Danfoss ICM 20 Operating instructions

Quick Start Guide

ICM/ICAD Motorized Valves

Installation, Programming, and Troubleshooting

The ICM motorized valve is comprised of up to 4

components:

• the valve body – often referred to as the ICV body

because it is used for ICM motor valves, ICS pilot

operated valves and ICLX solenoid valves.

• the function module – the ow regulating part of

the valve

• the top cover – on the ICM 20 through 65, the

function module and top cover are one part

• the ICAD motor actuator – the “brains”of the

valve

Actuator ICAD 600A ICAD 1200A Old ICAD 600* Old ICAD 900* Old ICAD 1200*

Valve Size ICM 20 ICM 40 ICM 20 ICM 40 ICM 40

Valve Size ICM 25 ICM 50 ICM 25 ICM 50 ICM 50

Valve Size ICM 32 ICM 65 ICM 32 ICM 65 ICM 65

Valve Size ICM 100 ICM 100

Valve Size ICM 125 ICM 125

Valve Size ICM 150 ICM 150

ICM/ICAD overview The combinations of valve and actuator are as follows:

* ICAD 600, 900 and 1200 were discontinued at the end of 2014. ICAD 600A is a direct replacement of ICAD 600 and ICAD 1200A is a

direct replacement of ICAD 900 or ICAD 1200.

Quick Start Guide |ICM/ICAD Motorized Valves - Installation, Programming, and Troubleshooting

Contents Page

ICM/ICAD overview .....................................................................................1

Identifying ICM sizes ....................................................................................3

1st and 2nd generation ICAD dierences ..................................................................4

Installation .............................................................................................5

Wiring the ICAD actuator ...............................................................................7

Electrical data ..........................................................................................7

ICAD Programming ....................................................................................11

Pre-start up checklist ..................................................................................13

Troubleshooting

Overview ..........................................................................................14

Service parameters ................................................................................14

Alarms.............................................................................................14

Tips ...............................................................................................15

Frequently asked questions ........................................................................16

Quick Start Guide |ICM/ICAD Motorized Valves - Installation, Programming, and Troubleshooting

Dierent ICM 20

cone and orice

designs

ICM20-A33

A33 has a groove here

for identication

ICM20-A (2nd gen.)

Introduced mid 2009

ICM20-A (1st gen.)

Discontinued mid 2009

ICM20-C

ICM 20 orice (valve seat)

ICM 20-A33

ICM 20-A (2nd gen.)

ICM 20-A (1st gen.), ICM 20-B,

ICM 20-B66, ICM 20-C

7 mm 5 mm

ICM20-B66

Introduced Jan. 2011

ICM20-B

Note:

The outside edges of the

B66 cone has more of a

cylindrical shape compared

to the B cone which forms

more of a conical shape.

Identifying ICM sizes All ICM sizes except ICM 20 have a stainless steel

ID tag located around the valve stem on the top

cover which the ICAD mounts on. When the ICAD

is mounted it can be dicult to locate this. The

sticker on the valve body of the large valves states

ICV and the valve size because the body is shared

between the ICM motor valves, ICS pilot operated

valves and ICLX solenoid valves.

The ICV size is the same size as the ICM size which

is needed during programming. ICM 20 only has a

sticker on the side of the valve body to identify the

size.

If the sticker is missing the size can be identied by

the shape of the cone. The below gure shows how

to indentify the ICM 20 size by looking at the cone.

Quick Start Guide |ICM/ICAD Motorized Valves - Installation, Programming, and Troubleshooting

Dierences between 1st and

2nd generation ICAD motor

actuators

The 2nd generation ICAD was released in the

beginning of 2010. The part numbers on the

label for the 2nd generation start with 027H9…

and the 1st generation part numbers started with

027H12… The cables of the 1st generation were

mounted through cable glands located in the

plastic top whereas the 2nd generation has the

cables mounted on connectors located in the

aluminum body.

Note: The wire colors are dierent between the two

generations and the following is a table with the

dierences and pictures of old and new generation.

1st Generation ICAD 2nd Generation ICAD

Power cable

(3-wire)

+ 19-24 V d.c. fail safe supply White (+) Black (+)

+ 24 V d.c. Brown (+) White (+)

- 24 C d.c. (GND) Green (-) Brown (-)

Communication

cable (7-wire)

Digital output (common alarm) White (-) Black (-)

Digital output (ICM fully open) Brown (-) Brown (-)

Digital output (ICM fully closed) Green (-) Red (-)

GND - ground Yellow (-) Orange (-)

Analog input (0/4-20 mA Grey (+) Yellow (+)

Analog input 0/2-10 V /

Digital ON/OFF input

Pink (+) Green (+)

Analog output 0/4-20 mA Blue (+) Blue (+)

Quick Start Guide |ICM/ICAD Motorized Valves - Installation, Programming, and Troubleshooting

Installation

1. All ICM valves and ICAD motor actuators must

be installed in horizontal pipelines with the

motor actuator in an upright position.

