DLC3000 Quick Start~Errata~Instruction Manual by RMC Process Controls & Filtration, LLC.

Errata Sheet

DLC3000 Series

June 2008

Errata Sheet for FIELDVUE DLC3000 Series Digital Level Controllers Form 5631, February 2007

The mounting kits in table 6-1 of the FIELDVUE DLC3000 Series Digital Level Controllers instruction manual, Form 5631, are no longer available for order using the part numbers listed. Contact your Emerson Process Management sales office for FS numbers for the following DLC3000 mounting options: 249 Series 誰 heat insulator for field mounting the DLC3010. Fisher

Masoneilan 12100, 12800 Series Masoneilan 12100, 12800 Series with heat insulator Masoneilan 12200, 12300 Series Masoneilan 12200, 12300 Series with heat insulator Yamatake Honeywell Type NQP

www.Fisher.com

Yamatake Honeywell Type NQP with heat insulator Foxboro Eckardt 134LD and 144LD Foxboro-Eckardt 134LD and 144LD with heat insulator Foxboro-Eckardt LP167 Foxboro-Eckardt LP167 with heat insulator

Note Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility for the selection, use, or maintenance of any product. Responsibility for the selection, use, and maintenance of any product remains with the purchaser and end-user.

DLC3000 Series

Errata Sheet June 2008

FIELDVUE and Fisher are marks owned by Fisher Controls International LLC, a member of the Emerson Process Management business division of Emerson Electric Co. Emerson Process Management, Emerson, and the Emerson logo are trademarks and service marks of Emerson Electric Co. Masoneilan is a mark owned by Dresser Industries, Inc. Foxboro is a mark owned by Invensys Systems, Inc. Honeywell is a registered trademark of Honeywell International, Inc. All other marks are the property of their respective owners. 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. Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility for the selection, use and maintenance of any product. Responsibility for the selection, use and maintenance of any product remains with the purchaser and end-user.

Emerson Process Management Marshalltown, Iowa 50158 USA Sorocaba, 18087 Brazil Chatham, Kent ME4 4QZ UK Dubai, United Arab Emirates Singapore 128461 Singapore www.Fisher.com 2 Fisher Controls International LLC 2008; All Rights Reserved Printed in USA

Instruction Manual Form 5631 February 2007

DLC3000 Series

FIELDVUER DLC3000 Series Digital Level Controllers Introduction

Principle of Operation

Installation

Setup and Calibration

Troubleshooting and Maintenance

Replaceable Parts

375 Field Communicator Basics

Loop Schematics/Nameplates

B 9

Glossary

Index

10 Index

This manual applies to: Model 375 Field Communicator

Type DLC3010 Firmware Revision

Hardware Revision

Device Description Revision

D102748X012

Device Revision

www.Fisher.com

DLC3000 Series

Unfold This Sheet to See the Model 375 Field Communicator Menu Structure

DLC3000 Series Model 375 Field Communicator Menu Tree for FIELDVUER DLC3000 Device Description (DD) Revision 2

Model 375 Compatibility Model 375

DLC3010 Hot Key 1 Range Values 2 PV Setup 3 Write Lock

Process Variables 3 1 < PV > Value 2 Process Temp 5 3 Elect Temp 4 PV Range Diag/ Service 1 Test Device 2 Loop Test 3 Hardware Alarms 4 Calibration 5 Write Lock

1-4

PV Range 1 URV 2 LRV

2-1

Test Device 1 Status 2 2 Meter

2-3

2-4

Basic Setup 1 Setup Wizard 2 Sensor Calibrate 3 PV Setup

3-2

Online 1 Process Variables 2 Diag/Service 3 Basic Setup 4 Detailed Setup 5 Review 3-3-1

PV Setup 1 PV & Temp Units 3-3 2 PV Range 3 Level Offset 4 4 PV Damp 5 Specific Gravity 4 6 PV is

3-3-2

2-4-2

Hardware Alarms 1 Alarm Jumper 2 NVM 3 Free Time 4 Level Snsr Drive 5 A/D TT Input Calibration 1 Sensor Calibrate 6 2 Temp. Calibration 3 Scaled D/A Trim

5-4

4-1-1-1 Displacer 1 Displacer Info 2 Inst Mounting 3 Sensor Calibrate 6

Displacer Info 1 Displacer Units 2 Length 3 Volume 4 Weight 5 Disp Rod

C 4-1-1-1-1

4-1-2

PV Range 1 URV 3-3-2-5 2 LRV 3 USL 4 LSL 5 Set Zero & Span

4-2-1

Analog Output 3 1 PV Value 2 AO 3 % Range 4 Alarm Jumper

4-3

4-4

Set Zero & Span 1 Set Zero (4 mA) 2 Set Span (20 mA) Sensors 1 Displacer 2 Torque Tube 3 Process Temp 4 Measure Spec Gr Output Condition 1 Analog Output 2 LCD Meter 3 Configure Alarms 4 Display Alarms

Device Information 1 HART 2 Version Info 3 Serial Numbers 4 Device ID

Trending 1 Trend Var 2 Trend Interval 3 Read Trend

Displacer Units 1 Length Units 2 Volume Units 3 Weight Units

Torque Tube 1 Material 2 Change Material Process Temp 1 Process Temp RTD 2 Digital Proc Temp

Factory Settings 1 TTube Rate 2 TTube Rate Units 3 TTube Temp Coeff. 4 Input Filter

2 Display Type LCD Meter 1 Meter Installed 4-2-2-2 1 PV Only 2 PV/Proc Temp 2 Display Type 2 3 % Range Only 3 Decimal Places 4 PV/% Range 2 Process Var 4-2-3-1 1 PV Hi Alrm 2 PV Hi-Hi Alrm 4-2-3 Configure Alarms 1 Process Var 3 PV Lo Alrm 2 Alarm Enable 4 PV Lo-Lo Alrm 3 Temperature 5 PV Alrm Deadband 4 Temp Alarm Enable Temperature 1 Proc. Temp Hi Alrm 2 Proc. Temp Lo Alrm 3 Elec. Temp Hi Alrm 4-2-3-3 HART 4 Elec. Temp Lo Alrm 1 HART Tag 5 Temp Alrm Deadband 4-3-1 2 Polling Address 3 Message 4 Descriptor 5 Date 6 Burst Mode 7 Burst Option 4-2-2

4-3-3

Serial Numbers 1 Instrument S/N 2 Displacer S/N 3 Final Asmbly Num

Model 375 Field Communicator Menu Tree for Device Description Revision 2

Version Info 1 Device Rev 4-3-2 2 Firmware Rev 3 Hardware Rev 4 HART Univ Rev 5 375 DD Rev

NOTES: 1 THIS MENU IS AVAILABLE BY PRESSING THE LEFT ARROW KEY FROM THE PREVIOUS MENU. 2 APPEARS ONLY IF LCD METER IS INSTALLED. 3 < PV > APPEARS AS LEVEL , INTERFACE , OR DENSITY , DEPENDING ON WHAT IS SELECTED FOR PV IS UNDER PV SETUP 4 APPEARS ONLY IF PV IS NOT DENSITY. IF PV IS DENSITY, PV RANGE BECOMES 3-3, AND PV IS BECOMES 3-3-4. 5 APPEARS ONLY IF RTD IS INSTALLED. IF THE CONFIGURATION DOES NOT HAVE AN RTD INSTALLED, PV RANGE BECOMES 1-3 AND ELECT TEMP BECOMES 1-2. 6 SEE MENU 3-2.

4-1-3

Detailed Setup 1 Sensors 2 Output Condition 4 3 Device Information 4 Trending

Field Communicator 1 Offline 2 Online 3 Frequency Device 4 Utility

DD Rev

PV & Temp Units 1 < PV > Units 3 2 Temp Units

4-2

Review 1 Device Params 2 Device Info 3 Device Troubleshoo 4 Factory Settings

Firmware Rev

Temp. Calibration 1 Process Temp 2 Proc Temp Offset 3 Elect Temp 4 Elect Temp Offset

Sensor Calibrate 1 Mark Dry Coupling 2 Two Point 3 Wet/Dry Cal 4 Single Point 5 Trim PV Zero 6 Weight-based Cal

4-1

4-1-1

Device Rev

DLC3000 Series 1

Hot Key 1 Range Values 2 PV Setup 3 Write Lock 2 NOTES: 1 APPEARS ONLY IF PV IS IS NOT DENSITY. IF PV IS DENSITY, PV RANGE BECOMES 2-3 AND PV IS BECOMES 2-4 2 < PV > APPEARS AS LEVEL, INTERFACE, OR DENSITY, DEPENDING ON WHAT IS SELECTED FOR PV IS UNDER PV SETUP

Range Values 1 LRV 2 URV 3 LSL 4 USL

PV Setup 1 PV & Temp Units 2 PV Range 1 3 Level Offset 4 PV Damp 5 Specific Gravity 6 PV is

2-1

PV & Temp Units 1 < PV > Units 2 2 Temp Units

1 2-2

2-2-5

Set Zero & Span 1 Set Zero 2 Set Span

PV Range 1 URV 2 LRV 3 USL 4 LSL 5 Set Zero & Span

Model 375 Field Communicator Fast-Key Sequence. The Sequence Describes the Steps to go to a Menu Item (1) Fast!Key Sequence

Coordinates(1)

Analog Output

4-2-1

5-E

Percent Range

4-2-1-3

5-E

Alarms, Display

4-2-4

4-F

Polling Address

4-3-1-2

5-G

4-2-1-4

5-E

Function

Condition

Alarm Jumper

Function

Process Temperature

Condition

Fast!Key Sequence

RTD installed

1-2

RTD NOT installed

N/A

Coordinates(1)

2-B

Basic Setup

2-C

Burst Mode

4-3-1-6

5-H

Process Variable Alarm Enable

4-2-3-2

5-G

Burst Option

4-3-1-7

5-H

Process Variable Alarm Limits

4-2-3-1

6-F

Calibration Damping, PV

2-4 PV is NOT Density

3-3-4

PV is Density

3-3-3

3-C

PV is

2-E Process Variable Range

Level or Interface

3-3-6

Density

3-3-4

RDT Installed

1-4

RTD NOT Installed

1-3

2-E

3-A

Date

4-3-1-5

5-H

Descriptor

4-3-1-4

5-H

Process Variable Units

3-3-1-1

3-D

2-F

PV Setup

Hot Key-2

4-3

4-G

Range Values

Hot Key-1

See menu above

2-B

Review

Displacer Info

4-1-1-1

6-B

RTD, Process Temperature

Displacer Serial Number

4-3-3-2

5-I

Detailed Setup Device Info Diagnostic and Service

Electronics Temperature

RTD Installed

1-3

RTD Not Installed

1-2

Filter, Input

2-B

2-G

4-1-3-1

5-D

Scaled D/A Trim

2-4-3

3-C

Sensor Calibrate

3-2

3-D

Set Zero & Span

3-3-2-5

4-E

3-1

2-C

5-4-4

3-H

4-3-2-2

5-H

2-3

3-B

HART Tag

4-3-1-1

5-G

Status

2-1-1

3-B

Instrument Mounting

4-1-1-2

5-C

Temperature Alarm Enable

4-2-3-4

5-G

Instrument Serial Number

4-3-3-1

5-I

Temperature Alarm Limits

4-2-3-3

6-G

4-2-2

5-F

Temperature Units

3-3-1-2

3-D

2-1

3-B

5-4-1

3-H

4-1-2-1

5-D

4-4

4-H 3-E

Firmware Rev Hardware Alarms

LCD Meter LCD Meter Installed LCD Meter Test

Level Offset Loop Test

2-1-2

LCD Meter NOT Installed

N/A

PV is NOT Density

3-3-3

PV is Density

N/A

Setup Wizard Specific Gravity

Test Device 3-B

2-E

Torque Tube Rate Torque Tube Material Trending

PV is NOT Density

3-3-5

PV is Density

N/A

2-E

2-2

2-B

URV (Upper Range Value)

3-3-2-1

LRV (Lower Range Value)

3-3-2-2

3-E

USL (Upper Sensor Limit)

3-3-2-3

3-E

LSL (Lower Sensor Limit)

3-3-2-4

3-E

Weight Based Calibration

3-2-6

3-D

Message

4-3-1-3

5-H

Write Lock

Hot Key-3

See menu above

4-2

4-F

Output Condition

1. Coordinates are to help locate the item on the menu tree on the facing page. N/A = Not available

iii

Introduction 1-1

Section 1 Introduction

Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3

Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3

Educational Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3

February 2007

1-1

DLC3000 Series Scope of Manual This instruction manual includes specifications, installation, operating, and maintenance information for FIELDVUE DLC3000 Series digital level controllers.

The manual describes the functionality of instruments with Firmware Revision 8. This instruction manual supports the Model 375 Field Communicator with device description revision 2, used with DLC3000 instruments with firmware revision 8. You can obtain information about the process, instrument, or sensor using the Model 375 Field Communicator or AMS Suite: Intelligent Device Manager. Contact your Emerson Process Management sales office to obtain the appropriate software Do not install, operate, or maintain a Type DLC3000 digital level controller without first being fully trained and qualified in valve, actuator, and accessory installation, operation and maintenance, and carefully reading and understanding the contents of this manual. If you have any questions concerning these instructions, contact your Emerson Process Management sales office before proceeding.

W7977 / IL

Figure 1-1. Type DLC3000 Digital Level Controller

sequence in the procedure heading is shown as (2-1-1). The path required to accomplish various tasks, the sequence of steps through the Field Communicator menus, is also presented in textual format. Menu selections are shown in italics, e.g., Calibrate. An overview of the Model 375 Field Communicator menu structure is shown on the inside front cover of this manual.

Description

Note Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility for the selection, use, and maintenance of any product. Responsibility for the selection, use, and maintenance of any product remains with the purchaser and end-user.

Conventions Used in this Manual Procedures that require the use of the Model 375 Field Communicator have the Field Communicator symbol in the heading. Some of the procedures also contain the sequence of numeric keys required to display the desired Field Communicator menu. For example, to access the Status menu, from the Online menu, press 2 (selects Diag/Service) followed by 1 (selects Test Device) followed by a second 1 (selects Status). The key

1-2

Type DLC3010 Digital Level Controllers Type DLC3010 digital level controllers (figure 1-1) are used with level sensors to measure liquid level, the level of interface between two liquids, or liquid specific gravity (density). Changes in level or specific gravity exert a buoyant force on a displacer, which rotates the torque tube shaft. This rotary motion is applied to the digital level controller, transformed to an electrical signal and digitized. The digital signal is compensated and processed per user configuration requirements, and converted back to a 4!20 mA analog electrical signal. The resulting current output signal is sent to an indicating or final control element. DLC3010 digital level controllers are communicating, microprocessor-based level, interface, or density sensing instruments. In addition to the normal function of providing a 4 to 20 milliampere current signal, DLC3010 digital level controllers, using the HART communications protocol, give easy access to information critical to process operation. You can gain information from the process, the instrument, or the sensor using a Model 375 Field Communicator with device descriptions (DDs) compatible with Type DLC3010 digital level controllers. The Field Communicator may be connected at the digital level controller or at a field junction box. Using the Field Communicator, you can perform several operations with the DLC3010 digital level February 2007

Introduction controller. You can interrogate, configure, calibrate, or test the digital level controller. Using the HART protocol, information from the field can be integrated into control systems or be received on a single loop basis. DLC3010 digital level controllers are designed to directly replace standard pneumatic and electro-pneumatic level transmitters. DLC3010 digital level controllers mount on a wide variety of Fisher 249 Series cageless and caged level sensors. They mount on other manufacturers displacer type level sensors through the use of mounting adaptors.

249 Series Caged Sensors (see table 1-6) Type 249, 249B, 249BF, 249C, 249K, and 249L sensors side-mount on the vessel with the displacer mounted inside a cage outside the vessel. (The Type 249BF is available only in Europe, Middle East, and Africa.)

249 Series Cageless Sensors (see table 1-7) Type 249BP, 249CP, and 249P sensors top-mount on the vessel with the displacer hanging down into the vessel. Type 249V sensor side-mounts on the vessel with the displacer hanging out into the vessel. Type 249W wafer-style sensor mounts on top of a vessel or on a customer-supplied cage.

Specifications Specifications for the Type DLC3000 digital level controllers are shown in table 1-1. Specifications for the 249 Series sensor are shown in table 1-3. Specifications for the Field Communicator can be found in the Product Manual for the Field Communicator.

Related Documents Other documents containing information related to the Type DLC3000 digital level controllers and 249 Series sensors include: FIELDVUE Type DLC3010 Digital Level Controllers (Bulletin 11.2:DLC3000)

February 2007

FIELDVUE DLC3000 Series Digital Level Controller Quick Start Guide ! From 5797 Supplement to HART Based FIELDVUE Instrument Instruction Manuals Using FIELDVUE Instruments with the Smart HART Loop Interface and Monitor (HIM) ! Form 5809 Supplement to HART Based FIELDVUE Instrument Instruction Manuals Audio Monitor for HART Communications ! Form 5811 Caged 249 Series Displacer Sensors Instruction Manual - Form 1802 Cageless 249 Series Displacer Sensors Instruction Manual - Form 1803 Type 249W Cageless Wafer Style Level Sensor Instruction Manual - Form 5729 Supplement to 249 Series Sensors Instruction Manual Simulation of Process Conditions for Calibration of Level-Trols - Form 5767 Supplement to 249 Series Sensors Instruction Manual Bolt Torque Information ! Form 5801 Technical Monograph 7: The Dynamics of Level and Pressure Control Technical Monograph 18: Level-Trol Density Transmitter Technical Monograph 26: Guidelines for Selection of Liquid Level Control Equipment These documents are available from your Emerson Process Management sales office. Also visit our website at www.Fisher.com.

Educational Services For information on available courses for the DLC3000 Series digital level controller, as well as a variety of other products, contact: Emerson Process Management Educational Services, Registration P.O. Box 190; 301 S. 1st Ave. Marshalltown, IA 50158!2823 Phone: 800!338!8158 or Phone: 641!754!3771 FAX: 641!754!3431 e-mail: education@emersonprocess.com

1-3

DLC3000 Series Table 1-1. Type DLC3000 Digital Level Controller Specifications

Available Configurations

Performance

Type DLC3010 Digital Level Controller: Mounts on Fisher 249 Series caged and cageless sensors. See tables 1-6 and 1-7 and sensor description. Function: Transmitter Communications Protocol: HART

PERFORMANCE CRITERIA

DLC3000 Digital Level Controller(1)

w/ NPS 3 249W, Using a 14-inch Displacer

w/ All Other 249 Series

Independent Linearity

$0.25% of output span

$0.8% of output span

$0.5% of output span

Hysteresis

<0.2% of output span

!!!

Repeatability

$0.1% of full scale output

$0.5% of output span

$0.3% of output span

Dead Band

<0.05% of input span

!!!

Hysteresis plus Deadband

!!!

<1.0% of output span

Input Signal(1) Level, Interface, or Density: Rotary motion of torque tube shaft proportional to changes in liquid level, interface level, or density that change the buoyancy of a displacer.

NOTE: At full design span, reference conditions. 1. To lever assembly rotation inputs.

Process Temperature: Interface for 2- or 3-wire 100 ohm platinum RTD for sensing process temperature, or optional user-entered target temperature to permit compensating for changes in specific gravity Output Signal(1)

At effective proportional band (PB)<100%, linearity, dead band, and repeatability are derated by the factor (100%/PB) Operating Influences

Analog: 4 to 20 milliamperes dc ( direct action increasing level, interface, or density increases output; or reverse action increasing level, interface, or density decreases output)

Power Supply Effect: Output changes <±0.2% of full scale when supply varies between min. and max voltage specifications. Transient Voltage Protection: The loop terminals are protected by a transient voltage suppressor. The specifications are as follows:

High saturation: 20.5 mA Low saturation: 3.8 mA High alarm: 22.5 mA Low Alarm: 3.7 mA

Pulse Waveform

Only one of the above high/low alarm definitions is available in a given configuration. NAMUR NE 43 compliant when high alarm level is selected. Digital: HART 1200 Baud FSK (frequency shift keyed)

Rise Time s)

Decay to 50% s)

Max VCL (Clamping Voltage) (V)

Max IPP (Pulse Peak @ Current) (A)

1000

93.6

121

Note: µs = microsecond

HART impedance requirements must be met to enable communication. Total shunt impedance across the master device connections (excluding the master and transmitter impedance) must be between 230 and 1100 ohms. The transmitter HART receive impedance is defined as: Rx: 42K ohms and Cx: 14 nF

Ambient Temperature: The combined temperature effect on zero and span without the 249 sensor is less than 0.03% of full scale per degree Kelvin over the operating range !40 to 80 C (!40 to 176 F)

Note that in point-to-point configuration, analog and digital signalling are available. The instrument may be queried digitally for information, or placed in Burst mode to regularly transmit unsolicited process information digitally. In multi-drop mode, the output current is fixed at 4 mA, and only digital communication is available.

Process Temperature: The torque rate is affected by the process temperature (see figure 1-2). The process density may also be affected by the process temperature. Process Density: The sensitivity to error in knowledge of process density is proportional to the differential density of the calibration. If the differential specific gravity is 0.2, an error of 0.02 specific gravity units in knowledge of a process fluid density represents 10% of span.

!continued!

1-4

February 2007

Introduction Table 1-1. Type DLC3000 Digital Level Controller Specifications (continued)

Electromagnetic Interference (EMI): Tested per IEC 61326-1 (Edition 1.1). Complies with European EMC Directive. Meets emission limits for class A equipment (industrial locations) and class B equipment (domestic locations). Meets immunity requirements for industrial locations (Table A.1 in the IEC specification document). Immunity performance is shown in table 1-2.

LCD Meter Indications LCD meter indicates analog output on a percent scale bar graph. The meter also can be configured to display: Process variable in engineering units only. Percent range only. Percent range alternating with process variable or Process variable, alternating with process temperature (and degrees of pilot shaft rotation).

Supply Requirements (See figure 3-11)

Electrical Classification

12 to 30 volts dc; instrument has reverse polarity protection.

Hazardous Area:

A minimum compliance voltage of 17.75 is required to guarantee HART communication.

Explosion proof, Intrinsic Safety Dust-Ignition proof

Compensation

APPROVED

Explosion proof, Non-incendive, Dust-Ignition proof, Intrinsic Safety

ATEX Intrinsic Safety, Type n, Flameproof

Transducer compensation: for ambient temperature. Density parameter compensation: for process temperature (requires user-supplied tables). Manual compensation: for torque tube rate at target process temperature is possible.

IECEx Intrinsic Safety, Type n SAA

Refer to Special Instructions for Safe Use and Installations in Hazardous Locations in the Installation section, tables 3-1, 3-2, 3-3, 3-4, and 3-5, and figures B-1, B-2, B-3, B-4, B-5, and B-6 for additional approvals information.

Digital Monitors Linked to jumper-selected Hi (factory default) or Lo analog alarm signal: Torque tube position transducer: Drive monitor and signal reasonableness monitor User-configurable alarms: Hi-Hi and Lo-Lo Limit process alarms

Flameproof

Electrical Housing: NEMA 4X, CSA Enclosure, and IP66 Minimum Differential Specific Gravity

HART-readable only: RTD signal reasonableness monitor: When RTD installed Processor free-time monitor. Writes-remaining in Non Volatile Memory monitor. User-configurable alarms: Hi and Lo limit process alarms, Hi and Lo limit process temperature alarms, and Hi and Lo limit electronics temperature alarms Diagnostics Output loop current diagnostic. LCD meter diagnostic. Spot specific gravity measurement in level mode: used to update specific gravity parameter to improve process measurement Digital signal-tracing capability: by review of troubleshooting variables , and Basic trending capability for PV, TV and SV.

With a nominal 4.4 degrees torque tube shaft rotation for a 0 to 100 percent change in liquid level (specific gravity=1), the digital level controller can be adjusted to provide full output for an input range of 5% of nominal input span. This equates to a minimum differential specific gravity of 0.05 with standard volume displacers. See 249 Series sensor specifications for standard displacer volumes and standard wall torque tubes. Standard volume for 249C and 249CP series is ∼980 cm3 (60 in3), most others have standard volume of ∼1640 cm3 (100 in3). Operating at 5% proportional band will degrade accuracy by a factor of 20. Using a thin wall torque tube, or doubling the displacer volume will each roughly double the effective proportional band. When proportional band of the system drops below 50%, changing displacer or torque tube should be considered if high accuracy is a requirement.

!continued!

February 2007

1-5

DLC3000 Series Table 1-1. Type DLC3000 Digital Level Controller Specifications (continued)

Mounting Positions Digital level controllers can be mounted right- or left-of-displacer, as shown in figure 3-7. Instrument orientation is normally with the coupling access door at the bottom, to provide proper drainage of lever chamber and terminal compartment, and to limit gravitational effect on the lever assembly. If alternate drainage is provided by user, and a small performance loss is acceptable, the instrument could be mounted in 90 degree rotational increments around the pilot shaft axis. The LCD meter may be rotated in 90 degree increments to accommodate this. Construction Materials DLC3000 Series Digital Level Controller: Case and Cover: Low-copper aluminum alloy Internal: Plated steel, aluminum, and stainless steel; encapsulated printed wiring boards; Neodymium Iron Boron Magnets Electrical Connections Two 1/2-14 NPT female conduit connections; one on bottom and one on back of terminal box. M20 adapters available. Options Heat insulator. See description under Ordering Information. Mountings for Masoneilan ,

Yamatake, and Foxboro -Eckhardt displacers available. Level Signature Series Test (Performance Validation Report) available (EMA only) for instruments factory-mounted on 249 sensor. Factory Calibration: available for instruments factory-mounted on 249 sensor, when application, process temperature and density(s) are supplied. Device is compatible with user-specified remote indicator.

Operating Limits Process Temperature: See table 1-4 and figure 3-9. Ambient Temperature and Humidity: See below Conditions

Normal Limits(1,2, 3)

Transport and Storage Limits(1)

Nominal Reference(1)

Ambient Temperature

!40 to 80 C (!40 to 176 F)

!40 to 85 C (!40 to 185 F)

25 C (77 F)

Ambient Relative Humidity

0 to 95%,

(non-condensing)

40%

Weight Less than 2.7 Kg (6 lbs)

1. Defined in ISA Standard S51.1 2. LCD meter may not be readable below !20 C (!4 F) 3. Contact your Emerson Process Management sales office or application engineer if temperatures exceeding these limits are required.

Table 1-2. Immunity Performance BASIC STANDARD

PERFORMANCE CRITERIA(1)

Electrostatic discharge (ESD)

IEC 61000-4-2

EM field

IEC 61000-4-3

Rated power frequency magnetic field

IEC 61000-4-8

Burst

IEC 61000-4-4

Surge

IEC 61000-4-5

Conducted RF

IEC 61000-4-6

PORT Enclosure

I/O signal/control

PHENOMENON

Note: RTD wiring must be shorter than 3 meters (9.8 feet). 1. A = No degradation during testing. B = Temporary degradation during testing, but is self-recovering. Specification Limit = +/! 1% of span.

1-6

February 2007

Introduction TORQUE RATE REDUCTION (NORMALIZED MODULUS OF RIGIDITY) 1.00 0.98 1 0.96

0.94 N05500 N06600

Gnorm

0.92 0.90

N10276 0.88 0.86 0.84

0.82 S31600

0.80 20

100

120

140

160

180

200

220

240

260

280

300

320

340

360

380

400

420

TEMPERATURE (_C)

TORQUE RATE REDUCTION (NORMALIZED MODULUS OF RIGIDITY) 1.00 0.98 1 0.96 0.94

Gnorm

0.92

N05500 N06600

0.90 N10276 0.88 0.86

0.84 0.82 0.80 50

100

150

200

250

300

350

400

450

500

550

600

650

700

750

S31600 800

TEMPERATURE (_F)

NOTE: DUE TO THE PERMANENT DRIFT THAT OCCURS NEAR AND ABOVE 260 C (500 F), N05500 IS 1 NOT RECOMMENDED FOR TEMPERATURES ABOVE 232 C (450 F).

Figure 1-2. Theoretical Reversible Temperature Effect on Common Torque Tube Materials

February 2007

1-7

DLC3000 Series Table 1-3. 249 Series Sensor Specifications

Input Signal Liquid Level or Liquid-to-Liquid Interface Level:From 0 to 100 percent of displacer length Liquid Density: From 0 to 100 percent of displacement force change obtained with given displacer volumeÂ&#x2014;standard volumes are 980 cm3 (60 inches3) for Types 249C and 249CP sensors or 1640 cm3 (100 inches3) for most other sensors; other volumes available depending upon sensor construction Sensor Displacer Lengths See tables 1-6 and 1-7 footnotes Sensor Working Pressures Consistent with applicable ANSI pressure/temperature ratings for the specific sensor constructions shown in tables 1-6 and 1-7 Caged Sensor Connection Styles Cages can be furnished in a variety of end connection styles to facilitate mounting on vessels;

Table 1-4. Allowable Process Temperatures for Common 249 Sensor Pressure Boundary Materials MATERIAL

MIN.

MAX.

!29 C (!20 F)

232 C (450 F)

Steel

!29 C (!20 F)

427 C (800 F)

Stainless Steel

!198 C (!325 F)

427 C (800 F)

N04400

!198 C (!325 F)

427 C (800 F)

!198 C (!325 F)

427 C (800 F)

!73 C (!100 F)

204 C (400 F)

1-8

Mounting Positions Most level sensors with cage displacers have a rotatable head. The head may be rotated through 360 degrees to any of eight different positions, as shown in figure 3-7. Construction Materials See tables 1-5, 1-6, and 1-7 Operative Ambient Temperature See table 1-4 For ambient temperature ranges, guidelines, and use of optional heat insulator, see figure 3-9. Options Heat insulator, see description under Ordering Information Gauge glass for pressures to 29 bar at 232 C (420 psig at 450 F), and Reflex gauges for high temperature and pressure applications

Table 1-5. Displacer and Torque Tube Materials PART

STANDARD MATERIAL

OTHER MATERIALS

304 Stainless Steel

316 Stainless Steel, N10276, N04400, Plastic, and Special Alloys

Displacer Stem Driver Bearing, Displacer Rod and Driver

316 Stainless Steel

N10276, N04400, other Austenitic Stainless Steels, and Special Alloys

Torque Tube

N05500(1)

316 Stainless Steel, N06600, N10276

PROCESS TEMPERATURE

Cast Iron

Graphite Laminate/SST Gaskets N04400/PTFE Gaskets

the equalizing connection styles are numbered and are shown in figure 3-2.

Displacer

1. N05500 is not recommended for spring applications above 232 C (450 F). Contact your Emerson Process Management sales office or application engineer if temperatures exceeding this limit are required.

February 2007

Introduction Table 1-6. Caged Displacer Sensors(1) TORQUE TUBE ORIENTATION

TYPE NUMBER 249(3)

249B, 249BF(4) Torque tube arm rotatable with respect to equalizing connections

1. 2. 3. 4. 5.

STANDARD CAGE, HEAD, AND TORQUE TUBE ARM MATERIAL Cast iron

Steel

EQUALIZING CONNECTION Style

1-1/2 or 2

Flanged

Screwed or optional socket weld

1-1/2 or 2

CL600

1-1/2

CL150, CL300, or CL600

1-1/2 or 2

CL600

1-1/2

CL150, CL300, or CL600

Raised face or optional ring-type joint flanged

316 stainless steel

PRESSURE RATING(2)

Screwed

Screwed 249C(3)

Size (NPS)

Raised face flanged

CL125 or CL250

249K

Steel

Raised face or optional ring-type joint flanged

1-1/2 or 2

CL900 or CL1500

249L

Steel

Ring-type joint flanged

2(5)

CL2500

Standard displacer lengths for all styles (except Type 249) are 14, 32, 48, 60, 72, 84, 96, 108 and 120 inches. Type 249 uses a displacer with a length of either 14 or 32 inches. EN flange connections available in EMA (Europe, Middle East and Africa). Not available in EMA. Type 249BF available in EMA only. Also available in EN size DN 40 with PN 10 to PN 100 flanges and size DN 50 with PN 10 to PN 63 flanges. Top connection is NPS 1 ring-type joint flanged for connection styles F1 and F2.

Table 1-7. Cageless Displacer Sensors(1) MOUNTING

Mounts on top of vessel

TYPE NUMBER

STANDARD HEAD(2), WAFER BODY(6) AND TORQUE TUBE ARM MATERIAL

CL150, CL300, or CL600

NPS 6 or 8 raised face

CL150 or CL300

NPS 3 raised face

CL150, CL300, or CL600

NPS 4 raised face or optional ring-type joint

CL900 or 1CL500 (EN PN 10 to DIN PN 250)

NPS 6 or 8 raised face

CL150, CL300, CL600, CL900, CL1500, or CL2500

NPS 4

CL125 or CL250

NPS 4 raised face or flat face

CL150

NPS 4 raised face or optional ring-type joint

CL300, CL600, CL900, or CL1500 (EN PN 10 to DIN PN 160)

NPS 4 ring-type joint

CL2500

NPS 4 raised face or flat face

CL150

NPS 4 raised face or optional ring-type joint

CL300, CL600, or CL900

WCC (steel) or CF8M (316 stainless steel)

NPS 3 raised face

CL150, CL300, or CL600

LCC (steel) or CF8M (316 Stainless Steel)

NPS 4 raised face

CL150, CL300, or CL600

Steel

249CP

316 Stainless Steel

Steel or stainless steel Cast Iron

Mounts on side of vessel

249V

Cast Steel

316 Stainless Steel Mounts on top of vessel or on customer supplied cage 1. 2. 3. 4. 5. 6.

249W

PRESSURE RATING(3)

NPS 4 raised face or optional ring-type joint

249BP(4)

249P(5)

FLANGE CONNECTION (SIZE)

Standard displacer lengths are 14, 32, 48, 60, 72, 84, 96, 108, and 120 inches. Not used with side-mounted sensors. EN flange connections available in EMA (Europe, Middle East and Africa). Not available in EMA. Type 249P available in EMA only. Wafer Body only applicable to Type 249W.

February 2007

1-9

DLC3000 Series

1-10

February 2007

Principle of Operation 2-2

Section 2 Principle of Operation HARTR Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2

Digital Level Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2

February 2007

2-1

DLC3000 Series +0.5 mA

ANALOG SIGNAL

!0.5 mA 1200 Hz 1

2200 Hz 0

AVERAGE CURRENT CHANGE DURING COMMUNICATION = 0 A6174/IL

Figure 2-1. HART Frequency Shift Keying Technique

HARTR Communication The HART (Highway Addressable Remote Transducer) protocol gives field devices the capability of communicating instrument and process data digitally. This digital communication occurs over the same two-wire loop that provides the 4 20 mA process control signal, without disrupting the process signal. In this way, the analog process signal, with its faster update rate, can be used for control. At the same time, the HART protocol allows access to digital diagnostic, maintenance, and additional process data. The protocol provides total system integration via a host device. The HART protocol uses the frequency shift keying (FSK) technique based on the Bell 202 communication standard. By superimposing a frequency signal over the 4 20 mA current, digital communication is attained. Two individual frequencies of 1200 and 2200 Hz are superimposed as a sinewave over the 4 20 mA current loop. These frequencies represent the digits 1 and 0 (see figure 2-1). The average value of this sinewave is zero, therefore no dc value is added to the 4 20 mA signal. Thus, true simultaneous communication is achieved without interrupting the process signal.

constitute the primary mechanical sensor. The angular deflection of the torque tube is measured by the instrument transducer, which consists of a magnet system moving over a Hall effect device. A liquid crystal display (LCD) meter can display the analog output; process variable (level, interface level, or density); the process temperature, if an RTD (resistance temperature detector) is installed; the degrees of torque tube rotation; and percent range. The instrument uses a microcontroller and associated electronic circuitry to measure the process variable, provide a current output, drive the LCD meter, and provide HART communications capability. Figure 2-2 shows the digital level controller assembly. Figure 2-3 is a block diagram of the main components in the instrument electronics; the LCD meter, the processor module, the transducer board, and the terminal board. The processor module contains the microprocessor, the analog-to-digital (A/D) converters, loop interface, signal conditioning, the digital-to-analog (D/A) output, power supply and interfaces to other boards. The transducer board contains the Hall sensor, a temperature sensor to monitor the Hall sensor temperature, and an EEPROM to store the coefficients associated with the Hall sensor. The terminal board contains the EMI filters, the loop connection terminals, and the connections for the optional RTD used to measure process temperature. A level, density, or interface level change in the measured fluid causes a change in the displacer position (figure 2-5). This change is transferred to the torque tube assembly. As the measured fluid changes, the torque tube assembly rotates up to 4.4 degrees for a 249 Series sensor, varying the digital level controller output between 4 and 20 mA. The rotary motion of the torque tube is transferred to the digital level controller lever assembly. The rotary motion moves a magnet attached to the lever assembly, changing the magnetic field that is sensed by the Hall effect sensor. The sensor converts the magnetic field signal to an electronic signal.

Digital Level Controller Operation

The microcontroller accepts the electronic signal, which is ambient-temperature-compensated and linearized. The microcontroller can also actively compensate for changes in liquid specific gravity due to changes in process temperature based on an input via HART protocol or via an optional RTD, if it is connected. The D/A output circuit accepts the microcontroller output and provides a 4 to 20 mA current output signal.

DLC3000 Series digital level controllers are loop-powered instruments that measure changes in liquid level, level of an interface between two liquids, or density of a liquid. Changes in the buoyancy of a displacer suspended in a vessel vary the load on a torque tube. The displacer and torque tube assembly

During normal operation, when the input is between the lower and upper range values, the digital level controller output signal ranges between 4 and 20 mA and is proportional to the input. See figure 2-4. If the input should exceed the lower and upper range values, the output will continue to be proportional to the input

The HART protocol allows the capability of multidropping, networking several devices to a single communications line. This process is well suited for monitoring remote applications such as pipelines, custody transfer sites, and tank farms.

2-2

February 2007

Principle of Operation

ADAPTER RING

TERMINAL BOX TERMINAL BOX COVER

TRANSDUCER BOARD

LEVER ASSEMBLY

HOUSING

ELECTRONICS ASSEMBLY LCD METER ASSEMBLY E0377 / IL

COVER

Figure 2-2. DLC3000 Series Digital Level Controller Assembly

Transducer Module

Electronics Temperature Sensor

Torque Tube Rotation

Shaft Position Transducer

Processor Module

Terminal Box

LCD Meter

RTD Process Temperature Interface

Loop / HART Interface

Linearization Data resident in NVM

E0378 / IL

Figure 2-3. DLC3000 Series Digital Level Controller Principle of Operation

February 2007

2-3

DLC3000 Series 24 22

Output Saturated (20.5 mA)

Ouput during Alarm with Alarm Jumper in Hi Position (22.5 mA)

18 16 Output (mA)

Normal Operation

12 10 8 6

Output Saturated (3.8 mA)

Ouput during Alarm with Alarm Jumper in Lo Position (3.7 mA)

4 2 !20%

20%

40%

60%

80%

100%

120%

PV Range E0379 / IL

Figure 2-4. Digital Level Controller Analog Output Signal

until the output reaches either 3.8 or 20.5 mA. At this time the output is considered saturated and will remain at this value until the input returns to the normal operating range. However, should an alarm occur, the output is driven to either 3.7 or 22.5 mA, depending upon the position of the alarm jumper. TORQUE TUBE

DISPLACER

Note The upper alarm value is compliant with NAMUR NE-43, but the lower alarm value is not. If using in a system with NAMUR NE-43 compatibility, the high alarm value may be an appropriate choice.

W1389-1*/IL

249 SERIES (SIDE VIEW)

Other circuits in the digital level controller provide reverse polarity protection, transient power surge protection, and electromagnetic interference (EMI) protection.

2-4

Figure 2-5. Typical Sensor Operation

February 2007

Installation 3-3

Section 3 Installation Configuration: On the Bench or in the Loop . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

Protecting the Coupling and Flexures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

Special Instructions for Safe Use and Installations in Hazardous Areas CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATEX Intrinsic Safety, Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATEX Flameproof, Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATEX Type n, Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IECEx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4 3-4 3-4 3-4 3-4 3-4 3-4

Mounting the 249 Series Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6

Digital Level Controller Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7

Mounting the Digital Level Controller on a 249 Series Sensor . . . . . . . . . . . . . .

3-7

Mounting the Digital Level Controller for High Temperature Applications . . .

3-8

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10

Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shielded Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12 3-12

Power/Current Loop Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12

RTD Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two-Wire RTD Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three-Wire RTD Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12 3-12 3-12

Communication Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12

Test Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13

Multichannel Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13

Alarm Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14

Changing Jumper Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14

Loop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14

Installation in Conjunction with a Rosemount Model 333 HARTR Tri-Loopt HARTR-to-Analog Signal Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-15

February 2007

3-1

DLC3000 Series This section contains digital level controller installation information including an installation flowchart (figure 3-1), mounting and electrical installation information, and a discussion of failure mode jumpers.

Configuration: On the Bench or in the Loop

2. If the displacer cannot be blocked because of cage configuration or other concerns, the transmitter is uncoupled from the torque tube by loosening the coupling nut, and the access handle will be in the locked position. Before placing such a configuration into service, perform the Coupling procedure found on page 4-7.

Configure the digital level controller before or after installation. It may be useful to configure the instrument on the bench before installation to ensure proper operation, and to familiarize yourself with its functionality.

3. For a cageless system where the displacer is not connected to the torque tube during shipping, the torque tube itself stabilizes the coupled lever position by resting against a physical stop in the sensor. The access handle will be in the unlocked position. Mount the sensor and hang the displacer. The coupling should be intact.

Protecting the Coupling and Flexures

4. If the controller was shipped alone, the access handle will be in the locked position. All of the Mounting, Coupling and Calibration procedures must be performed.

CAUTION Damage to flexures and other parts can cause measurement errors. Observe the following steps before moving the sensor and controller.

Mounting

Lever Lock The lever lock is built in to the coupling access door. When the door is open, it positions the lever in the neutral travel position for coupling. In some cases, this function is used to protect the lever assembly from violent motion during shipment. A DLC3010 controller will have one of the following mechanical configurations when received: 1. A fully assembled and coupled caged-displacer system shipped with the displacer or driver rod blocked within the operating range by mechanical means. In this case, the access handle (figure 3-5) will be in the unlocked position. Remove the displacer-blocking hardware before calibration. (See the appropriate sensor instruction manual). The coupling should be intact.

CAUTION When shipping an instrument mounted on a sensor, if the lever assembly is coupled to the linkage, and the linkage is constrained by the displacer blocks, use of the lever lock may result in damage to bellows joints or flexure.

3-2

The access handle includes a retaining set screw, as shown in figures 3-5 and 3-6. The screw is driven in to contact the spring plate in the handle assembly before shipping. It secures the handle in the desired position during shipping and operation. To open or close the access door, this set screw must be backed out so that its top is flush with the handle surface.

WARNING To avoid personal injury, always wear protective gloves, clothing, and eyewear when performing any installation operations. Personal injury or property damage due to sudden release of pressure, contact with hazardous fluid, fire, or explosion can be caused by puncturing, heating, or repairing a displacer that is retaining process pressure or fluid. This danger may not be readily apparent when disassembling the sensor or removing the displacer. Before disassembling the sensor or removing the displacer, observe the appropriate warnings provided in the sensor instruction manual. Check with your process or safety engineer for any additional measures that must be taken to protect against process media.

February 2007

Installation START HERE Check Alarm Jumper Position

Factory mounted on 249 sensor?

Wire Digital Level Controller

Yes

Power Digital Level Controller

No High temperature application?

Yes

Install heat insulator assembly

No Mount and Wire Digital level Controller

Enter Tag, Messages, Date, and check or set target application data

Power Digital level Controller Set Level Offset to Zero Use Setup Wizard to enter sensor data and calibration condition

Yes

Density Measurement?

No Using Temperature Correction?

Yes

Set Temperature Units Setup specific gravity tables

Set Specific Gravity

Calibrate sensor

Yes Using RTD?

Setup and Calibrate RTD

No Set Range Values

Enter Process Temperature

Disable Writes

NOTE: 1 IF USING RTD FOR TEMPERATURE CORRECTION, ALSO WIRE RTD TO DIGITAL LEVEL CONTROLLER 2 DISABLING WRITES IS EFFECTIVE ONLY IF THE DLC3000 REMAINS POWERED-UP

DONE

Figure 3-1. Installation Flowchart

February 2007

3-3

DLC3000 Series 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 requirements and/or conditions of safe use. Special instructions are listed by agency/approval. After reading and understanding these special conditions of use, proceed with standard installation procedures.

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.

Operating ambient temperature: !40 C to + 80 C Refer to table 3-3 for additional approval information, and figure B-4 for the ATEX approvals nameplate.

ATEX Flameproof, Dust Special Conditions for Safe Use Operating ambient temperature: !40 C to + 80 C The apparatus must be fitted with a certified EEx d IIC cable entry. Refer to table 3-3 for additional approval information, and figure B-4 for the ATEX approvals nameplate.

ATEX Type n, Dust Special Conditions for Safe Use

CSA

This equipment shaft can be used with a cable entry ensuring an IP66 minimum and being in compliance with the relevant European standards.

Special Conditions of Safe Use

Operating ambient temperature: !40 C to + 80 C

No special conditions for safe use.

Refer to table 3-3 for additional approval information, and figure B-4 for the ATEX approvals nameplate.

Refer to table 3-1 for approval information, figure B-1 for the CSA loop schematic, and figure B-3 for the nameplate.

IECEx Special Conditions for Safe Use

No special conditions for safe use.

Special Conditions of Safe Use

Refer to table 3-4 for approval information, and figure B-5 for the IECEx nameplate.

No special conditions for safe use. Refer to table 3-2 for approval information, figure B-2 for the FM loop schematic and figure B-3 for the nameplate.

SAA

ATEX Intrinsic Safety, Dust

1. It is a condition of safe use that on installations utilizing gland entries, the gland used must be Standards Australia certified and must be capable of maintaining the nominated IP rating.

Special Conditions for Safe Use The apparatus Type DLC3010 is an intrinsically safe apparatus; it can be mounted in a hazardous area. The apparatus can only be connected to an intrinsically safe certified equipment and this combination must be compatible as regards the intrinsically safe rules.

3-4

Conditions of Certification

2. It is a condition of safe use that the unused conduit entry is fitted with the original conduit plug provided with the equipment certified as part of this certification or other appropriately certified conduit plug. Refer to table 3-5 for additional approval information, and figure B-6 for the SAA approval nameplate.

February 2007

Installation Table 3-1. Hazardous Area Classifications—Canada (CSA) CERTIFICATION BODY

CERTIFICATION OBTAINED

(Intrinsic Safety) Class/Division Class I,II,III Division 1 GP A,B,C,D,E,F,G per drawing 28B5744 CSA

ENTITY RATING

Vmax = 30 Vdc Imax = 226 mA Ci = 5.5 nF Li = 0.4 mH

TEMPERATURE CODE

ENCLOSURE RATING

T6 (Tamb < 80°C)

(Explosion Proof) Class/Division Class I, Division 1 GP B,C,D

!!!

T6 (Tamb < 80 C)

Class I Division 2 GP A,B,C,D Class II Division 1, 2 GP E,F,G Class III

!!!

T6 (Tamb < 80°C)

3 Table 3-2. Hazardous Area Classifications—United States (FM) CERTIFICATION BODY

CERTIFICATION OBTAINED

(Intrinsic Safety) Class/Division Class I,II,III Division 1 GP A,B,C,D,E,F,G per drawing 28B5745 FM

ENTITY RATING

Vmax = 30 Vdc Imax = 226 mA Pi = 1.4 W Ci = 5.5 nF Li = 0.4 mH

TEMPERATURE CODE

ENCLOSURE RATING

T5 (Tamb < 80°C)

(Explosion Proof) Class/Division Class I, Division 1 GP A,B,C,D

!!!

T5 (Tamb < 80 C)

Class I Division 2 GP A,B,C,D Class II Division 1 GP E,F,G Class II Division 2 GP F,G

!!!

T5 (Tamb < 80°C)

Table 3-3. Hazardous Area Classifications—ATEX CERTIFICATE

ATEX

CERTIFICATION OBTAINED

II 1 G D Gas EEx ia IIC T6 Intrinsic Safety Dust T85C (Tamb < 80 C) II 2 G D Gas EEx d IIC T6 Flameproof Dust T85C (Tamb < 80 C) II 3 G D Gas EEx nCL IIC T4 Type n Dust T85C (Tamb < 80 C)

ENTITY RATING

TEMPERATURE CODE

ENCLOSURE RATING

T6 (Tamb < 80 C)

IP66

!!!

T6 (Tamb < 80 C)

IP66

!!!

T4 (Tamb < 80 C)

IP66

Ui = 30 Vdc Ii = 226 mA Pi = 1.4 W Ci = 5.5 nF Li = 0.4 mH

Table 3-4. Hazardous Area Classifications—IECEx CERTIFICATE

IECEx

CERTIFICATION OBTAINED

Ex ia IIC T5 Intrinsic Safety

Ex nA IIC T5 Type n

ENTITY RATING

Ui = 30 Vdc Ii = 226 mA Pi = 1.4 W Ci = 5.5 nF Li = 0.4 mH !!!

TEMPERATURE CODE

ENCLOSURE RATING

T5 (Tamb < 80 C)

IP66

T5 (Tamb < 80 C)

IP66

Table 3-5. Hazardous Area Classifications—SAA CERTIFICATE

SAA

February 2007

CERTIFICATION OBTAINED

Gas Ex d IIC T6 Flameproof

ENTITY RATING

TEMPERATURE CODE

ENCLOSURE RATING

!!!

T6 (Tamb < 80 C)

IP66

3-5

DLC3000 Series

3 STYLE 1 TOP AND BOTTOM CONNECTIONS, SCREWED (S-1) OR FLANGED (F-1)

STYLE 2 TOP AND LOWER SIDE CONNECTIONS, SCREWED (S-2) OR FLANGED (F-2)

STYLE 3 UPPER AND LOWER SIDE CONNECTIONS, SCREWED (S-3) OR FLANGED (F-3)

STYLE 4 UPPER SIDE AND BOTTOM CONNECTIONS, SCREWED (S-4) OR FLANGED (F-4)

28B5536-1 B1820-2 / IL

Figure 3-2. Style Number of Equalizing Connections

Mounting the 249 Series Sensor The 249 Series sensor is mounted using one of two methods, depending on the specific type of sensor. If the sensor has a caged displacer, it typically mounts on the side of the vessel as shown in figure 3-3. If the sensor has a cageless displacer, the sensor mounts on the side or top of the vessel as shown in figure 3-4. The Type DLC3000 digital level controller is typically shipped attached to the sensor. If ordered separately, it may be convenient to mount the digital level controller to the sensor and perform the initial setup and calibration before installing the sensor on the vessel.

Note Caged sensors have a rod and block installed on each end of the displacer to protect the displacer in shipping. Remove these parts before installing the sensor to allow the displacer to function properly.

3-6

A3789-1 / IL

Figure 3-3. Typical Caged Sensor Mounting

February 2007

Installation MOUNTING STUDS

ACCESS HOLE SHAFT CLAMP SET SCREW

A3788-1 / IL

Figure 3-4. Typical Cageless Sensor Mounting

PRESS HERE TO MOVE ACCESS HANDLE

SLIDE ACCESS HANDLE TOWARD FRONT OF UNIT TO EXPOSE ACCESS HOLE

Figure 3-5. Sensor Connection Compartment (Adapter Ring Removed for Clarity)

Digital Level Controller Orientation Mount the digital level controller with the torque tube shaft clamp access hole (see figure 3-5) pointing downward to allow accumulated moisture drainage.

Note If alternate drainage is provided by the user, and a small performance loss is acceptable, the instrument could be mounted in 90 degree rotational increments around the pilot shaft axis. The LCD meter may be rotated in 90 degree increments to accommodate this.

The digital level controller and torque tube arm are attached to the sensor either to the left or right of the displacer, as shown in figure 3-7. This can be changed in the field on the 249 Series sensors (refer to the appropriate sensor instruction manual). Changing the mounting also changes the effective action, because the torque tube rotation for increasing level, (looking at the protruding shaft), is clockwise when the unit is mounted to the right of the displacer and counterclockwise when the unit is mounted to the left of the displacer. February 2007

SET-SCREW

Figure 3-6. Close-up of Set-Screw

All caged 249 Series sensors have a rotatable head. That is, the digital level controller can be positioned at any of eight alternate positions around the cage as indicated by the position numbers 1 through 8 in figure 3-7. To rotate the head, remove the head flange bolts and nuts and position the head as desired.

Mounting the Digital Level Controller on a 249 Series Sensor Refer to figure 3-5 unless otherwise indicated. 1. If the set-screw in the access handle, (see figure 3-6) is driven against the spring plate, back it out until the head is flush with the outer surface of the handle, using a 2 mm hex key. Slide the access handle to the locked position to expose the access hole. Press on the back of the handle as shown in figure 3-5 then slide the handle toward the front of the unit. Be sure the locking handle drops into the detent.

3-7

DLC3000 Series SENSOR

LEFT-OF-DISPLACER

1 5

RIGHT-OF-DISPLACER

3 6

CAGED

1 5

4 3

CAGELESS

NOT AVAILABLE FOR SIZE NPS 2 CL300 AND CL600 TYPE 249C.

19B2787 Rev. D 19B6600 Rev. C B1407-2/IL

Figure 3-7. Typical Mounting Positions for Type DLC3010 Digital Level Controller on 249 Series Sensor

2. Using a 10 mm deep well socket inserted through the access hole, loosen the shaft clamp (figure 3-5). This clamp will be re-tightened in the Coupling portion of the Initial Setup section. 3. Remove the hex nuts from the mounting studs. Do not remove the adapter ring.

5. Carefully slide the mounting studs into the sensor mounting holes until the digital level controller is snug against the sensor. 6. Reinstall the hex nuts on the mounting studs and tighten the hex nuts to 10 N m (88.5 lbf in).

Mounting the Digital Level Controller for High Temperature Applications CAUTION Measurement errors can occur if the torque tube assembly is bent or misaligned during installation.

4. Position the digital level controller so the access hole is on the bottom of the instrument.

3-8

Refer to figure 3-8 for parts identification except where otherwise indicated. The digital level controller requires an insulator assembly when temperatures exceed the limits shown in figure 3-9. A torque tube shaft extension is required for a 249 Series sensor when using an insulator assembly. February 2007

Installation INSULATOR (KEY 57)

SHAFT EXTENSION (KEY 58)

SET SCREWS (KEY 60)

WASHER (KEY 78)

SHAFT COUPLING (KEY 59)

HEX NUTS (KEY 34)

CAP SCREWS (KEY 63)

MN28800 20A7423-C B2707 / IL

MOUNTING STUDS (KEY 33)

SENSOR

3 DIGITAL LEVEL CONTROLLER

!40 800

!30 !20

AMBIENT TEMPERATURE ( C) 10 20 30 40 50 !10 0

TOO HOT

HEAT INSULATOR REQUIRED

400

425 400 300 200 100

NO HEAT INSULATOR NECESSARY

!100 TOO

!325 COLD !40 !20

HEAT INSULATOR REQUIRED 20 40 60 80

!200 100 120

140

160 176

PROCESS TEMPERATURE ( C)

PROCESS TEMPERATURE ( F)

Figure 3-8. Digital Level Controller Mounting on Sensor in High Temperature Applications

2. Slide the access handle to the locked position to expose the access hole. Press on the back of the handle as shown in figure 3-5 then slide the handle toward the front of the unit. Be sure the locking handle drops into the detent.

3. Remove the hex nuts from the mounting studs.

AMBIENT TEMPERATURE ( F)

STANDARD TRANSMITTER

39A4070-B A5494-1/IL

NOTES: 1 FOR PROCESS TEMPERATURES BELOW !29 C (!20 F) AND ABOVE 204 C (400 F) SENSOR MATERIALS MUST BE APPROPRIATE FOR THE PROCESS Â&#x2014; SEE TABLE 1-4. 2. IF AMBIENT DEW POINT IS ABOVE PROCESS TEMPERATURE, ICE FORMATION MIGHT CAUSE INSTRUMENT MALFUNCTION AND REDUCE INSULATOR EFFECTIVENESS.

Figure 3-9. Guidelines for Use of Optional Heat Insulator Assembly

CAUTION Measurement errors can occur if the torque tube assembly is bent or misaligned during installation.

1. For mounting a digital level controller on a 249 Series sensor, secure the shaft extension to the sensor torque tube shaft via the shaft coupling and set screws, with the coupling centered as shown in figure 3-8.

February 2007

4. Position the insulator on the digital level controller, sliding the insulator straight over the mounting studs.

5. Install 4 washers (key 78) over the studs. Install the four hex nuts and tighten.

6. Carefully slide the digital level controller with the attached insulator over the shaft coupling so that the access hole is on the bottom of the digital level controller.

7. Secure the digital level controller and insulator to the torque tube arm with four cap screws.

8. Tighten the cap screws to 10 N m (88.5 lbf in).

3-9

DLC3000 Series 1

230 RL 1100

POWER SUPPLY

Reference meter for calibration or monitoring operation. May be a voltmeter across 250 ohm resistor or a current meter.

3 Signal loop may be grounded at any point or left ungrounded.

A HART-based communicator may be connected at any termination point in the signal loop. Signal loop must have between 250 and 1100 ohms load for communication.

E0363 / IL

NOTE: THIS REPRESENTS THE TOTAL SERIES LOOP RESISTANCE. 1

Figure 3-10. Connecting a Communicator to the Digital Level Controller Loop

Electrical Connections

Select wiring and/or cable glands that are rated for the environment of use (such as hazardous area, ingress protection and temperature). Failure to use properly rated wiring and/or cable glands can result in personal injury or property damage from fire or explosion.

Load (Ohms)

WARNING

Maximum Load = 43.5 X (Available Supply Voltage ! 12.0) 783

Operating Region 250

0 10 E0284 / IL

Proper electrical installation is necessary to prevent errors due to electrical noise. A resistance between 230 and 1100 ohms must be present in the loop for communication with a HART-based communicator. Refer to figure 3-10 for current loop connections.

Power Supply To communicate with the digital level controller, you need a 17.75 volt dc minimum power supply. The power supplied to the transmitter terminals is determined by the available supply voltage minus the product of the total loop resistance and the loop current. The available supply voltage should not drop below the lift-off voltage. (The lift-off voltage is the

3-10

LIFT-OFF SUPPLY VOLTAGE (VDC)

Figure 3-11. Power Supply Requirements and Load Resistance

minimum Â&#x201C;available supply voltageÂ&#x201D; required for a given total loop resistance). Refer to figure 3-11 to determine the required lift-off voltage. If you know your total loop resistance you can determine the lift-off voltage. If you know the available supply voltage, you can determine the maximum allowable loop resistance. If the power supply voltage drops below the lift-off voltage while the transmitter is being configured, the transmitter may output incorrect information. The dc power supply should provide power with less than 2% ripple. The total resistance load is the sum of the resistance of the signal leads and the load February 2007

Installation resistance of any controller, indicator, or related pieces of equipment in the loop. Note that the resistance of intrinsic safety barriers, if used, must be included.

4 TO 20 MA LOOP CONNECTIONS

TEST CONNECTIONS

Field Wiring

RTD CONNECTIONS

Note For intrinsically safe applications, refer to the instructions supplied by the barrier manufacturer.

INTERNAL GROUND CONNECTION

1/2-INCH NPT CONDUIT CONNECTION

FRONT VIEW

WARNING To avoid personal injury or property damage caused by fire or explosion, remove power to the instrument before removing the digital level controller cover in an area which contains a potentially explosive atmosphere or has been classified as hazardous.

EXTERNAL GROUND CONNECTION W8041 / IL

REAR VIEW

Figure 3-12. Digital Level Controller Terminal Box

All power to the digital level controller is supplied over the signal wiring. Signal wiring need not be shielded, but use twisted pairs for best results. Do not run unshielded signal wiring in conduit or open trays with power wiring, or near heavy electrical equipment. If the digital controller is in an explosive atmosphere, do not remove the digital level controller covers when the circuit is alive, unless in an intrinsically safe installation. Avoid contact with leads and terminals. To power the digital level controller, connect the positive power lead to the + terminal and the negative power lead to the ! terminal as shown in figure 3-12.

February 2007

CAUTION Do not apply loop power across the T and + terminals. This can destroy the 1 Ohm sense resistor in the terminal box. Do not apply loop power across the Rs and Â&#x2014; terminals. This can destroy the 50 Ohm sense resistor in the electronics module.

3-11

DLC3000 Series When wiring to screw terminals, the use of crimped lugs is recommended. Tighten the terminal screws to ensure that good contact is made. No additional power wiring is required. All digital level controller covers must be fully engaged to meet explosion proof requirements. For ATEX approved units, the terminal box cover set screw must engage one of the recesses in the terminal box beneath the terminal box cover.

Grounding

WARNING Personal injury or property damage can result from fire or explosion caused by the discharge of static electricity when flammable or hazardous gases are present. Connect a 14 AWG (2.1 mm2) ground strap between the digital level controller and earth ground when flammable or hazardous gases are present. Refer to national and local codes and standards for grounding requirements.

The digital level controller will operate with the current signal loop either floating or grounded. However, the extra noise in floating systems affects many types of readout devices. If the signal appears noisy or erratic, grounding the current signal loop at a single point may solve the problem. The best place to ground the loop is at the negative terminal of the power supply. As an alternative, ground either side of the readout device. Do not ground the current signal loop at more than one point.

