Danfoss ICF 50-4, ICF 65-3 Installation guide [de]
Installation Guide
Danf
27L20_08-2015
Valve station
ICF 50-4 and ICF 65-3
Orientation (all configurations) Einbaulage (alle Konfigurationen) Orientation (toutes les configurations) Orientación (todas las configuraciones)
Orientação (todas as configurações) Orientacja (wszystkie konfiguracje) Ориентация (все конфигурации) 指南(所有配置)
ICF 50-4 & ICF 65-3
027R9969
ICM
027R9969
4 x 90°
1a
Welding Schweißen Soudure Soldadura Soldagem Spawanie Сварка 焊接
TIG/MIG/SMAW
1b
Gas welding
Gasschweißen
Soudure au gaz
Soldadura con gas
Soldagem a gás
Spawanie gazowe
Газовая сварка
气焊
ICS
4 x 90°
ICSH
4 x 90°
ICLX
4 x 90°
oss
2 3
© Danfoss | DCS (MWA) | 2021.01
Info for UK customers only:Danfoss Ltd. Oxford Road, UB9 4LH Denham, UK
AN17198641964802-000301 | 1
Maintenance Instandhaltung Maintenance Mantenimiento
Manutenção Serwis Техническое обслуживание 维护
ICF 50-4 / ICF 65-3
Flat gasket
Flachdichtung
Joint plat
Junta plana
Junta plana
Płaska uszczelka
Плоская прокладка
平垫片
Flat gasket
Flachdichtung
Joint plat
Junta plana
Junta plana
Płaska uszczelka
Плоская прокладка
平垫片
Flat gasket
Flachdichtung
Joint plat
Junta plana
Junta plana
Płaska uszczelka
Плоская
прокладка
平垫片
Flat gasket
Flachdichtung
Joint plat
Junta plana
Junta plana
Płaska uszczelka
Плоская прокладка
平垫片
Flat gasket
Flachdichtung
Joint plat
Junta plana
Junta plana
Płaska uszczelka
Плоская прокладка
平垫片
Flat gasket
Flachdichtung
Joint plat
Junta plana
Junta plana
Płaska uszczelka
Плоская прокладка
平垫片
4
© Danfoss | DCS (MWA) | 2021.01
Flat gasket
Flachdichtung
Joint plat
Junta plana
Junta plana
Płaska uszczelka
Плоская прокладка
平垫片
Flat gasket
Flachdichtung
Joint plat
Junta plana
Junta plana
Płaska uszczelka
Плоская прокладка
平垫片
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3
3
1
2
2
2
1
1
2
3
3
Maintenance Instandhaltung Maintenance Mantenimiento
Manutenção Serwis Техническое обслуживание 维护
M1 M2 M3 M4
ICF 50-4
ICF 65-3
ICF 50-4 110 Nm (81.1 ft lbs)
ICF 65-3 110 Nm (81.1 ft lbs)
ICF 50-4 60 Nm (44.3 ft lbs)
ICF 65-3 60 Nm (44.3 ft lbs)
ICF 50-4 45 Nm (33.2 ft lbs)
33 Nm
(24.3 ft lbs)
57 Nm
(42 ft lbs)
33 Nm
(24.3 ft lbs)
140 Nm
(103.3 ft lbs)
150 Nm
(110.6 ft lbs)
33 Nm
(24.3 ft lbs)
57 Nm
(42 ft lbs)
5
ICS / ICSH
6
ICLX
ICM
7
8a
© Danfoss | DCS (MWA) | 2021.01
8b
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Manual operation Handbedienung Fonctionnement manuel Accionamiento manual
Operação manual Obsługa ręczna Ручное управление 手动操作
SVA-S / REG-SB
9
ICM
Open
Öffnen
Ouvrir
Abrir
Abrir
Otwarcie
Открыт
打开
Close
Schließen
Fermer
Cerrar
Fechar
Zamknięcie
Закрыт
关闭
ICS / ICLX / ICSH
10
11
Module and side port location Modul und Lage der seitlichen Ports Module et emplacement des ports latéraux
Ubicación de los módulos y puertos laterales Posição de módulo e de porta lateral Położenie modułów i przyłączy pomocniczych
Расположение модулей и боковых портов 模块和侧接口位置
12
ICF 50-4
M1 M3 M4
P2
P4 (opposite side)
(gegenüberliegende Seite)
(côté opposé)
(lado opuesto)
(lado oposto)
(po przeciwnej stronie)
(противоположная сторона)
M2
P1
P3 (opposite side)
(gegenüberliegende Seite)
(côté opposé)
(lado opuesto)
(lado oposto)
(po przeciwnej stronie)
(противоположная сторона)
(对侧)
(对侧)
M1 M3 M4
ICF 65-3
P2
P4
(opposite side)
(gegenüberliegende Seite)
(côté opposé)
(lado opuesto)
(lado oposto)
(po przeciwnej stronie)
(противоположная сторона)
P1
P3 (opposite side)
(gegenüberliegende Seite)
(côté opposé)
(lado opuesto)
(lado oposto)
(po przeciwnej stronie)
(противоположная сторона)
(对侧)
(对侧)
© Danfoss | DCS (MWA) | 2021.01
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ENGLISH
Refrigerants
Applicable to HCFC, non flammable HFC,
R717 (Ammonia) and R744 (CO2).
