BIFFI ICON-040 Installation, Operation And Maintenance Manual
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BIFFI ICON-040 Installation, Operation And Maintenance 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
Installation, Operation and Maintenance Manual
VCIOM-08500-EN
December 2019

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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 3: Table Of Contents

    Installation, Operation and Maintenance Manual Table of Contents VCIOM-08500-EN December 2019 Table of Contents Section 1: General Safety Instructions Range of Applications ................. 1 Safety Instructions for Installation in Hazardous Areas......... 1 1.2.1 Marking .................... 2 Applicable Standards and Regulations ............2 Terms and Conditions .................
  • Page 4 Table of Contents Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Section 5: Operating the ICON3000 Operation By Handwheel ................26 5.1.1 Operation By Handwheel in Absence of a Power Supply and With the Lithium Battery............26 Electrical Operation .................. 27 Local Control .....................
  • Page 5 Installation, Operation and Maintenance Manual Table of Contents VCIOM-08500-EN December 2019 Valve Data ....................70 9.2.1 Sample Configuration Procedure ............ 70 Maintenance ..................... 70 9.3.1 Set Password .................. 71 9.3.2 Clear Alarm Log ................71 9.3.3 Set Torque Reference ..............71 9.3.4 Set Curve Reference ................
  • Page 6 Table of Contents Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Appendix A: ICON3000 / ICON3000AD Safety Instructions .................. 116 A.1.1 General..................116 Instructions for Proper Installation ............116 A.2.1 Marking ..................117 Applicable General Standards and Regulations ........118 Terms and Conditions ................
  • Page 7 Installation, Operation and Maintenance Manual Table of Contents VCIOM-08500-EN December 2019 Appendix C: ICON3000 / ICON3000AD Safety Instructions .................. 137 C.1.1 General..................137 Instructions for Proper Installation ............137 C.2.1 Marking ..................138 Applicable General Standards and Regulations ........139 Terms and Conditions ................
  • Page 8 Table of Contents Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Appendix E: ICON3000 Safety Instructions .................. 156 E.1.1 General..................156 E.1.2 Identification of Main Parts ............157 Instructions for Proper Installation ............158 E.2.1 Marking ..................158 Applicable General Standards and Regulations ........159 Terms and Conditions ................

  • Page 9: Section 1: General Safety Instructions

    Section 1: General Safety Instructions Range of Applications The Biffi ICON3000 electric actuator covered in this manual is designed for the operation of any type of industrial valve used in heavy industrial, chemical, and petrochemical facilities. Emerson will not be liable for potential damage resulting from use in anything other than these designated applications.

  • Page 10: Marking

    Section 1: General Safety Instructions Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN 1.2.1 Marking Table 1. IECEx INE XX.ZZZZ IECEx reference certificate (CoC) XX ATEX ZZZZ ATEX reference certificate 0080 Notified body for ATEX quality assurance (INERIS) Group II (surface industries) Category 2 apparatus Explosive atmospheres caused by gas, mists, or vapors Explosive atmospheres caused by gas and dusts...

  • Page 11: Terms And Conditions

    Installation, Operation and Maintenance Manual Section 1: General Safety Instructions VCIOM-08500-EN December 2019 Figure 1 Internal gears Handwheel Absolute Encoder Terminal box Engagement lever Local interface Electric motor Terms and Conditions Emerson guarantees every product to be free from defects and to conform to industry standards.

  • Page 12: Section 2: Storage And Pre-Installation

    Section 2: Storage and Pre-Installation Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Section 2: Storage and Pre-Installation Tests to be Carried Out When the Actuator is Received If the actuator is received already mounted on the valve, all the below operations should have already been performed during valve/actuator assembly.

  • Page 13: Short-Term Storage (One Year Or Fewer)

    Installation, Operation and Maintenance Manual Section 2: Storage and Pre-Installation VCIOM-08500-EN December 2019 2.2.2 Short-term Storage (One Year or Fewer) 2.2.2.1 Indoor Storage Make sure that the actuator is kept in a dry place, laid on a wooden pallet, and protected from dust.
  • Page 14 Section 2: Storage and Pre-Installation Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 3 Figure 4 Figure 5 Storage and Pre-Installation...

  • Page 15: Checks To Be Performed Before Installation

    Installation, Operation and Maintenance Manual Section 2: Storage and Pre-Installation VCIOM-08500-EN December 2019 Figure 6 Checks to be Performed Before Installation • Make sure that the valve to be motorized is appropriate for coupling to the actuator. • The electrical supply cables must be suitable for the power rating (refer to the test certificate that comes with the actuator).

  • Page 16: Section 3: Installation

    Section 3: Installation Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Section 3: Installation Working Condition Standard actuators are suitable for the following environment temperatures: -20 °C +85 °C (-4 °F to +185 °F) Special versions are available for extreme environment temperatures: -40 °C +85 °C (-40 °F to +185 °F) -55 °C +65 °C (-67 °F to +149 °F) NOTICE...

  • Page 17: Coupling Block: Disassembly From The Actuator

    Installation, Operation and Maintenance Manual Section 3: Installation VCIOM-08500-EN December 2019 Coupling Block: Disassembly from the Actuator The bushing is delivered already assembled to the drive sleeve, even when it is unmachined. In order to perform the necessary machining, remove the bushing from its housing. Remove the fixing screws from the coupling block.
  • Page 18 Section 3: Installation Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 9 The internal thrust bearing will remain at the bottom of the block housing. Figure 10 NOTICE Before re-mounting the stem nut, make sure that coupling tolerances to the valve stem are correct.

  • Page 19: Type "B1" And "B2" Coupling Blocks

    Installation, Operation and Maintenance Manual Section 3: Installation VCIOM-08500-EN December 2019 3.2.1.2 Re-assembling the Internal Parts It is advisable to wash the dismantled parts with a suitable solvent and dry them with compressed air. Make sure that no metal filings or foreign bodies remain; spread a film of grease on all parts (for grease type, see Section 4, Lubrication).

  • Page 20: Type "B3" And "B4" Coupling Blocks

    Section 3: Installation Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 12 The internal thrust washer will remain at the bottom of the block housing. The bore can now be machined in the bushing to suit coupling requirements. The same procedure is also used if maintenance becomes necessary. 3.2.2.2 Re-assembling the Internal Parts It is advisable to wash the dismantled parts with a suitable solvent and dry them with...

  • Page 21: Attaching The Coupling Block To The Gear Reduction Unit

    Installation, Operation and Maintenance Manual Section 3: Installation VCIOM-08500-EN December 2019 Figure 14 Extract the bushing and machine it according to the mating needs. Figure 15 3.2.3.2 Re-assembling the Internal Parts It is advisable to wash the dismantled parts with a suitable solvent and dry them with compressed air.

