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Emerson Fisher FIELDVUE DVC6000 HW2, Instruction Manual

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Emerson Fisher FIELDVUE DVC6000 HW2 Instruction Manual Download Page 67

Instruction Manual

D103785X012

Maintenance and Troubleshooting

June 2017

67

  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 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 I/P Converter procedure.

2.  Remove the screen (key 231) from the supply port.

Summary of Contents for Fisher FIELDVUE DVC6000 HW2

Page 1: ...gnal Converter 17 Section 3 Configuration 19 Guided Setup 19 Manual Setup 19 Mode and Protection 20 Instrument Mode 20 Write Protection 20 Instrument 20 Identification 20 Serial Numbers 21 Units 21 Terminal Box 21 Input Range 21 Spec Sheet 22 Edit Instrument Time 22 Travel Pressure Control 22 Travel Pressure Select 22 Cutoffs and Limits 23 End Point Pressure Control 23 Pressure Control 24 Pressure...

Page 2: ...shooting 63 Module Base Maintenance 64 Tools Required 64 Removing the Module Base 64 Replacing the Module Base 66 Submodule Maintenance 67 I P Converter 67 Printed Wiring Board PWB Assembly 69 Pneumatic Relay 71 Gauges Pipe Plugs or Tire Valves 72 Terminal Box 72 Removing the Terminal Box 72 Replacing the Terminal Box 73 Travel Sensor 73 Disassembly 74 DVC6015 Remote Feedback Unit 74 DVC6025 Remot...

Page 3: ...ontroller 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 sales office or Local Busin...

Page 4: ...r Mounted on Rotary Control Valve Actuator W8373 Table 1 1 Instrument Level Capabilities CAPABILITY DIAGNOSTIC LEVEL 2 HC AD PD ODV Auto Calibration X X X X Custom Characterization X X X X Burst Communication X X X X Alerts X X X X Step Response Drive Signal Test Dynamic Error Band X X X Advanced Diagnostics Valve Signature X X X Performance Tuner X X X Travel Control Pressure Fallback X X X Suppl...

Page 5: ...45 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 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...

Page 6: ... Customs Union Technical Regulations Russia Kazakhstan Belarus and Armenia INMETRO National Institute of Metrology Quality and Technology Brazil PESO CCOE Petroleum and Explosives Safety Organisation Chief Controller of Explosives India Contact your Emerson sales office or Local Business Partner for classification certification specific information Connections Supply Pressure 1 4 NPT internal and ...

Page 7: ...at 5 5 bar 80 psig based on double acting relay 5 Temperature limits vary 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 p...

Page 8: ...ollers D103267X012 D Lock in Last Strategy D103261X012 D Fisher HF340 Filter Instruction Manual D102796X012 D 475 Field Communicator User s Manual D ValveLink Software Help or Documentation All documents are available from your Emerson sales office or Local Business Partner or at Fisher com Educational Services For information on available courses for the DVC6000 HW2 digital valve controller as we...

Page 9: ... 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 sales office or Local Business Partner Note A HART filter is typically NOT required for any of the Emerson Automation Solutions control systems including PROVOXt RS3t...

Page 10: ...15 19 volts Figure 2 2 Determining Voltage Available at the Instrument 3 The voltage available at the instrument is not the voltage measured at the instrument terminals Once the instrument is connected the instrument limits the measured voltage to approximately 8 0 to 9 5 volts 1 Obtain filter voltage drop The measured drop will be different than this value The measured filter voltage drop depends...

Page 11: ...0 020 0 069 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 wirin...

Page 12: ...able 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 cable 100 000pF 26pF ft 3846 ft Example 18AWG Shielded Audio Control and Instrumentation Cable Manufacturer s specifications include Nom Characteristic Impedance 2...

Page 13: ...th onboard 30 kOhm resistor or D A potentiometer used in conjunction with two fixed resistors potentiometer travel is the same as actuator travel WARNING Personal injury or property damage caused by wiring failure can 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 c...

Page 14: ...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 3RD PARTY FEEDBACK ELEMENT WITH 10...

