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BIFFI ICON3000 Series - User Manual

BIFFI ICON3000 Series
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Installation, Operation and Maintenance Manual
VCIOM-08500-EN
December 2019
Bif ICON3000
Electric Actuator
Copyright © Bif. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.bif.it or from your nearest Bif Center:
Bif Italia s.r.l. - Strada Bif 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: +39 0523 944 411 – bif_italia@bif.it

Table of Contents

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Summary

Section 1: General Safety Instructions

1.1 Range of Applications

Defines the intended use of the Biffi ICON3000 electric actuator in industrial settings.

1.2 Safety Instructions for Installation in Hazardous Areas

Provides safety guidelines for installing the actuator in potentially explosive environments.

1.3 Applicable Standards and Regulations

Lists the key international standards and regulations relevant to the actuator's design and operation.

1.4 Terms and Conditions

Outlines the warranty period and conditions for the product, including limitations.

Section 2: Storage and Pre-Installation

2.1 Tests to be Carried Out When the Actuator is Received

Specifies essential checks to perform upon receiving the actuator to ensure proper condition and functionality.

2.2 Storage Procedure

Details the recommended procedures for storing the actuator to maintain its condition and warranty.

2.3 Checks to be Performed Before Installation

Lists crucial checks to conduct on the actuator prior to its installation on site.

Section 3: Installation

3.1 Working Condition

Defines the acceptable ambient temperature ranges for standard and special versions of the actuator.

3.2 Coupling Block: Disassembly from the Actuator

Explains the process of removing the coupling block from the actuator for machining or maintenance.

3.3 Manual Operation

Describes how to engage and use the handwheel for manual operation of the actuator.

3.4 Mounting the Actuator onto the Valve

Provides instructions on how to physically attach the actuator to the valve, including coupling types.

3.5 Electrical Connections

Details the procedures and requirements for making electrical connections to the actuator.

3.5.1 Plant Requirements

Outlines necessary protection devices to be provided at the plant for the actuator's mains line.

3.6 Removing the Terminal Board Enclosure

Guides the user through the process of safely removing the terminal board enclosure for access.

3.7 Removing the Terminal Board Enclosure

Continues instructions on terminal board enclosure removal, focusing on cable entries and sealing.

3.8 Terminal Board

Covers the terminal board connections, grounding, and wiring diagram usage.

3.9 Instructions For Explosion-proof Enclosures

Provides specific instructions for handling and reassembling explosion-proof enclosures.

3.10 Installation in Environments with Explosive Dusts

Offers guidance for installing the actuator in areas with potentially explosive dusts.

Section 4: Lubrication

4.1 Lubrication Inspection

Details how to inspect and maintain the actuator's lubrication levels and recommended lubricants.

Section 5: Operating the ICON3000

5.1 Operation By Handwheel

Explains the procedure for manually operating the actuator using the handwheel.

5.1.1 Operation By Handwheel in Absence of a Power Supply and With the Lithium Battery

Describes handwheel operation when power is unavailable, utilizing the lithium battery for status updates.

5.2 Electrical Operation

Covers the steps and precautions for operating the actuator via electrical means.

5.3 Local Control

Details how to control the actuator using the on-unit selector and push-buttons.

5.4 Local Indication

Explains the information displayed on the actuator's local interface, including status and position.

5.5 Locking the 3-Position Selector

Describes how to lock the 3-position selector to prevent unauthorized changes.

5.6 Remote Control

Explains how to control the actuator remotely using external devices.

5.6.1 Remote Commands

Details the different wiring options and commands for remote operation.

5.6.2 Output Contacts

Describes the standard version's monitor and auxiliary output relays and their functions.

5.6.3 ESD Operation

Explains the Emergency Shut Down (ESD) functionality and its configuration.

5.6.4 Interlock Inputs

Covers the use of interlock inputs to inhibit actuator movement in specific directions.

5.7 Operating the ICON3000 for the First Time

Provides initial operating instructions and checks for first-time use.

5.8 Optional Modules

Introduces optional modules that can extend the actuator's functionality.

5.8.1 Fieldbus Interface for Remote Control via FIELDBUS

Describes the Fieldbus interface card for connecting the actuator to various fieldbus networks.

5.8.2 Ain;Aout Card

Explains the Analog Input/Output card for 4-20mA signals.

5.9 Base Card of the ICON3000

Provides an overview of the actuator's base card and its components.

5.10 Absolute Encoder of the ICON3000

Details the absolute encoder's function for position measurement and retention.

Section 6: Local Controls

6.1 Description of the Local Operator Interface

Details the components and functions of the actuator's local control interface.

6.2 Configuration Options

Explains how to configure actuator parameters via the local interface menus.

6.3 Entering the View Mode

Guides the user on how to access the actuator's configuration data for viewing.

6.4 Entering the Set-Up Mode

Describes the procedure to enter the set-up mode for configuring actuator parameters, including password entry.

6.5 Exit from View and Set-Up Mode

Lists the actions that will cause the actuator interface to exit view or set-up modes.

Section 7: Set-Up Menu

9.1 Actuator Set-Up

Details the routines for configuring actuator parameters like stroke limits, torque, and controls.

9.1.1 Set Stroke Limits

Explains how to configure the actuator's opening and closing limits based on position or torque.

9.1.2 Torque Set-up

Describes how to set the output torque limits for opening and closing the actuator.

9.1.3 ESD (Emergency Shut Down) Control

Covers the configuration of the Emergency Shut Down (ESD) function and its priorities.

9.1.4 Remote Controls

Explains the configuration options for controlling the actuator remotely using various wiring methods.

9.1.5 Local Controls

Details the configuration of control modes and LED colors for local operation.

