Instruction Manual Supplement
D103601X012
DVC6200 SIS Digital Valve Controller
September 2013
Safety manual for Fisherr FIELDVUE™ DVC6200
SIS Digital Valve Controller and Position Monitor
This supplement applies to
Instrument Level SIS
Device Type 130a
Device Revision 1 & 2
Hardware Revision 2
Firmware Revision 4, 5 & 6
DD Revision 3, 4 & 5
1. Purpose
This safety manual provides information necessary to design, install, verify and maintain a Safety
Instrumented Function (SIF) utilizing the Fisher DVC6200 SIS digital valve controller. The following
document must be thoroughly reviewed and implemented as part of the safety lifecycle. This
information is necessary for meeting the IEC 61508 or IEC 61511 functional safety standards.
WARNING
This instruction manual supplement is not intended to be used as a stand-alone document. It must be used in conjunction
with the following manuals:
Fisher FIELDVUE DVC6200 Series Quick Start Guide (D103556X012)
Fisher FIELDVUE DVC6200 SIS Instruction Manual (D103557X012)
Failure to use this instruction manual supplement in conjunction with the above referenced manuals could result in
personal injury or property damage. If you have any questions regarding these instructions or need assistance in obtaining
any of these documents, contact your Emerson Process Management sale office.
www.Fisher.com
DVC6200 SIS Digital Valve Controller
September 2013
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D103601X012
2. Description of the Device
The Fisher DVC6200 SIS digital valve controller is an instrument which delivers controlled
pneumatic pressure to modulate a valve actuator in response to an electrical signal. An optional
valve position monitor will either transmit a 420 mA signal in response to the actual valve travel or
open and close a discrete limit switch based on a configurable trip point.
This safety manual applies to the DVC6200 SIS instrument with electronics hardware revision 2
(HW2) and firmware revision 4, 5, and 6 with the following product options.
OPTION
MODEL CONSTRUCTION
DVC6200 SIS Integral, Aluminum √ √ √ √ √ √ √ √
DVC6200S SIS
DVC6205 SIS
DVC6215
Integral,
Stainless Steel
Remote Mount,
Aluminum
DETT ETT 4-20 mA 24 VDC Relay A Relay B Relay C
√ √ √ √ √ √ √ √
√ √ √ √ √ √ √ √
Position
Monitor
APPLICATION
DETT √ √ √ √ √ √
ETT √ √ √ √ √ √
4-20 mA √ √ √ √ √ √ √
24 VDC √ √ √ √ √ √
Accessories
LCP100 Local Control Panel, HART Only
LC340 Line Conditioner, 24 VDC
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3. Terms, Abbreviations, and Acronyms
β Beta factor for common cause effects of failure
DD
DETT Deenergize to Trip
DTM
DVC6200 SIS Digital Valve Controller, product model designation for Safety Instrumented System applications
ESD Emergency Shut Down
ETT Energize to Trip
FIT Failure In Time (1x109 failures per hour)
FMEDA Failure Mode Effect and Diagnostic Analysis
HART
HFT Hardware Fault Tolerance
λ
LC340
LCP100
Low Demand
Mode
Multidrop
PFD
AVG
PointtoPoint Operating mode of the DVC6200 SIS whereby the instrument is powered with 420 mA.
PVST Partial Valve Stroke Test
Relay A
Relay B
Relay C
Safety Freedom from unacceptable risk of harm.
Safety
Function
SFF Safe Failure Fraction
SIF Safety Instrumented Function
SIL Safety Integrity Level
SIS Safety Instrumented System
Type A
Element
Type B
Element
Device Description, an electronic data file that describes specific features and functions of a
device to be used by host applications.
Device driver that provides a unified structure for accessing device parameters, configuring and
operating the devices, and diagnosing problems.
Highway Addressable Remote Transducer, open protocol for digital communication
superimposed over a direct current.
Failure rate. λDD: dangerous detected; λDU: dangerous undetected; λSD: safe detected; λSU: safe
undetected.