Page 15: ...cted in series two fixed resistors and one potentiometer Three conditions must be met for the resistor combination to correctly operate the digital valve controller D The maximum resistance of the potentiometer Rpot max must be between 3 9 kOhm and 10 kOhm D The resistance of R1 is 4 25 times greater than Rpot max D The resistance of R2 is 4 times less than Rpot max WARNING To avoid personal injur...

Page 16: ...ead of the external potentiometer Rpot 5 Connect the second wire of the 3 conductor shielded cable between the middle lead wiper of the external potentiometer Rpot and Terminal 2 on the base unit 6 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 a...

Page 17: ...roduct Manual 00809 0100 4754 for complete installation information Figure 2 6 HART Tri Loop Installation Flowchart START HERE DONE Digital valve controller Installed Unpack the HART Tri Loop Review the HART Tri Loop Product Manual Set the digital valve controller Burst Option Set the digital valve controller Burst Mode No Yes Install the digital valve controller Install the HART Tri Loop See HART...

Page 18: ...age Configure Manual Setup Outputs Burst Mode 2 2 6 5 HC AD PD or 2 2 7 5 ODV Without I O Package Configure Manual Setup Outputs Burst Mode 2 2 6 2 HC AD PD or 2 2 7 2 ODV Select Burst Enable and follow the prompts to enable burst mode Then select Burst Command and follow the prompts to configure Loop Current PV SV TV QV Select the HART Variable Assignments Field Communicator With I O Package Conf...

Page 19: ...nual 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 1 Instrument...

Page 20: ...nstrument 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 remote...

Page 21: ... up to 12 characters Units D Pressure Units Defines the output and supply pressure units in either psi bar kPa or kg cm2 D Temperature Units Degrees Fahrenheit or Celsius The temperature measured is from a sensor mounted on the digital valve controller s printed wiring board D Analog Input Units Permits defining the Analog Input Units in mA or percent of 4 20 mA range Terminal Box D Calibration CA...

Page 22: ...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 Manual Setup Travel Pressure Control 2 2 3 Trave...

Page 23: ...et will not fall below the Lo Limit Point D 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 ins...

Page 24: ...High The high end of output pressure range Enter the pressure that corresponds with 100 valve travel when Zero Power Condition is closed or 0 valve travel when Zero Power Condition is open This pressure must be greater than the Pressure Range Lo D Pressure Range Lo The low end of the output pressure range Enter the pressure that corresponds to 0 valve travel when Zero Power Condition is closed or ...

Page 25: ...ls 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 targe...

Page 26: ...t Characteristics Zero Power Condition Closed Travel Target Ranged Set Point 25 0 125 100 25 0 125 100 25 0 125 100 Input Characteristic Linear Input Characteristic Equal Percentage Input Characteristic Quick Opening 100 0 25 125 Travel Target 100 0 25 125 Ranged Set Point Travel Target 100 0 25 125 Ranged Set Point A6535 1 ...

Page 27: ...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 se...

Page 28: ... E F G 4 4 4 8 5 5 6 2 7 2 3 0 3 0 3 0 3 1 3 6 35 35 35 35 34 H I J K L M 8 4 9 7 11 3 13 1 15 5 18 0 4 2 4 85 5 65 6 0 6 0 6 0 31 27 23 18 12 12 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 Perfor...

Page 29: ...w Spring G L Rotary Mounting Style Travel Sensor Motion A Clockwise B Counterclockwise C Clockwise D Counterclockwise 2052 1 2 3 Spring Diaphragm H J M Rotary Clockwise 3024C 30 30E 34 34E 40 40E 45 45E Spring Diaphragm E H K SStem Standard For Po operating mode air opens Counterclockwise For Ps operating mode air closes Clockwise GX 225 Spring Diaphragm X 1 SStem Standard Air to Open Air to Close...

Page 30: ...ternal instabilities before they 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 D Stabilize Optimize WARNING During Stabilize Optimize the valve may move causing process fluid or pressure to b...

