Danfoss ICF Series Valve Station Installation Guide

Danfoss ICF Series Valve Station

Valve Station

Types ICF 15, ICF 20, ICF 25, ICF SS 20 and ICF SS 25

Installation

Welding

TIG/MIG/SMAW

Gas welding Brazing

Maintenance

Tightening

ICF 15, ICF 20, ICF SS 20 Manual stem Max. 20 Nm (15 ft lbs) at stop. Automatic mode (ICFE ON/OFF by coil)

Max. 2.5 Nm (1.8 ft lbs) at stop. Manual mode (ICFE forced open)

ICF 25, ICF SS 25 Manual stem

Max. 40 Nm (30 ft lbs) (Closing ICFR, ICFN: max. 10 Nm (7 ft lbs) Max. 4 Nm (3 ft lbs) at stop. Automatic mode (ICFE ON/OFF by coil)
Max. 10 Nm (7 ft lbs) at stop. Manual mode (ICFE forced open)

ICFE 25, ICFE SS 25, ICFG 25, ICFE 20H, ICFE SS 20H Manual stem

Module location

ICFD: Disassembly/assembly Transport device and float

ICFG 25: Disassembly/assembly module

Refrigerants
Applicable to HCFC, non flammable HFC, R717 (Ammonia) and R744 (CO₂).

Exception:
ICFD is designed for ammonia and CO₂ only ICFD 20 = ammonia version
ICFD 20C = CO₂ version

The use of ICF valve stations with flammable hydrocarbons is not recommended.

The ICF is only recommended for use in closed circuits. For further information please contact Danfoss.

Temperature range
ICF in general:
–60/+120 °C (–76/+248 °F)

ICFD 20: -50/+50 °C (-58/+122 °F) at 28 bar g (406 psi g)

ICFD 20C: -50/+50 °C (-58/+122 °F) at
52 bar g(754 psi g)

Pressure range
The general ICF is designed for:
Max. working pressure: 52 bar g (754 psi g) ICF 20-2 housing with 65 bar function modules only:
Max. working pressure: 65 bar g (943 psi g)

ICFD 20 (Ammonia):
For ICF with ICFD module the max. working pressure is 28 bar g / 406 psi g. If the refrigeration system include ICFD 20 module, a test pressure of the system must not exceed 28 bar g / 406 psi g, unless the ICFD float is temporarily taken out before test. See fig. 11.

ICFD 20C (CO₂):
For ICF with ICFD 20C module the max. working pressure is 52 bar g / 754 psi g. If the refrigeration system include ICFD 20C module, a test pressure of the system must not exceed 52 bar g / 754 psi g, unless the ICFD 20C float is temporarily taken out before test. See fig. 11.

Application

The ICF can be used in suction, liquid, hot gas and liquid/vapor lines. The ICF is available with 2, 4 or 6 function modules. The ICF regulates the flow of the medium by modulation or on/off function, depending on function modules installed in the ICF.

Regulating range
Dependent on the chosen type and combination of modules installed in the valve.

Installation (fig. 1)
The ICF must be installed according to fig. 1. The ICF must be installed with the arrow in the direction of the flow).
ICM, ICFD and ICFG modules require horizontal valve orientation.
The ICF will be delivered with all the function modules fully assembled. The modules can be taken out for service or inspection and may be rotated 4 x 90° in relation to the valve body upon installation. Please make sure that the position of ICFD allows space for modules
at each side of the ICFD.
The ICF may be fitted with a spindle for manual opening of the solenoid valve.
The ICF 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 ICF is protected from pressure transients like “liquid hammer” in the system.

Welding (fig. 2 and 3)
The ICF valve station can be welded by using either TIG/MIG/SMAW welding (fig. 2) or gas welding/ brazing (fig. 3 a/b).
Always keep inlet and outlet protecting caps on the valve until the valve is ready to be installed, in order to prevent rust formation inside the valve station.

TIG/MIG/SMAW welding
It is not necessary to remove any of the function modules prior to TIG/MIG/SMAW welding (fig. 2) and auxiliary cooling is not needed at normal heat impact.

At excessive heat impact due to high ambient temperature, sun radiation, a wet cloth is recommended around the valve housing.

Every precaution must be taken to minimize welding spatter.
For ICF valve stations equipped with a stop valve in the first module (M1) and a stop-, regulating- or stop/check valve in the last module (M4 or M6), it is recommended to open these valves slightly (approx. 1 turn from closed position) to minimize welding heat impact to the Teflon seats.

