BIFFI ICON3000 Series, Installation, Operation And Maintenance Manual

Page 1: ...tuator Copyright Biffi The information in this document is subject to change without notice Updated data sheets can be obtained from our website www biffi it or from your nearest Biffi Center Biffi Italia s r l Strada Biffi 165 29017 Fiorenzuola d Arda PC Italy PH 39 0523 944 411 biffi_italia biffi it ...

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Page 3: ...erformed Before Installation 7 Section 3 Installation 3 1 Working Condition 8 3 2 Coupling Block Disassembly from the Actuator 9 3 2 1 Type A Coupling Block 9 3 2 2 Type B1 and B2 Coupling Blocks 11 3 2 3 Type B3 and B4 Coupling Blocks 12 3 2 4 Attaching the Coupling Block to the Gear Reduction Unit 13 3 3 Manual Operation 14 3 4 Mounting the Actuator onto the Valve 16 3 4 1 Coupling Type A 16 3 4...

Page 4: ...34 5 8 1 Fieldbus Interface for Remote Control via FIELDBUS 34 5 8 2 Ain Aout Card 35 5 9 Base Card of the ICON3000 37 5 10 Absolute Encoder of the ICON3000 39 Section 6 Local Controls 6 1 Description of the Local Operator Interface 40 6 2 Configuration Options 44 6 3 Entering the View Mode 46 6 4 Entering the Set Up Mode 47 6 5 Exit from View and Set Up Mode 47 Section 7 Set Up Menu Section 8 Vie...

Page 5: ...intenance Date 84 10 4 6Data Logger 84 10 5 Example of View Routine 87 10 5 1View Torque Set up 87 Section 11 Maintenance 11 1 Standard Maintenance 88 11 2 Special Maintenance 89 11 3 Lithium Battery Change 90 Section 12 Troubleshooting 12 1 The Electronics do not Switch on when Powered 94 12 2 DC Output Voltage not Available at the Terminals 95 12 3 The Actuator does not Work from Remote Controls...

Page 6: ...s with Explosive Dusts 122 A 8 Maintenance 122 A 8 1 Periodic Inspection 123 A 8 2 Disassembly and Re assembly 123 A 8 3 Repairs 124 Appendix B ICON3000 ICON3000AD ICON3000LP B 1 Safety Instructions 125 B 1 1 General 125 B 1 2 Identification of Main Parts 126 B 2 Instructions for Proper Installation 127 B 2 1 Marking 127 B 3 Applicable General Standards and Regulations 128 B 4 Terms and Conditions...

Page 7: ...ironments with Explosive Dusts 143 C 8 Maintenance 143 C 8 1 Periodic Inspection 143 C 8 2 Disassembly and Re assembly 144 C 8 3 Repairs 144 Appendix D ICON3000 D 1 Safety Instructions 145 D 1 1 General 145 D 1 2 Identification of Main Parts 146 D 2 Instructions for Proper Installation 147 D 2 1 Marking 147 D 3 Applicable Directives General Standards and Norms 148 D 4 Terms and Conditions 149 D 5 ...

Page 8: ...ds and Regulations 159 E 4 Terms and Conditions 160 E 5 Manufacturer s Liability 160 E 6 Storage and Pre Installation 160 E 6 1 Storage Procedure 160 E 6 2 Checks to be performed before installation 161 E 7 Installation 161 E 7 1 Working Condition 161 E 7 2 Identification of Entries 161 E 7 3 Electrical Connections 164 E 7 4 Cable Connection 164 E 7 5 Installation in Environments with Explosive Du...

Page 9: ...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 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 requireme...

Page 10: ...ate for Canada 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 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 E...

Page 11: ...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 a...

Page 12: ...ried 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 routin...

Page 13: ...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 loc...

Page 14: ...December 2019 6 Installation Operation and Maintenance Manual VCIOM 08500 EN Storage and Pre Installation Section 2 Storage and Pre Installation Figure 3 Figure 4 Figure 5 ...