9.1.6 Output Relays

Describes the configuration of monitor and auxiliary output relays for status indication and diagnostics.

9.1.7 Positioner

Explains the positioning function, including dead band, polarity, and input signal configuration.

9.1.8 Fail Safe

Details how to configure the actuator's action upon loss of input signals.

9.1.9 OUT 4-20 mA

Covers the configuration of the 4-20 mA analog output for position or torque signals.

9.1.10 Interlock

Explains the configuration of interlock inputs to inhibit actuator movement.

9.1.11 2-Speed Timer

Describes the routine for adjusting actuator travel time using configurable ON/OFF pulses.

9.1.12 BUS (or FDI Control)

Details the setup for actuators equipped with a fieldbus interface card.

9.1.13 Miscellaneous

Covers miscellaneous configuration routines like time, date, and torque limits.

9.1.13.1 Time and Date

Explains how to set and adjust the actuator's time and date for logging purposes.

9.1.13.2 Torque Limits

Describes how to configure torque limits for alarms and end-of-travel detection.

9.1.13.3 Lithium Battery

Details the configuration and status check for the internal lithium battery.

9.1.13.4 Torque Bypass (%)

Explains the torque bypass feature to temporarily disable torque alarms during specific operations.

9.1.13.5 Valve Jammed (Time)

Describes the setting for detecting valve jamming based on time and position variation.

Section 10: View Routines

10.1 Actuator Set-Up

Allows viewing the current actuator configuration without making changes.

10.2 Nameplate

Provides access to view data identifying the actuator, entered by the manufacturer.

10.3 Valve Data

Allows viewing data relevant to the valve, which should be entered by the user.

10.4 Maintenance

Provides access to view maintenance-related data.

10.4.1 Alarm Log

Allows viewing the log of all present alarms and warnings.

10.4.2 Torque Profile

Displays information on actuator working conditions compared to a reference torque profile.

10.4.3 Torque Curve

Shows actuator working conditions against a reference torque curve for process analysis.

10.4.4 Operation Log

Provides access to view general and recent operational data for maintenance analysis.

10.4.5 Maintenance Date

Allows viewing the last, next, and start-up maintenance dates.

10.4.6 Data Logger

Describes how to view configured data logger parameters and collected data.

Section 11: Maintenance

11.1 Standard Maintenance

Outlines recommended periodic inspections and general maintenance checks for the actuator.

11.2 Special Maintenance

Refers to troubleshooting sections for causes of actuator failure and spare parts ordering.

11.3 Lithium Battery Change

Provides instructions for safely replacing the actuator's internal lithium battery.

Section 12: Troubleshooting

12.1 The Electronics do not Switch on when Powered

Offers steps to diagnose and resolve issues where the actuator's electronics fail to power on.

12.2 DC Output Voltage not Available at the Terminals

Guides on troubleshooting scenarios where DC output voltage is missing from the terminals.

12.3 The Actuator does not Work from Remote Controls

Provides checks for when the actuator fails to respond to remote control commands.

12.4 The Motor is Very Hot and does not Start

Addresses issues related to an overheating motor that prevents startup.

12.5 The Motor Runs but the Actuator does not Move the Valve

Helps diagnose problems where the motor operates but the valve does not move.

12.6 The Manual Override Cannot be Engaged

Offers solutions for difficulties encountered when trying to engage the manual override lever.

12.7 The Valve does not Seat Correctly

Provides guidance on resolving issues where the valve fails to seat properly.

12.8 Valve Operation requires Excessive Torque

Discusses causes and solutions for situations where valve operation demands excessive torque.

12.9 The Actuator does not Stop in the Fully Open or Fully Closed Position

Addresses problems where the actuator fails to stop at the fully open or closed positions.

12.10 The Numeric Position Display Indicates -

Explains that stroke limits may need recalibration if the display shows "---".

12.11 Diagnostic Messages

Explains alarm and warning conditions indicated by the actuator and how to interpret them.

Section 13: Parts List and Drawings

Figure 89 Component Parts

Illustrates and lists the individual component parts of the actuator assembly.

Appendix A: ICON3000; ICON3000 AD

A.1 Safety Instructions

Provides safety instructions specific to ICON3000/ICON3000AD actuators, including general and installation guidelines.

A.1.1 General

General safety instructions for ICON3000/ICON3000AD actuators and their configurations.

A.2 Instructions for Proper Installation

Details proper installation procedures, focusing on nameplate checks and environmental suitability.

A.2.1 Marking

Explains the meaning of various markings found on the actuator's label for certification and identification.

A.3 Applicable General Standards and Regulations

Lists the relevant general standards and directives applicable to the actuator.

A.4 Terms and Conditions

Outlines the warranty and terms of sale for the product.

A.5 Manufacturers Liability

Specifies Emerson's liability limitations regarding product use and installation.

A.6 Storage and Pre-Installation

Covers procedures for storing and pre-installing the actuator, including checks before installation.

A.6.1 Storage Procedure

Outlines storage procedures for extensions and electronic cards.

A.6.2 Checks to be Performed Before Installation

Lists checks for installing extensions or electronic cards before the main installation.

A.7 Installation

Provides installation guidelines, especially concerning hazardous area classifications and working conditions.

A.7.1 Working Condition

Specifies the ambient temperature ranges for different actuator models.

A.7.1.1 Models and Temperature

Lists temperature ranges for specific ICON models.

A.7.2 Identification of Entries

Identifies conduit entry types and sizes for the base actuator.

A.7.2.1 Base Actuator

Details the thread form/size for entries on the base actuator.

