Httpsbiffi - Itdocumentsmanual Guides Icon3000 Iom en en Us 5152070 PDF
Httpsbiffi - Itdocumentsmanual Guides Icon3000 Iom en en Us 5152070 PDF
VCIOM-08500-EN Rev. 2
May 2022
Biffi ICON3000
Electric Actuator
Copyright © Biffi. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.biffi.it or from your nearest Biffi Center:
Biffi Italia s.r.l. - Strada Biffi 165, 29017 Fiorenzuola d’Arda (PC) – Italy PH: +39 0523 944 411 – [email protected]
Revision Details Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Revision Details
Revision Details
Installation, Operation and Maintenance Manual Table of Contents
VCIOM-08500-EN Rev. 2 May 2022
Table of Contents
Section 1: General Safety Instructions
1.1 Range of Applications ................................................................................... 1
1.2 Safety Instructions for Installation in Hazardous Areas ................................... 2
1.2.1 Marking .............................................................................................. 3
1.3 Applicable Standards and Regulations ........................................................... 3
1.4 Terms and Conditions ................................................................................... 4
Section 3: Installation
3.1 Working Condition ........................................................................................ 9
3.1.1 Heater Options ................................................................................... 9
3.2 Coupling Block: Disassembly from the Actuator .......................................... 11
3.2.1 Type “A” Coupling Block ................................................................... 11
3.2.2 Type “B1” and “B2” Coupling Blocks ................................................. 13
3.2.3 Type “B3” and “B4” Coupling Blocks ................................................. 14
3.2.4 Attaching the Coupling Block to the Gear Reduction Unit ................. 15
3.3 Manual Operation ....................................................................................... 16
3.4 Mounting the Actuator onto the Valve ........................................................ 18
3.4.1 Coupling Type “A” ............................................................................ 18
3.4.2 Coupling Types “B1”, “B2”,”B3” and “B4” ......................................... 18
3.4.3 Actuator Mounting ........................................................................... 19
3.5 Electrical Connections................................................................................. 20
3.5.1 Plant Requirements .......................................................................... 20
3.6 Removing the Terminal Board Enclosure...................................................... 20
3.7 Removing the Terminal Board Enclosure...................................................... 21
3.8 Terminal Board ............................................................................................ 22
3.9 Instructions For Explosion-proof Enclosures ................................................ 24
3.10 Installation in Environments with Explosive Dusts........................................ 25
Section 4: Lubrication
4.1 Lubrication Inspection................................................................................. 26
Table of Contents i
Table of Contents Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
ii Table of Contents
Installation, Operation and Maintenance Manual Table of Contents
VCIOM-08500-EN Rev. 2 May 2022
Appendix A: ICON3000/ICON3000AD
A.1 Safety Instructions .................................................................................... 120
A.1.1 General .......................................................................................... 120
A.2 Instructions for Proper Installation ............................................................ 120
A.2.1 Marking .......................................................................................... 121
A.3 Applicable General Standards and Regulations .......................................... 122
A.4 Terms and Conditions ............................................................................... 122
A.5 Manufacturer’s Liability ............................................................................. 122
A.6 Storage and Pre-Installation ...................................................................... 123
A.6.1 Storage Procedure.......................................................................... 123
A.6.2 Checks to be Performed Before Installation .................................... 123
A.7 Installation ................................................................................................ 123
A.7.1 Working Condition ......................................................................... 123
A.7.2 Identification of Entries................................................................... 124
A.7.3 Electrical Connections .................................................................... 125
A.7.4 Cable Connection ........................................................................... 125
A.7.5 Installation in Environments with Explosive Dusts ........................... 126
A.8 Maintenance ............................................................................................. 126
A.8.1 Periodic Inspection ......................................................................... 127
A.8.2 Disassembly and Reassembly.......................................................... 127
A.8.3 Repairs ........................................................................................... 128
Appendix B: ICON3000/ICON3000AD/ICON3000LP
B.1 Safety Instructions .................................................................................... 129
B.1.1 General .......................................................................................... 129
B.1.2 Identification of Main Parts ............................................................. 130
B.2 Instructions for Proper Installation ............................................................ 131
B.2.1 Marking .......................................................................................... 131
B.3 Applicable General Standards and Regulations .......................................... 132
B.4 Terms and Conditions ............................................................................... 133
B.5 Manufacturer’s Liability ............................................................................. 133
B.6 Storage and Pre-Installation ...................................................................... 133
B.6.1 Storage Procedure.......................................................................... 133
B.6.2 Checks to be Performed Before Installation .................................... 134
B.7 Installation ................................................................................................ 134
B.7.1 Working Condition ......................................................................... 134
B.7.2 Identification of Entries................................................................... 135
B.7.3 Electrical Connections .................................................................... 138
B.7.4 Cable Connection ........................................................................... 138
B.7.5 Installation in Environments with Explosive Dusts ........................... 139
B.8 Maintenance ............................................................................................. 139
B.8.1 Periodic Inspection ......................................................................... 139
B.8.2 Disassembly and Reassembly.......................................................... 140
B.8.3 Repairs ........................................................................................... 140
iv Table of Contents
Installation, Operation and Maintenance Manual Table of Contents
VCIOM-08500-EN Rev. 2 May 2022
Appendix C: ICON3000/ICON3000AD
C.1 Safety Instructions .................................................................................... 141
C.1.1 General .......................................................................................... 141
C.2 Instructions for Proper Installation ............................................................ 141
C.2.1 Marking .......................................................................................... 142
C.3 Applicable General Standards and Regulations .......................................... 143
C.4 Terms and Conditions ............................................................................... 143
C.5 Manufacturer’s Liability ............................................................................. 143
C.6 Storage and Pre-Installation ...................................................................... 144
C.6.1 Storage Procedure.......................................................................... 144
C.6.2 Checks to be Performed Before Installation .................................... 144
C.7 Installation ................................................................................................ 144
C.7.1 Working Condition ......................................................................... 144
C.7.2 Identification of Entries................................................................... 145
C.7.3 Electrical Connections .................................................................... 146
C.7.4 Cable Connection ........................................................................... 146
C.7.5 Installation in Environments with Explosive Dusts ........................... 147
C.8 Maintenance ............................................................................................. 147
C.8.1 Periodic Inspection ......................................................................... 147
C.8.2 Disassembly and Reassembly.......................................................... 148
C.8.3 Repairs ........................................................................................... 148
Appendix D: ICON3000
D.1 Safety Instructions .................................................................................... 149
D.1.1 General .......................................................................................... 149
D.1.2 Identification of Main Parts ............................................................. 150
D.2 Instructions for Proper Installation ............................................................ 151
D.2.1 Marking .......................................................................................... 151
D.3 Applicable Directives, General Standards, and Norms ............................... 152
D.4 Terms and Conditions ............................................................................... 152
D.5 Manufacturer’s Liability ............................................................................. 153
D.6 Storage and Pre-Installation ...................................................................... 153
D.6.1 Storage Procedure.......................................................................... 153
D.6.2 Checks to be Performed Before Installation .................................... 153
D.7 Installation ................................................................................................ 154
D.7.1 Working Condition ......................................................................... 154
D.7.2 Identification of Entries................................................................... 154
D.7.3 Electrical Connections .................................................................... 156
D.7.4 Cable Connection ........................................................................... 157
D.7.5 Installation in Environments with Explosive Dusts ........................... 158
D.8 Maintenance ............................................................................................. 158
D.8.1 Periodic Inspection ......................................................................... 158
D.8.2 Disassembly and Reassembly.......................................................... 158
D.8.3 Repairs ........................................................................................... 159
Table of Contents v
Table of Contents Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Appendix E: ICON3000
E.1 Safety Instructions .................................................................................... 160
E.1.1 General .......................................................................................... 160
E.1.2 Identification of Main Parts ............................................................. 161
E.2 Instructions for Proper Installation ............................................................ 162
E.2.1 Marking .......................................................................................... 162
E.3 Applicable General Standards and Regulations .......................................... 163
E.4 Terms and Conditions ............................................................................... 164
E.5 Manufacturer’s Liability ............................................................................. 164
E.6 Storage and Pre-Installation ...................................................................... 164
E.6.1 Storage Procedure.......................................................................... 164
E.6.2 Checks to be performed before installation .................................... 165
E.7 Installation ................................................................................................ 165
E.7.1 Working Condition ......................................................................... 165
E.7.2 Identification of Entries................................................................... 165
E.7.3 Electrical Connections .................................................................... 168
E.7.4 Cable Connection ........................................................................... 168
E.7.5 Installation in Environments with Explosive Dusts ........................... 169
E.8 Maintenance ............................................................................................. 169
E.8.1 Periodic Inspection ......................................................................... 169
E.8.2 Disassembly and Reassembly.......................................................... 170
E.8.3 Repairs ........................................................................................... 171
vi Table of Contents
Installation, Operation and Maintenance Manual Section 1: General Safety Instructions
VCIOM-08500-EN Rev. 2 May 2022
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
! WARNING
The warning symbol labelled on the actuator means that it is mandatory to read the
manual before installing, operating and servicing the equipment.
Biffi electric actuators are designed in accordance with the applicable international rules
and specifications; nonetheless, the following regulations must be observed in any case:
• The general installation and safety regulations
• The plant specific regulations and requirements
• The proper use of personal protective devices (glasses, clothing, gloves)
• The proper use of tools, lifting and transport equipment
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
1.2.1 Marking
Table 1.
IECEx INE XX.ZZZZ IECEx reference certificate (CoC)
XX ATEX ZZZZ ATEX reference certificate
0080 Notified body for ATEX quality assurance (INERIS)
II Group II (surface industries)
2 Category 2 apparatus
G Explosive atmospheres caused by gas, mists, or vapors
D Explosive atmospheres caused by gas and dusts
P66/68 Degree of protection
FM18US0279X FM reference certificate for USA
FM18CA0134X FM-c reference certificate for Canada
Table 2.
Hazardous Zones Zone Categories according to 2014/34/EU Directive
Gas, mists, or vapors 0 1G
Gas, mists, or vapors 1 2G or 1G
Gas, mists, or vapors 2 3G or 2G or 1G
Dust 20 1D
Dust 21 2D or 1D
Dust 22 3D or 2D or 1D
Figure 1
Internal gears
Handwheel
Absolute Encoder
Terminal box
Engagement lever
2.2.1 General
The actuator leaves the factory in perfect condition, guaranteed by an individual test
certificate. In order to maintain these characteristics until the actuator is installed
on-site, proper procedures must be followed for preservation during the storage period.
ICON3000 actuators are weatherproof to IP66/68; this condition can only be maintained if
the unit is correctly installed on-site and if the actuator was correctly stored. The standard
plastic plugs used to close the cable entries are not weather-proof; their only function is to
prevent the entry of foreign objects during transport.
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
If the actuator has been stored for a long period of time prior to its installation, make sure to:
• Check the condition of the O-ring seals.
• Check the installation of the plugs or conduit glands on the conduit entries.
• Check if the enclosure covers or the actuator body are cracked or broken.
• Check the oil level in the actuator and top up if necessary.
• Put the batteries back into place (see Section 11.3, Lithium Battery Change).
Section 3: Installation
3.1 Working Condition
Standard actuators are suitable for the following environment temperatures:
-20 °C +85 °C (-4 °F to +185 °F)
Special versions are available for extreme environment temperatures:
-40 °C +85 °C (-40 °F to +185 °F)
-55 °C +65 °C (-67 °F to +149 °F)
Altitude up to 4.000 meters max.
NOTICE
The above conditions apply only to Ex d or Ex de versions. For other applications, refer to
the applicable addendum.
Table 5.
Model Ambient Temperature Range Control type
Power ON and OFF
managed by
Extreme Low
thermostat
Heater Heater Power Heater Low Temperature Temperature
assembled on the kit;
Type Supply Power up to -40 °C (-40 °F) -41 °C (-41.8 °F) to
Power ON: < 0 °C ;
-60 °C (-76 °F)
Power OFF: > 10 °C
Heater Externally
powered
1 PTC - A 24 V DC max 15 W Optional N/A ✓
2 PTC -B 110-240 1 ph max 15 W Optional N/A ✓
3 PTC - C* 24 V DC max 65 W N/A Mandatory ✓
4 PTC - D* 110-240 1 ph max 45 W N/A Mandatory ✓
NOTICE
PTC (C) Actuator Power Supply ON ( Start up or after Power shortage)
In the event of an ambient temperature below -40 °C (°F), the Actuator Main Power supply
must be kept ON or preceded by a preheating time. Actuator Main Power supply can be
switch ON after a warming up period. The minimum heating time must not be less than
60 minutes in case of ambient temperatures down to -60 ° C.
Installation 9
Section 3: Installation Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
NOTICE
Installation in an environment where the ambient temperature range falls outside the
rated temperature will invalidate the warranty. Refer to the nameplate to verify the rated
ambient temperature.
Figure 7
10 Installation
Installation, Operation and Maintenance Manual Section 3: Installation
VCIOM-08500-EN Rev. 2 May 2022
Figure 8
Installation 11
Section 3: Installation Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Figure 9
The internal thrust bearing will remain at the bottom of the block housing.
Figure 10
NOTICE
Before remounting the stem nut, make sure that 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 motorized valve by screwing the nut entirely along the valve stem without excessive friction.
The bore can now be machined in the stem nut to suit coupling requirements.
The same procedure is also used if maintenance is required.
