TECHNICAL HANDBOOK

CASTEL
THE COMPANY AND THE PRODUCTS

Castel, a leading supplier of refrigeration and air conditioning components, is a 100% Italian-owned family-run company which has grown
and established a name for itself since 1961, thanks to its outstanding pursuit of innovation and unwavering desire to conquer markets not
only in Italy, but also abroad.

Mission
Supporting an increase in our customer base with reliable, durable, high quality and technologically advanced products, manufactured with
respect for the environment, and supported and improved upon by levels of service that exceed industry standards, in order to consolidate
the Castel brand’s presence in its existing markets, and make the brand known in emerging ones.

Castel is now present in more than 90 countries on 5 continents. In 2010, Castel opened an associated company in China, “Castel
Refrigeration (Shanghai) Co., Ltd”, to support development in these countries, creating a logistics and commercial development platform
for the entire Asian continent and the Pacific. Recently, an associated company in the United States, “Castel USA, Inc.”, was established to
support commercial and logistic development in the Americas.

Castel was one of the first Italian companies in the sector to obtain Business Quality System Certification issued by TÜV SÜD according
to EN ISO 9001:2015 standard before subsequently receiving certification also for its Environmental Management System from TÜV SÜD
according to EN ISO 14001:2015 standard. The company has also obtained several product certifications in conformity with European
Directives and Certification Marks (e.g. VDE) and extra-European (e.g “UL”, “EAC”) Quality Approvals.

Castel has dedicated constant attention for years to the evolution of the refrigerant market in adapting to international protocols aimed at
reducing harmful emissions and global warming. The implementation in the European Union of the so-called F-Gas Regulation and similar
legislation in important extra-European nations is leading to a progressive reduction and abandonment of many traditional refrigerants in
favor of alternative synthetic or natural refrigerants.

In response to these developments in the market, in recent years Castel has progressively restructured its offer and is now
proud to offer to its customers this 2023 Handbook about the line of products:

GOGREEN
Products developed specifically for refrigerant R744 within the A1 security group according to ASHRAE STANDARD,34-2019
 TABLE OF CONTENTS

1 - EXPANSION VALVES
1.1 Solenoid expansion valves Page 1.3

2 - SOLENOID VALVES
2.1 Normally closed solenoid valves Page 2.3

2.2 High pressure normally closed solenoid valves Page 2.9

2.3 Magnetic tool Page 2.17

3 - COILS
3.1 Coils and connectors Page 3.3

3.2 Coils and connectors, UL Approved Page 3.9

3.3 “Smart Connector” system Page 3.15

4 - SAFETY DEVICES
4.1 Safety valves in series 3030 Page 4.3

4.2 Safety valves in series 3060 Page 4.7

4.3 Safety valves in series 3061 Page 4.11

4.4 Safety valves in series 3065 Page 4.15

4.5 High pressure safety valves in series 3030E Page 4.19

4.6 High pressure safety valves in series 3061E Page 4.23

4.7 Selection criteria for safety valves Page 4.27

4.8 Bursting disc devices Page 4.37

4.9 Changeover valves Page 4.43

4.10 Shut-off valves Page 4.47

4.11 Fittings Page 4.49

5 - CHECK VALVES
5.1 Hermetic check valves Page 5.3
6 - PRESSURE REGULATORS
6.1 Evaporating pressure regulators Page 6.3

7 - REFRIGERATING SYSTEM PROTECTORS

7.1 Moisture / liquid indicators Page 7.3

7.2 Hermetic filter driers Page 7.9

7.3 Hermetic filter driers with moisture indicator Page 7.15

7.4 Replaceable solid core filter driers Page 7.21

7.5 High pressure replaceable solid core filter driers Page 7.27

7.6 Hermetic strainers Page 7.31

7.7 Inspectable strainers Page 7.35

8 - OIL CONTROL SYSTEMS

8.1 Electronic oil level regulators Page 8.3

8.2 Oil reservoir pressure valves Page 8.11

8.3 Oil indicators Page 8.13

8.4 Strainers Page 8.13

8.5 Normally closed solenoid valves Page 8.13

9 - VALVES
9.1 Valves with screw shutter Page 9.3

9.2 2-ways valves with ball shutter Page 9.9

9.3 3-ways manual valves with ball shutter Page 9.19

9.4 3-ways motorized valves with ball shutter Page 9.27

9.5 Actuators Page 9.37

9.6 Auxiliary contacts Page 9.41

9.7 Actuators adapters Page 9.43

10 - PIPING ACCESSORIES
10.1 Vibration absorbers Page 10.3

10.2 Threaded brass fittings Page 10.7

10.3 Access fittings and valve cores Page 10.17

REFERENCE STANDARDS

EXTERNAL LEAKAGE
All the products are submitted, one by one, to tightness tests as well as specific functional tests. The allowable external leakage, measurable
during the test, complies with the requirements of standards:
- EN 12178:2003 – Refrigerating systems and heat pumps
Liquid-level indicators - Requirements, testing and marking
- EN 21922: 2021 – Refrigerating systems and heat pumps.
Valves - Requirements, testing and marking
- EN 14276-1:2020 – Pressure equipment for refrigerating systems and heat pumps.
Part 1: Vessels - General requirements
- EN ISO 14903:2017 – Refrigerating systems and heat pumps
Qualification of tightness of components and joints

PRESSURE CONTAINMENT
All the products, if submitted to hydrostatic testing, guarantee a pressure strength at least equal to 1.43 x PS in compliance with Directive
2014/68/EU.
All the products, if submitted to burst testing, guarantee a pressure strength at least equal to 3 x PS in compliance with standard EN 378-
2:2016.
All the UL-certified products, if submitted to burst testing, guarantee a pressure strength at least equal to 3 x MWP in compliance with
standard UL 207.

WEIGHT
The weight of the items listed in this Handbook includes packaging and is not binding.
EXPANSION
VALVES
 CHAPTER 1

EXPANSION VALVES
1.1 – SOLENOID EXPANSION VALVES

APPLICATIONS range from orifice 00 to orifice 09 can be assembled. The last two
numbers in the part number identify the type of orifice that has
The solenoid expansion valves in series 2028E can be used in a been mounted on the valve at the factory. For example, part number
wide range of applications as listed below: 2028E/3S02 identifies a 3/8” valve with solder connections and
- Refrigeration systems (display cases in supermarkets, freezers, size 02 orifice. The orifices are interchangeable and can be mounted
ice cream and icemaker machines, refrigerated shipping, etc.). even after the valve is soldered on the system. If you wish to change
- Air conditioning systems orifice, purchase the corresponding spare parts kit, according to
- Heat pump systems the part number indicated in Table 3. Inside the valve body is a
These valves are considered “Pressure Accessories” according to ring mesh filter that traps dirt and contaminants at the valve inlet.
the definition provided in Article 2, Point 5 of the Directive 2014/68/
EU (PED Recast) and are subject to the classification indicated in Valves in series 2028E are sold exclusively without coil (suffix S).
Article 4, Points 1.c) and 3 of the same Directive. For these valves are available:
They can be installed on systems that use the R744 refrigerant • Coils in series 9120 (coils type HM3)
fluid belonging to Group 2, as defined in Article 13, Chapter 1, • Coils in series 9121 (coils type CM3)
Point (b) of Directive 2014/68/EU, with reference to EC Regulation • Coils in series 9160 (coils type HM4)
No. 1272/2008. • Coils, UL Recognized, in series 9125 (coils type HM3)
CAUTION!: these solenoid valves cannot be used with other • Coils, UL Recognized, in series 9185 (coils type CM3-N2)
refrigerant fluids. • Coils, UL Recognized, in series 9186 (coils type CM3-N4)

The main parts of the valves in series 2028E are manufactured

OPERATION with the following materials:
- Hot forged brass EN 12420 – CW617N for the body
The valve in series 2028E is a throttling device that receives liquid - Ferritic stainless steel EN 10088-3 – 1.4105 for the fixed and
from the condenser and injects it into the evaporator, creating the mobile plungers
necessary pressure drop across the expansion orifice. It regulates - Austenitic stainless steel EN 10088-3 – 1.4305 for mobile plunger
the refrigerant flow into the evaporator by modulating the opening valve sleeve and orifice
time phase of the shutter, allowing for a wide power range. It is - Austenitic stainless steel EN 10088-3 – 1.4301 for the mesh filter
an ON/OFF valve that must be regulated with the Pulse Width - Copper pipe EN 12735-1 – Cu--DHP for solder connections
Modulation (PWM) principle and it can be actuated by a very - P.T.F.E. for seat gaskets
simple electronic controller. According to the PWM principle, the - Ethylene propylene rubber (EPDM) for outlet seal gaskets
evaporator refrigerant flow rate, QT, required in a fixed period “T”, is
delivered by the valve in a time interval “t”, shorter than “T”, during
which the maximum flow rate is allowed (ON step). In time period
that remains, T - t, the valve stays closed (OFF phase). SELECTION
For an effective regulation, the PWM valve must be sized in such
a way that, under the most severe operating load conditions, the To dimension correctly a valve 2028E for a refrigerating system,
orifice of the valve is large enough to deliver the refrigerant required. the following design parameters must be available:
In these extreme conditions, the valve will stay open for the entire • Type of refrigerant
period “T”. • Evaporator capacity, Qe
The use of an electronic regulator allows a more accurate metering • Evaporating temperature/pressure, Te / pe
of the refrigerant, obtaining a greater efficiency in time (and a • Minimum condensing temperature/pressure, Tc / pc
sensible decrease in machinery management costs) and a faster • Liquid refrigerant temperature at valve inlet, Tl
response to the variations of the evaporator load. • Pressure drop in the liquid line, distributor and evaporator, Δp
The following procedure helps the correct dimensioning of an
expansion valve for a refrigeration plant.
CONSTRUCTION Step 1
Determine the pressure drop across the valve. The pressure drop
The valves in series 2028E are supplied complete with orifice. is calculated using the equation:
Ten different orifices with ten different maximum capacities that

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 1.4
GOGREEN HANDBOOK - 2023
 = ( + ) DIMENSIONING EXAMPLE
where: • Type of refrigerant R744
• Pc = condensing pressure • Evaporator capacity, Qe 2.8 kW
• Pe = evaporating pressure • Evaporating temperature, Te -30°C
• Δp = sum of pressure drops in the liquid line, distributor, • Minimum condensing temperature, Tc -5°C
and evaporator at the maximum flow rate, that is with the valve • Liquid refrigerant temperature, Tl -15°C
always open • Pressure drop in the liquid line, distributor and evaporator, Δp 2bar

Step 2 Step 1 - Determine the pressure drop across the valve.

Evaporator capacity correction with subcooling. The evaporator
capacity Qe must be suitably sized based on the subcooling • Condensing pressure at - 5 °C - Pc = 30.4 bar
value. The subcooling is calculated using the equation: • Evaporating pressure at – 30 °C - Pe = 14.3 bar

In the subcooling correction factor table, find the appropriate Step 2 - Determine required valve capacity
correction factor, Fsub, corresponding to the calculated ΔTsub value
and determine the required valve capacity using the equation:

From the subcooling correction factor Table 4B, we find the

appropriate correction factor, Fsub, equal to 1.05 for ΔTsub = 10
Step 3 °K. The required valve capacity is
Capacity correction based on the application. To obtain a correct
regulation with this valve, it is necessary it be oversized so that
its closing period is 25% to 50% of the regulator’s total period,
T. The correct choice of this potential margin depends on the
application, which can have variable flow rate peaks, and on the Step 3 - Capacity correction based on the application
control algorithm used by the electronic control unit. According to the above sizing criterion, a correction of + 25% is
Generally, however, this correction factor, Fev, is highly dependent applied to the calculated capacity:
by the evaporation temperature, Te, so it be assumed equal to 125%
for Te >= -15 °C and 150% for Te <-15 °C. These generic values
must be verified based on the specific application.
The capacity of the valve must be at least equal to: Step 4 - Determine the orifice size.
Using the capacity Table 4A enter the data:
• Pressure drop across the valve = 14.1 bar
• Evaporating temperature = - 30 °C
• Calculated evaporator capacity = 3.33 kW
Step 4
Select the corresponding orifice, 02 (Note: the expansion valve
Determine required orifice size. Use the pressure drop across the
capacity must be equal to or slightly greater than the calculated
valve, the evaporating temperature and the correct evaporator
evaporator capacity).
capacity, Qe, calculated above, to select the corresponding orifice
size from the capacity table corresponding to the chosen refrigerant
fluid.
CERTIFICATIONS
Step 5
Liquid line sizing. Since the valve operates under ON/OFF criteria, The American certification authority Underwriters Laboratories
during the opening phase, the flow rate can be much higher than the Inc. has approved the expansion valves in series 2028E with file
average flow rate in the time period. For this reason, the designer MH50005. These valves are certified UL-CSA Recognized for the
must size the diameter of the pipes of the liquid line according to USA and Canada with a Design Pressure of 1305 PSI, in compliance
the maximum flow rate across the orifice in the real conditions with American standard UL 429 and Canadian standard C22.2
of Δptot and to avoid that a drop-in load cause a reduction in the No. 139-13.
maximum valve power.

1.5
HANDBOOK - 2023
TABLE 1: GENERAL CARACTERISTICS OF PWM EXPANSION VALVES

Opening Pressure
ODS Connections
Differential [bar]
TS [°C]
Risk
Minimum
Kv Category
Orifice Operating Working PS
Catalogue number [in] [mm] Factor MOPD according
Type principles Time [bar]
[m3/h] to PED
[s]
Recast
MinOPD 9120
9120 9160
IN OUT IN OUT 9121 min. max.
(DC) (DC)
(AC)

2028E/3S00 3/8” 1/2” - -

00 0,003
2028E/M10S00 - - 10 12

2028E/3S01 3/8” 1/2” - -

01 0,010
2028E/M10S01 - - 10 12

2028E/3S02 3/8” 1/2” - -

02 0,017
2028E/M10S02 - - 10 12

2028E/3S03 3/8” 1/2” - -

03 0,023 50 35
2028E/M10S03 - - 10 12
50
2028E/3S04 3/8” 1/2” - -
04 0,043
2028E/M10S04 - - 10 12 PWM
0 (Pulse Width 1 90 -50 +100 Art.4.3
2028E/3S05 3/8” 1/2” - - Modulating)
05 0,065
2028E/M10S05 - - 10 12

2028E/3S06 3/8” 1/2” - -

06 0,113
2028E/M10S06 - - 10 12

2028E/4S07 1/2” 5/8” - -

07 0,200 32 23
2028E/M12S07 - - 12 16

2028E/4S08 1/2” 5/8” - -

08 0,230 27 26 20
2028E/M12S08 - - 12 16

2028E/4S09 1/2” 5/8” - -

09 0,250 19 17 16
2028E/M12S09 - - 12 16

1.6
GOGREEN HANDBOOK - 2023
 TABLE 2: DIMENSIONS AND WEIGHTS OF PWM EXPANSION VALVES WITH 9120 COILS

Weight
Catalogue number
[g]
H1 H2 H3 L1 L2

2028E/3S00

2028E/M10S00

2028E/3S01

2028E/M10S01

2028E/3S02

2028E/M10S02

2028E/3S03
119 675
2028E/M10S03

2028E/3S04

2028E/M10S04
66 38 58 47
2028E/3S05

2028E/M10S05

2028E/3S06

2028E/M10S06

2028E/4S07

2028E/M12S07

2028E/4S08
150 700
2028E/M12S08

2028E/4S09

2028E/M12S09

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

TABLE 3: ORIFICES - RATED CAPACITIES IN KW

Orifice
Orifice
Catalogue number Size R744
Type
[mm]

9151E/R61 00 0,3 0,58

9150E/R63 01 0,5 2,09

9150E/R64 02 0,7 4,16

9150E/R65 03 0,8 4,93

9150E/R66 04 1,1 7,98

9150E/R67 05 1,3 13,65

9150E/R68 06 1,7 18,93

9150E/R69 07 2,3 29,85

9150E/R78 08 2,5 35,98

9150E/R79 09 2,7 39,90

Rated capacities are based on:

- Evaporating temperature Tevap = -25 °C
- Condensing temperature Tcond = 0 °C
- Refrigerant liquid temperature ahead of valve Tliq = -4 °C

1.7
HANDBOOK - 2023
 Table 4A - Evaporating Temperature 5 °C

Orifice Type Pressure drop across valve [bar]

2 4 6 8 10 12 14 16 18 20 24 26 28 32

00 0,16 0,23 0,27 0,30 0,32 0,34 0,36 0,37 0,38 0,38 0,38 0,37 0,36 0,33

01 0,59 0,81 0,97 1,08 1,17 1,24 1,29 1,33 1,35 1,37 1,37 1,35 1,31 1,18

02 1,18 1,62 1,92 2,15 2,32 2,46 2,56 2,64 2,69 2,72 2,72 2,68 2,62 2,34

03 1,40 1,92 2,28 2,55 2,75 2,92 3,04 3,13 3,19 3,23 3,22 3,18 3,10 2,77

04 2,27 3,11 3,69 4,12 4,46 4,72 4,92 5,06 5,17 5,22 5,21 5,14 5,02 4,49

05 3,88 5,32 6,31 7,05 7,63 8,07 8,41 8,66 8,84 8,93 8,92 8,80 8,58 7,68

06 5,38 7,38 8,75 9,78 10,58 11,19 11,67 12,01 12,25 12,39 12,37 12,20 11,90 10,65

07 8,49 11,63 13,80 15,42 16,68 17,65 18,39 18,94 19,32 19,54 19,51 19,24 18,77 16,80

08 10,23 14,02 16,63 18,59 20,10 21,27 22,17 22,83 23,29 23,55 23,51 23,19 22,62 20,25

09 11,35 15,55 18,45 20,62 22,29 23,59 24,59 25,32 25,83 26,12 26,07 25,72 25,09 22,46

Table 4A - Evaporating Temperature 0 °C

Orifice Type Pressure drop across valve [bar]

2 4 6 8 10 12 14 16 18 20 24 26 28 32

00 0,18 0,25 0,29 0,33 0,36 0,38 0,40 0,41 0,42 0,43 0,43 0,43 0,43 0,41

01 0,65 0,89 1,06 1,19 1,29 1,36 1,43 1,47 1,51 1,54 1,56 1,55 1,54 1,48

02 1,29 1,78 2,11 2,36 2,56 2,72 2,84 2,93 3,01 3,06 3,10 3,09 3,06 2,94

03 1,53 2,10 2,50 2,80 3,03 3,22 3,36 3,48 3,56 3,62 3,67 3,66 3,63 3,49

04 2,48 3,41 4,05 4,53 4,91 5,21 5,45 5,63 5,77 5,86 5,94 5,93 5,88 5,64

05 4,25 5,83 6,92 7,75 8,40 8,91 9,32 9,63 9,86 10,03 10,17 10,14 10,05 9,65

06 5,89 8,08 9,60 10,75 11,65 12,36 12,92 13,35 13,68 13,91 14,10 14,06 13,94 13,38

07 9,28 12,74 15,13 16,95 18,36 19,49 20,37 21,06 21,57 21,93 22,23 22,18 21,98 21,10

08 11,19 15,36 18,24 20,43 22,14 23,49 24,55 25,38 26,00 26,44 26,80 26,73 26,50 25,44

09 12,41 17,03 20,23 22,65 24,55 26,05 27,23 28,15 28,84 29,32 29,72 29,64 29,38 28,21

Table 4A - Evaporating Temperature -10 °C

Orifice Type Pressure drop across valve [bar]

2 4 6 8 10 12 14 16 18 20 24 26 28 32

00 0,21 0,29 0,34 0,38 0,41 0,44 0,46 0,48 0,49 0,50 0,52 0,52 0,52 0,51

01 0,75 1,03 1,22 1,37 1,49 1,58 1,66 1,72 1,77 1,81 1,86 1,87 1,87 1,86

02 1,49 2,05 2,43 2,73 2,96 3,15 3,30 3,43 3,52 3,60 3,70 3,72 3,73 3,69

03 1,77 2,43 2,89 3,24 3,51 3,73 3,91 4,06 4,18 4,27 4,38 4,41 4,42 4,38

04 2,86 3,93 4,67 5,24 5,68 6,04 6,34 6,57 6,76 6,91 7,09 7,13 7,15 7,08

05 4,89 6,72 7,99 8,96 9,72 10,34 10,84 11,24 11,56 11,81 12,13 12,20 12,23 12,12

06 6,79 9,32 11,08 12,42 13,48 14,34 15,03 15,59 16,04 16,38 16,82 16,92 16,95 16,81

07 10,70 14,69 17,47 19,59 21,26 22,61 23,70 24,59 25,29 25,84 26,52 26,69 26,74 26,50

08 12,90 17,71 21,06 23,61 25,63 27,26 28,57 29,63 30,48 31,14 31,97 32,17 32,23 31,94

09 14,31 19,64 23,35 26,18 28,42 30,22 31,68 32,86 33,80 34,53 35,46 35,67 35,74 35,42

Table 4A - Evaporating Temperature -20 °C

Orifice Type Pressure drop across valve [bar]

2 4 6 8 10 12 14 16 18 20 24 26 28 32

00 0,23 0,32 0,38 0,42 0,46 0,49 0,51 0,53 0,55 0,56 0,58 0,58 0,59 0,59

01 0,84 1,15 1,36 1,53 1,66 1,76 1,85 1,92 1,98 2,02 2,09 2,11 2,12 2,12

02 1,67 2,28 2,71 3,04 3,30 3,51 3,68 3,82 3,94 4,03 4,15 4,19 4,22 4,22

03 1,97 2,71 3,21 3,60 3,91 4,16 4,36 4,53 4,66 4,77 4,92 4,97 5,00 5,00

04 3,20 4,38 5,20 5,83 6,33 6,73 7,06 7,33 7,55 7,72 7,97 8,04 8,09 8,10

05 5,47 7,49 8,90 9,97 10,83 11,51 12,08 12,54 12,91 13,21 13,63 13,75 13,83 13,85

06 7,58 10,39 12,34 13,83 15,01 15,97 16,75 17,39 17,91 18,32 18,90 19,07 19,18 19,20

07 11,95 16,39 19,47 21,81 23,67 25,18 26,41 27,42 28,24 28,90 29,80 30,08 30,25 30,28

08 14,41 19,75 23,46 26,29 28,53 30,35 31,83 33,05 34,04 34,83 35,92 36,26 36,46 36,50

09 15,98 21,90 26,02 29,16 31,64 33,66 35,30 36,65 37,74 38,62 39,84 40,20 40,43 40,48

continue →

1.8
GOGREEN HANDBOOK - 2023
 Table 4A - Evaporating Temperature -30 °C

Orifice Type Pressure drop across valve [bar]

2 4 6 8 10 12 14 16 18 20 24 26 28 32

00 0,25 0,35 0,41 0,46 0,50 0,53 0,56 0,58 0,59 0,61 0,63 0,63 0,64 0,64

01 0,91 1,25 1,48 1,66 1,80 1,91 2,00 2,08 2,14 2,19 2,26 2,29 2,30 2,31

02 1,82 2,49 2,95 3,30 3,58 3,80 3,99 4,14 4,26 4,36 4,50 4,55 4,58 4,61

03 2,16 2,95 3,50 3,91 4,24 4,51 4,72 4,90 5,05 5,17 5,34 5,39 5,43 5,46

04 3,49 4,77 5,66 6,33 6,86 7,29 7,65 7,93 8,17 8,36 8,64 8,73 8,79 8,84

05 5,98 8,17 9,68 10,83 11,74 12,48 13,08 13,57 13,98 14,31 14,78 14,93 15,04 15,12

06 8,29 11,33 13,43 15,02 16,28 17,30 18,14 18,82 19,39 19,84 20,49 20,71 20,85 20,96

07 13,07 17,86 21,17 23,68 25,67 27,28 28,60 29,68 30,57 31,29 32,32 32,65 32,88 33,06

08 15,75 21,53 25,52 28,55 30,94 32,88 34,47 35,78 36,84 37,71 38,95 39,36 39,63 39,84

09 17,47 23,87 28,30 31,66 34,31 36,47 38,23 39,67 40,86 41,82 43,20 43,64 43,95 44,19

Table 4A - Evaporating Temperature -40 °C

Orifice Type Pressure drop across valve [bar]

2 4 6 8 10 12 14 16 18 20 24 26 28 32

00 0,27 0,37 0,44 0,49 0,53 0,56 0,59 0,61 0,63 0,64 0,66 0,67 0,68 0,68

01 0,98 1,34 1,58 1,77 1,91 2,03 2,12 2,20 2,26 2,32 2,39 2,42 2,44 2,45

02 1,96 2,67 3,15 3,52 3,80 4,03 4,22 4,38 4,51 4,61 4,76 4,81 4,85 4,88

03 2,32 3,16 3,73 4,17 4,51 4,78 5,01 5,19 5,34 5,47 5,64 5,70 5,75 5,79

04 3,76 5,12 6,04 6,74 7,30 7,74 8,10 8,40 8,65 8,85 9,14 9,23 9,30 9,37

05 6,43 8,75 10,34 11,54 12,48 13,24 13,86 14,37 14,79 15,14 15,63 15,79 15,91 16,02

06 8,92 12,14 14,34 16,00 17,31 18,36 19,22 19,93 20,51 20,99 21,67 21,90 22,07 22,22

07 14,06 19,14 22,61 25,23 27,29 28,95 30,31 31,43 32,35 33,10 34,18 34,54 34,80 35,03

08 16,95 23,07 27,25 30,41 32,89 34,90 36,54 37,89 38,99 39,89 41,20 41,63 41,94 42,23

09 18,80 25,58 30,22 33,72 36,48 38,70 40,52 42,01 43,24 44,24 45,68 46,17 46,51 46,83

Table 4A - Evaporating Temperature -50 °C

Orifice Type Pressure drop across valve [bar]

2 4 6 8 10 12 14 16 18 20 24 26 28 32

00 0,29 0,39 0,46 0,51 0,55 0,59 0,61 0,64 0,65 0,67 0,69 0,70 0,70 0,71

01 1,05 1,42 1,67 1,85 2,00 2,12 2,21 2,29 2,35 2,41 2,48 2,51 2,53 2,54

02 2,08 2,82 3,31 3,69 3,98 4,21 4,40 4,56 4,69 4,79 4,94 4,99 5,03 5,06

03 2,47 3,34 3,93 4,37 4,71 4,99 5,22 5,40 5,55 5,68 5,86 5,92 5,96 6,00

04 3,99 5,40 6,36 7,07 7,63 8,08 8,44 8,74 8,99 9,19 9,48 9,58 9,65 9,71

05 6,83 9,24 10,87 12,09 13,05 13,82 14,44 14,95 15,38 15,72 16,21 16,38 16,50 16,62

06 9,48 12,82 15,08 16,77 18,10 19,16 20,03 20,74 21,32 21,80 22,49 22,72 22,88 23,04

07 14,94 20,22 23,78 26,45 28,53 30,21 31,58 32,70 33,62 34,37 35,46 35,82 36,08 36,34

08 18,01 24,37 28,66 31,88 34,39 36,42 38,07 39,42 40,53 41,43 42,74 43,18 43,49 43,80

09 19,97 27,02 31,79 35,35 38,14 40,39 42,21 43,71 44,94 45,95 47,39 47,88 48,23 48,57

TABLE 4B - Correction factors for subcoolingΔtsub ≠ 4°K

Δtsub [°K] 1 4 10 15 20 25 30 35 40 45

Fsub 0,96 1,00 1,05 1,10 1,15 1,20 1,25 1,29 1,39 1,43

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

1.9
HANDBOOK - 2023
 1.10
GOGREEN HANDBOOK - 2023
SOLENOID
VALVES
 CHAPTER 2

SOLENOID VALVES
2.1 – NORMALLY CLOSED SOLENOID VALVES

APPLICATION constructed with the following materials:

- Hot forged brass EN 12420 – CW 617N for body and cover
The normally closed solenoid valves are considered “Pressure - Copper tube EN 12735-1 – Cu-DHP for solder connections
Accessories” according to the definition provided in Article 2, - Austenitic stainless steel EN 10088-2 – 1.4303 for enclosure
Point 5 of the Directive 2014/68/EU (PED Recast) and are subject where the plunger moves
to the classification indicated in Article 4, Points 1.c) and 3 of the - Ferritic stainless steel EN 10088-3 – 1.4105 for the plunger
same Directive. - Austenitic stainless steel EN ISO 3506 – A2-70 for tightening
These valves have been developed by Castel for all those applications screws between body and cover.
that use the sub critical R744 refrigerant fluid belonging to Group 2, - Ethylene propylene rubber (EPDM) for outlet seal gaskets
as defined in Article 13, Chapter 1, Point (b) of Directive 2014/68/ - P.T.F.E. for seat gaskets
EU, with reference to EC Regulation No. 1272/2008.
CAUTION!: these solenoid valves cannot be used with other
refrigerant fluids. INSTALLATION
All the valves in this chapter can be installed on the three main
OPERATION branches of a plant (hot gas line, liquid line, and suction line), while
respecting the limits of use and the capacities indicated in TABLE 1.
A normally closed valves (NC) means that: TABLE 1 shows the following functional characteristics of a solenoid
• when the coil is not energised, the plunger closes the fluid flow valve:
• when the coil is energised, the plunger opens the valve seat - Connection dimensions
connecting the inlet to the outlet. - PS: maximum allowable pressure of the refrigerant
- TS: maximum / minimum allowable temperature of the refrigerant
NC solenoid valves for R744 are sold without coil (with the S suffix). - Kv: discharge factor
For these solenoid valves are available: - minOPD : minimum opening pressure differential. This is the
• Coils in series 9121 (coils type CM3) minimum pressure differential between inlet and outlet at which a
• Coils in series 9320 (coils type HF3) pilot-operated solenoid valve can open and stay opened or close
• Coils in series 9360 (coils type HF4) and maintain the seal.
- MOPD: maximum Opening Pressure Differential according to AHRI
The valves in series 1028EL are direct acting valves. Their operation STANDARD 760 : 2014. This is the maximum pressure differential
depends only on the magnetic field produced by the current flow
between inlet and outlet at which a solenoid valve can open.
into the coil. Opening/closing of main valve seat, the only seat, is
directly controlled by the mobile plunger.
Before connecting the valve to the pipe, it is advisable to make
These valves can work with zero pressure differential.
sure that the refrigerating system is clean. In fact, valves with
All the other NC valves are pilot-operated solenoid valves (piston P.T.F.E. gaskets, and particularly piston valves, are sensitive to
operated). Their operation depends not only on the magnetic field dirt and debris. Furthermore, check that the flow direction in the
produced by the current flow into the coil, but also on a minimum pipe corresponds to the arrow stamped on the valve body. All the
inlet pressure, which is necessary to: valves can be mounted in any position so long as the coil does not
- open the piston and keep it lifted off the main opening point downwards.
- close the piston and ensure the tightness on the main opening The brazing of valves with solder connections should be carried out
Opening/closing of main valve seat is controlled by the piston while with care, using a low melting point filler material. It is not necessary
opening/closing of pilot seat is controlled by the mobile plunger of to disassemble the valves before brazing, but it is important to
the coil. avoid direct contact between the torch flame and the valve body,
These valves cannot work with zero pressure differential. which could be damaged and compromise the proper functioning
of the valve.
Before connecting a valve to the electrical system, be sure that
CONSTRUCTION the line voltage and frequency correspond to the values marked
on the coil.
The main parts of the solenoid valves described in this chapter are

2.3
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 2.4
GOGREEN HANDBOOK - 2023
 TRACEABILITY
A laser marking on the valve enclosure of the mobile plunger
identifies:
• Direct action valves in series 1028EL
• Pilot-operated piston valves in series 1038EL, 1048EL
This laser marking includes the following data: valve code,
refrigerants, PS, TS and batch number.
All the other pilot-operated valves are identified by a plastic label
fit on the valve enclosure of the mobile plunger (under the coil
when indicated). This label includes the following data: valve code,
refrigerants, PS, TS and batch number.

2.5
HANDBOOK - 2023
 2.6
GOGREEN HANDBOOK - 2023
 TABLE 1: GENERAL CHARACTERISTICS OF NC VALVES WITH ODS CONNECTIONS

Copper connections
Opening Pressure Differential [bar] TS [°C]
ODS
MOPD Risk
Seat size Coil series Category
Operating Catalogue Kv Factor
nominal Ø PS [bar] according
Principles Number [m3/h]
Ø [in.] Ø [mm] [mm] min OPD min. max. to PED
9121
9360 9320 Recast
9320
(AC) (DC)
(AC)

1028EL/2S 1/4” – 2,2 0,15

Direct 1028EL/2S.E 1/4” –

0 28 35 21 60 -40 +130 Art. 4.3
Acting 1028EL/3S 3/8” – 3 0,23

1028EL/M10S – 10

1038EL/3S 3/8” –

1038EL/M10S – 10
6,5 1,0 0,05
1038EL/M12S – 12

1038EL/4S 1/2” – 18

1048EL/M12S – 12
2,4
1048EL/4S 1/2” – 12,5
Piston Art. 4.3
Pilot 1048EL/5S 5/8” 16 3,0 28 35 60 -40 +130
Operated 0,07
1058EL/5S 5/8” 16 3,8

1058EL/6S 3/4” – 16,5 4,8 16

1058EL/7S 7/8” 22 5,7

1098EL/9S 1.1/8” – 25 10
0,1
1078EL/11S 1.3/8” 35 27 16 18

1078EL/13S 1.5/8” – 34 25 0,15 I

TABLE 2: DIMENSIONS AND WEIGHTS OF NC VALVES WITH 9320 COILS

Dimensions [mm]
Operating Weight
Catalogue Number
Principles [g]
H1 H2 H3 L1 L2 Q

1028EL/2S 125 677

Direct 1028EL/2S.E 125 677

75 62,5 34 67 –
Acting 1028EL/3S 125 691

1028EL/M10S 125 691

1038EL/3S 111 765

1038EL/M10S 111 765

92,5 80,0 50,5 –
1038EL/M12S 127 786

1038EL/4S 127 786

1048EL/M12S 127 1074

1048EL/4S 100,5 84,5 56,5 127 45 1074

Piston
Pilot 1048EL/5S 175 67 1138
Operated
1058EL/5S 175 1574

1058EL/6S 121 93 65 175 57 1616

1058EL/7S 180 1470

1098EL/9S 157 127 99 235 60 2550

1078EL/11S 175 141 113 278 68 3210

1078EL/13S 190 153 125 280 88 4310

Connectors are not included in the boxes and have to be ordered separately
With coil 9360 the dimension L2 is equal to 57 and the weight must be decreased of 250 g

2.7
HANDBOOK - 2023
TABLE 3: REFRIGERANT FLOW CAPACITY [KW]

Operating
Catalogue Number Liquid line Suction line Hot Gas line
Principles

1028EL/2S 4,0 3,0

1028EL/2S.E 6,2
Direct
Acting
1028EL/3S 4,6

1028EL/M10S

1038EL/3S 27

1038EL/M10S
5 20
1038EL/M12S

1038EL/4S

1048EL/M12S 64
13 48
1048EL/4S
Piston
Pilot 1048EL/5S 80 16 61
Operated
1058EL/5S 102 20 77

1058EL/6S 129 25 97

1058EL/7S 153 30 115

1098EL/9S 268 53 202

1078EL/11S 429 85 323

1078EL/13S 670 133 505

Standard rating conditions according to AHRI Standard 760-2014

Condensing temperature 30 °F (-1,2 °C)

Liquid temperature 20 °F (-6,7 °C)

Subcooling 10 °R (5,5 °K)

Evaporating temperature -20 °F (-28,9°C)

Temperature leaving evaporator -10 °F (-23,4°C)

Evaporator superheating 10 °R (5,5 °K)

Suction line temperature -5 °F (-15 °C)

Suction superheating 15 °R (8,4 °K)

Discharge temperature 80 °F (26,6°C)

2.8
GOGREEN HANDBOOK - 2023
 CHAPTER 2

SOLENOID VALVES
2.2 – HIGH PRESSURE NORMALLY CLOSED SOLENOID VALVES

APPLICATION CONSTRUCTION
The high-pressure normally closed solenoid valves are considered - Hot forged brass EN 12420 – CW 617N for body and cover
“Pressure Accessories” according to the definition provided in - Copper tube EN 12735-1 – CuFe2P (k65) for solder connections
Article 2, Point 5 of the Directive 2014/68/EU (PED Recast) and of 1437E valves
are subject to the classification indicated in Article 4, Points 1.c) - Stainless steel tube AISI 304 for solder connections of 1438E
and 3 of the same Directive. valves
These valves have been developed by Castel for all those applications - Austenitic stainless steel EN 10088-3 – 1.4305 for enclosure
that use the trans-critical R744 refrigerant fluid belonging to Group where the plunger moves
2, as defined in Article 13, Chapter 1, Point (b) of Directive 2014/68/ - Ferritic stainless steel EN 10088-3 – 1.4105 for the plunger
EU, with reference to EC Regulation No. 1272/2008. - Austenitic stainless steel EN 10088-3 – 1.4301 for the mesh filter
CAUTION!: these solenoid valves cannot be used with other - Ethylene propylene rubber (EPDM) for outlet seal gaskets
refrigerant fluids. - PTFE, bronze filled, for seat

OPERATION INSTALLATION
A normally closed valves (NC) means that: All the valves in this chapter can be installed on the three main
• when the coil is not energised, the plunger closes the fluid flow branches of a plant (hot gas line, liquid line, and suction line), while
• when the coil is energised, the plunger opens the valve seat respecting the limits of use and the capacities indicated in TABLE 4.
connecting the inlet to the outlet. The valves in series 1417, 1418, 1427 and 1428 can also be used
on the oil lines of R744 systems.
High pressure NC solenoid valves for R744 are sold without coil TABLE 4 shows the following functional characteristics of a solenoid
(with the S suffix). For these solenoid valves are available: valve:
• Coils in series 9121 (coils type CM3) - Connection dimensions
• Coils in series 9320 (coils type HF3) - PS: maximum allowable pressure of the refrigerant
- TS: maximum / minimum allowable temperature of the refrigerant
The valves in series 1417E and 1418E are direct acting valves. - Kv: discharge factor
Their operation depends only on the magnetic field produced - minOPD : minimum opening pressure differential. This is the
by the current flow into the coil. Opening/closing of main valve minimum pressure differential between inlet and outlet at which a
seat, the only seat, is directly controlled by the mobile plunger. pilot-operated solenoid valve can open and stay opened or close
Inside the valve body there is a ring mesh filter that traps dirt and and maintain the seal.
contaminants at the valve inlet. - MOPD: maximum Opening Pressure Differential according to AHRI
These valves can work with zero pressure differential. STANDARD 760: 2014. This is the maximum pressure differential
between inlet and outlet at which a solenoid valve can open.
All the other high pressure NC valves are pilot-operated solenoid
valves (piston operated). Their operation depends not only on the Before connecting the valve to the pipe, it is advisable to make sure
magnetic field produced by the current flow into the coil, but also that the refrigerating system is clean. In fact, valves with PTFE,
on a minimum inlet pressure, which is necessary to: bronze filled, gaskets are sensitive to dirt and debris. Furthermore,
- open the piston and keep it lifted off the main opening check that the flow direction in the pipe corresponds to the arrow
- close the piston and ensure the tightness on the main opening stamped on the valve body. All the valves can be mounted in any
Opening/closing of main valve seat is controlled by the piston while position so long as the coil does not point downwards.
opening/closing of pilot seat is controlled by the mobile plunger of The brazing of connections of 1417E, 1427E and 1437E valves
the coil. should be carried out with care, using a low melting point filler
These valves cannot work with zero differential pressure. material (min 5% Ag). It is not necessary to disassemble the valves
before brazing, but it is important to avoid direct contact between
the torch flame and the valve body, which could be damaged and
compromise the proper functioning of the valve.

2.9
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 2.10
GOGREEN HANDBOOK - 2023
 We recommend TIG welding for steel connectors of 1418E,
1428E and 1438E valves, to be performed as quickly as possible
according to the method shown in the product instruction sheet.
The connection material is AISI 304: it is only possible to use AISI
308 filler material if welding to pipes made from the same type of
material. For pipes made from other materials, please contact your
welding supplies supplier.
Before connecting a valve to the electrical system, be sure that
the line voltage and frequency correspond to the values marked
on the coil.

2.11
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 2.12
GOGREEN HANDBOOK - 2023
 TABLE 4: GENERAL CHARACTERISTICS OF HP-NC VALVES WITH ODS CONNECTIONS

Connections R744 Oil

Opening Pressure Differential [bar]
ODS TS [°C] TS [°C]
Risk
Seat size Category
Operating Kv Factor PS
Catalogue Number nominal Ø R744 MOPD Oil MOPD according
Principles [m3/h] [bar]
[mm] to PED
min Recast
Ø [in.] Ø [mm] 9121 9121 min. max. min. max.
OPD 9320 9320
9320 9320
(DC) (DC)
(AC) (AC)

with reinforced copper connections (K65)

1417E/2S05 1/4” –
Direct
1,3 0,065 0 80 80 20 20
Acting
1417E/3S05 3/8” –

1427E/2S020 1/4” –
2 0,150 -10 +70
1427E/3S020 3/8” –
20 20
1427E/2S030 1/4” –
3 0,320 130 -40 + 150 Art. 4.3
1427E/3S030 3/8” –
Piston
0,4 80 80
Pilot Operated
1437E/3S050 3/8” –
5 0,800
1437E/4S050 1/2” –
NA NA NA NA
1437E/3S070 3/8” –
7 1,100
1437E/4S070 1/2” –

with stainless steel connections

1418E/M6S05 – 6
Direct
1,3 0,065 0 80 80 20 20
Acting
1418E/M10S05 – 10

1428E/M6S020 – 6
2 0,150 -10 +70
1428E/M10S020 – 10
20 20
1428E/M6S030 – 6
3 0,320 140 -40 +150 Art. 4.3
1428E/M10S030 – 10
Piston
0,4 80 80
Pilot Operated
1438E/M10S050 – 10
5 0,800
1438E/M12S050 – 12
NA NA NA NA
1438E/M10S070 – 10
7 1,100
1438E/M12S070 – 12

2.13
HANDBOOK - 2023
TABLE 5: DIMENSIONS AND WEIGHTS

Dimensions [mm]
Operating Catalogue Weight
Principles Number [g]
H H1 H2 L L1 L2 L3 L4 I

1417E/2S05 117 51 56
Direct
NA NA 35 67 NA 270
Acting
1417E/3S05 121 55 60

1427E/2S020
127 55 NA 96 64
1427E/2S030
NA 38 67 NA 398
1427E/3S020
131 59 100 68
Piston 1427E/3S030
Pilot
Operated 1437E/3S050
143 66 122 69
1437E/3S070
21 22,5 59 67 18 710
1437E/4S050
141 64 120 67
1437E/4S070

1418E/M6S05 119 53 58
Direct
NA NA 35 67 NA 250
Acting
1418E/M10S05 121 55 60

1428E/M6S020
127 55 NA 96 64
1428E/M6S030
NA 38 67 NA 390
1428E/M10S020
131 59 100 68
Piston 1428E/M10S030
Pilot
Operated 1438E/M10S050
143 66 122 69
1438E/M10S070
21 22,5 59 67 18 700
1438E/M12S050
141 64 120 67
1438E/M12S070

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

2.14
GOGREEN HANDBOOK - 2023
 TABLE 6: REFRIGERANT FLOW CAPACITY [KW]

Operating
Catalogue Number gas cooler line Suction line Hot Gas line
Principles

1417E/2S05
Direct
1,7 0,30 1,2
Acting
1417E/3S05

1427E/2S020
3,9 0,69 2,8
1427E/3S020

1427E/2S030
8,4 1,48 6,0
1427E/3S030
Piston
Pilot Operated
1437E/3S050
21,0 3,70 15,0
1437E/4S050

1437E/3S070
28,9 5,09 20,6
1437E/4S070

1418E/M6S05
Direct
1,7 0,30 1,2
Acting
1418E/M10S05

1428E/M6S020
3,9 0,69 2,8
1428E/M10S020

1428E/M6S030
8,4 1,48 6,0
Piston 1428E/M10S030
Pilot
Operated 1438E/M10S050
21,0 3,70 15,0
1438E/M12S050

1438E/M10S070
28,9 5,09 20,6
1438E/M12S050

Standard rating conditions according to AHRI Standard 760-2014

Gas-cooler outlet temperature 95 °F (35 °C)

Evaporating temperature 14 °F (- 10 °C)

Evaporator outlet temperature 23 °F (- 5 °C)

Evaporator superheating 9 °R (5 °K)

Suction line temperature 32 °F (0 °C)

Suction line superheating 9 °R (5 °K)

Discharge temperature 212 °F (110 °C)

2.15
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 2.16
GOGREEN HANDBOOK - 2023
 CHAPTER 2

SOLENOID VALVES
2.3 – MAGNETIC TOOL

APPLICATION
Castel supplies to its customers the permanent magnet tool code
9900/X91 for the normally closed solenoid valves illustrated in
the previous chapters. This tool can be used when brazing the
copper connections to the plant pipes: once fit on the valve stem
of the mobile plunger, instead of the coil, it allows the protective
gas (nitrogen) flow and avoids any damage to the plunger gasket
and to the diaphragm.