After welding it is recommended to close these valves again to avoid potential pull through of gases, and keep them closed until the system is ready for operation.
All other valve modules are able, in any module position, to compensate for normal welding heat impact and need no special attention.

Gas welding/ brazing
Remove all inserts before welding/ brazing (fig. 3 a/b).
Auxiliary cooling needed when brazing (fig. 3b) to reduce heat impact.

Follow these steps during brazing (fig. 3b):

1. Remove topcover/insert
2. Clean connections with cleaning agent
3. Wrap around wet cloth
4. Apply flux on piping ends
5. Apply inert gas internal
6. Heat up piping
7. Braze with recommended brazing material and within temperature range specified
8. Remove risidual flux

Every precaution must be taken to minimize welding spatter.
After welding, clean the valve inside for welding spatter and welding debris.
It is recommended to reinstall the modules right after welding and to close the manual-operable M1 and M4/M6 in order to protect the interior of the valve until the system is ready for operation. In case the valve is not assembled immediately make sure that rust protective oil is applied to the inside surfaces.

The housing must be free from stresses (external loads) after installation. The ICF must not be mounted in systems where the outlet side of the ICF is open to atmosphere. The outlet side of the ICF must always be connected to the system or properly capped off, for example with a welded-on end plate.
Surface protection and identification (not applicable for SS versions)

The external surface is zinc-chromatid to provide corrosion protection according to EN 12284:2003 8.13. The Zinc-Chromatization does not cover the welding connections. After installation has been completed the external surface of the valve must be protected against corrosion with a suitable top coating. Coverage of the ID label when painting the ICF is recommended.

Precise identification of the ICF is made via the ID label on each of the 2, 4 or 6 function modules.

Maintenance (fig. 4)
Do not to mix up carbon steel parts with stainless steel parts.

Service
The ICF valve stations are easy to service. Do not open the ICF while it is still under pressure. Upon opening and removal of the function modules:

• Check that the flat gaskets and/or O- rings between the function module and the housing and O-rings on the function module has not been damaged. Replace flat gaskets and O-rings if not intact.

A valve with damaged O-rings or flat gaskets do not regulate in accordance with its specifications.

Flat gaskets are present in ICF 15 module M1/M2 and ICF 20-2/ICF 25/ICF SS 25 all modules.

Rubber gaskets are present in these locations: (see fig 4a, 4b)
ICF 15: 1 rubber gasket in each module M3/M4
ICF 20-4/6 and ICF SS 20-4/6: 1 rubber gasket in all modules

CO2 applications
When used in CO2 systems the

O-rings (see fig. 4a and 4b) can swell (grow).
At service it is recommended to replace the actual number of used O-rings before the function modules are reinstalled in the ICF valve body.
ICFD 20C defrost module for CO₂: Make sure that the module is type ICFD 20C

• 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 has been damaged, the function module must be replaced.
  On ICM 20 motor valve modules check that the PEEK seat has not been damaged or scratched. If damaged or scratched; replace the PEEK seat. (Allen key 12 mm, torque 2 Nm (1.5 ft lb)).

Assembly

Remove any dirt from the housing before the ICF is assembled.

• Check that all channels in the ICF are free of  particles or similar debris. If possible, apply some refrigeration oil to ease the insertion of the modules and to protect the O-rings.

Tightening (fig. 5, 6 and 7)
Tighten the top cover with a torque wrench, to the values indicated in the table (see fig. 5).

Operating the manual stem (fig. 6 to 8) ICF 15, ICF 20, ICF SS 20 (fig. 6a and 6b)

• ICFS/ICFS SS – stop valve module
• ICFR/ICFR SS – manual regulating valve module
• ICFN/ICFN SS – stop/check valve module
• ICFO/ICFO SS – manual opening module Before remounting the cap on the modules
• ICFS/ICFS SS (stop valve module),
• ICFR/ICFR SS (manual regulating valve module) or
• ICFN/ICFN SS (stop/check valve module) please ensure that the gasket is present in the cap. Then tighten the cap with 16 Nm (12 ft lbs).

ICF 25, ICF SS 25 (see fig. 7a)

• ICFS/ICFS SS – stop valve module
• ICFR/ICFR SS – manual regulating valve module
• ICFN/ICFN SS – stop/check valve module
• ICFE/ICFE SS – manual opening module

Before remounting the cap on the modules ICFS/ICFS SS (stop valve module), ICFR/ICFR SS (manual regulating valve module) or ICFN/ICFN SS (stop/check valve module) please ensure that the gasket is present in the cap. Then tighten the cap with 24 Nm (18 ft lbs).