2. Preparation of Valve Body

ICM 20 (3/4”) valves: both the integrated

bonnet/function module and the separate

valve seat must be removed from the valve

body prior to welding. To remove the

ICM20-A33 or ICM20-A valve seat use a 13mm

socket and to remove the ICM20-B66, ICM 20-B

or ICM20-C valve seat, use a 12 mm hex key.

- ICM 25 to 65 (1”to 2-1/2”) valves, the

integrated bonnet and function module

should be removed as shown in the gure.

- ICM 100 to 150 (4”to 6”) valves, the function

module and bonnet are separate pieces and

do not need to be removed prior to welding.

However, some form of arc welding should

beusedtoweldthevalveintothepipingand

care should be taken to protect the valve

stem from becoming contaminated.

No. Part

1 Housing

2 Top cover / function module

2a O-ring

2b O-ring

2c O-ring

4 Gasket

4a Gasket

5 Bolts

11 Actuator

12 O-ring

13 O-ring

14 Seat

Removing the bonnet/function module from the body

of the ICM 25 to 65 valves.

Quick Start Guide |ICM/ICAD Motorized Valves - Installation, Programming, and Troubleshooting

Care should be taken to protect the ICM function module when it is removed and stored during

installation of valve body.

3. Weld the valve body in line making sure that the arrow on the valve body is pointing in the direction

of ow.

- For ICM 20 through 65, make sure that all debris is removed from valve body before bonnet/

function module is re-installed.

- For the ICM 20, make sure that the removable orice seat is re-installed in the valve body with the

small o-ring between the orice seat and the body. Use a 13mm socket to tighten the ICM20-A33 or

ICM20-A valve seat to a torque of 6.5 ft-lbs (9 N-m). Use a 12 mm hex key to tighten the ICM 20-B66,

ICM20-B or ICM20-C valve seat to a torque of 1.5 ft-lbs (2 Nm).

DO NOT OVERTIGHTEN THE REMOVABLE SEAT.

Make sure that the bonnet gasket is installed and in good condition.

- For the ICM 25 through ICM 65, check that the two o-rings are installed on the function module and

that the gasket located on the top of the valve body is installed and all are in good condition.

A light coating of refrigerant oil on the bonnet o-rings and the cover gasket will facilitate assembly

of the valve.

4. Install the bolts and torque to the following specications:

5. Install the ICAD Motor on the ICM valve:

The ICM valve must not be in its full opened position while the ICAD motor is calibrated with the valve

(at a later step). Therefore, if the opening degree of the ICM valve was changed from the factory

setting, it should be set to an opening degree between 0% and 75% using the manual magnet tool.

To easily ensure correct positioning, turn the manual tool counter-clockwise until it is clear that it

cannot be turned any further.

- Make sure that the ICM adapter/valve stem and inner ICAD magnets are completely dry and free

from any debris.

- For applications below freezing, the ICM adapter O-ring (position 2c in the diagram on page 5)

must be removed and Molycote G 4500 grease (supplied with ICAD motor) needs to be applied in

the O-ring groove on the adapter and on the O-ring before it is re-installed on the ICM adapter.

The Molycote grease ensures a good seal between the ICAD motor and the ICM adapter to prevent

moisture from entering the ICAD magnets.

- Place the ICAD motor on the valve stem.

- Push the ICAD motor completely down to the identication ring on the valve stem. Using a 2.5 mm

hex key, tighten the set screws evenly so the ICAD motor is centered on the ICM valve stem.

Torque the set screws to approximately 3 Nm (2.5 ft-lbs).

Installation (continued)

Valve Body Nm ft lbs

ICM 20 40 29

ICM 25 100 74

ICM 32 120 88

ICM 40 120 88

ICM 50 140 103

ICM 65 150 110

ICM 100 through 150 220 162

Quick Start Guide |ICM/ICAD Motorized Valves - Installation, Programming, and Troubleshooting

Wiring the ICAD actuator There are two cables which are connected to the ICAD motor with M12 connectors:

Supply voltage is galvanically isolated from input and output wires

Supply Voltage Fail Safe Supply

24 VDC + 10%/-15% Min. 19 VDC

Load ICAD 600A 1.2 A ICAD 600A 1.2 A

ICAD 1200A 2.0 A ICAD 1200A 2.0 A

Analog Input – Current or Voltage Analog Output

Current 0/4 – 20 mA 0/4 – 20 mA

Load: 200Ώ Load: ≤ 250 Ώ

Voltage 0/2 – 10 VDC

Load: 10k Ώ

Digital Input – Digital On/O input by means of voltfree contact with gold-plated contacts recommended

Voltage Input Used

ON: contact impedance < 50 Ώ

OFF: contact impedance > 100 k Ώ

Digital Output: 3 pcs. NPN transistor output

External Supply: 5 – 24 VDC (same supply as for ICAD can be used but note that galvanically

isolated system will be spoiled.

