Install and operate this product only if
you are qualified through training or
experience. If you have any questions
about this guide, contact your Fisher
Controls representative or sales office.
Product Description
DVC5000 Series 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 DVC5000 Series
digital valve controller communicates via HART
protocol.
DVC5000 Series digital valve controllers are designed
to directly replace standard pneumatic and
electro-pneumatic valve mounted positioners.
Use of this Guide
This guide describes how to install, setup, and
calibrate DVC5000 Series digital valve controllers with
firmware Revision 6. Additional information for
installing, operating, and maintaining the DVC5000
Series digital valve controllers can be found in the
related documents listed on page 5-2.
This guide describes instrument setup and calibration
using a Rosemount Model 275 HART Communicator.
For information on using the Model 275 HART
Communicator, see the Product Manual for the HARTCommunicator available from the Rosemount
Measurement Division. An abbreviated description of
HART Communicator operation is also contained in
the FIELDVUE instrument instruction manual.
You can also setup and calibrate the instrument using
an IBM compatible PC and FIELDVUE ValveLink
software or Asset Management software. For
information on using the software with a FIELDVUE
instrument, refer to the appropriate user guide.
Displaying the HART Communicator
Device Description Revision Number
Device Description (DD) revision identifies the version
of the Fisher Controls Device Description that resides
in the HART Communicator. It defines how the HART
Communicator interacts with the user and instrument.
November 1999
1-1
Page 6
DVC5000 Series
There are two device descriptions used with firmware
revision 6 instruments: 3 and 4. Device Description
revision 3 is available in HART Communicators with
1.25 megabyte memory modules. Device Description
revision 4 is available in HART Communicators with 4
and 8 megabyte memory modules.
You can display the DD revision from the Offline or
1
Online menu.
Offline Menu—To see the HART Communicator
device description revision number from the Offline
menu, select Utility, Simulation, Fisher Controls, and
DVC.
Online Menu—To see the HART Communicator
device description revision number from the Online
menu, connect the HART Communicator to an
instrument connected to a source supplying a 4 to 20
mA signal. From the Online menu, select Main Menu,
Display, 275 DD Rev.
Displaying the FIELDVUE Instrument
Firmware Revision Number
To view the instrument firmware revision, connect the
HART Communicator to an instrument connected to a
source supplying a 4 to 20 mA signal. From the Online
menu, select Main Menu, Display, Device Information,
and Firmware Rev.
1-2
November 1999
Page 7
NOTE:
1
APPLY LUBRICANT
E0031 / IL
Figure 2-1. Mounting the Type 67CFR Regulator on a DVC5000 Series Digital Valve Controller
SUPPLY CONNECTION
Mounting
If ordered as part of a control valve assembly, the
factory mounts the digital valve controller on the
actuator, makes pneumatic connections to the
actuator, sets up, and calibrates the instrument. If you
purchased the digital valve controller separately, you
will need a mounting kit to mount the digital valve
controller on the actuator. See the instructions that
come with the kit for mounting information.
Mounting the Type 67CFR Filter
Regulator
A Type 67CFR filter regulator, when used with the
DVC5000 Series digital valve controllers, can be
mounted three ways.
Installation
TYPE 67CFR
1
O-RING
CAP SCREWS
2-22
Yoke-Mounted Regulator
Mount the filter regulator with 2 cap screws to the
pre-drilled and tapped holes in the actuator yoke.
Thread a 1/4-inch socket-head pipe plug into the
unused outlet on the filter regulator. No O-ring is
required.
Casing-Mounted Regulator
Use the separate Type 67CFR filter regulator casing
mounting bracket provided with the filter regulator.
Attach the mounting bracket to the Type 67CFR and
then attach this assembly to the actuator casing.
Thread a 1/4-inch socket-head pipe plug into the
unused outlet on the filter regulator. No O-ring is
required.
Pressure Connections
Pressure connections are shown in figure 2-2. All
pressure connections on the digital valve controller are
1/4-inch NPT female connections. Use 3/8-inch (10
mm) tubing for all pressure connections. If remote
venting is required, refer to the vent subsection.
2
Integral-Mounted Regulator
Refer to figure 2-1. Lubricate an O-ring and insert it in
the recess around the SUPPLY connection on the
digital valve controller. Attach the Type 67CFR filter
regulator to the side of the digital valve controller.
Thread a 1/4-inch socket-head pipe plug into the
unused outlet on the filter regulator. This is the
standard method of mounting the filter regulator.
November 1999
Note
Make pressure connections to the digital valve controller using metal tubing
with at least 3/8-inch diameter.
2-1
Page 8
DVC5000 Series
2
1/4-18 NPT
OUTPUT CONNECTION
(OPTIONAL)
VENT
NOTE:
1
FOR DVC5010, IF VALVE TRAVEL EXCEEDS 2 INCHES, PLUG THE OUTPUT CONNECTION ON THE SIDE OF
THE INSTRUMENT AND USE THIS OUTPUT CONNECTION.
W7690 / IL
Supply Connections
Personal injury or property damage
may occur from an uncontrolled process if the supply medium is not
clean, dry, oil-free, or noncorrosive
gas. Industry instrument air quality
standards describe acceptable dirt,
oil, and moisture content. Due to the
variability in nature of the problems
these influences can have on pneumatic equipment, Fisher Controls has
no technical basis to recommend the
level of filtration equipment required
to prevent performance degradation
of pneumatic equipment. A filter or
filter regulator capable of removing
particles 40 microns in diameter
should suffice for most applications.
