Fisher Fieldvue DVC5010, Fieldvue DVC5020 Quick Start Manual

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Page 5

1-1 1

Using This Guide

W6164 / IL

Figure 1-2. Rotary Control Valve with Type

DVC5020 Digital Valve Controller

W6341 / IL

Figure 1-1. Sliding-Stem Control Valve with Type

DVC5010 Digital Valve Controller

Note

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 HART Communicator 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

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:

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

O-RING

CAP SCREWS

2-2 2

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.

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

1/4-18 NPT OUTPUT CONNECTION (OPTIONAL)

VENT

NOTE:

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

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.

November 1999

2-3

Page 10

DVC5000 Series

SAFETY GROUND

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

instructions provided with the mounting kit. Is the feedback linkage properly connected? If not, see installation instructions

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

page 2-1. Is the air supply connected and at proper pressure? If not connect supply as described on page

2-2. Also see specifications on page 5-1. Is the instrument output connected to the actuator? If not, connect instrument output as

described on page 2-2.

Electrical Connections

If necessary, is the conduit properly installed? If not, refer to local and national electrical

codes. Is the loop wiring properly connected to the LOOP + and – terminals in the terminal box? If not, con-

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

HART COMMUNICATOR TO CONTROL SYSTEM OUTPUT TERMINALS.

SEE FIGURE 2-3 FOR TERMINAL BOX DETAILS

38B6470-A / DOC A6194–2 / IL

–

HART FILTER

–

Figure 3-1. Connecting the HART Communicator to a FIELDVUE Instrument

3-3 3

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

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

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 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

Manufacturer Actuator Model

513 and 513R

585C and 585CR

Fisher Controls

Baumann All

Gulde

Masoneilan

Neles-Jamesbury Quadra-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 Parameter Default 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

0.5%

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 Calib Travel 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.

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.

November 1999

3-3

Page 14

DVC5000 Series

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 Message Possible 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 Decrease Response (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

3-1.

Is calibration complete? If not, perform Auto Calibrate Travel procedure on

page 3-4. Does the final control element correctly respond to a setpoint change and is it

stable? If not, perform Stabilizing or Optimizing Valve Response on page 3-4.

Final control element is ready to be placed on line.

November 1999

3-5

Page 16

DVC5000 Series

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

4-4 4

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 FIELDVUE ValveLink 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.

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 Stroke Output. 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.

4-1

Page 18

DVC5000 Series

TERMINAL BOX

MODULE BASE ASSEMBLY

HOUSING

CABLE TO CABLE TO TERMINAL BOX

W7654 / IL

Figure 4-2. Printed Wiring Board Cable Connections

TRAVEL SENSOR

PRINTED WIRING BOARD ASSEMBLY

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

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

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

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 FUNCTION SWITCH SWITCH POSITION

Multidrop Loop Multi-drop

Point-to-Point Loop Multi-drop

Auxiliary Terminal, Transmitter Auxiliary

Auxiliary Terminal, Switch Auxiliary

1. Refer to figure 4-6 for switch location..

2. Auxiliary terminal, transmitter is available only with the Process PID option.

BACK OF PWB ASSEMBLY SUB-MODULE

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

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)

DOWN UP (2)

DOWN

4-6

November 1999

Page 23

5-5 5

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

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)

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.