Danfoss ICSH 25-80 Dual Position Solenoid Valve Installation Guide

Danfoss ICSH 25-80 Dual Position Solenoid Valve

Installation

Refrigerants

Applicable to HCFC, HFC, R717(Ammonia) and R744 (CO2). Flammable hydrocarbons are not recommended. The valve is only recommended for use in closed circuits. For further information please contact Danfoss.

Temperature range

-60 – 120 °C / -76 – 248 °F

Pressure range

The valves are designed for a max. working pressure of 65 bar / 943 psig.
NOTE: The operating valve’s maximum working pressure is dependent on the maximum working pressure of installed pilots.

Application

The ICSH is designed for the hot gas line to open for the flow in 2 steps – 20% and 100%. The valve includes 2 identical EVM NC pilot valves with 2 identical coils energized in a controlled sequence by an external controller like PLC.

Design (fig. 4)

1. Body
2. Top cover
3. Function module
   • Valve plate (Teflon) (available as spare part)
   • Washer plate
4. Gasket
5. Bolts
6. Plug
7. GasketManual operating spindle
8. Plug
9. Gasket
10. Needle housing
11. Flat gasket

The ICSH can be oriented as shown in fig. 1 and must be installed with the arrow in the direction of the flow (fig. 2). The top cover can be rotated 4 X 90° in relation to the valve body. The valve is designed to withstand a high internal pressure. However, the piping system should be designed to avoid liquid traps and reduce the risk of hydraulic pressure caused by thermal expansion. It must be ensured that the valve is protected from pressure transients like “liquid hammer” in the system.

Welding (fig. 3, 4 and 5)

The top cover (fig. 4, pos. 2) and function module (fig. 4, pos. 3), must be removed before welding to prevent damage to o-rings and teflon (PTFE) in the function module and to avoid getting welding debris in the module.
Caution: After removing the top cover make sure to protect the vital parts protruding the underside of the cover. Never lay aside with the bottomside down (see fig. 3) The function module can be lifted out using a bolt size M6 or multi-function tool screwed into the threaded hole of the piston on the function module (fig. 3a). Debris blocking the bolt hole will need cleaning.

Note:
Remove all parts from the valve body before welding (as shown in fig. 5). The internal surfaces and weld connections of the enclosed ICSH valve has been applied anti-corrosion protection.

In order to maintain the effectiveness of this anti-corrosion treatment, it is important to ensure that the valve is disassembled just prior to the welding / brazing process being undertaken. In the event that the function modules are to be left disassembled for any length of time, please ensure that the function modules are further protected by placing in a polyethylene bag or by applying a rust protection agent (e.g. refrigeration oil or BRANOROL) on the surfaces. Only welding materials and welding methods compatible with the valve housing material must be used. The valve should be cleaned internally to remove welding debris on completion of welding and before the valve is reassembled. The valve body must be free from stresses (external loads) after installation.
The valves must never be mounted in systems where the outlet side of the valve is open to atmosphere. The outlet side of the valve must always be connected to the system or properly capped off, for example with a welded-on end plate.

Assembly

Remove welding debris and any dirt from pipes and valve body before assembly. Check that the o-rings are intact before replacing the function module. If possible, apply some refrigeration oil to facilitate the insertion and to protect the o-rings. Check that the top gasket has not been damaged. If the surface has been damaged or the gasket has been bent, it must be replaced.

Tightening/Operation of Manual spindle (fig.6)

Tighten the top cover with a torque wrench to the values indicated in the table.

If the manual opening spindle needs to be activated it is important not to exceed 15 Nm in any directions.

Corrosion protection and identification

The ICSH valves are Zinc-Chromated from the factory. The Zinc-Chromatization does not cover the welding areas. The external surface of the valve housing must be protected against corrosion with a suitable top coating after installation involving welding and consequent assembly. Identification of the valve is made via the ID plate on the top cover. Protection of the ID plate when painting the valve is recommended.

Configuration

The ICSH can be configured to 2 operation modes:

1. Dependent mode
   The functioning of the valve is always relying on the opening of step 1. Only when step 1 is working properly the step 2 can be mechanically activated.

