WARNING!

THIS MANUAL, AND THE GENERAL

INSTRUCTION MANUAL MUST BE READ PRIOR
TO TURBINE AND AUXILIARY EQUIPMENT
INSTALLATION, OPERATION, OR
MAINTENANCE.

ONLY QUALIFIED MECHANICAL AND

ELECTRICAL PERSONNEL FAMILIAR WITH
THE CONSTRUCTION AND OPERATION OF THIS
EQUIPMENT AND THE HAZARDS INVOLVED
SHOULD ATTEMPT TO INSTALL, OPERATE OR
SERVICE THIS EQUIPMENT.

FAILURE TO READ AND UNDERSTAND THIS

MANUAL IN IT’S ENTIRETY BEFORE
PROCEEDING COULD RESULT IN DAMAGE TO
THE EQUIPMENT AND/OR CAUSE BODILY
INJURY OR LOSS OF LIFE.

CAUTION!
A PROTECTIVE MYLAR FILM IS INSTALLED UNDER
EACH UPPER BEARING HALF, BETWEEN THE
BEARING AND THE TURBINE SHAFT. DO NOT
OPERATE THE TURBINE OR ATTEMPT TO ROTATE
THE SHAFT UNTIL THE MYLAR HAS BEEN REMOVED
FROM BOTH BEARINGS.
 DESIGN OPERATING CONDITIONS

Turbine Serial No. BUR5955 Project No. 110754

Rated Steam Pressure at Throttle - - - - - - - - - - - - - - - - 210 #/sq. in. ga.

Rated Steam Total Temperature at Throttle - - - - - - - - - 680 º F.
Rated Back Pressure at Exhaust - - - - - - - - - - - - - - - - - 1.02 #/sq. in. ga.
Rated Vacuum at Exhaust - - - - - - - - - - - - - - - - - - - - - - --- “ Hg. Abs.
Rated Horsepower - - - - - - - - - - - - - - - - - - - - - - - - - - - --- H.P.
K.W. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11875 K.W.
Rated Turbine Operating Speed - - - - - - - - - - - - - - - - - 4500 R.P.M.
Rated Gear Operating Speed - - - - - - - - - - - - - - - - - - - - --- R.P.M.
Turbine Rotation (Viewed from Gov. End) - - - - - - - - - - CW

Operating Data Viewed from Gov. End of Turbine:

For Assembly & Opening

Sequence see H.P. Control
Valve Assembly
1 2 3 4 5

Valve Data
Stm Stm. Temp. Exh Nozzle Compartment
Press Press H.P. RPM Remarks
PSIG
T.T. S.H. PSIG
#1 #2 #3 #4 #5 #6
210 680°F 288°F 1.02 16398 4500 OPEN OPEN OPEN OPEN OPEN MAXIMUM
210 680°F 288°F 1.02 15924 4500 OPEN OPEN OPEN OPEN OPEN NORMAL/GUARNTEE

4275 MIN. SPEED

4725 MAX. SPEED
5 3 1 2 4
SEQUENCE AND SIZE OF VALVE 4 3.50 3 3.25 4

LABYRINTH DIAMETRAL COLD CLEARANCES

Min. Max.
Steam End Rings 8-1/2” - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 0.014T 0.016T
Steam End Rings 10” ------------------------------- 0.016T 0.018T
Exhaust End Rings ------------------------------- 0.001L 0.003L
Diaphragm Ring(s) 2ND stage thru 5TH stage - - - - - - - - 0.001T 0.003T
TH TH
Diaphragm Ring(s) 6 stage thru 9 stage - - - - - - - - 0.014L 0.016L
Labyrinth Rings in Steam End Gland to be Arranged for Atmospheric & Above Operation.
Labyrinth Rings in Exhaust End Gland to be Arranged for Condensing Operation.

E-346
 Steam Turbine Business Unit
3800 West Avenue
Burlington, IA 52601
Ph: 319-753-5431
FAX: 319-752-1616

Murray Steam Turbine

Installation, Operation and Maintenance

Important Information on Steam Turbines

(Condensing)

02/16/09
COPYRIGHT
© Murray Turbomachinery, 1993
All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval
system, or translated into any language, in any form, by any means, without permission in
writing from Murray Turbomachinery.

2
 TABLE OF CONTENTS

Section Page Section Page

1 General Specifications 5.10 Handvalves 25
1.1 Unpacking 5 5.11 Sentinel Warning Valve 26
1.2 Storage 5 5.12 Steam Strainers 26
1.3 Cleaning 5 5.13 Gland Evacuation Equipment 26
5.14 Condensing Multi-Stage Turbines 27
2 Special Conditions
2.1 Top Exhaust 6 6 Operating The Turbine
2.2 Outdoor Installation 6 6.1 Operation 28
2.3 Quick Starting & Standby 6 6.2 Turbine Operating Instructions 28
Service
2.4 Reversed Rotation 6 6.3 Precautions 30

3 Installation & Mounting 7 Maintenance & Inspection

3.1 Installation 7 7.1 Maintenance & Inspection 31
3.2 Foundation & Baseplate 7 7.2 Internal Inspection 32
3.3 Erection 8
3.4 Alignment 8 8 Spare Parts & Field Service
3.5 Piping 14 8.1 Spare Parts 34
3.6 Recommended Blow-Down 15 8.2 Field Service 34
Procedure

4 Steam Seals 9 Steam Purity/Turbine Deposits

4.1 Gland Leak-Off System 16 9.1 Introduction 35
4.2 Gland Seal System – 17 9.2 Steam Purity 35
Condensing Turbines
4.3 Leak-Off Piping & Drains 18 9.3 Effects of Deposits on Turbine 35
9.4 Detection of Deposits 36
5 Ancillary Equipment 9.5 Detection of Corrosion 36
5.1 Governors 19
5.2 Governor Valve 20 10 Off-Season Storage
5.3 Trip Systems 20 10.1 Introduction 37
5.4 Ring Oil Lubrication 20 10.2 Turbine Steam Path 37
5.5 Pressure Lubrication 22 10.3 Lubrication System 38
5.6 Oil Flush Procedure 24 10.4 Other Recommendations 38
5.7 Lube Oil Recommendations 24
5.8 Bearings 25
5.9 Couplings 25

INTRODUCTION

There are several considerations and precautions in connection with installation, operation and
maintenance that must be understood and which apply to steam turbines in general, regardless of
size and type. That is the nature of the material in this manual.

This information must be familiar to all involved with the installation, operation and maintenance of
steam turbines. Even those previously experienced with steam turbines will find this material helpful.

3
4
 1
GENERAL INFORMATION

1.1 Unpacking

Murray steam turbines are carefully tested and adjusted at the factory before shipping. Then they are
packed and protected for shipment. Despite precautions taken at the factory, accidental damage may
result from improper handling during shipment. For that reason, it is extremely important that the
machine is unpacked carefully and that any damage is noted for a claim against the carrier.

Always check the shipment against the shipping manifest. DO NOT DISPOSE OF THE SHIPPING
CONTAINER UNTIL AFTER ACCOUNTING FOR ALL PARTS. Small, loose parts and accessories
are frequently removed from the turbine before shipment, boxed separately, and fastened to the
inside of the larger shipping box or crate.

1.2 Storage

Protective treatment is factory applied to turbine parts subject to corrosion. Transit carriers and
recipients of turbines are advised to take precautions against exposure of turbines to the elements.

Should it become necessary to store a turbine for a long period of time, Dresser-Rand should be
contacted for special storage procedures.

WHEN STORING A TURBINE PRIOR TO INSTALLATION, PRECAUTIONS MUST BE TAKEN TO

AVOID DAMAGE DUE TO CORROSION AND DIRT. THE MACHINE SHOULD BE STORED IN A
CLEAN, DRY, SHELTERED PLACE IF AT ALL POSSIBLE. IF NO SHELTER IS AVAILABLE, IT
SHOULD BE COVERED WITH WATERPROOF MATERIAL. Do not leave a turbine exposed to a
corrosive atmosphere. Even if the turbine is to be installed in the open air, precautions must be taken
to assure satisfactory condition when the turbine is started. The effects of storage differ widely with
local conditions.

1.3 Cleaning

Before a turbine is operated, certain parts must be cleaned to remove the effects of transit and
storage. Protective mylar sheets installed between the journal bearing and the shaft journal MUST
BE REMOVED PRIOR TO ROTATING THE SHAFT. (See Section 5.5 for instructions) Bearing caps
are easily removed. The interior of the bearing cases must be inspected for dust or other grit. If any
is present, the interior of the bearing cases must be flushed with kerosene or similar solvent.

Mechanical governor parts should be thoroughly washed with a spray of non-acetate solvent to
remove adhering dust particles. The interior of the turbine casing should be thoroughly cleaned so
the exhaust system will not become contaminated with dirt. This can be done easily with a water
hose through the exhaust opening. Valve stems and other exposed machined surfaces should be
cleaned with solvent to remove protective grease and/or dirt.

Exposed machined parts have been masked prior to painting. This masking serves as added
protection during shipment and is not removed before shipping. MASKING SHOULD BE REMOVED
DURING THE CLEANING PROCEDURE.

All loose parts (such as loose piping, etc.) should be cleaned and installed. Turbines packed for
export, or protected for long storage periods may need to be completely dismantled and cleaned to
remove all protective grease and flushing compound. Dresser-Rand will provide specific instructions
for turbines requiring complete dismantling.
5
 2

SPECIAL CONDITIONS

2.1 Top Exhaust

When required by site conditions, turbines are equipped with exhausts which point upward.
Turbines with a top exhaust must be provided with some means for keeping the turbine casing
drained. Dresser-Rand will provide specific instructions for each turbine shipped with a top exhaust.

2.2 Outdoor Installation

When specified on a purchase order, Murray turbines will be made suitable for outdoor installations.
However, if these machines are allowed to stand idle, corrosion will be more rapid and there is a
greater chance of the oil being contaminated with dirt and/or water. CONTACT DRESSER-RAND
FOR SPECIFIC INSTRUCTIONS BEFORE ALLOWING A TURBINE INSTALLED OUTDOORS TO
STAND IDLE.

2.3 Quick Starting & Stand-by Service

Turbines may be specified and used as a stand-by for motor drive installations. In such cases they
may be started automatically upon failure of the regular equipment. Starting is usually accomplished
by means of a control operating a motor operated throttle valve.

Some turbines used in quick starting applications must be maintained in a “warm” condition by having
a quantity of steam (to be specified by Dresser-Rand) passing through them at all times to ensure
safe start-up.

Turbines used only for stand-by should be operated for a short period at least once a month to ensure
that they will function properly when needed.

2.4 Reversed Rotation

Before running the turbine with the driven machine, be sure that no condition exists which can
produce reverse operation. As the turbine’s operating force diminishes in the stopping process, a
counterflow of process fluid (in case of centrifugal machines) may produce reversed rotation.

In such instances the speed governor and emergency overspeed governor are completely ineffective
since they control the supply of steam to the turbine.

Check-valves in the fluid lines (or non-reverse pawls in the driven machine) are common means used
to prevent reverse rotation. These items must be adequately maintained to ensure proper operation.

REVERSE ROTATION INVARIABLY RESULTS IN LUBRICATION FAILURE AND CONSEQUENT

DAMAGE TO LUBRICATED SURFACES UNLESS AN AUXILIARY OIL PUMP IS PROVIDED. IN
EXTREME CASES, THE TURBINE MAY OVERSPEED IN REVERSE TO THE POINT OF
DESTRUCTION.

6
 3

INSTALLATION & MOUNTING

3.1 Installation

Proper installation is extremely important. To obtain maximum service from Murray turbines it is
essential that turbines, reduction gears (when used), and on-site driven machines are installed with
the greatest care.

NOTE THAT DISTORTION OF THE BASEPLATE OR GENERAL MISALIGNMENT CAN CAUSE

SERIOUS FUTURE OPERATING DIFFICULTIES EVEN THOUGH THE TURBINE SEEMS TO RUN
SATISFACTORILY WHEN FIRST INSTALLED.

3.2 Foundation & Baseplate

Turbines, driven machines and reduction gears (when used) are customarily mounted on fabricated
steel baseplates. When baseplates are furnished, holes for the hold-down bolts are pre-drilled in the
baseplate. These baseplates are fastened to the foundation with anchor bolts and grouted. In some
cases, steel soleplates are used instead of baseplates under the entire unit.

Equipment should be located and aligned on the baseplate at site, in accordance with the outline
drawings, because it is not practical to locate and dowel rotating equipment to the baseplate at the
factory. Although the equipment has been assembled and operated as a unit in the factory, IT MUST
NOT BE ASSUMED THAT THE EQUIPMENT IS IN PROPER ALIGNMENT AFTER SHIPMENT
AND HANDLING.

Certified outline drawings will contain sufficient information (weights, dimensions, mounting hole
locations, etc.) to allow the user’s civil engineer to design the turbine foundation.

It is important that the top surface of concrete foundation is left rough to provide a good bond
between the grout and the foundation.

A convenient means of leveling the baseplate is to have foundation bolts threaded down to a point
flush with the top of the foundation and provide nuts for the foundation bolts for use under the
baseplate.

When the baseplate is lowered onto these nuts, they can be used in raising and leveling the base. If
it is not possible to provide for leveling in this manner, flat shims should be placed on opposite side of
each foundation bolt.

A vertical space of one inch should be provided for grouting. Less space is difficult to fill, while more
will increase shrinkage. Foundation bolts should be tightened only sufficiently to hold the baseplate
or soleplate in position while grouting, thus eliminating danger of springing.

When the baseplate is bolted and leveled, a retaining form can be built to retain the grout. The grout
should only be thin enough to flow readily. Excessive water produces greater shrinkage in drying.

Use a grout with non-shrink additives and be certain that the grout thoroughly fills the space. In
grouting soleplates, a two inch wide grout should surround the soleplate and be poured even with the
top of the soleplate.

7
3.3 Erection

Where all units of turbine driven equipment are to be installed on a common base, the following
erection guideline must be used.

• Place the baseplate with its equipment on the foundation over the foundation bolts. The position
of the turbine and other equipment should approximate the unit’s intended location on the
baseplate. Loosely bolt the equipment to the baseplate.

• Locate the baseplate in a horizontal plane on the foundation to suit existing conditions.

• Raise the entire baseplate from the foundation to the height to be allowed for grout. In most
cases, this is accomplished with bars and wedges. If nuts have been provided on the foundation
bolts under the baseplate, they can be used for this purpose.

• LEVEL THE BASEPLATE CAREFULLY USING AN ACCURATE METHOD ON A MACHINED

PAD OF THE BASE. THIS CAN BE ACCOMPLISHED WITH A TRANSIT, LASER OR SPIRIT
LEVEL (MINIMUM SIX FOOT LENGTH).

• Level and align the turbine and driven machine, locating equipment properly on the baseplate in
accordance with the outline drawing and maintaining the proper distance between the ends of
each shaft. See Section 3.4 for alignment procedures.

• Moderately tighten the foundation bolts and recheck the level of the baseplate and the alignment
and level of the turbine and driven machine.

• Tighten hold-down bolts and recheck level and alignment.

UNTIL THE UNIT HAS BEEN PROPERLY DOWELED, IT CANNOT BE SAFELY ASSUMED
THAT THE EQUIPMENT WILL REMAIN PROPERLY ALIGNED ONCE THE FOUNDATION
BOLTS AND MACHINE HOLD-DOWN BOLTS HAVE BEEN TIGHTENED.

THE IMPORTANCE OF HAVING THE TURBINE AND DRIVEN MACHINE IN CORRECT

ALIGNMENT AFTER ALL INSTALLATION WORK HAS BEEN COMPLETED CANNOT BE
OVER-EMPHASIZED.

• Grout the base to the foundation. For suggestions on grouting, refer to instructions on foundation
and baseplate in section 3.2.

• After grouting has cured, retighten all bolts and again check the alignment. The equipment is
then ready to be fitted with piping.

3.4 Alignment

“Alignment” refers to the proper relationship between the centerlines and the distance between the
turbine shaft and the driven machine.

INACCURATE ALIGNMENT CAN RESULT IN DESTRUCTIVE VIBRATION, LOOSENING OF

GROUT, BURNED OUT BEARINGS, A BENT SHAFT, AND OTHER CONDITIONS THAT COULD
LEAD TO EQUIPMENT FAILURE.

8
The following instructions and suggestions are made for guidance in alignment of newly installed
equipment and under the presumption that:

• The persons reading this have a general familiarity with high speed turbomachinery and that they
are aware of the basic principles of alignment.

• It is understood that the various procedures suggested for checking completed portions of the
system are in no way a substitution for proper design, engineering, and construction.
Additionally, the suggestions made represent only one of several acceptable alternatives.

• In the case of turbomachinery, many of the items vital to a good alignment have been done well
ahead of the actual “cold alignment” of the equipment. Unless the person responsible for the
alignment has first-hand knowledge that the preparations have been done properly, it is best to
verify these items. Some areas that warrant specific attention would be:

Piping. Assure that the piping is installed in agreement with design criteria, that it is
complete, and that it is in its functional state. Look for proper placement and adjustment of
guides, anchors, and supports; proper adjustment of tie-bolts on expansion joints; correct
positioning of spring hangers; complete make-up of flanges with gaskets in place and bolts
tightened; absence of slip-blinds which may have been installed for hydrotesting of pipelines; and
proper orientation of check valves.

Check the grouting to assure it is complete and appears to be well done.

Check all foundation bolts to assure tightness.

Check all shim packs for rust, improperly cut shims, folds and wrinkles, burrs, hammer marks,
and dirt. Shims are a vital link between the machine and the foundation and are essential to the
maintenance of alignment over long periods. Good practice dictates that as few shims as
possible be used, replace many thin shims with fewer shims of greater thickness. Shims of
stainless steel will pay for themselves many times over by minimizing shim deterioration. Also it
is important to make sure the equipment supports and soleplate/baseplate are clean and in good
condition.

Check for misalignment of machine supports relative to the soleplate, this is sometimes
referred to as a “soft foot” condition. Mounting a dial indicator on the machine support with the
indicator stem resting on the soleplate can make a simple test for this condition. Watch the
indicator as the hold-down bolts are loosened. If the movement of the indicator is more than
.005”, it is an indication of a problem which must be rectified. It is also appropriate to remove the
shim pack and check with feeler gauges to assure that the machine support is parallel with the
soleplate.

Check for piping strain. This can be accomplished by placing dial indicators on the machine
to monitor both vertical and horizontal movement of the casing or shaft. Then loosen all of the
hold-down bolts. If the machine moves more that the average observed in checking individual
supports, it is obviously the result of an external force and probably the piping.

Make sure that the bearings have been properly installed in the machines, are lubricated, and
the bearing covers are properly tightened.

The term “cold alignment” refers to the position of the centerline of the shaft of one piece of
equipment relative to the centerline of the shaft of an adjoining machine to which it is connected, as
well as the distance between the two shafts, with the machines in a non-operating or “cold” condition.
The term implies both offset and angularity. The importance of this cold alignment is that it is usually
the only check made to ascertain directly the relative position of the two shafts. The result of this
check is the basis for determining shaft alignment of the equipment during operation. It is the
fundamental benchmark and must be accurately done and properly recorded.

9
Many methods can be utilized to perform this alignment. The method described in this manual will be
that of using dial indicators. While the method of employing dial indicators is an old and well-
established technique, it is not without problems.

The most widely used of the traditional alignment methods is commonly referred to as the “Face-
O.D.” method as illustrated in Figure1. As shown in the figure, a bracket is attached to one shaft and
extends to the proximity of the coupling hub on the adjacent shaft. Dial indicators are affixed to this
bracket with the stem of one indicator resting on the face of the coupling hub and the stem of the
other indicator resting on the outside diameter of the same hub. The offset of the shafts is
determined by the “O.D.” readings, while angularity of the shafts is determined by the “face” readings.
It is suggested that the proper distance between the shafts be established before any alignment
method is used. This spacing dimension can be found on the outline drawing and/or the coupling
drawing for the specific project.

To eliminate inaccuracies in geometry of the coupling hub, turning of both shafts simultaneously such
that the indicator readings are taken always at the same place on the hub will give more precision.
This precaution can be difficult on larger equipment and may not be possible.

Face measurements taken by this method must have the axial float of the two shafts accounted for.
Axial movement must be taken into account when turning the shafts on equipment with hydrodynamic
thrust bearings or no thrust bearings. (Small machinery utilizing ball bearings will not encounter any
axial float.) The shafts must have axial positions rechecked each time a reading is taken. One
additional element that must be accounted for is the difference between the exhaust end shaft rise
and the steam end shaft rise. Typically, the steam end will rise more than the exhaust end due to
higher temperatures. This will result in the desire to have the coupling face “open” at the top. The
calculated shaft rise for both the steam and exhaust end can be found on the outline drawing for the
project.

Care must also be taken in the brackets that are used to hold the dial indicators. “Universal” or
makeshift brackets contrived on the spur of the moment can give inaccurate readings, which can lead
to improper alignments. Especially when the spans between the shafts are quite long, care must be
taken to assure that the bracket being utilized is stiff enough that it will not deflect under its own
weight.

A step up in accuracy and the elimination of some of the problems mentioned above with the “Face
O.D.” would be to utilize the “Reverse Indicator” method as illustrated in Figure 2. This method

10
employs indicator readings taken on the outside diameter of the coupling hubs or shaft only. The
sketch indicates two brackets used simultaneously, which is normally the preferred method. One
bracket could be utilized by switching back and forth for each set of readings but this is far less
convenient.

Use of the “Reverse Indicator” method eliminates the requirement for removing the coupling spacer in
a majority of cases. This reduces the wear and tear on the coupling. The error caused by coupling
hub run-out is entirely eliminated since both shafts turn as a unit (with spacer installed), and angular
misalignment is greatly magnified and more precisely diagnosed. Since face readings are eliminated,
there is no concern about axial float.

The single problem that carries over to the “Reverse Indicator” method which was present in the
“Face O.D.” method is that of deflection in the alignment bracket. This problem can be readily
handled by building the bracket with substantial material to prevent droop or by determining the
deflection in the alignment fixture and making the appropriate corrections in the alignment data.

For the purpose of example, Figure 3 shows a simple turbine-compressor to be aligned. It is desired
to place the compressor shaft .008” higher than the turbine to accommodate for calculated thermal
growth of the two machines. The alignment bracket is clamped to the turbine shaft with the indicator
stem resting upon the compressor shaft (or the rigid portion of the coupling hub).

11
 The indicator is “zeroed” on top and the following readings are observed as the shafts are
rotated at 90-degree intervals.

-6 -8 Turbine to Compressor

-14

A similar procedure is used with the complementary bracket and the indicator yields to
following:

+8 +12 Compressor to Turbine

+20

This data obtained is adequate to determine relative shaft positions. Record the readings
and indicate precisely what they represent. As they are shown above, the readings shown as
“Turbine to Compressor” indicates the alignment bracket is on the turbine shaft and the
indicator stem rests upon the compressor shaft.

Make any corrections for the deflection of the alignment bracket. For this example, we will
assume .004” TIR deflection. To make the correction for this error, simply add the TIR
reading (in mils) to the bottom number in each set.

0 0

-6 -8 +8 +12

-10 +24

Turbine to Compressor Compressor to Turbine

For ease of plotting, change each pair of numbers to “zero” and a positive number. Since
diametrically opposed numbers represent only a deviation from an arbitrary reference, a
given amount may be added to both sides without affecting the meaning. On the “Turbine to
Compressor” readings, for example, 10 is added to the vertical pair of numbers while 8 is
added to the horizontal pair. The other sets are handled in a similar manner. The absence of
negative numbers reduces errors in plotting.

12
 +10 0

+2 0 0 +4

0 +24

Turbine to Compressor Compressor to Turbine

In Figure 4, the points shown above have been plotted on a scaled sketch of the turbomachinery
train. Any convenient scale may be used. In this example, it is assumed the turbine will remain
stationary and the compressor will be shimmed to achieve the desired alignment. From the “Turbine
to Compressor” data, it can be seen that the centerline of the compressor shaft is .005” (one half of
the TIR reading) above the centerline of the turbine shaft for the point at which the indicator readings
were taken. Now referring to the “Compressor to Turbine” data, it can be seen the centerline of the
turbine shaft is .012” below the centerline of the compressor shaft for the point at which the indicator
readings were taken. With these two points determined, the position of the compressor shaft relative
to the turbine shaft is fixed. An extension of a line through these two points gives a graphical
representation of the alignment situation and indicates the shimming necessary to achieve the
desired alignment. It is also at this point in the alignment procedure that the offset required due to the
steam end rise be greater than the exhaust end rise must also be taken into consideration.

In this example, the vertical plane has been plotted. Alignment in the horizontal plane is obtained in
the same manner.

13
In recent years people have questioned the value of the traditional “Hot Check Alignment”. Not only
is it costly and time-consuming to bring a machine up to temperature, stop it, break couplings, and
attempt to determine alignment before it cools off, but the results are highly questionable. It is
normally not possible to make the check quickly enough to accurately determine the thermal growth
of the equipment. Also any hydraulic forces and torque reactions, which can be significant, are never
revealed by the traditional check methods because the forces disappear immediately upon stopping
the machine. Today’s generally accepted, superior alternative is to use the cold position of the shafts
as a benchmark, and deduce the hot alignment by monitoring the movement of the machine casings,
or shafts, from the cold position to the hot position. There are several methods used for this
monitoring. A variety of techniques have been applied to the actual determination of casing or shaft
movement. The most widely publicized methods employ optical or electronic (laser) techniques.

3.5 Piping

Inlet and exhaust piping for a steam turbine should be designed and installed by knowledgeable
persons experienced in turbine work.

The size of steam and exhaust lines indicated on the drawing is based upon velocities in the piping
generally accepted as being good practice for runs of straight pipe up to 200 feet, or the equivalent in
valves and fittings.

Piping for back pressure turbines should include a throttle valve in the steam inlet line and a stop
valve in the exhaust line. A suitable relief valve to protect the turbine exhaust casing must be
provided between the turbine exhaust flange and the exhaust stop valve.

Piping for condensing turbines should include a throttle valve in the steam inlet line. A suitable relief
valve or rupture disc to protect the turbine exhaust casing and surface condenser must be provided at
an appropriate location in the exhaust system before any shut-off valves, if present. Often the
location of choice is on the surface condenser.

The exhaust relief valve or the rupture disc should correspond in size to those indicated for steam
and exhaust lines in APPENDIX-A, NEMA SM23-8, Steam Piping Systems. These relief valves serve
to protect the turbine casing against over-pressurization in case the turbine is started with the exhaust
valve closed or the backpressure rises for any reason during operation.

The relief valve should be of sufficient capacity to relieve the rated steam flow of the turbine at the
maximum operating pressure specified when all hand valves are opened. Contact Dresser-Rand for
specifications on sizing the valve, relieving capacity, and over-pressurization limits.

No responsibility is assumed by Dresser-Rand in regard to pressure or temperature drops. THE

PERFORMANCE OF THE TURBINE SPECIFIED IS BASED UPON THE INLET PRESSURE AND
TEMPERATURE AS MEASURED AT THE MURRAY TURBINE STEAM INLET FLANGE.
SIMILARLY, THE EXHAUST PRESSURE IS MEASURED AT THE TURBINE EXHAUST FLANGE.

Steam and exhaust piping must be properly designed and supported so that its weight and thermal
expansion will not produce excessive strains on the turbine inlet or exhaust flanges, either when cold
or when at normal operating temperature. The piping must be designed so that it does not have to be
sprung into position for bolting to the turbine flanges when cold. Likewise, the piping must not spring
out of position when everything is at running temperature.

FORCE DUE TO THERMAL EXPANSION CAN BE VERY GREAT IF NOT PROVIDED FOR BY
EXPANSION AND SUPPORT OF PIPING.

These forces can cause misalignment. The maximum allowable forces and moments, per NEMA
standards, are indicated on the outline drawings. See Appendix A, NEMA SM23, Part 8 (Steam
Piping Systems) for additional information.

14
Moisture in the inlet steam not only increases the steam consumption but causes rapid wear of the
valve seats, nozzles and turbine blades. Contact Dresser-Rand for the maximum amount of moisture
allowable on each specific application.

Where turbines are to operate on saturated steam, a steam trap should be installed at the low point of
the inlet piping. In most cases, a moisture separator in addition to the steam trap is advisable.

Where exhaust piping bends upward after leaving the turbine, steam traps should be provided to
keep the exhaust line drained to prevent water from building up in the exhaust pipe and turbine
casing.
FAILURE TO KEEP THE EXHAUST LINE DRAINED MAY RESULT IN A RESTRICTION IN THE
EXHAUST LINE, CAUSING A LOSS OF POWER AND DAMAGE TO THE TURBINE ROTOR.

Connecting the steam line should always begin at the header or other source, the turbine connection
being made last. If an expansion joint is used in either line it must be securely anchored to prevent
axial strain on the turbine.

BE SURE TO BLOW OUT AND CLEAN ALL STEAM LINES BEFORE CONNECTING TO THE
TURBINE. FAILURE TO DO SO MAY RESULT IN DAMAGE TO THE STEAM STRAINER
SCREEN AND OTHER INTERNAL PARTS.

DRESSER-RAND ACCEPTS NO RESPONSIBILITY FOR DAMAGE RESULTING FROM THE

ENTRANCE OF FOREIGN MATERIALS.

3.6 Recommended blow-down procedure

Newly constructed steam piping should be blown-down to remove scale, weld beads and any other
foreign material. Such material can cause severe damage if it enters the steam turbine.

The blow-down connection should be as close to the turbine as possible. The diameter of the blow-
down connection should be a minimum of one half the diameter of the line being blown-down to
ensure that steam velocity in the piping is high enough to break loose and carry away any foreign
material stuck to the inside of the piping.

Blow-down should be done before the piping is insulated. Steam at full temperature and pressure
should be bled through the piping.

After the piping has been warmed up, the valve in the blow-down connection should be opened wide
for about 15 seconds to allow live steam to blow out any loose material in the piping. Piping should
be allowed to cool down to room temperature, about 6-8 hours.

Thermal expansion and contraction which occurs during warming up and cooling down, helps break
loose the foreign material inside the piping. Hammering around any welded joints in the piping will
also help to break loose foreign material

The above procedures of warm-up, blow-down and cool-off should be repeated as many times as
necessary to clean all foreign materials out of the piping. To check for clean piping, a target should
be placed about two feet away from the blow-down opening so that the steam will hit the target, and
any solids in the steam will become embedded in the target. Plywood, aluminum and polished
stainless steel are commonly used target materials. Piping can be considered clean when no
embedded particles and indentations are found in the target after a 15 second blow-down.

REMOVAL OF FOREIGN MATERIAL FROM THE PIPING IS THE RESPONSIBILITY OF THE

PARTY INSTALLING THE PIPING. The turbine warranty does not cover damage due to the
entrance of foreign material.

15
 4

STEAM SEALS

4.1 Gland leak-off system

Steam in non-condensing turbines tends to leak around the shaft since the pressure in the casing is
greater than atmospheric. Leaks should be limited for the following reasons:

• Steam finds its way to the bearing housings, condenses there and contaminates the oil.

• Efficiency is reduced since escaped steam produces no useful work.

• Each pound of steam lost requires adding one pound of make-up water to the boiler

• Excessive leaks cause an unpleasant working atmosphere.

The gland leak-off system for non-condensing applications and the gland seal system for condensing
machines, are used to minimize leaks. This is achieved with a system that permits steam leakage
where the gland seals make contact with the shaft, using the pressure differential between them as
an effective seal. A leak-off connection, just before the exterior inactive seals, is designed so steam
reaching that point will run through it instead of the seals.

Gland seals can either be of the segmented carbon ring type, the labyrinth type or a combination of
both. Unless one of these two types is specifically mentioned in this section they will simply be
referred to as “gland seals”.

CARBON RING TYPE GLANDS HAVE EXCELLENT SEALING CAPABILITIES WHEN NEW BUT
ARE SUBJECT TO WEAR. THEY SHOULD BE REPLACED EVERY ONE TO THREE YEARS.
NOTE THAT THEY LOSE EFFECTIVENESS WHEN THE PRESSURE DIFFERENTIAL IS
EXCESSIVE.

Some applications require labyrinth glands. These permit a larger leakage than carbon rings but last
two to three times longer than carbon rings and withstand much higher speeds, pressures and
temperatures.

Many turbines combine both labyrinth and carbon rings. The toughness and durability of labyrinths is
convenient in the highly active interior seals, and the sealing capacity of carbon rings is useful for the
less active outer seals.

Usually, a single leak-off system is enough to seal those turbines operating with moderate
temperatures and pressures. If a more effective seal is necessary, or if the working pressures are
higher, a double leak-off system is used. Refer to the steam P&ID in your manual for the leak-off
piping system on your turbine.

In these cases, leak-off connections closer to the casing (interior leak-offs) are connected to the same
pipe and to a header with a steam pressure of 10-20 PSIG (non-condensing turbine) or 1-5 PSIG (for
condensing machines). Exterior connections are either piped to the atmosphere or to an evacuation
device.

Turbines with a very high first stage pressure sometimes use a triple leak-off connection at the inlet
glands and a double connection at the exhaust.

The interior (high pressure) connection of the inlet is connected to a low pressure stage in the casing.
The middle connection on the inlet connects to the inner stage on the exhaust and to a 10-20 PSIG

16
header for non-condensing equipment or 1-5 PSIG for condensing machines. The exterior
connections are piped to the atmosphere or to an evacuation device.

The best system for any specific application depends upon the pressures involved, the required
efficiency, and the availability of low pressure lines at the installation site.

4.2 Gland seal system: condensing turbines

Condensing turbines are equipped with a gland seal system similar to that of non-condensing
machines, although the function is different. The purpose of the condensing system is to keep
outside air from leaking into the casing since it would reduce the vacuum and cause a loss of power.
The system is not as effective when the machine is standing idle as when it is operating.

The gland seal system works with a supply of 1-5 PSIG steam piped to the leak-off connection. If a
double connection system is used, the sealing steam is connected to both the interior leak-offs.

The exhaust pressure in the casing is always below atmospheric pressure. In the majority of
condensing turbines, the casing pressure is also below atmospheric when operating without load but
rises above atmospheric, in proportion to the increase in power, when a load is added.

When the pressure in the inlet glands rises over the sealing pressure, steam will escape through the
leak-off connection and the need for an external supply or sealing steam will be reduced. As the
amount of steam moving through the leak-off connection rises, the external supply sealing steam
becomes unnecessary. In this case, discharge the excess leak-off to the atmosphere or to some
evacuation device.

The remainder of this section refers to valves and gauges shown on the certified outline and P&ID
drawings and describes the operation of a single leak-off gland seal system.

Under initial (cold start) operation, the gland sealing steam supply valve is opened until the gland seal
pressure gauge indicates approximately 2 PSIG or until steam vapor is noted leaking through the
exhaust end seals.

The valve should then be throttled until the vapor just disappears. This prevents air from leaking into
the casing and spoiling the vacuum.

Unless the turbine has a very low inlet pressure (below about 50 PSIG), the first stage pressure will
be above atmospheric as the turbine approaches full load.

If the high pressure leakage is excessive, vapor will again appear outside the seals. When this vapor
appears, the valve should be closed. If vapor persists, open the gland leak-off valve until the vapor
just disappears or the gauge indicates 1 to 2 PSIG.

A reduction in turbine power demand will cause a reduction in the gland seal pressure as measured
by the gauge. If this pressure drops below 1 PSIG, the gland leak-off valve should be closed until you
obtain the correct pressure.

Note that the objective is to maintain 1-5 PSIG steam pressure in the gland seal piping at all times.
The amount of steam which must be admitted through the gland sealing steam supply valve, or
discharged through the gland leak-off valve, depends on turbine power output; inlet steam
temperature and pressure, exhaust vacuum, and the condition of the shaft seals.

If all of the turbine operating conditions remain fairly constant, and a trained operator checks on the
turbine every 1-2 hours, manual control of both valves may be satisfactory.

17
If the turbine will be subject to rapid and unpredictable changes in steam conditions or power
demand, or if the turbine will not be closely attended, the gland sealing steam supply valve should be
controlled by a pressure regulator.

4.3 Leak-off piping and drains

Where the rotor shaft passes through the turbine casing, packing glands of the segmented carbon
ring or labyrinth type are provided. These have leak-off connections piped to a common point.
FROM THIS POINT, THE CUSTOMER MUST PROVIDE SUITABLE PIPING OF A SIZE
INDICATED ON THE OUTLINE DRAWING.

If it is necessary to run the pipe for a long distance the size should be increased so that back
pressure does not build up on the packing gland. This pipe must slope down from the connection
point to avoid forming a water trap and must not contain a shut-off valve.

A small amount of steam will pass through this line at all times when the turbine is in non-condensing
operation. The amount of steam passing through the line will depend upon the amount of back
pressure.

The leak-off steam is commonly piped to a sewer or open header. If this line becomes partially
clogged, or the back pressure builds up for any reason, steam will blow about the shaft at the packing
gland.

Some machines, especially turbine generators, are equipped with a gland condenser which
condenses the gland leakage as well as steam leaking from other leak-off connections. The
condensate from this gland condenser can be returned to the feedwater system.

Turbines are provided with tapped drain openings which can be piped to a sewer or any other low
point that permits the waste to drain off by gravity. The location of these openings is shown on the
outline drawing.

Drains are provided at other points on the turbine for use in getting rid of excess moisture when
starting up. These drains should be fitted with valves that can be opened when steam is first
admitted to the turbine.

DRAIN VALVES ARE TO BE KEPT CLOSED DURING NORMAL OPERATION. SEE THE
TURBINE OUTLINE DRAWING FOR LOCATION OF THESE DRAINS.

18
 5

ANCILLARY EQUIPMENT

5.1 Governors

A governor is a device used to maintain operating speed in a turbine. The governor is also capable of
varying the operating speed by throttling the inlet valve (also called the governor valve). A governor
can be hydraulic, mechanical, mechanical-hydraulic, or electronic.

Hydraulic governor:
The hydraulic type governor is, in principle, an oil pump driven by the turbine shaft. When speed
increases or decreases, it causes a pressure variation which acts through the governor linkage,
increasing or decreasing the opening of the governor valve.

Mechanical governor:
The mechanical governor works on a system of weights and springs which move according to the
amount of centrifugal force generated by the speed of the shaft. Its movement acts on the governor
valve through linkage and throttles the steam flow.

Mechanical-hydraulic governor:
The mechanical-hydraulic governor combines the advantages of the mechanical and hydraulic type
governors. The mechanism consists of a system of fly-balls and springs which move proportionally to
the centrifugal force exerted by the spinning turbine shaft. With each change in position, they cause
movement of a pilot valve. In turn, the pilot-valve movement permits oil flow to a servo-motor or a
power cylinder which amplifies the fly-ball generated force and throttles the governor valve.

Electronic governor:
The electronic system consists of three parts: sensor, main governor, and actuator. The sensor
measures some operational parameter (speed, inlet pressure, back pressure, etc.) and produces an
electric current proportional to the values of the parameter being monitored.

The main governor receives signals from all the sensors, compares them to a programmed value,
determines the action to be taken by the governor valve, and sends an electrical signal to the
actuator. The actuator receives the signal and answers with the appropriate mechanical movement.
This movement either acts directly on the governor valve or through an oil relay system.

The greatest source of trouble for hydraulic or mechanical-hydraulic governors and actuators is
contaminants and foreign matter in the governor oil. Use only fresh, new oil of high quality. Be sure
that all containers used for governor oil storage are clean.

Foaming or the formation of sludge may occur if the oil is allowed to break down or oxidize, resulting
in excessive wearing of plungers, bushings, gear, etc. It may also cause parts to stick or seize.
Change the governor oil whenever it appears to be dirty or breaking down from contaminants or
excessive temperatures.

When changing governor oil, drain it while it is hot, flush the governor oil system with the lightest
grade of the same type oil, and refill with fresh oil of proper viscosity.

The time interval between governor oil changes depends on many factors. Some of those factors
include the type of service, operating temperatures, quality and type of oil, etc. Read and follow the
manufacturer’s recommendations on governor operation and maintenance.

19
5.2 Governor Valve

The governor valve is the device which controls the performance output of the turbine. The typical
control valve for a single valve turbine is a fully characterized, double seated, pressure balanced
valve constructed of stainless steel. The governor valve is actuated directly or indirectly by the speed
governor.

For multi-valve turbines the valves are either of the poppet type or the double seated balanced type of
four, five or six valve design, depending on the steam chest selection. All multi-valves are actuated
indirectly by the speed governor through an oil relay system.

5.3 Trip systems

A trip system refers to the device that stops the turbine in the event certain operational parameters
reach unsafe levels. Normally, these minimum parameters are overspeed, low oil pressure, and high
oil temperature. The trip system can be designed to act upon any operational condition.

A quick acting steam shut-off valve is supplied. The linkage system on these valves has been
provided with a small lever for manual operation and an automatic trip system. The automatic trip
can be mechanical (by means of springs and linkages), hydraulic (by means of oil pressure),
electronic (by means of electrical signals), hydraulic-electric (by means of solenoid valve that
discharges oil pressure), or pneumatic (by means of air pressure).

All trip systems are optional with the exception of the OVERSPEED SYSTEM WHICH IS
MANDATORY.

These overspeed systems can consist of an overspeed governor, incorporating a bolt equipped with a
weight and a spring, or an independent electronic system. With the mechanical overspeed bolt, when
the machine overspeeds, the centrifugal force overcomes the spring’s load and causes the overspeed
plunger to extend out of the shaft, striking the linkage that closes the trip valve. With the independent
electronic overspeed, shaft speed is monitored by magnetic pick-ups and trips the oil solenoid when
shaft speed reaches a set point. The operation of these systems should be checked periodically (at
least once every month) by slowly accelerating the machine to trip speed.

Butterfly type trip valves work by mechanical means and integrated trip and throttle valves usually trip
by means of oil pressure. The advantage of this second type is that it can be connected directly to
the lubrication piping and, in case the oil pressure drops, it can act automatically.

Dresser-Rand recommends using the hand trip lever every time the operation is stopped, since in
doing so the entire emergency trip system (with the exception of the overspeed governor) is
exercised.

5.4 Ring oil Lubrication

Oil requirements for ring oiled bearings is ISO 68. Brass oil rings running on the turbine shaft pick
up oil from reservoirs in the bearing housings. As the shaft and oil rings rotate together, oil flows from
oil rings onto the shaft, ultimately flowing into the bearings, providing lubrication. The oil level within
bearing housings must be maintained at a sufficient level to allow the oil rings to run in the oil. An oil
level that is too high results in oil leakage past the shaft seals. Oil rings cease to rotate sufficiently
when the shaft runs below 900 RPM, no longer providing adequate lubrication. Therefore, the turbine
should not be run at speeds less than 900 RPM.

CAUTION

DO NOT RUN turbines equipped with oil ring lubrication at speeds LESS
THAN 900 RPM. The OIL RINGS WILL NOT OPERATE CORRECTLY at
these speeds, causing BEARING FAILURE due to lack of lubrication.

20
Cooling of the bearing oil is accomplished by water jackets integral to the bearing housings.

Refer to the certified outline drawing in this manual for the location of cooling water connections on
bearing housings.

Cooling water should be piped into one of the lower connections and out from the upper connection
on the opposite side. If interconnection of water jackets on the two bearing housings is desired,
connect the outlet of the governor end bearing housing to the inlet of the drive end bearing housing.
All unused bearing housing connections should remain plugged.

Valves should be included in the cooling water piping to control the flow of water and allow it to be
shut off. The ideal system would employ two valves—one upstream of the bearing housing, acting as
a shut-off valve, and one downstream to control flow. This arrangement ensures that water jackets
are filled with water and allows water to be shut off without disturbing the flow adjustment. If one
valve is used, it should be downstream of the bearing housings.

Flow should be adjusted to maintain bearing oil sump temperature in the normal range shown in the
table below.

Recommended Bearing Oil Sump and Metal Temperatures

Bearing Oil Sump Temperature Bearing Metal Temperature

Operating Status °F °C °F °C
Normal Operation 130-180 54-82 150-200 66-93
Alarm 200 93 210 99
Trip 210 99 220 104

CAUTION

Do not allow COOLING WATER to COOL BEARING OIL SUMP

TEMPERATURE TO BELOW 130°F (54°C), as this may interfere with the
action of the oil rings or cause ATMOSPHERIC MOISTURE to
CONDENSE in the oil reservoir.

Cooling water for bearing housings must meet the following specifications.
Flow rate (per housing): 1 gpm (3.5 l/min)
(if interconnecting pipe used): 2 gpm (7.0 l/min)
Maximum inlet pressure: 150 PSIG (1035 kPag)
Maximum inlet temperature 90°F (32°C)

Constant Level Oiler

Turbines lubricated with oil rings are equipped with constant level oilers. The purpose of these oilers
is to maintain the correct oil level in the bearing housings. Instructions for Constant Level Oilers may
be found in this manual.

Oil Levels

Oil levels that should be maintained by proper adjustment of constant level oilers. The oil level gauge
on the side of the bearing housing indicates the oil level. A mark inscribed on the lower-half bearing
housing indicates the proper oil level.

21
Maintenance/Oil Changes

Oil levels in both bearing housings and the governor should be checked daily.

Low point drains in the bearing housing should be checked weekly for water.

Establish an oil change frequency based on oil tests. Otherwise, oil in bearing housings should be
changed monthly; or earlier, if there is reason to believe that the oil has been contaminated with
water, dirt, or by overheating.

CAUTION

The presence of oil in the constant level oilers does not necessarily mean
that oil in the bearing housings is at the proper level.

CAUTION

CLEANLINESS is ESSENTIAL for long and trouble free service from

BEARINGS and the GOVERNOR. Care must be taken to ensure that no
foreign material enters bearing housings, the governor, or constant level
oilers when performing maintenance, checking oil, adding oil, or making
adjustments.

5.5 Pressure Lubrication

Pressure lubrication is used on all Murray turbines. The system consists of a main oil pump powered
by a driving source such as the turbine shaft, a gear shaft or a motor.

Pressure relief valves are used in the pressure lubricating system to control pressures through the oil
filter, oil cooler, piping and optional auxiliary oil pump.

Always keep the proper oil level in the sight gauge. The system must supply continuous lubrication to
all contact surfaces. THE OIL LEVEL SHOULD BE CHECKED AT LEAST ONCE A DAY OR
EVERY 8 HOURS IF THE TURBINE OPERATES 24 HOURS A DAY.

Normally, a small amount of oil (of the recommended type and viscosity) should be added between oil
changes to maintain the proper oil level.

If an elevation in the oil level is observed in the sight gauge when no oil has been added, water is
probably collecting in the oil. If an abnormal decrease is observed, there are oil leaks in the system.
If an unexplained rise or drop in oil level is observed in the sight gauge, investigate immediately and
stop the machinery if necessary.

The tendency of oil to oxidize and deteriorate increases with temperature. A rise in oil temperature
also decreases viscosity which progressively lowers the ability of oil to lubricate machinery properly.

Pressure lubrication systems are equipped with external oil coolers. The supply of water to these
coolers should be opened at start-up and kept open through normal operation to maintain 110-120°F
oil supply to the bearings.

22
The operator should frequently observe the temperatures at the inlet and outlet of the oil cooler. Any
drastic change should be investigated. Keeping a record of temperatures is advisable since it
provides a good base for comparison.

Take reading from the pressure gauges every one or two hours and investigate any change (gradual
or sudden). The most frequently encountered difficulty is pressure drop, and the most common
causes are clogged oil filter, worn pump, faulty relief valves, insufficient oil in the reservoirs, clogged
piping, entrained air, and temperature elevation.

The most common sources of oil contamination are impurities picked up during storage, shipping, or
adding of the lubricant, dirt in the entrained air, water in the oil reservoirs, leaks in the oil cooler, or
condensation of gland leakage.

Always use a strainer when adding oil to the systems and cover the fill connection when finished.
Make sure the gland system works properly. For details, see Section 4 on Steam Seals.

Water gives oil a milky appearance, and it has a tendency to settle at the bottom of the reservoir
when the turbine is not running. If there is any reason to suspect water in the oil, open the reservoir
drain slightly. If water is present, it will be the first thing to come out of the drain.

The oil in turbines lacking very large, deep reservoirs should be inspected while the equipment is
standing idle. If the turbine operates constantly and has a small reservoir, take a small sample of oil
from the reservoir and let it sit a few hours. If any water is present it will settle to the bottom of the
container.

The probability of oil contamination will increase if:

• Gland seals are allowed to become excessively worn, if obstructions are allowed to develop in
leak-off piping

• If the turbine is allowed to stand idle with back pressure on the casing

• If there is too much sealing pressure on a condensing turbine.

Care should be taken to avoid these conditions.

TURBINES OPERATING OUTSIDE WITHOUT ANY INSULATION RUN A HIGHER RISK OF

HAVING THE OIL CONTAMINATED WITH WATER AND SHOULD BE CHECKED MORE
FREQUENTLY.

When oil is agitated it mixes with air and produces foam. Foam inhibits the ability of oil to lubricate
properly by reducing the oil pressure (which could result in hydraulic governor malfunction), excessive

23
wear of moving parts, rapid oil deterioration and oxidation, and loss of oil through seepage. The
problem is usually solved with oil additives, lowering water flow to the cooler and circulating the oil at
a slightly higher (not to exceed 120°F) temperature, lowering the oil circulation pressure (not less than
13 PSIG), and maintaining the proper oil level.

Sludge impairs oil circulation and causes oil temperature elevation, which accelerates oxidation and
reduces lubricant life and causes possible malfunction of hydraulic governors and oil relays. Any
sludge should be removed as soon as it is found. Sludge formation can be minimized by using high
quality oil and keeping the system free of impurities.

5.6 Lube oil flushing

Flushing the oil circulation system is recommended before starting a new turbine (or one that has
been in storage for a long time). On a new turbine, remove the mylar protection that stabilizes the
shaft during shipment. To do this, remove the upper half of the bearing housing, remove the upper
half of the bearing and remove the two pieces of mylar protection from the shaft. This must be done
at both the steam and exhaust end bearings. Leave the upper halves of both bearings out to allow for
more volume of oil to flow during the flush. Reseal the upper bearing housing cover and replace the
bolting.

Once the mylar has been removed and you are ready to begin the oil flushing procedure, the
following steps should be followed:

1. Bump the aux. lube oil pump motor to assure that the pump is rotating in the proper direction to
achieve pressure.
2. Remove the supply connection to the hydraulic actuator (if supplied with hydraulic actuator) and
plug the line to prevent flow of oil into the actuator.
3. Install 100 mesh plain weave (.0059 opening) screen mesh ahead of all bearing cases (steam,
thrust if separate, exhaust, and any driven equipment being supplied of the oil system).
4. Start up aux. oil pump and run the system for two hours. Shut down pump and check all
screens for particles. Screens should not have any particles bigger than .01 inch in diameter
and show random distribution. No metallic particles should be present. Flushing should
continue until screens show no more than 6 non-metallic particles.
5. Replace screens with new ones and continue flushing in one-hour intervals until no metallic
particles and no more than 6 non-metallic particles are present on any of the screens.
6. Once clean screens are present, remove all screens, bleed and reconnect the actuator line,
service the turbine bearings and replace them in the bearing housing. Housings must be
cleaned and resealed with Tite-Seal to prevent oil leaks at the case split line.
7. Check the condition and cleanliness of the oil filters furnished on the set and replace them with
new filters if needed before continuing with the start up.

5.7 Lubricating oil recommendations (100°F)

The basic turbine and gear oil for new units is a #32 which should exhibit an average viscosity of 162
SSU @ 100°F. For turbines with speed reduction gears (prior to Serial Number 5070) the oil is a #68
which has an average viscosity of 319 SSU @ 100°F. If there are any doubts about a particular oil for
turbine use, consult the Customer Service Department at Dresser-Rand.

Direct connected prior to 1957 140-200 SSU (ISO 32)

Direct connected over 6000 RPM since 1957 140-200 SSU (ISO 32)
Direct connected serial #4740 and over 140-200 SSU (ISO 32)
Direct connected below 6000 RPM since 1957 to serial #4740 250-350 SSU
Geared (MURRAY gears) 250-350 SSU
Geared (other manufacturers) Per gear nameplate
Ring Oiled 315-355 SSU (ISO 68)

24
5.8 Bearings

Murray turbine bearings perform two functions. The journal bearings support the rotor’s weight and
the thrust bearings protect the turbine against any type of excessive axial displacement. These
bearings are lubricated by a pressurized lubrication system.

All of Murray’s journal bearings are of the hydro-dynamic type, which means they operate by means
of an oil film between the contact surfaces to eliminate metal-to-metal contact. They can be straight
sleeves, pressure dam, or tilting pad types.

The pressure dam type is used in higher speed applications and is equipped with an oil pocket in the
upper half that eliminates oil whirls by creating an oil wedge that presses down on the journals.
When installing pressure dam bearings, always remember that they are installed with the grooved
part at the top and the direction arrow pointing in the direction of rotation.

Tilting pad journal bearings are used in applications that require additional stability (dampening
effect). The seat of these bearings can be placed in any of three ways – fixed seat, spherical seat,
and a cylindrical bearing in a spherical seat. The fixed seat holds the bearing firmly without play,
whereas the spherical seat permits a certain amount of play to compensate for various cold condition
alignment offsets. The cylindrical bearing with a spherical features the self-alignment of spherical
seats plus the convenience of replaceable sleeve segments.

Murray thrust bearings can be thrust collars, ball bearings, or multi-segmented tilting pad type. Thrust
collars are simply two rings, one at each side of the journal bearing, holding the shaft in place. Ball
bearings are used in applications under 6,000 RPM where space permits. They should be replaced
each 20,000 hours or when indicated by vibrations. The multi-segmented type is self-adjusting so
that the thrust is equally divided among all the shoes on either side of the collar.

THE ROTOR ASSEMBLY DRAWING IN THE INSTRUCTION MANUAL PROVIDES THE PROPER
BEARING CLEARANCE FOR EACH MACHINE.

5.9 Couplings

There are many types of flexible couplings on the market which are compatible with Murray turbines.
Among these are the gear, rubber bushing, and various steel spring types. Never use a coupling
which will transmit end thrust as this could overload the thrust bearings.

Lubricated type couplings should be inspected periodically to ensure that they contain sufficient
lubricant. Prolonged operation of these types without lubricant may result in rusting or freezing.
Manufacturer’s recommendations should be strictly followed.

Generally, the couplings in Murray turbines are mounted by means of a shrink fit using a key guide.
In special cases, or by customer request, a hydraulic fit is used. This is an arrangement that requires
special tools. Consult your assembly drawing to see if this is applicable.

5.10 Handvalves

Mechanical drive turbines and those driving small generators are commonly provided with hand
operated nozzle valves for one or more purposes. Closing a hand valve reduces the number of
steam nozzles being fed, thereby admitting less steam to the turbine and requiring the governor to
open the governor valve wider to increase the inlet pressure on the remaining nozzles.

The inlet pressure to the nozzles can usually be increased to within 95% of the throttle pressure
without loss in speed. When operating this high level inlet pressure, the turbine lacks reserve

25
capacity to handle an increase in load or to carry the present load with lower steam pressure or
higher back pressure.

Higher inlet pressure decreases steam consumption through improved efficiency. If a hand valve is
opened instead of closed, greater potential capacity is available, but the steam consumption is
increased.

The purpose of hand valves is to provide added efficiency when more than one load or steam
condition is anticipated. For the specific use of hand valves, refer to the sheet of operating
conditions.

5.11 Sentinel warning valve

Almost all turbines are provided with a sentinel warning valve in the exhaust casing. This valve is too
small to be considered a relief valve. Its purpose is to warn the operator of excessive pressure in the
turbine casing. It should be tested each time a general inspection is made to see that it is in
operating condition. This valve should be set to open at 10 to 15 PSIG above the normal back
pressure in non-condensing turbines.

For condensing turbines, the sentinel valve is usually set to open at 5 PSIG. Should the valve leak
under normal back pressure, it should be opened a few times by hand to allow any foreign material
which may have collected on the seat to be blown out. If this fails to correct the leakage, the seats
may be ground in or the entire valve replaced. DO NOT, UNDER ANY CIRCUMSTANCES, PIPE
THE DISCHARGE FROM THE SENTINEL VALVE AWAY FROM THE TURBINE.

5.12 Steam strainers

Some turbines are supplied with separate steam strainers for mounting in the steam line. These have
a corrosion resistant element which can be removed for cleaning without dismantling the steam
piping. Steam line strainers should be inspected periodically, and cleaned if necessary, to avoid
excessive steam pressure drop due to clogged strainer screens. Large pressure drops may not only
reduce the turbine load carrying capacity, but may result in a rupture of the strainer element.

On some turbines a built-in type of strainer is supplied. Built-in strainers should also be inspected
and cleaned periodically and checked for possible damage. A steam strainer affords some measure
of protection against foreign material passing through the nozzles and blades, but it cannot be
expected to stop heavy objects which move through the steam line at high velocity.

Pieces of weld metal, large pieces of scale, nuts, and other materials are commonly present in newly
erected steam lines. For that reason it is NECESSARY TO EMPHASIZE THE IMPORTANCE OF
BLOWING OUT ALL STEAM LINES WITH LIVE STEAM BEFORE CONNECTING THE TURBINE.
FAILURE TO DO SO MAY RESULT IN DAMAGE TO THE STRAINER OR MORE SERIOUS
DAMAGE SUCH AS BENT OR FAILED BLADES.

5.13 Gland evacuation equipment

This equipment can be used on high backpressure applications, those turbines operating with a high
pressure differential across the glands, and those which must operate for long periods of time
between shutdowns (some low pressure turbines also use these devices).

These devices are piped to the outer leak-off connections of the glands. They create a slight vacuum
on the outer leak-off areas, assuring that leakage will leave through leak-off piping and not past
inactive seals.

26
The simplest gland evacuating device is the water eductor. It creates a low pressure area by means
of water flowing through a nozzle. Its discharge (steam, air and water) is evacuated through the
sewers without contaminating the working area with escaped steam. These devices have limited
capacity and can only be used in low leak-off flow applications. Note that all of the water and steam
is lost in the sewers and cannot be recovered.

Another common device is the gland condenser and ejector. The gland condenser is a shell-and-
tube type heat exchanger in which cooling water is used to condense steam leakage from the glands.
The ejector is a steam nozzle which creates a low pressure area to remove any air which has leaked
into the system and thus maintains the vacuum in the leak-off areas.

These devices are available for all types of leak-off flows, large or small. The condensed leakage
steam and cooling water can be recovered and returned to the boiler. Note that the condenser tubes
and ejector both require periodic cleaning.

In a few cases, a motor-driven vacuum pump is used for gland evacuation. Vacuum pumps can be
selected for small or large gland leakage flows. They do not discharge steam into the turbine room,
and they require neither cooling water nor moving steam. Vacuum pumps are expensive to buy and
they require electricity. Like all rotating machines, they require maintenance, and should be kept in
use during turbine operation.

5.14 Condensing multi-stage turbine

The operator should be familiar with Section 2.1 (Top Exhaust), Section 4.2 (Gland Seal Systems:
Condensing Turbines). Condensing multi-stage turbines have relatively long and heavy rotors. They
are usually of the “flexible shaft” design. This means that the first critical speed or resonant rotor
frequency is normally below the minimum operating speed.

Operating a turbine at its critical speed can result in destructive vibration, so it is important to pass
through the critical speed quickly before such vibration builds up. The critical speed commonly
covers a band of 100-200 RPM above and below the critical speed indicated on the turbine
nameplate.

In starting multi-stage condensing turbines, the following precautions must be observed in addition to
the standard operating procedure as outlined under section 6.

If the turbine is warm because of a leaking throttle valve, it is possible that the shaft has taken a bow
because of heat distortion. It is returned to its normal shape by rotating slowly at 200-300 RPM for
30-60 minutes with the auxiliary oil pump in operation. If no auxiliary pump is available the initial
speed must be enough to establish 3-5 PSIG oil pressure.

Even if the throttle valve has not leaked, it is advisable to operate at the lowest speed that will
produce oil pressure for the turbine and driven machine for about 15-20 minutes. After this, the
turbine is accelerated moderately until near critical speed, and then accelerated rapidly through that
range. Once the turbine has passed through the critical range, acceleration should be more
moderate up to minimum control speed. After the governor takes over, the throttle valve can be fully
opened. As soon as full vacuum is established, the turbine is ready for load.

27
 6

OPERATING THE TURBINE

6.1 Operation

BEFORE ATTEMPTING TO OPERATE THE TURBINE, BE SURE THAT YOU HAVE READ AND
UNDERSTAND ALL THE INSTRUCTIONS IN THIS MANUAL. When placing a newly installed
turbine in operation the operator should proceed with caution and check all conditions carefully.

To protect your turbine during the starting operation, a man should be stationed at the emergency trip
lever at all times to stop the machine promptly if problems occur. Although Murray turbines are
adjusted at the factory, changes can occur during shipping and when coupled to a load.

Since normal operating speed of the turbine is maintained by the main governor, and the turbine is
protected against possible damage due to excessive speed by the emergency governor mechanism,
the operator must familiarize himself with the operation of these features before starting the turbine.

6.2 Condensing turbine, electronic governor

1. Read this instruction manual thoroughly.

2. Check oil reservoir or, if ring oil lubrication is used, check bearing oil reservoirs to be sure
there is the correct amount of oil.

3. Thoroughly drain condensate from steam supply line.

4. Open drain valves on turbine casing and gland seal system. Start Auxiliary oil pump if
provided.

5. Provide power to electronic governor. Follow operating instructions in governor manual to

place governor in turbine start mode. Set solenoid trip, turbine trip valve and overspeed trip
mechanism.

6. Open the exhaust shut-off valve, if installed.

7. Start cooling water flow to condenser.

8. Warm up the turbine, with drains open, by slowly opening throttle valve and verifying that the
governor is maintaining an idle speed in a range of 500-1000 RPM. Warm up the turbine for
a period of time in accordance with the time specified on Time vs. Speed Diagram on next
page. NOTE: IF RING OIL LUBRICATION IS USED, MAINTAIN IDLE SPEED ABOVE 900
RPM. Caution: When initially emitting steam into the turbine, it is important to verify
the governor is receiving the turbine speed signal and is maintaining speed control.
Due to variable conditions that exist on each application, the governing system may
not be able to control slow roll with full line pressure. If the system will not control
slow roll the main shut off valve will need to be throttled until the system takes control.

9. When casing is warm, close all casing drains after fully draining condensate. If casing drain
system is installed, check that it is drained and that atmospheric vents are closed and drains
to condenser and from turbine are open.

10. Place condenser in operation in accordance with manufacturer’s instructions.

11. Open sealing steam line to establish approximately 1 PSIG on steam seal system. Reduce
pressure if steam blows from glands.

28
 12. Check turbine for proper operation of lubrication system, for vibration, or for any unusual
noise or condition. In the event of any abnormal condition, investigate immediately and shut
down if necessary.

Time vs. Speed Diagram for Turbine Start-up

Min. Gov.
Turbine Speed

Idle

SRT Time

A period of slow roll at idle speed is required before the turbine can be run continuously. After slow
roll, the turbine speed can be increased to normal operating speed. Slow roll is shown in the above
diagram as a solid line. The dotted line shows where the turbine speed is ramped up to minimum
governor speed manually or with the electronic governor.

The amount of time required to slow roll at idle speed varies, depending on the inlet steam
temperature and the number of stages in the turbine. Use the following formula to determine the
minimum slow roll time required:

Ti-350
SRT = 20+ +Ns
50

where SRT = Slow Roll Time in minutes

Ti = Inlet Temperature in °F
Ns = Number of Turbine Stages

Example: Consider an R2GD3 turbine with an inlet temperature of 750°F.

So we know that Ti = 750, Ns = 4

750-350
SRT = 20+ +4=32
50

Therefore, this turbine should slow roll for a minimum of 32 minutes.

29
13. Once vacuum is established, switch the governor from idle to rated. The governor will
automatically ramp the turbine up to minimum speed setting. The governor program will
avoid critical speeds but the operator must monitor the turbine to insure that vibration levels
are not exceeded. Make sure turbine governor takes control and continues to control.

CAUTION: DO NOT OPERATE TURBINE AT OR NEAR CRITICAL SPEED SHOWN ON

NAMEPLATE.

14. Again, check general operation, oil pressures and temperatures, casing drain tank level,
vibration and noise. IN THE EVENT OF ANY ABNORMAL CONDITION, INVESTIGATE
IMMEDIATELY AND SHUT DOWN IF NECESSARY. Adjust water flow to oil cooler.
Maintain approximately 110-120°F oil temperature leaving cooler. If ring oil lubrication is
used, adjust water flow to maintain oil reservoir temperature of 130-180°F.

15. Check to see that condenser system is operating properly.

16. Check gland seal system. Under some load conditions there will be sufficient leakage of
steam from the high pressure or inlet end of turbine to seal the low pressure end. The steam
seal valve and the gland leak-off line valve is to be adjusted as required to prevent gland
blow.

17. Adjust to desired speed and apply load.

18. In the event of any abnormal condition, investigate immediately and shut down if necessary.

19. To shut down turbine remove load slowly, checking to see that governor maintains control.
Stop turbine by means of hand or solenoid trip. If unit is provided with an auxiliary oil pump,
operate pump for a minimum of thirty minutes after stopping or until the shaft is cool. Close
inlet stop valve. Shut down auxiliary equipment as required, open casing drains, shut off
sealing steam.

6.3 Precautions

If the turbine is showing excessive vibration, bring it to a stop immediately and recheck the coupling
and shaft alignment and other possible causes. Check all bearings.

If any other abnormal operating behavior becomes evident, stop the turbine and determine the cause
before putting the unit back into operation.

For pressure feed lubrication, the oil pressure should be observed frequently until the turbine has
been operated for several days as failure of oil pressure can result in extensive damage. The oil
reservoirs should be maintained at the proper level using oil of the recommended grade.

When starting a turbine with cold oil, the oil pressure will be somewhat higher than when the oil
reaches operating temperature. This is a natural condition due to the change in oil viscosity with
temperature. ANY ADJUSTMENT TO OIL PRESSURE SHOULD BE MADE WITH THE OIL AT
OPERATING TEMPERATURE.

By recording oil pressures and temperatures on the turbine log sheet, the development of conditions
which could damage the machine will be more evident. Refer to the section on lubrication for other
important factors (see Sec. 5.4).

Since all Murray turbines are provided with an overspeed trip device actuating either an emergency
stop valve or a trip throttle valve, this device should be tested at least once every month. The
effectiveness of this device depends upon it being properly maintained. It is a good practice to stop
the unit by means of the hand trip whenever it becomes necessary to shutdown.

30
 7

MAINTENANCE AND INSPECTION

7.1 Maintenance and inspection program

USE THIS SECTION TO STRUCTURE A REGULAR PROGRAM OF INSPECTION AND

MAINTENANCE.

Murray turbines are manufactured in various frame sizes and model numbers. Special features plus
variations in local conditions make it impossible to standardize on a general maintenance schedule
that would apply equally to all situations. THEREFORE, THIS SECTION IS DESIGNED TO HELP
OPERATORS BEGIN AND CUSTOMIZE A MAINTENANCE PROGRAM AND HELP ESTABLISH
GUIDELINES FOR PERIODIC INSPECTIONS AND MAINTENANCE.

Monthly inspection

• Check the overspeed trip by accelerating the turbine to trip speed.

Quarterly (3 months) inspection

• Clean all linkage systems and inspect for wear. Clean and oil or grease all the moving parts
(fulcrum points). For units with Inlet operating temperatures above 500deg F a high temperature
grease should be used for lubrication on linkage parts. (DuPont Krytox GPL407, Bostic Never-
Seez #235210 NHTC14 or equivalent)

Six month inspection

• Remove and inspect the bearings. Inspect the radial contact surfaces (journal) and the axial
contact surfaces (thrust faces). Make sure that there are no signs of overheating, excessive wear
(including dents, grooves or tears), or dirt.

• Check the effectiveness of all drains.

• Disconnect and separate couplings. Remove all grease and sludge and then flush. Inspect the
wear on the hub and cover teeth. Then dry and replenish with new, high quality grease.

• CHECK THE SENTINEL AND RELIEF VALVES TO ENSURE THAT THEY ARE
OPERATIONAL. The relief valve should start opening when the sentinel valve opens and should
completely open when the pressure in the casing is 10% above normal pressure.

• Operate the turbine without a load and inspect governor operation and vibrations.

Yearly inspection

• Drain the governor’s oil, if applicable, while it is hot; flush the governor’s pump clean with the
lightest grade of the same oil; replace with high quality oil of the recommended grade and
viscosity.

• Remove and clean governor valve and internal steam strainer. Make sure there are no leaks.

• In pressure lubricated turbines, drain and clean reservoirs. In machines with a large reservoir,
where the cost of oil is a consideration, it may be convenient to check a sample of the oil before
deciding to change it.

31
• Replace oil filters; replace oil with one of recommended viscosity and grade.

• If the equipment is insured, the insuring company’s inspector should be notified of the yearly
inspection so that he can be present. In many cases, the services of Dresser-Rand’ experienced
service personnel are used to ensure maximum efficiency.

THE TURBINE INTERNALS MUST BE PERIODICALLY INSPECTED. THE FREQUENCY OF

INSPECTION DEPENDS ON STEAM CONDITIONS AND OPERATION BUT SHOULD NOT
EXCEED 3 YEARS.

THE PROGRAM DESCRIBED IN THE ABOVE SECTION IS A LIST OF RECOMMENDATIONS

ONLY. IT MAY BE NECESSARY TO INSPECT MORE FREQUENTLY IF PROBLEMS ARISE
BETWEEN REGULAR INSPECTION PERIODS.

7.2 Internal inspection

To perform the thorough periodic inspections recommended by Dresser-Rand, it will be necessary to

remove the turbine cover. Housed under that cover are diaphragms, the turbine rotor, nozzle block,
shaft seals, the stationary blade segment, and the casing interior.

Inspection of other parts, such as bearings, governor and linkage, oil pump drive assembly, governor
valve and trip valve, can be accomplished without casing cover removal.

Where turbines have a top exhaust, the inspection procedure is more involved since the exhaust pipe
must first be removed to provide the necessary free space above the turbine. The casing cover can
then be removed by the following procedure:

It should be remembered that the casing assembly is a pressure tight vessel and that all joints are
necessarily sealed to prevent steam leakage. These include the main horizontal casing flange, gland
case splits and vertical surfaces.

These joints have been kept in contact by the bolts while under prolonged exposure to heat and
moisture. Even though joint compounds have been used at the factory which assist sealing and help
prevent sticking, it is to be expected that more or less sticking may occur from corrosion at one or
more of these points. IT IS THEREFORE NECESSARY TO PROCEED WITH CARE IN ORDER TO
AVOID DAMAGE TO THE ROTOR AND OTHER STATIONARY PARTS.

First, remove sheet metal covering, if provided, insulation and piping as required, then all horizontal
joint bolts. There are four tapped holes in the horizontal flange. These are provided for the use of
jack-bolts in order to “break” the main casing joint.

Insert bolts and apply reasonable torque to part the joint. In some cases, it may be necessary to use
penetrating oil and tap on the casing barrel while jack-bolts are fully tightened. After the joint
separates, continue to raise the casing cover with the jack-bolts. The rotor must remain free and
bearing caps must not lift as the cover is raised.

ROTATING THE SHAFT WHILE RAISING THE COVER WILL ASSURE THAT THE ROTOR IS
NOT IN CONTACT WITH ANY PARTS BEING RAISED. If the rotor rises with the cover, it indicates
that either the lower half of a diaphragm or a carbon ring retaining plate is rising
with the cover. This situation is brought about by diaphragm halves sticking together in Type “K” or
“R” turbines (while free in the base) or by retainer plates sticking in the casing cover and being free in
the base. In either case, the cover should be lifted with the jack-bolts only until all the clearance (1/6
to 1/8 inch) is taken up and the rotor starts to rise. Do not lift beyond this point, but retract two
diagonally opposite jack-bolts and rock the cover back and forth.

32
Try to determine where the sticking is occurring so that if the rocking does not release the stuck joint,
the use of penetrating oil and tapping on the outside of the casing will. DO NOT USE WEDGES OR
PRY BARS BETWEEN THE JOINT AS THIS WILL DAMAGE THE SURFACE AND CAUSE
LEAKAGE.

If there is persistent sticking of these parts, considerable care must be exercised to free them.
Tapping and rocking as described above should be continued; possibly tapping directly on the
circumference of the diaphragm or retainer plate by inserting a flat bar between the casing flanges
(against the diaphragm or plate) and tapping on the exposed end.

After the parts are free, a chain hoist can be used to remove cover and rotor. In the case of Type “U”
turbines, any sticking should be limited to the carbon ring retainer plates. The lower diaphragm
portion cannot rise and the upper portion is fastened to it.

No difficulty should be encountered in lifting the casing cover. The packing cases employ stainless
steel carbon ring retainer plates. Should the plates stick in the packing case, screw an eyebolt in the
horizontal flange and impose a lift strain by means of a hand operated chain hoist while tapping on
the upper portion of the packing case near the centerline.

If it is found that any retainer plates are stuck in the lower portion, these should be freed up with
penetrating oil. After the retainer plates are all free, the rotor, with retainer plates, may be lifted out
with a chain hoist.

The diaphragms are removed by rolling out, assisted by pulling on a clamp fastened on one corner
with a chain hoist. It may be necessary to free-up the diaphragms with penetrating oil before they can
be rolled out.

Before re-assembly, the pressure joints must be completely cleaned to the bare metal. The joints
must then be re-coated with sealing compound using a type which will not harden in service. Murray
joint compound is available for this purpose and will not “freeze” the joints.

The joint compound is also suitable as an anti-seize compound or pipe thread sealant. The
compound must be kept absolutely clean and free of metal particles which might interfere with proper
sealing.

Apply a light even coat, leaving about ¼ inch of the joint surface on the inside and outside uncoated
to avoid surplus squeeze-out. Coat only the casing joints and the packing case joints of bolted type
packing case. Do not apply closer than ¼ inch to carbon rings.

Do not coat diaphragm joints or grooves. Bearing caps should not be sealed with high temperature
joint compound. Instead, use a material intended for oil tight joints such as “Tite-Seal” or a similar
non-hardening Teflon-based paste compound.

CHECK THE CASING INTERIOR FOR FOREIGN MATERIAL BEFORE CLOSING.

The casing cover should be carefully lowered. If it appears to “hang up”, use a slight rocking motion
to assist proper mating of parts. Use the dowels on guide rods to assist positioning. The bolting
should be tightened uniformly, in about three stages, finally achieving approximately uniform torque
on all bolts of the same size. If the joint has been properly serviced, it should be as tight as before
the inspection.

33
 8

SPARE PARTS & FIELD SERVICE

8.1 Spare Parts

When ordering repair, replacement, or spare parts there is certain specific information Dresser-Rand
must have to properly identify the parts required. Omitting that information from your order may
cause a delay until the information is made available to Dresser-Rand’ Parts department. Such
delays can easily be avoided if reasonable care is taken to include the following information on all
orders.

• Turbine serial number (located on the turbine’s nameplate or coupling end of the shaft).

• Bill of material number, or assembly drawing number, along with item number shown on the bill of
material, or the assembly drawing, identifying the part required.

• Name of part as shown on the bill of material.

• Quantity required.

Example:
1 part #OA1157 Item 6, Spherical Rod
1 part #4A0377 Item 6, Spherical Rod End

#OA1157 refers to the bill of material, whereas #4A0377 refers to the assembly drawing number.
Either number may be used by Dresser-Rand’ order department in identifying your requirements.

Anticipate part needs in advance when possible. Dresser-Rand recognizes that anticipation of
repairs is not always possible and will make every reasonable effort to meet the needs of the client.
Since some spare parts require manufacturing time, it is worth emphasizing, “ANTICIPATE REPAIR
REQUIREMENTS WHEREVER POSSIBLE AND ORDER PARTS IN ADVANCE”.

8.2 Field Service

Dresser-Rand maintains a staff of trained and experienced field personnel available for installation,
inspection and repair work.

The services of factory servicemen are not included in the purchase price of Murray turbines unless
requested in the proposal stage and specifically mentioned in the contract or purchase order.

Customers not experienced with the installation or operation of steam turbines may wish to utilize the
experience of Dresser-Rand’ factory-trained field personnel on a per diem plus expenses basis.

To have a factory-trained technician sent to your job-site, simply contact your local Dresser-Rand
office or our manufacturing facility in Burlington, Iowa at (319) 753-5431. Provide a completed
purchase order and the serial number of the unit involved. A short description of the problem will
allow the Dresser-Rand technician to evaluate special tools and/or parts required. Two weeks’ notice
is considered standard operating procedure for all routinely scheduled inspections or maintenance.

34
 STEAM PURITY/TURBINE DEPOSITS

9.1 Introduction

It is generally recognized that the performance and reliability of a steam turbine can be adversely
affected by the admission of contaminated steam. When contaminants enter the turbine with the
steam supply, the usual result is the accumulation of deposits, either inert or highly reactive,
depending on the contaminants present. If the contaminants are reactive, they can cause serious
damage by corrosive attack on the turbine materials.

To avoid these deposits, adequate boiler water chemistry control and other precautions are required
along with the need for constant surveillance during operation and inspections. When deposits or
material attack are noted during inspections, investigations into the nature and origin of contaminants
should be conducted and a program for corrective action begun

9.2 Steam purity

Deposits and harmful ions come from additive chemical elements in boiler feedwater. Make-up water
for many steam systems utilizing Murray turbines is industrial grade water which contains dissolved
and suspended contaminants which must be removed prior to use in the steam system.

To avoid the likelihood of adverse effects from deposits and harmful ions, limits shown in Table 9.2.1
are established for Murray steam turbines. These limits are based on operating history and
recommendations from various consultants. Their maintenance will ensure protection of the turbine.
WARRANTY MAY BE VOID IN THE EVENT OPERATIONAL FAILURE IS ATTRIBUTED TO
INADEQUATE BOILER FEEDWATER TREATMENT.

Table 9.2.1 – Recommended limits for boiler water (based on drum water analyses).
Pressure at Outlet of Total OH Silica Phosphate Sulfite Hardness Chlorides
Steam Generating Solids Alkalinity ppm ppm ppm ppm ppm
Unit, PSIG ppm ppm
0-150 2,000 200 50 50 30 0 250
151-450 1,500 100 35 50 30 0 200
451-750 1,000 60 25 25 25 0 150
751-900 750 55 10 25 20 0 50

9.3 Effects of deposits and harmful ions on turbine

Efficiencies in a steam turbine are sensitive to surface finish because of the high velocities and sharp
turning that are required by the design. While corrosion and stress corrosion problems are unusual in
steam plants, such problems can result from boiler carry-over due to inadequate deaeration and
boiler feedwater treatment.

The chloride ion which is present in most industrial water, can cause stress corrosion problems, but
most typically it is associated with the pitting of turbine blades and nozzles, especially in the presence
of oxygen.

35
9.4 Detection of deposits

Indication of the accumulation of deposits in the steam path could include:

• Increased stage pressure.

• Reduced power output.
• Increased active thrust with increased oil or bearing temperatures in the thrust bearing.
• Excessive vibration

If deposits are observed in the turbine during inspection, samples should be taken and submitted for
chemical analysis by a laboratory to determine their make-up and what action is required to remove
them from the system.

9.5 Detection of corrosion

Indications of corrosion may be difficult to determine. A steam turbine’s efficient performance dictates
that its steam path possess tight corners and crevices, these areas can be susceptible to pitting due
to the collection of condensate that possesses harmful ions. The turbine’s blade and first stage
nozzles should be inspected during scheduled shutdown via borescope. If possible the upper half
casing should be removed, under supervision of a Dresser-Rand Service Representative for better
inspection.

Pitting of the blades and nozzles is evidence of a corrosive attack, making them susceptible to stress
corrosion cracking. Dresser-Rand’ Service Department should be consulted prior to restart of the
turbine. If residue or condensate is present in the turbine and corrosion is present, samples of the
residue or condensate should be submitted for chemical analysis to determine the presence of
excessive chlorides and other harmful ions.

36
 10

OFF-SEASON STORAGE
10.1 Introduction

Many of our turbines are used as “seasonal machines”, being out of service for as many as six to
eight months of the year. During the off-season, many turbines are subjected to moisture and
contaminants which will shorten the life expectancy of the machine. The turbine must be protected
from corrosion internally with a vapor type of corrosion inhibitor introduced in crystal form or clean dry
air/nitrogen purge.

The following suggested preventative maintenance procedures will greatly reduce the possibility of
damage to the turbine due to off-season storage. Frequent inspections, both internal and external,
for evidence of rust should be made. Cleaning and reapplication of preventatives may be necessary.

10.2 Turbine steam path

The following procedures are recommended to prevent off-season deterioration of the steam path:

• Gland cases should be opened, dried and inspected. If gland cases do not have removable
covers, low pressure air may be blown through drain lines to assist in drying the gland area.

Turbines having “sealing steam” must have a positive shut-off or disconnect to prevent steam
from entering the turbine inadvertently. Gland steam lines and drains should be capped to
prevent moisture from re-entering the turbine.

For extended storage, the carbon rings should be removed to prevent pitting of the shaft that may
occur due to any condensation.

• Warm, dry air may be circulated through the turbine to remove moisture from the steam path. Air
may be introduced through some other casing opening such as a handvalve boss.

The air can be exhausted through the exhaust flange, vacuum breaker, port or casing drains.

• Steam inlet and exhaust must have positive shut-off or disconnect to prevent steam entering the
turbine.

CAUTION: A PRESSURE RELIEF VALVE MUST BE INSTALLED BETWEEN THE EXHAUST

FLANGE AND EXHAUST LINE POSITIVE SHUT-OFF.

• Several types of rust preventatives are available and can be placed into the turbine casing to help
keep the turbine dry. If this type of corrosion inhibitor is used the main steam inlet and exhaust
connection must be sealed off with blank flanges (wood or metal) to prevent the loss of the vapor
inhibitor.

• Electric magnetic heaters can be applied to the casing to help keep the turbine dry.

• The turbine rotor should be rotated 450° once a week to eliminate any permanent bowing.
Bearings must receive lubrication before this is done.

• All valving needs to be exercised.

37
10.3 Lubrication System

The following procedures are recommended for preparing the lubrication system for off-season
storage:

• The complete lubrication system must be drained and cleaned. NEVER STORE A TURBINE
WITH OLD OIL IN IT. Contaminants in the oil may cause the turbine shaft to become etched
under the journal bearings.

• All low points in the lubrication system should be checked for moisture and cleaned as required.
Low points include bearing cases, power cylinders, drive gear cases, pilot valves, oil reservoir,
etc.

• Fresh oil should be circulated through the lubrication system prior to storage.

• Cooling water to oil coolers should be positively shut off or disconnected. Drain water from cooler
if lubrication system is an outdoor installation.

10.4 Other recommendations

If the turbine is to be idle for a period longer than eight months, Dresser-Rand should be consulted as
to the proper storage procedures. Any other questions or concerns regarding off-season storage
should be directed to the Dresser-Rand representative or the factory.

38
 TIGHTENING TORQUES (WITH WASHERS)

The following torques are to be applied to Socket Head and Hex Head Capscrews, Bolts
and Nuts of SAE Grade 8, alloy steel and 17-4 Ph Stainless Steel.

Size Final Torque

1/4" ------------------------------------- 120 in-lbs (13.6 N·m)

5/16” ------------------------------------ 250 in-lbs (28.3 N·m)

3/8” ------------------------------------- 445 in-lbs (50.3 N·m)

7/16” ------------------------------------ 60 ft-lbs (81 N·m)

1/2" -------------------------------------- 90 ft-lbs (122 N·m)

9/16” -------------------------------------130 ft-lbs (176 N·m)

5/8” -------------------------------------- 180 ft-lbs (244 N·m)

PERMANENT
3/4" -------------------------------------- 315 ft-lbs (427 N·m)
CONTROLLED
DRAWING
7/8” -------------------------------------- 515 ft-lbs (698 N·m)
TO:_______________
1” ---------------------------------------- 770 ft-lbs (1044 N·m)
DATE:____________
BY:_______________
1-1/8” ----------------------------------- 1100 ft-lbs (1491 N·m)

1-1/4” ----------------------------------- 1545 ft-lbs (2095 N·m)

1-3/8” ----------------------------------- 2025 ft-lbs (2746 N·m)

1-1/2” ----------------------------------- 2685 ft-lbs (3640 N·m)

NOTE: 1) Use with Never-Seez applied to all threads and bearing surfaces of nuts and washers.
2) Apply a factor of 0.9 to above values for Cadmium plated Capscrews.
3) Apply a factor of 0.8 to the above values for Cadmium plated Nuts and Bolts.
4) Use with heavy hardened washers under all bearing surfaces.
5) Apply a factor of 0.9 to the above values for bolting located internal to the Turbine Casing.
CHG (1) CHG (2) CHG (3) CHG (4)
NOTICE NOTICE NOTICE NOTICE
18 JUL 90 30 MAR 93 05 OCT 00 22 JUL 09
BOM- DRAWN DATE PROJECTION
S.O.T- EXCEPT AS NOTED DGM
REF- ALL DIMENSIONS
CHECKED DATE
ARE IN INCHES
--------
TOLERANCES PER APPROVED DATE
MATERIAL
1S101 UNLESS
OTHERWISE DGM 27 JAN 86 TIGHTENING TORQUES
SPECIFIED
----------------------------- DRAWING NUMBER REVISION
THIS DRAWING IS
SIZE
A
FINISH
---------------------
SCALE
-----------------
CONFIDENTIAL AND IS THE
SOLE PROPERTY OF
DRESSER-RAND COMPANY. 1S539 4
SHT 1 OF 2
 TIGHTENING TORQUES (WITHOUT WASHERS)

The following torques are to be applied to Socket Head and Hex Head Capscrews, Bolts
and Nuts of SAE Grade 8, alloy steel and 17-4 Ph Stainless Steel.

