Danfoss ICS 1 Pilot, ICS 3 Pilot Data sheet

Data Sheet

Pilot

-operated servo valve

Type ICS

Controlling pressure, temperature and ON/OFF in refrigeration systems

ICS pilot-operated servo valves belong to the ICV (I

The valve comprises three main components: valve body, function module and top cover.

ICS pilot-operated servo valves are pilot operated valves for regulating pressure, temperature and ON/OFF function in refrigeration systems. ICS valves are designed for low and high-pressure refrigerants.

ICS valves can be used on the high and lowpressure sides, in wet and dry suction lines and in liquid lines without phase change (i.e. where no expansion takes place in the valve).

ndustrial Control Valve) family.

The function of ICS valves is dependent on the pilot pressure applied from either a pilot valve or external pilot pressure source.

ICS 1 pilot has one pilot pressure connection and ICS 3 pilot has three pilot pressure connections.

AI241186442033en-001301

Pilot-operated servo valve, type ICS

Features

• Designed for industrial refrigeration applications for a maximum working pressure of 52 bar / 754 psig.

• Applicable to HCFC, HFC, R717 (Ammonia) and R744 (CO2).

• Direct coupled connections.

• Connection types include butt weld, socket weld, solder and threaded connections.

• Low temperature steel body.

• Low weight and compact design.

• V-port regulating cone ensures optimum regulating accuracy particularly at part load.

• Function module has a QPQ surface treated insert and a steel piston ring ensuring precise control accuracy.

• ICV 4 in., 5 in. and 6 in. ANSI with NPT threaded pressure outlet in the outlet of the valve.

• Replaceable Teon valve seat for ICS 25-80.

• Maintenance spare part kit available for ICS 100-150.

• Modular Concept:

◦ Each valve body is available with several ◦ Valve overhaul on ICS 25-80 is done by replacing the function module. ◦ Possible to convert ICS pilot-operated servo valve to ICM motor operated valve.

• Manual opening.

• The ICS valve is a multifunction valve where several pilot valves can be mounted into the pilot ports.

• The standard range of pilot valves can be used on all sizes of ICS valves. Pilot valves can be either screwed directly into the ICS valve, thus eliminating the need for solder/weld connections or external pilot lines.

• Pressure gauge connection port to measure valve inlet pressure.

• The top cover can be rotated into any possible position without aecting the operation of the valve.

• To get an updated list of certication on the products please contact your local Danfoss Sales Company.

dierent connection types and sizes.

8

p

2

2c

3f

2g

1b

p

3

1a

3c

3g

p

1

p

4

2d 2a 2b

Danfoss

27H436

2g

3b

3a

3d

3e

11a1b22a2b2c2d2e2f2g33a3b3c3d3e3f3g

p1p2p3p

4

8

Body

Pilot channel to inlet side

Circular gap between house and module

Top cover

Pilot channels in top cover

Pilot insertion hole

Pressure gauge connection

Piston top inlet channel

Cross channel SI to SII

Inlet channel

Circular groove

Function module

Cylinder

Piston

Valve plate

Spring

Cone

Equalisation orice

Piston rod

Inlet pressure

Pressure on piston

Pressure underneath piston

Outlet pressure

Manual operating spindle

Pilot-operated servo valve, type ICS

Functions

Figure 1: ICS 1 Pilot

Figure 2: ICS 3 Pilots

ICS 1 Pilot and ICS 3 Pilot

The ICS main valve is a pilot operated valve. The types of pilot valves used determine the function. The ICS main valve with pilot valve(s) controls refrigerant ow

by modulation or on/o in accordance with the pilot valve and

main valve status. The manual spindle can be used to open the valve plate.

The opening degree of the main valve is determined by the pressure dierence (dierential pressure) between pressure p2, which acts on top of the servo piston (3b), and pressure p3, which acts on the underside of the servo piston.

If this pressure dierence is 0, the main valve will be fully closed.

Pilot-operated servo valve, type ICS

If the pressure dierence is 0.2 bar (3 psi) or greater, the main valve will be fully open. At pressure

dierences (p2 -

p3) between 0.07 bar (1 psi) and 0.2 bar (3 psi), the degree of opening will be correspondingly proportional.

The port of the throttle cone (3e) is V-shaped, which provide good regulation characteristic to pilot operated main valves even at low loads. P3 pressure is equal to the valve outlet pressure (P4), due to a clearance between the piston rod (3g) and the function module. The opening degree of the ICS valve is therefore controlled by the application of P2 pressure acting on top of the servo piston, which is equal to or greater than valve outlet pressure (P4).

p2 = p4 ~ closed p2 = p4 + 0.2 bar (3 psi)~ fully open p4 ≤ p2 ≤ p4 + 0.2 bar (3 psi) ~ proportional degree of opening.