2. Independent mode:
   The full opening of the valve can be controlled independently of the state of step 1. If the partial opening of step 1 is not performed the full opening can be done by activation of step 2. Note: When choosing the independent configuration there is a risk of hydraulic shock due to instant full opening.

Dependent configuration is done by installing the 2 EVMs in port SI and SII and blanking off port P by Plug A+B. See fig. 7a. The SI coil must be activated for some period of time before SII is activated. Independent configuration is done by installing the 2 EVMs in port SI and P, and blanking off port SII by Plug A+B. See fig. 7b. The SI coil must be activated for some period of time before P is activated. The control of activating the coils is done by a PLC or a PLC / Timer (see fig. 8) and the required time delay must be decided based on in situ trials.

Wiring

The wiring of the 2 coils can be done directly by 2 wires from the controller, or by 1 wire controlling step 1 (SI) directly in parallel with a Timer relay controlling step 2. See fig. 8.

Maintenance

Service

The ICSH valves are easy to dismantle. Do not open the valve while the valve is still under pressure. The function module can be lifted out using a bolt size M6 screwed into the threaded hole of the piston on the function module (fig. 3). Debris blocking the bolt hole will need cleaning.
Upon opening and removal of the function module:

• Check that the o-rings on the function module has not been damaged. A valve with a damaged o-ring might not regulate according to the specification.
• Check that the piston and cylinder is free of scratches and look for wear marks. If the wear is excessive the function module should be replaced to prevent false pilot signal around the piston ring.
• Check that the movement of the cylinder and valve seat is free and with low friction.
• If the teflon valve plate is damaged it must be replaced. It is available as a spare part:**
  Type| Code number
  ---|---
  ICS 25 repair kit| 027H2219
  ICS 32 repair kit| 027H3017
  ICS 40 repair kit| 027H4015
  ICS 50 repair kit| 027H5015
  ICS 65 repair kit| 027H6017
  ICS 80 repair kit| 027H6017**

For mounting instructions please see DKRCI.PI.HS0.D.

Assembly

Remove any dirt from the body before the valve is assembled. Check that all channels in the valve are not blocked by any particles. If possible, apply some refrigeration oil to facilitate the insertion and to protect the o-rings. Tightening/Operation of Manual spindle (fig.6) Tightens the top cover with a torque wrench to the values indicated in the table.

If the manual opening spindle needs to be activated it is important not to exceed 15 Nm in any direction.

Note:
Always pay attention to the spindle during the operation of the manual opener

1. Pay attention to the C-clip reaching the top of the spacer between C-clip and manual stem top nut when turning the manual stem clockwise for opening the valve. Never use excessive torque and stop turning when the C-clip gets in contact with the spacer.
2. When turning the spindle anticlockwise, for deactivation of the manual opener, to the top point, tighten the spindle further anticlockwise to 8 Nm (5.9 lb/ft) torque for back-seating.
3. Remount the cap and tighten it clockwise to 8 Nm (5.9 lb/ft) torque. If the manual opener or needle housing assembly is damaged it must be replaced.

It is available as spare part:

• Use only original Danfoss parts, including O-rings and gaskets for replacement. Materials of new parts are certified for the relevant refrigerant.
• In cases of doubt, please contact Danfoss.
• Drawings are only for illustration, not for dimensioning or construction.
• Danfoss accepts no responsibility for errors and omissions. Danfoss Industrial Refrigeration reserves the right to make changes to products and specifications without prior notice.

The following text is applicable to the UL-listed products ICS 25-65
Applicable to all common non-flammable refrigerants, including R717 and to non-corrosive gases/liquids dependent on sealing material compatibility. The design pressure shall not be less than the value outlined in Sec. 9.2 of ANSI/ASHRAE 15 for the refrigerant used in the system.

Climate Solutions
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+45 7488 2222
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| Danfoss ICSH 25-80 Dual Position Solenoid Valve [pdf] Installation Guide
ICSH 25-80, Dual Position Solenoid Valve, Solenoid Valve, Dual Position Valve, Position Valve, Valve
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