Line Conditioner; product model designation for a device that is inserted in the loop when the
instrument (in Multidrop Mode) is powered with a lowimpedance 24 V source, to enable HARTr
communications.
Local Control Panel; product model designation for a device that can be connected to a DVC6200
SIS instrument to enable manuallyinitiated functions.
Mode of operation of a safety instrumented function where the demand interval is greater than
twice the proof test interval.
Operating mode of the DVC6200 SIS where the instrument controls the current drawn to enable
it to be powered with 24 VDC.
Average Probability of Failure on Demand
Pneumatic booster relay for double or single acting applications. Typical construction for double
acting DETT applications.
Pneumatic booster relay for single acting reverse applications. Typical construction for single
acting ETT applications.
Pneumatic booster relay for single acting direct applications. Typical construction for single
acting DETT applications.
Function of a device or combination of devices intended to be used within a Safety Instrumented
System to reduce the probability of a specific hazardous event to an acceptable level.
“NonComplex” element (using discrete components); for details see 7.4.4.1.2 of IEC 615082.
“Complex” element (using complex components such as micro controllers or programmable
logic); for details see 7.4.4.1.3 of IEC 615082.
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4. Related Literature
D Fisher DVC6200 Series Quick Start Guide (D103556X012)
D Fisher DVC6200 SIS Instruction Manual (D103557X012)
D 62.1:DVC6200 SIS, Fisher DVC6200 SIS Product Bulletin (D103555X012)
D HART Field Device Specification for Fisher DVC6200 SIS (D103638X012)
D IEC 61508: 2010 Functional safety of electrical/electronic/programmable electronic
safetyrelated systems
D ANSI/ISA 84.00.012004 (IEC 61511 Mod.) Functional Safety – Safety Instrumented Systems for
the Process Industry Sector
D Exida FMEDA Report for Fisher DVC6200 SIS, Position Monitor Applications
Report No. EFC 12/02027 R001
D Exida FMEDA Report for Fisher DVC6200 SIS, DETT Applications Report No. EFC 12/02027
R002
D Exida FMEDA Report for Fisher DVC6200 SIS, ETT Applications Report No. EFC 12/02027 R003
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5. General Requirements
WARNING
To ensure safe and proper functioning of equipment, users of this document must carefully read all
instructions, warnings, and cautions in this safety manual and the Quick Start Guide.
D Refer to the Fisher DVC6200 SIS Quick Start Guide (part number D103556X012) for mounting
and configuration.
D Tools needed:
D Flat Head Screwdriver, 3 mm Thin Blade (wiring terminations)
D Phillips Screwdriver
D 3/8” Hex Key (terminal box conduit plug)
D 6 mm Hex Key (module base screws)
D 5 mm Hex Key (terminal box screw)
D 2.5 mm Hex Key (I/P converter screws)
D 1.5 mm Hex Key (terminal box cover screw)
D Personnel performing maintenance and testing on the DVC6200 SIS shall be competent to do
so.
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6. Safety Instrumented System Design
When using the DVC6200 SIS digital valve controller in a safety instrumented system, the
following items must be reviewed and considered.
6.1 SIL Capability
6.2 Safety Function
6.3 Failure Rates
6.4 Application Limits
6.5 Environmental Limits
6.6 Application of the Switch Output for Diagnostic Annunciation
D103601X012
6.1. SIL Capability
D Systematic Integrity
SIL 3 Capable— the digital valve controller has met manufacturer design process
requirements of IEC 61508 Safety Integrity Level 3.
D Random Integrity
D The digital valve controller is classified as a Type A device according to IEC 61508. The
complete final element subsystem will need to be evaluated to determine the SFF. If the
SFF of the subsystem is >90%, and the PFD
< 103, the design can meet SIL 3 @ HFT=0.
avg
D The position monitor is classified as a Type B device according to IEC 61508. The
complete final element subsystem will need to be evaluated to determine the SFF. If the
SFF of the subsystem is >90%, and the PFD
If the SFF of the subsystem is between 60% and 90%, and the PFD
< 102, the design can meet SIL 2 @ HFT=0.
avg
< 101, the design
avg
can meet SIL 1 @ HFT=0.