  • Page 22: Manual Operation

    Section 3: Installation Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Manual Operation To engage manual operation, depress (by 20°-30°) the lever in the direction shown in Figure 18 and then let the lever automatically return to its rest position. If no engagement is obtained, slowly rotate the handwheel and repeat the operation.
  • Page 23 Installation, Operation and Maintenance Manual Section 3: Installation VCIOM-08500-EN December 2019 Engagement lever locked in handwheel operation position: operation with the electric motor is mechanically disengaged. TO CLOSE Figure 18 Figure 19 Figure 20 Installation...

  • Page 24: Mounting The Actuator Onto The Valve

    Section 3: Installation Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN   WARNING Never lift the valve/actuator assembly without securing slings to both the valve and the actuator. Never use the handwheel to lift the actuator. Table 5. Model Max. weight, kg (lb) 32 (70.6) 38 (83.8) 46 (101.4)

  • Page 25: Actuator Mounting

    Installation, Operation and Maintenance Manual Section 3: Installation VCIOM-08500-EN December 2019 3.4.3 Actuator Mounting NOTICE If the actuator is supplied without stud bolts and nuts, these must be provided by the customer and conform to the material requirements in Table 6.  ...

  • Page 26: Electrical Connections

    Section 3: Installation Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Electrical Connections Before powering the actuator check that the supply voltage details on the nameplate are correct for the receiving plant. Access to terminals for electrical connections and commissioning is via the terminal cover, since all settings are non-intrusive. The removal of any other covers without Emerson approval will invalidate the warranty;...

  • Page 27: Removing The Terminal Board Enclosure

    Installation, Operation and Maintenance Manual Section 3: Installation VCIOM-08500-EN December 2019 Figure 22 Removing the Terminal Board Enclosure The sealing of cables and conduit entries should be carried out in accordance with the relevant national standards or the regulatory authorities that certified the actuators. This is especially true 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 28: Terminal Board

    Section 3: Installation Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 23 If some parts of the cable glands have been removed while working on the conduit entries, put them back into place immediately to avoid misplacing the dismantled parts. Unused entries: •...
  • Page 29 Installation, Operation and Maintenance Manual Section 3: Installation VCIOM-08500-EN December 2019 Terminate the ground connections to the stud marked "ground". One internal ground stud and one external ground stud are provided. Before performing service or maintenance operations (unless otherwise indicated), ensure that power is turned off to the unit to avoid injury or damage to equipment.

  • Page 30: Instructions For Explosion-Proof Enclosures

    Instructions For Explosion-proof Enclosures NOTICE The Biffi ICON3000 electric actuator shall be installed and maintained according to the applicable rules regarding electrical installations in hazardous area (other than mines) classified as zone 1 (gas); for example: EN 60079-10 (hazardous area classification), EN 60079-14 (electrical installation), EN 60079-17 (maintenance), and/or other national standards.

  • Page 31: Installation In Environments With Explosive Dusts

    Explosive Dusts NOTICE The Biffi ICON3000 electric actuator shall be installed and maintained according to the applicable rules regarding electrical installation in hazardous areas (other than mines), classified as zone 21 (dust); for example: EN 50281-1-2 (dust) and/or other national standards.

  • Page 32: Section 4: Lubrication

    Section 4: Lubrication Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Section 4: Lubrication Lubrication Inspection The actuator is lubricated for the duration of its service life; under normal working conditions it is not necessary to replace or refill the oil. However, it is recommended to check the oil level every 3-5 years using holes 1 or 2 (per Figures 27 and 28) depending on what orientation the actuator was mounted.
  • Page 33 Installation, Operation and Maintenance Manual Section 4: Lubrication VCIOM-08500-EN December 2019 Should maintenance become necessary, the following GREASES are recommended: Ambient temperature from -20 °C to +85 °C • AGIP GREASE MU EP 2 or equivalent Ambient temperature from -40 °C to +85 °C •...

  • Page 34: Section 5: Operating The Icon3000

    Section 5: Operating the ICON3000 Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Section 5: Operating the ICON3000 Operation By Handwheel To operate the actuator via the handwheel, press down the lever and at the same time rotate the handwheel until the clutch is engaged. Release the lever and move the valve via the handwheel.

  • Page 35: Electrical Operation

    Installation, Operation and Maintenance Manual Section 5: Operating the ICON3000 VCIOM-08500-EN December 2019 Electrical Operation Before connecting power to the actuator check that the voltage is correct and corresponds to the indications on the nameplate. An incorrect power supply could cause permanent damage to the electrical components.
  • Page 36 Section 5: Operating the ICON3000 Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 30 Figure 31 Figure 32 Figure 33 OPEN/YES STOP CLOSE/NO Operating the ICON3000...
  • Page 37 Installation, Operation and Maintenance Manual Section 5: Operating the ICON3000 VCIOM-08500-EN December 2019 Figure 34 Operation Local selector Status or Position position request R% Figure 35 Operating the ICON3000...

  • Page 38: Locking The 3-Position Selector

    Section 5: Operating the ICON3000 Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Locking the 3-Position Selector The 3-position selector can be locked in any of its three positions by means of a padlock. Remote Control Place the 3-position selector in REMOTE to transfer the actuator control to a remote device. Local OPEN or CLOSE operation will be inhibited.
  • Page 39 Installation, Operation and Maintenance Manual Section 5: Operating the ICON3000 VCIOM-08500-EN December 2019 The signal levels are the following: • Minimum ON signal > 20 V DC or 20 V AC (50/60 Hz). • Maximum ON signal < 125 V DC or 120 V AC (50/60 Hz). •...

  • Page 40: Output Contacts

    Section 5: Operating the ICON3000 Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN 5.6.2 Output Contacts Standard version • Monitor relay: the voltage-free, change-over contacts of the monitor relay are available on the terminal board. The monitor relay indicates if the actuator can be remotely controlled or if there is a problem or condition that prevents remote control of the valve.

  • Page 41: Interlock Inputs

    Installation, Operation and Maintenance Manual Section 5: Operating the ICON3000 VCIOM-08500-EN December 2019 5.6.4 Interlock Inputs Two additional inputs are available to inhibit actuator movement in the open or closed direction. The controls are momentary, and the inhibiting action continues until the relevant signal is present.

  • Page 42: Operating The Icon3000 For The First Time

    Section 5: Operating the ICON3000 Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Operating the ICON3000 for the First Time Before attempting to operate the ICON3000 for the first time, check that the actuator is correctly mounted on to the valve. Place the 3-position selector to OFF and switch the power on.