Page 31: ... 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 D Proportional Gain The proportional gain for the pressure control tuning set Changing this parameter will also change the tuning set to Expert D MLFB Gain The minor loop feedback gain for the pressure control...

Page 32: ...dback 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 All SStem Roller Figure 3 3 Feedback Connection for Typical Sliding Stem Actuator Up to 4 inch Travel ACTUATOR STEM TRAVEL SENSOR SHAFT FEEDBACK ARM CONNECTOR ARM ADJUSTMENT ARM Figure 3 4 Feedback Connection for Typical Long Stroke Sliding Stem Ac...

Page 33: ...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 se...

Page 34: ...e 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...

Page 35: ...mits Actuator Style Relay Type Zero Power Condition PST Starting Point Partial Stroke Pressure Limit 1 Spring and Diaphragm A or C Closed Open Pmin 0 25 Bench Set High Bench Set Low Closed Pmax 0 25 Bench Set High Bench Set Low Open Open Pmax 0 25 Bench Set High Bench Set Low Closed Pmin 0 25 Bench Set High Bench Set Low B Closed Open Pmax 0 25 Bench Set High Bench Set Low Closed Pmin 0 25 Bench S...

Page 36: ...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 10 D Test Speed The rate at which the valve will move during the test The default value is 0 25 second D 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 Plot...

Page 37: ...perate 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 fail low 3 6 mA The output can be configured to fail high 22 5 mA when the positioner is powered When configured as a switch the output can be configured to drive Close...

Page 38: ...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 D Burst Enable Turns on or off the burst mode D 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 Ana...

Page 39: ...T DEFAULT ALERT SETTING DEFAULT SHUTDOWN SETTING Travel Sensor Failure Enabled Disabled Temperature Sensor Failure Enabled Disabled Minor Loop Sensor Failure Enabled Disabled Pressure Sensor Failure Enabled Disabled Drive Current Failure Enabled Disabled Critical NVM Failure Enabled Disabled Non Critical NVM Failure Enabled Disabled Flash Integrity Failure Enabled Disabled Reference Voltage Failur...

Page 40: ...ntrolling 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 HA...

Page 41: ...Field Communicator Configure 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 ...

Page 42: ...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 sele...

Page 43: ...s unstable and does not stay at an end point for the allotted time Select Manual Setup Tuning Travel Tuning Stabilize Optimize then Decrease Response selects next lower tuning set Insufficient travel 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 instructio...

Page 44: ...he current source adjustment affects the position accuracy 2 Adjust the current source until the valve is at 0 travel then press OK 3 Adjust the current source until the valve is at 100 travel then press OK 4 Adjust the current source until the valve is at 0 travel then press OK 5 Adjust the current source until the valve is at 100 travel then press OK 6 Adjust the current source until the valve i...

Page 45: ...lect the direction and size of change required to set the travel to 95 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 butto...

Page 46: ...ent 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 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 ...

Page 47: ...e 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 ba...

Page 48: ...k 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 to None 6 From the Calibrate menu select Sensor Calibratio...

Page 49: ...g the travel sensor counts tighten the screw that secures the 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 ...

Page 50: ...el 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 protect...

Page 51: ...k arm assembly and the arm assembly on the travel sensor shaft 11 Install the remote feedback unit on the actuator Figure 4 5 FIELDVUE DVC6025 Travel Sensor Arm Housing Back Plane Alignment TRAVEL SENSOR SHAFT ARM ASSEMBLY BACK OF HOUSING ARM ASSEMBLY PIN BACK EDGE OF ARM PARALLEL W BACK OF HOUSING A7025 Analog Input Calibration To calibrate the analog input sensor connect a variable current sourc...

Page 52: ... 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 re...

Page 53: ...E OUTPUT PRESSURE FOR DOUBLE ACTING RELAYS ROTATE ADJUSTMENT DISC IN THIS DIRECTION TO INCREASE OUTPUT PRESSURE W9034 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 prope...

Page 54: ...essure 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 a...

