DVC6200

www.Fisher.com Fisher� FIELDVUE™ DVC6200 Digital Valve Controller Contents Installation 3. . . . . . . . . . . . . . . . . . . . Mounting Guidelines 8. . . . . . . . . . . Pneumatic Connections 18. . . . . . . . Wiring and Electrical Connections 21. . . . . . . . . . . . . . . . Basic Setup 24. . . . . . . . . . . . . . . . . . . Loop Schematics and Nameplates 32. . . . . . . . . . . . . . . . Specifications 43. . . . . . . . . . . . . . . . Quick Start Guide D103410X012 DVC6200 Digital Valve Controller November 2011 This quick start guide provides installation and initial setup and calibration information for the DVC6200 digital valve controller using the 475 Field Communicator. W9713 This guide applies to the DVC6200 digital valve controller Instrument Level Device Type Device Revision Hardware Revision Firmware Revision DD Revision HC, AD, PD 03 2 1 9 & 10 3 AC 07 2 1 9 & 10 1 Quick Start Guide D103410X012 DVC6200 Digital Valve Controller November 2011 2 �Installation Check List DVC6200 digital valve controller correctly mounted on the actuator. See installation instructions provided with the mounting kit. Magnet assembly properly installed. See installation instructions provided with the mounting kit. Regulator correctly mounted. Perform one of the regulator mounting procedures on page 17. Air supply connected and at proper pressure. Connect supply as described on page 19. Also see specification on page 43. � � � Mounting Pneumatic Connections and Air Supply Wiring and Electrical Connections � � The conduit, if needed, properly installed. Refer to local and national electric codes. � Loop wiring connected to the LOOP + and - terminals in the terminal box. Connect loop wiring as described on page 21. Instrument output connected to the actuator. Connect instrument output as described on page 20. � � The HART� filter, if required, installed on your system. To determine if a HART filter is necessary, contact your Emerson Process Management sales office. For HART filter installation information, refer to the appropriate HART filter instruction manual. The FIELDVUE DVC6200 digital valve controller is a core component of the PlantWeb� digital plant architecture. The digital valve controller powers PlantWeb by capturing and delivering valve diagnostic data. Coupled with ValveLink� software, the DVC6200 provides users with an accurate picture of valve performance, including actual stem position, instrument input signal and pneumatic pressure to the actuator. Using this information, the digital valve controller diagnoses not only itself, but also the valve and actuator to which it is mounted. Quick Start Guide D103410X012 DVC6200 Digital Valve Controller November 2011 3 Note Do not install, operate, or maintain a DVC6200 digital valve controller without being fully trained and qualified in valve, actuator, and accessory installation, operation, and maintenance. To avoid personal injury or property damage, it is important to carefully read, understand, and follow all contents of this quick start guide, including all safety cautions and warnings. If you have any questions about these instructions, contact your Emerson Process Management sales office before proceeding. Installation WARNING Avoid personal injury or property damage from sudden release of process pressure or bursting of parts. Before proceeding with any Installation procedures: � Always wear protective clothing, gloves, and eyewear to prevent personal injury or property damage. � Do not remove the actuator from the valve while the valve is still pressurized. � Disconnect any operating lines providing air pressure, electric power, or a control signal to the actuator. Be sure the actuator cannot suddenly open or close the valve. � 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. � Vent the pneumatic actuator loading pressure and relieve any actuator