Shielded Wire Recommended grounding techniques for shielded wire usually call for a single grounding point for the shield. You can either connect the shield at the power supply or to the grounding terminals, either internal or external, at the instrument terminal box shown in figure 3-12.

Power/Current Loop Connections Use ordinary copper wire of sufficient size to ensure that the voltage across the digital level controller terminals does not go below 12.0 volts dc. Connect the current signal leads as shown in figure 3-10. After making connections, recheck the polarity and correctness of connections, then turn the power on.

3-12

RTD Connections An RTD that senses process temperatures may be connected to the digital level controller. This permits the instrument to automatically make specific gravity corrections for temperature changes. For best results, locate the RTD as close to the displacer as practical. For optimum EMC performance, use shielded wire no longer than 3 meters (9.8 feet) to connect the RTD. Connect only one end of the shield. Connect the shield to either the internal ground connection in the instrument terminal box or to the RTD thermowell. Wire the RTD to the digital level controller as follows (refer to figure 3-12):

Two-Wire RTD Connections 1. Connect a jumper wire between the RS and R1 terminals in the terminal box. 2. Connect the RTD to the R1 and R2 terminals.

Three-Wire RTD Connections 1. Connect the 2 wires which are connected to the same end of the RTD to the RS and R1 terminals in the terminal box. Usually these wires are the same color. 2. Connect the third wire to terminal R2. (The resistance measured between this wire and either wire connected to terminal RS or R1 should read an equivalent resistance for the existing ambient temperature. Refer to the RTD manufacturerÂ&#x2019;s temperature to resistance conversion table.) Usually this wire is a different color from the wires connected to the RS and R1 terminals.

Communication Connections WARNING Personal injury or property damage caused by fire or explosion may occur if this connection is attempted in an area which contains a potentially explosive atmosphere or has been classified as hazardous. Confirm that area classification and atmosphere conditions permit the safe removal of the terminal box cap before proceeding. The 375 Field Communicator interfaces with the Type DLC3000 digital level controller from any wiring termination point in the 4Â&#x2013;20 mA loop (except across the power supply). If you choose to connect the HART communicating device directly to the instrument, February 2007

Installation RLead ++

Instrument No. 1

! RLead

Readout Device No. 1

+ Battery Backup

dc Power Supply

! !

Instrument No. 2

+ RLead ! RLead

Between 230 and 1100 if no Load Resistor

E0364 / IL

Readout Device No. 2 To Additional Instruments

Figure 3-13. Multichannel Installations

attach the device to the loop + and ! terminals inside the terminal box to provide local communications with the instrument.

Voltage (on test meter) 1000 = milliamps example: Test meter Voltage X 1000 = Loop Milliamps

Test Connections WARNING Personal injury or property damage caused by fire or explosion may occur if the following procedure is attempted in an area which contains a potentially explosive atmosphere or has been classified as hazardous. Confirm that area classification and atmosphere conditions permit the safe removal of the terminal box cap before proceeding.

Test connections inside the terminal box can be used to measure loop current across an internal 1 ohm resistor. 1. Remove the terminal box cap. 2. Adjust the test meter to measure a range of 0.001 to 0.1 volts. 3. Connect the positive lead of the test meter to the + connection and the negative lead to the T connection inside the terminal box. 4. Measure Loop current as: February 2007

0.004 X1000 = 4.0 milliamperes 0.020 X 1000 = 20.0 milliamperes 5. Remove test leads and replace the terminal box cover.

Multichannel Installations You can connect several instruments to a single master power supply as shown in figure 3-13. In this case, the system may be grounded only at the negative power supply terminal. In multichannel installations where several instruments depend on one power supply, and the loss of all instruments would cause operational problems, consider an uninterruptible power supply or a back-up battery. The diodes shown in figure 3-13 prevent unwanted charging or discharging of the back-up battery. If several loops are connected in parallel, make sure the net loop impedance does not reach levels that would prevent communication. Note that to provide a 4!20 mA analog output signal, the DLC3010 must use HART polling address 0. Therefore, if a multichannel installation is used with all transmitters in 4!20 mA output mode, some means must be provided to isolate an individual transmitter for configuration or diagnostic purposes. A multichannel installation is most useful if the instruments are also in multi-drop mode and all signaling is done by digital polling.

3-13

DLC3000 Series Alarm Jumper

Each digital level controller continuously monitors its own performance during normal operation. This automatic diagnostic routine is a timed series of checks repeated continuously. If diagnostics detect a failure in the electronics, the instrument drives its output to either below 3.70 mA or above 22.5 mA, depending on the position (HI/LO) of the alarm jumper. An alarm condition occurs when the digital level controller self-diagnostics detect an error that would render the process variable measurement inaccurate, incorrect, or undefined, or a user defined threshold is violated. At this point the analog output of the unit is driven to a defined level either above or below the nominal 4!20 mA range, based on the position of the alarm jumper. On encapsulated electronics 14B5483X042 and earlier, if the jumper is missing, the alarm is indeterminate, but usually behaves as a FAIL LOW selection. On encapsulated electronics 14B5483X052 and later, the behavior will default to FAIL HIGH when the jumper is missing. Alarm Jumper Locations Without a meter installed The alarm jumper is located on the front side of the electronics module on the electronics side of the digital level controller housing, and is labeled FAIL MODE. With a meter installed The alarm jumper is located on the LCD faceplate on the electronics module side of the digital level controller housing, and is labeled FAIL MODE.

Changing Jumper Position WARNING Personal injury or property damage caused by fire or explosion may occur if the following procedure is attempted in an area which contains a potentially explosive atmosphere or has been classified as hazardous. Confirm that area classification and atmosphere conditions permit the safe removal of the instrument cover before proceeding. Use the following procedure to change the position of the alarm jumper: 1. If the digital level controller is installed, set the loop to manual.

3-14

2. Remove the housing cover on the electronics side. Do not remove the cover in explosive atmospheres when the circuit is alive. 3. Set the jumper to the desired position. 4. Replace the cover. All covers must be fully engaged to meet explosion proof requirements. For ATEX approved units, the set screw on the transducer housing must engage one of the recesses in the cover.

Loop Test

(2!2)

Loop test can be used to verify the controller output, the integrity of the loop, and the operations of any recorders or similar devices installed in the loop. To initiate a loop test, perform the following procedure: 1. Connect a reference meter to the controller. To do so, either connect the meter to the test connections inside the terminal box (see the Test Connections procedure) or connect the meter in the loop as shown in figure 3-10. 2. From the Online menu, select Diag/Services, and Loop Test, to prepare to perform a loop test. 3. Select OK after you set the control loop to manual. The Field Communicator displays the loop test menu. 4. Select a discreet milliamp level for the controller to output. At the Â&#x201C;Choose analog outputÂ&#x201D; prompt, select 4 mA, 20 mA, or Other to manually input a value between 4 and 20 milliamps. 5. Check the reference meter to verify that it reads the value you commanded the controller to output. If the readings do not match, either the controller requires an output trim, or the meter is malfunctioning. After completing the test procedure, the display returns to the loop test screen and allows you to choose another output value or end the test.

February 2007

Installation START HERE

A B

Unpack the HART Tri-Loop

Install the HART Tri-Loop. See HART Tri-Loop product manual

Review the HART Tri-Loop Product Manual

Digital level controller Installed?

Mount the HART Tri-Loop to the DIN rail.

Install the digital level controller.

Wire the digital level controller to the HART Tri-Loop.

Set the digital level controller Burst Option

Install Channel 1 wires from HART Tri-Loop to the control room.

Set the digital level controller Burst Mode

(Optional) Install Channel 2 and 3 wires from HART Tri-Loop to the control room.

Check troubleshooting procedures in HART Tri-Loop product manual.

DONE

Figure 3-14. HART R Tri-Loopt Installation Flowchart

Installation in Conjunction with a Rosemount Model 333 HARTR Tri-Loopt HARTR-to-Analog Signal Converter Use the Type DLC3000 digital level controller in operation with a Rosemount Model 333 HART Tri-Loop HART-to-Analog Signal Converter to acquire an independent 4!20 mA analog output signal for the process variable, % range, electronics temperature, and process temperature. The HART Tri-Loop divides the digital signal and outputs any or all of these variables into as many as three separate 4!20 mA analog channels. Refer to figure 3-14 for basic installation information. Refer to the Model 333 HART Tri-Loop HART-to-Analog Signal Converter Product Manual for complete installation information.

February 2007

Pass system test?

Yes

E0365 / IL

Configure the HART Tri-Loop to receive digital level controller burst commands

Commissioning the Digital Level Controller for use with the HARTR Tri-Loopt To prepare the digital level controller for use with a Model 333 HART Tri-Loop, you must configure the digital level controller to burst mode, and select the dynamic variables to burst. In burst mode, the digital level controller provides digital information to the HART Tri-Loop HART-to-Analog Signal Converter. The HART Tri-Loop converts the digital information to a 4 to 20 mA analog signal. The HART Tri-Loop divides the signal into separate 4 to 20 mA loops for the primary (PV), secondary (SV), tertiary (TV), and quaternary (QV) variables. Depending upon the burst option selected, the digital level controller will burst the variables as shown in table 3-6. The DLC3010 status words are available in the HART Burst messages. However, the Tri-Loop cannot be configured to monitor them directly. To commission a Type DLC3010 digital level controller for use with a HART Tri-Loop, perform the following procedure.

3-15

DLC3000 Series Table 3-6. Burst Variables Sent by Type DLC3010 BURST OPTION

VARIABLE

VARIABLE BURST(1)

BURST COMMAND

Read PV

Primary

Process variable (EU)

Read PV mA and % Range

Primary

Process variable (mA)

Secondary

Percent range (%)

Primary

Process variable (EU)

Secondary

Electronics temperature (EU)

Tertiary

Process temperature (EU)

Quaternary

Not used

Read Dynamic Vars

1. EU engineering units; mA current in milliamperes; % percent

3-16

Set the Burst Operation

(4-3-1-7)

1. From the Online menu, select Detailed Setup, Device Information, HART, and Burst Option. 2. Select the desired burst option and press ENTER

3. From the Hart menu, select Burst Mode. 4. Select On to enable burst mode and press ENTER. 5. Select SEND to download the new configuration information to the digital level controller.

February 2007

Setup and Calibration 4-4

Section 4 Setup and Calibration Initial Setup Preliminary Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5

Write Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5

Level Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5

Using the Setup Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5

Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7

Calibration Introduction: Calibration of Smart Instruments . . . . . . . . . . . . . . . . . . . . . . .

4-8

Quick Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9

PV Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9

Procedures that Affect the Zero of the PV Calculation . . . . . . . . . . . . . . . . . . .

4-9 4-9 4-10

Mark Dry Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trim PV Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedures that Affect the Gain of the PV Calculation . . . . . . . . . . . . . . . . . . . Two-Point Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single-Point Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet/Dry Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weight-Based Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theoretical Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11 4-11 4-11 4-12 4-12 4-13

Ranging Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13

Temperature Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13

Manual Entry of Process Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14

Output DAC Calibration:Scaled D/A Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14

Calibration Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-15

Level Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-15

Interface Application February 2007

4-1

DLC3000 Series

with standard displacer and torque tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with an overweight displacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-15 4-16

Density Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-17

Calibration at Process Conditions (Hot Cut-Over) when input cannot be varied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-18

Entering Theoretical Torque Tube Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-19

Accuracy Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-19

Effect of Proportional Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-19

Density Variations in Interface Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-20

High Process Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-20

Temperature Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-20

Detailed Setup Menu and Quick Key Sequence Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Cover Setting Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-21

Setting Up the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-21

Entering Displacer Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-21

Entering Torque Tube Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-21

Specifying Instrument Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-21

Process Temperature Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering RTD Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Temperature Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-21 4-21 4-22

Setting Up the Instrument for the Application . . . . . . . . . . . . . . . . . . . . . . . .

4-22

Selecting the Process Variable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-22

Setting PV Engineering Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-22 4-22 4-22 4-22

Process Variable Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Displacer Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Tube Rate Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting PV Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2

Instrument Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering the Upper and Lower Range Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Zero and Span . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-22 4-22 4-22 4-22 4-23

Setting Level Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-23

Setting PV Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-24

Setting Input Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-24

Setting the Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-25 February 2007

Setup and Calibration Setting Up the LCD Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-26

Testing the Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-26

Setting Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-26

Setting Process Variable Alarm Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-26

Process Variable High Alarm Process Variable High High Alarm Process Variable Low Alarm Process Variable Low Low Alarm Process Variable Alarm Deadband

Setting Temperature Alarm Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-27

Temperature High Alarm Temperature Low Alarm Electronics Temperature High Alarm Electronics Temperature Low Alarm Temperature Alarm Deadband

Enabling Process Variable Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-27

PV High Alarm PV High High Alarm PV Low Alarm PV Low Low Alarm

Enabling Temperature Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-28

PV Temperature High Alarm PV Temperature Low Alarm Electronics Temperature High Alarm Electronics Temperature Low Alarm

Entering HARTR Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-28

HART Tag Polling Address Message Descriptor Date

Multidrop Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-29

Temperature Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-30

February 2007

4-3

DLC3000 Series Initial Setup If a Type DLC3010 digital level controller ships from the factory mounted on a 249 Series sensor, initial setup and calibration is not necessary. The factory enters the sensor data, couples the instrument to the sensor, and calibrates the instrument and sensor combination.

Note If you received the digital level controller mounted on the sensor with the displacer blocked, or if the displacer is not connected, the instrument will be coupled to the sensor and the lever assembly unlocked. To place the unit in service, if the displacer is blocked, remove the rod and block at each end of the displacer and check the instrument calibration. (If the Â&#x201C;factory calÂ&#x201D; option was ordered, the instrument will be precompensated to the process conditions provided on the requisition, and will not appear to be calibrated if checked against room temperature 0 and 100% water level inputs).

If the displacer is not connected, hang the displacer on the torque tube, and re-zero the instrument by performing the Mark Dry Coupling procedure. If you received the digital level controller mounted on the sensor and the displacer is not blocked (such as in skid mounted systems), the instrument will not be coupled, to the sensor, and the lever assembly will be locked. To place the unit in service, unlock the lever assembly and couple the instrument to the sensor. Then perform the Mark Dry Coupling procedure. To review the configuration data entered by the factory, connect the instrument to a 24 volt dc power

4-4

supply as shown in figure 3-10. Connect the 375 Field Communicator to the instrument and turn it on. From the Online menu select Review then select Device Params (Device Parameters). You can then page through the configuration data using the NEXT and PREV keys. If your application data has changed since the instrument was factory-configured, refer to the Detailed Setup section for instructions on modifying configuration data. For instruments not mounted on a level sensor or when replacing an instrument, initial setup consists of entering sensor information. The next step is coupling the sensor to the digital level controller. When the digital level controller and sensor are coupled, the combination may be calibrated. Sensor information includes displacer and torque tube information, such as: Length units (meters, inches, or centimeters) Volume units (cubic inches, cubic millimeters, or milliliters) Weight units (kilograms, pounds, or ounce) Displacer Length Displacer Volume Displacer Weight Displacer Driver Rod Length (moment arm) (see table 4-1) Torque Tube Material Instrument mounting (right or left of displacer) Measurement Application (level, interface, or density)

Note A sensor with an N05500 torque tube may have NiCu on the nameplate as the torque tube material.

February 2007

Setup and Calibration Table 4-1. Moment Arm (Driver Rod) Length(1)

ASSEMBLY PRESSURE RATING DISPLACER PRESSURE RATING

SENSOR TYPE(2)

DISPLACER VOLUME SENSOR TYPE

INCH

249

203

8.01

249B

203

8.01

249BF

203

8.01

249BP

203

8.01

249C

169

6.64

249CP

169

6.64

249K

267

10.5

249L

229

9.01

249N

267

10.5

249P (CL125!CL600)

203

8.01

249P (CL900!CL2500)

229

9.01

DISPLACER WEIGHT

76543210 PSI

249B 1500 PSI

285/100 F WCB STL

2 x 32 INCHES

MONEL

4 3/4 LBS

103 CU-IN

K MONEL/STD

316 SST

TRIM MATERIAL TORQUE TUBE MATERIAL DISPLACER SIZE (DIAMETER X LENGTH)

ASSEMBLY MATERIAL

DISPLACER MATERIAL 23A1725-E sht 1 E0366 / IL

Figure 4-1. Example Sensor Nameplate

Preliminary Considerations

MOMENT ARM mm

249V

(Special)(1)

See serial card

249V (Std)

343

13.5

249W

203

8.01

1. Moment arm (driver rod) length is the perpendicular distance between the vertical centerline of the displacer and the horizontal centerline of the torque tube. See figure 4-2. If you cannot determine the driver rod length, contact your Emerson Process Management sales office and provide the serial number of the sensor. 2. This table applies to sensors with vertical displacers only. For sensor types not listed, or sensors with horizontal displacers, contact your Emerson Process Management sales office for the driver rod length. For other manufacturersÂ&#x2019; sensors, see the installation instructions for that mounting.

Write Lock To setup and calibrate the instrument, write lock must be set to Writes Enabled with the Field Communicator. (Write Lock is reset by a power cycle. If you have just powered up the instrument Writes will be enabled by default.) To change the write lock, press the Hot Key on the Field Communicator. Select Write Lock then select Writes Enabled.

Level Offset (3-3-3) The Level Offset parameter should be cleared to zero before running Setup Wizard. To clear Level Offset, select Basic Setup, PV Setup then select Level Offset. Enter the value 0.0 and press Enter and Send.

Setup Wizard (3-1)

Note Place the loop into manual operation before making any changes in setup or calibration.

February 2007

VERTICAL CL OF DISPLACER

MOMENT ARM LENGTH

E0283 / IL

HORIZONTAL CL OF TORQUE TUBE

Figure 4-2. Method of Determining Moment Arm from External Measurements

A Setup Wizard is available to aid initial setup. To use the Setup Wizard, from the Online Menu select Basic Setup then Setup Wizard. Follow the prompts on the Field Communicator display to enter information for the displacer, torque tube, and digital measurement units. Most of the information is available from the sensor nameplate, shown in figure 4-1. The moment arm is the effective length of the driver rod and depends upon the sensor type. For a 249 Series sensor, refer to table 4-1 to determine driver rod length. For a special sensor, refer to figure 4-2. 1. You are prompted for displacer length, weight, volume units and values, and moment arm length (in the same units chosen for displacer length).

4-5

DLC3000 Series 2. You are asked to choose Instrument Mounting (left or right of displacer, refer to figure 3-7). 3. You are asked to select measurement application (level, interface, or density).

Note For interface applications, if the 249 is not installed on a vessel, or if the cage can be isolated, calibrate the instrument with weights, water, or other standard test fluid, in level mode. After calibrating in level mode, the instrument can be switched to interface mode. Then, enter the actual process fluid specific gravity(s) and range values.

If the 249 sensor is installed and must be calibrated in the actual process fluid(s) at operating conditions, enter the final measurement mode and actual process fluid data now.

Note If Setup Wizard aborts on step 6, clear the Level Offset parameter before restarting Setup Wizard. 7. The default values of the alarm variables will be set as follows: Direct-Acting Instrument (Span = Upper Range Value ! Lower Range Value Alarm Variable

Default Alarm Value

Hi-Hi Alarm

Upper Range Value

Hi Alarm

95% span + Lower Range Value

Lo Alarm

5% span + Lower Range Value

Lo-Lo Alarm

Lower Range Value

Reverse-Acting Instrument (Span = Lower Range Value ! Upper Range Value Alarm Variable

Default Alarm Value

Hi-Hi Alarm

Lower Range Value

Hi Alarm

95% span + Upper Range Value

Lo Alarm

5% span + Upper Range Value

Lo-Lo Alarm

Upper Range Value

The PV alarm deadband is set to zero. The process variable alarms are all disabled. a. If you choose Level or Interface, the default process variable units are set to the same units chosen for displacer length. The default upper range value is set to equal the displacer length and the default lower range value is set to zero. b. If you choose Density, the default process variable units are set to SGU (Specific Gravity Units). The default upper range value is set to 1.0 and the default lower range value is set to 0.1 . 4. You are asked, Do you wish to make the instrument direct or reverse acting? Choosing reverse acting will swap the default values of the upper and lower range values (the process variable values at 20 mA and 4 mA). In a reverse acting instrument, the loop current will decrease as the fluid level increases. 5. You are given the opportunity to modify the default value for the process variable engineering units. 6. You are now given the opportunity to edit the default values that were entered for the upper range value (PV Value at 20 mA) and lower range value (PV Value at 4 mA).

4-6

8. You are asked if temperature compensation is to be used. a. If you select No Temperature Compensation If Density mode was chosen, the Setup Wizard is complete. If specific gravity temperature compensation tables exist in the instrument, you will be asked if it s ok to overwrite them with single values. You are prompted to enter the specific gravity of the process fluid (if interface mode, the specific gravities of the upper and lower process fluids).

Note If you are using water or weights for calibration, enter a specific gravity of 1.0 SGU. For other test fluids, enter the specific gravity of the fluid used.

b. If you select Temperature Compensation , February 2007

Setup and Calibration two data tables are available that may be entered in the instrument to provide specific gravity correction for temperature (see tables 4-3 and 4-4). For interface level applications, both tables are used. For level measurement applications, only the lower specific gravity table is used. Neither table is used for density applications. Both tables may be edited during detailed setup. The Setup Wizard asks if the tables should be used. If not, you must supply a single point specific gravity value (or two single point values for interface applications).

Note The existing tables may need to be edited to reflect the characteristics of the actual process fluid.

If Density mode was NOT chosen, you will be presented with the current specific gravity temperature compensation table (or lower fluid specific gravity temperature compensation table if interface application) for editing. You can accept the current table(s), modify an individual entry, or enter a new table manually. For an interface application, the user can switch between the upper and lower fluid tables. You are prompted to choose a torque tube material. The instrument loads the default torque tube temperature compensation table for the material chosen. If you choose Unknown for the material, the N05500 temperature compensation table is loaded. If you choose Special the current table in the instrument will be left unchanged, but the label for the material is changed to Special . This feature allows a special user table to be retained without overwriting, but does not allow it to be copied to a stored configuration.

February 2007

You are presented with the torque-tube temperature compensation table for editing. You can accept the table, edit an individual table entry, load a temperature compensation table for a different torque tube material, or enter a new table manually. If a temperature compensation table for a different material is chosen, the torque tube material will be updated to reflect the new material chosen. If a new table is entered manually, or an individual entry is modified, then the torque tube material will be changed to Special.

Note

In firmware version 07 and 08, the data tables for torque-tube correction are simply stored without implementation. The user may use the information to pre-compensate the measured torque-tube rate manually.

Coupling After entering the sensor information, the Setup Wizard prompts you to couple the digital level controller to the sensor. If not already coupled, perform the following procedure to couple the digital level controller to the sensor. 1. Slide the access handle to the locked position to expose the access hole. Press on the back of the handle as shown in figure 3-5 then slide the handle toward the front of the unit. Be sure the locking handle drops into the detent. 2. Set the displacer to the lowest possible process condition, (i.e. lowest water level or minimum specific gravity) or replace the displacer by the heaviest calibration weight.

4-7

DLC3000 Series Table 4-2. Relationships in the DLC3000 that can be User Calibrated or Configured

Note Interface or density applications with displacer/torque tube sized for a small total change in specific gravity are designed to be operated with the displacer always submerged. In these applications, the torque rod is sometimes resting on a stop while the displacer is dry. The torque tube does not begin to move until a considerable amount of liquid has covered the displacer. In this case, couple with the displacer submerged in the fluid with the lowest density and the highest process temperature condition, or with an equivalent condition simulated with the calculated weights.

If the sizing of the sensor results in a proportional band greater than 100% (total expected rotational span greater than 4.4 degrees), couple the transmitter to the pilot shaft while at the 50% process condition to make maximum use of available transmitter travel ($6_). The Mark Dry Coupling procedure is still performed at the zero buoyancy (or zero differential buoyancy) condition.

3. Insert a 10 mm deep well socket through the access hole and onto the torque tube shaft clamp nut. Tighten the clamp nut to a maximum torque of 2.1 N m(18 lbf in). 4. Slide the access handle to the unlocked position. (Press on the back of the handle as shown in figure 3-5 then slide the handle toward the rear of the unit.) Be sure the locking handle drops into the detent.

Calibration Introduction: Calibration of Smart Instruments Analog instruments generally have only one interface that can be calibrated by the user. A zero and span output calibration is normally performed at the

4-8

Torque Tube Rate Reference (dry) Coupling Point Driver Rod Length Displacer Volume

The scale factor between the internal digital representation of the measured pilot shaft rotation and the physical torque input to the sensor. The angle of pilot shaft rotation associated with the zero buoyancy condition. (The zero reference for the input of the PV calculation). The scale factor (moment arm) between a force input to the sensor driver rod and the torque developed as input to the torque tube. The scale factor relating the density of the process fluid to the maximum force that can be produced as an input to the driver rod of the sensor.

The density of the process fluid normalized to the density of water at reference conditions. The scale factor that transforms displacer volume and measured buoyancy into a level signal normalized to displacer length.

Displacer Length

The scale factor to convert normalized level to level on the displacer in engineering units.

URV (Upper Range Value)

The zero reference for the output of the PV calculation, referred to the location of the bottom of the displacer at zero buoyancy condition. The value of computed process variable at which a 20 mA output (100% Range) is desired.

LRV (Lower Range Value)

The value of computed process variable at which a 4 mA output (0% Range) is desired.

DAC Trim

The gain and offset of the D/A converter which executes the digital commands to generate output

Elec Temp Offset

Bias to improve the accuracy of the ambient temperature measurement used to provide temperature compensation for the mechanical-to-electronic transducer.

Proc Temp Offset

Bias to improve the accuracy of the (RTD) temperature measurement used to provide compensation for process-temperature-related density changes.

Level Offset

corresponding two input conditions. Zero/Span calibration is very simple to use, but provides little versatility. If the 0% and 100% input conditions are not available to the user, a calibration can sometimes be accomplished, but the gain and offset adjustments will likely interact, requiring considerable iteration to achieve accuracy. In contrast, intelligent instruments have many interfaces that can be calibrated or scaled by the user, with consequent increased versatility. Refer to table 4-2 for a list of relationships in the DLC3000 that can be calibrated or configured by the user. Note that not all relationships are listed here. These parameters are factory-set to the most common values for the 249 Series products. Therefore, for the bulk of units sold in simple level applications, it is possible to accept the defaults and proceed to a simple zero-and-span operation. If any of the advanced features of the instrument are to be used, accurate sensor and test fluid information should generally be entered before beginning the calibration. February 2007

Setup and Calibration Quick Calibration The following procedure may be used to calibrate the instrument as an analog transmitter replacement. The output 4 and 20 mA conditions will be related to a given pair of mechanical input conditions only, the PV in engineering units will not be calibrated. This approach will give satisfactory results for many of the simple level measurement applications encountered.

Note This procedure assumes that you are using the instrument in Level Measurement Mode, even if the process is interface or density. The SG value used for Level is the actual fluid SG, the SG value used for Interface is the difference between the SGs upper and lower fluid, and, the SG value entered for Density is the difference between the minimum and maximum density range of the application.

1. Connect a 24 V dc supply and make there is between 230 and 1100 Ohms series resistance in the loop. Hook up a 375 Field Communicator (or other HART master) across the instrument terminals or across the series resistor and establish communication with the transmitter. 2. Enter the mounting sense (4-1-1-1-2), then SEND. 3. Set Level Offset to zero (3-3-3); then SEND. 4. Set PV is (3-3-6) to LEVEL, then SEND. 5. Set Specific Gravity (3-3-5) to the difference between SGs of the upper and lower fluids. 6. Set up the lowest process condition (or hang weight equal to the displacer weight ! minimum buoyancy).

PV Sensor Calibration If the advance capabilities of the transmitter are to be used, it is necessary to calibrate the PV sensor instead of using the zero and span approach. The following is a description of the functionality of the various HART command procedures for calibrating the sensor. Subsequently, we will relate which procedures to use in a given scenario, and in which order to apply them.

Procedures that Affect the Zero of the PV Calculation Mark Dry Coupling (3-2-1)

This procedure captures the current pilot shaft rotation value and associates it with the zero buoyancy or dry displacer condition. (If the pilot shaft is not already physically coupled to the transmitter, perform the mechanical procedure under Coupling first). The Mark Dry Coupling procedure prompts you to hang the displacer, unlock the lever arm, and verify that the displacer is completely dry. From the Online menu select Basic Setup, Sensor Calibrate, and Mark Dry Coupling. Follow the prompts on the Field Communicator to mark the dry coupling point.

Note If the handle on the coupling access door is in the position towards the front of the transmitter, the coupling access hole is open and the lever is locked (pinned in the neutral travel position). In this condition, the true at-rest position of the linkage may not be captured correctly. Moving the handle to the rear of the transmitter closes the coupling-access hole and unlocks the lever.

7. Couple to the 249 Series sensor and close the access door (this unlocks the lever assembly). 8. Mark Dry-Coupling point (this marks zero differential buoyancy). (3-2-1). 9. Set Zero (3-3-2-5-1). 10. Set up the highest process condition (or hang a weight equal to the displacer weight minus the maximum buoyancy). 11. Set Span (3-3-2-5-2). 12. Set Meter Type to % Range Only (4-2-2-2-3). February 2007

The captured number can be read back as the Reference Coupling Point . It functions as the pre-calculation zero for the process measurement algorithm. This procedure can be run either before or after most of the gain calibrations, (with the exception of the single-point calibration, for which coupling point must have been marked first). However, the procedure returns a valid result at only one input condition ! zero buoyancy, although in Level mode, it is equivalent to zero differential buoyancy.

4-9

DLC3000 Series Trim PV Zero (3-2-5)

This procedure computes and adds an offset to the computed process variable, so that the computed value matches the user s external observation of the process measurement. For example (see figure 4-4), if the bottom of the displacer is 4 feet above the bottom of the vessel, and the user s observation is measured from the bottom of the vessel, a Level Offset value of 4 feet would be computed. The liquid level indicated by the PV would then be referenced to the bottom of the vessel. If the Level Offset is 0.0, the reference for the PV measurement is understood to be the location of the bottom of the displacer at the dry condition. Other useful references include the center of the displacer, the system set-point, or even sea level. (It may not be possible to use sea level as a reference in many cases, as there is currently a 100 ft. magnitude limit on the Level Offset parameter). The Level Offset parameter can also be edited manually under Basic Setup, PV Setup, Level Offset (3-3-3). If the computed process variable is biased due to the inability to mark the reference coupling point correctly, (which can happen when the sensor hardware is oversized to provide additional gain for some interface-level applications), the Level Offset (computed by Trim PV Zero or entered manually) can be used to trim out that bias. However, the reasonableness limits (USL, LSL) on the range values are also shifted by the Level Offset. If the magnitude of the Level Offset value exceeds 20% of the displacer length, at least one of the desired range values will no longer be inside the legal range. Checking range values against the USL and LSL is only done when writing the range values, so in systems that use the DLC3000 DD, it is possible to temporarily remove the offset, adjust the range values, and replace the offset afterwards.

Note On systems that cannot access the Level Offset, and that write the range values automatically during initialization, (such as a DeltaVt system), it is not advisable to use Trim PV Zero to compensate for an invalid Reference Coupling Point. If a communication drop-out occurs, DeltaV will attempt to write unit and range data to the DLC3000. DeltaV will continuously repeat initialization attempts when a range value is rejected. The other parameters that are successfully written during each iteration will rapidly use up the write-cycle life of the NVM in the DLC3000 s microprocessor. The Level Offset is effectively a post-calculation zero. Therefore, the Trim PV Zero procedure should be performed after the gain calibration, but it may be run at any valid process condition. The range values should be set after running Trim PV Zero if it is being used to shift the zero reference away from the bottom of the displacer. The range values must be set before running Trim PV Zero if it is being used to compensate for an invalid Reference Coupling Point.

Note The Trim PV Zero command and Level Offset parameter are not available in density measurement mode at firmware revision 8. If displacer sizing for a density application results in an overweight displacer, it will be necessary to set the system up in Level or Interface measurement mode to calibrate effectively. The output of the instrument will only make sense in % Range units in such a case, since density units are not available in Level or Interface Mode. From the Online menu select Basic Setup, Sensor Calibrate, and Trim PV Zero. Follow the prompts on the Field Communicator. 1. Adjust the process condition or simulation to any valid and observable value.

4-10

February 2007

Setup and Calibration 2. Enter the external observation of the measurement in the current PV units. The Level Offset is computed and stored. 3. Recheck the upper and lower range values against the USL and LSL. If the offset is being added to shift the physical zero reference, shift the range values by the same amount. If you are trimming out a Reference Coupling Point calibration error, note whether one of the range values has become illegal. If so, it will be necessary to temporarily remove the Level Offset before running the Setup Wizard or changing the range values. If the range values will be written automatically by any system, do not use the Trim PV Zero command for trimming out a Reference Coupling Point error. Instead, use Level measurement mode, enter the delta SG between fluids as the system SG, and Mark Dry Coupling point at the lowest process condition. The Reference Coupling Point will then represent the zero differential buoyancy condition, and the algorithm will compute the interface level correctly.

Procedures that Affect the Gain of the PV Calculation Two-Point Sensor Calibration (3-2-2) This procedure is usually the most accurate method for calibrating the sensor. It uses independent observations of two valid process conditions, together with the hardware dimensional data and SG information, to compute the effective torque rate of the sensor. The two data points can be separated by any span between a few percent to 100%, as long as they remain on the displacer. Within this range, the calibration accuracy will generally increase as the data-point separation gets larger. Accuracy is also improved by running the procedure at process temperature, as the temperature effect on torque rate will be captured. (It is possible to use theoretical data to pre-compensate the measured torque rate for a target process condition when the calibration must be run at ambient conditions.) An external method of measuring the process condition is required. This procedure may be run before or after marking the coupling point. It adjusts the calculation gain only, so the change in PV output will track the change in input correctly after this procedure. However, there may be a constant bias in the PV until the Mark Dry Coupling procedure has been run. From the Online menu, select Basic Setup, Sensor Calibrate, and Two Point. Follow the prompts on the Field Communicator to calibrate the sensor. 1. Put the control loop in manual control. February 2007

2. Adjust the process condition to a value near the top or bottom of the valid range. 3. Enter this externally measured process condition in the current PV units. 4. Adjust the process condition to a value near the bottom or top of the valid range, but at a position that is toward the opposite end of the range relative to the condition used in step 5. Enter this second externally measured process condition in the current PV units. The sensor torque rate is now calibrated. Be sure to verify that there is no bias in the PV calculation and that the upper and lower range values are correct before returning the loop to automatic control. Single-Point Sensor Calibration (3-2-4) This procedure uses the previously stored Reference Coupling Point, together with a single independent observation of the current process condition, to compute the sensor torque rate. The Single-Point sensor calibration procedure is useful when the dry condition can only be established during a plant shut down, and/or the process condition is difficult to change during operation. (e.g., a top or side-mounted cageless sensor on a large vessel.) An accurate means of externally measuring the process condition is required. A valid Reference Coupling Point, (representing either zero buoyancy or zero differential buoyancy), must have been previously stored. Actions that improve the accuracy of this calibration method include: a. entering the correct displacer information, b. entering the actual SG of the process fluid, and c. running the Mark Dry Coupling procedure with the torque tube at the same temperature it will reach under process conditions, (or an accurate simulation of that rotation). From the Online menu, select Basic Setup, Sensor Calibrate, and Single Point. Follow the prompts on the Field Communicator to calibrate the instrument and sensor. 1. Allow the process condition to settle to a stable, non-zero value. 2. Enter the externally measured process condition in the current PV units. The sensor torque rate is calibrated. Be sure to verify that the upper and lower range values are correct before returning the loop to automatic control. There should be no bias in the PV calculation if the previously stored Reference Coupling Point was accurate.

4-11

DLC3000 Series

If the PV does not match the observed process after using this procedure, there is likely to be both a gain error and a bias error present. This is due to a change in the actual zero buoyancy rotation compared to the stored value. If it is possible, repeat the Mark Dry Coupling and Single-Point calibration sequence at process temperature to improve the accuracy.

changes. If the displacer information has been entered prior to beginning the procedure, the instrument will be able to compute reasonable weight value suggestions for the calibration. However, the only preliminary data essential for the correct calibration of the torque rate is the length of the driver rod being used for the calibration.

Wet/Dry Calibration (3-2-3)

Weight equivalent to the net displacer weight at two valid process conditions must be available. The sensor must have been sized properly for the expected service, so that the chosen process conditions are in the free-motion linear range of the sensor. The coupling point should be marked at what is going to be the zero buoyancy weight or the zero differential-buoyancy weight, depending on the calibration approach. The instrument should normally be physically coupled to the pilot shaft at that condition. (However, if the expected operational travel of the pilot is greater than 5 degrees, it is advisable to couple the transmitter to the pilot shaft at the condition representing mid-travel instead. This will prevent hitting a stop in the transmitter before limiting in the sensor.) The Mark Dry Coupling procedure may be run either before or after the Weight-based Cal. However, the PV output is expected to have a bias error until the Reference Coupling Point is correctly marked.

The following procedure can be used to calibrate the sensor if the process condition can be changed to the equivalent of a completely dry and completely submerged displacer, but the actual precise intermediate values cannot be observed. (E.g., no sight glass is available, but the cage can be isolated and drained or flooded.) Correct displacer information and the SG of the test fluid must be entered before performing this procedure. It is only valid in Level measurement mode. It will work for an interface application that has been set up as a Level application using SG (lower fluid) ! SG (upper fluid) as the calibration SG. From the Online menu select Basic Setup, Sensor Calibrate, and Wet/Dry Cal. Follow the prompts on the Field Communicator to calibrate the instrument and sensor. 1. Set the control loop for manual control. 2. Enter the specific gravity for the liquid in the system. (Use difference between fluid SGs for an interface application being calibrated in Level measurement mode.) 3. Adjust the liquid level until the displacer is dry (or completely submerged in upper liquid). Allow the output to settle, then acknowledge establishment of the dry condition to the system. 4. Adjust the liquid level until the displacer is completely submerged in the lower liquid. Allow the output to settle, then acknowledge establishment of the wet condition of the system. The sensor torque rate is calibrated. If the Mark Dry Coupling procedure was run at the dry (or completely submerged in upper liquid) condition, the zero of the PV calculation will be correct also. Verify that the upper and lower range values are correct and return the loop to automatic control. Weight-Based Calibration (3-2-6) This procedure may be used on the bench or with a calibration jig that is capable of applying a mechanical force to the driver rod to simulate displacer buoyancy changes. It allows the instrument and sensor to be calibrated using equivalent weights or force inputs instead of using the actual displacer buoyancy

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To begin the weight-based calibration select Basic Setup, Sensor Calibrate, and Weight Based Cal from the Online menu. Follow the prompts on the Field Communicator to calibrate the sensor. 1. For interface level or density measurements, enter the specific gravity of the upper fluid and lower fluid as requested. 2. Place a weight on the displacer rod that is approximately equal to that indicated on the prompt. The suggested weight is equivalent to the effective displacer weight when the liquid is at its lowest level or the displacer is suspended in the liquid with the lower specific gravity. 3. After allowing the system to stabilize, enter the actual value of the weight suspended on the displacer rod. 4. Place a weight on the displacer rod that is approximately equal to that indicated on the prompt. The suggested weight is equivalent to the effective displacer weight when the liquid is at its highest level or the displacer is suspended in the liquid with the higher specific gravity. 5. After allowing the system to stabilize, enter the actual value of the weight suspended on the displacer rod. The sensor torque rate is calibrated. If the Mark Dry Coupling procedure was performed at the zero February 2007

Setup and Calibration buoyancy (or zero differential buoyancy) condition, the zero of the PV calculation will be correct also. Check the range values before putting the loop in service. Theoretical Calibration In cases where it is not possible to manipulate the input at all, the user may set up a nominal calibration using information available about the hardware and the process. The theoretical torque rate for the installed torque tube may be looked up and compensated for process temperatures. This value is then manually entered in the instrument configuration. The displacer information and fluid SGs are entered. The desired range values are entered manually. Finally, the Level Offset is adjusted, by using the Trim PV Zero command, to bias the computed PV to the current value of the process. It should be possible to control the loop with this rough calibration.

Note The theoretical torque rate for the installed torque tube is available in the Supplement to 249 Series Sensors Instruction ManualÂ&#x2014;Simulation of Process Conditions for Calibration of Level-Trols ! Form 5767 (part number D103066X012). Contact your Emerson Process Management sales office for information on obtaining this manual supplement.

Observations of the sight glass or other independent measurements may be logged against DLC outputs over time. The ratio of the independent-observable process changes to the DLC output changes may then be used as a scale factor to modify the theoretical torque rate stored in the instrument. After each gain adjustment, a new zero trim will be required. When a plant-maintenance shutdown occurs, the instrument may be isolated and calibrated in the normal manner.

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Note This method can cause problems with the Setup Wizard and with DeltaV, because the Level Offset will move the USL and LSL (reasonableness checks on the range values). If the required Level Offset is greater than 20% of the displacer length, one of the desired range values will appear illegal to the DLC. This reasonableness check is only performed while writing a range value, so the Setup Wizard can be accommodated by temporarily removing the Level Offset and replacing it after the procedure is complete. DeltaV does not have access to the Level Offset, so this method is not advisable in a DeltaV application, or with any similar HART-based control system that does not have access to the specific DLC3000 device description.

Ranging Operations The Set Zero and Set Span procedures capture the existing (engineering unit) PV values when they are run, and use them to compute scale and offset for the conversion of PV to %-range and mA-output commands. These procedures are provided for treating the instrument like a conventional analog transmitter. They are not normally used when running a full sensor calibration. When the full capability of the transmitter is used, it is usually better to edit the range values directly. To modify the output span with respect to the digital PV, press the Hot Key and select Range Values, or, from the Online menu, select Basic Setup, PV Setup, and PV Range. Follow the prompts on the Field Communicator to edit the URV and/or LRV.

Temperature Calibration (2-4-2) This procedure allows you to display the temperature as measured by the instrument. You can then trim the temperature reading so that it matches the actual temperature more closely in the region of interest. (This is an offset adjustment only. There is no ability to change the gain.)

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DLC3000 Series This calibration is initially performed at the factory. Performing it in the field requires an accurate independent measurement of the instrument housing temperature or process temperature, (as appropriate). The instrument should be at a steady-state condition with respect to that temperature when performing the procedure.

Note 4

The effectiveness of the instrument electronic temperature compensation depends upon the accuracy of the electronics temperature offset stored in the NVM (non-volatile memory). If the electronics temperature is incorrect, the temperature curve applied to the magnets and Hall sensor will be misaligned, resulting in over- or under-compensation.

From the Online menu select Diag/Service, Calibration, and Temp. Calibration. Follow the prompts on the Field Communicator to trim the temperature readings.

Temperature value may be used to document the process temperature at which the instrument was calibrated, or the process temperature for which the stored torque rate is pre-compensated. From the Online menu select Detailed Setup, Sensors, Process Temp, Digital Proc Temp. Follow the prompts on the Field Communicator to edit the Digital Proc Temp.

Output DAC Calibration: Scaled D/A Trim (2-4-3) This procedure allows trimming the gain and offset of the Digital-to-Analog (D/A) converter to adjust the accuracy at which the output follows 4 to 20 mA current commands from the firmware. This relationship is initially set in the factory, and should not require frequent user adjustment. Reasons for using this procedure include: Correction for component aging after the instrument has been in service for an extended period. Adjusting D/A calibration to be optimum at the normal operating temperature, when that temperature is considerably removed from room temperature conditions.

To display the process temperature reading, select Process Temp.

The procedure is iterative, and will eventually reach a resolution limit where attempts to improve the result will cycle at a few decimal places to either side of the target.

To display the electronics temperature reading, select Elect Temp.

From the Online menu select Diag/Service, Calibration, Scaled D/A Trim. Follow the prompts on the Field Communicator to trim the D/A output.

1. Display the temperature reading:

2. When you have noted the temperature reading, press EXIT. 3. If necessary, trim the temperature reading: To trim the process temperature reading, select Proc Temp Offset. To trim the electronics temperature reading, select Elect Temp Offset. 4. Enter the difference between the actual temperature and the reading noted in step 2. Manual Entry of Process Temperature (4-1-3-2) If a process temperature sensor (RTD) is not installed, it is possible to manually set the Digital Process Temperature variable to the target process temperature. This value will be used by any SG-compensation tables that the user has entered. If no compensation tables are active, the Digital Process

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1. Scale the output from 4 to 20 mA? If your reference meter is graduated in mA , select Proceed and go to step 5. If the reference reading is presented in some other unit system, such as % or mm , select Change and continue with step 2. 2. Enter the scale low output value. 3. Enter the scale high output value. 4. If the high and low output values are correct, select Proceed and continue to step 5. If they are not correct, select Change and return to step 2. 5. Connect a reference meter across the test connections in the terminal box. See the Test Connections procedure in the Installation section. You can also connect a reference meter in the loop as shown in figure 3-10. 6. The Field Communicator commands the instrument to set its output to 4 mA or the low output value. 7. Enter the reading from the reference meter. February 2007

Setup and Calibration 8. If the reference meter reading equals 4 mA or the low output value, select Yes and continue to step 9. If not, select No and return to step 7.

4. Select the Wet/Dry calibration (item 3) from the Sensor Calibration menu, and confirm that you are in the Dry condition at the prompt.

9. The Field Communicator commands the instrument to set its output to 20 mA or the high output value.

After the Dry point has been accepted, you will be prompted to completely cover the displacer with test liquid. (The completely covered condition should be higher than the 100% level mark to work correctly. e.g., 15 inches above the zero mark would generally be enough for a 14 inch displacer, because the amount of displacer rise expected is 0.6 inch.) Accept this as the Wet condition.

10. Enter the reading from the reference meter. 11. If the reference meter reading equals 20 mA or the high output value, select Yes and continue to step 12. If not, select No and return to step 10. 12. The Field Communicator commands the instrument to set its output back to the original value.

Calibration Examples Level Application with standard displacer and torque tube, using water as test fluid Standard practice is to initially calibrate the system at full design span to determine the sensitivity of the sensor/transmitter combination. (This practice has traditionally been called matching ). The data is recorded in transmitter non-volatile memory. The instrument may then be set up for a target fluid with a given specific gravity by changing the value of SG in memory. The value of SG in the instrument memory during the calibration process should match the SG of the test fluid being used in the calibration. 1. From the Online menu select: Basic Setup, PV Setup, Level Offset (3-3-3). Set Level Offset to 0.00, press ENTER and SEND. 2. Run through Setup Wizard (3-3-1) and verify that all sensor data is correct. Select Application = Level, Direct Action. Use No temperature compensation. Enter SG = 1.0 (for water) or actual SG of of test fluid if different than 1.0 3. After completing the Setup Wizard, raise the test fluid level to the process zero point, (e.g., if connection style is 1 or 3, up to the centerline of the lower side connection. It is often possible to watch the display and/or current output to recognize when the fluid hits the displacer, because the output will not start moving upward until that point.) From the Online menu select: Basic Setup, Sensor Calibrate, Mark Dry Coupling point (3-2-1). Follow all prompts, making sure that the coupling access door is closed to unlock the lever assembly and allow it to freely follow the input. February 2007

5. Adjust the test fluid level and check the instrument display and current output against external level at several points to verify the level calibration. a. For bias errors, try re-marking the coupling point at the exact zero level condition. b. For gain errors, try repeating the wet/dry sensor calibration. If the output doesn t come off 4 mA until the level is considerably above the bottom of the displacer, it is possible that the displacer is overweight and is lying on a travel stop until enough buoyancy is developed to allow the linkage to move. After the calibration, edit the SG parameter (3-3-5) to configure the instrument for the target process fluid. The sensor is calibrated.

Interface Application with standard displacer and torque tube This procedure assumes that process temperature is near ambient temperature and that the displacer is not overweight for the torque tube. If these assumptions are not correct for your installation, refer to the temperature correction or overweight displacer procedures in this section. 1. From the Online menu select Basic Setup, PV Setup, Level Offset. Set Offset to 0.00 in., press ENTER and SEND. 2. Run through the Setup Wizard and verify all displacer data is correct. Select Application = Level, Direct Action Use No temperature compensation. Enter SG =1.0 or actual SG of test fluid if different than 1.0 3. After completing the Setup Wizard, put a little of test fluid in the dry cage (up to CL [centerline] of lower side connection if connection style is 1 or 3, or just barely to bottom of displacer if the style is not 1 or 3). From the Online menu select Basic Setup, Sensor Calibrate, Mark Dry Coupling Point (3-2-1). Follow all prompts. 4. Fill the cage with test liquid to near top of displacer. From the Online menu select: Basic Setup, Sensor

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DLC3000 Series Calibration, Single Point (3-2-4). Follow the prompts and enter the actual test liquid level in the currently selected engineering units. 5. Adjust test fluid level and check instrument display and current output against external level at several points to verify the level calibration. If the display is slightly inaccurate: a. For bias errors, try re-marking the coupling point at the zero level condition.

b. For gain errors, try using the two-point sensor calibration to trim the torque tube rate. Use two separate fluid levels, on the displacer, separated by at least 10 inches. 6. When the water calibration is as accurate as you can get it, bring the actual lower process fluid to the zero interface level position and fill the rest of the cage with the actual lighter process liquid (the upper fluid). The output in % should now be approximately: 100 * SGupperfluid / SGlowerfluid From the Online menu select Basic Setup, PV Setup, PV is (3-3-6). (Note: if PV is has been set to density, the menu selection for PV is is 3-3-4.) Select Interface, press ENTER and SEND. 7. From the PV Setup menu (where you should be after finishing PV is selection), select the Specific Gravity menu. Use single point entry method, and enter the SG of the lower fluid and the SG of the upper fluid respectively at the prompts. 8. If you are using the actual upper fluid, make sure the displacer is completely covered. If you are simulating the upper fluid with water, you will need to fill the cage to SGupperfluid times displacer length plus a little extra to account for the amount that the displacer rises because of the increase in buoyancy.

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Note Information on computing precise simulation of this effect is available in the Supplement to 249 Series Sensors Instruction ManualÂ&#x2014;Simulation of Process Conditions for Calibration of Level-Trols ! Form 5767 (part number D103066X012). Contact your Emerson Process Management sales office for information on obtaining this manual supplement. From the Online menu select Basic Setup, Sensor Calibrate, Trim PV Zero (3-2-5). Enter 0.0 inches. This will trim out the displacer rise correction at the minimum buoyancy condition. (Check the Level Offset variable, to see how much correction was made. If the Level Offset exceeds 20% of displacer length there may be problems when using DeltaV [see the notes on pages 4-18 and 4-19 regarding DeltaV interaction]. However, the fraction of an inch that is trimmed out here will not hurt. This step is taken to make sure that a 4 mA output will be produced at the lowest measurable process condition. Since the output will not change any more for interface levels dropping below the bottom of the displacer, we arbitrarily re-label that point as zero. An alternative approach is to adjust the range values slightly to get 4 mA out at the lowest possible computed PV. 9. The sensor is calibrated. Check output against input to validate reconfiguration to Interface mode.

Interface ApplicationÂ&#x2014;with an overweight displacer An interface application can be mathematically represented as a level application with a single fluid whose density is equal to the difference between the actual fluid densities. 1. From the Online menu select Basic Setup, PV Setup (3-3). 2. Set Level Offset (3-3-3) to zero. 3. Set the range values (3-3-2) to: LRV = 0.0, URV = displacer length. 4. Mark the coupling point at lowest process condition (displacer completely submerged in the upper fluid!NOT dry). 5. Set PV is (3-3-6) to Level.

February 2007

Setup and Calibration 6. Set Specific Gravity (3-3-5) to the difference between the 2 fluid SGs. (For example, if SG upper = 0.87 and SG lower = 1.0, the specific gravity to enter is 0.13). 7. Use any of the sensor calibration methods to calibrate torque tube rate, but use actual process fluids, (or use a single test fluid to set up buoyancy conditions simulating the process conditions you are reporting to the instrument.) From the Online menu select Basic Setup, Sensor Calibrate (3-2).

Note Information on simulating process conditions is available in the Supplement to 249 Series Sensors Instruction Manual Simulation of Process Conditions for Calibration of Level-Trols ! Form 5767 (part number D103066X012). Contact your Emerson Process Management sales office for information on obtaining this manual supplement.

8. Trim the PV Zero with actual process: a. Adjust the process so you have an interface in the sight glass. b. From the Online menu select Basic Setup, Sensor Calibration, Trim PV zero. c. Enter the measured value at the prompt. Following are some guidelines on the use of the various sensor calibration methods when the application uses an overweight displacer: Weight-based: Use two accurately known weights between minimum and maximum buoyancy conditions. The full displacer weight is invalid because it will put the unit on a stop. Wet/dry: Dry now means submerged in the lightest fluid and wet means submerged in the heaviest fluid. Single-point: Set up any valid process condition that you can independently measure, (other than the condition that matches the coupling point). The higher the data point is, the better the resolution will be. Two point: Use any two interface levels that actually fall on the displacer. Accuracy is better if the levels are farther apart. The result should be close if you can move the level even 10%. February 2007

Theoretical: If the level cannot be changed at all, you can enter a theoretical value for torque tube rate manually. In this case you would not be able to mark the coupling point at the 0% interface condition. Because this means you will need a large offset to trim the PV to the process condition, there is no advantage to using the differential SG approach. The large offset requirement also means that this approach is not appropriate for use with DeltaV. Trim PV Zero: If you are trimming PV zero with an initial offset in place, be sure to report the independent level measurement with the same zero reference established by that initial offset. For example, if you manually put in an offset to make the instrument report level from the bottom of the tank, then when you are doing a zero trim you must measure from the bottom of the tank to the sight glass level. If you measure from the bottom of the displacer, the instrument will take out your initial offset.

Density Applications ! with Standard Displacer and Torque Tube

Note You will need to select PV Units when changing from level or interface to density. After sending the information, it is necessary to back out of the handheld menu that shows SG and Level Offset, and then re-enter that menu and select Range Values. The range values will need to be edited to provide reasonable magnitude in the new unit system. If the displacer is overweight, there is no way to get the output numerically correct in density mode, because the Level Offset is not available. Therefore, density calibration normally has to begin with the assumption that the displacer is free moving at zero buoyancy (dry) conditions. Mark the coupling point accurately at dry displacer conditions, and any of the four sensor calibration methods (weight-based, wet/dry, single-point, and two-point) can be used in density mode. The terminology can be confusing, because it usually refers to a level as the process condition to set up. When using one of these method, remember that you are in the density mode and enter observed PV in current units of SGU, g/L, lb/in3, kg/m3, etc. Weight Based: The weight-based method asks you for the lowest and highest density you want to use for the calibration points, and computes weight values for

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DLC3000 Series you. If you can t come up with the exact values asked for, you are allowed to edit the values to tell it what weights you actually used. Wet/dry: The wet/dry method essentially reverts to level mode during the calibration process. It asks for the SG of your test fluid first. Then, it has you set up first a dry and then a completely submerged displacer condition.

Single-point: When using the single-point calibration, you must report the density condition in current PV units when it asks you for the level in current PV units. In order for for single-point calibration to work, the coupling point must have been previously marked at the zero buoyancy state. Two-point: The two-point calibration method requires you to set up two different process conditions with as much difference as possible. You could use two standard fluids with well-known density and alternately submerge the displacer in one or the other. If you are going to try to simulate a fluid by using a certain amount of water, remember that the amount of displacer covered by the water is what counts, not the amount in the cage. The amount in the cage will always need to be slightly more because of the displacer motion. Because of this inconvenience, and the extra work of draining and flooding with two fluids, the two-point calibration method is probably the least attractive in density mode. Note: These calibration methods advise you to trim PV zero for better accuracy. That command is not available in density mode.

Sensor Calibration at Process Conditions (Hot Cut-Over) when input cannot be varied If the input to the sensor cannot be varied for calibration, you can configure the instrument gain using theoretical information and trim the output offset to the current process condition. This allows you to make the controller operational and to control a level around a setpoint. You can then use comparisons of input changes to output changes over time to refine the gain estimate. A new offset trim will be required after each gain adjustment. This approach is not recommended for a safety-related application, where exact knowledge of the level is important to prevent an overflow or dry sump condition. However, it should be more than adequate for the average level-control application that can tolerate large excursions from a midspan set point. There are a number of calibration methods available in the DLC3000 Device Description. Two-point calibration allows you to calibrate the torque tube using two input conditions that put the measured interface anywhere on the displacer. The accuracy of the method

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increases as the two points are moved farther apart, but if the level can be adjusted up or down even a few inches, it is enough to make a calculation. Most level processes can accept a small, manual adjustment of this nature. If your process cannot, then the theoretical approach is the only method available.

Note This approach is not recommended for use with DeltaV. It results in a large value being entered in the Level Offset parameter, which can trigger a recursive attempt to write range values to the digital level controller after a communications glitch. The non-volatile memory write-cycle life in the instrument will be exhausted rapidly. 1. Determine all the information you can about the 249 hardware: 249 type, mounting sense (controller to the right or left of displacer), torque tube material and wall thickness, displacer volume, weight, length, and driver rod length. (Driver rod length is called Disp Rod in the DD menus. It is not the suspension rod length, but the horizontal distance between the centerline of the displacer and the centerline of the torque tube). Also obtain process information: fluid densities, process temperature, and pressure. (The pressure is used as a reminder to consider the density of an upper vapor phase, which can become significant at higher pressures.) 2. Run the Setup Wizard and enter the various data that is requested as accurately as possible. Set the Range Values (LRV, URV) to the PV values where you will want to see 4 mA and 20 mA output, respectively. These might be 0 and 14 inches on a 14 inch displacer. 3. Mount and couple at the current process condition. It is not necessary to run the Mark Dry Coupling procedure, because it stores the current torque tube angle as the zero buoyancy condition, and will therefore not be accurate. 4. With the torque tube type and material information, find a theoretical value for the composite or effective torque!tube rate, (Refer to the Entering Theoretical Torque Tube (TT) Rates procedure in this section), and enter it in the instrument memory. The value can be accessed in the Review Menu under Factory Settings. 5. If the process temperature departs significantly from room temperature, use a correction factor February 2007

Setup and Calibration interpolated from tables of theoretical normalized modulus of rigidity. Multiply the theoretical rate by the correction factor before entering the data. You should now have the gain correct to within perhaps 10%, at least for the standard wall, short length torque tubes. (For the longer torque tubes (249K, L, N) with thin-wall and a heat insulator extension, the theoretical values are much less accurate, as the mechanical path departs considerably from the linear theory.)

Note Tables containing information on temperature effects on torque tubes can be found in the Supplement to 249 Series Sensors Instruction Manual Simulation of Process Conditions for Calibration of Level-Trols ! Form 5767 (part number D103066X012). Contact your Emerson Process Management sales office for information on obtaining this manual supplement. 6. Now using a sight glass or sampling ports, obtain an estimate of the current process condition. Run the Trim PV Zero procedure and report the value of the actual process in the PV engineering units. (for example, sight glass reads 11 inches.) The instrument will compute an offset to trim out the difference between your value and it s calculation, and store it in the Level Offset parameter. 7. You should now be able to go to automatic control. If observations over time show the instrument output exhibits, for example,1.2 times as much excursion as the sight glass input, you could divide the stored torque tube rate by 1.2 and send the new value to the instrument. Then run another Trim PV Zero procedure to correct the offset, and observe results for another extended period to see if further iteration is required. Entering Theoretical Torque Tube (TT) Rates The Supplement to 249 Series Sensors Instruction Manual Simulation of Process Conditions for Calibration of Level-Trols, Form 5767, provides the theoretical composite torque tube (TT) rate for 249 Series sensors with Type DLC3010 controllers. These numbers are nominal values. They should be within

February 2007

10% of the values that the instrument would compute when you perform a sensor calibration. They will be less accurate for the long torque tubes (Type 249K, L, N, V, and P), especially with thin-wall constructions. If you are unable to perform a sensor calibration during installation, you may enter the values into the instrument at the following menu item in the handheld: Review, Factory Settings, TT rate (5-4-1) Then, manually set the LRV and URV to the PV values at which you desire 4 and 20 mA output, respectively. Basic Setup, PV Setup, PV Range, URV LRV (3-3-2-2) Next, perform a Trim PV Zero operation to align the instrument output with the sight glass reading. Basic Setup, Sensor Calibrate, Trim PV Zero (3-2-5) These steps will provide an approximate PV calibration to get a system operational. Further refinements can then be made when it is possible to manipulate and observe the level and instrument output.

Note This approach is not advised when using the HART interface in a DeltaV installation, because the computed Level Offset can exceed 20% of displacer length, making one of the range values appear invalid during the DeltaV initialization process. This can lead to repetitive re-initialization attempts, using up the write-cycle life of the instrument NVM.

Accuracy Considerations Effect of Proportional Band If you are operating at low Proportional Band [PB = 100% times (full span torque tube rotation) / (4.4 degrees)], you can expect a degradation factor of about (100%)/(PB%) on the Transmitter accuracy specifications.

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DLC3000 Series Note

This formula is most correct for linearity errors that are relatively steep-sided. If the linearity error curve shape is simple with relatively gradual slope, the net effect of reducing span may be less. Instruments such as the DLC3000, that use a compensation technique to reduce the residual mechanical or electrical non-linearity, will generally have a complex shape for the net-error curve.