Page 55: ...are Revisions D HART Universal Revision D Write Protection provides a procedure to enable disable Table 5 1 Functions Available for Instrument Level Instrument Level Functions Available HC 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 percenta...

Page 56: ...d assembly D Drive Signal Alert This alert monitors the drive signal and calibrated travel If one of the following 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 3 Drive Signal 90 and Calibrated Travel 97 For the case where Zero Power Condition is defined as open Drive Signal 10 and Cali...

Page 57: ...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 D Minor Loop Sensor Alert This a...

Page 58: ...Hi Hi Point Once the alert is active the alert will clear when the Travel falls below the Travel Alert Hi Hi Point minus the Travel Alert Deadband D 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 D Travel Alert Lo Lo This alert is a...

Page 59: ...he 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 Figu...

Page 60: ...travel to the specified target Partial Stroke Test 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...

Page 61: ...ostics 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 configured Stroke Stroking Speed and Pause Time is displayed Choose Yes to run the test using these values Choose No to modify the values The default value for Stroke Speed is 0 25 second 6 The valve begins t...

Page 62: ...ure Control Configuration also provides a procedure to modify D Control Mode also provides a procedure to modify D Instrument Temperature D Travel Counts this is the raw travel sensor reading used for advanced adjustments D Maximum Recorded Temperature D Minimum Recorded Temperature D Number of Power Ups D Days Powered Up ...

Page 63: ...ypass valves or completely shut off the process to isolate the valve from process pressure Relieve process pressure from both sides of the valve D Use lock out procedures to be sure that the above measures stay in effect while you work on the equipment D Check with your process or safety engineer for any additional measures that must be taken to protect against process media D Vent the pneumatic a...

Page 64: ...roller 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 Tool Size Component Phillips Screwdriver Hex key Hex key He...

Page 65: ...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 ...

Page 66: ...ese 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 2 Connect the terminal box connector to the PWB assembly key 50 Orientation of the connector is requir...

Page 67: ... 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 subm...

Page 68: ...amage the two electrical leads that come out of the base of the I P 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 the O ring key 39 and screen key 231 in the module base key 2 Replace them if necessary Apply silicone lubricant to the O ...

Page 69: ...33 3 Lift the PWB assembly key 50 straight out of the module base key 2 4 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 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 modu...

Page 70: ... Table 6 3 Output Switch Configuration 1 Switch Label Function DIP Switch Position Transmitter LEFT Switch RIGHT 1 Refer to figure 6 5 for switch location X0432 Figure 6 5 Printed Wiring Board PWB Connections and Settings TRANSMITTER SWITCH SELECTION TRAVEL SENSOR CONNECTOR TERMINAL BOX CONNECTOR OPERATIONAL MODE SELECTION TRAVEL SENSOR CONNECTOR TERMINAL BOX CONNECTOR OPERATIONAL MODE SELECTION X...

Page 71: ...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 crisscr...

Page 72: ... 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 ...

Page 73: ...bricant 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 8 Apply lubricant key 63 to the 2 5 8 inch threads on 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 int...

Page 74: ...ent 2 Disconnect the adjustment arm from the connector arm and the feedback arm see figure 6 7 3 Remove the instrument from the actuator 4 Loosen the screw key 80 that secures the feedback arm key 79 to the travel sensor shaft 5 Remove the feedback arm key 79 from the travel sensor shaft 6 Disconnect the three travel sensor assembly wires from the terminals 7 Remove the screw key 72 that fastens t...

Page 75: ...t 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 termina...

Page 76: ... 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 6 Whil...

Page 77: ...e 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 term...

Page 78: ...embly 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 ARM ASSEMBLY KEY 91 FEEDBACK ARM ASSEMBLY KEY 84 NOTE INSTALL BIAS SPRI...

Page 79: ...t 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...

Page 80: ...E instrument 2 Set the control system to provide maximum output current 3 Set the resistance of the 1 kilohm potentiometer shown in figure 2 3 to zero 4 Record the current shown on the milliammeter 5 Adjust the resistance of the 1 kilohm potentiometer until the voltage read on the voltmeter is 10 0 volts 6 Record the current shown on the milliammeter 7 If the current recorded in step 6 is the same...