CONSTRUCTION
The permanent magnet tool code 9900/X91 consists of three
anisotropic ferrite rings in an anodized aluminium body.

2.17
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 2.18
GOGREEN HANDBOOK - 2023
COILS
 CHAPTER 3

COILS
3.1 – COILS AND CONNECTORS

APPLICATION Rubber gaskets assembled on the upper and lower ends of the coils
(only on the lower end for coils in series 9320 and 9360) complete
For NC solenoid valves (Chapter 2), Castel provides its customers the protection of the windings from humidity.
with the following series of coils that use the “FAST LOCK” system: The terminals of the coils in series 9120, 9160, 9320 and 9360
- Series 9320 (coils type HF3) are interchangeable with coils in consist of two Faston connectors plus a Faston ground connector.
series 9120 (coils type HM3). The coils in series 9320 can be All coils in this chapter are designed for continuous use. The
used on all the valves produced by Castel that used the coils in solid construction of these coils makes them suitable for use in
series 9120. refrigeration systems operating in heavy-duty environments
- Series 9360 (coils type HF4) are interchangeable with coils in
series 9160 (coils type HM4). The coils in series 9360 can be
used on all the valves produced by Castel that used the coils in CERTIFICATIONS
series 9160.
The “FAST LOCK” system (protected by law) guarantees secure Coils in series 9160, 9360 with 110 VAC, 220/230 VAC and 240
fixing, without errors or carelessness, of the coil on the valve, VAC power supply, and coils in series 9120, 9121 and 9320 with
making assembly and disassembly easy and quick. Coils using 220/230 VAC power supply are manufactured according to the
the “FAST LOCK” system can be assembled on valves, and later Low Voltage (LV) Directive (2006/95/EC). All coils in this chapter
disassembled, without the need of additional equipment. comply with the Electromagnetic Compatibility (EMC) Directive
(2004/108/EC).
For solenoid expansion valve (Chapter 1) the following type of coils
are available:
- Series 9120 (coils type HM3) equipped with DIN connection
- Series 9160 (coils type HM4) equipped with DIN connection
CONNECTORS
- Series 9121 (coils type CM3) equipped with an encapsulated
DIN 43650 standardized connectors 9150 represent an effective
co-moulded cable 7 m long.
system for the connection of the coil to the power system, thus
PS: these coils can be used also with NC solenoid valves in Chapter 2
ensuring safety also in the presence of moisture. Based on the
assembly requirements, these connectors allow you to choose the
Coils in series 9120, 9320 can be coupled with all connectors in
orientation of the outer casing with respect to the inner terminal
series 9150 and 9900 manufactured by Castel. The protection
block. The gland nut of the outer casing is suitable for receiving
rating guaranteed by the coil + connector system is IP65 according
cables with an external diameter of 6 to 9 mm and is equipped
to the EN 60529 standard.
with a self-locking device. Three-pole cables with a cross-section
greater than or equal to 0.75 mm2 are recommended.
Coils in series 9160, 9360 must be used preferably with connector
The connectors in series 9900 are available with co-moulded
type 9155/R01. The protection rating of the coil + connector 9155/
cables of different lengths. In these versions, the orientation of
R01 system is IP65/IP68 according to the EN 60529 standard.
the casing cannot be changed with respect to the terminal block.
Alternatively, these coils can be coupled with connectors in series
As long as they are used with the gaskets provided, both types
9150 or 9900. In this case, the protection rating of these systems
ensure IP65 protection rating according to EN 60529.
is IP65.
Castel developed specific connectors, series 9155, suitable for
use in refrigeration systems operating in heavy-duty environments,
CONSTRUCTION for example:
- exposure to the atmospheric conditions
In compliance with IEC standard 85, the coils in series 9120, - rooms with high degree of moisture
9121, 9160, 9320 and 9360 have Class F encapsulation, and their - cyclic condensing / evaporation on the valve
production is compliant with standards EN 60730-1 and EN 60730- - cyclic icing / defrosting on the valve
2-8. The windings are made of copper wire, with insulation class Based on the assembly requirements, these connectors allow you
H (180 °C), in compliance with IEC standard 85. The outer casing to choose the side orientation of the outer casing with respect to
is made of waterproof, dielectric resins that guarantee reinforced the inner terminal block. It is not possible to point the exit of the
insulation and allow any type of assembly. cable upwards. The gland nut of the outer casing is suitable for
All coils have Class I protection ratings against electric contacts. receiving cables with an external diameter of 6 to 9 mm and is
Consequently, their safety requires an efficient ground system. equipped with a self-locking device. It is again recommended that

3.3
HANDBOOK - 2023
 3.4
GOGREEN HANDBOOK - 2023
 three-pole cables with a cross-section greater than or equal to 0.75
mm2 be used. As long as they are used with the gaskets provided,
the connectors in series 9155 ensure IP65/IP68 protection rating
according to the EN 60529 standard.

3.5
HANDBOOK - 2023
 9900/X66

27,5 27,2
T11-Connect

27,5

44,5
9900/X66
9900/X84
9900/X73
9900/X55
9900/X54

3.6
GOGREEN HANDBOOK - 2023
 TABLE 1: GENERAL CHARACTERISTICS OF COILS

Insulation TA [°C]
Coil Voltage Voltage
Catalogue Number Frequecy [Hz] class Connection Connectors Protection Degree
Type [V] tolerance [%]
EN 60730 min. max.

Terminal block for DIN 9150/R02 IP 65

9120/RA6 HM3 220/230 A.C. +6 / -10 50 / 60 F -20 +50
43650/A 9900/X66 (with connector)

9121/RA6 CM3 220/230 A.C. +6 / -10 50 / 60 F -20 +50 Three wires cable _ IP 66

9320/RA6 220/230 A.C. +6 / -10 50 / 60

Terminal block for DIN 9150/R02 IP 65

9320/RD1 HF3 12 D.C. F -20 +50
43650/A 9900/X66 (with connector)
+10 / -5 _
9320/RD2 24 D.C.

9160/RA2 24 A.C.
+10 / -10 IP 65
9160/RA4 110 A.C. 9150/R02 (with connectors
Terminal block for DIN 9155/R01 9150 , 9900)
HM4 50 / 60 F -20 +50
43650/A 9155/R02 IP 65 / IP 68
9160/RA6 220/230 A.C. +6 / -10 9900/X66 (with connector
9155)
9160/RA7 240 A.C. +10 / -10

9360/RA2 24 A.C.
+10 / -10 IP 65
9360/RA4 110 A.C. 9150/R02 (with connectors
Terminal block for DIN 9155/R01 9150 , 9900)
HF4 50 / 60 F -20 +50
43650/A 9155/R02 IP 65 / IP 68
9360/RA6 220/230 A.C. +6 / -10 9900/X66 (with connector
9155)
9360/RA7 240 A.C. +10 / -10

TABLE 2: CONSUMPTIONS AND WEIGHTS OF COILS

Consumption at 20 °C [mA]

Coil Voltage Power Weight

Catalogue Number Start Working
type [V] [W] [g]

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

9120/RA6 HM3 220/230 A.C. 12 190 160 – 110 80 – 470

9121/RA6 CM3 220/230 A.C. 12 190 160 – 110 80 – 860

9320/RA6 220/230 A.C. 12 190 160 – 110 80 –

9320/RD1 HF3 12 D.C. 20 1720 1720 500

_ _ _ _
9320/RD2 24 D.C. 20 895 895

9160/RA2 24 A.C. 1490 1320 700 530

9160/RA4 110 A.C. 330 300 156 118

HM4 8 _ _ 230
9160/RA6 220/230 A.C. 162 142 76 57

9160/RA7 240 A.C. 147 130 70 53

9360/RA2 24 A.C. 1490 1320 700 530

9360/RA4 110 A.C. 330 300 156 118

HF4 8 _ _ 230
9360/RA6 220/230 A.C. 162 142 76 57

9360/RA7 240 A.C. 147 130 70 53

3.7
HANDBOOK - 2023
TABLE 3: GENERAL CHARACTERISTICS OF CONNECTORS

Catalogue Number Cable length [m] Cable thickness [mm2] Standard Degree of protection Class of insulation

9150/R02 _ _
DIN 43650 IP65 EN 60529
9900/X66 1 3 x 0,75 Gruppo C VDE 0110-1 / 89

9155/R01 _ _ _ IP65/IP68 EN 60529

3.8
GOGREEN HANDBOOK - 2023
 CHAPTER 3

COILS
3.2 – COILS AND CONNECTORS, UL APPROVED

APPLICATION All coils in this chapter are designed for continuous use. The
solid construction of these coils makes them suitable for use in
For solenoid expansion valve (Chapter 1) approved by the American refrigeration systems operating in heavy-duty environments
certification authority Underwriters Laboratories Inc., Castel
provides its customers with the following types of coils:
- Series 9125 (coil type HM3), with connection type DIN 43650 CERTIFICATIONS
- Series 9185 (coil type CM3-N2), with connection type “Junction
Box NEMA 2”. The American certification authority Underwriters Laboratories
- Series 9186 (coil type CM3-N4), with connection type “Conduit Inc. has approved coils in series 9125, 9185, and 9186 with file
Hub NEMA 4”. E243604. These coils are certified UL-CSA Recognized for the
USA and Canada with file E243604, in compliance with American
Coils in series 9125 must be coupled with connector type 9150UL/ standard UL 429 and Canadian standard C22.2 No. 139-13.
R02. The protection rating of the coil + connector system is IP65 The coils in series 9125, 9185, and 9186 with voltages of 120 VAC,
according to the EN 60529 standard. 208 VAC, 220/230 VAC, 240 VAC comply with the Low Voltage
The coils in series 9185 are complete with a connection system and Directive (2006/95/EC). All coils in this chapter comply with the
a metal sheath. The protection rating guaranteed by the “Junction Electromagnetic Compatibility (EMC) Directive (2004/108/EC).
Box” connection system is similar to IP12-32 according to the EN
60529 standard.
The coils in series 9186 are complete with a connection system and
a metal sheath. The protection rating guaranteed by the “Conduit
CONNECTORS
Hub” connection system is similar to IP54 according to the EN
Connector 9150UL/R02 has been approved by the American
60529 standard.
certification authority Underwriters Laboratories Inc. This connector
is certified UL-CSA Recognized for the USA and Canada with file
E333724, in compliance with American standard UL 1977 and
CONSTRUCTION Canadian standard C22.2 No. 182.3.
The DIN 43650 standardized connector 9150UL/R02 represents an
In compliance with IEC standard 85, the coils in series 9125, effective system for the connection of the coil to the power system,
9185 and 9186 have Class F encapsulation and their production thus ensuring safety also in the presence of moisture. Based on the
is compliant with standards EN 60730-1 and EN 60730-2-8. The assembly requirements, this connector allows you to choose the
windings are made of copper wire, with insulation class H (155°C), orientation of the outer casing with respect to the inner terminal
in compliance with IEC standard 85. The outer casing is made of block. The gland nut of the outer casing is suitable for receiving
waterproof, dielectric resins that guarantee reinforced insulation cables with an external diameter of 6 to 9 mm and is equipped
and allow any type of assembly. with a self-locking device. Three-pole cables with a cross-section
All coils have Class I protection ratings against electric contacts. greater than or equal to 0.75 mm2 are recommended.
Consequently, their safety requires an efficient ground system. As long as it is used with the gaskets provided, connector 9150UL/
Rubber gaskets assembled on the upper and lower ends of the coils R02 ensures IP65 protection rating according to the EN 60529
complete the protection of the windings from humidity. standard.
The coils in series 9125 are equipped with three flat terminals,
two Faston connections in line plus a Faston ground connection.
The coils in series 9185 are equipped with two cables, at least
153 mm long, and ground screws incorporated in the body of the
metal casing. The body of the casing is screwed onto the metal
reinforcement of the coil and there are two semi-sheared slots
to screw on a metal sheath. A metal cover screwed on the body
closes the casing and encloses the joints between the power cable
and the coil wires.
Coils in series 9186 are equipped with two wires, at least 457
mm long. The flange of the inlet plug is screwed to the metal
reinforcement of the coil. The inlet plug is threaded in order to
screw on a metal sheath.

3.9
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 3.10
GOGREEN HANDBOOK - 2023
 9125

9185

3.11
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 9186

9150UL

3.12
GOGREEN HANDBOOK - 2023
 TABLE 4: GENERAL CHARACTERISTICS OF COILS, UL RECOGNIZED APPROVED

Voltage Insulation TA [°C]

Coil Voltage Frequecy Protection
Catalogue Number tolerance class Connection Connectors
Type [V] [Hz] Degree
[%] IEC 85 min. max.

9125/RD1 12 D.C.
+10 / -5 -
9125/RD2 24 D.C.

9125/RA2 24 A.C.
Terminal block for DIN IP 65
9125/RA4 HM3 120 A.C. +10 / -10 F -20 +50 9150UL/R02
43650/A (with connector)
9125/RA5 208 A.C. 60

9125/RA6 220/230 A.C. +6 / -10

9125/RA7 240 A.C. +10 / -10

9185/RD1 12 D.C.
+10 / -5 -
9185/RD2 24 D.C.

9185/RA2 24 A.C.

9185/RA4 CM3-N2 120 A.C. +10 / -10 F -20 +50 Junction box NEMA 2 - ~ IP 12-32

9185/RA5 208 A.C. 60

9185/RA6 220/230 A.C. +6 / -10

9185/RA7 240 A.C. +10 / -10

9186/RD1 12 D.C.
+10 / -5 -
9186/RD2 24 D.C.

9186/RA2 24 A.C.

9186/RA4 CM3-N4 120 A.C. +10 / -10 F -20 +50 Conduit hub NEMA 4 - ~ IP 54

9186/RA5 208 A.C. 60

9186/RA6 220/230 A.C. +6 / -10

9186/RA7 240 A.C. +10 / -10

3.13
HANDBOOK - 2023
TABLE 5: CONSUMPTIONS AND WEIGHTS OF COILS

Consumption at 20 °C [mA]

Voltage Power Weight

Catalogue Number Coil type Start Working
[V] [W] [g]

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

9125/RD1 12 D.C. - 1720 - 1720

24
9125/RD2 24 D.C. - 895 - 895

9125/RA2 24 A.C. 2060 1015

9125/RA4 HM3 120 A.C. 506 261 470

9125/RA5 208 A.C. 20 286 - 152 -

9125/RA6 220/230 A.C. 260 133

9125/RA7 240 A.C. 235 122

9185/RD1 12 D.C. - 1720 - 1720

24
9185/RD2 24 D.C. - 895 - 895

9185/RA2 24 A.C. 2060 1015

9185/RA4 CM3-N2 120 A.C. 506 261 590

9185/RA5 208 A.C. 20 286 - 152 -

9185/RA6 220/230 A.C. 260 133

9185/RA7 240 A.C. 235 122

9186/RD1 12 D.C. - 1720 - 1720

24
9186/RD2 24 D.C. - 895 - 895

9186/RA2 24 A.C. 2060 1015

9186/RA4 CM3-N4 120 A.C. 506 261 530

9186/RA5 208 A.C. 20 286 - 152 -

9186/RA6 220/230 A.C. 260 133

9186/RA7 240 A.C. 235 122

TABLE 6: GENERAL CHARACTERISTICS OF CONNECTORS, UL RECOGNIZED APPROVED

Catalogue Number Standard Degree of protection Class of insulation Approval

IP65
9150UL/R02 DIN 43650 Gruppo C VDE 0110-1 / 89 UL Recognized
EN 60529

3.14
GOGREEN HANDBOOK - 2023
 CHAPTER 3

COILS
3.3 – “SMART CONNECTOR” SYSTEM

APPLICATION systems are special coils available in both the direct current version
(with 12 VDC and 24 VDC voltages) and rectified current version
The “SMART CONNECTOR” systems series 9910 are formed by (with 24 VRAC, 220 VRAC, or 240 VRAC).
coupling a connector in series 9152, equipped with an integrated These coils are in Class H, in accordance with IEC standard 85 and
electronic circuit in the connector, with a specific series 9300 coil their production is compliant with standards EN 60730-1 and EN
designed for the connector. These systems have been designed 60730-2-8. The windings are made of enamelled copper wire, with
by Castel to be installed on: insulation class H (180 °C), in compliance with IEC standard 85.
- Normally-closed solenoid valves The terminals of the coils consist of two Faston connectors plus a
- PWM expansion valves Faston ground connector. The outer casing is made of waterproof,
and allow: dielectric resins that guarantee reinforced insulation and allow any
- a reduction in energy consumption when fully operational type of assembly.
- a consequent reduction in the operating temperature They have Class I protection ratings against electric contacts.
- an extension of the coil life Consequently, their safety requires an efficient ground system. A
- an increase in the MOPD value rubber gasket assembled on the lower end of the coil completes
N.B.: Castel does not sell the two parts (coil and connector) that the protection of the windings from humidity. When coupled with
make up a “SMART CONNECTOR” system separately. connectors 9152, these coils guarantee an IP65 protection rating
according to standard EN 60529.
The coils are designed for continuous use. The solid construction
of these coils makes them suitable for use in refrigeration systems
CONNECTION CONSTRUCTION operating in heavy-duty environments The maximum ambient
temperature for all coils is 50 °C.
EN 175301-803 (former DIN 43650) standardized connectors Each coil in a “SMART CONNECTOR” system must be used
9152 represent an effective system for the connection of the coil only in combination with the type of connector with which it
to the power system, thus ensuring safety also in the presence of is coupled in the system. Incorrect use of the coil with other
moisture. types of connectors produced by Castel will quickly damage
Connectors 9152 are available in both the direct current version the coil and the connector.
(with 12 VDC and 24 VDC voltages) and in the alternating current
version (with 24 VAC or 220/240 VAC voltages).
The direct current versions are equipped with polarity inversion
protection. OPERATION
The alternating current versions are equipped with a bridge rectifier
circuit integrated on the circuit. Through the integrated circuit in the connector, and coupling with
All versions, both direct current and alternating current, are the specific coil, connectors 9152 are capable of improving the
equipped with a diode device that guarantees surge protection. All MOPD characteristics of Castel solenoid valves, reducing the power
versions have the voltage for use and the wiring diagram printed on consumption by up to 50% over time, extending the coil life, and
the casing. The gland nut of the outer casing is suitable for receiving decreasing the noise.
cables with an external diameter of 6 to 9 mm and is equipped with The integrated circuit located inside the connector works in different
a self-locking device. It is recommended that three-pole cables with modes based on the power supply voltage. Specifically, there are two
a cross-section greater than or equal to 0.75 mm2 be used. There main families with different operating logics.
are no versions with co-moulded cables.
Each connector in a “SMART CONNECTOR” system must be Connectors 9152/RD (direct current) supercharge the dedicated coil
used only for the type of coil with which it is coupled in the 9300 to its maximum allowed power for a short, pre-set interval.
system. Incorrect use of the connector with other types of This is called the “Boost” time. It generates a greater attraction
coils produced by Castel will quickly damage the coil and force on the valve’s magnetic unit, and consequently increases
the connector. the MOPD value. At the end of the “Boost” phase, during normal
operation, connectors 9152/RD maintain the electric consumption
of the dedicated coil 9300 at a lower value, from 45% to 55% lower
than the power absorbed by the coil. The power reduction occurs
COIL CONSTRUCTION by powering the coil with a high-frequency pulsed current (ON/OFF
cycles), from 15 to 30 kHz. This frequency is aimed at guaranteeing
Coils in series HF2 (9300) used in the “SMART CONNECTOR” the minimum magnetic force to keep the valve open during operation.

3.15
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 3.16
GOGREEN HANDBOOK - 2023
 Connectors 9152/RA (alternating current) supercharge the coils For proper evaluation of the real energy savings, it is necessary to
9300 for a pre-set interval. This is called the “Boost” time. It consider the number of coil interventions with respect to the normal
generates a greater attraction force on the valve’s magnetic unit, power supply time of the valve. If the number of interventions is
and consequently increases the MOPD value. Once this period is reduced, the consumption is reduced; if the number of interventions
over, the electronics remove one phase wave every second one, increases, the consumption grows.
with an effect comparable to powering the coil with pulsed/rectified
current with a frequency half of that of the network. By using this As indicated in the paragraph APPLICATION, the “SMART
system, you obtain an electric power consumption reduction of the CONNECTOR” systems can also be used with the series of valves
unit to a value from 35% to 45%, while maintaining the minimum PWM 2028 manufactured by Castel, if suitably sized to have
magnetic force that allows the valve to be opened. This operating opening / closing cycles with a frequency greater than 0.6 seconds.
logic makes the “Smart Connector” system powered in alternating
current very quiet, reducing the normal noise level, which can be up
to 13 dB, to values less than 4 dB based on the valve installation. CERTIFICATIONS
Using the afore-mentioned logic, it is possible to significantly reduce All connectors and coils in this chapter comply with the
the electricity consumption (which can be important considering the Electromagnetic Compatibility (EMC) Directive (2004/108/EC).
system of refrigerator aisles in a supermarket). Also, it leads to a The connectors with 220/240 VAC voltage and the coils with 220
lower operating temperature of the coil and therefore, in conclusion, VRAC and 240 VRAC voltage comply with the Low Voltage Directive
less wear on the electromechanical drive system. Obviously, these (2006/95/EC).
reductions in consumption are strictly related to the use of the coils.

3.17
HANDBOOK - 2023
TABELLA 7: GENERAL CHARACTERISTICS OF SYSTEMS SMART CONNECTOR

Working Nominal TA [°C]

Voltage Frequency Insulation Boost Time Protection
Catalogue Number Voltage [V] nominal power
tolerance [%] [Hz] class IEC 85 [msec] degree
power [W] tolerance [%] min max

9910/RD1 (1) 12 VDC 3

+/-10 - +/-10 H -20 +50 130 IP65
9910/RD2 (1) 24 VDC 5

9910/RA2 24 VAC

9910/RA6 220 VAC +/-10 50/60 7 +/-10 H -20 +50 200 IP65

9910/RA7 240 VAC

(1): Warning if these connectors are supplied via unidirectional direct current or rectified by means of the Graetz bridge, they could not perform a correct cycle of operation but always remain in
Boost conditions, leading to fast damage of the coil. For correct operation the kits series 9910/RD MUST be powered by direct current stabilized or rectified.

3.18
GOGREEN HANDBOOK - 2023
SAFETY
DEVICES
 CHAPTER 4

SAFETY DEVICES
4.1 – SAFETY VALVES IN SERIES 3030

GENERAL DESCRIPTION below. When calibration is complete, the position of the ring nut
is maintained unchanged by applying to the threaded coupling a
Safety valves in series 3030 are considered “Safety Accessories” high mechanical strength and low viscosity bonding agent. The low
according to the definition provided in Article 2, Point 4 of said viscosity promotes penetration. The calibration system is protected
Directive and are subject to the classification indicated in Article against subsequent unauthorized interventions by means of a
4, Point 1.d) of the same Directive. These valves are unbalanced, threaded cap nut, screwed on outside the head and sealed with
conventional direct-loaded safety valves. The valve is opened by a Castel lead seal.
the thrust from the fluid under pressure below the shutter, when
said thrust exceeds, under the calibrated conditions, the opposing
force of the spring acting on the shutter. SCOPE
Valves are identified by means of:
- a model number formed of an alphanumerical code that includes: Use: protection against possible overpressure of the apparatuses
- the family identity (for ex. 3030/44) listed below, with regard to the operating conditions for which they
- the type of inlet connection (for ex. C = NPT) have been designed:
- the set pressure, expressed in bar, multiplied by 10 (for ex. 250) - Refrigeration system or heat pump components, for instance:
- an alphanumerical serial number condensers, liquid receivers, evaporators, liquid accumulators,
positive displacement compressor discharge, heat exchangers, oil
separators, or piping.
CONSTRUCTION (reference standard: EN 378-2:2016)
Fluids: the valves in series 3030 can be used with refrigerant
Body: squared, obtained through hot moulding and subsequent fluid R744 in vapour or gaseous state, belonging to Group 2 with
machining. It houses the following elements: reference to Article 13, Para. 1(b) of Directive 2014/68/EU (EC
- the nozzle with flat sealing seat Regulation No. 1272/2008).
- the shutter guide
- the set spring slot
- the threaded seat of the setting adjustment ring nut MARKING
In the body, above the shutter guide, a small pressure relief hole
is provided through which the spring slot communicates with the In compliance with the provisions of Article 19 of Directive 2014/68/EU,
atmosphere. For this reason, during relief, there is a gas leak the following information is reported on the valve body:
through this orifice. - Manufacturer’s mark
Material used: EN 12420-CW617N brass - Country of manufacturing
Shutter: obtained through machining from bar stock and fit with - Indication of flow direction
gasket, it ensures the required degree of tightness on the valve - Maximum allowable pressure
seat. The gasket is made from PTFE (Polytetrafluorethylene), a - CE marking
material that, during the valve’s estimated service life, maintains - Identification number of the notified body involved in the production
good strength and does not cause the shutter to stick on the seat. control phase
The shutter is properly guided in the head and the guide action - Valve model
cannot fail. There are no glands or retaining rings that hamper its - Serial number
movement. - Set pressure
Material used: EN 12164-CW614N brass - Temperature range allowed
Spring: it opposes the pressure and the fluid dynamic forces, - Kd discharge coefficient
and always ensures closing of the valve following pressure relief. - Flow section
When the shutter has reached the maximum height determined - Production date
by the mechanical stop, the spring compression does not exceed
80% of the total compression. All the springs are compliant with
the compression helical spring requirements defined in EN ISO
4126-7:2013.
DOCUMENTATION
Material used: DIN 17223-1 steel for springs.
The safety valves in series 3030 are supplied with the following
Calibration system: hex-head threaded ring nut to be screwed
documentation provided in the packaging:
inside the upper portion of the head, compressing the spring

4.3
HANDBOOK - 2023
 4.4
GOGREEN HANDBOOK - 2023
 - operating instructions for the user, containing all information vessel and safety valve) or the downstream line (between safety
useful for safety in terms of assembly, commissioning, use, and valve and atmosphere) refer to Chapter 4.7 “Selection Criteria for
maintenance. Safety Valves” in this technical handbook.
- Declaration of Conformity for the equipment according to Directive
2014/68/EU, required in Article 17 and issued in compliance with
Annex IV of the same directive.
- Calibration certificate for the safety valve, printed on the reverse
side of the Declaration of Conformity.
N.B.: on the website: www.castel.it use the “DOWNLOAD” pull-
down menu to access the web-page “PRODUCT CERTIFICATION”
in the “DOWNLOAD CENTER”. On this page, you can download:
- the Declaration of Conformity / Calibration Certificate for each
valve by entering the 7-digit alphanumeric serial number. (SEARCH
BY SERIAL NUMBER)
- the general Declaration of Conformity referring to a specific model
of valve 3030 with a specific setting, for ex. 3030/44C250 or
3030/88C420. (SEARCH BY PRODUCT CODE)

VALVE SELECTION
Directive 2014/68/EU requires that pressure equipment, in which
permissible limits are reasonably likely to be exceeded, shall be
fitted with suitable protection devices, for instance safety devices
such as safety valves. Such devices shall prevent pressure from
permanently exceeding the maximum allowable pressure (PS) of the
equipment they protect. In any case, a short pressure peak limited
to 10% of maximum allowable pressure is permitted.
As to the selection and sizing of the suitable protection device, users
shall refer to the specific product and sector standards listed below:

- EN ISO 4126-1: 2013: “Safety devices for protection against

excessive pressure – Part 1: Safety valves” indicates the general
requirements for safety valves regardless of the fluid for which
they were designed.
- EN 378-2:2016: “Refrigerating systems and heat pumps – safety
and environmental requirements – Part 2: Design, construction,
testing, marking and documentation” provides a general outline of
the protection devices to be used in refrigerating systems and their
characteristics (Para. 6.2.5) and the criteria for the selection of the
device suitable for the type and size of the system component to
be protected (Para. 6.2.6).
- EN 13136:2013+A1: “Refrigerating systems and heat pumps –
Pressure relief devices and their associated piping – Methods for
calculation” highlights the possible causes of overpressure in a
system and provides users with the tools for sizing pressure relief
devices, among which safety valves.

To select the safety valves in series 3030, please see Chapter 4.7
“Selection Criteria for Safety Valves” in this technical handbook.

VALVE INSTALLATION
Safety valves type 3030 guarantee repeatable performance.
This means that, after the valves have operated, open/close,
the initial setting conditions are maintained. Nevertheless, it is
advisable to replace a 3030 valve once it has discharged as during
release debris, such as metal shavings or solder impurities, can
deposit on the valve gasket. This can inhibit the safety valve from
returning to its original conditions.
To calculate the pressure loss in either the upstream line (between

4.5
HANDBOOK - 2023
TABLE 1: GENERAL CHARACTERISTICS OF VALVES 3030

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

Inlet male 1/2” NPT 1/2” G 3/4” NPT 1” NPT

Connections
Outlet male 3/4” G 3/4” G 3/4” G 1.1/4” G

Inlet connection wrench torque (min/max) [Nm] 25/35 25/35 30/40 60/80

Flow Diameter [mm] 12 12 12 19,5

Flow Section [mm2] 113 113 113 298

Lift [mm] 4,1 4,1 4,1 6,8

Discharge Coefficient “Kd” 0,90 0,90 0,90 0,83

PS [bar] 55

TS [°C] - 50 / + 150

Set Pressure Range at atmospheric back pressure Pset [bar] 9 / 50

Overpressure + 5 % of Pset

Blowdown - 15 % of Pset

-15 % di Pset (9 bar < Pset < 31 bar)

Helium tightness
-10 % di Pset (31,1 bar < Pset < 50 bar)

Estimated service life 9 years

Risk Category according to PED Recast IV

TABLE 2: DIMENSIONS AND WEIGHTS OF VALVES 3030

Dimensions [mm]
Catalogue Number Weight [g]
ØD L Ch H1 H2 H3

3030/44C 38 38 28 44 115 159 780

3030/44G 38 38 28 44 115 159 780

3030/66C 38 38 28 44 115 159 780

3030/88C 50 56 40 58 158 216 1960

4.6
GOGREEN HANDBOOK - 2023
 CHAPTER 4

SAFETY DEVICES
4.2 – SAFETY VALVES IN SERIES 3060

GENERAL DESCRIPTION body and is fixed in this seat with an edge calking operation.

Safety valves in series 3060 are considered “Safety Accessories”

according to the definition provided in Article 2, Point 4 of said SCOPE
Directive and are subject to the classification indicated in Article
4, Point 1.d) of the same Directive. These valves are unbalanced, Use: protection against possible overpressure of the apparatuses
conventional direct-loaded safety valves. The valve is opened by listed below, with regard to the operating conditions for which they
the thrust from the fluid under pressure below the shutter, when have been designed:
said thrust exceeds, under the calibrated conditions, the opposing - Refrigeration system or heat pump components, for instance:
force of the spring acting on the shutter. condensers, liquid receivers, evaporators, liquid accumulators,
Valves are identified by means of: positive displacement compressor discharge, heat exchangers, oil
- a model number formed of an alphanumerical code that includes: separators, or piping.
- the family identity (for ex. 3060/45) (reference standard: EN 378-2:2016)
- the type of inlet connection (for ex. C = NPT) Fluids: the valves in series 3060 can be used with refrigerant
- the set pressure, expressed in bar, multiplied by 10 (for ex. 300) fluid R744 in vapour or gaseous state, belonging to Group 2 with
- an alphanumerical serial number reference to Article 13, Para. 1(b) of Directive 2014/68/EU (EC
Regulation No. 1272/2008).

CONSTRUCTION
MARKING
Body: squared, obtained through hot moulding and subsequent
machining. It houses the following elements: In compliance with the provisions of Article 19 of Directive
- the nozzle with flat sealing seat 2014/68/EU, the following information is reported on the valve
- the shutter guide body:
- the set spring slot - Manufacturer’s mark
- the threaded seat of the setting adjustment ring nut - Country of manufacturing
In the body, above the shutter guide, a small pressure relief hole - Indication of flow direction
is provided through which the spring slot communicates with the - Maximum allowable pressure
exit connection. For this reason, during relief, there is a no gas leak - CE marking
through this orifice. - Identification number of the notified body involved in the production
Material used: EN 12420-CW617N brass control phase
Shutter: obtained through machining from bar stock and fit with - Valve model
gasket, it ensures the required degree of tightness on the valve - Serial number
seat. The gasket is made from PTFE (Polytetrafluorethylene), a - Set pressure
material that, during the valve’s estimated service life, maintains - Temperature range allowed
good strength and does not cause the shutter to stick on the seat. - Kd discharge coefficient
The shutter is properly guided in the body and the guide action - Flow section
cannot fail. There are no glands or retaining rings that hamper its - Production date
movement.
Material used: EN 12164-CW614N brass
Spring: it opposes the pressure and the fluid dynamic forces, and
always ensures closing of the valve following pressure relief.
DOCUMENTATION
Material used: DIN 17223-1 steel for springs.
The safety valves in series 3060 are supplied with the following
Calibration system: hex-head threaded ring nut to be screwed
documentation provided in the packaging:
inside the upper portion of the body, compressing the spring
- operating instructions for the user, containing all information
below. When calibration is complete, the position of the ring nut
useful for safety in terms of assembly, commissioning, use, and
is maintained unchanged by applying to the threaded coupling a
maintenance.
high mechanical strength and low viscosity bonding agent. The
- Declaration of Conformity for the equipment according to Directive
calibration system is protected against subsequent unauthorized
2014/68/EU, required in Article 17 and issued in compliance with
interventions by means of a cap nut that is housed into the brass

4.7
HANDBOOK - 2023
 4.8
GOGREEN HANDBOOK - 2023
 Annex IV of the same directive.
- Calibration certificate for the safety valve, printed on the reverse
side of the Declaration of Conformity.
N.B.: on the website: www.castel.it use the “DOWNLOAD” pull-
down menu to access the web-page “PRODUCT CERTIFICATION”
in the “DOWNLOAD CENTER”. On this page, you can download:
- the Declaration of Conformity / Calibration Certificate for each
valve by entering the 7-digit alphanumeric serial number. (SEARCH
BY SERIAL NUMBER)
- the general Declaration of Conformity referring to a specific model
of valve 3060 with a specific setting, for ex. 3060/24C250 or
3060/45C420. (SEARCH BY PRODUCT CODE)

VALVE SELECTION
Directive 2014/68/EU requires that pressure equipment, in which
permissible limits are reasonably likely to be exceeded, shall be
fitted with suitable protection devices, for instance safety devices
such as safety valves. Such devices shall prevent pressure from
permanently exceeding the maximum allowable pressure (PS) of the
equipment they protect. In any case, a short pressure peak limited
to 10% of maximum allowable pressure is permitted.
As to the selection and sizing of the suitable protection device, users
shall refer to the specific product and sector standards listed below:

- EN ISO 4126-1: 2013: “Safety devices for protection against

excessive pressure – Part 1: Safety valves” indicates the general
requirements for safety valves regardless of the fluid for which
they were designed.
- EN 378-2:2016: “Refrigerating systems and heat pumps – safety
and environmental requirements – Part 2: Design, construction,
testing, marking and documentation” provides a general outline of
the protection devices to be used in refrigerating systems and their
characteristics (Para. 6.2.5) and the criteria for the selection of the
device suitable for the type and size of the system component to
be protected (Para. 6.2.6).
- EN 13136:2013+A1: “Refrigerating systems and heat pumps –
Pressure relief devices and their associated piping – Methods for
calculation” highlights the possible causes of overpressure in a
system and provides users with the tools for sizing pressure relief
devices, among which safety valves.

To select the safety valves in series 3060, please see Chapter 4.7
“Selection Criteria for Safety Valves” in this technical handbook.

VALVE INSTALLATION
Safety valves type 3060 do NOT guarantee repeatable
performance. This means that, after the valves have operated,
open/close, the initial setting conditions are NOT maintained.
To calculate the pressure loss in either the upstream line (between
vessel and safety valve) or the downstream line (between safety
valve and atmosphere) refer to Chapter 4.7 “Selection Criteria for
Safety Valves” in this technical handbook.

4.9
HANDBOOK - 2023
TABLE 3: GENERAL CHARACTERISTICS OF VALVES 3060

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

Inlet male 1/4” NPT 1/4” NPT 3/8” NPT 3/8” NPT 1/2” NPT 3/8” NPT 1/2” NPT
Connections
Outlet male 3/8” SAE 1/2” SAE 3/8” SAE 1/2” SAE 5/8” SAE 3/4” G 3/4” G

Inlet connection wrench torque (min/max) [Nm] 15/20 15/20 17/22 17/22 25/35 17/22 25/35

Flow Diameter [mm] 7,0 9,5 10,0

Flow Section [mm2] 38,5 70,9 78,5

Discharge Coefficient “Kd” 0,63 0,69 0,63 0,69 0,45 0,92 0,93

PS [bar] 55

TS [°C] - 50 / + 120
Set Pressure Range at atmospheric back pressure
9 / 50
Pset [bar]
Overpressure + 10 % of Pset

Blowdown - 50 % of Pset - 40 % of Pset

-20 % di Pset (9 bar < Pset < 31 bar)

Helium tightness
-10 % di Pset (31,1 bar < Pset < 50 bar)

Estimated service life 5 years

Risk Category according to PED Recast IV

TABLE 4: DIMENSIONS AND WEIGHTS OF VALVES 3060

Dimensions [mm]
Catalogue Number Weight [g]
ØD L Ch H1 H2 H3

3060/23C 21,5 35 20 33,5 46,5 80 180

3060/24C 21,5 35 20 33,5 46,5 80 195

3060/33C 21,5 35 20 33,5 46,5 80 195

3060/34C 21,5 35 20 33,5 46,5 80 195

3060/45C 24,5 39,0 23 37 52,5 89 240

3060/36C 30 40 27 37 59,5 96,5 360

3060/46C 30 40 27 40 59,5 99,5 380

4.10
GOGREEN HANDBOOK - 2023
 CHAPTER 4

SAFETY DEVICES
4.3 – SAFETY VALVES IN SERIES 3061

GENERAL DESCRIPTION below. When calibration is complete, the position of the ring nut
is maintained unchanged by applying to the threaded coupling a
Safety valves in series 3061 are considered “Safety Accessories” high mechanical strength and low viscosity bonding agent. The low
according to the definition provided in Article 2, Point 4 of said viscosity promotes penetration. The calibration system is protected
Directive and are subject to the classification indicated in Article against subsequent unauthorized interventions by means of a cap
4, Point 1.d) of the same Directive. These valves are unbalanced, nut that is housed into the brass body and is fixed in this seat with
conventional direct-loaded safety valves. The valve is opened by an edge calking operation.
the thrust from the fluid under pressure below the shutter, when
said thrust exceeds, under the calibrated conditions, the opposing
force of the spring acting on the shutter. SCOPE
Valves are identified by means of:
- a model number formed of an alphanumerical code that includes: Use: protection against possible overpressure of the apparatuses
- the family identity (for ex. 3061/3) listed below, with regard to the operating conditions for which they
- the type of inlet connection (for ex. C = NPT) have been designed:
- the set pressure, expressed in bar, multiplied by 10 (for ex. 200) - Refrigeration system or heat pump components, for instance:
- an alphanumerical serial number condensers, liquid receivers, evaporators, liquid accumulators,
positive displacement compressor discharge, heat exchangers, oil
separators, or piping.
CONSTRUCTION (reference standard: EN 378-2:2016)
Fluids: the valves in series 3061 can be used with refrigerant
Body: squared, obtained through hot moulding and subsequent fluid R744 in vapour or gaseous state, belonging to Group 2 with
machining. It houses the following elements: reference to Article 13, Para. 1(b) of Directive 2014/68/EU (EC
- the nozzle with flat sealing seat Regulation No. 1272/2008).
- the shutter guide
- the set spring slot
- the threaded seat of the setting adjustment ring nut MARKING
In the body, above the shutter guide, a small pressure relief hole
is provided through which the spring slot communicates with the In compliance with the provisions of Article 19 of Directive 2014/68/EU,
exit connection. For this reason, during relief, there is a no gas leak the following information is cast on the valve body:
through this orifice. - Manufacturer’s mark
Material used: EN 12420-CW617N brass - Country of manufacturing
Shutter: obtained through machining from bar stock and fit with - Indication of flow direction
gasket, it ensures the required degree of tightness on the valve seat. - Maximum allowable pressure
The gasket is made from modified PTFE (Polytetrafluorethylene), - Valve model
a material that, during the valve’s estimated service life, maintains - Serial number
good strength and does not cause the shutter to stick on the seat. - Set pressure
The shutter is properly guided in the body and the guide action - Allowable temperature range
cannot fail. There are no glands or retaining rings that hamper its - Kd discharge coefficient
movement. - Flow section
Material used: EN 12164-CW614N brass - Production date
Spring: it opposes the pressure and the fluid dynamic forces, - CE marking
and always ensures closing of the valve following pressure relief. - Identification number of the notified body involved in the production
When the shutter has reached the maximum height determined control phase
by the mechanical stop, the spring compression does not exceed
80% of the total compression. All the springs are compliant with
the compression helical spring requirements defined in EN ISO
4126-7:2013.
DOCUMENTATION
Material used: EN 10270-2 - FD steel for springs.
The safety valves in series 3061 are supplied with the following
Calibration system: hex-head threaded ring nut to be screwed
documentation provided in the packaging:
inside the upper portion of the head, compressing the spring

4.11
HANDBOOK - 2023
 4.12
GOGREEN HANDBOOK - 2023
 - operating instructions for the user, containing all information vessel and safety valve) or the downstream line (between safety
useful for safety in terms of assembly, commissioning, use, and valve and atmosphere) refer to Chapter 4.7 “Selection Criteria for
maintenance. Safety Valves” in this technical handbook.
- Declaration of Conformity for the equipment according to Directive
2014/68/EU, required in Article 17 and issued in compliance with
Annex IV of the same directive.
- Calibration certificate for the safety valve, printed on the reverse
side of the Declaration of Conformity.
N.B.: on the website: www.castel.it use the “DOWNLOAD” pull-
down menu to access the web-page “PRODUCT CERTIFICATION”
in the “DOWNLOAD CENTER”. On this page, you can download:
- the Declaration of Conformity / Calibration Certificate for each
valve by entering the 7-digit alphanumeric serial number. (SEARCH
BY SERIAL NUMBER)
- the general Declaration of Conformity referring to a specific
model of valve 3061 with a specific setting, for ex. 3061/2C250
or 3061/4C420. (SEARCH BY PRODUCT CODE)

VALVE SELECTION
Directive 2014/68/EU requires that pressure equipment, in which
permissible limits are reasonably likely to be exceeded, shall be
fitted with suitable protection devices, for instance safety devices
such as safety valves. Such devices shall prevent pressure from
permanently exceeding the maximum allowable pressure (PS) of the
equipment they protect. In any case, a short pressure peak limited
to 10% of maximum allowable pressure is permitted.
As to the selection and sizing of the suitable protection device, users
shall refer to the specific product and sector standards listed below:

- EN ISO 4126-1: 2013: “Safety devices for protection against

excessive pressure – Part 1: Safety valves” indicates the general
requirements for safety valves regardless of the fluid for which
they were designed.
- EN 378-2:2016 “Refrigerating systems and heat pumps – Safety
and environmental requirements – Part 2: Design, construction,
testing, marking and documentation” provides a general outline of
the protection devices to be used in refrigerating systems and their
characteristics (Para. 6.2.5) and the criteria for the selection of the
device suitable for the type and size of the system component to
be protected (Para. 6.2.6).
- EN 13136:2013+A1: “Refrigerating systems and heat pumps –
Pressure relief devices and their associated piping – Methods for
calculation” highlights the possible causes of overpressure in a
system and provides users with the tools for sizing pressure relief
devices, among which safety valves.