Use of suitable filtration equipment
and the establishment of a maintenance cycle to monitor its operation
is recommended.
TERMINAL BOX CAP
1/4-18 NPT
OUTPUT CONNECTION
1
Figure 2- 2 . DVC5000 Series Digital Valve Controller Typical Connections (Type DVC5010 Shown)
1/4-18 NPT
SUPPLY CONNECTION
1/2-14 NPT
CONDUIT CONNECTION
BOTH SIDES
DVC5000 SERIES WITH INTEGRAL
MOUNTED 67CFR FILTER/REGULATOR
Supply pressure must be clean, dry air or noncorrosive
gas that meets the requirements of ISA Standard
WARNING
S7.3. A Type 67CFR filter regulator, or equivalent,
may be used to filter and regulate supply air.
If you are using a Type 67CFR filter regulator, connect
the supply line to the1/4-inch NPT IN connection and
attach tubing from the output connection on the filter
regulator to the SUPPLY connection on the
instrument. If you are using an integral mounted Type
67CFR filter regulator, connect the supply to the IN
connection on the regulator.
Output Connection
A factory mounted digital valve controller has its
output piped to the supply connection on the actuator.
If mounting the digital valve controller in the field,
connect the 1/4-inch NPT digital valve controller output
connection to the pneumatic actuator input connection.
If using the Type DVC5010 on actuators with greater
than 2-inch travel, plug the output connection on the
side of the digital valve controller and use the output
connection on the back of the unit.
1/4-18 NPT
SUPPLY CONNECTION
2-2
November 1999
Page 9
Installation
Vent
WARNING
If a flammable, toxic, or reactive gas is
to be used as the supply pressure medium, personal injury and property
damage could result from fire or explosion of accumulated gas or from
contact with toxic or reactive gas. The
digital valve controller/actuator assembly does not form a gas-tight seal,
and when the assembly is in an enclosed area, a remote vent line, adequate ventilation, and necessary safety measures should be used. A remote vent pipe alone cannot be relied
upon to remove all hazardous gas.
Vent line piping should comply with
local and regional codes and should
be as short as possible with adequate
inside diameter and few bends to remove exhaust gases to a ventilated
area.
The relay output constantly bleeds supply air into the
area under the cover. The vent opening at the back of
the housing should be left open to prevent pressure
buildup under the cover. If a remote vent is required,
the vent line must be as short as possible with a
minimum number of bends and elbows.
To connect a remote vent to Type DVC5010,
DVC5030, and DVC5040 digital valve controllers—
sliding-stem The Type DVC5040 digital valve
controller has no pipe fitting for the vent. The vent is
purged under the actuator cover. For the Type
DVC5010 and DVC5030 digital valve controllers,
remove the plastic vent. The vent connection is
1/4-inch NPT female. Typically, 3/8-inch (10 mm)
tubing is used to provide a remote vent.
To connect a remote vent to Type DVC5020 digital
valve controllers—rotary Replace the standard
mounting bracket with the vent-away mounting
bracket. Install a pipe plug in the vent-away mounting
bracket. Mount the digital valve controller on the
actuator as described in the mounting instructions
included with the mounting kit.
Electrical Connections
WARNING
To avoid personal injury or property
damage caused by fire or explosion,
remove power to the instrument before removing the terminal box cover
in an area which contains a potentially explosive atmosphere or has been
classified as hazardous.
4 to 20 mA Loop Connections
The digital valve controller is normally powered by a
control system output card. The use of shielded cable
will ensure proper operation in electrically noisy
environments.
CAUTION
Do not connect the digital valve controller directly to a voltage source
when implementing the point-to-point
wiring mode, or damage to the printed
wiring board assembly submodule
may result. In point-to-point wiring
mode, the digital valve controller may
only be connected to a 4–20 mA current source.
Wire the digital valve controller as follows, refer to
figure 2-3:
1. Remove the terminal box cap.
2. Bring the field wiring into the terminal box. When
applicable, install conduit using local and national
electrical codes which apply to the application.
Note
In the next step, note that the position
of the LOOP + and – terminals is different than in previous units.
3. Connect the control system output card positive
wire ‘‘current output’’ to the LOOP + screw terminal in
the terminal box. Connect the control system output
card negative (or return) wire to the LOOP – screw
terminal in the terminal box.
2
November 1999
2-3
Page 10
DVC5000 Series
SAFETY GROUND
2
NOTE: THIS TERMINAL BOX IS DIFFERENT THAN PREVIOUS
UNITS. NOTE CHANGE IN POSITION OF LOOP + AND – TERMINALS.
38B6470-B
E0030 / IL
Figure 2-3. DVC5000 Series Digital Valve Controller
Terminal Box
TALK–
TALK+
EARTH GROUND
LOOP+
LOOP–
4. Connect the safety ground and the earth ground as
shown in figure 2-3. Replace and hand tighten the
terminal box cap. When the loop is ready for startup,
apply power to the control system output card.
WARNING
Personal injury or property damage
can result from the discharge of static
electricity. Connect a 14 AWG (2.08
mm2) ground strap between the digital valve controller and earth ground
when flammable or hazardous gases
are present. Refer to national and local codes and standards for grounding requirements.
