Krom Schroder IC 40 User manual

DK S N P GR
➔www.docuthek.com
D GB F NL I E
TR CZ PL RUS H
© 2015 Elster GmbH · Edition 11.15
Safety
Please read and keep in a safe place
Please read through these instructions
carefully before installing or operating. Following the
installation, pass the instructions on to the opera-
tor. This unit must be installed and commissioned
in accordance with the regulations and standards
in force. These instructions can also be found at
www.docuthek.com.
Explanation of symbols
• ,  ,  ,  ... = Action
▷= Instruction
Liability
We will not be held liable for damage resulting from
non-observance of the instructions and non-com-
pliant use.
Safety instructions
Information that is relevant for safety is indicated in
the instructions as follows:
DANGER
Indicates potentially fatal situations.
WARNING
Indicates possible danger to life and limb.
CAUTION
Indicates possible material damage.
All interventions may only be carried out by qualified
gas technicians. Electrical interventions may only be
carried out by qualified electricians.
Conversion, spare parts
All technical changes are prohibited. Only use OEM
spare parts.
Contents
Operating instructions
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Translation from the German
Actuator IC 40
Actuator IC 40..........................
Contents ..............................
Safety.................................
Checking the usage .....................
Intended use ...........................2
Type code .............................2
Part designations ........................2
Type label..............................2
Combination of actuator with butterfly valve....2
Combination of actuator with linear flow control. 2
Installation ............................
Wiring ................................
Connection diagram......................3
Feedback..............................3
Establishing a connection to a PC .........4
Commissioning.........................4
LED display ............................4
Calibration/Setting the closed position in BCSoft 5
Accessories ...........................5
Opto-adapter PCO 200 ...................5
Opto-adapter PCO 300 ...................5
BCSoft................................5
Adapter set for butterfly valve DKL, DKG ......5
“Single application” attachment set...........5
Maintenance ...........................5
Assistance in the event of malfunction .....6
Technical data .........................7
Logistics ..............................8
Certification ...........................8
Contact ...............................8
Safety
Contents

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Checking the usage
Intended use
Actuator IC 40
It is designed for all applications that require pre-
cise, controlled rotary movement between 0° and
90°. The combination of actuator IC40 and control
element is designed to adjust volumes of gas and
air on various appliances and flue gas lines. IC40
is adjusted and commissioned using the BCSoft
programming software.
IC40 and butterfly valve BV..(IB..) are designed for
control ratios of up to 10:1 for gas, cold and hot air
and flue gas.
IC40 and linear flow control VFC(IFC) are designed
for control ratios of up to 25:1 for gas and cold air.
This function is only guaranteed when used within the
specified limits– see page7 (Technical data). Any
other use is considered as non-compliant.
Type code
Code Description
IC 40 Actuator
SSafety closing function
AMains voltage: 100 – 230 V AC, 50/60 Hz


Torque:
2.5 Nm
3 Nm
A
D
4 – 20 mA analogue input
Digital input
R01) 1 kΩfeedback potentiometer
1)
Optional
Part designations
23
1
4
Housing cover
Position indicator
Red and blue LEDs
Type label
Mains voltage, electrical power rating, enclosure,
ambient temperature, torque and installation posi-
tion– see type label.
D-49018 Osnabrück, Germany
www.kromschroeder.com
IC
P:
U:
Combination of actuator with butterfly valve
Type IC 40 + butterfly valve BV..
IBG IC 40 + BVG (for gas)
IBGF IC 40 + BVGF (for gas, clearance-free
valve)
IBA IC 40 + BVA (for air)
IBAF IC 40 + BVAF (for air, clearance-free
valve)
IBH IC 40 + BVH (for hot air and flue gas)
IBHS IC 40S + BVHS (for hot air and flue gas,
with safety closing function)
CAUTION
The safety closing function should be used only for
the intended function. If the safety closing function
is used for controlled shut-down or for intermittent
switching of the burner, this will reduce the service
life of the butterfly valve.
Combination of actuator with linear flow
control
Type IC 40 + linear flow control
IFC  IC 40 + linear flow control VFC, size1
IFC  IC 40 + linear flow control VFC, size3
Installation
CAUTION
Please observe the following to ensure that the
actuator is not damaged:
– Do not store or install the unit in the open air.
▷Installation in the vertical or horizontal position,
not upside down.
▷ For information on the assembly of ac-
tuators and control elements along with
their installation in the pipework, see
www.docuthek.com →Elster Thermal Solutions→
Products→03Valves and butterfly valves→
Butterfly valves BV.. operating instructions or
Linear flow controls IFC, VFC operating instruc-
tions.
▷ Do not insulate the actuator with thermal insu-
lation.