To select the safety valves in series 3061, please see Chapter 4.7
“Selection Criteria for Safety Valves” in this technical handbook.

VALVE INSTALLATION
Safety valves type 3061 guarantee repeatable performance. This
means that, after the valves have operated, open/close, the initial
setting conditions are maintained. Nevertheless, it is advisable to
replace a 3061 valve once it has discharged as during release
debris, such as metal shavings or solder impurities, can deposit
on the valve gasket. This can inhibit the safety valve from returning
to its original conditions.
To calculate the pressure loss in either the upstream line (between

4.13
HANDBOOK - 2023
TABLE 5 : GENERAL CHARACTERISTICS OF VALVES 3061

Catalogue Number 3061/2C 3061/3C 3061/4C

Inlet male 1/4” NPT 3/8” NPT 1/2” NPT

Connections
Outlet male 3/8” G 1/2” G 1/2” G

Inlet connection wrench torque (min/max) [Nm] 15/20 17/22 25/35

Flow Diameter [mm] 7,5 7,5 7,5

Flow Section [mm2] 44,2 44,2 44,2

Lift [mm] - - -

Discharge Coefficient “Kd” 0,89 0,89 0,89

PS [bar] 70

TS [°C] - 50 / + 150
Set Pressure Range at atmospheric back pressure
11 / 60
Pset [bar]
Overpressure + 10 % of Pset

Blowdown - 15 % of Pset

- 20 % of Pset (11 bar < Pset < 14 bar)

Helium tightness - 15 % of Pset (14,1 bar < Pset < 24 bar)

- 10 % of Pset (24,1 bar < Pset < 60 bar)

Estimated service life 9 years

Risk Category according to PED Recast IV

TABLE 6: DIMENSIONS AND WEIGHTS OF VALVES 3061

Dimensions [mm]
Catalogue Number Weight [g]
ØD L Ch H1 H2 H3

3061/2C 28,5 33,5 23 30 61 91 200

3061/3C 28,5 33,5 23 30 61 91 230

3061/4C 28,5 33,5 23 35 61 96 260

4.14
GOGREEN HANDBOOK - 2023
 CHAPTER 4

SAFETY DEVICES
4.4 – SAFETY VALVES IN SERIES 3065

GENERAL DESCRIPTION below. When calibration is complete, the position of the ring nut
is maintained unchanged by applying to the threaded coupling a
Safety valves in series 3065 are considered “Safety Accessories” high mechanical strength and low viscosity bonding agent. The low
according to the definition provided in Article 2, Point 4 of said viscosity promotes penetration. The calibration system is protected
Directive and are subject to the classification indicated in Article against subsequent unauthorized interventions by means of a cap
4, Point 1.d) of the same Directive. These valves are unbalanced, nut that is housed into the brass body and is fixed in this seat with
conventional direct-loaded safety valves. The valve is opened by an edge calking operation.
the thrust from the fluid under pressure below the shutter, when
said thrust exceeds, under the calibrated conditions, the opposing
force of the spring acting on the shutter. SCOPE
Valves are identified by means of:
- a model number formed of an alphanumerical code that includes: Use: protection against possible overpressure of the apparatuses
- the family identity (for ex. 3065/4) listed below, with regard to the operating conditions for which they
- the type of inlet connection (for ex. C = NPT) have been designed:
- the set pressure, expressed in bar, multiplied by 10 (for ex. 140) - Refrigeration system or heat pump components, for instance:
- an alphanumerical serial number condensers, liquid receivers, evaporators, liquid accumulators,
positive displacement compressor discharge, heat exchangers, oil
separators, or piping.
CONSTRUCTION (reference standard: EN 378-2:2016)
Fluids: the valves in series 3065 can be used with refrigerant
Body: squared, obtained through hot moulding and subsequent fluid R744 in vapour or gaseous state, belonging to Group 2 with
machining. It houses the following elements: reference to Article 13, Para. 1(b) of Directive 2014/68/EU (EC
- the nozzle with flat sealing seat Regulation No. 1272/2008).
- the shutter guide
- the set spring slot
- the threaded seat of the setting adjustment ring nut MARKING
In the body, above the shutter guide, a small pressure relief hole
is provided through which the spring slot communicates with the In compliance with the provisions of Article 19 of Directive 2014/68/EU,
exit connection. For this reason, during relief, there is a no gas leak the following information is cast on the valve body:
through this orifice. - Manufacturer’s mark
Material used: EN 12420-CW617N brass - Country of manufacturing
Shutter: obtained through machining from bar stock and fit with - Indication of flow direction
gasket, it ensures the required degree of tightness on the valve seat. - Maximum allowable pressure
The gasket is made from modified PTFE (Polytetrafluorethylene), - Valve model
a material that, during the valve’s estimated service life, maintains - Serial number
good strength and does not cause the shutter to stick on the seat. - Set pressure
The shutter is properly guided in the body and the guide action - Allowable temperature range
cannot fail. There are no glands or retaining rings that hamper its - Kd discharge coefficient
movement. - Flow section
Material used: EN 12164-CW614N brass - Production date
Spring: it opposes the pressure and the fluid dynamic forces, - CE marking
and always ensures closing of the valve following pressure relief. - Identification number of the notified body involved in the production
When the shutter has reached the maximum height determined control phase
by the mechanical stop, the spring compression does not exceed
80% of the total compression. All the springs are compliant with
the compression helical spring requirements defined in EN ISO
4126-7:2013.
DOCUMENTATION
Material used: EN 10270-2 - FD steel for springs.
The safety valves in series 3065 are supplied with the following
Calibration system: hex-head threaded ring nut to be screwed
documentation provided in the packaging:
inside the upper portion of the head, compressing the spring

4.15
HANDBOOK - 2023
 4.16
GOGREEN HANDBOOK - 2023
 - operating instructions for the user, containing all information
useful for safety in terms of assembly, commissioning, use, and To calculate the pressure loss in either the upstream line (between
maintenance. vessel and safety valve) or the downstream line (between safety
- Declaration of Conformity for the equipment according to Directive valve and atmosphere) refer to Chapter 4.7 “Selection Criteria for
2014/68/EU, required in Article 17 and issued in compliance with Safety Valves” in this technical handbook.
Annex IV of the same directive.
- Calibration certificate for the safety valve, printed on the reverse
side of the Declaration of Conformity.
N.B.: on the website: www.castel.it use the “DOWNLOAD” pull-
down menu to access the web-page “PRODUCT CERTIFICATION”
in the “DOWNLOAD CENTER”. On this page, you can download:
- the Declaration of Conformity / Calibration Certificate for each
valve by entering the 7-digit alphanumeric serial number. (SEARCH
BY SERIAL NUMBER)
- the general Declaration of Conformity referring to a specific
model of valve 3061 with a specific setting, for ex. 3065/4C250
or 3065/6C420. (SEARCH BY PRODUCT CODE)

VALVE SELECTION
Directive 2014/68/EU requires that pressure equipment, in which
permissible limits are reasonably likely to be exceeded, shall be
fitted with suitable protection devices, for instance safety devices
such as safety valves. Such devices shall prevent pressure from
permanently exceeding the maximum allowable pressure (PS) of the
equipment they protect. In any case, a short pressure peak limited
to 10% of maximum allowable pressure is permitted.
As to the selection and sizing of the suitable protection device, users
shall refer to the specific product and sector standards listed below:

- EN ISO 4126-1: 2013: “Safety devices for protection against

excessive pressure – Part 1: Safety valves” indicates the general
requirements for safety valves regardless of the fluid for which
they were designed.
- EN 378-2:2016 “Refrigerating systems and heat pumps – Safety
and environmental requirements – Part 2: Design, construction,
testing, marking and documentation” provides a general outline of
the protection devices to be used in refrigerating systems and their
characteristics (Para. 6.2.5) and the criteria for the selection of the
device suitable for the type and size of the system component to
be protected (Para. 6.2.6).
- EN 13136:2013+A1: “Refrigerating systems and heat pumps –
Pressure relief devices and their associated piping – Methods for
calculation” highlights the possible causes of overpressure in a
system and provides users with the tools for sizing pressure relief
devices, among which safety valves.

For sizing of the safety valves in series 3065, please see Chapter
4.7 “Selection Criteria for Safety Valves” in this technical handbook.

VALVE INSTALLATION
Safety valves type 3065 guarantee repeatable performance.
This means that, after the valves have operated, open/close,
the initial setting conditions are maintained. Nevertheless, it is
advisable to replace a 3065 valve once it has discharged as during
release debris, such as metal shavings or solder impurities, can
deposit on the valve gasket. This can inhibit the safety valve from
returning to its original conditions.

4.17
HANDBOOK - 2023
TABLE 7 : GENERAL CHARACTERISTICS OF VALVES 3065

Catalogue Number 3065/4C 3065/6C

Inlet male 1/2” NPT 3/4” NPT

Connections
Outlet male 1” G 1” G

Inlet connection wrench torque (min/max) [Nm] 25/35 30/40

Flow Diameter [mm] 13,0 13,0

Flow Section [mm2] 132,7 132,7

Lift [mm] 6,3 6,3

Discharge Coefficient “Kd” 0,87 0,87

PS [bar] 70

TS [°C] - 50 / + 150
Set Pressure Range at atmospheric back pressure
11 / 60
Pset [bar]
Overpressure + 10 % of Pset

Blowdown - 15 % of Pset

- 20 % of Pset (11 bar < Pset < 18,5 bar)

Helium tightness - 15 % of Pset (18,6 bar < Pset < 31 bar)

- 10 % of Pset (31,1 bar < Pset < 60 bar)

Estimated service life 9 years

Risk Category according to PED Recast IV

TABLE 8: DIMENSIONS AND WEIGHTS OF VALVES 3065

Dimensions [mm]
Catalogue Number Weight [g]
ØD L Ch H1 H2 H3

3065/4C 38,5 40 32 40 72 112 520

3065/6C 38,5 40 32 40 72 112 520

4.18
GOGREEN HANDBOOK - 2023
 CHAPTER 4

SAFETY DEVICES
4.5 – HIGH PRESSURE SAFETY VALVES IN SERIES 3030E

GENERAL DESCRIPTION below. When calibration is complete, the position of the ring nut
is maintained unchanged by applying to the threaded coupling a
Safety valves in series 3030E are considered “Safety Accessories” high mechanical strength and low viscosity bonding agent. The low
according to the definition provided in Article 2, Point 4 of said viscosity promotes penetration. The calibration system is protected
Directive and are subject to the classification indicated in Article against subsequent unauthorized interventions by means of a
4, Point 1.d) of the same Directive. These valves are unbalanced, threaded cap nut, screwed on outside the head and sealed with
conventional direct-loaded safety valves. The valve is opened by a Castel lead seal.
the thrust from the fluid under pressure below the shutter, when
said thrust exceeds, under the calibrated conditions, the opposing
force of the spring acting on the shutter. SCOPE
Valves are identified by means of:
- a model number formed of an alphanumerical code that includes: Use: protection against possible overpressure of the apparatuses
- the family identity (for ex. 3030E/46) listed below, with regard to the operating conditions for which they
- the type of inlet connection (for ex. C = NPT) have been designed:
- the set pressure, expressed in bar, multiplied by 10 (for ex. 1250) - Refrigeration system or heat pump components, for instance:
- an alphanumerical serial number condensers, liquid receivers, evaporators, liquid accumulators,
positive displacement compressor discharge, heat exchangers, oil
separators, or piping.
CONSTRUCTION (reference standard: EN 378-2:2016)
Fluids: the valves in series 3030E can be used with refrigerant
Body: squared, obtained through hot moulding and subsequent fluid R744 in vapour or gaseous state, belonging to Group 2 with
machining. It houses the following elements: reference to Article 13, Para. 1(b) of Directive 2014/68/EU (EC
- the nozzle with flat sealing seat Regulation No. 1272/2008).
- the shutter guide
- the set spring slot
- the threaded seat of the setting adjustment ring nut MARKING
In the body, above the shutter guide, a small pressure relief hole
is provided through which the spring slot communicates with the In compliance with the provisions of Article 19 of Directive 2014/68/EU,
atmosphere. For this reason, during relief, there is a gas leak the following information is reported on the valve body:
through this orifice. - Manufacturer’s mark
Material used: EN 12420-CW617N brass - Country of manufacturing
Shutter: obtained through machining from bar stock and fit with - Indication of flow direction
gasket, it ensures the required degree of tightness on the valve - Maximum allowable pressure
seat. The gasket is made from PTFE 50% stainless steel filled, a - CE marking
material that, during the valve’s estimated service life, maintains - Identification number of the notified body involved in the production
good strength and does not cause the shutter to stick on the seat. control phase
The shutter is properly guided in the head and the guide action - Valve model
cannot fail. There are no glands or retaining rings that hamper its - Serial number
movement. - Set pressure
Material used: EN 12164-CW614N brass - Temperature range allowed
Spring: it opposes the pressure and the fluid dynamic forces, - Kd discharge coefficient
and always ensures closing of the valve following pressure relief. - Flow section
When the shutter has reached the maximum height determined - Production date
by the mechanical stop, the spring compression does not exceed
80% of the total compression. All the springs are compliant with
the compression helical spring requirements defined in EN ISO
4126-7:2013.
DOCUMENTATION
Material used: DIN 17223-1 steel for springs.
The safety valves in series 3030E are supplied with the following
Calibration system: hex-head threaded ring nut to be screwed
documentation provided in the packaging:
inside the upper portion of the head, compressing the spring

4.19
HANDBOOK - 2023
 4.20
GOGREEN HANDBOOK - 2023
 - operating instructions for the user, containing all information vessel and safety valve) or the downstream line (between safety
useful for safety in terms of assembly, commissioning, use, and valve and atmosphere) refer to Chapter 4.7 “Selection Criteria for
maintenance. Safety Valves” in this technical handbook.
- Declaration of Conformity for the equipment according to Directive
2014/68/EU, required in Article 17 and issued in compliance with
Annex IV of the same directive.
- Calibration certificate for the safety valve, printed on the reverse
side of the Declaration of Conformity.
N.B.: on the website: www.castel.it use the “DOWNLOAD” pull-
down menu to access the web-page “PRODUCT CERTIFICATION”
in the “DOWNLOAD CENTER”. On this page, you can download:
- the Declaration of Conformity / Calibration Certificate for each
valve by entering the 7-digit alphanumeric serial number. (SEARCH
BY SERIAL NUMBER)
- the general Declaration of Conformity referring to a specific model
of valve 3030E with a specific setting, for ex. 3030E/46C1250 or
3030E/610C800. (SEARCH BY PRODUCT CODE)

VALVE SELECTION
Directive 2014/68/EU requires that pressure equipment, in which
permissible limits are reasonably likely to be exceeded, shall be
fitted with suitable protection devices, for instance safety devices
such as safety valves. Such devices shall prevent pressure from
permanently exceeding the maximum allowable pressure (PS) of the
equipment they protect. In any case, a short pressure peak limited
to 10% of maximum allowable pressure is permitted.
As to the selection and sizing of the suitable protection device, users
shall refer to the specific product and sector standards listed below:

- EN ISO 4126-1: 2013: “Safety devices for protection against

excessive pressure – Part 1: Safety valves” indicates the general
requirements for safety valves regardless of the fluid for which
they were designed.
- EN 378-2:2016: “Refrigerating systems and heat pumps – safety
and environmental requirements – Part 2: Design, construction,
testing, marking and documentation” provides a general outline of
the protection devices to be used in refrigerating systems and their
characteristics (Para. 6.2.5) and the criteria for the selection of the
device suitable for the type and size of the system component to
be protected (Para. 6.2.6).
- EN 13136:2013+A1: “Refrigerating systems and heat pumps –
Pressure relief devices and their associated piping – Methods for
calculation” highlights the possible causes of overpressure in a
system and provides users with the tools for sizing pressure relief
devices, among which safety valves.

To select the safety valves in series 3030E, please see Chapter 4.7
“Selection Criteria for Safety Valves” in this technical handbook.

VALVE INSTALLATION
Safety valves type 3030E guarantee repeatable performance.
This means that, after the valves have operated, open/close,
the initial setting conditions are maintained. Nevertheless, it
is advisable to replace a 3030E valve once it has discharged as
during release debris, such as metal shavings or solder impurities,
can deposit on the valve gasket. This can inhibit the safety valve
from returning to its original conditions.
To calculate the pressure loss in either the upstream line (between

4.21
HANDBOOK - 2023
TABLE 9: GENERAL CHARACTERISTICS OF VALVES 3030E

Catalogue Number 3030E/36C 3030E/46C 3030E/410C 3030E/610C

Inlet male 3/8” NPT 1/2” NPT 1/2” NPT 3/4” NPT
Connections
Outlet male 3/4” G 3/4” G 1.1/4” G 1.1/4” G

Inlet connection wrench torque (min/max) [Nm] 17/22 25/35 25/35 30/40

Flow Diameter [mm] 7 7 11 11

Flow Section [mm2] 38,5 38,5 95,0 95,0

Lift [mm] 4,2 4,2 4,7 4,7

Discharge Coefficient “Kd” 0,97 0,97 0,91 0,91

PS [bar] 165

TS [°C] - 50 / + 150
Set Pressure Range at atmospheric back pressure
60 / 150
Pset [bar]
Overpressure + 10 % of Pset

Blowdown - 15 % of Pset

Helium tightness -10 % di Pset

Estimated service life 9 years

Risk Category according to PED Recast IV

TABLE 10: DIMENSIONS AND WEIGHTS OF VALVES 3030E

Dimensions [mm]
Catalogue Number Weight [g]
ØD L Ch H1 H2 H3

3030E/36C 38 38 28 41 114 155 730

3030E/46C 38 38 28 41 114 155 750

3030E410C 50 56 40 55 155 210 1830

3030E/610C 50 56 40 55 155 210 1860

4.22
GOGREEN HANDBOOK - 2023
 CHAPTER 4

SAFETY DEVICES
4.6 – HIGH PRESSURE SAFETY VALVES IN SERIES 3061E

GENERAL DESCRIPTION below. When calibration is complete, the position of the ring nut
is maintained unchanged by applying to the threaded coupling a
Safety valves in series 3061E are considered “Safety Accessories” high mechanical strength and low viscosity bonding agent. The low
according to the definition provided in Article 2, Point 4 of said viscosity promotes penetration. The calibration system is protected
Directive and are subject to the classification indicated in Article against subsequent unauthorized interventions by means of a cap
4, Point 1.d) of the same Directive. These valves are unbalanced, nut that is housed into the brass body and is fixed in this seat with
conventional direct-loaded safety valves. The valve is opened by an edge calking operation.
the thrust from the fluid under pressure below the shutter, when
said thrust exceeds, under the calibrated conditions, the opposing
force of the spring acting on the shutter. SCOPE
Valves are identified by means of:
- a model number formed of an alphanumerical code that includes: Use: protection against possible overpressure of the apparatuses
- the family identity (for ex. 3061E/3) listed below, with regard to the operating conditions for which they
- the type of inlet connection (for ex. C = NPT) have been designed:
- the set pressure, expressed in bar, multiplied by 10 (for ex. 900) - Refrigeration system or heat pump components, for instance:
- an alphanumerical serial number condensers, liquid receivers, evaporators, liquid accumulators,
positive displacement compressor discharge, heat exchangers, oil
separators, or piping.
CONSTRUCTION (reference standard: EN 378-2:2016)
Fluids: the valves in series 3061E can be used with refrigerant
Body: squared, obtained through hot moulding and subsequent fluid R744 in vapour or gaseous state, belonging to Group 2 with
machining. It houses the following elements: reference to Article 13, Para. 1(b) of Directive 2014/68/EU (EC
- the nozzle with flat sealing seat Regulation No. 1272/2008).
- the shutter guide
- the set spring slot
- the threaded seat of the setting adjustment ring nut MARKING
In the body, above the shutter guide, a small pressure relief hole
is provided through which the spring slot communicates with the In compliance with the provisions of Article 19 of Directive 2014/68/EU,
exit connection. For this reason, during relief, there is a no gas leak the following information is cast on the valve body:
through this orifice. - Manufacturer’s mark
Material used: EN 12420-CW617N brass - Country of manufacturing
Shutter: obtained through machining from bar stock and fit with - Indication of flow direction
gasket, it ensures the required degree of tightness on the valve - Maximum allowable pressure
seat. The gasket is made from PTFE 50% stainless steel filled, a - Valve model
material that, during the valve’s estimated service life, maintains - Serial number
good strength and does not cause the shutter to stick on the seat. - Set pressure
The shutter is properly guided in the body and the guide action - Allowable temperature range
cannot fail. There are no glands or retaining rings that hamper its - Kd discharge coefficient
movement. - Flow section
Material used: EN 12164-CW614N brass - Production date
Spring: it opposes the pressure and the fluid dynamic forces, - CE marking
and always ensures closing of the valve following pressure relief. - Identification number of the notified body involved in the production
When the shutter has reached the maximum height determined control phase
by the mechanical stop, the spring compression does not exceed
80% of the total compression. All the springs are compliant with
the compression helical spring requirements defined in EN ISO
4126-7:2013.
DOCUMENTATION
Material used: EN 10270-2 - FD steel for springs.
The safety valves in series 3061E are supplied with the following
Calibration system: hex-head threaded ring nut to be screwed
documentation provided in the packaging:
inside the upper portion of the head, compressing the spring

4.23
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 4.24
GOGREEN HANDBOOK - 2023
 - operating instructions for the user, containing all information vessel and safety valve) or the downstream line (between safety
useful for safety in terms of assembly, commissioning, use, and valve and atmosphere) refer to Chapter 4.7 “Selection Criteria for
maintenance. Safety Valves” in this technical handbook.
- Declaration of Conformity for the equipment according to Directive
2014/68/EU, required in Article 17 and issued in compliance with
Annex IV of the same directive.
- Calibration certificate for the safety valve, printed on the reverse
side of the Declaration of Conformity.
N.B.: on the website: www.castel.it use the “DOWNLOAD” pull-
down menu to access the web-page PRODUCT “CERTIFICATION”
in the “DOWNLOAD CENTER”. On this page, you can download:
- the Declaration of Conformity / Calibration Certificate for each
valve by entering the 7-digit alphanumeric serial number. (SEARCH
BY SERIAL NUMBER)
- the general Declaration of Conformity referring to a specific model
of valve 3061E with a specific setting, for ex. 3061E/2C1100 or
3061E/4C950. (SEARCH BY PRODUCT CODE)

VALVE SELECTION
Directive 2014/68/EU requires that pressure equipment, in which
permissible limits are reasonably likely to be exceeded, shall be
fitted with suitable protection devices, for instance safety devices
such as safety valves. Such devices shall prevent pressure from
permanently exceeding the maximum allowable pressure (PS) of the
equipment they protect. In any case, a short pressure peak limited
to 10% of maximum allowable pressure is permitted.
As to the selection and sizing of the suitable protection device, users
shall refer to the specific product and sector standards listed below:

- EN ISO 4126-1: 2013: “Safety devices for protection against

excessive pressure – Part 1: Safety valves” indicates the general
requirements for safety valves regardless of the fluid for which
they were designed.
- EN 378-2:2016 “Refrigerating systems and heat pumps – Safety
and environmental requirements – Part 2: Design, construction,
testing, marking and documentation” provides a general outline of
the protection devices to be used in refrigerating systems and their
characteristics (Para. 6.2.5) and the criteria for the selection of the
device suitable for the type and size of the system component to
be protected (Para. 6.2.6).
- EN 13136:2013+A1: “Refrigerating systems and heat pumps –
Pressure relief devices and their associated piping – Methods for
calculation” highlights the possible causes of overpressure in a
system and provides users with the tools for sizing pressure relief
devices, among which safety valves.

To select the safety valves in series 3061E, please see Chapter 4.7
“Selection Criteria for Safety Valves” in this technical handbook.

VALVE INSTALLATION
Safety valves type 3061E guarantee repeatable performance.
This means that, after the valves have operated, open/close,
the initial setting conditions are maintained. Nevertheless, it
is advisable to replace a 3061E valve once it has discharged as
during release debris, such as metal shavings or solder impurities,
can deposit on the valve gasket. This can inhibit the safety valve
from returning to its original conditions.
To calculate the pressure loss in either the upstream line (between

4.25
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TABLE 11 : GENERAL CHARACTERISTICS OF VALVES 3061E

Catalogue Number 3061E/2C 3061E/3C 3061E/4C

Inlet male 1/4” NPT 3/8” NPT 1/2” NPT

Connections
Outlet male 3/8” G 1/2” G 1/2” G

Inlet connection wrench torque (min/max) [Nm] 15/20 17/22 25/35

Flow Diameter [mm] 4,5 4,5 4,5

Flow Section [mm2] 15,9 15,9 15,9

Lift [mm] - - -

Discharge Coefficient “Kd” 0,90 0,90 0,90

PS [bar] 165

TS [°C] - 50 / + 150
Set Pressure Range at atmospheric back pressure
60 / 150
Pset [bar]
Overpressure + 10 % of Pset

Blowdown - 30 % of Pset

- 20 % of Pset (60 bar < Pset < 90 bar)

Helium tightness - 15 % of Pset (91 bar < Pset < 120 bar)

- 10 % of Pset (121 bar < Pset < 150 bar)

Estimated service life 9 years

Risk Category according to PED Recast IV

TABLE 12: DIMENSIONS AND WEIGHTS OF VALVES 3061E

Dimensions [mm]
Catalogue Number Weight [g]
ØD L Ch H1 H2 H3

3061E/3C 28,5 33,5 23 30 61 91 200

3061E/3C 28,5 33,5 23 30 61 91 230

3061E/4C 28,5 33,5 23 35 61 96 260

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GOGREEN HANDBOOK - 2023
 CHAPTER 4

SAFETY DEVICES
4.7 – SELECTION CRITERIA FOR SAFETY VALVES

CALCULATION OF THE DISCHARGE suction pressure and discharge pressure equivalent to the safety
valve setting.
CAPACITY (REF. EN 13136:2013+A1)
– Excessive pressure caused by expansion of trapped liquid
The calculation of the minimum discharge capacity is linked to the (Para. 6.4 - EN 13136:2013+A1).
system configuration on which the safety valve is installed, and to For protection against pressure caused expansion of trapped liquid,
the cause of the safety valve opening, i.e.: the effective area of the pressure valve shall be calculated based
on volume of the trapped liquid:
– External heat sources (Para. 6.2.1 - EN 13136:2013+A1).
The minimum required discharge capacity is determined by the = × [mm2]
following formula:
where:
[kg/h] - Kvolume = 0,04 [mm2 /l]
- Aeffective = if calculating this area the flow diameter is less than
1 mm, then the diameter must be selected to 1 mm
where:
- φ = density of heat flow rate, assumed to be 10 [kW/m2] and the effective area of the pressure valve is defined as:
- Asurf = external surface area of the vessel [m2]
- hvap = latent heat of vaporization of liquid at po = 1,1 x pset
[mm2]
[kJ/kg]
– If po is higher that the saturated pressure of the
refrigerant at critical temperature minus 5 °K, then hvap
shall be taken at critical temperature minus 5 °K S IZ ING OF SA FE T Y VA LV ES
– If the temperature at po is higher than the saturated DESIGNED TO DISCHARGE GAS
temperature (superheated gas), then hvap shall be taken
at saturated condition OR VAPOUR AT CRITICAL FLOW
Note: vessels only containing refrigerant in the gas phase do not (REF. EN ISO 4126-1: 2013 AND EN
produce a continuous mass flow under an external hear impact.
13136 :2013+A1)
Critical flow occurs when the back-pressure pb (the pressure
– Internal heat sources (Para. 6.2.2 - EN 13136:2013 + A1).
existing immediately at the outlet of the valve) is lower than or
The minimum required discharge capacity is determined by the
equal to the critical pressure:
following formula:

[kg/h] [bar abs]

where Qh = rate of heat production [kW] where:

– po = actual relieving pressure, upstream the valve. It’s equal to
– Increased pressure caused by a positive displacement the set pressure plus overpressure; that is, the pressure increase
compressor (Para. 6.3 - EN 13136:2013+A1). The minimum over the set pressure at which the shutter has its total lift [bar abs]
required discharge capacity is determined by the following formula: – k = isentropic exponent of gas or vapour, based on the actual
temperature and pressure conditions upstream of the valve during
[kg/h] the discharge phase under full glow.

where: If k is unknown or difficult to determine, it is possible to assume:

– V = theoretical displacement of compressor [m3]
[bar abs]
– n = rotational frequency of compressor [min–1]
– ρ0 = 97,6 [kg/m3]. Vapour density of R744, from the saturation
curve at a temperature of 0 °C [kg/m3]. A valve that discharges to the atmosphere, is under in critical flow
– ηv = volumetric efficiency of the compressor, estimated at conditions.

4.27
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 4.28
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 – Vessels joined by piping, of a diameter deemed by the
To calculate the flow rate of a safety valve designed to discharge gas manufacturer and the user to be adequate, without any stop
or vapour at critical flow, under specific operating conditions, use the valves between them, may be considered as a single vessel for
following formulas, provided in Para. 7.2.5.2 of EN 13136:2013+A1. the installation of a safety valve.

[kg/h] – The fitting between the valve and the equipment to be protected
must be as short as possible. Furthermore, the cross-section of
the piping must not be smaller than the valve inlet. In any case,
where: EN 13136:2013+A1 states that the pressure drop between the
– Qm = calculated mass flow rate of safety valve [kg/h] protected vessel and the safety valve, at discharge capacity, shall
– A = calculated flow area of the safety valve [mm2] not exceed 3% of the setting value, po, including any accessory
– Kd = certified discharge ratio of safety valve on the line.
– po = actual pressure upstream of the safety valve during
discharge of the entire flow, see definition above. [bar abs] – The location selected for installation of the safety valve must
– vo = specific volume of gas or vapour at discharge conditions consider that valve operation involves the discharge of the refrigerant
po and To, where To is the fluid temperature at valve inlet, defined fluid under pressure, sometimes at high temperature. Where there
by the user or by the designer [m3/kg] is the risk of causing injuries to people nearby, exhaust piping
– C = expansion rate as a function of the k coefficient in the must be provided, sized so as to not compromise valve operation.
isentropic equation calculated with the following formula: EN 13136:2013+A1 states that this piping must not generate, at
discharge capacity, a back-pressure exceeding 10% of pressure
po , for unbalanced, conventional valves. NB: If exhaust piping
is indispensable, minimize both the length and the number
of elbows; the discharge of carbon dioxide at temperatures
below the triple point may result in the formation of solid
for this calculation, the value of kR744 = 1,3 and C = 2,63 referring carbon dioxide (carbonic snow) that could block exhaust
to a temperature of 25 °C. (Para. 7.2.3, EN 13136:2013+A1 pipes that are too long or too curvy. In the event of multiple
standard). valves installed in parallel, it is highly recommended that each valve
be fit with a dedicated exhaust line rather than a single manifold
for all of the valves. The risk of the latter solution is to create an
If overpressure in the manifold determined when a valve discharges.
This overpressure can modify the operating characteristics of all
the other valves installed in parallel.
If

where: Pressure losses in the upstream line

– Qmd’ = adjusted discharge capacity of safety valve, used for
pressure drop calculation [kg/h] To calculate the pressure losses in the upstream line (between
vessel and safety valve) refer to Section 7.4 of EN 13136:2013+A1.
The flow area Ac is calculated from the adjusted discharge capacity The upstream pressure loss is given by:
Qmd’ as follows:

[mm2] [bar]

where:
– Ac = calculated flow area from the minimum required discharge
capacity Qmd’ [mm2]
INSTALLATION OF A SAFETY VALVE – Ain = cross-section area of inlet tube to valve [mm2]
(REF. EN 13136:2013+A1) – Kdr = Kd x 0.9 , reduced discharge coefficient
– C = expansion rate as a function of the k coefficient in the
isentropic equation for the refrigerant fluid
As far as the installation of safety valves is concerned, remember – ξ = sum of the of pressure loss coefficients ξn of the individual
these basic points: components and piping
The coefficients ξn refer to:
– Safety valves must be installed near an area of the system where – pipe element losses, such as fittings and elbows
vapours or gases are present and where there is no fluid turbulence. – valve losses
They must be placed in as close to an upright position as possible, – losses along the piping
with the inlet connector turned downwards. and are listed in standard EN 13136:2013+A1, Table A.4.

4.29
HANDBOOK - 2023
To ensure correct operation of safety valve

[bar]

Pressure losses in the downstream line

To calculate the pressure losses in the downstream line

(between safety valve and atmosphere) refer to Section 7.4 of EN
13136:2013+A1. [kg/h]
The downstream pressure loss is given by:
[bar] where:
- Kd = 0,97 , certified discharge ratio of safety valve 3030E/46
- A = 38,5 [mm2] , flow area of the safety valve 3030E/46
- vo = 0,00323 [m3/kg] , specific volume of the superheated vapour
upstream of the safety valve during operation. This value refers to
[bar abs] the following operating conditions upstream of the valve:
- Pressure, po = 133 [bar abs]
where: - Temperature, To = 89,1 [°C]
– P1 = inlet pressure to discharge line [bar abs]
– P2 = outlet pressure to discharge line, equal to atmospheric
pressure [bar abs] The adjusted discharge capacity of the safety valve, used for
– Ac = calculated flow area from the minimum required discharge pressure drop calculation is:
capacity Qmd’ [mm2]
– Aout = cross-section area of valve outlet pipe [mm2]
– Kdr = Kd x 0.9 , reduced discharge coefficient
– C = expansion rate as a function of the k coefficient in the
[kg/h]
isentropic equation for the refrigerant fluid
– po = actual pressure downstream of the safety valve during
discharge of the entire flow [bar abs]. The flow area Ac calculated with the adjusted discharge capacity
– ξ = sum of the of pressure loss coefficients ξn of the piping Qmd’ is:
The coefficients ξn refer to:
– pipe element losses, bends
– losses along the piping
and are listed in standard EN 13136:2013+A1, Table A.4..

To ensure correct operation of safety valve

[bar]

EXAMPLE: Calculation of the flow rate (Qmd’) and selection

of the safety valve (Increased pressure caused by a positive
displacement compressor)
Verification of the system upstream the safety valve
Compressor data
Assuming the valve installed is 3061/4C280, using a steel fitting
- Refrigerant fluid R744
with the following characteristics:
- Discharge pressure 98,6 bar
– din = 17 [mm] , fitting inside diameter
- Discharge temperature 89,1 °C
– Ain = 227 [mm2] fitting inside cross-section area
- Number of compressors 5
– L = 60 [mm] , fitting length
- Required discharge capacity 2713 kg/h
– Manifold connection: Flush with the housing and with a sharp
edge
The safety valve is installed on the discharge manifold of the
The following data is taken from Table A.4 in standard EN
compressors.
13136:2013+A1:
The PS of this manifold is 120 bar; then the set pressure of the
– ξ1 (inlet) = 0,25
safety valve must be: pset = 120 bar
– ξ2 (length) = λ x L/ din = 0,02 x 60/17 = 0,07
with λ = 0.02 for steel pipe
[bar abs] – ξT = ξ1 + ξ2 = 0,25 + 0,07 = 0,32
Between the safety valve and the steel fitting, a shut-off valve type
Choosing a safety valve in series 3030E/46 its mass flow rate is: 3064E/44 is installed.
The main characteristics of this valve are:

4.30
GOGREEN HANDBOOK - 2023
 – dR = 13 [mm] , inside valve diameter
– A R = 132.7 [mm2], inside valve cross-section area
– kv = 10 [m3/h] , valve kv coefficient
The pressure loss coefficient ξR of the shut-off valve is given by:

Total loss coefficient: ξT + ξR = 0,77

Recalling the previously calculated flow area Ac , the characteristics

of safety valve 3030E/46 and refrigerant fluid R744:
– Ac = 30,8 [mm2]
– Kdr = 0,97 x 0,9 =0,873
– C = 2,63

The pressure loss is given by:

The pressure loss value obtained is admissible because it is lower

than the value of 0.03 indicated in standard EN 13136:2013+A1.

Verification of system downstream the safety valve

Suppose it is necessary to construct a discharge pipe on safety

valve 3030E/46C120, using 1” gas pipe with the following
characteristics:
– dout = 30 [mm] , inside pipe diameter
– Aout = 707 [mm2] , inside pipe cross-section area
– L = 3000 [mm] , pipe length
– 90° elbow with bending radius, R, equal to three times external
diameter of pipe

The following information is taken from Table A.4 in standard EN

13136:2013+A1:
– ξ1 (elbow) = 0.25
– ξ2 (length) = λ x L/ dout = 0.02 x 3000/30 = 2 where λ = 0.02
for steel pipe
– ξT = ξ1 + ξ2 = 0,25 + 2 = 2,25

The pressure loss is given by:

The pressure loss value obtained is admissible because it is lower

than the value of 0.10 indicated in standard EN 13136:2013+A1.

