This manual supplements the Quick Start Guide (D103556X012), offering detailed specifications, setup guidance, maintenance procedures, and replacement part information for the DVC6200.
Document Scope and Purpose
This instruction manual serves as a comprehensive resource, expanding upon the information provided in the DVC6200 Series Quick Start Guide (D103556X012). It’s designed to equip personnel with the knowledge necessary for successful installation, configuration, calibration, and ongoing maintenance of the DVC6200 Digital Valve Controller.
The scope encompasses detailed product specifications, reference materials crucial for advanced setup, and procedures for routine maintenance. Furthermore, it provides essential details regarding replacement parts, facilitating efficient repairs and minimizing downtime. This document is intended for qualified individuals responsible for the operation and upkeep of valve control systems.
It details how to utilize a HART communicator, Fisher ValveLink™ software, and ValveLink Mobile software for optimal performance. Proper adherence to the guidelines within ensures reliable and accurate valve control.
Relationship to Quick Start Guide (D103556X012)
This instruction manual is explicitly designed to complement, not replace, the DVC6200 Series Quick Start Guide (D103556X012) included with each instrument. The Quick Start Guide provides a streamlined, initial setup process, focusing on getting the controller operational quickly.
However, it lacks the in-depth detail required for comprehensive understanding, advanced configuration, troubleshooting, and long-term maintenance. This manual bridges that gap, offering a complete reference for all aspects of the DVC6200’s lifecycle.
Users should always begin with the Quick Start Guide for initial power-up and basic functionality, then refer to this manual for detailed procedures, specifications, and diagnostic information. Consider this manual the definitive guide for maximizing the DVC6200’s capabilities and ensuring sustained, reliable performance.
Target Audience & Required Training
This instruction manual is intended for qualified personnel responsible for the installation, operation, maintenance, and troubleshooting of Fisher DVC6200 Digital Valve Controllers. The primary audience includes instrumentation technicians, process control engineers, and maintenance staff working within industrial environments.
Prior to working with the DVC6200, individuals must receive comprehensive training regarding the maintenance, operation, and installation of valves, actuators, and associated accessories. A foundational understanding of process control principles, HART communication protocols, and valve technology is essential.
Specifically, personnel should be proficient in using a HART communicator and, optionally, Fisher ValveLink™ or ValveLink Mobile software for configuration and calibration. Proper training ensures safe and effective operation, minimizing the risk of damage or process disruption.
DVC6200 Product Overview
The DVC6200 is a digital valve controller offering key features and benefits for precise control in various applications, with series variations available.
Key Features and Benefits
The FIELDVUE DVC6200 digital valve controller boasts exceptional performance and reliability, providing advanced process control capabilities. Its key features include enhanced diagnostics, facilitating quicker troubleshooting and reduced downtime.
Users benefit from improved accuracy and responsiveness, leading to optimized process efficiency. The controller supports HART communication, enabling seamless integration into existing systems. Furthermore, it offers versatile configuration options via HART communicators, Fisher ValveLink™ software, and ValveLink Mobile software.
Advanced calibration features ensure precise control, while the robust design guarantees long-term durability even in harsh environments. The DVC6200’s intuitive display simplifies operation and provides real-time process information. Ultimately, these features translate to increased productivity, reduced costs, and enhanced safety for plant operations.
Intended Applications
The Fisher DVC6200 digital valve controller is ideally suited for a wide range of process control applications across diverse industries. It excels in demanding environments requiring precise and reliable valve control, including oil and gas, chemical processing, and power generation.
Specifically, it’s designed for use with rotary and linear actuators, effectively managing flow, pressure, and temperature in critical processes. The DVC6200 is particularly valuable in applications where advanced diagnostics and remote monitoring are essential for maintaining operational efficiency and safety.
Its robust construction and versatile communication protocols make it suitable for both new installations and retrofits, enhancing the performance of existing valve control systems. The controller’s adaptability ensures optimal performance in various process conditions and configurations.
DVC6200 Series Variations
The DVC6200 series encompasses several variations designed to meet specific application needs. Key distinctions include communication protocol support, with models available for HART, FOUNDATION fieldbus, and PROFIBUS PA. These options ensure seamless integration into existing control systems.
Furthermore, variations exist based on enclosure type, offering choices for standard, explosion-proof, and weatherproof environments. Specialized models, like the DVC6200f for FOUNDATION fieldbus, provide enhanced functionality tailored to that protocol.
The DVC6200 SIS safety instrumented system version is also available, designed for critical safety applications requiring high reliability and diagnostic coverage. Understanding these variations is crucial for selecting the appropriate controller for a given process and ensuring optimal performance and safety.
Installation Procedures
Proper installation involves mounting the controller, making correct wiring connections, and establishing reliable HART communication, following all safety guidelines carefully.
