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SHELL PETROLEUM DEVELOPMENT COMPANY OF NIGERIA LIMITED EASTERN DIVISION ASSOCIATED GAS GATHERING PROJECTS PROJECT TITLE CAWTHORNE CHANNEL ASSOCIATED GAS GATHERING PROJECT CONTRACT No E- 08966 DOCUMENT CATEGORY TECHNICAL MANUAL DOCUMENT TITLE
TECHNICAL MANUAL: CONTROL VALVES

DOCUMENT NUMBER AWGP MA G 0027
CONTRACTOR DETAILS NAME Job No: CONTRACTOR : SUBCONTRACTOR : VENDOR : DAEWOO Mott MacDonald 62813
Procedure No:
Rev.
Rev No.
Date
Description
Author
Reviewed By.
Approved By.
SPDC Review
External Review
R1 A1
Oct. 03 Nov. 03
Issued for Review Issued for Approval
Vendor Vendor
A.Polain A.Polain
C.Gamblin C.Gamblin
This document contains information which is proprietary to Shell Petroleum Development Company of Nigeria Ltd. (SPDC). This information is to be held in confidence. Disclosure, reproduction, or other use of this document is prohibited without the prior written consent of SPDC.
SUMMARY OF REVISION HISTORY
Rev. No. R1 A1
Date Oct. 2003 Nov. 2003
Section or Pages, Revised -
Description of Change Issued for Comment Issued for Approval
AWGP-MA-G-0027
CONTROL VALVES
SPDC TECHNICAL MANUAL INDEX

PART 1 - LEADING PARTICULARS Equipment Tags AWGP-27LCV-012 AWGP-27LCV-015 AWGP-27LCV-019 AWGP-27LCV-025 AWGP-27PCV-019 AWGP-27PCV-029 AWGP-28PCV-061 AWGP-45PCV-031A AWGP-45PCV-031B AWGP-27PCV-009 AWGP-26PCV-084 AWGP-45FCV-003 AWGP-35PCV-007
Assembly details as below USER NOTE: CLICK ON THE RELEVANT BOX TO GO TO MANUFACTURERS DATA
Dresser Item No.
S-348730-1 S-348730-2 S-348730-3 S-348730-4 S-348730-5 S-348730-6 S-348730-7 S-348730-9 S-348730-10 S-348730-11 S-348730-12 S-348730-13 S-348730-15
Tag No.
27LCV-012 27LCV-015 27LCV-019 27LCV-025 27PCV-019 27PCV-029 28PCV-061 45PCV-031A 45PCV-031B 27PCV-009 26PCV-084 45FCV-003 35PCV-007
Model
88-41621 88-21124 88-21124 88-21114 38-41655 38-41655 87-41615 87-21714 88-21914 88-41635 88-41625 88-41655 88-21124
Body
EH3020 EH1080 EH1080 EH1080 EH3600 EH3600 EH3600 EH1080 EH1080 EH3600 EH3600 EH3600 EH1080
Actuator
ER8788 ER8788 ER8788 ER8788 ER3000 ER3000 ER8788 ER8788 ER8788 ER8788 ER8788 ER8788 ER8788
Positioner
5445 5445 5445 5445 5445 5445 5445 5445 5445 EW2000 5445 5445 5445
Air Filter Regulator

5144 5144 5144 5144 5144 5144 5144 5144 5144 5144 5144 5144 5144
Lock-Up Valve
Volumn Booster
ES0400 ES0400 ES0400 ES0400
Versa Valve
ES0400 EY7725 ES0400
VSP2301
ES0400 ES0400
Supply Requirements Performance Data Supplier
See Data Sheets by clicking on Matrix above See Data Sheets by clicking on Matrix above Dresser Flow Control 11100 West Airport Blvd Stafford TX 77477-3014 USA Tel: Fax: Website: 281-568-2211 281-568-1414 www.dresser.com
PO Number
DN38-2020
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AWGP-MA-G-0027
CONTROL VALVES

APPENDIX - TECHNICAL DATA 9.1 Body Type 21000 Globe EH1080 Table of Contents Introduction Installation Body Disassembly Maintenance/Repair Valve Body Reassembly Actuators
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AWGP-MA-G-0027
CONTROL VALVES

APPENDIX - TECHNICAL DATA (cont.) 9.2 Body Type 41000 Cage Guide Globe EH3020E Maintenance Parts Reference Trim Maintenance Plug Stem Adjustment
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AWGP-MA-G-0027
CONTROL VALVES

APPENDIX - TECHNICAL DATA (cont.) 9.3 Body Type 41000 Globe EH3600 Table of Contents Numbering System Disassembly Maintenance - Repair Valve Reassembly Actuator Parts Reference
4 of 12
AWGP-MA-G-0027
CONTROL VALVES

APPENDIX - TECHNICAL DATA (cont.) 9.4 Actuator 37/38 Spring Diaphragm Type ER3000E Maintenance Parts Recommended spare parts
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AWGP-MA-G-0027
CONTROL VALVES

APPENDIX - TECHNICAL DATA (cont.) 9.5 Actuator 87/88 Spring Diaphragm Type ER8788 Actuator Description Actuator Removal Maintenance Actuator Range Air Action Changes Actuator Installation on Valve Body and Plug Stem Adjustment Parts Spring Arrangement
6 of 12
AWGP-MA-G-0027
CONTROL VALVES

APPENDIX - TECHNICAL DATA (cont.) 9.6 Fieldvue Positioner DVC5000f Form 5445 Introduction Installation Initial Setup and Calibration Detailed Setup Calibration Viewing Device Information Principals of Operation Maintenance Parts Loop Schematics Function Block Overview Analog Output (AO) Function Block PID Function Block Discrete Input (DI) Function Block Discrete Output (DO) Function Block DD Installation Operation with Fisher-Rosemount DeltaV Block Parameter Index
7 of 12
AWGP-MA-G-0027
CONTROL VALVES

APPENDIX - TECHNICAL DATA (cont.) 9.7 SVI Positioner EW2000 Overview Mounting Operation - SVI Positioner Operation - SVI Controller Troubleshooting
8 of 12
AWGP-MA-G-0027
CONTROL VALVES

APPENDIX - TECHNICAL DATA (cont.)
9.8 Air Filter Regulators 67AF/67AFR Form 5144 Installation Startup and Adjustment/Shutdown/Maintenance Parts
9 of 12
AWGP-MA-G-0027
CONTROL VALVES

9.9 Air Lockup Valves 77-6 EY7725 Installation/Adjustment/Maintenance Parts
10 of 12
AWGP-MA-G-0027
CONTROL VALVES

9.10 Volume Booster Relays BR200/BR400 ESO400 Features Principals of Operation Flow Characteristics Installation/Operation Maintenance/Troubleshooting
11 of 12
AWGP-MA-G-0027
CONTROL VALVES

9.11 Versa Valve VSP2301 How to Select Versa Valve Actuating Devices 2-Way Valves 2/2
12 of 12
Complete Line of Rugged, Top Guided, Globe Valves with Lo-dBVAnti-Cavitation CapabiIities
flow Control
Instruction No EH 1080-04/02 21000 Series Valves
TABLE OF CONTENTS
I.
INTRODUCTION ............
.......
....2
3.
4. 5.
6.
............................................................................ 2 UNPACKING ................... ........... ......3

INSTALLATION ........................................................................... AIR PIPING ............. ............................... BODY DISASSEMBLY ................................................................
8. VALVE BODY REASSEMBLY ......................... 8.1 THREADED TRIM .....................................
3 3
6.1 THREADED TRIM ............. ....................................... ....................................... 6.2 QUICK-CHANGE TRIM ..... 7. MAINTENANCE/REPAIR .............................
3 4 4 4
8.2 QUICK-CHANGE TR ................................................. 10 8.3 HIGH PRESSURE & 9. ACTUATORS ............................................................................. 10 9.1 TYPES 87/88 ACTUATORS .......... .... 10
10. BELLOWS SEAL ASSEMBLY .................................................. 10
7.1 THREADED SEAT RING REMOVAL..................................... 4 7.2 BUSHING REMOVAL ............................................................ 4 7.3 LAPPING SEATS .................................................................. 4 7.3.1 THREADED TRIM ....................................................... 5 7.3.2 QUICK-CHANGE TRIM ............................................... 5 7.4 LO-dB PLUG .......................................................................... 6 7.5 PLUG STEM PINNING .......................................................... 6 7.6 PACKING BOX ...................................................................... 7 7 7.6.1 KEVLAR/PTFE PACK. RING (STANDARD) ................ 7.6.2 EXPANDED GRAPHITE P. RING (OPTION) ............... 7 7 7.6.3 LE PACKING (LOW EMISSION) (OPTION) ................ 7.7 SOFT SEAT PLUG ................................................................ 9
10.1 BELLOWS VALVE DISASSEMBLY .......16 10.1.1 THREADED TRIM ................................................. 16 10.1.2 QUICK-CHANGE TRIM ......................................... 16 10.2 REPAIR.............................................................................. 16 10.2.1 PLUG /STEM BELLOWS / BONNET EXTENSION SIA ................................... 16 10.3 PLUG AND SEAT RING SEATING SURFACES ................ 18 10.4 BONNET REASSEMBLY ................................................... 18 10.5 ACTUATOR TO BODY S/A AND PLUG STEM ADJUSTMENT ............................................. I8
1. Introduction
The following instructions should be thoroughly reviewed and understood prior to installing, operating or performing maintenance on this equipment. Throughout the text, safety andlor caution notes will appear and must be strictly adhered to, otherwise, serious injury or equipment malfunction could result. Masoneilan has a highly skilled After Sales Department available for start-up, maintenance and repair of our valves and component parts. Arrangements for this service can be made through your local Masoneilan Representative or After Sales Department. When performing maintenance use only Masoneilan replacement parts. Parts are obtainable through your local Masoneilan Representative or Spare Parts Department. When ordering parts, always include Model and Serial Number of the unit being repaired.
A series of reduced area trim is available to provide wide flow range capabilities in all valve sizes
Tight Shutoff Class IV leakage is standard. Optional constructions (one of which is the 21600 Series soft seat plug) meet IEC 534-4 and ANSVFCI 70.2 Class V and VI requirements. An optional Low Emission LE@Packing is available to assure compliance with the fugitive emission containment requirements. Replacing the conventional plug with the single stage Lo-dB design (21700 Series) provides excellent noise attenuation or anti-cavitation performance. The 21800 Series double stage anti-cavitation valve is derived from the 21 700 single stage anti-cavitation valve through a modification to the cage and plug. Substitution of the standard cage with an anti-cavitation cage permits the pressure drop to be split between the two stages efficiently. The 21900 Series double stage Lo-dB@ valve is also derived from the 21700 single stage Lo-dB valve through a modification to the cage and plug. Substitution of the standard cage, with a Lo-dB cage permits the pressure drop to be split between the two stages efficiently. In the 21800/21900 Series designs, enlargement of the plug head up to the cage diameter permits simultaneous throttling the plug Cv and the cage C" It also provides optimum tion of the pressure drop between the two stages along the entire plug travel.
2. General
These installation and maintenance instructions apply to all sizes and ratings of the Masoneilan 21 000 Series control valves regardless of the type of trim used.
21000 Series single ported top guided control valves are designed with built in versatility making them well-suited to handle a wide variety of process applications.
Standard construction offers a contoured plug (21100 Series) with a threaded seat ring or a quick change seat ring. The heavy top plug guiding provides maximum support to ensure plug stability.
Flow Control
Instruction No EH 1080-04/02 21 000 Series Valves
Plug Type
87 88 Spring Diaphragm Air to Close Spring Diaphragm Air to Open
0. 1. 6. 7.
Control Characteristic
0. Undefined 1. Linear 2. Equal Percentage
r
Seat Type
0. Undefined 4. Quick change 5. Threaded
Optional Configuration
Undefined Contoured Soft Seat Single Stage Lo-dB@/ Anti-cavitation 8. Double Stage Anti-cavitation 9. Double Stage Lo-dB@
A Angle Body BS Bellows

I
Figure 1 - Numbering System
Recommended spare parts required for maintenance are listed n the Parts Reference table on page 14. The model number, size, rating and serial number of the valve are shown on the identification tag located on the actuator. Refer to Figure 1 for the 21000 series numbering system.
4.4 For heat-insulated installation, do not insulate the valve bonnet. Take necessary protective measures relate to personal safety.
5. Air Piping
The actuators are designed to accept 1/4" NPT air supply piping. Use 1/4" OD tubing (4 x 6 mm) or equivalent for all air lines. If the supply air line exceeds 25 feet in length (7 meters) or if the valve is equipped with volume boosters, then 3/8" tubing (6 x 8 mm) is preferred. All connections must be free of leaks.
3. Unpacking
Care must be exercised when unpacking the valve to prevent damage to the accessories and component parts. Should any problems arise, contact the local Masoneilan Representative or After Sales Department.
4. Installation
4.1 Before installing the valve in the line, clean piping and valve of all foreign material such as welding chips, scale, oil, grease or dirt. Gasket surfaces should be thoroughly cleaned to insure leak-proof joints. 4.2 To allow for in-line inspection, maintenance or removal of the valve without service interruption, provide a manually operated stop valve on each side of the 21000 Series valve with a manually operated throttling valve mounted in the by-pass line (See Figure 2). 4.3 The valve must be installed so that the controlled substance will flow through the valve in the direction indicated by the flow arrow located on the body.
Caution : Do not exceed supply pressure indicated on serial plate located on the yoke of the actuator.
6. Body Disassembly
Access to the internal components of the body should be accomplished with the actuator removed. To remove the actuator from the body, refer to the actuator instruction No ER8788 for a type 87/88 multispring actuator.
Caution : Prior to performing maintenance on the valve, isolate the valve and vent the process pressure. Shut off the supply air line and the pneumatic or electric signal line.
With contoured plug (21100/21600) : flow-to-open or Lo-dB plug (21700/21900) On anti-cavitationdesign (21700/21800) : flow-to-close
Instruction No EH 1080 -04/02 21000 Series Valves
6.1 Threaded Trim (Figure 12 or 14)

After removing the actuator, disassemble the body using the following procedure :
A. If there is a leak detector connection on the lateral NPT port of the bonnet, disconnect this piping as well. B. Remove body stud nuts (10).
F. Remove plug (16) and plug stem (1) sub-assembly from the bonnet (8). Caution: Care must be taken to avoid damage to the plug and plug guide.
C. Remove bonnet (8), and plug stem (1) and plug (16) sub-assembly together as one unit.
Note: Spiral wound body gaskets (1 1) are standard in the 21000 Series design and it is imperative that a new gasket be installed each time the valve is disassembled.
D. Remove packing flange stud nuts (3),packing flange (4) and packing follower (5). E. Remove plug (16) and plug stem (1) sub-assembly from the bonnet (8).
G. Remove old packing (6) [and optional lantern ring (7) if a leak detection connection has been installed]. Refer to Figure 5.
H. All components may now be inspected for wear and service damage. After determining the maintenance required, proceed to the appropriate Section of this instruction manual.
7. Maintenance & Repair

The purpose of this section is to provide recommended maintenance and repair procedures. These procedures assume the availability of standard shop tools and equipment.
Caution: Care must be taken to avoid damage to the plug and plug guide. F. Remove old packing (6) [and optional lantern ring (7) if a leak detection connection has been installed]. Refer to Figure 5.
G. Bonnet (8), plug (16), bushing (12) and seat ring (14) may now be inspected for wear and service damage. After determining the maintenance required, proceed to the appropriate Section of this instruction manual.
7.1 Threaded Seat Ring Removal (Figure 12 or 14)

Threaded seat rings (14) are installed tightly by the manufacturer, and after years of service they may be difficult to remove.
To facilitate removal, seat ring wrenches can be fabricate to engage the seat ring lugs and adapted to a standard wrench. If the seat ring is exceptionally resistant to removal, the application of heat or penetrating oil should be helpful.
6.2 Quick-Change Trim (Figure 13 or 15)

After removing the actuator, disassemble the body using the following procedure:
A. If there is a leak detection connection on the lateral NPT port of the bonnet, disconnect this piping as well. B. Remove body stud nuts (10)
Caution : When using heating devices, insure that proper safety practices are observed. Flammability and toxicity of the process fluid must be considered and proper precautions taken.
7.2 Bushing Removal

The bushing (12) is press fit into the bonnet and does not normally require replacement. If necessary, it may be pulled or machined out. When machining the bushing out, care must be taken to maintain proper dimensions and tolerances in the bonnet. These will be furnished upon request.
C. Remove bonnet (8), and plug stem (1) and plug (16) sub-assembly together as one unit.
D. Since the cage (13), seat ring (14) and seat ring gasket (15) are held in place by the bonnet, they may now be removed.
7.3 Lapping Seats

Lapping is the process of working the valve plug against the seat ring with an abrasive to produce a close fit. If valve leakage is excessive, lapping becomes necessary. The plug and seat ring seating surfaces should be free of large scratches or other defects, and the contact surfaces of the seats should be as narrow as possible. This may require dressing both parts in a lathe. The seating surface angle of the plug is 28 degrees and the seat ring is 30 degrees (relative to the centerline axis). A good grade of fine grinding compound is required fo the lapping operation.
Note : Spiral wound gaskets (1 1 & 15) are standard in the 21000 Series design and it is imperative that new gaskets be installed each time the valve is disassembled.
E. Remove packing flange stud nuts (3),packing flange (4) and packing follower (5).
Flow Control
Instruction No EH 1080- 04/02 21000 Series Valves
The compound should be mixed with a small quantity of lubricant such as graphite. This will slow the cutting rate and prevent tearing of the seating surfaces. The amount of lapping required depends on the materials, condition of seating surfaces, and accuracy of machining. If a short period of lapping does not visibly improve seating, there is usually no advantage in continuing as excessive lapping may result in rough seats. The only remedy is replacement or re-machining of one or both parts. When lapping new plugs and seat rings, begin with a medium fine (240 grit) and finish with a finer grade (600 grit).
Caution: Avoid over-lapping as this can cause damage to the seating surface rather than improve leakage performance.
10.After completion of the lapping operation, remove bonnet and plug. The seating area of the seat ring and the plug must be cleaned of all lapping compound in preparation for reassembly. Do not remove seat ring.
7.3.2 Quick-Change Trim (Figure 13 or 15)

1. Clean body gasket surface areas.
Note : Lapping should produce a line contact area, not the entire surface, due to the difference in seat angles. Caution : Before lapping, the plug and stem sub-assembly must be concentric. (Seepinning operation, section 7.5). 7.3.1 Threaded Trim (Figure 12 or 14)
1. Clean body gasket surface areas. 2. When seat has been removed, insure that the sealing surface in the body bridge and the threads are thoroughly cleaned.
2. Install a new seat ring gasket (15) and insert seat ring (14) in the body.
Note: Gasket (15) is temporarily placed to hold the seat ring during lapping. I t i s imperative t o use a new gasket or a test part having the same geometrical characteristics in order to insure the correct position of the seat ring during lapping. This gasket (or similar part) can be kept after lapping for future use.
The gasket used for lapping must not be reused for the body reassembly. 3. Apply lapping compound at several spots equally spaced around the seating area of the seat ring.
4. Insert the cage (13) into the body. 5. Insert the stem and plug sub-assembly carefully into the body until it is seated.
Note: A sealant compatible with the process should be applied sparingly to the seat ring threads and sealing shoulder.
3. Install and tighten seat ring using fabricated wrench used for removal. Caution: Do not over-tighten. Do not strike seat ring lugs directly. This could distort the seat ring resulting in seat leakage.
4. Apply lapping compound on the plug at several spots
equally spaced around the seating area.

5. Insert the stem and plug sub-assembly carefully into the body until it is seated.
6. Place bonnet (8) on the body.
6. Place bonnet (8) on the body and fasten the bonnet to the body using four body stud nuts (10) spaced equally apart. Apply slight pressure and tighten evenly.
Caution : Insure that the seat ring (14), cage (13) and bonnet (8) are properly aligned. 7. Fasten the bonnet to the body using four body stud nuts (10) spaced equally apart. Apply slight pressure and tighten evenly. Caution: Do not tighten nuts to final torque specifications at this time. The bonnet is used temporarily for guiding purposes only.
8. Insert two or three pieces of packing into the packing box to assist in guiding the stem and plug during lapping. 9. Screw a drilled and tapped rod with a T-handle onto the plug stem and secure with a locknut (see Figure 4). Note: As an alternative, drill a hole through a flat steel plate and fasten to the plug stem using two locknuts. 10.Apply slight pressure on the stem, and rotate the stem in short oscillating strokes (around 8 to 10 times). Repeat this step as necessary.
Caution : Do not tighten nuts to final torque specifications at this time. The bonnet is used temporarily for guiding purposes only. 7. Insert two or three pieces of packing (6) into the packing box to assist in guiding the stem and plug during lapping.
8. Screw a drilled and tapped rod with a T-handle onto the plug stem and secure with a locknut (see Figure 4). Note: As an alternative, drill a hole through a flat steel plate and fasten to the plug stem using two locknuts. 9. Apply slight pressure on the stem, and rotate the stem in short oscillating strokes (around 8 to 10 times). Repeat this step as necessary. N o t e : The plug should be lifted and turned 90" each time before repeating Step (9). This intermittent lifting is required to keep the plug and seat ring concentric during lapping.
N o t e : The plug should be lifted and turned 90" each time before repeating Step (10). This intermittent lifting is required to keep the plug and seat ring concentric during lapping.
11.After completion of the lapping operation, remove bonnet and internal parts. The seating area of the seat ring and the plug must be cleaned of all lapping compound in preparation for reassembly.
If the plug guide area has a center mark, Place the plug guide on a V-block and use a suitable drill size to either: - Match the hole size in the plug, or
- Match Diameter C (see Figure 9)
Drill through the plug-stem assembly. If the plug guide area does not have any hole or any center mark,
- Measure Dimension D based on the plug guide diameter
7.4 Lo-dB@ Plug (Figure 8, 14 or 15)

The procedures used for performing maintenance on a valve equipped with Lo-dB plugs (21700/21800/21900 Series) are the same as those used for Threaded or Quick Change Trim.
~
and stem diameter (see Figure 9).

- Place the plug guide on a V-block, and make a center
Caution : Maintenance of the plug should be limited to cleaning of the ports and the procedures defined under Sections 7.3 (Lapping) and 7.5 (Pinning) as required.
mark on the plug guide area using a center punch.

-
Drill through the plug-stem assembly using a suitable size drill bit.
7.5 Plug Stem Pinning

Plug stem pinning in the field may be required for the following:
- Replacing existing plug and stem, or
In all cases after drilling : Remove any burrs from the plug guide hole by making a slight chamfer.
D. Pinning the Plug-Stem Assembly 1. Select the correct size pin based on the plug guide diameter and stem diameter (see Figure 9). Apply a small amount of grease on the pin and hand assemble it into the hole in the plug.
Replacing existing stem only
Replacing Plug and Stem

If it is necessary to replace the plug, then the plug stem must be replaced at the same time. The original pin hole in an existing stem will not provide the necessary fit, and might seriously impair the strength of the assembly.
A. Reference Marking on the Plug Stem
2. Press fit the pin into the hole using a hammer. Complete the pinning operation by taking care to ensure that the pin is recessed by the same amount at both sides (see Figure 9).
4 -
3. After the plug has been pinned, it should be placed in a

lathe to insure it is concentric with the stem.
If the assembly is not running true, then the stem should be placed in a collet with the plug guide against it and the plug should be adjusted. Alignment of plug stem can be performed by means of a soft faced mallet.
Measure the depth of the pilot recess in the plug (Dimension X in Figure 9), and make a reference mark on the plug stem at the same distance from the thread. Note: While pinning is being performed, care must be taken not to damage the seating surface or plug guide. Always use a soft metal or plastic vice jaws with cylindrical features to hold the plug guide area (see Figure 9). 6. Screwing Stem to Plug Hold the plug (with vise jaw assembly) in a vise. Lock two nuts against each other on the end of the new plug stem, and screw the stem solidly into the plug using a wrench on the upper nut. When properly assembled, the reference mark (see Section A above) should be flush with the end of the plug guide.
C. Drilling the New Parts
Replacing Existing Stem Only

A. Removing Existing Pin and Stem
1. Place the plug guide on a V-block and use a drift punch to drive out the old pin.
Note: If it is necessary to drill out the pin, use a drill bit slightly smaller than the pin diameter.
2. Hold the plug guide in a vise (see note on opposite side of page).
3. Lock one nut against another at the end of the plug

stem. Using a wrench on the lower nut, unscrew the stem from the plug. The stem is removed by turning it counterclockwise.
If the plug is already fully drilled (typical for 440 C hardened stainless steel material or solid stellite), then drill the stem to the same diameter (Diameter C in Figure 9) as the plug shank hole.
Flow Control
B. Screwing Stem to Plug

Refer to step B of the previous section on REPLACING PLUG AND STEM.
Note: On valves equipped with an optional lubricator connection, refer to Figure 10 for correct amount of rings to place under the lantern ring (7).
E. Replace packing follower (5) and packing flange (4).

F. Replace and tighten packing stud nuts (3).
C. Drilling the New Stem

Place the plug guide on a V-block and use a suitable size drill bit to drill the stem (use the hole in the plug as a guide). Note: If the hole in the plug guide has been slightly damaged while removing the old pin, choose a drill bit and a pin with a slightly larger diameter than the normal pin.
D. Pinning
(Caution:Do not overtiahten.

G. Place valve back in service and only tighten packing as necessary to stop external leakage.
Note: In an emergency; string packing may be used as a temporary repair only. It must be replaced with the correct packing as soon as possible.
Select the correct size pin based on the plug guide diameter and pin hole diameter. Proceed as described in part D of the previous section, taking care not to damage the plug guide area. Ensure plug stem alignment following the pinning operation.
7.6.2 Flexible Graphite Rings (Optional See Figure 6)
7.6 Packing Box (Figures 12 to 15)

Packing box maintenance is one of the principle action items of routine servicing. Tightness of the packing is maintained by packing compression. Compression is achieved by evenly tightening the packing flange nuts (3) against the packing flange (4). Care must be taken not to over tighten as this could prevent smooth operation of the valve. If all compression is used up and the valve leaks, then new packing is required.
Note : Flexible graphite packing rings replacement may require disconnecting the plug stem from the actuator stem and removal of the actuator if rings are not skive cut.
A. Remove actuator from the body S/A. Refer to actuator instruction No ER8788 for a type 87188 actuator. B. Loosen and remove packing flange nuts (3).
C. Remove packing flange (4) and packing follower (5) from the plug stem.
D. By means of a hooked instrument, remove packing (6) ensuring not to damage the sealing surfaces of the packing box or plug stem.
Caution : Valve must be isolated and the pressure vented before performing packing box maintenance.
Proceed as follows :
Note: On valves equipped with an optional lubricator connection, the lantern ring (7) must also be removed to gain access to lower packing rings.
E. Replace new packing set (6); first assemble a back-up ring (Graphite Filament Yarn braided ring), then the flexible graphite rings (smooth rings), and finally another braided back-up ring (refer to Figure 6).
7.6.1 Kevlar/PTFE Rings (Standard) (Figures 12 to 15)

Note: The Kevlar/PTFE packing rings have a skive cut allowing packing replacement without disconnecting the plug stem from the actuator connector or actuator stem.
Note: Assemble and compress rings one at a time into packing box. Note: On valves equipped with an optional lubricator connection, refer to Figure 10 for correct arrangement according to valve size.
F. Assemble packing follower (5) and packing flange (4).
A. Loosen and remove packing flange nuts (3).

B. Lift the packing flange (4) and packing follower (5) up the valve stem.
Note: They may be taped in place to keep them out of the way before proceeding.
G. Assemble and tighten packing stud nuts (3).
]Caution: Do not overtighten.

H. Proceed to appropriate instructions for actuator and valve assembly adjustment. 1.
C. By means of a hooked instrument, remove packing (6) insuring not to damage the sealing surfaces of the packing box or plug stem.
Note: On valves equipped with an optional lubricator connection, the lantern ring (7) must also be removed to gain access to lower packing rings.
Place valve back in service and only tighten packing as necessary to stop external leakage.
7.6.3 LE@ Packing (Optional - See Figure 7)

The Masoneilan LE (Low Emissions) Packing is a high performance packing system capable of containing fugitive emissions well below the specifications of the most severe recommendations. It is also available in a firesafe configuration.
D. Replace packing rings (6).

Note: Assemble and compress rings one at a time into packing box. The skive cut of each packing ring must be placed about 120 degrees apart.
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Instruction No EH 1080 -04102 21000 Series Valves
The packing is provided as a set of five pieces. It consists of two adapter rings and three V-rings. An alternating pattern of Perfluoroelastomer (PFE) and long carbon fiber filled Teflon (PTFE) V-rings are used. Applied properly, this packing exhibits very little cold flow (or creep). Consequently, it can effectively prevent fugitive emissions leaks from a control valve. The LE Packing system can directly replace conventional packing, requiring no modification to the control valve or actuator. A spring loaded, two-piece follower assembly is used to maintain a constant load on the packing, and is necessary for thermal cycling applications. As the definition of thermal cycling can vary, and processes are potentially subject to unpredicted thermal gradients, LE Packing is only available with the spring loaded follower. Installation should be performed as detailed in the following paragraphs. 7.6.3.1 Preparation 7.6.3.1.1 Stem Inspect stem for any nicks or scratches on the surface finish. Reject the stem for any of these reasons as they may damage packing. Note: A properly etched part number on the stem in the packing area will have no adverse effect on the performance of the packing. Stem finish should be 3-7 AARH (Ra0,1/0,2). 7.6.3.1.2 Packing Box Note: Bonnets that have a lube hole are unacceptable for use with the packing arrangement shown in Figure 7. Packing box should be clean and free of burrs, rust, and any foreign matter. Parts can be cleaned with denatured alcohol. Note: Packing box finish should be 125 AARH , 2 )or better. (Ra 3 The packing box may be bored or honed oversize by up to 0.015" (0.38 mm) above the nominal diameter to improve the finish. For instance, a nominal 0.875" (22.22mm) packing box may be bored or honed up to 0.890" (22.60mm) and the LE Packing will still seal properly. Packing box must be finished to the bottom of the bore. 7.6.3.1.3 Packing Inspect packing rings. Do not use packing if any nicks or scratches on packing are observed. Check packing and ensure that it is in the proper arrangement (see Figure below). PFE material can be identified by the gloss black molded finish. PTFE material has a dull black machined finish. 7.6.3.2 Packing Installation a. The packing must be lubricated with Krytox@ fluori nated grease prior to installation (Krytox GPL206 or equivalent). b. Packing should be lubricated as a set (not individually) to minimize getting lubricant between the rings. c. Packing should be lubricated with a generous application to the O.D. and I.D. of the packing set. Note : All exposed surfaces of the packing set must be covered with the lubricant. d. PFE/PTFE is to be installed as a set. Carefully slide the packing set down the stem. Do not cock or force the packing on the threads.
If the packing set separates while on the stem, do not remove. Continue installing the remaining pieces to put the set back together.
7.6.3.1.4 Spring Loaded Follower The spring loaded follower consists of an upper and lower follower and eight (8) disc springs (see Figure below). The springs are installed inside the lower follower and positioned alternately. The assembly is held together by tape, which must be removed before installation.
e. Gently press the packing into the packing box. Do not tap the packing down into the box.
f. The spring loaded follower is installed on top of the packing. This follower is installed as an assembly held together by tape. This tape should be removed after assembly. Proper assembly of the packing box will leave the top of the Lower Follower 0.25 - 0.50 inches (6 to 13 mm) above the bonnet.
A groove is scribed into the O.D. of the upper follower. The packing flange is tightened evenly until the top of the Lower Follower aligns with the scribe mar (groove) in the Upper Follower.
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Note: This is the optimum loading for this packing. Further tightening will shorten life of the packing. Thread locking compound can be used on packing nuts. For 3" - 6" valves:
a. Apply a light coat of lubricant to the O-ring and install on insert retainer. Caution: Insure any lubricant used is compatible with service conditions.
b. Install new insert on insert retainer and assemble as shown in Figure 3.
g. The packing should be checked for leakage. h. Packing load should be checked after the valve has cycled approximately 500 times. Adjust if necessary. No further adjustment should be required for the life of the packing.
7.7 Soft Seat Plug (Figure 3)

The soft seat plug used in the 21000 Series valve has a replaceable insert. To remove and replace the insert, proceed as follows.
c. Install plug tip into insert retainer sub-assembly insuring the plug tip seats evenly on the insert.
F. Carefully place the plug sub-assembly into a soft jaw vise, holding the plug by the flats provided on the upper end of the shank.
Caution: The shank OD is the plug guide. Extreme care must be taken to prevent scoring or marring this surface. Failure to do so could result in damage to the guide bushing and destruction of the plug. Two flats are provided for holding.
Caution: When using a vise to hold extreme care must be taken not to damage the plug shank. G. Using the appropriate tool used during disassembly, firmly tighten the plug tip. Caution: The plug tip must be tightened, allowed to set for approximately 4 hours, re-tightened, allowed to set another 4 hours, then tightened one more time. The purpose of this tightening sequence is to allow the insert material to "cold flow" into place on the plug sub-assembly.
H. Following the above tightening sequence, securely tighten the set screw down into the plug. Plug is ready for assembly into the valve.
A. Loosen set screw until the head of the set screw is flush with the OD of the shank.
Note : On 3/4"- 2" size valves, the plug tip has a machined slot into which a bar can be inserted for removal. On 3"-6" size valves, the plug tip has two machined holes into which a tool (fabricated with appropriate size pins) can be inserted for removal.
B. Carefully place plug sub-assembly into a soft jaw vise, holding the plug by the flats provided on the upper end of the shank.
Caution: When using a vise to hold the plug, extreme care must be taken not to damage the plug shank.
C. Using the appropriate tool, unscrew plug tip (counterclockwise) from the shank sub - assembly.
8. Valve Body Reassembly

After completion of the required maintenance, the valve should be reassembled using the following procedures: Note: If any of the following steps were completed during maintenance, then proceed to the next step.
D. Remove insert O-ring (for valve sizes 3"- 6" only) and insert retainer. Discard existing insert and O-ring.
E. Thoroughly clean all remaining metallic components and install new insert and O-ring as follows (according to valve size):
8.1 Threaded Trim (Figure 12 or 14)

A. Clean all gasket mating surfaces. B. Apply a small amount of sealant to the seat ring threads and sealing shoulder. Install seat ring into valve body.
For 3/4"- 2" valves :
a. Place new insert on shank and insert retainer as shown in Figure 3.

b. Install plug tip into shank sub-assembly. Hand tighten and insure plug tip seats evenly against insert.
Note: A sealant compatible with the process should be applied sparingly. C. Install and tighten seat ring using wrench used for removal.
Caution: Do not over-tighten. Do not strike seat ring lugs directly. This could distort the seat ring resulting in unwarrantedseat leakage.
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D. Carefully install plug and stem assembly.
Note: Valve should be lapped before final assembly. See Section 7.3.
E. Install body gasket (11).

Note: Spiral wound body gaskets (1 1) are standard in the 21000 Series design. It is imperative that a new gasket be installed each time the valve is disassembled.
(Cageshould be installed with parts at lower end, nea seat ring. Tighten nuts (10) unil metal to metal contact is obtained with proper bolt torque. Refer to Figure 11 for proper bolt torque and tightening sequence specifications. G. Insert packing (6) [and lantern ring (7) on valve equipped with an optional lubricator connection]. Refer to Section 7.6 for proper packing assembly procedure for standard or optional designs. H. Install packing follower (5) and packing flange (4).
1.
F . Assemble bonnet (8) and body stud nuts (10). Bonnet must be positioned so the packing flange studs are at 90 to the flow center line. Caution: Tighten n u t s (10) until metal to metal contact is obtained with proper bolt torque. Refer t o Figure 11 for proper bolt torque and tightening sequence specifications. G. Insert packing (6) [and lantern ring (7) on valve equipped with an optional lubricator connection]. Refer to Section 7.6 for proper packing assembly procedure for standard or optional designs. H. Install packing follower (5) and packing flange (4).
1. Install packing flange stud nuts (3).
Install packing flange stud nuts (3).
[Caution: Do not overtiahten (See Section 7.6. Packinn BOX").^ ~_____

J. If a leak detection connection was installed, connect it on the lateral NPT port in the bonnet. If not, insure that the 114 NPT plug remained in place (Figure 5).
K. For actuator assembly and plug stem adjustment, proceed to the actuator instruction No ER8788 for a type 87/88 multispring actuator.
8.3 High Pressure & Angle Design (Figures 16 & 17)

Standard trim is used within these optional body tions. Refer to the applicable sections within this instruction manual.
ICautian: Do not overtighten (See Section 7.6. Packing Box)./

J. If a leak detection connection was installed, connect it on the lateral NPT port in the bonnet. If not, insure that the 114 NPT plug remained in place (Figure 5).
K. For actuator assembly and plug stem adjustment, proceed to the actuator instruction No ER8788 for a type 87/88 actuator.
9. Actuators
9.1 Types 87/88 Actuators
Refer to Instruction No ER 8788 for removal, maintenance, assembly and adjustment.
8.2 Quick-Change Trim (Figure 13 or 15)

A. Clean all gasket mating surfaces. B. Install seat ring gasket (15) and seat ring (14).
Note: Spiral wound gaskets (1 I & 15) are standard in the 21000 Series design. It is imperative that a new gasket be installed each time the valve is disassembled.
10. Bellows Seal Assembly

Caution: SINCE THIS IS A SEALING BELLOWS, THE PLUGSTEMSHOULDNEVERBETURNEDUNDERANY CIRCUMSTANCES. There is a built-in anti-rotation feature, consisting of a double flat surface machined on the plug stem that slides into a rectangular slot machined in the upper bushing (30) of the bellows (see figure 19 Section a).
C. Install cage (13).

D. Carefully install plug and stem assembly.
Note: Valve should be lapped before final assembly. See Section 7.3.
E. Install body gasket (11). F. Assemble bonnet (8) and body stud nuts (10) and tighten. Bonnet must be positioned so the packing flange studs are at 90 to the flow center line. Caution: Care must be taken to ensure that the cage, seat, and bonnet are property aligned in the body.
IT IS IMPORTANT TO DISCONNECT THE ACTUATOR FROM THE VALVE BEFORE CHANGING THE ACTUATOR ROTATIONAL POSITION.
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c-
10
Figure 2
- Typical Installation
3/4"-
2" Valve Sizes
3"- 6" Valve Sizes
Figure 3
- Soft Seat Plugs (Optional)
Figure 4
- Seat Lapping Device
Figure 5
- Lubricator Connection (Optional)
Figure 6
- Flexible Graphite Rings Arrangement (Optional)
Figure 7 LE" (Low Emission) Packing Arrangement (Optional)
Figure 8 Lo-dB (Type 21900) and Anti-cavitation (Type 21800) Double Stage Trim (Optional)
11
C Dia.
Cylindrical machining
Figure 9 Plug Stem Pinning
c
Packina box with Kevlar/PTFE packing rings Br Back-
Packina box with Flexible GrapGte packing rings and Back-up rings
Figure 10 Packing Ring Arrangements with Optional Lubricator Connection
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12
Instruction No EH 1080-04/02 21 000 Series Valves
Assembly Torque Requirements
150
150 & 300

600
5/8"-11NC-2A
1"-8NC-2A
12 12
45 125
132
560
18 75
10 45
1.3
6
17
Notes: 1. Do not exceed Maximum Torque values listed. 2. Tighten in increments until required torque levels are reached. 3. Reject assembly if metal-to-metal contact is not achieved after reaching Maximum Torque. 4. Torque requirements shown are for standard 87 studs and 2H nuts.
Bellows Bonnet Assembly Torque Requirements
1/2"-13NC-2A 5/8"-11NC-2A
8 8
20 25
30 55
5 10
0.7
5 5
0.7 0.7
1.3
Notes: 1. Do not exceed Maximum Torque values listed. 2. Tighten in increments noted until required torque levels are reached. 3. Torque requirements shown are for standard 87 studs and 2H nuts.
,
Figure 11 Bolting Torques and Tightening Sequence
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Figure 12 Threaded Seat Ring Contoured Plug Full Capacity
Figure 13 Quick Change Trim Contoured Plug Full Capacity
0 0 @ 0
@
@ @
63 0 0
Figure 14 Threaded Seat Ring Lo-dB Plug
Figure 15 Quick Change Trim Lo-dB Plug
PARTS RI -ERENCE
Ref.
D
PartName
Plug Stem Packing Flange Stud Packing Flange Stud Nut Packing Flange Packing Follower Packing Lantern Ring (optional)
Ref.
8 9 10 011 12 013 014
Part Name
Bonnet Body Stud Body Stud Nut Body Gasket Plug Guide Bushing (Incl. w/ref. 8) Cage Seat Ring
3ef.
0 15 016
Part Name
Seat Ring Gasket Plug Plug Pin Body Drive Nut
1 2 3 4 5 6 7
017
18 19
0 Recommended spare parts
* Only on Quick Change Trim
14
Figure 16 21000 Series 314" to 2" Valve Sizes ANSI Class 900 to 2500
Figure 17 Angle Body Design 314" to 6" Valve Sizes ANSI Class 150 to 600 314" to 2" Valve Sizes ANSI Class 900 to 2500
15
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10.1 Bellows Valve Disassembly (Figure 19)

Note: Spiral wound flexitallic gaskets are standard in the
21000 BS Series design. IT IS RECOMMENDED THAT NEW GASKETS ARE INSTALLED EACH TIME THE VALVE IS DISASSEMBLED.
10.2.1 Plug/Stem Bellows/Bonnet Extension S/A

Plug stem pinning in the field may be required for: Replacing existing plug and stem-bellows S/A Replacing stem-bellows S/A only If the plug needs replacing, the stem-bellows sub-assembly should be replaced at the same time.
10.1.1 Threaded Trim

After removing the actuator, disassemble the body S/A using the following procedure: Disconnect the leak-off circuit from the bonnet (if this option is included). Remove nuts (27) and bonnet studs (26) from the bonnet (25). Remove packing flange stud nuts. (3), packing flange (4) and packing follower (5). Remove bonnet (25). Remove existing packing (6). Remove body stud nuts (10). Remove bonnet extension (29), stem bellows S/A (30) and plug (16) at the same time. Remove the plug pin (17), then remove the plug (16) from the plug stem (30). (See section 10.2.1.1 for unpinning the plug stem). Remove stem bellows S/A (30) by the top of the bonnet extension (29). If necessary, disengage the upper bushing of assembly (30) using a screwdriver in the groove provided for this purpose. Note: Be careful not to damage the seating surfaces of the bellows bushing. Remove the bonnet and spacer gaskets (28) and the body gasket (11). Bonnet extension (29), plug (16), guide bushings and seat ring (14) may now be inspected for wear and service damage. After determining the maintenance required, proceed to the appropriate section of these instructions.
The original pin hole in a stem which is being reused sometimes prevents a satisfactory result being obtained and can also weaken the plug-stem assembly. If the stem-bellows sub-assembly is being replaced, the new assembly can be fitted on an existing plug as long as it is in good condition and the removal of the pin has not deformed the hole or damaged it in any other way. Note: Always use soft metal vise jaws to hold the plug guide surface. Failure to take this precaution could result in damage to the plug guide surface during pinning (see figure 18). Be careful not to damage the plug seating surface during pin removal and assembly operations.
10.2.1.1 Unpinning the Plug Stem
Pull and hold the plug (16) out of the bonnet extension (29) to allow access to the plug pin (17). Place the plug guide on a V-block. Note: A lower mechanical stop has been provided to prevent damage of the bellows during this step. Using a drift punch, drive out the existing pin (17). Note: If it is necessary to drill out the pin, use a drill bit slightly smaller than the pin diameter. Be careful not to damage the hole of the plug guide. Lock two nuts against each other on the end of the plug stem, and use a flat spanner on the lower nut to prevent rotation while unscrewing the plug from the stem. The plug is removed by turning it counter-clockwise. Remove the two nuts from the plug stem. Complete step 10.1.1. Inspect the parts and carry out any necessary repairs, then reassemble the stem-bellows sub-assembly (30) through the upper hole in the bonnet extension (29) (see section 10.2.1.2).
10.2.1.2 Mounting of the Plug-StemlBellows S/A into the Bonnet Extension
10.1.2 Quick-Change Trim

Removal of the quick-change trim is accomplished using the same procedures as removal of the threaded trim. However, after the bonnet extension (29) has been removed from the body, remove the cage (13), the seat ring (14) and the seat ring gasket (15).
10.2 Repair
The purpose of this section is to provide recommended maintenance and repair procedures. These procedures assume the availability of standard shop tools and equipment.
Clean all contact surfaces of the bonnet extension (29) and the plug-stem/bellows S/A. Assemble a new gasket (28) on the upper flange of the bonnet extension.
Insert the new stem-bellows S/A through the top hole into the bonnet extension (29). Pin the plug on the stem (See section 10.2.1.3).
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16
- - . _ . . .
c
Cylindrical machining diameter of the jaws = plug guide diameter "E"
k

Pull plug out of the Bonnet Extension (29) for access to the plug pin
30
/
Lower Mechanical Stop to Protect the Bellows
1
17
J
E Dia.
F Dia.
1
LJ
Plug and Plug Stem-Bellows S/A Stem
Figure 18 - Unpinning and Pinning of the Plug to Stem 10.2.1.3 Plug Stem Pinning If the plug guide area has no hole or any center mark,
Replacing Plug and Stem/Bellows S/A

A. Screw Stem into Plug
- Measure
Dimension D based on the plug guide diameter and stem diameter (see Figure 18). mark on the plug guide area using a center punch.
- Lock two
- Place the plug guide on a V-block, and make a center - Drill through the plug-stem assembly using a suitable
size drill bit. In all cases after drilling: Remove any burrs from the plug guide hole by making a slight chamfer.
C. Pinning the Plug-Stem Assembly
nuts against each other on the end of the plug stem and use a flat spanner on the upper nut to prevent rotation of the stem-bellows SIA. Screw the plug onto the lower part of the stem while inserting the plug shank into the guide bushing (12) in the bonnet extension (29). hold the plug (16) out of the bonnet extension (29) to allow access to the plug pin (17).
- Pull and
- Select the correct size pin based on the plug guide

diameter and stem diameter (see figure 18). Apply a small amount of grease on the pin and handassemble it into the hole in the plug.
B. Drilling the New Parts

If the plug is already fully drilled, (typical for 440C hardened stainless steel material or solid stellite), then drill the stem to the same diameter (Diameter C in Figurel8) as the Plug Shank Hole. If the plug guide area has a center mark, Place the plug guide on a V-block and use a suitable size drill to either:
- Press fit
the pin into the hole using a hammer. Complete the pinning operation by ensuring that the pin is recessed by the same amount from both sides (see Figure 18).
- Match the hole size in the plug, or - Match Diameter C (see Figure 18),
- Drill through the plug-stem assembly.
17
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Replacing Stem/Bellows S/A Only
A. Screw Stem into Plug
10.5 Actuator to Body S/A and Plug Stem Adjustment

Refer to instruction No. ER 8788.
- Refer
to paragraph A of the previous section REPLACING PLUG AND STEM/BELLOWS S/A.
B. Drilling the New Stem
- Place the plug guide on a V-block and use a suitable

size drill bit to drill the stem (use the hole in the plug as a guide). Note: If the hole in the plug guide has been slightly damaged while removing of the old pin, choose a drill bit and a pin with a slightly larger diameter than the normal pin.
Warning: Assembly of the No. 6 actuator on a bellows seal valve requires a three-sectioned coupling. Follow coupling instructions as described for the No. 10, 16 and 23 actuators.
C. Pinning
Caution: The bellows assembly causes a spring back effect. Measure this plug spring back before referring to Instruction No. ER 8788. Be sure to add this spring back length to the over seat adjustment.
- Select
the correct size pin based on plug guide diameter and pin hole diameter. Proceed as described in Paragraph C above, taking care not to damage the plug guide area.
10.3 Plug and Seat Ring Seating Surfaces

It is not possible to lap the plug and seat ring seating surfaces after the bellows has been assembled to the stem.
If the seat ring shows signs of minor wear, it should be turned on a lathe to clean up the worn area. The seating surface of the seat ring is 30 degrees from centerline axis. However, no more than 0.010 in. (0.25 mm) of material should be removed. In cases where the seat ring cannot be repaired, or if the plug is also damaged the only alternative is to replace both parts.
10.4 Bonnet Reassembly

Install the bonnet (25) and assemble nuts (27) and studs (26). Bonnet must be positioned so the packing flange studs are at a 90 angle to the flow centerline. Refer to table in Figure 11 for proper bolt torque and tightening sequence.
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2
3
22
4 5 6 25
31
28 28 27 26
(+)30 '
9
10
11
12
13 14 15
Quick Change Trim

Figure 19 - 21000 BS Valve
Threaded Trim detail
, 1 2 3 4 5 t 6 9 10 111 12 113 t14
Ref.
Part Name
Plug Stem Packing Flange Stud. Packing Flange Nut Packing Flange Packing Follower Packing Body Stud Body Stud Nut Body Gasket Guide Bushing Cage Seat Ring
Ref.
m15 016 017 18 19 22 25 26 27 a28 29
PARTS REFERENCE
Part Name
Seat Ring Gasket Plug Plug Pin Valve Body Drive Nut Plug Stem Locknut Valve Bonnet Bonnet Stud Bonnet Stud Nut Bonnet Spacer Gasket Bonnet Extension Assembly Upper Flange
Ref.
Part Name
Spacer Lower Flange Bellow and Stem Assembly Stem Guide Bushing Bellows Upper Adapter (Bellows) Lower Adapter (Bellows) 1/8" NPT Plug
+
+
30
+ + +
31
a Recommended Spare Parts
+ These parts included in welded subassembly
n Quick change trim only
19
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AUSTRIA Dresser Valves Europe GmbH Kaiserallee 14 A-2100 Korneuburg (near Wien), Austria Phone: 43-2262-63689 Fax: 43-2263-6368915 BELGIUM Dresser Europe S.p.r.L. 281-283 Chaussee de Bruxelles 281-283 Brusselsesteenweg 1190 Brussels, Belgium Phone: 32-2-344-0970 Fax: 32-2-344-1123 BRAZIL Dresser lndustria E Comercio Ltda Divisao Masoneilan Rua Senador Vergueiro, 433 09521-320 Sao Caetano Do Sul Sao Paolo, Brazil Phone: 55-1 1-453-5511 Fax: 55-11-453-5565 CANADA Alberta Dresser Flow Control DI Canada, Inc. Suite 1300, 311-6th Ave., S.W. Calgary, Alberta T2P 3H2 Canada Phone: 403-290-000 1 Fax: 403-290-1526
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KOREA Dresser Korea, Inc. #2107 Kuk Dong Building 60-1, 3-Ka, Choongmu-ro Chung-Ku, Soeul, 100705 Phone: 82-2-274-0792 Fax: 82-2-274-0794 KUWAIT Dresser P.O. Box 242 Safat 13003, Kuwait Courier: Flat No. 36, Floor 8 Gaswa Complex, Mahboula Kuwait Phone: 965-9061 157 MALAYSIA Dresser Flow Control - Far East Business Suite 19A-9-1 Level 9, UOA Centre No. 19 Jalan Pinang 50450 Luala Lumpur, Malaysia Phone: 60-3-2163-2322 Fax: 60-3-2163-631 2 MEXICO Dresser Valve de Mexico, S.A. de C.V. Henry Ford No. 114, Esq. Fulton Fraccionamiento Industrial San Nicolas 54030 Tlalnepantla Estado de Mexico Phone: 52-5-310-9863 Fax: 52-5-310-5584 THE NETHERLANDS Dresser Valves Europe Steenhouwerstraat 11 3194 AG Hoogvliet The Netherlands Mailing Address: P.O. Box 640 NL3190 AN Hoogvliet RT The Netherlands Phone: 31-10-438-4122 Fax: 31-10-438-4443 SAUDI ARABIA Dresser Al Rushaid Valve & Instrument Company PO. Box 10145 Jubail Industrial City 31961 Saudi Arabia Phone: +966-3-341-0278 Fax: +966-3-341-0696 SINGAPORE Dresser Singapore, Pte. Ltd 16, Tuas Avenue 8 Singapore 639231 Phone: 65-6-861-6100 Fax: 65-6-861-7172 SOUTH AFRICA Dresser Ltd., South Africa Branch PO. Box 2234, 16 Edendale Road Eastleigh, Edenvale 1610 Republic of South Africa Phone: 27-1 1-452-1550 Fax: 27- 1 1-452-6542 SPAIN Masoneilan S.A C1 Murcia 39 C 08830 Sant Boi de Llobregat Barcelona, Spain Phone: 34-93-652-6430 Fax: 34-93-652-6444 SWITZERLAND Dresser Valves Europe SA Frauntalweg 76 CH-8045 Zurich, Switzerland
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CHINA Dresser Suite 2403, Capital Mansion 6 Xinyuannan Road Chao Yang district Beijing 100040 Phone: 86-10-6466-1 164 Fax: 86-10-6466-0195 FRANCE Dresser Produits Industriels S.A.S Division Masoneilan 4, place de Saverne 92400 Courbevoie France Phone: 33-1-49-04-90-00 0 Fax: 33-1-49-04-90-1 GERMANY Dresser Valves Europe GmbH Klein-Kollenburg-Strasse 78-80 47877 Willich, Germany Mailing Address: P.O. Box 1208 47860 Willich, Germany Phone: 49-2156-9189-0 Fax: 49-2156-9189-99 INDIA Dresser Valve India Pvt. Ltd. 3051306 "Midas" - Sahar Plaza Mathurdas Vasanji Road J.B. Nagar - Andheri East Mumbai, India 400 059 Phone: 91-22-835-4790 Fax: 91-22-835-4791 ITALY Dresser ltalia S.r.L.. Masoneilan Operation Via . Cassano. _ . . . . 77 80020 Casavatore (Naples), Italy Phone: 39-81-7892-111 Fax: 39-81-7892-208 JAPAN Niigata Masoneilan Company, Ltd. 20th Floor, Marive East Tower WBG 2-6 Nakase, Mihama-Ku Chiba-shi, Chiba 261-7120, Japan Phone: 81-43-297-9222 Fax: 81-43-299-1115
Copyright 2002. Dresser, Inc. EH1080, LaVigne Inc. #I8058 5/02 3M
UNITED STATES Northern Region Dresser Flow Control 85 Bodwell Street Avon, MA 02322-1 190 Phone: 508-586-4600 Fax: 508-427-8971
Southern Region Dresser Flow Control 11100 West Airport Blvd. Stafford, TX 77477-3014 Phone: 281-568-221 1 Toll Free: 800-847-1099 Fax: 281-568-1414 South Texas Operations Dresser Flow Control 4841 Leopard Street Corpus Christi, TX 78408-2621 Phone: 361-877-2414 Fax: 361-584-1196 Masoneilan Aftermarket Sales & Service Center 16030 Bear Bayou Drive Channelview, TX 77530 Phone: 281 -862-1500 Fax: 281 -862-1550 Western Region Dresser Flow Control Masoneilan 2950 East Birch Street Brea, CA 92821 Phone: 714-572-1528 Fax: 714-572-1463
UNITED ARAB EMIRATES Dresser Middle East Operations Post Box 61302 (mail) R/A 8, Units JAOliJA02 (courier) Jebel Ali Free Zone United Arab Emirates Phone: 971-4-8838-752 Fax: 971-4-8838-038
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General
These instructions apply to Masoneilan 41 400, 41500 and 41600 Series Control Valves, sizes 2 through 6 and ratings from ANSI Class 150 through 1500. When performing maintenance on these valves, always use Masoneilan replacement parts. They can be ordered through local Masoneilan offices or representatives, or directly from factory parts service department.
Training
Masoneilan conducts training schools at its Avon, Massachusetts plant. Arrangements for attending the school can be made by contacting the nearest Masoneilan office or representative.
Service
Masoneilan Service Engineers are available for assistance with special start-up or maintenance problems. Contact the nearest Masoneilan sales office or representative.
Installation
1 Before installing the valve in the pipeline, thoroughly clean the line of all dirt, welding chips, scale, oil, grease and other foreign material.
Spring-diaphragm Actuators Connect actuating air

pressure line to the h NPT opening in the upper diaphragm case. Use /4 O.D. tubing or equivalent for all air lines. If air line exceeds 25 ft. in length or if the valve is equipped with volume boosters, 3/8 tubing is preferred. Air lines must not leak.
2 To check the valve without interrupting the process, provide a hand-operated stop valve on each side of the 41 400, 41 500 or 41 600 Series valve with a hand-operated throttling valve mounted in a bypass line
3 Install valve so that the controlled fluid will flow through the valve body in the direction indicated
Pilot Caution
CAUTION: To bring the 41400 Series control valve on line after isolation and depressurization, Masoneilan recommends the valve be in the fully open position (unless service condi and the upstream isolation valve be pressurize the control valve in the proper direction.
li
the plug off the seat to its full stroke. handwheel may also be used.) (The
In case of a heat-insulated installation, insulate the valve body only
Warning: Do not use air pressure greater than soecified on serial date.
Maintenance
Caution: Beforedisassembly or maintenance,the valve and actuator must be free of all pressures. Actuator Removal Air-to-Extend
1. Shut off the air supply pressure and disconnect the air tubing to the actuator.
2. Remove the dust cover (84), loosen the locknuts (27) on the plug stem (5) and unscrew the valve stem from the actuator stem (80).
3 . Secure actuator using a suitable hoist. Remove drive nut (9) and lift actuator from the valve.
2. Remove the dust cover (84), loosen the locknuts (27) on the plug stem ( 5 ) , and unscrew the valve stem from the actuator stem (80).
3. Secure actuator using a suitable hoist. Remove drive nut (9) and lift actuator from valve.
Actuator Replacement Air-to-Extend

1. Replace actuator on body assembly.
2. Replace drive nut (9).
Ai r-to-Retract
1 Apply sufficient air pressure to the diaphragm to lift
1986 Masoneilan North American Operations, All rights reserved
3. Make plug stem adjustment (see page 8). 4. Connect air lines, accessories and install dust cover.
n
2. Remove plug (15),cage (16) and flat spring (1 7) from body by pulling upward on the plug stem (1). (Flat spring is used in the 6 size only.)
3. Remove plug from cage by lifting cage over top of the plug stem. If the valve is furnished with a graphite piston ring, care should be taken when removing the plug from the cage that the ring is not damaged. Inspect piston ring (11) and replace if it shows signs of wear (see Instruction No. 12 below).
@@U
Air-to-Retract
4. Reach inside valve body and lift out seat ring (13). Inspect all guiding and seat surfaces on the plug, cage and seat ring for excessive wear or damage. If repairs are necessary, refer to page 5. 5. Remove body and seat ring gaskets (10, 14) and clean the mating surfaces. 6. Remove packing flange (4), packing follower (23), packing (6), packing spacer (5) and guide bushing (22).
7. Inspect inside diameter of guide bushing (22). If it is excessively worn or if it shows scratches or grooves, it should be replaced.
8. Apply thin film of plastic lead seal No. 2 or equivalent to gasket and gasket mating surfaces.
Air-to-Extend
Air-to-Retract
1. Before replacing the actuator, the stem must be retracted by using either air pressure or operating the handwheel. 2. Replace actuator on body assembly.
3. Replace drive nut ( 9 )
4. Make plug stem adjustment (see page 8)
Cage
5. Connect air lines, accessories and install dust cover.
Valve Body Disassembly/Assembly

Warning: Disassemblevalve only when pipe line pressure is zero.
1 . Loosen packing flange (4) and remove bonnet (7).
The cage, plug and stem assembly should be held in place to avoid trim damage.
9. Place seat ring gasket (4) in position
10. Place seat ring (13) on seat ring gasket
GUIDE
Seat Ring
41600
Balanced Tight Shutoff Plug Construction 41400 Series
41500
Balanced Plug Construction 6 41 500 or 41 600 Series
Balanced Plug Construction 2*1-3~417 41 500 or 41 600 Series
PARTSREFERENCE
Ref.
Ref.
No.
Ref.
Part Name
Valve Plug Stem Packing Flange Bolt Packing Flange Nut Packing Flange Packing Spacer (Lantern Ring) Packing Bonnet Valve Body Nut
No.
9 10 11 12 13 14 15 16
Part Name
Plug Stem Pin Body Gasket Piston Ring Spring Seat Ring Seat Ring Gasket Valve Plug Cage
No.
17 18 19 20 21 22 23 27
Part Name
Flat Spring Body Retaining Ring Auxiliary Plug Valve Body Bolt Guide Bushing Packing Follower Back Up Ring

1 1 . Place piston ring (1 1 ) on valve plug. Slide cage
over top of plug-and-stem subassembly. Do not damage piston ring (1 1). A ring compressor is recommended for this operation. If a graphite piston ring is used, the following installation procedure should b e followed.
13. Placeflat spring (1 7 )in position.(Used in 6sizeonly.) 14. Place body gasket (10) in position. 15. Carefully lower valve bonnet (7) over plug stem (1) until
it rests firmly in position. 16. Lubricate stud threads and bearing surfaces of the body nuts (8),with Molykote G or Graphikote No. 143.
For Valve Size 6

New graphite piston rings are furnished as a complete ring and must b e broken into two approximately equal pieces. Using a sharp knife, score the graphite ring in two places approximately 1 8 0 deg. apart. Hold each side of the ring securely and strike it across the edge of a table or bench forcing it to break at the scribe marks. Install the backup ring ( 2 7 ) on the plug and then the two graphite pieces taking care to match the separated ends together again. Note that the separations should b e positioned approximately 90 deg. from the separation in the backup ring. Gently squeeze the two graphite pieces until the ends meet. Use a small piece of acetate film tape (such as Scotch brand #810 Magic Transparent Tape) over the separations to hold the ends together. To facilitate easy removal, use only enough tape needed to hold the ring ends together. Slide the cage over the plug and stem subassembly taking care not to damage the piston rings. Where graphite rings have been installed, dissolve the tape used to secure the ends b y applying a small quantity of acetone to the top of the plug and stroking 3 or 4 times. Remove the dissolved tape residue from the cylinder walls with a clean rag dipped in acetone.
17. Evenly tighten bonnet nuts in sequence to the required torque as shown on page 7. 18. Slide guide bushing (22) over top of plug stem, dropping
it to the bottom of the packing box.
19. Install five rings of packing. Place packing spacer (5) on top of packing rings and then fill the remainder of
the packing box with packing rings. 20. Install packing follower (23), flange (4), and nuts (3). Packing flange nuts should be finger-tightened at this time.
Note: When installing a new plug assembly or, a new pilot, the stem must be pinned in place. (See paragraph on Plug Stem Pinning, page 6).
Trim Maintenance
Any trim part which is scored or otherwise damaged on the guiding surfaces, to the extent that it could interfere with proper valve action, should b e replaced.
Seat Repair
Minor scratches or nicks, in the seating surfaces of either the plug or seat ring, should be repaired in the following manner:
For Valve Sizes 2 through 4

New graphite piston rings are furnished as a complete ring and must b e broken at one point before installation. Using a sharp knife, score the graphite rings in one location. Hold each side of the ring around the score mark between thumbs and forefingers and bend the ring to break at the scribe mark. Install the Grafoil backup ring (27) on the plug and then the three graphite rings. Note that the breaks should b e positioned approximately 1 2 0 deg. from each other. Place the plug cap onto the plug and stem subassembly and install the hex head screws and tab washers finger tight, being sure the pre-bent leg of the tab washers are properly oriented to engage the balance hole(s). Slide the cage over the plug and stem subassembly taking care not to damage the graphite rings. Evenly tighten the hex head screws until the plug cap contacts the plug evenly all around. Continue tightening the screws to a torque of 100 in.lbs. for 1/4-20 bolts and 50 in.lbs. for #lo-24 bolts. Once the screws are tightened do not remove the plug from the cage. If the plug is removed from the cage, the plug and plug cap must be reassembled with a new Grafoil backup ring. To prevent the screws from backing out, with a screwdriver bend one tab washer leg up against a hex head flat on each screw.
6 Sizes
1. In the 41 4 0 0 Series plug, install two /4-20UNC x 2.25 long capscrews through the holes provided in the auxiliary plug (20), engaging the capscrews in the holes provided in the plug (15).
2. Tighten capscrews simultaneously or alternately, one turn at a time, until the retaining ring (19) can be removed. Then loosen capscrews in same manner until auxiliary plug can be removed. 2 and 4 Sizes
1. On the 41 400 Series plug, pressure must b e applied on the auxiliary plug to compress the spring (12).
2 . The retaining ring (19) can now be removed, thus allowing separation of the auxiliary plug and spring from the valve plug.
2 and 6 Sizes
If the auxiliary plug tip or guide shows damage, the auxiliary plug must b e replaced. If other seating surfaces on the valve plug or seat ring show signs of minor damage, they should be turned on a lathe to remove the damaged areas. However, no more than 0.015 of material should b e removed and the seat angle shown must b e held.
Packing Box
For smooth valve operation, the packing should b e compressed just enough to effect a seal. Tightness of
12. Lower plug and cage into body until they rest squarely on the seat ring (13). Do not damage seat ring.

the packing box is maintained by the packing compression alone. This procedure may be repeated each time leakage occurs until all available compression is used up.
To add packing, take the valve out of service, then back off the packing follower and flange. Insert one or two rings of split-ring packing.
3. To facilitate lapping, screw a rod with T-handle on top of the valve stem and secure with a locknut. Or, as an alternative, drill a hole through a small flat piece of steel and fasten it to the plug stem with two locknuts 4. Lap by rotating the plug in short oscillating strokes. After 8 to 10 strokes, lift plug and turn 90". Repeat the lapping operation.
Lubrication
Standard packing does not require lubrication. For special applications, where different types of packing are used, lubrication may be used. Consult the factory or an authorized factory service representative when lubrication is required.
Grinding The Seat Ring

After the auxiliary plug, plug or seat ring seats have been turned, they must be ground as follows:
1 . Auxiliary plug lapping. Apply a good grade of fine

grinding compound at several spots equally spaced on the periphery of the seating surface of the plug.
2. Place auxiliary plug, with stem attached, in the seated position without assembling the pilot spring
Main Seat Lapping

Lapping the main seat is accomplished in basically the same manner as lapping the auxiliary plug. However, the trim including the gaskets should be assembled in the body. The bonnet, with the guide bushing in it, should be temporarily placed in position to act as an alignment fixture for the lapping operation. Otherwise, the lapping procedure is identical.
Plug Stem Pinning

If a plug and plug stem must be assembled, always use a new stem. Using the old stem with the original pinhole may seriously impair the assembly's strength.
31 30'
32O3O'b
~
Caution: When pinning, seating surfaces and plus guide must not be damaged.
The old pin may usually be removed by driving it out with a punch. If necessary to drill it out, use a drill somewhat smaller than the pin. Then drive out the remainder of the pin. When drilling, the plug should be placed with the guide section resting on a clean V-block.
MAIN PLUG
29O 30'
Caution: Do not mar the guide section of the plug by gripping it in the jaws of a vise.
The stem must be screwed solidly into the plug before starting to drill. This can be checked by measuring the depth of thread in the plug and making a reference mark on the stem at that distance from the end of the stem. When properly assembled, the reference mark should be flush with the end of the guide section. The stem can then be redrilled through the old hole in the guide section of the plug, using first a pilot drill of suitable size followed by a reamer to bring the hole to required size.
30 30'
SEAT RING
6
After all burrs and sharp corners are removed, a small amount of grease should be applied before inserting

the pin. The hole diameter should allow the pilot end of the pin to slip in about % to 3116 by hand. The pin must be driven the rest of the way. surface. After plug has been pinned, it should be placed in a lathe to see if it is running true. Place the stem in a chuck, If plug is not true, tap it with a plastic or rubber mallet to straighten
Make sure pin is recessed about 1/16 below plug guide
Size (in.)
2 2 3 3 4 4 6 6
ANSI Class
300-600 900-2500 300-600 900-1500 300-600 900-1500 150-600 900-1500
Stud Size
314-10 718-9 314-10 1 1/48 718-9 1 112-8 1-8 13/48
Torque (ft./lbs.)
75 110 75 360 110 680 170 1100
TIGHTENING SEQUENCE
Plug Stem Adjustment

Air-to-Extend Actuator
1 . Separate the plug stem (5) from the actuator stem (80). 2. Push plug stem down until plug seats. With no air pressure on the actuator diaphragm, position locknuts ( 2 7 ) and indicator disc (58) on plug stem so that the distance from the face of the indicator disc to the bottom of the actuator stem (80) is equal to the required valve stroke for the 41 500 and 41 600 Series control valves and to the required valve stroke minus the auxiliary plug stroke for the 41400 Series control valve. See Auxiliary Plug Stroke Table. 3. Stroke valve fully by applying sufficient air to actuator. Check actual stroke. If not correct, make further adjustments between plug stem and actuator stem.
U
Air-to-Retract
Air-to-Retract Actuator
1 . Apply sufficient air pressure to retract actuator stem to its maximum stroke.
2 . Adjust locknuts ( 2 7 ) and indicator disc (58) by screwing onto plug stem (5) as far as possible. Tighten locknuts ( 2 7 ) .
3. Screw plug stem (5) into actuator stem (80) as far as possible.
4. Release air pressure from actuator 5. Unscrew plug stem (5) from actuator stem (80) until
plug contacts seat.
6. Apply sufficient air pressure to actuator to raise plug approximately 'h".
7 . Turn plug stem (5) one full turn out of actuator stem for 41 500 and 41 600 Series control valves and one full turn plus the auxiliary plug stroke for the 41400 Series control valve.
U
Air-to-Extend
8. Loosen locknuts (27) and run them up until the indicator disc (58) contacts the actuator stem (80). 9. Release air pressure from actuator and adjust travel indicator (81)
Valve
; : :I
4
ANSI
Class
150-600 900-2500 150-1500 150-1500 150-1500
Auxiliary PlugStroke
.083/. 106 .083/. 106 .086/. 1 19
1 19 .086/.
.100/.200
Facilities: Brazil, Canada, France, Germany, Italy, Japan, Mexico, Netherlands, Singapore, Spain, United Kingdom, United States
Dresser Equipment Group, Inc. 85 Bodwell Street Avon, MA 02322-1190 Phone: 508-586-4600 Fax: 508-427-8971
Flow Control
ASAP 32406 1.5M 9/01
Complete Line of Heavy Duty, Balanced, Cage Guided, Globe Valves with Lo-dB@/A nt i-Cavitat ion biIities
. ..
Instruction No EH3600-07/02 41005 Series Valves
TABLE OF CONTENTS
1 .GENERAL .....................................................................
1.1. SCOPE ........................................................................................
3
3 3 3 3 3
6. VALVE REASSEMBLY
6.1.1. 6.1.2. 6.1.3. 6.1.4.
.................................................
7
7 7 7 8 8
8 8 9
6.1 PINNING THE VALVE PLUG STEM ............................................ Reference marking on the valve plug stem .................... Screwing in the valve plug stem ...................................... Drilling pin hole ................................................................. Pinning ...............................................................................
1.2. SERIAL PLATE ........................................................................... 1.3. AFTER SALES SERVICE ........................................................... 1.4. SPARE PARTS ............................................................................ 1.5. ACTUATOR AND ACCESSORIES .............................................
6.2. SEAL RING ASSEMBLY ................................................................. 6.2.1. Model 41305 ...................................................................... 6.2.2. Models 41405 and 41505 .................................................. 6.2.3. Model 41605 6.2.4. Model 41905
2 .NUMBERING SYSTEM .................................................

3 .INSTALLATION .............................................................
3.1. PIPING CLEANLINESS.............................................................. 3.2. ISOLATION BYPASS VALVE...................................................... 3.3. HEAT INSULATION .................................................................... 3.4. HYDRAULIC TEST AND CLEANING OF LINES ....................... 3.5. FLOW DIRECTION .....................................................................
3
4
4 4 4 4 4
4 .DISASSEMBLY .............................................................
...................................................................... 9 ...................................................................... 9 6.3. 41405 VALVE PLUG AND CAGE ASSEMBLY .......................... 9 9 6.3.1. Valve plug and auxiliary pilot plug assembly ................ 9 6.3.2. Cage assembly ................................................................. 6.4. COMPLETING VALVE BODY ASSEMBLY ......................................... 9 10 6.5. BONNET ASSEMBLY ......................................................................... 6.6. TIGHTENING BODY STUD NUTS...................................................... 10 10 6.6.1. Alignment of internal parts ........................................... 6.7. PACKING BOX ASSEMBLY ............................................................... 11
7 .ACTUATOR .................................................................
7.1. CONNECTING TYPE 88 NO. 6 ACTUATOR ............................ 7.2. CONNECTING TYPE 87 NO. 6 ACTUATOR ............................
4.1. ACTUATOR REMOVAL .............................................................. 4 4.1.1. Disconnect instruments ................................................... 4 4 4.1.2. Plug stems screwed into the actuator stem ................... 4.1.3. Stems attached with a stem connector ........................... 4 4 4.1.4. Actuator removal .............................................................. 4.2. OPENING PRESSURIZED CHAMBER ...................................... 4.3. PLUG STEM DISASSEMBLY 4 5 5
11
11 11
7.3. CONNECTING TYPE 87 NO. 10. 16 AND 23 ACTUATORS ....11 7.4. CONNECTING TYPE 88 NO. 10. 16 AND 23 ACTUATORS .... 12 7.5. CONNECTING TYPE 37 ACTUATOR ....................................... 7.6. CONNECTING TYPE 38 ACTUATOR ....................................... FIGURE OF BODY SUB ASSEMBLY ................................................. 12 12 13-14 15
.................................................... 4.4. AUXILIARY PILOT PLUG DISASSEMBLY ...............................
5 .MAINTENANCE .REPAIR ............................................

5.1. PACKING BOX ............................................................................ 5.1.1. PTFE packing .................................................................................. 5.1.2. Graphite packing .............................................................. 5.2. REPAIR OF PARTS..................................................................... 5.2.1. Guiding surfaces ............................................................... 5.2.2. Seating surfaces ............................................................... 5.2.3. Gasket seating surfaces ................................................... 5.2.4. Seal rings and gaskets ..................................................... 5.2.5. Valve plug and stem ..........................................................
5
5 5 6 6 6 6 7 7 7
FIGURE OF ACTUATOR .......................................................................... MASONEILAN DIRECT SALES OFFICES..........................
BACK COVER
Instruction No. EH3600-07/02 41005 Series Valves
1. General
1.1. Scope
The following instructions are designed to guide the user through the installation and maintenance of the 41 005 series cage-guided valves for all sizes and pressure classes. This instruction manual describes all the standard options in the 41 005 valve series. Special supplements or addendums to this instruction manual may be required for special designs developed to meet specific customer requirements.
and repair of its equipment. Contact the local Masoneilan representative or Masoneilan factory located closest to you.
1.4. Spare parts

Only Masoneilan replacement parts should be used when carrying out maintenance operations. Obtain replacement parts through our local representatives or Spare Parts Department. When ordering spare parts, the model and serial numbers indicated on the manufacturer's serial plate must be given. The recommended spare parts are indicated in the parts list included in this instruction manual.
1.2. Serial plate

The serial plate is usually fixed to the side of the actuator yoke. It indicates, amongst other things, the size and type of valve, the pressure class, the body and bonnet material, and the maximum supply pressure of the actuator.
1.5. Actuator and accessories

The valve is typically equipped with an actuator. Actuators and other valves accessories have their own instruction manuals, which provides information on the electric and pneumatic connections. The instruction manuals to be used for standard actuators are ER3000 for type 37/38 and ER8788 for type 87188.
1.3. After Sales Service

Masoneilan offers After Sales Service comprised of highly qualified technicians to support the operation, maintenance
2. Numbering System
,
Seal Type
0.
,
Trim Type/Characteristic
0. 1. 2. 3.
4. 5.
Actuator Type* 37 Spring Diaphragm : direct, air to close (fail open action) 38 Spring Diaphragm : reverse, air to open (fail to close) 84 Cylinder : spring return, direct, air to close, single or double-acting (fail open action) 85 Cylinder : spring return, reverse, air to open, single or double-acting (fail to close) 86 Cylinder : double-acting, without spring, air to open or air to close action 87 Spring Diaphragm : direct, air to close (fail open action) 88 Spring Diaphragm : reverse, air to open (fail close action)
IBody Series 41 Cage
-A Angle
Guided, Balanced Globe
3.
4.
5.
6. 9.
Undefined Pressure Energized PTFE Seal Ring Auxiliary Shut-off Plug (Pilot) Metal Seal Ring PTFE Seal Ring Graphite Seal Ring
Undefined Standard Cage/Linear Standard Cage/Equal YO Lo-dBYAnti-Cav Single Stage/Linear Lo-dB/Anti-Cav Single Stage with Diffuser/Linear Lo-dB Multi-StagelLinear VRT (stack) Type S/Linear VRT (partial stack) Type S/Modified VRT (cage) Type CRinear Anti-Cav Multi-Stage/Linear
6. 7.
8. 9.
* Refer to applicable product instructions manual for cylinder type actuator.
Engineered trim options are also available for high temperature and high pressure drop applications, including Multi-Stage Anti-Cavitation Trim. Please consult factory for details.
3. Installation
3.1. Piping cleanliness
Before installing the valve in the line, clean piping and valve of all foreign material such as welding chips, scale, oil, grease or dirt. Gasket mating surfaces must be thoroughly cleaned to insure leak-free joints.
3.2. Isolation bypass valve

To allow for in-line inspection, maintenance and removal of the valve without service interruption, provide a manually operated shutoff valve on each side of the control valve and a manually operated throttling valve in the bypass line.
4 . 1 . 3 . Stems attached with a stem connector

For air-to-retract actuators, apply sufficient air pressure on the actuator to retract the stem completely. Loosen the screws and remove the stem connector.
-- 7 [=Prior to disassembly, vent the process pressure and isolate the valve if
~. -. -.
____
._
3.3. Heat insulation

In case of a heat-insulated installation, do not insulate the valve bonnet and take protective measures relative to personal safety.
4.1.4Actuator removal
Disconnect all the air and electrical connections from and to the actuator. Loosen the yoke nut or attachment screws and lift the actuator, making sure that the concentricity and/or the thread of the bonnet is not damaged.
3.4. Hydraulic test and cleaning of lines

During this operation, the control valve must not be used as an isolating valve. This means that the valve must always be opened before carrying out pressure tests in the process line, cleaning of pipes, etc. Otherwise equipment damage or failure of the seal rings could result.
3.5. Flow direction

The valve must be installed so that the process fluid will flow through the valve in the direction indicated by the flow arrow located on the body.
4.2. Opening pressurized chamber (Figures 14 and 15)

The valve must always be reassembled with new packing sets and gaskets. Before disassembly, make sure that the appropriate parts are available.
A. Remove the packing flange nuts (3) then remove the packing flange (4) and the packing follower (23).
4. Disassembly
4.1 Actuator removal (Figures 16 and 17)
Access to the internal components of the body shoul, be accomplished with the actuator removed. To carry out this operation, follow the instructions below and refer to the specific actuator instructions (reference ER 8788 for type 87/88 actuators and ER 3000 for type 37/38 actuators).
B. Check that the exposed part of the valve plug stem (1) is clean enough for the bonnet (7) to be removed easily. C. Remove the body stud nuts (8).
D. Lift the bonnet (7) up and disassemble it from the valve body (18). During this operation, the valve plug stem (1) must be pushed downwards so that the valve plug remains in the valve body (18). E. Remove the spring washer (17) or cage gasket (36) and the body gasket (10). F. For Model 41 305, 41 505, 41605 and 41 905 valves, remove the valve plug stem (1) and valve plug (15) assembly from the cage by pulling the valve plug stem upward. Then disassemble the cage (16) from the body (18).
4 . 1 .I Disconnect instruments
Disconnect all mechanical connections between the positioner and the other instruments. Disconnect the valve stem/actuator stem coupling as described in the following sections.
4.1.2Plug stems screwed into the actuator stem

For air-to-retract actuators, apply sufficient air pressure to the actuator to retract the stem completely.
G. In the case of a 41405 valve, remove the valve plug and body cage assembly by pulling the valve plug stem upward. In this design, the valve plug has a shoulder which prevents the cage from falling. Remove the valve plug from the cage by pushing on the end of the valve plug stem. H. Remove the seat ring (13) and the seat ring gasket (14) from the valve body (18).
1.
4.4. Auxiliary pilot plug disassembly (Model 41405 Figure 14)
For size 2", 3" or 4" (50, 80 or 100 mm) valves: Exert a sufficient force on the auxiliary pilot plug (20) to compress the spring washers (12). The retaining ring (19) can then be removed, allowing for disassembly of the auxiliary pilot plug and spring washers. For size 6" to 16" (150 to 400 mm) valves: To carry out this operation safely, screws with diameters and lengths indicated in the table in figure 2 must be used. Thread the socket head cap screws through the holes in the auxiliary pilot plug (20). Tighten until the retaining ring (19) can be removed. Loosen the screws gradually, then remove the auxiliary pilot plug and the spring (12).
Remove the packing set (6), the packing spacer (5) and the guide bushing (22) from the bonnet (7).
__ __
-7a Note: A pacWng spacer (5) is only rsquimd for jbonnetwitha connection.
-_
4.3. Plug stem disassembly (1)

The valve plug stem is screwed and pinned into the valve plug (15). To disassemble the stem, the valve plug must be held as shown below, taking care not to damage the guiding surfaces. Disassemble the plug stem pin (9) from the assembly. By means of flats or using a nut and counter-nut on the end of the stem, unscrew the stem from the plug taking care not to apply a bending moment which could deform it.
6 8
150
200 250 300 400
2 2 2 3 3
2.25 2.75 2.50 4.00 2.50
57 70 63.5
~
1/4"- 20 UNC 2A
10
12 16
101.5 63.5
3/8"- 16 UNC 2A
Cylindrical machining diameter of the jaw = plug shank diameter : Dia. A

Tight only on this non-guiding
Figure 2
surface
Stop pin integrated in vise jaw and inserted intoa
soft metal vise jaw
5. Maintenance - Repair
5.1. Packing box
Tight sealing within the packing box is obtained by compression of the packing (6). Compression must be achieved by evenly tightening the packing flange nuts (3) on the packing flange (4). Periodic re-tightening of the packing flange nuts is required to maintain proper sealing. Be careful not to over tighten the packing as this could prevent proper operation of the valve. If leakage persists after maximum packing compression, then the packing needs to be changed.
A packing spacer (5) is only required for a bonnet with a leak detector connection.
I tighten on
Do not
w
Figure 1
5.1.1 PTFE packing

KevladPTFE, carbon/PTFE and pure PTFE packing rings are cut in such a way that they can be replaced without having to separate the valve plug stem from the actuator stem.
A. Unscrew and remove the packing flange nuts (3). B. Lift the packing flange (4) and packing follower (23) up along the valve stem.