A.7.2.2 Base Actuator With Extension [A] on the Control Compartment

Describes the thread form/size for an entry on an extension for the control compartment.

A.7.3 Electrical Connections

Covers the requirements for making electrical connections, including terminal types and torques.

A.7.3.1 Connection for Ex-e Terminals Enclosure

Specifies wiring methods for Ex-e terminal enclosures.

A.7.4 Cable Connection

Explains sealing of entries and ground connections for extensions.

A.7.5 Installation in Environments with Explosive Dusts

Provides specific attention points for installing the actuator in dusty, potentially explosive environments.

A.8 Maintenance

Covers general maintenance aspects for the actuator.

A.8.1 Periodic Inspection

Details the recommended schedule and procedures for periodic inspection of the actuator.

A.8.2 Disassembly and Re-assembly

Provides steps for safely disassembling and re-assembling explosion-proof enclosures.

A.8.3 Repairs

Outlines the procedures and requirements for performing repairs on the actuator.

Appendix B: ICON3000; ICON3000 AD; ICON3000 LP

B.1 Safety Instructions

Safety instructions applicable to ICON3000 series actuators, covering general and installation aspects.

B.1.1 General

General safety instructions for ICON3000 series actuators and their configurations.

B.1.2 Identification of Main Parts

Illustrates the base unit and units with extensions for identification.

B.2 Instructions for Proper Installation

Specific installation instructions, emphasizing nameplate checks and environmental suitability.

B.2.1 Marking

Details the markings on the actuator label, including ATEX and IECEx certifications.

B.3 Applicable General Standards and Regulations

Lists applicable general standards, directives, and norms for the actuator.

B.4 Terms and Conditions

Outlines warranty and terms of sale for the product.

B.5 Manufacturers Liability

Specifies manufacturer liability limitations related to product usage and installation.

B.6 Storage and Pre-Installation

Covers storage procedures and checks required before installation for extensions and cards.

B.6.1 Storage Procedure

Outlines storage procedures for extensions and electronic cards.

B.6.2 Checks to be Performed Before Installation

Lists checks for installing extensions or electronic cards before the main installation.

B.7 Installation

Installation guidelines for hazardous areas, including working conditions and entry identification.

B.7.1 Working Condition

Specifies ambient temperature ranges for ICON3000 models and their extensions.

B.7.1.1 Models and Temperature

Lists temperature ranges for specific ICON models.

B.7.2 Identification of Entries

Identifies conduit entry types and sizes for the base actuator.

B.7.2.1 Base Actuator

Details the thread form/size for entries on the base actuator.

B.7.2.2 Base Actuator With Extension [A] on the Control Compartment

Describes the thread form/size for an entry on an extension for the control compartment.

B.7.2.3 Base Actuator with Extensions [B] or [C] on the Terminal Board Compartment

Details thread forms/sizes for entries on extensions for the terminal board compartment.

B.7.3 Electrical Connections

Covers electrical connection requirements for external ATEX-certified apparatus.

B.7.3.1 Connection for Ex-e Terminals Enclosure

Specifies wiring methods for Ex-e terminal enclosures.

B.7.4 Cable Connection

Explains sealing of entries and ground connections for extensions.

B.7.5 Installation in Environments with Explosive Dusts

Provides specific attention points for installing in dusty, potentially explosive environments.

B.8 Maintenance

Covers general maintenance for actuators with extensions.

B.8.1 Periodic Inspection

Details periodic inspection for actuators with optional extensions.

B.8.2 Disassembly and Re-assembly

Provides steps for safe disassembly and re-assembly of explosion-proof enclosures.

B.8.3 Repairs

Outlines procedures and requirements for performing repairs on actuators with extensions.

Appendix C: ICON3000; ICON3000 AD

C.1 Safety Instructions

Safety instructions applicable to ICON3000/ICON3000AD actuators, covering general and installation aspects.

C.1.1 General

General safety instructions for ICON3000/ICON3000AD actuators and their configurations.

C.2 Instructions for Proper Installation

Specific installation instructions, emphasizing nameplate checks and environmental suitability.

C.2.1 Marking

Explains the markings on the actuator label, including ATEX and IECEx certifications.

C.3 Applicable General Standards and Regulations

Lists applicable general standards, directives, and norms for the actuator.

C.4 Terms and Conditions

Outlines warranty and terms of sale for the product.

C.5 Manufacturers Liability

Specifies manufacturer liability limitations related to product usage and installation.

C.6 Storage and Pre-Installation

Covers storage procedures and checks required before installation.

C.6.1 Storage Procedure

Outlines storage procedures for extensions and electronic cards.

C.6.2 Checks to be Performed Before Installation

Lists checks for installing extensions or electronic cards before the main installation.

C.7 Installation

Installation guidelines for hazardous areas, including working conditions and entry identification.

C.7.1 Working Condition

Specifies ambient temperature ranges for ICON3000/ICON3000AD models.

C.7.1.1 Models and Temperature

Lists temperature ranges for ICON-010 and ICON-020 models.

C.7.2 Identification of Entries

Identifies conduit entry types and sizes for the base actuator.

C.7.2.1 Base Actuator

Details the thread form/size for entries on the base actuator.

C.7.2.2 Base Actuator With Extension [A] on the Control Compartment

Describes the thread form/size for an entry on an extension for the control compartment.

C.7.3 Electrical Connections

Covers electrical connection requirements for external ATEX-certified apparatus.

C.7.3.1 Connection for Ex-e Terminals Enclosure

Specifies wiring methods for Ex-e terminal enclosures.

C.7.4 Cable Connection

Explains sealing of entries and ground connections for extensions.

C.7.5 Installation in Environments with Explosive Dusts

Provides specific attention points for installing in dusty, potentially explosive environments.