Page 15: ... 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 cra...

Page 16: ...85 F Special versions are available for extreme environment temperatures 40 C 85 C 40 F to 185 F 55 C 65 C 67 F to 149 F NOTICE The above conditions apply only to Ex d or Ex de versions For other applications refer to the applicable addendum NOTICE Installation in an environment where the ambient temperature range falls outside the rated temperature will invalidate the warranty Refer to the namepl...

Page 17: ... 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 n...

Page 18: ...ousing Figure 10 NOTICE Beforere mountingthestemnut makesurethatcouplingtolerancestothevalvestemare correct Thethreadedstemnutmustbecheckedeitherwithathreadgaugeorwiththestemof themotorizedvalvebyscrewingthenutentirelyalongthevalvestemwithoutexcessivefriction The bore can now be machined in the stem nut to suit coupling requirements The same procedure is also used if maintenance is required ...

Page 19: ...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 3 2 2 1 Pr...

Page 20: ...ntled 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 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 bu...

Page 21: ...hat 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 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 ...

Page 22: ...oses 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 re mounted 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 act...

Page 23: ...on and Maintenance Manual VCIOM 08500 EN Installation Section 3 Installation Engagement lever locked in handwheel operation position operation with the electric motor is mechanically disengaged Figure 18 Figure 19 Figure 20 YES NO TO CLOSE ...

Page 24: ...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 ...

Page 25: ...se must be provided by the customer and conform to the material requirements in Table 6 CAUTION Failure to use proper torque values can result in damage to the actuator and or valve Figure 21 Table 6 Model Tightening Torque Nm lb ft Material 010 40 29 5 Studs Bolts ISO Class 8 8 or ASTM A 320 Grade L7 or L7M 020 150 110 6 030 150 110 6 040 300 221 3 Nuts ISO Class 8 8 or ASTM A 194 Grade 4 050 150...

Page 26: ...rements 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 3 6 Removing the Terminal Board Enclosure Using an 8 mm Allen key loosen th...

Page 27: ...d 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 a...

Page 28: ...ction plugs supplied with the actuator with metal plugs 3 8 Terminal Board WARNING Installation configuration commissioning maintenance and repairs must be performed by approved and qualified personnel only 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 absolu...

Page 29: ...ration 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 The applicable plant and safety norms Assemble the power terminal protective barrier located in the termin...

Page 30: ...losures 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 7 Model Motor cover Terminal enclosure cover Local interface cover Material 010 M8x30 M10x30 M10x35 AISI 316 ASME B16 11 A182...

Page 31: ... 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 w...

Page 32: ... 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 tem...

Page 33: ...tion Should maintenance become necessary the following GREASES are recommended Ambient temperature from 20 C to 85 C AGIP GREASE MU EP 2 or equivalent Ambient temperature from 40 C to 85 C AEROSHELL GREASE 7 or equivalent Ambient temperature from 55 C to 65 C AEROSHELL GREASE 7 or equivalent Figure 27 Figure 28 ...

Page 34: ...pply 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 three 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 ST...

Page 35: ...sition 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 re...

Page 36: ...December 2019 28 Installation Operation and Maintenance Manual VCIOM 08500 EN Operating the ICON3000 Section 5 Operating the ICON3000 Figure 30 Figure 31 Figure 32 Figure 33 OPEN YES STOP CLOSE NO ...

Page 37: ...r 2019 29 Installation Operation and Maintenance Manual VCIOM 08500 EN Operating the ICON3000 Section 5 Operating the ICON3000 Figure 34 Figure 35 Status Operation or Position request R Local selector position ...

Page 38: ... 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 3 WIRES see the remote connections diagram in Figure 37 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 ...

Page 39: ...CON3000 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 Figure 37 Figure 38 Option A1 Option B1 Option A2 Option B2 Option A3 Option B3 ...

Page 40: ...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 maintaine...

Page 41: ...AL 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 The signal levels are the following...

Page 42: ...on 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 actuat...