If this is too much degradation, an improvement of 2.0 can be obtained by using a thin-wall torque tube. Additional gain can be achieved by increasing the displacer diameter. Available clearance inside the cage, and the need to keep the net displacer weight at the highest and lowest process conditions within the usable range of the torque tube / driver rod combination, place practical limits on how much the sizing can be adjusted. With an overweight displacer, the calibration process becomes more difficult, (because the zero buoyancy condition will occur with the linkage driven hard into a travel stop). In interface measurement mode it becomes impossible to mark the Â&#x201C;dryÂ&#x201D; coupling point correctly or use the single-point calibration. One simple and effective solution is to use Level measurement mode. Mark the coupling point at the lowest process condition instead of zero buoyancy, and enter the differential SG = (SGlowerfluid ! SGupperfluid). The algorithm then computes level correctly.

Density Variations in Interface Applications A high sensitivity to errors in the knowledge of fluid density can develop in some interface applications. For example: Suppose the whole input span is represented by an effective change in SG of 0.18. Then a change in the actual SG of the upper fluid from 0.8 to 0.81 could cause a measurement error of 5.6% of span at the lowest interface level. The sensitivity to the knowledge of a fluid density is maximum at the process condition where that fluid covers all of the displacer, and zero at the opposite extreme process condition.

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If the fluid density changes are batch-related or very gradual, it may be practical to keep track of the SG of the fluid and periodically reconfigure the transmitter memory to match the actual process condition. Frequent automatic updates to this variable are not advised, as the NVM location where it is stored has an expected lifetime of about 10,000 write operations. If changes are only a function of temperature, the characteristic of the fluid can be loaded once in the NVM table, and an RTD connected to measure the process temperature and drive the correction table. If temperature is not the driving influence, the best that can be done is to calibrate for the widest potential differential SG. (This will keep the variations as small a percentage of calibrated span as possible.) Then calculate an alarm threshold that will prevent vessel over- or under-flow at the worst case error.

Extreme Process Temperatures For applications that will run at extreme temperatures, the effect of process temperature on the torque tube must be taken into account. Best results are obtained by running the torque tube calibration at actual process temperature. However, the decrease in spring rate with temperature can be simulated at room temperature by increasing the load on the torque tube during room-temperature calibration. This will produce the same deflection that would occur at actual process conditions. This compensation is theoretical and not perfect, but is still an improvement over ambient calibration with no attempt at compensation.

Note For additional information, refer to the Supplement to 249 Series Sensors Instruction ManualÂ&#x2014;Simulation of Process Conditions for Calibration of Level-Trols ! Form 5767 (part number D103066X012). Contact your Emerson Process Management sales office for information on obtaining this manual supplement.

Temperature Compensation If the process temperature departs significantly from calibration temperature, you will need to apply a correction factor. Refer to Temperature Compensation at the end of this section for detailed setup information.

February 2007

Setup and Calibration Detailed Setup The DLC3000 Series digital level controller has the capability to communicate via the HART protocol. This section describes the advanced features that can be accessed with the Model 375 Field communicator. The Basic Setup and Detailed Setup selections from the Online Menu allow you to configure the digital level controller to your application.

length from table 4-1 or from the Field Communicator Help. Refer to figure 4-2 to physically measure this value.

Entering Torque Tube Data (4-1-2) To enter torque tube data, from the Online menu select Detailed Setup, Sensors, and Torque Tube. Select Material (Torque Tube Material) to display the torque tube material or Change Material to Change the torque tube material. Material Displays the torque tube material currently stored in the instrument.

Setting Protection Changing setup parameters may require enabling writing to the instrument with the Field Communicator. To change the write protection, press the Hot Key and select Write Lock, or, from the Online menu, select Diag/Service, Write Lock. Select Writes Enabled to enable writing setup and calibration data, or select Writes Disabled to disable writing data. Not that cycling power will clear the Write Lock condition to Writes Enabled .

Setting Up the Sensor Entering Displacer Data (4-1-1-1) To enter displacer data, from the Online menu select Detailed Setup, Sensors, Displacer, and Displacer Info. Follow the prompts on the Field Communicator display to enter Displ Units (Displacer Units), Length (Displacer Length), Volume (Displacer Volume), Weight (Displacer Weight), and Disp Rod (Displacer Rod Length). Displ Units Permits setting the units of measure for the displacer length (feet, meters, inches, or centimeters), volume (liters, cubic inches, cubic millimeters, or milliliters) and weight (grams, kilograms, pounds, or ounces). Length Enter the displacer length from the sensor nameplate. See figure 4-1. Volume Enter the displacer volume from the sensor nameplate. See figure 4-1.

4 Note A sensor with an N05500 torque tube may have NiCu on the nameplate as the torque tube material.

Change Material Enter the sensor torque tube material. You can also load a table with the material temperature coefficients. You can select to load the table with the defaults, or, if you select No, you can enter the torque tube temperature coefficient values. To enter the torque tube material temperature coefficients, from the Online menu select Review, Factory Settings, and TTube Temp. Coeff (Torque Tube Temperature Coefficient).

Specifying Instrument Mounting (4-1-1-2) To indicate on which side of the displacer the instrument is mounted, from the Online menu select Detailed Setup, Sensors, Displacer, and Inst Mounting. Specify if the instrument is to the right or left of the displacer. See figure 3-7.

Process Temperature Indications The digital level controller can receive the process temperature from a resistance temperature detector (RTD) connected to the unit or, if no RTD is connected to the unit, you can enter the process temperature directly. The digital level controller uses the process temperature to make specific gravity corrections.

Weight Enter the displacer weight from the sensor nameplate. See figure 4-1.

Entering RTD Data (4-1-3-1)

Disp Rod Enter the displacer rod length. The displacer rod length depends upon the sensor type. For a 249 Series sensor, obtain the displacer rod

If an RTD is connected to the digital level controller, select Detailed Setup, Sensors, Process Temp, and Process Temp RTD. Follow the prompts on the Field

February 2007

4-21

DLC3000 Series Communicator display to indicate an RTD is installed. Enter the type of RTD; either 2-wire or 3-wire.

kg/L kilograms per liter g/L grams per liter lb/in3 pounds per cubic inch SGU specific gravity units

For a 2-wire RTD, you must specify the connecting wire resistance. If you know the resistance, select Resistance and enter the resistance of the wire. 250 feet of 16 AWG wire has a resistance of 1 ohm. If you do not know the resistance, select Wire Gauge/Lngth and the Field Communicator will prompt you for the length and gauge of the wire and calculate the resistance.

For level and interface measurement: ft feet m meters in inches cm centimeters mm millimeters

Setting Temperature Units (3-3-1-2)

Displacer Units

To enter the temperature units, select Basic Setup, PV Setup, PV & Temp Units, and Temp Units. Select either degC (degrees centigrade) or degF (degrees Fahrenheit). Note that when using degF, the Temperature Alarm Deadband parameter is incorrectly displayed with a 32 bias.

Setting Up the Instrument for the Application

Weight:

Volume:

g grams

liter liters

kg kilograms

in3 cubic inches

lb pounds

mm3 cubic millimeters

oz ounces

mL milliliters

Length: (Same as level and interface process variable units.)

Torque Tube Rate Units

Selecting the Process Variable (3-3-6) The DLC3000 Series digital level controller can be used for level, interface level, or density measurements. To select the process variable to fit the application, from the Online menu select Basic Setup, PV Setup, and PV is. (Note: if PV is has been set to density, the menu selection for PV is will be 3-3-4.) Follow the prompts on the Field Communicator display to select Level, Interface, or Density.

lbf-in per deg pounds-force inches per degree rotation newton-m per deg newton-meters per degree rotation dyne-cm per deg dyne!centimeters per degree rotation

Setting PV Range (3-3-2) Instrument Action

Setting PV Engineering Units To set process variable units, press the Hot Key and select PV Setup, or, from the Online menu, select Basic Setup, and PV Setup. Select PV & Temp Units. The menu selection appears as one of the following:

Two methods are available for setting the range. You can enter the upper and lower range values, in engineering units, as described below or, if you are able to raise and lower the level, perform the Setting Zero and Span procedure.

Level Units if the PV is level,

Reverse Action

Interface Units if the PV is Interface, or

To obtain reverse action, set the lower range value higher than the upper range value. This is easiest to do in the Setup Wizard.

Density Units if the PV is Density. You can select from the following units:

Process Variable Units For density measurement: g/cm3 grams per cubic centimeter kg/m3 kilograms per cubic meter lb/gal pounds per gallon lb/ft3 pounds per cubic foot g/mL grams per milliliter

4-22

Entering the Upper and Lower Range Values Press the Hot Key and select Range Values, or, from the Online menu, select Basic Setup, PV Setup, and PV Range. Follow the prompts on the Field Communicator display to enter URV (Upper Range Value), LRV (Lower Range Value), and to display the LSL (Lower Sensor Limit), and USL (Upper Sensor Limit). February 2007

Setup and Calibration 7 FEET URV 6 FEET URV SPAN, 4 FEET

URV (10 FEET)

DISPLACER

SPAN, 4 FEET

ZERO, 3 FEET (2 FEET) LRV

LRV (6 FEET)

ZERO, 2 FEET

LEVEL OFFSET (6 FEET)

RESULTS OF SETTING SPAN FIRST URV UPPER RANGE VALUE LRV LOWER RANGE VALUE

E0368 / IL

E0367 / IL

Figure 4-3. Relationship of Zero and Span to Upper and Lower Range Value

URV Defines the operational end point from which the Analog Value, and the 100% point of the percent range are derived.

Figure 4-4. Example of the Use of Level Offset

To set zero and span select Basic Setup, PV Setup, PV Range, and Set Zero and Span from the Online menu. Follow the procedure to set zero and span.

Setting Zero 1. Select Set Zero from the Set Zero and Span menu.

LRV Defines the operational end point from which the Analog Value, and the 0% point of the percent range are derived.

2. Set the control loop for manual control.

LSL Indicates the minimum usable value for the Lower Range Value.

4. Press OK on the Field Communicator.

USL Indicates the maximum usable value for the Upper Range Value. When you have finished editing the range values, press the SEND key. The ranging operation is complete. Do not continued to the Set Zero / Set Span commands after changing the range values manually.

Setting Zero and Span (3-3-2-5) If you are able to raise and lower the liquid level or change the density between 0 and 100%, you can use Set Zero and Span to set the operational range. Always set the zero first, then the span. If you set the span first, the upper range value will shift when you set the zero. For example, refer to figure 4-3, suppose the zero is set to 2 feet from a previous ranging. If you set the span at 4 feet then the lower range value is 2 feet and the upper range value is 6 feet. The span is 4 feet (6 ! 2 = 4). If you now set the zero at, say 3 feet, the span is still 4 feet so the upper range value will shift to 7 feet (3 + 4 = 7). However, if you set the zero first then the span, the lower range value (zero) will stay fixed while you set the upper range value (span). February 2007

3. Set the process variable (level, interface, or density) to the lower range value.

5. Perform the Setting Span procedure.

Setting Span 1. Select Set Span from the Set Zero and Span menu. 2. Set the control loop for manual control. 3. Set the process variable (level, interface, or density) to the upper range value. 4. Press OK on the Field Communicator. 5. Return the control loop to automatic control.

Setting Level Offset Adding a level offset permits the process variable engineering units to correspond to the externally measured level or interface (see figure 4-4). To add a Level offset, press the Hot Key and select PV Setup, or, from the Online menu, select Basic Setup, Level Setup. Select Level Offset and follow the prompts on the Field Communicator to enter the offset value. If you set the level offset after you have set the range values, be sure to verify that the range values are still correct.

4-23

DLC3000 Series Table 4-3. Example Specific Gravity vs Temperature Table for Saturated Water

Note

Specific Gravity

1 2 3 4 5

26.7 93.3 176.7 248.9 304.4

80.0 200.0 350.0 480.0 580.0

0.9985 0.9655 0.8935 0.8040 0.7057

6 7 8 9 10

337.8 354.4 365.6 371.1 374.7

640.0 670.0 690.0 700.0 706.5

0.6197 0.5570 0.4940 0.4390 0.3157

If you can manipulate the level, you can also add a level offset by performing the Trim PV Zero procedure in the Calibration section.

Note On systems that cannot access the Level Offset, and that write the range values automatically during initialization, (such as DeltaV), it is not advisable to use Trim PV Zero to compensate for an invalid Reference Coupling Point. The Level Offset will move the USL and LSL (reasonableness checks on the range values). If the required Level Offset is greater than 20% of the displacer lengths, one of the desired range values will appear illegal to the DLC. If a communication drop-out occurs, DeltaV will attempt to write unit and range data to the DLC. DeltaV will continuously repeat initialization attempts when a range value is rejected. The other parameters that are successfully written during each iteration will rapidly use up the write-cycle life of the NVM in the DLC3000Â&#x2019;s microprocessor.

TEMPERATURE _C

!18 1.0

100

200

300

380

0.9 0.8 SPECIFIC GRAVITY

Temperature _C

Data Point

0.7 0.6 0.5 0.4 0.3 0

E0369 / IL

100

200

300

400

500

600

700

TEMPERATURE _F

Figure 4-5. Example Saturated Water Curve Plotted with Values from Table 4-3

Setting Response (5-4-4) Setting PV Damping (3-3-4) PV Damping changes the response time of the controller to smooth variations in output readings caused by rapid changes in input. Determine the appropriate damping setting based on the necessary response time, signal stability, and other requirements of the loop dynamics of your system. The default damping value is 0.2 seconds. and can be reset to any value between 0 and 16 seconds in 0.1 second increments. When set to 0, the damping function is off. To set PV damping select Basic Setup, PV Setup, and PV Damp from the Online menu. Net instrument response is a combination of analog input filtering and output filtering.

4-24

From the Online menu select Review, Factory Settings, and Input Filter. Follow the prompts on the Field Communicator display to configure the input filter. Input FilterÂ&#x2014;Time constant for the input filter, in seconds, for the A/D measurement. The filter is applied before PV processing, after the A/D conversion. Range is 0 to 16 seconds in 0.1 second increments. The default value is 0.0 seconds. To disable the filter, set the time constant to 0 seconds. This filter is provided for extreme input noise situations. Use of this filter normally should not be necessary. Net instrument response is a combination of analog input filtering and output filtering. February 2007

Setup and Calibration Table 4-4. Example Specific Gravity vs Temperature Table for Saturated Steam TEMPERATURE _C

SPECIFIC GRAVITY

1 2 3 4 5

126.7 210.0 271.1 304.4 326.7

260 410 520 580 620

0.00095 0.00850 0.02760 0.04900 0.07200

6 7 8 9 10

343.3 357.8 365.6 371.1 374.4

650 676 690 700 706

0.09800 0.13500 0.16800 0.21000 0.31570

DATA POINT

The resolution of the table entry for specific gravity is 5 decimal places. This means the smallest specific gravity value you can enter is 0.00001, which should be sufficient to allow a starting temperature around 15.6 C (60 F) for the steam specific gravity table. The example set of tables given are generated by visually laying linear segments over a reference curve, and are not guaranteed to provide any particular accuracy. They are provided to illustrate the guidelines for developing your own table:

TEMPERATURE _C 100

!18

200

300

375

0.35

SPECIFIC GRAVITY

0.30 0.25 0.20 0.15 0.10

1. Establish a table for the fluid(s) you are using over the expected operating range of process temperature. This allows you to make best use of the maximum of ten points to obtain the accuracy you require. If your fluid specific gravity is very linear over the operating temperature range, two data points may be sufficient. (The correction algorithm provides linear interpolation between data points, and bounds the result at the table end points.) 2. Pick points closer together in regions of higher slope.

0.05 0.0

terminated by entering zero for the specific gravity. Keep this in mind when setting up a table for a upper fluid, such as steam, whose specific gravity approaches 0 at lower temperatures.

100

E0370 / IL

200

300

400

500

600

700

TEMPERATURE _F

Figure 4-6. Example Saturated Steam Curve Plotted from Values in Table 4-4

Setting the Specific Gravity (3-3-5) Two specific gravity tables are available in the instrument to provide specific gravity correction for temperature. For level measurement applications, only the lower specific gravity table is used. For interface applications, both the upper and lower table can be displayed and edited. For density applications, no specific gravity correction table is presented. (Note: if PV is has been set to density, the menu selection 3-3-5 does not appear.) Example entries for saturated water are given in table 4-3. Figure 4-5 shows the curve that results when these values are plotted. Table 4-4 lists example entries for saturated steam. Figure 4-6 is the curve that results when these values are plotted. You can enter up to 10 temperature and specific gravity pairs in the table. The table entry function is February 2007

3. Pick linear segments that distribute the error equally on each side of the true curve. To enter or display the specific gravity, or to enter values in the specific gravity tables, from the Online menu select Basic Setup, PVSetup, and Specific Gravity. The Field Communicator prompts for either a single value for specific gravity or a table of specific gravity versus temperature. To enter a single specific gravity value, select Single Point and enter the specific gravity value. To display or enter values in the tables, select Table of SG vs T. The Field Communicator begins by prompting for the temperature of the first pair in the lower table. After entering the temperature for the first pair, press ENTER. Enter the specific gravity for the first pair and press ENTER. The Field Communicator then prompts for the temperature for the second pair. Enter this temperature and press ENTER. The Field Communicator then prompts for the specific gravity for the second pair. Continue entering each temperature and specific gravity pair. When finished, enter zero at the Field Communicator prompt for the next specific gravity value to exit the table. For level applications, the Field Communicator exits to the Basic Setup menu. For interface applications, the Field Communicator then prompts for the first temperature and specific gravity pair for the upper table.

4-25

DLC3000 Series Setting Up the LCD Meter (4-2-2) To set up the LCD meter, from the Online menu select Detailed Setup, Output Condition, and LCD meter. Follow the prompts on the Field Communicator to indicate if the meter is installed, set up the information the meter will display, and assign the number of decimal places.

ANALOG OUTPUT DISPLAY

PROCESS VARIABLE VALUE WHEN PRESENT, INDICATES WRITES DISABLED

Meter Installed Select this parameter to indicate if the meter is installed. If the meter is physically installed, select Installed. The meter must be installed before you can set the display type or the decimal places.

Display Type Select the type of information the meter should display and how it should be displayed. You can select for display: PV Only Displays the process variable (level, interface, or density) in engineering units. PV/Proc Temp Alternately displays the process variable in engineering units, the process temperature in the units selected under Temp Units (PV Setup), and the degrees of torque tube rotation. % Range Only Displays the process variable as a percent of span (determined by the LRV and URV). PV/% Range Alternately displays the process variable in engineering units and the process variable in percent of span. Decimal Places Selects the number of decimal places to display, up to four. Setting the value to zero puts the display in auto-scale mode. It will then display as may decimals places as will fit. If PV/Proc Temp or PV/% Range is selected, the display alternates every two seconds between the selected readings. The meter also simultaneously displays the analog output signal using a percent of scale bar graph around the perimeter of the display face as shown in figure 4-7, no matter what display type is selected. After you have selected the desired meter settings, press SEND on the Field Communicator to download the meter settings to the instrument.

Testing the Meter The meter activates all segments immediately after power-up, during a digital level controller self-test, or during a master reset sent by a host supporting HART communications. You can also test the meter by selecting Diag/Service from the Online menu. Select Test Device and Meter. Select Turn Cells On to turn on all display segments, including the analog output bar graph, or select Turn Cells Off to turn off all

4-26

PROCESS VARIABLE UNITS MODE

E0371 / IL

Figure 4-7. LCD Meter Display

display segments. When finished with the test, press OK to return the meter to normal display mode.

Setting Alarms The following menus are available for configuring Alarms.

Setting Process Variable (4-2-3-1) Alarm Limits Select Detailed Setup, Output Condition, Configure Alarms, and Process Var. Follow the prompts on the Field Communicator display to set: PV Hi Alrm (Process Variable High Alarm), PV Hi-Hi Alrm (Process Variable High-High Alarm), PV Lo Alrm (Process Variable Low Alarm), PV Lo-Lo Alrm (Process Variable Low-Low Alarm), and PV Alrm DeadBand (Process Variable Alarm Dead Band). PV Hi Alrm Process Variable High Alarm is the value of the process variable, in engineering units, which, when exceeded, sets the process variable High Alarm. PV Hi-Hi Alrm Process Variable High-High Alarm is the value of the process variable, in engineering units, which, when exceeded, sets the process variable High-High Alarm. PV Lo Alrm Process Variable Low Alarm is the value of the process variable, in engineering units, which, when exceeded, sets the Process Variable Low Alarm. PV Lo-Lo Alrm Process Variable Low-Low Alarm is the value of the process variable, in February 2007

Setup and Calibration ALARM IS SET

ALARM IS SET

PROCESS VARIABLE HIGH ALARM LIMIT

TEMPERATURE HIGH ALARM LIMIT

PROCESS VARIABLE ALARM DEADBAND

TEMPERATURE ALARM DEADBAND

PROCESS VARIABLE ALARM IS CLEARED

E0372 / IL

Figure 4-8. Process Variable Alarm Deadband (Process Variable High Alarm Example)

TEMPERATURE ALARM IS CLEARED

E0373 / IL

Figure 4-9. Temperature Alarm Deadband (Temperature High Alarm Example)

engineering units, which, when exceeded, sets the Process Variable Low Low Alarm.

in temperature units, which, when exceeded, will set the Electronics Low Alarm.

PV Alrm Deadband The Process Variable Alarm Deadband is the amount the process variable, in engineering units, must change to clear a process variable alarm, once it has been set. The deadband applies to all the process variable alarms. See figure 4-8.

Temp Alrm Deadband The Temperature Alarm Deadband is the amount the temperature, in temperature units, must change to clear a temperature alarm, once it has been set. The deadband applies to all the temperature alarms. See figure 4-9. In firmware revision 8, the Temp Alarm Deadband is displayed incorrectly when the units are DegF. (The number displayed is 32 more than the actual deadband.)

Setting Temperature Alarm (4-2-3-3) Limits Select Detailed Setup, Output Condition, Configure Alarms, and Temperature. Follow the prompts on the Field Communicator display to configure the following: Proc. Temp Hi Alrm (Process Temperature High Alarm), Proc. Temp Lo Alrm (Process Temperature Low Alarm), Elec. Temp Hi Alrm (Electronics Temperature High Alarm), Elec. Temp Lo Alrm (Electronics Temperature Low Alarm) and Temp Alrm Deadband (Temperature Alarm Deadband). Proc. Temp Hi Alrm Process Temperature High Alarm is the process variable temperature, in temperature units, which, when exceeded, will set the Process Temperature High Alarm. Proc. Temp Lo Alrm Process Temperature Low Alarm is the process variable temperature, in temperature units, which, when exceeded, will set the Temperature Low Alarm. Elec. Temp Hi Alrm Electronics Temperature High Alarm is the instrument electronics temperature, in temperature units, which, when exceeded, will set the Electronics High Alarm. Elec. Temp Lo Alrm Electronics Temperature Low Alarm is the instrument electronics temperature, February 2007

Enabling Process Variable (4-2-3-2) Alarms Select Detailed Setup, Output Condition, Configure Alarms and Alarm Enable. Follow the prompts on the Field Communicator display to configure the following: Hi Alrm Enabl (High Alarm Enable), Hi Hi Alrm Enabl (High High Alarm Enable), Lo Alrm Enabl (Low Alarm Enable), Lo Lo Alrm Enabl (Low Low Alarm Enable). Hi Alrm Enabl On or Off. High Alarm Enable activates checking the process variable against the PV High Alarm limit. High Alarm is set if the process variable rises above the PV High Alarm limit. Once the alarm is set, the process variable must fall below the PV High Alarm limit by the PV Alarm Deadband before the alarm is cleared. See figure 4-8.

Note If the Hi Hi Alarm or Lo Lo Alarm are enabled and either is set, the digital level controller output will go to below 3.75 mA or above 21.0 mA, depending on the position of the alarm jumper.

4-27

DLC3000 Series Hi Hi Alrm Enabl On or Off. High High Alarm Enable activates checking the process variable against the PV High-High Alarm limit. The High High Alarm is set if the process variable rises above the PV High High Alarm limit. Once the alarm is set, the process variable must fall below the PV High High Alarm limit by the PV Alarm Deadband before the alarm is cleared. See figure 4-8.

Lo Alrm Enabl On or Off. Low Alarm Enable activates checking the process variable against the PV Low Alarm limit. Low Alarm is set if the process variable falls below the PV Low Alarm limit. Once the alarm is set, the process variable must rise above the PV Low Alarm limit by the PV Alarm Deadband before the alarm is cleared. See figure 4-8. Lo Lo Alrm Enabl On or Off. Low Low Alarm Enable activates checking the process variable against the PV Low-Low Alarm limit. The Low Low Alarm is set if the process variable falls below the PV Low Low Alarm limit. Once the alarm is set, the process variable must rise above the PV Low Low Alarm limit by the PV Alarm Deadband before the alarm is cleared. See figure 4-8.

Temperature Low Alarm limit by the Temperature Alarm Deadband before the alarm is cleared. See figure 4-9. Elect Temp Hi Alrm On or Off. Electronics Temperature High Alarm Enable activates checking of the instrument electronics temperature against the Electronics Temperature High Alarm limit. Electronics Temperature High Alarm is set if the instrument electronics temperature rises above the Electronics Temperature High Alarm limit. Once the alarm is set, the instrument electronics temperature must fall below the Electronics Temperature High Alarm limit by the Temperature Alarm Deadband before the alarm is cleared. See figure 4-9. Elect Temp Lo Alrm On or Off. Electronics Temperature Low Alarm Enable activates checking of the instrument electronics temperature against the Electronics Temperature Low Alarm limit. Electronics Temperature Low Alarm is set if the instrument electronics temperature falls below the Electronics Temperature Low Alarm limit. Once the alarm is set, the instrument electronics temperature must rise above the Electronics Temperature Low Alarm limit by the Temperature Alarm Deadband before the alarm is cleared. See figure 4-9.

Enabling Temperature Alarms (4-2-3-4) Select Detailed Setup, Output Condition, Configure Alarms and Temp Alarm Enable. Follow the prompts on the Field Communicator display to configure the following: Proc Temp Hi Alr (Process Temperature High Alarm), Proc Temp Lo Alrm (Process Temperature Low Alarm), Elect Temp Hi Alrm (Electronics Temperature High Alarm), Elect Temp Lo Alrm (Electronics Temperature Low Alarm Enable). Proc Temp Hi Alrm On or Off. Process Temperature High Alarm Enable activates checking of the process variable temperature against the Process Temperature High Alarm limit. The Process Temperature High Alarm is set if the process variable temperature rises above the Process Temperature High Alarm limit. Once the alarm is set, the process variable temperature must fall below the Process Temperature High Alarm limit by the Temperature Alarm Deadband before the alarm is cleared. See figure 4-9. Proc Temp Lo Alrm On or Off. Process Temperature Low Alarm Enable activates checking of the process variable temperature against the Process Temperature Low Alarm limit. Process Temperature Low Alarm is set if the process variable temperature falls below the Process Temperature Low Alarm limit. Once the alarm is set, the process variable temperature must rise above the Process

4-28

Entering HARTR Information (4-3-1) From the Online menu select Detailed Setup, Device Information, and HART. Follow the prompts on the Field Communicator display to enter or view information in the following fields: HART Tag, Polling Address, Message, Descriptor, and Date. HART Tag—The HART tag is the easiest way to identify and distinguish between controllers in multi-controller environments. Use the HART tag to label controllers electronically according to the requirements of your application. The tag you define is automatically displayed when a HART-based communicator establishes contact with the controller at power-up. The tag may be up to eight characters long and has no impact on the primary variable readings of the controller. Polling Address If the digital level controller is used in a point-to-point configuration, the Polling Address is 0. When several devices are connected in the same loop, each device must be assigned a unique polling address. The Polling Address may be set to a value between 0 and 15. For the Field Communicator to be able to communicate with a device whose polling address is not 0, it must be configured to automatically search for February 2007

Setup and Calibration

BELL 202 MODEM LOAD HOST

POWER SUPPLY E0375 / IL

Figure 4-10. Typical Multidropped Network

all or specific connected devices. For information on configuring the Field Communicator for automatic polling, see the Model 375 Field Communicator Basics section, Appendix A.

Message—Message provides the most specific user-defined means for identifying individual controllers in multi-controller environments. it allows for 32 characters of information and is stored with the other configuration data. Message has no impact on the operation of the controller or the HART-based communicator.

Descriptor The Descriptor provides a longer user-defined electronic label to assist with more specific controller identification that is available with the HART tag. The descriptor may be up to 16 characters long and has no impact on the operation of the controller or HART-based communicator.

Date Date is a user-defined variable that provides a place to save the date of the last revision of configuration or calibration information. It has no impact on the operation of the controller or Field Communicator. Enter a date with the format MM/DD/YY. February 2007

Multidrop Communication Multidropping refers to the connection of several digital level controllers or transmitters to a single communications transmission line. Communication between the host and the field instruments takes place digitally with the analog output of the instruments deactivated. With the HART communications protocol, up to 15 field instruments can be connected on a single twisted pair of wires or over leased phone lines. Multidrop installations are not recommended where intrinsic safety is a requirement. The application of a multidrop installation requires consideration of the update rate necessary from each instrument, the combination of instrument models, and the length of the transmission line. Communication with the field instruments can be accomplished with commercially available Bell 202 modems and a host implementing the HART protocol. Each instrument is identified by a unique address (1!15) and responds to the commands defined in the HART protocol. Figure 4-10 shows a typical multidrop network. Do not use this figure as an installation diagram. Contact your Emerson Process Management sales office with specific requirements for multidrop applications. The Field Communicator can test, configure, and format a multidropped DLC3000 Series digital level controller in the same way as in a standard point-to-point installation.

4-29

DLC3000 Series Temperature Compensation

Note

DLC3000 Series digital level controllers are set to address 0 at the factory, allowing them to operate in the standard point-to-point manner with a 4!20 mA output signal. To activate multidrop communication, the address must be changed to a number between 1 and 15. This change deactivates the 4!20 mA analog output, sending it to 4 mA. The failure mode current also is disabled.

4-30

If the process temperature departs significantly from calibration temperature, you will need to apply a correction factor. Interpolate the correction factor from the material-specific tables of theoretical normalized modulus of rigidity versus temperature, as described in the Supplement to 249 Series Sensors Instruction ManualÂ&#x2014;Simulation of Process Conditions for Calibration of Level-Trols ! Form 5767. (Contact your Emerson Process Management sales office for information on obtaining a copy of this manual). Multiply the measured torque tube rate (editable in the review menu under factory settings) by the correction factor and enter the new value. When you cannot calibrate at process temperature this approach allows a better approximation of the actual torque tube behavior at process conditions.

February 2007

Troubleshooting and Maintenance 5-5

Section 5 Troubleshooting & Maintenance Diagnostic Messages

...............................................

5-3

Viewing Device Information Viewing Process Variable Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

Process Variable Electronics Temperature Process Variable Range

Viewing Output Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6

Process Variable Analog Output

% Range Alarm Jumper

Measuring Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6

Trending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7

Viewing the Device ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7

Viewing Version Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7

Field Device Revision Device Description Revision Software Revision Hardware Revision Universal Revision

Viewing Serial Number Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7

Displacer Serial Number Final Assembly Number Instrument Serial Number

Viewing Process and Temperature Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7

Viewing Hardware Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8

Viewing Instrument Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8

Hardware Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

Test Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

Removing the Digital Level Controller from the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9

Removing the Type DLC3010 Digital Level Controller from a 249 Series Sensor . . . . . . . . . . . . . . . . . . . . . . . . .

5-10

February 2007

5-1

DLC3000 Series

5-2

249 Series Sensor in Standard Temperature Application . . . . . . . . . . . . . . . . . . . . . . 249 Series Sensor in High Temperature Application . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10 5-10

LCD Meter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11

Removing the LCD Meter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11

Replacing the LCD Meter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-12

Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-13

Removing the Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-13

Replacing the Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-13

Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-13

Removing the Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-13

Replacing the Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-14

Removing and Replacing the Inner Guide and Access Handle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-14

Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-15

Removing the Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-15

Replacing the Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-15

Packing for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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February 2007

Troubleshooting and Maintenance DLC3000 Series digital level controllers feature modular design for easy maintenance. If you suspect a malfunction, check for an external cause before performing the diagnostics described in this section.

ANALOG DISPLAY OF OUTPUT

PROCESS VARIABLE VALUE

Sensor parts are subject to normal wear and must be inspected and replaced as necessary. For sensor maintenance information, refer to the appropriate sensor instruction manual. DIAGNOSTIC MESSAGE

WARNING To avoid personal injury, always wear protective gloves, clothing, and eyewear when performing any maintenance operations. Personal injury or property damage due to sudden release of pressure, contact with hazardous fluid, fire, or explosion can be caused by puncturing, heating, or repairing a displacer that is retaining process pressure or fluid. This danger may not be readily apparent when disassembling the sensor or removing the displacer. Before disassembling the sensor or removing the displacer, observe the appropriate warnings provided in the sensor instruction manual. Check with your process or safety engineer for any additional measures that must be taken to protect against process media.

CAUTION When replacing components, use only components specified by the factory. Always use proper component replacement techniques, as presented in this manual. Improper techniques or component selection may invalidate the approvals and the product specifications, as indicated in table 1-1. It may also impair operations and the intended function of the device.

February 2007

MODE

E0380 / IL

Figure 5-1. LCD Meter Diagnostic Display

Diagnostic Messages In addition to the output, the LCD meter displays abbreviated diagnostic messages for troubleshooting the digital level controller. To accommodate two-word messages, the display alternates between the first and second word. The meter displays messages simultaneously on the Process Variable and Process Variable Unit lines as shown in figure 5-1. Messages on the Process Variable line refer to general device conditions, while messages on the Process Variable Unit line refer to specific causes for these conditions. A description of each diagnostic message follows. [BLANK] If the meter does not appear to function, and the instrument is otherwise functioning correctly, make sure the digital level controller is configured for the LCD meter. The meter will not function if the Meter Installed selection is Not Installed. To check this function, connect the Field Communicator to the digital level controller and turn it on. From the Online menu, select Detailed Setup, Output Condition, LCD Meter, and Meter Installed. For information on setting up the LCD meter see Section 4. A diagnostic test for meter function is also detailed later in this section. FAIL HDWR This message indicates the existence of one or more of the following conditions: The primary sensor input conversion is out of range. The primary sensor drive current is out of range. The internal reference voltage for controlling the loop current is out of range.

5-3

DLC3000 Series Perform the diagnostic procedures detailed later in this section to isolate the specific failure. If diagnostics indicate a failure of a particular module, replace the indicated module with a new one. Otherwise, correct the mechanical input condition to clear the message.

3. Connect the positive lead of the test meter to the + connection and the negative lead to the T connection inside the terminal box. 4. Measure Loop current as: Voltage (on test meter) 1000 = milliamps

OFLOW The location of the decimal point, as configured in the meter setup, is not compatible with the value to be displayed by the meter. For example, if the meter is measuring a level greater that 99.999 mm, and the meter decimal point is set to 3 digit precision, the meter will display an OFLOW message because it is only capable of displaying a maximum value of 99.999 when set to 3 digit precision. The position of the decimal point may be adjusted by using the Field Communicator. From the Online menu, select Detailed Setup, Output Condition, LCD Meter, and Decimal Places. Selecting 0 will put the display in auto-scale mode. (The number of decimal places displayed will be the maximum remaining in the display field for the current value of PV.)

example: Test meter Voltage X 1000 = Loop Milliamps 0.004 X1000 = 4.0 milliamperes 0.020 X 1000 = 20.0 milliamperes 5. Remove test leads and replace the terminal box cover.

Viewing Device Information The following menus are available to define and/or view information about the instrument.

Viewing Process Variable Information (1)

Hardware Diagnostics If you suspect a malfunction despite the absence of diagnostic messages on the Field Communicator display, follow the procedures described in table 5-1 to verify that the digital level controller hardware and process connections are in good working order. Under each of the major symptoms, specific suggestions are offered for solving problems. Always deal with the most likely and easiest-to-check conditions first.

Test Terminals Test connections inside the terminal box can be used to measure loop current. These terminals are across an internal 1 ohm resistor that is in series with the loop.

To view the process variable and the corresponding ranges, from the Online Menu select Process Variables. Follow the prompts on the Field Communicator display to view the process variable (level, interface, or density), electronics temperature, or PV range. PV Indicates the type of measurement either level, interface (the interface of two liquids of different specific gravities), or density (measures the liquid specific gravity). The process variable displayed and measured depends on the entry for PV is under PV Setup. Process Temp Indicates the process temperature if a two-wire or three-wire RTD is present and has been set up in the instrument.

1. Remove the terminal box cap.

Elect Temp Indicates the electronics temperature in the units specified under PV Setup, Temp Units.

2. Adjust the test meter to measure a range of 0.001 to 0.1 volts.

PV Range Displays the Upper Range Value and Lower Range Value for the process variable.

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February 2007

Troubleshooting and Maintenance Table 5-1. Troubleshooting Symptom

Potential Source

Corrective Action

Loop Wiring

1. Check resistance between the power supply and the Field Communicator connection. The net resistance in the loop must be between 230 and 1100 Ohms for HART communication. 2. Check for adequate voltage to the digital level controller. Refer to figure 3-11 for requirements. Some models of battery-operated field calibrators do not have sufficient compliance voltage to operate a DLC3010 over the entire output current range. 3. Check for excessive capacitance in the field wiring. (Isolate the instrument from field wiring and try to communicate locally.)

Terminal Box

4. If the terminal box does not have a 4-digit date-code sticker inside the lower lip, it may have developed a high internal resistance. Try a new terminal box.

Electronics Module

5. Swap the electronics module with a known good part.

Transducer Module

6. If the electronics module and terminal box work on a known good transducer module, replace the old transducer module.

Loop Wiring

7. Check for open circuits. 8. Check for proper polarity at the signal terminals. See item 2. above.

Terminal Box

9. Check resistance between Loop+ and T terminals of terminal box. If greater than 1.1 Ohm, the internal sense resistor may be damaged. An external jumper may be added for a temporary repair. Replace terminal box and avoid applying loop voltage across T and Loop+ for long term solution. See item 4. above

Electronics Module

See item 5. above.

Transducer Module

See item 6. above.

Fixed Output ` 3.7 mA

Alarm Condition (Fail-low setting)

Connect the Field Communicator and: 10. Select Test Device (2-1-1) to isolate a module failure. 11. Check PV against Hi-Hi and Lo-Lo alarm thresholds and PV alarm deadband setting, if these alarms are enabled.

Fixed Output = 3.8 mA

Low Saturation

Connect the Field Communicator and: 12. Check the PV against the upper and lower range values. Check actual process condition and calibration adjustments.

Fixed Output = 20.5 mA

High Saturation

Connect the Field Communicator and: see item 12. above.

Fixed Output ` 22.5 mA

Alarm Condition (Fail-high setting)

Connect the Field Communicator and: see items 10. and 11. above.

Loop Wiring

13. Check for short circuits.

Terminal Box

14. Remove terminal box from the instrument, and apply 24 Volts between Loop+ and Loop! terminals, (with a series resistance of approximately 1200 Ohms to protect power supply). If any current flows, replace terminal box.

Electronics Module

See item 5. above.

Electronics Module

Connect the Field Communicator and: 15. Run Loop diagnostic test (2-2). If the forced output does not track commands, attempt Scaled DAC Trim procedure (2-4-3). If DAC calibration cannot be restored, replace Electronics Module.

Sensor

16. Check torque tube spring rate change versus process temperature per figure 1-2 and Form 5767. Use appropriate material for process temperature. Pre-compensate the calibration for target process condition.

Transducer Module

Connect the Field Communicator and: 17. Check Electronics Temperature (2-4-2-3) against an independent measurement of DLC3010 temperature. a) If inaccurate, trim the electronics temperature measurement (2-4-2-4) to improve ambient temperature compensation performance. b) If Electronics Temperature value is extreme, replace transducer module.

Electronics Module

Connect the Field Communicator and: 18. Run Loop diagnostic test (2-2). Leave instrument in fixed current mode at 12 mA command and observe analog output variation with ambient temperature. If drift exceeds specifications replace electronics module.

Configuration Data

Connect the Field Communicator and: 19. Check stored Specific Gravity values (3-3-5) against independent measurement of process density. If process SG has changed from calibration values, correct configuration data to match process

Loop Wiring

If output current enters a limit cycle between zero and a value within the 4!20 mA range when level reaches some arbitrary upper threshold, 20. Check for excessive loop resistance or low compliance voltage. (See items 2. and 4. above.)

Loop Wiring

see item 20. above. (Insufficient voltage to operate display)

LCD Assy

21. Swap LCD Assy with known good part.

Electronics Module

22. Connector solder joint failure in electronics module. Replace module.

Analog Output is within valid range but Instrument does not communicate with Field Communicator

Output ` 0 mA

Fixed Output > 22.5 mA

Output is within 4!20 mA range, but does not track displayed PV value (e.g., a) gain error, b) low saturation occurs at a value higher than 3.8 mA, c) high saturation occurs at a value lower than 20.5 mA)

Output Drifting while at fixed process input.

Erratic Output

Scrambled or erratic Display on LCD

February 2007

5-5

DLC3000 Series Viewing Output Information (4-2-1)

130 110 PV (% RANGE)

To view the analog output variables, from the Online Menu select Detailed Setup, Output Condition, and Analog Output. Follow the prompts on the Field Communicator display to view the process variable (level, interface, or density), analog output, percent range, or Alarm jumper.

150

90 70 50 30 10

PV Indicates the type of measurement either level, interface (the interface of two liquids of different specific gravities), or density (measures the liquid specific gravity). The process variable displayed and measured depends on the entry for PV is under PV Setup.

30 50 0

8 LRV

100

24 URV

150

% Range Indicates the current process variable in percent of the span determined by the lower range value and the upper range value.

ǒPVEU * LRVǓ PV(%range) + (URV * LRV)

DIRECT ACTION

AO Indicates the current analog output value of the instrument, in milliamperes.

Refer to figure 5-2. If the digital level controller is setup for direct action (i.e., the lower range value is less than the upper range value), 0% range corresponds to the lower range value (LRV) and 100% range corresponds to the upper range value (URV). If the digital level controller is setup for reverse action (i.e., the lower range value is greater than the upper range value), 0% range corresponds to the upper range value (URV) and 100% range corresponds to the lower range value (LRV). Use the following equation to calculate the % range values:

LEVEL (INCHES)

130 110 PV (% RANGE)

90 70 50 30 10 10 30 50 0

8 URV

24 LRV

LEVEL (INCHES) E0383 / IL

REVERSE ACTION

Figure 5-2. PV % Range Indication for Direct and Reverse Action with a 32-Inch Displacer Ranged for 8 to 24 Inches

where: PVEU = process variable in engineering units The LRV always represents the 0% range value and the URV always represents the 100% range value.

reference must have been obtained at the zero buoyance condition. Use as high a test level as possible to improve accuracy.

Alarm Jumper Displays the position of the hardware alarm jumper, either high current or low current.

To measure specific gravity, from the Online menu select Detailed Setup, Sensors, and Measure Spec Gr. Follow the prompts on the Field Communicator and the following procedure: 1. Set the control loop for manual control.

Measuring Specific Gravity (4-1-4) If the instrument and sensor are calibrated, you can have the digital level controller measure the liquid specific gravity, if it is not known. You must be able to manipulate the level and externally measure it to have the instrument measure the specific gravity. To work properly, this procedure must be in done in Level Measurement mode, and a valid dry coupling

5-6

2. Adjust the liquid level so that the displacer is partially submerged. 3. Enter the externally measured level, in engineering units. After you press OK on the Field Communicator, the instrument begins calculating the specific gravity. You can then elect to use this value as the specific gravity for all level measurements. If you select No, the February 2007

Troubleshooting and Maintenance instrument uses the specific gravity entered under PV Setup, or the values from the specific gravity tables. 4. When finished measuring specific gravity, return the control loop to automatic control.

Trending (4-4) The DLC3000 Series digital level controller can store up to five samples of a selected variable. This trend information can be communicated via the HART protocol to a HART-based control system. To set up the instrument for trending, from the Online menu, select Detailed Setup and Trending. Follow the prompts on the Field Communicator to specify the variable to be trended, the sampling rate, and to have the Communicator display the trend values. Trend Var Permits selecting the variable for trending: PV, Process Temperature, or Electronics Temperature. Off turns the trending function off. Trend Interval Permits selecting how often the instrument should sample and store the selected trend variable. Enter a sample interval between 0.2 and 10.0 seconds. Read Trend Permits viewing the five most recent samples on the Field Communicator display. The five sample values are displayed along with a sample number. The smaller sample number contains the oldest sample value. When finished viewing the displayed sample values, press OK on the Field Communicator to view the next five samples. Press ABORT to exit the display.

Viewing the Device ID (4-3-4) Each instrument has a unique Device Identifier. The device ID provides additional security to prevent this instrument from accepting commands meant for other instruments. To view the device ID, from the Online Menu select Detailed Setup, Device Information, and Device ID.

Viewing Version Information (4-3-2) The Version Information menu is available to view information about the instrument. From the Online menu, select Detailed Setup, Device Information, and Version Info. Follow the prompts on the Field Communicator display to view information in the following fields: Device Rev (Device Revision), Firmware Rev (Firmware Revision), Hardware Rev (Hardware Revision), HART Univ Rev (HART Universal Revision). February 2007

Device Rev Device Revision is the revision of the protocol for interfacing to the functionality of the instrument. Firmware Rev Firmware Revision is the revision number of the Fisher software in the instrument. Hardware Rev Hardware Revision is the revision number of the Fisher instrument hardware. HART Univ Rev HART Universal Revision is the revision number of the HART Universal Commands which are used as the communications protocol for the instrument. 375 DD Rev DD Rev is the revision level of the Device Description used by the 375 Field Communicator while communicating with the instrument.

Viewing Serial Number (4-3-3) Information To view or enter serial number information, from the Online menu select Detailed Setup, Device Information, and Serial Numbers. Follow the prompts on the Field Communicator display to enter or view the following serial numbers: Instrument S/N (Instrument Serial Number), Displacer S/N (Displacer Serial Number), and Final Assembly Num (Final Assembly Number). Instrument S/N Enter the serial number on the instrument nameplate, up to 12 characters. Displacer S/N Use this field to enter or view the displacer serial number. The displacer serial number is the same as the sensor serial number found on the sensor nameplate. Final Assembly Num The Final Assembly Number is a number that can be used to identify the instrument and sensor combination.

Viewing Process and (4-2-4) Temperature Alarms To view active process or temperature alarms, from the Online menu, select Detailed Setup, Output Condition, and Display Alarms. If a process or temperature alarm is active, it will appear when the Display Alarms menu is selected. If more than one alarm is active, they will appear on the display one at a time in the order listed below. 1. PV Exceeds Hi Alarm Limit

5-7

DLC3000 Series 2. PV Exceeds Hi Hi Alarm Limit 3. PV Exceeds Lo Alarm Limit 4. PV Exceeds Lo Lo Alarm Limit 5. Process Temperature Exceeds Hi Alarm Limit 6. Process Temperature Exceeds Lo Alarm Limit 7. Electronics Temperature Exceeds Hi Alarm Limit 8. Electronics Temperature Exceeds Lo Alarm Limit

Viewing Hardware Alarms (2-3)

To view hardware alarm information, from the Online menu select Diag/Service and Hardware Alarms. Follow the prompts on the Field Communicator display to view information in the following fields: Alarm Jumper, NVM (Non-Volatile Memory), Free Time, Level Snsr Drive (Level Sensor Drive), and A/D TT Input (Analog to Digital Torque Tube Input). Alarm Jumper Displays the position of the hardware alarm jumper, either high current or low current. NVM Displays the current value of the remaining number of NVM writes. Setup data is stored in NVM. If the remaining number of NVM writes seems to be decreasing rapidly, check to make sure the control system is not unnecessarily writing to the NVM. Reaching 0 will cause the NVM Write Limit Exceeded status to be activated. Free Time Displays the current microprocessor free time. If the free time limit check fails, the Free Time Limit Exceeded status is activated. Level Snsr Drive Displays the current limit and value of the Level Sensor Drive Signal. If the drive value exceeds the hardcoded limits, either above or below, the instrument forces the output current to the alarm value determined by the alarm jumper and activates the Field Device Malfunction status message. (The Level Snsr Drive Limit field is for factory use only.) A/D TT Input Displays the current limit and value of the A/D Torque Tube Input. If the input exceeds the hardcoded limits, either above or below, the Torque Tube A/D Input Failed status is activated. (The A/D TT Input Limit field is for factory use only.)

Viewing Instrument Status (2-1-1) To view the instrument status, from the Online menu select Diag/Service, Test Device, Status. The

5-8

following describes the various displays for the instrument Status menu. Torque Tube A/D Input Failed When active, indicates the torque tube position reading has exceeded the hardcoded limits, either above or below. When active the instrument forces the output current to the alarm value determined by the alarm jumper. If this status message appears, the lever assembly may been driven to a hard stop by a bad mechanical coupling condition. Try recoupling the instrument to clear it. If it does not clear, from the Online menu, select Diag/Serv, Hardware Alarms, A/D TT input (2-3-5). If the value is 1230 mV and does not respond to lever assembly motion, try installing a new Electronics Module. If a new Electronics Module does not clear the failure, the Transducer Module is at fault.

Note When using the handheld communicator, it is necessary to exit the menu item, move the lever, and re-enter the menu item with the lever in the new position. The variable is not read dynamically, only once per entry. In AMS Device Manager, this variable is updated dynamically, although at a slow rate.

Hall Current Readback Limit Failed When active, indicates the Hall current readback has exceeded the hardcoded limits, either above or below. When active the instrument forces the output current to the alarm value determined by the alarm jumper. This status typically indicates an electronics failure. If this status message appears, try cycling power to the instrument and see if it clears. If it does not clear, try replacing the Electronics Module. If the message still doesn t clear, the problem is on the transducer board. Contact your Emerson Process Management sales office for repair information. Reference Voltage Limit Failed When active, indicates the reference voltage reading of the A/D converter has exceeded the hardcoded limits, either above or below. When active the instrument forces the output current to the alarm value determined by the alarm jumper. If this status message appears, try cycling power to the instrument and see if it clears. If it does not clear, replace the Electronics Module. NVM Write Limit Exceeded When active, indicates the total number of writes to one of the three areas of NVM has exceeded the hardcoded limit. If February 2007

Troubleshooting and Maintenance this status message appears, run the hardware alarm diagnostics to determine which area of NVM is at zero count. From the Online menu, select Diag/Serv, Hardware Alarms, NVM (2-3-2). If the HC12 (Microprocessor) count is zero, correct the condition that is causing excessive writes to the transmitter. Try cycling power to the instrument and see if it clears. If it does not clear, replace the Electronics Module. If the Hall (Transducer) count is zero, replace the Transducer Module. Free Time Limit Exceeded When active, indicates the instrument has failed the free time check and the execution period cannot be maintained. If this status message appears, try cycling power to the instrument and see if it clears. If it does not clear, replace the Electronics Module. Process Temperature Sensor Failed When active, indicates the process temperature sensor (RTD) reading has exceeded the hardcoded limits (<10 ohms or >320 ohms). If this status message appears, reinstall the process temperature sensor (RTD). The following status messages appear whenever they are active. You do not need to access any specific Online menu item to see them. Field Device Malfunction When active, indicates that an attempt to write to NVM failed, usually in the message or date fields. Try to write the field again at a later time. Primary Variable Analog Output Fixed When active, indicates the analog and digital outputs for the Primary Variable are held at the requested value. They will not respond to the applied process. Primary Variable Analog Output Saturated When active, indicates the analog and digital outputs for the Primary Variable are beyond their limits and no longer represent the true applied process.

February 2007

Non-Primary Variable Out of Limits When active, indicates the process applied to a sensor, other than that of the Primary Variable, is beyond the operating limits of the device. This indicates a temperature alarm is active. Primary Variable Out of Limits When active, indicates the process applied to the sensor for the Primary Variable is beyond the operating limits of the device.

Removing the Digital Level Controller from the Sensor Because of its modular design, most of the service and maintenance to the digital level controller can be done without removing it from the sensor. However, if necessary to replace sensor to instrument mating parts or parts in the transducer housing, or to perform bench maintenance, perform the following procedures to remove the digital level controller from the sensor.

WARNING On an explosion-proof instrument, remove the electrical power before removing the instrument covers in a hazardous area. Personal injury or property damage may result from fire and explosion if power is applied to the instrument with the covers removed.

Tools Required Table 5-2 lists the tools required for maintaining the DLC3000 Series digital level controller.

5-9

DLC3000 Series Table 5-2. Tools Required TOOL

USAGE

KEYS

Handle Cover-lock set screws

31 20

Small cap screws

4 mm

Lever assembly mtg cap screw

Hex Key

5 mm

Terminal box mtg cap screw

Hex Socket

10 mm

Coupling nut

Open-end

13 mm

Transmitter mounting nuts

Phillips Screwdriver

Terminal screws Electronics module mtg screws

25 36

Small flat blade screwdriver

LCD assy mtg screws

Strap wrench

Helpful for removing a display cover that has been over-tightened

Large flat blade screwdriver(1)

Flex circuit mtg screws

Needle nose pliers(1)

Align/clamp ring extraction

Hex Key

2 mm

Hex Key

2.5 mm

Hex Key

SIZE

1. Needed to remove a flex circuit if date code numbers are requested for warranty information.

Removing the Type DLC3010 Digital Level Controller from a 249 Series Sensor

Note If the access handle will not slide, the sensor linkage is most likely in an extreme position. When the lever assembly is at a hard stop inside the housing, the locking pin on the access door may not be able to engage the mating slot in the lever assembly. This condition can occur if the displacer has been removed, if the sensor is lying on its side, or if the instrument had been coupled to the sensor while the displacer was not connected. To correct this condition, manipulate the sensor linkage to bring the lever assembly to within approximately 4 degrees of the neutral position before attempting to slide the handle. A probe inserted through the top vent of the 249 head may be required to deflect the driver rod to a position where the lever assembly is free.

4. Using a 10 mm deep well socket inserted through the access hole, loosen the shaft clamp (figure 3-5). 5. Loosen and remove the hex nuts (key 34) from the mounting studs (key 33). 6. Carefully pull the digital level controller straight off the sensor torque tube.

249 Series Sensor in Standard Temperature Applications 1. Loosen the set screw (key 31) in the terminal box cover assembly (key 6) so that the cover can be unscrewed from the terminal box. 2. After removing the cover (key 6), note the location of field wiring connections and disconnect the field wiring from the wiring terminals.

3. As shown in figure 3-5, locate the access handle on the bottom of the transducer housing. Using a 2 mm hex key, back out the set screw in the depression on the access handle until it is flush with the handle surface. Press on the back of the handle, as shown in the figure, and slide the handle toward the front of the unit, (the locked position), to expose the access hole. Be sure the locking handle drops into the detent.

5-10

CAUTION Tilting the instrument when pulling it off of the sensor torque tube can cause the torque tube shaft to bend. To prevent damage to the torque tube shaft, ensure that the digital level controller is level when pulling it off of the sensor torque tube. 7. When re-installing the digital level controller, follow the appropriate procedure outlined in the Installation section. Also setup the digital level controller as described in the Initial Setup section.

249 Series Sensor in High Temperature Application 1. Loosen the set screw (key 31) in the terminal box cover assembly (key 6) so that the cover can be unscrewed from the terminal box.

February 2007

Troubleshooting and Maintenance 2. After removing the cover (key 6), note the location of field wiring connections and disconnect the field wiring from the wiring terminals. 3. As shown in figure 3-5, locate the access handle on the bottom of the transducer housing. Using a 2 mm hex key, back out the set screw in the depression on the access handle until it is flush with the handle surface. Press on the back of the handle, as shown in the figure, and slide the handle toward the front of the unit, (the locked position), to expose the access hole. Be sure the locking handle drops into the detent.

CAUTION Tilting the instrument when pulling it off of the sensor torque tube can cause the torque tube shaft to bend. To prevent damage to the torque tube shaft, ensure that the digital level controller is level when pulling it off of the sensor torque tube. 7. Loosen and remove the hex nuts (key 34) from the mounting studs (key 33). 8. Pull the heat insulator (key 57) off the mounting studs.

4. Using a 10 mm deep well socket inserted through the access hole, loosen the shaft clamp (figure 3-5). 5. While supporting the instrument, loosen and remove the cap screws (key 63). 6. Carefully pull the digital level controller straight off the torque tube shaft extension (key 58). February 2007

9. When re-installing the digital level controller, follow the appropriate procedure outlined in the Installation section. Also setup the digital level controller as described in the Setup and Calibration section.

LCD Meter Assembly WARNING In an explosion-proof or flame-proof installation remove the electrical power before removing the instrument covers in a hazardous area. Personal injury or property damage may result from fire and explosion if power is applied to the instrument with the covers removed. The digital level controller is designed with a dual-compartment housing; one compartment contains the LCD meter and Electronics Module; the other contains all wiring terminals and the communication receptacles. The LCD meter is located in the compartment opposite the wiring terminals, as shown in figure 5-3.

Removing the LCD Meter Perform the following procedure to remove the LCD meter. 1. Disconnect power to the digital level controller. 2. Remove the cover from the transducer housing. In explosive atmospheres, do not remove the instrument cover when the circuit is alive, unless in an intrinsically safe installation.

5-11

DLC3000 Series TERMINAL BOX (KEY 5) STUD (KEY 33)

TERMINAL BOX COVER (KEY 6)

ADAPTER RING (KEY 32)

HEX NUT (KEY 34)

LEVER ASSEMBLY

TRANSDUCER ASSEMBLY ELECTRONICS MODULE (KEY 2) LCD METER ASSEMBLY (KEY 4)

W7927 / IL

COVER (KEY 3)

Figure 5-3. DLC3000 Series Digital Level Controller Assembly

3. Loosen the two screws that anchor the LCD meter to the Electronics Module. These screws are captive and should not be removed. 4. Firmly grasp the LCD meter and pull it straight away from the Electronics Module. Retain the six-pin dual header for later reinstallation.

Replacing the LCD Meter

4. Note the position of the alarm jumper on the LCD meter removed from the digital level controller. Remove the alarm jumper and install it on the replacement meter in the same position. 5. Install the six-pin dual header on the LCD meter. Carefully insert the LCD meter to mate with the interconnecting pins with the receptacles on the Electronics Module .

Perform the following procedure to replace the LCD meter. 1. Verify that the interconnection header is in the six-pin socket on the face of the Electronics Module. The longer set of pins should be inserted in the Electronics Module socket. 2. Decide which direction to orient the meter. The meter can be rotated in 90-degree increments for easy viewing. Position one of the four six-pin sockets on the back of the meter to accept the interconnection header, and insert the long meter screws into the two holes on the meter to coincide with the appropriate holes on the Electronics Module. 3. Attach the meter to the interconnection pins. Thread the long meter screws into the holes on the Electronics Module and tighten to secure the meter.

5-12

CAUTION To prevent damage to the interconnecting pins when installing the LCD Meter, use the guide pins to insert the LCD meter straight onto the Electronics Module, without twisting or turning.

6. Replace the cover. Tighten 1/3 of a revolution after the cover begins to compress the O-ring. Both instrument covers must be fully engaged to meet explosion-proof or flame-proof requirements. February 2007

Troubleshooting and Maintenance Electronics Module Removing the Electronics Module Perform the following procedure to remove the Electronics Module.

Note The electronics are sealed in a moisture-proof plastic enclosure referred to as the Electronics Module. The assembly is a non-repairable unit; if a malfunction occurs the entire unit must be replaced.

1. Disconnect power to the digital level controller. 2. Remove the cover from the transducer housing. In explosive atmospheres, do not remove the instrument cover when the circuit is alive, unless in an intrinsically safe installation. Remove the LCD meter assembly.

CAUTION To prevent damage to the interconnecting pins when installing the Electronics Module, use the guide pins to insert the Electronics Module straight onto the Transducer housing receptacles without twisting or turning.

2. Tighten the two mounting screws. Replace the LCD meter assembly. 3. Replace the cover. Tighten 1/3 of a revolution after the cover begins to compress the O-ring. Both instrument covers must be fully engaged to meet explosion-proof requirements.

Terminal Box The terminal box is located on the transducer housing and contains the terminal strip assembly for field wiring connections. Unless indicated otherwise, refer to figure 6-3.

3. Loosen the two screws that anchor the Electronics Module to the transducer housing. These screws are captive and should not be removed. 4. Firmly grasp the Electronics Module and pull it straight out of the housing.

Removing the Terminal Box

Replacing the Electronics Module

1. Loosen the set screw (key 31) in the terminal box cover assembly (key 6) so that the cover can be unscrewed from the terminal box.

Perform the following procedure to replace the Electronics Module. 1. Carefully insert the Electronics Module to mate the interconnecting pins with the receptacles on the Transducer housing. February 2007

2. After removing the cover (key 6), note the location of field wiring connections and disconnect the field wiring from the wiring terminals. 3. Remove the screw (key 7), and pull out the terminal box assembly.

5-13

DLC3000 Series SCREWS (KEY 13)

CAUTION To avoid damaging the terminal box assembly connector, pull the terminal box assembly straight out of the housing, without twisting or turning.

HANDLE ASSEMBLY (KEY 12)

VENT HOLES LUBRICATE THIS SURFACE

LUBRICATE THIS SURFACE

Replacing the Terminal Box VENT HOLE

Note 5

TRANSDUCER HOUSING

Inspect all O-rings for wear and replace as necessary.

INNER GUIDE (KEY 11) E0381 / IL

1. Apply sealant to the O-ring (key 27) and install the O-ring over the stem of the terminal box as shown in figure 6-3. 2. Orient the terminal box so that the connectors engage properly, and carefully insert the terminal box into the transducer housing until the O-ring is seated.

ZERO LOCKING PIN ACCESS HOLE

Figure 5-4. Installing Inner Guide and Access Handle Assembly

screw to engage the recesses but no more than 0.88 N m (7.8 lbf in). 8. Apply lubricant to the conduit entrance plug (key 28) and install it in the unused conduit entrance.

