CASTEL Products Handbook 2008

2
May 2008
3
Expansion t hermost at ic expansion valves wit h int erchangeable orifice assembly 16
valves PWM solenoid expansion valves wit h int erchangeable orifice 26
Sol enoi d valves for refrigerat ing syst ems 32
val ves coils 40
permanent magnet 43
connect ors 44
valves for dif ferent fluids 44
Saf et y devi ces safet y valves 3030 50
safet y valves 3060 57
ball shut -of f valves 59
changeover devices 60
unions 62
fusible plugs 63
Check val ves 65
Wat er regul at i ng val ves 71
Li qui d i ndi cat ors
Moi st ure l i qui d i ndi cat ors 77
Dehydrat ors dehydrat ion of refrigerant s 84
ant i-acid solid core filt er driers 85
filt er driers wit h replaceable ant i-acid solid core 94
mechanical filt ers wit h replaceable filt ering block 99
st rainers 104
Oi l separat ors 105
Val ves hermet ic valves 112
receiver valves 114
st op valves 116
diaphragm valves 118
rot alock valves 120
capped valves 122
globe valves 124
ball valves 126
gauge mount ing valves 129
line piercing valve 130
Threaded brass f i t t i ngs 131
Sol der copper f i t t i ngs 141
Access f i t t i ngs 153
Spare par t s 159
Index
4
The t echical dat a in t his handbook are indicat ive. Cast el reser ves t he
right t o modify t he same at any t ime wit hout any previous not ice.
The product s list ed in t his handbook are prot ect ed according t o t he law
5
From qualit y our nat ural
development
Aft er more t han for t y years in t he indust r y of Refrigerat ion and
Air Condit ioning component s, Cast el Qualit y Range of Product s
is well known and highly appreciat ed all over t he world.
Qualit y is t he main issue of our Company and it has a special
priorit y, in ever y st ep, all along t he product ion cycle.
We produce on hi gh t ech machi ner y and updat ed aut omat i c
product ion lines, operat ing in conformit y wit h t he safet y and
environment st andards current ly enforced.
Cast el of fers t o t he Market and t o Manufact urers fully t est ed
product s sui t abl e wi t h HCFC and HFC Ref ri gerant s current l y
used in t he Refrigerat ion & Air Condit ioning Indust r y.
UNI EN ISO 9001:2000 issued by ICIM cer tifies the Quality System
of the Factor y.
Moreover Cast el Product s count a number of cer t ificat ions in
conf or mi t y wi t h t he EEC Di rect i ves and wi t h European and
American Quality Approvals.
6
Appl i cat i on of Di rect i ve 97/ 23/ EC of t he European Parl i ament
and of t he Counci l , of 29 May 1997, concerni ng pressure
equi pment t owards Cast el ref ri gerat i on product s
Maxi mum / mi ni mum al l owabl e
t emperat ure (TS):
t he maximum/ minimum t emperat ures for
which t he equipment is designed, as
specified by t he manufact urer
Vol ume (V): t he int ernal volume of a
chamber, including t he volume of nozzles t o
t he first connect ion or weld and excluding
t he volume of permanent int ernal par t s.
Nomi nal si ze (DN): numerical designat ion
of size, which is common t o all component s
in a piping syst em.
Fl ui ds: gases, liquids and vapours in pure
phase as well as mixt ure t hereof.
Pressure equipment s referred t o in Ar t icle 3
are classified by cat egories in accordance wit h
Annex II, according t o ascending level of
hazard, on t he basis of:
St at e of t he fluid
Danger classificat ion of t he fluid
Type of equipment
Dimensions and energet ic pot ent ial:
V, DN, PS, PS x V, PS x DN
and must sat isfy t he Essent ial Safet y
Requirement set out in Annex I of PED.
Pressure equipment s below or equal t o t he
limit s in Ar t icle 3, sect ions 1.1, 1.2 and 1.3
and sect ion 2, must not sat isfy t he Essent ial
Safet y Requirement set out in Annex I. They
must be designed and manufact ured in
accordance wit h t he sound engineering pract ice
of a Member St at e in order t o ensure safe use
(Ar t icle 3, Sect ion 3).
In t he t ables of general charact erist ics,
collect ed in t his Handbook, it s showed t he risk
cat egor y in which ever y product is classified.
In Ar t i cl e 9 of PED t he f l ui ds are cl assi f i ed,
accordi ng t o t hei r hazard, i nt o t wo groups:
The Direct ive 97/ 23/ EC (PED) applies
t o t he design, manufact ure and conformit y
assessment of pressure equipment
and assemblies wit h a maximum allowable
pressure PS great er t han 0,5 bar wit h
t he except ion of t he possibilit ies list ed
in Ar t icle 1, Sect ion 3 of t he same
Direct ive.
Since 30 May 2002 t he Direct ive
has become mandat or y and,
in t he Member St at es of European Communit y,
it has been possible t o place
on t he market only pressure equipment s
CE marked according t o PED.
For t he purposes of t he Direct ive see t he
following definit ions, used in t his Handbook
t oo:
Pressure equi pment : vessels, piping,
safet y accessories, and pressure
accessories
Vessel : a housing designed and built t o
cont ain fluids under pressure.
Pi pi ng: piping component s int ended for t he
t ranspor t of fluids, when connect ed t oget her
for int egrat ion int o a pressure syst em.
Saf et y accessori es: devices designed t o
prot ect pressure equipment against t he
allowable limit s being exceeded.
Pressure accessori es: devices wit h an
operat ional funct ion and having pressure-
bearing housing. For example: solenoid
valves, valves, indicat ors.
Assembl i es: several pieces of pressure
equipment assembled by a manufact urer t o
const it ut e an int egrat ed and funct ional
whole.
Maxi mum al l owabl e pressure (PS):
t he maximum pressure for which t he
equipment is designed, as specified by t he
manufact urer.
7
Group I compri ses dangerous f l ui ds. A
dangerous f l ui d i s a subst ance or
preparat i on covered by t he def i ni t i ons i n
Ar t i cl e 2 of Counci l Di rect i ve 67/ 548/ EEC
of 27 June 1967 and f ol l owi ng
amendment s, rel at i ng t o t he cl assi f i cat i on,
packagi ng and l abel i ng of dangerous
subst ance. Group I compri ses f l ui ds
def i ned as: expl osi ve, ext remel y f l ammabl e,
hi ghl y f l ammabl e, f l ammabl e, ver y t oxi c,
t oxi c, oxi di zi ng.
Group II compri ses al l t he ot hers f l ui ds not
ref erred t o i n group I.
Cast el product s are sui t abl e f or usi ng
wi t h ref ri gerant f l ui ds proper t o t he Group
II.
These ref ri gerant f l ui ds are l i st ed and
cl assi f i ed L1 i n Annex E of st andard
EN 378-1, pl us f l ui ds R30, R123 and
R141b.
Among t he f l ui ds l i st ed i n t hi s st andard,
t here are t he wel l known R12; R22; R134a;
R404A; R407C; R401A; R502; R507.
EXTERNAL LEAKAGE
All t he product s illust rat ed in t his Handbook are
submit t ed, one by one, t o t ight ness t est s
besides t o funct ional t est s.
Allowable ext ernal leakage, measurable during
t he t est , agrees t o t he definit ion given in t he
St andard EN 12284 : 2003, Par. 9.4:
During t he t est , no bubbles shall form over a
period of at least one minut e when t he
specimen is immersed in wat er wit h low
sur face t ension, .
PRESSURE CONTAINMENT
All t he product s illust rat ed in t his Handbook, if
submit t ed t o hydrost at ic t est , guarant ee a
pressure st renght at least equal t o 1,43 x PS in
compliance wit h t he Direct ive 97/ 23/ EC.
All t he product s illust rat ed in t his Handbook, if
submit t ed t o burst t est , guarant ee a pressure
st rengt h at least equal t o 3 x PS according t o
t he St andard revision prEN 378-2 : 2006. A
great number of product s illust rat ed in t he
Handbook can guarant ee an higher pressure
st rengt h, equal t o 5 x PS according t o t he
St andard UL 207 : 2004. (for det ailed
informat ion about t hese product s please
cont act Cast el Technical Depar t ment ).
WEIGHTS
The weight s of t he it ems list ed in t his
Handbook include packaging and are not
binding for t he Company.
Applicat ion of Direct ive 2002/ 95/ EC of t he European Parliament and
of t he Council, of 27 January 2003, on t he rest rict ion of t he use of
cert ain hazardous subst ances in elect rical and elect ronic equipment
listed in the Annex of the same Directive;
among these applications the following
exceptions are par ticularly interesting in air
conditioning / refrigerating systems:
Lead as an alloying element in steel
containing up to 0,35% lead by weight,
aluminium containing up to 0,4% lead by
weight and as a copper alloy containing up to
4% lead by weight
Hexavalent chromium as an anti-corrosion of
the carbon steel cooling system in absorption
refrigerators
The Member States of European Community had
to adopt the two Directives 2002/ 95/ EC and
2002/ 96/ EC, with the next updating
2003/ 108/ EC, before 13 August 2004, unless
delays granted by the European Parliament.
For a long time Castel Company has star ted a
careful inquir y, together with its suppliers, to
identify the presence or not of the above-
mentioned hazardous substances, either in its
own products or in its own production
processes, and to remove them progressively.
At the end of this wide examination Castel
Company may declare that its products:
1. Do not contain mercur y, cadmium,
polybrominated biphenyls (PBB),
polybrominated diphenyl ethers (PBDE)
2. Do not contain hexavalent chromium, used for
the sur face treatments (yellow zinc plating) of
steel par ts. Castel Company has removed the
yellow zinc plating treatments from all its
products, before the end of 2005, and has
chosen:
other sur face treatments containing trivalent
chromium instead of hexavalent chromium.
where possible, other materials which don t
need sur face treatments.
3. Contain lead as an alloying element in steel,
aluminium and copper alloys within the
accepted limits according to the Annex of
RoHS Directive.
The purpose of Directive 2002/ 95/ EC (RoHS
Directive) is to prevent or restrict the use of
hazardous substances in electrical and
electronic equipment and to contribute to the
environmentally sound recover y and disposal of
waste electrical and electronic equipment.
RoHS Directive shall apply to electrical and
electronic equipment falling under the categories
1, 2, 3, 4, 5, 6, 7 and 10 set out in Annex 1A to
Directive 2002/ 96/ EC (WEEE Waste electrical
and electronic equipment) and to electric light
bulbs and luminaries in households.
The equipment proper to the first categor y,
Large household appliances , and to the
10th categor y, Aut omat ic dispensers , of
Annex 1A in WEEE Directive, are specified in
Annex 1B in the same Directive; this list of
products shows:
Large cooling appliance
Refrigerators
Freezers
Other large appliances used for refrigeration,
conser vation and storage of food
Air conditioner appliances
Other fanning, exhaust ventilation and
conditioning equipment
Automatic dispenser for hot or cold bottles
and cans
Ar ticle 10 of WEEE Directive establishes that,
from 13 August 2005, new electrical and
electronic equipment put on the market are
appropriately identified as waste subject to
separate collection, by means of the proper
symbol shown in Annex IV of the same Directive.
Ar ticle 4 of RoHS Directive establishes that,
from 1 July 2006, new electrical and electronic
equipment put on the market does not contain
the following substances:
Lead
Mercur y
Cadmium
Hexavalent chromium
Polybrominated biphenyls (PBB)
Polybrominated diphenyl ethers (PBDE)
The restriction of use of these hazardous
substances shall not apply to the applications
8
CONNECTIONS OF CASTEL PRODUCTS
Cast el product s can be supplied wit h dif ferent
connect ions.
In par t icular Cast el product s are produced
eit her wit h t hreaded connect ions or solder
connect ions.
Table 1 shows t he equivalence bet ween Cast el
codes and dimensions in inches. These codes
are commonly used in t he int ernat ional market .
Table 2 shows t he equivalence bet ween Cast el
codes and dimensions in millimet ers.
CASTEL
code
Dimension
[in]
TABLE 1 - Equi val ence bet ween Cast el code
and di mensi on i n i nches
CASTEL
code
Dimension
[mm]
. / M6
. / M10
. / M12
. / M15
. / M18
. / M22
. / M28
. / M42
. / M64
. / M80
6
10
12
15
18
22
28
42
64
80
TABLE 2: Equi val ence bet ween Cast el code
and di mensi on i n mi l l i met ers
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 wit h solder connect ion
wit h = 7/ 8
F.e. 4411/ M42A filt er drier wit h replaceable ant i-acid
solid core wit h solder connect ion wit h = 42 mm.
9
10
1) THREADED CONNECTIONS
They can be of t hree dif ferent t ypes:
FLARE
St raight t hreaded connect ion (according t o SAE
J513-92; ASME B1.1-89) for junct ion t o a
copper pipe wit h a suit able flared end, using a
right nut (see Table 3).
NPT
Taper t hreaded connect ion (according t o ASME
B1.20.1-92) t o joint fit t ings, valves, safet y
valves t o vessel or st eel pipes.
FPT
St raight t hreaded connect ion (according t o UNI
ISO 228/ 1) used in t he hydraulic syst em t o
joint fit t ings or valves t o vessel or st eel pipes.
F.e.: solenoid valves for wat er or air.
2) SOLDER CONNECTIONS
They can be of four dif ferent t ypes and can fit
pipes wit h diamet er bot h in inches and in
millimet ers:
ODS (or ODF)
Female solder connect ion for copper t ubes.
The indicat ed size corresponds t o t he out er
diamet er of t he copper t ube which t o joint .
F.e.: 1/ 2" ODS solder connect ion suit able t o receive
inside a copper pipe wit h a 1/ 2" out er diamet er.
ODM
Male solder connect ion for copper t ubes.
The indicat ed size corresponds t o t he out er
F.e.: 16 ODM solder connect ion suit able t o joint a
copper pipe wit h a 16 mm out er diamet er, by means of
an M16 female/ female copper sleeve (in t his case t he
t ype Cast el 7700/ M16).
IDS
Male solder connect ion for copper t ube.
The indicat ed size corresponds t o t he inner
F.e.: 10 IDS solder connect ion suit able t o receive
out side a copper pipe wit h an 10 mm inner diamet er).
W
Solder connect ion for st eel pipes.
The indicat ed size corresponds t o t he ext ernal
diamet er of t he st eel pipe which t o joint .
F.e.: 76,1 W solder connect ion suit able t o connect a
st eel pipe wit h a 76,1 mm ext ernal diamet er, by means
of but t welding.
FLARE
Suit able for
Copper t ube
t hread
1/ 4"
5/ 16"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
7/ 8"
1"
1/ 4"
5/ 16"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
7/ 8"
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: Fl are connect i ons
Descri pt i on of connect i ons t hat are current l y used f or Cast el
product s.
11
THE Kv FACTOR
Table 1 shows refrigerat ion capacit y values
wit h unit Kv relat ed t o t he nominal working
condit ions specified in Table 2.
Appropriat e correct ive coef ficient s may be
calculat ed t aking t he values shown from Table
3 t o Table 8 as a basis; t his will make it
possible t o predict act ual working condit ions.
As a result :
Liquid line:
Q = Kv Q
1
L
1
L
2
Suct ion line
Q = Kv Q
1
S
1
S
2
Hot gas line
Q = Kv Q
1
H
1
H
2
since:
Q = required refrigerat ion capacit y [kW];
Kv = charact erist ic valve coef ficient [m
3
/ h];
Q
1
= reference refrigerat ion capacit y [kW]
(Table 1).
L
1
S
1
H
1
= are correct ion fact ors of t he
refrigerat ion capacit y in t he presence of
operat ing t emperat ures dif ferent from
reference condit ions.
L
2
S
2
H
2
= are correct ion fact ors of t he
refrigerat ion capacit y for pressure drops
dif ferent from reference condit ions.
The correct sizing of t ubes and component s of
a refrigerat ing syst em is of t he ut most
impor t ance for all kinds of plant s; oversizing
and undersizing are bot h t o be avoided since
t hey are equally hazardous for t he correct
operat ion of t he syst em.
The correct select ion of a component is based
on t he knowledge of t he relat ionship bet ween
capacit y and pressure drop t hrough t hat
component . For t his purpose, EN 60534-1,
EN 60534-2-1 and EN 60534-2-3 st andards
require manufact urers t o specify t he Kv
coef ficient for ever y product .
The Kv f act or i s def i ned as t he col d wat er
f l ow (vol umi c mass = 1000 kg/ m
3
) i n
m
3
/ h resul t i ng i n a 1 bar pressure drop
wi t h a compl et el y open val ve.
This definit ion applies t o all product s described
in t his handbook.
The merely physical meaning, t his coef ficient
precisely defines t he fluid-dynamic and
const ruct ion charact erist ics of t he product , so
t hat , wit h t he addit ion of ot her paramet ers
more closely relat ed t o t he nat ure and
condit ions of t he fluid under considerat ion, t he
capacit y/ pressure drop rat io may be precisely
det ermined.
Cast el provides appropriat e t ables for t he most
commonly used refrigerant s in t ypical plant
working condit ions in order t o help engineers in
t he correct select ion of it s product s.
TABLE 1
Kv
Fact or
[m
3
/ h]
R134a
Liquid Vapour Hot Gas
Refrigerat ion Capacit y [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 - Nomi nal Worki ng Condi t i ons
+18
+38
0,15
1
Applicat ion
Suct ion Temperat ure
[C]
Condensing Temperat ure
[C]
Pr es s ur e dr op
[ bar ]
LIQUID
VAPOUR
HOT
GAS
Evaporat ing Temperat ure
[C]
12
Li qui d l i ne
TABLE 3 - Correct i on Fact ors L
1
of t he ref ri gerat i on capaci t y f or operat i ng t emperat ures di f f erent f rom nomi nal val ues
Liquid
Temperat ure
[C]
Refrigerant
+ 10 + 5 0 5 10 15 20 25 30 35 40
Evaporat ing Temperat ure [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 - Correct i on Fact ors L
2
of t he ref ri gerat i on capaci t y f or pressure drops di f f erent f rom nomi nal val ues
Pressure
drop
[bar]
0,01 0,03 0,05 0,10
L
2
0,263 0,456 0,59 0,81 1,00 1,15 1,30 1,40 1,54 1,64 1,72 1,82 1,92 2,00
0,15 0,20 0,25 0,30 0,35 0,40 0,45 0,50 0,55 0,60
13
Suct i on l i ne Hot gas l i ne
Q = Kv Q
1
S
1
S
2
[kW]
15 = Kv 2,68 0,70 0,82
15
Kv = = 9,75 [m
3
/ h]
1,538
The result involves t he select ion of a 1078/ 9
valve wit h Kv = 10 [m
3
/ h]
3) Hot gas l i ne:
Valve select ion under t he following condit ions:
Refrigerant : R407C
Set refrigerat ion capacit y: 20 [kW]
Condensat ion: + 40 [C]
Evaporat ion: 0 [C]
Set pressure drop: 0,5 [bar]
Q = Kv Q
1
H
1
H
2
[kW]
20 = Kv 11,62 0,94 0.7
20
Kv = = 2,61 [m
3
/ h]
7,64
The result involves t he select ion of a 1078/ 5
valve wit h Kv = 2,61 [m
3
/ h]
APPLICATION EXAMPLES
1) Li qui d l i ne:
Evaluat ion of pressure drop across t he valve
under t he following working condit ions:
Cast el 1078/ 5 valve: Kv = 2,61 [m
3
/ h]
Refrigerant : R407C
Evaporat ion: 0 [C]
Q = Kv Q
1
L
1
L
2
[kW]
35 = 2,61 18,74 0,82 L
2
[kW]
35
L
2
= = 0,87
40,11
A pressure drop slight ly above 0.11 bar
corresponds t o t he L
2
= 0.87 correct ion fact or.
Such a pressure drop is compat ible wit h t he
minimum dif ferent ial pressure required by t he
valve.
2) Suct i on l i ne:
Valve select ion under t he following condit ions:
Refrigerant : R407C
Evaporat ion: 10 [C]
Set pressure drop: 0,1 [bar]
TABLE 5 - Correction Factors - S
1
of the refrigeration capacity
for operating temperatures dif ferent fom nominal values
Evaporat ing
Temperat ure
[C]
+ 60 + 55 + 50 + 45 + 40 + 35 + 30
Condensing Temperat ure [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 - Correct i on Fact ors - S
2
of t he ref ri gerat i on capa-
ci t y f or pressure drops di f f erent f rom nomi nal val ues
Pressure
drop
[bar]
0,04 0,05 0,07 0,10 0,15 0,20 0,30 0,40 0,50 0,70
S
2
0,47 0,57 0,68 0,82 1,00 1,15 1,40 1,64 1,82 2,15
TABLE 8 - Correct i on Fact ors - H
2
of t he ref ri gerat i on capa-
ci t y f or pressure drops di f f erent f rom nomi nal val ues
Pressure
drop
[bar]
0,10 0,20 0,30 0,40 0,50 0,70 1,00 1,50 2,00 2,50
H
2
0,32 0,45 0,54 0,65 0,70 0,83 1,00 1,17 1,30 1,44
TABLE 7 - Correct ion Fact ors - H
1
of t he ref rigerat ion capacit y
f or operat ing t emperat ures dif f erent f rom nominal values
Evaporat ing
Temperat ure
[C]
+ 60 + 55 + 50 + 45 + 40 + 35 + 30
Condensing Temperat ure [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 pants, two indipendent circuits, with intermediate
temperature -10 C.
14
Expansion valves
16
diaphragm assembly by 1.5 met er lengt h of
capillar y t ubing, which t ransmit s bulb pressure
t o t he t op of t he valve s diaphragm. The
sensing bulb pressure is a funct ion of t he
t emperat ure of t he t hermost at ic charge t hat is
t he subst ance wit hin t he bulb.
The body is made from forged brass wit h
connect ion in angle configurat ion. The
int erchangeable orifice assembly can be
replaced t hrough t he inlet connect ion. A st eel
rod, inside t he body, t ransfers t he diaphragm
movement t o t he plug inside t he orifice
assembly. When t he t hermost at ic charge
pressure increases, t he diaphragm will be
deflect ed downward t ransferring t his mot ion t o
t he plug, which lift s from seat and allows t he
liquid passing t hrough orifice. A spring opposes
t he force underneat h t he diaphragm and t he
side spindle can adjust it s t ension. St at ic
superheat increases by t urning t he side spindle
clockwise and decreased by t urning t he spindle
count er clockwise.
The t hermost at ic element is hardly connect ed
by brazing t o t he forged brass body t o avoid any
leakage.
The body assembly can be supplied wit h
int ernal or ext ernal equalizer; bot h t ypes can
also be supplied eit her wit h flare connect ions
or wit h solder connect ions (out let and ext ernal
equalizer if present ).
The nut s for flare connect ion t ype and t he inlet -
APPLICATION
Cast el t hermost at ic expansion valves series 22
regulat e t he flow of refrigerant liquid int o
evaporat ors; t he liquid inject ion is cont rolled by
t he refrigerant superheat .
The new Cast el 22 series are designed t o
work wit h int erchangeable orifice assembly, to
provide flexibility in selection of capacities, and
can be used in a wide range of applicat ions as
list ed below:
Refrigerat ion syst ems (display cases in
supermarket s, freezers, ice cream and ice
maker machines, t ranspor t refrigerat ion et c).
Air condit ioning syst ems
Heat pump syst ems
Liquid chillers
which use refrigerant fluids proper t o t he Group
II (as defined in Ar t icle 9, Sect ion 2.2, of
Direct ive 97/ 23/ EC and referred t o in Direct ive
67/ 548/ EEC).
OPERATION
Cast el t hermost at ic expansion valves act s as
t hrot t le device bet ween t he high pressure and
t he low pressure sides of refrigerat ion syst ems
and ensure t hat t he rat e of refrigerant flow int o
t he evaporat or exact ly mat ches t he rat e of
evaporat ion of liquid refrigerant in t he
evaporat or. If t he act ual superheat is higher
t han t he set point t he valve feeds t he
evaporat or wit h more liquid refrigerant , if t he
act ual superheat is lower t han t he set point t he
valve decreases t he flow of liquid refrigerant t o
t he evaporat or. Thus t he evaporat or is fully
ut ilized and no liquid refrigerant may reach t he
compressor.
CONSTRUCTION
Cast el t hermost at ic expansion valve series 22
is made up of t wo par t s t hat must work
t oget her: t he first is t he body, which is t he
act uat or of t he regulat or, and t he second is t he
orifice, which cont ains t he valve and at t ends
t he expansion of t he refrigerat ing fluid.
Body assembl y: t wo par t s make it up: t he
t hermost at ic (power) element and t he body wit h
it s inner element s.
The t hermost at ic element is t he mot or of t he
valve; a sensing bulb is connect ed t o t he
THERMOSTATIC EXPANSION VALVES SERIES 22
WITH INTERCHANGEABLE ORIFICE ASSEMBLY
17
TABLE 1a: General Charact eri st i cs of Body Assembl i es of Li qui d Charge Thermost at i c Expansi on Val ves
ext ernal
equalizer
int ernal
equalizer
Cat alogue
number
IN OUT Equal. OUT OUT Equal. min max
PS
[bar]
SAE Flare ODS [mm] ODS [in]
R
e
f
r
i
g
e
r
a
n
t
E
v
a
p
o
r
a
t
i
n
g
T
e
m
p
e
r
a
t
u
r
e

R
a
n
g
e
[
C
]
M
a
x

b
u
l
b
t
e
m
p
e
r
a
t
u
r
e

[
C
]
MOP
TS [C]
Connect ions
2210/ 4E
2210/ M12SE
2210/ 4SE
2220/ 4E
2220/ M12SE
2220/ 4SE
2230/ 4E
2230/ M12SE
2230/ 4SE
2210/ 4
2210/ M12S
2210/ 4S
2220/ 4
2220/ M12S
2220/ 4S
2230/ 4
2230/ M12S
2230/ 4S
3/ 8"
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 4"
1/ 4"
1/ 4"
12
12
12
12
12
12
Equal.
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 4"
1/ 4"
1/ 4"
R22
R407C
R134a
R404A
R507
- 40
+ 10
wit hout
100
(1)
-60 +120 34
Risk
Cat egor y
according
t o
PED
Ar t . 3.3
(1) When valve is inst alled. 60 C wit h element not mount ed
TABLE 1b: General Charact eri st i cs of Body Assembl i es of MOP Charge Thermost at i c Expansi on Val ves
ext ernal
equalizer
int ernal
equalizer
Cat alogue
number
IN OUT Equal. OUT OUT Equal. min max
PS
[bar]
SAE Flare ODS [mm] ODS [in]
R
e
f
r
i
g
e
r
a
n
t
E
v
a
p
o
r
a
t
i
n
g
t
e
m
p
e
r
a
t
u
r
e
R
a
n
g
e