Packing gland (ICFE/ICFE SS) (see fig. 7b):
If the packing gland is leaking, tighten it carefully with a wrench. Do not apply too much force.
Danfoss recommends that you conduct a stepwise tightening of the packing gland. For each turn check for possible leaks.

Operating the manual stem on ICFE 25/ ICFE SS 25 solenoid module (see fig. 8a):
To force open the solenoid by the manual stem turn it counter clockwise full way up (manual mode).
To operate the solenoid in automatic mode, turn the manual stem clockwise until the locking ring stops.
Do not force the spindle further. If the locking ring is damaged or removed the spindle will start to leak.
The valve cannot be forced closed by the manual stem.

Operating the manual stem on ICFE 20H/ICFE SS 20H solenoid valve module (see fig. 8b) Remove the cap on the side of the ICFE 20H/ICFE SS 20H
At 9 o’clock position the manual opener is disabled (not active).

To force the ICFE 20H/ICFE SS 20H solenoid to open use a 5 mm Allen key and turn it clockwise to 3 o’clock position.

ICFD defrost module

Transportation protection
Remove the transport security device (pos. 1 in fig 10). Insert the drain plug

• alu gasket attached to the valve (pos. 2 in fig 10) and tighten with the torque indicated.

Test pressure maximum
If the system test pressure needs to exceed: ICFD 20 (Ammonia): 28 bar g / 406 psi g ICFD 20C (CO₂): 52 bar g / 754 psi g
it is necessary to prepare the ICFD module like shown in fig. 11:

1. Unscrew the 6 flange bolts and remove the Float housing.

2. + 3. Unscrew and remove the Lever together  with the Float assembly using A/F 4 mm. Caution – float end of lever must not be unscrewed and do not use float for unscrewing.

3. Remount the Float housing and tighten the 6 flange bolts with the torque indicated in fig 10.

4. Test with the system pressure higher than:
   ICFD 20 (Ammonia): 28 bar g / 406 psi g
   ICFD 20C (CO₂): 52 bar g / 754 psi g
   Reinstall the Lever together with the Float assembly using A/F 4 mm. Do not use float for tightening.

5. Remount the Float housing and tighten the 6 flange bolts with the torque indicated in fig 10.

It is recommended to replace the float housing gasket with a new gasket after this repeated compression.

Operating the manual stem on ICFD defrost module (see fig. 12)
Remove the cap on the side of the ICFD (pos. A in fig. 10).
At 9 o’clock position the manual opener is disabled (A = Automatic mode).
To force the ICFD to open use a 5 mm Allen key and turn it clockwise to approx.
2 o’clock position till it reaches the mechanical stop (M = Manual open mode).
Always return the manual opener to automatic mode for normal operation.
Remount the cap A in fig 10 and tighten with torque 80 Nm (59 ft lbs).

It is recommended to replace the Alu gasket if further openings of cap are required.

Operating the manual stem on ICFG 25 (see fig. 8a)
Always pay attention to the spindle during operation of the manual opener

1. Make sure that the locking ring is positioned on the spindle and is intact. A new locking ring is available in the inspection kit for the valve.

2. Pay attention to the locking ring 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 locking ring gets in contact with the top nut.

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

Module location (fig. 9a, 9b, 9c)

ICF with two modules

M1                               M2
ICFC| Check valve module| | M2
ICFC 20P1| Check valve module| | M2
ICFN 20| Stop & check valve module| | M2
ICFR| Manual regulating valve module M1                               M2
ICM| Motor valve module| M1|
ICFD 20| Defrost module| | M2
ICFS| Shut-off valve module| M1| M2
ICFF| Strainer module| | M2
ICM| Motor operated valve module| M1|

*) Not in combination with ICFO

ICF with four modules

Pilot-operated servo module

| | M2| | M4
ICFG| | | M3|

ICF with six modules

Pilot-operated servo module

| | M2| | M4| | M6
ICFG| | | M3| | |

Module locations are indicated by M1, M2, M3, M4, M5 and M6. With respect to refrigerant flow, M1 is closest to inlet.
location not possible

*) ICF 15 – M1 and M2 modules are fixed (stop valve and filter, respectively)

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.

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