BIFFI ICON3000 Series User manual

Installation, Operation and Maintenance Manual
VCIOM-08500-EN
December 2019
Bif ICON3000
Electric Actuator
Copyright © Bif. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.bif.it or from your nearest Bif Center:
Bif Italia s.r.l. - Strada Bif 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: [phone] – bif_italia@bif.it

Table of Contents
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Installation, Operation and Maintenance Manual
VCIOM-08500-EN
Table of Contents
Section 1: General Safety Instructions
1.1 Range of Applications ................................................................................. 1
1.2 Safety Instructions for Installation in Hazardous Areas................................. 1
1.2.1 Marking ............................................................................................ 2
1.3 Applicable Standards and Regulations ......................................................... 2
1.4 Terms and Conditions ................................................................................. 3
Section 2: Storage and Pre-Installation
2.1 Tests to be Carried Out When the Actuator is Received ................................ 4
2.2 Storage Procedure ...................................................................................... 4
2.2.1 General............................................................................................. 4
2.2.2 Short-term Storage (One Year or Fewer) ........................................... 5
2.2.3 Long-term Storage (More Than One Year) ......................................... 5
2.3 Checks to be Performed 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
3.4.2 Coupling Types “B1”, “B2”,”B3” and “B4” ....................................... 16
3.4.3 Actuator Mounting ......................................................................... 17
3.5 Electrical Connections ............................................................................... 18
3.5.1 Plant Requirements ........................................................................ 18
3.6 Removing the Terminal Board Enclosure .................................................... 18
3.7 Removing the Terminal Board Enclosure .................................................... 19
3.8 Terminal Board .......................................................................................... 20
3.9 Instructions For Explosion-proof Enclosures .............................................. 22
3.10 Installation in Environments with Explosive Dusts ..................................... 23
Section 4: Lubrication
4.1 Lubrication Inspection .............................................................................. 24

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Section 5: Operating the ICON3000
5.1 Operation By Handwheel .......................................................................... 26
5.1.1 Operation By Handwheel in Absence of a Power Supply
and With the Lithium Battery.......................................................... 26
5.2 Electrical Operation .................................................................................. 27
5.3 Local Control ............................................................................................. 27
5.4 Local Indication ......................................................................................... 27
5.5 Locking the 3-Position Selector ................................................................. 30
5.6 Remote Control......................................................................................... 30
5.6.1 Remote Commands ........................................................................ 30
5.6.2 Output Contacts ............................................................................. 32
5.6.3 ESD Operation ................................................................................ 32
5.6.4 Interlock Inputs .............................................................................. 33
5.7 Operating the ICON3000 for the First Time ............................................... 34
5.8 Optional Modules ..................................................................................... 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 Conguration 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: View Menu
Section 9: Set-Up Routines
9.1 Actuator Set-Up ........................................................................................ 53
9.1.1 Set Stroke Limits ............................................................................. 53
9.1.2 Torque Set-up ................................................................................. 55
9.1.3 ESD (Emergency Shut Down) Control ............................................. 55
9.1.4 Remote Controls ............................................................................ 56
9.1.5 Local Controls ................................................................................. 57
9.1.6 Output Relays ................................................................................. 58
9.1.7 Positioner ....................................................................................... 60
9.1.8 Fail Safe .......................................................................................... 62
9.1.9 OUT 4-20 mA .................................................................................. 64
9.1.10 Interlock ......................................................................................... 65
9.1.11 2-Speed Timer ................................................................................ 65
9.1.12 BUS (or FDI Control) ........................................................................ 66
9.1.13 Miscellaneous ................................................................................. 67

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9.2 Valve Data ................................................................................................. 70
9.2.1 Sample Conguration Procedure .................................................... 70
9.3 Maintenance ............................................................................................. 70
9.3.1 Set Password .................................................................................. 71
9.3.2 Clear Alarm Log .............................................................................. 71
9.3.3 Set Torque Reference ...................................................................... 71
9.3.4 Set Curve Reference ........................................................................ 72
9.3.5 Clear Recent Data Log ..................................................................... 72
9.3.6 Set Maintenance Date ..................................................................... 73
9.3.7 Set Data Logger .............................................................................. 74
9.4 Example of Set-Up Routine ........................................................................ 75
9.4.1 Torque Set-Up ................................................................................ 75
Section 10: View Routines
10.1 Actuator Set-Up ........................................................................................ 76
10.2 Nameplate ................................................................................................ 77
10.3 Valve Data ................................................................................................. 78
10.4 Maintenance ............................................................................................. 78
10.4.1 Alarm Log ....................................................................................... 78
10.4.2 Torque Prole ................................................................................. 79
10.4.3 Torque Curve .................................................................................. 80
10.4.4 Operation Log ................................................................................ 81
10.4.5 Maintenance Date .......................................................................... 84
10.4.6 Data Logger .................................................................................... 84
10.5 Example of View Routine ........................................................................... 87
10.5.1 View 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 .................................. 95
12.4 The Motor is Very Hot and does not Start .................................................. 96
12.5 The Motor Runs but the Actuator does not Move the Valve ........................ 96
12.6 The Manual Override Cannot be Engaged .................................................. 97
12.7 The Valve does not Seat Correctly ............................................................. 97
12.8 Valve Operation requires Excessive Torque ................................................ 98
12.9 The Actuator does not Stop in the Fully Open or Fully Closed Position ........ 99
12.10 The Numeric Position Display Indicates "---" ............................................... 99
12.11 Diagnostic Messages ................................................................................. 99
Section 13: Parts List and Drawings