4.31
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TABLE 13: MAXIMUM DISCHARGE CAPACITY OF VALVES

R744 subcritical Safety valves

Pset Po Tosat Vosat

3030/44-66 3030/88 3060/23-33 3060/24-34 3060/45 3060/36 3060/46 3061/2-/3-/4 3065/4-/6
[bar] [barsass] [°C] [mc/kg]
11,0 13,1 -32,5 0,029 1465 3563 349 383 459 1040 1052 567 1663
12,0 14,2 -30,2 0,027 1588 3863 379 415 498 1128 1140 614 1803
13,0 15,3 -27,9 0,025 1713 4165 408 447 537 1216 1229 662 1944
14,0 16,4 -25,8 0,023 1837 4468 438 480 576 1305 1319 711 2086
15,0 17,5 -23,8 0,022 1962 4773 468 513 616 1394 1409 759 2228
16,0 18,6 -21,8 0,021 2088 5079 498 545 655 1483 1499 808 2371
17,0 19,7 -20,0 0,019 2215 5387 528 578 695 1573 1590 857 2514
18,0 20,8 -18,2 0,018 2342 5697 559 612 735 1663 1681 906 2659
19,0 21,9 -16,5 0,017 2470 6008 589 645 775 1754 1773 956 2804
20,0 23,0 -14,9 0,016 2599 6322 620 679 815 1846 1866 1005 2951
21,0 24,1 -13,3 0,016 2729 6637 651 713 856 1938 1959 1056 3098
22,0 25,2 -11,7 0,015 2860 6955 682 747 897 2031 2053 1106 3246
23,0 26,3 -10,2 0,014 2991 7274 713 781 938 2124 2147 1157 3395
24,0 27,4 -8,8 0,014 3123 7596 745 816 980 2218 2242 1208 3546
25,0 28,5 -7,4 0,013 3257 7921 777 851 1022 2313 2338 1260 3697
26,0 29,6 -6,0 0,012 3391 8248 809 886 1064 2408 2434 1312 3850
27,0 30,7 -4,7 0,012 3527 8577 841 921 1106 2504 2531 1364 4004
28,0 31,8 -3,4 0,011 3663 8909 874 957 1149 2601 2630 1417 4159
29,0 32,9 -2,2 0,011 3801 9245 906 993 1192 2699 2728 1470 4315
30,0 34,0 -0,9 0,011 3940 9583 940 1029 1236 2798 2828 1524 4473
31,0 35,1 0,3 0,010 4080 9924 973 1066 1280 2898 2929 1578 4632
32,0 36,2 1,4 0,010 4222 10268 1007 1103 1324 2998 3030 1633 4793
33,0 37,3 2,6 0,009 4365 10616 1041 1140 1369 3100 3133 1688 4955
34,0 38,4 3,7 0,009 4509 10967 1075 1178 1414 3202 3237 1744 5119
35,0 39,5 4,8 0,009 4655 11322 1110 1216 1460 3306 3342 1801 5285
36,0 40,6 5,9 0,008 4803 11681 1145 1254 1506 3411 3447 1858 5452
37,0 41,7 6,9 0,008 4952 12043 1181 1293 1553 3517 3554 1916 5621
38,0 42,8 8,0 0,008 5103 12411 1217 1333 1601 3624 3663 1974 5793
39,0 43,9 9,0 0,008 5256 12782 1253 1373 1649 3732 3773 2033 5966
40,0 45,0 10,0 0,007 5411 13159 1290 1413 1697 3842 3884 2093 6142
41,0 46,1 11,0 0,007 5567 13540 1328 1454 1746 3954 3996 2154 6320
42,0 47,2 11,9 0,007 5727 13927 1365 1496 1796 4067 4110 2215 6501
43,0 48,3 12,9 0,007 5888 14320 1404 1538 1847 4181 4226 2278 6684
44,0 49,4 13,8 0,006 6052 14719 1443 1581 1898 4298 4344 2341 6870
45,0 50,5 14,7 0,006 6219 15124 1483 1624 1951 4416 4464 2405 7059
46,0 51,6 15,6 0,006 6388 15536 1523 1668 2004 4536 4585 2471 7252
47,0 52,7 16,5 0,006 6561 15956 1564 1713 2058 4659 4709 2538 7448
48,0 53,8 17,3 0,006 6737 16384 1606 1759 2113 4784 4835 2606 7647
49,0 54,9 18,2 0,006 6916 16820 1649 1806 2169 4911 4964 2675 7851
50,0 56,0 19,0 0,005 7100 17266 1693 1854 2227 5042 5096 2746 8059
51,0 57,1 19,9 0,005 7287 17723 1738 1903 2286 5175 5231 2819 8273
52,0 58,2 20,7 0,005 7480 18191 1784 1953 2346 5312 5369 2893 8491
53,0 59,3 21,5 0,005 7678 18672 1831 2005 2408 5452 5511 2970 8716
54,0 60,4 22,3 0,005 7881 19168 1879 2058 2472 5597 5657 3049 8947
55,0 61,5 23,0 0,005 8092 19679 1929 2113 2538 5746 5808 3130 9186
56,0 62,6 23,8 0,004 8310 20209 1981 2170 2606 5901 5965 3214 9433
57,0 63,7 24,6 0,004 8536 20760 2035 2229 2677 6062 6127 3302 9690
58,0 64,8 25,3 0,004 8773 21336 2092 2291 2752 6230 6297 3394 9959
59,0 65,9 26,0 0,004 9022 21942 2151 2356 2830 6407 6476 3490 10242
60,0 67,0 26,8 0,004 9286 22585 2214 2425 2913 6594 6666 3592 10542

4.32
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 TABLE 14: MAXIMUM DISCHARGE CAPACITY OF VALVES 3030E/36 AND 3030E/46 [KG/H]

Gas-cooler outlet temperatures Compressor discharge temperatures

Pset Po
[bar] [barsass] T= T= T= T= T= T= T= T= T= T= T= T= T= T= T= T= T= T= T= T=
20 °C 25 °C 30 °C 31 °C 35 °C 40 °C 45 °C 80 °C 85 °C 90 °C 95 °C 100 °C 105 °C 110 °C 115 °C 120 °C 125 °C 130 °C 135 °C 140 °C

60,0 67,0 2935 2810 2715 2347 2313 2281 2251 2223 2197 2172 2148 2125 2104 2083 2063 2045

65,0 72,5 3382 3171 3035 2571 2530 2493 2459 2426 2396 2367 2340 2314 2290 2267 2244 2223

70,0 78,0 6461 6249 5906 5790 4097 3609 3394 2801 2753 2710 2670 2633 2598 2566 2535 2506 2478 2452 2427 2403

75,0 83,5 6722 6526 6247 6170 5635 4204 3814 3037 2982 2932 2886 2843 2804 2767 2732 2700 2669 2639 2612 2585

80,0 89,0 6975 6789 6544 6482 6150 5145 4332 3281 3217 3159 3106 3058 3013 2971 2932 2896 2861 2829 2798 2768

85,0 94,5 7219 7042 6818 6765 6502 5932 4991 3533 3459 3392 3331 3276 3226 3179 3135 3095 3056 3020 2986 2954

90,0 100,0 7457 7286 7078 7030 6803 6389 5688 3793 3707 3630 3561 3499 3442 3390 3341 3296 3254 3214 3176 3140

95,0 105,5 7688 7523 7326 7281 7078 6738 6225 4062 3961 3874 3796 3726 3662 3604 3550 3500 3453 3409 3368 3329

100,0 111,0 7914 7753 7564 7522 7335 7040 6631 4338 4223 4123 4035 3957 3886 3821 3761 3706 3654 3606 3561 3519

105,0 116,5 8134 7977 7795 7756 7580 7314 6967 4623 4492 4379 4280 4192 4112 4041 3975 3914 3858 3806 3756 3710

110,0 122,0 8349 8195 8020 7982 7815 7570 7263 4916 4766 4639 4528 4430 4343 4263 4191 4125 4063 4006 3953 3903

115,0 127,5 8561 8409 8239 8202 8043 7813 7535 5214 5046 4904 4781 4672 4576 4489 4410 4338 4271 4209 4151 4097

120,0 133,0 8767 8618 8452 8416 8263 8045 7789 5516 5330 5173 5037 4918 4812 4717 4631 4552 4480 4413 4351 4293

125,0 138,5 8970 8823 8660 8626 8478 8270 8029 5820 5617 5445 5296 5165 5050 4947 4854 4769 4691 4618 4552 4489

130,0 144,0 9170 9024 8864 8830 8687 8487 8259 6124 5905 5718 5557 5415 5290 5179 5078 4986 4903 4825 4753 4687

135,0 149,5 9366 9222 9065 9031 8891 8698 8481 6423 6192 5992 5818 5667 5532 5412 5304 5206 5116 5033 4956 4885

140,0 155,0 9558 9416 9261 9228 9092 8905 8696 6716 6476 6265 6080 5918 5775 5646 5531 5426 5330 5241 5160 5084

145,0 160,5 9748 9606 9454 9422 9288 9106 8904 7002 6755 6535 6341 6170 6017 5881 5758 5646 5544 5451 5364 5284

150,0 166,0 9934 9794 9644 9612 9480 9303 9108 7278 7027 6801 6600 6420 6259 6115 5985 5867 5759 5660 5569 5484

R744 critical point: Pc = 73,8 bara ; Tc = 31,06 °C

4.33
HANDBOOK - 2023
TABLE 15: MAXIMUM DISCHARGE CAPACITY OF VALVES 3030E/410 AND 3030E/610 [KG/H]

Gas-cooler outlet temperatures Compressor discharge temperatures

Pset Po
[bar] [barsass] T = T= T= T= T= T= T= T= T= T= T= T= T= T= T= T= T= T= T= T=
20 °C 25 °C 30 °C 31 °C 35 °C 40 °C 45 °C 80 °C 85 °C 90 °C 95 °C 100 °C 105 °C 110 °C 115 °C 120 °C 125 °C 130 °C 135 °C 140 °C

60,0 67,0 6794 6504 6286 5434 5354 5281 5211 5147 5085 5028 4973 4920 4870 4823 4777 4733

65,0 72,5 7829 7342 7026 5951 5858 5771 5691 5616 5546 5480 5417 5358 5301 5247 5195 5146

70,0 78,0 14957 14466 13671 13403 9485 8354 7858 6483 6374 6274 6181 6095 6014 5939 5868 5801 5737 5676 5618 5563

75,0 83,5 15561 15107 14460 14284 13045 9733 8830 7031 6903 6787 6681 6582 6491 6405 6325 6249 6178 6110 6045 5984

80,0 89,0 16145 15717 15148 15006 14238 11910 10029 7596 7447 7313 7191 7079 6975 6879 6788 6704 6624 6548 6477 6409

85,0 94,5 16711 16302 15784 15660 15052 13731 11554 8179 8006 7852 7712 7585 7468 7359 7258 7164 7075 6992 6912 6837

90,0 100,0 17261 16867 16384 16273 15749 14789 13167 8781 8580 8403 8244 8100 7968 7847 7735 7630 7532 7439 7352 7270

95,0 105,5 17797 17415 16958 16855 16384 15598 14411 9402 9170 8968 8787 8625 8478 8342 8217 8101 7993 7892 7796 7706

100,0 111,0 18319 17947 17511 17414 16980 16296 15349 10043 9776 9545 9342 9159 8995 8845 8706 8579 8460 8348 8244 8146

105,0 116,5 18829 18465 18046 17954 17547 16930 16127 10702 10398 10136 9907 9703 9520 9354 9201 9061 8931 8809 8696 8589

110,0 122,0 19328 18971 18565 18477 18092 17524 16814 11379 11033 10738 10482 10256 10053 9870 9702 9549 9407 9274 9151 9035

115,0 127,5 19817 19466 19072 18986 18618 18086 17442 12069 11681 11352 11067 10816 10593 10391 10209 10041 9887 9743 9610 9484

120,0 133,0 20295 19950 19565 19483 19129 18624 18030 12770 12339 11974 11660 11384 11139 10919 10720 10538 10371 10216 10071 9937

125,0 138,5 20765 20425 20048 19968 19625 19143 18586 13474 13003 12604 12259 11958 11691 11452 11236 11039 10858 10691 10536 10392

130,0 144,0 21227 20890 20520 20441 20110 19647 19119 14176 13670 13237 12863 12536 12247 11988 11755 11543 11349 11170 11004 10849

135,0 149,5 21680 21347 20984 20907 20582 20136 19633 14869 14333 13871 13469 13118 12806 12528 12278 12050 11842 11651 11473 11308

140,0 155,0 22126 21797 21438 21363 21046 20613 20130 15548 14990 14502 14076 13700 13368 13070 12803 12560 12338 12133 11945 11769

145,0 160,5 22565 22238 21885 21810 21500 21079 20613 16208 15636 15128 14679 14282 13929 13613 13329 13070 12834 12618 12417 12231

150,0 166,0 22997 22672 22324 22250 21946 21535 21083 16847 16268 15745 15277 14861 14490 14156 13855 13582 13332 13103 12891 12695

R744 critical point: Pc = 73,8 bara ; Tc = 31,06 °C

4.34
GOGREEN HANDBOOK - 2023
 TABLE 16: MAXIMUM DISCHARGE CAPACITY OF VALVES 3061E/2 , 3061E/3 AND 3061E/4 [KG/H]

Gas-cooler outlet temperatures Compressor discharge temperatures

Pset Po
[bar] [barsass] T = T= T= T= T= T= T= T= T= T= T= T= T= T= T= T= T= T= T= T=
20 °C 25 °C 30 °C 31 °C 35 °C 40 °C 45 °C 80 °C 85 °C 90 °C 95 °C 100 °C 105 °C 110 °C 115 °C 120 °C 125 °C 130 °C 135 °C 140 °C

60,0 67,0 891 853 825 713 702 693 684 675 667 659 652 645 639 633 627 621

65,0 72,5 1027 963 922 781 768 757 747 737 727 719 711 703 695 688 682 675

70,0 78,0 1962 1898 1793 1758 1244 1096 1031 850 836 823 811 799 789 779 770 761 753 745 737 730

75,0 83,5 2041 1982 1897 1874 1711 1277 1158 922 906 890 876 863 851 840 830 820 810 801 793 785

80,0 89,0 2118 2062 1987 1968 1868 1562 1316 996 977 959 943 929 915 902 890 879 869 859 850 841

85,0 94,5 2192 2138 2070 2054 1974 1801 1516 1073 1050 1030 1012 995 980 965 952 940 928 917 907 897

90,0 100,0 2264 2212 2149 2135 2066 1940 1727 1152 1126 1102 1081 1063 1045 1029 1015 1001 988 976 964 954

95,0 105,5 2334 2284 2224 2211 2149 2046 1890 1233 1203 1176 1153 1131 1112 1094 1078 1063 1049 1035 1023 1011

100,0 111,0 2403 2354 2297 2284 2227 2138 2013 1317 1282 1252 1225 1201 1180 1160 1142 1125 1110 1095 1081 1068

105,0 116,5 2470 2422 2367 2355 2302 2221 2115 1404 1364 1330 1299 1273 1249 1227 1207 1189 1171 1156 1141 1127

110,0 122,0 2535 2489 2435 2424 2373 2299 2206 1493 1447 1409 1375 1345 1319 1295 1273 1253 1234 1217 1200 1185

115,0 127,5 2599 2553 2502 2490 2442 2372 2288 1583 1532 1489 1452 1419 1389 1363 1339 1317 1297 1278 1261 1244

120,0 133,0 2662 2617 2566 2556 2509 2443 2365 1675 1619 1571 1529 1493 1461 1432 1406 1382 1360 1340 1321 1303

125,0 138,5 2724 2679 2630 2619 2574 2511 2438 1767 1706 1653 1608 1569 1534 1502 1474 1448 1424 1402 1382 1363

130,0 144,0 2784 2740 2692 2681 2638 2577 2508 1859 1793 1736 1687 1644 1606 1573 1542 1514 1489 1465 1443 1423

135,0 149,5 2844 2800 2753 2742 2700 2641 2575 1950 1880 1820 1767 1721 1680 1643 1611 1581 1553 1528 1505 1483

140,0 155,0 2902 2859 2812 2802 2761 2704 2640 2039 1966 1902 1846 1797 1753 1714 1679 1647 1618 1592 1567 1544

145,0 160,5 2960 2917 2871 2861 2820 2765 2704 2126 2051 1984 1926 1873 1827 1786 1748 1714 1684 1655 1629 1604

150,0 166,0 3017 2974 2928 2919 2879 2825 2766 2210 2134 2065 2004 1949 1901 1857 1817 1782 1749 1719 1691 1665

R744 critical point: Pc = 73,8 bara ; Tc = 31,06 °C

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 4.36
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 CHAPTER 4

SAFETY DEVICES
4.8 – BURSTING DISC DEVICES

GENERAL DESCRIPTION reference to Article 13, Para. 1(b) of Directive 2014/68/EU (EC
Regulation No. 1272/2008).
Bursting disc in series 3070 are considered “Safety Accessories”
according to the definition provided in Article 2, Point 4 of said
Directive and are subject to the classification indicated in Article MARKING
4, Point 1.d) of the same Directive. This device is a pressure relief
device that cannot be closed again, in which a bursting disc is In compliance with the provisions of Article 19 of Directive 2014/68/EU,
sensitive to a positive differential pressure between the upstream the following information is reported on the bursting disc holder:
and downstream sections. It is designed to burst at a specified - Manufacturer’s mark
pressure. - CE marking
Bursting discs in series 3070 are identified by means of: - Identification number of the notified body involved in the production
- a model number formed of an alphanumerical code that includes: control phase
- the family identity (for ex. 3070/44C) - device model
- the type of connection (C = NPT) - Flow section
- the burst pressure, expressed in bar, multiplied by 10 (for ex. 140) - Indication of flow direction
- a serial number for the lot production. - Bursting pressure
- Performance tolerances
- Temperature associated with bursting pressure
CONSTRUCTION - Production date
- Lot number
Bursting disc holder: this is the body of the device; it is
manufactured in two halves, screwed together, that hold the burst
disc in position. The two body halves are obtained through bar DOCUMENTATION
machining. The lower half of the body houses the inlet connection,
while the upper half houses the outlet connection and two 1/8” NPT The bursting disc devices in series 3070 are supplied with the
female service ports for installing a gauge or a pressure transducer. following documents, provided in the packaging:
If you don’t use these ports pay attention to close them with two - operating instructions for the user, containing all information
NPT plugs code 7520/1. useful for safety in terms of assembly, commissioning, use, and
Material used: EN 12164-CW614N brass maintenance.
Bursting discs: the discs are designed and tested, according to - Declaration of Conformity for the equipment according to Directive
the requirements of EN ISO 4126-2:2003, to burst at a pre-defined 2014/68/EU, required in Article 17 and issued in compliance with
pressure. This pressure is called specified burst pressure, and is Annex IV of the same directive.
related to an associated temperature and a burst tolerance. The disc
is manufactured from a calibrated gauge of nickel sheet, contained
by a copper ring case.
BURSTING DISC DEVICES
SELECTION
SCOPE Directive 2014/68/EU requires that pressure equipment, in which
permissible limits are reasonably likely to be exceeded, shall be
Use: protection against possible overpressure of the apparatuses
fitted with suitable protection devices, for instance safety devices
listed below, with regard to the operating conditions for which they
such as bursting disc devices. Such devices shall prevent pressure
have been designed:
from permanently exceeding the maximum allowable pressure (PS)
- Refrigeration system or heat pump components, for instance:
of the equipment they protect. In any case, a short pressure peak
condensers, liquid receivers, evaporators, liquid accumulators,
limited to 10% of maximum allowable pressure is permitted.
positive displacement compressor discharge, heat exchangers, oil
The bursting disc safety device 3070 may be used either as sole
separators, or piping.
pressure relief device or in conjunction with a Castel safety valve.
(reference standard: EN 378-2:2016)
The disc and valve combination prevent refrigerant leakage through
Fluids: bursting disc in series 3070 can be used with refrigerant
the safety valve and the total loss of refrigerant after bursting. The
fluid R744 in vapour or gaseous state, belonging to Group 2 with
disc and valve combination can be also equipped with a suitable

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 4.38
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 pressure switch to detect if the valve has discharged. conditions, use the following formulas, provided in Para. 7.2.5.2
The bursting pressure of a bursting disc is affected by the operating of EN 13136:2013+A1.
temperature of fluid contained in the equipment to be protected.
The specified bursting pressure (Pb), stamped on the body of the
bursting disc, is the nominal bursting pressure at the associated
temperature of 22 °C. At higher operating temperatures, the
nominal bursting pressure is reduced while at lower operating where:
temperatures, the nominal bursting pressure is increased. Refer - A = calculated flow area of the bursting disc [mm2]
to table 6 for temperature adjustment factors for Pb. - Kdr = bursting disc de-rated coefficient of discharge.
As to the selection and sizing of the suitable protection device, users The following values shall be the maximum used depending on how
shall refer to the specific product and sector standards listed below: the pipe between the vessel and the bursting disc is mounted on
the vessel (see tab A.4 of EN 13136:2013+A1):
- Standard EN ISO 4126-2: 2003: “Safety devices for protection - Flush or flare connection: Kdr = 0.70
against excessive pressure – Part 2: Bursting disc safety - Inserted connection: Kdr = 0.55
devices” specifies the design, manufacturing, inspection, testing, The evaluation of the minimum required discharge capacity of the
certification, marking and packaging requirements for bursting bursting disc device is closely linked to the type of system where
disc safety devices. the equipment it protects is installed, with the causes that may
cause it to burst, i.e.:
- EN ISO 4126-3:2006 Safety devices for protection against - external heat sources
excessive pressure – Part 3: Safety valves and bursting disc safety - internal heat sources
devices in combination” specifies the general requirements for - increased pressure caused by a positive displacement compressor
design, application and marking for a product assembled from the For the calculation of minimum required discharge capacity in these
in-series combination of a safety valve and bursting disc safety three cases see Chapter 4.7 “Selection Criteria for Safety Valves”
device. in this technical handbook.

- EN ISO 4126-6: 2003: “Safety devices for protection against

excessive pressure – Part 6: Application, selection and installation SIZING OF COMBINED SAFETY
of bursting disc safety devices” gives guidance on the application,
selection and installation of bursting disc safety devices used to DEVICES DESIGNED TO
protect against overpressure. DISCHARGE GAS OR VAPOUR
- EN 378-2:2016: “Refrigerating systems and heat pumps – safety AT CRITICAL FLOW (Ref. EN ISO
and environmental requirements – Part 2: Design, construction, 4126-3:2006)
testing, marking and documentation” provides a general outline of
the protection devices to be used in refrigerating systems and their A combination is an installation which includes a bursting disc
characteristics (Para. 6.2.5) and the criteria for the selection of the safety device installed at most five pipe diameters before the inlet
device suitable for the type and size of the system component to of a safety valve. The combination of a specific safety valve with a
be protected (Para. 6.2.6). bursting disc device is characterized by a combination discharge
capacity coefficient “Fd”. According to EN ISO 4126-3: 2006, this
- EN 13136:2013+A1: “Refrigerating systems and heat pumps – coefficient is the ratio of the average of the discharge coefficients
Pressure relief devices and their associated piping – Methods for (“Kd”) of the combination, measured in test bench flow rate tests,
calculation” highlights the possible causes of overpressure in a to the certified discharge coefficient (“Kd)” of the safety valve alone.
system and provides users with the tools for sizing pressure relief The same standard also permits, as an alternative to the tests to
devices, among which safety valves. determine “Kd” of the group, the use of a predefined discharge
coefficient (“Fd”), equal to 0.9, a slightly lower value than that which
could be obtained from testing. Therefore, to size the combination
SIZING OF BURSTING DISC of a safety valve with a bursting disc safety device (3070), please
follow the procedure provided in Chapter 4.3, but multiply the
DEVICES DESIGNED TO certified coefficient of discharge (“Kd”) by 0.9.
DISCHARGE GAS OR VAPOUR
AT CRITICAL FLOW (Ref. EN ISO
INSTALLATION OF BURSTING DISC
4126-6:2003)
DEVICES AND COMBINATIONS
A bursting disc safety device which discharges to atmosphere
works at critical flow. For the definition of critical flow, please see Bursting disc safety device 3070 must never be subjected to
Chapter 4.3. a negative pressure differential upstream and downstream
To calculate the discharge capacity of a bursting disc designed to of the disc (for example: discharge to the atmosphere and
discharge gas or vapour at critical flow, under specific operating pressure inside the equipment to be protected lower than that

4.39
HANDBOOK - 2023
of the atmospheric pressure) to avoid damaging or breaking
the disk. For this reason, safety device 3070 must always be
used along with a cut-off device (such as valve 3064N/44)
which can exclude device 3070 any time there is a vacuum
in the equipment to be protected.

When the bursting disc discharges it is necessary to replace

the entire unit, as safety devices 3070 are sealed components
and the bursting disc cannot be replaced.
The maximum operating pressure of the equipment to be
protected must not be greater than 75 % of the burst pressure
of device 3070 to avoid damages to the disc or leakage. If
the operating pressure exceeds 85 % of the burst pressure,
safety device 3070 must be replaced immediately.

As far as the installation of bursting disc safety devices and

combined devices is concerned, remember these basic points:
- Safety devices must be installed in an area of the system where
vapours or gases are present and there is no fluid turbulence.
- Vessels joined by piping, of a diameter deemed by the manufacturer
and the user to be adequate, without any stop valves between them,
may be considered as a single vessel for the installation of a safety
device.
- The fitting between the combined device and the equipment
to be protected must be as short as possible. Furthermore, the
cross-section of the piping must not be smaller than the valve
inlet. In any case, EN 13136:2013+A1 states that the pressure
drop between the protected vessel and the combined device, at
discharge capacity, shall not exceed 3% of the pressure setting
value, including any accessories in the line.
- The location selected for installation of the safety device must
consider that its operation involves the discharge of the refrigerant
fluid under pressure, sometimes at high temperature. Where there is
the risk of causing injuries to people nearby, exhaust piping must be
provided, sized so as to not compromise the operation of the device.
When installing combined devices, EN 13136:2013+A1 requires
that this piping must not generate, at discharge capacity, a back-
pressure exceeding 10% of the valve setting pressure. In the event
of multiple valves installed in parallel, it is highly recommended
that each valve be fit with a dedicated exhaust line rather than a
single manifold for all of the valves. The risk of the latter solution
is to create an overpressure in the manifold determined when
a valve discharges. This overpressure can modify the operating
characteristics of all the other valves installed in parallel.

To calculate the pressure loss in either the upstream line (between

vessel and safety device) or the downstream line (between safety
device and atmosphere) refer to Chapter 4.7 “Selection Criteria for
Safety Valves” in this technical handbook.

4.40
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 TABLE 17: GENERAL CHARACTERISTICS OF RUPTURE DISCS 3070

Catalogue Number 3070/44

Inlet male 1/2” NPT

Connections Outlet female 1/2” NPT

Service 2 x 1/8” NPT

Inlet connection wrench torque (min/max) [Nm] 21/30

Flow Diameter [mm] 12

Flow Section [mm2] 113

TS [°C] - 50 / + 150

14,0
15,0
16,0
19,0
21,0
23,0
24,0
24,8
Bursting Pressure Pb [bar]
25,0
27,0
27,5
28,0
37,0
44,0
47,0
52,0

from 14 up to 19 bar +/- 15 %

Pb tolerance
from 21 up to 44 bar +/- 10%

Coincident temperature Ta [°C] 22

-50 °C 1,13
-35 °C 1,12
-25 °C 1,10
-10 °C 1,03
-0 °C 1,03
Correction factor of Pb
22°C 1,00
for Ta ≠ 22 °C
40°C 0,99
60 °C 0,97
80 °C 0,95
100 °C 0,94
150 °C 0,93

Max operating pressure 75 % Pb

Risk Category according to PED Recast IV

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 4.42
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 CHAPTER 4

SAFETY DEVICES
4.9 – CHANGEOVER VALVES

APPLICATIONS and superheated vapour discharge conditions.

The main parts of the valves in series 3032E are made from the
Changeover valves in series 3032E perform the role of a service following materials:
valve for a pair of safety valves, allowing the use of one and the - Hot forged brass EN 12420 – CW 617N for the body
exclusion of the other. This device allows the user to work on the - Steel, with proper surface protection, for the spindle.
isolated valve, for periodic inspection or replacement, while the line - Ethylene propylene rubber (EPDM) for outlet seal gaskets
is completely operative and the system safety is integral. - Glass reinforced PBT for the protective cap that covers the spindle.
N.B.: each safety valve located on the changeover valve must have - Hot forged steel EN 12420 – CW 617N for the protective cap of
sufficient capacity to protect the vessel alone. the spindle for models from 1” to 1-1/4” NPT.
These valves are considered “Pressure Accessories” according to
the definition provided in Article 2, Point 5 of said Directive and
are subject to the classification indicated in Article 4, Points 1.c)
and 3 of the same Directive.

Valves models 3032E/33 are supplied with:

- Two female 3/8” NPT threaded connections with swivel nut,
Castel code 3039/3
- Two O-Rings for these connections
These components ensure perfect alignment of a pair of safety
valves.

Valves models 3032E/44 are supplied with:

- Two female 1/2” NPT threaded connections with swivel nut,
Castel code 3039/4
- Two O-Rings for these connections
These components ensure perfect alignment of a pair of safety
valves.

Valves models: 3032E/64, 3032E/64L, 3032E/66, 3032E/66L,

3032E/88, 3032E/108 have not threaded connections with swivel
nuts on the outlet connection. Therefore, safety valves are screwed
directly onto the changeover valve.
NB: the safety valves 3030E/410C must be mounted on the
changeover valve 3032/64L and the safety valves 3030E/610C
must be mounted on the changeover valve 3032/66L.

The valves in series 3032E can be used only with refrigerant fluid
R744.

CONSTRUCTION
Valves in series 3032E are designed so that it is never possible
to exclude both safety valves simultaneously. Under working
conditions, the shutter must be clamped against one of the two
seats of the valve, front port or back port, in order to ensure
always full discharge to the corresponding safety valve. Intermediate
shutter positions must be avoided in order not to affect the operation
of both safety valves. The valve ensures a pressure drop perfectly
compatible with the safety valve operation under saturated vapour

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4.45
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TABLE 18: GENERAL CHARACTERISTICS, DIMENSIONS AND WEIGHTS OF VALVES 3032E

Kv TS [°C] Dimensions [mm] Inlet connection Risk Category

Catalogue PS Weight
Factor wrench torque according to
Number [bar] [g]
[m3/h] min max D A B H1 H2 L1 L2 L3 (min/max) [Nm] PED Recast

3032E/33 2,5 13 3/8” NPT 3/8” NPT 114 42 33 91 50 17/22 775

3032E/44 3,3 13 1/2” NPT 1/2” NPT 114 42 33 91 50 25/35 775

3032E/64 17,5 3/4” NPT 1/2” NPT 95 52 48 133 80 32/45 1750

9,0 150
3032E/64L 17,5 3/4” NPT 1/2” NPT 95 52 78 133 110 32/45 1770
-40 150 Art. 4.3
3032E/66 17,5 3/4” NPT 3/4” NPT 95 52 48 133 80 32/45 1730
9,0
3032E/66L 17,5 3/4” NPT 3/4” NPT 95 52 78 133 110 32/45 1750

3032E/88 14,5 22,0 1” NPT 1” NPT 120 71 66 185 110 50/65 3200
120
3032E/108 20,0 31,0 1.1/4” NPT 1” NPT 123 74 66 185 110 60/80 3200

4.46
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 CHAPTER 4

SAFETY DEVICES
4.10 – SHUT-OFF VALVES

APPLICATIONS CONSTRUCTION
Please remember that the operation of pressure equipment and Valves in series 3064E are supplied by Castel in the open position
pressure assemblies is not covered by Directive 2014/68/EU ; and the spindle cap protection is sealed with a Castel lead seal.
rather, it is regulated by the national legislation of the Member Any operation to close the valve requires causes the tampering with
States of the European Union. Therefore, the various Member the seal and must be performed exclusively by:
States have issued laws that call for periodic inspection of pressure - staff authorized to work on the system
equipment and pressure assemblies. Italy issued Ministerial Decree - an operator of a competent inspection body
329 dated 01/12/2004 regarding the provisions for the installation These persons will be responsible for the subsequent re-opening
and use of pressure equipment and pressure assemblies that of the valve and the application of a new cap seal with their own
comply with Directive 97/23/EC. Any intervention for periodic lead seal.
inspection or replacement of an installed safety device becomes The main parts of the valves in series 3064E are made from the
very difficult if the protected vessel is not equipped with a shut-off following materials:
valve. - Hot forged brass EN 12420 – CW 617N for the body
Shut-off valves in series 3064E installed between the protected - Hot forged brass EN 12420 – CW 617N, chromium plated, for
vessel and the safety valve, allow the device to be disassembled the ball
for inspection or replacement without blowing off all the refrigerant - Steel, with proper surface protection, for the spindle.
fluid from an entire section of the system. - P.T.F.E. for the ball seat gaskets
These valves are considered “Pressure Accessories” according to - Ethylene propylene rubber (EPDM) for outlet seal gaskets
the definition provided in Article 2, Point 5 of said Directive and - Hot forged brass EN 12420 – CW 617N for the protective cap
are subject to the classification indicated in Article 4, Points 1.c) of the spindle
and 3 of the same Directive.
The valves in series 3032E can be used only with refrigerant fluid
R744.

TABLE 19: GENERAL CHARACTERISTICS, DIMENSIONS AND WEIGHTS OF VALVES SERIES 3064E

Kv TS [°C] Dimensions [mm] Inlet connection Risk Category

Catalogue
Factor PS [bar] wrench torque Weight [g] according to PED
Number
[m3/h] min max ØD A C L H1 H2 H3 (min/max) [Nm] Recast

3064E/22 2,5 7 1/4” NPT 47 32 45 74 147 15/20 216

3064E/33 5 150 10 3/8” NPT 47 32 45 74 147 17/22 208

-40 +150 Art. 4.3
3064E/44 10 13 1/2” NPT 54 35 51 86 165 25/35 334

3064E/88 20 80 20 1” NPT 78 52 70 119 323 50/65 871

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 4.48
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 CHAPTER 4

SAFETY DEVICES
4.11 – FITTING

The fittings in series 3035 allow for the installation of:

- safety valves in series 3030, 3060, 3061, 3065, 3030E and
3061E
- bursting disc devices in series 3070
- shut-off valves in series 3064E
- changeover valves in series 3032E
near pressure equipment to be protected in the system.
These fittings are designed to be installed in two ways:
- Construct a copper pipe by-pass that connects the pressure
equipment to the fitting. Insert the end of the by-pass in the solder
connection of the fitting and then perform capillary brazing.
- Drill the inner/outer pipe near the pressure equipment (if possible,
it is best to build a collar on the pipe). Put the end of the fitting into
this hole and proceed to braze weld.
The fittings in series 3035 are produced by machining brass bars
EN 12164-CW614N.
Note: The fitting in series 3035 are excluded from the scope
of application of Directive 2014/68/EU as they are piping
components.

TABLE 20: GENERAL CHARACTERISTICS, DIMENSIONS AND WEIGHTS OF UNIONS 3035

Connections Dimensions
Catalogue Number PS [bar] Weight [g]
ODS
NPT D L Ch
Ø [mm]

3035/2 1/4” 12 18 33 21 58

3035/3 3/8” 18 22 36,5 26 90,5

150
3035/4 1/2” 22 28 44 32 165

3035/6 3/4” 28 35 51 40 255

3035/8 1” 35 42 72 45 364
120
3035/10 1.1/4” 42 54 67 55 613

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 4.50
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CHECK
VALVES
 CHAPTER 5

CHECK VALVES
5.1 – HERMETIC CHECK VALVES

APPLICATIONS in series 3137EW, 3147EW, 3187EW

- Stainless steel pipe AISI 304 for welded connections in series
The hermetic check valves are considered “Pressure Accessories” 3138EW, 3148EW 3188EW.
according to the definition provided in Article 2, Point 5 of the
Directive 2014/68/EU (PED Recast) and are subject to the
classification indicated in Article 4, Points 1.c) and 3 of the same INSTALLATION
Directive.
These valves have been developed by Castel for all the applications
The valves can be installed in any section of a refrigeration
that use the sub-critical or trans-critical R744 refrigerant fluid
system where it is necessary to avoid the consequences from
belonging to Group 2, defined in Article 13, Chapter 1, Point (b)
undesirable flow inversion, with respect for the operating limits
of Directive 2014/68/EU, with reference to EC Regulation No.
and the capacities indicated in Table 1. Table 1 shows the following
1272/2008.
functional characteristics of a check valve:
The check valves for plants that operate using refrigerant fluid
- PS and TS
R744 are the following:
- Kv factor
- Valves in series 3132EW, 3133EW, 3145EW and 3185EW, PS
- Minimum opening differential pressure at which the valve can
= 80 bar for trans-critical plants low and medium pressure sides.
open and remain opened.
- Valves in series 3137EW, 3147EW and 3187EW, PS = 130 bar
Before connecting the valve to the pipe, it is advisable to make
for trans-critical plants high-pressure side.
sure that the refrigerating system is clean. Valves with laminated
- Valves in series 3138EW, 3148EW and 3188EW, PS = 140 bar
fibreglass and PTFE gaskets are particularly sensitive to dirt and
for trans-critical plants high-pressure side.
debris. Furthermore, check that the flow direction in the pipe
CAUTION! The check valves in this chapter cannot be used
corresponds to the arrow stamped on the valve body.
with other refrigerant fluids.
Copper connections: The brazing of valves with copper connections
should be carried out with care, using a low melting point filler
CONSTRUCTION material (min. 5% Ag). It is not necessary to disassemble the valves,
but it is important to avoid direct contact between the torch flame
Only straight check valves in series 3132EW (standard spring) and the valve body, which could be damaged and compromise the
ensure a low opening differential; Δp = 0.04 bar. All the other proper functioning of the valve.
check valves for R744 (reinforced spring) ensure a high opening Steel connectors: TIG welding recommended, to be performed as
differential; Δp = 0.3 bar. quickly as possible according to the method shown in the product
To guarantee tightness between body the cover, the valves in instruction sheet. The connection material is AISI 304: it is only
series 3132EW, 3133EW, 3137EW, 3138EW, are equipped with possible to use AISI 308 filler material if welding to pipes made from
laser welds. To guarantee tightness between body the cover, the the same type of material. For pipes made from other materials,
valves in series 3145EW, 3147EW, 3148EW, 3185EW, 3187EW, please contact your welding supplies supplier.
3188EW are equipped with TIG welds. The allowed operating positions are the following:
The main parts of the check valves are made with the following
materials: - 3145EW, 3147EW, 3148EW:
- Brass bar EN 12164 - CW 614N for body and cover of the valves - with the piping axis horizontal and valve cover facing upward or
in series 3132EW, 3133EW, 3137EW, 3138EW. to the side, horizontal.
- Hot forged brass EN 12420 - CW 617N for body and cover of the - with the piping axis vertical and arrow facing either upward or
valves in series: 3145EW, 3147EW, 3148EW, 3185EW, 3187EW, downward.
3188EW. Note: valves 3145EW, 3147EW, 3148EW cannot be installed
- Austenitic stainless steel AISI 302 for the spring with the valve cover facing downward.
- Laminated glass fibre fabric and PTFE for seat gaskets of valves
in series 3132EW, 3133EW, 3137EW, 3138EW. - 3185EW, 3187EW, 3188EW:
- PTFE for seat gaskets of valves in series 3145EW, 3147EW, - with inlet pipe facing downward and valve cover facing upward.
3148EW, 3185EW, 3187EW, 3188EW. - with inlet pipe horizontal and outlet pipe vertical or horizontal.
- Copper pipe EN 12735-1 – Cu-DHP for welded connections in Note: valves 3185EW, 3187EW, 3188EW cannot be installed
series 3132EW, 3133EW, 3145EW, 3185EW. with the valve input facing upward and the valve cover facing
- Copper pipe EN 12735-1 – CuFe2P (K65) for welded connections downward.

5.3
HANDBOOK - 2023
 5.4
GOGREEN HANDBOOK - 2023
 - Valves 3132EW, 3133EW, 3137EW, 3138EW can be installed in are certified UL Listed for the USA, in compliance with American
any working position. standard UL 207 with a Design Pressure of:
• 1160 PSI for valves in series 3132EW, 3133EW, 3145EW and
3185EW
CERTIFICATIONS • 1740 PSI for valves in series 3137EW, 3147EW and 3187EW
• 2030 PSI for valves in series 3138EW, 3148EW and 3188EW

The American certification authority Underwriters Laboratories Inc.

has approved Castel check valves with file SA33319. These valves

5.5
HANDBOOK - 2023
 5.6
GOGREEN HANDBOOK - 2023
 TABLE 1: GENERAL CHARACTERISTICS OF HERMETIC CHECK VALVES

Connections
Minimum TS [°C] Risk Category
Kv Factor
Catalogue Number ODS Opening Pressure PS [bar] according to PED
[m3/h]
Differential [bar] Recast
Ø [in.] Ø [mm] min. max.

with reinforced copper connections

3132EW/2 1/4” – 0,5
3132EW/3 3/8” –
1,5
3132EW/M10 – 10
3132EW/M12 – 12
1,8
3132EW/4 1/2” – 0,04 80 – 40 +150 Art. 4.3
3132EW/5 5/8” 16 3,3
3132EW/M18 – 18
3132EW/6 3/4” – 5,0
3132EW/7 7/8” 22
with reinforced copper connections
3133EW/2 1/4” – 0,5
3133EW/3 3/8” –
1,5
3133EW/M10 – 10
3133EW/M12 – 12
1,8
3133EW/4 1/2” – 0,3 80 – 40 +150 Art. 4.3
3133EW/5 5/8” 16 3,3
3133EW/M18 – 18
3133EW/6 3/4” – 5,0
3133EW/7 7/8” 22
with K65 copper alloy connections (K65)
3137EW/2 1/4” – 0,5
3137EW/3 3/8” –
1,5
3137EW/4 1/2” – 0,3 130 -40 150 Art. 4.3
3137EW/5 5/8” 16 3,3
3137EW/6 3/4” – 5,0
with stainless steel connections
3138EW/M10 – 10
1,5
3138EW/M12 – 12 0,3 140 -40 150 Art. 4.3
3138EW/M16 – 16 3,3
with reinforced copper connections
3145EW/7 7/8” 22 8,1
3145EW/M28 – 28
10,4 Art. 4.3
3145EW/9 1.1/8” –
3145EW/11 1.3/8” 35 15,6 0,3 80 – 40 +150
3145EW/13 1.5/8” –
27,0
3145EW/M42 – 42 I
3145EW/17 2.1/8” 54 39,0
with K65 copper alloy connections (K65)
3147EW/7 7/8” 22 8,1
3147EW/9 1.1/8” – 10,4 Art. 4.3
3147EW/11 1.3/8” 35 15,6 0,3 130 – 40 +150
3147EW/13 1.5/8” – 27,0
I
3147EW/17 2.1/8” 54 39,0
with stainless steel connections
3148EW/M22 – 22 8,1
3148EW/M28 – 28 10,4 Art. 4.3
0,3 140 – 40 +150
3148EW/M35 – 33,4 15,6
3148EW/M42 – 42,2 27,0 I
with reinforced copper connections
3185EW/7 7/8” 22 9,0
3185EW/M28 – 28
19,0 0,3 80 – 40 +150 Art. 4.3
3185EW/9 1.1/8” –
3185EW/11 1.3/8” 35 29,0
with K65 copper alloy connections (K65)
3187EW/7 7/8” 22 9,0
3187EW/9 1.1/8” – 19,0 0,3 130 – 40 +150 Art. 4.3
3187EW/11 1.3/8” 35 29,0
with stainless steel connections
3188EW/M22 – 22 9,0
3188EW/M28 – 28 19,0 0,3 140 – 40 +150 Art. 4.3
3188EW/M35 – 33,4 29,0

5.7
HANDBOOK - 2023
TABLE 2: REFRIGERANT FLOW CAPACITY OF CHECK VALVES [KW]

subcritical system transcritical system

Catalogue Number
Liquid line Suction line Hot gas line Gas cooler line Suction line Hot gas line

3132EW/2 3133EW/2 13,4 2,7 10,1 2,3

3132EW/3 3133EW/3
40,2 8,0 30,3 6,9
3132EW/M10 3133EW/M10
3132EW/M12 3133EW/M12
48,2 9,5 36,3 8,3
3132EW/4 3133EW/4
3132EW/5 3133EW/5 88 17 67 15
3132EW/M18 3133EW/M18
3132EW/6 3133EW/6 134 27 101 23
3132EW/7 3133EW/7
3137EW/2 – 13,1 2,3 9,3
3137EW/3 3138EW/M10
39,4 6,9 28,0
3137EW/4 3138EW/M12
3137EW/5 3138EW/M16 87 15 62
3137EW/6 – 131 23 93
3145EW/7 217 43 163 38
3145EW/M28
279 55 210 48
3145EW/9
– 3145EW/11 418 83 315 72
3145EW/13
724 143 545 125
3145EW/M42
3145EW/17 1045 207 787 181
3147EW/7 3148EW/M22 213 38 151
3147EW/9 3148EW/M28 273 48 194
3147EW/11 3148EW/M35 410 72 292
3147EW/13 –
709 125 505
– 3148EW/M42
3147EW/17 – 1025 181 729
3185EW/7 241 48 182 42
3185EW/M28
– 509 101 383 88
3185EW/9
3185EW/11 777 154 585 134
3187EW/7 3188EW/M22 236 42 168
3187EW/9 3188EW/M28 499 88 355
3187EW/11 3188EW/M35 762 134 542

Standard rating conditions according to AHRI Standard 760-2014 for subcritical system

Condensing temperature 30 °F (- 1,2 °C)

Liquid temperature 20 °F (- 6,7 °C)
Subcooling 10 °R (5,5 °K)
Evaporating temperature - 20 °F (- 28,9 °C)
Evaporator outlet temperature - 10 °F (- 23,4 °C)
Evaporator superheating 10 °R (5,5 °K)
Suction line temperature - 5 °F (-15 °C)
Suction line superheating 15 °R (8,4 °K)
Discharge temperature 80 °F (26,6 °C)

Standard rating conditions according to AHRI Standard 760-2014 for transcritical system

Gas-cooler outlet temperature 95 °F (35 °C)

Evaporating temperature 14 °F (- 10 °C)
Evaporator outlet temperature 23 °F (- 5 °C)
Evaporator superheating 9 °R (5 °K)
Suction line temperature 32 °F (0°C)
Suction line superheating 9°R (5 °K)
Discharge temperature 212 °F (110 °C)

5.8
GOGREEN HANDBOOK - 2023
 TABLE 3: DIMENSIONS AND WEIGHTS OF CHECK VALVES

Dimensions [mm]
Catalogue Number Weight [g]
H H1 L L1 Q ØD

3132EW/2 3133EW/2 93 18 65

3132EW/3 3133EW/3
108 22 120
3132EW/M10 3133EW/M10

3132EW/M12 3133EW/M12
133 24 157
3132EW/4 3133EW/4

3132EW/5 3133EW/5 146 29 220

3132EW/M18 3133EW/M18

3132EW/6 3133EW/6 165 35 304

3132EW/7 3133EW/7 – – – –

3137EW/2 122 22 65

3137EW/3 126 22 120

3137EW/4 132 24 157

3137EW/5 146 29 220

3137EW/6 165 35 370

3138EW/M10 126 22 130

3138EW/M12 132 24 155

3138EW/M16 146 29 242

3145EW/7 170 1055

3145EW/M28 96 24 50
201 1062
3145EW/9

3145EW/11 115 29 232 56 1300

3145EW/13
148 36 255 67 3300
3145EW/M42

3145EW/17 167 44 285 79 5500

3147EW/7 170 1055

96 24 – 50
3147EW/9 201 1062
–
3147EW/11 115 29 232 56 1300

3147EW/13 148 36 255 67 3330

3147EW/17 167 44 285 79 5830

3148EW/M22 170 1055

96 24 50 –
3148EW/M28 201 1085

3148EW/M35 115 29 232 56 1610

3148EW/M42 148 36 255 67 3500

3185EW/7 146 94 111 88 45 600

3185EW/M28
196 149 51 1010
3185EW/9 141 123

3185EW/11 204 151 56 1300

3187EW/7 146 94 111 88 45 600

3187EW/9 196 149 51 1010

141 123
3187EW/11 204 151 56 1300

3188EW/M22 146 94 111 88 45 600

3188EW/M28 196 149 51 1000

141 123
3188EW/M35 204 151 56 1740

5.9
HANDBOOK - 2023
 5.10
GOGREEN HANDBOOK - 2023
PRESSURE
REGULATORS
 CHAPTER 6

PRESSURE REGULATORS
6.1 – EVAPORATING PRESSURE REGULATORS

APPLICATIONS of 2,5 bar in calibration pressure. The calibration range varies from
12 to 35 bar.
Evaporating pressure regulators are an accessory designed to
maintain a constant evaporating pressure and thereby a constant
surface temperature on the evaporator under varying evaporator CONSTRUCTION
loads. This valve prevents too low evaporating pressure and
therefore protects against freezing in water chiller or against coil The main parts of the evaporating pressure regulators are made
icing in air evaporators. These regulators allow multiple evaporators with the following materials:
to operate at different temperatures in a system with only one - Hot forged brass EN 12420 – CW 617N for the body
compressor. - Copper pipe EN 12735-1 – Cu--DHP for solder connections
The evaporating pressure regulators are considered “Pressure - Austenitic stainless steel AISI 321 for the bellows
Accessories” according to the definition provided in Article 2, - Austenitic stainless steel AISI 303 for the shutter
Point 5 of the Directive 2014/68/EU (PED Recast) and are subject - Brass bar EN 12164 – CW 614N for regulator ring
to the classification indicated in Article 4, Points 1.c) and 3 of the - Spring steel DIN 17223/84 Class C/D for setting spring
same Directive. - Ethylene propylene rubber (EPDM) for outlet seal gaskets
These valves have been developed by Castel for all applications that
use subcritical R744 refrigerant fluid belonging to Group 2, defined
in Article 13, Chapter 1, Point (b) of Directive 2014/68/EU, with
reference to EC Regulation No. 1272/2008.
CAUTION!: the evaporating pressure regulators in this chapter
INSTALLATION
cannot be used with other refrigerant fluids.
Evaporating pressure regulators in series 3335EL are installed in
the suction line between the evaporator and the compressor.
Refrigerating system with one compressor serving two or more
OPERATION evaporators in parallel, where different evaporating temperature
are required. In this case the evaporating pressure regulator is
Evaporating pressure regulators adjust the flow of hot gas according installed downstream the evaporator with the highest temperature.
to changes of suction pressure, upstream the regulator. When the Downstream of the evaporators with lower temperatures, it is
evaporating pressure is less than the regulator calibration pressure, necessary to install a check valve to avoid refrigerant condensing
the shutter remains closed. As the suction pressure rises above during compressor stops.
the regulator’s calibration setting, the shutter begins to open and
modulates in proportion to the variation in evaporating pressure. As
the evaporating pressure continues to rise, the shutter continues
to open, until the stroke limit is reached and the regulator is open
SELECTION
completely. When the shutter is fully open, a further increase in
To correctly select evaporating pressure regulators, all information
the valve capacity can be obtained only by increasing the load loss
on the system where it will be installed must be available. Selection
across the valve.
is based on the following data:
Evaporating pressure regulators only modulate based on the inlet
1. Type of refrigerant = R744
pressure change, pressure changes on the outlet side do not affect
2. Designed evaporator capacity.
their opening as the valve is equipped with an equalizer bellow with
3. Designed evaporating temperature.
an area equal to that of the valve seat
4. Minimum evaporating temperature. This data identifies the
valve calibration pressure.
The factory pressure settings for regulators in series 3335EL is 12
5. Allowable pressure drop across the valves at design load
bar. This means that until the condensation (discharge) pressure is
condition.
below 12 bar, the regulator remains closed. When it rises above 12
6. Liquid temperature
bar, the regulator begins to open. According to the characteristics of
The refrigerating capacities indicated in Table 3A are based on:
the refrigerating system it may be necessary to change the factory
• A liquid reference temperature of -6.7 °C.
setting by adjusting the adjustment ring on the top of the regulator
• An allowable variation in evaporating pressure of 1.12 bar.
body. Turn this ring clockwise to increase the regulator’s calibration
With liquid temperatures other than -6.7 °C and for variations in
pressure; turn it counter-clockwise to decrease the calibration
evaporating pressure other than 1.12 bar, the required cooling
pressure. Each turn of the ring corresponds to an increase/decrease

6.3
HANDBOOK - 2023
 6.4
GOGREEN HANDBOOK - 2023
 capacity of regulator is:

where:

Qevap = Evaporator capacity [kW]

K T liquid = Correction factor for Tliquid≠ -6.7 °C. (Table 3B)
K ΔP evap = Correction factor for ΔPvalve ≠ 1.12 bar. (Table 3C)
Qvalve = Refrigerating capacity requested at regulator. [kW]

TABLE 1: GENERAL CHARACTERISTICS OF EVAPORATOR PRESSURE REGULATORS

Connections TS [°C] TA [°C]

Regulating
range [bar] Factory Risk Category
Catalogue Kv Factor PS
ODS setting according to PED
Number SAE [m3/h] [bar]
[bar] min. max. min. max. Recast
Flare
Ø [in.] Ø [mm] min. max.