The maximum pressure (p2) can act on the top of the servo piston (3b). p2 normally corresponds to the pressure, p1 ICS main valve inlet pressure. Inlet pressure p1 is led, via the drilled channels (1a, 1b, 2f, 2b (pilot), 2a, 2d) in the valve body (1) and cover (2) through the individual pilot valves and onto the top of the servo piston (3b).

The degree of opening of the individual pilot valves determines the magnitude of pressure p2 and thus the degree of opening of the main valve. The equalisation hole (3f) in the servo piston (3b) ensures that pressure p2 is balanced in accordance with the degree of opening of the pilot valve.

 NOTE:

When ICS valves with 3 pilot ports are used with external pressure connector (Figure 2: ICS 3 Pilots, pos. 61), the valve port inlet pressure will be isolated.

The ICS can be tted with just a single screwed-in pilot valve or external pilot connection. The degree of opening of the main valve will be in accordance with the control status of the pilot valve or external pilot ow control.

ICS main valve with one pilot connection is fully closed when the pilot valve is fully closed and fully open when the pilot valve is fully open. Otherwise the degree of opening of the main valve is proportional to the degree of opening of the pilot valve.

The ICS 3 pilot version can be tted with one, two, or three pilot valves so that up to three regulating functions are possible. If the external pilot connection is used, more functions can be added.

In the ICS three pilot version, the pilot ports are related as follows:

• The pilot valves tted in ports SI and SII are connected in series.

• The ICS 3 pilot operated main valve will be fully closed if just one of the series-connected pilot valves is closed. The main valve can only open if both pilot valves are open at the same time.

• The pilot valve tted in port P is connected in parallel to the pilot valves in ports SI and SII.

The ICS valve will be fully open if the pilot valve in P is fully open, irrespective of the degree of opening of pilot valves SI and SII.

The ICS valve will be fully closed if the pilot valve in P is fully closed and at least one of the valves in SI or SII is fully closed at the same time. The relation between the pilot valves in ports SI, SII and P is shown in the table on the next page.

If the ICS is not tted with three pilot valves, the unused port(s) must be sealed with a blanking plug. If the blanking plug is tted as an assembled unit, A + B, the channels from the specic port will be closed. (See illustration below)

If only the top part, A, of the plug is tted, the channels from the ports in question will be open. If the degree of opening of the ICS main valve is not to be a function of the main valve inlet pressure, or if more than three regulating functions are required, ports SI, SII or P can be tted with a nipple for the connection of external pilot pressure. This applies to all ICS versions.

The pressure to which the external pilot line is connected will then determine pressure p2 on top of the servo piston. The pilot valves tted in that external pilot line will determine the main valve function. Pilot valves installed in external lines must be mounted in a type CVH housing.

Depending on the function of the pilot valves, the ICS regulating characteristic becomes:

AI241186442033en-001301 | 4

A

B

P

SI

SII

Pilot valve port

ICS valve

SI

SII

P

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Closed

Open

Pilot-operated servo valve, type ICS

• on/o

• proportional

• integral or

• cascade.

ICS main valves ar

e therefore especially suitable for all forms of temperature and pressure regulating systems.

An overview of the types of pilot valves available can be found in the literature “Pilot valves for operated main valves” (AI248786497190).

On the following pages, a number of conguration examples can be found. These are only for explanatory purpose. However, by using the literature regarding pilot valves these examples are easier to comprehend.

Table 1: Pilot valve port

Figure 3: Blanking plug A + B

Figure 4: Blanking plug AAFigure 5: Example (ICS with 3 pilot

valves)

Pilot-operated servo valve, type ICS

Media

Refrigerants

Applicable to HCFC, HFC, R717(

Use with ammable hydrocarbons cannot be recommended; please contact Danfoss.

Surface protection ICS 25-150: The external surface is zinc-chromated to provide good corrosion protection.

Ammonia) and R744 (CO2).

New refrigerants

Danfoss products are continually evaluated for use with new refrigerants depending on market requirements.

When a refrigerant is approved for use by Danfoss, it is added to the relevant portfolio, and the R number of the refrigerant (e.g. R513A) will be added to the technical data of the code number. Therefore, products for specic refrigerants are best checked at store.danfoss.com/en/

, or by contacting your local Danfoss representative.

Pilot-operated servo valve, type ICS

Product specication

Design

ICS valves ar dierence is 0 bar /0 psi, the ICS valve will be closed. If the pressure dierence is 0.2 bar /3 psi or more, the ICS valve will be fully open. At pressure dierences between 0.07 bar /1 psi and 0.2 bar /3 psi, the opening degree will be correspondingly proportional.