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Appendix A: ICON3000 / ICON3000AD
A.1 Safety Instructions .................................................................................. 116
A.1.1 General......................................................................................... 116
A.2 Instructions for Proper Installation .......................................................... 116
A.2.1 Marking ........................................................................................ 117
A.3 Applicable General Standards and Regulations ....................................... 118
A.4 Terms and Conditions ............................................................................. 118
A.5 Manufacturer’s Liability .......................................................................... 118
A.6 Storage and Pre-Installation .................................................................... 119
A.6.1 Storage Procedure ........................................................................ 119
A.6.2 Checks to be Performed Before Installation .................................. 119
A.7 Installation .............................................................................................. 119
A.7.1 Working Condition ....................................................................... 119
A.7.2 Identication of Entries ................................................................. 120
A.7.3 Electrical Connections .................................................................. 121
A.7.4 Cable Connection ......................................................................... 121
A.7.5 Installation in Environments 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 Identication 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 ............................................................................. 129
B.5 Manufacturer's Liability ........................................................................... 129
B.6 Storage and Pre-Installation .................................................................... 129
B.6.1 Storage Procedure ........................................................................ 129
B.6.2 Checks to be Performed Before Installation .................................. 130
B.7 Installation .............................................................................................. 130
B.7.1 Working Condition ....................................................................... 130
B.7.2 Identication of Entries ................................................................. 131
B.7.3 Electrical Connections .................................................................. 134
B.7.4 Cable Connection ......................................................................... 134
B.7.5 Installation in Environments with Explosive Dusts ......................... 135
B.8 Maintenance ........................................................................................... 135
B.8.1 Periodic Inspection ....................................................................... 135
B.8.2 Disassembly and Re-assembly ...................................................... 136
B.8.3 Repairs ......................................................................................... 136

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Appendix C: ICON3000 / ICON3000AD
C.1 Safety Instructions .................................................................................. 137
C.1.1 General......................................................................................... 137
C.2 Instructions for Proper Installation .......................................................... 137
C.2.1 Marking ........................................................................................ 138
C.3 Applicable General Standards and Regulations ........................................ 139
C.4 Terms and Conditions ............................................................................. 139
C.5 Manufacturer's Liability ........................................................................... 139
C.6 Storage and Pre-Installation .................................................................... 140
C.6.1 Storage Procedure ........................................................................ 140
C.6.2 Checks to be Performed Before Installation .................................. 140
C.7 Installation .............................................................................................. 140
C.7.1 Working Condition ....................................................................... 140
C.7.2 Identication of Entries ................................................................. 141
C.7.3 Electrical Connections .................................................................. 142
C.7.4 Cable Connection ......................................................................... 142
C.7.5 Installation in Environments 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 Identication 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 Manufacturer's Liability ........................................................................... 149
D.6 Storage and Pre-Installation .................................................................... 149
D.6.1 Storage Procedure ........................................................................ 149
D.6.2 Checks to be Performed Before Installation .................................. 149
D.7 Installation .............................................................................................. 150
D.7.1 Working Condition ....................................................................... 150
D.7.2 Identication of Entries ................................................................. 150
D.7.3 Electrical Connections .................................................................. 152
D.7.4 Cable Connection ......................................................................... 153
D.7.5 Installation in Environments with Explosive Dusts ......................... 154
D.8 Maintenance ........................................................................................... 154
D.8.1 Periodic Inspection ....................................................................... 154
D.8.2 Disassembly and Re-assembly ...................................................... 154
D.8.3 Repairs ......................................................................................... 155

