Emerson Fisher FIELDVUEDVC6200 Instruction Manual

Instruction Manual

D103605X012

DVC6200 Digital Valve Controller

Fisherr FIELDVUE™ DVC6200 Digital Valve Controller

This manual applies to

Instrument Level HC, AD, PD, ODV Device Type 09 Device Revision 1 & 2 Hardware Revision 2 Firmware Revision 2, 3, 4, 5 & 6 DD Revision 1, 2, 3, 4 & 5

Contents

Section 1 Introduction 3.................

Installation, Pneumatic and Electrical Connections,

and Initial Configuration 3.....................

Scope of Manual 3..............................

Conventions Used in this Manual 3................

Description 3..................................

Specifications 5................................

Related Documents 5...........................

Educational Services 8...........................

Section 2 Wiring Practices 9..............

Control System Requirements 9..................

HART Filter 9.................................

Voltage Available 9............................

Compliance Voltage 11........................

Auxiliary Terminal Wiring Length Guidelines 12....

Maximum Cable Capacitance 12.................

Installation in Conjunction with a Rosemountt 333 HART Tri‐Loopt HART‐to‐Analog

Signal Converter 13.........................

Section 3 Configuration 15...............

Guided Setup 15...............................

Manual Setup 15...............................

Mode and Protection 16........................

Instrument Mode 16.......................

Write Protection 16........................

Instrument 16................................

Identification 16...........................

Serial Numbers 17.........................

Units 17..................................

Terminal Box 17...........................

Input Range 17............................

Spec Sheet 18.............................

Edit Instrument Time 18....................

W9713

Travel/Pressure Control 18......................

Travel/Pressure Select 18...................

Cutoffs and Limits 19.......................

End Point Pressure Control 19................

Pressure Control 20........................

Pressure Fallback 20........................

Control Mode 21..........................

Characterization 21........................

Dynamic Response 23......................

Tuning 24....................................

Travel Tuning 24...........................

Pressure Tuning 27........................

Travel/Pressure Integral Settings 27..........

Valve and Actuator 28..........................

Partial Stroke Test 30..........................

Outputs 33...................................

Output Terminal Configuration 33............

Switch Configuration 33....................

HART Variable Assignments 34..............

Transmitter Output 34.....................

Alert Setup 35.................................

Change to HART 5 / HART 7 36....................

January 2015

www.Fisher.com

DVC6200 Digital Valve Controller

January 2015

Instruction Manual

D103605X012

Contents (continued)

Section 4 Calibration 37.................

Calibration Overview 37.........................

Travel Calibration 38...........................

Auto Calibration 38........................

Manual Calibration 39......................

Pushbutton Calibration 40..................

Sensor Calibration 41..........................

Pressure Sensors 41........................

Analog Input Calibration 42.................

Relay Adjustment 43...........................

Double‐Acting Relay 43.....................

Single‐Acting Relays 44.....................

PST Calibration 45.............................

Section 5 Device Information,

Diagnostics, and Alerts 47...............

Overview 47...................................

Status & Primary Purpose Variables 47............

Device Information 47.........................

Service Tools 48................................

Device Status 48..............................

Alert Record 48...............................

Electronics 48.............................

Pressure 49...............................

Travel 50.................................

Travel History 51..........................

Alert Record 51............................

Status 52.................................

Diagnostics 52................................

Stroke Valve 52............................

Partial Stroke Test (ODV only) 52.............

Variables 53...................................

Section 6 Maintenance and

Troubleshooting 55.....................

Replacing the Magnetic Feedback Assembly 56......

Module Base Maintenance 56.....................

Tools Required 56.............................

Component Replacement 57....................

Removing the Module Base 57..................

Replacing the Module Base 58...................

Submodule Maintenance 58......................

I/P Converter 59...............................

Printed Wiring Board (PWB) Assembly 61..........

Pneumatic Relay 63............................

Gauges, Pipe Plugs or Tire Valves 63..............

Terminal Box 64................................

Removing the Terminal Box 64..................

Replacing the Terminal Box 65...................

Troubleshooting 65.............................

Checking Voltage Available 65....................

Restart Processor 66............................

DVC6200 Technical Support Checklist 68...........

Section 7 Parts 69......................

Parts Ordering 69...............................

Parts Kits 69...................................

PWB Assembly 69.............................

Parts List 70...................................

Housing 70...................................

Common Parts 71.............................

Module Base 71...............................

I/P Converter Assembly 71......................

