Mech-Controller ...
   
 

 
 


 
Manual / Wiring Diagram
 

Oil Separator
     
Application

The advantages of the oil separator on the discharge line of a compressor in a refrigeration system are confirmed by many years of experience. The oil separator intercepts the oil mixed with compressed gas and returns it to the crankcase of the compressor thus assuring an efficient lubrication of its moving parts. Furthermore, the oil separator maintains a high coefficient of condenser and evaporator performance by almost completely removing oil deposits from their exchange surfaces. When a very high temperature at the end of the compression stage lead to the formation of oil vapours. Moreover, the oil separator, damping the valves pulsations, reduces system noise with an open or semi-hermetic compressor.

   

Finally, the use of an oil separator leads to:

 

a longer life of the compressor;

 

a better performance of the whole system with consequent energy saving;

 

A quieter operation by reducing pulsations.

 
Installation

 

The oil separators should be installed in the discharge line between the compressor and the condenser mounted securely in a vertical position and reasonably close to the compressor.
To prevent the return of refrigerant from condenser, during the off cycle of the system, it's advisable to install a check valve between the condenser and oil separator outlet connection.
Oil separator performs best when operating at or near the compressor discharge temperature. In location the oil separator, choose a position to avoid, as far as possible, chilling of the shell, which may result in condensing of liquid within the separator. If this is not possible, it is advisable to supply the separator with the better solutions (insulation, strap heater, others) to prevent the refrigerant in the system from condensing in the shell. Before the oil separator is i
nstalled, an initial charge of oil should be added to it. Refer to general characteristics of oil separators or to instruction sheet for the proper amount of oil. Oil pre-charge is very important, failure to pre-charge separator sump may result in damage to the oil return float mechanism. Use the same type of oil that is in the compressor crankcase.
Acting as the layout of refrigerating system, the return line may be run from the oil fitting to:

 

The compressor crankcase;

 

 

The suction line upstream the compressor or upstream the receiver, if present;

 

The oil reservoir if oil control system is being used.

 
   

A sight glass may be installed in the oil line, in a position that oil is flowing through the tube, to check the correct working of the oil separator.

     
Construction

 

Castle oil separators are manufactured from deep drawn special steel of adequate thickness.
End connections are manufactured from special steel bars.
The internal float ball is constructed of Stainless Steel.

 
 
Type Connection Rated Plant Capacity (KW)
  in Version R 22 R 134a R 404A R 12 R 502
Coub 1 3/8,1/ 2, 5/8 Flare/Solder 3.1 2.5 3.5 2.3 3.5
Coub 1 7/8,1.1/8 Solder 11.6 9.6 12.8 8.8 12.8
   
   
  Dehydration of Refrigerants
 

Among contaminating agents causing serious damages to refrigerating systems, moisture plays a major role. Its presence, even possible in the refrigerating system, is due to many factors: inadequate or insufficiently prolonged vacuum before refrigerant charging;oil used for topping up remained exposed to air humidity;refrigerant used for subsequent additions contained in non dried vessels; sealing defects especially in systems not designed for operation at low temperatures.
High temperatures combined with humidity give rise to complex phenomena enhancing acid formation both in lubricating oil and refrigerant.
Oil organic acids react with metal and favor the formation of sludge, which are viscous clots consisting of insoluble metal salts and large molecules of polymerized oil.
Sludge affects the lubrication of the moving elements of the compressor, can clog valves and filters and cause serious damages.
Acids, especially hydrofluoric acid, produced by the hydrolysis of the fluorinated refrigerant (in compressors iron and alumium act as catalysts) are particularly corrosive.
Acids etch metal surfaces with the consequent formation of crystal salts, which stick to surfaces and affect the total heat exchange coefficient in the condenser and in the evaporator.
In the sealed and semi-sealed groups, these saltsdamage the windings of electric motors as in these groups cold gas cools windings through direct contact. On the other hand, water solubility in refrigerants in a liquid phase, is quite reduced, especially at low temperatures. As a consequence, when in the system water exceeds the very low limits of solubility admitted at low temperature, excess water turns into ice, and blocks expansion valves and capillaries either partially or totally.
Consequently, refrigerating plants must be equipped with a filter drier on the liquid line.
In solid core dehydrators, dehydrating and deacidifying products with binders constitute the block.
Water adsorption combines with the neutralization of acids that may be present in the refrigerant, and with a strong filtering action. As there is no risk of abrasion, the position of the solid core dehydractor is not a problem.
It is always advisable to install a moisture indicator downstream the filter, which will show the refrigerant moisture and, consequently, the degree of efficiency of the filter.
The dehydrating capacity of a drier is relative to the charge of refrigerant and not to the refrigeration potential of the plant.
As a matter of fact, for the same refrigerant potential and for the same type of refrigerant fluid, there can be different refrigerant charges according to the type, design and working conditions of the plant as well as to the shutter degree.

