Danfoss ICS 25 Installation page 2

ENGLISH
Installation
Refrigerants
Applicable to HCFC, HFC, R717(Ammonia) and
R744 (CO ).
2
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 bar g (754 psi g).
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
Installation
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 cannot
be 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
2 | AN00008642027301-000702
the threaded hole of the piston on the function
module (fig. 3). 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 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)
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. (+++).
© Danfoss | DCS (ms) | 2020.03