6.2. Safety Function
D Deenergize to Trip Application: The application of the digital valve controller is limited for SIS
to low demand mode. Table 1 describes the normal and safe states of DVC6200 SIS for a DETT
configuration. The digital valve controller may be operated with one of the following control
signals:
D 024 VDC: Normal operation is with a 24 VDC signal applied to the digital valve
controller. A shutdown command is issued by interrupting the loop or taking the
voltage signal to 1 VDC or less.
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D 420 mA: Normal operation is with a 20 mA current loop signal to the digital valve
controller. A shutdown command is issued by taking the current signal to 4 mA
(nominal). If a looppowered LCP100 is attached, the shutdown command is issued by
taking the current signal to 8 mA (nominal).
Table 1. Normal and Safe States for De-Energize to Trip (DETT) Application
Action Relay
Single C or A
Double A
Input Voltage or
Current
0 VDC or 4 mA Port A < 1 psi
24 VDC or 20 mA
0 VDC or 4 mA
24 VDC or 20 mA
Normal State Safe State
Port A
≥ 95% of Supply
Port A pressure
≤ Port B pressure
Port A ≥ 95% of Supply
Port B < 1 psi
D Energize to Trip Application (a less common application): The application of the digital valve
controller is limited for SIS to low demand mode. Normal operation is with a 4 mA current
loop signal to the digital valve controller. If a looppowered LCP100 is attached, normal
operation is with an 8 mA (nominal) current loop signal to the digital valve controller. Table 2
describes the normal and safe states of DVC6200 SIS for an ETT configuration. A shutdown
command is issued by taking the current signal to 20 mA (nominal).
Table 2. Normal and Safe States for Energize to Trip (ETT) Application
Action Relay Input Current Normal State Safe State
Single B
Double A
4 mA Port B ≥ 95% of Supply
20 mA Port B < 1 psi
4 mA
20 mA
Port A < 1 psi
Port B ≥ 95% of Supply
Port A ≥ Port B
pressure
D Position Monitor Application: The safety function of the position transmitter output is to
transmit a 420 mA analog signal that represents valve position. On detection of a failure
whereby the valve position is undetermined, the output signal will fail to the user
configurable offrange high or offrange low current per NAMUR NE43. The safety function of
the limit switch output is to transmit a discrete signal that represents a user configurable
threshold of valve position. Table 3 describes the normal and alarm states of the Position
Monitor function of the DVC6200 SIS.
Table 3. Normal and Alarm States for the Position Monitor Application
Output Function Normal State Accuracy Alarm State
420 mA
Position Transmitter
0/1A
Limit Switch
1. Configurable high or low. Values are per NAMUR NE43.
2. On loss of loop circuit power, the limit switch will go to the open state.
Actual Valve Position 5%
CLOSED 5% OPEN
>22.5 mA or
<3.6 mA
(1)
(2)
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6.3. Failure Rates
The failure rate data listed in tables 4, 5, 6, and 7 is only valid for the 15year useful lifetime of the
DVC6200 SIS digital valve controller. The failure rates will increase after this time period. Reliability
calculations based on the data listed in the FMEDA report for mission times beyond the useful
lifetime may yield results that are too optimistic, i.e. the calculated Safety Integrity Level will not
be achieved. When used, the LCP100 failure rates and the LC340 failure rates are to be added to
the failure rates of the DVC6200 SIS. These failure rates assume that the self test shutdowns in the
DVC6200 SIS are disabled. Consult the FMEDA report for a detailed list of the assumptions used in
the analysis.