12 Installation
Installation, Operation and Maintenance Manual Section 3: Installation
VCIOM-08500-EN Rev. 2 May 2022
Figure 11
Installation 13
Section 3: Installation Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Figure 12
The internal thrust washer will remain at the bottom of the block housing.
The bore can now be machined in the bushing to suit coupling requirements.
The same procedure is also used if maintenance becomes necessary.
Figure 13
14 Installation
Installation, Operation and Maintenance Manual Section 3: Installation
VCIOM-08500-EN Rev. 2 May 2022
Figure 14
Figure 15
Installation 15
Section 3: Installation Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
! 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.
Figure 16
Figure 17
16 Installation
Installation, Operation and Maintenance Manual Section 3: Installation
VCIOM-08500-EN Rev. 2 May 2022
Engagement lever locked in handwheel operation position: operation with the electric
motor is mechanically disengaged.
TO CLOSE
Figure 18
Figure 19
Figure 20
YES NO
Installation 17
Section 3: Installation Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
! WARNING
Never lift the valve/actuator assembly without securing slings to both the valve and
the actuator. Never use the handwheel to lift the actuator.
Table 6.
Model Max. weight, kg (lb)
010 32 (70.6)
020 38 (83.8)
030 46 (101.4)
040 56 (123.5)
050 73 (160.9)
18 Installation
Installation, Operation and Maintenance Manual Section 3: Installation
VCIOM-08500-EN Rev. 2 May 2022
NOTICE
If the actuator is supplied without stud bolts and nuts, these must be provided by the
customer and conform to the material requirements in Table 7.
! CAUTION
Failure to use proper torque values can result in damage to the actuator and/or valve.
Figure 21
Table 7.
Model Tightening Torque, Nm (lb.ft) Material
010 40 (29.5) Studs/Bolts: ISO Class 8.8 or ASTM A 320
020 150 (110.6) Grade L7 or L7M
030 150 (110.6)
040 300 (221.3) Nuts: ISO Class 8.8 or ASTM A 194
050 150 (110.6) Grade 4
Installation 19
Section 3: Installation Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
NOTICE
All accessories (including cable glands) must comply with approved specifications for the
site requirements and be certified according to the standard directive.
! WARNING
Be careful to not damage the joint surfaces of the terminal cover or seal during removal.
! CAUTION
Using a fastener other than the approved type may result in damage to the actuator or
valve. Refer to Table 8.
NOTICE
If the screws of the cover must be replaced, a SS AISI 316 must be used with minimum yield
strength of 450 N/mm2 (65,266 psi).
! CAUTION
Failure to use proper torque values can result in damage to the actuator and/or valve.
20 Installation
Installation, Operation and Maintenance Manual Section 3: Installation
VCIOM-08500-EN Rev. 2 May 2022
Figure 22
NOTICE
All accessories (including cable glands) must comply with approved specifications
for the site requirements and be certified according to the standard directive.
To guarantee a weather-proof and explosion-proof fit, screw the cable glands tightly
(at least 5 turns) and coat them with a thread sealant. The use of a thread sealant is
necessary in explosion-proof and weather-proof applications.
Installation 21
Section 3: Installation Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Figure 23
If some parts of the cable glands have been removed while working on the conduit entries,
put them back into place immediately to avoid misplacing the dismantled parts.
Unused entries:
• For explosion-proof construction: unused entries must be plugged with metal
explosion-proof plugs and coated with a thread sealant.
• For weather-proof construction: replace the plastic standard protection plugs
(supplied with the actuator) with metal plugs.
! WARNING
The actuator is non-intrusive. The control compartment is sealed in dry and clean conditions
and contains no site-serviceable components. Do not open the control compartment unless
absolutely necessary. Unauthorized access will invalidate the warranty.
NOTICE
Be careful to not damage the joint surfaces of the terminal cover or seal during removal.
NOTICE
When removing the cover assembly or terminal block cover on existing installations, follow
all safety and applicable site-specific rules.
22 Installation
Installation, Operation and Maintenance Manual Section 3: Installation
VCIOM-08500-EN Rev. 2 May 2022
Figure 24
Ground
studs
Figure 25
Installation 23
Section 3: Installation Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Figure 26
Table 8.
Motor Terminal Local interface
Model Material
cover enclosure cover cover
AISI 316/ASME B16.11 A182-F316
010 M8x30 M10x30 M10x35
(yield strength ≥ 450 N/mm² (65,266 psi)
AISI 316/ASME B16.11 A182-F316
020 M8x30 M10x30 M10x35
(yield strength ≥ 450 N/mm² (65,266 psi)
AISI 316/ASME B16.11 A182-F316
030 M10x35 M10x30 M10x35
(yield strength ≥ 450 N/mm² (65,266 psi)
AISI 316/ASME B16.11 A182-F316
040 M10x35 M10x30 M10x35
(yield strength ≥ 450 N/mm² (65,266 psi)
AISI 316/ASME B16.11 A182-F316
050 M12x45 M10x30 M10x35
(yield strength ≥ 450 N/mm² (65,266 psi)
24 Installation
Installation, Operation and Maintenance Manual Section 3: Installation
VCIOM-08500-EN Rev. 2 May 2022
! DANGER
Do not electrically operate the actuator when the electrical covers are removed. Do not
open the actuator covers when an explosive atmosphere may be present. Ignoring the
above precautions may result in personal injury or death.
• Replace any weather-proof seals that may have been removed (O-ring for the covers,
O-ring for the explosion-proof joint of the motor).
Ensure that:
• The joint surfaces are greased with silicone oil or equivalent before assembly.
• The cable glands have minimum protection degree IP6X (EN 60529).
Installation 25
Section 4: Lubrication Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Section 4: Lubrication
4.1 Lubrication Inspection
The actuator is lubricated for the duration of its service life; under normal working
conditions it is not necessary to replace or refill the oil. However, it is recommended to
check the oil level every 3-5 years using holes 1 or 2 (per Figures 27 and 28) depending on
what orientation the actuator was mounted.
The actuator is fitted with oil plugs (parts 1, 2), such 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.
A spherical head lubricator (part 3) is fitted on the coupling block for the proper greasing of
the inside thrust or sliding bearings.
The actuator is supplied with oil and greased where necessary.
Should maintenance become necessary, the following OILS are recommended:
Ambient temperature from -20 °C to +85 °C
• SHELL - OMALA S4 WE 320 or equivalent
Ambient temperature from -40 °C to +85 °C
• SHELL - TELLUS S4 ME 46 or equivalent
Ambient temperature from -55 °C to +65 °C
• SHELL - TELLUS S4 VX 32 or equivalent
Table 9.
Model Oil quantity, liter (quart)
010 0.5 (0.53)
020 0.8 (0.85)
030 1.3 (1.37)
040 1.8 (1.90)
050 2.5 (2.64)
26 Lubrication
Installation, Operation and Maintenance Manual Section 4: Lubrication
VCIOM-08500-EN Rev. 2 May 2022
Figure 27
Figure 28
Lubrication 27
Section 5: Operating the ICON3000 Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Figure 29
! 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.
! CAUTION
Working outside the above limitations could damage the actuator.
Be careful if an inverter or generator is used as a power supply.
Figure 30
Figure 31
Figure 32
Figure 33
OPEN/YES
STOP
CLOSE/NO
Figure 34
Figure 35
Figure 36
Option A1)
Option B1)
Figure 37
Option A2)
Option B2)
Figure 38
Option A3)
Option B3)
! WARNING
Any certification relating to actuator operation in hazardous areas will be invalidated if the
client desires that the motor thermostat be bypassed during ESD operation.
Figure 39
Option D1)
Option D2)
Figure 40
Option E1)
Option E2)
Additional modules can be plugged in the base card of the ICON3000 to provide the
following functions:
A hardware alarm is generated if the ICON3000 is set to be equipped with a bus card but
the card is damaged or missing. A BUS REPORT is also present in the list of reports if the
card is present (Refer to Section 6). Refer to the specific manuals for instructions and
setting of the above modules.
Figure 41
• 4 - 20 mA analog output
The 4 - 20 mA output can be configured to provide a signal proportional to either
“position” or “torque”. The polarity option allows the relationship between position
(or torque) and the 4-20mA output signal to be reversed and the 4 - 20 mA output
signal. See “VIEW and SET-UP” features (Section 9.1.9, OUT 4 - 20 mA).
The 4 - 20 mA output is optically-isolated (opto-coupled). It should be powered by
a 20-30 V DC voltage (externally or internally generated) and the maximum load
(including cable resistance) should be less than 300 ohm.
Figure 42 shows the wiring diagram.
Figure 42
Actuator terminals Active loop External power supply
V+
B6 20-30
Cable V DC
4 - 20 mA
B7 Load: max 300 ohm
0V
Shield
GROUND
4 - 20 mA
B7
Cable Load: max 300 ohm
0V
C10
Shield
GROUND
If mains voltage is lost, behavior will be different if the power supply of the 4 - 20
mA output stage is internally- or externally-generated:
- Internal power supply (or passive loop):
If mains voltage is lost the output 4 - 20 mA drops to 0. The correct output
will be restored when mains voltage returns.
- External power supply (or active loop):
If the actuator is provided with a lithium battery (or supplied by the
auxiliary 24 V DC) and if mains voltage fails, the output 4 - 20 mA
maintains the last value. If the actuator is moved via the handwheel, the
output 4 - 20 mA will be updated. If the actuator is not provided with a
lithium battery (or not supplied by the auxiliary 24 V DC)
and mains voltage fails, the output 4 - 20 mA maintains the last
value. If the actuator is moved by handwheel, the output 4 - 20 mA will not
be updated.
• 4 - 20 mA analog input
The 4 - 20 mA analog input is the position request R% signal and is used by the
ICON3000 to position the valve in positioning (inching) and modulating actuators.
The “POSITIONER” routine processes the input signal, compares the present
actuator position % with the position request R%, and if the difference is greater
than the dead band - the actuator is driven to reach the requested position. 4 mA
corresponds to request R% = 0% = valve closed and 20 mA corresponds to request
R% = 100% = valve open. The relationship between position and request signals
can be reversed by the “Polarity” function. The 4 - 20 mA input is optically-isolated
(opto-coupled). The input impedance is less than 500 ohm. The loss of the
4 - 20 mA input signal is indicated as follows:
- Change-over of the monitor relay
- Alarm LED on
- List of ALARMS (see Section 12.11, Diagnostic messages)
- Alarm log
Figure 43 shows the wiring diagram.
Figure 43
Figure B
Actuator terminals
4 - 20 mA
B9 4 - 20 mA
Cable generator
0 V DC
B8
0V
GROUND Shield
The “VIEW and SET-UP” features can configure different options, which are described in
Section 9.1.7, Positioner.
If the POSITIONER function is active, the alpha-numeric display indicates the value of the
position request in % (R%: xxx.x).
Figure 44
Ain/Aout card
This optional card is used in place of the Terminal Board Adapter (TBA) card when an analog
4 - 20 mA input and output signal is requested.
Potentiometer card
This card can be used for some special FW versions of the ICON3000.
Figure 50
1. OLED Graphic display: during normal operation the alphanumeric display shows the
present status (NORMAL, ESD ON, ALARMS, WARNINGS, INTERLOCK, INT.EFS, SLEEP,
EFS OFF, PST ON), the 3-positionselector status (LOCAL, OFF, REMOTE), and the
actuator action (OPEN, OPENING, CLOSED, CLOSING, STOP, or R% : xxx.x). If the local
selector is in OFF or REMOTE, pressing the YES push-button allows the user to scroll
through the list of variables, alarms, and reports:
42 Local Controls
Installation, Operation and Maintenance Manual Section 6: Local Controls
VCIOM-08500-EN Rev. 2 May 2022
The data with * are only present if the relevant modules are present.
5. Three LEDs to indicate the actuator status according to the following logic:
• green ON/ red OFF: the actuator is stopped in the open position
• green OFF/ red ON: the actuator is stopped in the closed position
• green OFF/ red flashing: the actuator is running in the closing direction
• green flashing/ red OFF: the actuator is running in the opening direction
• green ON/ red ON: the actuator is stopped in an intermediate position
• yellow ON: alarm
• yellow flashing: warning
The above color combination is supplied as standard, but it may be changed
(red to green, green to red, and yellow to red), during actuator setup operations.
Local Controls 43
Section 6: Local Controls Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
The warning condition occurs when a variable reaches a critical value and/or a maintenance
action is required, but the actuator control functions are still available. The alarm condition
occurs when a variable moves out of its acceptable range and thus causes the actuator
control functions to become unavailable.
44 Local Controls
Installation, Operation and Maintenance Manual Section 6: Local Controls
VCIOM-08500-EN Rev. 2 May 2022
The alarm and warning lists only contain the present alarms and warnings. When the
fault condition disappears, the corresponding alarm or warning disappears from the
list. A reset routine is provided to clear the type of alarm/warning that is memorized
(over-torque, jammed valve, etc.).
The following drawing shows the use of the OPEN/YES, CLOSE/NO and STOP
push-buttons as a function of the local selector position.
Figure 53
Local Off Remote
3-position selector
= OPEN/YES push-button
= CLOSE/NO push-button
= STOP push-button
= OPEN/YES push-button
Press YES and STOP
Only OPEN, Press YES or NO to answer the Variable alarm
simultaneously to
CLOSE and STOP prompt (view? next?). and report list
enter VIEW and
controls available SET-UP menus If the prompt is “next?” press YES to
view the next variable; press NO to
return to the beginning.
