Emerson Fisher D3 User manual

www.Fisher.com
Fisher™D3 Control Valve with easy-Drive™Electric
Actuator
Contents
Introduction 1.................................
Scope of Manual 1.............................
Description 3.................................
Specifications 3...............................
Educational Services 3.........................
Installation 3..................................
Special Instructions for “Safe Use” and Installations
in Hazardous Locations 4.....................
Startup Overview 5............................
Important Technical Notice for easy-Drive
Electric Actuator 8..........................
Default Input Signals 9.........................
Configuration 9...............................
Input Configuration 9......................
Changing the Inputs from Default Settings 9...
Modbus Setup 9..............................
Calibration Instructions 11..................
Setting the Valve Flow Adjuster 15................
Troubleshooting 14.............................
Maintenance 16................................
Valve Plug and Seat Ring Maintenance 18.........
Packing Maintenance 20........................
Parts Ordering 22...............................
Parts Kits 22...................................
Parts List 22...................................
Appendix A - Modbus 25.........................
Figure 1. Fisher D3 Control Valve with easy-Drive
Electric Actuator
W9795-4
Introduction
Scope of Manual
This instruction manual provides installation, maintenance, and parts information for the Fisher D3 control valve with
easy-Drive electric actuator.
Do not install, operate, or maintain a D3 valve with easy-Drive electric actuator 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 the contents of this manual, including all
safety cautions and warnings. If you have any questions about these instructions, contact your Emerson sales office or
Local Business Partner before proceeding.
Instruction Manual
D103460X012
D3 Valve with easy-Drive Actuator
October 2017

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October 2017
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Table 1. Specifications
Valve Body Sizes, End Connection Styles, and Port
Diameters(1)
VALVE
SIZE,
NPS
PORT
DIAMETER,
(INCHES)
THREADED RAISED FACE
(RF) FLANGED
CL900 CL600
10.375, 0.75, 1 X X
20.375, 0.75, 1 X X
X = Available construction.
Maximum Inlet Pressures and Temperatures(1)
VALVE BODY SIZE
MAXIMUM INLET
PRESSURE TEMPERATURE RANGE
bar (psig) _C (_F)
NPS 1 NPT
CL900
155 (2250) -46 to 93 (-50 to 200)
150 (2185) 93 to 149 (200 to 300)
NPS 2 NPT
CL900
155 (2250) -46 to 93 (-50 to 200)
150 (2185) 93 to 149 (200 to 300)
NPS 1 RF
CL600
103 (1500) -46 to 93 (-50 to 200)
100 (1455) 93 to 149 (200 to 300)
NPS 2 RF
CL600
103 (1500) -46 to 93 (-50 to 200)
100 (1455) 93 to 149 (200 to 300)
Maximum Shutoff Pressure Drops(1)
MAXIMUM nP BAR (PSI) PER PORT SIZE
Port Size,
mm (inch) 9.5 (0.375) 19.1 (0.75) 25.4 (1.00)
Flow Up 155 (2250) 105 (1518) 75 (1089)
Flow Down 155 (2250) 155 (2250) 130 (1889)
Shutoff Classification per ANSI/FCI 70‐2
and IEC 60534‐4
Class IV
Flow Characteristic / Valve Plug Style
Equal percentage / Micro‐Form Valve Plug
Maximum Travel
15 mm (0.6 inch)
Material Temperature Capabilities(1)
Valve Body Assembly:
Standard Bonnet O-Ring: -40 to 135°C (-40 to 275°F)
Electric Actuator Assembly: -20 to 70°C
(-4 to 158°F), < 90% non-condensing humidity
Flow Direction
Flow up (standard), Flow down (optional)
Available Actuator Configurations
On/off (snap acting)
Positioning (flow or pressure control)
Power Requirements
12 or 24VDC, minimum 4 amp power supply required
(fuse to 5 amps)
Maximum Current Draw
4 amps
Idle Current Draw
38 mA
Conduit Connections
Two 3/4 NPT connections
Stroke Length
FloPro controlled between 10mm (0.4 inch) and
15mm (0.6 inch)
Nominal Stroke Speed(2)
3.9 mm/s (0.15 inch/s) at 24 VDC
2.2 mm/s (0.09 inch/s) at 12 VDC
Hazardous Area Approvals
CSA (C/US): ExplosionProof Class I, Division 1,
Groups C and D, T6, Ex d IIA T6, Class I, Zone 1, AEx d
IIA T6
ATEX Flameproof - Gas:
II 2 G ,Ex d IIA T6
IECEx Flameproof - Gas: Ex d IIA T6
Enclosure Rating
Type 4X and IP66
Duty Cycle
50% maximum
Enclosure Material
Cast aluminum alloy with powder coat paint
Approximate Weight:
18 - 27 kg (39 - 60 lbs), depending upon construction
1. The pressure or temperature limits in the referenced tables and any applicable ASME code limitations should not be exceeded.
2. 10% variation can be expected, based on temperature and pressure of application.

