Attuatore Danfoss ICAD 027H9075

⚠️Important Note: Il codice articolo 027H9075 corrisponde a ICAD600A (NON ICAD1200A).

ICAD 1200A part-number: 027H9077, corrente nominale 2,0 A.

027H9075: ICAD 600A, 24 VDC, rated 1.2 A, compatible with ICM20-32

027H9077: ICAD 1200A, 24 VDC, rated 2.0 A, compatible with ICM40-150

1. Scomposizione del codice modello

ICAD = Stepper-motor actuator for ICM motor-operated valves; Version A: built-in encoder + local LCD MMI keypad.

2. Parametri elettrici principali (ICAD-1200A 027H9077, 24 V 2.0 A)

3. Principio di funzionamento

The ICAD uses a high-speed stepper motor with magnetic-coupling gear-free transmission to drive the ICM motor-operated valve. A built-in position encoder provides closed-loop valve-position feedback.

Funzioni supportate:

1. Continuous modulating via 4-20 mA / 2-10 V analogue signal.
2. Digital dry-contact full-open / full-closed switching.
3. Local LCD keypad for parameter setup, position indication and fault-code reading.

Magnetic-coupling design: No rigid mechanical connection between actuator and valve body; eliminates refrigerant-leakage risk.

4. Assegnazione dei pin: M12-8-pin Signal Connector

4-pin M12 power connector: Main 24 VDC supply; optional connection for fail-safe UPS power.

5. Compatible Valve List

ICAD 600A (027H9075): ICM-20, ICM-25, ICM-32

ICAD 1200A (027H9077): ICM-40, 50, 65, 80, 100, 125, 150; also suitable for CVE pilot valves.

6. Scenari applicativi tipici

Industrial refrigeration, ammonia refrigeration, CO₂ transcritical refrigeration units

Liquid-line electronic expansion regulation

Suction-pressure / temperature regulation

Hot-gas bypass & hot-gas defrost control

Large cold-storage plants, refrigeration compressor stations, food-processing freezing lines

Insidie ​​della selezione & Risk Warnings

7. Do not mix-up part-numbers: 027H9075 = 600A (1.2 UN); 027H9077 = 1200A (2.0 UN). Mechanical mounting interfaces are identical, but output torque differs drastically. Never drive large-size valves with ICAD-600A; this triggers A1 valve-mismatch alarm.
8. Use isolated 24 VDC power supply only; 24 VAC is strictly forbidden. Calculate cable voltage drop; terminal voltage must not drop below 21 Vdc.
9. Outputs are NPN transistors; external power supply is mandatory. Do NOT connect relay coils directly to actuator outputs.
10. Raggio d'azione: -30 ℃ ~ +50 ℃. IP67 rating provides dustand splash-proof protection; permanent submersion is prohibited.
11. Parameter i26 must be set to match the actual ICM valve type, otherwise alarm A1 will activate.
12. Summary of Fault Codes

9. Informazioni sulla sostituzione

ICAD600A / 1200A are mature active-range products, not obsolete. Legacy ICAD600 / 900 / 1200 can be directly replaced by A-series units; mechanical interfaces are fully compatible. Simply re-configure valve-type parameter i26 after swap-out.

Domestic alternative note: No drop-in magnetically-coupled replacement actuator available. Full valve-body + actuator assembly replacement is required for third-party retrofits.

Commissioning Procedure for Danfoss ICAD 1200A (027H9077)

Modelli applicabili: ICAD-600A / ICAD-1200A (A-series with LCD panel); 24 VDC supply; for ICM motor-operated valves.

⚠️027H9075 is ICAD-600A with reduced torque. Do NOT use it for ICM40 or larger valves.

Prerequisites: Valve mechanically fitted, magnetic-coupling correctly engaged, piping pressure-test completed. All wiring performed with power removed; M12 connectors fully tightened.