4
C. By means of a puller, remove the packing (6) and packing spacer (5),being careful not to damage the sealing surface of the packing box or the valve plug stem.
D. Replace the packing rings, placing the cut in each ring about 120" apart from the adjacent ring. Press rings in one at a time in accordance with the table in Figure 3.
D. Replace new packing set (6): First assemble a back-up ring (Carbon/Graphite/lnconelbraided ring). Then assemble the expanded graphite rings (smooth rings) in accordance with Figure 4. Finally, assemble an additional braided back-up ring.
E. Reassemble the packing follower (23) and packing flange (4). F. Moderatelytighten the packing flange nuts (3).
G. Reassemble the valve plug stem to the actuator stem (see chapter on actuator reassembly). H. Open and close the valve several times then tighten the packing as required. 1.
Put the valve back into service and check for leakage. Tighten packing flange nuts (3) as required.
3 - 4 80-100
6 - 1 6 150-500
8
7
3
2
5 5
5.2. Repair of parts

Prior to reassembly, examine parts carefully for any scratches, unusual wear or other damage.
5.2.1 Guiding surfaces

Guiding surfaces of the cage, valve plug, guide bushing, plug stem, and auxiliary pilot plug must be checked. If there is only slight wear indications, then use a light abrasive to smooth out guiding surfaces. Otherwise the part must be replaced (see paragraph on spare parts).
5.1.2 Graphite packing

To carry out this operation, the valve plug stem must be disconnected from the actuator stem. See chapter on actuator disassembly.
Guiding surface
A. Loosen and remove packing flange nuts (3)

B. Remove packing flange (4) and packing follower (23) from the plug stem C. Remove packing rings (6), being careful not to damage the sealing surface of the packing box or plug stem.
Cage
Figure 5
Pilot
'Seating surface
5.2.2 Seating surfaces (Figure 6)

If the surface of the auxiliary pilot plug (20) is damaged, the auxiliary pilot plug must be replaced (see paragraph on spare parts).
4
Figure 4
The seat ring seating surface (13), valve plug seating surfaces (15) and the auxiliary pilot plug seat (20) must be completely free of dents, wear and scratches. Any seating surfaces showing signs of slight deterioration may be touched up on a lathe in accordance with the following guidelines.
A maximum of .010" (0.25 mm) of metal removal from seating surfaces is allowable for valve sizes 2", 3" or 4" (50, 80 or 100 mm). A maximum of ,015" (0.4 mm) of metal removal from seating surfaces is allowable for valve sizes 6" to 16" (150 to 400 mm). Make sure that the seating angles indicated in Figure 6 are within tolerance.
Guiding surface
Lapping can be repeated, but should be limited as much as possible so that the seat remains sufficiently narrow to guarantee tightness. After lapping, disassemble the parts to clean them, and then reassemble making sure that the seating angles are within tolerance.
5.2.3 Gasket seating surfaces

Gasket seating surfaces must be free of dents, scratches and corrosion.
surface
5.2.4 Seal rings and gaskets

Spiral-wound gaskets (Items 10, 14 and 36) must always be replaced after disassembly. Piston seal rings (Items 31, 35, 40, and 45) can be reused if they are free of scratches, erosion, corrosion, or other damage.
7
Valve Plug Seating surface
/
5.2.5 Valve plug and stem
If the valve plug needs to be replaced, then the stem must also be completely changed to guarantee correct pinning of the assembly. If only the valve stem needs to be replaced, then the valve plug can be reused.
6 - Valve reassembly
6.1. Pinning the valve plug stem
The valve plug (15) and stem (1) assembly consists of a stem threaded into the valve plug and pinned in place. If the valve plug (15) [or the auxiliary pilot plug (20) in the case of a 41405 valve] needs to be replaced, then a new stem should be used as well. Re-machining of the pin holes in the existing parts often prevents satisfactory results from being obtained, and can seriously impair the mechanical strength of the plug stem assembly.
Seat ring seat
Figure 6 If a slight defect exists on any of the above seating surfaces, lapping can be applied per the following instructions: Place the seat ring (13) in the body (noting the seating angle). For Models 41305, 41 505, 41605 and 41 905 assemble the cage (16) onto the seat ring. Spread a fine layer of high quality sealing compound on the seating surface. For Model 41405 valves, assemble the valve plug (15), cage (16) and stem (1). For Models 41305, 41505, 41605 and 41905, assemble the valve plug (15) and stem (1). Assemble the bonnet (7) and the guide bushing (22).
6.1.1 Reference marking on the valve plug stem

Make a reference mark on the valve plug stem at a distance "X' (Figures 7 and 8) equivalent to the stem recess in the valve plug.
6.1.2 Screwing in the valve plug stem

To carry out this operation, the valve plug must be prevented from moving by holding the plug shank with an appropriate tool. Screw two nuts onto the end of the new plug stem and lock them together. Screw the valve plug stem solidly into the plug, checking that the reference mark is level with the end of the plug shank.
Place an appropriate tool on the valve plug stem (1) thread to allow for manual rotation. Lap by slightly rotating the valve plug or the auxiliary pilot plug in alternate directions. After several rotations, lift the valve stem, turn it go", and repeat the operation.
112 518 314 1.0
12.7 15.87 19.05 25.4
.79 .98 1.38 1.66
20 25.5 35 44.5
0.14 0.2 0.2 0.2
3.5 5.0 5.0 5.0
.70 .95 1.2 1.58
18 24 30 40
.91 1.1
23 28
.24 .30 .75
6 8 19 25
11116 718 11116 1114
17 22 27 30
37 118 118 118
5 16 16 16
44 118 118 184
6 16 16 25
1.77 45
1.88 47.5 .98
Figure 7
Two flats of wrench size E

L
B
Y
Shouldered stem
Standard stem
-I
Figure 8
Shouldei stem
itandai stem
F
~
Stem pin
For shouldered stems, apply torque T using a wrench of dimension E.
.2. Seal ring assembly

6.2.1 Model 41 305 (Figures 9A and 9B)
These valves have spring-energized seal rings which must be assembled based on the specific valve operation (see Figure 9A). To insert the ring in the valve plug groove, place it over the conical top of the plug, then push down evenly from all sides until the qasket slips into the qroove (see Figure 9B). Flow-to-Open
6.1.3 Drilling hole (Figures 7 and 8) - pin . . For this operation, it is recommended clamping the valve plug-stem assembly by the plug shank to avoid damaging the guiding surfaces. Particular care must be taken so that the pin hole goes through the valve plug axis. If the valve plug is new, drill a hole of diameter C at a distance D from the end of the valve plug. Choose diameter C from Figure 7 according to the pin diameter used. If the hole is already drilled in the valve plug, use the hole as a guide to drill through the valve stem.
Flow-to-Close
6.1.4 Pinning
Insert the pin into the hole and press fit into the plug and stem. Make sure the pin is recessed by the same amount from both sides as shown in Figure 8. Place the assembly in the soft jaw chuck of a lathe to check alignment of the two parts. Correct any alignment defects by tapping it lightly with a plastic or rubber mallet.
I
Figure 9A
Using a sharp blade, make a notch in the graphite ring. Hold the ring on either side of the notch between the thumb and index and bend until it breaks.
\
Pushing direction
/'
Using a very fine file, adjust each end of the ring so that its external circumference corresponds to the internal circumference of the inside diameter of the cage (16). To adjust the length of the ring correctly, insert the new graphite ring into the cage with the ring against the inner wall o f the cage (allowing for minimum play between the two ends of the ring). First assemble the inner metal ring into the cage groove, then assemble the graphite ring over the metal ring. Be careful not to damage the parts.
-
__
--
Seal shown installed for FTO operation Figure 9B
Note: The cuts on each ring should be placed I a__

.
- -I
6.3.41405 Valve Plug and Cage Assembly (Figure 14)

6.3.1 Valve plug and auxiliary pilot plug assembly
Assemble either the flat spring washers (sizes 2" to 4") or the coil springs (sizes 6" to 16"), then assemble the valve plug and stem assembly. Using the same tools as those used for disassembly (see chapter on disassembly), compress the springs so that the retaining ring can be installed into the groove in the main plug.
6.2.2 Models 41405 and 41505 (Figures 14 and 15)

These valves are equipped with metal seal rings. The inner ring has a straight cut while the outer ring has a staggered cut. To insert the rings into the plug groove, open the rings slightly by hand and slide them along the plug without damaging any of the parts. Assemble the inner and outer rings separately.
6.3.2 Cage assembly 6.2.3 Model 41605 (Figure 15)

These valves are equipped with an inner elastomeric ring and an outer PTFE ring. Insert the elastomeric back-up ring (41) into the groove. Place the PTFE seal ring(40) in boiling water for a few minutes. Slide the seal ring along the plug until it slips into the groove. For optimum insertion of the ring, a Serflex type ring compressor can be used to compress the ring in the groove for several minutes. Assemble the cage over the valve plug assembly from the top of the plug stem. Make sure the seal ring in the plug groove stays positioned correctly.
6.4. Completing Valve Body Assembly (Figures 14 and 15)

Proceed as follows: After checking that the sealing surfaces are clean, assemble the seat ring gasket in the valve body. Make sure the gasket is centered properly in the body. Assemble the seat ring or internal diffuser seat. Assemble the cage (or the cagehalve plugktem assembly in the case of 41405 valves) into the valve body. In the case of valves other than 41405 valves, insert the valve plug/stem/ring assembly into the cage taking particular care as it goes past the ring or spring-energized seal ring. For valve sizes less than ( 2 " to 4 " ) , assemble the body/cage gasket into the valve body. Make sure it is centered as well as possible.
6.2.4 Model 41905 (Figure 15)

These valves are also equipped with an inner and outer ring arrangement. The inner metal ring has a straight cut and the outer ring is made of graphite. Replacement graphite seal rings (45) are supplied in a closed ring form, and a notch must be cut before being assembled to the plug.

a
For valve sizes 6" to 16", assemble either the cage gasket 4 (36) or the conical spring washer (17) with the concave side upwards (depending on the type of valve). Then place the body gasket into the valve body making sure that it is centered properly.
VALVE SIZE
Body Nuts
Assembly Torque
6.5. Bonnet Assembly
I
2
I I I
I
8
15Ol300 600 900 1500 150/300 600 900 1500 15Ol300 600 900 1500 150l300 600 900 1500 150l300 600 900
I 314 10 I
I
314 10 718 9 718 9 314 10 314 10 11/48 718 9 7/89 1112 8 11/28 18 18 13/48 13/48
I 11/48 I
I I
I
I
I I
6 6 8 8 8 8 6 6 8
8 6 6 8 12 8 8
1 1 1
I
1
104 163 156 222 133 163 563 815 170 259 889 1370 326 237 1370 1370 526 481 1370
140 210 220 300 180 220 760 1100 230 350 1850 1200 440 320 1850 1850 710 1850 650
I I
I
Make sure the packing (6), packing spacer ( 5 ) and guide bushing (22) have been removed from the bonnet. Position the bonnet (7) above the valve body, so that the packing flange studs (2) are perpendicular to the flow direction of the valve. Assemble the bonnet (7) over the valve stem (1) and push it down carefully until it is positioned correctly over the valve body studs (21). Grease the threads of the valve body studs (21) and the bearing surfaces of the body stud nuts (8). Assemble the body stud nuts by hand. Hand tighten the nuts evenly so that the internal parts are held in place. The face of the bonnet should be parallel to the upper face of the body. Slide the guide bushing (22) onto the valve plug stem and let it drop to the bottom of the packing box.
I I
I
I
1
I
I
I 11/48 I
I 11/48 I
8
12 8
I 13/48 I
I I I
I I I
6.6. Tightening Body Stud Nuts

6.6.1. Alignment of internal parts
In order to achieve perfect alignment of the body and the internal components, the plug stem should be loaded during tightening of the body nuts to obtain correct positioning of the various parts. The force can be applied with the pneumatic actuator as follows: Place the actuator on the valve bonnet (7) by means of the yoke nut (33) or attachment screws and connect the valve plug stem to the actuator stem. See chapter on actuators for installation instructions.
1
16
1500 150l300 600 900 1500
I 13/48 I I 11/28 I I 11/28 I
11/28 13/48
I I
16 12 16 20 20
I I
I I
1630 852 826 1111 1926
I I
I I
2200 1150 1250 1500 2600
II
Align the internal parts as follows: For air-to-extend actuators, supply air to the actuator at the maximum pressure indicated on the serial plate. In the case of spring-to-extend actuators, do not supply air to the actuator, so that the optimum positioning of the valve plug and seat can be obtained. Tighten the body nuts (8) evenly by applying the torque and tightening sequence indicated in the table in Figure 10.
Figure 10
10
6.7. Packing Box Assembly

Assemble the packing box components per the maintenance instructions in paragraphs 5.1.1 or 5.1.2.
G. Unscrew the plug stem until the valve plug is in contact with the seat. Do not turn the valve plug on the seat as this could damage the sealing surfaces. H. Screw the 2 nuts (1) as far as they will go and check that operation is correct.
7. Actuator
7.1. Connecting Type 88 No. 6 Actuator (Figure 17)
A. Tightly assemble the 2 hex nuts (1) onto the plug stem
7.3. Connecting Type 87 No. 10,16 and 23 Actuators (Figure 17)

A. Tightly assemble hex nut (1) onto the plug stem.
B. Screw the top stem connector assembly tightly onto the actuator stem.
B. Push down the actuator, and screw on the yoke nut (33) at the same time. Then assemble the bottom stem connector (2). As soon as it becomes possible, insert the valve stem into the actuator stem. The stem must be inserted far enough so that when there is no air in the actuator, the valve plug does not touch the seat.
C. Tighten the yoke nut. D. Unscrew the valve plug stem until the valve plug comes into contact with the seat. Do not turn the valve plug on the seat as this could damage the sealing surfaces.
C. Push down the actuator, and screw on the yoke nut (33) at the same time. Then assemble the bottom stem connector assembly by screwing until it comes into contact with the hex nut (1). D. Push down the actuator and tighten the yoke nut.
E. Supply the actuator with air at the initial pressure indicated on the spring scale.
E. Supply air to the actuator until the stem has travelled at least .40 inches (10 mm).
F. Position the stem connector assembly at distance "X" indicated in Figure 13.
G. Use the pointer (7) to set the travel scale (9) to the valve open position.
H. Supply the actuator with air at a high enough pressure to obtain a travel equal to the nominal travel of the valve
F. Unscrew the plug stem by the number of turns N1 specified in Figure 11.
G. Screw the 2 nuts (1) as far as they will go and check that operation is correct.
H. Use the pointer (7) to set the travel scale (9) to the valve closed position.
7.2. Connecting Type 87 No. 6 Actuator (Figure 17)

A. Tightly assemble the 2 hex nuts (1) onto the plug stem
B. Push down the actuator, and screw on the yoke nut (33) at the same time. Then assemble the bottom stem connector (2). As soon as it becomes possible, insert the valve stem into the actuator stem. The stem must be inserted far enough so that when there is no air in the actuator, the valve plug does not touch the seat.
1. With the plug correctly positioned on the seat, unscrew the bottom stem connector assembly until it comes into contact with the top stem connector. Tighten the socket head cap screws (5), hex nut (1) and lock nut (32) and check that the operation is correct.
I I
1" 3/4"
I I
1.25 1.25
I I
4.75 4.25
I 0.09 I 2.3 I I 0.08 I 2.0 I
C. Tighten the yoke nut.

D. Supply air to the actuator at the final pressure.
E. Use the pointer (7) to set the travel scale (9) to the valve open position.
Figure 11: Reverse Actuators - valve seating
F . Supply the actuator with air at a sufficiently high pressure

to obtain a travel equal to the nominal travel of the valve less dimension A in Figure 12.
Instruction No. EH3600-07/02 41 005 Series Valves
7.4. Connecting Type 88 No. 10,16 and 23 Actuator (Figure 17)

A. Tightly assembly hex nut (1) onto the plug stem.
B. Tightly screw the top stem connector assembly onto the

actuator stem.
10 10
0.8 1.5
20 38
5.12
130 4.62 117.3 5.44 138.2
C. Push down the actuator, and screw on the yoke nut (33) at the same time. Then assemble the bottom stem connector assembly by screwing until it comes into contact with the hex nut (1).
D. Push down the actuator and tighten the yoke nut. E. Unscrew the top stem connector in accordance with dimension X in Figure 13. F. With the plug correctly positioned on the seat, unscrew the bottom stem connector assembly to bring it into contact with the top stem connector. G. Supply air to the actuator until the stem has travelled at least 0.40inches (10mm). H. Unscrew the top stem connector by the number of turns N1 specified in Figure 1 1 then lock manually with hex nut (1). CAUTION: For 41405 valves, use the N2 values to insure seating tightness of the pilot plug.
2.0 16 23 23 23
I
0.8
1.5 2.0 2.5
20 38 5 1
8.25 209.5 8.62 218.9 9.12 231.6
23
63.5 9.59 243.6
Figure 13: Position of top stem connector
C. Assemble the two parts of the stem connector (51) and the
The number of threads inside the travel indicator (58). stem connection must be approximately equal for each stem. Tighten screw(s) (52).
1.
Release the pressure in the actuator. Use pointer (7) to set the travel scale (9) to the actuator supply pressure so that the two stem connectors come into contact. Then tighten the socket head cap screws (5), hex nut (l), and lock nut (32).
D. Check that the travel of the actuator stem corresponds to the normal travel of the valve, and that the closed position is obtained for the maximum spring range indicated on the serial plate. E. Shut off the air pressure. Use the pointer (58) to set the travel scale (56).The pointer (58)must indicate open when the air pressure is off.
J. Shut off the closed valve pressure and check that operation is correct.
7.6. Connecting Type 38 Actuator (Figure 16)
I I I
r l
2
150,300 or 600
900or1500
3& 4
I I
I I 0.08 I I 0.12 I
0.1 0.275
2.5 2 3
I 1 I
A. Connect a temporary air supply line to the actuator. Apply

sufficient pressure to the diaphragm to retract the actuator stem completely. Attach the actuator to the valve bonnet or attachment screws. with the yoke nut (33)
150,300or600
900 or 1500
I I
B. Shut off the air pressure completely. Increase the air pressure to retract the actuator stem by the value of a in Figure 1 1 .
I
10,12 & 16
I
C. Assemble the two stem connectors (51)and the pointer
Figure 12: Pilot plug travel
(58). The number of threads inside the stem connection must b e approximately equal for each stem. Tighten screw(s) (52).
7.5. Connecting Type 37 Actuator (Figure 16)

A. Push down on the plug stem (1) until the plug is seated. B. Attach the actuator to the valve bonnet with the yoke nut (33) or attachment screws. Apply a sufficient pressure to the diaphragm to extend the actuator stem by the normal valve travel for valves 41305,41505,41605 and 41905 and the travel minus the value of A in Figure 12 for 41405 valves.
D. Check that the travel of the actuator stem corresponds

to the effective travel of the valve, and that the closed position is obtained for the minimum spring range indicated on the serial plate.
E. Shut off the air pressure. Use the pointer (58)to set the The pointer (58)must indicate closed travel scale (56). when the air pressure is off.
12
Instruction No EH3600-07/02 41005 Series Valves
Figure 14 41405 Internal Parts
20 16 15
12
13
14
Pilot Trim for Valve Sizes 2" to 4"
Pilot Trim for Valve Sizes 6" to 16"
6" to 16"
Internal Diffuser Option for Valve Sizes 6" to 16"
13
Instruction No EH3600-07/02 41 005 Series Valves
Figure 15 Body Sub-Assembly
2 3
2" to 4"
7 8
21
10
36
10
6" to 16"
17
16 15
13 14 18
without conical spring with conical spring
45
46
40
41
35
46
31
>
41905
41605
41405 8141505
41305 (FTO)
Double cage
PARTS REFERENCE
Description
Plug Stem Pin Body Gasket Pilot Spring(s) Seat Ring Seat Ring Gasket Valve Plug (or Piston) Cage Conical Spring
Description
Valve Plug Stem Packing Flange Stud Packing Flange Nut Packing Flange Packing Spacer 0 6 Packing Bonnet Valve Body Nut
Ref. No.
0 9 010 :i 1 2 13 014 15 16 9 17 -
Ref. No.
Description
I k!'1
* 040
Description
PTFE Seal Ring Nordel 8 Backup Ring Graphite Seal Ring Ni-resist 8 Backup Ring 0 Washer (Body nuts) Double cage Pin
18 Valve Body
36 Cage Gasket
: i : l 9 Retaining Ring : i : 2 0 Auxiliary Pilot Plug

21 Valve Body Stud 22 Guide Bushing 23 Packing Follower 031 TecSeal ) 035 Ni-resist 8 Seal Ring
* 041
~ 5 75 76
o 045
O 046
m m
:i On 41405 Series Valves Only 9 On 6" to 16" Valves Sizes Only

(150 to 400rnrn)
On 41605 Series Valves Only 0 Recommended Spare Parts
I On 41905 Series Valves Only 1 On 41405/505 Series Valves Only
14
72 36
Plug stem coupling by actuator size (see details)
Type 87 NO. 10-16-23
Type 87 No. 6
u
Type 37 Type 38
26
52
57
1
Coupling parts (No.18 & 18 L actuators)
Coupling parts (No.24 actuators)
Type 88 NO. 10-16-23
PARTS REFERENCE
No.
PARTS REFERENCE
-
Description
Actuator Stem Drive Nut Spring Adjuster Coupling Coupling Screw
I I
Ref* No.
Description
Ref. No. 1 2 3 * 4 * 5 * 6 7
Description
Hex Nut Stem Connector, bottom Cap Screw, Hex head Stem Connector, top Cap Screw, socket head Connector Insert Pointer
Ref.
8 9 10 31 32 33
No. -
Description
Screw, Pan head Scale - Travel Actuator stem Yoke, machining Lock Nut Drive Nut
51 52
*
~
I
Figure 16 SPRING AND DIAPHRAGM ACTUATOR Type 37/38
* Not provided for Size 6 Actuator
Figure 17 SPRING DIAPHRAGM ACTUATORS Type 87/88 Multispring
15
me

AUSTRIA Dresser Valves Europe GmbH Kaiserallee 14 A-2100 Korneuburg (near Wien), Austria Phone: 43-2262-63689 Fax: 43-2263-6368915 BELGIUM Dresser Europe S.p.r.L. 281-283 Chaussee de Bruxelles 281 -283 Brusselsesteenweg 1190 Brussels, Belgium Phone: 32-2-344-0970 Fax: 32-2-344-1123 BRAZIL Dresser lndustria E Comercio Ltda Divisao Masoneilan Rua Senador Vergueiro, 433 09521-320 Sao Caetano Do Sul Sao Paolo, Brazil Phone: 55-11-453-5511 Fax: 55-1 1-453-5565 CANADA Alberta Dresser - Masoneilan DI Canada, Inc. Suite 1300, 31 1-6th Ave., S.W. Calgary, Alberta T2P 3H2 Canada Phone: 403-290-0001 Fax: 403-290-1526
Ontario Dresser - Masoneilan DI Canada, Inc. 5010 North Service Road Burlinqton, Ontario L7L 5R5 CanadB Phone: 905-335-3529 Fax: 905-336-7628
KOREA Dresser Korea, Inc. #2107 Kuk Dong Building 60-1, 3-Ka, Choongmu-ro Chung-Ku, Soeul, 100705 Phone: 82-2-274-0792 Fax: 82-2-274-0794 KUWAIT Dresser P.O. Box 242 Safat 13003, Kuwait Courier: Flat No. 36, Floor 8 Gaswa ComDlex. Mahboula Kuwait Phone: 965-9061 157 MALAYSIA Dresser Flow Control - Far East Business Suite 19A-9-1 Level 9, UOA Centre No. 19 Jalan Pinang 50450 Luala Lumpur, Malaysia Phone: 60-3-2163-2322 Fax: 60-3-2163-6312 MEXICO Dresser Valve de Mexico, S.A. de C.V. Henry Ford No. 114, Esq. Fulton Fraccionamiento Industrial San Nicolas 54030 Tlalnepantla Estado de Mexico Phone: 52-5-310-9863 Fax: 52-5-310-5584 THE NETHERLANDS Dresser Valves Europe Steenhouwerstraat 11 3194 AG Hoogvliet The Netherlands Mailing Address: P.O. Box 640 NL3190 AN Hoogvliet RT The NetherlandsPhone: 31-10-438-4122 Fax: 31-10-438-4443 SAUDI ARABIA Dresser Al Rushaid Valve & Instrument Company P.O. Box 10145 Jubail Industrial City 31961 Saudi Arabia Phone: +966-3-341-0278 Fax: +966-3-341-0696 SINGAPORE Dresser Singapore, Pte. Ltd. 16, Tuas Avenue 8 Singapore 639231 Phone: 65-6-861-6100 Fax: 65-6-861-7172 SOUTH AFRICA Dresser Ltd., South Africa Branch P.O. Box 2234, 16 Edendale Road Eastleigh, Edenvale 1610 Republic of South Africa Phone: 27-11-452-1550 Fax: 27-1 1-452-6542 SPAIN Masoneilan S.A. C/ Murcia 39 C 08830 Sant Boi de Llobregat Barcelona, Spain Phone: 34-93-652-6430 Fax: 34-93-652-6444 SWITZERLAND Dresser Valves Europe SA Frauntalweg 76 CH-8045 Zurich, Switzerland Mailing Address: P.O. Box 3568 CH-8021 Zurich, Switzerland Phone: 41 -1 -450 28 91 Fax: 41-1 -450 28 95
UNITED ARAB EMIRATES Dresser Middle East Operations Post Box 61302 (mail) RIA 8, Units JAOl/JA02 (courier) Jebel Ali Free Zone United Arab Emirates Phone: 971-4-8838-752 Fax: 971-4-8838-038 UNITED KINGDOM DI U.K. Limited Trevithick Works Gillibrands Estate, Skelmersdale Lancashire WN8 9TU, England United Kingdom Phone: 44-1695-52600 Fax: 44-1695-52662
DI U.K. Unit 4, Suite 1.1, Nobel House Grand Union Office Park Packet Boat Lane, Uxbridge Middlesex UB8 2GH, England United Kingdom Phone: 44-1895-454900 Fax: 44-1895-454919
CHINA Dresser Suite 2403, Capital Mansion 6 Xinyuannan Road Chao Yang district Beijing 100040 Phone: 86-10-6466-1 164 Fax: 86-10-6466-0195 FRANCE Dresser Produits Industriels S.A.S Division Masoneilan 4, place de Saverne 92400 Courbevoie France Phone: 33-1-49-04-90-00 Fax: 33-1-49-04-90-10 GERMANY Dresser Valves Europe GmbH Heiligenstrasse 75 41751 Viersen (Dulken) Germany Phone: 49-2162-81-70-0 Fax: 49-2162-81-70-200 INDIA Dresser Valve India Pvt. Ltd. 305/306 "Midas" - Sahar Plaza Mathurdas Vasanji Road J.B. Nagar - Andheri East Mumbai, India 400 059 Phone: 91-22-835-4790 Fax: 91-22-835-4791 ITALY Dresser M i a S.r.L.. Masoneilan Operation Via Cassano, 77 80020 Casavatore (Naples), Italy Phone: 39-81-7892-1 11 Fax: 39-81-7892-208 JAPAN Niigata Masoneilan Company, Ltd. 20th Floor, Marive East Tower WBG 2-6 Nakase, Mihama-Ku Chiba-shi, Chiba 261-7120, Japan Phone: 81-43-297-9222 Fax: 81 -43-299-1115
UNITED STATES Northern Region Dresser - Masoneilan 85 Bodwell Street Avon, MA 02322-1190 Phone: 508-586-4600 Fax: 508-427-8971
Southern Region Dresser - Masoneilan 2135 Highway 6 South Houston, TX 77077 Phone: 281-496-8100 Toll Free: 800-847-1099 Fax: 281-596-4222 South Texas Operations Dresser - Masoneilan 4841 Leopard Street Corpus Christi, TX 78408-2621 Phone: 361-877-2414 Fax: 361-584-1196 Masoneilan Aftermarket Sales & Service Center 16030 Bear Bayou Drive Channelview, TX 77530 Phone: 281-862-1500 Fax: 281-862-1550 Western Region Dresser - Masoneilan Masoneilan 2950 East Birch Street Brea, CA 92821 Phone: 714-572-1528 Fax: 714-572-1463
Copyright 2002. Dresser, Inc LaVigne Inc. Job #19414, 9/02 5M
Flow Control
description
Caution: Follow instructions whenever working on equipment to prevent damage or InJury.
The spring-diaphragm actuator is a simple, powerful mechanical device. There are two general types, Air-toExtend Stem and Air-to-Retract Stem Actuators are designated by case size: Nos. 9, 11, 13, 15, 18,ldLand 24. Case sizes are identified on the serial plate and by case and yoke dimensions.
If equipment differs from what is described on instructions, consult the nearest Masoneilan Sales Office or Representative, or Masoneilan International, Inc.
verted. On the No. 9 through 18 actuators a gasket (19) at the joint of the diaphragm case and yoke and a packing box around the actuator stem prevents air leakage. The diaphragm acts as a flexible upper guide and the packing box assembly as the lower guide for the actuator stem. Air connections are V4NPT on No. 9 through 18actuators and V2 NPT on No. 24 actuators. Connections are located in the upper diaphragm case (air-to-extend actuators) or yoke (air-to-retract actuators).
Warning: Do not exceed the recommendedair pressure shown on serial plate.
The nominal range of a spring-diaphragm actuator is the air pressurerange in pounds per square inch (psi) for rated stroke under no load. Common ranges are 3-15 and 6-30 psi. The spring range and maximum allowable supply pressure are marked on the serial plate. For a 3-15 psi nominal range, the stem will start to stroke when the air pressure reaches 3 psi and will complete the stroke when the pressure reaches 15 psi (plus or minus 5%). In the air-to-extend actuator, conformation of the molded diaphragm to the diaphragm plate serves as a flexible upper guide for the actuator stem (26). The lower guide is an oil impregnated, bronze bushing (37) located in the spring adjustor (36). The air-to-retract actuator differs from the air-to-extend unit in that the spring (22), spring barrel (71) and spring adjustor (36) are located above the diaphragm plate (40) and diaphragm (39) which are in-
Standard Actuator
Size
9
Effective
Diaphragm Area (sq. in.)

43 66
Maximum Stroke (in.)

314
11 13 15 18
1
1112
97
130
200
2
2112
I I
18L 24
I I
165
373
I I
I I
maintenance
Caution: Do not attempt to disassemble actuators, unless air pressure has been shut on.
Air-to-Extend Actuators
diaphragm replacement: Warning: Before disassembling the actuator, ail spring compression should be relieved by turning the spring adJustor(36), to prevent the upper case popping up when the cap screws (45) are removed. This is especially important on actuators with a high initial spring setting. Remove cap screws (45). nuts (46) and upper diaphragm case (43). Remove nut (30) or cap screw (76) and washer (41) to release the diaphragm (39). If possible, the replacement diaphragm should be of the molded type supplied by Masoneilan International. Inc. (see back cover for part numbers) but in an emergency a diaphragm may be cut from flat sheet stock for up to and including No. 15 actuators. To allow sufficient stroke without restriction due to flatness of the diaphragm, the diaphragm bolt circle should be about 10% greater than that of the diaphragm case.
Replace washer (41), nut (30) or cap screw (76) and upper diaphragm case.
pressure reaches minimum pressure of the rangestamped on the serial plate. This movement is most easily detected by feeling the stem as air pressure is applied. Note: Adjust spring compression only when there is no air pressure on diaphragm.
Air-to-Retract Actuators
diaphragm replacement: Procedure is the same as for air-to-extend actuators except that the entire upper case assembly (including spring barrel (71), upper diaphragm case (43), spring (22), spring seats (33 8 34), nut (30) and diaphragm plate (40)) must be removed to release the diaphragm. Install a new diaphragm and reassem ble the above parts. spring adjustment: Procedure is identical with that for air-to-extend actuators except that supply air is piped to the NPT in the yoke. packing box: The packing box is subject to low air pressure only and requires minimum maintenance. The packing is l/d (No. 9-15 actuators) or 3/16 (No. 18 and 24 actuator) string type graphite asbestos. The packing may be added to or completely replaced without disassembling either the actuator or the mechanism (or valve) to which it is attached. Be sure to tighten packing nut (20) lightly. Overtightening will cause excessive friction resulting in sluggish performance.
spring adjustment: An air supply, with a gauge and regulator, should be piped to the upper diaphragm case for this adjustment. Adjust spring compression so that the actuator stem (26) just begins to move when air
. . a , . . . . .
AIR-TO-EXTEND ACTUATORS
Case Nos. 9 , l l & 13
Case Nos. 15.18 & 18L
a
AIR-TO-RETRACT ACTUATORS
P 3 J --
i kx-&
Case Nos. 9,11, & 13 Case Nos.15,18 & 18L
Ref. NO. 1 5 17
PARTS REFERENCE
computer
Abbrev.
Gasket (packing box) Yoke Cap Screw (L. case to yoke] Gasket (L. case to yoke) Packing Nut Snap Ring Actuator Spring Actuator Spring Actuaator Stem Nut (actuator stem) Packing Box GASKET YOKE CAP SCR GASKET PKG NUT SNP RNG ACT SPR ACT SPR ACT STM NUT PKG BOX
32 33
18 19 20 21 22 22A 26 30 31
34 35
36
37 *39 40 4 1 43 44
Packing Spring Seat (upper) Spring Seat (lower) Pipe Plug Spring Adjustor Bushing (spring adjustor) Diaphragm Diaphragm Plate Diaphragm Washer Upper Diaphragm Case Lower Diaphraam Case
Cap Screw (diaph. case) Nut (diaph. case) Travel Indicator Scale Machine Screw Ball and Retainer Spring Barrel Spring Barrel Cap Ball Bearing Cap Cap Screw (SBL to U D CSE
CAP SCR NUT T I SCL MCN SCR BAL & RTN SPR BRL SBL CAP BBG RCE CAP SCR
Recommended spare parts
Air-lo-Extend
Air-to-Retract
Case No. 24
Ret. Part Name No. Yoke

17 20 22 22A 26 30 32
PARTS REFERENCE
Computer Abbrev.
YOKE PKG NUT ACT SPR ACT SPR ACT STM NUT PACKING
Ref.
No.
33 34 36 39 40 41 43 45
Part Name
Spring Seat (upper) Spring Seat (lower) Spring Adjustor Diaphragm Diaphragm Plate Diaphragm Washer Upper Diaphragm Case Cap Screw (diaph. case)
Computer
Abbrev.
USPRST LSPRST SPRADJ DIAPHRM DPH PLT DPHWSH UDCSE CAP SCR
Ref. No.
46 56 57 70 73 75 76
Part Name
Nut (diaph. case) Travel Indicator Scale Machine Screw Ball and Retainer Ball Bearing Race 0 Ring Diaphragm Cap Screw
computer
Abh.
NUT T I SCL MCH SCR BAL & RTN BBG RCE ORlNG CAP SCR
Packing Nut Actuator Spring Actuator Spring Actuator Stem Nut (actuator stem) Packing
dimensions
Actuator Size
9 11 11 13 16318 24118
cID
15 17112 20110 29%
13
-l
+
2 HOLES.
6-18 THD.
15
25518
35lh
D
NPT
18
20314
26710
36314
18L
20314
24
27112
34314
35112
Care No. 24 has t4" NPT
recommended spare parts*

For complete parts list, refer to
"Instruction
No. 6Ol8E-Parts Supplement"
Actuator Size
24 001904-604-426 19
Gasket
001 904-604-426 001 904-628-800
001 904-604-426 001 904-628-800 971 91 9-007-916 01 0275-023-686 971919-007-916 008387-002-658+ 008387-003-658&
32
Packing Diaphragm
1 1
97191 9-007-916 01 0274-022-686
971919-007-916 01 0275-023-686
L
'Air-to-Extend Actuators, order item 39 only. Air-to-RetractActuators. order item 15,19,32 & 39
+Direct
-Reverse
USEFUL EQUIVALENTS
U S . CUSTOMARY UNITS
Specific gravity of air G = 1 (reference for gases) Specific gravity of water = 1 (reference for liquids) 1 cubic foot of water = 62.34 Ibs @ std cond. (= density) 1 cubic foot of air = 0.076 Ibs @ std. cond. (= air density) Air molecular weight M = 29 G of any gas = molecular wt. of gas/29
U S gallon of water = 8 33 Ibs @ std. cond 1 cubic foot of water = 7.48 gallons Air specific volume = l/density = 13 1 cubic feet/lb G of any gas = density of gasl0.076
G of gas at flowing temp = G X 520 T + 460

Standard conditions (U S. customary) are at 14 69 psia & 60'F Flow conversion of gas SCFH = Lbs/hr X 379 SCFH = Lbs/hr density M Temperature Conversion Flow conversion of liquid GPM = -Lbs/hr - ___ 500 X G
SCFH = Lbs/hr X 13 1 G
F (Fahrenheit) = C(9/5) + 32
C (Celsius) = (F 32) 5/9
METRIC CONVERSION TABLES
Multiply
millimeters centimeters inches feet feet
BY
To Obtain
Multiply
LENGTH
0.039 0.394 2.54 30.48 n.304 inches inches centimeters centimeters meters cubic feet cubic feet liters liters
liters
gallons gallons gallons
81K9
sq. centimeters sq. centimeters sq. inches sq. inches sq. feet
0.155 0.00 1076 6.452 0.00694 929
sq.inches sq.feet sq.centimeters sq.feet sq. centimeters

Iiterdmin ftVmin rrPhr GPM GPM ftYmin GPM
pounds kilogram
ELQ!&wE
gallons US/minute (GPM) 3.785 gallons USminute 0.133 gallons US/minute 0.227 cubic feeWminute 7.481 cubic feethour 0.1247 cubic feethour 0.01667 cubic metershour 4.403 cubic metershour 35.31
ftYhr
VELOClTY
feet per second feet per second feet per second
0.3048 1.097 0.6818 meterdsecond km/hr mileshr
poundslsq. inch poundslsq. inch poundslsq. inch pounddsq. inch poundslsq. inch poundskq. inch pounddsq. inch poundslsq. inch atmosphere atmosphere atmosphere atmosphere
BY
28.32 7.4805 61.02 0.03531 0.264 3785 .O 231.O 0.1337 0.453 2.205 0.06895
To Obtain
liters gallons cubic inches cubic feet gallons cubic cm cubic inches cubic feet
kilogram pounds
0.06804
bar
kilogramlsq. cm kiloPascal
0.0703 6.895 2.307 0.703 5.171 2.036 14.69 1.Of3 1.033 101.3 14.50 14.22 0.145
bar atmosphere Kg/cm2 kPa h of H O , (4'C) m of H O , (4'C) cm of Hg (0%) in of Hg (OC) psi
bar
Kglcmz kPa psi psi psi
Facilities: Brazil, Canada, France, Germany, Italy, Japan, Mexico, Netherlands, Singapore, Spain, United Kingdom, United States
Flow Control
ASAP 32395 1M 9/01
Dresser Equipment Group, Inc. 85 Bodwell Street Avon, MA 02322-1190 Phone: 508-586-4600 Fax: 508-427-8971

Instruction ER8708 06/97 87/08 Actuator
TABLE OF CONTENTS
1.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . Actuator Removal
.2
2 2 .2
8.
Actuator Range . . . . . . . . . . . . . . . . . . . .7 - 8 Tables 1,2,3
2. 3.
4.
Actuator Description . . . . . . . . . . . . . . . . . . . .2
. . . . . . . . . . . . . . . . . . . . . . . . .7 9. Air Action Changes . . . . . . . . . . . . . . . .8 - 10

10.
5.
6.
Actuator Installation on Valve Body and Plug stem Adjustments . . . . . . . . .10 - 11 Parts Reference . . . . . . . . . . . . . . . . . . . . Table4
.12
. . . . . . . . . . . . . . . . . ..3 - 4 .4 - 7 7. Maintenance ......................
. . . . . . . . . . I . . . . . . . . . . . . . . . . . .13
1
The following instructions should be thoroughly reviewed and understood prior to installing, operating or performing maintenance on this equipment. Throughout the te caution notes will appear and must be adhered to strictly; otherwise, serious injury or equipment malfunction could result.
I
'
Actuator Type
87 00
Air to Close (extend stem) Air to Open (retract stem)
1. INTRODUCTION
The following instructions are designed to assist maintenance personnel in performing most of the maintenance required on the Model 87/88 actuator. Masoneilan has highly skilled service engineers available for start-up, maintenance and repair of our actuators and component parts. In addition, a regularly scheduled training program is conducted at the Training Center, to train customer service and instrumentation personnel in the operation, maintenance and application of our control valves and instruments. Arrangements for these services can be made through your Masoneilan Representative or Sales Office. When performing maintenance, use only Masoneilan replacement parts. Parts are obtainable through your local Masoneilan Representative or Sales Office. When ordering parts, always include Model and Serial Number of the unit being repaired.
3. ACTUATOR DESCRIPTIO..
The 87/88 Series are pneumatic spring diaphragm actuators which feature field reversibility (with no additional parts). Because of its multiple spring design, four standard spring ranges are achieved by varying spring quantity and placement. A molded rolling diaphragm and deep cases minimize area change, effecting a linear relationship between travel and air pressure.
Caution: For full automatic operation, the handwheel must be placed in the neutral position. If the handwheel is not in the neutral position, travel will be limited.
4. UNPACKING
Care must be exercised when unpacking the equipment to prevent damage to the accessories and component parts. Should any problems arise, contact your Masoneilan Representative or District Office.
2. GENERAL
These installation and maintenance instructions apply to the Masoneilan Model 87/88 actuator regardless of the valve body on which it is used. Actuator part numbers and recommended spare parts required for maintenance are listed in the Part Reference Table on page 12. The model number and action of the actuator are shown as part of the model number listed on the identification tag located on the actuator.
5. AIR PIPING
The Model 87/88 actuator is designed to accept 1/4" NPT air supply connections. If the actuator has been supplied with accessories, they are piped at the factory.
Caution: Do not exceed pressure indicated on identification tag.
0 1997 Dresser Industries, Inc. All rights reserved.

6. ACTUATOR REMOVAL
Maintenance on the valve body normally requires removal of the valve actuator. The steps in removal of the actuator are different depending on whether the actuator is air to close or air to open.
6 . 3 Air t o open (Model 88), size 6, no handwheel

(Figures 2 and 4)
Since removal of the valve plug stem from the actuator stem connector requires that the valve plug be off the seat, special provisions are necessary to assure that the valve is in the opened position. The actuator do not being equipped with a handwheel, proceed as follows:
Note: Actuator action may be checked by referring to the valve identification tag. Model 87 indicates unit is air to close and Model 88 indicates unit is air to open.
6.1 Air t o close (Model 87), size 6, with or without handwheel (Figure 2)
A. Shut off air supply to actuator and' rotate handwheel to the neutral position. [No force exerted on the stem connector by the pivot pins (33)].
Note: Since air supply piping connected to the actuator is normally rigid and the actuator will be moved, it is required that a manual loading panel ,with suitable flex tubing be used or some suitable type of flex connections be made between the supply piping and the actuator connection.
B. Disconnect air piping from diaphragm case.

C. Check the travel indicator (7) against the travel scale (9) to insure that the plug is up (off the seat).
Caution: Unreasonably high stress placed on rigid piping could cause breaking of the air supply,line. A flex connector is required.
A. Shut off air supply to the actuator.
Note: No air pressure is required to the actuator since the spring pressure tends to open the valve.
D. Loosen stem lock nuts (1).
B. Disconnect air supply piping to the actuator.

C. Connect manual loading panel tubing to the lower diaphragm case tubing connector. D. Apply required air pressure through the manual loading panel to open the valve as is indicated by the travel indicator (7) and travel indicator scale (9).
E. Re-tighten lock nuts (1) against each other so they will lock at a point that i s not against the stem connector (2).
~
Caution: At this time provisions must be made to support and lift the actuator off the body using recommended lift supports and procedures.
Caution: Do not exceed pressure indicated on the on the diaphragm case. tag (63)
E. Loosen stem lock nuts (1).
F. Loosen and remove drive nut.

required to slightly raise the actuator off the body to enable the plug stem to disengage from the actuator stem. The actuator must be raised straight
F. Re-tighten stem lock nuts (1) against each other so they will lock at a point that is not against the actuator stem connector (2).
G. Loosen and remove drive nut.
G. Turn the stem lock nut (1) counterclockwise and loosen the plug stem until it disengages from the actuator stem (10). Note: Do not allow the valve plug to drop or turn against the seat ring, as this could damage the seat and plug.
H. Remove actuator from the valve body.
required to slightly raise the actuator off the body to enable the plug stem to disengage from the actuator stem. The actuator must be raised straight off the body to prevent stress on the plug stem.
H. Turn the upper stem lock nut (1) counterclockwise and unscrew the valve plug stem until disengaged from the actuator stem (10).
Caution: Care should be taken in handling the actuator to prevent damage to gauges, tubing, and component parts.
Note: Do not allow the plug to drop or turn against the seat ring. This could damage the seat and plug.
I. Remove actuator from the valve body and shut off air supply pressure.
~
6.2 Air to open, Model 88, size 6, with handwheel

Caution: The stem connector (2) on this size is not fixed to the actuator stem and is a loose part with the plug stem removed. For safety, the handwheel must be in a free position and the actuator removed from the valve I using procedure 6 . 3 Air to Open without handwheel.
Caution: Care should be taken in handling the actuator to prevent damage to gauges, tubing, and component parts. In addition, since a flex connection is made between the actuator and air piping, care must be taken not to exert pressure on the flex tubing or air piping.

6.4 Air t o close (Model 87), sizes 10-23, with and without handwheel (Figure 3)
A. Shut off air supply to actuator and rotate handwheel to the neutral position.
E. Loosen stem lock nuts (1).
F. Remove cap screws (5) from stem connector (2, 4).

Note: Do not allow the valve plug to drop or turn against the seat ring, as this could damage the seat and plug.
~
B. Disconnect air piping from diaphragm case.

C. Check the travel indicator (7) against the travel scale (9) to insure that the plug is up (off the seat).
Note: No air pressure is required to the actuator since the spring pressure tends to open the valve.
D. Loosen stem lock nut (1).
G. Loosen and remove drive nut.
E. Remove cap screws ( 5 ) from stem connector (2, 4). Note: Do not allow the valve plug to drop or turn
against the seat ring, as this could damage the seat and plug.
Caution: Progressively raise actuator off the body to enable the top stem connector (4) disengage the bottom stem connector (2). The actuator must be raised straight off the body to prevent stress on the plug stem.
F. Loosen and remove drive nut.
H. Remove bottom stem connector parts (1, 2, 6) from

plug stem. I. Remove actuator from the valve and shut off air supply pressure.
Caution: Progressively raise actuator off the body to enable the top stem connector (4) disengage the bottom stem connector (2). The actuator must be raised straight off the body to prevent stress on the plug stem.
G. Remove bottom stem connector parts (1, 2, 6) from plug stem.
7. MAINTENANCE
Caution: It is recommended that disassembly or assembly work on these actuators be done in an upright position.
H. Remove actuator from the valve.
6.5 Air to open, Model 88, Size 10-23, with or without handwheel (Figure 4)
Since removal of the valve plug stem from the actuator stem connector requires that the valve plug be off the seat, special provisions are necessary to assure that the valve is in the opened position. Proceed as follows:
7.1 Replacing diaphragm air to open actuators (Model 88) with or without handwheel (Figure 4)
A. Shut off air supply to the actuator, isolate the control valve process pressure to eliminate the valve from moving with spring tension removed.
B. If valve is equipped with a handwheel, rotate handwheel to a neutral position.
Note: Since air supply piping connected to the actuator is normally rigid and the actuator will be moved, it is required that a manual loading panel with suitable flex tubing be used or some suitable type of flex connections be made between the supply piping and the actuator connection.
C. Remove diaphragm case cap screws and nuts (20 and 19).
Caution: Unreasonably high stress placed on rigid piping could cause breaking of the air supply line. A flex connector is required.
A. Shut off air supply to the actuator and rotate handwheel to the neutral position.
Caution: Diaphragm case is under spring tension and is equipped with tension bolts (27, 28 and 56) which must be removed last.
D. Remove tension bolts (27, 28 and 56) in multiple steps

to relieve spring tension gradually. Remove upper diaphragm case (24).
B. Disconnect air supply piping to the actuator.
C. Connect manual loading panel tubing to the lower diaphragm case tubing connector.
D. Apply required air pressure through the manual loading panel to open the valve as is indicated by the travel indicator (7) and stroke scale (9).
E. Note position of springs (21) and spring spacers (18) [if equipped] in the diaphragm plate (26), before to remove these parts.
F. Remove cap screw (23) [size 61 or jam nut (23)

[all other sizes] and diaphragm washer (22) [all sizes].
G. Remove diaphragm plate (26) and diaphragm (25).

H. Replace the new diaphragm (25) on the diaphragm plate (26).
Caution: Do not exceed pressure indicated on the tag (63)on the diaphragm case.
I.
Size 6 actuator coat the threads of cap screw (23) and

mounted through the yoke and secure the handwheel pivot (36) in place (see Figure 7). D. Let the complete handwheel assembly swing down and out of the way of the top stem connector (4) [bottom stem connector (2) on size 6 actuator]. E. Proceed with the instructions for air to close actuators without handwheel (7.3).
7.3 Replacing diaphragm air to close (Model 87) actuator without handwheel (Figures 2 or 3 and 7)
A. Shut off air supply to the actuator and remove air piping from the upper diaphragm case (24).
Figure 1
B. Remove the two socket head cap screws (5) which hold the top and bottom stem connector (2 and 4) together. Note: The size 6 actuator only has a bottom stem connector. For diaphragm replacement, the stem lock nuts ( 1 ) must be loosened. The plug stem is turned out at the actuator stem (10) in order to allow the actuator stem to rise with release of spring tension. Depending on stem length, it may be required, to allow this step, to separate the size 6 actuator off the valve body, as indicated in Section 6.1.
the surfaces of washer (22) with Dupont Sealant Compound Ill or equal. All other sizes, coat the actuator stem threads (10) and the surfaces of washer (22) with Dupont Sealant Compound Ill or equal.
J. Checking placement of spacer (14), reassemble diaphragm (25), diaphragm plate (26), washer (22) then tighten fastener (23) in proper locations.
K. Position springs (21) and spring spacers (18) [if used] in the diaphragm plate.
C. Remove diaphragm case cap screws and nuts

(20and 19).
Note: Arrange springs so that the coil ends are pointed toward the actuator stem as shown in Figure 1. This step assures best actuator performance.
Replace upper diaphragm case (24) and tension bolts (27, 28 and 56).
D. Remove tension bolts (27, 28 and 56) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24). E. Remove cap screw (23) [size 61 or jam nut (23) [all other sizes] and diaphragm washer (22) [all sizes]. F. Replace new diaphragm (25) on the diaphragm plate (26).
Note: Tension bolts should be spaced equally around the bolt circle o f the case.
M. Tighten the tension bolts (27, 28 and 56) in equal steps until the cases meet. Replace the remaining cap screws (20) and nuts (19).
Caution: Tighten cap screws and nuts evenly. Do not over-tighten as this could possibly warp the diaphragm cases. See Table 3 for torque values.
N. If so equipped, rotate handwheel to the desired

position.
7.2 Replacing diaphragm air t o close (Model 87) actuator with handwheel (Figures 2 or 3 and 7)
Caution: The handwheel assembly can hold spring tension in the actuator when the diaphragm case is removed. To prevent possible injury, remove handwheel per the following procedure.
~~
G. Size 6 actuator, coat the threads of cap screw (23) and the surfaces of washer (22) with Dupont Sealant Compound 111 or equal. All other sizes, coat the actuator stem threads (10) and the surfaces of washer (22) with Dupont Sealant Compound Ill or its equivalent. Install washer (22) and tighten fastener (23).
H. Replace upper diaphragm case (24) and tension bolts (27, 28 and 56).
Note: Tension bolts should be spaced equally around the bolt circle o f the case.
I. Tighten the tension bolts (27, 28 and 56) in equal steps until the cases meet. Replace the remaining cap screws (20) and nuts (19).
A. Shut off air supply to the actuator, isolate the control process pressure to eliminate the valve plug from moving with spring tension removed.
B. Rotate the handwheel (41) to a neutral position. C. Remove two handwheel pivot pins (33) which are
Caution: Tighten cap screws and nuts evenly. Do not overtighten as this could possibly warp the diaphragm cases. See Table 3 for torque values.

J. Position top and bottom stem connectors (2 and 4) and replace the two socket head cap screws (5) and recalibrate the seated position of the valve (Section 10.2).
E. Remove cap screw (38) and end flange (37). This will
release the bearing (34). F. Replace or clean to repack the bearing with new grease.
Note: Size 6 actuator- Screw the plug stem back into the actuator stem (10) thru the bottom stem connector and recalibrate the seated position of the valve. If the actuator has been removed from the valve body, reinstall it as indicated in Section 10.2).
G. Pack bearing (34) with Mobilux No. 2 grease or equal.

Note: It is important that the bearing be packed, not just coated, with grease.
H. For remounting, reverse removal procedures from step (E) through (B). '
Note: If the actuator has a handwheel (Section 7.2), continue with the following steps :
K. Swing handwheel assembly back up into place.
L. Install the two pivot pins (33) in the yoke and engage them into the handwheel pivot (36).
7.6 Replace diaphragm seal and stem sea'[, air to open (Model 88) actuators (Figure 2 or 4)
I
7.4 Replace or repack handwheel bearing, size 6 and 10 actuators (Figures 5 and 7)
A. Rotate handwheel to a free position.
B. Remove handwheel cap screw (20) and washer (42).
B. If valve is equipped with a handwheel, rotate handwheel to a free position.
C. Remove diaphragm case cap screws and nuts (20& 19). Caution: Diaphragm case is under spring tension and is equipped with tension bolts (27, 28 and 56) which must be removed last.
D. Remove tension bolts (27, 28 and 56) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24). E. Note position of springs (21) and spring spacers (18) [if equipped] in the diaphragm plate (26).
F. Remove springs (21) and spring spacers (18) if used.
C. Remove handwheel (41) and lock nut (43).

D. Remove pivot pins (33) from the yoke which hold the handwheel pivot (36).
E. Remove snap rings (46) and remove lever pin (45) to

release handwheel assembly. F. Turn handwheel stem (39) until it clears traveling nut (40).
G. Remove snap ring (38) and bearing ring (37) to release the handwheel stem (39) from the bearing.
On size 6 Actuator: G. Loosen lock nuts (1). Re-tighten lock nuts against each other so they will lock at a point that is not against the stem connector (2). By means of a wrench, hold the nuts (1) and plug stem. Turn the actuator stem (10) subassembly until it disengages from the plug stem and remove completely from actuator. On size 10, 16 and 23 Actuators: G. Loosen lock nut (32) on actuator stem (10). Hold the connector device (2, 4, 6). Turn the actuator stem (10) subassembly and remove it when it clears the connector insert (6), (on size 6), or the top stem connector (4), (on sizes 16 and 23). On all sizes:
H. Remove case cap screws (16) to gain access to seal washers (15).
H. Remove snap ring (35) to release bearing (34).

I. Replace or clean to repack bearing (34) with new grease.
J. Bearing should be packed with Mobilux No. 2 grease or equal.

Note: It is important that bearing be packed, not just coated, with grease.
K. To reassemble, reverse removal procedures from step

(H) through (B).
7.5 Replace or repack handwheel bearing size 16 and 23 actuators (Figures 6 and 7)
A. Rotate handwheel to a free position.
B. Remove pivot pins (33) which engage the handwheel pivot (36) thru the yoke.
Note: If seal washers (15) replacement is the only maintenance, proceed to Step N.
I. Remove lower diaphragm case (17) and stem bushing (30).
C. Remove snap rings (46) and remove lever pin (45) to release complete handwheel assembly.
D. Remove snap ring (35) and slide the handwheel pivot (36) off the bearing (34).
Note: Mark orientation of the case to the yoke.

J. Replace stem wiper (11) and O-rings (12 and 13).

K. Coat
O-rings (12and 13) and inside of stem bushing (30) with Dupont Compound Ill (or equivalent).
L. Install stem bushing (30) in the yoke with new O-rings (12and 13). M. Place the diaphragm case ( 17)on the yoke. N. Coat the surface of the spring guides (29) in contact with the diaphragm case with Dupont Sealant Compound Ill or equivalent. Assemble spring guides (29), new seal washers (15), and cap screws (16)in this order. 0. Re-install the actuator stem (10)Subassembly into the yoke bushing. Turn actuator stem into insert (6), (size lo), or into the top stem connector (4),(size 16 and 23). In case of size 6 actuator, turn actuator stem on the plug stem after installing the stem connector (2). Turn until stem spacer (14)contacts the lower diaphragm case (17). P. Tighten lock nut (32) against connector insert (6), (size l o ) , or against the top stem connector (4), (on sizes 16 and 23). In case of size 6 actuator, lock the stem connector (2)and the two nuts (1)against the lower part of actuator stem. Q. Position springs (21) and spring spacers (18) [if used] in the diaphragm plate. Note: Arrange springs so that the coil ends are pointed toward the actuator stem as shown in Figure 1. This step assures best actuator performance.
TABLE 1 ACTUATOR SPRING TRAVEL COLOR 38 (1.51 51 i2.01 64 (2.5)

TABLE 2
~ ~
BLUE GREEN YELLOW
SPRING POSITION SPRING NO. OF ON DIAPHRAGM SPRINGS RANGE PLATE REQUIRED psi (rn.bar) 3-15 (0.207-1.034) 3 BOTrOM 6-30 (0.414-2.069) 6 BOTTOM 3' PEDESTAL 11-23 (0.759-1.586) 6 PEDESTAL 21-45 (1.448-3.1 03)
SPRING SPACER (18) REQUIRED NO NO YES' YES'
TABLE 3
Bolt/Nut Reference Yoke Cap Screw (16)
._ ,
R. Replace upper diaphragm case (24)and the tension 28 and 56). bolts (27,
Note: Tension bolts should be spaced equally around the bolt circle of the case. S. Tighten the tension bolts (27, 28 and 56)in equal steps until the cases meet. Replace the remaining cap screws (20) and nuts (19). Caution: Tighten cap screws and nuts evenly. Do not over-tighten as this could possibly warp the diaphragm cases. See Table 3 for torque values.
T. If necessary, recalibrate the seated position of the valve (Section 10.1).
Case Bolt (19, 20) or Tension Bolt (27, 28) Actuator Stem Nut (23) or Cap Screw (23)
Socket Head Cap Screw (5)
121.5 I L W ~ (190) 7.5 12.5 (65) (110) 3.5 7.5 (25) (55) 4.5 (35)
__
45 (400) 17 (150) 13 (95) 17 (125)
, 23
68 (600) 19 (170) 20.5 (150) 17 11251
Handwheel Cap Screw (20)
7.5 (65)
Handwheel Stem Cap Screw (38)
7.5 (65)
17 17 (150) (150) 13.5 13.5 l(100) (loo)/
8. ACTUATOR RANGE 8.1 Actuator range change, air to open (Model 88).
A. Shut off air supply to the actuator, isolate the control valve process pressure to eliminate the valve from moving with spring tension removed. D. Remove tension bolts (27, 28 and 56) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24).
E. Position springs (21)[and
spring spacers (18), if new range uses them], in the diaphragm plate.
6. If valve is equipped with a handwheel, rotate

handwheel to a free position. C. Remove diaphragm case cap screws and nuts (20 and 19).
F. Refer to Tables 1 , 2 and 4 for spring information :

a. For 11 and 2 1 psi (0,759 and 1,448 bar) initials, the springs are placed directly on the upper pedestals in the diaphragm plate (26). b. For 3 and 6 psi (0.207 and 0.414bar) initials, the springs are placed in the bottom cavity in the diaphragm plate.
I

c. For 11 and 21 psi (0.759and 1.448 bar) initials and travel ranges larger than 0.8" (20mm), the spring
spacers (18) are placed as shown in the cross sectional view, Figure 4.
springs are placed directly on the upper pedestals in the diaphragm plate (26).
b. For 3 and 6 psi (0.207and0.414bar) initials, the

springs are placed in the bottom cavity in the diaphragm plate.
Note: Spring spacers (18) are not required for 0.8" (20 mm) travel ranges. Note: Arrange springs so that the coil ends are pointed toward the actuator stem as shown in Figure 1. This step assures best actuator performance. G. Replace upper diaphragm case (24) and tension bolts (27, 28 and 56). Note: Tension bolts should be spaced equally around the bolt circle of the case.
H. Tighten the tension bolts (27, 28 and 56) in equal steps until the cases meet. Replace the remaining cap screws (20) and nuts (19).
c. For 11 and 21 psi (0.759 and 1.448 bar) initials and travel ranges larger than 0.8" (20mm), the spring
spacers (18) are placed as shown in the cross sectional view, Figure 4.
Note: Spring spacers (18) are not required for 0.8" (20 mm) travel ranges. Note: Arrange springs so that the coil ends are pointed toward the actuator stem as shown in Figure 1. This step assures best actuator performance.
I. Replace the diaphragm plate (26) on the actuator stem (10) and over the springs. To ensure the springs are properly located, check the view hole in the diaphragm plate. A spring should be seen.
I. If so equipped, rotate handwheel to the desired position.
J. Install the diaphragm (25). K. Size 6 actuator coat the threads of cap screw (23) and the surfaces of washer (22) with Dupont Sealant Compound Ill or equal. All other sizes, coat the actuator stem threads (10) and the surfaces of washer (22) with Dupont Sealant Compound Ill or equal.
L. Replace upper diaphragm case (24) and the tension bolts (27, 28 and 56).
8.2 Actuator range change, air to close (Model 87)

Note: If actuator is equipped with a handwheel, please follow steps 7.2 A, B, C and D to disengage this assembly.
A. Shut off air supply to the actuator and remove air piping from the upper diaphragm case (24).
Note: Tension bolts should be spaced equally around the bolt circle of the case.
M. Tighten the tension bolts (27, 28 and 56) in equal steps until the cases meet. Replace the remaining cap screws (20) and nuts (19).
6. Remove the two socket head cap screws (5) which

hold the top and bottom stem connector (2 and 4) together.
Note: The size 6 actuator only has a bottom stem connector (2). For access to springs, the stem lock nuts (1) must be loosened. The plug stem is turned out at the actuator stem (10) to allow the actuator stem to rise with release of spring tension. Depending on stem length, it may be required, to allow this step, to separate the size 6 actuator off the valve body, as indicated in Section 6.1.
C. Remove diaphragm case cap screws and nuts (20and19).
N. Position top and bottom stem connectors (2 and 4) and replace the two socket head cap screws (5) and recalibrate the seated position of the valve (Section 10.2). Note: Size 6 actuator - Screw the plug stem back into the actuator stem (10) thru the bottom stem connector (2) and recalibrate the seated position of the valve. If the actuator has been removed from the valve body, re-install it as indicated in Section 10.2).
D. Remove tension bolts (27, 28 and 56) and compression nuts (28) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24).
Note: If the actuator has a handwheel (Section 7.2), continue with the following steps:
0. Swing handwheel assembly back up into place.
P. Install the two pivot pins (33) in the yoke and engage
them into the handwheel pivot (36).
E. Remove cap screw (23) [size 6 1 or jam nut (23) [all other sizes] and diaphragm washer (22).
F. Remove diaphragm plate (26) and diaphragm (25).
9. AIR ACTION CHANGES

9.1 Air to Open to Air to Close (Model 88 to Model 87)
G. Place springs (21) over the spring guides (29).
H. Refer to Tables 1, 2 and 4 for spring information:

a. For 11 and 21 psi (0.759 and 1.448 bar) initials, the

Instruction ER8788 06/97 87/88Actuator
B. If valve i s equipped with a handwheel, rotate handwheel to a neutral position.
until the cases meet. Replace the remaining cap screws (20) and nuts (19).
C. Remove snap rings (46) and remove lever pin (45) to allow handwheel assembly to swing away from the stem connector (2-4).
D. Remove the two socket head cap screws ( 5 ) which hold the top and bottom stem connector (2 and 4) together.
Note: The size 6 actuator only has a bottom stem connector (2). For changing of action, the stem lock nuts (1) must be loosened. The plug stem is turned out at the actuator stem (10) in order to allow the actuator stem to rise while springs installation in Model 87. Depending on stem length, it may be required, to allow this step, to separate the size 6 actuator off the valve body, as indicated in Section 6.3.
Caution: Tighten cap screws and nuts evenly. Do not over-tighten as this could possibly warp the diaphragm cases. See Table 3 for torque values. P. Position top and bottom stem connectors (2 and 4) and replace the two socket head cap screws (5) and recalibrate the seated position of the valve (Section 10.2).
Note: Size 6 actuator - Screw the plug stem back into the actuator stem (10) thru the bottom stem connector (2) and recalibrate the seated position of the valve. If the actuator has been removed from the valve body, re-install it as indicated in Section 10.2).
E. Remove diaphragm case cap screws and nuts (20and 19).
Note: If the actuator has a handwheel, continue with the following steps :
Q. Swing handwheel assembly back up into place. The handwheel (41) may have to be turned in order to position the lower pivot pins (33).
F. Remove tension bolts (27, 28 and 56) in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24). Remove springs (21) and spacer (18) if equipped.
R. With the pivot pins positioned on top of the stem

connector (2 and 4), replace the lever pin (45) and snap rings (46).
9.2 Air to Close to Air to Open, (Model 87 to Model 88)

Caution: The handwheel assembly can hold spring tension in the actuator when the diaphragm case is removed. To prevent possible injury, remove handwheel per the following procedure.
G. Remove cap screw (23) [size 61 or jam nut (23) [all other sizes] and diaphragm washer (22) [all sizes].
H. Remove diaphragm plate (26) and diaphragm (25). I. Place springs (21) over the spring guides (29).
J. Refer to Tables 1, 2 and 4 for spring information. Refer also to Section 8.1 F, Steps a., b., c.
Note: Spring spacers (18) are not required for 0.8 (20mm) travel ranges. Note: Arrange springs so that the coil ends are pointed toward the actuator as shown in Figure 1. This step assures best actuator performance.
K. Invert and replace the diaphragm plate (26) on the actuator stem (10) and over the springs.
A. Shut off air supply to the actuator, isolate the control

process pressure to eliminate the valve from moving with spring tension removed. B. Rotate the handwheel (41) to a neutral position.
C. Remove snap rings (46) and lever pins (45). D. The complete handwheel assembly can now swing out of the way of the top stem connector (2 and 4) [bottom stem connector (2) on the size 6 actuator]. E. Proceed with the instructions for actuators without handwheel (9.3 Step B).
Note: To ensure the springs are properly located, check the view hole in the diaphragm plate. A spring should be seen.
L. Install the diaphragm (25). M. Size 6 actuator coat the threads of cap screw (23) and the surfaces of washer (22) with Dupont Sealant Compound Ill or equal. All other sizes, coat the actuator stem threads (10) and the surfaces of washer (22) with Dupont Sealant Compound Ill or equal.
9.3 Air to Close to Air to Open (Model 87 to Model 88), without handwheel
A. Shut off air supply to the actuator and remove air
piping from the upper diaphragm case (24).
B. Remove the two socket head cap screws ( 5 ) which

hold the top and bottom stem connector (2 and 4) together.
Note: The size 6 actuator only has a bottom stem connector. For changing of action, the stem lock nuts (1) must be loosened. The plug stem is turned out at the actuator stem (10) in order to allow the actuator stem to rise with release of spring tension, while disassembly.
N. Replace upper diaphragm case (24) and tension bolts (27, 28 and 56).
Note: Tension bolts should be spaced equally around the bolt circle of the case.
0. Tighten the tension bolts (27, 28 and 56) in equal steps

Depending on stem length, it may be required, to allow this step, to separate the size 6 actuator off the valve body, as indicated in Section 6.1.
C. Remove diaphragm case cap screws and nuts (20&19).
Note: If the actuator has a handwheel, continue with the following steps.
0. Swing the handwheel assembly back into place.

P. It may require turning the handwheel (41) to position the lower pivot pins (33)under the stem [bottom stem connector (2) on the size connector (2-4), 6 actuator]. Q. Install the lever pin (45) and snap rings (46).
D. Remove tension bolts (27, 28 and 56)in multiple steps to relieve spring tension gradually. Remove upper diaphragm case (24).
10. ACTUATOR INSTALLATION ON VALVE BODY AND PLUG STEM ADJUSTMENT

Caution : SIZE 6 - The stem connector (2) is not fixed to the actuator stem and is a loose part with the stem nuts (1) backed off. For safety reasons, adjustments should only be made pneumatiqally.
These installation and plug stem adjustment procedures are available for mounting of the Models 87/88Actuators on most of the reciprocating and hard seat valves series. In case of the valves with spring loaded internal auxiliary tight shutoff plug (41400 Series), or valves with PTFE Soft seat ring, refer to instruction Add. No 184399 E or to the Section Models 87/88 Actuators Coupling on the specific instructions of the valve.
E. Remove cap screw (23)[size 61 or jam nut (23)

[all other sizes] and diaphragm washer (22) [all sizes].
F. Remove the diaphragm (25), diaphragm plate (26), springs (21) and spring spacers (18) if used.
G.Invert the diaphragm (25) and diaphragm plate (26).

H. Size 6 actuator coat the threads of cap screw (23) and the surfaces of washer (22)with Dupont Sealant Compound Ill or equal. All other sizes, coat the and the surfaces of washer actuator stem threads (10) (22) with Dupont Sealant Compound Ill or equal. I. Checking placement of spacer (14) reassemble diaphragm plate (26),washer (22) diaphragm (25), then tighten fastener (23) in proper locations.
J. Position springs (21) and spring spacers (18)[if used] in the diaphragm plate.
10.1 Air to open (Model 88)

A. Connect manual loading panel tubing to the lower diaphragm case.
K. Refer to Tables 1 , 2 and 4 for spring information. Refer . 1 F, Steps a., b., c. also to Section 8 Note: Spring spacers (18) are not required for 0.8 (20 mm) travel ranges. Note: Arrange springs so that the coil ends are pointed toward the actuator stem as shown in Figure 1. This step assures best actuator performance. L. Replace upper diaphragm case (24)and tension bolts (27, 28 and 56). Note: Tension bolts should be spaced equally around the bolt circle of the case.
M. Tighten the tension bolts (27, 28 and 56)in equal steps until the cases meet. Replace the remaining cap and nuts (19). screws (20)
B. Apply required air pressure through the manual loading 10). panel to completely retract the actuator stem (
C. Install actuator on the valve body with drive nut.

D. Position top and bottom stem connectors (2and 4)and replace the two socket head cap screws (5). Turn as far as possible the plug stem into lower part of the stem connector (2or 6).
Note Size 6 actuator - Screw the plug stem into the actuator stem (10) thru the bottom stem connector (2). Depending on stem length, it may be required, to allow this step, to progressively lower the actuator towards the body, during screwing plug stem into actuator stem.
E. Release air pressure, then ensure that the actuator stem is fully extended. F. Using the stem lock nuts (l), unscrew the plug stem until the plug touches the seat.
N. Position top and bottom stem connectors (2and 4) and replace the two socket head cap screws (5)and recalibrate the seated position of the valve (Section 10.1). Note: Size 6 actuator - Screw the plug stem back into the actuator stem (10) thru the bottom stem connector (2) and recalibrate the seated position of the valve. If the actuator has been removed from the valve body, re-install it as indicated in Section 10.1).
Caution: DO NOT TURN the plug against the seat as damage can occur.
G. Pneumatically or with the handwheel, stroke the actuator to raise the plug off the seat. Unscrew the plug stem one full turn and lock the stem in place with against the stem connector (2or 6). the lock nut(s) (1)
H. Line up the stroke scale (9)with the pointer (7)and check actuator for operation.
10

23
10.2 Air to close (Model 87)
A. Install actuator on the valve body with drive nut.
22
63
21
i
27
56
B. Position top and bottom stem connectors (2 and 4) and replace the two socket head cap screws (5). Turn as far as possible the plug stem into lower part of the stem connector (2 or 6).
Note: Size 6 actuator - Screw the plug stem into the actuator stem (10) thru the bottom stem connector (2). Depending on stem length, it may be required, to allow this step, to progressively lower the actuator towards the body, during screwing plug stem into actuator stem. C. Pneumatically or with the handwheel, stroke the actuator to the rated spring range or stroke (if using the handwheel).
-20
D. Using the stem lock nuts (1) unscrew the plug stem
until the plug touches the seat. Caution: DO NOT TURN the plug against the seat, as damage can occur.
E. Release the pressure in the actuator or back off the handwheel to raise the stem. F. Unscrew the stem 1/2 turn and lock the stem in place by tightening the stem nuts (1) against the stem connector (2 or 6).
with optional Handwheel
Size 16 Actuator Ail to Open (Model 88) Figure 2 Size 6 Actuator Air to Close (Model 87)
G. Line up the stroke scale (9) with the pointer (7) and check actuator for operation.
23
22
63
Figure 7 Handwheel Cover
Ref. No
1 2 3 4 5 6 7 8 9 10 0 11 012 013 14 0 15 16 17 18
Description
HexNut Stem Connector, bottom Cap Screw, Hex head Stem Connector, top Cap Screw, SOC. head Connector Insert Pointer Screw, Pan head Scale -Travel Actuator Stem Stem Wiper 0-Ring 0-Ring Spacer Seal Washer Cap Screw, Hex head Lower Diaphragm Case Spring Spacer
Ref. Na
19 20 21 22 ~ 2 24 025 26 27 28 29 30 31 *32 34 33
--
Parts References
.
~ ~
Size 23 Actuator with optional Handwheel
Description
HexNut Cap Screw, Hex head Spring Washer Nut, Jam 3 Upper Diaphragm Case Diaphragm Diaphragm Plate Cap Screw, Hex head Compression Nut Spring Guide Stem Bushing Yoke, machining Lock Nut Thrust Pivot Pin Bearing Retainina Ring Handwheel Pivot
Ref. No A 37 V 38 39 40 41 42 43 44 45 46 56 57 58 59 61 62 63
Description
End Flanae CaD Screw. Hex head Handwheel Stem Travelina Nut Handwheel Washer. Flat Lock Nut Lever Pin Lever Assembly Handwheel Retainina Ring Warning Plate Handwheel Cover Groove Pin 1/4 NPT Plug Serial Plate (Not Shown) Drive Screw (Not Shown) Caution Tag
* * *
35 36
Figure 3 Size 16 Actuator Air to Close (Model 87)
A Bearing Ring on Sizes 6 and 10 V Retaining Ring on Sizes 6 and 10
11
12

TABLE 4 Arrangement of springs into diaphragm plate according to actuator characteristics
13
Sales Offices and Distribution Centers

AUSTRIA
Masoneilan HP+HP GmbH Hans Kudlich-Strasse 35 A2100 Korneuburg (b. Wien), Austria Phone: 43-2262-63689 Fax: 43-2263-68915
ITALY
Dresser ltalia S.p.A. Masoneilan Operation Via Cassano, 77 80020 Casavatore (Naples), Italy Phone: 39-81-7892-111 Fax: 39-81-7892-208
SOUTH AFRICA
Dresser Ltd, South Africa Branch Valve Division P.O. Box 2234, 16 Edendale Road Eastleigh, Edenvale 1610 Republic of South Africa Phone: 27-11-452-1550 Fax: 27-11-452-6542
BELGIUM
Masoneilan Division of Dresser Europe, S.A. 281 -283 Chaussee de Bruxelles 281-283 Brusselsesteenweg 1190 Brussels, Belgium Phone: 32-2-344-0970 Fax: 32-2-344-1123
JAPAN
Niigata Masoneilan Company, Ltd. 20th Floor, Marive East Tower WBG 2-6 Nakase, Mihama-Ku Chiba-shi, Chiba 261-7120, Japan Phone: 81-43-297-9222 Fax: 81 -43-299-1115
SPAIN
Masoneilan, S.A. Zona Franca, Sector M., Calle Y 08040 Barcelona, Spain Phone: 34-93-223-4175 Fax: 34-93-223-4754
BRAZIL
Dresser lndustria E Comercio Ltda Divisao Masoneilan Rua Senador Vergueiro, 433 09521-320 Sao Caetano Do Sul Sao PaUlo, Brazil Phone: 55-11-453-5511 Fax: 55-11-453-5565
KOREA
Dresser Korea, Inc. #2107 Kuk Dong Building 60-1, 3-Ka, Choongmu-ro Chung-Ku, Soeul-100705, Korea Phone: 82-2-274-0792 Fax: 82-2-274-0794
SWITZERLAND
Dresser Europe SA Frauentalweg 76 CH-8045 Zurich, Switzerland Mailing Address: P.O. Box 3568 CH-8021 Zurich, Switzerland Phone: 41 -1-450 28 91 Fax: 41-1-450 28 95
Dresser Valve Division Alberta, Valve Division, Dresser Canada, Inc. P.O. Box 242 #300,444-58th Avenue S. E. Safat 13003, Kuwait Calgary, Alberta T2H OP4, Canada Courier: Phone: 403-299-2565 Flat No. 36, Floor 8 Fax: 403-299-2575 Gaswa Complex, Mahboula, Kuwait Ontario, Valve Division, Dresser Canada, Inc. Phone: 965-9061157 5010 North Service Road MEXICO Burlington, Ontario L7L 5R5, Canada Masoneilan Internacional, S.A. de C.V. Phone: 905-3353529 Henry Ford No. 114, Esq. Fulton Fax: 905-336-7628 Fraccionamiento Industrial San Nicolas FRANCE 54030 Tlalnepantla Estado de Mexico Dresser Produits lndustriels Phone: 52-5-310-9863 Division Masoneilan Fax: 52-5-310-5584 4 Place de Saverne THENETHERLANDS 92400 Courbevoie, France Dresser Industrial Products B.V. Mailing Address: Masoneilan Division 92971 Paris La Defense Cedex, France Steenhouwerstraat 11 Phone: 33-1-49-04-90-00 3194 AG Hoogvliet, The Netherlands Fax: 33-1-49-04-90-10 Mailing Address: Germany P.O. Box 640 NL-3190 AN Hoogvliet RT Masoneilan HP+HP GmbH The Netherlands Klein-Kollenburg-Strasse 78-80 Phone: 31-1 0-438-4122 47877 Willich, Germany Fax: 31 -10-438-4443 Mailing Address: P.O. Box 1208, 47860 Willich, Germany SINGAPORE Phone: 49-2156-9189-0 Fax: 49-2156-41058 Dresser Singapore Pte Ltd. Valve Division 16, Tuas Avenue 8 INDIA Singapore 639231 Dresser Valve India Pvt. Ltd. Phone: 65-861-6100 305-306 Midas-Sahar Plaza Fax: 65-861-7172 Mathurdas Vasanji Road J.B. Nagar-Andheri East Mumbai, India 400 059 Phone: 91-22-835-4790 Fax: 91-22-835-4791 Masoneilan is an international leader in the design, manufacture, and support of final control elements and solutions for efficient process automation. Masoneilan is an integral part of Dresser Industries Valve & Controls Division (DVCD), which also includes the Nil-Cor and Industrial Valve Operations. DVCD provides a comprehensive portfolio of control valves, corrosion resistant valves, pressure relief valves, and intelligent field instrumentation. ASAP 241 48 6/99 5M
CANADA
KUWAIT
UNITED ARAB EMIRATES

Dresser Valve Division Post Box 61302 Jabel Ali Free Zone United Arab Emirates Courier: Units Nos. JAOl+JA02 Roundabout 8 Jebel Ali Free Zone, United Arab Emiratc Phone: 971-4-838-752 Fax: 971-4-838-038
UNITED KINGDOM
Valve Division, Dresser U.K. Limited Trevithick Works Gillibrands Estate, Skelmersdale Lancashire WN8 9TU, England United Kingdom Phone: 44-1 695-52600 Fax: 44-1695-52662 Valve Division, U.K. Southern Sales Office Unit 5, Brook Business Centre Cowley Mill Road, Uxbidge Middlesex UB8 2FX, England, United Kingdom Phone: 44-1 895-454900 Fax: 44-1 895-454919
UNITED STATES
Northern Region, Valve Division Dresser Equipment Group, Inc. 85 Bodwell Street, Avon, MA 02322-1190 Phone: 508-586-4600 Fax: 508-427-8971 Southern Region, Valve Division Dresser Equipment Group, Inc. 11100 West Airport Blvd. Stafford, TX 77477-3014 Phone: 281-568-2211 Toll Free: 800-847-1099 Fax: 281 -568-1414
DVC50OOf Series
Instruction Manual Form 5445 September 2000
FlELDVUE@ DVC5000f Series Introduction Digital Valve Controllers for Installation FOUNDATIONfieldbus Initial Setup and Calibration
TM
Detailed Setup Calibration Viewing Device Information Principle of Operation Maintenance Parts Loop Schematics Function Block Overview Analog Output (AO) Function Block PID Function Block Discrete Input (DI) Function Block Discrete Output (DO) Function Block DD Installation Operation with Fisher-Rosemount@ DeltaV" Block Parameter Index Glossary Index
Glossaly
Index
I FISHER"^
,
FISHER-ROSEMOUNT"
DVC5000f Series
Cutaway view of FIELDVUP Type DVC5010f Digital Valve Controller Showing Master Module Assembly
Introduction
Section I Introduction
Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Device Descriptions and Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying the Device Description Version and Compatibility . . . . . . . . . . . . . . .
1-2 1-2 1-3 1-4
1-4
What This Manual Contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fieldbus Installation and Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other Related Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5 1-5 1-5 1-5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
September 2000
1-1
DVC5000f Series
Scope of Manual
This instruction manual includes specifications, installation, operating, and maintenance information for the DVC5000f Series digital valve controllers. The manual describes the functionality of FIELDVUE@ fieldbus instruments with device revision 7. This manual describes device setup using the FOUNDATION fieldbus specified DD (device description) parameter access and methods. The display and implementation of these parameters depends upon the host software available. Refer to the applicable host software documentation for information on executing methods and accessing parameters. For information on using the VL2000 Series ValveLink software with the instrument refer to the FlELDVUE VL2000 Series ValveLink *are User Guide Form 5446. 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.
Instrument Description
DVC5000f Series digital valve controllers for FOUNDATION fieldbus (figures 1-1 and 1-2) are interoperable, process controlling, communicating, microprocessor-based, digital-to-pneumatic instruments. In addition to the primary function of converting a digital input signal to a pneumatic output, the DVC5000f Series digital valve controller, using FOUNDATION fieldbus communications protocol, gives easy access to information critical to process operation as well as process control. You can gain information from the principal component of the process, the control valve itself, by using a personal computer or operators console within the control room. Using a compatible fieldbus configuration device, you can obtain information about the health of the instrument, the actuator, and the valve. You can also obtain asset information about the actuator or valve manufacturer, model, and serial number. You can set input and output configuration parameters and calibrate the instrument. Using the FOUNDATION fieldbus protocol, information from the instrument can be integrated into control systems. The DVC5000f Series digital valve controller is designed to directly replace standard single-acting valve mounted positioners.
Figure 1-1. Siding-Stem Control Valve with Type DVC501Gf Digital Valve Controller
Figure 1-2. Rofaary Control Valve with Type DVC502GfDigital Valve Controller
1-2
September 2000
Introduction
Device Description and Methods
FOUNDATION fieldbus technology uses Device
Descriptions (DD) and function blocks to achieve interoperability between instruments and control systems or hosts from various manufacturers. The DD provides information to describe the data interface to the device. For fieldbus devices, in addition to providing parameter definitions and other information required by the control system to communicate with the fieldbus device, the DD may also include methods. Methods can be used for a variety of functions including automatic calibration, setting protection, setting up the instrument, etc. These methods are a predetermined sequence of steps for information required to setup, calibrate, and perform other functions on the instrument. How the method prompts and how messages appear is determined by the host system. For information on using methods on the host system, see the appropriate host system documentation. The following methods are provided with the DVC5000f Series Device Description: Setup Wizard, Stabilize/Optimize, Restart, Protect Transducer Data, Input Characterization, Auto Travel Calibration, Manual Calibration, Cal Tvl Sensor, Pressure Sensor Cal, StorelRestore Data, and Stroke Valve. Following is a brief description of each of these methods. The Setup Wizard and StabilizelOptimize methods are only available via the transducer block and are described in detail in section 3.
0 Setup Wizard-The Setup Wizard performs the initial setup and calibration of the instrument. Note: this method includes the ability to invoke the Auto Travel Calibration method discussed below. The Setup Wizard can also invoke the StabilizelOptimize method.
The Protect Transducer Data and Input Characterization methods are available only via the transducer block and are described in detail in section 4.
0 Protect Transducer Data -The Protect Transducer Data method is required for changing transducer block data protection. 0 input Characterization-The Input Characterization method provides a mechanism for setting the instrument input characterization, including the custom array. This method provides the user a simple mechanism for setting the parameter and the array, including data integrity checks, data presentation, and commandlresponse processing.
The Auto Travel Calibration, Manual Calibration, Calibrate Travel Sensor, Calibrate Pressure Sensor, and Store/Restore Data methods are all available via the transducer block and are described in detail in section 5.
0 Auto Travel Calibration-The Auto Travel Calibration method is required to automatically calibrate the instrument travel. It is provided as an independent method and is also a part of the Setup Wizard. The Auto Travel Calibration method, as it is included in the Setup Wizard, is also described in detail in Section 3. 0 Manual Calibration-The Manual Calibration method is required to manually calibrate the instrument travel. 0 Cal Tvl Sensor-The Cal Tvl Sensor method is available to calibrate the travel sensor when the instrument is mounted on a competitive actuator or when the travel sensor is replaced.
0 Pressure Sensor Cal-The Pressure Sensor Cal method is required to calibrate the internal pressure sensor information for display to the user.
StabilizelOptimize-The StabilizelOptimize method is used to adjust the instrument tuning sets to improve performance of the final control system. It provides an interface to the instrument that integrates several parameters used during the stabilization process.
0
The Restart method is only available via the resource block and is described in detail in section 4. Restart-The Restart method is required for restarting the instrument without removing power. It also allows the user to set data within the instrument to its default state. In addition to restarting the instrument, this method also performs instrument integrity tests to verify that it is ok to Restart the instrument.
0
0 StorelRestore Data-The Store/Restore Data method is used to restore data in either the factory data or Field Setup section of Non-Volatile Memory (NVM). Store/Restore Data can also be used to store the current data into the Field Setup section of NVM. 0 Stroke Valve-The Stroke Valve method can be used to remotely stroke the valve via the host system. This method is available via the transducer block and is described in detail in section 8.
To use the DDs they must be installed on the host system. For information on installing the DDs, see Appendix F.
September 2000
1-3
DVC5000f Series
Displaying the Device Description Version and Compatibility
You can use the DD Version method to display the version and compatibility information for the device descriptions installed on the system. The DD Version method is included with the device description (DD) software. For information on using methods, see the host system documentation. This method is available via the resource block (method name About-DD) and the transducer block (method name About-DD-TB). Start DD Version. After initializing the method displays the following message: ys5s~z7<,z 5 3 6 9f Ds:ii ce ze:j.cr i p r icn
Section 3-Initial Setup and Calibration: explains how to get your FIELDVUE instrument operational and how to automatically calibrate travel using the Setup Wizard. Also explains how to stabilize or optimize performance. Section 4-Detailed Setup: explains how to modify resource and transducer block parameters to fit the instrument to your application. Section 5-Calibration: explains how to calibrate your FIELDVUE instrument. Section 6-Viewing Device Information: describes which resource and transducer block parameters to view to see information about the instrument. Section 7-Principle of Operation: explains how the FIELDVUE DVC5000f Series instruments work. Section 8-Maintenance: provides information for troubleshooting and maintaining your FIELDVUE instrument. Section 9-Parts: lists parts kits and replaceable parts for your FIELDVUE instrument.
-, 7 :--ease
press -,he e c t i r -ey- r-e sxit
r:,e:hsd.
where <value> is the current version, date, and compatibility, and the file name where the DDs are located. This manual applies to the following devices and device descriptions:
0
Section 10-Loop Schematics: contains loop schematics for installing your FIELDVUE instrument in intrinsically safe installations. Appendix A-Function Block Overview: describes function blocks that are common to all FOUNDATION fieldbus devices. It also describes specific attributes of each function block and provides examples of how function blocks work together to complete measurement and control tasks. Appendix B-Analog (AO) Function Block: describes the operation and parameters of the analog output function block Appendix C-PID Function Block: describes the operation and parameters of the proportional-plusintegral-plus-derivative function block. Appendix D-Discrete Input (DI) Function Block: describes the operation and parameters of the discrete input function block. Appendix E-Discrete Output (DO) Function Block: describes the operation and parameters of the discrete output function block. Appendix F-DD Installation: explains how to install the device description (DD) software for the FIELDVUE DVC5000f Series digital valve controllers on your host system. Appendix G-Operation with Fisher-Rosemount DeltaV : provides specific instructions for performing basic configuration operations on the DVC5000f Series digital valve controller using the Fisher-Rosemount DeltaV host system. Appendix H-Block Parameter Index: lists, by parameter name, the block parameters discussed in
September 2000
DVC5000f Series AO/PID digital valve controller
- Device Type: 5400 - Device Revision: 7