CAUTION To avoid damaging the mating pins in the Transducer housing, ensure that the guiding mechanism is engaged properly before applying force. 3. Fasten the terminal box to the transducer housing with the screw (key 7). Tighten the screw to 6 N m (53 lbf in). 4. Apply sealant to the O-ring (key 26) and install the O-ring over the cover threads on the terminal box. Use a tool to prevent cutting the O-ring while installing it over the threads.

Removing and Replacing the Inner Guide and Access Handle Assembly The access handle and inner guide are located on the transducer housing. Unless indicated otherwise, refer to figure 6-2. 1. Remove the digital level controller from the sensor as described in Removing the Digital Level Controller from the Sensor. 2. Loosen and remove the hex nuts (key 34) from the studs (key 33) and remove the adapter ring (key 32).

5. Reconnect the field wiring as noted in step 2 in the Removing the Terminal Box procedure. 6. Apply lubricant to the threads on the terminal box to prevent seizing or galling while installing the terminal box cover. 7. Screw the terminal box cover assembly (key 6) completely onto the terminal box to seat the O-ring (key 26). Loosen the cover (not more than 1 turn) until the set screw (key 31) aligns with one of the recesses in the terminal box beneath the cover. Tighten the set

5-14

Note In the next step the screws (key 13) will be attracted by the magnets on the lever assembly. Use care to keep the screws from falling beneath the coupling shield.

February 2007

Troubleshooting and Maintenance 3. Remove the coupling shield (key 16) by removing the two screws (key 13). Take care not to drop the screws into the lever assembly compartment where they will be attracted by the magnets. 4. Loosen and remove the two screws (key 13) in the handle assembly (key 12). Remove the handle assembly and the inner guide (key 11). 5. Apply thread lock to the internal threads of the replacement inner guide. Also apply a thin coat of a light grade of grease to the zero locking pin on the inner guide and on the surface that is opposite the zero locking pin, as shown in figure 5-4 (this surface contacts the transducer housing when installed). 6. Place the inner guide in the slot inside the transducer housing so that the vent holes in the inner guide (the milled slots in the inner guide, see figure 5-4) face the exterior of the housing and are over the access hole. 7. Apply a thin coat of a light grade of grease to the surface of the replacement handle assembly (see figure 5-4) where it will contact the transducer housing. 8. Install the handle assembly (key 12) in the slot of the transducer housing over the inner guide (key 11) so that the vent holes in the handle assembly are over the access hole. 9. Install two screws (key 13) to secure the handle assembly (key 12) to the inner guide (key 11). Tighten the screws to 0.48 N m (4.2 lbf in). 10. Press down on the handle as shown in figure 3-5 and slide it forward to make sure it works smoothly and that the zero locking pin engages the lever assembly. Also check for free travel of the lever assembly when the handle is in the unlocked position. 11. Install the coupling shield (key 16) and secure with the two screws (key 13). Tighten the screws to 0.48 N m (4.2 lbf in). 12. Refer to figure 6-1. Install the adapter ring (key 32) on the studs (key 33) and secure with hex nuts (key 34). 13. When re-installing the digital level controller, follow the appropriate procedure outlined in the Installation section. Also setup the digital level controller as described in the Setup and Calibration section.

February 2007

Lever Assembly Removing the Lever Assembly The lever assembly is located in the transducer housing. Unless indicated otherwise, refer to figure 6-2. 1. Remove the digital level controller from the sensor as described in Removing the Digital Level Controller from the Sensor. 2. Loosen and remove the hex nuts (key 34) from the studs (key 33) and remove the adapter ring (key 32). 3. Remove the coupling shield (key 16) by removing the two screws (key 13). Take care not to drop the screws into the lever assembly compartment where they will be attracted by the magnets. 4. Inspect the lever assembly alignment with the housing. If it is off center or not co-axial with the main housing, continue with the removal procedure. 5. Loosen and remove the mounting screw (key 14) from the lever assembly. 6. Loosen the flexure block from its machined pocket in the housing, by inserting a smooth tool into the hole for the mounting screw, and gently rocking it back and forth in what would be the vertical axis if the transmitter were installed. 7. Lift the lever assembly out of the housing. Inspect the flexure for damage. If the flexure is bent or torn, replace the lever assembly.

Replacing the Lever Assembly Replacing the lever assembly in the field may result in a slight degradation in linearity performance, since the factory characterizes the entire transducer module as a unit. For most applications, this degradation should not be noticeable. (If guaranteed restoration to factory specification is desired, the entire transducer module should be replaced.) 1. Move the zero-pin slide to the locking position. 2. Apply a thin coat of a light grade of grease to the internal thread of the hole for the lever mounting bolt. 3. Hold lever assembly by coupling block and guide the flexure block into its aligning slot in the housing without applying any downward force to the sprung parts of the lever assembly.

CAUTION To prevent damage to the flexure when inserting the flexure block into its aligning slot in the housing, apply pressure to the flexure block only.

5-15

DLC3000 Series A long pin inserted into the bolt-hole in the flexure block may be used to pull it against the inside corner of the aligning slot.

Packing for Shipment

4. Secure the block by reinstalling the M5x20 socket-head cap screw (key 14). Torque to 2.8 N m (25 lbf in) $10%.

If it becomes necessary to return the unit for repair or diagnosis, contact your Emerson Process Management sales office for returned goods information.

5. Mark bolt head and block with a movement-detecting sealant. 6. Install the coupling shield (key 16) and secure with the two screws (key 13). Tighten the screws to 0.48 N m (4.2 lbf in).

7. Refer to figure 6-1. Install the adapter ring (key 32) on the studs (key 33) and secure with hex nuts (key 34). When re-installing the digital level controller, follow the appropriate procedure outlined in the Installation section. Set up the digital level controller as described in the Setup and Calibration section.

5-16

CAUTION Lock the lever assembly when shipping the stand-alone instrument, to prevent damage to the flexure. Use the original shipping carton if possible.

February 2007

Replaceable Parts 6-6

Section 6 Replaceable Parts Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2

Mounting Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2

Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3

Type DLC3010 Digital Level Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3

Transducer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4

Terminal Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5

Terminal Box Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5

Mounting Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6 6-6

249 Series Sensor with Heat Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

February 2007

6-1

DLC3000 Series Table 6-1. Mounting Kits MASONEILAN

FOXBORO-ECKARDT

FISHER 249 SERIES

12100 or 12800

12200 or 12300

YAMATAKE NQP

144LD

LP167

Without Heat Insulator

---

28B5742X012

28B8444X012

GB0101X0012

29B5900X012

29B8480X012

With Heat Insulator

28B5741X012

28B5743X012

28B8445X012

GB0105X0012

29B8491X012

---

Parts Ordering

Mounting Kits

Whenever corresponding with your Emerson Process Management sales office about this equipment, always mention the controller serial number. When ordering replacement parts, refer to the 11-character part number of each required part as found in the following parts list. Parts that do not show part numbers are not orderable.

Heat Insulator Kit, for mounting Type DLC3010 on 249 Series sensor. Includes heat insulator (key 57), cap screws (key 61), shaft extension (key 58), shaft coupling (key 59), and set screws (key 60). 28B5741X012

WARNING

Use only genuine Fisher replacement parts. Components that are not supplied by Emerson Process Management, should not, under any circumstances, be used in any Fisher instrument. The use of components not manufactured by Emerson Process Management will void your warranty, might adversely affect the performance of the instrument, and could give rise to personal injury and property damage.

Note Contact your Emerson Process Management sales office for information on the availability of additional mounting kits.

Parts Kits 1*

Small Hardware Spare Parts Kit

19B1643X032

Spare O-Rings Kit Includes three each of keys 21, 26, and 27

6-2

Part Number

Includes Screw (key 7) Set Screw (key 20) Set Screw (key 31) Test Terminal (key 24 Wire Retainer (key 25) Lock Washer (key 31) Alarm Jumper (key 35) Header Assembly (key 38) Washer, Lock, Spring (key 47), Clamp Nut (key 76)

Note Neither Emerson, Emerson Process Management nor any of their affiliate entities assumes responsibility for the selection, use, and maintenance of any product. Responsibility for the selection, use, and maintenance of any product remains with the purchaser and end-user.

Description

Qty/kit 1 2 2 4 8 1 2 2 1 1 19B1643X022

Recommended spare part

February 2007

Replaceable Parts

NOTES: INSTALL ALARM JUMPER (KEY 35) ON ELECTRONICS ASSEMBLY (KEY2) WHEN LCD METER (KEY 4) IS NOT INSTALLED. 1 LOCATION OF ALARM JUMPER (KEY 35) WHEN LCD METER (KEY 4) IS INSTALLED. 2 APPLY LUB/THREADLOCK 58B5510-C /IL

Figure 6-1. DLC3000 Series Digital Level Controller Assembly

Parts List Key

Description

Part Number

Type DLC3010 Digital Level Controllers (figure 6-1) 1 2

3 4

Transducer Module(1) GE18497X012 Electronics Ass y, includes alarm jumper (key 35) and captive screws (key 36), and header ass y (key 38) and captive screws (key 40) For use with transducer module 48B5763X012 (has obsolete Hall sensor on Flex circuit) 18B5529X022 For use with transducer module GE18497X012 (has new Hall sensor on rigid boards) 18B5529X032 Cover Assy, includes O-ring (key 21) 38B5734X012 LCD Meter Ass y,includes alarm jumper (key 35) and captive screws (key 36), and header ass y (key 38) and captive screws (key 40) 28B5738X012 Terminal Box Ass y 28B5740X022

Key 6 7* 8 9 21* 32 33 34 35* 36 38* 40 66 67 70

Description Terminal Box Cover Ass y, includes labels (key 30 and 64) and set screw (key 31) Screw, hex socket(2) Nameplate Drive Screw, 18-8 SST O-ring, nitrile(3) Adaptor Ring, A03600 Stud, SST (4 req d) Hex Nut, 304 SST (4 req d) Alarm Jumper(2) Screw, captive, 18-8 SST For electronics ass y (2 req d) Header Assembly, dual row (not shown)(2) Screw, captive, 18-8 SST For LCD meter (2 req d) Anti-Seize Sealant (not furnished with instrument) Thread locking adhesive (medium strength) (not furnished with instrument) Lithium grease (not furnished with instrument)

Part Number 28B5531X012 11B9076X042 1A368228982 1K1810X0012 1N10160G012 1N10162G012 1N10252G012 18B5733X012 18B5732X022 18B5736X012 18B5732X012

* Recommended spare part 1. These parts are not replaced in the field due to serialization and characterization issues, but can be replaced at a qualified service center. Contact your Emerson Process Management sales office for additional information. 2. Included in small hardware spare parts kit. 3. Included in spare O-rings kit.

February 2007

6-3

DLC3000 Series

47 48 82

31 GE18497 / DOC

Figure 6-2. DLC3000 Series Digital Level Controller Transducer Assembly Key

Description

Part Number

Transducer Assembly (figure 6-2) 11 12 13 14 15 16 17 19

Inner Guide, aluminum Handle Ass y aluminum/SST Screw, hex socket, 18-8 SST (4 req d) Screw, cap, 18-8 SST Lever Assembly, aluminum/SST/NdFeB/CS Coupling Shield, 18-8 SST Ring, align/clamp Machine Screw, pan head

28B5482X012 18B5522X012 18B5513X012 18B5515X012 38B5509X022 38B5485X012 28B5479X022 18B5518X012

Key 20* 31* 47 48 67 68 79 80 81 82

Description Set Screw, 18-8 SST(2) Set Screw, hex socket, 18-8 SST(2) Spring Lock Washer, 18-8 SST(2) Clamp Nut, 18-8 SST(2) Thread Locking adhesive (medium strength) (not furnished with instrument) Sealant Transducer Board Assembly(1) Hall Guard Compound, silicone Bolt, lock, coupling block, SST

Part Number 18B5516X012 18B5517X012 19B0819X012 19B5497X012

GE14863X012 GE15488X012 28B5494X012

6-4

February 2007

Replaceable Parts

SECTION A-A

APPLY LUBRICANT 28B5740!B / DOC

Key

Figure 6-3. Terminal Box Assembly

Description

Part Number

Terminal Box Assembly (figure 6-3) 24* 25* 26* 27* 28 65 66

Test Terminal, 18-8 SST (2 req d)(2) Wire Retainer, 18-8 SST (8 req d)(2) O-Ring, nitrile(3) O-Ring, nitrile(3) Pipe Plug, 18-8 SST Lubricant, Silicone (not furnished with instrument) Anti-Seize Sealant (not furnished with instrument)

28B5716X012 18B5532X012 1H8762X0012 10A8218X032 1H5137X0012

Terminal Box Cover Assembly (figure 6-4) 28B5531-B / DOC

30 31* 64

Label, internal, plastic Set Screw, hex socket, 18-8 SST(2) Label, external

28B5721X012 18B5517X012 18B5537X012

Figure 6-4. Terminal Box Cover Assembly

* Recommended spare part 1. Included in small hardware spare parts kit. 2. Included in spare O-rings kit.

February 2007

6-5

DLC3000 Series

6 28B5741-A

Figure 6-5. Mounting Kit for 249 Series Sensor with Heat Insulator

Key

Description

Part Number

Key

Description

Masoneilan R

Part Number

Sensors (figures 6-6 and 6-7)

12100 or 12800 without Heat Insulator

Mounting Parts These parts are also available as a kit. Refer to the Mounting Kits section.

58 59 60 61 62 63

Shaft Extension, S31600 Shaft Coupling, S30300 Set Screw, hex socket, SST (2 req d) Screw, hex hd, 18-8 SST (4 req d) Mounting Adapter, A03560 Screw, hex socket, (4 req d)

10B2396X012 1A577935032 1E6234X0022 1A3816K0012 31B1453X012 10B7283X012

12100 or 12800 with Heat Insulator

249 Series Sensor with Heat Insulator (figure 6-5) 57 58 59 60 61 78

6-6

Heat Insulator, S30400 Shaft Extension, N05500 Shaft Coupling, S30300 Set Screw, hex socket, SST (2 req d) Screw, hex hd, SST (4 req d) Washer, plain (4 req d)

22A0033X012 1B681540022 1A577935032 1E6234X0022 1A3816K0012 1B865928982

57 58 59 60 61 62 63 78

Heat Insulator, S30400 Shaft Extension, N05500 Shaft Coupling, S30300 Set Screw, hex socket, SST (2 req d) Screw, hex hd, SST (4 req d) Mounting Adapter, A03560 Screw, hex socket, steel (4 req d) Washer, plain (4 req d)

22A0033X012 11B1454X012 1A577935032 1E6234X0022 1A3816K0012 31B1453X012 10B7283X012 1B865928982

February 2007

Replaceable Parts

29B8444-A

Figure 6-6. Mounting Kit for Masoneilan 12200 and 12300 Sensor without Heat Insulator

29B8445-A

Figure 6-7. Mounting Kit for Masoneilan 12200 and 12300 Sensor with Heat Insulator

Key

Description

Part Number

Shaft Extension N05500 Shaft Coupling, S30300 Hex Socket Screw (2 req d) Mounting Adaptor, A92024 Hex Nut, SST (4 req d) Hex Cap Screw, SST (4 req d)

February 2007

Description

Part Number

12200 or 12300 with Heat Insulator

12200 or 12300 without Heat Insulator

58 59 60 62 74 75

Key

1B681540022 1A577935032 1E6234X0022 39B8487X012 1A3457K0012 1A3904X0032

57 58 59 61 60 62 74 75 78

Heat Insulator, S30400 Shaft Extension N05500 Shaft Coupling, S30300 Hex Cap Screw, SST (4 req d) Hex Socket Screw (2 req d) Mounting Adaptor, A92024 Hex Nut, SST (4 req d) Hex Cap Screw, SST (4 req d) Washer, plain (4 req d) not shown

22A0033X012 19B8446X012 1A577935032 1A3816K0012 1E6234X0022 39B8487X012 1A3457K0012 1A9304X0032 1B865928982

6-7

DLC3000 Series Key

Description

Part Number

Key

Description

Foxboro R-Eckardt

Yamatake NQP Sensor

Part Number

Sensors

144LD without Heat Insulator Without Heat Insulator 58 59 60 62 63 71 72 73

Shaft Extension, S31600 Shaft Retainer, S30400 Hex Socket Screw, SST Mounting Adaptor, A96061 Hex Socket Screw, SST (3 req d) Hex Socket Screw, SST (3 req d) Shaft Adapter, S30400 Hex Socket Screw, SST (2 req d)

GB0099X0012 GB0104X0012 18B5517X012 GB0100X0012 1J6857X0012 18B5512X012 GB0107X0012 1U8830X0012

With Heat Insulator

57 58 59 60 61 62 63 71 72 73 78

6-8

Heat Insulator, S30400 Shaft Extension, N05500 Shaft Retainer, S30400 Hex Socket Screw, SST Hex Cap Screw, SST (4 req d) Mounting Adaptor, A96061 Hex Socket Screw, SST (3 req d) Hex Socket Screw, SST (3 req d) Shaft Adapter, S30400 Hex Socket Screw, SST (2 req d) Washer, plain (4 req d)

22A0033X012 GB0103X0012 GB0104X0012 18B5517X012 1A3816K0012 GB0100X0012 1J6857X0012 18B5512X012 GB0107X0012 1U8830X0012 1B865928982

58 59 60 62 74 75

Shaft Extension, S31600 Shaft Coupling, S30300 Set Screw, hex socket, SST (2 req d) Mounting Adapter, A92024 Hex Nut, steel (4 req d) Hex Cap Screw, steel (4 req d)

10B2396X012 19B5898X012 1E6234X0022 39B5899X012 19A4788X012 17B6153X012

144LD with Heat Insulator 57 58 59 60 61 62 74 75 78

Heat Insulator, S30400 Shaft Extension, 316 SST Shaft Coupling, S30300 Set Screw, hex socket, SST (2 req d) Screw, hex hd, SST (4 req d) Mounting Adapter, A92024 Hex Nut, steel (4 req d) Hex Cap Screw, steel (4 req d) Washer, plain (4 req d)

22A0033X012 11B1454X012 19B5898X012 1E6234X0022 1A3816K0012 39B5899X012 19A4788X012 17B6153X012 1B865928982

LP167 without Heat Insulator 58 59 60 62 63

Shaft Extension, S31600 Shaft Coupling, S30300 Set Screw, hex socket, SST (2 req d) Mounting Adapter, A92024 Screw, hex socket, (4 req d)

19B8478X012 19B5898X012 1E6234X0022 39B8479X012 19B8477X012

February 2007

375 Field Communicator Basics

Appendix A Model 375 Field Communicator Basics Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-2

Using the Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-2

On/Off Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-2

Navigation Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-2

Enter Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-2

Tab Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-2

Alphanumeric Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-2

Backlight Adjustment Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-3

Function Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-3

Multifunction LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-3

Using the Touch Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-3

Using the Soft Input Panel Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-3

Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-4

Offline Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Polling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reviewing Instrument Device Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-4 A-5 A-5 A-5 A-6

Online Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-6

Displaying the Field Communicator Device Description Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-6

February 2007

A-1

DLC3000 Series Display BLINKING HEART INDICATES COMMUNICATION WITH A FIELDVUE INSTRUMENT

HOT KEY

SCRATCH PAD

IrDA INTERFACE (TOP)

TOUCH SCREEN DISPLAY

HART AND fieldbus COMMUNICATION TERMINALS (TOP)

The Field Communicator communicates information through a 1/4 VGA (240 by 320 pixels) monochrome touch screen. It has a viewing area of approximately 9 cm by 12 cm.

STYLUS (BACK) DLC3000: Tag 1

Process Variables

OPTIONAL EXPANSION PORT (SIDE)

3 Setup 2 Basic Diag/Service 4 Detailed Setup 5 Review

Using the Keypad

ENTER KEY

On/Off Key NAVIGATION KEYS (FOUR ARROW KEYS) FUNCTION KEY

TAB KEY

ALPHANUMERIC KEYS POWER SUPPLY CHARGER CONNECTION (SIDE)

ON/OFF KEY

BACKLIGHT ADJUSTMENT KEY

MULTIFUNCTION LED

Figure A-1. Model 375 Field Communicator

The on/off key is used to turn the Field Communicator on and off. From the Main Menu, select HART Application to run the HART application. On startup, the HART Application automatically polls for devices. If a HART-compatible device is found, the Field Communicator displays the Online menu. For more information on Online and Offline operation, see Menu Structure in this section. The on/off key is disabled while any applications are open, making it necessary for you to exit the 375 Main Menu before using the on/off key. This feature helps to avoid situations where the Field Communicator could be unintentionally turned off while a device s output is fixed or when configuration data has not been sent to a device.

Navigation Keys

Note The Model 375 Field Communicator device description revision (DD) determines how the Field Communicator interfaces with the instrument. For information on displaying the device description revision, see page A-5.

This section discusses the display, keypad, and menu structure for the Field Communicator, shown in figure A-1. It includes information for displaying the Field Communicator device description revision number. For information on connecting the Field Communicator to the instrument, see the Installation section. For more information on the Field Communicator, such as specifications and servicing, see the User s Manual for the Field Communicator 00375-0047-0001, included with the Field Communicator. This manual also is available from Rosemount Inc., Measurement Division.

A-2

Four arrow navigation keys allow you to move through the menu structure of the application. Press the right arrow ( ) navigation key to navigate further into the menu.

Enter Key The enter key allows you perform the highlighted item, or to complete an editing action. For example, if you highlight the Cancel button, and then push the enter key, you will cancel out of that particular window. The enter key does not navigate you through the menu structure.

Tab Key The tab key allows you to move between selectable controls.

Alphanumeric Keys Figure A-2 shows the alphanumeric keypad. Data entry, and other options, using letters, number and February 2007

375 Field Communicator Basics #%&

ABC

DEF

Copy

Paste

Hot Key

GHI

JKL

MNO

Insert

+ Hot Key

PQRS

TUV

WXYZ

, ( ) J

Multifunction LED The multifunction LED indicates when the 375 Field Communicator is in various states. Green signifies that the Field Communicator is on, while flashing green indicates that it is in power saving mode. Green and orange indicate that the function key is enabled, and a green and orange flash indicates that the on/off button has been pressed long enough for the Field Communicator to power up.

Figure A-2. Model 375 Field Communicator Alphanumeric and Shift Keys

other characters can be performed using this keypad. The 375 Field Communicator will automatically determine the mode depending upon the input necessary for the particular field. To enter text when in alphanumeric mode, press the desired keypad button in quick repetition to scroll through the options to attain the appropriate letter or number. For example, to enter the letter Z , press the 9 key quickly four times. The alphameric keys are also used for the Fast Key sequence. The Fast Key sequence is a sequence of numerical button presses, corresponding to the menu options that lead you to a given task. See the Model 375 Field Communicator Menu Structures at the beginning of this manual.

Backlight Adjustment Key

Using the Touch Screen The touch screen display allows you to select and enter text by touching the window. Tap the window once to select a menu item or to activate a control. Double-tap to access the various options associated with the menu item.

CAUTION

The touch screen should be contacted by blunt items only. The preferred item is the stylus that is included with the 375 Field Communicator. The use of a sharp instrument can cause damage to the touch screen interface.

Use the back arrow button( ) to return to the previous menu. Use the terminate key ( ) in the upper right corner of the touch screen to end the application.

The backlight adjustment key has four settings allowing you to adjust the intensity of the display. Higher intensities will shorten the battery life.

Using the Soft Input Panel (SIP) Keyboard Function Key The function key allows you to enable the alternate functionality of select keys. The grey characters on the keys indicate the alternate functionality. When enabled, the orange multifunction LED light will appear and an indication button can be found on the soft input panel (SIP). Press the key again to disable the function key.

February 2007

As you move between menus, different dynamic buttons appear on the display. For example, in menus providing access to on-line help, the HELP button may appear on the display. In menus providing access to the Home menu, the HOME button may appear on the display. In many cases the SEND label appears indicating that you must select the button on the display to send the information you have entered on the keypad to the FIELDVUE instrument s memory. Online menu options include:

A-3

DLC3000 Series Hot Key Tap the Hot Key from any Online window to display the Hot Key menu. This menu allows you to quickly: Set instrument range values Perform PV setup Change the instrument protection For details on ranging, PV setup, and protection, and other configuration parameters, see the Detailed Setup section of this manual. The Hot Key can also be accessed by enabling the function key, and pressing the 3 key on the alphanumeric key pad.

is a text editor that allows SCRATCHPAD you to create, open, edit and save simple text (.txt) documents. HELP gives you information regarding the display selection. SEND sends the information you have entered to the instrument. HOME takes you back to the Online menu. EXIT takes you back to the menu from which you had requested the value of a variable that can only be read. ABORT cancels your entry and takes you back to the menu from which you had selected the current variable or routine. Values are not changed. OK takes you to the next menu or instruction screen. ENTER sends the information you have selected to the instrument or flags the value that is to be sent to the instrument. If it is flagged to be sent, the SEND dynamic label appears as a function key selection. ESC cancels your entry and takes you back to the menu from which you had selected the current variable or routine. Values are not changed. SAVE saves information to the internal flash or the configuration expansion module.

A-4

Menu Structure The Field Communicator is generally used in two environments: offline (when not connected to an instrument) and online (connected to an instrument).

Offline Operation Selecting HART Application when not connected to a FIELDVUE instrument causes the Field Communicator to display the message No device found at address 0. Poll? Selecting Yes or No will bring you to the HART Application menu. Three choices are available from this screen: Offline, Online and Utility. The Offline menu allows you to create offline configurations, as well as view and change device configurations stored on the 375 Field Communicator. The Utility menu allows you to set the polling option, change the number of ignored status messages, view the available Device Descriptions, perform a simulation, and view HART diagnostics. Do not change units in the offline mode. Changed units will be written back to the instrument when the online mode is entered. You can set up a reset to factory defaults function for saving a configuration of a new DLC3000. The function will be labeled DLCDEFAULTS. This function will allow you to return to factory defaults using the handheld communicator. Marking the Process Temp Offset and Electronics Temp Offset NOT TO SEND will prevent you from overwriting the factory characterizations of these variables in an instrument different than the one you saved the configuration from. If you are trying to restore these values for the same instrument, after having corrupted them in a DLC3010, you could mark them SEND. The choice of marking the HART data (tag, date, descriptor, etc.) at the end NOT TO SEND is correct if you entered all the data at one point with a handheld and don t want to have to recreate it. Note that the SAVE feature allows you to create a set of standard configurations that you can load to instruments quickly, and then go in and update just the variable info by hand. This feature is very useful if you have a few dozen similar installations. Refer to the the 375 Field Communicator instruction manual for discussion of the methods of saving configurations, editing configurations, and loading saved configurations to instruments. Following is a list of variables that are stored in a Saved Configuration in the handheld memory when you push the SAVE button. WriteProtect DisplacerWeightUnits DisplacerWeight DisplacerVolumeUnits February 2007

375 Field Communicator Basics DisplacerVolume DisplacerLengthUnits DisplacerLength MomentArmLength SensorAction TorqueTubeRateUnits TorqueTubeRate TorqueTubeMaterial primary_variable_code PV Units UPPER_RANGE_VALUE LOWER_RANGE_VALUE DAMPING_VALUE InputFilter LevelOffset TempUnits ProcTempOffset (Mark this NOT TO SEND) ElecTempOffset (Mark this NOT TO SEND) PV.HI_ALARM PV.HI_HI_ALARM PV.LO_ALARM PV.LO_LO_ALARM PV.DEADBAND PVAlarmEnable (packed binary) ElecTempHI_ALARM ElecTempLO_ALARM ProcTempHI_ALARM ProcTempLO_ALARM TempDEADBAND TempAlarmEnable (packed binary) MeterInstalled MeterType MeterDecimalPoint TrendVariable TrendInterval RTDType WireResistancetag (Mark this NOT TO SEND if desired) date (Mark this NOT TO SEND if desired descriptor (Mark this NOT TO SEND if desired) message (Mark this NOT TO SEND if desired) InstrumentSerialNumber (Mark this NOT TO SEND if desired) final_assembly_number (Mark this NOT TO SEND if desired) DisplacerSerialNumber (Mark this NOT TO SEND if desired) polling_address burst_mode_select

automatically search for all or specific connected devices. To enter a polling option, select Utility from the HART Application menu. Select Configure HART Application, and then select Polling. Tap ENTER to select the highlighted option. The Polling options are: 1. Never Poll connects to a device at address 0, and if not found will not poll for devices at addresses 1 through 15. 2. Ask Before Polling connects to a device at address 0, and if not found asks if you want to poll for devices at addresses 1 through 15. 3. Always Poll connects to a device at address 0, and if not found will automatically poll for devices at addresses 1 through 15. 4. Digital Poll automatically polls for devices at address 0 through 15 and lists devices found by tag. 5. Poll Using Tag asks for a device HART tag and then polls for that device. 6. Poll Using Long Tag allows you to enter the long tag of the device. (Only supported in HART Universal revision 6 devices.) To find individual device addresses, use the Digital Poll option to find each connected device in the loop and list them by tag. For more information on setting the polling address, see the Detailed Setup section.

System Information To access the Field Communicator system information, select Settings from the 375 Main Menu. About 375 includes software information about your 375 Field Communicator. Licensing can be viewed when you turn on the 375 Field Communicator and in the License settings menu. The license setting allows you to view the license on the System Card. Memory settings consists of System Card, Internal Flash size, and Ram size, as well as the Expansion Module if installed. It allows you to view the total memory storage and available free space.

Reviewing Instrument Device Descriptions The Field Communicator memory module contains device descriptions for specific HART-compatible devices. These descriptions make up the application software that the communicator needs to recognize particular devices. To review the device descriptions programmed into your Field Communicator, select Utility from the HART

A-5

DLC3000 Series Application menu, then select Available Device Descriptions. The manufacturers with device descriptions installed on the Field Communicator are listed.

Online Operation

Select the desired manufacturer to see the list of the currently installed device models, or types, provided by the selected manufacturer.

The figure on the front cover foldout shows an overview of the DLC3000 Series digital level controller menu structure.

The Online menu is the first to be displayed when connecting to a HART compatible device. It contains important information about the connected device.

Select the desired instrument model or type to see the available device revisions that support that instrument.

Simulation The Field Communicator provides a simulation mode that allows you to simulate an online connection to a HART-compatible device. The simulation mode is a training tool that enables you to become familiar with the various menus associated with a device without having the Field Communicator connected to the device.

To simulate an online connection, select Utility from the main menu. Select Simulation then select Fisher Controls. Select DLC3000 to see the menu structure for the DLC3000 Series digital level controller. Refer to the appropriate sections of this manual for information on the various menus.

A-6

Displaying the Field Communicator Device Description Revision Device Description (DD) Revision is the revision number of the Fisher Device Description that resides in the Field Communicator. It defines how the Field Communicator is to interact with the user and instrument. Field Communicators with device description revision 2 are used with DVC3000 Series instruments. You can display the device description revision when the Field Communicator is Offline or Online: to see the Field Communicator device description revision number from the Offline menu, select Utility, Simulation, Fisher Controls, and DLC3000. From the Online menu, select Detailed Setup, Device Information, Version Info, and Device Description (4-3-2-5).

February 2007

Loop Schematics/Nameplates

Appendix B

Loop Schematics/Nameplates

This section includes loop schematics required for wiring of intrinsically safe installations and the approvals nameplates. If you have any questions, contact your Emerson Process Management sales office.

28B5744-B / DOC

Figure B-1. CSA Schematic

February 2007

B-1

DLC3000 Series

28B5745-B / DOC

Figure B-2. FM Schematic

Figure B-3. CSA and FM Approvals Nameplate

B-2

February 2007

Loop Schematics/Nameplates

Figure B-4. ATEX Approvals Nameplate

Figure B-5. IECEx Approval Nameplate

Figure B-6. SAA Approval Nameplate

February 2007

B-3

DLC3000 Series

B-4

February 2007

Glossary

Glossary Alarm Deadband The amount by which the process variable must return within normal limits for the alarm to clear.

Alarm Limit An adjustable value that, when exceeded, activates an alert.

Control Loop An arrangement of physical and electronic components for process control. The electronic components of the loop continuously measure one or more aspects of the process, then alter those aspects as necessary to achieve a desired process condition. A simple control loop measures only one variable. More sophisticated control loops measure many variables and maintain specified relationships among those variables.

Algorithm A set of logical steps to solve a problem or accomplish a task. A computer program contains one or more algorithms.

Damping Output function that increases the time constant of the digital level controller output to smooth the output when there are rapid input variations.

Alphanumeric Consisting of letters and numbers.

ANSI (acronym) The acronym ANSI stands for the American National Standards Institute

Burst Burst mode is an extension to HART protocol that provides the continuous transmission of standard HART command response by a field device.

Byte A unit of binary digits (bits). A byte consists of eight bits.

Descriptor Sixteen-character field for additional identification of the digital level controller, its use, or location. The descriptor is stored in the instrument and can be changed using a Field Communicator and the device information function.

Device ID Unique identifier embedded in the instrument at the factory.

Device Revision Revision number of the interface software that permits communication between the Field Communicator and the instrument.

Firmware Revision Commissioning Functions performed with a Field Communicator and the digital level controller to test the instrument and loop and verify digital level controller configuration data.

Configuration Stored instructions and operating parameters for a FIELDVUE Instrument. February 2007

The revision number of the instrument firmware. Firmware is a program that is entered into the instrument at time of manufacture and cannot be changed by the user.

Free Time Percent of time that the microprocessor is idle. A typical value is 25%. The actual value depends on the number of functions in the instrument that are enabled and on the amount of communication currently in progress.

Glossary-1

Glossary

DLC3000 Series Gain The ratio of output change to input change.

Hardware Revision Revision number of the Fisher instrument hardware. The physical components of the instrument are defined as the hardware.

Menu A list of programs, commands, or other activities that you select by using the arrow keys to highlight the item then pressing ENTER, or by entering the numeric value of the menu item.

Message Thirty-two character field for any additional information the user may want to include.

HART (acronym) The acronym HART stands for Highway Addressable Remote Transducer. The communications standard that provides simultaneous analog and digital signal transmission between control rooms and field devices.

HART Tag An eight-character field for identifying the digital level controller. The HART tag is stored in the instrument and can be changed using a Field Communicator and the device information function.

Glossary

HART Universal Revision Revision number of the HART Universal Commands which are the communications protocol for the instrument.

Instrument Serial Number

Multidropping The connection of several field devices to a single communications transmission line.

Non-Volatile Memory (NVM) A type of semiconductor memory that retains its contents even though power is disconnected. NVM contents can be changed during configuration unlike ROM which can be changed only at time of instrument manufacture. NVM stores configuration data.

On-Line Configuration Configuration of the digital level controller operational parameters using a Field Communicator connected to the instrument.

Parallel Simultaneous: said of data transmission on two or more channels at the same time.

The serial number assigned to the instrument.

Polling Address Lower Range Value (LRV) Lowest value of the process variable that the digital level controller is currently configured to measure in the 4 to 20 mA loop.

Lower Sensor Limit (LSL) Lowest value of the process variable that the digital level controller can be configured to measure.

Memory A type of semiconductor used for storing programs or data. FIELDVUE instruments use three types of memory: Random Access Memory (RAM), Read Only Memory (ROM), and Non-Volatile Memory (NVM). See also these listings in this glossary.

Glossary-2

Address of the instrument. If the digital level controller is used in a point-to-point configuration, set the polling address to 0. If it is used in a multidrop configuration, or split range application, set the polling address to a value from 0 to 15.

Process Variable (PV) A physical quality or quantity which is monitored as part of a control strategy. The digital level controller can measure level, interface level between two liquids of different specific gravity, and liquid density.

Protocol A set of data formats and transmission rules for communication between electronic devices. Devices that conform to the same protocol can communicate accurately. February 2007

Glossary Random Access Memory (RAM) A type of semiconductor memory that is normally used by the microprocessor during normal operation that permits rapid retrieval and storage of programs and data. See also Read Only Memory (ROM) and Non-Volatile Memory (NVM).

Software Microprocessor or computer programs and routines that reside in alterable memory (usually RAM), as opposed to firmware, which consists of programs and routines that are programmed into memory (usually ROM) when the instrument is manufactured. Software can be manipulated during normal operation, firmware cannot.

Read-Only Memory (ROM) A memory in which information is stored at the time of instrument manufacture. You can examine but not change ROM contents.

Reranging Configuration function that changes the digital level controller 4 to 20 mA settings.

Span Algebraic difference between the upper and lower range values.

Temperature Sensor A device within the instrument that measures the instrumentÂ&#x2019;s internal temperature.

Upper Range Value (URV) RTD The abbreviation for resistance temperature detector. Temperature is measured by the RTD by correlating the resistance of the RTD element with temperature.

Send Data A Field Communicator command that transfers configuration data from the Field CommunicatorÂ&#x2019;s working register to the digital level controller memory.

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Highest value of the process variable that the digital level controller is currently configured to measure in the 4 to 20 mA loop.

Upper Sensor Limit (USL) Highest value of the process variable that the digital level controller can be configured to measure.

Working Register Memory location in a Field Communicator that temporarily stores data as it is being entered.

Glossary-3

Glossary

DLC3000 Series

Glossary

Glossary-4

February 2007

Index A access handle, 3-2 Alarm Jumper, 3-14 Changing Position, 3-14 Displaying Output Action, 5-6, 5-8

Connections Communication, 3-12 Power/Current Loop, 3-12 RTD, 3-12 Test, 3-13 connections, current loop, 3-10

alarm variables, default values, 4-6

Construction Materials, DLC3000, 1-6

Alarms Displaying, 5-7 Enabling Process Variable, 4-27 Temperature, 4-28 Hardware, Displaying, 5-8 Setting, 4-26 Setting Limits Process Variable, 4-26 Temperature, 4-27

Coupling, 4-7 protecting, 3-2

Ambient Temperature, Operative, 249 Series, 1-8 AMS Suite: Intelligent Device Manager, 1-2 ATEX, Special Conditions for Safe Use, 3-4 ATEX approved units, 3-12, 3-14

CSA, Special Conditions of Safe Use, 3-4

D D/A Trim, Scaled. See Calibration DAC Trim, 4-8 Damping. See Process Variable Damping Date, 4-29 Dead Band, 1-4 Density, Process, DLC3000, 1-4 Density Units, 4-22 Descriptor, 4-29 Device ID, 5-7

Bell 202 communication standard, 2-2

Device Id, 5-7

Burst Operation, 3-16

Device Revision, 5-7

Index

Diagnostics, 1-5

C Calibration PV Sensor Calibration, 4-9 Quick Calibration, 4-9 Scaled D/A Trim, 4-14 Temperature, 4-13 Calibration , 4-8 PV Sensor, Procedures that Affect the Zero of the PV Calculation Mark Dry Coupling, 4-9 Trim PV Zero, 4-10 Change Material, 4-21 Compensation Density parameter, 1-5 manual, 1-5 Transducer, 1-5

Digital Monitors, 1-5 Displacer Data, 4-21 Length, 4-21 Rod Length, 4-21 Serial Number, 5-7 Units, 4-21 Volume, 4-21 Weight, 4-21 Displacer Length, 4-8 Displacer Lengths, Sensor, 1-8 displacer rod, length, 4-21 Displacer Sensors Caged, 1-9 Cageless, 1-9 displacer serial number, 5-7 Displacer Units, 4-22

Configuration, digital level controller, 3-2

Displacer Volume, 4-8

Connection Styles, Caged Sensor, 1-8

Display Type, 4-26

February 2007

Index-1

DLC3000 Series DLC3000 Series Description, 1-2 Installation. See Installation Principle of Operation, 2-2 Removing from the Sensor, 5-9 Specifications, 1-3 Testing, 5-8 Driver Rod Length, 4-8

E Educational Services, 1-3 EEPROM, 2-2 Elec Temp Offset, 4-8 Elect Temp Hi Alrm, 4-28 Elect Temp Lo Alrm, 4-28 Electrical Classification, Hazardous Area ATEX, 1-5 CSA, 1-5 FM, 1-5 IECEx, 1-5 SAA, 1-5 Electrical Connections, 1-6, 3-10

Index

F Field Communicator Device Description Revision, A-6 Offline Menu, A-4 Online Menu, A-6 Online Simulation, A-6 Polling, A-5 Specifications, A-2 System Information, A-5 Using the Keypad, A-2 Field Device Malfunction, 5-9 Final Assembly Number, 5-7 Firmware Revision, 5-7 Flexures, protecting, 3-2 FM, Special Conditions of Safe Use, 3-4 Free Time, 5-8 Free Time Limit Exceeded, 5-9

G ground strap, 3-12 Grounding, 3-12 Shielded Wire, 3-12

Electromagnetic Interference, DLC3000, 1-5 electromagnetic interference (EMI) protection, 2-4

electronics, encapsulated, 3-14

Hall count, 5-9

Electronics Assembly, Part Number, 6-3

Hall Current Readback Limit Failed, 5-8

Electronics High Alarm, 4-27

Hall sensor, 2-2

Electronics Low Alarm, 4-27

Hardware Diagnostics, 5-4

Electronics Module Removing, 5-13 Replacing, 5-13

Hardware Revision, 5-7

electronics temperature, instrument, 4-28

HART protocol, 2-2

Electronics Temperature High Alarm, 4-27, 4-28

HART Tag, 4-28

Electronics Temperature High Alarm Enable, 4-28

HART Tri-Loop, Configuring DLC3000 for use with, 3-15

Electronics Temperature Low Alarm, 4-27, 4-28 Electronics Temperature Low Alarm Enable, 4-28

HART Communication, Principle of Operation, 2-2 HART communication, 1-5

HART Universal Revision, 5-7 Hazardous Area Approvals, 3-4

Electronics Temperature Low Alarm limit, 4-28

HC12 count, 5-9

EMC Directive, 1-5

Heat Insulator, Installation, 3-8

EMI filters, 2-2

High High Alarm, 4-28

Equalizing Connections, 3-6

High Temperature Applications, 3-8

Index-2

February 2007

Index Hysteresis, 1-4

LCD Meter Indications, 1-5

Hysteresis plus Deadband, 1-4

level measurement applications, 4-7 Level Offset, 4-5, 4-8, 4-24

Level Offset parameter, 4-6 Level Sensor Drive Signal, 5-8

IEC 61326-1 (Edition 1.1), 1-5

Level Signature Series Test, 1-6

IECEx, Conditions of Certification, 3-4

Level Snsr Drive, 5-8

Immunity Performance, 1-6

Level Units, 4-22

Independent Linearity, 1-4

Lever Assembly, 5-15 Removing, 5-15 Replacing, 5-15

Initial Setup, 4-4 Inner Guide and Access Handle Assembly, Removing and Replacing, 5-14

Lever Lock, 3-2

Input Filter, 4-24

lift-off voltage, 3-10

Input Signal 249 Series, 1-8 DLC3000, 1-4

loop connection terminals, 2-2

Installation, 3-2 DLC3010 on 249 Series Sensor, 3-7 Electrical, 3-10 Field Wiring, 3-11 Heat Insulator, 3-8 Multichannel, 3-13 Of 249 Series Sensor, 3-6 Power/Current Loop Connections, 3-12 RTD Connections, 3-12

Low Alarm Enable, 4-28

Instrument Mounting, Specifying, 4-21

loop interface, 2-2 Loop Test, 3-14 Low Low Alarm, 4-28 Low Low Alarm Enable, 4-28 LRV (Lower Range Value), 4-8, 4-23 LSL, 4-23

Instrument Serial Number, 5-7

material, torque tube, "Special", 4-7

Instrument Status, 5-8 interface level applications, 4-7

Materials 249 Series, 1-8 Process Temperature, 1-8 Displacer and Torque Tube, 1-8

Interface Units, 4-22

Message, 4-29

intrinsic safety, and multidrop installations, 4-29

Meter Installed, 4-26

intrinsically safe applications, 3-11

microprocessor, 2-2

instrument status, 5-8

Index

Minimum Differential Specific Gravity, DLC3000, 1-5

Model 375 Field Communicator, 1-2 modems, Bell 202, 4-29

LCD Meter Assembly, 5-11 Diagnostic Messages, 5-3 Part Number, 6-3 Removing, 5-11 Replacing, 5-12 Setup, 4-26 Testing, 4-26 LCD meter, 2-2 February 2007

moment arm, 4-5 Mounting, 3-2 249 Series Sensor, 3-6 Digital Level Controller Orientation, 3-7 DLC3010, On 249 Series Sensor, 3-7 Mounting Kits, 6-2 Mounting Positions 249 Series, 1-8

Index-3

DLC3000 Series DLC3000, 1-6 typical, DLC3010 digital level controller on 249 Series sensor, 3-8 Multichannel Installations, 3-13

Proc Temp Lo Alrm, 4-28 Proc Temp Offset, 4-8 Process Density, 1-4 process temperature, 4-26

multidrop communication, activating, 4-30

Process Temperature High Alarm, 4-28

Multidrop installations, intrinsic safety, 4-29

Process Temperature High Alarm Enable, 4-28

Multidropped Communication, Typical Multidropped Network, 4-29

Process Temperature High Alarm limit, 4-28 Process Temperature Low Alarm, 4-27, 4-28 Process Temperature Low Alarm Enable, 4-28

Process Temperature Sensor Failed, 5-9 Process Temperatures, extreme, 4-20

**Empty**, 5-9 NVM, 5-8 write-cycle life, 4-24 NVM (non-volatile memory), 4-14 NVM Write Limit Exceeded, 5-8

Process Variable Damping, 4-24 Offset, 4-23 Selecting, 4-22 setting range, 4-22 Units, 4-22 process variable, 4-26

O Orientation, 3-1, 3-7 Output Signal, DLC3000, 1-4

Index

P Packing for Shipment, 5-16 Parts, Ordering, 6-2

Process Variable Alarm Limits, Setting, 4-26 Process Variable Alarms Alarm Deadband, 4-27 High Alarm, 4-26 High Alarm Enable, 4-27 High-High Alarm, 4-26 Low Alarm, 4-26 Low-Low Alarm, 4-26 PV Alarm Deadband, 4-27 PV High Alarm, 4-27 Process Variable Units, 4-22 processor module, 2-2

Parts Kits, 6-2

Proportional Band, effect of, 4-19

Percent (%) Range Only, 4-26

Protection, 4-5, 4-21

Polling Address, 4-28

PV Alarm Deadband, 4-28

polling address, 4-30

PV Calculation, 4-9

Power Supply, Load Limits, 3-10

PV Engineering Units, setting, 4-22

Power Supply Effect, 1-4 Power/Current Loop Connections, 3-12 Pressure Boundary Materials, allowable process temperatures, 1-8 Primary Variable Analog Output Fixed, 5-9 Primary Variable Analog Output Saturated, 5-9 Primary Variable Out of Limits, 5-9 Principle of Operation DLC3000, 2-2 HART Communication, 2-2

Index-4

PV High-High Alarm limit, 4-28 PV Low Alarm limit, 4-28 PV Low Low Alarm limit, 4-28 PV Only, 4-26 PV/% Range, 4-26 PV/Proc Temp, 4-26

R Range Values, 4-22 entering, 4-22 February 2007

Index Read Trend, 5-7 Reference (dry) Coupling Point , 4-8 Reference Coupling Point, 4-9

T Table of SG vs T, 4-25

remote indicator, 1-6

Temperature Ambient, DLC3000, 1-4 Electronics, 5-4 Process, 1-4, 4-21 Units, 4-22

Repeatability, 1-4

Temperature Alarm Deadband, 4-27, 4-28

Reverse Action, 4-22

Temperature Alarm Limits, Setting, 4-27

reverse polarity protection, 2-4

temperature compensation specific gravity, currrent, 4-7 torque tube, default, 4-7

Reference Voltage Limit Failed, 5-8 Related Documents, 1-3

Revision Information, Field Communicator, Device Description, A-6 RTD Connections, 3-12 Setup, 4-22

Temperature Low Alarm, 4-27 temperature sensor, 2-2 terminal board, 2-2 Terminal Box, 5-13 Removing, 5-13 Replacing, 5-14

SAA, Conditions of Certification, 3-4

Test connections, 3-13

Serial Number Displacer, 5-7 Instrument, 5-7

Test Terminals, 3-13, 5-4

Setting Span, 4-23

Third-Party Approvals, 3-4 Torque Tube A/D Input Failed, 5-8

Setting Zero and Span, 4-23

Torque Tube Data Material, 4-21 Temperature Coefficient, 4-21

Setup Wizard, 4-5

Torque Tube Rate, 4-8

Setting Zero, 4-23

SG, 4-8 shaft extension, torque tube, 3-8 signal conditioning, 2-2 Span, setting, 4-23 Special Instructions for Safe Use and Installations in Hazardous Locations, 3-4 ATEX Flameproof, Dust, 3-4 ATEX Intrinsic Safety, Dust, 3-4 ATEX Type n, Dust, 3-4 CSA, 3-4 FM, 3-4 IECEx, 3-4 SAA, 3-4 Specific Gravity Measuring, 5-6 Setting, 4-25 Status. See Instrument Status Supply Requirements, DLC3000, 1-5 February 2007

Index

Torque Tube Rate Units, 4-22 torque-tube correction, data tables, 4-7 transducer board, 2-2 transient power surge protection, 2-4 Transient Voltage Protection, 1-4 Trend Interval, 5-7 Trend Var, 5-7 Trending, 5-7 Tri-Loop, 3-15 Turn Cells Off, 4-26

U Units displacer, 4-22 process variable, 4-22 torque tube rate, 4-22

Index-5

DLC3000 Series URV (Upper Range Value), 4-8, 4-23 USL, 4-23

W Weight, DLC3000, 1-6 Working Pressures, Sensor, 1-8

V Variables, Burst, 3-16 variables, alarm, default values, 4-6

Write Lock, 4-5 See also Protection

Z Zero, setting, 4-23

Version Information, 5-7

Zero and Span. See Setting Zero and Span

voltage, lift-off, 3-10

zero buoyancy, 4-8

Index

Index-6

February 2007

FIELDVUE and Fisher are marks owned by Fisher Controls International LLC, a member of the Emerson Process Management business division of Emerson Electric Co. AMS, DeltaV and Tri-Loop are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co. Emerson Process Management, Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co. HART is a mark owned by the HART Communications Foundation. All other marks are the property of their respective owners. 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. Neither Emerson, Emerson Process Management, nor any of their affiliated entities assumes responsibility for the selection, use and maintenance of any product. Responsibility for proper selection, use and maintenance of any product remains with the purchaser and end-user.

Emerson Process Management Marshalltown, Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 128461 www.Fisher.com Fisher Controls International, LLC 2000, 2007; All Rights Reserved Printed in USA

Instruction Manual Form 5335 May 1998

DVC5000 Series

FIELDVUEr DVC5000 Series Digital Valve Controllers Introduction

Installation

275 HART Communicator Basics

Initial Setup and Calibration

Detailed Setup

Calibration

Viewing Device Information

Principle of Operation

Maintenance

This manual applies to:

Loop Schematics

11 12

Glossary

Index

13 Index

Model 275 HART Communicator Device Description Revison 11 1, 2

D200442X012

DVC5000 Series Device Firmware Hardware Revision Revision Revision 2 3, 4 2, 3 3 5 4, 5

Parts

DVC5000 Series Model 275 HART Communicator Fast-Key Sequence Function/Variable

Fast窶適ey CoordiSequence nates(1)

Function/Variable

Alert Record, Clear

1-2-7-7-2

6-H

Manual Setup

Alert Record, Display

1-2-7-7-1

6-H

Message

Alert Record, Enabling Alert Groups

1-2-7-7-4

6-H

1-E

1-2-5-1

4-E

Polling Address

1-1-1

4-A

Pressure, Output

1-3-1-1

5-H

Pressure Units

Auxiliary Input Alert Enable

1-2-7-6-1

6-G

Protection

Burst Mode Command

1-2-1-5-2

5-C

Burst Mode Enable

1-2-1-5-1 1-4

Calibrate, Analog Input Calibrate, Travel (Auto)

Analog Input Analog Input Units and Range Configuration Auto Setup Auxiliary Input

Fast窶適ey CoordiSequence nates(1) 1-1-2

4-B

1-2-3-2

4-C

Minimum Closing Time

1-2-6-6-2

6-D

Minimum Opening Time

1-2-6-6-1

6-D

1-2-3-8

4-D

1-E

1-2-5-4

4-E

Hot Key-3

1-B

Restart

1-2-1-4

4-C

5-C

Restart Control Mode

1-2-1-3

4-C

2-E

Self Test Shutdown

1-2-8

4-G

1-4-1

3-H

Setup Wizard

1-1-1-1

4-A

1-4-2

3-H

Stabilize/Optimize

Hot Key-4

1-B

Calibrate, Travel (Manual)

1-4-3

4-H

Stroke Output

Calibrate, Pressure

1-4-4

3-H

Calibration Location

1-4-6

Calibration, Restore

1-4-5

Control Mode

Calibrate

1-5

3-I

Supply Pressure, Instrument

1-2-4-1

4-D

3-H

Temperature, Internal

1-3-1-2

5-H

3-H

Temperature Units

1-2-5-5

4-E

Hot Key-2

1-B

Travel

Cycle Count

1-2-7-4-4

5-H

Cycle Counter Alert Enable

1-2-7-4-1

Cycle Counter Alert Point

1-2-7-4-2

Cycle Counter Deadband

1-E

Travel Accumulator

1-2-7-3-4

5-H

6-G

Travel Accumulator Alert Enable

1-2-7-3-1

6-F

6-G

Travel Accumulator Alert Point

1-2-7-3-2

6-F

1-2-7-4-3

6-G

Travel Accumulator Deadband

1-2-7-3-3

6-F

Date

1-2-3-4

4-C

Travel Alert 1 Enable

1-2-7-1-1

6-E

Descriptor

1-2-3-3

4-C

Travel Alert 1 High Point

1-2-7-1-3

6-E

Device Description Revision, HART Communicator

1-3-3

3-G

Travel Alert 1 Low Point

1-2-7-1-4

6-E

Device Information

1-3-2

5-H

Travel Alert 2 Enable

1-2-7-1-2

6-E

Drive Alert Enable

1-2-7-5

4-G

Travel Alert 2 High Point

1-2-7-1-5

6-E

1-F

Travel Alert 2 Low Point

1-2-7-1-6

6-E

Dynamic Bypass Enable

1-2-6-4

4-F

Travel Alert Deadband

1-2-7-1-7

6-E

Factory Instrument Serial Number

1-2-3-6

4-D

Travel Cutoff High

1-2-6-5-3

6-D

Feedback Characteristic

1-2-4-2

4-D

Travel Cutoff Low

1-2-6-5-4

6-D

Field Instrument Serial Number

1-2-3-7

4-D

Travel Deviation Alert Enable

1-2-7-2-1

6-F

Firmware Revision

1-3-2-3

5-I

Travel Deviation Alert Point

1-2-7-2-2

6-F

Free Time

1-3-1-5

5-H

Travel Deviation Time

1-2-7-2-3

6-F

HART Tag

1-2-3-1

4-C

Travel Limit High

1-2-6-5-1

6-D

Drive Signal

Initial Setup

1-1

3-A

Travel Limit Low

1-2-6-5-2

6-D

Input Characterization

1-2-6-2

5-E

Travel Range High

1-2-5-2

4-E

Input Filter Time

1-2-6-3

4-F

Travel Range Low

1-2-5-3

4-E

1-2-7-7-3

6-H

Travel Sensor Adjust

1-4-7

3-H 5-H

Instrument Date and Time Instrument Level

1-3-2-5(2)

5-I

Travel Sensor Counts

1-3-1-6

Instrument Mode

Hot Key-1

1-B

Tuning Set

1-2-6-1

4-E

Instrument Status

2-F

Valve Serial Number

1-2-3-5

4-D

1-2-4-4

4-D

Zero Control Signal

1-2-4-3

4-D

Invert Feedback

1. Coordinates are to help locate the item on the menu structure on the next page. 2. For device description revision 11, use key sequence 1-3-2-6 for instrument level.

Unfold this sheet to see the Model 275 HART Communicator menu structure.

DVC5000 Series Model 275 HART Communicator Menu Structure for FIELDVUE DVC5000 (Device Description (DD) Revisions 1, 2, and 11) Model 275 Compatibility

Auto Setup 1-1-1 1 Setup Wizard...(4-3) 2 Auto Calib Travel...(4-6) 3 Stabilize/Optimize...(4-7) 1-1

Initial Setup 1 Auto Setup 2 Manual Setup

Manual Setup 1 Instrument Mode...(4-2) 2 Control Mode...(4-4) 3 Feedback Char 4 Inst Supply Press 5 Zero Ctrl Signal 1-1-2 6 Invert Feedback 7 Tvl Cutoff Low 8 Tuning Set...(4-5) 9 Auto Calib Travel...(4-6)

Hot Key 1 Instrument Mode...(5-3) 2 Control Mode...(5-4) 3 Protection...(5-4) 4 Stabilize/Optimize...(4-7)

1-2-1

1-2

Main Menu (Setup) 1 Initial Setup 2 Detailed Setup 3 Display 4 Calibrate 5 Stroke Output

DVC5000 Series Firmware Rev

Memory Module (Mb)

DD Rev

3&4

1.25, 4, & 8

1.25

4&8

Mode 1 Instrument Mode...(5-3) 2 Control Mode...(5-4) 3 Restart Ctrl Mode 4 Restart 1-2-1-5 5 Burst

1 Burst 1 Burst Enable 2 Burst Command

General 1 HART Tag 2 Message 1-2-3 3 Descriptor 4 Date 5 Valve Serial Num 6 Factory Inst S/N 7 Field Inst S/N 8 Polling Address

Detailed Setup 1 Mode 2 Protection...(5-4) 3 General 4 Actuator Info 5 Measured Var 6 Response Control 7 Alerts 8 Self Test Shutdown

1-2-6-5

Actuator Info 1 Inst Supply Press 2 Feedback Char 1-2-4 3 Zero Ctrl Signal 4 Invert Feedback

1-2-6-6

Measured Var 1 Analg In Units/Rng 2 Tvl Range High 3 Tvl Range Low 1-2-5 4 Pressure Units 5 Temp Units Input Char 1-2-6-2 1 Select Input Char 2 Define Response Control Custom Char 1 Tuning Set...(5-8) 2 Input Char 2 3 Input Filter Time 1-2-6 4 Dyn Bypass Enab 5 Limits & Cutoffs 6 Min Open/Close

Online 1 Main Menu (Setup) 2 Analog In 3 Press 4 Travel 5 Drive Sgl 6 Instrument Status

1-2-7-1

1-2-7-2

1-2-7-3

Instrument Status 1 Done 2 Valve Alerts 3 Failure Alerts 2 4 Alert Record 5 Operational Status

1-2-7

HART Communicator 1 Offline 2 Online 3 Frequency Device 4 Utility

1-3

Notes: 1-4

1 Indicates included on device description rev. 1 and 2 2 Indicates included on device description rev. 1 and 2, but function available only on device description rev 2

Calibrate 1 Analog In...(6-2) 2 Auto Calib Travel...(6-3) 3 Man Calib Travel 4 Pressure...(6-6) 5 Restore Calib 6 Calib Loc 7 Tvl Sensor Adjust...(6-6)

1-2-7-6

Man Calib Travel 1 Analog Calib Adj...(6-4) 2 Digital Calib Adj...(6-4)

Stroke Output 1 Done 2 Ramp Open 3 Ramp Closed 1-5 4 Ramp to Target 5 Step to Target 6 Stop

1-2-7-4

1-3-1

1-4-3

3 This menu is available by pressing the left arrow key from the previous menu. 4. 1-1-1 indicates fast-key sequence to reach menu 5. ...(6-5) indicates procedure or method. Numbers in parenthesis indicate page where procedure is found. 6. Not included on device description rev. 1 or 2

Display 1 Variables 2 Device Information 3 275 DD Rev

Alerts 1 Travel Alerts 2 Travel Dev Alert 3 Travel Accum Alert 4 Cycle Count Alert 5 Drive Alert Enab 6 Misc Alerts 7 Alert Record

Self Test Shutdown 1-2-8 1 Done 2 No Free Time Fail 3 RAM Fail 4 Critical NVM Fail 5 Temp Sensor Fail 6 Tvl Sensor Fail 7 Drive Current Fail 1

1-3-2

Model 275

Device Rev

Variables 1 Aux In 2 Temp 3 Cycl Count 4 Tvl Acum 5 Free Time 6 Tvl Sens Cts

1-2-7-7

Limits & Cutoffs 1 Tvl Limit High 2 Tvl Limit Low 3 Tvl Cutoff High 4 Tvl Cutoff Low

Travel Alerts 1 Tvl Alrt 1 Enab 2 Tvl Alrt 2 Enab 3 Tvl Alrt 1 High Pt 4 Tvl Alrt 1 Low Pt 5 Tvl Alrt 2 High Pt 6 Tvl Alrt 2 Low Pt 7 Tvl Alrt DB

Model 275 HART Communicator Menu Structure for Device Description Revision 11 and Device Description Revisions 1 and 2

Travel Dev Alert 1 Tvl Dev Alrt Enab 2 Tvl Dev Alrt Pt 3 Tvl Dev Time Travel Accum Alert 1 Tvl Acum Alrt Enab 2 Tvl Acum Alrt Pt 3 Tvl Acum DB 4 Tvl Acum

Cycle Count Alert 1 Cycl Cnt Alrt Enab 2 Cycl Count Airt Pt 3 Cycl Count DB 4 Cycl Count Misc Alerts 1 Aux In Alrt Enab 2 Aux In Alrt State Alert Record 2 1 Display Record 2 Clear Record 3 Inst Date & Time 4 Record Groups

Device Information 1 HART Univ Rev 2 Interface Rev 3 Firmware Rev 4 Hardware Rev 5 Output Bias Rev?(6) 6 Inst Level 7 Pressure Sensor 8 Device ID

Min Open/Close 1 Min Opening Time 2 Min Closing Time

G 1

I 6

DVC5000 Series

Cutaway View of FIELDVUEr Type DVC5010 Digital Valve Controller Showing Master Module Assembly

iii

Introduction 1-1

Section 1 Introduction

May 1998

Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3

Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3

1-1

DVC5000 Series Scope of Manual This instruction manual includes specifications, installation, operating, and maintenance information for the DVC5000 Series digital valve controllers.