[
C
]
M
a
x

b
u
l
b

t
e
m
p
e
r
a
t
u
r
e

[
C
]
MOP
TS [C]
Connect ions
2211/ 4E
2211/ M12SE
2211/ 4SE
2221/ 4E
2221/ M12SE
2221/ 4SE
2231/ 4E
2231/ M12SE
2231/ 4SE
2234/ 4E
2234/ M12SE
2234/ 4SE
2211/ 4
2211/ M12S
2211/ 4S
2221/ 4
2221/ M12S
2221/ 4S
2231/ 4
2231/ M12S
2231/ 4S
2234/ 4
2234/ M12S
2234/ 4S
3/ 8"
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 4"
1/ 4"
1/ 4"
1/ 4"
12
12
12
12
12
12
12
12
Equal.
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 2"
1/ 4"
1/ 4"
1/ 4"
1/ 4"
R22
R407C
R134a
R404A
R507
- 40
+ 10
- 60
- 25
+ 15 C
(95 psi)
+ 15 C
(55 psi)
+ 15 C
(120 psi)
- 20 C
(30 psi)
100
(1)
-60 +120 34
Risk
Cat egor y
according
t o
PED
Ar t . 3.3
(1) When valve is inst alled. 60 C wit h element not mount ed
18
Gas charge: t he behaviour of valves wit h gas
charge will be det ermined by t he lowest
t emperat ure at any par t of t he expansion valve
(t hermost at ic element , capillar y t ube or bulb). If
any par t s ot her t han t he bulb are subject ed t o
t he lowest t emperat ure, malfunct ion of
expansion valve may occur (charge migrat ion).
Cast el t hermost at ic expansion valves wit h gas
charge always feat ure MOP funct ions and
include ballast ed bulb. Ballast in t he bulb has a
damping ef fect on t he valve regulat ion and
leads t o slow opening and fast closure of t he
valve.
MOP (Maxi mum Operat i ng Pressure): t his
funct ionalit y limit s t he evaporat or pressure t o a
maximum value t o prot ect t he compressor from
t he overload condit ion (Mot or Overload
Prot ect ion). MOP is t he evaporat ing pressure at
which t he expansion valve will t hrot t le liquid
inject ion int o t he evaporat or and t hus prevent
t he evaporat ing pressure from rising. Expansion
valve operat es as superheat cont rol in normal
working range and operat es as pressure
regulat or wit hin MOP range. The MOP point will
change if t he fact or y superheat set t ing of t he
expansion valve is changed. Superheat
adjust ment s influence t he MOP point as
following:
increase of superheat
decrease of MOP
decrease of superheat
increase of MOP
Superheat : t his is t he cont rolling paramet er of
t he expansion valve. Superheat , measured at
t he evaporat or out let , is defined as t he
dif ference bet ween act ual bulb t emperat ure
and t he evaporat ing t emperat ure, deduce from
evaporat or pressure. In order t o prevent liquid
refrigerant from ent ering t he compressor, a
cer t ain minimum superheat must be
maint ained. In expansion valve operat ion t he
following t erms are used:
St at ic superheat : it s t he superheat above
t hat t he valve will begin t o open. Cast el
t hermo expansion valves are fact or y preset
at t he following values:
5 C for Cast el valves wit hout MOP
4 C for Cast el valves wit h MOP
with nominal operating conditions (see table 2)
Opening superheat : it s t he superheat above
t he st at ic one required t o produce a given
valve capacit y
Operat ing superheat : it s t he sum of st at ic
and opening superheat
brazing adapt er for solder connect ion t ype can
be ordered separat ely.
The main par t of body assembly are made wit h
t he following mat erials:
st ainless st eel for bulb, capillar y t ubing,
diaphragm casing, diaphragm and rod
hot forged brass EN 12420 CW 617N for
body
brass EN 12164 CW 614N for superheat
set t ing spindle and spring holder
st eel DIN 17223-1 for spring
copper t ube EN 12735-1 Cu DHP for solder
connect ion
Ori f i ce assembl y: int erchangeable orifice
assembly provide a wide range of capacit y from
0,5 up t o 15,5 kW (nominal capacit y wit h R22).
The ext ernal car t ridge cont ains t he following
element s: housing, plug (met ering device), seat ,
spring and st rainer. The rigid design of orifice
assembly and it s int ernal component s make
sure t hat plug and seat will wit hst and all t ypes
of crit ical operat ions (liquid hammering,
cavit at ion, sudden variat ion of pressure and
t emperat ure cont aminant s). The spring holds
t he plug firmly t o t he seat t o ensure t he
minimum leakage t hrough t he valve; for posit ive
shut -of f, t he inst allat ion of a solenoid valve is
required. Orifice assemblies are available in
t hese t wo solut ions:
wit h conical flanged st rainer, for valves wit h
SAE Flare t hreaded connect ions.
wit h flat flanged st rainer, for valves wit h ODS
solder connect ions, t o use wit h adapt er
series 2271.
Orifice assemblies st rainers can be cleaned or
exchanged, in t his last case it s possible t o
order separat ely t he following t wo t ypes of
st rainers.
st rainer 2290 for valves wit h SAE Flare
t hreaded connect ions.
st rainer 2290/ S for valves wit h ODS solder
connect ions.
THERMOSTATIC CHARGES
Li qui d charge: t he behaviour of valves wit h
liquid charge is exclusively det ermined by
t emperat ure changes at t he bulb and not
subject t o any cross-ambient int er ference. They
feat ure a fast response t ime and t hus react
quickly in t he cont rol circuit . Cast el
t hermost at ic expansion valves wit h liquid
charge cannot incorporat e MOP funct ions.
19
Subcool i ng: it s defined as t he dif ference
bet ween t he condensing t emperat ure (deduced
from condensing pressure) and t he act ual
t emperat ure at inlet valve. Subcooling generally
increases t he capacit y of refrigerat ion syst em
and may be account ed for when dimensioning
an expansion valve. Depending on syst em
design, subcooling may be necessar y t o
prevent flash gas from forming in t he liquid
line. If flash gas forms in t he liquid line, t he
capacit y of expansion valve will be great ly
reduced. All capacit y t ables, in t his chapt er, are
calculat ed for a subcooling value of 4 C; if t he
act ual subcooling is higher t han 4 C t he valve
capacit y comes from evaporat or capacit y
divided by t he correct ion fact or shown in t he
t ables below ever y capacit y t able.
4
1
,
5
4
2
20
St ep 3
Det ermine required orifice size. Use t he
pressure drop across t he valve, t he evaporat ing
t emperat ure and t he calculat ed evaporat or
capacit y t o select t he corresponding orifice size
from t he capacit y t able corresponding t o t he
chosen refrigerant .
St ep 4
Select a t hermost at ic charge. Chose t he t ype of
charge, liquid wit hout MOP or gas wit h MOP,
and t he t emperat ure range, normal
t emperat ure or low t emperat ure.
St ep 5
Det ermine if ext ernal equalizer is required.
Ext ernal equalizer is always required if a
dist ribut or is used or if t here is an appreciable
dif ference in pressure from t he valve out let t o
t he bulb locat ion. Finally det ermine t he t ype of
connect ions and t heir sizes.
SELECTION
To correct ly select a t hermo expansion valve on
a refrigerat ing syst em, t he following design
condit ions must be available:
Type of refrigerant
Evaporat or capacit y, Q
e
Evaporat ing t emperat ure/ pressure, T
e
/ p
e
Lowest possible condensing t emperat ure/
pressure, T
c
/ p
c
Liquid refrigerant t emperat ure, T
l
Pressure drop in t he liquid line, dist ribut or and
evaporat or, p
The following procedure helps t o select t he
correct valve for t he syst em.
St ep 1
Det ermine t he pressure drop across t he valve.
The pressure drop is calculat ed by t he formula:
where:
P
c
= condensing pressure
P
e
= evaporat ing pressure
p = sum of pressure drops in t he liquid line,
dist ribut or and evaporat or
St ep 2
Det ermine required valve capacit y. Use t he
evaporat ing capacit y Q
e
t o select t he required
valve size at a given evaporat ing t emperat ure. If
necessar y, correct t he evaporat or capacit y for
subcooling. Subcooling liquid refrigerant
ent ering t he evaporat or increase t he evaporat or
capacit y, so t hat a smaller valve may be
required.
The subcooling is calculat ed by t he formula:
From t he subcooling correct or fact or t able find
t he appropriat e correct or fact or F
sub
corresponding t o t he T
sub
calculat ed and
det ermine t he required valve capacit y by t he
formula:
sub
e
sub
F
Q
Q =
l c sub
T T T =
( ) p p p p
e c tot
+ =
TABLE 2: Ori f i ce Assembl i es - Rat ed Capaci t i es i n kW
Valves wit h
SAE Flare
connect ions
Cat alogue number
Valves wit h
ODS
connect ions
R22
R407C
R134a
R404A
R507
R404A
R507
Evaporat ing Temperat ure Range [C]
- 40 + 10 -60 -25
220X
2200
2201
2202
2203
2204
2205
2206
220X/ S
2200/ S
2201/ S
2202/ S
2203/ S
2204/ S
2205/ S
2206/ S
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
Rat ed capacit ies, for t emperat ure range
- 40 + 10, are based on:
Evaporat ing t emperat ure Tevap = + 5 C
Condensing t emperat ure Tcond = + 32 C
Refrigerant liquid t emperat ure ahead
of valve Tliq = + 28 C
Rat ed capacit ies, for t emperat ure range
- 60 - 25, are based on:
Evaporat ing t emperat ure Tevap = - 30 C
Condensing t emperat ure Tcond = + 32 C
Refrigerant liquid t emperat ure ahead
of valve Tliq = + 28 C
21
pressure drop across t he valve = 4,2 bar
evaporat ing t emperat ure = - 10 C
calculat ed evaporat or capacit y = 5,55 kW
select t he corresponding orifice 2205 (N.B.:
t he expansion valve capacit y must be equal
or slight ly more t han t he calculat ed
evaporat or capacit y)
MARKING
Main valve dat a are indicat ed on t he upper side
o f t h e t h e r mo s t a t i c e l e me n t a n d o n t h e
car t ridge sur face of t he orifice assembly.
On t he t hermost at ic element you may find t he
following dat a:
The valve code number
The refrigerant
The evaporat ing t emperat ure range
The MOP value, if present
The maximum allowable pressure PS
The dat e of product ion
On t he car t ri dge of ori f i ce assembl y you may
find t he following dat a:
The size of t he orifice
The dat e of product ion
On t he plast ic cap of t he orifice assembly
package t he orifice size is marked. The cap can
easily be fast ened around t he valve capillar y
t ube t o clearly ident ify t he valve size.
TABLE 3: Sol der adapt ers
Cat alogue number
ODS Connect ions
[in] [mm]
2271/ M6S
2271/ 2S
2271/ 3S
2271/ M10S
1/ 4"
3/ 8"
10
SIZING EXAMPLE
Type of refrigerant R134a
e
6 kW
Evaporat ing t emperat ure/
pressure, T
e
- 10 C
Lowest possible condensing
t emperat ure/ pressure, T
c
+ 30 C
l
+ 20 C
Pressure drop in t he liquid line, dist ribut or
and evaporat or, p 1,5 bar
STEP 1 - Det ermine t he pressure drop across
t he valve
Condensing pressure at
+ 30 C - p
c
= 6,71 bar
Evaporat ing pressure at
- 10 C - p
e
= 1,01 bar
p
tot
= 6,71 ( 1,01 + 1,5 ) = 4,2 bar
STEP 2 - Det ermine required valve capacit y
T
sub
= 30 20 = 10 C
From t he subcooling correct or fact or t able 5b,
we find t he appropriat e correct or fact or F
sub
equal t o 1,08 for T
sub
= 10 C Required valve
capacit y is:
Q
sub
=
6
/
1,08
= 5,55 kW
STEP 3 - Det ermine required orifice size
Using t he capacit y t able for R134a on page 25
wit h:
22
TABLE 4a: Ref ri gerant R22/ R407C - Capaci t i es i n kW f or t emperat ure range - 40 C +10 C
Orifice
code
Orifice
code
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
Evaporat ing t emperat ure = 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
Evaporat ing t emperat ure =-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
Evaporat ing t emperat ure = -40 C
220X 0,42 0,45 0,48 0,50 0,52 0,53
2200 0,8 0,86 0,92 0,95 0,98 0,99
2201 1,3 1,4 1,4 1,5 1,5 1,6
2202 1,7 1,9 2,0 2,0 2,1 2,1
2203 3,1 3,4 3,5 3,7 3,8 3,8
2204 4,6 4,9 5,2 5,4 5,6 5,7
2205 5,8 6,3 6,6 6,9 7,1 7,2
2206 7,1 7,7 8,1 8,4 8,7 8,8
Evaporat ing t emperat ure = +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: Ref ri gerant R22/ R407C - Correct i on f act or f or subcool i ng t sub > 4 C
t sub [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 t he expansion valve is over t han 4 C, adjust t he evaporat or capacit y by dividing by t he appropriat e
correct ion fact or found in t able 4b
23
TABLE 5a: Ref ri gerant R134a Capaci t i es i n kW f or t emperat ure range - 40 C + 10 C
Orifice
code
Orifice
code
Pressure drop accross valve [bar] Pressure drop accross valve [bar]
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: Ref ri gerant R134a - Correct i on f act or f or subcool i ng t sub > 4 C
t sub [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
24
TABLE 6a: Ref ri gerant R404A/ R507 Capaci t i es i n kW f or t emperat ure range - 40 C + 10 C
Orifice
code
Orifice
code
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: Ref ri gerant R404A/ R507 - Correct i on f act or f or subcool i ng t sub > 4 C
t sub [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
25
TABLE 7a: Ref ri gerant R404A/ R507 Capaci t i es i n kW f or t emperat ure range - 60 C - 25 C
Orifice
code
Orifice
code
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
TABLE 7b: Ref ri gerant R404A/ R507 - Correct i on f act or f or subcool i ng t sub > 4 C
t sub [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
26
PWM SOLENOID EXPANSION VALVE WITH
INTERCHANGEABLE ORIFICE
APPLICATION
Solenoid expansion valve Cast el t ype 2028
regulat es t he refrigerant flow int o t he
evaporat or by modulat ing t he opening t ime
phase of t he plug and so permit t ing a wide
range of power.
This valve must be used wit h a coil t ype HM4
(see t able 2), cont rolled by an elect ronic
regulat or device (not supplied by Cast el).
This valve is most frequent ly used in
refrigerat ion syst ems, in par t icular refrigerat ed
cabinet s in t he supermarket , which use
refrigerant fluids proper t o t he Group II (as
defined in Ar t icle 9, Sect ion 2.2 of Direct ive
97/ 23/ CE, and referred in Direct ive
67/ 548/ CE).
OPERATION
Valve t ype 2028 is a laminat ion device t hat
receives liquid from t he condenser and inject s
it int o t he evaporat or, operat ing t he necessar y
pressure drop across t he expansion orifice.
It s an ON/ OFF valve t hat must be regulat ed
wit h t he Pul se Wi dt h Modul at i on (PWM)
met hod and it can be act uat ed by a ver y simple
elect ronic cont roller. In according t o t he PWM
met hod, t he evaporat or refrigerant capacit y Q
T
,
required in a fixed period T , is delivered by
t he valve in a t ime int er val t , shor t er t han
T . During t he period t t he valve opens and
permit s maximum flow (ON phase); in t he
remaining period T-t t he valve closes wit h no
flow (OFF phase).
For an ef fect ive PWM regulat ion, t he valve must
be sized in such a way t hat in t he hardest
condit ions of t he syst em, t he orifice of t he
valve is big enough t o deliver t he refrigerant
request ed; in t hese ext reme condit ions t he
valve will last opened for t he ent ire period T .
The use of an elect ronic regulat or allows a
more accurat e met ering of t he refrigerant
reaching a great er ef ficiency (and t hen a
sensible decrement of t he machiner y
management cost s) and a fast er response t o
t he variat ions of t he evaporat ion load.
CONSTRUCTION
Valve is supplied complet e wit h it s orifice; t here
are seven dif ferent orifices corresponding t o
seven dif ferent evaporat or capacit ies , t hat
increase passing from orifice 01 t o orifice 07.
The orifices are int erchangeable and can be
mount ed even if t he valve is soldered on t he
syst em; in t his case use t he corresponding
spare par t s kit , in according t o t able 3.
The main par t s of t he valves are made wit h t he
following mat erials:
Hot forged brass EN 12420 CW 617N for
body and t he housing pipe of t he mobile plug
Copper t ube EN 12735-1 Cu-DHP for solder
connect ions
Aust enit ic st ainless st eel EN 10088-3
1.4301 for t he filt er
Ferrit ic st ainless st eel EN 10088-3 1.4105
for mobile and fixed plugs
Aust enit ic st ainless st eel EN 10088-3
1.4305 for orifices
Chloroprene rubber (CR) for out let seal
gasket s
P.T.F.E. for seat gasket s
COILS AND CONNECTORS
Coils t ype HM4 must be mount ed on t hese
valves. Table 2 present s t he most impor t ant
charact erist ics of coils and corresponding
connect ors. For fur t her t echnical charact erist ics
about HM4 coils and t heir connect ors see t o
t he solenoid valve chapt er.
SELECTION
To correct ly select a solenoid expansion valve
on a refrigerat ing syst em, t he following design
condit ions must be available:
Type of refrigerant
e
e
/ p
e
c
/ p
c
l
Pressure drop in t he liquid line, dist ribut or
and evaporat or, p
27
TABLE 1: General Charact eri st i cs of PWM sol enoi d expansi on val ves
Cat alogue
number
0,5 0,01
0,07 0,017
0,8 0,023
1,1 0,043
1,3 0,065
1,7 0,113
2,3 0,2
Orifice
Flow
[mm]
Kv
Fact or
[m
3
/ h]
MinOPD
0 18
P
W
M
(
P
u
l
s
e

W
i
d
t
h

M
o
d
u
l
a
t
i
n
g
)
1
-40 100
45
Ar t .
3.3
MOPD
AC/ RAC DC
O
p
e
r
a
t
i
n
g

p
r
i
n
c
i
p
l
e
s Minimum
working
t ime
[s]
Opening pressure dif ferent ial [bar]
min max
PS
[bar]
TS [C]
ODS Connect ions
[mm] [in]
IN OUT IN OUT
Risk
Cat egor y
according
t o
PED
2028/ 3S01 3/ 8 1/ 2
2028/ M10S01 10 12
2028/ 3S02 3/ 8 1/ 2
2028/ M10S02 10 12
2028/ 3S03 3/ 8 1/ 2
2028/ M10S03 10 12
2028/ 3S04 3/ 8 1/ 2
2028/ M10S04 10 12
2028/ 3S05 3/ 8 1/ 2
2028/ M10S05 10 12
2028/ 3S06 3/ 8 1/ 2
2028/ M10S06 10 12
2028/ 4S07 1/ 2 5/ 8
2028/ M12S07 12 16
18
14
Nominal capacit ies are referred t o:
Evaporat ing t emperat ure Tevap = +5C
Condensat ing t emperat ure Tcond = +32C
inlet t emperat ure of liquid Tliq = +28C
The following procedure helps t o select t he
correct valve for t he syst em.
St ep 1
Det ermine t he pressure drop across t he valve.
The pressure drop is calculat ed by t he formula:
( ) p p p p
e c tot
+ =
where:
P
c
= condensing pressure
P
e
= evaporat ing pressure
p = sum of pressure drops in t he liquid line,
dist ribut or and evaporat or
St ep 2
Subcooling correct ion. Use t he evaporat ing
capacit y Q
e
t o select t he required valve size at
TABLE 2: General Charact eri st i c of coi l s
Coil
t ype
Prot ect ion
Degree
IP65
Prot ect ion
Degree
IP65/ IP68
Connect ions Consumpt ion at 20C [mA]
St ar t
50 [Hz] D.C. 50 [Hz] D.C.
Working
Frequency
[Hz]
Volt age
t olerance [%]
Volt age
[V]
Cat alogue
number
HM4
9160/ RA2
9160/ RA6
9160/ RD1
9160/ RD2
9160/ RD6
24 A.C.
220/ 230 A.C.
12 D.C.
24 D.C.
220 RAC
1490
162
-
700
76
-
-
1350
650
77
-
1350
650
77
+6 / -10
+10 / -15
50
-
9155/ R01
9155/ R03
9150/ R02
9150/ R45
TABLE 3: Ori f i ce Nomi nal capaci t i es i n kW
Cat alogue number
Refrigerent
Orifice t ype
Orifice size
[mm] R22 R134a
R404A
R507
R407C
R410A
9150/ R63 01 0,5 1 0,9 0,8 1,1 1,3
9150/ R64 02 0,7 1,9 1,7 1,6 2 2,4
9150/ R65 03 0,8 2,5 2 1,9 2,4 3
9150/ R66 04 1,1 3,9 3,2 2,9 3,8 4,8
9150/ R67 05 1,3 6,7 5,6 5,1 6,7 8,4
9150/ R68 06 1,7 9,2 7,7 7 9,1 11,4
9150/ R69 07 2,3 14,7 12,2 11,3 15,3 18,2
28
a given evaporat ing t emperat ure. If necessar y,
correct t he evaporat or capacit y for subcooling.
Subcooling liquid refrigerant ent ering t he
evaporat or increase t he evaporat or capacit y, so
t hat a smaller valve may be required. The
subcooling is calculat ed by t he formula:
From t he subcooling correct or fact or t able find
t he appropriat e correct or fact or F
sub
corresponding t o t he T
sub
calculat ed and
det ermine t he required valve capacit y by t he
formula:
Q
sub
= F
sub
.
Q
e
St ep 3
Appl i cat i on cor r ect i on. To obt ai n a cor r ect
r egul at i on wi t h t hi s val ve, i s neces s ar y t o
oversize it so it s closing period is bet ween t he
25% and t he 50% of t he t ot al period T of t he
regul at or. The cor rect choi ce of t hi s cl osi ng
peri od depends on t he appl i cat i on, t hat can
have peaks of load, and on t he crit erion used by
t he elect ronic regulat or.
Generally, anyway, t his correct ing fact or Fev is
s t r i c t l y d e p e n d e n t b y t h e e va p o r a t i o n
t emperat ure so it be assumed t hat F
ev
= 1.25
for T
ev
>= -15C and F
ev
= 1.50 for T
ev
<=-15C.
These generic inst ruct ions must be verified on
t he real applicat ion.
The capacit y of t he valve will have t herefore t o
be at least equal t o:
Q
ev
= F
ev
.
Q
sub
St ep 4
Det ermine required orifice size. Use t he
pressure drop across t he valve, t he evaporat ing
t emperat ure and t he calculat ed evaporat or
capacit y Q
e
t o select t he corresponding orifice
size from t he capacit y t able corresponding t o
t he chosen refrigerant .
St ep 5
Liquid line sizing. Since t he 2028 is an ON/ OFF
valve, during t he opening phase of t he valve,
t he flow rat e can be t oo much higher t han t he
mean flow rat e. For t his reason t he designer
must size t he diamet er of t he pipes of t he
liquid line in according t o t he maximum flow
rat e across t he orifice in t he ef fect ive
condit ions of Pt ot and so avoiding t he
decrement of t he valve capacit y due t o t he
pressure drop.
l c sub
T T T =
SIZING EXAMPLE
Type of refrigerant R404A
e
2,8 kW
e
- 5 C
c
+ 35 C
l
+ 20 C
Pressure drop in t he liquid line, 2 bar
dist ribut or and evaporat or, p
St ep 1 - Det ermine t he pressure drop across
t he valve
Condensing pressure
at + 35 C - P
c
= 16,9 bar
Evaporat ing pressure
at 5 C - P
e
= 5,14 bar
p
tot
= 16,9 ( 5,14 + 2 ) = 9,76 bar
St ep 2 - Det ermine required valve capacit y
T
sub
= 35 20 = 15 C
From t he subcooling correct or fact or t able 5b,
we find t he appropriat e correct or fact or F
sub
equal t o 0,83 for T
sub
= 15 C. Required valve
capacit y is:
Q
sub
= 0,83
.
2,8 = 2,324 kW
St ep 3 - Det ermine applicat ion correct ion
In according t o t he above crit erion of sizing,
F
ev
= 1,25:
Q
ev
= 1,25
.
2,324 = 2,91 kW
St ep 4 - Det ermine orifice size
Using t he capacit y t able for R404A on page 29
wit h:
pressure drop across t he valve = 9,76 bar
evaporat ing t emperat ure = - 5 C
calculat ed evaporat or capacit y = 2,91 kW
select t he corresponding orifice 04 (N.B. : t he
expansion valve capacit y must be equal or
slight ly more t han t he calculat ed evaporat or
capacit y)
29
TABLE 4: Ref ri gerant R22 Capaci t i es i n kW
2
Pressure drop across valve [bar] Orifice
t ype
4 6 8
10 12 14 16 18
01 0,7 0,9 1,0 1,1 1,2 1,2 1,2 1,2 1,2
02 1,3 1,7 1,9 2,2 2,2 2,3 2,3 2,4 2,3
03 1,7 2,2 2,5 2,7 2,8 2,9 2,9 2,9 2,9
04 2,7 3,4 3,9 4,2 4,4 4,5 4,6 4,7 4,7
05 4,6 6,0 6,7 7,2 7,6 7,9 8,0 8,1 8,1
06 6,3 8,1 9,2 9,9 10,4 10,6 10,9 11,0 11,1
07 10,1 13,0 14,7 15,8 16,6 17,0 17,4 17,6 (1) 17,4 (2)
TABLE 5: Ref ri gerant R134a Capaci t i es i n kW
2
t ype
4 6 8
10 12 14 16 18
01 0,6 0,8 0,9 0,9 0,9 0,9 0,9 0,9 0,9
02 1,1 1,4 1,7 1,7 1,8 1,8 1,8 1,8 1,7
03 1,4 1,8 2,0 2,2 2,2 2,3 2,3 2,2 2,2
04 2,3 2,9 3,2 3,4 3,5 3,6 3,6 3,5 3,4
05 3,9 5,0 5,6 6,0 6,2 6,2 6,2 6,2 6,0
06 5,3 6,8 7,7 8,1 8,4 8,5 8,5 8,4 8,1
07 8,5 10,9 12,2 13,0 13,3 13,5 13,5 13,3 (1) 13 (2)
TABLE 6: Ref ri gerant R404A/ R507 Capaci t i es i n kW
2
t ype
4 6 8
10 12 14 16 18
01 0,6 0,7 0,8 0,8 0,9 0,8 0,8 0,8 0,8
02 1,1 1,3 1,6 1,6 1,7 1,7 1,6 1,6 1,4
03 1,3 1,7 1,9 2,0 2,0 2,0 2,0 1,9 1,8
04 2,2 2,8 2,9 3,1 3,2 3,2 3,1 3,1 2,9
05 3,8 4,7 5,1 5,5 5,6 5,6 5,6 5,4 5,1
06 5,0 6,4 7,0 7,4 7,6 7,7 7,6 7,4 6,9
07 8,1 10,3 11,3 11,9 12,2 12,2 12,1 11,8 (1) 11,2 (2)
TABLE 7: Ref ri gerant R407C Capaci t i es i n kW
2
t ype
4 6 8
10 12 14 16 18
01 0,7 1,0 1,1 1,1 1,2 1,2 1,2 1,2 1,2
02 1,4 1,8 2,0 2,0 2,3 2,3 2,4 2,4 2,3
03 1,7 2,3 2,4 2,7 2,8 2,9 2,9 2,9 2,9
04 2,9 3,6 3,8 4,3 4,5 4,6 4,7 4,7 4,7
05 4,9 6,2 6,7 7,5 7,8 7,9 8,1 8,1 8,0
06 6,7 8,5 9,1 10,2 10,5 10,8 11,0 11,0 10,9
07 10,7 13,6 15,3 15,7 16,9 17,2 17,6 17,6 (1) 17,2 (2)
(1) Pressure dif ferent ial not available wit h coils 9160/ RD2
(2) Pressure dif ferent ial not available wit h coils 9160/ RD1 and 9160/ RD2
30
TABLE 8: Ref ri gerant R410A Capaci t i es i n kW
2
t ype
4 6 8
10 12 14 16 18
01 0,9 1,1 1,3 1,4 1,5 1,5 1,6 1,6 1,6
02 1,7 2,2 2,4 2,6 2,8 2,9 3,0 3,0 3,0
03 2,0 2,7 3,0 3,2 3,4 3,6 3,7 3,7 3,8
04 3,2 4,2 4,8 5,2 5,5 5,7 5,9 6,0 6,1
05 5,6 7,4 8,4 9,1 9,6 10,0 10,2 10,4 10,9
06 7,7 10,0 11,4 12,3 13,1 13,5 13,9 14,1 14,3
07 12,2 15,9 18,2 19,8 20,9 21,6 22,2 22,7 (1) 22,9 (2)
TABLE 9: Correct i on f act or f or subcool i ng t sub > 4C
4K Refrigerant 10K 15K 20K 25K 30K 35K 40K 45K 50K
R22 1 0,94 0,9 0,87 0,83 0,8 0,77 0,74 0,72 0,69
R134a 1 093 0,88 0,84 0,8 0,76 0,73 0,7 0,68 0,65
R404A/ R507 1 0,91 0,83 0,78 0,73 0,68 0,65 0,61 0,59 0,56
R407C 1 0,93 0,88 0,83 0,79 0,75 0,72 0,69 0,66 0,64
R410A 1 0,95 0,9 0,85 0,81 0,77 0,73 0,7 0,67 0,64
correct ion fact or found in t able 8
(1) Pressure dif ferent ial not available wit h coils 9160/ RD2
(2) Pressure dif ferent ial not available wit h coils 9160/ RD1 and 9160/ RD2
The dimensions in braket s are referred t o 2028/ 4S07 & 2028/ M12S07 models
Solenoid valves
32
cover;
chloroprene rubber (CR) for out let seal
gasket s;
P.T.F.E. for seat gasket s.
INSTALLATION
The valves can be installed in all sections of a
refrigerating system, in compliance with the
limits and capacities indicated in Tables 3 and 6.
Tables 1 and 4 show t he following funct ional
charact erist ics of a solenoid valve:
PS;
TS;
Kv fact or;
minimum Opening Pressure Dif ferent ial
(minOPD), t hat is t he minimum pressure
dif ferent ial bet ween inlet and out let at which
a solenoid valve, pilot operat ed, can open
and st ay opened;
maximum Opening Pressure Dif ferent ial
(MOPD according t o ARI STANDARD 760:
2001), t hat is t he maximum pressure
a solenoid valve, pilot operat ed, can open.
Before connect ing t he valve t o t he pipe it is
advisable t o make sure t hat t he refrigerat ing
syst em is clean. In fact t he valves wit h P.T.F.E.
gasket s are par t icularly sensit ive t o dir t and
debris.
Fur t hermore check t hat t he flow direct ion in t he
pipe corresponds t o t he arrow st amped on t he
body of t he valve.
All valves can be mount ed in what ever posit ion
except wit h t he coil point ing downwards.
The brazing of valves wit h solder connect ions
should be carried out wit h care, using a low
melt ing point filler mat erial. It is not necessar y
t o disassemble t he valves before brazing but
it s impor t ant t o avoid direct cont act bet ween
t he t orch flame and t he valve body, which could
be damaged and compromise t he proper
funct ioning of t he valve.
Before connect ing a valve t o t he elect rical
syst em, be sure t hat t he line volt age and
frequency correspond t o t he values marked on
t he coil.
The NO valves have been designed t o work only
wit h direct current coils.
To use t hem in applicat ions wit h 220/ 230 VAC
suplly it s necessar y t o mat e t he NO valve wit h
t he following component s:
Coil 9120/ RD6 +
Connect or/ Rect ifier 9150/ R45
APPLICATIONS
The solenoid valves, shown in t his chapt er, are
classified Pressure accessories in t he sense
of t he Pressure Equipment Direct ive 97/ 23/ EC,
Ar t icle 1, Sect ion 2.1.4 and are subject of
Ar t icle 3, Sect ion 1.3 of t he same Direct ive.
They are designed for inst allat ion on
commercial refrigerat ing syst ems and on civil
and indust rial condit ioning plant s, which use
97/ 23/ EC and referred t o in Direct ive
67/ 548/ EEC).
OPERATION
The valves series 1020; 1028; 1050; 1058;
1059; 1064; 1068; 1070; 1078; 1079; 1090;
1098; 1099 are normally closed.
NC = when t he coil is de-energised t he plunger
st ops t he refrigerant flow.
The valves series 1150; 1158; 1164; 1168;
1170; 1178;1190; 1198 are normally open.
NO = when t he coil is energised t he plunger
st ops t he refrigerant flow.
The valves series 1020 and 1028 are direct
act ing, while t he valves of all t he ot her series
are pilot operat ed, wit h diaphragm or pist on.
The NC valves are supplied eit her wit hout coil
(S t ype) or wit h coil (example: A6 t ype wit h coil
HM2220 Vac).
The NO valves are supplied only wit hout coil (S
t ype).
N.B.: t he NO valve visually dif fers from t he
corresponding NC model by means of t he red
ring inst alled below t he yellow nut t hat fast ens
t he coil.
CONSTRUCTION
body and cover;
copper t ube EN 12735-1 Cu-DHP for solder
connect ions;
aust enit ic st ainless st eel EN 10088-2
1.4303 for enclosure where t he plunger
moves;
ferrit ic st ainless st eel EN 10088-3 1.4105
for plunger:
aust enit ic st ainless st eel EN ISO 3506 A2-
70 for t ight ening screws bet ween body and
SOLENOID VALVES FOR REFRIGERATING SYSTEMS
33
TABLE 1a: General Charact eri st i cs of NC val ves (normal l y cl osed) wi t h SAE Fl are connect i ons
Cat alogue
number
SAE
Flare
1/ 4"
3/ 8"
3/ 8"
1/ 2"
1/ 2"
5/ 8"
5/ 8"
3/ 4"
5/ 8"
3/ 4"
2,5
3
7
12,5
16,5
0,175
0,23
0,80
2,20
2,61
3,80
4,80
3,80
4,80
0
0,05
0,07
0,05
25
(3)
21
19
18
13
35
+105
(1)
+110
(2)
+105
(1)
45 Ar t . 3.3
Connect ions
Seat size
Nominal