To avoid static discharge from the
plastic cover, do not rub or clean the
cover with solvents. Clean with a mild
detergent and water only.
nInstallation Check List
Mounting
Is the instrument correctly mounted on the actuator? If not, see installation
j
instructions provided with the mounting kit.
Is the feedback linkage properly connected? If not, see installation instructions
j
provided with the mounting kit.
Pneumatic Connections and Air Supply
Is the regulator correctly mounted? If not, perform one of the regulator mounting procedures on
j
page 2-1.
Is the air supply connected and at proper pressure? If not connect supply as described on page
j
2-2. Also see specifications on page 5-1.
Is the instrument output connected to the actuator? If not, connect instrument output as
j
described on page 2-2.
Electrical Connections
If necessary, is the conduit properly installed? If not, refer to local and national electrical
j
codes.
Is the loop wiring properly connected to the LOOP + and – terminals in the terminal box? If not, con-
j
nect loop wiring as described on page 2-3.
You are ready to perform Initial Setup and Calibration in the next section.
2-4
November 1999
Page 11
CONTROL ROOM
Initial Setup and Calibration
HART COMMUNICATOR
CONNECTIONS
FIELD
FIELD INSTRUMENT
CONNECTION
HF200 SERIES
CONTROLLER
I/O
HART
COMMUNICATION
CONNECTION
NOTE:
NOT ALL CONTROL SYSTEMS REQUIRE A HART FILTER. IF NO HART FILTER IS PRESENT, CONNECT
1
HART COMMUNICATOR TO CONTROL SYSTEM OUTPUT TERMINALS.
2
SEE FIGURE 2-3 FOR TERMINAL BOX DETAILS
38B6470-A / DOC
A6194–2 / IL
–
+
HART FILTER
–
+
1
Figure 3-1. Connecting the HART Communicator to a FIELDVUE Instrument
3-33
Connecting the Model 275 HART
Communicator to the Digital V alve
Controller
The HART Communicator may be connected to the 4
to 20 mA loop wiring or directly to the digital valve
controller (see figure 3-1).
If the HART Communicator is connected directly to the
digital valve controller , attach the clip-on wires
provided with the HART Communicator to the TALK
terminals, or the LOOP + and – terminals, in the digital
valve controller terminal box (see figure 2-3).
Initial Setup
CAUTION
Changes to the instrument setup may
cause changes in the output pressure
or valve travel.
Before beginning initial setup, be sure the instrument
is correctly mounted. Refer to the installation
instructions supplied with the mounting kit.
4-20 MA LOOP
CONNECTIONS
2
NOTE: THE POSITION OF THE TALK TERMINALS
IS DIFFERENT THAN IN PREVIOUS UNITS
Connect a 4–20 mA current source to the instrument.
Connect the HART Communicator to the instrument
and turn it on. For information on connecting the
HART Communicator, see Connecting the Model 275
HART Communicator to the Digital Valve Controller .
Typical Mountings
The Setup Wizard determines the required setup
information for the actuators listed in table 3-1 based
upon the actuator manufacturer and model specified.
Turn on the HART Communicator and start the Setup
Wizard by proceeding through the menu sequence
shown in figure 3-2 or enter the fast-key sequence
1-1-1-1 on the keypad. Follow the prompts on the
HART Communicator display to setup the instrument.
If the actuator on which the instrument is mounted is
not listed by the Setup Wizard, specify OTHER as the
actuator manufacturer or actuator type and go to
“Other Mounting” on page 3-3 of this guide.
During initial setup, the Setup Wizard will ask you if
you want to use factory defaults. If you select YES,
the Setup Wizard sets the setup parameters to the
values listed in table 3-2. If you select NO, the setup
parameters listed in the table remain at their previous
settings
3
November 1999
3-1
Page 12
DVC5000 Series
1'Main Menu
2 Analog In12.42 mA
3 Pressure 10 psi
4 Travel 53.69%
5 Drive Sgl 58.15%
Main Menu (Setup)
1'Initial Setup
2 Detailed Setup
3
3 Display
4 Calibrate
5 Stroke Output
Initial Setup
1'Auto Setup
2 Manual Setup
From the DVC5000 online menu,
select Main Menu.
From the Main Menu, select Initial
Setup.
From the Initial Setup menu, select
Auto Setup.
Auto Setup
1'Setup Wizard
2 Auto Calib Travel
3 Stabilize/Optimize
From the Auto Setup menu, select Setup Wizard and follow the
on-line instructions.
Figure 3-2. Accessing the Setup Wizard on the Model 275 HART Communicator
Table 3-1. Actuators Available with Setup Wizard
ManufacturerActuator Model
513 and 513R
585C and 585CR
Fisher Controls
BaumannAll
Gulde
Masoneilan
Neles-JamesburyQuadra-Power II
657 and 667
1051 or 1052
1066SR
1250 and 1250R
System 9000
Camflex II
Sigma F, Minitorque
and Ball II
3024
3025
Table 3-2. DVC5000 Series Factory Default Settings
Setup ParameterDefault Setting
Analog Input Units
Input High
Input Low
Travel Range High
Travel Range Low
Control Mode
Restart Control Mode
Self-Test Shutdown
Dynamic Bypass Enabled
Input Filter Time
Input Characteristic
Travel Limit High
Travel Limit Low
Travel Cutoff High
Travel Cutoff Low
Minimum Opening Time
Minimum Closing Time
Polling Address
20.0 mA
4.0 mA
100%
Analog (RSP)
Resume Last
All Failures Disabled
0 secs
Linear
125%
–25%
99.5%
0 secs
0 secs
mA
0%
No
0.5%
0
3-2
November 1999
Page 13
Initial Setup and Calibration
ROLLER
STEM
CONNECTOR
27B6708-B
E0032 / IL
Figure 3-3. Feedback Connection for
Model 471 Sliding-Stem Actuator
CAM
After the Setup Wizard completes the setup, press OK
to return to the Auto Setup menu. Select Auto CalibTravel to automatically calibrate the instrument travel.
