Bulletin 62.1:DVC5000 January 2001 � FIELDVUE DVC5000 Series Digital Valve Controller DVC5000 Series digital valve controllers (figures 1 and 2) are communicating, microprocessor-based current to pneumatic instruments. In addition to the traditional function of converting a current signal to a pressure signal, these instruments, using HART communications protocol, provide easy access to information critical to process operation. Tables 1 and 2 list the information that is accessible through FIELDVUE ValveLink software or the Rosmount Model 275 HART Communicator, shown in figure 6. Much of the information is also available on a HART compatible distributed control system. W6164–B/IL ���������������������� Because the digital valve controller receives feedback ���������������� of the valve travel position, the instrument can not only diagnose itself but also the valve and actuator on which it is mounted. This provides you with very cost effective maintenance information, so that required maintenance can be performed on the instrument and valve when there really is a need. Wiring is economical because DVC5000 Series digital valve controllers use two-wire 4 to 20 mA loop power. This provides for low cost replacement of existing analog instrumentation and avoids the high cost of running separate power and signal wiring. W6164/IL Features �������������������������� ��������������������� � Improved Process Control—Two-way digital ��������������� communication provides current valve conditions. You can rely on this real-time information to make sound process management decisions. By analyzing valve W6341/IL dynamics with AMS ValveLink software, you can �������������������������� identify those control areas that need improvement ��������������������� ��������������������� and maintain a high level of system performance. Figure 1. FIELDVUE DVC5000 Series Digital Valve Controllers (continued on page 3) D200440X012 Bulletin 62.1:DVC5000 Specifications Available Configurations At 6.9 bar (100 psig) supply pressure: Less than 0.9 3 normal m /hr (34 scfh) Type DVC5010: Sliding-stem applications (2) Type DVC5020: Rotary and long-stroke Maximum Output Capacity sliding-stem applications At 1.4 bar (20 psig) supply pressure: 7.6 normal 3 Type DVC5030: Quarter-turn rotary applications m /hr (285 scfh) Type DVC5040: Sliding-stem application—Fisher At 4.1 bar (60 psig) supply pressure: 17.6 normal 3 Controls System 9000 actuator m /hr (658 scfh) (1) DVC5000 Series digital valve controllers mount on Independent Linearity Fisher Controls and other manufacturers’ rotary and ±0.5% of output span, typical sliding-stem actuators. Electromagnetic Interference (EMI) These instruments have the CE mark in accordance Input Signal with the Electromagnetic Compatibility (EMC) Point-to-Point: Directive. They meet the requirements of Analog Input Signal: 4 to 20 mA dc, nominal EN50081-1 (emissions for light industry) and Minimum Voltage Available at instrument terminals EN50082-2 (immunity for industrial environment). must be 11.5 volts dc for analog control, 12 volts dc for HART communication (see instrument Electrical Classification instruction manual for details) Hazardous Area: Explosion-proof, intrinsically Minimum Control Current: 4.0 mA safe, Division 2, and flameproof constructions are Minimum Current w/o Microprocessor Restart: 3.5 available to CSA, FM, CENELEC, and SAA mA standards. Refer to the hazardous-area Maximum Voltage: 30 volts dc classification bulletins. Overcurrent Protection: Input circuitry limits current Electrical Housing: Meets NEMA 4X, IEC 529 to prevent internal damage IP65 Reverse Polarity Protection: No damage occurs Connections from reversal of loop current Supply Pressure: 1/4-inch NPT female and Multi-drop: integral pad for mounting Type 67CFR regulator Instrument Power: 12 to 30 volts dc at Output Pressure: 1/4-inch NPT female approximately 8 mA Tubing: 3/8-inch metal, recommended Reverse Polarity Protection: No damage occurs Vent (pipe-away): 1/4-inch NPT female from reversal of loop current Electrical: 1/2-inch NPT female conduit connection, M20 adaptor optional (1) Output Signal Operating Ambient Temperature Limits Pneumatic pressure as required by the actuator, up –40 to 80�C (–40 to 175�F) to 95% of supply pressure. Minimum Span: 0.4 bar (6 psig) Construction Materials