.5

L3

L2

L1

34

VALV

ES

135www.castel.it

The valves are equipped with:– a little flange for fixing the valve to the

control panel;– a SAE-Flare connection for joining it to

the copper tube;– an NPT (type 8320) or a swivel SAE FLare

(8321) connection for mounting thegauge.

The main parts of this valve are made withthe following materials:– Hot forged brass EN 12420 – CW 617N

for body;– Steel, with proper surface protection, for

the spindle;– Chloroprene rubber (CR) and aramidic

fibers for gland seal;– Glass reinforced PBT for cap that covers

the spindle.

CONSTRUCTION

GAUGE MOUNTING VALVES

TABLE 1: General Characteristics, Dimensions and Weight

CatalogueNumber

1/4"

1/4"

1/4"

1/8"

1/4"

–

19

37

40

-60 +130 45 Art. 3.3

H1SAEFlare NPT

–

–

1/4" f

SAEFlare


min.

TS [°C]

max.

PS[bar]


to PED

8320/21

8320/22

8321/22

83

L1

35

L2

17

L3

140

186

Peso[g]

The valves, shown in this chapter, areclassified “Pressure accessories” in thesense of the Pressure Equipment Directive97/23/EC, Article 1, Section 2.1.4 and aresubject of Article 3, Section 1.3 of the sameDirective.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC). They are used formounting and intercepting the gauges oncontrol panels.

APPLICATIONS

136 www.castel.it

The main parts of the piercing valve aremade with the following materials:– Hot forged brass EN 12420 – CW 617N

for body;– Hardened steel for the needle;– Chloroprene rubber (CR) for the outlet

seal gaskets.

The threaded fork must be installed astrideof the copper tube, the valve is fastened tothe pipe by tightening the lower nut andscrewing it the needle pierces the pipe. Thehole, pierced by the needle, connects thepipe inlet with the SAE-Flare connection asshown in figures 1 and 2.

INSTALLATION

CONSTRUCTION

The valve, shown in this chapter, is classified“Pressure accessories” in the sense of thePressure Equipment Directive 97/23/EC,Article 1, Section 2.1.4 and are subject ofArticle 3, Section 1.3 of the same Directive.It is designed for installation on commercialrefrigerating systems and on civil andindustrial conditioning plants, which userefrigerant fluids proper to the Group II (asdefined in Article 9, Section 2.2 of Directive97/23/EC and referred to in Directive67/548/EEC).The piercing valve is a fast and cheap meansof providing a loading, outlet or inlet point inthe refrigerating system. It can be applied oncopper tube with a 6 mm to 10 mm diameter,and can be installed in any position on thesystem.

APPLICATIONS

LINE PIERCING VALVE

TABLE 1: General Characteristics, Dimensions and Weight

CatalogueNumber

1/4" 6 - 10 72 -10 +70 25 Art. 3.3

H1SAEFlare

Pipe diameter

[mm]


min.

TS [°C]

max.

PS[bar]


to PED

8330/A 25,5

L1

29

L2

36

L3

104

Weight[g]

L2

L1

H2

H1

open

ed v

alve

1/4"SAE flareFig. 1 - The valve is installed with the threaded forkastride of the copper pipe to be pierced.

Fig 2 - Tightening of lower screw nut.

137

THREADED BRASS FITTINGS

138 www.castel.it

connection/adapter system only interposingthe copper gasket 7580, supplied with thesame adapter.Flange joints 7630 consist of two brassbushes for brazing to the copper tubes.When the four flange screws are tightened,a gasket, put between the two bushes,assures the seal of flanged joints.

All nuts, from series 7010 to series 7050,and all the elbows, TEE and cross fittings,from series 7210 to series 7410, aremanufactured with hot forged brass EN 12420 – CW 617N.All straight fittings, from series 7110 toseries 7170, and all the plug, from series7510 to series 7520, are machined by brassbar EN 12164 – CW 614N.Seal caps series 7560 and gaskets series 7580 are made with copper Cu – ETP UNI 5649.The main parts of the flanges joints aremade with the following materials:– hot forged brass EN 12420 – CW 617N

for bushes and flanges;– aramidic fibers for seal gasket of the

flanges.

CONSTRUCTION

All the fittings, shown in this chapter, areexcluded from the scope of Directive97/23/EC, as specified in the Guidelines 1/8and 1/9, because they are pipingcomponents.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).

The sealing system between the end of amale connection and a nut series 7010,7020 and 7030 requires a special flaring ofthe end of copper tube, the so-called flaredconnection.The sealing system between the end of amale connection and a Flare-ODS adapterallows avoiding the flaring process oncopper tube end (national laws of someEuropean countries don’t accept thisoperation) because the tube end is brazedinto the solder connection of the adapter. We wish to remember to our customers thatthey may assure no leakage of the male

OPERATION

APPLICATIONS

THREADED BRASS FITTINGS

L

� D

Ch

TH

RE

AD

ED

BR

AS

S FIT

TIN

GS

139www.castel.it


CatalogueNumber


SAE Flare Ø

[in]Ø

[mm]

PS [bar]

Ø D L Ch

Copper pipe Dimensions [mm]Wrenchtorque

min / max[Nm]

Weight[g]

7010/22

7010/33

7010/44

7010/55

7010/66

7010/77

7010/88

NS4–4

NS4–6

NS4–8

NS4–10

NS4–12

NS4–14

NS4–16

1/4"

3/8"

1/2"

5/8"

3/4"

7/8"

1"

1/4"

3/8"

1/2"

5/8"

3/4"

7/8"

1"

6

–

–

16

–

22

–

45

6,5

9,7

13

16,2

19,4

22,5

25,6

15,5

19,5

22,5

25

29,5

36,5

36,5

17

22

25

28

33

41

11 / 14

20 / 25

34 / 47

54 / 75

68 / 71

90 /120

120 / 150

19

38

49

64

97

186

153

SAE Flare nuts (inch tubing)

L

Ch

7020/20

7020/X01

N5–4

CAP NUT

N5-5

CAP NUT

1/4"

5/16"

cieco cieco 45 –

15,5

16

17

19

11 / 14

14 / 20

20

25

SAE Flare cap nuts

L

� D

Ch

7020/32

7020/43

7020/54

7020/65

7020/87

NRS4–64

NRS4–86

NRS4–108

NRS4–1210

NRS4–1614

3/8"

1/2"

5/8"

3/4"

1"

1/4"

3/8"

1/2"

5/8"

7/8"

6

–

–

16

22

45

6,5

9,7

13

16,2

22,5

19,5

22,5

25

29,5

36,5

22

25

28

33

41

11 / 14

20 / 25

34 / 47

54 / 75

90 /120

38

53

69

104

160

SAE Flare reducing nuts (inch tubing)

L

� D

Ch

7030/3M8

7030/3M10

7030/4M10

7030/4M12

7030/4M14

7030/5M12

7030/5M14

7030/6M14

7030/6M18

–

3/8"

1/2"

5/8"

3/4"

–

8

10

10

12

14

12

14

14

18

45

8,3

10,3

10,3

12,3

14,3

12,3

14,3

14,3

18,3

19,5

22,5

25

29,5

22

25

28

33

20 / 25

34 / 47

54 / 75

68 / 71

37

36

53

50

47

70

68

106

98

SAE Flare nuts (metric tubing)

L

Ch

7050/2

7050/3

7050/4

7050/5

US4–4

US4–6

US4–8

US4–10

1/4"

3/8"

1/2"

5/8"