Page 43: ...nalog 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 ...

Page 44: ...put 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 clo...

Page 45: ...stallation Operation and Maintenance Manual VCIOM 08500 EN Operating the ICON3000 Section 5 Operating the ICON3000 Figure 44 5 9 Base Card of the ICON3000 Figure 45 Bottom View of Base Card Terminal Board Adaptor card TBA ...

Page 46: ...e 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 ...

Page 47: ...entiometer 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 ...

Page 48: ... 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 ALARM WARNING INTERLOCK the 3 positionselector status LOCAL OFF REMOTE and the actuator action OPEN OPENING CLOSED CLOSING STOP or R xxx x ...

Page 49: ...hed 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 st...

Page 50: ... range and thus causes the actuator control functions to become unavailable 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 o...

Page 51: ... or press YES and NO simultaneously to exit from VIEW and SET UP MENUS View and Setup menus Press YES and STOP simultaneously to enter VIEW and SET UP menus Press YES or NO to answer the prompt view next 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 enter the sub menu of the variable press NO to skip to the next var...

Page 52: ...guration 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 ...

Page 53: ...ew 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 manufacturer max 28 characters break OP tor...

Page 54: ...r re enter 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 Mov...

Page 55: ...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 av...

Page 56: ...WORD OK 0 0 0 0 DIGIT 2 OK 0 0 0 0 DIGIT 3 OK 0 0 0 0 DIGIT 4 OK 0 0 0 0 DIGIT 1 OK Z 0 0 0 DIGIT 1 OK Z K 0 0 DIGIT 2 OK Z K 9 0 DIGIT 3 OK Z K 9 R DIGIT 4 OK SETUP MODE OK PASSWORD CORRECT PASSWORD WRONG Display LOCAL REMOTE Press NO until the desired language appears and then press YES FROM EXIT TO VIEW MENU Press NO until the desired character appears and then press YES YES YES YES NO YES YES ...

Page 57: ...erlock 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 1 Routines with are only available if the relevant modules are present 2 Nameplate menu not available in Set up mode ENTER PASSWORD TO VIEW MENU Press YES or NO to answer the appropriate prompts change OK etc SELECT LANGUAGE R...

Page 58: ...XXXXXX CHANGE MAINTENANCE DATE CHANGE SET PASSWORD CHANGE MAINTENANCE CHANGE MISCELLANEOUS CHANGE CHANGE SETUP MODE OK YES YES NO NO NO YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES NO NO NO NO NO YES NO YES YES NO NO MISCELLANEOUS ROUTINE ROUTINE SERIAL NUMBER ROUTINE ROUTINE SET PASSWORD ROUTINE TO EXIT MAINTENANCE DATE ROUTINE TAG NAME ROUTINE STROKE LIMITS ROUTINE FROM ENTER PASS...

Page 59: ... NAME PLATE VIEW VALVE DATA VIEW MAINTENANCE VIEW EXIT OK Routines Stroke limits view Torque set up view ESD set up view Remote controls view Local controls view Output relays view Positioner view Fail Safe view Out 4 20mA view Interlock view 2 speed timer view Bus view Miscellaneous view Routines Serial number view Actuator type view Torque Thrust view Actuator speed view Power supply view Motor ...

Page 60: ...ALARM LOG VIEW XXXXXX XXXXXX VIEW MAINTENANCE DATE VIEW TAGE NAME VIEW SERIAL NUMBER VIEW XXXXXX XXXXXX VIEW SW VERSION VIEW NO NO NO YES YES YES YES YES NO NO NO YES NO NO NO YES YES YES YES YES YES NO ROUTINE ROUTINE ROUTINE MAINTENANCE DATE ROUTINE SERIAL NUMBER ROUTINE TAG NAME ROUTINE ALARM LOG ROUTINE TO EXIT SERIAL NUMBER ROUTINE MISCELLANEOUS ROUTINE SW VERSION ROUTINE STROKE LIMITS ROUTIN...

Page 61: ... 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...

Page 62: ...l selector to OFF Press YES to confirm 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 Move the...

Page 63: ...termined 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 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 invali...

Page 64: ...ersely 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 PRESE...

Page 65: ...r red alarm LED yellow or red Configuration procedure Move the local selector to OFF and then simultaneously press OPEN and STOP Select the language and then enter the password according to the instructions see Entering the set up mode When the message displayed is SET UP MODE OK press YES Press YES to select the Actuator Setup menu press NO to scroll through the list of available routines and the...

Page 66: ...ontacts 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 configurati...

Page 67: ...motor running blinker mid travel position local selected remote selected local stop active ESD signal on manual operation interlock PST icon heater only AS8 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 Warning warnings PST failed i e Partial Str...

Page 68: ...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 pr...

Page 69: ...0 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 The curves below 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 ...

Page 70: ...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 YE...

Page 71: ...O to scroll through the list of available routines and then press YES to select FAIL SAFE Press YES if the configured ACTION is correct open close stay put go to position xxx off If not press NO to change it and then press YES Press YES if the configured value of the DELAY is correct from 0 to 255 seconds If not press NO to change it and then press YES Example A Position request Input signal Confi...

Page 72: ... then simultaneously press OPEN and STOP Select the language and then enter the password according to the instructions see entering the set up mode When the message of the display is SET UP MODE OK press YES Press YES to select the Actuator Setup menu press NO to scroll through the list of available routines and then press YES to select Out 4 20 mA Press YES if the output is correct POSITION or TO...

Page 73: ...e When the message displayed is SET UP MODE OK press YES Press YES to select the Actuator Setup menu press NO to scroll through the list of available routines and then press YES to select INTERLOCK Press YES if the configured value of the Open Interlock is correct PRESENT ABSENT OFF If not press NO to change it and then press YES Press YES if the configured value of the Close Interlock is correct ...

Page 74: ...lsing control is correct if not press NO to scroll through the list of available values Press YES when the value is correct Opening direction Press YES if the status is OK or NO to change Press YES to confirm status On enables 2 speed timer operation in opening direction status Off disables timer operation in opening direction Press YES if the position value where pulsing control starts is correct...

Page 75: ...elect 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 st...

Page 76: ...nfigured with present If the battery is absent or if the above functions are not requested the flag lithium battery should be configured with absent Configuration procedure Move the local selector to OFF and then simultaneously press OPEN and STOP Select the language and enter the password according to the instructions see Entering the set up mode When the message displayed is SET UP MODE OK press...

Page 77: ...ress 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 v...

Page 78: ...o 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 b...

Page 79: ... 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 Move the local selector to OFF and then simultaneously press OPEN and STOP Select the language and enter the password according to the instructions see Entering the set up mode When...

Page 80: ... scroll the list of available routines and then press YES to select Set Curve Reference Press NO to scroll the list and then press YES to select the desired curves in opening and closing Press YES to update the torque curve reference 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 conte...

Page 81: ...nce menu Press NO to scroll through the list of available routines and press YES to select Maintenance Date Press YES to set the last maintenance date Press NO to skip to next maintenance date 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 Press YES if the da...

Page 82: ...f 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 sta...

Page 83: ...MOTE SELECT LANGUAGE ENTER PASSWORD SETUP MODE OK ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP CHANGE STROKE LIMIT CHANGE TORQUE SETUP CHANGE CLOSING TORQUE 55 OK CLOSING TORQUE 70 OK OPENING TORQUE 60 OK OPENING TORQUE 65 OK YES YES YES YES YES YES YES YES NO NO NO NO NO TO NEXT TO VIEW MENU Press NO until the desired value appears and t...

Page 84: ...up 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 Routine Parameters Stroke limits Close direction CW CCW close limit type torque or position open limit type torque or position Torque set up Closing torque limit opening torque limit ESD control ESD action signal type ESD priority Remote controls...

Page 85: ... 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 char...

