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Installation, Operation and Maintenance Manual
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
Rev. Date Description Prepared Checked Approved

2 May 2022 Document Update L. Piacenti - C. Doglio
1 December 2021 Document Update - - -
0 December 2019 Migration to new template - - -
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 2: Storage and Pre-Installation

2.1 Tests to be Carried Out When the Actuator is Received ................................. 5
2.2 Storage Procedure ........................................................................................ 5
2.2.1 General .............................................................................................. 5
2.2.2 Short-term Storage (One Year or Fewer) ............................................. 6
2.2.3 Long-term Storage (More Than One Year) .......................................... 6
2.3 Checks to be Performed Before Installation ................................................... 8
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
Section 5: Operating the ICON3000

5.1 Operation By Handwheel ............................................................................ 28
5.1.1 Operation By Handwheel in Absence of a Power Supply and With
the Lithium Battery .......................................................................... 28
5.2 Electrical Operation .................................................................................... 29
5.3 Local Control ............................................................................................... 29
5.4 Local Indication ........................................................................................... 29
5.5 Locking the 3-Position Selector ................................................................... 32
5.6 Remote Control........................................................................................... 32
5.6.1 Remote Commands.......................................................................... 32
5.6.2 Output Contacts .............................................................................. 34
5.6.3 ESD Operation .................................................................................. 34
5.6.4 Interlock Inputs ................................................................................ 35
5.7 Operating the ICON3000 for the First Time ................................................. 36
5.8 Optional Modules........................................................................................ 36
5.8.1 Fieldbus Interface for Remote Control via FIELDBUS .......................... 36
5.8.2 Ain/Aout Card .................................................................................. 37
5.9 Base Card of the ICON3000 ......................................................................... 39
5.10 Absolute Encoder of the ICON3000 ............................................................. 41
Section 6: Local Controls

6.1 Description of the Local Operator Interface ................................................. 42
6.2 Configuration Options ................................................................................ 46
6.3 Entering the View Mode .............................................................................. 48
6.4 Entering the Set-Up Mode ........................................................................... 49
6.5 Exit from View and Set-Up Mode ................................................................. 49
Section 7: Set-Up Menu

Set-Up Menu..........................................................................................................51
Section 8: View Menu

View Menu.............................................................................................................53
Section 9: Set-Up Routines

9.1 Actuator Set-Up .......................................................................................... 55
9.1.1 Set Stroke Limits............................................................................... 55
9.1.2 Torque Set-up ................................................................................... 57
9.1.3 ESD (Emergency Shut Down) Control ............................................... 57
9.1.4 Remote Controls .............................................................................. 58
9.1.5 Local Controls................................................................................... 59
9.1.6 Output Relays ................................................................................... 60
9.1.7 Positioner ......................................................................................... 62
9.1.8 Fail-Safe............................................................................................ 64
9.1.9 OUT 4 - 20 mA .................................................................................. 66
9.1.10 Interlock ........................................................................................... 67
9.1.11 2-Speed Timer .................................................................................. 67
9.1.12 BUS (or FDI Control) ......................................................................... 68
9.1.13 Miscellaneous ................................................................................... 69
ii Table of Contents
9.2 Valve Data ................................................................................................... 72

9.2.1 Sample Configuration Procedure ...................................................... 72
9.3 Maintenance ............................................................................................... 72
9.3.1 Set Password .................................................................................... 73
9.3.2 Clear Alarm Log ................................................................................ 73
9.3.3 Set Torque Reference........................................................................ 73
9.3.4 Set Curve Reference ......................................................................... 74
9.3.5 Clear Recent Data Log....................................................................... 74
9.3.6 Configuration (Backup/Restore) ....................................................... 75
9.3.7 Set PST Reference ............................................................................. 76
9.3.8 PST Command.................................................................................. 76
9.3.9 Set Maintenance Date ...................................................................... 77
9.3.10 Set Data Logger ................................................................................ 78
9.4 Example of Set-Up Routine .......................................................................... 79
9.4.1 Torque Set-Up .................................................................................. 79
Section 10: View Routines

10.1 Actuator Set-Up .......................................................................................... 80
10.2 Nameplate .................................................................................................. 81
10.3 Valve Data ................................................................................................... 82
10.4 Maintenance ............................................................................................... 82
10.4.1 Alarm Log ......................................................................................... 82
10.4.2 Torque Profile ................................................................................... 83
10.4.3 Torque Curve.................................................................................... 84
10.4.4 Operation Log .................................................................................. 85
10.4.5 Maintenance Date ............................................................................ 88
10.4.6 Data Logger...................................................................................... 88
10.5 Example of View Routine ............................................................................. 91
10.5.1 View Torque Set-up .......................................................................... 91
Section 11: Maintenance

11.1 Standard Maintenance ................................................................................ 92
11.2 Special Maintenance ................................................................................... 93
11.3 Lithium Battery Change .............................................................................. 94
Section 12: Troubleshooting

12.1 The Electronics do not Switch on when Powered ............................................ 98
12.2 DC Output Voltage not Available at the Terminals ....................................... 99
12.3 The Actuator does not Work from Remote Controls ................................................99
12.4 The Motor is Very Hot and does not Start .................................................. 100
12.5 The Motor Runs but the Actuator does not Move the Valve ....................... 100
12.6 The Manual Override Cannot be Engaged.................................................. 101
12.7 The Valve does not Seat Correctly ............................................................. 101
12.8 Valve Operation Requires Excessive Torque ............................................... 102
12.9 The Actuator does not Stop in the Fully Open or Fully Closed Position ....... 103
12.10 The Numeric Position Display Indicates "---" ............................................... 103
12.11 Diagnostic Messages ................................................................................. 103
Section 13: Parts List and Drawings

Parts List and Drawings........................................................................................109
Table of Contents iii

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
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
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
Section 1: General Safety Instructions

1.1 Range of Applications
The Biff ICON3000 and the ICON3000v2 electric actuators covered in this manual are
designed for the operation of any type of industrial valve used in heavy industrial, chemical,
and petrochemical facilities. Emerson will not be liable for potential damage resulting from
use in anything other than these designated applications. Such risk lies entirely with the
user. Where not explicitly highlighted with the generic indication ICON3000 it is intended
to refer to both ICON3000 and ICON3000v2 versions.
! 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
General Safety Instructions 1

Section 1: General Safety Instructions Installation, Operation and Maintenance Manual
1.2 Safety Instructions for Installation in

Hazardous Areas
! WARNING
When installing in a hazardous area as defined by the applicable rules, verify that the
actuator nameplate conforms to site safety requirements.
! WARNING
The ICON3000 is designed according to IEC/EN 60079-0, IEC/EN 60079-1, and

IEC/EN 50079-31 standards. Different types of protection are available, depending
on the marking printed on the actuator label:
• Ex d IIB Txx, Ex d IIC Txx with “Explosion-proof” terminal board enclosure, or
• Ex d e IIB Txx, Ex d e IIB+H2 Txx, Ex d e IIC Txx with “Increased safety”
terminal board enclosure
These are suitable for use in hazardous areas classified as at risk of explosion caused by the
presence of gas and dust.
The ICON3000 has IP66/68 degree of protection according to EN 60529.
2 General Safety Instructions

Installation, Operation and Maintenance Manual Section 1: General Safety Instructions
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
Table 3. Equipment Protection Level (EPL) EN 60079-14
Explosive atmosphere Zone EPL

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
1.3 Applicable Standards and Regulations

Table 4.
EN ISO 12100 Safety of machinery - General principle for design - Risk assessment and risk reduction
EN 60204-1 Safety of machinery - Electrical equipment of industrial machines
2006/42/EC Machinery directive
2014/35/EU Low voltage directive
2014/30/EU EMC directive
2014/34/EU ATEX directive
2014/53/EU RED directive
FM (for USA) FM3600, FM3810, ANSI/ISA 60079-0, ANSI/ISA 60079-1, ANSI/NEMA 250
FM-c CAN/CSA C22.2 No. 60079-0, CAN/CSA C22.2 No. 60079-1, CAN/CSA 61010-1,
(for Canada) CSA-C22.2 No. 94
General Safety Instructions 3

Section 1: General Safety Instructions Installation, Operation and Maintenance Manual
Low Voltage Requisition in accordance with IEC-61010-1

All MAINS circuits are to be considered in overvoltage CATEGORY II.
Applications at altitudes below 2,000 meters must comply with:
• All circuits connected to the actuator relays contacts (OUTPUT SIGNALS) must
refer to the same power supply system (both SELV or NON-SELV).
• All remote commands (INPUT SIGNALS) must refer to the same power
supply system.
Applications in altitude between 2.000 and 4.000 meter must have INPUT and OUTPUT
SIGNALS referred to the same power supply system (both SELV or NON-SELV).
Figure 1
Internal gears
Handwheel
Absolute Encoder
Terminal box
Engagement lever
Electric motor Local interface
1.4 Terms and Conditions

Emerson guarantees every product to be free from defects and to conform to industry
standards. The warranty period is one year from the date of installation by the first user,
or eighteen months from the date of shipment to the first user, whichever occurs first.
No warranty is given for products or components manufactured by third-party companies,
or for goods which have been subject to misuse, improper installation, corrosion, or which
have been modified or repaired by unauthorized personnel. Repair work due to improper
use will be charged at standard rates.
4 General Safety Instructions

Installation, Operation and Maintenance Manual Section 2: Storage and Pre-Installation
Section 2: Storage and Pre-Installation

2.1 Tests to be Carried Out When the Actuator
is Received
If the actuator is received already mounted on the valve, all the below operations should
have already been performed during valve/actuator assembly.
• Check that the display is active.
• Turn the handwheel until the valve is in a completely open position.
• Check that the display reads 100%, which indicates that the valve is completely open.
• Rotate the handwheel clockwise and bring the valve to a completely closed position.
• Check that the display reads 0%, which indicates that the valve is completely
closed. If the test result is satisfactory, the actuator has already been adjusted
and one can proceed with the electrical connection. If the actuator is delivered
separately from the valve or the above procedure shows that the position is
incorrect, all operations described in this manual must be carried out.
• Check that no damage has occurred during transport. Pay particular attention
to the push-buttons, the display area glass, and the selector.
• Check the information on the nameplate. In particular, check the serial number
and performance data (nominal torque, operation speed, protection class, motor
supply voltage, etc.) and verify that this data matches the data on the display
(see Section 10, View Routines).
Make sure all accessories have been received with the shipment as described in the
delivery documentation.
2.2 Storage Procedure

NOTICE
Not following the procedures according to this document will invalidate the product warranty.
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.
Storage and Pre-Installation 5

Section 2: Storage and Pre-Installation Installation, Operation and Maintenance Manual
2.2.2 Short-term Storage (One Year or Fewer)
2.2.2.1 Indoor Storage

Make sure that the actuator is kept in a dry place, laid on a wooden pallet, and protected
from dust.
2.2.2.2 Outdoor Storage

• Make sure that the actuator is protected from the elements (e.g. protected from
rain by covering with a canvas tarp).
• Place the actuator on a wooden pallet or some other raised platform, such that it is
not in direct contact with the ground.
• If the actuator is supplied with standard plastic plugs, remove them from the
conduit entries and replace them with weather-proof plugs.
2.2.3 Long-term Storage (More Than One Year)
2.2.3.1 Indoor Storage

In addition to the instructions in Section 2.2.2.1:
• If the actuator is supplied with standard plastic plugs, replace them with
weather-proof plugs.
• If the actuator is provided with a lithium battery, remove it and store it in a clean
and dry location (see Section 11.3, Lithium Battery Change).
2.2.3.2 Outdoor Storage

In addition to the instructions in Section 2.2.2.2:
• Check the general condition of the actuator, paying particular attention to the
terminal board and local display glass.
• If the actuator is provided with a lithium battery, remove it and store it in a clean
and dry location (see Section 11.3, Lithium Battery Change).
Figure 2
6 Storage and Pre-Installation

Installation, Operation and Maintenance Manual Section 2: Storage and Pre-Installation
Figure 3
Figure 4
Figure 5
Storage and Pre-Installation 7

Section 2: Storage and Pre-Installation Installation, Operation and Maintenance Manual
Figure 6
2.3 Checks to be Performed Before Installation

• Make sure that the valve to be motorized is appropriate for coupling to
the actuator.
• The electrical supply cables must be suitable for the power rating
(refer to the test certificate that comes with the actuator).
• Gather the right tools for assembly and for setting the actuator controls.
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).
8 Storage and Pre-Installation

Installation, Operation and Maintenance Manual Section 3: Installation
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.
3.1.1 Heater Options

Actuators are suitable for ambient temperature range as per Produc Data Sheet.
Heater options are available for specific application.
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 ✓
(*) Default in case of Extreme Low Temperature Range.
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
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
3.2 Coupling Block: Disassembly from the Actuator

The bushing is delivered already assembled to the drive sleeve, even when it is unmachined.
In order to perform the necessary machining, remove the bushing from its housing.
Remove the fixing screws from the coupling block. View the actuator from the coupling
side, with the block separated from the gearbox. Do not misplace the seal ring between the
coupling block and the gear reduction unit.
3.2.1 Type “A” Coupling Block
3.2.1.1 Preparing the Bushing

Using a spanner wrench, unscrew the lower ring nut.
Figure 8
Extract the stem nut from the block housing.
Installation 11
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
3.2.1.2 Reassembling the Internal Parts

It is advisable to wash the dismantled parts with a suitable solvent and dry them with
compressed air. Make sure that no metal filings or foreign bodies remain; spread a film of
grease on all parts (for grease type, see Section 4, Lubrication).
Proceed with the assembly of the internal parts by following the disassembly procedure
in reverse; tighten the lower ring nut with thread sealant LOCTITE 270 or equivalent,
and ensure that the stem nut still rotates freely. Attach the unit to the gear reducer as
described further on.
3.2.2 Type “B1” and “B2” Coupling Blocks

Using a spanner wrench, unscrew the lower ring nut.
Figure 11
Extract the bushing from the block housing.
Installation 13
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.

grease on all parts (for grease type, see Section 4, Lubrication). Proceed with assembly
of the internal parts by following the disassembly procedure in reverse order; tighten the
lower ring nut with thread sealant LOCTITE 270 or equivalent, and ensure that the bushing
still rotates freely. Attach the unit to the gear reducer as described further on.
3.2.3 Type “B3” and “B4” Coupling Blocks

