BIFFI ICON3000 Service Manual
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BIFFI ICON3000 Service Manual

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Biffi ICON3000
Electric Actuator
Copyright © Biffi. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.biffi.it or from your nearest Biffi Center:
Biffi Italia s.r.l. - Strada Biffi 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it
Service Manual
MDE 252 Rev. 1
December 2021

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  • Page 1 Electric Actuator Copyright © Biffi. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.biffi.it or from your nearest Biffi Center: Biffi Italia s.r.l. - Strada Biffi 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it...
  • Page 2 Revision Details Service Manual December 2021 MDE 252 Rev. 1 Revision Details Rev. Date Description Prepared Approved December 2021 General Update (Migration to new template) May 2018 Initial Release A.B. L.V. Revision Details...

  • Page 3: Table Of Contents

    Service Manual Table of Contents MDE 252 Rev. 1 December 2021 Table of Contents Section 1: General Safety Instructions General Safety Instrctions..................1 Section 2: Troubleshooting Alarms and Warnings ................... 3 Alarm Description ..................4 2.2.1 Alarm on Local Display: High Torque in Closing ........4 2.2.2 Alarm on Local Display: High Torque in Opening .........
  • Page 4 The Electrical Power is off and Numeric Display is Off ........28 2.15 Replacement of the 9 V Lithium Battery ............28 2.16 Logic card of ICON3000 ................30 2.17 Instruction to Disconnect C_GRID Connectors ..........32 Table of Contents...

  • Page 5: Section 1: General Safety Instructions

    Biffi will not be liable for any possible damage or physical injury resulting from use in other than the designated application or by lack of care during installation, operation, adjustment and maintenance of the machinery.

  • Page 6: Section 2: Troubleshooting

    December 2021 MDE 252 Rev. 1 Section 2: Troubleshooting The ICON3000 actuator has passed the functional test performed by Biffi Quality Assurance personnel. If the actuator does not work before troubleshooting, make sure that: The main supply voltage is the same as stated in the nameplate menu.

  • Page 7: Alarms And Warnings

    Service Manual Section 2: Troubleshooting MDE 252 Rev. 1 December 2021 Alarms and Warnings Warning is the condition that occurs when a variable reaches a critical value and/or when a maintenance action is required but all actuator functions are still available. The flashing of the alarm/warning LED indicates a warning condition.

  • Page 8: Alarm Description

    S/N) the valve. Power card If the actuator moves well, Mechanical transmission between please check carefully the the electric motor and the drive valve or the valve/actuator train (see VCIOM-08500) mechanical connection. For extraordinary repairing activity, please contact Biffi. Troubleshooting...

  • Page 9: Alarm On Local Display: High Torque In Opening

    S/N) the valve. Power card; If the actuator moves well, Mechanical transmission between please check carefully the the electric motor and the drive valve or the valve/actuator train (see VCIOM-08500) mechanical connection. For extraordinary repairing activity, please contact Biffi. Troubleshooting...

  • Page 10: Alarm On Local Display: Jammed Valve In Opening

    Section 2: Troubleshooting Service Manual December 2021 MDE 252 Rev. 1 2.2.3 Alarm on Local Display: Jammed Valve in Opening JAMMED VALVE IN OPENING If the actuator position % does not change within a preset value defined in the parameter "valve jammed time"...

  • Page 11: Alarm On Local Display: Jammed Valve In Closing

    Service Manual Section 2: Troubleshooting MDE 252 Rev. 1 December 2021 2.2.4 Alarm on Local Display: Jammed Valve in Closing JAMMED VALVE IN CLOSING If the actuator position % does not change within a preset value defined in the parameter "valve jammed time"...

  • Page 12: Alarm On Local Display: Motor Thermostat

    Section 2: Troubleshooting Service Manual December 2021 MDE 252 Rev. 1 2.2.5 Alarm on Local Display: Motor Thermostat MOTOR THERMOSTAT ALARM The contact of motor thermostat is open for high temperature in the motor windings. Any electrical command is cleared. Electrical controls of actuator becomes available when motor temperature decreases and contact of the thermostat closes.

  • Page 13: Alarm On Local Display: Internal Temperature

    Electrical control of actuator becomes available when temperature is within the range +90 °C, -40 °C. Check ambient temperature. Is ambient temperature in the range? The actuator is out of the application range. Replace the logic card. Please verify with Biffi if specific actuators are available for the particular climate conditions. Troubleshooting...

