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Pentair Biffi ICON 2000, Instructions And Operating Manual

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Pentair Biffi ICON 2000 Instructions And Operating Manual Download Page 77

Biffi

 ICON 2000 / ICON 2000 AD

Addendum e to InstructIon And operAtIng mAnuAl

c Ex d e IIB T4 Gb / c Ex tb IIIC T135°C Db IP66/68

c Ex d e ia IIB T4 Gb / c Ex tb IIIC T135°C Db IP66/68

index

1 

Safety instructions

 ���������������������������������

1

2 

instructions for right installation

 ���������

1

2�1 Marking ���������������������������������������������������� 1

3 

Applicable directives, general 
standards and norms

 �����������������������������

2

4 

Terms and conditions

 �����������������������������

2

5 

Manufacturer’s liability

 �������������������������

2

6 

Storage and pre-installation

 �����������������

2

6�1 

Storage procedure ����������������������������������� 2

6�2 

Checks to be performed before 
installation ������������������������������������������������ 2

7 installation

 ����������������������������������������������

3

7�1 

Working condition ������������������������������������ 3

7�1�1  Models and temperature������������������������� 3
7�2 

Identification of entries ���������������������������� 3

7�3 

Electrical connections ����������������������������� 3

7�4 

Cable connection ������������������������������������� 3

7�5 

Installation in ambient with 
explosive dusts ����������������������������������������� 3

8 Maintenance

 ��������������������������������������������

4

8�1 

Periodic inspections �������������������������������� 4

8�2 

Dismantling and reassembling �������������� 4

8�3 Repairs ����������������������������������������������������� 4

WArning

It is assumed that the installation, setting, 
commissioning, maintenance and repair works 
are carried out by qualified personnel and 
checked by responsible specialists.

1� SAfETy INSTRuCTIONS

1.1 generAl

This Addendum E to ICON 2000 main 
IOM VCIOM-01232 prescribes the safety 
instructions applicable to all the electric 
actuators ICON 2000-010, ICON-020, ICON-030, 
certified according to the IEC/EN 60079-0, 
60079-1, 60079-7, 60079-11 and 60079-31 
standards, for protection mode Ex d e and 
gas group IIC suitable to be installed in an 
ambient temperature range from -25°C (-13°f) 
to +60°C (+140°f)�

ICON 2000 is designed in accordance with the 
applicable international rules and specifications 
but in any case the following regulation must 
be observed:
- The general installation and safety 

regulations�

- The proper use of personal protective devices 

(glasses, clothing, gloves)�

- The proper use of tools, lifting and transport 

equipment�

www.pentair.com/valves

© 2012 Pentair plc� All rights reserved�

VCiOM-03026-en 15/03

2� INSTRuCTIONS fOR RIGhT 
INSTAllATION

WArning

Before the installation it is mandatory to check if 
the nameplate specifies the appropriate degree 
of protection and ambient temperature limits as 
requested by the rules applicable to the plant/
location where ICON 2000 are installed.
Installation in ambient with the presence of 
explosive atmosphere not covered by the specified 
grade of protection, or which could reach 
temperature higher than the maximum specified 
on the label, will invalidate the safety and the 
warranty.

iMpOrTAnT

Check if the label, as the following example, 
is fixed on the unit and completed with all the 
appropriate information.

2.1 MArking

Template of the label for ICON 2000 / ICON 2000 AD

Summary of Contents for Biffi ICON 2000

Page 1: ...Working condition 5 3 2 Coupling block disassembly from the actuator 5 3 3 Manual operation 8 3 4 Mounting the actuator onto the valve 9 3 5 Electrical connections 10 3 6 Removing the terminal board...

Page 2: ...uator 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 They are suitable...

Page 3: ...box Electric motor Local interface Engagement lever Internal sensor Internal gears Handwheel Equipment Protection Level EPL EN 60079 14 Explosive atmosphere Zone EPL Gas 0 Ga Gas 1 Ga or Gb Gas 2 Ga o...