C.8 Maintenance

Covers general maintenance for actuators with extensions.

C.8.1 Periodic Inspection

Details periodic inspection for actuators with optional extensions.

C.8.2 Disassembly and Re-assembly

Provides steps for safe disassembly and re-assembly of explosion-proof enclosures.

C.8.3 Repairs

Outlines procedures and requirements for performing repairs on actuators with extensions.

Appendix D: ICON3000

D.1 Safety Instructions

Safety instructions applicable to ICON3000 actuators, covering general and installation aspects.

D.1.1 General

General safety instructions for ICON3000 actuators and their configurations.

D.1.2 Identification of Main Parts

Illustrates the base unit and units with extensions for identification.

D.2 Instructions for Proper Installation

Specific installation instructions, emphasizing nameplate checks and environmental suitability.

D.2.1 Marking

Details the markings on the actuator label, including ATEX and IECEx certifications.

D.3 Applicable Directives, General Standards, and Norms

Lists applicable general standards, directives, and norms for the actuator.

D.4 Terms and Conditions

Outlines warranty and terms of sale for the product.

D.5 Manufacturers Liability

Specifies manufacturer liability limitations related to product usage and installation.

D.6 Storage and Pre-Installation

Covers storage procedures and checks required before installation.

D.6.1 Storage Procedure

Outlines storage procedures for extensions and electronic cards.

D.6.2 Checks to be Performed Before Installation

Lists checks for installing extensions or electronic cards before the main installation.

D.7 Installation

Installation guidelines for hazardous areas, including working conditions and entry identification.

D.7.1 Working Condition

Specifies ambient temperature ranges for ICON3000 models.

D.7.1.1 Models and Temperature

Lists temperature ranges for specific ICON models.

D.7.2 Identification of Entries

Identifies conduit entry types and sizes for the base actuator.

D.7.2.1 Base Actuator

Details the thread form/size for entries on the base actuator.

D.7.2.2 Base Actuator With Extension [A] on the Control Compartment

Describes the thread form/size for an entry on an extension for the control compartment.

D.7.2.3 Base Actuator with Extensions [B] or [C] on the Terminal Board Compartment

Details thread forms/sizes for entries on extensions for the terminal board compartment.

D.7.3 Electrical Connections

Covers electrical connection requirements for external ATEX-certified apparatus.

D.7.3.1 Connection for Ex-e Terminals Enclosure

Specifies wiring methods for Ex-e terminal enclosures.

D.7.4 Cable Connection

Explains sealing of entries and ground connections for extensions.

D.7.5 Installation in Environments with Explosive Dusts

Provides specific attention points for installing in dusty, potentially explosive environments.

D.8 Maintenance

Covers general maintenance for actuators with extensions.

D.8.1 Periodic Inspection

Details periodic inspection for actuators with optional extensions.

D.8.2 Disassembly and Re-assembly

Provides steps for safe disassembly and re-assembly of explosion-proof enclosures.

D.8.3 Repairs

Outlines procedures and requirements for performing repairs on actuators with extensions.

Appendix E: ICON3000

E.1 Safety Instructions

Safety instructions applicable to ICON3000 actuators, covering general and installation aspects.

E.1.1 General

General safety instructions for ICON3000 actuators and their configurations.

E.1.2 Identification of Main Parts

Illustrates the base unit and units with extensions for identification.

E.2 Instructions for Proper Installation

Specific installation instructions, emphasizing nameplate checks and environmental suitability.

E.2.1 Marking

Details the markings on the actuator label, including ATEX and IECEx certifications.

E.3 Applicable General Standards and Regulations

Lists applicable general standards, directives, and norms for the actuator.

E.4 Terms and Conditions

Outlines warranty and terms of sale for the product.

E.5 Manufacturers Liability

Specifies manufacturer liability limitations related to product usage and installation.

E.6 Storage and Pre-Installation

Covers storage procedures and checks required before installation.

E.6.1 Storage Procedure

Outlines storage procedures for extensions and electronic cards.

E.6.2 Checks to be performed before installation

Lists checks for installing extensions or electronic cards before the main installation.

E.7 Installation

Installation guidelines for hazardous areas, including working conditions and entry identification.

E.7.1 Working Condition

Specifies ambient temperature ranges for ICON3000 models.

E.7.1.1 Models and Temperature

Lists temperature ranges for specific ICON models.

E.7.2 Identification of Entries

Identifies conduit entry types and sizes for the base actuator.

E.7.2.1 Base Actuator

Details the thread form/size for entries on the base actuator.

E.7.2.2 Base Actuator With Extension [A] on the Control Compartment

Describes the thread form/size for an entry on an extension for the control compartment.

E.7.2.3 Base Actuator with Extensions [B] or [C] on the Terminal Board Compartment

Details thread forms/sizes for entries on extensions for the terminal board compartment.

E.7.3 Electrical Connections

Covers electrical connection requirements for external ATEX-certified apparatus.

E.7.3.1 Connection for Ex-e Terminals Enclosure

Specifies wiring methods for Ex-e terminal enclosures.

E.7.4 Cable Connection

Explains sealing of entries and ground connections for extensions.

E.7.5 Installation in Environments with Explosive Dusts

Provides specific attention points for installing in dusty, potentially explosive environments.

E.8 Maintenance

Covers general maintenance for actuators with extensions.

E.8.1 Periodic Inspection

Details periodic inspection for actuators with optional extensions.

E.8.2 Disassembly and Re-assembly

Provides steps for safe disassembly and re-assembly of explosion-proof enclosures.

E.8.3 Repairs

Outlines procedures and requirements for performing repairs on actuators with extensions.