Size Final Torque

1/4" ------------------------------------- 130 in-lbs (14.7 N·m)

5/16” ------------------------------------ 275 in-lbs (31.1 N·m)

3/8” ------------------------------------- 490 in-lbs (55.4 N·m)

7/16” ------------------------------------ 70 ft-lbs (95 N·m)

1/2" -------------------------------------- 100 ft-lbs (136 N·m)

9/16” -------------------------------------145 ft-lbs (197 N·m)

5/8” -------------------------------------- 200 ft-lbs (271 N·m)

PERMANENT
3/4" -------------------------------------- 350 ft-lbs (475 N·m)
CONTROLLED
DRAWING
7/8” -------------------------------------- 570 ft-lbs (773 N·m)
TO:_______________
1” ---------------------------------------- 850 ft-lbs (1152 N·m)
DATE:____________
BY:_______________
1-1/8” ----------------------------------- 1210 ft-lbs (1641 N·m)

1-1/4” ----------------------------------- 1700 ft-lbs (2305 N·m)

1-3/8” ----------------------------------- 2225 ft-lbs (3017 N·m)

1-1/2” ----------------------------------- 2950 ft-lbs (4000 N·m)

NOTE: 1) Use with Never-Seez applied to all threads and bearing surfaces of nuts and washers.
2) Apply a factor of 0.9 to above values for Cadmium plated Capscrews.
3) Apply a factor of 0.8 to the above values for Cadmium plated Nuts and Bolts.
4) Apply a factor of 0.9 to the above values for bolting located internal to the Turbine Casing.

CHG (1) CHG (2) CHG (3) CHG (4)

NOTICE NOTICE NOTICE NOTICE
18 JUL 90 30 MAR 93 05 OCT 00 22 JUL 09
BOM- DRAWN DATE PROJECTION
S.O.T- EXCEPT AS NOTED DGM
REF- ALL DIMENSIONS
CHECKED DATE
ARE IN INCHES
--------
TOLERANCES PER APPROVED DATE
MATERIAL
1S101 UNLESS
OTHERWISE DGM 27 JAN 86 TIGHTENING TORQUES
SPECIFIED
----------------------------- DRAWING NUMBER REVISION
THIS DRAWING IS
SIZE
A
FINISH
---------------------
SCALE
-----------------
CONFIDENTIAL AND IS THE
SOLE PROPERTY OF
DRESSER-RAND COMPANY. 1S539 4
SHT 2 OF 2
 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000212224 001 STEAM CASING

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 6R10604-1 STEAM CASING ASSEMBLY 1 EA

1 1 5R4808-1 STEAM CASING BASE MODIFICATION 1 EA

2 1 5R4809-1 STEAM CASING COVER MODIFICATION 1 EA

3 1 1S188-11 STUD 4 EA

4 1 1S643-7 WASHER-HARDENED 30 EA

5 1 1S304-15 HEXNUT 30 EA

6 1 1S188-20 STUD 26 EA

7 1 1S599-158 TAPER DOWEL #10 4 EA

8 1 1S187-65 STUD 1 8 X 6-5/8 COARSE 2 EA

9 1 1S641-2 WASHER-SPECIAL O.D. 10 EA

10 1 1S614-2 CAPTIVE NUT 1 IN 8 2 EA

11 1 1S290-17 STUD 1 1/8 7 X 7 3/8 COARSE 24 EA

12 1 1S643-6 WASHER-HARDENED 28 EA

13 1 1S304-18 HEXNUT 24 EA

14 1 1S290-18 STUD 1 1/8 7 X 5 5/8 COARSE 2 EA

15 1 1S641-8 WASHER (SPECIAL O.D.) 2 EA

16 1 1S639-1 CAPTIVE NUT 1-1/8 IN 7 6 EA

17 1 1S290-19 STUD 1 1/8 7 X 13 15/16 COARSE 2 EA

18 1 1S290-20 STUD 1 1/8 7 X 16 1/16 COARSE 2 EA

19 1 1S187-125 STUD 20 EA

20 1 1S643-5 WASHER-HARDENED 36 EA

21 1 1S304-10 HEXNUT 36 EA

22 1 1S187-115 STUD 1 8 X 5 3/8 COARSE 4 EA

23 1 1S614-1 CAPTIVE NUT 1 IN 8 8 EA

24 1 1S187-113 STUD 1 8 X 7.250 COARSE 4 EA

25 1 1S595-2 JACK BOLT SQ HD 3/4 X 4 2 EA

© 2011 DRESSER-RAND COMPANY 1000212224 Page 1 of 2

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000212224 001 STEAM CASING

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

26 1 1A10530-3 GUIDESTUD 2 EA

27 1 1S238-69 TAPER PIN PLAIN #10 X 4-1/2 2 EA

28 1 1S428-36 GARLOCK EDGE GASKET E-300# SPECIAL 1 EA

29 1 2-4151-53 BLIND FLANGE 1 EA

30 1 1S700-7 METRIC STUD 16 EA

31 1 1S702-1 STRUCTURAL WASHER 16 EA

32 1 1S701-1 HEXNUT METRIC 16 EA

33 1 1S700-8 METRIC STUD 8 EA

34 1 1S702-5 STRUCTURAL WASHER METRIC 8 EA

35 1 1S701-6 HEX NUT METRIC COARSE THREAD 8 EA

36 1 1A2653-4 PIPE PLUG ROUND 1/2 304 SST 16 EA

37 1 1S438-5 PIPE PLUG-ALLEN 1/2 1 EA

38 1 1S187-42 STUD 16 EA

© 2011 DRESSER-RAND COMPANY 1000212224 Page 2 of 2

 8 7 6 5 4 3 2 1

19 20 21

26
9 23 24 14 15 16
F
27 25
F

9 22 23
11 12 13

E E

8 9 10

36

D D

36 28 29
30 31 32
C
C
20 21 38
2

36

B
B

33 34 35
3 4 5

1 4 5 6

12 16 17
A BOM - 1000212224 UNLESS OTHERWISE SPECIFIED: NAME DATE
A
7 DRAWN DCO 2011-06-15

12 16 18
SERIAL -BUR5955 ALL DIMENSIONS STEAM TURBINE BUSINESS UNIT
DWP
37 ARE IN INCHES CHECKED 2011-06-23 Burlington, Iowa, USA
REF - 6R10161
APPROVED DWP 2011-06-23
TOLERANCES
PER
SW MODEL: 6R10604
M:\DWG\BUR5955\
STEAM CASING
LAST SAVED BY: doliver
DATE: Thursday, June 23, 2011 3:30:08 PM
1S101 UNLESS
OTHERWISE
PROPRIETARY AND CONFIDENTIAL ASSEMBLY
SPECIFIED THIS DRAWING CONTAINS
MATERIAL CONFIDENTIAL AND TRADE DRAWING NUMBER REV

6R10604 0
-------- SECRET INFORMATION AND IS THE
PROPERTY OF DRESSER-RAND COMPANY

D
SIZE FINISH AND IS PROVIDED TO THE
RECEIVER IN CONFIDENCE.
-------- SCALE: 1:8 WEIGHT: 5817 SHEET 1 OF 1
8 7 6 5 4 3 2 1
 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000174656 001 EXHAUST CASING 1000150862

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 6R10253-1 EXHAUST CASING ASSEMBLY 1 EA

1 1 7R11599-1 EXHAUST CASING BASE MACHINING DWG 1 EA

2 1 7R13080-1 EXHAUST CASING COVER MACHINING DWG. 1 EA

3 1 1S188-5 STUD 1 1/4 7 X 7 5/8 COARSE 16 EA

4 1 1S643-7 WASHER-HARDENED 88 EA

5 1 1S304-15 HEXNUT 88 EA

6 1 1S188-1 STUD 70 EA

7 1 1S188-15 STUD 2 EA

8 1 1S599-187 TAPER DOWEL #12 X 6 2 EA

9 1 1S599-181 TAPER DOWEL #12 X 4-1/2 2 EA

10 1 1S595-2 JACK BOLT SQ HD 3/4 X 4 2 EA

11 1 1A10530-3 GUIDESTUD 2 EA

12 1 1A2653-4 PIPE PLUG ROUND 1/2 304 SST 9 EA

13 1 1S595-5 JACK BOLT SQ HD 3/4 X 5 1/2 2 EA

14 1 3A4669-1 SPECIAL FLANGE 1 EA

15 1 3A4670-1 SPECIAL GASKET 1 EA

16 1 1S570-3 CAPSCRW HEX HD 5/8 X 1-1/2 10 EA

17 1 1A2653-5 PIPE PLUG ROUND 3/4 304 SST 2 EA

18 1 1A2653-9 PLUG-RD 2 IN 304 SST 1 EA

19 1 2-4151-48 BLIND FLANGE 1 EA

20 1 1S618-10 1-1/8 IN HEX HEAD CAPSCREW COARSE THD 20 EA

21 1 1S304-18 HEXNUT 20 EA

22 1 1S428-30 GARLOCK EDGE GASKET E-150# SPECIAL 1 EA

23 1 1S618-12 HEX HD CAPSCREW 1-1/8-7 GR8 1 EA

24 1 1S643-6 WASHER-HARDENED 1 EA

© 2011 DRESSER-RAND COMPANY 1000174656 Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

OR28683 001 TURBINE SUPPORTS OR28683

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 6R8936-1 TURBINE SUPPORT ASSEMBLY 1 EA

1 1 7R8513-1 STEAM SUPPORT (MACH DWG) 1 EA

2 1 7R11351-1 EXHAUST SUPPORT MACH DWG 1 EA

3 1 1A10426-2 EXHAUST SUPPORT KEY 2 EA

4 1 1S318-5 CAPSCRW SOC HD 3/4 X 2 1/4 4 EA

5 1 3R4578-1 CENTERING KEY 1 EA

6 1 1S188-9 STUD 1 1/4 7 X 5 13/16 COARS 14 EA

7 1 1S304-15 HEXNUT 14 EA

8 1 3A1956-302 WASHER 14 EA

9 1 3A1956-344 SPACER 14 EA

10 1 1S187-109 STUD 1 8 X 8 1/8 COARSE 2 EA

11 1 1S304-10 HEXNUT 2 EA

12 1 3A1956-369 WASHER 2 EA

13 1 3A1956-370 WASHER 2 EA

14 1 1A6533-1 GREASE FITTING 12 EA

15 1 1S573-6 CAPSCREW HEX HD 14 EA

16 1 3A1956-29 WASHER-STL 22 EA

17 1 1S595-6 SET SCREW SQ HD CUP POINT 10 EA

18 1 1S599-188 TAPER DOWELL #14 X 5 6 EA

19 1 3A4577-1 EXHAUST SUPPORT SHIM 2 EA

20 1 1S573-7 CAPSCREW HEX HD 8 EA

21 1 1S599-160 TAPER DOWEL #10 X 3-3/4 2 EA

22 1 1A12014-1 SHIM 2 EA

© 2011 DRESSER-RAND COMPANY OR28683 Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000210655 001 TURBINE ROTOR

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 6R10597-1 TURBINE ROTOR ASSY 1 EA

1 1 7R13478-1 TURBINE SHAFT 1 EA

2 1 1000210655-1 1ST STAGE DISC ASSY 1 EA

3 1 1000210655-2 2ND STAGE DISC ASSY 1 EA

4 1 1000210655-3 3RD STAGE DISC ASSY 1 EA

5 1 1000210655-4 4TH STAGE DISC ASSY 1 EA

6 1 1000210655-5 5TH STAGE DISC ASSY 1 EA

7 1 1000210655-6 6TH STAGE DISC ASSY 1 EA

8 1 1000210655-7 7TH STAGE DISC ASSY 1 EA

9 1 1000210655-8 8TH STAGE DISC ASSY 1 EA

10 1 1000210655-9 9TH STAGE DISC ASSY 1 EA

11 1 5A4804-1 ROTOR BALANCE RING 1 EA

12 1 1A5560-6 DISC KEY 6 EA

13 1 1A5560-9 DISC KEY 1 EA

14 1 1A5560-46 DISC KEY 1 EA

15 1 1A5560-47 DISC KEY 1 EA

16 1 1A5560-19 DISC KEY 1 EA

17 1 1A6076-161 STEAM DEFLECTOR RING 1 EA

18 1 1A10044-16 OIL SLINGER 2 EA

19 1 3A1910-73 KEY 1 EA

20 1 1A5462-54 TACH PICKUP GEAR 1 EA

21 1 1A14649-1 WEIGHT ROTOR BALANCE 1 OUNCE 1 EA

22 1 1S680-11 SET SCREW CUP PT 316 SST 1 EA

© 2011 DRESSER-RAND COMPANY 1000210655 Page 1 of 1

 8 7 6 5 4 3 2 1

NOTE! AFTER ROTOR HAS BEEN ASSEMBLED AS SHOWN ON THIS DRAWING,

IT MUST RUN TRUE WITHIN THE FOLLOWING LIMITS:
SHAFT: MAXIMUM INDICATOR READING AT ANY POINT ON SHAFT 0.0010",
WITH MAXIMUM INDICATOR READING AT JOURNAL 0.00025".
DISC: MAXIMUM INDICATOR READING AT SIDES OF DISCS
ABOUT 1" BELOW STEAM PASSAGE 0.015".

F
NOTE "A" BEARING DIAMETRAL COLD CLEARANCE. F
STEAM BRG. MAX. 0.0091" MIN. 0.0077"
EXHAUST BRG. MAX. 0.0121" MIN. 0.0105"
BEARING LIFT CHECK COLD CLEARANCE 81.719
STEAM BRG. MAX: 0.0102" MIN: 0.0086"
EXHAUST BRG. MAX. 0.0135" MIN. 0.0117" 76.219
2.500
NOTE "B" OIL RETAINING RING DIAMETRAL COLD CLEARANCE.
STEAM END MAX. 0.0135" MIN. 0.0120" 69.219
EXHAUST END MAX. 0.0175" MIN. 0.0160" 2.188
64.531
NOTE "C" FOR PROPER LABYRINTH RING DIAMETRAL COLD CLEARANCE, SEE
DESIGN OPERATING CONDITIONS SHEET IN INSTRUCTION MANUAL. 7.875
10 54.906
NOTE "D" WEIGH ALL BLADES PRIOR TO ASSEMBLY. BLADES TO BE ASSEMBLED
TO DISTRIBUTE THE WEIGHT EVENLY AROUND THE WHEEL. 2.250
15
50.906
NOTE! BEARINGS AND RETAINERS ARE FACTORY FITTED TO DIAMETRAL
COLD CLEARANCES AS SHOWN. BEARINGS OR RETAINERS 5.375
SHOWING EXCESSIVE WEAR SHOULD BE REPLACED. 9 43.781
E E
2.375
NOTE! ROTOR ASSEMBLY TO BE BALANCED PER QUALITY SYSTEM 14
OPERATING INSTRUCTION 9.8.3 DYNAMIC ROTOR BALANCE.
8 39.656
NOTE! THE FOLLOWING TOLERANCES ARE TO BE USED FOR THE 2.250
STACKING OF WHEELS ON A ROTOR ASSEMBLY. 13
FIRST STAGE WHEEL ±0.005" 35.656
ALL SUBSEQUENT WHEELS ±0.010"
7 6 5 3.125
4
33.469 12 12 12 30.781
12 3
30.750
11 12 2
22.750 .188
16 12
.188 DIAPHRAGMS
SEE NOTE "C".
17
STEAM END
D SEE NOTE "C". D
EXHAUST END
18 SEE NOTE "C".
.188

2.250

19 20
EDGE OF DISC
SEE NOTE "B" SEE NOTE "B" SEE NOTE "B"
.156 .156 .125 .406
.156
SEE NOTE "A" .583 .560 .125 SEE NOTE "A" * 1.438 * 1.438 C
C 1
* 11.500
.434 EDGE OF NOZZLE BLOCK
W SEE DETAIL W. .017
TOTAL END PLAY
.013
OR CLEARANCE
EDGE OF DIAPHRAGM
BEARING
CL EXHAUST

BEARING

BEARING
CL THRUST
CL STEAM
21
SEE NOTE "D".

22
B
B

PEEN ON 102.000 BEARING CENTERS 9.500

ASSEMBLY

DETAIL W
SCALE 2 : 1 *APPROXIMATELY 1/4" IS REQUIRED TO BE MACHINED OFF EACH
FILLER RING TO OBTAIN DIMENSIONS SHOWN. THESE ARE THEORETICAL
NOTE! DIMENSIONS. ACTUAL DIMENSIONS TO BE DETERMINED ON ASSEMBLY
THERE ARE 3 BALANCE GROOVES IN THE ROTOR. 1 BALANCE GROOVE IN THE 8TH AND 9TH AND RECORDED ON SPECIFICATION SHEET.
STAGE WHEELS AND 1 BALANCE GROOVE IN THE BALANCE RING LOCATED AFTER THE 9TH STAGE
WHEEL. THE ROTOR IS TO BE BALANCED BY ADDING WEIGHTS TO THESE LOCATIONS WHERE REQUIRED
AS SHOWN. DO NOT GRIND ON WHEELS IN THESE LOCATIONS.
A BOM - 1000210655 UNLESS OTHERWISE SPECIFIED: NAME DATE
A
DRAWN DCO 2011-06-08
SERIAL -BUR5955 ALL DIMENSIONS STEAM TURBINE BUSINESS UNIT
ARE IN INCHES CHECKED DWP 2011-06-28 Burlington, Iowa, USA
REF - 6R10284
APPROVED DWP 2011-06-28
TOLERANCES
PER
SW MODEL: 6R10597
M:\DWG\BUR5955\
TURBINE ROTOR
LAST SAVED BY: jlionberger
DATE: Tuesday, June 28, 2011 1:55:13 PM
1S101 UNLESS
OTHERWISE
PROPRIETARY AND CONFIDENTIAL ASSEMBLY
SPECIFIED THIS DRAWING CONTAINS
MATERIAL CONFIDENTIAL AND TRADE DRAWING NUMBER REV

6R10597 0
-------- SECRET INFORMATION AND IS THE
PROPERTY OF DRESSER-RAND COMPANY

D
SIZE FINISH AND IS PROVIDED TO THE
RECEIVER IN CONFIDENCE.
-------- SCALE: 1:6 WEIGHT: 6773 SHEET 1 OF 1
8 7 6 5 4 3 2 1
 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000210056 001 CMAF DIAPHRAGM

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

1 1 7R13475-1 DIAPHRAGM MACHINING DRAWING 1 EA

2 1 5A0921-32 LABYRINTH 1 EA

3 1 1A4099-44 LABYRINTH SPRING 2 EA

4 1 1S338-61 LABYRINTH STOP PIN 1 EA

5 1 1S338-67 ROLL PIN .187 X .875 4 EA

6 1 1S400-1 HEADLESS SCREW - COPPER SLOTD 2 EA

7 1 1S338-36 ROLL PIN .125 X .500 4 EA

8 1 1A5843-44 DIAPHRAGM KEY 2 EA

© 2011 DRESSER-RAND COMPANY 1000210056 Page 1 of 1

 Report Date: 28 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000210163 001 CMAF DIAPHRAGM 1000210163

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

1 1 7R13476-1 DIAPHRAGM MACHINING DRAWING 1 EA

2 1 5A0921-32 LABYRINTH 1 EA

3 1 1A4099-44 LABYRINTH SPRING 2 EA

4 1 1S338-61 LABYRINTH STOP PIN 1 EA

5 1 1S338-67 ROLL PIN .187 X .875 4 EA

6 1 1S400-1 HEADLESS SCREW - COPPER SLOTD 2 EA

7 1 1S338-36 ROLL PIN .125 X .500 4 EA

8 1 1A5843-44 DIAPHRAGM KEY 2 EA

© 2011 DRESSER-RAND COMPANY 1000210163 Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000210164 001 CMAF DIAPHRAGM 1000210164

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

1 1 7R13477-1 DIAPHRAGM MACHINING DRAWING 1 EA

2 1 5A0921-32 LABYRINTH 1 EA

3 1 1A4099-44 LABYRINTH SPRING 2 EA

4 1 1S338-61 LABYRINTH STOP PIN 1 EA

5 1 1S338-67 ROLL PIN .187 X .875 4 EA

6 1 1S400-1 HEADLESS SCREW - COPPER SLOTD 2 EA

7 1 1S338-36 ROLL PIN .125 X .500 4 EA

8 1 1A5843-44 DIAPHRAGM KEY 2 EA

© 2011 DRESSER-RAND COMPANY 1000210164 Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000170508 001 DIAPHRAGM CMAF

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

1 1 7R12953-1 DIAPHRAGM MACHINING DRAWING 1 EA

2 1 5A0921-32 LABYRINTH 1 EA

3 1 1A4099-44 LABYRINTH SPRING 2 EA

4 1 1S338-67 ROLL PIN .187 X .875 4 EA

5 1 1S338-61 LABYRINTH STOP PIN 1 EA

6 1 1A5843-44 DIAPHRAGM KEY 2 EA

7 1 1A5843-30 DIAPH. KEY 2 EA

8 1 1S338-36 ROLL PIN .125 X .500 8 EA

9 1 1S400-4 HEADLESS SCREW - COPPER 2 EA

© 2011 DRESSER-RAND COMPANY 1000170508 Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000170509 001 DIAPHRAGM CMAF

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

1 1 7R12954-1 DIAPHRAGM MACHINING DRAWING 1 EA

2 1 5A0921-32 LABYRINTH 1 EA

3 1 1A4099-44 LABYRINTH SPRING 2 EA

4 1 1S338-67 ROLL PIN .187 X .875 4 EA

5 1 1S338-61 LABYRINTH STOP PIN 1 EA

6 1 1A5843-44 DIAPHRAGM KEY 2 EA

7 1 1A5843-35 DIAPHRAGM KEY 2 EA

8 1 1S338-36 ROLL PIN .125 X .500 8 EA

9 1 1S400-4 HEADLESS SCREW - COPPER 2 EA

© 2011 DRESSER-RAND COMPANY 1000170509 Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000168415 001 DIAPHRAGM MODIFIED CMAF

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

1 1 7R12861-1 DIAPHRAGM MACHINING 1 EA

2 1 1A5843-22 DIAPH KEY 2 EA

3 1 1S338-36 ROLL PIN .125 X .500 4 EA

4 1 1S362-81 PIN 2 EA

5 1 5A0921-32 LABYRINTH 1 EA

6 1 1A4099-44 LABYRINTH SPRING 2 EA

7 1 1S338-67 ROLL PIN .187 X .875 4 EA

8 1 1S338-61 LABYRINTH STOP PIN 1 EA

9 1 1S338-42 ROLL PIN .125 X .875 4 EA

© 2011 DRESSER-RAND COMPANY 1000168415 Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

OR28751 001 DIAPHRAGM OR28751

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

1 1 7R11420-1 DIAPHRAGM MACHINING DRAWING 1 EA

5 1 5A0921-32 LABYRINTH 1 EA

6 1 1A4099-44 LABYRINTH SPRING 2 EA

7 1 1S338-67 ROLL PIN .187 X .875 4 EA

8 1 1S338-61 LABYRINTH STOP PIN 1 EA

© 2011 DRESSER-RAND COMPANY OR28751 Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

OR28752 001 DIAPHRAGM OR28752

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

1 1 7R11421-1 DIAPHRAGM MACHINING DRAWING 1 EA

5 1 5A0921-32 LABYRINTH 1 EA

6 1 1A4099-44 LABYRINTH SPRING 2 EA

7 1 1S338-67 ROLL PIN .187 X .875 4 EA

8 1 1S338-61 LABYRINTH STOP PIN 1 EA

© 2011 DRESSER-RAND COMPANY OR28752 Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

OA28747 001 DIAPHRAGM SUPPORTS OA28747

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 4A6398-1 DIAPHRAGM SUPPORT ASSEMBLY 1 EA

1 1 1A13408-1 HORIZONTAL CENTERING KEY 1 EA

2 1 1A13407-1 VERTICAL SHIM 2 EA

3 1 1A13405-1 VERTICAL CENTERING KEY(LEFT SIDE) 1 EA

4 1 1A13404-1 UPPER DIAPHRAGM RETAINER(LT) 1 EA

5 1 1S596-3 CAPSCRW 3/4X1 3/4 24-29RC 2 EA

6 1 1S596-68 CAPSCRW 1/2 X 1 IN 24-29RC- LOT 2 EA

7 1 1A13403-1 UPPER DIAPHRAGM RETAINER(RT) 1 EA

8 1 1A13406-1 VERTICAL CENTERING KEY(RIGHT SIDE) 1 EA

© 2011 DRESSER-RAND COMPANY OA28747 Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000214664 001 NOZZLE BLOCK CMAF 1000214664

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

1 1 7R13493-1 NOZZLE BLOCK MACHINING DRAWING 1 EA

2 1 1S596-6 CAPSCRW 3/4X2 3/4 24-29RC 60 EA

3 1 1S596-20 CAPSCRW 3/4 X2 1/4 24-29RC 42 EA

© 2011 DRESSER-RAND COMPANY 1000214664 Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

OR28708 001 LABYRINTH GLANDS OR28708

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 6R8959-1 LABYRINTH GLAND ASSY 1 EA

1 1 7R8507-2 LABYRINTH SLEEVE 1 EA

2 1 5A3621-2 LABYRINTH SEAL 8 FINGERS 5 EA

3 1 1A4099-4 LABYRINTH SPRING 10 EA

4 1 1S366-133 PIN 0.1875 X 3.250 416SST 8 EA

5 1 1S366-92 PIN 4 EA

6 1 1S338-61 LABYRINTH STOP PIN 13 EA

7 1 7R8508-2 LABYRINTH SLEEVE 1 EA

8 1 5A3621-1 LABY SEAL 3 EA

9 1 1A4099-31 LABYRINTH SPRING 6 EA

10 1 1S366-89 PIN 4 EA

11 1 5R4364-1 LABYRINTH GLAND CASE INNER 1 EA

12 1 5A4366-1 LABYRINTH OFFSET SEAL 8.0 5 EA

13 1 1S230-10 CAPSCRW SOC HD 1/2 X2 1/4 4 EA

14 1 1S366-150 PIN .1875 X 3.9375 4 EA

15 1 1S596-78 CAPSCREW-INTERNAL BOLTING 6 EA

16 1 5R1592-10 LABYRINTH GLAND 1 EA

17 1 1S571-15 CAPSCRW HEX HD 3/4 X 5 3 EA

18 1 1S571-6 CAPSCRW HEX HD 3/4 X 2-1/4 3 EA

19 1 1-1619-1 FITTING SCREW 2 EA

20 1 1S438-7 PIPE PLUG-ALLEN 1 2 EA

21 1 1S438-5 PIPE PLUG-ALLEN 1/2 16 EA

22 1 1A4099-32 LABYRINTH SPRING 10 EA

23 1 1S271-84 SETSCREW-CUP PT 1/4-1/2 X 1/8 2 EA

© 2011 DRESSER-RAND COMPANY OR28708 Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000167642 001 STEAM BEARING CASE

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 6R8952-1 STEAM BEARING CASE ASSY 1 EA

1 1 7R10590-1 STM END BRG CASE COVER 1 EA

2 1 7R11370-1 STM END BRG CASE BASE 1 EA

3 1 1A16038-1 6" WAUKESHA TPJ BEARING 1 EA

4 1 5A4728-3 OIL RETAINING RING 1 EA

5 1 1S187-53 STUD 1 8 X 4-3/8 COARSE 12 EA

6 1 1S341-14 STUD 6 EA

7 1 1S304-13 HEX NUT 1-3/8 8 GR 2H 6 EA

8 1 1S648-1 CAPTIVE NUT 1 IN 8 12 EA

9 1 1S641-2 WASHER-SPECIAL O.D. 12 EA

10 1 1S599-158 TAPER DOWEL #10 2 EA

11 1 1S599-155 TAPER DOWEL #10 X 2-1/2 4 EA

12 1 1S364-67 PIN - DRILL ROD 1 EA

13 1 1A8635-1 GUIDE STUD 2 EA

14 1 1S641-3 WASHER-SPECIAL O.D. 6 EA

16 1 1A3007-1 EYE BOLT 2 EA

17 1 1A15985-1 WAUKESHA 10.5 IN POCKET FEED THRUST BRG. 1 EA

18 1 3A4064-3 FILLER PIECE 10.5 THRUST BRG 2 EA

19 1 2A2580-1 THRUST BEARING OIL BAFFLE WELD ASSY. 1 EA

20 1 SPC-78-169-MT CABLE CLAMP 2 EA

21 1 1S491-1 MACHINE SCREW #6 RD HEAD 2 EA

© 2011 DRESSER-RAND COMPANY 1000167642 Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000167643 001 EXHAUST BEARING CASE

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 6R8958-1 EXHAUST BEARING CASE ASSEMBLY 1 EA

1 1 7R11373-2 EXHAUST BEARING CASE BASE 1 EA

2 1 7R10610-10 EXHAUST BEARING CASE COVER 1 EA

3 1 1A16039-1 8" WAUKESHA TPJ BEARING 1 EA

4 1 1A9275-1 SHIM 2 EA

5 1 3A4894-2 OIL RETAINING RING 2 EA

6 1 1S571-6 CAPSCRW HEX HD 3/4 X 2-1/4 4 EA

7 1 1S599-97 TAPER DOWEL #7 X 2-1/4 2 EA

8 1 1S573-4 CAPSCRW HEX HD 1 X 3 4 EA

9 1 1S599-118 TAPER DOWEL #8 X 2-3/4 2 EA

10 1 1S364-67 PIN - DRILL ROD 2 EA

11 1 1S438-9 PIPE PLUG-ALLEN 1-1/2 2 EA

12 1 1S438-6 PIPE PLUG-ALLEN 3/4 1 EA

13 1 1A3007-1 EYE BOLT 2 EA

14 1 1S438-1 PIPE PLUG-ALLEN 1/16 2 EA

15 1 1A6330-16 REDUCER INST 3 X 2 SW S40 T3 1 EA

16 1 3A0906-32 FLANGE 3 SW S40 150# 1 EA

17 1 SPC-78-169-MT CABLE CLAMP 1 EA

18 1 1S491-1 MACHINE SCREW #6 RD HEAD 1 EA

© 2011 DRESSER-RAND COMPANY 1000167643 Page 1 of 1

 INSTRUCTIONS

FOR

INSTALLING & OPERATING

TILTING PAD TYPE JOURNAL BEARINGS

WITH FORCED LUBRICATION

WAUKESHA BEARINGS CORPORATION

WAUKESHA, WISCONSIN 53186 U.S.A.

I. GENERAL DESCRIPTION

This is a tilting pad type journal bearing consisting of a number (generally five) of arcuate journal
pads retained within an annular shell and associated end plates. The bearing will accept radial load in
any direction and is particularly useful under high speed, light load conditions where bearing
instability may be encountered with other types of journal bearings.

Several basic types are produced, all based around the same journal pads. (These variations are shown
on page 4.) The differences in these basic types are in the housing seat configuration and whether a
thrust face is incorporated.

The journal pads are constructed so they are free to tilt in the bore of the shell. This action assists in
the generation of the hydrodynamic oil film at each pad and is basic to the inherent stability
characteristics of this type bearing.

II. DETAILED DESCRIPTION

The journal pads consist of a steel backing on which has been centrifugally cast a babbitt layer. The
babbitt surface is bored to provide the desired “pad clearance” (Cp) of the shaft diameter. The radial
thickness of the pad (at the pad center) is held close tolerance to establish the desired “bearing
clearance” (Cb) when the pads are assembled to the housing. The relationship of “bearing clearance”
and “pad clearance” establishes the “bearing preload.”
Preload in a tilting pad journal bearing is normally defined as follows:

Cb
preload = m = 1 −
Cp

The preload used for a particular bearing will depend on the application. Preload values are generally
between 0.0 and 0.5, with values of 0.2 to 0.3 common. Negative values are undesirable. Design
clearance values are given on the bearing assembly drawing.

The journal pads are retained loosely in the bearing shell by pins or dowels which prevent
circumferential movement. The bearing end plates position the pads axially.

Split housings and end plates are used where radial assembly of the bearing to the shaft is required.
Where axial assembly is permitted, solid shells (and end plates) may be used and this is common with
the flanged housing types. These use cap screws through the flange and into the bearing housing to
maintain axial and circumferential position. An anti-rotation pin, to locate in a corresponding hole or
slot in the bearing housing, is used on the non-flange types.

Lubricating and cooling oil of the proper viscosity, inlet temperature and pressure is to be supplied to
the annular groove in the OD (outside diameter) of the bearing shell. From here the oil flows radially
inward through the oil feed holes (located between the journal pads) and fills the pad cavity where is
used for lubrication and heat removal. The oil then flows axially along the shaft through the
clearance at the bore of the end plate seals.

If a thrust face is used, the oil discharge from that end of the pad cavity is used to lubricate the thrust
bearing.

The radial oil feed holes in the bearing shell and the end plate seal bore clearances are sized for the
particular application to establish the proper oil flow through the bearing.

III. INSTALLATION

These bearings are processed with a rust inhibitor and preservative prior to shipment from the factory.
This protection should not be removed until installation. At that time, the bearing should be
disassembled and all parts thoroughly cleaned with a lint-free cloth and a solvent such as acetone or
mineral spirits. The bearing is then reassembled (in halves, if a split bearing). Oil all parts at
reassembly to protect against corrosion. The journal pads are all interchangeable as to circumferential
position except as may be dictated by instrumentation, such as pad mounted thermocouples.
 IMPORTANT

Cleanliness and burr-free surfaces are vital to the proper performance

of the bearing. Remove any burrs or raised edges on the pad faces
with a scraper. Remove any light burrs or fine rust on the collar with
a fine oil stone. Deep rust or bruising will require refinishing.

Assemble to the shaft and secure with any cap screws, as required, noting the proper angular
positioning of the bearing. Assemble the remaining parts of the bearing housing. If temperature
sensors (as thermocouples or RTDs) are used in the bearing, route the leads out of the bearing housing
with care. Leave some slack where the leads exit the bearing shell or end plate to avoid binding the
associate pad.

IV. OPERATION

These bearings are designed for forced lubrication with outside cooling of the oil. Oil should be
supplied prior to rotation of the rotor and at all times during rotation. The supply pressure must be
controlled to the level specified. Maintenance of a clean oil supply is critical to the satisfactory
operation of the bearing. A suitable filter in the system is generally essential. A high quality turbine
type oil with rust and corrosion inhibitors is recommended for most applications.

As the bearing surfaces are separated completely by an oil film during operation there is virtually no
wear and thus no periodic adjustments or maintenance procedures are specified. The only attention
normally required is to maintain the proper supply of clean oil at the proper temperature.

The use of thermocouples or RTDs embedded into the journal pads is often made to provide a monitor
on bearing and machine performance. Such sensors, if used, provide a responsive and accurate check
on bearing operation. Normal operating temperatures are established and then alarm and/or shutdown
signals may be set.

V. SERVICE

Disassembly procedures generally follow from the assembly procedure for the specific bearing and
machine under consideration.

If replacement or repair of parts are required, prompt attention will be given by Waukesha Bearings
Corporation to supply the necessary service. Refer to the specific bearing drawing and item number
when ordering parts.
 Technical Manual 82450
(Revision P)
Original Instructions

TM-25LP, TM-200LP Actuators

Installation and Operation Manual

 This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
 DANGER—Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
DEFINITIONS  WARNING—Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
 CAUTION—Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
 NOTICE—Indicates a hazard that could result in property damage only (including
damage to the control).
 IMPORTANT—Designates an operating tip or maintenance suggestion.

The engine, turbine, or other type of prime mover should be equipped with an
overspeed shutdown device to protect against runaway or damage to the prime
mover with possible personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the prime mover
control system. An overtemperature or overpressure shutdown device may also
be needed for safety, as appropriate.

Read this entire manual and all other publications pertaining to the work to be performed before
installing, operating, or servicing this equipment. Practice all plant and safety instructions and
precautions. Failure to follow instructions can cause personal injury and/or property damage.

This publication may have been revised or updated since this copy was produced. To verify that
you have the latest revision, be sure to check the publications page on the Woodward website:
www.woodward.com/searchpublications.aspx
The current revision of all publications is shown in file "current.pdf".

The latest version of most publications is available on the publications page. If your publication is
not there, please contact your customer service representative to get the latest copy.

Any unauthorized modifications to or use of this equipment outside its specified mechanical,
electrical, or other operating limits may cause personal injury and/or property damage, including
damage to the equipment. Any such unauthorized modifications: (i) constitute "misuse" and/or
"negligence" within the meaning of the product warranty thereby excluding warranty coverage
for any resulting damage, and (ii) invalidate product certifications or listings.

To prevent damage to a control system that uses an alternator or battery-charging

device, make sure the charging device is turned off before disconnecting the battery
from the system.

To prevent damage to electronic components caused by improper handling, read

and observe the precautions in Woodward manual 82715, Guide for Handling and
Protection of Electronic Controls, Printed Circuit Boards, and Modules.

Revisions—Text changes are indicated by a black line alongside the text.

Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
© Woodward 1981
All Rights Reserved
Manual 82450 TM-25LP/TM-200LP Actuators

Contents

REGULATORY COMPLIANCE ........................................................................ II 

CHAPTER 1. GENERAL INFORMATION ........................................................... 1 
Description ..............................................................................................................1 
References .............................................................................................................1 
Direction of Output..................................................................................................1 
Single or Dual Coil ..................................................................................................1 
Terminal Shaft Options ...........................................................................................1 
CHAPTER 2. INSTALLATION.......................................................................... 2 
Introduction .............................................................................................................2 
Receiving ................................................................................................................3 
Storage ...................................................................................................................3 
Installation ..............................................................................................................3 
CHAPTER 3. INITIAL OPERATION OF THE ACTUATOR................................... 12 
Initial Operation ....................................................................................................12 
Adjustments ..........................................................................................................12 
CHAPTER 4. PRINCIPLES OF OPERATION ................................................... 13 
Introduction ...........................................................................................................13 
Operation ..............................................................................................................13 
CHAPTER 5. MAINTENANCE ....................................................................... 15 
Introduction ...........................................................................................................15 
Filter Cleaning ......................................................................................................15 
Troubleshooting ....................................................................................................15 
CHAPTER 6. REPLACEMENT PARTS ........................................................... 17 
Introduction ...........................................................................................................17 
Replacement Parts Information ............................................................................17 
CHAPTER 7. SERVICE OPTIONS ................................................................. 20 
Product Service Options .......................................................................................20 
Woodward Factory Servicing Options ..................................................................21 
Returning Equipment for Repair ...........................................................................21 
Replacement Parts ...............................................................................................22 
Engineering Services............................................................................................22 
How to Contact Woodward ...................................................................................23 
Technical Assistance ............................................................................................23 
REVISION HISTORY .................................................................................... 25 
DECLARATIONS ......................................................................................... 26 

Illustrations and Tables

Figure 2-1a. TM-25LP/TM-200LP Actuator ............................................................6 

Figure 2-1b. TM-25LP/TM-200LP Actuator with Rod End .....................................7 
Figure 2-2a. Dual Coil TM-25LP/TM-200LP Actuator with Position Feedback ......8 
Figure 2-2b. Dual Coil TM-25LP/TM-200LP Actuator without Position Feedback .9 
Figure 2-3. Single Coil Wiring ...............................................................................10 
Figure 2-4. Dual Coil Wiring .................................................................................11 
Figure 4-1. Single/Dual Coil Schematic, TM-25LP/TM-200LP Actuator ..............14 
Figure 6-1. TM-200LP Exploded View .................................................................19 

Woodward i
TM-25LP/TM-200LP Actuators Manual 82450

Regulatory Compliance
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking.

ATEX – Potentially Declared to 94/9/EEC COUNCIL DIRECTIVE of 23

Explosive March 1994 on the approximation of the laws of the
Atmospheres Member States concerning equipment and
Directive: protective systems intended for use in potentially
explosive atmospheres.
LCIE 02 ATEX 6221 X
Zone 1, Category 2, Group II G, EEx e II T3 X

Other European and International Compliance:

Compliance with the following European Directives or standards does not qualify
this product for application of the CE Marking:

EMC Directive: Not applicable to this product. Electromagnetically

passive devices are excluded from the scope of the
89/336/EEC Directive.

Machinery Directive: Compliant as a component with 98/37/EC COUNCIL

DIRECTIVE of 23 July 1998 on the approximation of
the laws of the Member States relating to machinery.

Pressure Equipment Compliant as “SEP” per Article 3.3 to Pressure

Directive: Equipment Directive 97/23/EC of 29 May 1997 on
the approximation of the laws of the Member States
concerning pressure equipment.

NOTE: This listing is limited to units bearing the TIIS certification labeling.
TIIS: The TM-25LP Single Coil Actuator is certified for use
in Japanese hazardous locations per TIIS Certificate
TC17927 as Ex e II T3 (155 °C).

NOTE: This listing is limited to units that are CE Marked as Zone 1, Category 2
compliant.
KGS: The TM-25LP Single Coil Actuator is certified for use
in Korean hazardous locations per KGS Certificate
06-2-045-Q1 as Ex e II T3 30V.

North American Compliance:

These listings are limited only to those units bearing the CSA and UL
identification.
CSA: CSA Certified for use in the United States and
Canada: Certificate 2399483.
Single and dual coil actuators certified for Class I,
Division 2, Groups A, B, C, & D.
Dual coil actuators certified for Class I, Division 1,
Groups C & D.

UL: UL Listed for use in the United States: UL file

E158654.
Single and dual coil actuators certified for Class I,
Division 2, Groups B, C, & D.
Dual coil actuators certified for Class I, Division 1,
Groups C & D.

ii Woodward
Manual 82450 TM-25LP/TM-200LP Actuators
Wiring must be in accordance with North American Class I, Division 1 or 2, or
European Zone 1, Category 2 wiring methods as applicable, and in accordance
with the authority having jurisdiction.

The TM-25LP and TM-200LP are certified to a Zone 1-Category 2 method of

protection. Wiring methods must comply with the Zone 1-Category 2 method of
protection when installed in a Zone 2 classified atmosphere.

Special Conditions for Safe Use:

Each torque motor must be provided with a 900 mA maximum fuse to be
installed before the torque motor.

Voltage to the torque motor must be limited to a nominal voltage of 30 V with a

switch-off voltage of 480 V.

Field wiring must be suitable for at least 90 °C and 10 °C above the ambient
operating temperature.

Connect ground terminal to earth ground.

EXPLOSION HAZARD—Do not remove covers or connect/disconnect

electrical connectors unless power has been switched off or the area
is known to be non-hazardous.

Substitution of components may impair suitability for Class I,

Division 2 or Zone 2.

RISQUE D’EXPLOSION—Ne pas enlever les couvercles, ni

raccorder / débrancher les prises électriques, sans vous en
assurez auparavant que le système a bien été mis hors
tension; ou que vous vous situez bien dans une zone non
explosive.

La substitution de composants peut rendre ce matériel

inacceptable pour les emplacements de Classe I, Division 2
ou Zone 2.

Woodward iii
TM-25LP/TM-200LP Actuators Manual 82450

iv Woodward
Manual 82450 TM-25LP/TM-200LP Actuators

Chapter 1.
General Information

Description
The TM-25LP and TM-200LP actuators are electric-hydraulic, proportional
actuators designed for use with Woodward 43027 and 2301 electric controls and
may interface with an adapter directly to a fuel flow control valve. They have an
aluminum case with through-hardened stainless steel internal parts.

In the actuator, a torque motor servovalve is energized by the electric control to

generate a pressure differential applied to the ends of, and to operate, the
second stage spool valve. Supply pressure is regulated by the spool valve to
move a double acting servo piston and provide 25 mm (1 inch) of linear output
shaft travel. Internal mechanical feedback is standard. The actuator is calibrated
at the factory for bias in the minimum fuel direction in the event of a loss of input
current.

Hydraulic fluid is sealed from the torque motor by a preformed packing ring
between the armature and the servovalve housing, eliminating the accumulation
of magnetic contaminants. A 40 µm nominal/70 µm absolute filter fitting is
provided at the hydraulic supply port for protection in the event of an upstream
filter failure.

References
Product Specification 82451 about the TM-25LP and TM-200LP is available on
our website (www.woodward.com).

Direction of Output
TM-25LP and TM-200LP actuators are available either to extend the terminal
shaft as the actuator signal increases or retract the terminal shaft as the actuator
signal increases. The reaction to signal change is a factory modification.

Single or Dual Coil

TM actuators are available with either single or dual coil torque motors. The dual
coil option provides redundant electrical channels in the torque motor. In the dual
coil models, the coils can be used independently or together to load share.

Terminal Shaft Options

TM actuators are available with either internal (female) 0.375-24 UNF threads as
shown in Figure 2-1a or external (male) 0.375-24 threads. A clevis-type rod end
can also be purchased and installed on the external threads as shown in Figure
2-1b.

Woodward 1
TM-25LP/TM-200LP Actuators Manual 82450

Chapter 2.
Installation

Introduction
Receiving, storage, and installation for the actuator are covered in this chapter.
See the outline drawing, Figure 2-1.

The engine, turbine, or other type of prime mover should be

equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
loss of life, or property damage.
The overspeed shutdown device must be totally independent of the
prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.

EXPLOSION HAZARD—External fire protection is not provided in the

scope of this product. It is the responsibility of the user to satisfy
any applicable requirements for their system.

EXPLOSION HAZARD—Do not remove covers or connect/disconnect

electrical connectors unless power has been switched off or the area
is known to be non-hazardous.
Substitution of components may impair suitability for Class I,
Division 2 or Zone 2.

Due to typical noise levels in turbine environments, hearing

protection should be worn when working on or around the TM
Actuator.

The surface of this product can become hot enough or cold enough
to be a hazard. Use protective gear for product handling in these
circumstances. Temperature ratings are included in the specification
section of this manual.

Be careful when installing the actuator. Do not damage the output shaft. Abuse of
the actuator can damage seals, installation surfaces, and alter the calibration of
the unit. Protect the hydraulic connections with plastic shipping caps when the
actuator is not connected to the normal piping.

2 Woodward
Manual 82450 TM-25LP/TM-200LP Actuators

Receiving
The actuator is calibrated and drained of calibration fluid at the factory. It is then placed
in a cardboard container filled with urethane foam for delivery to the customer.
Additional cleaning or calibration is not necessary before installation or operation.

To avoid personal injury from improper lifting or from dropping the

actuator, be sure to use appropriate equipment and safe-lifting
techniques when handling the actuator. Dry weight of the actuator is
approximately 9 kg (20 lb).

Storage
The actuator may be stored as received from the factory for a period of time
before installation.

Installation
See the outline drawing, Figure 2-1, for:
 overall dimensions
 installation hole locations
 hydraulic fitting sizes
 output shaft dimensions

Proper filtration of the hydraulic supply is extremely important. A 10 µm (nominal)

filter must be installed in the supply to the actuator within 1 meter of the supply
port. If a dedicated HPU supply system is installed, the distance from the filter to
the actuator is not important. It is necessary to keep the immediate area and
equipment clean and free of dirt and contaminants while working on and
connecting the hydraulic lines.

The attitude in which the actuator is installed does not affect the performance of
the actuator.

Connect all hydraulic lines to the actuator. Supply pressure for the TM-25LP or
TM-200LP actuator can be from either positive displacement or centrifugal type
pumps. Woodward recommends the use of a pressure switch to be sure that
correct supply pressure is established before start-up and maintained continually
thereafter.

It is very important that the linkage between the actuator output and the fuel
system be of correct relationship for proper operation. Use as much of the 25 mm
(1 inch) output travel as possible between minimum and maximum flow points.

Use the correct Woodward control manual when making all electrical
connections. A plant wiring diagram will be supplied upon request. In applications
where the actuator is not used with a Woodward electric control, electrical input
requirements will also be supplied upon request.

The TM-25LP and TM-200LP are certified to a Zone 1-Category 2

method of protection. Wiring methods must comply with the Zone 1-
Category 2 method of protection when installed in a Zone 2 classified
atmosphere.

Woodward 3
TM-25LP/TM-200LP Actuators Manual 82450

Due to the hazardous location listings associated with this product,

proper wire type and wiring practices are critical to operation.

Each torque motor must be provided with a 900 mA maximum fuse to

be installed before the torque motor. Voltage to the torque motor
must be limited to a nominal voltage of 30 V with a switch-off voltage
of 480 V.

Do not connect any cable grounds to “instrument ground”, “control

ground”, or any non-earth ground system. Make all required
electrical connections based on the wiring diagrams (Figures 2-3 &
2-4).

Supply Characteristics
TM-25LP
Fluid Types: Mineral or synthetic based oils, diesel fuels,
kerosenes, gasolines, or light distillate fuels
Specific Gravity: 0.6 to 1.0
Recommended Viscosity: 0.6 to 400 centistokes
150–200 SSU
ISO 32 Grade
External Filter: 10 µm nominal
Supply Pressure: Any nominal level between 552 and 2586 kPa
(80 and 375 psig)
Ambient Temperature
Range: –40 to +121 °C (–40 to +250 °F)
Hydraulic Fluid
Temperature Range: 16 to 79 °C (60 to 175 °F)
Hydraulic Cleanliness Level ISO 4406 20/18/15 minimum

TM-200LP
Fluid Types: Mineral or synthetic based oils, diesel fuels,
kerosenes, gasolines, or light distillate fuels
Specific Gravity: 0.6 to 1.0
Recommended Viscosity: 0.6 to 400 centistokes
150–200 SSU
ISO 32 Grade
External Filter: 10 µm nominal
Supply Pressure: Any nominal level between 2758 and 8274 kPa
(400 and 1200 psig)
Ambient Temperature
Range: –40 to +121 °C (–40 to +250 °F)
Hydraulic Fluid
Temperature Range: 16 to 79 °C (60 to 175 °F)
Hydraulic Cleanliness Level ISO 4406 20/18/15 minimum

4 Woodward
Manual 82450 TM-25LP/TM-200LP Actuators

Flow Requirements
TM-25LP
Supply Pressure Steady State Flow Max. Transient Flow Rated Max. Work
Single Coil or Dual Coil
552 kPa 3.8 L/min 18.9 L/min 15 J
80 psig 1.0 US gal/min 5.0 US gal/min 11 ft-lb
2586 kPa 3.8 L/min 18.9 L/min 72 J
375 psig 1.0 US gal/min 5.0 US gal/min 53 ft-lb

TM-200LP
Supply Pressure Steady State Flow Max. Transient Flow Rated Max. Work
Single Coil or Dual Coil
2758 kPa 3.8 L/min 18.9 L/min 76 J
400 psig 1.0 US gal/min 5.0 US gal/min 56 ft-lb
8274 kPa 3.8 L/min 18.9 L/min 231 J
1200 psig 1.0 US gal/min 5.0 US gal/min 170 ft-lb

Electrical Characteristics
TM-25LP
Input Current Range: 20 to 200 mA
Coil Resistance: 26 Ω at 21 °C (70 °F) single coil, 40 Ω dual coil
Maximum Coil Current: 250 mA

TM-200LP
Input Current Range: 20 to 200 mA
Coil Resistance: 26 Ω at 21 °C (70 °F) single coil, 40 Ω dual coil
Maximum Coil Current: 250 mA

Output Characteristics
TM-25LP
Linear Stroke: 25 mm (1.0 inch)
Output Force: 605 N (136 lb) maximum at 552 kPa (80 psig)
2833 N (637 lb) maximum at 2586 kPa (375
psig) (both directions)

TM-200LP
Linear Stroke: 25 mm (1.0 inch)
Output Force: 3025 N (680 lb) maximum at 2758 kPa (400
psig)
9074 N (2040 lb) maximum at 8274 kPa (1200
psig) (both directions)

Woodward 5
TM-25LP/TM-200LP Actuators Manual 82450

Figure 2-1a. TM-25LP/TM-200LP Actuator

6 Woodward
Manual 82450 TM-25LP/TM-200LP Actuators

Figure 2-1b. TM-25LP/TM-200LP Actuator with Rod End

Woodward 7
 TM-25LP/TM-200LP Actuators Manual 82450

Figure 2-2a. Dual Coil TM-25LP/TM-200LP Actuator with Position Feedback

8 Woodward
Manual 82450 TM-25LP/TM-200LP Actuators

Figure 2-2b. Dual Coil TM-25LP/TM-200LP Actuator without Position Feedback

Woodward 9
TM-25LP/TM-200LP Actuators Manual 82450

Figure 2-3. Single Coil Wiring

(Shields to be grounded at electronic control end only)

10 Woodward
Manual 82450 TM-25LP/TM-200LP Actuators

Figure 2-4. Dual Coil Wiring

(Shields to be grounded at electronic control end only)

Woodward 11
TM-25LP/TM-200LP Actuators Manual 82450

Chapter 3.
Initial Operation of the Actuator

Initial Operation
Before the initial operation of the actuator, be sure that all previous installation
and hookup procedures are accomplished and all linkages (if any), electrical
connections, and hydraulic fittings are secure and properly connected.

Be sure that the correct hydraulic supply pressure to the actuator is established
before start-up. Trapped air within the hydraulic system may cause momentary
erratic behavior of the actuator at the initial operation. Use the correct Woodward
manual for the Woodward electric control to begin prime mover operation.

Null current shifts of up to ±4% of maximum rated current (200 mA) can occur
due to variations in the following parameters:
 hydraulic supply and return pressures
 hydraulic fluid temperature
 servovalve and actuator wear

Due to the inherent null shifts and position drift of all hydraulic servovalves and
proportional actuators, engine control applications must be designed with these
errors in mind.

Woodward recommends that adequate dither be used on all hydraulic actuators

to minimize mA threshold and hysteresis which can result from second stage
static friction or hydraulic contamination.

Dither is a low amplitude, relatively high frequency periodic signal that is

superimposed on the servovalve input current signal. A typical dither signal
generated by a Woodward control is:
 25 Hz, 0–10 mA (tunable) amplitude
 25% duty cycle, bipolar, square wave

Adequate dither is defined as that amount which produces no more than 0.013
mm (0.0005 inch) total oscillation in output shaft position.

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.

Adjustments
Normally, all operating adjustments are made to the actuator during factory
calibration according to specifications provided by the customer and should not
require further adjustment. Do not attempt adjustments to the actuator unless
thoroughly familiar with the proper procedures.

12 Woodward
Manual 82450 TM-25LP/TM-200LP Actuators

Chapter 4.
Principles of Operation

Introduction
This chapter describes the operation of TM-25LP and TM-200LP actuators. A
schematic drawing, Figure 4-1, illustrates the working relationship of the various
parts.

Operation
The actuator consists of three basic sections:
 a torque motor servovalve
 a spring-centered, four-land spool valve
 a double-sided, equal-area servo piston with a linear output shaft

The TM-25LP and TM-200LP actuators have torque motor servovalves. They
use a double nozzle and flapper to generate a differential pressure to operate the
second-stage spool valve. The torque motor received dc current signals from the
electric control and applies torque to the single-piece armature and flapper which
is supported on a torsion flexure. The servovalve uses the flapper as a variable
flow restrictor and throttles the flow of hydraulic fluid from a nozzle on each side
of the flapper. The two nozzles are supplied hydraulic fluid from the actuator
supply pressure inlet via separate fixed orifices. During steady state operation,
the flapper is centered between the nozzles and the two pressures, Pc1 and Pc2,
are equal.

When input current is increased to the torque motor coil, the limited pivotal
movement of the flapper to increase (counterclockwise on the schematic)
restricts hydraulic flow from the lower nozzle while flow from the upper nozzle
increases. The resulting differential pressure is applied to the ends of the spool
valve, raising it from its spring-centered null position.

When raised, the spool valve directs supply pressure to the bottom side of the
servo piston and, at the same time, vents the top side to drain at the upper
control port. the servo piston then moves up, increasing actuator output shaft
position. Servo piston movement also provides position feedback to the
servovalve.

An extension of the flapper is held between the feedback spring and level
adjusting spring. Increasing servo piston movement increases the feedback
spring torque on the flapper to re-center it. When a force balance is obtained
among the torque motor, level adjusting spring, and the feedback spring, the
spool valve is re-centered and further servo movement is halted.

Operation of the actuator is similar in the decrease direction. Movement of the

flapper restricts flow from the upper nozzle, while increasing flow of the lower
nozzle. the pressure differential this time lowers the spool valve and uncovers
ports to direct supply pressure to decrease actuator output position. the re-
centering action is provided as servo piston movement decreases compression
of the lower spring, re-centering the flapper.

Woodward 13
TM-25LP/TM-200LP Actuators Manual 82450

Figure 4-1. Single/Dual Coil Schematic, TM-25LP/TM-200LP Actuator

14 Woodward
Manual 82450 TM-25LP/TM-200LP Actuators

Chapter 5.
Maintenance

Introduction

EXPLOSION HAZARD—Do not remove covers or connect/disconnect

electrical connectors unless power has been switched off or the area
is known to be non-hazardous.

Substitution of components may impair suitability for Class I,

Division 2 or Zone 2.

This chapter provides instructions for troubleshooting and preventive

maintenance of the TM-25LP and TM-200LP actuators.

The service life of the actuator is increased with the use of clean supply flow.
However, contaminant resistance of the actuator is excellent due to design
features and high working forces.

Filter Cleaning
The actuators are equipped with a 40 µm nominal/ 70 µm absolute filter fitting at
the supply connection. See the outline drawing (Figure 2-1) for the location of the
fitting. If the filter becomes clogged, as evidenced by sluggish response of the
actuator, it may be removed, cleaned ultrasonically, and back flushed with a light
solvent. Be prepared to replace the O-ring (part 80, Figure 6-1) after cleaning the
filter (part 79, Figure 6-1).

Do not run the actuator with the inlet filter fitting or the in-line filter
removed or bypassed, as extensive repairs can be made necessary
by only momentary exposure of the interior of the torque motor to
contaminants.

Troubleshooting
Malfunctions of the governing system are usually revealed as speed variations of
the prime mover, but it does not necessarily mean that such speed variations
indicate governing system problems. When improper speed variations appear,
inspect all components, including the turbine, for proper operation. See the
correct Woodward manual for assistance in isolating the trouble.

The following steps describe troubleshooting the actuator:

1. If, during the starting sequence, the actuator does not respond to electric
control input, check the actuator pressure supply and supply link.

2. If the actuator does not respond to electric input, disconnect the output
linkage and attach a power supply and millimeter. Increase current to the
actuator, and the output should follow smoothly with increasing current. DO
NOT exceed 250 mA.

Woodward 15
TM-25LP/TM-200LP Actuators Manual 82450
Disassembly of the actuator in the field is not recommended. Under unusual
circumstances where field repair becomes necessary, all work and calibration
should be done by personnel thoroughly trained in the proper procedures.

Refer to Chapter 7 for instructions on contacting a Woodward Service

Representative or for training on this product.

When requesting information or service help from Woodward, it is important to

include in your communication the part number and serial number of the
actuator.

16 Woodward
Manual 82450 TM-25LP/TM-200LP Actuators

Chapter 6.
Replacement Parts

Introduction
This chapter provides information for ordering replacement parts for the
TM-25LP and TM-200LP actuators.

Disassembly of the actuator in the field is not recommended. Under unusual

circumstances where field repair becomes necessary, all work and calibration
should be done by personnel thoroughly trained in the proper procedures.

Refer to Chapter 7 for instructions on contacting a Woodward Service

Representative or for training on this product.

When requesting information or service help from Woodward, it is important to

include in your communication the part number and serial number of the
actuator.

Replacement Parts Information

When ordering replacement parts, it is essential to include the following
information:
 Serial number and part number shown on the nameplate of the actuator
 Manual number 82450
 Part reference numbers in parts list and description of part and part name

Figure 6-1 illustrates the parts for the actuator. The part numbers assigned are
used as reference only and are not specific Woodward part numbers.

Woodward 17
TM-25LP/TM-200LP Actuators Manual 82450
REF. NO. PART NAME......................................................................... QTY.
82450-51 Cover ........................................................................................... 1
82450-52 Screw, 6-32 x 0.250
—single coil.................................................................................. 1
—dual coil .................................................................................... 2
82450-53 Washer, #6 lock washer
—single coil.................................................................................. 1
—dual coil .................................................................................... 2
82450-54 Wire clamp
—single coil.................................................................................. 1
—dual coil .................................................................................... 2
82450-55 Housing assembly ........................................................................ 1
82450-56 Torque motor ............................................................................... 1
82450-57 Screw, 0.250-20 x 1.000
—single coil.................................................................................. 8
—dual coil .................................................................................. 12
82450-58 Washer, 0.250 lock washer
—single coil.................................................................................. 8
—dual coil .................................................................................. 12
82450-59 O-ring; furnished with torque motor ................................................
82450-60 O-ring; furnished with torque motor ................................................
82450-61 Actuator body assembly ............................................................... 1
82450-62 Preformed packing, 0.351 x 0.072 (single coil only) ..................... 3
82450-63 Plug, 0.438-20 (single coil only) ................................................ 1-3
82450-64 Feedback spring assembly .......................................................... 1
82450-65 Trim spring ................................................................................... 1
82450-66 Preformed packing (single coil only) ............................................ 1
82450-67 Spring seat assembly, 0.299 ID x 0.103
(separate plug and spring seat on dual coil) ................................ 1
82450-68 Plug (single coil only) ................................................................... 1
82450-69 Plug assembly, 0.438-20 (single coil only) ................................... 1
82450-70 Preformed packing, 0.551 x 0.071 ............................................... 1
82450-71 Pilot valve bushing ....................................................................... 1
82450-73 Pilot valve plunger ........................................................................ 1
82450-74 Retainer assembly ....................................................................... 1
82450-75 Spring assembly .......................................................................... 1
82450-76 Preformed packing, /737 ID ......................................................... 1
82450-77 Spring support assembly ............................................................. 1
82450-78 Expansion plug ............................................................................ 1
82450-79 Filter fitting, 0.750-16 ................................................................... 1
82450-80 Preformed packing, 0.644 ID x 0.087 ........................................... 1
82450-81 Connector assembly, 0.875-14 UNF ............................................ 1
82450-82 Preformed packing, 0.755 ID x 0.097 ........................................... 1
82450-83 Step seal ...................................................................................... 2
82450-84 Preformed packing, 0.636 ID x 0.070 ........................................... 2
82450-85 Preformed packing, 1.487 ID x 0.031 ........................................... 1
82450-86 Piston guide ................................................................................. 1
82450-87 Retaining ring, 1.942 .................................................................... 1
82450-88 Seal, 1.750 OD ............................................................................ 1
82450-89 Preformed packing, 1.296 ID x 0.139 ........................................... 1
82450-90 Piston assembly ........................................................................... 1
82450-91 Preformed packing, 1.612 ID x 0.031 ........................................... 1
82450-92 Cover assembly ........................................................................... 1
82450-93 Washer, 0.375 split lock ............................................................... 4
82450-94 Screw, 0.375-24 x 1.250 .............................................................. 4
82450-95 Rod and seal ................................................................................ 1
82450-96 Preformed packing, 0.674 ID x 0.103 ........................................... 1
82450-97 Seal retainer................................................................................. 1
82450-98 Retaining ring, 1.111 dia .............................................................. 1
82450-99 Cover (see both views) ................................................................ 1
82450-100 1/4-28 Drilled socket head cap screw (single coil only) ................ 3
82450-100a Flat washers (single coil only) ...................................................... 3

18 Woodward
Manual 82450 TM-25LP/TM-200LP Actuators

Figure 6-1. TM-200LP Exploded View

Woodward 19
TM-25LP/TM-200LP Actuators Manual 82450

Chapter 7.
Service Options

Product Service Options

If you are experiencing problems with the installation, or unsatisfactory
performance of a Woodward product, the following options are available:
 Consult the troubleshooting guide in the manual.
 Contact the manufacturer or packager of your system.
 Contact the Woodward Full Service Distributor serving your area.
 Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In many cases, your
problem can be resolved over the phone. If not, you can select which course
of action to pursue based on the available services listed in this chapter.

OEM and Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.

Woodward Business Partner Support: Woodward works with and supports a

global network of independent business partners whose mission is to serve the
users of Woodward controls, as described here:
 A Full Service Distributor has the primary responsibility for sales, service,
system integration solutions, technical desk support, and aftermarket
marketing of standard Woodward products within a specific geographic area
and market segment.
 An Authorized Independent Service Facility (AISF) provides authorized
service that includes repairs, repair parts, and warranty service on Woodward's
behalf. Service (not new unit sales) is an AISF's primary mission.
 A Recognized Engine Retrofitter (RER) is an independent company that
does retrofits and upgrades on reciprocating gas engines and dual-fuel
conversions, and can provide the full line of Woodward systems and
components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.
 A Recognized Turbine Retrofitter (RTR) is an independent company that
does both steam and gas turbine control retrofits and upgrades globally, and
can provide the full line of Woodward systems and components for the
retrofits and overhauls, long term service contracts, emergency repairs, etc.

A current list of Woodward Business Partners is available by searching on

"25225" or "worldwide directory" at:
www.woodward.com/searchpublications.aspx

20 Woodward
Manual 82450 TM-25LP/TM-200LP Actuators

Woodward Factory Servicing Options

The following factory options for servicing Woodward products are available
through your local Full-Service Distributor or the OEM or Packager of the
equipment system, based on the standard Woodward Product and Service
Warranty (5-01-1205) that is in effect at the time the product is originally shipped
from Woodward or a service is performed:
 Replacement/Exchange (24-hour service)
 Flat Rate Repair
 Flat Rate Remanufacture

Replacement/Exchange: Replacement/Exchange is a premium program

designed for the user who is in need of immediate service. It allows you to
request and receive a like-new replacement unit in minimum time (usually within
24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime. This is a flat-rate program and
includes the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205).

This option allows you to call your Full-Service Distributor in the event of an
unexpected outage, or in advance of a scheduled outage, to request a
replacement control unit. If the unit is available at the time of the call, it can
usually be shipped out within 24 hours. You replace your field control unit with
the like-new replacement and return the field unit to the Full-Service Distributor.

Charges for the Replacement/Exchange service are based on a flat rate plus
shipping expenses. You are invoiced the flat rate replacement/exchange charge
plus a core charge at the time the replacement unit is shipped. If the core (field
unit) is returned within 60 days, a credit for the core charge will be issued.

Flat Rate Repair: Flat Rate Repair is available for the majority of standard
products in the field. This program offers you repair service for your products with
the advantage of knowing in advance what the cost will be. All repair work carries
the standard Woodward service warranty (Woodward Product and Service
Warranty 5-01-1205) on replaced parts and labor.

Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat
Rate Repair option with the exception that the unit will be returned to you in “like-
new” condition and carry with it the full standard Woodward product warranty
(Woodward Product and Service Warranty 5-01-1205). This option is applicable
to mechanical products only.

Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair,
please contact your Full-Service Distributor in advance to obtain Return
Authorization and shipping instructions.

When shipping the item(s), attach a tag with the following information:
 return authorization number;
 name and location where the control is installed;
 name and phone number of contact person;
 complete Woodward part number(s) and serial number(s);
 description of the problem;
 instructions describing the desired type of repair.

Woodward 21
TM-25LP/TM-200LP Actuators Manual 82450

Packing a Control
Use the following materials when returning a complete control:
 protective caps on any connectors;
 antistatic protective bags on all electronic modules;
 packing materials that will not damage the surface of the unit;
 at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
 a packing carton with double walls;
 a strong tape around the outside of the carton for increased strength.

To prevent damage to electronic components caused by improper

handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.

Replacement Parts
When ordering replacement parts for controls, include the following information:
 the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
 the unit serial number, which is also on the nameplate.

Engineering Services
Woodward offers various Engineering Services for our products. For these services,
you can contact us by telephone, by email, or through the Woodward website.
 Technical Support
 Product Training
 Field Service

Technical Support is available from your equipment system supplier, your local Full-
Service Distributor, or from many of Woodward’s worldwide locations, depending
upon the product and application. This service can assist you with technical
questions or problem solving during the normal business hours of the Woodward
location you contact. Emergency assistance is also available during non-business
hours by phoning Woodward and stating the urgency of your problem.

Product Training is available as standard classes at many of our worldwide

locations. We also offer customized classes, which can be tailored to your needs
and can be held at one of our locations or at your site. This training, conducted
by experienced personnel, will assure that you will be able to maintain system
reliability and availability.

Field Service engineering on-site support is available, depending on the product

and location, from many of our worldwide locations or from one of our Full-
Service Distributors. The field engineers are experienced both on Woodward
products as well as on much of the non-Woodward equipment with which our
products interface.

For information on these services, please contact us via telephone, email us, or
use our website: www.woodward.com.

22 Woodward
 Manual 82450 TM-25LP/TM-200LP Actuators

How to Contact Woodward

For assistance, call one of the following Woodward facilities to obtain the address
and phone number of the facility nearest your location where you will be able to
get information and service.

Electrical Power Systems Engine Systems Turbine Systems

Facility---------------- Phone Number
Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727
Germany--------- +49 (0) 21 52 14 51
India --------------- +91 (129) 4097100
Japan -------------- +81 (43) 213-2191
Korea -------------- +82 (51) 636-7080
Poland--------------- +48 12 295 13 00
United States ---- +1 (970) 482-5811
Facility---------------- Phone Number
Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727
Germany---------- +49 (711) 78954-0
India --------------- +91 (129) 4097100
Japan -------------- +81 (43) 213-2191
Korea -------------- +82 (51) 636-7080
The Netherlands - +31 (23) 5661111
United States ---- +1 (970) 482-5811
Facility---------------- Phone Number
Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727
India --------------- +91 (129) 4097100
Japan -------------- +81 (43) 213-2191
Korea -------------- +82 (51) 636-7080
The Netherlands - +31 (23) 5661111
Poland--------------- +48 12 295 13 00
United States ---- +1 (970) 482-5811

You can also contact the Woodward Customer Service Department or consult our
worldwide directory (search on "25225" or "worldwide directory" at:
www.woodward.com/searchpublications.aspx) for the name of your nearest
Woodward distributor or service facility.

Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:

Your Name
Site Location
Phone Number
Fax Number
Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application
Control/Governor #1
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #2
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #3
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number

If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.

Woodward 23
TM-25LP/TM-200LP Actuators Manual 82450

24 Woodward
 Revision History

Changes in Revision P—
 Updated Compliance listing information
 Added Figure 2-2b to show dual coil version without position feedback
Declarations
 We appreciate your comments about the content of our publications.
Send comments to: icinfo@woodward.com

Please reference publication 82450P.

PO Box 1519, Fort Collins CO 80522-1519, USA

1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811  Fax +1 (970) 498-3058

Email and Website—www.woodward.com

Woodward has company-owned plants, subsidiaries, and branches,

as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.

2011/5/Colorado

Product and Service Warranty
I. Woodward Product Warranty
“Woodward Products” covered under this
WARRANTY are warranted to be free from defects
in materials and workmanship, when installed and
used in the manner for which they are intended, for
a period of 18 months from the date of shipment
from Woodward.
Products characterized by Woodward as having
been Remanufactured are covered by this
WARRANTY the same as newly manufactured
Woodward Products.
“Woodward Products" include: (i) products
manufactured by Woodward, as well as parts or
components of such products as are manufactured
exclusively for Woodward, by another party, to
Woodward specifications and drawings, and, (ii)
software produced by Woodward.
"Non-Woodward Products" not covered by this
Warranty, include: (i) products supplied by Woodward
manufactured by another party, e.g. printers, computers,
subsystems, etc., and, (ii) operating systems and other
software installed under license in Woodward Products
and Non-Woodward Products. Such Non-Woodward
Products are resold by Woodward in their original
form and are not modified by Woodward in any
way. Purchaser's remedy for defective Non-
Woodward Products shall be limited to the
applicable warranty of the manufacturer or
supplier.
II. Woodward Service Warranty
Woodward warrants its Services, such as repairs,
site supervision and installation services, including
WARRANTY Services, to be free from defects in
materials and workmanship for a period of 180
days from the date of service completion.
Woodward Products installed as part of a Service
provided, will be covered by this WARRANTY for a
period of 12 months from date of installation.
Following WARRANTY Services, the period of
warranty coverage for the unexpired portion of the
PRODUCT WARRANTY shall also apply.
Limitations
The sole obligation of Woodward hereunder is to
repair or replace, at its option, and without charge,
any Woodward Product which is defective, or, in
the case of defective Services, to reperform such
Services. Other than the
5-01-1205
foregoing repair, replacement, or reperformance,
the purchaser shall have no other remedy against
Woodward, and Woodward shall not be liable for
loss or damage arising from statute, law, strict
liability in tort, or negligence resulting from any
defect in a Woodward Product or in Woodward
Services, even though the defect was caused by
negligence, breach of warranty or strict liability in
tort of Woodward. In any event, Woodward shall not
be liable for incidental and/or consequential
damages including loss of income or profits, lost
sales, or economic loss.
Conditions
Such repair, replacement, or reperformance will be
effected at a location of Woodward’s choice
(including Woodward plants and service facilities,
Woodward subsidiary plants, or authorized service
facilities). In replacing any Woodward Product
pursuant to this WARRANTY, Woodward may
replace such Woodward Product with a modified or
improved product or component.
Purchasers claiming warranty service should
contact the service department of the Woodward
location or Woodward distributor where the item
was purchased.
Other Exclusions
This WARRANTY does NOT APPLY TO:
• Prototypes and test units. These units or the
transactional documentation will be marked as
experimental, prototype, test, beta, or other
similar marking. Woodward grants no warranty
to such products and/or software, either
expressed or implied, as the purpose of these
products is research and development testing.
• Woodward Products which, in Woodward’s
opinion, have been damaged by misuse,
negligence, or accident.
• Woodward Products on which disassembly
and/or repairs have been attempted without
prior authorization from Woodward.
• Any Woodward Product if any component part
has been repaired or replaced by any part not
manufactured or furnished by Woodward.
Apart from the obligations set forth herein (unless
otherwise agreed in writing) Woodward makes no
other warranty or condition, expressed or implied
(by statute, common law, trade usage or otherwise),
and specifically excludes the implied warranties of
merchantability and fitness for a particular purpose,
as well as all other warranties expressed or implied.
PO Box 1519
1000 East Drake Road
Fort Collins CO, USA
80522-1519
Ph: (1)(970) 482-5811
Fax: (1)(970) 498-3058
www.woodward.com

Plants, Subsidiaries,
Branch/Regional Offices
Australia
Brazil
China
Czech Republic
England
Germany
India
Japan
Korea
Mexico
Netherlands
New Zealand
Poland
Scotland
Singapore
United Arab Emirates
United States

Distributors & Service

Woodward has an
international network of
distributors and service
facilities. For your nearest
representative call
(1)(800) 835-5182 or see
the Worldwide Directory
on our web site (http://
www.woodward.com/
industrial/address.htm).

Corporate Headquarters
Rockford IL, USA
Ph: (1)(815) 877-7441

This document is distributed

for informational purposes
only. It is not to be construed
as creating or becoming part
of any Woodward Governor
Company contractual or
warranty obligation unless
expressly stated in a written
sales contract.

© Woodward Governor
Company, 1999
All Rights Reserved
For more information contact:

Effective: 15Jun2001/F
 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000215178 001 HIGH PRESSURE CONTROL VALVES OR26252

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 6R10615-1 HIGH PRESS CONTROL VALVE ASSY 1 EA

1 1 7R7979-1 STEAM CHEST COVER PLATE 1 EA

2 1 3R2352-1 GASKET 1 EA

3 1 1R8992-1 LOCKING NUT 5 EA

4 1 3R3168-33 VALVE STEM 1 EA

5 1 3R3168-44 VALVE STEM 1 EA

6 1 3R3168-56 VALVE STEM 1 EA

7 1 3R4287-17 PILOT VALVE AND STEM 1 EA

8 1 3R4287-2 PILOT VALVE AND STEM 1 EA

9 1 1R13552-1 LIFTING ROD 2 EA

10 1 1S304-10 HEXNUT 4 EA

11 1 1A13553-1 BUSHING 2 EA

12 1 3R2292-1 LIFT BAR 1 EA

13 1 1A6870-1 PACKING FOLLOWER 2 EA

14 1 1S316-10 SOC HD CAPSCREW 6 EA

15 1 1A6895-1 PACKING 6 EA

16 1 1R8998-1 LOCKING PLATE 5 EA

17 1 1R13529-1 VALVE 3 IN (SPECIAL) 1 EA

18 1 3R3876-200 VALVE SEAT 1 EA

19 1 1A6892-1 BRKT COVER 2 EA

20 1 1S320-4 CAPSCRW SOC HD 1 - 8 X 2-3/4 8 EA

21 1 1S318-8 CAPSCRW SOC HD 3/4-10 X 3 4 EA

22 1 1S320-8 CAPSCRW SOC HD 1 - 8 X 4 32 EA

23 1 1A7795-1 LOCKING TAB 2 EA

24 1 1A6940-1 BUSHING 2 EA

25 1 1A7796-1 PIN 2 EA

© 2011 DRESSER-RAND COMPANY 1000215178 Page 1 of 2

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000215178 001 HIGH PRESSURE CONTROL VALVES OR26252

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

26 1 1S568-6 CAPSCRW HEX HD 1/2 X 1-3/4 3 EA

27 1 1S304-5 HEX NUT 1/2 13 GR 2H 3 EA

28 1 1A9143-1 HEX NUT 5 EA

29 1 3R3876-202 VALVE SEAT 1 EA

30 1 3R3876-201 VALVE SEAT 1 EA

31 1 3R3876-199 VALVE SEAT 2 EA

32 1 1R13083-1 VALVE 3-1/2 (SPECIAL) 1 EA

33 1 1R13082-1 VALVE 3-1/4 (SPECIAL) 1 EA

34 1 3R3162-1 VALVE 4 IN 2 EA

35 1 1A7792-1 VALVE INSERT 2 EA

© 2011 DRESSER-RAND COMPANY 1000215178 Page 2 of 2

 8 7 6 5 4 3 2 1

10 KEEP CLEAN AND

10 FREE FROM PAINT.
KEEP CLEAN AND F
F
FREE FROM PAINT.
9
9 NOTE!
FREEZE ITEM 11 TO INSTALL, RATHER THAN PRESSING
14 INTO PLACE, DUE TO WEAK SECTION IN PIECE.
14 NOTE!
BUSHING TO BE CHECKED WITH A REAMER SO BORE
13 13 1.004
IS 1.003 AFTER INSTALLATION.

21

11 11
19
E E

15 15

26 27
20 22
1

D D

8
2
7

6
5
28 4
10 10
3.188 16
C
C
23 3 .688 23 2.250
12 1.438
2X .188 THRU
25 FOR PIN ON
ASSEMBLY

STEAM INLET
VALVE CHEST VIEWED
CL STEAM INLET
FROM GOVERNOR END.

.250 .250

.125 .063 .063 .063 .125

24 32 33 34
TYP. 5 17
35
B
PLACES
25 24 B

34 35

NOTE!
TACK WELD VALVE
SEATS IN PLACE.