 
   
   
  Replaceable Solid Core Filter Driers
 


 
Manual / Wiring Diagram
 

Application

The filters are designed for installation on commercial refrigerating systems or civil and industrial refrigerating systems.

 
Installation

The driers can be mounted in horizontal or vertical positions, but flow of refrigerant must be as per the inlet and outlet direction as mentioned on the drier.

 
Construction

The filters are manufactured of steel including the connections.

 
Operation

In the case of filters with more than one block, the passage of liquid takes place in parallel, as a result the pressure drop does not increase proportionately to the number of blocks. A large ring between the inner surface of the filter permits the accumulation of solid particles and prevents clogging. Before leaving the filter, the refrigerant must pass through the mesh sieve on which the blocks are mounted. The danger that small particles of dehydrating material being introduced into the system is thus avoided.

 
MODEL ODF
(in)

Liquid Refrigeration Capacity

H
(in)
D
(in)
C
(in)
H1
(in)
E
(in)
Weight
(KG)
Cores
Qty

R134a

R12

R22

R404a

R502

CS-485T

5/8

28.2

28.2

35.2

28.2

28.2

9.31

 

6.05

4.5

6.09

3.13

5.5

1

CS-487T

7/8

35.2

35.2

45.8

35.2

35.2

9.5

6.25

3.25

CS-489T

1-1/8

35.2

35.2

52.8

35.2

35.2

9.38

6.31

3.25

CS-4811T

1-3/8

45.8

45.8

70.4

45.8

45.8

9.75

6.44

3.38

CS-967T

7/8

70.4

70.4

88

52.8

52.8

15.13

 

6.05

 

4.5

11.87

3.28

8

2

CS-969T

1-1/8

88

88

105.6

70.4

70.4

15.19

11.97

3.28

CS-9611T

1-3/8

105.6

105.6

123.2

88

88

15.31

12.06

3.38

CS-9613T

1-5/8

123.2

123.2

140.8

105.6

105.6

15.31

12.06

3.41

CS-1449T

1-1/8

105.6

105.6

140.8

105.6

105.6

20.5



6.05



4.5

17.25

3.25

 

10

3

CS-14411T

1-3/8

140.8

140.8

176

123.2

123.2

20.75

17.53

3.38

CS-14413T

1-5/8

158.4

158.4

193.6

140.8

140.8

20.75

17.53

3.41

CS-14417T

2-1/8

176

176

211.2

158.4

158.4

20.95

17.63

3.5

 
 
  RECEIVERS
 


 
Manual / Wiring Diagram
 

Features

Anticorrosive powder painting can withstand 500 hours salty
Spray test.

 

Durable filter shell can improve service life.

 

High quality rotolock valve

 

Maximum working pressure : 450 PSI

   
 
Model Capacity Connection (inch) Overall Dimension
Compressor
(hp)
Volume
(L)
Inlet Outlet L A
010 1/2 1 3/8" 1/4" 7.086 3.54
022 1 2.2 3/8" 3/8" 8.267 4.72
030 2 3 1/2" 3/8" 8.267 5.91
030B 2 3 1/2" 3/8" 9.84 5.196
037 2 3.7 1/2" 3/8" 13.77 4.72
040 3 4 1/2" 1/2" 10.629 5.91
060 5 6 1/2" 1/2" 11.84 6.14
060B 5 6 1/2" 1/2" 9.448 7.09
080 8 8 1/2" 1/2" 11.811 7.09
100 10 10 5/8" 5/8" 11.811 8.267
120 12 12 3/4" 5/8" 13.779 8.267
140 14 14 3/4" 5/8" 15.748 8.267
 
   
  SERIES SUCTION LINE ACCUMULATORS
 


 
Manual / Wiring Diagram
 

Series suction Line Accumulators is designed with bend pipe to prevent internal splashing and aid in the collection of refrigerant, and the bend pipe should be installed near the compressor as possible.