- Device Description: 1
0
DVC5000f Series DO/DI digital valve controller

- Device Type: 5900 - Device Revision: 7
- Device Description: 1
What This Manual Contains

This manual contains the following sections. Each section has its own table of contents. See the appropriate table of contents for the section for a complete listing of the subsections.
Section I-Introduction : provides the scope of the manual; describes the instrument, DDs (device descriptions), and methods; lists device specifications and sources of other related information. Section 2-Installation: explains how to mount the instrument on the actuator and how to make pneumatic and electrical connections.
7-4
Introduction
this manual. This list also includes a page number where more information about the parameter may be found. Glossary-Contains definitions, acronyms, and abbreviations of terms.
Other Related Information

Other documents containing information related to the DVC5000f Series digital valve controllers include:
FIELD W E @DVC5000f Series Fieldbus Digital Valve Controllers [Bulletin 62.1:DVC5000f) Mounting FIELD W E @Instruments on Piston Actuators (PS Sheet 62.1:FIELDVUE(B)) FIELD W E @VL2000 Series ValveLink %ware User Guide
Fieldbus Technical Overview, Form 8748
Related Information
Fieldbus Installation and Wiring Guidelines
This manual describes how to connect the fieldbus to the digital valve controller. For a technical description, planning, and installation information for a FOUNDATION fieldbus, refer to the fOUNDATlON Fieldbus Technical Overview available from the fieldbus FOUNDATION and the Fieldbus Supplement to Installing Your DeltaV Scalable Process System available from your Fisher Controls sales office or sales representative.
Specifications
Specifications for the DVC5000f Series digital valve controllers are shown in table 1-1.
September 2000
1-5
DVC5000f Series
Table 1- 1. Specifications Electrical Input Voltage Level: 9 to 32 volts Maximum Current: 26 mA Reverse Polarity Protection: Unit is not polarity sensitive Termination: Bus must be properly terminated per ISA SP50 guidelines Function Block Suites Either Fieldbus Logic or Standard Control as follows: W Fieldbus Logic (discrete connectivity) Includes DO and four DI function blocks W Standard Control (basic control) Includes A 0 and PID function blocks Digital Communication Protocol Manchester-encoded digital signal that conforms to IEC 1158-2 and ISA 50.02, basic stack Output Signal() Pneumatic pressure as required by the actuator, up to 95% of supply pressure Minimum Span: 0.4 bar (6 psi) Maximum Span: 6.2 bar (90 psi) Action: Direct only supply Pressure() Minimum and Recommended: 0.3 bar (5 psi) higher than maximum actuator requirements Maximum: 6.9 bar (100 psig) Steady-State Air Consumption(V2) At 1.4 bar (20psig) supply pressure: Less than 0.3 normal m3/hr (10 scfh) At 2.4bar (35 psig) supply pressure: Less than 0.4 normal m3/hr (15 scfh) At 4.I bar (60psig) supply pressure: Less than 0.6 normal m3/hr (22 scfh) At 6.9 bar (100 psig) supply pressure: Less than 0.9 normal m3/hr (34 scfh) Maximum Output Capacity(T2) At 1.4 bar (20 psig) supply pressure: 7.6 normal m3/hr (285 scfh) At 4.1 bar (60 psig) supply pressure: 15.3 normal m3/hr (570 scfh) Independent Linearity() +0.5% of output span Operating Ambient Temperature Limits -40C to 80C (-40F to 175F) Stem Travel (DVC5OlOf)
0 to 102 mm (4-inches) maximum 0 to 19 mm (0.75-inches) minimum

Shaft Rotation (DVC5020f)
0 to 90 degrees maximum
Electromagnetic Interference (EMI) Output signal changes less than +/- 0.1 Yo when tested per IEC 801-1 and 801-3,27 to 1000 MHz with field strength of 30 V/m (volts per meter) Electrical Classification Hazardous Area: Refer to Hazardous Area Classification Bulletins 9.2:OOl series and 9.2:002. Housing Classification: NEMA 4X, CSA Type 4X, IEC 60529 IP65 Connections Supply Pressure: 1/4-inch or R 1/4 NPT female and integral pad for mounting 67CFR 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 (terminal box on top) to allow the vent to drain. Weight Less than 2.7 Kg (6 Ibs) Options
W Supply and output pressure gauges mounted filter regulator

cubic feel par hour at 60F and 14.7 psia
H Integrally
1. Defined in ISA Standard 551.1. 2. Normal m3hr-Norrnal cubic meters per hour at 0C and 1.01325 bar, absolute; Sdh-Standard
7-6
September 2000
Installation
Section 2 Installation
Mounting
DVC501O f on Fisher Sliding-Stem Actuators: 657 and 667 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC501O f on Other Sliding-Stem Actuators:
Baumann Size 32.54. and 70 . . . . . . . . . . . . . Gulde Actuators . . . . . . . . . . . . . . . . .
...................
2-2 2-4 2-5 2-6 2-6 2-8 2-9 2-8 2-9 2-11 2-12 2-13 2-15 2-15 2-15
.......................... .............................
DVC5020f on Fisher Rotary Actuators:

1051. All sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................... 1052. All sizes . . . .
DVC5030f on Fisher Rotary Actuators:

1051 Size 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1051 Size 3 0 t o 6 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1052 Size 20 and 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1052 Size40to 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DVC5030f on Other than Fisher Actuators: Masoneilan Sigma F and Camflex II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Neles-Jamesbury QP-3. QP-4. and QP-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DVC5040f on System 9000 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67CFR Filter Regulator

Integral-Mounted Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yoke-Mounted Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Casing-Mounted Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pneumatic Connections
Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-15 2-16 2-16
Electrical Connections
FOUNDATION fieldbus Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communication Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simulate Enable Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-16 2-17 2-17 2-17 2-18
Commissioning Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
September 2000
2I
DVC5000f Series
0 APPLY LUB, SEALANT

4481852.01 DOC
Figure 2- 1. Type DVC5070f Digital Valve Controller with Integrally Mounted Filter Regulator Yoke-Mounted on Type 6571667 Size 30-60 Actuator
Mounting
Mounting Type DVC5010f on Fisher Sliding-Stem Actuators

657 and 667 Actuators
Unless otherwise noted, refer to figures 2-1 and 2-2 for key number locations.
Avoid personal injury or property damage from sudden release of process pressure or bursting of parts. Before mounting the DVC5000f Series digital valve controller:
0 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. 0 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. 0 Vent the pneumatic actuator loading pressure and relieve any actuator spring precompression.
0 Use lock-out procedures to be sure that the above measures stay in effect while you work on the equipment.
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.
September 2000
2-2
Installation
0 APPLY LUB. SEALANT

I30Bu2-DIDOC
Figure 2-2. Type DVC5Olof Digital Valve Controller with Integrally Mounted Filter Regulator Yoke-Mounted on Type 6571667 Size 70-100 Actuator
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).
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 9-1). 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 IOI),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.
@ $ I
Note
The alignment pin (key 46) is stored inside the digital valve controller housing in a threaded hole near the top of the module base.
7. Set the position of the feedback arm (key 79, figure 9-1) on the digital valve controller as follows:
0 For 657 actuators, insert the alignment pin (key 46) through the slot on the feedback arm marked B.
0 For 667 actuators, insert the alignment pin (key 46) through the hole in the feedback arm marked A
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).
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).
September 2000
2-3
DVC5000f Series
CAP SCREW, HEX SOCKET LOCKWASHER CAP SCREW, HEX SOCKET LOCK WASHER SPACER MOUNTING BRACKET CK WASHER PLAIN WASHER CAP SCREW
ADJUSTMENT AR
2TB6719-Ci
HEX NUT, FLANGED
LOCK WASHER
ooc
Figure 2-3. Type DVC50lM Digital Valve Controller Mounted on a Baumann Size 32, 54, or 70 Actuator
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). 1 1. Remove the alignment pin (key 46) and store it in the module base next to the IIP 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.
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.
Mounting Type DVCSOI Of on Other Sliding-Stem Actuators

Baumann Size 32, 54, and 70 Actuators
Refer to figure 2-3 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. 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.
3. Loosen the lower locknut on the valve stem. Slip the connector arm between the locknuts. Tighten the lower locknut against the connector arm.
@ h
Note
2-4
September 2000
Installation
(2) M8 SPUT LOCK WASHERS (2) MB HEX NUT
(2) SPACER
(2) MB CAP SCREWS (2) MB WASHERS, (2) MB NUTS
9 1 6 EX TOOTH LOCK WASHER # I 0 WASHER 10-24 X 318 SCREW
MOUNTING PLATE
(4) SPACER
(4) SPACERS (4) MB SPUT LOCK WASHERS (4) M B HEX NUTS
DVC5010
) M6 CAP SCREWS
I///
2886759-A
(4) 1/4-20 X 0.75 INCHES SCREWS
E0189, IL
Figure 2-4. Type DVC501Of Digital Valve Controller Yoke-Mounted on Gulde Pneumatic Actuator Type 30248
0 For fail-closed actuators, insert the alignment pin (key 46) through the slot on the feedback arm marked A.
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.
For fail-open actuators, insert the alignment pin (key 46) through the hole in the feedback arm marked
0
B
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. 11. As shown in figure 2-3, loosely fasten the adjustment arm to the connector arm with a machine screw, washer and lock washer. 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. 13. Remove the alignment pin (key 46) and store it in the module base next to the I/P assembly.
Note
Gulde Actuators
Refer to figure 2-4 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
September 2000
2-5
DVC5000f Series

4388150.6, W t
Figure 2-5. Type DVC502M Dgital Valve ControllerMounted on Type 1052 Size 33 Actuator with Casing-Mounted Filter Regulator
For Po (air opens) actuators, insert the alignment pin (key 46) through the hole in the feedback arm marked A
0 0 For P, (air closes) actuators, insert the alignment pin (key 46) through the slot on the feedback arm marked B.
10. Remove the alignment pin (key 46) and store in the module base next to the I/P assembly.
11. Attach the shield with two screws.
Mounting Type DVC5020f on Fisher Rotary Actuators

1051 and 1052 Actuators
Unless otherwise noted, refer to figure 2-5 or 2-6 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.
6. Apply lubricant to the pin of the adjustment arm. Place the pin into the slot of the feedback arm (key 79, figure 9-1) 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.
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.
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 on the adjustment arm.
Note
Go to step 12 if the actuator already has the cam (kev 94) installed.
2-6
September 2000
Installation
~~

,388yB-0,DOC
\ A
Figure 2-6. Type DVC502Of Digital Valve Controller with Integrally Mounted Filter Regulator Mounted on Type 1051 Size 40 Actuator
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.
Note
Do not change the position of the rod end bearina on the end of the turnbuckle.
6. Loosen the lever clamping bolt in the lever.
@$ Note
For information on the various actuator mounting styles and positions, refer to the appropriate actuator instruction manual.
7. Mark the leverhalve shaft orientation, and remove the lever.
Note
Linear Cam-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).
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.
5 . Disconnect the actuator turnbuckle from the lever arm.
8. Install the cam (key 94) on the actuator lever with the cam mounting screws (key 95).
September 2000
2- 7
DVC5000f Series
APPLY LUBRICANT APPLY SEALANT

YB719s-c I
wc
Figure 2-7. Type DVC503Of Digital Valve Controller Mounted on Type 1052 Size 33 Actuator with Casing-Mounted filter .Regulator
9. For actuator styles A and D,proceed to step 12. For actuator styles B and C, continue with step 10. 10. Slide the leverlcam 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.
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
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.
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.
11. Connect the turnbuckle and the lever arm. 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).
Mounting Type DVC5030f on Fisher Rotary Actuators

1051 Size 33 and 1052 Size 20 and 33 Actuators
Unless otherwise noted, refer to figure 2-7 for key number locations. 1. Isolate the control valve from the process line pressure, release pressure from both sides of the
September 2000
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
2-8
Installation
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 2-7 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. 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). 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 2-7 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 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 2-7 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).
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 2-7. 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 2-7. 7. Position the feedback arm (key 79, figure 9-3) 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.
September 2000
2-9
DVC50OOf Series
MACHINE SCR CAP SCREW PLAIN WASHER LOCK WASHER CAP SCREW
CAP SCREW CAP SCREW
FOR CAMFLEX I 1
, -
. / l S I E F ~
BIAS SPRING FEEDBACK ARM
PLAIN WASHER LOCK WASHER CAP SCREW NIPPLE
BUSHING DRIVE PLATE
BUSHING
u
PLAIN WASHER
AssEMOLyJ
4ae41e4-c
E03W,
IL
Figure 2-8. Momting a Type DVC5030f Digital Valve Controller on a Masoneilan Camflex I1 and Sigma F Actuator
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).
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. 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.
September 2000
6. Position the feedback arm (key 79, figure 9-3) so that, when the digital valve controller i s 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).
270
InstaIlation
USE THESE FOR MOUNTING
HOLES/
4 HOLES FOR ATTACHING DIGITAL VALVE CONTROLLER MOUNTING PLATE
USE THESE HOLE FOR MOUNTING ACTUATORS
Figure 2-9. Positioner Plate for Mounting Type DVC5030f Digital Valve Controller on Masoneilan Camflex II or Sgma F Actuators
DRIVE PLATE POSITION IF INCREASING OUTPUT ROTATES DRIVE SHAFT CLOCKWISE
DRIVE PLATE POSITION IF INCREASING OUTPUT ROTATES DRIVE SHAFT COUNTERCLOCKWlSE
Figure 2-10. Drive Plate Assembly Instadation
Mounting Type DVC5030f on Other than Fisher Actuators

Mounting on Masoneilan Sigma F and Camflex I1 Actuators
Refer to figure 2-8 and the parts list for parts identification, unless otherwise noted. 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.
Refer to figure 2-10. 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. Considering the top of the digital valve controller as the 12 oclock position, in the next step attach the drive plate assembly so that the pin is positioned as follows:
0 If increasing digital valve controller output rotates the drive plate assembly clockwise, position the pin at approximately the 7:30 position. 0 If increasing digital valve controller output rotates the drive plate assembly counterclockwise, position the pin at approximately the 10:30 position.
2. Using a 3116-inch hex wrench, remove the existing hub from the actuator shaft.
3. Attach the coupler to the actuator shaft using the 1/4-28 set screw. 4. Refer to figure 2-9. Attach the positioner plate to the actuator as follows:
0 For Camflex I1 actuators, attach the positioner plate with two 5/16-18 x 314 inch hex head cap screws. 0 For Sigma F actuators, attach the positioner plate with two 1/4-20 x 518 inch hex head cap screws.
7. Attach the drive plate assembly to the shaft connector as follows:

0 For Camflex II actuators, attach the drive plate assembly to the shaft connector with two no. 8 plain washers and 8-32 x 518 inch machine screws. 0 For Sigma F actuators, position the spacer between the shaft connector and drive plate assembly. Attach the drive plate assembly and spacer to the shaft connector with two no. 8 plain washers and 8-32 x 518 inch machine screws.
5. Using a 3116-inch hex wrench, remove the existing hub from the actuator shaft.
8. Attach the mounting plate to the digital valve controller with four 114-20 x 112 inch cap screws.
9. Position the digital valve controller, with mounting
6. Attach the shaft connector to the actuator shaft using a ll4-inch lock washer and 1/4-28 x 1-112 inch socket head cap screw.
September 2000
plate, over the drive plate assembly. Be sure the pin on the drive plate assembly engages the slot in the feedback arm and that the bias spring loads the pin as
2I1
DVC5000f Series
d. On the Type 67CFR regulator, remove the 114-inch NPT pipe plug and, using 318-inch (10 mm) outside diameter tubing, connect the regulator output to the 1/4-inch NPT bushing on the Fairchild relay. e. Make supply and electrical connections as described in Pneumatic Connections and Electrical Connections in this section. f. Refer to PS Sheet 62. I:FIELDVUE(B) Mounting FIELDVUE Instruments on Piston Actuators for Model 25463 spring adjustment information. Adjust the spring as necessary.
DRIVE SHAFT ASSEMBLY PIN
Mounting on Neles-Jamesbury QP-3, QP-4 and QP-5 Actuators

Refer to figure 2-12 and the parts list for parts identification, unless otherwise noted. 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 mounting bracket (key 3) to the actuator using four hex head screws (key 6). 3. Attach the coupler (key 4) to the actuator shaft using two 1\4-28 x 3/4 set screws (key 10).
4. Attach the travel indicator (key 1) to the coupler as follows:
Figure 2- 11. Positioning Drive Shaft Assembly Pin in the Feedback Arm
shown in figure 2-1 1. Using four 5116 plain washers and 5/16-18 x 112 inch hex head cap screws, attach the mounting plate to the positioner plate. 10. Make pneumatic connections to the actuator as follows:
0 For single-acting actuators, make connections as described in Pneumatic Connections in this section.
0 For double-acting actuators, DVC5000f Series digital valve controllers are direct-acting instruments. With a direct-acting instrument, as the input signal increases, the output signal increases. Determine whether the actuator piston rod should extend or retract upon increasing input signal then proceed as follows:
a. Determine the actuator action and mount the Fairchild reversing relay as follows:
0 If the actuator piston rod should extend from the cylinder upon increasing input signal, nipple mount the Fairchild relay to the lower cylinder connection. 0 If the actuator piston rod should retract into the cylinder upon increasing input signal, nipple mount the Fairchild relay to the upper cylinder connection.
a. If the valve is open without pressure to the actuator [push-down-to-close (PDTC) actuator mounting], position the travel indicator so that the pointer will be over the open mark on the travel indicator scale (key 2). Attach the travel indicator (key 1) to the coupler (key 4) using two washers (key 11) and machine screws (key 7). b. If the valve is closed without pressure to the actuator [push-down-to-open (PDTO) actuator mounting], position the travel indicator so that the pointer on the will be over the closed mark on the travel indicator scale. Attach the travel indicator (key 1) to the coupler (key 4) using two washers (key 11) and machine screws (key 7).
b. Using 318-inch (10 mm) outside diameter tubing, connect the 1/4-inch NPT or R 114 digital valve controller output connection to the pipe tee on the Fairchild relay.
c. Using 318-inch (10 mm) outside diameter tubing, connect the remaining cylinder connection to the pipe tee on the Fairchild relay.
5. Apply lubricant (key 63) to the travel indicator pin (key 1). 6. Position the feedback arm (key 79, figure 9-3) so that, when the digital valve controller is mounted on the actuator, the pin on the travel indicator (key 1) will slide into the slot on the feedback arm.
September 2000
2-12
Installation
(2) TRAVEL INDICATOR SCALE
(9) MOUNTING SCREW

2 8 ~ 0 0 ~ ~ EOl9l I IL
(4) COUPLER (10) 1/4-28 SET SCREW
Figure 2-12. Mounting a Type DVC5030f Digital Valve Controller on a Neles-Jamesbury QP-3, QP-4, and qp-5 Actuators
7. Position the digital valve controller on the mounting bracket (key 3). Be sure the pin on the travel indicator (key 1) 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. Attach the digital valve controller to the mounting bracket (key 3) using four hex head screws (key 6). 8. Attach the travel indicator scale (key 2) to the mounting bracket (key 3) with two washers (key 11) and threaded hex studs (key 5), and machine screws (key 7). Position the scale so that the OPEN or CLOSED mark is beneath the travel indicator pointer (key 1) and tighten the machine screws.
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.
Mounting Type DVC5040f on System 9000 Actuators

Refer to figures 2-13 and 9-4 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.
September 2000
2. Install the O-ring (key 167) as shown in figure 2-14 to the mounting flange of the digital valve controller.
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 2-14.
2-13
DVC5000f Series
oost,
Figure 2-13. System 9WO Actuator Assembly with Type DVC504Of Digital Valve Controller
Note
0 For fail-closed actuators, insert the alignment pin (key 46) through the hole on the feedback arm marked A.
Figure 2- 14. Digital Valve Controller Point of Connection (size 20 shown)
0 For fail-open actuators, insert the alignment pin (key 46) through the hole in the feedback arm marked B
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 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). 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 2-15). Tighten the machine screw (key 109).
September 2000
214
Installation
~
!
'
Travel Markings lnches(mm)
o.75
(19)
'
I
1.0
(32) 1.25
1.5
I
1.75
Actuator j Travel, Inches
0 . 7 5 ( ' )
1 50
20
bracket to the Type 67CFR and then attach this assembly to the actuator casing. Thread a l l 6 i n c h socket-head pipe plug (key 61) into the unused outlet on the filter regulator. The O-ring (key 60) is not required.
All pressure connections on the digital valve controller are 1/4-inch NPT or R 1/4 female connections. Use 318-inch (10 mrn) tubing for all pneumatic connections. If remote venting is required, refer to the vent subsection.
A10531 IL
Figure 2-15. Algnment of Travel Markings
Supply Connections
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. 9. Install the System 9000 actuator cover assembly.
Mounting the Type 67CFR Filter Regulator

A Type 67CFR filter regulator, when used with the DVC5000f Series digital valve controllers, can be mounted three ways.
Integral-Mounted Regulator
Refer to figures 2-1, 2-2 and 2-6. Lubricate an O-ring (key 60) and insert it in the recess around the SUPPLY connection on the digital valve controller. Attach the Type 67CFR filter regulator to the side of the digital valve controller. This is the standard method of mounting the filter regulator.
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.
Yoke-Mounted Regulator
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. 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 67CFR 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.
Casing-Mounted Regulator
Refer to figures 2-5 and 2-7. Use the separate Type 67CFR filter regulator casing mounting bracket provided with the filter regulator. Attach the mounting
September 2000
2-15
DVC5000f Series
Connect the nearest suitable supply source to thel/4-inch NPT IN connection on the filter regulator (if furnished) or to the Il4-inch NPT SUPPLY connection on the digital valve controller housing (if Type 67CFR filter regulator is not attached).
1-
Output Connections
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 1M-inch NPT or R 1/4 digital valve controller output connection to the pneumatic actuator input connection.
To connect a remote vent to Type DVC5020f digital valve controllers-rotary Replace the standard mounting bracket (key 74, figure 9-2) with the vent-away mounting bracket (key 74). Install a pipe plug (key 127, figure 9-2) 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.
FOUNDATION Fieldbus Connections
The digital valve controller is normally powered over the bus from a fieldbus 9 to 32 volt power supply. Refer to the site planning guide for proper wire types, termination, length, etc. for a fieldbus loop. Wire the digital valve controller as follows: (refer to figures 9-1 through 9-4 for identification of parts). Wiring should meet plant wiring standards. 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. The instrument is not polarity sensitive. Connect one wire from the control system output card to one of the LOOP screw terminals on the pwb/terminal strip assembly in the terminal box shown in figure 2-16. Connect the other wire from the control system output card to the other LOOP screw terminal in the terminal box.
Vent
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 controllerlactuator 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.
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. As shown in figure 2-16, two safety ground terminals are available for connecting a safety ground,
To connect a remote vent to Type DVC501Of, DVC5030f, and DVC5040f digital valve controllers-sliding-stem Remove the plastic vent (key 52, figure 9-1). The vent connection is Il4-inch NPT or R 114 female. Typically, 3/8-inch (10 mm) tubing is used to provide a remote vent.
2-76
September 2000
Installation
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 instrument current as:
Voltage (on test meter) >d 000 = Instrument Milliamps example: Test Meter Voltage = 0.025 Test Meter Voltage X 1000 = Instrument Milliamps 0.025 X 1000 = 25.0 milliamperes
L
I f
SIMULATE ENABLE
Y J=[
L \L ;
If the current is not approximately 25 milliamperes, check the field wiring and terminal box to printed wiring board connection inside the instrument. See the Maintenance section, Section 8, for information on disassembling the instrument.
5. Remove the test leads and replace the terminal box cover.
380W70~8 EWM, IL
Figure 2-16. DVC5000f Series Digital Valve Controller Terminal Box
Communication Connections
earth ground, or drain wire. The safety ground terminals are electrically identical. Make connections to these terminals following national and local codes and plant standards.
5. Replace and hand tighten the cover on the terminal box.
Test Connections
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. A FOUNDATION fieldbus communicating device, such as a personal computer running ValveLink VL2000 Series software, interfaces with the DVC5000f Series digital valve controller from any wiring termination point in the segment. If you choose to connect the fieldbus communicating device directly to the instrument, attach the device to the BUS terminals or to the LOCAL connections inside the terminal box to provide local communications with the instrument.
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.
Simulate Enable Jumper

The test connections inside the terminal box permit checking the instrument current by measuring the voltage 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.

September 2000
Install a jumper across the SIMULATE ENABLE terminals to enable the instrument to accept a simulate command. (These terminals are marked AUX on the terminal board, see figure 2-1 6.) With the jumper in place and the simulate parameter in the A 0 block set to enabled, the transducer block ignores the output of the A 0 block. The simulate value and status become the readback value and status to the A 0
2-17
DVC5000f Series
block and the transducer block is ignored. For more information on running simulations, see the FOUNDATION fieldbus specifications and the host system documentation.
tag. The device tag is used as an operational identification for the device and is usually defined by the piping and instrumentation diagram (P&ID). When commissioning more than one device on a fieldbus segment, identifying which device is at a particular location can be tedious without tags. The removable tag provided with the digital valve controller can be used to link the device ID and the physical installation location. The installer should note the physical location in both places on the removable commissioning tag and tear off the bottom portion. This should be done for each device on the segment. The bottom portion of the tags can be used for commissioning the segment in the control system.
Commissioning Tag
Your DVC5000f Series digital valve controller is supplied with a removable commissioning tag that contains both the device ID and a space to record the device tag. The device ID is a unique code that identifies a particular device in the absence of a device
2-78
September 2000
Initial Setur> and Calibration
Section 3 Initial Setup and Calibration

General Information Addressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2 3-2 3-2
Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Calibrate Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizing or Optimizing Valve Response . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
3-6
September 2000
31
DVC50OOf Series
General Information
Fieldbus is an all digital, serial, two-way communication protocol that interconnects devices such as valve controllers, transmitters, discrete devices, and controllers. It is a local-area network (LAN) for instruments that enables basic control and I/O to be moved to the field devices. The DVC5000f Series digital valve controllers use the FOUNDATION fieldbus technology developed and supported by Fisher-Rosemount and the other members of the independent Fieldbus Foundation. The Setup Wizard modifies transducer block parameters to setup the instrument. The Setup Wizard (method name Setup-Wizard) is included with the device description (DD) software.
Note
The A 0 block mode must be Out of Service for the Setup Wizard to operate properly.
Addressing
To be able to setup and calibrate a device and have it communicate with other devices on the fieldbus, a device must be assigned a permanent address. Unless requested otherwise, when the digital valve controller ships from the factory it is assigned an uninitialized address.
If there are two or more devices with the same address, the first device to start up will use the assigned address, for example 20. Each of the other devices will be given one of the four available temporary addresses. If a temporary address is not available, the device will be unavailable until a temporary address becomes available. Use the host system to commission a device and assign it a permanent address. For information on using the host system for device commissioning and assigning addresses, see the appropriate system documentation. The A 0 block mode can be set to Out of Service by setting the Resource block mode to Out of Service. However, setting the Resource block to Out of Service also sets all function blocks within the device to Out of Service, including the PID block. If the PID block is used to control another loop, be sure some other means are provided to control the loop before taking the block Out of Service. Before starting the Setup Wizard, the A 0 block should be Out of Service. If the A 0 block is not out of service, the A 0 block may interfere with calibration and stabilize/optimize. This interference could cause erratic or incorrect results. If the A 0 block is not Out of Service, the Setup Wizard provides you an opportunity to abort and set the A 0 block out of service.
Block Mode
Setting up and calibrating a digital valve controller requires modifying parameters in the transducer block. All blocks have a mode parameter, which determines the source of the set point, the destination of the output, and how the block executes. The ability to modify a block parameter is determined by the mode. For more information about block modes, see section 4.
Note
The instrument output will not track the input while the A 0 block is Out of Service.
1. Start the Setup Wizard. For information on starting the Setup Wizard from a DeltaV host system, see Appendix G. For information on running methods from other host systems, see the system documentation.
Initial Setup
Changes to the instrument setup may cause the valve to move.
2. The Setup Wizard first checks to see if the transducer block is Out-of-Service. If not, the Setup Wizard warns you that the transducer block will be placed out of service and of the possible results of doing so. Select Yes to continue or select No to abort the Setup Wizard.
September 2000
3-2
Initial Setup and Calibration

Table 3-1. Actuator Information for Initial Setup
Actuator Manufacturer Actuator Model Actuator Size
for Actuator Size Parameter Small
Starting Tuning set
Instrument Model
Travel Sensor Motion
513 or 513R 585C or 585CR 657 or 667
20 and 32
Fisher Controls
1250 or 1250R
I
1
System9000 1051 or1052 1051 or 1052 1066SR

I
1
I
'j
'
1
i
I
I
1
I
Baumann
All
Gulde
3024 3025 Camflex II
Masoneilan
Siama F. Minitorque, and Ball11 Quadra-Power II
NelesJamesbury
i 1
'i
Small F 25 Medium J 50 30 Medium DVC5010f K 34.40 Medium 45,50 Large , L 225 Medium H I 450 Medium J 1 Large L 675 Small D I 12.20 25,50 DVC5040f Small G 80 K l Medium 2 0 , 3 0 , 3 3 Medium 7 - z - - D V C 5 0 2 M 40 Medium Medium H I 20' 30933 40 Medium K DVC5030f 20 Small G 27, 75 Large L l 32 Small Expert H (' 54 Medium 70 Medium I 1 Small Expert(') GAI 21 1 DVC5010f GAI 31 H I Medium GA1.41 medium K~ P460. P462. P900 1 Laroe M I Small D 4.5 6 or 7 Medium H I Small D i A Medium B DVC5030f Medium C Medium H I QP2.QP3 QP4 Medium J i QP5 Medium K
~
513-Clockwise 513R-Counterclockwise 585CClockwise 585CR-Counterclockwise 6574lockwise 667-Counterclockwise 1250--Clockwise 1250R-Counterclockwise fail-closed-Counterclockwise fail-open-Clockwise 1051--Clockwise 1052--Clockwise
1
1
See table 3-2
Air to Extend-Clockwise Air to Retract-Counterclockwise
Air opens-Counterclockwise Air closes-Clockwise
See description for Travel Sensor Motion parameter.
1 For Baumann size 32 actuator High Performance Gain=l 9.High Performance Travel Rate=ll High Performance Pre ure Rate=70. Standard Gain=O.B, Standard Travel Rate=13 2 For Gulde Type 3024 size 1 2 1 High Performance Gain=3 0 Hlgh Performance Travel Rate=13 High Performance Pressure Rate=70. Standard Gain=l 0. Standard Travel Rate=13
Mounting Style(')
A B C D
Clockwise Counterclockwise Counterclockwise Clockwise

-~
0 On Loss of Instrument Power or Air, Valve (opens or closes)-This identifies whether the valve is fully open or fully closed when instrument air or power is removed. If you are unsure how to set this parameter, disconnect the power to the instrument and note the actuator response. If the actuator closes the valve, select closes. If the actuator opens the valve, select opens.
3. The Setup Wizard next initializes the instrument. Once initialization is complete, you are prompted for setup information. Table 3-1 provides the actuator information required to setup and calibrate the instrument.
0 Actuator Size (small, medium, or large)-Refer to table 3-1.
0 Feedback Connection (Rotary - All types, Sliding Stem - Standard Feedback, Sliding Stem Roller Feedback)-For rotary valves, select Rotary All types. For sliding-stem valves, if the feedback linkage consists of a connector arm, adjustment arm and feedback arm (similar to that shown in figure 3-I), select Sliding Stem - Standard Feedback. If the feedback linkage consists of a roller that follows a cam (similar to that shown in figure 3-2), select Sliding Stem - Roller Feedback.
September 2000
3-3
DVC5000f Series
n
TRAVEL SENSOR SHAFT 7
move the valve to determine travel sensor motion. If you answer Yes, the instrument will stroke the valve the full travel span to determine travel sensor motion. If you answer No, then you must specify the rotation for increasing air pressure: clockwise or counterclockwise. Determine rotation by viewing the end of the travel sensor shaft, as shown in figure 3-1, or refer to table 3-1. If increasing air pressure to the actuator causes the shaft to turn clockwise, select clockwise. If it causes the shaft to turn counterclockwise, select counterclockwise.
Changes to the tuning can result in valvelactuator instability.

A55361 IL
Figure 3-1. Sfiding Stem -Standard Feedback Connection
I
I
ROLLER7
0 Tuning Set-There are eleven tuning sets to choose from. Each tuning set provides preselected values for the digital valve controller gain and rate settings. Typically, tuning set C provides the slowest response and M provides the fastest response. For information on selecting a tuning set, refer to table 3-1 or select Help on the Setup Wizard display. To enter the values for the high performance and standard tuning parameters, select Expert.
STEM CONNECTOR
IFigure 3-2. Sliding Stem - Roller Feedback Connection
4. The Setup Wizard next asks if you want to use defaults for Travel Cutoff high, Travel Cutoff Low, and Input Characterization. If you select Yes, these parameters are changed to the default values. If you select No, they are left at their previous values. For parameter details, see the "Detailed Setup" section.
If you answer YES to the prompt for permission to move the valve, the instrument will move the valve through a significant portion of its travel range. To avoid personal injury and property damage caused by the release of pressure or process fluid provide some temporary means of control for the process.
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.
5. At this point, instrument setup is complete. You are asked if you would like to calibrate the valve. Select Yes and follow the prompts to automatically calibrate the valve 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.
0 Travel Sensor Motion (increasing air pressure causes the travel sensor shaft to rotate clockwise or counterclockwise)-The Setup Wizard asks if it can
If you select No, the Setup Wizard asks if you would like to run the StabilizelOptimize method. If the valve cycles or overshoots, or is unresponsive, select Yes to run the Stabilize/Optimize method and improve operation. For additional information, refer to
September 2000
3-4
Initial SetuD and Calibration

Stabilizing or Optimizing Valve Response in this section. If you select No, the Setup Wizard exits. Before exiting, the Setup Wizard asks if you want to return the transducer block mode to Auto, if the transducer block was in the Out-of-Service mode before the method started. Select Yes to change the transducer block mode to Auto. Select No to leave the transducer block in its current mode. Remember to restore the Analog Output (AO) block mode if you changed it to Out of Service before starting the Setup Wizard.
Auto Calibrate Travel

If you choose to calibrate the valve, the Setup Wizard starts the Auto Travel Calibrate method. Perform the following steps to automatically calibrate valve travel.
1. If the Feedback Connection is Sliding Stem Standard Feedback, you must set the crossover. Continue to step 2. For all other Feedback Connection selections, there is no user interaction during auto travel calibration. Go to step 5.
A5536
Figure 3-3. Crossover Point
crossover. This prompt includes the current travel value and asks you to select the direction and amount the valve should move in order to set the crossover.
4. 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 3-3. Once the feedback arm is in the right position, select Mark Current Position.
2. If the crossover must be set, there are three means of crossover adjustment: Manual (Initial Setup), Use Default (50%), or Use Last Value. Manual is the recommended choice. It permits you to manually set the crossover. If you select manual, continue to step 3.
If you select Use Last Value, no further user interaction is required during the calibration process. Go to step 5. The crossover setting currently stored in the instrument from the last travel calibration is used, followed by a series of actions that will automatically calibrate the instrument. Use this selection if you cannot use manual, such as when you cannot see the valve. If you select Use Default, this also does not require any further user interaction during the calibration process. Go to step 7. A value for the crossover is written to the instrument, followed by a series of actions that will automatically calibrate the instrument. Use this selection only as a last resort. Default assumes a midrange position on the travel sensor as the crossover point. However, this may not be an appropriate value to use for crossover because of variations in mounting and travel sensor calibration. 3. If you selected Manual for the crossover adjustment, the Setup Wizard prompts you to set the
September 2000
5. From here on the calibration process is automatic. No further interaction is required.
6. When calibration is complete, you are next asked to enter information about the calibration, including who performed the calibration, where was it performed, and the date on which it was performed.
7. After calibration is complete, the Setup Wizard asks if you want to run the Stabilize/Optimize method. If the valve cycles or overshoots, or is unresponsive, select Yes to run the StabilizelOptimize method and improve operation. For additional information, refer to Stabilizing or Optimizing Valve Response in this section. Begin with step 2. If you select No, the Setup Wizard exits. Before exiting, the Setup Wizard asks if you want to return the transducer block mode to Auto, if the transducer block was in the Out-of-Service mode before the method started. Select Yes to change the transducer block mode to Auto. Select No to leave the transducer block in its current mode. Remember to restore the Analog Output (AO) block mode if you changed it to Out of Service before starting the Setup Wizard.
3-5
DVC5000f Series
Stabilizing or Optimizing Valve Response
If after completing initial setup and auto calibration the valve cycles or overshoots, or is unresponsive, you can improve operation running the StabilizelOptirnize method. The Stabilize/Optimize (method name Stabilize-Optimize) is included with the device description (DD) software. For information on using methods on the host system, see the host system documentation. Before starting StabilizelOptimize, the A 0 block should be Out of Service. If the A 0 block is not out of service, you will not be able to check response because the method will not be able to adjust the transducer block set point. If the A 0 block is not Out of Service, StabilizelOptimize provides you an opportunity to abort and set the A 0 block out of service.
To Stabilize Valve Operation:

0 Select Standard Decrease to select the next lower tuning set (e.g., F to E ) . If the current tuning set is C, Stabilize/Optimize asks if the tuning set should be changed to Expert to allow you to adjust the gain below the tuning set value. 0 Select Small Decrease to decrease the High Performance Gain by 10% from the current value. StabilizelOptimize recalculates the other tuning parameters based on this gain value.
To Improve Valve Response:

0 Select Standard Increase to select the next higher tuning set (e.g., F to G). If the current tuning set is M, StabilizelOptimize asks if the tuning set should be changed to Expert to allow you to adjust the gain above the tuning set value. 0 Select Small Increase to increase the High Performance Gain by 10% from the current value. StabilizelOptimize recalculates the other tuning parameters based on this gain value.
Note
The instrument output will not track the input while the A 0 block is Out of Service.
3. When you have finished changing the response, select Done with Change Response to once again move the valve and check response.
1. Start the StabilizelOptimize method. For information on starting the StabilizelOptimize method from a DeltaV host system, see Appendix G. For information on running methods from other host systems, see the system documentation.
2. Move the valve open or closed either 10% or 20% to check response. If valve operation i s unsatisfactory, select Change Response then perform one or the other of the following:
4. When valve operation is satisfactory, select Exit StabilizelOptimize to exit the method. Before exiting, the method asks if you want to return the transducer block mode to Auto, if the transducer block was in the Out-of-Service mode before the method started. Select Yes to change the transducer block mode to Auto. Select No to leave the transducer block in its current mode. Remember to restore the Analog Output (AO) block mode if you changed it to Out of Service before starting the StabilizelOptimize method or if you entered this method from the Setup Wizard.
3-6
September 2000
Detailed Setup
Section 4 Detailed Setup

Block Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Restarting the Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resource Block Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block Tag Strategy Alert Key 4-2 4-2 4-4
Transducer Block Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.........
4-5 4-5 4-6
Data Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Device Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Block Tag Strategy Field lnst SIN Factory lnst SIN Inst. Model No. Calibration Person Calibration LOC. Calibration Date Message
Valve and Actuator Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Actuator Mfg Actuator Model Actuator SIN Actuator Size Act. Fail Action Feedback Connection Press Units Tvl Sensor Motion Valve Mfg Valve Model Valve SIN Valve Style
4-7
Setting Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Characterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameters Modified By the Input Characterization Method . . . . . . . . . . . . . . . . . . . . Travel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Travel Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Travel High Alert Travel High-High Alert Travel Low Alert Travel Low-Low Alert Travel Deviation Alert Travel Accumulator Alert
4-9 4-9 4-9 4-1 0 4-12 4-12 4-13
Temperature Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cycle Counter Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Block Time-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

September 2000
4-15
4-15 4-15
4- I
DVC5000f Series
This section describes the resource and transducer block parameters that must be modified to setup the instrument. Table 4-1 lists the parameters in this section in alphabetical order by label. It provides the block mode and protection necessary to modify the parameter and a page reference where more detail on the parameter can be found. Each parameter is identified by its label as well as its parameter name. The mode listed is the actual mode the block must be in to be able to modify the parameter. Access to each parameter depends upon the host system software. For information on using the host system to modify block parameters, see the appropriate system documentation. mode (see permitted mode). The user or host system can compare the actual mode to the normal mode and, based on the results, determine if the block is operating normally.
0 Target mode-(subindex 1) The Target mode is the mode requested by the user or host system. Only one mode is allowed to be set and it must be a permitted mode as defined by the permitted subindex of the mode parameter. 0 Actual mode-(subindex 2) This is the current mode of the block. The actual mode may differ from the target modes due to operating conditions of the block.
Block Modes
Setting up and calibrating a digital valve controller requires modifying parameters in the resource and transducer blocks. All blocks have a mode parameter, which determines the source of the set point, the destination of the output, and how the block executes. The ability to modify a block parameter is determined by the mode. The mode required to change the parameter is listed in the description for each parameter. The block mode is determined by the Block Mode parameter (parameter name MODE-BLK). It is a structured parameter composed of the subindexes actual, target, permitted, and normal. The following defines each of the subindexes. Permitted mode-(subindex 3) The permitted mode defines the modes allowed for the block. This is set by the user or host system but is restricted by the instrument to modes supported by the instrument for the particular block. Any change request to the Target or Normal subindex is checked against the permitted subindex to ensure the requested mode is permitted.
0
Changing the block mode requires accessing the Block Mode parameter. For information on using the host system to change the block mode via this parameter, see the appropriate host system documentation.
Restarting the Instrument
Restarting the instrument may cause loss o f process control. You can restart the instrument to reset parameters, links, etc. within the instrument. However, due to the effect that a restart can have on the instrument, and therefore the control loop, restarting the instrument should be used cautiously and only as a last measure. There are three different restarts: Restart Resource, Restart Processor, and Restart with Defaults. Following is a brief description of the effects for each of these restarts.
0 Restart Resource-Performing a Restart Resource sets the instrument dynamic parameters to their default values. Selecting this action to restart the instrument is not recommended. Use either Restart Processor or Restart with Defaults.
0 Restart Processor-Performing a Restart Processor has the same effect as removing power from the instrument and re-applying power.
When setting the Permitted mode, there is no check against any of the other subindexes (Normal or Target modes). Therefore, the instrument may be in a Normal or Target mode that is not permitted because the permitted subindex was modified after the Normal or Target mode was set. This will have no effect on the instrument until the user attempts to modify the Target or Normal mode. At this time these subindexes are tested against the Permitted modes, thus the user cannot change the Normal or Target modes to what was formerly permitted. Normal mode-(subindex 4) The normal mode is the mode the block should be in during normal operating conditions. The normal mode is set by the user or host system and can only be set to a permitted
0 Restart with Defaults-Performing a Restart with Defaults should be done with care. This restart resets the static parameters for all of the blocks in the
4-2
September 2000
Detailed Setup
I
Parameter Label
Parameter Name Number(
Block Mode Required to Modify Parameter All All All Out of Service All All All Out of Service All All All All All All All Out of Service All All
Data Protection that Affects Parameted2)
Page
I
I
~
Alert Key BlockTag Strategy Act. Fail Action Actuator Mfg Actuator Model
ALERT-KEY TAG-DESC STRATEGY ACT-FAIL-ACTIO N ACT-MAN- ID ACT-MODEL-NUM ACT-SN ACT-CODE SERVO-ALARM-SUMMARY.DISABLED ALERT-KEY SERVO-ALARM-PRIORITY TAG-DESC XD-CAL-DATE XD-CAL-LOC XD-CAL-WHO USER-CHAR CYCLE-COUNT SERVO-ALARM-CYCLE-COUNT.TH RESHOLD SERVO-ALARM-CYCLE-COUNT.LlMlT FACTORY-SN FEEDBACK-LINEARIZATION FIELD-SN SERVO GAIN ALGO-GAIN SERVO-RATE FLOW-CHARACT MESSAGE1 SERVO-ALARM-OUTBLK-TIMEOUT PRESSURE-UNITS.RB-UNITS SERVO-STD-GAI N SERVO-STD-RATE STRATEGY SERVO-ALARM-TEMP-HI SERVO-ALARM-TEMP- LO FINAL-VALUE-CUTOFF-H I FINAL-VALUE-CUTOFF-LO TRAVELLACCUM SERVO-ALARM-TRAVEL-ACCUM. LIMIT -
04 02 03 21 22 23 24 38 78.4 04 76 02 30 29 31 54 96 80.2 80. 1 34 35.2 33 18 50 20 53 98 93 56 61.1 61.2 03 87 88 15 16 95 81.1 81.2 86.3 86.1 86.2 82.2 82.1 83.2 83.1 84.2 84.1 85.2 85.1 35.1 25 26 27 28
subindex 1.
4-5 44 4-5
Mechanical Configuration Configuration Configuration Mechanical
1
i,
1
i
!
~
j
:
I
~
I
!
Alert Disabled Alert Key Alert Priority Block Tag Calibration Date Calibration LOC. Calibration Person Custom Char. Cycle Count Cycle Count DB Cycle Count Alrt Pt Factory lnst SIN Feedback Connection Field lnst SIN High Perf Gain High Perf Press Rate High Perf Tvl Rate Input Char. Messaqe OutputBlk Timeout Press Units Standard Gain Standard Tvl Rate Strategy Temp Hi Alrt Pt Temp Lo Alrt Pt Travel Cutoff High Travel Cutoff Low Tvl Accumulator Tvl Accum Alrt Pt Tvl Accum DB Tvl Dev Alrt DB Tvl Dev Alrt Pt Tvl Dev Alrt Time Tvl HI Alrt DB Tvl HI Alrt Pt Tvl HI HI Alrt DB Tvl Hi HI Alrt Pt Tvl Lo Alrt DB Tvl Lo Alrt Pt Tvl Lo Lo Alrt DB Tvl Lo Lo Alrt Pt Tvl Sensor Motion Valve Mfg Valve Model Valve SIN Valve Stvle
1 Digit after the decimal indic 2 Parameters wlthout anv dat
Calibration Calibration Calibration Configuration Mechanical
___
Out of Service All All
All
All All Out of Service All All All All All All All All All All All All All All All All All All All All All All All All Out of Service All All All All
Read only Mechanical Configuration Tuning Tuning Tuning Configuration
Configuration Tuning Tuning
Configuration Configuration Mechanical
SERVO-ALARM-TRAVEL-ACCUM.THRESHOLD SERVO-ALARM-TRAVEL-DEV.THRESHOLD SERVO-ALARM-TRAVEL-DEV LIMIT SERVO-ALARM-TRAVEL-DEV TIME-LIMIT SERVO-ALARM-TRAVEL-HLTHRESHOLD -_______ SERVO-ALARM-TRAVEL-HI LIMIT SERVO-ALARM-TRAVEL-HI-HI THRESHOLD SERVO-ALARM-TRAVEL-HI-HI LIMIT SERVO-ALARM-TRAVEL-LO THRESHOLD SERVO-ALARM-TRAVEL-LO LIMIT SERVO-ALARM-TRAVEL-LO-LO THRESHOLD SERVO-ALARM-TRAVEL-LO-LO LIMIT FEEDBACK- ROTATIO N VALVE-MAN-ID VALVE-MODEL-NUM VALVE-SN VALVE-TYPE
subindex number For example, 81 1 indicates parameter number oteclion listed are not affecled by any type of protection mechanisi
Mechanical Configuration Configuration Configuration Configuration
4-7 4-7 4-7 4-7 4-7 4-12 4-12 4-12 4-6 4-7 4-7 4-7 4-10 4-15 4-15 4-15 4-6 4-8 4-6 4-9 4-9 4-9 4-10 4-7 4-15 4-7 4-9 4-9 4-6 4-15 4-1 5 4-12 4-12 4-14 4-14 4-14 4-14 4-14 4-14 4-13 4-13 4-1 3 4-13 4-13 4-13 4-14 4-14 4-8 4-8 4-8 4-8 4-8
September 2000
4-3
DVC5000f Series
instrument to their initialized state. After a Restart with Defaults, you should run the Setup Wizard and download the instrument configuration from the control system to properly setup the instrument. You also may need to re-establish communication links and trends. Parameters that are set to their default state and their default values are listed in table 4-2. The Restart method (method name Restart-Device) is included with the device description (DD) software. This method should be used to restart the instrument. For information on using methods on the host system, see the host system documentation. 1. Start the method. Restart informs you about what can happen when an instrument restart is performed. Select Yes to continue or, if you do not want to restart the instrument, select No to abort the method without restarting.
Index Number 1 2 3 4 Parameter Name
~
Initial Value
ST-REV TAG-DESC STRATEGY ALERT-KEY MODE-BLK PERMllTED NORMAL DD-RESOURCE MANUFAC-ID DEV-TYPE DEV-REV DD-REV HARD-TYPES FEATURES
0 spaces 0 0
Auto or Out o f Service Auto spaces 0x51 00 0x5400 0x07 Ox01 0x0002 Reports supported Failsafe supported Soft write lock supported Output Readback supported same as FEATURES except no reports supported Scheduled Scheduled 3200 0 5760,000 0 0 15 MAX-NOTIFY 640000 Unlocked
5
9 10 11 12 13 15 17
2. Select the desired restart action or select Exit to

exit the Restart method. Select Help to get information on the restart actions.
0 If you select Restart Resource, Restart informs you the resource has been restarted. You must acknowledge the message to continue.
18 19 20 21 22 23 24 27 31 32 33 34 37 38 39 1 2 3 4
FEATURE-SEL CYCLE-TYPE CYCLE-SEL MIN-CYCLE-T MEMORY-SIZE NV-CYCLE-T SHED-RCAS SHED-ROUT M A X NOTIFY LIM-NOTIFY CONFIRM-TIME WRITE-LOCK R M IM .Al .-A.. .. . S I-. .. DISABLED
0 If you selected Restart with Defaults or Restart Processor, Restart informs you of the consequences of this action and asks if you want to continue. Select Yes to perform the restart action or select No to select another action or exit. Restart informs you when the restart is completed. You must acknowledge the message to continue.
,
~
1 0
ACK-OPTION I 0 WRITE-PRI 0 A 0 Block Parameters ST-REV TAG-DESC STRATEGY ALERT-KEY MODE-BLK PERMllTED NORMAL SP OUT PV-SCALE EU 100% EU 0% Engineering Units Decimal Places XD-SCALE EU 100% EU 0% Engineering Untis Decimal Places 10-OPTS STATUS-OPTS SP-RATE-DN SP- RATE- UP SP-HI-LIM SP-LO-LIM CHANNEL
0 spaces 0 0
Auto or Out of Service Auto
Resource Block Setup

The resource block describes the charac-Astics c the fieldbus device such as device name and type, manufacturer, serial number, amount of free memory, and free time. There is only one resource block in a DVC5000f Series digital valve controller.
8 9 11
100 0 % 2
12
Label: Block Tag Parameter Name: TAG-DESC Index Number: 2 Mode:All Range: Up to 32 characters Description: A unique description for the resource block. The block tag must be unique for each block within a system.
14 15
la
19 20 21 22
100 only 0 only YO only 2 0 0 -______ +INF +INF 100

0
_. -
_ .
Xonbnued-
4-4
September 2000
Detailed Setup
Table 4-2. Pamneters M o f i e d by Restart with Default (cont.)
Initial Value
I
Table 4-2. Parameters MoaSfied by Restart with Default (cont.)

Index Initial Value
FSTATE-TIME FSTATE-VAL
I ~4
1 2 3
PID Block Parameters 0 ST-REV spaces TAG-DESC 0 STRATEGY 0 ALERT-KEY

MODE-BLK PERMITTED NORMAL PV-SCALE EU 100% EU 0% Engineering Units Decimal Places OUT-SCALE EU 100% EU 0% Engineering Units Decimal Places CONTROL-OPTS STATUS-OPTS PV-FTIME BYPASS SP-RATE- DN SP-RATE- UP SP-HI-LIM SP LO LIM RESET BAL-TIME 1 RATE 1 OUT-HI-LIM OUT-LO-LIM BKCAL-HYS SHFO -. .-- OPT -. .
~ ~ ~
58 59
DV-HI-LIM DV-LO-PRI DV-LO-LIM ST-REV TAG-DESC STRATEGY ALERT-KEY MODE-BLK PERMllTED NORMAL
0 -iNF
Transducer Block Parameters
i o
1 1j
5
10
spaces 0 1 0 Auto or Out of Service Auto
Auto or Out of Service Auto

100 0 % 2 100 0 %
11
'
13 14 16 17 19 20 21
2 0 0 0
0 +INF +INF 100 0 1 1000
-~
Label: Strategy Parameter Name: STRATEGY Index Number: 3 Mode: All Range: 0 to 65535 Description: This parameter permits you to strategically group blocks so the operator can identify where the block is located. The blocks may be grouped by plant area, plant equipment, etc. This data is not checked or processed by the block. Label: Alert Key Parameter Name: ALERT-KEY Index Number: 4 Mode: All Range: 1 to 255 Description: An identification number that permits grouping alerts. This number may be used to indicate to the operator the source of the alert such as the instrument, plant unit, etc.
22 24 25 26 28
0
0 100 0 0.5% 0 100 0
%
29 30
'34 _.
37
TRK-SCALE
41
42 45
I
46 47 48 49
I
~
50
51 52 53 54 55
EU 100% EU 0% Engineering Units Decimal places j FF-SCALE !1 EU 100% EU 0% Engineering Units Decimal Places FF-GAIN ALARM-SUM DISABLED ACK-OPTION ALARM-HYS HI-HI-PRI HI-HI-LIM HI-PRI HI-LIM LO-PRI LO-LIM LO-LO-PRI LO-LO-LIM
-Continue
2
100 0 % 2 0
Transducer Block Setup

The transducer block decouples function blocks from the local output functions required to command output hardware. The transducer block typically contains setup and calibration information. Within the transducer block you can match the instrument to the valve and actuator, adjust tuning, characterize the instrument input, set travel control parameters, and set alerts.
0 0 0.5%
0
+INF 0 +INF 0 -INF 0 -INF
Data Protection
Protection is provided for certain transducer block parameters to prevent inadvertently overwriting key data by the host system or user. The Data Protection method (method name Protect-Data) provides a procedure for changing the transducer block data protection. It is included with the device description
September 2000
4-5
DVC5000f Series
Select Help to see a list of the parameters included in each of the data categories. 3. Once you select the desired protection, Data Protection executes the desired selection, and updates the display. 4. When you have completed setting the desired protection, select Done. This completes the Data Protection method
Device Parameters
Label: Block Tag Parameter Name: TAG-DESC Index Number: 2 Mode: All Range: Up to 32 characters Description: A unique description for the transducer block. The tag description must be unique for each block within a system. Label: Strategy Parameter Name: STRATEGY Index Number: 3 Mode: All Range: 0 to 65535 Description: This parameter permits you to strategically group blocks so the operator can identify where the block is located. The blocks may be grouped by plant area, plant equipment, etc. This data is not checked or processed by the block. Label: Factory lnst SIN Parameter Name: FACTORY-SN Index Number: 34 Description: The Serial .number of the Instrument as assigned at the factory. This is a read only parameter and can only be changed by the factory. Label: Field lnst SIN Parameter Name: FIELD-SN Index Number: 33 Mode: All Range: Up to 32 characters Description: A serial number for the instrument assigned by the user.
Figure 4-1. Data Protection Method Display on a DeltaV Host System
(DD) software. For information on using methods on the host system, see the host system documentation. Data Protection sets the protection for particular categories of data within the transducer block. Categories of protection are: Calibration, Configuration, Mechanical, and Tuning. 1. Start the Data Protection method. For information on starting the Data Protection from a DeltaV host system, see Appendix G. For information on running methods from other host systems, see the system documentation. 2. The method first initializes the instrument then displays the current protection and prompts for the desired protection as shown in figure 4-1. The * preceding each selection indicates that this item is currently active, therefore, only one column (either Protect or Unprotect) will contain an * for any given row. Thus, an * preceding the Configuration selection in the Unprotect column means data in the Configuration category is not protected. You can select to change the protection on any one data category, or you can select to Protect All or Unprotect All. Selecting Set Default protects data in the Tuning, Mechanical, and Tuning categories, but leaves the Configuration data unprotected.
@I
Note
The Setup Wizard method automatically changes the protection to Set Default as part of its normal setup routine.
DVC5000f Series digital valve controllers have three 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 by the user.
September 2000
4-6
Detailed SetuD
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 valve and actuator 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.
Valve and Actuator Information

Label: Actuator Mfg Parameter Name: ACT-MAN-ID Index Number: 22 Mode: All Range: 4 characters Descriotion: The actuator manufacturers identification number as defined by the Fieldbus Foundation. For Fisher Controls, the manufacturer ID is 20736 (005100 hex). Label: Actuator Model Parameter Name: ACT-MODEL-NUM Index Number: 23 Mode: All Range: Up to 32 characters Description: The actuator type number. Label: Actuator SIN Parameter Name: ACT-SN Index Number: 24 Mode: All Range: Up to 32 characters Description: The actuator serial number Label: Actuator Size Parameter Name: ACT-CODE Index Number: 38 Mode: Out of Service Range: Small (l), Medium (2), or Large (3) Description: Code used to describe the size of the actuator (small, medium, or large). Label: Act. Fail Action Parameter Name: ACT-FAIL-ACTION Index Number: 21 Mode: Out of Service Range: Self-closing (l), Self-opening (2), Hold last (3), Max value (4), or Min value (5) Description: Specifies the action the actuator takes in the case of loss of air pressure. Label: Press Units Parameter Name: PRESSURE-UNITS.RB-UNITS Index Number: 56 subindex 2 Mode: All bar (1137), or psig (1 143) Range: kPa (1133), Description: Defines the output pressure units in either psig, bar, or kPa.
Label: Calibration Person Parameter Name: XD-CAL-WHO Index Number: 31 Mode: All Range: Up to 32 characters Description: The name of the person responsible for the last instrument calibration.
Label: Calibration LOG. Parameter Name: XD-CAL-LOC Index Number: 29 Mode: All Range: Up to 32 characters Description: The physical location where the last positioner calibration was performed. (e.g., NIST, AcmeLabs).
Label: Calibration Date Parameter Name: XD-CAL-DATE Index Number: 30 Mode: All Range: See host system documentation Description: The date of the instrument calibration. Date may range from milliseconds to 99 years. See host system documentation for method of specifying date.
Label: Message Parameter Name: MESSAGE1 Index Number: 98 Mode: All Range: Up to 80 characters Description: User Message.
September 2000
4-7
DVC5000f Series
Label: Valve Mfg Parameter Name: VALVE-MAN-ID Index Number: 25 Mode: All Range: 4 characters Description: The valve manufacturers identification number as defined by the Fieldbus Foundation. For Fisher Controls, the manufacturer ID is 20736 (005100 hex).
Actuator Travel Sensor Motion
513R 5850 585CR 657 667 1250 1250R
Counterclockwise Clockwise Counterclockwise Clockwise Counterclockwise Clockwise Counterclockwise Clockwise Clockwise
Label: Valve Model Parameter Name: VALVE-MODEL-NUM Index Number: 26 Mode: All Range: 32 characters Description: Specifies the valve design letter or type number
1051 1052
Air to Retract
Counterclockwise
Mounting Style
Travel sensor Motion
Label: Valve SIN Parameter Name: VALVE-SN Index Number: 27 Mode: All Range: Up to 32 characters Description: The valve serial number.
Clockwise Counterclockwise Counterclockwise Clockwise
B C
D
Actuator
System 9000 fail-closed
Counterclockwise Clockwise
Label: Valve Style Parameter Name: VALVE-TYPE Index Number: 28 Mode: All Range: Sliding stem (1) or Rotary (2) Description: Specifies the type of valve: sliding stem or rotary
Svstem 9000 fail-open
Table 4-6. Feedback Connection Selections for Various Actuator Types

Actuator Type Feedback Connection
513 and 513R 657 and 667 1250 and 1250R System 9000 Baumann and Gulde 585 and 585R 1051and1052 1066SR and all Type DVC5030f applications
Sliding Stem
Label: Tvl Sensor Motion Parameter Name: FEEDBACK-ROTATION Index Number: 35 subindex 1 Mode: Out of Service Range: Clockwise (1) or Counterclockwise (2) Description: Establishes the proper feedback orientation for the travel sensor. Determine the desired travel sensor motion by viewing the rotation of the end of the travel sensor shaft. If increasing air pressure to the actuator causes the shaft to turn counterclockwise, enter 1 (counterclockwise). If it causes the shaft to turn clockwise, enter 2 (clockwise). Tables 4-3 through 4-5 show the required travel sensor motion selections for Fisher Controls and Baumann actuators.
Rotary
Label: Feedback Connection Parameter Name: FEEDBACK-LINEARIZATION Index Number: 35 subindex 2 Mode: Out of Service Range: Sliding Stem (1) or Rotary (2) Description: Specifies how the travel sensor is linked to the valve stem or valve shaft. Refer to table 4-6 to determine the required feedback connection.
September 2000
4-8
Detailed SetuD
~~
Setting Response
Tuning
Table 4-7. Gain and Rate Values for Preselected Tuning Sets()
TUNING
HIGH PERFORMANCE Gain Travel Rate 10.0 10.0 10.0 10.0 10.5 11.6 12.7 14.5 16.2 18.0 18.0 Pressure Rate 120 60 49 37 46 69 a2 62 50 31 25
STANDARD Gain Travel Rate
2.1 3.0
Changes to the tuning can result in valvelactuator instability.
The following parameters adjust the instrument tuning. Tuning consists of adjusting the high performance values and the standard values. Normally the instrument uses the high performance values. However, should the pressure sensor fail, the unit can continue to operate using the standard gain and rate values if the standard gain is not equal to 0. You can use the Setup Wizard or the Stabilize/ Optimize Tuning method to adjust tuning using tuning sets. See Section 3 Initial Setup for more information on the Setup Wizard and the Stabilize/Optimize Tuning method. Table 4-7 lists the tuning values for the various tuning sets.
L
M 10.0
0.40 0.50 0.60 0.75 1.00 1.30 2.00 3.00 3.99 5.25 6.99
13.0
13.0
1 For User Adjusted. lht igh Performance Gain and S idard Gain mav be adjusted independently For Expert. all tuning parameters may be adjusted independently See parameter descnptlons for range of adjustment
Label: Standard Gain Parameter Name: SERVO-STD-GAIN Index Number: 61 subindex 1 Mode: All Range: 0.1 to 10 Description: This parameter value is the standard gain. This is the gain of the instrument if the pressure sensor fails. Label: Standard Tvl Rate Parameter Name: SERVO-STD- RATE Index Number: 61 subindex 2 Mode: All Range: 5 to 20 Description: This parameter value is the standard travel rate. This is the travel rate feedback used by the instrument if the pressure sensor fails.
Label: High Perf Gain Parameter Name: SERVO-GAIN Index Number: 18 Mode: All Range: 0 or 0.1 to 20 Description: This parameter value is the high performance gain. This is the normal gain value used by the instrument.
Input Characterization
With input characterization you can modify the overall characteristic of the valve and instrument combination. Selecting an equal percentage, quick opening, square root, or custom input characteristic modifies the overall valve and instrument characteristic. 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). Figure 4-3 shows the four fixed characteristics available: linear, equal percentage, quick opening, or square root. Table 4-8 lists the values for these characteristics. The Input Characterization method is available to help you set the instrument input characterization, including defining the custom characterization array. The Input Characterization method (method name Input-Characterization) is included with the device description (DD) software. For information on using methods on the host system, see the host system documentation.
Label: High Perf Tvl Rate Parameter Name: SERVO-RATE Index Number: 20 Mode: All Range: 0 or 5 to 25 Description: This parameter value is the high performance travel rate. This is the normal travel rate feedback used by the instrument.
Label: High Perf Press Rate Parameter Name: ALGO-GAIN Index Number: 50 Mode: All Range: 15 to 150 Description: This parameter value is the high performance pressure rate. This is the normal pressure rate feedback used by the instrument.
September 2000
4-9
DVC5000f Series
1. Start the Input Characterization. The method warns you the valve will move and that there may be a loss of process control. Select Yes to continue or select No to abort Input Characterization. 2. Once the instrument is initialized, Input Characterization prompts you to select the characterization type. You can select one of the predefined characterization types (linear, equal percentage, quick opening, or square root) or you can define a custom characterization. Select Custom Characterization Type to set a baseline for the array or to edit the array. Custom characterization permits you to specify 49 points on a custom characteristic curve. Each point defines a travel target in percent of travel for a corresponding input, also in percent of travel. Input values range from -25% to 125% in 3.125% increments. You can begin your custom characteristic by selecting one of the predefined characterization types as a baseline for the array. Then select Edit the Array to edit each of the 49 points. If you select Edit Custom Characterization Array, Input Characterization checks the current characteristic type. If the current characteristic is not custom, Input Characterization asks if you want to change the input characterization to custom. Select Yes, to change the Characterization Type to Custom and select a baseline array or edit the array. Select No, to leave the Characterization Type unchanged. 3. If you selected Custom Characterization Type, Input Characterization prompts you to select an action. An action in this case is to either select a starting baseline for the array, edit the array, or save the array to the instrument. If you select Save Array, Input Characterization saves the array to the instrument and returns to step 2. Except for Set Baseline to a Constant Value, if you select Set Baseline..., Input Characterization initializes the array to the specified baseline. If you select Set Baseline to a Constant Value, Input Characterization asks you for the value to be used. The value entered must be between -25% and +125%.
4. If you selected Edit the Array in step 3, Input Characterization prompts you for the values to be used for each of the 49 points. You need not specify a value for each point. However, the value of each succeeding point must be greater than the value of the
Figure 4 2 . Pem:Ssible Custom Characterization Curves
preceeding point (i.e. no loops in the curve or backward bending curve, see figure 4-2) 5. When you are done editing the array, enter a value of 99 for the index number. 6. Input Characterization then asks if you want to save the array. Select Yes to save the array to the instrument, or select No to continue editing the array.
Parameters Modified by the Input Characterization Method

The following parameters are modified by the Input Characterization method: Label: Input Char. Parameter Name: FLOW-CHARACT Index Number: 53 Mode: Out of Service Range: Linear (0), Equal Yo ( I ) , Quick opening (Z), Square root (3), or Custom (4) Description: Defines the relationship between the ranged travel and ranged input. You can select from the fixed input characteristics shown in Figure 4-3 or you can define a custom characteristic. Figure 4-3 plots the characterized output values for each index number for the fixed input characteristics. Table 4-8 lists the values used to define the fixed input characteristics. Label: Custom Char. Parameter Name: USER-CHAR Index Number: 54 index 1 through 49 Mode: Out of Service Range: -25.00 to 125.00% The value entered for an index number cannot be less than the value entered for a lower index number. (The curve cannot loop upon itself.) Description: User defined flow characterization array for valve profile.
September 2000
4-10
Detailed Setup
Table 4-8. Input Characteristic Curve Values
In It
~
Characterized Output (%) Linear -25.00 -21.88 -1 8.75 -1 5.63 -12.50 -9.38 -6.25 -3.13 0.00 3.13 6.25 9.38 12.50 15.63 18.75 21.88 25.00 28.13 31.25 34.38 37.50 40.63 43.75 46.88 50.00 Equal Percentage -12.5 -10.94 -9.38 -7.81 -6.25 4.69 -3.1 3 -1.56 0.00 0.27 0.57 0.90 1.29 1.72 2.21 2.76 3.39 4.09 4.89 5.79 6.81 7.96 9.26 10.73 12.39 Quick Opening -3.18 -2.78 -2.38 -1.99 -1 5 9 -1.19 -0.79 -0.40 0.00 23.93 36.04 44.21 50.38 55.35 59.50 63.07 66.20 68.98 71.49 73.78 75.87 77.81 79.61 81.29 82.86 Square Root -25.00 -25.00 -25.00 -25.00 -25.00 -25.00 -25.00 -25.00 0.00 17.68 25.00 30.62 35.36 39.53 43.30 46.77 50.00 53.03 55.90 58.63 61.24 63.74 66.14 68.47 70.71
In It Index Number 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Percent 53.13 56.25 59.38 62.50 65.63 68.75 71.88 75.00 78.13 81.25 84.38 87.50 90.63 93.75 96.88 100.00 103.13 106.25 109.38 112.50 115.63 118.75 121.88 12500 Linear 53.13 56.25 59.38 62.50 65.63 68.75 71.88 75.00 78.13 81.25 84.38 87.50 90.63 93.75 96.88 100.00 103.13 106.25 109.38 112.50 115.63 118.75 1213 8 125.00
Characterized OutDut . (% . Equal Percentage 14.27 16.39 18.78 21.49 24.55 28.01 31.92 36.33 41.32 46.96 53.33 60.53 68.67 77.87 88.26 100.00 103.13 106.25 109.38 112.50 115.63 118.75 121.88 125.00 Quick Opening 84.35 85.75 87.08 88.34 89.55 90.70 91.80 92.85 93.86 94.83 95.77 96.67 97.55 98.39 99.21 100.00 103.13 106.25 109.38 112.50 115.63 118.75 121.88 125.00 Square Root 72.89 75.00 77.06 79.06 81.01 82.92 84.78 86.60 88.39 90.14 91.86 93.54 95.20 96.82 98.43 100.00 125.00 125.00 125.00 125.00 125.00 125.00 125.00 125.00
I
I
Index Number
Percent -25.00 -21 88 -18 75 -15.63 -12.50 -9 38 -6.25 -3 13 0.00 3 13 6.25 9 38 12 50 15 63 18 75 21 88 25 00 28 13 31 25 34 38 37 50 40 63 43 75 46 88 50 00
' ;
4 3
~5
I 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
'
'
'
I
1
$1
22
c2
K
s
! 3 -
2 n
3
:%
s
2 V
&I(
4 1
"i -""
x i
Figure 4-3. Input vs Output Values for Varbus Input Characteristics
September 2000
4-11
DVC5000f Series
To define a custom input characteristic, select 4 (custom) for the input characterization parameter. Then access the custom characterization parameter via the Input Characterization method to customize the input characteristic curve. Note: The value for each index number must be equal to or greater than the value for the previous index number.
Thousands Hundreds 8 1 4 1 2 1 1 Tens 8 1 4 1 2 1 1 Ones 8 1 4 3 1 2 2 1 1
8
15
4 1 2 1 1
1 4 / 1 3 / 1 2 1 1 ~ 1 0 ~ 97 ~ 1 6 81 5 1 4
Refer to table 4-9 to determine which bit is true for a given hexadecimal value. For example, a hexadecimal value of 400 indicates bit 10 is true. The following parameters determine the alert handling:
0 Alert Disabled-determines reported
Travel Control
Label: Travel Cutoff High Parameter Name: FINAL-VALUE-CUTOFF-HI Index Number: 15 Mode: All Range: -24.375 to 125 Description: Defines the high cutoff point for the travel in percent (Yo) of ranged travel. Above this cutoff, the travel target is set to 123.0% of the ranged travel. Travel Cutoff High is effectively deactivated by setting it to 125.0%. Label: Travel Cutoff Low Parameter Name: FINAL-VALUE-CUTOFF-LO Index Number: 16 Mode: All Range: -25 to 124.375 Description: Defines the low cutoff point for the travel in percent (%) of ranged travel. Travel Cutoff Low can be used to ensure proper seat load is applied to the valve. When below this cutoff, the travel target is set to -23.0% of the ranged travel. A Travel Cutoff Low of 0.5% is recommended to help ensure maximum shutoff seat loading. Travel Cutoff Low is effectively deactivated by setting it to -25%.
which alerts are
0 Alert Status-indicates currently active
which alerts are which alerts are
0 Alert Unreported-indicates unreported,
0 Alert Unacknowledged-indicates which alerts have not been acknowledged by the receiving device.
See Section 6 for a description of the Alert Status, Alert Unreported, and Alert Unacknowledged parameters. Label: Alert Disabled Parameter Name: SERVO-ALARM-SUMMARY. DISABLED Index Number: 78 subindex 4 Mode: All Range: 0 to 65535 (hex values 0000 to FFFF) Description: Identifies which alerts are disabled for reporting by the instrument. Enter the sum of all the values for alerts that are to be disabled. Entering a value of zero for this parameter, enables all alerts. See also Feature Select in Section 6.
Setting Alerts
The following alerts are available from the instrument. Each alert is represented by one of 15 bits within the specified parameter. The hexadecimal value listed is a common way of identifying which bit is true.
Alert Hexadecimal Value
Drive Failure Cycle Count Travel Accumulator Travel High Travel High-High Travel Low Travel Low-Low Travel Deviation Temperature High Temperature Low IIP Feedback Pressure High Pressure Low Pressure Deviation Servo Timeout NVM Writes
0001 0002 0004 0008 0010 0020 0040 0080 0100 0200 0400 0800 1000 2000 4000 8000
Label: Alert Key Parameter Name: ALERT-KEY Index Number: 4 Mode: All Range: 0 to 255 Description: An identification number that permits grouping alerts. This number may be used to indicate to the operator the source of the alert such as the instrument, plant unit, etc. Label: Alert Priority Parameter Name: SERVO-ALARM-PRIORITY Index Number: 76 Mode: All Range: 0 to 15 Description: Permits assigning a priority to transducer block alarms.
September 2000
4-12
Detailed Setup
ALERT I S ACTIVATED
ALERT IS CLEARED
7
V
DEADBAND
TRAVELALERT POINT
ALERT IS CLEAREDJ
mu-, IL
E03921 IL
ALERT IS ACTIVATED
Figure 4-4. Travel Alert Deadband Example (Travel High Alert Shown)
Figure 4-5. Travel Alert Deadband Example (Travel Low Alert Shown)
Setting Travel Alerts

Label: Tvl Hi Alrt Pt Parameter Name: SERVO-ALARM-TRAVEL-HI. LIMIT Index Number: 82 subindex 1 Mode: All Range: 0 to 125% Description: This parameter determines the travel high alert point. The travel high alert point is the value of the travel, in percent (%) of ranged travel, which, when exceeded, activates the Travel Hi Alert. Label: Tvl Hi Hi Alrt DB Parameter Name: SERVO-ALARM-TRAVEL-HI-HI. THRESHOLD Index Number: 83 subindex 2 Mode: All Range: 0 to 100% Description: This parameter determines the travel high-high alert deadband. The travel high-high alert deadband is the travel, in percent (Yo) of range travel, required to clear a Travel Hi-Hi Alert, once it has been activated. See figure 4-4.
Label: Tvl Hi Alrt DB Parameter Name: SERVO-ALARM-TRAVEL-HI. THRESHOLD Index Number: 82 subindex 2 Mode: All Range: 0 to 100% Description: This parameter determines the travel high alert deadband. The travel high alert deadband is the travel, in percent (%) of range travel, required to clear a Travel High Alert, once it has been activated. See figure 4-4.
Label: Tvl L o Alrt Pt Parameter Name: S ERVO-ALARM-TRAVE L- LO. LIMIT Index Number: 84 subindex 1 Mode: All Range:-25 to 100% Description: This parameter determines the travel low alert point. The travel low alert point is the value of the travel, in percent (%) of ranged travel, which, when exceeded, activates the Travel Lo Alert.
Label: Tvl Hi Hi Alrt Pt Parameter Name: SERVO-ALARM-TRAVEL-HI-HI. LIMIT Index Number: 83 subindex 1 Mode: All Range: 0 to 125% Description: This parameter determines the travel high-high alert point. The travel high-high alert point is the value of the travel, in percent (%) of ranged travel, which, when exceeded, activates the Travel Hi-Hi Alert.
Label: Tvl L o Alrt DB Parameter Name: SERVO-ALARM-TRAVEL-LO. THRESHOLD Index Number: 84 subindex 2 Mode: All Range: 0 to 100% Description: This parameter determines the travel low alert deadband. The travel low alert deadband is the travel, in percent (%) of ranged travel, required to clear a Travel Lo Alert, once it has been activated. See figure 4-5.
September 2000
4-s
DVC5000f Series
Label: Tvl Lo Lo Alrt Pt Parameter Name: SERVO-ALARM-TRAVEL-LO-LO. LIMIT Index Number: 85 subindex 1 Mode: All Range: -25 to 100% Description: This parameter determines the travel low-low alert point. The travel low-low alert point is the value of the travel, in percent (%) of ranged travel, which, when exceeded, activates the Travel Lo-Lo Alert. Label: Tvl Lo Lo Alrt DB Parameter Name: SERVO-ALARM-TRAVEL-LO-LO. THRESHOLD Index Number: 85 subindex 2 Mode: All Range: 0 to 100% Description: This parameter determines the travel low-low alert deadband. The travel low-low alert deadband is the travel, in percent (%) of ranged travel, required to clear a Travel Lo-Lo Alert, once it has been activated. See figure 4-5. Label: Tvl Dev. Alrt Pt Parameter Name: SERVO-ALARM-TRAVEL-DEV. LIMIT Index Number: 86 subindex 1 Mode:AIl Range: 0 to 125% Description: This parameter determines the travel deviation alert point. The 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 activated. Label: Tvl Dev. Alrt Time Parameter Name: SERVO-ALARM-TRAVEL-DEV. TIME-LIMIT Index Number: 86 subindex 2 Mode: All Range: 0 to 120 seconds Description: This parameter determines travel deviation time. The travel deviation time is the time, in seconds, that the travel must exceed the travel deviation alert point before the Travel Deviation Alert is activated. Label: Tvl Dev. Alrt DB Parameter Name: SERVO-ALARM-TRAVEL-DEV. THRESHOLD Index Number: 86 subindex 3 Mode: All Range: 0 to 100% Description: This parameter determines the travel deviation alert deadband. The travel deviation must fall below the travel deviation alert point minus the deadband value for a Travel Deviation Alert to clear once it has been activated. Label: Tvl Accumulator Parameter Name: TRAVEL-ACCUM Index Number: 95 Mode: All Description: 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 4-6. You can reset the Travel Accumulator by configuring it to zero. Label: Tvl Accum DB Parameter Name: SERVO-ALARM-TRAVELACCUM.THRESHOLD Index Number: 81 subindex 2 Mode: All Range: 0 to 100% Description: This parameter determines the travel accumulator deadband. The 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 4-6. Label: Tvl Accum Alrt Pt Parameter Name: SERVO-ALARM-TRAVELACCUM.LIMIT Index Number: 81 subindex 1 Mode: All Range: 0 to Description: This parameter determines the travel accumulator alert point. The travel accumulator alert point is the value of the travel accumulator, in percent (%) of ranged travel, which, when exceeded, activates the Travel Accumulator Alert.
4-14
September 2000
Detailed Setup
OEADBANDEXCEEDED. NEW REFERENCE POINT ESTABLISHED
DEADBAND EXCEEDED, AND DIRECTION CHANGED, NEW REFERENCE POINT ESTABLISHED
\THIS DEADBAND REFERENCE POINT

A6524
AMOUNT OF CHANGE IS ADDED TO THE TRAVEL ACCUMULATOR.
POINT AT WHICH POINT

M S l > l I IL
Figure 4-7. Cycle Counter Deadband (set at 10%) Figure 4-6. Travel Accumulator Deadband (set at 10%)
Temperature Alerts
Label: Temp Hi Alrt Pt Parameter Name: SERVO-ALARM-TEMP-HI Index Number: 87 Mode: All Range: 0 to 125C Description: This parameter determines the temperature high alert point, in degrees Celsius, for the temperature high alert.
Label: Cycle Count DB Parameter Name: SERVO-ALARM-CYCLE-COUNT. THRESHOLD Index Number: 80 subindex 2 Mode: All Range: 0 to 100% Description: This parameter determines the cycle counter alert deadband. The cycle counter alert 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 4-7. Label: Cycle Count Alrt Pt Parameter Name: SERVO-ALARM-CYCLE-COUNT. LIMIT Index Number: 80 subindex 1 Mode: All Range: 0 to Description: This parameter determines the cycle counter alert point. The cycle counter alert point is the value of the cycle counter, in cycles, which, when exceeded, activates the Cycle Counter Alert.
Label: Temp Lo Alrt Pt Parameter Name: SERVO-ALARM-TEMP-LO Index Number: 88 Mode:All Range: -60 to 100C Description: This parameter determines the temperature low alert point, in degrees Celsius, for the temperature low alert.
Cycle Counter Alert Output Block Time-out

Label: Cycle Count Parameter Name: CYCLE-COUNT Index Number: 96 Mode: All Description: 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 is counted as a cycle. Once a new cycle has occurred, a new deadband around the last travel is set. See figure 4-7. You can reset the cycle counter by configuring it as zero.
September 2000
Label: Output Blk Timeout Parameter Name: SERVO-ALARM-OUTBLKTIMEOUT Index Number: 93 Mode: All Range: A value greater than 0 up to 800 seconds Description: This parameter determines how long the transducer block waits for a set point change from the A 0 block before it activates the alarm. This time is the time, in seconds, between A 0 block executions.
4-15
DVC5000f Series
4-16
September 2000
Calibration
Section 5 Calibration
Calibrating Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Travel Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Travel Calibration . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .
5-2
5-2
5-3
5-4
5-5
Calibrating the Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storing and Restoring Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
September 2000
5- I
DVC5000f Series
Calibrating Travel
service, you will not be able to calibrate the instrument because Auto Travel Calibration will not be able to change the transducer block set point. If the A 0 block is not Out of Service, the method provides you an opportunity to abort and set the A 0 block out of service.
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.
1. Start Auto Travel Calibration. For information on starting calibration methods from a DeltaV host system, see Appendix G. For information on running methods from other host systems, see the system documentation. 2. Auto Travel Calibration warns you the valve will move and that there may be a loss of process control. Select Yes to continue or select No to abort Auto Travel Calibration.
3. Auto Travel Calibration next initializes the instrument. After initialization, if the Feedback Connection is Sliding Stem - Standard Feedback, Auto Travel Calibration prompts you to set the crossover. For all other Feedback Connections, Auto Travel Calibration skips to step 7. For details of the Feedback Connection parameter see the Detailed Setup section
4. If the crossover must be set, there are three means of crossover adjustment: Manual (Initial Setup), Use Default (50%), or Use Last Value. Manual is the recommended choice. It permits you to manually set the crossover. If you select manual, continue to step 5.
Note
The A 0 block mode must be Out of Service to be able to Calibrate Travel.
The A 0 block mode can be set to Out of Service by setting the Resource block mode to Out of Service. However, setting the Resource block to Out of Service also sets all function blocks within the device to Out of Service, including the PID block. If the PID block is used to control another loop, be sure some other means are provided to control the loop before taking the block Out of Service.
Automatic Travel Calibration

When a DVC5000f Series digital valve controller is ordered as part of a control valve assembly, the factory mounts the digital valve controller on the actuator, connects the feedback linkage, connects the necessary tubing, then sets up and calibrates the digital valve controller as specified on the order. You can calibrate the instrument travel automatically using the Auto Travel Calibration method. The Auto Travel Calibration method (method name Auto-Calibrate) is included with the device description (DD) software. For information on using methods on the host system and the Auto Travel Calibration method to automatically calibrate instrument travel, see the host system documentation. Before starting Auto Travel Calibration, the A 0 block should be Out of Service. If the A 0 block is not out of
If you select Use Last Value, no further user interaction is required during the calibration process. Go to step 7. The crossover setting currently stored in the instrument from the last travel calibration is used, followed by a series of actions that will automatically calibrate the instrument. Use this selection if you cannot use manual, such as when you cannot see the valve.
If you select Use Default, this also does not require any further user interaction during the calibration process. Go to step 7. A value for the crossover is written to the instrument, followed by a series of actions that will automatically calibrate the instrument. Use this selection only as a last resort. Default assumes a midrange position on the travel sensor as the crossover point. However, this may not be an appropriate value to use for crossover because of variations in mounting and travel sensor calibration.
5. If you selected Manual for the crossover adjustment, Auto Travel Calibration prompts you to set the crossover. This prompt includes the current travel value and asks you to select the direction and amount the valve should move in order to set the crossover.
September 2000
5-2
Calibration
Before starting Manual Calibration, the A 0 block should be Out of Service. If the A 0 block is not out of service, you will not be able to calibrate the instrument because Manual Calibration will not be able to change the transducer block set point. If the A 0 block is not Out of Service, the method provides you an opportunity to abort and set the A 0 block out of service.
1. Start Manual Calibration. For information on starting calibration methods from a DeltaV host system, see Appendix G. For information on running methods from other host systems, see the system documentation.
2. Manual Calibration warns you the valve will move and that there may be a loss of process control. Select Yes to continue or select No to abort Manual Calibration.
Figure 5-1. Crossover Point
6. 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 5-1. Once the feedback arm is in the right position, select Mark Current Position.
7. From here on the calibration process is automatic. No further interaction is required. 8. When calibration is complete, you are next asked to enter information about the calibration, including who performed the calibration, where it was performed, and the date on which it was performed. 9. Before exiting, Auto Travel Calibration asks if you want to return the transducer block mode to Auto, if the transducer block was in the Out-of-Service mode before the method started. Select Yes to change the transducer block mode to Auto. Select No to leave the transducer block in its current mode. Remember to restore the Analog Output (AO) block mode if you changed it to Out of Service before starting Auto Travel Calibration. This is the end of the Auto Travel Calibration method.
3. Manual Calibration next initializes the instrument. After initialization, if the Feedback Connection is Sliding Stem - Standard Feedback, Manual Calibration prompts you to set the crossover. For all other Feedback Connections Manual Calibration skips to step 5. For details of the Feedback Connection parameter see the Detailed Setup section
4. If the crossover must be set, there are three means of crossover adjustment: Manual (Initial Setup), Use Default (50%), or Use Last Value. Manual is the recommended choice. It permits you to manually set the crossover.
If you select Use Last Value the crossover setting currently stored in the instrument from the last travel calibration is used, followed by a series of actions that will automatically calibrate the instrument. Use this selection if you cannot use manual, such as when you cannot see the valve. If you select Use Default a value for the crossover is written to the instrument, followed by a series of actions that will automatically calibrate the instrument. Use this selection only as a last resort. Default assumes a midrange position on the travel sensor as the crossover point. However, this may not be an appropriate value to use for crossover because of variations in mounting and travel sensor calibration.
Manual Travel Calibration

You can calibrate the instrument travel manually using the Manual Calibration method. The Manual Calibration method (method name Man-Calibrate) is included with the device description (DD) software. For information on using methods on the host system and the Manual Calibration method to manually calibrate instrument travel, see the host system documentation.
September 2000
5. Manual Calibration first commands the instrument to mark end points of travel. You must acknowledge each message to continue. If the Feedback Connection is not Sliding Stem - Standard Feedback, go to step 8. If the Feedback Connection is Sliding Stem - Standard Feedback, and if you selected Manual for the crossover, continue to step 6. If you selected Use Last Value or Use Default, go to step 8.
5-3
DVC5000f Series
6. If you selected Manual for the crossover adjustment, Manual Calibration prompts you to set the crossover. This prompt includes the current travel value and asks you to select the direction and amount the valve should move in order to set the crossover.
7. 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 5-1. Once the feedback arm is in the right position, select Mark Current Position. 8. Select the direction and size of change required to set the travel at the closed end point. When the valve is at is full closed position, select Mark Current Position. 9. Select the direction and size of change required to set the travel at the open end point. When the valve is at is full open position, select Mark Current Position. An external gauge to measure the digital valve controller output is required to calibrate the pressure sensor. This gauge is referred to as the reference gauge in the following procedure. The instrument output gauge may be used as the reference gauge.
Note
The A 0 block mode must be Out of Service to be able to run the Pressure Sensor Cal method.
10. From here on the calibration process is automatic. No further interaction is required.
11. When calibration is complete, you are next asked to enter information about the calibration, including who performed the calibration, where it was performed, and the date on which it was performed. 12. Before exiting, Manual Calibration asks if you want to return the transducer block mode to Auto, if the transducer block was in the Out-of-Service mode before the method started. Select Yes to change the transducer block mode to Auto. Select No to leave the transducer block in its current mode. Remember to restore the Analog Output (AO) block mode if you changed it to Out of Service before starting Manual Calibration. This is the end of the Manual Calibration method.
The A 0 block mode can be set to Out of Service by setting the Resource block mode to Out of Service. However, setting the Resource block to Out of Service also sets all function blocks within the device to Out of Service, including the PID block. If the PID block is used to control another loop, be sure some other means are provided to control the loop before taking the block Out of Service.
Calibrating the Pressure Sensor
Before starting Pressure Sensor Cal, the A 0 block should be Out of Service. If the A 0 block is not out of service, you will not be able to calibrate the instrument because Pressure Sensor Cal will not be able to change the transducer block set point. If the A 0 block is not Out of Service, the method provides you an opportunity to abort and set the A 0 block out of service.
Note
The pressure sensor is normally adjusted at the factory and should not require adjustment.
~ ~~
1. Start Pressure Sensor Cal. For information on starting calibration methods from a DeltaV host system, see Appendix G. For information on running methods from other host systems, see the system documentation.
2. Pressure Sensor Cal warns you the valve will move and that there may be a loss of process control. Select Yes to continue or select No to abort Pressure Sensor Cal. 3. Enter the units to use for calibrating the pressure sensor.
4. Pressure Sensor Cal begins by setting the valve travel to -25% travel. After the pressure has stabilized, enter the pressure reading from the reference pressure gauge.
You can calibrate the instrument pressure sensor automatically using the Pressure Sensor Cal method. The Pressure Sensor Cal method (method name Calibrate-Pressure-Sensor) is included with the device description (DD) software. For information on using methods on the host system and the Pressure Sensor Cal method to automatically calibrate instrument travel, see the host system documentation.
5-4
September 2000
Calibration
5. Pressure Sensor Cal next sets the valve travel to 125% travel. After the pressure has stabilized, enter the pressure reading from the reference pressure gauge.
Parameter Label Act. Fail Action Actuator Size Actuator Stops Calibration Date Calibration LOC. Calibration Person Crossover FB Temp Coef Feedback Connection Feedback Hiah Feedback Low Feedback Span High Perf Gain High Perf Press Bias High Perf Press Rate High Perf Reset High Perf Tvl Rate Inst. Deadband Inst. Output Bias IVP Gain
I
Index Numbed') 21 38 36 30 29 31 43 41 35.2 39 40 42 18 51 50 19 20 47
6. Pressure Sensor Cal displays the calibrated actuator pressure. If this value is not correct, select No, and Pressure Sensor Cal returns to step 4 so that you can recalibrate pressure. If the value displayed is correct, select Yes to continue to the next step. 7. Before exiting, Pressure Sensor Cal asks if you want to return the transducer block mode to Auto, if the transducer block was in the Out-of-Service mode before the method started. Select Yes to change the transducer block mode to Auto. Select No to leave the transducer block in its current mode. Remember to restore the Analog Output (AO) block mode if you changed it to Out of Service before starting Pressure Sensor Cal. This is the end of the Pressure Sensor Cal method.
44
48 49 56.1 55.1 55.2 56.1 61.1 61.2 15 16 35.1
Storing and Restoring Data

The StorelRestore Data method (method name Restore-Data) permits you to restore instrument data from factory setup and calibration data or from the Field Setup section of the instrument Non-Volatile Memory (NVM). You can also use StorelRestore Data to store setup and calibration data in the Field Setup section of NVM. The Store/Restore Data method is typically used to store current instrument data so that in case of a problem during setup or calibration you can return the instrument to its previous configuration. The method is included with the device description (DD) software. For information on using methods on the host system, see the host system documentation. 1. Start the StorelRestore Data method. For information on starting calibration methods from a DeltaV host system, see Appendix G. For information on running methods from other host systems, see the system documentation. 2. Restore Data warns you that the valve will move and that there may be a loss of process control. Select Yes to continue, or select No to abort Restore Data. 3. There are three means of storing or restoring data:
IVP Offset Press Cal. Units Pressure Gain Pressure Offset Press Units Standard Gain Standard Tvl Rate Travel Cutoff High Travel Cutoff Low Tvl Sensor Motion
0 Restore Factory Configuration Data-Restore Data replaces the current values for the parameters listed in table 5-1 with the values stored in the factory data section of the instrument NVM. This restores the values for these parameters back to the values used to setup the instrument at the factory. Be sure to perform initial setup and calibration after restoring factory data.
0 Restore Field Configuration-Restore Data replaces the current values for the parameters listed in table 5-1 with the values that were last stored in the Field Setup section of the instruments's NVM.
September 2000
5-5
DVC5000f Series
0 Store Field Configuration-Restore Data stores the current values for the parameters listed in table 5-1 in the Field Setup section of the instrument's NVM.
Select the desired means of storing or restoring data, or select Exit Store/Restore Data to exit the method without storing or restoring configuration data.
4. Before exiting, Store/Restore Data asks if you want to return the transducer block mode to Auto, if the transducer block was in the Out-of-Service mode before the method started. Select Yes to change the transducer block mode to Auto. Select No to leave the transducer block in its current mode.
f$
Note
If you select Restore Factory Configuration or Restore Field Configuration, Restore Data sets the input characterization to linear.
This is the end of the StorelRestore Data method.
5-6
September 2000
Viewing Device Information
Section 6 Viewing Device Information

Resource Block Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manufacture ID Device Type Device Revision DD Revision Tag Description 6-3 6-3
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Memory Size Free Time Free Space Minimum Cycle Time Mode Minimum NVM Cycle Time Hardware Types Restart
6-3
.................. ................................................
RCas Timeout Rout Timeout Write Lock Device State
6-4
Strategy Fault State Set Fault State Clear Fault State Options
. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feature Select
6-5
Block Execution GranVDeny
Alarm . . . . . . . . . . . . . . . . . .
Write Priority Confirm Time Max Alerts Allow
................................................
Max Alerts Poss Alert Key
6-5
Transducer Block Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Parameters ....................................................