3335EL/M12S – – 12

3335EL/4S – 1/2” –
2,7 12 36 12 60 -40 +120 -40 +50 Art. 4.3
3335EL/5S – 5/8” 16

3335EL/7S – 7/8” 22

TABLE 2. DIMENSIONS AND WEIGHTS OF EVAPORATOR PRESSURE REGULATORS

Dimensions [mm]
Weight
Catalogue Number
[g]
H H1 H2 L L1 D

3335EL/M12S 183 100,5 69,5 64 510

3335EL/4S 183 100,5 69,5 64 480

37 32
3335EL/5S 183 100,5 69,5 64 500

3335EL/7S 194 112 81 75,5 560

6.5
HANDBOOK - 2023
TABLE 3A : REFRIGERANT FLOW CAPACITY OF EVAPORATOR PRESSURE REGULATORS 3335EL [KW]

Pressure Design evaporator temperature [°C]

drop across
Catalogue Number
regulator
[bar]
5 0 -5 -10 -15 -20 -25 -30 -35 -40

0,07 3,9 3,5 3,1 2,8 2,5 2,1 1,9 1,8 1,6 1,4
0,14 7,8 7,1 6,3 5,5 4,9 4,2 3,9 3,5 3,1 2,8
0,21 12,8 11,5 10,2 9,0 7,8 6,6 6,0 5,4 4,7 4,1
3335EL/4S 0,35 19,4 17,4 15,4 13,5 11,6 9,8 8,8 7,7 6,7 5,7
3335EL/M12S 0,42 26,6 23,7 20,7 17,8 15,1 12,4 11,0 9,5 8,1 6,6
0,56 40,0 35,3 30,6 25,9 21,7 17,5 15,2 13,0 10,7 8,5
0,81 49,2 43,3 37,4 31,5 26,2 20,9 18,1 15,3 12,5 9,7
1,12 59,5 52,3 45,0 37,8 31,3 24,8 21,4 17,9 14,5 11,1
0,07 4,8 4,4 4,0 3,5 3,1 2,6 2,5 2,3 2,1 1,9
0,14 9,9 9,0 8,1 7,1 6,2 5,4 5,0 4,6 4,2 3,9
0,21 14,9 13,5 12,1 10,8 9,4 8,0 7,5 6,9 6,3 5,8
0,35 20,8 18,9 16,9 15,0 13,1 11,1 10,3 9,6 8,8 8,0
3335EL/5S
0,42 27,6 25,0 22,4 19,8 17,2 14,6 13,6 12,5 11,4 10,3
0,56 37,3 33,8 30,2 26,7 23,1 19,6 18,1 16,7 15,2 13,7
0,81 43,7 39,5 35,4 31,2 27,0 22,9 21,2 19,5 17,7 16,0
1,12 51,1 46,2 41,3 36,4 31,6 26,7 24,7 22,7 20,7 18,7
0,07 5,4 4,9 4,4 3,9 3,4 3,0 2,7 2,5 2,2 2,0
0,14 11,1 10,0 9,0 7,9 7,0 6,0 5,5 5,0 4,5 3,9
0,21 18,2 16,4 14,5 12,7 11,1 9,4 8,5 7,6 6,7 5,8
0,35 27,3 24,5 21,7 18,9 16,4 13,8 12,3 10,9 9,5 8,0
3335EL/7S
0,42 36,7 32,7 28,6 24,5 20,8 17,1 15,1 13,1 11,1 9,1
0,56 55,1 48,7 42,2 35,8 29,9 24,1 21,0 17,9 14,8 11,7
0,81 64,4 56,8 49,2 41,7 34,8 28,0 24,3 20,7 17,0 13,4
1,12 76,4 67,3 58,2 49,1 40,9 32,7 28,3 24,0 19,6 15,2

Standard rating conditions according to AHRI Standard 770-2014

Condensing temperature 30°F -1,2°C

Liquid temperature 20°F -6,7°C
Subcooling 10° R 5,5°K
Evaporating temperature -20°F -28,9°C
Suction temperature -5°F -15°C
Superheating 15°R 8,4°K
Discharge temperature 80°F 26,6°C

Nominal evaporator pressure change (Tdesign evap -Tmin evap ) : 16 psi (1,12 bar)

TABLE 3B : CORRECTION FACTOR FOR LIQUID TEMPERATURE DIFFERENT FROM NOMINAL VALUE

Liquid temperature [°C]

-25 -20 -15 -10 -5 0 5 10 15

1,21 1,15 1,1 1,04 0,98 0,92 0,86 0,8 0,73

TABLE 3C : CORRECTION FACTOR FOR EVAPORATOR PRESSURE CHANGE DIFFERENT FROM NOMINAL VALUE

Evaporator pressure change [bar]

0,35 0,42 0,56 0,81 1,12 1,39 1,67 1,84 2,05

0,35 0,48 0,72 0,84 1 1,2 1,3 1,4 1,5

6.6
GOGREEN HANDBOOK - 2023
REFRIGERATING
SYSTEM PROTECTORS
 CHAPTER 7

REFRIGERATING SYSTEM PROTECTORS

7.1 – MOISTURE/LIQUID INDICATORS

APPLICATIONS - Hot forged brass EN 12420 – CW 617N for the body

- Copper tube EN 12735-1 – Cu-DHP for solder connections
The moisture/liquid indicators are considered “Pressure - Glass for lens
Accessories” according to the definition provided in Article 2, - PTFE for outlet gaskets
Point 5 of the Directive 2014/68/EU (PED Recast) and are subject Indicators in series 3740E, 3747E, and 3748E are manufactured
to the classification indicated in Article 4, Points 1.c) and 3 of the with the glass “lens” directly fused onto a steel metallic ring,
same Directive. with proper surface protection. This metallic ring, screwed on the
These indicators have been developed by Castel for all the indicator body, is equipped with an EPDM (ethylene-propylene)
applications that use the sub-critical or trans-critical R744 gasket. The main parts of these three series of indicators are
refrigerant fluid belonging to Group 2, defined in Article 13, manufactured with the following materials:
Chapter 1, Point (b) of Directive 2014/68/EU, with reference to EC - Hot forged brass EN 12420 – CW 617N for the body
Regulation No. 1272/2008. - Copper pipe EN 12735-1 – Cu-DHP for welded connections in
The moisture/liquid indicators for plants that operate using series 3740EL
refrigerant fluid R744 are the following: - Copper pipe EN 12735-1 – CuFe2P (K65) for welded connections
- Indicators in series 3940EL, PS = 60 bar for sub-critical plants. in series 3747E
- Indicators in series 3740E, PS = 80 bar for trans-critical plants - Stainless steel pipe AISI 304 for welded connections in series
low and medium pressure sides. 3748E
- Indicators in series 3747E, PS = 130 bar for trans-critical plants
high-pressure side.
- Indicators in series 3748E, PS = 140 bar for trans-critical plants
high-pressure side. INSTALLATION
CAUTION! The indicators in this chapter cannot be used with
other refrigerant fluids. At start-up, the colour of the sensitive element may be yellow, due
to exposure to air humidity or due to moisture in the circuit. When
the moisture of the refrigerant is returned to acceptable levels
OPERATION by the filter drier, the indicator colour turns green again. This is
evidence that equilibrium has been re-established. If the yellow
The moisture/liquid indicators consist of a sensitive ring element colour persists, measures must be taken to eliminate moisture. Only
that changes colour, from green to yellow, according to the percent when the sensitive element turns green again, is there evidence
moisture in the system. that measures adopted were effective.
The moisture content values that correspond to the “green” colour About 12 hours of system operation are required to achieve
can be considered admissible for the proper operation of the system. equilibrium. In any case, the moisture indication is usually read
When the sensitive element starts to yellow, “Chartreuse green”, the when the plant is in function and the fluid is flowing
threshold value has been reached and operating conditions could
become difficult. When the sensitive element becomes “yellow”, Copper connections: The brazing of indicators with copper
it’s time to replace the filter dryer. connections should be carried out with care, using a low melting
If the charge and operating conditions of the plant are normal, the point filler material (min. 5% Ag). It is important to avoid direct
refrigerant fluid appears perfectly liquid underneath the “lens” of contact between the torch flame and the body, which could be
the indicator. The presence of bubbles indicates that the refrigerant damaged and compromise the proper functioning of the indicator.
fluid is partially evaporating along the liquid line. Steel connectors: TIG welding recommended, to be performed as
quickly as possible according to the method shown in the product
instruction sheet. The connection material is AISI 304: it is only
possible to use AISI 308 filler material if welding to pipes made from
CONSTRUCTION the same type of material. For pipes made from other materials,
please contact your welding supplies supplier.
Liquid indicators in series 3940EL are manufactured in a total
hermetic construction to avoid any possible leaks. The glass “lens”, With indicators series 3740EL, 3747E and 3748E, it is necessary
with suitable gasket, is housed inside the brass body and is fixed to disassemble the ring before starting to braze/weld.
in its seat with an edge calking operation. The main parts of these
indicators are made from the following materials:

7.3
HANDBOOK - 2023
 7.4
GOGREEN HANDBOOK - 2023
 CERTIFICATIONS standard UL 207 with a Design Pressure of:
• 600 PSI for indicators in series 3940EL
The American certification authority Underwriters Laboratories Inc. • 1160 PSI for indicators in series 3740E
has approved Castel indicators with file SA33318. These indicators • 1885 PSI for indicators in series 3747E and 3748E
are certified UL Listed for the USA, in compliance with American

3940EL/..

3740E/..

3747E/..

3777E/..

3748E/..

7.5
HANDBOOK - 2023
TABLE 1: GENERAL CHARACTERISTICS OF LIQUID / MOISTURE INDICATORS

Connections
TS [°C] Risk Category
Catalogue Number Type ODS ODM PS [bar] according
to PED Recast
Ø [in.] Ø [mm] Ø [in.] min. max.

with copper connections

3940EL/M6 – 6 –

3940EL/2 1/4” – –

3940EL/3 3/8” – –

3940EL/M10 – 10 –

3940EL/M12 – 12 –
brazing

3940EL/4 1/2” – – 60 – 40 +120 Art. 4.3

3940EL/5 5/8” 16 –

3940EL/M18 – 18 –

3940EL/6 3/4” – –

3940EL/7 7/8” 22 –

3940EL/9 1.1/8” – –

with reinforced copper connections

3740E/M6 – 6 –

3740E/2 1/4” – –

3740E/3 3/8” – –

3740E/M10 – 10 –

3740E/M12 – 12 –
brazing

3740E/4 1/2” – – 80 – 40 +120 Art. 4.3

3740E/5 5/8” 16 –

3740E/M18 – 18 –

3740E/6 3/4” – –

3740E/7 7/8” 22 –

3740E/9 1.1/8” – –

with K65 copper alloy connections

3747E/2 1/4” – –

3747E/3 3/8” – –

3747E/4 1/2” – –

3747E/5 5/8” 16 –
brazing

120 – 40 +120 Art. 4.3

3747E/6 3/4” – –

3747E/7 7/8” 22 –

3747E/9 1.1/8” – –

3777E/11 1.3/8” 35 –

with stainless steel connections

3748E/M6 – – 6

3748E/M10 – – 10

3748E/M12 – – 12
welding

3748E/M16 – – 16 120 – 40 +120 Art. 4.3

3748E/M18 – – 18

3748E/M22 – – 22

3748E/M28 – – 28

7.6
GOGREEN HANDBOOK - 2023
 TABLE 2: DIMENSIONS AND WEIGHTS

Dimensions [mm]
Catalogue Number Weight [g]
H H1 L

with copper connections

3940EL/M6
22 15,5 113 120
3940EL/2

3940EL/3

3940EL/M10
34 21,5 117 185
3940EL/M12

3940EL/4

3940EL/5

3940EL/M18 34 21,5 131 195

3940EL/6

3940EL/7 37,5 23,5 151 306

3940EL/9 43,5 26 186 500

with reinforced copper connections

3740E/M6
140
3740E/2

3740E/3
43,5 31 117
3740E/M10
200
3740E/M12

3740E/4

3740E/5

3740E/M18 43,5 31 131 215

3740E/6

3740E/7 42,5 28,5 151 325

3740E/9 48,5 31 186 518

with K65 copper alloy connections

3747E/2

3747E/3 43,5 31 117 200

3747E/4

3747E/5
43,5 31 131 215
3747E/6

3747E/7 42,5 28,5 151 325

3747E/9 48,5 31 186 575

3777E/11 - 41,5 160 378

with stainless steel connections

3748E/M6 113

3748E/M10 43,5 31 200

117
3748E/M12

3748E/M16
43,5 31 131 234
3748E/M18

3748E/M22 42,5 28,5 151 304

3748E/M28 48,5 31 186 530

7.7
HANDBOOK - 2023
 7.8
GOGREEN HANDBOOK - 2023
 CHAPTER 7

REFRIGERATING SYSTEM PROTECTORS

7.2 – HERMETIC FILTER DRIERS

APPLICATIONS Required refrigeration flow capacity: 15 [kW]

Liquid temperature: - 10 [°C]
The hermetic filters driers in series DFxxxE are considered “Pressure Evaporating temperature: - 45 [°C}
Vessels” according to the definition provided in Article 2, Point 2 Set pressure drop: 0.14 [bar]
of the Directive 2014/68/EU (PED Recast) and are subject to the
classification indicated in Article 4, Points 1.a) and 3 of the same
Directive.
[kW]
These filters have been developed by Castel for all the applications
that use the sub-critical or trans-critical R744 refrigerant fluid
belonging to Group 2, defined in Article 13, Chapter 1, Point (b) Comparing the reference flow capacity obtained with the values
of Directive 2014/68/EU, with reference to EC Regulation No. indicated in Table 4, the choice falls on filter model DF308E/3S
1272/2008. with a flow capacity of 16,3 kW, with a pressure drop of 0.14 bar.

CONSTRUCTION CERTIFICATIONS
The filter body is made completely from steel with copper The American certification authority Underwriters Laboratories
connections, EN 12735-1 – Cu-DHP, offering the possibility to Inc. has approved hermetic filter driers in series DFxxxE with file
solder the copper pipe inside the connections (ODS). SA7054. These filters are certified UL-CSA Listed for the USA
The cartridges are made from moulding a dehydrating filler made and Canada with a Design Pressure of 1160 PSI, in compliance
completely from 3 Å molecular sieves, with a suitable binder. with American standard UL 207 and Canadian standard C22.2
The choice of using only 3 Å molecular sieves as the dehydrating No. 140.3-15.
material grants the cartridge extraordinary moisture adsorption
capacity while maintaining reasonable deacidifying characteristics.

FILTER SELECTION BASED ON DF3XXE/..

REFRIGERANT FLOW CAPACITY
Refrigerant flow capacities shown in Table 4 refer to the following
operating conditions according to ARI STANDARD 710-2009:
- Liquid temperature - 5 °C
- Evaporating temperature - 40 °C
Total pressure drop, including inlet and outlet connections, 0.07
bar / 0.14 bar
For different operating conditions apply the following formula:

where:
Q = required refrigeration flow capacity [kW]
Qref = reference refrigeration flow capacity [kW]
L1= flow capacity correction factor in presence of operative
temperatures different from reference conditions. (See Table 5)

EXAMPLE
Refrigerant: R744

7.9
HANDBOOK - 2023
 7.10
GOGREEN HANDBOOK - 2023
 TABLE 3: GENERAL CHARACTERISTICS OF HERMETIC FILTER DRIERS

Connections TS [°C]

Block Filtering
International
Reference
Risk

Nominal
Surface

Volume
[cm2]

[cm3]
Catalogue Number ODS PS [bar] Category according to PED
min. max. Recast
Ø [in.] Ø [mm]

DF303E/2S 032S 1/4” –

58 50
DF303E/3S 033S 3/8” –

DF305E/2S 052S 1/4” –

DF305E/3S 053S 104 80 3/8” –

DF305E/M10S – – 10

DF308E/2S 082S 1/4” –

DF308E/3S 083S 3/8” –

DF308E/M10S – 141 130 – 10

DF308E/M12S – – 12

DF308E/4S 084S 1/2” –

80 – 40 + 80 Art. 4.3
DF316E/3S 163S 3/8” –

DF316E/M10S – – 10

DF316E/M12S – 183 250 – 12

DF316E/4S 164S 1/2” –

DF316E/5S 165S 5/8” 16

DF330E/3S 303S 3/8” –

DF330E/4S 304S 345 500 1/2” –

DF330E/5S 305S 5/8” 16

DF341E/4S 414S 1/2” –

384 670
DF341E/5S 415S 5/8” 16

7.11
HANDBOOK - 2023
TABLE 4: REFRIGERANT FLOW CAPACITY , WATER CAPACITY AND DEHYDRATABLE CHARGE OF HERMETIC FILTER DRIERS

Flow capacity at Flow capacity at Water Capacity Dehydratable Charge Water Capacity Dehydratable Charge
Catalogue Number pressure drop pressure drop at + 24 °C (2) at + 24 °C at -6,6 °C (2) at -6,6 °C
0,07 bar (1) [kW] 0,14 bar (1) [kW] [g H2O] [kg R744] [g H2O] [kg R744]

DF303E/2S 5,8 7,0

4,2 4,4 5,1 5,4
DF303E/3S 10,8 12,9

DF305E/2S 7,3 9,5

DF305E/3S 11,4 14,9 9,5 9,9 11,5 12,0

DF305E/M10S 11,4 14,9

DF308E/2S 7,0 9,2

DF308E/3S 12,5 16,3

DF308E/M10S 12,5 16,3 14,2 14,8 17,2 17,9

DF308E/M12S 15,7 20,4

DF308E/4S 15,7 20,4

DF316E/3S 13,5 18,2

DF316E/M10S 13,5 18,2

DF316E/M12S 18,7 25,2 22,4 23,3 27,1 28,2

DF316E/4S 18,7 25,2

DF316E/5S 22,2 30,0

DF330E/3S 14,0 18,9

DF330E/4S 23,4 31,5 48,9 51,0 59,2 61,7

DF330E/5S 27,4 37,0

DF341E/4S 23,9 35,9

71,9 74,9 87,0 90,7
DF341E/5S 30,9 46,3

(1) : Maximum values of the refrigerant flow capacity at which the drier can be used when fluid dehydration is not the a major problem, provided that the original moisture is limited before the
installation of the drier.
The maximum refrigerant flow capacities are referred to a total pressure drop of 0,07 bar / 0,14 bar , inlet and outlet connections included, (according to ARI STANDARD 710-2009 - with
liquid temperature at -5 °C and evaporating temperature at - 40 °C )

(2) Drying capacity is based on the following moisture content test standards before and after drying:
EPD ; from 1110 ppm W to 50 ppm W at 24 °C
EPD ; from 445 ppm W to 50 ppm W at - 6,6 °C

7.12
GOGREEN HANDBOOK - 2023
 TABLE 5- CORRECTION FACTORS OF THE REFRIGERATION CAPACITY FOR TEMPERATURES DIFFERENT FROM STANDARD VALUES

Evaporating temperature [°C]

Liquid
Refrigerant
temperature [°C]
-20 -25 -30 -35 -40 -45 -50 -55 -60 -65 -70

-25 1,23 1,24 1,23 1,23 1,23 1,22 1,22 1,21

-20 1,18 1,18 1,18 1,17 1,17 1,17 1,16 1,15

-15 1,12 1,12 1,12 1,12 1,11 1,11 1,10 1,10

-10 1,06 1,06 1,06 1,06 1,05 1,05 1,04 1,04

R744 -5 1,00 1,00 1,00 1,00 0,99 0,99 0,98 0,98

0 0,94 0,94 0,94 0,94 0,93 0,93 0,92 0,92

5 0,88 0,88 0,88 0,87 0,87 0,87 0,86 0,85

10 0,81 0,81 0,81 0,81 0,81 0,80 0,80 0,79

15 0,75 0,75 0,75 0,74 0,74 0,74 0,73 0,72

TABLE 6: DIMENSIONS AND WEIGHTS OF HERMETIC FILTERS

Connections
Dimensions
Catalogue [mm]
ODS Weight [g]
Number

Ø [in.] Ø [mm] ØD L

DF303E/2S 1/4” – 101 152

42
DF303E/3S 3/8” – 105 186

DF305E/2S 1/4” – 112 406

DF305E/3S 3/8” – 64 116 414

DF305E/M10S – 10 120 414

DF308E/2S 1/4” – 133 502

DF308E/3S 3/8” – 137 514

DF308E/M10S – 10 64 141 520

DF308E/M12S – 12 141 520

DF308E/4S 1/2” – 137 514

DF316E/3S 3/8” – 157 616

DF316E/M10S – 10 161 616

DF316E/M12S – 12 64 161 616

DF316E/4S 1/2” – 157 626

DF316E/5S 5/8” 16 163 628

DF330E/3S 3/8” – 230 1450

DF330E/4S 1/2” – 76 230 1450

DF330E/5S 5/8” 16 236 1500

DF341E/4S 1/2” – 235 1775

89
DF341E/5S 5/8” 16 241 1886

7.13
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 7.14
GOGREEN HANDBOOK - 2023
 CHAPTER 7

REFRIGERATING SYSTEM PROTECTORS

7.3 – HERMETIC FILTER DRIERS WITH MOISTURE INDICATOR

APPLICATIONS INSTALLATION
The hermetic filters driers with moisture indicators in series DIxxxE At start-up, the colour of the sensitive element may be yellow, due
are considered “Pressure Vessels” according to the definition to exposure to air humidity or due to moisture in the circuit. When
provided in Article 2, Point 2 of the Directive 2014/68/EU (PED the moisture of the refrigerant is returned to acceptable levels
Recast) and are subject to the classification indicated in Article 4, by the filter drier, the indicator colour turns green again. This is
Points 1.a) and 3 of the same Directive. evidence that equilibrium has been re-established. If the yellow
These filters have been developed by Castel for all the applications colour persists, measures must be taken to eliminate moisture. Only
that use the sub-critical or trans-critical R744 refrigerant fluid when the sensitive element turns green again, is there evidence
belonging to Group 2, defined in Article 13, Chapter 1, Point (b) that measures adopted were effective. About 12 hours of system
of Directive 2014/68/EU, with reference to EC Regulation No. operation are required to achieve equilibrium. In any case, the
1272/2008. moisture indication is usually read when the plant is in function
For refrigerant flow capacity, water capacity and dehydratable and the fluid is flowing
charge of the filters in this paragraph see tab 4 of paragraph 7.2. Brazing of the filter/indicator with solder connections should be
carried out with care, using a low melting point filler material (min.
5% Ag). Avoid direct contact between the torch flame and the
CONSTRUCTION indicator body or glass, which could be damaged and compromise
the proper functioning of the indicator.
The driers with moisture indicators are drying filters for the liquid
line with a moisture/liquid indicator brazed directly onto the outlet DI305E..
of the filter. This unit reduces the amount of field brazing required DI308E..
and the potential risk for refrigerant fluid leaks. The indicators DI316E..
DI330E..
ensure fast safe inspection of the conditions of the refrigerant fluid DI341E..
in the circuit regarding regular flow and the presence of moisture.
The filter is completely manufactured in steel, with ODS soldered
connections in copper. The indicator is manufactured with the
glass “lens” directly fused onto a steel metallic ring, with proper
surface protection.
The cartridges are made from moulding a dehydrating filler made
completely from 3 Å molecular sieves, with a suitable binder.
The choice of using only 3 Å molecular sieves as the dehydrating
material grants the cartridge extraordinary moisture adsorption
capacity while maintaining reasonable deacidifying characteristics.

OPERATION
The moisture/liquid indicators consist of a sensitive ring element
that changes colour, from green to yellow, according to the percent
moisture in the system.
The moisture content values that correspond to the “green” colour
can be considered admissible for the proper operation of the system.
When the sensitive element starts to yellow, “Chartreuse green”, the
threshold value has been reached and operating conditions could
become difficult. When the sensitive element becomes “yellow”,
it’s time to replace the filter dryer.
If the charge and operating conditions of the plant are normal, the
refrigerant fluid appears perfectly liquid underneath the “lens” of
the indicator. The presence of bubbles indicates that the refrigerant
fluid is partially evaporating along the liquid line.

7.15
HANDBOOK - 2023
 7.16
GOGREEN HANDBOOK - 2023
 TABLE 7 GENERAL CHARACTERISTICS OF FILTER DRIERS WITH MOISTURE INDICATOR

Connections TS [°C]

Block Filtering
International
Reference
Risk

Nominal
Surface

Volume
[cm2]

[cm3]
Catalogue Number ODS PS [bar] Category according
min. max. to PED Recast
Ø [in.] Ø [mm]

DI305E/2S 052S 1/4” –

DI305E/3S 053S 104 80 3/8” –

DI305E/M10S – – 10

DI308E/2S 082S 1/4” –

DI308E/3S 083S 3/8” –

DI308E/M10S – 141 130 – 10

DI308E/M12S – – 12

DI308E/4S 084S 1/2” –

DI316E/3S 163S 3/8” –

80 – 40 + 80 Art. 4.3
DI316E/M10S – – 10

DI316E/M12S – 183 250 – 12

DI316E/4S 164S 1/2” –

DI316E/5S 165S 5/8” 16

DI330E/3S 303S 3/8” –

DI330E/4S 304S 345 500 1/2” –

DI330E/5S 305S 5/8” 16

DI341E/4S 414S 1/2” –

384 670
DI341E/5S 415S 5/8” 16

7.17
HANDBOOK - 2023
TABLE 8: REFRIGERANT FLOW CAPACITY , WATER CAPACITY AND DEHYDRATABLE CHARGE OF FILTER DRIERS WITH MOISTURE INDICATOR

Flow capacity at Flow capacity at Water Capacity Dehydratable Charge Water Capacity Dehydratable Charge
Catalogue Number pressure drop pressure drop at + 24 °C (2) at + 24 °C at -6,6 °C (2) at -6,6 °C
0,07 bar (1) [kW] 0,14 bar (1) [kW] [g H2O] [kg R744] [g H2O] [kg R744]

DI305E/2S 7,3 9,5

DI305E/3S 11,4 14,9 9,5 9,9 11,5 12,0

DI305E/M10S 11,4 14,9

DI308E/2S 7,0 9,2

DI308E/3S 12,5 16,3

DI308E/M10S 12,5 16,3 14,2 14,8 17,2 17,9

DI308E/M12S 15,7 20,4

DI308E/4S 15,7 20,4

DI316E/3S 13,5 18,2

DI316E/M10S 13,5 18,2

DI316E/M12S 18,7 25,2 22,4 23,3 27,1 28,2

DI316E/4S 18,7 25,2

DI316E/5S 22,2 30,0

DI330E/3S 14,0 18,9

DI330E/4S 23,4 31,5 48,9 51,0 59,2 61,7

DI330E/5S 27,4 37,0

DI341E/4S 23,9 35,9

71,9 74,9 87,0 90,7
DI341E/5S 30,9 46,3

(1) : Maximum values of the refrigerant flow capacity at which the drier can be used when fluid dehydration is not the a major problem, provided that the original moisture is limited before the
installation of the drier.
The maximum refrigerant flow capacities are referred to a total pressure drop of 0,07 bar / 0,14 bar , inlet and outlet connections included, (according to ARI STANDARD 710-2009 - with
liquid temperature at -5 °C and evaporating temperature at - 40 °C )

(2) Drying capacity is based on the following moisture content test standards before and after drying:
EPD ; from 1110 ppm W to 50 ppm W at 24 °C
EPD ; from 445 ppm W to 50 ppm W at - 6,6 °C

7.18
GOGREEN HANDBOOK - 2023
 TABLE 9: DIMENSIONS AND WEIGHTS OF FILTERS WITH MOISTURE INDICATOR

Connections
Dimensions
[mm]
Catalogue Number ODS Weight [g]
SAE Flare
Ø [in.] Ø [mm] ØD L

DI305E/2S – 1/4” – 166 650

DI305E/3S – 3/8” – 64 169 655

DI305E/M10S – – 10 171 655

DI308E/2S – 1/4” – 187 750

DI308E/3S – 3/8” – 190 765

DI308E/M10S – – 10 64 192 750

DI308E/M12S – – 12 196 765

DI308E/4S – 1/2” – 191 770

DI316E/3S – 3/8” – 210 860

DI316E/M10S – – 10 212 860

DI316E/M12S – – 12 64 216 870

DI316E/4S – 1/2” – 221 870

DI316E/5S – 5/8” 16 250 870

DI330E/3S – 3/8” – 282 1730

DI330E/4S – 1/2” – 76 286 1750

DI330E/5S – 5/8” 16 293 1820

DI341E/4S – 1/2” – 290 2204

89
DI341E/5S – 5/8” 16 297 2274

7.19
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 7.20
GOGREEN HANDBOOK - 2023
 CHAPTER 7

REFRIGERATING SYSTEM PROTECTORS

7.4 – REPLACEABLE SOLID CORE FILTER DRIERS

APPLICATIONS sieves – activated alumina, grant the cartridges a high deacidifying

capacity maintaining very good moisture adsorption characteristics.
The replaceable filter driers in series 4411E and 4412E are These cartridges are supplied without cover gasket as spare parts
considered “Pressure Vessels” according to the definition provided Cartridges 4490/BB: are made from moulding a dehydrating
in Article 2, Point 2 of the Directive 2014/68/EU (PED Recast) and filler, made from 25% 3 Å molecular sieves and 75% activated
are subject to the classification indicated in Article 4, Points 1.a) alumina, with a suitable binder. The use of a blend of molecular
and 3 of the same Directive. sieves and a big quantity of activated alumina, grant the cartridges
These filters have been developed by Castel for all the applications a very high deacidifying capacity. These cartridges can be used
that use the sub-critical R744 refrigerant fluid belonging to Group as a compressor motor burn-out core. They are supplied without
2, defined in Article 13, Chapter 1, Point (b) of Directive 2014/68/ cover gasket as spare part.s
EU, with reference to EC Regulation No. 1272/2008. Cartridges 4490/E: are made from moulding a dehydrating filler,
made completely from 3 Å molecular sieves, with a suitable binder.
The choice of using only 3 Å molecular sieves as the dehydrating
material grants the cartridge extraordinary moisture adsorption
OPERATION capacity while maintaining reasonable de-acidifying characteristics.
These cartridges are supplied with cover gasket as spare parts,
In the case of filters with two cartridges, the fluid passage takes
place in parallel. As a result, the pressure drop does not increase All the cartridges listed above have volume of 48 cubic inches
in proportion with the number of cartridges. A large ring area (equivalent to about 800 cm3), have a hollow cylinder shape and
between the cartridge and the inner surface of the filter allows for are of the same size as the corresponding products of the main
the accumulation of solid particles and prevents clogging. Before international brands. Consequently they are interchangeable. The
leaving the filter, the refrigerant fluid must pass through the mesh hollow cylinder shape provides a large surface area to the fluid
sieve in which cartridges are mounted. This eliminates the danger which to cross it in a radial direction. As a result, drying is highly
that small particles of drying material be dragged into circulation. efficient with a minimum loss of charge.
Furthermore, at the filter outlet, a plastic cup, the edge of which
closely adheres to the inner surface of the filter, prevents dirt Cartridge 4495: characterized by a large filter surface, these
from reaching the outlet connection during normal operation and consist of metal mesh fabric with a controlled porosity filter sieve
cartridge change. insert, which can retain solid particles to 20 microns. At both
ends, soft felt gaskets ensure perfect seal with the plastic cups.
These cartridges can be used in the 4411E and 4412E filter shell
CONSTRUCTION by replacing the internal components with spare 9151/R02. If the
4412E filter shell is used, the 9900/X74 centering disc is also
Filter shells: these are built with an aluminium cover, stainless steel required.
screws, and the steel body is equipped with brazing connections
machined from a steel bar EN 10025 S355JR.
They are sold in the following two configurations:
- Codes with an “A” suffix, equipped with 1/4” NPT threaded
cover for mounting an access fitting with valve core (for example
G9150/R05)
- Codes with a “B” suffix, equipped with blind cover

Cartridges 4490/B: are made from moulding a dehydrating filler,

made completely from 3 Å molecular sieves, with a suitable binder.
The choice of using only 3 Å molecular sieves as the dehydrating
material grants the cartridge extraordinary moisture adsorption
capacity while maintaining reasonable de-acidifying characteristics.
These cartridges are supplied without cover gasket as spare parts,
Cartridges 4490/AB: are made from moulding a dehydrating
filler, made from 80% 3 Å molecular sieves and 20% activated
alumina, with a suitable binder. The use of a blend of molecular

7.21
HANDBOOK - 2023
 7.22
GOGREEN HANDBOOK - 2023
 4411E
4412E

4490/..