45 –

32

40

46

51

17

22

25

28

11 / 14

20 / 25

34 / 47

54 / 75

39

78

105

140

SAE Flare twin nuts

– –

140 www.castel.it

L

Ch


CatalogueNumber


SAE Flare NPT

PS [bar]

L Ch


Weight[g]

7110/2

7110/3

7110/4

7110/5

7110/6

7110/8

U2–4

U2–6

U2–8

U2–10

U2–12

U2–16

1/4"

3/8"

1/2"

5/8"

3/4"

1"

– 45

38

44

50

58

63

72

12

17

20

23

27

36

23

46

73

113

164

304

SAE Flare unions

L

Ch

1/4" x 3/8"

1/4" x 1/2"

3/8" x 1/2"

3/8" x 5/8"

1/2" x 5/8"

5/8" x 3/4"

– 45

42

45

48

52

54

61,5

17

20

23

23

27

38

58

66

89

98

170

Reducing SAE Flare unions

L

Ch

7130/2

7130/3

7130/4

7130/6

7130/8

U1–4B

U1–6C

U1–8D

U1–12F

U1–16H

1/4"

3/8"

1/2"

3/4"

1"

1/4"

3/8"

1/2"

3/4"

1"

45

38,1

41,2

49,8

57,6

68

14

17

22

27

36

32

48

92

152

277

SAE Flare / NPT unions

L

Ch

7140/21

7140/32

7140/43

7140/54

U1–4A

U1–6B

U1–8C

U1–10D

1/4"

3/8"

1/2"

5/8"

1/8"

1/4"

3/8"

1/2"

45

32,9

41,1

45,2

53,8

12

17

20

23

20

39

64

102

SAE Flare / NPT reducing unions

Available on request

Until exhaustion of the stockE

R

7120/23

7120/24

7120/34

7120/35

7120/45

7120/56

UR2–64

UR2–84

UR2–86

UR2-106

UR2–108

UR2-1210

E

R

R

R

TH

RE

AD

ED

BR

AS

S FIT

TIN

GS

141www.castel.it

L

L

L

L

L

L

Ch

Ch

Ch

Ch

Ch

Ch


CatalogueNumber

InternationalReference SAE Flare ODS

m fNPT GAS

Ø[in.]

Ø[mm]

PS [bar]

L Ch


Weight[g]

7150/21

7150/32

7150/43

7150/54

7150/64

7150/65

U3–4A

UR3–46

UR3–68

UR3–810

UR3–812

UR3–1012

1/4"

3/8"

1/2"

5/8"

5/8"

3/4"

–

1/4"

3/8"

1/2"

1/2"

5/8"

1/8" f

–– – – 45

29

33

38

45

46,5

49,5

14

17

22

25

27

30

21

38

66

99

132

157

Male/female reducing unions (reduced female)

7150/23

7150/24

7150/34

7150/45

7150/46

7150/56

UR3–64

UR3–84

UR3–86

UR3–108

UR3–128

UR3–1210

1/4"

1/4"

3/8"

1/2"

1/2"

5/8"

3/8"

1/2"

1/2"

5/8"

3/4"

3/4"

– – – – 45

33

36

39

44

45

49

22

25

30

34

49

66

74

127

140

150

Male/female reducing unions (reduced male)

7154/2

7156/2

–

1/4"

1/4"

20 – 14 filetti sx. femmina

W 21,8 – 14 filetti dx. femmina

45 29

25

27

46

52

Cylinder adaptors

7160/2

7160/3

7160/4

R –

1/4"

3/8"

1/2"

1/4"

3/8"

1/2"

– – – – 45

30,5

36

41

17

22

25

31

57

84

Male/female unions

7164/2

7166/2

–

1/4"

–

–

1/4"

–

G1/4"

f

G1/4"

m

– – 45

32,5

32

20

17

45

25

Unions SAE Flare to BSP

7170/22

7170/2M8

7170/33

7170/3M10

7170/44

7170/4M12

7170/55

7170/6M18

US3–44

–

US3–66

–

US3–88

–

US3–1010

–

1/4"

3/8"

1/2"

5/8"

3/4"

– – –

1/4"

–

3/8"

–

1/2"

–

5/8"

–

–

8

–

10

–

12

16

18

45

26,5

33

35

42

45,5

12

17

20

23

27

17

39

55

82

123

Male SAE Flare/solder unions

Available on requestR

Copper seal

Copper pipe

Flare/ODS fitting

Nut Connection

SAE/Flare connection

L1L4 L3

L2

POS.3

142 www.castel.it


Item

Po

sitio

n

CatalogueNumber SAE

Flare

ODS

Ø[in.]

Ø[mm]

PS [bar]

L1 L2 L3 L4 Ch


Weight [g]

Wrenchtorque

min/max[Nm]

1

2

3

1

2

3

1

2

3

1

2

3

1

2

3

1

2

3

1

2

3

1

2

3

1

2

3

9900/X58

9900/X62

7580/2

9900/X58

9900/X70

7580/2

9900/X59

9900/X63

7580/3

9900/X59

9900/X71

7580/3

9900/X60

9900/X64

7580/4

9900/X60

9900/X72

7580/4

9900/X61

9900/X65

7580/5

9900/X68

9900/X69

7580/6

9900/X68

9900/X77

7580/6

1/4"

1/4"

3/8"

3/8"

1/2"

1/2"

5/8"

3/4"

3/4"

1/4"

–

3/8"

–

1/2"

–

5/8"

3/4"

–

–

6

–

10

–

12

16

–

18

45

–

21

–

21

–

23,5

–

23,5

–

26

–

–

26

–

27,5

–

30

–

30

–

3,5

–

3,5

–

4

–

4

–

4,5

–

–

4,5

–

5

–

5

–

5

16

–

–

16

–

–

18,5

–

–

18,5

–

–

21

–

–

21

–

–

22,5

–

–

25

–

–

25

–

–

12,5

–

12,5

–

14,7

–

14,7

–

17

–

–

17

–

18

–

20

–

20

–

17

–

17

–

22

–

22

–

27

–

–

27

–

30

–

36

–

36

–

67

83

114

130

207

226

271

404

455

11/14

–

11/14

–

20/25

–

20/25

–

34/47

–

34/47

–

54/75

–

68/71

–

68/71

–

Flare / ODS adapters

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H

L


CatalogueNumber

InternationalReference SAE Flare

m fNPT

PS [bar]

H L


Weight[g]

7210/2

7210/3

7210/4

7210/5

7210/6

E2–4

E2–6

E2–8

E2–10

E2–12

1/4"

3/8"

1/2"

5/8"

3/4"

– – 45

26

29,5

32,5

36

42,5

26

29,5

32,5

36

42,5

29

49

83

116

192

SAE Flare elbows

L

H

7220/2

7220/3

7220/4

7220/6

E1–4B

E1–6C

E1–8D

E1–12F

1/4"

3/8"

1/2"

3/4"

–

1/4"

3/8"

1/2"

3/4"

45

26

29,5

32,5

42,5

24

28,5

32

39,5

33

54

91

183

SAE Flare / NPT elbows

L

H

7230/21

7230/32

7230/43

7230/54

E1–4A

E1–6B

E1–8C

E1–10D

1/4"

3/8"

1/2"

5/8"

–

1/8"

1/4"

3/8"

1/2"

45

26

29,5

32,5

36

21

29,5

31

35

30

46

75

114

SAE Flare / reduced NPT elbows

H

L

7240/2

7240/3

7240/4

–

1/4"