  • Page 14: Alarm On Local Display: Position Sensor (Hardware 11 Or Hardware 12)

    Section 2: Troubleshooting Service Manual December 2021 MDE 252 Rev. 1 2.2.7 Alarm on Local Display: Position Sensor (Hardware 11 or Hardware 12) POSITION SENSOR The value of the actuator position is not valid in terms of bit, i.e. is not within the set range of bits. Reconfigure the stroke limits.

  • Page 15: Alarm On Local Display: Speed Sensor

    Service Manual Section 2: Troubleshooting MDE 252 Rev. 1 December 2021 2.2.8 Alarm on Local Display: Speed Sensor SPEED SENSOR The value of the motor speed is not valid in terms of bit, i.e. is not within the set range of bits. Switch off and then on the actuator.

  • Page 16: Alarm On Local Display: Mid Travel Alarm In Opening

    Section 2: Troubleshooting Service Manual December 2021 MDE 252 Rev. 1 2.2.9 Alarm on Local Display: Mid Travel Alarm in Opening MID TRAVEL ALARM IN OPENING The actuator moves in opening direction but during the travel the operation is suddenly stopped. The actuator can operate in closing direction.

  • Page 17: Alarm On Local Display: Mid Travel Alarm In Closing

    Service Manual Section 2: Troubleshooting MDE 252 Rev. 1 December 2021 2.2.10 Alarm on Local Display: Mid Travel Alarm in Closing MID TRAVEL ALARM IN CLOSING The actuator moves in closing direction but during the travel the operation is suddenly stopped. The actuator can operate in opening direction.

  • Page 18: Alarm On Local Display: Main Voltage

    Section 2: Troubleshooting Service Manual December 2021 MDE 252 Rev. 1 2.2.11 Alarm on Local Display: Main Voltage MAIN VOLTAGE Main Voltage power supply is lower than -20% or higher than +20% of the nominal value reported in the actuator nameplate and nameplate menu. All the electrical commands are cleared.

  • Page 19: Alarm On Local Display: Lost Phase

    The failure is not in the actuator. Verify internal wiring between terminal board (internal screws Verify failure causes external to Biffi actuator terminals) and power supply board and possibly in the plant conditions. (connector M2). Verify intern al wiring between power board (connector CN24) and logic board (connector CN11).

  • Page 20: Alarm On Local Display: K1 Contactor

    Section 2: Troubleshooting Service Manual December 2021 MDE 252 Rev. 1 2.2.13 Alarm on Local Display: K1 Contactor K1 CONTACTOR When an open or close command is sent (locally or remotely or via bus), the actuator internal automatic test routine reports a failure of K1 (section K1 of the reversing contactor). The actuator can move only in the direction that not use the contactor K1 and only in the direction which use K2 (i.e.

  • Page 21: Alarm On Local Display: K2 Contactor

    Service Manual Section 2: Troubleshooting MDE 252 Rev. 1 December 2021 2.2.14 Alarm on Local Display: K2 Contactor K2 CONTACTOR When an open or close command is sent (locally or remotely or via bus), the actuator internal automatic test routine reports a failure of K2 (section K2 of the reversing contactor). The actuator can move only in the direction that not use the contactor K2 and only in the direction which use K1 (i.e.

  • Page 22: Alarm On Local Display: Request Signal

    Section 2: Troubleshooting Service Manual December 2021 MDE 252 Rev. 1 2.2.15 Alarm on Local Display: Request Signal REQUEST SIGNAL The analogue 4 - 20 mA signal is not within the preset range (from 4 to 20) and the actuator does not work in accordance to the sent analogue signal.

  • Page 23: Alarm On Local Display: Low Lithium Battery

    Service Manual Section 2: Troubleshooting MDE 252 Rev. 1 December 2021 2.2.16 Alarm on Local Display: Low Lithium Battery The voltage of the lithium battery is too low (only detected if the battery is present and the relevant parameter of the miscellaneous routine is set to "present"). The electrical commands to move the valve are available.

  • Page 24: Alarm On Local Display: Hardware N

    Restart the actuator. Hardware 6= incorrect configuration ICON3000 card g Enter the "restricted menu" with the service password and re-set the Incorrect configuration of ICON3000 type; at Service level only. g Replace the logic board g Restart the actuator.

  • Page 25: Warning Description

    December 2021 Warning Description Warning status does not affect the ICON3000 operation, it only indicates that some variable is near to critical value and could in future generate an alarm. It is better to fix the warning as soon as possible.