Follow the prompts on the HART Communicator
display. The calibration procedure uses the valve and
actuator stops as the 0% and 100% calibration points.
For additional information, refer to Auto Calibrate
Travel in this section.
WARNING
If you answer YES to the prompt for
permission to move the valve, 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 pressure or process fluid,
provide some temporary means of
control for the process.
3
D Travel Sensor Motion (increasing air pressure
causes the travel sensor shaft to rotate clockwise or
counterclockwise), The Setup Wizard asks if it can
move the valve to determine travel sensor motion. If
you answer yes, the instrument will stroke the valve
the full travel span to determine travel sensor motion.
If you answer No, then you must specify the rotation
for increasing air pressure: clockwise or counterclockwise. Determine rotation by viewing the end of the
travel sensor shaft, as shown in figure 3-4. If
increasing air pressure to the actuator causes the
shaft to turn clockwise, enter CW (clockwise). If it
causes the shaft to turn counterclockwise, enter CCW
(counterclockwise).
Other Mountings
If the actuator on which the instrument is mounted is
not listed by the Setup Wizard, specify OTHER as the
actuator manufacturer or actuator type. You are then
prompted for setup parameters such as:
D Actuator Type (single-acting or double-acting)
D Valve Style (rotary or sliding-stem)
D Feedback Connection (Rotary - All, SStem -
Standard, SStem - Roller). For rotary valves, enter
Rotary - All. For sliding-stem valves, if the feedback
linkage consists of a connector arm, adjustment arm,
and feedback arm (as shown in figure 3-4), enter
SStem - Standard. If the feedback linkage consists of
a roller that follows a cam (as shown in figure 3-3),
enter SStem - Roller.
D On Loss of Instrument Signal, Valve (opens
or closes) This identifies whether the valve is fully
open or fully closed when the input is 0%. If you are
unsure how to set this parameter, disconnect the
current source to the instrument. (With direct acting
digital valve controllers, disconnecting the current
source is the same as setting the output pressure to
zero.)
D Instrument Supply Pressure Range. This
adjusts the range of the instrument pressure sensor.
Supply Pressure is configured in pressure units of psi,
bar, or kPa. Select a supply pressure range that
includes the instrument supply pressure.
CAUTION
Changes to the tuning set can result in
valve/actuator instability.
D Tuning Set There are eleven tuning sets to
choose from. Each tuning set provides preselected
values for the digital valve controller gain and rate
settings. Typically, tuning set C provides the slowest
response and M provides the fastest response. For
smaller actuators, use tuning set C or D. For larger
actuators , use tuning set F or G.
After the Setup Wizard completes the setup, press OK
to return to the Auto Setup menu. Select Auto CalibTravel to automatically calibrate the instrument travel.
Follow the prompts on the HART Communicator
display. The calibration procedure uses the valve and
actuator stops as the 0% and 100% calibration points.
For additional information, refer to Auto Calibrate
Travel in this section.
November 1999
3-3
Page 14
DVC5000 Series
3
A6536 / IL
ACTUATOR
STEM
Figure 3-4. Crossover Point
TRAVEL SENSOR SHAFT
FEEDBACK ARM
ADJUSTMENT ARM
CONNECTOR ARM
Auto Calibrate Travel
WARNING
During calibration the valve will move
full stroke. To avoid personal injury
and property damage caused by the
release of pressure or process fluid,
provide some temporary means of
control for the process.
Select Auto Calib Travel then follow the prompts on
the HART Communicator display to automatically
calibrate travel.
1. If the Feedback Connection is Sliding-Stem
Standard, the HART Communicator prompts you to
select the method of crossover adjustment: manual,
last value, or default. Manual adjustment is
recommended for initial travel calibration.
2. When prompted by the HART Communicator,
make the crossover adjustment by adjusting the
current source until the feedback arm is 90° to the
actuator stem, as shown in figure 3-4.
3. The remainder of the auto-calibration procedure is
automatic. After completing auto travel calibration, the
HART Communicator prompts you to place the
instrument In Service and verify that the travel
properly tracks the current source.
Table 3-3. Auto Calibrate Travel Error Messages
Error MessagePossible Problem and Remedy
Input current must
exceed 3.8 mA for
calibration.
Place Out Of Service
and ensure Calibrate
Protection is disabled
before calib.
Calibration Aborted.
An end point was not
reached.
Invalid travel value.
Check travel sensor
and feedback arm
adjustments, and inst
supply press. Then,
repeat Auto Calib.
The analog input signal to the instrument
must be greater than 3.8 mA. Adjust the
current output from the control system or the
current source to provide at least 4.0 mA.