Page 81: ...tput 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 PWB 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 ...

Page 82: ...0 ohms Replace I P assembly if damaged corroded clogged or open coil 3m I P 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 condi...

Page 83: ...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 ________________________...

Page 84: ...Instruction Manual D103785X012 Maintenance and Troubleshooting June 2017 84 ...

Page 85: ...Parts Kit kit contains parts to service one digital valve controller 19B5403X012 3 Conversion Kit DVC6015 to DVC6025 19B5405X012 4 Conversion Kit DVC6025 to DVC6015 14B5072X112 5 Alignment Pin Kit kit contains 15 alignment pins key 46 14B5072X092 6 Seal Screen Kit kit contains 25 seal screens key 231 and 25 O rings key 39 Standard and Extreme Temperature option 14B5072X182 fluorosilicone elastomer...

Page 86: ...7 2 Housing 1 Housing 11 Drive Screw 2 req d 20 Shield 52 Vent plastic 2 74 Mounting Bracket 16 248 Screw hex head 16 4 req d 249 Screw hex head 16 4 req d 250 Spacer 16 4 req d 267 Standoff 16 2 req d 271 Screen Common Parts 16 O ring 1 3 req d 29 Warning label for use only with LCIE hazardous area classifications 33 Mach Screw pan hd SST 2 3 req d 38 Cap Screw hex socket SST 2 10 3 req d 43 Cove...

Page 87: ...SST 2 13 164 Terminal Box Assembly 7 Feedback Connections Terminal Box 4 Terminal Box Cap 13 34 O ring 1 7 13 36 O ring 1 7 13 44 Wire Retainer pl stl 2 14 5 req d not shown 58 Set Screw hex socket SST 2 13 62 Pipe Plug hex hd SST 13 72 Cap Screw hex socket SST 2 13 3 req d 262 Adapter 13 263 O ring 13 Standard Extreme temperature option fluorosilicone 264 Terminal Box Assembly remote 13 Figure 7 ...

Page 88: ...d DVC6035 79 Feedback Arm for DVC6015 and DVC6035 80 Cap Screw hex socket SST 2 14 81 Square Nut SST 2 14 104 Cap Screw hex hd 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 Key Description Part Number 107 Mounting Bracket 14 DVC6015 only Not for mounting on 1250 and 1250R actuato...

Page 89: ...3785X012 Parts June 2017 89 Figure 7 2 FIELDVUE DVC6005 HW2 Base Unit Assembly APPLY LUB SEALANT SECTION A A NOTES 1 APPLY LUBRICANT KEY 65 TO ALL O RINGS UNLESS OTHERWISE SPECIFIED 49B3261 C SHT 1 2 SECTION B B SECTION C C ...

Page 90: ...2 Base Unit Assembly continued 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 3 SECTION E E PIPESTAND MOUNTING WALL MOUNTING OUTPUT A OUTPUT A SUPPLY OUTPUT B 1 E E SUPPLY OUTPUT B ...

Page 91: ...ical FIELDVUE DVC6005 HW2 Digital Valve Controller Gauge Configuration APPLY LUB SEALANT SINGLE ACTING DIRECT SINGLE ACTING REVERSE DOUBLE ACTING 1 NOTE 1 FOR SINGLE ACTING DIRECT OUTPUT B IS PLUGGED 2 FOR SINGLE ACTING REVERSE OUTPUT A IS PLUGGED 2 49B3261 C SHT 2 ...

Page 92: ...012 Parts June 2017 92 Figure 7 4 FIELDVUE DVC6015 Remote Feedback Unit Assembly APPLY LUB SEALANT NOTE 1 APPLY LUBRICANT KEY 65 TO ALL O RINGS UNLESS OTHERWISE SPECIFIED 49B7986 A SECTION A A SECTION B B SECTION D D SECTION C C ...

