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DVC6000 HW2 instruction manual (D103785X012)

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1. Manual Calibration Pushbutton Calibration Sensor Calibration PressureSensors Travel 5 Analog Input Calibration Relay Double Acting Single Acting Relays PST ROO Section 5 Device Information Diagnostics and Alerts 22 duis dicesseQa oie oe date ide Status amp Primary Purpose Variables Device Information Service 5 DeviceStatus Alert Record EIeCEPODICS ceo etu ope SOR POSS WRC ocu as raodo ir M eC Travel History Alert StAGUS doo Beate eae konnen veri em bre Rr Ee nece Stroke Partial Stroke Test ODV only Mal uae ad DORT Section 6 Maintenance Troubleshooting Module Base Maintenance Tools Required Removing the ModuleBase Instruction Manual D103785X012 Replacing the Module Base
2. ee et 10 Travel Target Travel Target 25 0 Ranged Set Point 100 125 25 0 Ranged Set Point Input Characteristic Linear 100 125 Input Characteristic Equal Percentage SLM UM 100 7777 n O Travel Target 25 0 Ranged Set Point 100 125 Input Characteristic Quick Opening 6535 1 Instruction Manual Configuration D103785X012 November 2015 Dynamic Response e SP Rate Open Maximum rate of valve travel per second at which the digital valve controller will move to the open position regardless of the rate of input current change A value of 0 will deactivate this feature and allow the valve to stroke open as fast as possible e SP Rate Close Maximum rate of valve travel per second at which the digital valve controller will move to the close position regardless of the rate of input current change A value of 0 will deactivate this feature and allow the valve to stroke close as fast as possible e Set Point Filter Time Lag Time The Set Point Filter Time Lag Time slows the response of the digital valve controller A value ranging from 0 2 to 10 0 can be used for noisy or fast processes to improve closed loop process control Entering a value of 0 0 will deactivate the lag filter Note Set Point Filter Time Lag Time is available for instrument level HC AD and PD e Lead Lag Set Point
3. Spec Edit Instrument Time www Fisher com Travel Pressure 22 Travel Pressure Select 22 Cutoffs and Limits 23 End Point Pressure Control 23 Pressure Control 24 Pressure 24 Control Mode 25 Characterization 25 Dynamic Response 2 28 Travel 28 Pressure Tuning 31 Travel Pressure Integral Settings 31 Valve and 32 Partial Stroke Test 34 Sun ick es oot et tend eae ere cad 37 Output Terminal Configuration 37 Switch Configuration 37 HART Variable Assignments 38 Transmitter Output 38 Burst Mode 38 Alert 39 Change to HART 5 7 40 s EMERSON Process Management DVC6000 HW2 Digital Valve Controller November 2015 Contents continued Section 4 Calibration Calibration Overview Travel Auto Calibration
4. converter ass y out of spec 3m I P converter assembly nozzle may have been adjusted Verify drive signal 55 to 80 for double acting 60 to 85 for single acting with the valve off the stops Replace I P converter ass y if drive signal is continuously high or low 3n Defective module base seal 3n Check module base seal for condition and position If necessary replace seal 3p Defective relay 3p Depress relay beam at adjustment location in shroud look for increase in output pressure Remove relay inspect relay seal Replace relay seal or relay if I P converter ass y good and air passages not blocked Check relay adjustment 3q Defective 67CFR regulator supply pressure gauge Replace 67CFR regulator jumps around 4 ValveLink diagnostic tests 4 Bent or defective pressure sensor 4a Replace PWB provide erroneous results 45 Pressure sensor O ring missing Ab Replace O ring 5 Field Communicator does 5 Battery pack not charged 5a Charge battery pack not turn on Note Battery pack can be charged while attached to the Field communicator or separately The Field Communicator is fully operable while the battery pack is charging Do not attempt to charge the battery pack in a hazardous area 82 Instruction Manual Maintenance and Troubleshooting D103785X012 November 2015 DVC6000 HW2 Troubleshooting Checklist 1 Instrument serial number as read from nameplate 2 Is the digital valve controll
5. Separate the module base from the housing by performing the Removing the Module Base procedure Remove the screw key 72 Pull the terminal box assembly straight out of the housing NJ A W Remove two wire retainers key 44 internal and external to the terminal box Instruction Manual Maintenance and Troubleshooting D103785X012 November 2015 Replacing the Terminal Box Note Inspect all O rings for wear and replace as necessary 1 Install two wire retainers key 44 internal and external to the terminal box NJ Apply silicone lubricant to the O ring key 34 and install the O ring over the stem of the terminal box 3 Insert the terminal box assembly stem into the housing until it bottoms out Position the terminal box assembly so that the hole for the screw key 72 in the terminal box aligns with the threaded hole in the housing Install the screw key 72 Connect the terminal box connector to the PWB assembly key 50 Orientation of the connector is required Reassemble the module base to the housing by performing the Replacing the Module Base procedure Reconnect the field wiring as noted in step 2 in the Removing the Terminal Box procedure SN DD UW Bf Apply silicone lubricant to the O ring key 36 and install the O ring over the 2 5 8 inch threads of the terminal box Use of a tool is recommended to prevent cutting the O ring while installing it over the threads Apply lubricant
6. 66 Submodule Maintenance 67 HP CONVERTE 67 Printed Wiring Board PWB Assembly 69 Pneumatic 71 Gauges Pipe Plugs or Tire Valves 72 Terminal BOX ah ee x IR VR 72 Removing the Terminal Box 72 Replacing the Terminal 73 Travel SehSOE va tute darte e ER Sees 73 ERU CERE 74 DVC6015 Remote Feedback Unit 74 DVC6025 Remote Feedback Unit 75 DVC6035 Remote Feedback Unit 75 ASSEINDIY cr etate or SEE MUR RM 75 DVC6015 Feedback Unit 75 DVC6025 Feedback Unit 76 DVC6035 Feedback Unit 78 6 80 Checking Voltage Available 80 DVC6000 HW2 Technical Support Checklist 83 SecHIOn Palts eiu eie da YES 85 Parts Ordering ice b DS bcd 85 seio Sors inttr aetati indus didus 85 Satin arate 86 DVC6005 Base Unit 86 Pressure Gauges Pipe Plugs or Tire Valve Assemblies 88 Remote Travel Sensor Parts 86 HARI FIEGIS 88 Appendix A Principle of Operation 95 HART Communication 95 DVC6200 Digital Valve Contr
7. controlled variable Current to Pressure I P Converter An electronic component or device that converts a milliamp signal to a proportional pneumatic pressure output signal Cycle Counter The capability of a FIELDVUE instrument to record the number of times the travel changes direction The change in direction must occur after the deadband has been exceeded before it can be counted as a cycle 107 Glossary November 2015 Cycle Counter Alert Checks the difference between the Cycle Counter and the Cycle Counter Alert Point Cycle Counter Alert is active when the cycle counter value exceeds the Cycle Counter Alert Point It clears after you reset the Cycle Counter to a value less than the alert point Cycle Counter Alert Point An adjustable value which when exceeded activates the Cycle Counter Alert Valid entries are O to 4 billion cycles Cycle Counter Deadband Region around the travel reference point in percent of ranged travel established at the last increment of the Cycle Counter The deadband must be exceeded before a change in travel can be counted as a cycle Valid entries are 0 to 100 Typical value is between 2 and 5 Deviation Usually the difference between set point and process variable More generally any departure from a desired or expected value or pattern Device ID Unique identifier embedded in the instrument at the factory Device Revision Revision number of the interface software that p
8. Relay Type Pressure Signal AorC Port A Port B B Port B Port A B Special App Port B C Special App Port A To manually set the partial stroke pressure limit you must examine current partial stroke test results using ValveLink software The following steps will guide you through the process 1 Connect the DVC6000 HW2 to a system running ValveLink software 2 Disable the following parameters e Deviation Alert set to 125 e End Point Pressure Control disable e Partial Stroke Pressure Limit disable by setting the appropriate value shown in table 3 6 34 Instruction Manual Configuration D103785X012 November 2015 Table 3 6 Values for Disabling Partial Stroke Pressure Limit Actuator Type Relay Type Zero Power Condition Partial Stroke Start Point Partial Stroke Pressure Limit Disabled in e Im Psupply ii Closed Double Acting A 5 GUI 3 Run a partial stroke test 4 Select the Press Time radio button on the partial stroke graph refer to the example in figure 3 6 bottom plot If the actuator pressure starts high and moves low find the minimum actuator pressure Pmin If the actuator pressure starts low and moves high find the maximum actuator pressure Pmax Double acting actuators will display differential pressure Use table 3 7 to estimate the partial stroke pressure limit Table 3 7 Estimates for Partial Stroke Pressure Limits Relay Type Partial
9. U Units Analog Input 21 Pressure 21 Temperature 21 V Valve Serial Number 21 118 Instruction Manual D103785X012 Valve Style 32 Valvelink software 4 Variable Out of Range 57 Variables Status amp Primary Purpose 55 Velocity Gain Travel Tuning 29 Vibration Testing Method 6 Voltage Available 9 Checking 80 W Weight DVC6005 HW2 base unit 6 DVC6015 feedback unit 6 DVC6025 feedback unit 6 DVC6035 feedback unit 6 Wiring Practices 9 Control System Requirements 9 Compliance Voltage 11 HART Filter 9 Voltage Available 9 Maximum Cable Capacitance 12 Write Protection 20 Z Zero Power Condition 33 Instruction Manual DVC6000 HW2 Digital Valve Controller D103785X012 November 2015 119 DVC6000 HW2 Digital Valve Controller Instruction Manual November 2015 D103785X012 Neither Emerson Emerson Process Management any of their affiliated entities assumes responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any product remains solely with the purchaser and end user Fisher FIELDVUE ValveLink PlantWeb PROVOX Rosemount Tri Loop DeltaV RS3 and THUM are marks owned by one of the companies in the Emerson Process Management business unit of Emerson Electric Co Emerson Process Management Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co HART is a registered trad
10. with I O Package For instrument level HC For instrument level AD For instrument level PD For instrument level ODV 87 Parts November 2015 Key Description Part Number Pressure Gauges Pipe Plugs or Tire Valve Assemblies see figure 7 3 47 Pressure Gauge nickel plated brass case brass connection Double acting 3 req d Single acting 2 req d PSI MPA Gauge Scale To 60 PSI 0 4 MPa 18B7713X042 To 160 PSI 1 1 MPa 18B7713X022 PSI bar Gauge Scale To 60 PSI 4 bar 18B7713X032 To 160 PSI 11 bar 18 7713 012 PSI KG CM2 Gauge Scale 60 PSI 4 KG CM2 18B7713X072 To 160 PSI 11 KG CM 18B7713X082 66 PipePlug hex hd For double acting and single acting direct w gauges none req d For single acting reverse w gauges 1 req d For all units w o gauges 3 req d 67 Tire Valve Assembly 3 req d Not for mounting on 1250 and 1250R actuators Remote Feedback Units Common Parts DVC6015 DVC6025 and DVC6035 see figures 7 4 7 5 and 7 6 23 Screw hex socket 14 15 2 req d 44 Wire Retainer pl 501415 9 req d 46 Alignment Pin 14 for DVC6015 and DVC6035 49 Screw self tapping 2 req d 58 Set Screw hex socket 14 62 PipePlug hex hd SST 14 64 Anti seize compound not furnished with the instrument 65 Lubricant silicone sealant not furnished with the instrument 72 Screw hex socket 2 14 2 req d for DVC6015 and DVC6025 78 Spring 5572 14 for DVC6015 and DVC6035 79
11. 24 0 to 125 0 of the calibrated pressure for more than 60 seconds If this alert is active check the instrument supply pressure ensure the printed wiring board assembly is properly mounted onto the module base assembly and ensure the pressure sensor O rings are properly installed If the alert persists after restarting the instrument replace the printed wiring board assembly e Minor Loop Sensor Alert This alert is active if the pneumatic relay position reading is outside the valid range If the alert persists replace the printed wiring board e Loop Current Validation Alert This alert is active if the loop current is significantly out of range or if there is a problem with the analog circuit electronics If this alert is active restart the instrument with the loop current verified to be in the 4 20 mA range If the alert persists replace the printed wiring board Note If the control system is known to output current 24 mA or above Shutdown on Loop Current Validation should not be enabled e Output Circuit Communication Failure This alert is active if the output circuit is not responding If configured as a position transmitter output first make sure the transmitter circuit is powered If the alert persists make sure the DIP switch on the main electronics matches the configuration of the OUT terminals If the alert is still active replace the main electronics e Instrument Time is Approximate Alert This alert is active if the i
12. Field Communicator Menu Trees Instruction Manual November 2015 D103785X012 Figure B 6 Manual Setup gt Mode and Protection 2 2 1 and Manual Setup gt Instrument 2 2 2 2 2 1 Mode and Protection 2 2 2 1 nm 1 Instrument Mode Identification 2 Change Instrument Mode 1 HART Tag 2 HART Long Tag lt q 3 Write Protection Manual Setup 4 Change Write Protection 3 Description 1 Mode and Protection 4 Message 2 Instrument y Instrument 5 Polling Address 3 Travel Pressure Control 4 Tuning 5 Valve and Actuator 6 Partial Stroke Test PST 7 Outputs 1 Identification 2 2 2 2 2 Serial Numbers Serial Numbers P 12 1 Instrument Serial Number 5 Analog Input Range 2 Valve Serial Number Units 1 Pressure Units 2 2 2 6 6 Spec Sheet 7 Edit Instrument Time Spec Sheet 2 Temperature Units 3 Analog Input Units Units 2 Valve 2 2 2 3 Terminal Box 3 4 Actuator 2 2 2 6 3 1 Calibration Button 5 Accessories TuS 2 Auxiliary Terminal Action lt 3 2 22 65 3 Edit Auxiliary Terminal Action lt 3 Accessories Seat Analog Input Range 1 Input Range Hi 2 Input Range Lo Leak Class Port Diameter Port Type Flow Direction Push Down To Flow Tends To Unbalanced Area 1 Volume Booster 2 Quick Release 3 Solenoid Valve 4 Position Transm
13. November 2015 D103785X012 Auxiliary Terminal Wiring Length Guidelines The Auxiliary Input Terminals of a DVC6000 HW2 with instrument level ODV can be used with a locally mounted switch for initiating a partial stroke test Some applications require that the switch be installed remotely from the DVC6000 HW2 The length for wiring connected to the Auxiliary Input Terminals is limited by capacitance For proper operation of the Auxiliary Input Terminals capacitance should not exceed 100 000 pF As with all control signal wiring good wiring practices should be observed to minimize adverse effect of electrical noise on the Aux Switch function Example Calculation Capacitance per foot or per meter is required to calculate the length of wire that may be connected to the Aux switch input The wire should not exceed the capacitance limit of 100 000 pF Typically the wire manufacturer supplies a data sheet which provides all of the electrical properties of the wire The pertinent parameter is the highest possible capacitance If shielded wire is used the appropriate number is the Conductor to Other Conductor amp Shield value Example 18AWG Unshielded Audio Control and Instrumentation Cable Manufacturer s specifications include Nom Capacitance Conductor to Conductor 1 KHz 26 pF ft Nom Conductor DC Resistance 20 Deg C 5 96 Ohms 1000 ft Max Operating Voltage UL 200 V RMS PLTC CMG 150 V RMS ITC Allowable Length with this cabl
14. To avoid personal injury and property damage caused by the release of pressure or process fluid isolate the valve from the process and equalize pressure on both sides of the valve or bleed off the process fluid 41 Calibration Instruction Manual November 2015 D103785X012 Travel Calibration If a double acting relay is used you will be prompted to run the relay adjustment when auto or manual calibration is selected Select Yes to adjust the relay select No to proceed with calibration For additional information refer to Relay Adjustment on page 52 Auto Calibration User interaction is only required with Auto Calibrate Travel when the feedback connection is SStem Standard Sliding Stem Standard A feedback connection of Rotary All SStem Roller Sliding Stem Roller requires no user interaction and you can start with step 6 For a SStem Standard feedback connection interaction provides a more accurate crossover adjustment Setting crossover establishes the zero degree point for the geometric correction used to translate the rotary motion observed by the travel sensor into the linear motion of the sliding stem valve 1 Select the method of crossover adjustment manual last value or default Manual is the recommended choice If you select Manual the Field Communicator will prompt you to adjust the crossover in step 3 If you select Last Value the crossover setting currently stored in the instrument is used and there are
15. online help Module Base Maintenance The digital valve controller contains a module base consisting of the I P converter printed wiring board assembly and pneumatic relay The module base may be easily replaced in the field without disconnecting field wiring or tubing Tools Required Table 6 1 lists the tools required for maintaining the DVC6000 HW2 digital valve controller Table 6 1 Tools Required Wd Phillips Screwdriver Relay printed wiring board assembly and cover screws Hex key Terminal box screw Hex key Terminal box cover screw Hex key I P converter screws Hex key Travel sensor screws Hex key 6mm Module base screws Open end wrench 1 2 inch Connector Arm screw DVC6015 Hex key 9 64 inch Feedback arm screw Open end wrench 7 16 inch DVC6015 mounting bolts Hex key 3 16 inch DVC6025 mounting bolts Removing the Module Base To remove the DVC6005 HW2 module base perform the following steps Refer to figure 7 2 for key number locations A WARNING To avoid personal injury or equipment damage from bursting of parts turn off the supply pressure to the digital valve controller and bleed off any excess supply pressure before attempting to remove the module base assembly from the housing 64 Instruction Manual Maintenance and Troubleshooting D103785X012 November 2015 1 For sliding stem applications only a protective shield for the feedback linkage is attached to the side of the module base asse
16. travel then press OK Adjust the current source until the valve is at 95 travel then press OK Placethe instrument In Service and verify that the travel properly tracks the current source Digital Calibration Adjust CON DU HRW Connect a variable current source to the instrument LOOP and LOOP terminals The current source should be set between 4 and 20 mA Follow the prompts on the Field Communicator display to calibrate the instrument s travel in percent 1 Adjust the input current until the valve is near mid travel Press OK Note 0 Travel Valve Closed 100 Travel Valve Open 44 Instruction Manual Calibration D103785X012 November 2015 2 From the adjustment menu select the direction and size of change required to set the travel at 0 Selecting large medium and small adjustments causes changes of approximately 10 0 1 0 and 0 1 respectively If another adjustment is required repeat step 2 Otherwise select Done and go to step 3 3 From the adjustment menu select the direction and size of change required to set the travel to 100 If another adjustment is required repeat step 3 Otherwise select Done and go to step 4 4 From the adjustment menu select the direction and size of change required to set the travel at 0 If another adjustment is required repeat step 4 Otherwise select Done and go to step 5 5 From the adjustment menu select the direction and size of change required to set
17. 1 Instrument Mode There are two instrument modes for the DVC6000 HW2 In Service or Out of Service In Service is the normal operating mode such that the instrument follows the 4 20 mA control signal Out of Service is required in some cases to modify configuration parameters or to run diagnostics Note Some changes that require the instrument to be taken Out Of Service will not take effect until the instrument is placed back In Service or the instrument is restarted Write Protection There are two Write Protection modes for the DVC6000 HW2 Not Protected or Protected Protected prevents configuration and calibration changes to the instrument The default setting is Not Protected Write Protection can be changed to Protected remotely However to change Write Protection to Not Protected you must have physical access to the instrument The procedure will require you to press a button on the terminal box as a security measure Instrument Field Communicator Configure gt Manual Setup gt Instrument 2 2 2 Follow the prompts on the Field Communicator display to configure the following Instrument parameters Identification e HART Tag A tag name up to 8 characters is available for the instrument The HART tag is the easiest way to distinguish between instruments in a multi instrument environment Use the HART tag to label instruments electronically according to the requirements of your application The tag you assign is automaticall
18. 2015 D103785X012 Figure 7 6 FIELDVUE DVC6035 Remote Feedback Unit Assembly LL Aw SECTION C C 4 SCA eid j pu S SN NJ PAY SECTION B B SECTION A A L APPLY LUB SEALANT THREAD LOCK NOTE 1 APPLY LUBRICANT KEY 65 TO ALL O RINGS UNLESS OTHERWISE SPECIFIED 49B7988 A 94 Instruction Manual Principle of Operation D103785X012 November 2015 Appendix A Principle of Operation HART Communication The HART Highway Addressable Remote Transducer protocol gives field devices the capability of communicating instrument and process data digitally This digital communication occurs over the same two wire loop that provides the 4 20 mA process control signal without disrupting the process signal In this way the analog process signal with its faster update rate can be used for control At the same time the HART protocol allows access to digital diagnostic maintenance and additional process data The protocol provides total system integration via a host device The HART protocol uses frequency shift keying FSK Two individual frequencies of 1200 and 2200 Hz are superimposed over the 4 20 mA current signal These frequencies represent the digits 1 and 0 see figure A 1 By superimposing a frequency signal over the 4 20 mA current digital communication is attained The average value of the HART s
19. 21 Principle of Operation DVC6200 95 HART Communication 95 Printed Wiring Board Assembly Parts List 87 Removing 69 Replacing 69 Setting DIP Switch 69 Proportional Gain Pressure Tuning 31 Travel Tuning 29 PST Calibration 54 PST Enable 36 PST Pressure Limit 34 PST Start Point 36 PST Variables 36 Pushbutton Calibration 45 R Reference Voltage Failure 56 Related Documents 7 Relay Adjustment 52 Relay Type 32 Remote Travel Sensor Connections Using a 10 kOhm External Potentiometer as 13 Using a Two Resistor Series as 15 Instruction Manual D103785X012 Restart Control Mode 25 Restart Processor 80 S Sensor Calibration 46 Serial Number Instrument 21 Valve 21 Service Tools 56 Device Status 56 Set Point Filter Lag Time 27 Set Point Filter Lead Lag Time 27 SP Rate Close 27 SP Rate Open 27 Spec Sheet 22 Special App Relay 32 Specifications 4 Stabilize Optimize 30 Status amp Primary Purpose Variables Device Information 55 Steady State Air Consumption 5 Stroke Valve 60 Supply Pressure 5 Supply Pressure Alert 57 Supply Pressure Sensor Calibration 47 Switch 37 Switch Closed 37 Switch Configuration 37 Alert Switch Source 37 Limit Switch Trip Point 37 Switch Closed 37 T Temperature Limits Operating Ambient 5 Temperature Sensor Alert 57 Temperature Units 21 Terminal Box 21 Auxiliary Terminal Action 21 Calibration CAL Butt
20. 5 THIS MENU ITEM IS TRANSMITTER OUTPUT WITH HART 5 BURST MODE IS AVAILABLE WITH HART 5 PERFORMANCE TUNER IS AVAILABLE FOR INSTRUMENT LEVEL AD PD AND ODV deb UU 104 2 Pressure Tuning 3 Travel Pressure Integral Settings Travel Pressure Integral Settings 1 Integral Dead Zone 2 Integrator Limit 6 Partial Stroke Test PST 2 2 5 7 Outputs Mad Valve and Actuator 1 Valve Style 2 Actuator Style 3 Feedback Connection 4 Relay Type 5 Zero Power Condition 6 Travel Sensor Motion 7 Maximum Supply Pressure 2 2 4 1 Travel Tuning Travel Tuning Set Proportional Gain Velocity Gain MLFB Gain Integral Enable Integral Gain Performance Tuner lt 51 Stabilize Optimize 2 4 3 Pressure Tuning 1 Pressure Tuning Set 2 Proportional Gain 3 MLFB Gain 4 Integral Enable 5 Integral Gain Partial Stroke Test PST C 1 PST Pressure Limit 2 PST Enable 3 PST Start Point 4 PST Variables WITHOUT I O PACKAGE 2 2 6 HD AD PD pr 22 7 ODV 2 2 7 1 ODV HART Var Assignments Outputs ble PV 1 Primary Variable PV 1 HART Var Assignments Burst 2 Secondary Variable SV 2 2 6 2 HC AD PD Burst Mode 1 Burst Enable 2 Burst Command 2 2 6 1 HC AD PD 3 Tertiary Variable TV 4 Quaternary Variable QV Instruction Manual Field Communicator Menu Trees D103785X012 November 2015 Figure B 9 Alert Setup 2 3 2 3 1 Electronics 2
21. ATA Hir D oa lt lt Rox an E SESS sa EN LA IDI DBA At VAL lt E SECTION E E 8 OUTPUT B OUTPUT B SUPPLY SUPPLY WALL MOUNTING PIPESTAND MOUNTING L APPLY LUB SEALANT NOTES 1 SEE FIGURE 7 3 FOR GAUGE CONFIGURATIONS 2 APPLY LUBRICANT KEY 65 TO ALL O RINGS UNLESS OTHERWISE SPECIFIED 49B3261 C SHT 2 amp 3 90 Instruction Manual Parts D103785X012 November 2015 Figure 7 3 Typical FIELDVUE DVC6005 HW2 Digital Valve Controller Gauge Configuration DOUBLE ACTING SINGLE ACTING DIRECT SINGLE ACTING REVERSE CL APPLY LUB SEALANT NOTE 1 FOR SINGLE ACTING DIRECT OUTPUT B IS PLUGGED 2 gt FOR SINGLE ACTING REVERSE OUTPUT A IS PLUGGED 49B3261 C SHT 2 91 Parts Instruction Manual November 2015 D103785X012 Figure 7 4 FIELDVUE DVC6015 Remote Feedback Unit Assembly AN m p E A A i SECTION B B gt n AT hee SUIL APPLY LUB SEALANT SECTION A A SECTION D D NOTE 1 APPLY LUBRICANT KEY 65 TO ALL O RINGS UNLESS OTHERWISE SPECIFIED 49B7986 A 92 Parts November 2015 Instruction Manual 0103785 012 Figure 7 5 FIELDVUE DVC6025 Remote Feedback Unit Assembly SECTION B B SECTION A A 1 APPLY LUBRICANT KEY 65 TO ALL O RINGS UNLESS OTHERWISE SPECIFIED 49B7987 A 1 APPLY LUB SEALANT THREAD LOCK NOTE 93 Parts Instruction Manual November
22. Belden 9501 cable Voltage available 18 5 volts at 21 05 mA 2 3 volts 48 ohms 0 02105 amps Voltage available 18 5 2 3 1 01 Voltage available 15 19 volts Figure 2 2 Determining Voltage Available at the Instrument TOTAL LOOP THUM ADAPTER CABLE RESISTANCE IF USED COMPLIANCE VOLTAGE CONTROL SYSTEM VOLTAGE HARTFILTER AVAILABLE AT THE if used if used INSTRUMENT Calculate Voltage Available at the Instrument as follows Example Calculation Control system compliance voltage 18 5 volts at 21 05 mA Filter voltage drop if used 1 2 3 volts for HF300 filter Intrinsic safety barrier resistance if used x maximum loop current 2 55 volts 121 ohms x 0 02105 amps Smart Wireless THUM adapter voltage drop if used 2 Total loop cable resistance x maximum loop current 1 01 volts 48 ohms x 0 02105 amps for 1000 feet of Belden 9501 cable Voltage available at the instrument 15 19 volts available if safety barrier 2 55 volts is not used NOTES Obtain filter voltage drop The measured drop will be different than this value The measured filter voltage drop epends upon control system output voltage the intrinsic safety barrier if used and the instrument See note 3 25 The voltage drop of the THUM adapter is linear from 2 25 volts at 3 5 mA to 1 2 volts at 25 mA The voltage available at the instrument is not the voltage measured at the instrument t