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
-60 – 120 °C / -76 – 248 °F
Pressure range
The ICF is designed for a max. working
pressure of 52 bar g / 754 psi g.
Application
The ICF can be used in suction, liquid,
hotgas and liquid/vapor lines. 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.
Orientation (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).
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 (fig. 1b).
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 (fig. 3).
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.
Every precaution must be taken to
minimize welding spatter.
To avoid any welding spatter entering the
valve station and to avoid heat impact
to the Teflon seat during welding, it is
recommended to open the valves slightly
(approx. 1 turn from closed position) in first
and last module (M1 and M4).
When welding is completed it is
recommended to close the 2 modules
again (M1 and M4) in order to protect the
interior of the valve until the system is
ready for operation.
Gas welding
Remove all inserts before welding (fig. 3).
Auxiliary cooling is not needed at normal
heat impact.
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 2
modules again (M1 and M4) 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.
Mounting of valves
- Make sure that piping into which a valve
is installed is properly supported and
aligned square and plumb to the joining
sections.
- Ensure that the finalized valve assembly
is free of any stresses from external loads.
- Use only new gaskets manufactured by
Danfoss.
- Ensure that installed valves are properly
pressure tested, leak tested, evacuated
before charging with refrigerant in
accordance with ANSI /IIAR 5, EN378-2 or
ISO 5149-2.
The enclosed 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.
Side port connections (fig. 12)
The ICF features 2 groups of 2 individual
side ports. The 2 smaller ports P1 and
P3 are intended for service devices like
service valve, gauge or sight glass, while
the bigger ports P2 and P4 can be used for
defrost drain from the evaporator when
doing defrost (typically hot gas).
P2 and P4 can be converted to side ports
similar to P1 and P3 by installing separate
accessories (see the ICF data sheet).
Surface protection and identification
The external surface is zinc-chromated 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 4 function
modules.
Maintenance (fig. 4)
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
modules:
- Check that the flat gaskets and/or
O-rings between the 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 a damaged o-ring/gasket
might not modulate according to the
specification.
Flat gaskets and O- are present in the
locations shown in fig. 4.
CO2 applications
When used in CO2 systems
the O-rings (see fig. 4) can swell
(grow).
At service it is recommended to replace
the actual number of used O-rings before
the modules are reinstalled in the ICF valve
body.
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)
Tighten the top covers and plugs with a
torque wrench, to the values indicated in
the table (see fig. 5).
Replacing or servicing the function
module in the ICS, ICM, ICLX and ICSH
modules:
ICS/ICSH module (fig. 6)
Remove the top cover.
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.
6). Debris blocking the bolt hole will need
cleaning.
- Remove the old module.
- Oil the O-rings on the new module with
a small amount of refrigeration oil.
ICM module (fg. 7)
Remove the existing module (fig. 7):
1. After removing the 4 bolts twist the
module approx. 45° in either direction.
2. Push two screwdrivers in between the
top cover and the valve body.
3. Pull the screwdrivers upwards to release
the function module and its o-rings.
- Remove the old module.
- Oil the O-rings on the new module with
a small amount of refrigeration oil.