Page 4: ...est certificate In order to maintain these characteristics until the actuator is installed on site proper procedures must be taken for preservation during the storage period Biffi actuators are weathe...

Page 5: ...ntenance Lithium battery change 3 Installation 3 1 Working condition The standard actuators are suitable for the following environment temperatures 30 C 85 C 22 F to 185 F Special versions are availab...

Page 6: ...he valve stem without excessive friction Now the bore can be machined in the stem nut to suit coupling requirements The same procedure is also used for possible maintenance 3 2 1 2 Re assembling the i...

Page 7: ...parts It is advisable to wash the dismantled parts with a suitable solvent dry them with compressed air make sure that there are no metal filings or foreign bodies spread a film of grease on all parts...

Page 8: ...counterclockwise the label must be removed and re mounted upside down Warning Do not manually operate the actuator with devices other than the handwheel and the declutch lever Using cheater bars wheel...

Page 9: ...sembly without securing slings to both the valve and the actuator YES NO Warning Never use the handwheel to lift the actuator 3 4 2 Couplings type B1 B2 B3 and B4 Check the dimensions of the valve mou...

Page 10: ...ties that have certified the actuators This is particularly true for units that are certified for use in hazardous areas where the method of sealing must be to an approved standard and cable glands re...

Page 11: ...d or other national standards During the dismantling and subsequent reassembling of the explosionproof enclosures covers cable glands joints be careful to bring these enclosures back to their original...

Page 12: ...oles 1 or 2 depending on mounting position The actuator is fitted with oil plugs parts 1 2 so that any assembly on the valve has at least one oil plug on the upper part of the housing and one on the l...

Page 13: ...nt place the 3 position selector in LOCAL and control the actuator by OPEN CLOSE and STOP push buttons If push to run was selected the actuator can be driven to the desired position by pressing and ho...

Page 14: ...onnections diagram shown beside With option 3 wires OPEN CLOSE COMMON the actuator can be driven in either push to run or latched with instant reverse mode In push to run mode the actuator can be driv...

Page 15: ...s menu AS7 8 relays not available Contact rating max voltage 250 V AC max current 2 A min switching capability 10 microA 10 m V DC 5 6 3 ESD operation An ESD Emergency Shut Down signal can be sent to...

Page 16: ...the configured parameters see paragraph 12 11 If the upper line of the display shows INT OFF an Interlock input is active If the upper line of the display shows ESD ON OFF the ESD input is active If t...

Page 17: ...20 mA will be updated If the actuator is not provided with an lithium battery or not supplied by the auxiliary 24 V DC and if the main voltage fails the output 4 20 mA maintains the last value If the...

Page 18: ...5 7 Operating the ICON 2000 for the first time 5 9 Base card of the ICON 2000 v4 Bottom view of base card Terminal Board Adaptor card TBA Fieldbus interface card The type of card depends on the field...

Page 19: ...buttons The STOP push button resets any existing command and is active both in local and remote If the 3 position selector is in LOCAL the OPEN YES and CLOSE NO push buttons work as OPEN and CLOSE co...

Page 20: ...inside the electronic compartment time present time date present date alarm list of present alarms see paragraph12 11 Diagnostic messages warning list of present warnings see paragraph 12 11 Diagnost...

Page 21: ...the prompt is next press YES to view the next variable press NO to return to the beginning If the prompt is view press YES to enter the sub menu of the variable press NO to skip to the next variable Y...

Page 22: ...and can only be viewed i e this menu is only available in View mode List of routines serial number actuator type torque thrust actuator speed power supply motor data test date wiring diagram enclosur...

Page 23: ...DE OK Press YES to answer prompt ENTER PASSWORD OK Enter password Enter one digit at a time Press YES if digit is correct press NO to scroll the list of available characters and then press YES when th...