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Description
The Fisher D3 with easyDrive electric actuator technology (figure 1) is a globe valve with electric actuator specifically
designed for upstream, low power applications. The easyDrive operates with 12 or 24VDC in either on/off or
Positioning configurations.
The on/off configuration has 2 different states; opened or closed, which are ideal for dump or snap acting applications.
The Positioning configuration extends the functionality to intermediate positions for flow and pressure control
applications.
Specifications
Table 1 lists specifications for the D3 control valve. Some of the specifications for a given control valve as it originally
comes from the factory are stamped on a nameplate located on the lower actuator housing.
Educational Services
For information on available courses for the Fisher D3 control valve with easy-Drive electric actuator, as well as a
variety of other products, contact:
Emerson Automation Solutions
Educational Services - Registration
Phone: [phone] or 1-800-338-8158
E-mail: [email protected]
emerson.com/fishervalvetraining
Installation
WARNING
Always wear protective gloves, clothing, and eyewear when performing any installation operations to avoid personal
injury.
To avoid personal injury or property damage caused by bursting of pressure‐retaining parts or by uncontrolled process
fluid, be certain the service conditions do not exceed the limits shown on the valve nameplate and in table 1. Use
pressure‐relieving devices required by government or accepted industry codes and good engineering practices.
Check with your process or safety engineer for any additional measures that must be taken to protect against process
media.
If installing into an existing application, also refer to the WARNING at the beginning of the Maintenance section in this
instruction manual.
WARNING
For explosionproof applications, ensure the actuator cover is properly bolted before applying power to the actuator.
Personal injury or property damage may result from fire or explosion if power is applied to the actuator with the cover
removed in a hazardous area.
For explosion‐proof applications, install rigid metal conduit and a conduit seal no more than 457 mm (18 inches) from the
actuator. Personal injury or property damage may result from explosion if the seal is not installed.
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.

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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.
CAUTION
When ordered, the valve configuration and construction materials were selected to meet particular pressure, temperature,
pressure drop, and controlled fluid conditions. Responsibility for the safety of process media and compatibility of valve
materials with process media rests solely with the purchaser and end‐user. Since some body/trim material combinations
are limited in their pressure drop and temperature ranges, do not apply any other conditions to the valve without first
contacting your Emerson sales office or Local Business Partner.
To avoid product damage, inspect the valve before installation for any damage or any foreign material that may have
collected in the valve body. Also remove any pipe scale, welding slag, or other foreign material from the pipeline.
1. Before installing the control valve assembly, inspect it for any damage and for any foreign material that may have
collected in the valve body.
2. Clean out all pipelines to remove scale, welding slag, and other foreign materials.
3. The control valve assembly may be installed in any orientation, but normally the actuator is vertical above the valve.
Install the valve so the flow direction arrow on the side of the valve indicates the direction of the process flow.
4. Install the valve following local and national piping codes when they apply to the application. For screwed
connections, treat the external pipe threads with a good grade pipe compound. For flanged connections, use
suitable gaskets between valve and pipeline flanges.
5. If continuous operation is required during inspection or maintenance, install a three‐valve bypass around the
control valve assembly.
Special Instructions for “Safe Use” and Installations in Hazardous
Locations
ATEX/IECEx
WARNING
To avoid static discharge from the enclosure, do not rub or clean the enclosure with solvents. To do so could result in an
explosion. Clean with a mild detergent and water only.
The enclosure is nonconducting and may generate an ignitioncapable level of electrostatic charges under certain extreme
conditions. The user should ensure that the equipment is not installed in a location where it may be subjected to external
conditions (such as highpressure steam) which might cause a buildup of electrostatic charges on nonconducting surfaces.
Additionally, cleaning of the equipment shall only be done with a damp cloth.
To avoid damage to the enclosure, when screws are fully tightened into blind holes in enclosure walls, with no washer
fitted, at least one full thread shall remain free at the base of the hole.