Table 4. Failure Rates for DVC6200 SIS with 024 VDC or 420 mA Control Signal, DETT
Failure Rate (in FIT)
Failure Category
Fail Safe Detected 182 0 - Fail Safe Undetected 279 461 29 19
Fail Dangerous Detected 79 0 - Fail Dangerous Undetected 41 120 1 No Effect 1,007 1,590 27 Annunciation Failure
Detected
Annunciation Failure
Undetected
w/PVST Diagnostics Normal
400 0 - -
183 0 - -
LCP100 LC340
Adders
Table 5. Failure Rates for DVC6200 SIS with 420 mA Control Signal, ETT
Failure Rate (in FIT)
Failure Category
Fail Safe Detected 60 0 0
Fail Safe Undetected 124 183 28
Fail Dangerous Detected 273 0 0
Fail Dangerous Undetected 94 367 2
No Effect 1,008 1,624 27
Annunciation Failure Detected 427 0 0
Annunciation Failure Undetected 189 0 0
w/PVST Diagnostics Normal
Adder for
LCP100
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Table 6. Failure Rates for DVC6200 SIS Position Monitor
Failure Rate (in FIT)
Failure Category
End Mounted Rotary LinkageLess,
NonContact Feedback
Position Transmitter or Limit Switch
All Other Mountings
Fail Safe Undetected 30 92
Fail Dangerous Detected
Fail Detected (detected by internal
diagnostics)
(1)
Fail High (detected by logic solver)
Fail Low (detected by logic solver)
(1)
(1)
160 203
30 30
141 141
Fail Dangerous Undetected 31 96
No Effect 167 258
Annunciation Failure Undetected 5 5
1. If the system is not able to detect any or all of these failure categories, the corresponding Failure Rate(s) must be applied to the Fail
Dangerous Undetected category.
Table 7. Failure Rates According to IEC 61508 in FIT
Application Device l
SD
(1)
l
SU
l
DD
l
DU
w/PVST Diagnostics 582 279 79 41 - 66%
DeEnergize to Trip
Normal 0 461 0 120 - -
Adder for LCP100 0 29 0 1 - -
Adder for LC340 0 19 0 0 - -
w/PVST Diagnostics 487 124 273 94 - 74%
Energize to Trip
Normal 0 183 0 367 - -
Adder for LCP100 0 28 0 2 - -
End Mounted Rotary
Position Monitor
LinkageLess,
NonContact
0 30 331 31 92.2% 91%
Feedback
All Other Mountings 0 92 374 96 82.9% 80%
1. The No Effect failures are no longer included in the Safe Undetected failure category according to IEC 61508, ed2, 2010.
2. Safe Failure Fraction needs to be calculated on (sub)system level.
3. Diagnostic coverage (DC) is λ
DD
/ ( λ
DD + λDU
)
SFF
(2)
September 2013
(3)
DC
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6.4. Application Limits
D Safety Instrumented Function design verification must be done for the entire collection of
equipment used in the Safety Instrumented Function including the DVC6200 SIS digital valve
controller. The SIS must fulfill the requirements according to the Safety Integrity Level,
especially the limitation of average Probability of Failure on Demand (PFDavg)
D In order to achieve the published failure rate and classification type for the 420 mA device,
the hardware shutdown function must be enabled. See figure 1.
D The system’s response time is dependent on the entire final element subsystem. The user
must verify the system response time is less than the process safety time for each final
element.
D The DVC6200 SIS digital valve controller fault reaction time is determined by the partial valve
stroke test interval plus the mean time to repair.
D The DVC6200 SIS position monitor safety function has a fault reaction time of 30 seconds
plus the mean time to repair.
D The position monitor with the remote mount construction is not safety certified.
D The valve actuation means must be of a type that automatically moves the valve to the safe
state when the digital valve controller achieves the safe state. Valve stroke timing under these
conditions may also need to be considered as part of the SIS design.
D When using the DVC6200 SIS in redundant applications, the owneroperator of the facility
should institute common cause training and more detailed maintenance procedures
specifically oriented toward common cause defense.
D An estimate for the common cause failure rate (b) as determined for the DVC6200 SIS used in
a redundant configuration is 2% for DETT and ETT applications and 5% for Position Monitor
applications.
D The digital valve controller safety function is intended for use in an independent SIF loop from
the position transmitter or limit switch application. Common cause failures between the
digital valve controller and position monitor were not considered as a part of the FMEDA
analysis.
D The supply pressure must not exceed 145 psig. The supply medium may be 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, oilfree and noncorrosive. H2S 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.