spring precompression. � Use lock‐out procedures to be sure that the above measures stay in effect while you work on the equipment. � Check with your process or safety engineer for any additional measures that must be taken to protect against process media. W9643 Figure 1. FIELDVUE DVC6200 Digital Valve Controller Mounted on a Fisher Sliding‐Stem Valve Actuator Quick Start Guide D103410X012 DVC6200 Digital Valve Controller November 2011 4 WARNING To avoid static discharge from the plastic cover, do not rub or clean the cover with solvents. To do so could result in an explosion. Clean with a mild detergent and water only. Special Instructions for “Safe Use” and Installations in Hazardous Locations Certain nameplates may carry more than one approval, and each approval may have unique installation/wiring requirements and/or conditions of “safe use”. These special instructions for “safe use” are in addition to, and may override, the standard installation procedures. Special instructions are listed by approval type. WARNING Failure to follow these conditions of “safe use” could result in personal injury or property damage from fire or explosion, or area re‐classification. WARNING The apparatus enclosure contains aluminum and is considered to constitute a potential risk of ignition by impact or friction. Avoid impact and friction during installation and use to prevent risk of ignition. CSA Special Conditions of Safe Use Intrinsically Safe, Explosion‐proof, Division 2, Dust Ignition‐proof No special conditions for safe use. Refer to table 1 for approval information, figure 23 for the CSA loop schematic, and figure 24 for the CSA nameplate. Table 1. Hazardous Area Classifications—CSA (Canada) Certification Body Certification Obtained Entity Rating Temperature Code Enclosure Rating CSA Ex ia Intrinsically Safe Class I,II,III Division 1 GP A,B,C,D,E, F,G per drawing GE42818 T5 Natural Gas Approved Vmax = 30 VDC Imax = 226 mA Ci = 5 nF Li = 0.55 mH Pi = 1.4 W T5(Tamb � 80�C) Type 4X, IP66 Single Seal Device Explosion‐proof Class I Division 1 GP B,C,D T6 Natural Gas Approved ‐ ‐ ‐ T6(Tamb � 80�C) Type 4X, IP66 Single Seal Device Class I Division 2 GP A,B,C,D T6 Class II Division 1 GP E,F,G T6 Class II Division 2 GP F,G T6 Class III Natural Gas Approved ‐ ‐ ‐ T6(Tamb � 80�C) Type 4X, IP66 Single Seal Device Quick Start Guide D103410X012 DVC6200 Digital Valve Controller November 2011 5 FM Special Conditions of Safe Use Intrinsically Safe, Explosion‐proof, Non-incendive, Dust Ignition‐proof 1. When product is used with natural gas as the pneumatic medium, the maximum working pressure of the natural gas supply shall be limited to 145 psi. 2. When product is used with natural gas as the pneumatic medium the product shall not be permitted in a Class I, Division 2, Group A, B, C, D location without the proper venting installation per the manufacturer's instruction manual. 3. The apparatus enclosure contains aluminum and is considered to constitute a potential risk of ignition by impact or friction. Care must be taken into account during installation and use to prevent impact or friction. 4. Part of the enclosure is constructed from plastic. To prevent the risk of electrostatic sparking the plastic surface should only be cleaned with a damp cloth. Refer to table 2 for approval information, figure 25 for the FM loop schematic, and figure 26 for the FM nameplate. Table 2. Hazardous Area Classifications—FM (United States) Certification Body Certification Obtained Entity Rating Temperature Code Enclosure Rating FM Intrinsically Safe Class I,II,III Division 1 GP A,B,C,D,E,F,G per drawing GE42819 T5 Natural Gas Approved Vmax = 30 VDC Imax = 226 mA Ci = 5 nF Li = 0.55 mH Pi = 1.4 W T5(Tamb � 80�C) NEMA 4X Explosion‐proof Class I Division 1 GP B,C,D T6 Natural Gas Approved - - - T6(Tamb � 80�C) NEMA 4X Class I Division 2 GP A,B,C,D T6 Class II Division 1 GP E,F,G T6 Class II Division 2 GP F,G T6 Class III Natural Gas Approved - - - T6(Tamb � 80�C) NEMA 4X ATEX Special Conditions for Safe Use Intrinsically Safe, Dust 1. This apparatus can only be connected to an intrinsically safe certified equipment and this combination must be compatible as regards the intrinsically safe rules. 