Relay 71.....................................

Terminal Box 72...............................

Feedback Connection Terminal Box 72............

Pressure Gauges, Pipe Plugs, or Tire

Valve Assemblies 72.........................

DVC6215 Feedback Unit 72.....................

HART Filters 72...............................

Appendix A Principle of Operation 79......

HART Communication 79........................

DVC6200 Digital Valve Controller 79...............

Appendix B Field Communicator

Menu Tree 83........................

Glossary 91............................

Index 97..............................

The FIELDVUE DVC6200 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 DVC6200 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

D103605X012

Section 1 Introduction

Installation, Pneumatic and Electrical Connections, and Initial Configuration

Introduction

January 2015

Refer to the DVC6200 Series Quick Start Guide (D103556X012) for DVC6200 installation, connection and initial configuration information. If a copy of this quick start guide is needed scan or click the QR code at the right, contact your Emerson Process Management sales office, or visit our website at www.Fisher.com.

Scan or click to access field support

Scope of Manual

This instruction manual is a supplement to the DVC6200 Series 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 the 475 Field 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 a DVC6200 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.

Communicator to set up and calibrate the instrument. You can

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 > Device Setup (2‐1‐1)

Refer to Appendix B for Field Communicator menu trees.

Description

DVC6200 digital valve controllers (figures 1‐1 and 1‐2) 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 DVC6200 digital valve controller, using the HARTr communications protocol, 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.

Using a personal computer and ValveLink software or AMS Suite: Intelligent Device Manager, or a Field Communicator, you can perform several operations with the DVC6200 digital valve controller. You can obtain general information concerning software revision level, messages, tag, descriptor, and date.

Introduction

January 2015

Instruction Manual

D103605X012

Figure 1‐1. FIELDVUE DVC6200 Digital Valve Controller Mounted on a Fisher Sliding-Stem Valve Actuator

W9643

Figure 1‐2. FIELDVUE DVC6200 Digital Valve Controller Integrally Mounted to a Fisher GX Control Valve

W9616

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 on a single loop basis.

The DVC6200 digital valve controller is designed to directly replace standard pneumatic and electro‐pneumatic valve mounted positioners.

Table 1‐1. Instrument Level Capabilities

CAPABILITY

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

Supply Pressure Sensor X X X

Performance Diagnostics X X

Solenoid Valve Testing X X

Lead/Lag Set Point Filter

1. Refer to brochure part # D351146X012 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.

(1)

HC AD PD ODV

DIAGNOSTIC LEVEL

(2)

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Introduction

January 2015

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 DVC6200 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.

Related Documents

This section lists other documents containing information related to the DVC6200 digital valve controller. These documents include:

D Bulletin 62.1:DVC6200 - Fisher FIELDVUE DVC6200 Digital Valve Controller (D103415X012)

D Bulletin 62.1:DVC6200 HC - Fisher FIELDVUE DVC6200 Digital Valve Controller (D103423X012)

D Bulletin 62.1:DVC6200(S1) Fisher FIELDUVE DVC6200 Digital Valve Controller Dimensions (D103543X012)

D Fisher FIELDVUE DVC6200 Series Digital Valve Controller Quick Start Guide (D103556X012)

D FIELDVUE Digital Valve Controller Split Ranging (D103262X012)

D Using FIELDVUE Instruments with the Smart HART Loop Interface and Monitor (HIM) (D103263X012)

D Using FIELDVUE Instruments with the Smart Wireless THUMt Adapter and a HART Interface Module (HIM)

(D103469X012)

D Audio Monitor for HART Communications (D103265X012)

D HART Field Device Specification - Supplement to Fisher FIELDVUE DVC6200 Digital Valve Controller (D103639X012)

D Using the HART Tri‐Loop HART‐to‐Analog Signal Converter with FIELDVUE Digital Valve Controllers (D103267X012)

D Implementation of 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 Process Management sales office. Also visit our website at www.FIELDVUE.com.

Introduction

January 2015

Table 1‐2. Specifications

Instruction Manual

D103605X012

Available Mounting

DVC6200 digital valve controller or DVC6215 feedback unit:

Control Valve and Actuator System mounting to Fisher rotary actuators linear applications

J Integral mounting to the Fisher GX

J Window

J Sliding‐stem

J Quarter‐turn rotary applications

DVC6205 base unit for 2 inch pipestand or wall mounting (for remote‐mount)

The DVC6200 digital valve controller or DVC6215 feedback unit can also be mounted on other actuators that comply with IEC 60534‐6-1, IEC 60534-6-2, VDI/VDE 3845 and NAMUR mounting standards.