A BOM - 1000215178 UNLESS OTHERWISE SPECIFIED: NAME DATE

A
DRAWN JDH 2011-06-27
SERIAL -BUR5955 ALL DIMENSIONS
29 18
STEAM TURBINE BUSINESS UNIT
ARE IN INCHES DWP 2011-07-11
30
CHECKED Burlington, Iowa, USA
REF - 6R7801
APPROVED DWP 2011-07-11
31 31 TOLERANCES
PER
SW MODEL: 6R10615
M:\DWG\BUR5955\
HIGH PRESSURE CONTROL
LAST SAVED BY: jhenman
DATE: Wednesday, July 06, 2011 3:29:17 PM
1S101 UNLESS
OTHERWISE
PROPRIETARY AND CONFIDENTIAL VALVE ASSEMBLY
SPECIFIED THIS DRAWING CONTAINS
MATERIAL CONFIDENTIAL AND TRADE DRAWING NUMBER REV

6R10615 0
-------- SECRET INFORMATION AND IS THE
PROPERTY OF DRESSER-RAND COMPANY

D
SIZE FINISH AND IS PROVIDED TO THE
RECEIVER IN CONFIDENCE.
-------- SCALE: 1:2 WEIGHT: 853.8 SHEET 1 OF 1
8 7 6 5 4 3 2 1
 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

OR28709 001 H.P. CONTROL LINKAGE OR28709

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 6R8960-1 H.P. CONTROL LINKAGE ASSEMBLY 1 EA

1 1 6R3263-1 ARM SHAFT WLD ASY 1 EA

2 1 3A1955-302 WASHER 4 EA

3 1 1A6901-1 DRAG LINK 4 EA

4 1 1A6885-1 BEARING 8 EA

5 1 1A6902-1 SHOULDER SCREW 4 EA

6 1 1A7050-2 BUSHING 1 EA

7 1 1A6902-4 HEX HEAD SHOULDER SCREW 4 EA

8 1 1A6887-1 BLOCK 1 EA

9 1 1A6896-2 U BOLT 3 EA

10 1 1S304-5 HEX NUT 1/2 13 GR 2H 6 EA

11 1 3A1955-225 WASHER 6 EA

12 1 3R3828-1 LIFTING BRACKET 1 EA

13 1 1A6893-1 BUSHING 2 EA

14 1 1A6939-1 ROD END 1 EA

15 1 1A6689-1 POWER CYLINDER 1 EA

16 1 1S317-23 CAPSCREW SOC HD 5/8-11 X 8-1/2 4 EA

17 1 1A6533-1 GREASE FITTING 12 EA

18 1 1A6998-1 SPRING 3 EA

19 1 3A2300-2 DRAG LINK 2 EA

20 1 1A6938-1 PIN 2 EA

21 1 1S568-10 CAPSCRW HEX HD 1/2 X 2-3/4 2 EA

22 1 1A6903-3 CYL SPACER 1 EA

23 1 1A6887-2 BLOCK 1 EA

24 1 3A1955-332 WASHER-BRASS 4 EA

25 1 1A5601-7 O RING PARKER 2 EA

© 2011 DRESSER-RAND COMPANY OR28709 Page 1 of 2

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

OR28709 001 H.P. CONTROL LINKAGE OR28709

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

26 1 1A6902-2 SHOULDER SCREW 4 EA

27 1 3A1679-1 CYLINDER GLAND 1 EA

28 1 1A4663-1 GLAND COVER 1 EA

29 1 1A5601-12 O RING PARKER 1 EA

30 1 1A5613-2 PARKER SEAL 2 EA

31 1 1A5614-1 WIPER RING PARKER 1 EA

32 1 1A4664-1 BACK-UP PLATE 1 EA

33 1 1S580-1 STUD 3/8-24 X 4 FINE 4 EA

34 1 1S256-3 HEX NUT 3/8-24 GR 8 FINE 4 EA

35 1 1A11258-1 U BOLT MOUNTING PLATE 3 EA

36 1 1A10235-1 MOUNTING PAD 1 EA

© 2011 DRESSER-RAND COMPANY OR28709 Page 2 of 2

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

OR26906 001 PILOT VALVE & GOVERNOR LINKAGE OR26906

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 6R6490-1 PILOT VALVE & GOV LINKAGE ASSY 1 EA

1 1 3R3889-7 GOVERNOR LEVER 2 EA

2 1 1S571-33 CAPSCRW HEX HD 3/4 X 7-3/4 IN 3 EA

3,40 1 1S304-8 HEXNUT 7 EA

4 1 1A2033-2 SPACER 3 EA

5 1 1S394-89 PIN - SST 1 EA

6 1 3A1955-304 WASHER 6 EA

7 1 1S447-3 COTTER PIN 1 X 1/8 10 EA

8 1 1S394-90 PIN - SST 1 EA

9 1 1A9608-5 CONN TUBE 1 EA

10 1 1S616-3 ROD END SPHERICAL 2 EA

11 1 1S256-7 HEX NUT 5/8-18 GR 8 FINE 2 EA

12 1 1S394-91 PIN - SST 1 EA

13 1 3A1955-305 WASHER 2 EA

14 1 1S447-7 COTTER PIN 2 X 1/8 2 EA

15 1 5R2130-1 LIFTING LEVER 1 EA

16 1 1S613-10 PIN 1 EA

17 1 3A1955-306 WASHER 2 EA

18 1 3A1957-293 SPACER 2 EA

19 1 1S566-6 CAPSCRW HEX HD 3/8 X 1-1/4 6 EA

20 1 1A7048-1 PIN 1 EA

21 1 1A6533-1 GREASE FITTING 1 EA

22 1 1S286-18 SETSCREW-CUP PT 3/8-24 RHTPI 1 EA

23 1 3A1979-6 ROD END 1 EA

24,33 1 1S256-3 HEX NUT 3/8-24 GR 8 FINE 3 EA

25 1 1A7050-1 BUSHING 2 EA

© 2011 DRESSER-RAND COMPANY OR26906 Page 1 of 2

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

OR26906 001 PILOT VALVE & GOVERNOR LINKAGE OR26906

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

26 1 3A1957-129 SPACER 2 EA

27 1 3A3330-117 DRAG LINK 2 EA

28 1 3A1957-193 SPACER 2 EA

29 1 1S296-5 SHOULDER SCREW 2 EA

31 1 7R10247-1 ACTUATOR BRKT & PILOT VLV HSG 1 EA

32 1 1S228-7 CAPSCRW SOC HD 3/8-16 X 1-1/2 4 EA

34 1 3R2298-1 PILOT VLV BUSHING 1 EA

35 1 1A4717-10 PILOT VALVE STEM 1 EA

36 1 3R2293-1 PILOT VALVE 1 EA

37 1 7R3793-1 PILOT VALVE HOUSING (MACH) 1 EA

38 1 1R6883-1 GASKET 1 EA

39 1 1S641-1 WASHER-SPECIAL O.D. 4 EA

40 1 1S318-5 CAPSCRW SOC HD 3/4 X 2 1/4 4 EA

41 1 3A1956-20 WASHER-STL 1 EA

42 1 1S251-5 MACH SCREW RD HD #10 X 3/8 4 EA

43 1 1S438-7 PIPE PLUG-ALLEN 1 4 EA

44 1 1U2288-7 COVER PLATE 1 EA

45 1 1A3138-1 FLEX BOOT SMALL 1 EA

46 1 3A3330-11 DRAG LINK 1 EA

47 1 1S394-110 PIN - SST 1 EA

48 1 3A1957-316 SPACER 2 EA

© 2011 DRESSER-RAND COMPANY OR26906 Page 2 of 2

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000177035 001 OIL CIRCUIT

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 4R7599-1 OIL CIRCUIT DIAGRAM 1 EA

1 1 7030203 PIPE 1/2 304 SST S40 SMLS 0 FT

2 1 7030204 PIPE 3/4 304 SST S40 SMLS 0 FT

3 1 7030205 PIPE 1 304 SST S 40 SMLS 0 FT

4 1 7030208 PIPE 2 304 SST S40 SMLS 0 FT

5 1 7030209 PIPE 3 304 SST S40 SMLS 0 FT

6 1 7030242 PIPE 4 304 SST S40 SMLS 0 FT

7 1 7030262 PIPE 6 304 SST SCH 40 SMLS 0 FT

8 1 1A5792-1 ELL 1/2 BW LR S40 90DEG 304SST 1 EA

9 1 1A5792-2 ELL 3/4 BW LR S40 90DEG 304SST 5 EA

10 1 1A5792-3 ELL 1 BW LR S40 90DEG 304SST 5 EA

11 1 1A5792-6 ELL 2 BW LR S40 90DEG 304SST 4 EA

12 1 1A5792-8 ELL 3 BW LR S40 90DEG 304SST 1 EA

13 1 1A5792-10 ELL 4 BW LR S40 90DEG 304SST 2 EA

14 1 1A7162-10 ELL 6 BW SR S40 90DEG 304SST 1 EA

15 1 1A8409-2 TEE 3/4 BW S40 304SST 3 EA

16 1 1A8409-3 TEE 1 BW S40 304SST 6 EA

17 1 1A8409-6 TEE 2 BW S40 304SST 1 EA

18 1 3A4288-5 FLEXIBLE HOSE 2 X 13 1 EA

19 1 3A4288-6 FLEXIBLE HOSE 4 X 16 1 EA

20 1 1A7171-8 ELL 3 BW S40 45DEG 304SST 2 EA

21 1 3A1993-30 FLANGE 2 SW 150# S40 304 1 EA

22 1 1A11128-2 HILCO OIL FILTER 1 EA

23 1 1A8411-1 REDUCER 3/4 X 1/2 BW S40 304SST 4 EA

24 1 1A8411-3 REDUCER 1 X 1/2 BW 304 S40 2 EA

25 1 1A8411-2 REDUCER 1 X 3/4 BW 304 S40 3 EA

© 2011 DRESSER-RAND COMPANY 1000177035 Page 1 of 3

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000177035 001 OIL CIRCUIT

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

26 1 1A8411-13 REDUCER 2 X 1 BW 304 S40 2 EA

27 1 1A8411-34 REDUCER 6 X 4 BW S40 1 EA

28 1 3A1993-14 FLANGE 3/4 WN S40 150# 304SST 6 EA

29 1 3A1950-22 GASKET 3/4 X 1/16 0 EA

30 1 1S657-6 CAPSCREW HEX HD 0 EA

31 1 1S662-7 LOCKWASHER SST 1/2 0 EA

32 1 1S655-5 HEX NUT 1/2 13 316 SST 0 EA

33 1 3A1993-15 FLANGE 1 WN S40 150# 304SST 18 EA

34 1 3A1950-19 GASKET 1 X 1/16 0 EA

35 1 1S657-7 CAPSCREW HEX HD 0 EA

36 1 3A1993-18 FLANGE 2 WN S40 150# 304SST 7 EA

37 1 3A1950-25 GASKET 2 X 1/16 0 EA

38 1 1S658-7 CAPSCREW HEX HD 0 EA

39 1 1S662-9 LOCKWASHER SST 5/8 0 EA

40 1 1S655-7 HEX NUT 5/8 11 316 SST 0 EA

41 1 3A1993-20 FLANGE 3 WN S40 150# 304SST 5 EA

42 1 3A1950-27 GASKET 3 X 1/16 0 EA

43 1 1S658-8 CAPSCREW HEX HD 0 EA

44 1 3A1993-22 FLANGE 4 WN S40 150# 304SST 4 EA

45 1 3A1950-31 GASKET 4 X 1/16 0 EA

46 1 3A1993-24 FLANGE 6 WM S40 150# 304SST 3 EA

47 1 3A1950-34 GASKET 0 EA

48 1 1S660-9 CAPSCREW HEX HEAD 0 EA

49 1 1S662-11 LOCKWASHER SST 3/4 0 EA

50 1 1S655-8 HEX NUT 0 EA

51 1 1A9814-1 SPECIAL FLANGE 304 SST 1 EA

© 2011 DRESSER-RAND COMPANY 1000177035 Page 2 of 3

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000177035 001 OIL CIRCUIT

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

52 1 1J8011-24 O RING 2 X 1-5/8 0 EA

53 1 1S327-7 CAPSCREW SOC HD 0 EA

54 1 3A0653-2 FLANGE 3/4 DIAMOND 304SST 4 EA

55 1 1J8011-19 O RING 0 EA

56 1 1S330-5 CAPSCREW SOC HD 0 EA

57 1 3A0653-3 FLANGE 1 DIAMOND 304SST 1 EA

58 1 1S327-5 CAPSCREW SOC HD 0 EA

59 1 1A6472-4 COUPLING 1/2 SCREWED 304 S80 2 EA

60 1 1A9813-2 SWIVEL ADAPTER SST CAT. #SS 6505-8-8 1 EA

61 1 1A9812-2 SWIVEL ADAPTER SST CAT. #SS 6505-8-10 1 EA

62 1 1S658-4 CAPSCREW COARSE THD. 5/8 0 EA

63 1 3A0652-3 FLANGE 2 SQUARE 304SST 1 EA

64 1 1J8011-28 O RING 3-1/8 X 2-3/4 0 EA

1 1A7162-8 ELL 4 BW SR S40 90DEG 304SST 1 EA

66 1 1A15719-2 SIGHT FLOW INDICATOR 1 EA

67 1 1A15719-3 SIGHT FLOW INDICATOR 1 EA

68 1 1A15719-4 SIGHT FLOW INDICATOR 1 EA

69 1 1A16026-2 ASHCROFT DIAL THERMOMETER 1 EA

70 1 1A15596-2 THERMOMETER WITH THERMOWELL, 0-250 2 EA

71 1 1A14620-3 SWING CHECK VALVE SST 1 EA

72 1 1A2653-4 PIPE PLUG ROUND 1/2 304 SST 0 EA

73 1 3A1993-34 FLANGE 4 SW S40 150# 304SST 1 EA

74 1 1A7162-4 ELL 2 BW SR S40 90DEG 304SST 1 EA

© 2011 DRESSER-RAND COMPANY 1000177035 Page 3 of 3

Quick-Start Guide
D102762X012
December 2009 DVC6000 Digital Valve Controllers
Fisherr FIELDVUEt DVC6000
Digital Valve Controllers
Using This Guide 1
Note:  This guide applies to DVC6010,
DVC6020, and DVC6030 digital valve controllers: Installation 2
Instrument Level HC, AD, PD AC
Device Type 03 07 Basic Setup and Calibration 3
Device Revision 2 2
Specifications and Related Documents 4
Hardware Revision 1 1
Firmware Revision 7, 9 7&9
Loop Schematics and Nameplates 5
DD Revision 1, 2 1

For details see page 1-1

Note
This guide provides installation and initial
setup and calibration information for
DVC6000 digital valve controllers. For
additional information, refer to the DVC6000
digital valve controllers instruction manual
(D102794X012), available from your
Emerson Process Management sales office,
or from our website at www.FIELDVUE.com.

The DVC6000 digital valve controller instruction manual

(D102794X012) can be found at www.FIELDVUE.com
http://www.documentation.emersonprocess.com/groups/public/documents/instruction_manuals/d102794x012.pdf

Refer to Related Documents on page 4-6 for other documents containing

information related to DVC6000 digital valve controllers

www.Fisher.com
 DVC6000 Digital Valve Controllers
Fast-Key Sequence for Instrument Level HC, AD, PD, and ODV
Fast-Key Coord- Fast-Key Coord-
Function/Variable Function/Variable
Sequence inates(1) Sequence inates(1)
Actuator Style 1-2-6-4 4-D Edit Feedback Connection 1-2-6-5 4-D
Alert Conditions 2-1 2-E End Point Control Enable(3) 1-2-2-2-5-1 6-C
1-2-3-6-2 1-2-3-6-5-1
Alert Record Full Enable 8-F Failure Group Enable 10-G
1-2-3-7-2 1-2-3-7-5-1
1-2-3-6-1 Firmware Revision 3-7-6 4-H
Alert Record Not Empty Alert Enable 8-F
1-2-3-7-1 Flash ROM Shutdown 1-2-3-1-3-5 11-C
Analog Input 3-1 2-F Hardware Revision 3-7-7 4-I
Analog Input Calibration 1-3-2-3 4-E 1-2-5-1-1 6-F
HART Tag
Analog Input Range Hi 1-2-5-3-1 6-H 3-7-1 4-H
Analog Input Range Lo 1-2-5-3-2 6-H HART Universal Revision 3-7-9 4-H
Analog Input Units 1-2-5-2-3 6-G Input Characterization 1-2-2-3 4-C
Auto Travel Calibration 1-3-1-1 4-E 1-2-4-1-2 8-G
Instrument Date and Time
Autocalibration in Progress Enable 1-2-4-2-2 8-H 1-2-5-8 5-F
3-6-1 5-G Instrument Level 3-7-8 4-H
Auxiliary Input
1-2-3-3-2-2 10-D Hot Key-1 1-A
Instrument Mode
Auxiliary Terminal Alert Enable 1-2-3-3-2-1 10-D 1-2-1-1 4-B
1-2-3-3-2-3 10-D Instrument Serial Number 1-2-5-1-6 6-F
Auxiliary Terminal Mode
1-2-5-7 5-F Instrument Time Invalid Enable 1-2-4-1-1 8-G
Burst Command 1-2-1-4-2 5-A 1-2-4-4-4 8-I
Integral Dead Zone
Burst Enable 1-2-1-4-1 5-A 1-2-2-1-2-1 9-A
Calibration in Progress Enab 1-2-4-2-1 8-H 1-2-4-4-3 8-I
Integral Limit
Calibration Location 1-2-5-9-2 6-H 1-2-2-1-2-2 9-B
1-2-3-6-4 Integrator Saturated Hi Enable 1-2-4-4-1 8-I
Clear Record 8-G
1-2-3-7-4 Integrator Saturated Lo Enable 1-2-4-4-2 8-I
1-2-1-4-3 5-A Lag Time(5) 1-2-2-5-3 6-C
Command 3 (Trending) Pressure
Hot Key-2 1-A Last Calibration Status 1-2-5-9-1 6-H
Control Mode 1-2-1-2 4-B Lead/Lag(3) 1-2-2-5-3 6-C
Critical NVM Shutdown 1-2-3-1-3-4 11-C Loop Current Validation(6) 1-2-3-3-3-9 9-E
1-2-3-5-1-2 10-F Low Power Write(6) 1-2-3-1-3-2 11-B
Cycle Count
3-6-5 4-H Manual Travel Calibration 1-3-1-2 4-E
Cycle Count Alert Enable 1-2-3-5-1-1 10-F 3-7-3 4-H
Manufacturer
Cycle Count Alert Point 1-2-3-5-1-3 10-F 1-2-6-1 4-D
Date 1-2-5-1-4 6-F Maximum Supply Pressure 1-2-5-6 5-F
Dead Band (Cycle Count / Travel Accum) 1-2-3-5-2-1 10-F Message 1-2-5-1-2 6-F
Define Custom Characteristic 1-2-2-4 4-C 1-2-3-6-5-3
Miscellaneous Group Enable 10-G
Descriptor 1-2-5-1-3 6-F 1-2-3-7-5-3
Device Description Information 3-8 2-G Model 3-7-4 4-H
Device ID 3-7-2 4-H Multi-Drop Alert Enable 1-2-4-3-2 8-H
Device Revision 3-7-5 4-H No Free Time Shutdown 1-2-3-1-3-6 11-C
Diagnostic Data Available Enable 1-2-4-2-4 8-H Non-Critical NVM Alert Enable 1-2-3-1-3-3 11-B
Diagnostic in Progress Enable 1-2-4-2-3 8-H 2-3-4 4-F
Number of Power Ups
1-2-3-6-3 3-6-9 5-H
Display Record 8-F
1-2-3-7-3 Offline/Failed Alert Enable 1-2-3-1-3-1 11-B
Drive Current Shutdown 1-2-3-1-1 9-D Partial Stroke Test 2-5 2-F
3-4 2-F Partial Stroke Test Enable(3) 1-2-7-1 3-D
Drive Signal
1-2-3-1-2-2 10-C Partial Stroke Test Pressure Limit(3) 1-2-3-6-1 8-F
Drive Signal Alert Enable 1-2-3-1-2-1 10-C Partial Stroke Test Start Point(3) 1-2-2-2-5-2 8-C
NOTE: Italicized Fast-Key Sequence indicates fast-key sequence is only applicable for instrument level ODV.
1. Coordinates are to help locate the item on the foldout menu tree.
3. Instrument level ODV only.
5. Instrument level HC, AD, and PD only.
6. Firmware 9 only.
continued on facing page

Unfold this sheet to see the Field Communicator Menu Tree

for Instrument Level HC, AD, PD, and ODV

i
 DVC6000 Digital Valve Controllers
Field Communicator Menu Tree for
Instrument Level HC, AD, PD, and ODV

Burst Mode
Hot Key 1-2-1-4 1 Burst Enable
1 Instrument Mode 2 Burst Command
2 Control Mode 3 Cmd 3(Trending)Press
3 Protection
4 Stabilize/Optimize Mode and Protection
1 Instrument Mode 1-2-2-1
Tuning
2 Control Mode 1 Travel Tuning
Basic Setup 1-2-1 3 Restart Ctrl Mode 2 Integral Settings
1-1 1 Setup Wizard 4 Burst Mode 3 Pressure Tuning
2 Performance Tuner 2
5 Protection
2 Stabilize/Optimize 4 Tvl/Press Control
1-2-2-2 1 Tvl/Press Select
2 Tvl/Press Cutoffs
Response Control 3 Travel Limits
Detailed Setup 1 Tuning 4 Pressure Control
1 Mode and Protection 1-2-2 2 Tvl/Press Control 5 End Pt Press Control 3
2 Response Control 3 Input Char
1-2 Dynamic Response
3 Alerts 4 Define Cust Char
4 Status 1-2-2-5 1 SP Rate Open
5 Dynamic Response
5 Instrument 2 SP Rate Close
6 Valve & Actuator 3 Lag Time 5
7 SIS/Partial Stroke 3 3 Lead/Lag 3

Alerts
Valve & Actuator 1 Electronics Alerts
1-2-7 Partial Stroke 2 Sensor Alerts
1 PST Enable 1 Manufacturer 1-2-3
1-2-6 3 Environment Alerts
2 PST Vars View/Edit 2 Valve Serial Num
3 3 Valve Style 4 Travel Alerts
4 Actuator Style 5 Travel History Alerts
5 Tvl Sensor Motion 6 SIS Alerts 3
1 Configure / Setup
6 Edit Feedback 6 Alert Record 6
1 Basic Setup
2 Detailed Setup Calibrate Connection
1-3 Status
3 Calibrate 1 Travel Calibration
2 Sensor Calibration 1-2-4 1 Instrument Time
1-3-1 Travel Calibration 2 Calibration and Diagnostics
3 Relay Adjust
1 AutoTvl Calib 3 Operational
4 Restore Factory
2 Man Tvl Calib 4 Integrator
4 Settings
1-3-2 Sensor Calibration
Online Device Diagnostics 1 Press Sensors
1 Configure / Setup 2 1 Alert Conditions 2 Tvl Sensor Adjust
2 Device Diagnostics 2 Status 3 Analog In Calib
3 Device Variables 3 Device Record General
4 Stroke Valve Instrument 1-2-5-1 1 HART Tag
5 Partial Stroke Test 3 1 General 2 Message
1-2-5
2 Units 3 Descriptor
3 Analog Input Range 4 Date
Device Variables Device Record
2-3 4 Relay Type 5 Valve Serial Num
1 Analog In 1 Temp Max
3 5 Zero Pwr Cond 6 Inst Serial Num
2 Tvl Set Pt 2 Temp Min
6 Max Supply Press 7 Polling Address
3 Travel 3 Run Time
4 Drive Signal 4 Num of Power Ups 7 Aux Term Mode
5 Pressures 8 Inst Date and Time
6 Variables 9 Calib Status and Loc
HART Applications 7 Device Information
1 Offline 8 DD Information
2 Online
1 3 Utility
4 HART Diagnostics Pressures
3-5 1 Pressure A Variables Units
2 Pressure B 1 Aux Input 1-2-5-2 1 Pressure Units
3 Pressure Diff 2 Temperature 2 Temp Units
4 Supply Press 2 3 Temp Max 3 Analog In Units
Notes: 3-6
4 Temp Min
5 Cycle Count Analog Input Range
1-1-1 indicates fast-key sequence to reach menu Device Information 6 Tvl Accum 1-2-5-3
1 Input Range Hi
1 HART Tag 7 Raw Tvl Input
1 This menu is available by pressing the left 2 Input Range Lo
2 Device ID 8 Run Time
arrow key from the previous menu. 3 Manufacturer 9 Num of Power Ups
3-7 4 Model 1-2-5-9 Calib Status and Loc
2 Not available in instrument level HC. 5 Device Rev 1 Last Calib Status
3 6 Firmware Rev 2 Calib Loc
Instrument level ODV only.
7 Hardware Rev
4 Instrument level HC only. 8 Inst Level
9 HART Univ Rev
5 Instrument level HC, AD, and PD only.
6 Fast key sequence for Alert Record with instrument level ODV is 1-2-3-7.
7 This menu item reads Power Starvation Alrt Enab in firmware 7.
8 Only available in firmware 9.

1 2 3 4 5 6

ii
 DVC6000 Digital Valve Controllers
1 Tvl Tuning Set
Travel Tuning 2 Tvl Prop Gain
1-2-2-1-1-1 3 Tvl Velocity Gain
1-2-2-1-1 1 Tvl Tuning Set
2 Tvl Integ Enable 4 Tvl MLFB Gain A
3 Tvl Integ Gain
4 Stabilize / Optimize
5 Peformance Tuner 2 Integral Settings
1-2-2-1-2
1 Integ DeadZ
2 Integ Limit
1-2-2-1-3 Pressure Tuning 1 Press Tuning Set
1 Press Tuning Set 1-2-2-1-3-1
2 Press Prop Gain
2 Press Integ Enab 3 Press MLFB Gain
3 Press Integ Gain

Tvl/Press Cutoffs
B
1-2-2-2-2 Processor Impaired Alerts
1 Tvl/Press Cut Hi
1 Offline/Failed Alrt Enab
1-2-2-2-3 Travel Limits 2 Tvl/Press Cut Lo
1-2-3-1-3 2 Low Power Write 7
1 Tvl Limit Hi
3 Non-Critical NVM Alrt Enab
2 Tvl Limit Lo
4 Critical NVM Shutdown
1-2-2-2-4 Pressure Control Drive Signal Alert 5 Flash ROM Shutdown
1-2-3-1-2
1 Press Range Hi 1 Drive Signal Alrt Enab 6 No Free Time Shutdown
End Pt Press Control 2 Press Range Lo 2 Drive Signal 7 Reference Voltage Shutdown
1-2-2-2-5
1 End Pt Control Enab
3 2 PST Start Pt C
3 Press Set Pt
Supply Press Lo Alrt
4 Press Sat Time 1-2-3-3-1 1 Supply Press Lo Alrt Enab
Electronics Alerts 2 Supply Press
2 3 Supply Press Lo Alrt Pt
1-2-3-1 1 Drive Current Shutdown
2 Drive Signal Alert Travel Deviation Alert
3 Processor Impaired Alerts HC 1-2-3-4-4 1 Tvl Dev Alrt Enab
1-2-3-3-1 Aux Terminal Alrt
2 Tvl Dev Alrt Pt
1 Aux Terminal Alrt Enab
Sensor Alerts HC, AD, PD 2 Aux Input 3 Tvl Dev Time
1-2-3-2 1 Tvl Sensor Shutdown 1-2-3-3-2 3 Aux Term Mode
Travel Limit Alerts
D
2 Temp Sensor Shutdown
3 Press Sensor Shutdown 1-2-3-4-5 1 Tvl Alrt Hi Hi Enab
2 Tvl Alrt Lo Lo Enab
3 Tvl Alrt Hi Hi Pt
Environment Alerts Travel Alerts
1-2-3-3 4 Tvl Alrt Lo Lo Pt
1 Supply Press Lo Alrt 2 1 Travel
2 Aux Terminal Alrt 2 Tvl Set Pt Travel Limit Hi/Lo Alerts
3 Loop Current Validation 3 Tvl Alrt DB 1-2-3-4-6 1 Tvl Alrt Hi Enab
Enable 8 1-2-3-4 4 Travel Deviation Alert 2 Tvl Alrt Lo Enab
5 Travel Limit Alerts 3 Tvl Alrt Hi Pt
Travel History Alerts 6 Travel Limit Hi/Lo Alerts 4 Tvl Alrt Lo Pt E
1-2-3-5 1 Cycle Count 7 Trave Limit / Cutoff Alerts
2 Cycle Count/Tvl Accum Deadband Travel Limit / Cutoff Alerts
3 Tvl Accum 1-2-3-4-7 1 Tvl Limit/Cutoff Hi Alrt Enab
Cycle Count 2 Tvl Limit/Cutoff Lo Alrt Enab
ODV SIS Alerts 1-2-3-5-1 1 Cycle Count Alrt Enab 3 Tvl/Press Cut Hi
1-2-3-6 1 PST Press Limit 2 Cycle Count 4 Tvl/Press Cut Lo
3 2 Press Dev Alrt Enab 3 Cycle Count Alrt Pt 5 Tvl Limit Hi
3 Press Dev Alrt Pt 1-2-3-5-2 6 Tvl Limit Lo
4 Press Dev Time 1 Deadband
F
HC, AD, PD Alert Record Tvl Accum
1-2-3-6 1 Alrt Record Not Empty Enab 1-2-3-5-3 1 Tvl Accum Alrt Enab
ODV 2 Alrt Record Full Enab 2 Tvl Accum
1-2-3-7 3 Display Record 3 Tvl Accum Alrt Pt
4 Clear Record
5 Alert Groups
HC, AD, PD
1-2-3-6-5 Alert Groups
Instrument Time 1 Failure Group Enab
1-2-4-1
1 Inst Time Invalid Enab
ODV
1-2-3-7-5
2 Valve Group Enab G
2 Inst Date and Time 3 Misc Group Enab

Calibration and Diagnostics

1-2-4-2 1 Cal in Progress Enab
2 Autocal in Progress Enab
3 Diag in Progress Enab
4 Diag Data Avail Enab

Operational
1-2-4-3
1 Press Ctrl Active Enab
H
2 Multi-Drop Enab

Integrator
1-2-4-4 1 Integrator Sat Hi Enab
2 Integrator Sat Lo Enab
3 Integ Limit
4 Integ DeadZ

7 8 9 10 11 12

iii
 DVC6000 Digital Valve Controllers
Fast-Key Sequence for Instrument Level HC, AD, PD, and ODV (continued)
Fast-Key Coord- Fast-Key Coord-
Function/Variable Function/Variable
Sequence inates(1) Sequence inates(1)
Partial Stroke Test Variables View/Edit(3) 1-2-7-2 3-D Temperature Sensor Shutdown 1-2-3-2-2 9-D
1-1-2 2-B Temperature Units 1-2-5-2-2 6-G
Performance Tuner(2)
1-2-2-1-1-5 8-A 3-3 2-F
Travel
Polling Address 1-2-5-1-7 6-F 1-2-3-4-1 10-E
Power Starvation Alert Enable(7) 1-2-3-1-3-2 11-B 1-2-3-4-7-3 12-F
Travel / Pressure Cutoff Hi
Pressure A 3-5-1 4-G 1-2-2-2-2-1 9-B
Pressure B 3-5-2 4-G 1-2-3-4-7-4 12-F
Travel / Pressure Cutoff Lo
Pressure Control Active Enable 1-2-4-3-1 8-H 1-2-2-2-2-2 9-B
Pressure Deviation Alert Enable (3) 1-2-3-6-2 8-F Travel / Pressure Select 1-2-2-2-1 6-B
Pressure Deviation Alert Point(3) 1-2-3-6-3 8-F 3-6-6 5-H
Travel Accumulator
Pressure Deviation Time(3) 1-2-3-6-4 8-F 1-2-3-5-3-2 10-F
Pressure Differential 3-5-3 4-G Travel Accumulator Alert Enable 1-2-3-5-3-1 10-F
Pressure Integral Control Enable 1-2-2-1-3-2 8-B Travel Accumulator Alert Point 1-2-3-5-3-3 10-F
Pressure Integral Gain 1-2-2-1-3-3 8-B Travel Alert Dead Band 1-2-3-4-3 10-E
Pressure MLFB Gain 1-2-2-1-3-1-3 10-B Travel Alert Hi Enable 1-2-3-4-6-1 12-E
Pressure Proportional Gain 1-2-2-1-3-1-2 10-B Travel Alert Hi Hi Enable 1-2-3-4-5-1 12-D
Pressure Range Hi 1-2-2-2-4-1 9-C Travel Alert Hi Hi Point 1-2-3-4-5-3 12-D
Pressure Range Lo 1-2-2-2-4-2 9-C Travel Alert Hi Point 1-2-3-4-6-3 12-E
Pressure Sat Time(3) 1-2-2-2-5-4 8-C Travel Alert Lo Enable 1-2-3-4-6-2 12-E
Pressure Sensor Shutdown(2) 1-2-3-2-3 9-D Travel Alert Lo Lo Enable 1-2-3-4-5-2 12-D
Pressure Sensors—Calibration 1-3-2-1 4-E Travel Alert Lo Lo Point 1-2-3-4-5-4 12-D
Pressure Set Point(3) 1-2-2-2-5-3 8-C Travel Alert Lo Point 1-2-3-4-6-4 12-E
Pressure Tuning Set 1-2-2-1-3-1-1 10-B Travel Deviation Alert Enable 1-2-3-4-4-1 12-D
Pressure Units 1-2-5-2-1 6-G Travel Deviation Alert Point 1-2-3-4-4-2 12-D
Hot Key-3 1-A Travel Deviation Time 1-2-3-4-4-3 12-D
Protection
1-2-1-5 4-B Travel Integral Control Enable 1-2-2-1-1-2 8-A
Raw Travel Input 3-6-7 5-H Travel Integral Gain 1-2-2-1-1-3 8-A
Reference Voltage Shutdown 1-2-3-1-3-7 11-C Travel Limit / Cutoff Hi Alert Enable 1-2-3-4-7-1 12-E
Relay Adjust 1-3-3 3-E Travel Limit / Cutoff Lo Alert Enable 1-2-3-4-7-2 12-E
Relay Type 1-2-5-4 5-F 1-2-3-4-7-5 12-F
Travel Limit Hi
Restart Control Mode 1-2-1-3 4-B 1-2-2-2-3-1 8-B
Restore Factory Settings 1-3-4 3-E 1-2-3-4-7-6 12-F
Travel Limit Lo
2-3-3 4-F 1-2-2-2-3-2 8-B
Run Time
3-6-8 5-H Travel MLFB Gain 1-2-2-1-1-1-4 10-A
Set Point Rate Close 1-2-2-5-2 6-C Travel Proportional Gain 1-2-2-1-1-1-2 10-A
Set Point Rate Open 1-2-2-5-1 6-C Travel Sensor Adjust 1-3-2-2 4-E
Setup Wizard 1-1-1 2-B Travel Sensor Motion 1-2-6-6 4-D
Hot Key-4 1-A Travel Sensor Shutdown 1-2-3-2-1 9-D
Stabilize/Optimize 1-1-2(4) 2-B 1-2-3-4-2 10-E
Travel Set Point
1-2-2-1-1-4 8-A 3-2 2-F
Status 2-2 2-E Travel Tuning Set 1-2-2-1-1-1-1 10-A
Stroke Valve 2-4 2-F Travel Velocity Gain 1-2-2-1-1-1-3 10-A
3-5-4 4-G 1-2-3-6-5-2
Supply Pressure(2) Valve Group Enable 10-G
1-2-3-3-3-2 10-C 1-2-3-7-5-2
Supply Pressure Lo Alert Enable 1-2-3-3-3-1 10-C 1-2-5-1-5 6-F
Valve Serial Number
Supply Pressure Lo Alert Point 1-2-3-3-3-3 10-D 1-2-6-2 4-D
Temperature 3-6-2 5-G Valve Style 1-2-6-3 4-D
3-6-3 5-G Zero Power Condition 1-2-5-5 5-F
Temperature Maximum
2-3-1 4-F
3-6-4 5-H
Temperature Minimum
2-3-2 4-F
NOTE: Italicized Fast-Key Sequence indicates fast-key sequence is applicable only for instrument level ODV.
1. Coordinates are to help locate the item on the foldout menu tree.
2. Not available in instrument level HC.
3. Instrument level ODV only.
4. Instrument level HC only.
5. Instrument level HC, AD, and PD only.6. Firmware 8 only.
7. Firmware 7 only.

v
DVC6000 Digital Valve Controllers
Fast-Key Sequence for Instrument Level AC
Fast-Key Fast-Key
Function/Variable Coordinates(1) Function/Variable Coordinates(1)
Sequence Sequence
Actuator Style 1-1-2-2-4 5-C 1-1-2-3-2-2 6-D
Pressure Proportional Gain
Analog Input Calibration 1-3-1 3-F 1-2-3-4-1-2 6-G
Analog Input Range Hi 1-2-2-2 4-E Pressure Range Hi 1-2-3-5-1 5-G
Analog Input Range Lo 1-2-2-3 4-E Pressure Range Lo 1-2-3-5-2 5-G
Analog Input Units 1-2-2-1 4-E 1-1-2-3-2-1 6-D
Pressure Tuning Set
1-1-2-3-4 5-D 1-2-3-4-1-1 6-G
Auto Travel Calibration 1-3-2 3-F 1-1-2-2-2 5-C
Pressure Units
1-1-1-3 5−D 1-2-2-4 4-E
Calibration Location 1-3-5 3-F Protection Hot Key-2 1-B
Date 1-2-1-4 4-D 1-1-1-2 4-B
Descriptor 1-2-1-3 4-D Relay Adjust 1-1-2-3-3 5-D
Device Description Revision 2-2 2-F 1-3-6 3-G
Device Identification 2-1-6 3-G Relay Type 1-2-4 3-D
Device Revision 2-1-2 3-G Restore Factory Settings 1-3-4 3-F
Feedback Connection 1-1-2-2-5 5-C Setup Wizard 1-1-1-1 4-B
Firmware Revision 2-1-3 3-G Travel Integral Gain 1-2-3-2-3 5-E
Hardware Revision 2-1-4 3-G Travel Integral Enable 1-2-3-2-2 5-E
HART Tag 1-2-1-1 4-D 1-1-2-3-1-4 6-D
Travel MLFB Gain
HART Universal Revision 2-1-1 3-G 1-2-3-2-1-4 6-E
Input Characterization 1-2-3-6 4-F 1-1-2-2-1 5-C
Travel / Pressure Select
Instrument Level 2-1-5 3-G 1-2-3-1 4-F
Hot Key-1 1-B 1-1-2-3-1-2 6-D
Instrument Mode Travel Proportional Gain
1-1-2-1 4-C 1-2-3-2-1-2 6-E
Instrument Serial Number 1-2-1-6 4-E Travel Sensor Adjust 1-3-7 3-G
Integral Dead Zone 1-2-3-3-1 5-F Travel Sensor Motion 1-1-2-2-6 5-C
Integral Limit 1-2-3-3-2 5-F 1-1-2-3-1-1 6-D
Travel Tuning Set
Manual Travel Calibration 1-3-3 3-F 1-2-3-2-1-1 6-E
Maximum Supply Pressure 1-1-2-2-3 5-C 1-1-2-3-1-3 6-D
Travel Velocity Gain
Message 1-2-1-2 4-D 1-2-3-2-1-3 6-E
Polling Address 1-2-1-7 4-E Valve Serial Number 1-2-1-5 4-D
Pressure Integral Control Enable 1-2-3-4-2 5-F Valve Style 1-1-2-2-7 5-C
Pressure Integral Gain 1-2-3-4-3 5-F Zero Power Condition 1-1-2-2-8 5-C
1-1-2-3-2-3 6-D
Pressure MLFB Gain
1-2-3-4-1-3 6-G
1. Coordinates are to help locate the item on the menu tree on the facing page.

vi
 DVC6000 Digital Valve Controllers
Field Communicator Menu Tree for A
Instrument Level AC

Hot Key
1 Instrument Mode
B
Auto Setup
2 Protection 1-1 Basic Setup 1 Setup Wizard
1-1-1
1 Auto Setup 2 Relay Adjust
2 Manual Setup 3 Auto Travel Calib
Press & Actuator
Manual Setup 1 Tvl/Press Select
1-1-2 1 Instrument Mode 2 Pressure Units
1-1-2-2 3 Max Supply Press
2 Press & Actuator
3 Tuning & Calib 4 Actuator Style
5 Feedback Conn C
6 Tvl Sensor Motion
7 Valve Style
8 Zero Pwr Cond
Tvl Tuning Set
1 Tvl Tuning Set
Tuning & Calib 1-1-2-3-1 2 Tvl Prop Gain
1-1-2-3 1 Tvl Tuning Set 3 Tvl Velocity Gain
2 Press Tuning Set 4 Tvl MLFB Gain
General 3 Relay Adjust
Detailed Setup 1 HART Tag 4 Auto Travel Calib
1-2 1 General
1-2-1
2 Message 1-1-2-3-2
Press Tuning Set
1 Press Tuning Set
D
2 Measured Var 3 Descriptor 2 Press Prop Gain
3 Response Control 4 Date 3 Press MLFB Gain
4 Relay Type 5 Valve Serial Num
6 Inst Serial Num
7 Polling Address

1
Setup
1 Basic Setup 1-2-2 Measured Var
2 Detailed Setup 1 Analog In Units
3 Calibrate 2 Input Range Hi
Tvl Tuning
Tvl Tuning E
3 Input Range Lo 1-2-3-2 1-2-3-2-1 1 Tvl Tuning Set
4 Pressure Units 1 Tvl Tuning Set 2 Tvl Prop Gain
2 Tvl Integ Enab 3 Tvl Velocity Gain
Response Control 3 Tvl Integ Gain 4 Tvl MLFB Gain
1-2-3 1 Tvl/Press Select
Online 2 Tvl Tuning Integral Settings
1-2-3-3
1 Setup 2 Display 3 Integral Settings 1 Integ DeadZ
2 Display 1 Device Information 4 Press Tuning 2 Integ Limit
2 DD Revision 5 Pressure Control
Calibrate
1 Analog In Calib
6 Input Char
1-2-3-4 Press Tuning F
2 Auto Travel Calib 1 Press Tuning Set
3 Man Travel Calib 2 Press Integ Enab
1-3 3 Press Integ Gain
4 Restore Factory Settings
5 Calib Loc
6 Relay Adjust 1-2-3-5 Pressure Control
7 Tvl Sensor Adjust 1 Press Range Hi
2 Press Range Lo
Device Information
1 HART Univ Rev Press Tuning Set
2-1
2 Device Rev 1 Press Tuning Set G
3 Firmware Rev 2 Press Prop Gain
1-2-3-4-1
4 Hardware Rev 3 Press MLFB Gain
5 Inst Level
6 Device ID
HART Applications
1 Offline
1 2 Online
3 Utility
H
Notes:

1-1-1 indicates fast-key sequence to reach menu

1 This menu is available by pressing the left
arrow key from the previous menu.

1 2 3 4 5 6

vii
 DVC6000 Digital Valve Controllers

THE FIELDVUE DVC6000 DIGITAL VALVE CONTROLLER IS A CORE COMPONENT OF THE PLANTWEBt
DIGITAL PLANT ARCHITECTURE. THE DIGITAL VALVE CONTROLLER POWERS PLANTWEB BY CAPTURING
AND DELIVERING VALVE DIAGNOSTIC DATA. COUPLED WITH VALVELINKt SOFTWARE, THE DVC6000
PROVIDES USERS WITH AN ACCURATE PICTURE OF VALVE PERFORMANCE, INCLUDING ACTUAL STEM
POSITION, INSTRUMENT INPUT SIGNAL AND PNEUMATIC PRESSURE TO THE ACTUATOR. USING THIS
INFORMATION, THE DIGITAL VALVE CONTROLLER DIAGNOSES NOT ONLY ITSELF, BUT ALSO THE VALVE
AND ACTUATOR TO WHICH IT IS MOUNTED.

FIELDVUE DVC6000 Digital Valve Controller

viii

11
W7957 / IL
Figure 1-1. FIELDVUE DVC6010 Digital Valve Controller
Mounted on a Fisher Sliding-Stem Valve Actuator
Note
Do not install, operate, or maintain a
DVC6000 digital valve controller
without being fully trained and
qualified in valve, actuator, and
accessory installation, operation, and
maintenance. To avoid personal injury
or property damage, it is important to
carefully read, understand, and follow
all contents of this quick start guide,
including all safety cautions and
warnings. If you have any questions
about these instructions, contact your
Emerson Process Management sales
office before proceeding.
December 2009
Using This Guide
W9418
Figure 1-2. Fisher Rotary Control Valve with FIELDVUE
DVC6020 Digital Valve Controller
Product Description
DVC6000 digital valve controllers (figure 1-1 and 1-2)
are communicating, microprocessor-based
current-to-pneumatic instruments. In addition to the
traditional function of converting an input current signal
to a pneumatic output pressure, the DVC6000 digital
valve controller communicate via HARTt protocol.
DVC6000 digital valve controllers are designed to
directly replace standard pneumatic and
electro-pneumatic valve mounted positioners.
Use of this Guide
This guide describes how to install, setup, and
calibrate DVC6000 digital valve controllers. Additional
information for installing, operating, and maintaining
the DVC6000 digital valve controller can be found in
the related documents listed on page 4-6. Refer to
table 1-1 for details on the capabilities of each
diagnostic tier.
This guide describes instrument setup and calibration
using a 475 Field Communicator. For information on
using the Field Communicator, see the 475 Field
Communicator User’s Manual, available from your
Emerson Process Management sales office.
1-1
 DVC6000 Digital Valve Controllers
Table 1-1. Instrument Level Capabilities
Diagnostic Level
Capability
AC HC AD PD ODV
Auto Calibration X X X X X
Custom Characterization X X X X X
Burst Communication X X X X

1 Alerts
Step Response, Drive Signal Test & Dynamic Error Band
X X
X
X
X
X
X
Advanced Diagnostics (Valve Signature) X X X
Performance Tuner X X X
Travel Control − Pressure Fallback X X X
Performance Diagnostics X X
Solenoid Valve Testing X X
Lead/Lag Input Filter(1) X
1. Refer to brochure part # D351146X012/D351146X412 for information on Fisher optimized digital valves for compressor antisurge applications.

menu, select Utility, Simulation, Fisher Controls, and

DVC6000.
Note Online Menu—To see the Field Communicator device
Menu sequences for the 475 Field description revision number from the Online menu,
Communicator are found at the connect the Field Communicator to an instrument
beginning of this guide. connected to a source supplying a 4-20 mA signal.
From the Online menu, select Device Variables and
These menu sequences are also
DD Information.
applicable to the 375 Field
Communicator.
Displaying the FIELDVUE Instrument
Firmware Revision Number
You can also setup and calibrate the instrument using
To view the instrument firmware revision, connect the
a personal computer and ValveLink software or AMSt
Field Communicator to an instrument connected to a
Suite: Intelligent Device Manager. For information on
source supplying a 4-20 mA signal. From the Online
using ValveLink software or AMS Device Manager
menu, select Device Variables, Device Information,
with a FIELDVUE instrument, refer to the appropriate
and Firmware Rev.
documentation or online help.

Displaying the Field Communicator

Device Description Revision Number Note
Device Description (DD) revision identifies the version Neither Emerson, Emerson Process
of the Fisher Device Description that resides in the Management, nor any of their affiliated
Field Communicator. The device description defines entities assume responsibility for the
how the Field Communicator interacts with the user selection, use, or maintenance of any
and instrument. You can display the DD revision from product. Responsibility for the
the Offline or Online menu. selection, use, and maintenance of any
product remains with the purchaser
Offline Menu—To see the Field Communicator and end user.
device description revision number from the Offline

1-2 December 2009


22-2
Installation
The DVC6000 can be used with either air or natural
gas as the supply medium. If using natural gas as the
pneumatic supply medium, natural gas will be used in
the pneumatic output connections of the DVC6000 to
any connected equipment. In normal operation the unit
will vent the supply medium into the surrounding
atmosphere unless it is remotely vented. When using
natural gas as the supply medium, in a non-hazardous
location in a confined area, remote venting of the unit
is required. Failure to do so could result in personal
injury, property damage, and area re-classification. For
hazardous locations remote venting of the unit may be
required, depending upon the area classification, and
as specified by the requirements of local, regional, and
federal codes, rules and regulations. Failure to do so
when necessary could result in personal injury,
property damage, and area re-classification.
Note
Gas Certified DVC6000 digital valve
controllers are FM and CSA Single Seal
approved for use with natural gas as
the supply medium.
WARNING
Avoid personal injury or property
damage from sudden release of
process pressure or bursting of parts.
Before proceeding with any
Installation procedures:
D Always wear protective clothing,
gloves, and eyewear to prevent
personal injury or property damage.
D Do not remove the actuator from
the valve while the valve is still
pressurized.
D Personal injury or property
damage may result from fire or
explosion if natural gas is used as the
supply medium and appropriate
preventive measures are not taken.
December 2009
Installation
Preventive measures may include, but
are not limited to, one or more of the
following: Remote venting of the unit,
re-evaluating the hazardous area
classification, ensuring adequate
ventilation, and the removal of any
ignition sources. For information on
remote venting of this controller, refer to
page 2-12. 2
D Disconnect any operating lines
providing air pressure, electric power, or
a control signal to the actuator. Be sure
the actuator cannot suddenly open or
close the valve.
D Use bypass valves or completely
shut off the process to isolate the valve
from process pressure. Relieve process
pressure from both sides of the valve.
D Vent the pneumatic actuator
loading pressure and relieve any
actuator spring precompression.
D Use lock-out procedures to be sure
that the above measures stay in effect
while you work on the equipment.
D Check with your process or safety
engineer for any additional measures
that must be taken to protect against
process media.
WARNING
To avoid static discharge from the
plastic cover, do not rub or clean the
cover with solvents. To do so could
result in an explosion. Clean with a
mild detergent and water only.
2-1
 DVC6000 Digital Valve Controllers
WARNING
This unit vents the supply medium
into the surrounding atmosphere.
When installing this unit in a
non-hazardous (non-classified)
location in a confined area, with
natural gas as the supply medium, you
must remotely vent this unit to a safe
2 location. Failure to do so could result
in personal injury or property damage
from fire or explosion, and area
re-classification.
When installing this unit in a
hazardous (classified) location remote
venting of the unit may be required,
depending upon the area
classification, and as specified by the
requirements of local, regional, and
federal codes, rules and regulations.
Failure to do so when necessary could
result in personal injury or property
damage from fire or explosion, and
area re-classification.
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
reduce case pressure buildup.
In addition to remote venting of the
unit, ensure that all caps and covers
are correctly installed. Failure to do so
could result in personal injury or
property damage from fire or
explosion, and area re-classification.
Special Instructions for “Safe Use” and
Installations in Hazardous Locations
Certain nameplates may carry more than one
approval, and each approval may have unique
installation/wiring requirements and/or conditions of
“safe use”. These special instructions for “safe use”
are in addition to, and may override, the standard
installation procedures. Special instructions are listed
by approval.
2-2
WARNING
Failure to follow these conditions of
“safe use” could result in personal
injury or property damage from fire or
explosion, or area re-classification.
CSA
Special Conditions of Safe Use
Intrinsically Safe, Explosion proof, Division 2,
Dust-Ignition proof
No special conditions for safe use.
Refer to table 4-3 for approval information, figure 5-1
for the CSA loop schematic, and figure 5-2 for the CSA
nameplate.
FM
Special Conditions of Safe Use
Intrinsically Safe, Explosion proof, Non-incendive,
Dust-Ignition proof
No special conditions for safe use.
Refer to table 4-3 for approval information, figure 5-3
for the FM loop schematic, and figure 5-4 for the FM
nameplate.
ATEX
Special Conditions for Safe Use
Intrinsically Safe, Dust
1. This apparatus can only be connected to an
intrinsically safe certified equipment and this
combination must be compatible as regards the
intrinsically safe rules.
2. The electrical parameters of this equipment must
not exceed any following values:
UOv 30 V; IO v226 mA; POv 1.4 W
3. Operating ambient temperature: −52_C or −40_C
to + 80_C
4. For the model with aluminum body: the apparatus
must not be submitted to frictions or mechanical
impacts.
Refer to table 4-5 for additional approval information,
and figure 5-5 for the the ATEX Intrinsically Safe, Dust
nameplate.
Flameproof, Dust
Operating ambient temperature: −52_C or −40_C to
+ 85_C
Refer to table 4-5 for additional approval information,
and figure 5-6 for the ATEX Flameproof, Dust
nameplate.
December 2009

Type n, Dust
Operating ambient temperature: −52_C or −40_C to
+ 80_C
Refer to table 4-5 for additional approval information,
and figure 5-7 for the ATEX Type n, Dust nameplate.
IECEx
Conditions of Certification
Intrinsically Safe, Flameproof, Type n
Ex ia / Ex d / Ex n
1. Warning: Electrostatic charge hazard. Do not rub
or clean with solvents. To do so could result in an
explosion.
EX d / Ex n
2. Do not open while energized.
Refer to table 4-6 for additional approval information,
and figure 5-9 for the IECEx nameplate.
NEPSI
Notes for Safe Use of the Certified Product
Intrinsically Safe, Dust and Flameproof, Dust
DVC6000 digital valve controllers (designated as
controller hereafter) have been proved to be in
conformity with the requirements specified in the
national standards GB3836.1-2000, GB3836.2-2000,
GB3836.4-2000, and GB12476.1-2000 through
inspections conducted by National Supervision and
Inspection Centre for Explosion Protection and Safety
of Instrumentation (NEPSI). The Ex markings for the
products are Ex d II CT5 (acetylene not included),
DIPA21T5 or Ex ia II CT5, DIPA21T5 respectively and
their Ex certificate numbers are GYJ04504 and
GYJ04505. When using the product , the user should
pay attention to the items stated below:
1. The specific product types of approved DVC6000
digital valve controllers this time are DVC6010,
DVC6020 and DVC6030.
2. The enclosure of the controller provides a
grounding terminal, and the user should install a
reliable grounding wire connected to it when mounting
and using the controller.
3. The controller’s cable entrance (1/2 NPT) must be
fitted with a cable entry device which is Ex-approved
through inspection of explosion protection, in
conformity with relevant standards of GB3836 and has
a corresponding rating of explosion protection.
4. The maximum operating ambient temperature
range of the controller is −40_C to +80_C.
December 2009
Installation
5. The principle of “Opening equipment’s cover is
allowed only after the power is off ” must be abided by
when using and maintaining the controller in the field.
6. The values for intrinsically safe parameters of the
controller (Intrinsically safe type) are as follow:
Ui = 30V, Ii = 226mA, Pi = 1.4W, Ci = 5nF, Li = 0.55mH
7. While the controller forms an intrinsically safe
explosion protection system together with a
corresponding associated equipment safety barrier,
the following requirements must be met: 2
Uo vUi , Io vIi , Po vPi , Co wCi + Cc , Lo wLi + Lc
Note
Where Cc and Lc represent distributing
capacitance and inductance of the
connecting cable respectively.
8. The safety barrier must be placed at safety
location, and the instruction manuals of both the
product and fitted safety barrier must be followed while
conducting system wiring and using the product; The
connecting cable should be a shield cable with the
area of core section being greater than 0.5mm2 and its
shield (or insulation screen) being grounded at a safe
location and insulated from the product enclosure; The
cable should be routed so that the electro-magnetic
interference can be eliminated as much as possible
and that the cable distributing parameters of
capacitance and inductance can be controlled within
0.06mF/1mH.
9. The user must not be allowed to replace the
internal electric components of the product and
change the condition of system wiring at will and on
his own.
10. The user must follow the relevant rules specified
by the product instruction manual, the “15th Section of
Electric Equipment Used in Explosive Gaseous
Environment: Electric Installation in Hazardous
Locations (except for coal mine)” of GB3836.15-2000
standard, the “Design Code for Electric Power
Installation in Explosive and Fire-hazardous
Environment” of GB50058-1992 standard, and the
“Safety Regulations against dust explosion” of
GB15577-1995 standard while performing installation,
operation, and maintenance for the product.
Refer to table 4-7 for additional approval information,
and figure 5-10 for the NEPSI approvals nameplate.
INMETRO
Special Conditions of Safe Use
Intrinsically Safe, Flameproof
Refer to table 4-8 and figures 5-11 and 5-12 for
approval information.
Contact your Emerson Process Management sales
office for additional safe use information.
2-3
 DVC6000 Digital Valve Controllers

CAP SCREW, FLANGED

MACHINE SCREW

SHIELD
ADJUSTMENT ARM
CONNECTOR ARM

CAP SCREW
PLAIN WASHER

29B1674-A / DOC

Figure 2-1. FIELDVUE DVC6010 Digital Valve Controller Mounted on Sliding-Stem Actuators with up to 2 Inches Travel

Mounting Guidelines mm (2 to 4 inch) travel. For actuators with greater than

Standard DVC6000 Digital Valve
Controllers
If ordered as part of a control valve assembly, the
factory mounts the digital valve controller on the
actuator, makes pneumatic connections to the
actuator, sets up, and calibrates the instrument. If you
purchased the digital valve controller separately, you
will need a mounting kit to mount the digital valve
controller on the actuator. See the instructions that
come with the mounting kit for detailed information on
mounting the digital valve controller to a specific
actuator model.
DVC6010 on Sliding-Stem Actuators Up
to 102 mm (4 Inches) of Travel
The DVC6010 digital valve controller mounts on
sliding-stem actuators with up to 102 mm (4 inch)
travel. Figure 2-1 shows a typical mounting on an
actuator with up to 51 mm (2 inch) travel. Figure 2-2
shows a typical mounting on actuators with 51 to 102
102 mm (4 inch) travel, see the guidelines for
mounting a DVC6020 digital valve controller.
Note
Do not use the stainless steel
DVC6010S in high vibration service
where the mounting bracket uses
standoffs (spacers) to mount to the
actuator.
Refer to the following guidelines when mounting on
sliding-stem actuators with up to 4 inches of travel.
1. Isolate the control valve from the process line
pressure and release pressure from both sides of the
valve body. Shut off all pressure lines to the actuator,
releasing all pressure from the actuator. Use lock-out
procedures to be sure that the above measures stay in
effect while you work on the equipment.
2. Attach the connector arm to the valve stem
connector.

2-4 December 2009

 Installation
HEX NUT
CAP SCREW, FLANGED

FEEDBACK ARM
EXTENSION, LOCK WASHER
BIAS SPRING

ADJUSTMENT ARM
SPACER

MACHINE SCREW, FLAT

HEAD
2
HEX NUT, FLANGED

MACHINE SCREW
LOCK WASHER
SHIELD
MACHINE SCREW,
LOCK WASHER, PLAIN WASHER
HEX NUT

CONNECTOR ARM

Figure 2-2. FIELDVUE DVC6010 Digital Valve Controller Mounted on Sliding-Stem Actuators with 2 to 4 Inches Travel

3. Attach the mounting bracket to the digital valve

controller housing.
4. If valve travel exceeds 2 inches, a feedback arm
extension is attached to the existing 2-inch feedback
arm. Remove the existing bias spring from the 2-inch
feedback arm. Attach the feedback arm extension to
the feedback arm as shown in figure 2-2.
5. Mount the digital valve controller on the actuator as
described in the mounting kit instructions.
6. Set the position of the feedback arm on the digital
valve controller to the no air position by inserting the
alignment pin through the hole on the feedback arm as
follows:
D For air-to-open actuators (i.e., the actuator
stem retracts into the actuator casing or cylinder as air
pressure to the casing or lower cylinder increases),
insert the alignment pin into the hole marked ‘‘A’’. For
this style actuator, the feedback arm rotates
counterclockwise, from A to B, as air pressure to the
casing or lower cylinder increases.
D For air-to-close actuators (i.e., the actuator
stem extends from the actuator casing or cylinder as
air pressure to the casing or upper cylinder increases),
insert the alignment pin into the hole marked ‘‘B’’. For
this style actuator, the feedback arm rotates clockwise,
from B to A, as air pressure to the casing or upper
cylinder increases.
Note
When performing the following steps,
ensure there is enough clearance
between the adjustment arm and the
feedback arm to prevent interference
with the bias spring.
7. Apply anti-seize to the pin of the adjustment arm.
As shown in figure 2-3, place the pin into the slot of the
feedback arm or feedback arm extension so that the
bias spring loads the pin against the side of the arm
with the valve travel markings.
8. Install the external lock washer on the adjustment
arm. Position the adjustment arm in the slot of the
connector arm and loosely install the flanged hex nut.
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 flanged hex nut.
10. Remove the alignment pin and store it in the
module base next to the I/P assembly.
11. After calibrating the instrument, attach the shield
with two machine screws.

December 2009 2-5

 DVC6000 Digital Valve Controllers

Note
Do not use the stainless steel
DVC6020S in high vibration service
where the mounting bracket uses
standoffs (spacers) to mount to the
actuator.
2
As shown in figure 2-4, two feedback arms are
SPRING RELAXED
available for the digital valve controller. Installations on
Fisher 1051 size 33 and 1052 size 20 and 33
FEEDBACK
ARM actuators use the short feedback arm [54 mm (2.13
BIAS SPRING
inches) from roller to pivot point]. Most other use the
long feedback arm. Make sure the correct feedback
arm is installed on the digital valve controller before
beginning the mounting procedure.
Refer to figure 2-4 for parts locations. Refer to the
following guidelines when mounting on rotary
ADJUSTMEN
actuators:
T BIAS
ARM PIN SPRING 1. Isolate the control valve from the process line
pressure and release pressure from both sides of the
SPRING UNDER TENSION OF
A7209-1
ADJUSTMENT ARM PIN
valve body. 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 a cam is not already installed on the actuator,
Figure 2-3. Locating Adjustment Arm Pin in Feedback Arm install the cam as described in the instructions
included with the mounting kit.
3. If a mounting plate is required, fasten the mounting
plate to the actuator.
DVC6020 on Sliding-Stem Actuators and
4. For applications that require remote venting, a
Rotary Actuators pipe-away bracket kit is available. Follow the
DVC6020 digital valve controllers use a cam (designed instructions included with the kit to replace the existing
for linear response) and roller as the feedback mounting bracket on the digital valve controller with
mechanism. Figure 2-4 shows the DVC6020 mounted the pipe-away bracket and to transfer the feedback
on rotary actuators. parts from the existing mounting bracket to the
pipe-away bracket.
5. Apply anti-seize to the arm assembly pin, as shown
in figure 2-5.
6. Mount the DVC6020 on the actuator as follows:
Note D If required, a mounting adaptor is included in the
All cams supplied with FIELDVUE mounting kit. Attach the adaptor to the actuator as
mounting kits are characterized to shown in figure 2-4. Then attach the digital valve
provide a linear response. controller assembly to the adaptor. The roller on the
digital valve controller feedback arm will contact the
actuator cam as it is being attached.

2-6 December 2009

 Installation

MACHINE SCREW
MOUNTING ADAPTOR
CAP SCREW, HEX SOCKET CAP SCREW,
HEX SOCKET

CAM
CAM
MACHINE SCREW 29B1672-A / DOC
29B2094-A / DOC

TYPICAL MOUNTING WITH SHORT FEEDBACK ARM TYPICAL MOUNTING WITH LONG FEEDBACK ARM
(FISHER 1052 SIZE 33 ACTUATOR SHOWN) (FISHER 1061 SIZE 30-68 ACTUATOR SHOWN)

Figure 2-4. FIELDVUE DVC6020 Digital Valve Controller Mounted on Rotary Actuators

MOUNTING
ADAPTER
Note
MOUNTING
BRACKET Due to NAMUR mounting limitations, do
BIAS SPRING
not use the stainless steel DVC6030S in
high vibration service.

ARM ASSEMBLY PIN

ARM ASSEMBLY
FEEDBACK
ARM ASSEMBLY
Figure 2-5. Locating Adjustment Arm Pin in Feedback Arm of a
FIELDVUE DVC6020 Digital Valve Controller
D If no mounting adaptor is required, attach the
digital valve controller assembly to the actuator or
mounting plate. The roller on the digital valve controller
feedback arm will contact the actuator cam as it is
being attached.
DVC6030 on Quarter-Turn Actuators
Figure 2-6 shows the DVC6030 digital valve controller
mounted on a quarter-turn actuator. Refer to figure 2-6
for parts locations. Refer to the following guidelines
when mounting on quarter-turn actuators:
1. Isolate the control valve from the process line
pressure and release pressure from both sides of the
valve body. Shut off all pressure lines to the 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, remove the existing hub from the
actuator shaft.
3. If a positioner plate is required, attach the
positioner plate to the actuator as described in the
mounting kit instructions.
4. If required, attach the spacer to the actuator shaft.
Refer to figures 2-7 and 2-8. The travel indicator
assembly can have a starting position of 7:30 or 10:30.
Determine the desired starting position then proceed
with the next step. Considering the top of the digital
valve controller as the 12 o’clock position, in the next
step attach the travel indicator, so that the pin is
positioned as follows:

December 2009 2-7

 DVC6000 Digital Valve Controllers
MOUNTING
BRACKET FEEDBACK ARM

TRAVEL INDICATOR PIN

2
29B1703-A / DOC
SPACER

TRAVEL INDICATOR

19B3879−A / DOC

Figure 2-6. Mounting a FIELDVUE DVC6030 Digital Valve Controller on a Rotary Actuator (Fisher 1032 Size 425A Shown)

STARTING POSITION OF TRAVEL

INDICATOR ASSEMBLY (DIGITAL
VALVE CONTROLLER OUTPUT A
AT 0 PSI. )
IN THIS POSITION, THE “B” HOLE
IN THE FEEDBACK ARM WILL BE
ALIGNED WITH THE REFERENCE
HOLE IN THE DIGITAL VALVE
CONTROLLERS HOUSING.

E0989 / DOC

DVC6030 FEEDBACK MOVEMENT OF TRAVEL

ARM MOVEMENT INDICATOR ASSEMBLY WITH
INCREASING PRESSURE FROM
OUTPUT A.

ACTUATOR SHAFT MOVEMENT

STARTING POSITION OF THE ACTUATOR TRAVEL

INDICATOR ASSEMBLY IF INCREASING PRESSURE
FROM OUTPUT A DRIVES THE INDICATOR
COUNTERCLOCKWISE (THE POTENTIOMETER
SHAFT WILL ROTATE CLOCKWISE AS VIEWED 19B3879-A / DOC-1
FROM THE BACK OF THE FIELDVUE INSTRUMENT)

NOTE: DVC6030 TRAVEL COUNTS (CLOCKWISE) = 3400  200

Figure 2-7. Explanation of FIELDVUE DVC6030 Travel Indicator Starting Position and Movement, if Clockwise Orientation is
Selected for “Travel Sensor Motion” in ValveLink Software or the Field Communicator

2-8 December 2009

 Installation

MOVEMENT OF TRAVEL E0989

INDICATOR ASSEMBLY WITH
INCREASING PRESSURE FROM
OUTPUT A. 2
DVC6030 FEEDBACK
ARM MOVEMENT

19B3879-A / DOC-2

STARTING POSITION OF
TRAVEL INDICATOR ASSEMBLY
(DIGITAL VALVE CONTROLLER
OUTPUT A AT 0 PSI).
IN THIS POSITION, THE “A” HOLE
IN THE FEEDBACK ARM WILL BE
ALIGNED WITH THE REFERENCE
HOLE IN THE DIGITAL VALVE
CONTROLLERS HOUSING.
NOTE: DVC6030 TRAVEL COUNTS (COUNTERCLOCKWISE) = 600  200
ACTUATOR SHAFT MOVEMENT
STARTING POSITION OF THE TRAVEL INDICATOR
ASSEMBLY IF INCREASING PRESSURE FROM
OUTPUT A DRIVES THE INDICATOR CLOCKWISE
THE POTENTIOMETER SHAFT WILL ROTATE
COUNTERCLOCKWISE AS VIEWED FROM THE
BACK OF THE FIELDVUE INSTRUMENT.

Figure 2-8. Explanation of FIELDVUE DVC6030 Travel Indicator Starting Position and Movement if Counterclockwise Orientation
is Selected for “Travel Sensor Motion” in ValveLink Software or the Field Communicator

D If increasing pressure from the digital valve

controller output A rotates the potentiometer shaft
HOLE A
clockwise (as viewed from the back of the HOLE B
instrument), mount the travel indicator assembly so
that the arrow is in the 10:30 position, as shown in
figure 2-7.

D If increasing pressure from the digital valve

controller output A rotates the potentiometer shaft
counterclockwise (as viewed from the back of the
instrument), mount the travel indicator assembly so
that the arrow is in the 7:30 position, as shown in
figure 2-8.
TRAVEL
INDICATOR PIN
FEEDBACK ARM
48B4164-B / DOC BIAS SPRING

Note
ValveLink software and the Field
Communicator use the convention of
clockwise (figure 2-7) and
counterclockwise (figure 2-8) when
viewing the potentiometer shaft from
the back of the FIELDVUE instrument.
Figure 2-9. Positioning Travel Indicator Pin in the Feedback Arm
(Viewed as if Looking from the FIELDVUE DVC6030
toward the Actuator)
5. Attach the travel indicator to the shaft connector or
spacer as described in the mounting kit instructions.
6. Attach the mounting bracket to the digital valve
controller.

December 2009 2-9

 DVC6000 Digital Valve Controllers
2
NOTE:
1 APPLY LUBRICANT
W8077-1 / IL
Figure 2-10. Mounting the Fisher 67CFR Regulator on a FIELDVUE DVC6000 Digital Valve Controller
7. Position the digital valve controller so that the pin
on the travel indicator, engages the slot in the
feedback arm and that the bias spring loads the pin as
shown in figure 2-9. Attach the digital valve controller
to the actuator or positioner plate.
8. If a travel indicator scale is included in the mounting
kit, attach the scale as described in the mounting kit
instructions.
Remote-Mount DVC6000 Instruments
Refer to the quick start guide supplement, Remote
Mount Installation Guidelines (D103421X012) or the
DVC6000 digital valve controller instruction manual
(D102794X012).
67CFR Filter Regulator
A 67CFR filter regulator, when used with the DVC6000
digital valve controller, can be mounted three ways.
Integral-Mounted Regulator
Refer to figure 2-10. Lubricate an O-ring and insert it in
the recess around the SUPPLY connection on the
digital valve controller. Attach the 67CFR filter
regulator to the side of the digital valve controller.
Thread a 1/4-inch socket-head pipe plug into the
unused outlet on the filter regulator. This is the
standard method of mounting the filter regulator.
2-10
FISHER
67CFR
CAP SCREWS
O-RING 1
SUPPLY CONNECTION
Yoke-Mounted Regulator
Mount the filter regulator with 2 cap screws to the
pre-drilled and tapped holes in the actuator yoke.
Thread a 1/4-inch socket-head pipe plug into the
unused outlet on the filter regulator. No O-ring is
required.
Casing-Mounted Regulator
Use the separate 67CFR filter regulator casing
mounting bracket provided with the filter regulator.
Attach the mounting bracket to the 67CFR and then
attach this assembly to the actuator casing. Thread a
1/4-inch socket-head pipe plug into the unused outlet
on the filter regulator. No O-ring is required.
Pressure Connections
Pressure connections are shown in figure 2-11. All
pressure connections on the digital valve controller are
1/4 NPT internal connections. Use 10 mm (3/8-inch)
tubing for all pressure connections. If remote venting is
required, refer to the vent subsection.
Note
Make pressure connections to the
digital valve controller using tubing
with at least 10 mm (0.375 inch)
diameter.
December 2009
 Installation
WARNING
Severe personal injury or property
LOOP CONNECTIONS damage may occur from an
TERMINAL BOX
uncontrolled process if the instrument
supply medium is not clean, dry,
1/2 NPT oil-free, and noncorrosive. While use
CONDUIT
CONNECTIONS and regular maintenance of a filter that
(BOTH SIDES)
removes particles larger than 40
micrometers in diameter will suffice in 2
OUTPUT A
CONNECTION
most applications, check with an
Emerson Process Management field
office and industry instrument air
quality standards for use with
SUPPLY
corrosive air or if you are unsure
CONNECTION about the amount of air filtration or
filter maintenance.

OUTPUT B
CONNECTION
Supply pressure must be clean, dry air that meets the
requirements of ISA Standard 7.0.01. A maximum 40
micrometer particle size in the air system is
acceptable. Further filtration down to 5 micrometer
W7963-1 / IL
particle size is recommended. Lubricant content is not
to exceed 1 ppm weight (w/w) or volume (v/v) basis.
Condensation in the air supply should be minimized.
Alternatively, natural gas may be used as the supply
pressure medium. Gas must be clean, dry, oil-free,
and noncorrosive. H2S content should not exceed 20
Figure 2-11. Pressure Connections
ppm.
If you are using a 67CFR filter regulator with standard
5 micrometer filter, connect the supply line to the 1/4
NPT IN connection and attach tubing from the output
Supply Connections connection on the filter regulator to the SUPPLY
connection on the instrument. If you are using an
integral mounted 67CFR filter regulator, connect the
supply to the IN connection on the regulator.
WARNING
Output Connection
To avoid personal injury and property
damage resulting from bursting of A factory mounted digital valve controller has its output
parts, do not exceed maximum supply piped to the supply connection on the actuator. If
pressure. mounting the digital valve controller in the field,
connect the 1/4 NPT digital valve controller output
connection to the pneumatic actuator input connection.

December 2009 2-11

 DVC6000 Digital Valve Controllers
2 Personal injury or property damage
W9131-1
Figure 2-12. FIELDVUE DVC6010 Digital Valve Controller
Mounted on Fisher 585C Piston Actuator
Single-Acting Actuators
When using a single-acting direct digital valve
controller (relay A or C) on a single-acting actuator,
connect OUTPUT A to the actuator pneumatic input.
When using a single-acting reverse digital valve
controller (relay B) on a single-acting actuator, connect
OUTPUT B to the actuator diaphragm casing.
Double-Acting Actuators
DVC6000 digital valve controllers on double-acting
actuators always use relay A. With no input current,
OUTPUT A is at 0 pressure and OUTPUT B is at full
supply pressure when the relay is properly adjusted.
To have the actuator stem extend from the cylinder
with increasing input signal, connect OUTPUT A to the
upper actuator cylinder connection. Connect OUTPUT
B to the lower cylinder connection. Figure 2-12 shows
the digital valve controller connected to a
double-acting piston actuator.
2-12
To have the actuator stem retract into the cylinder with
increasing input signal, connect OUTPUT A to the
lower actuator cylinder connection. Connect OUTPUT
B to the upper cylinder connection.
Vent
WARNING
can occur from cover failure due to
overpressure. Ensure that the housing
vent opening is open and free of
debris to prevent pressure buildup
under the cover.
WARNING
This unit vents the supply medium
into the surrounding atmosphere.
When installing this unit in a
non-hazardous (non-classified)
location in a confined area, with
natural gas as the supply medium, you
must remotely vent this unit to a safe
location. Failure to do so could result
in personal injury or property damage
from fire or explosion, and area
re-classification.
When installing this unit in a
hazardous (classified) location remote
venting of the unit may be required,
depending upon the area
classification, and as specified by the
requirements of local, regional, and
federal codes, rules and regulations.
Failure to do so when necessary could
result in personal injury or property
damage from fire or explosion, and
area re-classification.
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
reduce case pressure buildup.
In addition to remote venting of the
unit, ensure that all caps and covers
are correctly installed. Failure to do so
could result in personal injury or
property damage from fire or
explosion, and area re-classification.
The relay output constantly bleeds a small amount of
supply medium into the area under the cover. The vent
December 2009

openings 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 lines must be as
short as possible with a minimum number of bends
and elbows.
Wiring and Electrical Connections
WARNING
To avoid personal injury resulting
from electrical shock, do not exceed
maximum input voltage specified in
table 4-1 of this quick start guide, or
on the product nameplate. If the input
voltage specified differs, do not
exceed the lowest specified maximum
input voltage.
Personal injury or property damage
caused by fire or explosion may occur
if this connection is attempted in a
potentially explosive atmosphere or in
an area that has been classified as
hazardous. Confirm that area
classification and atmosphere
conditions permit the safe removal of
the terminal box cover before
proceeding.
WARNING
Select wiring and/or cable glands that
are rated for the environment of use
(such as hazardous area, ingress
protection and temperature). Failure to
use properly rated wiring and/or cable
glands can result in personal injury or
property damage from fire or
explosion.
Wiring connections must be in
accordance with local, regional, and
national codes for any given
hazardous area approval. Failure to
follow the local, regional, and national
codes could result in personal injury
or property damage from fire or
explosion
December 2009
Installation
SAFETY
TALK−
GROUND
TALK+
2
EARTH GROUND
LOOP+
39B3399-B Sheet 2
LOOP−
Figure 2-13. Loop Connections Terminal Box
4-20 mA Loop Connections
The digital valve controller is normally powered by a
control system output card. The use of shielded cable
will ensure proper operation in electrically noisy
environments.
Note
Connect the digital valve controller to a
4-20 mA current source for operation in
the point-to-point wiring mode. In the
point-to-point wiring mode, the digital
valve controller will not operate when
connected to a voltage source.
Wire the digital valve controller as follows, refer to
figure 2-13:
1. Remove the loop connections terminal box cap
(see figure 2-11).
2. Route the field wiring into the terminal box. When
applicable, install conduit using local and national
electrical codes which apply to the application.
3. Connect the control system output card positive
wire ‘‘current output’’ to the LOOP + screw terminal in
the terminal box. Connect the control system output
card negative (or return) wire to the LOOP − screw
terminal in the terminal box.
4. As shown in figure 2-13, two ground terminals are
available for connecting a safety ground, earth ground,
2-13
 DVC6000 Digital Valve Controllers
or drain wire. The safety ground is electrically identical
to the earth ground. Make connections to these
terminals following national and local codes and plant NON-HART BASED DCS
standards.
5. Replace and hand tighten the terminal box cap.
When the loop is ready for startup, apply power to the
I/O I/O
control system output card.

HART
2 WARNING FILTER

Personal injury or property damage,

caused by fire or explosion, can result 4-20 mA

from the discharge of static electricity. DIGITAL VALVE

CONTROLLER
Connect a 14 AWG (2.08 mm2) ground
strap between the digital valve
controller and earth ground when
Tx Tx
flammable or hazardous gases are VALVE

present. Refer to national and local

codes and standards for grounding A6188-1/IL

requirements.
To avoid static discharge from the Figure 2-14. HART Filter Application
plastic cover, do not rub or clean the
cover with solvents. Clean with a mild
detergent and water only.

is to effectively isolate the control system output from

HART Filter
Depending on the control system you are using, a
HART filter may be needed to allow HART
communication. The HART filter is a passive device
that is inserted in field wiring from the HART loop. The
filter is normally installed near the field wiring terminals
of the control system I/O (see figure 2-14). Its purpose
modulated HART communication signals and raise the
impedance of the control system to allow HART
communication. For more information on the
description and use of the HART filter, refer to the
appropriate separate HART filter instruction manual.
To determine if your system requires a filter contact
your Emerson Process Management sales office.

2-14 December 2009

 Installation

nInstallation Check List

Mounting
j Is the instrument correctly mounted on the actuator? If not, refer to appropriate
mounting procedure and see installation instructions provided with the mounting kit.

j Is the feedback linkage properly connected? If not, see installation instructions

provided with the mounting kit.
2
Pneumatic Connections and Air Supply

j Is the regulator correctly mounted? If not, perform one of the regulator mounting procedures on
page 2-10.

j Is the air supply connected and at proper pressure? If not, connect supply as described on page
2-11. Also see specifications on page 4-1.

j Is the instrument output connected to the actuator? If not, connect instrument output as
described on page 2-11.

Wiring and Electrical Connections

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

j Is the loop wiring properly connected to the LOOP + and − terminals in the terminal box? If not,
connect loop wiring as described on page 2-13.

j If necessary, is the HART filter installed on your system? To determine if a HART filter is necessary,
contact your Emerson Process Management sales office. For HART filter installation information,
refer to the appropriate HART instruction manual.

You are ready to perform Basic Setup and Calibration in the next section.

December 2009 2-15

 DVC6000 Digital Valve Controllers

2-16 December 2009

 Basic Setup and Calibration
FIELD
COMMUNICATOR
CONNECTIONS
CONTROL ROOM FIELD

HF340 HART FIELD INSTRUMENT 4-20 MA LOOP

FILTER CONNECTION CONNECTIONS
OR 0-24VDC

CONTROLLER
I/O − −
+ +
1

HART
COMMUNICATION
3
CONNECTION

NOTE:
1 NOT ALL CONTROL SYSTEMS REQUIRE A HART FILTER. IF NO HART FILTER IS PRESENT, CONNECT
FIELD COMMUNICATOR TO CONTROL SYSTEM OUTPUT TERMINALS.
2 SEE FIGURE 2-13 FOR TERMINAL BOX DETAILS.
38B6470-A / DOC
A6194−4 / IL

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

33-3
Connecting the Field Communicator Basic Setup (1-1)
to the Digital Valve Controller
The Field Communicator may be connected to the
WARNING
4-20 mA loop wiring or directly to the digital valve
Changes to the instrument setup may
controller (see figure 3-1).
cause changes in the output pressure
If the Field Communicator is connected directly to the or valve travel. Depending on the
digital valve controller, attach the clip-on wires application, these changes may upset
provided with the Field Communicator to the TALK process control, which may result in
terminals, or the LOOP + and − terminals, in the digital personal injury or property damage.
valve controller terminal box. The TALK terminals are
the same as the LOOP + and − terminals (see figure
2-13). Before beginning basic setup, be sure the instrument
is correctly mounted. Refer to the installation
instructions supplied with the mounting kit.

December 2009 3-1

 DVC6000 Digital Valve Controllers
From the DVC6000 DVC6000:
Online
Online menu, select 1'Configure / Setup
Configure / Setup 2 Device Diagnostics
3 Device Variables
WARNING
During calibration the valve will move
full stroke. To avoid personal injury
and property damage caused by the
release of pressure or process fluid,
provide some temporary means of
control for the process.

After completing the setup information, travel is

From the Configure / DVC6000: automatically calibrated. Follow the prompts on the
Setup menu, select Configure / Setup
3 Basic Setup.
1'Basic Setup
2 Detailed Setup
Field Communicator display. The calibration procedure
uses the valve and actuator stops as the 0% and
3 Calibrate 100% calibration points. For additional information,
refer to Auto Calibrate Travel in this section.
HOME When travel calibration is complete, you are asked if
you wish to adjust the relay (double-acting only).
Select yes to adjust the relay. For additional
From the Basic DVC6000: information, refer to Relay Adjustment in this section.
Basic Setup
Setup menu, 1'Setup Wizard
select Setup 2 Performance Tuner
Wizard and follow Non-Typical Actuators
the on-line If the actuator on which the instrument is mounted is
instructions not listed by the Setup Wizard, specify OTHER as the
HOME
actuator manufacturer or actuator type. You are then
prompted for setup parameters such as:
INSTRUMENT LEVEL
HC, AD, and PD D Actuator Style (spring & diaphragm, piston
double-acting without spring, piston single-acting with
Figure 3-2. Accessing the Setup Wizard on the spring, piston double-acting with spring)
Field Communicator
D Valve Style (rotary or sliding-stem)

D On Loss of Instrument Signal, Valve (opens

Connect a 4-20 mA current source to the instrument.
Connect the Field Communicator to the instrument
and turn it on. For information on connecting the Field
Communicator, see Connecting the Field
Communicator to the Digital Valve Controller.
Typical Actuators
The Setup Wizard determines the required setup
information based upon the actuator manufacturer and
model specified. Turn on the Field Communicator and
start the Setup Wizard by proceeding through the
menu sequence shown in figure 3-2 or enter the
fast-key sequence 1-1-1 on the keypad. Follow the
prompts on the Field Communicator display to setup
the instrument. If the actuator on which the instrument
is mounted is not listed by the Setup Wizard, specify
OTHER as the actuator manufacturer or actuator type
and refer to Non-Typical Actuators.
or closes) This identifies whether the valve is fully
open or fully closed when the input is 0%. If you are
unsure how to set this parameter, disconnect the
current source to the instrument. (With double-acting
and single-acting direct digital valve controllers,
disconnecting the current source is the same as
setting the output A pressure to zero. For single-acting
reverse digital valve controllers, disconnecting the
current source is the same as setting the output B
pressure to supply.)
D Feedback Connection (Rotary - All, SStem -
Standard, SStem - Roller). For rotary valves, enter
Rotary - All. For sliding-stem valves, if the feedback
linkage consists of a connector arm, adjustment arm,
and feedback arm (similar to figure 3-5), enter SStem -
Standard. If the feedback linkage consists of a roller
that follows a cam (similar to figure 3-3), enter SStem
- Roller.
D Travel Sensor Motion The Setup Wizard asks if
it can move the valve to determine travel sensor
motion. If you answer Yes, the instrument will stroke

3-2 December 2009

 Basic Setup and Calibration

ROLLER

STEM
CONNECTOR CAM 3

29B1665-A / DOC

Figure 3-3. Feedback Connection for Typical Long-Stroke Sliding-Stem Actuator (4 to 24 inches travel)

the valve the full travel span to determine travel Table 3-1. Factory Default Settings
sensor motion. If you answer No, then you must Setup Parameter Default Setting
specify the rotation for increasing air pressure: Analog Input Units mA
clockwise or counterclockwise. Determine rotation by Analog In Range High 20.0 mA
viewing the end of the travel sensor shaft. Analog In Range Low 4.0 mA
Control Mode Analog
Restart Control Mode Resume Last
Self-Test Shutdown All Failures Disabled
Set Point Filter Time Filter Off
Input Characteristic Linear
Travel Limit High 125%
Travel Limit Low −25%
WARNING Travel Cutoff High 99.5%
Travel Cutoff Low 0.5%
If you answer YES to the prompt for Minimum Opening Time 0 secs
permission to move the valve, the Minimum Closing Time 0 secs
instrument will move the valve Polling Address 0
through a significant portion of its Aux Terminal Mode Aux Input Alert
travel range. To avoid personal injury Command 3 Pressure
and property damage caused by the Double-acting actuators differential output pressure
release of pressure or process fluid, Single-acting actuators actuator pressure
provide some temporary means of
control for the process.

Note
Relay adjustment may be required
For instruments with relay A or C. If increasing air before the Setup Wizard can determine
pressure at output A causes the shaft to turn travel sensor motion. Follow the
clockwise, enter Clockwise. If it causes the shaft to prompts on the Field Communicator
turn counterclockwise, enter Cntrclockwise. display if relay adjustment is
necessary.
For instruments with relay B. If decreasing air
pressure at output B causes the shaft to turn
clockwise, enter Clockwise. If it causes the shaft to D Volume Booster The Setup Wizard asks if a
turn counterclockwise, enter Cntrclockwise. volume booster or quick release is present.

December 2009 3-3

 DVC6000 Digital Valve Controllers
D Tuning Set There are twelve tuning sets from
which to choose. Each tuning set provides preselected
values for the digital valve controller gain and rate
settings. Typically, tuning set B provides the slowest
response and M provides the fastest response. For
smaller actuators, use tuning set C or D. For larger
actuators, use tuning set F or G.
WARNING
3 Changes to the tuning set may cause
the valve/actuator assembly to stroke.
To avoid personal injury and property
damage caused by moving parts,
keep hands, tools, and other objects
away from the valve/actuator
assembly.
In addition, you can select User Adjusted or Expert,
which allows you to modify tuning of the digital valve
controller. With User Adjusted you can specify the
proportional gain. An algorithm in the Field
Communicator calculates the other gains. With Expert
you can specify not only the proportional gain but the
velocity and minor loop feedback gain as well.
Note
Use Expert tuning only if standard
tuning has not achieved the desired
results.
Stabilize/Optimize or Performance
Tuner may be used to achieve the
desired results more rapidly than
Expert tuning.
The tuning sets suggested by the Setup Wizard are
only recommended starting points. After you finish
setting up and calibrating the instrument, run the
Performance Tuner or use Stabilize/Optimize Tuning
to obtain optimum tuning.
Factory Defaults
During basic setup, the Setup Wizard will ask you if
you want to use factory defaults. If you select YES,
the Setup Wizard sets the setup parameters to the
3-4
values listed in table 3-1. (Yes is recommended for
initial setup). If you select NO, the setup parameters
listed in the table remain at their previous settings.
Relay Adjustment
The double-acting relay can be adjusted as part of the
Setup Wizard. The following is a brief description of
relay adjustment. For additional information, see the
Calibration section in the DVC6000 instruction manual.
Note
Relay B and C are not user-adjustable.
Double-Acting Relay (Relay A)
The double-acting relay is designated relay A. For
double-acting actuators, the valve must be near
mid-travel to properly adjust the relay. The Field
Communicator will automatically position the valve
when Relay Adjust is selected.
Rotate the adjustment disc, shown in figure 3-4, until
the value displayed on the Field Communicator is
between 50 and 70% of supply pressure. This
adjustment is very sensitive. Be sure to allow the
pressure reading to stabilize before making another
adjustment (stabilization may take up to 30 seconds or
more for larger actuators).
If the low bleed relay option has been ordered
stabilization may take approximately two minutes
longer than the standard relay.
Relay A may also adjusted for use in single-acting-
direct applications. Rotate the adjustment disc as
shown in figure 3-4 for single-acting direct operation.
Single-Acting Direct Relay (Relay C)
The single-acting direct relay is designated relay C,
and requires no adjustment.
Single-Acting Reverse Relay (Relay B)
The single-acting reverse relay is designated relay B.
Relay B is calibrated at the factory and requires no
further adjustment.
December 2009
 Basic Setup and Calibration
BLEED HOLES ARE
PLUGGED IN THE
LOW BLEED RELAY
OPTION

FOR SINGLE-ACTING DIRECT RELAYS:

ROTATE ADJUSTMENT DISC IN THIS
DIRECTION UNTIL IT CONTACTS THE
BEAM
FOR DOUBLE-ACTING RELAYS:
ROTATE ADJUSTMENT DISC IN
THIS DIRECTION TO DECREASE
OUTPUT PRESSURE

3
ADJUSTMENT DISC
FOR DOUBLE-ACTING RELAYS:
ROTATE ADJUSTMENT DISC IN
THIS DIRECTION TO INCREASE
OUTPUT PRESSURE

W9034

Figure 3-4. Relay A Adjustment (Shroud Removed for Clarity)

Auto Calibrate Travel

ACTUATOR
STEM TRAVEL SENSOR
WARNING SHAFT

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. FEEDBACK
ARM

The instrument is calibrated during the Setup Wizard.