3/8"

1/2"

1/4"

3/8"

1/2"

– 45

28,5

32

39,5

28

31

38

56

84

198

Male/female SAE Flare elbows

144 www.castel.it


CatalogueNumber

InternationalReference SAE Flare

(1) (2) (3) (4)

NPT(3)

PS [bar]

H L


Weight[g]

H

L

7310/2

7310/3

7310/4

7310/5

7310/6

T2–4

T2–6

T2–8

T2–10

T2–12

1/4"

3/8"

1/2"

5/8"

3/4"

1/4"

3/8"

1/2"

5/8"

3/4"

1/4"

3/8"

1/2"

5/8"

3/4"

– – 45

23,5

29

31,5

36

41,5

47

58

63

72

83

32

69

97

153

235

SAE Flare TEE

H

L

7320/223

7320/334

7320/445

7320/556

TR2–46

TR2–68

TR2–810

TR2–1012

1/4"

3/8"

1/2"

5/8"

1/4"

3/8"

1/2"

5/8"

3/8"

1/2"

5/8"

3/4"

– – 45

29

32,5

38

41,5

56

63

72

83

77

95

153

228

SAE Flare reducing TEE (reduced side connections)

H

L

7320/332

7320/443

7320/554

7320/665

TR2–64

TR2–86

TR2–108

TR2–1210

3/8"

1/2"

5/8"

3/4"

3/8"

1/2"

5/8"

3/4"

1/4"

3/8"

1/2"

5/8"

– – 45

28

32,5

38

41,5

58

63

72

83

77

101

158

220

SAE Flare reducing TEE (reduced central connection)

H

L

7330/221

7330/222

T1–4A

T1–4B

1/4"

1/4"

1/4"

1/4"

– –

1/8"

1/4"

45

28,5

39,5

28

38

56

198

SAE Flare / NPT TEE (taper central connection)

H

L

7340/222 T6–4 1/4" 1/4" 1/4" – – 45 27,5 56 78

Male/female SAE Flare TEE (female central connection)

H

L

7410/2 C1–4 1/4" 1/4" 1/4" 1/4" – 45 52 52 55

SAE Flare cross


CatalogueNumber

InternationalReference SAE

Flare NPTODS

Ø[in.]

Ø[mm]

PS [bar]

H L Ch

Connections Dimensions [mm]Wrenchtorque

min / max[Nm]

Weight[g]

L

Ch

7520/1

7520/2

7520/3

7520/4

7520/6

7520/8

121–B–02

121–B–04

121–B–06

121–B–08

121–B–12

121–B–16

–

1/8"

1/4"

3/8"

1/2"

3/4"

1"

– – 45 –

15,9

23,1

23,2

29,8

32,1

39

12

14

17

22

27

34

10 / 13

15 / 20

17 / 22

25 / 35

30 / 40

60 / 80

12

27

43

87

149

279

NPT plugs

L

Ch

7510/2

7510/3

7510/4

P2–4

P2–6

P2–8

1/4"

3/8"

1/2"

– – – 45 –

23

26

30

12

17

20

11 / 14

20 / 25

34 / 47

19

40

67

SAE Flare plugs

7560/2

7560/3

7560/4

7560/5

7560/6

7560/7

B1–4

B1–6

B1–8

B1–10

B1–12

B1–14

1/4"

3/8"

1/2"

5/8"

3/4"

7/8"

– – – 45 – – – –

0,5

1

1,5

2

4

10

Copper seal caps

7580/2

7580/3

7580/4

7580/5

7580/6

B2–4

B2–6

B2–8

B2–10

B2–12

1/4"

3/8"

1/2"

5/8"

3/4"

– – – 45 – – – –

0,5

0,5

1

1,5

3

Copper gaskets

L

H H 7630/7

7630/9

7630/11

7630/13

7630/M42

7630/17

– – –

7/8"

1.1/8"

1.3/8"

1.5/8"

–

2.1/8"

–

–

35

–

42

54

45

23

24

25

63

67

71

–

20 / 24

42 / 50

68 / 80

315

490

1045

1340

1940

Flange joints

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147

COPPER BRAZE-JOINT PRESSURE FITTINGS

148 www.castel.it

Reinforced series 79 show the followingselection of copper braze-joint fittings, withODS / IDS millimeters connections, limitedto some dimensions:– 7900 Female to female couplings– 7902 Female to female reducing

couplings– 7903 Male to female reducing couplings– 7916 45° female to female elbows– 7917 45° male to female elbows– 7918 90° female to female elbows –

long radius– 7919 90° male to female elbows –

long radius– 7932 Tees and reducing tees

Dimensions and tolerances of the ODS / IDSconnections ends in copper braze-jointfittings series 77, 78 and 79 are incompliance with the EN 1254-1 : 1998Standard.All copper braze-joint fittings series 77, 78and 79 are made of seamless copper tubeEN 12735-2 – CW024A, soft annealed.Technical characteristics of copper fittingsseries 77 and 78, depending on tubenominal diameters, are given in table 1,while technical characteristics of copperfittings series 79, always depending onnominal diameters, are given in table 2.Copper braze-joint fittings series 77, 78 and79, if submitted to ambient-temperatureburst test, guarantee a pressure strength atleast equal to 3 x PS (30 °C rated working-pressure as shown in tables 1 and 2)according to ASME B16.50 : 2001 Standard.

CONSTRUCTION

All the fittings, shown in this chapter, areexcluded from the scope of Directive97/23/EC, as specified in the Guidelines 1/8and 1/9, because they are pipingcomponents.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,made of seamless copper tube specified inEN 12735-1 : 2001 Standard, which userefrigerant fluids proper to the Group II (asdefined in Article 9, Section 2.2 of Directive97/23/EC and referred to in Directive67/548/EEC).

Series 77 show the following selection ofcopper braze-joint fittings, with ODS / IDSmillimeters connections, practically in alldiameter dimensions:– 7700 Female to female couplings– 7702 Female to female reducing

couplings– 7703 Male to female reducing couplings– 7708 90° female to female elbows –

short radius– 7709 90° male to female elbows –

short radius– 7716 45° female to female elbows– 7717 45° male to female elbows– 7718 90° female to female elbows –

long radius– 7719 90° male to female elbows –

long radius– 7732 Tees and reducing tees

Series 78 show a the following selection ofcopper braze-joint fittings, with ODS / IDSinch connections, limited to few diameterdimensions:– 7832 Tees and reducing tees

PRODUCTS RANGE

APPLICATIONS

COPPER BRAZE-JOINT PRESSURE FITTINGS

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The internal working pressure-temperaturerating for a copper fitting, is dependentupon, not only fitting strength, but also theadopted joining process and the used fillermetal. The working pressure-temperaturevalues given in tables 1 and 2 are referred toa brazing process, performed in accordancewith the sound engineering practice.We wish to remember the definition ofbrazing process, given in EN 13133 : 2000Standard.“The process of joining generally applied tothe joining of materials by a heating processduring which the parent materials do notmelt and the filler metal is drawn into thejoint by capillary action. It is generallyapplicable to joining systems where the fillermetal melts at 450 °C or above”.In actual practice brazing is done attemperatures ranging from 630 to 820 °Cand there are two general types of brazingfiller metals, normally used for joiningcopper tube:– Copper – Phosphorus alloys (the so

called B-CuP), proper to CP Class of EN1044 : 1999 Standard, that are normallyused without fluxes;

– Silver alloys (the so called B-Ag), properto AG Class of EN 1044 : 1999, that mustbe used with their specific fluxes.

