Honeywell KromSchroder IC 40 Manual

3 Edition 07.18
Technical Information · GB
Actuators IC 40
• For complex applications with programmable functions for
flexible adjustment to the process, with statistics and fault history
to support service personnel
• Position indicator that can be read externally
• Spacious connection chamber for ease of installation
• Actuators can be delivered ready installed on butterfly valves
BVG, BVGF, BVA, BVAF, BVH, BVHS or linear flow control VFC

IC 40 · Edition 07.18 2
▼= To be continued
Contents
Actuators IC 40 .....................................1
Contents ............................................2
1 Application ........................................4
1.1 Examples of application ...........................6
1.1.1 Staged control .........................................6
1.1.2 Staged control with three burner capacity levels .....6
1.1.3 Continuous control by three-point step signal........7
1.1.4 Staged control with pre-purge ........................8
1.1.5 Continuous control with defined ignition position ....9
1.1.6 Hot-air compensation ...............................10
1.1.7 Staged control with online adjustment of the
burner capacity............................................10
2 Certification ......................................11
3 Function ..........................................12
3.1 Operating modes .................................13
3.2 Standard and analogue operating modes ........13
3.3 Closed, low-fire rate, intermediate and open
position ...............................................13
3.4 Running times ....................................14
3.5 Standard operating modes 1–12 ................15
3.5.1 2-point operation....................................15
3.5.2 2-point operation with flame proving period .......16
3.5.3 2-stage operation with one or two digital inputs ....17
3.5.4 2-stage operation with two digital inputs ...........19
3.5.5 3-point step operation ..............................20
3.5.6 3-stage operation with one or two digital inputs ....21
3.5.7 2-point operation with switchover of the
adjustment angle for the “open” position .................23
3.5.8 2-point operation with input-dependent
adjustment angle for the “open” position .................25
3.5.9 2-point operation with switchover of the running
times.......................................................26
3.5.10 3-point step operation with running time
fractions ....................................................27
3.5.11 3-stage operation with two digital inputs .........29
3.5.12 3-point step operation with low position ..........30
3.6 Analogue operating modes 21–27 ..............31
3.6.1 2-point operation.....................................31
3.6.2 2-point operation with switchover of the
adjustment angle for the “open” position .................33
3.6.3 2-point operation with input-dependent
adjustment angle for the “open” position .................35
3.6.4 2-point operation with switchover of the running
times.......................................................36
3.6.5 2-point operation with characteristic curve
switchover I ................................................38
3.6.6 2-point operation with characteristic curve
switchover II ...............................................40
3.6.7 2-stage operation with two digital inputs and
variable adjustment angle for the “open” position ........ 42
3.6.8 Emergency closing function ........................43
3.7 Parameters....................................... 44
3.7.1 Parameter sets.......................................45
3.7.2 Factory default parameters...........................47
3.8 Inputs ............................................ 48
3.8.1 Digital................................................48
3.8.2 Analogue ............................................48
3.9 Outputs .......................................... 50
3.10 Manual mode ....................................51
3.10.1 Direct position preset ...............................51
3.10.2 Simulate inputs .....................................51
3.11 Statistics.........................................52
3.11.1 Counters ........................................... 52
3.11.2 Measured values................................... 52
3.11.3 Resetting statistics ................................ 52
3.11.4 Resetting a signal .................................. 52
3.12 Connection diagram.............................53
3.13 Display...........................................54
3.13.1 During operation ...................................54
3.13.2 Warnings and faults................................54
3.14 Relay outputs RO 1 and RO 2 function..........56