Actuator Pressure Drive Signal Cycle Count Travel Accumulator Device Information Instrument Temperature Non-Volatile Memory Write Count Travel Travel Status
6-6 6-6
........................................................
Diagnostic 8,Cal Revision
6-6
Instrument Model No. Hardware Revision
Instrument Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alert Status Alert Unacknowledged Alert Unreported Block Error Transducer Error Other Status
6-7
September 2000
6- 7
DVC5000f Series
Table 6-1. Listing of Block Parameters in this Section by Label and Parameter Name
Parameter Label
1
ALERT-KEY CLR-FSTATE CONFIRM-TIME CYCLE-SEL DD-REV DEV-REV RS-STATE DEV-TYPE FAULT-STATE FEATURE-SEL FREE-SPACE FREE-TIME HARD-TYPES MAN UFAC-I D MAX-NOTIFY MEMORY-SIZE MIN-CYCLE-T NV-CYCLE-T LIM-NOTIFY SHED-RCAS RESTART SHED-ROUT SET- FSTATE STRATEGY TAG-DESC WRITE-LOCK WRITE-PRI
Index Numbed')
Required to Parameter Modify
".a'.a
that Affects Parametedz)
r'"LeL.L'u''
Resource Block Parameters Alert Key Clear FState Confirm Time Block Execution DD Revision Device Revision Device State Device Type Fault State Feature Select Free Space Free Time Hardware Types Manufacturer ID Max Alerts Poss Memory Size Min Cycle Time Min NVM Cycle Time Max Alerts Allow RCas Timeout Restart Rout Timeout Set FState Strategy Tag Description Write Lock Write Priority Actuator Pressure Alert Status Alert Unacknowledged Alert Unreported Block Error Cycle Count Diag 8 Cal Rev.. Diagnostics Options Drive Signal Function Block Options Hardware Rev. Inst. Model No. Instrument Temp. NVM Write Count Other Status Transducer Error Travel Travel Status Tvl Accumulator
04 30 33 20 13 12 07 11 6-3 6-4
6-5
Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only Read Only
6-5 6-3 6-3 6-4 6-3 6-4
20
18 24 25 15 10 31 22 21 23 32 26 16 27 29 03 02 34 39
6-5
6-3 6-3 6-3 6-3 6-5 6-3 6-3 6-3 6-5 6-4 6-4 6-4 6-4 6-4 6-3 6-4 6-5
Transducer Block Param x s PRESSURE SERVO-ALARM-SUMMARY.CURRENT SERVO-ALARM-SUMMARY.UNACKNOWLEDGED SERVO-ALARM-SUMMARY.UNREPORTED BLOCK-ERR CYCLE-COUNT DIAG-CAL-REV RESERVED-DPR S-VAR-2 RESERVED-FBP ELECT-REV-NO INST-MODEL-CODE ELECT-TEMP NVM-WRITES SELFTEST-STATUS XD-ERROR FINAL-POSITION-VALUE.VALUE FINAL-POSITION-VALUESTATUS TRAVEL-ACCUM
57 78.1 78.2 70.3 06

96 102 106 64 107 101 37 70 100 97 11 17.1 17.2 95
ndex 1.
Read Only Read Only Read Only Read Only Read Only All Read Only Read Only Read Only All Read Only Read Only Read Only Read Only Read Only Read Only All
Read Only
Read Only Mechanical Read Only Read Only Read Only Mechanical Read Only Read Only Read Only Read Only Read Only Read Only Mechanical
6-6 6-7 6-7 6-7 6-8 6-6 6-6 6-7 6-6 6-7 6-6 6-6 6-6 6-6 6-8
6-8 6-6 6-6 6-6
1 Digit after the deamal indicates subindex number For example, 78 1 indicates parameter number 78 s 2 Parameters wthout any data protection listed are not affected by any type of protection mechanism
This section describes the resource and transducer block parameters that provide instrument information. Most of the parameters listed in this section are read only. Parameters that are used to set up the instrument are described in Section 3 "Initial Setup" or Section 4 "Detailed Setup." Some of the setup parameters may be listed in this section because they provide instrument information; however, no detail is given here for modifying them.
Table 6-1 lists the parameters in this section in alphabetical order by label with a page reference where more detail on the parameter can be found. Each parameter is identified by its label as well as its parameter name and index number. Access to each parameter depends upon the host system software. For information on using the host system to view block parameters, see the appropriate system documentation.
6-2
September 2000

Resource Block Parameters
ldentification
Label: Manufacturer ID Parameter Name: MANUFAC-ID Index Number: 10 Description: The manufacturer of the device where this block is located, used by the interface device to locate the DD file for this device. The ID number assigned by FOUNDATION fieldbus to Fisher Controls is 20736 (005100 hex). Label: Device Type Parameter Name: DEV-TYPE Index Number: 11 Description: Identifies the type of device where this block is located, used by the interface device to locate the DD file for this device. Label: Device Revision Parameter Name: DEV-REV Index Number: 12 Description: Manufacturer revision number associated with this device, used by the interface device to locate the DD file for this device. Label: DD Revision Parameter Name: DD-REV Index Number: 13 Description: Revision of the device description (DD) associated with this device, used by the interface device to locate the DD file for this device. Label: Tag Description Parameter Name: TAG-DESC Index Number: 2 Description: A unique description for the resource block. The tag description must be unique for each block within a system. Label: Alert Key Parameter Name: ALERT-KEY Index Number: 4 Description: An identification number that permits grouping alerts. This number may be used to indicate to the operator the source of the alert such as the instrument, plant unit, etc.
Hardware
Label: Memory Size Parameter Name: MEMORY-SIZE Index Number: 22 Description: Indicates memory, in kilobytes, available for additional function blocks. Because no additional function blocks may be added to DVC5000f Series instruments, this parameter value is 0. Label: Free Space Parameter Name: FREE-SPACE Index Number: 24 Description: Indicates the percentage of memory (see parameter 22, Memory Size) available for additional function blocks. Because no additional function blocks may be added to DVC5000f Series instruments, this parameter value is 0. Label: Free Time Parameter Name: FREE-TIME Index Number: 25 Description: Percent of the block processing time that is free to process additional blocks. Because no additional function blocks may be added to DVC5000f Series instruments, this parameter value is 0. Label: Min Cycle Time Parameter Name: MIN-CYCLE-T Index Number: 21 Description: The shortest time in which the device can execute its function block schedule (macrocycle). Label: Min NVM Cycle Time Parameter Name: NV-CYCLE-T Index Number: 23 Description: Minimum time interval required to write parameters to non-volatile memory. Zero indicates data cannot be written to non-volatile memory. Label: Hardware Types Parameter Name: HARD-TYPES Index Number: 15 Description: Indicates the types of hardware available as channel numbers on this device. O=Scalar Input l=Scalar Output 2=Discrete Input 3=Discrete Output
September 2000
6-3
DVC5000f Series
Label: Restart Parameter Name: RESTART Index Number: 16 Description: There are four possible initialization values that can be entered into the Restart parameter. See Restarting the Instrument on page 4-2. DVC5000f Series instruments only support scalar outputs.
1
HARDWARE FAILURE
~
1
1
STARTlRESTART
1 b I
I
HARDWARE
HARDWARE a MEMORY OK POWER UP OR RESTART *, INITIALIZATION
I OR ERDWARE' ALARMSCLEARED MEMORY UNIT OPERATIONAL FAILURE POWER UP OR RESTART ON-LINE LINKING HARDWARE OR
Label: Strategy Parameter Name: STRATEGY Index Number: 3 Description: This parameter permits strategic grouping of blocks so the operator can identify where the block is located. The blocks may be grouped by plant area, plant equipment, etc. This data is not checked or processed by the block. Label: Fault State Parameter Name: FAULT-STATE Index Number: 28 Description: Indicates a condition set by loss of communication to an output block, fault promoted to an output block, or a physical contact. When the Fault state is ACTIVE, the output function blocks perform their FSTATE actions. Label: Set FState Parameter Name: SET-FSTATE Index Number: 29 Mode: Range: 1 (OFF) or 2 (SET) Description: Allows manually placing the instrument in the fault state by selecting SET. See also Features Select. Label: Clear FState Parameter Name: CLR- FSTATE Index Number: 30 Mode: Range:l (OFF) or 2 (CLEAR) Description: Selecting CLEAR clears the device fault state, if no faults are currently active. See also Features Select. Label: RCas Timeout Parameter Name: SHED-RCAS Index Number: 26 Mode: Range: Description: Time duration, in 1/32 milliseconds, at which to give up on computer writes to function block
HARDWARE OR
ON-LINE
POWER UP OR RESTART
RCas locations. Shed from RCas shall never happen when Shed RCas is 0. Label: Rout Timeout Parameter Name: SHED-ROUT Index Number: 27 Mode: Range: Description: Time duration, in 1/32 milliseconds, at which to give up on computer writes to function block Rout locations. Shed from Rout shall never happen when Shed Rout is 0. Label: Write Lock Parameter Name: WRITE-LOCK Index Number: 34 Mode: Range: 1 (NOT LOCKED) or 2 (LOCKED) Description: If LOCKED, no writes from anywhere are allowed, except to unlock Write Lock. When locked, block inputs will continue to be updated. Label: Device State Parameter Name: RS-STATE Index Number: 7 Description: Indicates the state of the function blocks As shown in figure 6-1, five states are possible:
0 Start Restart-The instrument is in this state when power is applied. In this state the memory and other hardware necessary for reliable operation is tested. If all hardware tests pass, the instrument state moves to Initialization. If a hardware failure is detected, the instrument state changes to Failure. 0 Initialization-The instrument can enter this state from the StarVRestart or Failure states. In the Initialization state, all unreported function block alarms
6-4
September 2000

are automatically confirmed and acknowledged. Once the instrument is considered operational, block execution is scheduled and the instrument state moves to On-line Linking. Online Linking-In this state, all defined links are evaluated. Once defined links are established, the instrument state changes to Online.
0
0 Fault State-Selecting fault state enables the ability to manually set and clear the fault state. See Set FState and Clear FState. 0 Soft Write Lock-When selected, permits using the Write Lock parameter to prevent any external change to static or nonvolatile parameter values. Block connections and calculation results will proceed normally, but the configuration is locked. See also the Write Lock parameter description. 0 Output Readback-When selected, permits the transducer btock output to be fedback to the READBACK parameter in the A 0 block.
0 Online-The instrument will be in this state if it is operational and all defined links are established. If one or more defined links are detected as not established, the state changes to Online linking.
0 Standby-The instrument enters this state if the resource block mode is Out of Service. In this state all function block modes are forced to Out of Service. The transducer block mode is not affected. When the resource block mode is changed to Auto, the instrument state changes to Start Restart.
Default is all features selected.
Alarms
Label: Write Priority Parameter Name: WRITE-PRI Index Number: 39 Mode: Range: 0 to 15 Description: Priority of the alarm generated by setting Write Lock to NOT LOCKED. Label: Confirm Time Parameter Name: CONFIRM-TIME Index Number: 33 Mode: Range: Description: The time, in milliseconds, the instrument waits for confirmation of receipt of a report before trying again. The instrument does not retry if Confirm Time is 0. Label: Max Alerts Allow Parameter Name: LIM-NOTIFY Index Number: 32 Mode: Range: 0 to Max Notify Description: The maximum number of unconfirmed alert notify reports allowed. See Max Alerts Poss. If Max Alerts Allow is set to 0, no alerts are reported. Label: Max Alerts Poss Parameter Name: MAX-NOTIFY Index Number: 31 Description: The maximum number of unconfirmed alert reports that the instrument can send without getting a confirmation. This limit is determined by the amount of memory available for alert reports. Use Max Alerts Allow to set a number lower than Max Alerts Poss to control alert flooding.
~
0 Failure-This state may be entered from any other state except Standby. The instrument moves to this state whenever a hardware or memory failure is detected which would prevent reliable operation. When the failure clears, the instrument state moves to Initialization.
Options
Label: Block Execution Parameter Name: CYCLE-SEL Index Number: 20 Description: Indicates if function block execution can be scheduled. If bit 0 is active, the function blocks execute per the function block schedule. Default is schedule selected.
Label: Feature Select Parameter Name: FEATURE-SEL Index Number: 18 Mode: Range: 1 (reports supported), 2 (fault state supported), 3 (soft write lock supported), and 5 (output readback supported) Description: Permits selecting the desired feature from those that are available. Available features for DVC5000f Series instruments include:
0 Reports-Selecting reports enables alarm and event reporting. Reporting of specific alarms may be disabled, see Alarms in Section 4.
September 2000
6-5
DVC5000f Series
Transducer B Iock Para meters
Instrument Parameters
Label: Actuator Pressure Parameter Name: PRESSURE Index Number: 57 Description: Indicates the value of the instrument output pressure in psi, bar, or kPa. Label: Instrument Temp. Parameter Name: ELECT-TEMP Index Number: 70 Description: This parameter indicates the internal temperature of the instrument in degrees Celsius. Label: NVM Write Count Parameter Name: NVM-WRITES Index Number: 100 Description: Indicates the number of writes to non-volatile memory. Label: Travel Parameter Name: FINAL-POSITION-VALUE.VALUE Index Number: 17 subindex 1 Description: This parameter shows the value of the DVC5000f Series digital valve controller travel in percent (%) of ranged travel. Travel always represents how far the valve is open. Label: Travel Status Parameter Name: FINAL-POSITION-VALUE. STATUS Index Number: 17 subindex 2 Description: Indicates a fault that makes the travel measurement bad or prevents the actuator from responding. This information is passed along with each transmission of the travel in the form of a status attribute.
Label: Drive Signal Parameter Name: S-VAR-2 Index Number: 64 Description: Indicates the drive signal, as a percentage of the maximum drive available, going to the I/P converter from the printed wiring board.
@I
Note
In most applications, the drive signal ranges between 50% and 75% of the maximum drive signal.
Device Information
Label: Cycle Count Parameter Name: CYCLE-COUNT Index Number: 96 Description: Indicates the number of times the travel changes direction. 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. See Cycle Counter Deadband in Section 4. Label: Inst. Model No. Parameter Name: INST-MODEL-CODE Index Number: 37 Range: 1 through 4 Description: This parameter indicates the Instrument type number: 1=DVC501O f 2=DVC5020f 3=DVC5030f 4=DVC5040f Label: Hardware Rev. Parameter Name: ELECT-REV-NO Index Number: 101 Description: This parameter indicates the revision number of the electronics in the instrument. Label: Diag & Cal Rev.. Parameter Name: DIAG-CAL-REV Index Number: 102 Description: This parameter indicates the number of the Fisher Controls diagnostic and calibration revision in the instrument.
September 2000
Label: Tvl Accumulator Parameter Name: TRAVEL-ACCUM Index Number: 95 Description: This parameter indicates 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. See Travel Accumulator Deadband in Section 4.
6-6

Options
Thousands 8 1 4 1 2 1 1 15114113112 Hundreds 8 1 4 1 2 1 1 Il(101918 Tens Ones 8 / 4 / 2 / 1 8 1 4 1 2 1 1 7 1 6 1 5 1 4 3 1 2 1 1 / 0
Label: Diagnostics Options Parameter Name: RESERVED-DPR Index Number: 106 Description: This parameter indicates which of the following diagnostic capabilities is included in the instrument: Standard Diagnostics Public Diagnostics Advanced Diagnostics
Refer to table 6-2 to determine which bit is true for a given hexadecimal value. For example, a hexadecimal value of 400 indicates bit 10 is true. The following parameters determine the alert handling: Alert Status-indicates active which alerts are currently
0 Alert Unreported-indicates unreported,
which alerts are
0 Alert Unacknowledaed-indicates which alerts have not been acknowledged by the receiving device.
Label: Function Block Options Parameter Name: RESERVED-FBP Index Number: 107 Description: This parameter indicates which of the following function blocks or special functions is available with the instrument: Enhanced Servo PID
The value that appears with each parameter is the sum of the values of all the alerts being handled by that parameter. For example, a hexadecimal value of 0084 for the Alert Status indicates the Travel Accumulator (0004) and Travel Deviation (0080) alerts are active. A hexadecimal value of 0012 for the Alarm Unacknowledged parameter indicates that the Cycle Count (0002) and Travel High-High (0010) alerts have not been acknowledged by the receiving device. For information on enabling alerts, setting trip points, and deadbands, see section 4. Label: Alert Status Parameter Name: SERVO-ALARM-SUMMARY. CURRENT Index Number: 78 subindex 1 Description: Indicates which enabled alerts are active. The value is the sum of the hexadecimal values of all active alerts. Label: Alert Unacknowledged Parameter Name: SERVO-ALARM-SUMMARY. UNACKNOWLEDGED Index Number: 78 subindex 2 Description: Indicates which reported alerts are unacknowledged by the receiving device. The value is the sum of the hexadecimal values for all unacknowledged alerts. Label: Alert Unreported Parameter Name: SERVO-ALARM-SUMMARY. UNREPORTED Index Number: 78 subindex 3 Description: Indicates which active and enabled alerts are unreported. The value is the sum of the hexadecimal values of all unreported alerts.
Instrument Status
The following alerts are available from the instrument. Each alert is represented by one of 15 bits within the specified parameter. The hexadecimal value listed is a common way of identifying which bit is true.
Alert
Hexadecimal Value
Drive Failure Cycle Count Travel Accumulation Travel High Travel High-High Travel Low Travel Low-Low Travel Deviation Temperature High Temperature Low I/P Feedback Pressure High Pressure Low Pressure Derivative A 0 Timeout Alarm NVM Write
September 2000
0001 0002 0004 0008 0010 0020 0040 0080 0100 0200 0400 0800 1000 2000 4000 8000
6- 7
DVC5000f Series
Label: Block Error Parameter Name: BLOCK-ERR Index Number: 6 Range: 0 through 15 Description: This parameter indicates the error status of the hardware or software components associated with a block. Table 6-3 lists conditions reported in the Block Error parameter. Conditions in italics are not applicable for the transducer block and are provided only for your reference. Label: Transducer Error Parameter Name: XD-ERROR Index Number: 11 Range: 0 and 16 through 25 Description: One of the transducer error codes defined in the FF Transducer Specifications in section 4.7 Block Alarm Subcodes. O=No error 17=General error, pressure sensor failure(3) 19=Configuration error 20=Electronics failure, I/O processor failure 22=1/0 failure, position sensor 24=Sohare error DVC5000f Series instruments support alarm subcodes 17 (General error), 20 (Electronics failure), 22 (1/0 failure), and 24 (Software error). Label: Other Status Parameter Name: SELFTEST-STATUS Index Number: 97 Description: The following bits indicate the status of the instrument self test: 128=Tvl Snsr Hi Error 256=Tvl Snsr Lo Error 512=Voltage Ref Fail 1024=IOP Other Error 2048=lOP Configuration Error 4096=10P Timeout 8192=Press Snsr Fail 16384=Tvl Snsr Failure 32768=Simulate Jumper
Table 6-3. Block Error Conditions
Condition Number
0 1
Condition Name and Description Other -Error condition is not 0 in the transducer error oarameter. Block ConfigurationError (N1A) Link Configuration Error - No active link for alarm reporting Simulate Active (N/A) Local Override -Transducer block has started offline diagnostics, target and actual modes are Auto. Instrument Fault State -Transducer block actual mode is Out of Service, position sensor reading is not between Feedback Low and Feedback High values (Transducer 1 0 failure condition 22), 110 processor error parameter 1 error (Transducer error parameter Electronicsfailure condition 20), Pressure Sensor failure() (Transducer error parameter General error condition 17). Drive failure, Output Block Timeout, or NVM failure on read. Maintenance Needed Soon NVM failure on write, or Pressure Sensor failure lnput failurelprocess variable has Bad status (NIA)
3
4
Output failure (NIA)

Memory failure NVM failure on read or write 10 11 12
Lost Static Data (NIA) Lost NV Dafa (NIA)

Readback Check Failed Maintenance Needed Now - Position sensor reading is not between Feedback Low and Feedback High values, 110 processor error, or NVM failure on read Power Up (NIA) Out of Service -Transducer block actual mode is Out of Service, position sensor reading is not between Feedback Low and Feedback High values (Transducer error parameter I/O failure condition 22), 110 processor error (Transducer error parameter Electronics failure condition 20). Pressure Sensor failure(2)(Transducer error parameter General error condition 17). Drive failure, Output Block Timeout. or NVM failure on read.
13
14
15
1. Errorcoi ition occurs do to Dressure sensor failure onlv If Standard Gain tunina parameter is equal to 0 2 Error condition OCCULS do lo pressure sensor failure only If Standard Gain tuning parameter is not equal to 0
3. Thls enor wndition occurs only d the Standard Gain tuning parameter is equal
to 0.
6-8
September 2000
Principle of Operation
Section 7 Principle of Operation

FOUNDATION Fieldbus Communication
................................
7-2
7-2
Digital Valve Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
September2000
7-7
DVC5000f Series
9 TO 32 VOLT
Fir1 nmis
INPUT SIGNAL
AUXILIARY TERMINALS
PRESSURE SENSOR FOR ADVANCED DIAGNOSTICS
SUPPLY PRESSURE
STEM FEEDBACK
-d
PRESSURE
*6480-2m
Figure 7-1. DVC59OOf Series Digital Valve Controller Principle of Operation
FO uNDAT IoN FieIdbus Communicat ion

The DVC5000f Series digital valve controllers use t h e FOUNDATION fieldbus to communicate with other fieldbus instruments and the control system. Fieldbus is an all digital, serial, two-way communication system which interconnects field equipment such as transmitters, valve controllers, and process controllers. Fieldbus is a local-area network (LAN) for instruments used in both process and manufacturing automation with built-in capability to distribute the control application across the network. The fieldbus environment is the base level group of digital networks in the hierarchy of plant networks. The fieldbus retains the desirable features of analog systems such as:
0
0 reduced loading on control room equipment due to possible distribution of some control and inputloutput functions to field devices 0 speed options for process control and manufacturing applications.
For more information on the operation of the FOUNDATION fieldbus, refer to the FOUNDATION fieldbus specifications.
Digital Valve Controller Operation

DVC5000f Series digital valve controllers have a single master module that may be easily replaced in the field without disconnecting field wiring or tubing. The master module contains the following submodules: current-to-pneumatic (I/P) converter, printed wiring board assembly, and pneumatic relay. The master module can be rebuilt by replacing the submodules. See figures 7-1 and 7-2. DVC5000f Series digital valve controllers are bus-powered instruments that provide a control valve position in response to a digital input from the control room. The following describes a direct acting Type DVC5010f digital valve controller mounted on a Type 657 actuator. The input is routed into the terminal box through a single 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 increases, the drive signal to the I/P converter increases. This increases the pressure to
September 2000
a standardized physical interface to the wire bus powered devices on a single wire pair intrinsic safety options.
In addition, the FOUNDATION fieldbus enables:

0 Increased capabilities due to full digital communications
0 reduced wiring and wire terminations due to multiple devices on one pair of wires 0 increased selection of suppliers due to interoperability
7-2
Princide of ODeration
TERMINAL BOX ASSEMBLY
%TERMINAL BOX COVER
J
/- TRAVEL
SENSOR ASSEMBLY
ASSEMBLY
MODULE BASE ASSEMBLY
IIP CONVERTER
'\
2
HOUSING
GASKET
PNEUMATIC RELAY--/
GAUGES
dGa7
RELAY CAP
4BBpu1-*
L COVER ASSFMRI V
.
*,ox-2, IL
Figure 7-2 . DVC5000f Series Digital Valve Controller Assembly
the pneumatic relay submodule. As the pressure increases, the pneumatic relay opens the supply port and closes 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 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 decreases
the I/P drive signal reducing nozzle and relay pressure until the system is in equilibrium.
As the input decreases, the drive signal to the I/P converter submodule decreases, decreasing the pressure. The pneumatic relay closes the supply port and opens the exhaust port, releasing the actuator casing pressure to atmosphere. The stem moves upward until the correct position is attained. At this point the printed wiring board assembly increases the I/P drive signal until the system returns to equilibrium.
September 2000
7-3
DVC5000f Series
7-4
September 2000
Maintenance
Section 8 Maintenance
Stroking the Digital Valve Controller Output
Using the Stroke Valve Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3 8-3 8-6
Instrument Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Voltage Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Module Maintenance

Removing the Master Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Master Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6 8-7
SubModule Maintenance
I/P Converter
Replacing the I/P Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the I/P Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the I/P Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 8-8 8-9 8-9 8-9 8-9 8-9 8-10 8-10
Printed Wiring Board (PWB) Assembly

Removing the Printed Wiring Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Printed Wiring Board Assembly ................................ Setting the Mode Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pneumatic Relay
Removing the Pneumatic Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Pneumatic Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauges. Pipe Plugs or Tire Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Box
Removing the Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10 8-10
Travel Sensor
Disassembly
DVC501Of Digital Valve Controller (Sliding-Stem) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5020f Digital Valve Controller (Rotary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5030f Digital Valve Controller (Rotary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5040f Digital Valve Controller (Sliding-Stem) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 8-11 8-12 8-11
September 2000
8- 1
DVC5000f Series
Assembly
DVC5010f Digital Valve DVC5020f Digital Valve DVC5030f Digital Valve DVC5040f Digital Valve Controller (Sliding-Stern) ............................. Controller (Rotary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller (Rotary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller (Sliding-Stem) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 8-1 3 8-14 8-12 8-15
Calibrating the Travel Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DVC501O f Digital Valve Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5020f Digital Valve Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5030f Digital Valve Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5040f Digital Valve Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-15 8-16
8-15 8-15
8-2
September 2000
Maintenance
2. Stroke valve next displays the current set point and travel and prompts for the desired set point change.
Note
If the feedback arm (key 79) or feedback arm assembly (key 84) is removed from the DVC5000f Series digital valve controller, the travel sensor (key 77) must be recalibrated.
0 Move Open or Move Closed-adjusts the current set point by the amount indicated (+/- 10%) up to the maximum or minimum allowed. 0 Go to...-sets the current set point to the value indicated (5%, 50%, or 95% of travel). 0 Change Set Point-changes set point to specified value.
Because of the diagnostic capability of the DVC5000f Series digital valve controllers, predictive maintenance is available through the use of AMS 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 AMS VL2000 Series ValveLink Software User Guide.
0 Refresh Display-refreshes the current values for the set point and travel as the valve moves. Because the valve moves slower than the method executes, use refresh display to update the actual valve travel. 0 Exit Stroke Valve-Select this if you are done. This is the end of the Stroke Valve method.
Stroking the Digital Valve Controller output

Using the Stroke Valve Method
You can remotely stroke the digital valve controller output from a host system using the Stroke Valve method. The Stroke Valve method (method name Stroke-Valve) is included with the device description (DD) software. For information on using methods on the host system and the Stroke Valve method to remotely stroke the instrument output, see the host system documentation.
Instrument Troubleshooting
If communication or output difficulties are experienced with the instrument, refer to the troubleshooting chart provided in table 8-1. The following transducer block parameters are also available to aid troubleshooting the instrument.
Maintenance: Travel and Pressure

Label: AID Readback Parameter Name: AD-FEEDBACK Index Number: 62 Description: Indicates the analog-to-digital converter output for the feedback input. Label: Crossover Parameter Name: CROSSOVER Index Number: 43 Description: Indicates the bias point for the feedback mechanism in sliding-stem applications. Label: Feedback High Parameter Name: FEEDBACK-HI Index Number: 39 Description: Indicates the feedback value when the feedback arm is at its +60" position. Must be greater than the feedback low indication.
Note
The A 0 block mode must be Out of Service to be able t o run Stroke Valve.
Before starting Stroke Valve, the A 0 block should be Out of Service. If the A 0 block is not out of service, you will not be able stroke the valve because Stroke Valve will not be able to change the transducer block set point. If the A 0 block is not Out of Service, the method provides you an opportunity to abort and set the A 0 block out of service.
1. Start Stroke Valve.

September 2000
8-3
DVC5000f Series
Table 8-1. Instrument Troubleshooting
Symptom. Possible Cause Action
. Instrument will not communicate.
1a. Insufficient terminal voltage. l b . Cable capacitance too high. I c . Improper field wiring. Id. Disconnected loop wiring cable at PWB. l e . PWB failure.
If. Defective cable from terminal box. l g . Defective terminal box assembly printed wiring board. 2a. Travel sensor "frozen". will not turn. I. Instrument will not calibrate, ias sluggish performance or oscillates. 2b. Broken travel sensor wire(s). 2c. Travel sensor mis-adjusted. 2d. Open travel sensor. 2e. Cables not plugged into PWB correctly. 2f. Feedback arm loose on pot. 29. Feedback arm benudamaged or bias spring missingldarnaged. 2h. Configuration errors.
l a . Measure the terminal voltage. Terminal voltage should be between 9 and 32 Vdc. 1b. Wrong cable type or segment length too long. See Site Planning Guide. I c . Check integrity of wiring connections. Make sure cable shield is grounded only at the control system. I d . Verify connectors are plugged in correctly. l e . Measure voltage at test terminals. The voltage should be 0.025 volts 50.003 volts. If not, check terminal voltage. Replace the PWB if necessary. If. Check cable continuity. If necessary, replace the terminal box assembly. l g . Check for damaged printed wiring board lands and terminals. If necessary, replace the terminal box assembly. 2a. Rotate feedback arm to ensure it moves freely. If not, replace the potlbushing assy. 2b. Inspect wires for broken solder joint at pot or broken wire. Replace poffbushing assy. 2c. Perform Travel Sensor Adjustment procedure. 2d. Check for continuity in electrical travel range. If necessary, replace poffbushing assy. 2e. Inspect connections and correct. 2f. Perform Travel Sensor Adjustment procedure. 29. Replace feedback arm and bias spring. 2h. Verify configuration
1
2i. IIP assv restriction . & w_e . Drirnaw . _d .
21. Apply supply pressure and depress cleanout wire.

-
2k. Air blockage in IIP assy nozzle block, not cleared by 12k. Replace IIP assy. depressing cleanout wire. 21. Replace 0-ring(s). 21. O-ring@) between IIP assy missing or hard and flattened losing seal. 2m. Check for bent flapper, loose cleanout valve, 2m. IIP assy damagedIcorrodedIclogged. open coil (continuity), contamination, staining, or dirty air supply. Coil resistance should be between 1680 1860 ohms. Tighten cleanout valve, replace IIP assy i damaged, corroded, clogged, or open coil. 2n. IIP assy nozzle may have been adjusted. 2n. IIP assy out of spec. Verify drive signal (55% to 75%) Replace IIP assy if drive signal is continuously high or low.
2p. Defective gasket.
2q. Defective relay.
2p. Check gasket for closed holes, excessive deformation due to overtightening or "oozing". If necessary, replace gasket. 2q. Depress IIP 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 IIP assy good and air passages not blocked. 2r. Replace 67CFR regulator.
2r. Defective 67CFR regulator, supply pressure gauge !. Instrument will not calibrate, ias sluaoish performance or oscillates. iumps around.
8-4
September 2000
Maintenance
1b e rN :
0
1
Table 8-2. Calibration Status Bit Enumeration
I Calibrationstep I
Calibration Error
FullCloseMarked
Open Marked
~
Maintenance: IIP and Other
Description An error was found during calibration Valve fully closed position has been marked Valve fully open position has been marked Crossover point has been marked Calibration of the IVP is in progress Auto calibration is in progress Manual calibration is complete Auto calibration is complete
I I i 2 1
3
4
1
I
I
Label: IP Feedback Parameter Name: IP-FB Index Number: 68 Description: Indicates the feedback from the current-to-pressure (I/P) converter. Label: Voltage Ref Parameter Name: VOLTAGE-REF Index Number: 69 Description: Indicates the analog reference signal voltage in analog-to-digital converter counts. Use the following equation to convert the counts to voltage: Counts Volts 50.61
1 Crossover Marked
IVP in Progress Autocal In Progress Man Cal Done Auto Cal Done
6
7
Label: Feedback Low Parameter Name: FEEDBACK-LO Index Number: 40 Description: Indicates the feedback value when the feedback arm is at its -60 position. Must be less than the feedback high indication.
Label: 1 1 0 Proc Status Parameter Name: P-STATUS Index Number: 66 Description: Indicates the status of the internal I/O processor. Label: 1 1 0 Proc Count Parameter Name: P-COUNT Index Number: 67 Description: Indicates the I/O processor count status. Label: Alert Priority Parameter Name: SERVO-ALARM-PRIORITY Index Number: 76 Description: Indicates the priority for transducer block alarms. For more information on alerts, see Setting Alerts in Section 4. Label: Firmware Date Parameter Name: FIRMWARE-DATE Index Number: 103 Description: indicates date of firmware installed in the instrument. Label: Drive Signal Alert Parameter Name: SERVO-ALARM-DRIVE-SIGNAL Index Number: 79 Description: Indicates if drive signal alert reporting is disabled and if the alert is active. For more information on alerts, see Setting Alerts in Section 4. Label: Drive Sgl Alrt Pt Parameter Name: SERVO-ALARM-DRIVE-SIGNAL. LIMIT Index Number: 79 subindex 1 Mode: All Range: -25 to 125% Description: The value, in percent, which when exceeded by the difference between Drive Signal (IIP
Label: Pressure Gain Parameter Name: PRESSURE-SCALE.GAIN Index Number: 55 subindex 1 Description: Indicates the pressure sensor gain.
Label: Pressure Offset Parameter Name: PRESSURE-SCALE.OFFSET Index Number: 55 subindex 2 Description: Indicates the pressure sensor offset (bias).
Label: Press Cal. Units Parameter Name: PRESSURE-UNITS.CAL-UNITS Index Number: 56 subindex 1 Range: 1133 (kPa), 1137 (bar), or 1143 (psig) Description: Indicates calibration and readback units for actuator pressure (psig, bar, or kPa).
Label: Calibrate Status Parameter Name: CALIBRATE-STATUS Index Number: 73 Description: Indicates the status of the instrument as it progresses through the calibration procedures by activating a series of bits. The bit numbers and descriptions are listed in table 8-2.
September 2000
8-5
DVC5000f Series
current) and its readback value causes the Drive Signal Alert to become active, if the Drive Signal Alert Time has elapsed.
Checking Voltage Available
Label: Drive Sgl Alrt Time Parameter Name: SERVO-ALARM-DRIVE-SIGNAL. TIME-LIMIT Index Number: 79 subindex 2 Mode: All Range: 0 to 120 seconds Description: The difference between Drive Signal (IIP current) and its readback value must exceed the Drive Signal Alert Point for this time period, in seconds, before the Drive Signal Alert becomes active.
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. Measure the voltage at the instrument BUS terminals. The voltage measured should be between 9 and 32 volts. 2. Measure the voltage at the instrument TEST terminals. This voltage should be 0.025 k0.002volts.
Label: IIP Feedback Alert Parameter Name: SERVO-ALARM-IP-FB Index Number: 89 Description: Indicates if IIP feedback alert reporting is disabled and if the alert is active. For more information on alerts, see Setting Alerts in Section 4.
Master Module Maintenance

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.
Label: IIP FB Alrt Pt Parameter Name: SERVO-ALARM-IP-FB.LIMIT Index Number: 89 subindex 1 Mode: All Range: 0 to 254 Description: The value which when exceeded by the I/P feedback current causes the I/P Feedback Alert to become active, if the IIP Feedback Alert Time has elapsed.
Removing the Master Module

To remove the master module, perform the following steps. Refer to figures 9-1 through 9-4 for key number locations.
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.
Label: IIP FB Alrt Time Parameter Name: SERVO-ALARM-IP-FB. TI ME-LI MIT Index Number: 89 subindex 2 Mode: All Range: 0 to 120 seconds Description: The I/P feedback current must exceed the I/P Feedback Alert Point for this time period, in seconds, before the I/P Feedback Alert becomes active.
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).
8-6
September 2000
Maintenance
3. Using a Il4-inch hex wrench, loosen the four-socket head screws (key 38). These screws are captive in the module base by retaining rings (key 154).
SUB-MODULE
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.
NOTE X INDICATES PIN REMOVED FOR CONNECTOR KEYING.
MW?-IIIL
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.
Figure 8- 1. DVC5000f Series Digital Valve Controller Connector Locations
1. Ensure the gasket is aligned properly on the master module. 2. Connect the terminal box connector to the pwb assembly (key 50), shown in figure 8-1. Orientation of the connector is required. 3. Connect the travel sensor connector to the pwb assembly (key 50),shown in figure 8-1. Orientation of the connector is required.
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.
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 Ibf*in (16 N m ) .
Replacing the Master Module

To replace the master module, perform the following steps. Refer to figures 9-1 through 9-4.
6. Insert the cover hinge tabs into the module base. Swing the cover down into position and tighten the screw (key 4 1).
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.
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.
Submodule Maintenance
The digital valve controllers master module contains the following submodules: IlP converter, pwb assembly, and pneumatic relay. If problems occur,
~ ~ _ _ _ _ _ _
~
September 2000
8- 7
DVC5000f Series
these submodules may be removed from the master module and replaced with new submodules. After replacing a submodule, the master module may be put back into service.
@ $
Note
,SCREEN (FILTER) LOCATED IN IIP CONVERTER SUPPLY PORT
If the pwb assembly or IIP converter submodule is replaced, calibrate and configure the DVC5000f 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.
O-RING LOCATE IN IIP CON OUTPUT P

w7601, IL
Figure 8-2. IIP Filter Location
n
@ h
Note
Exercise care when you perform maintenance on the master module. Reinstall the cover to protect the IIP converter and gauges when servicing other submodules.
SHROUD
SOCKET-HEAD SCREWS (4)
I/P Converter
Refer to figures 9-1 through 9-4 for key number locations. The I/P converter (key 41) is located on the front of the master module.
Figure 8-3. IIP Converter
Replacing the IIP Filter

A screen in the supply port beneath the I/P converter serves as a secondary filter for the supply medium. To replace this filter, perform the following procedure:
1. Remove the I/P converter and shroud as described in the Removing the I/P Converter procedure.
Removing the IIP Converter

1. Remove the front cover, if not already removed. 2. Refer to figure 8-3. Remove the four socket-head screws that attach the shroud and I/P converter to the module base.
2. Remove the screen from the supply port.

3. Install a new screen in the supply port as shown in figure 8-2.
4. Inspect the O-ring in the I/P output port. if necessary, replace it. 5. Reinstall the I/P converter and shroud as described in the Replacing the I/P Converter procedure.
3. Remove the shroud; then pull the I/P converter straight out of the module base. Be careful not to damage the two electrical leads that come out of the base of the I/P converter.
4. Ensure that the O-ring and screen stay in the module base and do not come out with the I/P converter.
September 2000
8-8
Maintenance
Replacing the IIP Converter
1. Refer to figure 8-2. Inspect the condition of the O-ring and screen in the module base. Replace them, if necessary. Apply sealant to the O-rings. 2. Ensure the two boots shown in figure 8-3 are properly installed on the electrical leads. 3. Install the I/P converter straight into the module base, taking care that the two electrical leads feed into the guides in the module base. These guides route the leads to the printed wiring board assembly submodule. 4. Install the shroud over the I/P converter. 5. Install the four socket-head screws and evenly tighten them in a crisscross pattern to a final torque of 20.7 Ibf-in (2 N-m). 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 Ibf-in (1 N=m).
Pneumatic Relay
Refer to figures 9-1 through 9-4 for key number locations. The pneumatic relay (key 24) is located on the side of the master module.
PWB (Printed Wiring Board) Assembly

Refer to figures 9-1 through 9-4 for key number locations. The pwb assembly (key 50) is located on the back of the module base assembly.
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.
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.
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.
Replacing the PWB Assembly

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).
@ Y
Note
3. Use a flat-bladed screwdriver in the notch of the relay to pry the relay out of the module base.
If the pwb assembly submodule is replaced, calibrate and configure the DVC5000f Series digital valve controller to maintain accuracy specifications.
2. Properly orient the pwb assembly as you install it into the module base. The two electrical leads from the
September 2000
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.
8-9
DVC5000f Series
Replacing the Pneumatic Relay
1. Ensure the compartment in the module base that holds the relay is clean. 2. Visually inspect the 0,016-inch hole in the module base (the fixed bleed on the relay output) to ensure it is clean and free of obstructions. If cleaning is necessary, do not enlarge the hole. 3. Apply sealant (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. 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 9-1 through 9-4 for key number locations. The terminal box is located on the housing and contains the terminal strip assembly for field wiring connections.
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.
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. 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. 4. On Type DVC501O f and DVC5020f digital valve controllers, remove the mounting bracket to permit rotatating the terminal box.
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.
9. Install the relay cap on the module base. As the relay cap is installed, the spring washer fingers will grab the relay cap and retain the Belleville spring. Tighten the screws, in an crisscross pattern, to a final torque of 20.7 Ibf-in (2 N-m).
5. Remove the screw (key 72). Remove the terminal box as follows:
a For Type DVC501Of, DVC5020f, and DVC5030f, digital valve controllers, unscrew the terminal box assembly from the housing.
a For Type DVC5040f digital valve controllers, pull the terminal box straight out from the housing.
Gauges, Pipe Plugs, or Tire Valves

Depending on the options ordered, the DVC5000f 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 9-1 through 9-5 for key number locations. 1. Remove the front cover (key 43).
6. Remove two wire retainers (key 44), internal and external to the terminal box.
Replacing the Terminal Box
2. Remove the gauge, pipe plug, or tire valve as follows:

For gauges (key 47), use a wrench on the flats of the shaft underneath each gauge to remove the gauges from the module base. For pipe plugs (key 66) and tire valves (key 67), use a wrench to remove these from the module base.
Note
Inspect all O-rings for wear and replace as necessary.
1. Install two wire retainers (key 44), internal and external to the terminal box.
September 2000
8-10
Maintenance
2. Apply sealant (key 65) to the O-ring (key 36) and install the O-ring over the 2 4 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. 3. Apply lubricant (key 63) to the 2 4 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). Type DVCSOlOf, DVC5020f, and DVC5030f, digital valve controllers 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 1-114 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. Type DVC5040f digital valve controllers 6. Apply sealant (key 65) to the O-ring (key 35) and install the O-ring over the guide surface on the terminal box. Take care not to dameage the guide surface. 7. Push the terminal box assembly into the housing until it bottoms out. Install the screw (key 72). 8. Apply sealant (key 64) to the conduit entrance plug (key 62) and install it into the desired side of the terminal box.
Note
If the pwb assembly submodule is replaced, calibrate and configure the DVCSOOOf Series digital valve controller to maintain accuracy specifications.
Disassembly
Type DVC5070f and DVC5040f Digital Valve Controller
Refer to figure 9-1 or 9-4 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. 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. 8. Unscrew the travel sensor assembly (key 77) from the housing.
Type DVC5020f Digital Valve Controller

Refer to figure 9-2 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.
Travel Sensor
Replacing the travel sensor requires removing the digital valve controller from the actuator.
September 2000
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.
8-11
DVC5000f Series
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. 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. 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.
6. Attach the feedback arm (key 79) to the travel sensor shaft.
7. Loosen the set screw (key 58) that locks the travel sensor assembly against the housing.
8. Unscrew the travel sensor assembly (key 77) from the housing.

Refer to figure 9-3 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:
0 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.
The travel sensor may be adjusted using either a multimeter to measure the potentiometer resistance, or, if the instrument can be connected to a host system, use the Calibrate Travel Sensor method as described in this section. To use the multimeter, perform steps 7 through 13. To use the Calibrate Travel Sensor method, 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 side of the housing. 8. Connect a multimeter set to a resistance range of 3000 ohms to pins 2 and 3 of the travel sensor connector. Refer to figure 8-4 for pin location. 9. Adjust the travel sensor shaft to obtain a measured resistance of 1950 to 2050 ohms.
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.
0
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.
Assembly
Note
When installing the travel sensor assembly, take care to not wind up the wires inside the housing. This can damage the soldered connections.
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. 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.
September 2000
Type DVC5010f and DVC5040f Digital Valve Controllers

Refer to figure 9-1 or 9-4 for key number locations.
8-12
Maintenance
KEYED
DTHE POTENTIOMETERRESISTANCE BETWEEN PINS 2 AND 3 CAN BE

MEASURED AT THE CONNECTOR. INSERTTWO 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.
AE481L
NOTE:
Figure 8-4. Potentiometer Resistance Measurement
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.
Travel Sensor Adjustment Using the Calibrate Travel Sensor Method

Refer to figure 9-2 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.
The next two steps do not apply if you used a multimeter to adjust the travel sensor. Perform these steps only if you selected to adjust the travel sensor using the Calibrate Travel Sensor method. 14. Reassemble the master module to the housing by performing the Replacing the Master Module procedure. 15. Perform the appropriate Calibrating the Travel Sensor procedure.
September 2000
8-13
DVC5000f Series
The travel sensor may be adjusted using either a multimeter to measure the potentiometer resistance, or, if the instrument can be connected to a host system, use the Calibrate Travel Sensor method as described in this section. To use the multimeter, perform steps 7 through 17. To use the Calibrate Travel Sensor method, skip to step 18.
Travel Sensor Adjustment with a Multimeter
The next two steps do not apply if you used a multimeter to adjust the travel sensor. Perform these steps only if you selected to adjust the travel sensor using the Calibrate Travel Sensor method. 18. Reassemble the master module to the housing by performing the Replacing the Master Module procedure. 19. Perform the appropriate Calibrating the Travel Sensor procedure.
7. Connect a multimeter set to a resistance range of 7000 ohms to pins 2 and 3 of the travel sensor connector. Refer to figure 8-4 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. 9. Adjust the travel sensor shaft to obtain a measured resistance of 6250 to 6350 ohms.

Refer to figure 9-3 for key number locations. 1. Apply lubricant (key 63) to the bushing O-ring and threads. 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.
Note
In the next step, be sure the arm assembly outer surface remains flush with the end of the travel sensor shaft.
The travel sensor may be adjusted using either a multimeter to measure the potentiometer resistance, or, if the instrument can be connected to a host system, use the Calibrate Travel Sensor method as described in this section. To use the multimeter, perform steps 5 through 11. To use the Calibrate Travel Sensor method, skip to step 12.
Travel Sensor Adjustment with a Multimeter
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.
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 Using the Calibrate Travel Sensor Method
6. Connect a multimeter set to a resistance range of 3000 ohms to pins 2 and 3 of the travel sensor connector. Refer to figure 8-4 for pin location. 7. 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 outer surface remains flush with the end of the travel sensor shaft.
~
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 7. Paint the screw to discourage tampering with the connection.
September 2000
8-14
Maintenance
9. Disconnect the multimeter from the travel sensor connector.
DVC501Of, DVC5030f, and DVC5040f Digital Valve Controllers
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.
Travel Sensor Adjustment with the Calibrate Travel Sensor Method The A 0 block mode can be set to Out of Service by setting the Resource block mode to Out of Service. However, setting the Resource block to Out of Service also sets all function blocks within the device to Out of Service, including the PID block. If the PID block is used to control another loop, be sure some other means are provided to control the loop before taking the block Out of Service.
The next two steps do not apply if you used a multimeter to adjust the travel sensor. Perform these steps only if you selected to adjust the travel sensor using the Calibrate Travel Sensor method.
12. Reassemble the master module to the housing by performing the Replacing the Master Module procedure.
13. Perform the appropriate Calibrating the Travel Sensor procedure.
Before starting Cal Tvl Sensor, the A 0 block should be Out of Service. If the A 0 block is not out of service, you will not be able to calibrate the instrument because Cal Tvl Sensor will not be able to change the transducer block set point. If the A 0 block is no<Out of Service, the method provides you an opportunity to abort and set the A 0 block out of service. 1. Start Cal Tvl Sensor. For information on starting calibration methods from a DeltaV host system, see Appendix G. For information on running methods from other host systems, see the system documentation. 2. Cal Tvl Sensor warns you the valve will move and that there may be a loss of process control. Select Yes to continue or select No to abort Cal Tvl Sensor.
3. Cal Tvl Sensor displays the current instrument type and asks if it is correct. If the instrument type is correct select Yes. If not, select No to specify a different instrument model.
Calibrating the Travel Sensor
@ $ I
Note
The travel sensor is normally adjusted at the factory and should not require adjustment.
If the travel sensor has been replaced adjust the travel sensor by performing the following procedure. You can use the Cal Tvl Sensor method to adjust the travel sensor. The Cal Tvl Sensor method (method name Calibrate-Travel-Sensor) is included with the device description (DD) software. For information on using methods on the host system and the Cal Tvl Sensor method to calibrate the travel sensor, see the host system documentation.
4. Remove instrument and actuator pressure. 5. For a Type DVC501O f or DVC5040f, loosen or remove the adjustment arm. For a Type DVC5030f, indicate if increasing actuator pressure rotates the end of the travel sensor shaft clockwise or counterclockwise by responding to the Cal Tvl Sensor prompt.
@ h
Note
@ I
Note
The A 0 block mode must be Out of Service for Cal Tvl Sensor to operate properly.
The alignment pin (key 46) is stored inside the digital valve controller housing.
September 2000
8-15
DVC5000f Series
removed, connect the air supply, and recalibrate the travel.
L
FEEDBACK
ALIGNMENT
14. Also before exiting, Cal Tvl Sensor asks if you want to return the transducer block mode to Auto, if the transducer block was in the Out-of-Service mode before the method started. Select Yes to change the transducer block mode to Auto. Select No to leave the transducer block in its current mode. Remember to restore the Analog Output (AO) block mode if you changed it to Out of Service before starting Cal Tvl Sensor. This is the end of the Cal Tvl Sensor method.
DVC5020f Digital Valve Controllers (Calibrating the Travel Sensor)

1\1023, IL
Figure 8-5. Type DVC5010f Digital Valve Controller Showing Feedback Arm in Position for Travel Sensor Adjustment
6. Align the feedback arm (key 79) with the housing, as shown in figure 8-5, 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. 7. Loosen the screw that secures the feedback arm to the travel sensor shaft. To prevent binding, position the feedback arm so that the surface with the travel markings is flush with the end of the travel sensor shaft. 8. Rotate the end of the travel sensor shaft until the travel sensor count is 15000 f2000.Cal Tvl Sensor displays the travel sensor count as you adjust the travel sensor shaft. 9. If you havent finished adjusting the travel sensor, select Yes when Cal Tvl Sensor asks you if it should continue displaying the travel sensor counts. Select No to continue to the next step. 10. 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 range displayed on the Cal Tvl Sensor screen.
1 1. Cal Tvl Sensor redisplays the travel sensor count to verify the travel sensor shaft did not move while tightening the screw.
Before starting Cal Tvl Sensor, the A 0 block should be Out of Service. If the A 0 block is not out of service, you will not be able to calibrate the instrument because Auto Travel Calibrate will not be able to change the transducer block set point. If the A 0 block is not Out of Service, the method provides you an opportunity to abort and set the A 0 block out of service. 1. Start Cal Tvl Sensor. For information on starting calibration methods from a DeltaV host system, see Appendix G. For information on running methods from other host systems, see the system documentation.
2. Cal Tvl Sensor warns you the valve will move and that there may be a loss of process control. Select Yes to continue or select No to abort Cal Tvl Sensor.
3. Cat Tvl Sensor checks the values for feedback high and low, calculates the difference, and displays these values if they are out of specification. You can either abort the method to correct the error or continue.
4. Cal Tvl Sensor displays the current instrument type and asks if it is correct. If the instrument type is correct select Yes. If not, select No to specify a different instrument model.
5. Remove instrument and actuator pressure

6. See figure 8-6 for parts identification. Remove the instrument from the actuator. 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 instrument.
7. Loosen the screw that secures the arm assembly to the travel sensor shaft. To prevent binding, position the arm assembly so that the outer surface is flush with the end of the travel sensor shaft.
September 2000
12. If the travel sensor count is not within the displayed range, Cal Tvl Sensor permits you to correct the adjustment or exit. 13. Before exiting, Cal Tvl Sensor instructs you to remove the alignment pin, reinstall the instrument if
8-16
Maintenance
I
CAP SCREW, HEX SOCKET
MOUNTING BRACKET
BIAS SP ( K N 82) CAP SCREW, HEX HEAD
ARM ASSEMBLY PIN
FEEDBACK ARM ASSEMBLY (KEY 93)
Figure 8-6. Type DVC502Of Digital Valve Controller Mounted on Type 1052, Size 33 Actuator
8. 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 8-7.
9. Rotate the end of the travel sensor shaft until the travel sensor count is 30000 +2500. Cal Tvl Sensor displays the travel sensor count as you adjust the travel sensor shaft.
BACK EDGE OF ARM PARALLEL WIBACK OF HOUSING
ARM ASSEMBLY
1 J.
. d L
,
I
TRAVEL SENSOR SHAFT
10. If you haven't finished adjusting the travel sensor, select Yes when Cal Tvl Sensor asks you if it should continue displaying the travel sensor counts. Select No to continue to the next step.
17 . 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 range displayed on the Cal Tvl Sensor screen. 12. Cal Tvl Sensor redisplays the travel sensor count to verify the travel sensor shaft did not move while tightening the screw.
September 2000
-_I
--
! I
'
BACK OF HOUSING
A7025, , I
/-
Figure 8-7. Type DVC502Of Travel Sensor ArmlHousing Back Plane Alignment
8-1 7
DVC5000f Series
13. If the travel sensor count is not within the displayed range, Cal Tvl Sensor permits you to correct the adjustment or exit.
14. Before exiting, Cal Tvl Sensor instructs you to reinstall the instrument, connect the air supply, and recalibrate the travel. 15. Also before exiting, Cal Tvl Sensor asks if you want to return the transducer block mode to Auto, if
the transducer block was in the Out-of-Service mode before the method started. Select Yes to change the transducer block mode to Auto. Select No to leave the transducer block in its current mode. Remember to restore the Analog Output (AO) block mode if you changed it to Out of Service before starting Cal Tvl Sensor. This is the end of the Cal Tvl Sensor method.
8-18
Sepfember 2000
Parts
Section 9 Parts
Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 9-2 9-2 9-2 9-2 9-2 9-3 9-3 9-3
I/P Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Module Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PWB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Gauges. Pipe Plugs. or Tire Valve Assemblies . . . . . . . . . . . . . . Feedback Parts
............. ...............
...........................
9-3
Mounting Parts DVC501O f Digital Valve Controller on: 657 & 667. Size30-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 657 & 667. Size 70-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gulde Model GA and P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5020f Digital Valve Controller on: 585 & 585R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .................... .................... 1051. Size 30-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . ......................................... 1051. Size 33 . . . . . . . . . ......................................... 1052. Size 20 & 33 1052. Size 40-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DVC5030f 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 . ........................................... DVC5030f to Replace Positioners: Masoneilan Type 4600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neles-Jarnesbury Type NP600. NE600. & NP723 . . . . . . . . . . . . . . . . . . . . . . . . . . . Cam . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3 9-4 9-4 9-4 9-4 9-4 9-4 9-4 9-4 9-4 9-4 9-4 9-4 9-5 9-5 9-5 9-5 9-5
......................................
.....................
Filter Regulator Mounting Parts . . . . . . . . . . . . . . . . . .
September 2000
9- I
DVC5000f Series
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 1I-character part number of each required part as found in the following parts list. Parts which do not show part numbers are not orderable.
Key Description
Part Number
Common Parts
1 23 33 34' 36. 38 39' 40' 41 42' 43
Parts Kits
Conversion kit 6 listed below provides the parts required to convert a DVC5010f to a DVC5020f. Conversion kit 7 provides the parts required to convert a DVC5020f to a DVC5010f.
48 49 52 58 61
Key
1' 2' 3' 6 7 9
Description Elastomer Spare Parts Kit Relay Spare Parts Kit Smail Hardware Spare Parts Kit Conversion Kit (DVC5010f to DVC5020f) Also see note below Conversion Kit (DVC5020f to DVC501Of) Alignment Pin Kit (kit contains 15 alignment pins)
Part Number 1485072X012 1485072x022 1485072x032

1485072x102 1485072X112 1485072x092
62 63 64 65 74
Note Conversion kit key 6 contains a vent-away mounting bracket. Install a 116inch NPT socket head pipe plug in the tapped hole in the side of the mounting bracket if Type DVC5020f digital valve controller is not for vent-away construction.
75' 128
Housing, aluminum Cap Screw, hex socket, SST(3)(4 req'd) Mach Screw, pan hd, SST(3)(3 req'd) O-ring, nitrile(') (2 req'd) O-ring nitrile(') Cap Screw, hex socket, SST(3) (4 req'd) O-ring, nitrile(') (2 req'd) O-ring. nitrile(') IIP Assembly (See IIP Assembly listing below) Gasket, nitrile(') Cover Assembly, plastic For DVC5010f, DVC5020f, & DVC503M For DVC5040f Nameplate Drive Screw(3)(4 req'd) Vent, plastid3) Used wIDVC5010f and DVC5030f only Set Screw, hex socket. SST(3) Pipe Plug, hex socket, SST For DVC5010f, DVC5020f (std mntg). & DVC5030f For DVC5020f vent-away mounting (2 req'd) Pipe Plug, hex hd. SST Lubriplate Mag-I Lubricant (not furnished with the instrument) Zink-Plate No. 770 Anti-Seize Compound (not furnished with the instrument) Dow Coming 111 Lubricant (not furnished with the instrument) Mounting Bracket@) DVC5020f only Std Vent-away 0-Ring, nitrile(',@ DVC5020f Vent-away only Pipe Plug DVC5020f Vent-away only PI stl
1H3697X0032 14B1930X012 1OA3802X012 1H8762X0012 lP714638992 1D687506992 1481935X012 3480601X022 3480612X012 3782518X012
1168279x012 1481559x012
1C3335XOO32 1C3335X0032 lH5137X0012
4481 219x022 2481376x012 11A8741X052
SST
211 Lubricant, Nyogel760G (not furnished with the instrument)
1E823128982 1E823135042
I/P Assembly
Parts List
Parts which do not show part numbers are not orderable.
41 169 210' 231
IIP Converter wlshroud & boots IIP Converter Shroud Boot, nitrile (2 req'd) Seal, Screen
3886041x022 3487568x012 1284131X012 1886035XO12
Module Base
@ h
Note
Parts with footnote numbers shown are available in parts kits. Also see footnote information at the bottom of the page.
2 23 24 33 38
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)
1485071X022
3483169x012
* Recommended s are 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 DVCSOIM to DVC502M Conversion U t
9-2
September 2000
Parts
Key 39 41 154 Description O-ring, (2 req'd) I/P Assembly w1shroud 8 boots Retaining Ring (4 req'd) Part Number Key Description
Part Number
Feedback Parts
46 223 3480567X012 1483147x022 1481559x012
1H3697X0032
Terminal Box
4 44 58 72 Terminal Box Cap (~ req'd) ) Wire Retainer, pl s ~ I(2 Set Screw, hex socket, SST(3) Cap Screw, hex socket, SST(3) For DVC5010f, DVC5020f, DVC5030f For DVC5040f, Inch Metric Terminal Box Assembly For DVC5010f. DVC5020f, & DVC5030f For DVC5040f
78 79
1L545438992 1785168X012 3886470X012 3886471X012
164
24 24L 24M 25 26 31 32 152
Relay Module(2) O-Ring('* 2, (3 req'd) O-Ring(1. 2 ) Mach Screw, pan hd(2)(4 req'd) Cap Belleville Spring(2) Washe#) O-ring, (4 req'd)
80 81 82 83 84
3480583X022
PWB Assembly
50'
PWB Assembly Standard Control Standard Diagnostics Advanced Diagnostics Fieldbus Logic Standard Diagnostics Advanced Diagnostics 1886028X062 1886028x052 1886028X102 1886028X092
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) PSllMPNBAR 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/CM2 Gauge Scale Plastic case, brass connection To 25 PSI, 1.8 kg/cm2 To 50 PSI, 3.5 kg1cm2 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) 118404OXO12 1184040X022 1184040x032 1184039x012 1184039x022 1184039XO32
121 160 163
Alignment Pin(g) For DVC501M,DVC5030f & DVC5040f only Potentiometer and Bushing Assy For DVC501M & DVC5020f For DVC5030f For DVC5040f Bias Spring, SST(3) For DVC501Of, DVC5030f, 8 DVC5040f Feedback Arm, SST DVC5010f For 513, 513R, 529, 585C, 585CR, 656, 657/30-100, 667130-100, I250,1250R, Baumann, and Gulde DVC5040f For 9OOO/all sizes DVC5030f For all sizes 1032,1051, 1052, and 1066SR Cap Screw, hex socket, SST(3) Square Nut, SST(3) Bias Spring, SST(3) DVC5020f only Flange Bearing, RuIod6) DVC5020f only (2 req'd) Feedback Arm Assy, SST(6) DVC5020f only For 471, 585. 585R, 1051/30-60 1052/40-70 and 1061/30-100 For 1051/33 and 1052120, 33 E-ring, pl sd3) DVC5020f only (2 req'd) Plain Washer, pl stI@)DVC502Gf only (2 req'd) Follower Post, SST@)DVC502M only Roller, SST/PTFE@)DVC502M only Spring Lock Washer, pl stI@)DVC502M only Hex Nut, pl stI@)DVC5020f only Arm Assv. SST(6)DVC5020f ontv Cap ScrLw. hex socket@) DVC5b20f only (4 req'd) Torsion Spring, Feedback Arm@)DVC502M only Cap Screw, hex hd (4 req'd) For DVC5Ol M only Not for mounting on 1250 and 1250R actuators Mounting Bracket For DVC5OlOf only Not for mounting on 1250 and 1250R actuators Thread Lock, Loctite 242 (not furnished with instrument) Sealant, Toque Seal (not furnished with instrument) Plain Washer, SST
1480656X022 1485070X062 17B4030X022 1784031XO22 2460654x032
3785270x042
3 4 8 1929x022
3482179x022 1486978x012 16A6711XO32 2481532X012 13A1592x012
lE455338992 lA4988X0012 13A1656X012 13A1657X012 1K623638992 1A8396X0012 1480659X022 1L7325X0012 1481426X012 1A3917X0072
4480655x022
1486976X012
Mounting Parts
Type DVCSOlOf Digital Valve Controller
102 103 105 For Types 657 8 667, size 30-60 actuators Shield, polyester Mach Screw, pan hd. pl d3) (2 req'd) Screw, hex flg, pl stl Wlo side-mtd h'wheel (2 req'd) W1side-mtd h'wheel (none req'd) 3481428x012 llA6514X022 1481379X032
llB4040X042 1184040x052 11B4040X062 1D829328982 1D8293X0012 1N908899012
__-
66
67
Recommended spare 1 Available in the Elastomer Spare Parts Kit 2 Available in the Relay Spare Parts Kit 3 Available ifl the Small Hardware Spare Parts kt 6 Available in the DVCSOIM to DVC502M Conversion Kit 9 Available in the Alignment Pin Kit
*
September 2000
9-3
DVC5000f Series
Key 106 108 Description Adjustment Arm, aluminumlSST Connector Arm, stl Wlo side-mtd h'wheel Wlside-mtd h'wheel Lock Washer, ext, pl stl Cap Screw, hex hd. (2 req'd) Wlo side-mtd h'wheel For sizes 30, 34,40 (2 req'd) For sizes 4 5 4 0 (none req'd) Wlside-mtd h'wheel (none req'd) Spacer, pl stl Wlo side-mtd h'wheel (none req'd) Wlside-mtd h'wheel (2 req'd) For size 34, 40 For size 45-60 Washer, Wlo side-mtd h'wheel (none req'd) Wlside-mtd h'wheel (2 req'd) Cap screw, hex hd, SST Wlo side-mtd h'wheel (none req'd) Wlside-mtd h'wheel (2 req'd) For size 34. 40 For size 45-60 Washer, SST Wlo side-mtd h'wheel (2 req'd) For size 30, 34, 40 For size 45-60 Wlside-mtd h'wheel (none req'd) Hex Nut, flanged, SST For Types 657 8 667, size 70-100 actuators Bias Spring 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, aluminumlSST Connector Arm, stl Wlo side-mtd h'wheel Wlside-mtd h'wheel Lock Washer, ext, pl stl Washer, SST (2 req'd) For 657 8 667 size 70,667 size 76 For 657 8 667 size 80-1 00 Lock Washer, split, SST (2 req'd) For Gulde Model GA and P actuators Shield, polyester Mach Screw, pan hd, pl stl (2 req'd) Adjustment Arm, aluminumlSST Mounting Bracket, pl stl Connector Arm, 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 Lock Washer, pl stl (8 req'd) Part Number 2886046x012
2480652x012 3283526x012 1480698x022
Key
Description
Part Number

84 94 98 100 116 117 162 170 171
110 120
lA352524052
148
lJ830724092 1F906724092
172
149
___
18865928982 173 I 74
155
lA352524052 18787724052
175
156
176 ID716228982 lH723125072
___
203
1882293x212 2289009x022 4289010X022 1282922X012 1486701X012 lA3303X0012 1481554x01 2 4481429x012 1NlOl83X022 1481379x022 2886046x012 2289008X012 2389247x01 2 1480698x022 1485349x022 1K899525072 61000580X12 3481428x012 11A6514X012 2886046x012 4480224X012 2480652x012 1480698X012 4480225x012 19A4833X012 10B6605X012 1480226X012 19A4788X012 1086633XO12 1OB6609XO12 19A4775X012 11Y8560R082 116
78 97 98 99 100 101 102 103 105 106 108
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 8 33 actuators Cap Screw, hex socket, pl stl (8 req'd) Mounting Adaptor
1783156x012 27831 57x012 13A1618X022 lA6622X0012 lP7146XOO22 4481220X012 lA3291X0012 15A8804X342 186149X0012 166149X0032 lC597547362 1P506938982 1C631224052 10678926232 1P5068X0012 1A385026012 lA3580X0012 lE253726232 lE2537K0012 1783158x012
1P7146XOO22
lP7146XOO22 4481220X012

104 107 140
110 156
162 102 103 106 107 108 110 111 112 113 114 115 123 124 125 127
142 144 145 198 204 104 107 140 141 142 144 145 191 198 199 204 104 107 141 142
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, stllSST Washer, pl stl (4 req'd) For 1051 size 30-40 & 1052 size 40 For 1051 size 60 8 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 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
182905XOO12 3489501X012 lH723125072 lA518925072 2462183x012 24821 78x012 59061180x12 61000350X12 1A3303X0012 182905X0012 3489503x022 16865928982 1781702X012 2482183x012 2482178x012 1389244x012 lA381624052 61000350X12 lK261028992 lA3303X0012 182905X0012 3469502X012 1781701X012 2482183x012
3. Available in the Small Hardware Suare Parts Kit
9-4
September 2000
Parts
Key 144 145 191 198 204 104 107 140 Description 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 24821 78x012 59061300X12 lA353124052 61000350X12 lA3303X0012
1B2905X0012 3489503x012 1 2 3
18865928982 1H723125072 1A51 8925072 1781703X012 1781710x012 2482183x012 2482178x012 1482026X012 1482027X012 61000350X12 1K261028992
141
5 6 7 9
142 144 145
10 11 14
198 199
Feedback Arm To replace Neles-Jamesbury positioners Travel Indicator Travel Indicator Scale Mounting Bracket For QP3 For QP4 & QP3 Coupler For QP3 For QP4 & QP3 Threaded Hex Stud Hex Head Screw, 1/4-20 x 112 (4 req'd) Pan Head Machine Screw, 6-32 x 5/16 (4 req'd) Mounting Screws, hex head For QP3, 3/8-16 x1/2 (4 req'd) For QP4 & QP5, 1/2-13 x112 (4 req'd) Set Screw, 1/4-20 x 314 (2 req'd) Plain Washer, #6 (4 req'd) Split Lockwasher, (4 req'd) For QP3, QP4 & QP5, 114 For QP3 3/8 For QP4 & QP5 1/2
3482179x012 2482178X012 2482183x012 F2884801-02 F2884800-02 F2884801-01 F2884800-01 F2884801-03 182293x272 1882293x272 FH37516150HH FH37516150HH FH25028075SS 1882293x292 FH25000000SL FH37500000SL FH50000000SL
___
Cam
For DVC5020f only For Type 1051,size 30-60and 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)
204
lA3303X0012 94 95 94 95 94 95
Type DVC5030f Digital Valve Controller on Other Actuators

To replace Masoneilan positioners Mounting Plate Positioner Plate Drive Plate Ass'y Connector Shaff Pipe Bushing, hex For double-acting actuators only 114 x 1/8 NPT 3/8 x 114 NPT (2 req'd) Pipe Nipple, NPT For double-acting actuators only 1/8-27 x 1-112" 1/4-18 x 718" Pipe Tee, 1/4 NPT For double-acting actuators only Spacer For Sigma F actuators only Cap Screw, hex hd, For Camflex II actuators, 5/16-18 x 3/4" (2 req'd) For Sigma F actuators, 1/4-20 x 518" (2 req'd) Cap Screw, hex hd, 1/4-20 x 112" (4 req'd) Cap Screw, hex hd. 5/16-18 x 112" (4 req'd) Machine Screw, pan hd 8-32 x 518" (2 req'd) Cap Screw, hex socket, 1/4-28 x 1-1/2" Lock Washer, 1/4" Plain Washer, 5/16" (4 req'd) Plain Washer, No. 8 (2 req'd) Cap Screw, hex socket, 8-32 x 314" Plain Washer, Square Nut, 8-32 Alignment Pin Bias Spring
33A1613X022 13A1618X012 36A4653X022 13A1617X012 3081529x022 13A1617X012
4885236x012 2883835x012 2884644x012 2883834x012
1E2537K0012 186149X0032
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) 0-Ring, nitrile Pipe Plug, hex socket, SST For Casing Mounting Pipe Plug, hex socket, SST Hex Nut, pi 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) 0-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 lC398824052 1E591406992 lC333528992 1C333528992 1A352724122 10197024052 lF401225072 1C398824052 1C333528992 10678926232 lC3988XOO22 1E591406992 1C3335XOO12 lA352724122 lC197024052 lF401225072 1C678926232
1A3850X0012 1P506838982
1P506938982
2885971x012 lA3816K0012 lA4078X0052 182905XOO12 lC2752X0042 1882293x352 1882293x362 1884163X012 1882293x032 1E8730X0012 1486978x012 1882293x552 16A6711X032 1480656x022 2480654x032
* Recommendedspare
September 2000
DVC5000f Series
SECTION C-C
*Bse410A
DOC
SHTIDF2
SHi2 OF 2
Fjgure 9-1. T y p DVC5010f Digital Valve Controller Assembly
9-6
September 2000
Parts
'\
\
A-
SECTION A-A
SECTION B-B
Figure 9-2. Type DVC5020f Digital Valve Controller AssemtJy
September 2000
9-7
DVC5000f Series
' I /
SECTIONA-A
id:'
F-LL'/ '
48Wl3Oa!DX SHT 1 OF 2 SHT 2 OF 2
SECTION B-B
Figure 9-3. Type DVC5030f Digital Valve Controller Assembly
9-8
September 2000
Parts
0 APPLY LUB, SEALAN1

UIBoUObA! DOC
@)"" SECTION B-B
' \ s
SHTlOFZ SHT 2 OF 2
Figure 9-4. Type DVC5040f Digital Valve Controller AssernMy
6 --?-Z
1
4aBWI10 61 DOC
SHT 2 OF 2
DVC5000f SERIES WITH TIRE VALVES
DVC5000f SERIES WITH PIPE PLUGS
Figure 9-5. Typical DVC500M Series Digital Valve Controller with Tire Valves and Pipe Plugs
September 2000
9-9
DVC5000f Series
9-10
September 2000
LOODSchematics
Section 10 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
HAZARDOUS LOCATION
NON-HAZARDOUS LOCATION
FISHER TYPES DVC5010f DVC5020f. DVC5030f. DVCSOLOf Vmox 2L Vdc lmax = 226 mA CI = 5 n F LI 0
:
+
APPROVED BARRIER Voc52L V d t IscS226 rnA Co ? Ccoble + CI (ALL INSTRUMENTS) L o ? Lcoble + CI (ALL INSTRUMENTS1
- I
.
I
I I ,
, , I
i ! i
NOTES
1 . THE ENTITY CONCEPT ALLOWS INTERCDNNECTION OF INTRINSICALLY SAFE APPARATUS TO ASSOCIATED APPARATUS, NOT SPECIFICALLY EXAMINED IN SUCH COMBINATION. THE CRITERIA FOR INTERCONNECTION IS THAT THE VOLTAGE (Vrnox) AN0 THE CURRENT (Irnox) OF THE INTRINSICALLY SAFE APPARATUS MUST BE EOUAL TO OR GREATER THAN THE VOLTAGE (Vocl AND CURRENT (Iscl DEFINED BY THE ASSOCIATED APPARATUS. F THE MAXIMUM UNPROTECTED CAPACITANCE (Cil AND INDUCTANCE (Lil OF EACH IN ADDITION, THE SUM O INTRINSICALLY SAFE APPARATUS, AND THE INTERCONNECTING WIRING , MUST BE LESS THAN THE ALLOWABLE CAPACITANCE (Col AND INDUCTANCE (Lo1 DEFINED BY THE ASSOCIATED APPARATUS IF THESE CRITERIA ARE MET. THEN THE COMEINATION MAY BE CONNECTED. 2. LOOPS MUST BE CONNECTED ACCORDING TO THE BARRIER MANUFACTURER'S INSTRUCTIONS 3. SEE THE CANADIAN ELECTRICAL CODE lCECl PART I AND ANSI/ISA RP12.6 FOR GUIDANCE ON INSTALLATION.
m-llwn
a %
-*rill
CSA
Y L l l B
September 2000
70-7
DVC5000f Series
FM Schematics
HAZARDOUS LOCATION CLASS I. 11. Ill. DIV 1. GROUPS A.B.C.D.E.F.G FISHER TYPES: DVC5010f DVC5020f. DVC5030f. DVC5040f 2L Vdc Vrnox lmnx 226 mA Ci 5 nF Li 0 APPROVE0 BARRIER
+
NON-HAZARDOUS LOCATION
--
VocCZL Vdc Isc c 226 mA . Co L Ccoble + Ci (ALL INSTRUMENTS1
'
Lo
f Lcoble + Li (ALL INSTRUMENTSI
NOTES
r-l !
SEE NOTE 1
1 THE ENTITY CONCEPT ALLOWS INTERCONNECTION OF INTRINSICALLY SAFE APPARATUS TO ASSOCIATED APPARATUS, NOT SPECIFICALLY EXAMINED IN SUCH COMBINATION THE CRITERIA FOR INTERCONNECTION IS THAT THE VOLTAGE (Vmoxl AND CURRENT (Imoxl OF THE INTRINSICALLY SAFE APPARATUS MUST BE EOUAL TO OR GREATER THAN THE VOLTAGE (Voc or Vt) AND CURRENT Llsc or It1 DEFINED BY THE F THE MAXIMUM UNPROTECTED CAPACITANCE ICI) ASSOCIATED APPARATUS IN ADDITION THE SUM O AN0 INDUCTANCE (Li1 OF EACH INTRINSICALLY SAFE APPARATUS. AND THE INTERCONNECTING WIRING. MUST BE LESS THAN THE ALLOWABLE CAPACITANCE (Col AND INDUCTANCE (Lo1 DEFINED BY THE ASSOCIATED APPARATUS IF THESE CRITERIA ARE MET, THEN THE COMBINATION MAY BE CONNECTED 2 THE INSTALLATION MUST BE IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE (NECI. NFPA 70. ARTICLE 506 AN0 ANSIIISA RP12 6 3 CLASS 1. OIV 2 APPLICATIONS MUST BE INSTALLED AS SPECIFIED IN NEC ARTICLE 5 0 i - ~ a iWHEN BARRIERS ARE NOT USED L __. LOOPS O THE BARRIER - MUST BE CONNECTED ACCOROING T MANUFACTURER'S INSTRUCTIONS 5 MAXIMUM SAFE AREA VOLTAGE SHOULD NOT EXCEED 250 Vrms 6 RESISTANCE BETWEEN BARRIER GROUND AN0 EARTH GROUND MUST BE LESS THAN ONE OHM
10-2
September 2000
Function Block Overview
Appendix A FOUNDATION Fieldbus Technology and Fieldbus Function Blocks

Overview
This appendix introduces fieldbus systems that are common to all fieldbus devices. also defined a standard set of function block classes, such as input, output, control, and calculation blocks. Each of these classes also has a small set of parameters established for it. They have also published definitions for transducer blocks commonly used with standard function blocks. Examples include temperature, pressure, level, and flow transducer blocks. The FOUNDATION specifications and definitions allow vendors to add their own parameters by importing and subclassing specified classes. This approach permits extending function block definitions as new requirements are discovered and as technology advances. Figure A-I illustrates the internal structure of a function block. When execution begins, input parameter values from other blocks are snapped-in by the block. The input snap process ensures that these values do not change during the block execution. New values received for these parameters do not affect the snapped values and will not be used by the function block during the current execution. Once the inputs are snapped, the algorithm operates on them, generating outputs as it progresses. Algorithm executions are controlled through the setting of contained parameters. Contained parameters are internal to function blocks and do not appear as normal input and output parameters. However, they may be accessed and modified remotely, as specified by the function block. Input events may affect the operation of the algorithm. An execution control function regulates the receipt of input events and the generation of output events during execution of the algorithm. Upon completion of the algorithm, the data internal to the block is saved for use in the next execution, and the output data is snapped, releasing it for use by other function blocks. A block is a tagged logical processing unit. The tag is the name of the block. System management services locate a block by its tag. Thus the service personnel need only know the tag of the block to access or change the appropriate block parameters.
FOUNDATION has
Introduction
A fieldbus system is a distributed system composed of field devices and control and monitoring equipment integrated into the physical environment of a plant or factory. Fieldbus devices work together to provide I/O and control for automated processes and operations. The Fieldbus Foundation provides a framework for describing these systems as a collection of physical devices interconnected by a fieldbus network. One of the ways that the physical devices are used is to perform their portion of the total system operation by implementing one or more function blocks.
Function Blocks
Function blocks within the fieldbus device perform the various functions required for process control. Because each system is different, the mix and configuration of functions are different. Therefore, the Fieldbus Foundation has designed a range of function blocks, each addressing a different need. Function blocks perform process control functions, such as analog input (Al) and analog output (AO) functions as well as proportional-integral- derivative (PID) functions. The standard function blocks provide a common structure for defining function block inputs, outputs, control parameters, events, alarms, and modes, and combining them into a process that can be implemented within a single device or over the fieldbus network. This simplifies the identification of characteristics that are common to function blocks. The Fieldbus Foundation has established the function blocks by defining a small set of parameters used in all function blocks called universal parameters. The
September 2000
A-I
DVC5000f Series
Input Events Execution Control output Events
Input Parameter Linkages
Input Snap Processing Algorithm
_.
output Snap
*
Output Parameter Linkages
--*
I I I 11.14.1
status
I I I I 3-1 4.1
StatUS
Figure A-1. function Block Internal Structure
Function blocks are also capable of performing short-term data collection and storage for reviewing their behavior.
BLOCK OPERATION
In addition to function blocks, fieldbus devices contain two other block types to support the function blocks. These are the resource block and the transducer block. The resource block contains the hardware specific characteristics associated with a device. Transducer blocks couple the function blocks to local inpuffoutput functions.
Device Descriptions
Device Descriptions are specified definitions that are associated with the function blocks. Device descriptions provide for the definition and description of the function blocks and their parameters. To promote consistency of definition and understanding, descriptive information, such as data type and length, is maintained in the device description. Device Descriptions are written using an open language called the Device Description Language (DDL). Parameter transfers between function blocks can be easily verified because all parameters are described using the same language. Once written, the device description can be stored on an external medium, such as a CD-ROM or diskette. Users can then read the device description from the external medium. The use of an open language in the device description permits interoperability of function blocks within devices from various vendors. Additionally, human interface devices, such as operator consoles and computers, do not have to be programmed specifically for each type of device on the bus. Instead their displays and interactions with devices are driven from the device descriptions. Device descriptions may also include a set of processing routines called methods. Methods provide a procedure for accessing and manipulating parameters within a device, such as for setup and calibration.
Instrument-Specific Function Blocks

Resource Blocks
The resource block contains the hardware specific characteristics associated with a device; it has no input or output parameters. The algorithm within a resource block monitors and controls the general operation of the physical device hardware. The execution of this algorithm is dependent on the characteristics of the physical device, as defined by the manufacturer. As a result of this activity, the algorithm may cause the generation of events. There is only one resource block defined for a device. For example, when the mode of the resource block is Out of Service, it impacts all function blocks.
Transducer Blocks
Transducer blocks connect function blocks to local inpuffoutput functions. They read sensor hardware and write to effector (actuator) hardware. This permits the transducer block to execute as frequently as necessary to obtain good data from sensors and ensure proper writes to the actuator without burdening the function blocks that use the data. The transducer block also isolates the function block from the specific characteristics of the physical I/O.
w
Fieldbur Segment
Function Block Overview
LINK MASTER
BASIC DEVICES
U S = Link Active Scheduler
Figure A-2. Simple Single-Link Fieldbus Network
Alerts
When an alert occurs, execution control sends an event notification and waits a specified period of time for an acknowledgment to be received. This occurs even if the condition that caused the alert no longer exists. If the acknowledgment is not received within the pre-specified time-out period, the event notification is retransmitted. This assures that alert messages are not lost. Two types of alerts are defined for the block, events and alarms. Events are used to report a status change when a block leaves a particular state, such as when a parameter crosses a threshold. Alarms not only report a status change when a block leaves a particular state, but also report when it returns back to that state.
execution with the data transfers scheduled by the LAS.