Page 86: ...language according to the instructions see Entering the view mode When the message displayed is VIEW MODE OK press YES Press NO to scroll through the list of available menus and press YES to select the Valve Data menu Press YES to answer prompts view or next and see the data in the above list 10 4 Maintenance 10 4 1 Alarm Log View Procedure Move the local selector to OFF and then simultaneously pr...

Page 87: ...tion 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 positi...

Page 88: ... 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 c...

Page 89: ... 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 ge...

Page 90: ... Table 15 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 al...

Page 91: ...essary to the valve to move from the open position to the closed position expressed in hours minutes and seconds Contactor cycles 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 when the maximum allowable number of cycles of the contactor is reached see Section 12 11 Diagnostic messages If t...

Page 92: ...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 Last da...

Page 93: ...ng 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 rai...

Page 94: ... 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...

Page 95: ...exit from VIEW menu press YES and NO simultaneously or move the 3 position selector to LOCAL or REMOTE CLOSING TORQUE 55 NEXT TORQUE SETUP VIEW STROKE LIMIT VIEW VIEW ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP ACTUATOR SETUP VIEW MODE OK YES YES YES YES YES NO NO NO YES TO NEXT ROUTINE TO SETUP MENU SELECT LANGUAGE XXXXXX OFF STOP NEXT Display LOCAL REMOTE STOP YES OFF 3 position ...

Page 96: ...ons 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 inspecti...

Page 97: ...ion allows Full Stroke test FST or Partial Stroke Test PST if valve operation allows torque vs position diagram report via A Manager if Bluetooth or a serial cable connection is available Download iconfile viaA Manager ifBluetoothoraserialcableconnectionisavailable Identification of recommended spare parts based on inspection results Identification of next routine inspection date Identification of...

Page 98: ...1 Maintenance Maintenance 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 ...

Page 99: ...December 2019 91 Installation Operation and Maintenance Manual VCIOM 08500 EN Section 11 Maintenance Maintenance Figure 74 Remove the battery cover Figure 75 Figure 76 ...

Page 100: ...December 2019 92 Installation Operation and Maintenance Manual VCIOM 08500 EN Section 11 Maintenance Maintenance Figure 77 Replace the battery Figure 78 Figure 79 ...

Page 101: ...he 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 actua...

Page 102: ... 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 messag...

Page 103: ...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 con...

Page 104: ...umber 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...

Page 105: ...tegrity 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 ...

Page 106: ...ling 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 dam...

Page 107: ...arning 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 outs...

Page 108: ...ES 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 XXXXXX XXXXXX XXXXXX NEXT ALARMS VIEW ALARM H 1 NEXT ALARM H N NEXT RESET OK RESET OK WARNING H N NEXT WARNING H 1 NEXT WARN...

Page 109: ...mechanical parts Only close Only close Only close Close control Motor thermostat Motor thermostat open due to high temperature in the motor windings Wait until the motor cools down Not available Not available Configuration dependent When thermostat closes Internal temperature Temperature inside the actuator enclosure higher than 90 C 194 F or lower than 40 C 40 F Ambient temperature too high or to...

Page 110: ...use K1 contactor Control in opposite direction Configuration obj n The checksum of the EEPROM memory that contains the configuration data is wrong Re configure all parameters see details on next page Not available Not available Not available Memory OK Hardware n The diagnostic program detects some malfunction in the electronics controlling the actuator Some circuit is damaged and does not work see...

Page 111: ...ed in torque set up or stroke limits routine Check the torque necessary to move the valve Available Available Available Close control High torque in CL near max Measured torque is 10 lower than the relevant value configured in torque set up or stroke limits routines Check the torque necessary to move the valve Available Available Available Open control Internal temp near limits Temperature inside ...

Page 112: ...e 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 Hardware9 LogicCardcannotupdatethes...

Page 113: ... 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 ...

Page 114: ...Drawings Figure 89 Component Parts Table 21 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 ...

Page 115: ...il 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 E...

Page 116: ... 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 ...