[mm]
Kv
Fact or
[m
3
/ h]
Operat ing
Principles
min
OPD
MOPD
Coil t ype
Opening Pressure Dif ferent ial [bar]
HM4
(AC)
21
HM2
CM2
(AC)
HM3
(DC)
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
PED
Direct
Act ing
Diaphragm
Pilot
Operat ed
1020/ 2
1020/ 3
1064/ 3
1064/ 4
1070/ 4
1070/ 5
1050/ 5
1050/ 6
1090/ 5
1090/ 6
Pist on
Pilot
Operat ed
Diaphragm
Pilot
Operat ed
(1) Temperat ure peaks of 120 C are allowed during defrost ing.
(3) For informat ion about higher MOPD, please cont act Cast el Technical Depar t ement .
TABLE 1b: General Charact eri st i cs of NC val ves (normal l y cl osed) wi t h ODS connect i ons
Cat alogue
number
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
2,2
3
7
12,5
16,5
25,5
25
27
0,15
0,23
0,80
2,20
2,61
3,80
4,80
5,70
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 Ar t . 3.3
[in.]
[mm]
ODS
Connect ions
Seat size
Nominal

[mm]
Kv
Fact or
[m
3
/ h]
Operat ing
Principles
min
OPD
MOPD
Coil t ype
Opening Pressure Dif ferent ial [bar]
HM4
(AC)
21
HM2
CM2
(AC)
HM3
(DC)
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
PED
D
i
r
e
c
t

A
c
t
i
n
g
D
i
a
p
h
r
a
g
m

P
i
l
o
t

O
p
e
r
a
t
e
d
1028/ 2
1028/ 2E
1028/ 3
1028/ M10
1068/ 3
1068/ M10
1068/ M12
1068/ 4
1078/ M12
1078/ 4
1078/ 5
1079/ 7
1058/ 5
1058/ 6
1058/ 7
1059/ 9
1098/ 5
1098/ 6
1098/ 7
1099/ 9
1078/ 9
1079/ 11
1098/ 9
1099/ 11
1078/ 11
1079/ 13
1079/ M42
(3) For informat ion about higher MOPD, please cont act Cast el Technical Depar t ement .
P
i
s
t
o
n

P
i
l
o
t
O
p
e
r
a
t
e
d
D
i
a
p
h
r
a
g
m

P
i
l
o
t
O
p
e
r
a
t
e
d
P
i
s
t
o
n

P
i
l
o
t
O
p
e
r
a
t
e
d
34
SOLENOID VALVES FOR
REFRIGERATING SYSTEMS
TABLE 2: Di mensi ons and Wei ght s of NC val ves wi t h 9100 coi l (1)
Cat alogue
number
Weight
[g]
H
1
H
2
H
3
L
1
L
2
Q
75
82
91
121
106
115
157
175
62,5
69,5
75
93
78
96
127
141
34
40
47
65
50
72
99
113
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
80
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) Wit h coil t ype 9120 t he dimension L
2
is equal t o 64 mm and t he valves weight s must be increased of 305 g.
35
Connect ors are not included in t he boxes and have t o be ordered separat ely.
36
SOLENOID VALVES FOR REFRIGERATING SYSTEM
TABLE 3: Ref ri gerant Fl ow Capaci t y of NC val ves
Cat alogue
number
R134a R22 R407C R404A R134a R22 R407C R404A R134a R22 R407C R404A
Refrigerant Flow Capacit y [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
72,4
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
49,4
62,4
49,4
62,4
74,1
130,0
130,0
208,0
Refrigerant flow capacit y referred t o t he following operat ing condit ions: Par t icularly for hot gas:
Evaporat ing t emperat re: +4 C Suct ion t emperat ure: +18 C
Condensing t emperat ure: +38 C Pressure drop: 1 bar
Pressure drop: 0,15 bar
37
TABLE 4a: General Charact eri st i cs of NO val ves (normal l y open) wi t h SAE Fl are connect i ons
Cat alogue
number
0,05
0,07
0,05
SAE
Flare
3/ 8"
1/ 2"
5/ 8"
5/ 8"
3/ 4"
5/ 8"
3/ 4
7
12,5
16,5
0,80
2,20
2,61
3,80
4,80
3,80
4,80
21
19
35
+105
(1)
+110
(2)
+105
(1)
32 Ar t . 3.3
Connect ions
Seat size
nominal

[mm]
Kv
Fact or
[m
3
/ h]
Operat ing
Principles
MOPD
Opening Pressure
Dif ferent ial [bar]
min
OPD
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
PED
Coil
t ype
H
M
3

(
D
.
C
.
)
1164/ 3
1170/ 4
1170/ 5
1150/ 5
1150/ 6
1190/ 5
1190/ 6 R
R
R
R
R
R
R
Diaphragm
pilot
operat ed
Diaphragm
Pilot
Operat ed
Pist on
Pilot
Operat ed
Pist on
Pilot
Operat ed
Diaphragm
Pilot
Operat ed
Diaphragm pilot
operat ed
Pist on Pilot
Operat ed
Available on request . R
TABLE 4b: General Charact eri st i cs of NO val ves (normal l y open) wi t h ODS connect i ons
Cat alogue
number
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
3,80
4,80
5,70
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 Ar t . 3.3
[in.]
[mm]
ODS
Connect ions
Seat size
nominal

[mm]
Kv
Fact or
[m
3
/ h]
Operat ing
Principles
MOPD
Opening Pressure
Dif ferent ial [bar]
min
OPD
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
PED
Coil
t ype
H
M
3

(
D
.
C
.
)
1168/ 3
1168/ M10
1178/ M12
1178/ 4
1178/ 5
1158/ 5
1158/ 6
1158/ 7
1198/ 5
1198/ 6
1198/ 7
1178/ 9
1198/ 9
1178/ 11 R
R
R
R
R
R
R
R
R
R
R
R
R
R
38
Connect ors and coils are not included in t he boxes and have t o be ordered separat ely.
VALVOLE SOLENOIDI PER IMPIANTI FRIGORIFERI
1164/ 3
1168/ 3
1168/ M10
1170/ 4
1170/ 5
1178/ M12
1178/ 4
1178/ 5
1150/ 5
1150/ 6
1190/ 5
1190/ 6
1158/ 5
1158/ 6
1158/ 7
1198/ 5
1198/ 6
1198/ 7
1178/ 9
1198/ 9
1178/ 11
39
TABLE 5: Di mensi ons and Wei ght s of NO val ves wi t h 9120 coi l
Cat alogue
number
Weight
[g]
H
1
H
2
H
3
L
1
L
2
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: Ref ri gerant Fl ow Capaci t y of NO val ves
Cat alogue
number
R134a R22 R407C R404A R134a R22 R407C R404A R134a R22 R407C R404A
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
Evaporat ing t emperat re: +4 C Suct ion t emperat ure: +18 C
40
Protection against electric contacts is class I for
all the coils. Therefore, for safet y purposes,
coils must be ef fect ively connect ed t o an
ear t hing syst em. Rubber gasket s on t he upper
and lower ends of coil ensure moist ure
prot ect ion of winding. Coils HM2 and HM3 may
be joined t o all connect ors produced by Cast el
except t ype 9155/ R01; prot ect ion degree
guarant eed by t his syst em, coil (HM2, HM3) +
connect or, is IP65 according t o EN 60529.
Coils HM4 must be preferably used wit h
connect or t ype 9155/ R01; prot ect ion degree
guarant eed by t his ot her syst em, coil HM4 +
connect or 9155/ R01, is IP65/ IP68 according
t o EN 60529. Coils HM4 can be used wit h
connect ors series 9150 and 9900 t oo;
prot ect ion degree guarant eed by t his syst em is
IP65.
Eit her t he t erminals of coils series HM2 and
HM3 or t he ones of coils series HM4 consist of
t wo Fast on line connect ions plus one Fast on
ear t hing connect ion. Coil t ype CM2 has a pre-
assembled cable (lengt h 1 met er).
The coils are designed for cont inuous use. The
solid const ruct ion of t hese coils is suit able for
heavy-dut y applicat ions in refrigerant syst ems.
The maximum ambient t emperat ure for all coils
is 50 C.
ELECRIC TYPE APPROVAL
Coils series 9100, 220/ 230 VAC and 240 VAC
supply, are approved by t he german regist rat ion
body VDE.
Coils series 9105 are approved by
Under writ ers laborat ories Inc. of t he Unit ed
St at es.
Coils series 9100, 9110 and 9160, 110 VAC,
220/ 230 Vac and 240 VAC supply, and coils
series 9120, 220/ 230 VAC supply, are
manufact ured according t o low Volt age (LV)
Direct ive 2006/ 95/ EC. Coils series 9100,
9110, 9120 and 9160 are manufact ured
according t o Elect romagnet ic Compat ibilit y
(EMC) Direct ive 2004/ 108/ EC.
APPLICATION
For t he normally closed solenoid valves,
previously shown in t his Handbook, Cast el put s
t he following t ypes of coils at disposal of it s
own cust omers:
coils series HM2, only for A.C.
(cat alogue numbers 9100 - 9105).
coils series CM2, only for A.C.
(cat alogue number 9110);
coils series HM3,eit her for A.C. or for D.C.
(cat alogue number 9120).
coils series HM4, only for A.C.
(cat alogue number 9160).
For t he normally open solenoid valves, always
shown in t his Handbook, t he cust omer s
select ion must compulsorily apply t o t he coils
series HM3 D.C.
For applicat ions of t he NO solenoid valves wit h
a volt age supply of 220 VAC, Cast el has
designed a specific coil at 220 V RAC (code
9120/ RD6) t hat must be used solely wit h t he
220 VAC connect or/ rect ifier circuit (code
9150/ R45).
CONSTRUCTION
Coils HM2 (9100) are class H, whereas coils
CM2, HM3 and HM4 are class F, in compliance
wit h IEC 85 st andard and t heir const ruct ion is
in compliance wit h EN 60730-1 and EN 60730-
2-8 st andards. The windings are made wit h
copper wire, insulat ion class H 180 C, in
compliance wit h IEC 85 st andard. The out er
casing is provided wit h dielect ric and
wat erproof resins t hat assure a reinforced
insulat ion making t he coils suit able for all
assemblies.
Coils HM2 (9105) are class F, wit h UL
approved EIS (Elect rical Insulat ion Syst em), and
t heir const ruct ion is in compliance wit h UL 429
St andards.
COILS
41
TABLE 1: General Charact eri st i cs of coi l s
Coil
Type
Degree
of
prot ect ion
Connect ions
Frequency
[Hz]
Volt age
t ollerance
[%]
Volt age
[V]
Cat alogue
number
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
Junct ion box
DIN 43650
junct ion box
DIN 43650
Three wire cable
Junct ion box
DIN 43650
Junct ion box
DIN 43650 or
Connect or
9155/ R01 (1)
IP65
EN 60529
(wit h
junct ion box)
IP65 EN 60529
(wit h junct ion box)
IP65
EN 60529
IP65
EN 60529
(Wit h
junct ion box)
IP65 EN 60529
(wit h junct ion box)
IP65/ IP68
EN 60529
(wit h connect or)
(1) Coil HM4 can also be coupled t o connect ors series 9150 and 9900, achieving a degree of prot ect ion IP65, t he
versat ile degree of prot ect ion ( IP65/ IP68) is achieved coupling coil HM4 wit h four screws connect or 9155/ R01
CM2 HM2
42
TABLE 2: Coi l s consumpt i ons
Cat alogue
number
Coil
Type
50 [Hz]
Consumpt ions at 20 C [mA]
Dimensions
[mm]
Weight
[g]
60 [Hz] D.C. 50 [Hz] 60 [Hz] D.C.
St ar t 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
L
1
L
2
H
57,5
57,5
66,5
82
63
34
34
34
61
41
35
35
35
35
35
165
165
230
470
220
HM3
HM4
43
gland nut of casing is suitable to receive cables
with an external diameter of 6 9 mm and is
provided with a self-locking device. Cables sized 3
x 0,75 mm
2
are to be preferred for this junction
box too.
The junction box type 9155/ R01 of fers a
protection degree IP65/ IP68 against dust and
water, according to EN 60529, when correctly
installed with the proper gaskets, which are
supplied as standard.
The junction box 9150/ R45 is equipped with a
full-wave bridge rectifier plus VDR for protection.
The VDR device, Voltage e-Dependent-Resistor, is
a special type of resistor, placed in parallel to the
coil; its purpose is to protect the diodes and the
coil from any excessive voltage generated within
the ac supply circuit.
WARNING: t he junct ion box 9150/ R45 must be
solely used wit h coils 9120/ RD6 (220 VRAC).
The wrong use of t hese junct ion boxes wit h
ot her t ypes of Cast el coils t akes quickly t o t he
dest ruct ion of t he coil.
The junction boxes 9150, DIN 43650
standardized, represent an ef fective system for
the connection of the coil to the supply circuit,
thus ensuring safety also in the presence of
moisture.
These junction boxes, according to assembly
requirements, allow choosing the position of outer
casing compared to inner terminal block. The
clamping screw of casing may be PG9 or PG11,
which are respectively suitable for cables with an
external diameter of 6 8 or
8 10 mm. Cables sized 3 x 0,75 mm
2
are to be
preferred.
The junction box type 9900 is available with
cabled core of dif ferent length. In this case,
it is not possible to change the position of casing
compared to terminal block.
Both the two types of fer a protection degree IP65
against dust and water, according to
EN 60529, when correctly installed with the
proper gaskets, which are supplied as standard.
Castel has developed a specific junction box, type
9155/ R01, suitable for use on those refrigerating
systems working in heavy duty environments, for
example:
exposition to the atmospheric conditions;
rooms with high moisture degree;
cyclic condensing / evaporating on the valve;
cyclic icing / defrosting on the valve.
This junction box, according to assembly
requirements, allows choosing the side position of
outer casing compared to inner terminal block; but
it is not possible to point the cable upwards. The
CONNECTORS
TABLE 3: General Charact eri st i cs of connect ors
Cat alogue
number
Nominal
Supply Volt age
[V]
Maximum
Pg
Cable
lengt h
[m]
Cable
t hickness
[mm
2
]
St andard
Degree
of prot ect ion
Class
of insulat ion
9150/ R01
9150/ R02
9150/ R45
9155/ R01
9900/ X66
9900/ X84
9900/ X73
9900/ X55
9900/ X54
R
220 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
44
APPLICATIONS
The solenoid valves, shown in t his chapt er, are
They are designed for t he applicat ions specified
in Table 1 where t he dif ferent fluids are
indicat ed wit h t he following symbols, according
t o an already est ablished code:
W = Wat er;
L = Air;
B = Secondar y coolant s (solut ions of glycol
and wat er);
O = Light oils (gas oil).
In shor t t hese valves may be used:
wit h fluids in t he gaseous st at e proper t o t he
Group II (as defined in Ar t icle 9, Sect ion 2.2
of Direct ive 97/ 23/ EC and referred t o in
Direct ive 67/ 548/ EEC);
wit h fluids in t he liquid st at e proper t o t he
Group I (as defined in Ar t icle 9, Sect ion 2.1
of Direct ive 97/ 23/ EC and referred t o in
Direct ive 67/ 548/ EEC).
SOLENOID VALVES FOR DIFFERENT FLUIDS
APPLICATION
Castel supplies to its customers the permanent
magnet code 9900/ X91 for the normally closed
solenoid valves, shown in this chapter.
This product can be used during brazing of the
valve copper connections to the plant pipes;
slipping it on the armature, instead of the coil, it
allows the protective gas (nitrogen) flowing and
avoids any damage to the plunger gasket and to
the diaphragm.
CONSTRUCTION
The main par ts of the permanent magnet code
9900/ X91 are made with the following materials:
three rings of anisotropic ferrite;
anodized aluminum for the body.
PERMANENT MAGNET
45
OPERATION
All t he valves for dif ferent fluids are normally
closed. NC = when t he coil is de-energised t he
plunger st ops t he refrigerant flow.
The valves series 1512 and 1522 are direct
act ing, while t he valves series 1132 and 1142
are pilot operat ed wit h diaphragm.
CONSTRUCTION
body and cover;
aust enit ic st ainless st eel EN 10088-2
1.4303 for enclosure where t he plunger
moves;
ferrit ic st ainless st eel EN 10088-3 1.4105
for plunger;
aust enit ic st ainless st eel EN ISO 3506 A2-
70 for t ight ening screws bet ween body and
cover;
fluorocarbon rubber (FPM) for out let seal
gasket s;
fluorocarbon rubber (FPM) for seat gasket s;
fluorocarbon rubber (FPM) for diaphragms.
Nit ril rubber (NBR) for t he valves series
1142.
TABLE 1: General Charact eri st i cs
Cat alogue
number
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
Ar t . 3.3
FPT
Connect ions
Main
Use
Seat Size
nominal
[mm]
Kv
Fact or
[m
3
/ h]
O
p
e
r
a
t
i
n
g
P
r
i
n
c
i
p
l
e
s
MOPD
Opening
Pressure Dif ferrent ial
[bar]
min
OPD
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
PED
Coil
Type
H
M
2

(
A
.
C
.
)

-

C
M
2

(
A
.
C
.
)

-

H
M
3

(
A
.
C
.
;

D
.
C
.
)

-

H
M
4

(
A
.
C
.
)
D
i
r
e
c
t
A
c
t
i
n
g
D
i
a
p
h
r
a
g
m

P
i
l
o
t
O
p
e
r
a
t
e
d
1512/ 01
1522/ 02
1522/ 03
1522/ 04
1132/ 03
1132/ 04
1132/ 06
1132/ 08
1142/ 010
1142/ 012
INSTALLATION
Table 1 shows t he following funct ional
charact erist ics of a solenoid valve:
PS;
TS;
Kv fact or;
minimum Opening Pressure Dif ferent ial
(minOPD), t hat is t he minimum pressure
a solenoid valve, pilot operat ed, can open
and st ay opened;
maximum Opening Pressure Dif ferent ial
(MOPD according t o ARI STANDARD 760:
2001), t hat is t he maximum pressure
a solenoid valve, pilot operat ed, can open.
Before connect ing t he valve it is advisable t o
make sure t hat t he piping are clean and t hat
t he flow direct ion in t he pipe corresponds t o
t he arrow st amped on t he body of t he valve.
All valves can be mount ed in what ever posit ion
except wit h t he coil point ing downwards.
Before connect ing a valve t o t he elect rical
syst em, be sure t hat t he line volt age and
frequency correspond t o t he values marked on
t he coil.
46
AIR CAPACITY
Table 2 provides t he values of air capacit y
under t he following condit ions:
t emperat ure at valve inlet = 20 C;
discharge pressure (absolut e) = 1 bar;
Kv of the valve under consideration = 1 m
3
/ h.
The pressures upst ream t he valve specified in
t he t able are absolut e values.
EXAMPLE
Select t he valve suit able for use wit h
approximat ely 200 m
3
/ h of air, assuming an
absolut e pressure of 8 bars at valve inlet
( = 7 bars of relat ive pressure + 1 bar) and an
accept able pressure drop across t he valve of
1,5 bars.
In t he column of pressures upst ream t he valve,
t he value 8 is shown; where t his column
int ersect s t he horizont al column relat ing t o t he
pressure drop of 1,5, t he value of 87 m
3
/ h is
shown. This is t he capacit y value of a
hypot het ical valve wit h Kv = 1 working under
t he above ment ioned condit ions.
200 / 87 = 2,29
This is t he Kv value required in t he case under
considerat ion.
In Table 1, select t he valve wit h t he Kv value
nearest t o 2,29, rounding of f t he value and
subsequent ly checking t hat all t he
charact erist ics of t he select ed valve
(max. opening pressure dif ferent ial,
t emperat ure, connect ions, et c.)
are suit able.
When t he viscosit y of t he liquid is expressed as
dynamic viscosit y, i.e. cP, where:
1cP = 10
-3
N sec/ m
2
t he corresponding value of cinemat ic viscosit y
in cSt is obt ained by t he following relat ion:
where:
= cinemat ic viscosit y [cSt ];
= dynamic viscosit y [cP];
= volumic mass of t he fluid at t he
considered t emperat ure [kg/ dm
3
].
Moreover, t he fluid viscosit y may remarkably
var y according t o changes in t emperat ure.
Therefore, if t he t emperat ure of t he fluid does
not ensure viscosit y values compat ible wit h t he
correct operat ion of t he valve, t he valve may
not open.
LIQUIDS CAPACITY
The following rat io applies:
p
Q = Kv x
where:
Kv = Kv fact or of t he valve [m
3
/ h];
Q = capacit y [m
3
/ h];
p = pressure drop t hrough t he valve [bar];
= volumic mass of t he liquid [kg/ dm
3
].
Cinemat ic Viscosit y cSt Reducing fact or
12
12 30
30 45
1
0,8
0,7
VISCOSITY
The values of maximum dif ferential pressure
specified in Table 1 are suitable for fluids with
maximum cinematic viscosity of 12 cSt where:
1cSt = 10
-6
m
2
/ sec.
If t he cinemat ic viscosit y of t he fluid under
considerat ion is more t han 12 cSt it is
necessar y t o mult iply t he value of t he
maximum dif ferent ial pressure by t he following
reducing fact ors:
47
TABLE 2 - Ai r Capaci t y (Kv = 1)
Pressure
drop
[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
Capacit y [m
3
/ h] (1)
Inlet pressure (absolut e) [bar]
0,0025
0,005
0,010
0,015
0,025
0,05
0,1
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 8,8
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 t able provides air capacit y values in m
3
/ h under t he following condit ions:
t emperat ure at value inlet : + 20 C
pressure at out let (absolut e): 1 bar
Kv of t he solenoid valve: 1 m
3
/ h
48
Wit h coils 9120 t he dimension L
2
is equal t o 64 mm and t he weight must be increased of 305 g.
TABLE 3 - Di mensi ons and Wei ght s (val ves wi t h coi l s 9100)
Cat alogue
number
Weight
[g]
H
1
H
2
H
3
L
1
L
2
Q
91
101
136
69
71
75
81
103
57
59
47
52
82
34
36
75
88
168
44
51
50
104
50
45
57
104
664
641
1004
944
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
Connect ors are not included in t he boxes and have t o be ordered separat ely
H
2
H
1
L1
L2
H
3
H
2
L1
H
1
H
3
L2
1132/03
1132/04
Q
L1
H
2
H
1
Q
H
3
L2
1142/010
1142/012
1132/06
1132/08
H
2
H
3
H
1
L1
L2
H
2
H
3
H
1
L1
L2
1512/01
1522/03
1522/04
1522/02
Q
Saf et y
devices
50
at mosphere. For t his reason, during relief, a
gas leak occurs t hrough t his orifice.
Ut ilized mat erial:
EN 12420-CW617N brass.
Di sc: obt ained t hrough bar machining and
equipped wit h gasket , it ensures t he required
sealing degree on t he valve seat . The gasket is
made in P.T.F.E. (Polyt et rafluoret hylene), a
mat erial t hat , during valve est imat ed ser vice
life, maint ains a good st rengt h and does not
cause t he disc t o st ick on t he seat . The disc is
properly guided in t he body and t he guide
act ion can never fail; t here are no glands or
ret aining rings t hat hamper t he movement
t hereof.
Spri ng: it opposes t he pressure and t he fluid
dynamic act ions and always ensures valve re-
closing aft er pressure relief. The spring coils,
when t he disc has reached t he lift
corresponding t o t he st at e of relief at full flow
rat e, are spaced apar t by at least half t he wire
diamet er and, in any case, by not less t han 2
mm. The disc is equipped wit h a mechanic lock
and when it at t ains it , t he spring set does not
exceed 85% of t he t ot al set .
DIN 17223-1 st eel for springs.
Set t i ng syst em: hexagonal head, t hreaded
ring nut t o be screwed inside t he body t op by
compressing t he spring below. On set t ing
complet ion, t he posit ion at t ained by t he ring
nut is maint ained unchanged laying, in t he
t hreaded coupling, a bonding agent wit h high
mechanic st rengt h and low viscosit y feat ures t o
make penet rat ion t hereof easier. The set t ing
syst em is prot ect ed against subsequent
unaut horized int er vent ions by means of a cap
nut t hat is screwed out side t he body and is
sealed wit h Cast el lead t o it .
GENERAL DESCRIPTION
Valves series 3030 are safet y devices
according t o t he definit ion given in Ar t icle 1,
Point 2.1.3, 2nd dash of 97/ 23/ EC Direct ive
and are t he subject of Ar t icle 3, Point 1.4 of
aforesaid Direct ive.
The valves above ment ioned are st andard t ype,
unbalanced, direct -loaded safet y valves. Valve
opening is produced by t he t hrust t he fluid
under pressure exer t s on t he disc, when said
t hrust exceeds, under set t ing condit ions, t he
opposing force of t he spring act ing on t he disc.
Valves are ident ified by means of:
a model number formed of an
alphanumerical coding t hat includes:
in t he first par t t he family ident ificat ion
(e.g. 3030/ 44C);
in t he second par t t he set t ing pressure,
expressed in bars, mult iplied by 10 (e.g.
140);
an alphanumerical serial number.
CONSTRUCTION
Body: squared, obt ained t hrough die forging
and subsequent machining. It houses t he
following element s:
t he nozzle wit h flat sealing seat ;
t he disc guide;
t he set t ing spring holder;
t he t hreaded seat of t he set t ing adjust ing
ring nut .
In t he body, above t he disc guide, a small
pressure relief hole is provided t hrough which
t he spring holder is put int o cont act wit h t he
SAFETY VALVES 3030
TABLE 1: General Charact eri st i cs of val ves 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
Cat alogue number 3030/ 44C 3030/ 66C 3030/ 88C
Connect ions
Flow Diamet er [mm]
Flow Sect ion [mm
2
]
Lift [mm]
Discharge Coef ficient Kd
PS [bar]
TS [C]
Set Pressure Range [bar]
Overpressure
Blowdown
Risk cat egor y according t o PED
55
- 50 / + 150
8 / 50
5% of set pressure
15% of set pressure
IV
Inlet male
Out let male
51
wit h suit able prot ect ion devices, for inst ance
safet y devices such as safet y valves. Such
devices shall prevent pressure from
permanent ly exceeding t he max allowable
pressure PS of t he equipment t hey prot ect . In
any case, a shor t pressure peak limit ed t o 10%
of admissible maximum pressure is permit t ed.
As t o t he select ion and sizing of t he suit able
prot ect ion device, users shall refer t o t he
specific sect or or product st andards.
EN 378-2: 2000 St andard Refrigerat ing
syst ems and heat pumps safet y and
environment al requirement s Par t 2: Design,
const ruct ion, t est ing, marking and
document at ion , harmonized wit h 97/ 23/ EC
Direct ive, provides a general out line of t he
prot ect ion devices t o be adopt ed in
refrigerat ing syst ems and t heir feat ures (par
7.4). It also indicat es t he crit eria for t he
select ion of t he device suit able t o t he t ype and
sizes of t he syst em component t o be prot ect ed
(par. 7.4).
EN 13136: 2001 St andard Refrigerat ing
syst ems and heat pumps Pressure relief
devices and t heir associat ed piping Met hods
for calculat ion highlight s t he possible causes
of overpressure in a syst em and makes
available t o users t he inst rument s for pressure
relief device sizing, among which t he safet y
valves.
SCOPE
Use: prot ect ion against possible overpressures
of t he apparat uses list ed below, wit h regard t o
t he operat ing condit ions for which t hey have
been designed:
refrigerat ing syst em and heat pump
component s, for inst ance: condensers, liquid
receivers, evaporat ors, liquid accumulat ors,
posit ive displacement compressor
discharge, heat exchangers, oil separat ors,
piping
(reference: EN 378-2: 2000);
simple pressure vessels
(reference: 87/ 404/ EEC Direct ive).
Fl ui ds: t he valves can be used wit h:
refrigerant fluids, in t he physical st at e of gas
or vapour, belonging t o Group II according t o
t he definit ions of 97/ 23/ EC Direct ive, Ar t icle
9, Point 2.2 (wit h reference t o 67/ 548/ EEC
Direct ive of June 27t h, 1967);
air and nit rogen (reference: 87/ 404/ EEC
Direct ive).
MARKING
In conformit y wit h t he provisions of Ar t icle 15
of 97/ 23/ EC Direct ive, t he EC marking and t he
ident ificat ion number of t he not ified body
involved in t he product ion cont rol phase are
repor t ed on t he valve body.
St ill on t he body, t he following informat ion is
indicat ed:
manufact urer s mark, address and
manufact ure count r y;
valve model;
flow sect ion;
Kd discharge coef ficient ;
indicat ion of flow direct ion;
max allowable pressure;
allowable t emperat ure range;
set pressure;
product ion dat e;
serial number.
VALVE SELECTION
97/ 23/ EC Direct ive requires t hat pressure
equipment , in which permissible limit s are
reasonably likely t o be exceeded, shall be fit t ed
TABLE 2: Di mensi ons and Wei ght s of val ves 3030
Cat alogue
number
Weight
[g]
3030
D L Ch H
1
H
2
H
3
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
52
for t his calculat ion t he value of k shall be as
measured at 25 C. (Sect ion 7.2.3, St andard
EN 13136: 2001).
Values of k and calculat ed values of C for some
refrigerant s are given in t able A.1 of t he
aforesaid st andard.
Following we show t he values of k and C for t he
more useful refrigerant s.
SIZING OF SAFETY VALVES DESIGNED TO DISCHARGE GAS OR VAPOUR AT
CRITICAL FLOW (Ref. EN 13136: 2001)
Crit ical flow occurs when t he backpressure p
b
(t he pressure exist ing immediat ely at t he out let
of a safet y valve) is below or equal t o t he
crit ical pressure:
[bar abs]
wit h:
p
o
= act ual relieving pressure, upst ream t he
safet y valve; it s equal t o t he set pressure
plus overpressure. That is a pressure
increase over set pressure at which t he disc
has it s t ot al lift . [bar abs];
k = isent ropic exponent of gas or vapour,
based on t he act ual flowing condit ions at t he
safet y valve inlet .
If k is unknown or anyway dif ficult t o est ablish
it s possible t o suppose:
[bar abs]
A safet y valve, which discharges t o
at mosphere, works in crit ical flow.
The safet y valves designed t o discharge gas or
vapour at crit ical flow must be sized as follow:
[mm
2
]
wit h:
A
c
= minimum flow area of safet y valve
[mm
2
];
Q
md
= minimum required discharge capacit y,
of refrigerant , of safet y valve [kg/ h];
K
d
= cer t ified coef ficient of discharge;
p
o
= act ual relieving pressure, upst ream t he
safet y valve, see definit ion above
[bar abs];
v
o
= specific volume of gas or vapour at
relieving condit ions p
o
e T
o
meaning wit h T
o
fluid t emperat ure at valve inlet , set t led by
t he user or by t he designer [m
3
/ kg];
C = funct ion of isent ropic coef ficient k
calculat ed from:
C k
k
k
k