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Startup Overview
Figure 2. Flowchart
WIRE PER WIRING
INSTRUCTIONS ON
PAGES 6-8
IS YOUR CONTROL
METHOD LISTED IN
TABLE 2 ON PAGE 9?
YES NO
ARE YOU USING MODBUS
TO MONITOR REGISTERS?
PROCEED TO
MODBUS SETUP
SECTION ON
PAGE 9
PROCEED TO
MODBUS SETUP
SECTION ON
PAGE 9
PROCEED TO
STARTUP SECTION
ON PAGE 13
CHANGE INPUTS
PER INSTRUCTIONS
ON PAGE 11
YES
NO

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Figure 3. Fisher D3 Valve with easy-Drive Actuator Wiring Diagram
FIELD WIRING CONNECTIONS
MOTOR / GEARBOX ASSY
(GE48474)
CONTROLLER
POWER AND
CONTROL TERMINAL
GE47302-7
TOP VIEW CONTROLLER
Power Requirements
Ensure a stable DC power source is available, maintaining less than 5% ripple and sufficiently surge protected for the
application. A 4 amp (minimum) power supply is required. Use of a 36 volt transient voltage suppressor is highly
recommended.
Wiring Instructions
1. Observe local wiring requirements for hazardous location usage.
2. Conduit seals within 450 mm (18 inches) of the enclosure port are required for explosionproof installation.
3. 22AWG (0.33mm2) to 12AWG (3.31mm2) wire size required.
4. Fuse system to 5A.
5. Connect enclosure and analog signal shields.
6. Ensure power is turned off before connecting the wires.
Power
1. Connect 12 or 24 VDC reference to: –
2. Connect 12 or 24 VDC positive to: +
3. Be sure to tighten terminals sufficiently to ensure solid mechanical connection.

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Figure 4. Wiring - Analog Input
Analog Input
(420mA: 40033=1, 40034=1, 40043=0(1))
1. Connect signal to terminal 3
2. Connect reference to terminal 4
3. Connect 250 ohm resistor between
terminals 3 and 4 as shown.
NOTE:
1. 40043=0 SETS ANALOG INPUT TO 1-5V AND ASSUMES USE OF RECOMMENDED EXTERNAL 250 OHM RESISTOR.
IF NO EXTERNAL RESISTOR IS USED, SET 40043=1.
Figure 5. Wiring - L2e
L2e (dual dry contact:
40033=0, 40034=0, 40043=0)
1. Connect L2e brown wire to terminal 1 (COMM (com))
2. Connect L2e red wire to terminal 2 (N.O. (OPEN))
3. Connect L2e blue wire to terminal 3 (N.C. (CLOSE))
Your actuator may be labelled:
1. COMM
2. N.O.
3. N.C.
or
1. com
2. OPEN
3. CLOSE

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Figure 6. Wiring - Single Dry Contact
Dry Contact (single dry contact:
40033=0, 40034=0, 40043=1)
1. Connect one side of contact switch to terminal 1 (COMM)
2. Connect other side of contact switch to terminal 2 (N.O.)
Figure 7. Wiring - Modbus Input
Modbus Input: 40033=1
1. Connect Channel A (T+) to terminal 5
2. Connect Channel B (T-) to terminal 6
Modbus Defaults
Address 1
9600 Baud
Even parity
1 Stop Bit
Important Technical Notice for easyDrive Electric Actuator
When using the easyDrive electric actuator with a 420mA control signal, the unit should always have 12/24VDC
power present on the power input terminals prior to applying the 420mA signal, unless an external 250 ohm resistor
is installed per figure 4. Failure to do so could result in damage to the analog input circuitry.
It is strongly recommended to place an external 250 ohm resistor between terminals 3 and 4 when using a 4-20mA
signal to control the actuator. When the actuator is configured to 1-5V input with an external 250 ohm resistor in
place, a 4-20mA signal may be safely used without danger to input circuitry.