23. Filter ODV devices have access to a lead lag set point filter that can be used to improve a valve s dynamic response The lead lag filter is part of the set point processing routine that reshapes the input signal before it becomes travel set point Lead lag filters are characterized by lead and lag time constants Note Lead Lag is only available for instrument level ODV When the valve is in its active control region off the seat the lead lag filter improves small amplitude response by momentarily overdriving the travel set point This is useful when the actuator is large and equipped with accessories As a result any volume boosters that are present will be activated The longer the lag time the more pronounced the overdrive Since the lead lag input filter is used to enhance the dynamic response of a control valve filter parameters should be set after the tuning parameters have been established When the valve is at its seat the lead lag filter also has a boost function that sets the initial conditions of the filter artificially low so that small amplitude signal changes appear to be large signal changes to the filter The boost function introduces a large spike that momentarily overdrives the instrument and activates any external volume boosters that may be present The lead lag boost function is normally disabled except for those cases where the valve must respond to small command signals off the seat By setting the lead lag ratio in the ope
24. Integral Enable Yes or No Enable the pressure integral setting to improve static performance by correcting for error that exists between the pressure target and actual pressure Pressure Integral Control is disabled by default e Integral Gain Pressure Integral Gain also called reset is the gain factor applied to the time integral of the error signal between desired and actual pressure Changing this parameter will also change the tuning set to Expert Travel Pressure Integral Settings e Integral Dead Zone A window around the Primary Setpoint in which integral action is disabled This feature is used to eliminate friction induced limit cycles around the Primary Setpoint when the integrator is active The Dead Zone is configurable from 0 to 2 corresponding to a symmetric window from 0 to 2 around the Primary Setpoint Default value is 0 25 31 Configuration Instruction Manual November 2015 D103785X012 e Integrator Limit The Integrator Limit provides an upper limit to the integrator output The high limit is configurable from 0 to 100 of the drive signal Valve and Actuator Field Communicator Configure gt Manual Setup gt Valve and Actuator 2 2 5 Valve Style Enter the valve style rotary or sliding stem Actuator Style Enter the actuator style spring and diaphragm piston double acting without spring piston single acting with spring or piston double acting with spring View Edit Feedback Connection
25. Note Another mode Test may be displayed Normally the instrument should not be in the Test mode The digital valve controller automatically switches to this mode whenever it needs to stroke the valve during calibration or stroke valve for example However if you abort from a procedure where the instrument is in the test mode it may remain in this mode To take the instrument out of the Test mode select Change Control Mode and enter Analog or Digital e Change Control Mode Allows you to configure the control mode to Analog or Digital e Restart Control Mode Defines the Control Mode of the instrument after a restart e g power cycle Available choices are Resume Last Analog and Digital Characterization e Input Characterization Input Characterization defines the relationship between the travel target and ranged set point Ranged set point is the input to the characterization function If the zero power condition equals closed then a set point of 0 corresponds to a ranged input of 0 If the zero power condition equals open a set point of 0 corresponds to a ranged input of 100 Travel target is the output from the characterization function To select an input characterization select Input Characterization from the Characterization menu You can select from the three fixed input characteristics shown in figure 3 2 or you can select a custom characteristic Figure 3 2 shows the relationship between the travel target and ranged set
26. Range Low 2 2 3 4 AD PD Pressure Fallback 1 Tvl Dev Press Fallback 2 Tvl Dev Press Fallback Time 3 Fallback Recovery 2 2 3 4 HC 2 2 3 5 AD PD Control Mode 1 Control Mode 2 Change Control Mode 3 Restart Control Mode 103 Field Communicator Menu Trees Instruction Manual November 2015 0103785 012 Figure B 8 Manual Setup gt Tuning 2 2 4 through Manual Setup gt Outputs 2 2 7 Tuning 1 Travel Tuning Manual Setup 1 Mode and Protection 2 Instrument 3 Travel Pressure Control 4 Tuning 5 Valve and Actuator WITH I O PACKAGE Lid lt lt O WITH I O PACKAGE 2 2 6 HD AD PD 2 2 7 ODV Outputs 1 Output Terminal Config 2 Switch Configuration 3 Transmitter Output Q 4 HART Var Assignments 5 Burst Mode 2 2 6 1 HC AD PD 2 2 7 1 ODV 2 2 6 5 HC AD PD Output Terminal Config 2 2 7 5 ODV Burst Mode 1 Burst Enable 2 Burst Command 1 Output Terminal Enable 2 Function 3 Fail Signal 2 2 6 2 HC AD PD 2 2 7 2 ODV Switch Configuration 1 Limit Switch Trip Point 2 Alert Switch Source 2 2 6 4 HC AD PD 2 2 7 4 ODV HART Var Assignments 1 Primary Variable PV 2 Secondary Variable SV 3 Tertiary Variable TV 3 Switch Closed 4 Quaternary Variable QV NOTES PARTIAL STROKE TEST PST IS AVAILABLE FOR INSTRUMENT LEVEL ODV THIS MENU ITEM IS HART VAR ASSIGNMENTS WITH HART
27. Select 23 Fast Key Sequences Field Communicator 99 114 Instruction Manual D103785X012 Field Communicator Partial Stroke Test 61 Field Communicator Menu Trees 99 Field Device Malfunction 57 Filter Settings Typical Lead Lag 27 Flash Integrity Failure 56 FM Hazardous Area Approvals 6 frequency shift keying FSK 95 FSETAN Russia Kazakhstan Belarus and Armenia Certifications 6 Function Output Terminal Configuration Alert Switch 37 Limit Switch 37 Transmitter 37 G Gain Values Pressure Tuning Sets 31 Travel Tuning Sets 28 Gauges Tire Valves amp Pipe Plugs Parts List 88 Replacing 72 Guided Setup 19 H HART Communication principle of operation 95 HART Filter 9 Part Numbers 88 HART Long Tag 20 HART Tag 20 HART Tri Loop 17 Installation Flowchart 17 HART Variable Assignments 38 HARTr communications protocol 3 Hazardous Area Approvals CSA FM ATEX IECEx 6 Hi Limit Cutoff Point 23 Hi Limit Cutoff Select 23 Humidity Testing Method 6 Instruction Manual D103785X012 I P Converter Parts List 86 Removing 68 Replacing 68 Replacing Filter 67 IECEx Hazardous Area Approvals 6 Independent Linearity 5 INMETRO Brazil Certification 6 Input Characterization 25 Input Impedance 6 Input Range 21 Input Range Hi 21 Input Range Lo 22 Input Signal 5 Installation 3 Instrument Level Capabilities 4 Instrument Mode 20 Instrument Tim
28. Select Rotary All SStem Roller or SStem Standard For rotary valves enter Rotary All SStem Roller For sliding stem valves if the feedback linkage consists of a connector arm adjustment arm and feedback arm similar to figure 3 3 enter SStem Standard If the feedback linkage consists of a roller that follows a cam similar to figure 3 4 enter Rotary SStem Roller Figure 3 3 Feedback Connection for Typical Figure 3 4 Feedback Connection for Typical Sliding Stem Actuator Up to 4 inch Travel Long Stroke Sliding Stem Actuator 4 to 24 Inches Travel TRAVEL SENSOR SHAFT C M AER I aa FEEDBACK ARM ADJUSTMENT CONNECTOR f CONNECTOR 0914 Relay Type There three categories of relays that result in combinations from which to select Relay Type The relay type is printed on the label affixed to the relay body A double acting or single acting B single acting reverse C single acting direct Special App This is used in single acting applications where the unused output port is configured to read the pressure downstream of a solenoid valve Lo Bleed The label affixed to the relay body indicates whether it is a low bleed version 32 Instruction Manual Configuration D103785X012 November 2015 Zero Power Condition The position of the valve open or closed when the electrical power to
29. Stroke Pressure Limit Open Pmin 0 25 Bench Set High Bench Set Low Closed Pmax 0 25 Bench Set High Bench Set Low Open Pmax 0 25 Bench Set High Bench Set Low Closed Pmin 0 25 Bench Set High Bench Set Low Open Pmax 0 25 Bench Set High Bench Set Low Closed Pmin 0 25 Bench Set High Bench Set Low Open Pmin 0 25 Bench Set High Bench Set Low Closed Pmax 0 25 Bench Set High Bench Set Low Zero Power Condition PST Starting Point Closed Open Spring and Diaphragm Closed U 5 0 5 Pmin Closed Pmax 0 5 Psupply Pmax Open Open Pmax 0 5 Psupply Pmax Closed 0 5 Pmin Open Pmax 0 5 Psupply Pmax Closed 0 5 Pmin Open 0 5 Pmin Closed Pmax 0 5 Psupply Pmax Single Acting Piston Open Pmin 0 5 Psupply Pmin Closed Pmax 0 5 Psupply Pmax Double Acting Piston Open Pmax 0 5 Psupply Pmax Closed Pmin 0 5 Psupply Pmin 5 Enable the parameters that were previously disabled e Travel Deviation Alert set to 1 5 x the maximum travel deviation between travel set point and travel e End Point Pressure Control enable e Partial Stroke Pressure Limit calculate the value using table 3 7 35 Configuration Instruction Manual November 2015 D103785X012 PST Enable Yes or No This enables or disables the Partial Stroke Test PST Start Point Valve Open or Valve Closed This defines the travel sto
30. Tri Loop to receive digital valve controller burst commands Check Pass system troubleshooting test procedures in HART Tri Loop product manual 17 Wiring Practices Instruction Manual November 2015 D103785X012 Commissioning the Digital Valve Controller for use with the HART Tri Loop Signal Converter To prepare the digital valve controller for use with a 333 HART Tri Loop you must configure the digital valve controller to burst mode and select Burst Command 3 In burst mode the digital valve controller provides digital information to the HART Tri Loop HART to Analog Signal Converter The HART Tri Loop converts the digital information to a 4 to 20 mA analog signal Each burst message contains the latest value of the primary analog input secondary travel target tertiary configured output pressure and quaternary travel variables To commission a DVC6000 HW2 for use with a HART Tri Loop perform the following procedures Note The DVC6000 HW2 must be in HART 5 compatibility mode to use burst communications Enable Burst Operation With I O Package Configure gt Manual Setup gt Outputs gt Burst Mode 2 2 6 5 HC AD PD or 2 2 7 5 ODV Without I O Package Configure gt Manual Setup gt Outputs gt Burst Mode 2 2 6 2 HC AD PD or 2 2 7 2 ODV Field Communicator Select Burst Enable and follow the prompts to enable burst mode Then select Burst Command and follow the prompts to configure Loop Curre
31. bar 20 7 kPa 0 30 psi 0 0207 bar 2 07 kPa 0 03 psi 0 00207 bar 0 207 kPa respectively If the displayed value does not match the output pressure press OK then repeat this step step 4 to further adjust the displayed value When the displayed value matches the output pressure select Done and go to step 5 5 The instrument sets the output pressure to full supply The following message appears Use the Increase and Decrease selections until the displayed pressure matches the output x pressure Press OK when you have read the message 6 The value of the output pressure appears on the display Press OK to display the adjustment menu 7 From the adjustment menu select the direction and size of adjustment to the displayed value If the displayed value does not match the output pressure press OK then repeat this step step 7 to further adjust the displayed value When the displayed value matches the output pressure select Done and go to step 8 8 Place the instrument In Service and verify that the displayed pressure matches the measured output pressure 46 Instruction Manual Calibration D103785X012 November 2015 Supply Pressure Sensor Note Supply Pressure Sensor Calibration is not available for instrument level HC To calibrate the supply pressure sensor connect an external reference gauge to the output side of the supply regulator The gauge should be capable of measuring maximum instrument supply pressure
32. below Emissions Class A ISM equipment rating Group 1 Class A Lightning and Surge Protection The degree of immunity to lightning is specified as Surge immunity in table 1 3 For additional surge protection commercially available transient protection devices can be used Vibration Testing Method Tested per ANSI ISA S75 13 01 Section 5 3 5 A resonant frequency search is performed on all three axes The instrument is subjected to the ISA specified 1 2 hour endurance test at each major resonance Input Impedance An equivalent impedance of 500 ohms may be used This value corresponds to 10V 20 mA Humidity Testing Method Tested per IEC 61514 2 Electrical Classification Hazardous Area Approvals CSA Intrinsically Safe Explosion proof Division 2 Dust Ignition proof FM Intrinsically Safe Explosion proof Dust Ignition proof Non Incendive ATEX Intrinsically Safe Flameproof IECEx Intrinsically Safe Flameproof Type n Electrical Housing CSA Type 4X IP66 FM Type 4X IP66 ATEX IP66 IECEx IP66 Other Classifications Certifications CUTR Customs Union Technical Regulations Russia Kazakhstan Belarus and Armenia INMETRO National Institute of Metrology Quality and Technology Brazil continued Instruction Manual D103785X012 PESO CCOE Petroleum and Explosives Safety Organisation Chief Controller of Explosives India Contact your Emerson Process
33. no further user interactions with the auto calibration routine go to step 6 Use this selection if you cannot use manual such as when you cannot see the valve If you select Default an approximate value for the crossover is written to the instrument and there are no further user interactions with the auto calibration routine go to step 6 Use this selection only as a last resort Default assumes a midrange position on the travel sensor as the crossover point however this may not be an appropriate value to use for crossover because of variations in mounting and travel sensor calibration 2 The instrument seeks the high and low drive points and the minor loop feedback MLFB and output bias No user interaction is required in this step For a description of these actions see step 6 3 If you select Manual in step 1 you are asked to select an adjustment source either analog or digital If you use a current source to adjust the crossover select Analog and go to step 4 If you wish to adjust the current source digitally select Digital and go to step 5 4 f you selected Analog as the crossover adjustment source the Field Communicator prompts you to adjust the current source until the feedback arm is 90 to the actuator stem as shown in figure 4 1 After you have made the adjustment press OK and go to step 6 5 If you selected Digital as the crossover adjustment source the Field Communicator displays a menu to allow you to adjust the
34. reported by the digital valve controller is displayed on the Field Communicator 7 Oncethe valve has reached the endpoint check that the valve has reached the desired set point The valve should return to its original position For information on configuring the Partial Stroke Test see Partial Stroke Variables in the Detailed Setup section Variables Field Communicator Service Tools Variables 3 4 The Variables section provides current values of the instrument variables Below is a list of the variables available for viewing e Write Protection also provides a procedure to enable disable e Instrument Mode also provides a procedure to place in out of service e Analog Input e Setpoint e Travel e Drive Signal e Input Characterization also provides a procedure to modify e Cycle Counter e Travel Accumulator e Supply Pressure not available in Instrument Level HC 61 Device Information Diagnostics and Alerts November 2015 62 Actuator Pressure s Travel Pressure Control Configuration also provides a procedure to modify Control Mode also provides a procedure to modify Instrument Temperature Travel Counts this is the raw travel sensor reading used for advanced adjustments Maximum Recorded Temperature Minimum Recorded Temperature Number of Power Ups Days Powered Up Instruction Manual D103785X012 Instruction Manual Maintenance and Troubleshooting D103785X012 November 2015 Section 6 Mainten
35. rotary applications Mounting kit required for mounting feedback unit on actuator Mounting the instrument vertically with the vent at the bottom of the assembly or horizontally with the vent pointing down is recommended to allow drainage of moisture that may be introduced via the instrument air supply Communication Protocol B HART 5 or Bl HART 7 Input Signal Point to Point Analog Input Signal 4 20 mA DC nominal split ranging available Minimum Voltage Available at Instrument Terminals must be 9 5 VDC for analog control 10 VDC for HART communication Minimum Control Current 4 0 mA Minimum Current w o Microprocessor Restart 3 5 mA Maximum Voltage 30 VDC Overcurrent protected Reverse Polarity protected Multi drop Instrument Power 11 to 30 VDC at 10 mA Reverse Polarity protected Supply Pressure 2 Minimum Recommended 0 3 bar 5 psig higher than maximum actuator requirements Maximum 10 0 bar 145 psig or maximum pressure rating of the actuator whichever is lower Medium Air or Natural Gas Supply medium must be clean dry and non corrosive Introduction November 2015 Per ISA Standard 7 0 01 A maximum 40 micrometer particle size in the air system is acceptable Further filtration down to 5 micrometer particle size is recommended Lubricant content is not to exceed 1 ppm weight w w or volume v v basis Condensation in the air supply should be minimized Per ISO 8573 1 Maximum particle densit
36. the four screws that attach the relay key 24 to the module base These screws are captive in the relay 2 Remove the relay Replacing the Pneumatic Relay 1 Visually inspect the holes in the module base to ensure they are clean and free of obstructions If cleaning is necessary do not enlarge the holes 2 Apply silicone lubricant to the relay seal and position it in the grooves on the bottom of the relay as shown in figure 6 6 Press small seal retaining tabs into retaining slots to hold relay seal in place 3 Position the relay with shroud on the module base Tighten the four screws in a crisscross pattern to a final torque of 2 Nem 20 7 Ibfein 4 Using the Field Communicator verify that the value for the parameter Relay matches the relay type installed 5 After replacing the relay and verifying the relay type calibrate travel or perform touch up calibration to maintain accuracy specifications Figure 6 6 Pneumatic Relay Assembly RELAY SEAL W8074 71 Maintenance and Troubleshooting Instruction Manual November 2015 D103785X012 Gauges Pipe Plugs or Tire Valves Depending on the options ordered the DVC6000 HW2 will be equipped with either gauges key 47 pipe plugs key 66 ortire valves key 67 Single acting direct instruments will also have a screen key 236 figure 7 3 These are located on the top of the module base next to the relay Perform the following procedure to replace the gauges tire val
37. the valve in the application up to 12 characters Units e Pressure Units Defines the output and supply pressure units in either psi bar kPa or kg cm2 e Temperature Units Degrees Fahrenheit or Celsius The temperature measured is from a sensor mounted on the digital valve controller s printed wiring board e Analog Input Units Permits defining the Analog Input Units in mA or percent of 4 20 mA range Terminal Box e Calibration CAL Button This button is near the wiring terminals in the terminal box and provides a quick means to autocalibrate the instrument The button must be pressed for 3 to 10 seconds Autocalibration will move the valve through the full range of travel whether the Instrument Mode is In Service or Out of Service However if the Write Protection is Protected this button will not be active To abort press the button again for 1 second The calibration button is disabled by default e Auxiliary Terminal Action These wire terminals can be configured to initiate a partial stroke test upon detection of a short across the and terminals The terminals must be shorted for 3 to 10 seconds Note Auxiliary Terminal Action is only available for instrument level ODV Analog Input Range e Input Range Hi Permits setting the Input Range High value Input Range High should correspond to Travel Range High if the Zero Power Condition is configured as closed If the Zero Power Condition is configured as open Inp
38. to the feedback arm key 79 if not already installed 5 Attach the feedback arm key 79 to the travel sensor shaft 6 Using a Field Communicator perform the appropriate Travel Sensor Adjust procedure in the Calibration section Install the remote feedback unit on the actuator when travel sensor adjustment is complete Note If a Field Communicator is not available perform the Travel Sensor Adjustment with a Multimeter procedure below Travel Sensor Adjustment with a Multimeter DVC6035 1 Align the feedback arm key 79 to the housing key 1 by inserting the alignment pin key 46 through the hole marked A on the feedback arm Fully engage the alignment pin into the tapped hole in the housing Position the feedback arm so that the outer surface is flush with the end of the travel sensor shaft 2 Connect a multimeter set to a resistance range of 50 000 ohms Measure the resistance between terminals 1 and 3 of the remote feedback unit Refer to figure 6 8 for terminal location The resistance should be between 40 000 and 50 000 ohms 3 Multiply the result in step 2 by 0 042 to get a calculated resistance The calculated resistance should be in the range of 1680 to 2100 ohms 4 Re range the multimeter to a resistance of 3000 ohms between terminals 2 and 3 of the remote feedback unit Refer to figure 6 8 for terminal location 5 Adjust the travel sensor shaft to obtain the calculated resistance determined in step 3 100 oh
39. travel sensor reading the Travel variable will report pressure in percent of bench set range 38 Instruction Manual Configuration D103785X012 November 2015 Alert Setup Configure gt Alert Setup 2 3 An alert is a notification that the instrument has detected a problem A shutdown is an action that the instrument takes to drive the air output to the Zero Power Condition as per figure 3 5 Some alerts can be configured to shutdown the instrument Refer to table 3 8 for default alert and shutdown settings Alerts may be enabled or disabled with the instrument In Service Out of Service Protected or Not Protected However the instrument must be Not Protected to enable or disable a shutdown Alerts are not processed when a diagnostic is in progress If shutdown is enabled and the alert is active the instrument will latch in the shutdown state until power to the instrument is cycled and the alert has cleared While in the shutdown condition HART communication will continue if the instrument remains powered For a detailed explanation of the alerts and the recommended actions refer to Section 5 Table 3 8 Default Alert and Shutdown Settings ALERT DEFAULT ALERT SETTING DEFAULT SHUTDOWN SETTING ee 222 Enabled Critical NVM Failure Disabled Non Critical NVM Failure Disabled Flash Integrity Failure Disabled Reference Voltage Failure Disabled Drive Signal Out of Range Enabled Not Available Supply Pressure Low Not Available Tr
40. 015 Using a Potentiometer with Two Fixed Resistors as a Remote Travel Sensor Perform the following procedure if a potentiometer is used with the same or slightly longer travel than the actuator s travel Note The potentiometer must be capable of resistance close to 0 Ohms CAUTION To prevent damage to the potentiometer ensure that it is free to travel the entire length of the actuator s travel Note The digital valve controller must be configured using the SStem Roller selection on the menu of the appropriate setup device This procedure uses three resistors connected in series two fixed resistors and one potentiometer Three conditions must be met for the resistor combination to correctly operate the digital valve controller e The maximum resistance of the potentiometer Rpot max must be between 3 9 kOhm and 10 kOhm e The resistance of Rj is 4 25 times greater than Rpot max e The resistance of is 4 times less than Rpot max WARNING To avoid personal injury or property damage from an uncontrolled process ensure that the R1 resistor is properly insulated before installing it in the terminal box 1 On the base unit remove the feedback connections terminal box cap 2 If necessary install conduit between the two resistor series and the base unit following applicable local and national electrical codes Route the 3 conductor shielded cable between the two units refer to figure 2 5 15 Wiring Practices Inst
41. 1 Instrument Mode B 1 B 6 IN _ _ Instrument Time Approximate Enable B8 Cycle Count Alert An mes Gain Cyl Coun Foe ated gh rable 89 miegstrSaumatedlotnbie eo Cyde Count Travel Acem Deadband BS Days Powered Up B 11 Intgegral Dead Zone B 8 DD information T 0 86 Device Revision Lever Arm Length ese Drive Current Failure Shutdown B 9 IDE SIE Valve Close int Sith ke Open E a 5 99 Field Communicator Menu Trees Instruction Manual November 2015 D103785X012 Function Variable Lo Limit Cutoff Point B 7 B 9 Manual Calibration B 10 Manufacturer Device Maximum Supply Pressure Minor Loap Sensor Failure Shutdown 88 Non Crifa NVA Flare Shutdown 89 1 Output Crate Comm Fare ES MEN Packing Type Partial Stroke Test B 11 Partial Stroke Test PST B 8 ae feo 88 Position Transmite Pressure A B 3 B 11 Pressure A B B 3 B 11 Pressure B B 3 B 11 Pressure FallbackActwe tnae fes CO Pressure Sensor Failure shutdown B9 8 Pressure Units B NENNEN PST Enable 8 PST Start Point PST Variables 86 Stabilize Optimize Stem Diameter B6
42. 15 Pressure Tuning e Pressure Tuning Set There are twelve Pressure Tuning Sets to choose from Each tuning set provides a preselected value for the digital valve controller gain settings Tuning set C provides the slowest response and M provides the fastest response Tuning set B is appropriate for controlling a pneumatic positioner Table 3 5 lists the proportional gain pressure integrator gain and minor loop feedback gain values for preselected tuning sets Table 3 5 Gain Values for Preselected Pressure Tuning Sets Tuning Set Proportional Gain Integrator Gain Minor Loop Feedback Gain MW D E F G H J K L M X Expert User Adjusted User Adjusted User Adjusted In addition you can specify Expert tuning and individually set the pressure proportional gain pressure integrator gain and pressure minor loop feedback gain Individually setting or changing any tuning parameter will automatically change the tuning set to X expert Note Use Expert tuning only if standard tuning has not achieved the desired results Stabilize Optimize or Performance Tuner may be used to achieve the desired results more rapidly than Expert tuning Proportional Gain The proportional gain for the pressure control tuning set Changing this parameter will also change the tuning set to Expert MLFB Gain The minor loop feedback gain for the pressure control tuning set Changing this parameter will also change the tuning set to Expert
43. 16 6 4 kOhm e R4 6 4kOhm x 4 25 27 2 kOhm e R 6 4 kOhm 47 1 6 kOhm Instruction Manual D103785X012 Wiring Practices November 2015 Installation in Conjunction with a Rosemount 333 HART Tri Loop HART to Analog Signal Converter Use the DVC6000 HW2 digital valve controller in operation with a Rosemount 333 HART Tri Loop HART to Analog Signal Converter to acquire an independent 4 20 mA analog output signal for the analog input travel target pressure or travel The HART Tri Loop accepts any three of these digital signals and converts them into three separate 4 20 mA analog channels Refer to figure 2 6 for basic installation information Refer to the 333 HART Tri Loop HART to Analog Signal Converter Product Manual for complete installation information Figure 2 6 HART Tri Loop Installation Flowchart START HERE Unpack the HART Tri Loop Review the HART Tri Loop Product Manual Digital valve controller Installed Set the digital valve controller Burst Option Set the digital valve controller Burst Mode E0365 Install the digital valve controller Install the HART Tri Loop See HART Tri Loop product manual Mount the HART Tri Loop to the DIN rail Wire the digital valve controller to the HART Tri Loop Install Channel 1 wires from HART Tri Loop to the control room Optional Install Channel 2 and 3 wires from HART Tri Loop to the control room Configure the HART