Communication Protocol

J HART 5 or J 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

(1)

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

Air: Supply pressure must be clean, dry air that meets the requirements of ISA Standard 7.0.01.

Natural Gas: Natural Gas must be clean, dry, oil-free and noncorrosive. H

S content should not exceed 20

ppm.

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

-continued-

volume (v/v) basis. Condensation in the air supply should be minimized.

Per ISO 8573-1

Maximum particle density size: Class 7 Oil content: Class 3 Pressure Dew Point: Class 3 or at least 10 K less than

the lowest ambient temperature expected

Output Signal

Pneumatic signal, up to full supply pressure

Minimum Span: 0.4 bar (6 psig) Maximum Span: 9.5 bar (140 psig) Action:

Steady‐State Air Consumption

J Double, J Single Direct or J Reverse

(2)(3)

Standard Relay At 1.4 bar (20 psig) supply pressure:

Less than 0.38 normal m At 5.5 bar (80 psig) supply pressure: Less than 1.3 normal m

/hr (14 scfh)

/hr (49 scfh)

Low Bleed Relay

At 1.4 bar (20 psig) supply pressure:

Average value 0.056 normal m At 5.5 bar (80 psig) supply pressure: Average value 0.184 normal m

Maximum Output Capacity

At 1.4 bar (20 psig) supply pressure:

10.0 normal m

At 5.5 bar (80 psig) supply pressure:

29.5 normal m

/hr (375 scfh)

/hr (1100 scfh)

Operating Ambient Temperature Limits

/hr (2.1 scfh)

/hr (6.9 scfh)

(2)(3)

(1)(4)

-40 to 85_C (-40 to 185_F)

-52 to 85_C (-62 to 185_F) for instruments utilizing the Extreme Temperature option (fluorosilicone elastomers)

-52 to 125_C (-62 to 257_F) for remote‐mount feedback unit

Independent Linearity

(5)

Typical Value: ±0.50% of output span

Electromagnetic Compatibility

Meets EN 61326-1 (First Edition) Immunity—Industrial locations per Table 2 of the EN 61326-1 standard. Performance is shown in table 1‐3 below. Emissions—Class A ISM equipment rating: Group 1, Class A

Instruction Manual

D103605X012

Table 1‐2. Specifications (continued)

Introduction

January 2015

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, Type n 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 and Belarus)

INMETRO— National Institute of Metrology, Quality, and Technology (Brazil)

PESO CCOE— Petroleum and Explosives Safety Organisation - Chief Controller of Explosives (India)

Contact your Emerson Process 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, M20 adapter optional

Actuator Compatibility

Stem Travel (Sliding‐Stem Linear)

Minimum: 6.5 mm (0.25 inch) Maximum: 606 mm (23.875 inches)

Shaft Rotation (Quarter‐Turn Rotary)

Minimum: 45_ Maximum: 90_

Weight

DVC6200

Aluminum: 3.5 kg (7.7 lbs) Stainless Steel: 8.6 kg (19 lbs)

DVC6205: 4.1 kg (9 lbs) DVC6215: 1.4 kg (3.1 lbs)

Construction Materials

Housing, module base and terminal box: A03600 low copper aluminum alloy (standard) Stainless steel (optional)

Cover: Thermoplastic polyester Elastomers: Nitrile (standard)

Fluorosilicone (extreme temperature)

Options

J Supply and output pressure gauges or J Tire valves J Integral mounted filter regulator J Low‐Bleed Relay J Extreme Temperature J Remote Mount

J Integral 4‐20 mA Position Transmitter

(6)

J Stainless Steel

(7)

4‐20 mA output, isolated

Supply Voltage: 8‐30 VDC Fault Indication: offrange high or low Reference Accuracy: 1% of travel span

J Integral Switch

(7)

One isolated switch, configurable throughout the calibrated travel range or actuated from a device alert

Off State: 0 mA (nominal) On State: up to 1 A Supply Voltage: 30 VDC maximum Reference Accuracy: 2% of travel span

Contact your Emerson Process Management sales office or go to www.FIELDVUE.com for additional information

-continued-

Introduction

January 2015

Table 1‐2. Specifications (continued)

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D103605X012

Declaration of SEP

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

NOTE: Specialized instrument terms are defined in ANSI/ISA Standard 51.1 - Process Instrument Terminology.