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6.5. Environmental Limits
D Operating ambient temperature: 52 to 80°C (62 to 176°F).
D Humidity: tested per IEC 61514-2
D Electromagnetic Compatibility: Meets EN 61326‐1 (First Edition); Immunity‐Industrial
locations per Table 2 of the EN 61326‐1 standard
Emissions-Class A
ISM equipment rating: Group 1, Class A
D Vibration: tested per ANSI/ISA S75.13.01 Section 5.3.5. If excessive vibration can be
expected, special precautions shall be taken which may include, but are not limited to:
D Ensuring the integrity of the instrument mounting to the actuator.
D Ensuring the integrity of pneumatic connections.
September 2013
D Remote mounting the DVC6200 SIS on a pipestand or wall.
6.6. Application of the Switch Output for Diagnostic Annunciation
When using the Failure Rates “with PVST Diagnostics”, the system must be capable of monitoring
the DVC6200 SIS for alert conditions. To monitor the diagnostic detection, configure the switch
output to report an alert condition.
Make sure that the electronics hardware is configured for the switch output.
See figure 1.
With a user interface tool, configure the switch output to report “SIS Diagnostic Credit”
Table 8 lists the diagnostics that are included in the SIS Diagnostic Credit Alert.
Configure the switch to close on detection of an alert.
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7. Installation & Commissioning Guidelines
7.1. DVC6200 SIS DETT or ETT Safety Function
Verify that the DVC6200 SIS is suitable for use in this Safety Instrumented Function.
Verify that nameplate markings are suitable for the hazardous location (if required).
Verify appropriate connections to the logic solver are made by referring to the instruction
and safety manual of the logic solver.
For maximum availability and benefit of digital valve controller features, the unit must be
properly configured and calibrated, the Instrument Mode set to In Service, End Point Pressure
Control (EPPC) enabled, and the protection set to Config & Calib using the Instrument Setup >
Change Protection menu. With protection set, calibration and other protected parameters
cannot be changed, including the Instrument Mode. Figure 1 below identifies toggle switches
on the main electronics board that are configured as determined by the safety function and
system application.
Figure 1. Configuration Toggle Switches on the Main Electronics Board
POSITION TRANSMITTER / LIMIT SWITCH OUTPUT
DE-ENERGIZE TO TRIP / ENERGIZE TO TRIP SELECTION
HARDWARE SHUTDOWN ENABLE / DISABLE
CONTROL SIGNAL CONFIGURATION
0-24 VDC
4-20 mA
X0436
POINT-POINT / MULTIDROP SELECTION
Multi
PT-PT
When operating with a 024 VDC control signal, the Hardware Shutdown circuit must be
“Disabled” and an LC340 line conditioner is required to allow HART communication. An
impedance boosting multiplexer (available from MTL, Pepperl+Fuchs / Elcon and others) may
be used in place of the LC340. Refer to the documentation that comes with the product for
installation instructions.
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An LCP100 local control panel may be connected to the DVC6200 SIS to manually operate the
final control element or run a PVST. The LCP100 is a noninterfering device when used in DETT
applications. Refer to table 5, 6, 7 and 8 for failure rate adders when using the LCP100. Refer
to the documentation that comes with the product and LCP100 instruction manual for
installation and safety instructions.
The safety function of the DVC6200 SIS within the final control element subsystem along
with the overall SIS safety function must be tested after installation to ensure that it meets
safety demand and applicable process safety time requirements.
7.2. Position Monitor Safety Function
Note
The position monitor (transmitter or switch) with the remote mount construction is not safety certified.
Verify that the DVC6200 SIS with position monitor is suitable for use in this Safety
Instrumented Function.
Verify that nameplate markings are suitable for the hazardous location (if required).
Verify appropriate connections to the logic solver are made by referring to the instruction
and safety manual of the logic solver.
Ensure that the Output toggle switch (shown in figure 1) is set to the Transmitter position or
Switch position, depending on the application.
Ensure that the device configuration parameter for the function of the output terminal
matches the Output toggle switch setting.
