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Service Manual

MDE 252 Rev. 1

December 2021

Troubleshooting

Section 2: Troubleshooting

2.1

Alarms and Warnings

Warning is the condition that occurs when a variable reaches a critical value and/or when a

maintenance action is required but all actuator functions are still available. The flashing of

the alarm/warning LED indicates a warning condition.

Alarm is the condition that occurs when a variable is outside the acceptable range and

some actuator function is not available. If the alarm/warning LED is on and fixed there is an

alarm condition. When the fault condition disappears, the corresponding alarm or warning
also disappears from the list.

A reset routine is provided in the local menu to clear the types of alarms and warnings
that are memorised (over-torque, jammed valve, etc.) (see Installation, Operation and
Maintenance Manual, VCIOM-08500).

View procedure:

Move the 3-position selector to either OFF or REMOTE, then press NO to scroll the
list of available variables.

Press YES when the display shows message "ALARMS view?" Press YES to scroll the
list of alarms.

Press NO when the display shows message "ALARMS view?"

Press YES when the display shows message "WARNINGS view?" Press YES to scroll
the list of warnings.

Press YES to reset the alarms or warnings with memory.

Figure 3 shows the procedure to view the alarms or warnings detected by the electronics.

XXXXXX XXXXXX

XXXXXX NEXT?

ALARMS VIEW?

ALARM

H 1

NEXT?

ALARM

H N

NEXT?

RESET OK?

WARNING

H N

NEXT?

WARNING

H 1

NEXT?

WARNINGS

VIEW?

Display

3-position

selector

LOCAL

REMOTE

YES

OFF

VIEW

VARIABLES

Figure 3

Summary of Contents for ICON3000 Series

Page 1: ...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 Biffi ICON3000 Electric Actuator Service Manual MDE 252 Rev 1 December 2021 ...

Page 2: ...tails December 2021 Service Manual MDE 252 Rev 1 Revision Details Revision Details Rev Date Description Prepared Approved 1 December 2021 General Update Migration to new template 0 May 2018 Initial Release A B L V ...

Page 3: ...ay Mid Travel Alarm in Closing 13 2 2 11 Alarm on Local Display Main Voltage 14 2 2 12 Alarm on Local Display Lost Phase 15 2 2 13 Alarm on Local Display K1 Contactor 16 2 2 14 Alarm on Local Display K2 Contactor 17 2 2 15 Alarm on Local Display Request Signal 18 2 2 16 Alarm on Local Display Low Lithium Battery 19 2 2 17 Alarm on Local Display Configuration OBJ n 19 2 2 18 Alarm on Local Display ...

Page 4: ...ctuator Does Not Move the Valve 25 2 9 The Manual Override Cannot Be Engaged 26 2 10 The Valve Does Not Seat Correctly 27 2 11 Excessive Torque for Valve Operation 27 2 12 The Actuator Does Not Stop in Fully Open or Fully Closed Position 27 2 13 The Numeric Position Display Indicates 27 2 14 The Electrical Power is off and Numeric Display is Off 28 2 15 Replacement of the 9 V Lithium Battery 28 2 ...

Page 5: ...assumed that the installation the setting the commissioning and the maintenance and repair works are carried out by qualified personnel and checked by responsible specialists WARNING The actuator is non intrusive The control compartment was sealed in dry and clean conditions and contains no site serviceable components Do not open it unless absolutely necessary Unauthorized access will invalidate t...

Page 6: ...elector is in LOCAL or REMOTE 4 Move the local selector to OFF and check that the alphanumeric display shows one of the following messages NORMAL OFF ALARM OFF WARNING OFF ESD ON OFF INT OFF If the status is ESD ON or INT an ESD or Interlock command is present Check the electrical signals on ESD and Interlock terminals and check the ESD and Interlock settings see Installation Operation and Mainten...

Page 7: ...f alarms and warnings that are memorised over torque jammed valve etc see Installation Operation and Maintenance Manual VCIOM 08500 View procedure 1 Move the 3 position selector to either OFF or REMOTE then press NO to scroll the list of available variables 2 Press YES when the display shows message ALARMS view Press YES to scroll the list of alarms 3 Press NO when the display shows message ALARMS...

Page 8: ...ncrease the torque limit only if valve stem can accept more torque thrust without any damage 6 Verify if the closing command performs well 1 Switch off the actuator 2 Remove the actuator from the valve by leaving the coupling thrust block fixed onto the valve 3 Turn the selector in local 4 Switch on the actuator 5 Push close button in order to verify if the actuator moves without the valve 6 If th...

Page 9: ...e torque limit only if valve stem can accept more torque thrust without any damage 6 Verify if the opening command performs well 1 Switch off the actuator 2 Remove the actuator from the valve by leaving the coupling thrust block fixed onto the valve 3 Turn the selector in local 4 Switch on the actuator 5 Push open button in order to verify if the actuator moves without the valve 6 If the actuator ...