The Instrument Mode must be Out of Service
and the Protection must be None before the
instrument can be calibrated. For information
on changing instrument mode and protection,
see Instrument Mode and Configuration
Protection in this section.
The problem may be one or the other of the
following:
1. The tuning set selected is too low and the
valve does not reach an end point in the
allotted time. Press the Hot Key, select
Stabilize/Optimize then Increase Response
(selects next higher tuning set).
2. The tuning set selected is to high, valve
operation is unstable and does not stay at an
end point for the allotted time. Press the Hot
Key, select Stabilize/Optimize then DecreaseResponse (selects next lower tuning set).
Verify proper mounting by referring to the
appropriate mounting instructions.
Verify instrument supply pressure by referring
to the specifications in the appropriate
actuator instruction manual.
Verify travel sensor adjustment by performing
the appropriate Travel Sensor Adjust
procedure in the FIELDVUE DVC5000 Series
Digital Valve Controller Instruction Manual –
Form 5335.
Making the crossover adjustment with the
valve positioned at either end of its travel will
also cause this message to appear.
If the unit does not calibrate, refer to table 3-3 for error
messages and possible remedies.
If after completing auto setup and auto calibration the
valve cycles or overshoots, or is unresponsive, you
can improve operation by selecting Stabilize/Optimize
from the Auto Setup menu. For additional information,
refer to Stabilizing or Optimizing Valve Response in
this section.
Stabilizing or Optimizing Valve
Response
If after completing initial setup and auto calibration the
valve seems slightly unstable or unresponsive, you
can improve operation by pressing the Hot Key
and selecting Stabilize/Optimize, or select
Stabilize/Optimize from the Auto Setup menu.
To stabilize valve operation, select Decrease
Response. This selects the next lower tuning set (e.g.,
F to E). To make the valve more responsive, select
Increase Response. This selects the next higher
tuning set (e.g., F to G).
3-4
November 1999
Page 15
Initial Setup and Calibration
nInitial Setup and Calibration Check List
Is Initial setup complete? If not, perform Initial Setup procedure on page
j
3-1.
Is calibration complete? If not, perform Auto Calibrate Travel procedure on
j
page 3-4.
Does the final control element correctly respond to a setpoint change and is it
j
stable? If not, perform Stabilizing or Optimizing Valve Response on page
3-4.
Final control element is ready to be placed on line.
3
November 1999
3-5
Page 16
DVC5000 Series
3
3-6
November 1999
Page 17
TERMINAL BOX ASSEMBLY
TERMINAL BOX COVER
PRINTED WIRING BOARD
ASSEMBLY
Maintenance
MODULE BASE ASSEMBLY
SOCKET-HEAD SCREWS (4)
RETAINING CLIPS (4)
I/P CONVERTER
SHROUD
TRAVEL
SENSOR
ASSEMBLY
48B9444-A
A7026-1 / IL
HOUSING
0-RING
GASKET
PNEUMATIC RELAY
RELAY CAP
Figure 4-1 . DVC5000 Series Digital Valve Controller Assembly
4-44
Because of the diagnostic capability of the DVC5000
Series digital valve controllers, predictive maintenance
is available through the use of FIELDVUE ValveLink
Software. Using the digital valve controller, valve and
instrument maintenance can be enhanced, thus
avoiding unnecessary maintenance. For information
on using the ValveLink software, see the FIELDVUEValveLink VL2000 Series Software User Guide.
0-RINGS (4)
SCREWS (4)
PRESSURE
GAUGES
(OPTIONAL)
COVER
ASSEMBLY
COVER
SCREW
Master Module Maintenance
The digital valve controller contains a master module
consisting of the I/P converter, printed wiring board
assembly, and pneumatic relay. The master module
may be easily replaced in the field without
disconnecting field wiring or tubing.
Removing the Master Module
To remove the master module, perform the following
steps. Refer to figure 4-1 for parts identification.
4
Stroking the Digital Valve Controller
Output
Connect a 4–20 mA current source and the
recommended air supply (for the recommended supply
pressure, see the specifications in section 5) to the
instrument. Connect the HART Communicator to the
instrument as described in section 3 and turn it on.
From the Online menu, select Main Menu and StrokeOutput. Follow the prompts on the HART
Communicator display to ramp or step the valve
position.
November 1999
WARNING
To avoid personal injury or equipment
damage, turn off the supply pressure
to the digital valve controller before
attempting to remove the module
base assembly from the housing.
1. For sliding-stem applications only, a protective
shield for the feedback linkage is attached to the side
of the module base assembly. Remove this shield and
keep for reuse on the replacement module. The
replacement module will not have this protective
shield.
2. Unscrew the captive screw in the cover and
remove the cover from the module base.
3. Using a 5/16-inch hex wrench, loosen the
four-socket head screws. These screws are captive in
the module base by retaining rings.
CAUTION
To avoid affecting performance of the
instrument, take care not to damage
the master module gasket or guide
surface. Do not bump or damage the
bare connector pins on the printed wiring board assembly.
Replacing the Master Module
To replace the master module, perform the following
steps. Refer to figure 4-1.
CAUTION
To avoid affecting performance of the
instrument, inspect the guide surface
on the module and the corresponding
seating area in the housing before
installing the module base assembly.
These surfaces must be free of dust,
dirt, scratches, and contamination.
Ensure the gasket is in good condition. Do not reuse a damaged or worn
gasket.