44. 19B5403X012 19B5405X012 14B5072X112 14B5072X092 14B5072X182 Parts November 2015 Kit Description Part Number Note The following terminal boxes are only compatible with PWB Assembly electronics hardware revision 2 HW2 key 50 as shown in figure 7 1 Use only with replace in kind 7 Terminal Box Kit Without I O Package Standard Temperature nitrile elastomers 19B5401X142 Extreme Temperature fluorosilicone elastomers 19B5401X152 Without I O Package Natural Gas Approved Standard Temperature nitrile elastomers 19B5401X162 Extreme Temperature fluorosilicone elastomers 19B5401X172 With I O Package Standard Temperature nitrile elastomers 19B5401X182 Extreme Temperature fluorosilicone elastomers 19B5401X192 85 Parts November 2015 Kit Description Part Number 8 Converter Kit Standard 38B6041X152 For Extreme Temperature option fluorosilicone elastomers 38B6041X132 9 Adjustment Arm Kit includes washer nut and adjustment arm 14B5072X132 10 Spare Module Base Assembly Kit kit contains module base key 2 drive screws qty 2 key 11 shield label key 19 hex socket cap screw qty 3 key 38 self tapping screw qty 2 key 49 pipe plug qty 3 key 61 retaining ring qty 3 key 154 screen key 236 and flame arrestors qty 3 key 243 GE18654X012 11 Spare Shroud Kit GE29183X012 12 Remote Travel Sensor Assembly Note Contact your Emerson Process Management sales offic
45. 3 2 2 HC 2 3 2 AD PD ODV 2 3 3 2 AD PD ODV Supply Pressure Lo Alert lt 1 Travel Deviation 1 Travel Deviation 2 Travel Deviation Alert Enable 1 Supply Pressure Lo Alert Enable Alert Setup 2 Supply Pressure Lo Alert Point 3 Travel Deviation Alert Point 4 Travel Deviation Time Electronics Supply Pressure Alert 2 3 2 HC Travel 2 3 3 AD PD ODV 2 3 2 3 HC 1 2 3 4 Pressure Fallback Travel 2 3 3 3 AD PD ODV 5 Travel History 6 7 8 9 EPPC Deviation 1 Travel Alert DB Output Circuit Comm Failure Enable 447 2 Travel Deviation 1 Travel Alert Hi Hi Enable Shutdown On Alert 3 Travel Limit 2 Travel Alert Hi Hi Point Alert Record Instrument Time 4 Travel Limit Cutoff 3 Travel Alert Lo Lo Enable 4 Travel Alert Lo Lo Point 5 Travel Alert Hi Enable 5 Integrator 2 3 5 HC 2 3 2 5 HC 6 Travel Alert Hi Point 2 3 7 AD PD 2 3 3 5 AD PD ODV pts 7 Travel Alert Lo Enable 2 3 9 ODV I Integrator 8 Travel Alert Lo Point 1 Integrator Sat Hi Enable 2 Integrator Sat Lo Enable 2 3 2 4 HC 2 3 3 4 AD PD ODV Travel Limit Cutoff Alert Record Instrument Time 1 Alert Record Not Empty Enable 2 Alert Record Full Enable 3 View Alert Records 4 Clear Records 5 Instrument Alert Record 6 Instrument Time is Approximate Enable 7 EditInstrument Time 2 3 4 AD PD ODV 2 Hi Limit Cutoff Point 1 Pressure Fallback Active Enable 3 Hi Limit Cutoff Selec
46. 4 5 FIELDVUE DVC6025 Travel Sensor Arm Housing Back Plane Alignment BACK EDGE OF ARM PARALLEL W BACK OF HOUSING ARM ASSEMBLY ARM ASSEMBLY PIN RO TRAVEL SENSOR SHAFT BACK OF HOUSING 22 7025 Analog Input Calibration To calibrate the analog input sensor connect a variable current source to the instrument LOOP and LOOP terminals The current source should be capable of generating an output of 4 to 20 mA Follow the prompts on the Field Communicator display to calibrate the analog input sensor 1 Set the current source to the target value shown on the display The target value is the Input Range Low value Press OK 2 The following message appears Use the Increase and Decrease selections until the displayed current matches the target Press OK when you have read this message 51 Calibration Instruction Manual November 2015 D103785X012 3 The value of the Analog Input appears on the display Press OK to display the adjustment menu 4 From the adjustment menu select the direction and size of adjustment to the displayed value Selecting large medium and small adjustments causes changes of approximately 0 4 mA 0 04 mA and 0 004 mA respectively If the displayed value does not match the current source press OK then repeat this step step 4 to further adjust the displayed value When the displayed value matches the current sourc
47. 41 is located on the front of the module base Note After I P converter submodule replacement calibrate the digital valve controller to maintain accuracy specifications Replacing the I P Filter A screen in the supply port beneath the I P converter serves as a secondary filter for the supply medium To replace this filter perform the following procedure 1 Remove the I P converter key 41 and shroud key 169 as described in the Removing the Converter procedure 2 Remove the screen key 231 from the supply port Maintenance and Troubleshooting Instruction Manual November 2015 D103785X012 3 Install a new screen in the supply port as shown in figure 6 3 4 Inspect the O ring key 39 in the output port if necessary replace it 5 Reinstall the I P converter key 41 and shroud key 169 as described the Replacing the I P Converter procedure Figure 6 3 I P Filter Location O RING LOCATED CONVERTER SCREEN FILTER LOCATED IN I P OUTPUT PORT CONVERTER SUPPLY PORT Removing the I P Converter 1 Remove the front cover key 43 if not already removed 2 Refer to figure 6 4 Using a 2 5 mm hex socket wrench remove the four socket head screws key 23 that attach the shroud key 169 and I P converter key 41 to the module base key 2 3 Remove the shroud key 169 then pull the converter key 41 straight out of the module base key 2 Be careful not to damage the two electrical leads tha
48. 6 032 Single acting reverse relay 38B5786X102 Low Bleed Single acting direct relay C 38B5786X162 Double acting relay A 38B5786X082 Single acting reverse relay B 38B5786X122 Terminal Box 4 Terminal Box 13 34 0 7 13 36 0 7 13 44 Wire Retainer pl 54122 6 req d not shown 58 Set Screw hex socket SST 2 13 72 Screw hex socket SST 2 13 164 Terminal Box Assembly Feedback Connections Terminal Box 4 Terminal Box 13 34 QO ring 1 7 13 36 O ring 7 13 44 Wire Retainer pl 5412 14 5 req d not shown 58 Set Screw hex socket 5572 13 62 PipePlug hex hd SST 3 72 Screw hex socket SST 2 13 3 req d 262 Adapter 3 263 O ring Standard Extreme temperature option fluorosilicone 264 Terminal Box Assembly remote 13 Recommended spare 1 Available in the Elastomer Spare Parts Kit 2 Available in the Small Hardware Spare Parts Kit 7 Available in the Terminal Box Kit 13 Available in the Remote Terminal Box Kit Parts November 2015 Figure 7 1 Terminal Box WITHOUT I O PACKAGE WITH I O PACKAGE Key Description PWB Assembly 50 PWB Assembly for DVC6005 HW2 Note The following PWB Assemblies are only compatible with the terminal boxes shown in figure 7 1 Hardware Revision 2 HW2 without I O Package For instrument level HC For instrument level AD For instrument level PD For instrument level ODV Hardware Revision 2 HW2
49. 6 While observing the resistance tighten the screw key 80 to secure the feedback arm to the travel sensor shaft Be sure the resistance reading remains at the calculated resistance determined in step 3 100 ohms Paint the screw to discourage tampering with the connection 7 Disconnect the multimeter from the travel sensor connector 8 Travel sensor adjustment is complete Install the remote feedback unit on the actuator DVC6025 Feedback Unit Refer to figure 7 5 for DVC6025 key number locations 1 Insert the travel sensor assembly key 223 into the housing Secure the assembly with screw key 72 2 Connect the travel sensor assembly wires to the terminals as follows red terminal 1 white terminal 2 black terminal 3 3 Loosely assemble the screw key 80 plain washer key 163 and nut key 81 to the arm assembly key 91 if not already installed 4 Attach the arm assembly key 91 to the travel sensor assembly key 223 shaft 76 Instruction Manual Maintenance and Troubleshooting D103785X012 November 2015 Figure 6 8 Remote Feedback Terminals Potentiometer Resistance Measurement TERMINAL 2 TERMINAL 3 TERMINAL 1 5 Using a Field Communicator perform the appropriate Travel Sensor Adjust procedure in the Calibration section Install the remote feedback unit on the actuator when travel sensor adjustment is complete Note If a Field Communicator is not available perform the Travel Sensor Adju
50. Close 7 Outputs 3 View Edit Lag Time 2 2 Characterization 1 Input Characterization 2 2 3 2 Custom Characterization Travel Pressure Control ODV Travel Pressure Select 2 2 3 2 Cutoffs and Limits gt Cutoffs and Limits 1 Hi Limit Cutoff Select 2 HiLimit Cutoff Point End Point Pressure Control EPPC Pressure Control Pressure Fallback Control Mode Response Control 3 Lo Limit Cutoff Select 4 Lo Limit Cutoff Point 2 2 3 3 1 EPPC Enab 2 Change EPPC Enab Dynamic Response 2 2 3 8 Dynamic Response pt 1 SP Rat SP Rate Open 3 EPPC Set Point 4 EPPC Saturation Time 2 SP Rate Close 3 View Edit Lead Lag 2 2 3 4 Pressure Control 1 Pressure Range High 2 Pressure Range Lo 2 2 3 5 Pressure Fallback 1 Tvl Dev Press Fallback Characterization 1 Input Characterization 2 Custom Characterization 2 2 3 6 Control Mode 1 Control Mode 2 Change Control Mode 3 Restart Control Mode 2 Tvl Dev Press Fallback Time 3 Fallback Recovery NOTE 1 gt PRESSURE FALLBACK IS AVAILABLE FOR INSTRUMENT LEVEL AD PD AND ODV End Point Pressure Control EPPC Field Communicator Menu Trees November 2015 2 2 3 2 2 Cutoffs and Limits gt Cutoffs and Limits 1 Hi Limit Cutoff Select 2 Hi Limit Cutoff Point 3 Lo Limit Cutoff Select 4 Lo Limit Cutoff Point 2 2 3 3 Pressure Control 1 Pressure Range High 2 Pressure
51. Drive Signal Test amp Dynamic Error Band X X X Advanced Diagnostics Valve Signature Lo Performance Tuner Travel Control Pressure Fallback e NENNEN SupiPesweSemor PefomameDagmsiG _ SolencidValveTesting _ LeadjlagSetPointFite __ _ 1 Refer to brochure part 0351146 012 0351146 412 for information on Fisher optimized digital valves for compressor antisurge applications 2 HC HART Communicating AD Advanced Diagnostics PD Performance Diagnostics ODV Optimized Digital Valve Specifications WARNING Refer to table 1 2 for specifications Incorrect configuration of a positioning instrument could result in the malfunction of the product property damage or personal injury Specifications for DVC6000 HW2 digital valve controllers are shown in table 1 2 Specifications for the Field Communicator can be found in the product manual for the Field Communicator Instruction Manual D103785X012 Table 1 2 Specifications Available Mounting DVC6000 HW2 digital valve controllers can be mounted on Fisher and other manufacturers rotary and sliding stem actuators 1 DVC6005 HW2 Base unit for 2 inch pipestand or wall mounting DVC6015 Remotely mounted feedback unit for sliding stem applications DVC6025 Remotely mounted feedback unit for rotary or long stroke sliding stem applications or DVC6035 Remotely mounted feedback unit for quarter turn
52. ET E a SupWyPesueloAet 89 Temp Sensor Failure shutdown 86 Torque Units Transmitter Output Travel Travel Accumulator Travel Accumulator Alert Enable Travel Accumulator Alert Point Travel Alert Deadband Tavel Alert Hi Enable Travel Alert Hi Hi Enable Travel Alert Hi Hi Point B9 Travel Alert Hi Point BO Travel Alert Lo Enable Travel Alert Lo Lo Enable Travel Alert Lo Point Travel Counts Travel Deviation Merse Travel Deviation Pressure Faba B7 Travel Pressure Select Travel Sensor Failure Shutdown Bo Tad UnbalancedArea Timy eo 88 Push Down Trim PWB Serial Number B 3 Quick Release 86 Rated Travel Relay Adjust B 10 Valve Model Valve Size B0 X Valve Serial Number B 3 B 6 Relay Type 85 Reference Voltage Failure Shutdown B9 Reset Valve Stuck Alert B 11 Restart Control Mode B 11 Seat Type Trim 86 ShudwmowWet Solenoid Valve SP Rate Close Velocity Gain Volume 100 Instruction Manual D103785X012 Figure B 1 Hot Key Hot Key 1 Instrument Mode 2 Change Instrument Mode 3 Write Protection 4 Change Write Protection Figure B 3 Overview 1 Overview 1 8 HC 1 9 AD PD ODV Device Information Device Status Analog Input Setpoint Travel Supply Pressure QH Pressure
53. Feedback Arm for DVC6015 and DVC6035 80 Screw hex socket 557 2 14 81 Square Nut 5572 14 104 Screw hex 4 14 4 req d DVC6015 only Not for mounting on 1250 and 1250R actuators Mounting parts for 1250 and 1250R actuators are included in the mounting kit for these actuators 88 Instruction Manual D103785X012 Key Description Part Number 107 Mounting Bracket 4 DVC6015 only Not for mounting on 1250 and 1250R actuators Mounting parts for 1250 and 1250R actuators are included in the mounting kit for these actuators Feedback Linkage Shield Up to 50 4 mm 2 inch travel All sliding stem actuators except 585C size 60 50 4 mm 2 inch to 104mm 4 inch travel All sliding stem actuators except 585C size 60 585C size 60 19 mm 0 75 inch to 104 mm 4 inch travel 131 Retainer Wire 163 Plain Washer SST 2 14 223 Potentiometer Bushing Assembly Travel Sensor Assembly 14 DVC6015 and DVC6025 DVC6035 251 Feedback housing 4 252 Assembly Plate Shield 14 DVC6015 only 253 Terminal bracket 14 15 254 Terminal Strip 14 15 255 Terminal 14 256 O ring fluorosilicone 4 257 Machine Screw pan 4 1 2 req d DVC6015 only 258 Label cover 14 260 Hex Nut SST 2 req d 261 Nameplate 265 Plug 4 DVC6015 and DVC6035 only DVC6025 see figure 7 5 74 Mounting Bracket 82 Spring SST 83 Bearing Flange PTFE based 2 req d 84 Feedback Arm Assembly SST 85 pl
54. Follow the prompts on the Field Communicator display to calibrate the instrument s supply pressure sensor 1 Select a Zero Only or b Zero and Span gauge required a If Zero Only calibration is selected adjust the supply pressure requlator to remove supply pressure from the instrument Press OK Once calibration is complete go to step 5 b If Zero and Span calibration is selected adjust the supply pressure regulator to remove supply pressure from the instrument Press OK Adjust the supply regulator to the maximum instrument supply pressure Press OK Proceed with step 2 2 The following message appears Use the Increase and Decrease selections until the displayed pressure matches the supply pressure Press OK when you have read this message 3 The value of the pressure appears on the display 4 From the adjustment menu select the direction and size of adjustment to the displayed value Selecting large medium and small adjustments causes changes of approximately 3 0 psi 0 207 bar 20 7 kPa 0 30 psi 0 0207 bar 2 07 kPa and 0 03 psi 0 00207 bar 0 207 kPa respectively Adjust the displayed value until it matches the supply pressure select Done and go to step 5 5 Placethe instrument In Service and verify that the displayed pressure matches the measured supply pressure Travel Sensor The travel sensor is normally adjusted at the factory and should not require adjustment However if the travel sensor has been
55. HW2 digital valve controller These documents include e Bulletin 62 1 DVC6000 HW2 Fisher FIELDVUE DVC6000 HW2 Digital Valve Controller D103786X012 Bulletin 62 1 DVC6005 Fisher FIELDVUE DVC6005 Series Digital Valve Controller and DVC6015 DVC6025 DVC6035 Feedback Unit Dimension D103308X012 Fisher FIELDVUE DVC6005 Series Remote Mount Digital Valve Controller Quick Start Guide D103784X012 FIELDVUE Digital Valve Controller Split Ranging D103262X012 Using FIELDVUE Instruments with the Smart HART Loop Interface and Monitor HIM D103263X012 Introduction Instruction Manual November 2015 0103785 012 Using FIELDVUE Instruments with the Smart Wireless THUM Adapter HART Interface Module 0103469 012 Audio Monitor for HART Communications 0103265 012 HART Field Device Specification Fisher FIELDVUE DVC6000 HW2 Digital Valve Controller D103782X012 e Using the HART Tri Loop HART to Analog Signal Converter with FIELDVUE Digital Valve Controllers 0103267 012 e Lock in Last Strategy D103261X012 e Fisher HF340 Filter Instruction Manual D102796X01 2 e 475 Field Communicator User s Manual e Valvelink Software Help or Documentation All documents are available from your Emerson Process Management sales office Also visit our website at www FIELDVUE com Educational Services For information on available courses for the DVC6000 HW2 digital valve controller as well as a vari
56. ION IS NOT CONFIGURED 105 Field Communicator Menu Trees Instruction Manual D103785X012 November 2015 Figure B 10 Calibration 2 4 HART 5 4 Travel Calibration 1 Auto Calibration 2 Last AutoCal Status 3 Manual Calibration 4 Calibration Record Calibration HART 7 1 Travel Calibration HART 7 4 2 Relay Adjust 3 Sensor Calibration 4 PST Calibration lt 1 Travel Calibration 1 Auto Calibration 2 Last AutoCal Status 3 Manual Calibration 2 4 3 4 Calibration Type Sensor Calibration 5 Calibration Time 6 Calibrator 1 Travel Sensor Adjust 2 Pressures Sensors 3 Analog Input lt 2 NOTE L1 gt PST CALIBRATION IS AVAILABLE FOR INSTRUMENT LEVEL ODV 2 gt ANALOG INPUT IS NOT AVAILABLE WHEN THE DIP SWITCH IS SET TO MULTI DROP Figure B 11 Service Tools 3 3 2 Alert Record Service Tools 1 View Alert Records 2 Clear Records 1 Device Status 2 Alert Record 3 3 3 Diagnostics Diagnostics 4 Variables 5 Maintenance 1 Stroke Valve 2 Partial Stroke Test lt 1 3 5 3 4 Maintenance lt Variables 1 Performance Tuner 43 1 Travel Pressure 2 Stabilize Optimize 2 Control Mode 3 Restart Processor 3 Analog Input 4 Reset Valve Stuck Alert 4 Temperature 5 Changeto HART 5 G 5 Travel Counts 6 Characterization 7 Travel History 8 Run Time Extremes Run Time Extremes 1 Maximum Recorded Temperature 1 2 Minimum Re
57. Input Setpoint Travel Supply Pressure not available in Instrument Level HC Actuator Pressure s Travel Pressure Control Configuration Device Information Device Information provides details about the instrument construction including Tag Name Instrument Model Number Instrument Level see table 5 1 Device ID unique number used to prevent the instrument from accepting commands intended for other instruments Serial Numbers Firmware DD and Hardware Revisions HART Universal Revision Write Protection provides a procedure to enable disable Table 5 1 Functions Available for Instrument Level Instrument Level Functions Available HART Communicating Communicates with the Field Communicator and ValveLink software In addition HC provides travel cutoffs and limits minimum opening and closing times input characterization linear equal percentage quick opening and custom trending with ValveLink Solo and the following alerts travel deviation travel alert high low high high and low low drive signal cycle counter and travel accumulation Advanced Diagnostics Includes all functions listed above plus with ValveLink software all offline diagnostic tests dynamic error band drive signal step response and valve signature plus online trending Performance Diagnostics Includes all functions listed above plus all Performance Diagnostics online in service valve testing valve friction electronics and mechanic
58. Instruction Manual D103785X012 DVC6000 HW2 Digital Valve Controller November 2015 Fisher FIELDVUE DVC6000 HW2 Digital Valve Controller This manual applies to Instrument Level HC AD PD ODV 130b Firmware Revision 6 DD Revision 4 amp 5 Contents Section 1 Introduction Scopeol Malia Conventions Used in this Manual Biagio M Specifications Related Documents Educational 5 Section 2 Wiring Practices Control System Requirements HART Fiter oui tei ERU I dee Voltage Available Compliance Voltage Auxiliary Terminal Wiring Length Guidelines Maximum Cable Capacitance Installation in Conjunction with a Rosemount 333 HART Tri Loop HART to Analog Signal Converter Section 3 Configuration Guided Setup Manual Setup Mode and Protection Instrument Mode Write Protection In d Identification Serial Numbers jy 2505444 TermilalBOX uode sse ERE Input Range
59. Management sales office for classification certification specific information Connections Supply Pressure 1 4 NPT internal and integral pad for mounting 67CFR regulator Output Pressure 1 4 NPT internal Tubing 3 8 inch recommended Vent 3 8 NPT internal Electrical 1 2 NPT internal or M2007 Actuator Compatibility Stem Travel Sliding Stem Linear Linear Actuators with rated travel between 6 35 mm 0 25 inch and 606 mm 23 375 inches Shaft Rotation Quarter Turn Rotary Rotary Actuators with rated travel between 50 degrees and 180 degrees Mounting Weight DVC6005 HW2 Base Unit 4 1 kg 9 Ibs DVC6015 Remote Feedback Unit 1 3 kg 2 9 Ib DVC6025 Remote Feedback Unit 1 4 kg 3 1 Ibs DVC6035 Remote Feedback Unit 0 9 kg 2 0 Ib Construction Materials Housing module base and terminal box A03600 low copper aluminum alloy Cover Thermoplastic polyester Elastomers Nitrile standard Fluorosilicone extreme temperature Options Supply and output pressure gauges B Tire valves Integral mounted filter regulator Low Bleed Relay Extreme Temperature Integral 4 20 mA Position Transmitter 3 4 20 mA output isolated Supply Voltage 8 30 VDC Fault Indication offrange high or low Reference Accuracy 1 of travel span Options continued on next page Instruction Manual Introduction D103785X012 November 2015 Table 1 2 Specifications continued Options continued Declaration
60. Mounting kit installed per the instructions Yes _ No 7 What is the safe position of the valve Fail closed Fail open 83 Maintenance and Troubleshooting November 2015 84 Instruction Manual D103785X012 Instruction Manual D103785X012 Section Parts Parts Ordering Whenever corresponding with your Emerson Process Management sales office about this equipment always mention the controller serial number WARNING Use only genuine Fisher replacement parts Components that are not supplied Emerson Process Management should not under any circumstances be used in any Fisher instrument Use of components not supplied by Emerson Process Management may void your warranty might adversely affect the performance of the instrument and could cause personal injury and property damage Parts Kits Kit 17 2 6 Description Elastomer Spare Parts Kit kit contains parts to service one digital valve controller Standard Extreme Temperature option fluorosilicone elastomers Small Hardware Spare Parts Kit kit contains parts to service one digital valve controller Conversion Kit DVC6015 to DVC6025 Conversion Kit DVC6025 to DVC6015 Alignment Pin Kit kit contains 15 alignment pins key 46 Seal Screen Kit kit contains 25 seal screens key 231 and 25 O rings key 39 Standard and Extreme Temperature option fluorosilicone elastomers Recommended spare Part Number 19B5402X012 19B5402X022
61. Pressure B Pressure A B Device Information 1 Identification 3 Security 1 8 3 HC Security 1 93 AD PD ODV 1 Write Protection 2 Change Write Protection NOTES 1 gt SUPPLY PRESSURE IS AVAILABLE FOR INSTRUMENT LEVEL AD PD AND ODV L2 gt HARTLONG TAG IS AVAILABLE WITH HART 7 Figure B 4 Configure 2 Configure 1 Guided Setup 2 Manual Setup 3 Alert Setup 4 Calibration Field Communicator Menu Trees November 2015 Figure B 2 Online HART Application 1 Offline 2 gt Online 3 Utility 4 HART Diagnostics 1 Overview 2 Configure 3 Service Tools 1 8 1 HC 1 9 1 AD PD ODV Identification HART Tag 2 HARTLongTag lt 1 8 1 5 HC HART 5 Manufacturer 1 8 1 6 He HART 2 Model 9 1 5 AD PD ODV HART 5 Instrument Level 9 1 6 AD PD ODV HART 7 Device ID and Serial Numbers gt pevice ID and Serial Numbers 1 Device ID 2 Valve Serial Number Message Description 3 Instrument Serial Number 1 8 2 HC 4 PWB Serial Number 1 9 2 AD PD ODV 2 Revisions Revisions 1 HART Universal Revision 2 Device Revision 3 Hardware Revision 4 Firmware Revision 5 DD Information Figure B 5 Guided Setup 2 1 Guided Setup Device Setup 2 Performance Tuner lt 7 NOTES 1 gt THIS MENU ITEM IS STABILIZE OPTIMIZE FOR INSTRUMENT LEVEL HC 101
62. ROM which can be changed only at time of instrument manufacture NVM stores configuration restart data Parallel Simultaneous said of data transmission on two or more channels at the same time Polling Address Address of the instrument If the digital valve controller is used in a point to point configuration set the polling address to O If it is used in a multidrop configuration or split range application set the polling address to a value from to 15 Pressure Sensor A FIELDVUE instrument internal device that senses pneumatic pressure The DVC6000 HW2 has three pressure sensors one to sense supply pressure and two to sense the output pressures 110 Primary Master Masters are communicating devices A primary master is a communicating device permanently wired to a field instrument Typically a HART compatible control system or a computer running ValveLink software is the primary master In contrast a secondary master is not often permanently wired to a field instrument The Field Communicator or a computer running ValveLink software communicating through a HART modem could be considered a secondary master Note If one type of master takes an instrument Out Of Service the same type must put it In Service For example if a device set up as a primary master takes an instrument Out Of Service a device set up as a primary master must be used to place the instrument In Service Quick Opening A valve flow characte
63. RT DIGITAL VALVE CONTROLLER 09 69 Tx Tx VALVE A6188 1 Voltage Available The voltage available at the DVC6000 HW2 digital valve controller must be at least 10 VDC The voltage available at the instrument is not the actual voltage measured at the instrument when the instrument is connected The voltage measured at the instrument is limited by the instrument and is typically less than the voltage available Wiring Practices Instruction Manual November 2015 D103785X012 As shown in figure 2 2 the voltage available at the instrument depends upon e the control system compliance voltage e ifafilter wireless THUM adapter or intrinsic safety barrier is used and e the wire type and length The control system compliance voltage is the maximum voltage at the control system output terminals at which the control system can produce maximum loop current The voltage available at the instrument may be calculated from the following equation Voltage Available Control System Compliance Voltage at maximum current filter voltage drop if a HART filter is total cable resistance x maximum current barrier resistance x maximum current The calculated voltage available should be greater than or equal to 10 volts DC Table 2 1 lists the resistance of some typical cables The following example shows how to calculate the voltage available for a Honeywell TDC2000 control system with a HF340 HART filter and 1000 feet of
64. WB DIP switch not set properly 2h Check for incorrect setting or broken DIP switch on the back of the PWB Reset switch or replace PWB if switch is broken See table 6 2 for switch setting information 2j PWB failure 2j Use a 4 20 mA current source to apply power to the instrument Terminal voltage across the LOOP and LOOP terminals should be 8 to 9 5 VDC If the terminal voltage is not 8 to 9 5 VDC replace the PWB 2k Polling address incorrect 2k Use the Field Communicator to set the polling address refer to the Detailed Setup section From the Utility menu select Configure Communicator and Polling Select Always Poll Set the instrument polling address to 0 2l Defective terminal box 2l Check continuity from each screw terminal to the corresponding PWB connector pin If necessary replace the terminal box assembly 2m Defective Field Communicator or ValveLink 2m If necessary repair or replace cable modem cable 2n ValveLink modem defective or not compatible 2n Replace ValveLink modem with PC 3 Instrument will not 3a Rotate feedback arm to ensure it moves freely If not replace calibrate has sluggish the travel sensor pot bushing assembly performance or oscillates 3b Inspect wires for broken solder joint at potentiometer or broken wire Replace travel sensor pot bushing assembly 3c Perform Travel Sensor Adjust procedure in the Calibration section 3d Check for continuity in electrical travel rang