Follow the prompts on the Field Communicator display
ADJUSTMENT ARM
to automatically calibrate instrument travel. The
calibration procedure uses the valve and actuator
stops as the 0% and 100% calibration points.
For additional calibration information, refer to the
DVC6000 instruction manual.
1. If the Feedback Connection is Sliding-Stem CONNECTOR ARM
Standard, the Field Communicator prompts you to A6536-1 / IL

select the method of crossover adjustment: manual,

last value, or default. Manual adjustment is
recommended for initial travel calibration.
2. When prompted by the Field Communicator, make
the crossover adjustment by adjusting the current
source until the feedback arm is 90° to the actuator
stem, as shown in figure 3-5.
3. The remainder of the auto-calibration procedure is
automatic. After completing auto travel calibration, the
Figure 3-5. Crossover Point
Field Communicator prompts you to place the
instrument In Service and verify that the travel
properly tracks the current source.
If the unit does not calibrate, refer to table 3-2 for error
messages and possible remedies.

December 2009 3-5

 DVC6000 Digital Valve Controllers
Error Message
Input current must exceed 3.8 mA for
calibration.
Place Out Of Service and ensure Calibrate
Protection is disabled before calib.
Calibration Aborted. An end point was not
reached.
3 Invalid travel value. Check mounting and
feedback arm adjustments, and inst supply
press. Then, repeat Auto Calib.
Aborting due to response code or device
status.
Table 3-2. Auto Calibrate Travel Error Messages
Possible Problem and Remedy
The analog input signal to the instrument must be greater than 3.8 mA. Adjust the current output from
the control system or the current source to provide at least 4.0 mA.
The Instrument Mode must be Out of Service and the Protection must be None before the instrument
can be calibrated.
The problem may be one or the other of the following:
1. The tuning set selected is too low and the valve does not reach an end point in the allotted time.
Press the Hot Key, select Stabilize/Optimize then Increase Response (selects next higher tuning set).
2. The tuning set selected is too high, valve operation is unstable and does not stay at an end point for
the allotted time. Press the Hot Key, select Stabilize/Optimize then Decrease Response (selects next
lower tuning set).
Verify proper mounting by referring to the appropriate mounting instructions.
Verify instrument supply pressure by referring to the specifications in the appropriate actuator instruction
manual.
Making the crossover adjustment with the valve positioned at either end of its travel will also cause this
message to appear.
The instrument may have been taken out of service by a primary master. Put the instrument into service
with the primary master or cycle the power off and on.

If after completing setup and calibration the valve

cycles or overshoots (unstable), or is unresponsive Stabilizing or Optimizing ( or 1-1-2)
(sluggish), you can improve operation by selecting Valve Response
either Performance Tuner or Stabilize/Optimize from
the Basic Setup menu.

Note
Stabilize/Optimize is only available
through the Basic Setup menu for
Performance Tuner (1-1-2) instrument level HC.

If after completing setup and calibration the valve

Note
The Performance Tuner is not
available for instrument level
AC or HC.
The Performance Tuner is used to optimize digital
valve controller tuning. It can be used on most
sliding-stem and rotary designs, including Fisher and
other manufacturers’ products. Moreover, because the
Performance Tuner can detect internal instabilities
before they become apparent in the travel response, it
can generally optimize tuning more effectively than
manual tuning. Typically, the Performance Tuner
takes 3 to 5 minutes to tune an instrument, although
tuning instruments mounted on larger actuators may
take longer.
Access the Performance Tuner by selecting
Performance Tuner from the Basic Setup menu.
Follow the prompts on the Field Communicator display
to optimize digital valve controller tuning.
seems slightly unstable or unresponsive, you can
improve operation by pressing the Hot Key and
selecting Stabilize/Optimize, or select
Stabilize/Optimize from the Basic Setup menu.
Stabilize/Optimize permits you to adjust valve
response by changing the digital valve controller
tuning.
If the valve is unstable, select Decrease Response to
stabilize valve operation. This selects the next lower
tuning set (e.g., F to E). If the valve response is
sluggish, select Increase Response to make the valve
more responsive. This selects the next higher tuning
set (e.g., F to G).
If after selecting Decrease Response or Increase
Response the valve travel overshoot is excessive you
can adjust the damping by selecting Decrease
Damping or Increase Damping. By selecting Decrease
Damping or Increase Damping the tuning set will
become Expert, and allow you to select a damping
value that is not represented in a predefined tuning
set. Select Decrease Damping to select a damping
value that allows more overshoot. Select Increase
Damping to select a damping value that will decrease
the overshoot.

3-6 December 2009

 Basic Setup and Calibration

nBasic Setup and Calibration Check List

j Ispage
basic setup complete? If not, perform Basic Setup procedure on
3-1.

j Does the final control element correctly respond to a setpoint change and is it
stable? If not, perform Stabilizing or Optimizing Valve Response on page
3-6.

Final control element is ready to be placed on line.

3

December 2009 3-7

 DVC6000 Digital Valve Controllers

3-8 December 2009

 Specifications and Related Documents
44-4
Table 4-1. Specifications
Available Configurations
Valve-Mounted Instrument
DVC6010: Sliding-stem applications
DVC6020: Rotary and long-stroke sliding-stem
applications
DVC6030: Quarter-turn rotary applications
Remote-Mounted Instrument(1)
DVC6005: Base unit for 2 inch pipestand or wall
mounting
DVC6015: Feedback unit for sliding-stem
applications
DVC6025: Feedback unit for rotary or long-stroke
sliding-stem applications
DVC6035: Feedback unit for quarter-turn rotary
applications
DVC6000 digital valve controllers can be mounted
on Fisher and other manufacturers rotary and
sliding-stem actuators.
Input Signal
Point-to-Point:
Analog Input Signal: 4-20 mA DC, nominal
Minimum Voltage Available at instrument terminals
must be 10.5 volts DC for analog control, 11 volts
DC for HART communication (see instrument
instruction manual for details)
Minimum Control Current: 4.0 mA
Minimum Current w/o Microprocessor Restart: 3.5
mA
Maximum Voltage: 30 volts DC
Overcurrent Protection: Input circuitry limits current
to prevent internal damage.
Reverse Polarity Protection: No damage occurs
from reversal of loop current.
Multi-drop:
Instrument Power: 11-30 volts DC at approximately
8 mA
Reverse Polarity Protection: No damage occurs
from reversal of loop current.
Output Signal
Pneumatic signal as required by the actuator, up to
full supply pressure.
Minimum Span: 0.4 bar (6 psig)
Maximum Span: 9.5 bar (140 psig)
Action: Double, Single direct, and Single reverse
−continued−
December 2009
Supply Pressure(2)
Recommended: 0.3 bar (5 psig) higher than
maximum actuator requirements, up to maximum
supply pressure
Maximum: 10.0 bar (145 psig) or maximum
pressure rating of the actuator, whichever is lower
Medium: Air or Natural Gas(3)
Air Quality: Supply pressure must be clean, dry air
that meets the requirements of ISA Standard
7.0.01. A maximum 40 micrometer particle size in
the air system is acceptable. Further filtration down
4
to 5 micrometer particle size is recommended.
Lubricant content is not to exceed 1 ppm weight
(w/w) or volume (v/v) basis. Condensation in the air
supply should be minimized
Natural Gas: Natural gas must be clean, dry,
oil-free, and noncorrosive. H2S content should not
exceed 20 ppm.
Steady-State Air Consumption(4)
Standard Relay: At 1.4 bar (20 psig) supply
pressure: Less than 0.38 normal m3/hr (14 scfh)
At 5.5 bar (80 psig) supply pressure: Less than 1.3
normal m3/hr (49 scfh)
Low Bleed Relay(5): At 1.4 bar (20 psig) supply
pressure: Average value 0.056 normal m3/hr
(2.1 scfh)
At 5.5 bar (80 psig) supply pressure: Average value
0.184 normal m3/hr (6.9 scfh)
Maximum Output Capacity(4)
At 1.4 bar (20 psig) supply pressure:
10.0 normal m3/hr (375 scfh)
At 5.5 bar (80 psig) supply pressure:
29.5 normal m3/hr (1100 scfh)
Failure Modes
Refer to figure 4-1
Independent Linearity(6)
±0.50% of output span
4-1
 DVC6000 Digital Valve Controllers
Table 4-1. Specifications (continued)
Electromagnetic Compatibility
Meets EN 61326-1 (First Edition)
Immunity—Industrial locations per Table 2 of the
EN 61326-1 standard. Performance is shown
in table 4-2 below
Emissions—Class A
ISM equipment rating: Group 1, Class A
Lightning and Surge Protection—The degree of
immunity to lightning is specified as Surge immunity
in table 4-2. For additional surge protection
commercially available transient protection devices
can be used.
4 Vibration Testing Method
Tested per ANSI/ISA-75.13.01 Section 5.3.5. A
resonant frequency search is performed on all three
axes. The instrument is subjected to the ISA
specified 1/2 hour endurance test at each major
resonance, plus an additional two million cycles.
Input Impedance
The input impedance of the DVC6000 active
electronic circuit is not purely resistive. For
comparison to resistive load specifications, an
equivalent impedance of 550 ohms may be used.
This value corresponds to 11V @ 20 mA.
Operating Ambient Temperature Limits(2)
−40 to 80_C (−40 to 176_F) for most approved
valve-mounted instruments
−60 to 125_C (−76 to 257_F) for remote-mounted
feedback unit.
−52 to 80_C (−62 to 176_F) for valve-mounted
instruments utilizing the Extreme Temperature
option (fluorosilicone elastomers)
Humidity Limits
0 to 100% condensing relative humidity with
minimal zero or span shifts
Electrical Classification
Hazardous Area:
CSA— Intrinsically Safe, Explosion proof, Division
2, Dust-Ignition proof
FM— Intrinsically Safe, Explosion proof,
Non-incendive, Dust-Ignition proof
ATEX— Intrinsically Safe, Flameproof, Type n
IECEx— Intrinsically Safe, Flameproof, Type n
NEPSI— Intrinsically Safe, Flameproof
−continued−
4-2
INMETRO — Intrinsically Safe, Flameproof
Refer to Special Instructions for “Safe Use” and
Installation in Hazardous Locations in Section 2,
tables 4-3, 4-4, 4-5, 4-6, 4-7, and 4-8 and Section 5
for specific approval information.
Pollution Degree 2, Overvoltage Category III per
ANSI/ISA-82.02.01 (IEC 61010-1 Mod).
Electrical Housing:
CSA—Type 4X, IP66
FM—NEMA 4X
ATEX—IP66
IECEx—NEMA 4X, IP66
NEPSI—IP66
Other Classifications/Certifications
TIIS— Japan
KISCO— Korea Industrial Safety Corp.
GOST−R— Russian GOST-R
FSETAN— Russian − Federal Service of
Technological, Ecological and Nuclear Inspectorate
Contact your Emerson Process Management sales
office for classification/certification specific
information
IEC 61010 Compliance Requirements
(Valve-Mounted Instruments only)
Power Source: The loop current must be derived
from a Separated Extra-Low Voltage (SELV) power
source
Environmental Conditions: Installation Category I
Connections
Supply Pressure: 1/4 NPT internal and integral
pad for mounting 67CFR regulator
Output Pressure: 1/4 NPT internal
Tubing: 3/8-inch metal, recommended
Vent (pipe-away): 3/8 NPT internal
Electrical: 1/2 NPT internal conduit connection
optional—M20 internal conduit connection, spring
clamp terminal connection(7)
Stem/Shaft Travel
Linear Actuators with rated travel between 6.35 mm
(0.25 inch) and 606 mm (23.375 inches)
Rotary Actuators with rated travel between 50
degrees and 180 degrees.
December 2009
 Specifications and Related Documents
Table 4-1. Specifications (continued)

Mounting (8) Options

Designed for direct actuator mounting or remote J Supply and output pressure gauges or J Tire
pipestand or wall mounting. Mounting the valves, J Integral mounted filter regulator,
instrument vertically, with the vent at the bottom of J Stainless steel housing, module base and
the assembly, or horizontally, with the vent pointing terminal box (valve-mounted instruments only)
down, is recommended to allow drainage of J Low bleed relay J In-line 10 micron air filter
moisture that may be introduced via the instrument J Safety Instrumented System (SIS) Solutions
air supply. J Safety Related Nuclear Applications

Declaration of SEP
Weight Fisher Controls International LLC declares this
product to be in compliance with Article 3 paragraph
Valve-Mounted Instruments
Aluminum: 3.5 kg (7.7 lbs)
3 of the Pressure Equipment Directive (PED) 97 /
23 / EC. It was designed and manufactured in
4
Stainless Steel: 7.7 kg (17 lbs) accordance with Sound Engineering Practice (SEP)
Remote-Mounted Instruments and cannot bear the CE marking related to PED
DVC6005 Base Unit: 4.1 kg (9 lbs) compliance.
DVC6015 Feedback Unit: 1.3 kg (2.9 lbs) However, the product may bear the CE marking to
DVC6025 Feedback Unit: 1.4 kg (3.1 lbs) indicate compliance with other applicable European
DVC6035 Feedback Unit: 0.9 kg (2.0 lbs) Community Directives.
NOTE: Specialized instrument terms are defined in ISA Standard 51.1 − Process Instrument Terminology.
1. 3-conductor shielded cable, 22 AWG minimum wire size, is required for connection between base unit and feedback unit. Pneumatic tubing between base unit output connection and actuator
has been tested to 15 meters (50 feet) maximum without performance degradation.
2. The pressure/temperature limits in this quick start guide and any applicable code or standard should not be exceeded.
3. Gas Certified DVC6000 digital valve controllers are FM and CSA Single Seal approved for use with natural gas as the supply medium.
4. Values at 1.4 bar (20 psig) based on a single-acting direct relay; values at 5.5 bar (80 psig) based on double-acting relay.
5. The low bleed relay is offered as standard relay for DVC6000 SIS tier, used for On/Off applications.
6. Typical value. Not applicable for travels less than 19 mm (0.75 inch) or for shaft rotation less than 60 degrees. Also not applicable for DVC6020 digital valve controllers in long-stroke
applications.
7. ATEX/IEC approvals only.
8. Do not use the DVC6010S or DVC6020S in high vibration service where the mounting bracket uses standoffs (spacers) to mount to the actuator. Due to NAMUR mounting limitations, do
not use the DVC6030S in high vibration service.

Table 4-2. EMC Summary Results—Immunity

Performance Criteria(1)
Port Phenomenon Basic Standard Test Level Point-to- Multi-drop
Point Mode Mode
Electrostatic discharge 4 kV contact
IEC 61000-4-2 A(2) A
(ESD) 8 kV air
80 to 1000 MHz @ 10V/m with 1 kHz AM at 80%
Enclosure Radiated EM field IEC 61000-4-3 1400 to 2000 MHz @ 3V/m with 1 kHz AM at 80% A A
2000 to 2700 MHz @ 1V/m with 1 kHz AM at 80%
Rated power frequency
IEC 61000-4-8 60 A/m at 50 Hz A A
magnetic field
Burst IEC 61000-4-4 1 kV A(2) A
I/O signal/control Surge IEC 61000-4-5 1 kV (line to ground only, each) A(2) A
Conducted RF IEC 61000-4-6 150 kHz to 80 MHz at 3 Vrms A A
1. A = No degradation during testing. B = Temporary degradation during testing, but is self-recovering.
2. Excluding auxiliary switch function, which meets Performance Criteria B.

December 2009 4-3

 DVC6000 Digital Valve Controllers

RELAY TYPE LOSS OF

A Single Acting Direct (Relay C)
Double Acting (Relay A)
Single Acting Reverse (Relay B)
LOSS OF POWER
Instrument goes to zero air
output at port A.
Instrument goes to full supply
air output at port B. A goes to
zero air output.
Instrument goes to full supply
air output at port B.
PNEUMATIC SUPPLY
Failure direction per
actuator fail mode.
Failure direction cannot
be determined.
Failure direction per
actuator fail mode.

W7963-1 / IL

4 Figure 4-1. FIELDVUE DVC6000 Digital Valve Controller Failure Modes

Table 4-3. Hazardous Area Classifications—CSA (Canada)

Certification Body Type Certification Obtained Entity Rating Temperature Code Enclosure Rating
Ex ia Intrinsically Safe Vmax = 30 VDC
Class I,II,III Division 1 GP A,B,C,D,E, F,G Imax = 226 mA Type 4X, IP66
T5(Tamb v 80_C)
per drawing GE42818 T5 Ci = 5 nF Single Seal Device
Natural Gas Approved Li = 0.55 mH
Explosion Proof
DVC60x0 Type 4X, IP66
Class I Division 1 GP B,C,D T6 --- T6(Tamb v 80_C)
CSA DVC60x0S Single Seal Device
Natural Gas Approved
(x = 1,2,3)
Class I Division 2 GP A,B,C,D T6
Class II Division 1 GP E,F,G T6
Type 4X, IP66
Class II Division 2 GP F,G T6 --- T6(Tamb v 80_C)
Single Seal Device
Class III
Natural Gas Approved

Table 4-4. Hazardous Area Classifications—FM (United States)

Certification Body Type Certification Obtained Entity Rating Temperature Code Enclosure Rating
Intrinsically Safe Vmax = 30 VDC
Class I,II,III Division 1 GP A,B,C,D, E,F,G Imax = 226 mA
per drawing GE42819 T5 Ci = 5 nF T5(Tamb v 80_C) NEMA 4X
Natural Gas Approved Li = 0.55 mH
Pi = 1.4 W
DVC60x0 Explosion Proof
FM DVC60x0S Class I Division 1 GP B,C,D T6 −−− T6(Tamb v 80_C) NEMA 4X
(x = 1,2,3) Natural Gas Approved
Class I Division 2 GP A,B,C,D T6
Class II Division 1 GP E,F,G T6
Class II Division 2 GP F,G T6 −−− T6(Tamb v 80_C) NEMA 4X
Class III
Natural Gas Approved

4-4 December 2009

 Specifications and Related Documents
Table 4-5. Hazardous Area Classifications—ATEX
Certificate Type Certification Obtained Entity Rating Temperature Code Enclosure Rating
II 1 G & D Ui = 30 VDC
Gas
Ii = 226 mA
Ex ia IIC T5/T6—Intrinsically Safe T5(Tamb v 80_C)
Ci = 5 nF IP66
Dust T6(Tamb v75_C)
Li = 0.55 mH
Ex iaD 20 T100_C (Tamb v 80_C)
Pi = 1.4 W
Ex iaD 20 T85_C (Tamb v 75_C)
II 2 G & D
Gas
DVC60x0 Ex d IIB+H2 T5/T6—Flameproof T5(Tamb v 85_C)
ATEX DVC60x0S −−− IP66
Dust T6(Tamb v75_C)
(x = 1,2,3) Ex tD A21 IP66 T90_C (Tamb v 85_C)
Ex tD A21 IP66 T80_C (Tamb v 75_C)
II 3 G & D
Gas
Ex nCL IIC T5/T6—Type n T5(Tamb v 80_C)
−−− IP66
Dust T6(Tamb v75_C)
Ex tD A22 IP66 T85_C (Tamb v 80_C)
Ex tD A22 IP66 T80_C (Tamb v 75_C)
4
Table 4-6. Hazardous Area Classifications—IECEx
Certificate Type Certification Obtained Entity Rating Temperature Code Enclosure Rating
Intrinsically Safe Ui = 30 VDC
Gas Ii = 226 mA
T5(Tamb v 80_C)
Ex ia IIC T5/T6 per drawing GE42990 Ci = 5 nF NEMA 4X, IP66
T6(Tamb v 75_C)
Li = 0.55 mH
Pi = 1.4 W
DVC60x0
IECEx DVC60x0S Flameproof T5(Tamb v 80_C)
(x = 1,2,3) Gas −−− NEMA 4X, IP66
T6(Tamb v 75_C)
Ex d IIB+H2 T5/T6
Type n
T5(Tamb v 80_C)
Gas −−− NEMA 4X, IP66
T6(Tamb v 75_C)
Ex nC IIC T5/T6

Table 4-7. Hazardous Area Classifications—NEPSI

Enclosure
Certificate Type Certification Obtained Entity Rating Temperature Code
Rating
Intrinsically Safe Ui = 30 V
Gas Ii = 226 mA
T5(Tamb v 80_C) NEMA 4X,
Ex ia IIC T5/T6 Ci = 5 nF
T6(Tamb v 75_C) IP66
Dust Li = 0.55 mH
DVC60x0 DIP A21 T5 Pi = 1.4 W
NEPSI
(x = 1,2,3) Flameproof
Gas
T5(Tamb v 80_C) NEMA 4X,
Ex d IIC T5/T6(1) −−−
Dust T6(Tamb v 75_C) IP66
DIP A21 T5
1. Except acetylene.

Table 4-8. Hazardous Area Classifications—INMETRO

Enclosure
Certificate Type Certification Obtained Entity Rating Temperature Code
Rating
Intrinsically Safe Ui = 30 V
BR-Ex ia IIC T5 Ii = 180 mA
Ci = 5 nF T5(Tamb v 80_C) Type 4X, IP66
DVC60x0 Li = 0.55 mH
INMETRO
(x = 1,2,3) Pi = 1.4 W
Flameproof
−−− T6(Tamb v 60_C) Type 4X, IP66
BR-Ex d IIB+H2 T6

December 2009 4-5

 DVC6000 Digital Valve Controllers
Related Documents
This section lists other documents containing
information related to DVC6000 digital valve
controllers. These documents include:
D Bulletin 62.1:DVC6000—Fisher FIELDVUE
DVC6000 Digital Valve Controllers (D102758X012)
D Bulletin 62.1:DVC6000(S1) − Fisher FIELDVUE
DVC6000, DVC6000 SIS, and DVC6000f Digital Valve
Controller Dimensions (D103308X012)
D Bulletin 62.1:DVC6000(S2)—Fisher FIELDVUE
DVC6000 Digital Valve Controller Custom
Configuration (D103418X012)
4 Firmware 7 Digital Valve Controllers (D103273X012)
D Fisher FIELDVUE DVC6000 Digital Valve
Controllers Instruction Manual (D102794X012)
D Supplement to Fisher FIELDVUE DVC6000
Digital Valve Controller Quick Start Guide— Remote
Mount Installation Guidelines (D103421X012)
D Supplement to HART Communicating Fisher
FIELDVUE Digital Valve Controller Instruction
Manuals— FIELDVUE Digital Valve Controller Split
Ranging (D103262X012)
D Supplement to HART Communicating Fisher
FIELDVUE Instrument Instruction Manuals—Using
FIELDVUE Instruments with the Smart HART Loop
Interface and Monitor (HIM) (D103263X012)
D Supplement to HART Communicating Fisher
FIELDVUE Instrument Instruction Manuals—Audio
Monitor for HART Communications (D103265X012)
D Supplement to HART Communicating Fisher
FIELDVUE Instrument Instruction Manuals—HART
Field Device Specification (D103266X012)
D Supplement to HART Communicating Fisher
FIELDVUE Instrument Instruction Manuals—Using the
HART Tri-Loopt HART-to-Analog Signal Converter
4-6
with FIELDVUE Digital Valve Controllers
(D103267X012)
D Supplement to Fisher FIELDVUE DVC5000
(obsolete product) and DVC6000 Digital Valve
Controller Instruction Manuals—Hot Swap Procedure
(D103264X012)
D Supplement to Fisher FIELDVUE DVC6000
Digital Valve Controllers Instruction
Manual—Lock-in-Last Strategy (D103261X012)
D Supplement to Fisher FIELDVUE DVC6000 and
DVC6000 SIS Digital Valve Controllers Instruction
Manuals—275 HART Communicator Menu Trees for
D Fisher HF340 Filter Instruction Manual
(D102796X012)
D 2530H1 HART Interchange Multiplexer
Instruction Manual (D102237X012)
D ValveLink Software Help or Documentation
All documents are available from your Emerson
Process Management sales office. Also visit our
website at www.FIELDVUE.com.
Educational Services
For information on available courses for DVC6000
digital valve controllers, as well as a variety of other
products, contact:
Emerson Process Management
Educational Services, Registration
P.O. Box 190; 301 S. 1st Ave.
Marshalltown, IA 50158−2823
Phone: 800−338−8158 or
Phone: 641−754−3771
FAX: 641−754−3431
e-mail: education@emersonprocess.com
December 2009
 Loop Schematics and Nameplates
55-
This section includes loop schematics required for
wiring of intrinsically safe installations. It also contains
the approvals nameplates. If you have any questions,
contact your Emerson Process Management sales
office.
HAZARDOUS LOCATION NON-HAZARDOUS LOCATION

CLASS I, DIV 1, GROUPS A,B,C,D

CLASS II, DIV 1, GROUPS E,F,G
CLASS III

DVC6010, DC6020, DVC6030

DVC6010S, DC6020S, DVC6030S
Vmax = 30 VDC
Imax = 226 mA CSA APPROVED BARRIER
Ci = 5 nF
Li = 0.55 mH
5
1 NOTE 1, 3, 4, 5, 6

1 NOTE 7

THE ENTITY CONCEPT ALLOWS INTERCONNECTION OF INTRINSICALLY SAFE APPARATUS TO ASSOCIATED APPARATUS NOT SPECIFICALLY EXAMINED
1
IN SUCH COMBINATION. THE CRITERIA FOR INTERCONNECTION IS THAT THE VOLTAGE (Vmax or Ui), THE CURRENT (Imax or Ii), AND THE POWER (Pmax
or Pi) OF THE INTRINSICALLY SAFE APPARATUS MUST BE EQUAL TO OR GREATER THAN THE VOLTAGE (Voc or Uo), AND THE CURRENT (Isc or Io), AND
THE POWER (Po) DEFINED BY THE ASSOCIATED APPARATUS. IN ADDITION, THE SUM OF THE MAX UNPROTECTED CAPACITANCE (Ci) AND MAX
UNPROTECTED INDUCTANCE (Li), INCLUDING THE INTERCONNECTING CABLING CAPACITANCE (Ccable) AND CABLING INDUCTANCE (Lcable) MUST BE
LESS THAN THE ALLOWABLE CAPACITANCE (Ca) AND INDUCTANCE (La) DEFINED BY THE ASSOCIATED APPARATUS. IF THE ABOVE CRITERIA IS MET,
THEN THE COMBINATION MAY BE CONNECTED.
Vmax or Ui  Voc or Uo Imax or Ii  Isc or Io Pmax or Pi  Po Ci + Ccable  Ca Li + Lcable  La

3 INSTALLATION MUST BE IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE (CEC) PART 1 AND ANSI/ISA RP12.6

4 MAXIMUM SAFE AREA VOLTAGE SHOULD NOT EXCEED 250 Vrms

5 RESISTANCE BETWEEN INTRINSICALLY SAFE GROUND AND EARTH GROUND MUST BE LESS THE ONE OHM

6 LOOPS MUST BE CONNECTED ACCORDING TO THE BARRIER MANUFACTURER’S INSTRUCTIONS.

7 IF HAND-HELD COMMUNICATOR OR MULTIPLEXER IS USED IT MUST BE CSA APPROVED WITH ENTITY PARAMETERS AND INSTALLED PER THE MANUFACTURER’S
CONTROL DRAWING
GE42818 sheets 2 and 8
Figure 5-1. CSA Schematic for FIELDVUE DVC6010, DVC6020, and DVC6030

DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

LABEL FOR NATURAL GAS CERTIFIED TERMINAL BOX

Figure 5-2. CSA Nameplates for FIELDVUE DVC6010, DVC6020, and DVC6030

December 2009 5-1

 DVC6000 Digital Valve Controllers
HAZARDOUS LOCATION NON-HAZARDOUS LOCATION

I.S. CLASS I,II,III, DIV 1, GROUPS A,B,C,D,E,F,G

N.I. CLASS I, DIV 2, GROUPS A,B,C,D

DVC6010, DC6020, DVC6030

DVC6010S, DC6020S, DVC6030S
Vmax = 30 VDC
Imax = 226 mA
FM APPROVED BARRIER
Ci = 5 nF
Li = 0.55 mH
Pi = 1.4
1 NOTE 1, 3, 4, 5, 6

1 NOTE 7

5
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 (Vmax or Ui), THE CURRENT (Imax or Ii), AND THE POWER (Pmax or Pi) OF THE
INTRINSICALLY SAFE APPARATUS MUST BE EQUAL TO OR GREATER THAN THE VOLTAGE (Voc or Uo), AND THE CURRENT (Isc or Io), AND THE POWER (Po)
DEFINED BY THE ASSOCIATED APPARATUS. IN ADDITION, THE SUM OF THE MAX UNPROTECTED CAPACITANCE (Ci) AND MAX UNPROTECTED INDUCTANCE (Li),
INCLUDING THE INTERCONNECTING CABLING CAPACITANCE (Ccable) AND CABLING INDUCTANCE (Lcable) MUST BE LESS THAN THE ALLOWABLE CAPACITANCE
(Ca) AND INDUCTANCE (La) DEFINED BY THE ASSOCIATED APPARATUS. IF THE ABOVE CRITERIA IS MET, THEN THE COMBINATION MAY BE CONNECTED.
Vmax or Ui  Voc or Uo Imax or Ii  Isc or Io Pmax or Pi  Po Ci + Ccable  Ca Li + Lcable  La

3 INSTALLATION MUST BE IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE (NEC) NFPA70 AND ANSI/ISA RP12.6.01

4 MAXIMUM SAFE AREA VOLTAGE SHOULD NOT EXCEED 250 Vrms.

5 RESISTANCE BETWEEN INTRINSICALLY SAFE GROUND AND EARTH GROUND MUST BE LESS THE ONE OHM

6 LOOPS MUST BE CONNECTED ACCORDING TO THE BARRIER MANUFACTURER’S INSTRUCTION

7 IF HAND-HELD COMMUNICATOR OR MULTIPLEXER IS USED IT MUST BE FM APPROVED WITH ENTITY PARAMETERS AND INSTALLED PER THE MANUFACTURER’S
CONTROL DRAWING

GE42819 sheets 2 and 8

Figure 5-3. FM Schematic for FIELDVUE DVC6010, DVC6020, and DVC6030

DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

LABEL FOR NATURAL GAS

CERTIFIED TERMINAL BOX

Figure 5-4. FM Nameplates for FIELDVUE DVC6010, DVC6020, and DVC6030

5-2 December 2009

 Loop Schematics and Nameplates

DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

Figure 5-5. ATEX Nameplate; Intrinsically Safe, Dust-Tight

DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

Figure 5-6. ATEX Nameplate; Flameproof, Dust-Tight

DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

Figure 5-7. ATEX Nameplate; Type n, Dust-Tight

December 2009 5-3

 DVC6000 Digital Valve Controllers
HAZARDOUS LOCATION NON-HAZARDOUS LOCATION

ZONE 0, Ex ia IIC

DVC6010, DC6020, DVC6030

DVC6010S, DC6020S, DVC6030S
Vmax = 30 VDC
Imax = 226 mA IECEx APPROVED BARRIER
Ci = 5 nF
Li = 0.55 mH
Pi = 1.4

1 NOTE 1, 3, 4

1 NOTE 5

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 (Vmax or Ui), THE CURRENT (Imax or Ii), AND THE POWER (Pmax or Pi) OF THE
INTRINSICALLY SAFE APPARATUS MUST BE EQUAL TO OR GREATER THAN THE VOLTAGE (Voc OR Uo), AND THE CURRENT (Isc or Io), AND THE POWER (Po)
DEFINED BY THE ASSOCIATED APPARATUS. IN ADDITION, THE SUM OF THE MAX UNPROTECTED CAPACITANCE (Ci) AND MAX UNPROTECTED INDUCTANCE (Li),
INCLUDING THE INTERCONNECTING CABLING CAPACITANCE (Ccable) AND CABLING INDUCTANCE (Lcable) MUST BE LESS THAN THE ALLOWABLE CAPACITANCE
(Ca) AND INDUCTANCE (La) DEFINED BY THE ASSOCIATED APPARATUS. IF THE ABOVE CRITERIA IS MET, THEN THE COMBINATION MAY BE CONNECTED.
Vmax or Ui  Voc or Uo Imax or Ii  Isc or Io Pmax or Pi  Po Ci + Ccable  Ca Li + Lcable  La

3 INSTALLATION MUST BE IN ACCORDANCE WITH THE NATIONAL WIRING PRACTICES OF THE COUNTRY IN USE

4 LOOPS MUST BE CONNECTED ACCORDING TO THE BARRIER MANUFACTURER’S INSTRUCTIONS

5 IF HAND-HELD COMMUNICATOR OR MULTIPLEXER IS USED IT MUST BE IECEx APPROVED WITH ENTITY PARAMETERS AND INSTALLED PER THE MANUFACTURERS
CONTROL DRAWING
GE42990
Sheet 2 and 8 of 8
Figure 5-8. IECEx Schematic for FIELDVUE DVC6020, DVC6020, and DVC6030

DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

Figure 5-9. IECEx Nameplate

5-4 December 2009

 Loop Schematics and Nameplates

DVC6010, DVC6020, AND DVC6030

Figure 5-10. NEPSI Nameplate

DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

Figure 5-11. INMETRO Nameplate; Intrinsically Safe

DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

Figure 5-12. INMETRO Nameplate; Flameproof

December 2009 5-5

 DVC6000 Digital Valve Controllers

5 W8373
FIELDVUE DVC6005 BASE UNIT
AND DVC6025 FEEDBACK UNIT MOUNTED
ON A ROTARY CONTROL VALVE / ACTUATOR

FIELDVUE DVC6010 DIGITAL

VALVE CONTROLLER MOUNTED ON A
SLIDING-STEM CONTROL VALVE / ACTUATOR

W8115

FIELDVUE DVC6020 DIGITAL

VALVE CONTROLLER MOUNTED ON A
ROTARY CONTROL VALVE / ACTUATOR

Fisher, FIELDVUE, AMS, ValveLink, PlantWeb, and Tri-Loop are marks owned by by one of the companies in the Emerson Process
Management business division of Emerson Electric Co. Emerson Process Management, Emerson and the Emerson logo are trademarks and
service marks of Emerson Electric Co. HART is a mark owned by the HART Communication Foundation. All other marks are the property of their
respective owners. This product may be covered under one or more of the following patents (5,163, 463; 5,265,637; 5,381,817; 5,434,774;
5,439,021; 5,451,923; 5,502,999; 5,532,925; 5,533,544; 5,549,137; 5,558,115; 5,573,032; 5,687,098) or under pending patents.
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they
are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or
applicability. All sales are governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the
designs or specifications of such products at any time without notice. Neither Emerson, Emerson Process Management, nor any of their affiliated
entities assumes responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use, and maintenance of
any product remains solely with the purchaser and end user.

Emerson Process Management

Marshalltown, Iowa 50158 USA
Sorocaba, 18087 Brazil
Chatham, Kent ME4 4QZ UK
Dubai, United Arab Emirates
Singapore 128461 Singapore
www.Fisher.com
5-6
EFisher Controls International LLC 2002, 2009; All Rights Reserved
December 2009
 Instruction Manual
D102794X012
DVC6000 Digital Valve Controllers December 2009

Fisherr FIELDVUEt DVC6000

Digital Valve Controllers
Introduction and Specifications 1
This manual applies to:
Installation 2
Instrument Level HC, AD, PD, ODV AC
Device Type 03 07 Basic Setup
Device Revision 2 2
3
Hardware Revision 1 1 Detailed Setup 4
Firmware Revision 7&9 7&9
DD Revision 1&2 1 Calibration 5
Viewing Device Variables and Diagnostics 6
Maintenance and Troubleshooting 7
Parts 8
9
Appendices A
Principle of Operation A
Loop Schematics/Nameplates B
Glossary C
Glossary

Index 14
Index

Refer to Related Documents on page 1-3 for other documents containing

information related to DVC6000 digital valve controllers

www.Fisher.com
 DVC6000 Digital Valve Controllers
Fast-Key Sequence for Instrument Level HC, AD, PD, and ODV
Fast-Key Coord- Fast-Key Coord-
Function/Variable Function/Variable
Sequence inates(1) Sequence inates(1)
Actuator Style 1-2-6-4 4-D Edit Feedback Connection 1-2-6-5 4-D
Alert Conditions 2-1 2-E End Point Control Enable(3) 1-2-2-2-5-1 6-C
1-2-3-6-2 1-2-3-6-5-1
Alert Record Full Enable 8-F Failure Group Enable
1-2-3-7-2 1-2-3-7-5-1 10-G
1-2-3-6-1 Firmware Revision 3-7-6 4-H
Alert Record Not Empty Alert Enable 8-F
1-2-3-7-1 Flash ROM Shutdown 1-2-3-1-3-5 11-C
Analog Input 3-1 2-F Hardware Revision 3-7-7 4-I
Analog Input Calibration 1-3-2-3 4-E 1-2-5-1-1 6-F
HART Tag
Analog Input Range Hi 1-2-5-3-1 6-H 3-7-1 4-H
Analog Input Range Lo 1-2-5-3-2 6-H HART Universal Revision 3-7-9 4-H
Analog Input Units 1-2-5-2-3 6-G Input Characterization 1-2-2-3 4-C
Auto Travel Calibration 1-3-1-1 4-E 1-2-4-1-2 8-G
Instrument Date and Time
Autocalibration in Progress Enable 1-2-4-2-2 8-H 1-2-5-8 5-F
3-6-1 5-G Instrument Level 3-7-8 4-H
Auxiliary Input
1-2-3-3-2-2 10-C Hot Key-1 1-A
Instrument Mode
Auxiliary Terminal Alert Enable 1-2-3-3-2-1 10-C 1-2-1-1 4-B
1-2-3-3-2-3 10-D Instrument Serial Number 1-2-5-1-6 6-F
Auxiliary Terminal Mode
1-2-5-7 5-F Instrument Time Invalid Enable 1-2-4-1-1 8-G
Burst Command 1-2-1-4-2 5-A 1-2-4-4-4 8-I
Integral Dead Zone
Burst Enable 1-2-1-4-1 5-A 1-2-2-1-2-1 9-A
Calibration in Progress Enab 1-2-4-2-1 8-H 1-2-4-4-3 8-I
Integral Limit
Calibration Location 1-2-5-9-2 6-H 1-2-2-1-2-2 9-B
1-2-3-6-4 Integrator Saturated Hi Enable 1-2-4-4-1 8-I
Clear Record 8-G
1-2-3-7-4 Integrator Saturated Lo Enable 1-2-4-4-2 8-I
1-2-1-4-3 5-A Lag Time(5) 1-2-2-5-3 6-C
Command 3 (Trending) Pressure
Hot Key-2 1-A Last Calibration Status 1-2-5-9-1 6-H
Control Mode 1-2-1-2 4-B Lead/Lag(3) 1-2-2-5-3 6-C
Critical NVM Shutdown 1-2-3-1-3-4 11-C Loop Current Validation Enable(6) 1-2-3-3-3-3 9-E
1-2-3-5-1-2 10-F Low Power Write Fail Enable(6) 1-2-3-1-3-2 11-B
Cycle Count
3-6-5 4-H Manual Travel Calibration 1-3-1-2 4-E
Cycle Count Alert Enable 1-2-3-5-1-1 10-F 3-7-3 4-H
Manufacturer
Cycle Count Alert Point 1-2-3-5-1-3 10-F 1-2-6-1 4-D
Date 1-2-5-1-4 6-F Maximum Supply Pressure 1-2-5-6 5-F
Dead Band (Cycle Count / Travel Accum) 1-2-3-5-2-1 10-F Message 1-2-5-1-2 6-F
Define Custom Characteristic 1-2-2-4 4-C 1-2-3-6-5-3
Miscellaneous Group Enable 10-G
Descriptor 1-2-5-1-3 6-F 1-2-3-7-5-3
Device Description Information 3-8 2-G Model 3-7-4 4-H
Device ID 3-7-2 4-H Multi-Drop Alert Enable 1-2-4-3-2 8-H
Device Revision 3-7-5 4-H No Free Time Shutdown 1-2-3-1-3-6 11-C
Diagnostic Data Available Enable 1-2-4-2-4 8-H Non-Critical NVM Alert Enable 1-2-3-1-3-3 11-B
Diagnostic in Progress Enable 1-2-4-2-3 8-H 2-3-4 4-F
Number of Power Ups
1-2-3-6-3 3-6-9 5-H
Display Record 8-F
1-2-3-7-3 Offline/Failed Alert Enable 1-2-3-1-3-1 11-B
Drive Current Shutdown 1-2-3-1-1 9-D Partial Stroke Test 2-5 2-F
3-4 2-F Partial Stroke Test Enable(3) 1-2-7-1 3-D
Drive Signal
1-2-3-1-2-2 10-C Partial Stroke Test Pressure Limit(3) 1-2-3-6-1 8-F
Drive Signal Alert Enable 1-2-3-1-2-1 10-C Partial Stroke Test Start Point(3) 1-2-2-2-5-2 8-C
NOTE: Italicized Fast-Key Sequence indicates fast-key sequence is only applicable for instrument level ODV.
1. Coordinates are to help locate the item on the foldout menu tree.
3. Instrument level ODV only.
5. Instrument level HC, AD, and PD only.
6. Firmware 9 only.
continued on facing page

Unfold this sheet to see the 475 Field Communicator Menu Tree
for Instrument Level HC, AD, PD, and ODV

i
 DVC6000 Digital Valve Controllers
Field Communicator Menu Tree for
Instrument Level HC, AD, PD, and ODV

Burst Mode
Hot Key 1-2-1-4 1 Burst Enable
1 Instrument Mode 2 Burst Command
2 Control Mode 3 Cmd 3(Trending)Press
3 Protection
4 Stabilize/Optimize Mode and Protection
1 Instrument Mode 1-2-2-1
Tuning
2 Control Mode 1 Travel Tuning
Basic Setup 1-2-1 3 Restart Ctrl Mode 2 Integral Settings
1-1 1 Setup Wizard 4 Burst Mode 3 Pressure Tuning
2 Performance Tuner 2
5 Protection
2 Stabilize/Optimize 4 Tvl/Press Control
1-2-2-2 1 Tvl/Press Select
2 Tvl/Press Cutoffs
Response Control 3 Travel Limits
Detailed Setup 1 Tuning 4 Pressure Control
1 Mode and Protection 1-2-2 2 Tvl/Press Control 5 End Pt Press Control 3
2 Response Control 3 Input Char
1-2 Dynamic Response
3 Alerts 4 Define Cust Char
4 Status 1-2-2-5 1 SP Rate Open
5 Dynamic Response
5 Instrument 2 SP Rate Close
6 Valve & Actuator 3 Lag Time 5
7 SIS/Partial Stroke 3 3 Lead/Lag 3

Alerts
Valve & Actuator 1 Electronics Alerts
1-2-7 Partial Stroke 2 Sensor Alerts
1 PST Enable 1 Manufacturer 1-2-3
1-2-6 3 Environment Alerts
2 PST Vars View/Edit 2 Valve Serial Num
3 3 Valve Style 4 Travel Alerts
4 Actuator Style 5 Travel History Alerts
5 Tvl Sensor Motion 6 SIS Alerts 3
1 Configure / Setup
6 Edit Feedback 6 Alert Record 6
1 Basic Setup
2 Detailed Setup Calibrate Connection
1-3 Status
3 Calibrate 1 Travel Calibration
2 Sensor Calibration 1-2-4 1 Instrument Time
1-3-1 Travel Calibration 2 Calibration and Diagnostics
3 Relay Adjust
1 AutoTvl Calib 3 Operational
4 Restore Factory
2 Man Tvl Calib 4 Integrator
4 Settings
1-3-2 Sensor Calibration
Online Device Diagnostics 1 Press Sensors
1 Configure / Setup 2 1 Alert Conditions 2 Analog In Calib
2 Device Diagnostics 2 Status
3 Device Variables 3 Device Record General
4 Stroke Valve Instrument 1-2-5-1 1 HART Tag
5 Partial Stroke Test 3 1 General 2 Message
1-2-5
2 Units 3 Descriptor
3 Analog Input Range 4 Date
Device Variables Device Record
2-3 4 Relay Type 5 Valve Serial Num
1 Analog In 1 Temp Max
3 5 Zero Pwr Cond 6 Inst Serial Num
2 Tvl Set Pt 2 Temp Min
6 Max Supply Press 7 Polling Address
3 Travel 3 Run Time
4 Drive Signal 4 Num of Power Ups 7 Aux Term Mode
5 Pressures 8 Inst Date and Time
6 Variables 9 Calib Status and Loc
HART Application 7 Device Information
1 Offline 8 DD Information
2 Online
1 3 Utility
4 HART Diagnostics Pressures
3-5 1 Pressure A Variables Units
2 Pressure B 1 Aux Input 1-2-5-2 1 Pressure Units
3 Pressure Diff 2 Temperature 2 Temp Units
4 Supply Press 2 3 Temp Max 3 Analog In Units
Notes: 3-6
4 Temp Min
5 Cycle Count Analog Input Range
1-1-1 indicates fast-key sequence to reach menu Device Information 6 Tvl Accum 1-2-5-3
1 Input Range Hi
1 HART Tag 7 Raw Tvl Input
1 This menu is available by pressing the left 2 Input Range Lo
2 Device ID 8 Run Time
arrow key from the previous menu. 3 Manufacturer 9 Num of Power Ups
3-7 4 Model 1-2-5-9 Calib Status and Loc
2 Not available in instrument level HC. 5 Device Rev 1 Last Calib Status
3 6 Firmware Rev 2 Calib Loc
Instrument level ODV only.
7 Hardware Rev
4 Instrument level HC only. 8 Inst Level
9 HART Univ Rev
5 Instrument level HC, AD, and PD only.
6 Fast key sequence for Alert Record with instrument level ODV is 1-2-3-7.
7 This menu item reads Power Starvation Alrt Enab in firmware 7.
8 Only available in firmware 9.

1 2 3 4 5 6

ii
 DVC6000 Digital Valve Controllers
1 Tvl Tuning Set
Travel Tuning 2 Tvl Prop Gain
1-2-2-1-1-1 3 Tvl Velocity Gain
1-2-2-1-1 1 Tvl Tuning Set
2 Tvl Integ Enable 4 Tvl MLFB Gain A
3 Tvl Integ Gain
4 Stabilize / Optimize
5 Peformance Tuner 2 Integral Settings
1-2-2-1-2
1 Integ DeadZ
2 Integ Limit
1-2-2-1-3 Pressure Tuning 1 Press Tuning Set
1 Press Tuning Set 1-2-2-1-3-1
2 Press Prop Gain
2 Press Integ Enab 3 Press MLFB Gain
3 Press Integ Gain

Tvl/Press Cutoffs
B
1-2-2-2-2 Processor Impaired Alerts
1 Tvl/Press Cut Hi 1 Offline/Failed Alrt Enab
1-2-2-2-3 Travel Limits 2 Tvl/Press Cut Lo 2 Low Power Write Fail Enab 7
1 Tvl Limit Hi 1-2-3-1-3
3 Non-Critical NVM Alrt Enab
2 Tvl Limit Lo 4 Critical NVM Shutdown
1-2-2-2-4 Pressure Control Drive Signal Alert 5 Flash ROM Shutdown
1-2-3-1-2
1 Press Range Hi 1 Drive Signal Alrt Enab 6 No Free Time Shutdown
End Pt Press Control 2 Press Range Lo 2 Drive Signal 7 Reference Voltage Shutdown
1-2-2-2-5
1 End Pt Control Enab
3 2 PST Start Pt C
3 Press Set Pt
4 Press Sat Time 2
Supply Press Lo Alrt
Electronics Alerts 1-2-3-3-1 1 Supply Press Lo Alrt Enab
1-2-3-1 1 Drive Current Shutdown 2 Supply Press
2 Drive Signal Alert 3 Supply Press Lo Alrt Pt Travel Deviation Alert
3 Processor Impaired Alerts 1-2-3-4-4 1 Tvl Dev Alrt Enab
HC,
1-2-3-3-1 2 Tvl Dev Alrt Pt
Aux Terminal Alrt
Sensor Alerts AD, PD, ODV 1 Aux Terminal Alrt Enab 3 Tvl Dev Time
1-2-3-2 1 Tvl Sensor Shutdown 1-2-3-3-2 2 Aux Input Travel Limit Alerts
D
2 Temp Sensor Shutdown 3 Aux Term Mode
3 Press Sensor Shutdown 1-2-3-4-5 1 Tvl Alrt Hi Hi Enab
2 Tvl Alrt Lo Lo Enab
3 Tvl Alrt Hi Hi Pt
1-2-3-3 Environment Alerts Travel Alerts 4 Tvl Alrt Lo Lo Pt
1 Supply Press Lo Alrt 2 1 Travel
2 Aux Terminal Alrt 2 Tvl Set Pt Travel Limit Hi/Lo Alerts
3 Loop Current Validation 3 Tvl Alrt DB 1-2-3-4-6 1 Tvl Alrt Hi Enab
Enable 8 1-2-3-4 4 Travel Deviation Alert 2 Tvl Alrt Lo Enab
5 Travel Limit Alerts 3 Tvl Alrt Hi Pt
Travel History Alerts 6 Travel Limit Hi/Lo Alerts 4 Tvl Alrt Lo Pt E
1-2-3-5 1 Cycle Count 7 Trave Limit / Cutoff Alerts
2 Cycle Count/Tvl Accum Deadband Travel Limit / Cutoff Alerts
3 Tvl Accum 1-2-3-4-7 1 Tvl Limit/Cutoff Hi Alrt Enab
Cycle Count 2 Tvl Limit/Cutoff Lo Alrt Enab
ODV SIS Alerts 1-2-3-5-1 1 Cycle Count Alrt Enab 3 Tvl/Press Cut Hi
1-2-3-6 1 PST Press Limit 2 Cycle Count 4 Tvl/Press Cut Lo
3 2 Press Dev Alrt Enab 3 Cycle Count Alrt Pt 5 Tvl Limit Hi
3 Press Dev Alrt Pt 1-2-3-5-2 6 Tvl Limit Lo
4 Press Dev Time 1 Deadband
F
HC, AD, PD Alert Record Tvl Accum
1-2-3-6 1 Alrt Record Not Empty Enab 1-2-3-5-3 1 Tvl Accum Alrt Enab
ODV 2 Alrt Record Full Enab 2 Tvl Accum
1-2-3-7 3 Display Record 3 Tvl Accum Alrt Pt
4 Clear Record
5 Alert Groups
HC, AD, PD
1-2-3-6-5 Alert Groups
Instrument Time 1 Failure Group Enab
1-2-4-1
1 Inst Time Invalid Enab
ODV
1-2-3-7-5
2 Valve Group Enab G
2 Inst Date and Time 3 Misc Group Enab

Calibration and Diagnostics

1-2-4-2 1 Cal in Progress Enab
2 Autocal in Progress Enab
3 Diag in Progress Enab
4 Diag Data Avail Enab

Operational
1-2-4-3
1 Press Ctrl Active Enab
H
2 Multi-Drop Enab

Integrator
1-2-4-4 1 Integrator Sat Hi Enab
2 Integrator Sat Lo Enab
3 Integ Limit
4 Integ DeadZ

7 8 9 10 11 12

iii
 DVC6000 Digital Valve Controllers
Fast-Key Sequence for Instrument Level HC, AD, PD, and ODV (continued)
Fast-Key Coord- Fast-Key Coord-
Function/Variable Function/Variable
Sequence inates(1) Sequence inates(1)
Partial Stroke Test Variables View/Edit(3) 1-2-7-2 3-D Temperature Sensor Shutdown 1-2-3-2-2 9-D
1-1-2 2-B Temperature Units 1-2-5-2-2 6-G
Performance Tuner(2)
1-2-2-1-1-5 8-A 3-3 2-F
Travel
Polling Address 1-2-5-1-7 6-F 1-2-3-4-1 10-E
Power Starvation Alert Enable(7) 1-2-3-1-3-2 11-B 1-2-3-4-7-3 12-F
Travel / Pressure Cutoff Hi
Pressure A 3-5-1 4-G 1-2-2-2-2-1 9-B
Pressure B 3-5-2 4-G 1-2-3-4-7-4 12-F
Travel / Pressure Cutoff Lo
Pressure Control Active Enable 1-2-4-3-1 8-H 1-2-2-2-2-2 9-B
Pressure Deviation Alert Enable (3) 1-2-3-6-2 8-F Travel / Pressure Select 1-2-2-2-1 6-B
Pressure Deviation Alert Point(3) 1-2-3-6-3 8-F 3-6-6 5-H
Travel Accumulator
Pressure Deviation Time(3) 1-2-3-6-4 8-F 1-2-3-5-3-2 10-F
Pressure Differential 3-5-3 4-G Travel Accumulator Alert Enable 1-2-3-5-3-1 10-F
Pressure Integral Control Enable 1-2-2-1-3-2 8-B Travel Accumulator Alert Point 1-2-3-5-3-3 10-F
Pressure Integral Gain 1-2-2-1-3-3 8-B Travel Alert Dead Band 1-2-3-4-3 10-E
Pressure MLFB Gain 1-2-2-1-3-1-3 10-B Travel Alert Hi Enable 1-2-3-4-6-1 12-E
Pressure Proportional Gain 1-2-2-1-3-1-2 10-B Travel Alert Hi Hi Enable 1-2-3-4-5-1 12-D
Pressure Range Hi 1-2-2-2-4-1 9-C Travel Alert Hi Hi Point 1-2-3-4-5-3 12-D
Pressure Range Lo 1-2-2-2-4-2 9-C Travel Alert Hi Point 1-2-3-4-6-3 12-E
Pressure Sat Time(3) 1-2-2-2-5-4 8-C Travel Alert Lo Enable 1-2-3-4-6-2 12-E
Pressure Sensor Shutdown(2) 1-2-3-2-3 9-D Travel Alert Lo Lo Enable 1-2-3-4-5-2 12-D
Pressure Sensors—Calibration 1-3-2-1 4-E Travel Alert Lo Lo Point 1-2-3-4-5-4 12-D
Pressure Set Point(3) 1-2-2-2-5-3 8-C Travel Alert Lo Point 1-2-3-4-6-4 12-E
Pressure Tuning Set 1-2-2-1-3-1-1 10-B Travel Deviation Alert Enable 1-2-3-4-4-1 12-D
Pressure Units 1-2-5-2-1 6-G Travel Deviation Alert Point 1-2-3-4-4-2 12-D
Hot Key-3 1-A Travel Deviation Time 1-2-3-4-4-3 12-D
Protection
1-2-1-5 4-B Travel Integral Control Enable 1-2-2-1-1-2 8-A
Raw Travel Input 3-6-7 5-H Travel Integral Gain 1-2-2-1-1-3 8-A
Reference Voltage Shutdown 1-2-3-1-3-7 11-C Travel Limit / Cutoff Hi Alert Enable 1-2-3-4-7-1 12-E
Relay Adjust 1-3-3 3-E Travel Limit / Cutoff Lo Alert Enable 1-2-3-4-7-2 12-E
Relay Type 1-2-5-4 5-F 1-2-3-4-7-5 12-F
Travel Limit Hi
Restart Control Mode 1-2-1-3 4-B 1-2-2-2-3-1 8-B
Restore Factory Settings 1-3-4 3-E 1-2-3-4-7-6 12-F
Travel Limit Lo
2-3-3 4-F 1-2-2-2-3-2 8-B
Run Time
3-6-8 5-H Travel MLFB Gain 1-2-2-1-1-1-4 10-A
Set Point Rate Close 1-2-2-5-2 6-C Travel Proportional Gain 1-2-2-1-1-1-2 10-A
Set Point Rate Open 1-2-2-5-1 6-C Travel Sensor Adjust 1-3-2-2 4-E
Setup Wizard 1-1-1 2-B Travel Sensor Motion 1-2-6-6 4-D
Hot Key-4 1-A Travel Sensor Shutdown 1-2-3-2-1 9-D
Stabilize/Optimize 1-1-2(4) 2-B 1-2-3-4-2 10-E
Travel Set Point
1-2-2-1-1-4 8-A 3-2 2-F
Status 2-2 2-E Travel Tuning Set 1-2-2-1-1-1-1 10-A
Stroke Valve 2-4 2-F Travel Velocity Gain 1-2-2-1-1-1-3 10-A
3-5-4 4-G 1-2-3-6-5-2
Supply Pressure(2) Valve Group Enable 10-G
1-2-3-3-1-2 10-D 1-2-3-7-5-2
Supply Pressure Lo Alert Enable 1-2-3-3-1-1 10-D 1-2-5-1-5 6-F
Valve Serial Number
Supply Pressure Lo Alert Point 1-2-3-3-1-3 10-D 1-2-6-2 4-D
Temperature 3-6-2 5-G Valve Style 1-2-6-3 4-D
3-6-3 5-G Zero Power Condition 1-2-5-5 5-F
Temperature Maximum
2-3-1 4-F
3-6-4 5-H
Temperature Minimum
2-3-2 4-F
NOTE: Italicized Fast-Key Sequence indicates fast-key sequence is applicable only for instrument level ODV.
1. Coordinates are to help locate the item on the foldout menu tree.
2. Not available in instrument level HC.
3. Instrument level ODV only.
4. Instrument level HC only.
5. Instrument level HC, AD, and PD only.6. Firmware 8 only.
7. Firmware 7 only.

v
DVC6000 Digital Valve Controllers
Fast-Key Sequence for Instrument Level AC
Fast-Key Fast-Key
Function/Variable Coordinates(1) Function/Variable Coordinates(1)
Sequence Sequence
Actuator Style 1-1-2-2-4 5-C 1-1-2-3-2-2 6-D
Pressure Proportional Gain
Analog Input Calibration 1-3-1 3-F 1-2-3-4-1-2 6-G
Analog Input Range Hi 1-2-2-2 4-E Pressure Range Hi 1-2-3-5-1 5-G
Analog Input Range Lo 1-2-2-3 4-E Pressure Range Lo 1-2-3-5-2 5-G
Analog Input Units 1-2-2-1 4-E 1-1-2-3-2-1 6-D
Pressure Tuning Set
1-1-2-3-4 5-D 1-2-3-4-1-1 6-G
Auto Travel Calibration 1-3-2 3-F 1-1-2-2-2 5-C
Pressure Units
1-1-1-3 5−D 1-2-2-4 4-E
Calibration Location 1-3-5 3-F Protection Hot Key-2 1-B
Date 1-2-1-4 4-D 1-1-1-2 4-B
Descriptor 1-2-1-3 4-D Relay Adjust 1-1-2-3-3 5-D
Device Description Revision 2-2 2-F 1-3-6 3-G
Device Identification 2-1-6 3-G Relay Type 1-2-4 3-D
Device Revision 2-1-2 3-G Restore Factory Settings 1-3-4 3-F
Feedback Connection 1-1-2-2-5 5-C Setup Wizard 1-1-1-1 4-B
Firmware Revision 2-1-3 3-G Travel Integral Gain 1-2-3-2-3 5-E
Hardware Revision 2-1-4 3-G Travel Integral Enable 1-2-3-2-2 5-E
HART Tag 1-2-1-1 4-D 1-1-2-3-1-4 6-D
Travel MLFB Gain
HART Universal Revision 2-1-1 3-G 1-2-3-2-1-4 6-E
Input Characterization 1-2-3-6 4-F 1-1-2-2-1 5-C
Travel / Pressure Select
Instrument Level 2-1-5 3-G 1-2-3-1 4-F
Hot Key-1 1-B 1-1-2-3-1-2 6-D
Instrument Mode Travel Proportional Gain
1-1-2-1 4-C 1-2-3-2-1-2 6-E
Instrument Serial Number 1-2-1-6 4-E Travel Sensor Adjust 1-3-7 3-G
Integral Dead Zone 1-2-3-3-1 5-F Travel Sensor Motion 1-1-2-2-6 5-C
Integral Limit 1-2-3-3-2 5-F 1-1-2-3-1-1 6-D
Travel Tuning Set
Manual Travel Calibration 1-3-3 3-F 1-2-3-2-1-1 6-E
Maximum Supply Pressure 1-1-2-2-3 5-C 1-1-2-3-1-3 6-D
Travel Velocity Gain
Message 1-2-1-2 4-D 1-2-3-2-1-3 6-E
Polling Address 1-2-1-7 4-E Valve Serial Number 1-2-1-5 4-D
Pressure Integral Control Enable 1-2-3-4-2 5-F Valve Style 1-1-2-2-7 5-C
Pressure Integral Gain 1-2-3-4-3 5-F Zero Power Condition 1-1-2-2-8 5-C
1-1-2-3-2-3 6-D
Pressure MLFB Gain
1-2-3-4-1-3 6-G
1. Coordinates are to help locate the item on the menu tree on the facing page.

vi
 DVC6000 Digital Valve Controllers
Field Communicator Menu Tree for A
Instrument Level AC

Hot Key
1 Instrument Mode
B
Auto Setup
2 Protection 1-1 Basic Setup 1 Setup Wizard
1-1-1
1 Auto Setup 2 Relay Adjust
2 Manual Setup 3 Auto Travel Calib
Press & Actuator
Manual Setup 1 Tvl/Press Select
1-1-2 1 Instrument Mode 2 Pressure Units
1-1-2-2 3 Max Supply Press
2 Press & Actuator
3 Tuning & Calib 4 Actuator Style
5 Feedback Conn C
6 Tvl Sensor Motion
7 Valve Style
8 Zero Pwr Cond
Tvl Tuning Set
1 Tvl Tuning Set
Tuning & Calib 1-1-2-3-1 2 Tvl Prop Gain
1-1-2-3 1 Tvl Tuning Set 3 Tvl Velocity Gain
2 Press Tuning Set 4 Tvl MLFB Gain
General 3 Relay Adjust
Detailed Setup 1 HART Tag 4 Auto Travel Calib
1-2 1 General
1-2-1
2 Message 1-1-2-3-2
Press Tuning Set
1 Press Tuning Set
D
2 Measured Var 3 Descriptor 2 Press Prop Gain
3 Response Control 4 Date 3 Press MLFB Gain
4 Relay Type 5 Valve Serial Num
6 Inst Serial Num
7 Polling Address

1
Setup
1 Basic Setup 1-2-2 Measured Var
2 Detailed Setup 1 Analog In Units
3 Calibrate 2 Input Range Hi
Tvl Tuning
Tvl Tuning E
3 Input Range Lo 1-2-3-2 1-2-3-2-1 1 Tvl Tuning Set
4 Pressure Units 1 Tvl Tuning Set 2 Tvl Prop Gain
2 Tvl Integ Enab 3 Tvl Velocity Gain
Response Control 3 Tvl Integ Gain 4 Tvl MLFB Gain
1-2-3 1 Tvl/Press Select
Online 2 Tvl Tuning Integral Settings
1-2-3-3
1 Setup 2 Display 3 Integral Settings 1 Integ DeadZ
2 Display 1 Device Information 4 Press Tuning 2 Integ Limit
2 DD Revision 5 Pressure Control
Calibrate
1 Analog In Calib
6 Input Char
1-2-3-4 Press Tuning F
2 Auto Travel Calib 1 Press Tuning Set
3 Man Travel Calib 2 Press Integ Enab
1-3 3 Press Integ Gain
4 Restore Factory Settings
5 Calib Loc
6 Relay Adjust 1-2-3-5 Pressure Control
7 Tvl Sensor Adjust 1 Press Range Hi
2 Press Range Lo
Device Information
1 HART Univ Rev Press Tuning Set
2-1
2 Device Rev 1 Press Tuning Set G
3 Firmware Rev 2 Press Prop Gain
1-2-3-4-1
4 Hardware Rev 3 Press MLFB Gain
5 Inst Level
6 Device ID
HART Applications
1 Offline
1 2 Online
3 Utility
H
Notes:

1-1-1 indicates fast-key sequence to reach menu

1 This menu is available by pressing the left
arrow key from the previous menu.

1 2 3 4 5 6

vii
 DVC6000 Digital Valve Controllers

THE FIELDVUE DVC6000 DIGITAL VALVE CONTROLLERS IS A CORE COMPONENT OF THE PLANTWEBt
DIGITAL PLANT ARCHITECTURE. THE DIGITAL VALVE CONTROLLER POWERS PLANTWEB BY
CAPTURING AND DELIVERING VALVE DIAGNOSTIC DATA. COUPLED WITH VALVELINKt SOFTWARE,
THE DVC6000 PROVIDES USERS WITH AN ACCURATE PICTURE OF VALVE PERFORMANCE, INCLUDING
ACTUAL STEM POSITION, INSTRUMENT INPUT SIGNAL AND PNEUMATIC PRESSURE TO THE
ACTUATOR. USING THIS INFORMATION, THE DIGITAL VALVE CONTROLLER DIAGNOSES NOT ONLY
ITSELF, BUT ALSO THE VALVE AND ACTUATOR TO WHICH IT IS MOUNTED.

FIELDVUE DVC6000 Digital Valve Controller

viii
 Introduction and Specifications

Section 1 Introduction 1
Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Educational Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

December 2009 1-1

 DVC6000 Digital Valve Controllers
Table 1-1. Instrument Level Capabilities
DIAGNOSTIC LEVEL
CAPABILITY
AC HC AD PD ODV
Auto Calibration X X X X X
Custom Characterization X X X X X
Burst Communication X X X X

1 Alerts
Step Response, Drive Signal Test & Dynamic Error Band
X X
X
X
X
X
X
Advanced Diagnostics (Valve Signature) X X X
Performance Tuner X X X
Travel Control - Pressure Fallback X X X
Performance Diagnostics X X
Solenoid Valve Testing X X
Lead/Lag Input Filter(1) X
1. Refer to brochure part # D351146X012/D351146X412 for information on Fisher optimized digital valves for compressor antisurge applications.

Scope of Manual
This instruction manual includes specifications,
installation, operating, and maintenance information
for FIELDVUE DVC6000 digital valve controllers,
device revision 2, firmware revision 7 and 9,
instrument level AC, HC, AD, PD, and ODV.
This instruction manual describes using the 475 Field
Communicator with device description revision 1 and 2
to setup and calibrate the instrument. You can also
use Fisher ValveLink software version 7.3 or higher to
setup, calibrate, and diagnose the valve and
instrument. For information on using ValveLink
software with the instrument refer to ValveLink
software help or documentation.
Do not install, operate, or maintain a DVC6000 digital
valve controller without being fully trained and qualified
in valve, actuator, and accessory installation,
operation, and maintenance. To avoid personal injury
or property damage, it is important to carefully read,
understand, and follow all of the contents of this
W7957 / IL
manual, including all safety cautions and warnings. If
you have any questions about these instructions, Figure 1-1. Sliding-Stem Control Valve with
contact your Emerson Process Management sales FIELDVUE DVC6010 Digital Valve Controller
office before proceeding.

Some of the procedures also contain the sequence of

numeric keys required to display the desired Field
Conventions Used in this Manual Communicator menu. For example, to access the
Setup Wizard, from the Online menu, press 1 (selects
Configure / Setup) followed by a second 1 (selects
Basic Setup) followed by a third 1 (selects Setup
Procedures that require the use of the 475 Field Wizard). The key sequence in the procedure heading
Communicator have the Field Communicator symbol is shown as (1-1-1). The path required to accomplish
in the heading. various tasks, the sequence of steps through the Field
Communicator menus, is also presented in textual
Procedures that are accessible with the Hot Key format. Menu selections are shown in italics, e.g.,
on the Field Communicator will also have the Hot Key Calibrate. An overview of the Field Communicator
symbol in the heading. menu trees are shown at the beginning of this manual.

1-2 December 2009

 Introduction and Specifications
W9418
Figure 1-2. Rotary Control Valve with
FIELDVUE DVC6020 Digital Valve Controller
Note
475 Field Communicator menu
sequences used in this manual are for
instrument level HC, AD, PD, and ODV.
Refer to the AC menu tree at the
beginning of this manual for AC menu
sequences.
These menu sequences are also
applicable to the 375 Field
Communicator.
Description
DVC6000 digital valve controllers (figures 1-1 and 1-2)
are communicating, microprocessor-based
current-to-pneumatic instruments. In addition to the
normal function of converting an input current signal to
a pneumatic output pressure, the DVC6000 digital
valve controller, using the HART communications
protocol, gives easy access to information critical to
process operation. You can gain information from the
principal component of the process, the control valve
itself, using the Field Communicator at the valve, or at
a field junction box, or by using a personal computer
or operator’s console within the control room.
Using a personal computer and ValveLink software or
AMS Suite: Intelligent Device Manager, or a Field
Communicator, you can perform several operations
December 2009
with the DVC6000 digital valve controller. You can
obtain general information concerning software
revision level, messages, tag, descriptor, and date.
Diagnostic information is available to aid you when
troubleshooting. Input and output configuration
parameters can be set, and the digital valve controller
can be calibrated. Refer to table 1-1 for details on the
capabilities of each diagnostic tier. 1
Using the HART protocol, information from the field
can be integrated into control systems or be received
on a single loop basis.
DVC6000 digital valve controllers are designed to
directly replace standard pneumatic and
electro-pneumatic valve mounted positioners.
Specifications
WARNING
Refer to table 1-2 for specifications.
Incorrect configuration of a
positioning instrument could result in
the malfunction of the product,
property damage or personal injury.
Specifications for DVC6000 digital valve controllers
are shown in table 1-2. Specifications for the Field
Communicator can be found in the product manual for
the Field Communicator.
Related Documents
Other documents containing information related to
DVC6000 digital valve controllers include:
 Bulletin 62.1:DVC6000—Fisher FIELDVUE
DVC6000 Digital Valve Controllers (D102758X012)
 Bulletin 62.1:DVC6000(S1)—Fisher FIELDVUE
DVC6000, DVC6000 SIS, and DVC6000f Digital Valve
Controller Dimensions (D103308X012)
 Bulletin 62.1:DVC6000(S2)—Fisher FIELDVUE
DVC6000 Digital Valve Controller Custom
Configuration (D103418X012)
 Fisher FIELDVUE DVC6000 Digital Valve
Controllers Quick Start Guide (D102762X012)
1-3
 DVC6000 Digital Valve Controllers
 Supplement to HART Communicating Fisher  Fisher HF340 Filter Instruction Manual
FIELDVUE Digital Valve Controller Instruction (D102796X012)
Manuals— FIELDVUE Digital Valve Controller Split
Ranging (D103262X012)

 Supplement to HART Communicating Fisher  2530H1 HART Interchange Multiplexer

FIELDVUE Instrument Instruction Manuals—Using Instruction Manual (D102237X012)
1 FIELDVUE Instruments with the Smart HART Loop
Interface and Monitor (HIM) (D103263X012)
 ValveLink software help or documentation
 Supplement to HART Communicating Fisher
FIELDVUE Instrument Instruction Manuals— Audio
Monitor for HART Communications (D103265X012)
 Field Communicator User’s Manual
 Supplement to HART Communicating Fisher
FIELDVUE Digital Valve Controller Instruction
Manuals— HART Field Device Specification All documents are available from your Emerson
(D103266X012) Process Management sales office. Also visit our
website at www.FIELDVUE.com.
 Supplement to HART Communicating Fisher
FIELDVUE Instrument Instruction Manuals— Using
the HART Tri-Loop HART -to-Analog Signal
Converter with FIELDVUE Digital Valve Controllers
(D103267X012)

 Supplement to HART Communicating Fisher Educational Services

FIELDVUE DVC5000 (Obsolete Product) and
DVC6000 Digital Valve Controllers Instruction Manuals For information on available courses for DVC6000
— Hot Swap Procedure (D103264X012) digital valve controllers, as well as a variety of other
products, contact:
 Supplement to Fisher FIELDVUE DVC6000
Digital Valve Controllers Instruction Manual— Emerson Process Management
Implementation of Lock-in-Last Strategy Educational Services, Registration
(D103261X012) P.O. Box 190; 301 S. 1st Ave.
Marshalltown, IA 50158-2823
 Supplement to Fisher FIELDVUE DVC6000 Phone: 800-338-8158 or
Digital Valve Controllers Instruction Manual— 275 Phone: 641-754-3771
HART Communicator Menu Trees for Firmware 7 FAX: 641-754-3431
Digital Valve Controllers (D103273X012) e-mail: education@emersonprocess.com

1-4 December 2009

 Introduction and Specifications
Table 1-2. Specifications
Available Configurations
DVC6010: Sliding-stem applications
DVC6020: Rotary and long-stroke sliding-stem
applications [over 102 mm (4 inch) travel]
DVC6030: Quarter-turn rotary applications
Remote-Mounted Instrument(1)
DVC6005: Base unit for 2 inch pipestand or wall
mounting
DVC6015: Feedback unit for sliding-stem
applications
DVC6025: Feedback unit for rotary or long-stroke
sliding-stem applications
DVC6035: Feedback unit for quarter-turn rotary
applications
DVC6000 digital valve controllers can be mounted
on Fisher and other manufacturers rotary and
sliding-stem actuators.
Input Signal
Point-to-Point:
Analog Input Signal: 4-20 mA DC, nominal
Minimum Voltage Available at instrument terminals
must be 10.5 volts DC for analog control, 11 volts
DC for HART communication
Minimum Control Current: 4.0 mA
Minimum Current w/o Microprocessor Restart:
3.5 mA
Maximum Voltage: 30 volts DC
Overcurrent Protection: Input circuitry limits current
to prevent internal damage.
Reverse Polarity Protection: No damage occurs
from reversal of loop current.
Multi-drop:
Instrument Power: 11-30 volts DC at approximately
8 mA
Reverse Polarity Protection: No damage occurs
from reversal of loop current.
Output Signal
Pneumatic signal as required by the actuator, up to
full supply pressure.
Minimum Span: 0.4 bar (6 psig)
Maximum Span: 9.5 bar (140 psig)
Action: Double, Single direct, and Single reverse
Supply Pressure(2)
Recommended: 0.3 bar (5 psi) higher than
maximum actuator requirements, up to maximum
supply pressure
-continued-
December 2009
Maximum: 10 bar (145 psig) or maximum pressure
rating of the actuator, whichever is lower
Medium: Air or Natural Gas(3)
Air Quality: Supply pressure must be clean, dry air
that meets the requirements of ISA Standard
1
7.0.01. A maximum 40 micrometer particle size in
the air system is acceptable. Further filtration down
to 5 micrometer particle size is recommended.
Lubricant content is not to exceed 1 ppm weight
(w/w) or volume (v/v) basis. Condensation in the air
supply should be minimized
Natural Gas: Natural gas must be clean, dry,
oil-free, and noncorrosive. H2S content should not
exceed 20 ppm.
Steady-State Air Consumption(4,5)
Standard Relay:
At 1.4 bar (20 psig) supply pressure: Less than 0.38
normal m3/hr (14 scfh)
At 5.5 bar (80 psig) supply pressure: Less than 1.3
normal m3/hr (49 scfh)
Low Bleed Relay:
At 1.4 bar (20 psig) supply pressure: Average value
0.056 normal m3/hr (2.1 scfh)
At 5.5 bar (80 psig) supply pressure: Average value
0.184 normal m3/hr (6.9 scfh)
Maximum Output Capacity(4,5)
At 1.4 bar (20 psig) supply pressure: 10.0 normal
m3/hr (375 scfh)
At 5.5 bar (80 psig) supply pressure: 29.5 normal
m3/hr (1100 scfh)
Independent Linearity(6)
±0.50% of output span
Electromagnetic Compatibility
Meets EN 61326-1 (First Edition)
Immunity—Industrial locations per Table 2 of the
EN 61326-1 standard. Performance is shown
in table 1-3 below.
Emissions—Class A
ISM equipment rating: Group 1, Class A
Lightning and Surge Protection—The degree of
immunity to lightning is specified as Surge immunity
in table 1-3. For additional surge protection
commercially available transient protection devices
can be used.
1-5
 DVC6000 Digital Valve Controllers
Table 1-2. Specifications (continued)
Vibration Testing Method
Tested per ANSI/ISA-S75.13.01 Section 5.3.5. A
resonant frequency search is performed on all three
axes. The instrument is subjected to the ISA
specified 1/2 hour endurance test at each major
1 resonance, plus an additional two million cycles.
Input Impedance
The input impedance of the DVC6000 active
electronic circuit is not purely resistive. For
comparison to resistive load specifications, an
equivalent impedance of 550 ohms may be used.
This value corresponds to 11V @ 20 mA.
Operating Ambient Temperature Limits(2)
-40 to 80C (-40 to 176F) for most approved
valve-mounted instruments
-60 to 125C (-76 to 257F) for remote-mounted
feedback unit.
-52 to 80C (-62 to 176F) for valve-mounted
instruments utilizing the Extreme Temperature
option (fluorosilicone elastomers)
Humidity Limits
0 to 100% condensing relative humidity with
minimal zero or span shifts
Electrical Classification
Hazardous Area:
CSA—Intrinsically Safe, Explosion proof, Division 2,
Dust-Ignition proof
FM—Intrinsically Safe, Explosion proof,
Non-incendive, Dust-Ignition proof
ATEX—Intrinsically Safe, Flameproof, Type n
IECEx—Intrinsically Safe, Flameproof, Type n
NEPSI—Intrinsically Safe, Flameproof
INMETRO—Intrinsically Safe, Flameproof
Refer to Special Instructions for “Safe Use” and
Installation in Hazardous Locations in section 2,
tables 1-4, 1-5, 1-6, 1-7, 1-8, and 1-9, and
Appendix B.
Pollution Degree 2, Overvoltage Category III per
ANSI/ISA-82.02.01 (IEC 61010-1 Mod).
-continued-
1-6
Electrical Housing:
CSA—Type 4X, IP66
FM—NEMA 4X
ATEX—IP66
IECEx—NEMA 4X, IP66
NEPSI—IP66
Other Classifications/Certifications
TIIS—Japan
KISCO—Japan
GOST-R—Russian GOST-R
FSETAN—Russian - Federal Service of
Technological, Ecological and Nuclear Inspectorate
Contact your Emerson Process Management sales
office for classification/certification specific
information
IEC 61010 Compliance Requirements
(Valve-Mounted Instruments only)
Power Source: The loop current must be derived
from a Separated Extra-Low Voltage (SELV) power
source.
Environmental Conditions: Installation Category I
Connections
Supply Pressure: 1/4 NPT internal and integral
pad for mounting 67CFR regulator
Output Pressure: 1/4 NPT internal
Tubing: 3/8-inch metal, recommended
Vent: 3/8 NPT internal
Electrical: 1/2 NPT internal conduit connection,
optional—M20 internal conduit connection, spring
clamp terminal connection(7)
Stem/Shaft Travel
Linear Actuators with rated travel between 6.35 mm
(0.25 inch) and 606 mm (23.375 inches)
Rotary Actuators with rated travel between 50
degrees and 180 degrees
December 2009
 Introduction and Specifications
Table 1-2. Specifications (continued)

Mounting (8) Options

Designed for direct actuator mounting or remote  Supply and output pressure gauges or  Tire
pipestand or wall mounting. Mounting the valves,  Integral mounted filter regulator, 
instrument vertically, with the vent at the bottom of Stainless steel housing, module base and terminal
box (valve-mounted instruments only)
the assembly, or horizontally, with the vent pointing
down, is recommended to allow drainage of  Low bleed relay,  Inline 10 micrometer air filter 1
moisture that may be introduced via the instrument  Safety Instrumented System (SIS) Solutions
air supply.  Safety Related Nuclear Applications

Declaration of SEP
Weight Fisher Controls International LLC declares this
product to be in compliance with Article 3 paragraph
Valve-Mounted Instruments 3 of the Pressure Equipment Directive (PED) 97 /
Aluminum: 3.5 kg (7.7 lbs) 23 / EC. It was designed and manufactured in
Stainless Steel: 7.7 kg (17 lbs) accordance with Sound Engineering Practice (SEP)
and cannot bear the CE marking related to PED
Remote-Mounted Instruments compliance.
DVC6005 Base Unit: 4.1 kg (9 lbs)
DVC6015 Feedback Unit: 1.3 kg (2.9 lbs) However, the product may bear the CE marking to
DVC6025 Feedback Unit: 1.4 kg (3.1 lbs) indicate compliance with other applicable European
DVC6035 Feedback Unit: 0.9 kg (2.0 lbs) Community Directives.
NOTE: Specialized instrument terms are defined in ISA Standard 51.1 - Process Instrument Terminology.
1. 3-conductor shielded cable, 22 AWG minimum wire size, is required for connection between base unit and feedback unit. Pneumatic tubing between base unit output connection and actuator
has been tested to 15 meters (50 feet) maximum without performance degradation.
2. The pressure/temperature limits in this document and any applicable code or standard should not be exceeded.
3. Gas Certified DVC6000 digital valve controllers are FM and CSA Single Seal approved for use with natural gas as the supply medium.
4. Values at 1.4 bar (20 psig) based on a single-acting direct relay; values at 5.5 bar (80 psig) based on double-acting relay.
5. Normal m3/hour - Normal cubic meters per hour at 0C and 1.01325 bar, absolute. Scfh - Standard cubic feet per hour at 60F and 14.7 psia
6. Typical Value. Not applicable for travels less than 19 mm (0.75 inch) or for shaft rotation less than 60 degrees. Also, not applicable to DVC6020 digital valve controllers in long-stroke
applications.
7. ATEX/IEC approvals only.
8. Do not use the DVC6010S or DVC6020S in high vibration service where the mounting bracket uses standoffs (spacers) to mount to the actuator. Due to NAMUR mounting limitations, do
not use the DVC6030S in high vibration service.

Table 1-3. EMC Summary Results—Immunity

Performance Criteria(1)
Port Phenomenon Basic Standard Test Level Point-to- Multi-drop
Point Mode Mode
Electrostatic discharge 4 kV contact
IEC 61000-4-2 A(2) A
(ESD) 8 kV air
80 to 1000 MHz @ 10V/m with 1 kHz AM at 80%
Enclosure Radiated EM field IEC 61000-4-3 1400 to 2000 MHz @ 3V/m with 1 kHz AM at 80% A A
2000 to 2700 MHz @ 1V/m with 1 kHz AM at 80%
Rated power frequency
IEC 61000-4-8 60 A/m at 50 Hz A A
magnetic field
Burst IEC 61000-4-4 1 kV A(2) A
I/O signal/control Surge IEC 61000-4-5 1 kV (line to ground only, each) A(2) A
Conducted RF IEC 61000-4-6 150 kHz to 80 MHz at 3 Vrms A A
1. A = No degradation during testing. B = Temporary degradation during testing, but is self-recovering.
2. Excluding auxiliary switch function, which meets Performance Criteria B.

