Data Sheet Pilot-operated Servo Valve Type ICS

Data sheetPilot-operated servo valveType ICSThe valve comprises three main components: valvebody, function module and top cover.ICS pilot-operated servo valves are pilot operatedvalves for regulating pressure, temperature and ON/OFF function in refrigeration systems. ICS valves aredesigned for low and high-pressure refrigerants.ICS valves can be used on the high and low-pressuresides, in wet and dry suction lines and in liquid lineswithout phase change (i.e. where no expansion takesplace in the valve).The function of ICS valves is dependent on the pilotpressure applied from either a pilot valve or externalpilot pressure source.ICS 1 pilot has one pilot pressure connection and ICS 3pilot has three pilot pressure connections.Features Danfoss DCS (MWA) 2016.01 Designed for industrial refrigerationapplications for a maximum working pressureof 754 psig / 52 bar g. Applicable to HCFC, HFC, R717 (Ammonia) andR744 (CO2). Direct coupled connections Connection types include butt weld, socketweld, solder and threaded connections. Low temperature steel body Low weight and compact design. V-port regulating cone ensures optimumregulating accuracy particularly at part load. Function module has a QPQ surface treatedinsert and a steel piston ring ensuring precisecontrol accuracy. Modular Concept–– Each valve body is available with severaldifferent connection types and sizes–– Valve overhaul on ICS 25-80 is done byreplacing the function module–– Possible to convert ICS Pilot-operatedservo valve to ICM motor operated valve Manual opening. The ICS valve is a multifunction valve whereseveral pilot valves can be mounted into thepilot ports. Pressure gauge connection port to measurevalve inlet pressure. The top cover can be rotated into any possibleposition without affecting the operation of thevalve. Classification: DNV, CRN, BV, EAC etc.To get an updated list of certification on theproducts please contact your local DanfossSales Company.DKRCI.PD.HS2.A9.22 520H8639 1

Data sheet Pilot-operated servo valve, type ICSContentsPageFeatures. 1Design. 3Technical data. 3The ICS Concept. 3Function. 5Pilots and accessories for ICS. 7Material specification - ICS 25, 32, 40, 50, 65, 80. 8Material specification - ICS 100, 125, 150. 9Standard configurations.10Accessories.13ICV PM flanged valve housings.13Accessories.14Spare parts.15Ordering complete factory assembled valve without pilots .18Nominal capacities.19Dimensions and weights.42Connections.49 Danfoss DCS (MWA) 2016.01DKRCI.PD.HS2.A9.22 520H8639 2

Data sheet Pilot-operated servo valve, type ICSDesignICS valves are designed as pilot operated valvesrequiring minimal pressure differential to open. Ifthe pressure difference is 0 psi (0 bar), the ICS valvewill be closed. If the pressure difference is 2.9 psi(0.2 bar) or more, the ICS valve will be fully open.At pressure differences between 1 psi (0.07 bar)and 2.9 psi (0.2 bar), the opening degree will becorrespondingly proportional.The ICS is available for use with either one or threepilot valves.Two of the three pilot pressure connections (S1and S2) are connected in series while the third (P)is connected in parallel to S1 and S2. This allowsdifferent combinations of pilot valves to be used,thus providing numerous variations in controlfunctions.ApprovalsThe ICV valve concept is designed to fulfill globalrefrigeration requirements.For specific approval information, please contactDanfoss.The ICS valves are approved in accordance withthe European standard specified in the PressureEquipment Directive and are CE marked.For further details / restrictions - see InstallationInstructionValve body and top cover material:Low temperature steelThere is a very wide range of connection typesavailable with ICS valves.ICS valvesDN 25 (1 in.)Nominal boreDN 32-65 (11/4 - 2½ in.)Classified forFluid group ICategoryTechnical dataThe ICS ConceptDN 100-150 (4-6 in.)Article 3, paragraph 3 RefrigerantsApplicable to HCFC, HFC, R717 (Ammonia) andR744 (CO2).Use with flammable hydrocarbons cannot berecommended; please contact Danfoss. Temperature range–76/ 248 F(–60/ 120 C). Surface protectionICS 25-150:The external surface is zinc-chromated to providegood corrosion protection.IIIII Pressure rangeThe valve is designed for:Max. working pressure: 754 psig (52 bar)Opening differential pressure:Fully open: Min. 2.9 psig (0.2 bar)Max. Opening Pressure Differential (MOPD),solenoid valves only - at nominal conditions.– 10 W a.c. up to 305 psi (21 bar)– 20 W a.c. up to 580 psi (40 bar)The ICS concept is developed around a modular principle. Thisgives the possibility of combining function modules and topcovers with special valve body size that is available in a variety ofconnection possibilities. There are eight valve bodies available.ICV 25-80 Danfoss DCS (MWA) 2016.01ICV 100-125ICV 150DKRCI.PD.HS2.A9.22 520H8639 3

Data sheet Pilot-operated servo valve, type ICS Valve bodies in the sizes ICS 25-65 are availablewith a range of nominal through oversizedconnection sizes and types.ICS100 - 150 are available in butt-weld nominalsizesBWSOCODSFPTButt-weld ANSISocket weld ANSISolder ANSIFemale Pipe Thread Each valve body may be fitted with a 1 pilot or3 pilot top cover.In ICS, multiple inserts (function modules) areavailable to give different capacities. ICS 25 bodysize is available in reduced port modules for bettercontrol at low capacities.TypeKvCv(m3/h)(USgal/min)ICS 25-51.72.0ICS 25-103.54.16.07.0ICS 25-15 Danfoss DCS (MWA) 2016.01Valve bodysize25ICS 25-2089.3ICS 25-2511.513.3ICS 32321720ICS 40402731ICS 50504451ICS 65657081ICS 80808598ICS 100100142165ICS 125125207240ICS 150150354410DKRCI.PD.HS2.A9.22 520H8639 4