IC 40 · Edition 07.18 3
4 Replacement possibilities for actuators ..........57
4.1 GT 31 is to be replaced with IC 40 ................57
4.2 M 5/M 6 is to be replaced with IC 40 .............58
5 Selection ........................................ 59
5.1 Selection table ....................................59
5.2 Type code .........................................59
6 Project planning information .................... 60
6.1 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.1.1 Cable selection ......................................60
6.1.2 Digital inputs ........................................60
6.1.3 Feedback signalling ..................................61
6.2 Feedback potentiometer .........................62
6.3 Installation........................................62
6.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
7 Accessories ...................................... 64
7.1 Heat deflectors ....................................64
7.2 “Single application” attachment set...............64
7.3 BCSoft.............................................65
7.3.1 Opto-adapter PCO 200..............................65
7.4 Cable gland with pressure equalization element .65
8 Technical data ................................... 66
8.1 Running times and torques.......................67
8.2 Dimensions ...................................... 68
8.2.1 IC 40 .................................................68
9 Maintenance cycles ............................. 69
10 Glossary ........................................ 70
10.1 Start fuel flow rate ...............................70
10.2 Positions .........................................70
10.3 Adjustment angle for the “open” position .......70
11 Legend ..........................................71
Feedback ...........................................72
Contact.............................................72

IC 40 · Edition 07.18 4
Application
1 Application
Actuator IC 40 is designed for all applications that re-
quire precise, controlled rotary movement between 0°
and 90°. It can be mounted directly onto the butterfly
valves BVG, BVGF, BVA, BVAF, BVH, BVHS or linear flow
control VFC in order to control the gas and air flow rates
on gas burners.
Actuators and butterfly valves or linear flow control
VFC can also be delivered ready assembled as butter-
fly valves with actuator IBG, IBGF, IBA, IBAF, IBH, IBHS
or linear flow control IFC, see Technical Information
Butterfly valves BVG, BVA, BVH..., IB..., and Linear flow
controls VFC, IFC.
IBG (IC 40 + BVG) IFC (IC 40 + VFC)
An optional integrated feedback potentiometer offers
the option of monitoring the current position of the ac-
tuator. This checking function can be used in automa-
tion processes.
The IC 40 can be used on continuously-controlled
burners and on stage-controlled burners.
Settings on the actuator IC 40 can be made using a PC
with the programming software BCSoft. All the relevant
settings for the process are made using the software
via an optical interface. Various operating modes, which
may be modified, are stored in the unit. In addition, the
control type (two-point step signal, three-point step
signal or continuous control), running times, adjust-
ment angles and intermediate positions can be pro-
grammed.
The actuator can also be controlled “by hand” using the
software.
Once set, all the parameters can be saved on the PC
and copied from there into other actuators, thus saving
time during the commissioning process.
Service technicians can call up statistical data using
BCSoft, such as hours of operation, actuating cycles
and a fault history. Some values can also be set to zero,
for example to record data over a specific period of time.

IC 40 · Edition 07.18 5
Application
Roller hearth kiln in the ceramics
industry
Forging furnace

IC 40 · Edition 07.18 6
Application
1.1 Examples of application
1.1.1 Staged control
IC 40 + BVA BVA
VAG + VAS 1
M
Two-
point
step
For processes that require a homogeneous tempera-
ture distribution in the furnace. The actuator IC 40 is
controlled by a two-point controller and operates in
On/Off or High/Low intermittent mode. The actuator
closes when the voltage supply is interrupted. The run-
ning time can be infinitely adjusted between 5 and 25
seconds.
1.1.2
Staged control with three burner capacity levels
IC 40 + BVA BVA
VAG + VAS 1
M
PLC
For processes that require a homogeneous tempera-
ture distribution in the furnace and three burner capac-
ity levels. The actuator IC 40 is controlled by a program-
mable logic controller and works in High/Medium/Low
or High/Medium/Low/Off intermittent mode. This al-
lows the ignition stage to be started. The optional pres-
sure switch provides fail-safe monitoring of the maxi-
mum pilot air volume. The actuator running time can be
infinitely adjusted between 5 and 50 (75) seconds.