Remove the mounting bolts of the coupling flange.
Figure 13
14 Installation
Figure 14
Extract the bushing and machine it according to the mating needs.
Figure 15

grease on all parts (for grease type see Section 4, Lubrication).
Proceed with the assembly of the internal parts by following the disassembly procedure in
reverse order. Attach the unit to the gear reducer as described further on.
3.2.4 Attaching the Coupling Block to the Gear Reduction Unit

Check the integrity of the O-ring seal and place it in its slot on the coupling block.
Ensure that the lugs of the drive sleeve fit in the correct slots on the bushing.
Attach the screws previously removed.
Installation 15
3.3 Manual Operation

To engage manual operation, depress (by 20°-30°) the lever in the direction shown in
Figure 18 and then let the lever automatically return to its rest position. If no engagement
is obtained, slowly rotate the handwheel and repeat the operation.
Rotate the handwheel to achieve the desired operation (normally clockwise rotation
closes the valve).
A label is located on the handwheel with an arrow showing the closing direction
(clockwise by default). If the closing direction is counterclockwise, the label must be
removed and remounted upside-down.
! 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
Engagement lever locked in motor operation position: manual operation cannot be

engaged, thus preventing unwarranted local operation.
Figure 17
16 Installation
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
! 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)
3.4 Mounting the Actuator onto the Valve

Lubricate the valve stem.
Thoroughly clean the coupling surfaces of the valve and actuator flanges, and degrease
them carefully since torque is transmitted by friction.
Lift the actuator with slings suitable for its weight.
The actuator will operate properly in any position. When mounted upside-down, a 5 mm
diameter hole should be drilled in the end of the stem cover to avoid build-up of service
fluid or rainwater.
3.4.1 Coupling Type “A”

Place the actuator vertically on the stem, screw the threaded bushing of the coupling block
on the valve stem, and then rotate (normally counterclockwise) until the coupling block
and flange surfaces of the valve are securely in contact.
For safety purposes, rotate the handwheel in the opening direction for about two turns in
order to lift the valve gate from its seat to avoid imparting (during bolt fixing) excessive
axial thrust on the internal parts of the valve and the actuator.
Depending on the conditions of assembly, it could be easier to separate the thrust block
from the actuator and mount it onto the valve yoke.
3.4.2 Coupling Types “B1”, “B2”,”B3” and “B4”

Check the dimensions of the valve mounting details, and pay particular attention to the
protrusions of the valve stem in order to avoid any axial thrust on the internal parts of the
actuator or the valve when the screws are tightened.
Manually engage the actuator using the handwheel and place the actuator vertically on
the valve stem. Perform the coupling operations (with the aid of manual operation if
necessary); make sure no mating parts are forced.
18 Installation
3.4.3 Actuator Mounting
NOTICE
If the actuator is supplied without stud bolts and nuts, these must be provided by the
customer and conform to the material requirements in Table 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
3.5 Electrical Connections

Before powering the actuator check that the supply voltage details on the nameplate
are correct for the receiving plant. Access to terminals for electrical connections and
commissioning is via the terminal cover, since all settings are non-intrusive. The removal of
any other covers without Emerson approval will invalidate the warranty; Emerson will not
accept responsibility for any damage or deterioration that may be caused.
NOTICE
All accessories (including cable glands) must comply with approved specifications for the
site requirements and be certified according to the standard directive.
3.5.1 Plant Requirements

Protection devices (overcurrent breakers, magneto-thermal switches, or fuses) should be
provided at the plant by the administrating customer to protect the mains line in case of
motor overcurrent or loss of insulation between phases and earth.
For the proper sizing of protection devices, refers to certificate attached to the actuator
(Is current).
Protection devices must be easily reached and identifiable by the operator.
3.6 Removing the Terminal Board Enclosure

Using an 8 mm Allen key, loosen the four screws and remove the cover.
! 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
20 Installation
Figure 22
3.7 Removing the Terminal Board Enclosure

The sealing of cables and conduit entries should be carried out in accordance with the
relevant national standards or the regulatory authorities that certified the actuators.
This is especially true for units that are certified for use in hazardous areas, where the
method of sealing must be to an approved standard and cable glands, reducers, plugs, and
adapters must be approved and separately certified.
Standard cable entries (housing)
1" NPT, Qty 2
1-1/2" NPT, Qty 1
Optional: 3/4" NPT, up to Qty 2
On request, certified conduit entry adapters may be added
(Metric, Pg, Rc, ASA, etc.)
Remove the conduit entry plugs.
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
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.
3.8 Terminal Board

! WARNING
! 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
Terminate the ground connections to the stud marked “ground”.

One internal ground stud and one external ground stud are provided.
Before performing service or maintenance operations (unless otherwise indicated), ensure
that power is turned off to the unit to avoid injury or damage to equipment.
Check the wiring diagram (always included with the actuator) and the layout displayed on
the back of the terminal enclosure cover to ensure a correct electrical connection.
All terminations should be made with an insulated ring, or spade connectors using
the appropriate crimping tool. This operation will ensure an easily-made and correct
electrical connection.
Connect the motor supply cable previously sized in accordance with:
• The absorbed current corresponding to the actuator nominal torque with the
torque-limiting device set at 100% (see the test certificate attached to the
actuator, is current).
• The applicable plant and safety norms.
• Power cable maximum operating temperature greater than 85 °C.
Assemble the power terminal protective barrier located in the terminal board
compartment, using the enclosed screws. The control circuit (controls and signals) must
be connected by means of a multicore cable to the corresponding numbered terminals
according to the wiring diagram.
The internal cables of the actuator are also numbered according to the wiring diagram.
Actuators are always delivered with the motors wound and connected in accordance with
customer requests. Voltage and frequency values are stated on the motor nameplate.
Figure 24
Ground
studs
Figure 25
Installation 23
Figure 26
3.9 Instructions For Explosion-proof Enclosures

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

(covers, cable glands, joints), be careful to restore these enclosures back to their original
condition to maintain their integrity. In particular, ensure that the joint surfaces of all
enclosures are spread with a film of recommended grease (see Section 4, Lubrication).
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
AISI 316/ASME B16.11 A182-F316
030 M10x35 M10x30 M10x35
AISI 316/ASME B16.11 A182-F316
040 M10x35 M10x30 M10x35
AISI 316/ASME B16.11 A182-F316
050 M12x45 M10x30 M10x35
24 Installation
Important points to note:

• Do not damage the explosion-proof mating surfaces on the housing and on the
electrical covers.
• Reinstall all the screws associated with the dismantled parts, and coat them with
a thread sealant after coating them with a film of copper- or molybdenum-based
grease. This will prevent the screws from sticking and facilitate their removal when
maintenance is required.
• Check that the bolts and screws are of the same dimensions and at least equal
quality to those originally installed (as stated on the nameplate).
! 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).
3.10 Installation in Environments with

Explosive Dusts
NOTICE
The Biffi ICON3000 electric actuator shall be installed and maintained according to the
applicable rules regarding electrical installation in hazardous areas (other than mines),
classified as zone 21 (dust); for example: EN 50281-1-2 (dust) and/or other national standards.
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
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
• SHELL - TELLUS S4 ME 46 or equivalent
• 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
Should maintenance become necessary, the following GREASES are recommended:

• AGIP GREASE MU EP 2 or equivalent
• AEROSHELL GREASE 7 or equivalent
• AEROSHELL GREASE 7 or equivalent
Figure 27
Figure 28
Lubrication 27
Section 5: Operating the ICON3000 Installation, Operation and Maintenance Manual
Section 5: Operating the ICON3000

5.1 Operation By Handwheel
To operate the actuator via the handwheel, press down the lever and at the same
time rotate the handwheel until the clutch is engaged. Release the lever and move the
valve via the handwheel. The actuator will return to electrical operation only by energizing
the motor.
5.1.1 Operation By Handwheel in Absence of a Power Supply

and With the Lithium Battery
• The position is updated for strokes higher than a half turn of the wheel.
• The actuator position and battery status can be updated at any time by pressing
the STOP button for at least 3 seconds.
• The position is automatically checked and updated at least once a day.
At the end of each operation by handwheel, it is recommended to update the position by
pushing the STOP button.
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.
28 Operating the ICON3000

Installation, Operation and Maintenance Manual Section 5: Operating the ICON3000
5.2 Electrical Operation

Before connecting power to the actuator check that the voltage is correct and
corresponds to the indications on the nameplate. An incorrect power supply could
cause permanent damage to the electrical components. Checking phase rotation is not
necessary since the actuator is provided with automatic phase rotation correction. Rotate
the 3-position selector switch to OFF and then switch on the power. Do not operate the
actuator without first checking that the configuration is suitable for the required application
(see Section 6.4).
Power supply limits
Voltage: +/- 10% (continuous) +10% -15% (intermittent)
Nominal duty: -5% / 5% according to IEC 60034-1
Total Harmonic Distortion (THD): max 5% according to IEC 60034-1
Form and symmetry on voltages and currents: according to IEC 60034-1 (Section 7.2.1.1)
! CAUTION
Working outside the above limitations could damage the actuator.
Be careful if an inverter or generator is used as a power supply.
5.3 Local Control

If no alarm is present after configuring the actuator, place the 3-position selector in LOCAL
and control the actuator with the OPEN, CLOSE, and STOP push-buttons.
If “push-to-run” was selected: the actuator can be driven to the desired position by
pressing and holding the OPEN/YES or CLOSE pushbutton. As the push-button is released,
the motor is de-energized.
If “latched” was selected: as the OPEN or CLOSE push-button is pressed the motor is
energized, and it will continue to run after the control is released. To stop the motor,
press the STOP push-button. To reverse the direction, press the STOP push-button and then
press the push-button relevant to the opposite direction.
In “latched with instant reverse” mode the local controls work as in the “latched” mode,
but to reverse the motor direction one need only press the push-button relevant to the
opposite direction.
Depending on the position of the local selector, the OPEN/YES and CLOSE/NO
push-buttons work as follows:
• OPEN/CLOSE commands if the selector is in the LOCAL position.
• YES/NO to answer prompts in the menu, if the selector is in the OFF or
REMOTE positions.
5.4 Local Indication

By default, the upper display indicates the valve position as a percentage of opening
(open = 100%). The lower display in the upper part shows icons that indicate the actuator
status or the Menu, where the user is operating.
The lower display in the lower part is organized in two lines. The upper line indicates the
actuator status and the 3-position selector status. The lower line indicates the actuator
operation, or the position request % value, according to the configuration.
Two LEDs indicate the actuator position and operating direction (OPEN or CLOSE), while a
third and fourth LED indicate alarms and Bluetooth connectivity respectively.
Operating the ICON3000 29

Figure 30
Figure 31
Figure 32
Figure 33
OPEN/YES
STOP
CLOSE/NO

Figure 34
Status Operation Local selector

or Position position
request R%
Figure 35

5.5 Locking the 3-Position Selector

The 3-position selector can be locked in any of its three positions by means of a padlock.
5.6 Remote Control

Place the 3-position selector in REMOTE to transfer the actuator control to a remote device.
Local OPEN or CLOSE operation will be inhibited. Only the local STOP control remains active.
Using the “VIEW and SET-UP” features, one can configure different control modes.
The remote controls are optically-isolated (opto-coupled). A non-regulated 24 V DC
voltage (variable from 23 to 27 V DC, max. 4 W) is available on the actuator terminal board
to supply the remote controls or external devices.
5.6.1 Remote Commands

Using the “VIEW and SET-UP” features, one may configure different control modes.
4 WIRES (see the remote connections diagram in Figure 36)

In “4 wires latched” (OPEN, CLOSE, STOP, COMMON) mode with the OPEN or CLOSE signal
switched to ON, the motor is energized and it will continue to run after the signal returns to
OFF. To stop the motor, press STOP. To reverse the direction, press STOP and then press the
button relevant to the opposite direction. The action of the STOP signal (stop with signal
ON or stop with signal OFF) may be reversed using the VIEW and SET-UP features; see
Section 9.1.4, Remote Controls.

With the "3 wires" option (OPEN, CLOSE, COMMON), the actuator can be driven in either
“push-to-run” or “latched with instant reverse” mode.
In “push-to-run” mode, the actuator can be driven to the desired position by switching
the OPEN or CLOSE signal to ON. As the signal returns to OFF, the motor is de-energized.
In “latched with instant reverse” mode when the OPEN or CLOSE signal switches to
ON, the motor is energized and it continues to run after the signal returns to OFF. If the
signal relevant to the opposite direction goes ON, the actuator reverses its direction and
maintains the new direction if the signal returns to OFF.

With the “2 wires” option, two different activities may be selected:
In “2 wires, signal ON to open”, the actuator opens if the signal switches to ON and closes
if the signal goes to OFF. In “2 wires, signal ON to close”, the actuator closes if the signal
switches to ON and opens if the signal switches to OFF. This option requires two wires
(signal and common).
The circuits associated to the inputs can be supplied by the internally-generated 24 V DC or
by an external 20-125 V DC or 20-120 V AC (50/60 Hz).

The signal levels are the following:

• Minimum ON signal > 20 V DC or 20 V AC (50/60 Hz).
• Maximum ON signal < 125 V DC or 120 V AC (50/60 Hz).
• Maximum OFF signal < 3 V.
• Minimum signal duration > 500 ms.
• Total current drawn from remote controls < 25 mA.
Figure 36
Option A1)
Option B1)
Figure 37
Option A2)
Option B2)
Figure 38
Option A3)
Option B3)

5.6.2 Output Contacts

Standard version
• Monitor relay: the voltage-free, change-over contacts of the monitor relay are
available on the terminal board. The monitor relay indicates if the actuator can
be remotely controlled or if there is a problem or condition that prevents remote
control of the valve. The conditions that cause the relay to switch over are listed in
Section 9.1.6, Output Relays.
• AS1, 2, 3, 4, 5, 6, 7 relays: the voltage-free contacts of 7 latching relays are
available on the terminal board. The status (make or break) and the conditions
that cause switching of a given relay can be viewed and configured by using the
“VIEW and SET-UP” features. The status of the latching relays is immediately
updated if the associated conditions for change occur, or are cyclically updated
(every second).
• AS8 relay: a further voltage-free, change-over contact is available on the terminal
board. The conditions that cause the switching of the relay can be viewed and
configured by using the “VIEW and SET-UP” features.
• Contact rating:
Max. voltage 250 V AC / 30 V DC: max. current 5 A.
Min. voltage 5 V DC: min. current 5 mA.
5.6.3 ESD Operation

An ESD (Emergency Shut Down) signal can be sent to the actuator to override any existing
command and to drive the valve to a predetermined position.
The control is not self-maintained; that is, the ESD action continues until the relevant signal
is present. The “VIEW and SET-UP” features can configure the polarity of the ESD signal,
the valve position after the ESD action, and the priority of the ESD function, as described in
Section 9.1.3, ESD Control.
The ESD command is optically-isolated (opto-coupled). The circuits associated with the
input can be supplied by the internally generated 24 V DC or by an external 20-125 V DC or
20-120 V AC (50/60 Hz).
• Current drawn from ESD controls < 15 mA.
! 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.