The manual describes the functionality of FIELDVUER Instruments with Firmware Revision 5. It also applies to Firmware Revisions 3 and 4, except as noted. This instruction manual supports the Model 275 HARTR Communicator with device description revision 11, used with firmware revision 3 and 4 instruments. The manual also supports the Model 275 HART Communicator with device description revisions 1 and 2. Device description revisions 1 and 2 are used with firmware revision 5 instruments. Device description revision 1 is available in HART Communicators with 1.25 megabyte memory modules. Device description revision 2 is available in HART Communicators with 4 and 8 megabyte memory modules. For information on using the ValveLinkt VL2000 Series software with the instrument, refer to the ValveLink VL2000 Series User Guide. Only qualified personnel should install, operate, and maintain this instrument. If you have any questions concerning these instructions or for information not contained in this instruction manual, contact your Fisher Controls sales office or sales representative for more information.

W6341 / IL

Figure 1-1. Sliding-Stem Control Valve with Type DVC5010 Digital Valve Controller

Conventions Used in this Manual Procedures that require the use of the Model 275 HART Communicator have the HART Communicator symbol in the heading. Procedures that are accessible with the Hot Key on the HART Communicator will also have the Hot Key symbol in the heading. Some of the procedures also contain the sequence of numeric keys required to display the desired HART Communicator menu. For example, to access the Auto Setup menu, from the Online menu, press 1 (selects Main Menu) followed by a second 1 (selects Initial Setup) followed by a third 1 (selects Auto Setup). The key sequence in the procedure heading is shown as (1-1-1). The path required to accomplish various tasks, the sequence of steps through the HART Communicator menus, is also presented in textual format. Menu selections are shown in italics, e.g., Calibrate. An overview of the Model 275 HART Communicator menu structure is shown on the fold out page on the front cover of this manual.

1-2

W6164 / IL

Figure 1-2. Rotary Control Valve with Type DVC5020 Digital Valve Controller

Description DVC5000 Series digital valve controllers (figures 1-1 and 1-2) are communicating, microprocessor-based current-to-pneumatic instruments. In addition to the May 1998

Introduction normal function of converting an input current signal to a pneumatic output pressure, the DVC5000 Series digital valve controller, using the HART communications protocol, gives easy access to information critical to process operation. You can gain information from the principal component of the process, the control valve itself, using the HART Communicator at the valve, or at a field junction box, or by using a personal computer or operatorâ&#x20AC;&#x2122;s console within the control room. Using an IBM compatible PC and FIELDVUE ValveLink software, Asset Management software, or a Model 275 HART Communicator, you can perform several operations with the DVC5000 Series digital valve controller. You can obtain general information concerning software revision level, messages, tag, descriptor, and date. Diagnostic information is available to aid you when troubleshooting. Input and output configuration parameters can be set. DVC5000 Series digital valve controllers can be calibrated with a PC or Model 275 HART Communicator. Using the HART protocol, information from the field can be integrated into control systems or be received on a single loop basis. The DVC5000 Series digital valve controller can also be migrated to the FOUNDATIONt fieldbus communication protocol. The DVC5000 Series digital valve controller is designed to directly replace standard pneumatic and electro-pneumatic valve mounted positioners.

Related Documents Other documents containing information related to the DVC5000 Series digital valve controllers include: D FIELDVUER DVC5000 Series Digital Valve Controller (Bulletin 62.1:DVC5000)

D FIELDVUER Instrument Installation Requirements (PS Sheet 62.1:FIELDVUE(A)) D Mounting FIELDVUER Instruments on Piston Actuators (PS Sheet 62.1:FIELDVUE(B)) 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 Using Loop Tuners with FIELDVUE Instruments (PS Sheet 62.1:FIELDVUE(F)) D Audio Monitor for HARTR Communications (PS Sheet 62.1:FIELDVUE (G)) D Type HF100 FIELDVUER HARTR Filter Instruction Manual - Form 5340 D FIELDVUER HF200 Series HARTR Filters Instruction Manual - Form 5380

Specifications Specifications for the DVC5000 Series digital valve controllers are shown in table 1-1. Specifications for the HART Communicator can be found in the Product Manual for The HART Communicator.

May 1998

D Type 2530H1 HARTR Interchange Multiplexer Instruction Manual - Form 5407 D FIELDVUER ValveLinkt VL2000 Series User Guide

1-3

DVC5000 Series Table 1-1. Specifications

Electrical Input

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 Wiring Practices in the “Installation” section 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 Output Pressure(1) Ranges: As required by the actuator, up to 95% of supply pressure Minimum Span: 6 psi (0.4 bar) Maximum Span: 90 psi (6.2 bar) Action: Direct only Supply Pressure(1) Minimum and Recommended: 5 psi (0.3 bar)

higher than maximum actuator requirements Maximum: 100 psig (6.9 bar) Independent Linearity(1) ±0.5% of output span Operating Ambient Temperature Limits –40 F to 175 F (–40 C to 80 C) 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 Complies with European EMC directive. Connections Supply Pressure: 1/4-inch or R 1/4 NPT female and integral pad for mounting 67AFR regulator Output Pressure: 1/4-inch or R 1/4 NPT female Vent (pipe-away): 1/4-inch or R 1/4 NPT female Electrical: 1/2-inch NPT female, M20 female, or G 1/2 parallel (bottom entrance) Mounting Designed for direct actuator mounting. For weatherproof housing capability, the instrument must be mounted upright to allow the vent to drain. Weight Less than 6 lbs (2.7 Kg)

1. Defined in ISA Standard S51.1-1979.

1-4

May 1998

Installation 2-2

Section 2 Installation Mounting

DVC5010 on Fisher Sliding-Stem Actuators: 513 and 513R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657 and 667 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250 and 1250R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3 2-7 2-4 2-6

DVC5010 on Other Sliding-Stem Actuators: Baumann Size 32, 54, and 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gulde Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7 2-8

DVC5020 on Fisher Rotary Actuators: 1051, All sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1052, All sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-9 2-9

DVC5020 on Fisher Sliding-Stem Actuators: 471, All sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585 and 585R, All sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fairchild Model 25463 Reversing Relay Spring Adjustment . . . . . . . . . . . . . . . . . . . . .

2-11 2-13 2-14

DVC5030 on Fisher Rotary Actuators: 1051 Size 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1051 Size 30 to 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1052 Size 20 and 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1052 Size 40 to 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1066SR Sizes 20, 27, and 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-15 2-16 2-15 2-16 2-17

DVC5030 to Replace Positioners: Masoneilan Type 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neles-Jamesbury Type NE600, NP600, NE700 and NP700 . . . . . . . . . . . . . . . . . . . . PMV Model P1200, P1250, and P2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-17 2-18 2-19

DVC5040 on System 9000 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-20

67AF Filter Regulator Integral-Mounted Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yoke-Mounted Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Casing-Mounted Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-22 2-22 2-22

Pneumatic Connections Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-23

Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-23

Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-23

Electrical Connections 4 to 20 mA Loop Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . May 1998

2-23

2-1

DVC5000 Series Test Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-24

Communication Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-25

Wiring Practices Control System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2

HART Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compliance Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-25 2-25 2-25 2-25

Maximum Cable Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-27

HART Filter Use and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-27

May 1998

Installation

APPLY LUB, SEALANT 43B8456-C / DOC

Figure 2-1. Type DVC5010 Digital Valve Controller with Integrally Mounted Filter Regulator Yoke-Mounted on Type 513 Size 20 Actuator

Mounting Type DVC5010 on Fisher Sliding-Stem Actuators

Mounting WARNING Avoid personal injury or property damage from sudden release of process pressure or bursting of parts. Before mounting the DVC5000 Series digital valve controller: D 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. D Use bypass valves or completely shut off the process to isolate the valve from process pressure. Relieve process pressure from both sides of the valve. Drain the process media from both sides of the valve. D Vent the pneumatic actuator loading pressure and relieve any actuator spring precompression. D Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment.

May 1998

513 and 513R Actuators Unless otherwise noted, refer to figures 2-1 and 2-2 for key number locations. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. 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. For Type 513 and 513R size 20 actuators, loosen the lower lock nut below the travel indicator disc. Insert the connector arm (key 108) between the lock nuts and tighten the lower lock nut against the connector arm. For Type 513 and 513R size 32 actuators, attach the spacers (key 119) and connector arm (key 108) to the valve stem connector with screws (key 120). 3. Attach the mounting bracket (key 107) to the digital valve controller housing with screws (key 104). 4. Insert the screws (key 155) with washers (key 122) through the slot and hole in the mounting bracket (key 107). Install the spacers (key 118) and tighten the screws.

2-3

DVC5000 Series

APPLY LUB, SEALANT 43B8454 / DOC

Figure 2-2. Type DVC5010 Digital Valve Controller with Integrally Mounted Filter Regulator Yoke-Mounted on Type 513 Size 32 Actuator

10. Attach the shield (key 102) with two screws (key 103).

Note The alignment pin (key 46) is stored inside the digital valve controller housing. It is located above the supply pressure gauge.

657 and 667 Actuators Unless otherwise noted, refer to figures 2-3 and 2-4 for key number locations.

WARNING 5. Set the position of the feedback arm (key 79, figure 10-1) on the digital valve controller by inserting the alignment pin (key 46) through the hole on the feedback arm marked ‘‘A’’ for Type 513R actuators or the slot marked ‘‘B’’ for Type 513 actuators. 6. Apply lubricant (key 63) to the pin of the adjustment arm (key 106). Place the pin into the slot of the feedback arm (key 79) so that the bias spring loads the pin against the side of the arm with the valve travel markings. 7. Install the external lock washer (key 110) on the adjustment arm. Position the adjustment arm in the slot of the connector arm (key 108) and loosely install the washer (key 126) and screw (key 109). 8. Slide the adjustment arm pin in the slot of the connector arm until the pin is in line with the desired valve travel marking. Tighten the screw (key 109). 9. Remove the alignment pin (key 46) and store it in the module base next to the I/P assembly.

2-4

To avoid personal injury due to the sudden uncontrolled movement of parts, do not loosen the stem connector cap screws on a Type 667 actuator when the stem connector has spring force applied to it. Apply enough pressure to lift the plug off the seat before loosening the stem connector cap screws. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. 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 connector arm (key 108) to the valve stem connector. 3. Attach the mounting bracket (key 107) to the digital valve controller housing with screws (key 104). May 1998

Installation

APPLY LUB, SEALANT 44B1852-C

Figure 2-3. Type DVC5010 Digital Valve Controller with Integrally Mounted Filter Regulator Yoke-Mounted on Type 657/667 Size 30-60 Actuator

APPLY LUB, SEALANT 43B8442-C

Figure 2-4. Type DVC5010 Digital Valve Controller with Integrally Mounted Filter Regulator Yoke-Mounted on Type 657/667 Size 70-100 Actuator

May 1998

2-5

DVC5000 Series

APPLY LUB, SEALANT 43B8452-B / DOC

Figure 2-5. Type DVC5010 Digital Valve Controller with Integrally Mounted Filter Regulator Yoke-Mounted on Type 1250 Actuator

4. If valve travel exceeds 2 inches, a feedback arm extension (key 97) is required. Remove the bias spring (key 78) for up to 2-inch travel from the feedback arm (key 79, figure 10-1). Attach the bias spring (key 78) for up to 4-inch travel to the feedback arm extension. Attach the feedback arm extension to the feedback arm with screw (key 98), screw (key 99), spacer (key 101), lock washers (key 162), and hex nuts (key 100). Remove the pipe plug (key 61) from the output connection on the back of the housing, apply sealant (key 64), and reinstall in the output connection on the side of the housing. 5. Loosely install a hex flange screw (key 105) in the right hole of the lower actuator mounting boss. 6. Position the digital valve controller so the hole in the mounting pad of the mounting bracket goes onto the mounting screw (key 105). Slide the digital valve controller to the left to expose the left hole. Install the left screw (key 105). Tighten both screws (key 105).

Note The alignment pin (key 46) is stored inside the digital valve controller housing. It is located above the supply pressure gauge.

7. Set the position of the feedback arm (key 79, figure 10-1) on the digital valve controller by inserting the

2-6

alignment pin (key 46) through the hole on the feedback arm marked ‘‘A’’ for Type 667 actuators or the slot marked ‘‘B’’ for Type 657 actuators. 8. Apply lubricant (key 63) to the pin of the adjustment arm (key 106). Place the pin into the slot of the feedback arm (key 79) so that the bias spring loads the pin against the side of the arm with the valve travel markings. 9. Install the external lock washer (key 110) on the adjustment arm. Position the adjustment arm in the slot of the connector arm (key 108) and loosely install the washer (key 126) and screw (key 109). 10. Slide the adjustment arm pin in the slot of the connector arm until the pin is in line with the desired valve travel marking. Tighten the screw (key 109). 11. Remove the alignment pin (key 46) and store it in the module base next to the I/P assembly. 12. Attach the shield (key 102) with two screws (key 103). On Type 657 or 667 size 70-100 actuators, start the screws before installing the shield.

1250 and 1250R Actuators Unless otherwise noted, refer to figure 2-5 for key number locations. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. 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. May 1998

Installation SPACER CAP SCREW, FLANGED CAP SCREW

LOCK WASHER HEX NUT

MOUNTING BRACKET

MACHINE SCREW PLAIN WASHER LOCK WASHER CONNECTOR ARM ADJUSTMENT ARM CAP SCREW 27B6719 / DOC

Figure 2-6. Type DVC5010 Digital Valve Controller Mounted on a Type 529 or Baumann Size 32, 54, or 70 Actuator

2. Attach the connector arm (key 108) to the valve stem connector. 3. Attach the mounting bracket (key 107) to the housing (key 1) with screws (key 104). 4. Loosely attach the mounting bracket (key 107) to the leg post with U-bolts (key 114), washers (key 127), and hex nuts (key 115). Position the digital valve controller vertically so that the terminal box clears the diaphragm casing of the actuator. Tighten the hex nuts, securing the mounting bracket to the leg post.

Note The alignment pin (key 46) is stored inside the digital valve controller housing. It is located above the supply pressure gauge.

7. Install the external lock washer (key 110) on the adjustment arm. Position the adjustment arm in the slot of the connector arm (key 108) and loosely install the washer (key 126) and screw (key 109). 8. Loosely attach the brace (key 111) to the mounting bracket (key 107) with screws (key 112), washers (key 123), and hex nuts (key 115). Attach the brace (key 111) to the leg post with U-bolts (key 114), washers (key 127), and hex nuts (key 115). Tighten the screws and hex nuts (keys 112 and 115). 9. Slide the adjustment arm pin in the slot of the connector arm until the pin is in line with the desired valve travel marking. Tighten the screw (key 109). 10. Remove the alignment pin (key 46) and store in the module base next to the I/P assembly. 11. Attach the shield (key 102) with two screws (key 103).

Mounting Type DVC5010 on Other Sliding-Stem Actuators 5. Set the position of the feedback arm (key 79, figure 10-1) on the digital valve controller by inserting the alignment pin (key 46) through the hole on the feedback arm marked ‘‘A’’ for Type 1250R actuators or the slot marked ‘‘B’’ for Type 1250 actuators. 6. Apply lubricant (key 63) to the pin of the adjustment arm (key 106). Place the pin into the slot of the feedback arm (key 79) so that the bias spring loads the pin against the side of the arm with the valve travel markings. May 1998

529 and Baumann Size 32, 54, and 70 Actuators Refer to figure 2-6 for parts locations. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. Shut off all pressure lines to the pneumatic actuator, releasing all pressure from the actuator. Use lock-out procedures to be sure that the

2-7

DVC5000 Series above measures stay in effect while working on the equipment.

13. Remove the alignment pin (key 46) and store it in the module base next to the I/P assembly.

2. If necessary, remount the actuator on the valve so that the pipeline will be perpendicular to the yoke legs to provide clearance for the digital valve controller.

Gulde Actuators

3. Loosen the lower locknut on the valve stem. Slip the connector arm between the locknuts. Tighten the lower locknut against the connector arm.

4. Attach the mounting bracket to the digital valve controller with three cap screws. 5. Position the digital valve controller so the top hole in the mounting bracket mounting pad aligns with the threaded hole in the yoke mounting boss. Start the flanged cap screw with washer in the yoke boss. Do not tighten. 6. Position the digital valve controller so the bottom hole in the mounting bracket mounting pad aligns with the through hole in the yoke leg. 7. Position the spacer between the mounting bracket and yoke leg, then insert the cap screw through the mounting bracket, spacer and yoke leg. 8. Secure the assembly with the washer and hex nut. Align the digital valve controller with the actuator yoke and tighten the hex nut. Tighten the cap screw in the mounting bracket top hole.

Note The alignment pin (key 46) is stored inside the digital valve controller housing. It is located above the supply pressure gauge.

9. Set the position of the feedback arm (key 79, figure 10-1) on the digital valve controller by inserting the alignment pin (key 46) through the hole on the feedback arm marked ‘‘A’’ for fail-closed actuators or the slot marked ‘‘B’’ for fail-open actuators.

Refer to figure 2-7 for parts locations. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. Shut off all pressure lines to the pneumatic actuator, releasing all pressure from the actuator. Use lock-out procedures to be sure that the above measures stay in effect while working on the equipment. 2. Attach the connector arm to the valve stem connector. 3. Attach the mounting bracket to the instrument housing. 4. Loosely attach the mounting bracket to the actuator leg with U-bolts, washers, and hex nuts. Position the digital valve controller vertically so that the terminal box clears the diaphragm casing of the actuator. Tighten the hex nuts, securing the mounting bracket to the actuator leg.

Note The alignment pin (key 46) is stored inside the digital valve controller housing. It is located above the supply pressure gauge.

5. Set the position of the feedback arm (key 79, figure 10-1) on the digital valve controller by inserting the alignment pin (key 46) through the hole on the feedback arm marked ‘‘A’’ for a Po operating mode (air opens) or the slot marked ‘‘B’’ for Ps (air closes). 6. Apply lubricant to the pin of the adjustment arm. Place the pin into the slot of the feedback arm (key 79, figure 10-1) so that the bias spring loads the pin against the side of the arm with the valve travel markings.

10. Apply lubricant to the adjustment arm pin. Place the pin into the slot of the feedback arm (key 79) so that the bias spring loads the pin against the side of the arm with the valve travel markings.

7. Install the external lock washer on the adjustment arm. Position the adjustment arm in the slot of the connector arm and loosely install the washer and screw.

11. As shown in figure 2-6, loosely fasten the adjustment arm to the connector arm with a machine screw, washer and lock washer.

8. Loosely attach the brace to the mounting bracket with screws, washers, and hex nuts. Attach the brace to the actuator leg with U-bolts, washers, and hex nuts. Tighten the screws and hex nuts.

12. Slide the adjustment arm pin in the slot of the connector arm until the pin is in line with the desired valve travel marking. Tighten the machine screw.

2-8

9. Slide the adjustment arm pin in the slot of the connector arm until the pin is in line with the desired May 1998

Installation

2 CONNECTOR ARM ADJUSTMENT ARM

MOUNTING BRACKET

BRACE

SHIELD A7020 / IL

Figure 2-7. Type DVC5010 Digital Valve Controller with Integrally Mounted Filter Regulator Yoke-Mounted on Gulde Pneumatic Actuator Model GA

valve travel marking. Tighten the screw on the adjustment arm. 10. Remove the alignment pin (key 46) and store in the module base next to the I/P assembly.

Note Go to step 12 if the actuator already has the cam (key 94) installed.

11. Attach the shield with two screws.

Mounting Type DVC5020 on Fisher Rotary Actuators

2. Mark the positions of the travel indicator and actuator cover. Then, remove the actuator travel indicator machine screws, travel indicator, and actuator cover cap screws. 3. Remove the cover plate from the actuator housing.

1051 and 1052 Actuators Unless otherwise noted, refer to figure 2-8 or 2-9 for key number locations. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. Shut off all pressure lines to the pneumatic actuator, releasing all pressure from the actuator. Use lock-out procedures to be sure that the above measures stay in effect while working on the equipment. May 1998

Note For information on the various actuator mounting styles and positions, refer to the appropriate actuator instruction manual.

4. For actuator mounting styles A and D, proceed to the note before step 8. For actuator mounting styles B and C, continue with step 5.

2-9

DVC5000 Series

APPLY LUB, SEALANT 43B8450-B / DOC

Figure 2-8. Type DVC5020 Digital Valve Controller Mounted on Type 1052 Size 33 Actuator with Casing-Mounted Filter Regulator

APPLY LUB, SEALANT 43B8448-B / DOC

Figure 2-9. Type DVC5020 Digital Valve Controller with Integrally Mounted Filter Regulator Mounted on Type 1051 Size 40 Actuator

2-10

May 1998

Installation 5. Disconnect the actuator turnbuckle from the lever arm.

Note Do not change the position of the rod end bearing on the end of the turnbuckle.

6. Loosen the lever clamping bolt in the lever. 7. Mark the lever/valve shaft orientation, and remove the lever.

12. For Type 1051 size 33 and 1052 size 20 and 33 actuators, attach an adaptor (key 117) to the actuator with four screws (key 116). Then assemble the digital valve controller assembly to the adaptor. The roller on the digital valve controller feedback arm will contact the actuator cam as it is being attached. Install and tighten four screws (key 116). For other size 1051 and 1052 actuators, assemble the digital valve controller assembly to the front access opening of the actuator. The roller on the digital valve controller feedback arm will contact the actuator cam as it is being attached. Install and tighten four screws (key 116). 13. Replace the actuator cover and the travel indicator in the positions that were marked in step 2.

Note Note Linear Camâ&#x20AC;&#x201D;Cam A has the letter D (direct acting) on one side and the letter R (reverse acting) on the other side. Always install cam A with the letter D on the same side as the cam mounting screw heads (key 95).

Actuator cover alignment on the Type 1052 actuator can be aided by moving the actuator slightly away from its up travel stop using a regulated air source. If hole alignment cannot be obtained in this manner, temporarily loosen the cap screws that secure the housing to the mounting yoke, and shift the housing slightly. Do not completely stroke the actuator while the cover is removed.

8. Install the cam (key 94) on the actuator lever with the cam mounting screws (key 95). 9. For actuator styles A and D, proceed to step 12. For actuator styles B and C, continue with step 10. 10. Slide the lever/cam assembly (cam side first) onto the valve shaft. Orient the lever with the shaft as noted in step 7, and tighten the lever clamping bolt.

Note Refer to the appropriate actuator instruction manual to determine the distance required between the housing face and the lever face and to determine the proper tightening torque for the lever clamping bolt.

11. Connect the turnbuckle and the lever arm. May 1998

Mounting Type DVC5020 on Fisher Sliding-Stem Actuators 471 Actuators Mounting the Type DVC5020 digital valve controller requires an actuator with a tapped lower yoke boss. Refer to figure 2-10 for parts location. Also refer to PS Sheet 62.1:FIELDVUE(B) Mounting FIELDVUE Instruments on Piston Actuators for guidelines on using the digital valve controller with the Fairchild Model 25463 reversing relay. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. Shut off all pressure lines to the pneumatic actuator, releasing all pressure from the actuator. Use lock-out procedures to be sure that the above measures stay in effect while working on the equipment.

2-11

DVC5000 Series A

LOCK WASHER CAP SCREW MOUNTING PLATE

PLAIN WASHER

CAP SCREW, HEX SOCKET MOUNTING BRACKET

SPACER

HEX NUT

STUD, CONT THREAD

CAM

PIPE PLUG VENT PLAIN WASHER HEX NUT

STUD, CONT THREAD A SPACER NIPPLE

SECTION A-A

TEE NIPPLE BUSHING BUSHING 27B6708-A / DOC

BUSHING

FAIRCHILD MODEL 25463

Figure 2-10. Type DVC5020 Digital Valve Controller with a Fairchild Model 25463 Relay Mounted on a 471 Size 100 Actuator.

WARNING To avoid personal injury or property damage, in the following step do not loosen the stem connector cap screws when the stem connector has spring or loading pressure force applied to it.

2. Remove one of the stem connector cap screws and replace with the continuous thread stud. Thread the stud through the stem connector far enough to permit screwing a washer and hex nut onto the stud. 3. Place a washer and hex nut on the stud and tighten against the stem connector. In steps 4 through 7 hold the two halves of the stem connector together, until the cam is fastened in place, to keep the valve stem and the actuator piston rod from separating. 4. Remove the second stem connector cap screw and replace with the continuous thread stud. Thread the stud through the stem connector far enough to permit screwing a washer and hex nut onto the stud. 5. Place a washer and hex nut on the stud and tighten against the stem connector.

2-12

6. Place a spacer on each of the studs extending from the stem connector. 7. Place the cam on the studs as shown in figure 2-10. Be sure the stem connector is still clamping the actuator piston rod and valve stem. Fasten the spacers and cam in place with two washers and hex nuts. 8. To mount the digital valve controller requires a tapped lower yoke boss. Screw the continuous thread stud into the tapped hole in the lower yoke boss. 9. Fasten the mounting plate to the actuator upper yoke boss with two cap screws and lock washers, and to the lower yoke boss with a washer and hex nut. The mounting parts kit for the Type 471 actuator contains a mounting bracket with tapped holes for a pipe plug and vent. Steps 10 through 15 describe how to replace the existing mounting bracket on the digital valve controller with the mounting bracket from the parts kit and how to transfer the feedback parts from the existing mounting bracket to the mounting bracket in the kit. In the following step, refer to figure 10-2 for key number locations. 10. On the digital valve controller, disconnect the bias spring (key 82) from the arm assembly (key 91). Remove the mounting bracket (key 74) from the back of the digital valve controller. 11. On the mounting bracket just removed, note the orientation of the feedback parts, then remove the May 1998

Installation CAP SCREW

REVEERSE ROLLER ASSEMBLY

MACHINE SCREW, LOCK WASHER SPACER HEX NUT

MOUNTING ADAPTOR CAP SCREW, HEX SOCKET MOUNTING BRACKET

CAP SCREW CAM

NIPPLE TEE PIPE PLUG NIPPLE BUSHING

BUSHING

VENT

FEEDBACK ARM ASSEMBLY FOLLOWER ARM EXTENSION

BUSHING

FAIRCHILD MODEL 25463 27B6717-A / DOC

Figure 2-11. Type DVC5020 Digital Valve Controller with Fairchild Model 25463 Relay Mounted on a Type 585 Size 50 Actuator

E-ring that holds the feedback parts to the mounting bracket. Remove the feedback parts. 12. Assemble the feedback parts on the mounting bracket from the parts kit so that they are in the same orientation as they were before. 13. Assemble the mounting bracket with feedback parts to the back of the digital valve controller. 14. Reconnect the bias spring (key 82) between the feedback arm assembly (key 84) and the arm assembly (key 91). The long tang of the bias spring connects to the arm assembly (key 91). 15. Install the 1/8-inch NPT pipe plug in the tapped hole on the back of the mounting bracket. Install the vent in the 1/4-inch NPT tapped hole on the bottom of the mounting bracket. 16. Assemble the digital valve controller assembly to the mounting plate. The roller on the digital valve controller feedback arm will contact the actuator cam as it is being attached. Install and tighten the four hex socket cap screws. 17. Determine the valve actuator action and proceed as follows: a. If an increasing input signal to the digital valve controller closes the valve, nipple mount the Fairchild relay to the lower cylinder connection. May 1998

b. If an increasing input signal to the digital valve controller opens the valve, nipple mount the Fairchild relay to the upper cylinder connection. 18. Using 3/8-inch (10 mm) outside diameter tubing, connect the 1/4-inch NPT or R 1/4 digital valve controller output connection to the pipe tee on the Fairchild relay. 19. Using 3/8-inch (10 mm) outside diameter tubing, connect the remaining cylinder connection to the pipe tee on the Fairchild relay. 20. On the Type 67AF regulator, remove the 1/4-inch NPT pipe plug and, using 3/8-inch (10 mm) outside diameter tubing, connect the regulator output to the 1/4-inch NPT bushing on the Fairchild relay. 21. Make supply and electrical connections as described in the Pneumatic Connections and Electrical Connections subsections. 22. Refer to the Model 25463 spring adjustment description in this section and adjust the spring as necessary.

585 and 585R Actuators Refer to figure 2-11 for parts location. Also refer to PS Sheet 62.1:FIELDVUE(B) Mounting FIELDVUE Instruments on Piston Actuators for guidelines on using the digital valve controller with the Fairchild Model 25463 reversing relay. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the

2-13

DVC5000 Series valve body, and drain the process media from both sides of the valve. Shut off all pressure lines to the pneumatic actuator, releasing all pressure from the actuator. Use lock-out procedures to be sure that the above measures stay in effect while working on the equipment.

The mounting parts kit for the Type 585 actuator contains a mounting bracket with tapped holes for a pipe plug and vent. Steps 2 through 10 describe how to replace the existing mounting bracket on the digital valve controller with the mounting bracket from the parts kit and how to transfer the feedback parts from the existing mounting bracket to the mounting bracket in the kit. In the following step, refer to figure 10-2 for key number locations. 2. On the digital valve controller, disconnect the bias spring (key 82) from the arm assembly (key 91). Remove the mounting bracket (key 74) from the back of the digital valve controller. 3. On the mounting bracket just removed, note the orientation of the feedback parts, then remove the E-ring that holds the feedback parts to the mounting bracket. Remove the feedback parts. 4. Assemble the feedback parts on the mounting bracket from the parts kit so that they are in the same orientation as they were before. 5. Remove the follower post (key 87) from the feedback arm assembly (key 84). 6. Attach the follower arm extension to the feedback arm assembly with two machine screws, lock washers, and hex nuts as shown in figure 2-11. 7. Attach the follower post to the follower arm extension so that it is on the left side of the follower arm extension when viewing the back of the digital valve controller.

13. Insert the cap screws through the mounting adaptor as shown in figure 2-11. Place spacers on the cap screws. 14. Fasten the mounting adaptor to the actuator yoke. Tighten the cap screws. In the next step hold the two halves of the stem connector together, until the cam is fastened in place, to keep the valve stem and the actuator piston rod from separating. 15. Remove the two cap screws from the stem connector and attach the cam as shown in figure 2-11. 16. Assemble the digital valve controller assembly to the mounting adaptor. The roller on the digital valve controller feedback arm will contact the actuator cam as it is being attached. Install and tighten the four cap screws. 17. Determine the valve actuator action and proceed as follows: c. If an increasing input signal to the digital valve controller closes the valve, nipple mount the Fairchild relay to the lower cylinder connection. d. If an increasing input signal to the digital valve controller opens the valve, nipple mount the Fairchild relay to the upper cylinder connection. 18. Using 3/8-inch (10 mm) outside diameter tubing, connect the 1/4-inch NPT or R 1/4 digital valve controller output connection to the pipe tee on the Fairchild relay. 19. Using 3/8-inch (10 mm) outside diameter tubing, connect the remaining cylinder connection to the pipe tee on the Fairchild relay. 20. On the Type 67AF regulator, remove the 1/4-inch NPT pipe plug and, using 3/8-inch (10 mm) outside diameter tubing, connect the regulator output to the 1/4-inch NPT bushing on the Fairchild relay.

8. Assemble the mounting bracket with feedback parts to the back of the digital valve controller.

21. Replace the actuator front and back yoke covers. Discard the actuator blanking plate and four screws

9. Reconnect the bias spring (key 82) between the feedback arm assembly (key 84) and the arm assembly (key 91). The long tang of the bias spring connects to the arm assembly (key 91).

22. Make supply and electrical connections as described in the Pneumatic Connections and Electrical Connections subsections.

10. Install the pipe plug in the tapped hole on the back of the mounting bracket. Install the vent in the tapped hole on the bottom of the mounting bracket. In step 11, refer to the actuator instruction manual for key number locations, unless noted otherwise. 11. Loosen eight screws, and remove the front and back yoke covers (keys 18 and 20). 12. Loosen four screws, and remove the actuator blanking plate.

2-14

23. Refer to Model 25463 spring adjustment description in this section and adjust the spring as necessary.

Fairchild Model 25463 Reversing Relay Spring Adjustment The Fairchild Model 25463 is a spring biased reversing relay. It provides an output pressure which follows the equation Po = K â&#x20AC;&#x201C; Ps. Where Po is the output pressure, K is the spring bias and Ps is the signal pressure. The spring bias is adjusted during calibration as follows: May 1998

Installation

2 A

54B7195-B / DOC

Figure 2-12. Type DVC5030 Digital Valve Controller Mounted on Type 1052 Size 33 Actuator with Casing-Mounted Filter Regulator

Set the Model 25463 spring adjustment with the valve off the travel stops. Adjust the spring so that the average of the top and bottom cylinder pressures is 50% of the minimum available supply pressure. This is accomplished by adjusting the supply pressure to the minimum available, then adjusting the input current until the valve is off the stops. Next, turn the Model 25463 adjustment screw until the digital valve controller output gauge reads 50% of the minimum supply pressure. Restore the supply pressure to its normal operating pressure prior to placing the system in service. The following example uses a minimum supply pressure of 80 psig with the digital valve controller output applied to the upper cylinder connection. With a minimum supply pressure of 80 psig, the spring adjustment method described establishes K at 80 psig. An increasing DVC5000 output pressure moves the piston down. A DVC5000 output of 50 psig would yield a Model 25463 output of Po = K – Ps 80–50 = 30 psig A decreasing DVC5000 output moves the piston up. A DVC5000 output of 30 psig would yield a Model 25463 output of Po = K – Ps May 1998

80–30 = 50 psig

Mounting Type DVC5030 on Fisher Rotary Actuators 1051 Size 33 and 1052 Size 20 and 33 Actuators Unless otherwise noted, refer to figure 2-12 for key number locations. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. Shut off all pressure lines to the pneumatic actuator, releasing all pressure from the actuator. Use lock-out procedures to be sure that the above measures stay in effect while working on the equipment. In step 2, refer to the actuator instruction manual for key number locations. 2. Remove the self-tapping screws (key 38) and the travel indicator (key 37). Also remove the self-tapping screws (key 36) and the travel indicator scale (key 35). Before attaching the mounting bracket and travel indicator assembly, determine the desired position of the travel indicator scale (key 142) relative to the actuator hub (above, below, left, or right). Figure 2-12 shows the travel indicator scale to the left of the actuator hub. The travel indicator scale is not installed at this time. The travel indicator scale is installed in step 11.

2-15

DVC5000 Series 3. Position the mounting bracket (key 107) so that the travel indicator scale (key 142) will be in the desired position. The travel indicator scale is not installed at this time; it is installed in step 11. 4. Attach the mounting bracket (key 107) to the actuator using four hex head cap screws (key 191) and washers (key 140). 5. Place the spacer (key 141) on the actuator hub.

6. Attach the travel indicator assembly (key 144) to the spacer as follows: a. If the valve is open without pressure to the actuator [push-down-to-close (PDTC) actuator mounting], position the assembly so that the pointer on the travel indicator assembly will be over the open mark on the travel scale. Attach the travel indicator assembly (key 144) and spacer (key 141) to the actuator hub using two machine screws (key 145). For size 33 actuators only, also include two washers (key 199), as shown in figure 2-12. b. If the valve is closed without pressure to the actuator [push-down-to-open (PDTO) actuator mounting], position the assembly so that the pointer on the travel indicator assembly will be over the closed mark on the travel scale. Attach the travel indicator assembly (key 144) and spacer (key 141) to the actuator hub using two machine screws (key 145). For size 33 actuators only, also include two washers (key 199), as shown in figure 2-12. 7. Position the feedback arm (key 79, figure 10-3) so that, when the digital valve controller is mounted on the actuator, the pin on the travel indicator assembly (key 144) will slide into the slot on the feedback arm. 8. Apply lubricant (key 63) to the travel indicator assembly pin (key 144). 9. Position the digital valve controller on the mounting bracket (key 107). Be sure the pin on the travel indicator assembly (key 144) is in the feedback arm slot such that the bias spring (key 78) loads the pin against the side of the slot marked with an X. 10. Attach the digital valve controller to the mounting bracket (key 107) using four hex head cap screws (key 104). 11. Attach the travel indicator scale (key 142) to the mounting bracket (key 107) with two washers (key 198) and hex nuts (key 197). Position the scale so that the OPEN or CLOSED mark is beneath the travel indicator pointer (key 144) and tighten the hex nuts.

1051 Size 30 to 60 and 1052 Size 40 to 70 Actuators Unless otherwise noted, refer to figure 2-12 for key number locations.

2-16

1. Isolate the control valve from the process line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. Shut off all pressure lines to the pneumatic actuator, releasing all pressure from the actuator. Use lock-out procedures to be sure that the above measures stay in effect while working on the equipment. In steps 2 and 3, refer to the actuator instruction manual for key number locations. 2. Remove the self-tapping screws (key 38) and the travel indicator (key 37). Also remove self-tapping screws (key 36) and the travel indicator scale (key 35). 3. Remove the four hex head cap screws (key 34) and washers (key 63) that secure the actuator cover (key 33). Do not remove the cover. Set aside the screws and washers for later use. Before attaching the travel indicator assembly, determine the desired position of the travel indicator scale (key 142) relative to the actuator hub (above, below, left, or right). Figure 2-12 shows the travel indicator scale to the left of the actuator hub. The travel indicator scale is not installed at this time. The travel indicator scale is installed in step 11. 4. Attach the travel indicator assembly (key 144) to the spacer as follows: a. If the valve is open without pressure to the actuator [push-down-to-close (PDTC) actuator mounting], position the assembly so that the pointer on the travel indicator assembly will be over the open mark on the travel scale. Attach the travel indicator assembly (key 144) to the actuator hub using two machine screws (key 145). b. If the valve is closed without pressure to the actuator [push-down-to-open (PDTO) actuator mounting], position the assembly so that the pointer on the travel indicator assembly will be over the closed mark on the travel scale. Attach the travel indicator assembly (key 144) to the actuator hub using two machine screws (key 145). 5. Attach the digital valve controller to the mounting bracket assembly (key 107) using four hex head cap screws (key 104). 6. Position the feedback arm (key 79, figure 10-3) so that, when the digital valve controller is mounted on the actuator, the pin on the travel indicator assembly (key 144) will slide into the slot on the feedback arm. 7. Apply lubricant (key 63) to the travel indicator assembly pin (key 144). 8. Position the mounting bracket (key 107), with controller, so that the travel indicator scale (key 142) will be in the desired position. The travel indicator scale is not installed at this time; it is installed in step 11. May 1998

Installation 9. Be sure the pin on the travel indicator assembly (key 144) is in the feedback arm slot such that the bias spring (key 78) loads the pin against the side of the slot marked with an X. 10. Attach the mounting bracket to the actuator using the four hex head screws (key 34) and washers (key 63) removed in step 3. 11. Attach the travel indicator scale (key 142) to the mounting bracket (key 107) with two washers (key 198) and hex nuts (key 197). Position the scale so that the OPEN or CLOSED mark is beneath the travel indicator pointer (key 144) and tighten the hex nuts.

1066SR Sizes 20, 27, and 75 Actuators Unless otherwise noted, refer to figure 2-12 for key number locations. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. Shut off all pressure lines to the pneumatic actuator, releasing all pressure from the actuator. Use lock-out procedures to be sure that the above measures stay in effect while working on the equipment. In steps 2 and 3, refer to the actuator instruction manual for key number locations. 2. Remove the machine screws (key 24) and the travel indicator (key 22). 3. Remove the travel indicator scale (key 21) by removing the four cap screws (key 20). Set aside the screws for later use. Before attaching the mounting bracket and travel indicator assembly, determine the desired position of the travel indicator scale (key 142) relative to the actuator hub (above, below, left, or right). Figure 2-12 shows the travel indicator scale to the left of the actuator hub. The travel indicator scale is not installed at this time. The travel indicator scale is installed in step 12. 4. Position the mounting bracket (key 107) so that the travel indicator scale (key 142) will be in the desired position. The travel indicator scale is not installed at this time; it is installed in step 12. 5. Attach the mounting bracket (key 107) to the actuator using washers (key 140) and the four cap screws removed in step 3. 6. Place the spacer (key 141) on the actuator hub. 7. Attach the travel indicator assembly (key 144) to the spacer as follows: a. If the valve is open without pressure to the actuator [push-down-to-close (PDTC) actuator May 1998

mounting], position the assembly so that the pointer on the travel indicator assembly will be over the open mark on the travel scale. Attach the travel indicator assembly (key 144) and spacer (key 141) to the actuator hub using two machine screws (key 145) and washers (key 199). The washers are not required for size 75 actuators. b. If the valve is closed without pressure to the actuator [push-down-to-open (PDTO) actuator mounting], position the assembly so that the pointer on the travel indicator assembly will be over the closed mark on the travel scale. Attach the travel indicator assembly (key 144) and spacer (key 141) to the actuator hub using two machine screws (key 145) and washers (key 199). The washers are not required for size 75 actuators. 8. Position the feedback arm (key 79, figure 10-3) so that, when the digital valve controller is mounted on the actuator, the pin on the travel indicator assembly (key 144) will slide into the slot on the feedback arm. 9. Apply lubricant (key 63) to the travel indicator assembly pin (key 144). 10. Position the digital valve controller on the mounting bracket (key 107). Be sure the pin on the travel indicator assembly (key 144) is in the feedback arm slot such that the bias spring (key 78) loads the pin against the side of the slot marked with an X. 11. Attach the digital valve controller to the mounting bracket (key 107) using four hex head cap screws (key 104). 12. Attach the travel indicator scale (key 142) to the mounting bracket (key 107) with two washers (key 198) and hex nuts (key 197). Position the scale so that the OPEN or CLOSED mark is beneath the travel indicator pointer (key 144) and tighten the hex nuts.

Mounting Type DVC5030 to Replace Positioners Replacing Masoneilan Type 4600 Positioners Unless otherwise noted, refer to figure 2-13 for key number locations. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. Shut off all pressure lines to the pneumatic actuator, releasing all pressure from the actuator. Use lock-out procedures to be sure that the above measures stay in effect while working on the equipment. 2. Using a 3/16-inch hex wrench, remove the existing hub from the actuator shaft.

2-17

DVC5000 Series

SECTION A-A A 47B2824-B / DOC

Figure 2-13. Type DVC5030 Digital Valve Controller Assembly for Replacing a Masoneilan Type 4600 Positioner

3. Attach the shaft connector (key 179) to the actuator shaft using the socket head cap screw (key 185). 4. Attach the shaft connector cap assembly (key 181) to the shaft connector using two machine screws (key 188). 5. Attach the emulator (key 177) to the actuator using two socket head cap screws (key 186). The digital valve controller can mount to the actuator in any one of four possible mounting quadrants. Determine the desired mounting position then proceed with the next step. 6. Attach the positioner plate (key 178) to the emulator using the three spacers (key 182) and flathead cap screws (key 184). 7. On the Type DVC5030 digital valve controller, remove the feedback arm (key 79, figure 10-3) and slip the coupler (key 180) on the travel sensor shaft. Tighten the coupler set screw to secure the coupler on the travel sensor shaft. 8. Align the digital valve controller with the mounting holes in the positioner plate (key 178). Be sure the coupler slips onto the pin in the shaft connector cap assembly (key 181). Secure the controller to the positioner plate using four hex head cap screws (key 187). Leave the coupler loose on the connector cap assembly (key 181) until travel sensor adjustment is complete. 9. Perform the Travel Sensor Adjust procedure in the â&#x20AC;&#x153;Calibrationâ&#x20AC;? section, Section 6.

2-18

Replacing Neles-Jamesbury Type NE600, NP600, NE700 and NP700 Positioners Unless otherwise noted, refer to figure 2-14 for key number locations. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. Shut off all pressure lines to the pneumatic actuator, releasing all pressure from the actuator. Use lock-out procedures to be sure that the above measures stay in effect while working on the equipment. 2. Attach the emulator (key 177) to the actuator using three socket head cap screws (key 189). 3. Position the tie-bar assembly (key 190) in the actuator shaft slot so that it is approximately centered. Tighten the set screw to temporarily hold the tie-bar assembly in place. The digital valve controller can mount to the actuator in any one of four possible mounting quadrants. Determine the desired mounting position then proceed with the next step. 4. Attach the positioner plate (key 178) to the emulator using the three spacers (key 182) and flathead cap screws (key 184). 5. On the Type DVC5030 digital valve controller, remove the feedback arm (key 79, figure 10-3) and slip the coupler (key 180) on the travel sensor shaft. Tighten the coupler set screw to secure the coupler on the travel sensor shaft. 6. Align the digital valve controller with the mounting holes in the positioner plate (key 178). Once the coupler passes through the hole in the positioner May 1998

Installation

SECTION A-A

47B2826-B / DOC

Figure 2-14. Type DVC5030 Digital Valve Controller Assembly for Replacing Neles-Jamesbury Positioners

plate, place the valve position pointer (key 206) on the coupler. Slide the pointer onto the coupler until it rests on the controller housing. Position the pointer so that, during normal operation, it will not contact any of the spacers (key 182) when the actuator shaft rotates. 7. Be sure the coupler slips onto the pin in the tie-bar assembly (key 190). If necessary, loosen the set screw to allow the tie-bar assembly to slide in the actuator shaft slot. Secure the controller to the positioner plate using four hex head cap screws (key 187). 8. Rotate the coupler (key 180) to be sure it does not bind, then tighten the set screw to hold the tie-bar assembly (key 190) in place. Leave the coupler loose on the tie-bar assembly (key 190) until the travel sensor adjustment is complete. 9. Perform the Travel Sensor Adjust procedure in the â&#x20AC;&#x153;Calibrationâ&#x20AC;? section, Section 6. 10. Determine the actuator action (clockwise shaft rotation opens the valve or clockwise shaft rotation closes the valve) and select the appropriate indicator scale (key 207). Remove the paper backing from the indicator scale to expose the adhesive. 11. Slip the indicator scale (key 207) under the pointer and fasten it to the emulator (key 177 by pressing the scale in place. 12. Position the pointer as follows: a. If the valve is closed, position the pointer over the CLOSED mark on the indicator scale. May 1998

b. If the valve is open, position the pointer over the OPEN mark on the indicator scale. 13. Be sure the pointer (key 206) does not contact the emulator (key 177) or digital valve controller housing and tighten the screw (key 205) to secure the pointer on the coupler (key 180).

Replacing PMV Model P1200, P1250, and P2000 Positioners Unless otherwise noted, refer to figure 2-15 for key number locations. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. Shut off all pressure lines to the pneumatic actuator, releasing all pressure from the actuator. Use lock-out procedures to be sure that the above measures stay in effect while working on the equipment. 2. Remove the PMV positioner from the valve and remove the PMV spindle. 3. Machine the end of the spindle so that it matches the dimensions in figure 2-16. 4. Attach the emulator (key 177) to the actuator using three socket head cap screws (key 189). The digital valve controller can mount to the actuator in any one of four possible mounting quadrants. Determine the desired mounting position then proceed with the next step. 5. Attach the positioner plate (key 178) to the emulator using the three spacers (key 182) and flathead cap screws (key 184).

2-19

DVC5000 Series

SECTION A-A A 47A2828-C / DOC

Figure 2-15. Type DVC5030 Digital Valve Controller Assembly for Replacing PMV Positioners

10. Perform the Travel Sensor Adjust procedure in the “Calibration” section, Section 6. 11. Determine the actuator action (clockwise shaft rotation opens the valve or clockwise shaft rotation closes the valve) and select the appropriate indicator scale (key 207). Remove the paper backing from the indicator scale to expose the adhesive.

EXISTING SHAFT DEPENDENT ON ACTUATOR

SHAFT CONNECTOR

TYPE 1200, 1500 & 2000 SERIES PMV SPINDLE

ADDITIONAL MACHINING REQUIRED 17B4021–A / IL

Figure 2-16. PMV Spindle Dimensions Required to Fit Coupler (key 180)

6. On the Type DVC5030 digital valve controller, remove the feedback arm (key 79, figure 10-3) and slip the coupler (key 180) on the travel sensor shaft. Tighten the coupler set screw to secure the coupler on the travel sensor shaft. 7. Align the digital valve controller with the mounting holes in the positioner plate (key 178). Once the coupler passes through the hole in the positioner plate, place the valve position pointer (key 206) on the coupler. Slide the pointer onto the coupler until it rests on the controller housing. Position the pointer so that, during normal operation, it will not contact any of the spacers (key 182) when the actuator shaft rotates. 8. Install the machined spindle into the coupler (key 180) then slide the controller in until the spindle engages the actuator shaft. 9. Secure the controller to the positioner plate using four hex head cap screws (key 187). Leave the coupler loose on the spindle until the travel sensor adjustment is complete.

2-20

12. Slip the indicator scale (key 207) under the pointer and fasten it to the emulator (key 177 by pressing the scale in place. 13. Position the pointer as follows: a. If the valve is closed, position the pointer over the CLOSED mark on the indicator scale. b. If the valve is open, position the pointer over the OPEN mark on the indicator scale. 14. Be sure the pointer (key 206) does not contact the emulator (key 177) or digital valve controller housing and tighten the screw (key 205) to secure the pointer on the coupler (key 180).

Mounting Type DVC5040 on System 9000 Actuators Refer to figures 2-17 and 10-4 for key numbers. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the valve body, and drain the process media from both sides of the valve. Shut off all pressure lines to the pneumatic 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. May 1998

Installation

A6855/IL

Figure 2-17. System 9000 Actuator Assembly with Type DVC5040 Digital Valve Controller

WARNING To avoid personal injury due to the sudden uncontrolled movement of parts, do not loosen the stem connector cap screws when the stem connector has spring force applied to it. Apply enough pressure to lift the plug off the seat before loosening the stem connector cap screws.

POINT â&#x20AC;&#x2122;Aâ&#x20AC;&#x2122; O-RING LOCATION

2. Install the O-ring (key 167) as shown in figure 2-18 to the mounting flange of the digital valve controller. W6510*A/IL

3. Line up the O-ring from the previous step with its associated actuator port on the power module assembly and attach the digital valve controller to the System 9000 actuator power module assembly with two cap screws (key 116). See figure 2-18. May 1998

ACTUATOR PORT FOR FIELDVUE CONTROLLER

Figure 2-18. Digital Valve Controller Point of Connection

2-21

DVC5000 Series Note The alignment pin (key 46) is stored inside the digital valve controller housing. It is located above the supply pressure gauge.

Travel Markings Inches (mm) Actuator Travel, Inches

0.75 (19)

(32)

1.5

0.75(1)

1.0

1.25

1.50

1.75

2.0

1. For travels less than 0.75 inches, use the 0.75 (19) travel mark.

.75 (19)

2 4. Set the position of the adjustment arm (key 106) by inserting the alignment pin (key 46) through the hole on the feedback arm marked ‘‘A’’ for a fail-closed configuration or the hole marked ‘‘B’’ for fail-open configurations.

1.5

(32)

TRAVEL, INCH (mm)

34B1929 SHT 2 OF 2

5. Apply lubricant (key 63) to the pin portion of the adjustment arm (key 106). Place the pin into the slot of the feedback arm (key 79) so that the bias spring loads the pin against the side of the feedback arm with the valve travel markings. 6. Loosely install the washer (key 126) and machine screw (key 109) to attach the adjustment arm (key 106) to the actuator feedback bracket (key 108).

A7053 / IL

Figure 2-19. Alignment of Travel Markings

around the SUPPLY connection on the digital valve controller. Attach the Type 67AF filter regulator to the side of the digital valve controller. This is the standard method of mounting the filter regulator.

Yoke-Mounted Regulator

7. Slide the adjustment arm pin in the slot of the feedback arm until the pin is in line with the desired valve travel marking (see figure 2-19). Tighten the machine screw (key 109).

Mount the filter regulator with 2 screws (key 59) to the pre-drilled and tapped holes in the actuator yoke. Thread a 1/4-inch socket-head pipe plug (key 61) into the unused outlet on the filter regulator. The O-ring (key 60) is not required.

8. Remove the alignment pin (key 46) and store it in the threaded hole near the top of the digital valve controller module base. Install the digital valve controller cover.

Casing-Mounted Regulator

Mounting the Type 67AF Filter Regulator

Refer to figures 2-8 and 2-12. Use the separate Type 67AF filter regulator casing mounting bracket provided with the filter regulator. Attach the mounting bracket to the Type 67AF and then attach this assembly to the actuator casing. Thread a 1/4-inch socket-head pipe plug (key 61) into the unused outlet on the filter regulator. The O-ring (key 60) is not required.

A Type 67AF filter regulator, when used with the DVC5000 Series digital valve controllers, can be mounted three ways.

Pneumatic Connections

9. Install the System 9000 actuator cover assembly.

Integral-Mounted Regulator Refer to figures 2-1 through 2-5 and figure 2-9. Lubricate an O-ring (key 60) and insert it in the recess

2-22

All pressure connections on the digital valve controller are 1/4-inch NPT or R 1/4 female connections. Use 3/8-inch (10 mm) tubing for all pneumatic connections. If remote venting is required, refer to the vent subsection.

May 1998

Installation Supply Connections

Vent WARNING

WARNING 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.

Supply pressure must be clean, dry air or noncorrosive gas that meets the requirements of ISA Standard S7.3-1975 (R1981). A Fisher Controls Type 67AF filter regulator, or equivalent, may be used to filter and regulate supply air. A filter regulator can be integrally mounted onto the side of the digital valve controller, casing mounted separate from the digital valve controller, or mounted on the actuator mounting boss. Supply and output pressure gauges may be supplied on the digital valve controller. The output pressure gauge can be used as an aid for calibration. Connect the nearest suitable supply source to the1/4-inch NPT IN connection on the filter regulator (if furnished) or to the 1/4-inch NPT SUPPLY connection on the digital valve controller housing (if Type 67AF filter regulator is not attached).

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 use 3/8-inch (10 mm) outside diameter tubing to connect the 1/4-inch NPT or R 1/4 digital valve controller output connection to the pneumatic actuator input connection. May 1998

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 Remove the plastic vent (key 52, figure 10-1). The vent connection is 1/4-inch NPT or R 1/4 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 (key 74, figure 10-2) with the vent-away mounting bracket (key 74). Install a pipe plug (key 127, figure 10-2) in the vent-away mounting bracket (key 74). Mount the digital valve controller on the actuator as described in the “Installation” section of this manual.

Electrical Connections 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.

2-23

DVC5000 Series SAFETY GROUND

LOOP–

WARNING

LOOP+

TALK+ TALK–

SAFETY GROUND

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. 4. Connect the safety ground and the earth ground as shown in figure 2-20. Replace and hand tighten the cover on the terminal box. When the loop is ready for startup, apply power to the control system output card.

A6193-1/IL

Figure 2-20. Type DVC5000 Series Digital Valve Controller Terminal Box

Test Connections WARNING

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 pwb 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 figures 10-1 through 10-4 for identification of parts). 1. Remove the terminal box cap (key 4) from the terminal box (key 3). 2. Bring the field wiring into the terminal box. When applicable, install conduit using local and national electrical codes which apply to the application. 3. Connect the positive wire from the control system output card ‘‘current output’’ to the LOOP + screw terminal on the pwb/terminal strip assembly in the terminal box. Connect the negative (or return) wire from the control system output card to the LOOP – screw terminal in the terminal box as shown in figure 2-20.

2-24

Personal injury or property damage caused by fire or explosion may occur if the following procedure is attempted in an area which contains a potentially explosive atmosphere or has been classified as hazardous. Confirm that area classification and atmosphere conditions permit the safe removal of the terminal box cap before proceeding. Test connections inside the terminal box can be used to measure loop current across a 1 ohm resistor. 1. Remove the terminal box cap. 2. Adjust the test meter to measure a range of 0.001 to 0.1 volts. 3. Connect the positive lead of the test meter to the TEST + connection and the negative lead to the TEST – connection inside the terminal box. 4. Measure Loop current as: Voltage (on test meter) 1000 = milliamps example: Test meter Voltage X 1000 = Loop Milliamps 0.004 X1000 = 4.0 milliamperes 0.020 X 1000 = 20.0 milliamperes May 1998

Installation 5. Remove test leads and replace the terminal box cover.

D always install a filter, or D contact your Fisher Controls sales office or sales representative for their recommendation.

Communication Connections Voltage Available

WARNING Personal injury or property damage caused by fire or explosion may occur if this connection is attempted in an area which contains a potentially explosive atmosphere or has been classified as hazardous. Confirm that area classification and atmosphere conditions permit the safe removal of the terminal box cap before proceeding.

The voltage available at the DVC5000 Series digital valve controller must be at least 12 volts dc. The voltage available at the instrument is not the actual voltage measured at the instrument when the instrument is connected. The voltage measured at the instrument is limited by the instrument and is typically less than the voltage available. As shown in figure 2-21, the voltage available at the instrument depends upon: D the control system compliance voltage D if a filter or intrinsic safety barrier is used, and

A HART communicating device, such as a Model 275 HART Communicator or a personal computer running ValveLink software communicating through a HART modem, interfaces with the DVC5000 Series digital valve controller from any wiring termination point in the 4–20 mA loop. If you choose to connect the HART communicating device directly to the instrument, attach the device to the LOOP + and LOOP – terminals or to the TALK + and TALK – connections inside the terminal box to provide local communications with the instrument.

D the wire type and length. The control system compliance voltage is the maximum voltage at the control system output terminals at which the control system can produce maximum loop current. The voltage available at the instrument may be calculated from the following equation: Voltage Available = [Control System Compliance Voltage (at maximum current)] – [filter voltage drop (if a HART filter is used)] – [total cable resistance maximum current] – [barrier resistance x maximum current].

Wiring Practices

The calculated voltage available should be greater than or equal to 12 volts dc, minimum.

Control System Requirements

Table 2-1 lists the compliance voltage of tested control systems and other control system parameters. Table 2-2 lists the resistance of some typical cables.

There are several parameters that should be checked to ensure the control system is compatible with the DVC5000 Series digital valve controller.

HART Filter Depending upon the control system you are using, a HART filter may be needed to isolate the control system output from modulated HART communication signals. The filter is inserted in the field loop wiring. For information and specifications, refer to the Type HF100 FIELDVUE HART Filter Instruction Manual, Form 5340 or to the FIELDVUE HF200 Series HART Filter Instruction Manual, Form 5380. To determine if your system requires a filter, refer to table 2-1. Table 2-1 lists control systems that have been tested with FIELDVUE instruments. If your control system is not listed, you can either: May 1998

The following example shows how to calculate the voltage available for a Honeywell TDC2000 control system with a Type HF230 HART filter, and 1000 feet of Belden 9501 cable: Voltage available = [18.5 volts (at 21.05 mA)] – [2.3 volts] – [48 ohms 0.02105 amps] Voltage available = [18.5] – [2.3] – [1.01] Voltage available = 15.19 volts

Compliance Voltage If the compliance voltage of the control system is not known, perform the following compliance voltage test. 1. Disconnect the field wiring from the control system and connect equipment as shown in figure 2-22 to the control system terminals.

2-25

DVC5000 Series TOTAL LOOP CABLE RESISTANCE COMPLIANCE VOLTAGE

CONTROL SYSTEM

+ –

INTRINSIC SAFETY BARRIER (if used)

HART FILTER

+ –

VOLTAGE AVAILABLE AT THE INSTRUMENT

2 Calculate Voltage Available at the Instrument as follows: Control system compliance voltage – Filter voltage drop (if used)

Example Calculation 18.5 volts (at 21.05 mA)

– 2.3 volts (for HF200 series filter)

– Intrinsic safety barrier resistance (if used) x maximum loop current

– 2.55 volts (121 ohms x 0.02105 amps)

– Total loop cable resistance x maximum loop current

– 1.01 volts (48 ohms x 0.02105 amps for 1000 feet of Belden 9501 cable)

= Voltage available at the instrument

= 15.19 volts, available

NOTES: 1

Obtain filter voltage drop from table 2-1. The measured drop will be different than this value. The measured filter voltage drop depends upon control system output voltage, the intrinsic safety barrier (if used), and the instrument. See note 2.

The voltage available at the instrument is not the voltage measured at the instrument terminals. Once the instrument is connected, the instrument limits the measuired voltage to approximately 10.5 to 11.5 volts.

Figure 2-21. Determining Voltage Available at the Instrument 1 KILOHM POTENTIOMETER MILLIAMMETER

VOLTMETER

CIRCUIT UNDER TEST

A6192-1/IL

Figure 2-22. Voltage Test Schematic

2. Set the control system to provide maximum output current.

4. Record the voltage shown on the voltmeter. This is the control system compliance voltage.

3. Increase the resistance of the 1 kilohm potentiometer, shown in figure 2-22, until the current observed on the milliammeter begins to drop quickly.

For specific parameter information relating to your control system, contact your Fisher Controls sales representative or sales office.