4491
4496

7.23
HANDBOOK - 2023
TABLE 10: GENERAL CHARACTERISTICS OF FILTER DRIERS WITH REPLACEABLE SOLID CORE

Connections TS [°C]
Catalogue Number Nominal Volume

Number of Cores
Risk

Surface [cm2]
Core Filtering
ODS W Category
PS [bar] according
min. max. to PED
Theaded Blind Recast
[cu.in] [cm3] Ø [in.] Ø [mm] Ø [mm]
cover cover

Subcritical

4411E/5AF 4411E/5BF 5/8” 16 21,3

4411E/7AF 4411E/7BF 7/8” 22 26,9

4411E/9AF 4411E/9BF 1.1/8” – 33,7

4411E/11AF 4411E/11BF 1 420 48 800 1.3/8” 35 42,4

4411E/13AF 4411E/13BF 1.5/8” – 48,3

4411E/M42AF 4411E/M42BF – 42 48,3

4411E/17AF 4411E/17BF 2.1/8” 54 60,3 62 – 40 + 80 I

4412E/7AF 4412E/7BF 7/8” 22 26,9

4412E/9AF 4412E/9BF 1.1/8” – 33,7

4412E/11AF 4412E/11BF 1.3/8” 35 42,4

2 840 96 1600
4412E/13AF 4412E/13BF 1.3/8” 35 42,4

4412E/M42AF 4412E/M42BF – 42 48,3

4412E/17AF 4412E/17BF 2.1/8” 54 60,3

7.24
GOGREEN HANDBOOK - 2023
 TABLE 11: REFRIGERANT FLOW CAPACITY OF FILTERS WITH REPLACEABLE CORE

Catalogue Number
Flow capacity at pressure drop Flow capacity at pressure drop
0,07 bar (1)) [kW] 0,14 bar (1)) [kW]
Theaded cover Blind cover

4411E/5AF 4411E/5BF 52 62

4411E/7AF 4411E/7BF 91 119

4411E/9AF 4411E/9BF 125 162

4411E/11AF 4411E/11BF 145 189

4411E/13AF 4411E/13BF 156 203

4411E/M42AF 4411E/M42BF 156 203

4411E/17AF 4411E/17BF 156 203

4412E/7AF 4412E/7BF 91 119

4412E/9AF 4412E/9BF 141 183

4412E/11AF 4412E/11BF 191 248

4412E/13AF 4412E/13BF 208 281

4412E/M42AF 4412E/M42BF 208 281

4412E/17AF 4412E/17BF 208 281

(1) : Maximum values of the refrigerant flow capacity at which the drier can be used when fluid dehydration is not the a major problem, provided that the original moisture is limited before the
installation of the drier.
The maximum refrigerant flow capacities are referred to a total pressure drop of 0,07 bar / 0,14 bar , inlet and outlet connections included, (according to ARI STANDARD 710-2009 - with
liquid temperature at -5 °C and evaporating temperature at - 40 °C )

NOTE: for temperatures different from standard values use correction factors L1 listed on TABLE 5

TABLE 12: DIMENSIONS AND WEIGHTS OF FILTERS

Connections Dimensions [mm]

Catalogue Number
ODS W Weight [g]
Ø D1 Ø D2 H1 H2 H3 P
Theaded Blind
Ø [in.] Ø [mm] Ø [mm]
cover cover

4411E/5AF 4411E/5BF 5/8” 16 21,3 144 231 90 5158

4411E/7AF 4411E/7BF 7/8” 22 26,9

150 237 95 5300
4411E/9AF 4411E/9BF 1.1/8” – 33,7

4411E/11AF 4411E/11BF 1.3/8” 35 42,4 155 242 185 100 5400

4411E/13AF 4411E/13BF 1.5/8” – 48,3

167 254 112 5450
4411E/M42AF 4411E/M42BF – 42 48,3

4411E/17AF 4411E/17BF 2.1/8” 54 60,3 121 149 158 245 103 5500

4412E/7AF 4412E/7BF 7/8” 22 26,9

292 379 95 6600
4412E/9AF 4412E/9BF 1.1/8” – 33,7

4412E/11AF 4412E/11BF 1.3/8” 35 42,4 297 384 100 6800

324
4412E/13AF 4412E/13BF 1.5/8” – 48,3
309 396 112 6950
4412E/M42AF 4412E/M42BF – 42 48,3

4412E/17AF 4412E/17BF 2.1/8” 54 60,3 300 387 103 7000

7.25
HANDBOOK - 2023
TABLE 13: GENERAL CHARACTERISTICS, DIMENSIONS AND WEIGHTS OF SOLID CORES

Nominal Volume Dimensions [mm]

Filtering
Surface
[cm2]
Catalogue Number Batch characteristic Weight [g]
[cu.in] [cm3] Ø D1 Ø D2 H

4490/E (1)
High moisture adsorption
(100% molecular sieve)
4490/B (2)

Moisture and acid adsorption

4490/AB (2) 420 48 800 47 96 140 730
(80% molecular sieve + 20% activated alumina)

High acid adsorption, motor burn-out core

4490/BB (2)
(25% molecular sieve + 75% activated alumina)

(1): Supplied with cover gaskets as spare part

(2): Supplied without cover gasket as part part

TAB 14: WATER CAPACITY / DEHYDRATABLE CHARGE AND ACID CAPACITY OF SOLID CORES

Water Capacity Dehydratable Charge Water Capacity Dehydratable Charge

Acid Capacity (2)
Part number Dehydrating charge at + 24 °C (1) at + 24 °C at -6,6 °C (1) at -6,6 °C
[g]
[g H2O] [kg R744] [g H2O] [kg R744]

4490/B
100% Molecular sieve 75,7 78,8 91,6 95,4
4490/E

80% Molecular sieve +

4490/AB 64,1 66,8 77,6 80,8
20% activated alumina

25% Molecular sieve +

4490/BB 62
75% activated alumina

(1) Drying capacity is based on the following moisture content test standards before and after drying:
EPD ; from 1110 ppm W to 50 ppm W at 24 °C
EPD ; from 445 ppm W to 50 ppm W at - 6,6 °C

(2) : Neutralized oleic acid

TABLE 15: GENERAL CHARACTERISTIC, DIMENSIONS AND WEIGHTS OF MECHANICAL BLOCK

Filtering Surface Dimensions [mm]

Weight
Catalogue Number
[g]
[sq.in] [cm2] Ø D1 Ø D2 H

4495/C 127 820 60 87 138 480

7.26
GOGREEN HANDBOOK - 2023
 CHAPTER 7

REFRIGERATING SYSTEM PROTECTORS

7.5 – HIGH PRESSURE REPLACEABLE SOLID CORE FILTER DRIERS

APPLICATIONS sieves – activated alumina, grant the cartridges a high deacidifying

capacity maintaining very good moisture adsorption characteristics.
The high pressure replaceable filter driers in series 4431E and These cartridges are supplied without cover gasket as spare parts
4432E are considered “Pressure Vessels” according to the Cartridges 4490/BB: are made from moulding a dehydrating
definition provided in Article 2, Point 2 of the Directive 2014/68/ filler, made from 25% 3 Å molecular sieves and 75% activated
EU (PED Recast) and are subject to the classification indicated in alumina, with a suitable binder. The use of a blend of molecular
Article 4, Points 1.a) and 3 of the same Directive. sieves and a big quantity of activated alumina, grant the cartridges
These filters have been developed by Castel for all the applications a very high deacidifying capacity. These cartridges can be used
that use the trans-critical R744 refrigerant fluid belonging to Group as a compressor motor burn-out core. They are supplied without
2, defined in Article 13, Chapter 1, Point (b) of Directive 2014/68/ cover gasket as spare part.s
EU, with reference to EC Regulation No. 1272/2008. Cartridges 4490/E: are made from moulding a dehydrating filler,
made completely from 3 Å molecular sieves, with a suitable binder.
The choice of using only 3 Å molecular sieves as the dehydrating
material grants the cartridge extraordinary moisture adsorption
OPERATION capacity while maintaining reasonable de-acidifying characteristics.
These cartridges are supplied with cover gasket as spare parts,
In the case of filters with two cartridges, the fluid passage takes
place in parallel. As a result, the pressure drop does not increase All the cartridges listed above have volume of 48 cubic inches
in proportion with the number of cartridges. A large ring area (equivalent to about 800 cm3), have a hollow cylinder shape and
between the cartridge and the inner surface of the filter allows for are of the same size as the corresponding products of the main
the accumulation of solid particles and prevents clogging. Before international brands. Consequently they are interchangeable. The
leaving the filter, the refrigerant fluid must pass through the mesh hollow cylinder shape provides a large surface area to the fluid
sieve in which cartridges are mounted. This eliminates the danger which to cross it in a radial direction. As a result, drying is highly
that small particles of drying material be dragged into circulation. efficient with a minimum loss of charge.
Furthermore, at the filter outlet, a plastic cup, the edge of which
closely adheres to the inner surface of the filter, prevents dirt Cartridge 4495: characterized by a large filter surface, these
from reaching the outlet connection during normal operation and consist of metal mesh fabric with a controlled porosity filter sieve
cartridge change. insert, which can retain solid particles to 20 microns. At both
ends, soft felt gaskets ensure perfect seal with the plastic cups.
These cartridges can be used in the 4411E and 4412E filter shell
CONSTRUCTION by replacing the internal components with spare 9151/R02. If the
4412E filter shell is used, the 9900/X74 centering disc is also
Filter shells: these are built with a thick aluminium cover, stainless required.
steel screws, and the reinforced steel body is equipped with brazing
connections machined from a steel bar EN 10025 S355JR.
They are sold in the following two configurations: CERTIFICATIONS
- Codes with an “A” suffix, equipped with 1/4” NPT threaded
cover for mounting an access fitting with valve core (for example The American certification authority Underwriters Laboratories
G9150/R05) Inc. has approved filter driers in series 4431E and 4432E with file
- Codes with a “B” suffix, equipped with blind cover SA7054. These filters are certified UL-CSA Listed for the USA
and Canada with a Design Pressure of 1300 PSI, in compliance
Cartridges 4490/B: are made from moulding a dehydrating filler, with American standard UL 207 and Canadian standard C22.2
made completely from 3 Å molecular sieves, with a suitable binder. No. 140.3-15.
The choice of using only 3 Å molecular sieves as the dehydrating
material grants the cartridge extraordinary moisture adsorption
capacity while maintaining reasonable de-acidifying characteristics.
These cartridges are supplied without cover gasket as spare parts,
Cartridges 4490/AB: are made from moulding a dehydrating
filler, made from 80% 3 Å molecular sieves and 20% activated
alumina, with a suitable binder. The use of a blend of molecular

7.27
HANDBOOK - 2023
 7.28
GOGREEN HANDBOOK - 2023
 4431E
4432E

TABLE 16: GENERAL CHARACTERISTICS OF HIGH PRESSURE FILTER DRIERS WITH REPLACEABLE SOLID CORE

Connections TS [°C]
Catalogue Number Nominal Volume
Number of Cores

Risk
Surface [cm2]
Core Filtering

ODS W Category
PS [bar] according
min. max. to PED
Theaded Blind Recast
[cu.in] [cm3] Ø [in.] Ø [mm] Ø [mm]
cover cover

4431E/5AF 4431E/5BF 5/8” 16 21,3

4431E/7AF 4431E/7BF 7/8” 22 26,9

4431E/9AF 4431E/9BF 1.1/8” – 33,7

4431E/11AF 4431E/11BF 1 420 48 800 1.3/8” 35 42,4

4431E/13AF 4431E/13BF 1.5/8” – 48,3

4431E/M42AF 4431E/M42BF – 42 48,3

4431E/17AF 4431E/17BF 2.1/8” 54 60,3 90 – 40 + 80 II

4432E/7AF 4432E/7BF 7/8” 22 26,9

4432E/9AF 4432E/9BF 1.1/8” – 33,7

4432E/11AF 4432E/11BF 1.3/8” 35 42,4

2 840 96 1600
4432E/13AF 4432E/13BF 1.3/8” 35 42,4

4432E/M42AF 4432E/M42BF – 42 48,3

4432E/17AF 4432E/17BF 2.1/8” 54 60,3

7.29
HANDBOOK - 2023
TABLE 17: REFRIGERANT FLOW CAPACITY OF FILTERS WITH REPLACEABLE CORE

Catalogue Number
Flow capacity at pressure drop Flow capacity at pressure drop
0,07 bar (1)) [kW] 0,14 bar (1)) [kW]
Theaded cover Blind cover

4431E/5AF 4431E/5BF 52 62

4431E/7AF 4431E/7BF 91 119

4431E/9AF 4431E/9BF 125 162

4431E/11AF 4431E/11BF 145 189

4431E/13AF 4431E/13BF 156 203

4431E/M42AF 4431E/M42BF 156 203

4431E/17AF 4431E/17BF 156 203

4432E/7AF 4432E/7BF 91 119

4432E/9AF 4432E/9BF 141 183

4432E/11AF 4432E/11BF 191 248

4432E/13AF 4432E/13BF 208 281

4432E/M42AF 4432E/M42BF 208 281

4432E/17AF 4432E/17BF 208 281

(1) : Maximum values of the refrigerant flow capacity at which the drier can be used when fluid dehydration is not the a major problem, provided that the original moisture is limited before the
installation of the drier.
The maximum refrigerant flow capacities are referred to a total pressure drop of 0,07 bar / 0,14 bar , inlet and outlet connections included, (according to ARI STANDARD 710-2009 - with
liquid temperature at -5 °C and evaporating temperature at - 40 °C )

NOTE: for temperatures different from standard values use correction factors L1 listed on TABLE 5

TABLE 18: DIMENSIONS AND WEIGHTS OF FILTERS

Connections Dimensions [mm]

Catalogue Number
ODS W Weight [g]
Ø D1 Ø D2 H1 H2 H3 P
Theaded Blind
Ø [in.] Ø [mm] Ø [mm]
cover cover

4431E/5AF 4431E/5BF 5/8” 16 21,3 145 238 89 4210

4431E/7AF 4431E/7BF 7/8” 22 26,9 4240

151 244 95
4431E/9AF 4431E/9BF 1.1/8” – 33,7 4290

4431E/11AF 4431E/11BF 1.3/8” 35 42,4 156 249 185 100 4430

4431E/13AF 4431E/13BF 1.5/8” – 48,3 4570

168 261 112
4431E/M42AF 4431E/M42BF – 42 48,3 4550

4431E/17AF 4431E/17BF 2.1/8” 54 60,3 124 149 159 252 103 4480

4432E/7AF 4432E/7BF 7/8” 22 26,9 5780

293 385 95
4432E/9AF 4432E/9BF 1.1/8” – 33,7 5830

4432E/11AF 4432E/11BF 1.3/8” 35 42,4 298 390 100 5970

324
4432E/13AF 4432E/13BF 1.5/8” – 48,3 6110
310 402 112
4432E/M42AF 4432E/M42BF – 42 48,3 6090

4432E/17AF 4432E/17BF 2.1/8” 54 60,3 301 393 103 6020

7.30
GOGREEN HANDBOOK - 2023
 CHAPTER 7

REFRIGERATING SYSTEM PROTECTORS

7.6 – HERMETIC STRAINERS

APPLICATIONS
The hermetic strainers in series 45xxxE are considered “Pressure
Vessels” according to the definition provided in Article 2, Point 2
of the Directive 2014/68/EU (PED Recast) and are subject to the
classification indicated in Article 4, Points 1.a) and 3 of the same
Directive.
These strainers have been developed by Castel for all the applications
that use the sub-critical R744 refrigerant fluid belonging to Group
2, defined in Article 13, Chapter 1, Point (b) of Directive 2014/68/
EU, with reference to EC Regulation No. 1272/2008.

CONSTRUCTION
The strainers is completely manufactured in steel, with copper
plated solder connections, offering the possibility to solder the
copper pipe inside the connections (ODS).
Inside the strainers there is a screen basket, with large filter surface,
made of austenitic stainless steel AISI 304. The mesh filters are
not inspectable and therefore cannot be cleaned.

7.31
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 7.32
GOGREEN HANDBOOK - 2023
 TABLE 19: GENERAL CHARACTERISTICS OF STRAINERS

Connections TS [°C] TA [°C]

Useful Risk
Filtering Mesh
Passage Kv Factor Category
Catalogue Number Surface Opening ODS ODM PS [bar]
Surface [m3/h] according to
[cm2] [mm] min. max. min. max.
[%] PED Recast
Ø [in.] Ø [mm] Ø [in.] Ø [mm]

4520E/M10 – 10 – 12 2,4

4520E/M12 – 12 – 14
58 36,6 0,166 60 – 40 +80 – 20 +50 Art. 4.3
4520E/4 1/2” – 5/8” 16 3,4

4520E/5 5/8” 16 3/4” –

TABLE 20: DIMENSIONS AND WEIGHTS OF STRAINERS

Dimensions [mm]
Catalogue Number Weight [g]
ØD L

4520E/M10 109 195

4520E/M12 113 205

52
4520E/4 113 205

4520E/5 126 245

7.33
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 7.34
GOGREEN HANDBOOK - 2023
 CHAPTER 7

REFRIGERATING SYSTEM PROTECTORS

7.7 – INSPECTABLE STRAINERS

APPLICATIONS please contact your welding supplies supplier.

The inspectable strainers in series 4727E and 4728E are considered The allowed operating positions are the following:
“Pressure Accessories” according to the definition provided in - With horizontal piping axis, removable cover facing downward.
Article 2, Point 5 of the Directive 2014/68/EU (PED Recast) and - With vertical piping axis, arrow and removable cover facing
are subject to the classification indicated in Article 4, Points 1.c) downward.
and 3 of the same Directive. NOTE: Filters 4727E and 4728E cannot be installed with
These strainers have been developed by Castel for all applications the cover facing upward, in order to avoid that the dirt
that use trans-critical R744 refrigerant fluid belonging to Group 2, accumulated return into the plant when the filter is inspected/
defined in Article 13, Chapter 1, Point (b) of Directive 2014/68/EU, cleaned.
with reference to EC Regulation No. 1272/2008.
CAUTION!: the filters in this chapter cannot be used with other
refrigerant fluids. CERTIFICATIONS
The American certification authority Underwriters Laboratories Inc.
CONSTRUCTION has approved inspectable filters with file SA7054. These filters are
certified UL-CSA Listed for the USA and Canada, in compliance
The main parts of the inspectable strainers are made with the with American standard UL 207 and Canadian standard C22.2 No.
following materials: 140.3-15 with a Design Pressure of:
- Hot forged brass EN 12420 – CW 617N for body and cover • 1740 PSI for filters in series 4727E and 4728E, from 4728E/M18
- Austenitic stainless steel AISI 304 for the mesh filter • 2030 PSI for filters in series 4728E, up to 4728E/M16
- Un-sintered PTFE for the sealing gasket of the mesh filter
- Ethylene propylene rubber (EPDM) for outlet seal gaskets
- Copper pipe EN 12735-1 – CuFe2P (K65) for welded connections
in series 4274E
- Stainless steel pipe AISI 304 for welded connections in series
4278E

INSTALLATION
The inspectable strainers can be installed on all branches of a
refrigeration plant where it is necessary to avoid the accumulation of
dirt and sludge inside a highly delicate component. These strainers
can be disassembled to clean or replace the filter cartridge housed
inside. Table 24 lists the codes of the spare part filter cartridges
for replacement.
Table 21 shows the following operational characteristics of an
inspectable strainer:
- PS
- TS
- Kv factor
Copper connections: The brazing of filters with solder connections
should be carried out with care, using a low melting point filler
material (min.5 Ag). It is not necessary to disassemble the filters.
However, avoid direct contact between the torch flame and the body,
which could be damaged and compromise the proper functioning
of the filter.
Steel connectors: TIG welding recommended, to be performed as
quickly as possible according to the method shown in the product
instruction sheet. The connection material is AISI 304: it is only
possible to use AISI 308 filler material if welding to pipes made from
the same type of material. For pipes made from other materials,

7.35
HANDBOOK - 2023
 7.36
GOGREEN HANDBOOK - 2023
 TABLE 21 GENERAL CHARACTERISTICS OF INSPECTABLE STRAINER

Connections
Useful TS [°C] Risk Category
Filtering Mesh Opening Kv Factor
Catalogue Number Passage ODS PS [bar] according to PED
Surface [cm2] [mm] [m3/h]
Surface [%] Recast
Ø [in.] Ø [mm] min. max.

with K65 copper alloy connections

4727E/3 3/8” – 2,0

4727E/4 13 0,1 1/2” – 2,5

4727E/5 5/8” 16 3,0

4727E/6 3/4” – 6,0 Art. 4.3

4727E/7 18 26 7/8” 22 6,0 130 – 40 +140

4727E/9 1.1/8” – 6,0

0,2
4727E/11 31 1.3/8” 35 7,0

4727E/13 46 1.5/8” – 10,0

I
4727E/17 60 2.1/8” 54 15,0

with stainless steel connections

4728E/M10 – 10 2,0

4728E/M12 13 0,1 – 12 2,5

4728E/M16 – 16 3,0

4728E/M18 – 18 6,0 Art. 4.3

26 140 – 40 +140
4728E/M22 18 – 22 6,0

4728E/M28 0,2 – 28 6,0

4728E/M35 31 – 35 7,0

4728E/M42 46 – 42 10,0 I

7.37
HANDBOOK - 2023
TABLE 22: REFRIGERANT FLOW CAPACITY OF INSPECTABLE STRAINER

Transcritical system
Catalogue Number
Gas-cooling line Suction line Hot gas line

with K65 copper alloy connections

4727E/3 52,5 9,3 37,4

4727E/4 65,7 11,6 46,7

4727E/5 78,8 13,9 56,1

4727E/6 157,6 27,8 112,1

4727E/7 157,6 27,8 112,1

4727E/9 157,6 27,8 112,1

4727E/11 183,9 32,4 130,8

4727E/13 262,7 46,3 186,9

4727E/17 394,1 69,5 280,4

with stainless steel connections

4728E/M10 52,5 9,3 37,4

4728E/M12 65,7 11,6 46,7

4728E/M16 78,8 13,9 56,1

4728E/M18 157,6 27,8 112,1

4728E/M22 157,6 27,8 112,1

4728E/M28 157,6 27,8 112,1

4728E/M35 183,9 32,4 130,8

4728E/M42 262,7 46,3 186,9

Standard rating conditions according to AHRI Standard 760-2014 for transcritical system

Gas-cooler outlet temperature 95 °F (35 °C)

Evaporating temperature 14 °F (- 10 °C)
Evaporator outlet temperature 23 °F (- 5 °C)
Evaporator superheating 9 °R (5 °K)
Suction line temperature 32 °F (0 °C)
Suction line superheating 9 °R (5 °K)
Discharge temperature 212 °F (110 °C)

7.38
GOGREEN HANDBOOK - 2023
 TABLE 23: DIMENSIONS AND WEIGHTS OF INSPECTABLE STRAINERS

Dimensions [mm]
Catalogue Number Weight [g]
H H1 L Q

with K65 copper alloy connections

4727E/3 140 505

4727E/4 74 19 136 40 510

4727E/5 148 520

4727E/6 164 1005

4727E/7 96 24 170 50 1024

4727E/9 201 1084

4727E/11 115 29 208 56 1480

4727E/13 148 36 242 67 3490

4727E/17 167 44 285 79 5500

with stainless steel connections

4728E/M10 146 500

4728E/M12 74 19 142 40 500

4728E/M16 156 510

4728E/M18 164 1005

4728E/M22 96 24 170 50 1020

4728E/M28 201 1080

4728E/M35 115 29 206 56 1510

4728E/M42 148 36 240 67 3380

TABLE 24: GENERAL CHARACTERISTICS OF STRAINER BLOCKS

Catalogue Number Filtering Surface [cm2] Useful Passage Surface [%] Mesh Opening [mm] Suitable for strainer

4727E/3 4728E/M10
9151/R15
13 32 0,1 4727E/4 4728E/M12
9151/R16 4727E/5 4728E/M16
4727E/6 4728E/M18
9151/R17
18 4727E/7 4728E/M22
9151/R18 4727E/9 4728E/M28
26 0,2
9151/R19 31 4727E/11 4728E/M35
9151/R24 46 4727E/13 4728E/M42
9151/R25 60 4727E/17 -
4727E/3 4728E/M10
9151E/R54
13 4727E/4 4728E/M12
9151E/R55 4727E/5 4728E/M16
4727E/6 4728E/M18
9151E/R50 16 0,05
18 4727E/7 4728E/M22
9151E/R51 4727E/9 4728E/M28
9151E/R52 31 4727E/11 4728E/M35
9151E/R53 46 4727E/13 4728E/M42

7.39
HANDBOOK - 2023
 4727E..

4728E..

9151E..

7.40
GOGREEN HANDBOOK - 2023
OIL CONTROL
SYSTEMS
 CHAPTER 8

OIL CONTROL SYSTEMS

8.1 – ELECTRONIC OIL LEVEL REGULATORS

APPLICATIONS is based on light refraction phenomena since the light refraction

is different if the glass prism is immersed in a liquid or in a gas.
The electronic oil level regulators are considered “Pressure The oil level control and relative alarm condition is governed
Vessels” according to the definition provided in Article 2, Point 2 by electronic control unit that can maintain the desired level
of the Directive 2014/68/EU (PED Recast) and are subject to the by managing the number of “injection” and “waiting” cycles by
classification indicated in Article 4, Points 1.a) and 3 of the same operating the solenoid valve.
Directive. When a low level is detected, the electronic control unit commands
These regulators have been developed by Castel for all the the integrated solenoid valve. Incremental cycles inject oil into the
applications that use the trans-critical R744 refrigerant fluid compressor crankcase. Furthermore, the electronic control unit
belonging to Group 2, defined in Article 13, Chapter 1, Point (b)
is equipped with an alarm relay capable of generating a cut-off
of Directive 2014/68/EU, with reference to EC Regulation No.
1272/2008. signal for the compressor. Under normal operating conditions, this
The regulators for plants that operate using refrigerant fluid R744 relay is energized. Otherwise, if the level remains low even after a
are the following: specific number of injection cycles, an alarm signal is generated
- regulators in series 5650E with PS = 90 bar. by switching OFF the relay.
- regulators in series 5658E with PS = 140 bar.
CAUTION! The regulators in this chapter cannot be used with PLEASE NOTE:
other refrigerant fluids. Under alarm condition, the injection cycles continue: the electronic
control unit continues to command the integrated solenoid valve.
If the opto-electric sensors detect that a correct oil level is again
CONSTRUCTION reached, the alarm is automatically reset and the regulator returns
under normal operating conditions.
The regulator 5650E and 5658E is made up of an anodized
aluminium machined body in which several holes and the injection On both side of the regulator there are four LEDs that provide
seat allow the oil proper flow. The oil supply connection and the information about the operating conditions of the regulator.
integrated solenoid valve armature are made from stainless steel. Specifically:
In the body of the regulator there are: - “POWER” LED - GREEN
- The electronic control unit board protected by a plastic cover that Remains always on when the regulator is correctly powered.
guarantees a degree of protection IP65. This board is connected to - “OIL GOOD” LED - GREEN
the outside of the body by two EN 175301-803 industrial standard Remains on and steady when the oil level is correct.
Form C micro-connectors. Blinks when the level is low, but the injection cycles are not still
- The sight glass for visual control of the oil level active.
There are two symmetric versions of the electronic regulator: Off during active injection cycles.
- Version 5650E/11R and 5658E/07R with oil supply on the left - “OIL FILLING” LED - YELLOW
side and sight glass on the right. Off when the level measured is correct.
- Version 5650E/11L and 5658E/07L with the oil supply on the Blinks during the injection cycles with the solenoid valve open.
right side and the sight glass on the left. Remains on and steady during the injection cycles with the solenoid
Regulators 5650E and 5658E are sold with coil 24 VAC (A2 suffix) valve closed.
or with coil 220 VAC (A6 suffix). - “ALARM” LED - RED
On both sides of the regulator two membranes, related to four Remains on and steady when the electronic controller triggers the
LED indicator lights, show the operation condition of the regulator. alarm signal.
The specific construction of the regulator makes it capable of Off during the normal operating condition.
minimizing emulsion and foaming phenomena of the refrigerant.
Thus, during the oil injection phase, the correct level detection is
always guaranteed. INSTALLATION
The electronic regulator must be horizontally assembled in order
OPERATION to guarantee a correct level detection. The coil, supplied in the
regulator packaging, must be upwards oriented with a tolerance
The electronic regulators check the compressor oil level by using a of +/- 1 degree from the vertical axis.
combination of opto-electronic sensors. The level optical detection The regulator 5650E and 5658E cannot be directly coupled

8.3
HANDBOOK - 2023
 8.4
GOGREEN HANDBOOK - 2023
 (without an adapter) to the compressor crankcase. This
connection must always be performed using one of the
following adapters, sold separately:
- 5690/X11: two-flange adapter with length of 83 mm; fixed one
with 3 holes, mobile one with 4 holes.
- 5690/X12: adapter with mobile flange and 1.1/8” – 12 UNF
threaded end.
- 5690/X13: adapter with mobile flange and 1.1/8” – 18 UNEF
threaded end.
- 5690/X14: adapter mobile flange and 3/4” NPT threaded end.
- 5690/X15: two-flange adapter with length of 53 mm; fixed one
with 3 holes, mobile one with 4 holes.
- 5690/X17: adapter, with mobile flange and 1.1/4” – 12 UNF swivel
threaded end (rotalock).
- 5650E/X01: two-flange adapter with length of 53 mm; fixed one
with 6 holes, mobile one with 4 holes.

During installation of the electronic regulator, make sure of:

- The gasket is fit between the adapter and the regulator and that
it is well lubricated.
- The adapter fixing screws are tightened to the torque indicated
in the instructions.
- The gaskets under the micro-connectors (power supply and
alarms relay) are correctly positioned.
- The screw of the micro-connectors are tightened to the torque
indicated in the instructions.
- The gaskets under the coil connector is correctly positioned
and the coil connector is tightened to the torque indicated on the
instructions.
- The electric connections are performed according to the wiring
diagram on the instructions and on the front of the regulator.
- Upstream of the oil supply connection a strainer should be
installed.
After the installation of the electronic regulator, make sure that the
system has been correctly installed by performing a tightness test.
Before powering the system, check the oil level in the regulator
and in the compressor crankcase: it should be slightly above the
sight-glass centre line.

WIRING AND ELECTRIC

CONNECTIONS
Wiring is performed using two co-moulded cables with DIN
connectors to guarantee IP65 protection degree. One cable is
used for power supply and the other cable is used for the alarm
cut-off signals.
The cables length is 3 meters and the kit must be purchased
separately (part. number 9901/X26). The kit is supplied with
gaskets and fixing screws.
Electronic oil level regulator has two EN175301-803-C (9.4mm
pitch) connectors on top.
During the alarm condition, the relay is switched OFF and the circuit
is closed between contacts 1 (NC) and 3 (COM). During normal
operation, the relay is switched ON and therefore the circuit is
closed between contacts 2 (NO) and 3 (COM) (see the diagram).

8.5
HANDBOOK - 2023
5650E/R
5658E/R

5650E/L
5658E/L

8.6
GOGREEN HANDBOOK - 2023
 5690/X11
5690/x15

5690/X12 5690/X13

5690/X14 5690/X17

8.7
HANDBOOK - 2023
TABLE 1: GENERAL CHARACTERISTICS OF ELECTRONIC OIL LEVEL REGULATORS

Opening Pressure
Connections TS [°C]
Differential [bar}
Risk Category
Cables kit PS
Part number Version Adapters Oil inlet Weight [g] according
(1) [bar]
Min Max Min Max to PED Recast
(1) SAE FLARE

5650E/11RA2

Right

5690/X11
5650E/11RA6
5690/X12
5690/X13
5690/X14 3/8” 9901/X26 2 60 90 -30 +130 990 Art. 4.3
5690/X15
5690/X17
5650E/11LA2
5690E/X01

Left

5650E/11LA6

5658E/07RA2

Right

5690/X11
5658E/07RA6
5690/X12
5690/X13
5690/X14 3/8” 9901/X26 2 100 140 -30 +130 990 Art. 4.3
5690/X15
5690/X17
5658E/07LA2
5690E/X01

Left

5658E/07LA6

Note: (1) To be ordered separately

8.8
GOGREEN HANDBOOK - 2023
 TABLE 2: ELECTRICAL CHARACTERISTICS

Coil (1) Alarm contact

Voltage
Voltage Frequency Coil consumption Degree of
Part number Tolerance Insulation
[V] [Hz] Power at 20 °C [mA] protection Admissible Max
[%] Tipo class
[W] load voltage
EN 60730 Start Working

5650E/11RA2 24 A.C. +10 / -10 50 / 60 9300/RA2 H 8 920 527

5650E/11RA6 220 A.C. +10 / -10 50 / 60 9300/RA6 H 8 120 68

IP 65 3A 250 V

5650E/11LA2 24 A.C. +10 / -10 50 / 60 9300/RA2 H 8 920 527

5650E/11LA6 220 A.C. +10 / -10 50 / 60 9300/RA6 H 8 120 68

5658E/07RA2 24 A.C. +10 / -10 50 / 60 9300/RA2 H 8 920 527

5658E/07RA6 220 A.C. +10 / -10 50 / 60 9300/RA6 H 8 120 68

IP 65 3A 250 V

5658E/07LA2 24 A.C. +10 / -10 50 / 60 9300/RA2 H 8 920 527

5658E/07LA6 220 A.C. +10 / -10 50 / 60 9300/RA6 H 8 120 68

Note: (1) Enclosed into the package

TABLE 3: CABLES KIT CHARACTERISTICS

Degree of Cable length

Part number Use
protection [m]

A Power supply cable

9901/X26 B Coil cable IP 65 3

C Alarms cable

8.9
HANDBOOK - 2023
TABLE 4: ADAPTERS CHARACTERISTICS

TS [°C]
Catalogue Number Connections PS [bar] weight [g]
min max

Flanged with:
3 screws, distance between 1.7/8”
5690/X11 506
4 screws, distance between 50 mm
L = 83 mm

Threaded
5690/X12 254
1-1,8” - 12 UNF

Threaded
5690/X13 346
1 - 1,8” - 18 UNEF

Threaded
5690/X14 140 -30 +130 246
3/4” - 14 NPT

Flanged with:
3 screws, distance between 1.7/8”
5690/X15 405
4 screws, distance between 50 mm
L = 53 mm

5690/X17 Rotalock 1.1/4” - 12 UNF 390

Flanged with:
6 screws, distance between 1.7/8”
5690E/X01 405
4 screws, distance between 50 mm
L = 53 mm

Based on the compressor make and model number, it’s possible that an adapter may be required.
Please check the OEM compressor literature for specific requirements regard the need for an adapter

8.10
GOGREEN HANDBOOK - 2023
 CHAPTER 8

OIL CONTROL SYSTEMS

8.2 – OIL RESERVOIR PRESSURE VALVES

3150W/X04
APPLICATIONS 3150W/X05
3150W/X06
The oil reservoir pressure valves in series 3150W are considered
“Pressure Accessories” according to the definition provided in
Article 2, Point 5 of the Directive 2014/68/EU (PED Recast) and
are subject to the classification indicated in Article 4, Points 1.c)
and 3 of the same Directive.
These valves have been developed by Castel for all the applications
that use trans-critical R744 refrigerant fluid belonging to Group 2,
defined in Article 13, Chapter 1, Point (b) of Directive 2014/68/EU,
with reference to EC Regulation No. 1272/2008.
CAUTION! The check valves in this chapter cannot be used
with other refrigerant fluids.

CONSTRUCTION
Castel manufactures three oil reservoirs pressure relief valves with
different pressures. A higher-pressure differential will increase the
oil flow rate from the oil reservoir back to the compressor crankcase.
The selection of the model must consider both the individual
compressor crankcase pressures as well as the differential pressure
range of the oil regulators.
The main components of the valves are made with the following
materials:
- Hot forged brass EN 12164 – CW 614N for body and cover valves
series 3150W are equipped with laser welds between the body and
the cover to ensure that the product is hermetically sealed.
- Austenitic stainless steel AISI 302 for the spring
- Laminated glass fibre fabric and PTFE for gasket seat seals

INSTALLATION
These valves are used to relieve pressure in the oil reservoir while
maintaining a positive pressure differential between the reservoir
and the compressor crankcase. This positive pressure ensures
adequate oil supply to the oil level regulator. The calibrated pressure
relief valve is mounted directly on the 3/8” SAE Flare connection
of the reservoir and is piped to the suction line.

TABLE 5: GENERAL CHARACTERISTICS OF OIL RESERVOIR PRESSURE VALVES

SAE Flare
Kv TS [°C] Dimensions and weights Risk Category
Connections Pressure
Catalogue Number Factor PS [bar] according to PED
Differential [bar]
[m3/h] Recast
IN OUT min. max. D L Ch1 Ch2 [g]

3150W/X04 7

3150W/X05 3/8”- F 3/8”- M 1,6 9 140 – 40 +150 35 96 32 32 395 Art. 4.3

3150W/X06 12

8.11
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 8.12
GOGREEN HANDBOOK - 2023
 CHAPTER 8

OIL CONTROL SYSTEMS

8.3 – OIL INDICATORS
See: Chapter 7 - Paragraph 7.1

8.4 – STRAINERS
See: Chapter 7 - Paragraph 7.6 and 7.7

8.5 – NORMALLY CLOSED SOLENOID VALVES

See: Chapter 2 - Paragraph 2.1

8.13
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 8.14
GOGREEN HANDBOOK - 2023
VALVES
 CHAPTER 9

VALVES
9.1 – VALVES WITH SCREW SHUTTER

APPLICATIONS the spindle assembly, including the packing gland before brazing
the body. It is important to avoid direct contact between the torch
The valves with screw shutter are considered “Pressure flame and the body, which could be damaged and compromise the
Accessories” according to the definition provided in Article 2, proper functioning of the valves.
Point 5 of the Directive 2014/68/EU (PED Recast) and are subject
to the classification indicated in Article 4, Points 1.c) and 3 of the
same Directive.
These valves have been developed by Castel for all the applications
that use the sub-critical or trans-critical R744 refrigerant fluid
belonging to Group 2, defined in Article 13, Chapter 1, Point (b)
of Directive 2014/68/EU, with reference to EC Regulation No.
1272/2008.
CAUTION! The valves in this chapter cannot be used with
other refrigerant fluids.

HERMETIC VALVES
The hermetic valves are two-way shut-off valves with SAE flare
connections for types 6010E.
The main parts of these valves are made with the following materials:
- Hot forged brass EN 12420 – CW 617N for the body.
- Steel, with proper surface protection, or brass for the spindle
- Ethylene propylene rubber (EPDM) and aramid fibres for packing
gland seal.
- Glass-reinforced PBT for the protective cap that covers the spindle.

RECEIVER VALVES
The receiver valves are two-way valves with square connections,
SAE flare / ODS, types 6110E and 6120E.
The main parts of these valves are made with the following materials:
- Hot forged brass EN 12420 – CW 617N for the body.
- Steel, with proper surface protection, for the spindle.
- Ethylene propylene rubber (EPDM) and aramid fibres for packing
gland seal.
- Glass-reinforced PBT for the protective cap that covers the spindle.

CAPPED VALVES
The capped valves are two-way shut-off valves with ODS
connections, types 6420E.
The main parts of these valves are made with the following materials:
- Hot forged brass EN 12420 – CW 617N for the body
- Steel, with proper surface protection, for the spindle.
- Ethylene propylene rubber (EPDM) and aramid fibres for packing
gland seal.
- Glass-reinforced PBT for the protective cap that covers the spindle.

The brazing of capped valves should be carried out with care,

using a low melting point filler material. It is necessary to remove

9.3
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 9.4
GOGREEN HANDBOOK - 2023
 6010E

6012E

9.5
HANDBOOK - 2023
 6110E 6120E

TABLE 1: GENERAL CHARACTERISTICS OF VALVES FOR HERMETIC SYSTEMS

Connections
TS [°C] Risk Category
Catalogue Number ODS Kv Factor [m3/h] PS [bar] according to PED
SAE Flare Recast
Ø [in.] min. max.

6010E/2 1/4” 1/4” –

140 -40 +130 Art. 4.3
,27
6012E/22 1/4” – 1/4”

TABLE 2: DIMENSIONS AND WEIGHTS OF VALVES FOR HERMETIC SYSTEMS

Dimensions [mm]
Catalogue Number Weight [g]
H1 H2 I L1 L2

6010E/2 – 58 160
14 66 36
6012E/22 29 55,5 145

9.6
GOGREEN HANDBOOK - 2023
 TABLE 3: GENERAL CHARACTERISTICS OF RECEIVER VALVES

Connections TS [°C]
Kv Factor Risk Category according
Catalogue Number PS [bar]
[m3/h] to PED Recast
SAE Flare NPT min. max.

6110E/22 _ 1/4” 1/4” _

6110E/X02 _ _ 1/4” 1/4” F

0,44
6110E/X11 1/4” 1/4” _ _

6110E/X15 1/4” F 1/4” _ _

6110E/33 _ 3/8” 3/8” _

1,35 140 -40 +130 Art. 4.3
6110E/X13 3/8” F 3/8” _ _

6110E/44 _ 1/2” 1/2” _ 3,40

6120E/22 _ 1/4” 1/4” _ 0,44

6120E/33 _ 3/8” 3/8” _ 1,35

6120E/44 _ 1/2” 1/2” _ 3,40

TABLE 4: DIMENSIONS AND WEIGHTS OF RECEIVER VALVES

Dimensions [mm]
Catalogue Number Weight [g]
H1 H2 L1 L2

6110E/22 110
72 48 27,5
6110E/X02 100

6110E/X11 90,5 58 28,5 230

6110E/X15 83 48 27,5 – 130

6110E/33 77 140
50 31
6110E/X13 87 175

6110E/44 92 55,5 34,5 235

6120E/22 27,5 72 48 110

6120E/33 30 – 80 50 140

6120E/44 33 93 55,5 305

9.7
HANDBOOK - 2023
 6110E/X13 6420E
6110E/X15

TABLE 5: GENERAL CHARACTERISTICS OF CAPPED VALVES

Connections
TS [°C] Risk Category
Catalogue Number ODS Kv Factor [m3/h] PS [bar] according to PED
SAE Flare Recast
Ø [in.] min. max.

6420E/2 1/4” 0,40

–
6420E/3 3/8”
1,00 120 -40 +130 Art. 4.3
6420E/3S3 3/8” - OUT 3/8” - IN

6420E/4 – 1/2” 1,45

TABLE 6: DIMENSIONS AND WEIGHTS OF CAPPED VALVES

Dimensions [mm]
Weight
Catalogue Number
[g]
H1 H2 L1 d I

6420E/2 57 300

6420E/3 61
85,5 67 4,5 38
6420E/3S3 67,5 305

6420E/4 70

9.8
GOGREEN HANDBOOK - 2023
 CHAPTER 9

VALVES
9.2 – TWO-WAYS VALVES WITH BALL SHUTTER

APPLICATIONS - Ethylene propylene rubber (EPDM) for outlet seal gaskets

- P.T.F.E. for the ball seat gaskets
The 2-ways valves with ball shutter in series 6570EL, 6570E,
6577E, 6578E and 6588E are considered “Pressure Accessories” The main parts of 6588E are made with the following materials:
according to the definition provided in Article 2, Point 5 of the - Cast stainless steel AISI 304 for the body, connections and the
Directive 2014/68/EU (PED Recast) and are subject to the protective cap of the spindle.
classification indicated in Article 4, Points 1.c) and 3 of the same - Hot forged brass EN 12420 – CW 617N, chromium plated, for
Directive. the ball.
These valves have been developed by Castel for all the applications - Steel, with proper surface protection, for the spindle.
that use the sub-critical or trans-critical R744 refrigerant fluid - Ethylene propylene rubber (EPDM) for outlet seal gaskets
belonging to Group 2, defined in Article 13, Chapter 1, Point (b) - P.T.F.E. for the ball seat gaskets
of Directive 2014/68/EU, with reference to EC Regulation No.
1272/2008.
The ball valves for plants that operate using refrigerant fluid R744 INSTALLATION
are the following:
- Valves in series 6570EL, PS = 60 bar for sub-critical plants. The 2-ways valves with ball shutter can be installed in all sections of
- Valves in series 6570E, PS = 80 bar for trans-critical plants low a refrigerating system, in compliance with the limits and capacities
and medium pressure sides. indicated in Tables from 7 up to 12. These tables show the following
- Valves in series 6577E, PS = 130 bar for trans-critical plants functional characteristics of a valve with ball shutter.
high-pressure side. - PS
- Valves in series 6578E, PS = 140 bar for trans-critical plants - TS
high-pressure side. - Kv factor
- Valves in series 6588E, PS = 150 bar for trans-critical plants Copper connections: The brazing of valves with copper connections
high-pressure side. should be carried out with care, using a low melting point filler
CAUTION! The ball valves in this chapter cannot be used with material (min. 5% Ag). It is not necessary to disassemble the valves,
other refrigerant fluids. but it is important to avoid direct contact between the torch flame
and the valve body, which could be damaged and compromise the
proper functioning of the valve.
CONSTRUCTION Steel connectors: TIG welding recommended, to be performed as
quickly as possible according to the method shown in the product
The specific design of 2-ways valves with ball shutter: instruction sheet. The connection material is AISI 304: it is only
- ensures the internal pressure equilibrium when the valve is closed, possible to use AISI 308 filler material if welding to pipes made from
- permits the two-directional flow of the refrigerant the same type of material. For pipes made from other materials,
- prevents any risk of ejection or explosion of the spindle. please contact your welding supplies supplier.
The electric welding of the body and the spindle gaskets ensure
perfect hermetic seal of the valve.
CERTIFICATIONS
The valves in series 6570EL, 6577E and 6578E are available
without access fitting. The American certification authority Underwriters Laboratories Inc.
The valves in series 6570E and 6588E are available in two series: has approved valves with ball shutter with file SA33319. These
- 6570E/XX and 6588E/XX without access fitting. valves are certified UL Listed for the USA, in compliance with
- 6570E/XXA and 6588E/XXA with access fitting. These valves American standard UL 207 with a Design Pressure of:
are equipped with mechanism 8395/A4. • 1160 PSI for valves in series 6570E
• 1740 PSI for valves in series 6577E/13 and 6578E/M48
The main parts of 6570EL , 6570E, 6577E and 6578E are made • 1885 PSI for valves in series 6577E
with the following materials: • 2030 PSI for valves in series 6578E
- Hot forged brass EN 12420 – CW 617N for the body and the • 2176 PSI for valves in series 6588E
protective cap of the spindle NB: valves 6577E/17, 6578E/M60 and 6578E/M73 are not UL
- Hot forged brass EN 12420 – CW 617N, chromium plated, for approved.
the ball
- Copper pipe EN 12735-1 – Cu-DHP for welded connections in
series 6570EL and 6570E.
- Copper pipe EN 12735-1 – CuFe2P (K65) for welded connections
in series 6577E
- Stainless steel pipe AISI 304 for welded connections in series
6578E.
- Steel, with proper surface protection, for the spindle.

9.9
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 9.10
GOGREEN HANDBOOK - 2023
 6570EL
6577E

6570E/A

6588E

6588E/A

9.11
HANDBOOK - 2023
TABLE 7 GENERAL CHARACTERISTICS OF BALL VALVES WITH COPPER ODS CONNECTIONS

Connections
TS [°C]
Ball Risk Category according
Catalogue Number ODS Kv Factor [m3/h] PS [bar]
Port Ø [mm] to PED Recast

Ø [in.] Ø [mm] min. max.

6570EL/M6 – 6
0,8
6570EL/2 1/4” –

6570EL/3 3/8” –
10 3
6570EL/M10 – 10

6570EL/M12 – 12
5
6570EL/4 1/2” –

6570EL/5 5/8” 16 Art. 4.3

6570EL/M18 – 18 15 17
60 -40 +150
6570EL/6 3/4” –

6570EL/7 7/8” 22 19 29

6570EL/M28 – 28
25 51
6570EL/9 1.1/8” –

6570EL/11 1.3/8” 35 32 86

6570EL/13 1.5/8” –
40 117
6570EL/M42 – 42 I

6570EL/17 2.1/8” 54 50 214

TABLE 8: GENERAL CHARACTERISTICS OF BALL VALVES WITH REINFORCED COPPER ODS CONNECTIONS

Connections
TS [°C]
Ball Risk Category according
Catalogue Number ODS Kv Factor [m3/h] PS [bar]
Port Ø [mm] to PED Recast

Ø [in.] Ø [mm] min. max.

6570E/M6 – 6
0,8
6570E/2 1/4” –

6570E/3 3/8” –
10 3
6570E/M10 – 10

6570E/M12 – 12
5
6570E/4 1/2” –

6570E/5 5/8” 16 Art. 4.3

6570E/M18 – 18 15 17
80 -40 +150
6570E/6 3/4” –

6570E/7 7/8” 22 19 29

6570E/M28 – 28
25 51
6570E/9 1.1/8” –

6570E/11 1.3/8” 35 32 86

6570E/13 1.5/8” –
40 117
6570E/M42 – 42 I

6570E/17 2.1/8” 54 50 214

9.12
GOGREEN HANDBOOK - 2023
 TABLE 9: GENERAL CHARACTERISTICS OF BALL VALVES WITH REINFORCED COPPER ODS CONNECTIONS, ACCESS FITTING

Connections
TS [°C]
Ball Risk Category according
Catalogue Number ODS Kv Factor [m3/h] PS [bar]
Port Ø [mm] to PED Recast

Ø [in.] Ø [mm] min. max.