5.6.4 Interlock Inputs

Two additional inputs are available to inhibit actuator movement in the open or closed
direction. The controls are momentary, and the inhibiting action continues until the
relevant signal is present. The interlock controls work when the local selector is in either
LOCAL or REMOTE positions. The ESD control overrides the interlock controls. The “VIEW
and SET-UP” features can configure the polarity of INTERLOCK signal as described in
Section 9.1.10, Interlock Controls.
The interlock inputs are optically-isolated (opto-coupled) and can be supplied by the
internally generated 24 V DC or by an external 20-125 V DC or 20-120 V AC (50/60 Hz).
• Total current drawn from remote controls < 20 mA.
Figure 39
Option D1)
Option D2)
Figure 40
Option E1)
Option E2)

5.7 Operating the ICON3000 for the First Time

Before attempting to operate the ICON3000 for the first time, check that the actuator is
correctly mounted on to the valve. Place the 3-position selector to OFF and switch the
power on. The alphanumeric display will show "ICON3000" for a few seconds.
If an alarm is active (i.e. the Alarm icon is shown on the display), take the necessary action
to resolve the alarm before proceeding (see Section 12.11).
If a warning is active (i.e. the Warning icon is shown on the display) a warning condition is
present. One can proceed since the ICON3000 will continue to function, but some data are
not according to the configured parameters (see Section 12.11).
If the lower lines of the display show “INT OFF”, then an interlock input is active. If the lower
lines of the display show “ESD ON OFF”, the ESD input is active.
Do not operate the actuator without first checking that the configuration is according to
the required application by using the “VIEW and SET-UP” features (see Section 6/10).
Set torque limits, position limits and closing direction by means of the “stroke limits
routine” of the “actuator set-up” menu (see Section 9).
When the stroke limits and the configurations are correct, bring the 3-position selector to
LOCAL and drive the actuator to the open or closed position (see Section 5.3).
5.8 Optional Modules

! CAUTION
The actuator contains parts and assemblies susceptible to damage via Electrostatic
Discharge (ESD). Prior to performing work, use ESD protection or discharge static
electricity by touching grounded metal.
Additional modules can be plugged in the base card of the ICON3000 to provide the
following functions:
5.8.1 Fieldbus Interface for Remote Control via FIELDBUS

This card allows the ICON3000 to connect to a FIELDBUS. The following bus interface cards
are available:
• Profibus DPV0
• Profibus DPV1 with or without redundancy
• Profibus DPV2 with or without redundancy
• Foundation Fieldbus
• LonWorks
• Modbus RTU
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.

5.8.2 Ain/Aout Card

With the above card, the ICON3000 is provided with a 4-20 analog input and a
4 - 20 mA analog output. This card should be plugged on the base card, replacing
the “TERMINAL BOARD ADAPTOR” card supplied as standard. A hardware alarm is
generated if the ICON3000 was set to be equipped with an Ain/Aout card and the card
is damaged or missing.
An Ain/Aout REPORT is also present in the list of reports if the card is present (see Section 6).
Figure 41
Status OK Warning Alarm
• 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
Internal power supply Passive loop
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
5.9 Base Card of the ICON3000

Figure 45 Bottom View of Base Card
Terminal Board Adaptor card (TBA) only for

ICON3000. It is not necessary for ICON3000v2

Figure 46 Top View of Base Card
Top View of Base Card

Base card equipped with fieldbus interface card and Terminal Board Adapter (TBA) card.
Figure 47 Fieldbus interface card
Fieldbus interface card

The type of card depends on the fieldbus present in the plant.
Figure 48 Ain/Aout card
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.

Figure 49 Potentiometer card
Potentiometer card
This card can be used for some special FW versions of the ICON3000.
Figure 50
5.10 Absolute Encoder of the ICON3000

The ICON3000 absolute encoder can measure up to 8,000 output turns. The absolute encoder
maintains the actuator/valve position without electrical power and battery back-up.
Figure 51 Potentiometer card

Section 6: Local Controls Installation, Operation and Maintenance Manual

6.1 Description of the Local Operator Interface
The following functions are available via the ICON3000 local operator interface:
• Actuator Control
• Actuator Configuration
• Actuator Status Visualization
The figures on the following pages describe the function of each component of the local
operator interface.
Figure 52 Local Operator Interface Components
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
Table 10. List

output torque mot temp
motor speed term temp
main voltage log status
current wireless report
temperature node report *
time FDI report *
date base report
alarm term report
warning Ain/Aout report *
Ktemp
The data with * are only present if the relevant modules are present.
2. 3-position selector to set the following operation modes:

• LOCAL: for local control only
• OFF: no control is active but the actuator is still connected to the mains
• REMOTE: for remote control only
3. The ICON3000 can be provided with a radio-frequency wireless connection

based on a qualified Bluetooth class 1 module. This allows exchange of data with
a PDA or PC with built-in Bluetooth™ technology. The following tasks can be
wirelessly performed:
• View and change configuration
• Set maintenance function
• Read maintenance data
• Download new firmware to the ICON3000
• The blue LED indicates that communication with a host device is established
4. Numeric display to indicate the present valve position as a % of open position.

Display resolution is a function of the number of complete turns of the actuator
output shaft:
• From 2 to 4 turns = 0.2%
• From 4 to 8,000 turns = 0.1%
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
6. Local Controls: OPEN/YES, CLOSE/NO, and STOP push-buttons.

The STOP push-button resets any existing command and is active both in local and remote.
If the 3-position selector is in LOCAL, the OPEN/YES, and CLOSE/NO push-buttons work as
OPEN and CLOSE commands.
If the 3-position selector is in REMOTE or in OFF, the OPEN/YES and CLOSE/NO
pushbuttons work as YES and NO to answer prompts (next? OK? view?, change? exit?)
shown on the alphanumeric display.
In OFF, the OPEN/YES and CLOSE/NO push-buttons allow the user to scroll through the
menu, to view and change the actuator configuration, or to scroll through the list of
variables, status, and alarms.
In REMOTE, the OPEN/YES and CLOSE/NO push-buttons allow the list of variables, status,
alarms and reports to be scrolled through but the actuator configuration cannot be viewed
or changed.
Table 11. Description of Variables and Reports

Variable Report
Torque Output torque in % of the nominal torque stated in the NAMEPLATE menu
Motor speed RPM of electrical motor
Main voltage Voltage (V) and frequency (Hz) of mains
Current Current (A) absorbed by the motor
Temperature Temperature (°C), inside the electronic compartment
Time Present time
Date Present date
Alarm List of present alarms (see Section12.11, Diagnostic Messages)
Warning List of present warnings (see Section 12.11, Diagnostic Messages)
Ktemp Temperature factor
Mot temp Temperature (°C) of the electrical motor
Term temp Temperature (°C) inside the terminal board compartment
Data logger status (off, ready, in progress: E: event number - number of
Log status
memory cycle or R: sample number - number of memory cycle)
Wireless report Bluetooth interface status (ready, not ready)
Report of bus interface card (only present if the bus card is present;
Node report
refer to the relevant instruction manual)
Report of FDI function (only present if the LonWorks bus card is present;
FDI report
refer to the relevant instruction manual)
Base card report
- card code
Base report
- manufacturing week and year
- electrical diagram, etc.
Terminal board card report
- card code
Term report
Ain/Aout card report (only present if the card is present)
- card code
Ain/Aout report
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
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
ICON3000 ICON3000 ICON3000
XXXXXX LOCAL XXXXXX OFF XXXXXX REMOTE

XXXXXX ? STOP NEXT? XXXXXX NEXT?
Graphic display
= 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
6.2 Configuration Options

The ICON3000 actuator can be completely configured via the local interface by means
of a series of menus that can be selected from the alphanumeric display. The operator
can navigate through the different displays by answering YES or NO to the appropriate
prompt (change? OK?, view?, next?, etc.) in the right corner of the lower row of the
alphanumeric display.
To access the menus: set the local selector in OFF and then simultaneously press OPEN/YES
and STOP. The alphanumeric display will now show the present language. Press YES if the
language is correct; if not, press NO to scroll through the list of available languages and
then press YES to when the menu reaches the desired language.
After choosing the language, the next step is the selection between view and set-up mode.
Use “View” mode to see the actuator configuration, and use “Set-up” mode to change
the present configuration. Unauthorized access to the set-up mode is prevented by a
4-character alphanumeric password. The actuator is supplied by Emerson with the default
password “0 0 0 0”.
Once the correct password has been entered, the actuator parameters can be configured.
The current password can also be modified by the “set password” routine in the
Maintenance menu. After entering the new password the old one becomes invalid, so it is
important to record the new password in a secure location for future retrieval.
The configuration functions (view and set-up mode) are grouped in 4 main menus:
Actuator Set-up, Nameplate, Valve Data, and Maintenance.
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
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
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).
6.3 Entering the View Mode

The existing actuator configuration should be checked before commissioning.
The parameters are configured at the factory according to standard settings, or to
customer requirements. No password is required to access view mode, but no change of
parameters can be made.
• Ensure that mains power is supplied.
• Move the 3-position selector to OFF and then simultaneously press OPEN/YES
and STOP.
• The display shows the present language. Press YES to confirm or NO to scroll
through the list of available languages. Press YES to select a new language
Press YES to confirm.
• Press NO to scroll through the list of available menus (actuator set-up, nameplate,
valve data, maintenance) and then press YES to select the desired menu.
• Press NO to scroll through the list of available routines and press YES to select
the routine where the parameter to be changed is located.
• Press NO to scroll through the list of parameters and press YES to view the value.
48 Local Controls
6.4 Entering the Set-Up Mode

To change the existing settings or to set stroke limits it is necessary to enter the
correct password.
Ensure that mains power (or the external auxiliary supply) is supplied.
• Move the 3-position selector to OFF and then simultaneously press OPEN/YES
and STOP.
• The display shows the present language. Press YES to confirm or NO to scroll
through the list of available languages. Press YES to select. Press YES to confirm
the chosen language.
• Press NO when the message is “VIEW MODE OK?”. Press YES to answer the prompt
“ENTER PASSWORD OK?”.
• Enter the password. Enter one digit at a time. Press YES if a digit is correct;
otherwise, press NO to scroll through the list of available characters and then
press YES when the character is correct. Enter 4 digits. After entering the last digit,
the microprocessor checks the password. If it is correct the messages “PASSWORD
CORRECT” and then “SET-UP MODE OK?” appear. Press YES.
• Press NO to scroll through the list of available menus (actuator set-up, valve data,
maintenance) and press YES to select the desired menu.
• Press NO to scroll through the list of available routines and press YES to select the
routine where the parameter to be changed is located.
• Press YES and NO to answer the prompt on the display and change the parameter.
• If the password is wrong, the message “PASSWORD WRONG” appears and set-up
mode will not available.
All settings are automatically saved to a non-volatile memory and are retained if electrical
power is removed from the actuator.
All ICON3000 actuators are configured before shipping with a standard default setting
unless alternatives were requested on order. If complications arise during commissioning,
the default setting can be reinstated via the appropriate function in the ”miscellaneous”
routine in the actuator set-up menu. The actuator will return to its original configuration
and commissioning can resume.
6.5 Exit from View and Set-Up Mode

The following actions cause the actuator to exit from view and set-up mode:
• Moving the 3-position selector to LOCAL or REMOTE.
• Answering YES when the display asks “EXIT OK?”.
• Pressing YES and NO simultaneously.
• Automatic exit after 90 minutes without any parameter change or view.
• Removal of electrical power from the unit.
Local Controls 49
50
May 2022
Display
YES FROM EXIT?
YES
Figure 54
YES STOP TO VIEW MENU
XXXXXX OFF LANGUAGE ENGLISH VIEW MODE

STOP NEXT? OK? OK?
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 YES YES
“0” 0 0 0 0 “0” 0 0 0 0 “0” 0 0 0 0 “0” PASSWORD CORRECT

DIGIT 1 OK? DIGIT 2 OK? DIGIT 3 OK? DIGIT 4 OK?
Figure 54 shows the procedure to enter view and set-up mode.
NO YES NO YES NO YES NO YES
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
Set-Up Menu
OFF
LOCAL REMOTE Figure 55
Display
3-position selector
XXXXXX OFF
STOP NEXT? NO YES
YES NO NO NO
YES STOP
SETUP MODE ACTUATOR SETUP VALVE DATA MAINTENANCE EXIT?

SELECT OK? CHANGE? CHANGE? CHANGE?
LANGUAGE OK?
YES YES YES

NO
Routines:
- stroke limits change?
- torque set-up change?
- ESD set-up change? Routines: Routines:
- Remote controls change? - Tag name change? - Set password change?
- Local controls change? - Serial number change? - Clear alarm log OK?
ENTER - Output relays change? - Manufacturer change? - Set torque profile reference OK?
PASSWORD - Positioner * change? - Break OP torque change? - Set torque curve reference OK?
- Fail-safe * change? - Break CL torque change? - Clear recent data log OK?
TO VIEW MENU - Out 4 - 20 mA * change? - Max stem thrust change? - Maintenance date change?
- Interlock change? - Flange type change? - Data logger change?
- 2-speed timer change?
- Bus * change?
- Miscellaneous change?
To exit from SETUP menu press
YES and NO simultaneously or
move the 3-position selector to
LOCAL or REMOTE NO NO NO
Press YES or NO to answer the appropriate prompts (change? OK?, etc.)