2-26

May 1998

Installation Maximum Cable Capacitance

NON-HART BASED DCS

The maximum cable length for HART communication is limited by the characteristic capacitance of the cable. Maximum length due to capacitance can be calculated using the following formulas:

I/O

Length(ft) = [160,000 – Cmaster(pF)] [Ccable(pF/ft)] Length(m) = [160,000 – Cmaster(pF)] [Ccable(pF/m)]

HART FILTER

where: 160,000 = a constant derived for FIELDVUE instruments to insure that the HART network RC time constant will be no greater than 0.65 ms (per the HART specification). Cmaster = the capacitance of the control system or HART filter (see table 2-1)

2 4-20 mA DIGITAL VALVE CONTROLLER

VALVE

Ccable = the capacitance of the cable used (see table 2-2) A6188-1/IL

The following example shows how to calculate the cable length for a Foxboro I/A control system (1988) with a Cmaster of 50, 000 pF and a Belden 9501 cable with characteristic capacitance of 50pF/ft. Length(ft) = [160,000 – 50,000pF] [50pF/ft] Length = 2200 ft. The HART communication cable length is limited by the cable characteristic capacitance. To increase cable length, select a wire with lower capacitance per foot. Contact your Fisher Controls sales representative or sales office for specific information relating to your control system.

HART Filter Use and Specifications Depending on the control system being used, a filter may be needed to allow HART communication to work properly. The HART filter is an active device that is inserted in field wiring from the HART loop. Its purpose is to effectively isolate the control system output from modulated HART communication signals and raise the impedance of the control system to allow

May 1998

Figure 2-23. HART Filter Application

HART communication. The filter receives a 4 to 20 mA current signal from the control system, and drives the loop as a high impedance current source. The output current is a filtered replica of the input current. The current drive stage of the filter prevents the voltage modulation in the HART loop from being seen by, or having an effect on, the controller output. The filter requires a small amount of operating current (less than 60 microamps) and an input to output voltage drop of up to 2.3 Vdc to perform its function. The filter is normally installed near the field wiring terminals of the control system I/O (see figure 2-23). HART communication is possible only between the filter and the field instrument, not on the control system side of the filter. The filter is not designed or intended for use in the process environment. Refer to separate Type HF100 and HF200 Series filter instruction manuals for installation, calibration, and maintenance of the HART filter.

2-27

DVC5000 Series Table 2-1. Control System Parameters Control System(1)

Compliance Voltage(2)

Installation Requirement

Bailey Infi 90

15.5 V @ 20.8 mA 15.8 V @ 4.0 mA

Filter required Watch compliance voltage

Fischer–Porter DCI 40PC2000C

18.2 V @ 20.75 mA 21.7 v @ 3.89 mA

Filter required

Honeywell TDC 2000

18.5 V @ 21.05 mA 20.7 V @ 3.84 mA

Filter required

Multi-function controller Honeywell TDC 3000

High-density Process Manager (HPM) controller

18.5 20.7 18.4 20.7

V @ 21.05 mA V @ 3.84 mA V @ 20.0 mA V @ 4.0 mA

Filter required No filter required

FOXBORO I/A (1988)

18.2 V @ 20.0 mA 22.2 V @ 3.99 mA

No filter required Assume 50,000 pF Cmaster

Moore 352

No data available

No filter required

Valumet (output configured for straight through, not for 250 ohms

No data available

No filter required

Rosemount RS-3 Multiport with HART I/O

22.8 V @ 20.05 mA 24.2 V @ 4.0 mA

No filter required

20.7 V @ 22.09 mA 21.6 V @ 3.83 mA

Filter required

17.51 V @ 20.39 mA 18.08 V @ 3.82 mA

No filter required Assume 100,000 pF Cmaster

19.5 V @ 22.25 mA 20.3 V @ 3.85 mA

Filter required

Fisher–Rosemount PROVOX Configurable, Computing, and Interactive (IAC) Controllers Fisher–Rosemount PROVOX MUX (parallel) I/O Fisher–Rosemount PROVOX Control (serial) I/O

for AO for HART I/O

No data available

No filter required

Fisher–Rosemount TL108 with 24 volt dc power

17.2 V @ 20.0 mA 21.67 v @ 4.0 mA

No filter required Assume 12,000 pF Cmaster

Fisher-Rosemount TL108 with 45 volt dc power

27.0 V @ 20.0 mA

No filter required Assume 12,000 pF Cmaster

Fisher–Rosemount DPR900

20.67 V @ 19.94 ma 24.82 V @ 3.80 mA

Filter required

Fisher–Rosemount ROC 364

17.32 V @ 20.40 mA 22.63 V @ 3.66 mA

No filter required Assume 0 pF Cmaster

Type HF100 Filter

2.0 volts less than the control system

Assume 25,000 pF Cmaster

HF200 Series Filters

2.3 volts less than the control system

Assume 25,000 pF Cmaster

Transmation Model 1028 mA Calibrator 1. For control systems not listed, a filter is recommended, if the voltage available at the instrument is adequate (see Votage Available in this section). Filtering ensures proper communication and simplifies connecting a HART communicator or HART interchange.

2-28

No data available

Filter required

2. Some control systems have a compliance voltage that is power supply dependent. If the power supply voltage is below nominal, for example, due to a switch to battery backup, the compliance voltages will drop as much as the power supply drops.

May 1998

Installation Table 2-2. Cable Characteristics Cable Type

Capacitance(1) pF/Ft

Capacitance(1) pF/M

Resistance (2) Ohms/Ft

Resistance (2) Ohms/M

BS5308/1, 0.5 sq mm

61.0

200

0.022

0.074

BS5308/1, 1.0 sq mm

61.0

200

0.012

0.037

BS5308/1, 1.5 sq mm

61.0

200

0.008

0.025

BS5308/2, 0.5 sq mm

121.9

400

0.022

0.074

BS5308/2, 0.75 sq mm

121.9

400

0.016

0.053

BS5308/2, 1.5 sq mm

121.9

400

0.008

0.025

BELDEN 8303, 22 awg

63.0

206.7

0.030

0.098

BELDEN 8441, 22 awg

83.2

273

0.030

0.098

BELDEN 8767, 22 awg

76.8

252

0.030

0.098

BELDEN 8777, 22 awg

54.9

180

0.030

0.098

BELDEN 9501, 24 awg

50.0

164

0.048

0.157

BELDEN 9680, 24 awg

27.5

90.2

0.048

0.157

BELDEN 9729, 24 awg

22.1

72.5

0.048

0.157

BELDEN 9773, 18 awg

54.9

0.012

0.042

BELDEN 9829, 24 awg

27.1

0.048

0.157

BELDEN 9873, 20 awg

54.9

0.020

0.069

1. The capacitance values represent capacitance from one conductor to all other conductors and shield. This is the appropriate value to use in the cable length

May 1998

180 88.9 180

calculations. 2. The resistance values include both wires of the twisted pair.

2-29

DVC5000 Series

2-30

May 1998

275 HART Communicator Basics 3-3

Section 3 Model 275 HART Communicator Basics

May 1998

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

Action Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

On-Off Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

Up Arrow Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

Down Arrow Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

Left Arrow and Previous Menu Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

Right Arrow and Select Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2

Hot Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3

Software-Defined Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3

Alphanumeric and Shift Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3

Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4

Offline Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Polling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reviewing Instrument Device Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4 3-4 3-4 3-4 3-5

Online Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5

Displaying the HART Communicator Device Description Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5

3-1

DVC5000 Series INDICATES PRESENT DIRECTION OF THE SHIFT KEY INDICATES USE OF RIGHT ARROW KEY WILL OPEN MENU BRANCH

BLINKING HEART INDICATES COMMUNICATION WITH A FIELDVUE INSTRUMENT INDICATES LOW BATTERY

DVC: Tag Fisher Dig Vlv Ctrl 1 Main Menu (Setup) 2 Analog In 12.42mA 3 Pressure 4 Travel 53.69% 5 Drive Sgl 58.15% SAVE

INDICATES MENU ITEMS CAN BE FOUND BY USING AND KEYS

INDICATES THAT USE OF THE LEFT ARROW KEY WILL TAKE YOU BACK ONE MENU LEVEL

liquid crystal display (LCD). When connected to an instrument, the top two lines of the display indicate the instrument tag and type. The bottom line of the display is reserved for dynamic labels. These dynamic labels identify the software-defined functions assigned to the four function keys (F1 through F4) below the display.

FUNCTION KEYS

Action Keys 0

ABC DEF GHI 7 8 9 JKL MNO PQR 4 5 6 STU VWX YZ/ 1 2 3 : #%& 0

ACTION KEYS

On-Off Key ALPHANUMERIC KEYS

SHIFT KEYS A7021 / IL

Figure 3-1. Model 275 HART Communicator

Note The Model 275 HART Communicator device description revision (DD) determines how the HART Communicator interfaces with the instrument. For information on displaying the device description revision, see page 3-5.

This section discusses the display, keypad, and menu structure for the HART Communicator, shown in figure 3-1. This section also includes information for displaying the HART Communicator device description revision number. For information on connecting the HART Communicator to the instrument, see the “Installation” section, Section 2. For more information on the HART Communicator, such as specifications and servicing, see the Product Manual for the HART Communicator– MAN4275A00, included with the HART Communicator. This manual also is available from Rosemount Inc., Measurement Division.

Use this key to turn the HART Communicator on and off. When the HART Communicator is turned on, it goes through a self test routine and then automatically searches for a HART-compatible device. If no device is found, it displays the message “No Device Found.” then displays the main menu. Four choices are available from this screen: Offline, Online, Frequency Device, and Utility. If a HART-compatible device is found, the HART Communicator displays the Online menu. For more information on the Online and Offline menus, see Menu Structure in this section, page 3-4. When performing certain operations, the message “OFF KEY DISABLED” is displayed indicating the HART Communicator cannot be turned off. This feature helps to avoid situations where the HART Communicator could be unintentionally turned off while a device’s output is fixed or when configuration data has not been sent to a device.

Up Arrow Key Use this key to move the cursor up through a menu and to scroll through lists of available characters and options when editing a field.

Down Arrow Key Use this key to move the cursor down through a menu and to scroll through lists of available characters and options when editing a field.

Left Arrow and Previous Menu Key Use this dual-function key to move the cursor to the left or to return to the previous menu.

Display

Right Arrow and Select Key

The HART Communicator communicates information to you through an eight-line by twenty-one character

Use this dual-function key to move the cursor to the right or to select the highlighted menu option.

3-2

May 1998

275 HART Communicator Basics Hot Key

D ABORT—cancels your entry and takes you back to the menu from which you had selected the current variable or routine. Values are not changed.

Pressing this key turns on the HART Communicator and, if connected to a FIELDVUE instrument, displays the Hot Key menu. This menu allows you to quickly:

D OK—takes you to the next menu or instruction screen.

D Change the instrument mode D Change the control mode D Change the instrument protection D Stabilize/Optimize—permits increasing or decreasing the tuning to improve response For details on instrument mode, control mode, protection, tuning sets, and other configuration parameters, see the “Detailed Setup” section, Section 5, of this manual.

D ENTER—sends the information you have selected to the instrument or flags the value that is to be sent to the instrument. If it is flagged to be sent, the SEND dynamic label appears as a function key selection. D DEL—deletes the character at the current cursor position when entering a variable. D ESC—cancels your entry and takes you back to the menu from which you had selected the current variable. Values are not changed.

Note Software-Defined Function Keys Use the four function keys, marked F1 through F4, located below the LCD to select the software functions indicated by the dynamic labels. On any given menu, the label appearing above a function key indicates the function of that key for the current menu. As you move between menus, different dynamic labels appear over the four function keys. For example, in menus providing access to on-line help, the HELP label may appear above the F1 key. In menus providing access to the Home menu, the HOME label may appear above the F3 key. In many cases the SEND label appears indicating that you must press the corresponding function key to send the information you have entered on the keypad to the FIELDVUE instrument’s memory. Functions available include: D HELP—gives you information regarding the display selection. D SEND—sends the information you have entered to the instrument. D BACK—takes you to the previously displayed menu. D HOME—takes you back to the Online menu. D EXIT—takes you back to the menu from which you had requested the value of a variable that can only be read. May 1998

From time to time the SAVE dynamic label will appear. Do not press the function key associated with SAVE. This key has no application to FIELDVUE instruments.

Alphanumeric and Shift Keys Figure 3-2 shows the alphanumeric and shift keys. The alphanumeric keys perform two functions: the fast selection of menu options and data entry. From within any menu, you can select available options in two ways. You can use the up and down arrow keys and the select key to access available options, or just press the corresponding number on the alphanumeric keypad to select the desired option. Some menus require data entry. When you press an alphanumeric key alone from within an edit menu, the bold character in the center of the key appears. These large characters include the numbers zero through nine, the decimal point (.), and the dash symbol (–). To enter the other characters on the keys, first press and release the appropriate shift key. Do not press the keys simultaneously. Example: to enter the letter “R”, press the following key sequence: Pressing the right shift key activates shift and causes the right shift arrow icon to appear in the upper right

3-3

DVC5000 Series ABC DEF

7 JKL

MNO PQR

STU VWX STU

GHI

6 YZ/

#%&

one of the listed polling options, and press ENTER (F4) to select the highlighted option. The Polling options are: 1. Never Poll—connects to a device at address 0, and if not found will not poll for devices at address 1–15. 2. Ask Before Polling—connects to a device at address 0, and if not found asks if you want to poll for devices at address 1–15. 3. Always Poll—connects to a device at address 0, and if not found will automatically poll for devices at address 1–15. 4. Digital Poll—automatically polls for devices at address 0–15 and lists devices found by tag.

A7022 / IL

Figure 3-2. Model 275 HART Communicator Alphanumeric and Shift Keys

corner of the display. Pressing the ’6’ key causes an “R” to appear in the editable field.

To find individual device addresses, use the Digital Poll option to find each connected device in the loop and list them by tag. For more information on setting the polling address, see the “Detailed Setup” section, Section 5.

System Information

Menu Structure

To access the HART Communicator system information, select System Information from the Utility menu.

The HART Communicator is generally used in two environments: offline (when not connected to an instrument) and online (connected to an instrument).

The motherboard system information consists of the Serial Peripheral Interface Time (SPI Time) and the HART Communicator firmware revision number.

Offline Menu

The module system information consists of hardware and software data. For example, you can find the hardware revision, RAM size, and Flash size; or, the different software revisions and binary sizes.

Pressing the On/Off key when not connected to a FIELDVUE instrument causes the unit to perform a self test and inform you of the firmware and module revision numbers. After displaying the message “No Device Found.” the unit displays the main menu. Four choices are available from this screen: Offline, Online, Frequency Device, and Utility. The Offline menu allows you to configure the HART Communicator, view HART Communicator system information, and simulate an on-line connection. Offline configuration is not available for the DVC5000 Series digital valve controllers.

Polling When several devices are connected in the same loop, such as for split ranging, each device must be assigned a unique polling address. Use the Polling options to configure the HART Communicator to automatically search for all or specific connected devices. To enter a polling option, select Utility from the Offline menu. Select Configure Communicator then select Polling. Use the up and down arrow keys to highlight

3-4

The Data Pack system information consists of the EEPROM size and revision number.

Reviewing Instrument Device Descriptions The HART Communicator memory module contains device descriptions for specific HART-compatible devices. These descriptions make up the application software that the communicator needs to recognize particular devices. If you cannot find a specific HART-compatible device on your communicator, then the device revision you are looking for is not programmed into the memory module. In this instance you are limited to what is available within a generic device description. To review the device descriptions programmed into your HART Communicator, select Simulation from the Utility menu. The Manufacturer Menu appears. The Manufacturer Menu contains a list of each manufacturer with device descriptions currently installed in your communicator’s memory module. May 1998

275 HART Communicator Basics Once you select a manufacturer, the Model Menu appears. The Model Menu lists the currently installed device models, or types, provided by the selected manufacturer.

shows an overview of the DVC5000 Series digital valve controller menu structure.

Select one of the instrument models or types to see the instrument device description and the Model 275 HART Communicator device description revision that supports that instrument.

Displaying the HART Communicator Device Description Revision

Simulation

Device Description (DD) Revision is the revision number of the Fisher Controls Device Description that resides in the HART Communicator. It defines how the HART Communicator is to interact with the user and instrument.

The HART Communicator provides a simulation mode that allows you to simulate an online connection to a HART-compatible device. The simulation mode is a training tool that enables you to become familiar with the various menus associated with a device without having the HART Communicator connected to the device. To simulate an online connection, select Utility from the Offline menu. Select Simulation then select Fisher Controls. Select DVC to see the menu structure for the DVC5000 Series digital valve controller. Refer to the appropriate sections of this manual for information on the various menus.

Online Menu Pressing the On/Off key when connected to a FIELDVUE instrument causes the unit to perform a self test and inform you of the firmware and module revision numbers. The unit then displays the device Online menu. The figure on the front cover foldout

May 1998

HART Communicators with device description revision 11 are used with firmware 3 and 4 instruments. There are two device descriptions used with firmware revision 5 instruments: 1 and 2. Device Description Revision 1 is available in HART Communicators with 1.25 megabyte memory modules. Device Description Revision 2 is available in HART Communicators with 4 and 8 megabyte memory modules. You can display the device description from the Offline or Online menu: Offline Menuâ&#x20AC;&#x201D;To see the HART Communicator device description revision number from the Offline menu, select Utility, Simulation, Fisher Controls, and DVC. Online Menuâ&#x20AC;&#x201D;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.

3-5

DVC5000 Series

3-6

May 1998

Initial Setup and Calibration 4-4

Section 4 Initial Setup and Calibration

May 1998

Configuration Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2

Instrument Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2

Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2

Auto Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3 4-3

Manual Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4

Auto Calibrate Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6

Stabilizing or Optimizing Valve Response . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7

4-1

DVC5000 Series Current Regulator Diode Motorola 1N5314

Initial Setup

CAUTION Changes to the instrument setup may cause changes in the output pressure or valve travel.

– A6472/IL

Figure 4-1. Configuration Protection Jumper

Configuration Protection To setup and calibrate the instrument, the protection must be set to None with the HART Communicator. If the protection is not None, changing the protection requires placing a jumper across the Auxiliary terminals in the terminal box. D If the Auxiliary terminals are used as a transmitter input (see table 9-2), use the configuration jumper shown in figure 4-1. D If the Auxiliary terminals are used for a switch input (see table 9-2) use either the configuration jumper shown in figure 4-1 or a piece of wire with clips. To remove protection: 1. Connect a 4 to 20 mA source to the instrument. 2. Connect the HART Communicator to the instrument and turn it on. 3. Press the Hot key

on the HART

Communicator and select Protection. 4. From the Protection menu, select None. When prompted by the HART Communicator, temporarily attach the jumper to the AUX + and AUX – terminals in the instrument terminal box.

Instrument Mode

Note To setup and calibrate the instrument, the protection must be None and the Instrument Mode must be Out Of Service. See Configuration Protection and Instrument Mode at the beginning of this section for information on removing instrument protection and changing the instrument mode.

When the DVC5000 Series digital valve controller is ordered as part of a control valve assembly, the factory mounts the digital valve controller and sets up the instrument as specified on the order. When mounting to a valve in the field, the instrument needs to be setup to match the instrument to the valve and actuator. Before beginning initial setup, be sure the instrument is correctly mounted as described in the “Installation” section, Section 2, and that the travel sensor is adjusted correctly. Refer to the Travel Sensor Adjust procedures in the “Calibration” section, Section 6. There are two initial setup procedures: D Auto Setup—(Recommended for initial setup.) This procedure automatically selects the appropriate configuration parameters depending upon the actuator type and size specified. D Manual Setup—this procedure permits you to enter values for the following configuration parameters: D Instrument Mode

To setup and calibrate the instrument, the instrument mode must be Out Of Service.

D Control Mode

To view the instrument mode, press the Hot Key and select Instrument Mode. If the mode is not Out Of Service, select Out Of Service from the Instrument Mode menu and press ENTER (F4).

D Supply Pressure

4-2

D Feedback Char D Zero Control Signal D Invert Feedback May 1998

Initial Setup and Calibration D Travel Cutoff Low

Table 4-1. DVC5000 Series Factory Default Settings Setup Parameter

D Tuning Set D Auto Calib Travel

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

Auto Setup (1-1-1)

Default Setting

Analog Input Units Input High Input Low Travel Range High Travel Range Low

mA 20.0 mA 4.0 mA 100% 0% Analog (RSP) Resume Last All Failures Disabled No 0 secs Linear 125% –25% 99.5% 0.5%

Minimum Opening Time Minimum Closing Time Polling Address

Setup Wizard

(1–1–1–1)

To have the HART Communicator automatically setup the instrument using specified actuator information, from the Online Menu select Main Menu, Initial Setup, Auto Setup, and Setup Wizard. Follow the prompts on the HART Communicator display to setup the instrument. 1. Enter the manufacturer of the actuator on which the instrument is mounted. If the actuator manufacturer is not listed, select Other. 2. Enter the actuator type. If the actuator type is not listed, select Other. 3. Enter the actuator size. 4. Enter the instrument supply pressure. 5. Specify if factory defaults should be used for initial setup. If you select YES for factory default, the HART Communicator sets the setup parameters to the values listed in table 4-1. If you select NO for the factory defaults, the setup parameters listed in the table remain at their previous settings. Typically the setup wizard determines the required setup information based upon the actuator manufacturer and type specified. However, if you enter other for the actuator manufacturer or the actuator type, then you will be prompted for setup parameters such as: Actuator type (single-acting or double-acting), Feedback characteristic (rotary shaft or sliding-stem), Valve fail action (valve opens or closes when air is lost, see Zero Control Signal under Manual Setup), May 1998

0 secs 0 secs 0

WARNING If you answer YES to the prompt for permission to move the valve, the instrument may move the valve through its full 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. Travel sensor rotation. (increasing air pressure causes the travel sensor shaft to rotate clockwise or counterclockwise), The HART Communicator will ask if it can move the valve to determine travel sensor rotation. If you answer yes, the instrument may stroke the valve the full travel span to determine travel sensor rotation. If you answer No, then you will have to specify the rotation for increasing air pressure: clockwise or counterclockwise. Instrument supply pressure range (see Instrument Supply Pressure under Manual Setup), and Tuning set (see Tuning Set under Manual Setup). 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. If after completing auto setup and auto calibration the valve seems slightly unstable or unresponsive, you can improve operation by selecting Stabilize/Optimize from the Auto Setup menu. For additional information, refer to Stabilize/Optimize at the end of this section.

4-3

DVC5000 Series Manual Setup (1-1-2) If you want to enter the individual parameters for the instrument initial setup, from the Online Menu select Main Menu, Initial Setup, and Manual Setup. The following describe the parameters that appear during manual setup.

D Instrument Mode—Instrument Mode allows you to either take the instrument Out Of Service or place it In Service. The instrument must be Out Of Service to change configuration variables that affect control provided the calibration/configuration protection is set to None. D Control Mode—Control Mode lets you define where the instrument reads its set point. Choose one of the following control modes: Analog (RSP) or Digital. Choose Analog (RSP) if the instrument is to receive its set point over the 4–20 mA loop. Normally the instrument control mode is Analog (RSP). Choose Digital if the instrument is to receive its set point digitally, via the HART communications link. A third mode, Test, is also displayed. Normally the instrument should not be in the Test mode. The HART Communicator automatically switches to this mode whenever it needs to stroke the valve, for example during calibration or stroke output. However, if you abort from a procedure where the instrument is in the Test mode, it may remain in this mode. To take the instrument out of the Test mode, select Control Mode then select either Analog (RSP) or Digital. D Feedback Char—Select Rotary Shaft or Sliding Stem. Refer to table 4-2 to determine the required feedback characteristic. D Inst Supply Pressure—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. D Zero Ctrl Signal—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. The resulting valve travel is the Zero Control Signal. (With direct acting digital valve controllers, disconnecting the current source is the same as setting the output pressure to zero.)

4-4

Table 4-2. Feedback Characteristic Selections for Various Actuator Types Actuator Type

Feedback Characteristic

513 and 513R 657 and 667 1250 and 1250R System 9000 Baumann or Gulde

Sliding Stem

471 585 and 585R 1051 and 1052 1066SR and all Type DVC5030(1) applications

Rotary

1. Type DVC5030 digital valve controllers have the travel sensor shaft extending from the back of the housing as shown in figure 10-3.

Table 4-3. DVC5010 and DVC5020 Invert Feedback Selections Actuator

Invert Feedback Sliding-Stem Actuators

513

Yes

513R

585C

Yes

585CR

657

Yes

667

1250

Yes

1250R

No Rotary Actuators

1051

Yes

1052

Yes Baumann Actuators

Air to Extend

Yes

Air to Retract

Table 4-4. DVC5030 Invert Feedback Selections Type 1051, 1052, and 1066SR Actuators Mounting Style

Invert Feedback

Yes

Table 4-5. DVC5040 Invert Feedback Selections Actuator

Invert Feedback

System 9000 fail-closed

System 9000 fail-open

Yes

D Invert Feedback—Select YES or NO, or AUTO SET. Invert feedback establishes the proper valve travel feedback orientation. Determine the Invert Feedback selection by viewing the rotation of the end of the travel sensor shaft. If increasing air pressure to the actuator causes the shaft to turn clockwise, enter YES. If it causes the shaft to turn counter-clockwise, enter NO. Tables 4-3 through 4-5 list the required Invert Feedback selections for Fisher Controls actuators. To have the instrument determine the invert feedback, select Auto Set. May 1998

Initial Setup and Calibration Table 4-6. Tuning Set Selection Guidelines(Fisher Actuators) Actuator Type and Size

Tuning T ning Set

513 & 513R

585C & 585CR

657 & 667

1051 & 1052

1066SR

1250 & 1250R

20, 32

---

12, 20

---

25, 50

---

20, 30, 33

---

225

---

450

---

34, 40

---

45, 50

---

27, 75

675

---

46, 60, 70, 87, 80, 100

60, 70

---

Table 4-7. Tuning Set Selection Guidelines (Baumann Actuators) Tuning Set

Act ator Size Actuator

Table 4-10. Gain and Rate Values for Preselected Tuning Sets (1) TUNING SET

Table 4-8. Tuning Set Selection Guidelines (Gulde Actuators) ACTUATOR TYPE AND SIZE

TUNING SET

3024

3025

GA 1.21

---

GA 1.31

---

GA 1.41

---

P460, P462, P900

System 9000

HIGH PERFORMANCE GAIN

STANDARD

Tvl Rate

Press Rate

GAIN

Tvl Rate

C D E F G

0.8 1.4 1.8 2.2 2.8

10.0 10.0 10.0 10.0 10.5

75 43 33 27 35

0.40 0.50 0.60 0.75 1.00

13.0 13.0 13.0 13.0 13.0

H I J K L M

3.4 4.0 5.0 6.0 8.0 10.0

11.6 12.7 14.5 16.2 18.0 18.0

51 62 50 42 31 25

1.30 2.00 3.00 3.99 5.25 6.99

13.0 13.0 13.0 13.0 13.0 13.0

1. For user adjusted, the high performance gain and standard gain may be independently adjusted over the range of 0.01 to 25.

When a Travel Cutoff Low is set, the Travel Limit Low is deactivated, since only one of these parameters can be active. Travel Cutoff Low is deactivated by setting it to –25.0%.

Table 4-9. Tuning Set Selection Guidelines (Other Actuators) ACTUATOR TYPE AND SIZE TUNING SET

Neles-Jamesbury Quadra-Power II

Masoneilan Camflex II

Masoneilan Sigma F, Minitorque, & Ball II A

---

4.5

QP2, QP3

6 or 7

---

QP4

---

QP5

---

D Tvl Cutoff Low—Travel Cutoff Low defines the low cutoff point for the travel. Travel Cutoff Low can be used to ensure proper seat load is applied to the valve. When travel is below the travel cutoff low, instruments with firmware revision 5 set the output to zero or to full supply pressure, depending upon the zero control signal. Instruments with firmware revision 3 or 4 set the travel target to –23.0% of the ranged travel. A Travel Cutoff Low of 0.5% is recommended to help ensure maximum shutoff seat loading. May 1998

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 a preselected value for the digital valve controller gain and rate settings. Tuning set C provides the slowest response and M provides the fastest response. Table 4-10 lists the high performance and standard gain and rate values for preselected tuning sets used with firmware 5. Normally the instrument uses the high performance values. However, should the pressure sensor fail, the unit will continue to operate using the standard values. Instruments with firmware revisions 3 and 4 always use the standard values. In addition, you can select User Adjusted or Expert, which allows you to modify tuning of the digital valve controller. With User Adjusted you can specify the

4-5

DVC5000 Series high performance and standard gain. An algorithm in the HART Communicator calculates the rates. With Expert you can specify not only the high performance and standard gains but the rates as well. To setup an instrument with firmware 5 to respond similar to an instrument with firmware 4, select Expert then adjust the high performance gain and travel rate to match the standard gain and travel rate. Set the high performance pressure rate to zero.

Note 4

For Firmware Revision 3, only the eleven tuning sets are available. User Adjusted and Expert tuning is not available.

Table 4-6 provides tuning set selection guidelines for Fisher Controls actuators. Tables 4-7 through 4-9 list tuning set guidelines for Baumann, Gulde, and other actuators. These tuning sets are only recommended starting points. After you finish setting up and calibrating the instrument, you may have to select either a higher or lower tuning set to get the desired response. For an actuator not listed in the tables, you can estimate a starting tuning set by calculating the casing or cylinder volume. Then, in the tables, find an actuator with the closest equivalent volume and use the tuning set suggested for that actuator. After completing the manual setup, select Auto Calib Travel from the Manual Setup menu. Follow the prompts on the HART Communicator display to automatically calibrate the instrument travel. 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.

4-6

Auto Calibrate Travel (1-1-1-2) or (1-1-2-9) 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. User interaction is only required with Auto Calibrate Travel when the valve is sliding-stem. Rotary valves require no user interaction. For sliding-stem valves, interaction provides a more accurate crossover adjustment. Select Auto Calib Travel then follow the prompts on the HART Communicator display to automatically calibrate travel. 1. Select the method of crossover adjustment: manual, last value, or default. If you select Last Value, the crossover setting currently stored in the instrument is used and there are no further user interactions with the auto-calibration routine (go to step 4). If you select Default, an approximate value for the crossover is sent to the instrument and there are no further user interactions with the auto-calibration routine (go to step 4). If you select Manual, you are asked to select an adjustment source, either analog or digital. If you use a current source to adjust the crossover, select Analog and go to step 2. If you wish to adjust the current source digitally, select Digital and go to step 3. 2. If you selected Analog as the crossover adjustment source, the HART Communicator prompts you to adjust the current source until the feedback arm is 90° to the actuator stem, as shown in figure 4-2. After you have made the adjustment, press OK and go to step 4. 3. If you selected Digital as the crossover adjustment source, the HART Communicator displays a menu to allow you to adjust the crossover. Select the direction and size of change required to set the feedback arm so it is 90° to the actuator stem, as shown in figure 4-2. Selecting large, medium, and small adjustments to the crossover causes changes of approximately 10.0°, 1.0°, and 0.1°, respectively, to the rotation of the feedback arm. If another adjustment is required, repeat step 3. Otherwise, select Done and go to step 4.

May 1998

Initial Setup and Calibration Table 4-11. Auto Calibrate Travel Error Messages Error Message Input current must exceed 3.8 mA for calibration. Place Out Of Service and ensure Calibrate Protection is disabled before calib.

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 protection and mode, see the beginning of this section.

Calibration Aborted. An end point was not reached.

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).

Invalid travel value. Check travel sensor and feedback arm adjustments, and inst supply press. Then, repeat Auto Calib.

Verify proper mounting by referring to the appropriate mounting procedure in the “Installation” section, Section 2. 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 “Calibration” section, Section 6.

A6536

Figure 4-2. Crossover Point

4. The remainder of the auto-calibration procedure is automatic. It is completed when the Calibrate menu appears. 5. Place the instrument In Service and verify that the travel properly tracks the current source. If the unit does not calibrate, refer to table 4-11 for error messages and possible remedies.

Stabilizing or Optimizing Valve Response If after completing initial setup (either auto or manual) and auto calibration the valve seems slightly unstable

May 1998

Possible Problem and Remedy 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.

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).

4-7

DVC5000 Series

4-8

May 1998

Detailed Setup 5-5

Section 5 Detailed Setup Menu and Quick Key Sequence Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Cover Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3

Instrument Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3

Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

Restart Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

Burst Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

Restarting the Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6

HART Tag Message Descriptor Date Valve Serial Number Factory Instrument Serial Number Field Instrument Serial Number Polling Address

Actuator Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7

Instrument Supply Pressure Feedback Characteristic Zero Control Signal Invert Feedback

Measured Variable Units and Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7

Analog Input Units and Range Pressure Units Temperature Units

Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8

Tuning Set May 1998

5-1

DVC5000 Series Input Characteristic Input Filter Time Dynamic Bypass Enable Minimum Opening and Closing Time

Travel Ranges, Limits, and Cutoffs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10

Travel Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10

Travel Range High Travel Range Low

Travel Limits and Cutoffs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11

Travel Limit High Travel Limit Low Travel Cutoff High Travel Cutoff Low

Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11

Travel Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-12

Alerts 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deviation Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accumulation Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-12 5-12 5-13

Cycle Counter Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-13

Drive Signal Alert Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-14

Misc Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-14

Auxiliary Input Alert Enable Auxiliary Input Alert State

Alert Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-14

Display Record Copy Record Instrument Date and Time Record Groups

Self-Test Failures for Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-15

No Free Time Fail RAM Fail Critical NVM Fail Temperature Sensor Fail Travel Sensor Fail Drive Current Fail

5-2

May 1998

Detailed Setup Table 5-1. Factory Default Detailed Setup Parameters

Note Detailed setup is not available for instrument level AC. The Detailed Setup selection from the Main Menu allows you to configure the digital valve controller to your application. Table 5-1 lists the default settings for a standard factory configuration. You can adjust actuator response, set the various modes, alerts, ranges, travel cutoffs and limits. You can also restart the instrument and set the protection.

Setting Modes To view or change the mode, select Main Menu, Detailed Setup, Mode. Follow the prompts on the HART Communicator display to view or change information in the following fields: Instrument Mode, Control Mode, Restart Ctrl Mode (Restart Control Mode), Restart, and Burst Mode.

Instrument Mode You can change the instrument mode by selecting Instrument Mode from the Mode menu, or press the Hot Key and select Instrument Mode. Instrument Mode allows you to either take the instrument Out Of Service or place it In Service. Taking the instrument Out Of Service allows you to perform instrument calibration and also allows you to change configuration variables that affect control, provided the calibration/configuration protection is properly set. See Setting Protection.

Note Some changes that require the instrument to be taken Out Of Service will not take effect until the instrument is placed back In Service or the instrument is restarted.

May 1998

Setup Parameter Control Mode Restart Control Mode Burst Mode Enabled Burst Mode Command HART Tag Message Descriptor Date Valve Serial Number Polling Address Inst Supply Pressure Feedback Characteristic Zero Control Signal Invert Feedback

Default Setting(1) Analog (RSP) Resume Last No 3 As specified on order Blank Blank Factory Calibration Date Blank 0 20(2) Rotary Shaft(2) Open(2) Yes(2)

Analog Input Units Input Range High Input Range Low Travel Range High Travel Range Low

mA 20 mA 4.0 mA 100% 0%

Pressure Units Temperature Units Tuning Set Input Characteristic Input Filter Time

PSI F C(2) Linear Filter Off

Dynamic Bypass Enabled Travel Limit High Travel Limit Low Travel Cutoff High Travel Cutoff Low

No 125% –25% 99.5% 0.5%

Minimum Opening Time Minimum Closing Time Travel Alert 1 Enabled Travel Alert 2 Enabled

0 secs 0 secs No No

Travel Travel Travel Travel Travel

125% –25% 125% –25% 3%

Alert 1 High Point Alert 1 Low Point Alert 2 High Point Alert 2 Low Point Alert Deadband

Travel Deviation Alert Enable Travel Deviation Alert Point Travel Deviation Time Cycle Counter Alert Enable Cycle Counter Alert Point Cycle Counter Deadband Cycle Counter Travel Travel Travel Travel

Accumulator Alert Enable Accumulator Alert Point Accumulator Deadband Accumulator

Auxiliary Input Alert Enable Auxiliary Input Alert State Drive Alert Enable No Free Time Fail RAM Fail Drive Current Fail Critical NVM Fail Temperature Sensor Fail Travel Sensor Fail

No 125% 4 secs No 4,294,967,295 3% 0 No 4,294,967,295% 3% 0 No Closed No No No No No No No

1. The settings listed are for standard factory configuration. DVC5000 Series instruments can also be ordered with custom configuration settings. For the default custom settings, refer to the order requistion. 2. If the instrument is shipped mounted on an actuator, these values depend upon the actuator on which the instrument is mounted.

5-3

DVC5000 Series Control Mode You can change the control mode by selecting Control Mode from the Mode menu, or press the Hot Key and select Control Mode. Control Mode lets you define where the instrument reads its set point. Follow the prompts on the HART Communicator display to choose one of the following control modes: Analog (RSP) or Digital. Choose Analog (RSP) if the instrument is to receive its set point over the 4–20 mA loop. Normally the instrument control mode is Analog (RSP). Choose Digital if the instrument is to receive its set point digitally, via the HART communications link.

A third mode, Test is also displayed. Normally the instrument should not be in the Test mode. The HART Communicator automatically switches to this mode whenever it needs to stroke the valve, for example during calibration or stroke output. However, if you abort from a procedure where the instrument is in the Test mode, it may remain in this mode. To take the instrument out of the Test mode, select Control Mode then select either Analog (RSP) or Digital.

instrument is in burst mode. Between each burst mode transmission sent by the instrument, a short pause allows the HART Communicator or control system to initiate a request. The instrument receives the request, processes the response message, and then continues “bursting” the burst mode data. There are four burst mode commands. Command 3 is recommended for use with the RosemountR Model 333 HART Tri-Loopt HART-to-analog signal converter. The other three are not used at this time. Command 3 provides the following variables: D Primary variable—travel in % of ranged travel, D Secondary variable—travel setpoint in % of ranged travel, D Tertiary variable—actuator pressure in psig, bar, or kPa D Fourth variable—auxiliary input status in %; 0% equals open, 100% equals closed. To enable burst mode, select Main Menu, Detailed Setup, Mode, Burst, and Burst Enable. To send a burst mode command, select Main Menu, Detailed Setup, Mode, Burst, and Burst Command. Burst mode must be enabled before you can change the burst mode command.

Restart Control Mode (1-2-1-3) Restart Control Mode (Restart Ctrl Mode) lets you choose which operating mode you want the instrument to be in after a restart. Follow the prompts on the HART Communicator display to define the restart control mode as Resume Last, Analog (RSP), or Digital.

Restarting the Instrument (1-2-1-4) Restart resets the instrument in the same manner as when power to the instrument is interrupted. When Restart is issued, all of the newly entered configuration variables become active. Otherwise, they may not take effect until the instrument is placed In Service.

Burst Mode (1-2-1-5) Enabling burst mode provides continuous communication from the digital valve controller. All DVC5000 Series digital valve controllers with firmware revision 5 are capable of burst mode communication. Burst mode applies only to the transmission of burst mode data (travel, travel set point, actuator pressure, and auxiliary input status) and does not affect the way other data is accessed. Access to information in the instrument is normally obtained through the poll/response of HART communication. The Model 275 HART Communicator or the control system may request any of the information that is normally available, even while the

5-4

Setting Protection Some setup parameters may require changing the protection with the HART Communicator. In some cases, a jumper must be placed across the Auxiliary terminals in the terminal box in order to change protection. D If the Auxiliary terminals are used as a transmitter input (see table 9-2), use the configuration jumper shown in figure 5-1. D If the Auxiliary terminals are used for a switch input (see table 9-2) use either the configuration May 1998

Detailed Setup Table 5-2. Conditions for Modifying DVC5000 Series Digital Valve Controller Parameters In Service/ Config Protected

In Service/ Config Unprotected

Out of Service/ Config Protected

Control Mode Restart Ctrl Mode Burst Mode Enable Burst Mode Command Protection

-----

---

Tag Message Descriptor Date Valve Serial Num Field Inst S/N Polling Address

---------------

-----

---------------

Inst Supply Pressure Feedback Char Zero Ctrl Signal Invert Feedback

---------

Analog In Units/Rng Input Range High Input Range Low Tvl Range High Tvl Range Low Pressure Units Temp Units

-------------

Tuning Set Gain Input Char Define Custom Char Input Filter Time Dyn Bypass Enab

-------------

Tvl Tvl Tvl Tvl

Limit High Limit Low Cutoff High Cutoff Low

---------

Min Opening Time Min Closing Time

-----

Parameters

Tvl Tvl Tvl Tvl Tvl Tvl Tvl

Out of Service/ Config Unprotected

Alrt 1 Enab Alrt 2 Enab Alrt 1 High Pt Alrt 1 Low Pt Alrt 2 High Pt Alrt 2 Low Pt Alrt DB

Tvl Dev Alrt Enab Tvl Dev Alrt Pt Tvl Dev Time Cycl Cycl Cycl Cycl Tvl Tvl Tvl Tvl

Cnt Alrt Enab Count Alrt Pt Count DB Count

Acum Alrt Enab Acum Alrt Pt Acum DB Acum

Aux In Alrt Enab Aux In Alrt State Drive Alrt Enab —indicates parameter may be modified for instrument mode and protection shown.

–Continued–

May 1998

5-5

DVC5000 Series Table 5-2. Conditions for Modifying DVC5000 Series Digital Valve Controller Parameters (Continued) Parameters

In Service/ Config Protected

In Service/ Config Unprotected

Out of Service/ Config Protected

Out of Service/ Config Unprotected

-------------

No Free Time Fail RAM Fail Drive Current Fail Critical NVM Fail Temp Sensor Fail Tvl Sensor Fail

—indicates parameter may be modified for instrument mode and protection shown. Current Regulator Diode Motorola 1N5314

(Factory Instrument Serial Number), Field Inst S/N (Field Instrument Serial Number), and Polling Address.

HART Tag—Enter an up to 8 character HART tag for the instrument.

–

Message—Enter any message with up to 32 characters.

A6472/IL

Figure 5-1. Configuration Protection Jumper

jumper shown in figure 5-1 or a piece of wire with clips.

Descriptor—Enter a descriptor for the application with up to 16 characters. Date—Enter a date with the format MM/DD/YY.

Two levels of protection are available:

Config & Calib—Both setup and calibration are protected. Prohibits changing calibration and protected setup parameters. None—Neither setup nor calibration is protected. Allows changing calibration and setup parameters. Table 5-2 lists configurable parameters in the instrument and the requirements for modifying these parameters, in terms of instrument mode and protection. To change an instrument’s protection, press the Hot on the HART Communicator and select key

Protection. Select the desired level of protection. Follow the prompts on the HART Communicator display to set the protection level. If necessary, temporarily attach the jumper to the AUX + and AUX – terminals in the instrument terminal box when prompted by the HART Communicator.

General Information (1-2-3) Select Main Menu, Detailed Setup, and General. Follow the prompts on the HART Communicator display to enter or view information in the following fields: HART Tag, Message, Descriptor, Date, Valve Serial Num (Valve Serial Number), Factory Inst S/N

5-6

Valve Serial Num—Enter the serial number for the valve in the application with up to 12 characters. Factory Inst S/N—The Factory Instrument Serial Number is displayed. You cannot change this. Field Inst S/N—The Field Instrument Serial Number is assigned to the printed wiring board by the factory and can be changed in the field. A FIELDVUE instrument has three instrument serial numbers: One stamped on the instrument nameplate and two assigned to the printed wiring board. When the instrument ships from the factory, all three serial numbers are the same. The Factory Instrument Serial Number is assigned to the printed wiring board by the factory and cannot be changed. The Field Instrument Serial Number is also assigned to the printed wiring board by the factory but CAN be changed. If you replace the printed wiring board in an instrument or move it to a different instrument, change the Field Instrument Serial Number to match the serial number on the instrument nameplate where you are installing the printed wiring board. Factory Instrument and Field Instrument Serial Numbers that do not match identify a printed wiring board that is not the original board that shipped with the instrument from the factory.

Polling Address—If the digital valve controller is used in a point-to-point configuration, the Polling Address is 0. When several devices are connected in the same loop, such as for split ranging, each device must be assigned a unique polling address. The Polling Address is set to a value between 0 and 15. To change the polling address the instrument must be Out Of Service. May 1998

Detailed Setup For the HART Communicator to be able to communicate with a device whose polling address is not 0, it must be configured to automatically search for all or specific connected devices. For information on configuring the HART Communicator for automatic polling, see the “Model 275 HART Communicator Basics” section, Section 3.

Actuator Information (1-2-4) Select Main Menu, Detailed Setup, and Actuator Info. Follow the prompts on the HART Communicator display to enter or view information in the following fields: Inst Supply Press (Instrument Supply Pressure), Feedback Char (Feedback Characteristic), Zero Ctrl Signal (Zero Control Signal), and Invert Feedback.

Table 5-3. Feedback Characteristic Selections for Various Actuator Types Actuator Type

Feedback Characteristic

513 and 513R 657 and 667 1250 and 1250R System 9000 Baumann or Gulde

Sliding Stem

471 585 and 585R 1051 and 1052 1066SR and all Type DVC5030(1) applications

Rotary

1. Type DVC5030 digital valve controllers have the travel sensor shaft extending from the back of the housing as shown in figure 10-3.

Table 5-4. DVC5010 and DVC5020 Invert Feedback Selections Actuator

Invert Feedback Sliding-Stem Actuators

513

Yes

513R

585C

Yes

585CR

657

Yes

667

1250

Yes

1250R

Inst Supply Press—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.

No Rotary Actuators

1051

Yes

1052

Yes

Table 5-5. DVC5030 Invert Feedback Selections Type 1051, 1052, and 1066SR Actuators

Feedback Char—Select Rotary Shaft or Sliding Stem. Refer to table 5-3 to determine the required feedback characteristic. Zero Ctrl Signal—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. The resulting valve travel is the Zero Control Signal. (With direct acting digital valve controllers, disconnecting the current source is the same as setting the output pressure to zero.) Invert Feedback—Select YES, NO, or AUTO SET. Invert feedback establishes the proper valve travel feedback orientation. Determine the Invert Feedback selection by viewing the rotation of the end of the travel sensor shaft. If increasing air pressure to the actuator causes the shaft to turn clockwise, enter YES. If it causes the shaft to turn counter-clockwise, enter NO. Tables 5-4 through 5-6 show the required Invert Feedback selections for Fisher Controls actuators. To have the instrument determine the invert feedback, select Auto Set. May 1998

Mounting Style

Invert Feedback

Yes

Table 5-6. DVC5040 Invert Feedback Selections Actuator

Invert Feedback

System 9000 fail-closed

System 9000 fail-open

Yes

Measured Variable Units and Ranges (1-2-5) To define the measured variable units and ranges, select Main Menu, Detailed Setup, and Measured Var. Follow the prompts on the HART Communicator display to enter or view information in the following fields: Analog In Units/Rng (Analog Input Units and High and Low Input Ranges), Pressure Units, and Temp Units (Temperature Units).

5-7

DVC5000 Series Table 5-7. Tuning Set Selection Guidelines (Fisher Actuators)

Actuator Type and Size

Tuning T ning Set

513 & 513R

585C & 585CR

657 & 667

1051 & 1052

1066SR

1250 & 1250R

20, 32

---

12, 20

---

25, 50

---

20, 30, 33

---

225

---

450

---

34, 40

---

45, 50

---

27, 75

675

---

46, 60, 70, 87, 80, 100

60, 70

---

Analog In Units/Rng—Permits defining the Analog Input Units in mA or percent of 4–20 mA range. Also permits setting the Input Range High and Input Range Low values. Input Range High should correspond to Travel Range High and Input Range Low should correspond to Travel Range Low, if the Zero Control Signal is configured as closed. If the Zero Control Signal is configured as open, Input Range High corresponds to Travel Range Low and Input Range Low corresponds to Travel Range High. See figure 5-3. Pressure Units—Defines the output pressure units in either psi, bar, or kPa. Temp Units—Degrees Fahrenheit or Celsius. The temperature measured is from a sensor mounted on the digital valve controller’s printed wiring board.

Setting Response (1-2-6) Select Main Menu, Detailed Setup, and Response Control. Follow the prompts on the HART Communicator display to configure the following response control parameters: Tuning Set, Input Char, Input Filter Time, Dyn Bypass Enab (Dynamic Bypass Enable).

CAUTION Changes to the tuning set can result in valve/actuator instability.

5-8

System 9000

Table 5-8. Gain and Rate Values for Preselected Tuning Sets (1) HIGH PERFORMANCE

STANDARD

TUNING SET

GAIN

TRAVEL RATE

PRESSURE RATE

GAIN

TRAVEL RATE

C D E F G

0.8 1.4 1.8 2.2 2.8

10.0 10.0 10.0 10.0 10.5

75 43 33 27 35

0.40 0.50 0.60 0.75 1.00

13.0 13.0 13.0 13.0 13.0

H I J K L M

3.4 4.0 5.0 6.0 8.0 10.0

11.6 12.7 14.5 16.2 18.0 18.0

51 62 50 42 31 25

1.30 2.00 3.00 3.99 5.25 6.99

13.0 13.0 13.0 13.0 13.0 13.0

1. For user adjusted, the standard gain and rate may be adjusted over the range of 0.01 to 25. For expert, standard gain and rate may be independently adjusted over the range 0.01 to 25. High performance gain may be adjusted over the range 0.01 to 20; high performance travel rate may be adjusted over the range 5 to 25; and high performance pressure rate may be adjusted over the range 0 to 255.

Tuning Set—There are eleven tuning sets to choose from. Each tuning set provides a preselected value for the digital valve controller gain and rate settings. Tuning set C provides the slowest response and M provides the fastest response. Table 5-8 lists the high performance and standard gain and rate values for preselected tuning sets. Instruments with firmware 5 normally use the high performance values. However, should the pressure sensor fail, these instruments will continue to operate using the standard values. Instruments with firmware revisions 3 and 4 always use the standard values. In addition, you can select User Adjusted or Expert, which allows you to modify tuning of the digital valve controller. With User Adjusted, you specify the high performance gain and standard gain; an algorithm in the HART Communicator calculates the rates. With Expert you can specify the high performance and standard gains and rates.

May 1998

Detailed Setup Table 5-9. Tuning Set Selection Guidelines (Baumann Actuators) Tuning Set

Act ator Size Actuator

Table 5-10. Tuning Set Selection Guidelines (Gulde Actuators) ACTUATOR TYPE AND SIZE

TUNING SET

3024

3025

GA 1.21

---

GA 1.31

---

GA 1.41

---

P460, P462, P900

Table 5-11. Tuning Set Selection Guidelines (Other Actuators) ACTUATOR TYPE AND SIZE TUNING SET

Neles-Jamesbury Quadra-Power II

Masoneilan Camflex II

Masoneilan Sigma F, Minitorque, & Ball II A

---

4.5

QP2, QP3

6 or 7

---

QP4

---

QP5

---

To setup an instrument with firmware 5 to respond similar to an instrument with firmware 4, select Expert then adjust the high performance gain and travel rate to match the standard gain and travel rate. Set the high performance pressure rate to zero.

Note For Firmware Revision 3, only the eleven tuning sets are available. User adjusted or Expert tuning is not available.

actuator with the closest equivalent volume and use the tuning set suggested for that actuator.

Input Char—Defines the relationship between the ranged travel and ranged set point. Ranged setpoint is the input to the characterization function. If the zero control signal equals closed, then a setpoint of 0% corresponds to a ranged input of 0%. If the zero control signal equals open, a setpoint of 0% corresponds to a ranged input of 100%. Ranged travel is the output from the characterization function. You can select from the three fixed input characteristics shown in Figure 5-2 or, for instruments with firmware revision 5, you can select a custom characteristic. Figure 5-2 shows the relationship between the ranged travel and ranged set point for the fixed input characteristics, assuming the Zero Control Signal is configured as closed. For instruments with firmware revision 5, you can specify 37 points on a custom characteristic curve. Each point defines a travel target, in % of ranged travel, for a corresponding ranged set point, in % of ranged set point. Set point values range from –6.25% to 106.25% in 3.125% increments. Before modification, the custom characteristic is linear. To define a custom input characteristic, from the Input Char menu select Define Custom Char. Select the point you wish to define (1 to 37), then enter the desired ranged travel value corresponding to the ranged set point. When finished, select point 0 to return to the Input Char menu. With input characterization you can modify the overall characteristic of the valve and instrument combination. Selecting an equal percentage, quick opening, or custom (other than the default of linear) input characteristic modifies the overall valve and instrument characteristic. However, if you select the linear input characteristic, the overall valve and instrument characteristic is the characteristic of the valve, which is determined by the valve trim (i.e., the plug or cage). The factory default setting for input characterization is linear.

Table 5-7 provides tuning set selection guidelines for Fisher Controls actuators. Tables 5-9 through 5-11 list tuning set guidelines for Baumann, Gulde, and other actuators. These tuning sets are only recommended starting points. After you finish setting up and calibrating the instrument, you may have to select either a higher or lower tuning set to get the desired response. For an actuator not listed in the tables, you can estimate a starting tuning set by calculating the casing or cylinder volume. Then, in the tables, find an May 1998

Input Filter Time—Time constant for the input filter, in seconds. The input filter slows the response of the digital valve controller and is typically used with noisy or fast processes. The filter provides improved closed loop process control. Generally, an input filter is not required if dynamic bypass is enabled. To disable the filter, set the time constant to 0 seconds. Dyn Bypass Enab—Yes or No. Generally Dynamic Bypass is not required if the input filter is used. With Dynamic Bypass enabled, the instrument dynamic response to input changes will be similar to

5-9

DVC5000 Series 125

the first order lag exhibited by a Fisher Controls Type 546 I/P transducer connected directly to a large volume spring and diaphragm actuator.

100

Ranged Travel, %

This provides dampening to the final control element and can stabilize some process loops. It is generally beneficial in fast process loops and will improve process control. (See Fisher Controls technical monograph TM-36 for further discussion of positioner/booster guidelines.) Position feedback to the instrument is maintained with Dynamic Bypass enabled. Static performance is not affected.

–25 –25

Ranged Set Point, %

100

125

Input Characteristic = Linear 125

Min Closing Time—Minimum Closing Time is configured in seconds and defines the minimum time for the travel to decrease the entire ranged travel. This rate is applied to any travel decreases. A value of 0.0 seconds deactivates this feature and allows the valve to stroke closed as fast as possible.

Ranged Travel, %

100

Travel Ranges, Limits, and

–25 –25

Ranged Set Point, %

100

125

Cutoffs

Input Characteristic = Equal Percentage

Setting Travel Ranges

125

(1-2-5) 100

Select Main Menu, Detailed Setup, and Measured Var. Follow the prompts on the HART Communicator display to set the Tvl Range High (Travel Range High), and Tvl Range Low (Travel Range Low).

Ranged Travel, %

Min Opening Time—Minimum Opening Time is configured in seconds and defines the minimum time for the travel to increase the entire ranged travel. This rate is applied to any travel increases. A value of 0.0 seconds deactivates this feature and allows the valve to stroke open as fast as possible.

Note 0

–25 –25 A6535-1/IL

Ranged Set Point, %

100

125

Input Characteristic = Quick Opening

For Firmware Revision 5, the Travel Range High and Low values are preset in the instrument. Changing the Travel Range High and Low values has no effect. Travel Range High is set at 100%; Travel Range Low is set at 0%.

Figure 5-2. Ranged Travel Versus Ranged Set Point, for Various Input Characteristics (Zero Control Signal = Closed)

5-10

May 1998

Detailed Setup TRAVEL RANGE HIGH

will not exceed this limit. When a Travel Limit High is set, the Travel Cutoff High is deactivated, since only one of these parameters can be active. Travel Limit High is deactivated by setting it to 125.0%.

ZCS = OPEN

CALIBRATED TRAVEL, %

ZCS = CLOSED

The factory default setting for Travel Limit High is 125%.

Tvl Limit Low—Travel Limit Low defines the low limit for the travel in percent (%) of ranged travel. It is the minimum allowable travel (in percent of ranged travel) for the valve. During operation, the travel target will not exceed this limit. When a Travel Limit Low is set, the Travel Cutoff Low is deactivated, since only one of these parameters can be active. Travel Limit Low is deactivated by setting it to –25.0%.

THE SHAPE OF THESE LINES DEPENDS ON THE INPUT CHARACTERISTICS

TRAVEL RANGE LOW

INPUT RANGE LOW

ANALOG INPUT mA OR % OF 4-20 mA

INPUT RANGE HIGH

NOTE: ZCS = ZERO CONTROL SIGNAL A6531-1 / IL

Figure 5-3. Calibrated Travel to Analog Input Relationship

Tvl Range High—Travel Range High is the travel, in percent of calibrated travel, that corresponds to the Input Range High, if the Zero Control Signal is defined as closed. If the Zero Control Signal has been configured as open, the Travel Range High corresponds to the Input Range Low. See figure 5-3. The factory default setting for Travel Range High is 100%.

Tvl Range Low—Travel Range Low is the travel, in percent of calibrated travel, that corresponds to the Input Range Low, if the Zero Control Signal is configured as closed. If the Zero Control Signal has been configured as open, the Travel Range Low corresponds to the Input Range High. See figure 5-3. The factory default setting for Travel Range Low is 0%.

Setting Travel Limits and Cutoffs (1-2-6-5)

The factory default setting for Travel Limit Low is –25%.

Tvl Cutoff High—Travel Cutoff High defines the high cutoff point for the travel in percent (%) of ranged travel. Above this cutoff, the travel target is set to 123.0% of the ranged travel. When a Travel Cutoff High is set, the Travel Limit High is deactivated, since only one of these parameters can be active. Travel Cutoff High is deactivated by setting it to 125.0%. The factory default setting for Travel Cutoff High is 99.5%.

Tvl Cutoff Low—Travel Cutoff Low defines the low cutoff point for the travel. Travel Cutoff Low can be used to ensure proper seat load is applied to the valve. When below the travel cutoff low, instruments with firmware revision 5 set the output to zero or to full supply pressure, depending upon the zero control signal. Instruments with firmware revision 3 or 4 set the travel target to –23.0% of the ranged travel. A Travel Cutoff Low of 0.5% is recommended to help ensure maximum shutoff seat loading. When a Travel Cutoff Low is set, the Travel Limit Low is deactivated, since only one of these parameters can be active. Travel Cutoff Low is deactivated by setting it to –25.0%. The factory default setting for Travel Cutoff Low is 0.5%.

Select Main Menu, Detailed Setup, Response Control, and Limits & Cutoffs. Follow the prompts on the HART Communicator display to set the Tvl Limit High (Travel Limit High), Tvl Limit Low (Travel Limit Low), Tvl Cutoff High (Travel Cutoff High), and Tvl Cutoff Low (Travel Cutoff Low).

Setting Alerts

Tvl Limit High—Travel Limit High defines the high limit for the travel in percent (%) of ranged travel. It is the maximum allowable travel (in percent of ranged travel) for the valve. During operation, the travel target

The following menus are available for configuring Alerts. Items on the menus may be changed with the instrument In Service. Configuration does not need to be unprotected. Alerts are not processed when a Diagnostic is in progress.

May 1998

5-11

DVC5000 Series ALERT IS SET

Note

TRAVEL ALERT HIGH POINT

Alerts are not available with instrument level HC.

TRAVEL ALERT DEADBAND

ALERT IS CLEARED

A6532/IL

Note 5

For Firmware Revision 3, alerts are not processed if the instrument is Out of Service.

Setting Travel Alerts

(1-2-7-1) Setting Alerts 1 and 2 Select Main Menu, Detailed Setup, Alerts, and Travel Alerts. Follow the prompts on the HART Communicator display to set: Tvl Alrt 1 Enab (Travel Alert 1 Enable), Tvl Alrt 2 Enab (Travel Alert 2 Enable), Tvl Alrt 1 High Pt (Travel Alert 1 High Point), Tvl Alrt 1 Low Pt (Travel Alert 1 Low Point), Tvl Alrt 2 High Pt (Travel Alert 2 High Point), Tvl Alrt 2 Low Pt (Travel Alert 2 Low Point), and Tvl Alrt DB (Travel Alert Deadband).

Tvl Alrt 1 Enab—Yes or No. Travel Alert 1 Enable activates checking of the ranged travel against the Travel Alert 1 High and Low Points. Travel Alert 1 is set if either the high or low point is exceeded. Once a high or low point is exceeded, the ranged travel must clear that point by the Travel Alert Deadband before the alert is cleared. See figure 5-4. Tvl Alrt 2 Enab—Yes or No. Travel Alert 2 Enable activates checking of the ranged travel against the Travel Alert 2 High and Low Points. Travel Alert 2 is set if either the high or low point is exceeded. Once a high or low point is exceeded, the ranged travel must clear that point by the Travel Alert Deadband before the alert is cleared. See figure 5-4. Tvl Alrt 1 High Pt—Travel Alert 1 High Point is the value of the travel, in percent (%) of ranged travel,

5-12

Figure 5-4. Travel Alert Deadband

which, when exceeded, sets the Travel Alert 1 High alert.

Tvl Alrt 1 Low Pt—Travel Alert 1 Low Point is the value of the travel, in percent (%) of ranged travel, which, when exceeded, sets the Travel Alert 1 Low alert. Tvl Alrt 2 High Pt—Travel Alert 2 High Point is the value of the travel, in percent (%) of ranged travel, which, when exceeded, sets the Travel Alert 2 High alert. Tvl Alrt 2 Low Pt—Travel Alert 2 Low Point is the value of the travel, in percent (%) of ranged travel, which, when exceeded, sets the Travel Alert 2 Low alert. Tvl Alrt DB—Travel Alert Deadband is the travel, in percent (%) of ranged travel, required to clear a travel alert, once it has been set. The deadband applies to both Travel Alert 1 and Travel Alert 2. See figure 5-4.