INSTALLATION TABLE 1

Tube Nominal Diameter

6

–

8

–

10

12

–

14

15

16

18

22

–

28

–

35

–

42

54

64

–

67

76

–

80

89

106

–

1/4"

–

3/8"

–

–

1/2"

–

–

5/8"

–

7/8"

1"

–

1.1/8"

1.3/8"

1.5/8"

–

2.1/8"

–

2.5/8"

–

–

3.1/8"

–

3.1/2"

–

90

90

70

60

60

50

50

45

45

45

40

40

35

30

30

30

25

25

20

20

20

20

18

18

18

18

15

72

72

56

48

48

40

40

36

36

36

32

32

28

24

24

24

20

20

16

16

16

16

14

14

14

12

12

63

63

49

42

42

35

35

32

32

32

28

28

24

21

21

21

18

18

14

14

14

14

13

13

13

11

11

[mm] [in.] -40 / 30 °C 95 °C 150 °C

Working Pressure PS [bar],depending on temperature

TABLE 2

Tube Nominal Diameter

22

3/4

28

3/4

35

3/4

42

54

7/8”

1”

3/4

1.1/8”

1.3/8”

1.5/8”

3/4

2.1/8”

60

55

50

50

50

40

40

35

80

73

67

67

67

53

53

47

50

45

40

40

40

35

35

30

[mm] [in.] (1) (2) (1)

67

60

53

53

53

47

47

40

45

41

37

37

37

30

30

26

60

55

49

49

49

40

40

35

(2) (1)

-40 / 30 °C 150 °C 95 °C

(2)

Working Pressure PS [bar], depending on temperature

(1) PS values listed in this column are referred to a safetycoefficient 4, according to ASME B16.50 : 2001 Standard

(2) PS values listed in this column are referred to a safetycoefficient 3, minimum value warranted by Castel for all itsproducts

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

150 www.castel.it


International Code

Catalog Number IDS

Ø[mm]

ODSØ

[mm]

Weight [g] Note

Connections

7700/M6

7700/M8

7700/M10

7700/M12

7700/M14

7700/M16

7700/M18

7700/M22

7700/M28

7700/M35

7700/M42

7700/M54

7700/M76

7700/M89

5270/6

5270/8

5270/10

5270/12

5270/14

5270/16

5270/18

5270/22

5270/28

5270/35

5270/42

5270/54

5270/76

5270/89

– –

6

8

10

12

14

16

18

22

28

35

42

54

76

89

6

8

10

12

14

16

18

22

28

35

42

54

76

89

2

3

4

5

8

8

13

20

39

71

89

138

220

350

Female to female couplings (metric tubing)

7702/M10.6

7702/M10.8

7702/M12.8

7702/M12.10

7702/M14.10

7702/M14.12

7702/M16.10

7702/M16.12

7702/M16.14

7702/M18.12

7702/M18.16

7702/M22.12

7702/M22.14

7702/M22.16

7702/M22.18

7702/M28.12

7702/M28.18

7702/M28.22

7702/M35.22

7702/M35.28

7702/M42.28

7702/M42.35

7702/M54.35

7702/M54.42

7702/M67.54

7702/M76.54

5240/10.6

5240/10.8

5240/12.8

5240/12.10

5240/14.10

5240/14.12

5240/16.10

5240/16.12

5240/16.14

5240/18.12

5240/18.16

5240/22.12

5240/22.14

5240/22.16

5240/22.18

5240/28.12

5240/28.18

5240/28.22

5240/35.22

5240/35.28

5240/42.28

5240/42.35

5240/54.35

5240/54.42

5240/67.54

5240/76.54

– –

10

10

12

12

14

14

16

16

16

18

18

22

22

22

22

28

28

28

35

35

42

42

54

54

67

76

6

8

8

10

10

12

10

12

14

12

16

12

14

16

18

12

18

22

22

28

28

35

35

42

54

54

3

6

6

8

9

9

12

9

11

12

13

22

19

23

23

34

29

33

56

56

66

88

166

160

246

314

Female to female reducing couplings (metric tubing)

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International Code

Catalog Number IDS

Ø[mm]

ODSØ

[mm]

Weight [g] Note

Connections

7703/M8.6

7703/M10.6

7703/M10.8

7703/M12.6

7703/M12.8

7703/M12.10

7703/M14.10

7703/M14.12

7703/M16.10

7703/M16.12

7703/M16.14

7703/M18.10

7703/M18.12

7703/M18.14

7703/M18.16

7703/M22.12

7703/M22.14

7703/M22.16

7703/M22.18

7703/M28.12

7703/M28.14

7703/M28.16

7703/M28.18

7703/M28.22

7703/M35.18

7703/M35.22

7703/M35.28

7703/M42.22

7703/M42.28

7703/M42.35

7703/M54.28

7703/M54.42

7703/M67.42

7703/M67.54

7703/M76.42

7703/M80.42

7703/M106.54

5243/8.6

5243/10.6

5243/10.8

5243/12.6

5243/12.8

5243/12.10

5243/14.10

5243/14.12

5243/16.10

5243/16.12

5243/16.14

5243/18.10

5243/18.12

5243/18.14

5243/18.16

5243/22.12

5243/22.14

5243/22.16

5243/22.18

5243/28.12

5243/28.14

5243/28.16

5243/28.18

5243/28.22

5243/35.18

5243/35.22

5243/35.28

5243/42.22

5243/42.28

5243/42.35

5243/54.28

5243/54.42

5243/67.42

5243/67.54

5243/76.42

5243/80.42

5243/106.54

8

10

10

12

12

12

14

14

16

16

16

18

18

18

18

22

22

22

22

28

28

28

28

28

35

35

35

42

42

42

54

54

67

67

76

80

106

– –

6

6

8

6

8

10

10

12

10

12

14

10

12

14

16

12

14

16

18

12

14

16

18

22

18

22

28

22

28

35

28

42

42

54

42

42

54

2

3

3

3

6

4

8

5

9

9

8

12

9

11

8

23

20

20

21

32

31

33

29

32

50

65

50

90

102

93

125

146

197

246

270

306

784

= 7700/M6

= 7700/M8

= 7702/M10.6

= 7702/M10.8

= 7700/M10

= 7702/M12.10

= 7700/M12

= 7702/M14.10

= 7702/M14.12

= 7700/M14

= 7702/M16.10

= 7702/M16.12

= 7702/M16.14

= 7700/M16

Male to female reducing couplings (metric tubing)

152 www.castel.it


International Code

Catalog Number IDS

Ø[mm]

ODSØ

[mm]

Weight [g] Note

Connections

7708/M6

7708/M8

7708/M14

7708/M16

7708/M18

7708/M22

7708/M28

7708/M35

7708/M42

7708/M54

5090/6

5090/8

5090/14

5090/16

5090/18

5090/22

5090/28

5090/35

5090/42

5090/54

– –

6

8

14

16

18

22

28

35

42

54

6

8

14

16

18

22

28

35

42

54

4

5

12

13

22

34

56

119

163

298

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

7709/M16

7709/M18

7709/M22

7709/M28

7709/M35

7709/M42

7709/M54

5092/16

5092/18

5092/22

5092/28

5092/35

5092/42

5092/54

16

18

22

28

35

42

54

– –

16

18

22

28

35

42

54

18

26

34

67

114

184

304

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

7716/M16

7716/M18

7716/M22

7716/M28

7716/M35

7716/M54

7716/M80

5041/16

5041/18

5041/22

5041/28

5041/35

5041/54

5041/80

– –

16

18

22

28

35

54

80

16

18

22

28

35

54

80

16

21

35

61

119

231

740

45° female to female elbows (metric tubing)