For maximum availability and benefit of digital valve controller features, the unit must be
properly configured and calibrated, the Instrument Mode set to In Service, and the protection
set to Config & Calib using the Instrument Setup > Change Protection menu. With protection
set, calibration and other protected parameters cannot be changed, including the Instrument
Mode. Figure 1 identifies toggle switches on the main electronics board that are configured
as determined by the safety function and system application.
The sensor safety function of the position monitor along with the overall SIS safety function
must be tested after installation to ensure that it meets safety demand and applicable
process safety time requirements.
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8. Operation, Periodic Inspection, Test, and Repair
Periodic testing, consisting of proof tests and partial stroke testing, is an effective way to reduce
the PFD
Results of periodic inspections and tests should be recorded and reviewed periodically.
Note
Any time the SIF needs to be disabled, such as to perform a proof test or to take corrective action, appropriate
measures must be taken to ensure the safety of the process.
Note
To ensure corrective action, continuous improvement, and accurate reliability prediction, the user must also work
with their local Emerson Process Management service representative to see that all failures are reported.
of the DVC6200 SIS instrument as well as the valve and actuator it is connected to.
avg
8.1. Test Steps for the DVC6200 SIS and Position Monitor
Proof tests are fullstroke tests that are manually initiated. As part of the test, the capability of the
SIF to achieve the defined safe state must be verified. The proof test interval must be established
for the SIF based on the failure rates of all the elements within the function and the risk reduction
requirements. This determination is a critical part of the design of the SIS. A proof test will detect
77% (ETT) to 79% (DETT) of dangerous undetected failures not detected by the DVC6200 SIS
automatic diagnostics. A proof test includes the following steps:
Read the digital valve controller alert record using a HART communicating device such as the
475 Field Communicator, ValveLink software or a DD or DTM based host. Any active alert
messages must be investigated and resolved.
Bypass the final control element or take appropriate action to avoid a false trip.
If used, bypass the safety function of the position monitor or take appropriate action to avoid
a false trip.
If applying “with PVST” failure rates, verify that the Instrument Mode is In Service, End Point
Pressure Control (EPPC) is enabled, and that the instrument Protection is set to Config &
Calib.
Trip the DVC6200 SIS to its safe state by either deenergization (for DETT) or energization (for
ETT).
Observe that the actuator and valve move to its safe state within the required safety time
through an instrument independent means (visual or other).
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If used, observe that the position transmitter reports the actual valve position to within 5%
accuracy throughout the range of travel as required by the application through an
instrumentindependent means (visual or other).
If used, observe that the limit switch is open through an instrumentindependent means
(visual or other).
Restore the DVC6200 SIS to its normal state by either energization (for DETT) or
deenergization (for ETT).
Observe that the actuator and valve return to its normal state through an
instrumentindependent means (visual or other).
If applying “with PVST” failure rates, ensure that EPPC is operational by noting that output
pressure from the instrument goes to the Pressure Set Point after the Pressure Saturation
Time has elapsed (default 45 seconds).
If used, observe that the position transmitter reports the actual valve position to within 5%
accuracy throughout the range of travel as required by the application through an
instrumentindependent means (visual or other).
If used, observe that the limit switch is closed through an instrumentindependent means
(visual or other).
Check air filters to ensure they are clean and operating properly.
Inspect the unit for any loose screws or other incorrect mechanical condition.
Record the test results and any failures in your company’s SIF inspection database.
Remove the bypass and restore normal operation.
Partial stroke tests are designed to provide Diagnostic Coverage for many of the failure modes of
the final control element without affecting the process under control. To take credit for the “with
PVST” failure rates, the user must ensure that partial stroke tests are performed at least 10 times
between proof tests. A partial stroke test can be configured to be initiated by the following means:
D Schedule a partial stroke test to occur automatically on a time schedule (requires
configuration).
D Press the “test” button on the LCP100.
D Short the “aux” terminals on the DVC6200 SIS for 3 to 10 seconds (requires configuration).
D Initiate a partial stroke test using the 475 Field Communicator, ValveLink software or a DD or
DTM based host.