+
+ ( )
( )
3 948
2
1
1
1
,
A
Q
C K
v
p
c
md
d
o
o

3 469
0 9
,
,
p p
critical o
0 5 ,
p p
k
b o
k
k
_
,
2
1
1
Calculat ion of minimum required discharge
capacit y of safet y valve is closely linked t o
t he t ype of syst em where t he valve is
inst alled, wit h t he causes t hat may arouse
t he opening of safet y valve, i.e.:
ext ernal heat sources. The minimum
required discharge capacit y shall be
det ermined by t he following:
[kg/ h]
wit h:
= densit y of heat flow rat e, it s assumed
t o be 10 [kW/ m
2
];
A
sur f
= ext ernal sur face area of t he vessel
[m
2
];
h
vap
= heat of vaporizat ion of liquid at p
o
[kJ/ kg];
int ernal heat sources. The minimum required
discharge capacit y shall be det ermined by
t he following:
[kg/ h]
wit h
Q
h
= rat e of heat product ion [kW].
Excessive pressure caused by compressors.
The minimum required discharge capacit y
shall be det ermined by t he following:
[kg/ h]
Q V n
md v
60
10

Q
Q
h
md
h
vap
3600
Q
A
h
md
surf
vap
3600
Refrigerant
Isent ropic
coef ficient
k
Funct ion
of Isent ropic
coef ficient
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
53

v
= volumet ric ef ficiency est imat ed at
suct ion pressure and discharge pressure
equivalent t o t he safet y valve set t ing.
wit h:
V = t heoret ical displacement of
compressor [m
3
]
n = rot at ional frequency of compressor
[min
1
]

10
= vapour densit y at refrigerant
sat urat ion pressure / dew point at
10 C [kg/ m
3
]
These condit ions, set t led in any case by t he
designer, are considered t he most unfavorable
for t he safet y valve in consequence of
funct ional defect s as:
move mist ake;
non-working of aut omat ic safet y devices, set
t o operat e before safet y valve.
It shall be excluded:
closeness t he refrigerat ing syst em, t he
presence of flammable subst ances in so
large quant it ies t o be able t o feed a fire.;
inside t he vessel, t he presence of a hear t
source.
Cal cul at i on of mi ni mum di scharge capaci t y
Prudent ially leaving t he vapour overheat ing at
t he out let of t he liquid cooler out of account ,
t he volumet ric ef ficiency of compressor is:
and so t he minimum required discharge
capacit y:
= 60x0,00224x1450x26,34x0,83 = 4260 [kg/ h]
wit h
10
= 26,34 [kg/ m
3
], vapour densit y of
R407C at sat urat ion pressure / dew point at
10 C.
Q V n
md v
60
10

v
disch e
suction
p
p
1 0 04 1 0 04
27 25
6 33
0 83 , ,
,
,
,
arg
Syst em descri pt i on
Compact refrigerat ing syst em designed t o make
refrigerat ed wat er and consist ing of:
open t ype reciprocat ing compressor;
wat er-cooled, shell-and-t ube horizont ally
condenser wit h lower sect ion of shell used
as receiver;
shell-and-t ube horizont ally liquid cooler fed
wit h a t hermost at ic valve;
refrigerant fluid R407C.
Compressor dat a
Bore 82,5 mm
St roke 69,8 mm
Cylinder number 6
Rot at ional frequency 1450 rpm
Clearance 4%
The t heoret ical displacement of compressor is:
[m
3
]
Maximum allowable pressure of t he condenser,
refrigerant side: PS = 25 bar.
Set pressure of t he safet y valve inst alled on
t he upper shell sect ion of condenser:
p
set
= 25 bar
Act ual relieving pressure of safet y valve,
choosing one valve t ype 3030 wit h an
overpressure of 5%:
[bar abs]
Working condit ions of compressor
corresponding t o t he relieving of safet y valve:
Condensing t emperat ure:
+ 64 C (27,25 bar abs)
Evaporat ing t emperat ure:
+ 10 C (6,33 bar abs)
p p
set 0
1
5
100
1 27 25 +
_
,
+ ,
V
4
0 0825 0 0698 6 0 00224
2
, , ,
EXAMPLE OF CALCULATION OF MINIMUM REQUIRED DISCHARGE CAPACITY Q
md
AND SIZING OF
THE SAFETY VALVE FOR THE HIGH PRESSURE SIDE OF A REFRIGERATING SYSTEM
54
Si zi ng of mi ni mum f l ow area
of t he saf et y val ve
[mm
2
]
wit h:
C = 2,51, corresponding t o isent ropic
exponent k for R407C equal t o 1,14,
according t o t able A1 of st andard EN
13136:2001;
K
d
= 0,83, cer t ified coef ficient of discharge
for safet y valve 3030/ 88;
v
o
= 0,0104 [m
3
/ kg], specific volume of
overheat ing vapour upst ream t he safet y
valve during relieving.
This value is referred t o t he following
operat ing condit ions, upst ream t he safet y
valve:
pressure p
o
= 27,25 [bar abs];
t emperat ure T
o
= 100 [C] (precaut ionar y
t emperat ure, set t led in any case by t he
designer).
Concl usi on: t he select ed safet y valve is t he
model 3030/ 88 wit h t he following
charact erist ics:
cer tified coef ficient of discharge, Kd = 0,83;
flow sect ion, A
c
= 298 [mm
2
];
set pressure, p
set
= 25 bar.
In case of single-screw compressor wit h
inject ion of pressurized oil, t he t heoret ical
displacement is:
[m
3
]
wit h:
D = rot or diamet er [m]
L = rot or lengt h [m]
V
D
L
c

2
4

3 469
4260
2 51 0 9 0 83
0 0104
27 25
154 ,
, , ,
,
,
A
Q
C K
v
p
c
md
d
o
o

3 469
0 9
,
,
55
wit h:
A = flow area of safety valve [mm
2
];
A
in
= inside area of inlet t ube t o valve [mm
2
];
K
dr
= K
d
x 0,9, derated coef ficient of discharge;
C = funct ion of isent ropic coef ficient k;
= addit ion of pressure loss coef ficient s
n
of any component and piping;
The coef ficient s
n
are relevant t o:
pipe element s loss, as connect ions and
bends;
valves loss;
loss along t he pipe
and are list ed in EN 13136:2001 st andard,
Table A.4.
Exampl e: assume t o inst all, on t he condenser
of t he previous example, a safet y valve t ype
3030/ 88, set t o 25 bar, using a st eel union
wit h t he following charact erist ics:
d
in
= 28 [mm], inside diamet er;
A
in
= 616 [mm
2
], inside area;
L = 60 [mm], lengt h;
flush connect ion t o t he shell of condenser,
wit h a broken edge.
From t able A.4 it s possible t o have t hese dat a:

1 (inlet )
= 0,25

2 (lengt h)
= x L/ d
in
= 0,02 x 60/ 28 = 0,043
wit h = 0,02 for st eel t ube

T
=
1
+
2
= 0,25 + 0,043 = 0,293
Bet ween safet y valve and union it s inst alled a
shut -of f valve t ype 3033/ 88 (see page 59).
The main charact erist ics of t his valve are:
d
R
= 20 [mm], inside diamet er;
A
R
= 314 [mm
2
], inside area;
kv = 20 [m
3
/ h], kv fact or.
Pressure loss coef ficient
R
of shut -of f valve is
given by:
The t ot al pressure loss coef ficient is:
T
+
R
=
0,933
We remember t he main charact erist ics of
safet y valve 3030/ 88 and of refrigerant fluid
R407C:
A = 298 [mm
2
]
K
dr
= 0,83 x 0,9 =0,747
C = 2,51
Pressure loss in t he upst ream line is:
p
p
in
o

1
]
1
0 032
298
616
2 51 0 747 0 933 0 0245
2
, , , , ,
1
]
1

2 592
314
20
10 0 64
2
3
, ,
VALVE INSTALLATION
As far as t he inst allat ion of safet y relief valves
is concerned, t he fundament al point s list ed
below shall be t aken int o account :
safet y valves shall be inst alled near an area
of t he syst em where vapours or gases are
present and t here is no fluid t urbulence; t he
posit ion shall be as upright as possible, wit h
t he inlet connect or t urned downwards;
vessels, joined t oget her wit h piping right ly
select ed by t he manufact urer and wit hout
any st op valve bet ween t hem, may be
considered as only one vessel for t he
inst allat ion of a safet y valve;
t he union bet ween t he valve and t he
equipment t o be prot ect ed shall be as shor t
as possible. Fur t hermore, it s passage
sect ion shall not be narrower t han t he valve
inlet sect ion. In any case, EN 13136: 2001
st andard st at es t hat t he pressure loss
bet ween prot ect ed vessel and safet y valve,
at discharge capacit y, shall not exceed 3% of
t he set t ing value, including any accessor y
mount ed on t he upst ream line;
in select ing t he safet y valve locat ion, it shall
be t aken int o account t hat valve operat ion
involves t he discharge of t he refrigerant fluid
under pressure, somet imes even at high
t emperat ure. Where t he risk exist s t o cause
direct injuries t o t he persons nearby, an
exhaust conveying piping shall be provided,
which shall be sized in such a way as not t o
compromise valve operat ion.
EN 13136: 2001 st andard st at es t hat t his
piping shall not generat e, at discharge
capacit y, a back pressure exceeding 10% of
pressure p
o
, for st andard t ype valves,
unbalanced.
To calculat e t he pressure loss eit her in t he
upst ream line (bet ween vessel and safet y
valve) or in t he downst ream line (bet ween
safet y valve and at mosphere) refer t o
EN 13136: 2001 st andard, Chapt er 7.4.
Pressure l oss i n t he upst ream l i ne
Calculat ion of pressure loss is given by:
p
p
A
A
C K
in
o in
dr

1
]
1
0 032
2
,
56
A
out
= 2206 [mm
2
], inside area;
L = 3000 [mm], lengt h;
pipe bend 90 wit h bending radius R equal t o
t hree t imes ext ernal diamet er of t ube.
From t able A.4 it s possible t o have t hese dat a:

1 (bend)
= 0,25;

2 (length)
= x L/ d
in
= 0,02 x 3000/ 53 = 1,13
wit h = 0,02 for st eel t ube;

T
=
1
+
2
= 0,25 + 1,13 = 1,38.
Pressure loss in t he downst ream line is:
The obt ained value is admissible because lower
t han t he value of 0,10 forecast in
EN 13136:2001. st andard.

p
p
out
o
0 075 ,
0 064 138
298
2206
2 51 0 747 27 25
27 25
2
1
2
, , , , ,
,

_
,
1
]
1
The obt ained value is admissible because lower

t han t he value of 0,03 forecast in
EN 13136:2001. st andard.
Pressure l oss i n t he downst ream l i ne
Calculat ion of pressure loss is given by:
wit h:
A = flow area of safet y valve [mm
2
]
A
out
= inside area of out let t ube t o valve
[mm
2
]
K
dr
= K
d
x 0,9, derated coef ficient of discharge
C = funct ion of isent ropic coef ficient k
= addition of pressure loss coef ficients
n
of
piping
The coef ficient s
n
are relevant t o:
pipe elements loss, bends;
loss along the pipe
and are listed in EN 13136:2001 standard, Table
A.4.
Exampl e: assume t o inst all a discharge pipe
on safet y valve t ype 3030/ 88 of t he previous
example, using a st eel t ube nominal size 2
wit h t he following charact erist ics:
d
out
= 53 [mm], inside diameter;
p
p
A
A
C K p
p
out
o
out
dr o
o
_
,
1
]
1
1
0 064
2
1
2
,
57
SAFETY VALVES 3060
GENERAL DESCRIPTION
Valves series 3060 are safet y devices
according t o t he definit ion given in Ar t icle 1,
Point 2.1.3, 2nd dash of 97/ 23/ EC Direct ive
and are t he subject of Ar t icle 3, Point 1.4 of
aforesaid Direct ive.
The valves above ment ioned are st andard t ype,
unbalanced, direct -loaded safet y valves. Valve
opening is produced by t he t hrust t he fluid
under pressure exer t s on t he disc, when said
t hrust exceeds, under set t ing condit ions, t he
opposing force of t he spring act ing on t he disc.
Valves are ident ified by means of:
a model number formed of an
alphanumerical coding t hat includes:
in t he first par t t he family ident ificat ion
(e.g. 3060/ 45C);
in t he second par t t he set t ing pressure,
expressed in bars, mult iplied by 10 (e.g.
140);
an alphanumerical serial number.
CONSTRUCTION
Body: squared, obt ained t hrough die forging
and subsequent machining. It houses t he
following element s:
t he nozzle wit h flat sealing seat ;
t he disc guide;
t he set t ing spring holder;
t he t hreaded seat of t he set t ing adjust ing
ring nut .
In t he body, above t he disc guide, a small
pressure relief duct is provided t hrough which
t he spring holder is put int o cont act wit h t he
out put connect ion. For t his reason, during
relief, no gas leak occurs int o t he at mosphere.
Di sc: obt ained t hrough bar machining and
equipped wit h gasket , it ensures t he required
sealing degree on t he valve seat . The gasket is
made in P.T.F.E. (Polyt et rafluoret hylene), a
mat erial t hat , during valve est imat ed ser vice
life, maint ains a good st rengt h and does not
cause t he disc t o st ick on t he seat . The disc is
properly guided in t he body and t he guide
act ion can never fail; t here are no glands or
ret aining rings t hat hamper t he movement
t hereof.
Spri ng: it opposes t he pressure and t he fluid
dynamic act ions and always ensures valve re-
closing aft er pressure relief.
DIN 17223-1 st eel for springs.
Set t i ng syst em: hexagonal head, t hreaded
ring nut t o be screwed inside t he body t op by
compressing t he spring below. On set t ing
complet ion, t he posit ion at t ained by t he ring
nut is maint ained unchanged laying, in t he
t hreaded coupling, a bonding agent wit h high
mechanic st rengt h and low viscosit y feat ures t o
make penet rat ion t hereof easier. The set t ing
syst em is prot ect ed against subsequent
unaut horized int er vent ions by means of a cap
nut t hat is screwed out side t he body and is
sealed t o it wit h a punched copper rivet .
58
The following dat a are st amped on t he cap:
EC marking and t he ident ificat ion number of
t he not ified body involved in t he product ion
cont rol phase
valve model
flow sect ion
Kd discharge coef ficient
VALVE SELECTION
safet y devices such as safet y valves. Such
EN 378-2: 2000 St andard Refrigerat ing
document at ion , harmonized wit h 97/ 23/ EC
Direct ive, provides a general out line of t he
prot ect ion devices t o be adopt ed in
(par. 7.4).
EN 13136: 2001 St andard Refrigerat ing
TABLE 3: General Charact eri st i cs val ves 3060
1/ 4" NPT
3/ 8" SAE
0,63
7,0
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
Cat alogue number 3060/ 23C 3060/ 24C 3060/ 33C 3060/ 34C 3060/ 45C 3060/ 36C 3060/ 46C
Connect ions
Flow Diamet er [mm]
Flow Sect ion [mm
2
]
Discharge Coef ficient Kd
PS [bar]
TS [C]
St Pressure Range [bar]
Overpressure
Risk Cat egor y according t o PED
55
- 50 / + 150
9 / 50
10% of set pressure
IV
inlet male
out let male
SCOPE
Use: prot ect ion against possible overpressures
of t he apparat uses list ed below, wit h regard t o
t he operat ing condit ions for which t hey have
been designed:
refrigerat ing syst em and heat pump
component s, for inst ance: condensers, liquid
receivers, evaporat ors, liquid accumulat ors,
posit ive displacement compressor
discharge, heat exchangers, oil separat ors,
piping.
(reference: EN 378-2: 2000);
simple pressure vessels
Fl ui ds: t he valves can be used wit h:
Direct ive of June 27
t h
, 1967);
Air and nit rogen
MARKING
of 97/ 23/ EC Direct ive t he following informat ion
are repor t ed on t he valve body:
manufact urer s mark, address and
manufact ure count r y
indicat ion of flow direct ion
max allowable pressure
set pressure
allowable t emperat ure range
product ion dat e
serial number
59
for calculat ion highlight s t he possible causes
of overpressure in a syst em and makes
available t o users t he inst rument s for pressure
relief device sizing, among which t he safet y
valves.
For sizing and inst allat ion of safet y valves
series 3060 see t he previous chapt er of safet y
valves series 3030.
TABLE 4: Di mensi ons and Wei ght s of val ves 3060
Cat alogue
number
Weight
[g]
3060
D L Ch H
1
H
2
H
3
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
refrigerant from a sect ion of t he syst em. These
valves can be used wit h t he same fluids
foreseen for safet y valves series 3030 and
3060, in par t icularly:
t h
, 1967);
air and nit rogen
CONSTRUCTION
Cast el supplies t o it s cust omers t he valves
series 3033 and 3063 in open posit ion and t he
ball spindle is prot ect ed by means of a cap
screwed t o t he body and sealed wit h lead t o it .
Any closing int er vent ion on t he valve forcedly
causes t he t ampering of t he seal and t hen
t hese int er vent ions shall be per formed
exclusively by:
APPLICATIONS
We would like t o remember t o our cust omer
t hat t he running of pressure equipment s and
pressure assemblies is excluded by t he scope
of Direct ive 97/ 23/ EC but it s regulat ed in
compliance wit h nat ional regulat ions of
Member St at es of European Communit ies.
We t hink t hat t hese regulat ions, act ually on
updat ing wit h t he Compet ent Bodies of all t he
st at es t o avoid conflict s wit h t he ESR of PED,
could provide for periodical checks on t he
pressure equipment s and assemblies.
Any int er vent ion for periodic checking or
replacement of an inst alled safet y valve
becomes ver y dif ficult if t he prot ect ed vessel is
not equipped wit h a shut -of f valve.
The shut -of f valves series 3033 and 3063,
inst alled bet ween vessel and safet y valve, allow
t o remove t he valve for periodic checking or
replacement wit hout blowing of f all t he
60
TABLE 5: General Charact eri st i cs, di mensi ons and Wei ght s of val ves 3033, 3063
Cat alogue
number
Designed
for valve
Kv
Fact or
[m
3
/ h]
Risk
Cat egor y
according t o
PED
Weight
[g]
min max
PS [bar]
D A C L H
1
H
2
H
3
Ar t . 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
44,5
59
72
84,5
100
123
162
245
323
350
710
1070
st af f aut horized t o work on t he syst em;
public ser vant of a Compet ent Body.
These persons will be responsible for t he next
valve reopening and t he new cap sealing wit h
t heir own lead.
The main par t s of t hese valves are made wit h
body;
hot forged brass EN 12420 CW 617N,
chromium plat ed, for ball;
st eel, wit h proper sur face prot ect ion, for t he
spindle;
P.T.F.E. for seat ball gasket s;
gasket s;
glass reinforced PBT for cap t hat covers t he
spindle.
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 component s ensure t he per fect
alignment of t wo safet y valves 3060/ 45.
The valves series 3032 can be used wit h t he
same fluids foreseen for safet y valves series
3030 and 3060, in par t icularly:
APPLICATIONS
The changeover device type 3032 is a ser vice
valve for dual pressure relief valves that allows
using one valve while isolating the other from the
system. This device allows the user to work on
the isolated valve, for periodic checking or
replacement, while the system is completely
operative and the other valve is in ser vice.
N.B.: each safety valve placed on a changeover
device must have suf ficient capacity to protect
CHANGEOVER DEVICES FOR SAFETY VALVES
SEAL
VALVE 3030/ ..
BALL VALVE 3033/ ..
SEAL
61
operat ion under condit ions of discharge of
sat urat ed vapour as well as overheat ed vapour.
The main par t s of t hese valves are made wit h
body;
spindle;
chloroprene rubber (CR) and aramidic fibers
for gland seal;
gasket s;
spindle.
t h
, 1967);
air and nit rogen
CONSTRUCTION
The valve 3032 is designed so t hat it is never
possible t o close of f bot h por t s at t he same
t ime, excluding all t he t wo safet y valves. Under
working condit ions, t he shut t er must be
clamped against one of t he t wo seat s of t he
valve, front por t or back por t , in order t o
ensure always full discharge t o t he
corresponding safet y valve. Int ermediat e
posit ions of t he shut t er are not accept able in
order not t o af fect t he operat ion of bot h safet y
valves. The valve ensures a pressure drop
per fect ly compat ible wit h t he safet y valve
TABLE 6: General Charact eri st i cs, Di mensi ons and Wei ght s of val ves 3032
Cat alogue
number
Designed
for valve
Kv
Fact or
[m
3
/ h]
Risk
Cat egor y
according t o
PED
Weight
[g]
min max
PS [bar]
L
3
L
2
L
1
H
2
H
1
Ar t . 3.3
Dimensions [mm] TS [C]
3032/ 44
3032/ 64
3032/ 66
3032/ 88
3032/ 108
3060/ 45C
3060/ 46C
3030/ 44C
3030/ 66C
3030/ 88C
3,3
9,0
9,0
14,5
20,0
-50 +150 55
117
95
95
120
123
45
52
52
71
74
33
48
48
66
66
91
133
133
185
185
50
80
80
110
110
775
1750
1750
3200
3200
B
1/ 2"
NPT
1/ 2"
NPT
3/ 4"
NPT
1
NPT
1
NPT
A
1/ 2"
NPT
3/ 4"
NPT
3/ 4"
NPT
1
NPT
1 1/ 4"
NPT
D
13
17,5
17,5
22,0
31,0
62
Unions series 3035 allow assembling safet y
valves series 3030 and 3060 or shut -of f valves
series 3032, 3033 and 3063 close t o t he
pressure equipment s t o prot ect , set up in a
refrigerat ing syst em.
These unions are designed for inst allat ions
according t o t he following t wo ways:
Make a copper t ube joint ing t he pressure
equipment t o t he union, fit t he end of t his
t ube int o t he solder connect ion of t he union
and t hen make a capillar y brazing.
Drill t he inner/ out er pipe close t o t he
pressure equipment (if possible make a
collar on t he pipe), put t he end of t he union
int o t his drill and t hen make a braze welding.
The unions series 3035 are machined by brass
bar EN 12164-CW614N.
SAFETY VALVES UNIONS
TABLE 7: General Charact eri st i cs, Di mensi ons and Wei ght s of uni ons 3035
Cat alogue
number
ODS
[mm]
PS
[bar]
D L Ch
Weight
[g]
NPT
Connect ions Dimensions [mm]
3035/ 2
3035/ 3
3035/ 4
3035/ 6
3035/ 8
3035/ 10
1/ 4
3/ 8
1/ 2
3/ 4
1
1.1/ 4"
12
15
20
28
36
42
55
18
22
28
35
42
54
33
36,5
44
51
62
67
21
26
32
40
45
55
58
90,5
165
255
364
613
Copper pipe
63
MARKING
of 97/ 23/ EC Direct ive and of Point 7.3.3 of EN
378-2 : 2000 St andard t he following dat a are
repor t ed on t he hexagonal nut :
EC marking;
Manufact urer' s logo;
Max allowable pressure PS;
Melt ing point .
INSTALLATION
If a fusible plug is mount ed on a pressure
vessel or any ot her par t which it prot ect it shall
be placed in a sect ion where superheat ed
refrigerant would not af fect it s correct funct ion.
Fusible plug shall not be covered by t hermal
insulat ion. Discharge from fusible plugs shall
t ake place so t hat persons and proper t y are
not endangered by t he released refrigerant .
EN 378-2 : 2000 St andard, harmonized wit h
t he 97/ 23/ EC Direct ive, est ablishes t hat a
fusible plug shall not be used as t he sole
pressure relief device bet ween a refrigerant
cont aining component and t he at mosphere for
syst ems wit h a refrigerant charge larger t han:
2,5 kg of group L1 refrigerant (ex. R22;
R134a; R404A; R407C; R410A; R507).
1,5 kg of group L2 refrigerant .
1,0 kg of group L3 refrigerant .
FUSIBLE PLUG SELECTION
safet y devices such as fusible plugs. Such
EN 378-2 : 2000 St andard Refrigerat ing
document at ion provides a general out line of
t he prot ect ion devices t o be adopt ed in
GENERAL DESCRIPTION
Fusible plugs series 3080/ .C and 3082/ .C are
safet y devices according t o t he definit ion given
in Ar t icle 1, Point 2.1.3, 2
nd
dash of 97/ 23/ EC
Direct ive and are t he subject of Ar t icle 3, Point
1.4 of aforesaid Direct ive.
According t o t he definit ion given in Point 3.6.4
of EN 378-1 : 2000 St andard, fusible plug is a
device cont aining mat erial t hat melt s at a
predet ermined t emperat ure and t hereby
relieving t he pressure.
Cast el has resolved t o classify fusible plugs
series 3080/ .C and 3082/ .C in t he Cat egor y
of Risk I t herefore fixing t heir use, as prot ect ion
devices, on specific pressure equipment s,
proper t o t he same Cat egor y of Risk I, in
compliance wit h Annex II, Point 2, of 97/ 23/ EC
Direct ive.
In consequence of t his choice, fusible plugs
series 3080/ .C and 3082/ .C cannot be used,
as sole prot ect ion devices, on pressure
equipment s proper t o Cat egories of Risk higher
t han first .
CONSTRUCTION
The body of t he fusible plug is an NPT plug
drilled wit h a t aper hole. A predet ermined
quant it y of fusible alloy, wit h checked melt ing
point , is poured inside t his hole.
The par t s of t he fusible plugs are made wit h
Brass EN 12164 CW 614N, hot t inned, for
t he plug.
Eut ect ic alloy wit h several component s,
cadmium and lead free, for t he fusible
mat erial.
SCOPE
Use: t he fusible plugs are basically used t o
prot ect t he component s in a refrigerat ing
syst em or heat pump against possible
overpressures, wit h regard t o t he operat ing
condit ions for which t hey have been designed,
in case of an excessive ext ernal heat source,
such as fire.
Fl ui ds: t he fusible plugs can be used wit h
refrigerant fluids belonging t o Group 2
according t o t he definit ions of 97/ 23/ EC
Direct ive, Ar t icle 9, Point 2.2 (wit h reference t o
67/ 548/ EEC Direct ive of June 27
t h
, 1967).
FUSIBLE PLUGS
64
To find t he values of k and C for t he more
useful refrigerant s, see t he chapt er of safet y
valves series 3030
Calculat ion of minimum required discharge
capacit y of fusible plug is closely linked t o t he
main cause t hat may arouse t he opening of
fusible plug, which is t he ext ernal heat sources.
The minimum required discharge capacit y shall
be det ermined by t he following:
[kg/ h]
wit h
= densit y of heat flow rat e, it s assumed t o
be 10 [kW/ m
2
]
A
sur f
= ext ernal sur face area of t he vessel
[m
2
]
h
vap
= heat of vaporizat ion of liquid at p
o
[kJ/ kg]
EN 13136 : 2001 St andard also est ablishes
t hat t he following values for K
dr
shall be t he
maximum used depending on how t he pipe
bet ween t he vessel and t he fusible plug is
mount ed on t he vessel:
flush or flared connect ion: K
dr
= 0,70
inser t ed connect ion: K
dr
= 0,55.