If the prompt is “view?” press YES to TORQUE % next?
enter the sub-menu of the MOTOR SPEED RPM next?
VOLTAGE V,Hz next?
variable; press NO to skip to the CURRENT A next?
next variable. TEMPERATURE °C next? YES
TIME next?
DATE next?
NO ALARMS/ALARMS next/view?
NO WARNING/WARNINGS next/view?
K TEMP or POWER TEMP YES
(ICON LP) next?
MOTOR TEMP °C next?
TERM TEMP next?
LOG STATUS next?
Language WIRELESS REPORT view?
selection WIRELESS CONNECT view?
NO NODE REPORT view?
FDI REPORT view?
BASE REPORT view?
View/Set-up mode TERM REPORT view?
A in /A out REPORT view?
selection
NO
Place the
3-position
Password selector in
LOCAL or REMOTE
or press YES ALARM # 1 next?
NO ..................
View mode Set-up mode and NO ..................
simultaneously ALARM # n next?
to exit from VIEW YES
RESET ALARMS OK?
and SET-UP YES
MENUS
To view To set-up
menus menus WARNING # 1 next?
NO ..................
..................
WARNING # n next? YES
View and Setup menus RESET WARNING OK?
YES
msg # 1 next?
..................
.................. YES
YES msg # n next?
Local Controls 45
Section 6: Local Controls Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
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.
• Stroke limits
• Torque set-up
• ESD set-up
• PST set-up
• Remote controls
• Local controls
• Output relays
• Positioner *
• Fail-safe *
• Out 4 - 20 mA *
• Interlock
• 2-speed timer
• Bus *
• Miscellaneous
The routines with * are only available if the relevant modules are present. If the bus
interface is LonWorks, the “BUS” routine changes to “FDI control”.
46 Local Controls
Installation, Operation and Maintenance Manual Section 6: Local Controls
VCIOM-08500-EN Rev. 2 May 2022
Nameplate
This menu includes a series of data identifying the actuator characteristics, service, and
utilization mode. The data are entered by the manufacturer and can only be viewed
(not edited; as such, this menu is only available in View mode).
List of routines:
• serial number
• actuator type
• torque/thrust
• actuator speed
• power supply
• motor data
• test date
• wiring diagram
• enclosure
• certificate
• lubricant
• revision
• torque sensor
Valve Data
This menu includes a series of data relevant to the valve.
The valve manufacturer and end user should enter the data.
List of routines:
• tag name (max 28 characters)
• serial number (max 28 characters)
• manufacturer (max 28 characters)
• break OP torque (max 28 characters)
• max stem thrust (max 28 characters)
• flange type (max 28 characters)
Local Controls 47
Section 6: Local Controls Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Maintenance
This menu includes all diagnostic and historic data which can assist the operator if failures
occur or during maintenance operations. The Maintenance menu also includes the
“Set password” routine.
List of routines:
• Set-up Mode
— new password
— clear alarm log
— torque profile reference
— torque curve reference
— clear recent data log
— configuration (backup/restore) (only for ICON3000v2)
— maintenance date
— data logger
— PST reference (only if INTERLOCK = ADVANCED)
— PST cmd (only if INTERLOCK = ADVANCED)
• View Mode
— alarm log
— torque profile
— torque curve
— operation log
— maintenance date
— data logger
The parameters appear on the alphanumeric display in the same order in both view and
set-up mode. At the end of each routine, the program will automatically return to the
beginning of the routine and the operator can choose to either reenter (by pressing YES) or
move on to a next routine (by pressing NO).
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Local Controls 49
50
May 2022
Display
YES FROM EXIT?
Section 6: Local Controls
YES
Figure 54
NO YES NO NO
OFF
LOCAL REMOTE
Press
NO
until the
desired
LANGUAGE FRANCAIS ENTER PASSWORD
language OK? OK?
appears
and
then
press
YES YES PASSWORD WRONG
3-position selector
Enter View and Set-Up Mode
YES
TO SETUP
SETUP MODE
“Z” 0 0 0 Z “K” 0 0 Z K “9” 0 Z K 9 “R” MENU
OK?
DIGIT 1 OK? DIGIT 2 OK? DIGIT 3 OK? DIGIT 4 OK?
FROM EXIT?
Press NO until the desired character appears and then press YES
Local Controls
VCIOM-08500-EN Rev. 2
Installation, Operation and Maintenance Manual
Set-Up Menu
OFF
VCIOM-08500-EN Rev. 2
Display
3-position selector
XXXXXX OFF
STOP NEXT? NO YES
YES NO NO NO
Installation, Operation and Maintenance Manual
YES STOP
Section 7: Set-Up Menu
51
May 2022
Section 7: Set-Up Menu
52
May 2022
Section 7: Set-Up Menu
YES NO NO NO TO
Figure 56
EXIT?
ACTUATOR SETUP MAINTENANCE
VALVE DATA
SETUP MODE MAINTENANCE
OK? CHANGE? CHANGE?
CHANGE?
NO NO NO
YES YES YES
NO NO NO
YES YES
Figure 56 shows the procedure to navigate through the set-up routines.
MISCELLANEOUS MAINTENANCE
ROUTINE DATE
ACTUATOR SETUP ROUTINE
MAINTENANCE
MISCELLANEOUS YES MAINTENANCE DATE YES
CHANGE? CHANGE?
NO NO
Set-Up Menu
VCIOM-08500-EN Rev. 2
Installation, Operation and Maintenance Manual
View Menu
VCIOM-08500-EN Rev. 2
OFF
LOCAL REMOTE
Figure 57
XXXXXX OFF
STOP NEXT? NO YES
Installation, Operation and Maintenance Manual
YES NO NO NO YES
Section 8: View Menu
YES STOP
EXIT?
VIEW MODE ACTUATOR SETUP NAME PLATE VALVE DATA MAINTENANCE OK?
SELECT OK? VIEW? VIEW? VIEW? VIEW?
LANGUAGE
Press YES or NO to answer the appropriate prompts (OK?, view?, next?, etc.)
53
May 2022
Section 8: View Menu
54
May 2022
Section 8: View Menu
Figure 58
NO NO NO NO TO
YES
EXIT?
ACTUATOR NAME PLATE VALVE DATA MAINTENANCE
VIEW MODE SETUP
VIEW?
OK? VIEW? VIEW? VIEW?
TAG ALARM
STROKE SERIAL
NAME LOG
LIMITS NUMBER
ACTUATOR ROUTINE MAINTENANCE ROUTINE
ROUTINE NAME PLATE ROUTINE VALVE DATA
SETUP YES YES YES
STROKE LIMITS SERIAL NUMBER YES TAGE NAME ALARM LOG
VIEW? VIEW? VIEW? VIEW?
NO NO NO
NO
YES YES YES YES
SERIAL ................
................ ................ NUMBER ................
................ ................
Procedure to Move in the View Routines
ROUTINE ROUTINE
ACTUATOR ROUTINE ROUTINE VALVE DATA MAINTENANCE
SETUP NAME PLATE
YES SERIAL NUMBER
YES YES
XXXXXX XXXXXX XXXXXX XXXXXX YES XXXXXX XXXXXX
VIEW? VIEW? VIEW? VIEW?
NO NO NO NO
Figure 58 shows the procedure to navigate through the view routines.
SW MAINTENANCE
MISCELLANEOUS VERSION DATE
ROUTINE NAME PLATE ROUTINE ROUTINE
ACTUATOR MAINTENANCE
SETUP SW VERSION YES YES
MISCELLANEOUS YES MAINTENANCE DATE
VIEW? VIEW? VIEW?
NO NO NO
View Menu
VCIOM-08500-EN Rev. 2
Installation, Operation and Maintenance Manual
Installation, Operation and Maintenance Manual Section 9: Set-Up Routines
VCIOM-08500-EN Rev. 2 May 2022
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.
Select the language and then enter the password according to the instructions
(refer to “Entering the set-up mode”). When the message displayed is “SET-UP
MODE OK?” press YES. Press YES to select the "Actuator Setup" menu, and then
press YES again to start with the stroke limits routine.
• Press YES if the closing torque limit is correct or press NO to scroll through the list
of available values. When the value is correct, press YES.
• Press YES if the opening torque limit is correct or press NO to scroll through the list
of available values. When the value is correct press YES.
• Press YES if the rotation to close is correct (CW or CCW), or press NO to change.
When the value is correct press YES.
• Press YES to set the close limit, or press NO and then YES to set the open limit.
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Table 12.
Before leaving the stroke limits routine the microprocessor calculates the new value of
the position resolution. If the stroke turns are fewer than 2.7, the message “error retry”
appears and the stroke limits procedure must be repeated.
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Set-up Procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and then enter the password according to the instructions
(refer to “Entering the set-up mode”). When the message displayed is “SET-UP
MODE OK?” press YES. Press YES to select the "Actuator Setup" menu, press NO,
and then press YES to select the "Torque Setup" routine.
• Press YES if the opening torque limit is correct; otherwise, press NO to scroll
through the list of available values. Press YES when the value is correct.
• Press YES if the closing torque limit is correct; otherwise, press NO to scroll
through the list of available values. Press YES when the value is correct.
Function “ESD priority” allows the ESD command to override the following additional
situations: (*) motor thermostat alarm, (*) torque limit tripped, (*) local stop pressed,
3-position selector in LOCAL, 2-speed timer, (*) 3-position selector in OFF.
! WARNING
The user may select ESD to override the situations indicated by (*). If these situations
occur and if “ESD > ...” is configured, the actuator may be damaged. Therefore, selecting
“ESD > ...” will invalidate the warranty.
Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP. Select
the language and then enter the password according to the instructions (refer to
“Entering the set-up mode”). When the message displayed is “SET-UP MODE OK?”
press YES. Press YES to select the "Actuator Setup" menu, press NO to scroll through
the list of available routines, and then press YES to select "ESD Setup".
• Press YES if the ESD action is correct, or press NO to scroll through the list of
available options (off, open, close, stay-put, go to position xx %). Press YES to
select the desired option.
• Press either YES or NO to select the signal type (present, absent).
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• Press YES to change ESD priority with reference to the following signals or status:
- (*) Motor thermostat alarm. By choosing ESD > THERMOSTAT, the
ESD action will be carried out even in the event of motor over-heating.
Conversely, if ESD < THERMOSTAT was chosen, the ESD action will not be
performed in the event of motor over-heating.
- (*) Torque limit tripped. By choosing ESD > TORQUE LIMIT, the ESD
action will be carried out even if a torque alarm is present. Conversely,
if ESD < TORQUE LIMIT was chosen, the ESD action will not be performed
while a torque alarm is present.
- (*) Local stop pressed. By choosing ESD > LOCAL STOP, the ESD action
will override the local STOP signal. Conversely, if ESD < LOCAL STOP
was chosen, the ESD action will not be performed if the local STOP
push-button is pressed.
- Local selector in LOCAL. By choosing ESD > LOCAL CONTROLS, the
ESD action will be carried out also when the local selector is in LOCAL.
Conversely, if ESD < LOCAL CONTROLS was chosen, the ESD action will not
be performed if the 3-position selector is in LOCAL.
- 2-speed timer. By choosing ESD > 2-speed timer, the 2-speed timer function
will be inhibited during the ESD action. Conversely, if ESD < 2-speed timer was
chosen, the 2-speed timer function will remain enabled during ESD action.
- (*) Local selector in OFF. By choosing ESD > OFF, the ESD action will be
carried out also when the local selector is in OFF. Conversely, if ESD < OFF
was chosen, the ESD action will not be performed if the 3-position selector
is in OFF.
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Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and then enter the password according to the instructions
(see “Entering the set-up mode”). When the message displayed is “SET-UP MODE
OK?” press YES. Press YES to select the "Actuator Setup" menu, press NO to scroll
through the list of available routines, and then press YES to select "Remote Controls".
• Press YES if the control mode is correct or NO to scroll through the list of
available options: 4 wires, 3 wires, 2 wires, off. Press YES to select the desired
option. If 4 wires was chosen, use YES and NO to select the STOP signal; set MAKE
to stop when the signal is on and set BREAK to stop when the signal is off. If
“3 wires” was chosen, use YES or NO to answer the prompt on the display and
choose among “push-to-run” or “latched instant reverse” control modes.
If “2 wires” was chosen, use YES and NO to choose among “open if signal ON”
or “open if signal OFF” control modes.
Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and then enter the password according to the instructions
(see “Entering the set-up mode”). When the message displayed is “SET-UP MODE
OK?” press YES. Press YES to select the "Actuator Setup" menu, press NO to scroll
through the list of available routines, and then press YES to select "Remote Controls".
• Press YES if the control mode is correct or NO to scroll through the list of
available options: 4 wires, 3 wires, 2 wires, off. Press YES to select the desired
option. If 4 wires was chosen, use YES and NO to select the STOP signal; set MAKE
to stop when the signal is on and set BREAK to stop when the signal is off. If
“3 wires” was chosen, use YES or NO to answer the prompt on the display and
choose among “push-to-run” or “latched instant reverse” control modes.
If “2 wires” was chosen, use YES and NO to choose among “open if signal ON”
or “open if signal OFF” control modes.
Control Mode
• Press YES if the display shows the correct control mode or press NO to scroll through
the list of available options (push-to-run, latched). Press YES to confirm. Option
"push-to-run rel. AS5-6" is used when remote enabling of local commands is required.