2. The electrical parameters of this equipment must not exceed any following values: UO� 30 V; IO �226 mA; PO� 1.4 W 3. Operating ambient temperature: -52�C or -40�C to + 80�C 4. For the model with aluminum body: the apparatus must not be submitted to frictions or mechanical impacts. Refer to table 3 for additional approval information, and figure 27 for the the ATEX Intrinsically Safe, Dust nameplate. Quick Start Guide D103410X012 DVC6200 Digital Valve Controller November 2011 6 Flameproof, Dust Operating ambient temperature: -52�C or -40�C to + 85�C Refer to table 3 for additional approval information, and figure 28 for the ATEX Flameproof, Dust nameplate. Type n, Dust Operating ambient temperature: -52�C or -40�C to + 80�C Refer to table 3 for additional approval information, and figure 29 for the ATEX Type n, Dust nameplate. Table 3. Hazardous Area Classifications—ATEX Certificate Certification Obtained Entity Rating Temperature Code Enclosure Rating ATEX II 1 G & D Intrinsically Safe Gas Ex ia IIC T5/T6 Ga Dust Da Ex iaD 20 T100�C(Tamb � 80�C) Da Ex iaD 20 T85�C(Tamb � 75�C) Natural Gas Approved Ui = 30 V Ii = 226 mA Ci = 5 nF Li = 0.55 mH Pi = 1.4 W T5(Tamb � 80�C) T6(Tamb � 75�C) IP66 II 2 G & D Flameproof Ex d IIC T5/T6 Dust Ex tD A21 IP66 T90�C(Tamb � 85�C) Ex tD A21 IP66 T80�C(Tamb � 75�C) Natural Gas Approved - - - T5(Tamb � 85�C) T6(Tamb � 75�C) IP66 II 3 G & D Type n Ex nCnL T5/T6 Dust Ex tD A22 IP66 T85�C(Tamb � 80�C) Ex tD A22 IP66 T80�C(Tamb � 75�C) Natural Gas Approved - - - T5(Tamb � 80�C) T6(Tamb � 75�C) IP66 IECEx Conditions of Certification Intrinsically Safe, Flameproof, Type n Ex ia 1. Warning: Electrostatic charge hazard. Do not rub or clean with solvents. To do so could result in an explosion. -52�C/-40�C � Ta � +80�C; T6 (Ta � 75�C); T5 (Ta � 80�C) Electrical parameters for protection type “i”: Ui � 30V, li � 226 mA, Pi � 1.4W, Ci � 5 nF, Li � 0.55 mH EX d / Ex nC 1. Do not open while energized. 2. Warning: Electrostatic charge hazard. Do not rub or clean with solvents. To do so could result in an explosion. 52�C/-40�C � Ta � +80�C; T6 (Ta � 75�C); T5 (Ta � 80�C) Refer to table 4 for additional approval information, figure 31 for the IECEx loop schematic, and figure 32 for the IECEx nameplate. Quick Start Guide D103410X012 DVC6200 Digital Valve Controller November 2011 7 Table 4. Hazardous Area Classifications—IECEx Certificate Certification Obtained Entity Rating Temperature Code Enclosure Rating IECEx Intrinsically Safe Gas Ex ia IIC T5/T6 per drawing GE42990 Natural Gas Approved Ui = 30 VDC Ii = 226 mA Ci = 5 nF Li = 0.55 mH Pi = 1.4 W T5(Tamb � 80�C) T6(Tamb � 75�C) IP66 Flameproof Gas Ex d IIC T5/T6 Natural Gas Approved - - - T5(Tamb � 80�C) T6(Tamb � 75�C) IP66 Type n Gas Ex nC IIC T5/T6 Natural Gas Approved - - - T5(Tamb � 80�C) T6(Tamb � 75�C) IP66 INMETRO Standards used for Certification IEC 60079.0:2007 IEC 60079.1:2001 IEC 60079-11:1999 IEC60079-15:2001 Special Conditions of Safe Use Intrinsically Safe, Flameproof, Type n No special conditions of safe use. Refer to table 5 for approval information and figure 30 for the INMETRO approvals nameplate. Table 5. Hazardous Area Classifications—INMETRO Certificate Certification Obtained Entity Rating Temperature Code Enclosure Rating INMETRO Intrinsically Safe Gas BR‐Ex ia IIC T5/T6 Gb Natural Gas Approved Ui = 30 VDC Ii = 226 mA Ci = 5 nF Li = 0.55 mH Pi = 1.4 W T5(Tamb � 80�C) T6(Tamb � 75�C) IP66W Flameproof Gas BR‐Ex d IIC T5/T6 Gb Natural Gas Approved - - - T5(Tamb � 80�C) T6(Tamb � 75�C) IP66W Type n