65. al condition Optimized Digital Valve Includes all functions listed above plus partial stroke test and lead lag set point filter HC AD ODV 55 Device Information Diagnostics and Alerts Instruction Manual November 2015 D103785X012 Service Tools Service Tools 3 Device Status Instrument alerts when enabled detect many operational and performance issues that may be of interest If there are no alerts currently active this display will be empty Alert Record The DVC6000 HW2 will store 20 alerts Once the alert record is full no additional alerts will be stored until the record is cleared Below is a list of the alerts that can be detected by the instrument To enable or disable the alerts navigate to Configure gt Alert Setup e Offline Failed Alert This alert is active if a shutdown alert has put the device in a failed state and is therefore not controlling the input Press Enter to view the alert s that caused the shutdown Electronics e Drive Current Failure This alert is active when the drive current to the I P converter is not flowing as expected If this alert occurs check the connection between the I P converter and the printed wiring board assembly Try removing the I P converter and re installing it If the alert does not clear replace the I P converter or the printed wiring board assembly e Drive Signal Alert This alert monitors the drive signal and calibrated travel If one of the followi
66. alert is active if either the high or low point is exceeded Once a high or low point is exceeded the ranged travel must clear that point by the Travel Alert Deadband before the alert clears Four travel alerts are available Travel Alert Hi Travel Alert Lo Travel Alert Hi Hi and Travel Alert Lo Lo Travel Alert Deadband Travel in percent of ranged travel required to clear a travel alert once it is active Valid entries are 25 to 125 Travel Alert High Point Value of the travel in percent of ranged travel which when exceeded sets the Travel Alert Hi alert Valid entries are 25 to 125 Travel Alert High High Point Value of the travel in percent of ranged travel which when exceeded sets the Travel Alert Hi Hi alert Valid entries are 25 to 125 Travel Alert Low Point Value of the travel in percent of ranged travel which when exceeded sets the Travel Alert Lo alert Valid entries are 25 to 125 Travel Alert Low Low Point Value of the travel in percent of ranged travel which when exceeded sets the Travel Alert Lo Lo alert Valid entries are 25 to 125 Travel Cutoff Defines the cutoff point for the travel in percent of ranged travel There are two travel cutoffs high and low Once travel exceeds the cutoff the drive signal is set to either maximum or minimum depending on the Zero Control Signal and if the cutoff is high or low Minimum opening time or minimum closing time are not in effect w
67. ance and Troubleshooting DVC6000 HW2 digital valve controller enclosure is rated Type 4X and 66 therefore periodic cleaning of internal components is not required If the DVC6000 HW2 is installed in an area where the exterior surfaces tend to get heavily coated or layered with industrial or atmospheric contaminants however it is recommended that the vent key 52 be periodically inspected to ensure it is fully open If the vent appears to be clogged the vent can be removed cleaned and replaced Lightly brush the exterior of the vent to remove contaminant and run a mild water detergent solution through the vent to ensure it is fully open A WARNING Personal injury or property damage can occur from cover failure due to overpressure Ensure that the housing vent opening is open and free of debris to prevent pressure buildup under the cover A WARNING To avoid static discharge from the plastic cover when flammable gases or dust are present do not rub or clean the cover with solvents To do so could result in a spark that may cause the flammable gases or dust to explode resulting in personal injury or property damage Clean with a mild detergent and water only A WARNING Avoid personal injury or property damage from sudden release of process pressure or bursting of parts Before performing any maintenance procedures on the DVC6000 HW2 digital valve controller Always wear protective clothing gloves and eyewear e Do not r
68. ard cubic feet per hour at 60 F and 14 7 psia 4 Values at 1 4 bar 20 psig based on a single acting direct relay values at 5 5 bar 80 psig based on double acting relay 5 Temperature limits Vani based on hazardous area approval 6 Not applicable for travels less than 19 mm 0 75 inch or for shaft rotation less than 60 degrees Also not applicable for digital valve controllers in long stroke applications 7 M20 electrical connection only available with ATEX approvals 8 The electronic output is available with either the position transmitter or the switch Table 1 3 Summary Results Immunity Performance 1 Phenomenon Basic Standard Test Level Point to Multi drop Point Mode Mode Electrostatic discharge ESD IEC61000 4 2 A 2 8 kV air 80 to 1000 MHz 10V m with 1 kHz AM at 80 Enclosure Radiated EM field IEC 61000 4 3 1400 to 2000 MHz 3V m with 1 kHz AM at 80 A 2000 to 2700 MHz 1V m with 1 kHz AM at 80 61000 4 8 30A mat50 60Hz A 2 magnetic field A 61000 4 4 I O signal control 61000 4 5 Conducted RF IEC 61000 4 6 150 kHz to 80 MHz at 3 Vrms EE EE Performance criteria 1 effect 1 No degradation during testing B Temporary degradation during testing but is self recovering 2 Excluding auxiliary switch function which meets Performance Criteria B a Related Documents This section lists other documents containing information related to the DVC6000
69. at fastens the travel sensor assembly to the housing CON oO uU A Pull the travel sensor assembly key 223 straight out of the housing DVC6035 Remote Feedback Unit Refer to figure 7 6 for key number locations 1 Remove piping and fittings from the instrument 2 Remove the instrument from the actuator Loosen the screw key 80 that secures the feedback arm key 79 to the travel sensor shaft Remove the feedback arm from the travel sensor assembly shaft 3 Disconnect the three travel sensor assembly wires from the terminals 4 From within the housing unscrew the travel sensor assembly key 223 from the housing Assembly Note If the feedback arm key 79 or feedback arm assembly key 84 is removed from the digital valve controller the travel sensor assembly must be recalibrated DVC6015 Remote Feedback Unit Refer to figure 7 4 for key number locations 1 Insert the travel sensor assembly key 223 into the housing key 1 Secure the assembly with screw key 72 2 Connectthe travel sensor assembly wires to the terminals as follows red terminal 1 white terminal 2 black terminal 3 3 Loosely assemble the bias spring key 78 screw key 80 plain washer key 163 and nut key 81 to the feedback arm key 79 if not already installed 4 Attach the feedback arm key 79 to the travel sensor assembly shaft 75 Maintenance and Troubleshooting Instruction Manual November 2015 D103785X012 5 U
70. avel Deviation Not Available Pressure Fallback Active Not Available p High Travel Not Available Low Travel Not Available High High Travel Not Available Low Low Travel Not Available Travel Limit Cutoff High Not Available Travel Limit Cutoff Low Not Available Integrator Saturated High Not Available Integrator Saturated Low Not Available Cycle Count High Not Available Travel Accumulator High Not Available Output Circuit Communication Failure Not Available Alert Record Not Empty Not Available Alert Record Full Not Available Instrument Time is Approximate Disabled Not Available 1 Instrument level AD PD or ODV only 39 Configuration Instruction Manual November 2015 D103785X012 Change to HART 5 Change to HART 7 Field Communicator Service Tool Maintenance Change to HART 5 Change to HART 7 3 5 3 HC or 3 5 4 AD PD or 3 5 5 ODV Note This procedure must never be done while the valve is in service and controlling the process Depending on the control system or asset management system attached complete system reset may be required to reestablish HART communication Consult the system documentation for further information This procedure changes the instrument from HART Universal Revision 5 to HART Universal Revision 7 or vice versa Before proceeding verify that your systems are prepared to support HART Universal Revision 7 devices Follow the prompts on the Field Communicator display 40 Instruction Manual Cal
71. ay is designated by Relay C on label affixed to the relay itself Relay C requires no adjustment Single Acting Reverse Relay The single acting reverse relay is designated by Relay B on a label affixed to the relay itself Relay B is calibrated at the factory and requires no further adjustment 53 Calibration Instruction Manual D103785X012 November 2015 PST Calibration ODV Instrument Level only This procedure permits you to run the Partial Stroke Calibration which enables the Partial Stroke Test It establishes values for Partial Stroke Pressure Limit Pressure Set Point and Pressure Saturation Time for End Point Pressure Control Travel Deviation Alert Point and Travel Deviation Time The Partial Stroke Calibration also sets default values for max travel movement test speed and test pause time Note You must take the instrument out of service before running Partial Stroke Calibration Ensure that the instrument is put back in service after the completing the calibration procedure 54 Instruction Manual Device Information Diagnostics and Alerts D103785X012 November 2015 Section 5 Device Information Diagnostics and Alerts Overview Overview 1 Status amp Primary Purpose Variables The overview section provides basic information about the current state of the instrument and gives you access to the current values of Alert Status Communication Status Instrument Mode In Out of Service Analog
72. be initiated by the device as a scheduled auto partial stroke test a remote pushbutton located in the field or at the valve a Field Communicator or ValveLink software e Automatic Scheduled The Auto Partial Stroke Test allows the partial stroke test to be scheduled by the DVC6000 HW2 The test is scheduled in number of hours between tests Any power cycle will reset the test clock timer e Local Pushbutton A partial stroke test command may be sent to the digital valve controller using a set of contacts wired to the auxiliary terminals To perform test the contacts must be closed for 3 to 5 seconds and then opened To abort the test close the contacts for 1 second The last set of diagnostic data is stored in the instrument memory for later retrieval via ValveLink software Field Communicator 1 Connect the Field Communicator to the LOOP terminals on the DVC6005 HW2 base unit 2 Turnon the Field Communicator 3 From the Online menu select Service Tools gt Diagnostics gt Partial Stroke Test 4 Select either Standard 10 or Custom With the Custom Stroke Test the stroke may be entered up to 30 with configurable stroking speed and pause time 5 The currently confiqured Stroke Stroking Speed and Pause Time is displayed Choose Yes to run the test using these values Choose to modify the values The default value for Stroke Speed is 0 25 second 6 The valve begins to move and the actual travel
73. changes direction when it is outside of the deadband To clear the alert set the Cycle Counter to a value less than the alert point Travel Accumulator High Alert This alert is active if the Travel Accumulator exceeds the Travel Accumulator Alert Point The Travel Accumulator totalizes the travel of the valve when the deadband is exceeded To clear the alert set the Travel Accumulator to a value less than the alert point Note The Cycle Count Travel Accumulator Deadband applies to both the Cycle Count High Alert and the Travel Accumulator High Alert The deadband is the percent of ranged travel around a travel reference point The travel reference point gets re established to the point of travel reversal that occurs outside of the deadband The deadband must be exceeded before a change in travel direction will be counted as a cycle and the accumulated travel up to the point of travel reversal is added to the total accumulation See figure 5 2 Figure 5 2 Cycle Counter and Travel Accumulator Deadband Example set at 10 DEADBAND EXCEEDED NEW REFERENCE POINT ESTABLISHED DEADBAND REFERENCE POINT DEADBAND 5 a o LL gt 5 xe DEADBAND amm DARK SEGMENTS REPRESENT THE AMOUNT OF TRAVEL THAT WILL BE ADDED TO THE TRAVEL ACCUMULATOR 1 CYCLE COUNTER INCREMENTS E1473 Alert Record Alert Record Not Empty Alert This alert is active when there are 1 or more alerts stored in
74. corded Temperature Travel History 3 Days Powered Up 1 Cycle Counter 4 Number of Power Ups 2 Travel Accumulator NOTES PARTIAL STROKE TEST IS AVAILALBE FOR INSTRUMENT LEVEL ODV SUPPLY PRESSURE AND FALLBACK RECOVERY ARE AVAILABLE FOR AD PD ODV PERFORMANCE TUNER IS AVAILABLE FOR INSTRUMENT LEVEL AD PD AND ODV RESET VALVE STUCK ALERT IS AVAILABLE FOR INSTRUMENT LEVEL OD V THIS MENU ITEM READS CHANGE TO HART 7 WITH HART 5 106 3 4 1 3 4 6 Travel Pressure Setpoint Travel Drive Signal Supply Pressure Pressure Pressure B Pressure A B Travel Pressure Select Fallback Recovery 1 2 3 4 5 6 7 8 9 Control Mode 1 Control Mode 2 Change Control Mode 3 Restart Control Mode Characterization 1 Input Characterization 2 Custom Characterization Instruction Manual D103785X012 Glossary Alert Point An adjustable value that when exceeded activates an alert Algorithm A set of logical steps to solve a problem or accomplish a task A computer program contains one or more algorithms Alphanumeric Consisting of letters and numbers Analog Input Units Units in which the analog input is displayed and maintained in the instrument ANSI acronym The acronym ANSI stands for the American National Standards Institute ANSI Class Valve pressure temperature rating Bench Set Pressure supplied to an actuator required to drive the actuator through rated valve travel Expre
75. crossover Select the direction and size of change required to set the feedback arm so it is 90 to the actuator stem as shown in figure 4 1 Selecting large medium and small adjustments to the crossover causes changes of approximately 10 0 1 0 and 0 1 respectively to the rotation of the feedback arm If another adjustment is required repeat step 5 Otherwise select Done and go to step 6 6 The remainder of the auto calibration procedure is automatic It is completed when the Calibration menu appears During calibration the instrument seeks the high and low end points and the minor loop feedback MLFB and output bias By searching for the end points the instrument establishes the limits of physical travel i e the actual travel 0 and 100 positions This also determines how far the relay beam swings to calibrate the sensitivity of the MLFB sensor 42 Instruction Manual Calibration D103785X012 November 2015 Figure 4 1 Crossover Point ACTUATOR STEM 90 20 30 s lt 75 1 1 12 1 5 FEEDBACK ARM 6536 3 7 Place the instrument In Service and verify that the travel properly tracks the current source If the unit does not calibrate refer to table 4 1 for error messages and possible remedies Table 4 1 Auto Calibrate Travel Error Messages Possible Problem and Remedy Power failure occurred during Auto Calib from
76. ction 7 Disconnect the multimeter from the travel sensor connector 8 Apply anti seize key 64 to the pin portion of the arm assembly key 91 9 Position the mounting bracket over the back of the digital valve controller Push the feedback arm assembly key 84 toward the housing and engage the pin of the arm assembly into the slot in the feedback arm 10 Install the mounting bracket key 74 11 Install the bias spring key 82 as shown in figure 6 9 12 Travel sensor adjustment is complete Install the remote feedback unit on the actuator Figure 6 9 FIELDVUE DVC6025 digital Valve Controller Bias Spring key 82 Installation BIAS SPRING KEY 82 FEEDBACK ARM 84 91 INSTALL BIAS SPRING WITH SMALLER DIAMETER HOOK CONNECTED ARM ASSEMBLY KEY 91 AND WITH BOTH HOOK OPENINGS TOWARD CENTER OF BRACKET DVC6035 Remote Feedback Unit Refer to figure 7 6 for DVC6035 key number locations 1 Apply lubricant key 63 to the travel sensor assembly threads 2 Screw the travel sensor assembly key 223 into the housing until it is tight 3 Connect the travel sensor wires to the terminals as follows red terminal 1 white terminal 2 black terminal 3 78 Instruction Manual Maintenance and Troubleshooting D103785X012 November 2015 4 Loosely assemble the bias spring key 78 screw key 80 plain washer key 163 and nut key 81
77. dware installed set the Transmitter or Switch option according to table 6 3 Table 6 2 DIP Switch Configuration Switch Label Operational Mode DIP Switch Position PT PT 4 20 mA Point to Point Loop LEFT 24 VDC Multi Drop Loop RIGHT Table 6 3 Output Switch Configuration Switch Label Function DIP Switch Position RIGHT 1 Refer to figure 6 5 for switch location Figure 6 5 Printed Wiring Board PWB Connections and Settings TRANSMITTER SWITCH SELECTION TRAVEL SENSOR HART HART CONNECTOR TRAVEL SENSOR CONNECTOR EV TERMINAL BOX E CONNECTOR 8 OPERATIONAL MODE SELECTION Travel Im TERMINAL BOX gt OPERATIONAL MODE SELECTION X0463 0432 Note For the digital valve controller to operate with a 4 to 20 mA control signal be sure the DIP switch is in the point to point loop position 6 Reassemble the module base to the housing by performing the Replacing the Module Base procedure 7 Setup and calibrate the DVC6005 HW2 base unit 70 Instruction Manual Maintenance and Troubleshooting D103785X012 November 2015 Pneumatic Relay Refer to figure 7 2 for key number locations The pneumatic relay key 24 is located on the front of the module base Note After relay submodule replacement calibrate the digital valve controller to maintain accuracy specifications Removing the Pneumatic Relay 1 Loosen
78. e 100 000pF 26pF ft 3846 ft Example 18AWG Shielded Audio Control and Instrumentation Cable Manufacturer s specifications include Nom Characteristic Impedance 29 Ohms Nom Inductance 15 wH ft Nom Capacitance Conductor to Conductor 1 KHz 51 pF ft Nom Cap Cond to other Cond amp Shield 1 Khz 97 pF ft Allowable Length with this cable 100 000pF 97pF ft 1030 ft The AUX switch input passes less than 1 mA through the switch contacts and uses less than 5 V therefore neither the resistance nor the voltage rating of the cable are critical Ensure that switch contact corrosion is prevented It is generally advisable that the switch have gold plated or sealed contacts Maximum Cable Capacitance The maximum cable length for HART communication is limited by the characteristic capacitance of the cable Maximum length due to capacitance can be calculated using the following formulas Length ft 160 000 Cmaster pF Ccable pF ft Length m 160 000 Cmaster pF Ccable pF m where 160 000 a constant derived for FIELDVUE instruments to ensure that the HART network RC time constant will be no greater than 65 us per the HART specification Cmaster the capacitance of the control system or HART filter Instruction Manual Wiring Practices D103785X012 November 2015 Ccable the capacitance of the cable used see table 2 1 The following example shows how to calculate the cable length for a F
79. e Edit 22 Instrument Time is Approximate Alert 57 Instument Serial Number 21 Integral Dead Zone Travel Pressure Integral Settings 31 Integral Enable Pressure Tuning 31 Travel Tuning 30 Integral Gain Pressure Tuning 31 Travel Tuning 30 Integral Setting 31 Integrator Limit Travel Pressure Integral Settings 32 Integrator Saturated High Alert 58 Integrator Saturated Low Alert 58 Internal Sensor Out of Limits 57 L Lag Time 27 Lead Lag 27 typical filter settings 27 Lead Lag Time 27 Index November 2015 Lightning and Surge Protection 6 Limit Switch Function Output Terminal Configuration 37 Limit Switch Trip Point 37 Lo Limit Cutoff Point 23 Lo Limit Cutoff Select 23 Loop Current Validation Alert 57 Maintenance Troubleshooting 63 Manual Calibration 44 Manual Setup 19 Max Travel Movement 36 Maximum Cable Capacitance 12 Maximum Output Capacity 5 maximum supply pressure 33 Message 21 Minor Loop Sensor Alert 57 MLFB Gain Pressure Tuning 31 Travel Tuning 29 Mode Burst 38 Module Base Removal 64 Replacing 66 Module Base Parts List 86 Module Base Maintenance 64 Mountings 5 N natural gas as supply medium 63 Non Critical NVM Alert 56 O Offline Failed Alert 56 Options 6 7 Output Circuit Communication Failure 57 Output Pressure Sensor Calibration 46 Output Signal 5 115 Index November 2015 Output Terminal C
80. e If necessary replace pot bushing assembly e Cables not plugged into PWB correctly 3e Inspect connections and correct 3f Feedback arm loose on potentiometer 3f Perform Travel Sensor Adjust procedure in the Calibration section UJ 81 Maintenance and Troubleshooting Instruction Manual November 2015 D103785X012 Table 6 4 Instrument Troubleshooting Continued Symptom Possible Cause 3 Instrument will not 3g Feedback arm bent damaged or bias spring 3g Replace feedback arm and bias spring calibrate has sluggish missing damaged performance or oscillates 3h Configuration errors 3h Verify configuration If necessary set protection to None If Out of Service place In Service Check Travel Sensor Motion Tuning set Zero control signal Feedback Connection Control mode should be Analog Restart control mode should be Analog 3j Restricted pneumatic passages I P converter 3j Check screen in I P converter supply port of the module base Replace if necessary If passages in I P converter restricted replace I P converter O ring s between I P converter 55 missing or hard 3k Replace O ring s and flattened losing seal 3l converter ass y damaged corroded clogged 3l Check for bent flapper open coil continuity contamination staining or dirty air supply Coil resistance should be between 1680 1860 ohms Replace I P assembly if damaged corroded clogged or open coil 3m
81. e Travel in percent of calibrated travel that corresponds to the input range 112 Instruction Manual D103785X012 Travel Sensor A device within the FIELDVUE instrument that senses valve stem or shaft movement The travel sensor in the DVC6000 HW2 is mechanically connected to the valve stem or shaft Travel Sensor Motion Increasing or decreasing air pressure causes the shaft to rotate clockwise or counterclockwise Device Setup asks if it can move the valve to determine travel Tuning The adjustment of control terms or parameter values to produce a desired control effect Tuning Set Preset values that identify gain settings for a FIELDVUE instrument The tuning set and supply pressure together determine an instrument s response to input signal changes Watch Dog Timer A timer that the microprocessor must rearm periodically If the microprocessor is unable to rearm the timer the instrument goes through reset Zero Power Condition The position of the valve open or closed when the electrical power to the instrument is removed Zero Power Condition ZPC is determined by relay and actuator action as follows Single Acting Direct Relay C Upon loss of electrical power instrument goes to zero air output at port A Double Acting Relay A Upon loss of electrical power instrument goes to full supply air output at port B A goes to zero air output Single Acting Reverse Relay B Upon loss of electrical power instrume
82. e select Done and go to step 5 5 Setthe current source to the target value shown on the display The target value is the Input Range High value Press OK 6 The following message appears Use the Increase and Decrease selections until the displayed current matches the target Press OK when you have read this message 7 The value of the Analog Input appears on the display Press OK to display the adjustment menu 8 From the adjustment menu select the direction and size of adjustment to the displayed value If the displayed value does not match the current source press OK then repeat this step step 8 to further adjust the displayed value When the displayed value matches the current source select Done and go to step 9 9 Place the instrument In Service and verify that the analog input displayed matches the current source Relay Adjustment Before beginning travel calibration check the relay adjustment Replace the instrument cover when finished Note Relay B and C are not user adjustable Double Acting Relay The double acting relay is designated by Relay on a label affixed to the relay itself For double acting actuators the valve must be near mid travel to properly adjust the relay The Field Communicator will automatically position the valve when Relay Adjust is selected CAUTION Care should be taken during relay adjustment as the adjustment disc may disengage if rotated too far Rotate the adjus
83. e 475 Field Communicator to set up and calibrate the instrument You can also use Fisher ValveLink software or ValveLink Mobile software to setup calibrate and diagnose the valve and instrument For information on using ValveLink software with the instrument refer to ValveLink software help or documentation Do not install operate or maintain DVC6000 HW2 digital valve controller without being fully trained and qualified in valve actuator and accessory installation operation and maintenance To avoid personal injury or property damage it is important to carefully read understand and follow all of the contents of this manual including all safety cautions and warnings If you have any questions about these instructions contact your Emerson Process Management sales office before proceeding Conventions Used in this Manual Navigation paths and fast key sequences are included for procedures and parameters that can be accessed using the Field Communicator For example to access Device Setup Field Communicator Configure Guided Setup gt Device Setup 2 1 1 Refer to Appendix B for Field Communicator menu trees Description DVC6000 HW2 digital valve controllers figures 1 1 are communicating microprocessor based current to pneumatic instruments In addition to the normal function of converting an input current signal to a pneumatic output pressure the DVC6000 HW2 digital valve controller using the HART9 communications protoco
84. e alert will clear when the Travel falls below the Travel Alert Hi Hi Point minus the Travel Alert Deadband Travel Alert Lo This alert is active when the Travel is below the Travel Alert Lo Point Once the alert is active the alert will clear when the Travel exceeds the Travel Alert Lo Point plus the Travel Alert Deadband e Travel Alert Lo Lo This alert is active when the Travel is below the Travel Alert Lo Lo Point Once the alert is active the alert will clear when the Travel exceeds the Travel Alert Lo Lo Point plus the Travel Alert Deadband e Travel Limit Cutoff Hi Alert This alert is active when the Travel exceeds the Hi Limit Cutoff Point e Travel Limit Cutoff Lo Alert This alert is active when the Travel falls below the Lo Limit Cutoff Point e Integrator Saturated High Alert This alert is active if the instrument integrator is saturated at the high extreme e Integrator Saturated Low Alert This alert is active if the instrument integrator is saturated at the low extreme e Pressure Fallback Active Alert This alert is active when the instrument has detected a problem with the travel feedback and is now controlling the output like an I P transducer 58 Instruction Manual Device Information Diagnostics and Alerts D103785X012 November 2015 Travel History Cycle Count High Alert This alert is active if the Cycle Counter exceeds the Cycle Count Alert Point The Cycle Count records the number of times the travel
85. e for Remote Travel Sensor Assembly ordering information 13 Remote Terminal Box Kit GE00418X012 14 Feedback Unit DVC6015 49 7986 012 DVC6025 long arm 49B7987X012 DVC6025 Short Arm 49B7987X022 DVC6035 49 7988 012 DVC6035 for GX actuator 49B7988X022 15 Feedback Unit Termination Strip Kit GE00419X012 16 Pipestand Wall Mounting Kit GE00420X012 Parts List Note Contact your Emerson Process Management sales office for Part Ordering information Note Parts with footnote numbers shown are available in parts kits see footnote information at the bottom of the page 86 Instruction Manual D103785X012 Kit Description Part Number DVC6005 HW2 Base Unit see figure 7 2 Housing Housing 11 Drive Screw 2 req d 20 Shield 52 Vent plastic 74 Mounting Bracket 16 248 Screw hex head 19 4 req d 249 Screw hex head 19 4 req d 250 16 4 req d 267 Standoff 19 2 req d 271 Screen Common Parts 16 40 3 req d 29 Warning label for use only with LCIE hazardous area classifications 33 Screw pan hd SST 2 3 req d 38 Screw hex socket SST 2 10 3 req d 43 Cover Assembly includes cover screws Standard 38B9580X022 Extreme temperature option fluorosilicone elastomers 38B9580X032 48 Nameplate 49 Screw self tapping 2 req d 19 63 Lithium grease not furnished with the instrument 64 Pipe thread sealant not furnished with the instrument 65 Lubricant si