  • Page 43: Ain/Aout Card

    Installation, Operation and Maintenance Manual Section 5: Operating the ICON3000 VCIOM-08500-EN December 2019 5.8.2 Ain/Aout Card With the above card, the ICON3000 is provided with a 4-20 analog input and a 4-20 mA analog output. This card should be plugged on the base card, replacing the “TERMINAL BOARD ADAPTOR”...
  • Page 44 Section 5: Operating the ICON3000 Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN If mains voltage is lost, behavior will be different if the power supply of the 4-20 mA output stage is internally- or externally-generated: Internal power supply (or passive loop): If mains voltage is lost the output 4-20 mA drops to 0.

  • Page 45: Base Card Of The Icon3000

    Installation, Operation and Maintenance Manual Section 5: Operating the ICON3000 VCIOM-08500-EN December 2019 Figure 44 Base Card of the ICON3000 Figure 45 Bottom View of Base Card Terminal Board Adaptor card (TBA) Operating the ICON3000...
  • Page 46 Section 5: Operating the ICON3000 Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 46 Top View of Base Card Top View of Base Card Base card equipped with fieldbus interface card and Terminal Board Adapter (TBA) card. Figure 47 Fieldbus interface card Fieldbus interface card The type of card depends on the fieldbus present in the plant.

  • Page 47: Absolute Encoder Of The Icon3000

    Installation, Operation and Maintenance Manual Section 5: Operating the ICON3000 VCIOM-08500-EN December 2019 Figure 49 Potentiometer card Potentiometer card This card can be used for some special FW versions of the ICON3000. Figure 50 5.10 Absolute Encoder of the ICON3000 The ICON3000 absolute encoder can measure up to 8,000 output turns.

  • Page 48: Section 6: Local Controls

    Section 6: Local Controls Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Section 6: Local Controls Description of the Local Operator Interface The following functions are available via the ICON3000 local operator interface: • Actuator Control • Actuator Configuration • Actuator Status Visualization The figures on the following pages describe the function of each component of the local operator interface.
  • Page 49 Installation, Operation and Maintenance Manual Section 6: Local Controls VCIOM-08500-EN December 2019 Table 9. List output torque mot temp motor speed term temp main voltage log status current wireless report temperature node report * time FDI report * date base report alarm term report warning...
  • Page 50 Section 6: Local Controls Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Local Controls: OPEN/YES, CLOSE/NO, and STOP push-buttons. The STOP push-button resets any existing command and is active both in local and remote. If the 3-position selector is in LOCAL, the OPEN / YES, and CLOSE /NO pushbuttons work as OPEN and CLOSE commands.
  • Page 51 Installation, Operation and Maintenance Manual Section 6: Local Controls VCIOM-08500-EN December 2019 The alarm and warning lists only contain the present alarms and warnings. When the fault condition disappears, the corresponding alarm or warning disappears from the list. A reset routine is provided to clear the type of alarm/warning that is memorized (over-torque, jammed valve, etc.).

  • Page 52: Configuration Options

    Section 6: Local Controls Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Configuration Options The ICON3000 actuator can be completely configured via the local interface by means of a series of menus that can be selected from the alphanumeric display. The operator can navigate 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 alphanumeric display.
  • Page 53 Installation, Operation and Maintenance Manual Section 6: Local Controls VCIOM-08500-EN December 2019 Nameplate This menu includes a series of data identifying the actuator characteristics, service, and utilization mode. The data are entered by the manufacturer and can only be viewed (not edited;...

  • Page 54: Entering The View Mode

    Section 6: Local Controls Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Maintenance This menu includes all diagnostic and historic data which can assist the operator if failures occur or during maintenance operations. The Maintenance menu also includes the “Set password” routine. List of routines: •...

  • Page 55: Entering The Set-Up Mode

    Installation, Operation and Maintenance Manual Section 6: Local Controls VCIOM-08500-EN December 2019 Entering the Set-Up Mode To change the existing settings or to set stroke limits it is necessary to enter the correct password. Ensure that mains power (or the external auxiliary supply) is supplied. •...
  • Page 56 Section 6: Local Controls Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 54 shows the procedure to enter view and set-up mode. Figure 54 Enter View and Set-Up Mode Local Controls...

  • Page 57: Section 7: Set-Up Menu

    Installation, Operation and Maintenance Manual Section 7: Set-Up Menu VCIOM-08500-EN December 2019 Section 7: Set-Up Menu Figure 55 Set-Up Menu...
  • Page 58 Section 7: Set-Up Menu Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 56 shows the procedure to navigate through the set-up routines. Figure 56 Set-Up Menu...

  • Page 59: Section 8: View Menu

    Installation, Operation and Maintenance Manual Section 8: View Menu VCIOM-08500-EN December 2019 Section 8: View Menu Figure 57 View Menu View Menu...
  • Page 60 Section 8: View Menu Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 58 shows the procedure to navigate through the view routines. Figure 58 Procedure to Move in the View Routines View Menu...

  • Page 61: Section 9: Set-Up Routines

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines VCIOM-08500-EN December 2019 Section 9: Set-Up Routines Actuator Set-Up 9.1.1 Set Stroke Limits This routine allows the actuator to be configured according to the type of valve it is mounted on. The following parameters will be set: •...
  • Page 62 Section 9: Set-Up Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Close limit by torque • Move the local selector to LOCAL. The local controls can be used. • Press the CLOSE control. The actuator will move in the closing direction and when the configured torque value is reached, the motor will stop and the new position limit is memorized.

  • Page 63: Torque Set-Up

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines VCIOM-08500-EN December 2019 9.1.2 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 64: Remote Controls

    Section 9: Set-Up Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN • Press YES to change ESD priority with reference to the following signals or status: (*) Motor thermostat alarm. By choosing ESD > THERMOSTAT, the ESD action will be carried out even in the event of motor over-heating. Conversely, if ESD <...

  • Page 65: Local Controls

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines VCIOM-08500-EN December 2019 Configuration procedure • Move the local selector to OFF and then simultaneously press OPEN and STOP. Select the language and then enter the password according to the instructions (see “Entering the set-up mode”).

  • Page 66: Output Relays

    Section 9: Set-Up Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN LED colors • Press YES if the color of the open LED is correct. Press NO to change it, and then press YES to confirm. • Press YES if the color of the close LED is correct. Press NO to change it, and then press YES to confirm.
  • Page 67 Installation, Operation and Maintenance Manual Section 9: Set-Up Routines VCIOM-08500-EN December 2019 Auxiliary output relays For status indication or diagnostic purposes, 8 voltage-free contacts of 8 relays are available to be configured individually to switch upon occurrence of the following conditions: Status •...

  • Page 68: Positioner

    Section 9: Set-Up Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Configuration procedure • Move the local selector to OFF and then simultaneously press OPEN and STOP. Select the language and enter the password according to the instructions (see “Entering the set-up mode”). When the message displayed is “SET-UP MODE OK?”...
  • Page 69 Installation, Operation and Maintenance Manual Section 9: Set-Up Routines VCIOM-08500-EN December 2019 The following options can be configured via the local operator interface: • Dead band: configurable from “position resolution%” to 25.5% of the maximum position error. The configured value should be great enough to avoid a "hunting"...