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This order of operation must always be maintained when powering the unit on if no external 250 ohm resistor is used:
1. 12/24VDC power on
2. 420mA control signal engaged
This order of operation must always be maintained when powering the unit off:
1. 420mA control signal disengaged
2. 12/24VDC power off
The result of not following this order of operation could result in permanent damage to the analog input circuitry. This
damage can result in the inability of the controller to see the control signal, resulting in the actuator moving the valve
plug to the loss of signal position.
Default Input Signals
The D3 with easyDrive comes from the factory calibrated and ready for use with the following default input signals
shown in table 2.
Table 2. D3 easy-Drive Default Input Signals
CONFIGURATION ON/OFF POSITIONING
Input Signal L2e (dual dry contact) 4-20 mA
If the input signal of the application matches table 2, proceed to the Wiring Instructions section. If the input signal of
the application does not match table 2, proceed to the Configuration section.
Configuration
Input Configuration
There are 2 functional configurations available for the easyDrive electric actuator: On/Off and Positioning. It is not
possible to change an actuator from On/Off to Positioning after it has been delivered from the factory. Version 4.21
and higher firmware will allow a positioning unit to be changed to on/off.
All available input signals are shown in table 3.
Table 3. All Available Input Signals
CONFIGURATION ON/OFF POSITIONING
Control Source Modbus Local Modbus Local
Input Signal Modbus L2e Dual Dry
Contact (default) Single Dry Contact Modbus 4-20 mA (default) 1-5 V
If you are using the default inputs signals, and the valve has not been disassembled or adjusted in any way, there is no
need to recalibrate the assembly. You can proceed directly to Startup (page 12).
Changing the Inputs from Default Settings
All configuration within the valve is done by setting values in Modbus registers. This can be done using any Modbus
master (flow computer, PLC, PC). Configuration software, providing a visual interface to the registers, is available
through your Emerson sales office or Local Business Partner.
Modbus setup
Use the instructions in the instruction manual for the Modbus master to initiate the connection. The D3 with
easyDrive electric actuator Modbus factory defaults are Address 1, 9600 baud, even parity, 1 stop bit.

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When a connection has been achieved, the actuator may be configured to accept the input signal over the Modbus
link (ignoring the physical inputs) and the Modbus settings may be changed to accommodate the network to which it
is attached. Other changes to functionality are possible, such as:
D Low level cutoff: 40037 (default is 5%)
D Position upon loss of signal: 40035 (default is 0%)
See Appendix A for a full map of Modbus registers and their functions.
Figure 8. Fisher easy-Drive Configuration Software
Connecting using the Fisher easyDrive configuration software
The Fisher easyDrive configuration software allows configuration and diagnosing of the Fisher easyDrive electric
actuator with a graphical interface. Connect a PC to the actuator using a USB or serial device to Modbus RTU converter
using the wiring instructions above. The USB or serial device will be visible in the drop menu under Serial Port Settings.
Baud rate and parity should be set to the Modbus settings of the actuator. Default actuator settings are 9600 baud and
Even parity.
Use the Fisher easyDrive configuration software (figure 8) to make the desired changes, or register values may be
changed to allow different functionality. Modbus register 40034 dictates whether the unit will respond to a physical

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signal or to the value in Modbus register 40001. A value of 0 in register 40034 will result in the actuator responding to
the value in 40001 and a value of 1 will result in the actuator responding to physical control signals.
Note
If an actuator is on/off, a Modbus command of 049 in register 40001 will cause the valve to close fully, while a value of 50100 will
cause the valve to open fully.
Local to Modbus Control
Modbus
D Set register 40034 (Control Source)
D 1 = Local Control
D 0 = Modbus control
Configuration Software
D Use radio button to select Local Control or Modbus Control.
420mA to 15V Control
Modbus
D Set register 40043 (Analog I/P mode)
D 0 = 15V
D 1 = 420mA
Configuration Software
D Use radio button to select 420mA or 15V local analog control when Control Source is set to Local.
L2e (Dual dry contact) to Single Dry Contact Control
Modbus
D Set register 40043 (Analog I/P mode)
D 0 = L2e (Dual dry contact)
D 1 = Single dry contact
Configuration Software
D Use radio button to select L2e or Single pole local digital control when Control Source is set to Local.
Calibration Instructions
WARNING
To avoid personal injury or property damage, be aware that the valve will open fully and then close fully during the
calibration cycle.