86. e printed wiring board assembly was replaced If you suspect calibration has changed due to drift first perform a Valve Signature diagnostic test using ValveLink software to capture the as found data for future root cause analysis 45 Calibration Instruction Manual November 2015 D103785X012 Sensor Calibration Pressure Sensors Note The pressure sensor is calibrated at the factory and should not require calibration Output Pressure Sensor To calibrate the output pressure sensor connect an external reference gauge to the output being calibrated The gauge should be capable of measuring maximum instrument supply pressure Depending upon the sensor you wish to calibrate select either Output A Sensor or Output B Sensor Follow the prompts on the Field Communicator display to calibrate the instrument s output pressure sensor 1 Adjust the supply pressure regulator to the maximum instrument supply pressure Press OK 2 The instrument reduces the output pressure to 0 The following message appears Use the Increase and Decrease selections until the displayed pressure matches the output x pressure Press OK when you have read the message 3 The value of the output pressure appears on the display Press OK to display the adjustment menu 4 From the adjustment menu select the direction and size of adjustment to the displayed value Selecting large medium and small adjustments causes changes of approximately 3 0 psi 0 207
87. eck supply 1 Check supply pressure reverse acting relay pressure 2 Friction is too high Drive signal exceed high limit check supply 1 Check supply pressure direct acting relay pressure 2 Friction is too high 43 Calibration Instruction Manual November 2015 D103785X012 Manual Calibration Two procedures are available to manually calibrate travel Analog Adjust This procedure is used when you can manually change the 4 20 mA current source to move the valve Digital Adjust This procedure is used when the 4 20 mA current source cannot be manually changed Analog Calibration Adjust Connect a variable current source to the instrument LOOP and LOOP terminals The current source should be capable of generating 4 to 20 mA Follow the prompts on the Field Communicator display to calibrate the instrument s travel in percent Note 0 Travel Valve Closed 100 Travel Valve Open 1 Adjust the input current until the valve is near mid travel Press OK Note In steps 2 through 7 the accuracy of the current source adjustment affects the position accuracy Adjust the current source until the valve is at 0 travel then press OK Adjust the current source until the valve is at 100 travel then press OK Adjust the current source until the valve is at 0 travel then press OK Adjust the current source until the valve is at 100 travel then press OK Adjust the current source until the valve is at 5
88. emark of FieldComm Group All other marks are the property of their respective owners The contents of this publication are presented for informational 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 upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Cernay 68700 France Dubai United Arab Emirates Singapore 128461 Singapore j www Fisher com E M ERSON 2014 2015 Fisher Controls International LLC All rights reserved
89. emove the actuator from the valve while the valve is still pressurized Use bypass valves or completely shut off the process to isolate the valve from process pressure Relieve process pressure from both sides of the valve e Use lock out procedures to be sure that the above measures stay in effect while you work on the equipment Check with your process or safety engineer for any additional measures that must be taken to protect against process media Vent the pneumatic actuator loading pressure and relieve any actuator spring precompression so the actuator is not applying force to the valve stem this will allow for the safe removal of the stem connector e Disconnect any operating lines providing air pressure electric power or a control signal to the actuator Be sure the actuator cannot suddenly open or close the valve When using natural gas as the supply medium or for explosion proof applications the following warnings also apply e Remove electrical power before removing the housing cap Personal injury or property damage from fire or explosion may result if power is not disconnected before removing the cap e Remove electrical power before disconnecting any of the pneumatic connections e When disconnecting any of the pneumatic connections or any pressure retaining part natural gas will seep from the unit and any connected equipment into the surrounding atmosphere Personal injury or property damage may result from fire
90. er responding to the control signal Yes No If not describe Measure the voltage across the Loop and Loop terminal box screws when the commanded current is 4 0 mA 3 and 20 0 mA V 4 0 mA V Q 20 0 mA These values should be around 8 6 V 4 0 mA and 8 8 V 20 mA 4 s it possible to communicate via HART to the digital valve controller Yes __ _ 5 What is the Diagnostic Tier of the digital valve controller HC AD PD ODV 6 What is the firmware version of the digital valve controller 7 What is the hardware version of the digital valve controller 8 Is the digital valve controller s Instrument Mode In Service Yes No 9 Is the digital valve controller s Control Mode set to Analog Yes No_ 10 Is it on Travel or Pressure control 11 What are the following parameter readings Input Signal Drive Signal Supply Pressure Pressure A Pressure B Travel Target Travel 12 What are the following alert readings Fail alerts Valve alerts Operational status Alert event record entries 13 Export ValveLink data if available for the device Status Monitor Detailed Setup etc Mounting 1 Which DVC6000 HW2 do you have DVC6005 HW2 w DVC6015 DVC6025 DVC6035 2 What Make Brand Style Size etc actuator is the DVC6000 HW2 mounted on 3 What is the full travel of the valve 4 What is the Mounting Kit part number 5 If mounting kits are made by LBP Customer please provide pictures of installation 6 Is the
91. er the pressure that corresponds to 0 valve travel when Zero Power Condition is closed or 100 valve travel when Zero Power Condition is open This pressure must be less than the Pressure Range Hi Pressure Fallback Note Pressure Fallback is available for instrument level AD PD ODV e Tvl Dev Press Fallback When the difference between the travel target and the actual travel exceeds this value for more than the Tvl Dev Press Fallback Time the instrument will disregard the travel feedback and control based on output pressure e Tvl Dev Press Fallback Time The time in seconds that the travel target and the actual travel must be exceeded before the instrument falls back into pressure control e Fallback Recovery If the instrument has fallen into pressure control and the feedback problem is resolved recovery to travel control can occur automatically or with manual intervention To return to travel control when Manual Recovery is selected change the Fallback Recovery to Auto Recovery and then back to Manual Recovery if desired 24 Instruction Manual Configuration D103785X012 November 2015 Control Mode e Control Mode Displays the current control mode of the instrument This will show Analog if the instrument is in Point to Point mode and is using a 4 20 mA signal for its power and set point This will show Digital if the instrument is in Multidrop mode and is using 24 VDC for power and a digital set point for control
92. ercentage and Quick Opening Linearity dynamic Linearity independent is the maximum deviation from a straight line best fit to the opening and closing curves and a line representing the average value of those curves Memory Atype of semiconductor used for storing programs or data FIELDVUE instruments use three types of memory Random Access Memory RAM Read Only Memory ROM and Non Volatile Memory NVM See also these listings in this glossary Menu A list of programs commands or other activities that you select by using the arrow keys to highlight the item then pressing ENTER or by entering the numeric value of the menu item 109 Glossary November 2015 Instruction Manual D103785X012 Minimum Closing Time Minimum time in seconds for the travel to decrease through the entire ranged travel This rate is applied to any travel decrease Valid entries 0 to 400 seconds Deactivate by entering a value of 0 seconds Minimum Opening Time Minimum time in seconds for the travel to increase through the entire ranged travel This rate is applied to any travel increase Because of friction actual valve travel may not respond in exactly the same time frame Valid entries are 0 to 400 seconds Deactivate by entering a value of 0 seconds Non Volatile Memory NVM A type of semiconductor memory that retains its contents even though power is disconnected NVM contents can be changed during configuration unlike
93. erminals Once the instrument is connected the instrument limits the measured voltage to approximately 8 0 to 9 5 volts Instruction Manual Wiring Practices D103785X012 November 2015 Table 2 1 Cable Characteristics 1 1 Resistance Resistance pF Ft pF m Ohms ft Ohms m om 1 The capacitance values represent capacitance from one conductor to all other conductors and shield This is the appropriate value to use in the cable length calculations 2 The resistance values include both wires of the twisted pair Compliance Voltage If the compliance voltage of the control system is not known perform the following compliance voltage test 1 Disconnect the field wiring from the control system and connect equipment as shown in figure 2 3 to the control system terminals Figure 2 3 Voltage Test Schematic 1 POTENTIOMETER MILLIAMMETER VOLTMETER E wj CIRCUIT UNDER TEST 0 A6192 1 2 Set the control system to provide maximum output current 3 Increase the resistance of the 1 kQ potentiometer shown in figure 2 3 until the current observed on the milliammeter begins to drop quickly 4 Record the voltage shown on the voltmeter This is the control system compliance voltage For specific parameter information relating to your control system contact your Emerson Process Management sales office 11 Wiring Practices Instruction Manual
94. ermits communication between the Field Communicator and the instrument Drive Signal The signal to the I P converter from the printed wiring board It is the percentage of the total microprocessor effort needed to drive the valve fully open 108 Instruction Manual D103785X012 Drive Signal Alert Checks the drive signal and calibrated travel If one of the following conditions exists for more than 20 seconds the Drive Signal Alert is active If none of the conditions exist the alert is cleared If Zero Power Condition Closed The alert is active when drive signal 1026 and calibrated travel gt 3 drive signal gt 90 and calibrated travel lt 97 If Zero Power Condition Open The alert is active when drive signal lt 10 and calibrated travel lt 97 drive signal gt 90 and calibrated travel gt 3 Equal Percentage A valve flow characteristic where equal increments of valve stem travel produce equal percentage changes in existing flow One of the input characteristics available for a FIELDVUE Instrument See also Linear and Quick Opening Feedback Signal Indicates to the instrument the actual position of the valve The travel sensor provides the feedback signal to the instrument printed wiring board assembly Firmware Revision The revision number of the instrument firmware Firmware is a program that is entered into the instrument at time of manufacture and cannot be changed by the user Free Time Percent
95. est Note Partial Stroke Test is only available for instrument level ODV The Partial Stroke Test allows DVC6000 HW2 digital valve controllers with instrument level ODV to perform a Valve Signature type of test while the instrument is in service and operational In some applications it is important to be able to exercise and test the valve to verify that it will operate when commanded This feature allows the user to partially stroke the valve while continually monitoring the input signal If a demand arises the test is aborted and the valve moves to its commanded position The partial stroke valve travel is configurable between 1 and 3025 maximum travel in 0 1 increments Data from the last partial stroke test is stored in the instrument memory for retrieval by ValveLink software The Partial Stroke Test allows you to perform a partial 10 stroke test standard or a custom stroke test With the custom stroke test the stroke may be extended up to 30 Be sure to check plant guidelines before performing a custom stroke test The purpose of this test is to ensure that the valve assembly moves upon demand A partial stroke test can be initiated when the valve is operating at either 4 or 20 mA point to point mode In applications where a spurious trip is to be minimized 4 mA is the normal operating position 60 Instruction Manual Device Information Diagnostics and Alerts D103785X012 November 2015 When enabled a partial stroke test may
96. ety of other products contact Emerson Process Management Educational Services Registration Phone 1 641 754 3771 or 1 800 338 8158 Email education emerson com http www emersonprocess com education Instruction Manual Wiring Practices D103785X012 November 2015 Section 2 Wiring Practices Control System Requirements There are several parameters that should be checked to ensure the control system is compatible with the DVC6000 HW2 digital valve controller HART Filter Depending on the control system you are using a HART filter may be needed to allow HART communication The HART filter is a passive device that is inserted in field wiring from the HART loop The filter is normally installed near the field wiring terminals of the control system I O see figure 2 1 Its purpose is to effectively isolate the control system output from modulated HART communication signals and raise the impedance of the control system to allow HART communication For more information on the description and use of the HART filter refer to the appropriate HART filter instruction manual To determine if your system requires a filter contact your Emerson Process Management sales office Note A HART filter is typically NOT required for any of the Emerson Process Management control systems including PROVOX RS3 and DeltaV systems Figure 2 1 HART Filter Application NON HART BASED DCS IJO IJO FILTER 4 20 mA HA
97. ey become apparent in the travel response it can generally optimize tuning more effectively than manual tuning Typically the performance tuner takes 3 to 5 minutes to tune an instrument although tuning instruments mounted on larger actuators may take longer Stabilize Optimize A WARNING During Stabilize Optimize the valve may move causing process fluid or pressure to be released To avoid personal injury and property damage caused by the release of process fluid or pressure isolate the valve from the process and equalize pressure on both sides of the valve or bleed off the process fluid Stabilize Optimize permits you to adjust valve response by changing the digital valve controller tuning During this routine the instrument must be out of service however the instrument will respond to setpoint changes If the valve is unstable select Decrease Response to stabilize valve operation This selects the next lower tuning set e g F to E If the valve response is sluggish select Increase Response to make the valve more responsive This selects the next higher tuning set e g F to If after selecting Decrease Response or Increase Response the valve travel overshoot is excessive select Decrease Damping to select a damping value that allows more overshoot Select Increase Damping to select a damping value that will decrease the overshoot When finished select done 30 Instruction Manual Configuration D103785X012 November 20
98. f the instrument should the travel sensor fail There are four choices e Travel Control The instrument is controlling to a target travel Fallback is not enabled e Pressure Control The instrument is controlling to a target pressure Fallback is not enabled Fallback Sensor Failure The instrument will fallback to pressure control if a travel sensor failure is detected 22 Instruction Manual Configuration D103785X012 November 2015 e Fallback Sensor Tvl Deviation The instrument will fallback to pressure control if a travel sensor failure is detected or if the Tvl Dev Press Fallback setting is exceeded for more than the Tvl Dev Press Fallback Time Note Travel Pressure Select must be set to Travel for double acting actuators Cutoffs and Limits Hi Limit Cutoff Select When the Hi Cutoff Limit Select is configured for Cutoff the Travel Target is set to 123 when the Travel exceeds the Hi Cutoff Point When the Hi Cutoff Limit Select is configured for Limit the Travel Target will not exceed the Hi Limit Point e Hi Limit Cutoff Point This is the point within the calibrated travel range above which the Limit or Cutoff is in effect When using cutoffs a Cutoff Hi of 99 5 is recommended to ensure valve goes fully open The Hi Cutoff Limit is deactivated by setting it to 125 e Lo Limit Cutoff Select When the Lo Cutoff Limit Select is configured for Cutoff the Travel Target is set to 23 when the Travel is below the L
99. he feedback arm to the travel sensor shaft Be sure the travel sensor counts remain within the tolerances listed in table 4 2 Paint the screw to discourage tampering with the connection 8 Disconnect the Field Communicator and current source from the instrument 9 Remove the alignment pin and store it in the instrument housing 10 Install the remote feedback unit on the actuator DVC6025 Remote Feedback Unit WARNING Failure to remove air pressure may cause personal injury property damage from bursting parts 1 Remove supply air and remove the instrument from the actuator 2 See figure 4 4 for parts identification Disconnect the bias spring key 82 from the feedback arm assembly key 84 and the arm assembly key 91 Remove the mounting bracket key 74 from the back of the feedback unit Hold the arm assembly key 91 so that the arm assembly points toward the terminal box and the arm is parallel to the back of the housing as shown in figure 4 5 49 Calibration Instruction Manual November 2015 D103785X012 Figure 4 4 FIELDVUE DVC6025 Digital Valve Controller Mounted on Fisher 2052 Size 33 Actuator CAP SCREW HEX SOCKET MOUNTING KEY 116 ADAPTER KEY 117 MOUNTING BRACKET KEY 74 BIAS SPRING KEY 82 FEEDBACK ARM ASSEMBLY KEY 84 gt p n ARM ASSEMBLY KEY 91 FEEDBACK ARM TORSION SPRING KEY 93 X0919 3 Loosen the screw that secures the arm assembly to t
100. he travel sensor shaft Position the arm assembly so that the outer surface is flush with the end of the travel sensor shaft 4 Connect a current source to the instrument LOOP and LOOP terminals Set the current source to any value between 4 and 20 mA Connect the Field Communicator to the TALK terminals 5 Before beginning the travel sensor adjustment set the instrument mode to Out Of Service and the protection to None 6 From the Calibrate menu select Sensor Calibration Travel Sensor Follow the prompts on the Field Communicator display to adjust the travel sensor counts to the value listed in table 4 2 50 Instruction Manual Calibration D103785X012 November 2015 Note In the next step be sure the arm assembly outer surface remains flush with the end of the travel sensor shaft 7 While observing the travel sensor counts tighten the screw that secures the arm assembly to the travel sensor shaft Be sure the travel sensor counts remain within the tolerances listed in table 4 2 Paint the screw to discourage tampering with the connection 8 Disconnect the Field Communicator and current source from the instrument 9 Apply lubricant key 63 to the pin portion of the arm assembly key 91 10 Replace the mounting bracket on the back of the instrument and reconnect the bias spring between the feedback arm assembly and the arm assembly on the travel sensor shaft 11 Install the remote feedback unit on the actuator Figure
101. hile the travel is beyond the cutoff Use the travel cutoff to obtain the desired seat load or to be sure the valve is fully open 111 Glossary November 2015 Travel Deviation The difference between the analog input signal in percent of ranged input the target travel and the actual ranged travel Travel Deviation Alert Checks the difference between the target and the ranged travel If the difference exceeds the Travel Deviation Alert Point for more than the Travel Deviation Time the Travel Deviation Alert is active It remains active until the difference is less than the Travel Deviation Alert Point Travel Deviation Alert Point An adjustable value for the target travel and the ranged travel difference expressed in percent When this value is exceeded by the travel deviation for more than the Travel Deviation Time the Travel Deviation Alert is active Valid entries are 0 to 100 Typically this is set to 5 Travel Deviation Time The time in seconds that the travel deviation must exceed the Travel Deviation Alert Point before the alert is active Valid entries are 1 to 60 seconds Travel Limit A setup parameter that defines the maximum allowable travel in percent of ranged travel for the valve During operation the travel target will not exceed this limit There are two travel limits high and low Typically the travel limit low will be used to keep the valve from going completely closed Travel Rang
102. ibration D103785X012 November 2015 Section 4 Calibration Calibration Overview When DVC6000 HW2 digital valve controller is ordered as part of a control valve assembly the factory mounts the remote feedback unit on the actuator and connects the necessary tubing then sets up and calibrates the controller For digital valve controllers that are ordered separately recalibration of the analog input or pressure sensors generally is unnecessary However after mounting on an actuator perform the initial setup then calibrate travel by selecting Configure gt Calibration gt Travel Calibration gt Auto Calibration For more detailed calibration information refer to the following calibration procedures Field Communicator Configure gt Calibration 2 4 Auto Travel Calibration see page 42 Manual Travel Calibration see page 44 Pushbutton Calibration see page 45 Pressure Sensor Calibration see page 46 Travel Sensor Calibration see page 47 Analog Input Calibration see page 51 Relay Adjustment see page 52 PST Calibration ODV Instrument Level only see page 54 Note The Instrument Mode must be Out Of Service and the Protection set to None before the instrument can be calibrated If you are operating in burst mode we recommend that you disable burst before continuing with calibration Once calibration is complete burst mode may then be turned back on WARNING During calibration the valve will move full stroke
103. ignal is zero therefore no DC value is added to the 4 20 mA signal Thus true simultaneous communication is achieved without interrupting the process signal Figure A 1 HART Frequency Shift Keying Technique ANALOG SIGNAL 1200 Hz 2200 Hz s 99 0 AVERAGE CURRENT CHANGE DURING COMMUNICATION 0 A6174 The HART protocol allows the capability of multidropping i e networking several devices to a single communications line This process is well suited for monitoring remote applications such as pipelines custody transfer sites and tank farms See table 6 2 for instructions on changing the printed wiring board DIP switch configuration to multidrop DVC6000 HW2 Digital Valve Controller The DVC6000 HW2 digital valve controller housing contains the travel sensor terminal box pneumatic input and output connections and a module base that may be easily replaced in the field without disconnecting field wiring or tubing The module base contains the following submodules I P converter printed wiring board pwb assembly and pneumatic relay The relay position is detected by sensing the magnet on the relay beam via a detector on the printed wiring board This sensor is used for the minor loop feedback MLFB reading The module base can be rebuilt by replacing the submodules See figures A 3 95 Principle of Operation Instruction Manual November 2015 D103785X012 Figure A 2 Typical FIELDVUE Instrument to Personal Computer Connectio
104. ip Point When the function is configured as a Limit Switch the Limit Switch Trip Point defines the threshold for the limit switch in percent of calibrated travel e Alert Switch Source When the function is configured as an Alert Switch the Alert Switch Source determines which alert will activate the switch The alert choices are Travel Deviation or Pressure Fallback e Switch Closed Confiqures the action of the switch The choices are Below Trip Point Alert Not Active or Above Trip Point Alert Active 37 Configuration Instruction Manual November 2015 D103785X012 HART Variable Assignments Instrument variables can be reported via four different HART variable assignments The Primary Variable is always configured as Analog Input However the remaining three variables have additional options as listed below Primary Variable PV Analog Input Secondary Variable SV X Travel Travel Setpoint Pressure A Pressure B Pressure Supply Pressure Drive Signal or Analog Input default value is Travel Setpoint Tertiary Variable TV Travel Travel Setpoint Pressure A Pressure B Pressure A B Supply Pressure Drive Signal or Analog Input default value is Pressure A Quaternary Variable QV Travel Travel Setpoint Pressure A Pressure B Pressure Supply Pressure Drive Signal or Analog Input default value is Travel Transmitter Output This configures the relationship between the valve travel and the positio
105. is parameter will also change the tuning set to Expert MLFB Gain The minor loop feedback gain for the travel control tuning set Changing this parameter will also change the tuning set to Expert 29 Configuration Instruction Manual November 2015 D103785X012 e Integral Enable Yes or No Enable the integral setting to improve static performance by correcting for error that exists between the travel target and actual travel Travel Integral Control is enabled by default e Integral Gain Travel Integral Gain is the ratio of the change in output to the change in input based on the control action in which the output is proportional to the time integral of the input e Performance Tuner WARNING During performance tuning the valve may move causing process fluid or pressure to be released avoid personal injury and property damage caused by the release of process fluid or pressure isolate the valve from the process and equalize pressure on both sides of the valve or bleed off the process fluid Note The Performance Tuner is available for instrument level AD PD and ODV and can only be run while in Travel control mode The Performance Tuner is used to determine digital valve controller tuning It can be used with digital valve controllers mounted on most sliding stem and rotary actuators including Fisher and other manufacturers products Moreover because the performance tuner can detect internal instabilities before th
106. its analog input signal There are two instrument modes In Service For a fully functioning instrument the instrument output changes in response to analoq input changes Typically changes to setup or calibration cannot be made when the instrument mode is In Service Out of Service The instrument output does not change in response to analog input changes when the instrument mode is Out of Service Some setup parameters can be changed only when the instrument mode is Out of Service Glossary November 2015 Instrument Protection Determines if commands from a HART device can calibrate and or configure certain parameters in the instrument There are two types of instrument protection Configuration and Calibration Prohibits changing protected setup parameters prohibits calibration None Permits both configuration and calibration The instrument is unprotected Instrument Serial Number The serial number assigned to the printed wiring board by the factory but can be changed during setup The instrument serial number should match the serial number on the instrument nameplate Leak Class Defines the allowable leakage by a valve when it is closed Leak class numbers are listed in two standards ANSI FCI 70 2 and IEC 534 4 Linear A valve flow characteristic where changes in flow rate are directly proportional to changes in valve stem travel One of the input characteristics available for a FIELDVUE Instrument See also Equal P