Page 93: ...03785X012 Parts June 2017 93 Figure 7 5 FIELDVUE DVC6025 Remote Feedback Unit Assembly 49B7987 A NOTE 1 APPLY LUBRICANT KEY 65 TO ALL O RINGS UNLESS OTHERWISE SPECIFIED APPLY LUB SEALANT THREAD LOCK SECTION A A SECTION B B ...

Page 94: ...012 Parts June 2017 94 Figure 7 6 FIELDVUE DVC6035 Remote Feedback Unit Assembly 49B7988 A NOTE 1 APPLY LUBRICANT KEY 65 TO ALL O RINGS UNLESS OTHERWISE SPECIFIED APPLY LUB SEALANT THREAD LOCK SECTION B B SECTION A A SECTION C C ...

Page 95: ...lue 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 0 5V 0 5V 1200 Hz 1 2200 Hz 0 AVERAGE CURRENT CHANGE DURING COMMUNICATION 0 ANALOG SIGNAL 0 A6174 The HART protocol allows the capability of multidropping i e networking several devices to a single communications line This proc...

Page 96: ...tic 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 a...

Page 97: ...Digital Valve Controller Block Diagram E1569 INPUT SIGNAL 4 20 mA HART SUPPLY PRESSURE PRINTED WIRING BOARD PNEUMATIC RELAY I P CONVERTER OUTPUT A OUTPUT B VALVE TRAVEL FEEDBACK FEEDBACK CONNECTION TERMINAL BOX DRIVE SIGNAL VALVE AND ACTUATOR VENT AUXILIARY TERMINALS TERMINAL BOX REMOTE FEEDBACK UNIT ...

Page 98: ...Instruction Manual D103785X012 Principle of Operation June 2017 98 ...

Page 99: ... Cycle Count Alert Enable B 9 Cycle Count Alert Point B 9 Cycle Counter B 11 Cycle Count Travel Accum Deadband B 9 Days Powered Up B 11 DD Information B 3 Description B 3 B 6 Device ID B 3 Device Revision B 3 Device Setup B 5 Device Status B 3 B 11 Drive Current Failure Shutdown B 9 Drive Signal B 11 Function Variable See Figure Drive Signal Alert Enable B 9 Dynamic Torque B 6 Edit Cycle Counts B ...

Page 100: ...Restart Processor B 11 Seat Type Trim B 6 Setpoint B 3 B 11 Shutdown on Alert B 9 Solenoid Valve B 6 SP Rate Close B 7 Function Variable See Figure SP Rate Open B 7 Spring Rate B 6 Spring Rate Units B 6 Stabilize Optimize B 5 B 8 B 11 Stem Diameter B 6 Stroke Valve B 11 Supply Pressure B 3 B 11 Supply Pressure Lo Alert B 9 Switch Closed B 8 Temperature B 11 Temperature Units B 6 Temp Sensor Failur...

Page 101: ... Pressure A B 9 Device Information Revisions 1 HART Universal Revision 2 Device Revision 3 Hardware Revision 4 Firmware Revision 5 DD Information Security 1 Write Protection 2 Change Write Protection 1 9 AD PD ODV 1 9 1 AD PD ODV 1 9 2 AD PD ODV 1 8 3 HC 2 HART LONG TAG IS AVAILABLE WITH HART 7 NOTES Device ID and Serial Numbers 1 Device ID 2 Valve Serial Number 3 Instrument Serial Number 4 PWB Se...

Page 102: ...nalog Input Range 1 Input Range Hi 2 Input Range Lo 1 NOTES 3 1 HART LONG TAG IS AVAILABLE WITH HART 7 2 PARTIAL STROKE TEST IS AVAILABLE FOR INSTRUMENT LEVEL ODV Units 1 Travel Units 2 Length Units 3 Area Units 4 Spring Rate Units 5 Torque Units Trim 1 Seat Type 2 Leak Class 3 Port Diameter 4 Port Type 5 Flow Direction 6 Push Down To 7 Flow Tends To 8 Unbalanced Area Valve Travel 1 Rated Travel 2...