  • Page 70: Fail Safe

    Section 9: Set-Up Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Example D With input signal < 8 mA, the position request is 100% and the actuator is driven to open. With input signal = 16 mA , the position request is 0% and the actuator is driven to close. With input signal = 12 mA, the position request is 50% and the actuator is driven to reach position 50%.
  • Page 71 Installation, Operation and Maintenance Manual Section 9: Set-Up Routines VCIOM-08500-EN December 2019 Figure 61 Example A Example B Position request % Position request % 100% Configured values: Configured values: 100% % min = 0% % min = 25% % max = 100% % max = 75% Polarity : 4 mA = CL Polarity : 4 mA = CL...

  • Page 72: Out 4-20 Ma

    Section 9: Set-Up Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN 9.1.9 OUT 4-20 mA This routine is only available if the Ain/Aout card is present. With this card, the ICON3000 is provided with a 4-20 mA analog input and a 4-20 mA analog output. The 4-20 mA output can be configured to provide a current proportional to either “position”...

  • Page 73: Interlock

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines VCIOM-08500-EN December 2019 9.1.10 Interlock The interlock inputs can be used to inhibit the actuator movement in the open or closed direction. The controls are momentary; the inhibiting action continues while the relevant signal is present.

  • Page 74: Bus (Or Fdi Control)

    Section 9: Set-Up Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Configuration procedure • Move the local selector to OFF and then simultaneously press OPEN and STOP. Select the language and then enter the password according to the instructions (see “Entering the set-up mode”).

  • Page 75: Miscellaneous

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines VCIOM-08500-EN December 2019 9.1.13 Miscellaneous This includes different types of routines such as “time and date”, “lithium battery”, and "torque profile", used only for special applications or in particular conditions. 9.1.13.1 Time and Date Time and date are used in maintenance functions to associate time information to the memorized event (torque profile, alarm log, maintenance request, etc.).
  • Page 76 Section 9: Set-Up Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 64 Actuator Direction: Closing Closing torque % of nominal Breakout limit Ending limit Running limit Position % 100% Cl brk% Cl end % 0% Figure 65 Actuator Direction: Opening Opening torque % of nominal Breakout limit Ending limit...
  • Page 77 Installation, Operation and Maintenance Manual Section 9: Set-Up Routines VCIOM-08500-EN December 2019 9.1.13.4 Torque Bypass (%) Since a momentary high torque may be required to unseat certain valves, the torque bypass routine disables the torque alarm when an open or close command is received and the actuator is fully open or closed.

  • Page 78: Valve Data

    Section 9: Set-Up Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Valve Data The valve data allow identification of the valve and its function in the process. The valve manufacturer and the end user can enter the data. The following data can be entered: •...

  • Page 79: Set Password

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines VCIOM-08500-EN December 2019 9.3.1 Set Password The actuator is supplied by Emerson with the default password (“0 0 0 0”). The Set Password routine allows the user to enter a different password consisting of 4 alphanumeric characters.

  • Page 80: Set Curve Reference

    Section 9: Set-Up Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN 9.3.4 Set Curve Reference The “set curve reference” routine allows selection of 1 of 100 opening and closing torque curves in the memory of the ICON3000 and to transfer them to the torque curve reference registers.

  • Page 81: Set Maintenance Date

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines VCIOM-08500-EN December 2019 9.3.6 Set Maintenance Date The maintenance date routine allows the following operations: • to set the last maintenance date • to set the next maintenance date • to set the start-up date Configuration procedure •...

  • Page 82: Set Data Logger

    Section 9: Set-Up Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN 9.3.7 Set Data Logger The “data logger” routine allows setting of the data logger parameters (see VIEW mode, Maintenance, Data logger, Section 10.4.6). To start the data logger the following data should be set: Table 12.

  • Page 83: Example Of Set-Up Routine

    Installation, Operation and Maintenance Manual Section 9: Set-Up Routines VCIOM-08500-EN December 2019 Example of Set-Up Routine 9.4.1 Torque Set-Up Figure 66 REMOTE LOCAL ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP SETUP MODE TORQUE SETUP STROKE LIMIT CHANGE? CHANGE? CHANGE? 3-position selector Display Press NO until...

  • Page 84: Section 10: View Routines

    Section 10: View Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Section 10: View Routines 10.1 Actuator Set-Up The above menu allows the operator to view the present actuator configuration. No changes may be made to the present data. The following data can be viewed (see Table 13): Table 13.

  • Page 85: Nameplate

    Icc, max 99.9 A/TMax (for ICON LP) Duty (S2/15 min, etc.) Poles (2, 4, etc.) Biffi name, max. 28 characters Gear ratio, max. 1000 /M.R. Ratio (for ICON LP) • Test date: date of the in-house functional test of actuator.

  • Page 86: Valve Data

    Section 10: View Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN 10.3 Valve Data To identify the valve and its function in the process the following data can be viewed: • Tag name (max. 28 characters) • Serial number (max. 28 characters) •...

  • Page 87: Torque Profile

    Installation, Operation and Maintenance Manual Section 10: View Routines VCIOM-08500-EN December 2019 10.4.2 Torque Profile The torque profile routine gives important information on the actuator working conditions in comparison with a previously memorized reference profile. The torque profile can indicate a change in process conditions. Reference details are retained and the latest torque is expressed as a % of the nominal torque.

  • Page 88: Torque Curve

    Section 10: View Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN View Procedure • Move the local selector to OFF and then simultaneously press OPEN and STOP. Select the language according to the instructions (see “Entering the view mode”). When the message displayed is “VIEW MODE OK?” press YES. Press NO to scroll through the list of available menus and press YES to select the "Maintenance"...

  • Page 89: Operation Log

    Installation, Operation and Maintenance Manual Section 10: View Routines VCIOM-08500-EN December 2019 The amount of data to be viewed is large and the local display can only display one datum at a time. To use this function, it is recommended to utilize the features of A-Manager via a PDA or PC.
  • Page 90 Section 10: View Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 67 Table 15 shows the list of data collected by the general and recent data log: Table 15. General Data Recent Data Log Opening time Closing time Contactor cycles Contactor cycles Motor run time...
  • Page 91 Installation, Operation and Maintenance Manual Section 10: View Routines VCIOM-08500-EN December 2019 View Procedure • Move the local selector to OFF and then simultaneously press OPEN and STOP. Select the language according to the instructions (see “Entering the view mode”). When the message displayed is “VIEW MODE OK?” press YES. Press NO to scroll through the list of available menus and press YES to select the "Maintenance"...