107. itter 5 Limit Switch Valve Open 6 Limit Switch Valve Close 2 2 2 6 1 Units 1 Travel Units 2 2 2 6 4 Actuator 1 Actuator Manufacturer 1 Valve Manufacturer 2 Length Units 2 Actuator Model 2 Valve Model 3 Area Units 3 Actuator Size 3 Valve Size 4 Spring Rate Units 4 Actuator Selection 4 Valve Class 5 Torque Units 5 Lever Style 5 Stem Diameter 6 Lever Arm Length 6 Packing Type 2 2 2 6 2 7 7 Effective Area 7 Valve Travel Valve Travel 8 Spring Rate 8 9 Air 9 Inlet Outlet Pressures 1 Rated Travel Torque 2 Actual Travel 2 2 2 6 2 9 Torque 2 2 2 6 2 8 1 Dynamic Torque 2 Breakout Torque Inlet Outlet Pressures 1 Inlet Pressure NOTES 2 Outlet Pressure gt HART LONG TAG IS AVAILABLE WITH HART 7 2 gt PARTIAL STROKE TEST IS AVAILABLE FOR INSTRUMENT LEVEL ODV 3 gt AUXILIARY TERMINAL ACTION AND EDIT AUXILIARY TERMINAL ACTION ARE AVAILABLE FOR INSTRUMENT LEVEL 102 Instruction Manual D103785X012 Figure B 7 Manual Setup gt Travel Pressure Control 2 2 3 2 2 3 Travel Pressure Control AD PD 1 Travel Pressure Select 3 Pressure Control 4 Pressure Fallback 5 Control Mode 6 Characterization 7 Dynamic Response Manual Setup 1 Mode and Protection 2 Instrument HC AD PD 2 2 3 6 HC 3 Travel Pressure Control _2 2 3 7 AD PD 4 Tuning Dynamic Response 5 Valve and Actuator 1 SP Rate Open 6 Partial Stroke Test PST 2 SP Rate
108. key 63 to the 2 5 8 inch threads the terminal box to prevent seizing or galling when the cap is installed 9 Screw the cap key 4 onto the terminal box 10 Install a set screw key 58 into the cap key 4 Loosen the cap not more than 1 turn to align the set screw over one of the recesses in the terminal box Tighten the set screw key 58 11 Apply sealant key 64 to the conduit entrance plug key 62 and install it into the unused conduit entry of the terminal box Travel Sensor A WARNING Refer to the Maintenance WARNING at the beginning of this section Replacing the travel sensor requires removing the remote feedback unit from the actuator A WARNING To avoid personal injury or property damage caused by fire or explosion remove power to the instrument before removing the travel sensor assembly in an area which contains a potentially explosive atmosphere or has been classified as hazardous Maintenance and Troubleshooting Instruction Manual November 2015 D103785X012 Disassembly Note If the feedback arm key 79 or feedback arm assembly key 84 is removed from the digital valve controller the travel sensor assembly i e potentiometer bushing assembly key 223 must be recalibrated DVC6015 Remote Feedback Unit Refer to figure 7 4 for key number locations Remove piping and fittings from the instrument Disconnect the adjustment arm from the connector arm and the feedback arm see figure 6 7 Remo
109. l gives easy access to information critical to process operation You can gain information from the principal component of the process the control valve itself using the Field Communicator at the valve or at a field junction box or by using a personal computer or operator s console within the control room Introduction Instruction Manual November 2015 0103785 012 Using a personal computer ValveLink software Figure 1 1 DVC6000 HW2 Digital Valve Controller AMS Suite Intelligent Device Manager or a Field Communicator you can perform several operations with Mounted on Rotary Control Valve Actuator the DVC6000 HW2 digital valve controller You can obtain general information concerning software revision level messages tag descriptor and date Diagnostic information is available to aid you when troubleshooting Input and output configuration parameters can be set and the digital valve controller can be calibrated Refer to table 1 1 for details on the capabilities of each diagnostic tier Using the HART protocol information from the field can be integrated into control systems or be received ona single loop basis The DVC6000 HW2 digital valve controller is designed to directly replace standard pneumatic and electro pneumatic valve mounted positioners W8373 Table 1 1 Instrument Level Capabilities DIAGNOSTIC LEVEL 2 CAPABILITY ODV gE Auto Calibration Custom Characterization Step Response
110. le base assembly key 2 Note If the PWB assembly submodule is replaced calibrate and configure the digital valve controller to maintain accuracy specifications Removing the Printed Wiring Board Assembly 1 Separate the module base from the housing by performing the Removing the Module Base procedure NJ Remove three screws key 33 Lift the PWB assembly key 50 straight out of the module base key 2 Ensure that the O rings key 40 remain in the pressure sensor bosses on the module base assembly key 2 after the PWB assembly key 50 has been removed I UJ Replacing the PWB Assembly and Setting the DIP Switch 1 Apply silicone lubricant to the pressure sensor O rings key 40 and install them on the pressure sensor bosses in the module base assembly 2 Properly orient the PWB assembly key 50 as you install it into the module base The two electrical leads from the I P converter key 41 must guide into their receptacles in the PWB assembly and the pressure sensor bosses on the module base must fit into their receptacles in the PWB assembly 3 Push the PWB assembly key 50 into its cavity in the module base 4 Install and tighten three screws key 33 to a torque of 1 Nem 10 1 Ibfein 69 Maintenance and Troubleshooting Instruction Manual November 2015 D103785X012 5 Set the DIP switch on the PWB assembly according to table 6 2 On units that have the optional 4 20 mA position transmitter or switch har
111. licone sealant not furnished with the instrument 154 Retaining Ring 2 3 req d 237 Module Base Seall Module Base 2 Module Base 10 11 Drive 5 10 2 req d 12 O ring 19 Shield Assembly 0 61 Pipe Plug hex socket 10 3 req d 236 Screen for single acting direct units only 10 243 Flame Arrestor Assembly 10 3 req d I P Converter Assembly 23 Screw hex socket SST 2 11 4 req d 39 O ring 1 8 41 I P Converter 3 169 Shroud 11 210 Boot 1 8 2 req d also see figure 6 4 231 Seal Screen 1 6 8 Recommended spare 1 Available in the Elastomer Spare Parts Kit 2 Available in the Small Hardware Spare Parts Kit 6 Available in the Seal Screen Kit 8 Available in the I P Converter Kit 10 Available in the Spare Module Base Assembly Kit 11 Available in the Spare Shroud Kit 16 Available in the Pipestand Wall Mounting Kit Instruction Manual D103785X012 Key Description Part Number Relay 24 Relay Assembly includes shroud relay seal mounting screws Standard Single acting direct relay C 38B5786X132 Double acting relay A 38B5786X052 Single acting reverse relay B 38B5786X092 Low Bleed Single acting direct relay C 38B5786X152 Double acting relay A 38B5786X072 Single acting reverse relay B 38B5786X112 Extreme Temperature option fluorosilicone elastomers Standard Bleed Single acting direct relay C 38 5786 142 Double acting relay 38 578
112. lliammeter Adjust the resistance of the 1 kilohm potentiometer until the voltage read on the voltmeter is 10 0 volts Record the current shown on the milliammeter Mou If the current recorded step 6 is the same as that recorded in step 4 0 08 mA the voltage available is adequate 8 If the voltage available is inadequate refer to Section 2 Wiring Practices Restart Processor This is a soft reset of the device This procedure can only be performed while the instrument is out of service A soft reset will immediately put into effect changes that have been sent to the instrument Also if the device is configured to shutdown alert the soft reset will clear the shutdown 80 Instruction Manual Maintenance and Troubleshooting D103785X012 November 2015 Table 6 4 Instrument Troubleshooting Symptom Possible Cause 1 Analog input reading at 1a Control mode not Analog instrument does not match actual current provided 1 Check the control mode using the Field Communicator If in the Digital or Test mode the instrument receives its set point as a digital signal Control is not based on input current Change Control Mode to Analog 1b Low control system compliance voltage 1b Check system compliance voltage see Wiring Practices in the Installation section 1c Instrument shutdown due to self test failure 1c Check instrument status using the Field Communicator see Viewing I
113. lso contains an alphabetized function variable list to help locate the function variable on the appropriate menu tree All Fast Key Sequences referenced in the menu trees assume the Online menu see figure B 2 as the starting point Instrument Level HC AD PD and ODV Function Variable See Figure Function Variable See Figure Actual Travel 56 Drive Signal Alert Enable 59 Actuator Manufacture 56 Dynamic Torque 56 Actuator Model D NNNM Edit Cycle Counts Actuator Selection Edit Instrument Time B 6 B 9 Actuator Size Edit Travel Accumulator Actuator Sie Elective Area Acutator 88 End Point Pressure Control EPPO EPPC Deviation Alert Setup Fail Signal Fallback Recovery B 7 B 9 B 11 Feedback Connection Firmware Ae Record Full Enable Alert Record Not Empty Enable Swich Source HER 7 Analog Input B 3 B 11 Analog Input Calibration B 10 BO 89 88 7 AUG Flow to Ray Termin Rion 88 AuxifaryTerminalAction Ea BS Hardware Revision Device Burst Mode HART Tag B 3 B 6 Calibration Button 8 HART Universal Revision Calibration Record Hi Limit Cutoff Point Calibration HART Variable Assignments a 88 Torne Change to HART 5 B 11 Range Lo Clear Records B 9 B 1
114. mber 2015 Outputs Field Communicator Configure Manual Setup Outputs 2 2 6 HC AD PD or 2 2 7 ODV Note These menu items are only available on units that have the optional 4 20 mA position transmitter or switch hardware installed Output Terminal Configuration e Output Terminal Enable If using the optional output terminal for a Position Transmitter or Switch output this must be Enabled e Function The output terminals can be configured as one of the following Transmitter 4 20 mA output that represents 0 100 of the calibrated valve travel Limit Switch Discrete switch 1 max that trips at a configurable point within 0 100 of calibrated valve travel Alert Switch Discrete switch 1A max that trips based on a configurable device alert e Fail Signal Should the output circuit fail to operate properly the output will attempt to drive to a known state Depending on the nature of the failure the circuit may or may not be able to achieve this fail state When configured as a transmitter the output can be configured to drive high 22 5 mA or low 3 6 mA When configured as a switch the output can be configured to drive Closed or Open Note On loss of positioner power the switch circuit will always go to the open state However on loss of positioner power the transmitter output will continue to operate as long as the transmitter circuit is still powered and functioning Switch Configuration e Limit Switch Tr
115. mbly as shown in figure 6 1 Remove this shield and keep for reuse on the replacement module The replacement module will not have this protective shield Figure 6 1 Protective Shield for Feedback Linkage FEEDBACK ARM EXTENSION BIAS SPRING SHIELD X0908 2 Unscrew the four captive screws in the cover key 43 and remove the cover from the module base key 2 3 Using a 6 mm hex socket wrench loosen the three socket head screws key 38 These screws are captive in the module base by retaining rings key 154 Note The module base is linked to the housing by two cable assemblies Disconnect these cable assemblies after you pull the module base out of the housing 4 Pull the module base straight out of the housing key 1 Once clear of the housing swing the module base to the side of the housing to gain access to the cable assemblies 5 The base unit has two cable assemblies shown in figure 6 2 which connect the module base via the printed wiring board assembly to the travel sensor and the terminal box Disconnect these cable assemblies from the printed wiring board assembly on the back of the module base CAUTION To avoid affecting performance of the instrument take care not to damage the module base seal or guide surface Do not bump or damage the bare connector pins on the PWB assembly Damaging either the module base or guide surface may result in material damage which could compromise the instruments ability to mai
116. ms Note In the next step be sure the feedback arm outer surface remains flush with the end of the travel sensor shaft 6 While observing the resistance tighten the screw key 80 to secure the feedback arm to the travel sensor shaft Be sure the resistance reading remains at the calculated resistance determined in step 3 100 ohms Paint the screw to discourage tampering with the connection 7 Disconnect the multimeter from the travel sensor connector 8 Travel sensor adjustment is complete Install the remote feedback unit on the actuator as described in the Installation section 79 Maintenance and Troubleshooting Instruction Manual November 2015 D103785X012 Troubleshooting If communication or output difficulties are experienced with the instrument refer to the troubleshooting chart in table 6 4 Also see the DVC6000 HW2 Troubleshooting Checklist on page 83 Checking Voltage Available Personal injury or property damage caused by fire or explosion may occur if this test is attempted in an area which contains a potentially explosive atmosphere or has been classified as hazardous To check the Voltage Available at the instrument perform the following Connect the equipment in figure 2 3 to the field wiring in place of the FIELDVUE instrument Set the control system to provide maximum output current Set the resistance of the 1 kilohm potentiometer shown in figure 2 3 to zero Record the current shown on the mi
117. n firmware cannot Stroking Time The time in seconds required to move the valve from its fully open position to fully closed or vice versa Temperature Sensor A device within the FIELDVUE instrument that measures the instrument s internal temperature Travel Movement of the valve stem or shaft which changes the amount the valve is open or closed Travel Accumulator The capability of a FIELDVUE instrument to record total change in travel The value of the Travel Accumulator increments when the magnitude of the change exceeds the Travel Accumulator Deadband To reset the Travel Accumulator set it to zero Travel Accumulator Alert Checks the difference between the Travel Accumulator value and the Travel Accumulator Alert Point The Travel Accumulator Alert is active when the Travel Accumulator value exceeds the Travel Accumulator Alert Point It clears after you reset the Travel Accumulator to a value less than the alert point Travel Accumulator Alert Point An adjustable value which when exceeded activates the Travel Accumulator Alert Valid entries are 025 to 4 billion 25 Glossary November 2015 Travel Accumulator Deadband Region around the travel reference point established at the last increment of the accumulator This region must be exceeded before a change in travel can be accumulated Valid entries are 0 to 100 Travel Alert Checks the ranged travel against the travel high and low alert points The travel
118. n transmitter output signal There are two choices 4mA Valve Closed or 4mA Valve Open Burst Mode Burst mode provides continuous communication from the digital valve controller Burst mode applies only to the transmission of burst mode data HART Variable Assignments and does not affect the way other data is accessed Burst mode is only available in devices configured as HART Universal Revision 5 e Burst Enable Turns on or off the burst mode e Burst Command Defines which HART command is configured for burst reporting There are three options to choose from When using a Tri Loop select the third option Analog Input Command 1 Loop Current Travel Command 2 Loop Current PV SV TV QV Command 3 Note Access to information in the instrument is normally obtained through the poll response of HART communication The Field Communicator or the control system may request any of the information that is normally available even while the instrument is in burst mode Between each burst mode transmission sent by the instrument a short pause allows the Field Communicator or control system to initiate a request The instrument receives the request processes the response message and then continues bursting the burst mode data Burst mode will be disabled by ValveLink software during diagnostics tests such as Valve Signature Note If the instrument is configured to operate in pressure control mode or detects an invalid
119. ng conditions exists for more than 20 seconds the alert is set For the case where Zero Power Condition is defined as closed Drive Signal 10 and Calibrated Travel gt 3 Drive Signal gt 9025 and Calibrated Travel lt 97 For the case where Zero Power Condition is defined as open Drive Signal 10 and Calibrated Travel lt 97 Drive Signal gt 90 and Calibrated Travel gt 3 e Non Critical NVM Alert This alert is active if there is a failure associated with NVM non volatile memory that is not critical for instrument operation If this alert is active restart the instrument If the alert persists replace the printed wiring board assembly e Critical NVM Alert This alert is active if there is a failure associated with NVM that is critical for instrument operation If this alert is active restart the instrument If the alert persists replace the printed wiring board assembly e Flash Integrity Failure This alert is active if there is a failure associated with flash ROM read only memory If this alert is active restart the instrument If the alert persists replace the printed wiring board assembly e Reference Voltage Failure This alert is active if there is a failure associated with the internal voltage reference If this alert is active replace the printed wiring board assembly 56 Instruction Manual Device Information Diagnostics and Alerts D103785X012 November 2015 Variable Out of Range This aler
120. ning and closing directions to 1 0 the boost function can be enabled without introducing lead lag dynamics in the active control region See table 3 2 for typical lead lag filter settings Table 3 2 Typical Lead Lag Filter Settings for Instrument Level ODV Parameter Description Typical Value Lag Time First order time constant A value of 0 0 will disable the lead lag filter Opening Lead Lag Ratio Initial response to the filter in the opening direction Closing Lead Lag Ratio Initial response to the filter in the closing direction Lead Lag Boost Initial conditions of the lead lag filter when the lower travel cutoff is active 27 Configuration Instruction Manual November 2015 D103785X012 Tuning Field Communicator Configure gt Manual Setup gt Tuning 2 2 4 Travel Tuning WARNING Changes to the tuning set may cause the valve actuator assembly to stroke avoid personal injury and property damage caused by moving parts keep hands tools and other objects away from the valve actuator assembly Travel Tuning Set There are eleven tuning sets to choose from Each tuning set provides a preselected value for the digital valve controller gain settings Tuning set C provides the slowest response and M provides the fastest response Table 3 3 lists the proportional gain velocity gain and minor loop feedback gain values for preselected tuning sets Table 3 3 Gain Values for Preselected Travel Tuning Sets Tuning Se
121. ns for ValveLink Software CONTROL SYSTEM FIELD TERM E1568 DVC6000 HW2 digital valve controllers are loop powered instruments that provide a control valve position proportional to an input signal from the control room The following describes a double acting digital valve controller mounted on a piston actuator The input signal is routed into the terminal box through a single twisted pair of wires and then to the printed wiring board assembly submodule where it is read by the microprocessor processed by a digital algorithm and converted into an analog I P drive signal As the input signal increases the drive signal to the I P converter increases increasing the I P output pressure The I P output pressure is routed to the pneumatic relay submodule The relay is also connected to supply pressure and amplifies the small pneumatic signal from the I P converter The relay accepts the amplified pneumatic signal and provides two output pressures With increasing input 4 to 20 mA signal the output A pressure always increases and the output B pressure decreases The output A pressure is used for double acting and single acting direct applications The output B pressure is used for double acting and single acting reverse applications As shown in figure A 3 the increased output A pressure causes the actuator stem to move downward Stem position is sensed through the feedback linkage by the travel sensor which is electrically connected to the p
122. nstrument Status in the Viewing Device Information section 1d Analog input sensor not calibrated 1d Calibrate the analog input sensor see Analog Input Calibration in the Calibration section le Current leakage le Excessive moisture in the terminal box can cause current leakage Typically the current will vary randomly if this is the case Allow the inside of the terminal box to dry then retest 2a Calculate Voltage Available see Wiring Practices in the Installation section Voltage Available should be greater than or equal to 10 VDC 2b Install a HART filter after reviewing Control System Compliance Voltage requirements see Wiring Practices in the Installation section 2c Cable capacitance too high 2c Review maximum cable capacitance limits see Wiring Practices in the Installation section 2d HART filter improperly adjusted 2d Check filter adjustment see the appropriate HART filter instruction manual 2e Improper field wiring 2e Check polarity of wiring and integrity of connections Make sure cable shield is grounded only at the control system 2 Instrument will not communicate 2a Insufficient Voltage Available 2b Controller output Impedance too low 2f Controller output providing less than 4 mA to loop 2f Check control system minimum output setting which should not be less than 3 8 mA 2g Disconnected loop wiring cable at PWB 2g Verify connectors are plugged in correctly 2h P
123. nstrument has been powered down since the last time the instrument clock was set To clear the alert reset the instrument time Pressure e Supply Pressure Alert This alert is active if the supply pressure falls below the supply pressure alert point Note The Supply Pressure Lo alert is available for instrument level AD PD and ODV 57 Device Information Diagnostics and Alerts Instruction Manual November 2015 D103785X012 Travel Note The Travel Alert Deadband applies to the Travel Deviation Alert as well as the Travel Alert Hi Lo Hi Hi and Lo Lo e Travel Deviation Alert If the difference between the Travel Target and the Travel exceeds the Travel Deviation Alert Point for more than the Travel Deviation Time the Travel Deviation Alert is active It remains active until the difference between the travel target and the Travel is less than the Travel Deviation Alert Point minus the Travel Alert Deadband e Travel Alert Hi This alert is active when the Travel exceeds the Travel Alert Hi Point Once the alert is active the alert will clear when the Travel falls below the Travel Alert Hi Point minus the Travel Alert Deadband See figure 5 1 Figure 5 1 Travel Alert Deadband ALERT IS SET TRAVEL ALERT HIGH POINT EILEEN 0007 TRAVEL ALERT DEADBAND ALERT IS CLEARED 6532 Travel Alert Hi Hi This alert is active when the Travel exceeds the Travel Alert Hi Hi Point Once the alert is active th
124. nt PV SV TV QV Select the HART Variable Assignments With I O Package E Configure gt Manual Setup gt Outputs gt HART Variable Assignments 2 2 6 4 HC AD PD or 2 2 7 4 ODV Without I O Package Configure gt Manual Setup gt Outputs gt HART Variable Assignments 2 2 6 1 HC AD PD or 2 2 7 1 ODV Configure the HART Variable Assignments The Primary Variable PV is always Analog Input The Secondary Variable SV Tertiary Variable TV and Quaternary Variable QV can be configured to any of the following variables Setpoint Travel see note below Pressure A Pressure B Pressure A B Supply Pressure Drive Signal Analog Input Note If the instrument is configured to operate in pressure control mode or detects an invalid travel sensor reading the Travel variable will report pressure in percent of bench set range Instruction Manual Configuration D103785X012 November 2015 Section 3 Configuration Guided Setup Configure Guided Setup 2 1 The following procedures will guide you through the instrument setup process e Device Setup This procedure is used to configure actuator and valve information calibrate the valve assembly and assign the tuning set for the valve assembly e Performance Tuner instrument level AD PD ODV This procedure executes a simple step response test and then calculates a recommended set of gain values based on the response of the control valve See page 30 for addi
125. nt goes to full supply air output at Port B Instruction Manual D103785X012 Index A Actuator Compatibility 6 Actuator Style 32 Alert Record Full Alert 59 Alert Record Not Empty Alert 59 Alert Setup 39 Alert Switch Function Output Terminal Configuration 37 Alert Switch Source 37 AMS Suite Intelligent Device Manager 4 Analog Calibration Adjust 44 Analog Input Range 21 Input Range Hi 21 Input Range Lo 22 Analog Input Units 21 ATEX Hazardous Area Approvals 6 Auto Calibration 42 Error Messages 43 Auto Partial Stroke Test 61 AutoCal in Progress Alert 60 Auxiliary Terminal Wiring Length Guidelines 12 Auxiliary Terminal Action 21 B Burst Mode 38 Burst Operation setting for Tri Loop 18 C Calibration 41 Analog Input 51 Pressure Sensors 46 PST 54 Pushbutton 45 Relay Adjustment 52 Sensor 46 Travel 42 Auto 42 Manual 44 Index November 2015 Travel Sensor 47 Travel Sensor Adjust 47 Calibration CAL Button 21 Calibration in Progress Alert 60 Certifications CUTR Russia Kazakhstan Belarus and Armenia 6 INMETRO Brazil 6 PESO CCOE India 6 Change Control Mode 25 Change HART Universal Revision 40 Characterization 25 Custom Characterization 25 Input Characterization 25 Communication Protocol HART 7 or HART 5 5 Compliance Voltage 1 1 Configuration Initial 3 Connections 6 Electrical 3 Pneumatic 3 Construction Materials 6 Cont
126. ntain a pressure seal 65 Maintenance and Troubleshooting Instruction Manual November 2015 D103785X012 Figure 6 2 Printed Wiring Board Cable Connections TERMINAL BOX REMOTE 0 TERMINAL 1 x A MODULE BASE ASSEMBLY m HOUSING CABLE TO REMOTE TERMINAL BOX PRINTED WIRING BOARD ASSEMBLY CABLE TO TERMINAL BOX X0921 Replacing the Module Base To replace the DVC6005 HW2 module base perform the following steps Refer to figure 7 2 for key number locations Note To avoid affecting performance of the instrument inspect the quide surface on the module and the corresponding seating area in the housing before installing the module base assembly These surfaces must be free of dust dirt scratches and contamination Ensure the module base seal is in good condition Do not reuse a damaged or worn seal 1 Ensure the module base seal key 237 is properly installed in the housing key 1 Ensure the O ring key 12 is in place on the module base assembly Connect the terminal box connector to the PWB assembly key 50 Orientation of the connector is required Connect the travel sensor connector to the PWB assembly Orientation of the connector is required Insert the module base key 2 into the housing key 1 BR UJ N Install three socket head screws key 38 in the module base into the housing If not already installed press three retaining rings key 154 into