Maximum Span: 6 bar (90 psig) Housing, module base, and terminal box: ANSI Action: Direct only B360.0 low copper aluminum alloy Cover: Valox (1) Supply Pressure Elastomers: Nitrile Minimum and Recommended: 0.3 bar (5 psig) Stem Travel higher than maximum actuator requirements DVC5010: 0 to 102 mm (4 inches) maximum Maximum: 6.9 bar (100 psig) or maximum pressure 0 to 9.5 mm (3/8 inches) minimum rating of the actuator, whichever is lower. DVC5020: 0 to 606 mm (23-7/8 inches) maximum Shaft Rotation (DVC5020 and DVC5030) (1),(2) Steady-State Air Consumption 0 to 50 degrees minimum At 1.4 bar (20 psig) supply pressure: Less than 0.3 0 to 90 degrees maximum 3 normal m /hr (10 scfh) Mounting At 2.4 bar (35 psig) supply pressure: Less than 0.4 3 normal m /hr (15 scfh) Designed for direct actuator mounting. For At 4.1 bar (60 psig) supply pressure: Less than 0.6 weatherproof housing capability, mount the 3 normal m /hr (22 scfh) instrument upright to allow the vent to drain. (continued) 2 Bulletin 62.1:DVC5000 Specifications (continued) Dimensions Weight Less than 2.7 kg (6 lbs) See figures 9 and 10. For dimensions of a Type DVC5040 digital valve controller, see Bulletin Options 41.1:FloVue. � Standard Diagnostics or � HART communicating; � Supply and output pressure gauges or � tire valves; � Integrally mounted filter regulator 1. These terms are defined in ISA Standard S51.1. 3 2. Normal m /hr—Normal cubic meters per hour (0�C, 1.01325 bar, absolute); Scfh—Standard cubic feet per hour (60�F, 14.7 psia). and installation cost savings by replacing other devices in the process loop, such as positioners and limit switches. Because the digital valve controller is loop powered, it can replace analog instrumentation in new or existing installations, no additional wiring is required. � Built to Survive—Field-tough DVC5000 Series digital valve controllers have fully encapsulated printed wiring boards that resist the effects of vibration, temperature, and corrosive atmospheres. As shown in figure 7, a separate weather-tight field wiring terminal box isolates field wiring connections from other areas of the instrument. � Increased Uptime—With the self-diagnostic capability of DVC5000 Series digital valve controllers, you can answer questions about a valve’s performance, without pulling the valve from the line. You can compare the present valve/actuator signature (bench set, seat load, friction, etc.) against previously stored signatures to discover performance changes, before they cause process control problems. W6564/IL � Faster Commissioning—Quickly commission loops by using the HART communications protocol to Figure 2. DVC5000 Series Digital Valve Controller Mounted on FloVue� System 9000 Actuator remotely identify each instrument, verify its calibration, review stored maintenance notes, and more. � Enhanced Safety—Check instrument and valve � Easy Maintenance—With its patented design, operation from a remote location. Access is possible digital valve controller field repair consists of quick and at a field junction box, marshalling panel, or within the easy replacement of a single master module, without safety of the control room using either a HART disconnecting field wiring, pneumatic tubing, or valve Communicator, a notebook PC, or a system stem linkages. The master module may be then taken workstation. Minimize exposure to hazardous to the instrument shop for fast and easy environments and avoid having to access troubleshooting of critical components. hard-to-reach locations. � Environmental Protection—Avoid additional field wiring by connecting a leak detector or limit Diagnostics switch to the digital valve controller auxiliary terminals. If limits are exceeded, the instrument will issue an � Valve Assembly Diagnostics—When integrated alert. with a HART communication-based system, the DVC5000 Series digital valve controller � Hardware Savings—When placed in an user-configurable alerts provide real-time notification integrated system, DVC5000 Series digital valve of current and potential valve and instrument controllers allow you to realize significant hardware problems. With AMS ValveLink software, tests can be 3 Bulletin 62.1:DVC5000 communicate with non-HART distributed control systems through the Modbus interface, as shown in figure 4. This allows integrating critical information