  • Page 92: Maintenance Date

    Section 10: View Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN 10.4.5 Maintenance Date The routine allows the following dates to be viewed: • Last date • Next date • Start-up date • Recent log date (see Table 17 below) Table 17.
  • Page 93 Installation, Operation and Maintenance Manual Section 10: View Routines VCIOM-08500-EN December 2019 Data logger modes: • OFF: the data logger is not active. • RECORDER mode: the ICON3000 measures and memorizes the following 3 data: Main voltage supply (V) Motor temperature (°C) Temperature inside the electronics compartment (°C) •...
  • Page 94 Section 10: View Routines Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 69 shows the data logger in "T-Recorder" mode. Figure 69 T-Recorder Mode T-logger stops recording if a torque alarm is triggered. The last 256 samples remain in the actuator memory until a new start of the logger is initiated.

  • Page 95: Example Of View Routine

    Installation, Operation and Maintenance Manual Section 10: View Routines VCIOM-08500-EN December 2019 Figure 70 Event Mode 10.5 Example of View Routine 10.5.1 View Torque Set-up Figure 71 LOCAL REMOTE ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP STROKE LIMIT VIEW MODE TORQUE SETUP VIEW? VIEW? VIEW?

  • Page 96: Section 11: Maintenance

    Section 11: Maintenance Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Section 11: Maintenance 11.1 Standard Maintenance Approx. every 2 years: Under normal operating conditions, the ICON3000 requires no formal maintenance; however, visual inspection for oil leakage or external visible damage is recommended every two years. When conditions are severe (frequent operation or high temperatures), inspect the oil level and oil quality more frequently.

  • Page 97: Special Maintenance

    Installation, Operation and Maintenance Manual Section 11: Maintenance VCIOM-08500-EN December 2019 • If the stem is external, check that the valve stem is clean and lubricated. If not, clean and lubricate it in order to prevent damage to the threaded bush. •...

  • Page 98: Lithium Battery Change

    Section 11: Maintenance Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN 11.3 Lithium Battery Change • Isolate the main supply to the actuator and all other control voltages. • Remove the terminal board cover. • Disconnect two wires (+) (-) from the main board. •...
  • Page 99 Installation, Operation and Maintenance Manual Section 11: Maintenance VCIOM-08500-EN December 2019 Figure 74 — Remove the battery cover. Figure 75 Figure 76 Maintenance...
  • Page 100 Section 11: Maintenance Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 77 — Replace the battery. Figure 78 Figure 79 Maintenance...
  • Page 101 Installation, Operation and Maintenance Manual Section 11: Maintenance VCIOM-08500-EN December 2019 Figure 80 NOTICE The new battery must be the same type as the one provided: Lithium – SAFT LS 9V. NOTICE To check the battery status, press the STOP button for at least 3 seconds. In any event, the battery status is automatically checked at least once a day.

  • Page 102: Section 12: Troubleshooting

    Section 12: Troubleshooting Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Section 12: Troubleshooting This section assumes that the ICON3000 has passed a functional test performed by Emerson quality assurance personnel.   WARNING Installation, configuration, commissioning, maintenance, and repairs must be performed by approved and qualified personnel only.

  • Page 103: Dc Output Voltage Not Available At The Terminals

    Installation, Operation and Maintenance Manual Section 12: Troubleshooting VCIOM-08500-EN December 2019 12.2 DC Output Voltage not Available at the Terminals • Switch the main power supply off and disconnect all wires from terminals B1-B2 and C1. • Switch the main power supply on and check if the voltage on the terminals B1-B2 and C1 is between 23 and 27 V DC.

  • Page 104: The Motor Is Very Hot And Does Not Start

    Section 12: Troubleshooting Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN 12.4 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 (NC) contact of the thermal switch automatically resets before trying to operate the actuator again.

  • Page 105: The Manual Override Cannot Be Engaged

    Installation, Operation and Maintenance Manual Section 12: Troubleshooting VCIOM-08500-EN December 2019 If the local display changes the valve position indicators: • Verify that the stem nut fits correctly in the actuator base. • Verify that the stem nut has sufficient engagement with the valve stem. •...

  • Page 106: Valve Operation Requires Excessive Torque

    Section 12: Troubleshooting Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN 12.8 Valve Operation requires Excessive Torque • Clean, lubricate and check the valve stem. • If the valve packing is too tight, loosen the gland bolt nuts. • Coupling type “A”: if a tight fit between bush and stem is evident, increase the thread clearance on the drive coupling.

  • Page 107: The Actuator Does Not Stop In The Fully Open Or Fully Closed Position

    Installation, Operation and Maintenance Manual Section 12: Troubleshooting VCIOM-08500-EN December 2019 12.9 The Actuator does not Stop in the Fully Open or Fully Closed Position • Check that the actual open and close positions of the valve respectively correspond to 100% and 0% on the actuator display. •...
  • Page 108 Section 12: Troubleshooting Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 88 LOCAL REMOTE WARNINGS ALARMS VIEW? VIEW? 3-position selector Display XXXXXX XXXXXX WARNING ALARM XXXXXX NEXT? NEXT? NEXT? VIEW VARIABLES WARNING ALARM NEXT? NEXT? RESET RESET View procedure •...
  • Page 109 Installation, Operation and Maintenance Manual Section 12: Troubleshooting VCIOM-08500-EN December 2019 Table 19. Alarm Table Available Controls Display Alarm Condition for alarm Action message reset Local Remote Measured torque greater Operate the actuator in than the relevant value High torque opening direction.
  • Page 110 Section 12: Troubleshooting Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Available Controls Display Alarm Condition for alarm Action message reset Local Remote Check main voltage Main voltage lower than -20% supply and frequency Main or higher than+20% of the Main voltage on terminals L1, L2, Not available...
  • Page 111 Installation, Operation and Maintenance Manual Section 12: Troubleshooting VCIOM-08500-EN December 2019 Available Controls Display Alarm Condition for alarm Action message reset Local Remote Check the external Positioner The analog 4-20 mA signal 4-20 mA Request signal 4-20 mA generator Available function not Available is not correct...
  • Page 112 Section 12: Troubleshooting Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Available Controls Display Condition for alarm Action Alarm reset message Local Remote Motor current greater or Check electrical Motor current Available Available Available Current OK lower than limits motor The routine that Re-calibrate Wrong stroke...