7717/M22

7717/M28

7717/M35

7717/M42

7717/M54

7717/M80

5040/22

5040/28

5040/35

5040/42

5040/54

5040/80

22

28

35

42

54

80

– –

22

28

35

42

54

80

33

57

124

167

288

800

45° male to female elbows (metric tubing)

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International Code

Catalog Number IDS

Ø[mm]

ODSØ

[mm]

Weight [g] Note

Connections

7718/M10

7718/M12

7718/M14

7718/M16

7718/M18

7718/M22

7718/M28

7718/M35

7718/M42

7718/M54

7718/M64

7718/M67

7718/M76

7718/M80

7718/M89

5002/10

5002/12

5002/14

5002/16

5002/18

5002/22

5002/28

5002/35

5002/42

5002/54

5002/64

5002/67

5002/76

5002/80

5002/89

– –

10

12

14

16

18

22

28

35

42

54

64

67

76

80

89

10

12

14

16

18

22

28

35

42

54

64

67

76

80

89

7

11

15

20

29

46

79

146

216

353

420

505

880

1340

1670

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

7719/M12

7719/M14

7719/M16

7719/M18

7719/M22

7719/M28

7719/M35

7719/M42

7719/M54

7719/M64

7719/M67

7719/M76

7719/M80

5001/12

5001/14

5001/16

5001/18

5001/22

5001/28

5001/35

5001/42

5001/54

5001/64

5001/67

5001/76

5001/80

12

14

16

18

22

28

35

42

54

64

67

76

80

– –

12

14

16

18

22

28

35

42

54

64

67

76

80

11

16

20

30

47

86

144

210

390

470

550

915

1006

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

154 www.castel.it


International Code

Catalog Number IDS

Ø[mm]

ODSØ

[mm]

Weight [g] Note

Connections

7732/M6

7732/M8

7732/M10

7732/M12

7732/M14

7732/M16

7732/M18

7732/M22

7732/M28

7732/M35

7732/M42

7732/M54

7732/M64

7732/M67

7732/M80

5130/6

5130/8

5130/10

5130/12

5130/14

5130/16

5130/18

5130/22

5130/28

5130/35

5130/42

5130/54

5130/64

5130/67

5130/80

–

6

8

10

12

14

16

18

22

28

35

42

54

64

67

80

6

8

10

12

14

16

18

22

28

35

42

54

64

67

80

6

8

10

12

14

16

18

22

28

35

42

54

64

67

80

5

7

17

14

22

25

36

59

101

185

269

465

510

658

1084

Tees (metric tubing)

7732/M8.6.8

7732/M8.10.8

7732/M10.6.10

7732/M10.8.8

7732/M10.8.10

7732/M10.12.10

7732/M12.8.12

7732/M12.10.12

7732/M12.14.12

7732/M12.16.12

7732/M14.12.14

7732/M14.22.14

7732/M16.12.16

7732/M16.14.16

7732/M16.16.12

7732/M16.22.16

7732/M18.12.18

7732/M18.16.18

7732/M18.22.18

7732/M22.12.22

7732/M22.16.22

7732/M22.18.22

7732/M22.28.22

7732/M28.22.28

7732/M35.28.35

7732/M42.22.42

7732/M42.28.42

7732/M54.42.54

5130/8.6.8

5130/8.10.8

5130/10.6.10

5130/10.8.8

5130/10.8.10

5130/10.12.10

5130/12.8.12

5130/12.10.12

5130/12.14.12

5130/12.16.12

5130/14.12.14

5130/14.22.14

5130/16.12.16

5130/16.14.16

5130/16.16.12

5130/16.22.16

5130/18.12.18

5130/18.16.18

5130/18.22.18

5130/22.12.22

5130/22.16.22

5130/22.18.22

5130/22.28.22

5130/28.22.28

5130/35.28.35

5130/42.22.42

5130/42.28.42

5130/54.42.54

–

8

8

10

10

10

10

12

12

12

12

14

14

16

16

16

16

18

18

18

22

22

22

22

28

35

42

42

54

6

10

6

8

8

12

8

10

14

16

12

22

12

14

16

22

12

16

22

12

16

15

18

22

28

22

28

42

8

8

10

8

10

10

12

12

12

12

14

14

16

16

12

16

18

18

18

22

22

22

22

28

35

42

42

54

7

12

10

13

10

17

12

13

17

22

34

57

22

20

30

58

27

28

45

37

45

43

93

75

110

154

170

354

Reducing tees (metric tubing)

CO

PP

ER

BR

AZ

E-JO

INT

PR

ES

SU

RE

FITT

ING

S

155www.castel.it


International Code

Catalog Number IDS

Ø[mm]

ODSØ

[mm]

Weight [g] Note

Connections

7832/222

7832/333

5130/222

7832/333

–

1/4"

3/8

1/4"

3/8

1/4"

3/8

8

8

Tees (inch tubing)

7832/232

7832/323

5130/232

7832/323

–

1/4"

3/8

3/8"

1/4"

1/4"

3/8

11

14

Reducing tees (inch tubing)

156 www.castel.it


International Code

Catalog Number IDS

Ø[mm]

ODSØ

[mm]

Note

Connections

7900/M22

7900/M28

7900/M35

7900/M42

7900/M54

– – –

22

28

35

42

54

22

28

35

42

54

Female to female couplings, reinforced series (metric tubing)

7916/M22

7916/M28

7916/M35

7916/M42

7916/M54

– – –

22

28

35

42

54

22

28

35

42

54

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

7917/M22

7917/M28

7917/M35

7917/M42

7917/M54

–

22

28

35

42

54

– –

22

28

35

42

54

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

7902/M28.22

7902/M35.22

7902/M35.28

7902/M42.28

7902/M42.35

7902/M54.35

7902/M54.42

– – –

28

35

35

42

42

54

54

22

22

28

28

35

35

42

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

7903/M28.22

7903/M35.22

7903/M35.28

7903/M42.28

7903/M42.35

7903/M54.35

7903/M54.42

–

28

35

42

42

42

54

54

– –

22

22

28

28

35

35

42

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

CO

PP

ER

BR

AZ

E-JO

INT

PR

ES

SU

RE

FITT

ING

S

157www.castel.it


International Code

Catalog Number IDS

Ø[mm]

ODSØ

[mm]

Note

Connections

7918/M22

7918/M28

7918/M35

7918/M42

7918/M54

– – –

22

28

35

42

54

22

28

35

42

54

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

7919/M22

7919/M28

7919/M35

7919/M42

7919/M54

– – –

22

28

35

42

54

22

28

35

42

54

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

7932/M22

7932/M28

7932/M35

7932/M42

7932/M54

– –

22

28

35

42

54

22

28

35

42

54

22

28

35

42

54

Tees, reinforced series (metric tubing)

159

ACCESS FITTINGS & VALVE CORES

160 www.castel.it

The straight fittings are machined byhexagonal brass bar EN 12164 – CW 614N.The TEE and cross fittings are manufacturedwith hot forged brass EN 12420 – CW 617N.The main parts of the valve cores are madewith the following materials:– brass EN 12164 – CW 614N for body;– chloroprene rubber (CR) for seat gasket;– chloroprene rubber (CR) for outlet seal

gasket for types 8394/A and 8395/A;– PTFE for outlet seal gasket for type

8394/B.

