BIFFI EFS3000 Installation, Operation And Maintenance Manual

Electric fail-safe actuators

Quick Links

Download this manual

Installation, Operation and Maintenance Manual

FCIM-20208-EN Rev. 0

February 2025

Biffi EFS3000

Electric Fail-Safe Actuators

www.biffi.it or from your nearest Biffi Center: Biffi Italia s.r.l. - Strada Biffi 165, 29017 Fiorenzuola d' A rda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it

Table of Contents

Troubleshooting

Need help?

Do you have a question about the EFS3000 and is the answer not in the manual?

Questions and answers

Summary of Contents for BIFFI EFS3000

Page 1 Copyright © Biffi. The information in this document is subject to change without notice. Updated installation, operation and maintenance manuals 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’ A rda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it...
Page 2 Notes Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 This page is intentionally left blank.
Page 3: Table Of Contents
Installation in Hazardous Area ................3 Marking for Application in Hazardous Area ............. 3 1.7.1 Label for ICON3000 ................3 1.7.2 Label for EFS3000 ................. 4 Extract From the Standard ................... 4 Section 2: Device Description General ........................5 Main Parts Description ..................6 Operating Principle ....................
Page 4 Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Section 7: EFS Operation Operating the EFS3000 for the First Time ............19 ESD Clutch Status ....................20 Local Shutdown Operation, Reset and Autoreset ........20 EFS Shutdown Action ..................21 Manual Override Operation ................22 Partial Stroke Test ....................22...
Page 5 Installation, Operation and Maintenance Manual Table of Contents FCIM-20208-EN Rev. 0 February 2025 Section 12: View Menu View Menu ..........................51 Section 13: Set-Up Routines 13.1 Actuator Set-Up ....................53 13.1.1 Set Stroke Limits ..................53 13.1.2 Torque Set-Up ..................55 13.1.3 EFS Set-Up ....................55 13.1.4 Remote Controls ..................57 13.1.5...
Page 6 Hydraulic Control Group Diagram ..............97 16.2 Control Group Functions ..................98 16.2.1 Adjustment of Fail-Safe Time ............99 16.2.2 Manual Override to Operate the EFS3000 When Electrical Power is Not Available ........100 16.2.3 Accumulator Recharge ..............101 Section 17: Maintenance and Troubleshooting 17.1 Routine Maintenance ..................
Page 7: Section 1: General Safety Instructions
Such risks lie entirely with the user. Depending on the specific working conditions, additional precautions may be required. The EFS3000 is produced by Biffi Italia and identified on the proper label by the product designation: EFS-XXX_YY. WARNING...
Page 8: Terms And Conditions
Section 1: General Safety Instructions Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Terms and Conditions The manufacturer guarantees each single product to be free from defects and to conform with current goods specifications and regulations as applicable. The warranty period is 12 months from the date of installation by the first user or 18 months from the date of shipment to the first user, whichever occurs first.
Page 9: Installation In Hazardous Area
Installation in Hazardous Area WARNING In case the EFS3000 is to be installed in a hazardous area, as defined by the applicable rules, it is mandatory to check if the nameplates of the EFS3000 and associated ICON3000 specify that the assembly is suitable to be installed in hazardous area with the indication of appropriate degree of protection.
Page 10: Label For Efs3000
Section 1: General Safety Instructions Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 1.7.2 Label for EFS3000 Marking description: 0080 = Notified body for ATEX = Group II (surface) = Category 2 apparatus = Explosive atmosphere by gas...
Page 11: Section 2: Device Description
“fail-safe“ state (Fail Open or Fail Close), when the system is de-energized. As it’s described in the next sections, several modes for EFS3000 are available in order to move the valve in a “fail-safe“ state but it’s important to highlight that the “safety function“...
Page 12: Main Parts Description
February 2025 FCIM-20208-EN Rev. 0 Main Parts Description The EFS3000 actuator consists of six main parts: • A spring-return mechanism, which moves the valve in the predefined fail-safe condition when requested by an ESD signal or by a power failure.
Page 13: Operating Principle
ESD times. The position of the valve is continuously monitored both in electric mode and fail-safe condition by means of a position sensor directly connected the EFS3000 output drive. Device Description...
Page 14: Section 3: Storage And Pre-Installation
Section 3: Storage and Pre-Installation Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Section 3: Storage and Pre-Installation NOTICE Omitting the following procedures will invalidate the product warranty. Checks to Be Carried Out on Receipt of the Actuator •...
Page 15: Storage Procedure
Installation, Operation and Maintenance Manual Section 3: Storage and Pre-Installation FCIM-20208-EN Rev. 0 February 2025 Figure 3. Actuator’s Lifting Points Storage Procedure The actuators leave the factory in an excellent working condition and with an excellent finish (these conditions are guaranteed by an individual inspection certificate);...
Page 16: Section 4: Assembling The Actuator
• Assemble the insert into the EFS3000 as shown in Figure 4 (the engraving realized on the insert has to correspond to the engraving present on the EFS3000 bush, as shown in Figure 4).
Page 17 Installation, Operation and Maintenance Manual Section 4: Assembling the Actuator FCIM-20208-EN Rev. 0 February 2025 Figure 4. EFS3000 Mounting Pattern INSERT BUSH Ød4 Ød7 Ød3 ±0.2 Ød1 VIEW FROM "X" REFERENCE ENGRAVING HOLES FLOW LINE Ød3 (P.C.D.) Table 2. Fastener Thread Size and Recommended Torque...
Page 18: Section 5: Adjustment Of Angular Stroke
The adjustment of the angular stroke is performed by adjusting the travel stop screw mounted on the spring cartridge end flange and the travel stop screw mounted on the EFS3000 housing (see Figure 5). For the adjustment of the stop screw, proceed as follows: Loosen the lock nut.
Page 19: Section 6: Installation
Installation in environments with a temperature range outside the specified values will invalidate the warranty. Removing the Electrical Enclosures Covers The terminal enclosures for the EFS3000 are shown in Figure 6. Using an Allen key, loosen the four screws fixing the cover and then remove it. Figure 6.
Page 20: Electrical Connections
NOTICE All the accessories required for the EFS3000, in particular the cable glands, must be certified according to the Standard Directive and specific rules that apply for the specific application.
Page 21: Cable Entries
The sealing of cable and conduit entry should be carried out in accordance with national standards or the regulatory authorities that have certified the EFS3000. This is particularly the case for units that are certified for use in hazardous areas where the method of sealing must be to an approved standard and cable glands, reducers, plugs and adapters must be approved and separately certified.
Page 22 Section 6: Installation Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Figure 8. Entries on the Manually Operated Electrical Switch Enclosure M20x1.5 Figure 9. Entries on the Electromagnetic Clutch Device Enclosure M20x1.5 M20x1.5 M20x1.5 M20x1.5 Installation...
Page 23: Safety Instructions For Installation In Hazardous Area
Instructions for the Explosion-Proof Enclosures NOTICE Electric actuator EFS3000 must be installed and maintained according to the applicable rules regarding the electrical installation in hazardous areas (other than mines) classified as zone 1 and/or 2 (gas) and zone 21 and/or 22 (dust) according to EN 60079-10 (hazardous area classification).
Page 24: Installation In Ambient Temperature With Explosive Dusts
Explosive Dusts NOTICE Electric actuator EFS3000 must be installed and maintained according to the applicable rules regarding the electrical installation in hazardous areas (other than mines) classified as zone 1 and/or 2 (gas) and zone 21 and/or 22 (dust) according to IEC/EN 60079-10 (hazardous area classification).
Page 25: Section 7: Efs Operation
(see Section 15). If the upper line of the display shows “WARNING“, a warning condition is present. Continue if the EFS3000 is working okay, but some data is not according to the configured parameters (see Section 17). If the upper line of the display shows “INT“, an interlock input is active.
Page 26: Esd Clutch Status
Section 7: EFS Operation Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Do not operate the actuator without first checking that the configuration is according to the required application by using the “VIEW and SET-UP“ features (see Sections 11, 12, 13 and 14).
Page 27: Efs Shutdown Action
The EFS ESD action is carried out in case of loss of voltage supply of clutch coil (as it’s described in SM 037 (SIL Safety Manual – Actuator series EFS3000). The Local Shutdown actions are carried out if the local red mushroom push button is pressed.
Page 28: Manual Override Operation
Section 7: EFS Operation Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Manual Override Operation Figure 12. Manual Override Overview Hand pump Auto/manual selector Hand operated valve The AUTO/MANUAL selector allows selecting between MANUAL and AUTO mode. In MANUAL mode the ESD clutch is de-energized, the actuator remains in its current position, electrical commands are inhibited, the LED in the clutch enclosure is red, the message on the actuator display is INT EFS and the actuator can be manually moved by means of the hand pump and the hand operated spring-return valve...
Page 29: Partial Stroke Test
Installation, Operation and Maintenance Manual Section 7: EFS Operation FCIM-20208-EN Rev. 0 February 2025 Partial Stroke Test The PST function is available to check the functionality of the essential parts and to achieve the EFS safety function while the valve is in line and in service. The test consists in de-energizing the clutch to move the valve to the configured position (PST TRAVEL) by action of spring and then re-energizing the clutch to stop the valve moving.
Page 30: Command To Initiate Pst Cycle
Section 7: EFS Operation Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 7.6.1 Command to Initiate PST Cycle The PST cycle is initiated only if the actuator is in the correct end of travel (fully open with spring to close or fully close with spring to open). In PST AUTO mode, the test is performed at a configurable period of time and hour of the day (according to the configured parameters) if the actuator local selector is in LOCAL or REMOTE.
Page 31: Pst Curves And Pst Baseline
Installation, Operation and Maintenance Manual Section 7: EFS Operation FCIM-20208-EN Rev. 0 February 2025 7.6.4 PST Curves and PST Baseline During the PST cycle the time corresponding to any 1% of valve position variation is stored. With the above data it is possible to view the curve of the “valve position%“ versus “time“.
Page 32: Efs Local Report
Section 7: EFS Operation Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 EFS Local Report By the VIEW and SETUP menu of the local operator interface, the status of the EFS module can be viewed (see Section 10). The following data are available: •...
Page 33: Entering The View And Setup Menu Mode
Installation, Operation and Maintenance Manual Section 7: EFS Operation FCIM-20208-EN Rev. 0 February 2025 Entering the VIEW and SETUP Menu Mode If the option “SELECTOR in OFF: disabled“ is configured, move the selector to OFF and then press simultaneously OPEN/YES and STOP push buttons to enter in the VIEW and SETUP menu.
Page 34: Section 8: Actuator Operation
Section 8: Actuator Operation Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Section 8: Actuator Operation Actuator Local Controls For EFS “standard“ version: After configuring the actuator, if no alarm is present, place the 3-position selector in LOCAL and control the actuator by OPEN, CLOSE and STOP push-buttons. If “push-to-run“...
Page 35: Remote Commands
Installation, Operation and Maintenance Manual Section 8: Actuator Operation FCIM-20208-EN Rev. 0 February 2025 8.4.1 Remote Commands For EFS standard version: Using the “VIEW and SET-UP“ features may configure different control modes. • Four wires (see the remote connections diagram in Figure 16). In “4 wires latched“...
Page 36 Section 8: Actuator Operation Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 • Two wires (see the remote connections diagram in Figure 18). With the “2 wires“ option, 2 different activities may be selected: In “2 wires, signal ON to open“, the actuator opens if the signal switches to ON and closes if the signal goes to OFF.
Page 37: Output Contacts
Installation, Operation and Maintenance Manual Section 8: Actuator Operation FCIM-20208-EN Rev. 0 February 2025 8.4.2 Output Contacts Standard version: • Monitor relay: on the terminal board, a single voltage-free, change-over contact of the monitor relay is available. The monitor relay indicates that the actuator can be remotely controlled or that there is a problem or condition which prevents remote control of the valve.
Page 38: Interlock Inputs
Section 8: Actuator Operation Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 8.4.4 Interlock Inputs Two additional inputs are available to inhibit actuator movement in open or close direction. The controls are momentary, and the inhibit action continues until the relevant signal is present.
Page 39: Section 9: Optional Modules
HART ® A hardware alarm is generated if the EFS3000 was set to be equipped with BUS card, but the card is damaged or missing. A BUS REPORT is also present in the list of reports if the card is present (see Section 10.3). See the specific manuals for instructions and the settings of the above modules at www.biffi.en.
Page 40: The 4 To 20 Ma Analog Output
Section 9: Optional Modules Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 9.2.1 The 4 to 20 mA Analog Output The 4 to 20 mA output can be configured to provide a signal proportional to either ’position’ or ’torque’. The polarity option allows to reverse the relationship between the position or torque and the 4 to 20 mA output signal.
Page 41: The 4 To 20 Ma Analog Input
Installation, Operation and Maintenance Manual Section 9: Optional Modules FCIM-20208-EN Rev. 0 February 2025 9.2.2 The 4 to 20 mA Analog Input The 4 to 20 mA analog input is the position request R% signal and is used by the ICON3000 to position the valve in any position between 0 and 100% of the full stroke.
Page 42: Bluetooth Card
Section 9: Optional Modules Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Bluetooth Card The ICON3000 can be provided with a radiofrequency wireless connection based on a qualified Bluetooth class 1 module. This allows the actuator to establish a connection and exchange data with a PDA or PC with built-in Bluetooth technology.
Page 43: Base Card Of Efs3000
Installation, Operation and Maintenance Manual Section 9: Optional Modules FCIM-20208-EN Rev. 0 February 2025 Base Card of EFS3000 The following figures show the ’base card’ of the EFS3000 and its different optional cards. Figure 24. Base Card of the EFS3000 Terminal board...
Page 44 Section 9: Optional Modules Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 The type of card depends on the Fieldbus available in the plant. Figure 27. Top View of Base Card Equipped with Fieldbus Interface Figure 28. Bluetooth Card Figure 29.
Page 45: Section 10: Local Controls
Section 10: Local Controls FCIM-20208-EN Rev. 0 February 2025 Section 10: Local Controls 10.1 Description of the Local Operator Interface The following functions are available by the EFS3000 local operator interface: • Actuator control • Actuator configuration • Actuator status visualization •...
Page 46 Section 10: Local Controls Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 • Alphanumeric Display: during normal operation the alphanumeric display shows the present status (NORMAL, INT EFS, ALARM, WARNING, INTERLOCK), the 3-position selector status (LOCAL, OFF, REMOTE) and the actuator action (OPEN, OPENING, CLOSED, CLOSING, STOP or R%: xxx.x).
Page 47: Description Of Variables And Reports
Installation, Operation and Maintenance Manual Section 10: Local Controls FCIM-20208-EN Rev. 0 February 2025 10.3 Description of Variables and Reports Table 4. List of Variables Variables and Reports Description Torque Output torque in % of the nominal torque stated in the NAMEPLATE menu Motor speed RPM of electrical motor Main voltage...
Page 48 Section 10: Local Controls Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 The warning condition occurs when a variable reaches a critical value and/or a maintenance action is required, but the actuator control functions are still available. The alarm condition occurs when a variable is out of the acceptable range and the actuator control functions are not available.
Page 49: Configuration Options
10.4 Configuration Options The EFS3000 actuator can be totally configured from the local interface by means of a series of menus that can be selected from the alphanumeric display. The operator is guided through the different displays by answering YES or NO to the appropriate prompt (change?, OK?, view?, next?, etc.) in the right corner of the lower row of the...
Page 50: Actuator Set-Up
Section 10: Local Controls Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 10.4.1 Actuator Set-Up This menu includes the routines that allow the actuator to be configured according to the requested control mode and to the valve it is mounted on. List of routines: •...
Page 51: Valve Data
Installation, Operation and Maintenance Manual Section 10: Local Controls FCIM-20208-EN Rev. 0 February 2025 10.4.3 Valve Data Valve data includes a series of data relevant to the valve. The valve manufacturer and end user should enter the data. List of routines: •...
Page 52: Entering The View Mode
Section 10: Local Controls Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 10.4.5 Entering the View Mode The existing actuator configuration should be checked before commissioning. The parameters are pre-configured according to a standard setting, or to the customer requirements.
Page 53: Entering The Set-Up Mode
All settings are automatically saved to a non-volatile memory and retained also if the electrical power is removed from the actuator. All EFS3000 actuators are pre-configured with a default configuration, or to customers requirements. In case of difficulty during commissioning, the default configuration can be re-instated by the appropriate function in the routine “miscellaneous“...
Page 54: Exit From View And Set-Up Mode
Section 10: Local Controls Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 10.4.7 Exit from View and Set-Up Mode The following conditions cause the exit from view and set-up mode: • Move the 3-position selector to LOCAL or REMOTE. •...
Page 55: Section 11: Set-Up Menu
Installation, Operation and Maintenance Manual Section 11: Set-Up Menu FCIM-20208-EN Rev. 0 February 2025 Section 11: Set-Up Menu Figures 33 and 34 show the procedure to move in the set-up routines. Figure 33. Set-Up Menu Set-Up Menu...
Page 56 Section 11: Set-Up Menu Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Figure 34. Set-Up Menu Set-Up Menu...
Page 57: Section 12: View Menu
Installation, Operation and Maintenance Manual Section 12: View Menu FCIM-20208-EN Rev. 0 February 2025 Section 12: View Menu Figures 35 and 36 shows the procedure to move in the view routine . Figure 35. View Menu View Menu...
Page 58 Section 12: View Menu Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Figure 36. View Menu View Menu...
Page 59: Section 13: Set-Up Routines
Installation, Operation and Maintenance Manual Section 13: Set-Up Routines FCIM-20208-EN Rev. 0 February 2025 Section 13: Set-Up Routines 13.1 Actuator Set-Up 13.1.1 Set Stroke Limits This routine allows the actuator to be configured according to the type of valve it is mounted on.
Page 60 Section 13: Set-Up Routines Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Close limit by position • Move the local selector to LOCAL. The local controls can be used. • Move the valve to closed position by local electrical command. •...
Page 61: Torque Set-Up
Installation, Operation and Maintenance Manual Section 13: Set-Up Routines FCIM-20208-EN Rev. 0 February 2025 13.1.2 Torque Set-Up The output torque limits to close or to open may be configured between 40% and 100% of the nominal torque stated on the actuator nameplate. Set-up procedure •...
Page 62 Section 13: Set-Up Routines Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Set-up procedure EFS Set-up • Move the local selector to OFF and then simultaneously press OPEN and STOP within 20 seconds (see Section 10.4.6). Select the language and then enter the password according to the instructions.
Page 63: Remote Controls
Installation, Operation and Maintenance Manual Section 13: Set-Up Routines FCIM-20208-EN Rev. 0 February 2025 13.1.4 Remote Controls The actuator may be remotely controlled by 4, or 3, or 2 wires depending on the connection made on the terminal board of the actuator. The following options are available: •...
Page 64: Local Controls
Section 13: Set-Up Routines Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 13.1.5 Local Controls This routine allows: • To configure the control mode by means of the local controls when the 3-position selector is in LOCAL. The available options are ’push-to-run’, ’latched’, ’latched with instant reverse’.
Page 65: Output Relays
Installation, Operation and Maintenance Manual Section 13: Set-Up Routines FCIM-20208-EN Rev. 0 February 2025 13.1.6 Output Relays Monitor relay The voltage-free, change-over, contacts of the monitor relay indicate that the actuator is either available for remote control or that a problem or a condition preventing remote control of the valve exists.
Page 66 Section 13: Set-Up Routines Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 The contacts may be configured to make or break on condition. Configuration procedure • Move the local selector to OFF and then simultaneously press OPEN and STOP within 20 seconds (see Section 10.4.6).
Page 67 Installation, Operation and Maintenance Manual Section 13: Set-Up Routines FCIM-20208-EN Rev. 0 February 2025 Default # 2 Monitor relay • Main voltage failure • Speed sensor failure • Lost phase • Configuration error • Local/off selected • HW error • Local stop pressed •...
Page 68: Positioner
Press NO to exit. 13.1.7 Positioner The positioning function is only available in modulating EFS3000 actuators and allows to position the valve according to a ’position request R%’ command signal. The positioning function compares the present actuator position % with the position request R%, and if the difference is greater than the dead band the actuator is driven to reach the new requested position.
Page 69 Installation, Operation and Maintenance Manual Section 13: Set-Up Routines FCIM-20208-EN Rev. 0 February 2025 The following examples will clarify the above option: Example a): with input signal = 4 mA, the position request is 0% and the actuator is driven to close. With input signal = 20 mA, the position request is 100% and the actuator is driven to open.
Page 70: Fail-Safe
Section 13: Set-Up Routines Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Configuration procedure • Move the local selector to OFF and then simultaneously press OPEN and STOP within 20 seconds (see Section 10.4.6). Select the language and then enter the password according to the instructions (see Section 10.4.6).
Page 71: Out 4 To 20 Ma
Installation, Operation and Maintenance Manual Section 13: Set-Up Routines FCIM-20208-EN Rev. 0 February 2025 13.1.9 OUT 4 to 20 mA This routine is only available if the Ain/Aout card is present. With this card the ICON3000 is provided with a 4 to 20 mA analog input and a 4 to 20 mA analog output.
Page 72: Two-Speed Timer
Section 13: Set-Up Routines Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Configuration procedure • Move the local selector to OFF and then simultaneously press OPEN and STOP within 20 seconds (see Section 10.4.6). Select the language and then enter the password according to the instructions (see Section 10.4.6).
Page 73: Bus (Or Fdi Control)
Fieldbus, but the Fieldbus card is not present, a hardware alarm will be generated. Different interfaces are available to connect the EFS3000 to different types of Fieldbus. If the bus interface is LonWorks, the routine ’Bus’ changes in ’FDI control’.
Page 74: Time And Date
Section 13: Set-Up Routines Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 13.1.13.1 Time and Date Time and date are used in maintenance functions to associate the time information to the stored event (torque profile, alarm log, maintenance request, etc.). Time and date are entered at the time of manufacture, but they can be adjusted during commissioning or maintenance operations.
Page 75: Torque Limits
The parameter is located in the protected area of memory and it is available only by using a special password. In the EFS it must be always configured ’CCW’. It is necessary to call the Biffi service to modify the above parameter if factory setting routine is used.
Page 76: Lithium Battery
Section 13: Set-Up Routines Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 13.1.13.4 Lithium Battery On request, the actuator can be provided with a lithium battery to update the remote outputs (output relays status and bus messages) in case of electrical power failure and manual override operations.
Page 77: Valve Data
Installation, Operation and Maintenance Manual Section 13: Set-Up Routines FCIM-20208-EN Rev. 0 February 2025 13.1.13.5 Valve Jammed (Time) The valve jammed time is used to monitor the following situations: The time passed after receiving an open or close control is longer than the ’valve jammed time’, but the valve position variation is smaller than 0.5%.
Page 78: Maintenance
Section 13: Set-Up Routines Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 13.3 Maintenance A large amount of data is stored in the actuator memory and is available for future analysis or to assist the operator in the maintenance program. The maintenance menu also includes the set password routine, and the possibility to modify or start the maintenance functions.
Page 79: Clear Alarm Log
The ’set curve reference’ routine allows to select 1 off 100 opening and closing torque curves in the memory of the EFS3000 and to transfer them to the torque curve reference registers. The old reference data are lost and the new ones will be the new torque curves reference (see Section 14.4.3).
Page 80: Clear Recent Data Log
Section 13: Set-Up Routines Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 13.3.5 Clear Recent Data Log The clear recent data log routine allows to clear the counters of the recent operation log. This command does not affect the content of the ’general operation log’. The date of the ’...
Page 81: Set Data Logger
Installation, Operation and Maintenance Manual Section 13: Set-Up Routines FCIM-20208-EN Rev. 0 February 2025 Start-up date • Press YES if the date is correct, press NO to change it. • Enter day, month, and year. Press NO to scroll through the list of available values, press YES to select.
Page 82: Set Pst Reference
PST reference curve. If option ’normal’ is chosen, the data collected in the PST cycle are stored in the EFS3000 memory. Up to 16 PST curves can be stored When a new curve is achieved the oldest one is cancelled.
Page 83: Example Of Set-Up Routine: Torque Set-Up
Installation, Operation and Maintenance Manual Section 13: Set-Up Routines FCIM-20208-EN Rev. 0 February 2025 13.3.11 Example of Set-Up Routine: Torque Set-Up Figure 43. Torque Set-Up Menu LOCAL REMOTE ICON3000 ICON3000 ICON3000 ICON3000 ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP SETUP MODE STROKE LIMIT TORQUE SETUP CHANGE?
Page 84: Section 14: View Routines
Section 14: View Routines Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Section 14: View Routines 14.1 Actuator Set-Up The above menu allows viewing the present actuator configuration. No change can be made to the present data. The following data can be viewed: Table 9.
Page 85: Nameplate
Icc, maximum 999.9 A. • Duty (S2/15 min, etc.). • Poles (2, 4, etc.). • Biffi name, maximum 28 characters. • Gear ratio, maximum 1000. • Test date: date of the in-house functional test of actuator. • Wiring diagram (WD): wiring diagram number, maximum 28 characters.
Page 86: Valve Data
Section 14: View Routines Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 14.3 Valve Data To identify the valve and its function in the process the following data can be viewed. • Tag name (maximum 28 characters) • Serial number (maximum 28 characters) •...
Page 87: Torque Profile
Installation, Operation and Maintenance Manual Section 14: View Routines FCIM-20208-EN Rev. 0 February 2025 14.4.2 Torque Profile The torque profile routine gives important information on the actuator working conditions in comparison with a previously stored reference profile. It can give a summarized but significant indication of a change in the process conditions.
Page 88: Torque Curve
Section 14: View Routines Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 14.4.3 Torque Curve The torque curve routine gives important information on the actuator operating conditions in comparison with a previously stored reference torque curve. It can be used to perform a detailed analysis of a change in the process conditions. During a full valve stroke in opening or closing, the ICON3000 measures the torque values relevant to every 1% of position variation.
Page 89: Operation Log
Installation, Operation and Maintenance Manual Section 14: View Routines FCIM-20208-EN Rev. 0 February 2025 Figure 44. Torque Curves View procedure • Move the local selector to OFF and then simultaneously press OPEN and STOP within 20 seconds (see Section 10.4.6). Select the language according to the instructions (see Section 10.4.6).
Page 90 Section 14: View Routines Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Table 11 is the list of data collected by the general and recent data log. Table 11. Operation Log General Data Log Recent Data Log Opening time Closing time Contactor cycles Contactor cycles...
Page 91: Maintenance Date
• Next date: this is the date of the next scheduled actuator maintenance. When the date is reached, the EFS3000 generates a maintenance request warning. The date should be updated by the user after all maintenance operations (see Section 10.4.6).
Page 92: Data Logger
PDA or PC. The data can be uploaded from EFS3000 to PDA or PC by the Bluetooth wireless connection. The local display only allows to view the value of the configured parameters (see Section 10.4.6).
Page 93 Installation, Operation and Maintenance Manual Section 14: View Routines FCIM-20208-EN Rev. 0 February 2025 In T-RECORDER mode, recording operation is stopped also in case of an over-torque alarm, in opening or in closing direction. This additional feature allows memorizing the last 256 samples and to see the trend of torque, motor temperature and main voltage just before the alarm.
Page 94 Torque limit in CL is set to 90%; torque limit in OP is set to 100%. Blue graph shows Torque OP versus time, yellow graph shows Torque CL versus time. The data remains in the EFS3000 permanent memory until a new start of data logger is set. Event mode The ICON3000 detects the type of received command (OPEN or CLOSE), the source of the command (local controls, remote controls, bus, etc.) and date and time of...
Page 95: Example Of View Routine: Torque Set-Up
Installation, Operation and Maintenance Manual Section 14: View Routines FCIM-20208-EN Rev. 0 February 2025 14.4.7 Example of View Routine: Torque Set-Up Figure 48. Example of View Routine: Torque Set-Up REMOTE LOCAL ICON3000 ICON3000 ICON3000 ICON3000 ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP STROKE LIMIT VIEW MODE TORQUE SETUP...
Page 96: Pst Graph
FCIM-20208-EN Rev. 0 14.4.8 PST Graph The PST curves cannot be viewed on the local operator interface of the EFS3000. They can only be viewed by a PC or PDA connected by a Bluetooth interface and equipped with the A-manager software tool.
Page 97: Esd Graph
February 2025 14.4.9 ESD Graph The ESD curves cannot be viewed on the local operator interface of the EFS3000. They can only be viewed by a PC or PDA connected by a Bluetooth interface and equipped with the A-manager software tool.
Page 98: Section 15: Local Indicator Setting
Section 15: Local Indicator Setting Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Section 15: Local Indicator Setting Move the EFS3000 to the fully closed position. Remove the black plug. Figure 51. Visual Position Indicator Unscrew the central screw.
Page 99 Installation, Operation and Maintenance Manual Section 15: Local Indicator Setting FCIM-20208-EN Rev. 0 February 2025 Remove the indicator. Figure 53. Visual Position Indicator Unscrew the counter nut. Figure 54. Visual Position Indicator Local Indicator Setting...
Page 100 Section 15: Local Indicator Setting Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Rotate the indicator nut clockwise until it blocks at the end of the threads; rotate a few degrees counter clockwise until the flat surface is perfectly aligned with the CLOSE indication of the label.
Page 101 Installation, Operation and Maintenance Manual Section 15: Local Indicator Setting FCIM-20208-EN Rev. 0 February 2025 Replace the indicator, with the arrow corresponding to the CLOSE indication on the label. Figure 57. Visual Position Indicator Fix the central screw. Figure 58. Visual Position Indicator Local Indicator Setting...
Page 102 Section 15: Local Indicator Setting Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Replace the plug. Figure 59. Visual Position Indicator Local Indicator Setting...
Page 103: Section 16: Manual Operation
Installation, Operation and Maintenance Manual Section 16: Manual Operation FCIM-20208-EN Rev. 0 February 2025 Section 16: Manual Operation and Fail-Safe Speed Setting 16.1 Hydraulic Control Group Diagram NOTICE The diagram in shown for spring to close actuator. Figure 60. Hydraulic Control Group Diagram AUTOMATIC OPERATION ELECTRIC ACTUATOR...
Page 104: Control Group Functions
Figure 61. Remove the Cover 16.2 Control Group Functions The EFS3000 is equipped with a hydraulic control group with two base functions: • Adjustment of fail-safe time. • Manual override to operate the actuator when electrical power is not available.
Page 105: Adjustment Of Fail-Safe Time
Installation, Operation and Maintenance Manual Section 16: Manual Operation FCIM-20208-EN Rev. 0 February 2025 16.2.1 Adjustment of Fail-Safe Time The adjustable flow control valve (526) allows the user to adjust the fail-safe speed. This valve is located under the aluminium cover positioned on the upper side of the hydraulic manifold.
Page 106: Manual Override To Operate The Efs3000 When Electrical Power Is Not Available
16.2.2 Manual Override to Operate the EFS3000 When Electrical Power Is Not Available When electric power is not available, the EFS3000 can be locally operated through a hydraulic hand pump (540). Figure 64. AUTO/MANUAL Selector...
Page 107: Accumulator Recharge
Installation, Operation and Maintenance Manual Section 16: Manual Operation FCIM-20208-EN Rev. 0 February 2025 WARNING For safety reasons, it is required that at the end of operation by hand pump, the lever is removed from the hand pump yoke and the yoke is fixed using the existing split pin.
Page 108 Section 16: Manual Operation Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Figure 66. Hydraulic Manifold Needle valve (352) Drain/charge plug Figure 67. Hydraulic Manifold 1/4 inch NPT hose Figure 68. Hydraulic Manifold Plugs Purge Manual Operation...
Page 109: Section 17: Maintenance And Troubleshooting
Section 17: Maintenance and Troubleshooting WARNING The EFS3000 contains parts with springs, which can be compressed. Before any disassembling, all precautions must be taken in order to ensure that the main power spring is fully released and the spring accumulator is fully discharged.
Page 110: Special Maintenance
Biffi permission. Not performing this procedure will invalidate the product safety and contractual guarantee. Original spare parts must be required to the manufacturer: to ensure that right spare is provided, serial number printed on the EFS3000 unit enclosure label must be specified when spares are ordered. 17.4 Lithium Battery Change Isolate the main supply to the actuator and all other control voltages.
Page 111 Installation, Operation and Maintenance Manual Section 17: Maintenance and Troubleshooting FCIM-20208-EN Rev. 0 February 2025 Open the terminal board cover. Figure 69. Terminal Box Disconnect two wires (+) (-) from the main board. Bring the cover to a safe area. When in a safe area: —...
Page 112: Troubleshooting
Section 17: Maintenance and Troubleshooting Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 — Replace the battery. Figure 72. Battery NOTICE The new battery must be the same as the one provided: • Lithium - SAFT LS 9V 17.5 Troubleshooting If the actuator does not work before trouble-shooting make sure that:...
Page 113: The Led Of Efs Card Is Always Off
Installation, Operation and Maintenance Manual Section 17: Maintenance and Troubleshooting FCIM-20208-EN Rev. 0 February 2025 17.5.1 The LED of EFS Card is Always OFF Check the voltage supply of the EFS clutch. It should be in the range 24 V DC to 240 V AC. 17.5.2 The Electronics of Electric Actuator Do Not Switch on When Powered...
Page 114: The Motor Is Very Hot And Does Not Start
Section 17: Maintenance and Troubleshooting Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 17.5.5 The Motor Is Very Hot and Does Not Start • Check that no alarm other than motor overheating is present. • Wait until the motor cools down and the normally closed contact of the thermal switch automatically resets before trying to operate the actuator again.
Page 115: Excessive Torque For Valve Operation
Installation, Operation and Maintenance Manual Section 17: Maintenance and Troubleshooting FCIM-20208-EN Rev. 0 February 2025 17.5.7 Excessive Torque for Valve Operation • Clean, lubricate and check the valve stem. • Valve packing too tight: loosen the gland bolt nuts. • Coupling type ’...
Page 116 Section 17: Maintenance and Troubleshooting Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 View procedure • Move the 3-position selector to either OFF or REMOTE, and then press NO to scroll through the list of available variables. • Press YES when the display shows message ’...
Page 117: Alarm Table Available Controls
Installation, Operation and Maintenance Manual Section 17: Maintenance and Troubleshooting FCIM-20208-EN Rev. 0 February 2025 17.5.11 Alarm Table Available Controls Table 12. Alarm Table Display Condition for Alarm Action Local Remote Alarm Reset Message High torque Measured torque Operate the actuator in Only open Only open Open, control...
Page 118 Section 17: Maintenance and Troubleshooting Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Table 13. Alarm Table (Continued) Display Condition for Alarm Action Local Remote Alarm Reset Message Mid travel The valve does not Check status of actuator Only open Only open Open, control...
Page 119: Warning Table
Installation, Operation and Maintenance Manual Section 17: Maintenance and Troubleshooting FCIM-20208-EN Rev. 0 February 2025 17.5.12 Warning Table Table 14. Warning table Display Message Condition for Warning Action Local Remote Warning Reset High torque in OP Measured torque 10% lower Check the torque Available Available...
Page 120 Configuration object nr.: Number indicates the number of the parameters to be configured. To clear the alarm the table of all ICON3000 parameters is necessary. Please contact Biffi after sales service to solve the problem. If the alarm message is ’CONFIGURATION OBJ 9999’ only one of the ICON3000 parameters needs to be changed.
Page 121: Section 18: Exploded View And Parts List
Section 18: Exploded View and Parts List Installation, Operation and Maintenance Manual FCIM-20208-EN Rev. 0 February 2025 Section 18: Exploded View and Parts List Figure 75. EFS3000 Exploded View Table 15. Parts List Item Quantity Description Material ICON3000 electric actuator...
Page 122 Section 18: Exploded View and Parts List Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Figure 76. EFS3000 Exploded View 63 56 Table 16. Parts List Item Quantity Description Material Insert Carbon steel Screw Stainless steel O-ring Nitrile Butadiene Rubber (NBR)
Page 123 Section 18: Exploded View and Parts List Installation, Operation and Maintenance Manual FCIM-20208-EN Rev. 0 February 2025 Table 17. Parts List (Continued) Item Quantity Description Material Rock Alloy steel Bush Steel- polytetrafluoroethylene (PTFE)-Bronze O-ring O-ring Cable gland assembly Plug Carbon steel O-ring External cylinder Carbon steel...
Page 124: Parts List
Section 18: Exploded View and Parts List Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Figure 77. EFS3000 Exploded View ITEM Q.ty DESCRIPTION MATERIAL Table 18. Parts List Circlip Stainless steel Q-Ring NBR Rubber Item Quantity Description Material...
Page 125 Section 18: Exploded View and Parts List Installation, Operation and Maintenance Manual FCIM-20208-EN Rev. 0 February 2025 Figure 78. EFS3000 Exploded View Table 19. Parts List ITEM Q.ty DESCRIPTION MATERIAL Head spring ange Carbon steel Washer ------ Item Quantity Description...
Page 126 Section 18: Exploded View and Parts List Installation, Operation and Maintenance Manual February 2025 FCIM-20208-EN Rev. 0 Figure 79. EFS3000 Exploded View 13-14 29-30 11-12 26-27 9-10 22-23 14-16 38-39 45-46 49-50 42-43 41-14 9-10 58-59 Table 20. Parts List...
Page 127 Section 18: Exploded View and Parts List Installation, Operation and Maintenance Manual FCIM-20208-EN Rev. 0 February 2025 Table 21. Parts List (Continued) Item Quantity Description Material Screw Stainless steel O-ring Cover Aluminium Terminal Screw Stainless steel O-ring Sensor support Stainless steel Screw Proximity sensor Selector shaft...
Page 128: Section 19: Lubrication
Section 19: Lubrication For normal duty, the EFS3000 actuators are lubricated ’for life’. The EFS3000 is composed by different compartments each of them are lubricated or filled by different products. In case it is necessary to add lubricant, the following products (or equivalent) must be used.
Page 129: Section 20: Operational Tests And Inspections
Installation, Operation and Maintenance Manual Section 20: Operational Tests and Inspections FCIM-20208-EN Rev. 0 February 2025 Section 20: Operational Tests and Inspections NOTICE To ensure the guaranteed SIL Level, according to IEC 61508, the functionality of actuator must be checked with regular intervals of time, as described following. For safety related applications, the following test operation has to be performed: Full stroke of actuator once a year.
Page 130: Section 21: Disassembling And Take Down
Section 21: Disassembling and Take Down WARNING Before any disassembling, all the electrical supply connected to the EFS3000 must be disconnected. WARNING The EFS3000 contains parts with springs, which may be under compression. Before any disassembling or for take down, all precautions must be taken in order to be sure that the main spring (1) and the accumulator spring (2) are fully released.
Page 131 Installation, Operation and Maintenance Manual Notes FCIM-20208-EN Rev. 0 February 2025 This page is intentionally left blank.
Page 132 FCIM-20208-EN © 2025 Biffi. All rights reserved. Biffi Italia s.r.l. Strada Biffi 165 29017 Fiorenzuola d’Arda (PC) The contents of this publication are presented for informational purposes Italy only, and while every effort has been made to ensure their accuracy,...