Danfoss ICM 100-150 Motor Operated Valve

Product Overview & Technical Data

This guide provides detailed instructions for the installation and maintenance of the Danfoss ICM 100-150 Motor Operated Valve, designed for use with the ICAD 1200 actuator.

Brand: Danfoss

Model: ICM 100-150

Actuator Compatibility: ICAD 1200

Refrigerants: Suitable for HCFC, non-flammable HFC, R717 (Ammonia), and R744 (CO2). Not recommended for flammable hydrocarbons. For use in closed circuits.

Temperature Range:

• Media: -60 to +120 °C (-76 to +248 °F)
• Ambient: -30 to +50 °C (-22 to +122 °F)

Pressure: Maximum working pressure of 52 bar (754 psig).

Regulation Performance: Features a V-shaped opening in the insert for optimal regulation accuracy.

Valve Sizes: Available from ICM 100-B (kv: 142 m³/h) to ICM 150-B (kv: 370 m³/h).

Service Friendly Design: Delivered as a complete valve; spare part kits are available for servicing.

Components

The ICM 100-150 valve assembly includes:

1. Housing: The main body of the valve.
2. Top cover: Encloses the internal mechanism.
3. Gasket: Provides sealing between components.
4. Bolts: Used to secure the top cover.
5. Allen screws: Used for mounting the actuator.
6. Actuator: The motor unit (e.g., ICAD 1200) that controls valve operation.
7. Insert: Contains the valve seat and the V-shaped opening.
8. Magnetic coupling: Transmits rotational force from the actuator to the valve spindle.

Installation Procedures

General Installation:

• Install the ICM + ICAD unit horizontally with the actuator oriented upwards (as depicted in Figure 1).
• The top cover can be rotated freely without impacting valve function.
• The motor can be positioned before securing it with the Allen screws.
• Mount the valve with the flow direction arrow pointing correctly.
• Ensure no refrigerant escapes and prevent dirt ingress during installation.
• Design piping systems to avoid liquid traps and thermal expansion pressure. Protect the valve from pressure transients like "liquid hammer".
• The valve outlet must always be connected to the system or securely capped; it must not be exposed to the atmosphere.

Welding:

• Welding can be performed on an assembled valve if the process is controlled and free from debris.
• Internal surfaces are protected with an anti-corrosion treatment.
• If components are left disassembled, protect them in polyethylene bags or with rust protection agents.
• Use only welding materials and methods compatible with the valve body.
• Clean the valve interior thoroughly after welding. Open flame welding is prohibited.
• Ensure the valve body is free from external stresses post-installation.

Manual Operation:

• A multi-function tool (part number 027H0181) allows manual spindle rotation if the actuator is removed.
• Manual operation is also accessible via the actuator's built-in electronics when powered, enabling 1% incremental adjustments. Consult ICAD instruction sheets for details.

Surface Treatment and Identification:

• Valves are factory Zinc-Chromated. Painting is permissible for enhanced corrosion protection.
• Protect the magnetic coupling ? during any surface treatment.
• Identify the valve using the ID plate on the top cover.
• Protect the external surface near connections after welding and the ID plate during repainting.

Assembly and Tightening:

• Remove all welding debris and dirt from pipes and the valve body before assembly.
• Apply a small amount of refrigerant oil to O-rings for easier insert installation.
• Use the magnetic tool when fitting the top cover.
• Tighten the top cover/function module to 220 Nm (162 ft lbs) using a torque wrench ?.

Maintenance and Servicing

Service Intervals:

• Service intervals are not fixed and depend on operating conditions, such as operational frequency and system cleanliness.
• Annual inspection of the spindle and cast iron nut for wear is recommended (refer to Figure 12 for lubrication point).
• The ICM 100-150 is designed for easy dismantling, with spare parts kits available.
• Important: Never open the valve while it is under pressure. The valve can be pressurized from both sides. Use the manual magnet tool (Figure 4) to open the seat and equalize internal pressure before removing the top cover.

Replacing the Teflon Valve Plate:

• If the Teflon valve plate is damaged (as shown in Figure 11), it must be replaced.
• When reassembling the servo piston, use Loctite 586 or a similar product on the servo piston thread.

Dismantling and Servicing the Function Module:

• Dismantling Steps: Remove the top cover bolts (Figure 6). Use screwdrivers to carefully detach the top cover, then remove the insert/function module (Figures 6-7). Further disassembly involves unscrewing the spindle and bearing house (Figure 8-9) and dismantling the piston assembly (Figure 10).
• Servicing/Replacement: The function module can be serviced or replaced. Follow dismantling steps and replace worn parts with genuine Danfoss spare parts.
• Lubricate new O-rings with refrigerant oil during reassembly.

Lubrication Guidelines (Figure 12):

• For cast iron nuts (steel, from production week 49, 2021): Lubricate the spindle. (Sales codes: 027H7135, 027H7155, 027H7175).
• For PEEK nuts (plastic, until production week 49, 2021): Do not apply oil or grease to the spindle. (Sales codes: 027H7479, 027H7480, 027H7481).

General Notes:

• Use only original Danfoss spare parts, including O-rings and gaskets.
• New part materials are certified for the specified refrigerants.
• Contact Danfoss for any clarifications.
• Diagrams are illustrative and not for dimensional or constructional use.

UL Listed Products:

• Applicable to common non-flammable refrigerants, R717, and non-corrosive gases/liquids, subject to sealing material compatibility.
• Ensure design pressure meets ANSI/ASHRAE 15 requirements for the refrigerant in use.

Torque Specifications

• Top Cover / Function Module: 220 Nm (162 ft lbs)
• Piston Assembly (Figure 11): 80 Nm (59 ft lbs)