Summary

Section 1: General Safety Instructions

1.1 Range of Applications

Defines the intended use of the Biffi ICON3000 electric actuator in industrial settings.

1.2 Safety Instructions for Installation in Hazardous Areas

Provides safety guidelines for installing the actuator in potentially explosive environments.

1.3 Applicable Standards and Regulations

Lists the key international standards and regulations relevant to the actuator's design and operation.

1.4 Terms and Conditions

Outlines the warranty period and conditions for the product, including limitations.

Section 2: Storage and Pre-Installation

2.1 Tests to be Carried Out When the Actuator is Received

Specifies essential checks to perform upon receiving the actuator to ensure proper condition and functionality.

2.2 Storage Procedure

Details the recommended procedures for storing the actuator to maintain its condition and warranty.

2.3 Checks to be Performed Before Installation

Lists crucial checks to conduct on the actuator prior to its installation on site.

Section 3: Installation

3.1 Working Condition

Defines the acceptable ambient temperature ranges for standard and special versions of the actuator.

3.2 Coupling Block: Disassembly from the Actuator

Explains the process of removing the coupling block from the actuator for machining or maintenance.

3.3 Manual Operation

Describes how to engage and use the handwheel for manual operation of the actuator.

3.4 Mounting the Actuator onto the Valve

Provides instructions on how to physically attach the actuator to the valve, including coupling types.

3.5 Electrical Connections

Details the procedures and requirements for making electrical connections to the actuator.

3.5.1 Plant Requirements

Outlines necessary protection devices to be provided at the plant for the actuator's mains line.

3.6 Removing the Terminal Board Enclosure

Guides the user through the process of safely removing the terminal board enclosure for access.

3.7 Removing the Terminal Board Enclosure

Continues instructions on terminal board enclosure removal, focusing on cable entries and sealing.

3.8 Terminal Board

Covers the terminal board connections, grounding, and wiring diagram usage.

3.9 Instructions For Explosion-proof Enclosures

Provides specific instructions for handling and reassembling explosion-proof enclosures.

3.10 Installation in Environments with Explosive Dusts

Offers guidance for installing the actuator in areas with potentially explosive dusts.

Section 4: Lubrication

4.1 Lubrication Inspection

Details how to inspect and maintain the actuator's lubrication levels and recommended lubricants.

Section 5: Operating the ICON3000

5.1 Operation By Handwheel

Explains the procedure for manually operating the actuator using the handwheel.

5.1.1 Operation By Handwheel in Absence of a Power Supply and With the Lithium Battery

Describes handwheel operation when power is unavailable, utilizing the lithium battery for status updates.

5.2 Electrical Operation

Covers the steps and precautions for operating the actuator via electrical means.

5.3 Local Control

Details how to control the actuator using the on-unit selector and push-buttons.

5.4 Local Indication

Explains the information displayed on the actuator's local interface, including status and position.

5.5 Locking the 3-Position Selector

Describes how to lock the 3-position selector to prevent unauthorized changes.

5.6 Remote Control

Explains how to control the actuator remotely using external devices.

5.6.1 Remote Commands

Details the different wiring options and commands for remote operation.

5.6.2 Output Contacts

Describes the standard version's monitor and auxiliary output relays and their functions.

5.6.3 ESD Operation

Explains the Emergency Shut Down (ESD) functionality and its configuration.

5.6.4 Interlock Inputs

Covers the use of interlock inputs to inhibit actuator movement in specific directions.

5.7 Operating the ICON3000 for the First Time

Provides initial operating instructions and checks for first-time use.

5.8 Optional Modules

Introduces optional modules that can extend the actuator's functionality.

5.8.1 Fieldbus Interface for Remote Control via FIELDBUS

Describes the Fieldbus interface card for connecting the actuator to various fieldbus networks.

5.8.2 Ain;Aout Card

Explains the Analog Input/Output card for 4-20mA signals.

5.9 Base Card of the ICON3000

Provides an overview of the actuator's base card and its components.

5.10 Absolute Encoder of the ICON3000

Details the absolute encoder's function for position measurement and retention.

Section 6: Local Controls

6.1 Description of the Local Operator Interface

Details the components and functions of the actuator's local control interface.

6.2 Configuration Options

Explains how to configure actuator parameters via the local interface menus.

6.3 Entering the View Mode

Guides the user on how to access the actuator's configuration data for viewing.

6.4 Entering the Set-Up Mode

Describes the procedure to enter the set-up mode for configuring actuator parameters, including password entry.

6.5 Exit from View and Set-Up Mode

Lists the actions that will cause the actuator interface to exit view or set-up modes.

Section 7: Set-Up Menu

9.1 Actuator Set-Up

Details the routines for configuring actuator parameters like stroke limits, torque, and controls.

9.1.1 Set Stroke Limits

Explains how to configure the actuator's opening and closing limits based on position or torque.

9.1.2 Torque Set-up

Describes how to set the output torque limits for opening and closing the actuator.

9.1.3 ESD (Emergency Shut Down) Control

Covers the configuration of the Emergency Shut Down (ESD) function and its priorities.

9.1.4 Remote Controls

Explains the configuration options for controlling the actuator remotely using various wiring methods.

9.1.5 Local Controls

Details the configuration of control modes and LED colors for local operation.

9.1.6 Output Relays

Describes the configuration of monitor and auxiliary output relays for status indication and diagnostics.

9.1.7 Positioner

Explains the positioning function, including dead band, polarity, and input signal configuration.

9.1.8 Fail Safe

Details how to configure the actuator's action upon loss of input signals.