1. The pressure/temperature limits in this document and any other applicable code or standard should not be exceeded.

2. Normal m

3. 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.

4. Temperature limits vary based on hazardous area approval.

5. 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.

6. 4‐conductor shielded cable, 18 to 22 AWG minimum wire size, in rigid or flexible metal conduit, is required for connection between 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.

7. The electronic output is available with either the position transmitter or the switch.

/hour - Normal cubic meters per hour at 0_C and 1.01325 bar, absolute. Scfh - Standard cubic feet per hour at 60_F and 14.7 psia.

with Sound Engineering Practice (SEP) and cannot bear the CE marking related to PED compliance.

However, the product may bear the CE marking to indicate compliance with other applicable European Community Directives.

Table 1‐3. EMC Summary Results—Immunity

Port Phenomenon Basic Standard Test Level

Electrostatic discharge (ESD) IEC 61000‐4‐2

Enclosure

I/O signal/control

Performance criteria: +/- 1% effect.

1. A = No degradation during testing. B = Temporary degradation during testing, but is self‐recovering.

Radiated EM field IEC 61000‐4‐3

Rated power frequency magnetic field

Burst IEC 61000‐4‐4 1 kV A Surge IEC 61000‐4‐5 1 kV B Conducted RF IEC 61000‐4‐6 150 kHz to 80 MHz at 3 Vrms A

IEC 61000‐4‐8 30 A/m at 50/60Hz A

4 kV contact 8 kV air

80 to 1000 MHz @ 10V/m with 1 kHz AM at 80% 1400 to 2000 MHz @ 3V/m with 1 kHz AM at 80% 2000 to 2700 MHz @ 1V/m with 1 kHz AM at 80%

Performance

Criteria

(1)

Educational Services

For information on available courses for the DVC6200 digital valve controller, as well as a variety of other products, contact:

Emerson Process Management Educational Services - Registration Phone: +1-641‐754‐3771 or +1-800‐338‐8158 or e‐mail: education@emerson.com http://www.emersonprocess.com/education

Instruction Manual

D103605X012

Wiring Practices

January 2015

Section 2 Wiring Practices22

Control System Requirements

There are several parameters that should be checked to ensure the control system is compatible with the DVC6200 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 PROVOXt, RS3t, and DeltaVt systems.

Figure 2‐1. HART Filter Application

NON‐HART BASED DCS

I/O I/O

HART FILTER

4‐20 mA + HART

DIGITAL VALVE CONTROLLER

Tx Tx

A6188‐1

VALVE

Voltage Available

The voltage available at the DVC6200 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

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D103605X012

As shown in figure 2‐2, the voltage available at the instrument depends upon:

D the control system compliance voltage

D if a filter, wireless THUM adapter, or intrinsic safety barrier is used, and

D 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 used)] - [total cable resistance  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 Honeywellt TDC2000 control system with a HF340 HART filter, and 1000 feet of Beldent 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

COMPLIANCE VOLTAGE

CONTROL SYSTEM

Calculate Voltage Available at the Instrument as follows:

Control system compliance voltage

– Filter voltage drop (if used)

– 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)

– Total loop cable resistance x maximum loop current – 1.01 volts (48 ohms x 0.02105 amps for

= Voltage available at the instrument

NOTES:

Obtain filter voltage drop. The measured drop will be different than this value. The measured filter voltage drop

depends upon control system output voltage, the intrinsic safety barrier (if used), and the instrument. See note 3.

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 terminals. Once the instrument is

connected, the instrument limits the measured voltage to approximately 8.0 to 9.5 volts.

HART FILTER (if used)

CABLE RESISTANCE

INTRINSIC SAFETY BARRIER (if used)

THUM ADAPTER (IF USED)

Example Calculation

18.5 volts (at 21.05 mA)

– 2.3 volts (for HF300 filter)

1000 feet of Belden 9501 cable)

= 15.19 volts, available—if safety barrier (2.55 volts) is not used

VOLTAGE AVAILABLE AT THE

INSTRUMENT

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Wiring Practices

January 2015

Table 2‐1. Cable Characteristics

pF/Ft

(1)

