© Danfoss A/S (AC-MCI/MWA), 2012-01
DKRCI.PI.HS0.A3.52 / 520H0953
3
Installation
Refrigerants
Applicable to all common non-flammable
refrigerants, including R717 and non-
corrosive gases/liquids dependent on sealing
material compatibility.
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.
The valve must be protected
against back pressure. A check
valve should be installed upstream
of the ICS in installations where there
is a risk of back pressure. Back pressure can
affect the correct position of the piston ring.
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 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
027H2222
ICS 32
027H3222
ICS 40
027H4222
ICS 50
027H5222
ICS 65
027H6222
ICS 80
027H8222
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.
Always carry out this operation when the
manual operation device has been in use
(see fig 7)
1. Remove the cap (
A
) and tighten the
spindle (
B
) anticlockwise with 8 Nm
(5.9 lb/ft)
2. Remount the cap (
A
) and tighten it
clockwise with 8 Nm (5.9 lb/ft)
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. (+++).
ENGLISH