1. Routines with * are only available if the relevant
modules are present
2. Nameplate menu not available in Set-up mode
51
May 2022
52
May 2022
YES NO NO NO TO
Figure 56
EXIT?
ACTUATOR SETUP MAINTENANCE
VALVE DATA
SETUP MODE MAINTENANCE
OK? CHANGE? CHANGE?
CHANGE?
YES YES YES

FROM ENTER
PASSWORD YES YES YES
ROUTINE
STROKE TAG SET

LIMITS NAME PASSWORD
ACTUATOR SETUP ROUTINE ROUTINE MAINTENANCE ROUTINE
VALVE DATA
STROKE LIMITS
YES TAG NAME YES SET PASSWORD YES
CHANGE? CHANGE? CHANGE?
NO NO NO
YES YES YES
................ SERIAL ................

................ NUMBER ................
ACTUATOR SETUP ROUTINE ROUTINE ROUTINE
VALVE DATA MAINTENANCE
XXXXXX XXXXXX YES SERIAL NUMBER
YES YES
XXXXXX XXXXXX
CHANGE? CHANGE? CHANGE?
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
View Menu
OFF
LOCAL REMOTE
Figure 57
Display 3-position selector

View Menu
XXXXXX OFF
STOP NEXT? NO YES
YES NO NO NO YES
YES STOP
EXIT?
VIEW MODE ACTUATOR SETUP NAME PLATE VALVE DATA MAINTENANCE OK?
SELECT OK? VIEW? VIEW? VIEW? VIEW?
LANGUAGE
NO YES YES YES YES

Routines: Routines:
- Stroke limits view? - Serial number view?
- Torque set-up view? - Actuator type view? Routines: Routines:
- ESD set-up view? - Torque / Thrust view? - Tag name view? - Alarm log view?
- Remote controls view? - Actuator speed view? - Serial number view? - Torque profile view?
- Local controls view? - Power supply view? - Manufacturer view? - Torque curve view?
- Break OP torque view? - Operation log view?
- Output relays view? - Motor data view?
- Break CL torque view? - Maintenance date view?
TO SETUP - Positioner * view? - Test date view? - Max stem thrust view? - Data logger view?
- Fail-safe * view? - Wiring diagram view? - Flange type view?
MENU - Out 4-20mA * view? - Enclosure view?
- Interlock view? - Certificate view?
- 2-speed timer view? - Lubricant view?
To exit from VIEW menu press - Bus * view? - Revision view?
YES and NO simultaneously - Miscellaneous view? - Torque sensor view?
or move the 3-position selector to
LOCAL or REMOTE
Routines with * are only available if the NO NO NO NO

relevant modules are present.
Press YES or NO to answer the appropriate prompts (OK?, view?, next?, etc.)
53
May 2022
54
May 2022
Figure 58
NO NO NO NO TO
YES
EXIT?
ACTUATOR NAME PLATE VALVE DATA MAINTENANCE
VIEW MODE SETUP
VIEW?
OK? VIEW? VIEW? VIEW?
YES YES YES YES

FROM
LANGUAGE YES YES YES YES
SELECTION
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.
YES YES YES
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
Installation, Operation and Maintenance Manual Section 9: Set-Up Routines
Section 9: Set-Up Routines

9.1 Actuator Set-Up
9.1.1 Set Stroke Limits

This routine allows the actuator to be configured according to the type of valve it is
mounted on.
The following parameters will be set:
• Opening and closing torque limits: from 40% to 100% of the nominal torque.
The nominal torque corresponding to 100% is set in-house and is stated in the
nameplate menu for reference.
• Close direction: clockwise (CW) or counter-clockwise (CCW). Most valves require
clockwise rotation of the stem when viewed from the handwheel. Engage the
manual override and check if the valve closes with clockwise or counter-clockwise
rotation of the handwheel.
• Close and open limits type: by position or by torque. Use Table 11 to choose.
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.
Close limit type

Press YES if the close limit type is correct (torque or position); otherwise, press NO to
change it. Press YES when the limit type is correct.
Close limit by position

• Move the local selector to LOCAL. The local controls can be used.
• Move the valve to the closed position(via the CLOSE command or via the handwheel).
• Move the local selector to OFF.
• Press YES to confirm.
• Press YES to continue with the open limit setting, or press NO and again NO to
repeat the close limit setting procedure. Press NO and then YES to exit from the
stroke limits routine.
Set-Up Routines 55
Section 9: Set-Up Routines Installation, Operation and Maintenance Manual
Close limit by torque

• Move the local selector to LOCAL. The local controls can be used.
• Press the CLOSE control. The actuator will move in the closing direction and when
the configured torque value is reached, the motor will stop and the new position
limit is memorized.
• Press YES to continue with the close limit setting, or press NO and again NO to
repeat the close limit setting procedure. Press NO and then YES to exit from the
stroke limits routine.
Open limit type

• Press YES if the open limit type is correct (torque or position); otherwise,
press NO to change it.
Open limit by position

• Move the local selector to LOCAL. The local controls become active.
• Move the valve to the open position (via the OPEN command or via the handwheel).
• Press YES to exit, or press NO and then YES to repeat the close limit setting procedure.
Open limit by torque

• Move the local selector to LOCAL. The local controls become active.
• Press the OPEN control. The actuator will move in the opening direction and when
the configured torque value is reached, the motor will stop and the new position
limit is memorized.
• Press YES to exit or press NO and then YES to repeat the close limit setting procedure.
If the parameter “direction to close” is changed, both limits (open and close) must be set.
Table 12.
Valve type Close Limit Open Limit

Gate (solid, flexible and split wedge), globe,
Torque Position
metal-seated butterfly valves
Ball, gate (parallel slide), plug valves, rubber-seated
Position Position
butterfly valves
Linear valves with back-seating on stem Torque or Position Torque
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.
56 Set-Up Routines
9.1.2 Torque Set-up

The output torque limits to close or to open may be configured between 40% and 100% of
the nominal torque stated on the actuator nameplate.
Set-up Procedure
(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.
9.1.3 ESD (Emergency Shut Down) Control

An ESD signal can be connected to the actuator to override any existing command and
drive the valve to a predetermined position. The ESD control is not self-maintained: the
ESD action is only performed if the relevant input is active. The ESD control is active when
the 3-position selector is in REMOTE and no alarm is present.
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).
Set-Up Routines 57
• 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.
The factory configuration is the following:

action: CLOSE, signal type: PRESENT, priorities: ESD > LOCAL CONTROLS, ESD > 2-SPEED
TIMER, ESD < all other cases.
9.1.4 Remote Controls

The actuator may be remotely controlled by 4, or 3, or 2 wires depending on the
connection made on the terminal board of the actuator.
The following options are available:
• 4 wires latched: requires 2 momentary signals (since the control is self-maintained)
to open or close and one signal to stop in mid-travel. The action of the stop signal
can be reversed (stop when signal is On [MAKE] or stop when signal is Off [BREAK]).
• 3 wires latched instant reverse: requires 2 momentary signals
(since the control is self-maintained) to open or close. A reverse momentary
signal reverses the direction.
• 3 wires momentary: requires 2 push-to-run type signals
(since the control is not self-maintained) to open or close.
• 2 wires open if signal On: requires signal On to open and no signal to close.
• 2 wires open if signal Off: requires signal Off to open and signal On to close
By selecting the option "Off", the remote controls are disabled.
Configuration should be performed during actuator set-up.
58 Set-Up Routines
(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.
9.1.5 Local Controls

This routine allows for:
• Configuration of the control mode by means of the local controls when the
3-position selector is in LOCAL. The available options are “push-to-run AS5-AS6”,
“latched”, “latched with instant reverse”.
• Changing the colors of the LEDs. The following options are available:
- open LED: green or red
- close LED: green or red
- alarm LED: yellow or red
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).
Set-Up Routines 59
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,
• Press YES if the color of the alarm LED is correct. Press NO to change it,
9.1.6 Output Relays

Monitor relay
The voltage-free, change-over contacts of the monitor relay indicate that the actuator
is either available for remote control or that a problem or a condition preventing remote
control of the valve exists.
The monitor relay is normally energized and will be de-energized on:
• mains voltage failure
• lost phase
• internal temperature alarm
• K1 contactor failure
• K2 contactor failure
• position sensor failure
• speed sensor failure
• configuration error
• hardware error
• mid-travel alarm
• request signal (available if positioner enabled and request from 4 - 20 mA)
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
60 Set-Up Routines
Auxiliary output relays

For status indication or diagnostic purposes, 8 voltage-free contacts of 8 relays are available
to be configured individually to switch upon occurrence of the following conditions:
Status
• 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
Select the language and enter the password according to the instructions
though the list of available routines, and then press YES to select "Output Relays".
Configure output relays

• Press YES to change the monitor relay or NO to change auxiliary relays
AS1, 2, 3, 4, 5, 6, 7, 8.
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.
Auxiliary relays AS1, 2, 3, 4, 5, 6, 7 and 8

• Press NO to answer prompt “MONITOR RELAY change?”.
• Press YES to change AS1; otherwise, press NO to select the other relays.
• Press YES if the condition associated to AS1 relay is correct; otherwise,
press NO to scrolls through the list of conditions and press YES to set.
• Press YES or NO to either confirm or change the type of contact when
the condition occurs (break, make). Since relay AS8 is a change-over relay
(i.e. not a latching relay like AS1-AS7), this option is not available.
• Press NO to proceed to AS2 and then repeat the procedure for the other relays.
• Press NO to exit.
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.
62 Set-Up Routines
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%
The curves in Figure 61 may better clarify the above option:

Example A
With input signal = 4 mA, the position request is 0% and the actuator is driven to close.
With input signal = 20 mA, the position request is 100% and the actuator is driven to open.
With input signal = 12 mA, the position request is 50% and the actuator is driven to reach
position 50%.
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.
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.
position 50%.
Set-Up Routines 63
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.
position 50%.
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
OP/CL controls Fail-Safe action Interlocks ESD
Lowest priority Highest priority
64 Set-Up Routines
Figure 61
Example A Example B
Position request % Position request %

100%
Configured values: 100% Configured values:
% min = 0% % min = 25%
% max = 100% % max = 75%
Polarity : 4 mA = CL 0% Polarity : 4 mA = CL
0% Input signal
Input signal
4 20 mA 4 8 16 20 mA
Example C Example D
Position request % Position request %

100%
Configured values: 100% Configured values:
% min = 0% % min = 25%
% max = 100% % max = 75%
Polarity : 4 mA = OP 0% Polarity : 4 mA = OP
0%
Input signal Input signal
4 20 mA 4 8 16 20 mA
(see entering the set-up mode). When the message displayed is “SET-UP MODE
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.
Set-Up Routines 65
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
Output: position Output: position

Output mA Output mA
20 mA 20 mA
4 mA 4 mA
Position % Position %
0% 100% 0% 100%
Output: torque Output: torque
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
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.
66 Set-Up Routines
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).
(see entering the set-up mode). When the message displayed is “SET-UP MODE
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.
9.1.11 2-Speed Timer

The “2-speed timer” routine is used to extend the actuator travelling time in the opening and/
or closing direction, by driving the motor via pulses that results in duration (ON and OFF time)
becoming configurable. Pulsing control can be applied to full travel or only a part of it.
Start position and stop position may be adjusted from 0% - 100% separately in opening and
closing direction.
ON time may be adjusted from 2 - 200 seconds and OFF time may be adjusted from
1 - 200 seconds separately in both the opening and closing direction.
Figure 63
On On On
time Off time Off time Off
Motor time time time
Start position % Stop position %
Set-Up Routines 67
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
• Press YES if the value of the ON time of pulsing control is correct; if not, press NO
• Press YES if the value of the OFF time of pulsing control is correct; if not, press NO
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
• Press YES if the position value where pulsing control stops is correct; if not, press NO
• Press YES if the value of the ON time of pulsing control is correct; if not, press NO
• Press YES if the value of the OFF time of pulsing control is correct; if not, press NO
9.1.12 BUS (or FDI Control)

This routine is only available if a fieldbus interface card is present. The routine allows setting
of the most important parameters (node address, termination, etc.) necessary to connect
the actuator to a fieldbus. If the ICON3000 was set to work with a fieldbus but the relevant
fieldbus card is not present, a hardware alarm will be generated. Different interfaces are
available to connect the ICON3000 to different types of fieldbus. If the bus interface is
LonWorks, the routine “BUS” changes to “FDI control”. Refer to the specific manuals for
instructions and setting of the above modules.
68 Set-Up Routines
9.1.13 Miscellaneous
This includes different types of routines such as “time and date”, “lithium battery”, and
"torque profile", used only for special applications or in particular conditions.
9.1.13.1 Time and Date

Time and date are used in maintenance functions to associate time information to the
memorized event (torque profile, alarm log, maintenance request, etc.). Time and date
are entered at the time of manufacture, but they can be adjusted during commissioning or
maintenance operations.
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
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.
9.1.13.2 Torque Limits

Torque limits are used as a reference for the torque alarm and end of travel. With the
option “standard”, the torque limits are constant along the full stroke. The limits can be
configured in the “stroke limits” or “torque set-up” routines and can determine the torque
alarm or end of travel situations. In the same application it is useful to configure 3 different
torque thresholds for each traveling direction, to limit separately the unseating, running,
and ending torque. To select this option, pick “3-point limits” and then follow the torque
set-up and stroke limits routines (see Figure 64).
• 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.
Set-Up Routines 69
Figure 64 Actuator Direction: Closing
Closing torque % of nominal
Breakout limit
Ending limit
Running limit
Position %
100% Cl brk% Cl end % 0%
Figure 65 Actuator Direction: Opening
Opening torque % of nominal
Breakout limit
Ending limit
Running limit
Position %
0% Op brk% Op end % 100%
9.1.13.3 Lithium Battery

In the standard version, the actuator is provided with a lithium battery to keep visible the
local position display, to back-up the RTC (real-time-clock) for diagnostic functions, to
test the battery charge, and to update the remote outputs (output relays status when set
as "open limit" or "close limit" and 4 - 20 mA when externally supplied) in case of electrical
power failure and manual override operations.
The program runs the functions relevant to the battery only if the appropriate flag “lithium
battery” is configured with “present”. If the battery is absent or if the above functions are
not requested, the flag "lithium battery" should be configured with “absent”.
• 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.
70 Set-Up Routines
9.1.13.4 Torque Bypass (%)

Since a momentary high torque may be required to unseat certain valves, the torque
bypass routine disables the torque alarm when an open or close command is received and
the actuator is fully open or closed. The torque bypass is expressed as a % of position and is
configurable from 0% to 20%. For example: if a 10% bypass value is set, we may have:
• bypass active in Opening: from 0% to 10%
• bypass active in Closing: from 100% to 90%
To disable torque bypass, configure 0%.
• 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.
9.1.13.5 Valve Jammed (Time)