With the local selector in LOCAL, pressing the OPEN or CLOSE local push-buttons
causes relays AS5 or AS6 to switch, but no command is sent to the motor. The control
PLC should read the status of the above-mentioned relays and send an open or close
command to the remote inputs (refer to Section 5.6, push-to-run mode; see relevant
electrical diagram when the option is used).
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LED colors
• Press YES if the color of the open LED is correct. Press NO to change it,
and then press YES to confirm.
• Press YES if the color of the close LED is correct. Press NO to change it,
and then press YES to confirm.
• Press YES if the color of the alarm LED is correct. Press NO to change it,
and then press YES to confirm.
The following situations can be configured individually to not de-energize the monitor relay
when they occur:
• motor over-temperature
• over-torque
• jammed valve
• LOCAL/OFF selected
• manual operation
• ESD signal on (ESD-EFS)
• low lithium battery (if present)
• LOCAL/STOP pressed
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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/PST-efs
• manual operation
• interlock PST-icon
• heater (only AS8)
• EFS in Manual (*)
• EFS coil OFF (*)
Alarm
• motor over-temperature
• over-torque
• over-torque in OP
• over-torque in CL
• valve jammed
• valve jammed in OP
• valve jammed in CL
• low lithium battery (if present)
• mid travel alarm in CL/OP
• mains (only AS8)
• EFS mid travel alarm (*)
Warning
• warnings
• PST failed (i.e. Partial Stroke Test failure)
The contacts may be configured to make or break on condition. The options with (*) also
appear in the menu, but they are not available on the ICON3000 and ICON3000v2.
Set-Up Routines 61
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Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and enter the password according to the instructions
(see “Entering the set-up mode”). When the message displayed is “SET-UP MODE
OK?” press YES. Press YES to select the "Actuator Setup" menu, press NO to scroll
though the list of available routines, and then press YES to select "Output Relays".
Monitor relay
• Press YES or NO to enable or disable the following situations from the
conditions that normally de-energize the monitor relay: motor over-temperature,
over-torque, jammed valve, manual override, ESD signal on, low lithium battery
(if present), local STOP pressed, LOCAL/OFF selected.
9.1.7 Positioner
The positioning function is only available in positioning (inching) or modulating ICON3000
actuators and allows for positioning of the valve according to a “position request R%”
command signal.
The positioning function compares the present actuator position % with the position
request R%, and if the difference is greater than the dead band the actuator is driven to
reach the new requested position.
The “position request R%” signal may either be received from the bus or the 4 - 20 mA analog
input. If the ICON3000 is set to receive the position request R% from the bus, the relevant
fieldbus interface card must be present; otherwise, a hardware alarm will be generated.
If the ICON3000 is set to receive the position request R% from the 4 - 20 mA generator,
the Ain/Aout card must be present; otherwise, a hardware alarm will be generated.
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The following options can be configured via the local operator interface:
• Dead band: configurable from “position resolution%” to 25.5% of the
maximum position error. The configured value should be great enough to avoid
a "hunting" effect.
• Polarity of the 4-20 mA position request signal (see Figure 59): this allows reversal
of the relationship between the 4-20 mA input signal and the “position request
R%”, according to the following diagrams. This option is not available when the
ICON3000 is set to receive the “position request R%” from the bus.
• Motion inhibit time: this allows adjustment of the length of the delay time
between two cycles of the motor. It can be configured from 1 to 255 seconds and
allows the user to set the maximum number of starts/hour of the motor.
• % MIN and % MAX, 4 - 20 mA input signal range: this allows a change in the
relationship between the input signal and the position request R%. This function
is useful when a single 4 - 20 mA signal is used to control the position of 2 valves
(e.g. split range applications). This option is not available when the ICON3000 is
set to receive the “position request R%” from the bus.
Figure 59
Input 4 - 20 mA Input 4 - 20 mA
Polarity: 4 mA = CL Polarity: 4 mA = OP
Input request Input request
20 mA 20 mA
4 mA Position % 4 mA Position %
0% 100% 0% 100%
Example B
With input signal < 8 mA, the position request is 0% and the actuator is driven to close.
With input signal = 16 mA, the position request is 100% and the actuator is driven to open.
With input signal = 12 mA, the position request is 50% and the actuator is driven to reach
position 50%.
Example C
With input signal = 4 mA , the position request is 100% and the actuator is driven to open.
With input signal = 20 mA, the position request is 0% and the actuator is driven to close.
With input signal = 12 mA, the position request is 50% and the actuator is driven to reach
position 50%.
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Example D
With input signal < 8 mA, the position request is 100% and the actuator is driven to open.
With input signal = 16 mA , the position request is 0% and the actuator is driven to close.
With input signal = 12 mA, the position request is 50% and the actuator is driven to reach
position 50%.
Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP. Select
the language and then enter the password according to the instructions (refer to
Entering the set-up mode). When the message displayed is “SET-UP MODE OK?”
press YES. Press YES to select the "Actuator Setup" menu, press NO to scroll through
the list of available routines, and then press YES to select "POSITIONER".
• Press YES if the configured value of the Dead Band is correct (from “position
resolution %” to 25.5%). If not, press NO to change it and then press YES.
• Press YES if the configured value of the Polarity is correct (4 mA=CL or 4 mA=OP).
If not, press NO to change it and then press YES.
• Press YES if the configured value of the Motion Inhibit Time is correct
(from 1 to 255 seconds). If not, press NO to change it and then press YES.
• Press YES if the configured value of the % MIN is correct (from 0 to 75%).
If not, press NO to change it and then press YES. The standard value is 0.
• Press YES if the configured value of the % MAX is correct (from 25 to 100%). If not,
press NO to change it and then press YES. The difference between % MAX and %
MIN should be greater than 25%. The standard value is 100.
9.1.8 Fail-Safe
This function configures the actuator action if loss of the 4 - 20 mA input or bus signals
occurs. This action only takes place if the local selector is in REMOTE and if the positioning
function or the bus interface are active. When the 4 - 20 mA or bus signal is restored,
the ICON3000 resumes normal functionality. The Interlock and ESD controls override the
Fail-Safe action according to Figure 60:
Figure 60 Diagram
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VCIOM-08500-EN Rev. 2 May 2022
Figure 61
Example A Example B
0% Input signal
Input signal
4 20 mA 4 8 16 20 mA
Example C Example D
0%
Input signal Input signal
4 20 mA 4 8 16 20 mA
Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and then enter the password according to the instructions
(see entering the set-up mode). When the message displayed is “SET-UP MODE
OK?” press YES. Press YES to select the "Actuator Setup" menu, press NO to scroll
through the list of available routines, and then press YES to select “FAIL-SAFE”.
• Press YES if the configured ACTION is correct (open, close, stay-put, go to position
xxx%, off). If not, press NO to change it and then press YES.
• Press YES if the configured value of the DELAY is correct (from 0 to 255 seconds).
If not, press NO to change it and then press YES.
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9.1.9 OUT 4 - 20 mA
This routine is only available if the Ain/Aout card is present. With this card, the ICON3000 is
provided with a 4 - 20 mA analog input and a 4 - 20 mA analog output.
The 4 - 20 mA output can be configured to provide a current proportional to either “position”
or “torque”. The polarity option allows reversal of the relationship between the present
position or torque and the 4 - 20 mA output signal, according to the following diagrams:
Figure 62 Diagram
20 mA 20 mA
4 mA 4 mA
Position % Position %
0% 100% 0% 100%
Output: torque Output: torque
Polarity: 4 mA = CL Polarity: 4 mA = OP
Output mA Output mA
20 mA 20 mA
12 mA 12 mA
4 mA 4 mA
Torque % Torque %
100% CL 0% 100% OP 100% CL 0% 100% OP
Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP. Select
the language and then enter the password according to the instructions (see “entering
the set-up mode”). When the message of the display is “SET-UP MODE OK?” press
YES. Press YES to select the "Actuator Setup" menu, press NO to scroll through the list
of available routines, and then press YES to select "Out 4 - 20 mA".
• Press YES if the output is correct (POSITION or TORQUE). If not, press NO to
change it and then press YES.
• Press YES if the polarity is correct. If not, press NO to change it and then press YES.
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9.1.10 Interlock
The interlock inputs can be used to inhibit the actuator movement in the open or closed
direction. The controls are momentary; the inhibiting action continues while the relevant
signal is present. The interlock controls work when the local selector is in LOCAL or in
REMOTE. The ESD control overrides the interlock controls.
The following options can be configured:
- Interlock OP: active when signal is PRESENT, active when signal is ABSENT,
no action (OFF).
- Interlock CL: active when signal is PRESENT, active when signal is ABSENT,
no action (OFF).
Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and then enter the password according to the instructions
(see entering the set-up mode). When the message displayed is “SET-UP MODE
OK?” press YES. Press YES to select the "Actuator Setup" menu, press NO to scroll
through the list of available routines, and then press YES to select "INTERLOCK".
• Press YES if the configured value of the Open Interlock is correct
(PRESENT, ABSENT, OFF). If not, press NO to change it and then press YES.
• Press YES if the configured value of the Close Interlock is correct
(PRESENT, ABSENT, OFF). If not, press NO to change it and then press YES.
Figure 63
On On On
time Off time Off time Off
Motor time time time
Set-Up Routines 67
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Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and then enter the password according to the instructions
(see “Entering the set-up mode”). When the message displayed is “SET-UP MODE
OK?” press YES. Press YES to select the "Actuator Setup" menu, press NO to scroll
through the list of available routines, and then press YES to select "2-Speed Timer".
• Press YES to change the close direction parameters, press NO, and then press YES
to change only the open direction parameters.
Closing direction
• Press YES if the status is OK, or NO to change. Press YES to confirm (status = On,
enables 2-speed timer operation in closing direction; status = Off, disables timer
operation in closing direction).
• Press YES if the position value where pulsing control starts is correct; if not, press NO
to scroll through the list of available values. Press YES when the value is correct.
• Press YES if the position value where pulsing control stops is correct; if not, press NO
to scroll through the list of available values. Press YES when the value is correct.
• Press YES if the value of the ON time of pulsing control is correct; if not, press NO
to scroll through the list of available values. Press YES when the value is correct.
• Press YES if the value of the OFF time of pulsing control is correct; if not, press NO
to scroll through the list of available values. Press YES when the value is correct.
Opening direction
• Press YES if the status is OK, or NO to change. Press YES to confirm (status = On
enables 2-speed timer operation in opening direction; status = Off, disables timer
operation in opening direction).
• Press YES if the position value where pulsing control starts is correct; if not, press NO
to scroll through the list of available values. Press YES when the value is correct.
• Press YES if the position value where pulsing control stops is correct; if not, press NO
to scroll through the list of available values. Press YES when the value is correct.
• Press YES if the value of the ON time of pulsing control is correct; if not, press NO
to scroll through the list of available values. Press YES when the value is correct.
• Press YES if the value of the OFF time of pulsing control is correct; if not, press NO
to scroll through the list of available values. Press YES when the value is correct.
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9.1.13 Miscellaneous
This includes different types of routines such as “time and date”, “lithium battery”, and
"torque profile", used only for special applications or in particular conditions.
Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and enter the password according to the instructions (see
“Entering the set-up mode”). When the message displayed is “SET-UP MODE
OK?” press YES. Press YES to select the "Actuator Setup" menu, press NO to scroll
through the list of available routines, and then press YES to select "Miscellaneous".
• Press YES to enter the time and date routine.
• Press YES if the time is correct; otherwise, press NO to change it.
• Enter hours, minutes and seconds. Press NO to scroll the list of available values,
and press YES to select.
• Press YES when the time is correct.
• Press YES if the date is correct; otherwise, press NO to change.
• Enter day, month, and year. Press NO to scroll the list of available values, and YES
to select.
• Press YES if the date is correct.
Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and enter the password according to the instructions
(see “Entering the set-up mode”). When the message displayed is “SET-UP MODE
OK?” press YES. Press YES to select the "Actuator Setup" menu, press NO to scroll
through the list of available routines, and then press YES to select "Miscellaneous".
• Press NO and then NO to select “torque mode”. Press YES if setting is correct;
otherwise, press NO to change. Press YES when the value is correct.
• Repeat the stroke limits setting routine.
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Breakout limit
Ending limit
Running limit
Position %
Breakout limit
Ending limit
Running limit
Position %
Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and enter the password according to the instructions
(see “Entering the set-up mode”). When the message displayed is “SET-UP MODE
OK?” press YES. Press YES to select the "Actuator Setup" menu, press NO to scroll
through 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 "Lithium Battery".
Press YES if the setting is correct; otherwise, press NO to change. Press YES when the
value is correct.
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Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and enter the password according to the instructions
(see “Entering the set-up mode”). When the message displayed is “SET-UP MODE
OK?” press YES. Press YES to select the "Actuator Setup" menu, press NO to scroll
through 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 "Torque Bypass".
Press YES if the setting is correct; otherwise, press NO to change. Press YES when
the value is correct.
Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and enter the password according to the instructions
(see “Entering the set-up mode”.) When the message displayed is “SET-UP MODE
OK?” press YES. Press YES to select the "Actuator Setup" menu, press NO to scroll
through 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 "Valve Jammed".
Press YES if the setting is correct; otherwise, press NO to change. Press YES when the
value is correct.
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9.3 Maintenance
A large amount of data is stored in the actuator memory and is available for future analysis
or to assist the operator in a maintenance program. The maintenance menu also includes
the set password routine and the potential to modify or start the maintenance functions.
