Fisher Fisher D4 Control Valve with easy-Drive Electric Actuator Manuals & Guides

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Instruction Manual

D103597X012

D4 Valve with easy-Drive Actuator

October 2017

Fisher™ D4 Control Valve with easy-Drive Electric Actuator

Contents

Introduction 1.................................

Scope of Manual 1.............................

Description 3.................................

Specifications 3...............................

Educational Services 3.........................

Installation 4..................................

Special Instructions for “Safe Use” and Installations

in Hazardous Locations 5.....................

Startup Overview 6............................

Important Technical Notice for easy-Drive

Electric Actuator 10.........................

Default Input Signals 10........................

Configuration 10..............................

Input Configuration 10.....................

Changing the Inputs from Default Settings 11..

Modbus Setup 11.............................

Calibration Instructions 13..................

Troubleshooting 15.............................

Maintenance 16................................

Valve Plug and Seat Ring 17.....................

Valve Packing 18..............................

Parts Ordering 21...............................

Repair Kits 21..................................

Parts List 21...................................

Appendix A 25.................................

Figure 1. Fisher D4 Control Valve with easy-Drive Electric Actuator

W9933-1

™

Introduction

Scope of Manual

This instruction manual provides installation, maintenance, and parts information for the Fisher D4 control valve with easy-Drive electric actuator.

Do not install, operate, or maintain a D4 control 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

Local Business Partner before proceeding.

www.Fisher.com

D4 Valve with easy-Drive Actuator

October 2017

Table 1. Specifications

Instruction Manual

D103597X012

Valve Body Sizes and End Connection Styles

(1)

See table 2

Maximum Inlet Pressures and Temperatures

(1)

If the valve nameplate shows an ASME pressure‐temperature class, maximum inlet pressure and temperature is consistent with the applicable class per ASME B16.34. If the nameplate does not show an ASME class, it will show a maximum cold working pressure at 38_C (100_F) (for example, 293 bar [4250 psi])

Maximum Pressure Drops

(1)

See table 4

Shutoff Classification per ANSI/FCI 70‐2 and IEC 60534‐4

Class IV

Material Temperature Capabilities

(1)

Valve Body Assembly:

Standard Bonnet O‐Ring: -40 to 135°C (-40 to 275°F) Optional Fluorocarbon Bonnet O‐Ring: -23 to 204°C

(-10 to 400°F)

Flow Characteristic

Equal percentage

Flow Direction

Flow up only

Port Diameters

See table 2

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

19mm (0.75 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

Valve Plug Travel

19 mm (0.75 inch)

Valve Plug Style

Micro‐Form valve plug

Available Actuator Configurations

On/off (snap acting) Positioning (flow or pressure control)

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.

Duty Cycle

50% maximum

Enclosure Material

Cast aluminum alloy with powder coat paint

Approximate Weight:

22 - 51 kg (49 - 113 lbs), depending upon construction

Instruction Manual

D103597X012

D4 Valve with easy-Drive Actuator

October 2017

Description

The D4 control valve with easy-Drive electric actuator is a compact, rugged valve designed primarily for high‐pressure throttling applications. This valve is ideal for use on pressure and flow control applications within the oil and gas production industry. The D4 valve also makes an excellent dump valve for high‐pressure separators and scrubbers.

The D4 control valve meets the metallurgical requirements of NACE MR0175/ISO 15156 without environmental limits for temperatures below 135_C (275_F). If the temperature is above 135_C (275_F), the N07718 Belleville washers will impose some limits, as shown in table 3.

Specifications

Table 1 lists specifications for the D4 control valve with easy-Drive electric actuator. 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 enclosure.

Educational Services

For information on available courses for the Fisher D4 control valve with easy-Drive electric actuator, as well as a variety of other products, contact:

Emerson Automation Solutions Educational Services - Registration Phone: 1-641-754-3771 or 1-800-338-8158 E-mail: education@emerson.com emerson.com/fishervalvetraining

Table 2. Valve Sizes and Connection Styles

VALVE

SIZE,

NPS

X = Available construction.