0 polls devices for process loop data at scheduled transmission times. 0 distributes a priority-driven token to devices between scheduled transmissions.
The digital valve controller does not include an LAS However, not having an LAS does not affect device operation. Only one device can communicate at a time. Permission to communicate on the bus is controlled by a centralized token passed between devices by the LAS. Only the device with the token can communicate. The LAS maintains a list of all devices that need access to the bus. This list is called the Live List. Two types of tokens are used by the LAS. A time-critical token, compel data (CD), is sent by the LAS according to a schedule. A non-time critical token, pass token (PT), is sent by the LAS to each device in numerical order according to address.
NETWORK COMMUNICATION
Figure A-2 illustrates a simple fieldbus network consisting of a single segment (link).
Device Addressing Link Active Scheduler (LAS)

All links have one and only one Link Active Scheduler (LAS). The LAS operates as the bus arbiter for the link. The LAS does the following:
0
recognizes and adds new devices to the link. removes non-responsive devices from the link.
0 distributes Data Link (DL) and Link Scheduling (LS) time on the link. Data Link Time is a network-wide time periodically distributed by the LAS to synchronize all device clocks on the bus. Link Scheduling time is a link-specific time represented as an offset from Data Link Time. It is used to indicate when the LAS on each link begins and repeats its schedule. It is used by system management to synchronize function block
Fieldbus uses addresses between 0 and 255. Addresses 0 through 15 are reserved for group addressing and for use by the data link layer. If there are two or more devices with the same address, the first device to start will use its programmed address. Each of the other devices will be given one of four temporary addresses between 248 and 251. If a temporary address is not available, the device will be unavailable until a temporary address becomes available.
Sc heduled Transfers
Information is transferred between devices over the fieldbus using three different types of reporting.
0 Publisher/Subscriber: This type of reporting is used to transfer critical process loop data, such as the
September 2000
A-3
DVC5000f Series
LAS=Unk Active Scheduler

P=Publisher .
&Subscriber CD=Compel Data DT=Data Transfer Packet

82773.1, IL
__
Device
Device Y
Device Z
Figure A-3. Scheduled Data Transfer
process variable. The data producers (publishers) post the data in a buffer that is transmitted to the subscriber (S), when the publisher receives the Compel Data (CD) message from the LAS. The buffer contains only one copy of the data. New data completely overwrites previous data. Updates to published data are transferred simultaneously to all subscribers in a single broadcast. Transfers of this type can be scheduled on a precisely periodic basis.
0 Report Distribution: This type of reporting is used to broadcast and multicast event and trend reports. The destination address may be predefined so that all reports are sent to the same address, or it may be provided separately with each report. Transfers of this type are queued. They are delivered to the receivers in the order transmitted, although there may be gaps due to corrupted transfers. These transfers are unscheduled and occur in between scheduled transfers at a given priority. 0 ClienffServer: This type of reporting is used for request/ response exchanges between pairs of devices. Like Report Distribution reporting, the transfers are queued, unscheduled, and prioritized. Queued means the messages are sent and received in the order submitted for transmission, according to their priority, without overwriting previous messages. However, unlike Report Distribution, these transfers are flow controlled and employ a retransmission procedure to recover from corrupted transfers.
Figure A-3 diagrams the method of scheduled data transfer. Scheduled data transfers are typically used for the regular cyclic transfer of process loop data between devices on the fieldbus. Scheduled transfers use publisher/subscriber type of reporting for data transfer. The Link Active Scheduler maintains a list of transmit times for all publishers in all devices that need to be cyclically transmitted. When it is time for a device to publish data, the LAS issues a Compel Data (CD) message to the device. Upon receipt of the CD, the device broadcasts or "publishes" the data to all devices on the fieldbus. Any device that is configured to receive the data is called a "subscriber."
Unscheduled Transfers
Figure A-4 diagrams an unscheduled transfer. Unscheduled transfers are used for things like user-initiated changes, including set point changes, mode changes, tuning changes, and upload/download. Unscheduled transfers use either report distribution or clientkerver type of reporting for transferring data. All of the devices on the fieldbus are given a chance to send unscheduled messages between transmissions of scheduled data. The LAS grants permission to a device to use the fieldbus by issuing a pass token (PT) message to the device. When the device receives the PT, it is allowed to send messages until it has finished or until the "maximum token hold time" has expired, whichever is the shorter time. The message may be sent to a single destination or to multiple destinations.
A-4
September 2000
OZI
001
08
09
02
011
<
OOL
08
a(a4aoiaeW
09
OP
oz
I
SVl
DVC5000f Series
Function Block Scheduling
Figure A-5 shows an example of a link schedule. A single iteration of the link-wide schedule is called the macrocycle. When the system is configured and the function blocks are linked, a master link-wide schedule is created for the LAS. Each device maintains its portion of the link-wide schedule, known as the Function Block Schedule. The Function Block Schedule indicates when the function blocks for the device are to be executed. The scheduled execution time for each function block is represented as an offset from the beginning of the macrocycle start time.
To support synchronization of schedules, periodically s distributed. The beginning Link Scheduling (LS) time i of the macrocycle represents a common starting time for all Function Block schedules on a link and for the LAS link-wide schedule. This permits function block executions and their corresponding data transfers to be synchronized in time.
A-6
September 2000
Analog Output (AO) Function Block
Appendix B Analog Output (AO) Function Block

calculation input (BKCAL-IN) of the upstream block that provides CAS-IN. This provides bumpless transfer on mode changes and windup protection in the upstream block. The OUT attribute or an analog readback value, such as valve position, is shown by the process value (PV) attribute in engineering units. To support testing, you can enable simulation, which allows you to manually set the channel feedback. There is no alarm detection in the A 0 function block. To select the manner of processing the SP and the channel output value configure the setpoint limiting options, the tracking options, and the conversion and status calculations.
BZ,,bl
,i
CAS-IN = T h e remote setpoint value from another function block BKCAL-OUT = T h e value and status required by the BKCAL-IN input of another block to prevent reset windup and to provide bumpless transfer to closed loop control. = T h e block output and status. OUT READBACK = Actual valve posltion.
Figure 13-1. Analog Output (AO) Function Block
The Analog Output (AO) function block assigns an output value to a field device through a specified 110 channel. The block supports mode control, signal status calculation, and simulation. Figure B-2 illustrates the internal components of the A 0 function block, and table B-I lists the definitions of the block parameters. The digital valve controller measures and uses actual valve position for READBACK.
Set Point Selection and Limiting

To select the source of the SP value use the MODE attribute. In Automatic (Auto) mode, the local, manually-entered SP is used. In Cascade (Cas) mode, the SP comes from another block through the CAS-IN input connector. In Remotecascade (RCas) mode, the SP comes from a host computer that writes to RCAS-IN, The range and units of the sp are defined by the PV-SCALE attribute. In Manual (Man) mode the SP automatically tracks the PV value when you select the SP-PV Track in Man I/O option. The SP value is set equal to the PV value when the block is in manual mode, and is enabled (True) as a default. You can disable this option in Man or O/S mode only. The SP value is limited to the range defined by the setpoint high limit attribute (SP-HI-LIM) and the setpoint low limit attribute (SP-LO-LIM). In Auto mode, the rate at which a change in the SP is passed to OUT is limited by the values of the setpoint upward rate limit attribute (SP-RATE-UP) and the setpoint downward rate limit attribute (SP-RATE-DN). A limit of zero disabless rate limiting, even in Auto mode.
Setting the Output

To set the output for the A 0 block, you must first set the mode to define the manner in which the block determines its setpoint. In Manual mode the value of the output attribute (OUT) must be set manually by the user, and is independent of the setpoint. In Automatic mode, OUT is set automatically based on the value specified by the set point (SP) in engineering units and the 110 options attribute (10-OPTS). In addition, you can limit the SP value and the rate at which a change in the SP is passed to OUT. In Cascade mode, the cascade input connection (CAS-IN) is used to update the SP. The back calculation output (BKCAL-OUT) is wired to the back
September 2000
B-1
DVC5000f Series
c
RCAS IN SP- RATE- DN SP-RATE-UP READ

~
BACK
BKCAL OUT
Pv
CAS IN
~
OUT
I
Access Analog
I
Access Analog output CHANNEL
r l
827,7111
Position Feedback
Analog output
Figure 8-2. Analog Output Function Block Schematic
I
I
I
I
OUT (Mode i n CAS)
I
I
I I I I I
OUT (Mode in AUTO)

I I I I I I I I I I
I
OUT (Mode in MAN)
I I I
I
I
I
I
1
I
I
I
I
I I
I I I I
I I
SP
1 second
1 second
Figure 8-3. Analog Output Function Block Timing Diagram
B-2
September 2000

Table B-1. Analog Ou wt Function Block Parameter Definifions
Description
The identification number of the plant unit. This information may be used in the host for sorting alarms, etc. BKCAL-OUT The value and status required by the BKCAL-IN input of another block to prevent reset windup and to provide bumpless transfer to closed loop control. The block alarm is used for all configuration, hardware, connection failure, or system problems in the block. The cause of the alert is entered in the subcode field. The first alert to become active will set the active status in the status parameter. As soon as the Unreported status is cleared by the alert report ing task, and other block alert may be reported without clearing the Active status, if the subcode has changed. This parameter reflects the error status associated with the hardware or software components associated with a block. It is a bit string, so that multiple errors may be shown. see table 4. The remote setpoint value from another function block. Defines the output that drives the field device. Parameter not used by DVC5000f Series digital valve controller. Time from failure detection to reaction if failure still exists. Preset value to use if IIO-OPTS Fault State to Value or Use Fault State Value on Restart is set. Options for controlling access of host computers and local control panels to ooeratina. tunina. and alarm oarameters of the block. Allows you to select the type of tracking and the output value when a fault condition occurs. Increase-to-ODenand Increase-to-Close are not available. The actual, target, permitted, and normal modes of the block. Target: The mode to "go to" Actual: The mode the "block is currently in" Permitted: Allowed modes that target may take on Normal: Most common mode for target The primary value and status calculated by the block in Auto mode. OUT may be set manually in Man mode. The Drocess variable used in block execution. This value is converted from READBACK to show tne actuator position in the same units as the setpoint value The nigh and low scale values. the enaineerina units code, and the number of diairs to the right of the decimal point associated with the PV nos1 Taraet SP and status ov su~ewisow Block set point and status after The measured or implied actuator position associated with the OUT value, only if Feature Select is Output Readback supported. If not, READBACK is the simulated input if SIMULATE is enabled or the transducer block feedback if SIMULATE is disabled. Defines the action to be taken when the set point or ourput are not updated in a remote mode. Allows the transducer analog input or output to the block to be manually supplied when simulate is enabled. When simulate is disabled, the simulate value and status track the actual value and status. The analog set point of this block The highest set point value allowed. SP-HI-LIM must be greater than SP-LO-LIM. The lowest set point value allowed. SP-LO-LIM must be less than SP-HI-LIM. Ramp rate for downward set point changes. When the ramp rate is set to zero, the set point is used immediately. Ramp rate for upward set point changes. When the ramp rate is set to zero, the setpoint is used immediately. Options the user mav select for the block Drocessina of status. The strategy field can be used to identify grouping of blocks. This data is not checked or orocessed bv the block. The revision level of the static data associated with the function block. The revision value will be incremented each time a static pa rameter value in the block is chanaed. The user description of the intended application of the block.
Xontinued-
BLOCK-ALM
30
None
BLOCK-ERR CAS-IN CHANNEL FSTATE-TIME FSTATE-VAL GRANT-DENY 10-OPTS
06
17
None EU of PV-SCALE None Seconds EU of PV-SCALE None None
22 23 24 13 14
OUT PV PV-SCALE RCAS-IN RCAS-OUT READBACK
II
I
05
I
~
None
09
EUofXD-SCALE EUofPV-SCALE None EU of PV-SCALE
07 11 26
1
I
2a
16
I
I
EU of PV-SCALE EUofXD-SCALE
SHED-OPT SIMULATE
27
None EU of XD-SCALE EU of PV-SCALE
SP-HI-LIM SP-LO-LIM SP-RATE- DN SP-RATE-UP

1
20 21
EU of PV-SCALE EU of PV-SCALE EU of PV-SCALE per second

I
ia
19
EU of PV-SCALE per second

~~~
STATUS-OPTS STRATEGY ST-REV TAG-DESC
15 03
01
None None None None
02
September 2000
B-3
DVC5000f Series
Parameter Name Index Number Units None None Description This alert is generated by any changes to static data. The high and low scale values and engineering units code are read only. This parameter determines the number of digits to the right of the decimal point used with the value obtained from the transducer for a specified channel.
UPDATE- EVT
XD-SCALE
29 12
In Auto mode, the converted SP value is stored in the OUT attribute. In Man mode, the OUT attribute is set manually, and is used to set the analog output defined by the CHANNEL parameter. You can access the actuator position associated with the output channel through the READBACK parameter (in OUT units) and in the PV attribute (in engineering units). The digital valve controller supports position feedback and therefore provides the actual valve position in PV and READBACK directly. If the actuator does not support position feedback, the PV and READBACK values are based on the OUT attribute.
I/O Options
The I/O options parameter (10-OPTS) allows you to select how the I/O signals are processed. You can set I/O options in Manual or Out of Service mode only. The following I/O options are available in the A 0 block: Use PV for BKCAL-OUT-Changes the BKCAL-OUT value to the PV value. When the Use PV for BKCAL-OUT option is not enabled (False), the BKCAL-OUT value is the working setpoint value. Target t o Man if Fault State Activated-Set the target mode to Man, thus losing the original target, if Fault State is activated. This latches an output block into the manual mode. Use Fault State value o n Restart-Use the value of FSTATE-VAL for SP when power is restored of if the device is restarted, otherwise use the last value saved in non-volatile memory. This does not act like Fault State, it only uses the value of FSTATE-VAL. Fault State to Value-The output action to take when a fault occurs (if not selected, use hold last value; if selected, use FSTATE-VAL). Increase t o Close-Indicates whether or not the output value is inverted before it is communicated to the I/O channel. Note: in the digital valve controller the transducer block automatically accounts for Increase to Close/lncrease to Open valve action during calibration, therefore this parameter may only be set to disabled. SP-PV Track in LO or IMan-Permits the SP to track the PV when the actual mode of the block is LO or IMan. SP-PV Track in Man takes precedence over SP-PV Track in LO or IMan. SP-PV Track in Man must be enabled in order for SP-PV Track in LO or lMan to track when target mode is MAN. SP-PV Track i n Man-Permits the SP to track the PV when the block target mode is Man. SP Track retained Target-Causes the set point to track the RCAS or CAS parameter based on the retained target mode when the actual mode is MAN or LO.
Simulation
When simulation is enabled, the last value of OUT is maintained and reflected in the field value of the SIMULATE attribute. In this case, the PV and READBACK values and statuses are based on the SIMULATE value and the status that you enter.
Action On Fault Detection

To define the state to which you wish the valve to enter when the block is in CAS mode, and the CAS-IN input detects a bad status, configure the following parameters: 10-OPTS: Determines the action OUT will take upon a fault state. If the 10-OPTS Fault State to Value is not selected, then OUT holds its last position when Fault State is set. If Fault State to Value is selected, OUT goes to the FSTATE-VAL value when Fault State is set. FSTATE-TIME: The length of time, in seconds, that the A 0 block will wait to set Fault State. When Fault State is set, the OUT value goes to either the FSTATE-VAL value or holds its last position, depending on I/O-OPTS. When the block has a target mode of CAS, a fault condition will be detected if the CAS-IN has a BAD status or an Initiate Fault State substatus is received from the upstream block. FSTATE-VAL: Determines the OUT value if 10-OPTS Fault State to Value is selected. The OUT value transitions to FSTATE-VAL after FSTATE-TIME elapses and the fault condition has not cleared.
Block Errors
Table B-2 lists conditions reported in the BLOCK-ERR parameter. Conditions in italics are not applicable for the A 0 block and are provided only for your reference.

Table 5-2. BLOCK-ERR Conditions
Condition Name and Description
0 Initialization Manual (1man)-The path to the output hardware is broken and the A 0 block output will remain at the last position. This means the transducer block mode is Out of Service. 0 Local Override (LO)-The output of the block is not responding to OUT because the fault state action is active.
0 1 2
Otber(N/A) Block Configuration Error - SHED-OPT set to 0 Link Configuration Error (NIA) Simulate active - Simulation is enabled and the block is using a simulated value in its execution. Local Override - Device in fault state. Actual mode LO. Device Fault State Set - A 0 block in fault state after FSTATE-TIME because of Bad status or IFS substatus on CAS-IN or Resource block commanded fault state. Device Needs Maintenance Soon (NIA) Input failurelprocess variable has Bad status - PV has bad status and Feature Select in the Resource block has the Out Readback bit set. Output failure - PV has bad status. Memory Failure (NIA) Lost Static Data (NIA) Lost N V Data (NIA) Readback Check failed (MA) Device Needs Maintenance Now (NIA) Power Up -This condition exists after power up until actual mode is not Out of Service. Out of Service -The block is in Out of Service ( 0 6 ) mode.
The target mode of the block may be restricted to one or more of the following modes: Man, Auto, Cas, RCas, or O/S.
7 8
9
Shed Options
Shed from or climb to a remote mode is determined by the parameter SHED-OPT. A block climbs and sheds through the same path. For example, if SHED-OPT specifies that a block should shed to Auto, then, if the block target mode is set to RCas, the block goes through Auto on the way to RCas. You can configure the shed option as follows:
10 11 12 13
,4
l5
Shed With Return Options
Modes
The Analog Output function block supports the following modes:
0 Manual (Man)-You can manually set the output to the 110 channel through the OUT attribute. This mode is used primarily for maintenance and troubleshooting. 0 Automatic (Auto)-The block output (OUT) reflects the target operating point specified by the setpoint (SP) attribute. 0 Cascade (Cas)-The SP attribute is set by another function block through a connection to CAS-IN. The SP value is used to set the OUT attribute automatically. This is the most frequently used mode in the digital valve controller.
0 Remotecascade (RCas)-The SP is set by a host computer by writing to the RCAS-IN parameter The SP value is used to set the OUT attribute automatically.
Remote cascade connection failure shifts actual mode but keeps trying to restore remote cascade (in other words, the remote cascade target mode stays in effect). Normal-On failure of a remote cascade connection, the block attempts to attain the highest permitted non-remote mode until remote cascade is restored. On change to remote cascade target mode from any other mode, the block attempts to attain the highest permitted non-remote mode until a remote cascade connection is established. Retained Target-On failure of a remote cascade connection, the block attempts to attain the mode retained in the target mode. On change to the remote cascade target mode from any other mode, the block attempts to attain the mode retained by target mode until a remote cascade connection is established. Auto-On failure of a remote cascade connection, the block attempts to attain Auto, if permitted, until remote cascade is restored. On change to remote target mode from any other mode, the block attempts to attain Auto, if permitted, until a remote cascade connection is established. Man-On failure of a remote cascade connection, the block sheds to Man until a remote cascade connection is restored. On change to remote target mode, from any other mode, the block goes to Man until a cascade connection is established.
Out of Service (0IS)-The block is not processed. The output channel is maintained at the last value and the status of OUT is set to Bad: Out of Service. The BLOCK-ERR attribute shows Out of Service.
September 2000
B-5
DVC5000f Series
Shed With No Return Options
For any shed with no return option, the target mode changes as determined by the option. Therefore, there is no attempt to restore the connection following failure. The behavior on change to the remote cascade target mode is identical to that for Shed With Return Options. Normal-On failure of a remote cascade connection, the block sets the target mode to the highest permitted non-remote mode. On change to a remote cascade target mode from any other mode, the block attempts to attain the highest permitted non-remote mode until a remote cascade connection is established. Retained Target-On failure of a remote cascade connection, the block sets the target mode to mode retained in target mode. On change to the remote cascade target mode from any other mode, the block attempts to attain the mode retained by target mode until a remote cascade connection is established. The DeltaV system does not support the retained target shed. Selecting the retained target results in shed to Auto. This applies to any block, regardless of whether it is in a field device or a DeltaV controller. The writing device sets or clears the retained target bits in the target mode. Therefore, any workstation or other device (DeltaV controller applications, for example) that does not support retained target operation ignores the retained target bits. In a DeltaV system, regardless of where the block is located, the retained target bits are turned off, and the block sheds to Auto. Auto-On failure of a remote cascade connection, the block sets the target mode to Auto, if permitted. On change to the remote target mode from any other mode, the block attempts to attain Auto, if permitted, until a remote cascade connection is established. Man-On failure of remote cascade connection, the block sets the target mode to Man, if permitted. On change to the remote target mode from any other mode, the block goes to Man until a cascade connection is established. The user may configure SHED-OPT so that it calls for a target mode that is not permitted. When doing this, the mode logic uses the following rules as applied by the remote logic:
0 Shed logic never results in a non-permitted target mode. 0 Shed logic never attempts to attain an actual mode of Auto or Cas if that mode is not permitted.
Status Handling
Output or readback fault detection is reflected in the status of PV, OUT, and BKCAL-OUT. A limited SP condition is reflected in the BKCAL-OUT status. When simulation is enabled through the SIMULATE attribute, you can set the value and status for PV and READBACK. When the block is in Cas mode and the CAS-IN input goes bad, the block sheds mode to the next permitted mode.
Application Information
The configuration of an A 0 function block and its associated output channels depends on the specific application. A typical configuration for the Analog Output involves the following attributes: PV- SCALE Set the range and engineering units to values that correspond to the operation range. For the digital valve controller, PV-SCALE is typically set between 0 and 100%. If you are using the CAS-IN connector wired from another block, wire the BKCAL-OUT attribute to the other blocks BKCAL-IN attribute. Set the type of tracking and action upon fault state. Note: the digital valve controller does not use the Increase to Close 1 0 option. The valve action is determined by the transducer block during calibration. Set the action to be taken when the set point or output are not updated in a remote mode.
BKCAL-OUT
10-OPTS
SHED-OPT
B-6
September 2000
PID Function Block
Appendix C
BKCALL IN CAS- IN FF- VAL
PID Function Block

where GAIN: proportional gain value
T~:
S:
'
TRK-lN-I: TRK- VAL
u
PID
OUT The analog input value and status from another block's BKCAL _OUT output that is used for backward output tracking for bumpless transfer and to pass limit status. The remote setpoint value from another function block. The feedforward control Input value and status. The connection for the process variablefrom another function block. The value after scaling applied to OUT in Local Override mode.
BKCAL-OUT
integral action time constant (RESET parameter) in seconds laplace operator
q:
derivative action time constant (RATE parameter) fixed smoothing factor of 0.1 applied to RATE
BKCAL-IN
= = = =
a:
CAS-IN FF-VAL IN TRK-IN-D TRK-VAL
feedfonvard control contribution from the F: feedforward input (FF-VAL) To further customize the block for use in your application, you can configure filtering, feedforward inputs, tracking inputs, setpoint and output limiting, PID equation structures, and block output action. Table C-I lists the PID block parameters and their descriDtions. units of measure, and index numbers, and figure C-2 illustrates the internal components of the PID function block.
= Initiates the external tracking function.
BKCAL-OUT= The value and status required by the BKCAL-IN input of another function block to prevent reset windup and to provide bumpless transfer to closed loop control. OUT
02720, IL
= The block output and status.
Figure C-7. Proportional+lntegraI+Derivative (PD) Function Block
The PID function block combines all of the necessary logic to perform proportionaMntegrallderivative (PID) control. The block supports mode control, signalscaling and limiting, feedforward control, override tracking, alarm limit detection, and signal status propagation. The block supports two forms of the PID equation: Standard and Series. You can choose the appropriate equation using the FORM parameter. The Standard ISA PID equation is the default selection.
Set Point Selection and Limiting

The set point of the PID block is determined by the mode. Figure C-3 illustrates the method for set point selection. You can configure the SP-HI-LIM and SP-LO-LIM parameters to limit the set point. In Cascade or Remote Cascade mode, the set point is adjusted by another function block or by a host computer, and the output is computed based on the set point. In Automatic mode, the set point is entered manually operator, and the output is computed based on set point. In Auto mode, you can also adjust the set point limit and the set point rate of change using the SP-RATE-UP and SP-RATE-DN parameters. In Manual mode the output is entered manually by the operator, and is independent of the set point. In Remote Output mode, the output is entered by a host computer, and is independent of the set point.
s -
* *
Sbie
**>)-a
September 2000
c-I
DVC5000f Series
FF-GAIN FF-SCALE
TRK-IN-D
I
BKCAL-OUT RCAS-OUT ROUT-OUT
!
Limiting CAS-IN Operator SP HI LIM SPILOILIM SP-RATE-DN SP-RATE-UP Alarm Detection IN Scaling and Filtering PID Equation
ROUT-IN
I
output Limiting OUT
OUT-HI-LIM OUT-LO-UM OUT-SCALE
PV-SCALE PV-FILTER TRK-VAL Convert
HLHL LIM HILLIM DV-HLLIM DV-LO-LIM LO-LlM LO LO-LlM
Operator output
OUT-SCALE
Figure C-2. PID Function Block Schematic
Operator Set point
I
Man
SP-HILUM SP- LO-LIM

T
SP RATE UP SP-RATE-DN
1
by rapid changes in input. You can adjust the filter time constant (in seconds) using the PV-FTIME or SP-FTIME parameters. Set the filter time constant to zero to disable the filter feature.
---co
CAS
B2722, IL
Setpoint Limiting
Limiting
Feedforward Calculation
The feedforward value (FF-VAL) is scaled (FF-SCALE) to a common range for compatibility with the output scale (OUT-SCALE). A gain value (FF-GAIN) is applied to achieve the total feedforward contribution.
Figure C-3. PID Function Block Set Point Selection
Filtering
The filtering feature changes the response time of the device to smooth variations in output readings caused
c-2
September 2000
PID Function Block

Table C-1. PID Function Block System Parameters
Parameter Name Index Number 46 47
Units None Percent
Description Used to set auto acknowledgment of alarms. The amount the alarm value must return to within the alarm limit before the associated active alarm condition clears. The summaw alarm is used for all Drocess alarms in the block. The cause of the alert is entered in the subcode field. The f i k t alert to become active will set the Active status in the Status parameter. As soon as the Unreported status is cleared by the alert report ing task, another block alert may be reported without clearing the Active status, if the subcode has changed. The identification number of the plant unit. This information may be used in the host for sorting alarms, etc. The specified time for the internal working value of bias to return to the operator set bias. Also used to specify the time constant at which the integral term will move to obtain balance when the output is limited and the mode is AUTO, CAS, or RCAS. Used to set disturbance rejection vs. tracking response action for 2 degrees of freedom PID. The bias value used to calculate output for a PD structure. The amount the output value must change away from the its output limit before limit status is turned off. The analog input value and status from another blocks BKCAL-OUT output that is used for backward output tracking for bumpless transfer and to pass limit status. The value and status required by the BKCAL-IN input of another block to prevent reset windup and to provide bumpless transfer of closed loop control. The block alarm is used for all configuration, hardware, connection failure, or system problems in the block. The cause of the alert is entered in the subcode field. The first alert to become active will set the active status in the status parameter. As soon as the Unreported status is cleared by the alert report ing task, and other block alert may be reported without clearing the Active status, if the subcode has changed. This parameter reflects the error status associated with the hardware or software components associated with a block. It is a bit string so that multiple errors may be shown. Used to override the calculation of the block. When enabled, the SP is sent directly to the output. The remote setDoint value from another block. Allows you to specify control strategy options The supported control options for the PID block are Bypass Enable, SP-PV Track in Man, SP-PV Track in Rout, SP-PV Track in LO or IMAN, SP Tracks RCAS or CAS in LO, IMAN. Man, or Rout Direct Acting, Track enable, Track in Manual, Use PV for BKCAL OUT, Act on IR. Obey SP limits if CAS or RCAS, and No Out limits in Man The DV HI alarm data, which includes a value of the alarm, a timestamp of occurrence, and the state of the alarm The setting for the alarm limit used to detect the deviation high alarm condition. The Drioritv of the deviation hioh alarm. The DV LO alarm data, which includes a value of the alarm, a timestamp of occurrence, and the state of the alarm. The settinq for the alarm limit use to detect the deviation low alarm condition The priority of the deviation low alarm. The error (SP-PV) used to determine the control action. The feedforward gain value FF-VAL is multiplied by FF-GAIN before it is added to the calculated control output A value of 0 disables feedforward The hiah and low scale values, enqineerinq units code, and number of diqits to the rtqht of the decimal point associated with k e feedforward value (FF-VAL). The feedforward control i n w t value and status. Selects equation form (series or standard) The proportional gain value. This value cannot = 0. Used to set disturbance rejection vs. tracking response action for a 2.0 degree of freedom PID. Options for controlling access of host computers and local control panels to operating, tuning, and alarm parameters of the block. Not used by the device.
-Continued-
ACK-OPTIO N ALARM-HYS
ALARM-SUM
45
None
ALERT-KEY BAL-TIME BETA BIAS BKCAL-HYS BKCAL-IN BKCAL-OUT
04 25 73 66 30 27 31
None Seconds Percent EU of OUT-SCALE Percent EU of OUT-SCALE EU of PV-SCALE
BLOCK-ALM
44
None
BLOCK- ERR BYPASS CAS-IN
06 17 18
None None EU of PV-SCALE
CONTROL-OPTS
13
None
DV-HI-ALM DV-HI-LIM DV-HI-PRI DV-LO-ALM DV-LO-LIM DV-LO-PRI ERROR FF-GAIN FF-SCALE FF-VAL FORM GAIN GAMMA GRANT-DENY
64 57 56
None EU of PV-SCALE None None EU o f PV-SCALE None EU of PV-SCALE None None EU of FF SCALE None None Percent None
.~
65
59 58 67 42 41 40 70 23 72 12
September 2000
c-3
DVC5000f Series
Table C-1. PID Function Block System Parameters (Continued)
I
Units
Description
None HI-HI-ALM HI-HI-LIM HI-HI-PRI HI-LIM HI-PRI IDEADBAND

I
None EU of PV-SCALE None EU of PV-SCALE None

74
The HI alarm data, which includes a value of the alarm, a timestamp of occurrence. and the state of the alarm. The HI HI alarm data, which includes a value of the alarm, a timestamp of occurrence, and the state of the alarm. The setting for the alarm limit used to detect the HI HI alarm condition. The priority of the HI HI Alarm. The settinq for the alarm limit used to detect the HI alarm condition. The priority of the HI alarm. Integral action stops when ERROR is within IDEADBAND, proportional and derivative action continue. The connection for the PV input from another block. The LO alarm data, which includes a value of the alarm, a timestamp of occurrence, and the state of the alarm. The setting for the alarm limit used to detect the LO alarm condition. The LO LO alarm data, which includes a value of the alarm, a timestamp of occurrence, and the state of the alarm. The setting for the alarm limit used to detect the LO LO alarm condition. The priority of the LO LO alarm. The priority of the LO alarm. The actual. taraet. Dermitted. and normal modes of the block. Target: The mode to "go to" Actual: The mode the "block is currently in" Permitted: Allowed modes that target may take on Normal: Most common mode for target The block input value and status. The maximum output value allowed. OUT-HI-LIM must be greater than OUT-LO-LIM. The minimum output value allowed. OUT-LO-LIM must be less than OUT-HI-LIM. The high and low scale values, engineering units code, and number of digits to the right of the decimal Doint associated with OUT. The process variable used in block execution. The time constant of the first-order PV filter. It is the time required for a 63 percent change in the IN value. The high and low scale values, engineering units code, and number of diglts to the right of the decimal point associated with PV. The derivative action time constant. Target setpoint and status that is provided by a supervisory host. Used when mode is R. C S. . -.A._ Block setpoint and status after ramping, filtering, and limiting that is provided to a super visory host for back calculation to allow action to be taken under limiting conditions or mode chanqe. Used when mode is RCAS. The integral action time constant. Target output and status that is provided by a supervisory host. Used when mode is ROUT. Block output that is provided to a supervisory host for a back calculation to allow action to be taken under limitino conditions or mode chanae. Used when mode is RCAS
~~ ~ ~
EU of PV_SCALE
EU of PV-SCALE None EU of PV-SCALE None EU of PV-SCALE None None
IN LO-ALM LO-LIM LO-LO-ALM LO-LO-LIM
15
MODE-BLK
05
None
OUT OUT-HI-LIM OUT-LO-LIM OUT-SCALE PV PV-FTIME
09
EU of OUT SCALE EU of OUT SCALE EU of OUT-SCALE None

~ ~~~
28
29 11
07
EU of PV-SCALE
Seconds
16
None Seconds RCAS-IN RCAS-OUT RESET ROUT-IN ROUT-OUT SHED-OPT EU of PV-SCALE EU of PV-SCALE Seconds per repeat EU of OUT-SCALE
EU of
None EU of PV-SCALE
Defines action to be taken on remote control device timeout. The target block setpoint value. It is the result of setpoint limiting and setpoint rate of change limiting. The time constant of the first-order SP filter. It is the time required for a 63 percent change in the IN value. The highest SP value allowed. SP-HI-LIM must be greater than SP-LO-LIM. The lowest SP value allowed. SP-LO-LIM must be less than SP-HI-LIM. Ramp rate for downward SP changes. When the ramp rate is set to zero, the SP is used Ramp rate for upward SP changes. When the ramp rate is set to zero, the SP is used
SP-FTIME SP-HI-LIM SP-LO-LIM

~
Seconds EU of PV-SCALE EU of PV-SCALE
SP-RATE-DN SP-RATE-UP
&I
l9
EU of PV-SCALE per second EU of PV-SCALE oer second EU of PV-SCALE
I immediately.
1
II immediatelv.
1 The working set point of the block after limiting and filtering is applied.
-Conbnue&
PID Function Block

Table C-7. P1D function Block System Parameters (Continued)
Tracking
Output tracking is enabled through the control options. You can set control options in Manual or Out of Service mode only. The Track Enable control option must be set to True for the track function to operate. When the Track in Manual control option is set to True, the operator cannot override the tracking function in Manual mode. When Track in Manual is False, the operator can override the tracking function when the block is in Manual mode. Activating the track function causes the blocks actual mode to revert to Local Override. The TRK-VAL parameter specifies the value to be converted and tracked into the output when the track function is operating. The TRK-SCALE parameter specifies the range of TRK-VAL. When the TRK-IN-D parameter is True and the Track Enable control option is True, the TRK-VAL input is converted to the appropriate value and output in units of OUT-SCALE.
Set Point Tracking

You can configure the method for tracking the set point by configuring the following control options (CONTROL-OPTS):
0 SP-PV Track i n Man-Permits the SP to track the PV when the actual mode of the block is Man.
0 SP-PV Track in LO or IMan-Permits the SP to track the PV when the actual mode of the block is Local Override (LO) or Initialization Manual (IMan).
0 SP-PV Track in ROUT-Permits the SP to track the PV when the actual mode of the block is Remoteout (ROUT).
When one of these options is set, the SP value is set to the PV value while in the specified mode. You can select the value that a master controller uses for tracking by configuring the Use PV for BKCAL-OUT control option. The BKCAL-OUT value tracks the PV value. BKCAL-IN on a master controller connected to BKCAL-OUT on the PID block in an open cascade strategy forces its OUT to match BKCAL-IN, thus tracking the PV from the slave PID block into its cascade input connection (CAS-IN). If the Use PV for BKCAL-OUT option is not selected, the working set point (SP-WRK) is used for BKCAL-0 UT. You can set control options in Manual or Out of Service mode only. When the mode is set to Auto, the SP will remain at the last value (it will no longer follow the PV.
Output Selection and Limiting

Output selection is determined by the mode and the set point. In Automatic, Cascade, or Remote Cascade mode, the output is computed by the PID control equation. In Manual and Remote Output mode, the output may be entered manually (see also Set Point Selection and Limiting). You can limit the output by configuring the OUT-HI-LIM and OUT-LO-LIM parameters.
September 2000
c-5
DVC5000f Series
PID Equation Structures
Configure the STRUCTURE parameter to select the PID equation structure. You can select one of the following choices:
0 Proportional, integral, and derivative on error (PID)
Table C-2. BLOCK-ERR Conditions

Condition Number Condition Name and Description
Block Configuration Error-SHED-OPT Link Confiauration Error (NlA)
or BYPASS
Simulate Active (NIA) Local Override-The Enable is set. actual mode is LO and Track
Proportional and integral on error, derivative on PV (PI-D)

0 0 Integral on error, proportional and derivative on PV (I-PD)
5
6
I
I Device Needs Maintenance Soon (NIA)
Device Fault State Set (NIA)
I parameter linked to IN is indicating a Bad status.

I
Outmt Failure (NIA) Memory Failure (NIA)
lmut faiturebrocess variable has Bad status-The
Proportional on error, derivative on error (PD) Integral on error, derivative on error (ID) Integral on error, derivative on PV (I-D) Two degrees of Freedon (2DOF)
14 15
Power Up (NIA)
f Service Out of Service The actual mode is Out o

(01s).
Reverse and Direct Action

To configure the block output action, set the Direct Acting control option. This option defines the relationship between a change in PV and the corresponding change in output. With Direct Acting enabled (True), an increase in PV results in an increase in the output. You can set control options in Manual or Out of Service mode only.
0 Remoteoutput (Rout)-The OUT is provided by a host computer that writes to the ROUT-IN parameter 0 Local Override (LO)-The track function is active. OUT is set by TRK-VAL. The BLOCK-ERR parameter shows Local override. 0 Initialization Manual (IMan)-The output path is not complete (for example, the cascade-to-slave path might not be open). In lMan mode, OUT tracks BKCAL-IN. 0 Out of Service (0IS)-The block is not processed. The OUT status is set to Bad: Out of Service. The BLOCK-ERR parameter shows Out of service.
Block Errors
Table C-2 lists conditions reported in the BLOCK-ERR parameter. Conditions in italics are not applicable for the PID block and are provided only for your reference.
Modes
The PID function block supports the following modes:
0 Manual (Man)-The set manually.
You can configure the Man, Auto, Cas, and OIS modes as permitted modes for operator entry.
block output (OUT) may be
0 Automatic (Auto)-The SP may be set manually and the block algorithm calculates OUT. 0 Cascade (Cas)-The SP is calculated in another block and is provided to the PID block through the CAS-IN connection.
Shed Options
Shed from or climb to a remote mode is determined by the parameter SHED-OPT. A block climbs and sheds through the same path. For example, if SHED-OPTS specifies that a block should shed to Auto, then, if the block target mode is set to RCas, the block goes
September 2000
C-6
PID Function Block

through Auto on the way to RCas. You can configure the shed option as follows: shed. Selecting the retained target results in shed to Auto. This applies to any block, regardless of whether it is in a field device or a DeltaV controller. The writing device sets or clears the retained target bits in the target mode. Therefore, any workstation or other device (DeltaV controller applications, for example) that does not support retained target operation ignores the retained target bits. In a DeltaV system, regardless of where the block is located, the retained target bits are turned off, and the block sheds to Auto. Auto-On failure of a remote cascade connection, the block sets the target mode to Auto, if permitted. On change to the remote target mode from any other mode, the block attempts to attain Auto, if permitted, until a remote cascade connection is established. Man-On failure of remote cascade connection, the block sets the target mode to Man, if permitted. On change to the remote target mode from any other mode, the block goes to Man until a cascade connection is established. The user may configure SHED-OPTS so that it calls for a target mode that is not permitted. When doing this, the mode logic uses the following rules as applied by the remote logic:
0 Shed logic never results in a non-permitted target mode.

Remote cascade connection failure shifts actual mode but keeps trying to restore remote cascade (in other words, the remote cascade target mode stays in effect). Normal-On failure of a remote cascade connection, the block attempts to attain the highest permitted non-remote mode until remote cascade is restored. On change to remote cascade target mode from any other mode, the block attempts to attain the highest permitted non-remote mode until a remote cascade connection is established. Retained Target-On failure of a remote cascade connection, the block attempts to attain the mode retained in the target mode. On change to the remote cascade target mode from any other mode, the block attempts to attain the mode retained by target mode until a remote cascade connection i s established. Auto-On failure of a remote cascade connection, the block attempts to attain Auto, if permitted, until remote cascade is restored. On change to remote target mode from any other mode, the block attempts to attain Auto, if permitted, until a remote cascade connection is established. Man-On failure of a remote cascade connection, the block sheds to Man until a remote cascade connection is restored. On change to remote target mode, from any other mode, the block goes to Man until a cascade connection is established.
0 Shed logic never attempts to attain an actual mode of Auto or Cas if that mode is not permitted.
Alarm Detection
A block alarm will be generated whenever the BLOCK-ERR has an error bit set. The types of block error for the PID block are defined above. Process alarm detection is based on the PV value. You can configure the alarm limits of the following standard alarms:
0

For any shed with no return option, the target mode changes as determined by the option. Therefore, there is no attempt to restore the connection following failure. The behavior on change to the remote cascade target mode is identical to that for Shed With Return Options. Normal-On failure of a remote cascade connection, the block sets the target mode to the highest permitted non-remote mode. On change to a remote cascade target mode from any other mode, the block attempts to attain the highest permitted non-remote mode until a remote cascade connection is established. Retained Target-On failure of a remote cascade connection, the block sets the target mode to mode retained in target mode. On change to the remote cascade target mode from any other mode, the block attempts to attain the mode retained by target mode until a remote cascade connection is established. The DeltaV system does not support the retained target
September 2000
High (HI-LIM) High high (HI-HI-LIM) Low (LO-LIM) Low low (LO-LO-LIM)
Additional process alarm detection is based on the difference between SP and PV values and can be configured via the following parameters:
0
Deviation high (DV-HI-LIM) Deviation low (DV-LO-LIM)
c-7
DVC5000f Series
Table C-3. PI0 Function Block Alarm Priorities
Number
set point (SP) values and calculate a control output signal using a PID (Proportional Integral Derivative) function block. The proportional control function responds immediately and directly to a change in the PV or SP. The proportional term GAIN applies a change in the loop output based on the current magnitude of the error multiplied by a gain value. The integral control function reduces the process error by moving the output in the appropriate direction. The integral term RESET applies a correction based on the magnitude and duration of the error. To reduce reset action, configure the RESET parameter to be a large value. The derivative term RATE applies a correction based on the anticipated change in error. Derivative control is typically used in temperature control where large measurement lags exist.
]
I
2
3-f
--
8-,5
bv the svstem. The device monitors the alarm but does nbt repdrt it until requested by the host system. An alarm condition with a priority of 2 is reported to the operator, but generally does noi require operator attention (such as diagnostics and system alerts). Alarm conditions of orioritv 3 to 7 are advisow alarms of increasing priority. Alarm conditions of priority 8 to 15 are critical alarms of increasing priority.
.~
In order to avoid alarm chattering when the variable is oscillating around the alarm limit, an alarm hysteresis in percent of the PV span can be set using the ALARM-HYS parameter. The priority of each alarm is set in the following parameters:
0
HI-PRI HI-HI-PRI LO-PRI LO-LO-PRI DV-HI-PRI DV-LO-PRI
0 0
Application Example: Basic PID Block for Steam Heater Control

Situation A PID block is used with an Al block and an A 0 block to control the steam flow used to heat a process fluid in a heat exchanger. Figure C-4 illustrates the process instrumentation diagram. Solution Figure C-5 illustrates the correct function block configuration. The PID loop uses TTlOl as an input and provides a signal to the analog output TCVIOI . The BKCAL-OUT of the A 0 block and the BKCAL-IN of the PID block communicate the status and quality of information being passed between the blocks. The status indication shows that communications is functioning and the I/O is working properly.
0 0
Alarms are grouped into five levels of priority, as shown in table C-3.
Status Handling
If the input status on the PID block is Bad, the mode of the block reverts to Manual. In addition, you can select the Target to Manual if Bad IN status option to direct the target mode to revert to manual. You can set the status option in Manual or Out of Service mode only.
Application Example: Feedforward Control

Situation In the previous example, control problems can arise because of a time delay caused by thermal inertia between the two flow streams (TT100 and TT101). Variations in the inlet temperature (TT100) take an excessive amount of time to be sensed in the outlet (TTIOI). This delay causes the product to be out of the desired temperature range. Solution Figure C-7 illustrates the process instrumentation diagram of the steam heater control example with s feedforward control added. Feedfornard control i added to improve the response time of the basic PID control. Figure C-6 illustrates the correct function block configuration. The temperature of the inlet process
September 2000
The PID function block is a powerful, flexible control algorithm that is designed to work in a variety of control strategies. The PID block is configured differently for different applications. The following examples describe the use of the PID block for closed-loop control (basic PID loop), feedforward control, cascade control with master and slave, and complex cascade control with override.
Closed Loop Control

To implement basic closed loop control, compute the error difference between the process variable (PV) and
C-8
PID Function Block
82723 I
IL
1I
\ -
'
Al Function Block
\'
PID
C 7 - OUT
Function Block IN
OUT
CAS-IN
A0 Function Block
COUT
Figure C-5. Function Block Configuration Diagram for Steam Heater Control Example
fluid (TT100) is input to an Al function block and is connected to the FF-VAL connector on the PID block. Feedforward control is then enabled (FF-ENABLE), the feedforward value is scaled (FF-SCALE), and a gain (FF-GAIN) is determined.
modify the valve position to compensate for the steam pressure change. The process is slow and causes variations in the product temperature. Solution If the flow is controlled, steam pressure variations will be compensated before they significantly affect the heat exchanger temperature. The output from the master temperature loop is used as the set point for the slave steam flow loop. Figure C-9 illustrates the correct function block configuration. The BKCAL-IN and BKCAL-OUT connections on the PID blocks are used to prevent controller windup on the master loop when the slave loop is in Manual or Automatic mode, or it has reached an output constraint.
Application Example: Cascade Control with Master and Slave Loops

Situation A slave loop is added to a basic PID control configuration to measure and control steam flow to the steam heater. Figure C-8 illustrates the process instrumentation diagram. Variations in the steam pressure cause the temperature in the heat exchanger to change. The temperature variation will later be sensed by TTlOl. The temperature controller will
September 2000
c-9
DVC5000f Series
I-'
P
Function
OUT
IN
PID Function
OUT
CAS-IN
A0 Function Block
cOUT
1
I
lTIO1
I
TCVIOI
Inlet Temperature Input

I-; I
Al Function Block
1
8>?26
It
n100
Figure C-6. Function Block Configuration Diagram for Steam Heater Control Example with Feedforward Control
Steam Supply
82,251 IL
Figure C-7. Steam Heater Control Example with Feedforward
+
Steam Heater Condensate
c-I0
September 2000
PID Function Block
82721 i It
Condensate
Figure C-8. Steam Heater Control Example with Feedforward and Cascade Control
Outlet Temperature Input
BKCAL-IN
1- 1
7 \
\
Al Function Block
I
OUT
7 &,
I
I
Function Block ID
rrl01
TC101
I
BKCAL.OU1
I
\
Steam Flow Input

I- 1
1
m
BKCAL-IN BKCAL OUT
\
A l
Function Block OUT
CAS-IN IN
PID Function Block
OUT
IN
A0 Module Block
C-
Figure C-9. Function Block Configuration Diagram for Steam Heater Control Example with Feedforward and Cascade Control
September 2000
c-77
DVC5000f Series
C-72
September 2000
Discrete Input (DI) Function Block
Appendix D Discrete Input (DI) Function Block

Table D-1. Discrete Input Function Block Channel Definitions
FIELD-VAL-D S e t When
Valve position i s greater than 97% Valve position is less than 3% Valve Dosition is below Travel Lo Lo Alrt Pt Valve Dosition is below Travel Lo Alrt Pt Valve position is above Travel Hi Alrt Pt Valve position is above Travel Hi Hi Alri Pt
I
I Channel 1 I 1 1
TRANSDUCER BLOCK
1
I
I
1I
-1
OUT-D =The block output and status
3
4
5 6 7
Valve Dosition is within Droximitv , set bv I Travel Lo Lo Alrt Pt Valve Dosition is within Droximitv set bv Travel Lo Alrt Pt Valve position is within proximity set by Travel Hi Alrt Pt Valve position is within proximity set by Travel Hi Hi Alrt Pt
Figure D-7. Discrete lnput (Dl) Function Block
I I
9 10
0
I I
1 I
The Discrete Input (DI) function block processes a single discrete input from a field device and makes it available to other function blocks. You can configure inversion and alarm detection on the input value. In the DVC5000f Series digital valve controller, the discrete input function block can provide limit switch functionality and valve position proximity detection. The Discrete Input function block supports mode control, signal status propagation, and simulation. Normally, the block is used in Automatic mode so that the process variable (PV-D) is copied to the output (OUT-0). You can change the mode to Manual to disconnect the field signal and substitute a manually-entered value for the output. In this case, PV-D continues to show the value that will become the OUT-D when the mode is changed to Automatic. To support testing, you can enable simulation, which allows the measurement value to be supplied manually through the SIMULATE-D parameter. Figure D-2 illustrates the internal components of the DI function block, and table D-3 lists the definitions of the block parameters.
Fixed limit switch
0 Variable limit switch based on transducer block travel alarm settings 0 Proximity position detection based on transducer block travel alarm settings.
The CHANNEL parameter for each of the four DI blocks available in the digital valve controller may be set independently to achieve the desired position detection. The DI block CHANNEL definitions are listed in table D-I. Refer to the following descriptions for details of the operation of these channels.
Fixed Limit Switch

Channels 1 and 2 provide fixed open and closed limit switch functionality for the DI block. These channels will detect if the valve position is more than 97% for open detection or less than 3% for closed detection. These channels provide a fixed 1% deadzone to clear the detected position.
Variable Limit Switch
1 1 0 Selection
To select the I/O associated with the discrete
measurement, configure the value of the CHANNEL parameter. In the digital valve controller, the three classes of channels are
September 2000
Channels 3 through 6 provide variable limit switch functionality for the DI block. Trip points for this limit switch functionality are based on the Travel Alert settings in the transducer Block. The DI function block provides the same type of position detection as the travel alerts in the transducer block. Table D-2 lists the
0-7
DVC5000f Series
Discrete Signal
OUTD
Figure 0-2. Discrete Input Function Block Schematic
transducer block parameters used with DI block channels 3 though 6. Section 4 describes the transducer block travel alerts.
Table D-2. Transducer Block Parameters Used with Discrete Input Function Block Channels 3 through 6 (Variable Limit Switch)
Transducer Block Parameter Tvl Lo Lo Alrt Pt Tvl Lo Lo Alrt DB Tvl Lo AIR Pt Tvl Lo Alrt DB Tvl Hi Alrt Pt Tvl Hi Alrt DB Tvl Hi Hi Alrt Pt Tvl Hi Hi Alrt DB Parameter Function Lo Lo Limit Switch trip point Lo Lo Limit Switch deadband Lo Limit Switch trip point Lo Limit Switch deadband Hi Limit Switch trip point Hi Limit Switch deadband Hi Hi Limit Switch trip point
0 c
DISCRETE INPUT CLEARED
f
DISCRETE INPUT SET
LTRIGGER POINT FOR

DOWNWARDVALVE TRAVEL DETERMINED BY TRAVEL ALERT DEADBAND
. . . . . . . . . . . . . . . .. . . . . . .
TRffiER
POINT FOR
Hi Hi Limit Switch deadband
Valve Position Proximity Detection

Channels 7 through 10 provide valve position proximity detection for the DI block. The transducer block Travel Alrt Pt and Travel Alrt DB parameters are also used with the valve position proximity, but they provide a different function. The Travel Alrt Pt for the selected channel determines the center point for the position to be detected. The Travel Alrt DB for the selected channel sets the upper and lower trigger points, or the width of the proximity detection band. A 1% deadzone exists above and below this band that the travel must
Figure 0-3. Discrete Input Proximity Detection Function
exceed to clear the detected position. Figure D-3 illustrates the operation of the proximity detection function. Travel Alrt Pt refers to Tvl Lo Alrt PT, Tvl Hi Alrt Pt, Tvl Lo Lo Alrt Pt, and Tvl Hi Hi Alrt Pt in table D-4. Travel Alrt DB refers to Tvl Lo Alrt DB, Tvl Hi Alrt DB, Tvl Lo Lo Alrt DB, and Tvl Hi Hi Alrt DB in table 0-4.
September 2000
0-2

Parameter Name ACK-OPTIO N ALARM-SUM ALERT-KEY
Index Number
Units None None None
Description Used to set auto acknowledgement of alarms The current alsert status, unacknowledged states, unreported states, and disabled states of the alarms associated with the function block. The identification number of the plant unit. This information may be used in the host for sortina alarms, etc. The block alarm is used for all configuration. hardware, connection failure, or system problems in the block. The cause of the alert is entered in the subcode field. The first alert to become active will set the active status in the status parameter. As soon as the unreported status is cleared by the alert reporting task, and other block alert may be reported without clearing the active status, if the subcode has changed. This parameter reflects the error status associated with the hardware or software components associated with a block. Multiple errors may be shown, see table D-5. Defines the functionality of the discrete input. See 1 1 0 Selection for details. The status and time stamp associated with the discrete alarm. State of discrete input which will gererate and alarm. Priority of the discrete alarm. Raw value of the field device discrete input, with a status reflecting the transducer condition. Options for controlling access of host computers and local control panels to operating, tunina. and alarm Darameters of the block. Allows you to select how the 110 signals are processed. The supported 1 1 0 option for the DI function block is invert. The actual, target, permitted, and normal modes of the block. Target: The mode to "go to" Actual: The mode the "block is currently in" Permitted: Allowed modes that target may take on Normal: Most common mode for target
I
21
20
04
BLOCK-ALM
19
None
BLOCK-ERR CHANNEL
DISC-ALM
06
None None EU of PV-SCALE EU of PV-SCALE None OnlOff None None
15 24 23 22 17 12 13
DISC-LIM DISC-PRI FIELD-VAL-D GRANT-DENY 10-OPTS
MODE-BLK
05
None
OUT-D OUT-STATE
08 11 07 16 09
EU of OUT EU of OUT EU of Pv-sCALE Seconds None None
The Drimaw discrete value calculated as a result of executinq the function. Index to the text describing the states of a discrete output. The process variable used in block execution. This value is converted from Readback to show the actuator position in the same units as the set point value. Time that FIELD-VAL-D must be in a new state, before the change is reflected to PV-D and OUT-D. Allows the transducer discrete input or output to the block to be manually supplied when simulate is enabled. When simulation is disabled, the simulate value and status track the actual value and status. The revision level of the static data associated with the function block. The revision value will be incremented each time a static Darameter value in the block is chanaed. Options the user may select for the block processing of status The strategy field can be used to identify grouping of blocks This data is not chedked or processed by the block. The user description of the intended application of the block This alert IS generated by any change to the static data Index to the text describing the states of a discrete for the value obtained from the transducer
PV- D
PV-FTIME SIMULATE-D
STATUS-OPTS STRATEGY TAG-DESC UP DATE- EVT XD-STATE
14
None None None None
03 02
18
10
EU of XD-SCALE
September 2000
0-3
DVC5000f Series
Transducer Block Parameter Tvl Lo Lo Alrt Pt Tvl Lo Lo Alrt DB Tvl Lo Alrt Pt Tvl Lo Alrt DB Tvl Hi Alrt Pt Tvl Hi Alrt DB Tvl Hi Hi A M Pt Tvl Hi Hi Alrt DB Parameter Function Lo Lo Proximity Detection Center Point Lo Lo Proximity Detection Width Lo Proximity Detection Center Point Lo Proximity Detection Width
0 Simulate Enable-Disable determines whether the function block will use the actual process value and status, or Simulate Value and Simulate Status. 0 Transducer Value and Status reflect the process values provided by the transducer block. 0 Simulate Value and Status may be entered by the user when Simulate Enable-Disable is set to Enabled.
Hi Proximity Detection Center Point Hi Proximity Detection Width Hi Hi Proximity Detection Center Point Hi Hi Proximity Detection Width
Table D-4 lists the transducer block parameters used for proximity detection with DI block channels 7 though 10.
To use simulate, first install the simulate jumper in the terminal box, then set Simulate Enable-Disable to Enabled, then enter the desired values for Simulate Value and Status. When SIMULATE-D is Enabled, the Simulate Active bit of the BLOCK-ERR parameter is set (refer to the Block Errors description). When the simulate jumper is installed, the Simulate Jumper bit of the transducer block parameter SELFTEST-STATUS is set.
Block Initialization
The Fieldbus Foundation specification requires that certain parameters in the function blocks have initial values of uninitialized. In addition to setting the Resource block mode to AUTO, the control system or the user must change those parameters from their uninitialized value to a valid value in order for the function block to move from the Out of Service mode. For the DI function block, the CHANNEL parameter must be initialized.
Field Value Processing

The Invert bit of the 10-OPTS parameter may be used to logically invert the value of FIELD-VAL-D before it is stored as PV-D. PV-FTIME may be used to set the length of time that FIELD-VAL-D must be in a new state before that new state is reflected in PV-D. The PV-D value goes to the mode switch where it becomes OUT-D when the actual mode is AUTO. OUT-D is also tested for an alarm state.
Simulation
To support testing of the control strategy, you can Enable the SIMULATE-D parameter. Normally the measurement value and status used for FIELD-VAL-D in the DI block reflect actual process values as provided by the transducer block. When the SIMULATE-D parameter is Enabled, value and status used for FIELD-VAL-D is supplied by the user manually. To enable simulation in the DI function block, the simulate jumper must be installed. For information on the installation of this jumper, see the "Installation" section.
Note
Invert is the only I/O option that the DI block supports. You can set the 1 1 0 option only when the block mode is Out of Service.
Alarm Detection
To select the state that initiates an input alarm, and to set discrete alarm substatus in the output, configure the DISC-LIM parameter. You can enter any value between 0 and 255. A value of 255 disables the alarm. When OUT-D matches the DISC-LM state, the discrete value of an alarm is set.
The block does not respond to actual process values when SIMULATE-D is Enabled.
Block Errors
Table D-5 lists conditions reported in the BLOCK-ERR parameter. Conditions in italics are not applicable for the DI block and are provided only for your reference.
September 2000
The SIMULATE-D parameter has three components:
0-4

Table 0-5. BLOCK-ERR Conditions
STANDARD DISCRETE INPUT
t fl
DISCRETE INPUT VALUE
PROXIMITY DISCRETE INPUT
=flJ
Configurabl
DISCRETE INPUT VALUE
Figure 0-4. Proximity Discrete lnput Compared to a Standard Discrete Input
When the block is set to Manual mode, OUT-D is set to Good: Non-cascade, Constant status.
Modes
The Discrete Input function block supports the following modes:
0 Manual (Man)-The block output (OUT-D) is disconnected from the field and set manually. 0 Automatic (Auto)-The determines output.
Action on Failure
In case of hardware failure, FIELD-VAL-D, PV-D, and OUT-D change to a Bad status and the BLOCK- ERR parameter shows Process Variable has Bad Status. If the transducer block mode is Out of Service, the status of FIELD-VAL-D, PV-D, and OUT-D is set to Bad:Out of Service.
block algorithm
Figure D-4 compares the operation of a standard discrete input to a proximity discrete input. With the standard discrete input, the discrete input changes state when the valve position passes a configurable trip point. This can be used to indicate if the valve position is above or below the trip point. With the proximity discrete input a configurable band can be established about a central point. Whenever the valve position enters this configurable band, the discrete input changes state. A proximity discrete input is useful for applications which require knowing the location of the valve when the valve is not near 0% or 100%. The ESD or batch applications described in the DO application section are both great examples of that situation.
Out of Service (0IS)-The block is not processed. The OUT-D status is set to Bad: Out of Service. The BLOCK-ERR parameter shows Out of Service.
0
Status Handling
Under normal conditions, a Good: Non-Cascade status is passed through to OUT-D. The block also supports the Status Action On Failure and BLOCK- ERR indications. When SIMULATE-D is enabled, FIELD-VAL-D, PV-D, and OUT-D change to the simulated status.
September 2000
D-5
DVC5000f Series
D-6
September 2000
Discrete Output (DO) Function Block
Appendix E Discrete Output (DO) Function Block

CAS-IN-D
BKCAL-OUT-D
Value
0
Description
Function
Uninitialized Valve Control
Disables the DO block. Enables the DO block to set valve position
Block Initialization
CAS-1N.D BKCAL-OUT-D
OUT-D READBACK-D
= The remote set point value from anomer function block. = The value and status required by the BKCAL-IN-D input of another block for output tracking. = The block output and status. = Actual valve position
Figure f-1. Discrete Output (DO) Function Block
The Fieldbus Foundation specification requires that certain parameters have initial values of uninitialized in function blocks. In addition to setting the Resource block mode to AUTO, the control system or the user must change those parameters from their uninitialized value to a valid value in order for the function block to move from the Out of Service mode. For the DO function block, the parameters that must be initialized are: SHED-OPT (see page E4 for valid values) CHANNEL
The Discrete Output (DO) function block processes a discrete set point and outputs it to the specified I/O channel to produce an output signal. The DVC5000f Series digital valve controller discrete output block provides both normal open/closed control and the ability to position the valve in 5% increments for coarse throttling applications. The digital valve controller measures and uses actual valve position for READBACK-D. The DO block supports mode control and simulation. In operation, the DO function block determines its set point and sets the output. The transducer block provides a readback signal of actual position from the instrument. Figure E-I illustrates the primary inputs and outputs of the DO function block. Table E-2 lists definitions for the function block parameters.
Setting the Output

To set the output for the DO block, you must first set the mode to define the manner in which the block determines its set point and output. In Cascade mode, the set point equals the input value at the CAS-IN-D parameter. In Automatic or Manual mode, the set point must be entered manually by the user. For Automatic, the value must be written to the SP-D parameter and for Manual, the value must be written to OUT-D. In Remote Cascade mode, the set point is determined by a host computer that is writing to the RCAS-IN-D parameter. Table E-3 lists discrete states used by the digital valve controller for the set point. The SP-PV Track in Man option permits the set point to track the process variable when the block is in Manual mode. With this option enabled, the set point (SP-D) becomes a copy of the process variable (PV-D), and a manually-entered SP-D value is overwritten on the blocks next execution cycle. This option can prevent a state change when transitioning from Manual to Automatic mode. You can disable this option in Manual or Out of Service mode only. The Invert option inverts the set point at SP-D before it is stored in OUT-D. With this option enabled,
1 1 0 Selection
To select the I/O associated with the discrete output, configure the value of the CHANNEL parameter. Table E-I lists the valid Channel selections for the DO block.
September 2000
E- I
DVC5000f Series
Parameter Name
izzer
~
Table E-2. Discrete Output Function Block Parameter Definitions

Units
Description The identification number of the plant unit. This information may be used in the host for sorting alarms, etc. The value and status required by the BKCAL-IN-D input of another block for output tracking The block alarm is used for all configuration, hardware, connection failure, or system problems in the block. The cause of the alert is entered in the subcode field. The first alert to become active will set the active status in the status parameter. As soon as the Unreported status is cleared by the alert reporting task, and other block alert may be reported without clearing the Active status, if the subcode has changed.
ALERT-KEY BKCAL-OUT-D
04
None None
21
BLOCK-ERR CAS-IN-D CHANNEL FSTATE-TIME FSTATE-VAL- D GRANT-DENY
06 17 18 19 20 13
None None None Seconds EU of PV-STATE None
This parameter reflects the error status associated with the hardware or software components associated with a block. It is a bit string, so that multiple errors may be shown. See table The remote set point value from another block. Defines the output that drives the field device. For the digital valve controller, select channel to set valve position. Time from detection of a fault in the remote set point to the Fault State output action. Preset discrete SP-D value to use if 110 OPTS Fault State to Value is set. Options for controlling access of host computers and local control panels to operating, tunina. and alarm Darameters of the block. Allows you to select the type of tracking and the output value when a fault condition occurs. 1 0 options for the DO function block are SP Tracks PV in Man, SP Tracks PV in Supported 1 LO, SP Tracks Retained Target in Man or LO, Fault State to Value, Use Fault state on Restart. Taraet to Man if Fault State Activated, and Use PV for BKCAL-OUT. The actual, target, permitted, and normal modes of the block. Target: The mode to go to Actual: The mode the block is currently in Permitted: Allowed modes that target may take on Normal: Most common mode for target The primary discrete value calculated as a result of executing the function The discrete process variable calculated from READBACK-D. Index to the text describing the states of a discrete output. Target set point and status provided by a supervisory host to a discrete control or output block. Block set point and status provided to a supervisoy host for back calculation and to allow action to be taken under limiting conditions or mode change. The discrete feedback from the output in 5 % increments. Defines action to be taken on remote control device timeout. Allows the transducer discrete input or output to the block to be manually supplied when simulate is enabled. When simulation is disabled, the simulate value and status track the actual value and status. The discrete target block output value (set point). The revision level of the static data associated with the function block. The revision value will be incremented each time a static parameter value in the block is changed. Options the user may select for the block processing of status. The strategy field can be used to identify grouping of blocks. This data is not checked or processed by the block. The user description of the intended application of the block. This alert is generated by any change to the static data. Index to the text describing the states of a discrete for the value obtained from the transducer.
10-OPTS
14
None
MODE-BLK
05
None
OUT-D PV- D PV-STATE RCAS-IN-D RCAS-OUT-D
09
EU of OUT None EU of OUT EUofPV-STATE EU of PV-STATE
07
11 22
SHED-OPT SIMULATE-D
10
None None
ST-REV STATUS-OPTS STRATEGY TAG-DESC UP DATE- EVT XD-STATE 15
None None
EU of XD-SCALE
E-2
September 2000

RCAS OUT D BKCAL-OUT- D
CAS-IN-I
OUT-D
TRANSDUCER BLOCK FEEDBACK
TRANSDUCERBLOCK
Figure E-2. Discrete Output Function Block Schematic Table E-3. Valve Set Point for Discrete State
OUT-D becomes an inverted copy of SP-D where non-zero values of SP-D are considered a logic 1. With this option disabled, OUT-D is a direct copy of SP-D. The readback value is processed through the Invert option to become PV-D. The Use PV for BKCAL-OUT option specifies that BKCAL -OUT equal the value of the process variable (PV-D) instead of the set point (SP-D). If you do not enable this option, BKCAL-OUT will equal SP-D.
Simulation
To support testing of the control strategy, you can Enable the SIMULATE-D parameter. Normally, the valve position value and status used for READBACK-D in the DO block reflect actual process values to the nearest 5%, as provided by the transducer block. When the SIMULATE-D parameter is enabled, value and status used for READBACK-D is supplied by the user manually. To enable simulation in the DO function block, the simulate jumper must be installed. For information on the installation of this jumper, see the "Installation" section.
~ ~~
September 2000
E-3
DVC5QQQf Series
The valve holds its last position and does not respond t o user entered changes when SIMULATE-D i s Enabled. FSTATE-TIME: The length of time, in seconds, that the DO block will wait to set Fault State. When Fault State is set, the OUT-D value goes to either the FSTATE-VAL-D value or holds its last position, depending on I/O-OPTS. When the block has a target mode of CAS, a fault condition will be detected if the CAS-IN-D has a BAD status or an Initiate Fault State substatus is received from the upstream block. FSTATE-VAL-D: Determines the OUT-D value if 10-OPTS Fault State to Value is selected. The OUT-D value transitions to FSTATE-VAL-D after FSTATE-TIME elapses and the fault condition has not cleared.
@ A
Note
When simulate is active, the output block no longer writes values t o the transducer block. If the Output Blk Timeout period is exceeded, the transducer block will set the valve t o the NoAir position.
Block Errors
Table E-4 lists conditions reported in the BLOCK-ERR parameter. Conditions in italics are not applicable for the A 0 block and are provided only for your reference.
The SIMULATE-D parameter has three components: Simulate Enable-Disable determines whether the function block will use the actual valve position value and status, or Simulate Value and Simulate Status.
0 0 Transducer Value and Status reflect the process values provided by the transducer block. 0 Simulate Value and Status may be entered by the user when Simulate Enable-Disable is set to Enabled.
Modes
The DO block supports the following modes:
0 Manual (Man)-The block output OUT-D value may be entered manually. 0 Automatic (Auto)-The block algorithm uses the local set point SP-D value to determine OUT-D.
0 Cascade (Cas)-The block uses a set point supplied by another function block.
To use simulate, first install the simulate jumper in the terminal box, then set Simulate Enable-Disable to Enabled, then enter the desired values for Simulate Value and Status. When SIMULATE-D is Enabled, the Simulate Active bit of the BLOCK-ERR parameter is set (refer to the Block Errors description). When the simulate jumper is installed, the Simulate Jumper bit of the transducer block parameter SELFTEST-STATUS is set.
0 Remotecascade (RCas)-The point supplied by a host computer.
block uses a set
0 Out of Service (0IS)-The block is not processed and the output is not transferred to 110. The BLOCK-ERR attribute shows Out of service.
Shed Options
Shed from or climb to a remote mode is determined by the parameter SHED-OPT. A block climbs and sheds through the same path. For example, if SHED-OPT specifies that a block should shed to Auto, then, if the block target mode is set to RCas, the block goes through Auto on the way to RCas. You can configure the shed option as follows:
Action on Fault Detection

Fault State is caused by one of three sources: A status pertaining to CAS, A status pertaining to RCAS, or SET-FAULTSTATE in the resource block. To implement Fault State, configure the following parameters: 10-OPTS: Determines the action OUT-D will take upon a fault state. If the 10-OPTS Fault State to Value i s not selected, then OUT-D holds its last position when Fault State is set. If Fault State to Value is selected, OUT-D goes to the FSTATE-VAL-D value when Fault State is set.

Remote cascade connection failure shifts actual mode but keeps trying to restore remote cascade (in other words, the remote cascade target mode stays in effect).
September 2000
E-4

Table E-4.
BLOCK -ERR Conditions

For any shed with no return option, the target mode changes as determined by the option. Therefore, there is no attempt to restore the connection following failure. The behavior on change to the remote cascade target mode is identical to that for Shed With Return Options. Normal-On failure of a remote cascade connection, the block sets the target mode to the highest permitted non-remote mode. On change to a remote cascade target mode from any other mode, the block attempts to attain the highest permitted non-remote mode until a remote cascade connection is established. Retained Target-On failure of a remote cascade connection, the block sets the target mode to mode retained in target mode. On change to the remote cascade target mode from any other mode, the block attempts to attain the mode retained by target mode until a remote cascade connection is established. The DeltaV system does not support the retained target shed. Selecting the retained target results in shed to Auto. This applies to any block, regardless of whether it is in a field device or a DeltaV controller. The writing device sets or clears the retained target bits in the target mode. Therefore, any workstation or other device (DeltaV controller applications, for example) that does not support retained target operation ignores the retained target bits. In a DeltaV system, regardless of where the block is located, the retained target bits are turned off, and the block sheds to Auto. Auto-On failure of a remote cascade connection, the block sets the target mode to Auto, if permitted. On change to the remote target mode from any other mode, the block attempts to attain Auto, if permitted, until a remote cascade connection is established. Man-On failure of remote cascade connection, the block sets the target mode to Man, if permitted. On change to the remote target mode from any other mode, the block goes to Man until a cascade connection is established. The user may configure SHED-OPT so that it calls for a target mode that is not permitted. When doing this, the mode logic uses the following rules as applied by the remote logic:
0 Shed logic never results in a non-permitted target mode. 0 Shed logic never attempts to attain an actual mode of Auto or Cas if that mode is not permitted.
Condition Number ..-... - -.
I
Other(N/A)
Block Configuration Error - SHED-OPT or CHANNEL set to 0 (uninitialized) Link Configuration Error (NIA) Simulate active - Simulation is enabled and the block is using a simulated value in its execution. Local Override Device in fault state. Actual mode LO. Device Fault State Set DO block in fault state after FSTATE-TIME because of Bad status or IFS substatus on CAS-IN-D or Resource block commanded fault state. Device Needs Maintenance Soon Input failurelprocess variable has Bad status - PV has bad status and Feature Select in the Resource block has the Out Readback bit set or the transducer block mode is Out of Service. Output failure PV has bad status or the transducer block mode is Out of Service.
9
10 11
Memorv Failure (NIAJ Lost Static Data (N/A) Lost N V Data (NIA) Readback Check Failed ("A) Device Needs Maintenance Now INlAJ Power Up -This condition exists after power up until actual mode is not Out of Service. Out of Service - T h e block is in Out of Service (01s) mode.
12
13
14 15
Normal-On failure of a remote cascade connection, the block attempts to attain the highest permitted non-remote mode until remote cascade is restored. On change to remote cascade target mode from any other mode, the block attempts to attain the highest permitted non-remote mode until a remote cascade connection is established. Retained Target-On failure of a remote cascade connection, the block attempts to attain the mode retained in the target mode. On change to the remote cascade target mode from any other mode, the block attempts to attain the mode retained by target mode until a remote cascade connection is established. Auto-On failure of a remote cascade connection, the block attempts to attain Auto, if permitted, until remote cascade is restored. On change to remote target mode from any other mode, the block attempts to attain Auto, if permitted, until a remote cascade connection is established. Man-On failure of a remote cascade connection, the block sheds to Man until a remote cascade connection is restored. On change to remote target mode, from any other mode, the block goes to Man until a cascade connection is established.
Status Handling
Under normal operating conditions, the statuses of OUT-D and BKCAL-OUT-D are Good:Cascade. If the output hardware fails, the status of BKCAL-OUT-D is
September 2000
E-5
DVC5000f Series
set to 6ad:Device Fail, and the BLOCK-ERR shows Output Failure. If the hardware used for output feedback fails, the status of READBACK-D and PV-D is set to Bad:DeviceFail, and the BLOCK-ERR shows Process Variable has Bad Status. If the transducer block mode is Out of Service, the status of READBACK-D and PV-D is set to Bad:Out of Service. close, it doesnt. Its stuck. With 5% positioning the valve can be diagnosed to determine when it is starting to stick. By moving the valve to 95% or 90% the process is not at risk of shut down, but you know the valve will move when the process needs it to. In a batch environment, vessels are filled with on-off valves for speed, but there can be a problem at shutoff. The amount of material may not be close enough for the recipe and additional material may have to be added. This addition can be tricky and/or time consuming for the operator. The capability of being able to crack the valve to 5 to 10% and dribble in the correct amount either manually or automatically through recipe control can provide significant reduction in variability, and reduction in FDA-like reporting and certification. In addition, it can elminate the need for a second smaller on-off valve or the operator climbing up and dumping in a pail of material to add just the right amount.
In addition to the expected 100% and 0% position (On-Off switching) of the valve, the digital valve controller has the added capability to move the valve to any 5% position, for example 5%0,lo%, 15%, ..., 85%, 90%, etc. The advantage of this approach is that the valve works well in standard On-Off applications as well as two valued applications, for example, ESD and Batch. The most common problem with ESD valves is that when there is an emergency and the valve needs to
E-6
September 2000
DD Installation
Appendix F Installation
Overview
Device Description (DD)

format 005100). This number is also stored in the instrument Resource Block in the parameter Mfg ID (parameter name MANUFAC-ID). yyyy is the 4-digit hexadecimal equivalent of the device type, as defined by the manufacturer. The device types for the DVC5000f Series digital valve controller include 5200, 5400, or 5900 for example. This number is stored in the instrument Resource Block in the parameter Device Type (parameter name DEV-TYPE). is the 2-digit hexadecimal equivalent of the device revision, as defined by the manufacturer. It is stored in the instrument Resource Block in the parameter Device Revision (parameter name DEV-REV). is the 2-digit hexadecimal equivalent of the device description (DD) revision that applies to the device, as defined by the manufacturer. It must be equal to or greater than the value stored in the instrument Resource Block in the parameter DD Revision (parameter name DD-REV). The latest version of the DD, for a particular device revision, is the file with the largest value for this number. When part of the name of a capabilities file, this value is always the same as the device DD revision stored in the instrument Resource Block in the parameter DD Revis \, DD-REV). is a 2-digit hexadecimal equivalent for the capabilities files (.cff) revision, as defined by the manufacturer. The latest revision of the capabilities files, for a particular device revision, is the file with the largest value for this number. is the file extension. At this time, five extensions exist for files. thev are:
0 .ffo-This extension denotes a complete, tokenized, device description for the instrument.
Several support files are required for the DVC5000f Series digital valve controller. They are:
0 Device Description (DD) files-These files define the data interface to the digital valve controller (file extensions .sym and .ffo). 0 Capabilities File-These files allow a host to configure the control system off-line (e.g., without having a device physically attached to the host) (file extension .cff).
rr
DeltaV Registry File-This file is used by DeltaV to define the device interface (file extension .reg)
0 0 DeltaV f i x File-This file is used by DeltaV to define the device and the data interface to the device (file extension .fix). 0 DeltaV Windows Resource File-These files define the user interface for the device for DeltaV and include the definitions for the transducer block interface and the resource block interface (file extension .dll).
dd
The directory structure defined by the Fieldbus Foundation for device descriptions is as follows:
....\xxxxxx\yyyy\rrddcc.eee
where:
....\
is the path to the DD structure as implemented by the host system. This is typically defined as the base path to the DD since access to the specific device DD is predefined from the base folder. The Fieldbus Foundation defines a folder named release that is included with the CD-ROM, however, you do not need to retain this folder name.
cc
eee
xxxxxx is the 6-digit hexadecimal equivalent of the manufacturers identification number as defined by the Fieldbus Foundation. Fisher Controls ID number is 5100 (or in the folder
September 2000
F- 1
DVC500Of Series
0 .cff-This extension denotes a capabilities file for the instrument as defined by the FOUNDATION Fieldbus Common File Format specification.
Installing on DeltaV Workstations

Installation on DeltaV Pro Plus Worksfa fion
Set Up the Manufacture ID and Device Type Folders 1. Make sure that all copies of the DeltaV Explorer are closed.
2. Using Windows NT Explorer (NOT the DeltaV Explorer), locate the following folder on the DeltaV system:
0 .sym-This extension denotes a device description (DD) symbol file.
0 .fhx-This extension denotes a DeltaV device definition file.
0 .dll-This resource file.
extension denotes a windows
C:\DeltaV\DVData\amsdevices
.reg-This registry file.
0
extension denotes a DeltaV 3. Locate the folder where you have placed the new Fisher Controls support files (DD, fhx, dll, etc).
0 On the CD-ROM, this folder is called \amsdevices 0 For files downloaded from the internet, this folder is in the directory you specified when you decompressed (unzipped) the download file.
Installation
To install the DD on your host system, refer to your host system documentation. In general the following may apply:
Device descriptions furnished by Fisher Controls contain only those files applicable to Fisher Controls. All the files are located in the manufacturer ID Folder (005100 for xxxxxx in directory structure above). A readme file is included at the top level. Read this file for any additional information regarding DD installation.
0 0 Device descriptions furnished by the Fieldbus Foundation (on CD-ROM or diskette) contain the files for each registered manufacturer and their associated device(s). It is placed on the media starting with the release folder, which then contains a folder (xxxxxx) for each manufacturer as defined above. For Fisher Controls this folder is 005100. A readme file may be included at the top level. Read this file for any additional information regarding the DD
4. In the new support files folder, select the \amsdevices folder, then select the 005100 folder.
5. Copy this folder (and all its subfolders) to the \amsdevices folder on the DeltaV system. The system informs you if the folders already exist and asks if they should be replaced. Answer Yes to All, if asked, so the new folders are properly updated. Run the *.REG File
6. Perform one of the following procedures for each digital valve controller device type you are installing. If you have additional digital valve controller device types, perform the appropriate procedure for that device type.
0 For the DVC5000f AOlPlD Digital Valve Controller
a. The device type parameter for this unit is 5400. This device includes the A 0 and PID function blocks. From the Windows NT Explorer, select the amsdevices\005100\5400 folder. b. Double click on the DVC5400FR7.REG file to register the new device in Windows NT and DeltaV. c. Delete any previous version of the .ffo and .sym files. previous versions will have a DD version number smaller than the DD version number loaded. The DD version number is the last two digits of the file name (i.e., 0702.ffo. The DD version number is 02).
September 2000
0 The most recent device description for Fisher Controls devices can be dowloaded from the internet at www.FIELDVUE.com. If you are downloading from the internet, the file on the website will be compressed (zipped) and must be decompressed (unzipped) before proceeding. Refer to the website download and installation procedures for setting up the DD on your system. Note the folder where the decompressed files are placed. This information will be required later in the installation procedure.
F-2
DD Installation
~~~
d. When the pop-up window appears stating that the device has been successfully added to the registry, click ok.
0 For the DVC5000f DOlDl Digital Valve Controller
Verify Device Support
11. From DeltaV Explorer, select Library > Fieldbus Devices > Fisher Controls and verify the device or devices are now supported. Double click on the device name to display the device revision number.
Exit And Restart DeltaV Explorer
a. The device type parameter for this unit is 5900. This device includes the DO and DI function blocks. From the Windows NT Explorer, select the amsdevices\005100\5900 folder. b. Double click on the DVC5900FR7.REG file to register the new device in Windows NT and DeltaV. c. Delete any previous version of the .ffo and .sym files. previous versions will have a DD version number smaller than the DD version number loaded. The DD version number is the last two digits of the file name (i.e., 0702.ffo. The DD version number is 02). d. When the pop-up window appears stating that the device has been successfully added to the registry, click ok.
Use DeltaV Explore to Import the *.FHX File
12. Exit the DeltaV Explorer application. Wait approximately 15 seconds for the AMS server to shut down then start DeltaV Explorer again. The fieldbus device support files are now ready to use. 13. DD installation is complete. To update existing devices, go to the Updating Existing Devices procedure in this appendix. To Install new devices, refer to Appendix G.
Installation on DeltaV Application Workstation

Pro Plus Status
1. Prior to installing the Fieldbus Device on the Application Workstation, verify the ProPlus station has been updated with the new devices. If it has not, then install the devices on the ProPlus station, as described in the Installation on DeltaV Pro Plus Workstation procedure.
Installation
7. Start the DeltaV Explorer (NOT the Windows NT Explorer)

8. From the DeltaV Explorer File menu, select Import > Standard DeltaV Format... Browse to the required .fhx file in the folder(s) created above. The .fhx file is located in the same folder as the .REG file. 9. Import the .fhx file for each digital valve controller installed in step 6. Select YES if asked the following question; Do you wish to update the existing object in the database.
2. Repeat steps 1 through 12 of the Installation on DeltaV Pro Plus Workstation procedure for each Application Station on which you wish to run the AMS application.
3. DD installation is complete. To update existing devices, go to the Updating Existing Devices procedure in this appendix. To Install new devices, refer to Appendix G.
Installing on a Fieldbus Host System Other than DeltaV
Note
@ $ I
Note
I I
If errors or warnings appear upon conclusion of the import then there are possible conflicts within the .fhx file. Be sure to record the warninglerror messages from the message window in DeltaV Explorer so that it can be communicated to the DeltaV Technical Support Group.
This procedure is for installing Fieldbus device files (i.e. DD) on a host system that only requires the support files as defined by the Fieldbus Foundation
The following is a generic procedure for installing the device descriptions on a host system. Refer to your host system documentation for specific information.
1. Locate or create the folder on the host system to contain all the DD and capabilities files. If you are
10. Close the Import screen by clicking Close.
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F-3
DVC5000f Series
creating a folder, you can name this new folder whatever you would like and it can have any path you define. For this installation procedure, this folder will be referred to as the base folder.
@ I
Note
2. On the CD-ROM or in the website download files, locate the folder with the new support files. This folder is called \RELEASE.
3. Open this folder and select the folder named 005100. 4. Copy the 005100 folder from the CD-ROM or website download location to the base folder. If this is an update (the folders already exist), the system informs you that the folders already exist and asks if they should be replaced. Answer Yes or OK so the folders are properly updated.
Export the control modules in the following step (step 2) to make a backup copy. In case of a mistake while performing the procedure, the function block information can be retrieved from the backup copy. If the procedure is completed successfully, the backup copy may be deleted.
1. From the DeltaV Explorer screen, select the device to be upgraded.
5. The new support files are now installed. You may have to restart applications and drivers in order for the new files to become active.
6. DD installation is complete. Consult the system documentation for commissioning new devices or updating existing devices.
2. From Control Studio, record the function block assignments for all function blocks assigned to the device(s) to be upgraded. Also, export the control modules so that you have a backup copy. Once the assignments are recorded, proceed.
3. Right click on the device name or icon. From the context menu select Decommission. 4. Select Make spare to make the device a spare device.
Updating Existing Devices
5. At this point, the DVC5000f Series digital valve controller electronics should be upgraded. Remove the existing pwb assembly and replace with the new pwb assembly as described in the printed wiring board removal and replacement procedures in the "Maintenance" section, Section 8, of this manual.
6. Once the electronics are upgraded, upgrade the DeltaV placeholder as follows: a. Select the placeholder (the device icon) in the DeltaV explorer screen. b. Right click the placeholder. From the context menu select Properties. c. Select Manufacturer. From the Device Type drop-down list select the device type:
0 0300-The device type for digital valve controllers with revision 6 firmware. These devices included both A 0 and PID function blocks. Note: This is most likely the firmware revision of the device you are upgrading from. You will be upgrading to one of the following.
The following steps require taking the digital valve controller out of service. To avoid personal injury and property damage caused by the release of pressure or process fluid, observe the following before starting this procedure:
0 Provide some temporary means of control for the process before taking the digital valve controller out of service.
Be sure you have an updated printed wiring board (pwb) assembly available before starting this procedure. Perform the following procedure to upgrade devices that have been a part of the system and require upgrading due to installation of the device description upgrade.
0 5400-The device type for digital valve controllers with revision 7 firmware that include the A 0 and PID function blocks. 0 5900-The device type for digital valve controllers with revision 7 firmware that include the DO and DI function blocks.
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September 2000
DD Installation
d. From the Device Revision drop-down list select the device revision. (Depending upon your selection of device type, the system will automatically select the device revision.) e. Click OK to make the change If a red triangle appears for the device icon, close and reopen the DeltaV Explorer application. If this action does not correct the situation (the red triangle is still displayed), then there is a problem with one of the installation files. DO NOT PROCEED TO STEP 8! Check the library under fieldbus\Fisher to be sure that revision 7 appears. If revision 7 does not appear, then you have not completed the registry update. Go back and repeat step 6 of the DD installation procedure. If revision 7 does appear, close and reopen DeltaV Explorer. If the problem still exists, shut down DeltaV completely and restart. If the problem continues after you have done all of the above, consult your Fisher Controls representative or sales office. You may still be able to commission and download the device and any associated function blocks, but this is not recommended.
8. Once the devices are commisioned, reassign the function blocks using the assignments recorded in step 2. 9. The device is now successfully commissioned and downloaded; perform the initial setup, calibration, and configuration download procedures.
7. Verify correct operation by commissioning and downloading the new device as described in Appendix G. If the device cannot be commissioned, then the device type and/or revision within the digital valve controller may not match the device type and/or revision within the placeholder.
Note
When changing the Device Type, the function block assignments in the DeltaV system will be unassigned and will have to be re-assigned. The green valve icon should appear for the device in the port view on the DeltaV Explorer screen.
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F-5
DVC50OOf Series
F-6
September 2000
Operation with Fisher-Rosemount@ DeltaV
Appendix G Operation with Fisher-Rosemount@DeltaV

Introduction
0 Appendix B: Analog Output (AO) Function Block for complete information about the analog output function block and its parameters. 0 Appendix C: PID Function Block for complete information about the Proportional-plus-Integralplus-Derivative function block and its parameters. 0 Appendix D: Discrete Input (DI) Function Block for complete information about the discrete input function block and its parameters. 0 Appendx E: Discrete Output (DO) Function Block for complete information about the discrete output function block and its parameters.
@ h
Note
This appendix does not necessarily provide the latest information on using the DeltaV system. For the latest information on using the DeltaV system, refer to the on-line help or documentation supplied with the system.
This appendix provides specific instructions for performing basic setup operations on the DVC5000f Series digital valve controller using the Fisher-Rosemount DeltaV host system. It is not a comprehensive resource, rather a starting point. For more information, refer to the following sources: Section 3: Initial Setup and Calibration for detailed information regarding initial setup, travel calibration and stabilizing and optimizing valve performance.
0 Section 4: Detailed Setup for detailed information on setting up cutoffs, limits, alerts, input characterization and additional information for modifying resource block and transducer block parameters to fit the instrument to your application.
0 Section 5: Calibration for complete calibration information.
0 DeltaV On-line Help or Documentation for complete and current information about navigating in the DeltaV system.
Software Functionality
DVC5000f Series digital valve controllers are designed to permit remote setup, calibration, and testing using the Fisher-Rosemount DeltaV system. To use the methods, accessed as described in this appendix, requires that the device description (DD) for the DVC5000f Series digital valve controller be installed on the host system. For information on installing the device description, refer to Appendix F DD Installation and the host system documentation.
Initial Setup and Travel Calibration

Use the Setup Wizard method to perform initial setup and automatically calibrate travel for the DVC5000f Series digital valve controller. The Setup Wizard is available through the transducer block.
I :
0 Section 6: Viewing Device Information for complete information on which resource block and transducer block parameters to view to see infomation about the instrument. 0 Appendix A: FOUNDATION fieldbus Function Block Overview for general information about FOUNDATION fieldbus function blocks.
Accessing the Setup Wizard

Refer to figure G-1 and the following steps to access and start the Setup Wizard:
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G- 1
DVC5000f Series
Transducer Block
Iconand Name
Context Menu
Digital Valve Ccontroller Icon and Name
Figure G-7. Nawgating to the Setup Wizard
1. Start DeltaV Explorer by selecting DeltaV > Engineering > DeltaV Explorer from the Start menu. 2. Locate the digital valve controller icon in the All Containers pane and left-click once on the digital valve controller icon or name.
3. Locate the transducer block icon in the Contents of... pane and right-click once on the block icon or name.
4. Select StabilizelOptimize from the context menu. 5. Follow the on-screen instructions to adjust valve response. (Refer to section 3 of this manual.)
o f... pane and right-click once on the block icon or

name.
3. Locate the transducer block icon in the Contents
4. Select Setup Wizard from the context menu.

