Danfoss ICAD 900, ICAD 1200, ICAD 600, ICM 100, ICM 125 Installation guide

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Quick Start Guide

ICM/ICAD Motorized Valves Installation, Programming, and Troubleshooting

The ICM motorized valve is comprised of up to 4 components:

• the valve body – often referred to as the ICV body because it is used for ICM motor valves, ICS pilot operated valves and ICLX solenoid valves.

• the function module – the ﬂow regulating part of the valve

• the top cover – on the ICM 20 through 65, the function module and top cover are one part

• the ICAD motor actuator – the “brains” of the valve

ICM/ICAD overview The combinations of valve and actuator are as follows:

Actuator ICAD 600A ICAD 1200A Old ICAD 600* Old ICAD 900* Old ICAD 1200*

Valve Size ICM 20 ICM 40 ICM 20 ICM 40 ICM 40

Valve Size ICM 25 ICM 50 ICM 25 ICM 50 ICM 50

Valve Size ICM 32 ICM 65 ICM 32 ICM 65 ICM 65

Valve Size ICM 100 ICM 100

Valve Size ICM 125 ICM 125

Valve Size ICM 150 ICM 150

* ICAD 600, 900 and 1200 were discontinued at the end of 2014. ICAD 600A is a direct replacement of ICAD 600 and ICAD 1200A is a direct replacement of ICAD 900 or ICAD 1200.

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Quick Start Guide | ICM/ICAD Motorized Valves - Installation, Programming, and Troubleshooting

Contents Page

ICM/ICAD overview .....................................................................................1

Identifying ICM sizes ....................................................................................3

1st and 2nd generation ICAD diﬀerences ..................................................................4

Installation .............................................................................................5

Wiring the ICAD actuator ...............................................................................7

Electrical data ..........................................................................................7

ICAD Programming ....................................................................................11

Pre-start up checklist ..................................................................................13

Troubleshooting

Overview ..........................................................................................14

Service parameters ................................................................................14

Alarms.............................................................................................14

Tips ...............................................................................................15

Frequently asked questions ........................................................................16

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Quick Start Guide | ICM/ICAD Motorized Valves - Installation, Programming, and Troubleshooting

Identifying ICM sizes All ICM sizes except ICM 20 have a stainless steel

ID tag located around the valve stem on the top cover which the ICAD mounts on. When the ICAD is mounted it can be diﬃcult to locate this. The sticker on the valve body of the large valves states ICV and the valve size because the body is shared between the ICM motor valves, ICS pilot operated valves and ICLX solenoid valves.

The ICV size is the same size as the ICM size which is needed during programming. ICM 20 only has a sticker on the side of the valve body to identify the size.

Diﬀerent ICM 20 cone and oriﬁce designs

ICM20-A33

A33 has a groove here for identiﬁcation

7 mm

ICM20-A (2nd gen.)

Introduced mid 2009

If the sticker is missing the size can be identiﬁed by the shape of the cone. The below ﬁgure shows how to indentify the ICM 20 size by looking at the cone.

5 mm

ICM20-A (1st gen.)

Discontinued mid 2009

Note: The outside edges of the B66 cone has more of a cylindrical shape compared to the B cone which forms more of a conical shape.

ICM 20 oriﬁce (valve seat)

ICM20-B66

Introduced Jan. 2011

ICM 20-A33 ICM 20-A (2nd gen.)

ICM20-C

ICM20-B

ICM 20-A (1st gen.), ICM 20-B, ICM 20-B66, ICM 20-C

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Quick Start Guide | ICM/ICAD Motorized Valves - Installation, Programming, and Troubleshooting

Diﬀerences between 1st and 2nd generation ICAD motor actuators

The 2nd generation ICAD was released in the beginning of 2010. The part numbers on the label for the 2nd generation start with 027H9… and the 1

generation part numbers started with 027H12… The cables of the 1st generation were mounted through cable glands located in the plastic top whereas the 2nd generation has the cables mounted on connectors located in the aluminum body.

Power cable (3-wire)

Communication cable (7-wire)

+ 19-24 V d.c. fail safe supply White (+) Black (+)

+ 24 V d.c. Brown (+) White (+)

- 24 C d.c. (GND) Green (-) Brown (-)

Digital output (common alarm) White (-) Black (-)

Digital output (ICM fully open) Brown (-) Brown (-)

Digital output (ICM fully closed) Green (-) Red (-)

GND - ground Yellow (-) Orange (-)

Analog input (0/4-20 mA Grey (+) Yellow (+)

Analog input 0/2-10 V / Digital ON/OFF input

Analog output 0/4-20 mA Blue (+) Blue (+)

Note: The wire colors are diﬀerent between the two generations and the following is a table with the diﬀerences and pictures of old and new generation.