Q
A
h
md
surf
vap
3600

C k
k
k
k

+
+ ( )
( )
3 948
2
1
1
1
,
(par. 7.4).
EN 13136 : 2001 St andard Refrigerat ing
for calculat ion , harmonized wit h 97/ 23/ EC
Direct ive, highlight s t he possible causes of
overpressure in a syst em and makes available
t o users t he inst rument s for pressure relief
device sizing, among which t he fusible plugs.
SIZING OF FUSIBLE PLUG
(REF. EN 13136: 2001)
As t he fusible plugs discharge t o at mosphere,
t hey always work in crit ical flow (t o know t he
definit ion of crit ical flow, see t he chapt er of
safet y valves series 3030).
The fusible plugs must be sized as follow:
[mm
2
]
wit h:
A
c
= minimum flow area of fusible plug [mm
2
]
Q
md
= minimum required discharge capacit y,
of refrigerant , of fusible plug [kg/ h]
K
dr
=derat ed coef ficient of discharge of
fusible plug, equal t o 0,9 x K
d
p
o
= pressure upst ream t he fusible plug,
inside t he equipment t o be prot ect ed [bar
abs]
v
o
= specific volume of gas or vapour at
relieving condit ions p
o
e T
o
, [m
3
/ kg] (T
o
is t he
fluid t emperat ure at plug inlet , set t led by t he
user or by t he designer)
C = funct ion of isent ropic coef ficient k (as
measured at 25 C , see Sect ion 7.2.3 , EN
13136 : 2001 St andard) calculat ed from:

A
Q
C K
v
p
c
md
dr
o
o

3 469 ,
TABLE 8: General Charact eri st i cs, Di mensi ons and Wei ght s of f usi bl e pl ugs 3080 e 3082
Cat alogue
number
Connect ions
NPT
Flow
Diamet er
[mm]
Flow
Sect ion
[mm
2
]
Kd
PS
[bar]
Melt ing
point
[C]
H
e
x
a
g
o
n
a
l

K
e
y
Wrench
Torque
min/ max
[Nm]
Weight
[g]
Risk
Cat egor y
according t o
PED
3080/ 1C
3080/ 2C
3080/ 3C
3080/ 4C
3082/ 1C
3082/ 2C
3082/ 3C
3082/ 4C
1/ 8"
1/ 4"
3/ 8"
1/ 2"
1/ 8"
1/ 4"
3/ 8"
1/ 2"
4,9
5,7
8,5
9,3
4,9
5,7
8,5
9,3
18,8
25,5
56,7
67,9
18,8
25,5
56,7
67,9
0,91
42
30
79
138
12
17
12
12
17
22
7 / 10
10 / 15
14 / 20
21 / 30
7 / 10
10 / 15
14 / 20
21 / 30
11
23
39
76
11
23
39
76
I
Check valves
66
INSTALLATION
The valves can be inst alled in any sect ion of a
refrigerat ing syst em, where it is necessar y t o
avoid an inversion of t he refrigerat ing flow, in
compliance wit h t he limit s and capacit ies
indicat ed in t able 3.
Table 1 shows t he following funct ional
charact erist ics of a check valve:
PS;
TS;
Kv fact or;
minimum opening pressure dif ferent ial, t hat
is t he minimum pressure dif ferent ial
bet ween inlet and out let at which a check
valve can open and st ay opened.
Before connect ing t he valve t o t he pipe it is
advisable t o make sure t hat t he refrigerat ing
syst em is clean. In fact t he valves wit h P.T.F.E.
gasket s are par t icularly sensit ive t o dir t and
debris. Fur t hermore check t hat t he flow
direct ion in t he pipe corresponds t o t he arrow
st amped on t he body of t he valve.
The allowed operat ing posit ions are:
t ypes 3122 and 3142 wit h horizont al axis
and valve cover facing upward;
t ypes 3182 wit h inlet facing down and t he
valve cover facing upward;
t ypes 3110, 3130 and 3131, preferably wit h
ver t ical axis and arrow upward. Sloping axis,
up t o horizont al posit ion, are t olerable.
The brazing of valves wit h solder connect ions
should be carried out wit h care, using a low
melt ing point filler mat erial. Before st ar t ing t o
braze, it s necessar y t o disassemble t he valves
series 3122, while t his operat ion is not
necessar y wit h solder connect ion valves. In any
case, it s impor t ant t o avoid direct cont act
bet ween t he t orch flame and t he valve body,
which could be damaged and compromise t he
proper funct ioning of t he valve.
APPLICATIONS
The check valves, shown in t his chapt er, are
67/ 548/ EEC).
For heavy dut y, about t he operat ion
t emperat ure, for example inst allat ion on t he
discharge line close t o t he compressor, Cast el
has developed t hree new series of valves,
t ypes 3122, 3142 and 3182, equipped wit h
special gasket for high t emperat ure, bet ween
t he body and it s cover.
MATERIALS
body and cover;
connect ions;
aust enit ic st ainless st eel AISI 302 for t he
spring;
gasket s. Met al-rubber laminat ed gasket s for
t he valves series 3122, 3142 and 3182;
P.T.F.E. for seat gasket .
CHECK VALVES
67
Cat alogue
number
SAE
Flare
[in.]
[mm]
[in.]
[mm]
ODS ODM
Connect ions
Fact or
Kv
[m
3
/ h]
Minimum
Opening
Pressure
Dif ferent ial
[bar]
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
PED
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
Ar t . 3.3
I
Ar t . 3.3
I
Ar t . 3.3
I
68
TABLE 2: Di mensi ons and Wei ght s
Cat alogue
number
Weight
[g]
H H
1
L L
1
Q 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
28
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
69
3110
3122
3130
3131
3142
3182
70
TABLE 3: Ref ri gerant Fl ow Capaci t y
Cat alogue
Number
R134a R22 R407C R404A R410A R22 R407C R404A R410A R22 R407C R404A R410A
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
Evaporat ing t emperat ure: +4 C Suct ion t emperat ure: +18 C
Wat er regulat ing
valves
72
APPLICATIONS
The wat er regulat ing valve, employed wit h
condenser fed wit h eit her main or well wat er,
keeps t he condensat ion pressure const ant at
t he previously set value by adjust ing t he wat er
flow so as t o ensure a balanced heat exchange
under all condit ions.
At plant st ar t -up, t his adjust ment is designed t o
allow t he t hermost at ic valve t o rapidly reach
normal operat ing condit ions and subsequent ly,
during operat ions, t o avoid excessive pressure
increases or decreases under dif ferent flow
condit ions. An excessive rise of high pressure
af fect s t he refrigerat ing capacit y of t he syst em.
On t he ot her side, pressure lowering leads t o
insuf ficient refrigerant feeding of t he evaporat or
wit h a consequent increased gas overheat ing
and parallel reduct ion of gas pressure at
compressor suct ion.
Cast el valves are appropriat e for refrigerant
fluids HCFC and HFC and only for main and well
wat er.
OPERATIONS
The moving element s of t he valve are a met al
bellows and a shut t er.
The t hrust of t he refrigerant condensat ion
WATER REGULATING VALVES
1/4"
48
Ch
1/4"Flare
8
7
9
9
L
A02
M
A
D
E IN
ITA
LY
RANGE 5-18 bar
MEDIUM R134a-R404A-R12-R22-R502
MAX WATER TEMP. 80 |BC
MAX WATER PRESS. 10 bar
CAT.
B
C
A
pressure out side t he bellows favours t he
opening of t he valve and t he t hrust of t he
adjust ment spring on t he shut t er act s in t he
opposit e sense. Given a specific set t ing of t he
spring, t he valve progressively opens in line
wit h t he increasing condensat ion pressure, and
closes when t his pressure decreases.
When t he compressor st ops, t he valve closes:
wat er is no longer fed int o t he condenser, t his
being a not able operat ing economy.
Valve set t ing is per formed in t he works at a
pressure of 7,5 bars. Set t ing is modified by
t urning t he cont rol screw.
Three reference not ches, marked wit h let t ers A,
B, and C, are present on t he spring cover. Each
not ch is equivalent t o a dif ferent spring set t ing.
The not ches are referred t o t he following
condensat ion pressures:
let t er A equivalent t o about 7.5 bar
(valid for R134a at a t emperat ure of
condensat ion of 30 C);
let t er B equivalent t o about 14 bar
(valid for R404A, R407C and R507 at a
t emperat ure of condensat ion of 30 C);
let t er C equivalent t o about 18 bar
(t op limit of working pressure)
73
Wat er t emperat ure at t he condenser inlet :
14 C.
Expect ed t hermal dif ference: Dt = 10 C.
Condensat ion t emperat ure expect ed on t he
basis of t he wat er/ refrigerant heat exchange
in t he condenser:
approximat ely 6 C above t he wat er
t emperat ure at t he out let , equivalent t o 30
C (wit h a corresponding sat urat ion
pressure) (fig. 1).
Refrigerat ion yield at t he level of t he
evaporat or:
18,6 kW under t he following operat ing
condit ions,
condensat ion t emperat ure: + 30 C;
evaporat ion t emperat ure: 15 C.
Thermal power t o be disposed of at t he level of
t he condenser (Table 2):
18,6 x 1,325 = 24,65 [kW]
Wat er flow rat e:
24,65 x 860
= 2120 l/ h = 2,12 [m
3
/ h]
10
Fig. 1 Heat exchange pat t ern in t he condenser.
Cat alogue
number
Weight [g]
Connect ions
UNI ISO
228/ 1
Working
pressure
[bar]
Maximum
wat er
pressure
[bar]
Maximum
wat er
Temperat ure
[C]
Kv
Fact or
[m
3
/ h]
Refrigerant
max.
working
pressure
[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
20
27
32
70
74
1015
985
1010
MATERIALS
The mat erials used for t he main par t s are:
ST-UNI-EN 12165 - CW617N hot -forged brass
for t he main body;
aust enit ic st ainless st eel AISI 303 for t he
seat ;
nit ril rubber (NBR) for seat gasket ;
NBR coat ed-fabric for diaphragms.
INSTALLATION
The valve will be mount ed on t he wat er out let
side of t he condenser, preferably ver t ically, wit h
t he bellows downward.
The high pressure connect ion t o t he bellow
must show no deflect ion.
The arrow on t he valve body shows wat er flow
direct ion.
EXAMPLE OF VALVE SELECTION
A refrigerat ing syst em including a hermet ic
compressor and a condenser fed wit h mains
wat er.
Mains wat er pressure: 3 bar
74
When t he point of int ersect ion of pressure
dif ferent ial t hrough t he valve and flow range is
wit hin t he area bet ween t he cur ves of t wo
valves, select t he valve wit h larger diamet er.
When t he valve is complet ely closed, t he
pressure must be t he same as t he refrigerant
sat urat ion pressure at t he air t emperat ure of
t he place where t he condenser is inst alled.
When t he valve begins t o open, t he pressure is
about 0,2 bar above t he pressure when t he
valve is t ot ally closed.
The pressure drop corresponding t o t he wat er
flow rat e specified above in t he
condenser/ piping circuit , wit h t he exclusion of
t he wat er regulat ing valve, is about
2,5 bar.
The wat er regulat ing valve has t his pressure
dif ferent ial at it s disposal:
p = 3 2,5 = 0,5 bar
At p = 0,5 bar t he 3210/ 04 valve, complet ly
opened, ensures t he required flow rat e
(fig. 2).
0
0,5
0 1 2 3 4 5 6 7 8 9
1
0
1
1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
1
9
2
0
2
1
2
2
2
3
2
4
2
5
2
6
2
7
2
8
p [H
2
O]
1
1,5
2
2,5
3
3,5
4
4,5
5
5,5
6
6,5
7
0
0
,
1
2
5
0
,
2
5
0
,
3
7
5
0
,
5
0
,
6
2
5
0
,
7
5
0
,
8
7
5 1
1
,
1
2
5
1
,
2
5
1
,
3
7
5
1
,
5
1
,
6
2
5
1
,
7
5
1
,
8
7
5 2
2
,
1
2
5
2
,
2
5
2
,
3
7
5
2
,
5
2
,
6
2
5
2
,
7
5
p [bar]
Q [m
3
/h]
3210/04
3210/06
3210/03
Fig. 2 Charact erit ics cur ves when t he valves are complet ely open
75
TABLE 2: Thermal f act or f or hermet i c ref ri gerat i on compressors. Rel at i onshi p bet ween t he t ot al heat t o be di sposed of at
t he l evel of t he condenser and ref ri gerat i on capaci t y at t he l evel of t he evaporat or
Condensing
Temperat ure
[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 f act or f or open compressors (di rect or bel t dri ven). Rel at i onshi p bet ween t he t ot al heat t o be di sposed
of at t he l evel of t he condenser and t he ref ri gerat i on capaci t y at t he l evel of t he evaporat or
Condensing
Temperat ure
[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
1,530
1,371
1,405
1,441
1,485
1,330
1,367
1,396
1,437
1,482
1,291
1,320
1,350
1,390
1,431
1,243
1,279
1,306
1,342
1,381
1,426
1,474
1,213
1,240
1,265
1,295
1,334
1,369
1,410
1,178
1,202
1,224
1,252
1,288
1,320
1,355
1,143
1,168
1,185
1,211
1,241
1,274
1,330
1,114
1,133
1,152
1,175
1,120
1,228
1,255
Liquid Indicat ors &
Moist ure-Liquid Indicat ors
78
CONSTRUCTION
New liquid indicat ors, series 38, and new
liquid/ moist ure indicat ors, series 39, are
manufact ured in a t ot al hermet ic const ruct ion
t o avoid any possible refigerant leaks. The
glass lens , wit h it s proper gasket , is housed
int o t he brass body and is fixed in t his seat
wit h a edge calking operat ion.
The main par t s of t he indicat ors are made wit h
body;
connect ions;
Glass for lens;
PTFE for out let seal gasket s;
Liquid/ moist ure indicat ors series 3770, 3771,
3780 and 3781 are manufact ured wit h t he
glass lens direct ly fused ont o a st eel met allic
ring, wit h proper sur face prot ect ion.
APPLICATIONS
The indicators, shown in this chapter, are
classified Pressure accessories in the sense
of the Pressure Equipment Directive 97/ 23/ EC,
Ar ticle 1, Section 2.1.4 and are subject of
Ar ticle 3, Section 1.3 of the same Directive.
The indicators series 3780 are excluded from
the scope of Directive 97/ 23/ EC, as specified in
the Guidelines 1/ 8 and 1/ 9, because they are
piping components.
They are designed for installation on commercial
refrigerating systems and on civil and industrial
conditioning plants, which use refrigerant fluids
proper to the Group II
(as defined in Ar ticle 9, Section 2.2 of Directive
97/ 23/ EC and referred to in Directive
67/ 548/ EEC).
Liquid indicators and moisture liquid indicators
ensure a fast and safe inspection of the
conditions of the refrigerant fluid in the circuit
concerning regular flow and moisture. Liquid
indicators also ensure inspection of the regular
return of oil to the compressor crankcase.
OPERATION
The moist ure/ liquid indicat ors consist of a
sensit ive element as a ring, which changes
color passing from green t o yellow according t o
t he percent age of moist ure in t he syst em. The
dat a of moist ure cont ent , shown in t able 1 wit h
t he green color, can be considered
admissible for t he proper working of t he
syst em. When t he sensit ive element from green
LIQUID INDICATORS &
MOISTURE-LIQUID INDICATORS
TABLE 1: Moi st ure cont ai ned i n t he f l ui d [ p.p.m.]
Colour
R22 R134a R404A R407C R410A
Refrigerant fluid
Green
Green
Char t reuse
Yellow
<60
60
>60
<75
75
>75
<30
30
>30
<30
30
>30
<30
30
>30
R507
<30
30
>30
fade t o yellow, green Char t reuse , working
condit ions of t he syst em could become
dif ficult . When t he sensit ive element becomes
yellow , it s t ime t o subst it ut e t he dehydrat or
filt er.
If t he charge and working condit ion are normal,
t he refrigerant fluid appears per fect ly liquid
underneat h t he lens of t he indicat or. The
presence of bubbles indicat es t hat t he
refrigerant fluid is par t ial evaporat ing along t he
liquid line.
79
TABLE 2: General Charact eri st i cs of l i qui d i ndi cat ors
Cat alogue
number
Type
SAE
Flare
RIsk
Cat egor y
according t o
PED
PS [bar]
ODS
TS [C]

[mm]
max.
[in.]
min.
Ar t . 3.3
Connect ions
male-
male
soldering
male-
female
3810/ 22
3810/ 33
3810/ 44
3810/ 55
3810/ 66
3840/ 2
3840/ 3
3840/ M10
3840/ M12
3840/ 4
3840/ 5
3840/ M18
3840/ 6
3840/ 7
3840/ 9
3850/ 22
3850/ 33
3850/ 44
3850/ 55
3850/ 66
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"
7/ 8"
1.1/ 8"
10
12
16
18
22
30 +110 45
achieve equilibrium. However, t he moist ure
indicat ion is given normally when t he plant is in
funct ion and t he fluid is flowing.
The brazing of indicat ors wit h solder
connect ions should be carried out wit h care,
using a low melt ing point filler mat erial. In any
case, avoid direct cont act bet ween t he t orch
flame and t he indicat or body or glass, wich
could be damaged and compromise t he proper
funct ioning of t he indicat or.
Wit h indicat ors series 3780 and 3781 it s
necessar y t o disassemble t he ring before
st ar t ing t o braze.
INSTALLATION
At t he st ar t -up t he color of t he sensit ive
element may be yellow, due t o exposure t o air
humidit y and t o moist ure in t he circuit . When
t he moist ure of t he refrigerant is brought back
t o accept able levels wit h t he dehydrat or, t he
indicat or color is once again green. This is
evidence t hat equilibrium has been re-
st ablished. In case of persist ing yellow,
measures have t o be t aken t o eliminat e
moist ure. Only when t he sensit ive element
comes back t o green, t here is evidence t hat
adopt ed measures were ef fect ive. About 12
hours of syst em operat ion are required t o
80
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
TABLE 3: General Charact eri st i cs of l i qui d / moi st ure i ndi cat ors
Cat alogue
number
Type
SAE
Flare
Risk
Cat egor y
according
t o
PED
PS
[bar]
ODS ODM for pipe
TS [C]

[mm]

[mm]

[mm]
hole
[mm]
max.
[in.]
[in.]
[in.]
min.
Ar t . 3.3
I
Ar t . 3.3
I
Excluded
Connect ions
3910/ 22
3910/ 33
3910/ 44
3910/ 55
3910/ 66
3940/ 2
3940/ 3
3940/ M10
3940/ M12
3940/ 4
3940/ 5
3940/ M18
3940/ 6
3940/ 7
3940/ 9
3950/ 22
3950/ 33
3950/ 44
3950/ 55
3950/ 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
t ype
level glass
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
7/ 8"
1.1/ 8"
1.3/ 8"
2.1/ 8"
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
3810
3910
3840
3940 3850
3950
81
3770 3771
3780
3781
Moist ure
Liquid
Indicat ors
H H
1
L Ch
22
26,5
30
34
37,5
22
34
34
37,5
43,5
26,5
30
34
37,5
43,5
71,5
77,5
81,5
89,5
90
133
117
131
151
186
68
74
77
82
92
150
160
170
160
170
12
17
22
24
28
17
22
24
28
35
Cat alogue number

Liquid
Indicat ors
Weight [g]
3910/ 22
3910/ 33
3910/ 44
3910/ 55
3910/ 66
3940/ 2
3940/ 3
3940/ M10
3940/ M12
3940/ 4
3940/ 5
3940/ M18
3940/ 6
3940/ 7
3940/ 9
3950/ 22
3950/ 33
3950/ 44
3950/ 55
3950/ 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]
3810/ 22
3810/ 33
3810/ 44
3810/ 55
3810/ 66
3840/ 2
3840/ 3
3840/ M10
3840/ M12
3840/ 4
3840/ 5
3840/ M18
3840/ 6
3840/ 7
3840/ 9
3850/ 22
3850/ 33
3850/ 44
3850/ 55
3850/ 66
115
150
210
195
315
120
190
225
195
215
310
540
140
190
240
300
525
250
300
480
300
480
550
90
16,5
17,5
18,5
21,5
23,5
15,5
21,5
21,5
23,5
26
17,5
18,5
21,5
23,5
26
38
41,5
45
41,5
45
30
31
33
36
39,5
Dehydrat ors and Filt ers
84
In mol ecul ar si eve dri ers, wi t h a char ge
const i t ut ed by non-aggl omerat ed product s,
t he dehydrat i ng mass i s pressed i n bet ween
t wo f i ne st eel mesh di sks, or t wo f i l t eri ng
di sks of vari ous mat eri al , kept i n pl ace by a
spri ng.
In sol i d core dri ers, dehydrat i ng and
deaci di f yi ng product s wi t h bi nders const i t ut e
t he bl ock. Wat er adsorpt i on combi nes wi t h
t he neut ral i zat i on of aci ds t hat may be
present i n t he ref ri gerant , and wi t h a st rong
f i l t eri ng act i on.
Cast el have pl anned ei t her i t s product i on
l i nes of her met i c dri ers on t hi s second
sol ut i on t hat avoi d any ri sk of abrasi on of t he
char ge and consequent l y t he maki ng of
powder and per mi t t o put t he f i l t er i n any
posi t i on i nsi de t he ref ri gerat i ng syst em.
It i s al ways advi sabl e t o i nst al l a moi st ure
i ndi cat or downst ream t he f i l t er, whi ch wi l l
show t he ref ri gerant moi st ure and,
consequent l y, t he degree of ef f i ci ency of t he
f i l t er.
The dehydrat i ng capaci t y of Cast el dri er i s
rel at i ve t o t he char ge of ref ri gerant and not t o
t he ref ri gerat i on pot ent i al of t he pl ant . As a
mat t er of f act , f or t he same ref ri gerant
pot ent i al and f or t he same t ype of ref ri gerant
f l ui d, t here can be di f f erent ref ri gerant
char ges accordi ng t o t he t ype, desi gn and
worki ng condi t i ons of t he pl ant as wel l as t o
t he shut t er degree.
The dat a shown i n t he f ol l owi ng t abl es are
deduced f rom t he t est resul t s of t he present
Cast el product i on.
It i s i mpor t ant t o not e i n t he case of a hi gh
oi l l evel i n t he ci rcui t (> 5 %) t he dat a shown
i n t he t abl es wi l l be reduced consi derabl y.
Among cont ami nat i ng agent s causi ng seri ous
damages t o ref ri gerat i ng syst ems, moi st ure
pl ays a major rol e. It s presence, even
possi bl e i n t he ref ri gerat i ng syst em, i s due t o
many f act ors:
i nadequat e or i nsuf f i ci ent l y prol onged
vacuum bef ore ref ri gerant char gi ng;
oi l used f or t oppi ng up remai ned exposed
t o ai r humi di t y;
ref ri gerant used f or subsequent addi t i ons
cont ai ned i n non dri ed vessel s;
seal i ng def ect s especi al l y i n syst ems not
desi gned f or operat i on at l ow
t emperat ures.
Hi gh t emperat ures combi ned wi t h humi di t y
gi ve ri se t o compl ex phenomena enhanci ng
aci d f or mat i on bot h i n l ubri cat i ng oi l and
ref ri gerant .
Oi l or gani c aci ds react wi t h met al and f avor
t he f or mat i on of sl udge, whi ch are vi scous
cl ot s consi st i ng of i nsol ubl e met al sal t s and
l ar ge mol ecul es of pol ymeri zed oi l .
Sl udge af f ect s t he l ubri cat i on of t he movi ng
el ement s of t he compressor, can cl og val ves
and f i l t ers and cause seri ous damages.
Aci ds, especi al l y hydrof l uori c aci d, produced
by t he hydrol ysi s of t he f l uori nat ed ref ri gerant
(i n compressors i ron and al umi num act as
cat al yst s) are par t i cul arl y cor rosi ve.
Aci ds et ch met al sur f aces wi t h t he
consequent f or mat i on of cr yst al sal t s, whi ch
st i ck t o sur f aces and af f ect t he t ot al heat
exchange coef f i ci ent i n t he condenser and i n
t he evaporat or.
In t he seal ed and semi -seal ed groups, t hese
sal t s damage t he wi ndi ngs of el ect ri c mot ors
as i n t hese groups col d gas cool s wi ndi ngs
t hrough di rect cont act .
On t he ot her hand, wat er sol ubi l i t y i n
ref ri gerant s i n a l i qui d phase, i s qui t e
reduced, especi al l y at l ow t emperat ures. As a
consequence, when i n t he syst em wat er
exceeds t he ver y l ow l i mi t s of sol ubi l i t y
admi t t ed at l ow t emperat ure, excess wat er
t urns i nt o i ce, and bl ocks expansi on val ves
and capi l l ari es ei t her par t i al l y or t ot al l y.
Consequent l y, ref ri gerat i ng pl ant s must be
equi pped wi t h a f i l t er dri er on t he l i qui d l i ne
and t ypes avai l abl e on t he market are
essent i al l y t wo: mol ecul ar si eve dri ers and
sol i d core dri ers.
DEHYDRATION OF REFRIGERANTS
85
2 0 % of act i vat ed al umi na, and a s peci al
bi ndi ng agent i n appr opri at e pr opor t i ons .
The choi ce of bl end, mol ecul ar s i eves
act i vat ed al umi na, gi ves t o t he bl ock a
ver y hi gh capaci t y of aci d ads orpt i on al s o
mai nt ai ni ng ver y good dehydrat i ng
charact eri s t i cs . The pr es ence of a
cont r ol l ed and def i ned per cent age of
act i vat ed al umi na, l ower t han t he
maxi mum val ue r ecommended by
ASERCOM, keeps unchanged t he ori gi nal
concent rat i on of addi t i ves i n t he
pol yol es t er l ubri cant .
The bl ocks i n t he f i l t ers s eri es 4 3 ar e
mol ded f r om a bl end of dehydrat i ng
char ge, t ot al l y made of 3 mol ecul ar
s i eves , and a s peci al bi ndi ng agent i n
appr opri at e pr opor t i ons . The choi ce of t he
3 mol ecul ar s i eves , as s ol e dehydrat i ng
mat eri al , gi ves t o t he bl ock a s uperl at i ve
capaci t y of wat er ads orpt i on al s o
APPLICATIONS
The f i l t ers , s hown i n t hi s chapt er, ar e
cl as s i f i ed Pr es s ur e ves s el s i n t he s ens e
of t he Pr es s ur e Equi pment Di r ect i ve
9 4 / 2 3 / EC, Ar t i cl e 1 , Sect i on 2 . 1 . 1 and
ar e s ubj ect of Ar t i cl e 3 , Sect i on 1 . 1 of t he
s ame Di r ect i ve.
They ar e des i gned f or i ns t al l at i on on
commer ci al r ef ri gerat i ng s ys t ems and on
ci vi l and i ndus t ri al condi t i oni ng pl ant s ,
whi ch us e r ef ri gerant f l ui ds pr oper t o t he
Gr oup II (as def i ned i n Ar t i cl e 9 , Sect i on
2 . 2 of Di r ect i ve 9 7 / 2 3 / EC and r ef er r ed t o
i n Di r ect i ve 6 7 / 5 4 8 / EEC).
Fi l t ers s eri es 4 2 and s eri es 4 3 have been
devel oped f or s peci f i c i ns t al l at i ons on
r ef ri gerat i ng s ys t ems us i ng HFC r ef ri gerant
f l ui ds , par t i cul arl y R1 3 4 a, R4 0 4 A, R4 0 7 C,
R4 1 0 A ed R5 0 7 mi xed wi t h pol yol es t er
l ubri cant s . In s pi t e of t hi s , t he new bl ock
may be s ucces s f ul l y us ed al s o i n
r ef ri gerat i ng s ys t ems us i ng t he ol d CFC or
HCFC r ef ri gerant f l ui ds , mi xed wi t h mi neral
l ubri cant s .
CONSTRUCTION
The f i l t er i s compl et el y manuf act ur ed i n
s t eel , ei t her wi t h ni ckel -pl at ed Fl ar e
t hr eaded connect i ons . The pr oduct range
al s o i ncl udes t ypes wi t h copper pl at ed
s ol der connect i ons , of f eri ng t he pos s i bi l i t y
t o s ol der t he copper pi pe i ns i de t he
connect i ons (ODS) or out s i de t he
connect i ons , us i ng a copper s l eeve (ODM).
On s peci f i c cus t omers r eques t , Cas t el i s
al s o abl e t he s uppl y t hem f i l t ers s eri es 4 2
and 4 3 wi t h:
s ol der connect i ons made of copper t ube
EN 1 2 7 3 5 -1 Cu-DHP
ORFS (O-Ri ng Face Seal ) t hr eaded
connect i ons accor di ng t o SAE J 1 4 5 3
St andar d.
The bl ocks i n t he f i l t ers s eri es 4 2 ar e
mol ded f r om a bl end of dehydrat i ng
char ge, 8 0 % of 3 mol ecul ar s i eves and
ANTI-ACID SOLID CORE FILTER DRIERS WITH
MOLECULAR SIEVES AND ACTIVATED ALUMINA
SERIES 42
Approved by Underwri t ers Laborat ori es Inc.
SOLID CORE FILTER DRIERS WITH 100%
MOLECULAR SIEVES SERIES 43
Approved by Underwri t ers Laborat ori es Inc.
Sol i d core dehydrat or
1 Spring
2 Block
3 Felt
4 St ainless st eel mesh
86
mai nt ai ni ng qui t e good deaci di f yi ng
charact eri s t i cs .
The manuf act uri ng pr oces s gi ves a
cons i derabl e compact ed nes s and
s t out nes s t o bot h t he pr oduct s s o t hat
t hey ar e r es i s t ant t o s hocks and
abras i ons .
The s hape of t he bl ock i s des i gned i n
or der t o of f er t he maxi mum pos s i bl e
s ur f ace ar ea t o t he i ncomi ng f l ui d. The
i nt er nal cavi t y i s al s o pos i t i oned i n s uch a
way as t o have a uni f or m wal l t hi cknes s .
As a r es ul t , t he f l ui d encount ers a
cons t ant s t r engt h at al l poi nt s , f l ows
l i nearl y t hr ough t he bl ock, and ens ur es
ef f i ci ent dehydrat i on and mi ni mum char ge
l os s .
The bl ock i s chemi cal l y i ner t , not
del i ques cent , does not r eact wi t h
r ef ri gerat i ng f l ui ds , and i s capabl e of
bl ocki ng oi l by-pr oduct s dragged i nt o t he
ci r cui t . Impuri t i es accumul at e i n t he ri ng
bet ween t he met al s hel l and t he bl ock; t hi s
pr event s f i l t er cl oggi ng.
EXAMPLE OF SELECTION
Syst em dat a:
Refrigerant : R407C
Condensing t emperat ure: + 50 [C]
Weight of refrigerant : 34 [kg]
According t o DIN 8949:2000, t he adsorpt ion
capacit y of t he drier is given by:
(1.050 50) x 34 / 1.000 = 34 g of H
2
O
where:
1.050 ppm. = moist ure in t he refrigerant
ent ering t he filt er according t o DIN 8949:2000
50 ppm. = moist ure in t he refrigerant flowing
out t he filt er according t o DIN 8949:2000
Comparing t he absorpt ion capacit y required
wit h t he values shown in t able 2, drier
mod.4032 should be select ed, wit h a wat er
absorpt ion capacit y of 47,5 g at 50 C.
If t he dehydrat ing capacit y of product s is
expressed in wat er drops, it must be
remembered t hat :
1g H
2
O = 20 wat er drops
In t his case and when a molecular sieve drier is
select ed, t he following result is obt ained:
34 x 20 = 680 wat er drops.
If moist ure exceeds t he values specified in DIN
8949:2000, a drier wit h a higher adsorpt ion
capacit y shall be select ed.
f
l
o
w

d
i
r
e
c
t
i
o
n
87
TABLE 1a: General Charact eri st i cs of f i l t ers wi t h hi gh wat er capaci t y core (1).
SAE f l are connect i ons
Cat alogue
number
Block
Filt ering
Sur face
[cm
2
]
Nominal
Volume
[cm
3
]
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"
+80
45
(3)
Connect ions
40
TS [C]
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
032
033
052
053
082
083
084
162
163
164
165
303
304
305
304
305
415
416
47
70
103
155
310
255
330
50
80
130
250
500
500
670
Ar t . 3.3
International
Reference
min. max.
PS
[bar]
Risk
Cat egor y
according t o
PED
(1) 100% molecular sieves;
(2) Male-female connect ions (Inlet female)
(3) PS = 400 psig in compliance wit h t he UL approval
88
TABLE 1b: General Charact eri st i cs of f i l t ers wi t h hi gh wat er capaci t y core (1).
Sol der connect i ons
Cat alogue
number
International
Reference
Block
Filt ering
Sur face
[cm
2
]
Nominal
Volume
[cm
3
]
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 +80
45
(2)
Ar t . 3.3
I
[in.]
[mm]
[in.]
[mm]
ODS ODM
Connect ions
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according
t o
PED
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
032S
052S
053S
082S
083S
084S
163S