such as valve travel and alerts into the process operation. � HART-Based Control Systems—A control system with HART communication capabilies has the ability to directly gather information from DVC5000 Series digital valve controllers. Information such as valve travel and alerts can be seamlessly integrated into operational displays. Communication Figure 3. The Valve Signature Diagnostic Test Can Reveal Areas of Degradation HART Protocol The HART (Highway Addressable Remote Transducer) protocol gives field devices the capability performed to identify problems with the entire control of digitally communicating instrument and process valve assembly. Figure 3 shows an example of a data. This digital communication occurs over the same ValveLink display. Valve stem travel feedback and two-wire loop that provides the 4 to 20 mA process actuator pressure sensors, permit evaluating the control signal, without disrupting the process signal. health of the control valve. When compared with a The analog process signal, with its faster response, is benchmark Valve Signature, a later signature will used for control. At the same time, the HART digital reveal areas of valve degradation. This helps to communication provides access to calibration, pinpoint problems before the equipment fails. configuration, diagnostic, maintenance, and additional data. � Emerson Performance Solutions—Emerson Performance Solutions can use instruments with The HART protocol uses frequency shift keying (FSK). on-line diagnostic capability to evaluate the valve and Two individual frequencies of 1200 and 2200 Hz are the process while the loop is running. Performance superimposed over the 4 to 20 mA current signal. Diagnostics permit identifying and isolating the These frequencies represent the digits 1 and 0, as process element that is currently causing quality shown in figure 5. The average value of the HART problems. signal is zero, therefore no dc value is added to the 4 to 20 mA signal. Thus, true simultaneous communication is achieved without interrupting the process signal. Integration The HART protocol also provides the capability of multidropping several devices to a single � Non-HART Systems—Because they operate communications line. This type of connection is well with a traditional 4 to 20 milliamp dc control signal, suited for remote applications such as pipelines, DVC5000 Series digital valve controllers can replace custody transfer sites, and tank farms. older analog instruments. Microprocessor-based electronics provide improved performance along with repeatable and reliable configuration and calibration. Model 275 HART Communicator � HART Multiplexers and AMS ValveLink You can perform configuration and calibration at the Software with Modbus Interface—Integrating valve or anywhere on the two-wire loop via a Model DVC5000 Series instruments into a multiplexer 275 HART Communicator (figure 6). Powerful tools network and using AMS ValveLink software allows such as the Setup Wizard and Auto Travel Calibration monitoring multiple instruments for alarms. automate the tasks of commissioning DVC5000 Series Additionally, tasks such as configuration, calibration digital valve controllers. These automation tools not and diagnostic testing do not require special trips to only save time, but also provide accurate and the field. AMS ValveLink software can also repeatable results. 4 Bulletin 62.1:DVC5000 DISTRIBUTED CONTROL SYSTEM (DCS) AMS ValveLink Software MODBUS FIELD TERMINATION ASSEMBLY (FTA) RS232-TO-RS485 CONVERTER 4-20 mA HART 4-20 mA HART MULTIPLEXER Control System I/O + HART W8082-1 / IL Figure 4. Integrate Information from the Digital Valve Controller into a Non-HART Compatible Control System With AMS ValveLink Software’s Modbus Interface +0.5 mA 0 ANALOG SIGNAL –0.5 mA 1200 Hz 2200 Hz “1” “0” AVERAGE CURRENT CHANGE DURING COMMUNICATION = 0 A6174/IL � Figure 5. HART Frequency Shift Keying Technique AMS ValveLink Software W7125 / IL AMS ValveLink software is a Windows-based software package that allows easy access to the information Figure 6. Model 275 HART Communicator available from DVC5000 Series digital valve controllers. Use AMS ValveLink software to monitor Valve Signature, Dynamic Error Band, and Step the performance characteristics of the valve and Response are displayed in an intuitive user-friendly