Note
The master module is linked to the housing by two cable assemblies. Disconnect
these cable assemblies after you pull the
master module out of the housing.
4. Pull the master module straight out of the housing.
Once clear of the housing, swing the master module to
the side of the housing to gain access to the cable
assemblies.
5. The digital valve controller has two cable
assemblies, shown in figure 4-2, which connect the
master module, via the printed wiring board assembly,
to the travel sensor and the terminal box. Disconnect
these cable assemblies from the printed wiring board
assembly on the back of the master module.
1. Ensure the gasket is aligned properly on the
master module.
2. Connect the terminal box connector to the printed
wiring board assembly. Orientation of the connector is
required.
3. Connect the travel sensor connector to the pwb
assembly. Orientation of the connector is required.
4. Insert the module base into the housing.
5. Insert the four socket head screws in the master
module into the housing. If not already installed, press
four retaining rings into the module base. Evenly
tighten the screws in a crisscross pattern to a final
torque of 138 lbfSin (16 NSm).
6. Insert the cover hinge tabs into the module base.
Swing the cover down into position and tighten the
cover screw.
In the next two steps, refer to figure 2-2.
7. If not already installed, screw the vent into the vent
connection on the back of the housing.
8. If not already installed, apply sealant to the pipe
plug and install it in the output connection on the back
of the housing.
4-2
November 1999
Page 19
9. For sliding-stem applications only, install the
protective shield (key 102) onto the side of the
replacement module base assembly.
Submodule Maintenance
The digital valve controller’s master module contains
the following submodules: I/P converter, printed wiring
board assembly, and pneumatic relay. If problems
occur, these submodules may be removed from the
master module and replaced with new submodules.
After replacing a submodule, the master module may
be put back into service.
O-RING LOCATED
IN I/P CONVERTER
OUTPUT PORT
W7601 / IL
Maintenance
Figure 4-3. I/P Filter Location
SCREEN (FILTER)
LOCATED IN I/P
CONVERTER
SUPPLY PORT
4
Note
If the printed wiring board assembly or I/P
converter submodule is replaced, calibrate
and configure the DVC5000 Series digital
valve controller to maintain accuracy
specifications. If any other submodule
was replaced, recalibration or adjustment
of the digital valve controller, master module, or submodules is not necessary.
Exercise care when you perform maintenance on the master module. Reinstall the
cover to protect the I/P converter and
gauges when servicing other submodules.
I/P Converter
Refer to figure 4-1 for part identification. The I/P
converter is located on the front of the master module.
4. Inspect the O-ring in the I/P output port. if
necessary, replace it.
5. Reinstall the I/P converter and shroud as described
in the Replacing the I/P Converter procedure.
Removing the I/P Converter
1. Remove the front cover, if not already removed.
2. Refer to figure 4-4. Remove the four socket-head
screws that attach the shroud and I/P converter to the
module base.
3. Remove the shroud; then pull the I/P converter
straight out of the module base. Be careful not to
damage the two electrical leads that come out of the
base of the I/P converter.
4. Ensure that the O-ring and screen stay in the
module base and do not come out with the I/P
converter.
Replacing the I/P Converter
1. Refer to figure 4-3. Inspect the condition of the
O-ring and screen in the module base. Replace them,
if necessary. Apply sealant to the O-rings.
Replacing the I/P Filter
A screen in the supply port beneath the I/P converter
serves as a secondary filter for the supply medium. To
replace this filter, perform the following procedure:
1. Remove the I/P converter and shroud as described
in the Removing the I/P Converter procedure.
2. Remove the screen from the supply port.
3. Install a new screen in the supply port as shown in
figure 4-3.
November 1999
2. Ensure the two boots shown in figure 4-4 are
properly installed on the electrical leads.
3. Install the I/P converter straight into the module
base, taking care that the two electrical leads feed into
the guides in the module base. These guides route the
leads to the printed wiring board assembly submodule.
4. Install the shroud over the I/P converter.
5. Install the four socket-head screws and evenly
tighten them in a crisscross pattern to a final torque of
20.7 lbfSin (2 NSm).
4-3
Page 20
DVC5000 Series
4
I/P CONVERTER
A7027 / IL
Figure 4-4. I/P Converter
SHROUD
SOCKET-HEAD
SCREWS (4)
BOOTS
Printed Wiring Board Assembly
Refer to figure 4-1 for parts identification. The printed
wiring board assembly is located on the back of the
module base assembly.
Removing the Printed Wiring Board
Assembly
1. Remove the master module according to
instructions in this manual.
2. Remove three screws.
3. Lift the printed wiring board assembly straight out
of the module base.
4. Ensure that the O-ring is attached to the pressure
sensor or sensor plug after the printed wiring board
assembly has been removed from the module base.
Replacing the Printed Wiring Board
Assembly and Setting the Mode Switches
1. Apply sealant to the pressure sensor O-ring.
2. Properly orient the printed wiring board assembly
as you install it into the module base. The two
electrical leads from the I/P converter must guide into
their receptacles in the pwb assembly and the
pressure sensor or sensor plug on the printed wiring
board assembly must fit into its receptacle in the
module base.
3. Push the printed wiring board assembly into its
cavity in the module base.
4. Install and tighten three screws to a torque of 10.1
lbfSin (1 NSm).
5. Set the DIP switches on the printed wiring board
assembly according to table 4-1.