PORT

DIAMETER,

(INCHES)

0.25, 0.375,

0.5, 0.75

0.25, 0.375, 0.5

0.75, 1, 1.25

SCREWED RAISED FACE (RF) FLANGED

4250 psi CL150 CL300 CL600

X X X X X X X

CL900 and

CL1500

RING TYPE JOINT

(RTJ) FLANGED

CL600

CL900 and

CL1500

Table 3. D4 Environmental Limits for NACE MR0175/ISO 15156 with Sour Trim

MAXIMUM TEMPERATURE MAXIMUM H2S PARTIAL PRESSURE

_C _F MPa psia

232 450 0.2 30 No

204 400 1.4 200 No

199 390 2.3 330 No

191 375 2.5 360 No

149 300 2.8 400 No

135 275 No Limit Yes

Table 4. Fisher D4 easy-Drive Maximum Pressure Drop

PORT DIAMETER MAXIMUM PRESSURE DROP

mm Inch Bar psi

6.4

9.5

12.7

19.1

25.4

31.8

1. Downstream pressure, P2, is limited to 2250 psig.

0.25

0.375

0.5

0.75 1

1.25

293 293 247 105

56 34

COMPATIBLE WITH

ELEMENTAL SULFUR?

(1)

4250

(1)

4250

(1)

3576

1518

814 495

D4 Valve with easy-Drive Actuator

October 2017

Instruction Manual

D103597X012

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.

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

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.

or Local Business Partner.

WARNING

Avoid personal injury or property damage caused by possible actuator failure. The use of a rigidly‐mounted support on the actuator casing may cause additional stress on the actuator leading to premature wear and/or failure of the actuator components.

Instruction Manual

D103597X012

D4 Valve with easy-Drive Actuator

October 2017

CAUTION

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. Remove any pipe scale, welding slag, and other foreign material from the pipeline.

3. The control valve can be installed in any position, 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 valves, use suitable gaskets between valve and pipeline flanges.

5. If continuous operation is required during maintenance and inspection, install a conventional three‐valve bypass around the valve.

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 electrosatic 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

Instruction Manual

D103597X012

WIRE PER WIRING

INSTRUCTIONS ON

PAGES 7-9

ARE YOU USING MODBUS

TO MONITOR REGISTERS?

YES

PROCEED TO

MODBUS SETUP

SECTION ON

PAGE 10

IS YOUR CONTROL

METHOD LISTED IN

TABLE 5 ON PAGE 10?

PROCEED TO

STARTUP SECTION

ON PAGE 14

PROCEED TO

MODBUS SETUP

SECTION ON

PAGE 10

CHANGE INPUTS PER

INSTRUCTIONS ON

PAGE 12

Instruction Manual

D103597X012

Figure 3. Fisher D4 Valve with easy-Drive Actuator Wiring Diagram

CONTROLLER

POWER AND CONTROL TERMINAL

MOTOR / GEARBOX ASSY (GE48474)

GE47302-7

D4 Valve with easy-Drive Actuator

October 2017

FIELD WIRING CONNECTIONS

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 457 mm (18 inches) of the enclosure port are required for explosionproof installation.

3. 22AWG (0.33mm

) 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.

D4 Valve with easy-Drive Actuator

October 2017

Figure 4. Wiring - Analog Input

Instruction Manual

D103597X012

(420mA: 40033=1, 40034=1, 40043=0

Analog Input

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.

(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

Instruction Manual

D103597X012

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.)

D4 Valve with easy-Drive Actuator

October 2017

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

D4 Valve with easy-Drive Actuator

October 2017

Instruction Manual

D103597X012

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.

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 D4 with easyDrive comes from the factory calibrated and ready for use with the following default input signals shown in table 5.

Table 5. D4 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 5, proceed to the Wiring Instructions section. If the input signal of the application does not match table 5, 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 6.

Table 6. 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).

Instruction Manual

D103597X012

D4 Valve with easy-Drive Actuator

October 2017

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 local business partner or the Fisher website.

Modbus setup

Use the instructions in the instruction manual for the Modbus master to initiate the connection. The D4 with easyDrive electric actuator Modbus factory defaults are Address 1, 9600 baud, even parity, 1 stop bit.

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

D4 Valve with easy-Drive Actuator

October 2017

Instruction Manual

D103597X012

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 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 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)

Instruction Manual

D103597X012

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.

D4 Valve with easy-Drive Actuator

October 2017

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.

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 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 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

D4 Valve with easy-Drive Actuator

October 2017

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 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 lower, closed

position.

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 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.

Instruction Manual

D103597X012

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 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.

Instruction Manual

D103597X012

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

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

D4 Valve with easy-Drive Actuator

October 2017

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 15.

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).

D4 Valve with easy-Drive Actuator

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Instruction Manual

D103597X012

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

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 D4 is not accurate (proportional positioning units only)

a. If the valve plug opened during calibration, it is set to a D3. Change valve type to D4 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. Follow instructions in Analog Input Calibration, found in the Calibration section of this instruction manual.