Gas BR‐Ex nC IIC T5/T6 Gc Natural Gas Approved - - - T5(Tamb � 80�C) T6(Tamb � 75�C) IP66W Quick Start Guide D103410X012 DVC6200 Digital Valve Controller November 2011 8 Mounting Guidelines If ordered as part of a control valve assembly, the factory will mount the digital valve controller on the actuator and calibrate 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. The following procedures are general guidelines that you should consider when mounting the digital valve controller. See the instructions that come with the mounting kit for detailed information on mounting the digital valve controller to a specific actuator model. The DVC6200 housing is available in two different configurations, depending on the actuator mounting method. Figure 2 shows the available configurations. The feedback system for the DVC6200 digital valve controller utilizes a magnetic assembly for true linkage‐less, non‐contacting position measurement. In order to prevent inadvertent stem movement while the instrument is in operation, magnetic tools (such as a magnetic‐tipped screwdriver) should not be used. Note The magnet assembly may be referred to as a magnetic array in user interface tools. Figure 2. Housing Configurations LINEAR, M8 ROTARY NAMUR, M6 SLOTS FOR MOUNTING BOLTS HOUSING FOR LINEAR AND ROTARY ACTUATORS HOUSING FOR FISHER GX ACTUATORS HOLE FOR MOUNTING BOLTW9704W9703 INTEGRAL OUTPUT PRESSURE PORT CAUTION The magnet assembly material has been specifically chosen to provide a long‐term stable magnetic field. However, as with any magnet, care must be taken when handling the magnet assembly. Another high powered magnet placed in close proximity (less than 25 mm) can cause permanent damage. Potential sources of damaging equipment include, but are not limited to: transformers, DC motors, stacking magnet assemblies. Quick Start Guide D103410X012 DVC6200 Digital Valve Controller November 2011 9 CAUTION General Guidelines for use of High Power Magnets with Positioners Use of high power magnets in close proximity to any positioner which is operating a process should be avoided. Regardless of the positioner model, high power magnets can affect the positioner’s ability to control the valve. Technicians should avoid the use of high power magnets in close proximity with any positioner. Use of Magnetic Tools with the DVC6200 � Magnetic Tip Screw Drivers – Magnetic tip screw drivers can be used to work on the DVC6200. However, they should not be brought in close proximity to the magnet assembly (located at the back of the instrument) during process operations. � Calibrator Strap Magnets – These are high power magnets used to hold 4-20 ma calibrators. Normally, these calibrators would not be used while an instrument is controlling the process. High power magnets should be kept at least 15 cm (6 inches) from the DVC6200. Note As a general rule, do not use less than 60% of the magnet assembly travel range for full travel measurement. Performance will decrease as the assembly is increasingly subranged. The linear magnet assemblies have a valid travel range indicated by arrows molded into the piece. This means that the hall sensor (on the back of the DVC6200 housing) has to remain within this range throughout the entire valve travel. See figure 3. The linear magnet assemblies are symmetrical. Either end may be up. Figure 3. Travel Range INDEX MARK VALID TRAVEL RANGE 50 mm (2 INCH) SHOWN MAGNET ASSEMBLY (ATTACHED TO VALVE STEM) W9706 There are a variety of mounting brackets and kits that are used to mount the DVC6200 to different actuators. However, despite subtle differences in fasteners, brackets, and connecting linkages, the procedures for mounting can be categorized as follows: � Sliding‐stem linear actuators � Fisher rotary actuators � GX actuator � Quarter‐turn actuators See figure 4 for examples of the different travel feedback magnet