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Wiring
WARNING
Electric shocks can be fatal!
–Before working on possible live components,
ensure the unit is disconnected from the power
supply.
–It must be possible to isolate the actuator from
the power supply. Provide a double pole switch.
▷Install supply and signal lines separately.
▷ Conductors which have not been connected
(spare conductors) must be insulated at their
ends.
▷Cables should be installed well away from high-
voltage lines of other devices.
▷Observe EMC Directive for installation of signal
lines.
▷ If the power supply is susceptible to frequent
voltage peaks, we recommend that an electric
filter be used.
▷Use cables with wire end ferrules.
▷Cable cross-section: max. 2.5mm².
▷ For information on assignment of the inputs
and outputs, see www.docuthek.com →Elster
Thermal Solutions→Products→03Valves and
butterfly valves→ Actuators IC... → Technical
Information IC40.
 Disconnect the system from the electrical power
supply.
 Shut off the gas supply.
▷ Before opening the unit, the fitter should ground
himself.
3 4 5
6 Wire as shown on the connection diagram.
Connection diagram
7 Assign inputs according to application.
▷Digital input DI 1/DI 2: in the case of 24VDC,
check the polarity.
▷ Analogue input IN Analog: 4 – 20 mA, check
the polarity.
▷ For further information on the inputs, see
page7 (Technical data).
8 Assign outputs according to application.
▷Digital outputs RO 1 and RO 2: signalling con-
tacts designed as relay change-over contacts.
▷For further information on the outputs, contact
current and relay contacts, see page7 (Tech-
nical data).
Feedback
▷ A feedback potentiometer R10 offers the option
of monitoring the current position of the actuator.
▷As an option, the actuator is available with fitted
potentiometer. It cannot be retrofitted.
▷The potentiometer must be utilized as a voltage
divider. The change in position of the potentiom-
eter wiper (which corresponds to the actuator
position) can be measured as a changing voltage
between U-andUM.

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U+
UM
U-
22
21
20
Potentiometer
Wiper
(e.g. 1 V DC)
(ground)
▷ Other circuit layouts produce measurement
results that are inaccurate and do not remain
stable over a long period of time or are non-
reproducible. They also reduce the service life
of the feedback potentiometer.
▷The available range depends on the parameteri-
zation of the setting range.
▷Max. power = 0.25W, max. voltage= 15V.
▷ Follow the reverse procedure when reassembling.
▷ Carefully align the optical waveguides on the
circuit board with the marking on the housing
cover (circle).
9 10 11
▷Re-tighten the cover screws in order to ensure
that the housing cover is grounded.
▷
A PC or notebook, the BCSoft programming
software and an opto-adapter PCO200 or
PCO300 are required for further commission-
ing, see page5 (Accessories).
▷The opto-adapter establishes a connection be-
tween the PC and the actuator.
BCSoft
▷The current software and operating instructions
can be downloaded from www.docuthek.com,
see page5 (Accessories). To do so, registra-
tion in the DOCUTHEK is required.
▷BCSoft allows you to select the type of control,
the operating mode, running times, opening
angles and intermediate positions.
▷ Various operating modes, which may be modified,
are stored in the actuator.
▷
The actuator can also be controlled “by hand”
using BCSoft.
▷ Service technicians can call up statistical data
using BCSoft.
▷
Once set, all the parameters can be saved on the
PC and copied from there into other actuators.
▷ For detailed information on control, Manual
mode and statistics, see www.docuthek.com →
Elster Thermal Solutions →Products →
03Valves and butterfly valves → Actuators IC...
→ Technical Information IC40.
Establishing a connection to a PC
There are two ways of establishing a connection to
a PC:
▷Opto-adapter PCO 00: cable connection via
USB interface.
▷Opto-adapter PCO 00: wireless connection
using Bluetooth.
▷ Follow the instructions provided in the enclosed
operating instructions of the corresponding opto-
adapter for installation of the driver and connec-
tion establishment.
▷Operating instructions PCO 200 and PCO 300
(D,GB), see www.docuthek.com→Elster Ther-
mal Solutions→Products→03Valves and but-
terfly valves→Actuators IC20, IC40, IC50→
PCO...
• Place the sensor in the centre of the marking
(circle) provided for this purpose.
▷The film on the marking must be clean and un-
damaged.
▷When the mains is switched on, a connection is
established from the PC or notebook to the IC40
and if the identification process is successful, the
IC immediately conducts a zero position check.
▷ To do this, the actuator opens the control ele-
ment to approx. 30°. Then the actuator moves
to the position specified by the operating mode
and input signals.
▷If the identification process fails, the procedure
can be repeated by pressing function keyF3.
Commissioning
LED display
Blue LED Red LED Operating state
Moderately
flashing2) Off Zero position
check
Slow flashing3) Slow flashing3) Calibration
Lit Off Device in
Standby mode
Moderately
flashing2) Off Device in
motion
Fast flashing1) Off Manual mode
Fast flashing1) Off Moving in
Manual mode
Lit
Flashing
depending on
fault message
Fault
1)
Fast flashing: 5 x per second.
2)
Moderately
flashing: 3 x per second.
3)
Slow flashing: 1 x per
second.