164S
165S
303S
304S
305S
304S
305S
415S
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;
89
TABLE 2a: General Charact eri st i cs of f i l t ers wi t h ant i aci d core (1).
SAE Fl are connect i ons
Cat alogue
number
International
Reference
Block
Filt ering
Sur face
[cm
2
]
Nominal
Volume
[cm
3
]
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"
40 +80
45
(2)
Ar t . 3.3
Connect ions
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
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
032
033
052
053
082
083
084
162
163
164
165
303
304
305
304
305
415
416
47
70
103
155
310
255
330
50
80
130
250
500
500
670
(1) 80% molecular sieves + 20% act ivat ed alumina;
90
TABLE 2b: General Charact eri st i cs of f i l t ers wi t h ant i aci d core (1).
Sol der connect i ons
Cat alogue
number
International
reference
Block
Filt ering
Sur face
[cm
2
]
Nominal
Volume
[cm
3
]
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 +80
45
(2)
Ar t .
3.3
I
[in.]
[mm]
[in.]
[mm]
ODS ODM
Connect ions
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according
t o
PED
4203/ 2S
4205/ 2S
4205/ 3S
4205/ M10S
4208/ 2S
4208/ 3S
4208/ M10S
4208/ M12S
4208/ 4S
4216/ 3S
4216/ M10S
4216/ M12S
4216/ 4S
4216/ 5S
4230/ 3S
4230/ 4S
4230/ 5S
4232/ 4S
4232/ 5S
4241/ 5S
4241/ 6S
4241/ 7S
4275/ 4S
4275/ 5S
4275/ 6S
4275/ 7S
4275/ 9S
032S
052S
053S
082S
083S
084S
163S
164S
165S
303S
304S
305S
304S
305S
415S
416S
417S
754S
755S
756S
757S
759S
47
70
103
155
310
255
330
660
50
80
130
250
500
500
67
1340
(1) 80% molecular sieves + 20% act ivat ed alumina;
91
(1) (2) See capt ion on page 92.
TABLE 3: Ref ri gerant Fl ow Capaci t y and Wat er Capaci t y
Cat alogue
number
Refrigerant Flow Capacit y,
Pressure drop
0,07 bar (1)
[kW]
R
1
3
4
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
R
2
2
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
R
4
0
4
A
R
5
0
7
4,6
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
R
4
0
7
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
R
4
1
0
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
Wat er capacit y
at + 25 C (2)
[g H
2
O]
R
1
3
4
a
4,1
7,3
12,7
25,1
50,2
45,4
61,4
122,8
R
2
2
3,8
6,7
11,6
22,9
45,8
41,4
56,1
112,2
R
4
0
4
A
R
5
0
7
4,2
7,4
13,0
25,6
51,2
46,4
62,8
125,6
R
4
0
7
C
3,4
6,0
10,4
20,5
41,0
37,2
50,3
100,6
R
4
1
0
A
3,7
6,5
11,3
22,3
44,6
40,5
54,7
109,4
Dehydrat able Charge
at + 25 C
[kg refrigerant ]
R
1
3
4
a
4,4
7,8
13,7
27,0
54,0
48,8
66,0
132,0
R
2
2
4,0
7,2
12,5
24,6
49,2
44,5
60,3
120,6
R
4
0
4
A
R
5
0
7
4,5
8,0
13,9
27,5
55,1
49,9
67,5
135,1
R
4
0
7
C
3,6
6,4
11,2
22,0
44,1
40,0
54,1
108,2
R
4
1
0
A
3,9
7,0
12,2
24,0
48,0
43,5
58,8
117,6
Wat er capacit y
at + 50 C (2)
[g H
2
O]
R
1
3
4
a
3,5
6,3
10,9
21,6
43,2
39,1
53,0
106,0
R
2
2
3,0
5,3
9,3
18,4
36,8
33,2
45,0
90,0
R
4
0
4
A
R
5
0
7
3,9
6,9
12,0
23,8
47,6
43,1
58,3
116,6
R
4
0
7
C
2,7
4,8
8,4
16,5
33,0
29,9
40,5
81,0
R
4
1
0
A
2,9
5,2
9,1
18,0
36,0
32,6
44,1
88,2
at + 50 C
[kg refrigerant ]
R
1
3
4
a
3,8
6,8
11,8
23,2
46,5
42,0
57,0
114,0
R
2
2
3,2
5,7
10,0
19,8
39,6
35,7
48,4
96,8
R
4
0
4
A
R
5
0
7
4,2
7,4
13,0
25,6
51,2
46,3
62,7
125,4
R
4
0
7
C
2,9
5,2
9,0
17,7
35,5
32,2
43,5
87,1
R
4
1
0
A
3,2
5,6
9,8
19,4
38,7
35,1
47,4
94,8
92
TABLE 4: Ref ri gerant Fl ow Capaci t y and Wat er Capaci t y
Cat alogue
number
Wat er capacit y,
Pressure drop
0,07 bar (1)
[kW]
R
1
3
4
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
R
2
2
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
R
4
0
4
A
R
5
0
7
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
R
4
0
7
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
R
4
1
0
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 t he refrigerant flow capacit y at which t he drier can be used when fluid dehydrat ion is not t he a major
problem, provided t hat t he original moist ure is limit ed before t he inst allat ion of t he drier. The maximum refrigerant flow
capacit ies are referred t o a t ot al pressure drop of 0,07 bar, inlet and out let connect ions included, (according t o ARI
STANDARD 710:86 - wit h condensing t emperat ure at +30 C and evaporat ing t emperat ure at -15 C)
(2) Wat er capacit y values wit h R22 are referred t o t he following condit ions, fixed in ARI STANDARD 710:86:
- Liquid t emperat ures: 25 C and 50 C
- Equilibrium point dr yness, EPD: 60 ppm
Wat er capacit y values wit h t he ot her refrigerant fluids are referred t o t he following condit ions, fixed in DIN 8949:2000
St andard:
Wat er capacit y
at + 25 C (2)
[g H
2
O]
R
1
3
4
a
3,5
6,2
10,8
21,3
42,7
38,6
52,2
104,4
R
2
2
3,2
5,7
9,9
19,5
38,9
35,2
47,7
95,4
R
4
0
4
A
R
5
0
7
3,6
6,3
11,0
21,8
43,5
39,4
53,4
106,8
R
4
0
7
C
2,9
5,1
8,8
17,4
34,9
31,6
42,8
85,5
R
4
1
0
A
3,1
5,5
9,6
19,0
37,9
34,4
46,5
93,0
at + 25 C
[kg refrigerant ]
R
1
3
4
a
3,8
6,7
11,6
22,9
45,9
41,5
56,1
112,2
R
2
2
3,4
6,1
10,6
20,9
41,9
37,8
51,3
102,5
R
4
0
4
A
R
5
0
7
3,9
6,8
11,9
23,4
46,8
42,4
57,4
114,8
R
4
0
7
C
3,1
5,5
9,5
18,7
37,5
34,0
46,0
91,9
R
4
1
0
A
3,4
6,0
10,3
20,4
40,8
37,0
50,0
100,0
Wat er capacit y
at + 50 C (2)
[g H
2
O]
R
1
3
4
a
3,0
5,4
9,3
18,4
36,7
33,2
45,1
90,1
R
2
2
2,6
4,5
7,9
15,6
31,3
28,2
38,3
76,5
R
4
0
4
A
R
5
0
7
3,3
5,9
10,2
20,2
40,5
36,6
49,6
99,1
R
4
0
7
C
2,3
4,1
7,1
14,0
28,1
25,4
34,4
68,9
R
4
1
0
A
2,5
4,5
7,7
15,3
30,6
27,7
37,5
75,0
at + 50 C
[kg refrigerant ]
R
1
3
4
a
3,3
5,8
10,0
19,7
39,5
35,7
48,4
96,9
R
2
2
2,8
4,9
8,5
16,8
33,6
30,3
41,1
82,3
R
4
0
4
A
R
5
0
7
3,6
6,3
11,0
21,8
43,5
39,4
53,3
106,6
R
4
0
7
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
93
Cat alogue
number
4303/ 2
4303/ 2F
4303/ 2S
4303/ 3
4305/ 2
4305/ 2F
4305/ 2S
4305/ 3
4305/ 3S
4305/ M10S
4308/ 2
4308/ 2F
4308/ 2S
4308/ 3
4308/ 3F
4308/ 3S
4308/ M10S
4308/ M12S
4308/ 4
4308/ 4S
4316/ 2
4316/ 3
4316/ 3F
4316/ 3S
4316/ M10S
4316/ M12S
4316/ 4
4316/ 4S
4316/ 5
4316/ 5S
4330/ 3
4330/ 3S
4330/ 4
4330/ 4S
4330/ 5
4330/ 5S
4332/ 4
4332/ 4S
4332/ 5
4332/ 5S
4341/ 5
4341/ 5S
4341/ 6
4341/ 6S
4341/ 7S
4375/ 4S
4375/ 5S
4375/ 6S
4375/ 7S
4375/ 9S
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
367
373
378
378
378
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
SAE
Flare
[in.]
[mm]
D L
ODS
Connect ions
Dimensions
[mm]
Weight
[g]
male connect ions
male - female connect ions
(female - in)
solder connect ions
94
syst ems using t he old CFC or HCFC refrigerant
fluids, mixed wit h mineral lubricant s.
The blocks 4490, t ype A and t ype B, and t he
block 4491, t ype A, are molded from a blend of
dehydrat ing charge, t ot ally made of 3
molecular sieves, and a special binding agent in
appropriat e propor t ions. The choice of t he 3
molecular sieves, as sole dehydrat ing mat erial,
gives t o t he block a superlat ive capacit y of
wat er adsorpt ion also maint aining quit e good
deacidifying charact erist ics.
The blocks 4490, t ype AA and t ype AB, and t he
block 4491, t ype AA, are molded from a blend
of dehydrat ing charge, 80% of 3 molecular
sieves and 20 % of act ivat ed alumina, and a
special binding agent in appropriat e
propor t ions. The choice of blend, molecular
sieves act ivat ed alumina, gives t o t he block a
ver y high capacit y of acid adsorpt ion also
maint aining ver y good dehydrat ing
charact erist ics.
The presence of a cont rolled and defined
percent age of act ivat ed alumina, lower t han t he
maximum value recommended by ASERCOM,
keeps unchanged t he original concent rat ion of
addit ives in t he polyolest er lubricant .
FILTER DRIERS WITH REPLACEABLE ANTI-ACID
SOLID CORE
Approved by Underwri t ers Laborat ori es
Inc.
Except filt ers 4423/ 17A, / 21A, / 25A and
4424/ 25A, / 33A
APPLICATIONS
The filt ers, shown in t his chapt er, are classified
Pressure vessels in t he sense of t he
Pressure Equipment Direct ive 97/ 23/ EC,
67/ 548/ EEC).
OPERATIONS
In t he case of filt ers wit h more t han one block,
t he passage of t he fluid t akes place in parallel;
as a result , t he pressure drop does not
increase propor t ionat ely t o t he number of
blocks. A large ring bet ween t he block and t he
inner sur face of t he filt er permit s t he
accumulat ion of solid par t icles, and prevent s
clogging. Before leaving t he filt er, t he
refrigerant fluid must pass t hrough t he mesh
sieve on which blocks are mount ed. The danger
t hat small par t icles of dehydrat ing mat erial
being int roduced int o t he syst em is t hus
avoided. Fur t hermore, at filt er out let , a plast ic
cup, t he edge of which closely adheres t o t he
inner sur face of t he filt er, prevent s dir t from
reaching t he out let connect ion during normal
operat ion and block change.
CONSTRUCTION
The filt ers t ype 4410 are manufact ured in st eel,
wit h t he except ion of t he connect ions which are
made of EN 12735-1 Cu-DHP copper t ube.
The filt ers t ype 4420 are complet ely
manufact ured in st eel and solder connect ion,
are machined wit h a st eel bar EN 10025
S355JR.
The blocks series 4490 and 4491 has been
developed for specific inst allat ions on
refrigerat ing syst ems using HFC refrigerant
fluids, par t icularly R134a, R404A, R407C,
R410A ed R507 mixed wit h polyolest er
lubricant s. In spit e of t his, t he new block may
be successfully used also in refrigerat ing
95
The manufact uring process of blocks series
4490 and 4491 gives a considerable
compact ed ness and st out ness t o bot h t he
product s so t hat t hey are resist ant t o shocks
and abrasions.
The blocks series 4490 have a volume of 48
cu.in., equivalent t o approx. 800 cm
3
, and it is
used wit h t ype 4411, 4412, 4413 and 4414
filt ers.
The block series 4491 has a volume of 96
cu.in., equivalent t o approx. 1600 cm
3
. and it is
used wit h t ype 4421, 4423 and 4424 filt ers.
The t wo blocks are shaped as a hollow cylinder
and t heir overall dimensions correspond t o
t hose of ot her int ernat ional brands.
Consequent ly t hey are int erchangeable. The
hollow cylinder shape of fers a large sur face
area t o t he inflowing fluid, which crosses t he
block in radial sense. As a result , dehydrat ion
is highly ef ficient wit h a minimum loss of
charge.
Filt ers may be supplied also wit h an access
fit t ing kit G9150/ R05, t o be ordered
separat ely.
Cat alogue
number
Core
Filt ering
Sur face
[cm
2
]
Number
of Core
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"
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
60,3
76,1
88,9
88,9
114,3
40 +80
45 (1)
35 (1)
32
I
II
[in.]
[cm
3
] [cu.in]
[mm]
[mm]
ODS W
Connect ions
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
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 wit h UL approval
Sket ch of f i l t er wi t h 2 bl ocks
1 Block
2 Mesh sieve ser ving as block suppor t
3 Spring
4 Ret ainer cup
5 Access fit t ing 1/ 4 SAE flare
(t o order separat ely)
inlet
out let
96
TABLE 2a: Ref ri gerant Fl ow Capaci t y and Wat er Capaci t y (f i l t ers)
Cat alogue
number
Pressure drop
0,07 bar (1)
[kW]
4411/ 5A
4411/ 7A
4411/ 9A
4411/ 11A
4411/ 13A
4411/ M42A
4411/ 17A
4412/ 7A
4412/ 9A
4412/ 11A
4412/ M42A
4412/ 17A
4413/ 11A
4413/ 13A
4413/ M42A
4414/ 13A
4414/ M42A
4414/ 17A
4423/ 17A
4423/ 21A
4423/ 25A
4424/ 25A
4424/ 33A
83
146
200
233
250
146
226
306
333
327
361
426
447
492
670
737
1180
90
158
216
252
270
158
244
331
361
354
391
460
483
532
725
797
1276
59
103
141
164
176
103
159
215
234
230
254
300
315
346
472
519
830
89
156
214
250
268
156
242
328
357
351
387
456
479
527
719
791
1265
90
159
217
253
271
159
245
332
362
355
393
462
485
534
728
800
1281
R
1
3
4
a
R
2
2
R
4
0
4
A
R
4
0
7
C
R
4
1
0
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
R
1
3
4
a
R
2
2
R
4
0
4
A
R
4
0
7
C
R
4
1
0
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
R
1
3
4
a
R
2
2
R
4
0
4
A
R
4
0
7
C
R
4
1
0
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
R
1
3
4
a
R
2
2
R
4
0
4
A
R
4
0
7
C
R
4
1
0
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
R
1
3
4
a
R
2
2
R
4
0
4
A
R
4
0
7
C
R
4
1
0
A
Wat er Capacit y
at + 25 C (2)
[g H
2
O]
at + 25 C
[kg refrigerant ]
Wat er Capacit y
at + 50 C (2)
[g H
2
O]
at + 50 C
[kg refrigerant ]
(1) Maximum values of t he refrigerant flow capacit y at which t he drier can be used when fluid dehydrat ion is not t he a major
problem, provided t hat t he original moist ure is limit ed before t he inst allat ion of t he drier. The maximum refrigerant flow
capacit ies are referred t o a t ot al pressure drop of 0,07 bar, inlet and out let connect ions included, (according t o ARI
STANDARD 710:86 - wit h condensing t emperat ure at + 30 C and evaporat ing t emperat ure at -15 C)
(2) Wat er capacit y values wit h R22 are referred t o t he following condit ions, fixed in ARI STANDARD 710:86:
Wat er capacit y values wit h t he ot her refrigerant fluids are referred t o t he following condit ions, fixed in DIN 8949:2000
St andard:
(3) Maximum values of t he refrigerant flow capacit y (according t o ARI STANDARD 710:86) at which filt er driers:
- series 4411, 4412, 4413, and 4414 can be used wit h blocks t ype 4490/ AA and 4490/ AB
- series 4423 and 4424 can be used wit h blocks t ype 4491/ AA
when fluid dehydrat ion is not t he a major problem, are t he same achieved wit h block t ype 4490/ A, 4490/ B and 4491/ A.
TABLE 2b: Ref ri gerant Fl ow Capaci t y and Wat er Capaci t y (si ngl e bl ock)
Cat alogue
number
Pressure drop
0,07 bar (1)
[kW]
R
1
3
4
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
R
2
2
R
4
0
4
A
R
4
0
7
C
R
4
1
0
A
R
1
3
4
a
R
2
2
R
4
0
4
A
R
4
0
7
C
R
4
1
0
A
R
1
3
4
a
R
2
2
R
4
0
4
A
R
4
0
7
C
R
4
1
0
A
R
1
3
4
a
R
2
2
R
4
0
4
A
R
4
0
7
C
R
4
1
0
A
R
1
3
4
a
R
2
2
R
4
0
4
A
R
4
0
7
C
R
4
1
0
A
Wat er Capacit y
at + 25 C (2)
[g H
2
O]
at + 25 C
[kg refrigerant ]
Wat er Capacit y
at + 50 C (2)
[g H
2
O]
at + 50 C
[kg refrigerant ]
97
Cat alogue
number
4411/ 5A
4411/ 7A
4411/ 9A
4411/ 11A
4411/ 13A
4411/ M42A
4411/ 17A
4412/ 7A
4412/ 9A
4412/ 11A
4412/ M42A
4412/ 17A
4413/ 11A
4413/ 13A
4413/ M42A
4414/ 13A
4414/ M42A
4414/ 17A
4423/ 17A
4423/ 21A
4423/ 25A
4424/ 25A
4424/ 33A
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"
16
22
35
42
54
22
35
42
54
35
42
42
54
54
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
518
538
705
715
235
241
246
258
249
383
387
399
390
529
541
682
673
641
661
829
839
185
324
600
760
90
96
101
113
103
96
101
113
103
101
113
103
142
162
172
5360
5405
5395
5464
5435
5410
5585
6880
7015
6985
7136
8510
8470
8445
9940
10010
18000
18200
18400
21600
22000
[in.]
[mm]
[mm]
D
1
D
2
H
1
H
2
H
3
P
ODS W
Connect ions
Dimensions
[mm]
Weight
[g]
98
Blocks must be ordered separat ely from t he
filt er. They are supplied in individual packages,
which are hermet ically sealed in suit able
wrappings (t ype 4490), and in special bags
(t ype 4491) for safe st orage over long periods
of t ime.
Ever y car t ridge is equipped of t wo seals in
synt het ic mat erial t o use like seal bet ween t he
t wo car t ridges and bet ween t he car t ridge and
it s covers.
If t he filt er is inst alled in a syst em wit hout any
by-pass, t he block replacement has t o be done
following t hese inst ruct ions:
1 Close t he valve on t he depar t ing line.
2 St ar t t he compressor and it s auxiliaries in
order t o t ransfer t he refrigerant charge int o
t he high pressure side of t he plant (liquid
receiver).
3 St op t he compressor at a suct ion pressure
suf ficient ly higher t han t he at mospheric
pressure.
4 Shut t of f t he ser vice valve at t he suct ion
side of t he compressor.
NOTE: if during t he t ransfer of t he refrigerant
t o t he high-pressure side of t he plant , t he
discharge pressures reach t oo high values
(t he condenser is flooded due t o insuf ficient
capacit y of t he liquid receiver), shut of f t he
valve on t he compressor suct ion side and
st op immediat ely t he compressor.
5 Replace quickly t he filt er block. During t he
preparat ion of t he new block, close t he filt er
wit h a clean clot h. The slight over-pressure
inside t he filt er and t he abilit y of t he
t echnician will prevent air from get t ing int o
t he plant .
BLOCKS REPLACEMENT
TABLE 4: General Charact eri st i cs, di mensi ons and Wei ght s
Cat alogue
number
Core
Filt ering
Sur face
[cm
2
]
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] [cm
3
] D
1
D
2
H
Weight
[g]
4490
4491
Nominal
Volume
Dimensions
[mm]
(1) Supplied wit hout cover gasket as spare par t
6 The int ernal cleanliness of t he body is
guarant eed by t he cleaning ef fect of t he cup
which is charact erist ic of Cast el filt ers.
if air is supposed t o have ent ered t he plant
during filt er block replacement , produce a
vacuum in t he low-pressure side of t he plant ,
and always in t he sect or of t he circuit
involved.
7 Open t he valve on t he depar t ure of liquid line
8 Slowly open t he suct ion valve of t he
compressor and st ar t t he compressor and
it s auxiliaries.
9 Top t he charge up, if necessar y.
99
SUCTION LINE:
SELECTION CRITERION
Wit h clean syst ems, refrigerant flow capacit y
and pressure drops of t able 2 are repor t ed t o a
gas speed of 20 m/ s for pipes adequat e t o t he
filt er connect ions.
For refrigerant flow capacit ies dif ferent from t he
t able values, under t he ot her same condit ions,
gas speeds and relat ive pressure drops
t hrough t he filt er can be gained for simple
propor t ionalit y.
EXAMPLE
Syst em dat a:
Refrigerant : R407C
Refrigerant flow capacit y: 130 [kW]
Evaporat ing t emperat ure: + 5 [C]
Suct ion pipe: 2.1/ 8
Filt er: 4411/ 17C
In t able 2, corresponding t o filt er t ype
4411/ 17C refrigerant and evaporat ing
t emperat ure, t he following dat a is given:
refrigerant flow capacit y = 141,7 [kW];
pressure drop = 0,21 [bar].
The gas speed in t he suct ion line will be:
[m/ s]
Pressure drop t hrough t he filt er:
[bar]
Remember t hat t he dimensioning of t he suct ion
line in a refrigerat ing syst em requires great
at t ent ion.
In fact t he relat ive pressure loss,
included filt er, which implies a reduct ion of flow
capacit y sucked by t he compressor, influences
direct ly t he refrigerat ing capacit y of t he plant .
This line is normally sized t o have a t ot al
pressure loss lower t hen a variat ion of t he
sat urat ion t emperat ure of 1 C.
0, 21
130
141, 7
0,177
2
2
=
20
130
141, 7
16, 8
2
2
=
Approved by Underwri t ers Laborat ori es
Inc.
Except filt ers 4421/ 21C, / 25C, / 33C
APPLICATIONS
67/ 548/ EEC).
OPERATION
Good filt ering of t he refrigerant on t he low-
pressure side of t he syst em is a guarant ee of
prot ect ion for t he compressor. Syst em
cleanliness is ensured by micro filt ering cores,
which filt er out impurit ies derived from
manufact ure and assembly of t he refrigerat ing
syst em.
CONSTRUCTION
The filt ers t ype 4410 are manufact ured in
st eel, wit h t he except ion of t he connect ions
which are made of EN 12735-1 Cu-DHP
copper t ube.
The filt ers t ype 4420 are complet ely
manufact ured in st eel and solder connect ion,
are machined wit h a st eel bar EN 10025
S355JR.
Zinc plat ed wire clot hs and a filt ering
baf fle form t he block, which feat ures
a large sur face, wit h cont rolled porosit y.
The block can st op solid par t icles up
t o 20 micron. At t he t wo ends, soft
felt gasket s ensure per fect sealing
wit h t he plast ic cups. Filt ers are supplied wit h
an access fit t ing kit G9150/ R05.
MECHANICAL FILTERS WITH REPLACEABLE FILTERING
BLOCK
100
pressure loss in t he suct ion line.
To such purpose diagram 2 illust rat es t he
exist ing relat ion bet ween sat urat ion
t emperat ure, in t he suct ion line, and variat ion
of t he refrigerant flow capacit y of a compressor.
For example diagram 1, referred t o R22, allows
t o est imat e t he aforesaid variat ion in funct ion
of pressure loss and evaporat ing t emperat ure.
Aft er all it s always impor t ant t o remember t hat
t he refrigerant flow capacit y of a compressor,
under t he ot her same condit ions, can reduce
considerably because of t he decrease of t he
sat urat ion t emperat ure, consequent t o t he
Cat alogue
Number
Core
Filt ering
Sur face
[cm
2
]
Number
of Core
Core Cat .
Number
45 (1)
32
I
[in.]
[mm]
[mm]
ODS W
Connect ions
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
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"
22
35
42
54
76,1
88,9
114,3
40 +80
Sket ch of f i l t er wi t h
mechani cal bl ock
1 Block
2 ret ainer cup
3 Spring
inlet
out let
101
DIAGRAM 1
DIAGRAM 2
0 5 10 15 20 25 30 35
0
1
2
3
4
5
6
-45 -40 -35
-30
-25
-20
-15
-10
-5
0
+10
e
v
a
p
o
r
a
t
i
o
n

t
e
m
p
e
r
a
t
u
r
e
Pressure loss (kPa)
E
q
u
i
v
a
l
e
n
t

v
a
r
i
a
t
i
o
n

o
f

t
h
e

s
a
t
u
r
a
t
i
o
n

t
e
m
p
e
r
a
t
u
r
e
0
0,5
1
1,5
2
-40 -35 -30 -25 -20 -15 -10 -5 0 5 10
C
o
r
r
e
c
t
i
o
n

f
a
c
t
o
r

o
f

r
e
f
r
i
g
e
r
a
n
t

f
l
o
w

c
a
p
a
c
i
t
y
Saturation temperature at the suction (C)
102
TABLE 2: Ref ri gerant Fl ow Capaci t y and Pressure drop
Cat alogue
number
Refrigerant
[bar] [kW] [bar] [kW] [bar] [kW] [bar] [kW] [bar] [kW]
-30 -20 -10 0 +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 capacit ies and pressure drops are referred t o t he following working condit ions:
Liquid t emperat ure ahead expansion valve: + 35 C
Overheat ing of suct ion gas: 6 C
103
TABLE 4: General Charact eri st i cs,
di mensi ons and Wei ght s
Cat alogue
number
4495
4496
4495/ C
4496/ C
127
287
820
1850
60
80
87
113
138
168
480
750
[sq.in] [cm
2
] D
1
D
2
H
Filt ering
Sur face
Dimensions
[mm]
Weight
[g]
Cat alogue
Number
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"
22
35
42
54
76,1
88,9
114,3
121
163
149
200
154
159
171
162
186
187
205
215
241
246
258
249
273
308
328
338
185
200
96
101
113
103
128
142
162
172
5450
5375
5435
5410
5585
6030
12000
12200
12500
[in.]
[mm]
[mm]
D
1
D
2
H
1
H
2
H
3
P
ODS W
Connect ions
Dimensions
[mm]
Weight
[g]
104
CONSTRUCTION
The filt er is complet ely manufact ured in st eel,
eit her wit h nickel-plat ed Flare t hreaded
connect ions. The product range also includes
t ypes wit h copper plat ed solder connect ions,
of fering t he possibilit y t o solder t he copper
pipe inside t he connect ions (ODS) or out side
t he connect ions, using a copper sleeve (ODM).
Inside t he filt ers t here is a screen basket , wit h
wide filt ering sur face, made of aust enit ic
st ainless st eel AISI 304.
These filt ers may not be cleaned.
APPLICATIONS
67/ 548/ EEC).
STRAINERS
Cat alogue
number
Usefull
Passage
Sur face
[%]
Mesh
Opening
[mm]
Kv
Fact or
[m
3
/ h]
Filt ering
Sur face
[cm
2
] SAE
Flare
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 45 Ar t . 3.3
[in.]
[mm]
[in.]
[mm]
ODS ODM
Connect ions
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
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
Cat alogue
number
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
D L
Dimensions
[mm]
Weight
[g]
4510
4520
Oil separat ors
106
The body is manufact ured from st eel pipe of
adequat e t hickness. Flanges and cover are also
made of st eel.
Eit her t hreaded connect ions of
separat ors series 5520 or solder connect ions
of separat ors series 5540 are manufact ured,
machining, wit h st eel bar
EN 10277-3 11S Mn Pb 37 + C.
The int ernal device is simple in order t o assure
a t rouble-free long operat ion.
Appropriat e met allic screens, placed on t he
inlet and out let , rapidly reduce gas speed, and
creat e t he condit ions required for t he
separat ion of t he oil from t he refrigerant .
A float operat ed needle valve, set on t he
bot t om of t he vessel, ret urn t he oil t o t he
crankcase of compressor. The bot t om also
includes a chamber t hat collect s all met allic
debris. A permanent magnet holds t hese
impurit ies t o avoid t hey st op or damage t he
operat ion of needle, moved by float ing.
APPLICATIONS
The oil separat ors, shown in t his chapt er, are
classified Pressure vessels in t he sense of
t he Pressure Equipment Direct ive 97/ 23/ EC,
67/ 548/ EEC).
The advant ages of t he oil separat or on t he
discharge line of a compressor in a
refrigerat ion syst em are confirmed by many
years of experience. The oil separat or
int ercept s t he oil mixed wit h compressed gas
and ret urns it t o t he crankcase of t he
compressor t hus assuring an ef ficient
lubricat ion of it s moving par t s. Fur t hermore,
t he oil separat or maint ains a high coef ficient of
condenser and evaporat or per formance by
almost complet ely removing oil deposit s from
t heir exchange sur faces. When a ver y high
t emperat ure at t he end of t he compression
st age leads t o t he format ion of oil vapours, a
separat or wit h a capacit y exceeding t he values
shown in t he t able should be used. Moreover,
t he oil separat or, damping t he valves
pulsat ions, reduces syst em noise wit h an open
or semi-hermet ic compressor.
Finally, t he use of an oil separat or leads t o:
a longer life of t he compressor;
a bet t er per formance of t he whole syst em
wit h consequent energy saving;
a quiet er operat ion by reducing pulsat ions.
Table 1 and 3 show t he t echnical dat a relat ing
t o t he working condit ions of oil separat ors.
CONSTRUCTION
Cast el manufact ures t wo t ypes of oil
separat ors:
separat ors series 5520 can be overhauled
for maint enance and can be replaced from
t he syst em. They are equipped wit h t hreaded
connect ions, which can mat e t o t he
connect ions t ype 5590 (t o be ordered
separat ely)
separat ors series 5540 are closed t ype and
t hey cannot be dismant led from t he syst em,
except cut t ing t he piping.
OIL SEPARATORS
Fig. 1
tc (C)
vg (m
3
/kg)
te (C)
h (kJ/kg)
SPECIFIC ENTHALPY (kJ/kg)
P
R
E
S
S
U
R
E