assemblies. Quick Start Guide D103410X012 DVC6200 Digital Valve Controller November 2011 10 Figure 4. Magnet Assemblies RSHAFT END ASSEMBLY 90 DEG AVAILABLE CONSTRUCTIONS: SSTEM #1 ROLLER ASSEMBLY RSHAFT #1 WINDOW ASSEMBLY �(FISHER 2052 SIZE 2 & 3, 1051/1052 �SIZE 40‐70, 1061 SIZE 30‐100, �SLIDING‐STEM > 210 mm (8.25 INCHES) RSHAFT #2 WINDOW ASSEMBLY �(2052 SIZE 1, 1051/1052 SIZE 20-33) � � AVAILABLE CONSTRUCTIONS: SSTEM #19 ASSEMBLY (19 mm / 3/4 INCH) SSTEM #25 ASSEMBLY (25 mm / 1 INCH) AVAILABLE CONSTRUCTIONS: SSTEM #38 ASSEMBLY (38 mm / 1‐1/2 INCH) SSTEM #50 ASSEMBLY (50 mm / 2 INCH) SSTEM #100 ASSEMBLY (100 mm / 4 INCH) SSTEM #210 ASSEMBLY (210 mm / 8-1/4 INCH) Note Mounting the instrument vertically, with the vent at the bottom of the assembly, or horizontally, with the vent pointing down, is recommended to allow drainage of moisture that may be introduced via the instrument air supply. Sliding‐Stem Linear Actuators up to 210 mm (8.25 Inches) of Travel The DVC6200 digital valve controller has linkage‐less, non‐contact feedback on sliding‐stem actuators with up to 210 mm (8.25 inches) travel. Figure 5 shows a typical mounting on a sliding ‐stem actuator. For actuators with greater than 210 mm (8.25 inches) travel, see the guidelines on page 14. Figure 5. Mounting Parts for Sliding‐Stem Actuator with up to 210 mm (8.25 inches) Travel Quick Start Guide D103410X012 DVC6200 Digital Valve Controller November 2011 11 1. Isolate the control valve from the process line pressure and release pressure from both sides of the valve body. Shut off all pressure lines to the actuator, releasing all pressure from the actuator. Use lock‐out procedures to be sure that the above measures stay in effect while you work on the equipment. 2. Attach the mounting bracket to the actuator. 3. Loosely attach the feedback pieces and magnet assembly to the valve stem connector. Do not tighten the fasteners because fine adjustment is required. CAUTION Do not install a magnet assembly that is shorter than the physical travel of the actuator. Loss of control will result from the magnet assembly moving outside the range of the index mark in the feedback slot of the DVC6200 housing. 4. Using the alignment template (supplied with the mounting kit), position the magnet assembly inside the retaining slot. 5. Align the magnet assembly as follows: � For air‐to‐open actuators (e.g. Fisher 667) vertically align the magnet assembly so that the center line of the alignment template is lined up as close as possible with the upper extreme of the valid travel range on the magnet assembly. The magnet assembly should be positioned so that the index mark in the feedback slot of the DVC6200 housing is within the valid range on the magnet assembly throughout the range of travel. See figure 6. � For air‐to‐close actuators (e.g. Fisher 657) vertically align the magnet assembly so that the center line of the alignment template is lined up as close as possible with the lower extreme of the valid travel range on the magnet assembly. The magnet assembly should be positioned so that the index mark in the feedback slot of the DVC6200 housing is within the valid range on the magnet assembly throughout the range of travel. See figure 7. Figure 6. Air‐to‐Open Magnet Assembly Alignment W9718 ALIGNMENT TEMPLATE INDEX MARK RETAINING SLOT Figure 7. Air‐to‐Close Magnet Assembly Alignment ALIGNMENT TEMPLATE W9719 RETAINING SLOT INDEX MARK 6. Tighten the fasteners and remove the alignment template. Quick Start Guide D103410X012 DVC6200 Digital Valve Controller November 2011 12 7. Mount the digital valve controller to the mounting bracket, using the mounting bolts. 8. Check for clearance between the magnet assembly and the DVC6200 feedback slot. Note Ensure that there is clearance between the magnet assembly and the DVC6200 housing slot throughout the full range of travel. Fisher Rotary Ac