Danfoss ICS 25 – 65 (80) Pilot Operated Servo Valve Installation Guide

ICS 25 – 65 (80) Pilot Operated Servo Valve
Installation Guide

ICS 25 – 65 (80) Pilot Operated Servo Valve

Installation guide
Pilot operated servo valve
ICS 25 – 65 (80)

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 52 barg (754 psig).

Technical data

The ICS can be used in suction, liquid, hotgas and liquid/vapor lines. The ICS regulates the flow of the medium by modulation or on/off function, depen ding on the control impulse from the screwed on pilot valve or valves.
Regulating range
Dependent on the chosen type and combination of pilot valves.
Opening differential pressure (p)
The ICS main valve requires a minimum opening differential pressure of 0.07 bar (1 psi) to begin to open and 0.2 bar (3 psi) to be completely open.
** Back pressure to the ICS valve forces the piston to open and create a reverse flow. If reverse flow is not accepted, a checkvalve must be installed downstream of the ICS valve (be aware of the risk of trapped liquid).
Design (fig. 4)**

1. Body

2. Top cover

3. Function module
   3a Valve plate (Teflon) (available as spare part)
   3b Washer plate

4. Gasket

5. Bolts

6. Plug

7. Gasket

8. Manual operating spindle

9. Plug

10. Gasket

The valve must be installed with the spindle in vertically upwards position (fig. 1).
The valve must be installed with the arrow in the direction of the flow and the top cover upwards (fig. 2). The top cover can be rotated 4 X 90° in relation to the valve body.
The valve is fitted with a spindle for manual opening. If an external pilot valve is used, the pilot line must be connected to the upper side of the main line so that any dirt and oil from the plant will not find its way into the pilot line.
If the ICS 1 is to be used as a solenoid valve in a liquid line, external control pressure cannotbe recommended because it can cause liquid hammer.
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.
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. 3). Debris blocking the bolt hole will need cleaning.
N o te: Remove all parts from the valve body before welding (as shown in fig. 5).
**** The internal surfaces and weld connections of the enclosed ICS/ICM valve have been applied with an anti-corrosion treatment.
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 materials and welding methods, compatible with the valve body material, must be welded to the valve body. The valve should be cleaned internally to remove welding debris on completion of welding and before the valve is reassembled.
Avoid welding debris and dirt in the valve body and the function module. The valve body must be free from stresses (external loads) after installation.
The valves must not 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 ease 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 (fig. 6)
Tighten the top cover with a torque wrench, to the values indicated in the table.
Colours and identification
The ICS valves are Zinc-Chromated from factory. The Zinc-Chromatization does not cover the welding connections. If further corrosion protection is required, the valves can be painted. Precise identification of the valve is made via the ID plate on the top cover.
The external surface of the valve housing must be protected against corrosion with a suitable top coating after installation involving welding and consequent assembly.
Protection of the ID plate when painting the valve is recommended.

Maintenance

Service
The ICS valves are easy to dismantle.
Do not open the valve while the valve is still under pressure.
Pressure relief can be done by carefully opening the manual operating spindle. Small grooves along the thread will release refrigerant into open air. This operation must only be done after providing the correct countermeasures under local legislation.
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 modulate 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 spare part:

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 particles or similar.
If possible, apply some refrigeration oil to ease the insertion and to protect the o-rings.
Tightening (fig. 6)
Tighten the top cover with a torque wrench, to the values indicated in the table.
Note:
Always pay attention to the spindle during operation of the manual opener (see fig 7)

1. Make sure that the C-clip (C) is positioned on the spindle (B) and is intact. A new C-clip is available in the inspection kit for the valve.

2. Pay attention to the C-clip reaching the top nut of the packing gland 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 top nut.

3. When turning the spindle (B) anticlockwise, for deactivation of the manual opener, to the top point, tighten the spindle further anticlockwise to 8 Nm (5.9 lb/ft) torque.

4. Remount the cap (A) and tighten it clockwise to 8 Nm (5.9 lb/ft) torque.

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/excluding (+) 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. (+++).

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• +45 7488 2222
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© Danfoss | Climate Solutions | 2022.06

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