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 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

on both sides of the valve. Drain the process media from both sides of the valve.

D Vent the power 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 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.

Instruction Manual

D103597X012

D Check with your process or safety engineer for any additional measures that must be taken to protect against process

media.

D4 Valve with easy-Drive Actuator

October 2017

WARNING

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

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.

Valve Plug and Seat Ring

Disassembly

Key Numbers are referenced in figures 11 and 12.

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.

2. For Positioning Actuators

•Command the valve to anywhere between 10% and 20% travel.

•Isolate power and signal.

•Proceed to step 3.

For ON/OFF Actuators

•Command the valve to open or close, and cut the power when the valve is at midstroke.

•Isolate power and signal.

•Proceed to step 3.

3. Break the hammer nut (key 6) loose with a hammer. Continue turning the hammer nut by using a hammer or a

large adjustable wrench, tightened around one ear of the hammer nut. If the bonnet is stuck on the valve, continue to unscrew the hammer nut. The hammer nut will contact the spring pins (key 7) and will force the bonnet out of the valve. Carefully lift the actuator, bonnet, and valve plug assembly from the valve body.

WARNING

The spring pins must always be in place during valve operation. They provide a safeguard against injury when the unit is being disassembled.

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D103597X012

4. Use a socket wrench to loosen the seat ring (key 3).

5. Remove the seat ring (key 3) and seat ring gasket (key 9) from the valve body.

6. To replace the plug, the stem nut (key 42) must be removed to expose the groove pin (key 4). Open the

explosionproof enclosure (key 60), using a 13mm wrench.

7. Remove the stem nut (key 42) using a 11/16 inch wrench; insert a punch in the hole in the stem to restrict rotation

of the stem while removing the stem nut. The travel indicator (key 32) may need to be moved to expose the hole.

8. Push the stem downward just far enough to expose the groove pin (key 4) on the plug.

9. Remove the plug by driving out the groove pin and unscrewing the valve plug from the stem.

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.

Table 7. Torque for Seat Ring (Key 3)

VALVE SIZE RECOMMENDED TORQUE

NPS NSm LbfSft

1 407 300

2 698 515

Assembly

1. Make sure the bonnet O‐ring (key 8) is on the bonnet and lubricated with lithium grease (key 49).

2. Install the plug (key 2) on the stem (key 47) and insert a new groove pin (key 4).

3. Push the plug and stem upward to ensure the threads on the top of the stem are exposed. Thread the stem nut (key

42) onto the top of the stem and tighten the stem nut (key 42) to 39 N•m (29lbf•ft). Insert a punch in the hole in the stem to restrict rotation while tightening the stem nut.

4. Replace the top of the explosion proof enclosure (key 60) and tighten cap screws (key 64) to 20 N•m (15 lbf•ft).

5. Thoroughly clean the seat ring and bonnet threads in the valve body (key 1). Also clean the valve body seat ring

gasket surfaces.

6. Apply anti‐seize lubricant (key 54) to the threads of the seat ring (key 3), and its mating threads in the valve body.

7. Apply anti‐seize lubricant (key 54) to the seat ring gasket (key 9) and install into the valve body.

8. Screw the seat ring into the valve body. Use a socket wrench to tighten the seat ring to the torque values shown in

table 7. Remove all excess lubricant after tightening.

9. Lubricate (key 54) the threads on the valve body and hammer nut and the contact surfaces of the bonnet and

hammer nut flange. Install the bonnet and actuator assembly with pinned valve plug onto the valve body. Tighten the hammer nut using an adjustable wrench until the nut stops turning. A few hammer blows will be required to ensure that the assembly is tight.

Valve Packing

WARNING

Observe the warning at the start of the Maintenance section.

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D4 Valve with easy-Drive Actuator

October 2017

The valve stem packing can only be accessed from within the valve body.

Disassembly

1. Disassemble the valve per steps 1 through 12 of the Valve Plug and Seat Ring Disassembly section in this instruction

manual.

2. Unscrew the packing retainer (key 10) from the bonnet (key 5).

3. Remove the five Belleville springs (key 11), packing spacer (key 14), packing (key 13), and two anti‐extrusion rings

(key 12) from the bonnet, using a formed wire hook. To aid in packing removal, the stem may be removed.

4. 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 by contacting your Emerson

sales office or Local Business Partner.