  • Page 26: Warning On Local Display: Main Voltage (Near To Limit)

    Section 2: Troubleshooting Service Manual December 2021 MDE 252 Rev. 1 2.3.4 Warning on Local Display: Main Voltage (Near to Limit) Main voltage lower than –15% or higher than +10% of the value stated in the nameplate menu. Check main voltage supply and frequency on terminals L1, L2 and L3. Check current of motor and verify that wires section is correct.

  • Page 27: The Electronics Does Not Switch On When Powered

    Service Manual Section 2: Troubleshooting MDE 252 Rev. 1 December 2021 The Electronics Does Not Switch on When Powered Check that the value of the main voltage on terminals L1, L2, L3 is correct. Check the fuse mounted on the power card. Replace it if burnt. If the fuse is OK, check the wires between terminals L1, L2, L3 and connector M1 of the power card.

  • Page 28: The Actuator Does Not Work With Remote Controls

    Section 2: Troubleshooting Service Manual December 2021 MDE 252 Rev. 1 The Actuator Does Not Work with Remote Controls Move the 3-position selector to LOCAL and check that the actuator works with local controls. Move the local selector to REMOTE. If the ESD signal is active, the alphanumeric display indicates "ESD ON".

  • Page 29: The Motor Runs But The Actuator Does Not Move The Valve

    Service Manual Section 2: Troubleshooting MDE 252 Rev. 1 December 2021 The Motor Runs but the Actuator Does Not Move the Valve In case the local display does not change the valve position indicators: Check that the manual declutch lever is not stuck in manual operation position. Rotate the handwheel a few degrees to remove all possible sticking between the handwheel and the drive sleeve.

  • Page 30: The Manual Override Cannot Be Engaged

    Section 2: Troubleshooting Service Manual December 2021 MDE 252 Rev. 1 The Manual Override Cannot Be Engaged In case the engagement of the lever is too difficult, check whether the drive sleeve is stuck and proceed as follows: Open the cover. Try to move the drive sleeve by a screwdriver.

  • Page 31: The Valve Does Not Seat Correctly

    Service Manual Section 2: Troubleshooting MDE 252 Rev. 1 December 2021 2.10 The Valve Does Not Seat Correctly If the valve is stopped by the torque limit in closing, increase the actuator output torque limit. If the valve is stopped by the position limit in closing, check that the valve reaches its seat position, then readjust the setting of the position limit.

  • Page 32: The Electrical Power Is Off And Numeric Display Is Off

    Section 2: Troubleshooting Service Manual December 2021 MDE 252 Rev. 1 2.14 The Electrical Power is off and Numeric Display is Off The 9 V Lithium batteries is discharged or is not present or is configured as "absent". Check that battery is really discharged. Check current absorbed from battery and then change logic card.
  • Page 33 Service Manual Section 2: Troubleshooting MDE 252 Rev. 1 December 2021 Remove the battery cover. Figure 13 Replace battery. Figure 14. NOTICE The new battery must be: Lithium LS 9 V manufactured by SAFT. Troubleshooting...

  • Page 34: Logic Card Of Icon3000

    December 2021 MDE 252 Rev. 1 2.16 Logic card of ICON3000 The connector is made of two pieces, header and crimp housing. The header is welded on the printed circuit board, the crimp housing is connected to wires. Due to mechanical block, to disconnect the crimp housing from header can be difficult and could damage connector or wires.
  • Page 35 Service Manual Section 2: Troubleshooting MDE 252 Rev. 1 December 2021 Figure 16 Test Points: • TP1: 0 Vm • TP2: 3.3 Vh8 • TP3: 13 Vm • TP4: 12 Vm (in case of power supply by DC/DC converter) • TP7: 5 Vm Troubleshooting...

  • Page 36: Instruction To Disconnect C_Grid Connectors

    Section 2: Troubleshooting Service Manual December 2021 MDE 252 Rev. 1 2.17 Instruction to Disconnect C_GRID Connectors The connector is made of two pieces, header and crimp housing. The header is welded on the printed circuit board, the crimp housing is connected to wires. Due to mechanical block, to disconnect the crimp housing from header can be difficult and could damage connector or wires.
  • Page 37 Service Manual Notes MDE 252 Rev. 1 December 2021 This page is intentionally left blank...
  • Page 38 VCIOM-16949-EN ©2021 Biffi. All rights reserved. Biffi Italia s.r.l. Strada Biffi 165 The contents of this publication are presented for information purposes only, 29017 Fiorenzuola d’Arda (PC) and while every effort has been made to ensure their accuracy, they are not...

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