Page 10: ...tuator can operate in closing direction 3 An electrical command in close direction clears the alarm The fault reason may be reconducted to an external unconventional operation to the actuator and the stroke limit position need to be reset Please verify in sequence 1 Verify all the functionalities of the manual operation with the manual engagement of the handwheel the proper operation of the handwh...

Page 11: ...ctuator can operate in opening direction 3 An electrical command in open direction clears the alarm The fault reason may be reconducted to an external unconventional operation to the actuator and the stroke limit position need to be reset Please verify in sequence 1 Verify all the functionalities of the manual operation with the manual engagement of the handweel the proper operation of the handwhe...

Page 12: ...tween motor terminals TH1 and TH2 is open or closed 1 The contact is open and the motor temperature is low a Replace the electric motor 2 The contact is open and the motor temperature is high a Check operation duty of motor b Check motor current c Check winding resistance of each phase of stator In the above check are correct replace the electric motor The contact is closed and the motor is ok Thi...

Page 13: ...s higher than 90 C or lower than 40 C Any electrical command is cleared 2 Electrical control of actuator becomes available when temperature is within the range 90 C 40 C Check ambient temperature Replace the logic card 1 The actuator is out of the application range 2 Please verify with Biffi if specific actuators are available for the particular climate conditions Is ambient temperature in the ran...

Page 14: ...not within the set range of bits Reconfigure the stroke limits The fault reason may be reconducted to an external unconventional operation to the actuator Check in sequence 1 Verify the cabling between the position sensor and the logic card CN14 2 Replace the position sensor 3 Replace the logic card 4 Verify the mechanical integrity of the shaft of the position sensor If the alarm disappears recal...

Page 15: ... bit i e is not within the set range of bits Switch off and then on the actuator 1 Operate the actuator in open or close direction 2 If the alarm reappears please refer to the sequence of check on the right Check in sequence 1 Verify the cabling between the speed sensor and the logic card CN13 2 Replace the speed sensor 3 Replace the electric motor 4 Replace the logic card Alarm disappear YES NO ...

Page 16: ...tion An electrical command in close direction clears the alarm Check in sequence 1 Increase the parameter valve jammed time in the actuator setup miscellaneous routine refer to VCIOM 08500 2 Verify that the manual override is disengaged 3 Verify the mechanical integrity of the shaft of the position sensor 4 Verify the integrity of all the mechanical parts composing the transmission from the electr...

Page 17: ...ction An electrical command in open direction clears the alarm Check in sequence 1 Increase the parameter valve jammed time in the actuator setup miscellaneous routine refer to VCIOM 08500 2 Verify that the manual override is disengaged 3 Verify the mechanical integrity of the shaft of the position sensor 4 Verify the integrity of all the mechanical parts composing the transmission from the electr...

Page 18: ...d and set the new value of voltage span parameter Check replace in sequence 1 Cable connection between power and logic board 2 Replace the power board 3 Replace the logic board The failure is not related to the actuator The failure is not related to the actuator Problem solved 1 Main Voltage power supply is lower than 20 or higher than 20 of the nominal value reported in the actuator nameplate and...

Page 19: ...and L3 The failure is not in the actuator Verify failure causes external to Biffi actuator and possibly in the plant conditions Check in sequence 1 Verify the actuator electric parameters on the nameplate or in the technical data and check that the external wires sections to the actuator terminals are correct 2 Verify internal wiring between terminal board internal screws terminals and power suppl...

Page 20: ...command opposite to that one which has generated the alarm 2 Or via actuator menu as described on the VCIOM 08500 Once the alarm is reset repeat the same command which has generated the alarm The failure is removed and the actuator works but it is important to understand why the problem occurred and make all those operations necessary to avoid the problem to return The main reason for the K1 failu...

Page 21: ...command opposite to that one which has generated the alarm 2 Or via actuator menu as described on the VCIOM 08500 Once the alarm is reset repeat the same command which has generated the alarm The failure is removed and the actuator works but it is important to understand why the problem occurred and make all those operations necessary to avoid the problem to return The main reason for the K1 failu...

Page 22: ...A Check that on local LCD display the value R xxx reports the value zero with a tolerance of 0 5 Please recalibrate the 4 20 mA analogue input enter the restricted menu with the service password and set the new value of the parameters Connect a 4 20 mA signal source to terminals B9 B9 Set the signal source at 20 mA Check that on local LCD display the value R xxx reports the value 100 with a tolera...

Page 23: ... Display Configuration OBJ n CONFIGURATION OBJ n 1 The checksum of the EEPROM memory that contains the actuator configuration data is wrong 2 Any electrical command to move the valve is cleared 3 The ref number OBJ n reports the parameter that is wrong Enter in SET UP mode gactuator set up g torque set up gopening torque increase or descrease the set value of 1 gpush YES to confirm and exit from t...