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It is not necessary to calibrate your easyDrive electric actuator prior to use from a factory shipment.
If any of the following are true, recalibration will be required (see next section)
D A change in the FloPro setting
D The actuator has been remounted on a different valve since shipment
D Disassembly of the valve for trim or packing changes
D A new version of firmware has been loaded on the controller
The following scenarios do not require recalibrations
D New unit from the box
D Power dips or interruptions
D Changing of control method (i.e. from 420mA to Modbus control)
D Extended periods of storage
Calibration with the use of Modbus
1. After the unit has been properly wired and fused per instructions in the Wiring section of this instruction manual,
turn power to the unit on.
2. Calibrate using Modbus:
a. Send position command of 0% to actuator to prevent unexpected motion. Valve will move to commanded
position following the calibration procedure.
b. Send a value of 1 to register 40003. Valve plug will move to fully open position and then to fully closed. The valve
plug will then return to the commanded position.
If a Modbus connection is not available, and recalibration is desired, use the appropriate calibration method as
determined by the control method of your valve.
Calibration without the use of Modbus
1. Turn power to the actuator off.
2. Wait for 10 seconds to ensure all circuits have discharged.
3. Return power to the actuator and use the appropriate calibration method for your control signal. Calibration
sequence must be done within 15 seconds of power being switched on.
4. For On/Off operation using L2e dualinput dry contact:
a. Close the contact to create a short between pins 1 and 2 – valve plug will not move at this time.
b. Close the contact to create a short between pins 1 and 3 – valve plug will move to the upper, open position and
then to the lower, closed position.
5. For On/Off operation using single dry contact:
a. Close the contact to create a short between pins 1 and 2 – valve plug will not move at this time.
b. Open the contact to create an open circuit between pins 1 and 2 – valve plug will move to the upper, open
position and then to the lower, closed position.

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6. For positioning operation using 420mA:
a. Apply a 20mA signal between pins 3 and 4 – valve plug will not move at this time.
b. Apply a 4mA signal between pins 3 and 4 – valve plug will move to the upper stop, immediately followed by
moving to the lower, closed position.
c. If calibration of the analog input is desired to improve positional accuracy, an optional operation is listed in the
next section titled Analog Input Calibration.
7. For positioning operation using 15V:
a. Apply a 5V signal between pins 3 and 4 – valve plug will not move at this time.
b. Apply a 1V signal between pins 3 and 4 – valve plug will move to the upper stop, immediately followed by
moving to the lower, closed position.
c. If calibration of the analog input is desired to improve positional accuracy, an optional operation is listed in the
next section titled Analog Input Calibration.
8. The unit is now calibrated.
Analog Input Calibration
Improved positional accuracy may be obtained by calibrating the actuator to the analog signal input. The position of
the valve plug is linearly proportional to the analog control signal end points, with 4 mA/1V equating to fully closed
and 20 mA/5V equating to fully open.
1. Apply a 4 mA or 1V signal between pins 3 and 4 - valve plug will move to the fully open position.
2. Send a value of 1 to register 40004 or click Analog Cal at 0% in the configuration software.
3. Apply a 20 mA or 5V signal between pins 3 and 4 - valve plug will move to the fully closed position.
4. Send a value of 1 to register 40005 or click Analog Cal at 100% in the configuration software.
5. The unit is calibrated to your analog signal.
Start Up
WARNING
To avoid personal injury or property damage, be aware that the valve will move and respond to an input signal during start
up.
1. Before turning on power to the unit, be sure that a closed signal is being commanded to the unit.
D DryContact: contact is open.
D L2e (Dual Dry Contact): Contact closed across pins 1 & 3.
D Analog Input: signal < 4mA or 1V.
D Modbus: position demand = 0.
2. Turn on power to the unit.
3. Apply a change in position demand to ensure unit responds properly.