Mounting the DVC6200 Controller
Securely mounting the DVC6200 is crucial for optimal performance and longevity. Ensure the mounting surface is clean, flat, and rigid to prevent vibration and maintain accurate control. The controller can be mounted directly to the actuator using the provided mounting kit, or remotely using a suitable mounting bracket.
Pay close attention to orientation; the display should be easily visible for operation and diagnostics. Tighten mounting screws to the specified torque values to avoid over-tightening or loosening. Verify proper grounding to minimize electrical noise and ensure safety. Before mounting, inspect the controller for any physical damage.
Consider accessibility for future maintenance and calibration. Avoid mounting in locations exposed to extreme temperatures, corrosive environments, or excessive moisture. Proper mounting contributes significantly to the overall reliability and accuracy of the control system.
Wiring Requirements and Connections
Proper wiring is essential for reliable DVC6200 operation. Before commencing any wiring, ensure the power supply is disconnected to prevent electrical shock. Utilize appropriately sized wiring conforming to local and national electrical codes. The DVC6200 typically requires a 24 VDC power supply, though specific requirements vary by model.
Connections are made via a multi-conductor cable, adhering to the wiring diagram provided in the documentation. Pay close attention to polarity when connecting the power supply. HART communication utilizes the same wiring, superimposing a signal onto the 4-20 mA current loop.
Ensure all connections are secure and properly insulated to prevent shorts or signal interference. Grounding is critical for safety and noise reduction. Double-check all wiring before applying power, verifying correct connections and secure terminations. Incorrect wiring can damage the controller or compromise system performance.
HART Communication Setup
Establishing HART communication allows for remote configuration, monitoring, and diagnostics of the DVC6200. A standard HART communicator is required for initial setup and troubleshooting. Ensure the communicator is compatible with the DVC6200’s HART revision. Power up the controller and verify the 4-20 mA loop is active.
Connect the HART communicator to the appropriate terminals on the DVC6200, typically designated for HART access. Initiate a search on the communicator to identify the controller. Once identified, you can access device information, configuration parameters, and diagnostic data.
Proper termination resistors are crucial for reliable HART communication, especially over long distances. Refer to the documentation for specific resistor values. Configuration changes made via HART are immediately applied to the controller, so proceed with caution and document all modifications.
Configuration and Setup
The DVC6200 can be configured using a HART communicator, Fisher ValveLink™ software, or ValveLink Mobile software for streamlined setup and calibration.
Using a HART Communicator
A HART communicator provides a direct interface for configuring and calibrating the DVC6200 Digital Valve Controller. This method allows technicians to access all controller functions, including setting process variables, adjusting control parameters, and performing diagnostics, directly in the field.
To begin, establish communication between the HART communicator and the DVC6200 by connecting to the appropriate terminals. The communicator will then display the controller’s main menu, offering options for viewing device information, configuring operating parameters, and initiating calibration routines.
Navigating the menu structure is intuitive, allowing for precise adjustments to gain, range, and other critical settings. Detailed instructions within the communicator’s help files guide users through each step of the configuration process. Remember to save any changes made to ensure proper controller operation. Utilizing a HART communicator offers a robust and reliable method for initial setup and ongoing maintenance of the DVC6200.
Utilizing Fisher ValveLink™ Software
Fisher ValveLink™ software offers a powerful PC-based solution for advanced configuration, monitoring, and diagnostics of the DVC6200 Digital Valve Controller. This software provides a graphical user interface, simplifying complex tasks and enabling detailed analysis of controller performance.
Connecting the DVC6200 to a PC via a HART modem allows for comprehensive access to all controller parameters. ValveLink™ facilitates batch uploading of configurations, streamlining deployment across multiple devices. The software also features robust diagnostic capabilities, including trending of process variables and identification of potential issues.
Furthermore, ValveLink™ allows for creating and storing custom configurations, ensuring consistency and simplifying future maintenance. Detailed reports can be generated for documentation and analysis. Utilizing ValveLink™ enhances efficiency and provides a deeper understanding of the DVC6200’s operation, optimizing process control.
ValveLink Mobile Software Configuration
ValveLink Mobile software provides a convenient, portable solution for configuring and troubleshooting DVC6200 controllers directly in the field using a compatible mobile device. This application offers a streamlined interface for common tasks, eliminating the need for a laptop in many situations.
Connecting to the DVC6200 via a HART modem, ValveLink Mobile allows for quick access to key parameters and diagnostic information. Users can perform basic configuration changes, view process variables, and diagnose issues on-site. The software’s intuitive design simplifies navigation and reduces setup time.
ValveLink Mobile also supports creating and saving controller snapshots, facilitating easy restoration of previous configurations. This portability enhances maintenance efficiency and reduces downtime. Utilizing ValveLink Mobile empowers technicians with immediate access to critical information, optimizing field operations and improving overall process reliability.