IC 40 · Edition 07.18 7
Application
1.1.3 Continuous control by three-point step signal
The actuator IC 40 is controlled by the three-point step
controller 3PS and moves the butterfly valve BVA to the
ignition position. The burner starts.
Once the burner is operating, the operation signalling
contact of the burner control unit BCU 460 closes. The
BCU issues the controller enable signal to the tempera-
ture controller. The butterfly valve opens or closes be-
tween the low-fire and high-fire rate positions depend-
ing on the capacity demand of the burner. When the
three-point step signal is disconnected, the butterfly
valve stops at its current position.
If both inputs on the IC 40 (DI 1 and DI 2) are activated
after the burner has been shut down, the butterfly valve
closes further than the low-fire rate position (see Op-
erating mode 12, 3-point step operation with low posi-
tion).
DI 1 DI 2 IC 40 position Valve position
Off Off Idle/Stop Idle
On Off Open to high position Open to high-fire rate
Off On Close to middle position Close to low-fire rate
On On low Valve closes further
VAG
BVA
BCU 460
IC 40
12
L1, N, PE
4
4DI 1 7
DI 2
18
19
16
17
9
53
BIO/
BIC
µC
V1
M
3PS
P
µC
VAGVAS
PLC

IC 40 · Edition 07.18 8
Application
1.1.4 Staged control with pre-purge
The central control system starts the pre-purge. Input
DI 2 is activated via the air valve output of the BCU and
the butterfly valve BVA is set to the pre-purge position.
In the event of a temperature demand, the burner con-
trol unit BCU activates input DI 1 via the valve output
V1 and moves the butterfly valve to the ignition position
(precondition: the IC 40 must have reached the ignition
position on the instant of ignition). The burner starts.
To activate the high-fire rate, DI 2 is actuated via the air
valve output on terminal 26 of the BCU.
The butterfly valve moves cyclically between the high-
fire rate position and the low-fire rate position (see
Operating mode 11, 2-stage operation with two digital
inputs).
DI 1/V1 DI 2/air valve IC 4 position Valve position
Off Off closed Closed
On Off low Ignition position/low-fire rate
On On middle High-fire rate
Off On high Pre-purge
BVA
VAG
BCU 460..L
IC 40
12 26
L1, N, PE
9
4 7
DI 1 DI 2
53
BIO/
BIC
µC
V1
M
4
18
19
16
17
22
P
23
A
P
VAGVAS
PLC

IC 40 · Edition 07.18 9
Application
1.1.5 Continuous control with defined ignition position
The central control system starts the pre-purge. Input
DI 2 is activated via the air valve output of the BCU and
the butterfly valve BVA is set to the pre-purge position.
In the event of a temperature demand, the burner con-
trol unit BCU activates input DI 1 via the valve output
V1 and moves the butterfly valve to the ignition position
(precondition: the IC 40 must have reached the ignition
position on the instant of ignition). The burner starts.
The BCU activates DI 2 via the air valve output. This
enables the analogue input IN on the actuator IC 40.
Depending on the capacity demand of the temperature
controller, the butterfly valve BVA moves steplessly to
the position between the low-fire rate and the high-fire
rate as specified by the analogue input IN (see Operat-
ing mode 27, 2-stage operation with two digital inputs
and variable adjustment angle for the open position).
DI 1/V1 DI 2/air valve IC 40 position Valve position
Off Off closed Closed
On Off low Ignition position/low-fire rate
On On analogue chart 1 In acc. with chart 1
Off On high Pre-purge/high-fire rate
BVA
VAG
IC 40
12 26
L1, N, PE
9
18
IN 4 7
53
BIO/
BIC
µC
V1
M
mA
DI 1 DI 2
BCU 460..L
4
18
19
16
17
22
P
P
µC
VAGVAS
PLC

IC 40 · Edition 07.18 10
Application
1.1.6 Hot-air compensation
GIK
IC 40 +
BVH
WPS
Two
point
M
VAG +VAS 1
VAS
For processes in which preheated combustion air at a
temperature of up to 450°C must be controlled. In this
example, the actuator IC 40 is controlled by a two-point
controller to adjust the burner capacity. It runs in High/
Low intermittent mode. The running time can be ad-
justed between 5 and 25 seconds.
1.1.7
Stagedcontrolwithonlineadjustmentoftheburner
capacity
IC 40 + BVA BVA
4–20 mA
VAG +VAS 1
VAS
PLC M
For processes that require a homogeneous tempera-
ture distribution and high temperature accuracy in the
furnace.
If only a low heat output is required, for example to
maintain the temperature in the furnace, the burner can
continue to be operated in intermittent mode. The ad-
justment angle of the valve is reduced via the analogue
input (4–20 mA) of the actuator and the burner capac-
ity is therefore lowered. This ensures uniform tempera-
ture distribution even with a low heat output.
This function of the actuator IC 40 can also be used in
the ceramics industry to correct the lambda value or for
temperature compensation purposes in hot-air applica-
tions.