Note For Firmware Revision 3, the Travel Alert Deadband applies to the Travel Deviation as well as Travel Alert 1 and Travel Alert 2.

Setting Travel Deviation Alert (1-2-7-2) Select Main Menu, Detailed Setup, Alerts, and Travel Dev Alert. Follow the prompts on the HART Communicator display to configure the following: Tvl Dev Alrt Enab (Travel Deviation Alert Enable), Tvl Dev May 1998

Detailed Setup Alrt Pt (Travel Deviation Alert Point), and Tvl Dev Time (Travel Deviation Time).

Deadband exceeded, new Reference Point established

Tvl Dev Alrt Enab—Yes or No. Travel Deviation Alert Enable activates checking of the difference between the target and the ranged travel. If the difference exceeds the Travel Deviation Alert Point for more than the Travel Deviation Time, the Travel Deviation Alert is set. It remains set until the difference is less than the Travel Deviation Alert Point.

Note For Firmware Revision 3, the Travel Deviation Alert remains set until the Travel difference between the target and the ranged travel is less than the Travel Deviation Alert Point minus the Travel Alert Deadband.

Tvl Dev Alrt Pt—Travel Deviation Alert Point is the alert point for the difference, expressed in percent (%), between the targeted travel and the ranged travel. When the difference exceeds the alert point for more than the Travel Deviation Time, the Travel Deviation Alert is set. Tvl Dev Time—Travel Deviation Time is the time, in seconds, that the travel must exceed the Travel Deviation Alert Point before the alert is set.

Deadband Reference Point A6534/IL

This amount of change is added to the Travel Accumulator.

Deadband (+/– 5%)

Figure 5-5. Travel Accumulator Deadband (set at 10%)

Tvl Acum DB—Travel Accumulator Deadband is the area around the travel reference point, in percent (%) of ranged travel, that was established at the last increment of the accumulator. This area must be exceeded before a change in travel can be accumulated. See figure 5-5. Tvl Acum Alrt Pt—Travel Accumulator Alert Point is the value of the Travel Accumulator, in percent (%) of ranged travel, which, when exceeded, sets the Travel Accumulator Alert. Tvl Acum—Travel Accumulator records the total change in travel, in percent (%) of ranged travel, since the accumulator was last cleared. The value of the Travel Accumulator increments when the magnitude of the change exceeds the Travel Accumulator Deadband. See figure 5-5. You can reset the Travel Accumulator by configuring it to zero.

Setting Travel Accumulation Alert

Cycle Counter Alert (1-2-7-3) Select Main Menu, Detailed Setup, Alerts, and Travel Accum Alert. Follow the prompts on the HART Communicator display to configure the following: Tvl Acum Alrt Enab (Travel Accumulator Alert Enable), Tvl Acum DB (Travel Accumulator Deadband), Tvl Acum Alrt Pt (Travel Accumulator Alert Point), Tvl Acum (Travel Accumulator).

Tvl Acum Alrt Enab—Yes or No. Travel Accumulator Alert Enable activates checking of the difference between the Travel Accumulator value and the Travel Accumulator Alert Point. The Travel Accumulator Alert is set when the Travel Accumulator value exceeds the Travel Accumulator Alert Point. It is cleared after you reset the Travel Accumulator to a value less than the alert point. May 1998

(1-2-7-4) Select Main Menu, Detailed Setup, Alerts, and Cycle Count Alert. Follow the prompts on the HART Communicator display to configure the following: Cycl Cnt Alrt Enab (Cycle Counter Alert Enable), Cycl Count DB (Cycle Counter Deadband), Cycl Count Alrt Pt (Cycle Counter Alert Point), Cycl Count (Cycle Counter).

Cycl Cnt Alrt Enab—Yes or No. Cycle Counter Alert Enable activates checking of the difference between the Cycle Counter and the Cycle Counter Alert point. The Cycle Counter Alert is set when the value exceeds the Cycle Counter Alert point. It is cleared after you reset the Cycle Counter to a value less than the alert point.

5-13

DVC5000 Series Deadband exceeded, and direction changed, new Reference Point established

For the case where Zero Control Signal is defined as open: Drive Signal < 10% and Calibrated Travel < 97% Drive Signal > 90% and Calibrated Travel > 3%

Miscellaneous Alerts (1-2-7-6) Deadband Reference Point

Point at which cycle is counted.

Deadband (+/– 5%)

A6533-1/IL

Select Main Menu, Detailed Setup, Alerts, and Misc Alerts. Follow the prompts on the HART Communicator display to configure the Aux In Alrt Enab (Auxiliary Input Alert Enable) and Aux In Alrt State (Auxilliary Input Alert State).

Figure 5-6. Cycle Counter Deadband (set at 10%)

Cycl Count DB—Cycle Counter Deadband is the area around the travel reference point, in percent (%) of ranged travel, that was established at the last increment of the Cycle Counter. This area must be exceeded before a change in travel direction can be counted as a cycle. See figure 5-6. Cycl Count Alrt Pt—Cycle Counter Alert Point is the value of the Cycle Counter, in cycles, which, when exceeded, sets the Cycle Counter Alert. Cycle Count—Cycle Counter records the number of times the travel changes direction. The change in direction must occur after the deadband has been exceeded before it can be counted as a cycle. See figure 5-6. You can reset the Cycle Counter by configuring it as zero.

Drive Alert Enable (1-2-7-5) Select Main Menu, Detailed Setup, Alerts, and Drive Alert Enab. Follow the prompts on the HART Communicator display to configure the drive signal alert.

Drive Alrt Enab—Yes or No. Drive Alert Enable activates checking of the relationship between the Drive Signal and the calibrated travel. If one of the following conditions exists for more than 20 seconds, the Drive Alert is set. For the case where Zero Control Signal is defined as closed: Drive Signal < 10% and Calibrated Travel > 3% Drive Signal > 90% and Calibrated Travel < 97%

5-14

Aux In Alrt Enab—Yes or No. Auxiliary Input Alert Enable activates checking the status of the auxiliary input, which is a contact or discrete input. When enabled, the Auxiliary Input Alert is set when the auxiliary input terminals are either open or closed, depending upon the selection for the Aux In Alrt State. Aux In Alrt State—Open or Closed. Determines which state of the contacts (open or closed) connected to the auxiliary input terminals causes the auxiliary input alert to be active.

Alert Record (1-2-7-7) Firmware revision 5 instruments have an alert record that can store alerts from any of the enabled alert groups: Valve Alerts, Failure Alerts or Miscellaneous Alerts. Select Main Menu, Detailed Setup, Alerts, and Alert Record. Follow the prompts on the HART Communicator display to Display Record, Clear Record, set the Inst Date & Time (Instrument Date and Time), and enable Record Groups. Alert Record is only available for instruments with firmware revision 5. Display Record—Displays all recorded alerts and the date and time the alerts were recorded. Clear Record—Clears the alert record. To clear the alert record, all alerts in enabled groups must be inactive. Inst Date and Time—Permits setting the instrument clock. When alerts are stored in the alert record, the date and time (obtained from the instrument clock) that they were stored is also stored in the record. May 1998

Detailed Setup Record Groups—Permits enabling one or more alert groups. Table 5-12 lists the alerts included in each of the groups. When any alert from an enabled group becomes active, active alerts in all enabled groups are stored. Table 5-12. Alerts Included in Alert Groups for Alert Record Alert Group

Alerts Include in Group Travel 1 low Travel 1 high Travel 2 low Travel 2 high Travel deviation Drive signal No free time RAM fail Drive current fail NVM fail Temperature sensor fail Pressure sensor fail Travel sensor fail

Valve Alerts

Failure Alerts(1)

Miscellaneous Alerts

Auxiliary input

1. The Failure Alerts group is only available for instruments with firmware revision 5 in hardware revision 5.

shutdown, the instrument attempts to drive its output pressure to the zero current condition and no longer executes its control function. In addition, the appropriate failure statuses are set. Once the problem that caused the shutdown has been fixed, the instrument can be restarted by cycling the power or selecting Restart from the Mode menu of the HART Communicator. Also see the DVC5000 Series Digital Valve Controller Instrument Status section on page 7-3 for further details about failures.

Done—Select this if you are done modifying the self test shutdown criteria. No Free Time Fail—When enabled, the instrument shuts down whenever there is a failure associated with No Free Time. RAM Fail—When enabled, the instrument shuts down whenever there is a failure associated with RAM (random access memory). Critical NVM Fail—When enabled, the instrument shuts down whenever there is a failure associated with critical NVM (non-volatile memory).

Self Test Failures for Instrument Shutdown

(1-2-8)

Select Main Menu, Detailed Setup, and Self Test Shutdown. Follow the prompts on the HART Communicator display to determine the self test shutdown criteria from the following selections: Done, No Free Time Fail (No Free Time Failure), RAM Fail (Random Access Memory Failure), Critical NVM Fail (Critical Non-Volatile Memory Failure), Temp Sensor Fail (Temperature Sensor Failure),Tvl Sensor Fail (Travel Sensor Failure), or Drive Current Fail. Upon

May 1998

Temp Sensor Fail—When enabled, the instrument shuts down whenever there is a failure associated with the internal temperature sensor. Tvl Sensor Fail—When enabled, the instrument shuts down whenever there is a failure associated with the travel sensor. Drive Current Fail—When enabled, the instrument shuts down whenever the drive current does not match the drive signal. Drive Current Fail is only available with instrument firmware revision 5 in hardware revision 5.

5-15

DVC5000 Series

5-16

May 1998

Calibration 6-6

Section 6 Calibration

May 1998

Restoring Calibration to Factory Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2

Analog Input Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2

Auto Calibrate Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3

Manual Calibrate Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4

Pressure Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6

Travel Sensor Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6

DVC5010 Digital Valve Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6

DVC5020 Digital Valve Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7

DVC5030 Digital Valve Controllers on Fisher Actuators . . . . . . . . . . . . . . . . . . . .

6-6

DVC5030 Digital Valve Controllers on Other Actuators . . . . . . . . . . . . . . . . . . . . .

6-8

DVC5040 Digital Valve Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6

6-1

DVC5000 Series When a DVC5000 Series digital valve controller is ordered as part of a control valve assembly, the factory mounts the digital valve controller on the actuator and connects the necessary tubing, then sets up and calibrates the controller. For digital valve controllers that are ordered separately, recalibration of the analog input or pressure sensors generally is unnecessary. However, after mounting on an actuator, perform the initial setup (either auto or manual) then calibrate travel by selecting Auto Calib Travel from the Auto Setup or Manual Setup menus. For more detailed calibration information, refer to the following calibration procedures, available from the Calibrate menu: D Analog Input—This procedure permits calibrating the analog input sensor.

D Auto Calibrate Travel—This procedure automatically calibrates the travel. The calibration procedure uses the valve and actuator stops as the 0% and 100% calibration points. D Manual Calibrate Travel—This procedure permits manual calibration of the travel. This calibration procedure allows you to determine the 0% and 100% calibration points. D Pressure Sensor—This procedure permits calibrating the pressure sensor. D Restore Calibration—This procedure permits you to restore the calibration settings back to the factory settings. D Calibrate Location—Indicates the location of the last instrument calibration. The calibration location is either FACTORY or FIELD. A new instrument will display FACTORY. As soon as calibration is performed on one of the measured variables, such as Analog Input, Travel, or if the tuning set is changed, the Calibration Location is set to FIELD. When you select Restore Calib, under the Calibrate menu, the calibration parameters are reset to the original factory settings. D Travel Sensor Adjust—This procedure permits calibrating the travel sensor. To display the calibrate menu, select Calibrate from the Main Menu.

6-2

Note The Instrument Mode must be Out Of Service and the Protection set to None before the instrument can be calibrated.

WARNING During calibration, the valve may move. 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.

Restoring Calibration to Factory Settings

(1-4-5)

Select Main Menu, Calibrate, and Restore Calib. Follow the prompts on the HART Communicator display to restore calibration to the factory settings. You should only restore the calibration if it is not possible to calibrate an individual sensor. Restoring calibration returns the calibration of all of the sensors and the tuning set to their factory settings. Following restoration of the factory calibration, the individual sensors should be recalibrated.

Analog Input Calibration

(1-4-1)

To calibrate the analog input sensor, connect a variable current source to the instrument terminals labeled LOOP+ and LOOP–. The current source should be capable of generating an output of 4 to 20 mA. Select Analog In from the Calibrate menu, then follow the prompts on the HART Communicator display to calibrate the analog input sensor. 1. Set the current source to the target value shown on the display. The target value is the Input Range Low value. Press OK. 2. The following message appears: May 1998

Calibration Use Increase and Decrease selections until the displayed current matches the target. Press OK when you have read this message. 3. The value of the Analog Input appears on the display. Press OK to display the adjustment menu. 4. From the adjustment menu, select the direction and size of adjustment to the displayed value. Selecting large, medium, and small adjustments causes changes of approximately 0.4 mA, 0.04 mA, and 0.004 mA, respectively. If the displayed value does not match the current source, press OK, then repeat this step (step 4) to further adjust the displayed value. When the displayed value matches the current source, select Done and go to step 5. 5. Set the current source to the target value shown on the display. The target value is the Input Range High value. Press OK. 6. The following message appears:

Use Increase and Decrease selections until the displayed current matches the target.

7. The value of the Analog Input appears on the display. Press OK to display the adjustment menu. 8. From the adjustment menu, select the direction and size of adjustment to the displayed value. Selecting large, medium, and small adjustments causes changes of approximately 0.4 mA, 0.04 mA, and 0.004 mA, respectively. If the displayed value does not match the current source, press OK, then repeat this step (step 8) to further adjust the displayed value. When the displayed value matches the current source, select Done and go to step 9. 9. Place the instrument In Service and verify that the analog input displayed matches the current source.

(1-4-2)

User interaction is only required with Auto Calibrate Travel when the feedback characteristic is sliding-stem. A feedback characteristic of rotary requires no user interaction and you can start with May 1998

Figure 6-1. Crossover Point

step 4. For a sliding-stem feedback characteristic, interaction provides a more accurate crossover adjustment. Select Auto Calib Travel from the Calibrate menu, then follow the prompts on the HART Communicator display to automatically calibrate travel. 1. Select the method of crossover adjustment: manual, last value, or default.

Press OK when you have read this message.

Auto Calibrate Travel

A6536/IL

If you select Last Value, the crossover setting currently stored in the instrument is used and there are no further user interactions with the auto-calibration routine (go to step 4). If you select Default, an approximate value for the crossover is written to the instrument and there are no further user interactions with the auto-calibration routine (go to step 4). If you select Manual, you are asked to select an adjustment source, either analog or digital. If you use a current source to adjust the crossover, select Analog and go to step 2. If you wish to adjust the current source digitally, select Digital and go to step 3. 2. If you selected Analog as the crossover adjustment source, the HART Communicator prompts you to adjust the current source until the feedback arm is 90째 to the actuator stem, as shown in figure 6-1. After you have made the adjustment, press OK and go to step 4. 3. If you selected Digital as the crossover adjustment source, the HART Communicator displays a menu to allow you to adjust the crossover. Select the direction and size of change required to set the feedback arm so it is 90째 to the actuator stem, as shown in figure 6-1. Selecting large, medium, and small adjustments to the crossover causes changes of

6-3

DVC5000 Series approximately 10.0°, 1.0°, and 0.1°, respectively, to the rotation of the feedback arm. If another adjustment is required, repeat step 3. Otherwise, select Done and go to step 4. 4. The remainder of the auto calibration procedure is automatic. It is completed when the Calibrate menu appears 5. Place the instrument In Service and verify that the travel properly tracks the current source.

1. For firmware revisions 4 and 5, adjust the input current until the valve moves. Then, reduce the input current until the output pressure is 0. Press OK. 2. If the feedback characteristic is specified as rotary, go to step 6. If the feedback characteristic is specified as sliding-stem, you are prompted to set the crossover point. Adjust the current source until the feedback arm is 90° to the actuator stem, as shown in figure 6-1. Then press OK. 3. Adjust the current source until the valve is at 0% travel, then press OK. 4. Adjust the current source until the valve is at 100% travel, then press OK.

Manual Calibrate Travel

(1-4-3)

Two procedures are available to manually calibrate travel:

D Analog Calibration Adjust

5. Adjust the current source until the valve is at 50% travel, then press OK. 6. Adjust the current source until the valve is at 0% travel, then press OK. 7. Adjust the current source until the valve is at 100% travel, then press OK.

D Digital Calibration Adjust

8. Steps 9 and 10 repeat some of the above steps to further improve the accuracy of the calibration.

Analog Calibration Adjust

(1-4-3-1)

Select Main Menu, Calibrate, Man Calib Travel, and Analog Calib Adj. Connect a variable current source to the instrument termination LOOP + and LOOP –. The current source should be capable of generating 4 to 20 mA. Follow the prompts on the HART Communicator display to calibrate the instrument’s travel in percent.

Note For firmware revisions 3 and 4, configure the Travel Range High at 100% and Travel Range Low at 0% before calibrating. If the travel is to be subranged, change Travel Range High and Low after completing the travel calibration.

9. Adjust the current source until the valve is at 0% travel, then press OK. 10. Adjust the current source until the valve is at 100% travel, then press OK. 11. Place the instrument In Service and verify that the travel properly tracks the current source.

Digital Calibration Adjust

(1-4-3-2)

Select Main Menu, Calibrate, Man Calib Travel, and Digital Calib Adj. Connect a variable current source to the instrument LOOP + and LOOP – terminals. The current source should be set between 4 and 20 mA. Follow the prompts on the HART Communicator display to calibrate the instrument’s travel in percent.

Note Note 0% Travel = Valve Closed 100% Travel = Valve Open

6-4

For firmware revisions 3 and 4, configure the Travel Range High at 100% and Travel Range Low at 0% before calibrating. If the travel is to be subranged, change Travel Range High and Low after completing the travel calibration.

May 1998

Calibration Note 0% Travel = Valve Closed 100% Travel = Valve Open

6. From the adjustment menu, select the direction and size of change required to set the travel to 100%. Selecting large, medium, and small adjustments causes changes of approximately 10.0°, 1.0°, and 0.1°, respectively, to the feedback arm rotation for a sliding-stem valve or to the travel for a rotary valve. If another adjustment is required, repeat step 6. Otherwise, select Done and go to step 7.

1. For firmware revisions 4 and 5, from the adjustment menu, select the direction and size of change required to adjust the output until the valve moves. Selecting large, medium, and small adjustments causes changes of approximately 10.0°, 1.0°, and 0.1°, respectively, to the feedback arm rotation. If another adjustment is required, repeat step 1. Otherwise, reduce the output pressure to 0, select Done and go to step 2. 2. If the feedback characteristic is specified as rotary, go to step 8. If the feedback characteristic is specified as sliding-stem, adjust the feedback arm to the crossover point by pressing OK to get to the adjustment menu. 3. From the adjustment menu, select the direction and size of change required to set the feedback arm so it is 90° to the actuator stem, as shown in figure 6-1. Selecting large, medium, and small adjustments to the crossover causes changes of approximately 10.0°, 1.0°, and 0.1°, respectively, to the feedback arm rotation. If another adjustment is required, repeat step 3. Otherwise, select Done and go to step 3. 4. The following message appears.

Adjust travel to the indicated value using the menu selections. Press OK to display the adjustment menu. 5. From the adjustment menu, select the direction and size of change required to set the travel at 0%. Selecting large, medium, and small adjustments causes changes of approximately 10.0°, 1.0°, and 0.1°, respectively, to the feedback arm rotation for a sliding-stem valve or to the travel for a rotary valve. If another adjustment is required, repeat step 5. Otherwise, select Done and go to step 6. May 1998

7. From the adjustment menu, select the direction and size of change required to set the travel to 50%. Selecting large, medium, and small adjustments causes changes of approximately 10.0°, 1.0°, and 0.1°, respectively, to the feedback arm rotation for a sliding-stem valve or to the travel for a rotary valve. If another adjustment is required, repeat step 7. Otherwise, select Done and go to step 8. 8. From the adjustment menu, select the direction and size of change required to set the travel to 0%. Selecting large, medium, and small adjustments causes changes of approximately 10.0°, 1.0°, and 0.1°, respectively, to the feedback arm rotation for a sliding-stem valve or to the travel for a rotary valve. If another adjustment is required, repeat step 8. Otherwise, select Done and go to step 9. 9. From the adjustment menu, select the direction and size of change required to set the travel to 100%. Selecting large, medium, and small adjustments causes changes of approximately 10.0°, 1.0°, and 0.1°, respectively, to the feedback arm rotation for a sliding-stem valve or to the travel for a rotary valve. If another adjustment is required, repeat step 9. Otherwise, select Done and go to step 10. 10. From the adjustment menu, select the direction and size of change required to set the travel to 0%. Selecting large, medium, and small adjustments causes changes of approximately 10.0°, 1.0°, and 0.1°, respectively, to the feedback arm rotation for a sliding-stem valve or to the travel for a rotary valve. If another adjustment is required, repeat step 10. Otherwise, select Done and go to step 11. 11. From the adjustment menu, select the direction and size of change required to set the travel to 100%. Selecting large, medium, and small adjustments causes changes of approximately 10.0°, 1.0°, and 0.1°, respectively, to the feedback arm rotation for a sliding-stem valve or to the travel for a rotary valve. If another adjustment is required, repeat step 11. Otherwise, select Done and go to step 12. 12. Place the instrument In Service and verify that the travel properly tracks the current source.

6-5

DVC5000 Series Pressure Sensor Calibration (1-4-4) Select Main Menu, Calibrate, and Pressure. Follow the prompts on the HART Communicator display to calibrate the instrument’s output pressure sensor. 1. Adjust the supply pressure regulator until the output pressure matches the target value shown on the display. Press OK. 2. The following message appears.

Use the Increase and Decrease selections until the displayed press matches the target.

Press OK when you have read this message. 3. The value of the pressure appears on the display. Press OK to display the adjustment menu. 4. From the adjustment menu, select the direction and size of adjustment to the displayed value. Selecting large, medium, and small adjustments causes changes of approximately 3.0 psi/0.207 bar/20.7 kPa, 0.30 psi/0.0207 bar/2.07 kPa, and 0.03 psi/0.00207 bar/0.207 kPa, respectively. If the displayed value does not match the supply pressure, press OK, then repeat this step (step 4) to further adjust the displayed value. When the displayed value matches the supply pressure, select Done and go to step 5. 5. Set the supply pressure to the target value shown on the display. Press OK. 6. The following message appears.

Use the Increase and Decrease selections until the displayed press matches the target. Press OK when you have read this message. 7. The value of the pressure appears on the display. Press OK to display the adjustment menu. 8. From the adjustment menu, select the direction and size of adjustment to the displayed value. Selecting large, medium, and small adjustments causes changes of approximately 3.0 psi/0.207 bar/20.7 kPa, 0.30 psi/0.0207 bar/2.07 kPa, and 0.03 psi/0.00207 bar/0.207 kPa, respectively. If the displayed value does not match the supply pressure, press OK, then repeat this step (step 8) to further adjust the displayed

6-6

value. When the displayed value matches the supply pressure, select Done and go to step 9. 9. Place the instrument In Service and verify that the displayed pressure matches the measured output pressure.

Travel Sensor Adjust

(1-4-7)

DVC5010, DVC5030 on Fisher Actuators, and DVC5040 Digital Valve Controllers The travel sensor is normally adjusted at the factory and should not require adjustment. However, if the travel sensor has been replaced, adjust the travel sensor by performing the following procedure. See the Maintenance section, Section 9 for travel sensor replacement procedures. 1. Remove supply air and remove the instrument from the actuator.

Note The alignment pin (key 46) is stored inside the digital valve controller housing. It is located above the supply pressure gauge.

2. As shown in figure 6-2, align the feedback arm (key 79) with the housing by inserting the alignment pin (key 46) through the hole marked “A” on the feedback arm. Fully engage the alignment pin into the tapped hole in the housing. Position the feedback arm so that the surface with the travel markings is flush with the end of the travel sensor shaft. 3. Loosen the screw that secures the feedback arm to the travel sensor shaft. 4. Connect a current source to the instrument LOOP – and LOOP + terminals. Set the current source to any value between 4 and 20 mA. Connect the HART Communicator to the TALK terminals. 5. Before beginning the travel sensor adjustment, set the instrument mode to Out Of Service and the protection to None. 6. Select Main Menu, Display, Device Information, and Hardware Revision. Note the hardware revision number. 7. Select Main Menu, Calibrate, Tvl Sensor Adjust. Follow the prompts on the HART Communicator display to adjust the travel sensor counts to the value listed in table 6-1. May 1998

Calibration 9. Disconnect the HART Communicator and current source from the instrument. 10. Remove the alignment pin and store it in the instrument housing next to the supply gauge. Feedback Arm (key 79)

Alignment Pin (key 46) Bias Spring (key 78)

Travel Sensor Shaft

11. Install the digital valve controller on the actuator as described in the “Installation” section, Section 2.

Travel Sensor Adjust for DVC5020 The travel sensor is normally adjusted at the factory and should not require adjustment. However, if the travel sensor has been replaced, adjust the travel sensor by performing the following procedure. See the “Maintenance” section, Section 9, for travel sensor replacement procedures. 1. Remove supply air and remove the instrument from the actuator.

A7023 / IL

Figure 6-2. Type DVC5010 Digital Valve Controller Showing Feedback Arm in Position for Travel Sensor Adjustment

Table 6-1. DVC5000 Series Digital Valve Controller Travel Sensor Counts Hardware Revision Number

Digital Valve Controller Type

Revision 2

Revisions 3, 4, & 5

Type 5010 or 5040

2000 ±300

4000 ±300

Type 5020

6700 ±300

7200 ±300

Type 5030 mounted on actuator Types 1051, 1052, and 1066SR

2000 ±300

3500 ±300

Ty e 5030 mounted Type on other actuators

clockwise shaft rotation (1) 10000 ±300 counterclockwise shaft rotation (1) 2000 ±300

clockwise shaft rotation (1) 10000 ±300 counterclockwise shaft rotation (1) 3500 ±300

1. Travel sensor shaft rotation for actuator increasing air pressure, when viewing the end of the travel sensor shaft.

Note In the next step, be sure the feedback arm surface with the travel markings remains flush with the end of the travel sensor shaft.

8. While observing the travel sensor counts, tighten the screw that secures the feedback arm to the travel sensor shaft. Be sure the travel sensor counts remain within the tolerances listed in table 6-1. Paint the screw to discourage tampering with the connection. May 1998

2. See figure 6-3 for parts identification. Disconnect the bias spring (key 82) from the feedback arm assembly (key 84) and the arm assembly (key 91). Remove the mounting bracket (key 74) from the back of the digital controller. Hold the arm assembly (key 91) so that the arm assembly points toward the terminal box and the arm is parallel to the back of the housing, as shown in figure 6-4. 3. Loosen the screw that secures the arm assembly to the travel sensor shaft. Position the arm assembly so that the outer surface is flush with the end of the travel sensor shaft. 4. Connect a current source to the instrument LOOP – and LOOP + terminals. Set the current source to any value between 4 and 20 mA. Connect the HART Communicator to the TALK terminals. 5. Before beginning the travel sensor adjustment, set the instrument mode to Out Of Service and the protection to None. 6. Select Main Menu, Display, Device Information, and Hardware Revision. Note the hardware revision number. 7. Select Main Menu, Calibrate, Tvl Sensor Adjust. Follow the prompts on the HART Communicator display to adjust the travel sensor counts to the value listed in table 6-1.

Note In the next step, be sure the arm assembly outer surface remains flush with the end of the travel sensor shaft. 8. While observing the travel sensor counts, tighten the screw that secures the arm assembly to the travel

6-7

DVC5000 Series

MOUNTING ADAPTER (KEY 117)

CAP SCREW, HEX SOCKET (KEY 116)

MOUNTING BRACKET (KEY 74)

BIAS SPRING (KEY 82) CAP SCREW, HEX HEAD (KEY 92)

ARM ASSEMBLY PIN

ARM ASSEMBLY (KEY 91)

FEEDBACK ARM TORSION SPRING (KEY 93)

A7024 / IL

FEEDBACK ARM ASSEMBLY (KEY 84)

Figure 6-3. Type DVC5020 Digital Valve Controller Mounted on Type 1052, Size 33 Actuator

BACK EDGE OF ARM PARALLEL W/BACK OF HOUSING

within the tolerances listed in table 6-1. Paint the screw to discourage tampering with the connection. 9. Disconnect the HART Communicator and current source from the instrument.

ARM ASSEMBLY

10. Apply lubricant (key 63) to the pin portion of the arm assembly (key 91). ARM ASSEMBLY PIN

11. Replace the mounting bracket on the back of the instrument and reconnect the bias spring between the feedback arm assembly and the arm assembly on the travel sensor shaft. 12. Install the digital valve controller on the actuator as described in the “Installation” section, Section 2.

TRAVEL SENSOR SHAFT

BACK OF HOUSING A7025 / IL

Figure 6-4. Type DVC5020 Travel Sensor Arm/Housing Back Plane Alignment

sensor shaft. Be sure the travel sensor counts remain

6-8

Travel Sensor Adjust for DVC5030 on Other Actuators Travel sensor adjustment is part of the installation procedure when installing the Type DVC5030 digital valve controller on other than Fisher actuators. Install the digital valve controller as described in the May 1998

Calibration “Installation” section, Section 2. When you are ready to perform the step that requires travel sensor adjustment, perform the following procedure: 1. Connect a current source to the instrument LOOP – and LOOP + terminals. Set the current source to any value between 4 and 20 mA. Connect the HART Communicator to the TALK terminals. 2. Before beginning the travel sensor adjustment, set the instrument mode to Out Of Service and the protection to None. 3. Select Main Menu, Display, Device Information, and Hardware Revision. Note the hardware revision number.

4. Select Main Menu, Calibrate, Tvl Sensor Adjust. Follow the prompts on the HART Communicator display to adjust the travel sensor counts to the value listed in table 6-1. Note the travel sensor shaft rotation with increasing air pressure and adjust the travel sensor counts accordingly. 5. Tighten the coupler set screw to secure the coupler to the shaft connector cap pin, tie bar assembly, or spindle. If the coupler set screw is not accessible due to obstructions, loosen the coupler set screw on the travel sensor shaft and rotate the coupler. Then, tighten the coupler set screw and repeat step 4. 6. After completing the travel sensor adjustment, perform the remainder of the installation procedure in the “Installation” section.

May 1998

6-9

DVC5000 Series

6-10

May 1998

Viewing Device Information 7-7

Section 7 Viewing Device Information Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2

Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2

Output Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2

Drive Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2

Additional Instrument Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2

Auxiliary Input Internal Temperature Cycle Count Travel Accumulator Free Time Travel Sensor Counts

Device Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 7-3

HART Universal Revision Interface Revision Firmware Revision Hardware Revision Output Bias Revised? Advanced Diagnostics Instrument Level Pressure Sensor Device Identifier

Instrument Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3

Valve Alerts Failure Alerts Alert Record Operational Status

May 1998

7-1

DVC5000 Series The following menus are available to define and/or view information about the instrument.

the display, select the variable and a detail display of that variable with its value will appear. A variable’s value does not appear on the menu if the value becomes too large to fit in the allocated space on the display, or the variable requires special processing, such as Free Time or Aux In.

Viewing Variables

D Aux In—The Auxiliary Input is a discrete input that can be used with an independent limit or pressure switch. Its value is either open or closed.

Analog Input, Output Pressure, Travel, and Drive Signal

D Temp—The internal temperature of the instrument is displayed in either degrees Fahrenheit or Celsius.

Note These variables are not available for instrument level AC.

The following variables are displayed on the Online menu: Analog In shows the value of the instrument analog input in mA (milliamperes) or % (percent) of ranged input. Press shows the value of the instrument output pressure in psi, bar, or kPa. Travel shows the value of the DVC5000 Series digital valve controller travel in % (percent) of ranged travel. Travel always represents how far the valve is open. Drive Sgl shows the value of the instrument drive signal in % (percent) of maximum drive.

Additional Instrument Variables

D Cycl Count—Cycle Counter displays the number of times the instrument has cycled. Only changes in direction of the travel after the travel has exceeded the deadband are counted as a cycle. Once a new cycle has occurred, a new deadband around the last travel is set. The value of the Cycle Counter can be reset from the Cycle Count Alert menu. See Cycle Counter Deadband in Section 5 for more details. D Tvl Acum—Travel Accumulator contains the total change in travel, in percent of ranged travel. The accumulator only increments when travel exceeds the deadband. Then the greatest amount of change in one direction from the original reference point (after the deadband has been exceeded) will be added to the Travel Accumulator. The value of the Travel Accumulator can be reset from the Travel Accum Alert menu. See Travel Accumulator Deadband in Section 5 for more details. D Free Time—Free Time is the percent of time that the firmware is idle. A typical value is 25%. The actual value depends on the number of functions in the instrument that are enabled and also on the amount of communication currently in progress.

(1-3-1)

Note Note These variables are not available for instrument level AC. The Variables menu is available to view additional variables, such as the status of the auxiliary input, the instrument internal temperature, cycle count, travel accumulation, device free time, and travel sensor counts. To view one of these variables, from the Online menu select Main Menu, Display, and Variables. If a value for a variable does not appear on

7-2

Do not use the the following travel sensor counts indication for calibrating the travel sensor. The following should only be used for a relative indication to be sure the travel sensor is working and that it is moving in the correct direction. Perform the Travel Sensor Adjust procedure in Section 6 to calibrate the travel sensor.

D Tvl Sens Cts—Travel Sensor Counts indicates the travel sensor position in analog-to-digital converter May 1998

Viewing Device Information counts. When the travel sensor is operating correctly, this number changes as the valve strokes.

Viewing Device Information

Table 7-1. Functions Available for Instrument Level Instrument Level

Functions Available

Communicates with Model 275 HART Communicator Provides initial setup and calibration.

Communicates with Model 275 HART Communicator and ValveLink software. In addition to above, provides: travel cutoffs and limits, minimum opening and closing times, input characterization (linear, equal percentage, quick opening, and custom). Diagnostics limited to: travel, cycle counter, drive signal, and pressure readback.

Includes all functions listed above plus: Alerts: travel deviation, travel alert 1 & 2 (high and low), travel limits & cutoffs (high and low), drive signal, auxiliary terminal, cycle counter, travel accumulation. With ValveLink software, provides all offline diagnostic tests (dynamic error band, drive signal, output signal, and step response) except valve signature.

Includes all functions listed above plus (with ValveLink software) valve signature diagnostic test

(1-3-2) The Device Information menu is available to view information about the instrument. From the Online menu, select Main Menu, Display, and Device Information. Follow the prompts on the HART Communicator display to view information in the following fields: HART Univ Rev (HART Universal Revision), Interface Rev (Interface Revision), Firmware Rev (Firmware Revision), Hardware Rev (Hardware Revision), Output Bias Rev (Output Bias Revision), Instrument Level, Pressure Sensor and Device ID. D HART Univ Rev—HART Universal Revision is the revision number of the HART Universal Commands which are used as the communications protocol for the instrument. D Interface Rev—Interface Revision is the revision number of the interface software for communications between the HART Communicator and the instrument. This is the same as the Device Revision defined in the HART communication protocol. D Firmware Rev—Firmware Revision is the revision number of the Fisher Controls firmware in the instrument. D Hardware Rev—Hardware Revision is the revision number of the Fisher Controls instrument hardware. D Output Bias Rev?—Yes or No. Output Bias Revised indicates if the instrument output bias has been updated to the latest I/P and relay combination. D Inst Level—Indicates the instrument level AC—Auto Calibrate HC—HART Communicating SD—Standard Diagnostics AD—Advanced Diagnostics

D Device ID—Each instrument has a unique Device Identifier. The device ID provides additional security to prevent this instrument from accepting commands meant for other instruments.

Viewing Instrument Status

Note Instrument status is not available for instrument level AC. To view the instrument status, from the Online menu select Instrument Status. The following describes the various displays for the Instrument Status menu. D Done—Select this when you are done viewing the instrument status.

Note Alerts are not available with instrument level HC.

Table 7-1 lists the functions available for each instrument level. D Pressure Sensor—Yes or No. Indicates if the instrument includes a pressure sensor. May 1998

D Valve Alerts—If a valve alert is active, it will appear when the Valve Alerts menu item is selected. If

7-3

DVC5000 Series more than one alert is active, they will appear on the display one at a time in the order listed below. 1. Non-critical NVM Alert 2. Cycle Counter Alert 3. Tvl Accumulation Alert 4. Aux Terminal Alert 5. Tvl Alrt 1-High Alrt 6. Tvl Alrt 1-Low Alrt 7. Tvl Alrt 2-High Alrt 8. Tvl Alrt 2-Low Alrt 9. Tvl Deviation Alrt 10. Tvl Lim/Cutoff High 11. Tvl Lim/Cutoff Low 12. Drive Signal Alert

D Failure Alerts—If a self-test failure has occurred, it will appear when the Failure Alerts menu item is selected. If there are multiple failures, they will appear on the display one at a time in the order listed below. 1. Offline/Failed—This failure is indicated when a failure, enabled from the Self Test Shutdown menu, causes an instrument shutdown. Press Enter to see which of the specific failures caused the Offline/Failed indication. 2. No Free Time—This failure is indicated if the instrument is unable to complete all of the configured tasks. This will not occur with a properly functioning instrument. 3. RAM Fail—This failure is indicated when the Random Access Memory integrity test fails. Dynamic data is stored in RAM. If this failure is indicated, restart the instrument and see if it clears. If it does not clear, replace the PWB Assembly. 4. Drive Current Fail—This failure is indicated when the drive current does not match the drive signal. If this failure occurs, check the connection between the I/P converter and the pwb assembly. Try removing the I/P converter and re-installing it. If the failure does not clear, replace the I/P converter or the pwb assembly.

6. Temperature Sensor Fail—This failure is indicated when the instrument temperature sensor fails, or the sensor reading is outside of the range of –40 to 176_F (–40 to 80_C). The temperature reading is used internally for temperature compensation of inputs. If this failure is indicated, restart the instrument and see if it clears. If it does not clear, replace the PWB Assembly. 7. Pressure Sensor Fail—This failure is indicated when the actuator pressure is outside the range of –24.0 to 125.0% of the calibrated pressure for more than 60 seconds. If this failure is indicated, check the instrument supply pressure. If the failure persists, ensure the PWB assembly is properly mounted onto the Module Base Assembly, and the pressure sensor O-ring is properly installed. If the failure does not clear after restarting the instrument, replace the PWB Assembly. 8. Travel Sensor Fail—This failure is indicated when the sensed travel is outside of the range of –25.0 to 125.0% of the calibrated travel. If this failure is indicated, check the instrument mounting and the travel sensor adjustment. Also, check that the electrical connection from the travel sensor is properly plugged into the PWB assembly. After restarting the instrument, if the failure does not clear, replace the PWB Assembly. D Alert Record—Firmware revision 5 instruments have an alert record that can store alerts from any of the enabled alert groups: Valve Alerts, Failure Alerts or Miscellaneous Alerts. Table 7-2 lists the alerts included in each of the groups. The alert record also includes the date and time (from the instrument clock) the alert occurred. D Operational Status—This menu item indicates the status of the Operational items listed below. The status of more than one operational may be indicated. If more than one Operational status is set, they will appear on the display one at a time in the order listed below. 1. Out of Service 2. Input Char Selected 3. Custom Char Selected 4. High Performance in Effect 5. Diagnostic in Progress 6. Calibration in Progress

5. Critical NVM Alert—This failure is indicated when the Non-Volatile Memory integrity test fails. Configuration data is stored in NVM. If this failure is indicated, restart the instrument and see if it clears. If it does not clear, replace the PWB Assembly.

7-4

7. Dynamic Bypass Enabled 8. Calib—Valve Cntrl Inactive 9. Burst Mode is Enabled May 1998

Viewing Device Information Table 7-2. Alerts Included in Alert Groups for Alert Record Alert Group

Valve Alerts

Failure Alerts(1)

Miscellaneous Alerts

1. The Failure Alerts group is only available for instruments with firmware revision 5 in hardware revision 5.

May 1998

7-5

DVC5000 Series

7-6

May 1998

Principle of Operation 8-8

Section 8 Principle of Operation HART Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2

Digital Valve Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2

May 1998

8-1

DVC5000 Series +0.5 mA

CONTROL SYSTEM

ANALOG SIGNAL

–0.5 mA

HART MODEM 1200 Hz “1”

2200 Hz “0”

AVERAGE CURRENT CHANGE DURING COMMUNICATION = 0 A6174/IL

Figure 8-1. HARTr Frequency Shift Keying Technique FIELD TERM.

HART Communication

The HART (Highway Addressable Remote Transducer) protocol gives field devices the capability of communicating instrument and process data digitally. This digital communication occurs over the same two-wire loop that provides the 4–20 mA process control signal, without disrupting the process signal. In this way, the analog process signal, with its faster update rate, can be used for control. At the same time, the HART protocol allows access to digital diagnostic, maintenance, and additional process data. The protocol provides total system integration via a host device. The HART protocol uses the frequency shift keying (FSK) technique based on the Bell 202 communication standard. By superimposing a frequency signal over the 4–20 mA current, digital communication is attained. Two individual frequencies of 1200 and 2200 Hz are superimposed as a sinewave over the 4–20 mA current loop. These frequencies represent the digits 1 and 0 (see figure 8-1). The average value of this sinewave is zero, therefore no dc value is added to the 4–20 mA signal. Thus, true simultaneous communication is achieved without interrupting the process signal. The HART protocol allows the capability of multidropping, networking several devices to a single communications line. This process is well suited for monitoring remote applications such as pipelines, custody transfer sites, and tank farms. See table 9-2 for instructions on changing the mode switch configuration to multidrop.

Digital Valve Controller Operation DVC5000 Series digital valve controllers have a single master module that may be easily replaced in the field without disconnecting field wiring or tubing. This master module contains the following submodules: I/P

8-2

A6761 / IL

Figure 8-2. Typical FIELDVUE Instrument to Personal Computer Connections for ValveLink Type VL2010 or VL2020 Software

converter, printed wiring board (printed wiring board) assembly, and pneumatic relay. The master module can be rebuilt by replacing the submodules. See figures 8-3 and 8-4. DVC5000 Series digital valve controllers are loop-powered instruments that provide a control valve position proportional to an input signal from the control room. The following describes a direct acting Type DVC5010 digital valve controller mounted on a Type 657 actuator. The input signal is routed into the terminal box through a single twisted pair of wires and then to the printed wiring board assembly submodule where it is read by the microprocessor, processed by a digital algorithm, and converted into an analog I/P drive signal. As the input signal increases, the drive signal to the I/P converter increases. This makes the magnetic attraction between the core and armature of the I/P converter increase, causing the flapper to restrict the nozzle, which increases the nozzle pressure. The nozzle pressure is routed to the input diaphragm of the pneumatic relay submodule. As the nozzle pressure increases, the pneumatic relay diaphragm assembly moves, causing the valve plug to open the supply port and close the exhaust port, increasing the output pressure to the actuator. The increased output pressure causes the actuator stem to move downward. Stem position is sensed through the feedback linkage by the travel sensor which is May 1998

Principle of Operation 4â&#x20AC;&#x201C;20 mA + HART

INPUT SIGNAL

AUXILIARY TERMINALS

PRINTED WIRING BOARD PRESSURE SENSOR FOR ADVANCED DIAGNOSTICS

OUTPUT

STEM FEEDBACK

I/P

SUPPLY PRESSURE

RELAY

PRESSURE

A6480-1/IL

Figure 8-3. DVC5000 Series Digital Valve Controller Principle of Operation TERMINAL BOX ASSEMBLY (KEY 164)

TERMINAL BOX COVER (KEY 4)

8 PRINTED WIRING BOARD ASSEMBLY (KEY 50) MODULE BASE ASSEMBLY (KEY 20) I/P CONVERTER (KEY 41)

PRESSURE GAUGES (KEY 47)

TRAVEL SENSOR ASSEMBLY (KEY 77) HOUSING (KEY 1)

GASKET (KEY 42)

COVER ASSEMBLY (KEY 43) RELAY (KEY 24)

A7026 / IL

RELAY CAP (KEY 26)

Figure 8-4. DVC5000 Series Digital Valve Controller Assembly

electrically connected to the printed wiring board assembly submodule. The stem continues to move downward until the correct stem position is attained. At this point the printed wiring board assembly stabilizes the I/P drive signal. This positions the flapper to prevent any further increase in nozzle pressure. May 1998

As the input signal decreases, the drive signal to the I/P converter submodule decreases, decreasing the nozzle pressure. The pneumatic relay diaphragm assembly moves, causing the valve plug to close the supply port and open the exhaust port, releasing the actuator casing pressure to atmosphere. The stem

8-3

DVC5000 Series

CONTROL SYSTEM RS-232/485 CONVERTER

HART INTERCHANGE

FIELD TERM.

A6760 / IL

Figure 8-5. Typical FIELDVUE Instrument to Personal Computer Connections for ValveLink Type VL2030 Software

moves upward until the correct position is attained. At this point the printed wiring board assembly stabilizes the I/P drive signal. This positions the flapper to prevent any further decrease in nozzle pressure.

8-4

May 1998

Maintenance 9-9

Section 9 Maintenance Stroking the Digital Valve Controller Output Using the 275 HART Communicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3

Manually Stroking the Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3

Instrument Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3

Checking Voltage Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3

Master Module Maintenance Removing the Master Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-5

Replacing the Master Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-6

SubModule Maintenance I/P Converter Clearing the Primary Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the I/P Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the I/P Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-7 9-7 9-7 9-7

Printed Wiring Board (PWB) Assembly Removing the Printed Wiring Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Printed Wiring Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the Mode Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-8 9-8 9-8

Pneumatic Relay Removing the Pneumatic Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Pneumatic Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-8 9-9

Gauges, Pipe Plugs or Tire Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-10

Terminal Box Removing the Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-10

Replacing the Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-10

Travel Sensor Disassembly DVC5010 Digital Valve Controller (Sliding-Stem) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5020 Digital Valve Controller (Rotary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5030 Digital Valve Controller (Rotary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5040 Digital Valve Controller (Sliding-Stem) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . May 1998

9-11 9-11 9-11 9-11

9-1

DVC5000 Series Assembly DVC5010 Digital Valve Controller (Sliding-Stem) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5020 Digital Valve Controller (Rotary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5030 Digital Valve Controller (Rotary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5040 Digital Valve Controller (Sliding-Stem) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-11 9-13 9-14 9-11

9-2

May 1998

Maintenance Note If the feedback arm (key 79) or feedback arm assembly (key 84) is removed from the DVC5000 Series digital valve controller, the travel sensor (key 77) must be recalibrated.

D Ramp to Target—ramps the travel to the specified target at the rate of 1.0% per second of the ranged travel. D Step to Target—steps the travel to the specified target. D Stop—stops the command.

Manually Stroking the Output Refer to figure 9-1. 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.

Stroking the Digital Valve Controller Output Stroking the Output Using the 275 HART Communicator

To increase output pressure, depress the I/P armature by gently pressing on the flapper mounting screw. After viewing the output pressure, gently lift the I/P armature by lifting on the flapper mounting screw to return the output pressure to its original value. To decrease output pressure, gently lift the I/P armature by lifting on the flapper mounting screw. After viewing the output pressure, press on the flapper mounting screw slightly to return the output pressure to its original value.

Instrument Troubleshooting If communication or output difficulties are experienced with the instrument, refer to the troubleshooting chart shown in table 9-1.

(1-5)

Checking Voltage Available

Note Stroke output is not available with instrument level AC. From the Online menu, select Main Menu and Stroke Output. Follow the prompts on the HART Communicator display to select from the following: Done, Ramp Open, Ramp Closed, Ramp to Target, Step to Target, and Stop. D Done—Select this if you are done. All ramping is stopped when DONE is selected. D Ramp Open—ramps the travel toward open at the rate of 1.0% per second of the ranged travel. D Ramp Closed—ramps the travel toward closed at the rate of 1.0% per second of the ranged travel. May 1998

WARNING Personal injury or property damage caused by fire or explosion may occur if this test is attempted in an area which contains a potentially explosive atmosphere or has been classified as hazardous. To check the Voltage Available at the instrument, perform the following: 1. Connect the equipment in figure 2-22 to the field wiring in place of the FIELDVUE instrument. 2. Set the control system to provide maximum output current. 3. Set the resistance of the 1 kilohm potentiometer shown in figure 2-22 to zero.

9-3

DVC5000 Series Table 9-1. Instrument Troubleshooting Symptom 1. Instrument will not communicate.

Possible Cause 1a. Insufficient Voltage Available.

1b. Controller output Impedance too low.

1c. Cable capacitance too high.

1d. HART filter improperly adjusted. 1e. Improper field wiring.

1f. Controller output providing less than 4 mA to loop. 1g. Disconnected loop wiring cable at PWB. 1h. PWB DIP switches not set properly.

1h. Check for incorrect setting or broken DIP switches on the back of the PWB. Reset switches or replace PWB, if switches are broken. See table 9-2 for switch setting information

1j. PWB failure.

1j. Use a 4–20 mA current source to apply power to the instrument. Terminal voltage across the LOOP+ and LOOP– terminals should be 10 to 11.5 Vdc. If the terminal voltage is not 10 to 11.5 Vdc; over 100mA has been applied to the input terminals. Replace the PWB. 1k. Use the HART Communicator to set the polling address (refer to the Detailed Setup section, Section 5). From the Utilities menu, select Always Poll. Set the polling address to 0.

1k. Polling address incorrect.

Action 1a. Calculate Voltage Available (see Wiring Practices in the “Installation” section, Section 2). Voltage Available should be greater than or equal to 12 Vdc. 1b. Install a HART filter after reviewing Control System Compliance Voltage requirements (see Wiring Practices in the “Installation” section, Section 2). 1c. Review maximum cable capacitance limits (see Wiring Practices in the “Installation” section, Section 2). 1d. Check filter adjustment (see the appropriate HART filter instruction manual). 1e. Check polarity of wiring and integrity of connections. Make sure cable shield is grounded only at the control system. 1f. Check control system minimum output setting, which should not be less than 3.8 mA. 1g. Verify connectors are plugged in correctly.

1l. Defective cable from terminal box. 1m. Defective terminal box assembly printed wiring board.

1l. Check cable continuity. If necessary, replace the terminal box assembly. 1m Check for damaged printed wiring board lands and terminals. If necessary, replace the terminal box assembly. 1n. If necessary, repair or replace cable.

1n. Defective HART Communicator or ValveLink modem cable. 1p. ValveLink modem defective or not compatible with 1p. Replace ValveLink modem. PC. 1q. ValveLink hardlock defective or not programmed. 1q. Replace if defective or return to factory for programming. 2. Instrument will not calibrate, 2a. Travel sensor “frozen”, will not turn. 2a. Rotate feedback arm to ensure it moves freely. If has sluggish gg performance or oscillates. not, replace the pot/bushing assy. 2b. Broken travel sensor wire(s). 2b. Inspect wires for broken solder joint at pot or broken wire. Replace pot/bushing assy. 2c. Travel sensor mis-adjusted. 2c. Perform Travel Sensor Adjust procedure in “Calibration” section, Section 6. 2d. Open travel sensor. 2d. Check for continuity in electrical travel range. If necessary, replace pot/bushing assy. 2e. Cables not plugged into PWB correctly. 2e. Inspect connections and correct. 2f. Feedback arm loose on pot. 2g. Feedback arm bent/damaged or bias spring missing/damaged.

2f. Perform Travel Sensor Adjust procedure in “Calibration” section, Section 6. 2g. Replace feedback arm and bias spring.

–continued–

9-4

May 1998

Maintenance Table 9-1. Instrument Troubleshooting (Continued) Symptom

Possible Cause

Action

2h. Configuration errors.

2j. I/P assy primary restriction plugged. 2k. Air blockage in I/P assy nozzle block, not cleared by depressing cleanout wire. 2l. O-ring(s) between I/P assy missing or hard and flattened losing seal. 2m. I/P assy damaged/corroded/clogged.

2n. I/P assy out of spec.

2p. Defective gasket.

2k. Replace I/P assy. 2l. Replace O-ring(s). 2m. Check for bent flapper, loose cleanout valve, open coil (continuity), contamination, staining, or dirty air supply. Coil resistance should be between 1680 1860 ohms. Tighten cleanout valve, replace I/P assy if damaged, corroded, clogged, or open coil. 2n. I/P assy nozzle may have been adjusted. Verify drive signal (55% to 75%) Replace I/P assy if drive signal is continuously high or low. 2p. Check gasket for closed up holes, excessive deformation due to overtightening or “oozing”. If necessary, replace gasket. 2q. Depress I/P assy armature, look for increase in output pressure. Remove relay, inspect for missing Belleville washer, missing valve spring, missing valve plug. Inspect “lip” under top O-ring for breakage due to relay removal. Inspect O-rings and replace if hard or damaged. Replace parts or relay if I/P assy good and air passages not blocked.

2q. Defective relay.

3. ValveLink diagnostic g tests provide erroneous results. lt

2h. Verify configuration: If necessary, set protection to None. If Out of Service, place In Service. Check: Invert feedback. Tuning set Zero control signal Feedback characteristic Control mode (should be RSP) Restart control mode (should be RSP) Tvl Range Low and High 2j. Apply supply pressure and depress cleanout wire.

2r. Defective 67AFR regulator, supply pressure gauge 2r. Replace 67AFR regulator. jumps around. 3a. Bent or defective pressure sensor. 3a. Replace PWB. 3b. Pressure sensor O-ring missing.

3b. Replace O-ring.

4. No advanced diagnostics indicated 4a. Variable not available in PWB. when instrument has pressure sensor.

4a. Replace PWB, return old PWB to factory for correction.

5. HART Communicator does not turn 5a. Dead AA batteries or battery pack not charged. on.

5a. Replace AA batteries or charge battery pack. Note: Battery pack will not charge if installed on HART communicator. Remove battery pack to charge.

4. Record the current shown on the milliammeter.

Master Module Maintenance

5. Adjust the resistance of the 1 kilohm potentiometer until the voltage read on the voltmeter is 12.0 volts.

The digital valve controller contains a master module consisting of the I/P converter, pwb assembly, and pneumatic relay. The master module may be easily replaced in the field without disconnecting field wiring or tubing.

6. Record the current shown on the milliammeter. 7. If the current recorded in step 6 is the same as that recorded in step 4 (± 0.08 mA), the voltage available is adequate.

Removing the Master Module

8. If the voltage available is inadequate, refer to Wiring Practices in the “Installation” section, Section 2.

To remove the master module, perform the following steps. Refer to figures 10-1 through 10-4 for key number locations.

May 1998

9-5

DVC5000 Series 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 (key 102) 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 (key 43) and remove the cover from the module base (key 2). 3. Using a 1/4-inch hex wrench, loosen the four-socket head screws (key 38). These screws are captive in the module base by retaining rings (key 154).

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 (key 1). 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 which connect the master module, via the pwb assembly, to the travel sensor and the terminal box. Disconnect these cable assemblies from the pwb assembly on the back of the master module.

Replacing the Master Module To replace the master module, perform the following steps. Refer to figures 10-1 through 10-4.

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. 1. Ensure the gasket is aligned properly on the master module. 2. Connect the terminal box connector to the pwb assembly (key 50). Orientation of the connector is required. 3. Connect the travel sensor connector to the pwb assembly (key 50). Orientation of the connector is required. 4. Insert the module base (key 2) into the housing (key 1). 5. Install four screws (key 38) in the master module into the housing. If not already installed, press four retaining rings (key 154) into the module base. Evenly tighten the screws in a crisscross pattern to a final torque of 138 lbfDin (16 NDm). 6. Insert the cover hinge tabs into the module base. Swing the cover down into position and tighten the screw (key 41). 7. If not already installed, screw the vent (key 52) into the vent connection on the back of the housing. 8. If not already installed, apply sealant (key 64) to the pipe plug (key 61) and install it in the output connection on the back of the housing. 9. For sliding-stem applications only, install the protective shield (key 102) onto the side of the replacement module base assembly.

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 pwb assembly.

9-6

Submodule Maintenance The digital valve controllerâ&#x20AC;&#x2122;s master module contains the following submodules: I/P converter, pwb assembly, and pneumatic relay. If problems occur, these submodules may be removed from the master May 1998

Maintenance I/P ARMATURE (UNDER SHROUD SHROUD

FLAPPER MOUNTING SCREW

CLEAN-OUT PLUNGER

B Figure 9-1. I/P Converter O module and replaced with new submodules. After I/P Converter O replacing a submodule, the master module may be put Refer to figures 10-1 through 10-4 for key number back into service. locations. The I/P converter TS (key 41) is located on the front of the master module. A7027 / IL

Clearing the Primary Orifice

Note If the pwb 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.

Note 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.

If the primary orifice becomes clogged, affecting performance, depress the cleanout plunger (see figure 9-1). This operation runs a wire through the orifice to clear the hole. Unscrew the single captive screw in the cover (key 43) and remove the cover from the digital valve controller to gain access to the cleanout plunger.

Manual Output Test Manually stroke the output as described on page 9-3.

Removing the I/P Converter 1. Remove the front cover (key 43), if not already removed. 2. Remove the four socket-head screws (key 23) that attach the I/P converter to the module base. 3. Pull the I/P converter (key 41) 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 two O-rings (key 39) stay in the module base and do not come out with the I/P converter.

Replacing the I/P Converter 1. Inspect the condition of the two O-rings (key 39) in the module base. Replace them, if necessary. Apply sealant (key 65) to the O-rings.

May 1998

9-7

DVC5000 Series 2. Ensure the two boots (see figure 9-1) 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 pwb assembly submodule. 4. Install four socket-head screws (key 23) and evenly tighten them in a crisscross pattern to a final torque of 20.7 lbfDin (2 NDm).

2. Properly orient the pwb 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 pwb assembly must fit into its receptacle in the module base. 3. Push the pwb assembly into its cavity in the module base. 4. Install and tighten three screws (key 33) to a torque of 10.1 lbfDin (1 NDm).

PWB (Printed Wiring Board) Assembly Refer to figures 10-1 through 10-4 for key number locations. The pwb assembly (key 50) is located on the back of the module base assembly.

5. Set the DIP switches on the pwb assembly according to table 9-2.

Removing the Printed Wiring Board Assembly 1. Remove the master module according to instructions in this manual. 2. Remove three screws (key 33). 3. Lift the pwb assembly straight out of the module base.

4. Ensure that the O-ring (key 40) is attached to the pressure sensor or sensor plug after the pwb assembly has been removed from the module base. If the O-ring remained in the module base, remove it and place it back on the pressure sensor or sensor plug.

Replacing the PWB Assembly and Setting the Mode Switches 1. Apply sealant (key 65) to the O-ring (key 40) and install it on the pressure sensor or sensor plug located on the pwb assembly (key 50).

Note If the pwb assembly submodule is replaced, calibrate and configure the DVC5000 Series digital valve controller to maintain accuracy specifications.

9-8

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 PWB assembly submodule may result. In point-to-point wiring mode, the digital valve controller may only be connected to a 4â&#x20AC;&#x201C;20 mA current source.

Pneumatic Relay Refer to figures 10-1 through 10-4 for key number locations. The pneumatic relay (key 24) is located on the side of the master module.

Removing the Pneumatic Relay 1. Loosen the four screws (key 25) that attach the relay cap (key 26) to the module base. The screws are captive in the relay cap by O-rings (key 152). 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.

May 1998

Maintenance Table 9-2. DIP Switch Configuration (1) DIP SWITCH FUNCTION

SWITCH

Multidrop Loop

Multi-drop

Point-to-Point Loop

Multi-drop

Auxiliary Terminal, Transmitter

Auxiliary

Auxiliary Terminal, Switch

Auxiliary

SWITCH POSITION UP

DOWN UP

(2)

DOWN

1. Refer to figure 9-2 for switch location.. 2. Auxiliary terminal, transmitter is available only with the Process PID option.

CAUTION BACK OF PWB ASSEMBLY SUB-MODULE MULTI-DROP SWITCH

AUXILIARY SWITCH

DOWN

X X

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.

Replacing the Pneumatic Relay 1. Ensure the compartment in the module base that holds the relay is clean.

NOTE: X INDICATES PIN REMOVED FOR CONNECTOR KEYING. A6191-1/IL

Figure 9-2. DVC5000 Series Digital Valve Controller DIP Switch Location

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 (key 65) to three O-rings (key 24L) and one additional O-ring (key 24M) 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.

Note The Belleville spring (key 31) is captivated in the relay cap by a spring washer (key 32). 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.

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 (key 25) through the cap. Install the O-rings (key 152) 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 (key 31) in the relay cap, with its inside diameter contacting the relay cap. Place the spring washer (key 32), with its three fingers pointing up, against the Belleville spring.

3. Use a flat-bladed screwdriver in the notch of the relay to pry the relay out of the module base. May 1998

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.

9-9

DVC5000 Series Tighten the screws, in an crisscross pattern, to a final torque of 20.7 lbfDin (2 NDm).

5. Remove two wire retainers (key 44), internal and external to the terminal box.

Gauges, Pipe Plugs, or Tire Valves

Replacing the Terminal Box

Depending on the options ordered, the DVC5000 Series digital valve controller will be equipped with either two gauges (key 47), two pipe plugs (key 66), or two tire valves (key 67). These are located on the top of the master module next to the I/P converter. Perform the following procedure to replace the gauges, tire valves, or pipe plugs. Refer to figures 10-1 through 10-5 for key number locations.

Note Inspect all O-rings for wear and replace as necessary.