December 2009 1-7

 DVC6000 Digital Valve Controllers
Table 1-4. Hazardous Area Classifications—CSA (Canada)
Certification Enclosure
Type Certification Obtained Entity Rating Temperature Code
Body Rating
Ex ia Intrinsically Safe Vmax = 30 VDC
Class I,II,III Division 1 GP A,B,C,D,E, Imax = 226 mA Type 4X, IP66
T5(Tamb v 80C)
F,G per drawing GE42818 T5 Ci = 5 nF Single Seal Device
Natural Gas Approved Li = 0.55 mH

1 DVC60x0
DVC60x0S
Explosion Proof
Class I Division 1 GP B,C,D T6 --- T6(Tamb v 80C)
Type 4X, IP66
Single Seal Device
Natural Gas Approved
(x = 1,2,3)
Class I Division 2 GP A,B,C,D T6
Class II Division 1 GP E,F,G T6
Type 4X, IP66
Class II Division 2 GP F,G T6 --- T6(Tamb v 80C)
Single Seal Device
Class III
Natural Gas Approved
Ex ia Intrinsically Safe Vmax = 30 VDC Voc = 9.6 VDC
Class I,II,III Division 1 GP A,B,C,D, Imax = 226 mA Isc = 3.5 mA Type 4X, IP66
T5(Tamb v 80C)
E,F,G per drawing GE42818 T5 Ci = 5 nF Ca = 3.6 uF Single Seal Device
Natural Gas Approved Li = 0.55 mH La = 100 mH
Explosion Proof
CSA Type 4X, IP66
Class I Division 1 GP B,C,D T6 --- T6(Tamb v 80C)
DVC6005 Single Seal Device
Natural Gas Approved
Class I Division 2 GP A,B,C,D T6
Class II Division 1 GP E,F,G T6
Type 4X, IP66
Class II Divison 2 GP FG T6 --- T6(Tamb v 80C)
Single Seal Device
Class III
Natural Gas Approved
Vmax = 30 VDC
Ex ia Intrinsically Safe T4(Tamb v 125C)
Imax = 17.5 mA
Class I,II,III Division 1 GP A,B,C,D, T5(Tamb v 95C) Type 4X, IP66
Ci = 0 uF
E,F,G per drawing GE42818
Li = 0 mH T6(Tamb v 80C)

DVC60x5 T4(Tamb v 125C)

Explosion Proof
(x = 1,2,3) --- T5(Tamb v 95C) Type 4X, IP66
Class I Division 1 GP B,C,D T6
T6(Tamb v 80C)
Class I Division 2 GP A,B,C,D T6 T4(Tamb v 125C)
Class II Division 1,2 GP E,F,G T6 --- T5(Tamb v 95C) Type 4X, IP66
Class III T6(Tamb v 80C)

1-8 December 2009

 Introduction and Specifications
Table 1-5. Hazardous Area Classifications—FM (United States)
Certification Enclosure
Type Certification Obtained Entity Rating Temperature Code
Body Rating
Intrinsically Safe Vmax = 30 VDC
Class I,II,III Division 1 GP A,B,C,D, Imax = 226 mA
E,F,G per drawing GE42819 T5 Ci = 5 nF T5(Tamb v 80C) NEMA 4X
Natural Gas Approved Li = 0.55 mH

DVC60x0 Explosion Proof

Pi = 1.4 W
1
DVC60x0S Class I Division 1 GP B,C,D T6 −−− T6(Tamb v 80C) NEMA 4X
(x = 1,2,3) Natural Gas Approved
Class I Division 2 GP A,B,C,D T6
Class II Division 1 GP E,F,G T6
Class II Division 2 GP F,G T6 −−− T6(Tamb v 80C) NEMA 4X
Class III
Natural Gas Approved
Intrinsically Safe Vmax = 30 VDC Voc = 9.6 VDC
Class I,II,III Division 1 GP A,B,C,D,E, Imax = 226 mA Isc = 3.5 mA T4(Tamb v 125C)
F,G per drawing GE42819 T5 Ci = 5 nF Ca = 3.6 uF T5(Tamb v 95C) NEMA 4X
Natural Gas Approved Li = 0.55 mH La = 100 mH T6(Tamb v 80C)
Pi = 1.4 W Po = 8.4 mW
FM Explosion Proof
DVC6005 Class I Division 1 GP B,C,D T6 −−− T6(Tamb v 60C) NEMA 4X
Natural Gas Approved
Class I Division 2 GP A,B,C,D T6
Class II Division 1 GP E,F,G T6
Class II Division 2 GP F,G T6 −−− T6(Tamb v 60C) NEMA 4X
Clas III
Natural Gas Approved
Vmax = 30 VDC
Intrinsically Safe Imax = 17.5 mA T4(Tamb v 125C)
IS Class I,II,III Division 1 GP A,B,C,D, Ci = 0 nF T5(Tamb v 95C) NEMA 4X
E,F,G per drawing GE42819 Li = 0 mH T6(Tamb v 80C)
Pi = 105 mW
DVC60x5 T4(Tamb v 125C)
(x = 1,2,3) Explosion Proof
−−− T5(Tamb v 95C) NEMA 4X
XP Class I Division 1 GP A,B,C,D
T6(Tamb v 80C)
NI Class I Division 2 GP A,B,C,D T4(Tamb v 125C)
DI Class II Division 1 GP E,F,G −−− T5(Tamb v 95C) NEMA 4X
S Class II Division 2 GP F,G T6(Tamb v 80C)

December 2009 1-9

 DVC6000 Digital Valve Controllers
Table 1-6. Hazardous Area Classifications—ATEX
Enclosure
Certificate Type Certification Obtained Entity Rating Temperature Code
Rating
II 1 G & D Ui = 30 VDC
Gas
Ii = 226 mA
Ex ia IIC T5/T6—Intrinsically Safe T5(Tamb v 80C)
Ci = 5 nF IP66
Dust T6(Tamb v75C)
Li = 0.55 mH
Ex iaD 20 T100C (Tamb v 80C)
1 Ex iaD 20 T85C (Tamb v 75C)
Pi = 1.4 W
II 2 G & D
Gas
DVC60x0 Ex d IIB+H2 T5/T6—Flameproof T5(Tamb v 85C)
DVC60x0S −−− IP66
Dust T6(Tamb v75C)
(x = 1,2,3) Ex tD A21 IP66 T90C (Tamb v 85C)
Ex tD A21 IP66 T80C (Tamb v 75C)
II 3 G & D
Gas
Ex nCL IIC T5/T6—Type n T5(Tamb v 80C)
−−− IP66
Dust T6(Tamb v75C)
Ex tD A22 IP66 T85C (Tamb v 80C)
Ex tD A22 IP66 T80C (Tamb v 75C)
II 1 G & D
Ui = 30 VDC Uo = 9.6 VDC
Gas
Ii = 226 mA Io = 3.5 mA
Ex ia IIC T5/T6—Intrinsically Safe T5(Tamb v 80C)
Ci = 5 nF Co = 3.6 uF IP66
Dust T6(Tamb v75C)
Li = 0.55 mH Lo = 100 mH
Ex iaD 20 T100C (Tamb v 80C)
Pi = 1.4 mW Po = 8.4 mW
Ex iaD 20 T85C (Tamb v 75C)
II 2 G & D
Gas
Ex d IIB T5/T6—Flameproof T5(Tamb v 80C)
DVC6005 −−− IP66
Dust T6(Tamb v75C)
Ex tD A21 IP66 T85C (Tamb v 80C)
ATEX
Ex tD A21 IP66 T75C (Tamb v 70C)
II 3 G & D
Gas
Ex nL IIC T5/T6—Type n T5(Tamb v 80C)
−−− IP66
Dust T6(Tamb v75C)
Ex tD A22 IP66 T85C (Tamb v 80C)
Ex tD A22 IP66 T80C (Tamb v 75C)
II 1 G & D
Gas Ui = 30 VDC
Ex ia IIC T4/T5/T6—Intrinsically Safe Ii = 17.5 mA T4(Tamb v 125C)
Dust Ci = 0 uF T5(Tamb v 95C) IP66
Ex iaD 20 T135C (Tamb v 125C) Li = 0 mH T6(Tamb v 80C)
Ex iaD 20 T100C (Tamb v 95C) Pi = 105 mW
Ex iaD 20 T85C (Tamb v 80C)
II 2 G & D
Gas
Ex d IIC T4/T5/T6—Flameproof T4(Tamb v 125C)
DVC60x5 −−−
Dust T5(Tamb v 95C) IP66
(x = 1,2,3) Ex tD A21 IP66 T130C (Tamb v 125C) T6(Tamb v 80C)
Ex tD A21 IP66 T100C (Tamb v 95C)
Ex tD A22 IP66 T85C (Tamb v 80C)
II 3 G & D
Gas
Ex nA IIC T4/T5/T6—Type n T4(Tamb v 125C)
Dust −−− T5(Tamb v 95C) IP66
Ex tD A22 IP66 T130C (Tamb v 125C) T6(Tamb v 80C)
Ex tD A22 IP66 T100C (Tamb v 95C)
Ex tD A22 IP66 T85C (Tamb v 80C)

1-10 December 2009

 Introduction and Specifications
Table 1-7. Hazardous Area Classifications—IECEx
Enclosure
Certificate Type Certification Obtained Entity Rating Temperature Code
Rating
Intrinsically Safe Ui = 30 VDC
Gas Ii = 226 mA
T5(Tamb v 80C) NEMA 4X,
Ex ia IIC T5/T6 per drawing GE42990 Ci = 5 nF
T6(Tamb v 75C) IP66
Li = 0.55 mH
DVC60x0
DVC60x0S Flameproof
Pi = 1.4 W

T5(Tamb v 80C) NEMA 4X,

1
(x = 1,2,3) Gas −−−
T6(Tamb v 75C) IP66
Ex d IIB+H2 T5/T6
Type n
T5(Tamb v 80C) NEMA 4X,
Gas −−−
T6(Tamb v 75C) IP66
Ex nC IIC T5/T6
Intrinsically Safe Ui = 30 VDC Uo = 9.6 VDC
Gas Ii = 226 mA Io = 3.5 mA
T5(Tamb v 80C) NEMA 4X,
Ex ia IIC T5/T6 per drawing GE42990 Ci = 5 nF Co = 3.6 uF
T6(Tamb v 75C) IP66
Li = 0.55 mH Lo = 100 mH
Pi = 1.4 W Po = 8.4 mW
IECEx DVC6005 Flameproof T5(Tamb v 80C) NEMA 4X,
Gas −−−
T6(Tamb v 75C) IP66
Ex d IIB T5/T6
Type n
T5(Tamb v 80C) NEMA 4X,
Gas −−−
T6(Tamb v 75C) IP66
Ex nC IIC T5/T6
Intrinsically Safe Ui = 30 VDC
Gas Ii = 17.5 mA T4(Tamb v 125C)
NEMA 4X,
Ex ia IIC T4/T5/T6 Ci = 0 uF T5(Tamb v 95C)
IP66
Li = 0 mH T6(Tamb v 80C)
Pi = 105 mW
DVC60x5 Flameproof T4(Tamb v 125C)
(x = 1,2,3) NEMA 4X,
Gas −−− T5(Tamb v 95C)
IP66
Ex d IIC T4/T5/T6 T6(Tamb v 80C)
Type n T4(Tamb v 125C)
NEMA 4X,
Gas −−− T5(Tamb v 95C)
IP66
Ex nA IIC T4/T5/T6 T6(Tamb v 80C)

Table 1-8. Hazardous Area Classifications—NEPSI

Enclosure
Certificate Type Certification Obtained Entity Rating Temperature Code
Rating
Intrinsically Safe Ui = 30 V
Gas Ii = 226 mA
T5(Tamb v 80C) NEMA 4X,
Ex ia IIC T5/T6 Ci = 5 nF
T6(Tamb v 75C) IP66
Dust Li = 0.55 mH
DVC60x0 DIP A21 T5 Pi = 1.4 W
NEPSI
(x = 1,2,3) Flameproof
Gas
T5(Tamb v 80C) NEMA 4X,
Ex d IIC T5/T6(1) −−−
Dust T6(Tamb v 75C) IP66
DIP A21 T5
1. Except acetylene.

Table 1-9. Hazardous Area Classifications—INMETRO

Enclosure
Certificate Type Certification Obtained Entity Rating Temperature Code
Rating
Intrinsically Safe Ui = 30 V
BR-Ex ia IIC T5 Ii = 180 mA
Ci = 5 nF T5(Tamb v 80C) Type 4X, IP66
DVC60x0 Li = 0.55 mH
INMETRO
(x = 1,2,3) Pi = 1.4 W
Flameproof
−−− T6(Tamb v 60C) Type 4X, IP66
BR-Ex d IIB+H2 T6

December 2009 1-11

 DVC6000 Digital Valve Controllers

1-12 December 2009

 Installation
2-2

Section 2 Installation
Special Instructions for “Safe Use” and
Installations in Hazardous Areas 2
CSA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
FM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
ATEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
IECEx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
NEPSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
INMETRO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Mounting Guidelines
DVC6010 on Sliding-Stem Actuators (up to 4 inches travel) . . . . . . . . . . . . . . . . 2-5
DVC6020 on Long-Stroke
Sliding-Stem Actuators (4 to 24 inches travel) and Rotary Actuators . . . . . . . 2-8
DVC6030 on Quarter-Turn Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
DVC6005 Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Wall Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Pipestand Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
DVC6015 on Sliding-Stem Actuators (up to 4 inches travel) . . . . . . . . . . . . . . . . 2-13
DVC6025 on Long-Stroke Sliding-Stem Actuators
(4 to 24 inches travel) and Rotary Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
DVC6035 on Quarter-Turn Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
67CFR Filter Regulator
Integral-Mounted Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Yoke-Mounted Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Casing-Mounted Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Pneumatic Connections
Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Single-Acting Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Double-Acting Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Special Construction to Support Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Electrical Connections
4-20 mA Loop Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

December 2009 2-1

 DVC6000 Digital Valve Controllers
Remote Travel Sensor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Test Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Communication Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Wiring Practices
Control System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
HART Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2 Voltage Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Compliance Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Maximum Cable Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Installation in Conjunction with a Rosemount

333 HART Tri-Loop HART-to-Analog
Signal Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

2-2 December 2009


Installation
The DVC6000 can be used with either air or natural
gas as the supply medium. If using natural gas as the
pneumatic supply medium, natural gas will be used in
the pneumatic output connections of the DVC6000 to
any connected equipment. In normal operation the unit
will vent the supply medium into the surrounding
atmosphere unless it is remotely vented. When using
natural gas as the supply medium, in a non-hazardous
location in a confined area, remote venting of the unit
is required. Failure to do so could result in personal
injury, property damage, and area re-classification. For
hazardous locations remote venting of the unit may be
required, depending upon the area classification, and
as specified by the requirements of local, regional, and
federal codes, rules and regulations. Failure to do so
when necessary could result in personal injury,
property damage, and area re-classification.
Note
Gas Certified DVC6000 digital valve
controllers are FM and CSA Single
Seal approved for use with natural gas
as the supply medium.
WARNING
Avoid personal injury or property
damage from sudden release of
process pressure or bursting of parts.
Before proceeding with any
Installation procedures:
 Always wear protective clothing,
gloves, and eyewear.
 Personal injury or property
damage may result from fire or
explosion if natural gas is used as the
supply medium and appropriate
preventive measures are not taken.
Preventive measures may include, but
are not limited to, one or more of the
following: Remote venting of the unit,
re-evaluating the hazardous area
classification, ensuring adequate
ventilation, and the removal of any
ignition sources. For information on
remote venting of this controller, refer
to page 2-19.
December 2009
Installation
 If installing this into an existing
application, also refer to the WARNING
at the beginning of the Maintenance
section of this instruction manual.
 Check with your process or safety
engineer for any additional measures
that must be taken to protect against
process media.
2
WARNING
To avoid static discharge from the
plastic cover, do not rub or clean the
cover with solvents. To do so could
result in an explosion. Clean with a
mild detergent and water only.
WARNING
This unit vents the supply medium
into the surrounding atmosphere.
When installing this unit in a
non-hazardous (non-classified)
location in a confined area, with
natural gas as the supply medium,
you must remotely vent this unit to a
safe location. Failure to do so could
result in personal injury or property
damage from fire or explosion, and
area re-classification.
When installing this unit in a
hazardous (classified) location remote
venting of the unit may be required,
depending upon the area
classification, and as specified by the
requirements of local, regional, and
federal codes, rules and regulations.
Failure to do so when necessary
could result in personal injury or
property damage from fire or
explosion, and area re-classification.
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
reduce case pressure buildup.
continued on next page
2-3
 DVC6000 Digital Valve Controllers
In addition to remote venting of the
unit, ensure that all caps and covers
are correctly installed. Failure to do so
could result in personal injury or
property damage from fire or
explosion, and area re-classification.
2 intrinsically safe rules.
Special Instructions for “Safe Use”
and Installations in Hazardous
Locations
Certain nameplates may carry more than one
approval, and each approval may have unique
installation/wiring requirements and/or conditions of
safe use. These special instructions for “safe use” are
in addition to, and may override, the standard
installation procedures. Special instructions are listed
by approval.
WARNING
Failure to follow these conditions of
“safe use” could result in personal
injury or property damage from fire or
explosion, or area re-classification.
CSA
Special Conditions of Safe Use
Intrinsically Safe, Explosion proof, Division 2,
Dust-Ignition proof
No special conditions for safe use.
Refer to table 1-4 for approval information, figures B-1
and B-3 for CSA loop schematics, and figures B-2 and
B-4 for CSA nameplates.
FM
Special Conditions of Safe Use
Intrinsically Safe, Explosion proof, Non-incendive,
Dust-Ignition proof
No special conditions for safe use.
Refer to table 1-5 for approval information, figures B-5
and B-7 for FM loop schematics, and figures B-6 and
B-8 for FM nameplates.
2-4
ATEX
Special Conditions for Safe Use
Intrinsically Safe, Dust
1. This apparatus can only be connected to an
intrinsically safe certified equipment and this
combination must be compatible as regards the
2. The electrical parameters of this equipment must
not exceed any following values:
UOv 30 V; IO v226 mA; POv 1.4 W
3. Operating ambient temperature: −52C or −40C
to + 80C
4. For the model with aluminum body: the apparatus
must not be submitted to frictions or mechanical
impacts.
Refer to table 1-6 for additional approval information,
and figure B-9 for the ATEX Intrinsic Safety, Dust
nameplates.
Flameproof, Dust
Operating ambient temperature: −52C or −40C to
+ 85C
Refer to table 1-6 for additional approval information,
and figure B-10 for ATEX Flameproof, Dust
nameplates.
Type n, Dust
Operating ambient temperature: −52C or −40C to
+ 80C
Refer to table 1-6 for additional approval information,
and figure B-11 for ATEX Type n, Dust nameplates.
IECEx
Conditions of Certification
Intrinsically Safe, Type n, Flameproof
Ex ia / Ex d / Ex n
1. Warning: Electrostatic charge hazard. Do not rub
or clean with solvents. To do so could result in an
explosion.
EX d / Ex n
2. Do not open while energized.
Refer to table 1-7 for additional approval information,
and figures B-12 and B-14 for IECEx loop schematics,
and figures B-13 and B-15 for IECEx nameplates.
December 2009

NEPSI
Notes for Safe Use of the Certified Product
Intrinsically Safe, Dust and Flameproof, Dust
DVC6000 digital valve controllers (designated as
controller hereafter) have been proved to be in
conformity with the requirements specified in the
national standards GB3836.1-2000, GB3836.2-2000,
GB3836.4-2000, and GB12476.1-2000 through
inspections conducted by National Supervision and
Inspection Centre for Explosion Protection and Safety
of Instrumentation (NEPSI). The Ex markings for the
products are Ex d II CT5 (acetylene not included),
DIPA21T5 or Ex ia II CT5, DIPA21T5 respectively and
their Ex certificate numbers are GYJ04504 and
GYJ04505. When using the product , the user should
pay attention to the items stated below:
1. The specific product types of approved DVC6000
digital valve controllers this time are DVC6010,
DVC6020 and DVC6030.
2. The enclosure of the controller provides a
grounding terminal, and the user should install a
reliable grounding wire connected to it when mounting
and using the controller.
3. The controller’s cable entrance (1/2 NPT) must be
fitted with a cable entry device which is Ex-approved
through inspection of explosion protection, in
conformity with relevant standards of GB3836 and has
a corresponding rating of explosion protection.
4. The maximum operating ambient temperature
range of the controller is −40C to +80C.
5. The principle of “Opening equipment’s cover is
allowed only after the power is off ” must be abided by
when using and maintaining the controller in the field.
6. The values for intrinsically safe parameters of the
controller (Intrinsically safe type) are as follow:
Ui = 30V, Ii = 226mA, Pi = 1.4W, Ci = 5nF,
Li = 0.55mH
7. While the controller forms an intrinsically safe
explosion protection system together with a
corresponding associated equipment safety barrier,
the following requirements must be met:
Uo vUi , Io vIi, Po vPi , Co wCi + Cc,
Lo wLi + Lc
Note
Where Cc and Lc represent distributing
capacitance and inductance of the
connecting cable respectively.
8. The safety barrier must be placed at safety
location, and the instruction manuals of both the
product and fitted safety barrier must be followed while
December 2009
Installation
conducting system wiring and using the product; The
connecting cable should be a shield cable with the
area of core section being greater than 0.5mm2 and its
shield (or insulation screen) being grounded at a safe
location and insulated from the product enclosure; The
cable should be routed so that the electro-magnetic
interference can be eliminated as much as possible
and that the cable distributing parameters of
capacitance and inductance can be controlled within
0.06mF/1mH.
2
9. The user must not be allowed to replace the
internal electric components of the product and
change the condition of system wiring at will and on
his own.
10. The user must follow the relevant rules specified
by the product instruction manual, the “15th Section of
Electric Equipment Used in Explosive Gaseous
Environment: Electric Installation in Hazardous
Locations (except for coal mine)” of GB3836.15-2000
standard, the “Design Code for Electric Power
Installation in Explosive and Fire-hazardous
Environment” of GB50058-1992 standard, and the
“Safety Regulations against dust explosion” of
GB15577-1995 standard while performing installation,
operation, and maintenance for the product.
Refer to table 1-8 for additional approval information,
and figure B-16 for the NEPSI approvals nameplate.
INMETRO
Special Conditions of Safe Use
Intrinsically Safe, Flameproof
Refer to table 1-9 for approval information and figure
B-17 for INMETRO nameplates.
Contact your Emerson Process Management sales
office for additional safe use information.
Mounting Guidelines
DVC6010 on Sliding-Stem Actuators Up
to 102 mm (4 Inches) of Travel
If ordered as part of a control valve assembly, the
factory mounts the digital valve controller on the
actuator, makes pneumatic connections to the
actuator, sets up, and calibrates the instrument. If you
purchased the digital valve controller separately, you
will need a mounting kit to mount the digital valve
controller on the actuator. See the instructions that
come with the mounting kit for detailed information on
mounting the digital valve controller to a specific
actuator model.
2-5
 DVC6000 Digital Valve Controllers

CAP SCREW, FLANGED

MACHINE SCREW

SHIELD

ADJUSTMENT ARM

CONNECTOR ARM

CAP SCREW
PLAIN WASHER

29B1674-A / DOC

Figure 2-1. FIELDVUE DVC6010 Digital Valve Controller Mounted on Sliding-Stem Actuator with up to 2 Inches Travel

The DVC6010 digital valve controller mounts on
sliding-stem actuators with up to 102 mm (4 inch)
travel. Figure 2-1 shows a typical mounting on an
actuator with up to 51 mm (2 inch) travel. Figure 2-2
shows a typical mounting on actuators with 51 to 102
mm (2 to 4 inch) travel. For actuators with greater than
102 mm (4 inch) travel, see the guidelines for
mounting a DVC6020 digital valve controller.
Note
Do not use the stainless steel
DVC6010S in high vibration service
where the mounting bracket uses
standoffs (spacers) to mount to the
actuator.
Refer to the following guidelines when mounting on
sliding-stem actuators with up to 4 inches of travel.
Where a key number is referenced, refer
to figure 8-2.
1. Isolate the control valve from the process line
pressure and release pressure from both sides of the
valve body. Shut off all pressure lines to the actuator,
releasing all pressure from the actuator. Use lock-out
procedures to be sure that the above measures stay in
effect while you work on the equipment.
2. Attach the connector arm to the valve stem
connector.
3. Attach the mounting bracket to the digital valve
controller housing.
4. If valve travel exceeds 2 inches, a feedback arm
extension is attached to the existing 2-inch feedback
arm. Remove the existing bias spring (key 78) from
the 2-inch feedback arm (key 79). Attach the feedback
arm extension to the feedback arm (key 79) as shown
in figure 2-2.
5. Mount the digital valve controller on the actuator as
described in the mounting kit instructions.
6. Set the position of the feedback arm (key 79) on
the digital valve controller to the no air position by
inserting the alignment pin (key 46) through the hole
on the feedback arm as follows:

2-6 December 2009

 Installation
HEX NUT
CAP SCREW, FLANGED

FEEDBACK ARM
EXTENSION, LOCK WASHER
BIAS SPRING

ADJUSTMENT ARM
SPACER

MACHINE SCREW, FLAT

HEAD
2
HEX NUT, FLANGED

MACHINE SCREW
LOCK WASHER
SHIELD
MACHINE SCREW,
LOCK WASHER, PLAIN WASHER
HEX NUT

CONNECTOR ARM

Figure 2-2. FIELDVUE DVC6010 Digital Valve Controller Mounted on Sliding-Stem Actuator with 2 to 4 Inches Travel

 For air-to-open actuators (i.e., the actuator

stem retracts into the actuator casing or cylinder as air
pressure to the casing or lower cylinder increases),
insert the alignment pin into the hole marked ‘‘A’’. For
this style actuator, the feedback arm rotates
counterclockwise, from A to B, as air pressure to the
casing or lower cylinder increases.

 For air-to-close actuators (i.e., the actuator

stem extends from the actuator casing or cylinder as
air pressure to the casing or upper cylinder increases),
insert the alignment pin into the hole marked ‘‘B’’. For SPRING RELAXED
this style actuator, the feedback arm rotates
clockwise, from B to A, as air pressure to the casing or FEEDBACK ARM
upper cylinder increases. BIAS SPRING

Note ADJUSTMENT
ARM PIN
When performing the following steps, BIAS
SPRING
ensure there is enough clearance
between the adjustment arm and the A7209-1
SPRING UNDER TENSION OF
feedback arm to prevent interference ADJUSTMENT ARM PIN
with the bias spring.
Figure 2-3. Locating Adjustment Arm Pin in Feedback Arm

8. Install the external lock washer on the adjustment

7. Apply anti-seize (key 64) to the pin of the
adjustment arm. As shown in figure 2-3, place the pin
into the slot of the feedback arm or feedback arm
extension so that the bias spring loads the pin against
the side of the arm with the valve travel markings.
arm. Position the adjustment arm in the slot of the
connector arm and loosely install the flanged hex nut.
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 flanged hex nut.

December 2009 2-7

 DVC6000 Digital Valve Controllers
CAM/ROLLER POSITION MARK LOCK WASHER
A
CAP SCREW
CAP SCREW, HEX
SOCKET

PLAIN WASHER
HEX NUT

2 STUD, CONT
THREAD

CAM
VENT MOUNTING PLATE
STUD, CONT THREAD

HEX NUT

A PLAIN WASHER
VENT ADAPTOR
29B1665-B / DOC
SPACER
SECTION A‐A

Figure 2-4. FIELDVUE DVC6020 Digital Valve Controller Mounted on Long-Stroke Sliding-Stem Actuator

10. Remove the alignment pin (key 46) and store it in

the module base next to the I/P assembly.
11. After calibrating the instrument, attach the shield
with two machine screws.
DVC6020 on Long-Stroke (4 to 24 Inch
Travel) Sliding-Stem Actuators and
Rotary Actuators
If ordered as part of a control valve assembly, the
factory mounts the digital valve controller on the
actuator, makes pneumatic connections to the
actuator, sets up, and calibrates the instrument. If you
purchased the digital valve controller separately, you
will need a mounting kit to mount the digital valve
controller on the actuator. See the instructions that
come with the mounting kit for detailed information on
mounting the digital valve controller to a specific
actuator model.
Note
Do not use the stainless steel
DVC6020S in high vibration service
where the mounting bracket uses
standoffs (spacers) to mount to the
actuator.
DVC6020 digital valve controllers use a cam (designed
for linear response) and roller as the feedback
mechanism. Figure 2-4 shows an example of
mounting on sliding-stem actuators with travels from 4
inches to 24 inches. Some long-stroke applications will
require an actuator with a tapped lower yoke boss.
Figures 2-5 and 2-6 show the DVC6020 mounted on
rotary actuators.

As shown in figure 2-5, two feedback arms are

available for the digital valve controller. Most
long-stroke sliding-stem and rotary actuator
installations use the long feedback arm [62 mm (2.45
Note inches) from roller to pivot point]. Installations on
Fisher 1051 size 33 and 1052 size 20 and 33
All cams supplied with FIELDVUE actuators use the short feedback arm [54 mm (2.13
mounting kits are characterized to inches) from roller to pivot point]. Make sure the
provide a linear response. correct feedback arm is installed on the digital valve
controller before beginning the mounting procedure.

2-8 December 2009

 Installation

MACHINE SCREW
MOUNTING ADAPTOR
CAP SCREW, HEX SOCKET CAP SCREW,
HEX SOCKET

CAM
29B1672-A / DOC CAM
MACHINE SCREW
29B2094-A / DOC

TYPICAL MOUNTING WITH SHORT FEEDBACK ARM TYPICAL MOUNTING WITH LONG FEEDBACK ARM
(FISHER 1052 SIZE 33 ACTUATOR SHOWN) (FISHER 1061 SIZE 30-68 ACTUATOR SHOWN)

Figure 2-5. FIELDVUE DVC6020 Digital Valve Controller Mounted on Rotary Actuator

Refer to figures 2-4, 2-5, and 2-6 for parts locations. FOLLOWER ARM
EXTENSION
Also, where a key number is referenced, refer to figure MACHINE SCREW,
8-3. Refer to the following guidelines when mounting LOCK WASHER,
HEX NUT
on sliding-stem actuators with 4 to 24 inches of travel
CAP SCREW,
or on rotary actuators: HEX SOCKET

1. Isolate the control valve from the process line

pressure and release pressure from both sides of the
valve body. Shut off all pressure lines to the
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 a cam is not already installed on the actuator, CAP SCREW

install the cam as described in the instructions
included with the mounting kit. For sliding-stem
actuators, the cam is installed on the stem connector.
3. If a mounting plate is required, fasten the mounting
plate to the actuator.
4. For applications that require remote venting, a
pipe-away bracket kit is available. Follow the
instructions included with the kit to replace the existing
mounting bracket on the digital valve controller with
the pipe-away bracket and to transfer the feedback
parts from the existing mounting bracket to the
pipe-away bracket.
29B1673-A / DOC CAM
Figure 2-6. FIELDVUE DVC6020 Digital Valve Controller with
Long Feedback Arm and Follower Arm Extension Mounted on a
Rotary Actuator
5. Larger size actuators may require a follower arm
extension, as shown in figure 2-6. If required, the
follower arm extension is included in the mounting kit.
Follow the instructions included with the mounting kit
to install the follower arm extension.
6. Apply anti-seize (key 64) to the arm assembly pin
as shown in figure 2-7.

December 2009 2-9

 DVC6000 Digital Valve Controllers
MOUNTING
ADAPTER
MOUNTING
BRACKET
BIAS SPRING
ARM ASSEMBLY PIN
2 ARM ASSEMBLY
FEEDBACK
ARM ASSEMBLY
Figure 2-7. Locating Adjustment Arm Pin in Feedback Arm of a
FIELDVUE DVC6020 Digital Valve Controller
7. Mount the DVC6020 on the actuator as follows:
 If required, a mounting adaptor is included in the
mounting kit. Attach the adaptor to the actuator as
shown in figure 2-5. Then attach 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.
 If no mounting adaptor is required, attach the
digital valve controller assembly to the actuator or
mounting plate. The roller on the digital valve
controller feedback arm will contact the actuator cam
as it is being attached.
8. For long-stroke sliding-stem actuators, after the
mounting is complete, check to be sure the roller
aligns with the position mark on the cam (see
figure 2-4). If necessary, reposition the cam to attain
alignment.
DVC6030 on Quarter-Turn Actuators
If ordered as part of a control valve assembly, the
factory mounts the digital valve controller on the
actuator, makes pneumatic connections to the
actuator, sets up, and calibrates the instrument. If you
purchased the digital valve controller separately, you
will need a mounting kit to mount the digital valve
controller on the actuator. See the instructions that
come with the mounting kit for detailed information on
2-10
mounting the digital valve controller to a specific
actuator model.
Figure 2-8 shows the DVC6030 digital valve controller
mounted on a quarter-turn actuator. Refer to figure 2-8
for parts locations. Refer to the following guidelines
when mounting on quarter-turn actuators:
Note
Due to NAMUR mounting limitations,
do not use the stainless steel
DVC6030S in high vibration service.
1. Isolate the control valve from the process line
pressure and release pressure from both sides of the
valve body. Shut off all pressure lines to the
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, remove the existing hub from the
actuator shaft.
3. If a positioner plate is required, attach the
positioner plate to the actuator as described in the
mounting kit instructions.
4. If required, attach the spacer to the actuator shaft.
Refer to figures 2-9 and 2-10. The travel indicator
assembly can have a starting position of 7:30 or
10:30. Determine the desired starting position then
proceed with the next step. Considering the top of the
digital valve controller as the 12 o’clock position, in the
next step attach the travel indicator, so that the pin is
positioned as follows:
 If increasing pressure from the digital valve
controller output A rotates the potentiometer shaft
clockwise (as viewed from the back of the
instrument), mount the travel indicator assembly such
that the arrow is in the 10:30 position, as shown in
figure 2-9.
 If increasing pressure from the digital valve
controller output A rotates the potentiometer shaft
counterclockwise (as viewed from the back of the
instrument), mount the travel indicator assembly such
that the arrow is in the 7:30 position, as shown in
figure 2-10.
December 2009
 Installation
MOUNTING BRACKET
FEEDBACK ARM

TRAVEL INDICATOR PIN

2
29B1703-A / DOC
SPACER

TRAVEL INDICATOR

19B3879−A / DOC

Figure 2-8. Mounting a FIELDVUE DVC6030 Digital Valve Controller on a Rotary Actuator (Fisher 1032 Size 425A Shown)

STARTING POSITION OF TRAVEL

INDICATOR ASSEMBLY (DIGITAL
VALVE CONTROLLER OUTPUT A
AT 0 PSI. )
IN THIS POSITION, THE “B” HOLE
IN THE FEEDBACK ARM WILL BE
ALIGNED WITH THE REFERENCE
HOLE IN THE DIGITAL VALVE
CONTROLLERS HOUSING.

E0989 / DOC

DVC6030 FEEDBACK MOVEMENT OF TRAVEL

ARM MOVEMENT INDICATOR ASSEMBLY WITH
INCREASING PRESSURE FROM
OUTPUT A.

ACTUATOR SHAFT MOVEMENT

STARTING POSITION OF THE ACTUATOR TRAVEL

INDICATOR ASSEMBLY IF INCREASING PRESSURE
FROM OUTPUT A DRIVES THE INDICATOR
COUNTERCLOCKWISE (THE POTENTIOMETER
SHAFT WILL ROTATE CLOCKWISE AS VIEWED 19B3879-A / DOC-1
FROM THE BACK OF THE FIELDVUE INSTRUMENT)

NOTE: DVC6030 TRAVEL COUNTS (CLOCKWISE) = 3400  200

Figure 2-9. Explanation of FIELDVUE DVC6030 Travel Indicator Starting Position and Movement, if Clockwise Orientation is Selected
for “Travel Sensor Motion” in ValveLink Software or the Field Communicator

December 2009 2-11

 DVC6000 Digital Valve Controllers

MOVEMENT OF TRAVEL E0989

INDICATOR ASSEMBLY WITH
2 INCREASING PRESSURE FROM
OUTPUT A.
DVC6030 FEEDBACK
ARM MOVEMENT

19B3879-A / DOC-2

STARTING POSITION OF
TRAVEL INDICATOR ASSEMBLY
(DIGITAL VALVE CONTROLLER
OUTPUT A AT 0 PSI).
IN THIS POSITION, THE “A” HOLE
IN THE FEEDBACK ARM WILL BE
ALIGNED WITH THE REFERENCE
HOLE IN THE DIGITAL VALVE
CONTROLLERS HOUSING.
ACTUATOR SHAFT MOVEMENT
STARTING POSITION OF THE TRAVEL INDICATOR
ASSEMBLY IF INCREASING PRESSURE FROM
OUTPUT A DRIVES THE INDICATOR CLOCKWISE.
THE POTENTIOMETER SHAFT WILL ROTATE
COUNTERCLOCKWISE AS VIEWED FROM THE
BACK OF THE FIELDVUE INSTRUMENT.

NOTE: DVC6030 TRAVEL COUNTS (COUNTERCLOCKWISE) = 600  200

Figure 2-10. Explanation of FIELDVUE DVC6030 Travel Indicator Starting Position and Movement if Counterclockwise Orientation is
Selected for “Travel Sensor Motion” in ValveLink Software or the Field Communicator

Note
HOLE A
ValveLink software and the Field
HOLE B Communicator use the convention of
clockwise (figure 2-9) and
counterclockwise (figure 2-10) when
viewing the potentiometer shaft from
the back of the FIELDVUE instrument.

5. Attach the travel indicator, to the shaft connector or

spacer as described in the mounting kit instructions.
6. Attach the mounting bracket to the digital valve
controller.
TRAVEL
INDICATOR PIN
7. Position the digital valve controller so that the pin
FEEDBACK ARM
on the travel indicator engages the slot in the feedback
48B4164-B / DOC BIAS SPRING
arm and that the bias spring loads the pin as shown in
figure 2-11. Attach the digital valve controller to the
actuator or positioner plate.
Figure 2-11. Positioning Travel Indicator Pin in the Feedback Arm 8. If a travel indicator scale is included in the
(Viewed as if Looking from the FIELDVUE DVC6030 toward the mounting kit, attach the scale as described in the
Actuator) mounting kit instructions.

2-12 December 2009


10C1796-A / Doc
Figure 2-12. FIELDVUE DVC6005 Base Unit with Mounting
Bracket (Rear View)
DVC6005 Base Unit
For remote-mounted digital valve controllers, the
DVC6005 base unit ships separately from the control
valve and does not include tubing, fittings or wiring.
See the instructions that come with the mounting kit
for detailed information on mounting the digital valve
controller to a specific actuator model.
For remote-mounted instruments, mount the DVC6005
base unit on a 50.8 mm (2-inch) pipestand or wall. The
included bracket is used for either mounting method.
Wall Mounting
Refer to figures 2-12 and 2-13. Drill two holes in the
wall using the dimensions shown in figure 2-12. Attach
the mounting bracket to the base unit using four
spacers and 25.4 mm (1-inch) 1/4-20 hex head
screws. Attach the base unit to the wall using suitable
screws or bolts.
Pipestand Mounting
Refer to figure 2-13. Position a standoff on the back of
the base unit. Using two 101.6 mm (4-inch) 1/4-20 hex
head screws loosely attach the base unit to the
pipestand with the mounting bracket. Position the
second standoff, then using the remaining 101.6 mm
(4-inch) hex head screws, securely fasten the base
unit to the pipe stand.
DVC6015 on Sliding-Stem Actuators Up
to 102 mm (4 Inches) of Travel
If ordered as part of a control valve assembly, the
factory mounts the digital valve controller on the
December 2009
Installation
actuator, makes pneumatic connections to the
actuator, sets up, and calibrates the instrument. If you
purchased the digital valve controller separately, you
will need a mounting kit to mount the digital valve
controller on the actuator. See the instructions that
come with the mounting kit for detailed information on
mounting the digital valve controller to a specific
actuator model.
2
Note
Refer to DVC6005 Base Unit mounting
guidelines on page 2-13 when
installing a DVC6015 remote feedback
unit.
The DVC6015 remote feedback unit mounts on
sliding-stem actuators with up to 102 mm (4-inch)
travel. Figure 2-1 shows a typical mounting on an
actuator with up to 51 mm (2 inch) travel. Figure 2-2
shows a typical mounting on actuators with 51 to 102
mm (2 to 4 inch) travel. For actuators with greater than
102 mm (4 inch) travel, see the guidelines for
mounting a DVC6025 remote feedback unit.
Note
While the housing differs on the
DVC6015 and the DVC6010, feedback
parts are the same.
Refer to the following guidelines when mounting on
sliding-stem actuators with up to 4 inches of travel.
Where a key number is referenced, figure 8-7.
1. Isolate the control valve from the process line
pressure and release pressure from both sides of the
valve body. Shut off all pressure lines to the actuator,
releasing all pressure from the actuator. Use lock-out
procedures to be sure that the above measures stay in
effect while you work on the equipment.
2. Attach the connector arm to the valve stem
connector.
3. Attach the mounting bracket to the digital valve
controller housing.
4. If valve travel exceeds 2 inches, a feedback arm
extension is attached to the existing 2-inch feedback
2-13
 DVC6000 Digital Valve Controllers
SPACER
this style actuator, the feedback arm rotates
counterclockwise, from A to B, as air pressure to the
casing or lower cylinder increases.
1-INCH 1/4-20
HEX HEAD SCREW

 For air-to-close actuators (i.e., the actuator

stem extends from the actuator casing or cylinder as
air pressure to the casing or upper cylinder increases),
insert the alignment pin into the hole marked ‘‘B’’. For
this style actuator, the feedback arm rotates
2 clockwise, from B to A, as air pressure to the casing or
upper cylinder increases.

W8473 / IL
MOUNTING BRACKET
Note
WALL MOUNTING
When performing the following steps,
ensure there is enough clearance
between the adjustment arm and the
feedback arm to prevent interference
with the bias spring.

7. Apply lubricant to the pin of the adjustment arm. As

STANDOFF
4-INCH 1/4-20
HEX HEAD SCREW
MOUNTING BRACKET
W8474 / IL PIPESTAND MOUNTING
Figure 2-13. FIELDVUE DVC6005 Base Unit Mounting
arm. Remove the existing bias spring (key 78) from
the 2-inch feedback arm (key 79). Attach the feedback
arm extension to the feedback arm (key 79) as shown
in figure 2-2.
5. Mount the digital valve controller on the actuator as
described in the mounting kit instructions.
6. Set the position of the feedback arm (key 79) on
the digital valve controller to the no air position by
inserting the alignment pin (key 46) through the hole
on the feedback arm as follows:
 For air-to-open actuators (i.e., the actuator
stem retracts into the actuator casing or cylinder as air
pressure to the casing or lower cylinder increases),
insert the alignment pin into the hole marked ‘‘A’’. For
shown in figure 2-3, place the pin into the slot of the
feedback arm or feedback arm extension so that the
bias spring loads the pin against the side of the arm
with the valve travel markings.
8. Install the external lock washer on the adjustment
arm. Position the adjustment arm in the slot of the
connector arm and loosely install the flanged hex nut.
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 flanged hex nut.
10. Remove the alignment pin (key 46) and store it in
the module base next to the I/P assembly.
11. After calibrating the instrument, attach the shield
with two machine screws.
DVC6025 on Long-Stroke (4 to 24 Inch
Travel) Sliding-Stem Actuators and
Rotary Actuators
If ordered as part of a control valve assembly, the
factory mounts the digital valve controller on the
actuator, makes pneumatic connections to the
actuator, sets up, and calibrates the instrument. If you
purchased the digital valve controller separately, you
will need a mounting kit to mount the digital valve
controller on the actuator. See the instructions that
come with the mounting kit for detailed information on
mounting the digital valve controller to a specific
actuator model.

2-14 December 2009


Note
Refer to DVC6005 Base Unit mounting
guidelines on page 2-13 when
installing a DVC6015 remote feedback
unit.
DVC6025 remote feedback units use a cam and roller
as the feedback mechanism. Figure 2-4 shows an
example of mounting on sliding-stem actuators with
travels from 4 inches to 24 inches. Some long-stroke
applications will require an actuator with a tapped
lower yoke boss. Figures 2-5 and 2-6 show examples
of mounting on rotary actuators.
Note
While the housing differs on the
DVC6025 and the DVC6020, feedback
parts are the same.
As shown in figure 2-5, two feedback arms are
available for the digital valve controller. Most
long-stroke sliding-stem and rotary actuator
installations use the long feedback arm [62 mm (2.45
inches) from roller to pivot point]. Installations on 1051
size 33 and 1052 size 20 and 33 actuators use the
short feedback arm [54 mm (2.13 inches) from roller to
pivot point]. Make sure the correct feedback arm is
installed on the digital valve controller before
beginning the mounting procedure.
Refer to figures 2-4, 2-5, and 2-6 for parts locations.
Refer to the following guidelines when mounting on
sliding-stem actuators with 4 to 24 inches of travel or
on rotary actuators:
1. Isolate the control valve from the process line
pressure and release pressure from both sides of the
valve body. Shut off all pressure lines to the
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 a cam is not already installed on the actuator,
install the cam as described in the instructions
included with the mounting kit. For sliding-stem
actuators, the cam is installed on the stem connector.
3. If a mounting plate is required, fasten the mounting
plate to the actuator.
December 2009
Installation
4. For applications that require remote venting, a
pipe-away bracket kit is available. Follow the
instructions included with the kit to replace the existing
mounting bracket on the digital valve controller with
the pipe-away bracket and to transfer the feedback
parts from the existing mounting bracket to the
pipe-away bracket.
5. Larger size actuators may require a follower arm
extension, as shown in figure 2-6. If required, the
follower arm extension is included in the mounting kit. 2
Follow the instructions included with the mounting kit
to install the follower arm extension.
6. Apply anti-seize (key 64) to the arm assembly pin
as shown in figure 2-7.
7. Mount the DVC6025 on the actuator as follows:
 If required, a mounting adaptor is included in the
mounting kit. Attach the adaptor to the actuator as
shown in figure 2-5. Then attach 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.
 If no mounting adaptor is required, attach the
digital valve controller assembly to the actuator or
mounting plate. The roller on the digital valve
controller feedback arm will contact the actuator cam
as it is being attached.
8. For long-stroke sliding-stem actuators, after the
mounting is complete, check to be sure the roller
aligns with the position mark on the cam (see
figure 2-4). If necessary, reposition the cam to attain
alignment.
DVC6035 on Quarter-Turn Actuators
If ordered as part of a control valve assembly, the
factory mounts the digital valve controller on the
actuator, makes pneumatic connections to the
actuator, sets up, and calibrates the instrument. If you
purchased the digital valve controller separately, you
will need a mounting kit to mount the digital valve
controller on the actuator. See the instructions that
come with the mounting kit for detailed information on
mounting the digital valve controller to a specific
actuator model.
Note
Refer to DVC6005 Base Unit mounting
guidelines on page 2-13 when
installing a DVC6015 remote feedback
unit.
2-15
 DVC6000 Digital Valve Controllers
Figure 2-8 shows an example of mounting on a
quarter-turn actuator. Refer to figure 2-8 for parts
locations. Refer to the following guidelines when DVC6035
DVC6035 FEEDBACK ARM
mounting on quarter-turn actuators: FEEDBACK ARM MOVEMENT
MOVEMENT

E0989

Note
49B7988 / Doc

2
While the housing differs on the
DVC6035 and the DVC6030, feedback
parts are the same.

ACTUATOR SHAFT MOVEMENT

1. Isolate the control valve from the process line ACTUATOR SHAFT MOVEMENT

pressure and release pressure from both sides of the

valve body. Shut off all pressure lines to the pneumatic STARTING POSITION OF THE TRAVEL
INDICATOR ASSEMBLY IF INCREASING
actuator, releasing all pressure from the actuator. Use PRESSURE FROM OUTPUT A DRIVES
lock-out procedures to be sure that the above THE INDICATOR CLOCKWISE. THE
POTENTIOMETER SHAFT WILL ROTATE
measures stay in effect while working on the COUNTERCLOCKWISE AS VIEWED FROM
THE BACK OF THE INSTRUMENT.
equipment.
NOTE: DVC6035 TRAVEL COUNTS
(COUNTERCLOCKWISE) = 600  200
2. If necessary, remove the existing hub from the
actuator shaft. Figure 2-14. FIELDVUE DVC6035 Travel Indicator Installation
STARTING POSITION OF THE TRAVEL
INDICATOR ASSEMBLY IF INCREASING
PRESSURE FROM OUTPUT A DRIVES
THE INDICATOR COUNTERCLOCKWISE.
THE POTENTIOMETER SHAFT WILL
ROTATE CLOCKWISE AS VIEWED
FROM THE BACK OF THE INSTRUMENT
NOTE: DVC6035 TRAVEL COUNTS
(CLOCKWISE) = 3400  200

3. If a positioner plate is required, attach the

positioner plate to the actuator as described in the
mounting kit instructions.
4. If required, attach the spacer to the actuator shaft.
Refer to figure 2-14. The travel indicator assembly can
have a starting position of 7:30 or 10:30. Determine
the desired starting position then proceed with the next
step. Considering the top of the remote travel sensor
as the 12 o’clock position, in the next step attach the
travel indicator, so that the pin is positioned as follows:
Note
ValveLink software and the Field
Communicator use the convention of
clockwise (figure 2-9) and
counterclockwise (figure 2-10) when
viewing the potentiometer shaft from
the back of the FIELDVUE instrument.

 If increasing pressure from the digital valve
controller output A rotates the digital valve
controllers potentiometer shaft counterclockwise
(as viewed from the back of the instrument), mount
the travel indicator assembly such that the arrow is in
the 7:30 position, as shown in figures 2-10 and 2-14.
 If increasing pressure from the digital valve
controller output A rotates the digital valve
controllers potentiometer shaft clockwise (as
viewed from the back of the instrument), mount the
travel indicator assembly such that the arrow is in the
10:30 position, as shown in figures 2-9 and 2-14.
5. Attach the travel indicator, to the shaft connector or
spacer as described in the mounting kit instructions.
6. Attach the mounting bracket to the digital valve
controller.
7. Position the digital valve controller so that the pin
on the travel indicator, engages the slot in the
feedback arm and that the bias spring loads the pin as
shown in figure 2-11. Attach the digital valve controller
to the actuator or positioner plate.
8. If a travel indicator scale is included in the
mounting kit, attach the scale as described in the
mounting kit instructions.

2-16 December 2009

 Installation

FISHER 67CFR

2
CAP SCREWS

O-RING 1
NOTE:
1 APPLY LUBRICANT
SUPPLY CONNECTION
W8077 / IL

Figure 2-15. Mounting the Fisher 67CFR Regulator on a FIELDVUE DVC6000 Digital Valve Controller

67CFR Filter Regulator Pressure Connections

A 67CFR filter regulator, when used with DVC6000
digital valve controllers, can be mounted three ways. WARNING
Refer to the Installation WARNING at
the beginning of this section.
Integral-Mounted Regulator
Refer to figure 2-15. Lubricate an O-ring and insert it
in the recess around the SUPPLY connection on the
digital valve controller. Attach the 67CFR filter
regulator to the side of the digital valve controller.
Thread a 1/4-inch socket-head pipe plug into the Note
unused outlet on the filter regulator. This is the
standard method of mounting the filter regulator. Make pressure connections to the
digital valve controller using tubing
with at least 3/8-inch diameter.
Yoke-Mounted Regulator
Mount the filter regulator with 2 cap screws to the Pressure connections are shown in figure 2-16. All
pre-drilled and tapped holes in the actuator yoke. pressure connections on the digital valve controller are
1/4 NPT internal connections. Use 10 mm (3/8-inch)
Thread a 1/4-inch socket-head pipe plug into the tubing for all pneumatic connections. If remote venting
unused outlet on the filter regulator. The O-ring is not is required, refer to the vent subsection.
required.

Supply Connections

Casing-Mounted Regulator WARNING

Use the separate 67CFR filter regulator casing
mounting bracket provided with the filter regulator. To avoid personal injury and property
Attach the mounting bracket to the 67CFR and then damage resulting from bursting of
attach this assembly to the actuator casing. Thread a parts, do not exceed maximum supply
1/4-inch socket-head pipe plug into the unused outlet pressure.
on the filter regulator. The O-ring is not required.

December 2009 2-17

 DVC6000 Digital Valve Controllers
WARNING
Severe personal injury or property
LOOP CONNECTIONS damage may occur from an
TERMINAL BOX
uncontrolled process if the
instrument supply medium is not
clean, dry, oil-free, and noncorrosive.
While use and regular maintenance of
1/2 NPT
CONDUIT a filter that removes particles larger
2 CONNECTION
than 40 micrometers in diameter will
suffice in most applications, check
with an Emerson Process
Management field office and industry
instrument air quality standards for
use with corrosive supply medium or
if you are unsure about the proper
amount or method of filtration or filter
maintenance.

Supply pressure must be clean, dry air that meets the

FEEDBACK CONNECTIONS
TERMINAL BOX requirements of ISA Standard 7.0.01. A maximum 40
micrometer particle size in the air system is
acceptable. Further filtration down to 5 micrometer
DVC6005 BASE UNIT particle size is recommended. Lubricant content is not
to exceed 1 ppm weight (w/w) or volume (v/v) basis.
Condensation in the air supply should be minimized.
Alternatively, natural gas may be used as the supply
pressure medium. Gas must be clean, dry, oil-free,
and noncorrosive. H2S content should not exceed 20
1/2 NPT ppm.
CONDUIT
CONNECTIONS
(BOTH SIDES)
A 67CFR filter regulator with standard 5 micrometer
filter, or equivalent, may be used to filter and regulate
supply medium. A filter regulator can be integrally
OUTPUT A
CONNECTION 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
SUPPLY on the digital valve controller. The output pressure
CONNECTION
gauges can be used as an aid for calibration.
Connect the nearest suitable supply source to the
OUTPUT B 1/4 NPT IN connection on the filter regulator (if
CONNECTION
furnished) or to the 1/4 NPT SUPPLY connection on
the digital valve controller housing (if 67CFR filter
regulator is not attached).
W7963 / IL

VALVE MOUNTED UNIT Output Connections

NOTE:
PNEUMATIC CONNECTIONS APPLICABLE TO BOTH VALVE-MOUNTED
INSTRUMENTS AND DVC6005 BASE UNIT.
Figure 2-16. FIELDVUE DVC6000 Digital Valve Controller
Connections
A factory mounted digital valve controller has its
output piped to the pneumatic input connection on the
actuator. If mounting the digital valve controller in the
field, or installing the remote-mounted DVC6005 base
unit, connect the 1/4 NPT digital valve controller
output connections to the pneumatic actuator input
connections.

2-18 December 2009


W9131-1
Figure 2-17. FIELDVUE DVC6010 Digital Valve Controller
Mounted on Fisher 585C Piston Actuator
Single-Acting Actuators
When using a single-acting direct digital valve
controller (relay A or C) on a single-acting actuator
connect OUTPUT A to the actuator pneumatic input.
When using a single-acting reverse digital valve
controller (relay B) on a single-acting actuator connect
OUTPUT B to the actuator diaphragm casing.
Double-Acting Actuators
DVC6000 digital valve controllers on double-acting
actuators always use relay A. With no input current,
OUTPUT A is at 0 pressure and OUTPUT B is at full
supply pressure when the relay is properly adjusted.
To have the actuator stem extend from the cylinder
with increasing input signal, connect OUTPUT A to the
upper actuator cylinder connection. Connect OUTPUT
B to the lower cylinder connection. Figure 2-17 shows
the digital valve controller connected to a
double-acting piston actuator.
To have the actuator stem retract into the cylinder with
increasing input signal, connect OUTPUT A to the
December 2009
Installation
lower actuator cylinder connection. Connect OUTPUT
B to the upper cylinder connection.
Special Construction to Support Solenoid
Valve Testing
In single-acting actuator applications with a solenoid
valve installed, the DVC6000 can be configured to test
the operation of the solenoid valve. This is
accomplished by connecting the “unused” output port
from the DVC6000 to the pneumatic line between the 2
solenoid valve and the actuator, as shown in figure
2-18. When single-acting, direct relay C is installed,
the “unused” output port is port B. When single-acting,
reverse relay B is used, the unused port is port A.
Note
Solenoid valve testing is only available
for instrument level PD and ODV.
Note
This application is called “special
application” in the Setup Wizard relay
selection.
This configuration is not possible with
a double-acting actuator or when
using relay A in single-acting mode.
Vent
WARNING
Personal injury or property damage
can occur from cover failure due to
overpressure. Ensure that the
housing vent opening is open and
free of debris to prevent pressure
buildup under the cover.
2-19
 DVC6000 Digital Valve Controllers
CONTROL SIGNAL 24/48 VDC
(4-20 mA, 0-20 mA, 110/220 VAC, etc.
0-24 VDC)

CONTROL LINE

Port A

2 DVC6000 DIGITAL VALVE

Port B

CONTROLLER WITH RELAY C SUPPLY PRESSURE

MONITORING LINE

NOTES:
1/4-18 NPT X 3/8 OD TUBING
ELECTRICAL WIRING SPRING RETURN ACTUATOR
E1048

Figure 2-18. Pneumatic Hookup for Solenoid Testing

could result in personal injury or

WARNING property damage from fire or
explosion, and area re-classification.
This unit vents the supply medium
into the surrounding atmosphere.
When installing this unit in a
non-hazardous (non-classified)
location in a confined area, with
natural gas as the supply medium,
you must remotely vent this unit to a
safe location. Failure to do so could The relay output constantly bleeds supply medium into
the area under the cover. The vent opening at the
result in personal injury or property
back of the housing should be left open to prevent
damage from fire or explosion, and
area re-classification. pressure buildup under the cover. If a remote vent is
required, the vent line must be as short as possible
When installing this unit in a with a minimum number of bends and elbows.
hazardous (classified) location remote
venting of the unit may be required, To connect a remote vent to DVC6010 and
depending upon the area DVC6030 digital valve controllers and DVC6005
classification, and as specified by the base unit—remove the plastic vent (key 52, figures
requirements of local, regional, and 8-2 and 8-5). The vent connection is 3/8 NPT internal.
federal codes, rules and regulations. At a minimum, 12.7 mm (1/2-inch) tubing should be
Failure to do so when necessary used when installing a remote vent to prevent
could result in personal injury or excessive pressure from building up under the cover.
property damage from fire or
explosion, and area re-classification. To connect a remote vent to DVC6020 digital valve
controllers—replace the standard mounting bracket
Vent line piping should comply with (key 74, figures 8-3 and 8-5) with the vent-away
local and regional codes and should bracket (key 74). Install a pipe plug in the vent-away
be as short as possible with adequate mounting bracket (key 74). Mount the digital valve
inside diameter and few bends to controller on the actuator as described in the
reduce case pressure buildup. Installation section of this manual. The vent
connection is 3/8 NPT internal. At a minimum, 12.7
In addition to remote venting of the mm (1/2-inch) tubing should be used when installing a
unit, ensure that all caps and covers remote vent to prevent excessive pressure from
are correctly installed. Failure to do so building up under the cover.

2-20 December 2009

 Installation
Electrical Connections SAFETY GROUND
TALK−
TALK+

WARNING
To avoid personal injury resulting
from electrical shock, do not exceed
the maximum input voltage specified
in table 1-2 of this instruction manual,
or on the product nameplate. If the
input voltage specified differs, do not 2
exceed the lowest specified maximum
input voltage.
Select wiring and/or cable glands that
are rated for the environment of use
(such as hazardous area, ingress EARTH GROUND
protection and temperature). Failure LOOP+
to use properly rated wiring and/or 39B3399-B Sheet 2
LOOP−
cable glands can result in personal
injury or property damage from fire or
explosion.
Figure 2-19. FIELDVUE DVC6000 Digital Valve Controller
Wiring connections must be in Terminal Box
accordance with local, regional, and
national codes for any given
hazardous area approval. Failure to
follow the local, regional, and national WARNING
codes could result in personal injury
or property damage from fire or To avoid personal injury or property
explosion. damage from the sudden release of
process pressure, be sure the valve is
not controlling the process. The valve
may move when the source is applied.
WARNING
To avoid personal injury or property
damage caused by fire or explosion, Wire the digital valve controller as follows: (unless
remove power to the instrument indicated otherwise, refer to figures 8-2 through 8-4 for
before removing the terminal box identification of parts).
cover in an area which contains a 1. Remove the terminal box cap (key 4) from the
potentially explosive atmosphere or terminal box (key 3).
has been classified as hazardous.
2. Bring the field wiring into the terminal box. When
applicable, install conduit using local and national
electrical codes which apply to the application.
4-20 mA Loop Connections 3. Refer to figure 2-19. Connect the control system
The digital valve controller is normally powered by a output card positive wire ‘‘current output’’ to the LOOP
control system output card. The use of shielded cable + screw terminal in the terminal box. Connect the
will ensure proper operation in electrically noisy control system output card negative (or return) wire to
environments. the LOOP − screw terminal.

December 2009 2-21

 DVC6000 Digital Valve Controllers
WARNING
Personal injury or property damage,
caused by fire or explosion, 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
2 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 2-19, two ground terminals are
available for connecting a safety ground, earth ground,
or drain wire. These ground terminals are electrically
identical. Make connections to these terminals
following national and local codes and plant standards.
5. Replace and hand tighten the terminal box cap.
When the loop is ready for startup, apply power to the
control system output card.
Remote Travel Sensor Connections
The DVC6005 base unit is designed to receive travel
information via a remote sensor. The remote can be
any of the following:
 Emerson Process Management supplied
DVC6015, DVC6025 or DVC6035 feedback unit,
 An under-traveled 10 kOhm potentiometer used
in conjunction with onboard 30 kOhm resistor, or
 A potentiometer used in conjunction with two
fixed resistors (potentiometer travel is the same as
actuator travel).
2-22
WARNING
Personal injury or property damage,
caused by wiring failure, can result if
the feedback wiring connecting the
base unit with the remote feedback
unit shares a conduit with any other
power or signal wiring.
Do not place feedback wiring in the
same conduit as other power or
signal wiring.
Note
3-conductor shielded cable, 22 AWG
minimum wire size, is required for
connection between base unit and
feedback unit. Pneumatic tubing
between base unit output connection
and actuator has been tested to 15
meters (50 feet) maximum without
performance degradation.
Using the DVC6015, DVC6025 & DVC6035
Feedback Unit as a Remote Travel Sensor
1. On the feedback unit, remove the housing cap.
2. On the base unit, remove the feedback
connections terminal box cap (see figure 2-16).
3. If necessary, install conduit between the feedback
unit and the base unit following applicable local and
national electrical codes. Route the 3-conductor
shielded cable between the two units (refer to
figure 2-20).
4. Connect one wire of the 3-conductor shielded cable
between terminal 1 on the feedback unit and terminal
1 on the base unit.
5. Connect the second wire of the 3-conductor
shielded cable between terminal 2 on the feedback
unit and terminal 2 on the base unit.
December 2009
 Installation

FEEDBACK CONNECTIONS
TERMINAL BOX

2
W8477 / IL

W8475 / IL

GROUND BASE UNIT FEEDBACK UNIT

SCREW

TO FEEDBACK UNIT TERMINAL 3

TO FEEDBACK UNIT TERMINAL 2

TO FEEDBACK UNIT TERMINAL 1

TERMINAL 1

TERMINAL 2

TERMINAL 3

W8476 / IL
W8478-1 / IL

FEEDBACK CONNECTIONS TERMINAL BOX FEEDBACK UNIT

Figure 2-20. Terminal Details for Connecting Base Unit and Feedback Units of Remote-Mounted Digital Valve Controllers

6. Connect the third wire of the 3-conductor shielded Using an External 10 kOhm External
cable between terminal 3 on the feedback unit and Potentiometer as a Remote Travel Sensor
terminal 3 on the base unit.

7. Connect the cable shield or drain wire to the

ground screw in the feedback connections terminal
box of the base unit.
Note
Potentiometer travel must be between
1.3 and 1.6 times greater than the
actuator travel. For example: if an
actuator has a travel of 9 inches, then
Note a linear potentiometer must be
selected with a rated travel between
Do not connect the shield or drain wire
11.7 and 14.4 inches. The resistive
to any terminal on the feedback unit,
element must be tapered from 0 kOhm
to the earth ground, or any other
to 10 kOhm over rated travel of the
alternative ground.
potentiometer. The actuator will only
use 63 to 76 % of the potentiometer
rated travel.
8. Replace and hand-tighten all covers.

December 2009 2-23

 DVC6000 Digital Valve Controllers

Note 2

The digital valve controller must be INTERNAL

configured using the SStem/Roller 1 " 10k W

(30k W)
selection on the menu of the
30k
appropriate setup device.

2
The base unit (DVC6005) was designed to work with a
40 kOhm potentiometer for travel feedback. However, BASE UNIT TERMINATION BOX 3RD PARTY FEEDBACK ELEMENT
(DVC6005) (WITH 10k W POTENTIOMETER)
there are linear potentiometers that are readily
available with a rated resistance of 10 kOhm.
Figure 2-21. Terminal Details for Connecting a FIELDVUE
Therefore, the feedback connections terminal box of
DVC6005 Base Unit and a 10k Ohm External Potentiometer
the DVC6005 contains an additional 30 kOhm fixed
resistor that may be added to the circuit. This brings
the total resistance up to the required 40 kOhm.
1. Mount the external 10 kOhm potentiometer to the
actuator such that the mid-travel position of the
Note
potentiometer (5 kOhm) corresponds to the mid-travel The potentiometer must be capable of
position of the actuator. This will leave an equal resistance close to 0 Ohms.
amount of unused resistive element on both ends of
the travel, which is required by the digital valve
controller to function properly.
2. On the base unit, remove the feedback CAUTION
connections terminal box cap (see figure 2-16).
To prevent damage to the
3. If necessary, install conduit between the
potentiometer, ensure that it is free to
potentiometer and the base unit following applicable
travel the entire length of the
local and national electrical codes. Route the
actuator’s travel.
3-conductor shielded cable between the two units
(refer to figure 2-21).
4. Connect one wire of the 3-conductor shielded cable
between the terminal labeled “30kW” on the base unit
and one end lead of the potentiometer.
5. Connect the second wire of the 3-conductor
Note
shielded cable between the middle lead (wiper) of the The digital valve controller must be
10 kOhm potentiometer to Terminal 2 on the base configured using the SStem/Roller
unit. selection on the menu of the
6. Connect the third wire of the 3-conductor shielded appropriate setup device.
cable between Terminal 3 on the base unit and the
other end-lead of the 10 kOhm potentiometer.
This procedure uses three resistors connected in
7. Connect the cable shield or drain wire to the series, two fixed resistors and one potentiometer.
ground screw in the feedback connections terminal Three conditions must be met for the resistor
box of the base unit. Do not connect the shield or combination to correctly operate the digital valve
drain wire to the external potentiometer. controller:
8. Replace and tighten the base unit cover.  The maximum resistance of the potentiometer
(Rpot(max)) must be between 3.9 kOhm and 10 kOhm.
Using a Potentiometer with Two Fixed
 The resistance of R1 is 4.25 times greater than
Resistors as a Remote Travel Sensor Rpot(max).
Perform the following procedure if a potentiometer is
used with the same, or slightly longer travel than the  The resistance of R2 is 4 times less than
actuator’s travel. Rpot(max).

2-24 December 2009

 Installation
WARNING
3

To avoid personal injury or property

2
damage from an uncontrolled process (R2)

ensure that the R1 resistor is properly

1
insulated before installing it in the
terminal box. 30kW
" (Rpot)
(R1)

1. On the base unit, remove the feedback
connections terminal box cap (see figure 2-16).
2. If necessary, install conduit between the
two-resistor series and the base unit following
applicable local and national electrical codes. Route
the 3-conductor shielded cable between the two units
(refer to figure 2-22).
3. Install the fixed resistor (R1) across the unlabeled
bottom Terminal and Terminal #1. The bottom terminal
does not have a screw. The screw on the 30 kOhm
terminal can be used. R1 must be properly insulated
when installed in the terminal box to prevent personal
injury or property damage.
4. Connect one wire of the 3-conductor shielded cable
between the unlabeled bottom Terminal on the base
unit and an end-lead of the external potentiometer
(Rpot).
5. Connect the second wire of the 3-conductor
shielded cable between the middle lead (wiper) of the
external potentiometer (Rpot) and Terminal 2 on the
base unit.
6. Connect the third wire of the 3-conductor shielded
cable between between a lead on fixed resistor (R2)
and terminal #3 of the base unit.
7. Connect the available end-lead on the
potentiometer (Rpot) with the available lead on fixed
resistor (R2).
8. Connect the cable shield or drain wire to the
ground screw in the feedback connections terminal
box of the base unit. Do not connect the shield or
drain wire to the two-resistor series.
2
BASE UNIT TERMINATION BOX THREE-RESISTOR SERIES
(DVC6005)
Figure 2-22. Terminal Details for Connecting a FIELDVUE
DVC6005 Base Unit and a Three-Resistor Series
Test Connections
WARNING
Personal injury or property damage
caused by fire or explosion may occur
if this connection is attempted in a
potentially explosive atmosphere, or
in an area that has been classified as
hazardous. Confirm that area
classification and atmosphere
conditions permit the safe removal of
the terminal box cap before
proceeding.
Test connections inside the terminal box can be used
to measure loop current across a 1 ohm resistor.
1. Remove the terminal box cap.
2. Adjust the test meter to measure a range of 0.001
to 0.1 volts.
3. Connect the positive lead of the test meter to the
TEST + connection and the negative lead to the TEST
− connection inside the terminal box.

9. Replace and tighten the base unit cover.
Example: Using a linear potentiometer rated at 400
Ohms/inch on an actuator with 16” of travel.
 Rpot(max) is 400 Ohms/in x 16” = 6.4 kOhm
 R1 = 6.4 kOhm x 4.25 = 27.2 kOhm
 R2 = 6.4 kOhm / 4 = 1.6 kOhm
4. Measure Loop current as:
Voltage (on test meter)  1000 = milliamps
example:
Test meter Voltage X 1000 = Loop Milliamps
0.004 X1000 = 4.0 milliamperes
0.020 X 1000 = 20.0 milliamperes
5. Remove test leads and replace the terminal box
cover.

December 2009 2-25

 DVC6000 Digital Valve Controllers
Communication Connections
NON-HART BASED
DCS
WARNING
Personal injury or property damage I/O I/O
caused by fire or explosion may occur
if this connection is attempted in a
potentially explosive atmosphere or in HART
FILTER
an area that has been classified as
2 hazardous. Confirm that area
classification and atmosphere
4-20 mA
conditions permit the safe removal of DIGITAL VALVE
the terminal box cap before CONTROLLER
proceeding.

Tx Tx VALVE
A HART communicating device, such as a 475 Field
Communicator or a personal computer running
ValveLink software communicating through a HART A6188-1/IL

modem, interfaces with the DVC6000 digital valve

controller from any wiring termination point in the 4-20
mA loop. If you choose to connect the HART
communicating device directly to the instrument,
attach the device to the LOOP + and LOOP −
terminals or to the TALK + and TALK − connections
inside the terminal box to provide local
communications with the instrument.
Wiring Practices
Control System Requirements
There are several parameters that should be checked
to ensure the control system is compatible with the
DVC6000 digital valve controller.
HART Filter
Depending on the control system you are using, a
HART filter may be needed to allow HART
communication. The HART filter is a passive device
that is inserted in field wiring from the HART loop. The
filter is normally installed near the field wiring terminals
Figure 2-23. HART Filter Application
of the control system I/O (see figure 2-23). Its purpose
is to effectively isolate the control system output from
modulated HART communication signals and raise the
impedance of the control system to allow HART
communication. For more information on the
description and use of the HART filter, refer to the
separate HART filter instruction manual.
Contact your Emerson Process Management sales
office if assistance is needed to determine if your
system requires a filter.
Note
A HART filter is NOT required for any
of the Emerson Process Management
control systems, including PROVOXt,
RS3t, and DeltaVt systems.

2-26 December 2009

 Installation
TOTAL LOOP THUM ADAPTER
CABLE RESISTANCE (IF USED)
COMPLIANCE VOLTAGE

CONTROL
SYSTEM
VOLTAGE
+ INTRINSIC SAFETY R AVAILABLE AT
HART BARRIER + THE
− FILTER (if used) − INSTRUMENT

Calculate Voltage Available at the Instrument as

follows:
Example Calculation 2
Control system compliance voltage 18.5 volts (at 21.05 mA)

– Filter voltage drop (if used) 1 – 2.3 volts (for HF300 filter)

– Intrinsic safety barrier resistance (if used) x maximum loop current – 2.55 volts (121 ohms x 0.02105 amps)
– Smart Wireless THUMt adapter voltage drop (if used) 2
– Total loop cable resistance x maximum loop – 1.01 volts (48 ohms x 0.02105 amps for
current 1000 feet of Belden 9501 cable)

= Voltage available at the instrument 3 = 15.19 volts, available—if safety barrier (2.55 volts)
is not used
NOTES:
1 Obtain filter voltage drop. The measured drop will be different than this value. The measured filter voltage drop
depends upon control system output voltage, the intrinsic safety barrier (if used), and the instrument. See note 2.

2 The voltage drop of the THUM adapter is linear from 2.25 volts at 3.5 mA to 1.2 volts at 25 mA.

3 The voltage available at the instrument is not the voltage measured at the instrument terminals. Once the instrument is
connected, the instrument limits the measured voltage to approximately 9.0 to 10.5 volts.

Figure 2-24. Determining Voltage Available at the Instrument

Voltage Available The voltage available at the instrument may be

The voltage available at the DVC6000 digital valve
controller must be at least 11 volts DC. The voltage
available at the instrument is not the actual voltage
measured at the instrument when the instrument is
connected. The voltage measured at the instrument is
limited by the instrument and is typically less than the
voltage available.
As shown in figure 2-24, the voltage available at the
instrument depends upon:
 the control system compliance voltage
 if a filter, wireless THUM adapter, or intrinsic
safety barrier is used, and
 the wire type and length.
The control system compliance voltage is the
maximum voltage at the control system output
terminals at which the control system can produce
maximum loop current.
calculated from the following equation:
Voltage Available = [Control System Compliance
Voltage (at maximum current)] − [filter voltage drop (if
a HART filter is used)] − [total cable resistance 
maximum current] − [barrier resistance x maximum
current].
The calculated voltage available should be greater
than or equal to 11 volts DC.
Table 2-1 lists the resistance of some typical cables.
The following example shows how to calculate the
voltage available for a Honeywell TDC2000 control
system with a HF340 HART filter, and 1000 feet of
Belden 9501 cable:
Voltage available = [18.5 volts (at 21.05 mA)] − [2.3
volts] − [48 ohms  0.02105 amps]
Voltage available = [18.5] − [2.3] − [1.01]
Voltage available = 15.19 volts

December 2009 2-27

 DVC6000 Digital Valve Controllers
Table 2-1. Cable Characteristics
Capacitance(1) Capacitance(1) Resistance(2) Resistance(2)
Cable Type
pF/Ft pF/m Ohms/ft Ohms/m
BS5308/1, 0.5 sq mm 61.0 200 0.022 0.074
BS5308/1, 1.0 sq mm 61.0 200 0.012 0.037
BS5308/1, 1.5 sq mm 61.0 200 0.008 0.025
BS5308/2, 0.5 sq mm 121.9 400 0.022 0.074
BS5308/2, 0.75 sq mm 121.9 400 0.016 0.053
BS5308/2, 1.5 sq mm 121.9 400 0.008 0.025
2 BELDEN 8303, 22 awg 63.0 206.7 0.030 0.098
BELDEN 8441, 22 awg 83.2 273 0.030 0.098
BELDEN 8767, 22 awg 76.8 252 0.030 0.098
BELDEN 8777, 22 awg 54.9 180 0.030 0.098
BELDEN 9501, 24 awg 50.0 164 0.048 0.157
BELDEN 9680, 24 awg 27.5 90.2 0.048 0.157
BELDEN 9729, 24 awg 22.1 72.5 0.048 0.157
BELDEN 9773, 18 awg 54.9 180 0.012 0.042
BELDEN 9829, 24 awg 27.1 88.9 0.048 0.157
BELDEN 9873, 20 awg 54.9 180 0.020 0.069
1. The capacitance values represent capacitance from one conductor to all other conductors and shield. This is the appropriate value to use in the cable length calculations.
2. The resistance values include both wires of the twisted pair.

1 kW POTENTIOMETER
MILLIAMMETER

VOLTMETER

CIRCUIT
UNDER
TEST

A6192-1/IL

Figure 2-25. Voltage Test Schematic

Compliance Voltage 3. Increase the resistance of the 1 kW potentiometer,

If the compliance voltage of the control system is not shown in figure 2-25, until the current observed on the
known, perform the following compliance voltage test. milliammeter begins to drop quickly.

1. Disconnect the field wiring from the control system 4. Record the voltage shown on the voltmeter. This is
and connect equipment as shown in figure 2-25 to the the control system compliance voltage.
control system terminals.
For specific parameter information relating to your
2. Set the control system to provide maximum output control system, contact your Emerson Process
current. Management sales office.

2-28 December 2009

 Installation
START HERE

A
B
Unpack the
Install the HART
HART Tri-Loop
Tri-Loop. See
HART Tri-Loop Configure the
product manual HART Tri-Loop
Review the HART to receive digital
Tri-Loop Product valve controller
Manual burst commands
Mount the
HART Tri-Loop
to the DIN rail.
2
Check
No Pass system No troubleshooting
Digital valve Install the digital Wire the digital
controller valve controller to test? procedures in
valve controller. HART Tri-Loop
Installed? the HART Tri-Loop.
product manual.

Yes Yes
Install Channel 1
wires from HART
Set the digital Tri-Loop to the
valve controller control room.
Burst Option DONE

(Optional) Install
Set the digital Channel 2 and 3 wires
valve controller from HART Tri-Loop
Burst Mode to the control room.

A B
E0365 / IL

Figure 2-26. HART Tri-Loop Installation Flowchart

Maximum Cable Capacitance sales office for specific information relating to your
control system.
The maximum cable length for HART communication
is limited by the characteristic capacitance of the
cable. Maximum length due to capacitance can be
calculated using the following formulas: Installation in Conjunction with a
Length(ft) = [160,000 − Cmaster(pF)] [Ccable(pF/ft)] Rosemountt 333 HART Tri-Loop
Length(m) = [160,000 − Cmaster(pF)] [Ccable(pF/m)] HART-to-Analog Signal Converter
Use the DVC6000 digital valve controller in operation
where: with a Rosemount 333 HART Tri-Loop
160,000 = a constant derived for FIELDVUE HART-to-Analog Signal Converter to acquire an
instruments to ensure that the HART network RC time independent 4-20 mA analog output signal for the
constant will be no greater than 65 μs (per the HART analog input, travel target, pressure, or travel. The
specification). HART Tri-Loop accepts any three of these digital
signals and converts them into three separate 4-20
Cmaster = the capacitance of the control system or mA analog channels.
HART filter
Refer to figure 2-26 for basic installation information.
Ccable = the capacitance of the cable used (see table Refer to the 333 HART Tri-Loop HART-to-Analog
2-1) Signal Converter Product Manual for complete
installation information.
The following example shows how to calculate the
cable length for a Foxboro I/A control system (1988)
with a Cmaster of 50, 000 pF and a Belden 9501 cable Commissioning the Digital Valve
with characteristic capacitance of 50pF/ft.
Controller for use with the HART
Length(ft) = [160,000 − 50,000pF] [50pF/ft] Tri-Loop Signal Converter
Length = 2200 ft.
To prepare the digital valve controller for use with a
The HART communication cable length is limited by 333 HART Tri-Loop, you must configure the digital
the cable characteristic capacitance. To increase valve controller to burst mode, and select Burst
cable length, select a wire with lower capacitance per Command 3. In burst mode, the digital valve controller
foot. Contact your Emerson Process Management provides digital information to the HART Tri-Loop

December 2009 2-29

 DVC6000 Digital Valve Controllers
HART-to-Analog Signal Converter. The HART
Tri-Loop converts the digital information to a 4 to 20
mA analog signal. Each burst message contains the
latest value of the primary (analog input), secondary
(travel target), tertiary (configured output pressure),
and quaternary (travel) variables.
To commission a DVC6000 digital valve controller for
use with a HART Tri-Loop, perform the following
2 procedures.
Note
Instrument level AC does not support
HART Command 3 or Burst Mode
communications.
2-30
Set the Burst Operation (1-2-1-4)
1. From the Online menu, select Configure / Setup,
Detailed Setup, Mode and Protection, and Burst
Mode.
2. Select Burst Enable. Select Enable then press
ENTER and SEND.
3. Select Burst Command. Select the desired
command (HART Univ Command 3).
4. Select Cmd 3 Press. Select the pressure you
desire the HART Tri-Loop to use as the tertiary
variable.
Command 3 provides the following variables:
Primary variable—analog input in % or ma,
Secondary variable—travel target in % of ranged
travel,
Tertiary variable—supply or output pressure in psig,
bar, kPa, or kg/cm2. Select Select Cmd 3 Press from
the Burst menu to select if the output A, output B,
differential (A−B), or supply pressure is sent.
Quaternary variable—travel in % of ranged travel.
December 2009
 Basic Setup
3-3

Section 3 Basic Setup

Instrument Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Configuration Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3

Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Setup Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Using the Performance Tuner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Stabilizing/Optimizing Valve Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

December 2009 3-1

 DVC6000 Digital Valve Controllers
Instrument Mode
To setup and calibrate the instrument, the instrument
mode must be Out Of Service.
To view the instrument mode, press the Hot Key and
select Instrument Mode. If the mode is not Out Of
Service, select Out Of Service from the Instrument
Mode menu and press ENTER.
Configuration Protection
To setup and calibrate the instrument, the protection
must be set to None with the Field Communicator. If
the protection is not None, changing the protection
requires placing a jumper across the Auxiliary
terminals in the terminal box.
To remove protection:
1. Connect a 4-20 mA source to the instrument.
2. Connect the Field Communicator to the instrument
and turn it on.
3. Press the Hot key on the Field Communicator and
select Protection.
Note
If the Aux Terminal Mode is configured
for Auto Travel Calibration, be sure the
jumper remains across the auxiliary
terminals until the Field Communicator
prompts you to remove it. Removing
the jumper too soon will cause the
instrument to begin auto travel
calibration.
4. From the Protection menu, select None. When
prompted by the Field Communicator, temporarily
attach the jumper to the AUX + and AUX − terminals
in the instrument terminal box.
3-2
Basic Setup (1-1)
WARNING
Changes to the instrument setup may
cause changes in the output pressure
or valve travel. Depending on the
application, these changes may upset
process control, which may result in
personal injury or property damage.
Note
To setup and calibrate the instrument,
the protection must be None and the
Instrument Mode must be Out Of
Service. See Configuration Protection
and Instrument Mode at the beginning
of this section for information on
removing instrument protection and
changing the instrument mode.
If you are operating in burst mode, we
recommend that you disable burst
before continuing with calibration.
Once calibration is complete, burst
mode may then be turned back on.
When the DVC6000 digital valve controller is ordered
as part of a control valve assembly, the factory
mounts the digital valve controller and sets up the
instrument as specified on the order. When mounting
to a valve in the field, the instrument needs to be
setup to match the instrument to the valve and
actuator.
Before beginning Basic Setup, be sure the instrument
is correctly mounted as described in the Installation
section.
Setup Wizard (1-1-1)
To have the Field Communicator automatically setup
the instrument using specified actuator information,
from the Online Menu select Configure / Setup, Basic
Setup, and Setup Wizard. Follow the prompts on the
Field Communicator display to setup the instrument.
Table 4-5 provides the actuator information required to
setup and calibrate the instrument.
1. Select travel or pressure control. Travel control is
the typical mode of operation.
2. Enter the pressure units: psi, bar, kPa, or kg/cm2.
December 2009
 Basic Setup
Table 3-1. Factory Default Settings values listed in table 3-1. If you select NO for the
Setup Parameter Default Setting factory defaults, the setup parameters listed in the
Analog Input Units mA table remain at their previous settings.
Analog In Range High 20.0 mA
Analog In Range Low 4.0 mA
Typically the Setup Wizard determines the required
Control Mode Analog setup information based upon the actuator
Restart Control Mode Resume Last manufacturer and model specified. However, if you
Self-Test Shutdown All Failures Disabled enter other for the actuator manufacturer or the
Setpoint Filter Time 0 secs actuator model, then you will be prompted for setup
Input Characteristic Linear parameters such as:
Travel Limit High 125%
Travel Limit Low −25%
Actuator style (spring & diaphragm, piston
Travel Cutoff High 99.5%
double-acting without spring, piston single-acting with
Travel Cutoff Low 0.5% spring, piston double-acting with spring),
Minimum Opening Time 0 secs Valve style (rotary or sliding stem), 3
Minimum Closing Time 0 secs On Loss of Instrument Signal (valve opens or
Polling Address 0 closes), see Zero Power Condition in the Detailed
Aux Terminal Mode Aux Input Alert Setup section.
Command 3 Pressure
For double-acting actuators differential output pressure
Feedback connection (rotary-all, sstem-roller, or
For single-acting actuators actuator pressure sstem-standard), see Feedback Connection in the
Detailed Setup section.
3. Enter the maximum instrument supply pressure. Travel Sensor motion (increasing air pressure
After entering the maximum instrument supply causes the travel sensor shaft to rotate clockwise or
pressure, the Setup Wizard prompts you for actuator counterclockwise). The Field Communicator will ask if
information. it can move the valve to determine travel sensor
motion. If you answer yes, the instrument may stroke
4. Enter the manufacturer of the actuator on which the valve the full travel span to determine travel
the instrument is mounted. If the actuator sensor rotation. If you answer No, then you will have
manufacturer is not listed, select Other. to specify the rotation for increasing air pressure:
5. Enter the actuator model or type. If the actuator clockwise or counterclockwise. (see Travel Sensor
model is not listed, select Other. Motion in the Detailed Setup section).
Volume booster (indicate if volume booster or quick
6. Enter the actuator size. release is present)
7. Select whether the valve is open or closed under Tuning set (see Tuning Set in the Detailed Setup
the zero power condition. section).
After completing the setup information, travel is
automatically calibrated. Follow the prompts on the
WARNING Field Communicator display. The calibration procedure
uses the valve and actuator stops as the 0% and
In the next step, if you answer YES to 100% calibration points. For additional information,
the prompt for permission to move refer to Auto Calibrate Travel on page 5-2 of the
the valve when the Field Calibration section.
Communicator is determining the
travel sensor motion, the instrument When travel calibration is complete, you are asked if
will move the valve through its full you wish to adjust the relay (double-acting only).
travel range. To avoid personal injury Select yes to adjust the relay. For additional
and property damage caused by the information, refer to Relay Adjustment on page 5-10 of
release of pressure or process fluid, the Calibration section.
provide some temporary means of
control for the process.