The valve jammed time is used to monitor the following situations:
1. The time passed after receiving an open or close control is greater than the “valve
jammed time,” but the variation in valve position is smaller than 0.5%. The motor is
stopped, the command is cleared and a “valve jammed” alarm indication is generated.
2. The valve is moving, but during valve travel the variation in valve position is smaller
than 0.5% of the time equal to “valve jammed time”. The motor is stopped, the
command is cleared and a “mid-travel alarm” indication is generated.
The valve jammed time is expressed in seconds and can be configured from
0 to 100 seconds. Configure “0” to disable the routine.
(see “Entering the set-up mode”.) When the message displayed is “SET-UP MODE
• 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.
Set-Up Routines 71
9.2 Valve Data

The valve data allow identification of the valve and its function in the process. The valve
manufacturer and the end user can enter the data. The following data can be entered:
• 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)
9.2.1 Sample Configuration Procedure

Tag name
OK?” press YES. Press NO to scroll through the list of available menus and then
press YES to select the "Valve Data" menu.
• Press NO to scroll the list of available routines and then press YES to select
"Tag Name".
• Press YES if the 1st character of the string is correct. Press NO to scroll through the
list of available characters. Press YES to select the desired character.
• Enter up to 28 characters. Enter a blank character, followed by “←” (character left
arrow) to mark the end of the string.
The configuration of all other valve data items is performed in the same way, by selecting
the relevant item from the list of available routines.
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)
72 Set-Up Routines
9.3.1 Set Password

The actuator is supplied by Emerson with the default password (“0 0 0 0”). The Set
Password routine allows the user to enter a different password consisting of 4 alphanumeric
characters. After entering the new password, the old one becomes invalid. Therefore, it is
mandatory to NOT FORGET THE PASSWORD (or store the password in a secure location)
after the default one has been modified. Losing the new password makes it impossible to
enter the set-up menu and to configure the actuator.
press YES to select the "Maintenance" menu.
"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.
9.3.2 Clear Alarm Log

Clear procedure
OK?” press YES. Press NO to scroll 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
"Clear Alarm Log".
• Press YES to clear the alarm log.
9.3.3 Set Torque Reference

The set torque profile reference routine allows transfer of the last torque profile to the
reference profile registers. The old reference data are lost and the new data are used as a
new reference torque profile.
"Set Torque Reference".
• Press YES to update the torque reference data.
Set-Up Routines 73
9.3.4 Set Curve Reference

The “set curve reference” routine allows selection of 1 of 100 opening and closing torque
curves in the memory of the ICON3000 and to transfer them to the torque curve reference
registers. The old reference data are lost and the new data will become the new torque
curves’ reference (see VIEW mode, Maintenance, Torque curve, Section 10.4.3).
"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.
9.3.5 Clear Recent Data Log

The clear recent data log routine allows the user to clear the counters of the recent
operation log. This command does not affect the content of the “general operation log”.
The date of the “clear recent data log” is memorized and can be viewed in the maintenance
date routine of the "View" menu.
Clearing procedure
OK?” press YES. Press NO to scroll through the list of available menus and press
YES to select the "Maintenance" menu.
"Clear Recent Data Log".
• Press YES.
• Press YES to clear or press NO to exit.
74 Set-Up Routines
9.3.6 Configuration (Backup/Restore)

Only available on ICON3000v2
This routine allows the user to save or restore a copy of the current actuator configuration.
After completing the configuration operations and verifying that they are working
properly, the Backup sub-routine creates a copy of the configuration in the actuator’s
permanent memory. The copy thus created can be used by means of the Restore
sub-routine in the future to return to a known condition to cancel any subsequent changes.
Backup procedure
YES to select the " Configuration (Backup/Restore)" menu.
"Backup".
• Press YES to confirm the operation or press NO to exit.
• At the end of the operation the display shows the message “BACKUP DONE” for a
few seconds.
Restore procedure
YES to select the “Configuration (Backup/Restore)” menu.
• Press NO to scroll through the list of available routines and then press YES to
select “Restore”.
• Press YES to confirm the operation or press NO to exit.
• At the end of the operation, the display shows the message "RESTORE DONE" for a
few seconds.
Set-Up Routines 75
9.3.7 Set PST Reference

This routine allows the user to select as reference a PST curve among the curves
already stored.
press YES. Press NO to scroll through the list of available menus and press YES to
select the "PST reference" menu.
"Sel. curve".
• Press NO to scroll through the list of the available curves from 1 to 16 considering
that 16 is the index of the last curve, press YES to select the selected curve.
• At the end of the operation the display shows the message "REFERENCE OK" for a
few seconds.
9.3.8 PST Command

This routine allows the user to execute on the actuator a PST command.
press YES. Press NO to scroll through the list of available menus and press YES to
select the " PST cmd" menu.
• In the menu “New base line” select if the PST that is going to be executed is a
reference curve: press NO to scroll through the list of available options “Enabled”
or “Disabled” and press YES to confirm the selection.
• Press YES to confirm the PST execution and follow the instructions on the
local display.
76 Set-Up Routines
9.3.9 Set Maintenance Date

The maintenance date routine allows the following operations:
• to set the last maintenance date
• to set the next maintenance date
• to set the start-up date
OK?” press YES. Press NO to scroll through the list of available menus and then YES
to select the "Maintenance" menu.
"Maintenance Date".
• Press YES to set the last maintenance date. Press NO to skip to
“next maintenance date”.
Last maintenance 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.
Next maintenance date

Start-up date
Set-Up Routines 77
9.3.10 Set Data Logger

The “data logger” routine allows setting of the data logger parameters (see VIEW mode,
Maintenance, Data logger, Section 10.4.6).
To start the data logger the following data should be set:
Table 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
“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).
78 Set-Up Routines
9.4 Example of Set-Up Routine
9.4.1 Torque Set-Up
Figure 66
OFF
LOCAL REMOTE
YES YES NO NO
ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP
SETUP MODE STROKE LIMIT TORQUE SETUP

OK? CHANGE? CHANGE? CHANGE?
3-position
selector
YES
YES
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.
Set-Up Routines 79
Section 10: View Routines Installation, Operation and Maintenance Manual
Section 10: View Routines

10.1 Actuator Set-Up
The above menu allows the operator to view the present actuator configuration.
No changes may be made to the present data. The following data can be viewed
(see Table 14):
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
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.
80 View Routines
Installation, Operation and Maintenance Manual Section 10: View Routines
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
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.
View Routines 81
10.3 Valve Data

To identify the valve and its function in the process the following data can be viewed:
• Tag name (max. 28 characters)
• Serial number (max. 28 characters)
• Manufacturer (max. 28 characters)
• Break OP torque (max. 28 characters)
• Max stem thrust (max. 28 characters)
• Flange type (max. 28 characters)
The data should be entered by the valve manufacturer or by the end user during
set-up operations.
View Procedure
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
10.4.1 Alarm Log

View Procedure
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 YES to answer the prompt “Alarm log view?”.
• Press YES to scroll through the list of alarms (“Alarms view?”).
• Press NO to move on to “Warnings view?” and then YES to scroll through the
list of warnings.
82 View Routines
10.4.2 Torque Profile

The torque profile routine gives important information on the actuator working conditions
in comparison with a previously memorized reference profile. The torque profile can
indicate a change in process conditions.
Reference details are retained and the latest torque is expressed as a % of the nominal torque.
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)
View Routines 83
View Procedure
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.
10.4.3 Torque Curve

The torque curve routine gives important information on the actuator working conditions
in comparison with a previously memorized reference torque curve. It can be used to
perform a detailed analysis of a change in the process conditions.
During a full valve stroke in opening or closing, the ICON3000 measures the torque values
relevant to every 1% of position variation. At the end of the stroke the collected 101 values
(one torque value every 1% of position change) are saved in the ICON3000 memory together
with the time and date of strokes, main voltage, motor temperature, temperature inside the
electronics compartment, and temperature inside the terminal board compartment. Up to
100 curves in opening and 100 curves in closing can be saved. When a new curve becomes
available, the oldest one is canceled and the new one is memorized. The above data are
updated at the end of every full valve stroke. Data relevant to a partial stroke are disregarded.
The function “set curve reference”, in the SET-UP MENU, Maintenance, Section 7, allows
the user to save the full set of data relevant to 1 of 100 “torque curves” in the “torque
curve reference”. The “torque curve reference” will not be updated until a new “set curve
reference” command is entered.
The user can compare the last 100 torque curves in opening and closing in relation to the
last 200 valve strokes with the torque curve reference saved before.
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%
84 View Routines
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
• 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.
10.4.4 Operation Log

The operation log consists of different counters and routines that provide information
to assist in the maintenance program. The data are grouped into 2 families: general
and recent data. The general data log collects data from “test date” to “present date”.
The test date is set in-house and can be viewed in the "Nameplate" menu, but cannot be
changed. The recent data log collects data from the last “clear recent data log” date to
“present date”.
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.
View Routines 85
Figure 67
Table 16 shows the list of data collected by the general and recent data log:
Table 16.
General Data Recent Data Log

Opening time -
Closing time -
Contactor cycles Contactor cycles
Motor run time Motor run time
No power time No power time
Utilization rate Utilization rate
Temperature min Temperature min
Temperature max Temperature max
Term temp min Term temp min
Term temp max Term temp max
Motor temp max Motor temp max
Thermostat alarms Thermostat alarms
Torque alarms Torque alarms
86 View Routines
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.
"Operation Log".
• Press YES to select general data or press NO to skip to recent data.
• Press YES to view the recent data log or press NO to exit.
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.
View Routines 87
10.4.5 Maintenance Date

The routine allows the following dates to be viewed:
• Last date
• Next date
• Start-up date
• Recent log date
(see Table 18 below)
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
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.
10.4.6 Data Logger

The “data logger” routine allows collection of different types of data useful for
maintenance or for diagnostic programs. Since the amount of collected data is very large,
the data logger can only be viewed via a PDA or PC. The data can be uploaded from the
ICON3000 to a PDA or PC via a Bluetooth wireless connection.
The local display only allows viewing of configured parameter values (see also SET-UP
menu, Maintenance, Set data logger, Section 9.3.7).
The following data can be viewed on the local display:
• Logger mode
• Sampling time
• Memory mode
• Date
• Time
88 View Routines
Data logger modes:

• OFF: the data logger is not active.
• RECORDER mode: the ICON3000 measures and memorizes the following 3 data:
- Main voltage supply (V)
- Motor temperature (°C)
- Temperature inside the electronics compartment (°C)
• T-RECORDER mode: the ICON3000 measures and memorizes the following 3 data:
- Torque in OP/CL
- Motor temperature (°C)
- Voltage
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).
Figure 68 Recorder Mode
View Routines 89
Figure 69 shows the data logger in "T-Recorder" mode.
Figure 69 T-Recorder Mode
T-logger stops recording if a torque alarm is triggered. The last 256 samples remain in the
actuator memory until a new start of the logger is initiated.
• 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
• 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.
90 View Routines
Figure 70 Event Mode
10.5 Example of View Routine
10.5.1 View Torque Set-up
Figure 71
OFF
LOCAL REMOTE
YES YES NO
ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP
VIEW MODE STROKE LIMIT TORQUE SETUP

OK? VIEW? VIEW? VIEW?
3-position
selector
YES
Display
NO
ACTUATOR SETUP
XXXXXX OFF CLOSING TORQUE
STOP NEXT? 55% NEXT?
NO
YES STOP YES
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.
View Routines 91
Section 11: Maintenance Installation, Operation and Maintenance Manual
Section 11: Maintenance

11.1 Standard Maintenance
Approx. every 2 years:
Under normal operating conditions, the ICON3000 requires no formal maintenance;
however, visual inspection for oil leakage or external visible damage is recommended every
two years. When conditions are severe (frequent operation or high temperatures), inspect
the oil level and oil quality more frequently. Replace all seals that permit oil leakage or
water ingress.
! WARNING
! 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
• 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.
11.2 Special Maintenance

In case actuator failure, please 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.
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
11.3 Lithium Battery Change

• Isolate the main supply to the actuator and all other control voltages.
• Remove the terminal board cover.
• Disconnect two wires (+) (-) from the main board.
• Bring the cover to a safe area. When in this safe area:
— Remove the label.
Figure 72
Figure 73
94 Maintenance
Figure 74
— Remove the battery cover.
Figure 75
Figure 76
Maintenance 95
Figure 77
— Replace the battery.
Figure 78
Figure 79
96 Maintenance
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
Section 12: Troubleshooting

This section assumes that the ICON3000 has passed a functional test performed by
Emerson quality assurance personnel.
! WARNING
! 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.
If the actuator is not functioning correctly, before troubleshooting ensure that:

• the numeric display indicates xx %;
• the local selector is not in OFF;
• the mains supply voltage is the same as stated in the nameplate menu;
• the local selector is moved to OFF and the alphanumeric display shows one of
the following messages:
— “normal off”
— “alarm off”
— “warning off”
— “ESD ON off”
— “INT off”
If the above checks are passed, attempt to locate the fault using the diagnostic facilities.
12.1 The Electronics do not Switch on when Powered

• Check that the value of the mains voltage on terminals L1, L2, L3 is correct.
• Remove the cover of the compartment where the electronic cards are located.
• Check the fuse mounted on the power card. Replace it if burnt.
• If the fuse is OK, check the wires between terminals L1, L2, L3 and connector M1 of
the power card. If the wiring is correct, replace the power card.
98 Troubleshooting
Installation, Operation and Maintenance Manual Section 12: Troubleshooting
12.2 DC Output Voltage not Available at

the Terminals
• Switch the main power supply off and disconnect all wires from terminals B1-B2
and C1.
• Switch the main power supply on and check if the voltage on the terminals B1-B2
and C1 is between 23 and 27 V DC.
• If the voltage is correct, check the external wiring and the electrical load. It should
not exceed 4 W.
• If the voltage is not correct, replace the power card.
Figure 82
1. Power card
2. Fuse
12.3 The Actuator does not Work from Remote Controls