5. Follow the on-screen instructions through the initial setup and calibration steps. (Refer to section 3 of this manual.)
Calibration and Detailed Setup

In addition to initial setup, the insturment can be more closely matched to the application by modifying other transducer block parameters. Access to these parameters is described in Set Digital Valve Controller Configuration Parameters in this appendix. You can also calibrate the instrument using the methods described in the Calibration section. Access to these methods is described in Calibrating the Digital Valve Controller in this appendix. If you know the instrument has been setup correctly (for example, the instrument was mounted on the valvelactuator assembly at the factory), you can proceed to Configuring the Loop. Otherwise calibrate the instrument as described in Calibrating the Digital Valve Controller in this appendix and in the Calibration section and perform the detailed setup as described in Set Digital Valve Controller Configuration Parameters in this appendix and in the Detailed Setup section. Then proceed to Configuring the Loop.
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Stabilizing and Optimizing Valve Response

You can invoke the Stabilize/Optimize method from the Setup Wizard, or refer to figure G-2 and the following steps to access and start the Stabilize/Optimize method:
1. Start DeltaV Explorer by selecting DeltaV > Engineering > DeltaV Explorer from the Start menu. 2. Locate the digital valve controller icon in the All Containers pane and left-click once on the digital valve controller icon or name.
G-2
Operation with Fisher-Rosemount@ DeltaV'"

Transducer Block
Icon and Name
Digital Valve CcontrollerIcon and Name
Context Menu
Figure G-2. Navgating to the StabilizelOptimizeMethod
Configuring the Loop

To completely configure the digital valve controller for use in a fieldbus loop, you must perform the following procedures:
1. Create a device place holder-A place holder is an electronic representation of the digital valve controller that exists in the DeltaV database with no associated physical device.
Note
The following procedures assume that the DeltaV system and the digital valve controller are installed and powered.
2. Define a control strategy-The control strategy is the relationship between all of the function blocks on the fieldbus segment.
3. Commission the device-Commissioning the device involves downloading applicable parameters from the device place holder to the physical device.
4. Set the digital valve controller block parameters-Setting the digital valve controller block parameters sets up the digital valve controller for use in your specific application. 5. Download the control strategy t o the device-Downloading the control strategy to the device transfers the control strategy from the DeltaV system to the digital valve controller.
Create a Device Place Holder

1. Start DeltaV Explorer by selecting DeltaV > Engineering > DeltaV Explorer from the start menu. 2. Navigate through the file structure to the listing of fieldbus ports (see figure G-3).
3. Right click on the port to which you wish to connect the new fieldbus device and select New Fieldbus Device from the menu that appears. The Fieldbus Device Properties dialog box, shown in figure G-4, appears. 4. Enter all the appropriate device information in the dialog box.
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G-3
DVC5000f Series
Define the Control Strategy
1. Start DeltaV Control Studio by selecting DeltaV > Engineering > Control Studio from the Start menu.
2. Refer to figure G-5. From the menu along the right side of the window, select the function blocks you wish to add. For the purpose of this example, we will add an Al, a PID, and an A 0 block.
3. Connect the blocks as you want them to execute. For the purpose of this example, we connected the blocks as shown in figure G-6.
@$ Note
If you are not able t o draw connections between the blocks, select the Connect button and try again.
Figure G-3. Location of Fieldbus Ports
4. To rename the block with an appropriate tag, right click on each block and select Rename from the menu that appears. 5. To assign the I/O to a fieldbus device, right click on each block and select Assign 1 1 0 > t o Fieldbus... and enter the device block in the dialog box that appears (see figure G-7). Select Browse to select the device block to which you wish to assign each control block. You will have to navigate through the correct controller, I/O card, and port to reach the device and its blocks.
6. Save the control strategy.

7. To assign the strategy to the correct node in the controller, select the Assign to Node button.
Commission the Device

Figure G-4. Fieldbus Device Properties Dialog Box
To commission the digital valve controller, you simply need to drag the appropriate device from the Decommissioned Fieldbus Device folder to the appropriate device place holder.
1. Start DeltaV Explorer by selecting DeltaV > Engineering > DeltaV Explorer from the Start menu.
The DeltaV system automatically completes the address field. You can customize these fields, but it usually is not necessary. Select the device type and device revision based upon the digital valve controllers t o be used.
2. Select the device you wish to commission from the Decommissioned Fieldbus Devices folder. The device will be listed with its unique device identifier (Dev ID).
3. Drag the decommissioned device to the device place holder that you created earlier (see figure G-8). The Device Commissioning Wizard-Start window shown in figure G-9 appears. 4. Select Next. The Device Commissioning Wizard-Reconcile Block window for the resource block, shown in figure G-10, appears.
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5. Select OK to add the device to the segment. The device appears on the segment as a non-commissioned fieldbus device.
G-4
Operation with Fisher-Rosemount@ DeltaV"
Figure G-5. Main Control Studio Screen
FY-IUIIFFAOS
Figure G-6. A Basic Control Strategy
Figure G-7. Assign to Fieldbus Dialog Box
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G-5
DVC5000f Series
igital Valve Controller Place Holder
=
'
is . 1
Figure G-8. Sampk Location of a Digital Valve Controller place holder In DeltaV Explorer
window for the Resource Block
Figure G-9. Devke Commissioning Wizard Start window
Figure G-77. Device Commissioning Wizard--Reconcile Block Window for the Transducer Block
Note
If you wish to reconcile differences between the Resource block in the digital valve controller and the Resource block in the device place holder that you created, select Reconcile Block. If you wish to override the settings in the device place holder with the settings in the device, go to step 5.
Note
If you wish to reconcile differences between the Transducer block in the digital valve controller and the Transducer block in the device place holder that you created, select Reconcile Block. If you wish to override the settings in the device place holder with the settings in the device, go to step 6.
5. Select Next. The Device Commissioning Wizard-Reconcile Block window for the transducer block, shown in figure G-I 1, appears.
6. Select Next. The Device Commissioning Wizard-Finish window shown in figure G-I 2 appears.
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G-6
ODeration with Fisher-Rosemount@ DeltaV TM
CommissionedDigital Valve Controller
Figure G-12. Device Commissioning Wizard-Finish
Wndow
, ,
- a::
Figure G-14. Sample Location of a C&misioned Digital Valve Controller in DeltaV Explorer
Figure G-15. List of Function Blocks for a Digital Valve Controller in DeltaV Explorer
following steps to access and start the Data Protection method.

Figure G-13. Device Commissioning Wizard-Waiting Wndow
1. Start DeltaV Explorer by selecting DeltaV > Engineering > DeltaV Explorer from the Start menu. 2. Navigate through the file structure to find the digital valve controller you wish to configure (see figure
7. Select Finish. The window shown in figure G-I 3 appears informing you that DeltaV is waiting for the device to change from a decommissioned ( $ r > )to a commissioned ( 5 t *:-)state. This process may take several minutes. Once the DeltaV finishes commissioning the device, the icon in DeltaV Explorer changes from non-commissioned to commissioned.
i
G-14).
3. Double click the digital valve controller. The function blocks within the digital valve controller appear in the right pane of the DeltaV Explorer window (see figure G-15). Right-click once on the block icon or name.
Set Digital Valve Controller Configuration Parameters

Changing the Transducer Block Protection
Modifying some of the transducer block parameters requires changing the block protection. For information on the block protection required to change a parmeter, see table 4-1 in the Detailed Setup section or table 6-1 in the Viewing Device Information section. The Data Protection method is available to change the transducer block parameter protection. For a detailed description of this method, see Data Protection in the Detailed Setup section. Refer to figure G-16 and the
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4. Select Data Protection from the context menu.

5. Follow the on-screen instructions to change transducer block parameter protection.
Changing the Transducer Block Mode

Modifying some of the transducer block parameters requires changing the block mode to Out of Service (O/S). For information on which parmeters require the block mode to be Out of Service, see table 4-1 in the Detailed Setup section or the individual parameter descriptions in sections 4, 5, 6, and 8. Perform the following procedure to change the block mode. 1. Start DeltaV Explorer by selecting DeltaV > Engineering > DeltaV Explorer from the Start menu.
G-7
DVC5000f Series
Transducer Block
Icon and
Context Menu
Digital Valve Ccontroller Icon and Name
Figure G-16. Navigating to the Data Protection Method
Figure G-18. Transducer Block Modify Parameters Warning
@ $ I
Figure G-I 7. Transducer Block Properties Window
Note
2. Double click on the TRANSDUCER block icon. The transducer block properties window shown in figure G-17 appears.
3. Select the Mode tab.
As shown in figure G-18, DeltaV warns you that whenever you make changes to transducer block parameters the changes you make may upset the process and create a dangerous situatuation. Before you click OK,verify that the control loop is in manual control.
4. Select Out of Service (OIS) and deselect Auto in the Target Mode region of the window. The mode you change in the properties window remains highlighted as in figure G-17 so you can easily track changes.
5. Click the Apply button.
Once the requested change is made, DeltaV warns you, as shown in figure G-19. that the control system does not match the device configuration and that the changes you made may change the device output. To avoid bumping the process, check the device output
September 2000
G-8
Operation with Fisher-Rosemount@ DeltaV

avoid bumping the process, check the device output before placing the control loop in Auto. Click OK to close the properties page.
Download the Control Strategy to the Device

1. Select DeltaV > Engineering > Control Studio from the Start menu. The main control studio window shown in figure G-5 appears.
Figure G-19. Transducer Block Modify Parameters Warning
2. Open the control strategy that you defined earlier.
before placing the control loop in Auto. Click OK to return to the properties page.
3. Click the Download button ( 2and ) follow the on-line instructions to download the control strategy to the digital valve controller,
Modifying Transducer Block Parameters

1. If you just changed the transducer block mode, the properties window should be displayed. Skip to step 5. If the properties window is not being displayed, go to step 2.
2. Locate the icon for the digital valve controller you wish to configure in the DeltaV Explorer All Containers pane. Left-click once on the digital valve controller icon or name.
3. Locate the transducer block icon in the Contents of... pane and right-click once on the block icon or name.
Calibrating the Digital Valve Controller

The following methods are included with the device description for calibrating the Instrument:
0 Auto Travel Calibration-Use this method to automatically calibrate the instrument travel. It is provided as an independent method and is also a part of the Setup Wizard. 0 Manual Calibration-Use this method to manually calibrate the instrument travel. 0 Cal Tvl Sensor-Use this method to calibrate the travel sensor when the instrument is mounted on a competitive actuator or when the travel sensor is replaced. 0 Pressure Sensor Cal-Use this method to calibrate the internal pressure sensor information for display to the user.
0 StorelRestore Data-Use this method to restore factory configuration data or to store and restore field configuration data.
4. Double click on the TRANSDUCER block icon. The transducer block properties window shown in figure G-I 7 appears.
5. Select the parameter you wish to configure and

enter the appropriate changes. The parameters you change in the properties window remain highlighted so you can easily track changes. 6. After making all the desired changes, click the OK button.
Note
A detailed description of these methods is found in Section 5, Calibration. Refer to figure G-20 and the steps below to access the calibration methods.
As shown in figure G-18, DeltaV warns you that whenever you make changes to transducer block parameters the changes you make may upset the process and create a dangerous situatuation. Before you click OK, verify that the control loop is in manual control.
1. Select DeltaV > Engineering > DeltaV Explorer from the Start menu. 2. Locate the diaital valve controller icon in the All Containers winiow and left-click once on the digital valve controller icon or name.
3. Locate the transducer block icon in the Contents of... window and right-click once on the block icon or name.
4. Select Calibrate from the context menu.
Once the requested changes are made, DeltaV warns you, as shown in figure G-I 9, that the control system does not match the device configuration and that the changes you made may change the device output. To
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5. Select the desired calibration method from the drop-down menu.
G-9
DVC5000f Series
Transducer Block
Icon and Name
Drop-Down Menu
Context Menu
Figure G-20. Navigating to the Calibration Methods
6. Follow the on-screen instructions to perform the desired calibration.
G-10
September 2000
BIock Parameter Index
Appendix H
Block Parameter Index

BLOCK-ERR A 0 Block, B4 DO Block, E4 DI Block, D4 PID Block, C6 Transducer Block, 6-8
The following is an alphabetical list of the parameter names for the block parameters as listed in the device description (DD). Each parameter name is followed by a page number reference where a detailed description of the parameter can be found.
ACT-CODE, 4-7 ACT-FA1 L-ACTION, 4-7 ACT-MAN-ID, 4-7 ACT-MODEL-N UM, 4-7 ACT-SN, 4-7 AD-READBACK, 8-3 ALARM-HYS, C8 ALERT-KEY A 0 Block, B3 DI Block, D3 DO Block, E2 PID Block, C3 Resource Block, 4-5, 6-3 Transducer Block, 4-12 ALGO-GAIN, 4-9
C
CALI BRATE-STATUS, 8-5 CAS-IN A 0 Block, B I , B4, 85, B6 PID Block, C5, C6 CAS-IN-D, DO Block, E l , E5 CHANNEL DI Block, D I , D4 DO Block, E l CLR-FSTATE, 6-4 CONFIRM-TIME, 6-5 CONTROL-OPTS, C5 CROSSOVER, 8-3 CYCLE-COUNT, 4-1 5, 6-6
B
BKCAL- IN A 0 Block, B I , B3, B6 PID Block, C5, C6, C8, C9 BKCAL-OUT A 0 Block, B I , B6, C8 PID Block, C5, C9 BKCAL-OUT-D, DO Block, E3, E5
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DD-REV, 6-3 DEV-REV, 6-3 DEV-TYPE, 6-3 DIAG-CAL-REV, 6-6 DISC-LIM, DI Block, D4 DV-HI-LIM, C7 DV-HI-PRI, C8 DV-LO-LIM, C7
H-I
DVC5000f Series
DV-LO-PRI, C8
G
GAIN, C1, C8
E
ELECT-REV-NO, 6-6 ELECT-TEMP, 6-6
H
HARD-TYPES, 6-3 HI-HI-LIM, C7 HI-HI-PRI, C8
F
FACTORY-SN, 4-6 FAULT-STATE, 6-4 FEATURE-SEL, 6-5 FEEDBACK-HI, 8-3 FEEDBACK-LINEARIZATION, 4-8 FEEDBACK-LO, 8-5 FEEDBAC K- ROTAT I 0N, 4-8 FF-GAIN, C2, C9 FF-SCALE, C2, C9 FF-VAL, C2, C9 FIELD-SN, 4-6 FIELD-VAL-D, DI Block, D4 FINAL-POS ITION-VALUE, 6-6 FI NA L-VA LUE-CUT0 FF- HI, 4- 12 FINAL-VALUE-CUTOFF-LO, 4-1 2 FIRMWARE-DATE, 8-5 FLOW-CHARACT, 4-1 0 FORM, C1 FREE-SPACE, 6-3 FREE-TIME, 6-3 FSTATE-TIME, B4 DO Block, E4 FSTATE-VAL, B4 FSTATE-VAL-D, DO Block, E4
HI-LIM, C7 HI-PRI, C8
1
I/O-OPTS, D Bloc,., D4 INST-MODEL-CODE, 6-6 10-OPTS, B1, 84, B6 DO Block, E4 IP-FB, 8-5
LIM-NOTIFY, 6-5 LO-LIM, C7 LO-LO-LIM, C7 LO-LO-PRI, C8 LO-PRI, C8
MANUFAC-ID, 6-3 MAX-NOTIFY, 6-5

MEMORY-S IZE, 6-3
MESSAGEI, 4-7
MIN-CY CLE-T, 6-3
NV-CYCLE-T, 6-3
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H-2
Block Parameter Index

NVM-WRITES, 6-6 READBACK, A 0 Block, B1 READBACK-D, DO Block, E l , E3, E6 RESET, C1, C8 RESTART, 6-4 OUT A 0 Block, B1, B4, B5, B6 PID Block, C5 OUT-D DI Block, D1, D4 DO Block, E l , E4 OUT-HI-LIM, C5 OUT-LO-LIM, C5 OUT-SCALE, C2, C5 ROUT-IN, C6 RS-STATE, 6-4
S
S-VAR-2, 6-6 SELFTEST-STATUS DI Block, D4 DO Block, E4 Transducer Block, 6-8
SERVO-ALARM-CYCLE-COUNT, 4-1 5 SERVO-ALARM-DRIVE-SIGNAL,
P
P-COUNT, 8-5 P-STATUS, 8-5 PRESSURE, 6-6 PRESSURE-SCALE, 8-5
PRESSURE-UNITS.CAL-UNITS,
8-5
SERVO-ALARM-I P-FB, 8-6

SERVO-ALARM-OUTBLK-TIMEOUT, 4-1 5
SERVO-ALARM-PRIORITY, 4-12, 8-5 8-5 SERVO-ALARM-SUMMARY, 4-12, 6-7 SERVO-ALARM-TEM P-HI, 4-15 SERVO-ALARM-TEMP-LO, 4-1 5
S ERVO-ALARM-TRAVEL-ACCUM .THR ESHOLD, 4-14
PRESSURE- UNITS.RB- UNITS, 4-7 PV A 0 Block, B1, 84, B5, B6 PID Block, C5, C6, C7, C8 PV- D DI Block, D1, D4 DO Block, E l , E5, E6 PV-FTI ME DI Block, D4 PID Block, C2 PV-SCALE, B1, B6
SERVO-ALARM-TRAVEL-DEV, 4-14 SERVO-ALARM-TRAVEL-HI, SERVO-ALARM-TRAVEL-LO, SERVO-GAIN, 4-9 SERVO-RATE, 4-9 SERVO-STD-GAI N, 4-9
S ERVO-STD- RATE, 4-9
4-13 4-13 4-1 3 4-14
SERVO-ALARM-TRAVEL-HI-HI, SERVO-ALARM-TRAVEL-LO-LO,
R
RATE, C1, C8 RCAS- IN A 0 Block, B I , B 5 PID Block, C6 RCAS-IN-D, DO Block, E l
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SET-FSTATE, 6-4 SHED-OPT, B6 A 0 Block, 85 DO Block, E4 PID Block, C6
H-3
DVC5000f Series
SHED-RCAS, 6-4 SHED-ROUT, 6-4 SIMULATE, A 0 Block, B4 S IMULATE-D DI Block, D I , D4 DO Block, E3 SP A 0 Block, B1, B3, B4, 85, B6 PID Block, C5, C6, C7, C8 SP-D, DO Block, E l SP-FTIME, C2 S P- H I-LI M A 0 Block, B1 PID Block, C1 S P-LO-LI M A 0 Block, B1 PID Block, C1 SP-RATE-DN A 0 Block, B1 PID Block, C1 SP-RATE-UP A 0 Block, B1 PID Block, C1 SP-WRK, PID Block, C5 STRATEGY A 0 Block, B3 DI Block, D3 DO Block, E2 PID Block, C5 Resource Block, 4-5, 6-4 Transducer Block, 4-6 STRUCTURE, C6 XD-CAL-DATE, 4-7 USER-CHAR, 4-10 DI Block, D3 DO Block, E2 PID Block, C5 Resource Block, 4-4, 6-3 Transducer Block, 4-6 TRAVEL-ACCUM, 4-14, 6-6 TRK-IN-D, C5 TRK-SCALE, C5 TRK-VAL, C5, C6
v
VALVE- MAN- ID, 4-8 VALVE-M 0DEL- NUM, 4-8 VALVE-SN, 4-8 VALVE-TYPE, 4-8 VOLTAGE-REF, 8-5
WRITE-LOCK, 6-4 WRITE-PRI, 6-5
T
TAG- DESC A 0 Block, B3
XD-CAL-LOC, 4-7 XD-CAL-WHO, 4-7 XD-ERROR, 6-8
H-4
September 2000
Glossary
Glossary
Algorithm
A set of logical steps to solve a problem or accomplish a task. A computer program contains one or more algorithms.
Controller
A device that operates automatically to regulate a
controlled variable.
Crossover Point Alphanumeric

Consisting of letters and numbers. 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.
ANSI (acronym)
The acronym ANSI stands for the American National Standards Institute
Deadband
Region around a reference point that must be exceeded before a new event occurs.
ANSI Class
Valve pressure/temperature rating.
Deviation
Usually, the difference between set point and process variable. More generally, any departure from a desired or expected value or pattern.
Bench Set
Pressure, supplied to an actuator, required to drive the actuator through rated valve travel. Expressed in pounds per square inch.
Device ID
Unique identifier embedded in the instrument at the factory.
Byte
A unit of binary digits (bits). Usually a byte consists of eight bits.
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%.
Configuration
Stored instructions and operating parameters for a FIELDVUE Instrument.
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.
September 2000
Feedback Arm
The mechanical connection between the valve stem linkage and the FIELDVUE Instrument travel sensor.
Feedback Signal
Indicates to the instrument the actual Dosition 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.
Glossary
Glossary-I
DVC5000f Series
Firmware
The combination of a hardware device and computer instructions and data that reside as read-only software on that device.
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).
Non-Volatile Memory (NVM)
@ h
Note
1. This term (firmware) is sometimes used to refer only to the hardware device or only to the computer instructions or data, but these meanings are deprecated.
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 restart data.
2. The confusion surrounding this term has led some to suggest that it be avoided altogether. The term i s included here because of its use in older documentation and culture.
Octet
See byte
Parallel
Simultaneous: said of data transmission on two or more channels at the same time.
Gain
The ratio of output change to input change.
Pressure Sensor
A FIELDVUE instrument internal device that senses the output pressure from the pneumatic relay.
Hardware Revision
Revision number of the Fisher Controls instrument hardware. The physical components of the instrument are defined as the hardware.
Random Access Memory (RAM)

A type of semiconductor memory that is normally used by the microp'rocessor during normal operation that permits rapid retrieval and storage of programs and data. See also Read Only Memory (ROM) and Non-Volatile Memory (NVM).
HART (acronym)
The acronym HART stands for Highway Addressable Remote Transducer.
Rate
Amount of change in output proportional to the rate of change in input.
Instrument Level
Determines the functions available for the instrument.
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.
Leak Class
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).
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.
a
Glossary
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.
Software
Computer programs, procedures, and possibly associated documentation and data pertaining to the operation of a computer system.
September 2000
Glossary-2
Glossary
Temperature Sensor
A device within the FIELDVUE instrument that measures the instruments internal temperature.
Tuning
The adjustment of control terms or parameter values to produce a desired control effect.
Travel
Movement of the valve stem or shaft which changes the amount the valve is open or closed.
Tuning Set
Preset values that identify gain and rate settings for a FIELDVUE instrument. The tuning set and supply pressure together determine an instruments response to input signal changes.
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.
Watch Dog Timer

A timer that the microprocessor must pulse periodically. If the microprocessor is unable to pulse the timer, the instrument shuts down.
LIB
Glossary
September 2000
Glossary-3
DVC5000f Series
@B
Notes
c1
Glossary
Glossary-4
September 2000
Index
Index
A
Actuator Pressure, Viewing Value, 6-6 Address Field, DeltaV, G4 Addressing, 3-2, A3 Alarm Detection, DI Block, D4 Alerts Definition, A3 Enabling Alert Reporting, 4-12 Setting Alert Deadband Travel Accumulator, 4-14 Travel Alerts, 4-13 Travel Deviation Alert, 4-14 Setting Alert Points Cycle Counter Alert, 4-15 Drive Signal, 8-6 I/P Feedback, 8-6 Temperature Alert, 4-1 5 Travel Accumulator Alert, 4-14 Travel Alerts, 4-13 Travel Deviation Alert, 4-14 Setting Alert Time Drive Signal, 8-6 I/P Feedback, 8-6 Travel Deviation Alert, 4-14 Setting Priority, 4-12 Viewing Alert Status, 6-7 Analog Output (AO) Block, B1 Action on Fault Detection, B4 Diagram, B1 I/O Options, 84 Set Point Selection and Limiting, B1 Setting the Output, B1 Shed Options, B5 Simulation, B4 Status Handling, B6 Application Information A 0 Block, B6 DI Block, D5 DO Block, E6 PID Block, C8
September 2000
B
Block Error A 0 Block, 84 DI Block, D4 DO Block, E4 PID Block, C6 Transducer Block, 6-8 Block Initialization, DO Block, E l Block Mode, 4-2 Block Protection, 4-6 Bumpless Transfer, C5
C
Calibration Pressure Sensor, 5-4 Travel, 5-2 Travel Sensor, 8-1 5 with DeltaV, G9 Cascade Control, with Master and Slave Loops, c 9 Closed Loop Control, C8 Commissioning Tag, 2-18 Commissioning the Device, G4 Compel Data (CD), A3, A4 Connections Communication, 2-17 Fieldbus, 2-16 Pneumatic OUtpUt, 2-16 S ~ p p l y2-15 , Test, 2-17 Vent, 2-16 Control Strategy, defining in DeltaV, G4, G9 Crossover Auto Travel Calibration, 5-2 Manual Travel Calibration, 5-3 Cycle Counter Resetting, 4-15
Index-1
DVC50OOf Series
Setting Alert Point, 4-15 Setting Deadband, 4-15 Viewing Value, 6-6
F
Factory Instrument Serial Number, 4-6 Feedback Connection, 3-3, 4-8 Feedforward Calculation, C2 Control, C8 Field Instrument Serial Number, 4-6 Field Value Processing, DI Block, D4 Fixed Limit Switch, using the DI block as, D1 FOUNDATION Fieldbus Communication, Principle of Operation, 7-2 Function Blocks Definition, A1 Operation, A2 Scheduling, A6
D
Decommissioned Device, G4 DeltaV, Operating the device with, G I Device Description (DD) Description, 1-3, A2 Installation, F1 Device Place Holder, Creating, G3 Direct Action, C6 Discrete Input (DI) Block, D1 Action on Failure, D5 Alarm Detection, D4 Block Initialization, D4 Diagram, D1 Field Value Processing, D4 Fixed Limit Switch, D1 I/O Selection, D1 Simulation, D4 Status Handling, D5 Valve Position Proximity Detection, D2 Variable Limit Switch, D1 Discrete Output (DO) Block, E l Action on Fault Detection, E4 Block Initialization, E l Diagram, El I/O Selection, E l Setting the Output, E l Shed Options, E4 Simulation, E3 Status Handling, E5 Dribble Control, E6 Drive Signal Setting Alert Point, 8-6 Setting Alert Time, 8-6 Viewing Value, 6-6 DVC5000f Series Description, 1-2 Principle of Operation, 7-2 Specifications, 1-5
Gauges, Tire Valves, & Pipe Plugs Parts List, 9-3 Replacing, 8-10
1
I/O Options, A 0 Block, B4
I/O Selection
DI Block, D1 DO Block, E l I/P Converter Parts List, 9-2 Removing, 8-8 Replacing, 8-9 Replacing the Filter, 8-8 Initial Setup Setup Wizard, 3-2 Stabilize/Optimize, 3-6 Input Characteristic, 4-10 Internal Temperature Setting Alert Points, 4-15 Viewing Value, 6-6
1
E
ESD, E6 LAS, A3 Limiting Output, PID Block, C5
September 2000
Index-2
Index
Set Point A 0 Block, B1 PID Block, C1 Link Active Scheduler, A3 Live List, Definition, A3 Loop Schematics CSA, 10-1 FM. 10-2 Parts Cam, 9-5 Common Parts, 9-2 Feedback Parts, 9-3 Gauges, Tire Valves, & Pipe Plugs, 9-3 I/P Assembly, 9-2 Kits, 9-2 Module Base, 9-2 Mounting Parts DVC50 1Of, 9-3 DVC5020f, 9-4 DVC5030f On Fisher Actuators, 9-4 On Other Actuators, 9-5 Filter Regulator, 9-5 Ordering, 9-2 Printed Wiring Board Assembly, 9-3 Relay, 9-3 Terminal Box, 9-3 Pass Token (PT), A3, A4 PID Block, C1 Alarm Detection, C7 Closed Loop Control, C8 Diagram, C1 Filtering, C2 Output Selection and Limiting, C5 Set Point Selection and Limiting, C1 Shed Options, C6 Status Handling, C8 Tracking, C5 Place Holder, Creating, G3 Pneumatic Relay Parts List, 9-3 Removing, 8-9 Replacing, 8-10 Pressure Units, 4-7 Printed Wiring Board Assembly Parts List, 9-3 Removing, 8-9 Replacing, 8-9 Proximity Detection, using the DI block for, D2 Publisher (P), A4
Macrocycle, A6 Master Module Parts List, 9-2 Removal, 8-6 Replacing, 8-7 Methods Description About DD, 1-4 Auto Travel Calibration, 5-2 Cal Tvl Sensor, 8-1 5 Data Protection, 4-6 Input Characterization, 4-9 Manual Calibration, 5-3 Pressure Sensor Cal, 5-4 Restart, 4-4 Setup Wizard, 3-2 StabilizelOptimize, 3-6 Store/Restore Data, 5-5 Stroke Valve, 8-3 Mounting, 2-2 67CFR, 2-15 DVC501Of on: 657 & 667, 2-2 Baumann Actuators, 2-4 Gulde Actuators, 2-5 DVC5020f on:, 1051 &1052,2-6 DVC5030f on: 1051 Size 30 to 60, 2-9 1051 Size 33, 2-8 1052 Size 20 & 33, 2-8 1052 Size 40 to 70, 2-9 Masoneilan Actuators, 2-1 1 Neles-Jamesbury Actuators, 2-12 DVC5040f on:, System 9000, 2-13
Output Block Time-out, 4-1 5

September 2000
Reconciling differences in DeltaV Resource Block, G4 Transducer Block, G6
Index-3
DVC5000f Series
Related Documents, 1-5 Resource Block, Definition, A2 Restarting the Instrument, 4-2 Reverse Action, C6 Terminal Box Parts List, 9-3 Removing, 8-10 Replacing, 8-10 Tracking, C5 Transducer Block, Definition, A2 Segment, Definition, A3 Serial Number Actuator, 4-7 Factory Instrument, 4-6 Field Instrument, 4-6 Instrument Nameplate, 4-6 Valve, 4-8 Set Point Selection and Limiting A 0 Block, B1 PID Block, C1 Setting the Output A 0 Block, B1 DO Block, E l Setup Wizard, 3-2 Accessing with DeltaV, G I Shed Options A 0 Block, B5 DO Block, E4 PID Block, C6 Simulate Jumper, 2-17 Simulation A 0 Block, B4 DI Block, D4 DO Block, E3 Stabilize/Optimize, 3-6 Accessing with DeltaV, G2 Status Handling A 0 Block, B6 DI Block, D5 DO Block, E5 PID Block, C8 Storing and Restoring Data, 5-5 Stroking the Output, 8-3 Subscriber (S), A4 System Management, A l , A3 Travel Accumulator Resetting, 4-14 Setting Alert Deadband, 4-14 Setting Alert Point, 4-14 Viewing Value, 6-6 Travel Cutoffs, 4-12 Travel Sensor Adjustment using Cal Tvl Sensor method DVC5010f, 8-15 DVC5020f, 8-16 DVC5030f, 8-15 DVC5040f, 8-1 5 with a multimeter DVC5010f, 8-12 DVC5020f, 8-14 DVC5030f, 8-14 DVC5040f, 8-12 Parts List, 9-3 Removing OVC501Of, 8-11 DVC5020f, 8-1 1 DVC5030f, 8-12 DVC5040f, 8-1 1 Replacing DVC501Of, 8-12 DVC5020f, 8-13 DVC5030f, 8-14 DVC5040f, 8-12 Travel Sensor Motion, 3-4, 4-8 Troubleshooting, 8-3
v
Variable Limit Switch, using the DI block as, D1 Voltage Available, Checking, 8-6
Index-4
September 2000
Thrs proaxt m y oe covered by one or more of the fo.,owing patents (5,451,923, 5 434.774. 5,439,021. 5.265.637)or under pending patent applicabons.
PlanlWeo FIELDVJE. VaiveLnr. F.sner. Feher-Rosemount, and Managing The Process Bener are mams owned by Fisner Controls International. Inc. or Ffsner-Rosemount Systems. Inc dART s a mark ownea oy tne tiART Communcations Foundation FOUNDATION C e ab,s 1 s a maw owned ~y the F eldbbs Foundauon PJ Other marc. are me properly of tne.r respective owners 5Fisner Controls International. Inc. 1999, 2000; All Rignts Reserve0 The wnfems ol mts pu&cam are presentedfor infonnauonal purposesonty, and h i k every effort has been made to ensure Ben accuracy, mey are m 10 be m m d as warranks o r guarantees,express or mpled. regarding the p r c d m M s e ~ c e s d m M nerem or ther use or apphcabildy. We r e s m the ngm to mcddy or lmpmve Me designs or specnk'abons d such produds at any bme wlfhou( n m e . For infornabon, contact Fisher : Marshalltown, Iowa 50158 USA Cernay 68700 France Sao Paulo 05424 Brazil Singapore 128461
FISHER")
,esycled paper
Printed in U.S.A.
mC J
FISHER-ROSEMOUNT'
Masoneilan is a registered trademark of Dresser Industries Inc., A Halliburton Company SVI is a registered trademark of Dresser Industries, Inc. ValVue is a trademark of Dresser Industries, Inc. HART is a registered trademark of the Hart Foundation Pentium is a trademark of Intel Corporation Copyright 1999 by Dresser Equipment Group, Inc. All rights reserved
TABLE OF CONTENTS Chapter 1 .Overview
...........................................
Scopeof Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVI Features and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Safety Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hardware Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 2 4 5 9 12 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Pushbutton Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 EPC (Electropneumatic Converter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SpoolValve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Sensors (Position, Pressure and Temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SVI Inputs/Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I . . . . . . . . . . . . .15 System Description-Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 System Description- PID Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 2
.Mounting
...........................................
20
20 23 .23 26 29 31 32 35 35 35 38 39 39 39 39 40
40
Standard Rotary Valve Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standa rd Rec ip rocat ing Va Ive Mo u nt i ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting the SVI on Masoneilan 87/88 Multi-Spring actuators . . . . . . . . . . . . . . . . . . Mounting the SVI on other Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lever and Linkage Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pneumatic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazardous Area Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Factory Mutual approved model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CSA (Canadian Standards Association) approved model . . . . . . . . . . . . . . . . . . . . . . . CENELEC Approved Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVIlnterconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Positioner or Controller with HART Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Impedance Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Noise Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interference with DCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cabling and Interconnection Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Split Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 41
Chapter 3 .Operation .SVI Positioner
.............................
42
42 42 46 46 47 48 49
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pushbuttons/Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NORMAL OPERATE Mode and Manual Mode Menus . . . . . . . . . . . . . . . . . . . . . . . . . Configure Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibrate Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ExamineMenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Operation .Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 51 Parameters and Options Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Local Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Return to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Examine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ! . . . . . . . . . . . . .54 Functions . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Examine Calibration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Examine Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Display/Clear FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Positioner Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
m
Chapter 4
- Operation-SVI Controller ..............................
58
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Pushbuttons/Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Menustructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Normal Operate Mode and Manual Mode Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Configure Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Calibrate Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Controller Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Examine Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Parameter and Message Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Normal Operation - Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Parameters and Options Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Controller Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Local Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Return to Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Examine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Examine Calibration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Examine Configuration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Display/Clea r FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Controller Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Operation - SVI Positioner / Controller using HART Handheld Communicator . . . . . . . . . . .76 Operation - SVI Positioner / Controller using ValVue Software . . . . . . . . . . . . . . . . . . . . . . 76
Chapter 5 -Troubleshooting
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77
77 77 77 78
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Factory Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pneumatic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Verifying Supply Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 80 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Verify Wiring and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Ground Practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 83 HARTCompliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power-oncheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 .84-85 Troubleshooting Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Valve Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 . Confirming Configuration, Setup. Calibration. and Limit Stops . . . . . . . . . . . . . . . . . . . . . 86 Initiate Valve Movement (50%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 .I. . . . . . . . . . . . .87 Initiate Valve Movement (95%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fail-safe Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 AutoTune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 AutoTune Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 .,. . . . . . . . . . . . . 90 Auto Tune Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Damping Coefficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 II Unacceptable Response Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Position Instability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 . . Oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Limit Cycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 92 BiasAdjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bias Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 SpoolValve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 HART Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Setup and Administration Communication Port and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Use of Laptop Computers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Mouselnterference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Hand Held Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Failure to Communicate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Fatal and Non-Fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Fatal Errors: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Non-fatal Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
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Diagrams
Figure 1. Figure 2 . Figure 3 . Figure 3a . Figure 4 . Figure 5 . Figure 6 . Figure 7 . Figure 8 . Figure 9 . Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Smart Valvelnterface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Block Diagram of SVI Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Block Diagram of SVI Controller/Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SVI Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Input/Output Diagram of SVI Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 System Diagram - Intrinsically Safe Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 16 System Diagram - Explosionproof (Flameproof) Installation . . . . . . . . . . . . . . . . . 16 Single Loop PID Configuration with No Process Feedback . . . . . . . . . . . . . . . . . .17 Single Loop PID Configuration with Process Feedback . . . . . . . . . . . . . . . . . . . . . 17 Intrinsically Safe Single Loop PID Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Local Set with Voltage Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Local Set with Voltage Source-Two Leads to Field . . . . . . . . . . . . . . . . . . . . . . . . 19 SVI Rotary Mounting Bracket with Valve Side Lever on Camflex Valves . . . . . . . .21 SVI Rotary Mounting Bracket with Valve Side Lever on Ball and Butterfly Valves .21 Orientation of SVI Lever and SVI Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 15. Figure 16. Figure 17. Figure 19. Figure 18. Figure 20 . Figure 21 . Figure 21a . Figure 22 . Figure 23 . Figure 24 . Figure 24a . Figure 24b . Figure 25 . Figure 26 . Figure 27 . Figure 28 . Figure 29 . Figure 30. Figure 30a . Figure 30b. Figure 31 . Figure 32 . Figure 33 . Figure 34 . Figure 35 . Figure 36 . Figure 36a. Figure 36b. Figure 37 . Figure 38 . Figure 39. Figure 40 . Figure 41 . Figure 42 . Figure 43 . Figure 44 . Figure 44a . Figure 45 .
SVI Mounting on Rotary Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Top View of SVI Mounted on a Reciprocating Valve . . . . . . . . . . . . . . . . . . . . . . . 23 SVI Lever for 87/88 Multi-Spring Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Side View of SVI Mounted on a Reciprocating Valve . . . . . . . . . . . . . . . . . . . . . . . 25 SVI Mounting Bracket for 87/88 Multi-Spring Actuator . . . . . . . . . . . . . . . . . . . . . . 25 Typical SVI Mounting on 37/38 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Typical SVI Mounting on 84/85 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Smart Valve Interface Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 SVI Mounting Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 SVI Lever Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Electrical Connections to Main Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Electrical Connections to Main Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . 33 General Area Purpose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Approved Intrinsically Safe Installation Control Drawing . . . . . . . . . . . . . . . . . . . . 36 Impedance vs Frequency for Typical Current Source . . . . . . . . . . . . . . . . . . . . . . 39 Resistor Add in Series with Current Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Split Range - Active Barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Compliance Voltage Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Local Display and Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . ............. 42 Pushbutton Guide for SVI Version 1.0.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Pushbutton Guide for SVI Version 1.0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 NORMAL OPERATE, MODE SELECT, and MANUAL Menu Structures . . . . . . . . .46 CONFIGURE Menu Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 CALIBRATE Menu Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 EXAMINE Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Parameter and Message Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Local Display and Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Hand Held Communicator Guide for SVI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Pushbutton Guide for SVI Version 1.0.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Normal Operate, Mode Select, and Manual Mode Menus . . . . . . . . . . . . . . . . . . .62 Configure Menu Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Calibrate Menu Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Controller Menu Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Examine Menu Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Parameter and Message Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Exhaust, Actuator and Air Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Wiring Connections - 1999 Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Pilot Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Table 1. Table 2 . Table 3 . Table 4 . Table 5. Table 6 . Table 7. Table 8 . Table 9 .
Tables
Performance Specifications (Positioner Mode Only) . . . . . . . . . . . . . . . . . . . . . . . . Electrical Safety Design Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVI Lever Hole Locations for 87/88 Multi-Spring Actuator . . . . . . . . . . . . . . . . . . . . . Recommended Lever Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Linkage Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Positioner Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 9 24 29 30 51 56-57 68 .74-75
IV
Use of DANGER, WARNING, CAUTION, a n d NOTE.

These instructions contain DANGER, WARNING, CAUTION, and NOTE where necessary to alert you to safety related or other important information.
DANGER WARNING CAUTION NOTE
Hazards which result in severe personal injury or death. Hazards which could result in personal injury. Hazards which could result in equipment or property damage Alerts you to pertinent facts and conditions
Although DANGER and WARNING hazards are related to personal injury, and the CAUTION hazards involve equipment or property damage, it should be understood that operation of damaged equipment could, unde certain operational conditions, result in degraded process system performance which may lead to persona injury or death. Therefore, comply fully with all DANGER, WARNING, and CAUTION notices.
IMPORTANT: SAFETY WARNING

Please read these instructions carefully BEFORE this instrument is installed or maintained. These positioners and controllers are intended for use with industrial compressed air systems only. Ensure that adequate pressure relief provision is installed if application of system supply pressure could cause downstream equipment to malfunction. Installation should be in accordance with local and national compressed air and instrumentation codes. Products certified for use in explosionproof / flameproof or intrinsically safe installations MUST: a) Be installed in accordance with local and national codes for hazardous area installations. Only be used in situations which comply with the certification conditions stated in this handbook. c) Only be maintained by qualified personnel with adequate training on hazardous area instrumentation.
Before using these products with fluids other than air or for non-industrial applications, consult Dresser Masoneilan. Not intended for use in life support systems. Items sold by Dresser Masoneilan are warrantied to be free from defects in materials and workmanship for a period of one year from the date of shipment, provided said items are used according to Dresser Masoneilans recommended usages. Dresser Masoneilan reserves the right to discontinue manufacture of any product or change product materials, design, or specifications without notice.
b)
Chapter 1 - Overview
Scope of Manual
This manual describes the procedures for installing,configuring, calibrating, operating and troubleshooting the MasoneiIanB Smart Valve Interface (SVP) Positioner and Controller. A companion software product, ValVueB, can be used to configure, calibrate, and perform valve diagnostics with the SVI from a remote Windows-based computer. In addition, SVI can be configured, calibrated and perform valve diagnostics with a HART hand-held communicator. I
Product Description
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The Smart Valve Interface, as shown in Figure 1, is a digital valve positioner and/or process controller that can be either configured, calibrated, and operated locally or remotely. Local functions are controlled by means of local pushbuttons and digital display. Remote operation requires the use of the ValVue product, or a hand-held unit loaded with the registered HART Device Description (DD). 1 The 'SVI controller version can also function as a single-loop PID controller which accepts standard inputs for process variable and set point. It positions the valve to achieve the desired value of the process variable. The Controller version can be configured as either a positioner or controller; however entering of some of the controller parameters requires use of either ValVue software or a HART protocol hand-held unit. ValVue, the software for remote communication of the SVI, runs on standard IBM-compatible computers such as 486 or Pentium. Minimum requirements are 4 MB RAM, Windows 3.1 or better, one available serial port with a HARTB modem, and a hard disk drive. The basic functions performed by ValVue are: Remote display of valve position, actuator pressure, set point, calibration parameters, con figuration parameters, and status/error indicators Remote calibration of the SVI Remote configuration of the SVI Remote operation of the SVI - Manual control of valve position - Perform valve diagnostics and display results (signature, friction, stroking speed, cumulative travel, cycles, and operation in near-closed position) - Recall previous test results for comparison with current data For more details on ValVue software, refer to the ValVue Users Manual. These remote functions can also be performed with a hand-held unit, however, the handheld unit cannot display graphical representation of the diagnostics.
Figure 7 .
Smart Valve Interface

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SVI Features and Functions

Precision valve positioning control Advanced valve diagnostics Automatic setup and tuning Local operation/calibration/configuration using optional explosionproof pushbuttons and digital display Two-way data communication using industry-standard HART protocol Remote operation/calibration/configuration/diagnostics using ValVue software or a HART hand-held I User-configurable tight shut off adjust ment Optional PID controller with remote set point and process variable input User-adjustable response times Direct or reverse acting operation Compatible with air-to-close or air-to-open actuators Span and zero configurable for split-range operation I Local operation functions include: - Calibrate valve stroke range, tight shutoff point, position limit stops - Display and/or set parameters for valve configuration - Select characterization (linear, equal percentage 50, equal percentage 30, quick opening, or custom) - Display/clear fault codes Display valve position Display faults Remote operation functions include all of the above plus: - Display totalized stem travel, number of valve cycles and other data useful for predicting valve life - Run valve diagnostics
Performance Spec if icat io ns

CAUTION: Table 1. Performance Specifications (Positioner Mode Only) Do not exceed operative limits. This may cause damage and/or performance of the positioner or controller.
Item
Positioner Inputs Split Range Capabilities
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Specification
4-20 mA signal input with HART prytocol. Programmable zero and span adjustments, 5 mA miniI mum span.
3.6 mA operating minimum.
Minimum Current for Operation Compliance Voltage

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12 volts maximum loop voltage drop in mA mode (typical 10.5 volts). HART 6 3 Communication protocol signal from ValVueB software on personal computer or from HART Hand-held Communicator. HART slave and burst modes multidrop, up to 5 loops with 20 volts minimum at SVI. 4 mA load at 20 volts. Nominally 1-5 volts or 4-20 mA with a 250 Ohm resistor. One seven character line of 14 segment alpha numeric. One six character line of 7 segment numeric. 22 segment bar graph.
Digital Communication
Controller (Process Variable) Input Local Display - Liquid Crystal (optional) Push Button Limit Switch Input Remote Position Sensing Accuracy Linearity (conformity ) Hysteresis Plus Deadband Actuator Pressure Measurement Accuracy Start-up Drift Long Term Drift Supply Pressure Air Delivery at 60 PSI Air Consumption
Three (3) explosionproof / flameproof push buttons. Two SPST with common. Cold contacts. Non isolated.
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10 K Ohms potentiometer.
Total accuracy 0.5% of span (typical 0.25%).

< 0.2% (typical 0.1 %).
< 0.2% of span (typical 0.1 Yo). < 0.3% of full scale.
Less than 0.02% during first hour. Less than 0.003% per month 20-100 psi (1.4 - 7 bar) 25 cubic meters / hour (15 SCFM) 0.4 cubic meters / hour (7SLPM)
5
Table 1, Performance Specifications (cont.)
Specification
- 40 C to 80' C - 45O
to
+ 93O c
~
I I 1 I
Temperature Effect Supply Pressure Effect Relative Humidity Humidity Effect
< 0.01% / degree C typical.
0.05% psi
0 to 100%
2
Insulation Resistance Fast Transient Burst Magnetic Field Connections: Pneumatic Electrical Enclosure Rating
Less than 0.2% after 2 days at 40' C, 95% RH. Greater than 10 G Ohms at 50% RH.
50 years based on MIL handbook calculation for electronic parts and field data on mechanical parts. Electrostatic discharge -- No effect with contact discharge level of 4KV and air discharge level of 8 KV (IEC 1000-4-2). Radio frequency interference -- Less than 0.2% at 10 volts per meter (EN 50140). No effect at 2 KV (Coupling clamp IEC 1000-4-4). Negligible at 30 A/m (EN61000-4-8). EC MARK certified to EN50081-2 and EN50082-2.
1/4 inch NPT Two (2) 1/2 inch NPT or M20
IP 65, NEMA 4X. Suitable for coastal environment, atmosphere with acids, atmosphere with dust (fly ash). Rotarv: 18 to 100 degrees (short travel version 9 - 50 degrees). Recimocatina: 12 to 64 mm, 0.5 to 4.5 inches. Short travel version 6 to 32 mm, 0.25 to 1.25 inches. Above 64 mm consult factory for mounting. Linear Equal percentage (50:l or 30:l) Quick opening (inverse of 50:l equal percentage) User configurable for 10 segments Tight Shut-off (0 - 20% of input)
Position Travel Limits
Flow Characterization
Table 1. Performance Specifications (cont.)
Item
Positioner Auto Tune
Spec if icat ion

SVI performs an automatic determination of the optimal valve position control parameters. In addition to P, I, D, the position algorithm uses damping, symmetry for exhaust and fill time constants, dead zone and magnitude characterization parameters. Auto Tune is optimized for 5% step changes with negligible overshoot. After the Autc Tune process is completed the user can further adjust the positioner tuning parameters to more ,conservative or to more responsive values to produce various dynamic response to the control signal. Proportional gain: Integral time: Derivative: Dead Zone: Padj: NL Coefficient: Damping: Full open position: * (if not at stop) 0 to 5000% 0 to 1000 seconds 0 to 200 seconds 0 to 1Yo (0 ti, 2% deadband) +/- 3000 (depends on P) -8 to -9 0 to 9 60 to 100%
Action
4
Instrument Air Vibration Limits Measured at the SVI Housing
Direct, increasing signal increases output. Reverse, increasing signal decreases output (software or hardware reversible).
Best performance is obtained with supply pressure regulated 5 to 10 psi higher than spring range of actuator. Air quality requirement per ISA S7.3.
4 mm at 5 to 15 Hz -- negligible. 2 G at 15 to 150 Hz -- less than 2% of span. 1 G at 150 to 2000 Hz -- less than 2% of span
5G
Timeout of hardware watchdog timer clamps output to fail. safe condition and initiates CPU reset. Timeout of software (microprocessor COP) watchdog timer initiates CPU reset. Pushbuttons include four levels of authorization. Level is set using ValVue or HART hand-held controller. ValVue includes six levels of authorization. Password pro tected.
Hi / Low limits (not latched) Deviation * time (not latched) Deviation time (latched, initiates failsafe) Failsafe Unread status messages
Table 1. Performance Specifications (cont.)
Item
Controller Alarms Process Controller Functions
Specification
~
Programmable Hi / Lo process alarms 0 to loo%, absolute or deviation Local setpoint, remote setpoint, manual. Ratio control with setpoint bias Local setpoint tracking. I
~~
Process Controller Settings
Output rate limit: Manual reset: Proportional gain: Integral time: Derivative time: Derivative gain: Gain non-linearity: Dead zone: Hi/lo set point limits:
0 to 61 Yo per sampling period. 0 to 90%. ! 0 to 1,OOO% 0 to 1,000 seconds 0 to 32 seconds 2t0100 I - 9 to 9 0 to 20% 25% above hi PV or below low PV.
Status Messages
POSITION ERROR PRESSURE ERROR POSITION SENSOR ERROR PRESSURE SENSOR ERROR CURRENT SENSOR ERROR REFERENCE VOLTAGE ERROR BIAS OUT OF RANGE SELF CHECK FAILURE HART ERROR SOFTWARE ERROR RESET OCCURRED DATA OVERRUN INTERNAL TEMP ERROR EEPROM W R ITE FA ILED FIND STOPS FAILED Friction (in units of pressure) Lo spring (in units of pressure) Hi spring (in units of pressure) Lo pressure (full exhaust) Hi pressure (full supply) Time to open Time to close Time open Time closed Time near closed Reversals (cycles) Tota I accumuI at ed stem t raveI
~~
Diagnostics Stored in SVI NonVolatile Memory (can be accessed using a HART Hand-held Communicator or ValVue Software).
I
Diagnostics Plots Using ValVue Position vs. time Stem position vs. actuator pressure Stem position vs. position setpoint Process, process setpoint, position, position setpoint vs. time (90 second window)
I
Electrical Safety Specifications

Table 2. Electrical Safety Design Specifications
Agency
Service
Applicable Class
Factory Mutual Approvals
CSA Approvals
CENELEC Approvals
Explosionp roof Dust -ign it ionp roof Intrinsically Safe Non-incendive Suitable for Enclosure Rating Explosionproof Dust -ign it ionp roof Intrinsically Safe Non-incendive Suitable for Enclosure Rating FIa meproof Intrinsic Safety Enclosure Rating
CE Conformity
Class I, Division 1. Groups 6, C, and D Class Ill Ill, Division 1, Groups E, F, and G Class I, Ill Ill, Division 1, Groups A, 6, C, D, E, F, and G Class I, Division 2, Groups A, 6, C, and D Class II, Ill, Division 2, Groups F and G NEMA 4X Class I, Division 1, Groups 6 ,C, and D Class II, Ill, Division 1, Groups E, F, and G Class I, II, Ill, Division 1, Groups A, B, C, D, E, F, and G Class I, Division 2, Groups A, 6, C, and D Class II, Ill, Division 2, Groups F and G Type 4X EEx d llB + H2 T5 (ambient temp. not to exceed 80C) per EN 50014 and EN 50018 EEx ia IIC T4 (ambient temperature not to exceed 80C) per EN 50014 and EN 50020 IP 65 per EN 60529 Yes
PUSH BUTTON GUIDE FOR SVI
enter a new CALibrate

CONFlGure CONTROLLER OPERATE
4
Version 1.0.6 SVlware
i ' A
SETPOINT ISETPOINT CANCEL
--c SELECT:
CALIBRATE FAULTS NORMAL MODE DISPLAY SEQUENCE
4t
OPERATE
SlNGLElDOUBLE CONTROLLER ONlOFF ATOlATC LINEAR/50X/30^//QUlCK/CUSTOMlLRECIPROCATING TIGHT SHUT OFF ONlOFF LO POSITION LIMIT HI POSITION LIMIT ENGLlSHlFRANCl AS MANUAL
position input signal pressure
DISPLAY VALUE OF:
DISPLAY VALUE OF:
DISPLAY FAULT: POSERR position error RESET reset occurred PRESEN pressure sensor error BISAERR bias error STOPERR find stops Failed TEMPERR temperature Fault WTRERR eeprom write fault TIMRERR watchdog timeout CALFAIL measurement out of range REFERR reference standards HWERR self check fault OVERRUN data out of range CLEARFAULTMESSAGE
LO POSITION SIG
HI POSITION SIG
HI PRESSURE
ACTUATOR TYPE CONTROLLER STATE ACTUATOR ACTION CHARACTERIZATION TIGHT SHUT OFF LO POSITION LIMIT HI POSITION LIMIT LANGUAGE
SELECTS OR TOGGLES VALUE INCREASES VALUE OR STEPS FORWARD DECREASES VALUE OR STEPS BACKWARD
* Use HART Command "000 Read Identifier" and Look

at "Hardware Revision = X". Then Subtract One
ANY BUTTON TO EXIT NORMAL MODE DISPLAY SEQUENCE
1 EXAMINE
'
Hot Key
2 Change Pos
&IEXAMINE 1 ldrntlfler
CONTROLLER
2 3 A 5 6 7
posnloner conflguratlon calibration diagnostic dala read status clear status posnioner PID
2 modeandSP 3 PID setting

A
~
1 controller view
4 controller param 5 alarms vlew
- -+
4
..
ratlo gain
CHOOSE 1 SP Value 1 SPMcde
_____
MANUAL MODE
P W 1 8 D CvFlmh M S P = S 3ox P o 2% R-S2 Curlmln
LOCAL MODE CHOOSE 1 SP Value 1 SPMode

PV-41 L-S-42
CvFlmin
u )CvFhnin
8 error llmlis
9 switch positions controller configuratlon cnntroll~r catib controller PI0 controller parameters controller SP mode check SVI
OUTES.l% P O S S 3% R-SMBS 3 CuFlmin
*' NORMAL MODE '* 1 valve p"Sitl0"
3 Inpuf signal
1
HART Communicator
4 TO MANUAL MODE
6 EXAMINE
Manual Set Polnt 1 set point 2 fullope" 13 fullclosed
II
1
tight shutoff language units nr~ssure button
locks
1 valve ~ o s i t ~ o n
* MANUAL MODE MENU

11 NORMAL MODE 2 CONFiG MENU
2 system Information 3 listen for p c 4 storage location 5 slmulatlon
L
fail high
controller bumpless h w reverse poslilon error lime 1 time 2 pressure time
startup made
HAND HELD COMMUNICATOR GUIDE for SVI
,
2 readdlag
CHOOSE
DIAGNOSTIC MENU 1 perform std
CHOOSE 1 primary
action PV ,miis remole SP sunns

set low value enter hi value
3 pressure 4 viewsigs
ratio control local SP controller rate
2 standard
primary signal s i c o n d a i slgnai pressure
1 signals
Stop adjust
CHOOSE friction I" spring hi spring lo pressure llpper pressure time to open lime to close
I 1 PI0 time closed time open
4
m
EXAMINE
a MODIFY
near closed cycles
Beta. Damp Comp. Dead
When configured as an electropneumatic valve positioner, (Figure 2) the SVI accepts a 4-20 mA current signal from a controller or other device,(i.e. HART protocol digital signal) and compares the input signal to the valve position. The difference between the input and position feedback is conditioned by the position control algorithm and converted to a pneumatic signal. This signal is boosted by a pneumatic relay and drives the actuator. When the valve position agrees with the value called for by the position setpoint input signal, the system stabilizes with no further movement of the actuator.
SET POINT
SET POINT
(CURRENT OR
PID POSITION CONTROL ALGORITHM
CURRENT TO PRESSURE CONVERTER
VALVE
PNEUMATIC RELAY
When configured as a PID controller, (Figure 3) the SVI accepts a local control setting, (4-20 mA signal or a HART communications protocol signal). The primary process measurement made by the process transmitter is fed to the controller as a voltage signal of 1 to 5 V dc. The difference between the set point and process measurement is conditioned by both the PID controller algorithm and position control algorithm and converted to a pneumatic signal. This signal is boosted by a pneumatic relay and drives the actuator. When primary measurement and set point signals agree there is no further movement of the actuator and system is in stable control.
PROCESS SET POINT
(LOCAL, CURRENT OR DIGITAL)
PID
CONTROLLER
ALGORITHM
ALGORITHM
CONVERTER
PROCESS VARIABLE INPUT
POSITION FEEDBACK
B
12
Figure 3.
Block Diagram of SVI Controller/Positioner
Hardware Description
The SVI is housed in a rugged, weatherproof, corrosion resistant aluminum housing which has been designed for operation in hazardous areas as listed in Table 2. Two j / 2 NPT conduit entries and three 1/4 NPT pneumatic ports provide signal connections to the SVI. Within the housing are the following components interconnected as shown in Figure 3a, "SVI Block Diagram". Electronics Module Display and Pushbuttons Electropneumatic Converter (EPC) Spool Valve Sensors (position, pressure and temperature)
supply
Pressure
Pressure Sensor
- 20 mA
o +
S
Display
0 to
Set Point
Electronics Module
A
1.4 mA
E PC
4.5 to 7.5 PSI
Spool Valve
m
Buttons
I l l
KG
11
b
b
Exhaust
Potentiometer
Figure 3a. SVI Block Diagram
13
Electronics Module
The electronics module contains the power supply, 16 Bit AID Converters, 12 Bit D/A Converters and the microprocesser. Using the internal programmed Positioner and/or Process Control algorithm, it computes the required output based on information received from the measurement sensors. If the display and pushbutton option is selected it contains the electronics for these functions.
Pushbutton Switches
Three pushbutton switches operating in conjunction with the display permit reaqing and modification of the instrument operating parameters without a PC or HART hand-held communicator. These switches perform "genedc" functions - Increase, Decrease, and Accept by movement through a conventional menu structure. The switches can be operated in a hazardous environment without compromising the flameproof enclosure.
E PC (EIect ropne umatic Converter)
The;EPC converts a current signal to a pressure signal in the following manner. A coil operating in a magnetic field is mechanically connected to a flapper. Movement of the coil when current is changed causes the flapper to move towards a nozzle and restrict the air flow through the nozzle. The restricting action causes the back pressure on the nozzle to increase with an increase in the coil current. Removing electrical power from the EPC causes the output pressure to go low. This defines the startup and fail-safe characteristics of the SVI.
Spool Valve
The spool valve is a two way, air-piloted valve that can supply or exhaust air. The pilot pressure, which is controlled by the EPC, in turn controls the rate of air flow that fills or exhausts the actuator.
Sensors (Position, Pressure and Temperature)

Position sensing of the valve stem is accomplished by use of an internally mounted potentiometer mechanically linked to the stem. The output of the potentiometer is connected to the electronics module and provides the input signal to the position control algorithm. The potentiometer resistance is 10,000 ohms and has a full scale travel range of 120 degrees rotation. Full valve stroke must provide 18 degrees minimum * and 100 degrees maximum rotation from reference position. "Open" or "Closed" valve settings establish the reference position. The position sensor also provides, through the electronics module, readout of valve position on the display, communication of valve position via HART protocol and on newer SVI models a 4-20 mA signal proportional to valve position transmitted on a separate pair of leads. If the SVI cannot be mounted on the valve, an optional remote feedback potentiometer can be used to supply the position signal to the SVI. The pressure sensor measures the pressure to the actuator with a range of 0 to 100 psi. This pressure can be read out on the internal display, Hart communicator or Val Vue PC. The temperature sensor is located in the electronics module and measures ambient temperature. This measurement is used to provide temperature compensation for the pressure sensor and other internal electronic components.
* A short stroke version SVI is available; Consult Factory.
14
SVI Inputs/O ut puts

As shown in the block diagram below, the SVI unit has the following inputs and outputs:
SET POINT SIGNAL FOR VALVE POSITION OR PID CONTROLLER SET POINT INPUT (SEE NOTE I )
2 UNPOWERED CONTACT CLOSURE INPUTS OR REMOTE FEEDBACK POT FOR VALVE POSITION + (WHEN CONFIGUREDJ - OR PROCESS VARIABLE WHEN CONFIGURED AS A PID CONTROLLER (SEE NOTE 2)
-+ +
; I
A B
C
0 - 100 PSI
AIR PRESSURE OUTPUTTO ACTUATOR (SEE NOTE 3)
SVI SMART VALVE INTERNFACE
I
, q
INTERNAL 10K POT
o - l o o PSI!
PRESSURE FROM ACTUATOR (SEE NOTE 3)
4 -
AIR SUPPLY (25 TO 100 PSl)
MECHANICAL POSITION FEEDBACK FROM VALVE STEM (NOT USED WHEN REMOTE FEEDBACK POT IS CONFIGURED)
3 LOCAL PUSHBUTTONS
DIGITAL DISPLAY
Figure 4.
Inputloutput Diagram of SVI Unit
NOTES: 1. Set point signal can come from a 4-20 mA current input or from HART,protocol digital input. With digital input, operating power can be from 4-20 mA input or from 12/24 V dc Multidrop Supply. 2. PID Controller Process Variable signal must be dc voltage signal of 1.O-5.0 V dc or a 4-20 mA signal through a 250 Ohm resistor. User configurable as dictated by actuator operating pressure range.
3.
NOTE: When SVI Positioner or Controller are ordered without pushbuttons or display, configuration and calibration must be done using HART protocol Handheld Communicator or from ValVue software on personal computer. The SVI unit accepts the following inputs: Set point signal for valve posilion (when configured as a positioner) or for a PID controller (when configured as a controller) Actuator pressure Valve position Remote valve position
As an alternative, the remote valve position input connection can be assigned as follows: Up to two cold contact closures (unpowered for intrinsic safety), or A process variable input signal (when the PID controller function is configured) 15
System Desc r ipt ion- Pos itio ner

Typical system setups are shown in Figures 5 and 6. In these diagrams, the SVI is configured as a positioner and is located in a hazardous area (wiring diagrams are descriptive only, actual wiring must adhere to Electrical Installation section of manual and local electrical codes). Valve position is determined by an internal feedback potentiometer mechanically linked to the valve stem. The SVI input signal can be a 4-20 mA or a HART communication protocol signal from ValVue software on a personal computer or from a HART Hand Held Communicator. The process controller (or other source of input signal to the SVI) is located in a non-hazardous location and an intrinsic safety barrier (with ground) may be placed between the controller and the SVI or the system can be installed as explosionproof (flameproof). Communication with the remote PC is handled via a modem connected to the remote PC through a serial port. Communication can also be established from a HART Hand-held Communicator. The PC, which is intrinsically safe, must be connected to the circuit on the non-hazardous side of the intrinsic safety barrier if the valve is located in a hazardous area. The SVI unit can be operated, calibrated, configured, and interrogated either by using local pushbuttons/display, or using a remote PC running ValVue software or with the Hand-held Communicator.
NONHAZARDOUS LOCATION
I
I
HAZARDOUS LOCATION
' 7
SET POINT
PROCESS CONTROLLER
PROCESS VARIABLE
q=+
24 V
TO SERIAL
INTRINSIC SAFETY BARRIER

I
,/
POSITION FEEDBACK FROM VALVE STEM
(HART PROTOCOL COMMUNlCATlONj
DIGITAL DISPLAY AND 3 PUSHBUTTONS
NONHAZARDOUS LOCATION
HAZARDOUS LOCATION
Figure 6.
System Diagram - Explosionproof (Flameproof) Installation
16
System Description- PID Controller

When the SVI unit is configured as a PID controller, the + and - terminals are used to power SVI and to remotely set the controllers input. The primary process measurement, made by the process transmitter is fed to the controller as a 1-5 V dc signal, and connected to terminals marked A and B. Various configuration s,chemes using remote set point input are illustrated in Figure 7, Figure 8, and Figure 9. (Wiring diagrams are descriptive only, actual wiring must adhere to Electrical Installation section of manual).
PROCESS
TRANSMITTER
SVI
CONTROLLER
4-20mA
Figure 7.
Single Loop PID Configuration with No Process Feedback
Figure 7 is the simplest configuration for the controller. It requires two 2-wire lines to the field. The sense resistor is located across the A and B terminals of the SVI unit. There is no sensing of the controlled variable in the control room - which is acceptable for applications such as a heat exchanger where the primary variable is temperature and the secondary is flow. In such a case, the SVI is the flow controller and the control room temperature controller sets flow based on the requirements of the temperature loop (with no need to monitor flow in the control room). In the configuration shown in Figure 8, there are three 2-wire connections to the field. With this connection the process transmitter output can be monitored in the control room. The 250 Ohm resistor is located in the control room in this configuration.
TRANSMITTER
CONTROLLER
SETPOINT
Figure 8.
Single Loop PID Configuration with Process Feedback

17
The circuit shown in Figure 9 is an intrinsically safe configuration. The 788R+ barrier supplies the operating power to the 4-20 mA process transmitter. This barrier contains a 250 ohm resistor in its current return leg across which a 1-5 V dc voltage is developed. This voltage is fed through the 710+ or 728+ barrier to the A and B (process variable input) terminals in the SVI Controller. The 4-20 mA remote control setpoint, and power to the SVI are supplied through the 728+ barrier.
MTL 788R+
24 VCD
+
I
PV to DCS
e
V
MTL 710+ or 728+
I
Y
0-
Controller
+ 03
I
4 R 0 mA m
MTL 728+
1 SP to DCS
TC
Figure 9.
Intrinsically Safe Single Loop PID Configuration
18
The circuits shown in Figures 10 and 11 are Controllers with local setpoint set by the pushbuttons on the housing. The 24 V dc supply with a series current limiting resistor replaces the 4-20 mA source and can also be used to power the process transmitter. If these circuits are used in hazardous areas, the wiring and mounting of the external resistors must conform to explosionproof requirements, or I S . barriers must be used on all wiring between the control room and the hazardous area.
+
24 VDC
.
+
SVI
A
Figure 70. Local Set with Voltage Source
24 VDC
Figure 7 1 . Local Set with Voltage Source-Two Leads to Field
1700 Ohms
-1
/ I
I
sv,
19
Chapter 2 Mounting
WARN ING:
If the SVI is to be mounted on an existing valve in a process line, the following procedures and precautions are mandatory. If valve is located in a hazardous area make sure area has been certified as safe or that all electrical power to the area has been disconnected before removing any covers or disconnecting any leads. I Shut off air supply to the actuator and to any valve mounted equipment. Ensure the valve is isolated from the process by either shutting off process or using bypass valves for isolation. Tag shutoff or bypass valves to guard against turn-on while work is in progress. Bleed air from actuator and check that valve is in its un-energized position.
It is now safe to disconnect and remove any valve mounted equipment that is being replaced.
NOTE:
The SVI should be mounted with the conduit connections down in order to facilitate drainage of condensate from the conduit and ensure the best dynamic performance.
Standard Rotary Valve Mounting

This section describes the procedure for mounting the SVI on all Masoneilan rotary control valves. Tools required: 3/16 inch Hex Wrench 4 mm Hex Wrench 7/16 inch Combination Wrench
1. Mount the SVI mounting bracket to the valve actuator using two (2) 5/16 - 18 UNC flat-head cap screws. Unless otherwise specified the SVI will be mounted assuming the actuator/valve will be mounted in the normal upright position (i.e., lettering on actuator right side up). This requires the long end of the mounting bracket to be to your right when facing the actuator. Note that the mounting bracket for ball and butterfly valves differs slightly from the Camflex and Varimax bracket but the mounting is identical. 2. Bolt the valve side lever to the valve position take-off shaft using a 1/4 - 28 UNF cap screw, spacer and washer. The spacer goes between the take off shaft and lever, and the washer under the head of the cap screw. On Camflex and Varimax valves, orientate valve side lever 90( from valve position indicator as shown in Figure 12 and securely tighten cap screw. On ball and butterfly valve actuators, orientate the lever so it is midway between the two bracket mounting holes (450 from horizontal) as shown in Figure 13 and tighten cap screw. Alternatively, for all rotary mountings, the actuator can be pressurized to mid-stroke and lever secured in a horizontal position.
20
F
I
Valve Side
Lever
Valve
Cap Screw
SVI Mounting Bracket
Figure 72. SVI Rotary Mounting Bracket with Valve Side Lever on Camflex Valves
.
Valve Side
1/4-28 UNF Cap Screw
Lever
5/16-18 UNC Flat Head Cap

Screw
SVI Mounting
Bracket
Figure 73. SVI Rotary Mounting Bracket with Valve Side Lever on Ball and Butterfly Valves
3. Clamp the SVI lever to the SVI shaft. The flat on the SVI shaft must always face the pneumatic block
with the lever orientated facing the cover as shown in Figure 14. When using a standard lever, the orientation of the lever to the SVI is set by clamping screw location relative to flat on shaft. Leave approximately 1/I 6 space the SVI housing and back of lever. See Figure 15.
4.
Loosely assemble the SVI to the mounting bracket using only the two top 1/4 - 20 UNC socket-head cap screws. Pull the SVI away from the actuator to allow the pin on the valve side lever to be inserted into the slot in the SVI lever under the anti-backlash spring. See Figure 15. Assemble the two bottom bolts and securely tighten all four bolts.
21
Flat On Shaft Must
Be Orientated Toward
Block As Shown
&
Figure 14. Orientation of SVI Lever and SVI Shaft
Valve Actuator
SVI Rotary
K Z g--\
Spacer
Lever with Pin Anti- Backlash
Figure 15. SVI Mounting on Rotary Valves
22
St a nda rd Reciprocating Va Ive Mount ing

Mounting the SVI on Masoneilan 87/88 Multi-Spring actuators.
Tools' required:
7/16 inch Combination Wrench (2 required) 3/8 inch Combination Wrench 1/2 inch Combination Wrench 4 mm Hex Wrench 3/16 inch Hex Wrench 1. Mount the SVI mounting bracket to the actuator using two (2) 5/16 - 18 UNC cap screws. Unless otherwise specified, the SVI mounting assumes that the actuator is in the normal upright position. The slotted opening of the mounting bracket is to be to the left when facing the actuator.
2. Clamp the SVI lever to the SVI shaft. The flat on the SVI shaft must always face the pneumatic block with the lever orientated facing the cover as shown in Figure 14. When using a standard lever, the orientation of the lever to the SVI is set by clamping screw location relative to flat on shaft. Leave approximately 1/16 space the SVI housing and back of lever. See Figure. 16.
SVI Lever
RodEnd
1
I [
fr
Air Outpul 114" NPT
I
Clamping Screw
I
1
Figure 76. Top View of SVI Mounted on a Reciprocating Vahe
23
3. Attach the right hand threaded rod end to the SVI lever using a 1/4 - 20 x 1 cap screw. The lever hole position to be used is dependent upon the specific valve stroke. Refer to Figure 17 and Table 3 (shown below).
PN 055000-276-600
Figure 17. SVI Lever for 87/88 Multi-Spring Actuator
I
Valve Stroke mm (inches) 20.3 (0.8) 25.4 (1.O) 38.1 (1.5) 50.8 (2.0) 63.5 (2.5)
Lever Hole
A A
6
C C
Table 3. SVI Lever Hole Locations for 87/88 Multi-Spring Actuator
Note: For valve strokes less than 19.1 mm (.75 in.) use the Short Stroke model SVI with the rod end
attached to the lever A hole.
4. Mount the SVI to the mounting bracket using four 1/4 - 20 UNC socket-head cap screws. The set of mounting holes to be used is dependent upon the specific valve stroke. Refer to Figure 18. 5. Screw the take-off rod to the actuator stem connector, refer to Figure 19. Ensure that the travel s correctly positioned. pointer i 6. Bolt the left hand threaded rod end to the take-off rod with 1/4 - 20 UNC nut. 7. Connect turnbuckle and lock nuts to each rod end. Refer to Figure 19. Turnbuckle length is a function of actuator size. Verify proper length per following: #6 and #10 Actuators, length = 1.25. #16 Actuator, length = 2.90. #23 Actuator, length = 5.25. 8. Position valve at mid-stroke by supplying air to the actuator or using a manual handwheel if applicable. 9. Adjust the turnbuckle such that the SVI lever is horizontal. Tighten the turnbuckle lock nuts.
24
SVI 87\88
Mounting Bracket
PN 055000-253-002
-1
0.8and 1.0 STROKE
I -
2.0and 2.5 S T R O K E .-.
Figure 18. SVI Mounting Bracket f s / 8 8 i S p r i n g Actuator
25
Mounting the SVI on other Valves

The SVI can be mounted on many other valve types of both Masoneilan design and those of other manufacturers. Typical mounting on Masoneilan Type 37/38 and 84/85 Actuators is shown in Figures 20 and 21. Figure 21a Smart Valve Interface Outline Drawing shows mounting and overall dimensions. When mounting the SVI to other valves use it as a guide to ensure proper clearances, access room for cover removal and making of pneumatic and electrical connections. The following section describes the general requirements for mounting the SVI on any valve. This section is intended to be used by an Engineering group with basic understanding of instrument mounting on control valves. The following minimum technical requirements must be adhered to: Minimum SVI shaft rotation for full travel is 18. Maximum recommended linkage assembly non-linearity is +/- 1.O%. Minimum mounting bracket thickness is 5.0 mm. In order to mount a SVI on a valve the following parts are required: Mounting Bracket SVI Lever and Linkage for Position Feedback (Reciprocating) SVI Lever and Valve Side Lever for Position Feedback (Rotary) To ensure that the SVI position feedback performs correctly, the plane of the flat on the SVI shaft must be vertical and facing the pneumatic block of the SVI when the valve is at mid travel. The lever must point away from the pneumatic block. See Figure 14. For a reciprocating valve,the bracket, lever, and linkages should be designed such that the lever is perpendicular to the actuator stem when the valve is at mid-stroke. The linkage pivot point on the SVI lever should be on the same centerline as the valve stem at mid-stroke. (turnbuckle centered on and parallel to stem). For a rotary valve it is recommended that the Masoneilan design valve side lever and SVI lever be used since they incorporate an anti-backlash spring feature. The mounting bracket should accommodate the four mounting holes of the SVI. Adequate space must be left between the SVI and the Actuator to accommodate the lever and linkage or the rotary lever coupling. Clearance space is required for the output air connection and SVI end cover. See Figure 22 for mounting interface requirements.
26

I
1 I
Figure 20. Typical SVI Mounting on 37/38 Actuator
7
I
i -
-5
Figure 27. Typical SVI Mounting on 84/85 Actuator
27
AIR
OUTPUl
II4
NPT
Minimuinlo
Remoue Cwu
VIEW A - A
157.0
r rA
@--
- 51
Mlnlmumlo
Remove Cover
4 A
CONDUIT ENTRY ( 2 )
1/2 NFl
1E.7
Figure 21a. Smart Valve Interface Outline Drawing
.
B--2
7-
28
Actuator Centerline
SVI Centerline
053.8
Clearance for SVI Boss
t
-
I
I
Clearance for
I
Through hole
1/4" Thread
SVI Cover
or M6 Thread
Figure 22. SVI Mounting Interface
Lever and Linkage Design

A lever length should be chosen depending on the stroke of the given actuator. Table 4 can be used as a guide in determining lever lengths.
The recommended lever material is aluminum 6061 temper TI, anodized for corrosion protection. This lever should be designed to the basic dimensions as shown in Figure 23. If designed in a material other than aluminum, the clamping effort for the M5 screw must be reviewed to ensure proper attachment to the SVI shaft.
Valve Stroke mm (inches)

12.7 25.4 50.8 101.6
152.4
Lever Length mm (inches)

19.1 31.8 76.2 139.7 203.2 (0.75) (1.25) (3.00)
(5.50)
~
(0.5) (1.O) (2.0)
(4.01
(6.0)
(8.00)
Table 4. Recommended Lever Lengths
29
@ 5 . 1 1 ( . 2 0 1 ) DRILL
TAP , 2 5 0 - 2 0 UNC-26 THRU. 3 HOLES
10.00 DEEP
r@ 6.351-18
12.70
Figure 23. SVI Lever Design
The linkage design is usually made up of two rod ends. One each attached to the SVI lever and the valve stem. A turnbuckle is used to attach the rod ends together and for final adjustment. Table 5 may be used as a guide to determine the proper linkage lengths. Lock nuts should be provided to ensure that the set length of the linkage is not changed. See Figure 19 for typical mounting on a reciprocating actuator.
Valve Stroke m m (inches)

12.7 25.4 50.8 101.6 152.4 (0.5) (1.0) (2.0) (4.0) (6.0)
Linkage Length mm (inches)

25.4 50.8 76.2 127.0 228.6 (1.00) (2.00)
(3.00) (5.00)
(9.00)
Table 5. Recommended Linkage Lengths
30
Pneumatic Installation
The SVI Positioner and Controller are designed to operate only with clean, dry, oil-free, instrument grade air to ANSMSA-57.3 1975 (R1981) or ISA-S7.3-1975 (R1981).
Dew Point: Particulate matter: Oil content:
At least 18" F
(lo" C) below minimum anticipated ambient temperature.

