Danfoss Valve Station Installation Guide

Types ICF 15, ICF 20, ICF 25, ICF SS 20 and ICF SS 25

Introduction

This guide provides detailed instructions for the installation, operation, and maintenance of Danfoss ICF valve stations, including models ICF 15, ICF 20, ICF 25, ICF SS 20, and ICF SS 25. It covers various aspects such as module selection, welding and brazing procedures, tightening specifications, manual operation of stems, and specific considerations for refrigerants like CO2 and ammonia.

General Information and Safety

The ICF valve stations are designed for use with HCFC, non-flammable HFC, R717 (Ammonia), and R744 (CO2) refrigerants. The ICFD module is specifically designed for ammonia and CO2. Use of ICF valve stations with flammable hydrocarbons is not recommended. ICF stations are intended for closed-circuit systems only. Always ensure the system is designed to prevent liquid traps and hydraulic pressure from thermal expansion. Protect the ICF from pressure transients like 'liquid hammer'. The housing must be free from stresses after installation. The ICF must not be mounted in systems where the outlet side is open to atmosphere. The outlet side must always be connected to the system or properly capped off.

Module Installation and Location

The ICF valve stations are supplied with all function modules fully assembled. Modules can be rotated 4 x 90° relative to the valve body during installation. Ensure sufficient space for modules on each side of the ICFD module. Module locations (M1 to M6) are indicated in the diagrams, with M1 being closest to the inlet. Refer to the module location tables for specific module compatibility and placement.

Welding and Brazing

The ICF valve station can be welded using TIG/MIG/SMAW or gas welding/brazing. Always keep inlet and outlet protective caps on the valve until installation is complete to prevent rust. For TIG/MIG/SMAW welding, module removal is not necessary, and auxiliary cooling is not required under normal heat impact. For gas welding/brazing, remove all inserts and use auxiliary cooling to reduce heat impact. Follow specific steps for brazing, including cleaning connections, applying flux, using inert gas, heating the pipe, and brazing within the recommended temperature range. Take precautions to minimize welding spatter and clean the valve interior after welding.

Tightening Specifications

Tighten top covers with a torque wrench according to the values indicated in the tables. Specific torque values are provided for different modules and assembly steps.

Manual Stem Operation

Instructions are provided for operating the manual stem on various modules, including ICFE 25/ICFE SS 25, ICFE 20H/ICFE SS 20H, ICFD defrost modules, and ICFG 25. This includes details on switching between manual and automatic modes and safety precautions.

Maintenance

The ICF valve stations are easy to service. Do not open the ICF while it is under pressure. During service, check flat gaskets and O-rings for damage and replace if necessary. For CO2 applications, O-rings may swell, so it is recommended to replace them before reinstallation. Ensure that carbon steel parts are not mixed with stainless steel parts.

Specific Module Information

ICFD Defrost Module

For ICFD modules, especially for CO2 applications, specific procedures are outlined for handling high test pressures. This includes preparing the ICFD module by disassembling and reassembling the float housing and lever. It is recommended to replace the float housing gasket after repeated compression.

ICFE/ICFE SS Solenoid Modules

Instructions detail the manual operation of the solenoid valve stem for ICFE 25/ICFE SS 25 and ICFE 20H/ICFE SS 20H modules, including how to force open the valve and switch between manual and automatic modes.

Refrigerant Compatibility and Limitations

The ICF valve stations are compatible with various refrigerants. Specific limitations and recommendations are provided for ammonia (ICFD 20) and CO2 (ICFD 20C), including maximum working pressures and test pressures. The use of ICF stations with flammable hydrocarbons is not recommended. ICF is recommended for closed-circuit systems.

Temperature and Pressure Ranges

General temperature ranges for ICF and specific ranges for ICFD 20 and ICFD 20C are provided. Maximum working pressures are also detailed for different configurations.

Application

The ICF can be used in suction, liquid, hot gas, and liquid/vapor lines. It regulates flow through modulation or on/off functions depending on the installed modules.

Troubleshooting and Safety

General safety precautions are mentioned throughout the document, emphasizing the importance of following installation and maintenance procedures correctly. Specific warnings are given regarding pressure handling and potential hazards.

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