The ICS is available for use with either one or three pilot valves.

Two of the three pilot pressure connections (S1 and S2) are connected in series whilst the third (P) is connected in parallel to S1 and S2. This allows dierent combinations of pilot valves to be used, thus providing numerous variations in control functions.

Valve body and top cover material Low temperature steel

e designed as pilot operated valves requiring minimal pressure dierential to open. If the pressure

Pressure and temperature range

Temperature range

-60 °C /+120 °C (-76 °F /+248 °F).

Pressure range

The valve is designed for: Max. working pressure: 52 bar (754 psig)

Surface protection

ICS 25-150: The external surface is zinc-chromated to provide good corrosion protection.

Opening

Fully open: Min. 0.2 bar (min. 3 psig); Max. Opening Pressure Dierential (MOPD), solenoid valves only - at nominal conditions.

dierential pressure:

• 10 W a.c. up to 21 bar (305 psi)

• 20 W a.c. up to 40 bar (580 psi)

AI241186442033en-001301 | 7

ICV25 ICV32 ICV40 ICV50 ICV65

ICV 100 ICV 125 ICV 150

D A J SOC SD SA FPT

Butt-weld DIN Butt-weld ANSI Butt-weld JIS Socket weld ANSI Solder DIN Solder ANSI Female Pipe Thread

Pilot-operated servo valve, type ICS

The ICS Concept

The ICS conc

ept is developed around a modular principle. This gives the possibility of combining function modules

and top covers with special valve body size that is available in a variety of connection possibilities.

There are eight valve bodies available.

Figure 6: Valve bodies

Valve bodies in the sizes ICV 20-ICV65 are available with a range of undersizes through oversized connection sizes and types.

V 100 - ICV 150 are available in butt-weld DIN and butt-weld ANSI nominal sizes

IC

Figure 7: Valve body in sizes

Each valve body may be tted with a 1 pilot or 3 pilot top cover.

AI241186442033en-001301 | 8

Danfoss

27H8258

Danfoss

27H8259

Type

Valve body size

K

v

(m3/h)

C

v

(USgal/min)

ICS 25-5

25

1.7

2.0

ICS 25-10

3.5

4.1

ICS 25-15

6.0

7.0

ICS 25-20

8

9.3

ICS 25-25

11.5

13.3

ICS 32

321720

ICS 40

402731

ICS 50

504451

ICS 65

657081

ICS 80

808598

ICS 100

100

142

165

ICS 125

125

207

240

ICS 150

150

354

410

Pilot-operated servo valve, type ICS

Figure 8: 1 pilot top cover

Figure 9: 3 pilot top cover

In ICS, multiple inserts (function modules) are available to give dierent

Figure 10: ICS function modules

capacities.

T

ØD

Danfoss

A148B15.10

SizemmSize

in.ODmmTmmODin.Tin.

20

(¾)

26.9

2.3

1.059

0.09125(1)

33.7

2.6

1.327

0.10332(1¼)

42.4

2.6

1.669

0.10240(1½)

48.3

2.6

1.902

0.103

50

(2)

60.3

2.9

2.37

0.11

65

(2½)

76.1

2.930.1180(3)

88.9

3.2

3.50

0.13

100

(4)

114.3

3.6

4.5

0.14

125

(5)

140.745.5

0.16

150

(6)

168.3

6.3

6.6

0.25

T

ØD

SizemmSize

in.ODmmTmmODin.Tin.

Schedule

(20)¾26.9

4.0

1.059

0.15880(25)133.7

4.6

1.327

0.18180(32)1¼42.4

4.9

1.669

0.19380(40)1½48.3

5.1

1.902

0.201

80

(50)260.3

3.9

2.37

0.15

40

(65)2½73.0

5.2

2.87

0.2040(80)388.9

5.5

3.50

0.22

40

Pilot-operated servo valve, type ICS

Connections

There is a v

ery wide range of connection types available with ICS valves:

• D: Butt weld, DIN (2448)

• A: Butt weld, ANSI (B 36.10)

• J: Butt weld, JIS (B S 602)

• SOC: Socket weld, ANSI (B 16.11)

• SD: Solder connection, DIN (2856)

• SA: Solder connection, ANSI (B 16.22)

• FPT: Female pipe thread (ANSI/ASME B 1.20.1)

Figure 11: D: Butt-weld DIN (2448)

Table 2: Butt-weld DIN

Figure 12: A: Butt-weld ANSI (B 36.10)

Table 3: Butt-weld ANSI

AI241186442033en-001301 | 10

SizemmSize

in.ODmmTmmODin.Tin.