Page 24: ...2 OK Z K 9 0 DIGIT 3 OK Z K 9 R DIGIT 4 OK SETUP MODE OK PASSWORD CORRECT PASSWORD WRONG Display LOCAL REMOTE Press NO until the desired language appears and then press YES FROM EXIT TO VIEW MENU Pre...

Page 25: ...aneous change To exit from SETUP menu press YES and NO simultaneously or move the 3 position selector to LOCAL or REMOTE 1 Routines with are only available if the relevant modules are present 2 Namepl...

Page 26: ...XXXX CHANGE MAINTENANCE DATE CHANGE SET PASSWORD CHANGE MAINTENANCE CHANGE MISCELLANEOUS CHANGE ACTUATOR SETUP CHANGE SETUP MODE OK YES YES NO NO NO YES YES YES YES YES YES YES YES YES YES YES YES YES...

Page 27: ...CE VIEW EXIT Routines Stroke limits view Torque set up view ESD set up view Remote controls view Local controls view Output relays view Positioner view Fail Safe view Out 4 20mA view Interlock view 2...

Page 28: ...ES YES YES SERIAL NUMBER VIEW VALVE DATA VIEW MAINTENANCE VIEW ALARM LOG VIEW XXXXXX XXXXXX VIEW MAINTENANCE DATE VIEW TAGE NAME VIEW SERIAL NUMBER VIEW XXXXXX XXXXXX VIEW SW VERSION VIEW NO NO NO YES...

Page 29: ...peat the close limit setting procedure 9 Set up routines 9 1 Actuator set up 9 1 1 Set stroke limits This routine allows the actuator to be configured according to the type of valve it is mounted on T...

Page 30: ...ay be remotely controlled by 4 or 3 or 2 wires depending on the connection made on the terminal board of the actuator The following options are available 4 wires latched requires 2 momentary signals s...

Page 31: ...alve LOCAL OFF selected manual operation ESD signal on ESD EFS low lithium battery if present LOCAL STOP pressed The contacts may be configured to make or break on condition The options EFS in manual...

Page 32: ...al may either be received from the bus or the 4 20 mA analog input If the ICON 2000 is set to receive the position request R from the bus a fieldbus interface card must be present or a Hardware alarm...

Page 33: ...ed values min 25 max 75 Polarity 4 mA OP Configuration procedure Move the local selector to OFF and then simultaneously press OPEN and STOP Select the language and then enter the password according to...

Page 34: ...the password according to the instructions see entering the set up mode When the message displayed is SET UP MODE OK press YES Press YES to select the actuator set up menu press NO to scroll the list...

Page 35: ...configurable Pulsing control can be applied to full travel or only a part of it Press YES if the position value where pulsing control stops is correct press NO to scroll the list of available values P...

Page 36: ...ium battery absent Torque profile standard Torque by pass 4 Valve jammed 4 sec 9 1 13 3 Torque limits Torque limits are used as a reference for torque alarm and end of travel With the option standard...

Page 37: ...control is greater than the valve jammed time but the valve position variation is smaller than 0 5 The motor is blocked the command is cleared and the valve jammed alarm indication is generated 2 The...

Page 38: ...t password routine and the possibility to modify or start the maintenance functions The following data are available set password clear alarm log set torque reference set curve reference clear recent...

Page 39: ...ogger routine allows to set the data logger parameters see VIEW mode Maintenance Data logger paragraph 10 4 6 To start the data logger the following data should be set Logger mode recorder event off S...

Page 40: ...CHANGE CLOSING TORQUE 55 OK CLOSING TORQUE 70 OK OPENING TORQUE 60 OK OPENING TORQUE 65 OK YES YES YES YES YES YES YES YES NO NO NO NO NO TO NEXT TO VIEW MENU To exit from SETUP menu press YES and NO...

Page 41: ...cknowledgment Actuator type max 28 characters describes the type of actuator with reference to Biffi catalog Torque Thrust nominal torque or thrust of actuator Actuator speed nominal speed of actuator...

Page 42: ...orque profile relevant to the last valve stroke with the torque profile reference saved before The following definitions will be used Breakout maximum torque in position interval 0 10 in opening or 10...