127. o None 6 From the Calibrate menu select Sensor Calibration Travel Sensor Follow the prompts on the Field Communicator display to adjust the travel sensor counts to the value listed in table 4 2 Table 4 2 Travel Sensor Counts Remote Feedback Unit Travel Sensor Counts DVC6015 700 200 DVC6025 2100 200 DVC6035 Counterclockwise shaft rotation 600 200 DVC6035 Clockwise shaft rotation 3400 200 1 Refer to figure 4 3 to determine the desired starting position for the DVC6035 based on potentiometer shaft counterclockwise or clockwise 48 Instruction Manual Calibration D103785X012 November 2015 Figure 4 3 Travel Indicator Assembly Starting Position Counterclockwise or Clockwise DVC6035 FEEDBACK ARM MOVEMENT DVC6035 FEEDBACK ARM MOVEMENT ACTUATOR SHAFT MOVEMENT ACTUATOR SHAFT MOVEMENT STARTING POSITION OF THE TRAVEL INDICATOR ASSEMBLY IF STARTING POSITION OF THE TRAVEL INDICATOR ASSEMBLY INCREASING PRESSURE FROM OUTPUT A DRIVES THE INDICATOR IF INCREASING PRESSURE FROM OUTPUT A DRIVES THE CLOCKWISE THE POTENTIOMETER SHAFT WILL ROTATE INDICATOR COUNTERCLOCKWISE THE POTENTIOMETER COUNTERCLOCKWISE AS VIEWED FROM THE BACK OF THE SHAFT WILL ROTATE CLOCKWISE AS VIEWED FROM THE INSTRUMENT BACK OF THE INSTRUMENT Note In the next step be sure the feedback arm surface remains flush with the end of the travel sensor shaft 7 While observing the travel sensor counts tighten the screw that secures t
128. o Cutoff Point When the Hi Cutoff Limit Select is configured for Limit the Travel Target will not fall below the Lo Limit Point e Lo Limit Cutoff Point This is the point within the calibrated travel range below which the Limit or Cutoff is in effect When using cutoffs a Cutoff Lo of 0 5 is recommended to help ensure maximum shutoff seat loading The Lo Limit Cutoff is deactivated by setting it to 25 End Point Pressure Control EPPC Note End Point Pressure Control is available for instrument level ODV e EPPC Enable Select Yes or No End Point Pressure Control allows the digital valve controller to pull back from saturation of the pneumatic output after reaching the travel extreme Rather than having the instrument provide full supply pressure saturation continuously at the travel extreme the digital valve controller switches to an End Point Pressure Control where the output pressure pressure controller set point to the actuator is maintained at a certain value This value is configured through the Upper Operating Pressure feature Because the digital valve controller is constantly in control and not allowed to reach a dormant or saturated state it is constantly testing its own pneumatic system If there is an output pressure deviation for example the instrument will issue an alert To ensure there is an alert when an output pressure deviation occurs setup the alert as described under Pressure Deviation Alert 23 Configurati
129. of SEP Integral Switch 3 One isolated switch configurable throughout the calibrated travel range or actuated from a device alert Off State 0 mA nominal On State upto 1 A Supply Voltage 30 VDC maximum Reference Accuracy 2 of travel span Fisher Controls International LLC declares this product to be in compliance with Article 3 paragraph 3 of the Pressure Equipment Directive PED 97 23 EC It was designed and manufactured in accordance with Sound Engineering Practice SEP and cannot bear the CE marking related to PED compliance Contact your Emerson Process Management sales However the product may bear the CE marking to office or go to www FIELDVUE com for additional indicate compliance with other applicable European information Community Directives NOTE Specialized instrument terms are defined in ANSI ISA Standard 51 1 Process Instrument Terminology 1 4 conductor shielded cable 18 to 22 AWG minimum wire size in rigid or flexible metal conduit is connection between base unit and feedback unit Pneumatic tubing between base unit output connection and actuator has been tested to 91 meters 300 E At 15 meters 50 feet there was no performance degradation At 91 meters there was minimal pneumatic lag 2 The pressure temperature limits in this document and any other applicable code or standard should not be exceeded 3 Normal m3 hour Normal cubic meters per hour at 0 C and 1 01325 bar absolute Scfh Stand
130. of time that the microprocessor is idle A typical value is 25 The actual value depends on the number of functions in the instrument that are enabled and on the amount of communication currently in progress Full Ranged Travel Current in mA that corresponds with the point where ranged travel is maximum i e limited by the mechanical travel stops Gain The ratio of output change to input change Hardware Revision Revision number of the Fisher instrument hardware The physical components of the instrument are defined as the hardware Instruction Manual D103785X012 HART acronym The acronym HART stands for Highway Addressable Remote Transducer HART Universal Revision Revision number of the HART Universal Commands which are the communications protocol for the instrument Input Characteristic The relationship between the ranged travel and ranged input Possible values include linear equal percentage and quick opening Input Current The current signal from the control system that serves as the analog input to the instrument See also Input Signal Input Range The analog input signal range that corresponds to the travel range Input Signal The current signal from the control system The input signal can be displayed in milliamperes or in percent of ranged input Instrument Level Determines the functions available for the instrument See table 5 1 Instrument Mode Determines if the instrument responds to
131. oller 95 Appendix B Field Communicator Menu Tree c 99 E E 107 E kos ae 113 The FIELDVUE DVC6000 HW2 digital valve controller is a core component of the PlantWeb digital plant architecture The digital valve controller powers PlantWeb by capturing and delivering valve diagnostic data Coupled with ValveLink software the DVC6000 HW2 provides users with an accurate picture of valve performance including actual stem position instrument input signal and pneumatic pressure to the actuator Using this information the digital valve controller diagnoses not only itself but also the valve and actuator to which it is mounted Instruction Manual Introduction D103785X012 November 2015 Section 1 Introduction Installation Pneumatic and Electrical Connections and Initial Configuration Refer to the DVC6005 Series Remote Mount quick start quide D103784X012 for DVC6000 HW2 installation connection and initial configuration information If a copy of this quick start quide is needed contact your Emerson Process Management sales office or visit our website at www Fisher com Scope of Manual This instruction manual is a supplement to the DVC6005 Series Remote Mount quick start guide that ships with every instrument This instruction manual includes product specifications reference materials custom setup information maintenance procedures and replacement part details This instruction manual describes using th
132. on 21 Parts List 87 Removing 72 Index November 2015 Replacing 73 Test Speed 36 Transmitter 37 Function Output Terminal Configuration 37 Transmitter Output 38 Travel Accumulator High Alert 59 Travel Alert Hi 58 Travel Alert Hi Hi 58 Travel Alert Lo 58 Travel Alert Lo Lo 58 Travel Calibration 42 Travel Control Travel Pressure Select 22 Travel Deviation Alert 58 Travel Limit Cutoff Hi Alert 58 Travel Limit Cutoff Lo Alert 58 Travel Sensor Adjusting DVC6015 47 DVC6025 49 DVC6035 47 Parts List 88 Removing DVC6015 74 DVC6025 75 DVC6030 75 Replacing DVC6015 75 DVC6025 76 DVC6035 78 Travel Sensor Adjust 47 Travel Sensor Alert 57 Travel Sensor Motion 33 Travel Tuning 28 Performance Tuner 30 Stabilize Optimize 30 Travel Tuning Set 28 Travel Tuning Sets Gain Values 28 Travel Pressure Control 22 Control Mode 25 Cutoffs and Limits 23 End Point Pressure Control 23 Fallback Recovery 24 Pressure Control 24 Pressure Fallback 24 Travel Pressure Select 22 117 Index November 2015 Dev Press Fallback 24 Dev Press Fallback Time 24 Travel Pressure Select 22 Fallback Sensor Tvl Deviation 23 Pressure Control 22 Pressure Sensor Failure 22 Travel Control 22 Troubleshooting Instrument 80 Tuning 28 Integral Settings 31 Pressure 31 Travel 28 Tuning Set Pressure 31 Travel 28 Dev Press Fallback 24 Dev Press Fallback Time 24
133. on Instruction Manual November 2015 D103785X012 e EPPC Set Point Used in conjunction with End Point Pressure Control End Point Pressure Control Set Point allows you to select a pressure to be delivered by the instrument at the travel extreme For a fail closed valve this pressure must be sufficient to maintain the fully open position For a fail open valve this pressure which is automatically set to supply pressure must be sufficient to fully close the valve and maintain its rated shutoff classification For double acting spring return actuators this is the differential pressure required to either maintain the fully open or fully closed position depending on the valve and actuator configuration For a double acting actuator without springs with fail close valve this is 95 of the supply pressure If the valve is fail open the upper operating pressure for all actuators is set to the supply pressure e EPPC Saturation Time End Point Pressure Control Saturation Time is the time the digital valve controller stays in hard cutoff before switching to pressure control Default is 45 seconds Pressure Control e Pressure Range High The high end of output pressure range Enter the pressure that corresponds with 10075 valve travel when Zero Power Condition is closed or 025 valve travel when Zero Power Condition is open This pressure must be greater than the Pressure Range Lo e Pressure Range Lo The low end of the output pressure range Ent
134. onfiguration 37 Output Terminal Enable 37 Outputs 37 Burst Mode 38 HART Variable Assignments 38 Output Terminal Configuration 37 Switch Configuration 37 Transmitter Output 38 Overview 55 Device 61 Status amp Primary Purpose Variables 55 Partial Stroke Test Automatic scheduled 61 PST Enable 36 PST Pressure Limit 34 PST Start Point 36 PST Variables 36 Pause Time 36 Test Speed 36 Partial Stroke Test ODV only 60 Auxiliary Terminal Local Pushbutton 61 Field Communicator 61 Partial Stroke Test PST 34 PST Variables Max Travel Movement 36 Parts Common Parts 86 Feedback Parts 88 Gauges Tire Valves amp Pipe Plugs 88 HART Filters 88 I P Converter Assembly 86 Kits 85 Module Base 86 ordering 85 Printed Wiring Board Assembly 87 Relay 87 Terminal Box 87 Pause Time 36 Performance Tuner 30 PESO CCOE India Certification 6 Pneumatic Connections 3 Pneumatic Relay Parts List 87 Removing 71 Replacing 71 116 Instruction Manual D103785X012 Polling Address 21 Position Transmitter 37 Pressure Control 24 Pressure Range High 24 Pressure Range Lo 24 Travel Pressure Select 22 Pressure Control Active Alert 60 Pressure Fallback Active Alert 58 Pressure Range High 24 Pressure Range Lo 24 Pressure Sensor Alert 57 Pressure Sensors Calibration 46 Pressure Tuning 31 Pressure Tuning Set 31 Pressure Tuning Sets Gain Values 31 Pressure Units
135. or explosion if natural gas is used as the supply medium and appropriate preventive measures are not taken Preventive measures may include but are not limited to one or more of the following Remote venting of the unit re evaluating the hazardous area classification ensuring adequate ventilation and the removal of any ignition sources e Ensure that all caps and covers are correctly installed before putting this unit back into service Failure to do so could result in personal injury or property damage from fire or explosion Maintenance and Troubleshooting Instruction Manual November 2015 D103785X012 CAUTION When replacing components use only components specified by the factory Always use proper component replacement techniques as presented in this manual Improper techniques or component selection may invalidate the approvals and the product specifications as indicated in table 1 2 It may also impair operations and the intended function of the device Note If the feedback arm key 79 or feedback arm assembly key 84 is removed from the digital valve controller the travel sensor must be recalibrated Because of the diagnostic capability of the DVC6000 HW2 predictive maintenance is available through the use of ValveLink software Using the digital valve controller valve and instrument maintenance can be enhanced thus avoiding unnecessary maintenance For information on using the ValveLink software refer to the ValveLink software
136. orresponds to the mid travel position of the actuator This will leave an equal amount of unused resistive element on both ends of the travel which is required by the digital valve controller to function properly 2 Onthe base unit remove the feedback connections terminal box cap 3 If necessary install conduit between the potentiometer and the base unit following applicable local and national electrical codes Route the 3 conductor shielded cable between the two units refer to figure 2 4 Figure 2 4 Terminal Details for Connecting a FIELDVUE DVC6005 HW2 Base Unit and a 10k Ohm External Potentiometer BASE UNIT TERMINATION BOX 3RD PARTY FEEDBACK ELEMENT DVC6005 HW2 WITH 10k Q POTENTIOMETER 4 Connect one wire of the 3 conductor shielded cable between the terminal labeled 30kQ2 on the base unit and one end lead of the potentiometer 5 Connect the second wire of the 3 conductor shielded cable between the middle lead wiper of the 10 kOhm potentiometer to Terminal 2 on the base unit 6 Connect the third wire of the 3 conductor shielded cable between Terminal 3 on the base unit and the other end lead of the 10 kOhm potentiometer 7 Connect the cable shield or drain wire to the ground screw in the feedback connections terminal box of the base unit Do not connect the shield or drain wire to the external potentiometer 8 Replace and tighten the base unit cover Instruction Manual Wiring Practices D103785X012 November 2
137. oxboro IJA control system 1988 with a Caster of 50 000 pF and a Belden 9501 cable with characteristic capacitance of 50pF ft Length ft 160 000 50 000pF 50pF ft Length 2200 ft The HART communication cable length is limited by the cable characteristic capacitance To increase cable length select a wire with lower capacitance per foot Contact your Emerson Process Management sales office for specific information relating to your control system Remote Travel Sensor Connections The DVC6005 HW2 base unit is designed to receive travel information via a remote sensor The remote can be any of the following Emerson Process Management supplied DVC6015 DVC6025 or DVC6035 remote feedback unit refer to the DVC6005 Series Remote Mount Digital Valve Controller quick start quide D103784X012 that ships with the product e Anunder traveled 10 kOhm potentiometer used in conjunction with onboard 30 kOhm resistor or e A potentiometer used in conjunction with two fixed resistors potentiometer travel is the same as actuator travel WARNING Personal injury property damage caused by wiring failure result if the feedback wiring connecting the base unit with the remote feedback unit shares a conduit with any other power or signal wiring Do not place feedback wiring in the same conduit as other power or signal wiring Note 3 conductor shielded cable 22 AWG minimum wire size is required for connection bet
138. p that the valve needs to be at before a partial stroke test can be initiated This also defines the travel stop for end point pressure control Setting this value to Not Configured will disable partial stroke tests and end point pressure control PST Variables Follow the prompts on the Field Communicator display to enter or view information for following PST Variables e Max Travel Movement The percentage of total span that the valve moves away from its normal operating state towards its tripped state during the test The default value is 1025 e Test Speed The rate at which the valve will move during the test The default value is 0 25 second e Pause Time The pause time between the up and down strokes of the test The default value is 5 seconds Figure 3 6 Example Time Series Plots of Travel Set Point Travel Error and Actuator Pressure 5 TESTSTARTPOINT dall coe ACTUAL TRACE FROM TEST TYPICAL un 550 TRAV TEST SPEED tae PERCENT SEC T 7 90 0 IIS A TEST PAUSE TIME SEC 65 0 0 0 10 0 15 0 20 0 25 0 30 0 35 0 TIME SEC S ACTUAL TRACE FROM TEST TYPICAL ME m 02 ET 5 10 0 15 0 20 0 25 0 30 0 35 0 TIME SEC e Lia Z 5 un LL Z A TIME SEC 36 Instruction Manual Configuration D103785X012 Nove
139. point for the fixed input characteristics assuming the Zero Power Condition is configured as closed You can specify 21 points on a custom characteristic curve Each point defines a travel target in of ranged travel for a corresponding set point in of ranged set point Set point values range from 6 25 to 106 2526 Before modification the custom characteristic is linear e Custom Characterization To define a custom input character select Custom Characterization from the Characterization menu Select the point you wish to define 1 to 21 then enter the desired set point value Press Enter then enter the desired travel target for the corresponding set point When finished select point 0 to return to the Characterization menu With input characterization you can modify the overall characteristic of the valve and instrument combination Selecting an equal percentage quick opening or custom other than the default of linear input characteristic modifies the overall valve and instrument characteristic However if you select the linear input characteristic the overall valve and instrument characteristic is the characteristic of the valve which is determined by the valve trim i e the plug or cage 25 26 Configuration Instruction Manual November 2015 0103785 012 Figure 3 2 Travel Target Versus Ranged Set Point for Various Input Characteristics Zero Power Condition Closed e eee
140. rclockwise Maximum Supply Pressure Enter the maximum supply pressure that is required to fully stroke the valve 33 Configuration Instruction Manual November 2015 D103785X012 Partial Stroke Test PST Instrument Level ODV only Configure gt Manual Setup gt Partial Stroke 2 2 6 Note Partial Stroke is only available for instrument level ODV Partial Stroke Test PST e PST Pressure Limit This defines the actuator pressure at which a partial stroke test will abort This prevents the DVC6000 HW2 from exhausting or building excessive pressure to the actuator in an attempt to move a stuck valve During Device Setup or Auto Travel Calibration the Partial Stroke Pressure Limit will be set automatically as follows Single Acting Actuators For those actuators that exhaust pressure from the partial test start point the Pressure Limit will be a minimum value For those actuators that build pressure from the partial test start point the Pressure Limit will be a maximum value Double Acting Actuators The Pressure Limit will be set to a negative value for actuators where the partial stroke start point is opposite of the Zero Power Condition e g Partial Stroke Start Point Open and Zero Power Condition Closed and to a positive valve for actuators where the partial stroke start point is the same as the Zero Power Condition The pressure signal used to determine this parameter depends on relay type and is summarized below
141. replaced adjust the travel sensor by performing the appropriate procedure See the Maintenance section for travel sensor assembly replacement procedures DVC6015 and DVC6035 Remote Feedback Units WARNING Failure to remove air pressure may cause personal injury or property damage from bursting parts 1 Remove supply air and remove the instrument from the actuator 47 Calibration Instruction Manual November 2015 0103785 012 2 As shown figure 4 2 align the feedback arm key 79 with the housing by inserting the alignment key 46 through the hole marked A on the feedback arm Fully engage the alignment pin into the tapped hole in the housing Note The alignment pin key 46 is stored inside the remote feedback unit housing Figure 4 2 FIELDVUE DVC6015 Remote Feedback Unit Showing Feedback Arm in Position for Travel Sensor Adjustment ALIGNMENT PIN KEY 46 FEEDBACK ARM KEY 79 TRAVEL SENSOR SHAFT X0918 3 Loosen the screw that secures the feedback arm to the travel sensor shaft Position the feedback arm so that the surface of the feedback arm is flush with the end of the travel sensor shaft 4 Connect a current source to the instrument LOOP and LOOP terminals Set the current source to any value between 4 and 20 mA Connect the Field Communicator to the TALK terminals 5 Before beginning the travel sensor adjustment set the instrument mode to Out Of Service and the protection t
142. rinted wiring board assembly submodule The stem continues to move downward until the correct stem position is attained At this point the printed wiring board assembly stabilizes the I P drive signal This positions the flapper to prevent any further increase in nozzle pressure As the input signal decreases the drive signal to the I P converter submodule decreases decreasing the I P output pressure The pneumatic relay decreases the output A pressure and increases the output B pressure The stem moves upward until the correct position is attained At this point the printed wiring board assembly stabilizes the I P drive signal This positions the flapper to prevent any further decrease in nozzle pressure 96 Instruction Manual Principle of Operation D103785X012 November 2015 Figure A 3 FIELDVUE DVC6000 HW2 Digital Valve Controller Block Diagram 4 20 mA SIGNAL HART AUXILIARY TERMINALS TERMINAL BOX PRINTED WIRING BOARD FEEDBACK CONNECTION TERMINAL BOX TINTE OUTPUT A CONVERTER SUPPLY PRESSURE OUTPUT B VALVE AND ACTUATOR VALVE TRAVEL FEEDBACK E1569 97 Principle of Operation November 2015 98 Instruction Manual D103785X012 Instruction Manual Field Communicator Menu Trees 0103785 012 November 201 Appendix B Field Communicator Menu Trees This section contains the Field Communicator menu trees for instrument level HC AD PD and ODV It a
143. ristic where most of the change in flow rate takes place for small amounts of stem travel from the closed position The flow characteristic curve is basically linear through the first 40 percent of stem travel One of the input characteristics available for a FIELDVUE Instrument See also Equal Percentage and Linear Random Access Memory RAM Atype of semiconductor memory that is normally used by the microprocessor during normal operation that permits rapid retrieval and storage of programs and data See also Read Only Memory and Non Volatile Memory NVM Rate Amount of change in output proportional to the rate of change in input Read Only Memory ROM A memory in which information is stored at the time of instrument manufacture You can examine but not change ROM contents Seat Load Force exerted on the valve seat typically expressed in pounds force per lineal inch of port circumference Seat load is determined by shutoff requirements Instruction Manual D103785X012 Set Point Filter Time Lag Time The time constant in seconds for the first order input filter The default of 0 seconds will bypass the filter Software Microprocessor or computer programs and routines that reside in alterable memory usually RAM as opposed to firmware which consists of programs and routines that are programmed into memory usually ROM when the instrument is manufactured Software can be manipulated during normal operatio
144. rol Mode 25 Change Control Mode 25 Control Mode 25 Restart Control Mode 25 Critical NVM Alert 56 crossover adjustment 42 CSA Hazardous Area Approvals 6 Custom Characterization Defining 25 Cutoffs and Limits 23 Hi Limit Cutoff Point 23 Hi Limit Cutoff Select 23 Lo Limit Cutoff Point 23 Lo Limit Cutoff Select 23 Cycle Count High Alert 59 D Declaration of SEP 7 Default Parameters Detailed Setup 19 Descriptor 21 Device Diagnostics 56 Device Information 55 113 Index November 2015 Device Status 56 Alert Record 56 Alert Record 59 Electronics 56 Pressure 5 Status 60 Travel 58 Travel History 59 Diagnostic Data Available Alert 60 Diagnostic in Progress Alert 60 Diagnostics 60 Partial Stroke Test 60 Stroke Valve 60 Digital Calibration Adjust 44 DIP Switch Setting 69 Drive Current Failure 56 Drive Signal Alert 56 Dynamic Response 27 Lag Time 27 SP Rate Close 27 SP Rate Open 27 E Edit Instrument Time 22 Educational Services 8 Electrical Classification 6 Electrical Connections 3 Electrical Housing 6 Electromagnetic Compatibility 6 EMC Summary Results Immunity 7 End Point Pressure Control 23 End Point Pressure Control EPPC 23 Expert tuning travel tuning 28 31 F Fail Signal Output Terminal Configuration 37 Fallback Recovery 24 Fallback Sensor Failure Travel Pressure Select 22 Fallback Sensor Tvl Deviation Travel Pressure
145. ruction Manual November 2015 0103785 012 Figure 2 5 Terminal Details for Connecting a FIELDVUE DVC6005 HW2 Base Unit and Three Resistor Series BASE UNIT TERMINATION BOX THREE RESISTOR SERIES DVC6005 HW2 Install the fixed resistor R1 across the unlabeled bottom Terminal and Terminal 1 The bottom terminal does not have a screw The screw on the 30 kOhm terminal can be used R1 must be properly insulated when installed in the terminal box to prevent personal injury or property damage Connect one wire of the 3 conductor shielded cable between the unlabeled bottom Terminal on the base unit and an end lead of the external potentiometer Connect the second wire of the 3 conductor shielded cable between the middle lead wiper of the external potentiometer and Terminal 2 on the base unit Connect the third wire of the 3 conductor shielded cable between between a lead on fixed resistor R2 and terminal 3 of the base unit 7 Connect the available end lead on the potentiometer Rpot with the available lead on fixed resistor R2 9 Connect the cable shield or drain wire to the ground screw in the feedback connections terminal box of the base unit Do not connect the shield or drain wire to the two resistor series Replace and tighten the base unit cover Example Using a linear potentiometer rated at 400 Ohms inch on an actuator with 16 of travel Rpot max 5 400 Ohms in x
146. sing a Field Communicator perform the appropriate Travel Sensor Adjust procedure in the Calibration section Install the remote feedback unit on the actuator when the travel sensor adjustment is complete Note If a Field Communicator is not available perform the Travel Sensor Adjustment with Multimeter procedure below Travel Sensor Adjustment with a Multimeter DVC6015 1 Align the feedback arm key 79 to the housing key 1 by inserting the alignment pin key 46 through the hole marked A on the feedback arm Fully engage the alignment pin into the tapped hole in the side of the housing Position the feedback arm so that the surface is flush with the end of the travel sensor shaft 2 Connect a multimeter set to a resistance range of 50 000 ohms Measure the resistance between terminals 1 and 3 of the remote feedback unit Refer to figure 6 8 for terminal location The resistance should be between 40 000 and 50 000 ohms 3 Multiply the result in step 2 by 0 046 to get a calculated resistance The calculated resistance should be in the range of 1840 to 2300 ohms 4 Re range the multimeter to a resistance of 3000 ohms between terminals 2 and 3 of the remote feedback unit Refer to figure 6 8 for terminal location 5 Adjust the travel sensor shaft to obtain the calculated resistance determined in step 3 100 ohms Note In the next step be sure the feedback arm surface remains flush with the end of the travel sensor shaft