1. Pre-power-on Wiring Check (Obbligatorio)
2. Confirm isolated 24 VDC power supply; 24 VAC forbidden. Power-supply rating ≥ 2.5 A.
3. Secure M12-4-pin power and M12-8-pin signal connectors. Cables undamaged; cable shield single-ended earthed.
4. NPN output circuit: External 24 V must be supplied from PLC side. Never connect relay coils directly to actuator outputs.
5. Analogue-signal circuit: Total loop impedance for 4-20 mA input ≤ 200 Ω. 2-10 V input impedance ≥ 10 kΩ.
6. Verify valve stem free from mechanical obstruction. Magnetic-coupling ring correctly fitted, no disengagement.
7. Power-up & Initial Self-test
8. Apply 24 VDC supply; LCD illuminates and actuator performs automatic self-test.
9. If alarm codes appear after self-test: record alarm code first, do not reset immediately.
10. ⚠️First-time power-on: No valve selected, alarm A1 is normal expected behaviour.
11. Basic Parameter Setup via LCD Keypad
12. Entra nel menù: Press and hold OK key for 3 seconds.
13. Locate parameter i26 Valve type

ICAD-1200A (ICM40-150): Select actual valve size (ICM-40 /50 /65 /80 /100 /125 /150).

ICAD-600A (027H9075): Only ICM-20-25-32 permitted.

3. Save setting. Actuator executes full-stroke auto-calibration.

Behaviour: Actuator travels automatically to full-closed position, then full-open. Do not cut power or apply external force during calibration.

4. When calibration completes, alarm A1 clears. If A1 persists: double-check i26 setting; inspect magnetic-coupling for slipping.

Frequently-used Parameter Table

4. Functional Tests

4.1 Local Manual Mode Test

1. Set i03 = `0 Local manual`.
2. Use up/down keys to adjust valve position from 0 %-100 %.
3. Compare LCD indicated position with actual valve movement.

No valve movement: Check magnetic-coupling, inceppamenti meccanici, i26 misconfiguration.

4. Drive valve to 0 % (full-closed) and 100 % (full-open); confirm mechanical end-stops are reached.

4.2 External Analogue-signal Control Test (PLC / DCS)

1. Set i03 to `1 (4-20 mA)` or `2 (2-10 V)` as appropriate.
2. Send minimum signal (4 mA / 2 V) from PLC; confirm valve moves to 0 % full-closed.
3. Send maximum signal (20 mA / 10 V); confirm valve moves to 100 % full-open.
4. Send intermediate 50 % reference; verify position tracking. Read analogue feedback output for cross-validation.

4.3 Digital-output Verification (NPN outputs)

Monitor three NPN outputs via PLC:

Full-open output: Conducts at 100 % valve position.

Full-closed output: Conducts at 0 % valve position.

Alarm output: Conducts when actuator fault is active.

NPN logic: Conducted = pin short-circuited to GND; non-conducted = high-impedance state.

5. Alarm Acknowledgement
6. Transient alarms: Navigate to `Acknowledge alarm` menu item, press OK to confirm.
7. Persistent alarms: Alarm recurs immediately after reset. Resolve root-cause fault before acknowledgement; avoid repeated blind resetting.
8. Post-commissioning Final Steps
9. Restore i03 to the control-source required by the plant-control system.
10. Exit parameter menu to return to main position-display screen.
11. Retighten M12 connectors; implement cable-strain-relief protection.
12. Document commissioning data: i26 valve setting, i40 fail-safe mode for project records.
13. On-site Troubleshooting Summary

8. Commissioning Hard-Rules (Operazioni proibite)
9. ❌ Hot-plug M12 connectors: Risk of IO-board electrostatic burnout.
10. ❌ Operate actuator without configuring i26 valve-type: Magnetic-coupling damage risk.
11. ❌ Use ICAD-600A (027H9075) for ICM40-and-larger valves: Insufficient torque causes recurring A2 and magnetic-coupling destruction.
12. ❌ Power-loss during auto-calibration: Loss of stroke-calibration data.
13. ❌ 24 VAC power supply: Permanent actuator power-supply-circuit destruction.

Difetti comuni & Troubleshooting for Danfoss ICAD-600A / ICAD-1200A (A-series LCD-type)

Applicable part-numbers: 027H9075 ICAD600A, 027H9077 ICAD1200A; 24 VDC supply, for ICM modulating valves.

Split into LCD-displayed alarm codes and non-alarming functional anomalies.

1. Panel Alarm Codes (LCD Axx display)

2. Functional Abnormalities Without Active Alarms

Fault 1: Local manual works; external PLC reference has zero response

-Sintomo: Valve responds 0-100 % from keypad; no reaction to 4-20 mA / 2-10 V remote signal, no alarm.