  • Page 113: Section 13: Parts List And Drawings

    Installation, Operation and Maintenance Manual Section 13: Parts List and Drawings VCIOM-08500-EN December 2019 Section 13: Parts List and Drawings This Section includes the drawings and parts list of each component and sub-assembly of the ICON3000.   CAUTION Using a fastener other than the approved type may result in damage to the actuator or valve. NOTICE - When ordering spare parts, be sure to indicate the serial number embossed on the actuator nameplate.
  • Page 114 Section 13: Parts List and Drawings Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 89 Component Parts Table 21. Item Description Housing Lower bearing Hollow shaft Worm wheel Circlip Driver sleeve Driver sleeve spring Spring retaining ring Seal kit 9.1 * O-ring 9.2 *...
  • Page 115 Installation, Operation and Maintenance Manual Section 13: Parts List and Drawings VCIOM-08500-EN December 2019 Item Description 9.9 * O-ring 9.10 * O-ring 9.11 * Q-ring 9.12 * O-ring 9.13 * Seal ring 9.14 * O-ring 9.15 * O-ring 9.16 * Seal ring Upper bearing Cover retaining ring...
  • Page 116 Section 13: Parts List and Drawings Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Item Description 50 * Power card Column Screw 53 * Processor card Power card cover (only for models 010, 020, 030) Local interface assembly Screw Screw 59 * Terminal board Circlip...
  • Page 117 Installation, Operation and Maintenance Manual Section 13: Parts List and Drawings VCIOM-08500-EN December 2019 Figure 90 Electric Motor 25.1 25.2 25.3 25.4 25.5 25.6 25.7 25.8 25.1 25.2 25.3 25.4 Table 22. Electric Motor Item Description 25.1 * Electric motor 25.2 Speed magnetic sensor 25.3...
  • Page 118 Section 13: Parts List and Drawings Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 91 Electric Motor (ICON LP) Table 23. Electric Motor (ICON LP) Item Description Material 25.1 * Electric motor 25.2 Flange Carbon steel 25.3 Screw Stainless steel 25.4 Motor coupling Carbon steel...
  • Page 119 Installation, Operation and Maintenance Manual Section 13: Parts List and Drawings VCIOM-08500-EN December 2019 Figure 92 Finger Assembly 29.1 29.2 29.3 29.4 29.5 29.6 29.7 29.1 Table 25. Finger Assembly Item Description 29.1 Circlip 29.2 Cover finger 29.3 Finger 29.4 29.5 Bending spring 29.6...
  • Page 120 Section 13: Parts List and Drawings Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 93 Lever Assembly 36.1 36.2 36.3 36.4 36.5 36.6 36.7 Table 26. Lever Assembly Item Description 36.1 Lever 36.2 36.3 Shoulder washer 36.4 Bearing 36.5 Spring 36.6 Retainer ring...
  • Page 121 Installation, Operation and Maintenance Manual Section 13: Parts List and Drawings VCIOM-08500-EN December 2019 Figure 94 Local Interface Assembly 55.1 55.2 55.3 55.4 55.5 55.6 Table 27. Local Interface Assembly Item Description 55.1 Ball 55.2 Spring 55.3 O-ring 55.4 Selector 55.5 Screw 55.6...
  • Page 122 Section 13: Parts List and Drawings Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure 95 Thrust Block Assembly 75.1 75.2 75.3 75.4 75.5 75.6 75.7 75.8 Table 28. Thrust Block Assembly Item Description 75.1 O-ring 75.2 Thrust block housing 75.3* Greaser 75.4...
  • Page 123 Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 Figure 96 Wiring Loom and Cables Identification Table 29. Wiring Loom and Cables Identification Item Cable Type Description CAB0100 I/O remote cable CAB0150 Remote control supply cable CAB0160 Inlet power cable CAB0270 Motor power cable CAB0350...

  • Page 124: Appendix A: Icon3000 / Icon3000Ad

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Appendix A: ICON3000 / ICON3000AD Ex db eb h IIB+H2 T4 Gb / Ex h tb IIIC T135°C Db IP66/68 Ex db eb h ia IIB+H2 T4 Gb / Ex h tb IIIC T135°C Db IP66/68 Safety Instructions A.1.1 General...

  • Page 125: Marking

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 A.2.1 Marking Figure A-1 Template of the label for ICON3000 / ICON3000AD IECEx INE YY.NNNNX = IECEx reference certificate (CoC) INERIS YY ATEX NNNNX = ATEX reference certificate 0080 = Notified body for ATEX quality assurance (INERIS) = Group II (surface industries) = Category 2 apparatus = Explosive atmospheres caused by gas, mists, or vapors...

  • Page 126: Applicable General Standards And Regulations

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Applicable General Standards and Regulations Table A-3. 2006/42/EC Machinery directive 2014/30/EU EMC directive 2014/35/EU Low voltage directive 2014/34/EU ATEX directive Safety of machinery - Basic concepts, general principles for design. EN ISO 12100-1 Part 1 - Basic terminology, methodology.

  • Page 127: Storage And Pre-Installation

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 Storage and Pre-Installation A.6.1 Storage Procedure NOTICE Not following the procedures according to this document will invalidate the product warranty. The standard plastic plugs used to protect the conduit entries during transport are neither explosion-proof nor waterproof;...

  • Page 128: Identification Of Entries

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN A.7.2 Identification of Entries The ICON3000 electric actuator as it pertains to this appendix can be equipped with up to 5 conduit entries (3 are standard; the 4th and 5th are supplied upon request). With reference to Figure A-2, the thread form/size for each entry is as follows: Table A-4.

  • Page 129: Electrical Connections

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 A.7.3 Electrical Connections External wires or connections of external ATEX-certified apparatus via the conduit entry of an additional extension must be wired to the internal cards of the ICON3000, in accordance with the wiring diagram and general instructions on the actuator label. A.7.3.1 Connection for Ex-e Terminals Enclosure The wires must be terminated in accordance with the following method:...

  • Page 130: Installation In Environments With Explosive Dusts

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN NOTICE The cables and cable glands MUST be selected considering the maximum temperature of the cable indicated on the label fixed to the base ICON3000 unit. When selecting cables and cable glands, the maximum temperature of the cable (indicated on the product label of the base ICON3000) must be considered.

  • Page 131: Periodic Inspection

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 A.8.1 Periodic Inspection • Inspect the general condition of the ICON3000/3000AD at regular intervals. The recommended frequency of inspection is once every two years but this frequency could change depending on the installation and working conditions. Any crack on the surface, broken windows, or loose bolts must be reported for repair.

  • Page 132: Repairs

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN A.8.3 Repairs When needed, repairs may only be carried out using spare parts supplied by the manufacturer. All accessories must comply with approved specifications and follow the application and site requirements.  ...

  • Page 133: Appendix B: Icon3000 / Icon3000Ad / Icon3000Lp

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 Appendix B: ICON3000 / ICON3000AD / ICON3000LP Ex db h IIB T4 Gb / Ex h tb IIIC T135°C Db IP66/68 Ex db h ia IIB T4 Gb / Ex h tb IIIC T135°C Db IP66/68 Safety Instructions B.1.1 General...