9.1.9 OUT 4-20 mA

Covers the configuration of the 4-20 mA analog output for position or torque signals.

9.1.10 Interlock

Explains the configuration of interlock inputs to inhibit actuator movement.

9.1.11 2-Speed Timer

Describes the routine for adjusting actuator travel time using configurable ON/OFF pulses.

9.1.12 BUS (or FDI Control)

Details the setup for actuators equipped with a fieldbus interface card.

9.1.13 Miscellaneous

Covers miscellaneous configuration routines like time, date, and torque limits.

9.1.13.1 Time and Date

Explains how to set and adjust the actuator's time and date for logging purposes.

9.1.13.2 Torque Limits

Describes how to configure torque limits for alarms and end-of-travel detection.

9.1.13.3 Lithium Battery

Details the configuration and status check for the internal lithium battery.

9.1.13.4 Torque Bypass (%)

Explains the torque bypass feature to temporarily disable torque alarms during specific operations.

9.1.13.5 Valve Jammed (Time)

Describes the setting for detecting valve jamming based on time and position variation.

Section 10: View Routines

10.1 Actuator Set-Up

Allows viewing the current actuator configuration without making changes.

10.2 Nameplate

Provides access to view data identifying the actuator, entered by the manufacturer.

10.3 Valve Data

Allows viewing data relevant to the valve, which should be entered by the user.

10.4 Maintenance

Provides access to view maintenance-related data.

10.4.1 Alarm Log

Allows viewing the log of all present alarms and warnings.

10.4.2 Torque Profile

Displays information on actuator working conditions compared to a reference torque profile.

10.4.3 Torque Curve

Shows actuator working conditions against a reference torque curve for process analysis.

10.4.4 Operation Log

Provides access to view general and recent operational data for maintenance analysis.

10.4.5 Maintenance Date

Allows viewing the last, next, and start-up maintenance dates.

10.4.6 Data Logger

Describes how to view configured data logger parameters and collected data.

Section 11: Maintenance

11.1 Standard Maintenance

Outlines recommended periodic inspections and general maintenance checks for the actuator.

11.2 Special Maintenance

Refers to troubleshooting sections for causes of actuator failure and spare parts ordering.

11.3 Lithium Battery Change

Provides instructions for safely replacing the actuator's internal lithium battery.

Section 12: Troubleshooting

12.1 The Electronics do not Switch on when Powered

Offers steps to diagnose and resolve issues where the actuator's electronics fail to power on.

12.2 DC Output Voltage not Available at the Terminals

Guides on troubleshooting scenarios where DC output voltage is missing from the terminals.

12.3 The Actuator does not Work from Remote Controls

Provides checks for when the actuator fails to respond to remote control commands.

12.4 The Motor is Very Hot and does not Start

Addresses issues related to an overheating motor that prevents startup.

12.5 The Motor Runs but the Actuator does not Move the Valve

Helps diagnose problems where the motor operates but the valve does not move.

12.6 The Manual Override Cannot be Engaged

Offers solutions for difficulties encountered when trying to engage the manual override lever.

12.7 The Valve does not Seat Correctly

Provides guidance on resolving issues where the valve fails to seat properly.

12.8 Valve Operation requires Excessive Torque

Discusses causes and solutions for situations where valve operation demands excessive torque.

12.9 The Actuator does not Stop in the Fully Open or Fully Closed Position

Addresses problems where the actuator fails to stop at the fully open or closed positions.

12.10 The Numeric Position Display Indicates -

Explains that stroke limits may need recalibration if the display shows "---".

12.11 Diagnostic Messages

Explains alarm and warning conditions indicated by the actuator and how to interpret them.

Section 13: Parts List and Drawings

Figure 89 Component Parts

Illustrates and lists the individual component parts of the actuator assembly.

Appendix A: ICON3000; ICON3000 AD

A.1 Safety Instructions

Provides safety instructions specific to ICON3000/ICON3000AD actuators, including general and installation guidelines.

A.1.1 General

General safety instructions for ICON3000/ICON3000AD actuators and their configurations.

A.2 Instructions for Proper Installation

Details proper installation procedures, focusing on nameplate checks and environmental suitability.

A.2.1 Marking

Explains the meaning of various markings found on the actuator's label for certification and identification.

A.3 Applicable General Standards and Regulations

Lists the relevant general standards and directives applicable to the actuator.

A.4 Terms and Conditions

Outlines the warranty and terms of sale for the product.

A.5 Manufacturers Liability

Specifies Emerson's liability limitations regarding product use and installation.

A.6 Storage and Pre-Installation

Covers procedures for storing and pre-installing the actuator, including checks before installation.

A.6.1 Storage Procedure

Outlines storage procedures for extensions and electronic cards.

A.6.2 Checks to be Performed Before Installation

Lists checks for installing extensions or electronic cards before the main installation.

A.7 Installation

Provides installation guidelines, especially concerning hazardous area classifications and working conditions.

A.7.1 Working Condition

Specifies the ambient temperature ranges for different actuator models.

A.7.1.1 Models and Temperature

Lists temperature ranges for specific ICON models.

A.7.2 Identification of Entries

Identifies conduit entry types and sizes for the base actuator.

A.7.2.1 Base Actuator

Details the thread form/size for entries on the base actuator.

A.7.2.2 Base Actuator With Extension [A] on the Control Compartment

Describes the thread form/size for an entry on an extension for the control compartment.

A.7.3 Electrical Connections

Covers the requirements for making electrical connections, including terminal types and torques.

A.7.3.1 Connection for Ex-e Terminals Enclosure

Specifies wiring methods for Ex-e terminal enclosures.

A.7.4 Cable Connection

Explains sealing of entries and ground connections for extensions.