• Move the 3-position selector to LOCAL and check that the actuator works from
local controls.
• Move the local selector to REMOTE. If the ESD signal is active, the alphanumeric
display indicates “ESD On”. Check the signal on terminals C3 and C4 and adjust
the ESD configuration. If the alphanumeric display indicates “INT”, an interlock
control is present. Check the signal on terminals B3, B4 and B5, and adjust the
Interlock configuration.
• Check that:
— the wiring to terminals B1-B2 and C1 is correct;
— there is no short-circuit between wires;
— the electrical load does not exceed 4 W;
— the value is in the range 20-120 V AC 50/60 Hz or 20-125 V DC,
if an external voltage supply is used.
Troubleshooting 99
12.4 The Motor is Very Hot and does not Start

• Check that no alarm other than motor overheating is present.
• Wait until the motor cools down and the normally closed (NC) contact of the
thermal switch automatically resets before trying to operate the actuator again.
• Check that the number of operations per hour and their duration is suitable for the
actuator service (refer to the nameplate menu).
• Check that the valve operating torque is within the range of the unit’s designed
operating torque.
• Always check for causes of abnormal operation.
12.5 The Motor Runs but the Actuator does not

Move the Valve
If the valve position indicators do not change on the local display:
• Check that the manual de-clutch lever is not stuck in the manual operation position.
• Rotate the handwheel a few degrees to remove any possible sticking between the
handwheel and the drive sleeve.
Figure 83
Figure 84
100 Troubleshooting
If the local display changes the valve position indicators:

• Verify that the stem nut fits correctly in the actuator base.
• Verify that the stem nut has sufficient engagement with the valve stem.
• Verify that the key correctly fits in bore/keyways applications.
• Check that the valve works in manual operation. If not, check the manual control
area as follows:
— Loosen the handwheel security dowel.
— Remove the handwheel.
— Remove the cover supporting the handwheel.
— Check the integrity of the internal parts.
— Proceeding with the assembly, follow the reverse order of the disassembly.
— Ensure that no foreign bodies are present.
Be careful not to damage the O-ring seals.
Figure 85
12.6 The Manual Override Cannot be Engaged

If engagement of the manual override lever proves difficult, check whether the drive sleeve
is stuck and proceed as follows:
• Open the cover.
• Try to move the drive sleeve with a screwdriver.
• Reassemble the cover.
12.7 The Valve does not Seat Correctly

• If the valve is stopped by the torque limit in closing, increase the actuator output
torque limit.
• If the valve is stopped by the position limit in closing, check that the valve reaches
its seat position, and then readjust the setting of the position limit.
• The internal trim of the valve may be damaged.
Troubleshooting 101
12.8 Valve Operation Requires Excessive Torque

• Clean, lubricate and check the valve stem.
• If the valve packing is too tight, loosen the gland bolt nuts.
• Coupling type “A”: if a tight fit between bush and stem is evident,
increase the thread clearance on the drive coupling.
• Coupling types “B1”, “B2”, “B3” and “B4”: ensure that there are no axial forces on
the valve stem by leaving adequate axial clearance between the stem and the drive
bush. Also check that all transmission shafts, universal joints, or bulkhead passages
are sufficiently lubricated and check that the transmission shafts are not bent.
• Check that the internal valve trim or the reducer gears are well lubricated and
not damaged.
• Check the alphanumeric display for diagnostic messages, and proceed with
the suitable corrective actions as described in this section, Section 12.11,
Diagnostic Messages.
Figure 86
Figure 87
102 Troubleshooting
12.9 The Actuator does not Stop in the Fully Open

or Fully Closed Position
• Check that the actual open and close positions of the valve respectively
correspond to 100% and 0% on the actuator display.
• Ensure that the torque and travel limits are correctly set (see Section 9.1,
Actuator Set-up).
12.10 The Numeric Position Display Indicates "---"

• Stroke limits must be recalibrated (see Section 9.1, Actuator Set-up).
12.11 Diagnostic Messages

The alarm and warning lists contain the alarms and warnings momentarily present.
A Warning is a condition that occurs when a variable reaches a critical value and/or when a
maintenance action is required but all actuator functions remain available. The Warning icon
on the lower display and the flashing of the alarm/warning LED indicate a warning condition.
An Alarm is a condition that occurs when a variable is outside its acceptable range and/or
some actuator functionality is not available. The Alarm icon on the lower display and the
alarm/warning LED ON indicate an alarm condition. When the fault condition disappears,
the corresponding alarm or warning also disappears from the list.
A reset routine is available to clear certain types of alarms that are memorized by the
actuator (over-torque, jammed valve, etc.).
Troubleshooting 103
Figure 88
OFF
NO
LOCAL REMOTE
NO
WARNINGS
3-position ALARMS VIEW? VIEW?
selector
Display YES YES
NO NO
XXXXXX XXXXXX ALARM H1 WARNING H1

XXXXXX NEXT? NEXT?
NEXT?
YES YES YES
NO NO
VIEW YES
VARIABLES
ALARM HN WARNING HN
NEXT? NEXT?
YES NO YES NO
YES YES
RESET OK? RESET OK?
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
Table 19. Alarm Table
Display Available Controls Alarm

Condition for alarm Action
message Local Remote ESD reset
Measured torque greater Operate the actuator in
High torque than the relevant value opening direction. Check Configuration
Only open Only open Open control
in closing configured in torque set- the torque needed to dependent
up or stroke limits routine operate the valve
Measured torque greater Operate the actuator
High torque than the relevant value in closing direction. Configuration
Only close Only close Close control
in opening configured in torque set- Check the torque needed dependent
up or stroke limits routine to operate the valve
Jammed No position change Check status of actuator
valve in after receiving a CLOSE and valve mechanical Only open Only open Only open Open control
closing control command parts
Jammed No position change Check status of actuator
valve in after receiving an OPEN and valve mechanical Only close Only close Only close Close control
opening control command parts
Motor thermostat open When
Motor Wait until the motor Not Not Configuration
due to high temperature thermostat
thermostat cools down available available dependent
in the motor windings closes
Temperature Control
Ambient temperature
inside the actuator temperature
Internal- too high or too low. Not Not
enclosure higher than Not available <90 °C (194 °F)
temperature Verify insulation among available available
90 °C (194 °F) or lower or
actuator and heat source
than -40 °C (-40 °F) >-40 °C (-40 °F)
Replace position sensor
Position Value of the actuator Not Not Position signal
or recalibrate both stroke Not available
sensor position is not valid available available correct
limits
Measure of motor speed Not Not Speed signal
Speed sensor Replace speed sensor Not available
is not valid available available correct
Check status of actuator
The valve does not move
Mid travel and valve mechanical
in presence of an open Only close Only close Only close Close control
alarm in OP parts. Recalibrate both
control
stroke limits
Check status of actuator
The valve does not move
Mid travel and valve mechanical
in presence of a close Only open Only open Only open Open control
alarm in CL parts. Recalibrate both
control
stroke limits
Troubleshooting 105

Check main voltage
Main voltage lower than -20%
supply and frequency Main
or higher than+20% of the Not Not
Main voltage on terminals L1, L2, Not available voltage
value stated in the nameplate available available
L3. Check that wires correct
menu
section is correct
K1 contactor The test routine Not available Control in
Opposite Opposite
(not available reports a failure of K1 Check the contactor if ESD use K1 opposite
direction direction
for ICON LP) (coil or auxiliary contact) contactor direction
K2 contactor The test routine Not available Control in
Opposite Opposite
(not available reports a failure of K2 Check the contactor if ESD use K1 opposite
direction direction
for ICON LP) (coil or auxiliary contact) contactor direction
The checksum of the EEPROM Reconfigure all
Configuration Not Not Memory
memory that contains the parameters (see Not available
obj n° available available OK
configuration data is wrong details on next page)
The diagnostic program Some circuit is
detects some malfunction damaged and does Not Not Hardware
Hardware n° Not available
in the electronics controlling not work (see details available available OK
the actuator on next page)
The voltage of the
lithium battery is too low
(only detected if the lithium Available Available Available
Low lithium Change lithium Lithium
battery is present and the with main with main with main
battery battery battery OK
relevant parameter of the voltage voltage voltage
miscellaneous routine is set to
“present”)
The alarm appears only with
Lost phase LP 3-phase mains supply. The
Check main power
Configuration alarm is generated when a Not Not
supply on terminals Not available Phase OK
(not available fault exists in one of the phases available available
L1, L2, L3
for ICON LP) that supplies the actuator
transformer
106 Troubleshooting

Check the external Positioner
The analog 4 - 20 mA 4 - 20 mA
Request signal 4 - 20 mA generator Available function not Available
signal is not correct input OK
and wiring available
Correct
LP Configuration ICON LP Configuration is Check the
Available Available Available the wrong
(for ICON LP only) not correct parameters setting
parameters
Power
Driver Fault Check the Power
Power Card Failure Available Available Available Card works
(for ICON LP only) Card
properly
Correct the
Direction Motor rotates in the wrong Check the motor
Available Available Available motor wiring
(for ICON LP only) direction wiring
and reset
Table 20. Warning Table
Display Available Controls

Condition for alarm Action Alarm reset
message Local Remote ESD
Measured torque greater
Check the torque
High torque in OP than the relevant value
necessary to move Available Available Available Close control
(near max.) configured in torque set-up
the valve
or stroke limits routine
Measured torque is 10%
lower than the relevant Check the torque
High torque in CL
value configured in torque necessary to move Available Available Available Open control
(near max.)
set-up or stroke limits the valve
routines
Control
Temperature inside the
Find the heat temperature
Internal temp actuator enclosure higher
source and insulate Available Available Available >-35 °C (-31 °F)
(near limits) than 80 °C (176 °F) or lower
the actuator and
than -35 °C (-31 °F)
<80 °C (176 °F)
Value of the main voltage
Check section of
out of the correct range
Main voltage wires and values Main voltage
(-15% or +10% of the value Available Available Available
(near limits) of voltage and correct
stated in the nameplate
frequencies
menu) or wrong frequency
(Max.) contactor Change contactor
Max. number of contactor Clear recent
cycles (not available and reset operation Available Available Available
cycles reached data log
for ICON LP) log
Perform maintenance
Maintenance Date of the next
and set next Available Available Available Change date
request maintenance reached
maintenance date
Troubleshooting 107
Display Available Controls

Condition for alarm Action Alarm reset
message Local Remote ESD
Motor current greater or Check electrical
Motor current Available Available Available Current OK
lower than limits motor
The routine that
Recalibrate
Wrong stroke monitors the stroke Recalibrate both
Available Available Available both stroke
limits limits detects a wrong stroke limits
limits
end-of-travel condition
Check bus
Bus Fieldbus not working Available Available Available Bus OK
communication
Check the
Reset or redo
Low speed mechanics or
Set speed not reached Available Available Available Open/Close
(for ICON LP only) parameters
Control
setting
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
Section 13: Parts List and Drawings

This section includes the drawings and parts list of each component and sub-assembly of
the ICON3000.
! CAUTION
Using a fastener other than the approved type may result in damage to the actuator or valve.
NOTICE
- When ordering spare parts, be sure to indicate the serial number embossed on the
actuator nameplate.
- When ordering spare parts, refer to the item number on the attached drawings.
Parts List and Drawings 109

Section 13: Parts List and Drawings Installation, Operation and Maintenance Manual
Figure 89 Component Parts
Table 21. Component Parts
Item Qty Description

1 1 Housing
2 1 Lower bearing
3 1 Hollow shaft
4 1 Worm wheel
5 1 Circlip
6 1 Driver sleeve
7 1 Driver sleeve spring
8 1 Spring retaining ring
9* 1 Seal kit
9.1 * 1 O-ring
9.2 * 1 Seal ring
9.3 * 1 Q-ring
9.4 * 1 O-ring
9.5 * 1 O-ring
9.6 * 1 O-ring
9.7 * 1 Seal ring
9.8 * 1 O-ring
* Recommended spare parts
110 Parts List and Drawings


9.9 * 1 O-ring
9.10 * 1 O-ring
9.11 * 1 O-ring
9.12 * 1 O-ring
9.13 * 1 Seal ring
9.14 * 1 O-ring
9.15 * 2 O-ring
9.16 * 1 Seal ring
10 1 Upper bearing
11 2 Cover retaining ring
12 2 Plug
13 1 Cover shoulder washer
14 1 Cover
15 1 Handwheel
16 1 Oil plug
17 4 Screw
18 1 Stem protection tube
19 1 Taper bearing
20 1 Worm shaft
21 1 Taper bearing
22 1 Worm shaft flange
23 2 Screw
24 4 Screw
25 * 1 Electric motor assembly
26 1 Motor cover
27 4 Screw
28 1 Oil plug
29 * 1 Finger assembly
30 2 Screw
31 1 Bush
32 1 Shoulder washer
33 1 Fork
34 1 Bearing bush
35 1 Lever washer
36 1 Lever assembly
37 1 Lever screw block
38 1 Screw
39 1 Earth stud
40 2 Earth stud nut
41 2 Washer
42 1 Earth stud indication plate
43 2 Bearing
44 1 Position sensor shaft
45 2 Screw
46 1 Absolute Encoder flange
47 * 1 Absolute Encoder assembly
48 3 Screw
49 4 Column


50 * 1 Power card
51 4 Column
52 4 Screw
53 * 1 Processor card
54 1 Power card cover (only for models 010, 020, 030)
55 1 Local interface assembly
56 8 Screw
57 1 Screw
59 * 1 Terminal board
60 1 Circlip
61 1 Power terminals cover
62 2 Screw
63 4 Screw
64 1 Terminal board plate
65 1 Terminal board cover
70 1 Data plate
71 1 Circlip
75 1 Thrust block assembly
76 4 Screw
Optional
A* 1 Bus interface card
B 1 Battery assembly
*Recommended spare parts

Figure 90 Electric Motor
25.1
25.2
25.3
25.4
25.5
25.6
25.7
25.8 25.1
25.2
25.3
25.4
Table 22. Electric Motor

25.1 * 1 Electric motor
25.2 1 Speed magnetic sensor
25.3 3 Spring
25.4 1 Screw
25.5 * 1 Speed magnetic card assembly
25.6 2 Screw
25.7 1 Motor terminals board
25.8 1 Screw
Speed magnetic card assembly
25.5.1 1 Speed magnetic card
25.5.2 1 Rubber ring
25.5.3 1 Speed sensor cover
25.5.4 1 Speed sensor cable

Figure 91 Electric Motor (ICON LP)
Table 23. Electric Motor (ICON LP)
Item Qty Description Material