1. Remove the front cover (key 43). 2. Remove the gauge, pipe plug, or tire valve as follows:

1. Install two wire retainers (key 44), internal and external to the terminal box.

For gauges (key 47), use a wrench on the flats of the shaft underneath each gauge to remove the gauges from the module base.

2. Apply sealant (key 65) to the O-ring (key 36) and install the O-ring over the 2-5/16 inch thread on the terminal box. Use of a tool is recommended to prevent cutting the O-ring while installing it over the threads.

For pipe plugs (key 66) and tire valves (key 67), use a wrench to remove these from the module base. 3. Apply sealant (key 64) to the threads of the replacement gauges, pipe plugs, or tire valves.

4. Using a wrench, screw the gauges, pipe plugs, or tire valves into the module base.

Terminal Box Refer to figures 10-1 through 10-4 for key number locations. The terminal box is located on the housing and contains the terminal strip assembly for field wiring connections.

Removing the Terminal Box 1. Loosen the set screw (key 58) in the cap (key 4) so that the cap can be unscrewed from the terminal box. 2. After removing the cap (key 4), note the location of field wiring connections and disconnect the field wiring from the terminal box.

3. Apply lubricant (key 63) to the 2-5/8 inch threads on the terminal box to prevent seizing or galling when the cap is installed. 4. Screw the cap (key 4) onto the terminal box. 5. Install a set screw (key 58) into the cap (key 4). Loosen the cap (not more than 1 turn) to align the set screw over a slot in the terminal box. Tighten the set screw (key 58). 6. Apply sealant (key 65) to the O-ring (key 35) and install the O-ring over the 15/16 inch thread on the terminal box. Use of a tool is recommended to prevent cutting the O-ring while installing it over the threads. 7. Apply sealant (key 64) to the 15/16 inch thread on the terminal box to prevent seizing or galling when the terminal box assembly is installed onto the housing. 8. Screw the terminal box assembly onto the housing until it bottoms out. Back off the terminal box assembly a maximum of 1-1/4 turns for proper orientation of the terminal box to the housing. Install the screw (key 72) to prevent the terminal box assembly from rotating. 9. Apply sealant (key 64) to the conduit entrance plug (key 62) and install it into the desired side of the terminal box.

3. Remove the master module, disconnecting the cable assembly from the terminal box assembly. This cable assembly attaches to the pwb assembly on the back of the master module.

Travel Sensor

4. Remove the screw (key 72). Unscrew the terminal box assembly from the housing.

Replacing the travel sensor requires removing the digital valve controller from the actuator.

9-10

May 1998

Maintenance Disassembly

8. Unscrew the travel sensor assembly (key 77) from the housing.

Type DVC5010 and DVC5040 Digital Valve Controller

Type DVC5030 Digital Valve Controller

Refer to figure 10-1 or 10-4 for key number locations. 1. Remove piping and fittings from the instrument. 2. Disconnect the adjustment arm from the connector arm and the feedback arm. 3. Remove the digital valve controller from the actuator. 4. Loosen the screw (key 80) that secures the feedback arm (key 79) to the travel sensor shaft. 5. Remove the feedback arm (key 79) from the travel sensor shaft. 6. Separate the master module from the housing by performing the Removing the Master Module procedure.

Refer to figure 10-3 for key number locations. 1. Remove piping and fittings from the instrument. 2. Depending upon the actuator mounting, perform one or the other of the following: D For units mounted on Fisher actuators Remove the digital valve controller from the actuator. Loosen the screw (key 80) that secures the feedback arm (key 79) to the travel sensor shaft. Remove the feedback arm from the travel sensor shaft. D For units mounted on other than Fisher actuators Loosen the screw that secures the coupler to the travel sensor shaft. Remove the digital valve controller from the actuator.

The travel sensor assembly (key 77) consists of a bushing and potentiometer joined with thread lock, therefore the two components must be removed as one unit.

3. Separate the master module from the housing by performing the Removing the Master Module procedure. 4. From within the housing, unscrew the travel sensor assembly (key 77) from the housing.

7. Loosen the set screw (key 58) that locks the travel sensor assembly against the housing.

Assembly

8. Unscrew the travel sensor assembly (key 77) from the housing.

Type DVC5020 Digital Valve Controller Refer to figure 10-2 for key number locations. 1. Remove piping and fittings from the instrument. 2. Remove the digital valve controller from the actuator. 3. Disconnect the bias spring (key 82) from the feedback arm assembly (key 84) and the arm assembly (key 91). Remove the mounting bracket (key 74) from the back of the digital controller. 4. Loosen the screw (key 80) that secures the arm assembly to the travel sensor shaft. 5. Remove the arm assembly (key 91) from the travel sensor assembly (key 77) shaft. 6. Separate the master module from the housing by performing the Removing the Master Module procedure. The travel sensor assembly (key 77) consists of a bushing and potentiometer joined with thread lock, therefore the two components must be removed as one unit. 7. Loosen the set screw (key 58) that locks the travel sensor assembly against the housing. May 1998

9 Note When installing the travel sensor assembly, take care to not wind up the wires inside the housing. This can damage the soldered connections.

Type DVC5010 and DVC5040 Digital Valve Controllers Refer to figure 10-1 or 10-4 for key number locations. 1. Apply lubricant (key 63) to the travel sensor assembly (key 77) threads. 2. Insert the travel sensor assembly into the housing. Reach inside the housing and grasp the wires attached to the connector. 3. Screw the travel sensor assembly into the housing, simultaneously guiding the wires to prevent them from winding up inside the housing. This will reduce potential damage to the soldered connections. 4. Tighten the travel sensor assembly against the housing and tighten the set screw (key 58) to lock the assembly in place.

9-11

DVC5000 Series PIN 2

PIN 3

1 KEYED

3 CW

9 NOTE: 1 THE POTENTIOMETER RESISTANCE BETWEEN PINS 2 AND 3 CAN BE MEASURED AT THE CONNECTOR. INSERT TWO SHORT LENGTHS OF 22 AWG WIRE INTO THE PIN 2 AND 3 RECEPTACLES IN THE CONNECTOR. CLIP ON LEADS FROM A DVM (DIGITAL VOLTMETER) TO MEASURE THE RESISTANCE. A6481/IL

Figure 9-3. Potentiometer Resistance Measurement

5. Loosely assemble the bias spring (key 82), screw (key 80), and nut (key 81) to the feedback arm (key 79), if not already installed.

side of the housing. Position the feedback arm so that the surface with the travel markings is flush with the end of the travel sensor shaft.

6. Attach the feedback arm (key 79) to the travel sensor shaft.

8. Connect a multimeter set to a resistance range of 1000 ohms to pins 2 and 3 of the travel sensor connector. Refer to figure 9-3 for pin location.

Two methods are available for adjusting the travel sensor. You can use a multimeter to measure the potentiometer resistance, or if you have a HART Communicator with device description revision 9 or later, you can use the procedure in the “Calibration” section, Section 6. To use the multimeter, perform steps 7 through 13. To use the HART Communicator, skip to step 14. Travel Sensor Adjustment with a Multimeter 7. Align the feedback arm (key 79) to the housing (key 1) by inserting the alignment pin (key 46) through the hole marked “A” on the feedback arm. Fully engage the alignment pin into the tapped hole in the

9-12

9. Adjust the travel sensor shaft to obtain a measured resistance of 1950 to 2050 ohms.

Note In the next step, be sure the feedback arm surface with the travel markings remains flush with the end of the travel sensor shaft.

May 1998

Maintenance 10. While observing the resistance, tighten the screw (key 80) to secure the feedback arm to the travel sensor shaft. Be sure the resistance reading remains within the range listed in step 9. Paint the screw to discourage tampering with the connection. 11. Disconnect the multimeter from the travel sensor connector. 12. Reassemble the master module to the housing by performing the Replacing the Master Module procedure. 13. Travel sensor replacement is complete. Install the digital valve controller on the actuator as described in the “Installation” section, Section 2.

steps 7 through 17. To use the HART Communicator, skip to step 18. Travel Sensor Adjustment with a Multimeter 7. Connect a multimeter set to a resistance range of 1000 ohms to pins 2 and 3 of the travel sensor connector. Refer to figure 9-3 for pin location. 8. Hold the arm assembly (key 91) in a fixed position so that the arm is parallel to the housing back plane and pointing toward the terminal box. Position the arm assembly so that the outer surface is flush with the end of the travel sensor shaft. 9. Adjust the travel sensor shaft to obtain a measured resistance of 6250 to 6350 ohms.

Travel Sensor Adjustment with the HART Communicator The next two steps do not apply if you used a multimeter to adjust the travel sensor. Perform these steps only if you elected to adjust the travel sensor using the HART Communicator. 14. Reassemble the master module to the housing by performing the Replacing the Master Module procedure. 15. Perform the appropriate Travel Sensor Adjust procedure in the “Calibration” section, Section 6.

Type DVC5020 Digital Valve Controller Refer to figure 10-2 for key number locations. 1. Apply lubricant (key 63) to the bushing threads. 2. Insert the travel sensor assembly (key 77) into the housing. Reach inside the housing and grasp the wires attached to the connector. 3. Start threading the travel sensor assembly into the housing, simultaneously guiding the wires to prevent them from winding up inside the housing. This will reduce potential damage to the soldered connections. 4. Tighten the travel sensor assembly against the housing and tighten the set screw (key 58) to lock the assembly in place. 5. Loosely assemble the screw (key 80) and nut (key 81) to the arm assembly (key 91), if not already installed. 6. Attach the arm assembly (key 91) to the travel sensor assembly (key 77) shaft. Two methods are available for adjusting the travel sensor. You can use a multimeter to measure the potentiometer resistance, or if you have a HART Communicator with device description revision 9 or later, you can use the procedure in the “Calibration” section, Section 6. To use the multimeter, perform May 1998

Note In the next step, be sure the arm assembly outer surface remains flush with the end of the travel sensor shaft. 10. While observing the resistance, tighten the screw (key 80) to secure the feedback arm to the travel sensor shaft. Be sure the resistance reading remains within the range listed in step 9. Paint the screw to discourage tampering with the connection. 11. Disconnect the multimeter from the travel sensor connector. 12. Apply lubricant (key 63 or equivalent) to the pin portion of the arm assembly (key 91). 13. Push the feedback arm into the housing, engaging the pin of the arm assembly into the slot in the feedback arm. 14. Install the washer (key 86) and E-ring (key 85) next to the inboard flange bearing (key 83). 15. Install the bias spring (key 93). 16. Reassemble the master module to the housing by performing the Replacing the Master Module procedure 17. Travel sensor replacement is complete. Install the digital valve controller on the actuator as described in the “Installation” section, Section 2. Travel Sensor Adjustment with the HART Communicator The next two steps do not apply if you used a multimeter to adjust the travel sensor. Perform these steps only if you elected to adjust the travel sensor using the HART Communicator. 18. Reassemble the master module to the housing by performing the Replacing the Master Module procedure

9-13

DVC5000 Series 19. Perform the appropriate Travel Sensor Adjust procedure in the “Calibration” section, Section 6.

Type DVC5030 Digital Valve Controller Refer to figure 10-3 for key number locations. 1. Apply lubricant (key 63) to the bushing O-ring and threads.

Note In the next step, be sure the feedback arm outer surface remains flush with the end of the travel sensor shaft.

2. Screw the bushing into the housing until it is tight. 3. For units that mount on other than Fisher actuators, go to step 12. 4. For units that mount on Fisher actuators, attach the feedback arm (key 79) to the travel sensor shaft. Two methods are available for adjusting the travel sensor. You can use a multimeter to measure the potentiometer resistance, or if you have a HART Communicator with device description revision 9 or later, you can use the procedure in the “Calibration” section, Section 6. To use the multimeter, perform steps 5 through 11. To use the HART Communicator, skip to step 12. Travel Sensor Adjustment with a Multimeter

8. While observing the resistance, tighten the screw (key 80) to secure the feedback arm to the travel sensor shaft. Be sure the resistance reading remains within the range listed in step 9. Paint the screw to discourage tampering with the connection. 9. Disconnect the multimeter from the travel sensor connector. 10. Reassemble the master module to the housing by performing the Replacing the Master Module procedure. 11. Travel sensor replacement is complete. Install the digital valve controller on the actuator as described in the “Installation” section, Section 2.

5. Align the feedback arm (key 79) to the housing (key 1) by inserting the alignment pin (key 46) through the hole marked “A” on the feedback arm. Fully engage the alignment pin into the tapped hole in the side of the housing. Position the feedback arm so that the outer surface is flush with the end of the travel sensor shaft.

Travel Sensor Adjustment with the HART Communicator

6. Connect a multimeter set to a resistance range of 1000 ohms to pins 2 and 3 of the travel sensor connector. Refer to figure 9-3 for pin location.

12. Reassemble the master module to the housing by performing the Replacing the Master Module procedure.

7. Adjust the travel sensor shaft to obtain a measured resistance of 1950 to 2050 ohms.

13. Perform the appropriate Travel Sensor Adjust procedure in the “Calibration” section, Section 6.

9-14

The next two steps do not apply if you used a multimeter to adjust the travel sensor. Perform these steps only if you elected to adjust the travel sensor using the HART Communicator.

May 1998

Parts 10-10

Section 10 Parts Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3

Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3

Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3

I/P Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3

Module Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3

Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-4

Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-4

PWB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-4

Pressure Gauges, Pipe Plugs, or Tire Valve Assemblies . . . . . . . . . . . . . . . . . . .

10-4

Feedback Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-4

Mounting Parts DVC5010 Digital Valve Controller on: 513 & 513R, Size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513 & 513R, Size 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657 & 667, Size 30–60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657 & 667, Size 70–100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250 & 1250R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gulde Model GA and P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5020 Digital Valve Controller on: 585 & 585R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1051, Size 30–60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1051, Size 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1052, Size 20 & 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1052, Size 40–70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5030 Digital Valve Controller on Fisher Actuators: 1051, Size 30–60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1051, Size 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1052, Size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1052, Size 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1052, Size 40–70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1066SR, Size 20, 27, & 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5030 to Replace Positioners: Masoneilan Type 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neles-Jamesbury Type NP600, NE600, & NP723 . . . . . . . . . . . . . . . . . . . . . . . . . . . PMV Model P1200, P1500, & P2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . May 1998

10-4 10-5 10-5 10-5 10-5 10-5 10-5 10-5 10-5 10-5 10-5 10-5 10-5 10-6 10-5 10-5 10-6 10-6 10-6 10-6 10-6

10-1

DVC5000 Series Filter Regulator Mounting Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-6

HART Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-7

10-2

May 1998

Parts Key

Parts Ordering Whenever corresponding with your Fisher Controls sales office or representative about this equipment, always mention the controller serial number. When ordering replacement parts, refer to the 11-character part number of each required part as found in the following parts list. Parts which do not show part numbers are not orderable.

Parts Kits Conversion kit 6 listed below provides the parts required to convert a DVC5010 to a DVC5020. Conversion kit 7 provides the parts required to convert a DVC5020 to a DVC5010. Key 1* 2* 3* 6 7 9

Description Elastomer Spare Parts Kit Relay Spare Parts Kit Small Hardware Spare Parts Kit Conversion Kit (DVC5010 to DVC5020) Also see note below Conversion Kit (DVC5020 to DVC5010) Alignment Pin Kit (kit contains 15 alignment pins)

Part Number 14B5072X012 14B5072X022 14B5072X032 14B5072X102 14B5072X112 14B5072X092

Note Conversion kit key 6 contains a vent-away mounting bracket. Install a 1/4-inch NPT socket head pipe plug in the tapped hole in the side of the mounting bracket if Type DVC5020 digital valve controller is not for vent-away construction.

Description

Part Number

Common Parts 1 23 33 34* 36* 38 39* 40* 41 42* 43

48 49 52 58 61 62 63 64 65 74

75* 128 211

Housing, aluminum Cap Screw, hex socket, SST(3) (4 req’d) Mach Screw, pan hd, SST(3) (3 req’d) O-ring, nitrile(1) (2 req’d) O-ring nitrile(1) Cap Screw, hex socket, SST(3) (4 req’d) O-ring, nitrile(1) (2 req’d) O-ring, nitrile(1) I/P Assembly (See I/P Assembly listing below) Gasket, nitrile(1) Cover Assembly, plastic For DVC5010, DVC5020, & DVC5030 For DVC5040 Nameplate Drive Screw(3) (4 req’d) Vent, plastic(3) Used w/DVC5010 and DVC5030 only Set Screw, hex socket, SST(3) Pipe Plug, hex socket, SST Pipe Plug, hex hd, SST Lubriplate Mag-1 Lubricant (not furnished with the instrument) Zink-Plate No. 770 Anti-Seize Compound (not furnished with the instrument) Dow Corning 111 Lubricant (not furnished with the instrument) Mounting Bracket(6) DVC5020 only Std Vent-away O-Ring, nitrile(1,6) DVC5020 Vent-away only Pipe Plug, pl stl DVC5020 Vent-away only Lubricant, Nyogel 760G (not furnished with the instrument)

1H3697X0032 14B1930X012 10A3802X012 1H8762X0012 1P714638992 1D687506992 14B1935X012 34B0601X022 34B0612X012 37B2518X012

11B8279X012 14B1559X012 1C3335X0032 1H5137X0012

44B1219X022 24B1376X012 11A8741X052 1E823128982

I/P Assembly 41 169 210*

I/P Converter w/shroud & boots I/P Converter Shroud Boot, nitrile (2 req’d)

34B9710X022

12B4131X012

Parts List Parts which do not show part numbers are not orderable.

Note Parts with footnote numbers shown are available in parts kits. Also see footnote information at the bottom of the page.

Module Base 2 23 24 33 38 39 41 154

Master Module Assembly The following parts are included in the master module assembly. Module Base Assembly Cap Screw, (4 req’d) Relay Module(2) (See Relay listing below) Machine Screw, (3 req’d) Cap Screw, hex socket(3) (4 req’d) O-ring, (2 req’d) I/P Assembly w/shroud & boots Retaining Ring (4 req’d)

14B5071X022

34B3169X012

* Recommended spare 1. Available in the Elastomer Spare Parts Kit 2. Available in the Relay Spare Parts Kit 3. Available in the Small Hardware Spare Parts Kit 6. Available in the DVC5010 to DVC5020 Conversion Kit

May 1998

10-3

DVC5000 Series Key

Description

Part Number

Key 78

Terminal Box 4 44 58 72

164

Terminal Box Cap Wire Retainer, pl stl(3) (2 req’d) Set Screw, hex socket, SST(3) Cap Screw, hex socket, SST(3) For DVC5010, DVC5020, DVC5030 For DVC5040, Inch Metric Terminal Box Assembly For DVC5010, DVC5020, & DVC5030 For DVC5040

34B0567X012 14B3147X012 14B1559X012 1H3697X0032 1L545438992 17B5168X012 34B8797X012 37B8798X012

Relay 24 24L 24M 25 26 31 32 152

Relay Module(2) O-Ring(1, 2) (3 req’d) O-Ring(1, 2) Mach Screw, pan hd(2) (4 req’d) Cap Belleville Spring(2) Washer(2) O-ring, (4 req’d)

34B0583X022

PWB Assembly 50*

PWB Assembly For instrument For instrument For instrument For instrument

level level level level

AC HC SD AD

17B8801X062 17B8801X072 17B8801X082 17B8801X092

80 81 82 83 84

85 86 87 88 89 90 91 92 93 104

107

Pressure Gauges, Pipe Plugs, or Tire Valve Assemblies 47*

Pressure Gauge (2 req’d) PSI/MPA/BAR Gauge Scale Plastic case, brass connection To 25 PSI, 170 kPa, 1.7 bar To 50 PSI, 345 kPa, 3.4 bar To 100 PSI, 690 kPa, 6.9 bar SST case, SST connection To 25 PSI, 170 kPa, 1.7 bar To 50 PSI, 345 kPa, 3.4 bar To 100 PSI, 690 kPa, 6.9 bar PSI/KG/CM 2 Gauge Scale Plastic case, brass connection To 25 PSI, 1.8 kg/cm2 To 50 PSI, 3.5 kg/cm2 To 100 PSI, 7.0 kg/cm2 Pipe Plug, hex hd (2 req’d) Plated steel SST Tire Valve Assembly, pl stl (2 req’d)

160

Alignment Pin(9) For DVC5010, DVC5030 & DVC5040 only Potentiometer and Bushing Assy For DVC5010 & DVC5020 For DVC5030 For DVC5040

10-4

Part Number

Bias Spring, SST(3) For DVC5010, DVC5030, & DVC5040 24B0654X032 Feedback Arm, SST DVC5010 For 513, 513R, 529, 585C, 585CR, 656, 657/30-100, and 667/30-100 37B5270X012 For all sizes 1250 and 1250R 37B5270X022 DVC5040 For 9000/all sizes 34B1929X012 DVC5030 For all sizes 1051, 1052, and 1066SR 34B2179X012 Cap Screw, hex socket, SST(3) 14B6978X012 Square Nut, SST(3) 16A6711X032 Bias Spring, SST(3) DVC5020 only 24B1532X012 Flange Bearing, Rulon(6) DVC5020 only (2 req’d) 13A1592X012 Feedback Arm Assy, SST(6) DVC5020 only For 471, 585, 585R 1051/30-60 and 1052/40-70 14B1557X022 For 1051/33 and 1052/20, 33 14B1377X022 E-ring, pl stl(3) DVC5020 only (2 req’d) 1E455328982 1A498828982 Plain Washer, pl stl(6) DVC5020 only (2 req’d) Follower Post, SST(6) DVC5020 only 13A1656X012 13A1657X012 Roller, SST/PTFE(6) DVC5020 only Spring Lock Washer, pl stl(6) DVC5020 only 1H267228982 Hex Nut, pl stl(6) DVC5020 only 1A839628982 Arm Assy, SST(6) DVC5020 only 14B0659X022 Cap Screw, hex socket(6) DVC5020 only (4 req’d) 1L7325X0012 Torsion Spring, Feedback Arm(6) DVC5020 only 14B1426X012 Cap Screw, hex hd (4 req’d) For DVC5010 only 1A3917X0052 Not for mounting on 1250 and 1250R actuators, see mounting parts below. Mounting Bracket For DVC5010 only 44B0655X022 Not for mounting on 1250 and 1250R actuators, see mounting parts below. Thread Lock, Loctite 242 (not furnished with instrument) Sealant, Torque Seal (not furnished with instrument) Plain Washer, SST 14B6976X012

11B4040X012 11B4040X022 11B4040X032

163

11B4039X012 11B4039X022 11B4039X032

Mounting Parts Type DVC5010 Digital Valve Controller

11B4040X042 11B4040X052 11B4040X062 1D829328982 1D8293X0012 1N908899012

Feedback Parts 46

121

Description

102 103 106 108 109 110 118 119 120 122 126

For Types 513 and 513R, size 20 actuators Shield, polyester Mach Screw, pan hd, pl stl(3) (2 req’d) Adjustment Arm, aluminum/SST Connector Arm, pl stl Mach Screw, hex hd, pl stl Lock Washer, ext, pl stl Spacer, pl stl (2 req’d) Spacer, SST (2 req’d) Cap Screw, hex hd, pl stl (2 req’d) Plain Washer, pl stl (2 req’d) Plain Washer, pl stl

34B1428X012 11A6514X012 24B0651X032 24B8879X012 13A1617X012 14B0698X012 1N254224102 1L759024092 1C870224052 1B865928982 14B4140X012

14B0656X022 14B5070X052 17B4030X012 17B4031X012

May 1998

Parts Key 155 102 103 106 108 109 110 118 119 120 122 126 155 102 103 105

106 108

109 110 126 148

155

156

97 98 99 100 101 102 103 105 106 108

109 110 126 156

162

102 103 104 106

Description Cap Screw, hex hd, pl stl (2 req’d) For Types 513 and 513R, size 32 actuators Shield, polyester Mach Screw, pan hd, pl stl(3) (2 req’d) Adjustment Arm, aluminum/SST Connector Arm, pl stl Mach Screw, hex hd, pl stl Lock Washer, ext, pl stl Spacer, pl stl (2 req’d) Spacer, pl stl (2 req’d) Cap Screw, hex hd, pl stl (2 req’d) Plain Washer, pl stl (2 req’d) Plain Washer, pl stl Cap Screw, hex hd, pl stl (2 req’d) For Types 657 & 667, size 30-60 actuators Shield, polyester Mach Screw, pan hd, SST(3) (2 req’d) Screw, hex flg, SST W/o side-mtd h’wheel (2 req’d) W/side-mtd h’wheel (none req’d) Adjustment Arm, aluminum/SST Connector Arm, stl W/o side-mtd h’wheel W/side-mtd h’wheel Mach Screw, hex hd, SST Lock Washer, ext, pl stl Plain Washer, SST Spacer, pl stl W/o side-mtd h’wheel (none req’d) W/side-mtd h’wheel (2 req’d) For size 34, 40 For size 45–60 Cap screw, hex hd, SST W/o side-mtd h’wheel (none req’d) W/side-mtd h’wheel (2 req’d) For size 34, 40 For size 45–60 Washer, SST W/o side-mtd h’wheel (2 req’d) W/side-mtd h’wheel (none req’d) For Types 657 & 667, size 70-100 actuators Feedback Arm Ext, SST Mach Screw, hex hd, SST Mach Screw, flat hd, SST Hex Nut, SST (2 req’d) Spacer, SST Shield, SST Mach Screw, pan hd, SST(3) (2 req’d) Screw, hex flg, SST (2 req’d) Adjustment Arm, aluminum/SST Connector Arm, stl W/o side-mtd h’wheel W/side-mtd h’wheel Mach Screw, hex hd, SST Lock Washer, ext, pl stl Plain Washer, SST Washer, SST (2 req’d) For 657 size 70 For 657 size 80–100 Lock Washer, split, SST For Types 1250 & 1250R actuators, all sizes and Gulde Model GA and P actuators Shield, polyester Mach Screw, pan hd, pl stl(3) (2 req’d) Cap Screw, hex hd, pl stl (4 req’d) Adjustment Arm, aluminum/SST

Part Number 1B787724052 34B1428X012 11A6514X012 24B0651X032 24B0652X012 13A1617X012 14B0698X012 1N254224102 1L759024092 1C870224052 1B865928982 14B4140X012 1B787724052 34B1428X012 11A6514X022 14B1379X032 ––– 24B0651X032 24B0652X012 32B3526X012 13A1617X022 14B0698X012 14B4140X022 ––– 1J830724092 1F906724092

Key 107 108 109 110 111 112 113 114 115 123 124 125 126 127

84 94 98 100 116 117 162 170 171

172

173 174

1A352538992 1B7877X0012

175

1B8659X0012 –––

176

42B9010X012 12B2922X012 14B6701X012 1A3303X0012 14B1554X012 44B1429X012 1N10183X022 14B1379X032 24B0651X032

203

14B5349X022 1K8995X0022 61000580X12

34B1428X012 11A6514X012 1A3917X0052 24B0651X032

Part Number 44B0224X012 34B0223X012 13A1617X012 14B0698X012 44B0225X012 19A4833X012 10B6605X012 14B0226X012 19A4788X012 10B6633X012 10B6609X012 19A4775X012 14B4140X012 11Y8560R082

Type DVC5020 Digital Valve Controller

–––

22B9008X012 23B9247X012 13A1617X022 14B0698X012 14B4140X022

Description Mounting Bracket, pl stl Connector Arm, pl stl Mach Screw, hex hd, pl stl Lock Washer, ext, pl stl Brace Cap Screw, hex hd, pl stl (2 req’d) Cap Screw, hex hd, pl stl (2 req’d) U-Bolt, pl stl (4 req’d) Hex Nut, pl stl (10 req’d) Plain Washer, pl stl (2 req’d) Plain Washer, pl stl (2 req’d) Cap Screw, hex hd, pl stl Plain Washer, pl stl Lock Washer, pl stl (8 req’d)

116

116 117

For Type 585 and 585R Actuators Feedback Arm Ass’y, SST Cam, SST Machine Screw, hex hd, SST (2 req’d) Hex Nut, SST (2 req’d) Cap Screw, hex socket, pl stl (8 req’d) Mounting Adaptor Lock Washer, SST (2 re’d) Reversing Relay Pipe Bushing, hex (2 req’d) Plated steel SST Pipe Tee Plated steel SST Cap Screw, hex hd, pl stl (2 req’d) Pipe Nipple Plated steel SST Pipe Nipple Plated steel SST Pipe Bushing, hex Plated steel SST Follower Arm Extension, SST For Type 1051, size 30-60 and Type 1052, size 40-70 actuators Cap Screw, hex socket, SST (4 req’d) For Type 1051, size 33 and Type 1052 size 20 & 33 actuators Cap Screw, hex socket, SST (8 req’d) Mounting Adaptor

17B3156X012 27B3157X012 13A1618X022 1A6622X0012 1P7146X0022 44B1220X012 1A3291X0012 15A8804X352 1B6149X0012 1B6149X0032 1C597547362 1P506938982 1C631224052 1C678926232 1P5068X0012 1A385026012 1A3580X0012 1E253726232 1E2537K0012 17B3158X012

1P714638992

1P714638992 44B1220X012

Type DVC5030 Digital Valve Controller 104 107 140

142 144 145 198 204 104 107

For Types 1051, size 30-60 and Type 1052, size 40-70 actuators Cap Screw, hex head, SST (4 req’d) Mounting Bracket Ass’y, stl/SST Washer, pl stl (4 req’d) For 1051 size 30–40 & 1052 size 40 For 1051 size 60 & 1052 size 60–70 Travel Indicator Scale, SST Travel Indicator Ass’y, SST Machine Screw, pan hd, SST (2 req’d) Plain Washer, SST (2 req’d) Hex Nut, SST (2 req’d) For Type 1051 and 1052, size 33 actuators Cap Screw, hex hd, SST (4 req’d) Mounting Bracket Ass’y

1B2905X0012 34B9501X012 1H723125072 1A518925072 24B2183X012 24B2178X012 59061180X12 61000350X12 1A3303X0012 1B2905X0012 34B9503X012

3. Available in the Small Hardware Spare Parts Kit.

May 1998

10-5

DVC5000 Series Key 140 141 142 144 145 191 198 199 204 104 107 141 142 144 145 191 198 204 104 107 140

141

142 144 145

198 199

204

Description Washer, pl stl (4 req’d) Spacer, pl stl Travel Indicator Scale, SST Travel Indicator Ass’y, SST Machine Screw, pan hd, SST (2 req’d) Cap Screw, hex hd, pl stl (4 req”d) Plain Washer, SST (2 req’d) Washer, pl stl (2 req’d) Hex Nut, SST (2 req’d) For Type 1052, size 20 actuators Cap Screw, hex hd, SST (4 req’d) Mounting Bracket Ass’y stl/SST Spacer, pl stl Travel Indicator Scale, SST Travel Indicator Ass’y, SST Machine Screw, pan hd, SST (2 req’d) Cap Screw, hex hd, pl stl (4 req”d) Plain Washer, SST (2 req’d) Hex Nut, SST (2 req’d) For Type 1066SR actuators Cap Screw, hex hd, SST (4 req’d) Mounting Bracket Ass’y Washer, pl stl (4 req’d) For size 20 For size 27 For size 75 Spacer, pl stl For sizes 20 & 27 For size 75 Travel Indicator Scale, SST Travel Indicator Ass’y, SST Machine Screw, pan hd, SST (2 req’d) For sizes 20 & 27 For size 75 Plain Washer, SST (2 req’d) Washer, pl stl For sizes 20 & 27 (2 req’d) For size 75 (none req’d) Hex Nut, SST (2 req’d)

Part Number 1B865928982 17B1702X012 24B2183X012 24B2178X012 13B9244X012 1A381624052 61000350X12 1K261028992 1A3303X0012 1B2905X0012 34B9502X012 17B1701X012 24B2183X012 24B2178X012 59061300X12 1A353124052 61000350X12 1A3303X0012 1B2905X0012 34B9503X012 1B865928982 1H723125072 1A518925072 17B1703X012 17B1710X012 24B2183X012 24B2178X012 14B2026X012 14B2027X012 61000350X12 1K261028992 ––– 1A3303X0012

Type DVC5030 Digital Valve Controller on Other Actuators 177 178 179 180 181 182 184 185 186 187 188 177 178 180 182 184 187 189 190

To replace Masoneilan positioners Emulator, steel Positioner Plate, steel Shaft Connector, pl stl Coupler, SST Connector Cap Ass’y, stl/SST Spacer, pl stl (3 req’d) Cap Screw, SST (3 req’d) Cap Screw, SST Cap Screw, SST (2 req’d) Cap Screw, SST (4 req’d) Machine Screw, SST (2 req’d) To replace Neles-Jamesbury positioners Emulator, steel Positioner Plate, steel Coupler, SST Spacer, pl stl (3 req’d) Cap Screw, SST (3 req’d) Cap Screw, SST (4 req’d) Cap Screw, SST (3 req’d) Tie Bar Ass’y, SST

37B2821X012 37B2819X012 27B2804X012 17B2810X012 17B3929X012 17B2806X012 17B2807X012 17B2978X012 1P714638992 1A391738992 17B2808X012 37B2811X012 37B2817X012 17B2810X012 17B2814X012 17B2815X012 1A391738992 1C2752X0042 27B2816X012

Key 205 206 207

177 178 180 182 184 187 189 205 206 207

Description Screw, self-tapping, pl stl Pointer, nylon Scale, plastic For clockwise rotation opens valve For clockwise rotation closes valve To replace PMV positioners Emulator, steel Positioner Plate, steel Coupler, SST Spacer, pl stl (3 req’d) Cap Screw, SST (3 req’d) Cap Screw, SST (4 req’d) Cap Screw, SST (2 req’d) Screw, self-tapping, pl stl Pointer, nylon Scale, plastic For clockwise rotation opens valve For clockwise rotation closes valve

Part Number 12B6373X012 22B6372X012 27B3853X012 27B3854X012 37B2821X012 37B2819X012 17B2810X012 1R793424492 17B2822X012 1A391738992 1C2752X0042 12B6373X012 22B6371X012 27B3906X012 27B3907X012

Cam 94 95 94 95 94 95

For DVC5020 only For Type 1051, size 30-60 and 1052, size 40-70 actuators Cam, SST Mach Screw, hex hd, SST (2 req’d) For Type 1052, size 20 actuators Cam, SST Mach Screw, hex hd, SST (2 req’d) For Type 1051 and 1052, size 33 actuators Cam, SST Mach Screw, hex hd, SST (2 req’d)

33A1613X022 13A1618X022 36A4653X022 13A1617X022 30B1529X022 13A1617X022

Filter Regulator Mounting Parts 59 60* 61 61 69 70 71 59 61 161 59 60* 61 69 70 71 161

For use only when filter regulator is specified. For Integral Mounting Cap Screw, hex hd, SST (2 req’d) O-Ring, nitrile Pipe Plug, hex socket, SST For Casing Mounting Pipe Plug, hex socket, SST Hex Nut, pl stl (2 req’d) Cap Screw, hex hd, pl stl (2 req’d) Mounting Bracket, pl stl For Yoke Mounting Cap Screw, hex hd, SST (2 req’d) Pipe Plug, hex socket, SST For Wall Mounting Pipe Nipple, galv stl For Universal Mounting Cap Screw, hex hd, SST (2 req’d) O-Ring, nitrile Pipe Plug, hex socket, SST Hex Nut, pl stl (2 req’d) Cap Screw, hex hd, pl stl (2 req’d) Mounting Bracket Pipe Nipple, galv stl

1C3988X0022 1E591406992 1C3335X0012 1C3335X0012 1A352724122 1C197024052 1F401225072 1C3988X0022 1C3335X0012 1C678926232 1C3988X0022 1E591406992 1C3335X0012 1A352724122 1C197024052 1F401225072 1C678926232

* Recommended spare

10-6

May 1998

Parts

C B

SECTION A-A

SECTION B-B

SECTION C-C

APPLY LUB, SEALANT 43B8444-J / DOC SHT 1 OF 2 SHT 2 OF 2

Figure 10-1. Type DVC5010 Digital Valve Controller Assembly

Key

Description

Part Number

HART Filters HF100, HART Filter HF210, cage clamp, normal polarity HF210, cage clamp, reverse polarity

May 1998

14B1934X012 17B1181X012 17B1182X012

Key

Description HF220, screw terminal, normal polarity HF220, screw terminal, reverse polarity HF230, tiered terminal HF240, DIN rail mount HF240, DIN rail Mount, pass through (no filter)

Part Number 17B1184X012 17B1185X012 17B1186X012 17B1187X012 17B1188X012

10-7

DVC5000 Series

C B

SECTION A-A

SECTION B-B

SECTION C-C

APPLY LUB, SEALANT 43B8446-J / DOC SHT 2 OF 3

Figure 10-2. Type DVC5020 Digital Valve Controller Assembly

10-8

May 1998

Parts

B B

SECTION A-A

SECTION B-B

APPLY LUB, SEALANT 44B3158-D / DOC SHT 1 OF 2 SHT 2 OF 2

Figure 10-3. Type DVC5030 Digital Valve Controller Assembly

May 1998

10-9

DVC5000 Series

SECTION A-A A

10 APPLY LUB, SEALANT

SECTION B-B

47B0907-C / DOC SHT 2 OF 2

Figure 10-4. Type DVC5040 Digital Valve Controller Assembly

APPLY LUB, SEALANT 47B8444-J / DOC SHT 2 OF 2

DVC5000 SERIES WITH TIRE VALVES

DVC5000 SERIES WITH PIPE PLUGS

Figure 10-5. Typical DVC5000 Series Digital Valve Controller with Tire Valves and Pipe Plugs

10-10

May 1998

Parts TYPE HF210 HART FILTER

HART COMMUNICATION WIRE PAIR

PLUG TERMINATING HART COMMUNICATION WIRE PAIR

W6599 / IL

TYPE HF230 HART FILTER

FIELD INSTRUMENT CONNECTION

W6601 / IL

Figure 10-6. Type HF210 HART Filter Mounted on Control System Cage–Clamp Style Termination

FIELD INSTRUMENT CONNECTION

Figure 10-8. Type HF230 HART Filter Mounted on Control System Two–Tier–Screw–Terminal (Staggered) Termination

CONTROL SYSTEM CONNECTION HART COMMUNICATION WIRE PAIR

HART COMMUNICATION CONNECTION

TYPE HF220 HART FILTER

FIELD INSTRUMENT CONNECTION PLUG TERMINATING HART COMMUNICATION WIRE PAIR W6600 / IL

Figure 10-7. Type HF220 HART Filter Mounted on Control System Single–Row–Screw–Terminal Style Termination

May 1998

FIELD INSTRUMENT CONNECTION W6493*/ IL

Figure 10-9. Type HF240 HART Filter (DIN Rail Mount)

10-11

DVC5000 Series

10-12

May 1998

Loop Schematics 11-11

Section 11 Loop Schematics This section includes loop schematics required for wiring of intrinsically safe installations. If you have any questions, contact your Fisher Controls sales

representative or sales office.

CSA Schematics

24B8244-C SHT 2 DOC

CSA Schematic Sheet 1

May 1998

11-1

DVC5000 Series CSA Schematics (continued)

24B8244-A SHT 3 / DOC

CSA Schematic Sheet 2

24B8244-A SHT 4 / DOC

11-2

CSA Schematic Sheet 3

May 1998

Loop Schematics CSA Schematics (continued)

24B8244-B SHT 5 / DOC

CSA Schematic Sheet 4

May 1998

11-3

DVC5000 Series FM Schematics

FM Schematic Sheet 1 24B8243-B SHT 1 OF 2 / DOC

24B8243-B SHT 2 OF 2 / DOC

11-4

FM Schematic Sheet 2

May 1998

Glossary L-L-

Glossary Alert Point An adjustable value that, when exceeded, activates an alert.

Algorithm A set of logical steps to solve a problem or accomplish a task. A computer program contains one or more algorithms.

Alphanumeric

Byte A unit of binary digits (bits). Usually a byte consists of eight bits.

Calibration Location Where the instrument was last calibrated; either in the factory or in the field.

Configuration Stored instructions and operating parameters for a FIELDVUE Instrument.

Consisting of letters and numbers.

Control Loop Analog Input Units Units in which the analog input is displayed and maintained in the instrument.

ANSI (acronym) The acronym ANSI stands for the American National Standards Institute

ANSI Class Valve pressure/temperature rating.

Auxiliary Input Alert Checks the status of the auxiliary input; a discrete input. When enabled, the Auxiliary Input Alert is active when the auxiliary input terminals are closed (shorted).

Auxiliary Terminal (Indicator) Indicates whether auxiliary wiring terminals are open or closed (such as by an external switch contact).

Bench Set Pressure, supplied to an actuator, required to drive the actuator through rated valve travel. Expressed in pounds per square inch. May 1998

An arrangement of physical and electronic components for process control. The electronic components of the loop continuously measure one or more aspects of the process, then alter those aspects as necessary to achieve a desired process condition. A simple control loop measures only one variable. More sophisticated control loops measure many variables and maintain specified relationships among those variables.

Control Mode Defines where the instrument reads its set point. The following control modes are available for a FIELDVUE Instrument: RSP (Remote Set Point) The instrument receives its travel set point over the 4â&#x20AC;&#x201C;20 mA loop. COM and SUPV work the same. COM Computer SUPV Supervisory AUTO (Automatic) The instrument receives its set point digitally, via the HART communications link. MAN (Manual) DDC (Direct Digital Control) The instrument receives its set point digitally, via the HART communications link.

Control Mode, Restart Determines the instrument control mode after a restart. See Control Mode for the available restart control modes.

Glossary-1

Glossary

DVC5000 Series Controller A device that operates automatically to regulate a controlled variable.

Crossover Point The mid-point of the stroking range of a sliding-stem actuator. A visual indication of the crossover point is found when the slot in the instrument feedback arm forms a 90-degree angle with the valve stem.

Device ID Unique identifier embedded in the instrument at the factory.

Drive Signal The signal to the I/P converter from the printed wiring board. It is the percentage of the total microprocessor effort needed to drive the valve fully open. In most applications, drive signal ranges from 55% to 75% in the active travel range. The drive signal may be higher or lower at the travel end points.

Current-to-Pressure (I/P) Converter An electronic component or device that converts a milliamp signal to a proportional pneumatic pressure output signal.

Cycle Counter The capability of a FIELDVUE instrument to record the number of times the travel changes direction. The change in direction must occur after the deadband has been exceeded before it can be counted as a cycle.

Drive Signal Alert Checks the drive signal and calibrated travel. If one of the following conditions exists for more than 20 seconds, the Drive Signal Alert is active. If none of the conditions exist, the alert is cleared. If Zero Control Signal = Closed The alert is active when: drive signal <10% and calibrated travel >3% drive signal >90% and calibrated travel <97% If Zero Control Signal = Open

Cycle Counter Alert Checks the difference between the Cycle Counter and the Cycle Counter Alert Point. Cycle Counter Alert is active when the cycle counter value exceeds the Cycle Counter Alert Point. It clears after you reset the Cycle Counter to a value less than the alert point.

Glossary

Cycle Counter Alert Point An adjustable value which, when exceeded, activates the Cycle Counter Alert. Valid entries are 0 to 4 billion cycles.

The alert is active when: drive signal <10% and calibrated travel <97% drive signal >90% and calibrated travel >3%

Equal Percentage A valve flow characteristic where equal increments of valve stem travel produce equal percentage changes in existing flow. One of the input characteristics available for a FIELDVUE Instrument. See also, Linear and Quick Opening.

Factory Instrument Serial Number Cycle Counter Deadband Region around the travel reference point, in percent of ranged travel, established at the last increment of the Cycle Counter. The deadband must be exceeded before a change in travel can be counted as a cycle. Valid entries are 0% to 100%. Typical value is between 2% and 5%.

Deviation Usually, the difference between set point and process variable. More generally, any departure from a desired or expected value or pattern.

Glossary-2

The serial number assigned to the printed wiring board by the factory that cannot be changed.

Feedback Arm The mechanical connection between the valve stem linkage and the FIELDVUE Instrument travel sensor.

Feedback Characteristic Identifies to the FIELDVUE Instrument if the feedback signal is coming from a rotary or sliding-stem valve. May 1998

Glossary Feedback Signal Indicates to the instrument the actual position of the valve. The travel sensor provides the feedback signal to the instrument printed wiring board assembly. A mechanical linkage connects the travel sensor to the valve stem or shaft.

HART Universal Revision Revision number of the HART Universal Commands which are the communications protocol for the instrument.

Input Characteristic Field Instrument Serial Number The serial number assigned to the printed wiring board by the factory but can be changed during setup. The field instrument serial number should match the serial number on the instrument nameplate.

Firmware Revision The revision number of the instrument firmware. Firmware is a program that is entered into the instrument at time of manufacture and cannot be changed by the user.

The relationship between the ranged travel and ranged input. Possible values include: linear, equal percentage, and quick opening.

Input Current The current signal from the control system that serves as the analog input to the instrument. See also Input Signal.

Input Filter Time The time constant, in seconds, for the first-order input filter.

Input Range The analog input signal range that corresponds to the travel range.

Input Signal Full Ranged Travel Current, in mA, that corresponds with the point where ranged travel is maximum, i.e., limited by the mechanical travel stops.

The current signal from the control system. The input signal can be displayed in milliamperes or in percent of ranged input.

Glossary

Instrument Level Gain The ratio of output change to input change.

Hardware Revision Revision number of the Fisher Controls instrument hardware. The physical components of the instrument are defined as the hardware.

HART (acronym) The acronym HART stands for Highway Addressable Remote Transducer.

HART Tag An eight-character name that identifies the physical instrument. May 1998

Determines the functions available for the instrument. See table 7-1, page 7-3.

Instrument Mode Determines if the instrument responds to its analog input signal. There are two instrument modes: In Service: For a fully functioning instrument, the instrument output changes in response to analog input changes. Typically changes to setup or calibration cannot be made when the instrument mode is In Service. Out of Service: The instrument output does not change in response to analog input changes when the instrument mode is Out of Service. Some setup parameters can be changed only when the instrument mode is Out of Service.

Glossary-3

DVC5000 Series Instrument Protection Determines if commands from a HART device can calibrate and/or configure certain parameters in the instrument. There are three types of instrument protection: Configuration and Calibration: Prohibits changing protected setup parameters; prohibits calibration. Configuration: Prohibits changing protected setup parameters; permits calibration. None: Permits both configuration and calibration. The instrument is â&#x20AC;?unprotected.â&#x20AC;?

Menu A list of programs, commands, or other activities that you select by using the arrow keys to highlight the item then pressing ENTER, or by entering the numeric value of the menu item.

Interface Revision Revision number of the interface software that permits communication between the HART Communicator and the instrument.

Minimum Closing Time Minimum time, in seconds, for the travel to decrease through the entire ranged travel. This rate is applied to any travel decrease. Valid entries are 0 to 400 seconds. To deactivate, enter a value of 0 seconds.

Invert Feedback Establishes feedback orientation. While viewing the end of the travel sensor shaft, if increasing air pressure to the actuator causes the shaft to rotate clockwise, invert feedback is YES. If increasing air pressure causes the shaft to rotate counterclockwise, invert feedback is NO.

Minimum Opening Time Minimum time, in seconds, for the travel to increase through the entire ranged travel. This rate is applied to any travel increase. Because of friction, actual valve travel may not respond in exactly the same time frame. Valid entries are 0 to 400 seconds. To deactivate, enter a value of 0 seconds.

Leak Class

Glossary

Defines the allowable leakage by a valve when it is closed. Leak class numbers are listed in two standards: ANSI/FCI 70-2-1991 and IEC 534-4 (1986).

Linear A valve flow characteristic where changes in flow rate are directly proportional to changes in valve stem travel. One of the input characteristics available for a FIELDVUE Instrument. See also, Equal Percentage and Quick Opening.

Parallel Simultaneous: said of data transmission on two or more channels at the same time.

Polling Address Linearity, dynamic Linearity (independent) is the maximum deviation from a straight line best fit to the opening and closing curves and a line representing the average value of those curves.

Glossary-4

Address of the instrument. If the digital valve controller is used in a point-to-point configuration, set the polling address to 0. If it is used in a multidrop configuration, or split range application, set the polling address to a value from 0 to 15. May 1998

Glossary Pressure Sensor A FIELDVUE instrument internal device that senses the output pressure from the pneumatic relay.

Primary Master Masters are communicating devices. A primary master is a communicating device permanently wired to a field instrument. Typically, a computer running ValveLink VL2000 Series software is the primary master. In contrast, a secondary master is not often permanently wired to a field instrument. The Model 275 HART Communicator or a computer running ValveLink software communicating through a HART modem could be considered a secondary master. Note: If one type of master takes an instrument Out Of Service, the same type must put it In Service. For example, if a device set up as a primary master takes an instrument Out Of Service, a device set up as a primary master must be used to place the instrument In Service.

Quick Opening A valve flow characteristic where most of the change in flow rate takes place for small amounts of stem travel from the closed position. The flow characteristic curve is basically linear through the first 40 percent of stem travel. One of the input characteristics available for a FIELDVUE Instrument. See also, Equal Percentage and Linear.

Random Access Memory (RAM) A type of semiconductor memory that is normally used by the microprocessor during normal operation that permits rapid retrieval and storage of programs and data. See also Read Only Memory (ROM) and Non-Volatile Memory (NVM).

Rate Amount of change in output proportional to the rate of change in input.

Read-Only Memory (ROM) A memory in which information is stored at the time of instrument manufacture. You can examine but not change ROM contents. May 1998

Seat Load Force exerted on the valve seat, typically expressed in pounds force per lineal inch of port circumference. Seat load is determined by shutoff requirements.

Stroking Time The time, in seconds, required to move the valve from its fully open position to fully closed, or vice versa.

Temperature Sensor A device within the FIELDVUE instrument that measures the instrumentâ&#x20AC;&#x2122;s internal temperature.

Travel Movement of the valve stem or shaft which changes the amount the valve is open or closed.

Travel Accumulator The capability of a FIELDVUE instrument to record total change in travel. The value of the Travel Accumulator increments when the magnitude of the change exceeds the Travel Accumulator Deadband. To reset the Travel Accumulator, set it to zero.

Travel Accumulator Alert Checks the difference between the Travel Accumulator value and the Travel Accumulator Alert Point. The Travel Accumulator Alert is active when the Travel Accumulator value exceeds the Travel Accumulator Alert Point. It clears after you reset the Travel Accumulator to a value less than the alert point.

Travel Accumulator Alert Point An adjustable value which, when exceeded, activates the Travel Accumulator Alert. Valid entries are 0% to 4 billion %.

Glossary-5

Glossary

DVC5000 Series Travel Accumulator Deadband Region around the travel reference point established at the last increment of the accumulator. This region must be exceeded before a change in travel can be accumulated. Valid entries are 0% to 100%.

Travel Alert Checks the ranged travel against the Travel Alert High and Low Points. The travel Alert is active if either the high or low point is exceeded. Once a high or low point is exceeded, the ranged travel must clear that point by the Travel Alert Deadband before the alert clears. Two travel alerts are available: Travel Alert 1 and Travel Alert 2.

Travel Deviation Alert Checks the difference between the target and the ranged travel. If the difference exceeds the Travel Deviation Alert Point for more than the Travel Deviation Time, the Travel Deviation Alert is active. It remains active until the difference is less than the Travel Deviation Alert Point.

Travel Deviation Alert Point An adjustable value for the target travel and the ranged travel difference, expressed in percent, When this value is exceeded by the travel deviation for more than the Travel Deviation Time, the Travel Deviation Alert is active. Valid entries are 0% to 100%. Typically this is set to 5%.

Travel Deviation Time Travel Alert Deadband Travel, in percent of ranged travel, required to clear a travel alert, once it is active. Valid entries are –25% to 125%.

Travel Alert High Point Value of the travel, in percent of ranged travel, which, when exceeded, sets the Travel Alert High alert. Valid entries are –25% to 125%.

Travel Alert Low Point

Glossary

Value of the travel, in percent of ranged travel, which, when exceeded, sets the Travel Alert Low alert. Valid entries are –25% to 125%.

Travel Cutoff Defines the cutoff point for the travel, in percent of ranged travel. There are two travel cutoffs: high and low. Once travel exceeds the cutoff, the drive signal is set to either maximum or minimum, depending on the Zero Control Signal and if the cutoff is high or low. Minimum opening time or minimum closing time are not in effect while the travel is beyond the cutoff. Use the travel cutoff to obtain the desired seat load or to be sure the valve is fully open.

The time, in seconds. that the travel deviation must exceed the Travel Deviation Alert Point before the alert is active. Valid entries are 1 to 60 seconds.

Travel Limit A setup parameter that defines the maximum allowable travel (in percent of ranged travel) for the valve. During operation, the travel target will not exceed this limit. There are two travel limits: high and low. Typically the travel limit closed will be used to keep the valve from going completely closed.

Travel Range Travel, in percent of calibrated travel, that corresponds to the input range.

Travel Sensor A device within the FIELDVUE instrument that senses valve stem or shaft movement. The travel sensor is mechanically connected to the valve stem or shaft.

Tuning The adjustment of control terms or parameter values to produce a desired control effect.

Tuning Set Travel Deviation The difference between the analog input signal (in percent of ranged input), the “target” travel, and the actual “ranged” travel.

Glossary-6

Preset values that identify gain and rate settings for a FIELDVUE instrument. The tuning set and supply pressure together determine an instrument’s response to input signal changes. May 1998

Glossary Watch Dog Timer A timer that the microprocessor must recycle periodically. If the microprocessor is unable to recycle the timer, the instrument shuts down.

Zero Control Signal A setup parameter that determines whether the valve is fully open or fully closed when the input signal is 0%.

Glossary

May 1998

Glossary-7

DVC5000 Series Notes

Glossary

Glossary-8

May 1998

Index M-M-

Index A Alert Record Clearing, 5-14 Displaying, 5-14, 7-4 Enabling Alert Groups, 5-15 Alerts Displaying Alert Status, 7-4 Enabling Auxiliary Input, 5-14 Cycle Counter, 5-13 Drive Signal, 5-14 Travel Accumulator, 5-13 Travel Alerts 1 & 2, 5-12 Travel Deviation, 5-13 Analog Calibration Adjust, 6-4 Analog Input Calibration, 6-2 Displaying Value, 7-2

Communication Cable Capacitance, 2-27 Connections Electrical 4 to 20 mA Loop, 2-23 Communication, 2-25 Test, 2-24 Pneumatic Output, 2-23 Supply, 2-23 Vent, 2-23 Control Mode, 5-4 Control System Requirements Compliance Voltage, 2-25 HART Filter, 2-25 Voltage Available, 2-25 Cycle Counter Displaying Value, 7-2 Enabling Alert, 5-13 Resetting, 5-14

Analog Input Units, 5-8 Auto Calibrate Travel, 6-3 Error Messages, 4-7 Auxiliary Input Displaying Status, 7-2 Enabling Alert, 5-14

D Date, 5-6 Descriptor, 5-6 Device Information, 7-3 Digital Calibration Adjust, 6-4

B Burst Mode Commands, 5-4 Enabling, 5-4

Index

Drive Signal Displaying Value, 7-2 Enabling Alert, 5-14 DVC5000 Series Description, 1-2 Principle of Operation, 8-2 Specifications, 1-3

Dynamic Bypass, 5-10

Calibration Analog Input, 6-2 Auto Calibrate Travel, 6-3 Manual Calibrate Travel, 6-4 Pressure Sensor, 6-6 Travel Sensor, 6-6

May 1998

Factory Instrument Serial Number, 5-6 Fairchild Model 25463 Spring Adjustment, 2-14

Index-1

DVC5000 Series Feedback Characteristic, 5-7 Field Instrument Serial Number, 5-6 Free Time Displaying Value, 7-2 Self Test Failure, enabling to cause instrument shutdown, 5-15

Replacing, 9-7 Initial Setup, 4-2 Auto Calibrate Travel, 4-6 Auto Setup, 4-3 Factory Default Settings, 4-3 Manual Setup, 4-4 Stabilize/Optimize, 4-7 Input Characteristic, 5-9

G Gauges, Tire Valves, & Pipe Plugs Parts List, 10-4 Replacing, 9-10

Input Filter Time, 5-9 Input Range, 5-8 Instrument Clock, Setting, 5-14 Instrument Level, 7-3 Instrument Mode, 4-2, 5-3

13 Index

Instrument Supply Pressure, 5-7

HART Communication, Principle of Operation, 8-2

Internal Temperature Displaying Value, 7-2 Self Test Failure, enabling to cause instrument shutdown, 5-15

HART Communicator Action Keys Down Arrow Key, 3-2 Hot Key, 3-3 Left Arrow, Previous Menu Key, 3-2 On/Off Key, 3-2 Right Arrow, Select Key, 3-2 Up Arrow Key, 3-2 Alphanumeric & Shift Keys, 3-3 Device Description Revision, 3-5 Display, 3-2 Dynamic Labels, 3-2 Offline Menu, 3-4 Online Menu, 3-5 Online Simulation, 3-5 Polling, 3-4 Software Defined Keys, 3-3 Specifications, 3-2 System Information, 3-4 HART Filter Part Numbers, 10-7 Use & Specifications, 2-27 HART Tag, 5-6 Hot Key, HART Communicator, 3-3

Invert Feedback, 5-7

L Loop Schematics CSA, 11-1 FM, 11-4

M Manual Calibrate Travel, 6-4 Manual Conventions, 1-2 Master Module Parts List, 10-3 Removal, 9-5 Replacing, 9-6 Message, 5-6 Minimum Closing Time, 5-10 Minimum Opening Time, 5-10 Mode Switches, Setting, 9-8

I I/P Converter Clearing the Primary Orifice, 9-7 Parts List, 10-3 Removal, 9-7

Index-2

Mounting, 2-3 67AF, 2-22 DVC5010 on: 1250 & 1250R, 2-6 513 & 513R, 2-3 529, 2-7 657 & 667, 2-4 May 1998

Index Bauman Actuators, 2-7 Gulde Actuators, 2-8 DVC5020 on: 1051 &1052, 2-9 471, 2-11 585 & 585R, 2-13 DVC5030 on: 1051 Size 30 to 60, 2-16 1051 Size 33, 2-15 1052 Size 20 & 33, 2-15 1052 Size 40 to 70, 2-16 1066SR Sizes 20, 27 & 75, 2-17 DVC5030 to replace: Masoneilan 4600, 2-17 Nelesâ&#x20AC;&#x201C;Jamesbury NE600, NP600, NE700 & NP700, 2-18 PMV P1200, P1250 & P2000, 2-19 DVC5040 on:, System 9000, 2-20

O Operationals, 7-4 Output Pressure, Displaying Value, 7-2

P Parts Cam, 10-6 Common Parts, 10-3 Feedback Parts, 10-4 Gauges, Tire Valves, & Pipe Plugs, 10-4 HART Filters, 10-7 I/P Assembly, 10-3 Kits, 10-3 Module Base, 10-3 Mounting Parts DVC5010, 10-4 DVC5020, 10-5 DVC5030 On Fisher Actuators, 10-5 On Other Actuators, 10-6 Filter Regulator, 10-6 Ordering, 10-3 Printed Wiring Board Assembly, 10-4 Relay, 10-4 Terminal Box, 10-4 Pneumatic Relay Parts List, 10-4 Removing, 9-8 Replacing, 9-9 Polling Address, 5-6 May 1998

Pressure Sensor Calibration, 6-6 Pressure Units, 5-8 Printed Wiring Board Assembly Parts List, 10-4 Removing, 9-8 Replacing, 9-8 Setting Mode Switches, 9-8 Protection, 4-2, 5-4

R Related Documents, 1-3 Restart Control Mode, 5-4 Restarting the Instrument, 5-4

S Self Test Failures Displaying Status, 7-4 Enabling to cause instrument shutdown, 5-15 Serial Number Factory Instrument, 5-6 Field Instrument, 5-6 Instrument Nameplate, 5-6 Valve, 5-6 Setup Wizard, 4-3 Stabilize/Optimize, 4-7 Stroking the Output Manually, 9-3 with HART Communicator, 9-3

13 Index

T Temperature Units, 5-8 Terminal Box Parts List, 10-4 Removing, 9-10 Replacing, 9-10 Travel, Displaying Value, 7-2 Travel Accumulator Displaying Value, 7-2 Enabling Alert, 5-13 Resetting, 5-13 Travel Cutoffs, 5-11 Travel Limits, 5-11

Index-3

DVC5000 Series Travel Range, 5-11 Travel Sensor Adjusting DVC5010, 6-6 DVC5020, 6-7 DVC5030 On Fisher Actuators, 6-6 On Other Actuators, 6-8 DVC5040, 6-6 Displaying Counts, 7-3 Parts List, 10-4 Removing DVC5010, 9-11 DVC5020, 9-11 DVC5030, 9-11 DVC5040, 9-11 Replacing DVC5010, 9-11 DVC5020, 9-13 DVC5030, 9-14 DVC5040, 9-11 Self Test Failure, enabling to cause instrument shutdown, 5-15 Troubleshooting, 9-3

Tuning Set, 5-8

V Valve Serial Number, 5-6 Voltage Available Calculating, 2-25 Checking, 9-3

W Wiring Practices Communication Cable Capacitance, 2-27 Control System Requirements, 2-25 Compliance Voltage, 2-25 HART Filter, 2-25 Voltage Available, 2-25

Z Zero Control Signal, 5-7

13 Index

Index-4

May 1998

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. Fisher-Rosemount satisfies all obligations coming from legislation to harmonise product requirements in the European Union. 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. 1994, 1998; All Rights Reserved

For information, contact Fisher Controls: Marshalltown, Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 128461

Printed in U.S.A.