  • Page 134: Identification Of Main Parts

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN B.1.2 Identification of Main Parts Figure B-1 Base Unit Figure B-2 Base Unit with Extension [A] Figure B-3 Base Unit with Extensions [B] or [C] Appendix...

  • Page 135: Instructions For Proper Installation

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 Instructions for Proper Installation   WARNING Before installation, it is mandatory to check if the nameplate associated with the extension for additional entry specifies the appropriate degree of protection and ambient temperature limits as requested by the rules applicable to the plant/location where the ICON3000 is installed.

  • Page 136: Applicable General Standards And Regulations

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Table B-1. Hazardous zone Categories according to 2014/34/EU Directive Gas, mists, or vapors Zone 0 Gas, mists, or vapors Zone 1 2G or 1G Gas, mists, or vapors Zone 2 3G or 2G or 1G Dust Zone 20 Dust...

  • Page 137: Terms And Conditions

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 Terms and Conditions Emerson guarantees every product to be free from defects and to conform to industry standards. Unless otherwise specified, the warranty period is one year from the date of installation by the first user or eighteen months from the date of shipment to the first user, whichever occurs first.

  • Page 138: Checks To Be Performed Before Installation

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN B.6.2 Checks to be Performed Before Installation Before installing extensions for additional entries or additional electronic cards on a base ICON3000 unit, the following checks are recommended: • Condition of joint surfaces between compartment covers and the main housing. •...

  • Page 139: Identification Of Entries

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 B.7.1.2 Base Unit With Extensions [A] or [B] or [C] When an extension is installed on a base ICON3000 unit, the whole assembly is suitable for the following ambient temperatures: ICON-010 and ICON-020 from –...
  • Page 140 Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure B-5 Base Actuator XTE3000 B.7.2.2 Base Actuator With Extension [A] on the Control Compartment Extension [A] provides an additional entry for a cable or conduit connection or for connection of an external ATEX-certified apparatus. With reference to Figure B-6, the thread form/size for the entry is as follows: Table B-5.
  • Page 141 Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 B.7.2.3 Base Actuator with Extensions [B] or [C] on the Terminal Board Compartment Extension B provides up to 9 additional entries for cable or conduit connection. Extension [C] is equipped with an electronic card (Profibus or Lonworks Removable Connection Modules) and provides up to 6 additional entries.

  • Page 142: Electrical Connections

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN B.7.3 Electrical Connections External wires or connections of external ATEX-certified apparatus via the conduit entry of an additional extension must be wired to the internal cards of the ICON3000, in accordance with the wiring diagram and general instructions on the actuator label. B.7.3.1 Connection for Ex-e Terminals Enclosure The wires must be terminated in accordance with the following method:...

  • Page 143: Installation In Environments With Explosive Dusts

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 Figure B-8 Internal earth stud External earth stud B.7.5 Installation in Environments with Explosive Dusts Special attention must be paid to the following points: • Before assembly, joint surfaces must be greased with Aeroshell grease. •...

  • Page 144: Disassembly And Re-Assembly

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN B.8.2 Disassembly and Re-assembly   CAUTION Using a fastener other than the approved type may result in damage to the actuator or valve. Refer to Table 7.   CAUTION Failure to use proper torque values can result in damage to the actuator and/or valve. If disassembly and subsequent re-assembly of the explosion-proof enclosure is required, take the necessary care to maintain all parts in their original condition.

  • Page 145: Appendix C: Icon3000 / Icon3000Ad

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 Original spare parts must be ordered from the manufacturer; to ensure that correct spares are provided, the serial number printed on the ICON3000 product label must be specified when an order for spares is placed. Appendix C: ICON3000 / ICON3000AD Ex db h IIC T4 Gb / Ex h tb IIIC T135°C Db IP66/68 Ex db h ia IIC T4 Gb / Ex h tb IIIC T135°C Db IP66/68...

  • Page 146: Marking

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN NOTICE Check that the label (as shown by the example Figure C-1) is fixed to the unit and is complete with all the appropriate information. C.2.1 Marking Figure C-1 Template of the label for ICON3000 IECEx INE YY.NNNNX = IECEx reference certificate (CoC) INERIS YY ATEX NNNNX = ATEX reference certificate...

  • Page 147: Applicable General Standards And Regulations

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 Applicable General Standards and Regulations Table C-3. 2006/42/EC Machinery directive 2014/30/EU EMC directive 2014/35/EU Low voltage directive 2014/34/EU ATEX directive Safety of machinery - EN ISO 12100-1 Basic concepts, general principles for design. Part 1 - Basic terminology, methodology.

  • Page 148: Storage And Pre-Installation

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Storage and Pre-Installation C.6.1 Storage Procedure NOTICE Not following the procedures according to this document will invalidate the product warranty. The standard plastic plugs used to protect the cable entries during transport are neither explosion-proof nor waterproof;...

  • Page 149: Identification Of Entries

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 C.7.1.1 Models and Temperature ICON-010 and ICON-020 from -60°C to +85°C (from -76°F to +185°F) C.7.2 Identification of Entries The ICON3000 electric actuator is equipped with 5 entries (3 are standard; the 4th and 5th are supplied upon request).

  • Page 150: Electrical Connections

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN C.7.3 Electrical Connections The electrical connections shall be made in accordance with the wiring diagram and to the general instructions associated with the documentation of the base unit. C.7.3.1 Connection for Ex-e Terminals Enclosure The wires must be terminated in accordance with the following method: Type of terminal: Insulated ring tongue...

  • Page 151: Installation In Environments With Explosive Dusts

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 To guarantee that weather-proof and explosion-proof characteristics are maintained, screw the cable gland or the external ATEX-certified apparatus tightly (at least 5 turns of engagement) and coat them with a thread sealant. NOTICE The cables and cable glands MUST be selected considering the maximum temperature of the cable indicated on the label fixed to the base ICON3000 unit.

  • Page 152: Disassembly And Re-Assembly

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN C.8.2 Disassembly and Re-assembly   CAUTION Using a fastener other than the approved type may result in damage to the actuator or valve. Refer to Table 7.   CAUTION Failure to use proper torque values can result in damage to the actuator and/or valve. If disassembly and subsequent re-assembly of the explosion-proof enclosure is required, take the necessary care to maintain all parts in their original condition.

  • Page 153: Appendix D: Icon3000

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 Appendix D: ICON3000 Ex db eb h IIC T4 Gb / Ex h tb IIIC T135°C Db IP66/68 Ex db eb h ia IIC T4 Gb / Ex h tb IIIC T135°C Db IP66/68 Safety Instructions D.1.1 General...

  • Page 154: Identification Of Main Parts

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN D.1.2 Identification of Main Parts Figure D-1 Base Unit Figure D-2 Base Unit with Extension [A] Figure D-3 Base Unit with Extensions [B] or [C] Appendix...