1
Filtered to below 5 microns.

>
Less than 1 ppm w/w or v/v.
Contaminant's: Free of all corrosive contaminants and hazardous gasses, flammable or toxic.
The supply, output and exhaust connections for the SVI (located on the pneumkic block) are tapped 1/4" NPT, The output connection is located on the back of the block. The supply and exhaust are located on the side of the block with the exhaust above the supply and fitted with a plastic plug. Two pressure gauges, output on top, supply on bottom, are located on the front of the pneumatic block. The use of a Masoneilan filter regulator with a 5 micron filter is recommended for the air supply. Tubing used for piping between filter regulator, SVI , and actuator should be 1/4" minimum with 3/8" used for larger actuators.
CAUTION: Do not use pipe thread sealant tapes on pneumatic fittings as it tends to shred small particles
which can cause instrument malfunction. The use of a soft setting anaerobic hydraulic seal such as Loctite Hydraulic Seal 542 is recommended. Follow manufacturers instructions.
CAUTION: Do not use an excessive amount as it will not set and may migrate into the instrument.
Maximum allowable air supply pressure to the SVI varies according to actuator and valve size and type. See pressure drop tables in valve specification sheets to determine correct positioner supply pressure. Minimum supply pressure should be no less than 10 psi above maximum spring pressure.
DANGER: Never exceed actuator or SVI maximum supply pressure. Damage to equipment or injury to
personnel may result.
31
Electrical Installation
Electrical connections are made to the main terminal board as shown on Figure 24. The terminals will accept wire sizes up to A.W.G 14 Figure 24 shows, layout of terminal board currently in production.
Jumpers t o Select Voltage (Multi-Drop) or Current Input Signal
Terminals for Connecting 4-20 mA Current Input or 12/24 V DC Multi-Drop Digital Input Signal (HART Protocol)
Set Point
Input
Signal
External Position Feedback Pot
A B C
Contact Closure Inputs
BO I
Terminals for Connecting External Pot for Position Feedback or for Process Variable Input When SVI i s Used as a PID Controller
I -c+
Process Variable Voltage Signal
'
250 OHM Resistor is necessary for Current Input Signal only if this resistor does not already exist in the wiring in the control room.
Figure 24. Electrical Connections to Main Terminal Board

(Current Production)
32
Figure 24a reflects a design change to be released in early 1999 which incorporates the following enhancements. Additional terminals D and E allow the contact input feature to be used with the controller option.
0 ,
Optional terminals POS + and POS - provide an isolated 4-20 mA signal related to characterized valve stem position. The voltage compliance of the position output terminals is 11-50 V dc. The H A R P signal is not available on the position terminals. The HART protocol is available on the +/- LOOP terminals. The software revision reported by the HART ID command is 6.
All terminals (both versions) accept wire sizes up to A.W.G. 14.
0PT I 0 N AL POSITION OUTPUT
SETPOINT INPUT SIGNAL
SUPPLY CONNECTION
PROCESS VARIABLE 1/5 VOLTS

A R
UNPOWERED \ CONTACT INPUT r n c
Figure 24a. Electrical Connections to Main Terminal Board
33
When operated with current input, the loop controller or any other current source must be capable of supplying 4-20 mA with an output voltage compliance of at least 12 V. Before applying power to the SVI make sure currentholtage jumper is in correct position. The available output voltage of a current source will be reduced by loop wiring resistance. This can be checked by connecting a resistor of value (600 ohms + loop resistance ) across the output of the current source and verifying that 20 mA is obtainable at full scale output. The SVI is normally supplied with two 1/2 NPT conduit entries. (M20 adapters are available) Internal and I external ground terminals are provided for use if grounding is required.
I
WARNING: The SVI must be installed in accordance with local and national codes of practice in both general purpose and hazardous area locations. The electrical components are fully isolated from ground and therefore grounding is unnecessary for functional purposes. Grounding may be necessary to conform to installation codes.
Figure 24b is a composite wiring installation diagram applicable to both SVI versions and to the controller option. It is suitable for general purpose locations and to explosionproof (flameproof) installations when applicable wiring codes are observed.
I
Optional Position output Terminals (2)
Optional 4/20 mA Position Output
n
-
24 VDC from DCS
1 to 5 Volts POSITION
FEEDBACK to DCS
Model 275
+ SVI +o
LOOP
4 to 20 mA SETPOINl
0
A B C D E
from DCS
0 0
~
Optional Screen
Optional Connection For Potentiometer or Un-Powered Contacts Optional 115 Volt Process o SVI Variable Input l
i A
Optional Process Variable Transmitter
Optional Screen
250 Ohm
Optional Screen
1 to 5 Volts Process Variable to OCS
Figure 24b. General Area Purpose Installation
34
Hazardous Area Installations

The SVI is available in versions suitable for use in hazardous areas. The labeling on the positioner indicates approved areas of use.
WARNING: Installation of any hazardous area equipment must be made in accordance with the appropriate hazardous area installation codes and the manufacturers installation and operating instructions. The user must make no changes or attempt any repairs of a certified instrument since this will invalidate the certified design.lf a certified instrument should fail it must be returned to the manufacturer for repair. Factory Mutual approved model
Explosionproof:
Class I, Division 1, Groups B, C, and D. Temperature Classification T6 @ 75" C ambient, T 5 @ 82" C ambient, indoor and outdoor (NEMA Type 4X) hazardous (classified) locations. Class II / Ill, Division 1, Groups E, F, and G. Class I, Division 2, Groups A, B, C, and D. Class I 1 / Ill, Division 2, Groups
Dust-lgnitionproof: Non-lncendive: Suitable for:
F and G.
Installation must be in accordance with the current edition of the National Electrical Code ANSI / NFPA70, any applicable local codes and manufacturers instructions.
Intrinsically Safe:
Class I / II / Ill, Division 1, Groups A, B, C, D, E, F, and G hazardous indoor / outdoor NEMA 4X locations. Temperature Classification T4 @ 40" C ambient, T3B @ 70" C ambient, T3A @ 82" C ambient.
Installation must be in accordance with the current edition of the National Electrical Code ANSI / NFPA70, ANSI / ISA RP 12.6 "Installation of Intrinsically Safe Instrument Systems in Class I Hazardous (Classified) Locations", Figure 25 - Installation Control Drawing ES-641 - on Page 34, and manufacturers instructions.
CSA (Canadian Standards Association) approved model

Explosionproof:
Class I, Groups B, C, and D, Class 11, Groups E, F, and G, Class Ill. Supply 28 Vdc, 4-20 mA. Enclosure Type 4X, Temp. Code T6 @ 75" C, T5 @ 82" C. Max. Ambient 82" C. Class I, Division 2, Groups A, B, C, and D, Class II, Division 2, Groups F and G, Class Ill. Supply 28 Vdc, 4-20 mA, Enclosure Type 4X, Temp. Code T6 @ I 75" C Ambient, T5 @ 82" C. Max Ambient 82" C.
Division 2:
Installation must be in accordance with the current edition of the Canadian National Electrical Code Part I, any applicable local codes and manufacturers instructions.
35
Intrinsically Safe:
Class I, Groups A, B, C, and D, Class II, Groups E, F, and G, Class Ill. Supply 28 Vdc 4-20 mA. Enclosure Type 4X. Temp. Code T4 @ 40" C Ambient; T3B 8 70" C Ambient; T3A @ 82" C Ambient. Max. Ambient 82" C.
Installation must be in accordance with the current edition of the Canadian National Electrical Code Part 1, Figure 25 - Installation Drawing ES-641 - (shown below), and manufacturers instructions.
SVI (SMART VALVE INTERFACE) FACTORY MUTUAL AND CANADIAN STANDARDS ASSOCIATION APPROVED INTRINSICALLY SAFE INSTALLATION C'ONTROL DRAWING
Non Hazardous Location. Unspecitied Except That Barriers Must Not Be Supplied From Nor Conlain Under Normal or Abnormal Condilions A Source of Potential With Respect to Eanh ~nExcess 01 250 Vons
Hazardous Location
Class I. 11. 111 D i m o n 1 8 2
RMS Or 250 Volts
DC
Groups A. B
C.D. E. F. andG
See Notes
1. 4
Optional 4/20 mA Position Output Optional Position output Terminals (2)
24 VDC from DCS

1 to 5 Volts POSITION FEEDBACK to DCS
Optional Hand Held Communicator
Optional Screen
Safely Barrier
Trsnsmitter type with sensing resrstor example MTL 766R (Scc Note 5)
+ SVI
See Notes 8 9
PPP
See Note 3
:&
LOOP See Notes 1 4
Oplionai Screen
from DCS
Connection For Potentiometer or Un-Powered

See Notes 1. 4
Shun1 Zener Diode Safely Barrier CorlUulln "UlPUl type erample MTL 728 (See Note 5)
Optional 115 Volt Process Variable Input to SVI
Oplionai Screen
Optional Intrinsically Safe T Process r a Variable n s m i n
--.
104-
strunt zellel
Diode Safely Barrier Transmitter type
with sensing
t
See Notes 1 4
I ,
L
,,
-03
-04
IS Transminer
0 I
24 VDC from DCS
: I
* I ,I
2 0
b
1 to 5 Volts Process Variable to DCS
Figure 25. Approved Intrinsically Safe Installation Control Drawing
36
Notes:
1. The electrical circuit in the hazardous area must be capable of withstanding an A.C. test voltage of 500 volts R.M.S. to earth or frame of the apparatus for 1 minute. 2.
Entity Parameters: SVI (+) and (-) LOOP Terminals Vmax = 30 Vdc lmax = 125 mA Ci = 2.2 nF Li = 96 uH
I
Pmax = 900 mW
SVI (+) and (-) POS Terminals Vmax = 30 Vdc lmax = 125 mA Ci = 2.2 nF Li = 96 uH
!
Pmax = 900 mW
SVI (A), (B), (C), (D), AND (E) Terminals Vmax = 30 Vdc lmax = 125 mA Ci = 0 nF Li = 0 uH
3. Terminals (C), (D), and (E) may be connected to an external position sensing potentiometer or to
unpowered switch contacts, both of which fall in the category of "simple apparatus'' and located in the hazardous area within 10 feet of the SVI positioner.
4.
Cable capacitance and inductance plus the I.S. apparatus unprotected capacitance (Ci) and inductance (Li) must not exceed the allowed capacitance (Ca) and inductance (La) indicated on the associated apparatus. If the optional Hand Held Communicator is used, then the capacity and inductance must be added. Also, the current output of the Hand Held Communicator must be included in the current output of the associated equipment. Positive polarity shunt Zener diode safety barrier approved by FMRC or CSA for groups A, B, C, D, E, F, and G with output parameters: Voc or Vt 5 30 Vdc lsc or It 5 125 mA Ca ICi
5.
+ C cable
La 2 Li + L cable
6. The intrinsically Safe Transmitter is any transmitter approved by FMRC or CSA for groups A, B, C, D, E, F, and G having entity parameters consistent with the connecting FM or CSA approved barrier.
7. The installation including the barrier earthing requirements must comply with the installation requirements of the country of use, i.e., ANSMSA RP12.6 (Installation of Intrinsically Safe Systems for Hazardous (Classified) Locations) and the National Electrical Code. ANSVNFPA 70 or Canadian Electrical Code Part 1. Installation must be in accordance with manufacturers guidelines. Division 2 installations must be installed per the National Electrical Code. ANSIINFPA 70 or Canadian Electrical Code Division 2 Wiring Methods. 8.
SVI Temp Code: T4 at 40" C. Maximum Ambient Temperature T3B at 70" C. Maximum Ambient Temperature T3A at 82" C. Maximum Ambient Temperature Dust-tight conduit seal must be used when installed in Class II and Class Ill environments.
1.
9.
10 The model 275 Hand Held Communicator is Factory Mutual approved with the entity parameters printed on the 275 label.
37
CENELEC Approved Model

Flameproof: Coded as EEx d IIB + H2 T5 (Ta +80" C.)
Installation must be in accordance with current editions of applicable country codes and manufacturers instructions. Intrinsically Safe: Coded as EEx ia IIC T4 Tamb = - 40" C to +80" C
Installation must be in accordance with current editions of applicable country codes and manufacturers instructions. The intrinsic safety barriers must be suitable for use with the SVI safety description given below:
Field Connector, +, - (Power Input) Ui = 30 Vdc Ii = 125 mA Pi = 0.9 W Ci = 2.2nF Li = 96 uH
Field Connector, A, B, C (Controller Link) Ui = 30 Vdc Ci = 0 UF Li = 0 mH
Housing Protection Rating: IP 65
38
SVI Interconnections
Basic Positioner
The basic positioner functions to position the valve in response to the magnitude of the 4-20 mA current input., The connection between the positioner and control system is by a two conductor cable. The recommended configuration is use of twisted pair, shielded cable, with the shield and loop grounded at one point onIy.
Positioner or Controller with HART Communication

Impedance Constraints
HART communication is based on the "talking" device generating an AC current superimposed on the 420 mA control signal. Two frequencies are generated; one representing the digital value "0" and one representing the digital value "1". the "listening" device responds to the voltage generated when the AC current flows through the loop impedance. (In order to generate a voltage from a current there must be an impedance.) HART Protocol required that this impedance be at least 220 Ohms at the tone signaling frequencies. At DC (zero frequency) a current source presents a very high impedance. (Little change in current for a large change in voltage.)
IMPEDANCE VS FREQUENCY FOR TYPICAL CURRENT SOURCE
Figure 26. Impedance vs Frequency for Typical Current Source
2 2
Log Frequency
I\
However, at higher frequencies, the impedance may be lower. For example, a noise reduction capacitor across the output of a current source will lower the impedance at higher frequency and thus lower the signaling voltage. Ideally the current source will be supplied with an impedance versus frequency characteristic (see fig 26). The heavy band in the sketch represents the range of frequencies for signaling tones. In practice, this detailed information is seldom available. To be certain that at least 220 Ohms of impedance is presented by the current source a resistor may be added in series with the current source (see figure 27). However, this will reduce the effective compliance voltage of the current source by 20 mA times the value of the series resistor. for example, a 250 Ohm resistor will reduce the effective compliance voltage by 5 Volts. Consider that the compliance voltage of a typical current source is 24 Volts, and the voltage requirement of the SVI is 12 Volts (typically only about 10.5 Volts) there is plenty of compliant voltage even with 5 volts dropped by the series resistor.
Figure 27. Resistor Add in Series with Current Source
39

I
Noise Constraints
Hart Communication depends on converting two frequencies into digital values 0 and 1. Noise can cause errors in the conversion. Conventional good wiring practice such as use of twisted shielded pair cable with the shield and signal loop grounded at one point only will minimize the effects of noise.
Interference with DCS

The HART signaling frequencies are a 1mA peak AC current. This AC current, flowing in the DSC output, can cause a shift in the DCS 4/20 mA DC signal. both Honeywell and Mopre Products DCS require a filter between the DCS and the HART signaling devices to prevent the HART frequencies from upset ting the DCS output. The filter also serves to establish a minimum impedance of greater then 250 Ohms, and to prevent AC frequencies generated in the DCS from interfering with the HART communication.
Cabling and Interconnection Constraints

Interconnections should be made using shielded twisted pair cables. The shield must be connected to ground at one point only. The signal loop should also be grounded at one point only.
40
Split Range
Split range SVI requires special consideration of the compliance voltage. the SVI requires about 11 Volts (the spec is 12 Volts). Two SVI in series will therefore require about 22 Volts. But the typical current source can only deliver about 24 Volts, so the system will be Voltage starved. One solution is to use an active barrier for each loop. Using an active barrier allows up to three SVI to be operated from a single 4/20 mA DCS output. Each barrier has a low compliance Voltage input requirement and a high voltage output capacity. So three barriers can be connected in series input. I Figure 28 shows the same barriers as are used in the multiplexer.
%
Figure 28. Split Range Active Barrier
Another approach is to boost the compliance voltage of the DCS using a power supply (see figure 29). The DCS vendor should be contacted to validate this approach.
I
DCS
I sy
I
+
SVI 2
I
Figure 29. Compliance Voltage Boost
A further constraint on the split range system is that the minimum span is 5 mA, the upper range value is 8 to 20 mA and the lower range value is 4 to 14 mA. (Example 4-9 mA; 9-14 mA, 14-20 mA.
41
Chapter 3 - Operation - SVI Positioner

Introduction
Operation of the SVI Positioner as a local device is controlled through the optional device-mounted pushbuttons and digital display, as shown in Figure 30. Using the display, you can read: (1) the input signal (2) pneumatic output signal, and (3) valve position. The display sequences from one variable to the next every 1.5 seconds. Using the pushbuttons, you can exit from operating mode at any time and step through a menu structure to perform a wide range of manual operation, calibration, confi'guration, and monitoring functions, all of which are described later in this section. Before you can perform any of these functions, however, you must first ensure that the ValVue software (if used) has placed the pushbuttons in the "unlocked" mode. (See ValVue User Manual for more details.) The pushbuttons do not support any diagnostics functions.
NOTE: If the SVI unit is specified without local pushbuttons and display, local operation is not available.
Pushbuttons/Dis play
As shown in Figure 30, the upper line is a 7-digit numeric display and the lower line is a 7-digit alphanumeric display. The upper line is used for displaying values such as input signal or valve position, and the lower one is primarily used for messages and parameter identification.
7-DIGIT NUMERIC 7-DIGIT ALPHANU MERlC D IS PLAY
LOCAL PUSHBUTTONS
"
S E LECT" 0R "A C C EPT"
BUTTON "DECREASE VALUE" OR "MOVE UP (BACK)" IN MENU BUTTON
"INCREASE VALUE" OR "MOVE DOWN (NEXT)" IN MENU BUTTON
Figure 30. Local Display and Pushbuttons
42
The three pushbuttons perform the following functions:

The left button, marked with *, permits you to select or accept the value or parameter option currently displayed. The middle button, marked (-), permits you to move back through the menu structure to the previous item in the menu, or to decrement the value currently shown in the digital display. When used to decrease a displayed value, holding this button down causes the value to decrease at a faster rate. The right button, marked (+), permits you to move down through the rdenu structure to the next item in the menu, or to increment the value currently shownin the digital display. When used to increase a displayed value, holding this button down causes the value to increase at a faster rate.
To determine how to display and/or select a particular parameter value or configuration option, refer to the menu structure diagrams in Figure 31 through Figure 35. By using these diagrams as a map, you can quickly move through the menus to the function you want to perform.
NOTE:
If the buttons are pushed after being locked by the ValVue software, the message LOCKED will appear. Please refer to ValVue Software Manual to unlock pushbuttons.
NOTE:
When an SVI is turned on, it is advisable to apply the air supply before applying the electrical input signal.
43
PUSH BUTTON GUIDE FOR SVI Version 1.0.6 SVlware
t
+ POSMAN
CALibrate
CONFlGure EXAMINE
4
+ -
I MANUAL
CONTROLLER OPERATE
I
1
~-
SELECT: REMOTSlLOCAL SETPOINT ISETPOINT CANCEL OK
'
r
,I CONFIGURE 4
FAULTS
I
r
enter a new position value
SELECT: FIND STOPS STOP OPEN VALUE BIAS MIDPOINT AUTO FUNE POSITIONER LOW POSlTlONER SIG HIGH POSITIONER SIG HI PRESURE VALUE MANUAL SELECT:
I
I
1 CONFIGURE 4
FAULTS
P P
NORMAL MODE DISPLAY SEQUENCE
SlNGLElDOUBLE CONTROLLER ONlOFF ATOlATC LINEARl50"/./30"/~lQUICKlCUSTOMlLRECIPROCATING TIGHT SHUT OFF ONlOFF LO POSITION LIMIT HI POSITION LIMIT ENGLlSHlFRANClAS -~ MANUAL
OPERATE
------+
r'
DISPLAY VALUE OF: LO POSITION SIG HI POSITION SIG HI PRESSURE
I
I
DISPLAY VALUE OF:
DISPLAY FAULT: POSERR position error RESET reset occurred PRESEN pressure sensor error BISAERR bias error STOPERR find stops failed TEMPERR temperature fault WTRERR eeprom write falilt TIMRERR watchdog tirneout CALFAIL measurement out of range REFERR reference standards HWERR self check fault OVERRUN data out of range CLEAR FAULT MESSAGE
SELECTS OR TOGGLES VALUE INCREASES VALUE OR STEPS FORWARD
Use HART Command "000 Read Identifier" and Look at "Hardware Revision = X , Then Subtract One.
DECREASESVALUEORSTEPSBACKWARD
Figure 30a. Pushbutton Guide for SVI Version 1.0.6
PUSH BUTTON GUIDE FOR SVI
POSMAN 4 CONFlGure EXAMINE OPERATE
MANUAL EXAMINE OPERATE
1
CALIBRATE FAULTS DISPLAY SEQUENCE
/I CALIBRATE^+
FAULTS MANUAL

I
.
I
enter a n e w position value
L
-1
SELECT:
FIND STOPS STOPOPENVALUE BIAS MIDPOINT AUTO FUN POSlTlONER LOW POSITIONER SIG HIGH POSITIONER SIG HI PRESURE VALUE MANUAL
----c SELECT:
SINGLEDOUBLE CONTROLLER ONlOFF ATOlATC LINEAR/50"~130"/~lQUlCK/CUSTOM TlGHT SHUT OFF ONlOFF LO POSITION LIMIT HI POSITION LIMIT ENGLlSHlFRANClAS MANUAL
DISPLAY VALUE OF:
DISPLAY VALUE OF:
LO POSITION SIG HI POSITION SIG ni PRESSURE
__
DISPLAY FAULT: POSERR position error RESET reset occurred PRESEN pressure sensor error BISAERR bias error STOPERR find stops failed TEMPERR temperature fault WTRERR eeprom write fault TIMRERR watchdog timeout CALFAIL measurement out of range REFERR reference standards HWERR self check fault OVERRUN data out o f range CLEAR FAULT MESSAGE
~-
SELECTS OR TOGGLES VALUE INCREASES VALUE OR STEPS FORWARD
* Use HART Command "000 Read Indentifier" and Look

at "Hardware Revision = X". Than Subtract One.
DECREASESVALUEORSTEPSBACKWARD
Figure 30b. Pushbutton Guide for SVI Version 1.0.5
Menu Structure
The menu structure for operating the SVI from the local pushbuttons and display is shown in Figure 31 to Figure 35 on the following pages.
NORMAL OPERATE Mode and Manual Mode Menus

Note that when you leave the NORMAL OPERATE mode to go to MANUAL mode, the valve is placed in the last position it was in when it left NORMAL OPERATE. When in the MANUAL mode, the device will not respond to the 4-20 mA signals. However, the SVI unit can still respond to HART commands, including HART commands to position the valve. Note also that when you go to EXAMINE from the normal OPERATE MODE MENU, the valve is still in NORMAL OPERATE mode and still responds to the 4-20 mA signal.
OPERATE MODE DISPLAY
POSITIONER
OPERATE MODE MENU
--c
TO CONFIG IN EXAMINE MENU

NAL V E IS STILL IN OPERATE MODE,
IN OPERATE- MODE THE DISPLAY SEOUENCES THROUGH VALVE POSITION, INPUT SIGNAL, AND ACTUATOR PRESSURE- O N A ? 5-SECOND INTERVAL
PRESS + O R - T O INCRIDECR VALVE POSITION. PRESS * TO ACCEPT
r $ - I
+POS MAN
T O DISPLAY SEQUENCE
+
1
A
W).# 1
CALIBRATE
~
TOSTOPSIN CALIBRATE
TO SINGLE OR-DOUBLE IN CONFIG MENU
##,#
1 4EXAMINE
i k
TOTONFIG IN EXAMINE MENU
L -
Figure 31. NORMAL OPERATE, MODE SELECT, and MANUAL Menu Structures
46
Configure Menu
Because calibration depends on certain configuration options, you must perform Configuration before you perform Calibration when installing the SVI the first time.
CONFIGURE MENU
FROM --) CONFIG IN MANUAL MENU
SELECTTYPEOFACTUATOR (DOUBLE NOT IMPLEMENTED AT PRESENT)
PRESS TO SELECT OPTION SINGLE DOUBLE
1 PRESS + OR - T O ACCEPT AND
SELECT CONTROLLER OPTION, CTL OFF IS ALWAYS SELECTED IF NO CONTROLLER IS PRESENT, EVEN IF NO LIMIT SW IS USED,
CTL OFF
~
PRESS * TO SELECT OPTION PRESS + OR. TO ACCEPT AND PROCEED TO NEXT MENU ITEM
SELECT AIR TO CLOSE OR AIR TO OPEN (VERY IMPORTANT TO SET CORRECTLY)
PRESS+OR-TOACCEPTAND PROCEED TO NEXT MENU ITEM
+
I
SELECT CHARACTERIZATION
If *I
--+
CUSTOM
* / A --u
TURN TIGHT SHUTOFF OFF OR ON (PROVIDES MAX SEATING FORCE AT 0% POSITION)
f##
TS ON
4 -
DISPLAYS TS VALUE IF TURNED ON PRESS * T O CHANGE ONlOFF STATUS DISPLAYS VALUE WHEN CHANGED FROM OFF TO ON PRESS iOR - T O ENTER NEW VALUE
PRESSTOACCEPTNEWVALUEANDPROCEEDTO
+
SOFTWARE LOWER LIMIT STOP SETTINGS. VALUE DISPLAYED IF SET TO ON. IF ON, VALVE CANNOT GO BEYOND LIMIT
-7
1
NEXT MENU ITEM DISPLAYS PL VALUE IF TURNED ON
+I
SOFTWARE UPPER LIMIT STOP SETTINGS, VALUE DISPLAYED IF SET TO ON. IF ON, VALVE CANNOT GO BEYOND LIMIT
PRESS + OR - T O ENTER NEW VALUE. PRESS * TO ACCEPT NEW VALUE AND PROCEED TO NEXTMENUITEM DISPLAYS PU VALUE IF TURNED ON. PRESS * TO CHANGE ONlOFF STATUS DISPLAYS VALUE WHEN CHANGED FROM OFF TO ON.
+
SELECT DISPLAY LANGUAGE
1 RETURN TO POS I
Figure 32. CONFIGURE Menu Structures
47
Calibrate Menu
If a change is made in the Air-to-Open/Air-to-Closeor Direct/Reverse configuration options, or if you move the SVI to a different valve or make any change to the valve position linkage, you must run the find "STOPS" ca Iib ration again.
CALIBRATE MENU
CAUTION: THIS FUNCTION STROKES THE VALVE OVER ITS FULL RANGE. DO NOT EXECUTE WHILE THE VALVE IS CONTROLLING THE PROCESS
II FROM
"
CONFIG" IN MANUAL MENU
DETERMINES WHAT VALVE POSITIONS CORRESPOND TO FULLY OPEN AND FULLY CLOSED
*
f RUNNING THIS TASK, THE TASK IS INTERRUPTED
RESETS 100% POINT TO "NOMINAL MAXIMUM TRAVEL"
PARTIALLY IMPLEMENTED NOW. USE TO DETERMINE POSITIONERS TUNING PARAMETERS
INITIATES AUTO TUNE FUNCTION AND RETURNS TO " T U N E WHEN FINISHED. PRESSING ANY BUTTON STOPS THE TUNING PROCESS.
VALUE OF INPUT SIGNAL FOR FULLY CLOSED (OR FULLY OPEN)
DISPLAYS VALUE OF SIG LO. PRESS + OR - T O ENTER NEW VALUE. PRESS * TO ACCEPT NEW VALUE AND PROCEED TO NEXT MENU ITEM.
VALUE OF INPUT SIGNAL FOR FULLY CLOSED (OR FULLY OPEN]
##.#
SIG HI
I------------
-;
____________.
j
DISPLAY VALUE
7 DISPLAYS VALUE OF SIG HI.
: PRESS + OR
j
TO ENTER NEW VALUE. PRESS ' TO ACCEPT NEW VALUE AND PROCEED TO NEXT MENU ITEM.
~
w.#
SUPPLYPRESSURE PRES HI
; VALUE I
L-------------
PRESSURE AS ENTERED PRESS + OR. TO ENTER NEW VALUE. PRESS * TO ACCEPT NEW VALUE AND PROCEED TO NEXT MENU ITEM
I RETURNSTO
"POS MAN" IN MANUAL MENU
I
I
Figure 33. CALiBRATE Menu Structures
48
Examine Menu
This menu can be entered either from the Manual Mode Menu or from the NORMAL OPERATE Mode Menu. The EXAMINE menu allows the user to read the current configuration, calibration, and status information. This information, however, cannot be changed from the EXAMINE menu. When you exit from the EXAMINE menu, you return to the menu from which you entered.
EXAMINE MENU
IN MANUAL MENU OR FROM OPERATE MENU
_i
' CONFIG
% PRESS + OR - T O STEP THROUGH CONFIGURATION

~
PARAMETERS IN SEQUENCE. PRESS * TO RETURN TO T O N F I G AT ANY TIME.
+
~
PRESS + OR - T O STEP THROUGH CALIBRATION PARAMETERS IN SEQUENCE. PRESS * TO RETURN TO 'CALIB AT ANY TIME.
p k
* FAULTS
I
I
PRESS + OR - T O STEP THROUGH FAULT MESSAGES IN SEQUENCE. PRESS' TO RETURN AT ANY TIME. DISPLAYS "CLEAR" AT END OF SEQUENCE. PRESS * TO CLEAR FAULTS AND RETURN TO "FAULTS" IN EXAMINE MENU.
RETURNS TO MANUAL OR OPERATE MENU. DEPENDS ON ENTRY STATE. (SEE NOTE BELOW)
-b MANOR
-b OPER DEPENDS ON ENTRYSTATE
NOTE: In order to quit EXAMINE MENU if entry IS from MANUAL MENU, then at step -+ MAN it IS necessary to key * (which dlsplays + OPER) and key again to return to MANUAL MENU
Figure 34. EXAMINE Menu Structure
49
CONFIGURATION PARAMETERS
FROM 'CONFIG IN "EXAMINE" MENU
CALIBRATION PARAMETERS
FROM 'CALIB IN "EXAMINE" MENU
FAULT MESSAGES
FROM "FAULTS IN "EXAMINE" MENU
I ,
f
* *
9
SINGLE
*
v
8
CTL OFF
RETURNS
TO '"CALIB" IN EXAMINE MENU
i
t
SIG LO
w
POS ERR
20.00
* I
RESET
RETURNS
F
LINEAR
*t
RETURNS
'"CONFIG" IN EXAMINE MENU
w P- i
TO
+
+
TS OFF
PL OFF
TO
"'FAULTS" IN EXAMINE MENU
"OTHER FAULTS"
-I
I
30.00
PRES
H I
A t
MESSAGES CLEAR f
"OTHER FAULTS"
100.0
PU OFF
, L
Figure 35. Parameter and Message Displays
ENGLISH
50

I
Normal Operation - Positioner

Functions
In normal operation, the SVI unit operates as a positioner using a 4-20 mA input signal as set point. The local digital display sequentially displays valve position, input signal, and actuator pressure on a 1.5-second interval. Pressing any button moves you to the (OPER option in the OPERATE MODE MENU, as shown in Figure 31 on page 34.
The OPERATE MODE MENU has 3 options:
EXAMINE (go to EXAMINE Menu), and -)OPER (return to display of current position, pres; Menu), sure, and signal). Use the pushbuttons to move from one option to the next. Press the * button to go to the item displayed in the menu.
-' MAN (put valve
in manual mode and go to MANUAL
Configuration
I
Parameters and Options Available You ,can configure the following options by pressing the local pushbuttons in the procedure described below. We recommend that you use the menu structure diagrams in Figure 31 to Figure 35 on pages 34 to 38 as a road map in following the procedures described.
As noted previously, configuration should be performed before calibration. Also note that configuration can be performed only when the valve is in manual mode. The configurable options are as described in Table 6.
MENU ITEM
DESCRIPTION OF OPTIONS
SINGLE (or DOUBLE) CTL OFF (or ON)
Select single or double acting actuator (not presently available) Select PID Controller function (OFF or ON) !Select Air-to-Open or Air-to-Close actuator operation Select desired valve characteristic curve (linear, equal percentage 50, equal percentage 30, quick opening, or custom curve). The custom curve must have been entered through the remote PC. Display and set value of tight shutoff point. Default is 0.0% Display is set value of the lower software position limit stop. Default is 0.0% Display is set value of the upper software position limit stop. Default is 0.0% Select language for displays (English or French)
IATO (or ATC)

LINEAR (or EQUAL 50, EQUAL 30, QUICK, CUSTOM) TS (OFF or ON) PL (OFF or ON) PU (OFF or ON) ENGLISH (or FRENCH)
51
Procedures
To configure the SVI unit, execute the following procedure: -)OPER will be displayed. Press + to get to the 1. If in NORMAL OPERATE mode, press any button. -)MAN menu item.
2. Press * to move to MANUAL menu. (POS MAN displayed) This locks the valve in position and places it in Manual Mode.
3. Press + twice to move to -)CONFIG option.

Press * to put the SVI in the configure mode and display the first item in the CONFIGURE menu. 5. If Single or Double displayed is the one desired, press + to move to the next item. If not, press * to select the alternate choice. When OK, press + to move to next item. (Note: DOUBLE is not presently implemented.) 6. In CTL ON (OFF), OFF should be displayed for positioner. If display shows ON press to select OFF. Press + to move to the next item. 7 . In AT0 (ATC), if option displayed is correct, press + to move to the next item. If not, press * to select the alternate choice. When OK, press + to move to the next item. a. In LINEAR (or other curve), if option displayed is the one desired, press + to move to the next item. If not, press to select the other options. When OK, press + to move to next item. If custom is selected, the custom curve must have been entered through the ValVue software program. The curve itself cannot be entered from the local pushbuttons. 9. The tight shutoff (TS) option allows the user to configure the positioner to apply full supply pressure (or atmospheric pressure) to the actuator whenever the signal directs the valve near the closed position. If the tight shutoff option is on, the value of the TS option determines the near value at which the valve is forced fully shut. In TS OFF (ON), if status and value displayed are satisfactory, press + to move to next item. If not, press * to change on/off status and display value. Then press + or - buttons to increase or decrease value displayed. (When status is changed from ON to OFF, no value is displayed). When value is OK, press * to accept value and move to next item. 10 The SVI allows the user to configure a lower (PL) and upper (PU) software position limit stop. When in operation with these limits on, the valve will not move below the lower limit stop or above the upper limit stop. (Caution: These are software limit stops. If the SVI fails for any reason including power fail ure or air failure, the SVI cannot enforce these limit stops and the valve will go to fail-safe. Furthermore, the FULL OPEN AND FULL CLOSED buttons in ValVue bypass the limit stop controls. If safety requires the use of limit stops, mechanical limit stops should be used). In PL OFF (ON), if status and value displayed are satisfactory, press + to move to next item. If not, press * to change on/off status and display value. Then press + or - buttons to increase or decrease value displayed. (When status is changed from ON to OFF, no value is displayed). When value is OK, press * to accept value and move to next item. 11 In PU OFF (ON), if status and value displayed are satisfactory, press + to move to next item. If not, press * to change on/off status and display value. Then press + or - buttons to increase or decrease value displayed. (When status is changed from ON to OFF, no value is displayed.) When value is OK, press * to accept value and move to next item. 12. The SVI local display may be configured to display English or French. If the language displayed is correct, press + to move to next item. If not, press * repeatedly to display other language options. When the desired language is displayed, press + to move to next item.
4. 13. At
MAN, press + to move to the top of the CONFIGURATION menu or - to move back to the previous item. To leave the CONFIGURATION menu, press *. This returns you to the MANUAL menu. (POS MAN displayed) This completes the configuration procedure
)
14. To continue with calibration press
- to move to -CAL option. Continue with Step 4 below.

52
Local Calibration
NOTE:
Perform configuration before running calibration functions.
Functions
You can perform the following calibration functions with the SVI product: Low and high values for input signal Low and high values for actuator pressure output Set the minimum and maximum stops for valve position
Procedures
Refer to the menu structure diagrams in Figures 31 through 35 on pages 46 to 50 for assistance in following the procedures described.
To calibrate the SVI unit using the local pushbuttons, execute the following procedure:
CAUTION: Since some calibration functions stroke the valve over its full range, the valve should be is0 lated from the process before starting calibration.
1.
2.
3. 4. 5.
If in NORMAL OPERATE mode, press any button, -)OPER will be displayed. Press + to get to the MAN menu item. Press to move to MANUAL MENU (POS MAN displayed) Press + to move to ->CAL option.
Press * to go to CALIBRATE menu. STOPS will be displayed. In STOPS, press * to initiate the operation, which moves the valve to fully closed, then fully open, and then returns to the starting position. (This operation calibrates the end points for the position feedback potentiometer.) When the operation is complete, press + to move to the next item.
CAUTION: This function strokes the valve over its full range. Do not execute while valve is controlling the process.
6.
On some valves, the full travel is larger than the nominal travel of the valve and it may be desirable to have the reported 100% position correspond to the nominal travel rather than the full stroke. The STOP OP option allows this correction. If a correction is to be made, press to move valve to the 100% position. Using the + and - buttons, position the valve to the nominal full open position. Press to accept this position as the new 100/o position. 7. The Bias is the signal sent to the internal I/P that causes the actuator to neither fill nor exhaust. The pneumatics are adjusted at the factory and should not need further adjustment. If the pneumatics need to be readjusted for any reason, the BIAS option should be selected by pressing *. This will output a value of 2750 to the I/P. The adjustment screw on the top of the pneumatics section can be adjusted until the valve is nearly stationary near mid travel. See Bias Adjustment in Troubleshooting. Press + to move to the next menu item. 8. The TUNE menu item allows the user to initiate the automatic position control tuning function which will select appropriate PID parameters for the position controller. Press * to initiate AUTO TUNE function. This procedure may take from 1 to 5 minutes. During this time the valve will make a series of steps (Caution: This procedure should not be performed while the valve is controlling the process.) When the function is completed, you return to TUNE. Press + to advance to the next item.
53
9.
SIG LO displays the input signal that should correspond to the full closed or full open position of the valve (depending upon whether the valve is air-to-open or air-to-close and whether the positioner is direct or reverse). In SIG LO, if the displayed value is correct, press + to advance to the next item. If not, press * to display value of SIG LO. Use + and - buttons to change the value. When OK, press to return to menu and move to next item. 10. SIG HI displays the input signal that should correspond to the full open or full closed position of the valve (depending upon whether the valve is air-to-open or air-to-close and whether the positioner is direct or reverse. SIG HI must be larger than SIG LO by at least 5 mA. In SIG HI, if the displayed value is correct, press + to advance to the next item. If not, press * to display value of SIG HI. Use + and buttons to change the value. When OK, press to return to menu and move to next item. 11. The PRES HI menu item allows the user to enter the supply pressure. This pressure is used for scal; ing of the pressure data in the SVI. In PRES HI, if the displayed value is correct, press + to advance to the next item. If not, press * to display value of PRES HI. Use + and - buttons to change the value. When OK, press * t o return to menu and move to next item.
12. Calibration as a positioner is now complete. At -)MAN, press * to return to the MANUAL mode. (POS ) MAN displayed) I
Return to Normal Operation

To return to NORMAL OPERATE mode from any menu, press + or - repeatedly until -)MAN ( or -)OPER) is displayed. If - OPER appears, press * to return to NORMAL OPERATE mode. If -> MAN appears, press * to return to Manual Mode Menu. Then press + repeatedly until +OPER appears. Then press to return to NORMAL OPERATE mode and normal operation.
Examine
Functions
The EXAMINE menu permits you to display calibration parameters, configuration parameters, and to display and/or clear fault status messages and codes. (Refer to the Table 8 for explanations of fault messages.) You may enter the Examine menu either from NORMAL OPERATE Mode or from Manual Mode. When entered from NORMAL OPERATE mode the valve still responds to changes in set point input signal and the values displayed change in accordance with changes in input signal.When entered from Manual mode, the valve is locked in position. When you exit from the EXAMINE menu, you return to the menu from which you entered.
Procedures
Examine Calibration Parameters To examine the calibration parameters, execute the following procedure:
1. If in NORMAL OPERATE mode, press any button. 2. Press + to move through the options until you reach the EXAMINE menu item. Press * to go to EXAMINE menu. (This leaves valve in NORMAL OPERATE mode.) If in MANUAL mode, press + repeatedly until the EXAMINE menu item is reached. Press * to select the EXAMINE mode. 3. Press + repeatedly to move through the EXAMINE menu until *CALI9 is reached. Press * to display the list of calibration values. To move forward through the calibration parameters in sequence, press +. To move back through the list, press -. Press * at any time to return to *CALI9 in the EXAMINE menu.
54
Examine Configuration Parameters To examine the configuration parameters, execute the following procedure: 1. 2.
3.
4.
5.
If in NORMAL OPERATE mode, press any button. Press + to move through the options until you reach the EXAMINE menu item. Press to go to EXAM INE menu. (This leaves valve in NORMAL OPERATE mode.) If in MANUAL mode, press + repeated ly until the EXAMINE menu item is reached. Press to select the EXAMINE mode. Press + repeatedly to move through the EXAMINE menu until CONFIG is reached. Press to display the list of configuration values. To move forward through the configuration parameters in sequence, press +. To move back through the list, press -. At any time, to return to CONFIG in the EXAMINE menu, press .
Display/Clear FAULTS To examine and /or clear fault codes and messages, execute the following procedure: 1. 2.
If in NORMAL OPERATE mode, press any button. Press + to move through the options until you reach the EXAMINE menu item. Press * to go to EXAM INE menu. (This leaves valve in NORMAL OPERATE mode.) If in MANUAL mode, press + repeated ly until the EXAMINE menu item is reached. Press to select the EXAMINE mode. 3. Press + repeatedly to move through the EXAMINE menu until *FAULTS is reached. Press to display the list of status values. To move forward through the faults in sequence, press +. To move back through the list, press -. The last item in the list is CLEAR. When this message is displayed, you can clear all faults by pressing *. This will also return you to FAULTS in the EXAMINE menu. If you do not want to clear all fault messages, press + or - to move to another item in the list. You can then press * to return to FAULTS in the EXAMINE menu without clearing fault messages. This completes the EXAMINE functions.
55
Positioner Fault Messages

Table 7 lists the fault codes/messages that may appear on the display. The table also explains the meaning of each message, the probable cause of the fault, and recommended action you should take to correct the fault. Table 7. Positioner Fault Messages
Display Code
FauIt Message
Position Error
Meaning
Valve position did not agree with SVI output command within
Latched Error *
I
Probable Cause
Valve is stuck or feedback linkage is disconnected or brolken
I
0s ERR
31AS ERR point is out of range
J
The position sensor has failed or is not aligned properly The pressure sensor has failed
Supply pressure too low or incorrect pneumatic block adjustment Failed or linkage aligned incorrectly
0s SEN
Position Sensor Error
IRES SEN
Pressure Sensor Error
I
J
Failure
SIG SEN
Current Sensor Error
The primary signal (4-20) sensor has
Failure
3EF ERR
Reference Voltage Error
The A/D reference voltage is incorrect
Failure
S W ERR
Self Check Failure
SVI failed self-check diagnostics
Failure
3ESET
Reset
SVI has reset since last status clear
Power loss
IVER RUN
1Data Overrun
Internal check failed to process data in
Hardware failure
Latched Errors are historical data that may or may not effect valve operation. To check Latched Errors, use the Clear Status command via pushbuttons, valve, or HART handheld.
56
Table 7. Positioner Fault Messages (continued)
Display Code
TEMP ERR
Fault Message
Meaning
Latched Error *
Probable Cause
I
~
Circuit Temperature internal SVI temperature out Error of range

~~
J
I
WRT ERR
EEP Prom Write Failed
Device failed to write to nonvolatile memor!
TIMER SEN
Watchdog Timer Ti meout
SVI failed to send D/A output within timeout Signal or pressure calibration
Hardware failure
CAL FAIL
Calibration Failed
Bad value set in calibration mode
STOP ERR
Find Stops Failed
The auto POS calibration failed
1 Pressure sensor not

working or bias adj. not correct, or valve will not move Primary sensor failurc or linkage not aligned correctly on the potentiometer
FAIL SAFE
Fail-safe Position placed in the fail-safe position
Latched Errors are historical data that may or may not effect valve operation. To check Latched Errors, use the Clear Status command via pushbuttons, valve, or HART handheld.
57
Chapter 4 - Operation-SVI Controller

Introduction
NOTE: The SVI must have the controller option installed at the factory. With this option installed, the SVI can be operated as either a positioner or controller, selectable by Val-Vue, HART Communicator or the local pushbuttons. (Local pushbuttons support limited controller functions.) Operation of the SVI Controller with firmware version 1.0.5 requires that all controller operating parameters be entered from either ValVue software or from a HART 275 Hand Held Communicator with Masoneilan SVI Software. The operating parameters that are used for both controllers and positioners can be entered either from the local pushbuttons or ValVue or the Hand-held. The primary process measurement, made by the process transmitter is fed to the controller as a 1-5 V dc signal and connected to terminals A and B on the SVI terminal board. An SVI with firmware version 1.0.6 allows local pushbutton entry of setpoint values and choice of local or remote setpoint. The main controller operating parameters (P, I, D, etc.) still must be entered via ValVue or HART Handheld Communicator. The version 1.0.6 display shows: (1) setpoint-remote or local as configured (2) process variable (3) valve position and (4) pneumatic output signal pressure. The display sequences from one variable to the next every 1.5 seconds. Using the pushbuttons, you can exit from operating mode at any time and step through a menu structure to perform a wide range of manual operation, calibration, configuration, and monitoring functions, all of which are described later in this section. Before you can perform any of these functions, however, you must first ensure that the ValVue software (if used) has placed the pushbuttons in the unlocked mode. (See ValVue User Manual for more details).
NOTE:
If the SVI unit is specified without local pushbuttons and display, local operation is not available, therefore, ValVue Software or a HART handheld communicator is required. When an SVI is turned on, it is advisable to apply the air supply before applying the electrical input signal.
NOTE:
58
Pushbuttons/Display
As shown in Figure 36, the upper line is a 7-digit numeric display and the lower line is a 7-digit alphanumeric display. The upper line is used for displaying values such as input signal or valve position, and the lower one is primarily used for messages and parameter identification.
7-DIGIT NUMERIC DISPLAY
7-DIGIT ALPHA NU MERlC DISPLAY
SELECT OR ACCEPT BUTTON
DECREASE VALUE OR MOVE UP (BACK) IN MENU BUTTON
INCREASE VALUE OR MOVE DOWN (NEXT) I N MENU BUTTON
Figure 36. Local Display and Pushbuttons The three pushbuttons perform the following functions: The left button, marked with , permits you to select or accept the value or parameter option currently displayed. The middle button, marked (-), permits you to move back through the menu structure to the previous item in the menu, or to decrement the value currently shown in the digital display. When used to decrease a displayed value, holding this button down causes the value to decrease at a faster rate. The right button, marked (+), permits you to move down through the menu structure to the next item in the menu, or to increment the value currently shown in the digital display. When used to increase a displayed value, holding this button down causes the value to increase at a faster rate.
To determine how to display and/or select a particular parameter value or configuration option, refer to the menu structure diagrams in Figure 37 through Figure 42. By using these diagrams as a map, you can quickly move through the menus to the function you want to perform.
NOTE: If the buttons are pushed after being locked by the ValVue software, the message LOCKED will appear. Please refer to ValVue Software Manual to unlock pushbuttons.
59
Hot Key
qzF
2 Change Pos
send
1 Identifier
2 positloner conflguratlon 3 cnlihration 4 diagnoslic data 5 read slalus 6 clear status 7 positioner PID 8 errorllmils 9 swllch poslllons conlroller conflguratlon controller calih conlroller PID conlroller paramelers controller SP mode
'
CONTROLLER I controller view 2 modeandSP 3 PID setting 4 controller param 5 alarms vlew
MANUAL MODE
4 -
+XI
CHOOSE 1 SPValue 1 SPMode
PW2.BD C v F h Y-SP=5&?3%
--
R-SF-652
CuFlmhl
LOCAL MODE
A CHOOSE 1 SPValue 1 SPMode

lo alarm Ilm
-+
1-
V I I 7 1
Imanreset
hl alarm Ilm
CONFIGMENU
1 1
1 2 nochange remote SP
3 local SP 14 manual
SP track freeze ou(pu( derivative alarm hlpe
descrlplor message final assy num
HART Communlcalor 1 Offline 4 2 Online
Manual Sel Polnl 1 se1 point 2 fill1 open 3 full closed 7 SVI RESET light shutoff pressure unlls language button
*MANUAL MODE 1 valve position 2 act presslire 3 lnpul siqnal
+.
0
2 syslem Informatlon 3 listen for pc
4 sloraae locallon
5 CONTROLLER
MANUAL MODE MENU 1 NORMALMODE 2 CONFIG MENU 3 CALIBRATEMENU 4 A DIAGNOSTIC MENU * h
3 selup 4 conlroller
7 SVI RESET
CALIBRATE MENU 1 range 2 tuning 3 signals
reverse lnstr fall high conlroller humpless hw reverse posillon enor time 1
locks
near closed
I
1 performstd 2 read dlag
sladup mode
* acllnn PV unilz
CHOOSE 1 primary 4 2 secondary 3 pressure I 4 view slgs 4 5 resel l o factory sel low value enler hl value remole SP sunus rallo control local SP controller rate
HAND HELD CO M MUNIC ATOR GUIDE for SVI
B
I n sprlnq
hi spring 1 0 preSSllrP upper pressure lime lo open
CHOOSE 1 continuous 2 standard
I
t"lil1 travel lime closed lime open near closed cycles
,
EXAMINE
a MODIFY
Beta. Damp Comp. Dead
Figure 36a. Hand Held Communicator Guide for SVI
PUSH BUTTON GUIDE FOR SVI Version 1.0.6
POSMAN 4 CALibrate CONFlGure
position value
OPERATE
'C
II
EXAMINE OPERATE
SETPOINT ISETPOINT CANCEL
FIND STOPS STOP OPEN VALUE BIAS MIDPOINT AUTO FUNE POSITIONER LOW POSITIONER SIG HIGH POSITIONER SIG HI PRESURE VALUE MANUAL
I
SELECT:
CALIBRATE4
NORMAL MODE DISPLAY SEQUENCE
w
OPERATE DISPLAY
FAULTS 1 MANUAL
SlNGLElDOUBLE CONTROLLER ONlOFF ATOlATC LINEAR/50"/~130"/~lQUICK/CUSTOMILRECIPROCATING TIGHT SHUT OFF ONlOFF LO POSITION LIMIT HI POSITION LIMIT ENGLlSHlFRANClAS MANUAL
1
DISPLAY VALUE OF:
DISPLAY VALUE OF:
ACTUATOR TYPE CONTROLLER STATE ACTUATOR ACTION LO POSITION SIG CHARACTERIZATION HI POSITION SIG TIGHT SHUT OFF HI PRESSURE LO POSITION LIMIT I HI POSITION LIMIT LANGUAGE
. . .
Use HART Command "000 Read Identifier" and Look at "Hardware Revision = X". Then Subtract One.
Figure 36b. Pushbutton Guide for SVI Version 1.0.6
POSERR position error RESET reset occurred PRESEN pressure sensor error BISAERR bias error STOPERR find stops failed TEMPERR temperature fault WTRERR eeprom write fault TIMRERR watchdog timeout CALFAIL measurement out of range REFERR reference standards HWERR self check fault OVERRUN data out of range CLEAR FAULT MESSAGE
SELECTS OR TOGGLES VALUE INCREASES VALUE OR STEPS FORWARD DECREASES VALUE OR STEPS BACKWARD
Menu Structure
The menu structure for operating the SVI from the local pushbuttons and display is shown in Figures 37 through 42 on the following pages.
Normal Operate Mode and Manual Mode Menus

Note that when you leave the NORMAL OPERATE mode to go to MANUAL mode, the valve is placed in the last position it was in when it left NORMAL OPERATE. When in the MANUAL mode, the device will not respond to the 4-20 mA signals. However, the SVI unit can still respond to HART commands, including HART commands to position the valve. Note also that when you go to EXAMINE from the NORMAL OPERATE MODE MENU, the valve is still in "NORMAL OPERATE" mode and still responds to the 4-20 mA signal.
NORMAL OPERATE MODE DISPLAY
r '
~
__
\
OPERATEMODEMENU
R-SP or LSP
+'
14 MAN
*
A -
T O 'CONFIG' IN EXAMINE M E N U
WALVEISSTILL I N 'OPERATE MODE]
i
IN "OPERATE" MODE. THE DISPLAY SEQUENCES THROUGH -PROCESS V A R I A B L E VALVE POSITION "ACTUATOR PRESSURE' AND -LSP" or 'R-SP" O N A 1.5 SECOND INTERVAL
+l
* ~
T O 'REMOTE' IN CONTROLLER MENU
, MANUALMENU
'
- PRESS'TOACCEPT
T O DISPLAY SEQUENCE
i_--
A A
I
1
CALBRCTE M E N U
*
-
TO SINGLE'OR DOUBLE INCONFIG MENU
1O"REMOTEIN CONTROLLERMENU,
4 EXAMINE
zb
+
TO EXAMINE 'CONFIG MENU IN
T O T H E NORMAL O P E W T E MODE DISPLAY DISPLAY SEOUENCE
___~~__
~~
Figure 37. Normal Operate, Mode Select, and Manual Mode Menus
62
Configure Menu
Because calibration depends on certain configuration options, you must perform Configuration before you perform Calibration when installing t h e SVI the first time.
CONFIGURE MENU
FROM CONFIG IN MANUAL MENU
I
SELECT TYPE OF ACTUATOR (DOUBLE NOT IMPLEMENTED AT PRESENT) PRESS TO SELECT OPTION
SELECT CONTROLLER OPTION. c n OFF- IS ALWAYS SELECTED IF NO CONTROLLER IS PRESENT, EVEN IF NO LIMIT SW IS USED.
CTL OFF
CTL ON
PRESS TO SELECT OPTION. PRESS + OR - T O ACCEPT AND PROCEED TO NEXT MENU ITEM
PRESS TO SELECT OPTION SELECT AIR TO CLOSE OR AIR TO OPEN (VERY IMPORTANT TO SET CORRECTLY)
PRESS+OR-TOACCEPT AND
PROCEED TO NEXT MENU ITEM
SELECT CHARACTERIZATION
--
*
N R N TIGHT SHUTOFF OFF OR ON [PROVIDES MAX SEATING FORCE AT 0% POSITION)
~
DISPLAYS T S VALUE IF TURNED ON. PRESS TO CHANGE ONlOFF STATUS. DISPLAYS VALUE WHEN CHANGED FROM OFF TO ON PRESS + OR - T O ENTER NEW VALUE. PRESS * TO ACCEPT NEW VALUE AND PROCEED TO NEXT MENU ITEM DISPLAYS PL VALUE IF TURNED ON. PRESS TO CHANBE ONlOFF STATUS. DISPLAYS VALUE WHEN CHANGED FROM OFF TO ON PRESS + OR - T O ENTER NEW VALUE. PRESS TO ACCEPT NEW VALUE AND PROCEED TO NEXT MENU ITEM DISPLAYS PU VALUE IF TURNED ON. OFF TO ON
4*
+
SOFTWARE LOWER LIMIT STOP SETTINGS. VALUE DISPLAYED IF SET TO ON. IF ON, VALVE CANNOT GO BEYOND LIMIT
7
f PL ON
I *
!z
*-
SOFTWARE UPPER LIMIT STOP SETTINGS. VALUE DISPLAYED IF SET TO ON. IF ON, VALVE CANNOT GO BEYOND LIMIT
----C PUOFF
; i
; I -PRESS
,P,p:,;,,,:~:~~~~NS~~ROM
+I
SELECT DISPLAY LANGUAGE
-I
O R . TO ENTER NEW VALUE. PRESS * TO ACCEPT NEW VALUE AND PROCEED TO NEXT MENU ITEM.
TO MOVE TO NEXT OPTION, PRESS. PRESS TO ACCEPT AND PROCEED TO NEXT MENU ITEM.
RETURN TO POS MAN IN MANUAL
Figure 38. Configure Menu Structures
63
Calibrate Menu
If a change is made in the Air-to-Open/Air-to-Close or Direct/Reverse configuration options, or if you move ihe SVI to a different valve or make any change to the valve position linkage, you must run the find "STOPS" calibration again.
CALIBRATE MENU
I
1
FROM
"*
C A L " I N MANUAL MENU

~
' VALVE OVER ITS FULL RANGE.

1 CONTROLLING THE PROCESS
CAUTION: THIS FUNCTION STROKES THE

DO NOT EXECUTE WHILE THE VALVE IS
1I
i i
DETERMINES WHAT VALVE POSITIONS CORRESPOND TO FULLY OPEN A N D FULLY CLOSED
+
STOP OP
MOVES VALVE TO CLOSED AND OPEN STOPS AND RETURNS TO STARTING VALUE (VALVE MUST BE OFF PROCESS) IF BUTTON IS PUSHED WHILE RUNNING THIS TASK, THE TASK IS INTERRUPTED A N D THE VALVE RETURNS TO STARTING POSITION.
RESETS 100% POINT TO "NOMINAL MAXIMUM TRAVEL"
PRESS ' T O ACCEPT NEW VALUE
+ T O CALIBRATE BIAS PRESSURE O N PNEUMATIC BLOCK

4 -
PARTIALLY IMPLEMENTED NOW. USE TO DETERMINE POSITIONER TUNING PARAMETERS
*
TUNE
'
I
SETS THE IIP CURRENT TO THE NORMAL B I A S V A L U E PRESS + OR - T O RETURN TO CALIBRATE MENU
INITIATES AUTO TUNE FUNCTION A N D RETURNS T O "TUNE" WHEN FINISHED PRESSING ANY BUTTON STOPS THE TUNING PROCESS

~~
,_---------~
4 + I
A
##.#
-I*
DISPLAYS VALUE OF SIG L O PRESS + OR - T O ENTER NEW VALUE i PRESS ' TO ACCEPT NEW VALUE A N D _ _ - _ _ _ _ _. _ ! PROCEED __TO NEXT MENU ITEM.
SIG HI
4 I i VALUE
-- - - - - - - - - - - -
SUPPLY PRESSURE
r-'
##.#
1
1
+j
PRESS + OR - T O ENTER NEW VALUE PRESS * TO ACCEPT NEW VALUE ----_-------! A N D PROCEED TO NEXT MENU ITEM
I
i DISPLAYS VALUE OF SIG HI
j , A
I
PRES HI
+ Iv
DISPLAYS VALUE OF SUPPLY PRESSURE AS ENTERED + i VALUE : PRESS + OR - T O ENTER NEW VALUE PRESS' TO ACCEPT NEW VALUE I------------. A N D PROCEED TO NEXT MENU ITEM
-*
.------------i
-i
i
'
RETURNS T O "POS MAN" IN MANUALMENU
- 1I
Figure 39. Calibrafe Menu Structures
64
Controller Menu
This menu can be entered from either the MANUAL Mode Menu or the NORMAL OPERATE Mode Menu. The Controller menu allows the user to read and change the controller mode, local setpoint, and startup setpqint. When you exit from the CONTROLLER menu, you return to the menu from which you entered.
CONTROLLER MENU
a
FROM "--b CTLR"
I*
REMOTE OR LOCAL
PRESS * TO TOGGLE
' G I
SETPOINT
! +
k
PRESS + OR - T O ENTER NEW VALUE
- PRESS * TO EXIT BACK TO SETPOINT
* -+ PRESS + OR - T O ENTER NEW VALUE

- PRESS * TO EXIT BACK TO I SETPOINT
I SETPOINT
M
CANCEL
*
+
RETURN TO NORMAL OR MANUAL MENU WITHOUT SAVING CHANGES
RETURN TO NORMAL OR MANUAL MENU WITH SAVING CHANGES
Figure 40, Controller Menu Structures
65
Examine Menu
This menu can be entered either from the MANUAL Mode or from the NORMAL OPERATE Mode. The EXAMINE menu allows the user to read the current configuration, calibration, and status information. This information, however, cannot be changed from the EXAMINE menu. When you exit from the EXAMINE menu, you return to the menu from which you entered.
EXAMINE MENU
IN MANUAL MENU OR FROM OPERATE MENU
bl-t
*L
* CONFIG
PRESS + OR - TO STEP THROUGH CONFIGURATION PARAMETERS IN SEQUENCE. - PRESS ' TO RETURN TO TONFIG AT ANY TIME.
% PRESS + OR - T O STEP THROUGH CALIBRATION

__
PARAMETERS IN SEQUENCE. PRESS * TO RETURN TO T A L I B AT ANY TIME.
t
RETURNS TO MANUAL OR OPERATE MENU. DEPENDS ON ENTRY STATE. (SEE NOTE BELOW) MANOR OPER DEPENDS ON ENTRYSTATE
PRESS + OR - T O STEP THROUGH FAULT MESSAGES IN SEQUENCE. PRESS TO RETURN AT ANY TIME. __ DISPLAYS "CLEAR" AT END OF SEQUENCE. PRESS ' TO CLEAR FAULTS AND RETURN TO "FAULTS" IN EXAMINE MENU.
t ,
-b
-b
NOTE: In order to quit EXAMINE MENU if entry is from MANUAL MENU, then at step -+ MAN it is necessary to key * (which displays 4 OPER) and key * again to return to MANUAL MENU
Figure 4 1. Examine Menu Structures
66
Parameter and Message Displays
C 0 N FIG U RATION PARAMETERS

FROM T O N F I G IN "EXAMINE" MENU
CALIBRATION PARAMETERS
FROM 'CALIB IN "EXAMINE" MENU
FAULT MESSAGES
FR0M"FAULTS IN "EXAMINE" MENU
L
*
t -
*
*
7 5 w +5 1 1
SIG LO
SINGLE
POS ERR
CTL OFF
RETURNS TO "'CALlE" IN EXAMINE MENU
20.00
LINEAR
PRES HI
I1
30.00
RETURNS TO ""FAULTS" IN EXAMINE MENU
"OTHER FAULTS"
RETURNS
TO
"'CONFIG" IN EXAMINE MENU
,-
+
TS OFF
CLEAR + MESSAGES
I *
PL OFF
*- I t
+ i-1
ENGLISH
100.0
PU OFF
t
Figure 42. Parameter and Message Displays 67
Normal Operation Controller Functions

In normal operation, the SVI unit operates as a controller using a local or remote input signal as set point. The primary process measurement, made by the process transmitter, is fed to the controller as a 1-5 Vdc signal. The local digital display sequentially displays set point-remote or local as configured, process variable, valve position, and actuator pressure on a 1.5-second interval. Pressing any button moves you to the -'OPER option in the OPERATE MODE MENU, as shown in Figure 37 on page 62. The OPERATE MODE MENU has 4 options: -' MAN (put valve in manual mode and go to MANUAL Menu), (CTLR (go to CONTROLLER Menu), EXAMINE (go to EXAMINE Menu), and +OPER (return to display of current position, pressure, and signal). Use the pushbuttons to move from one option to the next. Press the ' button to go to the item displayed in the menu.
)
Configuration
Parameters and Options Available The Controller version of SVI must have the controller parameters configured from either Val-Vue or a HART Hand Held Communicator. Normally all of the operating parameters will be configured from Val-Vue or the Hand Held Communicator, however any parameters common to both the positioner and controller versions can be entered or changed via the pushbuttons. Controller setpoint values and selection of local or remote setpoint can also be entered via the pushbuttons. You can configure the following options by pressing the local pushbuttons in the procedure described below. We recommend that you use the menu structure diagrams in Figures 37 through 42 (pages 62 to 67) as a road map in following the procedures described. As noted previously, configuration should be performed before calibration. Also note that configuration can be performed only when the valve is in manual mode. The configurable options are as described in Table 8.
MENU ITEM SINGLE (or DOUBLE) CTL OFF (or ON) AT0 (or ATC) LINEAR (or EQUAL 50, EQUAL 30, QUICK, CUSTOM), L-RECIP TS (OFF or ON)
PL (OFF or ON)
DESCRIPTION
OF OPTIONS
Select single or double acting actuator (not presently available) Select PID Controller function (OFF or ON) Select Air-to-Open or Air-to-Close actuator operation Select desired valve characteristic curve (linear, equal percentage 50, equal percentage 30, quick opening, or custom curve). The custom curve must have been entered through the remote PC. Displav and set value of tight shutoff point. Default is 0.0% Display is set value of the lower software position limit stop. Default is 0.0% Display is set value of the upper software position limit stop. Default is 100.Oo/o Select language for displays (English or French)
PU (OFF or ON) ENGLISH (or FRENCH)
68
Procedures
To configure or modify the SVI controller pushbutton configurable parameters, execute the following procedure: 1. If in NORMAL OPERATE mode, press any button. -,OPER will be displayed. Press + to get to the
+MAN menu item.
2.
Press * to move to MANUAL menu. places it in Manual Mode. Press
(POS MAN
option.
displayed) This locks the valve in position and
3.
4. 5.
+ twice to move to
-,CONFIG
Press * to put the SVI in the configure mode and display the first item in the CONFIGURE menu. If Single or Double displayed is the one desired, press + to move to the next item. If not, press to select the alternate choice. When OK, press + to move to next item. (Note: DOUBLE is not presently implemented.) In CTL ON (OFF), ON should be displayed for controller. If display shows OFF press to select ON. Press + to move to the next item. NOTE: Any SVI that has been factory set for controller operation can be operated as a positioner by simply changing CTL ON-OFF back to OFF. In AT0 (ATC), if option displayed is correct, press + to move to the next item. If not, press to select the alternate choice. When OK, press + to move to the next item. In LINEAR (or other curve), if option displayed is the one desired, press + to move to the next item. If not, press to select the other options. When OK, press + to move to next item. If custom is selected, the custom curve must have been entered through the ValVue software program. The curve itself cannot be entered from the local pushbuttons. The tight shutoff (TS) option allows the user to configure the positioner to apply full supply pressure (or atmospheric pressure) to the actuator whenever the signal directs the valve near the closed position. If the tight shutoff option is on, the value of the TS option determines the near value at which the valve is forced fully shut. In TS OFF (ON), if status and value displayed are satisfactory, press + to move to next item. If not, press to change on/off status and display value. Then press + or - buttons to increase or decrease value displayed. (When status is changed from ON to OFF, no value is displayed.) When value is OK, press * to accept value and move to next item.
6.
7.
8.
9.
10. The SVI allows the user to configure a lower (PL) and upper (PU) software position limit stop. When in operation with these limits on, the valve will not move below the lower limit stop or above the upper limit stop. (Caution: These are software limit stops. If the SVI fails for any reason including power fail ure or air failure, the SVI cannot enforce these limit stops and the valve will go to fail-safe. Furthermore, the FULL OPEN AND FULL CLOSED buttons in ValVue bypass the limit stop controls. If safety requires the use of limit stops, mechanical limit stops should be used). In PL OFF (ON), if status and value displayed are satisfactory, press + to move to next item. If not, press * to change on/off status and display value. Then press + or - buttons to increase or decrease value displayed. (When status is changed from ON to OFF, no value is displayed.) When value is OK, press * to accept value and move to next item.
11. In PU OFF (ON), if status and value displayed are satisfactory, press
+ to move to next item. If not, press * to change on/off status and display value. Then press + or - buttons to increase or decrease value displayed. (When status Is changed from ON to OFF, no value is displayed.) When value is OK, press * to accept value and move to next item.
12. The SVI local display may be configured to display English or French. If the language displayed is correct, press + to move to next item. If not, press * repeatedly to display other language options. When the desired language is displayed, press + to move to next item. 13. At +MAN, press + to move to the top of the CONFIGURATION menu or - to move back to the previous item. To leave the CONFIGURATION menu, press *. This returns you to the MANUAL menu. This completes the configuration procedure. (POS MAN displayed).
69

I
Controller Functions
If the controller set point parameters were not set during initial configuration using Val-Vue or HART Hand Held, they may be set by the following procedure.
1. Press + to move to CONTROLLER Menu
2. Press to toggle between REMOTE AND LOCAL. Leave on desired action and press + to move to
SETPOl NT.
3. Press + or - to enter new value. Press * to exit back to SETPOINT. Press +to move to I SETPOINT. 4. Press + or - to enter new valie. Press * to exit back to I SETPOINT. Press + to move to CANCEL. 5. Press to return to NORMAL or MANUAL Menu without saving changes. Ptess + to move to OK. 6. Press * to return to NORMAL or MANUAL Menu with changes saved.
7. To continue with calibration press - twice to move to
)
CAL option. Continue with Step 4 below.
Local Calibration
NOTE: Perform configuration before running calibration functions.
Functions
You can perform the following calibration functions with the SVI product: Low and high values for input signal Low and high values for actuator pressure output Set the minimum and maximum stops for valve position
Procedures
Refer to the menu structure diagrams in Figures 37 through 42 (pages 62 to 67) for assistance in following the procedures described.
CAUTION: Since some calibration functions stroke the valve over its full range, the valve should be isolated from the process before starting calibration.
To calibrate the SVI unit using the local pushbuttons, execute the following procedure:
1.
If in NORMAL OPERATE mode, press any button, (OPER will be displayed.) Press + to get to the MAN menu item.
)
2. 3.
4.
Press to move to MANUAL MENU (POS MAN displayed.) Press + to move to --,CAL option. Press * to go to CALIBRATE menu. (STOPS will be displayed.) In STOPS, press * to initiate the operation, which moves the valve to fully closed, then fully open, and then returns to the starting position. (This operation calibrates the end points for the position feedback potentiometer.) When the operation is complete, press + to move to the next item.
5.
CAUTION: This function strokes the valve over its full range. Do not execute while valve is controlling the process.
70
6.
On some valves, the full travel is larger than the nominal travel of the valve and it may be desirable
to have the reported 100% position correspond to the nominal travel rather than the full stroke. The
STOP OP option allows this correction. If a correction is to be made, press * to move valve to the 100% position. Using the + and - buttons, position the valve to the nominal full open position. Press to accept this position as the new 100% position. 7. The Bias is the signal sent to the internal I/P that causes the actuator to neither fill nor exhaust. The pneumatics are adjusted at the factory and should not need further adjustment. If the pneumatics need to be readjusted for any reason, the BIAS option should be selected by pressing . This will out put a value of 2750 to the I/P. The adjustment screw on the top of the pneumatics section can be adjusted until the valve is nearly stationary near mid travel. See Bias Adjustment in Troubleshooting. Press + to move to the next menu item. The TUNE menu item allows the user to initiate the automatic position control tuning function which will select appropriate PID parameters for the position controller. Press * to initiate AUTO TUNE function. This procedure may take from 1 to 5 minutes. During this time the valve will make a series of steps (Caution: This procedure should not be performed while the valve is controlling the process.) When the function is completed, you return to TUNE. Press + to advance to the next item.
a.
9.
SIG LO displays the input signal that should correspond to the full closed or full open position of the valve (depending upon whether the valve is air-to-open or air-to-close and,whether the positioner is direct or reverse). In SIG LO, if the displayed value is correct, press + to advance to the next item. If not, press * to display value of SIG LO. Use + and - buttons to change the value. When OK, press * to return to menu and move to next item.
10. SIG HI displays the input signal that should correspond to the full open or full closed position of the valve (depending upon whether the valve is air-to-open or air-to-close and whether the positioner is direct or reverse). SIG HI must be larger than SIG LO by at least 5 mA. In SIG HI, if the displayed value is correct, press + to advance to the next item. If not, press * to display value of SIG HI. Use + and - buttons to change the value. When OK, press * to return to menu and move to next item.
11. The PRES HI menu item allows the user to enter the supply pressure. This pressure is used for sca-
ling of the pressure data in the SVI. In PRES HI, if the displayed value is correct, press + to advance to the next item. If not, press * to display value of PRES HI. Use + and - buttons to change the value. When OK, press * to return to menu and move to next item.
12. Calibration as a positioner is now complete. At -)MAN, press * to return to the MANUAL mode. (POS MAN displayed)
71
Return to Normal Operation

To return to NORMAL OPERATE mode from any menu, press + or - repeatedly until +MAN ( or -,OPER) is displayed. If OPER appears, press * to return to NORMAL OPERATE mode. If -' MAN appears, press * to return to Manual Mode Menu. Then press + repeatedly until -'OPER appears. Then press * to return to NORMAL OPERATE mode and normal operation.
Examine
I
Functions
The EXAMINE menu permits you to display calibration parameters, configuration parameters, and to display and/or clear fault status messages and codes. (Refer to Table 9 for explanations of fault messages.) You may enter the Examine menu either from NORMAL OPERATE Mode or from Manual Mode. When entered from NORMAL OPERATE mode the valve still responds to changes in,set point input signal and the values displayed change in accordance with changes in input signal.When entered from Manual mode, the dalve is locked in position. When you exit from the EXAMINE menu, you return to the menu from which you entered.
Procedures
Examine Calibration Parameters To examine the calibration parameters, execute the following procedure:
1.
If in NORMAL OPERATE mode, press any button. Press + to move through the options until you reach the EXAMINE menu item. Press * to go to EXAMINE menu. (This leaves valve in NORMAL OPERATE mode.) If in MANUAL mode, press + repeat edly until the EXAMINE menu item is reached. Press * to select the EXAMINE mode.
2.
3. Press + repeatedly to move through the EXAMINE menu until *CALIB is reached. Press * to display the list of calibration values. To move forward through the calibration parameters in sequence, press +. To move back through the list, press -. Press * at any time to return to *CALIB in the EXAMINE menu.
Examine Configuration Parameters To examine the configuration parameters, execute the following procedure:
1.
If in NORMAL OPERATE mode, press any button. Press + to move through the options until you reach the EXAMINE menu item. Press * to go to EXAMINE menu. (This leaves valve in NORMAL OPERATE mode.) If in MANUAL mode, press + repeated ly until the EXAMINE menu item is reached. Press * to select the EXAMINE mode. Press + repeatedly to move through the EXAMINE menu until *CONFIG is reached. Press * to display the list of configuration values.
2.
3.
4.
To move forward through the configuration parameters in sequence, press +. To move back through the list, press -.
5.
At any time, to return to *CONFIG in the EXAMINE menu, press *.
72
DisplayKlear FAULTS
To examine and /or clear fault codes and messages, execute the following procedure:
1.
If in NORMAL OPERATE mode, press any button.

Press + to move through the options until you reach the EXAMINE menu item. Press * to go to EXAMINE menu. (This leaves valve in NORMAL OPERATE mode.) If in MANUAL mode, press + repeatedly until the EXAMINE menu item is reached. Press * to select the EXAMINE mode. Press + repeatedly to move through the EXAMINE menu until 'FAULTS is reached. Press * to display the list of status values. To move forward through the faults in sequence, press +. To move back through the list, press -. The last item in the list is CLEAR. When this message is displayed, you can clear all faults by pressing *. This will also return you to FAULTS in the EXAMINE menu. If you do not want to clear all fault messages, press + or - to move to another item in the list. You can then press ' to return to FAULTS in the EXAMINE menu without clearing fault messages. ' This completes the EXAMINE functions.
I
2.
3.
73
Control ler Fa uIt Messages

Table 9 lists the fault codes/messages that may appear on the display. The table also explains the meaning of each message, the probable cause of the fault, and recommended action you should take to correct the fault.
Table 9. Controller Fault Messages
Display Code
Fa ult Message Position Error
Meaning Valve position did not agree with SVI output command within acceptable time Bias is out of range
Latched Error *
Probable Cause Valve is stuck or feedback linkage is disconnected or broken

~~
0s ERR
3IAS ERR
I/P Output at null point is out of range Position Sensor Error
J
The position sensor has failed or is not aligned properly The pressure sensor has failed
I
I
Supply pressure too low or incorrect pneu matic block adjustment Failed or linkage aligned incorrectly
'0s SEN
'RES SEN

I
I
Failure
;IG SEN
Error
(4-20) sensor has failed
Failure
~~
IEF ERR
Reference Voltage Error
The A/D reference voltage is incorrect
Failure
J
Failure
; W ERR
Self Check Failure
SVI failed self-check diagnostics
3ESET
Reset
SVI has reset since last status clear
3VER RUN
Data Overrun
Internal check failed to process data in time
/
Hardware failure
74
Table 9. Controller Fault Messages (cont.)
Display Code
Fault Message
Meaning
Latched Error *
Probable Cause
rEMP ERR
Circuit Temperature Internal SVI temperature out Error of range EEP Prom Write Failed Device failed to write to nonvolatile memory
J
Hardware failure
URT ERR
TIMER SEN
Watchdog Timer Timeout
SVI failed to send D/A output within timeout Signal or pressure calibration
Hardware fa i Iu re
CAL FAIL
Calibration Failed
Bad value set in calibration mode
STOP ERR
Find Stops Failed
The auto POS calibration failed
Pressure sensor not working or bias adj. not correct, or valve will not move Primary sensor failurc or linkage not aligned correctly on the potentiometer
FAIL SAFE
Fail-safe Position
Valve has been placed in the fail-safe position
75
Operation SVI Positioner / Controller using HART Handheld Communicator

A HART 275 Handheld Communicator with Masoneilan SVI Software can be used to set up and calibrate an SVI Positioner or Controller. It's capabilities extend well beyond the range of pushbutton functions in that it allows positioner tuning and controller tuning parameters to be individually entered, and it also supports limited diagnostics.
Refer to HART Communicator Manual MAN 4250 for basic instructions on using the Handheld communicator. The manual covers General Instructions, Hot Key customization, conn'ections, and Off-line functions. \
~
The menu structure on Page 60 is a guide to all the operations which can be performed on both SVI Positioners and SVI Controllers using the HART Handheld.
Operation SVI Positioner / Controller using ValVue Software

Use of ValVue Software provides the most comprehensive menu selections for configuring, calibrating and monitoring the SVI Positioner and Controller. All operating and calibration parameters be entered and additionally a very comprehensive diagnostics program is available. The diagnostics program allows recall of stored test data to compare current performance of the valve, positioner and actuator with previous test results or factory data. Operation of the SVI Positioner and Controller with ValVue is covered in the separate manual furnished with ValVue software.
76
Chapter 5 - Troubleshooting
Introduction
This section of the manual offers procedures and options to confirm setup and configuration and allows you to exhaust many service options before seeking assistance from a factory-trained technician. By first following these procedures, you can save time, prevent costly downtime, and provide the service technician with more detailed information about the possible problem. Although this section is written primarily for use with the pushbutton/local i s p l a y version of the SVI Positioner, it also applies to Val-Vue and HART handheld operation and in applicable areas, to the PID Controller version.
Factory Service
Trained service personnel perform high-level SVI troubleshooting and servicing. Should the SVI unit require replacement of internal parts, the unit will be replaced with a new or rebuilt unit. An extensive replacement inventory is available for immediate shipment. If this service is needed, contact your local salesperson or contact Masoneilan Dresser at www.masoneilan.com.
Common Problems
The troubleshooting checklist guides the user through a number of possible faults. However prior to utilizing this list, the user should make an initial assessment of the installation; looking at the following items:
0
I s the mounting of the SVI correct and the linkage orientation proper? Are all linkage mechanical
connections securely tightened? Are all pneumatic connections tight and is the supply pressure the correct value for actuator being used? Are electrical connections made to the correct terminals and securely tightened? Assuming the display is active, the user should carefully check that all configuration parameters are compatible with the valve under control and properly entered in to the positioner. If the SVI has been under control of ValVue and left in the full open or full closed position, the buttons cannot take control of position in the Manual Mode. To regain control, go to Normal Mode in ValVue and then to Manual before exiting ValVue or power down/power up the SVI.
0 0
77
The SVI requires a regulated air supply of clean, dry, oil-free instrument air conforming to the requirements od ISA-S-7.3, Quality Standard for Instrument Air. Figure 43 shows the locations of supply, outputand exhaust connections on the pneumatic block.
EXHAUST ACTUATOR SUPPLY
AIR SUPPLY
Figure 43. Exhaust, Actuator and Air Supply Connections Additionally the following conditions must be met: Ensure that the exhaust port can vent to atmosphere (e.g., no obstructions or foreign matter blocking ports). Connect the actuator port (behind the pneumatic block) to the actuator. For best response times use 318 tubing. Confirm that the supply pressure gauge reads the supply pressure and that the supply pressure registers 20 psi minimum. (Actual supply pressure used is a function of actuator supply rating). Momentarily disconnect the supply current (voltage) to the SVI and verify that the output pressure registers close to 0 psi and that the valve sits against a stop.
Note:
Air-to-open (ATO) requires a normally closed valve; Air-to-close (ATC) requires a normally open valve.
78
Supply Pressure
SVI requires sufficient supply pressure to drive the valve against the stops. For best results the supply pressure should be 5 to 10 psi higher than the actuator nominal pressure range as shown on the data plate.
For example, if the spring range is 11-23 psi, set supply to between 28 and 33 psi. The maximum pressure rating of the SVI is 100 psi; however in most cases the actuator pressure rating is the controlling factor in determining supply pressure. If pressures higher than 100 psi are required, consult factory.
I
I DANGER: Never exceed actuator or SVI maximum pressure. Damage to equipment or injury to personnel may result.
Verifying Supply Pressure

The following procedure may be used to verify whether supply pressure is suffiaient to drive valve against stops. Close the holes in the exhaust plug by blocking air path. The output pressure should slowly rise to supply pressure and the valve should drive to the high pressure stop. If output pressure does not go to or close to supply pressure, there may be a leak within the pneumatic block. Consult Factory.
If the valve does not drive against the stops when the output gauge reads a pressure higher than the actuator specification, then the actuator may be defective or improperly installed, the valve may be jammed due to improperly installed packing, or the valve body contains an obstruction.
79
The SVI requires an electrical input from a 4-20 mA current source or a voltage input from a 12/24 V dc Multidrop supply. The 4-20 mA signal can provide both operating power and signal information, or if a digital input signal is used, provide only operating power. The 12/24 V dc Multidrop supply can be used only when the input signal is digital. Selection of current or voltage input is by position of a jumper on the main terminal board. See Figures 44 and 44a.
Caution:
Make sure the voltage/current jumper is in the proper position (V or mA) before applying power. Failure to do so may result in damage to the SVI.
Jumpers to Select Voltage (Multi-Drop) or Curient Input Signal Terminals for Connecting 4-20 mA Curient Input or 12/24 V DC Multi-Drop Digital Input Signal (HART Protocol)
G T x , ,
Set Input Point Signal
mfi U
4- Internal Ground
(Enernel Ground
Located Beneath Display/
Pushbunon Coverl
External Position Feedback Pot
A B C
C
Contact Closure Inputs
Terminals for Connecting External Pot for Position Feedback or for Process Variable input When SVI is Used as a PID Controlier
Process Variable Voltage Signal
I
250 OHM Resistor is necessary for Current Input Signal only if this resistor does not already exist in the wiring in the control room.
Figure 44. Wiring Connections
80
The terminal board shown in Figure 44a reflects a design change to be released in early 1999 which incorporates the following enhancements. Additional terminals D and E allow the contact input feature to be used with the controller option.
0 8
Optional terminals POS + and POS - provide an isolated 4-20 mA signal related to characterized valve stem position. The voltage compliance of the position output terminals is 11-50 V dc. The HART@ signal is not available on the position terminals. The HART protocol is available on the +/- LOOP terminals. The software revision reporled by the HART ID command is 6.
SET INPUl
OPTIONAL / POSITION OUTPUT Ma)
Loop
Pos
SUPPLY CON NECTlON WIRING MUST BE FOR 85OC MINIMUM
PROCESS VARIABLE 1/5 VOLTS

AR
Figure 44a. Wiring Connections
UNPOWERED CONTACT lNPlJT C.D.E
- 1999 Release
81
The SVI is polarity sensitive so the positive lead must be connected to the positive (+) terminal and the negative lead to the negative (-) terminal. Reversal of input will not cause damage but the unit will not function.
Verify Wiring and Connections

Check that the SVI is properly powered per following: Connect a dc voltmeter across the input terminals.
I
Note: Test pins, located adjacent to the terminal strip facilitate connection of the voltmeter. For any inpuf current value between 3.8 and 22 mA the voltage should be between 9.5and 11 V.
If voltage exceeds 11.5 V check that polarity is correct and that V/mA jumper is in correct position. I
0
If voltage is less than 9.5 volts and polarity and jumper are correct, voltage compliance of current source may be inadequate. Connect milliammeter in series with current signal and verify that source can supply 20 mA to SVI input. If 20 Ma is not attainable, current source may be inadequate for this type of service, or other loads or inclusion of Intrinsic Safety barriers may be limiting the source drive capability.
Ground Practice
Make sure that case, signal and if utilized, process controller, ground connections are made in compliance with plants normal grounding practices. The case grounding screw is located on the outside of the case to the lower right of the display cover. Signal grounding should follow normal rules for the facility. Any point in the loop may be referenced to ground but there should never be more than one ground point.
If the SVI has the Process Controller option, auxiliary terminal B must be connected to the same ground reference as the negative input current terminal.
Note:
Improper or inadequately grounded installations may cause noise in or instability of the control loop.
If noise or instability are present, set positioner to Manual Mode of operation and manually position valve over its entire range. If valve is stable in manual mode, then problem may be noise in control loop. Recheck all wiring connections and ground points. If noise and instability are still present in manual mode, problem is most likely with electronics module. Consult Factory.
82
HART Compliance
SVI requires a HART-compliant communications loop. The HART protocol specifies the noise level, impedance requirements and configuration of the loop.
Note: When an intrinsically safe barrier separates the communicating device, a HART-compliant barrier
must be used.
Conventional current output loops consisting of the following components usublly meet requirements for HART compliance. \ Quality current source (e.g. low noise, high impedance) Minimum loop impedance of 250 ohms Twisted pair cable suitable for 4-20 mA current loops
I
Note:
(I
If there are suspected HART compliance problems, prepare a detailed description of the loop, including all devices on the loop, type of wiring used, loop length, and presence of any possible interference sources before contacting the factory for assistance.
Power-on Check
After checking pneumatic and electrical connections, apply power to the SVI. Restoring power will result in one of five possible images on the local display.
Normal
Blank Fail-safe Random segments displayed Reset
The normal display is an alpha-numeric reading in the manual or operate mode. The display may sequence between three variables (four in controller) at a 1.5 second rate. If a normal display is seen, no further action is required.
If the display is not normal, go to appropriate problem listing in Troubleshooting Checklist.
83
TROU BL ESHOOT1NG CHECKLlST

PROBLEM
POSSIBLE CAUSE
~~ ~~ ~
ACTION
Totally unresponsive SVI; Instrument not receiving no. display on LCD read- power due to: Improper Wiring out
See Electrical Co nnect ions Contact Factory Service Contact Factory Service See Pneumatic Connect io ns
Faulty Electronics module LCD readout shows random segments LCD readout active with unresponsive or incorrect valve position Faulty Electronics module Pneumatic supply/ connection problem
Improper Configuration See Testing valve Performance and Improper Calibration / continue with sections following Bias Error FAILSAFE shown on display Potentiometer shaft orientation or linkage incorrect Check that mounting and linkage are correctly installed. Refer to Mounting in instructions Use Examine menu to view error(s). Take required corrective action. See Fail-safe Display
HardwareEoftware fault
RESET appears on display
Momentary display on power-up is normal Continued display indicates problem Contact Factory Service
a4
TROUBLESHOOTING CHECKLIST (CONT.)