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D DryContact:
D Closed contact between pins 1 & 2 will open the valve.
D Dual contact / L2e only (40043=0) : Closed contact between pins 1 & 2 will open the valve. Closed contact
between pins 1 & 3 will close the valve.
D Analog Input: valve will respond to proportional demand.
D Modbus: valve will respond to positional demand in register 40001. 0 = fully closed and 100 = fully open.
4. If the valve does not respond as expected, proceed to Troubleshooting guide on page 14.
5. Check conduit ports.
D Conduit seal must be in place within 450mm (18 inches) of the enclosure.
D Unused conduit ports must be sealed with an explosionproof port plug.
6. Replace the cover and tighten all 8 bolts to 20 Nm (15 ftlbs).
Troubleshooting
1. Unit does not move.
a. Verify that 12VDC to 24VDC is present on the power terminals as shown on the cover.
b. Verify that all wires are firmly attached on both ends.
c. Verify that wires are connected to the correct terminals - see Wiring in the manual.
d. Verify mode of operation (on/off or positioning) matches control signal.
e. Verify mode of control (local or Modbus) matches control signal.
2. Unit does not respond to 420mA signal
a. Verify that 12VDC to 24VDC is present on the power terminals as shown on the cover.
b. Verify that the 420mA signal is wired correctly and that the terminals are firmly on the wires.
c. Verify mode of operation matches control signal (local control: 40033=0, positioning: 40034=1).
d. Check the value of the analog input in register 40025 (middle right of configuration software screen) to
determine if it is 0 or greater.
i. If register 40025 shows 0 and the circuit board is green (not blue), it is possible a 420mA signal was applied
without power to the power terminals and damage to the input circuitry has occurred. Contact your Emerson
sales office or Local Business Partner for further information.
3. Unit moves to fully open when 1V signal is applied and closed when 5V signal is applied.
a. Unit is likely configured as an on/off unit with local control; on/off units can not be controlled as an analog
device.
i. If on/off control is desired, use a dry contact switch to control in local mode or change to Modbus mode to
control the unit.

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ii. If positioning control is desired, contact your Emerson sales office or Local Business Partner to upgrade your
actuator to positioning control.
4. Diagnostics show a Motor Stall Fault.
a. The easyDrive electric actuator is designed to operate in a manner consistent with a pneumatic actuator. This
means that if the valve plug can not move to its commanded position, the actuator will stop, without damage,
and issue a Motor Stall Fault warning. When the command signal changes outside of the deadband (Modbus
register 40036), it will attempt to move again. Recalibrate the actuator span per instructions in the Startup
section of this manual.
5. Position on D3 is not accurate (proportional positioning units only).
a. If the position of a D3 is too high (i.e. 50% is much higher than 50% on the bonnet), check the valve type. If valve
type is D4, change to D3, cycle power, and recalibrate.
b. If the local analog input is being used (420mA or 15V), the analog inputs of the actuator may be calibrated to
match the input signal.
i. Command 0% (4mA or 1V).
ii. Using a Modbus link, send a 1 to register 40004 or use the Fisher easyDrive configuration software by clicking
the button “Analog Cal at 0%”.
iii. Command 100% (20mA or 5V).
iv. Using a Modbus link, send a 1 to register 40005 or use the Fisher easyDrive configuration software by clicking
the button “Analog Cal at 100%”.
Figure 9. Adjusts to Vary Flow Capacity (Shown with Valve Plug in Seated Position)
CLOSED
50%
100%
CLOSED
50%
100%
USE 5/32 INCH
ALLEN KEY
FULL CAPACITY SETTING (FACTORY SET)
15 mm (0.6 INCH) TRAVEL
NOTE: USE THE WIDELY-SPACED TRAVEL INDICATORS,
AS SHOWN ON THE LEFT PORTION OF THIS VIEW.
REDUCED CAPACITY SETTING
10 mm (0.4 INCH) TRAVEL
NOTE: USE THE CLOSELY-SPACED TRAVEL INDICATORS,
AS SHOWN ON THE RIGHT PORTION OF THIS VIEW.
STEM CONNECTOR
INDICATES TRAVEL
STEM CONNECTOR
INDICATES TRAVEL
Setting the Valve Flow Adjuster
The flow setting may only be adjusted if the 0.375 and 0.75 inch port sizes are installed and only when using the on/off
version.