Page 117: ... Figure 90 Electric Motor Item Qty Description 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 Table 22 Electric Motor Recommended spare parts ...

Page 118: ...tion 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 5 4 Screw Stainless steel 25 6 1 Bracket Aluminum 25 7 1 Motor terminals board Plastic 25 8 2 Screw Stainless steel 25 9 2 Washer Plastic 25 10 2 Inductance coil 25 11 2 Screw Stainless steel 25 12 2 Washer Plastic 25 13 1 Electronic card 25 14 2 Screw Stainless steel 2...

Page 119: ...on and Maintenance Manual VCIOM 08500 EN Section 13 Parts List and Drawings Parts List and Drawings Figure 92 Finger Assembly Item Qty Description 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 Table 25 Finger Assembly ...

Page 120: ...n and Maintenance Manual VCIOM 08500 EN Section 13 Parts List and Drawings Parts List and Drawings Figure 93 Lever Assembly Table 26 Lever Assembly Item Qty Description 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 ...

Page 121: ...enance Manual VCIOM 08500 EN Section 13 Parts List and Drawings Parts List and Drawings Figure 94 Local Interface Assembly Table 27 Local Interface Assembly Recommended spare parts Item Qty Description 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 ...

Page 122: ...Section 13 Parts List and Drawings Parts List and Drawings Figure 95 Thrust Block Assembly Item Qty Description 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 Table 28 Thrust Block Assembly Recommended spare parts ...

Page 123: ...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 ...

Page 124: ...an ambient temperature range from 25 C 13 F to 60 C 140 F WARNING Installation configuration commissioning maintenance and repairs must be performed by approved and qualified personnel only The ICON3000 is designed in accordance with the applicable international rules and specifications but the following regulations must be observed in every case General installation and safety regulations The pro...

Page 125: ... 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 2 Equipment Protection Level EPL EN 60079 14 Explosive atmosphere Zone EPL Gas 0 Ga 1 Ga or Gb 2 Ga or Gb or Gc Dust 20 Da 21 Da or Db 22 Da or Db or Dc Hazardous zone Categories according to 94 9 CE Directive Gas mists or vapors Zone 0 1G G...

Page 126: ...tees every product to be free from defects and to conform to industry standards Unless otherwise specified the warranty period is one year from the date of installation by the first user or eighteen months from the date of shipment to the first user whichever occurs first No warranty is given for products that are subject to improper storage improper installation misuse or are modified or repaired...

Page 127: ...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 Haza...

Page 128: ...ry is as follows Table A 4 Identification of Entries Figure A 2 Electric Actuator 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 5 optional 3 4 M25x1 5 4 1 2 3 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...

Page 129: ...bles 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 ...

Page 130: ...ces 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 o...

Page 131: ...f cable connections and mounting bolts any loose connection must be tightened A 8 2 Disassembly and Re assembly CAUTION Using a fastener other than the approved type may result in damage to the actuator or valve Refer to Table 7 CAUTION Failure to use proper torque values can result in damage to the actuator and or valve If disassembly and subsequent re assembly of the explosion proof enclosure is...

Page 132: ...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 permit...

Page 133: ...ctronic 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 ...

Page 134: ...6 Installation Operation and Maintenance Manual VCIOM 08500 EN Appendix Appendix 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 ...

Page 135: ... warranty will be invalidated if the ICON3000 is installed in explosive atmospheres not covered by the appropriate grade of protection and or in environments where temperatures exceed the maximum temperature specified on the product label B 2 1 Marking Figure B 4 Template of the label for ICON3000 ICON3000AD ICON3000LP IECEx INE YY NNNNX IECEx reference certificate CoC INERIS YY ATEX NNNNX ATEX re...

Page 136: ...ere Zone EPL Gas 0 Ga 1 Ga or Gb 2 Ga or Gb or Gc Dust 20 Da 21 Da or Db 22 Da or Db or Dc 2006 42 EC Machinery directive 2014 30 EU EMC directive 2014 35 EU Low voltage directive 2014 34 EU ATEX directive EN ISO 12100 1 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN ISO 12100 2 Safety of machinery Basic concepts general principles for desi...