Note
Be sure the multidrop switch is set for
operation in a point-to-point loop and
the auxiliary switch is set for switch
operation, i.e., both switches down.
4-4
November 1999
Page 21
Maintenance
Pneumatic Relay
Refer to figures 4-1 and 4-5 for parts identification.
The pneumatic relay is located on the side of the
master module.
Removing the Pneumatic Relay
1. Loosen the four screws that attach the relay cap to
the module base. The screws are captive in the relay
cap by O-rings.
2. Remove the relay cap. If there is resistance, use a
flat-bladed screwdriver in the notch around the
perimeter of the cap to pry it off. Pry evenly around the
circumference of the relay cap until it is free.
Note
The Belleville spring is captivated in the
relay cap by a spring washer. A coil spring
is retained on the valve plug by an interference fit on the inside diameter of the
spring. The valve plug is captive internally
in the relay by an O-ring on the valve plug.
These parts may drop out as you remove
the cap.
INPUT
DIAPHRAGM
O-RINGS
SPRING
WASHER
BELLEVILLE
SPRING
4
VALVE PLUG
O-RING
COIL SPRING
3. Use a flat-bladed screwdriver in the notch of the
relay to pry the relay out of the module base. Pry
evenly around the circumference of the relay until the
relay is free.
RELAY CAP
W7655 / IL
Figure 4-5. Pneumatic Relay Assembly
November 1999
4-5
Page 22
DVC5000 Series
DIP SWITCH FUNCTIONSWITCHSWITCH POSITION
Multidrop LoopMulti-drop
Point-to-Point LoopMulti-drop
Auxiliary Terminal, TransmitterAuxiliary
Auxiliary Terminal, SwitchAuxiliary
1. Refer to figure 4-6 for switch location..
2. Auxiliary terminal, transmitter is available only with the Process PID option.
4
BACK OF PWB ASSEMBLY
SUB-MODULE
UP
DOWN
NOTE:
X INDICATES PIN REMOVED FOR CONNECTOR KEYING.
A6191-2/IL
Figure 4-6. DVC5000 Series Digital Valve Controller
Do not use excessive force with the
screwdriver when prying out the relay.
The lip of the notch may break, which
would not allow the O-ring to seal
properly.
MULTI-DROP SWITCH
DIP Switch Location
CAUTION
AUXILIARY SWITCH
X
X
Table 4-1. DIP Switch Configuration
Replacing the Pneumatic Relay
1. Ensure the compartment in the module base that
holds the relay is clean.
2. Visually inspect the 0.016-inch hole in the module
base (the fixed bleed on the relay output) to ensure it
is clean and free of obstructions. If cleaning is
necessary, do not enlarge the hole.
3. Apply sealant to four O-rings on the relay.
4. Insert the relay submodule into the module base.
You will feel a slight resistance as the O-rings engage.
No orientation of the relay is necessary.
5. Push on the relay until the O-rings are seated in
their respective bores and the input diaphragm makes
contact with the bottom of the bore. Take care not to
damage the supply port during assembly.
6. If not already installed, attach the coil spring and
O-ring onto the valve plug, and insert the valve plug
through the supply port of the relay.
7. Insert the four screws through the cap. Install the
O-rings on the screws until the O-rings are inside the
counterbored holes and not protruding past the
surface of the cap.
8. Place the Belleville spring in the relay cap, with its
inside diameter contacting the relay cap. Place the
spring washer, with its three fingers pointing up,
against the Belleville spring.
9. Install the relay cap on the module base. As the
relay cap is installed, the spring washer fingers will
grab the relay cap and retain the Belleville spring.
Tighten the screws, in an crisscross pattern, to a final
torque of 20.7 lbfSin (2 NSm).
(1)
UP
DOWN
UP (2)
DOWN
4-6
November 1999
Page 23
5-55
Specifications and Related Documents
Table 5-1. Specifications
Available Configurations
Type DVC5010: Sliding stem applications—Fisher
Controls actuator Types 657 and 667
Type DVC5020: Rotary applications—Fisher
Controls actuator Types 1051 and 1052
Type DVC5030: Rotary applications—Fisher
Controls actuator Types 1066SR, 1051, 1052, and
other quarter-turn actuators
Type DVC5040: Sliding-stem application—Fisher
Controls System 9000 actuator
DVC5000 Series digital valve controllers can be
mounted on those actuators listed as well as on
other Fisher and other manufacturers rotary and
sliding-stem actuators
Input Signal
Point-to-Point:
Analog Input Signal: 4 to 20 mA dc, nominal
Minimum Voltage Available at instrument terminals
must be 11.5 Vdc for analog control, 12 Vdc for
HART communication (see instrument instruction
manual for details)
Minimum Control Current: 4.0 mA
Minimum Current w/o Microprocessor Restart: 3.5
mA
Maximum Voltage: 30 volts dc
Overcurrent Protection: Input circuitry limits current
to prevent internal damage (Hardware revisions 4
and 5 only. Instruments with earlier hardware
revisions may be damaged if connected directly to a
voltage source while in point-to-point mode.)