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Calibration/Setting the closed position in
BCSoft
 After automatic identification, select the IC40
in the “Devices” display by double-clicking on
it. The individual program options are displayed.
 Select the “Commissioning..” program option.
 Select the control element.
BVH, BVHS
4 Select “Start calibration”.
▷
The slow flashing blue and red LEDs indicate
that the actuator is moving.
▷ The setting process for the valve’s zero point/
closed position takes place automatically.
▷ When the blue LED is lit continuously, calibration
is completed.
BVG, BVGF, BVA, VFC ...
4 Select “Start calibration”.
▷ The control element moves to the zero point/
closed position.
• Move the actuator manually using the “OPEN”
and “CLOSE” buttons.
▷ The current position can be entered as the closed
position by clicking on “Accept zero position”.
▷ When the blue LED is lit continuously, calibration
is completed.
BVH, BVHS, BVG, BVGF, BVA, BVAF, VFC...
5 After the calibration process has been com-
pleted, check the selected operating mode or
select a new operating mode for the application.
▷ The setting up of the parameters and assignment
of the inputs and outputs must be co-ordinated.
CAUTION
The selected operating mode is responsible for the
setting properties of the device!
Accessories
Opto-adapter PCO 00
Cable connection via USB interface.
BCSoft CD-ROM included
Order No.: 74960625
Opto-adapter PCO 00
Wireless connection using Bluetooth.
®
BCSoft CD-ROM included
Order No.: 74960617
BCSoft
For BCSoft software and operating instructions, see
www.docuthek.com→Elster Thermal Solutions→
Products→03Valves and butterfly valves→Actua-
tors IC20, IC40, IC50→BCSoft.
▷ In order to be able to download the software,
registration in the DOCUTHEK is required.
Adapter set for butterfly valve DKL, DKG
M 6
Ø 130
Ø 90
40
53,5
10
8
0,4 kg
Order No.: 74921672
“Single application” attachment set
This attachment set is required if the actuator is
mounted onto control elements other than DKL,
DKG, BV.. orVFC.
Ø 8
Ø 17
Ø 130
Ø 90
ø 4H12
Ø 5,5
0,4 kg
7
16
25
20
Order No.: 74921671
Maintenance
Actuators IC 40 suffer little wear and require little ser-
vicing. We recommend a function check once a year.
If a service note has been activated in BCSoft, a
warning signal is issued after
3 million cycles (0 – 90 – 0°/0 – 100 – 0%),
3 million relay switching operations,
5 million changes of direction.