Schedule

(100)4114.364.5

0.24

(125)5140.7

6.5

5.5

0.26

(150)6168.3

7.1

6.6

0.28

T

ØD

SizemmSize

in.ODmmTmmODin.Tin.

(20)¾26.9

4.0

1.059

0.158

(25)133.7

4.6

1.327

0.181

(32)1¼42.4

4.9

1.669

0.193

(40)1½48.3

5.1

1.902

0.201

(50)260.3

3.9

2.37

0.15

(65)2½76.3

5.2

3.0

0.20

SizemmSize

in.ODmmTmmODin.Tin.LmmLin.

(20)¾27.2

4.6

1.071

0.181130.51

(25)133.9

7.2

1.335

0.284130.51

(32)1¼42.7

6.1

1.743

0.240130.51

(40)1½48.8

6.6

1.921

0.260130.51

(50)261.2

6.2

2.41

0.24160.63

(65)2½74

8.8

2.91

0.344160.63

L

ID

Pilot-operated servo valve, type ICS

Figure 13: J: Butt-weld JIS

Table 4: Butt-weld JIS

Figure 14: SOC: Socket welding ANSI (B 16.11)

Table 5: Socket welding ANSI

Figure 15: SD: Soldering (DIN 2856)

SizemmIDmmL mm

22

22.08

16.52828.082635

35.072542

42.07

28

54

54.09

33

76

76.1

33

L

ID

Size

in.ODin.Lin.

⅞

0.875

0.6501⅛1.125

1.0241⅜1.375

1.0241⅝1.625

1.102

2⅛

2.125

1.300

2⅝

2.625

1.300

SizemmSize

in.

Inside pipe thread

(20)

¾

(¾ × 14 NPT)

(25)

1

(1 × 11.5 NPT)

(32)

1¼

(1¼ × 11.5 NPT)

Pilot-operated servo valve, type ICS

Table 6: SD: Soldering DIN

Figure 16: SA: Soldering (ANSI B 16.22)

Table 7: Socket welding ANSI

Figure 17: FPT: Female

ead

pipe thr

ANSI/ASME B

, (

1.20.1)

Table 8: Socket welding ANSI

AI241186442033en-001301 | 12

B

A

D

3b

E

3a

C

3c

8

7

5

2

9

10

4

6

P

3

C

3c

1

Type

Screw

ICS 25

M12 × 30 A2-70 DIN 933

ICS 32

M14 × 35 A2-70 DIN 933

ICS 40

M14 × 40 A2-70 DIN 933

ICS 50

M16 × 40 A2-70 DIN 933

ICS 65

M16 × 50 A2-70 DIN 933

No.

Part

Material

EN

ASTM

JIS

1

Body

Low temperature steel

G20Mn5QT, EN 10213-3

LCC A352

SCPL1 G5151

2

Top cover

Low temperature steel

G20Mn5QT, EN 10213-3 P285QH+QT 10222-4

LCC A352 LF2, A350

SCPL1 G5151

3

Function module (assembled)3ao-ring

Cloroprene (Neoprene)

3b

o-ring

Cloroprene (Neoprene)

3c

Washer plate

Steel

A

Cylinder

SteelBPiston

SteelCValve plate

PTFE

D

Spring

Steel

Pilot-operated servo valve, type ICS

Material specication

Figure 18: ICS 25, 32, 40, 50, 65

Table 9: Type and size of Bolt (pos. 5)

Table 10: Material and parts list (ICS 25, 32, 40, 50, 65)

No.

Part

Material

EN

ASTM

JIS

E

Cone

Steel4Gasket

Fiber, non-asbestos

5

Bolts

Stainless steel

A2-70, EN 1515-1

Grade B8 A320

A2-70, B 1054

6

Plug

Steel7Gasket

Aluminium

8

Manual operating spindle

Steel

9

Plug

Steel10Gasket

Aluminium

1

2

3

3a

Danfoss

M27H0069

3b

3c

3d

3e

3f

3g

3h

4

5

6

7

8

Type

Screw

ICS 100

M20 × 60 A2-70 DIN 933

ICS 125

M20 × 60 A2-70 DIN 933

ICS 150

M20 × 70 A2-70 DIN 933

Pilot-operated servo valve, type ICS

Figure 19: ICS 100, 125, 150

Table 11: Type and size of Bolt (pos. 5)

AI241186442033en-001301 | 14

No.