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When shipped from the factory, the actuator has the flow adjuster set at the maximum flow rate position for the given
port size.
1. Ensure the valve plug is in the seated position.
2. To change the valve flow rate, loosen the flow adjuster socket head cap screws (key 15) with a 5/32 inch Allen key,
and reposition the flow adjuster halves (key 13 and 14) to the desired flow rate position. See figure 9 for flow rate
settings.
3. Retighten the socket head screws (key 15) to 3 NSm (26 lbfSin).
4. Follow instructions for recalibration on page 10.
Maintenance
Refer to figure 12.
Valve parts are subject to normal wear and must be inspected and replaced as necessary. The frequency of inspection
and maintenance depends on the severity of the service conditions.
WARNING
Avoid personal injury from sudden release of process pressure or bursting of parts. Before performing any maintenance
operations:
D Do not remove the actuator from the valve while the valve is still pressurized.
D Always wear protective gloves, clothing, and eyewear when performing any maintenance operations to avoid personal
injury.
D Disconnect any operating lines providing 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
on both sides of the valve. Drain the process media from both sides of the valve.
D Use lock‐out procedures to be sure that the above measures stay in effect while you work on the equipment.
D The valve packing box may contain process fluids that are pressurized, even when the valve has been removed from the
pipeline. Process fluids may spray out under pressure when removing the packing hardware or packing rings.
D Check with your process or safety engineer for any additional measures that must be taken to protect against process
media.
WARNING
For explosionproof applications, ensure the actuator cover is properly bolted before applying power to the actuator.
Personal injury or property damage may result from fire or explosion if power is applied to the actuator with the cover
removed in a hazardous area.
Do not remove the actuator cover for 10 minutes after power is disconnected if the UPS option is installed.
For explosion‐proof applications, install rigid metal conduit and a conduit seal no more than 457 mm (18 inches) from the
transducer. Personal injury or property damage may result from explosion if the seal is not installed.
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.

Instruction Manual
D103460X012
D3 Valve with easy-Drive Actuator
October 2017
17
Figure 10. Packing and Belleville Spring Stacking Order
7
10
10
12
8
12
16
43
3
11
LUBRICATE WITH 3mm (1/8 INCH
BEAD) OF SUPPLIED HIGH
PERFORMANCE FLUORINATED
GREASE (KEY 44)
LUBRICATE WITH 3mm (1/8
INCH BEAD) OF SUPPLIED HIGH
PERFORMANCE FLUORINATED
GREASE
FEMALE PACKING ADAPTOR
MALE PACKING ADAPTOR
PACKING RING
LUBRICATION LOCATIONS
ON PACKING
9

Instruction Manual
D103460X012
D3 Valve with easy-Drive Actuator
October 2017
18
Figure 11. Packing and Belleville Spring Stacking Order
VALVE PLUG, BELLEVILLE SPRINGS, AND PACKING RETAINER CORRECTLY
INSTALLED AND TIGHTENED
BELLEVILLE SPRINGS FULLY ENCLOSED BY
THE PACKING RETAINER
PACKING RETAINER
(KEY 8)
UNTIGHTENED,
NOTE THE GAP
FULLY TIGHTENED,
NO GAP
Valve Plug and Seat Ring Maintenance
Trim Disassembly
Key numbers are referenced in figures 10, 12, and 13.
1. Isolate the control valve from the line pressure, release pressure from both sides of the valve body (key 1), and drain
the process media from both sides of the valve.
CAUTION
The following steps are intended to prevent damage to the valve plug (key 3) and seat ring (key 2) during the removal of the
bonnet and actuator.
For ON/OFF Actuators
2. Command the valve open.
3. Place an open end wrench or a similar obstruction about 6 mm (1/4 inch) thick under the FloPro.
4. Command the valve closed.
For Positioning Actuators
5. Command the valve to anywhere between 10% and 20% travel.
6. Isolate power and signal.