Should alarms, alerts, or failures be detected during operation, maintenance or periodic
inspection and test, record the alarms, alerts, or failures, and immediately take corrective action.
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To ensure corrective action, continuous improvement, and accurate reliability prediction, the user
must also work with their local Emerson Process Management service representative to see that all
failures are reported. Table 8 shows the diagnostics that are used to calculate the detected failure
rates.
Table 8. Assumed Diagnostics for Determining Failure Rates Labeled “with PVST”
HART Command 48
Byte 0, Bit 7 Flash Integrity Failure The flash ROM is corrupted. Alert
Byte 0, Bit 6 Minor Loop Sensor Alert
Byte 0, Bit 5
Byte 0, Bit 4 Drive Current Failure
Byte 0, Bit 3 Critical NVM Failure
Byte 0, Bit 2
Byte 0, Bit 1 Pressure Sensor Failure
Byte 0, Bit 0 Travel Sensor Failure
Byte 1, Bit 2
Byte 2, Bit 7 SIS Hardware Failure
Byte 2, Bit 6 NonCritical NVM Alert
Byte 3, Bit 6 Valve Stuck A PVST has failed. Alert
Byte 3, Bit 4
Byte 4, Bit 3 Travel Deviation Alert
Byte 4, Bit 0 Drive Signal Alert
Byte 5, Bit 2
1. HART communication can be used for informational purposes but is not safety certified for diagnostic annunciation.
2. This alert can be independently enabled to force the DVC6200 SIS output to the safe state (shutdown on alert - enabled).
(1)
Alert Name Description
The pneumatic relay position reading is out of
the valid range.
Reference Voltage
Failure
Temperature Sensor
Failure
SIS Program Flow
Failure
End Point Pressure
Deviation Alert
Output Circuit
Communication Failure
The electronics has detected a problem with
the internal voltage reading.
The I/P converter should be flowing current, but
is not.
Data is corrupted in the critical section of
configuration memory.
The temperature sensor is reporting a
temperature <60C or >100C.
One or more pressure sensors is outside the
expected operating range.
The travel sensor signal is outside the expected
operating range.
The firmware is not performing the expected
series of calculations.
A demand has occurred, but the electronics
hardware failed to take control of the I/P drive.
Data is corrupted in the noncritical section of
configuration memory.
The instrument is in pressure control and the
pressure is not tracking the set point within the
configured deviation allowance.
The valve travel is not tracking the set point
within the configured deviation allowance.
The controller servo output is out of the normal
operating range.
The output circuit is not responding. Alert
Digital Valve
Controller Action
(2)
(2)
Alert
(2)
Alert
(2)
Alert
(2)
Alert
(2)
Alert
(2)
Alert
(2)
Alert
(2)
Alert
(2)
Alert
Alert
Alert
Alert
Alert
Within table 8, the diagnostics detection time for the failures that can affect the safety function of
the DVC6200 SIS instrument is 15 seconds.
The diagnostics detection time for all failures including the PVST is determined by the PVST
interval which is configured by the user.
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8.2. Test Steps for the Position Monitor
Proof tests are fullstroke tests that are manually initiated. As part of the test, the capability of the
SIF to achieve the defined safe state must be verified. If the Position Monitor is used, the Safety
Function must be verified. The proof test interval must be established for the SIF based on the
failure rates of all the elements within the function and the risk reduction requirements. This
determination is a critical part of the design of the SIS. A proof test will detect 88% of dangerous
undetected failures not detected by the DVC6200 SIS automatic diagnostics. A proof test includes
the following steps:
D Proof Test for the Position Transmitter
Bypass the safety function of the position transmitter or take appropriate action to avoid a
false trip.
Using the 475 Field Communicator, ValveLink Software or a DD or DTM based host, verify
that the DVC6200 SIS instrument mode is “In Service” and that the instrument protection is
set to “Config & Calib.”
Inspect the feedback elements for any loose screws or other incorrect mechanical condition.
Change the valve position away from it’s current state by more than 5% throughout the range
of travel as required by the application.