(
b
a
r
)
107
Check of gas speed, referred t o t he cross
sect ion of oil separat or, is given by:
[m/ s] wit h:
S = gross cross section of shell separator [m
2
]
INSTALLATION
The oil separat ors t ype 5520 and 5540 should
be inst alled in t he discharge line bet ween t he
compressor and t he condenser mount ed
securely in a ver t ical posit ion and reasonably
close t o t he compressor.
To prevent t he ret urn of refrigerant from
condenser, during t he of f cycle of t he syst em,
it s advisable t o inst all a check valve bet ween
t he condenser and oil separat or out let
connect ion.
Oil separat or per forms best when operat ing at
or near t he compressor discharge
t emperat ure. In locat ion t he oil separat or,
choose a posit ion t o avoid, as far as possible,
chilling of t he shell, which may result in
condensing of liquid wit hin t he separat or. If
t his is not possible, it is advisable t o supply
t he separat or wit h t he bet t er solut ions
(insulat ion, st rap heat er, ot hers) t o prevent t he
refrigerant in t he syst em from condensing in
t he shell.
Before t he oil separat or is inst alled, eit her one
5520 or one 5540, an init ial charge of oil
should be added t o it . Refer t o general
charact erist ics of oil separat ors or t o
inst ruct ion sheet for t he proper amount of oil.
Oil pre-charge is ver y impor t ant , failure t o pre-
charge separat or sump may result in damage
t o t he oil ret urn float mechanism. Use t he
same t ype of oil t hat is in t he compressor
crankcase.
Act ing as t he lay out of refrigerat ing syst em,
t he ret urn line may be run from t he oil fit t ing
t o:
t he compressor crankcase;
t he suct ion line upst ream t he compressor or
upst ream t he receiver, if present ;
t he oil reser voir if oil cont rol syst em is being
used.
A sight glass may be inst alled in t he oil line, in
a posit ion t hat oil is flowing t hrough t he t ube,
t o check t he correct working of t he oil
separat or.
v
Q
S
=
SELECTING THE SIZE
OF AN OIL SEPARATOR
The select ing of an oil separat or should be
done comparing t he charact erist ics of t he
inst alled compressor, est ablishing:
inlet connect ion must agree wit h t he
discharge diamet er of t he compressor
refrigerant flow capacit y wit h fixed working
condit ions (sat urat ed discharge t emperat ure
sat urat ed suct ion t emperat ure, event ually
liquid subcooling, sucked vapour
overheat ing).
This is necessar y t o define t he gas speed
referred t o t he cross sect ion of oil separat or,
assigned an end compression t emperat ure. It
is advisable t he above-ment ioned speed
doesn t exceed 0,5 m/ s, t o avoid great swirl
phenomena.
Table 3 has being writ t en following t his
principle.
Generally, fixed t he following dat a: refrigerat ing
capacit y of compressor, t ype of refrigerant and
working condit ions, t he volumet ric capacit y Q,
of compressed gas, is given by:
[m
3
/ s] wit h:
P = refrigerant flow capacit y [kW]
H = heat cont ent dif ferent ial, see diagram
(fig. 1). [kJ/ kg]
v
g
= specific volume of compressed gas,
separat or inlet (fig. 1). [m
3
/ kg].
Q
P
H
v
g
=
108
Cat alogue
number
Cat alogue
number
Max.
dif ferent ial
pressure
[bar]
Oil
addit ion
[kg]
Oil
connect ion
[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
30
21
30
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
45
32
45
I
II
I
[in.]
[mm]
[in.]
[mm]
[in.]
[mm]
ODS ODM ODS (1)
Solder Connect ions
Couple of solder connect ions
IN / OUT
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
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 t he separat or s connect ions must agree wit h t he discharge diamet er of t he compressor.
out let screen

cylinder
st eel plat e
oil ret urn t ube
st ainless
st eel needle
permanent
magnet
t ype 5540
t ype 5520
st ainless
st eel ball
inlet screen
cylinder
out let screen
cylinder
st eel plat e
st ainless st eel
ball
st ainless
st eel needle
permanent
magnet
oil ret urn t ube
inlet screen
cylinder
109
TABLE 2: Di mensi ons and Wei ght
Separat or
Cat alogue
number
connect ions
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
[in.]
[mm]
D
1
D
2
H
1
H
2
H
3
H
4
ODS
Solder Connect ions Dimensions [mm]
Weight
[g]
Gasket
110
TABLE 3: Ref ri gerant Fl ow Capaci t y
Cat alogue
number
Cat alogue
number
of solder
connect ions
Refrigerant Capacit y (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 capacit y wit h a condensing t emperat ure of + 40 C and a normal overheat ing values of vapour sucked by
compressor. No liquid subcooling.
Maximum pressure drop of 0,15 bar
Valves
112
plus a third one for charging or manometer
connect ion, t ypes:
6065 wit h right access connect ion;
6075 wit h left access connect ion.
N.B. : t he t hird way must be equiped wit h a
valve core (for example t ype 8394/ A or ot her
similar ones) t o be ordered separat ely.
The main par t s of t he hermet ic valves are
made wit h t he following mat erials:
body;
st eel, wit h proper sur face prot ect ion, or
brass for t he spindle;
for gland seal;
spindle.
APPLICATIONS
The hermet ic valves, shown in t his chapt er, are
67/ 548/ EEC).
CONSTRUCTION
These valves are available in t he following t wo
t ypes:
t wo-ways shut -of f valves t ypes 6010/ 2 and
6012/ 22;
t hree-ways valves; t wo main connect ions
HERMETIC VALVES
Cat alogue
number
Kv
Fact or
[m
3
/ 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
-40
+130
+110 45 Ar t . 3.3
(1) (2) (3)
[in.]
[mm]
SAE Flare ODS (4)
Connect ions
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
PED
6010/ 2
6012/ 22
6020/ 222
6020/ 233
6020/ 244
6020/ 255
6065/ 22M6
6065/ 23M10
6075/ 22M6
6075/ 23M8
6075/ 23M10
6075/ 24M12
6075/ 25M16
6010/ 2
113
Cat alogue
number
H
1
H
2
H
3
H
4
H
5
I L
1
L
2
L
3
P
1
Dimensions [mm]
Weight
[g]
6010/ 2
6012/ 22
6020/ 222
6020/ 233
6020/ 244
6020/ 255
6065/ 22M6
6065/ 23M10
6075/ 22M6
6075/ 23M8
6075/ 23M10
6075/ 24M12
6075/ 25M16
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
58,5
68
69
115
127
1
36
29
62
67
77
79
25
58
55,5
25
72
84
30,5
32
160
145
360
370
520
530
205
200
205
210
220
310
320
6012/ 22
6020
6065
6075
114
CONSTRUCTION
These valves are available in t he following t wo
t ypes:
t wo-ways valves, 90 angle connect ions,
t ypes 6110 and 6120;
t hree-ways valves; t wo main connect ions
(90 angle) plus a t hird one for charging,
t ype 6132. The access connect ion may be
shut of f by t he back-seat ing of t he spindle;
t wo-ways valves, 120 angle connect ions,
t ype 6140.
The main par t s of t he receiver valves are made
wit h t he following mat erials:
body;
spindle;
for gland seal;
spindle.
APPLICATIONS
The receiver valves, shown in t his chapt er, are
defined in Ar t icle 9,
Sect ion 2.2 of Direct ive 97/ 23/ EC and referred
t o in Direct ive 67/ 548/ EEC).
RECEIVER VALVES
Cat alogue
number
Kv
Fact or
[m
3
/ 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 Ar t . 3.3
(1) (2) (3)
SAE Flare NPT
Connect ions
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
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
115
H
1
H
2
L1
2
3
6110
L1
L2
H
1
NPT
2
3
6120
H
1
L2
L1
NPT
3
2
6140
L2
L1
H
1
H
2
1
2
3
NPT
6132
NPT
H
2
H
1
L1
6110/X13
6110/X15
1
2
Cat alogue
number
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
H
1
H
2
L
1
L
2
Dimensions [mm]
Weight
[g]
116
The main par t s of t he st op valves are made
body;
brass EN 12164 CW 614N for spindle and
prot ect ion cap;
gasket s for series 6165 and 6175;
for gland seal, only for series 6170.
APPLICATIONS
The st op valves, shown in t his chapt er, are
67/ 548/ EEC).
CONSTRUCTION
The ver y compact design of t hese brass valves
allows minimum dimensional sizes and t he
fixing flange complies wit h current market
requirement s.
Valves 6170 and 6175 must be complet ed wit h
t he following devices, t o be ordered separat ely:
valve code 8394/ A or code 8394/ B;
cap wit h gasket code 8392/ A.
STOP VALVES
Cat alogue
number
Kv
Fact or
[m
3
/ 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 Ar t . 3.3
Way
Nr.
(1) (2)
[in.]
[mm]
SAE Flare ODS (3)
Connect ions
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
PED
6165/ 22
6165/ 33
6175/ 33
6175/ 44
6175/ 55
6170/ 66
6170/ 77
117
Cat alogue
number
H
1
H
2
H
3
D L
1
L
2
L
3
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
H
3
L1
H
1
H
2
L1
H
3
H
1
H
2
D D
6170
6165 6175

6
.
5

6
.
5
2 2
3
3
1
118
CONSTRUCTION
Diaphragm valves don t have gland seal. The
ext ernal sealing is ensured by some t hin met al
discs (diaphragms), which hermet ically divide
t he spindle chamber from t he fluid flow area.
body;
brass EN 12164 CW 614N for spindle;
harmonic st eel for spring;
nylon for seat sealing gasket s.
APPLICATIONS
The diaphragm valves, shown in t his chapt er,
are classified Pressure accessories in t he
sense of t he Pressure Equipment Direct ive
97/ 23/ EC, Ar t icle 1, Sect ion 2.1.4 and are
subject of Ar t icle 3, Sect ion 1.3 of t he same
Direct ive.
67/ 548/ EEC).
DIAPHRAGM VALVES
Cat alogue
number
Kv
Fact or
[m
3
/ 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 Ar t . 3.3
[in.]
[mm]
SAE Flare
(1)
ODS (2)
Connect ions
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
PED
6210/ 2
6210/ 3
6210/ 4
6210/ 5
6210/ 6
6220/ 2
6220/ 3
6220/ 4
6220/ 5
6220/ 6
6220/ 7
119
Cat alogue
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
H
1
H
2
L
1
d I D
Dimensions [mm]
Weight
[g]
D
L1
d
H
1
H
2
I
D
H
2
H
1
d
L1
I
A94 A94
2 2
6210
6220
1 1
120
body;
spindle;
for gland seal;
spindle;
st eel bar EN 10277-3 11 S Mn Pb 37 for
7910 fit t ings;
P.T.F.E. for 7990 gasket s.
APPLICATIONS
The rot alock valves, shown in t his chapt er, are
67/ 548/ EEC).
CONSTRUCTION
Rot alock valves, mount ed wit h 7910 fit t ings
and 7990 gasket s, assure fast inst allat ion and
safe sealing.
Before t ight ening it is possible t o t urn t he valve
in ever y direct ion.
All Rot alock valves have an addit ional charging
connect ion, which can be excluded by t he back
sealing of t he spindle.
Fit t ings 7910 and gasket s 7990 have t o be
ordered separat ely.
ROTALOCK VALVES
Cat alogue
number
Kv
Fact or
[m
3
/ 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 Ar t . 3.3
(1) (2) (3)
SAE Flare Swivel nut
Connect ions
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
PED
6310/ 2
6310/ 3
6310/ 4
6320/ 3
6320/ 4
6320/ 5
6320/ 6
Valves 6310
6320
Gasket 7990
Coupling 7910
121
L2
L1
H
1
H
2
6310
6320
1
2
3
Cat alogue
number
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
H
1
H
2
L
1
L
2
Dimensions [mm]
Weight
[g]
122
INSTALLATION
The brazing of capped valves wit h solder
connect ions, t ype 6420, should be carried out
wit h care, using a low melt ing point filler
mat erial. It s necessar y t o remove t he spindle
assembly, wit h gland t oo, before brazing t he
body. It s impor t ant t o avoid direct cont act
bet ween t he t orch flame and t he valve body,
which could be damaged and compromise t he
proper funct ioning of t he valve.
APPLICATIONS
The capped valves, shown in t his chapt er, are
67/ 548/ EEC).
CONSTRUCTION
The main par t s of t he capped valves are made
body;
spindle;
for gland seal;
spindle.
CAPPED VALVES
Cat alogue
number
Kv
Fact or
[m
3
/ 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 Ar t . 3.3
[in.]
[mm]
SAE Flare
(2) (1)
ODS (3)
Connect ions
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
PED
6410/ 2
6410/ 3
6410/ 4
6410/
6410/ 6
6420/ 2
6420/ 3
6420/ M10
6420/ M12
6420/ 4
6420/ 5
6420/ M18
6420/ 6
6420/ M22
6420/ 7
6460/ 22A E
Unt il exhaust ion of t he st ock E
123
Cat alogue
number
H
1
H
2
L
1
L
2
L
3
P
1
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 t he valve 6460/ 22A is closed, connect ions A-B are open and C is st opped; when opened, all connect ions are open.
6410
6460/ 22A 6420
124
CONSTRUCTION
These val ves are avai l abl e i n t he f ol l owi ng t wo
t ypes:
6512 wi t h st rai ght sol der connect i ons;
6532 wi t h sol der angl e connect i ons;
The mai n par t s of t he gl obe val ves are made
wi t h t he f ol l owi ng mat eri al s:
hot f orged brass EN 12420 CW 617N f or
body, cover and cap t hat covers t he spi ndl e;
st eel , wi t h proper sur f ace prot ect i on, f or
t he spi ndl e;
chl oroprene r ubber (CR) and arami di c f i bers
f or gl and seal ;
met al -r ubber l ami nat ed f or out l et seal
gasket s
P. T. F. E. f or seat gasket s.
APPLICATIONS
The gl obe val ves, shown i n t hi s chapt er, are
cl assi f i ed Pressure accessori es i n t he
sense of t he Pressure Equi pment Di rect i ve
97/ 23/ EC, Ar t i cl e 1, Sect i on 2. 1. 4 and are
subject of Ar t i cl e 3, Sect i on 1. 3 of t he same
Di rect i ve.
They are desi gned f or i nst al l at i on on
commerci al ref ri gerat i ng syst ems and on ci vi l
and i ndust ri al condi t i oni ng pl ant s, whi ch use
ref ri gerant f l ui ds proper t o t he Group II (as
def i ned i n Ar t i cl e 9, Sect i on 2. 2 of Di rect i ve
97/ 23/ EC and ref erred t o i n Di rect i ve
67/ 548/ EEC).
GLOBE VALVES
Cat alogue
number
Kv
Fact or
[m
3
/ 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
40,0
8,2
9,1
18,7
38,0
48,5
-35 +160 45
Ar t . 3.3
I
Ar t . 3.3
I
[in.]
[mm]
ODS
[mm]
[in.]
ODM
Connect ions
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
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
125
Cat alogue
number
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 H
1
L L
1
Q A
Dimensions [mm]
Weight
[g]
6512
6532
126
BALL VALVES
APPLICATIONS
The ball valves, shown in this chapter, are
classified Pressure accessories in the sense
of the Pressure Equipment Directive 97/ 23/ EC,
Ar ticle 1, Section 2.1.4 and are subject of
Ar ticle 3, Section 1.3 of the same Directive.
They are designed for installation on commercial
proper to the Group II (as defined in Ar ticle 9,
Section 2.2 of Directive 97/ 23/ EC and referred
to in Directive 67/ 548/ EEC).
CONSTRUCTION
The specific design of Castel ball valves:
ensures the internal equilibrium of pressures
when the valve is closed;
permits the bi-directional flow of the
refrigerant and, consequently, the assembly
on the plant without taking into account the
direction of the refrigerant;
prevents any risk of ejection or explosion of
the spindle.
The opening and closing of the valve is realized
by turning the spindle one four th of a turn. A
standstill in turning realizes either a full opening
or a full closing, moreover the arrow printed on
the spindle head shows the flow direction.
The electric welding of the bodies and the seal
gaskets, assembled on the spindle, prevent any
leaks.
Ball valves are available in the following two
types:
type 6590 (full por t) and type 6591 (reduced
por t) without access fitting.
type 6590/ A (full por t) and type 6591/ A
(reduced por t) with access fitting.
These ball valves are equipped with valve core
8394/ A and cap 8392/ A.
body;
hot forged brass EN 12420 CW 617N,
chromium plat ed, for ball;
connect ions;
spindle;
gasket s;
P.T.F.E. for seat ball gasket s;
spindle. Hot forged brass EN 12420 CW
617N for caps on sizes from 6590/ M64A up
t o 6591/ 34A.
INSTALLATION
The brazing of ball valves should be carried out
with care, using a low melting point filler material.
It is impor tant to avoid direct contact between
the torch flame and the valve body, which could
be damaged and compromise the proper
functioning of the valve.
6590
127
Wit hout
access
fit t ing
Wit h
access
fit t ing
Cat alogue number
Kv
Fact or
[m
3
/ 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
5
14,5
24
40
68
100
178
293
430
-40 +150
45
42
Ar t . 3.3
I
[in.]
[mm]
Ball Por t
[mm]
ODS
Connect ions
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
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
128
Cat alogue
number
H H
1
H
2
L L
1
L
2
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
127
148
172,5
196,5
20
24
27,5
30
37
44
54
62
75
33
36
38
41
45
45
53
64
70
121
138
141
177
175
206
206
248
210
239
253
275
330
350
380
400
65
73,5
74
92
93
108,5
109
130
112
126
133
149
175
185
199
209
24
32
33
43
43
48
58
58
68
76
86
18
30
75
M5
M6
M10
260
300
290
410
450
760
800
1050
1518
2470
2520
4360
4400
8120
8090
8310
8350
12400
12450
12500
6590/ ..A
129
CONSTRUCTION
The valves are equipped wit h:
a lit t le flange for fixing t he valve t o t he
cont rol panel;
a SAE-Flare connect ion for joining it t o t he
copper t ube;
an NPT (t ype 8320) or a swivel SAE FLare
(8321) connect ion for mount ing t he gauge.
The main par t s of t his valve are made wit h t he
body;
St eel, wit h proper sur face prot ect ion, for t he
spindle;
Chloroprene rubber (CR) and aramidic fibers
for gland seal;
Glass reinforced PBT for cap t hat covers t he
spindle.
GAUGE MOUNTING VALVES
Cat alogue
number
1/ 4"
1/ 4"
1/ 4"
1/ 8"
1/ 4"
19
37
40
-60 +130 45 Ar t . 3.3
H
1
SAE
Flare
NPT
1/ 4" f
SAE
Flare
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
PED
8320/ 21
8320/ 22
8321/ 22
83
L
1
35
L
2
17
L
3
140
186
Weight
[g]
APPLICATIONS
The valves, shown in t his chapt er, are
67/ 548/ EEC). They are used for mount ing and
int ercept ing t he gauges on cont rol panels.
8320
8321
130
CONSTRUCTION
The main par t s of t he piercing valve are made
body;
Hardened st eel for t he needle;
Chloroprene rubber (CR) for t he out let seal
gasket s.
INSTALLATION
The t hreaded fork must be inst alled ast ride of
t he copper t ube, t he valve is fast ened t o t he
pipe by t ight ening t he lower nut and screwing it
t he needle pierces t he pipe. The hole, pierced
by t he needle, connect s t he pipe inlet wit h t he
SAE-Flare connection as shown in figures 1 and 2.
APPLICATIONS
The valve, shown in this chapter, is classified
Pressure accessories in the sense of the
Pressure Equipment Directive 97/ 23/ EC, Ar ticle
1, Section 2.1.4 and is subject of Ar ticle 3,
Section 1.3 of the same Directive.
It is designed for installation on commercial
proper to the Group II (as defined in Ar ticle 9,
Section 2.2 of Directive 97/ 23/ EC and referred
to in Directive 67/ 548/ EEC).
The piercing valve is a fast and cheap means of
providing a loading, outlet or inlet point in the
refrigerating system. It can be applied on copper
tube with a 6 mm to 10 mm diameter, and can
be installed in any position on the system.
LINE PIERCING VALVE
TABLE 1: General charact eri st i cs, di mensi ons and wei ght
Cat alogue
number
1/ 4" 6 - 10 72 -10 +70 25 Ar t . 3.3
H
1
SAE
Flare
Pipe
diamet er
[mm]
min.
TS [C]
max.
PS
[bar]
Risk
Cat egor y
according t o
PED
8330/ A 25,5
L
1
29
L
2
36
L
3
104
Weight
[g]
o
p
e
n
e
d

v
a
l
v
e
Threaded brass f it t ings
132
All st raight fit t ings, from series 7110 t o series
7170, and all t he plug, from series 7510 t o
series 7520, are machined by brass bar EN
12164 CW 614N.
Seal caps series 7560 and gasket s
series 7580 are made wit h copper
Cu ETP UNI 5649.
The main par t s of t he flanges joint s are made
bushes and flanges;
aramidic fibers for seal gasket of t he
flanges.
APPLICATIONS
All t he fit t ings, shown in t his chapt er, are
excluded from t he scope of Direct ive
97/ 23/ EC, as specified in t he Guidelines 1/ 8
and 1/ 9, because t hey are piping component s.
67/ 548/ EEC).
OPERATION
The sealing syst em bet ween t he end of a male
connect ion and a nut series 7010, 7020 and
7030 requires a special flaring of t he end of
copper t ube, t he so-called flared connect ion.
The sealing syst em bet ween t he end of a male
connect ion and a Flare-ODS adapt er allows
avoiding t he flaring process on copper t ube end
(nat ional laws of some European count ries
don t accept t his operat ion) because t he t ube
end is brazed int o t he solder connect ion of t he
adapt er.
We wish t o remember t o our cust omers t hat
t hey may assure no leakage of t he male
connect ion/ adapt er syst em only int erposing t he
copper gasket 7580, supplied wit h t he same
adapt er.
Flange joint s 7630 consist of t wo brass bushes
for brazing t o t he copper t ubes. When t he four
flange screws are t ight ened, a gasket , put
bet ween t he t wo bushes, assures t he seal of
flanged joint s.
CONSTRUCTION
All nut s, from series 7010 t o series 7050, and
all t he elbows, TEE and cross fit t ings, from
series 7210 t o series 7410, are manufact ured
wit h hot forged brass
EN 12420 CW 617N.
THREADED BRASS FITTINGS
133
Cat alogue
number
Int ernat ional
Reference
SAE
Flare
[in]
[mm]
PS
[bar]
D L Ch
Copper pipe Dimensions [mm]
Wrench
t orque
min / max
[Nm]
Weight
[g]
7010/ 22
7010/ 33
7010/ 44
7010/ 55
7010/ 66
7010/ 77
7010/ 88
NS44
NS46
NS48
NS410
NS412
NS414
NS416
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
7/ 8"
1"
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
7/ 8"
1"
6
16
22
45
6,5
9,7
13
16,2
19,4
22,5
25,6
15,5
19,5
22,5
25
29,5
36,5
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 Fl are nut s (i nch t ubi ng)
7020/ 20
7020/ X02
N54
CAP NUT
N5-5
CAP NUT
1/ 4"
5/ 16"
blind blind 45
15,5
15
17
15
11 / 14
8,5 / 11,5
20
14
SAE Fl are cap nut s
7020/ 32
7020/ 43
7020/ 54
7020/ 65
7020/ 87
NRS464
NRS486
NRS4108
NRS41210
NRS41614
3/ 8"
1/ 2"
5/ 8"
3/ 4"
1"
1/ 4"
3/ 8"
1/ 2"
5/ 8"
7/ 8"
6
16
22
45
6,5
9,7
13
16,2
22,5
19,5
22,5
25
29,5
36,5
22
25
28
33
41
20 / 25
34 / 47
54 / 75
68 / 71
120 / 150
38
53
69
104
160
SAE Fl are reduci ng nut s (i nch t ubi ng)
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 Fl are nut s (met ri c t ubi ng)
7050/ 2
7050/ 3
7050/ 4
7050/ 5
US44
US46
US48
US410
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 Fl are t wi n nut s

134
Cat alogue
number
Int ernat ional
Reference
SAE Flare NPT
PS
[bar]
L Ch
Weight
[g]
7110/ 2
7110/ 3
7110/ 4
7110/ 5
7110/ 6
7110/ 8
U24
U26
U28
U210
U212
U216
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
1"
45
38
44
50
58
63
72
12
17
20
23
27
36
23
46
73
113
164
304
SAE Fl are uni ons
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
Reduci ng SAE Fl are uni ons
7130/ 2
7130/ 3
7130/ 4
7130/ 6
7130/ 8
U14B
U16C
U18D
U112F
U116H
1/ 4"
3/ 8"
1/ 2"
3/ 4"
1"
1/ 4"
3/ 8"
1/ 2"
3/ 4"
1"
45
38,1
41,2
49,8
57,6
68
14
17
22
27
36
32
48
92
152
277
SAE Fl are / NPT uni ons
7140/ 21
7140/ 32
7140/ 43
7140/ 54
U14A
U16B
U18C
U110D
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 Fl are / NPT reduci ng uni ons
Available on request
Unt il exhaust ion of t he st ock E
R
7120/ 23
7120/ 24
7120/ 34
7120/ 35
7120/ 45
7120/ 56
UR264
UR284
UR286
UR2-106
UR2108
UR2-1210
E
R
R
R
135
Cat alogue
number
Int ernat ional
Reference
SAE Flare ODS
m f
NPT GAS
[in.]
[mm]
PS
[bar]
L Ch
Weight
[g]
7150/ 21
7150/ 32
7150/ 43
7150/ 54
7150/ 64
7150/ 65
U34A
UR346
UR368
UR3810
UR3812
UR31012
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
3/ 4"
1/ 4"
3/ 8"
1/ 2"
1/ 2"
5/ 8"
1/ 8" f
45
29
33
38
45
46,5
49,5
14
17
22
25
27
30
21
38
66
99
132
157
Mal e / f emal e reduci ng uni ons (reduced f emal e)
7150/ 23
7150/ 24
7150/ 34
7150/ 45
7150/ 46
7150/ 56
UR364
UR384
UR386
UR3108
UR3128
UR31210
1/ 4"
1/ 4"
3/ 8"
1/ 2"
1/ 2"
5/ 8"
3/ 8"
1/ 2"
1/ 2"
5/ 8"
3/ 4"
3/ 4"
45
33
36
39
44
45
49
22
25
30
34
49
66
74
127
140
150
Mal e / f emal e reduci ng uni ons (reduced mal e)
7154/ 2
7156/ 2
1/ 4"
1/ 4"
20 14 left t hread, female
W 21,8 14 right t hread, female
45 29
25
27
46
52
Cyl i nder adapt ors
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
Mal e / f emal e uni ons
7164/ 2
7166/ 2
1/ 4"
1/ 4"
G1/ 4"
f
G1/ 4"
m
45
32,5
32
20
17
45
25
Uni ons SAE Fl are t o BSP
7170/ 22
7170/ 2M8
7170/ 33
7170/ 3M10
7170/ 44
7170/ 4M12
7170/ 55
7170/ 6M18
US344
US366
US388
US31010
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 4"

1/ 4"
3/ 8"
1/ 2"
5/ 8"
10
12
16
18
45
26,5
33
35
42
45,5
12
17
20
23
27
17
39
55
82
123
Mal e SAE Fl are / sol der uni ons
Available on request R
136
I
t
e
m

p
o
s
i
t
i
o
n
Cat alogue
number
SAE
Flare
ODS
[in.]
[mm]
PS
[bar]
L
1
L
2
L
3
L
4
Ch
Weight
[g]
Wrench
t orque
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"
10
12
16
18
45
21
21
23,5
23,5
26
26
27,5
30
30
3,5
3,5
4,5
4,5
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
Fl are - ODS adapt ers

POS. 1
POS. 2
POS. 3
Flare/ ODS fit t ing
Nut Connect ion Copper seal
Copper pipe SAE/ Flare connect ion
137
Cat alogue
number
Int ernat ional
Reference
SAE Flare
m f
NPT
PS
[bar]
H L
Weight
[g]
7210/ 2
7210/ 3
7210/ 4
7210/ 5
7210/ 6
E24
E26
E28
E210
E212
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
45
24,5
29,5
32,5
36
42,5
24,5
29,5
32,5
36
42,5
26
49
83
116
192
SAE Fl are el bows
7220/ 2
7220/ 3
7220/ 4
7220/ 6
E14B
E16C
E18D
E112F
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 Fl are / NPT el bows
7230/ 21
7230/ 32
7230/ 43
7230/ 54
E14A
E16B
E18C
E110D
1/ 4"
3/ 8"
1/ 2"
5/ 8"
1/ 8"
1/ 4"
3/ 8"
1/ 2"
45
24,5
29,5
32,5
36
23,5
29,5
31
35
25
46
75
114
SAE Fl are / reduced NPT el bows
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
Mal e / f emal e SAE Fl are el bows
138
Cat alogue
number
Int ernat ional
Reference
SAE Flare
(1) (2) (3) (4)
NPT
(3)
PS
[bar]
H L
Weight
[g]
7310/ 2
7310/ 3
7310/ 4
7310/ 5
7310/ 6
T24
T26
T28
T210
T212
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
45
23,5
29
31,5
36
41,5
47
58
63
72
83
32
69
97
153
235
SAE Fl are TEE
7320/ 223
7320/ 334
7320/ 445
7320/ 556
TR246
TR268
TR2810
TR21012
1/ 4"
3/ 8"
1/ 2"
5/ 8"
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
45
29
32,5
38
41,5
56
63
72
83
77
95
153
228
SAE Fl are reduci ng TEE (reduced si de connect i ons)
7320/ 332
7320/ 443
7320/ 554
7320/ 665
TR264
TR286
TR2108
TR21210
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 Fl are reduci ng TEE (reduced cent ral connect i on)
7330/ 221
7330/ 222
T14A
T14B
1/ 4"
1/ 4"
1/ 4"
1/ 4"