The following data are available:
• new password
• clear alarm log
• torque profile reference
• torque curve reference
• clear recent data log
• configuration (backup/restore) (only for ICON3000v2)
• maintenance date
• data logger
• PST reference (only if INTERLOCK = ADVANCED)
• PST cmd (only if INTERLOCK = ADVANCED)
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Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and enter the password according to the instructions
(see “Entering the set-up mode”). When the message displayed is “SET-UP MODE
OK?” press YES. Press NO to scroll through the list of available menus and then
press YES to select the "Maintenance" menu.
• Press NO to scroll the list of available routines and then press YES to select
"Set Password". Press YES again to select "Enter New Password".
• Enter the new password one digit at a time. Press YES if the digit is correct;
otherwise, press NO to scroll through the list of available characters and then
press YES to select. Enter 4 digits. When the display shows the message "Password
Changed", the old password is no longer valid.
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Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and then enter the password according to the instructions
(see “Entering the set-up mode”). When the message displayed is “SET-UP MODE
OK?” press YES. Press NO to scroll through the list of available menus and then
press YES to select the "Maintenance" menu.
• Press NO to scroll the list of available routines and then press YES to select
"Set Curve Reference".
• Press NO to scroll the list and then press YES to select the desired curves
(in opening and closing).
• Press YES to update the torque curve reference.
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Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and enter the password according to the instructions
(see “Entering the set-up mode”). When the message displayed is “SET-UP MODE
OK?” press YES. Press NO to scroll through the list of available menus and then YES
to select the "Maintenance" menu.
• Press NO to scroll through the list of available routines and press YES to select
"Maintenance Date".
• Press YES to set the last maintenance date. Press NO to skip to
“next maintenance date”.
Start-up date
• Press YES if the date is correct; otherwise, press NO to change it.
• Enter day, month, and year. Press NO to scroll through the list of available values;
press YES to select.
• Press YES if the date is correct.
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Table 13.
Logger mode recorder, event, off
Sampling time from 1 to 3600 seconds (the sampling time is only used in recorder mode)
stop when memory is full, continuous (stop after overwriting the memory
Memory mode
5000 times (event) and 10000 times (recorder/T-recorder)
Start date date when the logger starts
Start time time when the logger starts
Configuration procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language and then enter the password according to the instructions
(see “Entering the set-up mode”). When the message displayed is “SET-UP MODE
OK?” press YES. Press NO to scroll through the list of available menus and then
press YES to select the "Maintenance" menu.
• Press NO to scroll through the list of available routines and then press YES to select
“data logger”.
• Press YES if the mode is correct; otherwise, press NO to scroll through the list of
modes and press YES to select the desired value .
• Press YES if the sampling time is correct; otherwise, press NO to scroll through the
list of times and press YES to select the desired value.
• Press YES if the memory mode is correct (stop when full or continuous); otherwise,
press NO to change and press YES to select.
• Press YES if the start time is correct; otherwise, press NO to scroll through the list
and press YES to select the desired sampling times (hour, min, sec).
• Press YES if the start date is correct; otherwise, press NO to scroll through the list
and press YES to select the desired sampling times (day, month, year).
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Figure 66
OFF
LOCAL REMOTE
YES YES NO NO
Display
YES
Press
NO ACTUATOR SETUP ACTUATOR SETUP
XXXXXX OFF until the OPENING TORQUE CLOSING TORQUE
STOP NEXT? desired 60% OK? 55% OK?
value
NO appears
and
NO YES NO
YES STOP then YES
press
YES
TO VIEW MENU
SELECT
LANGUAGE ACTUATOR SETUP
ACTUATOR SETUP
CLOSING TORQUE
OPENING TORQUE 70% OK?
65% OK?
TO NEXT
ENTER YES
PASSWORD
To exit from the SETUP menu, press YES and NO simultaneously or move the 3-position
selector to LOCAL or REMOTE.
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Table 14.
Routine Parameters
Close direction (CW, CCW), close limit type (torque or position),
Stroke limits
open limit type (torque or position)
Torque set-up Closing torque limit %, opening torque limit %
ESD control ESD action, signal type, ESD priority
PST set-up PST configuration. Available if INTERLOCK= ADVANCED
Remote controls Control type
Local controls Control type, color of LEDs
Output relays Monitor relay conditions, ASi conditions, contact action
Dead band, motion inhibit time, polarity, %min, %max (%min and %max are
Positioner *
present only if “position request R%” is from 4 - 20 mA input)
Fail-safe * Action, delay
Out 4 - 20 mA * Output signal (position or torque), polarity
Interlock Signal type in OP, signal type in CL
Close direction: status, start, stop, on time, off time
2-speed timer
Open direction: status, start, stop, on time, off time
Bus * Node address, terminations, etc. depending on fieldbus type
Time and date, torque mode, lithium battery, torque bypass %,
Miscellaneous
valve jammed time
The routines with * can only be viewed if the relevant electronic cards are present. If the bus
interface is LonWorks, the "BUS" routine changes to “FDI control”. Detailed descriptions of the
above routines and their parameters can be found in Section 9.
View Procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language according to the instructions (see “Entering the view mode”).
When the message displayed is “VIEW MODE OK?” press YES. Press YES to select
the “Actuator Setup” menu.
• Press NO to scroll through the list of available routines and press YES to select.
• Press YES to answer the prompt “view” or “next” and to see the data.
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10.2 Nameplate
Use this menu to view the data identifying the actuator. The data are entered in-house and
can only be changed by the manufacturer. The following data may be viewed:
• Serial number: max. 28 characters, unique identifier of the actuator with reference
to the Emerson order acknowledgment.
• Actuator type: max. 28 characters, describes the type of actuator with reference to
the Emerson catalog.
• Torque / Thrust: nominal torque or thrust of actuator.
• Actuator speed: nominal speed of actuator.
• Speed Loop: parameters to set the speed loop (for ICON3000LP (Low Power) only)
• Power supply: nominal voltage and frequency of actuator.
• Motor data: includes the following data relevant to the electrical motor:
- Power type (3ph, 1ph, dc) - Power rating, max. 99.9 kW
- In, max. 99.9 A
- Is, max. 99.9 A/KT (for ICON LP)
- Icc, max 99.9 A/TMax (for ICON LP)
- Duty (S2/15 min, etc.)
- Poles (2, 4, etc.)
- Biffi name, max. 28 characters
- Gear ratio, max. 1000 /M.R. Ratio (for ICON LP)
• Test date: date of the in-house functional test of actuator.
• Wiring diagram (WD): wiring diagram number, max 28 characters.
• Enclosure: type of enclosure (Ex d, etc.), max. 28 characters.
• Certificate: number of certificate, max. 28 characters.
• Lubricant: type of lubricant, max. 28 characters.
• Revision: hardware revision of base card, software revision of CPU microprocessor,
software revision of PIC microprocessor, hardware revision of the encoder,
software revision of the encoder.
• Torque sensor: data relevant to the relationship between motor torque and speed.
This set of data also includes the factory torque limit setting, “Torque set CL” and
“Torque set OP”.
View Procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language according to the instructions (see “Entering the view mode”).
When the message displayed is “VIEW MODE OK?” press YES. Press NO to scroll
through the list of available menus and press YES to select the "Nameplate" menu.
• Press YES to answer the prompt “view” or “next” and see the data in the above list.
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View Procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language according to the instructions (see “Entering the view mode”).
When the message displayed is “VIEW MODE OK?” press YES. Press NO to scroll
through the list of available menus and press YES to select the "Valve Data" menu.
• Press YES to answer prompts “view” or “next” and see the data in the above list.
10.4 Maintenance
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Reference details are retained and the latest torque is expressed as a % of the nominal torque.
At the end of a full stroke in opening or closing, the ICON3000 stores the 3 maximum
torque values in position intervals 0%-10%, 10%-90%, 90%-100% in opening, and the 3
maximum torque values in position intervals 100%-90%, 90%-10%, 10%-0% in closing.
Time and date of valve strokes are also saved. The above data are updated at the end of
every full valve stroke and the previous data are overwritten. The “set torque reference"
function in the SET-UP MENU, Maintenance, (Section 7), allows saving of the “torque
profile” data in the “torque profile reference” with a date and time. The “torque profile
reference” will not be updated until a new “set torque reference” command is entered. The
user can compare the last torque profile relevant to the last valve stroke with the torque
profile reference saved before.
The following definitions will be used:
• Breakout: maximum torque % in position interval 0-10% in opening or
100%-90% in closing = max. % of torque to unseat the valve.
• Peak running: maximum torque % in position interval 10-90% in opening or
90% - 10% in closing = max. % of torque when the valve runs from Breakout to
Ending (maximum mid-travel).
• Ending: maximum torque % in position interval 90-100% in opening or
10%-0% in closing = max. % of torque to seat the valve.
The following data may be viewed:
Closing torque
• Breakout %
• Breakout reference %
• Peak run %
• Peak run reference %
• Ending %
• Ending reference %
• Date of the last stroke
• Date of reference (same of opening)
Opening torque
• Breakout %
• Breakout reference %
• Peak run %
• Peak run reference %
• Ending %
• Ending reference %
• Date of the last stroke
• Date of reference (same of closing)
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View Procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP.
Select the language according to the instructions (see “Entering the view mode”).
When the message displayed is “VIEW MODE OK?” press YES. Press NO
to scroll through the list of available menus and press YES to select the
"Maintenance" menu.
• Press NO to scroll through the list of routines and press YES to select
"Torque Profile".
• Press YES to scroll through the list of values.
Table 15 shows the list of saved data for each opening or closing curve:
Table 15.
Date Date of the valve stroke
Time Time of the valve stroke
Temperature Temperature (°C) inside the electronics compartment during the valve stroke
Term temp Temperature (°C) inside the terminal board compartment during the valve stroke
Motor temp Temperature of the electrical motor (°C) during the valve stroke
Main voltage Main voltage supply (V) during the valve stroke
Closing / Opening time
Torque value in % of the nominal torque / thrust stated in the Name Plate menu.
Torque 0 In opening “Torque 0” corresponds to position 0% and in closing “Torque 0” cor-
responds to position 100%
Torque value in % of the nominal torque / thrust stated in the Name Plate menu.
Torque 100 In opening “Torque 100” corresponds to position 100% and in closing “Torque
100” corresponds to position 0%
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The amount of data to be viewed is large and the local display can only display one datum
at a time. To use this function, it is recommended to utilize the features of A-Manager via a
PDA or PC. Figure 67 below shows an example of a graph available on the PDA or PC screen,
showing the reference opening torque curve and the latest opening torque curve.
View Procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP. Select
the language according to the instructions (see “Entering the view mode”). When the
message displayed is “VIEW MODE OK?” press YES. Press NO to scroll through the list
of available menus and press YES to select the "Maintenance" menu.
• Press NO to scroll through the list of routines and press YES to select torque curve.
• Press NO to scroll through the list of available curves (from 100 to 1 and reference).
Curve 100 is the latest and curve 1 is the oldest. Press YES to select.
• Press YES to select the opening or closing curve. Press NO to exit.
• Press YES to scroll through the list of values. Press NO to exit.
Command “clear recent data log” is available in the SET-UP MENU, maintenance, Section 7.
This command clears the content of the recent data log and resets the counters to 0.
The old data are lost.
The main differences between “general” and “recent” data log are the following:
• The general data log gives information relevant to the full life of the actuator,
starting from the manufacturing date.
• In the recent data log the same data are collected starting from a date set by the
user. The date may be viewed in the MAINTENANCE DATE Section.
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Figure 67
Table 16 shows the list of data collected by the general and recent data log:
Table 16.
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View Procedure
• Move the local selector to OFF and then simultaneously press OPEN and
STOP. Select the language according to the instructions (see “Entering the
view mode”). When the message displayed is “VIEW MODE OK?” press YES.
Press NO to scroll through the list of available menus and press YES to select the
"Maintenance" menu.
• Press NO to scroll through the list of available routines and press YES to select
"Operation Log".
• Press YES to select general data or press NO to skip to recent data.
• Press YES to scroll through the list of values.
• Press YES to view the recent data log or press NO to exit.
• Press YES to scroll through the list of values.
Table 17.
General Data
This datum is only available in the general data log. It is updated at the end of
every full valve stroke of the valve in opening direction. The data of the previous
Opening time
stroke are lost. It gives the time necessary to the valve to move from the closed
position to the open position, expressed in hours, minutes and seconds.
This datum is only available in the general data log. It is updated at the end of
every full valve stroke of the valve in closing direction. The data of the previous
Closing time
stroke are lost. It gives the time necessary to the valve to move from the open
position to the closed position, expressed in hours, minutes and seconds.
This number counts the cycles of contactors K1 and K2. The value indicated in
the general data log is also used to generate the “max. contactor cycles” warning
Contactor when the maximum allowable number of cycles of the contactor is reached (see
cycles Section 12.11, Diagnostic messages). If the main power is DC or single phase and
the actuator supports modulating duty, the counters (general and recent) are
held to 0.
Motor run time This number counts the hours with the motor energized.
No power time This number counts the hours without electrical power.
This number % is incremented every 200 full strokes of the actuator.
Utilization rate
It reaches 100% after 20,000 full strokes.
Temperature This is the lowest temperature value (in °C) measured inside the electronics
min compartment.