6570E/M6A – 6
0,8
6570E/2A 1/4” –

6570E/3A 3/8” –
10 3
6570E/M10A – 10

6570E/M12A – 12
5
6570E/4A 1/2” –

6570E/5A 5/8” 16 Art. 4.3

6570E/M18A – 18 15 17
80 -40 +150
6570E/6A 3/4” –

6570E/7A 7/8” 22 19 29

6570E/M28A – 28
25 51
6570E/9A 1.1/8” –

6570E/11A 1.3/8” 35 32 86

6570E/13A 1.5/8” –
40 117
6570E/M42A – 42 I

6570E/17A 2.1/8” 54 50 214

TABLE 10: GENERAL CHARACTERISTICS OF BALL VALVES WITH K65 COPPER ALLOY ODS CONNECTIONS

Connections
TS [°C]
Ball Risk Category according
Catalogue Number ODS Kv Factor [m3/h] PS [bar]
Port Ø [mm] to PED Recast

Ø [in.] Ø [mm] min. max.

6577E/2 1/4” – 0,8

6577E/3 3/8” – 10 3

6577E/4 1/2” – 5

6577E/5 5/8” 16
15 17 Art. 4.3
6577E/6 3/4” – 130
-40 +150
6577E/7 7/8” 22 19 29

6577E/9 1.1/8” – 25 51

6577E/11 1.3/8” 35 32 86

6577E/13 1.5/8” – 40 117

I
6577E/17 2.1/8” 54 50 214 120

9.13
HANDBOOK - 2023
TABLE 11: GENERAL CHARACTERISTICS OF BALL VALVES WITH STAINLESS STEEL CONNECTIONS

Connections
TS [°C]
Ball Risk Category according
Catalogue Number W Kv Factor [m3/h] PS [bar]
Port Ø [mm] to PED Recast

Ø [mm] min. max.

6578E/M6 6 0,8

6578E/M10 10 10 3

6578E/M12 12 5

6578E/M16 16
15 17 Art. 4.3
6578E/M18 18
140
6578E/M22 22 19 29
-40 +150
6578E/M28 28 25 51

6578E/M35 35 32 86

6578E/M42 42
40 117
6578E/M48 48,3
I
6578E/M60 60,3 50 214
120
6578E/M73 73 60 380

TABLE 12: GENERAL CHARACTERISTICS OF STAINLESS STEEL BALL VALVES

Connections
TS [°C]
Ball Risk Category according
Catalogue Number W Kv Factor [m3/h] PS [bar]
Port Ø [mm] to PED Recast

Ø [mm] min. max.

6588E/M10 10 3
10
6588E/M12 12 5

6588E/M16 16
15 17
6588E/M18 18 Art. 4.3

6588E/M22 22 19 29
150 -40 +150
6588E/M28 28 25 51

6588E/M35 35 32 86

6588E/M42 42
40 117
6588E/M48 48,3 I

6588E/M60 60,3 50 214

9.14
GOGREEN HANDBOOK - 2023
 TABLE 13: GENERAL CHARACTERISTICS OF STAINLESS STEEL BALL VALVES, ACCESS FITTING

Connections
TS [°C]
Ball Risk Category according
Catalogue Number W Kv Factor [m3/h] PS [bar]
Port Ø [mm] to PED Recast

Ø [mm] min. max.

6588E/M10A 10 3
10
6588E/M12A 12 5
6588E/M16A 16
15 17
6588E/M18A 18 Art. 4.3
6588E/M22A 22 19 29
150 -40 +150
6588E/M28A 28 25 51
6588E/M35A 35 32 86
6588E/M42A 42
40 117
6588E/M48A 48,3 I
6588E/M60A 60,3 50 214

TABLE 14: REFRIGERANT FLOW CAPACITY OF BALL VALVES [KW]

Catalogue Number Subcritical system Transcritical system

w/o access fitting with access fitting liquid line suction line hot gas line gas cooler line suction line hot gas line

with copper connections

6570EL/M6
21 4,2 16
6570EL/2
6570EL/3
80 16 61
6570EL/M10
6570EL/M12
134 27 101
6570EL/4
6570EL/5
6570EL/M18 456 90 343
-
6570EL/6
6570EL/7 777 154 585
6570EL/M28
1367 270 1029
6570EL/9
6570EL/11 2305 456 1735
6570EL/13
3136 620 2361
6570EL/M42
6570EL/17 5735 1134 4319
with reinforced copper connections
6570E/M6 6570E/M6A
21 4,2 16 3,7
6570E/2 6570E/2A
6570E/3 6570E/3A
80 16 61 14
6570E/M10 6570E/M10A
6570E/M12 6570E/M12A
134 27 101 23
6570E/4 6570E/4A
6570E/5 6570E/5A
6570E/M18 6570E/M18A 456 90 343 79
6570E/6 6570E/6A
6570E/7 6570E/7A 777 154 585 134
6570E/M28 6570E/M28A
1367 270 1029 236
6570E/9 6570E/9A
6570E/11 6570E/11A 2305 456 1735 398
6570E/13 6570E/13A
3136 620 2361 542
6570E/M42 6570E/M42A
6570E/17 6570E/17A 5735 1134 4319 991

continue →

9.15
HANDBOOK - 2023
TABLE 14: REFRIGERANT FLOW CAPACITY OF BALL VALVES [KW]

Catalogue Number Subcritical system Transcritical system

w/o access fitting with access fitting liquid line suction line hot gas line gas cooler line suction line hot gas line

with K65 copper alloy connections

6577E/2 21 3,7 15
6577E/3 79 14 56
6577E/4 131 23 93
6577E/5
447 79 318
6577E/6
6577E/7 762 134 542
6577E/9 1340 236 953
6577E/11 2259 398 1607
6577E/13 3074 542 2187
6577E/17 5622 991 4000
with stainless steel connections
6578E/M6 21 3,7 15
6578E/M10 79 14 56
6578E/M12 131 23 93
6578E/M16
447 79 318
6578E/M18
6578E/M22 762 134 542
6578E/M28 1340 236 953
6578E/M35 2259 398 1607
6578E/M42
3074 542 2187
6578E/M48
6578E/M60 5622 991 4000
6578E/M73 9983 1759 7102
with stainless steel body / connections
6588E/M10 6588E/M10A 79 14 56
6588E/M12 6588E/M12A 131 23 93
6588E/M16 6588E/M16A
447 79 318
6588E/M18 6588E/M18A
6588E/M22 6588E/M22A 762 134 542
6588E/M28 6588E/M28A 1340 236 953
6588E/M35 6588E/M35A 2259 398 1607
6588E/M42 6588E/M42A
3074 542 2187
6588E/M48 6588E/M48A
6588E/M60 6588E/M60A 5622 991 4000

Standard rating conditions according to AHRI Standard 760-2007 Standard rating conditions according to AHRI Standard 760-2007
for subcritical systems for transcritical systems

Condensing temperature 30 °F (- 1,2 °C) Gas-cooler outlet temperature 95 °F (35 °C)

Liquid temperature 20 °F (- 6,7 °C) Evaporating temperature 14 °F (- 10 °C)
Subcooling 10 °R (5,5 °K) Evaporator outlet temperature 23 °F (- 5 °C)
Evaporating temperature - 20 °F (- 28,9 °C) Evaporator superheating 9 °R (5 °K)
Evaporator outlet temperature - 10 °F (- 23,4 °C) Suction line temperature 32 °F (0 °C)
Evaporator superheating 10 °R (5,5 °K) Suction line superheating 9 °R (5 °K)
Suction line temperature - 5 °F (-15 °C) Discharge temperature 212 °F (110 °C)
Suction line superheating 15 °R (8,4 °K)
Discharge temperature 80 °F (26,6 °C)

9.16
GOGREEN HANDBOOK - 2023
 TABLE 15: DIMENSIONS AND WEIGHTS OF BALL VALVES

Catalogue Number Dimensions [mm]

Weight [g]
w/o access fitting with access fitting H H1 H2 L L1 L2 I d

with copper connections

6570EL/M6

6570EL/2

6570EL/3
47 15 121 65 18 216
6570EL/M10

6570EL/M12

6570EL/4
M4
6570EL/5

6570EL/M18 54 19 139 73 25,5 333

- - -
6570EL/6

6570EL/7 70 23 175 94 610

6570EL/M28 30
78 27 203 109 834
6570EL/9

6570EL/11 100 32 213 115 1500

6570EL/13 42
114 39 242 130 M6 2396
6570EL/M42

6570EL/17 137 49 282 154 55 4260

with reinforced copper connections

6570E/M6 6570E/M6A

6570E/2 6570E/2A

6570E/3 6570E/3A
47 15 29 121 65 24,5 18 216
6570E/M10 6570E/M10A

6570E/M12 6570E/M12A

6570E/4 6570E/4A
M4
6570E/5 6570E/5A

6570E/M18 6570E/M18A 55 19 32 139 73 30 25,5 333

6570E/6 6570E/6A

6570E/7 6570E/7A 70 23 34 175 94 39,5 610

6570E/M28 6570E/M28A 30
78 27 37 203 109 45 834
6570E/9 6570E/9A

6570E/11 6570E/11A 100 32 40,5 213 115 43,5 1600

6570E/13 6570E/13A 42
114 39 44 242 130 48 M6 2570
6570E/M42 6570E/M42A

6570E/17 6570E/17A 137 49 50 282 154 61 55 4660

with K65 copper alloy connections

6577E/2 115 62

6577E/3 47 15 123 18 213

66
6577E/4 121 M4

6577E/5 333
54 19 139 70 25,5
6577E/6 337
- - -
6577E/7 76 26 175 93 18 M5 754

6577E/9 82 28 208 111 30 1104

6577E/11 100 32 213 115 1670

42 M6
6577E/13 114 39 242 130 2614

6577E/17 137 49 282 154 55 4942

continue →

9.17
HANDBOOK - 2023
TABLE 15: DIMENSIONS AND WEIGHTS OF BALL VALVES

Catalogue Number Dimensions [mm]

Weight [g]
w/o access fitting with access fitting H H1 H2 L L1 L2 I d

with stainless steel connections

6578E/M6 119 64

6578E/M10 47 15 18 210
123 66
6578E/M12 M4

6578E/M16
54 19 142 74 25,5 333
6578E/M18

6578E/M22 76 26 176 94 18 M5 722

- - -
6578E/M28 82 28 208 111 30 1035

6578E/M35 100 32 213 115 1610

6578E/M42 240 129 42 M6 2442

114 39
6578E/M48 242 130 2650

6578E/M60 137 49 282 154 55 4800

6578E/M73 186 70 312 164 89 M8 12424

with stainless steel body / connections

6588E/M10 6588E/M10A
48 15 24 108 50 28 18 210
6588E/M12 6588E/M12A

6588E/M16 6588E/M16A 322

55 19 27 126 66 25,5 M4
6588E/M18 6588E/M18A 350

6588E/M22 6588E/M22A 69 23 29 130 69 30 600

30
6588E/M28 6588E/M28A 77,5 27 32 144 79 780

6588E/M35 6588E/M35A 100 32 35,5 160 85

6588E/M42 6588E/M42A 39 42
114 39 185 100 35 M6 774
6588E/M48 6588E/M48A 42

6588E/M60 6588E/M60A 138 49 49 214 119 30 55

9.18
GOGREEN HANDBOOK - 2023
 CHAPTER 9

VALVES
9.3 – THREE-WAYS MANUAL VALVES WITH BALL SHUTTER

APPLICATIONS adapter to be used with Castel or other brands actuators, refer to

the specific Castel brochure.
The 3-ways manual valves are considered “Pressure Accessories” The actuator can be mounted on the valve in four different positions,
according to the definition provided in Article 2, Point 5 of the oriented at 90° to each other. The 3-way ball valves can be mounted
Directive 2014/68/EU (PED Recast) and are subject to the in any orientation and any limitations on their mounting must be
classification indicated in Article 4, Points 1.c) and 3 of the same found on the instructions of the actuator itself.
Directive. Copper connections: The brazing of valves with solder connections
These valves have been developed by Castel for all the applications should be carried out with care, using a low melting point filler
that use the sub-critical or trans-critical R744 refrigerant fluid material (min.5 Ag). It is important to avoid direct contact between
belonging to Group 2, defined in Article 13, Chapter 1, Point (b) the torch flame and the valve body, which could be damaged and
of Directive 2014/68/EU, with reference to EC Regulation No. compromise the proper functioning of the entire valve.
1272/2008. Steel connectors: TIG welding recommended, to be performed as
The 3-way valves for plants that operate using refrigerant fluid quickly as possible according to the method shown in the product
R744 are the following: instruction sheet. The connection material is AISI 304: it is only
- valves in series 6690E and 6690/EB, PS = 80 bar for trans- possible to use AISI 308 filler material if welding to pipes made from
critical plants low and medium pressure sides. the same type of material. For pipes made from other materials,
- valves in series 6697E and 6697EB, PS = 120 bar for trans- please contact your welding supplies supplier.
critical plants high-pressure side.
- valves in series 6698E and 6698EB, PS = 140 bar trans-critical
plants high-pressure side.
CAUTION! The 3-way valves with ball shutter in this chapter cannot
be used with other refrigerant fluids.

CONSTRUCTION
The specific design of 3-ways valves with ball shutter prevents any
risk of ejection or explosion of the spindle. The electric welding of
the body and the spindle gaskets ensure perfect hermetic seal of
the valve.
The main parts of these valves are made with the following materials:
- Hot forged brass EN 12420 – CW 617N for the body
- Hot forged brass EN 12420 – CW 617N, chromium plated, for
the ball
- Stainless steel EN 10088-3 – 1.4305 for spindles
- Ethylene propylene rubber (EPDM) for outlet seal gaskets
- PTFE for the ball seat gaskets
- Hot forged brass EN 12420 – CW 617N for the protective cap
of the spindle
- Copper pipe EN 12735-1 – Cu-DHP for solder connections in
series 6690E, 6690/EB
- Copper pipe EN 12735-1 – CuFe2P (K65) for welded connections
in series 6697E, 6697/EB
- Stainless steel pipe AISI 304 for welded connections in series
6698E, 6698/EB

INSTALLATION
The 3-way valves with ball shutter act as changeover valves, not
allowing for bi-direction flow of the refrigerant fluid. The input is
always in the centre position, and the two outputs in the lateral
positions.
These valves can be coupled with:
- Castel actuators in series 9700, 9720 and 9730
- actuators of other brands at disposal on the market
using specific flanged adapters between the two parts. To find the

9.19
HANDBOOK - 2023
 9.20
GOGREEN HANDBOOK - 2023
 FIG. 1

6690E
6697E
6698E

FIG. 2

6690EB
6697EB
6698EB

9.21
HANDBOOK - 2023
TABLE 16: GENERAL CHARACTERISTICS OF 3-WAYS MANUAL VALVES

Connections
TS [°C] Risk Category
Ball Kv Factor PS
Catalogue Number ODS according to
Port Ø [mm] [m3/h] [bar]
W [mm] PED Recast
Ø [in.] Ø [mm] min. max.

with reinforced copper ODS connections

6690E/3 3/8” -

6690E/M10 - 10

6690E/M12 - 12

6690E/4 1/2” - 13,5 4,6

6690E/5 5/8” 16

6690E/M18 - 18 Art. 4.3

6690E/6 3/4” - – 80 -40 +150

6690E/7 7/8” 22 19 11

6690E/M28 – 28 24 16

6690E/9 1.1/8” – 24 16

6690E/11 1.3/8” 35 28 20,5

6690E/13 1.5/8” –
37 39 I
6690E/M42 – 42

with K65 copper alloy ODS connections

6697E/3 3/8” -

6697E/4 1/2” -
13,5 4,6
6697E/5 5/8” 16

6697E/6 3/4” - Art. 4.3

– 130 -40 +150
6697E/7 7/8” 22 19 11

6697E/9 1.1/8” – 24 16

6697E/11 1.3/8” 35 28 20,5

6697E/13 1.5/8” – 37 39 I

with stainless steel connections

6698E/M10 10

6698E/M12 12
13,5 4,6
6698E/M16 16

6698E/M18 18 Art. 4.3

– – 140 -40 +150
6698E/M22 22 19 11

6698E/M28 28 24 16

6698E/M35 35 28 20,5

6698E/M42 42 37 39 I

9.22
GOGREEN HANDBOOK - 2023
 TABLE 17: DIMENSIONS AND WEIGHTS OF 3-WAYS MANUAL VALVE

Dimensions [mm]
Catalogue Number Figure Weight [g]
H H1 L L1

with reinforced copper ODS connections

6690E/3
894
6690E/M10
142 62 144 85
6690E/M12
899
6690E/4

6690E/5 904

6690E/M18 150 68 158 92

909
6690E/6 1

6690E/7 165 82 172 94 1210

6690E/M28
186 100 208 111 1540
6690E/9

6690E/11 203 103 211 113 2117

6690E/13
226 121 240 127 3447
6690E/M42

with K65 copper alloy ODS connections

6697E/3 146 66 152 89

894
6697E/4 142 62 144 85

6697E/5 949
150 68 158 92
6697E/6 959
1
6697E/7 165 82 172 94 1210

6697E/9 186 100 208 111 1610

6697E/11 204 101 211 113 2449

6697E/13 226 121 240 127 3660

with stainless steel connections

6698E/M10 146 66 152 86 899

6698E/M12 142 62 144 85 909

6698E/M16 154 72 166 96 949

6698E/M18 154 72 166 96 959

1
6698E/M22 165 82 172 94 1180

6698E/M28 186 100 208 111 1600

6698E/M35 202 101 209 112 2250

6698E/M42 225 120 238 126 3290

9.23
HANDBOOK - 2023
TABLE 18: GENERAL CHARACTERISTICS OF 3-WAYS VALVES TO BE MOTORIZED

Connections
TS [°C] Risk Category
Ball Kv Factor PS
Catalogue Number ODS according to
Port Ø [mm] [m3/h] [bar]
W [mm] PED Recast
Ø [in.] Ø [mm] min. max.

with reinforced copper ODS connections

6690EB/3 3/8” -

6690EB/M10 - 10

6690EB/M12 - 12

6690EB/4 1/2” - 13,5 4,6

6690EB/5 5/8” 16

6690EB/M18 - 18 Art. 4.3

6690EB/6 3/4” - – 80 -40 +150

6690EB/7 7/8” 22 19 11

6690EB/M28 – 28 24 16

6690EB/9 1.1/8” – 24 16

6690EB/11 1.3/8” 35 28 20,5

6690EB/13 1.5/8” –
37 39 I
6690EB/M42 – 42

with K65 copper alloy ODS connections

6697EB/3 3/8” -

6697EB/4 1/2” -
13,5 4,6
6697EB/5 5/8” 16

6697EB/6 3/4” - Art. 4.3

– 130 -40 +150
6697EB/7 7/8” 22 19 11

6697EB/9 1.1/8” – 24 16

6697EB/11 1.3/8” 35 28 20,5

6697EB/13 1.5/8” – 37 39 I

with stainless steel connections

6698EB/M10 10

6698EB/M12 12
13,5 4,6
6698EB/M16 16

6698EB/M18 18 Art. 4.3

– – 140 -40 +150
6698EB/M22 22 19 11

6698EB/M28 28 24 16

6698EB/M35 35 28 20,5

6698EB/M42 42 37 39 I

9.24
GOGREEN HANDBOOK - 2023
 TABLE 19: DIMENSIONS AND WEIGHTS OF 3-WAYS VALVES TO BE MOTORIZED

Dimensions [mm]
Catalogue Number Figure Weight [g]
H H1 L L1 Ch

with reinforced copper ODS connections

6690EB/3 575

6690EB/M10 575
92 62 144 85
6690EB/M12 580

6690EB/4 580

6690EB/5 585
9
6690EB/M18 100 68 158 92 590

6690EB/6 2 590

6690EB/7 156 82 172 94 1210

6690EB/M28 1540
177 100 208 111
6690EB/9 1540

6690EB/11 186 103 211 113 2117

6690EB/13 11
209 121 240 127 3447
6690EB/M42

with K65 copper alloy ODS connections

6697EB/3 96 68 152 89 575

6697EB/4 92 62 144 85 575

6697EB/5 630
100 68 158 92 9
6697EB/6 640
2
6697EB/7 156 82 172 94 1300

6697EB/9 177 100 208 111 1600

6697EB/11 186 103 211 113 2130

11
6697EB/13 209 121 240 127 3500

with stainless steel connections

6698EB/M10 96 68 152 89 580

6698EB/M12 101 62 144 85 590

6698EB/M16 104 73 630

166 96 9
6698EB/M18 112 72 640
2
6698EB/M22 156 82 172 94 1400

6698EB/M28 177 100 208 111 1700

6698EB/M35 186 102 209 112 2230

11
6698EB/M42 209 120 238 126 3550

9.25
HANDBOOK - 2023
 9.26
GOGREEN HANDBOOK - 2023
 CHAPTER 9

VALVES
9.4 – THREE-WAYS MOTORIZED VALVES WITH BALL SHUTTER

APPLICATIONS INSTALLATION
The 3-ways motorized valves are considered “Pressure The 3-way valves with ball shutter act as changeover valves, not
Accessories” according to the definition provided in Article 2, allowing for bi-direction flow of the refrigerant fluid. The input is
Point 5 of the Directive 2014/68/EU (PED Recast) and are subject always in the centre position, and the two outputs in the lateral
to the classification indicated in Article 4, Points 1.c) and 3 of the positions. These valves are coupled directly to actuators and do
same Directive. not require a flanged adapter between the two parts. The actuator
These valves have been developed by Castel for all the applications can be mounted on the valve in four different positions, oriented
that use the sub-critical or trans-critical R744 refrigerant fluid at 90° to each other.
belonging to Group 2, defined in Article 13, Chapter 1, Point (b) The 3-way valves in series: 6690EM, 6697EM, and 6698EM can
of Directive 2014/68/EU, with reference to EC Regulation No. be mounted:
1272/2008. - With horizontal output connections and vertical input connection,
The 3-way valves for plants that operate using refrigerant fluid facing downward.
R744 are the following: - With vertical output connections and horizontal input connection.
- valves in series 6690EM, PS = 80 bar for trans-critical plants The actuator for the 3-way valves can never be mounted:
low and medium pressure sides. - Upside-down, oriented facing downward
- valves in series 6697EM, PS = 120 bar for trans-critical plants - Vertically, with the cable oriented upwards
high-pressure side.
- valves in series 6698EM, PS = 140 bar trans-critical plants Once the valve / actuator has been coupled, remote movement of
high-pressure side. the valve is possible. In the event power is cut-off, the valve can
CAUTION! The 3-way valves with ball shutter in this chapter be operated manually, excluding the actuator with a release clutch.
cannot be used with other refrigerant fluids. The actuators 9700 and 9720 can be equipped with auxiliary
contacts in series 9750, sold separately. For more information
on the actuators , please see Chapter 8.5.
CONSTRUCTION
Copper connections: The brazing of valves with solder connections
The specific design of the 3-way valves with ball shutter in series should be carried out with care, using a low melting point filler
6690EM, 6697EM, 6698EM: material (min.5 Ag). It is important to avoid direct contact between
- Fixing flange with 4 holes the torch flame and the valve body, which could be damaged and
- Extended spindle compromise the proper functioning of the entire valve.
- No mechanical stops on the spindle rotation (OPEN and CLOSED Steel connectors: TIG welding recommended, to be performed as
positions) quickly as possible according to the method shown in the product
makes them suitable for operating only when coupled with actuators instruction sheet. The connection material is AISI 304: it is only
in series 9700, 9720 and 9730. For this reason, these valves possible to use AISI 308 filler material if welding to pipes made from
are always sold including the actuators and relative fixing plate in the same type of material. For pipes made from other materials,
versions with suffix A2 (24 VAC) or suffix A6 (230 VAC). please contact your welding supplies supplier.
3-ways valves in series 6690EM, 6697EM, and 6698EM
cannot be used without an actuators.
The electric welding of the body and the seal gaskets, assembled
on the spindle, ensure perfect hermetic seal of the valve. The
spindle construction eliminates the danger of explosion/expulsion.
The main parts of these valves are made with the following materials:
- Hot forged brass EN 12420 – CW 617N for the body
- Hot forged brass EN 12420 – CW 617N, chromium plated, for
the ball
- Stainless steel EN 10088-3 – 1.4305 for spindles
- Ethylene propylene rubber (EPDM) for outlet seal gaskets
- PTFE for the ball seat gaskets
- Hot forged brass EN 12420 – CW 617N for the protective cap
of the spindle
- Copper pipe EN 12735-1 – Cu-DHP for solder connections in
series 6690EM
- Copper pipe EN 12735-1 – CuFe2P (K65) for welded connections
in series 6697EM
- Stainless steel pipe AISI 304 for welded connections in series
6698EM

9.27
HANDBOOK - 2023
 9.28
GOGREEN HANDBOOK - 2023
 6690EM FIG. 1
6697EM

6690EM FIG. 2
6697EM

6698EM FIG. 3

6698EM FIG. 4

9.29
HANDBOOK - 2023
TABLE 20: ELECTRICAL CHARACTERISTICS OF 3-WAYS MOTORIZED VALVES

Active Power {W] Apparent Power [VA] Wiring Connections

Voltage Switching
Voltage Frequecy Protection
Catalogue Number tolerance Cable 1 m output Continuos
[V] [Hz] Degree
[%] Operation Standstill Operation Standstill 2 point output
(Open/ (0 - 10V)
Close)
with reinforced copper ODS connections
24 A.C. +20 / -20 50 / 60
6690EM/3A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6690EM/3A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6690EM/M10A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6690EM/M10A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6690EM/M12A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6690EM/M12A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6690EM/4A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6690EM/4A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6690EM/5A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6690EM/5A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6690EM/M18A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6690EM/M18A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6690EM/6A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6690EM/6A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6690EM/7A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6690EM/7A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6690EM/M28A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6690EM/M28A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6690EM/9A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6690EM/9A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6690EM/11A2 2,4 0,26 4,3 0,48 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6690EM/11A6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6690EM/13A2 2,4 0,26 4,3 0,48 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6690EM/13A6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6690EM/M42A2 2,4 0,26 4,3 0,48 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6690EM/M42A6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 3 x 0,75 mm2 YES NO IP 43

continue →

9.30
GOGREEN HANDBOOK - 2023
 TABLE 20: ELECTRICAL CHARACTERISTICS OF 3-WAYS MOTORIZED VALVES

Active Power {W] Apparent Power [VA] Wiring Connections

Voltage Switching
Voltage Frequecy Protection
Catalogue Number tolerance Cable 1 m output Continuos
[V] [Hz] Degree
[%] Operation Standstill Operation Standstill 2 point output
(Open/ (0 - 10V)
Close)
with K65 copper alloy ODS connections
24 A.C. +20 / -20 50 / 60
6697EM/3A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/3A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6697EM/4A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/4A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6697EM/5A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/5A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6697EM/6A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/6A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6697EM/7A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/7A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6697EM/9A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/9A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6697EM/11A2 2,4 0,26 4,3 0,48 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/11A6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6697EM/13A2 2,4 0,26 4,3 0,48 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/13A6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 3 x 0,75 mm2 YES NO IP 43
with stainless steel connections
24 A.C. +20 / -20 50 / 60
6698EM/M10A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M10A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6698EM/M12A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M12A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6698EM/M16A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M16A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6698EM/M18A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M18A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6698EM/M22A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M22A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6698EM/M28A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M28A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6698EM/M35A2 2,4 0,26 4,3 0,48 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M35A6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6698EM/M42A2 2,4 0,26 4,3 0,48 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M42A6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 3 x 0,75 mm2 YES NO IP 43

9.31
HANDBOOK - 2023
TABLE 21: ELECTRICAL CHARACTERISTICS OF 3-WAYS MOTORIZED VALVES

Active Power {W] Apparent Power [VA] Wiring Connections

Voltage
Voltage Frequecy Switching Protection
Catalogue Number tolerance Cable 1 m Continuos
[V] [Hz] output Degree
[%] Operation Standstill Operation Standstill output
2 point
(0 - 10V)
(Open/Close)

with reinforced copper ODS connections

24 A.C. +20 / -20 50 / 60

6690EM/3A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _

6690EM/3A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43

24 A.C. +20 / -20 50 / 60

6690EM/M10A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _

6690EM/M10A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43

24 A.C. +20 / -20 50 / 60

6690EM/M12A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _

6690EM/M12A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43

24 A.C. +20 / -20 50 / 60

6690EM/4A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _

6690EM/4A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43

24 A.C. +20 / -20 50 / 60

6690EM/5A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _

6690EM/5A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43

24 A.C. +20 / -20 50 / 60

6690EM/M18A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _

6690EM/M18A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43

24 A.C. +20 / -20 50 / 60

6690EM/6A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _

6690EM/6A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43

24 A.C. +20 / -20 50 / 60

6690EM/7A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _

6690EM/7A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43

24 A.C. +20 / -20 50 / 60

6690EM/M28A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _

6690EM/M28A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43

24 A.C. +20 / -20 50 / 60

6690EM/9A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _

6690EM/9A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43

24 A.C. +20 / -20 50 / 60

6690EM/11A2 2,4 0,26 4,3 0,48 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _

6690EM/11A6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 3 x 0,75 mm2 YES NO IP 43

24 A.C. +20 / -20 50 / 60

6690EM/13A2 2,4 0,26 4,3 0,48 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _

6690EM/13A6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 3 x 0,75 mm2 YES NO IP 43

24 A.C. +20 / -20 50 / 60

6690EM/M42A2 2,4 0,26 4,3 0,48 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _

6690EM/M42A6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 3 x 0,75 mm2 YES NO IP 43

continue →

9.32
GOGREEN HANDBOOK - 2023
 TABLE 21: ELECTRICAL CHARACTERISTICS OF 3-WAYS MOTORIZED VALVES

Active Power {W] Apparent Power [VA] Wiring Connections

Voltage
Voltage Frequecy Switching Protection
Catalogue Number tolerance Cable 1 m Continuos
[V] [Hz] output Degree
[%] Operation Standstill Operation Standstill output
2 point
(0 - 10V)
(Open/Close)

with K65 copper alloy ODS connections

24 A.C. +20 / -20 50 / 60
6697EM/3A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/3A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6697EM/4A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/4A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6697EM/5A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/5A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6697EM/6A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/6A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6697EM/7A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/7A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6697EM/9A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/9A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6697EM/11A2 2,4 0,26 4,3 0,48 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/11A6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6697EM/13A2 2,4 0,26 4,3 0,48 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6697EM/13A6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 3 x 0,75 mm2 YES NO IP 43
with stainless steel connections
24 A.C. +20 / -20 50 / 60
6698EM/M10A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M10A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6698EM/M12A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M12A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6698EM/M16A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M16A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6698EM/M18A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M18A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6698EM/M22A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M22A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6698EM/M28A2 4,8 1,5 8,7 3 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M28A6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6698EM/M35A2 2,4 0,26 4,3 0,48 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M35A6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 3 x 0,75 mm2 YES NO IP 43
24 A.C. +20 / -20 50 / 60
6698EM/M42A2 2,4 0,26 4,3 0,48 5 x 0,5 mm2 YES YES IP 54
24 D.C. +20 / -20 _
6698EM/M42A6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 3 x 0,75 mm2 YES NO IP 43

9.33
HANDBOOK - 2023
TABLE 22: REFRIGERANT FLOW CAPACITY OF 3-WAYS VALVES [KW]

Catalogue Number Subcritical system Transcritical system

Kv
manual to be motorized motorized liquid line suction line hot gas line gas cooler line suction line hot gas line

Rese unitarie 26,80 5,30 20,18 26,27 4,63 18,69

with reinforced copper ODS connections

6690E/3 6690EB/3 6690EM/3 4,6 123 24,4 93 21,3

6690E/M10 6690EB/M10 6690EM/M10 4,6 123 24,4 93 21,3

6690E/M12 6690EB/M12 6690EM/M12 4,6 123 24,4 93 21,3

6690E/4 6690EB/4 6690EM/4 4,6 123 24,4 93 21,3

6690E/5 6690EB/5 6690EM/5 4,6 123 24,4 93 21,3

6690E/M18 6690EB/M18 6690EM/M18 4,6 123 24,4 93 21,3

6690E/6 6690EB/6 6690EM/6 4,6 123 24,4 93 21,3

6690E/7 6690EB/7 6690EM/7 11 295 58,3 222 50,9

6690E/M28 6690EB/M28 6690EM/M28 16 429 84,8 323 74,1

6690E/9 6690EB/9 6690EM/9 16 429 84,8 323 74,1

6690E/11 6690EB/11 6690EM/11 20,5 549 108,7 414 94,9

6690E/13 6690EB/13 6690EM/13 39 1045 206,7 787 180,6

6690E/M42 6690EB/M42 6690EM/M42 39 1045 206,7 787 180,6

with K65 copper alloy ODS connections

6697E/3 6697EB/3 6697EM/3 4,6 121 21,3 86

6697E/4 6697EB/4 6697EM/4 4,6 121 21,3 86

6697E/5 6697EB/5 6697EM/5 4,6 121 21,3 86

6697E/6 6697EB/6 6697EM/6 4,6 121 21,3 86

6697E/7 6697EB/7 6697EM/7 11 289 50,9 206

6697E/9 6697EB/9 6697EM/9 16 420 74,1 299

6697E/11 6697EB/11 6697EM/11 20,5 539 94,9 383

6697E/13 6697EB/13 6697EM/13 39 1025 180,6 729

with stainless steel connections

6698E/M10 6698EB/M10 6698EM/M10 4,6 121 21,3 86

6698E/M12 6698EB/M12 6698EM/M12 4,6 121 21,3 86

6698E/M16 6698EB/5 6698EM/5 4,6 121 21,3 86

6698E/M18 6698EB/M18 6698EM/M18 4,6 121 21,3 86

6698E/M22 6698EB/M22 6698EM/M22 11 289 50,9 206

6698E/M28 6698EB/M28 6698EM/M28 16 420 74,1 299

6698E/M35 6698EB/M35 6698EM/M35 20,5 539 94,9 383

6698E/M42 6698EB/M42 6698EM/M42 39 1025 180,6 729

Standard rating conditions according to AHRI Standard 760-2007 Standard rating conditions according to AHRI Standard 760-2007
for subcritical system for transcritical system

Condensing temperature 30 °F (- 1,2 °C) Gas-cooler outlet temperature 95 °F (35 °C)

Liquid temperature 20 °F (- 6,7 °C) Evaporating temperature 14 °F (- 10 °C)
Subcooling 10 °R (5,5 °K) Evaporator outlet temperature 23 °F (- 5 °C)
Evaporating temperature - 20 °F (- 28,9 °C) Evaporator superheating 9 °R (5 °K)
Evaporator outlet temperature - 10 °F (- 23,4 °C) Suction line temperature 32 °F (0 °C)
Evaporator superheating 10 °R (5,5 °K) Suction line superheating 9 °R (5 °K)
Suction line temperature - 5 °F (-15 °C) Discharge temperature 212 °F (110 °C)
Suction line superheating 15 °R (8,4 °K)
Discharge temperature 80 °F (26,6 °C)

9.34
GOGREEN HANDBOOK - 2023
 TABLE 23: DIMENSIONS AND WEIGHTS OF 3-WAYS MOTORIZED VALVES

Dimensions [mm]
Catalogue Number Figure Weight [g]
H H1 H2 (1) L L1 Ch

with reinforced copper ODS connections

6690EM/3A2 1 158 190 1,4

6690EM/3A6 2 179 201 2,3

6690EM/M10A2 1 158 190 1,4

6690EM/M10A6 2 179 201 2,3

62 144 85
6690EM/M12A2 1 158 190 1,4

6690EM/M12A6 2 179 201 2,3

6690EM/4A2 1 158 190 1,4

-
6690EM/4A6 2 179 201 2,3

6690EM/5A2 1 165 197 1,4

6690EM/5A6 2 186 208 2,3

6690EM/M18A2 1 165 197 1,4

68 158 92
6690EM/M18A6 2 186 208 2,3

6690EM/6A2 1 165 197 1,4

6690EM/6A6 2 186 208 2,3

6690EM/7A2 1 188 246 2,6

82 172 94
6690EM/7A6 2 210 246 2,7

6690EM/M28A2 1 210 268 3,5

100 208 111 6
6690EM/M28A6 2 231 268 3,6

6690EM/9A2 1 210 268 3,5

100 208 111
6690EM/9A6 2 231 268 3,6

6690EM/11A2 2 4,2
240 103 273 211 113
6690EM/11A6 2 4,3

6690EM/13A2 2 5,2
263 121 296 240 127 10
6690EM/13A6 2 5,3

6690EM/M42A2 2 5,2
263 121 296 240 127
6690EM/M42A6 2 5,3

with K65 copper alloy ODS connections

6697EM/3A2 1 162 194 1,4

66 152
6697EM/3A6 2 183 205 2,3
89
6697EM/4A2 1 158 190 1,4
62 144
6697EM/4A6 2 179 201 2,3
-
6697EM/5A2 1 165 197 1,4

6697EM/5A6 2 186 208 2,4

68 158 92
6697EM/6A2 1 165 197 1,4

6697EM/6A6 2 186 208 2,4

6697EM/7A2 1 188 246 2,8

82 172 94
6697EM/7A6 2 210 246 3,0
6
6697EM/9A2 1 210 268 3,7
100 208 111
6697EM/9A6 2 231 268 3,9

6697EM/11A2 1 4,5
240 103 273 211 113
6697EM/11A6 2 4,6
10
6697EM/13A2 1 5,5
263 121 296 240 127
6697EM/13A6 2 5,6

(1): total height with optional auxiliary contact continue →

9.35
HANDBOOK - 2023
TABLE 23: DIMENSIONS AND WEIGHTS OF 3-WAYS MOTORIZED VALVES

Dimensions [mm]
Catalogue Number Figure Weight [g]
H H1 H2 (1) L L1 Ch

with stainless steel connections

6690EM/M10A2 3 162 194 1,4

66 152 89
6690EM/M10A6 4 183 205 2,3

6690EM/M12A2 3 158 190 1,4

62 144 85
6690EM/M12A6 4 179 201 2,3
-
6690EM/M16A2 3 169 201 1,4

6690EM/M16A6 4 190 212 2,4

72 166 96
6690EM/M18A2 3 169 201 1,4

6690EM/M18A6 4 190 212 2,4

6698EM/M22A2 3 188 246 2,8

82 172 94
6698EM/M22A6 4 210 246 3,0
6
6698EM/M28A2 3 210 268 3,7
100 208 111
6698EM/M28A6 4 231 268 3,9

6698EM/M35A2 4 4,5
240 103 273 211 113
6698EM/M35A6 4 4,6
10
6698EM/M42A2 4 5,5
263 121 296 240 127
6698EM/M42A6 4 5,6

(1): total height with optional auxiliary contact

9.36
GOGREEN HANDBOOK - 2023
 CHAPTER 9

VALVES
9.5 – ACTUATORS

APPLICATIONS The actuators in series 9740 have a maximum rotational angle of

90°, allowed by the mechanical construction and the maximum
The actuators in series 9700, 9720, 9730 and 9740 can be stroke must be set by the customer, following the instructions.
assembled using suitable flanged connections (to be purchased The housings of actuators 9700/RA6 and 9720/RA6 have an IP43
separately) to: protection rating according to EN 60529, and a Class II electric
- 2-way valves with ball shutter in series 6570EL, 6570E, 6577E, shock protection rating according to EN 60730-1. In the event
6578E and 6588E. of outdoor installation, it is recommended that the actuators be
- 3-way manual valves with ball shutter in series 6690E, 6690EB, protected from the weather.
6697E, 6697EB, 6598E and 669EB. The housings of actuators 9700/RA2, 9720/RA2, 9730/RA2 and
Once this coupling has been performed, the valves can be opened 9730/RA6 have an IP54 protection rating according to EN 60529,
or closed remotely. Alternatively, the actuator can be excluded and and a Class III electric shock protection rating according to EN
the valve operated manually. 60730-1.In the event of outdoor installation, it is recommended
The actuators in series 9700 and 9720 are also included in the that the actuators be protected from the weather.
package of 3-way motorized valve with ball shutter in series The housings of actuators 9740 have an IP66 protection rating
6690EM, 6697EM and 6698E. according to EN 60529, and a Class II electric shock protection
rating according to EN 60730-1.
To install the actuators on the valves and cable them, follow the
CONSTRUCTION instructions provided in the package.

Actuators in series 9700 and 9720: Casing in two parts of

self-extinguishing synthetic material, lower part black, upper part CERTIFICATIONS
blue. The upper part of the casing holds the actual motor (step or
synchronous) and all control and cut-out electronics based on the Actuator powered with 230 VAC are compliant with the Low Voltage
torque. The lower part of the casing holds the gear reducer, which Directive, 2006/95/EC.
requires no maintenance, and the self-centring fixing system for All actuators in this chapter comply with the Electromagnetic
the spindle. Compatibility (EMC) Directive (2004/108/EC).
Note: If the casing is opened and tampered with, any and all The American certification authority Underwriters Laboratories Inc.
the guarantees by Castel will be null and void. In the event of a has approved the actuators in series 9740.
power outage to the actuator, the gear reducer can be disengaged
using the specific lever or a button to permit manual use of the
valve.
Actuators in series 9730: Casing in two parts of self-extinguishing
synthetic black material with light gray cover. Inside the enclosure is
contained the actual motor (step-by-step), the gear reducer, which
requires no maintenance, and all control and cut-out electronics
based on the torque.
Note: If the casing is opened and tampered with, any and all
the guarantees by Castel will be null and void. In the event of a
power outage to the actuator, the gear reducer can be disengaged
using the specific lever to permit manual use of the valve.
Actuators in series 9740: Casing in two parts of self-extinguishing
synthetic material, lower part black, upper part red. The upper
part of the casing holds the actual motor (step or synchronous)
and all control and cut-out electronics based on the torque. The
lower part of the casing holds the gear reducer, which requires no
maintenance, and the star fixing system for the spindle.
Note: If the casing is opened and tampered with, any and all
the guarantees by Castel will be null and void. In the event of a
power outage to the actuator, the gear reducer can be disengaged
using the emergency manual override, under the position round
indicator.
The actuators in series 9700, 9720 and 9730 have a maximum
rotational angle of 95°, allowed by the mechanical construction.
Models 9700/RA6, 9720/RA2, 9720/RA6, 9730RA2, and 9730/
RA6 are factory set for a maximum stroke of 90°. In model 9700/
RA2, the maximum stroke of 90° must be set by the customer,
following the instructions.