Page 103: ... Lo Limit Cutoff Select 4 Lo Limit Cutoff Point 2 2 3 3 2 2 3 7 AD PD 2 2 3 6 AD PD 2 2 3 4 AD PD 2 2 3 5 AD PD Travel Pressure Control ODV 1 Travel Pressure Select 2 Cutoffs and Limits 3 End Point Pressure Control EPPC 4 Pressure Control 5 Pressure Fallback 6 Control Mode 7 Response Control 8 Dynamic Response HC AD PD Cutoffs and Limits 1 Hi Limit Cutoff Select 2 Hi Limit Cutoff Point 3 Lo Limit ...

Page 104: ...2 Integrator Limit Tuning 1 Travel Tuning 2 Pressure Tuning 3 Travel Pressure Integral Settings Travel Tuning 1 Travel Tuning Set 2 Proportional Gain 3 Velocity Gain 4 MLFB Gain 5 Integral Enable 6 Integral Gain 7 Performance Tuner 8 Stabilize Optimize 2 2 5 2 2 4 2 2 6 2 HC AD PD 2 2 4 3 2 2 4 1 Switch Configuration 1 Limit Switch Trip Point 2 Alert Switch Source 3 Switch Closed 1 PARTIAL STROKE ...

Page 105: ...avel Accumulator 7 Travel Accumulator Alert Point 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 Edit Instrument Time 2 3 3 HC 2 3 5 HC 1 SUPPLY PRESSURE LO ALERT IS AVAILABLE FOR INSTRUMENT LEVEL AD PD AND ODV 1 Pressure Fallback 1 Pressure Fallback Act...

Page 106: ...g Input 4 Temperature 5 Travel Counts 6 Characterization 7 Travel History 8 Run Time Extremes Control Mode 1 Control Mode 2 Change Control Mode 3 Restart Control Mode 3 3 Travel Pressure 1 Setpoint 2 Travel 3 Drive Signal 4 Supply Pressure 5 Pressure A 6 Pressure B 7 Pressure A B 8 Travel Pressure Select 9 Fallback Recovery Characterization 1 Input Characterization 2 Custom Characterization Travel...

Page 107: ...hose 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...

Page 108: ...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 10 and calibrated travel 3 drive signal 90 and calibrated travel 97 If Zero Power Condition Open The alert is active when drive signal 10 and calibrated travel 97 drive signal 90 and calib...

Page 109: ... Out of Service 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 se...

Page 110: ...vices 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 ...

Page 111: ...ound 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 alert is active if either the high or low point is exceeded Once a high or low point is exceeded the ranged travel must ...

Page 112: ...ve from going completely closed Travel Range Travel in percent of calibrated travel that corresponds to the input range 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...

Page 113: ... Travel 42 Auto 42 Manual 44 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 Comp...

Page 114: ...covery 24 Fallback Sensor Failure Travel Pressure Select 22 Fallback Sensor Tvl Deviation Travel Pressure Select 23 Fast Key Sequences Field Communicator 99 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 Kaz...

Page 115: ...turated 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 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 M Maintenance and Troubleshooting 63 Manua...

Page 116: ...nce Tuner 30 PESO CCOE India Certification 6 Pneumatic Connections 3 Pneumatic Relay Parts List 87 Removing 71 Replacing 71 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 Pressur...

Page 117: ...iary Terminal Action 21 Calibration CAL Button 21 Parts List 87 Removing 72 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 C...

Page 118: ...vl Dev Press Fallback Time 24 U Units Analog Input 21 Pressure 21 Temperature 21 V Valve Serial Number 21 Valve Style 32 ValveLink software 4 Variable Out of Range 57 Variables Status 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 Wi...

Page 119: ...Instruction Manual D103785X012 DVC6000 HW2 Digital Valve Controller June 2017 119 ...

Page 120: ...right to modify or improve the designs or specifications of such products at any time without notice E 2014 2017 Fisher Controls International LLC All rights reserved Neither Emerson Emerson Automation Solutions nor 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 remai...

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