Temperature This is the highest temperature value (in °C) measured inside the electronics
max compartment.
This is the lowest temperature value (in °C) measured inside the terminal board
Term temp min
enclosure.
This is the highest temperature value (in °C) measured inside the terminal board
Term temp max
enclosure.
Motor temp
This is the highest temperature value (in °C) measured in the electrical motor.
max
Thermostat This counts the number of alarms due to high temperature of the electrical motor
alarms and resultant tripping of the motor thermostat.
Torque alarms This counts the number of alarms due to high torque in opening and closing.
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Table 18.
This is the date of the previous maintenance operation. This date should be updated
Last date
by the user after all maintenance operations (see Section 9.3).
This is the date of the next scheduled actuator maintenance. When the date is
Next date reached, the ICON3000 generates a maintenance request warning. The date
should be updated by the user after all maintenance operations (see Section 9.3).
This is the date of actuator start-up. During commissioning, the user should enter
Start-up date
the start-up date (see Section 9.3).
This is updated after entering command “Clear recent data log” (see Section 9.3).
Recent log
This command clears the “recent data log” counters. The content of “recent log” is
date
updated starting from “recent log date”.
View procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP. Select
the language according to the instructions (see “Entering the view mode”). When
the message displayed is “VIEW MODE OK?” press YES. Press NO to scroll through
the list of available menus and press YES to select the "Maintenance" menu.
• Press NO to scroll through the list of available routines and press YES to select the
"Maintenance Date" date routine.
• Press YES to scroll the list of dates.
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In RECORDER and T-RECORDER mode, the SAMPLING TIME fixes the time interval among
two sets of measures. Up to 256 sets of measures (equivalent to 256x4 samples) can be
memorized. The sampling time can be configured from 1 to 3600 seconds. As the memory
becomes full, the recorder stops recording or overwrites the previous data according to the
selected MEMORY MODE (“stop when full” or “continuous”). If “continuous” was selected,
as a new set of measures is achieved the oldest one is canceled and the new one becomes
the latest. Up to 10,000 cycles of full memory overwriting are performed, and then the
recorder stops. In T-RECORDER mode, the recording operation is also stopped if a torque
alarm is raised in opening or in closing. This additional feature allows the user to maintain
memory of the last 256 samples and see the trend of torque, motor temperature, and
main voltage prior to the alarm. A new start of T-RECORDER clears the data stored in the
memory. By using a PDA or PC, the recorded data can be viewed by a graph where time is
on the X axis and the measured data on the Y axis.
Figure 68 below shows a graph with a sampling time of 2 seconds in RECORDER mode
(electronics temperature and motor temperature).
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T-logger stops recording if a torque alarm is triggered. The last 256 samples remain in the
actuator memory until a new start of the logger is initiated.
• EVENT mode: the ICON3000 detects the type of received command (OPEN or CLOSE),
the source of the command (local controls, remote controls, bus, etc.), and the date
and time of the command. Up to 128 EVENTS can be memorized. As the memory
becomes full, the logger stops memorizing events or overwrites the previous data
according to the selected MEMORY MODE (“stop when full” or “continuous”). If
“continuous” was selected, old events are canceled in place of new events and the
newest event becomes the latest. Up to 50 cycles of full memory overwriting are
possible before the logger stops. The START DATE and START TIME fix date and time to
start a recording operation. By using a PDA or PC, the collected data can be viewed via
a graph or event table. The parameter “sampling time” is not used. Figure 70 shows an
example of a report in EVENT mode.
View procedure
• Move the local selector to OFF and then simultaneously press OPEN and STOP. Select
the language according to the instructions (see “Entering the view mode”). When the
message displayed is “VIEW MODE OK?” press YES. Press NO to scroll through the list
of available menus and press YES to select the "Maintenance" menu.
• Press NO to scroll through the list of routines and press YES to select "Data logger".
• Press YES to view the MODE, the SAMPLING time, the MEMORY mode, the start
DATE, and the start TIME.
• Press YES to return to the data logger. Press NO to exit.
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Figure 71
OFF
LOCAL REMOTE
YES YES NO
Display
NO
ACTUATOR SETUP
XXXXXX OFF CLOSING TORQUE
STOP NEXT? 55% NEXT?
NO
TO SETUP MENU
YES
SELECT LAN- YES
GUAGE ACTUATOR SETUP
TO NEXT ROUTINE
To exit from VIEW menu, press YES and NO simultaneously or move the 3-position selector
to LOCAL or REMOTE.
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! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
! WARNING
Before performing service or maintenance operations (unless otherwise indicated),
ensure that power is turned off to the unit to avoid injury and/or damage to equipment.
! WARNING
The actuator is non-intrusive. The control compartment is sealed in dry and clean conditions
and contains no site serviceable components. Do not open it unless absolutely necessary.
Unauthorized access will invalidate the warranty.
! CAUTION
Using a fastener other than the approved type may result in damage to the actuator or valve.
The following checks will assure optimum performance and can be considered as good
practice in preventive and/or predictive maintenance:
• External visual inspection and general health check
• Electrical enclosures: Check the external parts for possible damage and replace them
immediately if necessary. If the window glass is broken, the complete cover must be
replaced (see Section 13, Parts list and drawings for individual item numbers).
• Electrical enclosures: perform an internal check of the cable glands and tightness
of cable terminals, and replace the cover O-ring.
• Make sure that there are no oil leaks from the actuator housing. Check the oil
level; it should be approximately 20 mm from the fill plug. Top-up the oil volume if
needed (see Section 4, Lubrication).
• Lubricate the internal components of the coupling block (if present) via the
spherical head lubricator using suggested greases (see Section 4, Lubrication).
92 Maintenance
Installation, Operation and Maintenance Manual Section 11: Maintenance
VCIOM-08500-EN Rev. 2 May 2022
• If the stem is external, check that the valve stem is clean and lubricated.
If not, clean and lubricate it in order to prevent damage to the threaded bush.
• Check that all nuts and bolts securing the actuator to the valve are tight.
If necessary, retighten them with a torque wrench (for tightening torque
values see Section 3.4.3, Actuator Mounting).
• For actuators provided with lithium batteries, make sure that the
display is still visible when the power is off and that there is no “Battery
low” warning message. If the "Battery low” warning appears, replace
the battery (see Section 11.3 Maintenance - Lithium battery change).
Always replace batteries if the actuator has been subjected to long periods without
power (see Section 12, Troubleshooting).
• Manual override operation check (if valve operation allows)
• Check local and remote electrical commands (if valve operation allows)
• Full Stroke test (FST) or Partial Stroke Test (PST) (if valve operation allows),
torque vs. position diagram report (via AManager, if Bluetooth or a serial cable
connection is available)
• Download .icon file (via AManager, if Bluetooth or a serial cable connection is
available)
• Identification of recommended spare parts based on inspection results
• Identification of next routine inspection date
• Identification of maintenance needs during next planned plant outage/shut down
• Final report, including .icon file
• Repaint all areas where paint is missing. In chemically aggressive or
saline environments, remove rust from surfaces and protect the unit with a
rust preventative.
• For severe applications or if actuator operation is infrequent, more frequent
maintenance checks are recommended.
NOTICE
In cases of actuator failure, refer to Section 12, Troubleshooting for possible causes.
Spare parts can be ordered from Emerson; refer to the individual item number shown in
Section 13, Parts list and Drawings.
Maintenance 93
Section 11: Maintenance Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Figure 72
Figure 73
94 Maintenance
Installation, Operation and Maintenance Manual Section 11: Maintenance
VCIOM-08500-EN Rev. 2 May 2022
Figure 74
Figure 75
Figure 76
Maintenance 95
Section 11: Maintenance Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Figure 77
Figure 78
Figure 79
96 Maintenance
Installation, Operation and Maintenance Manual Section 11: Maintenance
VCIOM-08500-EN Rev. 2 May 2022
Figure 80
NOTICE
The new battery must be the same type as the one provided: Lithium – SAFT LS 9 V.
NOTICE
To check the battery status, press the STOP button for at least 3 seconds. In any event,
the battery status is automatically checked at least once a day. The expected battery life
is up to 4 years but this can vary depending on frequency of usage and environmental
conditions. Battery life may be reduced at high and low temperatures.
! WARNING
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.
Figure 81
Maintenance 97
Section 12: Troubleshooting Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
! WARNING
The ICON3000 actuator is non-intrusive. The control compartment is sealed in dry and
clean conditions and contains no site-serviceable components. Do not open the control
compartment unless absolutely necessary. Unauthorized access will invalidate the warranty.
! WARNING
Before performing service or maintenance operations (unless otherwise indicated), ensure
that power is turned off to the unit to avoid injury and/or damage to equipment.
98 Troubleshooting
Installation, Operation and Maintenance Manual Section 12: Troubleshooting
VCIOM-08500-EN Rev. 2 May 2022
Figure 82
1. Power card
2. Fuse
Troubleshooting 99
Section 12: Troubleshooting Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Figure 83
Figure 84
100 Troubleshooting
Installation, Operation and Maintenance Manual Section 12: Troubleshooting
VCIOM-08500-EN Rev. 2 May 2022
Figure 85
Troubleshooting 101
Section 12: Troubleshooting Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Figure 86
Figure 87
102 Troubleshooting
Installation, Operation and Maintenance Manual Section 12: Troubleshooting
VCIOM-08500-EN Rev. 2 May 2022
Troubleshooting 103
Section 12: Troubleshooting Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Figure 88
OFF
NO
LOCAL REMOTE
NO
WARNINGS
3-position ALARMS VIEW? VIEW?
selector
NO NO
NO NO
VIEW YES
VARIABLES
ALARM HN WARNING HN
NEXT? NEXT?
YES NO YES NO
YES YES
View procedure
• Move the 3-position selector to either OFF or REMOTE, and then press NO to scroll
through the list of available variables.
• Press YES when the display shows the message “ALARMS view?” Press YES to scroll
through the list of alarms.
• Press NO when the display shows the message “ALARMS view?”.
• Press YES when the display shows the message “WARNINGS view?” Press YES to
scroll through the list of warnings.
• Press YES to reset alarms or warnings held within the actuator’s memory.
104 Troubleshooting
Installation, Operation and Maintenance Manual Section 12: Troubleshooting
VCIOM-08500-EN Rev. 2 May 2022
Troubleshooting 105
Section 12: Troubleshooting Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
106 Troubleshooting
Installation, Operation and Maintenance Manual Section 12: Troubleshooting
VCIOM-08500-EN Rev. 2 May 2022
Troubleshooting 107
Section 12: Troubleshooting Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Configuration obj n°
N° indicates the number of the parameter to be configured. To clear the alarm, a table of
all ICON3000 parameters is necessary. Call Emerson After-Sales service to solve the problem.
If the alarm message is “CONFIGURATION OBJ 9999”, only one of the ICON3000 parameters
needs to be changed. For example: enter the SET-UP menu, go to “Actuator Setup”, then
“Torque Setup”, and then either increase or decrease the closing torque by 1%. As the alarm
message disappears reenter the SET-UP menu, go to “Actuator Setup”, then “Torque Setup”,
and then set the previous value (see Section 9.1, Actuator Set-up).
Hardware n°
N° indicates the module that is not working. The problem may be due to a malfunction
of the module, to an incorrect wiring between modules, or to an incorrect setting of the
ICON3000. Call Emerson After-Sales service to solve the problem. The following hardware
alarms can be detected:
• Hardware 1 = incorrect coding of local push-buttons and selector
• Hardware 2 = incorrect configuration of Ain/Aout optional module
• Hardware 3 = no communication between Ain/Aout optional module and base card
• Hardware 4 = incorrect configuration of type of terminal board
• Hardware 5 = no communication between terminal board and base card
• Hardware 6 = incorrect configuration ICON3000/F01
• Hardware 7 = incorrect configuration of type of bus card
• Hardware 8 = no communication between bus card and base card
• Hardware 9 = Logic Card cannot update the settings of the Power Card (for ICON LP only)
• Hardware 10 = Logic Card cannot communicate with the Power Card (for ICON LP only)
• Hardware 11 = no communication between bus card (redundant Profibus card)
and base card
• Hardware 12 = no communication between encoder and base card
• Hardware 13 = encoder damaged or wrongly configured
108 Troubleshooting
Installation, Operation and Maintenance Manual Section 13: Parts List and Drawings
VCIOM-08500-EN Rev. 2 May 2022
! CAUTION
Using a fastener other than the approved type may result in damage to the actuator or valve.
NOTICE
- When ordering spare parts, be sure to indicate the serial number embossed on the
actuator nameplate.
- When ordering spare parts, refer to the item number on the attached drawings.
25.1
25.2
25.3
25.4
25.5
25.6
25.7
25.8 25.1
25.2
25.3
25.4
29.2
29.3
29.4
29.5
29.6
29.7
29.1
36.1
36.2
36.3
36.4
36.5
36.6
36.7
55.1
55.2
55.3
55.4
55.5
55.6
75.1
75.2
75.3
75.4
75.5
75.6
75.7
75.8
2
6
10
4
3 5.1
8 7
Appendix 119
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Appendix A: ICON3000/ICON3000AD
Ex db eb h IIB+H2 T4 Gb / Ex h tb IIIC T135 °C Db IP66/68
Ex db eb h ia IIB+H2 T4 Gb / Ex h tb IIIC T135 °C Db IP66/68
A.1.1 General
This Appendix A is supplemental to Installation, Operation, and Maintenance Manual
MAN-02-04-97-0713 and prescribes the safety instructions applicable to electric actuators
ICON3000-040 and ICON3000-050. The subject actuator is certified according to EN and
IEC Standards 60079-0, 60079-1, 60079-7, 60079-11, 60079-31, and EN ISO 80079-36,
80079-37 for protection type Ex db eb h or Ex db eb h ia for gas group IIB+H2 and Ex h tb
for dust group IIIC. The actuator is suitable for installation in an ambient temperature range
from -25 °C (-13 °F) to +60 °C (+140 °F).