     
Features

Type U siphon designed keeps Max refrigerant flow capacity and the least oil acquisition

 

Entrance of type U siphon is in the back of inlet oriented pipe, to prevent liquid enter to compressor and destroy it

 

Throttle hole is matching with system capability to ensure the best about the liquid refrigerant that flow into compressor

 

To prevent rusting of outside by surface painting with endure rusty of static Maximum working pressure : 420 PSI

   

Part

Welding ODF

description

End cover

 

Oriented Pipe

 

U shape bending pipe

 

Copper tube

 

Throttle hole

 
Model Connections L
(in)
LI
(in)
A
(in)
Liquid Flow Capacity (KW)
R-12 R-22/R410A R-502
204 1/2 7.87 2.0 4.0 3.5 3.3 3.4
205 5/8 9.84 2.0 4.0 4.4 4.0 4.2
206 3/4 10.23 3.11 5.5 6.1 6.8 6.2
207 7/8 12.59 3.11 5.5 9.8 9.0 9.3
208 1-1/8 14.96 3.22 6.25 14.2 13.3 13.7
209 1-3/8 19.29 3.22 6.25 21.8 20.5 21.2
210 1-5/8 21.65 3.22 6.25 23.8 22.5 23.1
2117 2-1/8 14.17 4.17 8.62 15.2 14.5 15.0
   
   
  Water Flow Switch
 


 
Manual / Wiring Diagram
 

Application

The paddle type WFS series flow controllers are specifically designed for use on liquid lines such as water, ethylene glycol or any other fluid which is not harmful to brass or phosper bronze and which is not classified as a hazardous fluid.
 
Installation

The flow controller can be mounted in a horizontal or vertical pipeline but must be located in a section of pipe where there is a straight run of atleast 5 pipe diameters on each side of the switch.
The "T" type flow switch eliminates at the installers end the problems of locating the switch in the middle of the pipe and its related leakages.
 
Construction

The controller is made from various plastics and metals which are listed below in the specifications chart.
Special Stainless Steel body flow switches are also available on request.
 
Features of T type flow

does not require center adjustment as with standard flow switch
switch

saves a lot of installation time
 

no welding of adopter required
 

forged / brazed as per model thereby eliminating leakages.
   

SPECIFICATIONS

   Pipe Connection   1/2", 3/4", 1"
   Materials of construction   Brass / SS304 (CF8)
    Phosphor Bronze
    Mild Steel
    Plastic
   Maximum Operating Pressure   10 bar (150PSI)
   Liquid Temperature   1 to 1000C
   Set point Adjustment   Screw under cover
   Ambient Temperature Limits   0 to 600C
   Flow Rates   Chart provided gives flow rates in m3h, Lpm and US Gpm.
   Bellow Life   5,00,000 cycles
   Switch Action   SPDT, Snap-acting.
   Electrical Ratings   Upto to 250VAC, 15(7.5) A, 50/60 Hz
   Wire Connections   Screw-down Terminals
   Paddles   Supplied in set of 5 sizes 1",2",3",5", and 6"
   Enclosure Protection Class   I.P 55
   Conduit Opening   22 mm diameter hole for 1/2 Conduit.
   Dimensions   In the instruction leaflet provided with the controller.
   Shipping Weight   0.7 kg.
   
   
  Air Flow Switch
 


 
Manual / Wiring Diagram
 

Application

These are suitable for monitoring the air or non-corrosive gasses internally of distribution air ducts for airconditioning or air treatments.
 
Construction

The switch is a dust-tight microswitch with both heat and cool switching contacts.
The housing is ABS with a galvanised steel sheet for the flow switch baseplate.
It has a IP65 rating from the duct external side.
 
Installation

The flow switch may be installed in any position duly orientated on stream. If the pipe is vertical, reset range to balance vane weight.
Install the provided gasket in the device fixing base to pipe.
   