IC 40 · Edition 07.18 11
Certification
2 Certification
Certificates–see Docuthek.
EU certified
Meets the requirements of the
– Low Voltage Directive (2014/35/EU)
– EMC Directive (2014/30/EU)
Standards:
– EN 60730214
Eurasian Customs Union
The product IC 40 meets the technical specifications of
the Eurasian Customs Union.
ANSI/CSA approved
American National Standards Institute/Canadian
Standards Association–ANSI/UL 429 and CSA C22.2.
Class number: C322102, Class number: C322182
www.csagroup.org.
Directive on the restriction of the use of hazardous
substances (RoHS) in China
Scan of the Disclosure Table China RoHS2 – see certifi-
cates at www.docuthek.com
UL listed
Underwriters Laboratories–UL 607301 “Automatic
Electrical Controls for Household and Similar Use”,
UL 60730214 “Automatic Electrical Controls for
Household and Similar Use; Part 2: Particular Require-
ments for Electric Actuators”, File No. E4436.

IC 40 · Edition 07.18 12
Function
3 Function
The actuator IC 40 moves the butterfly valve towards 0°
or 90°. There are 4 possible positions which the actua-
tor can approach in steps. Any intermediate position is
possible in continuous three-point step mode. Option-
ally, the actuator can also approach any intermediate
position via an additional current input.
The slow flashing blue LED indicates that the motor of
actuator IC 40 is moving. The position indicator on the
housing indicates the opening angle. Further visualiza-
tion and operation are performed on a PC using the
BCSoft software.
BCSoft
The sequence of opening and closing is programmed
using the BCSoft software and can be adapted indi-
vidually to any application.
All settings for the actuator IC 40 are made using
BCSoft. Commissioning and calibration of the “closed”
position are performed conveniently using the software.
BCSoft offers the option of moving and adjusting the
butterfly valve in Manual mode via the actuator, see
page 51 (Manual mode).
A detailed manual is available for the BCSoft PC soft-
ware:
www.docuthek.com Home Elster Thermal Solu-
tions Products 03 Valves and butterfly valves 
Actuators IC BCSoft (D, GB)

IC 40 · Edition 07.18 13
Function
3.1 Operating modes
The operating mode is responsible for the setting prop-
erties of the IC 40.
The running times and dwell positions of the actuator
are stored in the various operating modes but can be
reprogrammed at any time using BCSoft (if mounted on
butterfly valve BV..).
The actuator operates in continuous and intermittent
mode with various adjustment angles for the “open”
position. The adjustment angles for the “open” position
indicate the approached position of the actuator in the
case of intermittent operation. They can be changed in
BCSoft.
The corresponding operating modes are displayed in
BCSoft as flowcharts by way of example to visualize the
opening/closing behaviour of the actuator.
3.2 Standard and analogue operating modes
In the standard operating modes, two digital inputs
(DI 1 and DI 2) of the actuator are pre-assigned at the
works as universal inputs. If a voltage of 24 V DC or
100–230 V AC is applied to the input, this is recog-
nized as “On” signal (positive logic). It is not necessary
to set or readjust the voltage magnitude or voltage type.
In the analogue operating modes, an additional input
(IN) is assigned for the actuator. If an actuator IC 40..A
with 4–20 mA analogue input is connected (option),
further operating modes are available in addition to the
standard operating modes. The actuator can approach
corresponding intermediate positions via a current sig-
nal to the additional input, see page 49 (Priority and
running time in operating modes 1–10).
3.3 Closed, low-fire rate, intermediate and open
position
Depending on the set operating mode, there are 4 posi-
tions which the actuator can approach:
Closed = 0° = 0%,
Low = low-fire rate position,
Middle = intermediate position,
High = open position.
The positions not used by the operating mode are
barred.
The “closed position” is always the calibrated zero posi-
tion of the device and cannot be readjusted. The other
positions can be defined on site.
▼