Capacitance

Cable Type

BS5308/1, 0.5 sq mm 61.0 200 0.022 0.074

BS5308/1, 1.0 sq mm 61.0 200 0.012 0.037

BS5308/1, 1.5 sq mm 61.0 200 0.008 0.025

BS5308/2, 0.5 sq mm 121.9 400 0.022 0.074

BS5308/2, 0.75 sq mm 121.9 400 0.016 0.053

BS5308/2, 1.5 sq mm 121.9 400 0.008 0.025

BELDEN 8303, 22 awg 63.0 206.7 0.030 0.098

BELDEN 8441, 22 awg 83.2 273 0.030 0.098

BELDEN 8767, 22 awg 76.8 252 0.030 0.098

BELDEN 8777, 22 awg 54.9 180 0.030 0.098

BELDEN 9501, 24 awg 50.0 164 0.048 0.157

BELDEN 9680, 24 awg 27.5 90.2 0.048 0.157

BELDEN 9729, 24 awg 22.1 72.5 0.048 0.157

BELDEN 9773, 18 awg 54.9 180 0.012 0.042

BELDEN 9829, 24 awg 27.1 88.9 0.048 0.157

BELDEN 9873, 20 awg 54.9 180 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.

Capacitance

pF/m

(1)

Resistance

Ohms/ft

(2)

Resistance

(2)

Ohms/m

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

kW POTENTIOMETER

VOLTMETER

CIRCUIT UNDER TEST

A6192‐1

MILLIAMMETER

2. Set the control system to provide maximum output current.

3. Increase the resistance of the 1 kW 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.

Wiring Practices

January 2015

Instruction Manual

D103605X012

Auxiliary Terminal Wiring Length Guidelines

The Auxiliary Input Terminals of a DVC6200 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 DVC6200.

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 & 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 cable = 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 μH/ft Nom. Capacitance Conductor to Conductor @ 1 KHz: 51 pF/ft Nom. Cap. Cond. to other Cond. & 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 5V, 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 - C

Length(m) = [160,000 - C

where:

master

(pF)]  [C

cable

(pF/ft)]

(pF/m)]

160,000 = a constant derived for FIELDVUE instruments to ensure that the HART network RC time constant will be no greater than 65 μs (per the HART specification).

= the capacitance of the control system or HART filter

master

Instruction Manual

D103605X012

= the capacitance of the cable used (see table 2‐1)

cable

The following example shows how to calculate the cable length for a Foxboro

I/A control system (1988) with a C

Wiring Practices

January 2015

master

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.

Installation in Conjunction with a Rosemount 333 HART Tri‐Loop HART‐to‐Analog Signal Converter

Use the DVC6200 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 2‐4 for basic installation information. Refer to the 333 HART Tri‐Loop HART‐to‐Analog Signal Converter

Product Manual for complete installation information.

Figure 2‐4. HART Tri‐Loop Installation Flowchart

START HERE

Unpack the HART Tri‐Loop

Review the HART Tri‐Loop Product Manual

Digital valve

controller Installed?

Yes

Set the digital valve controller Burst Option

Set the digital valve controller Burst Mode

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 Tri‐Loop to receive digital valve controller burst commands

Pass system

test?

Yes

DONE

Check troubleshooting procedures in HART Tri‐Loop product manual.

E0365

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January 2015

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D103605X012

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 DVC6200 for use with a HART Tri‐Loop, perform the following procedures.

Note

The DVC6200 must be in HART 5 compatibility mode to use burst communications.

Enable Burst Operation

With I/O Package

Field Communicator

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

With I/O Package

Field Communicator

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.

D Setpoint

D Travel (see note below)

D Pressure A

D Pressure B

D Pressure AB

D Supply Pressure

D Drive Signal

D 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.

Configure > Manual Setup > Outputs > HART Variable Assignments (2-2-6-4) HC, AD, PD or (2-2-7-4) ODV

Without I/O Package

Configure > Manual Setup > Outputs > HART Variable Assignments (2-2-6-1) HC, AD, PD or (2-2-7-1) ODV

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Configuration

January 2015

Section 3 Configuration

Guided Setup

Field Communicator Configure > Guided Setup (2‐1)

To quickly setup the instrument, the following procedures will guide you through the process.

D 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.

D 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 26 for additional information.

D Stabilize Optimize (instrument level HC)—This procedure permits you to adjust valve response by changing the

digital valve controller tuning. See page 26 for additional information.