Observe that the position transmitter reports the actual valve position to within 5% accuracy
throughout the tested range of travel through an instrumentindependent means (visual or
other).
Restore the valve to its normal state.
Observe that the position transmitter reports the actual valve position to within 5% accuracy
through an instrumentindependent means (visual or other).
Record the test results and any failures in your company’s SIF inspection database.
Remove the bypass and restore normal operation.
D Proof Test for the Limit Switch
Bypass the safety function of the limit switch or take appropriate action to avoid a false trip.
Using the 475 Field Communicator, ValveLink Software or a DD or DTM based host, verify
that the DVC6200 SIS instrument mode is “In Service” and that the instrument protection is
set to “Config & Calib.”
Inspect the feedback elements for any loose screws or other incorrect mechanical condition.
Change the valve position such that the limit switch trip point is exceeded.
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Observe that the limit switch changed to the open state within 5% of the trip point through
an instrumentindependent means (visual or other).
Restore the valve to its normal state.
Observe that the limit switch changed to the closed state within 5% of the trip point through
an instrumentindependent means (visual or other).
Record the test results and any failures in your company’s SIF inspection database.
Remove the bypass and restore normal operation.
8.3. Maintenance
D The effective time to repair the DVC6200 SIS is approximately 2 hours. This comprises of
disassembly, repair, reassembly, and recalibration. This value can be used to determine the
total mean time to restore (MTTR).
D Digital valve controller preventive maintenance consists, at a minimum, of replacing all
critical elastomeric seals and diaphragms in the device and a visual inspection of moving
components to verify satisfactory condition. The SIS Preventive Maintenance Kit includes all
elastomeric seals and diaphragms and is available through your local Emerson Process
Management sales office. Following maintenance, the digital valve controller must be
calibrated per the Auto Travel Calibration or Manual Travel Calibration menu. After
calibration, the digital valve controller functional safety must be validated.
D A conservative approach is taken in estimating the service interval for the digital valve
controller in Safety Instrumented Systems. For SIS applications, preventive maintenance
must be performed on the digital valve controller at eight to ten year intervals from the date
of shipment. If the instrument is exposed to the upper or lower extremes of the
environmental limits, the interval for preventative maintenance may need to be reduced.
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DVC6200 SIS Digital Valve Controller
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9. Decommissioning Guidelines
When decommissioning a DVC6200 SIS instrument, proper procedures must be followed.
Decommissioning includes the following steps:
Bypass the final control element or take appropriate action to avoid a false trip.
Bypass the safety function of the position monitor or take appropriate action to avoid a false
trip.
Avoid personal injury or property damage from sudden release of process pressure or
bursting of parts. Before proceeding with any decommissioning procedures:
D Always wear protective clothing, gloves, and eyewear to prevent personal injury or
property damage.
D Do not remove the actuator from the valve while the valve is still pressurized.
D Isolate and disconnect any operating supply lines providing air pressure, electric power,
or a control signal to the DVC6200 SIS. Be sure the actuator cannot suddenly open or
close the valve.
D Use bypass valves or completely shut off the process to isolate the valve from process
pressure. Relieve process pressure from both sides of the valve.
D Vent the pneumatic actuator loading pressure and relieve any actuator spring
precompression.
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.
Disconnect the electrical wiring to and from the DVC6200 SIS instrument.
Disconnect the pneumatic tubing between the DVC6200 SIS instrument and actuator.
Remove the DVC6200 SIS instrument, mounting parts and feedback elements from the
actuator.
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of any product. Responsibility for proper selection, use, and maintenance of any product remains solely with the purchaser and end user.
Fisher, FIELDVUE, and ValveLink are a marks owned by one of the companies in the Emerson Process Management business unit of Emerson Electric Co.
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products at any time without notice.
Emerson Process Management
Marshalltown, Iowa 50158 USA
Sorocaba, 18087 Brazil
Chatham, Kent ME4 4QZ UK
Dubai, United Arab Emirates
Singapore 128461 Singapore
www.Fisher.com
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E 2012, 2013 Fisher Controls International LLC. All rights reserved.
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