IC 40 · Edition 07.18 14
Function
Basically, the following parameter limits must be noted.
Ascending sequence of positions:
0% = closed –>
low –>
middle –>
high ≤100%
The “high position” must not be selected less than
10 %.
If the positions have been changed in the software,
BCSoft checks the new values for compliance with the
limits and adapts the positions.
3.4 Running times
Up to 6 running times (t1to t6), each between 0 and
max. 25.5 seconds, can be set dependent on the oper-
ating mode.
A minimum running time is required for each change in
position.
Minimum actuator running time tmin:
tmin = 4.5 s x change in position%
100%
Times which are too short are automatically corrected
by the IC 40 to the minimum possible value. If the ac-
tuator is to operate as fast as possible, a time of 0 sec-
onds can be preset.
In the case of position changes < 16.2%, the maximum
running time is reduced from 25.5 s percentage-wise.
The IC 40 corrects the time to the maximum possible
value.
After they have been entered, the valid parameters are
automatically read out and displayed in BCSoft.
We recommend switching to Manual mode when com-
missioning in order to establish the right positions
and running times for the application, see page 51
(Manual mode).
Outputs
In addition to feedback signals, it is also possible to
assign freely adjustable position ranges to the two out-
puts, RO 1 and RO 2, see page 50 (Outputs).
Statistics
The statistical data stored in the unit, such as faults
which have occurred, various counter readings and
measured values, are displayed and read out in BCSoft,
see page 52 (Statistics).
Emergency closing function
A pre-tensioned spiral spring moves the drive shaft with
valve disc to the closed position in the event of faults or
if the continuous supply voltage is interrupted, within
the closing time < 1 s, see page 43 (Emergency clos-
ing function).

IC 40 · Edition 07.18 15
t [s]
high
low
closed
DI 1
t [s]
t1t2
Function
3.5 Standard operating modes 1 – 12
General description, see page 13 (Operating modes).
3.5.1 2-point operation
Operating mode 1
In idle state (DI 1 with no signal), the actuator is in “low”
position (“low” position may also be 0° = “closed” posi-
tion).
If a signal is applied to digital input DI 1, the actua-
tor moves to “high” position within running time t1.
When the signal at digital input DI 1 drops, the actuator
moves back to “low” position within running time t2.
DI 1 Position
Off low/closed
On high
If the signal at digital input DI 1 is deactivated before
“high” position is reached, the actuator moves directly to
“low” position within the percentage time of t2.
The actuator operates in high/low (high/closed) inter-
mittent mode.
Possible parameter sets for this operating mode:
P68017, P68018 and P68019, see page 45 (Param-
eter sets).
Operating mode 1

IC 40 · Edition 07.18 16
t [s]
high
middle
low
closed
DI 1
t [s]
t1t4
t3
t2
Function
3.5.2 2-point operation with flame proving period
Operating mode 2
In idle state (DI 1 with no signal), the actuator is in “low”
position (“low” position may also be 0° = “closed” posi-
tion).
If digital input DI 1 is activated, the actuator moves to
“middle” position within running time t1.
After waiting time t2, the actuator automatically moves
further to “high” position within running time t3.
As the voltage at digital input DI 1 drops, the actuator
closes to “low” position within running time t4.
DI 1 Position
Off low/closed
On high
If the signal at digital input DI 1 is deactivated before
“high” position is reached, the actuator moves directly to
“low” position within the percentage time of t4.
The actuator operates in high/middle/low (high/mid-
dle/closed) intermittent mode.
On burners which must ignite during opening of the
butterfly valve, waiting time t2is appropriate for flame
proving.
Possible parameter set for this operating mode:
P 68021, see page 45 (Parameter sets).
Operating mode 2