  • Page 155: Instructions For Proper Installation

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 Instructions for Proper Installation   WARNING Before installation, it is mandatory to check if the nameplate associated with the extension for additional entry specifies the appropriate degree of protection and ambient temperature limits as requested by the rules applicable to the plant/location where the ICON3000 is installed.

  • Page 156: Applicable Directives, General Standards, And Norms

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Table D-1. Hazardous zone Categories according to 2014/34/EU Directive Gas, mists, or vapors Zone 0 Gas, mists, or vapors Zone 1 2G or 1G Gas, mists, or vapors Zone 2 3G or 2G or 1G Dust Zone 20 Dust...

  • Page 157: Manufacturer's Liability

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 Manufacturer's Liability Emerson will not accept any liability in the event of: • Use of product in a fashion that contravenes local safety at work legislation. • Incorrect installation relating to, disregard for, or incorrect application of the instructions as provided on the product nameplate and in the Installation, Operation, and Maintenance Manual MAN-02-04-97-0713 and Appendix D within.

  • Page 158: Installation

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Installation NOTICE Installation must be carried out in accordance to the applicable standards IEC/EN 60079-14 and IEC/EN 60079-17 regarding the electrical installations in Hazardous Areas (other than mines) classified as Zones 1, 2 (gas) and Zones 21, 22 (dust) following IEC/EN 60079-10-1 and IEC/EN 60079-10-2 and any other applicable national standards and rules.
  • Page 159 Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 Figure D-5 Base Actuator Base actuator with extensions [B] or [C] on the terminal board compartment Entries from A to K NOTICE When alternative entries according to ISO 965 are used, indication of the dimensions is imprinted on the adapter bush or directly on the housing when ISO 965 entries are created by machining the housing.

  • Page 160: Electrical Connections

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN D.7.2.3 Base Actuator with Extensions [B] or [C] on the Terminal Board Compartment Extension B provides up to 9 additional entries for cable or conduit connection. Extension [C] is equipped with an electronic card (Profibus or Lonworks Removable Connection Modules) and provides up to 6 additional entries.

  • Page 161: Cable Connection

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 D.7.4 Cable Connection When optional extensions for additional entries or additional electronic cards are connected to external cables or conduits, the sealing of these entries must be carried out in accordance with the national standards or regulatory authorities that certified the extension(s).

  • Page 162: Installation In Environments With Explosive Dusts

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN D.7.5 Installation in Environments with Explosive Dusts Special attention must be paid to the following points: • Before assembly, joint surfaces must be greased with Aeroshell grease. • The cable glands must at a minimum possess a protection degree of IP66 or IP68 (15 m depth / 90 hours) according to IEC/EN 60529 standard.

  • Page 163: Repairs

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019   CAUTION Failure to use proper torque values can result in damage to the actuator and/or valve. If disassembly and subsequent re-assembly of the explosion-proof enclosure is required, take the necessary care to maintain all parts in their original condition. To achieve this, the following steps must be taken: •...

  • Page 164: Appendix E: Icon3000

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Appendix E: ICON3000 Ex db eb h IIB T4 Gb / Ex h tb IIIC T135°C Db IP66/68 Ex db eb h ia IIB T4 Gb / Ex h tb IIIC T135°C Db IP66/68 Safety Instructions E.1.1 General...

  • Page 165: Identification Of Main Parts

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 E.1.2 Identification of Main Parts Figure E-1 Base Unit Figure E-2 Base Unit with Extension [A] Figure E-3 Base Unit with Extensions [B] or [C] Appendix...

  • Page 166: Instructions For Proper Installation

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Instructions for Proper Installation   WARNING Before installation, it is mandatory to check if the nameplate associated with the extension for additional entry specifies the appropriate degree of protection and ambient temperature limits as requested by the rules applicable to the plant/location where the ICON3000 is installed.

  • Page 167: Applicable General Standards And Regulations

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 Table E-1. Hazardous zone Categories according to 2014/34/EU Directive Gas, mists, or vapors Zone 0 Gas, mists, or vapors Zone 1 2G or 1G Gas, mists, or vapors Zone 2 3G or 2G or 1G Dust Zone 20 Dust...

  • Page 168: Terms And Conditions

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Terms and Conditions Emerson guarantees every product to be free from defects and to conform to industry standards. Unless otherwise specified, the warranty period is one year from the date of installation by the first user or eighteen months from the date of shipment to the first user, whichever occurs first.

  • Page 169: Checks To Be Performed Before Installation

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 E.6.2 Checks to be performed before installation Before installing extensions for additional entries or additional electronic cards on a base ICON3000 unit, the following checks are recommended: • Condition of joint surfaces between compartment covers and the main housing. •...
  • Page 170 Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN Figure E-5 Base Actuator NOTICE When alternative entries according to ISO 965 are used, indication of the dimensions is imprinted on the adapter bush or directly on the housing when ISO 965 entries are obtained by machining the housing.
  • Page 171 Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 E.7.2.3 Base Actuator with Extensions [B] or [C] on the Terminal Board Compartment Extension B provides up to 9 additional entries for cable or conduit connection. Extension [C] is equipped with an electronic card (Profibus or Lonworks Removable Connection Modules) and provides up to 6 additional entries.

  • Page 172: Electrical Connections

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN E.7.3 Electrical Connections External wires or connections of external ATEX-certified apparatus via the conduit entry of an additional extension must be wired to the internal cards of the ICON3000, in accordance with the wiring diagram and general instructions on the actuator label. E.7.3.1 Connection for Ex-e Terminals Enclosure The wires must be terminated in accordance with the following method:...

  • Page 173: Installation In Environments With Explosive Dusts

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 Figure E-7 Internal earth stud External earth stud E.7.5 Installation in Environments with Explosive Dusts Special attention must be paid to the following points: • Before assembly, joint surfaces must be greased with Aeroshell grease. •...

  • Page 174: Disassembly And Re-Assembly

    Appendix Installation, Operation and Maintenance Manual December 2019 VCIOM-08500-EN E.8.2 Disassembly and Re-assembly   CAUTION Using a fastener other than the approved type may result in damage to the actuator or valve. Refer to Table 7.   CAUTION Failure to use proper torque values can result in damage to the actuator and/or valve. If disassembly and subsequent re-assembly of the explosion-proof enclosure is required, take the necessary care to maintain all parts in their original condition.

  • Page 175: Repairs

    Installation, Operation and Maintenance Manual Appendix VCIOM-08500-EN December 2019 E.8.3 Repairs When needed, repairs may only be carried out using spare parts supplied by the manufacturer. All accessories must comply with approved specifications and follow the application and site requirements.  ...
  • Page 177 ©2019 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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