Page 43: ...d The recent data log collects data from the last clear recent data log date to present date Command clear recent data log is available in the SET UP MENU maintenance chapter 7 This command clears the...

Page 44: ...outines and press YES to select the maintenance date routine Press YES to scroll the list of dates Last date This is the date of the last maintenance operation The date should be updated by the user a...

Page 45: ...cording to the selected MEMORY MODE stop when full or continuous If continuous was selected as a new event is achieved the oldest one is cancelled and the new one becomes the latest Up to 50 cycles of...

Page 46: ...SETUP VIEW VIEW MODE OK YES YES YES YES YES NO NO NO NO YES TO NEXT ROUTINE TO SETUP MENU SELECT LANGUAGE To exit from VIEW menu press YES and NO simultaneously or move the 3 position selector to LOC...

Page 47: ...e refer to chapter 12 Troubleshooting for possible causes Spare parts can be required to Biffi please refer to the individual item number shown in chapter 13 Parts list and drawings Important Before s...

Page 48: ...is located in a hazardous area a hot work permit must be obtained unless the actuator can be moved to a non hazardous area 11 3 Lithium battery change Isolate the main supply to the actuator and all o...

Page 49: ...lace the power card 12 2 DC output voltage not available at the terminals Switch the main power supply off and disconnect all wires from terminals B1 B2 and C1 Switch the main power supply on and chec...

Page 50: ...with the suitable corrective actions as described in this chapter paragraph 12 11 Diagnostic messages 12 9 The actuator does not stop in fully open or fully closed position Check that the actual open...

Page 51: ...s 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 XXXXXX XXXXXX XXXXXX NEXT AL...

Page 52: ...arts Recalibrate both stroke limits Only close Only close Only close Close control Mid travel alarm in CL The valve does not move in presence of a close control Check status of actuator and valve mech...

Page 53: ...01 2000 Hardware 7 incorrect configuration of type of bus card Hardware 8 no communication between bus card and base card Warning table Display message Condition for warning Action Available controls...

Page 54: ...6 1 Motor cover 27 4 Screw 28 1 Oil plug 29 1 Finger assembly 30 2 Screw 31 1 Bush 32 1 Shoulder washer 33 1 Fork 34 1 Bearing bush 35 1 Lever washer 36 1 Lever assembly 37 1 Lever screw block 38 1 Sc...

Page 55: ...1 Speed magnetic sensor 25 3 3 Spring 25 4 1 Screw 25 5 1 Speed magnetic card assembly 25 6 2 Screw 25 7 1 Motor terminals board 25 8 1 Screw Speed magnetic card assembly 25 5 1 1 Speed magnetic card...

Page 56: ...bly Position sensor assembly Table 4 Lever assembly Item Qty Description 36 1 1 Lever 36 2 1 Key 36 3 1 Shoulder washer 36 4 1 Bearing 36 5 1 Spring 36 6 1 Retainer ring 36 7 1 Pin Table 5 Position se...

Page 57: ...cal interface assembly Item Qty Description 55 1 1 Ball 55 2 1 Spring 55 3 1 O ring 55 4 1 Selector 55 5 1 Screw 55 6 1 Plug Recommended spare parts Table 7 Thrust block assembly Item Qty Description...

Page 58: ...AB0280 Thermostat cable 7 CAB0300 Position sensor cable 8 CAB0200 Internal controls cable 9 CAB0250 Contact controls cable 10 CAB0170 Earth wire PENTAIR VALVES CONTROLS www pentair com valves All Pent...

Page 59: ...sts 1 Safety instructions 1 1 General This Addendum A is an integration to ICON 2000 main IOM VCIOM 01232 to prescribe the safety instructions applicable to all the electric actuators Series ICON 2000...

Page 60: ...21 Da or Db Dust 22 Da or Db or Dc 2006 42 EC Machinery Directive 2004 108 EC EMC Directive 2006 95 EC Low Voltage Directive 94 9 EC ATEX Directive EN ISO 12100 1 Safety of machinery Basic concepts g...