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
The ICON3000 is designed in accordance with the applicable international rules and
specifications, but the following regulations must be observed in every case:
• General installation and safety regulations.
• The proper use of personal protective devices (glasses, clothing, gloves).
• The proper use of tools, lifting equipment, and transport equipment.
Safety warnings and warranty will be invalidated if the ICON3000 is installed in explosive
atmospheres not covered by the appropriate grade of protection, and/or in environments
where temperatures exceed the maximum temperature specified on the product label.
120 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
A.2.1 Marking
Table A-1.
Appendix 121
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
122 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
NOTICE
Not following the procedures according to this document will invalidate the product warranty.
The standard plastic plugs used to protect the conduit entries during transport are neither
explosion-proof nor waterproof; these plugs are only designed to prevents the entry of foreign
objects during transport. The general storage procedure stated in Section 2 must be followed.
A.7 Installation
NOTICE
Installation must be carried out in accordance to the applicable standards IEC/EN 60079-14
and IEC/EN 60079-17 regarding the electrical installations in Hazardous Areas (other than
mines) classified as Zones 1, 2 (gas) and Zones 21, 22 (dust) following IEC/EN 60079-10-1
and IEC/EN 60079-10-2 and any other applicable national standards and rules.
! WARNING
Verify that the actuator nameplate conforms to the applicable certification, ambient
temperature range, and site safety requirements.
7.1.1 Models ICON-040 and ICON-050 from -25 °C to +60 °C (from -13 °F to +140 °F)
Appendix 123
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
5 4
1 2 3
NOTICE
When alternative entries according to ISO 965 are used, indication of the dimensions
is imprinted on the adapter bush or directly on the housing when ISO 965 entries are
obtained by machining the housing.
! WARNING
Unused entries may remain unmachined or must be plugged with a certified plug suitable
for the subject environment.
124 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
NOTICE
To prevent water infiltration through the line cable conduits, be sure the cable glands
used possess the minimum degree of protection required by the plant and are specified
on the actuator label. If a rigid conduit makes a connection to the plant, it is recommended
to place a flexible pipe connection between the conduit and the conduit entry of the
additional extension.
Appendix 125
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
NOTICE
The cables and cable glands MUST be selected considering the maximum temperature of
the cable indicated on the label fixed to the base ICON3000 unit.
Figure A-3
Connection for Ex-e
terminals enclosure
A.8 Maintenance
! WARNING
Before performing service or maintenance operations (unless otherwise indicated),
ensure that power is turned off to the unit to avoid injury and/or damage to equipment.
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
126 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
! CAUTION
Using a fastener other than the approved type may result in damage to the actuator or
valve. Refer to Table 8.
! CAUTION
Failure to use proper torque values can result in damage to the actuator and/or valve.
Appendix 127
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
A.8.3 Repairs
When needed, repairs may only be carried out using spare parts supplied by the
manufacturer. All accessories must comply with approved specifications and follow the
application and site requirements.
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
! WARNING
The values of gaps of explosion-proof joints are lower than the maximum specified on
Tables of IEC/EN 60079-1 Standard and the values of widths of the explosion-proof
joints are greater than the values specified in the tables of the Standard IEC/EN 60079-1.
Should maintenance require the replacement of any component that forms part of
an explosion-proof joint, only an original spare provided by Emerson can be used.
Direct repair or reconstruction of the above components is not permitted without
Emerson authorization. Not performing this procedure will invalidate the product safety
and contractual guarantee.
Original spare parts must be ordered from the manufacturer; to ensure that correct spares
are provided, the serial number printed on the ICON3000 product label must be specified
when an order for spares is placed.
128 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
Appendix B: ICON3000/ICON3000AD/
ICON3000LP
Ex db h IIB T4 Gb / Ex h tb IIIC T135 °C Db IP66/68
Ex db h ia IIB T4 Gb / Ex h tb IIIC T135 °C Db IP66/68
B.1.1 General
This Appendix B supplemental to Installation, Operation, and Maintenance Manual
MAN-02-04-97-0713 and prescribes the Safety Instructions applicable to electric actuators
of Series ICON3000/ICON3000AD/ICON3000LP either as a base unit or when they are
equipped with:
a. an additional entry mounted on the control compartment or when they
are equipped with an optional extension
b. additional entries or with an optional extension
c. an optional electronic card mounted on the terminal board compartment,
as shown in Figure B-3. The subject actuator is certified according to
EN and IEC standards 60079-0, 60079-1, 60079-7, 60079-11 and
60079-31 and EN ISO 80079-36, 80079-37, for protection type Ex db h or
Ex db h ia for gas group IIB and Ex h tb for dust group IIIC. The actuator is
suitable for installation in an ambient temperature range from -25 °C
(-13 °F) to +60 °C (+140 °F).
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
Both the base unit ICON3000 and optional extension are designed in accordance with the
applicable international rules and specifications, but the following regulations must be
observed in every case:
• The general installation and safety regulations.
• The proper use of personal protective devices (glasses, clothing, gloves).
• The proper use of tools, lifting and transport equipment.
Appendix 129
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
130 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
Safety warnings and warranty will be invalidated if the ICON3000 is installed in explosive
atmospheres not covered by the appropriate grade of protection, and/or in environments
where temperatures exceed the maximum temperature specified on the product label.
B.2.1 Marking
Appendix 131
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Table B-1.
Hazardous zone Categories according to 2014/34/EU Directive
Gas, mists, or vapors Zone 0 1G
Gas, mists, or vapors Zone 1 2G or 1G
Gas, mists, or vapors Zone 2 3G or 2G or 1G
Dust Zone 20 1D
Dust Zone 21 2D or 1D
Dust Zone 22 3D or 2D or 1D
132 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
NOTICE
Not following the procedures according to this document will invalidate the product warranty.
Normally the optional extension for additional entry or additional electronic card
is directly mounted on the base model of ICON3000 and leaves the factory in perfect
condition. In this case, the general storage procedure as stated in Section 2 must be followed.
When the above extension is shipped separately for a field upgrade on an existing ICON3000
unit, this extension must be stored in a protected area while ensuring that the explosion-proof
joints are well-protected and kept free of damage. The standard plastic plugs used to protect
the cable entries during transport are not explosion-proof nor water-proof; these plugs are
only intended to prevent entry of foreign objects. The extension for additional entry/entries
or additional electronic cards maintains the same weather-proof degree of protection as the
base ICON3000 model. Good operating condition can only be maintained if the extension is
correctly installed/connected on-site and if it has been correctly stored.
Appendix 133
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
B.7 Installation
NOTICE
Installation must be carried out in accordance to the applicable standards IEC/EN 60079-14
and IEC/EN 60079-17 regarding the electrical installations in Hazardous Areas (other than
mines) classified as Zones 1, 2 (gas) and Zones 21, 22 (dust) following IEC/EN 60079-10-1
and IEC/EN 60079-10-2 and any other applicable national standards and rules.
! WARNING
Verify that the actuator nameplate conforms to the applicable certification, ambient
temperature range, and site safety requirements.
134 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
Table B-4.
NOTICE
When alternative entries according to ISO 965 are used, indication of the dimensions is
imprinted on the adapter bush or directly on the housing when ISO 965 entries are created
by machining the housing.
! WARNING
Unused entries may remain unmachined or must be plugged with a certified plug suitable
for the subject environment.
Appendix 135
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
XTE3000
5 4 6
1 2 3
Table B-5.
Entry Standard Size Optional
6 M25x1.5 3/4" NPT
Figure B-6 Base actuator with extension [A] on the control compartment
Entry 6
136 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
Table B-6.
Entries Option 1 Standard Entries Option 2 Alternative Entries (ISO 965)
A, B, C, D, E, F, G, H, K 1/2" NPT M20x1.5
NOTICE
When alternative entries according to ISO 965 are used, indication of the dimensions is
imprinted on the adapter bush or directly on the housing when ISO 965 entries are created
by machining the housing.
! WARNING
Unused entries may remain unmachined or must be plugged with a certified plug suitable
for the subject environment.
Entries from A to K
Appendix 137
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
NOTICE
To prevent water infiltration through the line cable conduits, ensure that the cable
glands used possess the minimum degree of protection required by the plant and are
specified on the actuator label. If a rigid conduit makes a connection to the plant, it is
recommended to place a flexible pipe connection between the conduit and the conduit
entry of the additional extension.
NOTICE
All accessories (including cable glands) must comply with approved specifications for the
site requirements and be certified according to the standard directive.
138 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
Figure B-8
B.8 Maintenance
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
Appendix 139
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
! CAUTION
Using a fastener other than the approved type may result in damage to the actuator or
valve. Refer to Table 8.
! CAUTION
Failure to use proper torque values can result in damage to the actuator and/or valve.
B.8.3 Repairs
When needed, repairs must only be carried out using spare parts supplied by the
manufacturer. All accessories must comply with approved specifications and follow the
application and site requirements.
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
! WARNING
The values of gaps of explosion-proof joints are lower than the maximum specified on Tables
of IEC/EN 60079-1 Standard and the values of widths of the explosion-proof joints are greater
than the values specified in the tables of the Standard IEC/EN 60079-1. Should maintenance
require the replacement of any component that forms part of an explosion-proof joint, only
an original spare provided by Emerson can be used. Direct repair or reconstruction of the
above components is not permitted without Emerson authorization. Not performing this
procedure will invalidate the product safety and contractual guarantee.
140 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
Original spare parts must be ordered from the manufacturer; to ensure that correct spares
are provided, the serial number printed on the ICON3000 product label must be specified
when an order for spares is placed.
Appendix C: ICON3000/ICON3000AD
Ex db h IIC T4 Gb/Ex h tb IIIC T135 °C Db IP66/68
Ex db h ia IIC T4 Gb/Ex h tb IIIC T135 °C Db IP66/68
C.1.1 General
This Appendix C to Installation, Operation, and Maintenance Manual MAN-02-04-97-0713
prescribes the Safety Instructions applicable to electric actuators ICON3000-010
and ICON3000-020. The subject actuator is certified according to EN and IEC Standards
60079-0, 60079-1, 60079-11, 60079-31 and EN ISO 80079-36, 80079-37 for protection
type Ex db h or Ex db h ia for gas group IIIC. The actuator is suitable for installation in an
ambient temperature range from -60 °C (-76 °F) to +85 °C (+185 °F).
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
The ICON3000 is designed in accordance with the applicable international rules and
specifications, but the following regulations must be observed in every case:
• General installation and safety regulations.
• The proper use of personal protective devices (glasses, clothing, gloves).
• The proper use of tools, lifting equipment, and transport equipment.
Safety warnings and warranty will be invalidated if the ICON3000 is installed in explosive
atmospheres not covered by the appropriate grade of protection, and/or in environments
where temperatures exceed the maximum temperature specified on the product label.
Appendix 141
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
NOTICE
Check that the label (as shown by the example Figure C-1) is fixed to the unit and is
complete with all the appropriate information.
C.2.1 Marking
Table C-1.
Hazardous zone Categories according to 2014/34/EU Directive
Gas, mists, or vapors Zone 0 1G
Gas, mists, or vapors Zone 1 2G or 1G
Gas, mists, or vapors Zone 2 3G or 2G or 1G
Dust Zone 20 1D
Dust Zone 21 2D or 1D
Dust Zone 22 3D or 2D or 1D
142 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
Appendix 143
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
NOTICE
Not following the procedures according to this document will invalidate the
product warranty.
The standard plastic plugs used to protect the cable entries during transport are neither
explosion-proof nor waterproof; these plugs are only designed to prevents the entry of
foreign objects during transport. The general storage procedure stated in Section 2 must
be followed.
C.7 Installation
NOTICE
Installation must be carried out in accordance to the applicable standards IEC/EN 60079-14
and IEC/EN 60079-17 regarding the electrical installations in Hazardous Areas (other than
mines) classified as Zones 1, 2 (gas) and Zones 21, 22 (dust) following IEC/EN 60079-10-1
and IEC/EN 60079-10-2 and any other applicable national standards and rules.
! WARNING
Verify that the actuator nameplate conforms to the applicable certification, ambient
temperature range, and site safety requirements.
144 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
Table C-4.
Entry NPT size Alternative (Metric size ISO 965)
1 1" M32x1.5
2 1 1/2" M40x1.5
3 1" M32x1.5
4 (optional) 3/4" M25x1.5
5 (optional) 3/4" M25x1.5
XTE3000
5 4 6
1 2 3
NOTICE
When alternative entries according to ISO 965 are used, indication of the dimensions
is imprinted on the adapter bush or directly on the housing when ISO 965 entries are
obtained by machining the housing.
! WARNING
Unused entries may remain unmachined or must be plugged with a certified plug suitable
for the subject environment.