Manual Setup33

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 Restart Control Mode Resume Last Analog In Range Low 4 mA Analog In Range High 20 mA

Instrument Configuration

Dynamic Response and Tuning

Analog Input Units mA Local AutoCal Button Disabled Polling Address 0 Burst Mode Enable No Burst Command 3 Cmd 3 (Trending) Pressure A-B Input Characterization Linear Travel Limit High 125% Travel Limit Low -25% Travel/Pressure Cutoff High 99.46% Travel/Pressure Cutoff Low 0.50% Set Point Rate Open 0%/sec Set Point Rate Close 0%/sec Set Point Filter Time (Lag Time) 0 sec Integrator Enable Yes Integral Gain 9.4 repeats/minute Integral Deadzone 0.26%

-continued on next page-

(1)

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Table 3‐1. Default Detailed Setup Parameters (continued)

Setup Parameter Default Setting

Travel Deviation Alert Enable Yes Travel Deviation Alert Point 5% Travel Deviation Time 9.99 sec

Deviation & Other Alerts

1. The settings listed are for standard factory configuration. DVC6200 instruments can also be ordered with custom configuration settings. Refer to the order requisition for the custom settings.

2. Adjust to bar, kPa, or Kg/cm

Pressure Deviation Alert Enable Yes Pressure Deviation Alert Point 5 psi Pressure Deviation Alert Time 5.0 sec Drive Signal Alert Enable Yes Supply Pressure Alert Enable Yes

if necessary

(1)

(2)

Mode and Protection

Field Communicator Configure > Manual Setup > Mode and Protection (2‐2‐1)

Instrument Mode

There are two instrument modes for the DVC6200; 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 DVC6200: 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 > Manual Setup > Instrument (2‐2‐2)

Follow the prompts on the Field Communicator display to configure the following Instrument parameters:

Identification

D 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 automatically displayed when the Field Communicator establishes contact with the digital valve controller at power‐up.

D HART Long Tag (HART Universal Revision 7 only)—A tag name up to 32 characters is available for the instrument.

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D103605X012

D 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.

D 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.

D 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.

For the 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.

Configuration

January 2015

Serial Numbers

D Instrument Serial Number—Enter the serial number on the instrument nameplate, up to 12 characters.

D Valve Serial Number—Enter the serial number for the valve in the application, 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 (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.

D 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

D 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, Input Range High corresponds to Travel Range Low. See figure 3‐1.

Configuration

January 2015

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D103605X012

D 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

CALIBRATED TRAVEL, %

TRAVEL RANGE LOW

ZPC = OPEN

ZPC = CLOSED

THE SHAPE OF THESE LINES DEPENDS ON THE INPUT CHARACTERISTICS LINEAR CHARACTERISTIC SHOWN

ANALOG INPUT

INPUT RANGE

NOTE: ZPC = ZERO POWER CONDITION

A6531‐1

LOW

mA OR % OF 4‐20 mA

INPUT RANGE

HIGH

Spec Sheet

The Spec Sheet provides a means to store the entire control valve specifications on board the DVC6200.

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)

Travel/Pressure Select

This defines the operating mode of the instrument as well as the behavior of the instrument should the travel sensor fail. There are four choices.

D Travel Control—The instrument is controlling to a target travel. Fallback is not enabled.

D Pressure Control—The instrument is controlling to a target pressure. Fallback is not enabled.

D Fallback-Sensor Failure—The instrument will fallback to pressure control if a travel sensor failure is detected.

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Configuration

January 2015

D 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

D 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.

D 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%.

D 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 Lo Cutoff Point. When the Hi Cutoff/Limit Select is configured for Limit, the Travel Target 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 instrument level ODV.

D 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.

Configuration

January 2015

Instruction Manual

D103605X012

D EPPC Set Point—Used in conjunction with End Point Pressure Control, End Point Pressure Control Set Point allows

the user 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 a fail‐close valve, this is 95% of the supply pressure. If the valve is fail‐open, the upper operating pressure for all actuator is set to the supply pressure.

D 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

D Pressure Range 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 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.

D 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.

D Tvl Dev Press Fallback Time—This is the time, in seconds, that the travel target and the actual travel must be

exceeded before the instrument falls back into pressure control.

D 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).

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Configuration

January 2015

Control Mode

D Control Mode—This 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.

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.

D Change Control Mode—This allows the user to configure the control mode to Analog or Digital.

D Restart Control Mode—This defines the Control Mode of the instrument after a restart (e.g. power cycle). Available

choices are Resume Last, Analog and Digital.

Characterization

D 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 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 106.25%. Before modification, the custom characteristic is linear.

D 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).