MAX CUT -OUT VALUE
m/se
MAX CUT IN-VALUE
m/sec
MAX AIR TEMPERATURE
oC
8 9.2 85
 
MODEL MIN CUT -OUT VALUE
m/sec
MIN CUT IN-VALUE
m/sec
AFS-1 1 2.5
   
   
  Pressure Controls
 


 
Manual / Wiring Diagram
 

These controls can be used not only in florinated refrigerants, but also in the air and liquid (allowed liquid temperature: -45 C + 120 C). Micro-switch structure ensures reliable switch function. Single pressure controls can be supplied by single high and single low, they can be respectively equipped on high and low pressure side of compressor

JC35-6 Pressure differential Controls consists of two oppositely located bellows. One is H.P. Bellow and the other is an L.P. Bellow. The pressure differential actuating on two oppositely located bellows is balanced by a spring. If the pressure differential is less than the set point, owing to the lever action, the switch is on and keeps the electric heater in the time delay mechanism in operation. The contact of the time delay switch are then in off position after certain time delay interval (about 90 sec.) the power supply is cut off. A manual reset device is mounted in the time delay mechanism of the control. When the compressor has stopped due to oil pressure failure, the control cannot be reset automatically after it has actuated. Push the reset button after the error has been corrected. Then the time delay switch in the time delay mechanism will close the motor control circuit and start up the compressor.
   
           HP, LP.HP/LP suitable for all refrigerants other than Ammonia
 
Model Range Differential Factory Set
Min Max Min Max off (on) on (off)
306f Low Side -10 87 9 58 44 29
High Side 72 435 Fixed 44 to 72 290 217
Range Low Side -10 87 9 58 44 29
High Side 72 435 Man. 290 Man.
  6F -10 87 9 58 44 29
  30F 72 435 Fixed 44 to 72 290 217
  30FS 72 435 Man. 290 Man.
 
Oil differential switch suitable for all refrigerant other than Ammonia
 

   Function & Data JC35-6

 
   Pressure Differential Regulation Range    0.5 to 3.5 bar (7.14 to 50 psig)
   Switch Differential    0.5 bar (7.14 psig)
   Factory Set Pressure Differential    1 bar (14.2 psig)
   Time Relay Release    90 sec.
   Electrical Data    220V/16A  11V/24A
                                               Products of foreign origin
 
   
  Moisture Liquid Indicators
   


 
Manual / Wiring Diagram
 

Application

Moisture Liquid Indicators ensure failsafe inspection of the conditions of the refrigerant fluid in the system as regards to the regular flow and moisture.
Liquid indicators also ensure inspection of the regular flow of oil feed-back to the compressor sump.
     
Installation

Before start up the moisture indicator colour may show colour as per the wet colour. This may be due to exposure to air and humidity and moisture in the circuit.
When the moisture of the refrigerant fluid is brought back to acceptable levels with the dehydrator, the indicator colour will show the appropriate colour corresponding to dry.
     
Construction

Castle liquid indicators are manufactured with imported glass which has been directly fused onto the metal nut. This construction allows the total elimination of sealing gaskets between the glass disc and the metal structure with the consequent elimination of possible refrigerants.
The materials used for the main parts are :
 

BS-218 forged brass for the flare brass indicators
 

Refrigeration grade copper tube for copper end indicators
 

Neoprene rings for sealing
   
MODEL CONNECTIONS DIMENSIONS (MM) Weight
Flare ODS H H1 L gm
   MLI-6 1/4"   31 20.5 70 133
   MLIS-6   1/4" 31 20.5 70 136
   MLI-10 3/8"   30.5 20.5 70 142
   MLIS-10   3/8" 31 20.5 70 138
   MLI-12 1/2"   33 20.5 70 180
   MLIS-12   1/2" 30.5 20.5 70 125
   MLI-15 5/8"   35 23 81 231
   MLIS-15   5/8" 40 26.5 78.5 200
   MLIS-22   7/8" 77 38.5 144 250
   MLIS-28   1.1/8" 81 40.5 144 320
   MLIS-34   1.3/8" 87 43.5 142 380
   MLIS-40   1.5/8" 95 47.5 147 450
   MLIS-54   2.1/8" 20 60 152 610
   MLIS-65   2.5/8" 135 67.5 152 680
   
   
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