1st Generation ICAD 2nd Generation ICAD

Pink (+) Green (+)

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Quick Start Guide | ICM/ICAD Motorized Valves - Installation, Programming, and Troubleshooting

Installation

1. All ICM valves and ICAD motor actuators must

be installed in horizontal pipelines with the motor actuator in an upright position.

2. Preparation of Valve Body

ICM 20 (3/4”) valves: both the integrated bonnet/function module and the separate valve seat must be removed from the valve body prior to welding. To remove the ICM20-A33 or ICM20-A valve seat use a 13mm socket and to remove the ICM20-B66, ICM 20-B or ICM20-C valve seat, use a 12 mm hex key.

- ICM 25 to 65 (1” to 2-1/2”) valves, the integrated bonnet and function module should be removed as shown in the ﬁgure.

- ICM 100 to 150 (4” to 6”) valves, the function module and bonnet are separate pieces and do not need to be removed prior to welding. However, some form of arc welding should be used to weld the valve into the piping and care should be taken to protect the valve stem from becoming contaminated.

Removing the bonnet/function module from the body of the ICM 25 to 65 valves.

No. Par t

1 Housing

2 Top cover / function module

2a O-ring

2b O-ring

2c O-ring

4 Gasket

4a Gasket

5 Bolts

11 Actuator

12 O-ring

13 O-ring

14 Seat

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Quick Start Guide | ICM/ICAD Motorized Valves - Installation, Programming, and Troubleshooting

Installation (continued)

Care should be taken to protect the ICM function module when it is removed and stored during installation of valve body.

3. Weld the valve body in line making sure that the arrow on the valve body is pointing in the direction of ﬂow.

- For ICM 20 through 65, make sure that all debris is removed from valve body before bonnet/ function module is re-installed.

- For the ICM 20, make sure that the removable oriﬁce seat is re-installed in the valve body with the small o-ring between the oriﬁce seat and the body. Use a 13mm socket to tighten the ICM20-A33 or ICM20-A valve seat to a torque of 6.5 ft-lbs (9 N-m). Use a 12 mm hex key to tighten the ICM 20-B66, ICM20-B or ICM20-C valve seat to a torque of 1.5 ft-lbs (2 Nm). DO NOT OVERTIGHTEN THE REMOVABLE SEAT. Make sure that the bonnet gasket is installed and in good condition.

- For the ICM 25 through ICM 65, check that the two o-rings are installed on the function module and that the gasket located on the top of the valve body is installed and all are in good condition. A light coating of refrigerant oil on the bonnet o-rings and the cover gasket will facilitate assembly of the valve.

4. Install the bolts and torque to the following speciﬁcations:

Valve Body Nm ft lbs

ICM 20 40 29

ICM 25 100 74

ICM 32 120 88

ICM 40 120 88

ICM 50 140 103

ICM 65 150 110

ICM 100 through 150 220 162

5. Install the ICAD Motor on the ICM valve: The ICM valve must not be in its full opened position while the ICAD motor is calibrated with the valve (at a later step). Therefore, if the opening degree of the ICM valve was changed from the factory setting, it should be set to an opening degree between 0% and 75% using the manual magnet tool. To easily ensure correct positioning, turn the manual tool counter-clockwise until it is clear that it cannot be turned any further.

- Make sure that the ICM adapter/valve stem and inner ICAD magnets are completely dry and free from any debris.

- The ICM adapter O-ring (position 2c in the diagram on page 5)must be removed and Molycote 55 grease (supplied with ICAD motor) needs to be applied in the O-ring groove on the adapter and on the O-ring before it is re-installed on the ICM adapter. The Molycote grease ensures a good seal between the ICAD motor and the ICM adapter to prevent moisture from entering the ICAD magnets.

- Place the ICAD motor on the valve stem.

- Push the ICAD motor completely down to the identiﬁcation ring on the valve stem. Using a 2.5 mm hex key, tighten the set screws evenly so the ICAD motor is centered on the ICM valve stem. Torque the set screws to approximately 3 Nm (2.5 ft-lbs).

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Danfoss ICAD 900, ICAD 1200, ICAD 600, ICM 100, ICM 125 Installation guide

Specifications and Main Features

Frequently Asked Questions

User Manual