9.37
HANDBOOK - 2023
 9.38
GOGREEN HANDBOOK - 2023
9.39
HANDBOOK - 2023
TABLE 24: GENERAL CHARACTERISTICS OF ACTUATORS

Active Power {W] Apparent Power [VA] Wiring Connections TA [°C]

Voltage Running
Catalogue Voltage Frequecy Torque Rotation Switching Auxiliary Protection
tolerance Time output Continuos switches Degree
Number [V] [Hz] [Nm] Angle
[%] Operation Operation [sec] 2 point output min. max.
Standstill Standstill
(Open/ (0 - 10V)
Close)

24 A.C. +20 / -20 50 / 60

9700/RA2 4,8 1,5 8,7 3 YES YES IP 54
external see
24 D.C. +20 / -20 _ 10 60
tab. 22

9700/RA6 230 A.C. +15 / -15 50 / 60 2,9 0,5 5,6 5,1 YES NO IP 43
-20 +50
24 A.C. +20 / -20 50 / 60
9720/RA2 2,4 0,26 4,3 0,48 YES YES IP 54
external see
24 D.C. +20 / -20 _ 30 120
tab. 22

9720/RA6 230 A.C. +15 / -15 50 / 60 3,7 1,1 4,7 2,7 YES NO IP 43

24 A.C. +20 / -20 50 / 60 90

9730/RA2 13,5 1,5 16,5 ND NO YES IP 54
24 D.C. +20 / -20 _ 60 150 internal -30 +50

9730/RA6 230 A.C. +15 / -15 50 / 60 13 2,0 20 ND YES NO IP 54

24 A.C. +20 / -20 50 / 60

9740/RA2 45 ND 60 ND 100 120 NO YES IP 66
24 D.C. +20 / -20 _
internal -10 55
230 A.C. +10 / -10 50 / 60
9740/RA6 45 ND 60 ND 100 120 YES NO IP 66
230 D.C. +10 / -10 _

9.40
GOGREEN HANDBOOK - 2023
 CHAPTER 9

VALVES
9.6 – AUXILIARY CONTACTS

APPLICATIONS Contact 9750/X01 has an IP54 protection rating according to

EN 60529, and a Type 1C classification for automatic operation
Auxiliary contacts in series 9750 are accessories to be used with according to EN 60730-1.
actuators in series 9700 and 9720. They are double switching Contact 9750/X02 has an IP40 protection rating according to
contacts and can be set to any position between 0° and 90°. No EN 60529, and a Type 1C classification for automatic operation
auxiliary contacts are at disposal for actuators in series 9730. according to EN 60730-1.
In the event of outdoor installation, it is recommended that the
contacts be protected from the weather.
CONSTRUCTION
Casing in two parts of self-extinguishing synthetic material, lower OPERATION
part black, upper part yellow.
Note: If the casing is opened and tampered with, any and all To install the contacts on the actuators and cable them, follow the
the guarantees by Castel will be null and void. instructions provided in the package carefully. The settings for the
Functional limits of the contacts: admissible load 5A, voltage 250 switching positions must be performed using the two trimmers
VAC. present on the yellow cover (see the instructions).

9750/X01

9750/X02

TABLE 25: GENERAL CHARACTERISTICS OF AUXILIARY SWITCHS

TA [°C]
Designed Contact
Catalogue Number Admissible load Voltage Range Cable Protection Degree
for actuator type
min. max.

9750/X01 9700/RA2 IP 54

6 x 0,5 mm2
double 5(2) A 24 ÷ 230 V -20 +50
9700/RA6 1m
9750/X02 9720/RA2 IP 40
9720/RA6

9.41
HANDBOOK - 2023
 9.42
GOGREEN HANDBOOK - 2023
 CHAPTER 9

VALVES
9.7 – ADAPTERS FOR ACTUATORS

APPLICATIONS OPERATION
Castel has developed two series of flange adapters to be able to To assemble the adapter on the valve and then the actuator to the
connect the series ball valves: 6570EL, 6570E, 6577E, 6578E adapter, carefully follow:
and 6588E with: - the instruction sheet in the adapter packaging
• Castel servomotors (by SAUTER) series 9700, 9720, 9730 and - the instruction sheet in the actuator packaging
9740.
• BELIMO and WATERGATES servomotors. Table 25 indicate for each ball valve and for the main two voltages
All these adapters allow the transformation from a manual to a (24V or 230 VAC):
motorized ball valves. - the Castel actuator (or the BELIMO-WATERGATES actuator) that
must be assembled
- the auxiliary switches, if necessary, that must be chosen
CONSTRUCTION - the Castel adapter that must be selected to mate the valve with
the above actuator
The main parts of the adapters are manufactured with the following Then the customers can use this table as a guidebook when
materials: choosing components (actuator, auxiliary contacts, and adapter)
- Hot forged brass EN 12420 – CW 617N for lug and round flange when they need to motorize a ball valve.
- Stainless steel AISI 303 for the swivel ring
- Stainless steel AISI 303 for the spindle
- Stainless steel AISI 304 for the motor plate
- Stainless steel for all screws

FIG. 1

9901/X58
9901/X60
9901/X73

FIG. 2

9.43
HANDBOOK - 2023
 9.44
GOGREEN HANDBOOK - 2023
 FIG. 3

9901/X57
9901/X74
9901/X75

FIG. 4

9901/X76

9901/X76

9901/X95 FIG. 6

9.45
HANDBOOK - 2023
MOTORIZATION COUPLING SCHEME: VALVE + SERVOMOTOR + ADAPTER + AUXILIARY SWITCH

CASTEL BELIMO CASTEL WATERGATES CASTEL

Part number Part number Part number Part number Part number Part number

servomotor Adapter switch servomotor Shaped handle switch Adapter servomotor switch Adapter

BALL VALVES WITH COPPER ODS CONNECTIONS W/O ACCESS FITTING

6570EL/M6

6570EL/2

6570EL/3

6570EL/M10

6570EL/M12 9700/RA2 9901/X58 9750/X01 9901/X45 9901/X45

6570EL/4

6570EL/5
SR24A-R NA032100
6570EL/M18 ZSV-11
SR230A-R NA034100
S1A
(1)
6570EL/6 S2A

6570EL/7
9700/RA2 9901/X60 9750/X01
6570EL/M28 --- --- --- 9901/X46 9901/X46
9700/RA6 9901/X57 9750/X02
6570EL/9

6570EL/11
9720/RA2
6570EL/13 9901/X75 9901/X02 9901/X68 9901/X68
9720/RA6
6570EL/M42

9730/RA2 GR24A-R NA0052100

6570EL/17 9901/X76 (1) ZGV-14 9901/X69 9901/X69
9730/RA6 GR230A-R NA0054100

BALL VALVES WITH REINFORCED COPPER ODS CONNECTIONS W/O ACCESS FITTING

6570E/M6

6570E/2

6570E/3

6570E/M10

6570E/M12 9700/RA2 9901/X58 9750/X01 9901/X45 9901/X45

6570E/4

6570E/5
SR24A-R NA032100
6570E/M18 ZSV-11
SR230A-R NA034100
S1A
(1)
6570E/6 S2A

6570E/7
9700/RA2 9901/X60 9750/X01
6570E/M28 --- --- --- 9901/X46 9901/X46
9700/RA6 9901/X57 9750/X02
6570E/9

6570E/11
9720/RA2
6570E/13 9901/X75 9750/X02 9901/X68 9901/X68
9720/RA6
6570E/M42

9730/RA2 GR24A-R NA0052100

6570E/17 9901/X76 (1) ZGV-14 9901/X69 9901/X69
9730/RA6 GR230A-R NA0054100

(1) internal
(2) coupling scheme valid also for ball valves with access fitting, where available

9.46
GOGREEN HANDBOOK - 2023
 MOTORIZATION COUPLING SCHEME: VALVE + SERVOMOTOR + ADAPTER + AUXILIARY SWITCH

CASTEL BELIMO CASTEL WATERGATES CASTEL

Part number Part number Part number Part number Part number Part number

servomotor Adapter switch servomotor Shaped handle switch Adapter servomotor switch Adapter

BALL VALVES WITH K65 ODS CONNECTIONS W/O ACCESS FITTING

6577E/2

6577E/3

6577E/4 9700/RA2 9901/X58 9750/X01 9901/X45 9901/X45

6577E/5

6577E/6
SR24A-R NA032100
ZSV-11
SR230A-R NA034100
9700/RA2 9901/X73 9750/X01 S1A
(1)
6577E/7 --- --- --- S2A
9700/RA6 9901/X74 9750/X02 9901/X80 9901/X80

6577E/9 9901/X74
9720/RA2
6577E/11 9750/X02
9720/RA6
9901/X75 9901/X68 9901/X68
6577E/13

9730/RA2 GR24A-R NA0052100

6577E/17 9901/X76 (1) ZGV-14 9901/X69 9901/X69
9730/RA6 GR230A-R NA0054100

BALL VALVES WITH STAINLESS STEEL CONNECTIONS W/O ACCESS FITTING

6578E/M6

6578E/M10

6578E/M12 9700/RA2 9901/X58 9750/X01 9901/X45 9901/X45

6578E/M16

6578E/M18
SR24A-R NA032100
9700/RA2 9901/X73 9750/X01 ZSV-11
SR230A-R NA034100
6578E/M22 --- --- --- S1A
(1)
9700/RA6 9901/X74 9750/X02 S2A 9901/X80 9901/X80

6578E/M28 9901/X74

6578E/M35
9720/RA2
9750/X02
9720/RA6
6578E/M42 9901/X75 9901/X68 9901/X68

6578E/M48

9730/RA2 GR24A-R NA0052100

6578E/M60 9901/X76 ZGV-14 9901/X69 9901/X69
9730/RA6 GR230A-R NA0054100
(1)
9740/RA2
6578E/M73 9901/X95 - - - - - - -
9740/RA6

(1) internal
(2) coupling scheme valid also for ball valves with access fitting, where available

9.47
HANDBOOK - 2023
MOTORIZATION COUPLING SCHEME: VALVE + SERVOMOTOR + ADAPTER + AUXILIARY SWITCH

CASTEL BELIMO CASTEL WATERGATES CASTEL

Part number (2) Part number Part number Part number Part number Part number

servomotor Adapter switch servomotor Shaped handle switch Adapter servomotor switch Adapter

STAINLESS STEEL BALL VALVES W/O ACCESS FITTING

6588E/M10

6588E/M12
9700/RA2 9901/X58 9750/X01 9901/X45 9901/X45
6588E/M16

6588E/M18

9700/RA2 9901/X73 9750/X01

SR24A-R NA032100
6588E/M22 --- --- --- ZSV-11
SR230A-R NA034100
9700/RA6 9901/X74 9750/X02 S1A 9901/X46 9901/X46
(1)
S2A
6588E/M28 9901/X74

6588E/M35
9720/RA2
9750/X02
9720/RA6
6588E/M42 9901/X75 9901/X68 9901/X68

6588E/M48

9730/RA2 GR24A-R NA0052100

6588E/M60 9901/X76 (1) ZGV-14 9901/X69 9901/X69
9730/RA6 GR230A-R NA0054100

(1) internal
(2) coupling scheme valid also for ball valves with access fitting, where available

TABLE 27: BALL VALVES MOTORIZATION, COUPLING SCHEME: DIMENSIONS

Part numbers Dimensions [mm]

Ball valve servomotor Adapter switch Figure H H1 H2 (1) L L1 I d Ch

BALL VALVES WITH COPPER ODS CONNECTIONS

6570EL/M6
9700/RA2 9901/X58 9750/X01
6570EL/2
6570EL/3
9700/RA2 9901/X58 9750/X01 147 15 179 121 65 18
6570EL/M10
6570EL/M12
9700/RA2 9901/X58 9750/X01 1
6570EL/4
6570EL/5 9700/RA2 9901/X58 9750/X01
6570EL/M18 154,3 19 186,3 139 73 25,5 M4
9700/RA2 9901/X58 9750/X01
6570EL/6
9700/RA2 9901/X60 9750/X01 167 199
6570EL/7 23 175 94
9700/RA6 9901/X57 9750/X02 3 188,6 210,2 6
9700/RA2 9901/X60 9750/X01 1 175,2 207,2
6570EL/M28 30
9700/RA6 9901/X57 9750/X02 3 197 218,5
27 203 109
9700/RA2 9901/X60 9750/X01 1 175,2 207,2
6570EL/9
9700/RA6 9901/X57 9750/X02 3 197 218,5
9720/RA2
6570EL/11 9901/X75 9750/X02 3 211,9 32 237,5 213 115
9720/RA6
9720/RA2
6570EL/13 9901/X75 9750/X02 42
9720/RA6
3 225,4 39 251 242 130 M6
9720/RA2
6570EL/M42 9901/X75 9750/X02
9720/RA6
9730/RA2
6570EL/17 9901/X76 - 5 237,8 49 - 282 154 55 20
9730/RA6

9.48
GOGREEN HANDBOOK - 2023
 TABLE 27: BALL VALVES MOTORIZATION, COUPLING SCHEME: DIMENSIONS

Part numbers Dimensions [mm]

Ball valve servomotor Adapter switch Figure H H1 H2 (1) L L1 I d Ch

BALL VALVES WITH REINFORCED COPPER ODS CONNECTIONS

6570E/M6
9700/RA2 9901/X58 9750/X01
6570E/2
6570E/3
9700/RA2 9901/X58 9750/X01 147 15 179 121 65 18
6570E/M10
6570E/M12
9700/RA2 9901/X58 9750/X01 1
6570E/4
6570E/5 9700/RA2 9901/X58 9750/X01
6570E/M18 154,3 19 186,3 139 73 25,5 M4
9700/RA2 9901/X58 9750/X01
6570E/6
9700/RA2 9901/X60 9750/X01 167 199
6570E/7 23 175 94
9700/RA6 9901/X57 9750/X02 3 188,6 210,2 6
9700/RA2 9901/X60 9750/X01 1 175,2 207,2
6570E/M28 30
9700/RA6 9901/X57 9750/X02 3 197 218,5
27 203 109
9700/RA2 9901/X60 9750/X01 1 175,2 207,2
6570E/9
9700/RA6 9901/X57 9750/X02 197 218,5
9720/RA2
6570E/11 9901/X75 9750/X02 211,9 32 237,5 213 115
9720/RA6
9720/RA2 3
6570E/13 9901/X75 9750/X02 42
9720/RA6
225,4 39 251 242 130 M6
9720/RA2
6570E/M42 9901/X75 9750/X02
9720/RA6
9730/RA2
6570E/17 9901/X76 - 5 237,8 49 - 282 154 55 20
9730/RA6
BALL VALVES WITH K65 COPPER ALLOY ODS CONNECTIONS

6577E/2 9700/RA2 9901/X58 9750/X01 115 62

6577E/3 9700/RA2 9901/X58 9750/X01 147 15 179 123 18

66
6577E/4 9700/RA2 9901/X58 9750/X01 121 M4
1
6577E/5 9700/RA2 9901/X58 9750/X01
154,3 19 186,3 139 70 25,5
6577E/6 9700/RA2 9901/X58 9750/X01
6
6577E/7 9700/RA2 9901/X73 9750/X01 172,7 205,2
26 175 93 18 M5
6577E/7 9700/RA6 9901/X74 9750/X02 194,4 216

9720/RA2
6577E/9 9901/X74 9750/X02 200 28 221,5 208 111 30
9720/RA6
3
9720/RA2
6577E/11 9901/X75 9750/X02 211,9 32 237,5 213 115
9720/RA6
42 M6
9720/RA2
6577E/13 9901/X75 9750/X02 225,4 39 251 242 130
9720/RA6
9730/RA2
6577E/17 9901/X76 - 5 237,8 49 - 282 154 55 20
9730/RA6

9.49
HANDBOOK - 2023
TABLE 27: BALL VALVES MOTORIZATION, COUPLING SCHEME: DIMENSIONS

Part numbers Dimensions [mm]

Ball valve servomotor Adapter switch Figure H H1 H2 (1) L L1 I d Ch

BALL VALVES WITH STAINLESS STEEL CONNECTIONS

6578E/M6 9700/RA2 9901/X58 9750/X01 1 119 64

6578E/M10 9700/RA2 9901/X58 9750/X01 1 147 15 179 18

123 66
6578E/M12 9700/RA2 9901/X58 9750/X01 1 M4

6578E/M16 9700/RA2 9901/X58 9750/X01 1

154,3 19 186,3 142 74 25,5
6578E/M18 9700/RA2 9901/X58 9750/X01 1
6
9720/RA2 9901/X73 9750/X01 2 172,7 26 205,2
6578E/M22 176 94 18 M5
9700/RA6 9901/X74 9750/X02 4 194,4 26 216
9720/RA2
6578E/M28 9901/X74 9750/X02 4 200 28 221,5 208 111 30
9720/RA6
9720/RA2
6578E/M35 9901/X75 9750/X02 4 211,9 32 237,5 213 115
9720/RA6
9720/RA2
6578E/M42 9901/X75 9750/X02 4 240 129 42 M6
9720/RA6
225,4 39 251
9720/RA2
6578E/M48 9901/X75 9750/X02 4 242 130
9720/RA6
9730/RA2
6578E/M60 9901/X76 - 5 237,8 49 - 282 154 55 20
9730/RA6
9740/RA2
6578E/M73 9901/X95 - 6 370,4 70 - 312 164 89 M8 -
9740/RA6
STAINLESS STEEL BALL VALVES

6588E/M10 9700/RA2 9901/X58 9750/X01

147 15 179 108 50 18
6588E/M12 9700/RA2 9901/X58 9750/X01

2
6588E/M16 9700/RA2 9901/X58 9750/X01
154,3 19 186,3 126 66 25,5 M4
6588E/M18 9700/RA2 9901/X58 9750/X01

9720/RA2 9901/X73 9750/X01 166,4 23 199

6588E/M22 130 69 6
9700/RA6 9901/X74 9750/X02 188,1 23 213,7
30
9720/RA2
6588E/M28 9901/X74 9750/X02 196,6 27 222,2 144 79
9720/RA6
9720/RA2
6588E/M35 9901/X75 9750/X02 211,9 32 237,5 160 85
9720/RA6 4
9720/RA2
6588E/M42 9901/X75 9750/X02 42
9720/RA6
225,6 39 251,2 185 100 M6
9720/RA2
6588E/M48 9901/X75 9750/X02
9720/RA6
9730/RA2
6588E/M60 9901/X76 - 5 237,8 49 - 214 119 55 20
9730/RA6

9.50
GOGREEN HANDBOOK - 2023
PIPING
ACCESSORIES
 CHAPTER 10

PIPING ACCESSORIES
10.1 – VIBRATION ABSORBERS

APPLICATIONS It is given that best installation calls for the vibration absorber to
be linear. A misalignment from the axis of no more than 3% of the
The vibration absorbers in series 7690N are considered “Pressure length of the corrugated hose is allowed.
Accessories” according to the definition provided in Article 2, Point WARNING! Ensure a gap corresponding to the 2% of the
5 of the Directive 2014/68/EU (PED Recast) and are subject to the total length of the vibration absorber to compensate any
classification indicated in Article 4, Points 1.c) and 3 of the same extensions due to possible thermal expansion.
Directive.
The function of this item is to avoid the transmission of compressor’s
vibrations to the refrigerating system pipes. They can also
compensate small thermal expansion of the piping.
These products have been developed by Castel for all the applications
that use the sub-critical R744 refrigerant fluid belonging to Group
2, defined in Article 13, Chapter 1, Point (b) of Directive 2014/68/
EU, with reference to EC Regulation No. 1272/2008.

CONSTRUCTION
The main union between various parts are TIG welded (figure 1).
This solution makes the vibration absorbers particularly resistant
to the overheating during connection to the piping.
The main parts of vibration absorbers are manufactured with the
following materials:

- Stainless steel EN 10088-1 – 1.4305/1.4301 for connections

- Stainless steel EN 10028-7 – 1.4541/1.4404 for corrugate
flexible
- Stainless steel EN 10028-7 – 1.4301 for net holder
- Stainless steel EN 10088-3 – 1.4301/1.406 for wire “braid”

INSTALLATION
The vibration absorbers can be installed both on suction and
discharge lines, as close as possible to the compressor. They are
not designed to compensate possible piping misalignment.
Vibration absorbers should be installed perpendicularly to the
direction of vibration. In the case of vertical and horizontal vibrations,
two vibrations absorbers should be used perpendicular to each
other, as shown in Fig. 2 and 3. For the maximum absorption of
vibrations, the refrigerant line should be anchored at the vibration
absorber end, as shown in Fig. 2 and 3.
Castel vibration absorbers can be installed vertically too, because
they are designed to avoid the retention of condensation in the wavy
area near to the connections. There are no issues when employing
them at temperatures below 0°C.
Vibration absorbers are not designed to absorb axial or torsional
stress. Care should be taken to allow sufficient space to avoid
compression or tension, after installation.
High-speed refrigerant fluid can produce vibrations and noise
phenomena. In this case, it is recommended that a larger size
vibration absorber be installed
The connection of the vibration absorbers to the piping is normally
performed by brazing. The specific design and construction of
vibration absorbers allows the installer to perform this operation
without special protection to prevent overheating, generated in
this phase.

10.3
HANDBOOK - 2023
 10.4
GOGREEN HANDBOOK - 2023
 1 2 5

3 4
1 - STEEL CONNECTION
2 - NET HOLDER
3 - CORRUGATED FLEXIBLE WELDING
4 - CORRUGATED FLEXIBLE
5 - STAINLESS STEEL WIRE BRAID

COMPRESSOR COMPRESSOR
FIXED POINT

VERTICAL DIRECTION

SPRING
SUPPORT

FIXED POINT VERTICAL DIRECTION

10.5
HANDBOOK - 2023
TABLE 1: GENERAL CHARACTERISTICS OF VIBRATION ABSORBERS

Connections
Working pressure (PS), depending on fluid
Length Risk Category
temperature [bar]
Catalogue Nr. ODS Weight [g] according to PED
Recast
[mm] [inch] [mm] -80 / +100 °C + 120 °C +140 °C

7690N/3 - 3/8 91

7690N/M10 10 - 98
230
7690N/M12 12 - 122

7690N/4 - 1/2 120

7690N/M15 15 - 190

7690N/5 16 5/8 200 Art. 4.3

255
7690N/M18 18 - 180

7690N/6 - 3/4 180 50 49 48

7690N/7 22 7/8 290 317

7690N/M28 28 - 380
330
7690N/9 - 1.1/8 416

7690N/11 35 1.3/8 375 846

7690N/13 - 1.5/8 1088

430 II
7690N/M42 42 - 1200

7690N/17 54 2.1/8 510 2060

10.6
GOGREEN HANDBOOK - 2023
 CHAPTER 10

PIPING ACCESSORIES
10.2 – THREADED BRASS FITTINGS

APPLICATIONS
The threaded brass fittings are excluded from the scope of
application of Directive 2014/68/EU, as specified in Guidelines
1/8 and 1/9, because they are piping components.
These fittings have been developed by Castel for all the applications
that use the sub-critical or trans-critical R744 refrigerant fluid
belonging to Group 2, defined in Article 13, Chapter 1, Point (b)
of Directive 2014/68/EU, with reference to EC Regulation No.
1272/2008.

CONSTRUCTION
All nuts series 7020, all plugs series 7521 and all the elbows, T and
cross fittings, from series 7210 to series 7410, are manufactured
with hot forged brass EN 12420 – CW 617N.
All straight fittings, from series 7110 to series 7170, and all plugs
series 7510 are machined from brass bars EN 12164 – CW 614N.
Tapered gaskets in series 7580 are from copper Cu – ETP UNI
5649.

10.7
HANDBOOK - 2023
 10.8
GOGREEN HANDBOOK - 2023
 TABLE 2: GENERAL CHARACTERISTICS OF UNIONS

Dimensions [mm]
Wrench
Catalogue International
SAE Flare PS [bar] torque min / Weight [g]
Number Reference
max [Nm]
L Ch

SAE-Flare cap nuts

7020/20 (1) N5–4 1/4” 15 16 8,5 / 11,5 16

140
7020/30 N5–6 3/8” 19,5 22 20 / 25 41

7020/40 N5–8 1/2” 22,5 25 34 / 47 60

SAE-Flare twin nuts

7050/2 US4–4 1/4” 32 17 11 / 14 39

7050/3 US4–6 3/8” 40 22 20 / 25 75

140
7050/4 US4–8 1/2” 46 25 34 / 47 105

7050/5 US4–10 5/8” 51 28 54 / 75 140

(1): copper gasket doesn’t need

10.9
HANDBOOK - 2023
TABLE 3: GENERAL CHARACTERISTICS OF UNIONS

Connections Dimensions [mm]

Catalogue International
PS [bar] Weight [g]
Number Reference
SAE Flare NPT L Ch

SAE-Flare unions

7110/2 U2–4 1/4” 38 12 23

7110/3 U2–6 3/8” 44 17 46

7110/4 U2–8 1/2” 50 20 73

– 140
7110/5 U2–10 5/8” 58 23 113

7110/6 U2–12 3/4” 63 27 164

7110/8 U2–16 1” 72 36 304

Reducing SAE-Flare unions

7120/23 UR2–64 1/4” x 3/8” 42 17 38

7120/24 UR2–84 1/4” x 1/2” 45 58

20
7120/34 UR2–86 3/8” x 1/2” 48 66

7120/35 UR2–106 3/8” x 5/8” – 140 52 23 89

7120/45 UR2–108 1/2” x 5/8” 54 23 98

7120/46 UR2–128 1/2” x 3/4” 57,5 27 136

7120/56 UR2–1210 5/8” x 3/4” 61,5 27 150

SAE Flare / NPT unions

7130/2 U1–4B 1/4” 1/4” 38,1 14 32

7130/3 U1–6C 3/8” 3/8” 41,2 17 48

7130/4 U1–8D 1/2” 1/2” 140 49,8 22 92

7130/6 U1–12F 3/4” 3/4” 57,6 27 152

7130/8 U1–16H 1” 1” 68 36 277

SAE Flare / NPT reducing unions

7140/21 U1–4A 1/4” 1/8” 32,9 12 20

7140/32 U1–6B 3/8” 1/4” 41,1 17 39

7140/34 U1–6D 3/8” 1/2” 140 45,8 22 77

7140/43 U1–8C 1/2” 3/8” 45,2 20 63

7140/54 U1–10D 5/8” 1/2” 53,8 23 102

10.10
GOGREEN HANDBOOK - 2023
 TABLE 4: GENERAL CHARACTERISTICS OF UNIONS

Connections
Dimensions [mm]
Catalogue International Weight
SAE Flare ODS PS [bar]
Number Reference [g]
NPT GAS
m f Ø [in.] Ø [mm] L Ch

Male/female reducing unions (reduced female)

7150/21 U3–4A 1/4” – 1/8” f 29 14 21
7150/32 UR3–46 3/8” 1/4” 33 17 38
7150/42 UR3–48 1/2” 1/4” 35 22 75
7150/43 UR3–68 1/2” 3/8” – – – 140 38 22 66
–
7150/54 UR3–810 5/8” 1/2” 45 25 99
7150/64 UR3–812 3/4” 1/2” 46,5 27 132
7150/65 UR3–1012 3/4” 5/8” 49,5 30 157
Male/female reducing unions (reduced male)
7150/X29 – – 1/4” 1/8” 24 17 24
7150/X27 – – 1/4” 1/4” 30 17 35
7150/23 UR3–64 1/4” 3/8” 33 22 49
7150/24 UR3–84 1/4” 1/2” 36 66
– – – 140 25
7150/34 UR3–86 3/8” 1/2” 39 74
–
7150/45 UR3–108 1/2” 5/8” 44 30 125
7150/46 UR3–128 1/2” 3/4” 45 34 142
7150/56 UR3–1210 5/8” 3/4” 49 34 157
Male/female unions

7160/2 1/4” 1/4” 30,5 17 31

7160/3 – 3/8” 3/8” – – – – 140 36 22 57

7160/4 1/2” 1/2” 41 25 84

Unions SAE-Flare to BSP

7164/2 1/4” – G1/4” f 32,5 20 45

– – – – 140

7166/2 – 1/4” G1/4” m 32 17 25

Male SAE-Flare/solder unions

7170/22 US3–44 1/4” –
1/4” 26,5 12 17
7170/2M8 – – 8
7170/33 US3–66 3/8” –
7170/3M8 – – 8
3/8” 33 17 39
7170/3M10 – – 10
7170/34 US3–68 1/2” –
7170/44 US3–88 – – – 1/2” – 140
1/2” 35 20 53
7170/4M12 – – 12
7170/55 US3–1010 5/8” 5/8” 16 42 23 82
7170/6M18 – – 18
45,5 27 123
7170/65 US3–1210 3/4” 5/8” 16
7170/67 US3–1214 7/8” 22 45,5 30 124
7170/87 US3–1614 1” 7/8” 22 50 36 241
Female swivel SAE-Flare/solder unions

9901/X88 – 1/4” – – 3/8” – 35,5 19 70

– 140

9901/X89 – 3/8” – – 3/8” – 32 22 70

10.11
HANDBOOK - 2023
TABLE 5: GENERAL CHARACTERISTICS OF UNIONS

Connections
Dimensions Wrench
[mm] torque
Catalogue Item Weight
ODS PS [bar] min /
Number Position SAE [g]
max
Flare [Nm]
Ø [in.] Ø [mm] L1 L2 L3 L4 Ch

Flare / ODS adapters

1 – – 16 12,5 17 11 / 14
9901/X11 2 1/4” – 6 21 3,5 – – – 274
–
3 –
1 – – 18,5 14,7 22 20 / 25
9901/X12 2 3/8” – 10 23,5 4 – – – 393
–
3 –
1 – – 21 17 27 34 / 47
9901/X13 2 1/2” – 12 26 4,5 – – – 672
–
3 –
1 – – 22,5 18 30 54 / 75
9901/X14 2 5/8” 5/8” 16 27,5 5 – – – 511
–
3 –
1 – – 25 20 36 68 / 71
9901/X15 2 3/4” – 18 30 5 – – – 806
–
3 –
1 – – 16 12,5 17 11 / 14
140
9901/X16 2 1/4” 1/4” – 21 3,5 – – – 274
–
3 –
1 – – 18,5 14,7 22 20 / 25
9901/X17 2 3/8” 3/8” – 23,5 4 – – – 383
–
3 –
1 – – 21 17 27 34 / 47
9901/X18 2 1/2” 1/2” – 26 4,5 – – – 672
–
3 –
1 – – 25 20 36 68 / 71
9901/X19 2 3/4” 3/4” – 30 5 – – – 806
–
3 –
9901/X58 1 1/4” – – – – 16 12,5 17 11 / 14 23
9901/X59 1 3/8” – – – – 18,5 14,7 22 20 / 25 39
9901/X60 1 1/2” – – – – 21 17 27 34 / 47 67
9901/X61 1 5/8” – – – – 22,5 18 30 54 / 75 83
9901/X68 1 3/4” – – – – 25 20 36 68 / 71 129

Flare/ODS fitting

Nut Connection Copper seal

Copper pipe SAE/Flasre connection

10.12
GOGREEN HANDBOOK - 2023
 TABLE 6: GENERAL CHARACTERISTICS OF UNIONS

Connections Dimensions [mm]

Catalogue International
SAE Flare PS [bar] Weight [g]
Number Reference
NPT H L
m f

SAE-Flare elbows

7210/2 E2–4 1/4” 24,5 24,5 24

7210/3 E2–6 3/8” 29,5 29,5 60

7210/4 E2–8 1/2” – – 140 32,5 32,5 80

7210/5 E2–10 5/8” 36 36 116

7210/6 E2–12 3/4” 42,5 42,5 192

SAE-Flare / NPT elbows

7220/2 E1–4B 1/4” 1/4” 26 24 33

7220/3 E1–6C 3/8” 3/8” 29,5 28,5 54

– 140

7220/4 E1–8D 1/2” 1/2” 32,5 32 91

7220/6 E1–12F 3/4” 3/4” 42,5 39,5 183

SAE-Flare / reduced NPT elbows

7230/21 E1–4A 1/4” 1/8” 24,5 23,5 25

7230/32 E1–6B 3/8” 1/4” 29,5 29,5 46

– 140

7230/43 E1–8C 1/2” 3/8” 32,5 31 97

7230/54 E1–10D 5/8” 1/2” 36 35 112

Male/female SAE-Flare elbows

7240/2 1/4” 1/4” 28,5 28 56

7240/3 – 3/8” 3/8” – 140 32 31 80

7240/4 1/2” 1/2” 39,5 38 200

10.13
HANDBOOK - 2023
TABLE 7: GENERAL CHARACTERISTICS OF UNIONS

Connections Dimensions [mm]

Catalogue International Weight

SAE Flare PS [bar]
Number Reference NPT [g]
H L
(3)
(1) (2) (3) (4)

SAE-Flare TEE

7310/2 T2–4 1/4” 1/4” 1/4” 23,5 47 35

7310/3 T2–6 3/8” 3/8” 3/8” 29 58 70

7310/4 T2–8 1/2” 1/2” 1/2” – – 140 31,5 63 98

7310/5 T2–10 5/8” 5/8” 5/8” 36 72 150

7310/6 T2–12 3/4” 3/4” 3/4” 41,5 83 235

SAE-Flare reducing TEE ( reduced side connections)

7320/223 TR2–46 1/4” 1/4” 3/8” 29 56 77

7320/334 TR2–68 3/8” 3/8” 1/2” 32,5 63 95

– – 140
7320/445 TR2–810 1/2” 1/2” 5/8” 38 72 153

7320/556 TR2–1012 5/8” 5/8” 3/4” 41,5 83 228

SAE-Flare reducing TEE ( reduced central connection)

7320/332 TR2–64 3/8” 3/8” 1/4” 28 58 77

7320/443 TR2–86 1/2” 1/2” 3/8” 32,5 63 101

– – 140
7320/554 TR2–108 5/8” 5/8” 1/2” 38 72 149

7320/665 TR2–1210 3/4” 3/4” 5/8” 41,5 83 232

SAE-Flare / NPT TEE ( taper central connection)

7330/221 T1–4A 1/4” 1/4” 1/8” 21 47 33

7330/222 T1–4B 1/4” 1/4” – – 1/4” 140 24 51 45

7330/332 T1–6B 3/8” 3/8” 1/4” 28 58 65

Male/female SAE-Flare TEE (female central connection)

7340/222 T6–4 1/4” 1/4” 1/4” – – 140 27,5 56 73

SAE-Flare cross

7410/2 C1–4 1/4” 1/4” 1/4” 1/4” – 140 52 52 72

10.14
GOGREEN HANDBOOK - 2023
 TABLE 8: GENERAL CHARACTERISTICS OF UNIONS

Connections
Dimensions [mm]
Wrench
Catalogue International Weight
PS [bar] torque min/
Number Reference [g]
SAE Flare NPT max [Nm]
L Ch

SAE-Flare plugs

7510/2 P2–4 1/4” 23 12 11 / 14 19

7510/3 P2–6 3/8” – 140 26 17 20 / 25 40

7510/4 P2–8 1/2” 30 20 34 / 47 67

NPT plugs

7521/1 121–B–02 1/8” 15,9 12 10 / 13 17

7521/2 121–B–04 1/4” 23,1 14 15 / 20 26

7521/3 121–B–06 3/8” 23,2 17 17 / 22 36

– 140
7521/4 121–B–08 1/2” 29,8 22 25 / 35 112

7521/6 121–B–12 3/4” 32,1 27 30 / 40 160

7521/8 121–B–16 1” 39 34 60 / 80 247

Copper gaskets

7580/2 (1) B2–4 1/4” 0,2

7580/3 (1) B2–6 3/8” 0,5

7580/4 (1) B2–8 1/2” 0,7

7580/5 (1) B2–10 5/8” 1,1

7580/6 (1) B2–12 3/4” 1,2

– 140 – – –
7581/2 (2) B2–4 1/4” 0,2

7581/3 (2) B2–6 3/8” 0,4

7581/4 (2) B2–8 1/2” 0,6

7581/5 (2) B2–10 5/8” 0,9

7581/6 (2) B2–12 3/4” 1,1

(1) Nominal thickness 1 mm

(2) Nominal thickness 0,5 mm

10.15
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 10.16
GOGREEN HANDBOOK - 2023
 CHAPTER 10

PIPING ACCESSORIES
10.3 – ACCESS FITTINGS AND VALVE CORE

APPLICATIONS
The access fittings are excluded from the scope of application
of Directive 2014/68/EU, as specified in Guidelines 1/8 and 1/9,
because they are piping components.
The valve core is considered “Pressure Accessory” according to
the definition provided in Article 2, Point 5 of said Directive and is
subject to the classification indicated in Article 4, Points 1.c) and
3 of the same Directive.
The access fittings and the valve core have been developed by
Castel for all the applications that use the sub-critical or trans-
critical R744 refrigerant fluid belonging to Group 2, defined in Article
13, Chapter 1, Point (b) of Directive 2014/68/EU, with reference to
EC Regulation No. 1272/2008.

OPERATION
The access fittings allow creating a loading or draining point rapidly
and with a minimum expense. After completion of the filling or
draining operations, use of the cap and gasket (p/n 8392/A or
8391/A) prevents any refrigerant leakage.
For special customer requirements, the cap 8392/A can be replaced
by a blind union p/n 7020/20. The latter solution requires that the
union be tightened using a torque wrench to 8.5 / 11.5 Nm. Note:
it is not necessary to use a copper gasket between union
7020/20 and the filling connector chosen.
If a component other than the two blind unions in series 7020 must
be tightened on the access fittings (for example a pressure gauge), a
tapered gasket with tang (p/n 8580/2) must be positioned between
the component and the chosen access fitting.
The access fittings have different shapes and sizes, according
to varying customer requirements. For all access fittings, the
valve core seat is manufactured according to the ARI STANDARD
720:1997.
After tightening the valve core inside the access fitting with
the dedicated wrench, p/n 8390/A, to the indicated torque,
the refrigerant passage, filling or draining is obtained simply by
activating the needle on the valve core.

CONSTRUCTION
The straight fittings are machined by hexagonal brass bar EN
12164 – CW 614N.
The T and cross fittings are hot forged in brass EN 12420 – CW
617N.
Caps 8392/A and 8392/B are machined from hexagonal brass
bar EN 12164 – CW 614N, with chloroprene rubber (CR) gasket.
Valve core 8395/A4 is equipped with ethylene propylene rubber
(EPDM) gaskets
The tapered gasket with tang, 8580/2, is manufactured from
copper Cu - ETP UNI 5649.

10.17
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 10.18
GOGREEN HANDBOOK - 2023
 TABLE 9: GENERAL CHARACTERISTICS OF ACCESS FITTINGS

Connections Dimensions [mm]

Weight
Drawing Part number SAE Flare ODS IDS PS [bar]
[g]
NPT L Ch
Valve
m f Ø [in.] Ø [mm] Ø [in.] Ø [mm]
core

Straight access fittings

8350/22 1/4” – – – 1/4” – 3/8” – 26 11 12

8350/X10 1/4” – – – 1/4” – – 10 26 11 12

140

8350/X01 1/4” – – – – 6 – – 20 11 10

8350/X03 1/4” – – – – – – 6 90 11 23

8350/X06 1/4” – – – – – 1/4” – 126 11 28

120
8350/X07 1/4” – – – – – 1/4” – 326 11 58

8350/X12 1/4” – – – – – – 6 180 11 36

8351/2 1/4” – – – – 6 – 8 - 10 30 11 13

8351/X04 1/4” – – – – – 6 26 11 11

8351/X01 1/4” – – – – 1/8” – 6 36 11 13

1/4”
8351/X02 1/4” – – – – 5 5/16” – 26 11 11
3/8”
6
8351/X06 1/4” – – – – – – 8 28 11 13
10

140
8352/22 1/4” 1/4” – – – – – – 31 11 15

8354/21 1/4” – – 1/8” – – – – 28 11 13

8354/22 1/4” – – 1/4” – – – – 33 14 25

8354/23 1/4” – – 3/8” – – – – 38 17 41

8362/22 1/4” – 1/4” – – – – – 35 17 42

10.19
HANDBOOK - 2023
TABLE 10: GENERAL CHARACTERISTICS OF ACCESS FITTINGS

Connections Dimensions [mm]

Weight
Drawing Part number SAE Flare IDS PS [bar] Note
[g]
NPT L H
m f Ø [mm]

TEE access fittings

8380/122 1/4” – 1/8” – 45 24 31

140

8380/222 1/4” – 1/4” – 49,5 25,5 44

8380/X01 1/4” – – 6 43 24 28

The valve core may be

installed on each of the
two 1/4” SAE Flare male
connections

8380/X02 1/4” – – 7 140 48 22 33

8380/X09 1/4” 1/4” – – 56 27 70

10.20
GOGREEN HANDBOOK - 2023
 TABLE 11: GENERAL CHARACTERISTICS OF ACCESS FITTINGS

Connections Dimensions [mm]

Weight
Drawing Part number SAE Flare IDS PS [bar] Note
[g]
NPT L H
m f Ø [mm]

Cross access fittings

8382/1222 1/4” – 1/8” – 140 48 50 49

The valve core may be

installed on each of the
8382/X02 1/4” – 1/4” – 140 48 50 53
three 1/4” SAE Flare male
connections

8382/X01 1/4” – – 7-10 48 47 47

140

8382/X03 1/4” – – 6 48 44 42

Copper gaskets with neck

8580/2 1/4” – – – 140 – – 0,3

10.21
HANDBOOK - 2023
TABLE 12: GENERAL CHARACTERISTICS OF CAPS WITH GASKET

Connections TS [°C] Dimensions [mm]

Weight
Drawing Part number PS [bar]
[g]
SAE Flare min max L D

8392/A - 1/4” 80 -20 +100 13 13 7

8392/B (1) - 1/4” 80 -20 +100 22 13 7

8393/A - 5/16” 80 -20 +100 22 13 7

Note:
(1) The key needs to remove the valve core

TABLE 13: GENERAL CHARACTERISTICS OF VALVE CORES

Operating Wrench
Dimensions torque
Gaskets Max Static Operating Temperature Peak
Part Refrigerant [mm] min / Weight
Drawing Spring Pressure Pressure [°C] Temperature
number Fluids max [g]
[bar] [bar] (1) [°C]
(2)
body seat min max L D [Nm]

5,2 x
0,4/0,5
8395/A4 outside EPDM EPDM R744 140 80 -35 +120 150 16,3 0,705 0,7
Nm
V0.07.1

Note:
(1) permitted value for shot period
(2) To remove the valve core use the key code 8390/A

10.22
GOGREEN HANDBOOK - 2023
 TABLE 14: GENERAL CHARACTERISTICS OF MANIFOLDS WITH ACCESS FITTINGS

Connections Dimensions [mm]

PS Weight
Drawing Part number Note
[bar] [g]
SAE Flare L H

9901/X43 1/4” 140 275 49 650 N° 6 access fittings

9901/X44 1/4” 140 335 49 851 N° 6 access fittings

TABLE 15: GENERAL CHARACTERISTICS OF MANIFOLDS WITH ACCESS FITTINGS AND VALVE

SAE Flare Connections Dimensions [mm]

PS Weight
Drawing Part number Note
swivel [bar] [g]
female L H1 H2
female

9901/X90 1/4” 1/4” 140 152,5 14,5 20 368 N° 2 access fittings

9901/X94 2 x 1/4” 1/4” 140 182,5 14,5 20 769 N° 2 access fittings

10.23
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 10.24
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NOTES

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NOTES

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NOTES

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 HBG-ED 01/2023-EN

Castel can accept no responsibility for any errors or changes in the catalogues, handbooks, brochures
and other printed material. Castel reserves the right to make changes and improvements to its products
without notice. All trademarks mentioned are the property of their respective owners.
The name and Castel logotype are registered trademarks of Castel Srl.
All rights reserved.

Via Provinciale, 2-4 Tel. +39 02.957021 [email protected]

20042 Pessano con Bornago (MI) Fax +39 02.95741317 castel.it