Calibration Procedures
The DVC6200 requires careful calibration for optimal performance; procedures range from basic steps to advanced options, with verification essential for accuracy.
Basic Calibration Steps
Initiating the basic calibration process for the DVC6200 typically involves utilizing a HART communicator, Fisher ValveLink™ software, or the ValveLink Mobile application. Before commencing, ensure the valve and controller are properly installed and connected, with stable process conditions.
The initial step usually focuses on zero and span calibration. Zero calibration establishes the controller’s understanding of the lowest expected input signal, while span calibration defines the highest. This is achieved by applying known input signals (e.g., 4mA and 20mA) and adjusting the controller’s parameters accordingly.
Carefully follow the on-screen prompts or communicator instructions, verifying each step before proceeding. Accurate calibration is crucial for precise valve positioning and process control. Document all calibration settings for future reference and troubleshooting purposes; Regularly reviewing and recalibrating ensures continued optimal performance.
Advanced Calibration Options
Beyond basic zero and span calibration, the DVC6200 offers advanced features for fine-tuning performance. These include dynamic calibration, which accounts for valve stiction and hysteresis, improving responsiveness. Linkage calibration optimizes the relationship between the controller’s output and the valve’s stem position, enhancing accuracy.
Equal percentage and linear characterization options allow tailoring the valve’s response to specific process requirements. Furthermore, the controller supports multiple calibration sets, enabling quick switching between different operating conditions or fluids.
Utilizing ValveLink™ software unlocks access to detailed diagnostic data and calibration history, aiding in precise adjustments. Proper implementation of these advanced options requires a thorough understanding of the process and valve characteristics. Always document any changes made during advanced calibration for traceability and future adjustments.
Calibration Verification
Following any calibration procedure, verifying the DVC6200’s accuracy is crucial. This involves comparing the controller’s output signal to the actual valve position across its entire stroke. Utilize a calibrated pressure indicator and position indicator for precise measurements.
Step changes in the input signal should result in corresponding, linear movements of the valve stem. Observe the controller’s display for any discrepancies or error messages during verification. ValveLink™ software provides tools for graphical analysis of calibration data, facilitating easy identification of potential issues.
Document all verification results, including date, time, and measured values. Repeat the verification process periodically to ensure continued accuracy and reliable operation. Any significant deviations indicate a need for recalibration or troubleshooting.
Operational Information
The DVC6200 features a clear display for process data and diagnostics. Understanding these messages and normal operating parameters ensures optimal valve control performance.
Understanding the DVC6200 Display
The DVC6200’s display provides crucial operational information at a glance. It cycles through various screens, showcasing process variable (PV), setpoint (SP), controller output (OP), and diagnostic messages. The display utilizes a standardized format for easy interpretation, regardless of the configured parameters.
Key display elements include percentage indicators for valve position and output signal, along with status indicators for communication health and self-diagnostics. Users can navigate through different display screens using the buttons on the controller. Understanding the meaning of each displayed value and symbol is essential for effective monitoring and troubleshooting.
Diagnostic messages are presented with specific codes, referencing the instruction manual for detailed explanations and recommended actions. The display’s brightness can be adjusted to suit varying ambient light conditions, ensuring optimal visibility. Regular observation of the display allows operators to proactively identify and address potential issues before they escalate.
Interpreting Diagnostic Messages
The DVC6200 utilizes a comprehensive system of diagnostic messages to alert users to potential issues. These messages are displayed on the controller’s screen as alphanumeric codes, each corresponding to a specific fault or condition. It’s crucial to consult the instruction manual for a complete listing and detailed explanation of each code.
Diagnostic messages are categorized by severity, ranging from warnings indicating potential problems to critical alerts requiring immediate attention. Understanding the message’s priority helps prioritize troubleshooting efforts. Common messages relate to communication errors, valve actuator issues, or internal controller malfunctions.
When a diagnostic message appears, record the code and refer to the manual’s troubleshooting section. The manual provides step-by-step guidance on resolving the issue, including potential causes and corrective actions. Ignoring diagnostic messages can lead to process instability or equipment damage, so prompt investigation is essential.
Normal Operating Parameters
The DVC6200 is designed to operate reliably within specific environmental and electrical parameters. Typically, the controller functions optimally within a temperature range of -40°C to 85°C (-40°F to 185°F), though specific limits may vary based on the model. Humidity should be maintained within acceptable levels to prevent condensation and corrosion.
Regarding electrical supply, the DVC6200 generally accepts a 24 VDC input, with allowable voltage fluctuations specified in the technical documentation. Proper grounding is essential for safe and reliable operation. Supply voltage outside the specified range can cause malfunction or damage.