8. Specify if a volume booster or quick release valve

is present.
Note
9. Specify if factory defaults should be used for basic Relay Adjustment is only available for
setup. If you select YES for factory default, the Field the double-acting relay (Relay A).
Communicator sets the setup parameters to the

December 2009 3-3

 DVC6000 Digital Valve Controllers
If after completing the Setup Wizard the valve seems
slightly unstable or unresponsive, you can improve
operation by selecting either Performance Tuner or
Stabilize/Optimize from the Basic Setup menu. For
additional information on using the Performance
Tuner, refer to Using the Performance Tuner in this
section. For additional information on stabilizing or
optimizing valve response, refer to Stabilize/Optimize
at the end of this section.
Using the Performance Tuner (1-1-2)
3 Stabilize/Optimize is only available
Note
The Performance Tuner is not
available for instrument level AC or
HC.
The Performance Tuner is used to optimize digital
valve controller tuning. It can be used with digital valve
controllers mounted on most sliding-stem and rotary
actuators, including Fisher and other manufacturers’
products. Moreover, because the Performance Tuner
can detect internal instabilities before they become
apparent in the travel response, it can generally
optimize tuning more effectively than manual tuning.
Typically, the Performance Tuner takes 3 to 5 minutes
to tune an instrument, although tuning instruments
mounted on larger actuators may take longer.
Access Performance Tuner by selecting Performance
Tuner from the Basic Setup menu. Follow the prompts
3-4
on the Field Communicator display to optimize digital
valve controller tuning.
Stabilizing/Optimizing or (1-1-2)
Valve Response
Note
through the Basic Setup menu for
instrument level HC.
If after completing setup and calibration the valve
seems slightly unstable or unresponsive, you can
improve operation by pressing the Hot Key and
selecting Stabilize/Optimize, or select
Stabilize/Optimize from the Basic Setup menu.
Stabilize/Optimize permits you to adjust valve
response by changing the digital valve controller
If the valve is unstable, select Decrease Response to
stabilize valve operation,. This selects the next lower
tuning set (e.g., F to E). If the valve response is
sluggish, select Increase Response to make the valve
more responsive. This selects the next higher tuning
set (e.g., F to G).
If after selecting Decrease Response or Increase
Response the valve travel overshoot is excessive
select Decrease Damping to select a damping value
that allows more overshoot. Select Increase Damping
to select a damping value that will decrease the
overshoot. When finished, select done.
December 2009
 Detailed Setup
4-4

Section 4 Detailed Setup

Menu and Quick Key Sequence Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Cover

Detailed Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Mode and Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4
Instrument Mode
Control Mode
Restart Control Mode
Burst Mode
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Protection
Response Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Travel Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Travel Tuning Set
Travel Tuning Set
Travel Proportional Gain
Travel Velocity Gain
Travel MLFB Gain
Travel Integral Control Enable
Travel Integral Gain
Stabilize/Optimize
Performance Tuner
Integral Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Integral Dead Zone
Integral Limit
Pressure Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Pressure Tuning Set
Pressure Tuning Set
Pressure Proportional Gain
Pressure MLFB Gain
Pressure Integral Control Enable
Pressure Integral Gain
Travel/Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Travel/Pressure Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Travel/Pressure Cutoffs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Travel/Pressure Cutoff Hi
Travel/Pressure Cutoff Lo
Travel Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Travel Limit Hi
Travel Limit Lo

December 2009 4-1

 DVC6000 Digital Valve Controllers
Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Pressure Range Hi
Pressure Range Lo
End Point Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
End Point Control Enable
PST Start Point
Pressure Set Point
Pressure Sat Time
Input Characterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Define Custom Characterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Dynamic Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
SP Rate Open
SP Rate Close
4 Lag Time
Lead / Lag
Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Electronic Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Drive Current Shutdown
Drive Signal Alert
Drive Signal Alert Enable
Drive Signal
Processor Impaired Alerts
Offline/Failed Alert Enable
Power Starvation Alert Enable
Non-Critical NVM Alert Enable
Critical NVM Shutdown
Flash ROM Shutdown
No Free Time Shutdown
Reference Voltage Shutdown
Sensor Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Travel Sensor Shutdown
Temperature Sensor Shutdown
Pressure Sensor Shutdown
Environmental Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Supply Pressure Lo Alert
Supply Pressure Lo Alert Enable
Supply Pressure
Supply Pressure Lo Alert Point
Aux Terminal Alert
Auxiliary Terminal Alert Enable
Auxiliary Input
Auxiliary Terminal Mode
Loop Current Validation Enable
Travel Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Travel
Travel Set Point
Travel Alert Dead Band
Travel Deviation Alert
Travel Limit Alerts
Travel Limit Hi/Lo Alerts

4-2 December 2009

 Detailed Setup
Travel Cutoff Alerts
Travel History Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Cycle Count
Cycle Count/Travel Accumulator Deadband
Travel Accumulator
SIS Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
PST Pressure Limit
Pressure Deviation Alert Enable
Pressure Deviation Alert Point
Pressure Deviation Time
Alert Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Alrt Record Not Empty Enab
Alrt Record Full Enab
Display Record 4
Clear Record
Alert Groups
Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Instrument Time
Calibration and Diagnostics
Operational
Integrator
Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
General
Units
Analog Input Range
Relay Type
Zero Power Condition
Maximum Supply Pressure
Auxiliary Terminal Mode
Instrument Date and Time
Calibration Status and Location
Valve & Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Manufacturer
Valve Serial Number
Valve Style
Actuator Style
Travel Sensor Motion
Edit Feedback Connection
Partial Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
PST Enable
PST Variables View/Edit

December 2009 4-3

 DVC6000 Digital Valve Controllers
Detailed Setup (1-2) Table 4-1. Factory Default Detailed Setup Parameters
Setup Parameter Default Setting(1)
Control Mode Analog
Restart Control Mode Resume Last
Zero Power Condition Valve Open(2)
Analog In Range Low 4 mA

Note Analog In Range High

Analog Input Units
20 mA
mA
Detailed Setup is not available for Feedback Connection Rotary − All(2)
instrument level AC. Instrument Travel Sensor Motion Clockwise(2)
Configuration Auxiliary Terminal Mode Disabled
Max Supply Pressure 20(2)
Pressure Units PSI
Temperature Units F
The Detailed Setup selection from the Configure /
Polling Address 0
Setup menu allows you to configure the digital valve
4 controller to your application. Table 4-1 lists the default
Burst Mode Enable
Burst Command
No
3
settings for a standard factory configuration. You can Cmd #3 (Trending) Pressure A−B
adjust actuator response, set the various modes, Tuning Set F(2)
alerts, ranges, travel cutoffs and limits. You can also Input Characteristic Linear
restart the instrument and set the protection. Travel Limit High 125%
Travel Limit Low −25%
Travel/Pressure Cutoff High 99.50%
Dynamic Travel/Pressure Cutoff Low 0.50%
Response and
Set Point Rate Open 0%/sec
Mode and Protection (1-2-1) Tuning
Set Point Rate Close 0%/sec
Set Point Filter Lag Time 0 sec
Mode Integrator Enable Yes
Integral Gain 9.4 repeats/minute
Integral Deadband 0.25%
 Instrument Mode Cycle Counter Alert Enable No
Cycle Counter Alert Deadband 1%
Cycle Counter Alert Point 1,000,000
You can change the instrument mode by selecting Travel History
Travel Accumulator Alert
Alerts No
Mode and Protection, Instrument Mode from the Enable
Detailed Setup menu, or press the Hot Key and select Travel Accumulator Deadband 1%
Instrument Mode. Travel Accumulator Alert Point 1000000%
Travel Deviation Alert Enable Yes
Instrument Mode allows you to either take the Travel Deviation Alert Point 5%
instrument Out Of Service or place it In Service. Travel Deviation Time 10 sec
Taking the instrument Out Of Service allows you to Pressure Deviation Alert
Yes
Enable
perform instrument calibration and also allows you to Deviation &
Other Alerts Pressure Deviation Alert Point 5 psi
change setup variables that affect control, provided
Pressure Deviation Alert Time 10 sec
the calibration/configuration protection is properly set.
Drive Signal Alert Enable Yes
See Setting Protection.
Supply Pressure Alert Enable Yes
Supply Pressure Alert Point 19 psi
Travel Alert Lo Enable No
Lo Point −25%
Travel Alert Hi Enable No
Hi Point 125%
Note Travel Alerts Travel Alert Lo Lo Enable
Lo Lo Point
No
−25%
Some changes that require the Travel Alert Hi Hi Enable No
instrument to be taken Out Of Service Hi Hi Point 125%
will not take effect until the instrument Deadband 5%
is placed back In Service or the Shutdown Activated Yes
Electronic
instrument is restarted. Power Starvation Alert Enable No
Alerts
Non-Critical NVM Alert Enable No
−continued on next page−

4-4 December 2009


Table 4-1. Factory Default Detailed Setup Parameters
(continued)
Setup Parameter
Default
Setting(1)
Instrument Time Invalid Enable
Calibration in Progress Enable
Autocalibration in Progress
Enable
Diagnostics in Progress Enable
Informational
Diagnostics Data Available
Status
Enable
Integrator Saturated Hi Enable
Integrator Saturated Lo Enable
Pressure Control Active Enable
Multi-Drop Alert Enable
Valve Alerts Enable
Failure Alerts Enable
Misc Alerts Enable
Alert Record
Alert Record Not Empty Enable
Alert Record Full Enable
1. The settings listed are for standard factory configuration. DVC6000 instruments
can also be ordered with custom configuration settings. For the default custom
settings, refer to the order requisition.
2. If the instrument is shipped mounted on an actuator, these values depend upon
the actuator on which the instrument is mounted.
 Control Mode
You can change the control mode by selecting Control
Mode from the Mode and Protection menu, or press
the Hot Key and select Control Mode.
Control Mode lets you define where the instrument
reads its set point. Follow the prompts on the Field
Communicator display to choose one of the following
control modes: Analog or Digital.
Choose Analog if the instrument is to receive its set
point over the 4-20 mA loop. Normally the instrument
control mode is Analog.
Choose Digital if the instrument is to receive its set
point digitally, via the HART communications link.
A third mode, Test, is also displayed. Normally the
instrument should not be in the Test mode. The Field
Communicator automatically switches to this mode
whenever it needs to stroke the valve during
calibration or stroke valve, for example. However, if
you abort from a procedure where the instrument is in
the Test mode, it may remain in this mode. To take
the instrument out of the Test mode, select Control
Mode then select either Analog or Digital.
 Restart Ctrl Mode
Restart Control Mode lets you choose which operating
mode you want the instrument to be in after a restart.
Access Restart Control mode by selecting Restart Ctrl
Mode from the Mode and Protection menu. Follow the
prompts on the Field Communicator display to define
the restart control mode as Resume Last, Analog, or
Digital.
December 2009
Detailed Setup
 Burst Mode
Enabling burst mode provides continuous
communication from the digital valve controller. Burst
Yes mode applies only to the transmission of burst mode
No data (analog input, travel target, pressure, and travel)
and does not affect the way other data is accessed.
No
No Access to information in the instrument is normally
obtained through the poll/response of HART
Yes
communication. The Field Communicator or the
Yes
control system may request any of the information that
Yes
Yes
is normally available, even while the instrument is in
No
burst mode. Between each burst mode transmission
Yes
sent by the instrument, a short pause allows the Field
Yes
No
Communicator or control system to initiate a request.
The instrument receives the request, processes the
4
Yes response message, and then continues “bursting” the
Yes burst mode data.
To enable burst mode, select Burst Mode, and Burst
Enable from the Mode and Protection menu.
 Burst Enable—Yes or no. Burst mode must
be enabled before you can change the burst mode
command.
 Burst Command—There are four burst mode
commands. Command 3 is recommended for use
with the 333 HART Tri-Loop HART-to-analog signal
converter. The other three are not used at this
time.
 Cmd 3(Trending)Press—Command 3
provides the following variables:
Primary variable—analog input in % or ma,
Secondary variable—travel target in % of ranged
travel,
Tertiary variable—supply or output pressure in psig,
bar, kPa, or kg/cm2. Select Select Cmd 3 Press from
the Burst menu to select if the output A, output B,
differential (A−B), or supply pressure is sent.
Quaternary variable—travel in % of ranged travel.
Protection
 Protection
Some setup parameters may require changing the
protection with the Field Communicator. To remove
protection (change protection to None) requires
placing a jumper across the Auxiliary terminals in the
terminal box in order to change protection.
4-5
 DVC6000 Digital Valve Controllers
Table 4-2. Gain Values for Preselected Travel Tuning Sets
Tuning Minor Loop
Proportional Gain Velocity Gain
Note Set
B 2.0 3.0
Feedback Gain
35
C 4.4 3.0 35
If the Aux Terminal Mode is configured
D 4.8 3.0 35
for Auto Travel Calibration, be sure the E 5.5 3.0 35
jumper remains across the auxiliary F 6.2 3.1 35
terminals until the Field Communicator G 7.2 3.6 34
prompts you to remove it. Removing H 8.4 4.2 31
the jumper too soon will cause the I 9.7 4.8 27
J 11.3 5.6 23
instrument to begin auto travel K 13.1 6.0 18
calibration. L 15.5 6.0 12
M 18.0 6.0 12
X
User Adjusted User Adjusted User Adjusted
(Expert)
4
WARNING
If the jumper is removed too soon, Response Control (1-2-2)
and auto travel calibration begins, the Select Configure/Setup, Detailed Setup, and
valve will move full stroke. To avoid Response Control. Follow the prompts on the Field
personal injury and property damage Communicator display to configure the following
caused by the release of pressure or response control parameters: Tuning, Tvl/Press
process fluid, provide some Control (Travel/Pressure Control), Input Char (Input
temporary means of control for the Characteristic) Define Custom Char (Define Custom
process. Characteristic), and Dynamic Response.
Tuning
Two levels of protection are available: Travel Tuning (1-2-2-1-1)

 Config & Calib—Both setup and calibration are

protected. Prohibits changing calibration and protected
setup parameters.
 None—Neither setup nor calibration is protected.
Allows changing calibration and setup parameters.
Table 4-3 lists configurable parameters in the
instrument and the requirements for modifying these
parameters, in terms of instrument mode and
protection.
To change an instrument’s protection, press the Hot
key on the Field Communicator and select Protection
or from the Online menu, select Configure/Setup,
Detailed Setup, Mode and Protection, and Protection.
Select the desired level of protection. Follow the
prompts on the Field Communicator display to set the
protection level. If necessary, temporarily attach the
jumper to the AUX + and AUX − terminals in the
instrument terminal box when prompted by the Field
Communicator.
WARNING
Changes to the tuning set may cause
the valve/actuator assembly to stroke.
To avoid personal injury and property
damage caused by moving parts,
keep hands, tools, and other objects
away from the valve/actuator
assembly.
 Tvl Tuning Set (1-2-2-1-1-1)
Tvl Tuning Set— There are twelve tuning sets to
choose from. Each tuning set provides a
preselected value for the digital valve controller
gain settings. Tuning set B provides the slowest
response and M provides the fastest response.
Table 4-2 lists the proportional gain, velocity gain
and minor loop feedback gain values for
preselected tuning sets.

4-6 December 2009

 Detailed Setup
Table 4-3. Conditions for Modifying FIELDVUE DVC6000 Digital Valve Controller Parameters
In Service/ In Service/ Out of Service/ Out of Service/
Parameters
Config Protected Config Unprotected Config Protected Config Unprotected
Control Mode --- ---  
Restart Ctrl Mode --- --- --- 
Burst Mode Enable    
Burst Mode Command --- --- --- 
Protection    
HART Tag ---  --- 
Message ---  --- 
Descriptor ---  --- 
Date ---  --- 
Valve Serial Num ---  --- 
Inst Serial Num --- --- --- 
Polling Address --- --- --- 
Relay Type --- --- --- 
Max Supply Pressure --- --- --- 
Actuator Style --- --- ---  4
Feedback Connection --- --- --- 
Travel Sensor Motion --- --- --- 
Valve Style --- --- --- 
Zero Ctrl Signal --- --- --- 
Analog In Units --- --- --- 
Input Range High --- --- --- 
Input Range Low --- --- --- 
Pressure Units --- --- --- 
Temp Units    
Tuning Set ---  --- 
Prop Gain --- --- --- 
Velocity Gain --- --- --- 
MLFB Gain --- --- --- 
Input Char --- --- --- 
Define Custom Char --- --- --- 
Set Pt Filter Time --- --- --- 
Tvl Limit High --- --- --- 
Tvl Limit Low --- --- --- 
Tvl Cutoff High --- --- --- 
Tvl Cutoff Low --- --- --- 
Set Point Rate Open --- --- --- 
Set Point Rate Close --- --- --- 
Tvl Hi/Lo Enab    
Tvl HH/LL Enab    
Tvl Alert Hi Pt    
Tvl Alert Lo Pt    
Tvl Alert HiHi Pt    
Tvl Alert LoLo Pt    
Tvl Alrt DB    
Tvl Dev Alrt Enab    
Tvl Dev Alrt Pt    
Tvl Dev Time    
Cycl Cnt Alrt Enab    
Cycl Count Alrt Pt    
Cycl Count DB    
Cycl Count    
Tvl Acum Alrt Enab    
Tvl Acum Alrt Pt    
Tvl Acum DB    
Tvl Acum    
Aux Terminal Mode --- --- --- 
Aux In Alrt Enab --- --- --- 
Aux In Alrt State --- --- --- 
Drive Alrt Enab    
Supply Press Alrt    
—indicates parameter may be modified for instrument mode and protection shown.
−Continued−

December 2009 4-7

 DVC6000 Digital Valve Controllers
Table 4-3. Conditions for Modifying FIELDVUE DVC6000 Digital Valve Controller Parameters (Continued)
In Service/ In Service/ Out of Service/ Out of Service/
Parameters
Config Protected Config Unprotected Config Protected Config Unprotected
Flash ROM Fail --- --- --- 
No Free Time --- --- --- 
Ref Voltage Fail --- --- --- 
Drive Current Fail --- --- --- 
Critical NVM Fail --- --- --- 
Temp Sensor Fail --- --- --- 
Press Sensor Fail --- --- --- 
Tvl Sensor Fail --- --- --- 
—indicates parameter may be modified for instrument mode and protection shown.

For an actuator not listed in the tables, you can

estimate a starting tuning set by calculating the

4 Note casing or cylinder volume. Then, in the tables, find

an actuator with the closest equivalent volume and
When selecting a tuning set for a use the tuning set suggested for that actuator.
DVC6015, DVC6025 or DVC6035 remote Tvl Prop Gain—Travel Proportional Gain is the
mount unit, it may be necessary to proportional gain for the travel control tuning set.
reduce the tuning set, due to the Changing this parameter will also change the
effects of the long tubing between the tuning set to Expert.
digital valve controller and the
Tvl Velocity Gain—Travel Velocity Gain is the
actuator.
velocity gain for the travel control tuning set.
Changing this parameter will also change the
tuning set to Expert.
In addition, you can select User Adjusted or Expert, Tvl MLFB Gain—Travel MLFB Gain is the minor
which allows you to modify tuning of the digital loop feedback gain for the travel control tuning set.
valve controller. With User Adjusted, you specify Changing this parameter will also change the
the proportional gain; an algorithm in the Field tuning set to Expert.
Communicator calculates the velocity gain and
 Tvl Integ Enable—Yes or No. Enable the
minor loop feedback gain. With Expert you can
integral setting to improve static performance by
specify the proportional gain, velocity gain, and
correcting for error that exists between the travel
minor loop feedback gain.
target and actual travel. Travel Integral Control is
enabled by default.
 Tvl Integ Gain—Travel Integral Gain is the
ratio of the change in output to the change in input,
Note based on the control action in which the output is
proportional to the time integral of the input.
Use Expert tuning only if standard
tuning has not achieved the desired  Stabilize/Optimize —Stabilize/Optimize
results. permits you to adjust valve response by changing
Stabilize/Optimize or Performance the digital valve controller tuning.
Tuner may be used to achieve the If the valve is unstable, select Decrease Response
desired results more rapidly than to stabilize valve operation. This selects the next
Expert tuning. lower tuning set (e.g., F to E). If the valve response
is sluggish, select Increase Response to make the
valve more responsive. This selects the next higher
Table 4-5 provides tuning set selection guidelines tuning set (e.g., F to G).
for Fisher, Baumann, and Gulde actuators. These If after selecting Decrease Response or Increase
tuning sets are only recommended starting points. Response the valve travel overshoot is excessive,
After you finish setting up and calibrating the select Decrease Damping to select a damping
instrument, you may have to select either a higher value that allows more overshoot. Select Increase
or lower tuning set to get the desired response. Damping to select a damping value that will
You can use the Performance Tuner to optimize decrease the overshoot. When finished, select
tuning. done.

4-8 December 2009

 Detailed Setup
 Performance Tuner Table 4-4. Gain Values for Preselected Pressure Tuning Sets
Pressure Pressure
Tuning Pressure
Integrator Minor Loop
Set Proportional Gain
Gain Feedback Gain
B 0.5 0.3 35
Note C
D
2.2
2.4
0.1
0.1
35
35
The Performance Tuner is not E 2.8 0.1 35
F 3.1 0.1 35
available for instrument level HC. G 3.6 0.1 34
H 4.2 0.1 31
I 4. 0.1 27
The Performance Tuner is used to optimize digital J 5.6 0.1 23
valve controller tuning. It can be used with digital valve K 6.6 0.1 18
L 7.8 0.1 12
controllers mounted on most sliding-stem and rotary M 9.0 0.1 12
actuators, including Fisher and other manufacturers’ X
products. Moreover, because the performance tuner User Adjusted User Adjusted User Adjusted
can detect internal instabilities before they become
(Expert)
4
apparent in the travel response, it can generally slowest response and M provides the fastest
optimize tuning more effectively than manual tuning. response.
Typically, the performance tuner takes 3 to 5 minutes
Tuning set B is appropriate for controlling a
to tune an instrument, although tuning instruments
pneumatic positioner. Table 4-4 lists the
mounted on larger actuators may take longer.
proportional gain, pressure integrator gain and
Integral Settings (1-2-2-1-2) minor loop feedback gain values for preselected
tuning sets.
 Integ DeadZ—Integral Dead Zone is a
window around the Primary Setpoint in which
integral action is disabled. This feature is used to
eliminate friction induced limit cycles around the
Primary Setpoint when the integrator is active. The Note
Dead Zone is configurable from 0% to 2%,
corresponding to a symmetric window from 0% to When selecting a tuning set for a
+/−2% around the Primary Setpoint. Default value DVC6015, DVC6025 or DVC6035 remote
is 0.25%. mount unit, it may be necessary to
reduce the tuning set, due to the
 Integ Limit—The Integral Limit provides an effects of the long tubing between the
upper limit to the integrator output. The high limit is digital valve controller and the
configurable from 0 to 100% of the I/P drive signal. actuator.

Pressure Tuning (1-2-2-1-3)

WARNING
Changes to the tuning set may cause
the valve/actuator assembly to stroke.
To avoid personal injury and property
damage caused by moving parts,
keep hands, tools, and other objects
away from the valve/actuator
assembly.
 Press Tuning Set (1-2-2-1-3-1)
Press Tuning Set—There are twelve Pressure
Tuning Sets to choose from. Each tuning set
provides a preselected value for the digital valve
controller gain settings. Tuning set B provides the
In addition, you can specify Expert tuning and
individually set the pressure proportional gain,
pressure integrator gain, and pressure minor loop
feedback gain. Individually setting or changing any
tuning parameter will automatically change the
tuning set to X (expert).
Note
Use Expert tuning only if standard
tuning has not achieved the desired
results.
Stabilize/Optimize and performance
tuner may be used to achieve the
desired results more rapidly than
Expert tuning.

December 2009 4-9

 DVC6000 Digital Valve Controllers
Table 4-5. Actuator Information for Initial Setup
Starting Travel Sensor Motion
Actuator Actuator Feedback
Actuator Size Actuator Style Tuning
Manufacturer Model Connection Relay A or C Relay B
Set
25 Piston Dbl w/ or F SStem-Standard
50, 60 w/o Spring. See J for travels up to Depends upon pneumatic connections.
585C & 585CR 60, 80 actuator instruction L 4 inches. SStem- See description for Travel Sensor
100, 130 manual and M Roller for longer Motion
nameplate. travels
30 H
34, 40 K
Spring &
657 45, 50 L SStem-Standard Clockwise Counterclockwise
Diaphragm
46, 60, 70, 76, &
80-100 M
30 H
34, 40 K
Spring &
667 45, 50 L SStem-Standard Counterclockwise Clockwise
Diaphragm
4 46, 60, 70, 76, &
80-100 M
20, 30 H
33 Spring & I
1051 & 1052 Rotary Clockwise Counterclockwise
40 Diaphragm K
60, 70 M
30 J
Depends upon pneumatic connections.
40 Piston Dbl w/o K
1061 Rotary See description for Travel Sensor
60 Spring L
Fisher Motion
68, 80, 100, 130 M
Depends upon pneumatic connections.
Piston Dbl w/o
1066 20, 27, 75 Specify Rotary See description for Travel Sensor
Spring
Motion

Depends upon mounting style, see

20 G
1066SR Piston Sgl w/Spring Rotary actuator instruction manual and
27, 75 L
table 4-6

1 Spring & K
2052 Rotary Clockwise Counterclockwise
2 Diaphragm J
For Po operating For Po operating
mode (air opens), mode (air opens),
GA 1.21 E
Spring & Counterclockwise Clockwise
3024 GA 1.31 H SStem-Standard
Diaphragm For Ps operating For Ps operating
GA 1.41 K
mode (air closes), mode (air closes),
Clockwise Counterclockwise
P460, P462, Spring &
3025 M Rotary Specify
P900 Diaphragm
225 X(1) Air to
Spring &
GX 750 K SStem-Standard Open Close
Diaphragm
1200 M Counterclockwise Clockwise
Air to Extend 16 C Clockwise Counterclockwise
32 E SStem-Standard
Air to Retract 570 Spring & K Counterclockwise Clockwise
Baumann
10 Diaphragm E
Rotary 25 H Rotary Specify
54 J
1. X = Expert Tuning. Proportional Gain = 4.2; Velocity Gain = 3.0; Minor Loop Feedback Gain = 18.0

Table 4-6. Travel Sensor Motion Selections for the FIELDVUE

DVC6030 on a Fisher 1066SR Actuator
Travel Sensor Motion
Mounting Style
Relay A or C Relay B
A Clockwise Counterclockwise
B Counterclockwise Clockwise
C Counterclockwise Clockwise
D Clockwise Counterclockwise

4-10 December 2009


Press Prop Gain—Pressure Proportional Gain is
the proportional gain for the pressure control tuning
set. Changing this parameter will also change the
tuning set to Expert.
Press MLFB Gain—Pressure MLFB Gain is the
minor loop feedback gain for the pressure control
tuning set. Changing this parameter will also
change the tuning set to Expert.
 Press Integ Enable—Yes or No. Enable the
pressure integral setting to improve static
performance by correcting for error that exists
between the pressure target and actual pressure.
Pressure Integral Control is disabled by default.
 Press Integ Gain—Pressure Integral Gain
(also called reset) is the gain factor applied to the
time integral of the error signal between desired
and actual pressure. Changing this parameter will
also change the tuning set to Expert.
Tvl/Press Control (1-2-2-2)
 Tvl/Press Select
Travel / Pressure Select determines if the
instrument is set up for position or pressure control.
Select Travel, Pressure, Travel with Pressure
Fallback/Auto recovery or Travel with Pressure
Fallback/Manual Recovery. If the travel sensor
fails, and Travel with Pressure Fallback/Auto
Recovery is selected, it will return to travel control
when the travel sensor starts working again. Travel
with Pressure Fallback/Manual recovery will stay in
pressure control until Travel Pressure Select is
changed to Travel or Travel with Pressure
Fallback/Auto recovery. It is not necessary to
enable the Travel Sensor Alert for Pressure
Fallback to occur.
Tvl/Press Cutoffs (1-2-2-2-2)
 Tvl/Press Cut Hi—Travel Cutoff High defines
the high cutoff point for the travel in percent (%) of
ranged input current. Above this cutoff, the travel
target is set to 123.0% of the ranged input current.
When a Travel Cutoff High is set, the Travel Limit
High is deactivated, since only one of these
parameters can be active. Travel Cutoff Hi is
deactivated by setting it to 125.0%.
Pressure Cutoff Hi defines the high cutoff point for
the pressure in percent (%) of pre-characterized
setpoint. Above this cutoff, the pressure target is
set to 123.0%. A Pressure Cutoff Hi of 99.5% is
recommended to ensure valve goes fully open.
Pressure Cutoff Hi is deactivated by setting it to
125%.
December 2009
Detailed Setup
 Tvl/Press Cut Lo—Travel Cutoff Low defines
the low cutoff point for the travel set point. Travel
Cutoff Low can be used to ensure proper seat load
is applied to the valve. When below the travel
cutoff low, the output is set to zero or to full supply
pressure, depending upon the zero power
condition. A Travel Cutoff Low of 0.5% is
recommended to help ensure maximum shutoff
seat loading. When a Travel Cutoff Low is set, the
Travel Limit Low is deactivated, since only one of
these parameters can be active. Travel Cutoff Low
is deactivated by setting it to −25%.
Pressure Cutoff Lo defines the low cutoff point for
the pressure in percent (%) of pre-characterized
setpoint. Below this cutoff, the pressure target is
set to −23%. A Pressure Cutoff Lo of 0.5% is
4
recommended to help ensure maximum shutoff
seat loading. Pressure Cutoff Lo is deactivated by
setting it to −25.0%
Travel Limits (1-2-2-2-3)
 Tvl Limit Hi—Travel Limit High defines the
high limit for the travel in percent (%) of ranged
travel. If is the maximum allowable travel (in
percent of ranged travel) for the valve. During
operation, the travel target will not exceed this limit.
When a Travel Limit High is set, the Travel Cutoff
High is deactivated, since only one of these
parameters can be active. Travel Limit High is
deactivated by setting it to 125.0%
 Tvl Limit Lo—Travel Limit Low defines the low
limit for the travel in percent (%) of ranged travel. It
is the minimum allowable travel (in percent of
ranged travel) for the valve. During operation, the
travel target will not exceed this limit. When a
Travel Limit Low is set, the Travel Cutoff Low is
deactivated, since only one of these parameters
can be active. Travel Limit Low is deactivated by
setting it to −25.0%.
Pressure Control (1-2-2-2-4)
 Press Range Hi—Pressure Range Hi is the
high end of output pressure range. Enter the
pressure that corresponds with 100% valve travel
when Zero Power Condition is closed, or 0% valve
travel when Zero Power Condition is open. This
pressure must be greater than the Pressure Range
Lo.
 Press Range Lo—Pressure Range Low is the
low end of the output pressure range. Enter the
pressure that corresponds to 0% valve travel when
Zero Power Condition is closed, or 100% valve
travel when Zero Power Condition is open. This
pressure must be less than the Pressure Range Hi.
4-11
 DVC6000 Digital Valve Controllers
End Pt Press Control (1-2-2-2-5)
Note
End Point Pressure Control is only
available for instrument level ODV.
 End Pt Control Enab— Select Yes or No. End
Point Pressure Control allows the digital valve
controller to pull back from saturation of the
4 pneumatic output after reaching the travel extreme.
Rather than having the instrument provide full
supply pressure (saturation) continuously at the
travel extreme, the digital valve controller switches
to an End Point Pressure Control where the output
pressure (pressure controller set point) to the
actuator is maintained at a certain value. This value
is configured through the Upper Operating
Pressure feature. Because the digital valve
controller is constantly in control and not allowed to
reach a dormant or saturated state, it is constantly
testing its own pneumatic system. If there is an
output pressure deviation, for example, the
instrument will issue an alert. To ensure there is an
alert when an output pressure deviation occurs,
setup the alert as described under Pressure
Deviation Alert.
 PST Start Pt—Defines the travel stop the
valve needs to be at before a partial stroke test can
be initiated. Also defines the travel stop for end
point pressure control. Setting this value to Not
Configured will disable partial stroke tests and end
point pressure control.
 Press Set Point—Used in conjunction with
End Point Pressure Control, Pressure Set Point
allows the user to select a pressure to be delivered
by the instrument at the travel extreme. For a
fail-closed valve, this pressure must be sufficient to
maintain the fully open position. For a fail-open
valve, this pressure (which is automatically set to
supply pressure) must be sufficient to fully close
the valve and maintain its rated shutoff
classification. For double-acting spring return
actuators, this is the differential pressure required
to either maintain the fully open or fully closed
position, depending on the valve and actuator
configuration. For a double-acting actuator without
springs with a fail-close valve, this is 95% of the
supply pressure. If the valve is fail-open, the upper
operating pressure for all actuator is set to the
supply pressure.
4-12
 Press Sat Time—Pressure Sat Time is the
amount of time the digital valve controller stays in
hard cutoff before switching to pressure control.
Default is 45 seconds.
Input Char (1-2-2-3)
Input Characterization defines the relationship
between the travel target and ranged set point.
Ranged set point is the input to the characterization
function. If the zero power condition equals closed,
then a set point of 0% corresponds to a ranged input
of 0%. If the zero power condition equals open, a set
point of 0% corresponds to a ranged input of 100%.
Travel target is the output from the characterization
function.
To select an input characterization, select Select Input
Char from the Input Char menu. You can select from
the three fixed input characteristics shown in figure 4-1
or you can select a custom characteristic. Figure 4-1
shows the relationship between the travel target and
ranged set point for the fixed input characteristics,
assuming the Zero Power Condition is configured as
closed.
You can specify 21 points on a custom characteristic
curve. Each point defines a travel target, in % of
ranged travel, for a corresponding set point, in % of
ranged set point. Set point values range from −6.25%
to 106.25%. Before modification, the custom
characteristic is linear.
Define Custom Char (1-2-2-4)
To define a custom input character, from the Input
Char menu select Define Custom Char. Select the
point you wish to define (1 to 21), then enter the
desired set point value. Press Enter then enter the
desired travel target for the corresponding set point.
When finished, select point 0 to return to the Input
Char menu.
With input characterization you can modify the overall
characteristic of the valve and instrument combination.
Selecting an equal percentage, quick opening, or
custom (other than the default of linear) input
characteristic modifies the overall valve and
instrument characteristic. However, if you select the
linear input characteristic, the overall valve and
instrument characteristic is the characteristic of the
valve, which is determined by the valve trim (i.e., the
plug or cage).
Dynamic Response (1-2-2-5)
 SP Rate Open—Maximum rate (% of valve travel
per second) at which the digital valve controller will
move to the open position regardless of the rate of
input current change. A value of 0 will deactivate this
feature and allow the valve to stroke open as fast as
possible.
December 2009
 Detailed Setup
125
 SP Rate Close—Maximum rate (% of valve travel
per second) at which the digital valve controller will
move to the close position regardless of the rate of
100
input current change. A value of 0 will deactivate this
feature and allow the valve to stroke close as fast as
possible.
Travel Target, %

0
Note
Lag Time is only available for
−25
−25 0 Ranged Set Point, % 100 125
instrument level HC, AD, and PD. 4
Input Characteristic = Linear

125

 Lag Time—Slows the response of the digital

100 valve controller. A value ranging from 0.2 to 10.0 can
be used for noisy or fast processes to improve closed
loop process control. Entering a value of 0.0 will
deactivate the lag filter.
Travel Target, %

0
Note
−25 Lead/Lag is only available for
−25 0 Ranged Set Point, % 100 125 instrument level ODV.
Input Characteristic = Equal Percentage

125

 Lead/Lag—ODV tiered devices have access to a

100
lead-lag input filter that can be used to improve a
valve’s dynamic response. The lead-lag input filter is
part of the set point processing routine that reshapes
the input signal before it becomes travel set point.
Travel Target, %

Lead-lag filters are characterized by lead and lag time

constants.

When the valve is in its active control region (off the

seat), the lead-lag filter improves small amplitude
0
response by momentarily overdriving the travel set
point. This is useful when the actuator is large and
equipped with accessories. As a result, any volume
−25
−25 0 Ranged Set Point, % 100 125 boosters that are present will be activated. The longer
A6535-1/IL Input Characteristic = Quick Opening the lag time, the more pronounced the overdrive.
Since the lead-lag input filter is used to enhance the
Figure 4-1. Travel Target Versus Ranged Set Point, for Various dynamic response of a control valve, filter parameters
Input Characteristics (Zero Power Condition = Closed) should be set after the tuning parameters have been
established.

December 2009 4-13

 DVC6000 Digital Valve Controllers
Table 4-7. Typical Lead/Lag Filter Settings
Parameter Description
First order time constant. A value of 0.0 will disable the
Lag Time
lead-lag filter.
Opening Lead/Lag Ratio Initial response to the filter in the opening direction.
Closing Lead/Lag Ratio Initial response to the filter in the closing direction.
Initial conditions of the lead-lag filter when the lower
Lead-Lag Boost
travel cutoff is active.
When the valve is at its seat, the lead-lag filter also
has a boost function that sets the initial conditions of
the filter artificially low so that small amplitude signal
changes appear to be large signal changes to the
filter. The boost function introduces a large spike that
momentarily overdrives the instrument and activates
4 any external volume boosters that may be present.
The lead-lag boost function is normally disabled
except for those cases where the valve must respond
to small command signals off the seat. By setting the
lead/lag ratio in the opening and closing directions to
1.0, the boost function can be enabled without
introducing lead-lag dynamics in the active control
region. See table 4-7 for typical lead-lag filter settings.
Alerts (1-2-3)
The following menus are available for configuring
Alerts. Items on the menus may be changed with the
instrument In Service. Protection does not need to be
removed (no need to set to None). Alerts are not
processed when a Diagnostic is in progress. Select
Configure / Setup, Detailed Setup, and Alerts. Follow
the prompts on the Field Communicator display to
configure the following Alerts: Electronic Alerts,
Sensor Alerts, Environmental Alerts, Travel Alerts,
Travel History Alerts, SIS Alerts (instrument level ODV
only), and Alert Record.
Note
The Alerts section covers alerts and
shutdowns. An alert, if enabled, can
provide information on operation and
performance issues. A shutdown, if
enabled, will typically shut down the
instrument down if there is a failure
associated with the enabled shutdown.
4-14
Typical Value
0.2 sec
2.0
2.0
Off
 Electronic Alerts (1-2-3-1)
 Drive Current Shutdown— When enabled, the
instrument shuts down whenever the drive current
does not read as expected.
Drive Signal Alert (1-2-3-1-2)
Drive Signal Alert checks the drive signal and
calibrated travel. If one of the following conditions
exists for more than 20 seconds, the Drive Signal
Alert is set.
For the case where Zero Power Condition is
defined as closed:
Drive Signal < 10% and Calibrated Travel > 3%
Drive Signal > 90% and Calibrated Travel < 97%
For the case where Zero Power Condition is
defined as open:
Drive Signal < 10% and Calibrated Travel < 97%
Drive Signal > 90% and Calibrated Travel > 3%
 Drive Signal Alert Enable—Yes or No. Drive
Signal Alert Enable activates checking of the
relationship between the Drive Signal and the
calibrated travel.
 Drive Signal—Shows the value of the
instrument drive signal in % (percent) of maximum
drive.
Processor Impaired Alerts (1-2-3-1-3)
 Offline/Failed Alrt Enab—If enabled, set when
the device is in a failed state and not controlling the
input.
 Power Starvation Alrt Enab—When enabled,
an alert is generated whenever power starvation is
detected. Only available in firmware 7.
 Low Power Write Alert Enabled—When
enabled, an alert is generated if a write to the
instrument is attempted and fails when the loop
current is less than 3.5 mA. Only available in
firmware 9.
 Non-Critical NVM Alrt Enab—When enabled,
an alert is generated whenever there is a failure
December 2009

associated with non-critical NVM (non-volatile
memory).
 Critical NVM Shutdown—When enabled, the
instrument shuts down whenever there is a failure
associated with critical NVM (non-volatile memory).
 Flash ROM Shutdown—When enabled, the
instrument shuts down whenever there is a failure
associated with flash ROM (read only memory).
 No Free Time Shutdown—When enabled, the
instrument shuts down whenever there is a failure
associated with No Free Time.
 Reference Voltage Shutdown—When
enabled, the instrument shuts down whenever
there is a failure associated with the internal
voltage reference.
 Sensor Alerts (1-2-3-2)
 Tvl Sensor Shutdown
When enabled, the instrument shuts down
whenever there is a failure associated with the
travel sensor.
 Temp Sensor Shutdown
When enabled, the instrument shuts down
whenever there is a failure associated with the
temperature sensor.
 Press Sensor Shutdown
When enabled, the instrument shuts down
whenever there is a failure associated with the
pressure sensor.
 Environment Alerts
Supply Press Lo Alert (1-2-3-3-1)
Note
The Supply Pressure Lo alert is not
available in instrument level HC.
 Supply Press Lo Alrt Enab—When enabled,
the instrument shuts down whenever there is a
failure associated with the supply pressure.
 Supply Press—Supply Pressure displays the
instrument supply pressure in kPa,bar, psi, or
kg/cm2.
December 2009
Detailed Setup
 Supply Press Lo Alrt Pt—Supply Pressure Lo
Alert Point. When the supply pressure falls below
the supply pressure alert point, the supply pressure
alert is active. To disable the supply pressure alert,
set Supply Press Alrt Pt to zero.
Aux Terminal Alerts
(1-2-3-3-1) HC
(1-2-3-3-2) (AD, PD, ODV)
 Aux Terminal Alrt Enab—Yes or No. Auxiliary
Input Alert Enable activates checking the status of
the auxiliary input when the Auxiliary Terminal
Mode is Aux Input Alert. When enabled, the
Auxiliary Input Alert is set when the auxiliary input
terminals are either open or closed, depending
upon the selection for the Aux In Alrt State. 4
 Aux Input—The auxiliary input is a contact or
discrete input, which may be open or closed.
 Aux Term Mode—Aux Input Alert or Auto
Travel Calib. Selecting Aux Input Alert then Aux In
Alrt Enab activates checking the status of the
auxiliary input contacts. Selecting Auto Travel Calib
permits starting an automatic travel calibration
procedure by placing a jumper across the auxiliary
input terminals for 3 to 5 seconds.
 Loop Current Validation Enable (1-2-3-3-2)
When enabled, the instrument shuts down
whenever there is a failure associated with the
measured loop current being out-of-range. Only
available in firmware 9.
 Travel Alerts (1-2-3-4)
 Travel—Travel displays the actual position of
the valve in percent (%) of calibrated travel.
 Tvl Set Pt—Travel set point is the input to the
characterization function.
 Tvl Alrt DB—Travel Alert Deadband is the
travel, in percent (%) of ranged travel, required to
clear a travel alert, once it has been set. The
deadband applies to both Travel Alert Hi/Lo and
Travel Alert Hi Hi/Lo Lo. See figure 4-2.
Deviation Alert (1-2-3-4-4)
If the difference between the travel target and the
actual target exceeds the Travel Deviation Alert
Point for more than the Travel Deviation Time, the
Travel Deviation Alert is set. It remains set until the
difference between the travel target and the actual
travel is less than the Travel Deviation Alert Point
minus the Travel Alert Deadband.
 Tvl Dev Alrt Enable—Travel Deviation Alert
Enable, select Yes or No. When enabled, checks
4-15
 DVC6000 Digital Valve Controllers
the difference between the travel target and the
actual travel.
 Tvl Dev Alrt Pt—Travel Deviation Alert Point
is the alert point for the difference, expressed in
percent (%), between the travel target and the
actual travel. When the difference exceeds the
alert point for more than the Travel Deviation Time,
the Travel Deviation Alert is set.
 Tvl Dev Time—Travel Deviation Time is the
time, in seconds, that the travel deviation must
exceed the Travel Deviation Alert Point before the
alert is set.
4 Limit Alerts (1-2-3-4-5)
Travel Alert Hi Hi is set if the ranged travel rises
above the alert high point. Once the alert is set, the
ranged travel must fall below the alert high high
point by the Travel Alert Deadband before the alert
is cleared. See figure 4-2.
Travel Alert Lo Lo is set if the ranged travel falls
below the alert low low point. Once the alert is set,
the ranged travel must rise above the alert low low
point by the Travel Alert Deadband before the alert
is cleared.
 Tvl Alrt Hi Hi Enab—Yes or No. Travel Alert
HiHi Enable activates checking of the ranged travel
against the Travel Alert High-High points.
 Tvl Alrt Lo Lo Enab—Yes or No. Travel Alert
LoLo Enable activates checking of the ranged
travel against the Travel Alert Low-Low points.
 Tvl Alrt Hi Hi Pt—Travel Alert High-High Point
is the value of the travel, in percent (%) of ranged
travel, which, when exceeded, sets the Travel Alert
Hi Hi alert.
 Tvl Alrt Lo Lo Pt—Travel Alert Low-Low Point
is the value of the travel, in percent (%) of ranged
travel, which, when exceeded, sets the Travel Alert
Lo Lo alert.
Travel Limit Hi/Lo Alerts (1-2-3-4-6)
Travel Alert Hi is set if the ranged travel rises
above the alert high point. Once the alert is set, the
ranged travel must fall below the alert high point by
the Travel Alert Deadband before the alert is
cleared. See figure 4-2.
Travel Alert Lo is set if the ranged travel falls below
the alert low point. Once the alert is set, the ranged
travel must rise above the alert low point by the
Travel Alert Deadband before the alert is cleared.
4-16
ALERT IS SET
TRAVEL ALERT
HIGH POINT
TRAVEL ALERT
DEADBAND
ALERT IS CLEARED
A6532/IL
Figure 4-2. Travel Alert Deadband
 Tvl Alrt Hi Enab—Yes or No. Travel Alert Hi
Enable activates checking of the ranged travel
against the Travel Alert High Point.
 Tvl Alrt Lo Enab—Yes or No. Travel Alert Lo
Enable activates checking of the ranged travel
against the Travel Alert Lo Point.
 Tvl Alrt Hi Point—Travel Alert High Point is
the value of the travel, in percent (%) of ranged
travel, which, when exceeded, sets the Travel Alert
High alert.
 Tvl Alrt Lo Point—Travel Alert Low Point is
the value of the travel, in percent (%) of ranged
travel, which, when exceeded, sets the Travel Alert
Low alert.
Travel Limit Cutoff Alerts (1-2-3-4-7)
 Tvl Limit/Cutoff Hi Alrt Enab—Yes or No.
Travel Limit /Cutoff Hi Alert Enable activates the
Travel Limit / Cutoff Hi alert.
 Tvl Limit/Cutoff Lo Alrt Enab—Yes or No.
Travel Limit /Cutoff Lo Alert Enable activates the
Travel Limit/Cutoff Lo alert.
 Tvl/Press Cut Hi—Travel Cutoff Hi defines the
high cutoff point for the travel in percent(%) of
pre-characterized set point. Above this cutoff, the
travel target is set to 123.0% of the ranged travel.
Travel Cutoff Hi is deactivated by setting it to
125.0%.
Pressure Cutoff Hi defines the high cutoff point for
the pressure in percent (%) of pre-characterized
set point. Above this cutoff,the pressure target is
set to 123.0%. A Pressure Cutoff Hi of 99.5% is
recommended to ensure valve goes fully open.
Pressure Cutoff Hi is deactivated by setting it to
125%
 Tvl/Press Cut Lo—Travel Cutoff Lo defines
the low cutoff point for the travel in percent (%)of
December 2009

Deadband exceeded,
new Reference Point
established
This amount of change is
Deadband Reference added to the Travel
Accumulator.
Point
A6534/IL
Deadband (+/− 5%)
Figure 4-3. Travel Accumulator Deadband (set at 10%)
pre-characterized set point. Below this cutoff, the
travel target is set to −23%. A Travel Cutoff Lo of
0.5% is recommended to help ensure maximum
shutoff seat loading. Travel Cutoff Lo is deactivated
by setting it to−25.0%
Pressure Cutoff Lo defines the low cutoff point for
the pressure in percent (%) of pre-characterized
set point. Below this cutoff,the pressure target is
set to −23%. A Pressure Cutoff Lo of 0.5% is
recommended to help ensure maximum shutoff
seat loading. Pressure Cutoff Lo is deactivated by
setting it to −25.0%
 Tvl Limit High—Travel Limit High defines the
high limit for the travel in percent (%) of ranged
travel. It is the maximum allowable travel (in
percent of ranged travel) for the valve. During
operation, the travel target will not exceed this limit.
When a Travel Limit High is set, the Travel Cutoff
High is deactivated, since only one of these
parameters can be active. Travel Limit High is
deactivated by setting it to 125.0%.
 Tvl Limit Lo—Travel Limit Low defines the low
limit for the travel in percent (%) of ranged travel. It
is the minimum allowable travel (in percent of
ranged travel) for the valve. During operation, the
travel target will not exceed this limit. When a
Travel Limit Low is set, the Travel Cutoff Low is
deactivated, since only one of these parameters
can be active. Travel Limit Low is deactivated by
setting it to −25.0%.
 Travel History Alerts
Cycle Count (1-2-3-5-1)
 Cycle Count Alrt Enab—Yes or No. Cycle
Counter Alert Enable activates checking of the
December 2009
Detailed Setup
Deadband exceeded, and direction
changed, new Reference Point
established
Point at which
cycle is counted.
Deadband Reference
Point
A6533-1/IL Deadband (+/− 5%)
4
Figure 4-4. Cycle Counter Deadband (set at 10%)
difference between the Cycle Counter and the
Cycle Counter Alert point. The Cycle Counter Alert
is set when the value exceeds the Cycle Counter
Alert point. It is cleared after you reset the Cycle
Counter to a value less than the alert point.
 Cycle Count—Cycle Counter records the
number of times the travel changes direction. The
change in direction must occur after the deadband
has been exceeded before it can be counted as a
cycle. See figure 4-4. You can reset the Cycle
Counter by configuring it as zero.
 Cycle Count Alrt Pt—Cycle Counter Alert
Point is the value of the Cycle Counter, in cycles,
which, when exceeded, sets the Cycle Counter
Alert.
Cycle Count/Tvl Accum Deadband (1-2-3-5-2)
 Deadband
Cycle Counter Deadband is the area around the
travel reference point, in percent (%) of ranged
travel, that was established at the last increment of
the Cycle Counter. This area must be exceeded
before a change in travel direction can be counted
as a cycle. See figure 4-4.
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 4-3.
Tvl Accum (1-2-3-5-3)
 Tvl Accum Alrt Enab—Yes or No. Travel
Accumulation Alert Enable activates checking of
the difference between the Travel Accumulator
value and the Travel Accumulator Alert Point. The
4-17
 DVC6000 Digital Valve Controllers
Travel Accumulation Alert is set when the Travel
Accumulator value exceeds the Travel Accumulator
Alert Point. It is cleared after you reset the Travel
Accumulation to a value less than the alert point.
 Tvl Accum—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 4-3. You can
reset the Travel Accumulator by configuring it to
zero.
 Tvl Accum Alrt Pt—Travel Accumulator Alert
4 Point is the value of the Travel Accumulator, in
percent (%) of ranged travel, which, when
exceeded, sets the Travel Accumulator Alert.
 SIS Alerts (1-2-3-6)
Note
SIS Alerts are only available for
instrument level ODV.
 PST Press Limit—Partial Stroke Test
Pressure Limit defines the output pressure that will
cause the partial stroke test to stop. For actuators
that vent from the test starting point, the pressure
limit will be a minimum value. For actuators that fill
from the test starting point, the pressure limit will
be a maximum value.
 Press Dev Alrt Enab—Pressure Deviation
Alert Enable, select Yes or No. This alert notifies a
monitoring system when a deviation in the actuator
pressure has occurred. This is used when the
instrument is controlling via pressure (Pressure
Control Mode is enabled) to the actuator (rather
than valve position) to prevent saturation of the
pneumatic output. When enabled, this alert checks
the difference between the target pressure and the
actual pressure. If the difference exceeds the
Pressure Deviation Alert Point for more than the
pressure deviation time, the Pressure Deviation
Alert is set. It remains set until the difference
between the target pressure and the actual
pressure is less than the Pressure Deviation Alert
Point. The pressure deviation alert point and
deviation alert time are configurable and can be
disabled altogether.
4-18
Table 4-8. Alerts Included in Alert Groups for Alert Record
Alert Group Alerts Include in Group
Travel Lo Alert
Travel Hi Alert
Travel Lo Lo Alert
Valve Alerts
Travel Hi Hi Alert
Travel Deviation Alert
Drive Signal Alert
Flash ROM Fail
No Free Time
Reference Voltage Fail
Drive Current Fail
Failure Alerts
Critical NVM Fail
Temperature Sensor Fail
Pressure Sensor Fail
Travel Sensor Fail
Miscellaneous Alerts Auxiliary input
 Press Dev Alrt Pt—Pressure Deviation Alert
Point is the alert point for the difference between
the pressure target and the actual pressure. When
the difference exceeds the alert point for more than
the Pressure Deviation Time, the Pressure
Deviation Alert is set. After completion of the Setup
Wizard or Auto Travel calibration a default value of
2 psi is set. This will generate an alert when the
actuator pressure is not within $2 psi of the target
pressure.
 Press Dev Time—Pressure Deviation Time is
the time, in seconds, that the pressure deviation
must exceed the Pressure Deviation Alert Point
before the alert is set. The Pressure Deviation
Time is set to 30 seconds by default.
 Alert Record
(1-2-3-6) HC, AD, and PD
(1-2-3-7) ODV
To be recorded, an alert must both be enabled for
reporting, and the group in which it resides must be
enabled for recording. Table 4-8 lists the alerts
included in each of the groups. When any alert from
an enabled group becomes active, active alerts in all
enabled groups are stored.
 Alrt Record Not Empty Enab—Yes or No.
When enabled indicates when an alert has been
recorded.
 Alrt Record Full Enab—Yes or No. When
enabled indicates when the Alert Record is full.
 Display Record—Displays all recorded alerts
and the date and time the alerts were recorded.
 Clear Record—Clears the alert record. To
clear the alert record, all alerts in enabled groups
must be inactive.
December 2009

Alert Groups
(1-2-3-6-5) HC, AD, and PD
(1-2-3-7-5) ODV
 Failure Group Enab—Permits enabling the
Failure Alert group. Table 4-8 lists the alerts
included in each of the groups.
 Valve Group Enab—Permits enabling the
Valve Alert group. Table 4-8 lists the alerts
included in each of the groups.
 Misc Group Enab—Permits enabling the
Miscellaneous Alert group. Table 4-8 lists the alerts
included in each of the groups.
Status (1-2-4)
Select Configure / Setup, Detailed Setup, and Status.
Follow the prompts on the Field Communicator display
to configure the following parameters: Instrument
Time, Calibration and Diagnostics, Operational, and
Integrator.
 Instrument Time (1-2-4-1)
 Inst Time Invalid Enab—Yes or No. When
enabled indicates if the Instrument Time Invalid
alert is active.
 Inst Date and Time—Permits setting the
instrument clock. When alerts are stored in the
alert record, the record includes the time and date.
The instrument clock uses a 24-hour format.
 Calibration & Diagnostics (1-2-4-2)
 Cal in Progress Enab—Yes or No. When
enabled indicates that calibration is in progress.
 AutoCal in Progress Enab—Yes or No. When
enabled indicates that auto calibration is in
progress.
 Diag in Progress Enab—Yes or No. When
enabled indicates that a diagnostic test is in
progress.
 Diag Data Avail Enab—Yes or No. When
enabled indicates when there is diagnostic data
available.
 Operational (1-2-4-3)
 Press Cntrl Active Enab—Yes or No. When
enabled indicates when Pressure Control is active.
December 2009
Detailed Setup
 Multi-Drop Enab—Yes or No. When enabled
indicates the digital valve controller is operating in a
multi-drop loop.
 Integrator (1-2-4-4)
 Integrator Sat Hi Enab—Yes or No. When
enabled indicates when the Integrator Saturated
High alert is active.
 Integrator Sat Lo Enab—Yes or No. When
enabled indicates when the Integrator Saturated Lo
alert is active.
 Integ Limit—The Integral Limit provides an
upper limit to the integrator output. The high limit is
configurable from 0 to 100% of the I/P drive signal.
4
 Integ DeadZ—Integral Dead Zone is a window
around the Primary Setpoint in which integral
action is disabled. This feature is used to eliminate
friction induced limit cycles around the Primary
Setpoint when the integrator is active. The Dead
Zone is configurable from 0% to 2%, corresponding
to a symmetric window from 0% to +/−2% around
the Primary Setpoint. Default value is 0.25%.
Instrument (1-2-5)
Select Configure / Setup, Detailed Setup, and
Instrument. Follow the prompts on the Field
Communicator display to configure the following
Instrument parameters: General, Units, Analog Input
Range, Relay Type, Zero Pwr Condition (Zero Power
Condition), Max Supply Press (Maximum Supply
Pressure), Aux Term Mode (Auxiliary Terminal Mode)
Inst Date and Time (Instrument Date and Time), and
Calib Status and Loc (Calibration Status and
Location).
 General (1-2-5-1)
 HART Tag—Enter an up to 8 character HART
tag for the instrument. The HART tag is the easiest
way to distinguish between instruments in a
multi-instrument environment. Use the HART tag to
label instruments electronically according to the
requirements of your application. The tag you
assign is automatically displayed when the Field
Communicator establishes contact with the digital
valve controller at power-up.
 Message—Enter any message with up to 32
characters. Message provides the most specific
user-defined means for identifying individual
instruments in multi-instrument environments.
 Descriptor—Enter a descriptor for the
application with up to 16 characters. The descriptor
4-19
 DVC6000 Digital Valve Controllers
TRAVEL
RANGE
HIGH
ZPC = OPEN
ZPC = CLOSED
CALIBRATED TRAVEL, %
THE SHAPE OF
THESE LINES DEPENDS ON
THE INPUT CHARACTERISTICS
TRAVEL LINEAR CHARACTERISTIC SHOWN
RANGE
LOW
4
ANALOG INPUT
INPUT RANGE mA OR % OF 4-20 mA
LOW
NOTE:
ZPC = ZERO POWER CONDITION
A6531-1 / IL
Figure 4-5. Calibrated Travel to Analog Input Relationship
provides a longer user-defined electronic label to
assist with more specific instrument identification
than is available with the HART tag.
 Date—Enter a date with the format
MM/DD/YY. Date is a user-defined variable that
provides a place to save the date of the last
revision of configuration or calibration information.
 Valve Serial Num—Enter the serial number
for the valve in the application with up to 12
characters.
 Inst Serial Num—Enter the serial number on
the instrument nameplate, up to 12 characters.
 Polling Address—If the digital valve controller
is used in point-to-point operation, the Polling
Address is 0. When several devices are connected
in the same loop, such as for split ranging, each
device must be assigned a unique polling address.
The Polling Address is set to a value between 0
and 15. To change the polling address the
instrument must be Out Of Service.
For the Field Communicator to be able to
communicate with a device whose polling address
is not 0, it must be configured to automatically
search for all or specific connected devices.
4-20
 Units (1-2-5-2)
 Pressure Units—Defines the output and
supply pressure units in either psi, bar, kPa, or
kg/cm2.
 Temp Units—Degrees Fahrenheit or Celsius.
The temperature measured is from a sensor
mounted on the digital valve controller’s printed
wiring board.
 Analog In Units—Permits defining the Analog
Input Units in mA or percent of 4−20 mA range.
 Analog Input Range (1-2-5-3)
INPUT RANGE
HIGH  Input Range Hi—Permits setting the Input
Range High value. Input Range High should
correspond to Travel Range High, if the Zero
Power Condition is configured as closed. If the
Zero Power Condition is configured as open, Input
Range High corresponds to Travel Range Low.
See figure 4-5.
 Input Range Lo—Permits setting the Input
Range Low value. Input Range Low should
correspond to Travel Range Low, if the Zero Power
Condition is configured as closed. If the Zero
Power Condition is configured as open, Input
Range Low corresponds to Travel Range High.
See figure 4-5.
 Relay Type
There are three categories of relays that result in
combinations from which to select.
Relay Type: The relay type is printed on the label
affixed to the relay body.
A = double-acting or single-acting
B = single-acting, reverse
C= single-acting, direct
Special App: This is used in single-acting
applications where the “unused” output port is
configured to read the pressure downstream of a
solenoid valve. See page 2-19 for additional
information.
Lo Bleed: The label affixed to the relay body
indicates whether it is a low bleed version.
December 2009
 Detailed Setup

RELAY TYPE
A PNEUMATIC SUPPLY
Single Acting Direct (Relay C)
Double Acting (Relay A)
Single Acting Reverse (Relay B)
B
LOSS OF POWER
Instrument goes to zero air out-
put at port A.
Instrument goes to full supply
air output at port B. A goes to
zero air output.
Instrument goes to full supply
air output at port B.
LOSS OF
Failure direction per
actuator fail mode.
Failure direction cannot
be determined.
Failure direction per
actuator fail mode.

4
Figure 4-6. Zero Power Condition

 Zero Pwr Cond Valve & Actuator (1-2-6)

The position of the valve (open or closed) when the
electrical power to the instrument is removed. Zero
Power Condition (ZPC) is determined by relay and
actuator action, as shown in figure 4-6.
 Max Supply Press
Select Configure / Setup, Detailed Setup, and Valve &
Actuator. Follow the prompts on the Field
Communicator display to configure the following
instrument parameters: Manufacturer, Valve Serial
Num (Valve Serial Number), Valve Style, Actuator
Style, Feedback Conn (Feedback Connection), and
Tvl Sensor Motion (Travel Sensor Motion).

Enter the maximum supply pressure in psi, bar, kPa,
or kg/cm2, depending on what was selected for
pressure units.
 Aux Term Mode
Aux Input Alert or Auto Travel Calib. Selecting Aux
Input Alert then Aux In Alrt Enab activates checking
the status of the auxiliary input contacts. Selecting
Auto Travel Calib permits starting an automatic travel
calibration procedure by placing a jumper across the
auxiliary input terminals for 3 to 5 seconds.
 Inst Date and Time
Date is a user-defined variable that provides a place to
save the date of the last revision of configuration or
calibration information.
 Manufacturer
Enter the manufacturer of the actuator on which the
instrument is mounted. If the actuator manufacturer is
not listed, select Other.
 Valve Serial Num
Enter the serial number for the valve in the application
with up to 12 characters.
 Valve Style
Enter the valve style, rotary or sliding-stem
 Actuator Style
Enter the actuator style, spring and diaphragm, piston
double-acting without spring, piston single-acting with
spring, or piston double-acting with spring.
 Tvl Sensor Motion

 Calib Status and Loc (1-2-5-9)
 Last Calib Status—Indicates the status of the
last instrument calibration.
 Calib Loc—Indicates the location of the last
instrument calibration.
Select Clockwise, or Counterclockwise. Travel Sensor
Motion establishes the proper travel sensor rotation.
Determine the rotation by viewing the end of the travel
sensor shaft from the perspective of the actuator.
For instruments with Relay A and C: If increasing
air pressure at output A causes the shaft to turn
clockwise, enter Clockwise. If it causes the shaft to
turn counterclockwise, enter Counterclockwise.

December 2009 4-21

 DVC6000 Digital Valve Controllers
ACTUATOR
STEM TRAVEL SENSOR SHAFT
FEEDBACK ARM
ADJUSTMENT
ARM
4 29B1665-A / DOC
CONNECTOR
ARM
Figure 4-7. Feedback Connection for Typical Sliding-Stem
Actuator (Up to 4 inch Travel)
For instruments with Relay B: If increasing air
pressure at output B causes the shaft to turn
counterclockwise, enter Clockwise. If it causes the
shaft to turn clockwise, enter Counterclockwise.
 Edit Feedback Connection
Select Rotary All, SStem - Roller or SStem - Standard.
For rotary valves, enter Rotary - All, SStem - Roller.
For sliding-stem valves, if the feedback linkage
consists of a connector arm, adjustment arm, and
feedback arm (similar to figure 4-7), enter SStem -
Standard. If the feedback linkage consists of a roller
that follows a cam (similar to figure 4-8), enter Rotary
All, SStem - Roller.
Partial Stroke (1-2-7)
Note
Partial Stroke is only available for
instrument level ODV.
Select Configure / Setup, Detailed Setup, and Partial
Stroke. Follow the prompts on the Field Communicator
display to configure the following partial stroke
parameters: PST Enable (Partial Stroke Test Enable),
and PST Vars View/Edit (View/Edit Partial Stroke Test
Variables).
4-22
ROLLER
STEM
CONNECTOR CAM
Figure 4-8. Feedback Connection for Typical Long-Stroke
Sliding-Stem Actuator (4 to 24 Inches Travel)
 PST Enable
Yes or No. Enables or disables the Partial Stroke Test.
 PST Vars View/Edit
Follow the prompts on the Field Communicator display
to enter or view information for the following PST
Variables: Partial Stroke Tvl (Partial Stroke Travel),
Stroke Speed, Pause Time, PST Press Limit (Partial
Stroke Pressure Limit), PST Mode Enable (Partial
Stroke Enable), Pressure Set Point (Pressure Set
Point), and End Pt Contrl Enab (End Point Control
Enable).
Max Travel Movement—The default value for Max
Travel Movement is 10%. It may be set to a value
between 1 and 30% in 0.1% increments.
Note
The Max Travel Movement is the
percentage of total span that the valve
moves away from its operating state
towards its fail state during a Partial
Stroke Test.
Stroke Speed—The stroke speed can be set for
1%/second, 0.5%/second, 0.25%/second,
0.12%/second, or 0.06%/second. The default value for
Partial Stroke Speed is 0.25%/second.
Pause Time—The Setup Wizard sets the Partial
Stroke Pause Time to 5 seconds. This is the pause
time between the up and down strokes of the test. It
can be set for 5, 10, 15, 20 or 30 seconds.
December 2009
 Detailed Setup
PST Press Limit (single acting actuators)—During the Table 4-9. Values for Disabling Partial Stroke Pressure Limit
Setup Wizard, or Auto Travel Calibration, the Partial Partial
Stroke Pressure Limit value will be set to a positive Actuator
Zero Partial Stroke
value. For single acting actuators that vent from the Relay Type Power Stroke Pressure
Type
Condition Start Point Limit
test starting point, the pressure limit will be a minimum
(Disabled)
value. For those actuators that fill from the test starting
Open 0.0
point, the pressure limit will be a maximum value. The Closed
Closed Psupply
pressure signal used for this threshold depends on A or C
Open Psupply
relay type and is summarized below. Open
Single Closed 0.0
Acting Open Psupply
Relay Type Pressure Signal Closed
Closed 0.0
A or C Port A − Port B B
Open 0.0
B Port B − Port A Open
Closed Psupply
B Special App. Port B
C Special App. Port A Closed
Open
Closed
−Psupply
Psupply
4
Double
PST Diff Press— During the Setup Wizard or Auto A
Acting Open Psupply
Travel Calibration, the PST Press Limit will be set to a Open
Closed −Psupply
negative value for actuators where the Partial Stroke
Start Point is opposite of the Zero Power Condition
(e.g., Partial Stroke Start Point = Open and Zero
Power Condition = Closed) and to a positive valve for
To manually set the partial stroke pressure limit,
actuators where the Partial Stroke Start Point is the
disable the travel deviation alert by setting Travel Dev
same as the Zero Power Condition.
Alert Pt to 125%. Also disable “end point pressure
To set the partial stroke pressure limit manually for control” and disable the partial stroke pressure limit by
single acting actuators select min pressure. Select min setting the values shown in table 4-9.
diff press for double acting actuators.
Run the partial stroke test using the Field
Communicator. Once the test is completed download
the partial stroke test results using ValveLink software.
Note Select the Press/Time radio button from the partial
stroke valve signature graph. If actuator pressure
In order to manually set the partial
starts high and moves low, find the minimum actuator
stroke pressure limit with the correct
pressure, Pmin. Otherwise, find the maximum actuator
value, you must be able to run a valve
pressure, Pmax. Use table 4-10 to estimate the partial
signature test using ValveLink
stroke pressure limit.
software. It is then possible to set the
partial stroke pressure limit with the
Field Communicator, using the The default value is 0.
information generated by the valve
signature test. For double acting valves, the differential pressure is
used.

December 2009 4-23

 DVC6000 Digital Valve Controllers
Table 4-10. Estimates for Partial Stroke Pressure Limits
Zero Power
Actuator Style Relay Type PST Starting Point Partial Stroke Pressure Limit(1)
Condition
Open Pmin − 0.25 * (Bench Set High − Bench Set Low)
Closed
Closed Pmax + 0.25 * (Bench Set High − Bench Set Low)
A or C
Open Pmax + 0.25 * (Bench Set High − Bench Set Low)
Open
Spring and Closed Pmin − 0.25 * (Bench Set High − Bench Set Low)
Diaphragm Open Pmax + 0.25 * (Bench Set High − Bench Set Low)
Closed
Closed Pmin − 0.25 * (Bench Set High − Bench Set Low)
B
Open Pmin − 0.25 * (Bench Set High − Bench Set Low)
Open
Closed Pmax + 0.25 * (Bench Set High − Bench Set Low)

Open 0.5 * Pmin

Closed
Closed Pmax + 0.5 * (Psupply − Pmax)
A or C
Pmax + 0.5 * (Psupply − Pmax)
4 Open
Open
Closed 0.5 * Pmin
Single Acting Piston
Open Pmax + 0.5 * (Psupply − Pmax)
Closed
Closed 0.5 * Pmin
B
Open 0.5 * Pmin
Open
Closed Pmax + 0.5 * (Psupply − Pmax)

Open Pmin − 0.5 * (Psupply + Pmin)

Closed
Double Acting Closed Pmax + 0.5 * (Psupply − Pmax)
A
Piston Open Pmax + 0.5 * (Psupply − Pmax)
Open
Closed Pmin − 0.5 * (Psupply + Pmin)

4-24 December 2009

 Calibration
5-5

Section 5 Calibration
Calibration Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Travel Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Auto Calibrate Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Manual Calibrate Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Analog Calibration Adjust 5
Digital Calibration Adjust
Touch-Up Travel Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Pressure Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Output Pressure Sensor Calibration
Supply Pressure Sensor Calibration
Travel Sensor Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
DVC6010, DVC6015, DVC6030 and DVC6035 Digital Valve Controllers
DVC6020 and DVC6025 Digital Valve Controllers
Analog Input Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Relay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Double-Acting Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Single-Acting Direct Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Single-Acting Reverse Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Restore Factory Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

December 2009 5-1

 DVC6000 Digital Valve Controllers
Calibration Overview
When a DVC6000 digital valve controller is ordered as
part of a control valve assembly, the factory mounts Note
the digital valve controller on the actuator and
connects the necessary tubing, then sets up and The Instrument Mode must be Out Of
calibrates the controller. For remote-mounted digital Service and the Protection set to None
valve controllers, the DVC6005 base unit ships before the instrument can be calibrated.
separately from the control valve and does not include
tubing, fittings or wiring. If you are operating in burst mode, we
recommend that you disable burst before
For digital valve controllers that are ordered continuing with calibration. Once
separately, recalibration of the analog input or calibration is complete, burst mode may
pressure sensors generally is unnecessary. However, then be turned back on.
after mounting on an actuator, perform the initial setup
(either auto or manual), then calibrate travel by
selecting Calibrate, Travel Calibration, and Auto Tvl
Calib (Auto Travel Calibration) from the Configure /
Setup menu. For more detailed calibration information,
5 refer to the following calibration procedures, available WARNING
from the Calibrate menu:
During calibration, the valve may
Travel Calibration
move. To avoid personal injury and
 Auto Travel Calibrate —This procedure property damage caused by the
automatically calibrates the travel. The calibration release of pressure or process fluid,
procedure uses the valve and actuator stops as the provide some temporary means of
0% and 100% calibration points. control for the process.

 Manual Travel Calibrate —This procedure

permits manual calibration of the travel. This
calibration procedure allows you to determine the 0%
and 100% calibration points and obtain the optimum
linearity on a sliding-stem valve.
Sensor Calibration
 Pressure Sensor Calibration—This procedure
permits calibrating the three pressure sensors.
Normally the sensors are calibrated at the factory and
should not need calibration.
 Travel Sensor Adjust—This procedure permits
calibrating the travel sensor. Normally the travel
sensor is calibrated at the factory. Calibrating the
travel sensor should only be necessary if the travel
sensor is replaced.
 Analog In Calibration—This procedure permits
calibrating the analog input sensor. Normally the
sensor is calibrated at the factory and should not need
calibration.
Relay Adjustment—This procedure permits
adjustment of the pneumatic relay.
Restore Factory Settings—This procedure permits
you to restore the calibration settings back to the
factory settings.
To display the calibrate menu, from the Online menu,
select Configure / Setup and Calibrate.
Travel Calibration
There are two procedures available for calibrating
travel:
 Automatically (Auto Calibrate Travel)
 Manually (Manual Calibrate Travel)
Once the travel is calibrated by performing either the
Auto Calibrate Travel or Manual Calibrate Travel
procedures, the travel calibration can be “touched-up”
using Touch-Up Travel Calibration.
Auto Calibrate Travel (1-3-1-1)
User interaction is only required with Auto Calibrate
Travel when the feedback connection is SStem -
Standard (Sliding Stem - Standard). A feedback
connection of Rotary - All, SStem - Roller (Sliding
Stem - Roller) requires no user interaction and you
can start with step 6.
For a SStem - Standard feedback connection,
interaction provides a more accurate crossover
adjustment. Setting crossover establishes the zero
degree point for the geometric correction used to
translate the rotary motion observed by the travel
sensor into the linear motion of the sliding-stem valve.

5-2 December 2009


When a double-acting actuator is used, you will be
prompted to run the Relay Adjustment when Auto
Travel Calibration is selected. Select Yes to adjust the
relay. Select No to proceed with Auto Travel
Calibration. For additional information, refer to Relay
Adjustment in this section.
Select Auto Tvl Calib from the Calibrate menu, then
follow the prompts on the Field Communicator display
to automatically calibrate travel.
1. Select the method of crossover adjustment:
manual, last value, or default. Manual is the
recommended choice. If you select Manual, the Field
Communicator will prompt you to adjust the crossover
in step 3.
If you select Last Value, the crossover setting
currently stored in the instrument is used and there
are no further user interactions with the
auto-calibration routine (go to step 6). Use this
selection if you cannot use manual, such as when you
cannot see the valve.
If you select Default, an approximate value for the
crossover is written to the instrument and there are no
further user interactions with the auto-calibration
routine (go to step 6). 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.
2. The instrument seeks the high and low drive points
and the minor loop feedback (MLFB) and output bias.
No user interaction is required in this step. For a
description of these actions see step 6.
3. If you select Manual in step 1, you are asked to
select an adjustment source, either analog or digital. If
you use a current source to adjust the crossover,
select Analog and go to step 4. If you wish to adjust
the current source digitally, select Digital and go to
step 5.
4. If you selected Analog as the crossover adjustment
source, the Field Communicator prompts you to adjust
the current source until the feedback arm is 90° to the
actuator stem, as shown in figure 5-1. After you have
made the adjustment, press OK and go to step 6.
5. If you selected Digital as the crossover adjustment
source, the Field Communicator displays a menu to
allow you to adjust the crossover.
Select the direction and size of change required to set
the feedback arm so it is 90° to the actuator stem, as
shown in figure 5-1. Selecting large, medium, and
small adjustments to the crossover causes changes of
December 2009
Calibration
ACTUATOR
STEM
90_
FEEDBACK ARM
5
A6536−3 / IL
Figure 5-1. Crossover Point
approximately 10.0°, 1.0°, and 0.1°, respectively, to
the rotation of the feedback arm.
If another adjustment is required, repeat step 5.
Otherwise, select Done and go to step 6.
6. The remainder of the auto calibration procedure is
automatic.
During calibration, the instrument seeks the high and
low end points and the minor loop feedback (MLFB)
and output bias. By searching for the end points, the
instrument establishes the limits of physical travel, i.e.,
the actual travel 0 and 100% positions. This also
determines how far the relay beam swings to calibrate
the sensitivity of the beam position sensor.
Adjusting the minor loop feedback bias is done around
mid travel. The valve position is briefly moved back
and forth to determine the relay beam position at
quiescence. Essentially, it establishes the zero point
for the Minor Loop Feedback circuit. The back and
forth motion is performed to account for hysteresis.
Adjusting the output bias aligns the travel set point
with the actual travel by computing the drive signal
required to produce 0% error. This is done while the
valve is at 50% travel, making very small adjustments.
Calibration is complete when the “Auto Calibration has
completed” message appears.
7. Place the instrument In Service and verify that the
travel properly tracks the current source.
If the unit does not calibrate, refer to table 5-1 for error
messages and possible remedies.
5-3
 DVC6000 Digital Valve Controllers
Manual Calibrate Travel (1-3-1-2)
It is recommended that you adjust the relay before
manually calibrating travel. For additional information
refer to Relay Adjustment in this section.
Note
Relay Adjustment is only available for
the double-acting relay (Relay A).
Two procedures are available to manually calibrate
5 travel:
 Analog Adjust
 Digital Adjust
Analog Calibration Adjust
From the Calibrate menu, select Man Tvl Calib and
Analog Adjust. Connect a variable current source to
the instrument LOOP + and LOOP − terminals. The
current source should be capable of generating 4 to 20
mA. Follow the prompts on the Field Communicator
display to calibrate the instrument’s travel in percent.
Note
0% Travel = Valve Closed
100% Travel = Valve Open
1. Adjust the input current until the valve is near
mid-travel. Press OK.
2. If the feedback connection is Rotary - All, SStem -
Roller, go to step 6. If the feedback connection is
SStem - Standard, you are prompted to set the
crossover point. Adjust the current source until the
feedback arm is 90° to the actuator stem, as shown in
figure 5-1. Then press OK.
5-4
Table 5-1. Auto Calibrate Travel Error Messages
Error Message Possible Problem and Remedy
The analog input signal to the instrument
Input current must
must be greater than 3.8 mA. Adjust the
exceed 3.8 mA for
current output from the control system or the
calibration.
current source to provide at least 4.0 mA.
The Instrument Mode must be Out of Service
Place Out Of Service
and the Protection must be None before the
and ensure Calibrate
instrument can be calibrated. For information
Protection is disabled
on changing instrument protection and mode,
before calib.
see the beginning of this section.
The problem may be one or the other of the
following:
1. The tuning set selected is too low and the
valve does not reach an end point in the
allotted time. Press the Hot Key, select
Calibration Aborted.
Stabilize/Optimize then Increase Response
An end point was not
(selects next higher tuning set).
reached.
2. The tuning set selected is too high, valve
operation is unstable and does not stay at an
end point for the allotted time. Press the Hot
Key, select Stabilize/Optimize then Decrease
Response (selects next lower tuning set).
Prior to receiving this message, did the
instrument output go from zero to full supply?
If not, verify instrument supply pressure by
referring to the specifications in the
appropriate actuator instruction manual. If
supply pressure is correct, check instrument
pneumatic components (I/P converter and
Invalid travel value. relay).
Check travel sensor
and feedback arm If the instrument output did go from zero to
adjustments, and inst full supply prior to receiving this message,
supply press. Then, then verify proper mounting by referring to the
repeat Auto Calib. appropriate mounting procedure in the
Installation section.
Verify travel sensor adjustment by performing
the appropriate Travel Sensor Adjust
procedure in the Calibration section.
Making the crossover adjustment with the
valve positioned at either end of its travel will
also cause this message to appear.
The instrument may have been taken out of
Aborting due to
service by a primary master. Put the
response code or
instrument into service with the primary
device status.
master or cycle the power off and on.
Note
In steps 3 through 7, the accuracy of
the current source adjustment affects
the position accuracy.
3. Adjust the current source until the valve is at 0%
travel, then press OK.
4. Adjust the current source until the valve is at 100%
travel, then press OK.
5. Adjust the current source until the valve is at 50%
travel, then press OK.
December 2009

6. Adjust the current source until the valve is at 0%
travel, then press OK.
7. Adjust the current source until the valve is at 100%
travel, then press OK.
8. Adjust the current source until the valve is near 5%
travel, then press OK.
9. Adjust the current source until the valve is near
95% travel, then press OK.
10. Place the instrument In Service and verify that the
travel properly tracks the current source.
Digital Calibration Adjust
From the Calibrate menu, select Man Tvl Calib and
Digital Adjust. Connect a variable current source to the
instrument LOOP + and LOOP − terminals. The
current source should be set between 4 and 20 mA.
Follow the prompts on the Field Communicator display
to calibrate the instrument’s travel in percent.
Note
0% Travel = Valve Closed
100% Travel = Valve Open
1. From the adjustment menu, select the direction and
size of change required to adjust the output until the
valve is near mid-travel. Selecting large, medium, and
small adjustments causes changes of approximately
10.0°, 1.0°, and 0.1°, respectively, to the feedback
arm rotation.
If another adjustment is required, repeat step 1.
Otherwise, select Done and go to step 2.
2. If the feedback connection is Rotary - All, SStem -
Roller, go to step 7. If the feedback connection is
SStem - Standard, adjust the feedback arm to the
crossover point by using the adjustment menu.
3. From the adjustment menu, select the direction and
size of change required to set the feedback arm so it
is 90° to the actuator stem, as shown in figure 5-1.
Selecting large, medium, and small adjustments to the
crossover causes changes of approximately 10.0°,
1.0°, and 0.1°, respectively, to the feedback arm
rotation.
If another adjustment is required, repeat step 3.
Otherwise, select Done and go to step 4.
4. From the adjustment menu, select the direction and
size of change required to set the travel at 0%.
Selecting large, medium, and small adjustments
December 2009
Calibration
causes changes of approximately 10.0°, 1.0°, and
0.1°, respectively, to the feedback arm rotation.
If another adjustment is required, repeat step 4.
Otherwise, select Done and go to step 5.
5. From the adjustment menu, select the direction and
size of change required to set the travel to 100%.
Selecting large, medium, and small adjustments
causes changes of approximately 10.0°, 1.0°, and
0.1°, respectively, to the feedback arm rotation.
If another adjustment is required, repeat step 5.
Otherwise, select Done and go to step 6.
6. From the adjustment menu, select the direction and
size of change required to set the travel to 50%.
Selecting large, medium, and small adjustments
causes changes of approximately 10.0°, 1.0°, and
0.1°, respectively, to the feedback arm rotation.
If another adjustment is required, repeat step 6. 5
Otherwise, select Done and go to step 7.
7. From the adjustment menu, select the direction and
size of change required to set the travel to 0%.
Selecting large, medium, and small adjustments
causes changes of approximately 10.0°, 1.0°, and
0.1°, respectively, to the feedback arm rotation for a
sliding-stem valve or to the travel for a rotary valve.
If another adjustment is required, repeat step 7.
Otherwise, select Done and go to step 8.
8. From the adjustment menu, select the direction and
size of change required to set the travel to 100%.
Selecting large, medium, and small adjustments
causes changes of approximately 10.0°, 1.0°, and
0.1°, respectively, to the feedback arm rotation for a
sliding-stem valve or to the travel for a rotary valve.
If another adjustment is required, repeat step 8.
Otherwise, select Done and go to step 9.
9. From the adjustment menu, select the direction and
size of change required to set the travel to near 5%.
Selecting large, medium, and small adjustments
causes changes of approximately 10.0°, 1.0°, and
0.1°, respectively, to the feedback arm rotation for a
sliding-stem valve or to the travel for a rotary valve.
If another adjustment is required, repeat step 9.
Otherwise, select Done and go to step 10.
10. From the adjustment menu, select the direction
and size of change required to set the travel to near
95%. Selecting large, medium, and small adjustments
causes changes of approximately 10.0°, 1.0°, and
0.1°, respectively, to the feedback arm rotation for a
sliding-stem valve or to the travel for a rotary valve.
If another adjustment is required, repeat step 10.
Otherwise, select Done and go to step 11.
11. Place the instrument In Service and verify that the
travel properly tracks the current source.
5-5
 DVC6000 Digital Valve Controllers
Touch-Up Travel Calibration
Once the travel is calibrated by performing either the
Auto Calibrate Travel or Manual Calibrate Travel
procedures, the travel calibration can be “touched-up”
by shorting the Aux Terminal Connections for 3 to 5
seconds to activate Touch-Up Calibration. Touch-Up
Travel Calibration uses Last Value for the crossover
adjustment. You can abort the procedure by shorting
the auxiliary terminals for 1 second.
To enable Touch-Up Travel Calibration the Aux
Terminal Mode must be set to Auto Travel Calib. The
instrument Operational Status during calibration is
Calibration in Progress.
Use Touch-Up Calibration to calibrate the digital valve
controller travel whenever the I/P converter or relay is
replaced. Do not use Touch-Up calibration for initial
5 calibration when mounting the instrument on an
actuator, or if the travel sensor assembly or printed
wiring board assembly was replaced.
You can use Touch-Up Travel Calibration to calibrate
the digital valve controller if you suspect calibration
has changed due to drift. However, prior to initiating
Touch-Up Travel Calibration, perform a Valve
Signature diagnostic test, using ValveLink software.
This will capture the as-found data for future root
cause analysis.
Sensor Calibration
Pressure Sensors (1-3-2-1)
There are three pressure sensors: output A, output B
and supply. Select the appropriate menu depending
upon which pressure sensor you are calibrating.
Note
The pressure sensors are calibrated at
the factory and should not require
calibration.
Output Pressure Sensor Calibration
To calibrate the output pressure sensors, connect an
external reference gauge to the output being
calibrated. The gauge should be capable of measuring
5-6
maximum instrument supply pressure. From the
Calibrate menu, select Sensor Calibration and Press
Sensors (Pressure Sensors). Depending upon the
sensor you wish to calibrate, select either Output A
Sensor or Output B Sensor. Follow the prompts on the
Field Communicator display to calibrate the
instrument’s output pressure sensor.
1. Adjust the supply pressure regulator to the desired
supply pressure. Press OK.
2. Select a) Zero only, or b) Zero and Span (gauge
required) sensor calibration.
a. If Zero only calibration is selected, wait until
output x pressure has completely exhausted, then
continue. Once calibration is completed, go to step
6. The output x pressure corresponds to A or B,
depending on which output you are calibrating.
b. If Zero and Span calibration is selected, wait
until output x pressure has completely exhausted,
then continue. You will then be asked to wait until
output x pressure has reached full supply, then
continue. The output x pressure corresponds to A
or B, depending on which output you are
calibrating. Proceed with step 3.
3. The instrument sets the output pressure to full
supply. The following message appears:
Use the Increase and
Decrease selections
until the displayed
pressure matches the
output x pressure.
The output x pressure corresponds to A or B,
depending on which output you are calibrating. Press
OK when you have read the message.
4. The value of the output pressure appears on the
display.
5. From the adjustment menu, select the direction and
size of adjustment to the displayed value. Selecting
large, medium, and small adjustments causes
changes of approximately 3.0 psi/0.207 bar/20.7 kPa,
0.30 psi/0.0207 bar/2.07 kPa, and 0.03 psi/0.00207
bar/0.207 kPa, respectively. Adjust the displayed value
until it matches the output pressure, select Done and
go to step 6.
6. Place the instrument In Service and verify that the
displayed pressure matches the measured output
pressure.
December 2009
 Calibration
Supply Pressure Sensor Calibration

Alignment Pin
(key 46)
Note Feedback Arm
(key 79)
Supply Pressure Sensor Calibration is
not available for instrument level HC.