25.1 * 1 Electric motor -
25.2 1 Flange Carbon steel
25.3 4 Screw Stainless steel
25.4 1 Motor coupling Carbon steel
25.6 1 Bracket Aluminum
25.7 1 Motor terminals board Plastic
25.9 2 Washer Plastic
25.10 * 2 Inductance coil -
25.13 * 1 Electronic card -

Figure 92 Finger Assembly

29.1
29.2
29.3
29.4
29.5
29.6
29.7
29.1
Table 24. Finger Assembly

29.1 2 Circlip
29.2 1 Cover finger
29.3 1 Finger
29.4 1 Pin
29.5 1 Bending spring
29.6 1 Bush
29.7 1 Spring

Figure 93 Lever Assembly
36.1
36.2
36.3
36.4
36.5
36.6
36.7
Table 25. Lever Assembly

36.1 1 Lever
36.2 1 Key
36.3 1 Shoulder washer
36.4 1 Bearing
36.5 1 Spring
36.6 1 Retainer ring
36.7 1 Pin

Figure 94 Local Interface Assembly
55.1
55.2
55.3
55.4
55.5
55.6
Table 26. Local Interface Assembly

55.1 1 Ball
55.2 1 Spring
55.3 1 O-ring
55.4 1 Selector
55.5 1 Screw
55.6 1 Plug

Figure 95 Thrust Block Assembly
75.1
75.2
75.3
75.4
75.5
75.6
75.7
75.8
Table 27. Thrust Block Assembly

75.1 1 O-ring
75.2 1 Thrust block housing
75.3* 1 Greaser
75.4 4 Thrust washer
75.5 1 Stem nut
75.6* 2 Thrust bearing
75.7* 1 Quad ring
75.8 1 Lower ring nut

Installation, Operation and Maintenance Manual Appendix
Figure 96 Wiring Loom and Cables Identification
2
6
10
4
3 5.1
8 7
Table 28. Wiring Loom and Cables Identification
Item Cable Type Description

1 CAB0100 I/O remote cable
2 CAB0150 Remote control supply cable
3 CAB0160 Inlet power cable
4 CAB0270 Motor power cable
5 CAB0350 Speed sensor cable
5.1 CAB0354 Speed sensor cable
6 CAB0280 Thermostat cable
7 CAB0300 Absolute Encoder cable
8 CAB0200 Internal controls cable
9 CAB0250 Contact controls cable
10 CAB0170 Earth Wire
Appendix 119
Appendix Installation, Operation and Maintenance Manual
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 Safety Instructions
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
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.
A.2 Instructions for Proper Installation

! WARNING
Verify that the actuator nameplate conforms to the applicable certification, ambient
temperature range, and site safety requirements.
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
A.2.1 Marking
Figure A-1 Template of the label for ICON3000/ICON3000AD
IECEx INE YY.NNNNX = IECEx reference certificate (CoC)

INERIS YY ATEX NNNNX = ATEX reference certificate
0080 = Notified body for ATEX quality assurance (INERIS)
II = Group II (surface industries)
2 = Category 2 apparatus
G = Explosive atmospheres caused by gas, mists, or vapors
D = Explosive atmospheres caused by gas dusts
IP66/68 = Degree of protection
Table A-1.
Hazardous zone Categories according to 94/9/CE 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
Table A-2. Equipment Protection Level (EPL). EN 60079-14
Explosive atmosphere Zone EPL

0 Ga
Gas 1 Ga or Gb
2 Ga or Gb or Gc
20 Da
Dust 21 Da or Db
22 Da or Db or Dc
Appendix 121
A.3 Applicable General Standards and Regulations

Table A-3.
Safety of machinery - Basic concepts, general principles for design.
EN ISO 12100-1
Part 1 - Basic terminology, methodology.
Safety of machinery - Basic concepts, general principles for design.
EN ISO 12100-2
Part 2 - Technical principles and specification.
EN 60079-0: 2012/A11:2013 IEC 60079-0: 2011
EN 60079-1: 2014 IEC 60079-1: 2014
EN 60079-7: 2015 IEC 60079-7: 2015
EN 60079-11: 2012 IEC 60079-11: 2011
EN 60079-31: 2014 IEC 60079-31: 2013
EN ISO 80079-36:2016 ISO 80079-36:2016
EN ISO 80079-37:2016 ISO 80079-37:2016
A.4 Terms and Conditions

standards. Unless otherwise specified, the warranty period is one year from the date of
installation by the first user or eighteen months from the date of shipment to the first user,
whichever occurs first.
No warranty is given for products that are subject to improper storage, improper
installation, misuse, or are modified or repaired by unauthorized personnel.
Repair work resulting from improper use will be charged at standard rates.
A.5 Manufacturer’s Liability

Emerson will not accept any liability in the event of:
• Use of product in a fashion that contravenes local safety at work legislation.
• Incorrect installation relating to, disregard for, or incorrect application of the
instructions as provided on the product nameplate and in the Installation,
Operation, and Maintenance Manual MAN-02-04-97-0713 and Appendix A within.
• Modification of the product without Emerson authorization.
• Work done on the product by unqualified or unsuitable personnel.
122 Appendix
A.6 Storage and Pre-Installation
A.6.1 Storage Procedure
NOTICE
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.6.2 Checks to be Performed Before Installation

Before installation, the following checks are recommended:
• Condition of joint surfaces between compartment covers and the main housing.
• Condition of the threads on the conduit entries.
• Whether the enclosure covers or the actuator body are cracked or broken.
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.
A.7.1 Working Condition
! WARNING
7.1.1 Models ICON-040 and ICON-050 from -25 °C to +60 °C (from -13 °F to +140 °F)
Appendix 123
A.7.2 Identification of Entries

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

Entry NPT size Metric size ISO 965 (alternative)
1 1" M32x1.5
2 1 1/2" M40x1.5
3 1" M32x1.5
4 (optional) 3/4" M25x1.5
Figure A-2 Electric Actuator
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
A.7.3 Electrical Connections

External wires or connections of external ATEX-certified apparatus via the conduit entry of
an additional extension must be wired to the internal cards of the ICON3000, in accordance
with the wiring diagram and general instructions on the actuator label.
A.7.3.1 Connection for Ex-e Terminals Enclosure

The wires must be terminated in accordance with the following method:
Type of terminal: Insulated ring tongue
Eye dimensions: 5.5 mm (0.22 in.) for power cable
3.2 mm (0.13 in.) for control cables
Recommended tightening torques: 2.0 - 2.8 Nm (17.7 - 24.8 lb.in) for power cables
1.0 - 1.5 Nm (8.9 - 13.3 lb.in) for control cables
Wires section: 4 mm² (0.006 in²) for power cables
2.5 mm² (0.004 in²) for control cables
A.7.4 Cable Connection

Sealing of conduit entries must be carried out in accordance with national standards or as
indicated by the relevant regulatory authorities.
Sealing methods and cable glands must be approved and separately certified for use in
hazardous areas.
Two earth connection points - one internal and one external - are located on the ICON3000
base model (see Figure A-3) for connection to ground cables.
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.
To guarantee that weather-proof and explosion-proof characteristics are maintained,

screw the cable gland or the external ATEX-certified apparatus tightly (at least 5 turns of
engagement) and coat them with a thread sealant.
Appendix 125
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
Internal earth stud External earth stud
A.7.5 Installation in Environments with Explosive Dusts

Special attention must be paid to the following points:
• Before assembly, joint surfaces must be greased with Aeroshell grease.
• The cable glands must at a minimum possess a protection degree of IP66 or IP68
(15 m depth/90 hours) according to IEC/EN 60529 standard.
• Periodically measure the quantity of dust deposited on the surface of the
actuator body. Clean the dust if it accumulates to more than 5mm high
(relative to the actuator body).
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
126 Appendix
A.8.1 Periodic Inspection

• Inspect the general condition of the ICON3000/3000AD at regular intervals. The
recommended frequency of inspection is once every two years but this frequency
could change depending on the installation and working conditions. Any crack on
the surface, broken windows, or loose bolts must be reported for repair.
• Keep the external surfaces of the unit clean: if the unit is installed in a dusty
environment, the specification stated in IEC/EN 60079-14 is to be followed
(ensuring in particular that the dust layer does not exceed 5 mm.)
• If the actuator is covered by an intumescent coating (“Kmass”), an electrostatic
charge risk is present; only anti-static cloth may be used when cleaning is required.
When performing maintenance, avoid rubbing actions against the actuator (or any
other friction-inducing action) that could electrostatically charge the unit.
• Check the condition of cable connections and mounting bolts; any loose
connection must be tightened.
A.8.2 Disassembly and Reassembly
! CAUTION
! CAUTION
If disassembly and subsequent reassembly of the explosion-proof enclosure is required,

take the necessary care to maintain all parts in their original condition.
To achieve this, the following steps must be taken:
• Do not damage the explosion-proof mating surfaces on the housing or on the
electrical enclosure cover.
• Reinstall all the screws that came with the dismantled parts and coat them with a
film of molybdenum-based grease. This will prevent the screws from sticking and
make future maintenance operations easier.
• If the screws need to be changed, the new screws must be of equal dimensions
and at least equal material quality to the screws originally supplied with the unit.
• Replace the weather-proof seals that may have been removed, i.e. O-Rings
for the cover.
• In particular, be sure to spread a film of Aeroshell grease over the joint surfaces of
all enclosures.
Appendix 127
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
! 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
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 Safety Instructions
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
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 tools, lifting and transport equipment.
Appendix 129
B.1.2 Identification of Main Parts
Figure B-1 Base Unit
Figure B-2 Base Unit with Extension [A]
Figure B-3 Base Unit with Extensions [B] or [C]
130 Appendix
B.2 Instructions for Proper Installation

! WARNING
Before installation, it is mandatory to check if the nameplate associated with the
extension for additional entry specifies the appropriate degree of protection and ambient
temperature limits as requested by the rules applicable to the plant/location where the
ICON3000 is installed.
B.2.1 Marking
Figure B-4 Template of the label for ICON3000/ICON3000AD/ICON3000LP

Appendix 131
Table B-1.
Hazardous zone Categories according to 2014/34/EU Directive
Dust Zone 20 1D
Table B-2. Equipment Protection Level (EPL). EN 60079-14

Explosive Atmosphere Zone EPL
0 Ga
Gas 1 Ga or Gb
2 Ga or Gb or Gc
20 Da
Dust 21 Da or Db
22 Da or Db or Dc
B.3 Applicable General Standards and Regulations

Table B-3.
EN ISO 12100-1 Safety of machinery - Basic concepts, general principles for design.
EN ISO 12100-2 Safety of machinery - Basic concepts, general principles for design.
EN 60079-0: 2012/A11:2013 IEC 60079-0: 2011
EN 60079-1: 2014 IEC 60079-1: 2014
EN 60079-11: 2012 IEC 60079-11: 2011
EN 60079-31: 2014 IEC 60079-31: 2013
EN ISO 80079-36:2016 ISO 80079-36:2016
EN ISO 80079-37:2016 ISO 80079-37:2016
132 Appendix
B.4 Terms and Conditions

B.5 Manufacturer’s Liability

Operation, and Maintenance Manual MAN-02-04-97-0713 and Appendix B within.
B.6 Storage and Pre-Installation

B.6.1 Storage Procedure
NOTICE
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
B.6.2 Checks to be Performed Before Installation

Before installing extensions for additional entries or additional electronic cards on a base
ICON3000 unit, the following checks are recommended:
B.7 Installation
NOTICE
B.7.1 Working Condition
! WARNING
B.7.1.1 Models and Temperature

ICON-010 and ICON-020
from - 60 °C to +65 °C (from -76 °F to +149 °F)
ICON-030, ICON-040 and ICON-050
134 Appendix
B.7.1.2 Base Unit With Extensions [A] or [B] or [C]

When an extension is installed on a base ICON3000 unit, the whole assembly is suitable for
the following ambient temperatures:
ICON-010 and ICON-020
from – 20 °C to +65 °C (from -4 °F to +149 °F)
ICON-030, ICON-040 and ICON-050
For all models the maximum permissible temperature depends on the type of motor
(SM, TM, DM, or LP) installed on the base ICON3000 unit.
B.7.2 Identification of Entries
B.7.2.1 Base Actuator

The ICON3000 electric actuator is equipped with 5 entries (3 are standard; the 4th and 5th
are supplied upon request). With reference to Figure B-5, the thread form/size for each
entry is as follows:
Table B-4.
Entry NPT size Alternative (Metric size ISO 965)

1 1" M32x1.5
2 1 1/2" M40x1.5
3 1" M32x1.5
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
Appendix 135
Figure B-5 Base Actuator
XTE3000
5 4 6
1 2 3
B.7.2.2 Base Actuator With Extension [A] on the Control Compartment

Extension [A] provides an additional entry for a cable or conduit connection or for
connection of an external ATEX-certified apparatus.
With reference to Figure B-6, the thread form/size for the entry is as follows:
Table B-5.
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
B.7.2.3 Base Actuator with Extensions [B] or [C] on the

Terminal Board Compartment
Extension B provides up to 9 additional entries for cable or conduit connection.
Extension [C] is equipped with an electronic card (Profibus or Lonworks Removable
Connection Modules) and provides up to 6 additional entries.
With reference to Figure B-7, the thread form/size for the entries is as follows:
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
! WARNING
Figure B-7 Base actuator with extensions [B] or [C] on the

terminal board compartment
Entries from A to K
Appendix 137
B.7.3 Electrical Connections

B.7.3.1 Connection for Ex-e Terminals Enclosure

B.7.4 Cable Connection

When optional extensions for additional entries or additional electronic cards are
connected to external cables or conduits, the sealing of these entries must be carried
out in accordance with the national standards or regulatory authorities that certified
the extension(s). The method of sealing and cable glands used must be approved and
separately certified for use in hazardous areas.
base model (see Figure B-8) for connection to ground cables.
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.
To guarantee that the weather-proof and explosion-proof characteristics are maintained,

NOTICE
138 Appendix
Figure B-8
B.7.5 Installation in Environments with Explosive Dusts

• Periodically measure the quantity of dust deposited on the surface of the actuator
body. Clean the dust if it accumulates to more than 5mm high (relative to the
actuator body).
B.8 Maintenance
! WARNING
B.8.1 Periodic Inspection