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January 2015

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D103605X012

Figure 3‐2. Travel Target Versus Ranged Set Point, for Various Input Characteristics (Zero Power Condition = Closed)

125

100

Travel Target, %

-25

-25 0 125100

Ranged Set Point, %

Input Characteristic = Linear

125

100

125

100

Travel Target, %

-25

-25 0 125100

Ranged Set Point, %

Input Characteristic = Equal Percentage

A6535‐1

Travel Target, %

-25

-25 0 125100

Ranged Set Point, %

Input Characteristic = Quick Opening

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Configuration

January 2015

Dynamic Response

D 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. In firmware 2, 3, and 4 this parameter should be set to 0.

D 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. In firmware 2, 3, and 4 this parameter should be set to 0.

D 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. In firmware 2, 3, and 4 this parameter should be set to 0.

Note

Set Point Filter Time (Lag Time) is available for instrument level HC, AD, and PD.

D Lead/Lag Set Point 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 opening 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. 0.2 sec

Opening Lead/Lag Ratio Initial response to the filter in the opening direction. 2.0

Closing Lead/Lag Ratio Initial response to the filter in the closing direction. 2.0 Lead‐Lag Boost Initial conditions of the lead‐lag filter when the lower travel cutoff is active. Off

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January 2015

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D103605X012

Tuning

Field Communicator Configure > Manual Setup > Tuning (2‐2-4)

Travel Tuning

WARNING

Changes to the tuning set may cause the valve/actuator assembly to stroke. To avoid personal injury and property damage caused by moving parts, keep hands, tools, and other objects away from the valve/actuator assembly.

D 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 Set Proportional Gain Velocity Gain Minor Loop Feedback Gain

E F

G H

J K L

X (Expert) User Adjusted User Adjusted User Adjusted

4.4

4.8

5.5

6.2

7.2

8.4

9.7

11.3

13.1

15.5

18.0

3.0

3.1

3.6

4.2

4.85

5.65

6.0

35 35 35 35 34

31 27 23 18 12 12

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 routint 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.

Instruction Manual

D103605X012

Table 3‐4. Actuator Information for Initial Setup

Actuator

Manufacturer

Fisher

Baumann

NOTE: Refer to figure table 3‐6 for feedback connection (magnet assembly) information.

1. X = Expert Tuning. Proportional Gain = 4.2; Velocity Gain = 3.0; Minor Loop Feedback Gain = 18.0

2. Travel Sensor Motion in this instance refers to the motion of the magnet assembly.

3. Values shown are for Relay A and C. Reverse for Relay B.

Actuator Model Actuator Size Actuator Style

585C & 585CR

657

667

1051 & 1052

1061

1066SR

2052

3024C

Air to Extend

Air to Retract Away from the top of the instrument

Rotary

50 60

68, 80

100, 130

30 34, 40 45, 50

46, 60, 70, 76, &

80‐100

30 34, 40 45, 50

46, 60, 70, 76, &

80‐100

20, 30

40 60, 70

68, 80, 100, 130

20 27, 75

1 2 3

30, 30E

34, 34E, 40, 40E

45, 45E

225 750 K

1200 M

Piston Dbl w/ or w/o Spring. See actuator

instruction manual and

nameplate.

Spring & Diaphragm

(Window‐mount)

Piston Dbl w/o Spring

Piston Sgl w/Spring

Spring & Diaphragm

(Window‐mount)

Spring & Diaphragm

Starting

Tuning Set

I J

K L

M H

K L

M H

J K L

(1)

C E

Configuration

January 2015

Travel Sensor Motion

Relay A or C

User Specified

Away from the top of the instrument

Towards the top of the instrument

Away from the top of the instrument

Depends upon pneumatic connections. See

description for Travel Sensor Motion

Mounting Style Travel Sensor Motion

Away from the top of the instrument

For Po operating mode (air opens): Towards the top of the instrument For P

operating mode (air closes):

Away from the top of the instrument

Air to Open

Towards the top of

the instrument

Towards the top of the instrument

Towards the top of the

Specify

(2)

(3)

Away from the top of

the instrument

instrument

Away from the top of

the instrument

Air to Close

Away from the top of

the instrument

D Proportional Gain—the proportional gain for the travel control tuning set. Changing this parameter will also change

the tuning set to Expert.

D Velocity Gain—the velocity gain for the travel control tuning set. Changing this parameter will also change the

tuning set to Expert.