Output Load: 50 Ώ

Load Max. 50 mA

Electrical data

Communication connector / cable

Ref. Color Description

A Black – Common Alarm

B Brown – ICM fully open

C Red – ICM fully closed

D Orange – GND ground

E Yellow + 0/4 - 20 mA Input*

F Green + 0/2 - 10 V Input. Also used with GND (orange wire) as a digital input #1 for

on-o operation or oating 3-point control

G Blue + 0/4 - 20 mA Output*

Power connector/cable (3 wires)

I Black + Fail safe supply

Battery / UPS (uninterruptable power supply) 19 V d.c.

II White + Supply voltage

24 V d.c.

III Brown –

}

Digital

Ouput

III

4 pin male connector 8 pin male connector

* If using oating 3-point control (parameter i02=3) then wire colors yellow and blue are combined to make the 2nd digital input

Quick Start Guide |ICM/ICAD Motorized Valves - Installation, Programming, and Troubleshooting

Wiring the ICAD actuator Wiring diagram showing ICAD wired to a PLC or other type of third party electronics

Note: The ICAD supplies the power for the 4-20 mA feedback signal.

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White

Brown

Yellow

Orange

PLC

Blue

Active 4-20 mA PLC output to control ICAD

Passive 4-20 mA PLC input

for valve position feedback

Passive 4-20 mA PLC input

for valve position feedback

Black

Optional UPS/battery back up

Active 4-20 mA PLC output to control ICAD

Power supply cable

Control cable

Terminal box

(customer supplied)

Wiring diagram showing ICAD wired to a Danfoss EKC controller

Note: For instructions on completely wiring an EKC controller, please see the relevant EKC controller manual.

Orange(ground)

Yellow

Blue (+ 4-20 mA)

White

Brown

Optional position

feedback

Only possible

with EKC 347

24 V d.c

Power

Supply

(+ 4-20 mA)

Black

Optional UPS/battery back up

CUSTOMER SUPPLIED

Power supply cable

Control cable

Terminal box

(customer supplied)

Quick Start Guide |ICM/ICAD Motorized Valves - Installation, Programming, and Troubleshooting

AKS4100/4100U

AKS 41

Connections

upper level

DI1 - main switch

4-20 mA

CANbus connection

to other EKE controllers

plug for

remote display

ModBUS

4-20 mA

24 V DC

orange Optional ICAD/ICM

Valve Position

Feedback

ICAD 2nd gen

blue

24 V AC

–

orange

ICAD 2nd gen (2010 +)

yellow

brown

white

24 V+

15 V+

5 V+

COM

AI 5

AI 4

AI 3

AI 2

AI 1

COM

DI 2

DI 1

COM

R120

CAN H

CAN L

GND

R GND

D+

D-

COM

AO 1

CAN RJ

24 V DC

15 16 17 18 19 20 21 22 23 24

2 3 4 5 6 7 8 9 10 11 12 13 14

Upper level

Wiring diagram showing ICAD wired to a Danfoss EKE controller

Note: For instructions on completely wiring an EKE controller, please see the relevant EKE controller manual.

Wiring the ICAD actuator

continued

Quick Start Guide |ICM/ICAD Motorized Valves - Installation, Programming, and Troubleshooting

Wiring the ICAD actuator

continued

CUSTOMER SUPPLIED

White

Brown

Green

Orange

Relay

Black Optional UPS/battery

back up

24 V d.c

Power

Supply

Wiring diagram showing ICAD wired with one digital input for ON/OFF solenoid valve operation

Note: The ICAD motor can be programmed to open or close when the relay is closed. See parameter ¡09 in

programming section.

CUSTOMER SUPPLIED

5-24 V d.c

K1 : Common Alarm

K2 : ICM fully open

K3 : ICM fully closed

Auxillary relays

Black

Brown

Red

Orange

White

Brown

24 V d.c

Power

Supply

Power

Supply

Black Optional UPS/

battery back up

Wiring diagram showing ICAD digital outputs wired with customer supplied auxiliary relays

NOTE: The same 24 V d.c. power that powers the ICAD can be used with the ICAD digital outputs to power

auxiliary relays (or other small load devices) but the system will no longer be galvanically isolated.

White

Black

Brown

Green

Orange

Yellow

Blue

ICAD power cable

AD communication cable

Relay for DI1 (Digital Input1)

Relay for DI2 (Digital Input2)

Default setting

Par. i13=0 (Direct operation)

DI1=DI2=OFF: maintains

current position

DI1=DI2=ON: maintains

current position

DI1=ON, DI2=OFF: openin

degree increases

DI1=OFF, DI2=ON: opening

degree decreases

–

24 V d.c

Power

Supply

Optional UPS/battery

back up

Wiring diagram for oating 3-point control (open-neutral-close)

Customer supplied

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