Page 24: ... Restart the actuator Hardware 5 no communication between terminal board and logic card g Replace the terminal board gReplace the logic board g Restart the actuator Hardware 6 incorrect configuration ICON3000 card g Enter the restricted menu with the service password and re set the Incorrect configuration of ICON3000 type at Service level only g Replace the logic board g Restart the actuator Hardw...

Page 25: ... any damage 4 Repeat stroke limit setup procedure in case of change of torque limit and valve closes or open by torque 2 3 2 Warning on Local Display High Torque in Opening Near to Maximum The measured torque is near to maximum torque minus 10 1 Check the valve and the torque needed to move the valve 2 Check the torque limits in Actuator Setup Stroke limits and torque setup 3 Increase the torque l...

Page 26: ...transformer on the power card or in the cable between power module and control module It needs to change the power module control module 2 3 5 Warning on Local Display Contactor Cycles The contactor has reached the maximum number of cycles The power card that have the contactors on board should be changed as soon as possible 2 3 6 Warning on Local Display Maintenance Request The date for the sched...

Page 27: ... power card If it is correct replace the power card 2 5 DC Output Voltage Not Available at the Actuator Terminals 1 Switch the main power supply off and disconnect all wires from terminals B1 B2 and C1 2 Switch the main power supply on and check if the voltage on the terminals B1 B2 and C1 is between 23 and 27 V DC If the voltage is correct check the external wiring and the electrical load It shou...

Page 28: ...ng to terminals B1 B2 and C1 is correct b There is no short circuit between wires c The electrical load does not exceed 4 W d If external voltage supply is used check that the value is in the range 20 120 V AC 50 60 Hz or 20 125 V DC 2 7 The Motor is Very Hot and Does Not Start 1 Check that no alarm other than motor overheating is present 2 Wait until the motor cools down and the normally closed c...

Page 29: ...position indicators 1 Verify the stem nut correctly fits in the actuator base 2 Verify the stem nut has sufficient engagement with the valve stem 3 Verify the key correctly fits in bore keyways applications 4 Check that the valve works in manual operation If not it is necessary to check the manual control area as follows a Loosen the handwheel security dowel b Remove the handwheel c Remove the cov...

Page 30: ...ubleshooting 2 9 The Manual Override Cannot Be Engaged In case the engagement of the lever is too difficult check whether the drive sleeve is stuck and proceed as follows 1 Open the cover 2 Try to move the drive sleeve by a screwdriver 3 Reassemble the cover Figure 9 Figure 10 ...

Page 31: ...ck the alphanumeric display for diagnostic messages and proceed with the suitable corrective actions as described in this manual 2 12 The Actuator Does Not Stop in Fully Open or Fully Closed Position 1 Check that the actual open and close positions of the valve respectively correspond to 100 and 0 on the actuator display 2 Make sure that the torque and travel limits are correctly set see Installat...

Page 32: ...ion Operation and Maintenance Manual VCIOM 08500 2 15 Replacement of the 9 V Lithium Battery WARNING Since the control and terminal board compartments contain a 9 V and 3 6 V lithium batteries only open it in safe area If the actuator is located in a hazardous area a hot work permit must be obtained unless the actuator can be moved to a non hazardous area Isolate the main supply to the actuator an...

Page 33: ... Manual MDE 252 Rev 1 December 2021 Troubleshooting 29 Section 2 Troubleshooting NOTICE The new battery must be Lithium LS 9 V manufactured by SAFT Remove the battery cover Figure 13 Replace battery Figure 14 ...

Page 34: ...wo pieces header and crimp housing The header is welded on the printed circuit board the crimp housing is connected to wires Due to mechanical block to disconnect the crimp housing from header can be difficult and could damage connector or wires Figure 15 Terminal Board Power Card Position encoder Local controls Motor temperature Speed sensor ...

Page 35: ...nual MDE 252 Rev 1 December 2021 Troubleshooting 31 Section 2 Troubleshooting Figure 16 TP1 TP3 TP7 TP2 TP4 Test Points TP1 0 Vm TP2 3 3 Vh8 TP3 13 Vm TP4 12 Vm in case of power supply by DC DC converter TP7 5 Vm ...

Page 36: ... wires Due to mechanical block to disconnect the crimp housing from header can be difficult and could damage connector or wires Figure 17 Header Crimp housing Mechanical block Crimp housing mechanical block Disconnection between header and crimp housing can be helped by using a screwdriver By the screwdriver force the mechanical block in the direction indicated in Figure 18 until the crimp housing...

Page 37: ...Service Manual MDE 252 Rev 1 December 2021 Notes This page is intentionally left blank ...

Page 38: ...publication 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 ...

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