• Inspect the general condition of the ICON3000 and the possible optional
additional extension at regular intervals. The recommended frequency of
inspection is once every two years but this frequency could change depending
on the installation and working conditions. Any crack on the surface, broken
windows, or loose bolts must be reported for repair.
(ensuring in particular that the dust layer does not exceed 5 mm).
Appendix 139
B.8.2 Disassembly and Reassembly
! CAUTION
! CAUTION

• Replace the weather-proof seals that may have been removed, i.e. O-Rings for
the cover.
all enclosures.
B.8.3 Repairs
When needed, repairs must only be carried out using spare parts supplied by the
! WARNING
! 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
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 Safety Instructions
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
C.2 Instructions for Proper Installation

! WARNING
Appendix 141
NOTICE
Check that the label (as shown by the example Figure C-1) is fixed to the unit and is
complete with all the appropriate information.
C.2.1 Marking
Figure C-1 Template of the label for ICON3000

Table C-1.
Dust Zone 20 1D
Table C-2. Equipment Protection Level (EPL). EN 60079-14

0 Ga
Gas 1 Ga or Gb
2 Ga or Gb or Gc
20 Da
Dust 21 Da or Db
22 Da or Db or Dc
142 Appendix
C.3 Applicable General Standards and Regulations

Table C-3.
Safety of machinery -
EN ISO 12100-1
Basic concepts, general principles for design.
EN ISO 12100-2
EN 60079-0: 2012/A11:2013 IEC 60079-0: 2011
EN 60079-1: 2014 IEC 60079-1: 2014
EN 60079-11: 2012 IEC 60079-11: 2011
EN 60079-31: 2014 IEC 60079-31: 2013
EN ISO 80079-36:2016 ISO 80079-36:2016
EN ISO 80079-37:2016 ISO 80079-37:2016
C.4 Terms and Conditions

C.5 Manufacturer’s Liability

Operation, and Maintenance Manual MAN-02-04-97-0713 and Appendix C within.
Appendix 143
C.6 Storage and Pre-Installation
C.6.1 Storage Procedure
NOTICE
Not following the procedures according to this document will invalidate the
product warranty.
The standard plastic plugs used to protect the cable entries during transport are neither
explosion-proof nor waterproof; 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.6.2 Checks to be Performed Before Installation

Before installation, the following checks are recommended:
C.7 Installation
NOTICE
C.7.1 Working Condition
! WARNING
144 Appendix
C.7.1.1 Models and Temperature

ICON-010 and ICON-020 from -60 °C to +85 °C (from -76 °F to +185 °F)
C.7.2 Identification of Entries

are supplied upon request).
With reference to Figure C-2, the thread form/size for each entry is as follows:
Table C-4.
1 1" M32x1.5
2 1 1/2" M40x1.5
3 1" M32x1.5
Figure C-2 Base Actuator
XTE3000
5 4 6
1 2 3
NOTICE
! WARNING
Appendix 145
C.7.3 Electrical Connections

The electrical connections shall be made in accordance with the wiring diagram and
to the general instructions associated with the documentation of the base unit.
C.7.3.1 Connection for Ex-e Terminals Enclosure

Wires section: 4 mm² (0.006 in²) for power cables 2.5 mm²
(0.004 in²) for control cables
C.7.4 Cable Connection

Sealing of conduit entries must be carried out in accordance with national standards or as
indicated by the relevant regulatory authorities.
Sealing methods and cable glands must be approved and separately certified for use in
hazardous areas.
base model (see Figure C-3) for connection to ground cables.
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
To guarantee that weather-proof and explosion-proof characteristics are maintained,

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.7.5 Installation in Environments with Explosive Dusts

actuator body).
C.8 Maintenance
! WARNING
C.8.1 Periodic Inspection

Appendix 147
C.8.2 Disassembly and Reassembly
! CAUTION
! CAUTION

• Do not damage the explosion-proof mating surfaces on the housing and on the
film of molybdenum-based grease. This will keep screws from sticking and make
maintenance future operations easier.
• In case the screws need to be changed it is mandatory to assure that the new screws
are of the same dimension and same material as the original ones as stated in this
manual, or of a better quality.
• Replace the weatherproof seals that may have been removed, i.e. O-Rings for
the cover.
• In particular, be sure the joint surfaces of all enclosures are spread with a film of
Aeroshell grease.
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.
148 Appendix
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 Safety Instructions
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:
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
Appendix 149
D.1.2 Identification of Main Parts
Figure D-1 Base Unit
Figure D-2 Base Unit with Extension [A]
Figure D-3 Base Unit with Extensions [B] or [C]
150 Appendix
D.2 Instructions for Proper Installation

! WARNING
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
Figure D-4 Template of the label for ICON3000/ICON3000AD/ICON3000LP
IECEx INE XX.ZZZZ = IECEx reference certificate (CoC)

XX ATEX ZZZZ = ATEX reference certificate
Appendix 151
Table D-1.
Dust Zone 20 1D
Table D-2. Equipment Protection Level (EPL). EN 60079-14

0 Ga
Gas 1 Ga or Gb
2 Ga or Gb or Gc
20 Da
Dust 21 Da or Db
22 Da or Db or Dc
D.3 Applicable Directives, General Standards,

and Norms
Table D-3.
EN ISO 12100-1
EN ISO 12100-2
EN 60079-0: 2012/A11:2013 IEC 60079-0: 2011
EN 60079-1: 2014 IEC 60079-1: 2014
EN 60079-7: 2015 IEC 60079-7: 2015
EN 60079-11: 2012 IEC 60079-11: 2011
EN 60079-31: 2014 IEC 60079-31: 2013
EN ISO 80079-36:2016 ISO 80079-36:2016
EN ISO 80079-37:2016 ISO 80079-37:2016
D.4 Terms and Conditions

152 Appendix
D.5 Manufacturer’s Liability

Operation, and Maintenance Manual MAN-02-04-97-0713 and Appendix D within.
D.6 Storage and Pre-Installation

D.6.1 Storage Procedure
NOTICE
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
correctly installed/connected on site and if it has been correctly stored.
D.6.2 Checks to be Performed Before Installation

Appendix 153
D.7 Installation
NOTICE
D.7.1 Working Condition
! WARNING
D.7.1.1 Models and Temperature

ICON-010, ICON-020 and ICON-030 from -25 °C to +60 °C (from -13 °F to +140 °F)
D.7.2 Identification of Entries
D.7.2.1 Base Actuator

With reference to Figure D-5, the thread form/size for each entry is as follows:
Table D-4.
1 1" M32x1.5
2 1 1/2" M40x1.5
3 1" M32x1.5
154 Appendix
Figure D-5 Base Actuator

Base actuator with extensions [B] or [C]
on the terminal board compartment
Entries from A to K
NOTICE
! WARNING
D.7.2.2 Base Actuator With Extension [A] on the Control Compartment

connection of an external ATEX-certified apparatus. With reference to Figure D-2, the
thread form/size for the entry is as follows:
Table D-5.
Entry Standard size Optional
6 M25x1.5 3/4" NPT
Appendix 155
D.7.2.3 Base Actuator with Extensions [B] or [C] on the

With reference to Figure D-6, the thread form/size for the entries is as follows:
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
! WARNING
D.7.3 Electrical Connections

D.7.3.1 Connection for Ex-e Terminals Enclosure

156 Appendix
D.7.4 Cable Connection

base model (see Figure D-6) for connection to ground cables.
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
Appendix 157
D.7.5 Installation in Environments with Explosive Dusts

actuator body).
D.8 Maintenance
! WARNING
D.8.1 Periodic Inspection

• If the actuator is covered by an intumescent coating ("Kmass"), an electrostatic
D.8.2 Disassembly and Reassembly
! CAUTION
158 Appendix
! CAUTION

the cover.
all enclosures.
D.8.3 Repairs
! WARNING
! WARNING
Appendix 159
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 Safety Instructions
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:
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
160 Appendix
E.1.2 Identification of Main Parts
Figure E-1 Base Unit
Figure E-2 Base Unit with Extension [A]
Figure E-3 Base Unit with Extensions [B] or [C]
Appendix 161
E.2 Instructions for Proper Installation

! WARNING
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 if the label, as the example here above, is fixed on the unit and completed with all
the appropriate information.
E.2.1 Marking
Figure E-4 Template of the label for ICON3000

162 Appendix
Table E-1.
Dust Zone 20 1D
Table E-2. Equipment Protection Level (EPL). EN 60079-14

0 Ga
Gas 1 Ga or Gb
2 Ga or Gb or Gc
20 Da
Dust 21 Da or Db
22 Da or Db or Dc
E.3 Applicable General Standards and Regulations

Table E-3.
EN ISO 12100-1
EN ISO 12100-2
EN 60079-0: 2012/A11:2013 IEC 60079-0: 2011
EN 60079-1: 2014 IEC 60079-1: 2014
EN 60079-7: 2015 IEC 60079-7: 2015
EN 60079-11: 2012 IEC 60079-11: 2011
EN 60079-31: 2014 IEC 60079-31: 2013
EN ISO 80079-36:2016 ISO 80079-36:2016
EN ISO 80079-37:2016 ISO 80079-37:2016
Appendix 163
E.4 Terms and Conditions

E.5 Manufacturer’s Liability

Operation, and Maintenance Manual MAN-02-04-97-0713 and Appendix E within.
E.6 Storage and Pre-Installation
E.6.1 Storage Procedure
NOTICE
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
correctly installed/connected on site and if it has been correctly stored.
164 Appendix
E.6.2 Checks to be performed before installation

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.
E.7.1 Working Condition
! WARNING
E.7.1.1 Models and Temperature

ICON3000-010, ICON-020, ICON-030, ICON-040, ICON-050 from -25 °C to +60 °C
(from -13 °F to +140 °F)
E.7.2 Identification of Entries
E.7.2.1 Base Actuator

With reference to Figure E-5, the thread form/size for each entry is as follows:
Table E-4.
1 1" M32x1.5
2 1 1/2" M40x1.5
3 1" M32x1.5
Appendix 165
Figure E-5 Base Actuator
5 4
1 2 3
NOTICE
! WARNING
E.7.2.2 Base Actuator with Extension [A] on the Control Compartment

connection of an external ATEX-certified apparatus.
With reference to Figure E-6, the thread form/size for the entry is as follows:
Table E-5.
Entry Standard size Optional

6 M25x1.5 3/4" NPT
166 Appendix
E.7.2.3 Base Actuator with Extensions [B] or [C] on the

With reference to Figure E-6, the thread form/size for the entries is as follows:
Table E-6.
Entry 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
! WARNING
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
Appendix 167
E.7.3 Electrical Connections

E.7.3.1 Connection for Ex-e Terminals Enclosure

Eye dimensions: 5.5 mm (0.22 in) for power cable
3.2 mm (0.13 in) for control cables
E.7.4 Cable Connection

base model (see Figure E-7) for connection to ground cables.
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
168 Appendix
Figure E-7
E.7.5 Installation in Environments with Explosive Dusts

(15 m depth / 90 hours) according to IEC/EN 60529 standard.
actuator body).
E.8 Maintenance
! WARNING
E.8.1 Periodic Inspection

• Inspect the general condition of the ICON3000 and the possible optional additional
extension at regular intervals. The recommended frequency of inspection is once
every two years but this frequency could change depending on the installation and
working conditions. Any crack on the surface, broken windows, or loose bolts must
be reported for repair.
• If the actuator is covered by an intumescent coating ("Kmass"), an electrostatic charge
risk is present; only anti-static cloth may be used when cleaning is required. When
performing maintenance, avoid rubbing actions against the actuator (or any other
friction-inducing action) that could electrostatically charge the unit.
Appendix 169
E.8.2 Disassembly and Reassembly
! CAUTION
! CAUTION

the cover.
all enclosures.
170 Appendix
E.8.3 Repairs
! WARNING
! WARNING
Appendix 171
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Installation, Operation and Maintenance Manual

Rev. Date Description Prepared Checked Approved

Section 2: Storage and Pre-Installation

Section 5: Operating the ICON3000

Section 6: Local Controls

Section 7: Set-Up Menu

Section 8: View Menu

Section 9: Set-Up Routines

9.2 Valve Data ................................................................................................... 72

Section 10: View Routines

Section 11: Maintenance

Section 12: Troubleshooting

Section 13: Parts List and Drawings

Table of Contents iii

Section 1: General Safety Instructions

General Safety Instructions 1

1.2 Safety Instructions for Installation in

The ICON3000 is designed according to IEC/EN 60079-0, IEC/EN 60079-1, and

2 General Safety Instructions

Table 3. Equipment Protection Level (EPL) EN 60079-14

Explosive atmosphere Zone EPL

1.3 Applicable Standards and Regulations

General Safety Instructions 3

Low Voltage Requisition in accordance with IEC-61010-1

Electric motor Local interface

1.4 Terms and Conditions

4 General Safety Instructions

Section 2: Storage and Pre-Installation

2.2 Storage Procedure

Storage and Pre-Installation 5

2.2.2 Short-term Storage (One Year or Fewer)

2.2.2.1 Indoor Storage

2.2.2.2 Outdoor Storage

2.2.3 Long-term Storage (More Than One Year)

2.2.3.1 Indoor Storage

2.2.3.2 Outdoor Storage

6 Storage and Pre-Installation

Storage and Pre-Installation 7

2.3 Checks to be Performed Before Installation

8 Storage and Pre-Installation

3.1.1 Heater Options

(*) Default in case of Extreme Low Temperature Range.

3.2 Coupling Block: Disassembly from the Actuator

3.2.1 Type “A” Coupling Block

3.2.1.1 Preparing the Bushing

Extract the stem nut from the block housing.

3.2.1.2 Reassembling the Internal Parts

3.2.2 Type “B1” and “B2” Coupling Blocks

3.2.2.1 Preparing the Bushing

Extract the bushing from the block housing.

3.2.2.2 Reassembling the Internal Parts

3.2.3 Type “B3” and “B4” Coupling Blocks

3.2.3.1 Preparing the Bushing

Extract the bushing and machine it according to the mating needs.

3.2.3.2 Reassembling the Internal Parts

3.2.4 Attaching the Coupling Block to the Gear Reduction Unit

3.3 Manual Operation

Engagement lever locked in motor operation position: manual operation cannot be

3.4 Mounting the Actuator onto the Valve

3.4.1 Coupling Type “A”

3.4.2 Coupling Types “B1”, “B2”,”B3” and “B4”

3.4.3 Actuator Mounting

3.5 Electrical Connections