147. ssed in pounds per square inch Byte A unit of binary digits bits A byte consists of eight bits Calibration Location Where the instrument was last calibrated either in the factory or in the field Configuration Stored instructions and operating parameters for a FIELDVUE Instrument Glossary November 2015 Control Loop An arrangement of physical and electronic components for process control The electronic components of the loop continuously measure one or more aspects of the process then alter those aspects as necessary to achieve a desired process condition A simple control loop measures only one variable More sophisticated control loops measure many variables and maintain specified relationships among those variables Control Mode Defines where the instrument reads its set point The following control modes are available for a FIELDVUE Instrument Analog The instrument receives its travel set point over the 4 20 mA loop Digital The instrument receives its set point digitally the HART communications link Test This is not a user selectable mode The Field Communicator or ValveLink software places the instrument in this mode whenever it needs to move the valve such as for calibration or diagnostic tests Control Mode Restart Determines the instrument control mode after a restart See Control Mode for the available restart control modes Controller A device that operates automatically to regulate
148. stl 2 req d 86 Plain Washer pl stl 2 req d 87 Follower Post SST 88 X Roller SST PTFE 89 Spring Lock Washer pl stl 90 HexNut pl stl 91 Arm Assembly SST 92 CapScrew hex socket 4 req d 93 Spring Feedback Arm HART Filters HF340 DIN rail mount 39B5411X022 HF341 DIN rail Mount pass through no filter 39B5412X012 Recommended spare 2 Available in the Small Hardware Spare Parts Kit 5 Available in Alignment Pin Kit 14 Available in Feedback Unit Kit 15 Available in Feedback Unit Termination Strip Kit Parts November 2015 Instruction Manual 0103785 012 Figure 7 2 FIELDVUE DVC6005 HW2 Base Unit Assembly lt lt E M u E d ed gt lt lt UE zi NP cT AN d NDS Vi Ss Zo RING JG maroniensis a P CES ASA DI lt pe ann lt EP a PO LLL RAAF ez 2 A 2 2 ENS NND 1 se SECTION B B L APPLY LUB SEALANT NOTES 1 APPLY LUBRICANT KEY 65 TO ALL O RINGS UNLESS OTHERWISE SPECIFIED 49B3261 C SHT 1 amp 2 89 Instruction Manual Parts D103785X012 November 2015 Figure 7 2 FIELDVUE DVC6005 2 Base Unit Assembly continued 154 Cr d 169
149. stment with Multimeter procedure below Travel Sensor Adjustment with a Multimeter DVC6025 1 Connect a multimeter set to a resistance range of 50 000 ohms Measure the resistance between terminals 1 and 3 of the remote feedback unit Refer to figure 6 8 for terminal location The resistance should be between 40 000 and 50 000 ohms 2 Multiply the result in step 1 by 0 142 to get a calculated resistance The calculated resistance should be in the range of 5680 to 7100 ohms 3 Re range the multimeter to a resistance of 7000 ohms between terminals 2 and 3 of the remote feedback unit Refer to figure 6 8 for terminal location 4 Hold the arm assembly key 91 in a fixed position so that the arm is parallel to the housing back plane and pointing toward the terminal box Position the arm assembly so that the outer surface is flush with the end of the travel sensor shaft 5 Adjust the travel sensor shaft to obtain the calculated resistance determined in step 2 100 ohms Note In the next step be sure the arm assembly outer surface remains flush with the end of the travel sensor shaft 77 Maintenance and Troubleshooting Instruction Manual November 2015 D103785X012 6 While observing the resistance tighten the screw key 80 to secure the feedback arm to the travel sensor shaft Be sure the resistance reading remains at the calculated resistance determined step 2 100 ohms Paint the screw to discourage tampering with the conne
150. t 2 Travel Pressure Select 4 Travel Limit Cutoff Lo Enable 3 Fallback Recovery 5 LoLimit Cutoff Point 2 3 4 HC 6 Lo Limit Cutoff Select 2 3 6 AD PD 2 3 3 HC ae 2 3 5 AD PD ODV Shutdown On Alert 2 3 8 ODV lt d History 1 Sensors 2 3 6 ODV 1 Cycle Count Travel Accum Deadband 2 Electronics EPPC Deviation Z 2 Cycle Count Alert Enable m 3 Edit Cycle Counts 2 3 4 1 HC 1 EPPC Deviation Alert Enable 4 Cycle Count Alert Point 2 3 6 1 AD PD 2 EPPC Set Point 5 Travel Accumulator Alert Enable 2 3 8 1 ODV 3 EPPC Deviation Alert Point 6 Edit Travel Accumulator Electronics ax 4 EPPC Deviation Time 7 Accumulator Alert Point 1 Drive Current Failure Shutdown 2 Critical NVM Failure Shutdown 3 Non Critical NVM Failure Shutdown 2 3 4 2 HC 4 Flash Integrity Failure Shutdown 2 3 6 2 AD PD 5 Reference Voltage Failure Shutdown 2 3 8 2 ODV Sensors G 1 Travel Sensor Failure Shutdown 2 Temp Sensor Failure Shutdown 3 Minor Loop Sensor Failure Shutdown 4 Pressure Sensor Failure Shutdown NOTES SUPPLY PRESSURE LO ALERT IS AVAILABLE FOR INSTRUMENT LEVEL AD PD AND ODV PRESSURE FALLBACK IS AVAILABLE FOR INSTRUMENT LEVEL AD PD AND ODV EPPC DEVIATION IS AVAILABLE FOR INSTRUMENT LEVEL ODV OUTPUT CIRCUIT COMM FAILURE ENABLE IS AVAILABLE WHEN THE TRANSMITTER FUNCTION IS CONFIGURED FAST KEY SEQUENCES FOR THESE MENUS DROP ONE MENU SEQUENCE WHEN THE TRANSMITTER FUNCT
151. t Proportional Gain Velocity Gain Minor Loop Feedback Gain C D E F G H L M X Expert User Adjusted User Adjusted User Adjusted In addition you can specify Expert tuning and individually set the proportional gain velocity gain and minor loop feedback gain Individually setting or changing any tuning parameter or running the Performance Tuner or Stabilize Optimize routine will automatically change the tuning set to X expert Note Use Expert tuning only if standard tuning has not achieved the desired results Stabilize Optimize or Performance Tuner may be used to achieve the desired results more rapidly than manual Expert tuning Table 3 4 provides tuning set selection guidelines for Fisher and Baumann actuators These tuning sets are only recommended starting points After you finish setting up and calibrating the instrument you may have to select either a higher or lower tuning set to get the desired response You can use the Performance Tuner to optimize tuning 28 nstruction Manual 0103785 012 Table 3 4 Actuator Information for Initial Setup Actuator Actuator Actuator Size Manufacturer Model 585 amp 585CR 100 130 34 40 657 45 50 46 60 70 76 amp 80 100 30 34 40 667 45 50 46 60 70 76 amp 1051 amp 1052 Fisher 1061 68 80 100 130 20 10665 27 78 2052 30 30E 3024C 34 34E 40 40 45 45E 225 cx Air to Extend Air to Retract Baumann Actuator St
152. t come out of the base of the converter 4 Ensure that the O ring key 39 and screen key 231 stay in the module base and do not come out with the I P converter key 41 Replacing the I P Converter 1 Refer to figure 6 3 Inspect the condition of O ring key 39 and screen key 231 in the module base key 2 Replace them if necessary Apply silicone lubricant to the O rings 2 Ensure the two boots key 210 shown in figure 6 4 are properly installed on the electrical leads 3 Install the I P converter key 41 straight into the module base key 2 taking care that the two electrical leads feed into the quides in the module base These quides route the leads to the printed wiring board assembly submodule 4 Install the shroud key 169 overthe I P converter key 41 5 Install the four socket head screws key 23 and evenly tighten them in a crisscross pattern to a final torque of 1 6 Nem 14 Ibfein 6 After replacing the I P converter calibrate travel or perform touch up calibration to maintain accuracy specifications 68 Instruction Manual Maintenance and Troubleshooting D103785X012 November 2015 Figure 6 4 I P Converter SHROUD 169 CONVERTER 41 C SOCKET HEAD SCREWS 4 KEY 23 BOOTS 5 5 KEY 210 W9328 PWB Printed Wiring Board Assembly Refer to figure 7 2 for key number locations The PWB assembly key 50 is located on the back of the modu
153. t is active if one or more of the measured analog sensor readings loop current pressure temperature or travel is saturated or reading out of its configured range The condition may be due to improper configuration or physical setup and not be due to a sensor malfunction Field Device Malfunction This alert is active if the pressure position or temperature sensors are providing invalid readings Internal Sensor Out of Limits This alert is active if there is a problem with either the pressure sensor or the printed wiring board assembly Travel Sensor Alert This alert is active if the sensed travel is outside the range of 25 0 to 125 0 of calibrated travel If this alert is active check the instrument mounting Also check that the electrical connection from the travel sensor is properly plugged into the printed wiring board assembly After restarting the instrument if the alert persists troubleshoot the printed wiring board assembly or travel sensor Temperature Sensor Alert This alert is active when the instrument temperature sensor fails or the sensor reading is outside of the range of 60 to 100 C 76 to 212 F The temperature reading is used internally for temperature compensation of inputs If this alert is active restart the instrument If the alert persists replace the printed wiring board assembly Pressure Sensor Alert This alert is active if any of the 3 pressure sensor readings are outside the range of
154. the alert record Alert Record Full Alert This alert is active when the alert record is full Additional alerts that are detected will not be saved to the alert record until the alert record is cleared 59 Device Information Diagnostics and Alerts Instruction Manual November 2015 D103785X012 Status e Calibration in Progress Alert This alert is active when calibration is in progress AutoCal in Progress Alert This alert is active when auto calibration is in progress Diagnostic in Progress Alert This alert is active when a diagnostic test is in progress e Diagnostic Data Available Alert This alert is active when diagnostic data has been collected and is being stored in the instrument e Pressure Control Active Alert This alert is active when the instrument is controlling like an I P transducer Pressure Control instead of Travel Control Diagnostics Stroke Valve Follow the prompts on the Field Communicator display to select from the following e Done Select this if you are done All ramping is stopped when DONE is selected e Ramp Open ramps the travel toward open at the rate of 1 0 per second of the ranged travel e Ramp Closed ramps the travel toward closed at the rate of 1 075 per second of the ranged travel e Rampto Target ramps the travel to the specified target at the rate of 1 075 per second of the ranged travel Step to Target steps the travel to the specified target Partial Stroke T
155. the control system or the current source to provide at least 4 0 mA The problem may be one or the other of the following 1 The tuning set selected is too low and the valve does not reach an end point in the allotted time Select Manual Setup gt Tuning gt Travel Tuning gt Stabilize Optimize then Increase Response selects next Auto Calib did not complete within the time limit higher tuning set 2 The tuning set selected is too high valve operation is unstable and does not stay at an end point for the allotted time Select Manual Setup gt Tuning gt Travel Tuning gt Stabilize Optimize then Decrease Response selects next lower tuning set Prior to receiving this message did the instrument output go from zero to full supply If not verify instrument supply pressure by referring to the specifications in the appropriate actuator instruction manual If supply pressure is correct check instrument pneumatic components I P converter and relay Insufficient travel If the instrument output did go from zero to full supply prior to receiving this message then verify proper mounting by referring to the appropriate mounting procedure in the Installation section Verify travel sensor adjustment by performing the appropriate Travel Sensor Adjust procedure in the Calibration section Making the crossover adjustment with the valve positioned at either end of its travel will also cause this message to appear Drive signal exceed low limit ch
156. the instrument is removed Zero Power Condition ZPC is determined by relay type as shown in figure 3 5 Figure 3 5 Zero Power Condition Relay Type Loss of Electrical Power Single Acting Direct Relay Aor C Port A pressure to zero Port A pressure to zero Port B pressure to full supply Double Acting Relay A Single Acting Reverse Relay B Port B pressure to full supply X0797 Travel Sensor Motion WARNING If you answer YES to the prompt for permission to move the valve when determining travel sensor motion the instrument will move the valve through a significant portion of its travel range To avoid personal injury and property damage caused by the release of process fluid or pressure isolate the valve from the process and equalize pressure on both sides of the valve or bleed off the process fluid Travel Sensor Motion Select Clockwise or Counterclockwise Travel Sensor Motion establishes the proper travel sensor rotation Determine the rotation by viewing the end of the travel sensor shaft from the perspective of the actuator e For instruments with Relay A and C If increasing air pressure at output A causes the shaft to turn clockwise enter Clockwise If it causes the shaft to turn counterclockwise enter Counterclockwise e Forinstruments with Relay B If increasing air pressure at output B causes the shaft to turn counterclockwise enter Clockwise If it causes the shaft to turn clockwise enter Counte
157. the module base Evenly tighten the screws in a crisscross pattern to a final torque of 16 Nem 138 Ibfein 66 Instruction Manual Maintenance and Troubleshooting D103785X012 November 2015 A WARNING Personal injury property damage or disruption of process control can result if the cable assemblies wiring are damaged when attaching the cover to the module base assembly Ensure that the cable assemblies wiring are positioned in the cavity of the module base so they do not get compressed or damaged when attaching the cover to the module base assembly in step 6 6 Attach the cover key 43 to the module base assembly 7 For sliding stem applications only install the protective shield onto the side of the replacement module base assembly refer to figure 6 1 Submodule Maintenance The base unit s module base contains the following submodules I P converter PWB assembly and pneumatic relay If problems occur these submodules may be removed from the module base and replaced with new submodules After replacing a submodule the module base may be put back into service CAUTION Exercise care when performing maintenance on the module base Reinstall the cover to protect the I P converter and gauges when servicing other submodules In order to maintain accuracy specifications do not strike or drop the I P converter during submodule maintenance I P Converter Refer to figure 7 2 for key number locations The I P converter key
158. the travel to 100 If another adjustment is required repeat step 5 Otherwise select Done and go to step 6 6 From the adjustment menu select the direction and size of change required to set the travel to 5 If another adjustment is required repeat step 6 Otherwise select Done and go to step 7 7 From the adjustment menu select the direction and size of change required to set the travel to 9526 If another adjustment is required repeat step 7 Otherwise select Done and go to step 8 8 Place the instrument In Service and verify that the travel properly tracks the current source Pushbutton Calibration A pushbutton near the wiring terminals in the terminal box provides a quick means to autocalibrate the instrument The button must be pressed for 3 to 10 seconds Autocalibration will move the valve through the full range of travel whether the Instrument Mode is In Service or Out of Service However if the Write Protection is Protected this button will not be active To abort press the button again for 1 second The calibration button is disabled by default To enable it go to Manual Setup gt Instrument gt Calibration Button Note Pressure range used for Pressure Fallback is not recalibrated during this procedure This calibration procedure is recommended whenever the I P converter or pneumatic relay is replaced Do not use the pushbutton calibration for initial calibration when mounting the instrument on an actuator or if th
159. tional information e Stabilize Optimize instrument level HC This procedure permits you to adjust valve response by changing the digital valve controller tuning See page 30 for additional information Manual Setup Manual Setup allows you to configure the digital valve controller to your application Table 3 1 lists the default settings for a standard factory configuration You can adjust actuator response set the various modes alerts ranges travel cutoffs and limits You can also restart the instrument and set the protection Table 3 1 Default Detailed Setup Parameters Setup Parameter Default Setting Control Mode Analog In Range Low 4 mA Instrument Analog Input Units Burst Command Cmd 3 Trending Pressure A B Input Characterization Linear Travel Limit Low 25 Set Point Filter Time Lag Time Integrator Enable Yes continued on next page 19 Configuration Instruction Manual November 2015 D103785X012 Table 3 1 Default Detailed Setup Parameters continued Default Setting Deviation amp Other Alerts ET 3 ssa 1 The settings listed are for standard factory configuration DVC6000 HW2 instruments can also be ordered with custom configuration settings Refer to the order requisition for custom settings if specified 2 Adjust to bar kPa or Kg cm if necessary Mode and Protection Field Communicator Configure Manual Setup Mode and Protection 2 2
160. tment disc shown in figure 4 6 until the output pressure displayed on the Field Communicator is between 50 and 70 of supply pressure This adjustment is very sensitive Be sure to allow the pressure reading to stabilize before making another adjustment stabilization may take up to 30 seconds or more for large actuators 52 Instruction Manual Calibration D103785X012 November 2015 If the low bleed relay option has been ordered stabilization may take approximately two minutes longer than the standard relay Relay A may also be adjusted for use in single acting direct applications Rotate the adjustment disc as shown in figure 4 6 for single acting direct operation Figure 4 6 Relay A Adjustment Shroud Removed for Clarity FOR SINGLE ACTING DIRECT RELAYS ROTATE ADJUSTMENT DISC IN THIS DIRECTION UNTIL IT CONTACTS THE BEAM FOR DOUBLE ACTING RELAYS ROTATE ADJUSTMENT DISC IN THIS DIRECTION TO DECREASE OUTPUT PRESSURE ADJUSTMENT DISC FOR DOUBLE ACTING RELAYS ROTATE ADJUSTMENT DISC IN THIS DIRECTION TO INCREASE OUTPUT PRESSURE Single Acting Relays WARNING For Instrument Level ODV only If the unused port is monitoring pressure ensure that the pressure source conforms to ISA Standard 7 0 01 and does not exceed the pressure supplied to the instrument Failure to do so could result in personal injury or property damage caused by loss of process control Single Acting Direct Relay The single acting direct rel
161. ut Range High corresponds to Travel Range Low See figure 3 1 21 Configuration Instruction Manual November 2015 D103785X012 e Input Range Lo Permits setting the Input Range Low value Input Range Low should correspond to Travel Range Low if the Zero Power Condition is configured as closed If the Zero Power Condition is configured as open Input Range Low corresponds to Travel Range High See figure 3 1 Figure 3 1 Calibrated Travel to Analog Input Relationship TRAVEL RANGE HIGH ZPC OPEN ZPC CLOSED d A O gt e lt HE SHAPE OF THESE LINE DEPENDS ON THE INPUT CHARACTERISTICS LINEAR TRAVEL CHARACTERISTIC SHOWN RANGE 17 49 LOW ANALOG INPUT INPUTRANGE 4 20 LOW HIGH NOTE ZPC ZERO POWER CONDITION A6531 1 Spec Sheet The Spec Sheet provides a means to store the entire control valve specifications on board the DVC6000 HW2 Edit Instrument Time Permits setting the instrument clock When alerts are stored in the alert record the record includes the time and date The instrument clock uses a 24 hour format Travel Pressure Control Field Communicator Configure gt Manual Setup gt Travel Pressure Control 2 2 3 Travel Pressure Select This defines the operating mode of the instrument as well as the behavior o
162. ve the instrument from the actuator Loosen the screw key 80 that secures the feedback arm key 79 to the travel sensor shaft Remove the feedback arm key 79 from the travel sensor shaft Disconnect the three travel sensor assembly wires from the terminals Remove the screw key 72 that fastens the travel sensor assembly to the housing Pull the travel sensor assembly key 223 straight out of the housing CON DU Figure 6 7 FIELDVUE DVC6015 Adjustment Arm FEEDBACK ARM KEY 79 ADJUSTMENT ARM CONNECTOR ARM X0910 74 Instruction Manual Maintenance and Troubleshooting D103785X012 November 2015 DVC6025 Remote Feedback Unit Refer to figure 7 5 for key number locations 1 Remove piping and fittings from the instrument 2 Remove the instrument from the actuator 3 Disconnect the bias spring key 82 from the feedback arm assembly key 84 and the arm assembly key 91 Remove the mounting bracket key 74 from the back of the digital controller If the torsion spring key 93 needs to be replaced ensure that the shaft on which it is installed is smooth and free of rough spots Replace the entire feedback arm assembly if necessary Loosen the screw key 80 that secures the arm assembly to the travel sensor assembly shaft Remove the arm assembly key 91 from the travel sensor assembly shaft Disconnect the three travel assembly wires from the terminals Remove the screw key 72 th
163. ves or pipe plugs Refer to figure 7 2 for key number locations 1 Remove the front cover key 43 2 Remove the gauge pipe plug or tire valve as follows For gauges key 47 the flats are on the gauge case Use a wrench on the flats of the gauge to remove the gauge from the module base For double acting instruments to remove the supply gauge remove one of the output gauges For pipe plugs key 66 and tire valves key 67 use a wrench to remove these from the module base 3 Apply pipe thread sealant key 64 to the threads of the replacement gauges pipe plugs or tire valves 4 Using a wrench screw the gauges pipe plugs or tire valves into the module base Terminal Box WARNING Refer to the Maintenance WARNING at the beginning of this section Refer to figure 7 2 for key number locations The terminal box is located on the housing and contains the terminal strip assembly for field wiring connections Removing the Terminal Box A WARNING To avoid personal injury or property damage caused by fire or explosion remove power to the instrument before removing the terminal box cover in an area which contains a potentially explosive atmosphere or has been classified as hazardous 1 Loosen the set screw key 58 in the cap key 4 so that the cap can be unscrewed from the terminal box After removing the cap key 4 note the location of field wiring connections and disconnect the field wiring from the terminal box
164. ween base unit and feedback unit Pneumatic tubing between base unit output connection and actuator has been tested to 91 meters 300 feet At 15 meters 50 feet there was no performance degradation At 91 meters there was minimal pneumatic lag Using an External 10 kOhm External Potentiometer as a Remote Travel Sensor Note Potentiometer travel must be between 1 3 and 1 6 times greater than the actuator travel For example if an actuator has a travel of 9 inches then a linear potentiometer must be selected with a rated travel between 11 7 and 14 4 inches The resistive element must be tapered from 0 kOhm to 10 kOhm over rated travel of the potentiometer The actuator will only use 63 to 76 of the potentiometer rated travel Wiring Practices Instruction Manual November 2015 D103785X012 Note The digital valve controller must be configured using the SStem Roller selection on the menu of the appropriate setup device The DVC6005 HW2 base unit was designed to work with a 40 kOhm potentiometer for travel feedback However there are linear potentiometers that are readily available with a rated resistance of 10 kOhm Therefore the feedback connections terminal box of the DVC6005 HW2 contains an additional 30 kOhm fixed resistor that may be added to the circuit This brings the total resistance up to the required 40 kOhm 1 Mount the external 10 kOhm potentiometer to the actuator such that the mid travel position of the potentiometer 5 kOhm c
165. y displayed when the Field Communicator establishes contact with the digital valve controller at power up e HART Long Tag HART Universal Revision 7 only A tag name up to 32 characters is available for the instrument Instruction Manual Configuration D103785X012 November 2015 e Description Enter a description for the application with up to 16 characters The description provides a longer user defined electronic label to assist with more specific instrument identification than is available with the HART tag e Message Enter any message with up to 32 characters Message provides the most specific user defined means for identifying individual instruments in multi instrument environments e Polling Address If the digital valve controller is used in point to point operation the Polling Address is 0 When several devices are connected in the same loop such as for split ranging each device must be assigned a unique polling address The Polling Address is set to a value between 0 and 63 for HART 7 and 0 and 15 for HART 5 To change the polling address the instrument must be Out Of Service Forthe Field Communicator to be able to communicate with a device whose polling address is not 0 it must be configured to automatically search for all or specific connected devices Serial Numbers e Instrument Serial Number Enter the serial number on the instrument nameplate up to 12 characters e Valve Serial Number Enter the serial number for
166. y size Class 7 Oil content Class 3 Pressure Dew Point Class 3 or atleast 10 C less than the lowest ambient temperature expected Output Signal Pneumatic signal as required by the actuator up to full supply pressure Minimum Span 0 4 bar 6 psig Maximum Span 9 5 bar 140 psig Action Bl Double Single Direct or Reverse Steady State Air Consumption 4 Standard Relay At 1 4 bar 20 psig supply pressure Less than 0 38 normal D 14 scfh At 5 5 bar 80 psig supp pressure Less than 1 3 normal m hr 49 scfh Low Bleed Relay At 1 4 bar 20 psig supply pressure Average value 0 056 normal m hr 2 1 scfh At 5 5 bar 80 psig supply pressure Average value 0 184 normal m hr 6 9 scfh Maximum Output Capacity 3 4 At 1 4 bar 20 psig supply pressure 10 0 normal m hr 375 scfh At 5 5 bar 80 psig supply pressure 29 5 normal m hr 1100 scfh Operating Ambient Temperature Limits 2 5 40 to 85 C 40 to 185 F for base unit 52 to 85 C 62 to 185 F for base unit utilizing the Extreme Temperature option fluorosilicone elastomers 52 to 125 C 62 to 257 F for remote mount feedback unit Independent Linearity Typical Value 0 50 of output span Introduction November 2015 Table 1 2 Specifications continued Electromagnetic Compatibility Meets EN 61326 1 2013 Immunity Industrial locations per Table 2 of the EN 61326 1 standard Performance is shown in table 1 3
167. yle Piston Dbl with or w out Spring See actuator instruction manual and nameplate Spring amp Diaphragm Spring amp Diaphragm Spring amp Diaphragm Piston Dbl w o Spring Piston Sgl w Spring Spring amp Diaphragm Spring amp Diaphragm Spring amp Diaphragm Spring amp Diaphragm Starting Tuning Set 1 X Expert Tuning Proportional Gain 4 2 Velocity Gain 3 0 Minor Loop Feedback Gain 18 0 Feedback Connection SStem Standard for travels up to 4 inches SStem Roller for longer travels SStem Standard SStem Standard Configuration November 2015 Travel Sensor Motion Relay A or 1 Depends upon pneumatic connections See description for Travel Sensor Motion Clockwise Counterclockwise Rotary SStem Standard Clockwise Depends upon pneumatic connections See description for Travel Sensor Motion Mounting Styl Clockwise For Pg operating mode air opens Counterclockwise For P operating mode air closes Clockwise SStem Standard SStem Standard Rotary Counterclockwise Clockwise Clockwise Counterclockwise Specify 2 Values shown are for Relay A and C Reverse for Relay B e Proportional Gain The proportional gain for the travel control tuning set Changing this parameter will also change the tuning set to Expert e Velocity Gain The velocity gain for the travel control tuning set Changing th

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