Page 137: ...f the product without Emerson authorization Work done on the product by unqualified or unsuitable personnel B 6 Storage and Pre Installation B 6 1 Storage Procedure NOTICE Not following the procedures according to this document will invalidate the product warranty Normally the optional extension for additional entry or additional electronic card is directly mounted on the base model of ICON3000 an...

Page 138: ...n 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 B 7 1 Working Condition WARNING Verify that the actuator nameplate confo...

Page 139: ... 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 NOTICE When alternative entries according to ISO 965 are used indication of the dimensions is im printed ...

Page 140: ...ion 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 Figure B 6 Base actuator with extension A on the control compartment Entry Standard Size Optional 6 M25x1 5 3 4 NPT Entry 6 ...

Page 141: ...o Figure B 7 the thread form size for the entries is as follows Table B 6 NOTICE When alternative entries according to ISO 965 are used indication of the dimensions is imprinted on the adapter bush or directly on the housing when ISO 965 entries are created by machining the housing WARNING Unused entries may remain unmachined or must be plugged with a certified plug suitable for the subject enviro...

Page 142: ... 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 Two earth connection points one internal and one external are located on the ICON3000 base model see Figure B 8 for connection to ground cables NOTICE To prevent water infiltration through the line cable conduits ensure...

Page 143: ...dition 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 Keep the external surfaces of the unit clean if the unit is installed in a du...

Page 144: ...s 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 B 8 3 Repairs When needed repairs must only be carried out using spare parts supplied by the manufacturer All accessories must comply with approved specifications and follow the ...

Page 145: ...a for gas group IIIC The actuator is suitable for installation in an ambient temperature range from 60 C 76 F to 85 C 185 F WARNING Installation configuration commissioning maintenance and repairs must be performed by approved and qualified personnel only The ICON3000 is designed in accordance with the applicable international rules and specifications but the following regulations must be observed...

Page 146: ... for ATEX quality assurance INERIS II Group II surface industries 2 Category 2 apparatus G Explosiveatmospherescausedbygas mists orvapors D Explosive atmospheres caused by gas dusts IP66 68 Degreeofprotection Table C 1 Table C 2 Equipment Protection Level EPL EN 60079 14 Hazardous zone Categories according to 2014 34 EU Directive Gas mists or vapors Zone 0 1G Gas mists or vapors Zone 1 2G or 1G Ga...

Page 147: ... 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 C within Modification of the product without Emerson authorization Work done on the product by unqualified or unsuita...

Page 148: ... 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 C 7 Installation NOTICE Installation must be carried out in accordance to the applicable standards IEC EN 60079 14 and IEC EN 60079 17 regarding t...

Page 149: ... thread form size for each entry is as follows Table C 4 Figure C 2 Base Actuator NOTICE When alternative entries according to ISO 965 are used indication of the dimensions is imprinted on the adapter bush or directly on the housing when ISO 965 entries are obtained by machining the housing WARNING Unused entries may remain unmachined or must be plugged with a certified plug suitable for the subje...

Page 150: ...er cables 2 5 mm 0 004 in 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 Two earth connection points one internal and one external are located on the ICON3000 base...

Page 151: ...the dust if it accumulates to more than 5mm high relative to the actuator body C 8 Maintenance WARNING Installation configuration commissioning maintenance and repairs must be performed by approved and qualified personnel only C 8 1 Periodic Inspection Inspect the general condition of the ICON3000 and the possible optional additional extension at regular intervals The recommended frequency of insp...

Page 152: ...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 pro...

Page 153: ...itional entries c an optional electronic card mounted on the terminal board compartment The subject actuator is certified according to IEC EN 60079 0 60079 1 60079 7 60079 11 and 60079 31 standards with protection type Ex db eb h IIC or Ex db eb h ia IIC for gas and Ex h tb IIIC for dust suitable for installation in an ambient temperature range from 25 C 13 F to 60 C 140 F WARNING Installation con...