obtain vital information without having to pull the valve environment that allows easy interpretation of the from the line. Results from diagnostic tests such as data. Diagnostic graphs can be superimposed over 5 Bulletin 62.1:DVC5000 TERMINAL BOX ASSEMBLY TERMINAL BOX COVER PRINTED WIRING BOARD ASSEMBLY MODULE BASE ASSEMBLY I/P CONVERTER SHROUD TRAVEL SENSOR ASSEMBLY GASKET PRESSURE GAUGES HOUSING (OPTIONAL) PNEUMATIC RELAY COVER ASSEMBLY W8153all / IL RELAY CAP Figure 7. DVC5000 Series Digital Valve Controller Assembly those previously stored to view areas of valve sends a signal to the I/P converter submodule. The I/P degradation. This allows plant personnel to converter transforms the input signal to a pressure concentrate efforts on equipment that needs repair, signal. This signal is sent to a pneumatic relay, where avoiding unnecessary maintenance. This diagnostic it is amplified and delivered as the output signal to an capability is readily accessible and available to you actuator. The output signal is also sensed by a either in the control room or on the plant floor. In pressure sensor located on the printed wiring board addition to the diagnostic features, AMS ValveLink assembly submodule and used for valve/actuator software contains an Audit Trail, Batch Runner for diagnostics. Stem position of the valve and actuator is automating repetitive tasks, and Trending to view brought as an input to the printed wiring board valve performance. assembly submodule and used as feedback for the digital valve controller. Gauges are available in the digital valve controller to give visual indication of supply pressure and output pressure. Principle of Operation As shown in figure 7, DVC5000 Series digital valve controllers have a single master module that contains Installation the I/P converter, printed wiring board assembly, pneumatic relay submodules, and gauges. The master The Type DVC5010 digital valve controller module can be rebuilt by replacing the submodules. yoke-mounts on sliding stem actuators, as shown in figure 9. The Type DVC5020 digital valve controller The digital valve controller receives the 4 to 20 mA typically mounts on rotary actuators, as shown in input signal and power through a single twisted pair of figure 10. The Type DVC5030 mounts on most wires brought into the terminal box, as shown in figure quarter-turn rotary actuators, including both Fisher and 8. The input signal is routed to the printed wiring board other manufacturers actuators (figure 11). The Type assembly submodule, where any characterization, DVC5040 digital valve controller is designed for limits, and other signal preconditioning may be integral mounting on the FloVue System 9000 actuator applied. The printed wiring board assembly submodule (figure 12). 6 Bulletin 62.1:DVC5000 Figure 8. Digital Valve Controller Principle of Operation Figure 9. Type DVC5010 Digital Valve Controller Mounted on Type 657 Actuator All pressure connections on the digital valve the terminal box are through a 1/2-inch NPT conduit controllers are 1/4-inch NPT female connections. connection. If necessary, a remote vent may be Typically, 3/8-inch (9.5 mm) outside diameter tubing is connected to the digital valve controller. used between the digital valve controller output connection and the actuator. Electrical connections to 7 Bulletin 62.1:DVC5000 1/2-14 NPT CONDUIT CONNECTION MOUNTING BOTH SIDES ADAPTOR 4.88 (124.0) 1 CENTERLINE OF ACTUATOR BODY 9.19 (233.4) 3.94 (100.1) 6.31 1/4-18 NPT CONNECTION 1/4-18 NPT SUPPLY (160.3) FOR GAS TIGHT APPLICATIONS 8.00 CONNECTION INSTRUMENT REMOVAL (203.2) CLEARANCE 2.81(71.4) 1/4-18 OUTPUT CONNECTION NOTE: INCH 1 MOUNTING ADAPTOR REQUIRED FOR TYPE 1051 SIZE 33 AND TYPE 1052 SIZE 20 OR SIZE 33 ONLY. (mm) E0525 / IL Figure 10. Type DVC5020 Digital Valve Controller Mounted on Type 1052 Actuator 3. Maximum actuator travel or rotation Ordering Information Refer to the specifications on page 2. Carefully review 4. Options each specification and indicate your choice whenever a selection is to be made. a. HART Communicating or Standard Diagnostics When ordering, specify: b. Integrally-mounted supply pressure regulator 1. Type number 2. Actuator type and size c. Supply and output gauges or tire valves 8 Bulletin 62.1:DVC5000 ACTUATOR FEEDBACK ARM 27B6733-B / DOC MOUNTING BRACKET