A.7.5 Installation in Environments with Explosive Dusts

Provides specific attention points for installing the actuator in dusty, potentially explosive environments.

A.8 Maintenance

Covers general maintenance aspects for the actuator.

A.8.1 Periodic Inspection

Details the recommended schedule and procedures for periodic inspection of the actuator.

A.8.2 Disassembly and Re-assembly

Provides steps for safely disassembling and re-assembling explosion-proof enclosures.

A.8.3 Repairs

Outlines the procedures and requirements for performing repairs on the actuator.

Appendix B: ICON3000; ICON3000 AD; ICON3000 LP

B.1 Safety Instructions

Safety instructions applicable to ICON3000 series actuators, covering general and installation aspects.

B.1.1 General

General safety instructions for ICON3000 series actuators and their configurations.

B.1.2 Identification of Main Parts

Illustrates the base unit and units with extensions for identification.

B.2 Instructions for Proper Installation

Specific installation instructions, emphasizing nameplate checks and environmental suitability.

B.2.1 Marking

Details the markings on the actuator label, including ATEX and IECEx certifications.

B.3 Applicable General Standards and Regulations

Lists applicable general standards, directives, and norms for the actuator.

B.4 Terms and Conditions

Outlines warranty and terms of sale for the product.

B.5 Manufacturers Liability

Specifies manufacturer liability limitations related to product usage and installation.

B.6 Storage and Pre-Installation

Covers storage procedures and checks required before installation for extensions and cards.

B.6.1 Storage Procedure

Outlines storage procedures for extensions and electronic cards.

B.6.2 Checks to be Performed Before Installation

Lists checks for installing extensions or electronic cards before the main installation.

B.7 Installation

Installation guidelines for hazardous areas, including working conditions and entry identification.

B.7.1 Working Condition

Specifies ambient temperature ranges for ICON3000 models and their extensions.

B.7.1.1 Models and Temperature

Lists temperature ranges for specific ICON models.

B.7.2 Identification of Entries

Identifies conduit entry types and sizes for the base actuator.

B.7.2.1 Base Actuator

Details the thread form/size for entries on the base actuator.

B.7.2.2 Base Actuator With Extension [A] on the Control Compartment

Describes the thread form/size for an entry on an extension for the control compartment.

B.7.2.3 Base Actuator with Extensions [B] or [C] on the Terminal Board Compartment

Details thread forms/sizes for entries on extensions for the terminal board compartment.

B.7.3 Electrical Connections

Covers electrical connection requirements for external ATEX-certified apparatus.

B.7.3.1 Connection for Ex-e Terminals Enclosure

Specifies wiring methods for Ex-e terminal enclosures.

B.7.4 Cable Connection

Explains sealing of entries and ground connections for extensions.

B.7.5 Installation in Environments with Explosive Dusts

Provides specific attention points for installing in dusty, potentially explosive environments.

B.8 Maintenance

Covers general maintenance for actuators with extensions.

B.8.1 Periodic Inspection

Details periodic inspection for actuators with optional extensions.

B.8.2 Disassembly and Re-assembly

Provides steps for safe disassembly and re-assembly of explosion-proof enclosures.

B.8.3 Repairs

Outlines procedures and requirements for performing repairs on actuators with extensions.

Appendix C: ICON3000; ICON3000 AD

C.1 Safety Instructions

Safety instructions applicable to ICON3000/ICON3000AD actuators, covering general and installation aspects.

C.1.1 General

General safety instructions for ICON3000/ICON3000AD actuators and their configurations.

C.2 Instructions for Proper Installation

Specific installation instructions, emphasizing nameplate checks and environmental suitability.

C.2.1 Marking

Explains the markings on the actuator label, including ATEX and IECEx certifications.

C.3 Applicable General Standards and Regulations

Lists applicable general standards, directives, and norms for the actuator.

C.4 Terms and Conditions

Outlines warranty and terms of sale for the product.

C.5 Manufacturers Liability

Specifies manufacturer liability limitations related to product usage and installation.

C.6 Storage and Pre-Installation

Covers storage procedures and checks required before installation.

C.6.1 Storage Procedure

Outlines storage procedures for extensions and electronic cards.

C.6.2 Checks to be Performed Before Installation

Lists checks for installing extensions or electronic cards before the main installation.

C.7 Installation

Installation guidelines for hazardous areas, including working conditions and entry identification.

C.7.1 Working Condition

Specifies ambient temperature ranges for ICON3000/ICON3000AD models.

C.7.1.1 Models and Temperature

Lists temperature ranges for ICON-010 and ICON-020 models.

C.7.2 Identification of Entries

Identifies conduit entry types and sizes for the base actuator.

C.7.2.1 Base Actuator

Details the thread form/size for entries on the base actuator.

C.7.2.2 Base Actuator With Extension [A] on the Control Compartment

Describes the thread form/size for an entry on an extension for the control compartment.

C.7.3 Electrical Connections

Covers electrical connection requirements for external ATEX-certified apparatus.

C.7.3.1 Connection for Ex-e Terminals Enclosure

Specifies wiring methods for Ex-e terminal enclosures.

C.7.4 Cable Connection

Explains sealing of entries and ground connections for extensions.

C.7.5 Installation in Environments with Explosive Dusts

Provides specific attention points for installing in dusty, potentially explosive environments.

C.8 Maintenance

Covers general maintenance for actuators with extensions.

C.8.1 Periodic Inspection

Details periodic inspection for actuators with optional extensions.

C.8.2 Disassembly and Re-assembly

Provides steps for safe disassembly and re-assembly of explosion-proof enclosures.