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Assistance in the event of
malfunction
• Read the warning, error and fault messages in
the BCSoft diagnostic system.
WARNING
To avoid harm to persons and damage to the unit,
please observe the following:
– Electric shocks can be fatal! Before working
on possible live components, ensure the unit
is disconnected from the power supply.
– Never remove the circuit board!
– Unauthorized repairs or incorrect electrical con-
nections may cause the control element to open
resulting in defects.
? Fault
! Cause
• Remedy
? Blue LED lights up in accordance with op-
erating state, red LED flashes? (warning)
! Flashes once: internal temperature >90°C. Ambi-
ent temperature too high.
• Reset.
• Reduce ambient/medium temperature.
! Flashes twice: drift > 5%. Control element me-
chanically offset or moving against its mechanical
stop.
! Flashes 3 times: drift > 10%. Control element
mechanically offset or moving against its me-
chanical stop.
• Check control element opens and closes without
restrictions.
• Recalibrate. Adjust the closed position.
! Flashes 4/5 times: control element blocked, large
mechanical offset, internal error, actuator offset.
• Check control element opens and closes without
restrictions.
! Flashes 6 times: analogue input AI <4mA.
• Check analogue input signal.
! Flashes 7 times: maximum number of OPEN/
CLOSE cycles exceeded.
! Flashes 8 times: maximum number of changes
in direction of rotation exceeded.
! Flashes 9 times: relay output RO1 or RO2
switched too often.
• Carry out reset using BCSoft.
? Blue LED flashes, red LED permanently lit?
(fault)
! Flashes once: internal fault.
• Restart unit and software.
• Check/adjust the parameterization.
! Flashes twice: control element blocked, internal
error, actuator offset, BVHS: valve not closed.
! Flashes 3 times: control element blocked, internal
error, actuator offset.
• Check control element opens and closes without
restrictions.
• Disconnect the IC from the electrical power sup-
ply. Once the mains power has been connected
again, the actuator IC40 conducts a zero posi-
tion check.
! Flashes 6, 7, 8, 9 times: saving error.
• Remove the unit and return it to the manufacturer.
? The drive shaft does not move?
! No permanent voltage supply to the unit.
• Check supply voltage.
! No signal at the unit.
• Check signal.
! Signal at incorrect input.
• Check correct assignment: DI1/DI2.
! Signal voltage incorrect.
• Check signal voltage, see page7 (Technical
data).
! Selected operating mode does not correspond
with signal specifications.
• Adjust the unit or signals.
? Blue LED does not light – but the control
element opens?
! LED defective.
• Remove the unit and return it to the manufacturer
for inspection.
? No LED lights – unit is not functioning?
! No voltage supply to the unit.
• Check supply voltage.
! Unit defective.
• Remove the unit and return it to the manufacturer.
? Red and blue LEDs flash?
! Calibration of the closed position is active.
• Wait for the calibration process to finish.
• If the calibration process is not completed suc-
cessfully, cancel it and check control element
opens and closes without restrictions
? No reaction despite input signal?
! The selected operating mode is not reading this
input– incorrectly parameterized.
• Set the parameters for the operating mode/input
in BCSoft to suit your requirements.
? No output signal?
! Minimum and maximum current values not ob-
served.
• Check/adjust the current value.
! The function is not activated in the software.
• Set the parameters in the software to suit your
requirements.
! Change-over relay terminals incorrectly assigned.
• Check electrical wiring.