Figure 11. Type DVC5030 Digital Valve Controller Mounted on Typical Quarter-Turn Actuator A6870*A/IL Figure 12. Type DVC5040 Digital Valve Controller Mounted on FloVue System 9000 Actuator 9 Bulletin 62.1:DVC5000 Table 1 Information Accessible through AMS ValveLink Software or a Model 275 HART Communicator INFORMATION TYPE OF INFORMATION DESCRIPTION CATEGORY Analog Input The input current value on the primary terminals, in milliamps or percent Actuator Pressure The actuator presssure in psig, kPa, or bar Measure Travel The actual stem or shaft position in percent Variables Temperature The internal instrument temperature in �F or �C Auxiliary Input The contacts connected to the auxiliary terminals are open or closed Tag The instrument or loop tag Instrument Serial Number The serial number assigned to the digital valve controller Valve Serial Number The serial number of the valve on which the digital valve controller is mounted Descriptor A description of the application Date The last date the instrument was calibrated or the next date assigned for instrument Identification calibration Calibration Location The instrument was calibrated in the field or at the factory Revision Level The instrument and firmware revision level Message A user entered message of up to 32 characters. May be used for maintenance history information. Engineering Units Psig, kPa, bar, or % Travel Cutoffs Low cutoff drives valve to seat when travel is less than a user configurable point. High cutoff drives valve open when travel is greater than a user configurable point. Feedback Connection The specific valve mounting choice of sliding stem or rotary Minimum Opening and The minimum time for full travel or rotation of the valve stem or shaft Input/Output Closing Time Characteristics Travel Limits The user configurable software upper and lower travel limit Dynamic Bypass The dynamic response of the digital valve controller to emulate a transducer Manual Output The command for the digital valve controller to move to a determined position Protection Prohibits unauthorized changes to configuration and calibration Restart Control Mode Selects the control mode in the event of a restart Failure Selftest Shutdown Selects type of failure that causes an instrument shutdown Calibration Input Range Sets the input current range (4 to 20 mA, typical) Deviation Alert Alerts when the valve travel deviates from the correct value Travel Alert Establishs alert points based on stem or shaft position Drive signal Alert Alerts when the internal drive signal is out of bounds Cycle Counter Records the number of changes in stem direction Cycle Alert Alerts when a user configurable number of cycles are exceeded Diagnostics Travel Accumulation Records total accumulated stem or shaft travel Travel Accumulation Alert Alerts when a user configurable travel accumulation is exceeded Auxiliary Terminal Alert Alerts when the contacts connected to the auxiliary terminals are open or closed (alert can be configured to occur with either open or closed contacts) Instrument Status The status of internal instrument checks Configuration Changed Flag The instrument configuration has been changed Table 2. Additional information Accessible with AMS ValveLink Software INFORMATION TYPE OF INFORMATION DESCRIPTION CATEGORY Dynamic Error Band Runs an input versus travel test of the instrument and valve Valve Signature Runs an actuator pressure versus travel test to determine valve/actuator friction, bench Diagnostics set, spring rate, and seating load Step Response Runs a multipoint travel versus time test for various step inputs N97 These products are covered under the following patents (5,265,637; 5,434,774; 5,439,021; 5,451,923) and may be covered by one or more pending patents. FIELDVUE, ValveLink, Fisher, and Fisher-Rosemount are marks owned by Fisher Controls International, Inc. or Fisher-Rosemount Systems, Inc. HART is a mark owned by the HART Communication Fourndation All other marks are the property of their respective owners. �Fisher Controls International, Inc. 1994, 2001; All Rights Reserved ���������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� ������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� For information, contact Fisher: Marshalltown, Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 128461 10 Printed in U.S.A.