CONSTRUCTION

All the access fittings and valve cores,shown in this chapter, are excluded from thescope of Directive 97/23/EC, as specified inthe Guidelines 1/8 and 1/9, because theyare piping components.They are designed for installation oncommercial refrigerating systems and oncivil and industrial conditioning plants,which use refrigerant fluids proper to theGroup II (as defined in Article 9, Section 2.2of Directive 97/23/EC and referred to inDirective 67/548/EEC).The access fittings allow to create a loadingor draining point rapidly and with aminimum expense.After completion of the loading or drainingoperations, the cap with gasket (cod. 8392/A) prevents any leakage.For particular customer’s requirements, the 7020/20 flare blind nut with combined8580/2 copper flare gasket may replace the 8392/A cap.This solution requires to screw the nut witha torque wrench at 8,5 ÷ 11,5 Nm.For system using R410A refrigerant, Castelhas developed three specific access fittingswith 5/16” SAE-Flare connection (codes8350/X09 , 8351/X05 and 8351/X07) thathave to be used with the following parts:– valve core, code 8395/A;– flare blind nut, code 7020/X01;– copper gaskets, code 8580/2.Also this solution requires to screw the nutwith a torque wrench at 8,5 ÷ 11,5 Nm.

The valve consists of a body that can havedifferent shapes and sizes, according to thedifferent requirements of the customers.Inside the valve, the valve core seat ismanufactured according to the ARI STANDARD 720:1997.When the internal valve core has beeninserted through the fitting, by the mountingtool (code 8390/A), the fluid flows justacting on the valve needle.

OPERATION

APPLICATIONS

ACCESS FITTINGS & VALVE CORES

Nut

Gasket

Valve core

Fitting

Access fitting with inserted valve core

L

Ch

L

Ch

L

Ch

L

Ch

L

Ch

Ch

L

L

Ch

L

Ch

AC

CE

SS

FITT

ING

S &

VALV

E C

OR

ES

161www.castel.it


CatalogueNumber SAE Flare ODS IDS

m fNPT

Ø[in.]

Ø[in.]

Ø[mm]

Ø[mm]

PS [bar]

L Ch D H


8350/22 1/4" –

–

–

–

–

–

–

–

–

–

–

–

1/4" – – – 26 11 – –

Straight access fittings

8350/X01 1/4" – 6 3/8" – 20 11 – –

1/4" – – – 6

90

130

11 – –

L

H

D

Ch8350/X09 5/16" 1/4" – – – 27 14 9,4 2,1

8351/2

8351/X04

8351/X05

8351/X07

1/4"

5/16"

–

6

–

–

–

3/8"

8-10

6

7

6

30

26

27

11

14

– –

8351/X02 1/4" – 5

1/4"

–

3/8"

8 26 11 – –

8352/22 1/4" – – – – – – 31 11 – –

1/4" –

1/8"

1/4"

3/8"

– – – –

28

33

38

11

14

17

– –

1/4" 1/4" – – – – – 35 17 – –

8354/21

8354/22

8354/23

8362/22

8350/X03

8350/X11

45

162 www.castel.it


CatalogueNumber SAE Flare IDS

m fNPT

Ø[in.]

Ø[mm]

PS [bar]

L Ch D H


Note

H

L

L

H

1/4" – – – 6

45

43 – – 24

The valve core may be installed on each of the two 1/4" SAE Flareconnections.

8380/122 1/4" – 1/8" – – 45 – – 24

TEE access fittings

8380/X01

H

L

1/4" 1/4" – – – 35

50

49

– – 30

With valve-core openingdevice on femaleconnection.The valve core may beinstalled on each of thetwo 1/4" SAE Flareconnections.

The valve core may beinstalled on each of thetwo 1/4" SAE Flareconnections.

TEE access fittings with swivel nuts

8380/X06

8380/X08

AC

CE

SS

FITT

ING

S &

VALV

E C

OR

ES

163www.castel.it



m fNPT

Ø[in.]

Ø[mm]

PS [bar]

L Ch D H


Note

L

H

L

H

L

H

1/4" – 1/8" – –

45

48 – – 50

The valve core may beinstalled on each of thethree 1/4" SAE Flareconnections.

1/4" – 1/4" – – 48 – – 50

Cross access fittings

1/4" – – – 6 48 – – 44

8382/1222

L

H

1/4" 1/4" – – – 35 50 – – 46

With valve-core openingdevice on femaleconnection.The valve core may beinstalled on each of thethree 1/4" SAE Flareconnections.

Cross access fittings with swivel nuts

8382/X04

8382/X02

8382/X03

164 www.castel.it



m fNPT

Ø[in.]

Ø[mm]

PS [bar]

L Ch D H


Note

L

� D

L– – – – – – 75 – – –8390/A

L

� D

– 1/4” – – – 35

13

– 13 –

Caps with gasket

8392/A

22 The key needs to remove the valve core.8392/B

– – – – –

(1)

(2)

(3)

– – – –

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

8394/A

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

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

8394/B

8395/A

Core remover (for all types)

1/4" – – – – 45 2,8 – 5,2 –8580/2

Copper gasket with neck

L

H

1/4" – – – – 35

175

– –

30 Four ways

L

H

162 30 Three ways9900/X87

Manifolds with access fittings

Spare valve cores

9900/X47

165

ACCESSORIES AND SPARE PARTS

KIT Nº ITEMS CODE DESCRIPTION SUITABLE FOR PRODUCTS NOTE

166 www.castel.it

ACCESSORIES AND SPARE PARTS FOR SOLENOID VALVES

9900/X94

G9150/R06

9150/R07

9150/R08

9150/R09

9150/R10

9150/R48

9150/R50

9150/R11

9150/R43

008217

008218

008229

004238

200193

009060

008323

200292

004254

008323

200292

200646

004259

008323

200292

009003

004257

004298

008323

004571

200431

004266

004299

008323

004571

009262

004251

004625

008323

004571

009278

009277

004251

004625

008323

200292

004118

004253

004256

004254

004692

008387

008415

008393

004251

008966

004256

004692

Yellow nut for fixing coil

Black screw for fixing coil

O Ring for yellow nut

O Ring under coil

Enclosure

Bracket

Screw

Plunger

Plunger spring

Nut/body O Ring

Plunger

Plunger spring

Diaphragm

Nut/body O Ring

Plunger

Plunger spring

Diaphragm

Cover/body O Ring

Cover/body screws

Plunger

Plunger spring

Diaphragm

Cover/body O Ring

Cover/body screws

Plunger

Plunger spring

Diaphragm

Cover/body O Ring

Cover/body screws

Plunger

Plunger spring

Piston

Piston ring

Cover/body O Ring

Cover/body screws

Plunger

Plunger spring

Diaphragm

Cover/body O Ring

Pilot O Ring

Nut/cover O Ring

Cover/body screws

Piston

Piston ring

Piston spring

Cover/body O Ring

New pilot O Ring

Old pilot O Ring

Cover/body screws

All the solenoid valves




All the N.C. solenoid valves

N.C.and N.O. solenoid valves type:

1020/..; 1028/..;

1064/..; 1068/..;

1070/4 - /5; 1078/4 - /5 - /M12; 1079/7;

1164/..; 1168/..;

1170/4 - /5; 1178/4 - /5 - /M12;

1512/..; 1522/..; 1132/03 - /04

N.C. solenoid valves type:

1020/..; 1028/..


1064/..; 1068/..

1098/9; 1099/11

1078/11; 1079/13 - /M42


1070/4 - /5; 1078/4 - /5 - /M12;

1079/7


1070/6; 1078/6 - /7; 1079/9


1090/5 - /6; 1098/5 - /6 - /7; 1099/9


1050/5 - /6; 1058/5 - /6 - /7; 1059/9


1078/9; 1079/11


1098/9; 1099/11

1198/9

Diaphragm pilot

operated spare parts for:

1098/9; 1099/11;

1078/11; 1079/13 - /M42

Valves out of stock

Main piston pilot

operated spare parts


167www.castel.it

RICAMBI PER VALVOLE SOLENOIDI

9150/R39

9150/R35

9150/R34

9150/R49

9150/R51

9150/R42

9150/R15

9150/R12

9150/R13

9150/R14

008387

008415

008393

004691

008966

004256

004692

N.D.

200646

004259

004238

008757

009003

004257

004254

004238

004298

008757

009262

004251

004254

004238

004625

008757

009278

009277

004251

004254

004238

004625

008757

004118

004253

004256

004254

004238

004692

200581

200292

004242

200581

200292

200520

004244

004298

200581

200292

004617

004625

200581

200292

200552

004246

004242

004309

Piston

Piston ring

Piston spring

Cover/body O Ring

New pilot O Ring

Old pilot O Ring

Cover/body screws

Pre-assembled armature with nuts

Diaphragm

Nut/body O Ring

O Ring under coil

N.O. armature group

Diaphragm

Cover/body O Ring

Nut/cover O Ring

O Ring under coil

Cover/body screws

N.O. armature group

Diaphragm

Cover/body O Ring

Nut/cover O Ring

O Ring under coil

Cover/body screws

N.O. armature group

Piston

Piston ring

Cover/body O Ring

Nut/cover O Ring

O Ring under coil

Cover/body screws

N.O. armature group

Diaphragm

Cover/body O Ring

Pilot O Ring

Nut/cover O Ring

O Ring under coil

Cover/body screws

Plunger

Plunger spring

Nut/body O Ring

Plunger

Plunger spring

Diaphragm

Cover/body O Ring

Cover/body screws

Plunger

Plunger spring

Diaphragm

Cover/body screws

Plunger

Plunger spring

Diaphragm

No 2 pilot O Rings

Nut/cover O Ring

Cover/body screws


1078/11; 1079/13 - /M42

1178/11

N.O. solenoid valves type:

1164/..; 1168/..

1198/9

1178/11


1170/4- /5; 1178/4 - /5 - /M12


1190/5 - /6; 1198/5 - /6 - /7


1150/5 - /6; 1158/5 - /6 - /7


1178/9

Solenoid valves for different fluids type:

1512/..

1522/..


1132/03 - /04


1132/06 - /08


1142/010 - /012

Main piston pilot

operated spare parts

Diaphragm pilot

operated spare parts for:

1198/9

1178/11


168 www.castel.it

ACCESSORIES AND SPARE PARTS FOR CHECK VALVES

9150/R16

9150/R17

9150/R18

9150/R19

9150/R52

9150/R53

9150/R54

9150/R55

003558

001869

004251

004299

003559

000728

004691

004692

003854

000728

008002

004302

003855

001857

004261

004302

003558

001869

008863

004299

003559

000728

009174

004692

003854

000728

009175

004302

003855

001857

009176

004302

Piston

Spring

Cover/body O Ring

Cover/body screws

Piston

Spring

Cover/body O Ring

Cover/body screws

Piston

Spring

Cover/body O Ring

Cover/body screws

Piston

Spring

Cover/body O Ring

Cover/body screws

Piston

Spring

Cover/body gasket

Cover/body screws

Piston

Spring

Cover/body gasket

Cover/body screws

Piston

Spring

Cover/body gasket

Cover/body screws

Piston

Spring

Cover/body gasket

Cover/body screws

Check valves type:

3120/7 - /9 - /M22 - /M28

3140/7 - /9 - /M28

3180/7 - /9 - /M28

Check valves type:

3120/11

3140/11

3180/11

Check valves type:

3120/13 - /M42

3140/13 - /M42

Check valves type:

3120/17

3140/17 - /21 - /25

3160/17; 3180/13 - /M42 - /17

Check valves type:

3122/7 - /9 - /M22 - /M28

3142/7 - /9 - /M28

3182/7 - /9 - /M28

Check valves type:

3122/11

3142/11

3182/11

Check valves type:

3122/13 - /M42

3142/13 - /M42

Check valves type:

3122/17

3142/17 - /21 - /25

3182/13 - /M42 - /17

Valves out of stock

Valves out of stock

Valves out of stock

Valves out of stock

ACCESSORIES AND SPARE PARTS FOR INDICATORS

9150/R20

9150/R21

003575

007779

004259

004270

007780

004259

Nut

Protection cap

Nut/body O Ring

Pre-assembled nut

Protection cap

Nut/body O Ring

Liqud indicators type:

3610/..; 3620/..; 3640/..; 3650/..

Moisture - liquid indicators type:

3710/..; 3720/..; 3740/..; 3750/..;

3770/..; 3771/..; 3780/..; 3781/..


169www.castel.it

ACCESSORIES AND SPARE PARTS FOR FILTERS

G9150/R05

9150/R57

9150/R58

8354/22

8392/A

8394/B

003319

003322

009406

003324

007677

005535

004592

008336

008304

008305

008307

008403

008345

008344

008303

008306

Access fitting

Cap with gasket

Valve core

Spring

Flange gasket

Dehydrating block cover

Dehydrating block bottom

Filtering tube

Mechanical block cover

Mechanical block bottom

Flange gasket

Dehydrating block cover

Dehydrating block bottom

Screw for filtering tube

Filtering tube

Filtering tube

Filtering tube

Mechanical block cover

Mechanical block bottom

Filters with replaceable block type:

4411/..; 4412/..; 4413/..; 4414/..

4421/..; 4423/..; 4424/..

All the filters series 44


4411/..; 4412/..; 4413/..; 4414/..


4411/..A; 4412/..A; 4413/..A; 4414/..A


4411/..C


4421/..; 4423/..; 4424/..


4421/..A; 4423/..A; 4424/..A

Filters with replac. block type: 4421/..A



Filters with replac. block type:

4421/..C

ACCESSORIES AND SPARE PARTS FOR OIL SEPARATORS

5590/5

5590/7

003879

5590/9

5590/11

003870

5590/13

5590/M42

003965

003322

Pair of connections 5/8" ODS

Pair of connections 7/8" ODS

Connection gasket

Pair of connections 1.1/8" ODS


Connection gasket


Pair of connections M42 ODS

Connection gasket

Flange gasket

Oil separators type 5520/C

Oil separators type 5520/D

Oil separators type 5520/E

Oil separators type 5520/.

To be ordered separately




170 www.castel.it

ACCESSORIES AND SPARE PARTS FOR CHANGEOVER VALVES

9150/R24

9150/R25

004297

004329

004330

004348

000529

000534

000535

001039

3039/4

004260

009036

008281

Gland

Gland seal gaskets

Gland seal gaskets

Washer

Gland

Gland seal gaskets

Gland seal gaskets

Washer

Pair of connections 1/2"NPT female

Connection/body O Ring

Cap

Cap

All the changeover devices type

3032/44 - /64 - /66

Changeover valve type

3032/108

Changeover valve 3032/44

Changeover valve 3032/64 - /66

RICAMBI PER RUBINETTI PER SISTEMI FRIGORIFERI ERMETICI

9150/R23

G9150/R33

003664

000384

000957

000382

007486

000913

004307

004326

Gland

Gland seal gaskets

Gland seal gaskets

Washer

Cap

Spindle

Screw

Spring washer

All the hermetic valves type:

6010/..; 6012/..; 6020/..; 6060/..;

6070/..

Hermetic valves type 6010/2;

6012/22

Hermetic valves type 6020/..

ACCESSORIES AND SPARE PARTS FOR HERMETIC VALVES

9150/R23

9150/R24

9150/R25

003664

000384

000957

000382

007486

000913

001641

004297

004329

004330

004348

009036

001647

000529

000534

000535

001039

008282

001038

Gland

Gland seal gaskets

Gland seal gaskets

Washer

Cap

Spindle

Spindle

Gland

Gland seal gaskets

Gland seal gaskets

Washer

Cap

Spindle

Gland

Gland seal gaskets

Gland seal gaskets

Washer

Cap

Spindle

Receiver valves type:

6110/21 - /22 - /23 - /32 - /33

6120/22 - /23 - /33

6132/..

6140/22 - /23


6110/21 - /22; 6120/22; 6140/22 - /23


6110/23 - /32 - /33; 6120/23 - /33


6110/43 - /44 - /54

6120/43 - /44 - /54


6110/66

6120/66

ACCESSORIES AND SPARE PARTS FOR BALL SHUT-OFF VALVES

009035

009256

Cap

Cap

Ball shut-off valves 3033/..

Ball shut-off valves 3063/44


171www.castel.it

ACCESSORIES AND SPARE PARTS FOR STOP VALVES

9150/R26 000822

000823

000824

007476

Gland

Gland seal gaskets

Gland seal gaskets

Washer

Stop valves type:

6170/66 - /77

ACCESSORIES AND SPARE PARTS FOR ROTALOCK VALVES

9150/R23 003664

000384

000957

000382

7910/6

7990/6

7910/8

7990/8

Gland

Gland seal gaskets

Gland seal gaskets

Washer

Steel solder connection

3/4" UNF-16

PTFE gasket for 7910/6

Steel solder connection

1" UNS-16

PTFE gasket for 7910/8

Rotalock valves types:

6310/..

6320/..

To be ordered

separately

ACCESSORIES AND SPARE PARTS FOR CAPPED VALVES

9150/R23 003664

000384

000957

000382

007486

002337

005174

007619

007676

Gland

Gland seal gaskets

Gland seal gaskets

Washer

Cap

Spindle

Nipple/body O Ring

Spindle

Nipple/body O Ring

Capped valves type:

6410/..; 6420/..; 6460/..

Capped valves type:

6410/2 - /3 - /4 - /5

6420/2 - /3 - /M10 - /M12 - /4 - /5

6460/22A.

Capped valves type:

6410/6

6420/M18 - /6 - /M22 - /7


172 www.castel.it

ACCESSORIES AND SPARE PARTS FOR GLOBE VALVES

9150/R24

9150/R27

9150/R28

9150/R26

9150/R29

9150/R30

004297

004329

004330

004348

001635

004296

007637

004299

004251

008863

007638

004692

004291

009174

000822

000823

000824

007476

001228

000830

004302

007639

008002

009175

007640

004261

009176

Gland

Gland seal gaskets

Gland seal gaskets

Washer

Cap

Cap gasket

Spindle/plate group

Cover/body screws

Cover/body O Ring

Cover/body gasket

Spindle/plate group

Cover/body screws

Cover/body O Ring

Cover/body gasket

Gland

Gland seal gaskets

Gland seal gaskets

Washer

Cap

Cap gasket

Cover/body screws

Spindle/plate group

Cover/body O Ring

Cover/body gasket

Spindle/plate group

Cover/body O Ring

Cover/body gasket

Globe valves type:

(1) 6510/M22 - /7 - /M28 - /9 - /11

6512/M22 - /7 - /M28 - /9 - /11

(1) 6520/7 - /9 - /11

(1) 6530/M22 - /7 - /M28 - /9 - /11

6532/M22 - /7 - /M28 - /9 - /11

Globe valves type:

(1) 6510/M22 - /7 - /M28 - /9

6512/M22 - /7 - /M28 - /9

(1) 6520/7 - /9

(1) 6530/M22 - /7 - /M28 - /9

6532/M22 - /7 - /M28 - /9

Globe valves type:

(1) 6510/M22 - /7 - /M28 - /9

(1) 6520/7 - /9

(1) 6530/M22 - /7 - /M28 - /9

Globe valves type:

6512/M22 - /7 - /M28 - /9

6532/M22 - /7 - /M28 - /9

Globe valves type:

(1) 6510/11; 6512/11

(1) 6520/11; (1) 6530/11; 6532/11

Globe valves type:

(1) 6510/11; (1) 6520/11; (1) 6530/11

Globe valves type:

6512/11; 6532/11

Globe valves type:

(1) 6510/13 - /M42 - /17

6512/13 - /M42 - /17

(1) 6520/13 - /M42 - /17

(1) 6530/13 - /M42 - /17

6532/13 - /M42 - /17

Globe valves type:

(1) 6510/13 - /M42

6512/13 - /M42

(1) 6520/13 - /M42

Globe valves type:

(1) 6510/13 - /M42

(1) 6520/13 - /M42

Globe valves type:

6512/13 - /M42

Globe valves type:

(1) 6510/17; 6512/17

(1) 6520/17; (1) 6530/13 - /M42 - /17

6532/13 - /M42 - /17

Globe valves type:

(1) 6510/17; (1) 6520/17

(1) 6530/13 - /M42 - /17

Globe valves type:

6512/17

6532/13 - /M42 - /17

(1) valves out of stock


173www.castel.it

ACCESSORIES AND SPARE PARTS FOR BALL VALVES

G9150/R46

009055

009036

009037

009038

009207

009208

8394/A

8392/A

Cap

Cap

Cap

Cap

Cap

Gasket

Valve core

Cap with gasket

Ball valves type:

6590/M6 - /2 - /3 - /3A - /M10 - /M10A

- /M12 - /M12A - /4 - /4A

6591/5

6590/M15 - M15A - /5 - /5A - /M18

- /M18A - /6 - /6A

6591/7

Ball valves type:

6590/7 - /7A

6591/M28 - /9

6590/M28 - /M28A - /9 - /9A

6591/11

Ball valves type:

6590/11 - /11A

6591/13 - /M42

6590/13 - /13A - /M42 - /M42A

6591/17

Ball valves type:

6590/17 - /17A

6591/21 - /21A

Ball valves type:

6590/M64A - /21A

6591/24A - /25A

Ball valves with access fitting

ACCESSORIES AND SPARE PARTS FOR COMPRESSOR VALVES

9150/R23 003664

000384

000957

000382

Gland

Gland seal gaskets

Gland seal gaskets

Washer

Compressor valves type 6640

ACCESSORIES AND SPARE PARTS FOR GAUGE MOUNTING VALVES

9150/R23 003664

000384

000957

000382

Gland

Gland seal gaskets

Gland seal gaskets

Washer

Gauge mounting valves

8320/21 - /22

Progetto grafico: Giorgio D’Andrea Impaginazione e fotolito: Ruta - Milano Stampa: B.S.Z. srl - Mazzo di Rho (Mi)

castel product handbook eng

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