5. Inspect the valve stem for scratches or wear, and valve plug for wear or damage. Replace if necessary.

Figure 9. Fisher D4 Packing Installation

UPPER PACKING SPACER (KEY 48)

PACKING RETAINER (KEY 8)

BELLEVILLE SPRINGS FULLY ENCLOSED BY

THE PACKING RETAINER

UNTIGHTENED, NOTE THE GAP

FULLY TIGHTENED, NO GAP

VALVE PLUG, BELLEVILLE SPRINGS, AND PACKING RETAINER

CORRECTLY INSTALLED AND TIGHTENED

D4 Valve with easy-Drive Actuator

October 2017

Figure 10. Lubrication Locations on Packing

FEMALE PACKING ADAPTER

Instruction Manual

D103597X012

PACKING RING

MALE PACKING ADAPTER

LUBRICATE WITH 3mm (1/8 INCH BEAD) OF SUPPLIED HIGH PERFORMANCE FLUORINATED GREASE

Assembly

Refer to figures 9, 10, 11, and 12.

1. If the stem was removed during packing disassembly, insert the stem back into the valve/actuator assembly.

2. Ensure the upper packing spacer (key 48) is installed, as shown in figure 9.

3. Using a non‐marring installation tool, such as a 12‐inch length of 1/2 inch PVC pipe, push the first anti‐extrusion

washer (key 12) fully into the packing box by hand. Then, use the packing spacer (key 14) to fully seat the anti‐extrusion washer by firmly tapping the packing spacer against the anti‐extrusion washer with a hammer and the PVC pipe.

4. Remove the packing spacer from the packing bore.

CAUTION

All D4 packing kits include a single use packet of high performance fluorinated grease. This is the only acceptable D4 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.

5. 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).

6. 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.

7. Install the male packing adaptor, lower anti‐extrusion washer (key 10), and lower packing spacer over the valve

stem as shown in figure 9.

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8. Firmly press all packing parts into the packing bore with a tube.

9. Install the five Belleville springs (key 11) over the valve stem. The Belleville springs should be single‐stacked with the

inside diameter of the inner spring contacting the packing spacer (key 14), and the outside diameter of the outer spring contacting the packing retainer (key 10).

10. Lubricate the threads of the packing retainer with anti‐seize and install into the bonnet using a 1‐5/8 inch wrench. Make sure the Belleville springs are completely enclosed by the packing retainer as shown in figure 9.

11. Torque the packing retainer to 136 NSm (100 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 5). The packing retainer threads should be completely enclosed by the bonnet.

12. Follow steps 1 through 9 of the Valve Plug and Seat Ring Assembly section in this instruction manual.

Parts Ordering

Each D4 control valve is assigned a serial number, which can be found on the nameplate. Refer to the number when contacting your Emerson sales office

WARNING

or Local Business Partner for assistance or when ordering replacement parts.

Use only genuine Fisher replacement parts. Components that are not supplied by Emerson Automation Solutions should not, under any circumstances, be used in any Fisher valve, because they may void your warranty, might adversely affect the performance of the valve, and could cause personal injury and property damage.

Repair Kits

Note

All repair kits are supplied with hydrogenated nitrile bonnet O‐ring. FKM (fluorocarbon) bonnet O‐ring must be ordered separately when required.

Description Part Number

* Packing Repair Kit

Includes key numbers 4, 8, 12 (2 req'd), 13, and high performance fluorinated grease RD4X0000012

Parts List

Note

For part numbers not shown, contact your Emerson sales office Business Partner.