A
To calibrate the supply pressure sensor, connect an B
external reference gauge to the output side of the Travel
Sensor
supply regulator. The gauge should be capable of Shaft
measuring maximum instrument supply pressure.
From the Calibrate menu, select Sensor Calibration,
Press Sensors (Pressure Sensors), and Supply
Sensor. Follow the prompts on the Field A7023 / IL 5
Communicator display to calibrate the instrument’s Figure 5-2. FIELDVUE DVC6010 Digital Valve Controller
supply pressure sensor. Showing Feedback Arm in Position for Travel Sensor
Adjustment
1. Select a) Zero Only, or b) Zero and Span (gauge
required).
5. Place the instrument In Service and verify that the
a. If Zero Only calibration is selected, adjust the displayed pressure matches the measured supply
supply pressure regulator to remove supply pressure.
pressure from the instrument. Press OK. Once
calibration is complete, go to step 5.
Travel Sensor Adjust (1-3-2-2)
b. If Zero and Span calibration is selected, adjust The travel sensor is normally adjusted at the factory
the supply pressure regulator to remove supply and should not require adjustment. However, if the
pressure from the instrument. Press OK. Adjust the travel sensor has been replaced, adjust the travel
supply regulator to the maximum instrument supply sensor by performing the appropriate procedure. See
pressure. Press OK. Proceed with step 2. the Maintenance section for travel sensor replacement
procedures.
2. The following message appears:

DVC6010, DVC6015, DVC6030 and

Use the Increase and
Decrease selections until
the displayed pressure
matches the instrument
supply pressure.
Press OK when you have read this message.
3. The value of the pressure appears on the display.
4. From the adjustment menu, select the direction and
size of adjustment to the displayed value. Selecting
large, medium, and small adjustments causes
changes of approximately 3.0 psi/0.207 bar/20.7 kPa,
0.30 psi/0.0207 bar/2.07 kPa, and 0.03 psi/0.00207
bar/0.207 kPa, respectively. Adjust the displayed value
until it matches the supply pressure, select Done and
go to step 5.
DVC6035 Digital Valve Controllers
WARNING
Failure to remove air pressure may
cause personal injury or property
damage from bursting parts.
1. Remove supply air and remove the instrument from
the actuator.
2. As shown in figure 5-2, align the feedback arm (key
79) with the housing by inserting the alignment pin
(key 46) through the hole marked “A” on the feedback
arm. Fully engage the alignment pin into the tapped
hole in the housing.

December 2009 5-7

 DVC6000 Digital Valve Controllers
BACK EDGE
OF ARM PARALLEL
W/BACK OF HOUSING
ARM ASSEMBLY
ARM ASSEMBLY PIN
TRAVEL SENSOR
SHAFT
BACK OF HOUSING
A7025 / IL
5 Figure 5-3. FIELDVUE DVC6020 Travel Sensor Arm/Housing
Back Plane Alignment
Note
The alignment pin (key 46) is
stored inside the digital valve
controller housing.
3. Loosen the screw that secures the feedback arm to
the travel sensor shaft. Position the feedback arm so
that the surface of the feedback arm is flush with the
end of the travel sensor shaft.
4. Connect a current source to the instrument LOOP
− and LOOP + terminals. Set the current source to
any value between 4 and 20 mA. Connect the Field
Communicator to the TALK terminals.
5. Before beginning the travel sensor adjustment, set
the instrument mode to Out Of Service and the
protection to None.
6. From the Calibrate menu select Sensor
Calibration,and Tvl Sensor Adjust (Travel Sensor
Adjust). Follow the prompts on the Field
Communicator display to adjust the travel sensor
counts to the value listed in table 5-2.
5-8
Table 5-2. Travel Sensor Counts
Digital Valve Controller Travel Sensor Counts
DVC6010 / DVC6015 700 ±200
DVC6020 / DVC6025 2100 ±200
DVC6030(1) / DVC6035(2)
600 ±200
Counterclockwise shaft rotation
DVC6030(3) / DVC6035(2)
3400 ±200
Clockwise shaft rotation
1. Refer to figure 2-9 to determine the desired starting position for the DVC6030
based on counterclockwise potentiometer shaft rotation.
2. Refer to figure 2-14 to determine the desired starting position for the DVC6035
based on potentiometer shaft; counterclockwise or clockwise.
3. Refer to figure 2-10 to determine the desired starting position for the DVC6030
based on colckwise potentiometer shaft rotation.
Note
In the next step, be sure the feedback
arm surface remains flush with the end
of the travel sensor shaft.
7. While observing the travel sensor counts, tighten
the screw that secures the feedback arm to the travel
sensor shaft. Be sure the travel sensor counts remain
within the tolerances listed in table 5-2. Paint the
screw to discourage tampering with the connection.
8. Disconnect the Field Communicator and current
source from the instrument.
9. Remove the alignment pin and store it in the
instrument housing.
10. Install the digital valve controller on the actuator.
DVC6020 and DVC6025 Digital Valve
Controllers
WARNING
Failure to remove air pressure may
cause personal injury or property
damage from bursting parts.
1. Remove supply air and remove the instrument from
the actuator.
2. See figure 5-4 for parts identification. Disconnect
the bias spring (key 82) from the feedback arm
assembly (key 84) and the arm assembly (key 91).
Remove the mounting bracket (key 74) from the back
of the digital controller. Hold the arm assembly
(key 91) so that the arm assembly points toward the
terminal box and the arm is parallel to the back of the
housing, as shown in figure 5-3.
3. Loosen the screw that secures the arm assembly
to the travel sensor shaft. Position the arm assembly
December 2009
 Calibration

MOUNTING CAP SCREW, HEX SOCKET

ADAPTER (KEY 116)
(KEY 117)

MOUNTING BRACKET
(KEY 74)

BIAS SPRING
(KEY 82) 5
CAP SCREW, HEX HEAD
(KEY 92)

ARM ASSEMBLY PIN

ARM ASSEMBLY
(KEY 91)

FEEDBACK ARM ASSEMBLY

FEEDBACK ARM (KEY 84)
TORSION SPRING
A7024 -2/ IL
(KEY 93)

Figure 5-4. FIELDVUE DVC6020 Digital Valve Controller Mounted on Fisher 1052, Size 33 Actuator

so that the outer surface is flush with the end of the

travel sensor shaft.

4. Connect a current source to the instrument LOOP

Note
− and LOOP + terminals. Set the current source to In the next step, be sure the arm
any value between 4 and 20 mA. Connect the Field assembly outer surface remains flush
Communicator to the TALK terminals. with the end of the travel sensor shaft.

5. Before beginning the travel sensor adjustment, set

the instrument mode to Out Of Service and the
protection to None.
6. From the Calibrate menu, select Sensor Calibration
and Tvl Sensor Adjust (Travel Sensor Adjust). Follow
the prompts on the Field Communicator display to
adjust the travel sensor counts to the value listed in
table 5-2.
7. While observing the travel sensor counts, tighten
the screw that secures the arm assembly to the travel
sensor shaft. Be sure the travel sensor counts remain
within the tolerances listed in table 5-2. Paint the
screw to discourage tampering with the connection.
8. Disconnect the Field Communicator and current
source from the instrument.

December 2009 5-9

 DVC6000 Digital Valve Controllers
9. Apply lubricant (key 63) to the pin portion of the
arm assembly (key 91).
10. Replace the mounting bracket on the back of the
instrument and reconnect the bias spring between the
feedback arm assembly and the arm assembly on the
travel sensor shaft.
11. Install the digital valve controller on the actuator.
Analog Input Calibration (1-3-2-3)
To calibrate the analog input sensor, connect a
variable current source to the instrument LOOP+ and
LOOP− terminals. The current source should be
5 capable of generating an output of 4 to 20 mA. From
the Configure / Setup menu select Calibrate, Sensor
Calibration, and Analog In Calib (Analog Input
Calibration). Follow the prompts on the Field
Communicator display to calibrate the analog input
sensor.
1. Set the current source to the target value shown on
the display. The target value is the Input Range Low
value. Press OK.
2. The following message appears:
Use Increase and
Decrease selections
until the displayed
current matches the
current source.
Press OK when you have read this message.
3. The value of the Analog Input appears on the
display.
4. From the adjustment menu, select the direction and
size of adjustment to the displayed value. Selecting
large, medium, and small adjustments causes
changes of approximately 0.4 mA, 0.04 mA, and 0.004
mA, respectively. Adjust the displayed value until it
matches the current source, select Done and go to
step 5.
5. Set the current source to the target value shown on
the display. The target value is the Input Range High
value. Press OK.
5-10
6. The following message appears:
Use Increase and
Decrease selections
until the displayed
current matches the
current source.
Press OK when you have read this message.
7. The value of the Analog Input appears on the
display.
8. From the adjustment menu, select the direction and
size of adjustment to the displayed value. Selecting
large, medium, and small adjustments causes
changes of approximately 0.4 mA, 0.04 mA, and 0.004
mA, respectively. Adjust the displayed value until it
matches the current source, select Done and go to
step 9.
9. Place the instrument In Service and verify that the
analog input displayed matches the current source.
Relay Adjustment (1-3-3)
Before beginning travel calibration, check the relay
adjustment. To check relay adjustment, select Relay
Adjust from the Calibrate menu, then follow the
prompts on the Field Communicator display. Replace
the digital valve controller cover when finished.
Note
Relay B and C are not user-adjustable.
Double-Acting Relay
The double-acting relay is designated by “Relay A” on
a label affixed to the relay itself. For double-acting
actuators, the valve must be near mid-travel to
properly adjust the relay. The Field Communicator will
automatically position the valve when Relay Adjust is
selected.
Rotate the adjustment disc, shown in figure 5-5, until
the output pressure displayed on the Field
Communicator is between 50 and 70% of supply
pressure. This adjustment is very sensitive. Be sure to
allow the pressure reading to stabilize before making
another adjustment (stabilization may take up to 30
seconds or more for large actuators).
December 2009

ADJUSTMENT DISC
W9034
Figure 5-5. Relay A Adjustment (Shroud Removed for Clarity)
If the low bleed relay option has been ordered
stabilization may take approximately two minutes
longer than the standard relay.
Relay A may also adjusted for use in single-acting-
direct applications. Rotate the adjustment disc as
shown in figure 5-5 for single-acting direct operation.
Single-Acting Relays
WARNING
If the unused port is monitoring
pressure, ensure that the pressure
source conforms to ISA Standard
7.0.01 and does not exceed the
pressure supplied to the instrument.
Failure to do so could result in
personal injury or property damage
caused by loss of process control.
December 2009
Calibration
FOR SINGLE-ACTING DIRECT RELAYS:
ROTATE ADJUSTMENT DISC IN THIS
DIRECTION UNTIL IT CONTACTS THE
BEAM
FOR DOUBLE-ACTING RELAYS:
ROTATE ADJUSTMENT DISC IN
THIS DIRECTION TO DECREASE
OUTPUT PRESSURE
FOR DOUBLE-ACTING RELAYS:
ROTATE ADJUSTMENT DISC IN
THIS DIRECTION TO INCREASE
OUTPUT PRESSURE
5
Single-Acting Direct Relay
The single-acting direct relay is designated by “Relay
C” on a label affixed to the relay itself. Relay C
requires no adjustment.
Single-Acting Reverse Relay
The single-acting reverse relay is designated by
“Relay B” on a label affixed to the relay itself. Relay B
is calibrated at the factory and requires no further
adjustment.
Restoring Factory Settings (1-3-4)
From the Online menu, select Configure / Setup, then
select Calibrate, and Restore Factory Settings. Follow
the prompts on the Field Communicator display to
restore calibration to the factory settings. You should
only restore the calibration if it is not possible to
calibrate an individual sensor. Restoring calibration
returns the calibration of all of the sensors and the
tuning set to their factory settings. Following
restoration of the factory calibration, the individual
sensors should be recalibrated.
5-11
 DVC6000 Digital Valve Controllers

5-12 December 2009

 Viewing Device Variables and Diagnostics
6-6

Section 6 Viewing Device Variables and

Diagnostics
Device Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Alert Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Device Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Stroke Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Partial Stroke Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6
Device Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Travel Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Drive Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Number of Power Ups
Device Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
DD Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

December 2009 6-1

 DVC6000 Digital Valve Controllers
Device Diagnostics
Note
Device Diagnostics are not available
for instrument level AC.
Alert Conditions (2-1)
Instrument Alert Conditions, when enabled, detect
6 many operational and performance issues that may be
of interest. To view these alerts, from the Online menu
select Device Diagnostics, and Alert Conditions. The
alert conditions for each group of alerts are listed
below. If there are no alerts active for a particular
group the group will not be displayed on the Field
Communicator. See table 6-1 for alert groups.
 Electronics— If an electronics alert is active it
will appear under ELECT ALERTS.
Drive Current
Drive Current Alert—This alert is indicated when the
drive current does not read as expected. If this alert
occurs, check the connection between the I/P
converter and the printed wiring board assembly. Try
removing the I/P converter and re-installing it. If the
failure does not clear, replace the I/P converter or the
printed wiring board assembly.
Drive Signal
Drive Signal Alert—This alert is indicated when the
Drive Signal is greater or less than the expected
maximum or minimum.
Processor Impaired
Offline/Failed Alert—This alert is indicated if a
failure, enabled from the Self Test Shutdown menu,
caused an instrument shutdown. Press Enter to see
which of the specific failures caused the Offline/Failed
indication.
Power Starvation Alert—This alert is indicated if the
instrument does not have enough power to function
properly Only available in firmware 7.
6-2
Low Power Write Alert— This alert is activated if a
write to the instrument is attempted when the loop
current is less than approximately 3.5 mA. Only
available in firmware 9.
Non-Critical NVM Alert—This alert is indicated if the
checksum for data, which are not critical for instrument
operation, has failed.
Critical NVM Alert—This alert is indicated when the
Non-Volatile Memory integrity test fails. Configuration
data is stored in NVM. If this failure is indicated,
restart the instrument and see if it clears. If it does not
clear, replace the printed wiring board assembly.
Flash ROM Alert—This alert indicates that the Read
Only Memory integrity test failed. If this alert is
indicated, restart the instrument and see if it clears. If
it does not clear, replace the printed wiring board
assembly.
No Free Time Alert—This alert is indicated if the
instrument is unable to complete all of the configured
tasks. This will not occur with a properly functioning
instrument.
Reference Voltage Alert—This failure is indicated
whenever there is a failure associated with the internal
voltage reference. If this alert is indicated replace the
printed wiring board assembly.
Internal Sensor Out of Limits—This alert is indicated
if there is a possible problem with either the pressure
sensor or the printed wiring board assembly
submodule.
Variable Out of Range—This alert is indicated if
there is a possible problem with one or more of the
following: the Analog Input Signal, the I/P converter
submodule, the pneumatic relay submodule, or the
printed wiring board.
Field device malfunction—The alert is indicated if
the pressure, position, or temperature sensors are
providing invalid readings.
 Sensor— If a sensor alert is active it will appear
under SENSOR ALERTS.
Travel Sensor
Travel Sensor Alert—This alert is indicated if the
sensed travel is outside the range of −25.0 to 125.0%
of calibrated travel. If this alert is indicated, check the
instrument mounting and the travel sensor adjustment.
Also, check that the electrical connection from the
travel sensor is properly plugged into the printed wiring
board assembly. After restarting the instrument, if the
alert does not clear, troubleshoot the printed wiring
board assembly or travel sensor.
Pressure Sensors
Pressure Sensor Alert—This alert is indicated if the
actuator pressure is outside the range of −24.0 to
125.0% of the calibrated pressure for more than 60
December 2009
 Viewing Device Variables and Diagnostics
seconds. If this alert is indicated, check the instrument Table 6-1. Alerts Included in Alert Groups for Alert Record
supply pressure. If the failure persists, ensure the Alert Group Alerts Include in Group
printed wiring board assembly is properly mounted Travel Alert Lo
onto the Module Base Assembly, and the pressure Travel Alert Hi
sensor O-rings are properly installed. If the alert does Valve Alerts
Travel Alert Lo Lo
not clear after restarting the instrument, replace the Travel Alert Hi Hi
Travel deviation
printed wiring board assembly. Drive signal
No free time
Flash ROM fail
Drive current fail
Ref Voltage fail
Failure Alerts
NVM fail
Temperature sensor fail
Note Pressure sensor fail
Travel sensor fail
The pressure sensor alert is used for Miscellaneous Alerts Auxiliary input
output A, output B, and the supply
pressure sensor. Check the pressure
values to see which sensor is causing Travel Deviation
the alert. Travel Deviation Alert—The difference between
Setpoint and Travel is greater than the configured
limits.
Travel Limit 6
Temperature Sensor Travel Alert Hi Hi—This alert is indicated if the
Temperature Sensor Alert—This alert is indicated Travel is greater than the configured limit.
when the instrument temperature sensor fails, or the Travel Alert Lo Lo—This alert is indicated if the
sensor reading is outside of the range of −40 to 85C Travel is lower than the configured limit.
(−40 to 185F). The temperature reading is used Travel Limit Hi/Lo
internally for temperature compensation of inputs. If Travel Alert Hi—This alert is indicated if the Travel
this alert is indicated, restart the instrument and see if is greater than the configured limit.
it clears. If it does not clear, replace the printed wiring
Travel Alert Lo—This alert is indicated if the Travel
board assembly.
is lower than the configured limit.

 Environment— If an environment alert is active Travel Limit / Cutoff

it will appear under ENVIRO ALERTS.
Supply Pressure
Supply Pressure Lo Alert—This alert is indicated
when supply pressure is lower than the configured
limit.
Aux Terminal Alert
Aux Terminal Alert—This alert is set when the
auxiliary input terminals are either open or closed,
depending upon the selection for the Aux In Alrt State.
Loop Current Validation Alert— This alert is
activated if the loop current is out of valid range. If the
control system is known to output currents outside of
this range, the loop current shutdown should not be
enabled. If this alert is indicated, clear the alert by
restarting the instrument with the loop current verified
to be in the valid range. If the alert does not clear,
replace the printed wiring board. Only available in
firmware 9.
 Travel— If a travel alert is active it will appear
under TRAVEL ALERTS.
Travel Limit/Cutoff Hi—This alert is indicated if the
Travel is limited high or the high cutoff is in effect.
Travel Limit/Cutoff Lo—This alert is indicated if the
Travel is limited low or the low cutoff is in effect.
 Travel History— If a travel history alert is active
it will appear under TVL HIST ALERTS.
Cycle Count
Cycle Count Alert—This alert is indicated if the
Cycle Counter exceeds the Cycle Count Alert Point.
Travel Accumulator
Travel Accumulator Alert—This alert is indicated if
the Travel Accum exceeds the Travel Accumulator
Alert Point.
 SIS (ODV tier only)— If an SIS alert is active it
will appear under SIS ALERTS.
Partial Stroke Test (PST)
Valve Stuck or Pressure/Travel Path
Obstructed—This alert is indicated if the valve is stuck
or the pressure/travel path is obstructed.
End Point Pressure Deviation
Pressure Deviation Alert—The alert is indicated if

December 2009 6-3

 DVC6000 Digital Valve Controllers
the difference between the target pressure and the Device Record (2-3)
actual pressure exceeds the Pressure Deviation Alert
Point for a period of time greater than the Pressure
Deviation Time.

Locked in Safety Alert—This alert is indicated if the Note

ODV unit is locked in the safety position.
 Alert Record
Alert Record not Empty—This alert indicates that an
alert has been saved to the alert record.
Alrt Record Full—This alert indicates that the alert
record is full.
Viewing Instrument Status (2-2)
6
Note
Status is not available for instrument
level AC.
Device Record is not available for
instrument level AC.
From the Online menu, select Device Diagnostics and
Device Record. Follow the prompts on the Field
Communicator display to view the following Device
Record parameters: Temp Max (Maximum
Temperature), Temp Min (Minimum Temperature),
Run Time, and Num of Power Ups (Number of Power
Ups).
 Temp Max—Maximum Recorded Temperature
shows the maximum temperature the instrument has
experienced since installation.
 Temp Min—Minimum Recorded Temperature
shows the minimum temperature the instrument has
experienced since installation.
 Run Time—Indicates in hours or days the total
elapsed time the instrument has been powered up.

 Num of Power Ups—Number of Power Ups

indicates how many times the instrument has cycled
To view the instrument status, from the Device power.
Diagnostics menu select Status. This menu item
indicates the status of the Operational items listed
below. The status of more than one operational item Stroking the Digital Valve Controller
may be indicated.
Output (2-4)
Instrument Time
Inst Time Invalid
Calibration and Diagnostics Note
Cal in Progress Stroke Valve is not available with
instrument level AC.
Autocal in Progress
Diag in Progress From the Online menu, select Device Diagnostics and
Stroke Valve. Follow the prompts on the Field
Diag Data Avail Communicator display to select from the following:
Operational Done, Ramp Open, Ramp Closed, Ramp to Target,
Step to Target, and Stop.
Press Ctrl Active  Done—Select this if you are done. All ramping is
Multi-Drop stopped when DONE is selected.

Integrator  Ramp Open—ramps the travel toward open at

the rate of 1.0% per second of the ranged travel.
Integrator Sat Hi
 Ramp Closed—ramps the travel toward closed at
Integrator Sat Lo the rate of 1.0% per second of the ranged travel.

6-4 December 2009

 Viewing Device Variables and Diagnostics
 Ramp to Target—ramps the travel to the
specified target at the rate of 1.0% per second of the
ranged travel.
 Step to Target—steps the travel to the specified
target.
Partial Stroke Test (2-5)
Note
Partial Stroke Test is only available for
instrument level ODV.
WARNING
During the partial stroke test the valve
will 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.
The Partial Stroke Test allows the DVC6000 digital
valve controllers with instrument level ODV to perform
a Valve Signature type of test while the instrument is
in service and operational. In some applications, it is
important to be able to exercise and test the valve to
verify that it will operate when commanded. This
feature allows the user to partially stroke the valve
while continually monitoring the input signal. If a
demand arises, the test is aborted and the valve
moves to its commanded position. The partial stroke
valve travel is configurable between 1 and 30%
maximum travel, in 0.1% increments. Data from the
last partial stroke test is stored in the instrument
memory for retrieval by ValveLink software.
The Partial Stroke Test allows you to perform a partial,
10%, stroke test (standard) or a custom stroke test.
With the custom stroke test, the stroke may be
extended up to 30%. Be sure to check plant guidelines
before performing a custom stroke test. The purpose
of this test is to ensure that the valve assembly moves
upon demand.
A partial stroke test can be initiated when the valve is
operating at either 4 or 20 mA (point-to-point mode). In
applications where a spurious trip is to be minimized, 4
mA is the normal operating position.
December 2009
When enabled, a partial stroke test may be initiated by
the device (as a scheduled, auto partial stroke test), a
remote push button located in the field or at the valve,
the 475 Field Communicator, or ValveLink software.
Device (Digital Valve Controller)
The Auto Partial Stroke Test allows the partial stroke
test to be scheduled by the DVC6000. The test is
scheduled in number of hours between tests. Any
power cycle will reset the test clock timer.
Auxiliary Terminal
The auxiliary terminal can be used for different
applications. The default configuration is for a partial
stroke test initiated by shorting the contacts wired to
the auxiliary +/− terminals of the DVC6000. Refer to
Auxiliary Terminal Wiring Length Guidelines below.
 Local Push Button
A partial stroke test command may be sent to the 6
digital valve controller using a set of contacts wired to
the auxiliary +/− terminals. To perform a test, the
contacts must be closed for 3 to 5 seconds and then
opened. To abort the test, close the contacts for 1
second. The last set of diagnostic data is stored in the
instrument memory for later retrieval via ValveLink
software.
 Local DI
When configured by the user interface, the Auxiliary
Terminal can be used as a discrete input from a
pressure switch, temperature switch etc., to provide an
alert.
Auxiliary Terminal Wiring Length Guidelines
The Auxiliary Input Terminals of a DVC6000 with
instrument level ODV can be used with a
locally-mounted switch for initiating a partial stroke
test. Some applications require that the partial stroke
test be initiated from a remote location.
The length for wiring connected to the Auxiliary Input
Terminals is limited by capacitance. For proper
operation of the Auxiliary Input Terminals capacitance
should not exceed 18000 pF. As with all control signal
wiring, good wiring practices should be observed to
minimize adverse effect of electrical noise on the Aux
Switch function.
Example Calculation: Capacitance per foot or per
meter is required to calculate the length of wire that
may be connected to the Aux switch input. The wire
should not exceed the capacitance limit of 18000 pF.
Typically the wire manufacturer supplies a data sheet
which provides all of the electrical properties of the
wire. The pertinent parameter is the highest possible
6-5
 DVC6000 Digital Valve Controllers
capacitance. If shielded wire is used, the appropriate
number is the “Conductor to Other Conductor &
Shield” value.
Example — 18AWG Unshielded Audio, Control
and Instrumentation Cable
Manufacturer’s specifications include:
Nom. Capacitance Conductor to Conductor @ 1 KHz: 26 pF/ft
Nom. Conductor DC Resistance @ 20 Deg. C: 5.96 Ohms/1000 ft
Max. Operating Voltage − UL 200 V RMS (PLTC, CMG),150 V RMS
(ITC)
Allowable Length with this cable = 18000pF /(26pF/ft) = 692 ft
Example — 18AWG Shielded Audio, Control and
Instrumentation Cable
Manufacturer’s specifications include:
Nom. Characteristic Impedance: 29 Ohms
Nom. Inductance: .15 μH/ft
6 Nom. Capacitance Conductor to Conductor @ 1 KHz: 51 pF/ft
Nom. Cap. Cond. to other Cond. & Shield @ 1 KHz 97 pF/ft
Allowable Length with this cable = 18000pF /(97pF/ft) = 185 ft
The AUX switch input passes less than 1 mA through
the switch contacts, and uses less than 5V, therefore,
neither the resistance nor the voltage rating of the
cable are critical. Ensure that switch contact corrosion
6-6
is prevented. It is generally advisable that the switch
have gold-plated or sealed contacts.
Field Communicator
1. Connect the Field Communicator to the LOOP
terminals on the digital valve controller.
2. Turn on the Field Communicator.
3. From the Online menu, select Device Diagnostics
and Partial Stroke Test.
4. Select either Standard (10%) or Custom. With the
Custom Stroke Test, the stroke may be entered up to
30% with configurable stroking speed and pause time.
5. The currently configured Stroke, Stroking Speed,
and Pause Time is displayed. Choose “Yes” to run the
test using these values. Choose “No” to modify the
values. The default value for Stroke Speed is
0.25%/second.
6. The valve begins to move and the actual travel
reported by the digital valve controller is displayed on
the Field Communicator.
7. Once the valve has reached the endpoint, check
that the valve has reached the desired set point. The
valve should return to its original position.
For information on configuring the Partial Stroke Test,
see Partial Stroke Variables in the Detailed Setup
section.
December 2009
 Viewing Device Variables and Diagnostics
Device Variables
The following menus are available to define and/or
view information about the instrument. From the
Online menu select Device Variables.
Note
These variables are not available for
instrument level AC. Supply Pressure
alert is not available for instrument
level HC.
Analog In (3-1)
Analog Input shows the value of the instrument analog
input in mA (milliamperes) or % (percent) of ranged
input.
Travel Set Point (3-2)
Travel Set Point shows the requested valve position in
% of ranged travel.
Travel (3-3)
Travel shows the value of the DVC6000 digital valve
controller travel in % (percent) of ranged travel. Travel
always represents how far the valve is open.
Drive Signal (3-4)
Drive Signal shows the value of the instrument drive
signal in % (percent) of maximum drive.
Pressures (3-5)
Shows the value of the instrument supply and output
pressures in psi, bar, kPa, or kg/cm2. Also shows the
output pressure differential. To display pressures may
require selecting the variable; a detail display of that
variable with its values will appear.
 Pressure A— Pressure A shows the value of
Output Pressure A in psi, bar, kPa, or kg/cm2.
 Pressure B— Pressure B shows the value of
Output Pressure A in psi, bar, kPa, or kg/cm2.
December 2009
 Pressure Diff—Pressure Differential shows the
value of the output pressure differential in psi, bar,
kPa, or kg/cm2.
 Supply Pressure—Supply Pressure displays the
instrument supply pressure in psi ,bar, kPa, or kg/cm2.
Not available in instrument level HC.
Variables (3-6)
Note
These variables are not available for
instrument level AC.
The Variables menu is available to view additional
variables, including; Aux Input (Auxiliary Input),
Temperature, Temp Max (Maximum Temperature),
Temp Min (Minimum Temperature), Cycle Count, Tvl 6
Accum (Travel Accumulator), Raw Tvl Input (Raw
Travel Input), Run Time, and Num of Power Ups
(Number of Power Ups).
To view one of these variables, from the Online menu
select Device Variables and Variables. If a value for a
variable does not appear on the display, select the
variable and a detailed display of that variable with its
value will appear. A variable’s value does not appear
on the menu if the value becomes too large to fit in the
allocated space on the display, or if the variable
requires special processing, such as Aux Input.
 Aux Input—The Auxiliary Input is a discrete input
that can be used with an independent limit or pressure
switch. Its value is either open or closed.
 Temperature—The internal temperature of the
instrument is displayed in either degrees Fahrenheit or
Celsius.
 Temp Max—Maximum Recorded Temperature
shows the maximum temperature the instrument has
experienced since installation.
 Temp Min—Minimum Recorded Temperature
shows the minimum temperature the instrument has
experienced since installation.
 Cycle Count—Cycle Counter displays the
number of times the valve travel has cycled. Only
changes in direction of the travel after the travel has
exceeded the deadband are counted as a cycle. Once
a new cycle has occurred, a new deadband around
the last travel is set. The value of the Cycle Counter
can be reset from the Cycle Count Alert menu. See
page 4-17 of the Detailed Setup section for additional
information.
6-7
 DVC6000 Digital Valve Controllers
 Tvl Accum—Travel Accumulator contains the
total change in travel, in percent of ranged travel. The
accumulator only increments when travel exceeds the
deadband. Then the greatest amount of change in one
direction from the original reference point (after the
deadband has been exceeded) will be added to the
Travel Accumulator. The value of the Travel
Accumulator can be reset from the Travel Accum
menu. See page 4-17 of the Detailed Setup section for
additional information.
Note
Do not use the following raw travel
input indication for calibrating the
travel sensor. The following should
6 only be used for a relative indication to
be sure the travel sensor is working
and that it is moving in the correct
direction. Perform the Travel Sensor
Adjust procedure in the Calibration
section to calibrate the travel sensor.
 Raw Tvl Input—Raw travel input indicates the
travel sensor position in analog-to-digital converter
counts. When the travel sensor is operating correctly,
this number changes as the valve strokes.
 Run Time—Indicates in hours or days the total
elapsed time the instrument has been powered up.
 Num of Power Ups—Number of Power Ups
Indicates how many times the instrument has cycled
power.
6-8
Device Information (3-7)
The Device Information menu is available to view
information about the instrument. From the Online
menu, select Device Variables and Device
Information. Follow the prompts on the Field
Communicator display to view information in the
following fields: HART Tag, Device ID, Manufacturer,
Model, Device Rev (Device Revision), Firmware Rev
(Firmware Revision), Hardware Rev (Hardware
Revision), Inst Level (Instrument Level), and HART
Univ Rev (HART Universal Revision).
 Hart Tag—A HART tag is a unique name (up to
eight characters) that identifies the physical
instrument.
 Device ID—Each instrument has a unique Device
Identifier. The device ID provides additional security to
prevent this instrument from accepting commands
meant for other instruments.
 Manufacturer—Identifies the manufacturer of the
instrument.
 Model—Identifies the instrument model.
 Device Rev—Device Revision is the revision
number of the software for communication between
the Field Communicator and the instrument.
 Firmware Rev—Firmware Revision is the revision
number of the firmware in the instrument.
 Hardware Rev—Hardware Revision is the
revision number of the electrical circuitry within the
instrument printed wiring board.
 Inst Level—Indicates the instrument level
AC—Auto Calibrate
HC—HART Communicating
AD—Advanced Diagnostics
PD—Performance Diagnostics
ODV—Optimized Digital Valve
December 2009
 Viewing Device Variables and Diagnostics
Table 6-2. Functions Available for Instrument Level Table 6-2 lists the functions available for each
Instrument instrument level.
Functions Available
Level
Communicates with the Field Communicator.  HART Univ Rev—HART Universal Revision is
AC the revision number of the HART Universal
Provides basic setup and calibration.
Communicates with the Field Communicator and Commands which are used as the communications
ValveLink software. protocol for the instrument.
In addition to above, provides: travel cutoffs and limits,
minimum opening and closing times, input
 DD Information (3-8)
HC characterization (linear, equal percentage, quick
opening, and custom), trending with ValveLink Solo,
and the following alerts: travel deviation; travel alert
DD Information contains the device description in the
high, low, high high, and low low; drive signal; auxiliary Field Communicator. To access DD Information from
terminal; cycle counter; and travel accumulation. the Online menu, select Device Variables and DD
Includes all functions listed above plus (with ValveLink Information.
software) all offline diagnostic tests (dynamic error
AD
band, drive signal, step response, and valve signature)
plus online trending
Includes all functions listed above plus all Performance
PD Diagnostics online/in-service valve testing (valve
friction, electronics, and mechanical condition)
Includes all functions listed above plus partial stroke
ODV
test and lead/lag input filter.

December 2009 6-9

 DVC6000 Digital Valve Controllers

6-10 December 2009

 Maintenance and Troubleshooting
7-7

Section 7 Maintenance and Troubleshooting

Module Base Maintenance
Removing the Module Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Replacing the Module Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Submodule Maintenance
I/P Converter
Removing the I/P Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Replacing the I/P Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Printed Wiring Board (PWB) Assembly
Removing the Printed Wiring Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Replacing the Printed Wiring Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Setting the Printed Wiring Board Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Pneumatic Relay 7
Removing the Pneumatic Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Replacing the Pneumatic Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Gauges, Pipe Plugs or Tire Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Terminal Box
Removing the Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Replacing the Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Travel Sensor
Disassembly
DVC6010 Digital Valve Controller and DVC6015 Remote
Feedback Unit (Sliding-Stem) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
DVC6020 Digital Valve Controller and DVC6025 Remote
Feedback Unit (Rotary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
DVC6030 Digital Valve Controller and DVC6035 Remote
Feedback Unit (Rotary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Assembly
DVC6010 Digital Valve Controller and DVC6015 Remote
Feedback Unit (Sliding-Stem) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
DVC6020 Digital Valve Controller and DVC6025 Remote
Feedback Unit (Rotary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
DVC6030 Digital Valve Controller and DVC6035 Remote
Feedback Unit (Rotary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Checking Voltage Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Checking Loop Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

December 2009 7-1

 DVC6000 Digital Valve Controllers
The DVC6000 digital valve controller enclosure is
rated NEMA 4X and IP66, therefore periodic cleaning
of internal components is not required. If the DVC6000
is installed in an area where the exterior surfaces tend
to get heavily coated or layered with industrial or
atmospheric contaminants, however, it is
recommended that the vent (key 52) be periodically
inspected to ensure it is fully open. If the vent appears
to be clogged, the vent can be removed, cleaned and
replaced. Lightly brush the exterior of the vent to
remove contaminant and run a mild water/detergent
solution through the vent to ensure it is fully open.
WARNING
Personal injury or property damage
can occur from cover failure due to
overpressure. Ensure that the
housing vent opening is open and
free of debris to prevent pressure
buildup under the cover.
7 medium, or for explosion proof
WARNING
To avoid static discharge from the
plastic cover, do not rub or clean the
cover with solvents. To do so could
result in an explosion. Clean with a
mild detergent and water only.
WARNING
Avoid personal injury or property
damage from sudden release of
process pressure or bursting of parts.
Before performing any maintenance
procedures on the DVC6000 digital
valve controller:
 Always wear protective clothing,
gloves, and eyewear.
 Do not remove the actuator from
the valve while the valve is still
pressurized.
 Disconnect any operating lines
providing air pressure, electric power,
or a control signal to the actuator. Be
sure the actuator cannot suddenly
open or close the valve.
7-2
 Use bypass valves or completely
shut off the process to isolate the valve
from process pressure. Relieve process
pressure from both sides of the valve.
 Vent the pneumatic actuator
loading pressure and relieve any
actuator spring precompression.
 Use lock-out procedures to be
sure that the above measures stay in
effect while you work on the
equipment.
 Check with your process or safety
engineer for any additional measures
that must be taken to protect against
process media.
WARNING
When using natural gas as the supply
applications, the following warnings
also apply:
 Remove electrical power before
removing the housing cap. Personal
injury or property damage from fire or
explosion may result if power is not
disconnected before removing the
cap.
 Remove electrical power before
disconnecting any of the pneumatic
connections.
 When disconnecting any of the
pneumatic connections or any
pressure retaining part, natural gas
will seep from the unit and any
connected equipment into the
surrounding atmosphere. Personal
injury or property damage may result
from fire or explosion if natural gas is
used as the supply medium and
appropriate preventive measures are
not taken. Preventive measures may
include, but are not limited to, one or
more of the following: Remote
venting of the unit, re-evaluating the
hazardous area classification,
ensuring adequate ventilation, and
the removal of any ignition sources.
For information on remote venting of
this controller, refer to page 2-19.
 Ensure that all caps and covers
are correctly installed before putting
December 2009
 Maintenance and Troubleshooting
this unit back into service. Failure to Table 7-1. Tools Required
do so could result in personal injury or Tool Size Component
property damage from fire or Phillips Screwdriver Relay, printed wiring board
explosion. assembly, and cover screws
Hex key 5 mm Terminal box screw
Hex key 1.5 mm Terminal box cover screw
Hex key 2.5 mm I/P converter screws
Hex key 5 mm Travel sensor screws
Hex key 6 mm Module base screws
Open-end wrench 1/2-inch Connector Arm screw (DVC6010)
Hex key 9/64-inch Feedback arm screw
Open-end wrench 7/16-inch DVC6010 mounting bolts
Hex key 3/16-inch DVC6020 mounting bolts
CAUTION
assembly, and pneumatic relay. The module base may
When replacing components, use only be easily replaced in the field without disconnecting
components specified by the factory. field wiring or tubing.
Always use proper component
replacement techniques, as presented
in this manual. Improper techniques or
component selection may invalidate Tools Required
the approvals and the product
Table 7-1 lists the tools required for maintaining the
specifications, as indicated in table
DVC6000 digital valve controller.
1-2. It may also impair operations and
the intended function of the device.
7
Removing the Module Base
To remove the module base for DVC6010, DVC6020
and DVC6030 digital valve controllers, perform the
following steps. Refer to figures 8-2, 8-3 and 8-4,
respectively, for key number locations.

Note
If the feedback arm (key 79) or
feedback arm assembly (key 84) is
removed from the digital valve
controller, the travel sensor (key 77)
must be recalibrated.
Because of the diagnostic capability of the DVC6000,
predictive maintenance is available through the use of
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, refer to
the ValveLink software online help.
Module Base Maintenance
The digital valve controller contains a module base
consisting of the I/P converter, printed wiring board
WARNING
To avoid personal injury or equipment
damage from bursting of parts, turn
off the supply pressure to the digital
valve controller and bleed off any
excess supply pressure before
attempting to remove the module
base assembly from the housing.
1. For sliding-stem applications only, a protective
shield for the feedback linkage is attached to the side
of the module base assembly (see figures 2-1
and 2-2). Remove this shield and keep for reuse on
the replacement module. The replacement module will
not have this protective shield.
2. Unscrew the four captive screws in the cover
(key 43) and remove the cover from the module
base (key 2).
3. Using a 6 mm hex socket wrench, loosen the
three-socket head screws (key 38). These screws
are captive in the module base by retaining rings
(key 154).

December 2009 7-3

 DVC6000 Digital Valve Controllers
Note
The module base is linked to the
housing by two cable assemblies.
Disconnect these cable
assemblies after you pull the
module base out of the housing.
4. Pull the module base straight out of the housing
(key 1). Once clear of the housing, swing the module
base to the side of the housing to gain access to the
cable assemblies.
5. The digital valve controller has two cable
assemblies, shown in figure 7-1, which connect the
module base, via the printed wiring board assembly, to
7 the travel sensor and the terminal box. Disconnect
these cable assemblies from the printed wiring board
assembly on the back of the module base.
CAUTION
To avoid affecting performance of the
instrument, take care not to damage
the module base seal or guide surface.
Do not bump or damage the bare
connector pins on the PWB assembly.
Damaging either the module base or
guide surface may result in material
damage, which could compromise the
instruments ability to maintain a
pressure seal.
Replacing the Module Base
To replace the module base, for DVC6010, DVC6020
and DVC6030 digital valve controllers, perform the
following steps. Refer to figures 8-2, 8-3 and 8-4,
respectively, for key number locations.
7-4
TERMINAL BOX
MODULE BASE
ASSEMBLY
HOUSING CABLE TO
TRAVEL SENSOR PRINTED WIRING
CABLE TO BOARD ASSEMBLY
TERMINAL BOX
W8073
Figure 7-1. Printed Wiring Board Cable Connections
Note
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 module base seal is in
good condition. Do not reuse a
damaged or worn seal.
1. Ensure the module base seal (key 237) is properly
installed in the housing (key 1). Ensure the O-ring
(key 12) is in place on the module base assembly.
2. Connect the terminal box connector to the PWB
assembly (key 50). Orientation of the connector is
required.
3. Connect the travel sensor connector to the PWB
assembly (key 50). Orientation of the connector is
required.
4. Insert the module base (key 2) into the housing
(key 1).
5. Install three socket head screws (key 38) in the
module base into the housing. If not already installed,
press three retaining rings (key 154) into the module
base. Evenly tighten the screws in a crisscross pattern
to a final torque of 16 Nm (138 lbfin).
December 2009
 Maintenance and Troubleshooting
6. Attach the cover (key 43) to the module base
assembly.
7. For sliding-stem applications only, install the
protective shield onto the side of the replacement
module base assembly (see figures 2-1 and 2-2).
Submodule Maintenance
The digital valve controller’s module base contains the
following submodules: I/P converter, PWB assembly,
and pneumatic relay. If problems occur, these
submodules may be removed from the module base
and replaced with new submodules. After replacing a
submodule, the module base may be put back into
service.
CAUTION
Exercise care when performing
maintenance on the module base.
Reinstall the cover to protect the I/P
converter and gauges when servicing
other submodules.
In order to maintain accuracy
specifications, do not strike or drop
the I/P converter during submodule
maintenance.
I/P Converter
Refer to figures 8-2 through 8-9 for key number
locations. The I/P converter (key 41) is located on the
front of the module base.
Note
After I/P converter submodule
replacement, calibrate the digital valve
controller to maintain accuracy
specifications.
December 2009
O-RING LOCATED SCREEN (FILTER)
IN I/P CONVERTER
OUTPUT PORT
LOCATED IN I/P
CONVERTER
W8072 SUPPLY PORT
Figure 7-2. I/P Filter Location
Replacing the I/P Filter
A screen in the supply port beneath the I/P converter 7
serves as a secondary filter for the supply medium. To
replace this filter, perform the following procedure:
1. Remove the I/P converter (key 41) and shroud
(key 169) as described in the Removing the I/P
Converter procedure.
2. Remove the screen (key 231) from the supply port.
3. Install a new screen in the supply port as shown in
figure 7-2.
4. Inspect the O-ring (key 39) in the I/P output port. if
necessary, replace it.
5. Reinstall the I/P converter (key 41) and shroud
(key 169) as described in the Replacing the I/P
Converter procedure.
Removing the I/P Converter
1. Remove the front cover (key 43), if not already
removed.
2. Refer to figure 7-3. Using a 2.5 mm hex socket
wrench, remove the four socket-head screws (key 23)
that attach the shroud (key 169) and I/P converter
(key 41) to the module base (key 2).
3. Remove the shroud (key 169); then pull the I/P
converter (key 41) straight out of the module base
(key 2). 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 (key 39) and screen
(key 231) stay in the module base and do not come
out with the I/P converter (key 41).
7-5
 DVC6000 Digital Valve Controllers
SHROUD BACK OF PWB ASSEMBLY
(KEY 169) SUB-MODULE

DIP SWITCH

I/P CONVERTER SOCKET-HEAD

(KEY 41) SCREWS (4)
(KEY 23) UP

DOWN

BOOTS
(KEY 210)

Figure 7-3. I/P Converter TERMINAL BOX TRAVEL SENSOR

W9328
CONNECTOR CONNECTOR
PINS REMOVED FOR CONNECTOR KEYING.

Replacing the I/P Converter Figure 7-4. DIP Switch Location

1. Refer to figure 7-2. Inspect the condition of the
O-ring (key 39) and screen (key 231) in the module
base (key 2). Replace them, if necessary. Apply
7 silicone lubricant to the O-rings.
2. Ensure the two boots (key 210) shown in figure 7-3 Note
are properly installed on the electrical leads.
If the PWB assembly submodule is
3. Install the I/P converter (key 41) straight into the replaced, calibrate and configure
module base (key 2), taking care that the two electrical the digital valve controller to
leads feed into the guides in the module base. These maintain accuracy specifications.
guides route the leads to the printed wiring board
assembly submodule.
4. Install the shroud (key 169) over the I/P converter
(key 41).
5. Install the four socket-head screws (key 23) and
evenly tighten them in a crisscross pattern to a final Removing the Printed Wiring Board
torque of 1.6 Nm (14 lbfin). Assembly
1. Separate the module base from the housing by
6. After replacing the I/P converter, calibrate travel or
performing the Removing the Module Base procedure.
perform touch-up calibration to maintain accuracy
specifications. 2. Remove three screws (key 33).
3. Lift the PWB assembly (key 50) straight out of the
module base (key 2).
PWB (Printed Wiring Board) Assembly 4. Ensure that the O-rings (key 40) remain in the
Refer to figures 8-2 through 8-9 for key number pressure sensor bosses on the module base assembly
locations. The PWB assembly (key 50) is located on (key 2) after the PWB assembly (key 50) has been
the back of the module base assembly (key 2). removed.

7-6 December 2009


Table 7-2. DIP Switch Configuration(1)
Operational Mode
Multidrop Loop
UP
Point-to-Point Loop
DOWN
1. Refer to figure 7-4 for switch location.
Replacing the PWB Assembly and Setting
the DIP Switch
1. Apply silicone lubricant to the pressure sensor
O-rings (key 40) and install them on the pressure
sensor bosses in the module base assembly.
2. Properly orient the PWB assembly (key 50) as you
install it into the module base. The two electrical leads
from the I/P converter (key 41) must guide into their
receptacles in the PWB assembly and the pressure
sensor bosses on the module base must fit into their
receptacles in the PWB assembly.
3. Push the PWB assembly (key 50) into its cavity in
the module base.
4. Install and tighten three screws (key 33) to a torque
of 1 Nm (10.1 lbfin).
5. Set the DIP switch on the PWB assembly
according to table 7-2.
Note
For the digital valve controller to
operate with a 4 to 20 mA control
signal, be sure the DIP switch is in the
point-to-point loop position, i.e.,
switch in down position.
6. Reassemble the module base to the housing by
performing the Replacing the Module Base procedure.
7. Setup and calibrate the digital valve controller.
Pneumatic Relay
Refer to figures 8-2 through 8-9 for key number
locations. The pneumatic relay (key 24) is located on
the front of the module base.
December 2009
Maintenance and Troubleshooting
Switch Position
RELAY SEAL
W8074
Figure 7-5. Pneumatic Relay Assembly
Note
After relay submodule replacement,
calibrate the digital valve controller
to maintain accuracy specifications.
Removing the Pneumatic Relay
7
1. Loosen the four screws that attach the relay
(key 24) to the module base. These screws are
captive in the relay.
2. Remove the relay.
Replacing the Pneumatic Relay
1. Visually inspect the holes in the module base to
ensure they are clean and free of obstructions. If
cleaning is necessary, do not enlarge the holes.
2. Apply silicone lubricant to the relay seal and
position it in the grooves on the bottom of the relay as
shown in figure 7-5. Press small seal retaining tabs
into retaining slots to hold relay seal in place.
3. Position the relay (with shroud) on the module
base. Tighten the four screws, in a crisscross pattern,
to a final torque of 2 Nm (20.7 lbfin).
4. Using the Field Communicator, verify that the value
for Relay Type parameter matches the relay type
installed.
5. After replacing the relay and verifying the relay
type, calibrate travel or perform touch-up calibration to
maintain accuracy specifications
Gauges, Pipe Plugs, or Tire Valves
Depending on the options ordered, the DVC6000 will
be equipped with either gauges (key 47), pipe plugs
(key 66), or tire valves (key 67). Single-acting direct
instruments will also have a screen (key 236, figure
8-6). These are located on the top of the module base
next to the relay.
7-7
 DVC6000 Digital Valve Controllers
Perform the following procedure to replace the
gauges, tire valves, or pipe plugs. Refer to figures 8-5
through 8-6 for key number locations.
1. Remove the front cover (key 43).
2. Remove the gauge, pipe plug, or tire valve as
follows:
For gauges (key 47), the flats are on the gauge case.
Use a wrench on the flats of the gauge to remove the
gauge from the module base. For double-acting
instruments, to remove the supply gauge remove one
of the output gauges.
For pipe plugs (key 66) and tire valves (key 67),
use a wrench to remove these from the module base.
3. Apply sealant (key 64) to the threads of the
replacement gauges, pipe plugs, or tire valves.
4. Using a wrench, screw the gauges, pipe plugs, or
tire valves into the module base.
7 5. Remove two wire retainers (key 44), internal and
Terminal Box
WARNING
Refer to the Maintenance WARNING at
the beginning of this section.
Refer to figures 8-2 through 8-9 for key number
locations.
The terminal box is located on the housing and
contains the terminal strip assembly for field wiring
connections.
Note
This procedure also applies to the
DVC6005 remote terminal box.
7-8
Removing the Terminal Box
WARNING
To avoid personal injury or property
damage caused by fire or explosion,
remove power to the instrument
before removing the terminal box
cover in an area which contains a
potentially explosive atmosphere or
has been classified as hazardous.
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. Separate the module base from the housing by
performing the Removing the Module Base procedure.
4. Remove the screw (key 72). Pull the terminal box
assembly straight out of the housing.
external to the terminal box.
Replacing the Terminal Box
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.
2. Apply silicone lubricant to the O-ring (key 35) and
install the O-ring over the stem of the terminal box.
3. Insert the terminal box assembly stem into the
housing until it bottoms out. Position the terminal box
assembly so that the hole for the screw (key 72) in the
terminal box aligns with the threaded hole in the
housing. Install the screw (key 72).
4. Connect the terminal box connector to the PWB
assembly (key 50). Orientation of the connector is
required.
5. Reassemble the module base to the housing by
performing the Replacing the Module Base procedure.
6. Reconnect the field wiring as noted in step 2 in the
Removing the Terminal Box procedure.
7. Apply silicone lubricant to the O-ring (key 36) and
install the O-ring over the 2-5/8 inch threads of the
December 2009
 Maintenance and Troubleshooting
terminal box. Use of a tool is recommended to prevent
cutting the O-ring while installing it over the threads.
8. Apply lubricant (key 63) to the 2-5/8 inch threads
on the terminal box to prevent seizing or galling when
the cap is installed.
9. Screw the cap (key 4) onto the terminal box.
10. 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 one of the recesses in the terminal box.
Tighten the set screw (key 58).
11. Apply sealant (key 64) to the conduit entrance
plug (key 62) and install it into the unused conduit
entry of the terminal box.
Travel Sensor
WARNING
Refer to the Maintenance WARNING at
the beginning of this section.
Replacing the travel sensor requires removing the
digital valve controller from the actuator.
WARNING
To avoid personal injury or property
damage caused by fire or explosion,
remove power to the instrument
before removing the potentiometer in
an area which contains a potentially
explosive atmosphere or has been
classified as hazardous.
Disassembly
Note
If the feedback arm (key 79) or
feedback arm assembly (key 84) is
removed from the digital valve
controller, the travel sensor (key 77)
must be recalibrated.
December 2009
DVC6010 Digital Valve Controller and
DVC6015 Remote Feedback Unit
Refer to figure 8-2 for DVC6010 and 8-7 for DVC6015
key number locations.
1. Remove piping and fittings from the instrument.
2. Disconnect the adjustment arm from the connector
arm and the feedback arm (see figures 2-1 and 2-2).
3. Remove the instrument 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.
If disassembling a DVC6010 digital valve controller,
use step 6a. If disassembling a DVC6015 remote
feedback unit, use step 6b.
6. a. Separate the module base from the housing by
performing the Removing the Module Base procedure.
b. Disconnect the three potentiometer assembly
wires from the terminals.
7. Remove the screw (key 72) that fastens the travel
sensor assembly to the housing.
7
8. Pull the travel sensor assembly (key 223) straight
out of the housing.
DVC6020 Digital Valve Controller and
DVC6025 Remote Feedback Unit
Refer to figure 8-3 for DVC6020 and 8-8 for DVC6025
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. If the torsion
spring (key 93) needs to be replaced, ensure that the
shaft on which it is installed is smooth and free of
rough spots. Replace the entire feedback arm
assembly if necessary.
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.
If disassembling a DVC6020 digital valve controller,
use step 6a. If disassembling a DVC6025 remote
feedback unit use step 6b.
6. a. Separate the module base from the housing by
performing the Removing the Module Base procedure.
b. Disconnect the three potentiometer assembly
wires from the terminals.
7-9
 DVC6000 Digital Valve Controllers
7. Remove the screw (key 72) that fastens the travel
sensor assembly to the housing.
8. Pull the travel sensor assembly (key 223) straight
out of the housing.
DVC6030 Digital Valve Controller and
DVC6035 Remote Feedback Unit
Refer to figure 8-4 for DVC6030 and 8-9 for DVC6035
key number locations.
1. Remove piping and fittings from the instrument.
2. 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.
If disassembling a DVC6030 digital valve controller
use step 3a. If disassembling a DVC6035 remote
feedback unit use step 3b.
3. a. Separate the module base from the housing by
performing the Removing the Module Base procedure.
7 4. Attach the feedback arm (key 79) to the travel
b. Disconnect the three potentiometer assembly
wires from the terminals.
4. From within the housing, unscrew the travel sensor
assembly (key 223) from the housing.
Assembly
Note
If the feedback arm (key 79) or
feedback arm assembly (key 84) is
removed from the digital valve
controller, the travel sensor (key 77)
must be recalibrated.
DVC6010 Digital Valve Controller and
DVC6015 Remote Feedback Unit
Refer to figure 8-2 for DVC6010 and 8-7 for DVC6015
key number locations.
1. Insert the travel sensor assembly (key 223) into the
housing (key 1). Secure the travel sensor assembly
with screw (key 72).
If assembling a DVC6010 digital valve controller, use
step 2a. If assembling a DVC6015 remote feedback
unit, use step 2b.
7-10
2. a. Connect the travel sensor connector to the PWB
as described in the Replacing the Module Base
procedure.
b. Connect the three travel sensor wires to the
terminals.
Note
For the DVC6015 feedback unit,
connect the potentiometer assembly
(key 223) wires to the terminals as
follows:
red  terminal 1
white  terminal 2
black  terminal 3
3. Loosely assemble the bias spring (key 78), screw
(key 80), plain washer (key 163), and nut (key 81) to
the feedback arm (key 79), if not already installed.
sensor shaft.
Two methods are available for adjusting the travel
sensor. You can use a multimeter to measure the
potentiometer resistance, or if you have a Field
Communicator, you can use the procedure in the
Calibration section. To use the multimeter, perform
steps 5 through 13. To use the Field Communicator,
skip to step 14.
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. Position the feedback arm so that
the surface is flush with the end of the travel sensor
shaft.
6. Connect a multimeter set to a resistance range of
50,000 ohms. Measure the resistance between pins 1
and 3 of the travel sensor connector. Refer to figure
7-6 for pin location. The resistance should be between
40,000 and 50,000 ohms.
7. Multiply the result in step 6 by 0.046 to get a
calculated resistance. The calculated resistance
should be in the range of 1840 to 2300 ohms.
8. Re-range the multimeter to a resistance of 3000
ohms between pins 2 and 3 of the travel sensor
connector. Refer to figure 7-6 for pin location.
9. Adjust the travel sensor shaft to obtain the
calculated resistance determined in step 7, $100
ohms.
December 2009
 Maintenance and Troubleshooting

PIN 2

PIN 3

KEYED

TRAVEL SENSOR WIRES,

REMOTE MOUNT FEEDBACK UNITS
(DVC6015, DVC6025 AND DVC6035)

19B6835-B

7
TRAVEL SENSOR CONNECTOR 3
1
(DVC6010, DVC6020 AND DVC6030) CW

A6481/IL

NOTE:
1 THE POTENTIOMETER RESISTANCE BETWEEN PINS 2 AND 3 CAN BE
MEASURED AT THE CONNECTOR. INSERT TWO SHORT LENGTHS OF
22 AWG WIRE INTO THE PIN 2 AND 3 RECEPTACLES IN THE CONNECTOR.
CLIP ON LEADS FROM A DVM (DIGITAL VOLTMETER) TO MEASURE THE
RESISTANCE.

Figure 7-6. Potentiometer Resistance Measurement

12. For the DVC6010, connect the travel sensor

Note
In the next step, be sure the feedback
arm surface remains flush with the end
of the travel sensor shaft.
10. While observing the resistance, tighten the screw
(key 80) to secure the feedback arm to the travel
sensor shaft. Be sure the resistance reading remains
at the calculated resistance determined in step 7,
$100 ohms. Paint the screw to discourage tampering
with the connection.
11. Disconnect the multimeter from the travel sensor
connector.
connector to the PWB as described in Replacing the
Module Base.
13. Travel sensor replacement is complete. Install the
digital valve controller on the actuator.
Travel Sensor Adjustment with the Field
Communicator
The next two steps do not apply if you used a
multimeter to adjust the travel sensor. Perform these
steps only if you elected to adjust the travel sensor
using the Field Communicator.
14. For the DVC6010, connect the travel sensor
connector to the PWB as described in Replacing the
Module Base.

December 2009 7-11

 DVC6000 Digital Valve Controllers
15. For both the DVC6010 and the DVC6015, perform
the appropriate Travel Sensor Adjust procedure in the
Calibration section.
DVC6020 Digital Valve Controller and
DVC6025 Remote Feedback Unit
Refer to figure 8-3 for DVC6020 and 8-8 for DVC6025
key number locations.
1. Insert the travel sensor assembly (key 223) into the
housing. Secure the travel sensor assembly with
screw (key 72).
If assembling a DVC6020 digital valve controller, use
step 2a. If assembling a DVC6025 remote feedback
unit, use step 2b.
2. a. Connect the travel sensor connector to the PWB
as described in Replacing the Module Base.
b. Connect the three travel sensor wires to the
7 terminals.
Note
For the DVC6025 feedback unit,
connect the potentiometer assembly
(key 223) wires to the terminals as
follows:
red  terminal 1
white  terminal 2
black  terminal 3
3. Loosely assemble the screw (key 80), plain washer
(key 163), and nut (key 81) to the arm assembly
(key 91), if not already installed.
4. Attach the arm assembly (key 91) to the travel
sensor assembly (key 223) shaft.
Two methods are available for adjusting the travel
sensor. You can use a multimeter to measure the
potentiometer resistance, or if you have a Field
Communicator, you can use the procedure in the
Calibration section. To use the multimeter, perform
steps 5 through 17. To use the Field Communicator,
skip to step 18.
7-12
BIAS SPRING
(KEY 82)
FEEDBACK
ARM
ASSEMBLY
(KEY 84)
ARM ASSEMBLY
(KEY 91)
NOTE:
INSTALL BIAS SPRING WITH SMALLER DIAMETER HOOK
CONNECTED TO ARM ASSEMBLY (KEY 91) AND WITH BOTH HOOK
OPENINGS TOWARD CENTER OF BRACKET.
Figure 7-7. FIELDVUE DVC6020 digital Valve Controller,
Bias Spring (key 82) Installation
Travel Sensor Adjustment with a Multimeter
5. Connect a multimeter set to a resistance range of
50,000 ohms. Measure the resistance between pins 1
and 3 of the travel sensor connector. Refer to figure
7-6 for pin location. The resistance should be between
40,000 and 50,000 ohms.
6. Multiply the result in step 5 by 0.142 to get a
calculated resistance. The calculated resistance
should be in the range of 5680 to 7100 ohms.
7. Re-range the multimeter to a resistance of 7000
ohms between pins 2 and 3 of the travel sensor
connector. Refer to figure 7-6 for pin location.
8. Hold the arm assembly (key 91) in a fixed position
so that the arm is parallel to the housing back plane
and pointing toward the terminal box. Position the arm
assembly so that the outer surface is flush with the
end of the travel sensor shaft.
9. Adjust the travel sensor shaft to obtain the
calculated resistance determined in step 6, $100
ohms.
Note
In the next step, be sure the arm
assembly outer surface remains flush
with the end of the travel sensor shaft.
December 2009
 Maintenance and Troubleshooting
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
at the calculated resistance determined in step 6,
$100 ohms. Paint the screw to discourage tampering
with the connection.
11. Disconnect the multimeter from the travel sensor
connector.
12. Apply anti-seize (key 64) to the pin portion of the
arm assembly (key 91).
13. Position the mounting bracket over the back of the
digital valve controller. Push the feedback arm
assembly (key 84) toward the housing and engage
the pin of the arm assembly into the slot in the
feedback arm.
14. Install the mounting bracket (key 74).
15. Install the bias spring (key 82) as shown in
figure 7-7.
16. For the DVC6020 only, connect the travel sensor
connector to the PWB as described in Replacing the
Module Base.
17. Travel sensor replacement is complete. Install the
digital valve controller on the actuator.
Travel Sensor Adjustment with the Field
Communicator
The next two steps do not apply if you used a
multimeter to adjust the travel sensor. Perform these
steps only if you elected to adjust the travel sensor
using the Field Communicator.
18. For the DVC6020 only, connect the travel sensor
connector to the PWB as described in Replacing the
Module Base.
19. For both the DVC6020 and the DVC6025, perform
the appropriate Travel Sensor Adjust procedure in the
Calibration section.
DVC6030 Digital Valve Controller and
DVC6035 Remote Feedback Unit
Refer to figure 8-4 for DVC6030 and 8-9 for DVC6035
key number locations.
1. Apply lubricant (key 63) to the travel sensor
assembly threads.
2. Screw the travel sensor assembly (key 223) into
the housing until it is tight.
If assembling a DVC6030 digital valve controller, use
step 3a. If assembling a DVC6035 remote feedback
unit, use step 3b.
December 2009
3. a. Connect the travel sensor connector to the PWB
as described in the Replacing the Module Base
procedure.
b. Connect the three travel sensor wires to the
terminals.
Note
For the DVC6035 feedback unit,
connect the potentiometer assembly
(key 223) wires to the terminals as
follows:
red  terminal 1
white  terminal 2
black  terminal 3
4. Loosely assemble the bias spring (key 78), screw
(key 80), plain washer (key 163), and nut (key 81) to
the feedback arm (key 79), if not already installed.
5. Attach the feedback arm (key 79) to the travel
7
sensor shaft.
Two methods are available for adjusting the travel
sensor. You can use a multimeter to measure the
potentiometer resistance, or if you have a Field
Communicator, you can use the procedure in the
Calibration section. To use the multimeter, perform
steps 6 through 14. To use the Field Communicator,
skip to step 15.
Travel Sensor Adjustment with a Multimeter
6. 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
housing. Position the feedback arm so that the outer
surface is flush with the end of the travel sensor shaft.
7. Connect a multimeter set to a resistance range of
50,000 ohms. Measure the resistance between pins 1
and 3 of the travel sensor connector. Refer to figure
7-6 for pin location. The resistance should be between
40,000 and 50,000 ohms.
8. Multiply the result in step 7 by 0.042 to get a
calculated resistance. The calculated resistance
should be in the range of 1680 to 2100 ohms.
9. Re-range the multimeter to a resistance of 3000
ohms between pins 2 and 3 of the travel sensor
connector. Refer to figure 7-6 for pin location.
10. Adjust the travel sensor shaft to obtain the
calculated resistance determined in step 8, $100
ohms.
7-13
 DVC6000 Digital Valve Controllers
Note
In the next step, be sure the feedback
arm outer surface remains flush with
the end of the travel sensor shaft.
11. 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
at the calculated resistance determined in step 8,
$100 ohms. Paint the screw to discourage tampering
with the connection.
12. Disconnect the multimeter from the travel sensor
connector.
13. For the DVC6030 only, connect the travel sensor
connector to the PWB as described in Replacing the
Module Base.
14. Travel sensor replacement is complete. Install the
7 digital valve controller on the actuator as described in
the Installation section.
Travel Sensor Adjustment with the Field
Communicator
The next two steps do not apply if you used a
multimeter to adjust the travel sensor. Perform these
steps only if you elected to adjust the travel sensor
using the Field Communicator.
15. For the DVC6030 only, connect the travel sensor
connector to the PWB as described in Replacing the
Module Base.
16. For both the DVC6030 and the DVC6035, perform
the appropriate Travel Sensor Adjust procedure in the
Calibration section.
7-14
Troubleshooting
If communication or output difficulties are experienced
with the instrument, refer to the troubleshooting chart
in table 7-3. Also see the DVC6000 Troubleshooting
Checklist on page 7-18.
Checking Voltage Available
WARNING
Personal injury or property damage
caused by fire or explosion may occur
if this test is attempted in an area
which contains a potentially explosive
atmosphere or has been classified as
hazardous.
To check the Voltage Available at the instrument,
perform the following:
1. Connect the equipment in figure 2-25 to the field
wiring in place of the FIELDVUE instrument.
2. Set the control system to provide maximum output
current.
3. Set the resistance of the 1 kilohm potentiometer
shown in figure 2-25 to zero.
4. Record the current shown on the milliammeter.
5. Adjust the resistance of the 1 kilohm potentiometer
until the voltage read on the voltmeter is 11.0 volts.
6. Record the current shown on the milliammeter.
7. If the current recorded in step 6 is the same as that
recorded in step 4 (± 0.08 mA), the voltage available is
adequate.
8. If the voltage available is inadequate, refer to
Wiring Practices in the Installation section.
December 2009
 Maintenance and Troubleshooting

0.020

LOOP + / TEST +
MULTIMETER
(SEE NOTES TEST −
BELOW)

LOOP + / TEST +
LOOP −

− +
4−20mA
CURRENT TEST −
SOURCE
LOOP + / TEST +

DCS SYSTEM (OR OTHER

CURRENT SOURCE) DVC6000 DIGITAL VALVE
CONTROLLER TERMINAL BOX

NOTES:
1. MULTIMETER MEASURING 0.000 TO 1.0000 VDC
7
2. TYPICAL READINGS 0.004 VDC TO 0.020 VDC
3. OHM’S LAW—V = I x R, WHERE R = PRECISION 1 OHM RESISTOR, V = I x 1, SO V= I

Figure 7-8. Check the Loop Current using the TEST Terminals

Checking the Loop Current Without

Disturbing the Loop Wiring
To check the loop current without disturbing the loop
wiring perform the following procedure.
WARNING 1. With the FIELDVUE instrument connected to a
current source connect a digital multimeter reading
Personal injury or property damage
Volts DC ( 0 to 1 VDC or mV scale) to the TEST
caused by fire or explosion may occur
terminals as shown in figure 7-8.
if this test is attempted in an area
which contains a potentially explosive 2. The reading at the test terminals is proportional to
atmosphere or has been classified as the loop current [0.004 V = 0.004 A (4 MA)] mA of
hazardous. loop current). Refer to Specifications, table 1-2, to
determine if the current is sufficient.

December 2009 7-15

 DVC6000 Digital Valve Controllers
Table 7-3. Instrument Troubleshooting
Symptom Possible Cause
1. Analog input reading at 1a. Control mode not Analog.
instrument does not match
actual current provided.
1b. Low control system compliance voltage.
1c. Instrument shutdown due to self test failure.
1d. Analog input sensor not calibrated.
1e. Current leakage.
2. Instrument will not 2a. Insufficient Voltage Available.
communicate.
2b. Controller output Impedance too low.
2c. Cable capacitance too high.
2d. HART filter improperly adjusted.
7 2e. Improper field wiring.
2f. Controller output providing less than 4 mA to loop.
2g. Disconnected loop wiring cable at PWB.
2h. PWB DIP switch not set properly.
2j. PWB failure.
2k. Polling address incorrect.
2l. Defective terminal box.
2m. Defective Field Communicator or ValveLink
modem cable.
2n. ValveLink modem defective or not compatible
with PC.
2p. ValveLink hardlock defective or not programmed.
3. Instrument will not 3a. Travel sensor seized, will not turn.
calibrate, has sluggish
performance or oscillates. 3b. Broken travel sensor wire(s).
3c. Travel sensor misadjusted.
3d. Open travel sensor.
3e. Cables not plugged into PWB correctly.
3f. Feedback arm loose on pot.
3g. Feedback arm bent/damaged or bias spring
missing/damaged.
7-16
Action
1a. Check the control mode using the Field Communicator. If
in the Digital or Test mode, the instrument receives its set
point as a digital signal. Control is not based on input current.
Change Control Mode to Analog.
1b. Check system compliance voltage (see Wiring Practices
in the Installation section.
1c. Check instrument status using the Field Communicator
(see Viewing Instrument Status in the Viewing Device
Information section).
1d. Calibrate the analog input sensor (see Analog Input
Calibration in the Calibration section).
1e. Excessive moisture in the terminal box can cause current
leakage. Typically the current will vary randomly if this is the
case. Allow the inside of the terminal box to dry, then retest.
2a. Calculate Voltage Available (see Wiring Practices in the
Installation section). Voltage Available should be greater than
or equal to 11 VDC.
2b. Install a HART filter after reviewing Control System
Compliance Voltage requirements (see Wiring Practices in the
Installation section).
2c. Review maximum cable capacitance limits (see Wiring
Practices in the Installation section).
2d. Check filter adjustment (see the appropriate HART filter
instruction manual).
2e. Check polarity of wiring and integrity of connections. Make
sure cable shield is grounded only at the control system.
2f. Check control system minimum output setting, which
should not be less than 3.8 mA.
2g. Verify connectors are plugged in correctly.
2h. Check for incorrect setting or broken DIP switch on the
back of the PWB. Reset switch or replace PWB, if switch is
broken. See table 7-2 for switch setting information
2j. Use a 4−20 mA current source to apply power to the
instrument. Terminal voltage across the LOOP+ and LOOP−
terminals should be 9 to 10.5 VDC. If the terminal voltage is
not 9 to 10.5 VDC, replace the PWB.
2k. Use the Field Communicator to set the polling address
(refer to the Detailed Setup section). From the Utilities menu,
select Configure Communicator and Polling. Select Always
Poll. Set the instrument polling address to 0.
2l. Check continuity from each screw terminal to the
corresponding PWB connector pin. If necessary, replace the
terminal box assembly.
2m. If necessary, repair or replace cable.
2n. Replace ValveLink modem.
2p. Replace if defective or return to factory for programming.
3a. Rotate feedback arm to ensure it moves freely. If not,
replace the pot/bushing assy.
3b. Inspect wires for broken solder joint at pot or broken wire.
Replace pot/bushing assy.
3c. Perform Travel Sensor Adjust procedure in the Calibration
section.
3d. Check for continuity in electrical travel range. If necessary,
replace pot/bushing assy.
3e. Inspect connections and correct.
3f. Perform Travel Sensor Adjust procedure in the Calibration
section.
3g. Replace feedback arm and bias spring.
December 2009
 Maintenance and Troubleshooting
Table 7-3. Instrument Troubleshooting (Continued)
Symptom Possible Cause Action
3. Instrument will not 3h. Configuration errors. 3h. Verify configuration:
calibrate, has sluggish If necessary, set protection to None.
performance or oscillates. If Out of Service, place In Service.
Check:
Travel Sensor Motion
Tuning set
Zero control signal
Feedback Connection
Control mode (should be Analog)
Restart control mode (should be Analog)
3j. Restricted pneumatic passages in I/P converter. 3j. Check screen in I/P converter supply port of the module
base. Replace if necessary. If passages in I/P converter
restricted, replace I/P converter.
3k. O-ring(s) between I/P converter ass’y missing or hard 3k. Replace O-ring(s).
and flattened losing seal.
3l. I/P converter ass’y damaged/corroded/clogged. 3l. Check for bent flapper, open coil (continuity),
contamination, staining, or dirty air supply. Coil resistance
should be between 1680 - 1860 ohms. Replace I/P assy if
damaged, corroded, clogged, or open coil.
3m. I/P converter ass’y out of spec. 3m. I/P converter ass’y nozzle may have been adjusted. Verify
drive signal (55 to 80% for double-acting; 60 to 85% for
single-acting) with the valve off the stops. Replace I/P
converter ass’y if drive signal is continuously high or low.
3n. Defective module base seal. 3n. Check module base seal for condition and position. If
necessary, replace seal.
3p. Defective relay. 3p. Depress relay beam at adjustment location in shroud, look 7
for increase in output pressure. Remove relay, inspect relay
seal. Replace relay seal or relay if I/P converter ass’y good
and air passages not blocked. Check relay adjustment.
3q. Defective 67CFR regulator, supply pressure gauge 3q. Replace 67CFR regulator.
jumps around.
4. ValveLink diagnostic tests 4a. Bent or defective pressure sensor. 4a. Replace PWB.
provide erroneous results. 4b. Pressure sensor O-ring missing. 4b. Replace O-ring.
5. Field Communicator does 5a. Battery pack not charged. 5a. Charge battery pack.
not turn on. Note: Battery pack can be charged while attached to the Field
communicator or separately. The Field Communicator is fully
operable while the battery pack is charging. Do not attempt to
charge the battery pack in a hazardous area.