Appendix 145
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
Figure C-3
NOTICE
To prevent water infiltration through the line cable conduits, be sure the cable glands
used possess the minimum degree of protection required by the plant and are specified
on the actuator label. If a rigid conduit makes a connection to the plant, it is recommended
to place a flexible pipe connection between the conduit and the conduit entry of the
additional extension.
146 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
NOTICE
The cables and cable glands MUST be selected considering the maximum temperature of
the cable indicated on the label fixed to the base ICON3000 unit.
C.8 Maintenance
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
Appendix 147
Appendix Installation, Operation and Maintenance Manual
May 2022 VCIOM-08500-EN Rev. 2
! CAUTION
Using a fastener other than the approved type may result in damage to the actuator or
valve. Refer to Table 8.
! CAUTION
Failure to use proper torque values can result in damage to the actuator and/or valve.
C.8.3 Repairs
When needed, repairs may only be carried out using spare parts supplied by the manufacturer.
! WARNING
The values of gaps of explosion-proof joints are lower than the maximum specified
on Tables of IEC/EN 60079-1 Standard and the values of widths of the explosion-proof
joints are greater than the values specified in the tables of the Standard IEC/EN 60079-1.
Should maintenance require the replacement of any component that forms part of an
explosion-proof joint, only an original spare provided by Emerson can be used. Direct
repair or reconstruction of the above components is not permitted without Emerson
authorization. Not performing this procedure will invalidate the product safety and
contractual guarantee.
Original spare parts must be ordered from the manufacturer; to ensure that correct spares
are provided, the serial number printed on the ICON3000 product label must be specified
when an order for spares is placed.
148 Appendix
Installation, Operation and Maintenance Manual Appendix
VCIOM-08500-EN Rev. 2 May 2022
Appendix D: ICON3000
Ex db eb h IIC T4 Gb/Ex h tb IIIC T135 °C Db IP66/68
Ex db eb h ia IIC T4 Gb/Ex h tb IIIC T135 °C Db IP66/68
D.1.1 General
This Appendix D is supplemental to Installation, Operation, and Maintenance Manual
MAN-02-04-97-0713 and prescribes the safety instructions applicable to electric actuators
ICON3000-010, ICON3000-020, and ICON3000-030, either as a base unit or when they are
equipped with:
a. an additional entry mounted on the control compartment or when they
are equipped with an optional extension
b. additional entries
c. an optional electronic card mounted on the terminal board compartment
The subject actuator is certified according to IEC/EN 60079-0, 60079-1, 60079-7,
60079-11 and 60079-31 standards, with protection type Ex db eb h IIC or Ex db eb h ia IIC
for gas and Ex h tb IIIC for dust, suitable for installation in an ambient temperature range
from -25 °C (-13 °F) to +60 °C (+140 °F).
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
The ICON3000 is designed in accordance with the applicable international rules and
specifications, but the following regulations must be observed in every case:
• General installation and safety regulations.
• The proper use of personal protective devices (glasses, clothing, gloves).
• The proper use of tools, lifting equipment, and transport equipment.
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Installation in environments with the presence of an explosive atmosphere not covered by the
specified grade of protection, or in environments that could reach a temperature higher than
the maximum specified on the label, will invalidate the safety warnings and the warranty.
NOTICE
Check that the label (as shown by the example Figure D-4) is fixed to the unit and is complete
with all the appropriate information.
D.2.1 Marking
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Table D-1.
Hazardous zone Categories according to 2014/34/EU Directive
Gas, mists, or vapors Zone 0 1G
Gas, mists, or vapors Zone 1 2G or 1G
Gas, mists, or vapors Zone 2 3G or 2G or 1G
Dust Zone 20 1D
Dust Zone 21 2D or 1D
Dust Zone 22 3D or 2D or 1D
NOTICE
Not following the procedures according to this document will invalidate the product warranty.
Normally the optional extension for additional entry or additional electronic card is directly
mounted on the base model of ICON3000 and leaves the factory in perfect condition.
In this case the general storage procedure as stated in section 2 must be followed. When the
above extension is shipped separately for a field upgrade on an existing ICON3000 unit, this
extension must be stored in a protected area while ensuring that the explosion-proof joints
are well-protected and kept free of damage. The standard plastic plugs used to protect the
conduit entries during transport are not explosion-proof nor waterproof; these plugs are
only intended to prevent entry of foreign objects. The extension for additional entry/entries
or additional electronic cards maintains the same weather-proof degree of protection as the
base ICON3000 model. Good operating condition can only be maintained if the extension is
correctly installed/connected on site and if it has been correctly stored.
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D.7 Installation
NOTICE
Installation must be carried out in accordance to the applicable standards IEC/EN 60079-14
and IEC/EN 60079-17 regarding the electrical installations in Hazardous Areas (other than
mines) classified as Zones 1, 2 (gas) and Zones 21, 22 (dust) following IEC/EN 60079-10-1
and IEC/EN 60079-10-2 and any other applicable national standards and rules.
! WARNING
Verify that the actuator nameplate conforms to the applicable certification, ambient
temperature range, and site safety requirements.
Table D-4.
Entry NPT size Alternative (Metric size ISO 965)
1 1" M32x1.5
2 1 1/2" M40x1.5
3 1" M32x1.5
4 (optional) 3/4" M25x1.5
5 (optional) 3/4" M25x1.5
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Entries from A to K
NOTICE
When alternative entries according to ISO 965 are used, indication of the dimensions is
imprinted on the adapter bush or directly on the housing when ISO 965 entries are created
by machining the housing.
! WARNING
Unused entries may remain unmachined or must be plugged with a certified plug suitable
for the subject environment.
Table D-5.
Entry Standard size Optional
6 M25x1.5 3/4" NPT
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Table D-6.
Option 2 Alternative Entries
Entry Option 1 Standard Entries
(ISO 965)
A, B, C, D, E, F, G, H, K 1/2" NPT M20x1.5
NOTICE
When alternative entries according to ISO 965 are used, indication of the dimensions is
imprinted on the adapter bush or directly on the housing when ISO 965 entries are created
by machining the housing.
! WARNING
Unused entries may remain unmachined or must be plugged with a certified plug suitable
for the subject environment.
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Figure D-6
Connection for Ex-e
terminals enclosure
NOTICE
To prevent water infiltration through the line cable conduits, ensure that the cable
glands used possess the minimum degree of protection required by the plant and are
specified on the actuator label. If a rigid conduit makes a connection to the plant, it is
recommended to place a flexible pipe connection between the conduit and the conduit
entry of the additional extension.
NOTICE
All accessories (including cable glands) must comply with approved specifications for the
site requirements and be certified according to the standard directive.
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D.8 Maintenance
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
! CAUTION
Using a fastener other than the approved type may result in damage to the actuator or
valve. Refer to Table 8.
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! CAUTION
Failure to use proper torque values can result in damage to the actuator and/or valve.
D.8.3 Repairs
When needed, repairs may only be carried out using spare parts supplied by the
manufacturer. All accessories must comply with approved specifications and follow the
application and site requirements.
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
! WARNING
The values of gaps of explosion-proof joints are lower than the maximum specified on Tables
of IEC/EN 60079-1 Standard and the values of widths of the explosion-proof joints are greater
than the values specified in the tables of the Standard IEC/EN 60079-1. Should maintenance
require the replacement of any component that forms part of an explosion-proof joint, only
an original spare provided by Emerson can be used. Direct repair or reconstruction of the
above components is not permitted without Emerson authorization. Not performing this
procedure will invalidate the product safety and contractual guarantee.
Original spare parts must be ordered from the manufacturer; to ensure that correct spares
are provided, the serial number printed on the ICON3000 product label must be specified
when an order for spares is placed.
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Appendix E: ICON3000
Ex db eb h IIB T4 Gb / Ex h tb IIIC T135 °C Db IP66/68
Ex db eb h ia IIB T4 Gb / Ex h tb IIIC T135 °C Db IP66/68
E.1.1 General
This Appendix E is supplemental to Installation, Operation, and Maintenance Manual
MAN-02-04-97-0713 and prescribes the Safety Instructions applicable to ICON3000
electric actuators in sizes 010, 020, 030, 040, and 050 either as a base unit or when they are
equipped with:
a. an additional entry mounted on the control compartment or when they
are equipped with optional extension
b. additional entries or with an optional extension
c. an optional electronic card both mounted on the terminal board
compartment, shown in Figure E-3.
The subject actuator is certified according to EN and IEC standards 60079-0, 60079-1,
60079-7, 60079-11 and 60079-31 and EN ISO 80079-36, 80079-37, for protection type
Ex db eb h or Ex db eb h ia for gas group IIB and Ex h tb for dust group IIIC. The actuator
is suitable for installation in an ambient temperature range from -25 °C (-13 °F) to +60 °C
(+140 °F).
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
The ICON3000 is designed in accordance with the applicable international rules and
specifications, but the following regulations must be observed in every case:
• General installation and safety regulations.
• The proper use of personal protective devices (glasses, clothing, gloves).
• The proper use of tools, lifting equipment, and transport equipment.
160 Appendix
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NOTICE
Check if the label, as the example here above, is fixed on the unit and completed with all
the appropriate information.
E.2.1 Marking
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Table E-1.
Hazardous zone Categories according to 2014/34/EU Directive
Gas, mists, or vapors Zone 0 1G
Gas, mists, or vapors Zone 1 2G or 1G
Gas, mists, or vapors Zone 2 3G or 2G or 1G
Dust Zone 20 1D
Dust Zone 21 2D or 1D
Dust Zone 22 3D or 2D or 1D
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NOTICE
Not following the procedures according to this document will invalidate the product warranty.
Normally the optional extension for additional entry or additional electronic card is directly
mounted on the base model of ICON3000 and leaves the factory in perfect condition. In
this case the general storage procedure as stated in section 2 must be followed. When the
above extension is shipped separately for a field upgrade on an existing ICON3000 unit, this
extension must be stored in a protected area while ensuring that the explosion-proof joints
are well-protected and kept free of damage. The standard plastic plugs used to protect the
conduit entries during transport are not explosion-proof nor waterproof; these plugs are
only intended to prevent entry of foreign objects. The extension for additional entry/entries
or additional electronic cards maintains the same weather-proof degree of protection as the
base ICON3000 model. Good operating condition can only be maintained if the extension is
correctly installed/connected on site and if it has been correctly stored.
164 Appendix
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E.7 Installation
NOTICE
Installation must be carried out in accordance to the applicable standards EN/IEC 60079-14
and EN/IEC 60079-17 regarding the electrical installations in Hazardous Areas (other than
mines) classified as Zones 1, 2 (gas) and Zones 21, 22 (dust) following EN/IEC 60079-10-1
and EN/IEC 60079-10-2 and any other applicable national standards and rules.
! WARNING
Verify that the actuator nameplate conforms to the applicable certification, ambient
temperature range, and site safety requirements.
Table E-4.
Entry NPT size Alternative (Metric size ISO 965)
1 1" M32x1.5
2 1 1/2" M40x1.5
3 1" M32x1.5
4 (optional) 3/4" M25x1.5
5 (optional) 3/4" M25x1.5
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5 4
1 2 3
NOTICE
When alternative entries according to ISO 965 are used, indication of the dimensions
is imprinted on the adapter bush or directly on the housing when ISO 965 entries are
obtained by machining the housing.
! WARNING
Unused entries may remain unmachined or must be plugged with a certified plug suitable
for the subject environment.
Table E-5.
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Table E-6.
NOTICE
When alternative entries according to ISO 965 are used, indication of the dimensions is
imprinted on the adapter bush or directly on the housing when ISO 965 entries are created
by machining the housing.
! WARNING
Unused entries may remain unmachined or must be plugged with a certified plug suitable
for the subject environment.
Figure E-6
Base actuator with extension [A] Base actuator with extensions [B] or [C] Connection for Ex-e
on the control compartment on the terminal board compartment terminals enclosure
Entry 6
Entries from A to K
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NOTICE
To prevent water infiltration through the line cable conduits, ensure that the cable glands used
possess the minimum degree of protection required by the plant and are specified on the
actuator label. If a rigid conduit makes a connection to the plant, it is recommended to place a
flexible pipe connection between the conduit and the conduit entry of the additional extension.
NOTICE
All accessories (including cable glands) must comply with approved specifications for the
site requirements and be certified according to the standard directive.
168 Appendix
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Figure E-7
E.8 Maintenance
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
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! CAUTION
Using a fastener other than the approved type may result in damage to the actuator or
valve. Refer to Table 8.
! CAUTION
Failure to use proper torque values can result in damage to the actuator and/or valve.
170 Appendix
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E.8.3 Repairs
When needed, repairs may only be carried out using spare parts supplied by the
manufacturer. All accessories must comply with approved specifications and follow the
application and site requirements.
! WARNING
Installation, configuration, commissioning, maintenance, and repairs must be performed
by approved and qualified personnel only.
! WARNING
The values of gaps of explosion-proof joints are lower than the maximum specified on Tables
of IEC/EN 60079-1 Standard and the values of widths of the explosion-proof joints are greater
than the values specified in the tables of the Standard IEC/EN 60079-1. Should maintenance
require the replacement of any component that forms part of an explosion-proof joint, only
an original spare provided by Emerson can be used. Direct repair or reconstruction of the
above components is not permitted without Emerson authorization. Not performing this
procedure will invalidate the product safety and contractual guarantee.
Original spare parts must be ordered from the manufacturer; to ensure that correct spares
are provided, the serial number printed on the ICON3000 product label must be specified
when an order for spares is placed.
Appendix 171
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