-Root-causes:

1. `i03 Control signal` set to 0 (local manual), remote reference blocked.
2. Signal-type parameter mismatch (hardware 4-20 mA but i03 set for 2-10 V).
3. Missing common-GND between signal source and actuator; floating signal.
4. Broken signal cable, faulty PLC analogue channel.

-Azione correttiva:

1. Set i03 to correct source: 1 = 4-20 mA; 2 = 2-10 V.
2. Connect signal negative to actuator signal-GND (pin 6).
3. Measure signal directly at actuator-side terminals with multimeter to isolate PLC-side versus actuator-side faults.

Fault 2: Reversed valve-position tracking; 4 mA = full-open, 20 mA = full-closed

-Root-cause: Reversed signal-span configuration.

-Azione correttiva: Swap numerical values of i04 minimum-signal and i05 maximum-signal; alternatively invert output scaling inside PLC program.

Fault 3: Chattering / hunting; valve moves intermittently, position oscillates

-Root-causes:

1. High internal valve-spool friction, fouling / scaling.
2. Voltage sag under load from undersized power-supply / cablaggio.
3. Electrical-noise interference; unshielded cables routed alongside power cables.

-Azione correttiva:

1. Evaluate valve-body service; perform overhaul if fouled.
2. Maintain terminal voltage ≥ 21 VDC under load; upgrade power-cable cross-section.
3. Use shielded cable with single-end shield-earthing; separate signal wiring from power-cable routes.

Fault 4: No feedback from NPN digital outputs (full-open / full-closed / allarme)

-Sintomo: LCD indicates full-open status but PLC receives no feedback signal.

-Principio di funzionamento: ICAD NPN open-collector outputs draw no voltage themselves; they only provide a switch-to-GND path.

-Root-causes:

1. No external 24 V supply fed into PLC DI-input circuit.
2. Mis-wiring; relay coil connected directly to output terminal.
3. Incorrect output-threshold parameter settings.

-Azione correttiva:

1. Supply external 24 V to PLC DI-channel; output pin pulls low to GND when active.
2. Never drive relay coils directly; install intermediate relay.

Fault 5: No LCD illumination; actuator completely dead on power-up

-Root-causes:

1. Zero 24 VDC supply; reversed power-supply polarity.
2. Crimp-failure / bent pins inside M12 power connector.
3. Surge-damage to internal power-supply circuit.

-Azione correttiva:

1. Measure voltage and polarity at M12 power-connector terminals.
2. Inspect connector pins for retraction / danno.
3. Correct supply voltage present yet no display: internal hardware failure, replace actuator.
4. Frequent Human-induced Field Faults (Selezione / Installazione / Commissioning-related)
5. ICAD-600A (027H9075) driving ICM40-or-larger valves

Insufficient torque triggers repeated A2 travel-fault alarms and rapid magnetic-coupling wear. Must upgrade to ICAD-1200A (027H9077).

2. Running unit without i26 valve-type configuration and auto-calibration

Incorrect stroke-data leads to incomplete valve-closure / incomplete opening; magnetic-coupling damage risk.

3. Hot-swapping M12 circular connectors

ESD-stress may destroy IO-board electronics, triggering A5 internal-fault alarm.

4. 24 VAC mains supply applied

Permanent destruction of actuator power-supply circuit, total unit loss.

5. Power-interruption during auto-calibration

Calibration-stroke data lost; persistent A2 alarms; full recalibration required.

4. Standardised General Troubleshooting Workflow
5. Record LCD alarm-code; document operating conditions (temperatura, medio, valve-position).
6. Spegnimento; inspect mechanical assembly: actuator mounting, magnetic-coupling, valve-spool jamming.
7. Power-on; measure M12-terminal supply-voltage under load; confirm 21-26.4 VDC.
8. Cross-check key parameters: i26 valve-type, i03 control-source, i40 fail-safe setting.
9. Execute complete automatic valve-stroke calibration.
10. Isolate fault-location by testing local manual mode:

✅ Local manual works: Fault lies in PLC, cabling or external control-system.

❌ Fault persists in local manual: Defect in actuator hardware, valve-body mechanics or magnetic-coupling.

Spare-part note: Magnetic-coupling ring is a consumable component and can be ordered separately; full-actuator replacement is not always required.