Reverse Polarity Protection: No damage occurs
from reversal of loop current
Multi-drop:
Instrument Power: 12 to 30 volts dc at
approximately 8 mA
Reverse Polarity Protection: No damage occurs
from reversal of loop current
Supply Pressure
Minimum and Recommended: 0.3 bar (5 psi)
higher than maximum actuator requirements
Maximum: 6.9 bar (100 psig)
Steady-State Air Consumption
At 1.4 bar (20 psig) supply pressure: Less than 0.3
normal m3/hr (10 scfh)
At 2.4 bar (35 psig) supply pressure: Less than 0.4
normal m3/hr (15 scfh)
At 4.1 bar (60 psig) supply pressure: Less than 0.6
normal m3/hr (22 scfh)
At 6.9 bar (100 psig) supply pressure: Less than 0.9
normal m3/hr (34 scfh)
Maximum Output Capacity
At 1.4 bar (20 psig) supply pressure: 7.6 m3/hr (285
scfh)
At 4.1 bar (60 psig) supply pressure: 17.6 normal
m3/hr (658 scfh)
Independent Linearity
±0.5% of output span
Electromagnetic Interference (EMI)
Output signal changes less than ±0.1% when tested
per IEC 801-1 and 801-3, 27 to 1000 MHz with field
strength of 30 V/m (volts per meter)
These instruments have the CE mark in accordance
with the Electromagnetic Compatibility (EMC)
Directive. They meet the requirements of
EN50081-1 (emissions for light industry) and
EN50082-2 (immunity for industrial environment).
Electrical Classification
Hazardous Area: Explosion-proof, intrinsically
safe, Division 2, and flameproof constructions
available to CSA, FM, CENELEC, and SAA
standards. Refer to Hazardous Area Classification
Bulletins 9.2:001 series and 9.2:002.
Electrical Housing: Meets NEMA 4X, IEC 529
IP65
(1)
(1,2)
(2)
(1)
5
Output Signal
Pneumatic signal as required by the actuator, up to
95% of supply pressure
Minimum Span: 0.4 bar (6 psig)
Maximum Span: 6.2 bar (90 psig)
Action: Direct only
November 1999
(1)
Connections
Supply Pressure: 1/4-inch NPT female and
integral pad for mounting 67CFR regulator
Output Pressure: 1/4-inch NPT female
Tubing: 3/8-inch metal
Vent (pipe-away): 1/4-inch NPT female
Electrical: 1/2-inch NPT female, M20 female, or G
1/2 parallel (bottom entrance)
–continued–
5-1
Page 24
DVC5000 Series
Table 5-1. Specifications (continued)
Operating Ambient Temperature Limits
–40_C to 80_C (–40_F to 175_F)
Stem Travel (DVC5010)
0 to 102 mm (4-inches) maximum
Mounting
Designed for direct actuator mounting. For
weatherproof housing capability, the instrument
must be mounted upright to allow the vent to drain.
0 to 19 mm (0.75-inches) minimum
Shaft Rotation (DVC5020 and DVC5030)
0 to 90 degrees maximum
1. Defined in ISA Standard S51.1.
2. Normal m3/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.
Related Documents
This section lists other documents containing
5
information related to the DVC5000 Series digital
valve controllers. These documents include:
D FIELDVUER DVC5000 Series Digital Valve
Weight
Less than 2.7 Kg (6 lbs)
D Audio Monitor for HARTR Communications (PS
Sheet 62.1:FIELDVUE (G))
D Guidelines for Manually Tuning FIELDVUE
Instruments with Firmware Revision 5 (PS Sheet
62.1:FIELDVUE(H))
Controllers Instruction Manual, Form 5335
D Using the HARTR Tri-Loop HART-to-Analog
D FIELDVUER DVC5000 Series Digital Valve
Controller (Bulletin 62.1:DVC5000)
D Mounting FIELDVUER Instruments on Piston
Actuators (PS Sheet 62.1:FIELDVUE(B))
Signal Converter with FIELDVUER Instruments (PS
Sheet 62.1:FIELDVUE(J))
D FIELDVUER HF200 Series HARTR Filters
Instruction Manual - Form 5380
R
D FIELDVUER Instrument Split Ranging (PS Sheet
62.1:FIELDVUE(C))
D FIELDVUER Instrument Status Flags on
Rosemount RS3 DCS (PS Sheet 62.1:FIELDVUE(D))
D Proportional Control Loop with FIELDVUE
R
Instruments (PS Sheet 62.1:FIELDVUE(E))
D Type 2530H1 HARTR Interchange Multiplexer
Instruction Manual - Form 5407
D FIELDVUER ValveLinkt VL2000 Series User
Guide
All these documents are available from your Fisher
Controls representative or sales office. Also please
visit our website at www.FIELDVUE.com.
D Using Loop Tuners with FIELDVUER Instruments
(PS Sheet 62.1:FIELDVUE(F))
This product may be covered by one or more of the following patents (5,451,923; 5,434,774;
5,439,021; 5,265,637) or under pending patent applications.
FIELDVUE, ValveLink, Tri-Loop, Rosemount, Fisher, Fisher-Rosemount, and Managing The Process Better are marks owned by Fisher Controls
International, Inc., Fisher-Rosemount Systems, Inc., or Rosemount Inc. HART is a mark owned by the HART Communications Foundation
All other marks are the property of their respective owners.
EFisher Controls International, Inc. 1999; All Rights Reserved
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied,
regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.
For information, contact Fisher Controls:
Marshalltown, Iowa 50158 USA
Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 128461
5-2
Printed in U.S.A.
November 1999
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