1/ 8"
1/ 4"
45
21
24
47
51
56
198
SAE Fl are / NPT TEE (t aper cent ral connect i on)
7340/ 222 T64 1/ 4" 1/ 4" 1/ 4" 45 27,5 56 78
Mal e / f emal e SAE Fl are (f emal e cent ral connect i on)
H
L
7410/ 2 C14 1/ 4" 1/ 4" 1/ 4" 1/ 4" 45 52 52 55
SAE Fl are cross
139
Cat alogue
number
Int ernat ional
Reference
SAE
Flare
NPT
ODS
[in.]
[mm]
PS
[bar]
H L Ch
Wrench
t orque
min / max
[Nm]
Weight
[g]
7520/ 1
7520/ 2
7520/ 3
7520/ 4
7520/ 6
7520/ 8
121B02
121B04
121B06
121B08
121B12
121B16
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 pl ugs
7510/ 2
7510/ 3
7510/ 4
P24
P26
P28
1/ 4"
3/ 8"
1/ 2"
45
23
26
30
12
17
20
11 / 14
20 / 25
34 / 47
19
40
67
SAE Fl are pl ugs
7560/ 2
7560/ 3
7560/ 4
7560/ 5
7560/ 6
7560/ 7
B14
B16
B18
B110
B112
B114
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
7/ 8"
45
0,5
1
1,5
2
4
10
Copper seal caps
7580/ 2
7580/ 3
7580/ 4
7580/ 5
7580/ 6
B24
B26
B28
B210
B212
1/ 4"
3/ 8"
1/ 2"
5/ 8"
3/ 4"
45
0,5
0,5
1
1,5
3
Copper gasket
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
42
22
23
24
25
63
67
71
20 / 24
42 / 50
68 / 80
315
490
1045
1340
1940
Fl ange j oi nt s
Copper braze - joint
pressure f it t ings
142
dimensions:
7832 Tees and reducing t ees
Reinforced series 79 show t he following
select ion of copper braze-joint fit t ings, wit h ODS
/ IDS millimet ers connect ions, limit ed t o some
dimensions:
7900 Female t o female couplings
7902 Female t o female reducing
couplings
7903 Male t o female reducing couplings
7916 45 female t o female elbows
7917 45 male t o female elbows
long radius
long radius
CONSTRUCTION
Dimensions and t olerances of t he ODS / IDS
connect ions ends in copper braze-joint fit t ings
series 77, 78 and 79 are in compliance wit h
t he EN 1254-1 : 1998 St andard.
All copper braze-joint fit t ings series 77, 78 and
79 are made of seamless copper t ube EN
12735-2 CW024A, soft annealed.
Technical charact erist ics of copper fit t ings
series 77 and 78, depending on t ube nominal
diamet ers, are given in t able 1, while t echnical
charact erist ics of copper fit t ings series 79,
always depending on nominal diamet ers, are
given in t able 2.
Copper braze-joint fit t ings series 77, 78 and
79, if submit t ed t o ambient -t emperat ure burst
t est , guarant ee a pressure st rengt h at least
equal t o 3 x PS (30 C rat ed working-pressure
as shown in t ables 1 and 2) according t o ASME
B16.50 : 2001 St andard.
APPLICATIONS
All t he fit t ings, shown in t his chapt er, are
excluded from t he scope of Direct ive
97/ 23/ EC, as specified in t he Guidelines 1/ 8
and 1/ 9, because t hey are piping component s.
and indust rial condit ioning plant s, made of
seamless copper t ube specified in EN 12735-1
: 2001 St andard, which use refrigerant fluids
proper t o t he Group II (as defined in Ar t icle 9,
Sect ion 2.2 of Direct ive 97/ 23/ EC and referred
t o in Direct ive 67/ 548/ EEC).
PRODUCTS RANGE
Series 77 show t he following select ion of
copper braze-joint fit t ings, wit h ODS / IDS
millimet ers connect ions, pract ically in all
diamet er dimensions:
7700 Female t o female couplings
7702 Female t o female reducing
couplings
7703 Male t o female reducing couplings
shor t radius
shor t radius
long radius
long radius
Series 78 show t he following select ion of
copper braze-joint fit t ings, wit h ODS / IDS inch
connect ions, limit ed t o few diamet er
COPPER BRAZE-JOINT PRESSURE FITTINGS
143
INSTALLATION
The int ernal working pressure-t emperat ure
rat ing for a copper fit t ing, is dependent upon,
not only fit t ing st rengt h, but also t he adopt ed
joining process and t he used filler met al. The
working pressure-t emperat ure values given in
t ables 1 and 2 are referred t o a brazing
process, per formed in accordance wit h t he
sound engineering pract ice.
We wish t o remember t he definit ion of brazing
process, given in EN 13133 : 2000 St andard.
The process of joining generally applied t o t he
joining of mat erials by a heat ing process during
which t he parent mat erials do not melt and t he
filler met al is drawn int o t he joint by capillar y
act ion. It is generally applicable t o joining
syst ems where t he filler met al melt s at 450 C
or above .
In act ual pract ice brazing is done at
t emperat ures ranging from 630 t o 820 C and
t here are t wo general t ypes of brazing filler
met als, normally used for joining copper t ube:
Copper Phosphorus alloys (t he so called B-
CuP), proper t o CP Class of EN 1044 : 1999
St andard, t hat are normally used wit hout
fluxes;
Silver alloys (t he so called B-Ag), proper t o
AG Class of EN 1044 : 1999, t hat must be
used wit h t heir specific fluxes.
TABLE 1
Tube
Nominal Diamet er
6
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 t emperat ure
TABLE 2
Tube
Nominal Diamet er
22
28
35
42
54
7/ 8
1
1.1/ 8
1.3/ 8
1.5/ 8
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 +95 C +150 C
(2)
Working Pressure PS [bar], depending on t emperat ure
(1) PS values list ed in t his column are referred t o a safet y coef ficient 4, according t o ASME B16.50 : 2001 St andard
(2) PS values list ed in t his column are referred t o a safet y cef ficient 3, minimum value warrant ed by Cast el for all it s product s
Not e: working pressure shown in t his t able are in
comparison wit h rat ed working pressures est ablished in
ASME B16.50 : 2001 St andard.
144
Int ernat ional
Reference
Cat alogue
number IDS
[mm]
ODS
[mm]
Weight
[g]
Not e
Connect ions
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
Femal e t o f emal e coupl i ngs (met ri c t ubi ng)
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
Femal e t o f emal e reduci ng coupl i ngs (met ri c t ubi ng)
145
Int ernat ional
Reference
Cat alogue
number IDS
[mm]
ODS
[mm]
Weight
[g]
Not e
Connect ions
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
Mal e t o f emal e reduci ng coupl i ngs (met ri c t ubi ng)
146
Int ernat ional
Reference
Cat alogue
number IDS
[mm]
ODS
[mm]
Weight
[g]
Not e
Connect ions
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
90f emal e t o f emal e el bows - shor t radi us (met ri c t ubi ng)
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
90mal e t o f emal e el bows - shor t radi us (met ri c t ubi ng)
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
45f emal e t o f emal e el bows (met ri c t ubi ng)
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
45mal e t o f emal e el bows (met ri c t ubi ng)
147
Int ernat ional
Reference
Cat alogue
number IDS
[mm]
ODS
[mm]
Weight
[g]
Not e
Connect ions
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
90f emal e t o f emal e el bows - l ong radi us (met ri c t ubi ng)
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
90mal e t o f emal e el bows - l ong radi us (met ri c t ubi ng)
148
Int ernat ional
Reference
Cat alogue
number IDS
[mm]
ODS
[mm]
Weight
[g]
Not e
Connect ions
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 (met ri c t ubi ng)
7732/ M8.6.8
7732/ M8.10.8
7732/ M10.6.10
7732/ M10.8.8
7732/ M10.8.10
7732/ M10.12.10
7732/ M12.8.12
7732/ M12.10.12
7732/ M12.14.12
7732/ M12.16.12
7732/ M14.12.14
7732/ M14.22.14
7732/ M16.12.16
7732/ M16.14.16
7732/ M16.16.12
7732/ M16.22.16
7732/ M18.12.18
7732/ M18.16.18
7732/ M18.22.18
7732/ M22.12.22
7732/ M22.16.22
7732/ M22.18.22
7732/ M22.28.22
7732/ M28.22.28
7732/ M35.28.35
7732/ M42.22.42
7732/ M42.28.42
7732/ M54.42.54
5130/ 8.6.8
5130/ 8.10.8
5130/ 10.6.10
5130/ 10.8.8
5130/ 10.8.10
5130/ 10.12.10
5130/ 12.8.12
5130/ 12.10.12
5130/ 12.14.12
5130/ 12.16.12
5130/ 14.12.14
5130/ 14.22.14
5130/ 16.12.16
5130/ 16.14.16
5130/ 16.16.12
5130/ 16.22.16
5130/ 18.12.18
5130/ 18.16.18
5130/ 18.22.18
5130/ 22.12.22
5130/ 22.16.22
5130/ 22.18.22
5130/ 22.28.22
5130/ 28.22.28
5130/ 35.28.35
5130/ 42.22.42
5130/ 42.28.42
5130/ 54.42.54
8
8
10
10
10
10
12
12
12
12
14
14
16
16
16
16
18
18
18
22
22
22
22
28
35
42
42
54
6
10
6
8
8
12
8
10
14
16
12
22
12
14
16
22
12
16
22
12
16
18
28
22
28
22
28
42
8
8
10
8
10
10
12
12
12
12
14
14
16
16
12
16
18
18
18
22
22
22
22
28
35
42
42
54
7
12
10
13
10
17
12
13
17
22
34
57
22
20
30
58
27
28
45
37
45
43
93
75
110
154
170
354
Reduci ng t ees (met ri c t ubi ng)
149
Int ernat ional
Reference
Cat alogue
number IDS
[mm]
ODS
[mm]
Weight
[g]
Not e
Connect ions
7832/ 222
7832/ 333
5130/ 222
5130/ 333
1/ 4"
3/ 8
1/ 4"
3/ 8
1/ 4"
3/ 8
8
8
Tees (i nch t ubi ng)
7832/ 323 5130/ 323 3/ 8 1/ 4" 3/ 8 14
Reduci ng t ees (i nch t ubi ng)
150
Int ernat ional
Reference
Cat alogue
number IDS
[mm]
ODS
[mm]
Not e
Connect ions
7900/ M22
7900/ M28
7900/ M35
7900/ M42
7900/ M54

22
28
35
42
54
22
28
35
42
54
Femal e t o f emal e coupl i ngs, rei nf orced seri es (met ri c t ubi ng)
7916/ M22
7916/ M28
7916/ M35
7916/ M42
7916/ M54

22
28
35
42
54
22
28
35
42
54
45f emal e t o f emal e el bows, rei nf orced seri es (met ri c t ubi ng)
7917/ M22
7917/ M28
7917/ M35
7917/ M42
7917/ M54
22
28
35
42
54

22
28
35
42
54
45mal e t o f emal e el bows, rei nf orced seri es (met ri c t ubi ng)
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
Femal e t o f emal e reduci ng coupl i ngs, rei nf orced seri es (met ri c t ubi ng)
7903/ M28.22
7903/ M35.22
7903/ M35.28
7903/ M42.28
7903/ M42.35
7903/ M54.35
7903/ M54.42
28
35
35
42
42
54
54

22
22
28
28
35
35
42
Mal e t o f emal e reduci ng coupl i ngs, rei nf orced seri es (met ri c t ubi ng)
151
Int ernat ional
Reference
Cat alogue
number IDS
[mm]
ODS
[mm]
Not e
Connect ions
7918/ M22
7918/ M28
7918/ M35
7918/ M42
7918/ M54

22
28
35
42
54
22
28
35
42
54
90f emal e t o f emal e el bows - l ong radi us, rei nf orced seri es (met ri c t ubi ng)
7919/ M22
7919/ M28
7919/ M35
7919/ M42
7919/ M54

22
28
35
42
54
22
28
35
42
54
90mal e t o f emal e el bows - l ong radi us, rei nf orced seri es (met ri c t ubi ng)
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, rei nf orced seri es (met ri c t ubi ng)
Access f it t ings &
valve cores
154
CONSTRUCTION
The st raight fit t ings are machined by hexagonal
brass bar EN 12164 CW 614N.
The TEE and cross fit t ings are manufact ured
wit h hot forged brass EN 12420 CW 617N.
The main par t s of t he valve cores are made
brass EN 12164 CW 614N for body;
chloroprene rubber (CR) for seat gasket ;
gasket for t ypes 8394/ A and 8395/ A;
PTFE for out let seal gasket for t ype 8394/ B.
APPLICATIONS
All t he access fit t ings and valve cores, shown
in t his chapt er, are excluded from t he scope of
Direct ive 97/ 23/ EC, as specified in t he
Guidelines 1/ 8 and 1/ 9, because t hey are
piping component s.
67/ 548/ EEC).
The access fit t ings allow t o creat e a loading or
draining point rapidly and wit h a minimum
expense.
Aft er complet ion of t he loading or draining
operat ions, t he cap wit h gasket
(cod. 8392/ A) prevent s any leakage.
For par t icular cust omer s requirement s,
t he 7020/ 20 flare blind nut wit h combined
8580/ 2 copper flare gasket may replace
t he 8392/ A cap.
This solut ion requires t o screw t he nut wit h a
t orque wrench at 8,5 11,5 Nm.
For syst em using R410A refrigerant , Cast el has
developed t hree specific access fit t ings wit h
5/ 16 SAE-Flare connect ion (codes 8350/ X09,
8351/ X05 and 8351/ X07) t hat have t o be
used wit h t he following par t s:
valve core, code 8395/ A1;
flare blind nut , code 7020/ X02;
Also t his solut ion requires t o screw t he nut wit h
a t orque wrench at 8,5 11,5 Nm.
OPERATION
The valve consist s of a body t hat can have
dif ferent shapes and sizes, according t o t he
dif ferent requirement s of t he cust omers. Inside
t he valve, t he valve core seat is manufact ured
according t o t he ARI STANDARD 720:1997.
When t he int ernal valve core has been inser t ed
t hrough t he fit t ing, by t he mount ing t ool (code
8390/ A), t he fluid flows just act ing on t he valve
needle.
ACCESS FITTINGS & VALVE CORES
Access fit t ing wit h inser t ed valve core
155
Cat alogue
number
SAE Flare ODS IDS
m f
NPT
[in.]
[in.]
[mm]
[mm]
PS
[bar]
L Ch D H
8350/ 22 1/ 4"
1/ 4" 26 11
St rai ght access f i t t i ngs
8350/ X01 1/ 4" 6 3/ 8" 20 11
1/ 4" 6 90 11
8350/ X09 5/ 16" 1/ 4" 27 14 9,4 2,1
8351/ 2
8351/ X04
8351/ X05
8351/ X07
1/ 4"
5/ 16"
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
45
156
Cat alogue
number
SAE Flare IDS
m f
NPT
[in.]
[mm]
PS
[bar]
L Ch D H
Not e
1/ 4" 6
45
43 24
The valve core may be
inst alled on each of t he
t wo 1/ 4 SAE Flare
connect ions.
8380/ 122 1/ 4" 1/ 8" 45 24
TEE access f i t t i ngs
8380/ X01
1/ 4" 1/ 4" 45
50
49
24
Wit h valve-core opening
device on female
connect ion.
t wo 1/ 4 SAE Flare
connect ions
t wo 1/ 4 SAE Flare
connect ions
TEE access f i t t i ngs wi t h swi vel nut s
8380/ X06
8380/ X08
157
Cat alogue
number
SAE Flare IDS
m f
NPT
[in.]
[mm]
PS
[bar]
L Ch D H
Not e
1/ 4" 1/ 8"
45
48 50
t hree 1/ 4 SAE Flare
connect ions
1/ 4" 1/ 4" 48 50
Cross access f i t t i ngs
1/ 4" 6 48 44
8382/ 1222
1/ 4" 1/ 4" 45 50 46
Wit h valve-core opening
device on female
connect ion.
t hree 1/ 4 SAE Flare
connect ions
Cross access f i t t i ngs wi t h swi vel nut s
8382/ X04
8382/ X02
8382/ X03
158
Cat alogue
number
SAE Flare IDS
m f
NPT
[in.]
[mm]
PS
[bar]
L max min Ch D H
Connect ions Dimensions [mm] TS [C]
Not e
75 8390/ A
1/ 4 35
13
13
Caps wi t h gasket
8392/ A
22
The key needs t o remove
t he valve core.
8392/ B
Core remover (f or al l t ypes)
1/ 4" 45 2,8 5,2 8580/ 2
Copper gasket wi t h neck
1/ 4" 45
175

30
Four ways
162 30
Three ways
9900/ X87
Mani f ol ds wi t h access f i t t i ngs
9900/ X47

(1) -40 +100
(2) -30 +90
(4) -40 +100

Out side spring.
Torque wrench
0,4 / 0,8 Nm.
(1) - St at ic pressure: 40
[bar]
(1) - working pressure: 28
[bar]
Out side spring.
Torque wrench
0,4 / 0,5 Nm.
[bar]
(4) -working pressure: 60
[bar]
8394/ A
Out side spring.
Torque wrench
0,30 / 0,35 Nm.
[bar]
(2) - working pressure: 28
[bar]
8394/ B
8395/ A1
Spare val ve cores
Accessories and
spare part s
160
KIT N ITEM CODE DESCRIPTION SUITABLE FOR PRODUCTS NOTE
ACCESSORIES AND SPARE PARTS FOR SOLENOID VALVES
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
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
Pist on
Pist on 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
Pist on
Pist on ring
Pist on spring
Cover/ body O Ring
New Pilot O Ring
Old Pilot O Ring
Cover/ body screws
All t he solenoid valves
N.C. and N.O. solenoid valves t ype:
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 t ype:
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 operat ed spare
par t s for:
1098/ 9; 1099/ 11; 1078/ 11;
1079/ 13 - / M42
Valves out of st ock
Main pist on pilot operat ed
spare par t s
161
ACCESSORIES AND SPARE PARTS FOR SOLENOID VALVES
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
200286
008757
009262
004251
004254
004238
004625
200286
008757
009278
009277
004251
004254
004238
004625
200286
008757
004118
004253
004256
004254
004238
004692
200286
200581
200292
004242
200581
200292
200520
004244
004298
200581
200292
004617
004625
200581
200292
200552
004246
004242
004309
Pist on
Pist on ring
Pist on spring
Cover/ body O Ring
New pilot O Ring
Old pilot O Ring
Cover/ body screws
Pre-assembled armat ure wit h nut s
Diaphragm
Nut / body O Ring
O Ring under coil
N.O. armat ure group
Diaphragm
Cover/ body O Ring
Nut / body O Ring
O Ring under coil
Cover/ body screws
Nut
Diaphragm
Cover/ body O Ring
Nut / cover O Ring
O Ring under coil
Cover/ body screws
Nut
Pist on
Pist on ring
Cover/ body O Ring
Nut / cover O Ring
O Ring under coil
Cover/ body screws
Nut
N.O. armat ure group.
Diaphragm
Cover/ body O Ring
Pilot O Ring
Nut / cover O Ring
O Ring under coil
Cover/ body screws
Nut
Punger
Plunger spring
Nut / body O Ring
Plunger
Plunger spring
Diaphragm
Cover/ body O Ring
Cover/ body screws
Plunger
Plunger spring
Diaphragm
Cover/ body screws
Plunger
Plunger spring
Diaphragm
No 2 pilot O Ring
Nut / cover O Ring
Cover/ body screws
1078/ 11; 1079/ 13 - / M42
1178/ 11
N.O. solenoid valves t ype:
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 dif ferent fluids t ype:
1512/ ..
1132/ 03 - / 04
1132/ 06 - / 08
1142/ 010 - / 012
Main pist on pilot operat ed
spare par t s
Diaphragm pilot operat ed spare
par t s for:
1198/ 9
1178/ 11
162
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
Pist on
Spring
Cover/ body O Ring
Cover/ body screws
Pist on
Spring
Cover/ body O Ring
Cover/ body screws
Pist on
Spring
Cover/ body O Ring
Cover/ body screws
Pist on
Spring
Cover/ body O Ring
Cover/ body screws
Pist on
Spring
Cover/ body gasket
Cover/ body screws
Pist on
Spring
Cover/ body gasket
Cover/ body screws
Pist on
Spring
Cover/ body gasket
Cover/ body screws
Pist on
Spring
Cover/ body gasket
Cover/ body screws
Check valves t ype:
3120/ 7 - / 9 - / M22 - / M28
3140/ 7 - / 9 - / M28
3180/ 7 - / 9 - / M28
Check valves t ype:
3120/ 11
3140/ 11
3180/ 11
Check valves t ype:
3120/ 13 - / M42
3140/ 13 - / M42
Check valves t ype:
3120/ 17
3140/ 17 - / 21 - / 25
3160/ 17; 3180/ 13 - / M42 - / 17
Check valves t ype:
3122/ 7 - / 9 - / M22 - / M28
3142/ 7 - / 9 - / M28
3182/ 7 - / 9 - / M28
Check valves t ype:
3122/ 11
3142/ 11
3182/ 11
Check valves t ype:
3122/ 13 - / M42
3142/ 13 - / M42
Check valves t ype:
3122/ 17
3142/ 17 - / 21 - / 25
3182/ 13 - / M42 - / 17
ACCESSORIES AND SPARE PARTS FOR INDICATORS
9150/ R20
9150/ R21
003575
007779
004259
004270
007780
004259
Nut
Prot ect ion cap
Nut / body O Ring
Pre-assembled nut
Prot ect ion cap
Nut / body O Ring
Liquid indicat ors t ype:
3610/ ..; 3620/ ..; 3640/ ..; 3650/ ..
Moist ure - liquid indicat ors t ype:
3710/ ..; 3720/ ..; 3740/ ..; 3750/ ..;
3770/ ..; 3771/ ..; 3780/ ..; 3781/ ..
163
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 fit t ing
Cap wit h gasket
valve core
Spring
Flange gasket
Dehydrat ing block cover
Dehydrat ing block bot t om
Filt ering t ube
Mechanical block cover
Mechanical block bot t om
Flange gasket
Dehydrat ing block cover
Dehydrat ing block bot t om
Screw for filt ering t ube
Filt ering t ube
Filt ering t ube
Filt ering t ube
Mechanical block cover
Mechanical block bot t om
Filt ers wit h replaceable block t ype:
4411/ ..; 4412/ ..; 4413/ ..; 4414/ ..
4421/ ..; 4423/ ..; 4424/ ..
All t he filt ers 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
Filt ers wit h replac. block t ype: 4421/ ..A
t ipo: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 connect ions 5/ 8" ODS
Pair of connect ions 7/ 8" ODS
Connect ion gasket
Pair of connect ions 1.1/ 8" ODS
Connect ion gasket
Pair of connect ions M42 ODS
Connect ion gasket
Flange gasket
Oil separat ors t ype 5520/ C
Oil separat ors t ype 5520/ D
Oil separat ors t ype 5520/ E
Oil separat ors t ype 5520/ .
To be ordered
separat ely
To be ordered
separat ely
To be ordered
separat ely
164
CHANGEOVER VALVES
9150/ R24
9150/ R25
004297
004329
004330
004348
000529
000534
000535
001039
3039/ 44
004260
009036
008281
Gland
Gland seal gasket s
Gland seal gasket s
Washer
Gland
Gland seal gasket s
Gland seal gasket s
Washer
Pair of connet ions 1/ 2" NPT female
Connect ion/ body O Ring
Cap
Cap
Changeover devices 3032/ 44
- / 64 - / 66
Changeover valve 3032/ 108
Changeover valve 3032/ 44
Changeover valve 3032/ 64 - / 66
HERMETIC VALVES
9150/ R23
G9150/ R33
003664
000384
000957
000382
007486
000913
004307
004326
Gland
Gland seal gasket s
Gland seal gasket s
Washer
Cap
Spindle
Screw
Spring washer
All t he hermet ic valves t ype:
6010/ ..; 6012/ ..; 6020/ ..; 6060/ ..;
6070/ ..
Hermet ic valves t ype:
6010/ 2; 6012/ 22
Hermet ic valves t ype: 6020/ ..
RECEIVER 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 gasket s
Gland seal gasket s
Washer
Cap
Spindle
Spindle
Gland
Gland seal gasket s
Gland seal gasket s
Washer
Cap
Spindle
Gland
Gland seal gasket s
Gland seal gasket s
Washer
Cap
Spindle
Receiver valves t ype:
6110/ 21 - / 22 - / 23 - / 32 - / 33
6120/ 22 - / 23 - / 33
6132/ ..
6140/ 22 - / 23
6110/ 21 - / 22; 6120/ 22; 6140/ 22 -
6110/ 23 - / 32 - / 33; 6120/ 23 - / 33
6110/ 43 - / 44 - / 54
6120/ 43 - / 44 - / 54
6110/ 66
6120/ 66
BALL SHUT-OFF VALVES
009035
009256
Cap
Cap
Ball shut -of f valves 3033/ ..
Ball shut -of f valves 3063/ 44
165
STOP VALVES
9150/ R26 000822
000823
000824
007476
Gland
Gland seal gasket
Gland seal gasket
Washer
St op valves t ype:
6170/ 66 - / 77
ROTALOCK VALVES
9150/ R23 003664
000384
000957
000382
7910/ 6
7990/ 6
7910/ 8
7990/ 8
Gland
Gland seal gasket
Gland seal gasket
Washer
St eel solder connect ion
3/ 4" UNF-16
PTFE gasket for 7910/ 6
St eel solder connect ion
1" UNS-16
PTFE gasket for 7910/ 8
Rot alock valves t ype:
6310/ ..
6320/ ..
To be ordered separat ely
CAPPED VALVES
9150/ R23 003664
000384
000957
000382
007486
002337
005174
007619
007676
Gland
Gland seal gasket
Gland seal gasket
Washer
Cap
Spindle
Nipple/ body O Ring
Spindle
Nipple/ body O Ring
Capped valves t ype:
6410/ ..; 6420/ ..; 6460/ ..
6410/ 2 - / 3 - / 4 - / 5
6420/ 2 - / 3 - / M10 - / M12 - / 4 - / 5
6460/ 22A.
6410/ 6
6420/ M18 - / 6 - / M22 - / 7
166
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
004691
009174
000822
000823
000824
007476
001228
000830
004302
007639
008002
009175
007640
004261
009176
Gland
Gland seal gasket s
Gland seal gasket s
Washer
Cap
Cap gasket
Spindle/ plat e group
Cover/ body screws
Cover/ body O Ring
Cover/ body gasket
Cover/ body screws
Cover/ body O Ring
Cover/ body gasket
Gland
Gland seal gasket s
Gland seal gasket s
Washer
Cap
Cap gasket
Cover/ body screws
Cover/ body O Ring
Cover/ body gasket
Cover/ body O Ring
Cover/ body gasket
Globe valves t ype:
(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 t ype:
(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 t ype:
(1) 6510/ M22 - / 7 - / M28 - / 9
(1) 6520/ 7 - / 9
(1) 6530/ M22 - / 7 - / M28 - / 9
Globe valves t ype:
6512/ M22 - / 7 - / M28 - / 9
6532/ M22 - / 7 - / M28 - / 9
Globe valves t ype:
(1) 6510/ 11; 6512/ 11
(1) 6520/ 11; (1) 6530/ 11;
6532/ 11
Globe valves t ype:
(1) 6510/ 11; (1) 6520/ 11;
(1) 6530/ 11
Globe valves t ype:
6512/ 11; 6532/ 11
Globe valves t ype:
(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 t ype:
(1) 6510/ 13 - / M42
6512/ 13 - / M42
(1) 6520/ 13 - / M42
Globe valves t ype:
(1) 6510/ 13 - / M42
(1) 6520/ 13 - / M42
Globe valves t ype:
6512/ 13 - / M42
Globe valves t ype:
(1) 6510/ 17; 6512/ 17
(1) 6520/ 17; (1) 6530/ 13 - / M42 - / 17
6532/ 13 - / M42 - / 17
Globe valves t ype:
(1) 6510/ 17; (1) 6520/ 17
(1) 6530/ 13 - / M42 - / 17
Globe valves t ype:
6512/ 17
6532/ 13 - / M42 - / 17
(1) Valves out of st ock
167
BALL VALVES
9150/ R46
009055
009750
003752
009036
009751
004296
009037
009752
000530
009038
009753
009754
009207
009208
8394/ A
8392/ A
Plast ic cap
Brass cap
Brass cap gasket
Plast ic cap
Brass cap
Brass cap gasket
Plast ic cap
Brass cap
Brass cap gasket
Plast ic cap
Brass cap
Brass cap gasket
Brass cap
Brass cap gasket
Valve core
Cap wit h gasket
Ball valves t ype:
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 t ype:
6590/ 7 - / 7A
6591/ M28 - / 9
6590/ M28 - / M28A - / 9 - / 9A
6591/ 11
Ball valves t ype:
6590/ 11 - / 11A
6591/ 13 - / M42
6590/ 13 - / 13A - / M42 - / M42A
6591/ 17
Ball valves t ype:
6590/ 17 - / 17A
6591/ 21 - / 21A
6591/ M64 - / M64A
Ball valves t ype:
6590/ M64A - / 21A
6591/ 24A - / 25A
6590/ 25A
6591/ 28A - / 29A - / 33A - / 34A
Ball valves wit h access fit t ing
COMPRESSOR VALVES
9150/ R23 003664
000384
000957
000382
Gland
Gland seal gasket
Gland seal gasket
Washer
Compressor valves t ype:
6640
GAUGE MOUNTING VALVES
9150/ R23 003664
000384
000957
000382
Gland
Gland seal gasket
Gland seal gasket
Washer
Gauge mount ing valves:
8320/ 21 - / 22
168
NOTE

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CASTEL Products Handbook 2008

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2

The obt ained value is admissible because lower

Cat alogue number

out let screen

Fl are - ODS adapt ers

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