Data sheet Pilot-operated servo valve, type ICSFunctionICS 1 PilotICS 1 Pilot and ICS 3 Pilot1. Body1a Pilot channel to inlet side1b Circular gap between house andmodule2. Top cover2a Pilot channels in top cover2b Pilot insertion hole2c Pressure gauge connection2d Piston top inlet channel2e Cross channel SI to SII2f Inlet channel2g Circular groove3 Function module3a Cylinder3b Piston3c Valve plate3d Spring3e Cone3f Equalization orifice3g Piston rodp1p2p3p48Inlet pressurePressure on pistonPressure underneath pistonOutlet pressureManual operating spindleFig. 1ICS 3 PilotsThe ICS main valve is a pilot operated valve. Thetypes of pilot valves used determine the function.The ICS main valve with pilot valve(s) controlsrefrigerant flow by modulation or on/off inaccordance with the pilot valve and main valvestatus. The manual spindle can be used to manuallyopen the valve.The opening degree of the main valve isdetermined by the pressure difference (differentialpressure) between pressure p2, which acts on topof the servo piston (3b), and pressure p3, which actson the underside of the servo piston.If this pressure difference is 0, the main valve will befully closed.If the pressure difference is 2.9 psi (0.2 bar) orgreater, the main valve will be fully open.At pressure differences (p2 - p3) between 1 psi (0.07bar) and 2.9 psi (0.2 bar), the degree of opening willbe correspondingly proportional.The port of the throttle cone (3e) is V-shaped, whichprovide good regulation characteristic to pilotoperated 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) andthe function module. The opening degree of theICS valve is therefore controlled by the P2 pressureacting on top of the servo piston, which is equal toor greater than valve outlet pressure (P4).The maximum pressure (p2) can act on the top ofthe servo piston (3b). p2 normally corresponds tothe pressure, p1 - ICS main valve inlet pressure. Danfoss DCS (MWA) 2016.01Fig. 2Inlet pressure p1 is led, via the drilled channels (1a,1b, 2f, 2b (pilot), 2a, 2d) in the valve body (1) andcover (2) through the individual pilot valves andonto the top of the servo piston (3b).The degree of opening of the individual pilotvalves determines the magnitude of pressure p2and thus the degree of opening of the main valve.The equalization hole (3f ) in the servo piston (3b)ensures that pressure p2 is balanced in accordancewith the degree of opening of the pilot valve.Note:When ICS valves with 3 pilot ports are used withexternal pressure connector (fig. 2, pos. 61), thevalve port inlet pressure will be isolated.The ICS can be fitted with just a single screwed-inpilot valve or external pilot connection. The degreeof opening of the main valve will be in accordancewith the control status of the pilot valve or externalpilot flow control.ICS main valve with one pilot connection is fullyclosed when the pilot valve is fully closed andfully open when the pilot valve is fully open.Otherwise the degree of opening of the main valveis proportional to the degree of opening of the pilotvalve.The ICS 3 pilot version can be fitted with one, two,or three pilot valves so that up to three regulatingfunctions are possible. If the external pilotconnection is used, more functions can be added.DKRCI.PD.HS2.A9.22 520H8639 5

Data sheet Pilot-operated servo valve, type ICSFunction (continued)In the ICS three pilot version, the pilot ports arerelated as follows: The pilot valves fitted in ports SI and SII areconnected in series. The ICS 3 pilot operated main valve will befully closed if just one of the series-connected pilot valves is closed. The main valve can onlyopen if both pilot valves are open at the sametime. The pilot valve fitted in port P is connected inparallel to the pilot valves in ports SI and SII.The ICS valve will be fully open if the pilot valve in Pis fully open, irrespective of the degree of openingof pilot valves SI and SII.The ICS valve will be fully closed if the pilot valve inP is fully closed and at least one of the valves in SIor SII is fully closed at the same time. The relationbetween the pilot valves in ports SI, SII and P isshown in Table 1 below.If the ICS is not fitted with three pilot valves, theunused port(s) must be sealed with a pilot cap Aor a combination of pilot cap A and blanking plugB. If the pilot cap and blanking plug are fitted asan assembled unit, A B, the channels from thespecific port will be closed. (See Figure 1)of external pilot pressure. This applies to all ICSversions.The pressure to which the external pilot line isconnected will then determine the main valvefunction. Pilot valves installed in external lines mustbe mounted in a type CVH housing.Depending on the function of the pilot valves, theICS regulating characteristic becomes: on/off proportional integral or cascade.ICS main valves are therefore especially suitable forall forms of temperature and pressure regulatingsystems.An overview of the types of pilot valves availablecan be found in Table 2 (on the following page),or technical leaflet: “Pilot valves for operated mainvalves” (RD4XC).On the following pages, a number of standardconfiguration examples can be found. These areonly for explanatory purpose. However, by usingthe literature regarding pilot valves these examplesare easier to comprehend.If only cap A is fitted, the channels from the portsin question will be open. If the degree of openingof the ICS main valve is not to be a function of themain valve inlet pressure, or if more than threeregulating functions are required, ports SI, SII orP can be fitted with a nipple for the connectionTable 1Figure 2Pilot valve portICS dClosedClosedExample (ICS with 3 pilot losedOpenOpenFigure 1Pilot cap A Blanking plug B Danfoss DCS (MWA) 2016.01Pilot cap ADKRCI.PD.HS2.A9.22 520H8639 6