Page 154: ...6 Installation Operation and Maintenance Manual VCIOM 08500 EN Appendix Appendix 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 ...

Page 155: ...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 ICON3000...

Page 156: ...ates Hazardous zone Categories according to 2014 34 EU Directive Gas mists or vapors Zone 0 1G Gas mists or vapors Zone 1 2G or 1G Gas mists or vapors Zone 2 3G or 2G or 1G Dust Zone 20 1D Dust Zone 21 2D or 1D Dust Zone 22 3D or 2D or 1D Explosive Atmosphere Zone EPL Gas 0 Ga 1 Ga or Gb 2 Ga or Gb or Gc Dust 20 Da 21 Da or Db 22 Da or Db or Dc 2006 42 EC Machinery directive 2014 30 EU EMC directi...

Page 157: ...l 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 ...

Page 158: ...ules D 7 1 Working Condition WARNING Verify that the actuator nameplate conforms to the applicable certification ambient temperature range and site safety requirements 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 The ICON3000 electric actuator is equipped with 5 entries 3 are standard the 4t...

Page 159: ... Unused entries may remain unmachined or must be plugged with a certified plug suitable for the subject environment D 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 D 2 the thread form size for the entry is as follows Table D...

Page 160: ...ay remain unmachined or must be plugged with a certified plug suitable for the subject environment D 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 D 7 3 1 Connection ...

Page 161: ... 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 ...

Page 162: ...xtension 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 i...

Page 163: ...over the joint surfaces of all enclosures D 8 3 Repairs When needed repairs may only be carried out using spare parts supplied by the manufacturer All accessories must comply with approved specifications and follow the application and site requirements WARNING Installation configuration commissioning maintenance and repairs must be performed by approved and qualified personnel only WARNING The val...

Page 164: ...l 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 ...

Page 165: ...7 Installation Operation and Maintenance Manual VCIOM 08500 EN Appendix 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 ...

Page 166: ... 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 IECEx INE YY NNNNX I...

Page 167: ... 0 Ga 1 Ga or Gb 2 Ga or Gb or Gc Dust 20 Da 21 Da or Db 22 Da or Db or Dc 2006 42 EC Machinery directive 2014 30 EU EMC directive 2014 35 EU Low voltage directive 2014 34 EU ATEX directive EN ISO 12100 1 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN ISO 12100 2 Safety of machinery Basic concepts general principles for design Part 2 Techni...

Page 168: ...f the product without Emerson authorization Work done on the product by unqualified or unsuitable personnel E 6 Storage and Pre Installation E 6 1 Storage Procedure NOTICE Not following the procedures according to this document will invalidate the product warranty Normally the optional extension for additional entry or additional electronic card is directly mounted on the base model of ICON3000 an...

Page 169: ... 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 Verify that the actuator nameplate conforms to the applicable certification ambient temperature range and site safety requirements E 7 1 1 Models and Temperature ICON3000 010 ICO...

Page 170: ...tries 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 E 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 E 6 the t...

Page 171: ...is as follows Table E 6 NOTICE When alternative entries according to ISO 965 are used indication of the dimensions is imprinted on the adapter bush or directly on the housing when ISO 965 entries are created by machining the housing WARNING Unused entries may remain unmachined or must be plugged with a certified plug suitable for the subject environment Figure E 6 Entry Option 1 Standard entries O...

Page 172: ... 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 Two earth connection points one internal and one external are located on the ICON3000 base model see Figure E 7 for connection to ground cables NOTICE To prevent water infiltration through the line cable conduits ensure...

Page 173: ...dition 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 Keep the external surfaces of the unit clean if the unit is installed in a du...

Page 174: ...n 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 sc...

Page 175: ...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 permit...

Page 176: ......

Page 177: ...tion are presented for information purposes only and while every effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability All sales are governed by our terms and conditions which are available on request We reserve the right to modify or improve the des...