IC 40 · Edition 07.18 17
t [s]
high
low
closed
DI 1
DI 2
t [s]
middle
t1t4
t3
t2t1t2
Function
3.5.3 2-stage operation with one or two digital inputs
Operating mode 3
In idle state (DI 1 and DI 2 with no signal), the actua-
tor is in “low” position (“low” position may also be 0° =
“closed” position).
Control via two digital inputs
If digital input DI 2 is activated, the actuator moves
from “low” position to “middle” position within running
time t1.
If, in addition, digital input DI 1 is activated, the actuator
approaches “high” position within running time t2.
When the signal at DI 1 drops, the actuator moves back
to “middle” position within running time t3and closes
the control element to “low” position within running
time t4if the signal is also disconnected from DI 2.
The actuator operates in high/middle/low (high/mid-
dle/closed) intermittent mode.
DI 1 DI 2 Position
Off Off low/closed
On Off high (DI 1 has priority)
Off On middle
On On high
In this operating mode, digital input DI 1 has priority
and its signal always leads to opening of the actuator to
“high” position.
Operating mode 3
▼

IC 40 · Edition 07.18 18
t [s]
high
low
closed
DI 1
DI 2
t [s]
middle
t
1
t
2
Function
This may prove to be practical in order to purge a fur-
nace or kiln via DI 1 (independently of DI 2), for instance.
It is then possible to operate with both inputs in high/
middle/low intermittent mode.
Possible parameter sets for this operating mode:
P 68015, P68016, see page.45 (Parameter sets).
Control via one digital input
If digital input DI 1 is activated (DI 2 with no signal), the
actuator moves to “high” position. The running times t1
and t2run directly in succession.
Likewise, the actuator closes within the successive run-
ning times t3and t4if signal DI 1 drops. The “middle”
position serves as an interpolation point and can be
freely programmed.
Owing to the two successive running times, the open-
ing characteristic of the butterfly valve can be changed.
For example, the characteristic of the air circuit can be
adapted to that of the gas circuit.
Running times up to 51 s (2 x 25.5 s) are possible in this
operating mode. If the signal at digital input DI 1 is de-
activated before “high” position is reached, the actuator
moves directly to “low” position within the percentage
times of t3and t4.
The actuator operates in high/low (high/closed) inter-
mittent mode.
DI 1 DI 2 Position
Off Off low/closed
On Off high
Operating mode 3

IC 40 · Edition 07.18 19
middle
t [s]
high
low
closed
DI 1
DI 2
t [s]
t
1
t2t3t4
Function
3.5.4 2-stage operation with two digital inputs
Operating mode 4
The function corresponds to operating mode 3 with dif-
ferent priority of the digital inputs.
Digital input DI 2 has priority over DI 1. This means that
a signal at DI 1 has no effect unless a signal is also ap-
plied to DI 2.
DI 1 DI 2 Position
Off Off low/closed
On Off low/closed (DI 2 has priority)
Off On middle
On On high
Possible parameter set for this operating mode:
P 68022, see page 45 (Parameter sets).
Operating mode 4

IC 40 · Edition 07.18 20
t [s]
high
low
closed
DI 1
DI 2
t [s]
t
1
t2
Function
3.5.5 3-point step operation
Operating mode 5
If only digital input DI 1 is active, the actuator opens. If
only digital input DI 2 is active, the actuator closes.
If neither of the digital inputs or both digital inputs are
active simultaneously, the actuator stops in its position.
This means that it can be stopped in any position.
The actuator operates in continuous mode and is con-
trolled via a 3-point step signal. The setting function is
limited by the “low” and “high” positions (“low” position
may also be 0° = “closed” position).
The opening speed is preset via the time t1for the entire
“low” to “high” setting travel. Accordingly, the closing
speed is set with t2for the entire “high” to “low” setting
travel.
Possible parameter sets for this operating mode:
P68012, P68013, P68014, see page 45 (Parameter
sets).
DI 1 DI 2 Reaction
Off Off Idle/Stop
On Off Open to “high” position at max.
Off On Close to “low” position (“closed” position) at min.
On On Idle/Stop
This method of control is frequently used on furnaces
and kilns in the sector of ceramics, steel and aluminium.
Operating mode 5