~ ~
PROBLEM dalve will not stroke over ull travel range
POSSIBLE CAUSE
ACTION
lnsuff icient compliance See Electrical voltage from current Connections source Potentiometer shaft orientation or linkage incorrect Check that mounting and linkage are correctly installed. Refer to Mounting in instructions
Insufficient pressure to See Pne umat ic fully stroke actuator Connections Incorrect software position limits Valve position exhibits mstable oscillation or hunting behavior Improperly grounded unit Slipping or loose linkage Defective spool s rbassembly Incorrect positioner PID values Valve works for some input values, and goes to Fa iI- Safe ope ration for others Potentiometer shaft orientation or linkage incorrect See confirming Configuration.. . See Electrical C o nnect ions Check and tighten
See Spool Valve Maint e nance See Testing Valve Pe rf o rmanc e Check that mounting and linkage are correctly installed. Refer to Mounting in instructions
Linkage produces morc Check that mounting and than 120 degrees of linkage are correct for potentiometer shaft actuator travel rotation
a5
Testing Valve Performance

The following preliminary valve performance test checks the physical part of the system and isolates several potential problems. It bypasses the microprocessor configuration.
1. Place the SVI in Manual mode using pushbuttons, Val Vue or handheld. If using pushbuttons, in Manual mode select POS MAN
2. By holding the and buttons down confirm that the valve moves to open and closed positions. This may take some time with a large actuator. (If using ValVue or handheld, use the FULL OPEN and FULL CLOSED commgnds).
I+
I-
If the valve correctly performs the open/close command in manual mode, continue with Confirming Configuration procedure below. If the valve does not perform the open/close command, review the following:
1. Gonfirm that the air pressure is on, set to proper pressure and connected to proper port. 2.
Check that spool valve is not sticking. Refer to Spool Valve Maintenance on Page
3. See Bias Adjustment on Page 92 and adjust bias if necessary.

4.
If FAILSAFE shows on display refer to FAILSAFE on Troubleshooting Checklist for appropriate action.
5.
If items 1, 2, 3, and 4 above are OK, the EPC (electropneumatic converter) may be faulty. SVI must be returned to factory for service on this component.
Confirming Configuration, Setup, Calibration, and Limit Stops

If the valve has performed properly in the manual mode, continue with followin,g procedure. This series of checks confirms proper configuration, setup, calibration, and establishes parameters for further testing.
1.
Place the SVI in the Manual Mode using ValVue, the handheld, or the pushbuttons. Check the following conditions: Confirm the accuracy of configuration and setup parameters by going to Configure and Calibrate menus and verifying that the parameters are correct. Run Find Stops. Perform an Auto Tune from the Calibration section. If continuing to experience problems, run AutoTune again. If using ValVue or the handheld set the PID parameters to values recommended in the PID parameters list. If problems persist, consult factory.
2.
3. If above test results are satisfactory, continue with Initiate Valve Movement (50%)
86
Initiate Valve Movement (50%)

Use the series of checks in this procedure to confirm that the configuration is correct.
1.
Place the SVI in Manual Mode using ValVue, handheld or the pushbuttons. Set the p,osition setpoint to 50%. Confirm whether valve moved to set position.
0
2.
If valve is in proper position; continue with Initiate Valve Movement (95%) procedure below.
If valve is not in proper position, set to full open and check whether position is at 100%. If not, re-run Find Stops. If this does not correct problem return unit to factory.
If valve oscillates review the following conditions:
1. Check for improper tuning. Perform either another Auto Tune or if ValV,ue or handheld are
available, input manual values from the parameters table and re-test. (Manually inputting values of P=50, 1=100, D=10, Padj=O, Beta=8, PosComp=6, and Damping=O should produce stable but perhaps sluggish operation on any valve.)
2. Check that ground connections are made to correct ground points and that connections are
secure.
3. Check the linkage between the position sensor and valve for excessive play.
4. Check that spool valve is not sticking.
5. Check for excessive friction in the valve packing; it is one cause of limit cycling. Limit cycling can be caused by tight valve stem packing, an undersized actuator, or foreign material in the spool valve. Identify limit cycling conditions by a process of elimination (e.g. not noise, not oscillation). Install valve packing only tight enough to prevent leakage. Evaluate the valve packing by running the ValVue diagnostic program to determine if the friction is consistent with the type of valve. If you determine that the spool valve is the source of limit cycling, it should be cleaned or replaced.
Initiate Valve Movement (95%)

Use this procedure to confirm that the SVI and valve systems are performing properly.
1. Place the SVI in Manual mode using ValVue, handheld or the pushbuttons. Set the position setpoint to 95%.
2. Confirm that valve is in the set position (95%).
If valve is in proper position, the SVI and valve systems are functioning properly. Place the SVI in OPERATE mode. It is recommended that if possible the valve be cycled through its full stroke using the control room 4-20 mA source. This will verify
a7
that the valve control loop is not noisy and that compliance voltage is high enough to properly drive the SVI.
If the valve does not travel to 95%, review the following: 1.

Check that air supply pressure is adequate for actuator
2. Repeat previous tests as necessary to determine cause of problem. If consistent

and proper operation cannot be obtained, return SVI to factory.
1
FaiI-Safe Display
A reading of Fail-safe on the display indicates a fatal or non-fatal error in the SVI and acknowledges that the computer holds the output in a fail-safe condition. Use the pushbuttons, Hand Held or ValVue to see the cause of the fail-safe condition, a list of error codes, and the necessary cortective action.
Note: Not all errors are fatal (e.g., not all errors cause a fail-safe condition.)
Latches: Certain errors occur and self-correct. The SVI clears the bit in the status when the error disappears and uses latches to show you an error occurred (although it is not currently an error). Errors that latch include RESET, POSSEN, PRESSEN, REFERR, and TEMPERR. Table contains a description of fatal and nonfatal SVI errors. The following list of error latches defines each term: DRIFT HARTERR HWERR OVERRUN POSERR POSSEN PRESSEN REFERR RESET SIGSEN STOPERR SWERR TEMPERR
WRT ERR
Drifting of bias Continuous communication error Hardware failed self-check Data overrun error (processor error) Position error Position sensor error Pressure sensor error Reference voltage error Reset occurred Current sensor error Find stops procedure failed Software error Circuit board temperature out of range
A write to the EPROM failed
88
Au t oTu ne
Running the positioner AutoTune procedure automatically determines position control parameters such as P, Padj, I, D, and dead zone. If the SVI is a Positioner/Controller model running autotune sets the positioner tuning parameters; the controller tuning parameters have to be entered via a Hand Held or ValVue.
Note:
Confirm that the Bias settings appear in a reasonable range, with a low signal-noise level, before running Aut oTune.
AutoTune Procedures
Initiate positioner AutoTune either by selecting the AutoTune button in the ValVue SVI Calibration Window or by using the SVI local buttons (Refer to Calibrate menu in Operation section of manual) or by initiating auto tuning from the hand-held. The AutoTune procedure includes three steps: ' Bias search Estimate control parameters Refine control parameters In Bias Search, the SVI local displays values (such as 23530 and 2761 0) that approach, or converge on,
a real Bias value. Expect the valve to move back and forth, slow down, and remain still by the end of this
step.
In estimating control parameters, SVI displays three types of values: input step sizes (such as 80 and 320), valve relative opening (such as 1874 and 1756), and dead time (such as 4.00 and 7.00). Expect the valve to move back and forth several times. SVI uses these tests to estimate the preliminary control parameters based on position control characteristics.
In refining the estimated control parameters, SVI displays several numbers (such as 1211 and 6). Interpret the number 1211 as the rising time (T98 is 12 x 0.05 sec = 0.6 sec) and overshoot is 11%. The code number 6 indicates a specific control parameter adjustment.
89
Auto Tune Results

A successful AutoTune provides position step responses, in both air fill and exhausting directions, that meet the tuning criteria. Overshoots range between 0 and 8%, and rising times range from 0.3 second for a small actuator to 1.5 second for a large actuator. A successful AutoTune updates the previous control parameters. AutoTune usually results in fast position responses (0 to 8% overshoots). If you prefer a smooth response without overshoots, reduce the P value by 10 to 20%. If you prefer a slow response, set the damping coefficient at 1 to 9 (e.g., zero equals no damping, 9 equals maximum damping)
Damping Coefficient
The following chart lists the damping coefficient, which displays after AutoTune and indicates the AutoTune result:
Damping Coefficient
Message
Action
0
44
Self-tuning is successful Bias searching fails after 20 times trying
None Stabilize the SVI in the range between 20-80% oper and wait until the valve is stable at its setpoint. Then re-run the self-tuning again. Adjust the Bias
55
The found Bias is not in the required range, and self-tuning is cancelled
66
Self-tuning for air fill direction Check supply pressure; check noise; check the fails after 30 times trying pneumatic block, especially spool S/A Self-tuning for air exhausting Check the pneumatic block, direction fails after 30 times especially spool S/A trying
77
Note:
The Damping Coefficient adjustment range is 0 to 9. The out-of-range value is equivalent to 0, or no damping.
90
Unacceptable Response Characteristics

Valve position responses depend on many factors including the condition of the valve, actuator, and process; ambient temperature; noise; the SVI itself; supply pressure; and the setup and step change size for the positioner control parameters.
Note: A 5% step change should be made when the valve is in the 20 to 80% opening range.
With damping coefficient of zero (no damping), consider the following valve responses unacceptable: Overshoot greater than 20% Rising time (T98) greater than 1.5 seconds for small actuators and 2.5 seconds for large actuators Dead time greater than 0.5 seconds Limit cycling peak-to-peak measurement greater than 0.5% Position steady-state error greater than 0.5% if the dead zone is less than 0.2%.
Position Insta biIity

The possible sources of position instability include: Control loop (measurement) noise Process noise Line frequency noise Oscillation Limit cycling Control loop noise only appears in the Normal mode (never the Manual mode). For best control, reduce control loop noise by re-tuning the process controller (in the SVI or an external controller). You may also dampen the SVI response. Process noise results from process pressure and flow changes that apply forces to the valve plug and cause changes in position. Although the SVI restores the plug position, the response is not instantaneous. Poor grounding of the signals and case, or power supply ripple in the 4-20 mA control signal, can introduce line frequency noise. Line frequency noise converts to low-frequency noise when a noisy signal sampling occurs during a period not integrally related to the line frequency. The resulting frequency measures more than 1 Hz, a frequency too high for resolution by the process trend record.
A pulsating sound of escaping air at the exhaust port usually indicates line frequency noise. In extreme cases, the valve stem may appear to pulsate
Correct a line frequency noise problem by proper grounding (page 82) or by eliminating ripple noise from the current source. (HART compliance requires less than 4 *A of current ripple).
91
Oscillation
If using a HART Communicator or ValVue, set the following values to identify PID oscillation: If SVI is pushbutton model, re-run auto-tune. If oscillations persist contact factory. P = 20 I = O D=O Dead zone = 0
Padj = 0 Beta = 0 Damping = 0 Position Compensation Coefficient = 0
I
If the position remains stable, then the problem is related to the positioner settings of the PID. Re-run A utoTune.
Limit Cycling
The characteristics of limit cycling include at least a 4-second period and a squared off (as opposed to sinusoidal) trend record. Excessive friction in the valve/actuator assembly, or dirt in the spool valve assembly, can cause limit cycling. The SVI diagnostic identifies excessive friction in the valve/actuator assembly as a reported friction value greater than 30% of the actuator span.
Bias Adjustment
Masoneilan adjusts the bias of the pneumatic block at the factory in order to accommodate most environmental effects. This setting usually makes bias adjustment neither necessary or desirable. Situations do arise, however, when bias adjustment becomes necessary. For example, after replacing the spool valve, or when the unit experiences extreme environmental conditions, adjusting the bias can optimize positioner performance.
For either of the following cases, do not adjust bias:
After calibrating the limit stops of the valve and setting the parameters, an offset may occur between the SVI position indicated on ValVue (or in the push-button display) and the actual valve position. On start-up, after leaving the unit without power for an extended period of time, an offset sometimes occurs between the signal and actual valve position. On startup, this offset begins moving slowly. This offset exists because the present bias setting differs from the setting recorded when the unit last saved the bias.
Note:
These offsets resolve themselves because the SVI saves the bias value every hour, which provides a more accurate signalhalve position reading. For more rapid adjustment. select the Calibrate screen and return to Manual Mode which automatically saves the value.
For the following case bias may need to be adjusted:

If full open or full close wont cause the valve to move fully to the stops, you may need to adjust the bias.
92
Bias Adjustment Procedure

An SVI-generated pilot pressure controls the spool position. The pilot pressure range is displayed as a dimensionless value between 0 and 5500. The exact number can be displayed when using ValVue or a Handheld Configurator for calibrating the SVI. The value is not displayed when using pushbuttons, but is automatically set to the calibrate value of 2750 when in bias adjust mode.
If using pushbutton model SVI, follow menu steps to "CAL" and then to "BIAS" . Press the "*" button. If using Handheld or ValVue, go to manual screen, click Calibrate button, enter 2750 in "Output Value to VP" box, then click on "Output" ,,
Note valve position. If near to 50%, adjustment is not required. If adjustment is required, using a 7 mm open end wrench, remove the cap nut on the top of the pneumatic block and loosen the locknut. Using a 2 mrn hex wrench, adjust the bias screw until the valve is at 50% position and stable. If movement of ttie adjusting screw does not re-position valve, return unit to factory for servicing.
I
After adjustment is complete, tighten locknut and replace cap nut
Spool Valve Maintenance

If troubleshooting procedures have shown the spool valve to be a suspect component, use the following procedures to clean the pilot subassembly and replace deteriorated parts. This procedure describes the steps necessary to disassemble the spool valve. To minimize maintenance time, Masoneilan recommends replacing the entire pilot subassembly. Using a replacement subassembly allows you to work on the old unit as time permits. Prior to any disassembly, make sure new "0"rings of proper material are available. The old rings should not be re-used.
Warning :
Cleaning the pilot subassembly and replacing deteriorated parts requires shutting down the positioner and isolating the valve from the process. Failure to do so can result in damage to the system or personal injury. Figure 45 illustrates the components of the pilot subassembly.
Pilot Subassembly (8)
P l l O t Spool
Extension Pin
Plug
Spring
End Plug
Figure 45. Pilot Subassembly
93
Disassembly Procedure
Completely shut down the SVI. Isolate the valve from the process 'Put the positioner out of service Shut off air supply Install warning signs or lockouts as necessary to ensure against accidental re-activation of SVI.
WARNING : Failure to completely shut down SVI can damage the system or result in personal injury.
Unscrew pilot subassembly and disengage it from the body.
Note: Turn the pilot subassembly while removing to prevent damage to "0"rings.
Remove the end plug and withdraw the spring, plug, and extension pin. Do not disassemble or adjust the extension pin. Wipe the parts with a clean soft cloth and blow clean compressed air through the orifices. Clean all surfaces with isopropyl alcohol only. Do not use chloride-based solvents
Reassembly
Install three new "0"rings on the pilot spool. Apply a light coating of a compatible lubricant to each ring. Insert the extension pin and the plug into the pilot spool, with the countersunk end first. Note: The plug should slide into the spool by its own weight. Install the spring in the pilot spool with the small diameter end contacting the plug. Screw the pilot end plug into the pilot spool. Install the pilot subassembly into the body.
94
HART Communications
This section contains information about computer and peripheral connections necessary to achieve proper communication, so that SVI can communicate with ValVue or a Hand-Held device. The ValVue manual contains setup and administration procedures for HART communications. Refer to HART Communicator manual MAN 4250 for for basic instructions on using the Hand Held communicator. The manual covers General Instructions, Hot Key Customization, Connections, and O f f l i n e functions. Use of the Hand Held with SVI is facilitated by use of the Hand Held Communicator Guide flowchart in the Instructions section of this manual.
Setup and Administration

Load ValVue version 1.0.4, or higher, for proper operation of the PC.The ValVue version number and the SVI version number must match (or use a higher ValVue version than the SVI version software).
Note:
ValVue demo software does not communicate with SVI.
Communication Port and Settings

Plug the modem into the serial port (COM1 or COM2) of the PC. The user selects the serial port during ValVue installation, or in the properties of the ValVue icon, or you manually can set ValVue to use the same port as the modem. The user manual for your computer contains more information about proper use of serial ports. Typical PC operation includes the following settings: COM1 or COM2 as the physical connector Default settings for the interrupt level and interrupt address (e.g., the correct BlOS settings use the serial port with a modem and enable the interrupt)
Use o f Laptop Computers

Laptop computers sometimes require non-conventional settings and support Power Management features that can disable the COM ports. Check your laptop user manual for additional information.
Mouse Interference
Modem settings sometimes conflict with proper mouse operation, and the mouse "hangs up" after initiating ValVue. Select another port for either the mouse or the modem.
Hand Held Considerations

A hand-held terminal must include the SVI device description in order to perform diagnostic and calibration functions. The HART 275 hand-held terminal will report the primary and secondary variable, tag, message, and other basic values. Note: The communication connection of a PC with ValVue or a HART 275 hand-held terminal is not polarity sensitive.
95
Failure to Communicate
If the PC fails to communicate with the SVI (the PC displays the message "No Hart Device" or "Device Not Responding") then the PC cannot establish a link to the SVI. Possible causes of communications failure related to installation include: Poor wiring contacts Improper connection of the HART modem to the computer Incorrect serial port Using ValVue with another HART master terminal in service lnsuff icient loop impedance (Require a minimum of 250 ohms) Polling address set to non-zero value. The polling address, which can be set only by using the HART 275 Hand-held must be set to 0 in order for ValVue to communidate with the SVI. Do not change polling address from 0 with HART 275 Communicator.
I
Note:
You cannot use ValVue and attempt to connect another HART master terminal device (e.g., a
hand-held device). ValVue will not operate with a second terminal device (either primary master or secondary master).
96
Fatal and Non-Fatal Errors

Fatal Errors: The following definitions describe typical fail-safe (fatal) errors:
Error
Description
Explanation
Likely Cause(s)
POSERR
Position Error
The valve did not go to the requested position within the time configured in Position Error Time 2
Valve lost air pressure Valve movement is blocked Setting of Position Error Timq 2 is too low for the size of valve Improperly adjusted linkage resulting in the potentiometer out of range at one limit or the other Potentiometer connector is disconnected A broken wire Electronic failure within the module EIect ronic fa iIure with in the module Electronic failure within the module
POSSEN
Position Sensor Error
Position sensor failed
SIGSEN
Current Sensor Error Reference Vo Itage Error Self-check Failure Data Overrun
The input signal sensor has failed The reference voltage within the SVI is out of range The SVI failed an internal self-check
REFERR
HWERR OVERRUN
The SVI could not process Electronic failure within the input data the module
97
Non-fatal Errors
The following definitions describe typical non-fatal errors. SVI reports these errors; they do not cause a fa i I-safe condition.
Error POSERR
Description Position Error
Explanation The valve did not go to the requested position within the time configured in Position Error Time 1
Likely Cause(s) Valve lost air pressure Valve movement is blocked Setting of Position Error Time 1 is too low for the size of valve
\late: Setting Position Error Time 2 to a positive number may cause the device to fail-safe on a POSERR.
~~ ~ ~ ~~ ~
RESSEN
The pressure sensor failed While the SVI can function in normal operation with a failed pressure sensor, other calibration functions depend upon the pressure sensor.
~~
31ASERR
Bias Out or Range
The bias (the output to the EPC within the SVI that controls the actuator fill/exhaust) is out range
This error indicates an improperly adjusted bias. Adjust the bias as needed. If the SVI once functioned properly, this error usually indicates an improperly working pneumatics section. SVI reset occurred because of a power loss or a command from ValVue.
3ESET
Reset Occurred Position Calibration Failed Circuit Temperat ure Error
A SVI reset occurred
STOP PERR
The self-position calibration The most likely causes are loss of air pressure or the routine failed pressure or position sensor not working properly. The internal SVI temperature is outside the normal operating temperature range in the SVI specifications
98
TEMPERR
Non-Fatal Errors Continued.
.Error
~
Description
Explanation
Likely Cause(s)
NRTERR
EEPROM Write Failed
A write of data to the inter- If you detect this error, nal permanent memory of issue a reset and check the the SVI Failed. configuration and calibration parameters
rlMRERR
Watchdog Timer Time-out
An internal timer that checks proper SVI operation has timed out, indicating improper operation of the SVI. An attempt to recalibrate the primary of secondary signal or the pressure sensors failed.
On watchdog timer timeout, the SVI issues a self reset. This error indicates that such a reset already occurred The normal cause is sending the SVI calibration values outside the allowed range, or trying to calibrate two values too close together (e.g., with insufficient range for accurate ca Iib r at ion),
3ALFAIL
Signal Calibration Failed
99
Types 67AF and 67AFR
Fisher Controls
Instruction Manual
FISHEd
March 1986
Form 5144
Introduction
Scope of Manuai
This manual describes and provides instructions and parts lists for Type 67AF and 67AFR regulators. Although sometimes shipped separately for line or panel mounting, these regulators are usually shipped installed on other equipment. Instructions and parts lists for other equipment, as well as for other 67 Series regulators not covered in this manual, are found in separate manuals.
TYPE 67AF OR 67AFR REGULATOR
Product Description
Type 67AF and 67AFR self-operated, aluminum-body, filter regulators provide constant reduced pressures in a variety of applications. They are commonly used as supply pressure regulators for pneumatic instruments as shown in figure 1.
A Type 67AF or 67AFR regulator with a cellulose or stainless steel filter removes particles greater than 0.001 6 inch (0.040 mm) in dtameter, or with a glass filter removes particles greater than 0.0004 inch (0.01G mm) in diameter.
TYPICAL POSITIONER
The Type 67AFR regulator additionally has an integral low-capacity internal relief valve. In this construction, the stem seats against a soft-seated orifice in the diaphragm assembly. A downstream pressure increase above the outlet pressure setting moves the diaphragm assembly off the stem, venting the excess pressure through a hole drilled or tapped in the spring case.
Specifications
Table 1 gives some general Type 67AF and 67AFR regulator ratings and other specifications. A label on the spring case gives the recommended and actual control spring range for a given regulatcr as it comes from the factory.
K3117
1
Figure 1 . Type 67AF or 67AFR Regulator Mounted on Control Valve Assembly
Table I . Specifications
BODY SIZE AND END CONNECTION STYLE
1/4-inch NPT screwed
MAXIMUM ALLOWABLE INLET

PRESSURE(1)
250 psig (17 bar)
INTERNAL RELIEF PERFORMANCE (TYPE 67AFR REGULATOR ONLY)
Low capacity for seat leakage only; external relief valve must be provided if inlet pressure can exceed maximum emergency outlet pressure Nitrile Parts: - 2OoF to 15OOF
( - 29C to 66OC)
OUTLET PRESSURE RANGES
3 to 100 psig (0.21 to 6.9bar) with the springs shown in parts list key
TEMPERATURE CAPABILITIES(1I
'
9
MAXIMUM EMERGENCY OUTLET PRESSURE(1)
Fluoroelastomer Parts: 0F to 350F ( - 18C to 177C)

PRESSURE REGISTRATION
50 psig (3.4 bar) over outlet pressure setting, or 100 psig (7.6 bar), whichever is greater
Internal
1. The pressureltemperaturellmits In this manual. and any applicable code or standard limitations. must not be exceeded
Installation
Note If the regulator is shipped mounted on another unit, install that unit according to the appropriate instruction manual.
Personal injury, property damage, equipment damage, or leakage due to escaping gas or bursting of pressure-containing parts may result if this regulator is overpressured or is installed where service conditions could exceed the limits given in table 1, or where conditions exceed any ratings of the adjacent piping or piping connections. To avoid such injury or damage, provide pressure-relieving or pressure-limiting devices (as required by the appropriate code, regulation, or standard) to prevent service conditions from exceeding those limits. A Type 67AFR regulator, because of its low-capacity internal relief, does provide very limited downstream overpressure protection, but it should not be considered complete protection against overpressure. Additionally, physical damage to the regulator could cause personal injury or property damage due to escaping gas. To avoid such injury or damage, install the regulator in a safe location. Regulator operation within ratings does not preclude the possibility of damage from debris in the lines or from external sources. A regulator should be inspected for damage periodically and after any overpressure condition.
1. Only personnel qualified through training and experience should install, operate, and maintain a regulator. For a regulator that is shipped separately, make sure that there is no damage to, or foreign material in, the regulator. Also ensure that all tubing and piping have been blown free.
2. Install the regulator so that flow is from the IN to the OUT connection as marked on the regulator body. Cutout dimensions for a panel-mounting regulator are shown in figure 2.
3. For best filter drainage, orient the drain valve (key
17,figure 2) to the lowest possible point on the filter cap (key 25,figure 2).This orientation may be improved by
rotating the filter cap with respect to the body assembly (key 1, figure 2).
A regulator may vent some gas to the atmosphere. In hazardous or flammable gas service, vented gas may accumulate and cause personal injury, death, or property damage due to fire or explosion. Vent a regulator in hazardous gas service to a remote, safe location away from air intakes or any hazardous area. The vent line or stack opening must be protected against condensation or clogging.

4. A clogged spring case vent hole may cause the regulator to function improperly. To keep this vent hole from being plugged (and to keep the spring case from collecting moisture, corrosive chemicals, or other foreign material) orient the vent to the lowest possible point on the spring case or otherwise protect it. Inspect the vent hole regularly to make sure it has not been plugged. Spring case vent hole orientation may be changed by rotating the spring case with respect to the body. A Type 67AF or 67AFR regulator with a tapped spring case may be remotely vented by installing obstruction-free tubing or piping into the 1/4-inch NPT vent tapping. Provide protection on a remote vent by installing a screened vent cap in the remote end of the vent pipe.
of pressure containing parts or explosion of accumulated gas, never adjust the control spring to produce an outlet pressure higher than the upper limit of the outlet pressure range for that particular spring. If the desired outlet pressure is not within the range of the control spring, install a spring of the proper range according to the diaphragm parts maintenance procedure.
Note Each regulator is factory-set for the pressure setting specified on the order. If no setting was specified, outlet pressure was factory-set at the midrange of the control spring.
5. For use in regulator shutdown, install upstream and downstream vent valves or provide some other suitable means of properly venting the regulator inlet and outlet pressures.
6. If using pipe, apply a good grade of pipe compound to the pipe threads before making the connections.
7. Install tubing or piping into the 1/4-inch NPT inlet connection on the body assembly (key 1, figure 2) and also into the 1/4-inch NPT body outlet connection, unless this connection already has been factory-piped to another unit.
3. If outlet pressure adjustment is necessary, monitor outlet pressure with a gauge during the adjustment procedure. A standard Type 67AF or 67AFR regulator is adjusted by loosening the locknut (key 11, if used) and turning the adjusting screw or handwheel (key 10) clockwise to increase, or counterclockwise to decrease, the outlet pressure setting. Then, tighten the locknut (if used) to maintain the adjustment position. On some regulators, a closing cap (key 28, not shown) must be removed before adjustment and replaced afterward.
Startup and Adjustment Shutdown

Key numbers are referenced in figure 2.
1. With proper installation completed and downstream equipment properly adjusted, slowly open the upstream and downstream shutoff valve while using pressure gauges to monitor pressure.
2. Regulator outlet pressure may be monitored on a gauge installed at some point downstream from the regulator, such as the supply pressure gauge of a pneumatic instrument for which the regulator is providing reduced pressure. Or, outlet pressure may be monitored on a gauge (key 21, not shown) installed on the body of a regulator with a tapped side outlet. If the regulator has no gauge but the side outlet is tapped and plugged, the pipe plug (key 21, not shown) may be removed and a gauge temporarily installed for monitoring.
First close the nearest upstream shutoff valve and then close the nearest downstream shutoff valve to vent the regulator properly. Next, open the vent valve between the regulator and the downstream shutoff valve nearest to it. All pressure between these shutoff valves will be released through the open vent valve, since a Type 67AF or 67AFR regulator remains open in response to the decreasing downstream pressure.
Maintenance
Regulator parts are subject to normal wear and must be inspected and replaced as necessary. The frequency of inspection and replacement ,of parts depends on the severity of service conditions and upon applicable codes and government regulations. Open the drain valve (key 17, figure 2) periodically to empty accumulated moisture from the filter cap (key 25, figure 2).
To avoid personal injury, property damage, or equipment damage caused by bursting

adjusting screw or handwheel (key 10) until compress i o n is removed f r o m the c o n t r o l spring (key 9). 2. Remove the machine screws (key 12) and separate
the spring case (key 2) from the body assembly (key 1).
To avoid personal injury, property damage, or equipment damage caused by sudden release of pressure or explosion of accumulated gas, do not attempt any maintenance or disassembly without first isolating the regulator from system pressure and relieving all internal pressure from the regulator. Note
If sufficient clearance exits, the body assembly (key 1) may remain mounted on other equipment or in a line or panel unless the entire regulator will be replaced.
Remove the control spring seat and control spring (keys 8 and 9).
3. Remove the, diaphragm assembly (key 7) and inspect the diaphragm.
4. Install the dikphragm assembly (key 7) and push down on it to see if the plug/stem assembly (key 4)
strokes smoothly and approximately 1/16 inch (2 mm).

Note
hey numbers are referenced in figure 2 unless otherwise noted.
Filter Element and Trim Parts

1. Use a 12-point socket wrench to remove the cap screws (key 18). Remove the filter cap and gasket (keys 25 and 19).
In step 5, if installing a control spring of a different range from the one that was removed, be sure to delete the spring range originally appearing on the control spring label (key 20, not shown) and indicate the new spring range.
2. The retainer assembly and filter element (keys 43 and 29) may come off with the filter cap; if not, remove these parts to let the plug spring (key 6),plug spring seat (key 5), and plug/stem assembly (key 4) drop freely from the body. 3. Inspect the removed parts, replace as necessary, and make sure the plug seating surfaces are free from debris. A dirty filter element may be cleaned with solvent and blown dry. 4. Apply a good grade of lubricant to the gasket (key 19) before installing it. Stack the gasket, retainer assembly, filter element, plug spring, plug spring seat, and plug/stem assembly (keys 19, 43, 29, 6, 5,and 4) on the filter cap (key 25). Install the filter cap with stacked parts into the body assembly (key 1) and secure with the cap screws (key 18).
5. Stack the control spring and control spring seat (keys 9 and 8) onto the diaphragm assembly (key 7).
6. Install the spring case (key 2) on the body assembly (key 1) with the vent oriented to prevent clogging or entrance of moisture. Install the machine screws (key 12) and torque to 5 to 7 foot-pounds (7 to 9 Nom).
7. When all maintenance is complete, refer to the startup and adjustment section to put the regulator back into operation and adjust the pressure setting. Tighten the locknut if used (key 1l ) , and install the closing cap if used (key 28, not shown).
Parts Ordering
When corresponding with the Fisher sales office or sales representative about this regulator, include the type number and all other pertinent information stamped on the bottom of the filter cap and on the control spring label. Specify the eleven-character part number when ordering new parts from the following parts list.
Diaphragm Parts
1. Remove the closing cap if used (key 28, not shown), loosen the locknut if used (key ll), and back out the

I
I
I
Parts List (figure 2)

Description
Part Number
Key 4'
Description
Part Number
Key 7'
Description
Part Number
/I
i
~
11
i
~
!i
Ii
i
Parts Kit (included are keys 4, 5, 6, 7, 17, 19. and 29) For Type 67AF regulator w/o internal relief With nonbrass parts to provide sour gas corrosion resistance cap?bility(l) R67AF XOON12 With brass parts for other than sour gas corrosion resistance applications R67AF XOOO12 For Type 67AFR regulator w/internal relief With nonbrass parts to provide sour gas corrosion resistance capability R67AFR XON12 With brass parts for other than sour gas corrosion resistance applications R67AFR X0012
1
Plug/Stem Assembly (Continued) For other than sour gas corrosion resistance applications Nitrile plug w/brass stem 1D5604 000A2 Nitrile plug w/stainless steel stem 1D5604 00082 Fluoroelastomer plug w/brass 1N3798 71662 stem Fluoroelastomer plug w/stainless steel stem 1N3798 OOOC2 All-brass plug and stem 1C7503 14012 All-stainless steel plug and stem 1C7503 35032 Plug Spring Seat For use w/stainless steel stem and to provide sour gas corrosion resistance capability, 316 1L2511 35072 stainless steel For use w/brass stem and for other than sour gas corrosion resistance applications, 1E5322 11052 aluminum Plug Spring To provide sour gas corrosion resistance capability, InconeP) 19A2856 XO12 For other than sour gas corrosion resistance applications, 302 stainless steel 1C1273 37022 Diaphragm Assembly For Type 67AF regulator w/o internal relief To provide sour gas corrosion resistance capability, nitrile diaphragm w/heattreated AlSl steel diaphragm plate and control spring seat guide 187980 X0112 For other than sour gas corrosion resistance applications Nitrile diaphragm w/pl steel diaphragm plate and control spring seat guide 187980 00082 Fluoroelastomer diaphragm w/pl steel diaphragm plate and control spring seat guide 187980 OOOC2 For Type 67AFR regulator wlinternal relief To provide sour gas corrosion resistance capability, nitrile diaphragm w/aluminum relief valve seat 8 soft molded insert 19A7667 X032
5'
I
~
i;
!
1
I
2
4'
Body Assembly To provide sour gas corrosion resistance capability, aluminum w/316 stainless steel bushing One outlet 15A5969 X052 Two outlets 15A5969 X062 For other than sour gas corrosion resistance applications Aluminum w/brass bushing One outlet 15A5969 X012 Two outlets 15A5969 X032 Aluminum w/304 stainless steel bushing One outlet 15A5969 X022 Two outlets 15A5969 X042 Spring Case W/drilled-hole vent, aluminum 287974 08012 W/1/4-inch NPT vent tapping To provide sour gas corrosion resistance capability, aluminum 25A6220 X012 For other than sour gas corrosion resistance applications, brass W/o closing cap 1E l 674 000A2 W/closing cap 10A3075 X012 For 1-hole panel mtg, aluminum 2080667 X012 For 3-hole panel mtg, zinc w/stainless steel bushing 389855 00082 Plug/Stem Assembly To provide sour gas corrosion resistance capability, nitrile plug w/stainless steel stem 105604 00082
6'
Diaphragm Assembly (Continued) For other than sour gas corrosion resistance applications Nitrile diaphragm w/brass relief valve seat 8 soft molded insert 19A7667 XO12 Nitrile diaphragm wlstainless steel relief valve seat 8 soft molded insert 19A7667 X022 Fluoroelastomer diaphragm w/ brass relief valve seat 8 soft molded insert 19A7667 X042 Fluoroelastomer diaphragm w/ stainless steel relief valve seat 8 soft molded insert 19A7667 X052 Control Spring Seat To provide sour gas corrosion resistance capability. heat-treated AlSl steel 187985 X0012 For other than sour gas corrosion resistance applications, Zn pl steel 187985 25062 Control Spring See following table Adjusting Screw, pl steel For spring case w/o closing cap 187986 28982 For spring case w/closing cap 1H3050 28982 Handwheel For 1-hole panel mtg. Zn pl steel 2082830 XO12 For 3-hole panel mtg Zinc 187992 000A2 Chrome pl steel 1U1715 O O O C 2 Locknut (not used w/panel mtg spring case, pl steel 1A9463 24122 Mounting Nut (for use only w/l-hole panel mtg spring case), 303 stainless steel 1082657 X012 Machine Screw, pl steel (6 req'd) To provide sour gas corrosion resistance capability and for 1-hole panel mtg 8 1/4-inch NPT tapped spring cases 182752 28982 For all other constructions 107839 28982 Mounting Screw (for use only w/3-hole panel mtg spring casej, steel (2 req'd) 1C2760 28992
9 10
7'
10
11
11
12
14
I
I
Recommended spare part As detailed in National Association of Corrosion Engineers (NACE) standard MR-01-75 2 Trademark of international Nickel Co
*

I
DRILL 0.19 INCH (4.9 mm) HOLES FOR 10-24 SCREW SIZE
w--
1-HOLE PANEL MOUNTING DETAIL

NOTES D 0 . 7 2 (18.3) SPRING CASE PANEL BOSS.
3-HOLE PANEL MOUNTING DETAIL
D1.47 TO 1.48 (37.4 TO 37.7) SPRING CASE PANEL BOSS.

--A
35A19561.C B?ws
Figure 2. Type 67AF and 67AFR Regulator Assemblies
Key 17'
Description
Part Number
Key 21
Description
Part Number
Key 21
Description
Part Number
Drain Valve To provide sour gas corrosion resistance capability, 1K4189 00082 aluminum For other than sour gas corrosion resistance applications Aluminum 1K4189 00082 Brass 1K4189 18992 Stainless steel AH3946 00082 Cap Screw, Cd pl steel (4 req'd) 1K7647 24052 Gasket, neoprene 1C1280 03012 Control Spring Label (not shown), paper See following table
18 19' 20
Pipe Plug (for use only w/2-outlet body-not shown) To provide sour gas corrosion resistance capability, hex head, Cd pl steel 1A7675 24662 For other than sour gas corrosion resistance applications Hex head, Cd pl steel 1A7675 24662 Square head, brass 1A5726 14012 Socket head. steel 1C3335 28992
25 28
Pressure gauge (for use only w/2-outlet body-not shown) 0 to 30 ~ s i g ( ~ ) 1J9460 99012 0 to 60 ~ s i g ( ~ ) 1J9752 99012 0 to 100 ~ s i g ( ~ ) 1J9753 99012 0 to 160 ~ s i g ( ~ ) 159754 99012 Filter Cap, aluminum 35A5963 X012 Closing Cap For use wltapped spring case 25A6220 X012 to provide sour gas corrosion resistance capability, 1H2369 XOO12 aluminum
'Recommended spare part.
3. Consult your Fisher sales office or sales representatwe tor gauges in other units.
35A5972 C
COMPLETE REGULATOR WITHOUT CLOSING CAP
Figure 2. Type 67AF and 67AFR Regulator Assemblies (Continued)
Key 28
Description
Part Number
Key 43
Description
Part Number
Key 44
Description
Part Number
29'
Closing Cap (Continued) For use w/tapped spring case 10A3075 X012 for other than sour gas corrosion resistance applications, brass 1H2369 14012 Filter Element 0.0004-inch (0.010 mm) rating, glass 17A1457 X012 0,0016-inch (0.040 rnm) rating 1F2577 06992 Cellulose Stainless steel 15A5967 X012
Retainer Assembly To provide sour gas corrosion resistance capability, Zn pl steel retainer w/lnconel spring 17A9423 X022 For other than sour gas corrosion resistance applications, pl steel retainer w/302 stainless steel spring 17A9423 X012
45
NACE Tag (for use only on constructions w/sour gas corrosion resistance capability-not shown), 18-8 stainless steel 19A6034 X012 Tag Wire (for use only w/NACE tag key 44-not shown), 304 stainless steel 1U7851 X0012
'Recommended spare part
r
I
I FISHER"^
OUTLET PRESSURE RANGE SERVICE, MATERIAL U.S. Units, Psig

I
~
Metric Units, Bar With All Other Spring Cases
CONTROL SPRING KEY 9 Part Number
With Panel-Mtg With All Other With Panel-Mtg Spring Case Spring Cases Spring Case All, pl steel
Color Code Green Cad plated
SPRING LABEL KEY 20
3 to 5 to 30 to 35 to
18 30 50
3 to 20
5 to 35 30 to 60 35 to 100
80
0.21 0.34 2.1 2.4
to to to to
1.2 2.1 3.4 5.5
1
i
0.2: 0.34 2.7 2.4
to to to to
1.4 3.4 4.1 6.9
189860 27272 187883 27022 187884 27022 1K7485 27202
Blue
Red
1C3763 06032 103764 06032 1C3766 06032 i 103765 06032

~
Keys 9 and 20 Type 67AFR Control Spring and Contrcl Spiing Labe: OUTLET PRESSURE RANGE SERVICE, MATERIAL
*
U.S. Units, Psig
Metric Units, Bar With Ali Other' Spring Cases
CONTROL SPRING KEY 9 Part Number
With Panel-Mtg With Ail Other With Panel-Mtg Spring Case Spring Cases Spring Case For sour gas corrosion resistance CaDabilitv. lnconel
I Color Code
Cad plated
CONTROL SPRING LABEL KEY 20
5 to 35 30 to 60
1I
__--0.21 0.34 2.1 2.4

tc to to to
0.34 to 3.4 2.1 to 4.1 0.21 0.34 2.1 2.4

to to to to
1SA2852 X012
1C3764 06032 1C3766 06032 103764 06032 103766 06032
For other than sour gas corrosion resistance applications, pl steel
3 to 18 5 to 30 30 to 50 35 to 80
3 to 20 5 to 35
30 to 60 35 to 100
1.2 2.1 3.4
5.5
1.4 3.4 4.1 6.9
While this information is presented in good faith and believed to he accurate. Fisher Controls does not guarantee satisfactory results from reliance upon such information Nothing contained herein is tc be construed as a warranty or quarantee. express or implied. regardinq the performance. merchantability, fitness
or any other matter with respect l o the oroducts, nor as a recommendationto

use any product or process in conflict with any patent Fisher Controls reserves the nght. without notice. to alter or improve the designs or specifications of I he products described herein
[FISHER]
Printed in USA
Fisher Controls
For inlormatron. contact Fisher Controls Marshalltown,Iowa 501% USA Ceinay 68700 France
Sac Paulo 05424 Brazil Singapore 0512
& & 0 T recycled i paper
INSTALLATION
AIR SUPPLY TO BE AT LEAST 5 psi HIGHERTHAN REGULATOR SETTING NOT TO EXCEED 250 psi
SIGNAL PRESSURE LINE '5% " 0 D COPPERTUBING OR EQUIVALENT
clutkn: DonoturspOralrpnrswrrcwexccrclcllng
2so pel.
Prior to installing, clean all lines thoroughly to remove all dirt, scale or other foreign matter. Install Lock-up valve in controller output line as near control valve diaphragm chamber as possible, holding number of connections to a minumum, so that the air flows through the body in the direction indicated by the words INLET and OUTLET marked on the underside of valve body. The signal pressure line should be connected upstream of the air supply regulator to provide effective response of the lock-up valve in event of air failure. Be sure all connections are tight.
0TritRPhE~MATICPI.OT OPtRATEDEOJ P M t N l
NO 77-4
/@
AIR OPERATED CONTROL VALVE
FILTER-REGULATOR SET AT20psi FOR 3-15psi INSTRUMENTOUTPUT OR 35psi FOR 6 . 3 0 ~ ~ INSTRUMENT 1 OUTPUT
INSTRUMENTOUTPUT LINE' 3/&" 0 D COPPERTUBING OR EOUIVALENT

NO 77-6 AIR LOCK-UP VALVE SHOULD BE INSTALLED AS SHOWN, AS NEAR CONTROL VALVE DIAPHRAGM CHAMBER AS POSSIBLE USING A MINIMUM NUMBER OF CONNECTIONS
ADJUSTMENT
The lock-up valve is normally factory set (i.e., 23 psi for 3-15 psi operation or 35 psi for 6-30psi operation) and should not require adjustment. If, however, it becomes necessary to adjust the setting, an air supply with a gauge and regulator, should be piped to the signal pressure connection after (1) relieving compression on range spring of lock-up valve and (2) connecting instrument output line to inlet connection of lock-up valve. Instrument output pressure need be sufficient only to determine open and closed position of lock-up valve. Turn air supply pressure on until pressure gauge indicates the desired set pressure, then turn adjusting screw down until no air pressure may be felt coming from the outlet of the lock-up valve. Valve will be fully closed at this point. Finally, tighten adjusting screw locknut and connect (1) the lock-up valve outlet connection to control valve diaphragm chamber and (2) the signal pressure line to the signal pressure connection of the lock-up valve. Turn on and set air supply to operating pressure.
THE NO 77-6 AIR LOCK-UP VALVE IS NORMALLY SET AS FOLLOWS 6.30~~ CONTROL 1 VALVE OPERATION SET TO CLOSE AT 35psi 3-15psi CONTROL VALVE OPERATION SET TO CLOSE AT 23 psi
TYPICAL INSTALLATION
MAINTENANCE
Q u l i l r m : prkr8opweorpnlng~bolrtrr tk.trrdt,-tNomupr#wtnndrdknrrrpr(lng oacrrlnawdonlybrlokingd f%
Note: Due to their design and intended application, maintenance difficulties should not be encountered with these valves. If they fail to perform satisfactorily, malfunction is normally due to accumulation of dirt in one or more ports. The valve may only need partial disassembly to allow access for cleaning.
MAINTENANCE (cont.)
To disassemble the valve proceed as follows: Remove the four body cap screws; body cap (15), body cap O-ring (14), range spring (3), upper spring button(2) and spring case (9) will come free from body (7). To free diaphragm SIA (10) and inlet valve SIA (12) form body, place wrench on insert retainer (13) and unscrew from body insert (5). Remove body insert O-ring (6) and slide diaphragm SIA, body insert and inlet valve SIA from body. Holding inlet valve from turning, unscrew inlet valve locknut (4) and remove diaphragm SIA from inlet valve. Turn inlet valve out of body insert. Check all ports to be sure they are clear of dirt. Inspect diaphragm SIA for rupture or for damage around the edge. If necessary, install new diaphragm SIA. Check inlet valve for wear. If inlet valve in scored or pitted, replace with new one.
To reassemble the lock-up valve, perform all operations
7
._ i
in reverse order to that used in disassembly. Note: O-ring on inlet valve stem should be lubricated before inlet valve is reassembled in body insert.
TYPICAL 77-6
SIGNAL P R E S S U R E
PARTS REFERENCE
1 1 Adjusting Screw 2 __ 97141 7-019-1 10 060803-001-002 000040-117-130 000041-054-130 971511-010-110 060805-002-400 971 886-088-680 060800-006-609 971514-002-110
Upper Spring Button 5-40 psi Range 1 3 Spring 5-100 psi 4 1 Inlet Valve Locknut 1 5 Body Insert 2 0-Rings 6 . __ 1 7 Body ___ 1 Locknut 8 Recommended Spare Part
1
14. 15
Spring Case Diaphragm SIA Inlet Valve 0-Ring Inlet Valve SIA Insert Retainer Body Cap 0-Ring Body Cap Body Cap Screws
060802-001~609008643-006-999 971886-039-680 008605-015-999 008638-013-400 971886-056-680 060813-002-609 971 270-018-1 10
'
Signature Press 5/97/2M
Masoneilan is a registered trademark of Dresser Flow Control, Dresser Inc., Copyright 2001 by Dresser, Inc. All rights reserved
Instruction ES0400 02/02 BR400 Booster Relay
Product Description
The BR400 and BR200 are high capacity volume boosters for applications that require fast stroking speeds using pneumatic actuaturs. Stable operation over a whide range of actuator sizes can be obtained by adjusting the bypass valve on the booster to modify the dynamic response. The BR400 and BR200 are equally suitable for use on diaphragm or piston actuators.
Features and Benefits

Flow characteristics suitable for control valves
Provides short stroking times with consistanetly stable operation
I
Built-in bypass valve with locking screw to adjust sensitivity and dynamic response Filters on both the supply and signal ports Corrosion resistant finish and stainless assembly hardware to permit use in corrosive atmosphere
Instruction ES0400 02102 BR400 Booster Relay
The input signal pressure is applied to the upper diaphragm to produce a force that is opposed in a 1:l ratio by the output pressure acting on the lower diaphragm through the seal plate orifice. An increase in the input signal pressure will depress the top diaphragm and open the pilot valve, allowing supply pressure to the output until the output pressure action on the lower diaphragm re-balances the forces. conversely, a decrease in the input signal pressure allows the exhaust valve to open until the output pressure falls to the same value as the input signal pressure. A bypass valve allows a controlled flow of input signal direct to the output to obtain stable control for small or slow changing input signals.
Signal Pressure
Output Diaphragm
Supply Pressure
. c I , Output Pressure
Figure I
- Cut-away View of BR400 Booster Relay
Specifications
Maximum Supply Pressure Maximum Signal Pressure Operating Temperature Limits Input / Output Ratio Approximate Weight Materials of Construction Maximum Cv (supply) Maximum Cv (exhaust)
150 psi (1.03 MPa, 10.3 bar) 150 psi (1.03 Mpa, 10.3 bar) -3OOC to + 100C (Optional - 5 5 O C to 1:I 3 Ibs. (1.4 kg) See Figure 3 and Table 2
I
+looo C)
2.6 (See Figure 2)

2.4 (See Figure 2)
Table I
- Specifications
Flow Characteristics
(Output Pressure-Signal Pressure) ,/Signal Pressure (%)
Figure 2 - Flow Characteristics
Pneumatic Supply
The BR400 and BR200 Booster Relays require a source of clean, dry, oil-free, instrument grade air to ANSIIASA57.3 1975 (R1981) or ISA-S7.3-1075 (R1981).
Dew Point Particulate Matter Oil Content: Contaminants
At least 18" F (10" C ) below minimum anticipated ambient temperature. Filtered to below 5 microns. Less than 1 ppm wlw or vlv. Free of all corrosive contaminants and hazardous gasses, flammable or toxic.
The pneumatic connection locations are shown on Figure 1 and are also stamped on relay body. The supply and output connections are %" NPT and the signal connection is l/q" NPT. The supply and output tubing should be a minimum of %. Blow out all piping prior to connecting to booster. Use of a soft setting anaerobic hydraulic seal, such as Loctite Hydraulic Seal 542 is recommended on the male threads of all connections.
A A
CA UT 10 N C A UT 10 N
Do not use an excessive amount of hydraulic sealant as it will not set and may migrate into the pnematic passages.
Do not use pipe thread sealant tape on pneumatic fittings, as it tends to shred small particles which can cause instrument malfunction.
Installation
The booster relay should be close coupled to the actuator. Use of a short % , , pipe nipple between the relay output and the actuator provides both the pneumatic connection and mounting means. The preferred orientation is with the exhaust openings pointing down; however horizontal mounting is acceptable.
Operation
Prior to applying supply pressure to the relay, open the bypass needle valve approximately one turn. After applying pressure, note response of actuator to open and close commands from the positioner. If excessive overshoot or hunting is seen, open needle valve until stable operation is obtained. If valve is sluggish, close needle valve until unstable operation occurs, then back off until stable operation is obtained. Turning valve clockwise (closing) speeds response but can lead to instability. Turning valve counterclockwise aids stability but will slow down the actuator's response. Proper setting provides stable operation and acceptable response time.
Maintenance
The BR400 Booster Relay does not require any routine maintenance. If a contaminated air supply has been used, then there may be need to clean the filters or disassemble the relay to clean the supply and exhaust seats and valves.
Troubleshooting
If the output pressure does not respond to changes in the input pressure, check that kupply pressure is at proper value and that signal and supply filters are not plugged with foreign matter. Check also that supply and exhaust valve seats are clean. If output pressure is not stable or is slow to respond, check setting of bypass needle valve. See bypass valve setting procedure under "Operation".
87mm
(3.4 inches)
Figure 3
- Construction and Dimensions

7
&
Materials of Construction
Standard Material
Aluminum Alloy Die Casting Rubber Aluminum Alloy Die Casting Chloroprene I Polyester Chloroprene I Polyester Aluminum Alloy Plate Acetal Copolymer Copper Alloy Piston
Case Upper Diaphragm Lower Diaphragm Lower Diaphragm Plate Exhaust 0 - R i n g Exhaust Seat
11 12 13
Plug Cap Coil Spring
Copper Alloy Austenitic Stainless Steel
3
4
Plua
Austenitic Stainless Steel Acetal Copolymer Austenitic Stainless Steel Glass Fiber Reinforced Thermoplastic Polyester Austenitic Stainless Steel Austenitic Stainless Steel
5
6
71
8
9
Seal Plate Exhaust Seal Guide
Austenitic Stainless Steel Copper Alloy 18
1
I
Sup~lv Filter Signal Filter

I
Table 2 Materials of Construction
AUSTRIA Dresser Valves Europe GmbH Kaiserallee 14 A-2100 Korneuburg (near Wien), Austria Phone: 43-2262-63689 Fax: 43-2263-6368915 BELGIUM Dresser Europe S.p.r.L. 281-283 Chaussee de Bruxelles 281-283 Brusselsesteenweg 1190 Brussels, Belgium Phone: 32-2-344-0970 Fax: 32-2-344-1123 BRAZIL Dresser lndustria E Comercio Ltda Divisao Masoneilan Rua Senador Vergueiro, 433 09521-320 Sao Caetano Do Sul Sao Paolo, Brazil Phone: 55-11-453-5511 Fax: 55-11-453-5565 CANADA Alberta Dresser Flow Control DI Canada, Inc. Suite 1300, 311-6th Ave., S.W. Calgary, Alberta T2P 3H2 Canada Phone: 403-290-0001 Fax: 403-290-1526 Ontario Dresser Flow Control DI Canada, Inc. 5010 North Service Road Burlington, Ontario L7L 5R5 Canada Phone: 905-335-3529 Fax: 905-336-7628 CHINA Dresser Suite 2403, Capital Mansion 6 Xinyuannan Road Chao Yang district Beijing 100040 Phone: 86-10-6466-1164 Fax: 86-10-6466-0195 FRANCE Dresser Produits lndustriels S.A.S. Division Masoneilan 4, place de Saverne 92400 Courbevoie France Phone: 33-1-49-04-90-00 Fax: 33-1-49-04-90-10 GERMANY Dresser Valves Europe GmbH Klein-Kollenburg-Strasse78-80 47877 Willich, Germany Mailing Address: PO. Box 1208 47860 Willich, Germany Phone: 49-2156-9189-0 Fax: 49-2156-9189-99
INDIA Dresser Valve India Pvt. Ltd. 305/306 "Midas" - Sahar Plaza Mathurdas Vasanji Road J.B. Nagar - Andheri East Mumbai, India 400 059 Phone: 91-22-835-4790 Fax: 91-22-835-4791 ITALY Dresser ltalia S.r.L.. Masoneilan Operation Via Cassano, 77 80020 Casavatore (Naples), Italy Phone: 39-81-7892-111 Fax: 39-81-7892-208 JAPAN Niigata Masoneilan Company, Ltd. 20th Floor, Marive East Tower WBG 2-6 Nakase, Mihama-Ku Chiba-shi, Chiba 261-7120, Japan Phone: 81-43-297-9222 Fax: 81-43-299-1115 KOREA Dresser Korea, Inc. #2107 Kuk Dong Building 60-1, 3-Ka, Choongmu-ro Chung-Ku, Soeul, 100705 Phone: 82-2-274-0792 Fax: 82-2-274-0794 KUWAIT Dresser P.O. Box 242 Safat 13003, Kuwait Courier: Flat No. 36, Floor 8 Gaswa Complex, Mahboula Kuwait Phone: 965-9061157 MALAYSIA Dresser Flow Control - Far East Business Suite 19A-9-1 Level 9, UOA Centre No. 19 Jalan Pinang 50450 Luala Lumpur, Malaysia Phone: 60-3-2163-2322 Fax: 60-3-2163-6312 MEXICO Dresser Valve de Mexico, S.A. de C.V. Henry Ford No. 114, Esq. Fulton Fraccionamiento Industrial San Nicolas 54030 Tlalnepantla Estado de Mexico Phone: 52-5-310-9863 Fax: 52-5-310-5584 THE NETHERLANDS Dresser Valves Europe Steenhouwerstraat 11 3194 AG Hoogvliet The Netherlands Mailing Address: P.O. Box 640 NL3190 AN Hoogvliet RT The Netherlands Phone: 31-10-438-4 122 Fax: 31-10-438-4443
SAUDI ARABIA I Dresser Al Rushaid Valve & Instrument Company P.O. Box 10145 Jubail Industrial City 31961 ' Saudi Arabia Phone: +966-3-341-0278 Fax: +966-3-341-0696 SINGAPORE I Dresser Singapore, Pte. Ltd. 16, Tuas Avenue 8 Singapore 639231 Phone: 65-861-6100 Fax: 65-861-7172 SOUTH AFRICA Dresser Ltd.. South Africa Branch P.O. Box 2234, 16 Edendale Road Eastleigh, Edenvale 1610 Republic of South Africa Phone: 27-11-452-1550 Fax: 27-11-452-6542 SPAIN Masoneilan S.A. C/ Murcia 39 C 08830 Sant Boi de Llobregat Barcelona, Spain Phone: 34-93-652-6430 Fax: 34-93-652-6444 SWITZERLAND Dresser Valves Europe SA Frauntalweg 76 CH-8045 Zurich, Switzerland Mailing Address: P.O. Box 3568 CH-8021 Zurich, Switzerland Phone: 41-1-450 28 91 Fax: 41-1-450 28 95 UNITED ARAB EMIRATES Dresser Middle East Operations Post Box 61302 (mail) RfA 8, Units JAOl/JA02 (courier) Jebel Ali Free Zone United Arab Emirates Phone: 971-4-8838-752 Fax: 971-4-8838-038
UNITED KINGDOM DI U.K. Limited Trevithick Works Gillibrands Estate, Skelmersdale Lancashire WN8 9TU, England United Kingdom Phone: 44-1695-52600 Fax: 44-1695-52662 DI U.K. Unit 4, Suite 1.1, Nobel House Grand Union Office Park Packet Boat Lane, Uxbridge Middlesex UB8 2GH. England United Kingdom Phone: 44-1895-454900 Fax: 44-1895-454919
UNITED STATES Northern Region Dresser Flow Control 85 Bodwell Street Avon, MA 02322-1190 Phone: 508-586-4600 Fax: 508-427-8971 Southern Region Dresser Flow Control 11100 West Airport Blvd. Stafford, TX 77477-3014 Phone: 281-568-221 1 Toll Free: 800-847-1099 Fax: 281-568-1414 South Texas Operations Dresser Flow Control 4841 Leopard Street Corpus Christi. TX 78408-2621 Phone: 361-877-2414 Fax: 361-584-1196 Masoneilan Aftermarket Sales 8 Service Center 16030 Bear Bayou Drive Channelview, TX 77530 Phone: 281-862-1500 Fax: 281-862-1550 Western Region Dresser Flow Control Masoneilan 2950 East Birch Street Brea, CA 92821 Phone: 714-572-1528 Fax: 714-572-1463
Copyright 2001
- Dresser Flow Control -
Dresser. Inc
HOW TO SELECT A VERSA VALVE^

v
PNEUMATIC
S
RETURN
SPRING
G
SOLENOID PILOT-ACTUATED
4
FOUR-WAY
5
1R" NPT
2
SIDE PORTS
2
TWO POSITION
U
SIYLE
14
SlLENCERlDUST EXCLUDER NUT
-A120
12OVBO
SERVICE
(INPILOT)
SOLENOID OPERATOR EOUIPPED WITH
BASIC PRODUCT NUMBER
v
T
v.........
Valve
neumei c sewlce 10
200 psi (14 bar)
Valve Hydraullc servlc~ TO
2 Two-way 9 Three-Way 4 four-Way 6 Fivs-Way (Dual Pressure Four-Way)
500 psi (95 bar)
7 Two-Outlet (Directional
Three-Way-Divener)
8 Two-Inlet (Directional Three-Way-Selector) 7 with suffix-1 2 provides 1V.4' f32mrn) caoacitv h r h I'NPT'side: ports or 1114- NPT
subplate ports
For slzes 1/s TO V z : IS0 228/1 ' G ' type threads are indicated by addllional use of suffix '-28". Contact factory lor avallablllry.
'Basic valve size
SUFFIX DETAILS
~ ~~~
6ufllr dotells Indloate rnodilioalions or varie[Ions to the basic valve. When specifying simply add those sutlix details reauired in alphabeilcal and/or numerical order.
A
,
L idfad _.__ ~-below are the a u b detail rnoddiopliono lound In this oatalon and !he o
.
~
. _ . . .-. .. . .
. . . ..
m on whrh !hey am notad.
0 SlDEPOATE&EkPllOT
Body wllh integral,, plpe threaded pons. Thls type ot body is dlreclly connected to pressure lines and is used for mechanical, manual and EXPilot' type solenold or pllot acruated
TWO-WAY or THREFWAY VALVES l k o Posllian
1 Normally Closed (aCtUat-
date mounting- This type of body I S screwconnected lo a subplate or manifold thar Is connected TO Dressure lines and is used for mechanlcal, manual and EXPilot' type 6olenold or pllot actuated valves.
valves. SUBPUTE HOUNTIWGEXPILOT Body-portad for sub-
2 Normally Open (actuatino dewlce musl be on l e t end of valve) THREE-WAY VALVES Three Pooilion 3 All ports blocked In center posrtlon FOUR-WAYVALVES Two Poolllun 2 SUndard flow pattern: Inlet alternalely open to . iindor cpposlta cylindir pon ahernately open to exhaust.
2
ing device must be on rlght end of value)
'
Adustor Orfenlalion: -218A lhru -2180, Hand Lever, Daoe V-10.1 -220 cam acluaior. age V-10.2 -227i thm -227C. J o l aetuaror. page V-10.2 -3470. Treadle actualor, page V-56 rhru 61 cDIi/cOll Homing: -243, tiommeled housing. woe v-3.8 -HC,-HCC. DIN conneclor, age V4.5 8 3.8
41,C ~ W BH 0011,peae V - 3 j L 70.1
. Comblnallan Acruaion:
'
4 % .
-P, Plu -In coil Ponad coil, page V-10.4 8 70.1
-&
Solenoid actuated valws requin a Coil Code that indicates the specific coil currentdrequency and vohage. The Coil Code consists of a lener to indicate the currenl lrequancy:
Rating Cuds;
-114, -1141. Hanan-detenr. paoe V-69.1 -116. Palm bUHORR-d8ltlnI. paon V-69.1 -130, -13OA. -130L Handkpnng return. paoe V-68.2, V-88.1 -198, Palm btnlon/spring return, V-68.1
413, -1131, HanM-detent. page V-69.1
-138,Solenoidlsprhg miurn. a@ V 69.3
A= 60Hz frequency D= Oimn Curront (DC) E= 50Hz freauency

Three numbers lollow the Rating Code to indicsts voltage:
'
2 SIDEPORTED INPILOT Body same as ' 0 ' above, except it has an auxiliary Internal passage 10 supply INPilot" type colenoid and pilot actuators.
h o Pasitlon
Standard flow pattsrn: each inlet port o an (alrernately) to one winder port; op osite cylinder pan open (alkrnetely) to exhaust
~~&$yv~~vEs
3 SUBPUTE MfJUNTIN8INPILOT
mree ori it ion
Body same as '1' above. eYcaPt It has

infernal auxlllaV Pas-
sa e to supply I N k h ' ' b 0 solmid

and pilot a c h o r s . 'Separate pressure line conflecrion needed to SUPPlY solenoid-pilot, differential pilot return or to control pressure pilot. --lnternai auxiliary
DlVERTER & SELECTOR VALVES
Cylinder ports open 10 exhausl fl Mat@) apen la bath cylinder pons Q All ports open 4 &yition arts blocked in center position
.
All pons blooked
Offset flows as standard low patterns, above) I Cenler Poelllon
- 1 ~PIIOn.det8nf. . page V-6t.2 ~ 1 5 8PlloUsprino , return, psoe V-68.3 ~173, Solenoldlapring return, paon V49.3 naramous SONICO soisnoioa: -3687, .LB-XN. Flamaproof(d). Low Wan. EEr d 116tH 16. p a w V-3.7 & 70.1 4 T , .TRIO.lT, 8laln1~6s 6 W d hous~tltl. p o V-3.8 6 70.1 .XOAS, -XDAT, Aameproof(d). E&,d 1lC pa e V 3 7 & 3.5 -XIFA. -XIFB, - W E , lnirlnslc sals(lb),EEr rnibkl i6: paea V-3.7 8 3 . 6 -XIEP, Inlrn6ic sate(ia). EEr ia IIC T6. page V-3.7 B 3.5 -XMM, -)IMAB, -XMAUE, -XMAG, Encapsularlon(me), EEX me II15/16, PBDE v-3.7 a 3.5 -XMR. -XMFB, -XMR, -XMFO, Encapsulation(me), EEr me II 76, page V-3.7 8 3.5 -XN. Flameoroat a) EEr d IlBtHz 14.paoe V-3.7 8 3.5 -XX. Flameproof[d): NEMA 7 B 9, page V-3.7 & 3.5 Manuel Ovenlae ( p ~ V-10.4): g ~ -6, Guaroed -66% Guaraea-locklng
8.
Examples:
izovao =
24VDC=
24v60=
l ! n h m u R
024 120
024
See page V-3.5 for specific coil and codes.
Bean:
-M. Unguarded - M R . UnguardeO-locking
-EP,Elhylana ropylana EPA, page V-3.1 8ped8l senlee/eubrlcsllon: -1, Bleed pilm, page V-4.7
-21, INPllOrnPllOl -33, Retainer u p .page V-66
-3, Cominuoue duly 6 O ~ ~ ~ ~ remp dm~ core. g hlluorocarbon FKM. puae V4.6 10.4 -11. Hioh nitnle NBR. page V-3.1. 3.4 & 3.6 -31. U-cup pilot. pa e V-3 3 -166. FiuorocarDonBKM, page V-3.1,3.4 & 3.6
-Id, Sllencorlduatproof coil cover nut, pags V-10.4
I )
poning supplies res surized medlum gelno controlled to pilot, solepilot return.
noid-pilot or dlflerenrlal
4 6 A . FDA approved slllcona orsasa. oaaa V-3.4 -5SM. Slllcone grease. page V.3.4 -187, Eleclroless nickel plating-external. pagu V4.1 -200.Plus pressure milno to 200 psi (14 bar], page V-3.3 -210, Electroles nickel plafing-infernal. page V-3.1 -H, Threaded solenoid exhausl, p a y V-10.4 & 70.1 -H600, Hydraulic solenoid rated 10 60 psi (31 ber), peoe V-3.9
'
ACTUATING DEVICES
Versa has evallablc: over thiny sundard devices 10 actuale Series V or Series T valves. The basic purpose of the actuating devlce Is teprovide a means of mlnlng m e valve spnol back and forth In order that it may pedOrm the VerlOU6 valvlng functions necessary. Beceuse of the balanced deslgn and actlon of the wslwe spool. rho farce roqulrod to ehffl thie epool le oeparate and unaffected by the pressure being controlled by lhe valve.
The aauators are designed for application within 3 ranges of valve sizes: one range of actuators lor all valve styles, types, and 8lzes VaO through W ;another range of actuatorsfor sizes 3/4' through 1'; and one raws of actuators for 1W' valves. Within their broad respective ranges, ,Versa aCtUBtOrS are completely interchangeable on all body styles, types ,and eltes. Excepl for valves that are spacifirally normally closed or normally open, mese actuators mey even be shined from end-to-end on Ihe valve body to sult any specific piplng layout or spec8 requiremenl. Illustrated with brief descriptions, are the basic type6 of actuators in most frequent use. The 'leners' referred to by the actuator types coincide wlth the prefix leners umd in the product numberingsystem. Many varlalions and modlfication6 of ihese basic actuators are also avaitable. A few are described on Page V-4.8 under Sufflx Details. Others, 6uch es mmbinallon acluerors, can be found on Pages V-68.1 thru 69.3.
c] PARTS INFORMATION the number inslde the box refers to the page number for parts informellon. Dimensionlng Information Is found in each of the speolfic valve eemlona.
MANUAL
A push or pull rnatlon may be ueed to operare the hand devlce In order to shltl the valve epaol. If used with o detenl device (W' o r '23 or a no-Spflng Uevlce (IN') the handle must be aauated and returned manually. Wlth a spring centering device (W)the handle will normally be in the center position when not actuated, or wlll return to the center position afrer being actuaied. To actuate o one offset position with a sprlng centering devlce, Ihe handle mu61 be pulled T and pushed to tho other. Tho prooke dlfferencae of oaah of the thmo hand actuating devlces are described below.
HAND LEVER (Offset Mounted)
TYPE "H" HAND LEVER (Offset Mounted)

The handle of this device is offset from the valve, and may be located on elther side at the walva. Standard asaernbly places the handle on rho side havlng tho outlel ports. The entire hand aauallng device may be rotated into posltlons at 0 ' from venlcal. (For various options available see below.) increments of 8 When mounted so that handle works in B vertical plane a back and fonh motion is provlded. When mounted so!hat handle works in a horlzontal plane a rotary motion ia provlded. STAUMRD POSITION OF HANDLE
HAND LEVER
--
--~
+BE: .-.
.< .
!5+-.----.
(Centerllns Mounted)
...
I '
J I
OPTIONS Hand valves are supplied amording to elendard position. Seven other posltlond are evallable (SuffIx-218A Thru 218G). To order simply Include the Suffix number shown.
k! %<
+w?; ...
OPTIONAL
STANDARD
Example; VSH-4302-218E.
TYPE "L" HAND LEVER (Centerllne Mounted) The handle of this device 1 6 In the vertical plene through the tenterllne of the valve body and is required when dustproof feature is desired. On models up to Vz" pipe size, a rubber boot provides protection from din and dusi. The entire dovica may be maiea Into poslrlons at increment6 of 90' trom venical. To indicate, use Suffix -218A, -2188, or -218C as shown above for onset mounted hand lever.
TYPE "I" PALM BUlTON (Panel Mounting le Stendard) The body Of the Palm Button actuator i6 supplied with a thread and nut that allows the actuator, when required, to be fastened to a panel with the valve
behind the panel. The button will rhen praject through and be viaible from The front panel. Pushing or pulling rhe button activates the valve.
FOOT
t-
TYPE "F" PEDAL

Applied to 2-positlon valvos only and is u ~ u a l l yused wlth elther
8
spring return ('S") or dlfferential pilot return ('K") device. The pedal lends itself to tiptoe operation. Actuation is accomplished when operator depresses pedal. When operaror removes fool from pedal, pedal 1 5 relurned or reset to unactuated position by return devlce on other ena of valve.
TYPE "T" TREADLE

Provides full suppon lor the foot of the operator. This device may be used with 2-poslrlon or 3-posirlon valves. When used in conjunction wlrh a sprlng return ( " S " )ar B dlflerentlal pilor refurn ("K"). actuatlan IS provided by the operator depressing the treadle with his heel. When used wlth a reverse sprlng device ('R"). actuation is provided when operator depresses the treadle with his toe. With a detenl devlce ('U" or "Z"), a no-spring return device ("N"), or a spring centering device ( ' B " ) aotuatlon is providod by dapraasing wlfh the heel to one olfset position and by depressing with the toe to the other offset position.
MECHANICAL
The cam roller may be actuated by a cam, trip bar or a straight line push from some machlne member. Standard assembly provides the roller revolving in a horlzontal plane, but enrlre device may be rotated so that cam roller acts In a plane perpendlcular lo mounting surface (see arrangement optlons below).
TYPE "C" CAM ACTUATOH (Normal Duty)

Urlllres case hardened roller. Recommended maximum pressure angle 15'. TYPE "C" *suffix "-18s" (Heavy Duty) CAM ACTUATOR
Roller is a double shlelded ball bearing. Provides ovenravel of V4" for easier mountlng and valve prolenlon. Recommended maximum pressure angle 15'.
OPTiONS For Both q p e a

Cam valves are supplled wllh roller axis perpendlcular lo the mounting surface. Shoula you requlre tne ax~s parallel 10 me mountlng surlace (shown a1 left) slmply Include suffix number shown.
Example; VSC-A302-226.
CAM ACTUATOR (Normal Duty)
OPTIONAL (SUFFIX-228)
ROLLER AX16
PARALLEL
STANDARD ROLLER AXIS PERPENDlCUlAR
PILOT
The pllot actuator is a small cylinder and piston that Is an inlegral pan of h e valve and which, when prescurlzed or unpressurlzed, acluates Ihe valve.
TYPE ~~P~~ PRESSURE PILOT (for 2-posit1onvalves) N P E "J" PRESSURt PILOT (tor 3-posltlon valves) This pilot requires pressure ro actuate the valve, end release of Ihe pressure
r o rerum the valve. Usually II I6 canrrolled by a small Three-Way valve. The pilot port on the '/a" through V2" valve6 may be rotated to any positlon in 90"
inoremenu lrom verlioel. (See option errengernente below).
When used In pairs for 2-position valvas, it is not necessary to malntain pressure on lhe actuated pilot in order for the valve to remain in actualed position. Valve will remain in lasr poshlon unill signalled by the opposite pllor D raturn. When used with spring cenlering leature (".I"), valve wlll remaln In cenler position until actuated by either pilot. To remaln In actuated positlon, pilot must remain pressurized untll ir Is required for valve to return to center position.
',
mjmm
2 2 7 ~
,--.
.__I
PILOT
OPTION8
STANDARD
ZZTC
'
POSITION OF PILOT INLET
'
Pllot actuated valves ('18" lhru W'] are supoiled with the pilot pon faclng the same dlrection as rhe Inlei port of the valve proper. Three other positions are avallable (Suffix-227Athru -227C). To order simply include the suffix number shown. Example: VSP-4302-227A.
TYPE P(+suffix -1) BLEED PILOT
.
,
The bleed type pilot le constantly supplied with pressure from the inlei of the valve and requires valve body for INPilot operalion. In order to actuate the bleea rype pllol, 11 IS necessary to dlscnerge pressure from h e pdot causing a pressure drop sufflcrent for ihe refurn device to operale. Usuallythe bleed typ0 pilot I s used in pairs and is operated by Two-way valves.
TYPE w DIAPHRAGM PILOT (for 2-poslt1onvalves) TYPE Y DIAPHRAGM PILOT (for 3-pqsltlon valves)
1661
167)
A large pllal area allows tho dlsphragm pilo1 to funotlon on very low algnal
DIAPHRAGM PILOT
pressures. Usually controlled by a Three-Way vBlve, the diaphragm pilot requires pressure to actuate. When used in pairs for 2-position valves, it Is not necessary lo maintain preasure on actuated pllot in order for valve to remain in actuated posltlon. Valve will remaln in last posltlon unlll signalled by oppovalve will site pllot to return. When uaed with spring centering lealure (Y) remain in cenler position until acruared by pilot. To remain in actuated position, pilot mu81 remain pressurized until it is required for vslva to return to center position.
SOLENOID/PILOT
A low power solenoid nonlrots a built-in pilo?whloh provides rhe positive form for shlfrlng (he valve spool. When used wkh a spring reNm (9) or differenlal pllol relum (K) h e valve will be aaualed when the solenold Is energized and will return when the solenoid is deenerglzed. When used in pairs for 2-poeition valves, the solenoid need only be energized momentarily In order to shift the valve. The valve wlll then remain in rhe shltled pOSlIlOn until signallea 10 relurn by the oppo6lre solenoid. in spring centering models (X) the valve will rarnaln in rhe center posirlon untll on8 of the Golanoids is onorgired. It in nooessary to maintain energy on the solenoid as long as If Is deslrad for the valve to remain In the shifted poshion. When de-energized, the valve wII1 return to m e cenler poslilon.
STANDARD COILS are epoxy molded. For AC and DC voltages available, see page V-3.5.
Two Pllollng devices are available dependlng upon the service 10 which they
wlll be applied:
INPllot- utilizes the pressure from the inlet of the valve, through internal pasrages. to the solenoid-pilot. In fhis type valvs, only one pressure connection, T h e inlet. is necessary.
EXPllor- requires a separate auxiliary pressure line 10 rhe solenoid-piiol. Should be used when valve is CO~tiOlllng vacuum. when pressure will be below the mlnlmum recommendedfor INPilot operation or when vlscosity of conrrolled medium I s such that it will impode rhe opood of aotuetion. In any case, lhe pressure 6ource may be either air or liquld and is independent of the medium which is being controlled by lhe valve.
INLINE SOLENOID
TYPE G INLINE SOLENOIIWPILOT (for position V ~ I V ~ S j621 ) TYPE X INLINE SOLENOID/PILOT (for 3-posltion valves) 63
Coils of actuafor are placed on end of valve in line with !he longitudinal axis through the valve. Allows valve to be tucked away inro relatlvely narrow spaces.
TYPE G (+WffIX 4) UPRIGHT SOLENOID/PILOT

(for 2-posltlon valves) TYPE X (+eufflx 4) UPRIGHT SOLENOIDPILOT [for 3-posltlon valves)
lszl E l
SOLENOIP PILOT
-.
Colls of actuator are placed on top of solenoid cap so as 10 be perpendicular to the longltudinel axls of Ihe valve, ShOnenS OVen3ll lengrh of valve. Used as standard lor valvas equipped with hazardous location solenoids (sutfix -XX) or plug-in solenolds, (sufllx -F).
111:
SOME OPTIONS AVAILABLE Hazardous Servlce solenoid: See page V-3.7 8 7 0 . 1 Low Wan Hazardous Servlce Solenoid: See paoe V-3.7 K 70.1 DIN Coil 8 Connector: (Sufix -HC. -HCC, -HCCL, -HCL) Coil poKed within houslng; NEMA 4/4X Rating: (Suffix -Pc) Manual Ovenlde: (Suffix -G, -GSR, -M, -MSR) Threaded Solenoid Exhaust Abapler; (Suffix -H) Continuous D u t y Solenoid: (Suffix -3) Dust excluder nut for solenoid exhausr: (Sutfix -14)
SPRING RETURN (671

A device for returning the value spool
-M MANUALOVERRIDE
r o 1 1 s OrlglnBl posltlon In 2-pOSlClotl
valves.
TYPE S
Can be used on any type valve. Pushes valve spool.
-HC DIN COIL & CONNECTOR
TYPE R
For usa with Hand or Treadle Operared valves usually. Pulls valve spool.
NO-SPRING RETURN
TVPE N
For use on Hand or Treadle Operated valves only. Used when aulomatlc relurn of valve spool is not deslred. Spool will stay in last posltlon placed until opek ared lo another posillon.
DETENT
les(
I I speclfls
A dcvlce Ihat eftablichoo a definite Yeel indioaring whon valvo is in
poaition. Also prevents spool from shifilng should excessive vlbrarlon be prer Treadle Operated valves, bur can ale0 be sent. Generally used with Hand o suppiled, In come cases, for Pllot and SolenoidPilot Operated valves as a Camblnetion Actuator.
SPRING RETURN
NO SPRING RETURN
TYPE U
3-pocltlon detent for 3-pocitlon walvee. Provide8 dereni in eaeh o b a t poairion
DETENT
and center position a6 well.
TYPE 2
2-positton detent for 2-position valves. Provides d e m ! In both offset positions.
DIFFERENTIAL PILOT RETURN

rYPE K
Utilizes air or oil prosaura in place of sprlng return In oraer 10 shlh valve spool. Can be used In any 2-position valve. INPllel type uses pressure from inlet of valvc; no auxlllary piping roquirad. EXPllot type requlres suxlllary source of pressure. Used when pressure being controiled by lhe valve is not sufllclent to shift valve spool.
PILOT RETURN
SPRING CENTERING DEVICE

A device for returning the valve spool 1 0 canter posltlon In Hand and TrBadle Operated valves only. Sprlng centering devices for Pilot or SolenoidPllot
Opereted valves are an integral pan of the specific actuaror. lYPE Bsprlng centers from both offset positions. TYPE D sprlng Centers from only one offset poslrton; pulls spool to cen,
:el. TYPE E spring center8 from only one oHset position; pushes spool to
center.
*..
_--_.., .. .. .. .....
9)WAY VALVES 212

Two-way Valves are on-off valves. They ate supplied wlth an Inlet and an outlet port that is either normally closed or normally open to the inlet in the unactuated position. Two-way Valves are usually used to open or close a pressure line such as in applications involving spraying, air ejection, clearing chips, powering an air motor or aperatlng the pilot of bleed-pilot valves.
NOMINAL PRESSURE RANGE (Consult pressure rating chart on page V-3.3 for specific pressure rating of each valve.)
ACTUATION
MANUAL MECHANICAL, PILOT or SOLENOID-PILOT
Stwirn V: partial vacuum to 200 pi (14 bar) pneumatic Serles T:M O O psi (35bar) hydtaulic
BODY TYPES:
SIDE-P 0 RTED
All Series V & TTwo-way Valves are available in the two body types described below. Actuators used with ehher body type are completely interchangeable.
SUB-PLATE MOUNTING The Sub-plate rnounllng valve is shown mounted on an individual sub-plate. See page V-25.1 for details on the sub-plare.
The side-paned body provides threaded pons In tne bouy of the valve.
PORT SIZES: 118, 114.310. 112. 314, and 1 NPT v e , I&, 3/e, and i t 2 d
PORT SIZES: 118, 114, 318. 1t2. 3t4, 1, 1.114 NPTand G
SPECIFICATIONS
Refer to pages V-3.1 through V-3.8 for information concerning: Construction
Seals Port Slzes Flow Pressure Ranges Electrical
Temperature
Filtration 8 Lubrlcadon
STANDARD FLOW PATTERNS

ONE INLET, ONE OUTLET 212
Valves must be connected in accordance wilh rhe pon markings so that the flow is from the inlet port to the outlet port. The flow within the valve should never be reversed. Note: When used In a vecuurn system, the vacuum pump is connected to the outlet port.
TWO POSITION
1. VALVE NORMALLY CLOSED (actuator mounted on right end of valve)
UNACTUATEO
ACTUATED
2. VALVE NORMALLY OPEN (actuator mounted on left end of valve)
UNACTUATED
ACTUATED

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TECHNICAL MANUAL: CONTROL VALVES

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SUMMARY OF REVISION HISTORY

Date Oct. 2003 Nov. 2003

Section or Pages, Revised -

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Air Filter Regulator

ES0400 EY7725 ES0400

Supply Requirements Performance Data Supplier

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SPDC TECHNICAL MANUAL INDEX

9.9 Air Lockup Valves 77-6 EY7725 Installation/Adjustment/Maintenance Parts

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SPDC TECHNICAL MANUAL INDEX

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SPDC TECHNICAL MANUAL INDEX

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Instruction No EH 1080-04/02 21000 Series Valves

............................................................................ 2 UNPACKING ................... ........... ......3

8. VALVE BODY REASSEMBLY ......................... 8.1 THREADED TRIM .....................................

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Instruction No EH 1080-04/02 21 000 Series Valves

A Angle Body BS Bellows

Figure 1 - Numbering System

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Instruction No EH 1080 -04/02 21000 Series Valves

6.1 Threaded Trim (Figure 12 or 14)

7. Maintenance & Repair

7.1 Threaded Seat Ring Removal (Figure 12 or 14)

6.2 Quick-Change Trim (Figure 13 or 15)

7.2 Bushing Removal

7.3 Lapping Seats

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Instruction No EH 1080- 04/02 21000 Series Valves

7.3.2 Quick-Change Trim (Figure 13 or 15)

equally spaced around the seating area.

6. Place bonnet (8) on the body.

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Instruction No EH 1080-04/02 21000 Series Valves

7.4 Lo-dB@ Plug (Figure 8, 14 or 15)

and stem diameter (see Figure 9).

mark on the plug guide area using a center punch.