Page 61: ...d out in accordance to the applicable standards IEC EN 60079 14 and IEC EN 60079 17 regarding the electrical installations in Hazardous Areas other than mines classified as Zones 1 2 gas and Zones 21...

Page 62: ...carried out in accordance with national standards or the regulatory authorities that have certified the extension with additional conduit entry Method of sealing and cable glands must be approved and...

Page 63: ...make maintenance future operations easier In case the screws need to be changed it is mandatory to assure that the new screws are of the same dimension and same material as the original ones as state...

Page 64: ...personnel and checked by responsible specialists 1 Safety instructions 1 1 General This Addendum B is an integration to ICON 2000 main IOM VCIOM 01232 to prescribe the safety instructions applicable...

Page 65: ...21 Da or Db Dust 22 Da or Db or Dc 2006 42 EC Machinery Directive 2004 108 EC EMC Directive 2006 95 EC Low Voltage Directive 94 9 EC ATEX Directive EN ISO 12100 1 Safety of machinery Basic concepts g...

Page 66: ...mines classified as Zones 1 2 gas and Zones 21 22 dust following IEC EN 60079 10 1 and IEC EN 60079 10 2 and any other applicable national standards and rules Important When alternative entries are u...

Page 67: ...carried out in accordance with national standards or the regulatory authorities that have certified the extension with additional conduit entry Method of sealing and cable glands must be approved and...

Page 68: ...make maintenance future operations easier In case the screws need to be changed it is mandatory to assure that the new screws are of the same dimension and same material as the original ones as state...

Page 69: ...ICON 2000 010 and ICON 2000 020 certified according to the EN 60079 0 and IEC Standards 60079 1 60079 11 60079 31 for protection mode Ex d or Ex d ia for gas group IIC and Ex tb IIIC for dust suitabl...

Page 70: ...stallation disregard or incorrect application of the instructions provided on the product nameplate and in VCIOM 01232 main Instruction and Operating Manual and relevant Addendum C Modification of the...

Page 71: ...ons of VCIOM 01232 main Instruction and Operating Manual applies 7 4 Cable connection Sealing of cables entries must be carried out in accordance with national standards or the regulatory authorities...

Page 72: ...d make maintenance future operations easier In case the screws need to be changed it is mandatory to assure that the new screws are of the same dimension and same material as the original ones as stat...

Page 73: ...030 certified according to the IEC EN 60079 0 60079 1 60079 7 60079 11 and 60079 31 standards for protection mode Ex d e and gas group IIC suitable to be installed in an ambient temperature range from...

Page 74: ...stallation disregard or incorrect application of the instructions provided on the product nameplate and in VCIOM 01232 main Instruction and Operating Manual and relevant Addendum D Modification of the...

Page 75: ...tructions of VCIOM 01232 main Instruction and Operating Manual applies 7 4 Cable connection Sealing of cables entries must be carried out in accordance with national standards or the regulatory author...

Page 76: ...d make maintenance future operations easier In case the screws need to be changed it is mandatory to assure that the new screws are of the same dimension and same material as the original ones as stat...

Page 77: ...030 certified according to the IEC EN 60079 0 60079 1 60079 7 60079 11 and 60079 31 standards for protection mode Ex d e and gas group IIC suitable to be installed in an ambient temperature range from...

Page 78: ...stallation disregard or incorrect application of the instructions provided on the product nameplate and in VCIOM 01232 main Instruction and Operating Manual and relevant Addendum E Modification of the...

Page 79: ...nstructions of VCIOM 01232 main Instruction and Operating Manual applies 7 4 Cable connection Sealing of cables entries must be carried out in accordance with national standards or the regulatory auth...

Page 80: ...d make maintenance future operations easier In case the screws need to be changed it is mandatory to assure that the new screws are of the same dimension and same material as the original ones as stat...

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