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? The drive shaft does not move as required?
! The selected operating mode reads the inputs
differently to expectations.
• Set the parameters for the operating mode in
BCSoft to suit your requirements.
? The drive shaft moves constantly?
! Current signal fluctuates.
• Check control loop, if possible attenuate it.
• Increase the hysteresis and filtering in BCSoft.
! 3-point step signal commands too many chang-
es of direction.
! Check/adjust the 3-point step controller.
? No communication possible between PC
and IC40?
! Incorrect interface used on the PC.
• Set the interface to the correct configuration
using BCSoft– see page4 (Commissioning).
! Opto-adapter not positioned correctly.
• Position the magnetic head of the opto-adapter
in the circle provided.
! Optical waveguide bent.
• Carefully align the optical waveguides on the
circuit board with the marking on the housing
cover (circle).
! Housing cover not correctly secured.
• Close the housing and tighten all the screws.
! Film on the marking on cover (circle) dirty or dam-
aged.
• Clean the film; if it is damaged, replace the cover.
! Opto-adapter defective.
• Check the adapter using the BCSoft test func-
tion.
• Replace the opto-adapter.
? The parameters cannot be set in the soft-
ware?
! No writing access granted.
• Enter password for writing access (see BCSoft
operating instructions).
? Unit does not react to signal change– the
blue LED flashes quickly?
! The unit is in Manual mode.
• Deactivate Manual mode in BCSoft or disconnect
device from the mains.
? The motor and drive shaft of the actuator
no longer function as required?
! The gear is defective.
• Remove the unit and return it to the manufacturer.
! The selected nominal valve size is too big and
has reduced the service life of the mechanical
components due to excessive stress.
• Check the system design.
• Adjust the valve size and/or actuator.
! Gear load is too great.
• Check the torque – see page 7 (Technical
data).
? Feedback potentiometer indicates incorrect
values?
! Connections on the terminal strip mixed up.
• Check the contact assignment on the terminal
strip.
! Incorrect potentiometer utilization.
• Utilize the potentiometer as a voltage divider.
! The windings in the potentiometer are defective.
• Remove the unit and return it to the manufacturer
for inspection.
? Software problem and/or problem with set-
tings?
! Software version obsolete.
• The current software and operating instructions
can be downloaded from www.docuthek.com,
see page5 (Accessories).
? Is it not possible for the fault to be elimi-
nated with the measures described above?
• Remove the unit and return it to the manufacturer
for inspection.
Technical data
Mains voltage: 100–230VAC, ±10%, 50/60Hz,
the actuator automatically adjusts to the respec-
tive mains voltage.
Power consumption: 8.4 W.
Switch-on peak current: max. 8 A for max. 10 ms.
Screw terminals using the elevator principles for
cables up to 4 mm2(single core cables) and for
cables up to 2.5 mm2with wire end ferrules.
Angle of rotation: 0 – 90°, setting accuracy
<0.05°.
Holding torque = torque as long as mains voltage
is applied.
2 digital inputs:
24 V DC or 100 – 230 V AC each.
Current requirement of digital inputs:
3mA ± 1.5mA.
1 analogue input (optional):
4 – 20 mA (internal load impedance: max. 500 Ω
at 20 mA).
Potentiometer (optional): 1 kΩ ± 20%,
linearity tolerance: ± 2%, max. capacity: 0.25W,
conductive plastic element.
Tap wiper at high resistance, see page3
(Feedback).

Elster GmbH
Postfach 28 09, D-49018 Osnabrück
Strotheweg 1, D-49504 Lotte (Büren)
T [phone]
F [phone]
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Contact
If you have any technical questions, please contact
your local branch office/agent. The addresses are
available on the Internet or from ElsterGmbH.
We reserve the right to make technical modifications
in the interests of progress. [e-mail], www.kromschroeder.com
Contact
2 digital outputs:
Signalling contacts designed as relay change-over
contacts. Contact current of digital outputs: min.
5mA (resistive) and max. 2A. The relay contacts
can be connected to 100 – 230VAC or 24V
DC. If the contacts have been connected with a
voltage >24V and a current >0.1A once, the
gold plating on the contacts will have been burnt
through. This contact can then only be connected
with this power rating or higher power rating.
Enclosure: IP65.
Safety class: I.
Duty cycle: 100%.
Electrical connection:
Line entrance: 3 x M20 plastic cable glands.
Ambient temperature:
-20 to +60°C, no condensation permitted.
Storage temperature: -20 to +40°C.
Type Running time [s/90°] Torque [Nm]
50 Hz/60 Hz 50 Hz 60 Hz
IC 40 4.5 – 76.5 2.5 2.5
IC40S 4.5 – 76.5 3 3
On the IC40, the running time and torque are
independent of the mains frequency. The running
time can be freely programmed between the limits
of 4.5 and 76.5s.
Logistics
Transport
Protect the unit from external forces (blows, shocks,
vibration). On receipt of the product, check that the
delivery is complete, see page 2 (Part designa-
tions). Report any transport damage immediately.
Storage
Store the product in a dry and clean place.
Storage temperature: see page7 (Technical data).
Packaging
The packaging material is to be disposed of in ac-
cordance with local regulations.
Disposal
Components are to be disposed of separately in
accordance with local regulations.
Certification
Declaration of conformity
We, the manufacturer, hereby declare that the prod-
uct IC40 complies with the requirements of the fol-
lowing Directives and Standards:
Directives:
– 2006/95/EC
– 2004/108/EC
Standards:
– DIN EN 60730
Elster GmbH
Scan of the Declaration of conformity (D,GB)– see
www.docuthek.com
Eurasian Customs Union
The product IC40 meets the technical specifications
of the Eurasian Customs Union.