Danfoss ICS 25 – 65 (80) Pilot Operated Servo Valve Installation Guide
- June 3, 2024
- Danfoss
Table of Contents
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)**
-
Body
-
Top cover
-
Function module
3a Valve plate (Teflon) (available as spare part)
3b Washer plate -
Gasket
-
Bolts
-
Plug
-
Gasket
-
Manual operating spindle
-
Plug
-
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:
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 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)
-
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.
-
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. -
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.
-
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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• danfoss.com
• +45 7488 2222
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