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Appendix E: ICON3000
E.1 Safety Instructions .................................................................................. 156
E.1.1 General......................................................................................... 156
E.1.2 Identication of Main Parts ........................................................... 157
E.2 Instructions for Proper Installation .......................................................... 158
E.2.1 Marking ........................................................................................ 158
E.3 Applicable General Standards 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 Identication of Entries ................................................................. 161
E.7.3 Electrical Connections .................................................................. 164
E.7.4 Cable Connection ......................................................................... 164
E.7.5 Installation in Environments with Explosive Dusts ......................... 165
E.8 Maintenance ........................................................................................... 165
E.8.1 Periodic Inspection ....................................................................... 165
E.8.2 Disassembly and Re-assembly ...................................................... 166
E.8.3 Repairs ......................................................................................... 167

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General Safety Instructions
Section 1: General Safety Instructions
Section 1: General Safety Instructions
1.1 Range of Applications
The Bif ICON3000 electric actuator covered in this manual is designed for the operation of
any type of industrial valve used in heavy industrial, chemical, and petrochemical facilities.
Emerson will not be liable for potential damage resulting from use in anything other than
these designated applications. Such risk lies entirely with the user.
WARNING
Installation, conguration, commissioning, maintenance, and repairs must be performed
by approved and qualied personnel only.
Bif electric actuators are designed in accordance with the applicable international rules
and specications; nonetheless, the following regulations must be observed in any case:
• The general installation and safety regulations
• The plant specic 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 dened by the applicable rules, verify that the
actuator nameplate conforms to site safety requirements.
WARNING
Installation, conguration, commissioning, maintenance, and repairs must be performed
by approved and qualied personnel only.
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 classied 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.

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General Safety Instructions
Section 1: General Safety Instructions
1.2.1 Marking
Table 1.
Table 2.
Table 3. Equipment Protection Level (EPL) EN 60079-14
1.3 Applicable Standards and Regulations
Table 4.
IECEx INE XX.ZZZZ IECEx reference certicate (CoC)
XX ATEX ZZZZ ATEX reference certicate
0080 Notied body for ATEX quality assurance (INERIS)
II Group II (surface industries)
2Category 2 apparatus
GExplosive atmospheres caused by gas, mists, or vapors
DExplosive atmospheres caused by gas and dusts
P66/68 Degree of protection
FM18US0279X FM reference certicate for USA
FM18CA0134X FM-c reference certicate 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
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
(for Canada)
CAN/CSA C22.2 No. 60079-0, CAN/CSA C22.2 No. 60079-1, CAN/CSA 61010-1,
CSA-C22.2 No. 94

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General Safety Instructions
Section 1: General Safety Instructions
Figure 1
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 rst
user, or eighteen months from the date of shipment to the rst user, whichever occurs
rst. 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 modied or repaired by unauthorized personnel. Repair
work due to improper use will be charged at standard rates.
Terminal box
Electric motor Local interface
Engagement lever
Absolute Encoder
Internal gears
Handwheel

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Storage and Pre-Installation
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
certicate. 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.

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Storage and Pre-Installation
Section 2: Storage and Pre-Installation
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, Maintenance - 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, Maintenance - Lithium battery change).
Figure 2

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Storage and Pre-Installation
Section 2: Storage and Pre-Installation
Figure 3
Figure 4
Figure 5

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Storage and Pre-Installation
Section 2: Storage and Pre-Installation
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 certicate 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, Maintenance - Lithium battery change).

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Installation
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)
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 nameplate to verify the rated
ambient temperature.
Figure 7

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Installation
Section 3: 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 xing 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.

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Installation
Section 3: Installation
Figure 9
The internal thrust bearing will remain at the bottom of the block housing.
Figure 10
NOTICE
Before re-mounting the stem nut, make sure that coupling tolerances to the valve stem are
correct. 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.

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Installation
Section 3: Installation
3.2.1.2 Re-assembling the Internal Parts
It is advisable to wash the dismantled parts with a suitable solvent and dry them with
compressed air. Make sure that no metal lings or foreign bodies remain; spread a lm 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 Preparing the Bushing
Using a spanner wrench, unscrew the lower ring nut.
Figure 11
Extract the bushing from the block housing.

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Installation
Section 3: Installation
Figure 12
The internal thrust washer will remain at the bottom of the block housing.
The bore can now be machined in the bushing to suit coupling requirements.
The same procedure is also used if maintenance becomes necessary.
3.2.2.2 Re-assembling the Internal Parts
It is advisable to wash the dismantled parts with a suitable solvent and dry them with
compressed air. Make sure that no metal lings or foreign bodies remain; spread a lm 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
bushing still rotates freely. Attach the unit to the gear reducer as described further on.
3.2.3 Type “B3” and “B4” Coupling Blocks
3.2.3.1 Preparing the Bushing
Remove the mounting bolts of the coupling ange.
Figure 13