Part

Material

EN

ASTM

JIS

1

Body

Low temperature steel

G20Mn5QT, EN 10213-3

LCC A352

SCPL1 G5151

2

Top cover

Low temperature steel

G20Mn5QT, EN 10213-3

LCC A352

SCPL1 G5151

3

Function module (assembled)3aPiston/rod

Stainless steel / steel

3b

Piston ring

Steel3cInsert

Steel

3d

Spring

Steel3eCone

Stainless steel / steel

3f

Teon plate

Teon unlled

3g

Washer plate

PTFE3hO-ring

Cloroprene (Neoprene)

4

Gasket

Fiber, non-asbestos

5

Bolts

Stainless steel

A2-70, EN 1515-1

Grade B8 A320

A2-70, B 1054

6

Plug

Steel7Eye bolt

Galvanized steel

8

Manual operating spindle

Steel

Example no. 1-1

Products

Danfoss

27H467

Products

Danfoss

27H468

Constant pressure regulation

• CVP

-L (-0.66 to 7 bar g) (19.5 in. Hg to 102 psig)

• CVP-M (4 to 28 bar g) (58 to 406 psig)

• CVP-H (25 to 52 bar g) (363 to 754 psig)

1 × ICS 1 Pilot 1 × CVP-L/M/H

1 × ICS 3 Pilots 1 × CVP-L/M/H 2 × Blank

ing plugs SI: A + B SII: A

Example no. 1-2

Products

Danfoss

27H469

Products

Danfoss

27H470

Dierential pressure r

egu-

lation

• CVPP-L (0.66 to 7 bar g) (19.5 in. Hg to 102 psig)

• CVPP-M (4 to 28 bar g) (58 to 406 psig)

1 × ICS 1 Pilot 1 × CVPP-L/M

1 × ICS 3 Pilots 1 × CVPP-L/M 2 × Blank

ing plugs SI: A + B SII: A

Example no. 1-3

Products

Danfoss

27H471

Products

Danfoss

M27H0076

On/o regulation (solenoid valv

e)

1 × ICS 1 Pilot 1 × EVM 1 × coil

1 × ICS 3 Pilots 1 × EVM 1 × coil 2 × Blank

ing plugs SI: A + B SII: A

Example no. 1-4

Products

Danfoss

27H472

Products

Danfoss

M27H0077

Regulation with external contr

ol pressure

1 × ICS 1 Pilot 1 × nipple for ex

ternal

control pressure

1 × ICS 3 Pilots 1 × nipple for ex

ternal control pressure 2 × Blanking plugs SI: A + B SII: A

Pilot-operated servo valve, type ICS

Table 12: Material and parts list (ICS 100, 125, 150)

Conguration examples

Table 13: Example no. 1

Example no. 1-5

Products

Danfoss

27H471

Products

Danfoss

M27H0076

On/o regulation (solenoid valv

e)

1 × ICS 1 Pilot 1 × EVM-NO (12 W c

oil)

1 × ICS 3 Pilots 1 × EVM-NO (12 W c

oil) 2 × Blanking plugs SI: A + B SII: A

Example no. 1-6

Products

Crankcase pressure regulation. (Max. suction pr

es-

sure regulation)

• -0.45 to 7 bar g (13.3 in. Hg to 102 psig)

1 × ICS 1 Pilot 1 × CVC-L

1 × ICS 3 Pilots 1 × CVC-L 2 × Blanking plugs SI: A + B SII: A

Example no. 1-7

CVE

Danfoss

27H475

Products

Electronically controlled media temperatur

e regu-

lation

• -0.66 to 8 bar g (19.5 in. Hg to 116 psig)

1 × ICS 1 Pilot 1 × CVE

1 × ICS 3 Pilots 1 × CVE 2 × Blanking plugs SI: A + B SII: A

Example no. 2-1

Products

Constant pressure regulation combined with electrical shut

o

• -0.66 bar to 7 bar (19.5 in. Hg to 102 psig)

1 × ICS 3 Pilots 1 × blanking plug (A + B) 1 × C

VP-L 1 × EVM 1 × coil

Example no. 2-2

Products

Constant pressure regulation combined with electrical wide open

1 × ICS 3 Pilots 1 × blanking plug (A

) 1 × CVP-L 1 × EVM

Example no. 2-3

Products

Constant pressure regulation combined with electrical shut

o and wide open

• -0.66 bar to 7 bar (19.5 in. Hg to 102 psig)

1 × ICS 3 Pilots 1 × CVP-L 2 × E

VM

2 × coils

Pilot-operated servo valve, type ICS

Table 14: Example no. 2

AI241186442033en-001301 | 16

Danfoss ICS 1 Pilot, ICS 3 Pilot Data sheet

Specifications and Main Features

Frequently Asked Questions

User Manual