Instruction Manual
D103460X012
D3 Valve with easy-Drive Actuator
October 2017
19
7. Break the bonnet nut (key 5) loose with a hammer. Continue turning the bonnet nut by using a hammer or a large
adjustable wrench, tightened around one ear of the bonnet nut. If the bonnet (key 7) is stuck in the valve, continue
to unscrew the bonnet nut. The bonnet nut will contact the spring pins (or pipe plugs) (key 6, figure 12) and jack the
bonnet out of the valve. Carefully lift the actuator assembly from the valve body.
WARNING
The spring pins/pipe plugs (key 6) must always be in place during valve operation. They provide a safeguard against injury
when the unit is being disassembled.
8. Completely remove the packing retainer (key 8) using a 1‐1/8 inch wrench.
9. Remove the valve plug by driving out the pin (key 43) and unscrewing the valve plug from the stem. Do not remove
the Belleville springs (key 9) from the stem, in order to retain the Belleville stacking orientation as shown in figure
10.
10. Use a 1‐3/16 inch socket wrench to loosen and remove the seat ring (key 2).
CAUTION
Inspect the seat ring and valve body interior for wear, erosion, or damage in the following steps.
11. Inspect the seat ring for wear or damage. If the seating surface has been damaged, discard the seat ring.
12. Visually inspect the valve body interior below the seat ring for erosion or damage. Replace the valve body if
necessary.
WARNING
Be careful to avoid damaging the seating surface on the valve plug or seat ring as damage in these areas will allow excessive
leakage at shutoff. Avoid damaging the highly polished valve stem surface. A damaged valve stem could cut the packing
and allow process fluid to leak to the atmosphere.
Cover the opening in the valve body to prevent foreign material from getting into the valve body cavity.
Trim Assembly
1. Ensure the threads of the valve stem (key 16) and valve plug (key 3) are clean and free of debris.
2. Make sure the Belleville springs (key 9) are properly installed on the valve stem, as shown in figure 11.
3. Install the valve plug on the stem and insert a new pin (key 43).
4. Lubricate the threads of the packing retainer with anti‐seize and install into the bonnet using a 1‐1/8 inch wrench.
Make sure the Belleville springs (key 9) are completely enclosed by the packing retainer as shown in figure 11.
5. Torque the packing retainer to 81 NSm (60 lbfSft). The packing retainer has been installed correctly when a
metal‐to‐metal contact has been made between the packing retainer end and the bonnet (key 7). The packing
retainer threads should be completely enclosed by the bonnet (see figure 11).
6. Thoroughly clean the seat ring (key 2) threads and the mating threads in the valve body (key 1).
7. Apply anti‐seize lubricant to the threads of the seat ring and its mating threads in the valve body.
8. Screw the seat ring into the valve body. Use a 1‐3/16 inch socket wrench to tighten the seat ring to 170 NSm
(125 lbfSft). Remove all excess lubricant after tightening.
9. Lubricate the bonnet O‐ring (key 4) with lithium grease and install on the bonnet.

Instruction Manual
D103460X012
D3 Valve with easy-Drive Actuator
October 2017
20
10. Apply anti‐seize lubricant to the threads on the valve body and bonnet nut (key 5) and the contact surfaces of the
bonnet and bonnet nut flange. Install the bonnet and actuator assembly onto the valve body. Tighten the bonnet
nut until the nut stops turning. A few hammer blows will be required to ensure that the assembly is tight.
Packing Maintenance
WARNING
Observe the warning at the start of the Maintenance section.
Key numbers are referenced in figure 10.
The valve stem packing can only be serviced by removing the bonnet from the valve body.
Packing Disassembly
1. Disassemble the valve per steps 1 ‐ 9 in the Trim Disassembly section of the Valve Plug and Seat Ring Maintenance
section of this manual.
2. Remove the five Belleville springs (key 9), lower packing spacer (key 12), packing set (key 11), and two
anti‐extrusion washers (key 10) from the bonnet (key 7) using a formed wire hook.
3. Clean and inspect the packing box wall to ensure that the packing surfaces are not damaged. If the surface
condition is damaged and cannot be improved by light sanding, replace the bonnet.
4. Inspect the valve stem (key 16) and valve plug (key 3) for scratches or wear and replace if necessary.
Packing Assembly
The following steps define the proper procedure for installing the packing in a D3 valve. Improper packing assembly
can lead to poor valve performance. The proper packing arrangement is shown in figures 10 and 11.
1. Ensure the upper packing spacer (key 12) is installed.
2. Use the lower packing spacer (key 12) and a tube to push the upper anti‐extrusion washer (key 10) into place. Using
the lower packing spacer in this manner will ensure the upper anti‐extrusion washer is fully seated and flat when
installed in the packing bore.
3. Remove the lower packing spacer from the packing bore.
CAUTION
All D3 packing kits include a single use packet of high performance fluorinated grease. This is the only acceptable D3
packing lubricant.
Note
In the following procedure, carefully install each packing ring individually over the valve stem and push completely into the packing
box with a non‐marring tube. A 12‐inch length of 1/2 inch PVC pipe works well for this. It is recommended that the lubricated
packing rings be installed individually rather than pushed in as a set.
4. Apply a 3mm (1/8 inch) bead of the supplied high performance fluorinated grease (key 44) around the groove of
the female packing adaptor as shown in figure 10 and install over the valve stem (key 16).
5. Apply a 3mm (1/8 inch) bead of the supplied high performance fluorinated grease (key 44) around the groove of
the packing ring as shown in figure 10 and install over the valve stem.