© Danfoss | DCS (MWA) | 2021.01
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ICLX modules (fig. 8a and 8b)
Often the cover and function module can
be removed while still assembled (fig. 8a).
1. Unscrew and remove all top cover
screws.
2. Push two screwdrivers in between the
top cover and the valve body and pull
the screwdrivers downwards to
release the function module and its
o-rings.
If the internal O-rings stick to the metal
surface it is necessary to disassemble in 2
steps (fig. 8b).
1. Remove spindle sign, lock ring and lock
washer and turn the spindle downwards,
out of thread.
Remove the top cover.
2. Insert two screwdrivers into the two
grooves in the function module and
press the screwdrivers downwards to
release the function module and its
o-rings.
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 operate according to the
specification.
- The insert and piston assembly can
be disassembled and wear parts can be
replaced.
For detailed information please see the
installation guide for ICS, ICM, ICLX or ICSH
valves.
Backseating SVA-S or REG-SB
module (fig. 9)
To backseat turn the spindle counterclockwise until the valve is fully open.
Before remounting the cap on the modules
please ensure that the gasket is present in
the cap. Then tighten the cap with 16 Nm
(12 ft lbs).
Manual operation of
ICLX module (fig. 10)
Normal operation mode:
For the valve to operate normally under the
influence of the pilot valves the spindle of
the manual operation device needs to be
turned fully clockwise.
Manual forced opening:
To manually open the valve the spindle of
the manual operation device needs to be
turned fully counter clockwise.
Manual operation of
ICS/ICSH module (fig. 10)
Normal operation mode:
For the valve to operate normally under the
influence of the pilot valves the spindle of
the manual operation device needs to be
turned fully counter clockwise.
Manual forced opening:
To manually open the valve the spindle of
the manual operation device needs to be
turned fully clockwise.
Note:
Always pay attention to the spindle
during operation of the manual opener
1. Pay attention to the C-clip reaching the
top of the manual stem top nut (ICSH:
spacer between C-clip and manual stem
top nut) 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 Nut/Spacer.
2. When turning the spindle anticlockwise,
for deactivation of the manual opener, to
the top point, tighten the spindle further
anticlockwise to 8 Nm (5.9 lb/ft) torque
for back-seating.
3. Remount the cap and tighten it
clockwise to 8 Nm (5.9 lb/ft) torque.
Manual operation of
ICM module (fig. 11)
A magnetic coupling can be used to rotate
the spindle manually when the actuator
has been removed. To make use of the
manual operation, a multi-function tool
(optional) is used (see fig. 11).
Manual operation is also possible with the
actuator mounted on the valve and the
power supply connected to the actuator.
No matter if the signal connections are
wired to the actuator it will be possible to
use the manual operation function built
into the actuator electronics allowing the
motor to step in 1% increments meaning
that 100 steps will correspond to a
fully open valve. Please refer to the
separate instruction on ICAD to address the
manual function.
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.
For further service / maintenance details
on the modules ICM, ICS, ICSH, ICLX,
SVA-S, REG-SB and FIA; please refer to the
individual product installation guide, which
can be downloaded from danfoss.com.
Module and side port location (fig. 12)
ICF 50-4
Function Module Type Can be installed in these locations
ICM Motor operated valve module M3
ICS Pilot operated serco valve module M3
ICSH Dual position solenoid valve module M3
ICLX Solenoid valve module M3
SVA-S Shut-off valve module M1 M4
REG-SB Regulating valve module M4
FIA Strainer module M2
P1 & P3 (P3 on the opposite side of P1): Side ports for gauge valve, sight glass, etc..
P2 & P4 (P4 on the opposite side of P2): Side ports for defrost drain or other purposes.
ICF 65-3
Function Module Type Can be installed in these locations
ICM Motor operated valve module M3
ICS Pilot operated servo valve module M3
ICLX Solenoid valve module M3
SVA-S Shut-off valve module M1 M4
REG-SB Regulating valve module M4
P1 & P3 (P3 on the opposite side of P1): Side ports for gauge valve, sight glass, etc..
P2 & P4 (P4 on the opposite side of P2): Side ports for defrost drain or other purposes.
location not possible
*) Modules are fixed
*)
*)
© Danfoss | DCS (MWA) | 2021.01
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