December 2009 7-17

 DVC6000 Digital Valve Controllers
DVC6000 Troubleshooting Checklist

1. Instrument serial number as read from nameplate ________________________________________________

2. Is the digital valve controller responding to the control signal? Yes _________ No _________

If not, describe ___________________________________________________________________________

3. Measure the voltage across the “Loop −” and Loop +” terminal box screws when the commanded current is
4.0 mA and 20.0 mA: __________V @ 4.0 mA __________V @ 20.0 mA.
(For a DVC6000 pwb built prior to 2003, these values should be around 9.4 V @ 4.0 mA. For a DVC6000 pwb
built after 2003, these values should be around 9.6 V @ 4.0 mA and 10.3 V @ 20 mA.
4. Is it possible to communicate via HART to the digital valve controller? Yes _________ No _________
5. What is the Diagnostic Tier of the digital valve controller? AC ____ HC ____ AD ____ PD ____ ODV____
6. What is the firmware version of the digital valve controller? ______________
7. What is the hardware version of the digital valve controller? ______________
8. Is the digital valve controller’s Instrument Mode “In Service”? Yes _________ No _________
9. Is the digital valve controller’s Control Mode set to “Analog”? Yes _________ No _________
10. Is it on Travel or Pressure control?
11. What are the following parameter readings?
7
Input Signal _________ Drive Signal _________%

Supply Pressure _________ Pressure A _________ Pressure B _________

Travel Target _________% Travel _________%

12. What are the following alert readings?

Fail alerts _______________________________________________________________________________

Valve alerts _____________________________________________________________________________

Operational status ________________________________________________________________________

Alert event record entries __________________________________________________________________

13. Export ValveLink data (if available) for the device (Status Monitor, Detailed Setup, etc.).

Mounting

1. Which DVC6000 do you have? DVC6010 ____ DVC6020 ____ DVC6030 ____ Remote Mount? ____
2. What Make, Brand, Style, Size, etc. actuator is the DVC6000 mounted on? ________________________
3. What is the full travel of the valve? ____________________________________________________________
4. What is the Mounting Kit part number? _________________________________________________________
5. If mounting kits are made by LBP/Customer, please provide pictures of installation.
6. Is the Mounting kit installed per the instructions? Yes _________ No _________
7. What is the safe position of the valve? Fail closed _________ Fail open _________
8. For a DVC6010 or DVC6030: During full travel of the actuator, does the DVC6000 feedback arm move below
the “A” or above the “B” alignment positions? (It should not) Yes _________ No _________

7-18 December 2009

 Parts
8-8

Section 8 Replaceable Parts

Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Common Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Module Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
I/P Converter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Feedback Connections Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
PWB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8
Pressure Gauges, Pipe Plugs, or Tire Valve Assemblies . . . . . . . . . . . . . . . . . . . 8-5
Feedback / Remote Travel Sensor Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
HART Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

December 2009 8-1

 DVC6000 Digital Valve Controllers
Parts Ordering Parts Kits
Whenever corresponding with your Emerson Process Conversion kit 3 listed below provides the parts
Management sales office about this equipment, required to convert a DVC6010 to a DVC6020 or a
always mention the controller serial number. When DVC6015 to a DVC6025. Conversion kit 4 provides
ordering replacement parts, refer to the 11−character the parts required to convert a DVC6020 to a
part number of each required part as found in the DVC6010 or a DVC6025 to a DVC6015.
following parts list. Parts which do not show part
Kit Description Part Number
numbers are not orderable. 1* Elastomer Spare Parts Kit (kit contains parts to
service one digital valve controller)
Standard 19B5402X012
Extreme Temperature option
WARNING (fluorosilicone elastomers) 19B5402X022
2* Small Hardware Spare Parts Kit (kit contains parts
Use only genuine Fisher replacement to service one digital valve controller) 19B5403X012
parts. Components that are not 3 Conversion Kit (DVC6010 to DVC6020 or
DVC6015 to DVC6025)
supplied by Emerson Process Also see note below 19B5405X012
Management should not, under any
Note
circumstances, be used in any Fisher
instrument. Use of components not When converting a DVC6010 to a DVC6020 for
supplied by Emerson Process pipe−away construction, also order pipe−away bracket
Management may void your warranty, kit, item 6.
might adversely affect the 4 Conversion Kit (DVC6020 to DVC6010 or
performance of the instrument, and DVC6025 to DVC6015) 14B5072X112
could cause personal injury and
property damage. 5 Feedback Arm Kit (contains feedback arm assembly
to convert a 2052 size 2 and 3 DVC6020 to a
8 2051 size 1 DVC6020) GE44419X012

6 Alignment Pin Kit

[kit contains 15 alignment pins (key 46)] 14B5072X092
7 Pipe−Away Bracket Kit (DVC6020) [kit contains
mounting bracket (key 74) and O−ring (key 75)]

Note Standard
Extreme Temperature option
19B5404X012

(fluorosilicone elastomers) 19B5404X022

Neither Emerson, Emerson Process 8* Seal Screen Kit
Management, nor any of their affiliated [kit contains 25 seal screens (key 231)
entities assumes responsibility for the and 25 O−rings (key 39)]
selection, use, and maintenance of any Standard and Extreme Temperature option 14B5072X182
(fluorosilicone elastomers)
product. Responsibility for the 9 Terminal Box Kit, aluminum
selection, use, and maintenance of any Standard 19B5401X012
product remains with the purchaser Standard, Natural Gas approved 19B5401X032
and end user.
Extreme Temperature option (fluorosilicone
elastomers) 19B5401X022
Extreme Temperature option (fluorosilicone
elastomers) Natural Gas Approved 19B5401X042

10* I/P Converter Kit

Standard 38B6041X152

Note For Extreme Temperature option

(fluorosilicone elastomers) 38B6041X132
11 Adjustment Arm Kit
All part numbers are for both (includes washer, nut and adjustment arm 14B5072X132
aluminum and stainless steel 12* PTFE Sleeve Kit
constructions, unless otherwise [For pot bushing assembly (kit includes 10 sleeves and
indicated. Lubricant)]
DVC6010 and DVC6020 GE08726X012
DVC6030 GE08727X012

*Recommended spare

8-2 December 2009

 Parts
Kit Description Part Number Kit Description Part Number
13* Spare Module Base Assembly Kit, aluminum
[kit contains module base (key 2); drive screws, qty. 2,
(key 11); shield/label (key 19); hex socket cap screw, qty. 3,
(key 38); self tapping screw, qty. 2 (key 49); pipe plug, qty. 3
(key 61); retaining ring, qty. 3 (key 154); screen (key 236);
and flame arrestors, qty. 3 (key 243)]
Parts List
GE18654X012 Parts which do not show part numbers are not
14* Spare Housing Assembly Kit, aluminum orderable as individual parts. In most cases, they are
[kit contains housing (key 1); drive screw, qty. 2 (key 11);
shield (key 20); and screen (key 271)]
available in one of the parts kits listed under Parts
DVC6010/DVC6020 GE18652X012 Kits.
DVC6030 GE18653X012

15 DVC6020 Cam Adjustment Tool GE12742X012

16* Spare Shroud Kit GE29183X012
Remote Mount Kits
17 Remote Terminal Box Kit
Note
Standard GE00418X012
18 Feedback Unit Parts with footnote numbers shown
DVC6015 49B7986X012 are available in parts kits. Also see
DVC6025 long arm 49B7987X012 footnote information at the bottom of
DVC6025 Short Arm 49B7987X022 the page.
DVC6035 49B7988X012

19 Remote Mount Retrofit Kit

Note
Key Description Part Number
This kit converts an existing DVC6000 in the remote
mounted version. Note that the DVC6030 cannot be
converted to the DVC6035.
Housing 8
DVC6010 to DVC6005/DVC6015 DVC6015RMTR DVC6010, DVC6020, DVC6030, DVC6005
DVC6010 to DVC6005/DVC6035 DVC6035RMTR
DVC6020 to DVC6005/DVC6025 (short arm DVC6025RMSA
(see figures 8-2, 8-3, 8-4, and 8-5)
DVC6020 to DVC6005/DVC6025 (long arm) DVC6025RMLA 1 Housing(14)
11 Drive Screw(14) (2 req’d)
20 Feedback Unit Termination Strip Kit GE00419X012 20 Shield(14)
21 Pipestand/Wall Mounting Kit GE00420X012 52 Vent, plastic(2) DVC6010, DVC6030, and DVC6005 only
Severe Service Linkage Kits 74 Mounting Bracket
DVC6020 Std(3) or pipe−away(7), and DVC6005(21)
Note 75* O−Ring(7), DVC6020 only
All metallic parts (except coil springs) in the corrosion 245 Pipe Plug, pl stl(7), DVC6020 Vent−away only
248 Screw, hex head(21) (4 req’d), (DVC6005 only)
kit and parts that experience rubbing or wear in the
249 Screw, hex head(21) (4 req’d), (DVC6005 only)
wear kit are coated with a proprietary tungsten carbon 250 Spacer(21) (4 req’d), (DVC6005 only)
coating. 267 Standoff(21) (2 req’d), ( (DVC6005 only)
271 Screen(14)
22 Corrosion Kit
DVC6010 0.25 to 2 Inch travel GE22667X012
DVC6010 2 to 4 Inch travel GE22668X012
DVC6020 short arm GE22670X012
Common Parts
DVC6020 long arm GE22671X012 DVC6010, DVC6020, DVC6030, DVC6005
DVC6030 rotary GE22672X012 (see figures 8-2, 8-3, 8-4, and 8-5)
DVC6030 linear GE22673X012
23 Wear Kit 16* O−ring(1) (3 req’d)
DVC6010 0.25 to 2 Inch travel GE22674X012 29 Warning label, for use only with LCIE hazardous area
DVC6010 2 to 4 Inch travel GE22675X012 classifications
DVC6020 short arm GE22676X012 33 Mach Screw, pan hd, SST(2) (3 req’d)
DVC6020 long arm GE22677X012 38 Cap Screw, hex socket, SST(2,13) (3 req’d)
DVC6030 rotary GE22678X012
DVC6030 linear GE22679X012
24 Kit, Spring *Recommended spare
DVC6010 0.25 to 2 inch travel [kit contains 10 bias 1. Available in the Elastomer Spare Parts Kit
2. Available in the Small Hardware Spare Parts Kit
springs w/tungsten carbon coating] GE37413X012 3. Available in the DVC6010 to DVC6020 Conversion Kit
DVC6010 2 to 4 inch travel, [kit contains 10 bias 7. Available in the Pipe−Away Bracket Kit
springs w/tungsten carbon coating] GE37414X012 13. Available in the Spare Module Base Assembly Kit
14. Available in the Spare Housing Assembly Kit
21. Available in the Pipestand/Wall Mounting Kit

December 2009 8-3

 DVC6000 Digital Valve Controllers
Key Description Part Number
43* Cover Assembly (includes cover screws)
Aluminum Construction
Standard 38B9580X012
Extreme temperature option
(fluorosilicone elastomers) 38B9580X032
Stainless Steel Construction
Standard 38B9580X022
Extreme temperature option
(fluorosilicone elastomers) 38B9580X042
48 Nameplate
49 Screw, self tapping (2 req’d)(13)
63 Lithium grease (not furnished with the instrument) GAS−BLOCKING
PRESS−FIT ADAPTOR
64 Anti−seize compound (not furnished with the instrument)
65 Lubricant, silicone sealant (not furnished with the instrument)
154 Retaining Ring(2) (3 req’d)
237 Module Base Seal(1)
WIRING CONNECTOR

Module Base
DVC6010, DVC6020, DVC6030, DVC6005
W9528
(see figures 8-2, 8-3, 8-4, 8-5, and 8-6)
2 Module Base(13)
11 Drive Screw(13) (2 req’d)
Figure 8-1. Terminal Box of Natural Gas Certified
12 O−ring(1) FIELDVUE DVC6000 Digital Valve Controller
19 Label, Shield Assembly(13)
61 Pipe Plug, hex socket(13) (3 req’d)
Key Description Part Number
236 Screen, for single−acting direct units only(13)
243 Flame Arrestor Assy(13) (3 req’d) Terminal Box
8 DVC6010, DVC6020, DVC6030, DVC6005
I/P Converter Assembly (see figures 8-1, 8-2, 8-3, 8-4, and 8-5)
DVC6010, DVC6020, DVC6030, DVC6005
4 Terminal Box Cap(17)
(see figures 8-2, 8-3, 8-4, and 8-5) 34* O−ring(1,9,17)
23 Cap Screw, hex socket, SST(2,16) (4 req’d) 36* O−ring(1,9,17)
39* O−ring (1,10) 44 Wire Retainer, pl stl(2) (6 req’d) (not shown)
41 I/P Converter(10) 58 Set Screw, hex socket, SST(2,17)
169 Shroud(10,16) 72 Cap Screw, hex socket, SST(2,17)
210* Boot, nitrile(1,10) (2 req’d) (also see figure 7-3) 164 Terminal Box Assembly(9)
231* Seal Screen(1,8,10)

Relay Feedback Connections Terminal Box

DVC6005 (see figure 8-5)
DVC6010, DVC6020, DVC6030, DVC6005
(see figures 8-2, 8-3, 8-4, and 8-5) 4 Terminal Box Cap(17)
34* O−ring(1,9,17)
24* Relay Assembly, (includes shroud, relay seal, mounting screws)
36* O−ring(1,9,17)
Standard
44 Wire Retainer, pl stl(2,18) (5 req’d) (not shown)
Single−acting direct (relay C) 38B5786X132
58 Set Screw, hex socket, SST(2,17)
Double−acting (relay A) 38B5786X052
62 Pipe Plug, hex hd, SST(17)
Single−acting reverse (relay B) 38B5786X092
72 Cap Screw, hex socket, SST(2,17) (3 req’d)
Low Bleed
262 Adapter(17)
Single−acting direct (relay C) 38B5786X152
263* O−ring(17)
Double−acting (relay A) 38B5786X072
Standard 1F463606992
Single−acting reverse (relay B) 38B5786X112
Extreme temperature option, (fluorosilicone) 1F4636X0092
Extreme Temperature option (fluorosilicone elastomers)
264 Terminal Box Assembly, remote(17)
Standard Bleed
Single−acting direct (relay C) 38B5786X142
Double−acting (relay A) 38B5786X032
Single−acting reverse (relay B) 38B5786X102 *Recommended spare
Low Bleed 1. Available in the Elastomer Spare Parts Kit
2. Available in the Small Hardware Spare Parts Kit
Single−acting direct (relay C) 38B5786X162 8. Available in the Seal Screen Kit
Double−acting (relay A) 38B5786X082 9. Available in the Terminal Box Kit
Single−acting reverse (relay B) 38B5786X122 10. Available in the I/P Converter Kit
13. Available in the Spare Module Base Assembly Kit
16. Available in the Spare Shroud Kit
17. Available in the Remote Terminal Box Kit
18. Available in Feedback Unit Kit

8-4 December 2009

 Parts
Key Description Part Number Key Description Part Number
79 Feedback Arm
PWB Assembly for DVC6010, DVC6015, DVC6030 and DVC6035
80 Cap Screw, hex socket, SST(2,18)
DVC6010, DVC6020, DVC6030, DVC6005
81 Square Nut, SST(2,18)
(see figures 8-2, 8-3, 8-4, and 8-5) 104 Cap Screw, hex hd(18) (4 req’d)
Note Aluminum Construction
DVC6010 and DVC6015
Contact your Emerson Process Management sales
Not for mounting on 1250 and 1250R actuators.
office for PWB Assembly FS numbers.
Mounting parts for 1250 and 1250R actuators are
50* PWB Assembly included in the mounting kit for these actuators.
Standard
For instrument level AC 107 Mounting Bracket(4,18), DVC6010 and DVC6015 only
For instrument level HC Not for mounting on 1250 and 1250R actuators.
For instrument level AD Mounting parts for 1250 and 1250R actuators are
For instrument level PD included in the mounting kit for these actuators.
For instrument level ODV − − − Feedback Linkage Shield, see figures 2-1 and 2-2
Up to 50.4 mm (2 inch) travel
Extreme Temperature option (fluorosilicone elastomers) All sliding−stem actuators except 585C size 60 39B2268X012
For instrument level AC 50.4 mm (2 inch) to 104mm (4 inch) travel
For instrument level HC All sliding−stem actuators except 585C size 60 49B2267X012
For instrument level AD 585C size 60, 19 mm (0.75 inch) to
For instrument level PD 104 mm (4 inch) travel 49B3844X012
For instrument level ODV 163 Plain Washer, SST(2,18)
223* Potentiometer/Bushing Assy
Pressure Gauges, Pipe Plugs, or Tire Standard Elastomers
Valve Assemblies (see figure 8-6) DVC6010, DVC6020 GE31447X012
DVC6030 GE31448X012
47* Pressure Gauge, nickel−plated brass case, brass connection Extreme Temperature option
Double−acting (3 req’d); Single−acting (2 req’d) (fluorosilicone elastomers)
DVC6010 and DVC6020 GE31450X012
PSI/MPA Gauge Scale
To 60 PSI, 0.4 MPa 18B7713X042 DVC6030 GE31451X012 8
To 160 PSI, 1.1 MPa 18B7713X022 DVC6015 and DVC6025(18) GE31453X012
PSI/bar Gauge Scale DVC6035(18) GE31454X012
To 60 PSI, 4 bar 18B7713X032
To 160 PSI, 11 bar 18B7713X012 DVC6020 and DVC6025
PSI/KG/CM2 Gauge Scale (see figures 8-3 and 8-8)
To 60 PSI, 4 KG/CM2 18B7713X072
74 Mounting Bracket, DVC6025 only
To 160 PSI, 11 KG/CM2 18B7713X082
(also in Housing parts for DVC6020)
66 Pipe Plug, hex hd
82 Bias Spring, SST(3)
For double−acting and single acting direct w/gauges
83 Bearing Flange, PTFE−based(3) (2 req’d)
(none req’d)
84 Feedback Arm Assy, SST(3)
For Single−acting reverse w/gauges (1 req’d)
85 E−ring, pl stl(3) (2 req’d)
For all units w/o gauges (3 req’d)
86 Plain Washer, pl stl(3) (2 req’d)
87 Follower Post, SST(3)
67 Tire Valve Assembly (3 req’d)
Stainless Steel Construction
88 Roller, SST/PTFE(3)
DVC6010 (oversized) (4 req’d)
89 Spring Lock Washer, pl stl(3)
Not for mounting on 1250 and 1250R actuators.
90 Hex Nut, pl stl(3)
Feedback / Remote Travel Sensor Parts 91
92
Arm Assy, SST
Cap Screw, hex socket(3) (4 req’d)
Common Feedback Parts 93 Torsion Spring, Feedback Arm(3)
DVC6010, DVC6020, DVC6030, DVC6015, DVC6025,
and DVC6035 (see figures 8-2, 8-3, 8-4, 8-7, 8-8,
DVC6015, DVC6025, and DVC6035
and 8-9)
(see figures 8-7, 8-8, and 8-9)
46 Alignment Pin(6,18) 23 Cap Screw, hex socket(18,20) (2 req’d)
for DVC6010, DVC6030, DVC6015 and DVC6035 44 Wire Retainer, pl stl(18,20) (9 req’d)
64 Anti−seize compound (not furnished with the instrument) 49 Screw, self tapping (2 req’d)
65 Lubricant, silicone sealant (not furnished with the instrument) 58 Set Screw, hex socket(18)
72 Cap Screw, hex socket(2,18) (2 req’d) 62 Pipe Plug, hex hd, SST(18)
for DVC6010, DVC6020, DVC6015, and DVC6025
78 Bias Spring, SST(2,18) *Recommended spare
for DVC6010, DVC6030, DVC6015 and DVC6035 2. Available in the Small Hardware Spare Parts Kit
3. Available in the DVC6010 to DVC6020 Conversion Kit
4. Available in the DVC6020 to DVC6010 Conversion Kit
6. Available in Alignment Pin Kit
18. Available in Feedback Unit Kit
20. Available in Feedback Unit Termination Strip Kit

December 2009 8-5

 DVC6000 Digital Valve Controllers

A 11
20

11
19

OUTPUT A

SECTION A-A

243

64
8 SECTION C-C
61
271
OUTPUT B

E E
49 SUPPLY

SECTION E-E SECTION D-D

APPLY LUB, SEALANT
NOTES:
1 SEE FIGURE 8-6 FOR GAUGE CONFIGURATIONS
2. APPLY LUBRICANT KEY 65 TO ALL O−RINGS UNLESS OTHERWISE
SPECIFIED
48B7710−K SHT 1 & 2 / DOC

Figure 8-2. FIELDVUE DVC6010 Digital Valve Controller Assembly

Key Description Part Number Key Description Part Number

131 Retainer Wire 261 Nameplate
251 Feedback housing(18) 265 Plug(18) (DVC6015 and DVC6035 only)
252 Assembly Plate Shield(18) (DVC6015 only)
253 Terminal bracket(18,20)
254 Terminal Strip(18,20)
255 Terminal Cap(18) HART Filters
256 O−ring, fluorosilicone(18)
HF340, DIN rail mount 39B5411X022
257 Machine Screw, pan head(18) (2 req’d) (DVC6015 only)
HF341, DIN rail Mount, pass through (no filter) 39B5412X012
258 Label, cover(18)
260 Hex Nut, SST (2 req’d)
*Recommended spare
18. Available in Feedback Unit Kit
20. Available in Feedback Unit Termination Strip Kit

8-6 December 2009

 Parts

B
H

D D
B C C E E

A
SECTION A-A

SECTION H-H

SECTION B-B

SECTION C-C
SECTION D-D

SECTION E-E
APPLY LUB, SEALANT
1. APPLY LUBRICANT KEY 65 TO ALL O−RINGS UNLESS OTHERWISE SPECIFIED

48B9596−K/IL SHT 1 & 2 / DOC

Figure 8-3. FIELDVUE DVC6020 Digital Valve Controller Assembly

December 2009 8-7

 DVC6000 Digital Valve Controllers

61
64
APPLY LUB, SEALANT
NOTES:
1 SEE FIGURE 8-6 FOR GAUGE CONFIGURATIONS
2. APPLY LUBRICANT KEY 65 TO ALL O-RINGS UNLESS OTHERWISE SPECIFIED
48B9596-K SHT 3 / DOC

Figure 8-3. FIELDVUE DVC6020 Digital Valve Controller Assembly (continued)

8-8 December 2009

 Parts

11
243 20
SECTION B-B
19

11 OUTPUT A

271
SUPPLY
64
D D
61
B A
B

49 OUTPUT B

SECTION A-A
8

C C

SECTION C-C
SECTION D-D

APPLY LUB, SEALANT, THREAD LOCK

NOTES:
1 SEE FIGURE 8-6 FOR GAUGE CONFIGURATIONS
2. APPLY LUBRICANT KEY 65 TO ALL O−RINGS UNLESS OTHERWISE
SPECIFIED
48B9597−K SHT 1 & 2 / DOC

Figure 8-4. FIELDVUE DVC6030 Digital Valve Controller Assembly

December 2009 8-9

 DVC6000 Digital Valve Controllers

SECTION A-A

SECTION C-C

SECTION B-B

APPLY LUB, SEALANT

NOTES:
1. APPLY LUBRICANT KEY 65 TO ALL O−RINGS UNLESS OTHERWISE
SPECIFIED
49B3261−C SHT 1 & 2

Figure 8-5. FIELDVUE DVC6005 Base Unit

8-10 December 2009

 Parts

E E

SECTION E-E

OUTPUT A

8
OUTPUT A

OUTPUT B OUTPUT B
SUPPLY SUPPLY

WALL MOUNTING PIPESTAND MOUNTING

APPLY LUB, SEALANT

NOTES:
1 SEE FIGURE 8-6 FOR GAUGE CONFIGURATIONS
2. APPLY LUBRICANT KEY 65 TO ALL O−RINGS UNLESS OTHERWISE
SPECIFIED
49B3261−C SHT 2 & 3 / DOC

Figure 8-5. FIELDVUE DVC6005 Base Unit (continued)

December 2009 8-11

 DVC6000 Digital Valve Controllers

DOUBLE−ACTING
SINGLE−ACTING DIRECT SINGLE−ACTING REVERSE
APPLY LUB, SEALANT
NOTE:
1 FOR SINGLE−ACTING DIRECT, OUTPUT B IS PLUGGED.
2 FOR SINGLE−ACTING REVERSE, OUTPUT A IS PLUGGED.
48B7710−K SHT 2 / DOC

Figure 8-6. Typical FIELDVUE DVC6000 Digital Valve Controller Gauge Configuration

SECTION C-C

SECTION B-B

SECTION A-A SECTION D-D

APPLY LUB, SEALANT
NOTE:
1. APPLY LUBRICANT KEY 65 TO ALL O−RINGS UNLESS OTHERWISE SPECIFIED
49B7986−A

Figure 8-7. FIELDVUE DVC6015 Digital Valve Controller Assembly

8-12 December 2009

 Parts

SECTION B-B

8
SECTION A-A

APPLY LUB, SEALANT, THREAD LOCK

NOTE:
1. APPLY LUBRICANT KEY 65 TO ALL O−RINGS UNLESS OTHERWISE SPECIFIED

49B7987−A/IL

Figure 8-8. FIELDVUE DVC6025 Digital Valve Controller Assembly

December 2009 8-13

 DVC6000 Digital Valve Controllers

SECTION C-C

SECTION B-B

8
APPLY LUB, SEALANT, THREAD LOCK
NOTE:
1. APPLY LUBRICANT KEY 65 TO ALL O−RINGS SECTION A-A
UNLESS OTHERWISE SPECIFIED
49B7988−A

Figure 8-9. FIELDVUE DVC6035 Digital Valve Controller Assembly

8-14 December 2009

 Principle of Operation
A-A-

Appendix A Principle of Operation

HART Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

DVC6000 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

December 2009 A-1

 DVC6000 Digital Valve Controllers

+0.5 V CONTROL SYSTEM

0
ANALOG
SIGNAL

−0.5V HART
MODEM
1200 Hz 2200 Hz
“1” “0”

AVERAGE CURRENT CHANGE DURING COMMUNICATION = 0

A6174/IL

Figure A-1. HART Frequency Shift Keying Technique

FIELD
TERM.

HART Communication
The HART (Highway Addressable Remote
Transducer) protocol gives field devices the capability
of communicating instrument and process data
digitally. This digital communication occurs over the
same two-wire loop that provides the 4-20 mA process A6761 / IL

control signal, without disrupting the process signal. In

this way, the analog process signal, with its faster
update rate, can be used for control. At the same time,
the HART protocol allows access to digital diagnostic,
maintenance, and additional process data. The
protocol provides total system integration via a host
device.
The HART protocol uses frequency shift keying (FSK).
Two individual frequencies of 1200 and 2200 Hz are
superimposed over the 4-20 mA current signal. These
A frequencies represent the digits 1 and 0 (see figure
A-1). By superimposing a frequency signal over the
4–20 mA current, digital communication is attained.
The average value of the HART signal is zero,
therefore no dc value is added to the 4-20 mA signal.
Thus, true simultaneous communication is achieved
without interrupting the process signal.
The HART protocol allows the capability of
multidropping, i.e., networking several devices to a
single communications line. This process is well suited
for monitoring remote applications such as pipelines,
custody transfer sites, and tank farms. See table 7-2
for instructions on changing the printed wiring board
DIP switch configuration to multidrop.
DVC6000 Operation
The DVC6000 digital valve controller housing contains
the travel sensor, terminal box, pneumatic input and
output connections and a module base that may be
easily replaced in the field without disconnecting field
wiring or tubing. The module base contains the
Figure A-2. Typical FIELDVUE Instrument to Personal
Computer Connections for ValveLink Software
following submodules: I/P converter, printed wiring
board (pwb) assembly, and pneumatic relay. The relay
position is detected by sensing the magnet on the
relay beam via a detector on the printed wiring board.
This sensor is used for the minor loop feedback
(MLFB) reading. The module base can be rebuilt by
replacing the submodules. See figures A-3 and A-4.
DVC6000 digital valve controllers are loop-powered
instruments that provide a control valve position
proportional to an input signal from the control room.
The following describes a double-acting DVC6010
digital valve controller mounted on a piston actuator.
The input signal is routed into the terminal box through
a single twisted pair of wires and then to the printed
wiring board assembly submodule where it is read by
the microprocessor, processed by a digital algorithm,
and converted into an analog I/P drive signal.
As the input signal increases, the drive signal to the
I/P converter increases, increasing the I/P output
pressure. The I/P output pressure is routed to the
pneumatic relay submodule. The relay is also
connected to supply pressure and amplifies the small
pneumatic signal from the I/P converter. The relay
accepts the amplified pneumatic signal and provides
two output pressures. With increasing input (4 to 20
mA signal), the output A pressure always increases

A-2 December 2009

 Principle of Operation

4−20 mA
INPUT SIGNAL
+
HART

AUXILIARY
TERMINALS

TERMINAL BOX

VALVE TRAVEL
PRINTED FEEDBACK
WIRING BOARD
DRIVE
SIGNAL

OUTPUT A

I/P
CONVERTER
SUPPLY
PNEUMATIC PRESSURE
RELAY

OUTPUT B

VALVE AND ACTUATOR

E0408 / IL

Figure A-3. FIELDVUE DVC6000 Digital Valve Controller Block Diagram

and the output B pressure decreases. The output A
pressure is used for double-acting and single-acting
direct applications. The output B pressure is used for
double-acting and single-acting reverse applications.
As shown in figure A-3 the increased output A
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 stabilizes
the I/P drive signal. This positions the flapper to
prevent any further increase in nozzle pressure.
As the input signal decreases, the drive signal to the
I/P converter submodule decreases, decreasing the
I/P output pressure. The pneumatic relay decreases A
the output A pressure and increases the output B
pressure. The stem moves upward until the correct
position is attained. At this point the printed wiring
board assembly stabilizes the I/P drive signal. This
positions the flapper to prevent any further decrease in
nozzle pressure.

December 2009 A-3

 DVC6000 Digital Valve Controllers
TERMINAL BOX
TERMINAL BOX COVER

HOUSING

PNEUMATIC RELAY GAUGES

COVER

TRAVEL SENSOR

PRINTED WIRING BOARD ASSEMBLY

W9329
MODULE BASE ASSEMBLY I/P CONVERTER

Figure A-4. FIELDVUE DVC6000 Digital Valve Controller Assembly

A-4 December 2009

 Loop Schematics/Nameplates
B-B-

Appendix B Loop Schematics/Nameplates

CSA
Loop Schematics for DVC6010, DVC6020, and DVC6030 . . . . . . . . . . . . . . . . . B-2
Nameplates for DVC6010, DVC6020, and DVC6030 . . . . . . . . . . . . . . . . . . . . . . B-2
Loop Schematics for DVC6005 with DVC6015, DVC6025, and DVC6035 . . B-3
Nameplates for DVC6005, DVC6015, DVC6025, and DVC6035 . . . . . . . . . . . B-3

FM
Loop Schematics for DVC6010, DVC6020, and DVC6030 . . . . . . . . . . . . . . . . . B-4
Nameplates for DVC6010, DVC6020, and DVC6030 . . . . . . . . . . . . . . . . . . . . . . B-4
Loop Schematics for DVC6005 with DVC6015, DVC6025, and DVC6035 . . B-5
Nameplates for DVC6005, DVC6015, DVC6025, and DVC6035 . . . . . . . . . . . B-5

ATEX
Nameplates; Intrinsically Safe, Dust−Tight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Nameplates; Flameproof, Dust−Tight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Nameplates; Type n, Dust−Tight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

IECEx
Loop Schematics for DVC6010, DVC6020, and DVC6030 . . . . . . . . . . . . . . . . . B-9 B
Nameplates for DVC6010, DVC6020, and DVC6030 . . . . . . . . . . . . . . . . . . . . . . B-9
Loop Schematics for DVC6005 with DVC6015, DVC6025, and DVC6035 . . B-10
Nameplates for DVC6005, DVC6015, DVC6025, and DVC6035 . . . . . . . . . . . B-10

NEPSI
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

INMETRO
Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11

December 2009 B-1

 DVC6000 Digital Valve Controllers
This section includes loop schematics required for
wiring of intrinsically safe installations. It also contains
the approvals nameplates. If you have any questions,
contact your Emerson Process Management sales
office.

B GE42818 sheets 2 and 8 Figure B-1. CSA Loop Schematic for FIELDVUE DVC6010, DVC6020, and DVC6030

DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

LABEL FOR NATURAL GAS

CERTIFIED TERMINAL BOX

Figure B-2. CSA Nameplates for FIELDVUE DVC6010, DVC6020, and DVC6030

B-2 December 2009

 Loop Schematics/Nameplates

GE42818 sheets 5 and 8

Figure B-3. CSA Loop Schematic for FIELDVUE DVC6005 with DVC6015, DVC6025, and DVC6035

DVC6005—LABEL FOR
NATURAL GAS CERTIFIED
DVC6005 TERMINAL BOX

DVC6015, DVC6025, DVC6035

Figure B-4. CSA Nameplates for FIELDVUE DVC6005, DVC6015, DVC6025, and DVC6035

December 2009 B-3

 DVC6000 Digital Valve Controllers

GE42819−A Sheet 2 and 8

Figure B-5. FM Loop Schematic for FIELDVUE DVC6010, DVC6020, and DVC6030

DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

LABEL FOR NATURAL GAS

CERTIFIED TERMINAL BOX

Figure B-6. FM Nameplates for FIELDVUE DVC6010, DVC6020, and DVC6030

B-4 December 2009

 Loop Schematics/Nameplates

GE42819−A Sheet 5 and 8

Figure B-7. FM Loop Schematic for FIELDVUE DVC6005 with DVC6015, DVC6025, and DVC6035

DVC6005—LABEL FOR NATURAL

GAS CERTIFIED TERMINAL BOX
DVC6005

DVC6015, DVC6025, DVC6035

Figure B-8. FM Nameplates for FIELDVUE DVC6005, DVC6015, DVC6025, and DVC6035

December 2009 B-5

 DVC6000 Digital Valve Controllers

DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

DVC6005

B
DVC6015, DVC6025, DVC6035

Figure B-9. ATEX Nameplates; Intrinsically Safe, Dust-Tight

B-6 December 2009

 Loop Schematics/Nameplates

DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

DVC6005

B
DVC6015, DVC6025, DVC6035

Figure B-10. ATEX Nameplates; Flameproof, Dust-Tight

December 2009 B-7

 DVC6000 Digital Valve Controllers

DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

DVC6005

B
DVC6015, DVC6025, DVC6035

Figure B-11. ATEX Nameplates; Type n, Dust-Tight

B-8 December 2009

 Loop Schematics/Nameplates

GE42990
Sheet 2 and 8 of 8

Figure B-12. IECEx Loop Schematic for FIELDVUE DVC6020, DVC6020, and DVC6030

DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

Figure B-13. IECEx Nameplate for FIELDVUE DVC6010, DVC6020, and DVC6030

December 2009 B-9

 DVC6000 Digital Valve Controllers

GE42990
Sheet 5 and 8 of 8

Figure B-14. IECEx Loop Schematic for FIELDVUE DVC60005 with DVC6015, DVC6025, and DVC6035

DVC6005

DVC6015, DVC6025, DVC6035

Figure B-15. IECEx Nameplates for DVC60005, DVC6015, DVC6025, and DVC6035

B-10 December 2009

 Loop Schematics/Nameplates

DVC6010, DVC6020, AND DVC6030

Figure B-16. NEPSI Nameplate

INTRINSICALLY SAFE
DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

FLAMEPROOF
DVC6010, DVC6020, DVC6030, DVC6010S, DVC6020S, DVC6030S

Figure B-17. INMETRO Nameplates

December 2009 B-11

 DVC6000 Digital Valve Controllers

B-12 December 2009


C-C-
Glossary
Alert Point
An adjustable value that, when exceeded,
activates an alert.
Algorithm
A set of logical steps to solve a problem or
accomplish a task. A computer program contains
one or more algorithms.
Alphanumeric
Consisting of letters and numbers.
Analog Input Units
Units in which the analog input is displayed and
maintained in the instrument.
ANSI (acronym)
The acronym ANSI stands for the American
National Standards Institute
ANSI Class
Valve pressure/temperature rating.
Auxiliary Input Alert
Checks the status of the auxiliary input; a discrete
input. When enabled, the Auxiliary Input Alert is
active when the auxiliary input terminals are open
or closed (shorted), depending upon the selection
for Auxiliary Input Alert State.
Auxiliary Terminal (Indicator)
Indicates whether auxiliary wiring terminals are
open or closed (such as by an external switch
contact).
Bench Set
Pressure, supplied to an actuator, required to
drive the actuator through rated valve travel.
Expressed in pounds per square inch.
December 2009
Glossary
Byte
A unit of binary digits (bits). A byte consists of
eight bits.
Calibration Location
Where the instrument was last calibrated; either
in the factory or in the field.
Configuration
Stored instructions and operating parameters for
a FIELDVUE Instrument.
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.
B
Control Mode
Defines where the instrument reads its set point. Glossary
The following control modes are available for a
FIELDVUE Instrument:
Analog The instrument receives its travel set
point over the 4-20 mA loop.
Digital The instrument receives its set point
digitally, via the HART communications link.
Test This is not a user-selectable mode. The
Field Communicator or ValveLink software places
the instrument in this mode whenever it needs to
move the valve, such as for calibration or
diagnostic tests.
Control Mode, Restart
Determines the instrument control mode after a
restart. See Control Mode for the available
restart control modes.
Glossary-1
 DVC6000 Digital Valve Controllers
Controller
A device that operates automatically to regulate a
controlled variable.
Crossover Point
The point at which the feedback pin is closest to
the axis of rotation of the travel sensor. 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.
Current-to-Pressure (I/P) Converter
An electronic component or device that converts
a milliamp signal to a proportional pneumatic
pressure output signal.
Cycle Counter
The capability of a FIELDVUE instrument to
record the number of times the travel changes
direction. The change in direction must occur
after the deadband has been exceeded before it
can be counted as a cycle.
Cycle Counter Alert
Checks the difference between the Cycle Counter
and the Cycle Counter Alert Point. Cycle Counter
Alert is active when the cycle counter value
exceeds the Cycle Counter Alert Point. It clears
after you reset the Cycle Counter to a value less
than the alert point.
B Cycle Counter Alert Point
An adjustable value which, when exceeded,
Glossary
activates the Cycle Counter Alert. Valid entries
are 0 to 4 billion cycles.
Cycle Counter Deadband
Region around the travel reference point, in
percent of ranged travel, established at the last
increment of the Cycle Counter. The deadband
must be exceeded before a change in travel can
be counted as a cycle. Valid entries are 0% to
100%. Typical value is between 2% and 5%.
Deviation
Usually, the difference between set point and
process variable. More generally, any departure
from a desired or expected value or pattern.
Glossary-2
Device ID
Unique identifier embedded in the instrument at
the factory.
Device Revision
Revision number of the interface software that
permits communication between the Field
Communicator and the instrument.
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.
Drive Signal Alert
Checks the drive signal and calibrated travel. If
one of the following conditions exists for more
than 20 seconds, the Drive Signal Alert is active.
If none of the conditions exist, the alert is cleared.
If Zero Power Condition = Closed
The alert is active when:
drive signal <10% and calibrated travel >3%
drive signal >90% and calibrated travel <97%
If Zero Power Condition = Open
The alert is active when:
drive signal <10% and calibrated travel <97%
drive signal >90% and calibrated travel >3%
Equal Percentage
A valve flow characteristic where equal
increments of valve stem travel produce equal
percentage changes in existing flow. One of the
input characteristics available for a FIELDVUE
Instrument. See also, Linear and Quick Opening.
Feedback Arm
The mechanical connection between the valve
stem linkage and the FIELDVUE Instrument
travel sensor.
Feedback Connection
Identifies the type of feedback linkage: rotary,
sliding-stem roller or sliding-stem standard.
Feedback Signal
Indicates to the instrument the actual position of
the valve. The travel sensor provides the
feedback signal to the instrument printed wiring
board assembly. A mechanical linkage connects
the travel sensor to the valve stem or shaft.
December 2009

Firmware Revision
The revision number of the instrument firmware.
Firmware is a program that is entered into the
instrument at time of manufacture and cannot be
changed by the user.
Free Time
Percent of time that the microprocessor is idle. A
typical value is 25%. The actual value depends
on the number of functions in the instrument that
are enabled and on the amount of communication
currently in progress.
Full Ranged Travel
Current, in mA, that corresponds with the point
where ranged travel is maximum, i.e., limited by
the mechanical travel stops.
Gain
The ratio of output change to input change.
Hardware Revision
Revision number of the Fisher Controls
instrument hardware. The physical components
of the instrument are defined as the hardware.
HART (acronym)
The acronym HART stands for Highway
Addressable Remote Transducer.
HART Tag
An eight-character name that identifies the
physical instrument.
HART Universal Revision
Revision number of the HART Universal
Commands which are the communications
protocol for the instrument.
Input Characteristic
The relationship between the ranged travel and
ranged input. Possible values include: linear,
equal percentage, and quick opening.
Input Current
The current signal from the control system that
serves as the analog input to the instrument. See
also Input Signal.
December 2009
Glossary
Input Range
The analog input signal range that corresponds to
the travel range.
Input Signal
The current signal from the control system. The
input signal can be displayed in milliamperes or in
percent of ranged input.
Instrument Level
Determines the functions available for the
instrument. See table 6-2, page 6-9.
Instrument Mode
Determines if the instrument responds to its
analog input signal. There are two instrument
modes:
In Service: For a fully functioning instrument, the
instrument output changes in response to analog
input changes. Typically changes to setup or
calibration cannot be made when the instrument
mode is In Service.
Out of Service: The instrument output does not
change in response to analog input changes
when the instrument mode is Out of Service.
Some setup parameters can be changed only
when the instrument mode is Out of Service.
Instrument Protection
Determines if commands from a HART device
can calibrate and/or configure certain parameters
in the instrument. There are two types of
instrument protection: B
Configuration and Calibration: Prohibits
changing protected setup parameters; prohibits Glossary
calibration.
None: Permits both configuration and calibration.
The instrument is ”unprotected.”
Instrument Serial Number
The serial number assigned to the printed wiring
board by the factory but can be changed during
setup. The instrument serial number should
match the serial number on the instrument
nameplate.
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 and IEC 534-4.
Glossary-3
 DVC6000 Digital Valve Controllers
Linear
A valve flow characteristic where changes in flow
rate are directly proportional to changes in valve
stem travel. One of the input characteristics
available for a FIELDVUE Instrument. See also,
Equal Percentage and Quick Opening.
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.
Memory
A type of semiconductor used for storing
programs or data. FIELDVUE instruments use
three types of memory: Random Access Memory
(RAM), Read Only Memory (ROM), and
Non-Volatile Memory (NVM). See also these
listings in this glossary.
Menu
A list of programs, commands, or other activities
that you select by using the arrow keys to
highlight the item then pressing ENTER, or by
entering the numeric value of the menu item.
Minimum Closing Time
Minimum time, in seconds, for the travel to
decrease through the entire ranged travel. This
rate is applied to any travel decrease. Valid
entries are 0 to 400 seconds. Deactivate by
B entering a value of 0 seconds.
Glossary
Minimum Opening Time
Minimum time, in seconds, for the travel to
increase through the entire ranged travel. This
rate is applied to any travel increase. Because of
friction, actual valve travel may not respond in
exactly the same time frame. Valid entries are 0
to 400 seconds. Deactivate by entering a value of
0 seconds.
Non-Volatile Memory (NVM)
A type of semiconductor memory that retains its
contents even though power is disconnected.
NVM contents can be changed during
configuration unlike ROM which can be changed
only at time of instrument manufacture. NVM
stores configuration restart data.
Glossary-4
Parallel
Simultaneous: said of data transmission on two or
more channels at the same time.
Polling Address
Address of the instrument. If the digital valve
controller is used in a point-to-point configuration,
set the polling address to 0. If it is used in a
multidrop configuration, or split range application,
set the polling address to a value from 0 to 15.
Pressure Sensor
A FIELDVUE instrument internal device that
senses pneumatic pressure. DVC6000 digital
valve controllers have three pressure sensors:
one to sense supply pressure and two to sense
the output pressures.
Primary Master
Masters are communicating devices. A primary
master is a communicating device permanently
wired to a field instrument. Typically, a
HART-compatible control system or a computer
running ValveLink software is the primary master.
In contrast, a secondary master is not often
permanently wired to a field instrument. The Field
Communicator or a computer running ValveLink
software communicating through a HART modem
could be considered a secondary master.
Note: If one type of master takes an instrument
Out Of Service, the same type must put it In
Service. For example, if a device set up as a
primary master takes an instrument Out Of
Service, a device set up as a primary master
must be used to place the instrument In Service.
Quick Opening
A valve flow characteristic where most of the
change in flow rate takes place for small amounts
of stem travel from the closed position. The flow
characteristic curve is basically linear through the
first 40 percent of stem travel. One of the input
characteristics available for a FIELDVUE
Instrument. See also, Equal Percentage and
Linear.
Random Access Memory (RAM)
A type of semiconductor memory that is normally
used by the microprocessor during normal
operation that permits rapid retrieval and storage
of programs and data. See also Read Only
Memory (ROM) and Non-Volatile Memory (NVM).
December 2009

Rate
Amount of change in output proportional to the
rate of change in input.
Read-Only Memory (ROM)
A memory in which information is stored at the
time of instrument manufacture. You can
examine but not change ROM contents.
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.
Set Point Filter Time
The time constant, in seconds, for the first-order
input filter.
Software
Microprocessor or computer programs and
routines that reside in alterable memory (usually
RAM), as opposed to firmware, which consists of
programs and routines that are programmed into
memory (usually ROM) when the instrument is
manufactured. Software can be manipulated
during normal operation, firmware cannot.
Stroking Time
The time, in seconds, required to move the valve
from its fully open position to fully closed, or vice
versa.
Temperature Sensor
A device within the FIELDVUE instrument that
measures the instrument’s internal temperature.
Travel
Movement of the valve stem or shaft which
changes the amount the valve is open or closed.
Travel Accumulator
The capability of a FIELDVUE instrument to
record total change in travel. The value of the
Travel Accumulator increments when the
magnitude of the change exceeds the Travel
Accumulator Deadband. To reset the Travel
Accumulator, set it to zero.
December 2009
Glossary
Travel Accumulator Alert
Checks the difference between the Travel
Accumulator value and the Travel Accumulator
Alert Point. The Travel Accumulator Alert is active
when the Travel Accumulator value exceeds the
Travel Accumulator Alert Point. It clears after you
reset the Travel Accumulator to a value less than
the alert point.
Travel Accumulator Alert Point
An adjustable value which, when exceeded,
activates the Travel Accumulator Alert. Valid
entries are 0% to 4 billion %.
Travel Accumulator Deadband
Region around the travel reference point
established at the last increment of the
accumulator. This region must be exceeded
before a change in travel can be accumulated.
Valid entries are 0% to 100%.
Travel Alert
Checks the ranged travel against the travel high
and low alert points. The travel alert is active if
either the high or low point is exceeded. Once a
high or low point is exceeded, the ranged travel
must clear that point by the Travel Alert
Deadband before the alert clears. Four travel
alerts are available: Travel Alert Hi, Travel Alert
Lo, Travel Alert Hi Hi, and Travel Alert Lo Lo.
Travel Alert Deadband
Travel, in percent of ranged travel, required to
clear a travel alert, once it is active. Valid entries
are −25% to 125%.
Travel Alert High Point B
Value of the travel, in percent of ranged travel,
Glossary
which, when exceeded, sets the Travel Alert Hi
alert. Valid entries are −25% to 125%.
Travel Alert High High Point
Value of the travel, in percent of ranged travel,
which, when exceeded, sets the Travel Alert Hi Hi
alert. Valid entries are −25% to 125%.
Travel Alert Low Point
Value of the travel, in percent of ranged travel,
which, when exceeded, sets the Travel Alert Lo
alert. Valid entries are −25% to 125%.
Travel Alert Low Low Point
Value of the travel, in percent of ranged travel,
which, when exceeded, sets the Travel Alert Lo
Lo alert. Valid entries are −25% to 125%.
Glossary-5
 DVC6000 Digital Valve Controllers
Travel Cutoff
Defines the cutoff point for the travel, in percent
of ranged travel. There are two travel cutoffs:
high and low. Once travel exceeds the cutoff, the
drive signal is set to either maximum or minimum,
depending on the Zero Control Signal and if the
cutoff is high or low. Minimum opening time or
minimum closing time are not in effect while the
travel is beyond the cutoff. Use the travel cutoff to
obtain the desired seat load or to be sure the
valve is fully open.
Travel Deviation
The difference between the analog input signal (in
percent of ranged input), the “target” travel, and
the actual “ranged” travel.
Travel Deviation Alert
Checks the difference between the target and the
ranged travel. If the difference exceeds the Travel
Deviation Alert Point for more than the Travel
Deviation Time, the Travel Deviation Alert is
active. It remains active until the difference is less
than the Travel Deviation Alert Point.
Travel Deviation Alert Point
An adjustable value for the target travel and the
ranged travel difference, expressed in percent,
When this value is exceeded by the travel
deviation for more than the Travel Deviation
Time, the Travel Deviation Alert is active. Valid
entries are 0% to 100%. Typically this is set to
5%.
B Travel Deviation Time
The time, in seconds. that the travel deviation
Glossary
must exceed the Travel Deviation Alert Point
before the alert is active. Valid entries are 1 to 60
seconds.
Travel Limit
A setup parameter that defines the maximum
allowable travel (in percent of ranged travel) for
the valve. During operation, the travel target will
not exceed this limit. There are two travel limits:
high and low. Typically the travel limit low will be
used to keep the valve from going completely
closed.
Travel Range
Travel, in percent of calibrated travel, that
corresponds to the input range.
Glossary-6
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.
Travel Sensor Motion
Establishes motion of the travel sensor. While
viewing the end of the travel sensor shaft, if
increasing air pressure to the actuator causes the
shaft to rotate clockwise, travel sensor motion is
CW. If increasing air pressure causes the shaft to
rotate counterclockwise, travel sensor motion is
CCW.
Tuning
The adjustment of control terms or parameter
values to produce a desired control effect.
Tuning Set
Preset values that identify gain settings for a
FIELDVUE instrument. The tuning set and supply
pressure together determine an instrument’s
response to input signal changes.
Watch Dog Timer
A timer that the microprocessor must rearm
periodically. If the microprocessor is unable to
rearm the timer, the instrument goes through
reset.
Zero Power Condition
The position of the valve (open or closed) when
the electrical power to the instrument is removed.
Zero Power Condition (ZPC) is determined by
relay and actuator action as follows:
Single Acting Direct (Relay C) Upon loss of
power instrument goes to zero air output at port
A. On loss of pneumatic supply failure direction is
per the actuator fail mode.
Double Acting (Relay A) Upon loss of power
instrument goes to full supply air output at port B.
A goes to zero air output. The failure direction
upon loss of pneumatic supply cannot be
determined.
Single Acting Reverse (Relay B) Upon loss of
power instrument goes to full supply air output at
Port B. On loss of pneumatic supply failure
direction is per the actuator fail mode.
December 2009
 Index

Index
D-D-

Analog Calibration Adjust, 5-4

A
Analog Input
AC, (Auto Calibrate), 6-8 Displaying Value, 6-7
Units, 4-20
Actuator Style, 4-21
Analog Input Calibration, 5-10
AD, (Advanced Diagnostics), 6-8
Analog Input Range, 4-20
Advanced Diagnostics, (AD), 6-8
ATEX
Alert Conditions, 6-2 Hazardous Area Classifications, 1-6, 1-10
Alert Record, 6-4 Nameplates, B-6, B-7, B-8
Electronics, 6-2 Special Conditions for Safe Use, 2-4
Environment, 6-3
Sensor, 6-2 Auto Calibrate, (AC), 6-8
SIS, 6-3 Auto Calibrate Travel, 5-2
Travel, 6-3 Error Messages, 5-3, 5-4
Travel History, 6-3
Aux Term Mode , 4-21
Alert Groups, 4-19 Aux Terminal Mode, 4-6
Failure Alerts, 4-18
Miscellaneous, 4-18 Auxiliary Input, Displaying Status, 6-7
Valve Alerts, 4-18 Auxiliary Terminal, Wiring Length Guidelines,
Alert Record, 4-18 6-5

Alerts, 4-14
Alert Record, 4-18
Alert Groups, 4-19
B
Enabling Alert Groups, 4-18 bias spring, 2-14
Electronic, 4-14
Drive Signal Alert, 4-14 Burst Mode, 4-5
Processor Impaired Alerts, 4-14 Commands, 2-30, 4-5
Environment, 4-15 Enabling, 4-5
Index
Environmental Burst Operation, 2-30
Aux Terminal Alerts, 4-15
Supply Press Lo Alert, 4-15
Sensor, 4-15
SIS, 4-18
C
Travel, 4-15 Calibration
Deviation Alert, 4-15 Analog Input, 5-10
Limit Alerts, 4-16 Auto Calibrate Travel, 5-2
Travel Limit Cutoff Alerts, 4-16 Error Messages, 5-4
Travel Limit Hi/Lo Alerts, 4-16 Manual Calibrate Travel, 5-4
Travel History, 4-17
Cycle Count, 4-17
Pressure Sensors, 5-6
Relay Adjustment, 5-10
G
Cycle Count/Tvl Accum Deadband, 4-17 Sensor Calibration, 5-6
Tvl Accum, 4-17 Pressure Sensors, 5-6

December 2009 Index-1

 DVC6000 Digital Valve Controllers
Touch-Up Travel, 5-6 Device Information, 6-8
Travel
Device Record, 6-4
Auto, 5-2
Manual, 5-4 Device Revision, 6-8
Analog Calibration Adjust, 5-4 Device Variables, 6-7
Digital Calibration Adjust, 5-5
Travel Sensor, 5-7 Digital Calibration Adjust, 5-5
Travel Sensor Adjust, 5-7 DIP Switch, Setting, 7-7
Calibration , Travel, 5-2 Drive Signal, Displaying Value, 6-7
Calibration & Diagnostics, 4-19 Dynamic Response, 4-12
Calibration Status and Location, 4-21
Communication Cable Capacitance, 2-29 E
Connections
Electrical Educational Services, 1-4
4 to 20 mA Loop, 2-21 Electrical Classification, Hazardous Area, 1-6
Communication, 2-26
Electromagnetic Compatibility, 1-5
Test, 2-25
Pneumatic End Point Pressure Control, 4-12
Output, 2-18 Error Messages, Auto Calibrate Travel, 5-4
to support solenoid testing, 2-19
Supply, 2-17
Vent, 2-19
F
Control Mode, 4-5
Factory Default Settings, Initial Setup, 3-3
Control System Requirements
Compliance Voltage, 2-28 Factory Settings, Restoring, 5-11
HART Filter, 2-26 Feedback Connection, 4-22
Voltage Available, 2-27
Firmware Revision, 6-8
CSA
Hazardous Area Classifications, 1-6, 1-8 FM
Loop Schematic, B-3 Hazardous Area Classifications, 1-6, 1-9
Loop Schematics, B-2 Loop Schematic, B-4, B-5
Nameplates, B-2, B-3 Nameplates, B-4, B-5
Special Conditions of Safe Use, 2-4 Special Conditions of Safe Use, 2-4

Cycle Count, 4-17 Free Time, Self Test Failure, enabling to

cause instrument shutdown, 4-15
Cycle Counter
Displaying Value, 6-7
Index Enabling Alert, 4-17
Resetting, 4-17
G
Gauges, Tire Valves, & Pipe Plugs
Parts List, 8-5
D Replacing, 7-7

Date, 4-20, 4-21

DD Information, 6-9 H
Define Custom Characteristic, 4-12 Hardware Revision, 6-8
G Description, DVC6000 Series, 1-3 HART Communicating, (HC), 6-8
Descriptor, 4-20 HART Filter, Part Numbers, 8-6
Detailed Setup, 4-4 HART Tag, 4-19

Index-2 December 2009

 Index
HART Tri-Loop, Configuring DVC6000 for use Lead/Lag, 4-13
with, 2-29 typical filter settings, 4-14
Hazardous Area Approvals, 2-4 Loop Current, checking, 7-15
HC, (HART Communicating), 6-8 Loop Schematic
CSA, B-3
FM, B-4, B-5
IECEx, B-9, B-10
I Loop Schematics, CSA, B-2
I/P Converter
Parts List, 8-4
Removing, 7-5 M
Replacing, 7-6
Replacing Filter, 7-5 Manual Calibrate Travel, 5-4

IECEx Manual Conventions, 1-2

Conditions of Certification, 2-4 Manufacturer, 4-21
Hazardous Area Classifications, 1-6, 1-11
Maximum Output Capacity, 1-5
Loop Schematic, B-9, B-10
Nameplates, B-9, B-10 Maximum Supply Pressure, 4-21
Initial Setup, 3-2 Message, 4-19
INMETRO Minimum Differential Pressure, setting
Hazardous Area Classifications, 1-6, 1-11 manually, 4-23
Nameplates, B-11 Minimum Partial Stroke Pressure, setting
Special Conditions of Safe Use, 2-5 manually, 4-23
Input Characterization, 4-12 Module Base
Removal, 7-3
Input Range, 4-20 Replacing, 7-4
Installation, 2-3 Module Base, Parts List, 8-4
Instrument Clock, Setting, 4-19 Module Base Maintenance, 7-3
Instrument Date and Time, 4-21 Mounting, 2-5
Instrument Level, 6-9 67CFR, 2-17
capabilities, 1-2 DVC6005 base unit, 2-13
Pipestand, 2-13
Instrument Mode, 3-2, 4-4 Wall, 2-13
DVC6010, 2-5
Instrument Serial Number, 4-20
DVC6015, 2-13
Instrument Status, 6-4 DVC6020, 2-8
Index
Viewing, 6-4 DVC6025, 2-14
DVC6030, 2-10
Integral Action, Enable Integral Settings, 4-8
DVC6035, 2-15
Integral Dead Zone, 4-19
Integral Limit, 4-9
Integral Settings, 4-9
N
Nameplates
Internal Temperature, Displaying Value, 6-7
ATEX, B-6, B-7, B-8
CSA, B-2, B-3

L
FM, B-4, B-5
IECEx, B-9, B-10
G
INMETRO, B-11
Lag Time, 4-13 NEPSI, B-11

December 2009 Index-3

 DVC6000 Digital Valve Controllers
NEPSI Parts List, 8-4
Hazardous Area Classifications, 1-6, 1-11 Removing, 7-7
Nameplates, B-11 Replacing, 7-7
Notes for Safe Use of the Certified Product,
Polling Address, 4-20
2-5
Pressure Control, 4-11
Number of Power Ups, Displaying Status, 6-8
Pressure Sensor Calibration, 5-6
Pressure Set Point, 4-12
O Pressure Tuning Sets, Gain Values, 4-9
ODV, (Optimized Digital Valve), 6-8 Pressure Units, 4-20
Optimized Digital Valve, (ODV), 6-8 Principle of Operation
DVC6000, A-2
Output Pressure, Displaying Value, 6-7
HART Communication, A-2
Printed Wiring Board Assembly
P Parts List, 8-5
Removing, 7-6
Parameters, Factory Default, Detailed Setup, Replacing, 7-7
4-4 Setting DIP Switch, 7-7
Partial Stroke, 4-22 Protection, 3-2, 4-5
Partial Stroke Test, 6-5
Configuring
Minimum Differential Pressure, 4-23 R
Partial Stroke Pressure Limit, 4-23
Raw Travel Input, Displaying Status, 6-8
Partial Stroke Tvl, 4-22
Pause Time, 4-22 Related Documents, 1-3
Stroke Speed, 4-22
Relay
Initiating, 6-5
Double-Acting, 5-10
Device (Digital Valve Controller), 6-5
Single-Acting Direct, 5-11
Field Communicator, 6-6
Single-Acting Reverse, 5-11
Remote Push Button, 6-5
Local DI, 6-5 Relay A, 5-10
Local Push Button, 6-5 Relay Adjustment, 5-10
Parts Double-Acting, 5-10
Common Parts, 8-3 Relay B, 5-11
Feedback Parts, 8-5
Gauges, Tire Valves, & Pipe Plugs, 8-5 Relay C, 5-11
Index HART Filters, 8-6 Relay Type, 4-20
I/P Converter Assembly, 8-4
Kits, 8-2 Remote Travel Sensor Connections, 2-22
Module Base, 8-4 Using a 10 kOhm External Potentiometer
as, 2-23
Ordering, 8-2
Using a Two-Resistor Series as, 2-24
Printed Wiring Board Assembly, 8-5
Using the DVC6015, DVC6025 and
Relay, 8-4
DVC6035 Feedback unit as, 2-22
Terminal Box, 8-4
reset, 4-11
PD, (Performance Diagnostics), 6-8
Restart Control Mode, 4-5
Performance Diagnostics, (PD), 6-8
G Performance Tuner, 3-4, 4-9
Revision Information, DVC6000
Device, 6-8
Pneumatic Relay Firmware, 6-8
Adjusting, 5-10 Hardware, 6-8

Index-4 December 2009

 Index
HART Universal, 6-9 Terminal Box
Parts List, 8-4
Run Time, Displaying Status, 6-8
Removing, 7-8
Replacing, 7-8
TEST Terminals, 7-15
S
Third-Party Approvals, 2-4
Serial Number Touch-Up Travel Calibration, 5-6
Instrument, 4-20
Valve, 4-20, 4-21 Travel, Displaying Value, 6-7

Set Point Rate Close, 4-13 Travel / Pressure Control, 4-11

Cutoffs, 4-11
Set Point Rate Open, 4-12 End Point Pressure Control, 4-12
Setup Wizard, 3-2 Limits, 4-11
Pressure Control, 4-11
SIS, Pressure Mode Enable, 4-12
Travel Accumulation Alert Enable, 4-17
SIS Alerts, 4-18
Travel Accumulator
Solenoid Valve Testing, 2-19 Displaying Value, 6-8
special application, 2-19 Enabling Alert, 4-17
Resetting, 4-18
Special Instructions for Safe Use and
Travel Accumulator Alerts, 4-17
Installations in Hazardous Locations, 2-4
ATEX Flameproof, Dust, 2-4 Travel Cutoff Alerts, 4-16
ATEX Intrinsic Safety, Dust, 2-4 Travel Cutoffs, 4-11
ATEX Type n, Dust, 2-4
CSA, 2-4 Travel Deviation Alert, 4-15
FM, 2-4 Travel History Alerts, 4-17
IECEx Intrinsic Safety, Type n, Flameproof,
travel indicator, 2-10
2-4
INMETRO, 2-5 Travel Limits, 4-17
Specifications, 1-3 Travel Sensor
Adjusting
Stabilize/Optimize, 3-4, 4-8 DVC6010, 5-7
Status, 4-19 DVC6015, 5-7
Calibration & Diagnostics, 4-19 DVC6020, 5-8
Instrument Time, 4-19 DVC6025, 5-8
Integrator, 4-19 DVC6030, 5-7
Operational, 4-19 DVC6035, 5-7
Parts List, 8-5
Steady-State Air Consumption, 1-5 Removing
Index
Stroke Valve, 6-4 DVC6010, 7-9
DVC6015, 7-9
Stroking the Output, with Field Communicator, DVC6020, 7-9
6-4
DVC6025, 7-9
Supply Pressure, 1-5 DVC6030, 7-10
Displaying Value, 6-7 DVC6035, 7-10
Replacing
DVC6010, 7-10
T DVC6015, 7-10
DVC6020, 7-12
DVC6025, 7-12
Temperature
Maximum Recorded, Displaying Value, 6-7 DVC6030, 7-13 G
Minimum Recorded, Displaying Value, 6-7 DVC6035, 7-13
Units, 4-20 Travel Sensor Adjust, 5-7

December 2009 Index-5

 DVC6000 Digital Valve Controllers
Travel Sensor Motion, 4-21 Valve Style, 4-21
Travel Target, Displaying Value, 6-7 Voltage Available
Travel Tuning Sets, Gain Values, 4-6 Calculating, 2-27
Checking, 7-14
Troubleshooting, Instrument, 7-14
Tuning, 4-6
Pressure, 4-9
Travel, 4-6 W
Tuning Sets
Wiring Length Guidelines, Auxiliary Terminal ,
Pressure, 4-9
6-5
Gain Values, 4-9
Travel, 4-6 Wiring Practices
Gain Values, 4-6 Communication Cable Capacitance, 2-29
Control System Requirements, 2-26
Compliance Voltage, 2-28
U HART Filter, 2-26
Voltage Available, 2-27
Upper Operating Pressure, 4-12

V Z
Valve Serial Number, 4-20, 4-21 Zero Power Condition, 4-21

Index

Index-6 December 2009

Fisher, FIELDVUE, AMS, ValveLink, PlantWeb, PROVOX, Rosemount, Tri-Loop, DeltaV, RS3 and THUM are marks owned by one of the
companies in the Emerson Process Management business division of Emerson Electric Co. Emerson Process Management, Emerson, and the
Emerson logo are trademarks and service marks of Emerson Electric Co. HART is a mark owned by the HART Comunication Foundation. All
other marks are the property of their respective owners. This product may be covered under one or more of the following patents (5,163, 463;
5,265,637; 5,381,817; 5,434,774; 5,439,021; 5,451,923; 5,502,999; 5,532,925; 5,533,544; 5,549,137; 5,558,115; 5,573,032; 5,687,098) or under
pending patents.
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy,
they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or
applicability. All sales are governed by our terms and conditions, which are available upon request. We reserve the right to modify or improve the
designs or specifications of such products at any time without notice. Neither Emerson, Emerson Process Management, nor any of their affiliated
entities assumes responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use, and maintenance of
any product remains solely with the purchaser and end user.
Emerson Process Management
Marshalltown, Iowa 50158 USA
Sorocaba, 18087 Brazil
Chatham, Kent ME4 4QZ UK
Dubai, United Arab Emirates
Singapore 128461 Singapore
www.Fisher.com

Fisher Controls International LLC 2001, 2009; All Rights Reserved

1
OPERATING AND MAINTENANCE INSTRUCTIONS
HILCO FILTER MODEL 310 SERIES FILTERS
1.0 INSTALLATION & START-UP
1.1 Read these instructions carefully before installing. operating or
servicing the filter. Refer to Assembly Drawing (DD-617-3 for
standard models) . .
1.2 Upon receipt of the filter, inspect for shipping damage. If
filter is damaged, notify carrier immediately.
1.3 Remove 3/8" cap screws securing the cover to the casing. Remove
the casing with the head up. Inspect for the correct cartridge.
To replace the casing with the cartridge, refer to paragraph 3.0.
1.4 After the housing is reassembled and the cap screws are
tightened, locate the filter so there is adequate clearance to
remove casing and cartridge. Refer to Assembly drawing (DD-617-3
for standard models).
NOTE: If there are any questions regarding the piping system
configuration, contact your HILCO representative.
1.5 Install filter housing in process line. Line size should be
sufficiently large to handle the rated fluid flow without
excessive pressure drop. All piping connections must be clean.
NOTE: If the filter is being installed without shut-off valves
on inlet, it must be located above the highest oil level
in the system.
1.6 Remove all air from the filter during filling by opening the vent
line or bleeding the air at a higher elevation. Close the vent
line when fluid appears.

2.0 WHEN TO CHANGE OUT FILTER CARTRIDGES

2.1 Filter cartridges should be changed out when the differential
pressure across the cartridge reaches 20-25 psi above the start-
up differential pressure or every twelve months, whichever occurs
first.
2.2 A periodic analysis of fluid condition should be used to
determine cartridge changing intervals in critical applications.

3.0 HOW TO CHANGE FILTER CARTRIDGES

NOTE: Handle all filter components with care to prevent f16']
detrimental damage to sealing surfaces. 00
.?

Revision Level: B 2501-00-107-A

2 1 9
Date of Revision: August 7, 1995 Issue Date: E?!&03 9
I
 3.1 If no bypass line is installed, stop equipment, shut down pump
and close inlet and outlet valves, if installed. If a bypass is
installed, open bypass line and close inlet valve to filter.
(This can be accomplished with a single three way valve.) Close
outlet valve.
3.2 Open filter drain and bleed off all pressure. When pressure is
relieved, remove vent plug.
3.3 Loosen cover bolts and remove casing. Casing has an O-ring seal
and must be pulled off straight. Retain the old cartridge in the
casing until it is removed. Be careful not to nick or scratch
the centerpost in the head.

3 . 4 Inspect the cover O-ring. If it is hard or damaged, discard.

Lubricate the O-ring with a grease compatible with the process
fluid.
3.5 Remove the cartridge from the housing and discard. Inspect the
sealing surface of the housing, checking for scratches or nicks.
If the new cartridge has O-rings, lubricate them with a grease
compatible with the process fluid. Install the new cartridge in
the casing, over the centerpost at the bottom.
3.6 Align the top of the cartridge with the center post in the head
and install the casing. Use care when bringing the head and
casing together to avoid damaging the sealing surfaces. Do not
force casing or pinch O-ring during installation. Once the
casing is secured against the head, line up the bolt holes and
start the 3/8" cap screws.
3.7 Torque the cap screws to 10-12 ft.lbs.

3.8 Reinstall drain and vent plugs.

3.9 Open inlet and outlet valves (if installed).

3.10 Close bypass valve (if applicable). For systems without bypass
installed; restart equipment and/or pump.
3.11 Remove all air from filter by loosening the vent plug.

I
I 4.0 PERIODIC SERVICE

4.1 Depending on the system design, it may be necessary to bleed off

trapped air periodically. This applies to arrangements where the
filter is at the highest point in the system.

Revision Level: B 2501-00-107-A

Date of Revision: August 7 , 1 9 9 5 Issue Date: May 2, 1 9 9 4
Page 2 of 2
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I I 1
I I I I
I
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DESCRIPTION I
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1
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1
I I
I I
I I
I 114 FNPT VENT 1
I CONNECTION I
I ( PLUGGED ) I
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I 1/4-20 UNC-2B MOUNTING HOLES I
NOTES
MAXIHUM WORKING PRESSURE - 250 PSI (17.2 EAR)
I TWO EACH SIDE I
I. I
MAXIMUM WORKING TEMPERATURE - 250 'F (121 " C )
I
I
2. I
I 3 . FILTER CARTRIDGES AS SPECIFIED ON DROER. I

-
I 4 . SEE 2501-00-107-A FOR OPERATING INSTRUCTIONS. I
I
I 5 . MATERIAL SPECIFICATIONS: I
I MODEL 01310 - CARBON STEEL. I
I MODEL 21310 - 304L ANOAR 304 STAINLESS STEEL I
I
OUTLET 6. TO COMPLY WITH OSHA STANDARDS, 00 NOT USE THIS I
I
NOTE 9 VESSEL FOR L I W I O S HEATED ABOVE THEIR FLASH I
I POINT OR HAVING A FLASH POINT BELOW 200 'F (931 'C). I
I 7 . VESSELS CAN HOUSE EITHER HILCO FLAT GASKET (-C 1 OR I
I O-RING ( -CG 1 STYLE CARTRIDGES. I
I E . BUM-N GASKETS STANDARD. OPTIONAL VITON GASKETS I
I I
AVAILABLE.
I I
I
9. 3/4' FNPT OR I' FNPT INLETmLlTLET CONNECTION TO BE
I
I
SPECIFIED ON ORDER. I
I
10. REMOVABLE CENTERTUBE FOR THO CARTRIDGE HOUSINGS ONLY. I
I I
I I
I I
I I
I I
I I
I I
I THE HILLIARD'CORPORATI[N I
I I
I
100 VEST FOllRTH STREET
WD I&' IRAIN CW. I
I ELMIRA, MY YORK 14902 I
I TELEPHONE : 607-733-7I21 I
I I
I I
I I
I I
I 1/2' FNPT HALF CPLG. Y CLEARME REO 0. I
I DRAIN CONNECTION FE CARTPIOGE &IOVK I
I 1 I
I I
I
- - - - - - A
 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000176901 001 LEAK-OFF PIPING AND STEAM SEAL ASSY

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 4R7598-1 LEAK-OFF PIPING AND STEAM SEAL 1 EA

1 1 5210361 PIPE 1/2 S80 SMLS A106 GR B 0 FT

2 1 5210362 PIPE 3/4 S80 SMLS A106 GR B 0 FT

3 1 5210363 PIPE 1 S80 SMLS A106 GR B 0 FT

4 1 5210365 PIPE 1 1/2 S80 SMLS A106 GRB 0 FT

5 1 5210316 PIPE 2 S40 SMLS A106 GR B 0 FT

6 1 1A5724-4 ELL 1/2 THD 3000# 90DEG 2 EA

7 1 1A2653-4 PIPE PLUG ROUND 1/2 304 SST 0 EA

8 1 1A5725-5 ELL 3/4 SW S80 3000# 90DEG 4 EA

9 1 1A5725-6 ELL 1 SW S80 3000# 90DEG 11 EA

10 1 1A5725-8 ELL 1-1/2 SW S80 3000# 90 DEG 5 EA

11 1 1A5725-9 ELL 2 SW S80 3000# 90DEG 3 EA

12 1 1A5762-5 TEE 1 SW S80 3000# 3 EA

13 1 1A5762-7 TEE 1-1/2 SW S80 3000# 2 EA

14 1 1A5762-8 TEE 2 SW S80 3000# 2 EA

15 1 1A15479-1 3000# THD OUTLET 1/2 NPT x 3/4 -36 STL 2 EA

16 1 1A5743-7 BUSHING HEX 3/4 X 1/2 1 EA

17 1 1A5820-4 REDUCER 1 X 3/4 SW S80 T1 2 EA

18 1 1A5799-4 COUPLET 3/4 SW 2 EA

19 1 1A5812-5 REDUCER 1-1/2 X 1 SW 80 T2 2 EA

20 1 1A5819-11 REDUCER 2 X 3/4 SW 80 T3 2 EA

21 1 1A5799-5 COUPLET 1 SW 3000# MAX 1 EA

22 1 1A5812-6 REDUCER 2 X 1-1/2 SW S80 T2 1 EA

23 1 1A5819-20 REDUCER 3 X 3/4 SW S80 T3 1 EA

24 1 1-6205-19 ADAPTER 1 EA

25 1 1-6205-132 ADAPTER 1 EA

© 2011 DRESSER-RAND COMPANY 1000176901 Page 1 of 3

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000176901 001 LEAK-OFF PIPING AND STEAM SEAL ASSY

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

26 1 3A1973-26 FLANGE 3/4 SW S80 150# 10 EA

27 1 1S428-14 GARLOCK GRAPHONIC G-150# STANDARD 0 EA

28 1 1S568-6 CAPSCRW HEX HD 1/2 X 1-3/4 0 EA

29 1 1S563-7 LOCKWASHER 0 EA

30 1 1S304-5 HEX NUT 1/2 13 GR 2H 0 EA

31 1 3A1973-27 FLANGE 1 SW S80 150# 18 EA

32 1 1S428-15 GARLOCK GRAPHONIC G-150# STANDARD 0 EA

33 1 1S568-7 CAPSCRW HEX HD 1/2 X 2 0 EA

34 1 3A1973-29 FLANGE 1-1/2 SW 150# S80 STL 10 EA

35 1 1S428-16 GARLOCK GRAPHONIC G-150# STANDARD 0 EA

36 1 1S568-8 CAPSCRW HEX HD 1/2 X 2-1/4 0 EA

37 1 3A0906-30 FLANGE 2 SW S40 150# 9 EA

38 1 1S428-28 GARLOCK GRAPHONIC G-150# STANDARD 0 EA

39 1 1S570-7 CAPSCREW HEX HD 0 EA

40 1 1S563-9 LOCKWASHER 0 EA

41 1 1S304-7 HEX NUT 5/8 11 GR 2H 0 EA

42 1 1S570-4 CAPSCRW HEX HD 5/8 X 1-3/4 0 EA

43 1 3A0906-32 FLANGE 3 SW S40 150# 1 EA

44 1 1S428-32 GARLOCK GRAPHONIC G-150# STANDARD 0 EA

45 1 1S570-5 CAPSCRW HEX HD 5/8 X 2 0 EA

46 1 3A1976-29 FLANGE 1 SW S80 300# 6 EA

47 1 1S428-26 GARLOCK GRAPHONIC G-300# STANDARD 0 EA

48 1 1S570-6 CAPSCRW HEX HD 5/8 X 2-1/4 0 EA

49 1 1A16196-1 3/4 INCH BAUMANN CONTROL VALVE ASSEMBLY 1 EA

50 1 1A16197-1 3/4 INCH BAUMANN CONTROL VALVE ASSEMBLY 1 EA

51 1 1A16199-1 1-1/2 INCH BAUMANN CONTROL VALVE ASSEMBLY 1 EA

© 2011 DRESSER-RAND COMPANY 1000176901 Page 2 of 3

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000176901 001 LEAK-OFF PIPING AND STEAM SEAL ASSY

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

52 1 1A10927-18 CROSBY SERIES 900 PRESSURE RELIEF VALVE 1 EA

53 1 1A16198-1 3/4 INCH BAUMANN CONTROL VALVE ASSEMBLY 1 EA

© 2011 DRESSER-RAND COMPANY 1000176901 Page 3 of 3

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000177406 001 AIR PURGE PIPING

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 2A2801-1 AIR PURGE PIPING ASSEMBLY 1 EA

1 1 7030259 TUBING 1/4OD X .035 HYD SST 1 FT

2 1 7030261 TUBING 1/2 X .065 316 SST 1 FT

3 1 1A10385-19 SWAGELOK MALE CONNECTOR 1/4 T X 1/16 NPT 3 EA

316 SST

4 1 1A11555-6 TEE 1/2 UNION PARKER TUBE SST 4 EA

5 1 1A5597-5 MALE CONN 1/4 T-1/4 NPT 1 EA

6 1 1A5597-14 MALE CONN 1/2 T-1/4 NPT 5 EA

7 1 1A10280-11 FEMALE CONN 1/2 T-1/2 NPT 1 EA

8 1 1A11555-3 TEE 1/4 UNION TUBE SIZE 2 EA

9 1 1A11793-1 FISHER PRESSURE REGULATOR 1 EA

10 1 1A11838-1 MOUNTING PLATE AIR PURGE REGUL 1 EA

11 1 1S565-16 CAPSCREW HEX HD 2 EA

12 1 1S564-1 CAPSCRW HEX HD 1/4-20 X 1/2 2 EA

13 1 1S304-2 HEX NUT 5/16 18 GR 2H 2 EA

© 2011 DRESSER-RAND COMPANY 1000177406 Page 1 of 1

 Lubricating Oil Recommendations

The following listing is a collection of recommended oil for use in Dresser-Rand supplied
equipment. This is not an all-inclusive list and therefore should not be viewed as such. The
basic turbine and gear oil for new units is a #32 which should exhibit an average viscosity of
162 SSU @ 100˚ F. For turbines with speed reduction gears (prior to Serial Number 5070)
the oil is a #68 which has an average viscosity of 319 SSU @ 100˚ F. If there are any doubts
about a particular oil for turbine use, consult the Customer Service Department at Dresser-
Rand.

Turbine Oil Data

Company Oil Type
#32 #68

Amoco American Industrial Oil #32 American Industrial Oil #68

BP Oil, Inc. Energol HL 32 Energol HL 68
CITGO Pacemaker T-32 Pacemaker T-68
ConocoPhillips Syncon R&O 32 Syncon R&O 68
Exxon Teresstic 32 Teresstic 68
Lubrication Engineers, Inc. 6401 Monolec 6403 Monolec
Mobil DTE Light DTE Heavy Medium
Pennzoil R&O 32 R&O 68
Phillips 66 Magnus 32 Magnus 68
Shell Turbo 32 Turbo 68
Sun Refining Sunvis 916 Sunvis 931
Texaco Regal R&O 32 Regal R&O 68
Texas Refinery TRC Hyd. 10 TRC Hyd. 68
ConocoPhillips Turbine Oil 32 Turbine Oil 68
ConocoPhilips Multipurpose
R&O Turbine Oil 32 Turbine Oil 68
ConocoPhillips Hydroclear Diamond Class Turbine Oil 32 Diamond Class Turbine Oil 68
76 Lubricants Turbine Oil 32 Turbine Oil 68
76 Lubricants Turbine Oil XD 32 Turbine Oil XD 68

Revised 06/16/2008

D-5678
 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

OA28981 001 PROBE ADAPTERS OA28981

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 2A2462-1 PROBE ADAPTER ASSEMBLY 1 EA

1 1 3A4438-1 PROBE ADAPTER 4 EA

2 1 1J8011-19 O RING 4 EA

3 1 1S228-4 CAPSCRW SOC HD 3/8-16 X 7/8 10 EA

4 1 3A4439-1 PROBE ADAPTER 1 EA

5 1 1J8011-16 O RING 1-3/8 X 1-1/8 1 EA

© 2011 DRESSER-RAND COMPANY Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000169299 001 R.T.D.'S & ACCESSORIES

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 4A7443-1 R.T.D.'S & ACCESSORIES ASSEMBLY 1 EA

1 1 1A15577-1 MINCO CABLE SEAL 3 EA

2 1 1A5731-5 PIPE CPLG 3/4 THD 3000# 2 EA

3 1 5210362 PIPE 3/4 S80 SMLS A106 GR B 1 FT

© 2011 DRESSER-RAND COMPANY 1000169299 Page 1 of 1

 OPERATING LIMITS

VIBRATION (mils) ALARM TRIP

TURBINE RADIAL BEARINGS 1.25 X 12,000 3.0

MAX RPM

TURBINE THRUST (FROM MID SPAN) 10.0 15.0

GEAR RADIAL H.S 2.5 5.0
L.S. 3.5 6.0
GENERATOR RADIAL 3.0 6.0
TEMPERATURE (˚F)
TURBINE BEARING RTD’S OR TC’S 210 220
GEAR BEARING RTD’S OR TC’S 210 225
GENERATOR BEARING RTD’S OR TC’S 180 190
GENERATOR STATOR RTD’S OR TC’S * *

*REFER TO GENERATOR NAMEPLATE WHICH WILL INDICATE

THE TEMPERATURE RISE ABOVE AMBIENT TEMPERATURE.
SET THE ALARM AT TEMPERATURE RISE + AMBIENT AND THE
TRIP AT +5˚F. ABOVE ALARM.

THE ABOVE BEARING TEMPERATURE LIMITS ARE MAXIMUM VALUES. THE

ACTUAL VALUES SET IN THE INSTRUMENT SHOULD BE DETERMINED ONCE
THE UNIT IS AT FULL LOAD, STEADY STATE CONDITIONS. THE ALARM SHOULD
BE SET 15˚F. OVER NORMAL AND TRIP 10˚F. ABOVE ALARM.

LUBE SYSTEM
PRESSURE (PSIG) NORMAL ALARM TRIP
LUBE OIL 15 7 6
CONTROL OIL 85-100 80 70
FILTER DIFERENTIAL 0-15 20 25
AUXILIARY OIL PUMP START 8 PSIG

TEMPERATURE (˚F) NORMAL ALARM TRIP

OIL DRAIN 130-150 155 165
OIL SUPPLY 120 130 135

Rev. 28AUG08

E-1071
 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

OA11323 001 STATIC BRUSH OA11323

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

0 1 2A1020-1 STATIC BRUSH ASSY 0 EA

1 1 1A4743-1 STATIC BRUSH 1 EA

2 1 1A4750-1 BRUSH SCREW 1 EA

3 1 3A2902-2 SPRING 1 EA

4 1 3A1718-1 BRUSH HOUSING 1 EA

© 2011 DRESSER-RAND COMPANY OA11323 Page 1 of 1

 8 7 6 5 4 3 2 1

D D

NOTE!
THIS IS THE APPROXIMATE
LOCATION. EXACT LOCATION
TO BE DETERMINED ON ASSEMBLY.
CL TURBINE

6.4
.250 4
3
C C

5
B 1 B
2
2X #15 (0.180")(4.6mm) .375 (9.5mm)
FOR #10 SELF TAPPING MACHINE
SCREWS ON ASSEMBY WITH
EXHAUST BEARING CASE COVER.

UNLESS OTHERWISE SPECIFIED:

BOM - OA11323 NAME DATE

DRAWN RLJ 1973-07-11

SERIAL -4711 ALL DIMENSIONS STEAM TURBINE BUSINESS UNIT
ARE IN INCHES CHECKED RHS 1973-07-17 Burlington, Iowa, USA
REF - 2A0791
A APPROVED MH 1973-07-17 A
TOLERANCES PER
1S101 UNLESS
SW MODEL: 2A01020
M:\SolidworksFiles\Misc\2A\
STATIC BRUSH
LAST SAVED BY: jlionberger
DATE: Monday, October 03, 2011 2:59:36 PM
OTHERWISE
SPECIFIED
PROPRIETARY AND CONFIDENTIAL ASSEMBLY
THIS DRAWING CONTAINS
MATERIAL CONFIDENTIAL AND TRADE DRAWING NUMBER REV

2A1020 2
REVISIONS ------ SECRET INFORMATION AND IS THE
PROPERTY OF DRESSER-RAND COMPANY

B
REV. DATE SIZE FINISH AND IS PROVIDED TO THE
1 2003-07-09 RECEIVER IN CONFIDENCE.
------ SCALE: 2:1 WEIGHT: 0.27 SHEET 1 OF 1
2 2011-09-29
8 7 6 5 4 3 2 1
 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000170336 001 MATING FLANGES

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

1 1 3A1993-15 FLANGE 1 WN S40 150# 304SST 2 EA

2 1 3A1950-19 GASKET 1 X 1/16 2 EA

3 1 1S657-7 CAPSCREW HEX HD 8 EA

4 1 1S655-5 HEX NUT 1/2 13 316 SST 8 EA

5 1 1S662-7 LOCKWASHER SST 1/2 8 EA

6 1 3A1993-24 FLANGE 6 WM S40 150# 304SST 1 EA

7 1 3A1950-34 GASKET 1 EA

8 1 1S660-9 CAPSCREW HEX HEAD 8 EA

9 1 1S655-8 HEX NUT 8 EA

10 1 1S662-9 LOCKWASHER SST 5/8 12 EA

11 1 3A1993-18 FLANGE 2 WN S40 150# 304SST 1 EA

12 1 3A1950-25 GASKET 2 X 1/16 1 EA

13 1 1S658-7 CAPSCREW HEX HD 4 EA

14 1 1S655-7 HEX NUT 5/8 11 316 SST 4 EA

15 1 3A1976-29 FLANGE 1 SW S80 300# 2 EA

16 1 1S428-26 GARLOCK GRAPHONIC G-300# STANDARD 2 EA

17 1 1S573-10 CAPSCRW HEX HD 1 X 5-1/2 8 EA

18 1 1S304-10 HEXNUT 110 EA

19 1 1S563-15 LOCKWASHER 1 HELICAL SPRING 8 EA

20 1 3A1973-26 FLANGE 3/4 SW S80 150# 2 EA

21 1 1S428-14 GARLOCK GRAPHONIC G-150# STANDARD 2 EA

22 1 1S568-6 CAPSCRW HEX HD 1/2 X 1-3/4 8 EA

23 1 1S304-5 HEX NUT 1/2 13 GR 2H 12 EA

24 1 1S563-7 LOCKWASHER 12 EA

25 1 3A1973-30 FLANGE 2 SW S80 150# 1 EA

26 1 1S428-28 GARLOCK GRAPHONIC G-150# STANDARD 1 EA

© 2011 DRESSER-RAND COMPANY 1000170336 Page 1 of 2

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000170336 001 MATING FLANGES

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

27 1 1S570-7 CAPSCREW HEX HD 4 EA

28 1 1S304-7 HEX NUT 5/8 11 GR 2H 4 EA

29 1 1S563-9 LOCKWASHER 4 EA

30 1 3A1973-27 FLANGE 1 SW S80 150# 2 EA

31 1 1S428-15 GARLOCK GRAPHONIC G-150# STANDARD 2 EA

32 1 1S568-7 CAPSCRW HEX HD 1/2 X 2 8 EA

33 1 1A14682-1 EXHAUST GASKET 2 EA

34 1 1S187-35 STUD 1 8 X 4-7/8 COARSE 102 EA

35 1 1S643-5 WASHER-HARDENED 102 EA

© 2011 DRESSER-RAND COMPANY 1000170336 Page 2 of 2

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

BUR5955ACC 001 ACCESSORIES (NOT ON BILL OF MATERIAL)

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

1 1A13237-1 SENTINEL WARNING VALVE SET @ 5# 1 EA

1 8R10594-1 TURBINE OUTLINE BUR5955 1 EA

.2 NOMATERIAL NO MATERIAL REQUIRED 1 EA

1 1A11304-1 HILCO FILTER ELEMENT 1 EA

1 1A13367-3 LP1840 PRIMER 1000 DEG GRAY 1 EA

1 1A10377-1 WOODWARD TM-25LP ACTUATOR 1 EA

1 1A13367-33 PAINT, SILICONE ALUMINUM 9 EA

1 1A13424-23 PAINT - SPRAY CAN 10 EA

1 6R10294-1 SHIPPING SKID 1 EA

1 1000172098 HIGH SPEED ROTOR BALANCE 1 EA

1 1A16819-1 NAMEPLATE DATA ENGLISH 1 EA

.2 1A15708-1 NAMEPLATE - STANDARD (TEST DATA) 1 EA

1 1A16820-1 NAMEPLATE DATA METRIC 1 EA

.2 1A15708-1 NAMEPLATE - STANDARD (TEST DATA) 1 EA

1 4A7843-1 WIRING DIAGRAM 1 EA

.2 NOMATERIAL NO MATERIAL REQUIRED 1 EA

1 4A7842-1 STEAM SYSTEM PID 1 EA

.2 NOMATERIAL NO MATERIAL REQUIRED 1 EA

1 4A7841-1 OIL SYSTEM PID 1 EA

.2 NOMATERIAL NO MATERIAL REQUIRED 1 EA

1 1A4239-1 ROTATION ARROW 1 EA

© 2011 DRESSER-RAND COMPANY BUR5955ACC Page 1 of 1

 Report Date: 25 October 2011
PARTS LIST

Assembly Item Rev Assembly Item Description Drawing/Illustration

1000206760 001 TURBINE SPARE PARTS BUR5955

Designator/Illus BOM Item Number Item Description Qty UOM

Number Level

1 1 TITE SEAL 1 PINT CAN OF TITE SEAL 1 EA

2 1 TURBO-SEAL TURBO-SEAL IGS P/N TURBO-RXQT 1 EA

3 1 1000184761 JOINT COMPOUND - QUART CAN 4010 NM 1 EA

© 2011 DRESSER-RAND COMPANY 1000206760 Page 1 of 1

Parts Express
Service for Steam Turbines

Dresser-Rand Parts Express is a parts fulfillment service for single-stage

For a complete listing of products and and multi-stage steam turbines manufactured in North America. It helps
services, visit us on the Internet at clients maintain reliability and efficiency throughout the life cycle of their
www.dresser-rand.com
equipment.
or contact one of the following
Dresser-Rand locations:
D-R keeps more than 1,000 steam turbine parts in stock. Within the United
Dresser-Rand
States, orders for such products are ready to ship within 24 hours. Orders
Corporate Headquarters
received from outside the U.S. are ready to ship within 48 to 72 hours
West8 Tower Suite 1000 (proper paperwork and shipping information must be provided).
10205 Westheimer Road
Houston, TX 77042 USA
Tel: (Int'l+1) 713-354-6100 Examples of frequently shipped parts are trip Genuine OEM Parts

Fax: (Int'l+1) 713-354-6110 valve components, throttle valve and trip lever
email: info@dresser-rand.com assembly items, bearings, carbon rings, springs,
steam and oil seals, and other wear parts. Each
Regional Headquarters
order is shipped in its entirety, unless otherwise
The Americas specified in writing by the client. 100’s of parts from
Dresser-Rand our shelf to your
shop in 24 hours.
West8 Tower Suite 1000
10205 Westheimer Road Placing Orders
Houston, TX 77042 USA
Tel: (Int'l+1) 713-354-6100
There are no special procedures required to place or receive Parts Express
Fax: (Int'l+1) 713-354-6110 orders. All parts, whether or not they are shipped through the Parts Express
service, can be contained in the same order. If an order contains express
European Served Areas (ESA) and non-express items, it will be shipped complete at the earliest availability
Dresser-Rand S.A.
31, Boulevard Winston Churchill
of all parts, unless the shipment contains back-ordered items or partial
Cedex 7013 shipment is authorized in writing by the client. Parts orders can be placed
Le Havre 76080 France through your local D-R representative or directly from a D-R product center.
Tel: (Int'l+33) 2-35-25-5225
Fax: (Int'l+33) 2-35-25-5366/5367
All parts orders require a serial number to identify the equipment and to
Asia Pacific ensure shipment of the correct parts. Model identification and serial number
Dresser-Rand Asia Pacific Sdn Bhd can be found on the nameplate of your turbine. Use the contact list below
Unit 8-1, 8th Floor,
to order directly from a product center; this will expedite your request for a
Bangunan Malaysian Re
17 Lorong Dungun, Damansara Heights quote (RFQ).
50490 Kuala Lumpur, Malaysia
Tel: (Int'l+60) 3-2093-6633
Fax: (Int'l+60) 3-2093-2622 Steam Turbine Parts Contact List
©2008 Dresser-Rand. Printed in U.S.A.
Turbine Type Model US and Canada International
This document comprises a general overview of Telephone / Fax
the products described herein. It is solely for
informational purposes, does not represent a Single-stage TF, RL, RLH, RLV 1-888-268-8726 +1-508-595-1700
warranty or guarantee of the information con- / 508-595-1788
tained herein, and is not to be construed as
an offer to sell or a solicitation to buy. Contact Single-stage SST 300, SST 1-800-828-2818 +1-585-596-3100
Dresser-Rand for detailed design and engineering
500, SST 700 / 585-593-5815
information suitable to your specific applications.
Dresser-Rand reserves the right to modify its prod- Multi-stage R, K, U 1-888-614-9168 +1-319-753-5431
ucts and related product information at any time
without prior notice.
/ 319-752-1616
Multi-stage S, TS, T 1-800-828-2818 +1-585-596-3100
Form 2172
/ 585-593-5815