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D103605X012

D MLFB Gain—the minor loop feedback gain for the travel control tuning set. Changing this parameter will also change

the tuning set to Expert.

D 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.

D 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.

D Performance Tuner

WARNING

During performance tuning 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.

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 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 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 G).

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.

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Configuration

January 2015

Pressure Tuning

D 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

B C D E

G H

I J

X (Expert) User Adjusted User Adjusted User Adjusted

0.5

2.2

2.4

2.8

3.1

3.6

4.2

4.8

5.6

6.6

7.8

9.0

0.3

0.1

35 35 35 35 35 34

31 27 23 18 12 12

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.

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 tuning set. Changing this parameter will also

change the tuning set to Expert.

D 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.

D 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

D 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

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D103605X012

is configurable from 0% to 2%, corresponding to a symmetric window from 0% to +/-2% around the Primary Setpoint. Default value is 0.25%.

D Integrator Limit—The Integrator Limit provides an upper limit to the integrator output. The high limit is configurable

from 0 to 100% of the I/P drive signal.

Valve and Actuator

Field Communicator Configure > Manual Setup > 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.

Feedback Connection—Refer to table 3‐6 for Feedback Connection options. Choose the assembly that matches the actuator travel range.

Note

As a general rule, do not use less than 60% of the magnet assembly travel range for full travel measurement. Performance will decrease as the assembly is increasingly subranged.

The linear magnet assemblies have a valid travel range indicated by arrows molded into the piece. This means that the hall sensor (on the back of the DVC6200 housing) has to remain within this range throughout the entire valve travel. The linear magnet assemblies are symmetrical. Either end may be up.

Table 3‐6. Feedback Connection Options

Magnet Assembly

SStem #7 4.2-7 0.17-0.28 -

SStem #19 8-19 0.32-0.75 -

SStem #25 20-25 0.76-1.00 -

SStem #38 26-38 1.01-1.50 -

SStem #50 39-50 1.51-2.00 -

SStem #110 51-110 2.01-4.125 -

SStem #210 110-210 4.125-8.25

SStem #1 Roller > 210 > 8.25 60-90_

RShaft Window #1 - - 60-90_

RShaft Window #2 - - 60-90_

RShaft End Mount - - 60-90_

mm Inch Degrees

Travel Range

Relay Type—There are 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.

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Configuration

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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 type, as shown in figure 3‐3.

Figure 3‐3. Zero Power Condition

Relay Type

Single‐Acting Direct (Relay A or C)

Double‐Acting (Relay A)

Single‐Acting Reverse (Relay B)

Loss of Electrical Power

Port A pressure to zero.

Port A pressure to zero. Port B pressure to full supply.

Port B pressure to full supply.

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.

Select Clockwise/Toward Bottom, or Counterclockwise/Toward Top. Travel Sensor Motion establishes the proper travel sensor rotation. For quarter‐turn actuators determine rotation by viewing the rotation of the magnet assembly from the back of the instrument.

Note

Travel Sensor Motion in this instance refers to the motion of the magnet assembly. Note that the magnet assembly may be referred to as a magnetic array in user interface tools.

D For instruments with Relay A and C: If increasing air pressure at output A causes the magnet assembly to move

down or the rotary shaft to turn clockwise, enter CW/To Bottom Inst. If it causes the magnet assembly to move up, or the rotary shaft to turn counterclockwise, enter CCW/To Top Inst.

D For instruments with Relay B: If decreasing air pressure at output B causes the magnet assembly to down, or the

rotary shaft to turn clockwise, enter CW/To Bottom Inst. If it causes the magnet assembly to move up, or the rotary shaft to turn counterclockwise, enter CCW/To Top Inst.

Maximum Supply Pressure

Enter the maximum supply pressure that is required to fully stroke the valve.

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Partial Stroke Test (PST) (Instrument Level ODV only)

Field Communicator Configure > Manual Setup > Partial Stroke (2-2-6)

Note

Partial Stroke is only available for instrument level ODV.

Partial Stroke Test (PST)

D PST Pressure Limit— This defines the actuator pressure at which a partial stroke test will abort. This prevents the

DVC6200 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.

Relay Type Pressure Signal

A or C 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 DVC6200 to a system running ValveLink software.

2. Disable the following parameters:

D Travel Deviation Alert - set to 125%.

D End Point Pressure Control - disable

D Partial Stroke Pressure Limit - disable by setting the appropriate value shown in table 3‐7.

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Emerson Fisher FIELDVUEDVC6200 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual