ICON2000

2000

MAN 618

INSTRUCTION HANDBOOK MAN 618

ICON2000
!@#$ flow control

Electric actuator

Section 618/1
General instructions for installation
page 5

Section 618/2
Operation and configuration
page 27

Section 618/3
Maintenance and trouble-shooting
page 73

Section 618/4
Spare parts and drawings
page 87

NOTES: BIFFI Italia has taken every care in collecting and verifying the documentation contained in this instruction and operating manual. Nevertheless Biffi Italia does not provide any guarantees for this instruction manual. BIFFI Italia will not be responsible for any mistakes contained in it or for any damage either accidental or due to the use of this manual. The information herein contained is reserved property of BIFFI Italia and is subject to being modified without notice.

A !@#$ INTERNATIONAL LTD. COMPANY Section 618/1 Contents may change without notice.“ICON2000” instruction and operating manual Section 618/1 4 © Copyright by BIFFI Italia. . All rights reserved.

.... Lubrication inspection.....................................................7 1.................. Tests to be carried out when the actuator is received............... Working condition.......................................................................................... Storage procedure............................. Terminal board.....8 CHAPTER “B” STORAGE AND PRE-INSTALLATION........ Instructions for the explosion-proof enclosures........................9 2................................................................. Cable entries..................................... All rights reserved.............................................................9 1.................................. Coupling block: disassembly from the actuator.......20 7..................................................18 5...................................... Checks to be performed before installation........................23 10................................................................23 CHAPTER “D” LUBRICATION......................................... Terms and conditions.......................................................... Mounting the actuator onto the valve...................25 Contents may change without notice.......................................................................... Manual operation......................................................................................... Electrical connections..........17 4...8 3................................25 1..13 3............................................................................................... COMPANY Section 618/1 5 Section 618/1 ...................................... Applicable standards and regulations.............................................. Installation in environment with explosive dusts..................22 9.... © Copyright by BIFFI Italia...........................................................................7 2............................................20 6............................... Removing the electrical enclosures’ covers.........................................“ICON2000” instruction and operating manual !@#$ flow control Section 618/1 General instructions for installation INDEX CHAPTER “A” GENERAL SAFETY INSTRUCTIONS..........9 3..................................21 8..............................................................................................11 CHAPTER “C” INSTALLATION.................................. A !@#$ INTERNATIONAL LTD...........13 2............. Safety instructions for installation in hazardous area..................13 1...........................

A !@#$ INTERNATIONAL LTD.“ICON2000” instruction and operating manual Section 618/1 6 © Copyright by BIFFI Italia. COMPANY Section 618/1 Contents may change without notice. . All rights reserved.

Safety instructions for installation in hazardous area Warning: In case the electric actuator must be installed in an HAZARDOUS AREA. They are suitable for use in hazardous area classified against the risk of explosion due to the presence of gas and dust. A !@#$ INTERNATIONAL LTD.1 MARKING XX ATEX ZZZZ 0080 II 2 G D IP 68 Contents may change without notice. maintenance and repair works are carried out by qualified personnel and checked by responsible Specialists. Actuators have IP 68 degree of protection according to EN 60529. All rights reserved. = ATEX REFERENCE CERTIFICATE = notified body for ATEX quality assurance (INERIS) = group II (surface) = category 2 apparatus = explosive atmospheres caused by gas. COMPANY 7 Section 618/1 It is assumed that the installation. . as defined by the local Rules. 618/1 page 2) • the plant specific regulations and requirements (see Sect. Standard reference ISO 11202 (1st ed. it is mandatory to check if the nameplate of the electric actuator specifies the appropriate degree of protection. Electric actuators ICON2000 have been designed and manufactured according to EN 50014 / 50018 / 50281-1-1 standards. gloves) • the proper use of tools. designed for use in heavy industrial.“ICON2000” instruction and operating manual GENERAL SAFETY INSTRUCTIONS This Instruction Manual applies to ICON2000 electric actuators. petrochemical plants. A 1. Maintenance and repair works must be carried out by qualified personnel and checked by responsible Specialists. 1. A © Copyright by BIFFI Italia. commissioning. The noise emitted by the electric actuator in normal working conditions is less than 66 dB (A) with peak value 115 dB (C). 1995-12-15). mists or vapors = explosive atmospheres caused by dusts = degree of protection Section 618/1 chapt.. type of protection EEx d IIB TXX??. lifting and transport equipment. setting. chemical. Warning: CHAPTER The electric actuators are designed in accordance with the applicable International Rules and Specifications but the following Regulations must be observed in any case: • the general installation and safety regulations (see Sect.618/1 page 2) • the proper use of personal protective devices (glasses. clothing.

The warranty period is one year from the date of installation by the first user. Part 2Technical principles and specification. general principles for design.Basic concepts. EEC 73/23: Low voltage directive. Terms and conditions Biffi guarantees each single product to be free from defects and to conform to current goods specifications. general principles for design.General requirements. Repair work due to improper use will be charged at standard rates. or eighteen months from the date of shipment to the first user. No warranty is given for products or components (such as electric or pneumatic mechanisms) manufactured by third-party companies. EN 292/2: Safety of machinery . Part 1-Basic terminology. improper installation. whichever occurs first. mists or vapours Gas. Applicable standards and regulations EN 292/1: Safety of machinery . mists or vapours Gas.Basic concepts. EEC 98/37: Machinery directive. EEC 89/336: EMC Directive ATEX 94/9 EEC Directive Section 618/1 3. All rights reserved. A !@#$ INTERNATIONAL LTD. Internal gears Handwheel Internal sensor Terminal box Engagement lever Electric motor Local interface 8 © Copyright by BIFFI Italia.“ICON2000” instruction and operating manual Hazardous zone Gas. corrosion. En 60204/1: Electrical equipment of industrial machines. mists or vapours Dust Dust Dust Zone 0 Zone 1 Zone 2 Zone 20 Zone 21 Zone 22 Categories according to 94/9/CE Directive 1G 2G 3G 1D 2D 3D 2. COMPANY Section 618/1 chapt. . or for goods which have been subject to misuse. A Contents may change without notice. Part 1. or which have been modified or repaired by unauthorised personnel. methodology.

618/2 chapt. they just prevent the entry of undesired objects during transport.“ICON2000” instruction and operating manual STORAGE AND PRE-INSTALLATION 1. proper procedures must be taken for preservation during the storage period. especially to the push-buttons. Tests to be carried out when the actuator is received If the actuator is received already mounted on the valve. B 9 Section 618/1 . all operations should have already been performed during valve/actuator assembly. Contents may change without notice. COMPANY Section 618/1 chapt. as guaranteed by an individual test certificate. © Copyright by BIFFI Italia. .Check the information on the nameplate: serial number and performance data (nominal torque. .Check that the display is active. Storage procedure Important: Not performing the following procedures will invalidate the product guarantee. all operations described in this manual must be carried out. If the actuator is delivered separately from the valve. If the test result is satisfactory.). the display area glass and the selector. In order to maintain these characteristics until the actuator is installed on site.check that the display reads 0% indicating that the valve is completely closed. the actuator has already been adjusted and you can proceed with the electrical connection. . BIFFI actuators are weatherproof to IP 68. or the above procedure shows that the position is incorrect. L). as described in the delivery documentation. etc.check that the display reads 100% indicating that the valve is completely open. A !@#$ INTERNATIONAL LTD. The standard plastic plugs used to close the cable entries are not weatherproof. motor supply voltage. This condition can only be maintained if the units are correctly installed/connected on site and if they have been correctly stored.Check that no damage has occurred during transport.Turn the handwheel until the valve is in a completely open position.rotate the handwheel clockwise and bring the valve to a completely closed position. operation speed. . Make sure all accessories have been received with the shipment. 2. . and verify the corresponding data on the display (see sect. CHAPTER B 2. . All rights reserved. protection class.1 GENERAL The actuator leaves the factory in perfect condition. .

2.2 STORAGE FOR A BRIEF PERIOD (less than one year): 2.In case the actuator is provided with an alkaline battery. 618/3 chapt. 2.if the actuators are supplied with standard plastic plugs. All rights reserved. . .make sure that the actuators are protected from the direct action of weather agents (protection by a canvas tarp or similar cover). so that they are not in direct contact with the ground.2. remove it and store in dry and clean place (see Sect. or some other raised platform. Section 618/1 2. 618/3 chapt.2 OUTDOOR STORAGE: .place the actuators on a wooden pallet.1 INDOOR STORAGE: In addition to the instructions at point 2.make sure that the actuators are kept in a dry place.“ICON2000” instruction and operating manual 2. M par. B Contents may change without notice.1 INDOOR STORAGE: . laid on a wooden pallet and protected from dust.2. COMPANY Section 618/1 chapt.check the general conditions of the actuator. M par. paying particular attention to the terminal board.2.2): . A !@#$ INTERNATIONAL LTD. 3) 2. replace them with weatherproof plugs.if the actuators are supplied with standard plastic plugs. remove them from the cable entries and replace them with weatherproof plugs.In case the actuator is provided with an alkaline battery. remove it and store in dry and clean place (see Sect.3. .3 LONG PERIOD STORAGE (more than one year): 2. fuse enclosure and local display glass. 3) 10 © Copyright by BIFFI Italia. . .1): .2 OUTDOOR STORAGE: In addition to point 2.3.

check the oil level in the actuator and top up if necessary.The electrical supply cables must be suitable for the power rating (see the test certificate that comes with the actuator). If a long storage period has occurred.Make sure the valve to be motorised is the appropriate one for coupling to the actuator . .check the installation of the plugs or cable glands on the cable entries. please: . .check the status of the O-ring seals. A !@#$ INTERNATIONAL LTD. M par. COMPANY Section 618/1 chapt. before reinstalling the actuator. .618/3 chapt. . B 11 Section 618/1 . .Gather the right tools for the assembly and for setting the actuator controls. © Copyright by BIFFI Italia. Checks to be performed before installation . Contents may change without notice.put the batteries back into place (see Sect.check whether the enclosure covers or the actuator body are cracked or broken.3). All rights reserved.“ICON2000” instruction and operating manual 3.

“ICON2000” instruction and operating manual

Section 618/1

12

© Copyright by BIFFI Italia. All rights reserved. A !@#$ INTERNATIONAL LTD. COMPANY

Section 618/1 chapt. B

Contents may change without notice.

“ICON2000” instruction and operating manual

INSTALLATION
1. Working condition
The standard actuators are suitable for the following environment temperatures: -30°C +85°C (-22°F to +185°F) Special versions are available for extreme environment temperatures: -40°C +70°C (-40°F to +158°F) -55°C +70°C (-67°F to +158°F)

Important:

Check the "temperature environment range" embossed on the nameplate, for the correct utilisation with respect to the environment temperature.

CHAPTER

C

2. 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. Actuator view from the coupling side, with the block separated from the gearbox. Do not lose the seal ring between the coupling block and the gear reduction unit.

Contents may change without notice.

© Copyright by BIFFI Italia. All rights reserved. A !@#$ INTERNATIONAL LTD. COMPANY

Section 618/1 chapt. C

13

Section 618/1

“ICON2000” instruction and operating manual
2.1 TYPE “A” COUPLING BLOCK
2.1.1 PREPARING THE BUSHING

Section 618/1

With a compass key, unscrew the lower ring nut. Extract the stem nut from the block housing.

The internal thrust bearing will remain at the bottom of the block housing.

Now the bore can be machined in the stem nut to suit coupling requirements. The same procedure is also used for possible maintenance.

Important:

Before re-mounting the stem nut, make sure the coupling tolerances to the valve stem are correct. The threaded stem nut must be checked either with a thread gauge or with the stem of the valve to be motorised by screwing it all along the valve stem without excessive friction.

14

© Copyright by BIFFI Italia. All rights reserved. A !@#$ INTERNATIONAL LTD. COMPANY

Section 618/1 chapt. C

Contents may change without notice.

618/1 chapt. Now the bore can be machined in the bushing to suit coupling requirements. make sure that there are no metal filings or foreign bodies. Proceed with the assembly of the internal parts following the reverse order of the disassembly. see Sect. A !@#$ INTERNATIONAL LTD. fix the unit to the gear reducer as described further on. Proceed with the assembly of the internal parts following the reverse order of the disassembly. making sure the stem nut still rotates freely. tighten the lower ring nut with thread sealant LOCTITE 270 or equivalent.2 RE-ASSEMBLING THE INTERNAL PARTS It is advisable to wash the dismantled parts with a suitable solvent. dry them with compressed air.2. dry them with compressed air. © Copyright by BIFFI Italia. The same procedure is also used for possible maintenance. Contents may change without notice. fix the unit to the gear reducer as described further on. Extract the bushing from the block housing. 618/1 chapt. spread a film of grease on all parts (for grease type. The internal thrust washer will remain at the bottom of the block housing.2. C 15 Section 618/1 2.2. D). spread a film of grease on all parts (for grease type.2 TYPE “B1” AND “B2” COUPLING BLOCKS . tighten the lower ring nut with thread sealant LOCTITE 270 or equivalent.“ICON2000” instruction and operating manual 2.1 PREPARING THE BUSHING With a compass key. 2.1. All rights reserved. 2. unscrew the lower ring nut. D). COMPANY Section 618/1 chapt. see Sect. make sure there are no metal filings or foreign bodies. RE-ASSEMBLING THE INTERNAL PARTS It is advisable to wash the dismantled parts with a suitable solvent. making sure the bushing still rotates freely.

1 PREPARING THE BUSHING Remove the fixing screws of the coupling flange. . Section 618/1 Remove the circlip by means of suitable pliers. spread a film of grease on all parts (for grease type see Sect. Make sure the lugs of the drive sleeve fit in the correct slots on the bushing. 618/1 Chap D).3 TYPE “B3” AND “B4” COUPLING BLOCKS 2. C Contents may change without notice. COMPANY Section 618/1 chapt. 2.4 FIXING THE COUPLING BLOCK TO THE GEAR REDUCTION UNIT Check the integrity of the O-ring seal and place it in its slot on the coupling block.2 RE-ASSEMBLING THE INTERNAL PARTS It is advisable to wash the dismantled parts with a suitable solvent.“ICON2000” instruction and operating manual 2.3. make sure there are no metal filings or foreign bodies. 16 © Copyright by BIFFI Italia. Remove the carbon steel thrust ring. dry them with compressed air. Extract the bushing and machine it according to the mating needs. 2. Fix the screws previously removed. Remove the flange and the bush. All rights reserved. A !@#$ INTERNATIONAL LTD.3. Proceed with the assembly of the internal parts following the reverse order of the disassembly. Fix the unit to the gear reducer as described further on.

Then let the lever automatically return to its rest position. Manual operation Engagement lever locked in motor operation position: the manual operation cannot be engaged. © Copyright by BIFFI Italia. Engagement lever locked in handwheel operation position: the operation with electric motor is mechanically disengaged. COMPANY Section 618/1 chapt. slowly rotate the handwheel and repeat the operation.“ICON2000” instruction and operating manual 3. To engage manual operation. Rotate the handwheel to obtain the desired operation (normally clockwise rotation to close the valve). If no engagement is obtained. Using cheater bars. All rights reserved. C 17 Section 618/1 . or other such devices on the actuator handwheel or declutch lever may cause serious personal injury and/or damage to the actuator or valve Contents may change without notice. wheel wrenches. depress (by 20°-30°) the lever in the direction shown on the photo. pipe wrenches. Warning: Do not manually operate the actuator with devices other than the handwheel and the declutch lever. A !@#$ INTERNATIONAL LTD. and this excludes unwanted local operations.

When mounted upside down. the end of the stem cover tube should be drilled Ø5 mm to avoid build up of service fluid or rainwater. Lift the actuator with slings suitable for its weight. Size 010 020 030 040 050 Max. . YES NO Warning: Never use the handwheel to lift the actuator. degreasing them carefully since torque is transmitted by friction. A !@#$ INTERNATIONAL LTD. The actuator will operate satisfactorily in any position. COMPANY Section 618/1 chapt.“ICON2000” instruction and operating manual 4. Thoroughly clean the coupling surfaces of the valve and actuator flanges. All rights reserved. weight 32 Kg 38 Kg 46 Kg 56 Kg 73 Kg Section 618/1 Warning: Never lift the valve/actuator assembly without securing slings to both the valve and the actuator. C Contents may change without notice. 18 © Copyright by BIFFI Italia. Mounting the actuator onto the valve Lubricate the valve stem.

“ICON2000” instruction and operating manual 4.3 ACTUATOR FIXING Important: In case the actuator is supplied without stud bolts and nuts the following materials must be used as a minimum: . All rights reserved. Carry out the coupling operations (if necessary with the help of manual operation). make sure no mating parts are forced. screw the threaded bushing of the coupling block on the valve stem.8 for studs bolts and nuts or • ASTM A 320 Grade L7 (or L7M) for studs bolts • ASTM A 194 Grade 4 for nuts Model 010 020 030 040 050 Tightening torque 40 Nm 150 Nm 150 Nm 300 Nm 150 Nm Contents may change without notice. rotating (normally counter-clockwise) until the coupling block and flange surfaces of the valve are securely in contact.ISO class 8. engage the manual operation. Engage the manual operation. Place the actuator vertically on the valve stem. COMPANY Section 618/1 chapt. For safety purposes.”B3” AND “B4” Check the dimensions of the valve mounting details. A !@#$ INTERNATIONAL LTD. rotate the handwheel in the opening direction for about two turns in order to lift the valve gate from its seat to avoid (during bolt fixing) excessive axial thrusts on the internal parts of the valve and of the actuator. © Copyright by BIFFI Italia. paying particular attention to the protrusions of the valve stem in order to avoid any axial thrusts to the internal parts of the actuator or the valve when the screws are tightened. 4.2 COUPLINGS TYPE “B1”. “B2”. C 19 Section 618/1 .1 COUPLING TYPE “A” Place the actuator vertically on the stem. 4.

As of 30 June 2003. Biffi will not accept any responsibility for any damage or deterioration that may be caused. 6. Electrical connections Before powering to the actuator check that the supply voltage details on the nameplate are correct for the plant. C Contents may change without notice. The removal of any other covers without Biffi's approval will invalidate the warranty. to protect the mains line in case of motor overcurrent or loss of insulation between phases and earth. magneto-thermal switches or fuses) should be provided on the plant at Customer care. Section 618/1 Important: All the accessories (in particular cable glands) must be certified. Important: In case the screws of the cover must be replaced. .1 TERMINAL BOARD ENCLOSURE Using a 8mm Allen key. a SS AISI 316 must be used with minimum yield strength of 450Nm 2 20 © Copyright by BIFFI Italia.“ICON2000” instruction and operating manual 5. since all settings are non-intrusive. Warning: Do not damage the mating surface of the cover. Removing the electrical enclosures’ covers 6. Access to terminals for electrical connections and commissioning is through the terminal cover.1 PLANTS REQUIREMENTS Protection devices (overcurrent breakers. the above accessories must carry the CE certification conforming with 94/9/CE Directive. 5. COMPANY Section 618/1 chapt. A !@#$ INTERNATIONAL LTD. loosen the four screws and remove the cover. All rights reserved.

A !@#$ INTERNATIONAL LTD. reducers. If some parts of the cable glands have been removed while working on the cable entries put them back into place now to avoid losing the dismantled parts. COMPANY Section 618/1 chapt. This is particularly true for units that are certified for use in hazardous areas where the method of sealing must be to an approved standard. make sure the cable glands have the minimum protection degree required by the plant. C 21 Section 618/1 (cable entries 2x1”+1x11/2”+ (optional) 1x3/4”) (cable entries 2x1”+1x11/2”) (cable entries 2xM32+1xM40) (cable entries 2xPg21+1xPg29) . All rights reserved. • if rigid conduits are used. Contents may change without notice. screw the cable glands tightly (at least 5 turns) and block them with a thread sealant. To guarantee weatherproof and explosionproof fit. Unused entries: • for explosionproof construction: unused entries must be plugged with metal explosionproof plugs and blocked with a thread sealant. Cable entries The sealing of cables and conduit entries should be carried out in accordance with National Standards or the Regulatory Authorities that have certified the actuators. © Copyright by BIFFI Italia.“ICON2000” instruction and operating manual 7. we suggest placing a flexible pipe connection between the conduit and the terminal board. Certified cable entries: • standard Rc ISO7/1 • standard ASA/NPT • metric BS 3643 • Pg DIN 40430 Important: • to prevent any water infiltration through the line cable conduits. and cable glands. plugs and adapters must be approved and separately certified. • for weatherproof construction: replace the plastic standard protection plugs supplied with the actuator with metal plugs. The use of a thread sealant is necessary in case of explosionproof application. Remove the cable entry plugs.

All rights reserved. C Contents may change without notice. COMPANY Section 618/1 chapt. This operation will ensure easy and correct electrical connection. . The internal cables of the actuator are also numbered according to the wiring diagram. Actuators are always delivered with the motors wound and connected in accordance to customer requests. Check the wiring diagram (always enclosed with the actuator) and the layout displayed on the back of the terminals enclosure cover. 22 © Copyright by BIFFI Italia. The control circuit (controls and signals) must be connected by means of a multicore cable to the corresponding numbered terminals according to the wiring diagram.“ICON2000” instruction and operating manual 8. Voltage and frequency values are stated on the motor name-plate. Terminal board Important: The removal of any other covers without Biffi's approval will invalidate the warranty. to ensure a correct electrical connection. All terminations should be made by insulated ring or spade connectors using the appropriate crimping tool. Assemble the power terminals protective barrier. A !@#$ INTERNATIONAL LTD. located in the terminal board compartment.the absorbed current correspondent to the actuator nominal torque with the torque limiting device set at 100 percent (see the test certificate attached to the actuator) . using the enclosed screws. One internal and one external ground studs are provided.the applicable plant and safety norms. Biffi will not accept any responsibility for any damage or deterioration that may occur as a result of cover removal. Section 618/1 Ground studs Terminate the ground connections to the ground stud marked . Connect the motor supply cable previously sized in accordance with: .

joints) be careful to bring these enclosures back to their original condition to maintain their integrity. and block them with a thread sealant after spreading them with a film of copper. Contents may change without notice. Please make sure that: • the joint surfaces are greased with silicon oil or equivalent before assembly • the cable glands have minimum protection degree IP6X (EN 60529) • periodically verify the quantity of dust deposited on the enclosure and clean it if more than 5mm. All rights reserved. Warning: Do not operate the actuator electrically when the electrical enclosures are removed. be sure the joint surfaces of all enclosures are spread with a film of recommended grease (see Sect. 10. Installation in environment with explosive dusts Important: Electric actuator ICON2000 shall be installed and maintained according to the applicable rules regarding the electrical installations in hazardous area (other than mines) classified as zone 21 (dust). or of a better quality. example: EN 60079-10 (hazardous area classification).or molybdenum-based grease. O-ring for the explosionproof joint of the motor). During the dismantling and subsequent reassembling of the explosionproof enclosures (covers. © Copyright by BIFFI Italia. This will keep screws from sticking and make maintenance operations easier. and/or other national standards). • Replace the weatherproof seals that may have been removed (O-ring for the covers. • Reinstall all the screws that go with the dismantled parts. EN 60079-14 (electrical installation). D). example: EN 50281-1-2 (dust) and/or other national standards). A !@#$ INTERNATIONAL LTD.“ICON2000” instruction and operating manual 9. In particular. C 23 Section 618/1 . cable glands. Instructions for the explosionproof enclosures Important: Electric actuator ICON2000 shall be installed and maintained according to the applicable rules regarding the electrical installations in hazardous area (other than mines) classified as zone 1 (gas). So please: • Do not damage the explosionproof mating surfaces on the housing and on the electrical enclosures covers. 618/1 chapt. • Check that the bolts and screws are the same dimension and quality as the original ones (as stated on the nameplate). EN 60079-17 (maintenance). Operating the unit with the electrical enclosures removed could cause personal injury. COMPANY Section 618/1 chapt.

C Contents may change without notice. COMPANY Section 618/1 chapt. A !@#$ INTERNATIONAL LTD. .“ICON2000” instruction and operating manual Section 618/1 24 © Copyright by BIFFI Italia. All rights reserved.

COMPANY Section 618/1 chapt. therefore under normal working conditions it is not necessary to replace or refill the oil. so that any assembly on the valve has at least one oil plug on the upper part of the housing and one on the lower part. 2). 1 2 CHAPTER D The actuator is fitted with oil plugs (parts 1. All rights reserved. However it is recommended to check the oil level every 3-5 years using holes 1 or 2 depending on mounting position. © Copyright by BIFFI Italia. 3 A spherical head lubricator (part 3) is fitted on the coupling block for the proper greasing of the inside thrust or sliding bearings. Lubrication inspection The actuator is lubricated for life. D 25 Section 618/1 .1 4.“ICON2000” instruction and operating manual LUBRICATION 1.8 3. ACTUATOR SIZE 010 020 030 040 050 OIL QUANTITY (l) 0.0 6. The actuator is supplied with oil and greased where necessary. A !@#$ INTERNATIONAL LTD.7 1.5 Contents may change without notice.

COMPANY Section 618/1 chapt. A !@#$ INTERNATIONAL LTD.KLUBERSYNTH EG4-320 Ambient Temperature from -55°C to +65°C • SHELL .“ICON2000” instruction and operating manual In case of maintenance the following oils are recommended: Ambient Temperature from -30°C to +85°C • SHEEL .MADRELA OIL 46 Other equivalent: • SYNECO .WINTER PLUS In case of maintenance the following greases are recommended: Ambient Temperature from -30°C to +85°C • ISO viscosity grade X1 (EP1) Other equivalent: • ESSO BEACON EP1 • AGIP GR MU/EP1 Ambient Temperature from -55°C to +65°C • FUCHS FN20 Other equivalent: • TEXACO low temperature grease EP • AGIP FN20/00 26 © Copyright by BIFFI Italia.GLYGOYLE HE 320 • KLUBER LUBRICATION .TIVELA OIL SC320 Other equivalent: • EXXON TERESSTIC SHP320 Section 618/1 • MOBIL OIL . . All rights reserved. D Contents may change without notice.

..... ...... .. ............ ............. .... ...“ICON2000” instruction and operating manual !@#$ flow control Section 618/2 Operation and configuration INDEX CHAPTER “E” OPERATING THE ICON2000. Local control................. ..... COMPANY Section 618/2 27 Section 618/2 .. ... ...... ............................... ............... .. .............69 1.... ..... .......... ..... .......... ..................................... .......... .. ....... ......... ....... Description of the local operator interface......... Example of view routine.............39 4... .................69 3............. ................................... Actuator set-up....... Lock of the 3-position selector......................... ........ Valve data. ... Valve data.... ...................... ..................................... ................... ................................ ...................67 CHAPTER “L” VIEW ROUTINES........... M a i n t e n a n c e ......... . ..................... ....................... . .................... ..... Local indication...... . ... .. .48 CHAPTER “I” SET-UP ROUTINES............ ............ .. .........................................38 3.... .................................... ........... Actuator set-up............. . Entering the set-up mode.....40 5.......... . . .. ........................ 6 4 4.....69 2..................30 4.......................... ....... Configuration options. ... ..................... .....................44 CHAPTER “H” VIEW MENU... . Electrical operation. ........... .. . .....................29 3.. ...................... ... ........ ............ .31 7... .......... ................. Remote control..................... ......... . Optional modules..... . .......... ........................................... ............ ............. ........... .............. ...... ....40 CHAPTER “G” SET-UP MENU.... ...................... .............53 1.............. .....34 8........ ..... .... ........................35 2...... ...34 CHAPTER “F” LOCAL CONTROLS.......... ........... ............................................64 3.. .......35 1. ............. .. .......... ... Exit from view and set-up modes... ........................................... A !@#$ INTERNATIONAL LTD. 7 0 5........................ M a i n t e n a n c e .................. ........................ Operation by handwheel...................... Example of set-up routine....... ...................... ............................................... Name plate..... .................................... © Copyright by BIFFI Italia.. ..... Operating the ICON2000 for the first time.. ...............................31 6................... ... ............... ..... ......................... . .............. .... ............. ....... ........... .. .... .72 Contents may change without notice....53 2..........29 1... ................ ... .......... .............. .................... .................. ...... All rights reserved....... ........ ............. ........ ............... .... .................... ................... ... ......29 2... ....... ... .. . ...................... ............. .. Entering the view mode... ....... .................................. ........ ...............30 5........... .......... ...........70 4. ............................

“ICON2000” instruction and operating manual

Section 618/2

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Section 618/2

Contents may change without notice.

“ICON2000” instruction and operating manual

OPERATING THE ICON2000
1. Operation by handwheel
To operate the actuator by handwheel, press the lever and at the same time rotate the handwheel until the clutch is engaged. Release the lever and move the valve by handwheel. The actuator will return to electrical operation only by energising the motor.

Warning:

Do not manually operate the actuator with devices other than the handwheel and the declutch lever. Using cheater bars, wheel wrenches, pipe wrenches, or other such devices on the actuator handwheel or declutch lever may cause serious personal injury and/or damage to the actuator or valve.

CHAPTER Section 618/2

E
2. Electrical operation
Before connecting power to the actuator check that the voltage is correct and according to the indications on the nameplate. Wrong power supply could cause a permanent damage to the electrical components. Check of phase rotation is not necessary since the unit is provided with automatic phase rotation correction. Place the 3-position selector in OFF and then switch on the power. Do not operate the actuator without first checking that the configuration is according to the required application. Using the "VIEW and SET-UP" features can do this (see Sect. 618/2 chapt. F par. 4).

Contents may change without notice.

© Copyright by BIFFI Italia. All rights reserved. A !@#$ INTERNATIONAL LTD. COMPANY

Section 618/2 chapt. E

29

“ICON2000” instruction and operating manual 3. Local control
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” was selected the actuator can be driven to the desired position by pressing and holding the OPEN/YES or CLOSE push-button. As the push-button is released, the motor is de-energised. If “latched” was selected, as the OPEN or CLOSE push-button is pressed the motor is energised, and it runs on after the control is released. To stop the motor, press the STOP push-button. To reverse the direction, press the STOP push-button and then press the push-button relevant to the opposite direction. In “latched with instant reverse” mode, the local controls work as in the “latched” mode, but to reverse the motor direction you only need to press the push-button relevant to the opposite direction.

Section 618/2

4. Local indication
The upper display (3-_ LCD) indicates the valve position as a percentage of opening (open = 100%). The lower display has two alphanumeric lines. The upper line indicates the actuator status and the 3-position selector status. The lower line indicates the actuator operation. Two LED’s indicate the actuator position / operation, while a third LED indicates alarms.

30

© Copyright by BIFFI Italia. All rights reserved. A !@#$ INTERNATIONAL LTD. COMPANY

Section 618/2 chapt. E

Contents may change without notice.

6. Local OPEN or CLOSE operation will be inhibited. To reverse the direction.“ICON2000” instruction and operating manual 5. the motor is energised. press STOP. Only local STOP control remains active. COMMON) mode. and it runs on after the signal returns to OFF. max. 4W) is available on the actuator terminal board to supply the remote controls or external devices. Using the "VIEW and SET-UP" features may configure different control modes. A non-regulated 24VDC voltage (variable from 23 to 27 Vdc. CLOSE. 4 WIRES (see the remote connections diagram shown below) In “4 wires latched” (OPEN. 6. The remote controls are opto-coupled. To stop the motor. E 31 Section 618/2 . press STOP and then press the button relevant to the opposite direction. © Copyright by BIFFI Italia. STOP. Remote control Place the 3-position selector in REMOTE to transfer the actuator control to a remote device. A !@#$ INTERNATIONAL LTD. COMPANY Section 618/2 chapt.1 REMOTE COMMANDS Using the "VIEW and SET-UP" features may configure different control modes. Contents may change without notice. Lock of the 3-position selector The 3-position selector can be locked in any of its three positions by means of a padlock. All rights reserved. with the OPEN or CLOSE signal switched to ON.

E Contents may change without notice. The circuits associated to the inputs can be supplied by the internally-generated 24VDC or by an external 20-125VDC or 20-120VAC (50/60Hz). the actuator can be driven in either "push-to-run” or “latched with instant reverse” mode. . the actuator can be driven to the desired position by switching the OPEN or CLOSE signal to ON. A !@#$ INTERNATIONAL LTD. If the signal relevant to the opposite direction goes ON. when the OPEN or CLOSE signal switches to ON. All rights reserved.“ICON2000” instruction and operating manual 3 WIRES (see the remote connections diagram shown below) With option "3 wires" (OPEN. In “latched with instant reverse” mode. the motor is de-energised. In “ push-to-run ” mode. signal ON to open". Section 618/2 2 WIRES (see the remote connections diagram shown below) With the "2 wires" option 2 different activities may be selected: In “2 wires. and it runs on after the signal returns to OFF. the motor is energised. COMMON). the actuator closes if the signal switches to ON and opens if the signal switches to OFF. The signal levels are the following: • Minimum ON signal > 20 VDC or 20 VAC (50/60Hz) • Maximum ON signal < 125 VDC or 120 VAC (50/60Hz) • Maximum OFF signal < 3 VDC or VAC • Minimum signal duration > 300 ms. CLOSE. the actuator opens if the signal switches to ON and closes if the signal goes to OFF. • Total current drawn from remote controls < 25mA 32 © Copyright by BIFFI Italia. COMPANY Section 618/2 chapt. the actuator reverses its direction and maintains the new direction also if the signal returns to OFF. As the signal returns to OFF. In “2 wires. signal ON to close".

2 OUTPUT CONTACTS • Monitor relay: on the terminal board. current 5mA 6. The status of the latching relays is immediately updated as the associated conditions for change occur. Warning: If customers wish the motor thermostat to be by-passed during ESD operation any certification for actuator enclosure in hazardous area would be invalidated. E 33 Section 618/2 . The circuits associated to the input can be supplied by the internally generated 24VDC or by an external 20-125VDC or 20-120VAC (50/60Hz). Min. © Copyright by BIFFI Italia. Moreover. All rights reserved. change-over contacts of the monitor relay are available. A !@#$ INTERNATIONAL LTD. • AS1. The ESD command is opto-coupled. • Contact rating: Max. the ESD action continues until the relevant signal is present. The signal levels are the following: • Minimum ON signal > 20 VDC or 20 VAC (50/60Hz) • Maximum ON signal < 125 VDC or 120 VAC (50/60Hz) • Maximum OFF signal < 3 VDC or VAC • Current drawn from ESD controls < 15mA Contents may change without notice. voltage 250VAC/30VDC.3 ESD OPERATION An ESD (Emergency Shut Down) signal can be sent to the actuator to override any existing command and to drive the valve to a predetermined position. max.3. The status (make or break) and the conditions that cause the switching of the relay can be viewed and configured by using the “VIEW and SET-UP” features. the status of the above contacts is cyclically updated (every 500ms).“ICON2000” instruction and operating manual 6.4 relays: on the terminal board. 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. the voltage-free. The "VIEW and SET-UP" features can configure different ESD options.2. the voltage-free contacts of 4 latching relays are available. COMPANY Section 618/2 chapt. The conditions that cause the relay to switch over are listed in paragraph “Output relays”. that is. min. The control is not self-maintained. voltage 5VDC. current 5A.

“ICON2000” instruction and operating manual 7. . E Contents may change without notice. AS6. remove the alarm before proceeding (see Sect. B par. 8. Operating the ICON2000 for the first time Before attempting to operate the ICON2000 for the 1st time. AS7) • 4-20 mA position and torque retransmission • 4-20 mA position servoamplifier Refer to the specific instruction manuals for the setting of the above modules Section 618/2 34 © Copyright by BIFFI Italia. When the strokes limits and the configurations are correct. Place the 3-position selector in OFF and switch the power on. 3). 1. 618/2 chapt. COMPANY Section 618/2 chapt. 4 & chapt. If the display shows “ALARM OFF”. bring the 3-position selector to LOCAL and drive the actuator to either open or closed position (see Sect.1 and 1. B). B par. 3 & chapt.618/3 chapt.2). A !@#$ INTERNATIONAL LTD. position limits and close direction by means of the “stroke limits routine” of the “actuator set-up” menu (see Sect. Set torque limits. E par. E par. check that the actuator is correctly mounted on the valve. 618/2 chapt. 618/2 chapt. F)). Do not operate the actuator without first checking that the configuration is according to the required application (through the “VIEW and SET-UP” features (see Sect. Optional modules Additional modules can be installed to provide the following functions: • fieldbus interface for remote control via FIELDBUS • 3 auxiliary relays (AS5. Check that the indication in the upper row of the alphanumeric display is “NORMAL OFF". All rights reserved.

COMPANY Section 618/2 chapt. F F Contents may change without notice. Description of the local operator interface The following functions are available by the ICON2000 local operator interface: • actuator control • actuator configuration • actuator status visualisation The figures on the following pages describe the function of each component of the local operator interface CHAPTER Section 618/2 © Copyright by BIFFI Italia. All rights reserved. A !@#$ INTERNATIONAL LTD.“ICON2000” instruction and operating manual LOCAL CONTROLS 1. 35 .

CLOSED. The alarm and warning lists contain the present alarms and warnings. CLOSE/NO.5 to 13. the OPEN / YES and CLOSE / NO push-buttons work as YES and NO to answer the prompt (next? OK? view?. F Contents may change without notice. change? exit?) of the alphanumeric display. the above push-buttons allow scrolling the list of variables. All rights reserved. If the 3-position selector is in REMOTE or in OFF. to view and change the actuator configuration or to scroll the list of variables. but it may be changed (red with green. Local controls: OPEN/YES.7 to 10 000 turns = 0. In OFF. If the 3-position selector is in LOCAL. In REMOTE.). REMOTE) and the actuator action (OPEN. and alarms. the corresponding alarm or warning disappears from the list.2 % • From 27. The STOP push-button resets any existing command and is active both in local and remote. If the local selector is in OFF or REMOTE. and CLOSE /NO push-buttons work as OPEN and CLOSE commands.“ICON2000” instruction and operating manual LOCAL OPERATOR INTERFACE Numeric display to indicate the present valve position as a % of the opening Display resolution in function of the actuator stroke turns: • From 2. and STOP push-buttons. OFF.8 turns = 0.7 turns = 0. STOP). green with red. the 3position selector status (LOCAL. The alarm condition occurs when a variable is out of the acceptable range and the actuator control functions are not available. the OPEN / YES and CLOSE / NO push-buttons allow to scroll down the menu. status. jammed valve. COMPANY Section 618/2 chapt. but the actuator control functions are still available. A !@#$ INTERNATIONAL LTD.1 % Three LED’s to indicate the actuator status according to the following logic: • green ON/ red OFF: the actuator is stopped in open position • green OFF/ red ON: the actuator is stopped in closed position • green OFF/ red flashing: the actuator is running in closing direction • green flashing/ red OFF: the actuator is running in opening direction • green ON/ red ON: the actuator is stopped in intermediate position • yellow ON: alarm • yellow flashing: warning The above colour combination is supplied as standard.5 turns = 1 % • From 5.5 % • From 13. ALARM. OPENING. and alarms.8 to 27. etc. but the actuator configuration cannot be viewed or changed. and yellow with red). 36 © Copyright by BIFFI Italia. CLOSING. A reset routine is provided to clear the alarm / warning that are memorised (over-torque. . pressing the YES push-button it is possible to scroll the list of variables and alarms below: • output torque • motor speed • main voltage supply • motor current • temperature inside the actuator enclosure • time • date • alarm list • warning list The warning condition occurs when a variable reaches a critical value and/or a maintenance action is required. WARNING). When the fault condition disappears. the OPEN / YES. during actuator setting operations open stop Section 618/2 close 3-position selector to set the following operation modes: • LOCAL: for local control only • OFF: no control is active but the actuator is still connected to the mains • REMOTE: for remote control only Alphanumeric display: during normal operation the alphanumeric display shows the present status (NORMAL. status.8 to 5. ESD ON.

...... A !@#$ INTERNATIONAL LTD.... CLOSE and STOP controls available Press YES and STOP simultaneously to enter VIEW and SET-UP menus Press YES or NO to answer the prompt (ok? view? next?) YES to VIEW and SETUP MENUS Place the 3-position selector in LOCAL or REMOTE or press YES and NO simultaneously to exit from VIEW and SET-UP MENUS NO VIEW AND SETUP MENUS xxxxxxx TORQUE xx% MOTOR SPEED xxxx RPM VOLTAGE xxx V CURRENT xxxA TEMPERATURE XX °C TIME DATE ALARMS WARNINGS next? next? next? next? next? next? next? view? view? YES NO NO YES YESY NO YES next? ALARM # 1 ... All rights reserved......... LOCAL OFF REMOTE 3-position selector = OPEN/YES push-button = CLOSE/NO push-button = STOP push-button xxxxxx xxxxxx local next ? xxxxxx STOP OFF next ? xxxxxx xxxxxx REMOTE next ? ALPHANUMERIC DISPLAY Section 618/2 Variable and alarm list xxxxxx xxxxxx xxxxxx xxxxxx ? Only OPEN..........“ICON2000” instruction and operating manual The following drawing shows the use of the OPEN / YES..................... ...... CLOSE / NO and STOP push-buttons in function of the local selector position... F 37 . COMPANY Section 618/2 chapt..... . next? ALARM # n RESET ALARMS OK? YES next? WARNING # 1 .. © Copyright by BIFFI Italia... next? WARNING # n RESET WARNING OK? YES Contents may change without notice.......

. 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. All rights reserved. etc. COMPANY Section 618/2 chapt. The operator is guided through the different displays by answering YES or NO to the appropriate prompt (change? OK?. Valve data. To access the menus: set the local selector in OFF and then simultaneously press OPEN/YES and STOP. view?. Once the correct password has been entered. press NO to scroll the list of available languages and then YES to select.“ICON2000” instruction and operating manual 2. A !@#$ INTERNATIONAL LTD. The actuator is supplied by BIFFI with the default password “ 0 0 0 0 “. Configuration options The ICON2000 actuator can be totally configured from the local interface by means of a series of menus that can be selected from the alphanumeric display. After choosing the language. and use “Set-up” mode to change the present configuration. Section 618/2 The configuration functions (view and set-up mode) are grouped in 4 main menus: Actuator set-up. next?. The data are entered by the manufacturer and can only be viewed. the next step is the selection among view and set-up mode. Press YES if the language is correct. the old one ceases to be valid. Nameplate. the actuator parameters can be configured. and utilisation mode. Unauthorised access to the set-up mode is prevented by a 4character alphanumeric password. After entering the new password. List of routines: ❑ serial number ❑ actuator size ❑ nominal torque ❑ actuator speed ❑ power supply ❑ motor poles ❑ motor type ❑ motor rating ❑ motor current ❑ motor duty ❑ test date ❑ wiring diagram ❑ enclosure ❑ certificate ❑ lubricant ❑ HW version ❑ SW version ❑ Torque sensor 38 © Copyright by BIFFI Italia. The alphanumeric display will now show the present language. service. so it is important to record the password in a secure location for future retrieval. Maintenance. F Contents may change without notice. Use “View” mode to see the actuator configuration. List of routines: ❑ stroke limits ❑ torque set-up ❑ ESD control ❑ remote controls ❑ local controls ❑ output relays ❑ 2-speed timer ❑ miscellaneous Nameplate This menu includes a series of data identifying the actuator characteristics. The present password can also be modified by the “set password" routine in the Maintenance menu.) in the right corner of the lower row of the alphanumeric display.

“ICON2000” instruction and operating manual Valve data This menu includes a series of data relevant to the valve. Entering the view mode The existing actuator configuration should be checked before commissioning. Press YES to confirm. • Press NO to scroll the list of parameters and press YES to view the value. Press YES to select a new language. but no change of parameters can be made. List of routines: ❑ tag name ❑ serial number Maintenance This menu includes all diagnostic and historic data which can help the operator in case of failure or during maintenance operations. no password is requested. The valve manufacturer and end user should enter the data. All rights reserved. valve data. F 39 Section 618/2 . • The display shows the present language. List of routines: ❑ set password ❑ alarm log ❑ maintenance date ❑ torque profile ❑ operation log The parameters appear on the alphanumeric display in the same order both in view and set-up mode. The Maintenance menu also includes the "Set password" routine. • Ensure the electrical main power is applied. • Move the 3-position selector to OFF and then simultaneously press OPEN/YES and STOP. • Press NO to scroll the list of available routines and press YES to select the routine where the parameter to be changed is located. © Copyright by BIFFI Italia. The parameters are configured in factory according to a standard setting. nameplate. Contents may change without notice. A !@#$ INTERNATIONAL LTD. Press YES to confirm or NO to scroll the list of available languages. In view mode. • Press NO to scroll the list of available menus (actuator set-up. and the operator can choose to either re-enter (by pressing YES) or to move on to a next routine (by pressing NO). At the end of each routine the program will automatically return to the beginning of the routine. 3. COMPANY Section 618/2 chapt. maintenance) and then press YES to select the desired menu. or to customer requirements.

• The display shows the present language. • Press YES and NO to answer the prompt on the display and change the parameter. • Press NO to scroll the list of available menus (actuator set-up. Press YES to answer prompt “ENTER PASSWORD OK?" • Enter password. the microprocessor checks the password. Enter 4 digits. In case of difficulty during commissioning. Press YES to confirm or NO to scroll the list of available languages. Press YES if digit is correct. F Contents may change without notice. COMPANY Section 618/2 chapt. Press YES to select. • Press NO when the message is “VIEW MODE OK? ”. After entering the last digit. Enter one digit at a time. press NO to scroll the list of available characters and then press YES when the character is correct. the default setting can be re-instated by the appropriate function in the routine ”miscellaneous” of the actuator set-up menu. All rights reserved. maintenance) and press YES to select the desired menu • Press NO to scroll the list of available routines and press YES to select the routine where the parameter to be changed is located. 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 • answer YES when the display asks “EXIT OK? ” • press YES and NO simultaneously • automatic exit after 5 minutes without any parameter change or view • remove the electrical power from the unit 40 © Copyright by BIFFI Italia. All ICON2000 actuators are configured before shipping with a standard default setting unless alternatives were requested on order. All settings are automatically saved to a non-volatile memory and retained also if the electrical power is removed from the actuator. • Ensure the electrical main power (or the external auxiliary supply) is applied. Entering the set-up mode To change the existing settings or to set the stroke limits it is necessary to enter the correct password. If it is correct the messages “PASSWORD CORRECT” and then “SET-UP MODE OK?” appear. . Section 618/2 5.“ICON2000” instruction and operating manual 4. Press YES. • Move the 3-position selector to OFF and then simultaneously press OPEN/YES and STOP. A !@#$ INTERNATIONAL LTD. • If the password is wrong the message “PASSWORD WRONG” appears and set-up mode will not available. valve data. The actuator returns to its original configuration and commissioning can be resumed. Press YES to confirm the chosen language.

COMPANY Section 618/2 chapt. All rights reserved. © Copyright by BIFFI Italia. F 41 Section 618/2 .“ICON2000” instruction and operating manual Contents may change without notice. A !@#$ INTERNATIONAL LTD.

A !@#$ INTERNATIONAL LTD.“ICON2000” instruction and operating manual The figure below shows the procedure to enter view and set-up mode Display YES xxxxxx YES STOP language english ok ? STOP OFF next ? OFF LOCAL Section 618/2 NO YES REMOTE Press NO until the desired language appears and then press YES language francais ok ? 3-position selector YES YES “0” 0 0 0 digit 1 ok ? 0 “0“ 0 0 digit 2 ok ? NO YES NO YES “z” 0 0 0 digit 1 ok ? z “k“ 0 0 digit 2 ok ? Press NO until the desired character 42 © Copyright by BIFFI Italia. COMPANY Section 618/2 chapt. . All rights reserved. F Contents may change without notice.

COMPANY Section 618/2 chapt. A !@#$ INTERNATIONAL LTD. All rights reserved. © Copyright by BIFFI Italia.“ICON2000” instruction and operating manual FROM EXIT ? YES view mode ok ? TO VIEW MENU NO NO enter password ok ? YES password wrong YES 0 0 “0“ 0 digit 3 ok ? 0 0 0 “0” digit 4 ok ? password correct NO YES NO YES YES z k “9“ 0 digit 3 ok ? z k 9 “r” digit 4 ok ? setup mode ok ? TO SETUP MENU FROM EXIT ? appears and then press YES Contents may change without notice. F 43 Section 618/2 .

G Contents may change without notice. All rights reserved.“ICON2000” instruction and operating manual SET-UP MENU CHAPTER Section 618/2 G 44 © Copyright by BIFFI Italia. A !@#$ INTERNATIONAL LTD. . COMPANY Section 618/2 chapt.

G 45 Section 618/2 . © Copyright by BIFFI Italia. COMPANY Section 618/2 chapt. A !@#$ INTERNATIONAL LTD.“ICON2000” instruction and operating manual Contents may change without notice. All rights reserved.

All rights reserved. G Contents may change without notice. COMPANY Section 618/2 chapt. . A !@#$ INTERNATIONAL LTD.“ICON2000” instruction and operating manual The figure below shows the procedure to move in the set-up routines Section 618/2 46 © Copyright by BIFFI Italia.

COMPANY Section 618/2 chapt. G 47 Section 618/2 .“ICON2000” instruction and operating manual Contents may change without notice. © Copyright by BIFFI Italia. A !@#$ INTERNATIONAL LTD. All rights reserved.

H Contents may change without notice. All rights reserved. A !@#$ INTERNATIONAL LTD. . COMPANY Section 618/2 chapt.“ICON2000” instruction and operating manual VIEW MENU CHAPTER Section 618/2 H 48 © Copyright by BIFFI Italia.

COMPANY Section 618/2 chapt. © Copyright by BIFFI Italia. A !@#$ INTERNATIONAL LTD. H 49 Section 618/2 . All rights reserved.“ICON2000” instruction and operating manual Contents may change without notice.

A !@#$ INTERNATIONAL LTD. COMPANY Section 618/2 chapt.“ICON2000” instruction and operating manual The figure below shows the procedure to move in the view routines VIEW MODE ok ? ACTUATOR SETUP VIEW ? NAME PLATE VIEW ? Section 618/2 50 © Copyright by BIFFI Italia. All rights reserved. . H Contents may change without notice.

A !@#$ INTERNATIONAL LTD. H 51 Section 618/2 . COMPANY Section 618/2 chapt. © Copyright by BIFFI Italia. All rights reserved.“ICON2000” instruction and operating manual VALVE DATA VIEW ? Contents may change without notice.

H Contents may change without notice. COMPANY Section 618/2 chapt. All rights reserved. A !@#$ INTERNATIONAL LTD. .“ICON2000” instruction and operating manual Section 618/2 52 © Copyright by BIFFI Italia.

COMPANY Section 618/2 chapt. • Press YES to set the close limit. When the value is correct. or NO to change. All rights reserved. • Press YES if the opening torque limit is correct or NO to scroll the list of available values. front seal butterfly valves • Ball.“ICON2000” instruction and operating manual SET-UP ROUTINES 1. or NO and then YES to set the open limit. Most valves require clockwise rotation of the stem when viewed from the handwheel. Actuator set-up 1. The nominal torque corresponding to 100% is set in-house and is stated in the name plate menu. When the value is correct press YES. globe. and then press YES again to start with the stroke limits routine. I 53 Section 618/2 I • Position . When the value is correct press YES. press NO to change it. plug valves • Linear valves with back-seating on stem Close limit • Torque Valve type • Position • Torque or position • Position • Torque Set-up procedure: • Engage the manual override and move the valve to the mid-travel position • Move the local selector to OFF and then simultaneously press OPEN and STOP. Close limit type Press YES if the close limit type is correct (torque or position). Contents may change without notice. flexible and split wedge). The following parameters will be set: • opening and closing torque limits: from 40 % to 100 % of the nominal torque. Press YES when the type is correct. Press YES to select the actuator set-up menu. Engage the manual override and check if the valve closes with clockwise or counter-clockwise rotation of the handwheel • close and open limits type: by position or by torque. • close direction: clockwise (CKW) or counter-clockwise (CCKW). A !@#$ INTERNATIONAL LTD. • Press YES if the closing torque limit is correct or NO to scroll the list of available values. When the message displayed is “SET-UP MODE OK?” press YES.1 SET STROKE LIMITS This routine allows the actuator to be configured according to the type of valve it is mounted on. press YES. • Press YES if the rotation to close is correct (CKW or CCKW). Select the language and then enter the password according to the instructions (see “Entering the set-up mode”). © Copyright by BIFFI Italia. Use the following table to choose: CHAPTER Valve type • Gate (solid. gate (parallel slide).

Open limit by torque • Move the local selector to LOCAL. • Press the OPEN control. press NO to change it. The actuator moves in opening direction and when the configured torque value is reached the motor is stopped and the new position limit is memorised. both limits (open and close) must be set. • Move the valve to open position (by OPEN control or by handwheel) • Move the local selector to OFF • Press YES to confirm • Press YES to set the open limit or press NO and again NO to repeat open limit setting procedure. Press NO and then YES to exit from the stroke limits routine. Press NO and then YES to exit from the stroke limits routine. Section 618/2 1. Open limit by position • Move the local selector to LOCAL. Press YES to confirm. I Contents may change without notice. Close limit by torque • Move the local selector to LOCAL. The local controls become active. If the stroke turns are less than 2. All rights reserved. Press NO and then YES to exit from the stroke limits routine. 54 © Copyright by BIFFI Italia. • Press the CLOSE control. the message “error re-try” appears and the stroke limits procedure must be repeated. Before leaving the stroke limits routine the microprocessor calculates the new value of the position resolution. COMPANY Section 618/2 chapt. A !@#$ INTERNATIONAL LTD. Open limit type • Press YES if the open limit type is correct (torque or position).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. • Move the local selector to OFF • Press YES to confirm • Press YES to set the open limit or press NO and again NO to repeat the close limit setting procedure. The local controls can be used. Press NO and then YES to exit from the stroke limits routine. • Move the valve to closed position (by CLOSE control or by handwheel) • Move the local selector to OFF • Press YES to confirm • Press YES to set the open limit or press NO and again NO to repeat the close limit setting procedure. • Move the local selector to OFF • Press YES to confirm • Press YES to set the open limit or press NO and again NO to repeat the open limit setting procedure. .7. If parameter “direction to close” is changed. The local controls become active. The actuator moves in closing direction and when the configured torque value is reached the motor is stopped and the new position limit is memorised. The local controls can be used.“ICON2000” instruction and operating manual Close limit by position • Move the local selector to LOCAL.

When the message displayed is “SET-UP MODE OK?” press YES. Choosing ESD > LOCAL STOP. press NO and then press YES to select the torque set-up routine. go to position xx %). 2-speed timer. close. Vice-versa. Select the language and then enter the password according to the instructions (see “Entering the set-up mode”). • (*) local stop pressed. 1. Contents may change without notice. if ESD < LOCAL STOP was chosen. • Press either YES or NO to select the signal type (present. if ESD < TORQUE LIMIT was chosen. selecting “ESD > .. Function "ESD priority" allows the ESD command to override the following additional situations: (*) motor thermostat alarm. A !@#$ INTERNATIONAL LTD. Press YES to select actuator set-up menu.“ICON2000” instruction and operating manual Set-up procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. COMPANY Section 618/2 chapt. the ESD action will be carried out also in case of torque alarm. When the message displayed is “SET-UP MODE OK?” press YES. Press YES to select the actuator set-up menu. Vice-versa.” is configured. • Press YES if the opening torque limit is correct. Therefore. (*) local stop pressed. the actuator may be damaged. or press NO to scroll the list of available options (off. I 55 Section 618/2 Warning: The user may select ESD to override the situations indicated by (*). © Copyright by BIFFI Italia. Press YES to select the desired option. Vice-versa. the ESD action will not be performed if the local STOP push-button is pressed. The ESD control is active when the 3-position selector is in REMOTE and no alarm is present.” will invalidate the warranty. If these situations occur and if “ESD > . (*) 3-position selector in OFF Configuration procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. press NO to scroll the list of available values. All rights reserved.. Choosing ESD > THERMOSTAT. the ESD action will not be done in case of motor over-heating. • Press YES if the closing torque limit is correct. (*) torque limit tripped. Select the language and then enter the password according to the instructions (see “Entering the set-up mode”). • Press YES if the ESD action is correct.3 ESD CONTROL An ESD signal can be connected to the actuator to override any existing command and drive the valve to a predetermined position. the ESD action will not be done in case of torque alarm. The ESD control is not self-maintained: the ESD action is only performed if the relevant input is active. the ESD action will override the local STOP signal. Press YES when the value is correct.. Press YES when the value is correct. stay-put. . the ESD action will be carried out also in case of motor over-heating. if ESD < THERMOSTAT was chosen. press NO to scroll the list of available routines and then press YES to select ESD set-up. open. Choosing ESD > TORQUE LIMIT.. • (*) torque limit tripped. press NO to scroll the list of available values. absent) • Press YES to change ESD priority with reference to the following signals or status: • (*) motor thermostat alarm. 3position selector in local.

By choosing ESD > OFF. • to set the LED’s colour. All rights reserved.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. I Contents may change without notice. if ESD < 2-speed timer was chosen. Press YES to select actuator set-up menu. • 2-speed timer. Vice-versa. 3 wires. If “2 wires” was chosen. 1. or 2 wires depending on the connection made on the terminal board of the actuator. "latched with instant reverse". COMPANY Section 618/2 chapt.“ICON2000” instruction and operating manual • local selector in LOCAL. close LED: green or red. The available options are “push-to-run". Choosing ESD > LOCAL CONTROLS. ESD > 2-speed timer. The factory configuration is the following: action: CLOSE. 2 wires. Choosing ESD > 2-speed timer. Select the language and then enter the password according to the instructions (see “Entering the set-up mode”). the ESD action will be carried out also when the local selector is in OFF. The following options are available: • 4 wires latched: requires 2 momentary signals (since the control is self-maintained) to open or close and one signal to stop in mid-travel • 3 wires latched instant reverse: requires 2 momentary signals (since the control is self-maintained) to open or close. Section 618/2 1. • 3 wires momentary: requires 2 push-to-run type signals (since the control is not self-maintained) to open or close • 2 wires open if signal On: requires signal On to open and no signal to close • 2 wires open if signal Off: requires signal Off to open and signal On to close Configuration should be done during actuator set-up. use YES or NO to answer the prompt on the display and choose among “push-to-run” or “latched instant reverse” control modes. • (*) local selector in OFF. or 3. Vice-versa.4 REMOTE CONTROLS The actuator may be remotely controlled by 4. Configuration procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. When the message displayed is “SET-UP MODE OK?” press YES. . the ESD action will not be performed if the 3-position selector is in OFF. If “3 wires” was chosen. the 2-speed timer function will be active during ESD action. Reverse momentary signal reverses the direction. signal type: PRESENT. use YES and NO to choose among “open if signal ON” or “open if signal OFF” control modes. Vice-versa. press NO to scroll the list of available routines and then press YES to select Remote controls. the ESD action will be carried out also when the local selector is in LOCAL. 56 © Copyright by BIFFI Italia. • Press YES if the control mode is correct or NO to scroll the list of available options: 4 wires. if ESD < LOCAL CONTROLS was chosen. the 2-speed timer function will be inhibited during ESD action. alarm LED: yellow or red. The following options are available: open LED: green or red. the ESD action will not be performed if the 3-position selector is in LOCAL. A !@#$ INTERNATIONAL LTD. ESD < all other cases. “latched". Press YES to select the desired option. priorities: ESD > LOCAL CONTROLS. if ESD < OFF was chosen.

latched). Press YES to confirm. change-over. then YES to confirm • Press YES if the colour of the alarm LED is correct. All rights reserved.“ICON2000” instruction and operating manual Configuration procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. I 57 Section 618/2 1. Press NO to change it. 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. press NO to scroll the list of available routines and then press YES to select Local controls. COMPANY Section 618/2 chapt. Select the language and then enter the password according to the instructions (see “Entering the set-up mode”). A !@#$ INTERNATIONAL LTD. LED’s colour • Press YES if the colour of the open LED is correct. Press NO to change it. then YES to confirm • Press YES if the colour of the close LED is correct. © Copyright by BIFFI Italia. Press NO to change it.6 OUTPUT RELAYS . Press YES to select the actuator set-up menu. The monitor relay is normally energised and will be de-energised on: • main voltage failure • lost phase • internal temperature alarm • K1 contactor failure • K2 contactor failure • position sensor failure • speed sensor failure • configuration error • HW error • mid-travel alarm The following situation can be configured individually to switch-over the monitor relay: Motor over-temperature Over-torque Jammed valve LOCAL/OFF selected Manual operation ESD signal on Low alkaline battery (if present) LOCAL/STOP pressed Contents may change without notice. • Press YES to change control mode. or press NO to proceed to LED’s colour setting Control mode • Press YES if the display shows the correct control mode or press NO to scroll the list of available options (push to run. When the message displayed is “SET-UP MODE OK?” press YES. then YES to confirm Monitor relay The voltage-free.

Configuration procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. make AS2 : close limit.“ICON2000” instruction and operating manual Auxiliary output relays For status indication or diagnostic purposes. 4 voltage-free contacts of 4 relays are available to be configured individually to switch for the following conditions: STATUS • open limit • closed limit • position >= xx % • position <= xx % • closing • opening • motor running • blinker • mid-travel position • local selected • remote selected • local stop active • ESD signal on • manual operation ALARM • motor over-temperature • over-torque • over-torque in OP • over-torque in CL • valve jammed • warnings • valve jammed in OP • valve jammed in CL • low alkaline battery (if present) • mid travel alarm in CL/OP The contacts may be configured to make or break on condition. or press NO to change • Press YES to select DEFAULT #2. • Press YES to select DEFAULT #1. . or press NO to configure the output relays DEFAULT # 1 Monitor relay • main voltage failure • lost phase • local/off selected • local stop pressed • manual operation • internal temperature alarm • K1 contactor failure • K2 contactor failure • position sensor failure Auxiliary relays AS1 : open limit. When the message displayed is “SET-UP MODE OK?” press YES. Press YES to select actuator set-up menu. press NO to scroll the list of available routines and then press YES to select Output relays. break • speed sensor failure • configuration error • HW error • motor over-temperature • over-torque • jammed valve • low alkaline battery (if present) • mid-travel alarm Section 618/2 58 © Copyright by BIFFI Italia. All rights reserved. break AS4 : close limit. COMPANY Section 618/2 chapt. I Contents may change without notice. make AS3 : open limit. Select the language and enter the password according to the instructions (see “Entering the set-up mode”). A !@#$ INTERNATIONAL LTD.

Contents may change without notice. On time On time Off time Start position % Off time On time Off time Stop position % Motor Start position and stop position may be adjusted from 0% . ESD signal on. A !@#$ INTERNATIONAL LTD. 4 • Press NO to answer prompt “MONITOR RELAY change?” • Press YES to change AS1.7 2-SPEED TIMER The "2-speed timer" routine is used to extend the actuator travelling time in opening and / or closing direction.100 % separately in opening and closing direction. break AS4 : motor running. Auxiliary relays AS1. low alkaline battery (if present).200 sec separately in opening and closing direction. 3.“ICON2000” instruction and operating manual DEFAULT # 2 Monitor relay • main voltage failure • lost phase • local/off selected • local stop pressed • manual operation • internal temperature alarm • K1 contactor failure • K2 contactor failure • position sensor failure Auxiliary relays AS1 : open limit. make). press NO to select the other relays • Press YES if the condition associated to AS1 relay is correct. by driving the motor by pulses which duration (ON and OFF time) is configurable. Pulsing control can be applied to full travel or only a part of it. 3. Monitor relay • Press YES or NO to enable or disable the following situations from the conditions which de-energise the monitor relay: motor over-temperature. • Press NO to pass to AS2 and then repeat the procedure for the other relays • Press NO to exit • speed sensor failure • configuration error • HW error • motor over-temperature • over-torque • jammed valve • low alkaline battery (if present) • mid-travel alarm 1. local STOP pressed. jammed valve. ON time and OFF time may be adjusted from 1 sec . break AS3 : local selected. COMPANY Section 618/2 chapt. over-torque. 2. break Configure output relays • Press YES to change the monitor relay or NO to change auxiliary relays AS1. • Press YES or NO to either confirm or change the type of contact when the condition occurs (break. press NO to scrolls the list of conditions and press YES to set. I 59 Section 618/2 . break AS2 : close limit. 2. © Copyright by BIFFI Italia. manual override. 4. All rights reserved. LOCAL/OFF selected.

Press YES when the value is correct • Press YES if the value of the OFF time of pulsing control is correct. Press YES to confirm (status = On enables 2-speed timer operation in opening direction. COMPANY Section 618/2 chapt. status = Off. When the message displayed is “SET-UP MODE OK?” press YES.“ICON2000” instruction and operating manual Configuration procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. When the message displayed is “SET-UP MODE OK?” press YES. Press YES when the value is correct • Press YES if the position value where pulsing control stops is correct. Press YES to select actuator set-up menu. press NO to scroll the list of available values. A !@#$ INTERNATIONAL LTD. . Press YES when the value is correct Section 618/2 1. press NO to scroll the list of available routines and then press YES to select 2-speed timer. I Contents may change without notice. press NO to scroll the list of available values. All rights reserved. 60 © Copyright by BIFFI Italia. press NO to scroll the list of available values. status = Off. • Press YES if the position value where pulsing control starts is correct. Press YES when the value is correct • Press YES if the value of the OFF time of pulsing control is correct. Press YES when the value is correct • Press YES if the value of the ON time of pulsing control is correct. press NO to scroll the list of available values. etc. • Press YES if the position value where pulsing control starts is correct.8 MISCELLANEOUS It includes different types of routines as “time and date”. Select the language and then enter the password according to the instructions (see “Entering the set-up mode”). Select the language and enter the password according to the instructions (see “Entering the setup mode”). used only for special application or in particular conditions. disables timer operation in closing direction). Press YES when the value is correct Opening direction • Press YES if the status is OK. enables 2-speed timer operation in closing direction. press NO to scroll the list of available values. “torque profile”. press NO to scroll the list of available values. “factory settings”. press NO to scroll the list of available values. alarm log. 1. Press YES to select actuator set-up menu. • Press YES to change close direction parameters. Configuration procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. press NO to scroll the list of available values. Time and date are entered at the time of manufacture. Press YES when the value is correct • Press YES if the position value where pulsing control stops is correct. but they can be adjusted during commissioning or maintenance operations. etc. Press YES to confirm (status = On.8. disables timer operation in opening direction). or NO to change. maintenance request. press NO to scroll the list of available routines and then press YES to select Miscellaneous. press NO and then YES to change only open direction parameters Closing direction • Press YES if the status is OK. or NO to change.).1 TIME AND DATE Time and date are used in maintenance functions to associate the time information to the memorised event (torque profile. “alkaline battery”. Press YES when the value is correct • Press YES if the value of the ON time of pulsing control is correct.

© Copyright by BIFFI Italia. • Press YES when the time is correct • Press YES if the date is correct.“ICON2000” instruction and operating manual • Press YES to enter the time and date routine. • Press YES if the time is correct. I 61 Section 618/2 . Press YES to select the actuator set-up menu.2 FACTORY SETTINGS The above routine resets the present configuration and restores the default configuration as below: stroke limits close direction: CKW close limit: by position open limit: by position Closing torque: 40% Opening torque: 40% ESD action: close ESD signal: present ESD priority: ESD < motor thermostat ESD < torque limit ESD < local stop ESD > local controls ESD > 2-speed timer ESD < OFF Control type: 4 wires latched Control type: latched with instant reverse LED’s colour: green = open / opening red = close / closing yellow = alarm / warning Default #1 Opening direction: off Closing direction: off Alkaline battery : absent Torque profile: standard torque by-pass: 4% valve jammed: 4 sec. A !@#$ INTERNATIONAL LTD.8. month. • Press YES if the date is correct 1. Contents may change without notice. press NO to change • Enter day. press YES to select. Press NO to scroll the list of available values. press YES to select. Press NO to scroll the list of available values. press NO to scroll the list of available routines and then press YES to select Miscellaneous. Select the language and then enter the password according to the instructions (see “Entering the set-up mode”). press NO to change it • Enter hours. and year. Press YES to download the standard configuration. When the message displayed is “SET-UP MODE OK?” press YES. press NO to exit. Torque set-up ESD set-up Remote controls Locals controls Output relay 2-speed timer Miscellaneous Configuration procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. minutes and seconds. All rights reserved. • Press No to scroll the list of routines and press YES to select factory configuration. COMPANY Section 618/2 chapt.

press NO to scroll the list of available routines and then press YES to select Miscellaneous. A !@#$ INTERNATIONAL LTD. When the message displayed is “SET-UP MODE OK?” press YES. Press YES to select actuator set-up menu. The program runs the functions relevant to the battery only if the appropriate flag “alkaline battery” is configured with “present”. the actuator can be provided with an alkaline battery to update the remote outputs (output relays status and bus messages) in case of electrical power failure and manual override operations.8. Configuration procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP.4 TORQUE LIMITS TYPE Actuator direction: closing Actuator direction: opening Torque limits are used as a reference for torque alarm Closing torque % of nominal Opening torque % of nominal and end of travel. Select the language and enter the password according to the instructions (see “Entering the set-up mode”). • Press NO to scroll the list of routines and press YES to select 3-point torque limits. Configuration procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. • Repeat stroke limits setting routine.3 ALKALINE BATTERY On request. All rights reserved. Select the language and enter the password according to the instructions (see “Entering the setup mode”). press NO to change. to limit separately the unseating.8. The limits can be configured in Position % Position % the "stroke limits" or Cl end % 0 % 0 % Op brk% Op end % 100 % "torque set-up" routines 100 % Cl brk% and determine the torque alarm or end of travel situations. When the message displayed is “SET-UP MODE OK?” press YES. I Contents may change without notice. . Press YES if the setting is correct. Press YES to select actuator set-up menu. running and ending torque. Press YES when the value is correct. the torque limits are constant Running limit Running limit along the full stroke. Press YES when the value is correct. Section 618/2 62 © Copyright by BIFFI Italia. Press YES if the setting is correct. With the Breakout limit Breakout limit Ending limit Ending limit option "standard".“ICON2000” instruction and operating manual 1. press NO to scroll the list of available routines and then press YES to select Miscellaneous. • Press No to scroll the list of routines and press YES to select alkaline battery. In the same particular application it is useful to configure 3 different torque thresholds for each travelling direction. press NO to change. If the battery is absent or if no updating of remote outputs is requested. the above flag should be configured with “absent". COMPANY Section 618/2 chapt. 1. To select this option pick "3-point limits" and then follow the torque set-up and stroke limits routines (see figure).

5%. The time passed after receiving an open or close control is greater than the "valve jammed time". but the valve position variation is smaller than 0. press NO to scroll the list of available routines and then press YES to select Miscellaneous. but the valve position variation is smaller than 0. I 63 Section 618/2 . the motor speed is correct. • Press No to scroll the list of routines and press YES to select torque by pass.5% in a time equal to "valve jammed time" and motor speed is 0 RPM.by-pass active in Closing: from 100% to 90% To exclude torque by-pass configure 0%. if a 10% by-pass value is set.5 TORQUE BY-PASS (%) Since a high torque may be required to unseat certain valves. • Press No to scroll the list of routines and press YES to select valve jammed. press NO to scroll the list of available routines and then press YES to select Miscellaneous. but during the travel the position valve variation is smaller than 0. The time after receiving an open or close control is greater than the "valve jammed time". Contents may change without notice. Configuration procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. Press YES if the setting is correct. the command is cleared and an alarm indication is generated.by-pass active in Opening: from 0% to 10% .) When the message displayed is “SET-UP MODE OK?” press YES. Select the language and enter the password according to the instructions (see “Entering the set-up mode”). Configuration procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. The valve jammed time is expressed in seconds and can be configured from 0 to 100 sec. Configure "0" to exclude the routine.6 VALVE JAMMED (TIME) The valve jammed time is used to monitor the following situations: 1. Condition 1 is Ok.5% and motor speed is 0 RPM. 1. the command is cleared and the "valve jammed" alarm indication is generated. Press YES to select actuator set-up menu. Press YES when the value is correct.8. For example.“ICON2000” instruction and operating manual 1.8. The motor is blocked. press NO to change. All rights reserved. 2. COMPANY Section 618/2 chapt. the torque by-pass routine masks the torque alarm when an open or close command is received and the actuator is fully open or closed. The torque by-pass is expressed in % of position and is configurable from 0% to 20%. © Copyright by BIFFI Italia. A !@#$ INTERNATIONAL LTD. press NO to change. When the message displayed is “SET-UP MODE OK?” press YES. Select the language and enter the password according to the instructions (see “Entering the setup mode”. Press YES to select actuator set-up menu. 3. The motor is blocked. The motor is blocked. the command is cleared and the "mid-travel alarm" indication is generated. we may have: . Press YES if the setting is correct. Press YES when the value is correct.

) 2. Section 618/2 2. I Contents may change without notice. and “➔” as end of string. Press NO to scroll the list of available characters. Press NO to scroll the list of available menus and then press YES to select valve data menu. and “ ➔ ” as end of string. 3.2 SERIAL NUMBER Configuration procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. All rights reserved. Press YES to select the desired character. • Press NO to scroll the list of available routines and then press YES to select Serial number. When the message displayed is “SET-UP MODE OK?” press YES. 28 char. Select the language and enter the password according to the instructions (see “Entering the setup mode”). Select the language and enter the password according to the instructions (see “Entering the setup mode”). The following data can be entered: • tag name (max. The maintenance menu also includes the set password routine. Press NO to scroll the list of available menus and then press YES to select valve data menu. Therefore it is mandatory “NOT TO FORGET THE PASSWORD” after the default one has been modified.“ICON2000” instruction and operating manual 2. Forgetting the new password makes it impossible to enter the set-up menu and to configure the actuator. the old one ceases to be valid. 64 © Copyright by BIFFI Italia. • Press YES if the 1st character of the string is correct. Enter a blank character. • Enter up to 28 characters. The following data are available: • set password • clear alarm log • set reference torque data • clear recent data log • set maintenance date 3. A !@#$ INTERNATIONAL LTD. • Press NO to scroll the list of available routines and then press YES to select Tag name.1 SET PASSWORD The actuator is supplied by BIFFI with a default password (“0 0 0 0”). The valve manufacturer and the end user can enter the data. Valve data The valve data allow identifying the valve and its function in the process. . Press NO to scroll the list of characters. After entering the new password.1 TAG NUMBER Configuration procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. • Press YES if the 1st character of the string is correct. • In the above way enter up to 28 characters. Enter a blank character. By the above routine the end user can enter a different password consisting of 4 alphanumeric characters. 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. Press YES to select. COMPANY Section 618/2 chapt. 28 char. When the message displayed is “SET-UP MODE OK?” press YES.) • serial number (max.

Enter 4 digits. When the message displayed is “SET-UP MODE OK?” press YES. 3. The old reference data are lost and the new ones are used as a new reference torque profile. • Press NO to scroll the list of available routines and then press YES to select Set torque reference. When the message displayed is “SET-UP MODE OK?” press YES. Press NO to scroll the list of available menus and then press YES to select Maintenance menu. © Copyright by BIFFI Italia. COMPANY Section 618/2 chapt.2 CLEAR ALARM LOG Clear procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. 3. • Press YES to clear alarm list. Contents may change without notice. 3. The following counters will be cleared: • recent contactor operations • recent motor run time • recent time without electrical power • recent utilisation rate The date of the “clear recent data log” is memorised and can be viewed in the maintenance date routine of the view menu.3 SET TORQUE REFERENCE The set torque profile reference routine allows to transfer the last torque profile to the reference profile registers. • Press NO to scroll the list of available routines and then press YES to select Set password. Select the language and enter the password according to the instructions (see “Entering the set-up mode”). I 65 Section 618/2 . When the display shows the message Password changed the old password is no longer valid. Press YES again to select Enter new password. Press YES if the digit is correct. • Enter the new password one digit at a time. press NO to scroll the list of available characters and then press YES to select. • Press NO to scroll the list of available routines and then press YES to select clear alarm log. A !@#$ INTERNATIONAL LTD. • Press YES to update the torque reference data.“ICON2000” instruction and operating manual 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”). All rights reserved. Press NO to scroll the list of available menus and then press YES to select maintenance menu. Press NO to scroll the list of available menus and then press YES to select the Maintenance menu. Select the language and enter the password according to the instructions (see “Entering the set-up mode”). • Move the local selector to OFF and then simultaneously press OPEN and STOP.4 CLEAR RECENT DATA LOG The clear recent data log routine allows clearing the counters of the recent operation log. When the message displayed is “SET-UP MODE OK?” press YES.

I Contents may change without notice. Select the language and enter the password according to the instructions (see “Entering the setup mode”.“ICON2000” instruction and operating manual Clearing procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. press YES to select • Press YES if the date is correct Section 618/2 66 © Copyright by BIFFI Italia. • Press YES to set the last maintenance date.5 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: • Move the local selector to OFF and then simultaneously press OPEN and STOP. Last maintenance date: • Press YES if the date is correct. month. press NO to change it • Enter day. A !@#$ INTERNATIONAL LTD. and year. month. press YES to select • Press YES if the date is correct Start-up date: • Press YES if the date is correct. month. press NO to change it • Enter day.) When the message displayed is “SET-UP MODE OK?” press YES. Press NO to scroll the list of available menus and press YES to select the maintenance menu. and year. COMPANY Section 618/2 chapt. • Press YES • Press YES to clear or press NO to exit. • Press NO to scroll the list of available routines and then press YES to select clear recent data log. Select the language and enter the password according to the instructions (see “Entering the setup mode”). When the message displayed is “SET-UP MODE OK?” press YES. press NO to change it • Enter day. 3. and year. Press NO to skip to “next maintenance date”. • Press NO to scroll the list of available routines and press YES to select maintenance date. Press NO to scroll the list of available menus and then YES to select the maintenance menu. Press NO to scroll the list of available values. . Press NO to scroll the list of available values. All rights reserved. press YES to select • Press YES if the date is correct Next maintenance date: • Press YES if the date is correct. Press NO to scroll the list of available values.

A !@#$ INTERNATIONAL LTD. I 67 Section 618/2 . COMPANY Section 618/2 chapt. Example of set-up routine 4.“ICON2000” instruction and operating manual 4. © Copyright by BIFFI Italia.1 TORQUE SET-UP Contents may change without notice. All rights reserved.

I Contents may change without notice. A !@#$ INTERNATIONAL LTD. .“ICON2000” instruction and operating manual Section 618/2 68 © Copyright by BIFFI Italia. All rights reserved. COMPANY Section 618/2 chapt.

A !@#$ INTERNATIONAL LTD. 28 char. stop. Is. When the message displayed is “VIEW MODE OK?” press YES. • Press YES to answer at the prompt “view” or “next” and to see the data 2. off time • open direction: status. The following data can be viewed: ROUTINE • stroke limits • torque set-up • ESD control • remote controls • local controls • output relays • 2-speed timer PARAMETERS • close direction. Icc (A) • motor poles • test date • wiring diagram (max. L 69 Section 618/2 L . 28 char. ESD priority • control type • control type. ASi conditions.“ICON2000” instruction and operating manual VIEW ROUTINES 1. Select the language according to the instructions (see “Entering the view mode”). The following data may be viewed: • serial number (max. LED’s colour • default #1. start. 28 char.) • actuator size (max. opening torque limit • ESD action. Name plate Use this menu to view the data identifying the actuator. 28 char. on time. off time • miscellaneous • time and date. Press YES to select the actuator set-up menu. Actuator set-up The above menu allows to view the present actuator configuration. on time. open limit type • closing torque limit. contact action • close direction: status. All rights reserved. stop.) • lubricant (max. © Copyright by BIFFI Italia. 28 char.) • enclosure (max. valve jammed time.) • certificate (max. signal type. The data are entered in-house and can only be changed by the manufacturer. torque by-pass%. No change can be made to the present data. • Press NO to scroll the list of available routines and press YES to select. default #2. COMPANY Section 618/2 chapt. 28 char.) • HW version • SW version • Torque sensor data Contents may change without notice.) • nominal torque/thrust • actuator speed • motor type • power supply • motor rating (Kw) • motor duty • motor current In. close limit type. start. various status CHAPTER View procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. monitor relay conditions.

. 28 char. 4. • Press YES to answer the prompt “Alarm log view?”.) • serial number (max. The “clear alarm log” routine of the set-up menu should be used to clear the list. All rights reserved. L Contents may change without notice. Valve data To identify the valve and its function in the process the following data can be viewed. It can give an indication of a change in the process conditions. A !@#$ INTERNATIONAL LTD. Details are given of the reference and latest torque expressed in % of the nominal torque. • Press YES to answer prompts “view” or “next” and see the data in the above list. Maintenance 4. Select the language according to the instructions (see “Entering the view mode”). Press NO to scroll the list of available menus and press YES to select the Maintenance menu. When the message displayed is “VIEW MODE OK?” press YES.“ICON2000” instruction and operating manual View procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. Section 618/2 4. • Press NO to move on to “Warnings view?” and then YES to scroll the list of warnings. • Press YES to scroll the list of alarms (“Alarms view?”).2 TORQUE PROFILE The torque profile routine gives important information on the actuator working conditions in comparison with a previously memorised reference profile. View procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. When the message displayed is “VIEW MODE OK?” press YES. When the message displayed is “VIEW MODE OK?” press YES. • tag name (max. Select the language according to the instructions (see “Entering the view mode”). View procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. 70 © Copyright by BIFFI Italia. Press NO to scroll the list of available menus and press YES to select the nameplate menu • Press YES to answer the prompt “view” or “next” and see the data in the above list 3. 28 char.1 ALARM LOG The alarm log routine is used to view the list of the latest 5 alarms and 5 warnings and the data when they occurred.) The data should be entered by the valve manufacturer or by the end user during set-up operations. COMPANY Section 618/2 chapt. Press NO to scroll the list of available menus and press YES to select the valve data menu. Select the language according to the instructions (see “Entering the view mode”).

• Press YES to select general data or press NO to skip to recent data • Press YES to scroll the list of values. • Press YES to scroll the list of values • ending reference torque in closing • breakout torque in closing • peak reference torque in closing • ending torque in closing • date of the last “set torque reference” • date of the last torque profile in opening • date of the last torque profile in closing 4. • Press NO to scroll the list of routines and press YES to select torque profile. The data are grouped into 2 families: general and recent data. • Press YES to view the recent data log or press NO to exit • Press YES to scroll the list of values. When the message displayed is “VIEW MODE OK?” press YES. Contents may change without notice. GENERAL DATA LOG • opening time of the last stroke (h:m:s) • closing time of the last stroke (h:m:s) • total contactor operations • motor run time (hours) • time without electrical power (hours) • utilisation rate (%) RECENT DATA LOG • recent contactor operations • recent motor run time (hours) • recent time without electrical power (hours) • recent utilisation rate (%) View procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP.3 OPERATION LOG The operation log consists of different counters and routines that provide information to assist in the maintenance program. All rights reserved. Select the language according to the instructions (see “Entering the view mode”). Select the language according to the instructions (see “Entering the view mode”). Press NO to scroll the list of available menus and press YES to select the Maintenance menu. • Press NO to scroll the list of available routines and press YES to select operation log. The general data log collects data from "test date" to "present date". COMPANY Section 618/2 chapt. L 71 Section 618/2 . © Copyright by BIFFI Italia. Press NO to scroll the list of available menus and press YES to select the Maintenance menu.“ICON2000” instruction and operating manual The following data may be viewed: • breakout reference torque in opening • peak running reference torque in opening • ending reference torque in opening • breakout torque in opening • peak running torque in opening • ending torque in opening • breakout reference torque in closing • peak running reference torque in closing View procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. A !@#$ INTERNATIONAL LTD. The recent data log collects data from the last "clear recent data log" date to "present date". When the message displayed is “VIEW MODE OK?” press YES.

All rights reserved. Press NO to scroll the list of available menus and press YES to select the Maintenance menu. • start-up date View procedure: • Move the local selector to OFF and then simultaneously press OPEN and STOP. A !@#$ INTERNATIONAL LTD. COMPANY Section 618/2 chapt. • Press NO to scroll the list of available routines and press YES to select the maintenance date routine • Press YES to scroll the list of date 5.4 MAINTENANCE DATE The routine allows viewing the following dates: • last maintenance date • next maintenance date • date of the last “clear recent data log “. Select the language according to the instructions (see “Entering the view mode”). . Example of view routine Section 618/2 5. L Contents may change without notice.1 VIEW TORQUE SET-UP 72 © Copyright by BIFFI Italia. When the message displayed is “VIEW MODE OK?” press YES.“ICON2000” instruction and operating manual 4.

. The motor runs but the actuator does not move the valve................... DC output voltage not available at the terminals....................81 5............. COMPANY Section 618/3 73 Section 618/3 ....................................76 CHAPTER “N” TROUBLE-SHOOTING.........“ICON2000” instruction and operating manual !@#$ flow control Section 618/3 Maintenance and trouble-shooting INDEX CHAPTER “M” MAINTENANCE................................ © Copyright by BIFFI Italia... The actuator does not stop in fully open or fully closed position...................... The actuator does not work from remote controls...................... Diagnostic messages.....................75 2.... A !@#$ INTERNATIONAL LTD.82 8...75 1..........82 11.................................76 3....................................................................80 4..........................81 6................... All rights reserved........82 10.........80 3...................80 2......................................................................................................................................... Alkaline battery change........................................................................................ Special maintenance............................................................................................................................... Standard maintenance................................................................................................................ The manual override can’t be engaged .83 Contents may change without notice.................................. The valve does not seat correctly......... The numeric position display indicates "E01".... Excessive torque for valve operation.82 9.........................79 1............................................................................................................. The electronics do not switch on when powered............ The motor is very hot and does not start..........................................82 7....

COMPANY Section 618/3 Contents may change without notice.“ICON2000” instruction and operating manual Section 618/3 74 © Copyright by BIFFI Italia. All rights reserved. . A !@#$ INTERNATIONAL LTD.

5. perform maintenance checks more often. .3). The control compartment was sealed in dry and clean conditions and contains no site serviceable components.Lubricate the internal components of the coupling block by means of the spherical head lubricator using suggested greases (see Sect. every 2 years: Under normal operating conditions. even though visual inspection for oil leakage or external visible damages is recommended every two years. . . 3).Make sure there are no oil leaks from the actuator housing. The following checks will assure optimum performance: .Check that all nuts and bolts securing the actuator to the valve are tight. Standard maintenance Approx. . M 75 Section 618/3 . 20 mm. The oil level should be approx. COMPANY Section 618/3 chapt.For actuators provided with alkaline batteries.6V lithium battery. © Copyright by BIFFI Italia. 618/1 chapt. In chemically aggressive or saline environments. Replace all seals that permit oil leakage or water ingress. . Important: Before starting any maintenance operation. CHAPTER Warning: M Warning: The actuator is non-intrusive. D). All rights reserved. from the fill plug (see Sect. D). remove rust from surfaces and protect with a rust preventative.Repaint all areas where paint is missing. In case the window glass is broken.“ICON2000” instruction and operating manual MAINTENANCE 1. clean it and lubricate it in order to prevent damages to the threaded bush. the ICON2000 is maintenance-free: no actuator maintenance is formally required.For severe applications or if actuator operation is infrequent. Since the control compartment contains a 3. Do not open it unless absolutely necessary. If necessary. Always replace batteries if the actuator has been subjected to long periods without power (see Sect. B par. Unauthorised access will invalidate the warranty. B par. make sure that the mains and all other service voltage connected to terminal board are switched-off. re-tighten with a dynamometric key (for tightening torque values see Sect. 3). C par. 618/1 chapt. the complete cover must be replaced (see Sect. 618/4 for individual item numbers). A !@#$ INTERNATIONAL LTD. If the actuator is located in a hazardous area a “hot work” permit must be obtained unless the actuator can be moved to a non-hazardous area.Check the external parts for possible damage and replace them immediately. . 618/1 chapt. When conditions are severe (frequent operation or high temperatures). Contents may change without notice. check that the valve stem is clean and lubricated. inspect the oil level and oil quality more often. only open it in safe area. If "Battery low" warning appears. if necessary. 618/1 chapt. make sure that the display is still visible when power is off and that there is no “Battery low” warning message.If the stem is external. 618/1 chapt. replace the battery (see Sect. . If not.

Special maintenance In case actuator failure.Bring the cover to a safe area. . 76 © Copyright by BIFFI Italia. Note: Special maintenance is also recommended when. Spare parts can be required to BIFFI: please refer to the individual item number shown in Section 618/4.Disconnect two wires (+) (-) from the main board. All rights reserved. .“ICON2000” instruction and operating manual 2.Open the terminal boards cover. during operations. . 3. . the actuator generates an excessive noise. please refer to Section 618/3 chapter N for possible causes. M Contents may change without notice. A !@#$ INTERNATIONAL LTD. COMPANY Section 618/3 chapt.Isolate the main supply to the actuator and all other control voltages. Alkaline battery change . When in a safe area: Section 618/3 • Remove the label.

© Copyright by BIFFI Italia. COMPANY Section 618/3 chapt.“ICON2000” instruction and operating manual • Remove the battery cover. M 77 Section 618/3 . A !@#$ INTERNATIONAL LTD. • Replace the battery.Duracell UltraCan style: PP3 Voltage: 9.EnergizerCan style: PP3 Voltage: 9. All rights reserved. Important: Note: the new battery must be chosen between the following types: • Alkaline Manganese.0 Contents may change without notice.0 • Alkaline Manganese.

.“ICON2000” instruction and operating manual Section 618/3 78 © Copyright by BIFFI Italia. M Contents may change without notice. A !@#$ INTERNATIONAL LTD. COMPANY Section 618/3 chapt. All rights reserved.

N If the above checks are satisfactory try to locate the fault using the diagnostic facilities. If the actuator is located in a hazardous area.“normal. The control compartment was sealed in dry and clean conditions and contains no site serviceable components. stop” . Warning: CHAPTER Since the control compartment contains a 3. N 79 Section 618/3 If the actuator does not work. Unauthorised acces will invalidate the warranty. a “hot work” permit must be obtained unless the actuator can be moved to a non-hazardous area.“ICON2000” instruction and operating manual TROUBLE-SHOOTING The ICON2000 actuator has passed the functional test performed by Biffi Quality Assurance personnel. only open it in safe area. COMPANY Section 618/3 chapt. A !@#$ INTERNATIONAL LTD. off. Warning: The actuator is non-intrusive. © Copyright by BIFFI Italia. off. before trouble-shooting make sure that: • the numeric display indicates xx % • the local selector is not in OFF • the main supply voltage is the same as stated in the name plate menu • you move the local selector to OFF and check that the alphanumeric display shows one of the following messages: .“alarm.6V lithium battery.“warning. Do not open it unless absolutely necessary. All rights reserved. stop” . off. Contents may change without notice. stop” .

. and the Vdc if the voltage not correct replace the power wiring . .Switch the main power supply on and check if the wires from terminals B1-B2B1-B2 and C1 is between voltage on the terminals and C1 . N Contents may change without notice.Move the local selector to REMOTE. DC output voltage not available . If the ESD signal is active.Switch the main power supply off and disconnect all at the terminals Section 618/3 3.Check the fuse mounted on the power card. DC output voltage not available at the terminals 2. L2. the alphanumeric display indicates “ESD On”. The electronics do not switch on when powered Power card Fuse .“ICON2000” instruction and operating manual 1. Replace it if burnt. if external voltage supply is used 80 © Copyright by BIFFI Italia. .if the voltage is not correct replace the power card 2.Check that: • the wiring to terminals B1-B2 and C1 is correct • there is no short-circuit between wires • the electrical load does not exceed 4W • the value is in the range 20-120 Vac 50/60Hz or 20-125 Vdc. A !@#$ INTERNATIONAL LTD. The actuator does not work from remote controls . L3 is correct . L2.If the fuse is OK.If the voltage isis correct check the external card and the electrical load. Check the signal on terminals C3 and C4 and adjust the ESD configuration. check the wires between terminals L1. All rights reserved. wires from terminals B1-B2 and C1 -witch off the main power supply and disconnect all . It should not exceed 4W. It should not exceed 4W.Check that the value of the main voltage on terminals L1. If it is correct. L3 and connector M1 of the power card. replace the power card.Remove the cover of the compartment where the electronic cards are located . .Move the 3-position selector to LOCAL and check that the actuator works from local controls. .23 and on the main power supply and check if the switch 27 Vdc voltage on the is correct check the external wiring .If the voltage terminals B1-B2 and C1 is between 23 and 27electrical load. COMPANY Section 618/3 chapt.

• Proceeding with the assembly. .Check that the number of operations per hour and their duration is suitable for the actuator service (see the name-plate menu) .“ICON2000” instruction and operating manual 4. . .Verify the key correctly fits in bore/keyways applications. N 81 Section 618/3 . Pay attention not to damage the O-ring seals. • Remove the handwheel.Check that the valve works in manual operation.Verify the stem nut has sufficient engagement with the valve stem.Check that the valve operating torque is within the range of the unit’s designed operating torque . • Make sure there are no foreign bodies. COMPANY Section 618/3 chapt. follow the reverse order of the disassembly. © Copyright by BIFFI Italia.Always check the causes of abnormal operation 5. .Check that the manual de-clutch lever is not stuck in manual operation position.Verify the stem nut correctly fits in the actuator base.Check that no alarm other than motor overheating is present.Rotate the handwheel a few degrees to remove all possible sticking between the handwheel and the drive sleeve. The motor is very hot and does not start . Contents may change without notice. • Check the integrity of the internal parts. If not. A !@#$ INTERNATIONAL LTD. . .Wait until the motor cools down and the normally closed contact of the thermal switch automatically resets before trying to operate the actuator again. The motor runs but the actuator does not move the valve In case the local display does not change the valve position indicators: . it is necessary to check the manual control area as follows: • Loosen the handwheel security dowel. In case the local display changes the valve position indicators: . • Remove the upper cover handwheel sleeve unit. All rights reserved.

Excessive torque for valve operation .Coupling types “B1”. B par.The internal trim of the valve may be damaged.Valve packing too tight: loosen the gland bolt nuts. . All rights reserved.2). . increase the actuator output torque limit. . The actuator does not stop in fully open or fully closed position . N Contents may change without notice.Try to move the drive sleeve by a screw-driver .1 and 1. par. Section 618/3 9. 11. A !@#$ INTERNATIONAL LTD. 82 © Copyright by BIFFI Italia.Open the cover . The manual override can’t be engaged In case the engagement of the lever is too difficult. 8. COMPANY Section 618/3 chapt. 4 & chapt.1 and 1.Make sure that the torque and travel limits are correctly set (see Sect. “B2”. E par. Also check that all transmission shafts. 618/2 chapt. . universal joints or bulkhead passages have sufficient lubrication and check that the transmission shafts are not bent. and proceed with the suitable corrective actions as described in this Chapter.If the valve is stopped by the position limit in closing.2). check whether the drive sleeve is stuck and proceed as follows: . then readjust the setting of the position limit. 10. lubricate and check the valve stem.Coupling type “A”: tight fit between bush and stem: increase the thread clearance on the drive coupling. E par.Check the alphanumeric display for diagnostic messages. The valve does not seat correctly . 1.It is necessary to re-calibrate the stroke limits (see Sect.Reassemble the cover 7. B par. 618/2 chapt.Check that the internal valve trim or the reducer gears are well lubricated and not damaged.“ICON2000” instruction and operating manual 6. . .Check that the actual open and close positions of the valve respectively correspond to 100% and 0% on the actuator display .If the valve is stopped by the torque limit in closing. check that the valve reaches its seat position. “B3” and “B4”: ensure there are no axial forces on the valve stem by leaving an adequate axial clearance between the stem and the drive bush. .Clean. The numeric position display indicates "E01" . 4 & chapt. . 1.