C.8.3 Repairs

Outlines procedures and requirements for performing repairs on actuators with extensions.

Appendix D: ICON3000

D.1 Safety Instructions

Safety instructions applicable to ICON3000 actuators, covering general and installation aspects.

D.1.1 General

General safety instructions for ICON3000 actuators and their configurations.

D.1.2 Identification of Main Parts

Illustrates the base unit and units with extensions for identification.

D.2 Instructions for Proper Installation

Specific installation instructions, emphasizing nameplate checks and environmental suitability.

D.2.1 Marking

Details the markings on the actuator label, including ATEX and IECEx certifications.

D.3 Applicable Directives, General Standards, and Norms

Lists applicable general standards, directives, and norms for the actuator.

D.4 Terms and Conditions

Outlines warranty and terms of sale for the product.

D.5 Manufacturers Liability

Specifies manufacturer liability limitations related to product usage and installation.

D.6 Storage and Pre-Installation

Covers storage procedures and checks required before installation.

D.6.1 Storage Procedure

Outlines storage procedures for extensions and electronic cards.

D.6.2 Checks to be Performed Before Installation

Lists checks for installing extensions or electronic cards before the main installation.

D.7 Installation

Installation guidelines for hazardous areas, including working conditions and entry identification.

D.7.1 Working Condition

Specifies ambient temperature ranges for ICON3000 models.

D.7.1.1 Models and Temperature

Lists temperature ranges for specific ICON models.

D.7.2 Identification of Entries

Identifies conduit entry types and sizes for the base actuator.

D.7.2.1 Base Actuator

Details the thread form/size for entries on the base actuator.

D.7.2.2 Base Actuator With Extension [A] on the Control Compartment

Describes the thread form/size for an entry on an extension for the control compartment.

D.7.2.3 Base Actuator with Extensions [B] or [C] on the Terminal Board Compartment

Details thread forms/sizes for entries on extensions for the terminal board compartment.

D.7.3 Electrical Connections

Covers electrical connection requirements for external ATEX-certified apparatus.

D.7.3.1 Connection for Ex-e Terminals Enclosure

Specifies wiring methods for Ex-e terminal enclosures.

D.7.4 Cable Connection

Explains sealing of entries and ground connections for extensions.

D.7.5 Installation in Environments with Explosive Dusts

Provides specific attention points for installing in dusty, potentially explosive environments.

D.8 Maintenance

Covers general maintenance for actuators with extensions.

D.8.1 Periodic Inspection

Details periodic inspection for actuators with optional extensions.

D.8.2 Disassembly and Re-assembly

Provides steps for safe disassembly and re-assembly of explosion-proof enclosures.

D.8.3 Repairs

Outlines procedures and requirements for performing repairs on actuators with extensions.

Appendix E: ICON3000

E.1 Safety Instructions

Safety instructions applicable to ICON3000 actuators, covering general and installation aspects.

E.1.1 General

General safety instructions for ICON3000 actuators and their configurations.

E.1.2 Identification of Main Parts

Illustrates the base unit and units with extensions for identification.

E.2 Instructions for Proper Installation

Specific installation instructions, emphasizing nameplate checks and environmental suitability.

E.2.1 Marking

Details the markings on the actuator label, including ATEX and IECEx certifications.

E.3 Applicable General Standards and Regulations

Lists applicable general standards, directives, and norms for the actuator.

E.4 Terms and Conditions

Outlines warranty and terms of sale for the product.

E.5 Manufacturers Liability

Specifies manufacturer liability limitations related to product usage and installation.

E.6 Storage and Pre-Installation

Covers storage procedures and checks required before installation.

E.6.1 Storage Procedure

Outlines storage procedures for extensions and electronic cards.

E.6.2 Checks to be performed before installation

Lists checks for installing extensions or electronic cards before the main installation.

E.7 Installation

Installation guidelines for hazardous areas, including working conditions and entry identification.

E.7.1 Working Condition

Specifies ambient temperature ranges for ICON3000 models.

E.7.1.1 Models and Temperature

Lists temperature ranges for specific ICON models.

E.7.2 Identification of Entries

Identifies conduit entry types and sizes for the base actuator.

E.7.2.1 Base Actuator

Details the thread form/size for entries on the base actuator.

E.7.2.2 Base Actuator With Extension [A] on the Control Compartment

Describes the thread form/size for an entry on an extension for the control compartment.

E.7.2.3 Base Actuator with Extensions [B] or [C] on the Terminal Board Compartment

Details thread forms/sizes for entries on extensions for the terminal board compartment.

E.7.3 Electrical Connections

Covers electrical connection requirements for external ATEX-certified apparatus.

E.7.3.1 Connection for Ex-e Terminals Enclosure

Specifies wiring methods for Ex-e terminal enclosures.

E.7.4 Cable Connection

Explains sealing of entries and ground connections for extensions.

E.7.5 Installation in Environments with Explosive Dusts

Provides specific attention points for installing in dusty, potentially explosive environments.

E.8 Maintenance

Covers general maintenance for actuators with extensions.

E.8.1 Periodic Inspection

Details periodic inspection for actuators with optional extensions.

E.8.2 Disassembly and Re-assembly

Provides steps for safe disassembly and re-assembly of explosion-proof enclosures.

E.8.3 Repairs

Outlines procedures and requirements for performing repairs on actuators with extensions.

BIFFI ICON3000 Series Specifications

General IconGeneral
CategoryController
SeriesICON3000
Operating Temperature-40°C to +85°C (-40°F to +185°F)
Input Signal4-20 mA
Enclosure RatingIP66, NEMA 4X
MountingDirect Mounting on Actuator
CommunicationHART
Housing MaterialAluminum

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