During normal operation, the controller’s display should show stable process variable readings and setpoint tracking. Regular monitoring of these parameters ensures the valve is responding correctly. Deviations from expected values may indicate a problem requiring investigation and potential calibration.
Maintenance and Troubleshooting
Routine maintenance includes visual inspections and verifying proper operation. Common issues involve communication errors or calibration drift, addressed via diagnostics and recalibration procedures.
Routine Maintenance Schedule
To ensure optimal performance and longevity of the DVC6200 Digital Valve Controller, a consistent maintenance schedule is crucial. Initially, a visual inspection should be performed monthly, checking for any physical damage to the controller housing, wiring connections, and associated hardware.
Every six months, verify the integrity of all electrical connections, tightening as needed, and inspect for corrosion. Annually, a full functional test is recommended, including a calibration verification to confirm accuracy and responsiveness.
Pay close attention to the operating environment; excessive dust or moisture may necessitate more frequent inspections and cleaning. Document all maintenance activities, including dates, findings, and any corrective actions taken. Following this schedule will help prevent unexpected failures and maintain reliable valve control.
Common Troubleshooting Issues
Several issues may arise during DVC6200 operation. A frequent problem is communication failure, often stemming from incorrect HART setup or wiring. Verify proper termination and address configuration. Another common issue involves erratic valve positioning, potentially caused by calibration drift or mechanical binding within the valve actuator.
Diagnostic messages displayed on the DVC6200’s screen provide valuable clues; consult the manual for interpretation. If the controller fails to power on, check the electrical supply and wiring connections.
For unresponsive displays, attempt a reset. Remember to document all troubleshooting steps and findings. If issues persist, consult with qualified personnel or contact Fisher support for assistance, providing detailed information about the observed symptoms and any attempted solutions.
Replacement Parts Information
Maintaining the DVC6200 requires access to genuine replacement parts. Common replaceable components include the printed circuit board (PCB), the display module, and potentially the HART communicator interface module. Always refer to the parts list within this instruction manual or contact Fisher directly to ensure compatibility and correct part numbers.
When ordering, specify the DVC6200 series and any specific model variations. Utilizing non-approved parts can compromise performance and void warranties. Keep a small inventory of frequently used parts, such as connectors and wiring components, to minimize downtime.
Proper handling and storage of replacement parts are crucial to prevent damage. Document all part replacements for maintenance records and future reference. Fisher provides detailed diagrams illustrating component locations for simplified replacement procedures.
Technical Specifications
This section details the DVC6200’s electrical, environmental, and physical characteristics, including dimensions, weight, and operating parameter limits for reference.
Electrical Specifications
The DVC6200 operates with a wide range of power supplies, typically requiring 10.5 to 30 VDC with a maximum current draw of 22mA (normal operation) and 35mA (with communication). It’s designed to withstand voltage fluctuations and provides reverse polarity protection. The controller features isolated input/output circuitry, enhancing safety and reducing noise interference.
Input impedance is high, minimizing loading effects on the control signal. Output signals are also isolated, ensuring compatibility with various instrumentation systems. The DVC6200’s electrical design adheres to stringent industry standards for electromagnetic compatibility (EMC), ensuring reliable performance in challenging industrial environments. Grounding is crucial for proper operation and safety; follow the recommended grounding procedures outlined in the installation section.
Power-up time is typically less than 500ms, allowing for quick system restarts.
Environmental Specifications
The DVC6200 is engineered for robust performance across a broad spectrum of environmental conditions. It’s designed to operate reliably in temperatures ranging from -40°C to 85°C (-40°F to 185°F), making it suitable for extreme climates. The controller boasts a high degree of humidity resistance, functioning effectively in environments with up to 95% relative humidity (non-condensing).
It’s also built to withstand exposure to industrial contaminants, including salt spray and various chemicals. The enclosure provides NEMA 4X / IP66 protection, safeguarding internal components against dust and water ingress. Vibration and shock resistance meet stringent industry standards, ensuring continued operation in demanding applications.
Altitude operation is specified up to 2000 meters (6562 feet). Proper installation and enclosure selection are vital for maintaining these environmental ratings.
Physical Dimensions and Weight
The DVC6200 controller is designed with a compact footprint to facilitate installation in space-constrained environments. Its overall dimensions are approximately 10.8 cm (4.25 in.) in height, 15.2 cm (6.0 in.) in width, and 12.7 cm (5.0 in.) in depth, varying slightly depending on the specific model and configuration.
The standard aluminum housing contributes to its durability while maintaining a manageable weight. Typically, the DVC6200 weighs around 1.36 kg (3.0 lbs), though this can increase with optional features or mounting accessories.
Precise dimensions and weight specifications are crucial for proper mounting and integration into existing systems. Detailed drawings and CAD models are available from Fisher to assist with mechanical design and installation planning, ensuring compatibility and optimal performance.