View procedure: • Move the 3-position selector to either OFF or REMOTE. N 83 Section 618/3 . The flashing of the alarm/warning LED indicates a warning condition. • Press NO when the display shows message “ALARMS view?" • Press YES when the display shows message “WARNINGS view?" Press YES to scroll the list of warnings.“ICON2000” instruction and operating manual 11. A !@#$ INTERNATIONAL LTD. © Copyright by BIFFI Italia. the corresponding alarm or warning also disappears from the list. etc. • Press YES to reset the alarms or warnings with memory. All rights reserved. jammed valve. Diagnostic messages The alarm and warning lists contain the alarms and warnings momentarily present. A reset routine is provided to clear the types of alarms and warnings that are memorised (over-torque. • Press YES when the display shows message “ALARMS view?" Press YES to scroll the list of alarms. When the fault condition disappears. Warning is the condition that occurs when a variable reaches a critical value and/or when a maintenance action is required but all actuator functions are still available. If the alarm/warning LED is on there is an alarm condition.). Contents may change without notice. Alarm is the condition that occurs when a variable is outside the acceptable range and some actuator function is not available. COMPANY Section 618/3 chapt. then press NO to scroll the list of available variables.

L2. Change control card. L2. A !@#$ INTERNATIONAL LTD. L3. L3 available with main voltage available with main voltage available with main voltage ALKALINE BATTERY OK LOST PHASE not available not available not available PHASE OK 84 © Copyright by BIFFI Italia.1 ALARM TABLE DISPLAY MESSAGE HIGH TORQUE IN CLOSING CONDITION FOR ALARM Measured torque greater than the relevant value configured in torque set-up or stroke limits routine Measured torque greater than the relevant value configured in torque set-up or stroke limits routine No position change after receiving a CLOSE control and motor speed is 0 RPM No position change after receiving an OPEN control and motor speed is 0 RPM Motor thermostat open for high temperature in the motor windings Temperature inside the actuator enclosure higher than 90°C or lower than -40°C ACTION Operate the actuator in open direction. Check that wires section is correct Check the contactor only close only close only close MID TRAVEL ALARM IN CL only open only open only open OPEN CONTROL MAIN VOLTAGE CORRECT Section 618/3 MAIN VOLTAGE not available not available not available K1 CONTACTOR opposite direction opposite direction opposite direction opposite direction not available CONTROL if ESD use K1 IN OPPOSITE contactor DIRECTION CONTROL not available if ESD use K2 IN OPPOSITE DIRECTION contactor not available K2 CONTACTOR The test routine reports a failure of K2 (coil or auxiliary contact) Check the contactor The checksum of the EEPROM CONFIGURATION memory that contains the ERROR configuration data is wrong The diagnostic program detects some malfunction in the electronics controlling the actuator Re-configure all parameters not available not available MEMORY OK HW ERROR The circuit is damaged. . All rights reserved. Recalibrate both stroke limits. available Verify insulation among actuator and heat source Replace position sensor or re-calibrate both stroke limits not available not available not available POSITION SENSOR Value of the actuator position not valid not available not available SPEED SENSOR Measure of motor speed not valid The valve does not move in presence of an open control and motor speed is 0 RPM The valve does not move in presence of a close control and motor speed is 0 RPM Main voltage lower than -20% or higher than+20% of the value stated in the name plate menu or wrong frequency The test routine reports a failure of K1 (coil or auxiliary contact) Replace speed sensor not available not available not available MID TRAVEL ALARM IN OP Check status of actuator and valve mechanical parts. Check main voltage supply and frequency on terminals L1. COMPANY Section 618/3 chapt. not available not available not available HW OK LOW ALKALINE BATTERY The voltage of the alkaline battery is too low (only detected if the alkaline battery is present and the Change alkaline battery relevant parameter of the miscellaneous routine is set to “present”) The alarm appears only with 3-phase main supply. The alarm is generated in case of fault of one of the phases that supply the actuator transformer Check main power supply on terminals L1. Recalibrate both stroke limits. Check the torque needed to operate the valve Check status of actuator and valve mechanical parts Check status of actuator and valve mechanical parts Wait until the motor cools down AVAILABLE CONTROLS Local only open ALARM RESET Remote only open ESD configuration dependent configuration dependent CLOSE CONTROL OPEN CONTROL OPEN CONTROL CLOSE CONTROL WHEN THERMOSTAT CLOSE CONTROL TEMPERATURE <90°C or >-40°C POSITION SIGNAL CORRECT SPEED SIGNAL CORRECT CLOSE CONTROL HIGH TORQUE IN OPENING only close only close JAMMED VALVE IN CLOSING JAMMED VALVE IN OPENING MOTOR THERMOSTAT only open only open only open only close only close only close not available not available configuration dependent INTERNALTEMPERATURE Ambient temperature too high not or too low. N Contents may change without notice. Check status of actuator and valve mechanical parts.“ICON2000” instruction and operating manual 10. Check the torque needed to operate the valve Operate the actuator in close direction.

“ICON2000” instruction and operating manual 10. N 85 Section 618/3 .) CONDITION FOR WARNING Measured torque 10% lower than the relevant value configured in torque set-up or stroke limits routines Measured torque 10% lower than the relevant value configured in torque set-up or stroke limits routines Temperature inside the actuator enclosure higher than 80°C or lower than -35°C Value of the main voltage out of the correct range (-15% or +10% of the value stated in the name plate menu) or wrong frequency Max.) Check the torque necessary to move the valve available available available OPEN CONTROL INTERNAL TEMP. COMPANY Section 618/3 chapt. number of contactor cycles reached ACTION Check the torque necessary to move the valve AVAILABLE CONTROLS Local available ALARM RESET Remote available ESD available CLOSE CONTROL HIGH TORQUE IN CL (NEAR MAX.) CONTACTOR CYCLES Change contactor and reset operation log available available available CLEAR RECENT DATA LOG MAINTENANCE REQUEST Date of the next maintenance reached Perform maintenance and set next maintenance date available available available CHANGE DATE MOTOR CURRENT Motor current greater or lower than limits Check electrical motor available available available CURRENT OK WRONG STROKE LIMITS The routine that monitors the stroke limits detects a wrong end of travel condition Re-calibrate both stroke limits available available available RE-CALIBRATE BOTH STROKE LIMITS Contents may change without notice. All rights reserved. © Copyright by BIFFI Italia.2 WARNING TABLE DISPLAY MESSAGE HIGH TORQUE IN OP (NEAR MAX. A !@#$ INTERNATIONAL LTD. (NEAR LIMITS) Find the heat source and insulate the actuator available available available CONTROL TEMPERATURE >-35°C and <80°C MAIN VOLTAGE CORRECT MAIN VOLTAGE (NEAR LIMITS) Check section of wires and values of voltage and frequency available available available (MAX.

A !@#$ INTERNATIONAL LTD. All rights reserved. N Contents may change without notice. . COMPANY Section 618/3 chapt.“ICON2000” instruction and operating manual Section 618/3 86 © Copyright by BIFFI Italia.

.................... All rights reserved. COMPANY Section 618/4 87 Section 618/4 ......“ICON2000” instruction and operating manual !@#$ flow control Section 618/4 Spare parts and drawings INDEX CHAPTER “O” PARTS LIST AND DRAWINGS... A !@#$ INTERNATIONAL LTD................. © Copyright by BIFFI Italia.........................................................................89 Contents may change without notice............................89 1.......................................... Introduction.......

All rights reserved. COMPANY Section 618/4 Contents may change without notice. A !@#$ INTERNATIONAL LTD. .“ICON2000” instruction and operating manual Section 618/4 88 © Copyright by BIFFI Italia.

“ICON2000” instruction and operating manual PARTS LIST AND DRAWINGS 1. Important: When ordering spare parts. COMPANY Section 618/4 chapt. please refer to the marked part list items on the attached drawings. A !@#$ INTERNATIONAL LTD. Recommended spares are marked with this sign • on parts list. please indicate the serial number embossed on the actuator nameplate. Contents may change without notice. CHAPTER Important: O Important: When ordering spare parts. © Copyright by BIFFI Italia. O 89 Section 618/4 . Introduction This section includes the drawings and parts list of each component and subassembly of ICON2000 actuators. All rights reserved.

COMPANY Section 618/4 chapt. A !@#$ INTERNATIONAL LTD. O Contents may change without notice.“ICON2000” instruction and operating manual ICON2000 table 1 Section 618/4 90 © Copyright by BIFFI Italia. . All rights reserved.

All rights reserved. © Copyright by BIFFI Italia. O 91 Section 618/4 .“ICON2000” instruction and operating manual ICON2000 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Q.ISO5210 Screw Bearing Position sensor shaft • Quad ring • Seal ring Position sensor flange Screw Position sensor Screw Column Power card Column Screw Processor card Display plate O-ring Local interface assembly Screw O-ring I/O card Terminal board Circlip Power terminals cover Screw Screw Terminals label O-ring Screw Terminal board cover • • • • • • • • • OPTIONAL 1 A 1 B • • • • Bus interface card Battery assembly Contents may change without notice. A !@#$ INTERNATIONAL LTD.ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 2 1 4 1 1 1 4 1 1 1 2 1 1 1 1 1 1 1 1 1 2 • Recommended spare parts Description Housing Lower bearing Hollow shaft Worm wheel Circlip Driver sleeve Driver sleeve spring Spring retaining ring • O-ring Upper bearing Quad ring Cover retaining ring Plug O-ring Cover plastic washer Cover Handwheel Oil plug Screw Bearing Worm shaft Taper bearing Quad ring O-ring Worm shaft flange Screw Seal ring Screw Electric motor assembly O-ring Motor cover Screw O-ring Oil plug Finger assembly Screw DU bush Shoulder washer Fork Shoulder washer Shoulder washer Lever assembly Spring washer Screw Earth stud Earth stud nut • Item 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 Q.ty 1 2 1 4 2 1 1 1 1 2 1 3 4 1 4 4 1 1 1 1 4 1 1 1 1 1 2 4 1 1 4 1 table 1 • Recommended spare parts Description Earth stud indication plate • Quad ring Thrust block assembly . COMPANY Section 618/4 chapt.type A .

Electric motor table 2 • Recommended spare parts • Section 618/4 Item 29.2 29.4 29. All rights reserved.ty 1 1 1 1 2 1 1 2 Description Electric motor Speed magnetic sensor Speed magnetic card Rubber ring Screw Speed sensor cover Motor terminals board Screw • 92 © Copyright by BIFFI Italia.5 29.3 29.6 29. . O Contents may change without notice.8 Q. A !@#$ INTERNATIONAL LTD. COMPANY Section 618/4 chapt.“ICON2000” instruction and operating manual ICON2000 .Electric motor table 2 ICON2000 .7 29.1 29.

COMPANY Section 618/4 chapt.6 35.Finger assembly table 3 ICON2000 .5 35.1 35. All rights reserved.“ICON2000” instruction and operating manual ICON2000 .2 35. © Copyright by BIFFI Italia. O 93 Section 618/4 .3 35.ty 1 2 1 1 1 1 1 Description Cover Circlip Finger Pin Bending spring Bush Spring table 3 • Recommended spare parts Contents may change without notice.4 35.Finger assembly Item 35.7 Q. A !@#$ INTERNATIONAL LTD.

O Contents may change without notice.5 42.Lever assembly table 4 • Recommended spare parts Section 618/4 Item 42. All rights reserved.3 42. .Lever assembly table 4 ICON2000 . COMPANY Section 618/4 chapt.6 42. A !@#$ INTERNATIONAL LTD.ty 1 1 1 1 1 1 1 Description Lever Key Shoulder washer Bearing Spring Retainer ring Pin • 94 © Copyright by BIFFI Italia.4 42.2 42.“ICON2000” instruction and operating manual ICON2000 .1 42.7 Q.

Thrust block assembly table 5 ICON2000 .3 49.8 Q. COMPANY Section 618/4 chapt. © Copyright by BIFFI Italia.ty 1 1 1 4 2 1 1 1 Description Thrust block housing O-ring Greaser Thrust washer Thrust bearing Stem nut Quad ring Lower ring nut table 5 • Recommended spare parts • • • Contents may change without notice.“ICON2000” instruction and operating manual ICON2000 .7 49. All rights reserved. A !@#$ INTERNATIONAL LTD.5 49.2 49.6 49.Thrust block assembly Item 49.1 49.4 49. O 95 Section 618/4 .

5 57.“ICON2000” instruction and operating manual ICON2000 . All rights reserved.Position sensor assembly table 6 ICON2000 . .Position sensor assembly table 6 • Recommended spare parts • • Section 618/4 Item 57.ty 1 1 2 1 1 2 Description Cover Sensor card Bearing Magnetic disk Base Screw 96 © Copyright by BIFFI Italia.2 57.6 Q. O Contents may change without notice.3 57. COMPANY Section 618/4 chapt.1 57. A !@#$ INTERNATIONAL LTD.4 57.

3 66.Local interface assembly table 7 ICON2000 .5 66. A !@#$ INTERNATIONAL LTD. © Copyright by BIFFI Italia.ty 1 1 1 1 1 1 Description Ball Spring O-ring Selector Screw Plug table 7 • Recommended spare parts • • • • • • Contents may change without notice. O 97 Section 618/4 .1 66. COMPANY Section 618/4 chapt.6 Q.Local interface assembly Item 66.2 66.“ICON2000” instruction and operating manual ICON2000 . All rights reserved.4 66.

A !@#$ INTERNATIONAL LTD. . O Contents may change without notice. COMPANY Section 618/4 chapt.Wiring loom and cables identification table 8 4 5 10 6 1 2 3 7 9 8 ICON2000 .“ICON2000” instruction and operating manual ICON2000 . All rights reserved.Wiring loom and cables identification Item 1 2 3 4 5 6 7 8 9 10 Cable type Cab10 Cab15 Cab16 Cab27 Cab35 Cab28 Cab30 Cab20 Cab25 Cab17 table 8 Description • Recommended spare parts I/O remote cable Remote control supply cable Inlet power cable Motor power cable Speed sensor cable Thermostat cable Position sensor cable Internal controls cable Contactor controls cable Earth wire Section 618/4 98 © Copyright by BIFFI Italia.

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A.r.01 MAN618/Rev. Sales department.biffi.000/06.it . C. +39 0523 944411fax +39 0523 943923 e-mail biffi_italia@biffi./Grafiche Malvezzi/3. 0 Biffi Italia s.Italy tel. Headquarters.it website: www. 29017 Fiorenzuola d’Arda .l.

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