or Local

Key Description Part Number

1 Valve Body 2* Valve Plug

S41000 / S41600 HT NPS 1 valve

0.25 inch port diameter 20C3692X012

0.375 inch port diameter 20C3693X012

0.5 inch port diameter 20C3694X012

0.75 inch port diameter GE01557X012 NPS 2 valve

0.25 inch port diameter GE00992X012

0.375 inch port diameter GE00993X012

0.5 inch port diameter GE00994X012

0.75 inch port diameter GE01558X012 1‐inch port diameter GE01561X012

1.25 inch port diameter GE01555X012 S17400 H1150 Dbl NPS 1 valve

0.25 inch port diameter 20C3692X032

0.375 inch port diameter 20C3693X032

0.5 inch port diameter 20C3694X032

0.75 inch port diameter GE01557X032 NPS 2 valve

0.25 inch port diameter GE00992X032

0.375 inch port diameter GE00993X032

0.5 inch port diameter GE00994X032

0.75 inch port diameter GE01558X032 1‐inch port diameter GE01561X032

1.25 inch port diameter GE01555X032 Tungsten Carbide NPS 1 valve

*Recommended spare parts

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Key Description Part Number

0.25 inch port diameter 20C3696X012

0.375 inch port diameter 20C3697X012

0.5 inch port diameter 20C3698X012

0.75 inch port diameter 20C3699X012 NPS 2 valve

0.25 inch port diameter 20C3682X012

0.375 inch port diameter 20C3683X012

0.5 inch port diameter 20C3685X012

0.75 inch port diameter 20C3686X012 1‐inch port diameter 20C3687X012

1.25 inch port diameter 20C3688X012

3* Seat Ring

S17400 H1150 Dbl NPS 1 valve

0.25 inch port diameter GE00982X032

0.375 inch port diameter GE00983X032

0.5 inch port diameter GE00984X032

0.75 inch port diameter GE00985X032 NPS 2 valve

0.25 inch port diameter GE00986X032

0.375 inch port diameter GE00987X032

0.5 inch port diameter GE00988X032

0.75 inch port diameter GE00989X032 1‐inch port diameter GE00990X032

1.25 inch port diameter GE00991X032 Tungsten Carbide NPS 1 valve

0.25 inch port diameter GE07347X012

0.375 inch port diameter GE07363X012

0.5 inch port diameter GE07364X012

0.75 inch port diameter GE07365X012 NPS 2 valve

0.25 inch port diameter GE07389X012

0.375 inch port diameter GE07394X012

0.5 inch port diameter GE07397X012

0.75 inch port diameter GE07398X012 1‐inch port diameter GE07399X012

1.25 inch port diameter GE07406X012

Key Description Part Number

4* Groove Pin GE01163X012 5 Bonnet 6 Hammer Nut 7 Spring Pin 8* Bonnet O‐ring

Hydrogenated Nitrile

-46 to 149_C (-50 to 300_F) 10C3680X012 FKM, -23 to 204_C (-10 to 400_F) 10C3680X022

9* Seat Ring Gasket

For NPS 1 valve 1B198636042

For NPS 2 valve 1B198836042 10 Packing Retainer 11 Belleville Springs, 5 req'd 12* Anti‐Extrusion Washer, 2 req'd 12B6335X022 13* Packing Set 12B6667X012 14 Packing Spacer 16 Valve Nameplate 17 Drive Screw 18 O‐ring 13A9576X052 19 Stem O‐ring 1K7561X0072 32 Travel Indicator 42 Stem Nut 47* Valve Stem GE48549X012 48 Upper packing spacer 49 Lubricant (lithium grease) 54 Lubricant (anti‐seize) 56 High Performance Fluorinated Grease

Packing Lubricant 58 Enclosure O-ring 59 Motor/gearbox/controller assembly 60 Upper Enclosure 61 Lower Enclosure 62 Motor Cap Screws (4 req'd) 63 Motor Cap Screw Washers (4 req'd) 64 Enclosure Cap Screws (8 req'd) 65 Enclosure Cap Screw Retaining Washers (8 req'd) 66 Ground Screw 68 Certification Nameplate 69 easy-Drive Label

*Recommended spare parts

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Figure 11. D4 Valve Assembly

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13 mm

11/16 INCH

1-1/2 INCH

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Figure 12. Fisher D4 Valve Assembly

Instruction Manual

D103597X012

APPLY LUBRICANT

GE49375-B

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D4 Valve with easy-Drive Actuator

October 2017

Appendix A - Modbus

A.1 Register Summary

Table 8. Register Summary

DATA LEGAL FUNCTION CODES REGISTER (PHYSICAL) TYPE R/W DESCRIPTION

03 – Read Holding Reg

Position Demand – Proportional

Reset Diagnostics

Recalibrate Demand

Analog Cal at 0%

Analog Cal at 100%

Reserved 03 – Read Holding Reg 40006 (0x0005) UINT16 R Read will return power up default of 0 Reserved 03 – Read Holding Reg 40007 (0x0006) UINT16 R Read will return power up default of 0 Reserved 03 – Read Holding Reg 40008 (0x0007) UINT16 R Read will return power up default of 0

Test Register 03 – Read Holding Reg 40009 (0x0008) UINT16 R

Actual Position 03 – Read Holding Reg 40010 (0x0009) UINT16 R Value 0-100 = 0-100% Position

Actual Demand 03 – Read Holding Reg 40011 (0x000A) UINT16 R

Diagnostic Flags 03 – Read Holding Reg 40012 (0x000B) UINT16 R

Number of cycles 03 – Read Holding Reg

Hours Running 03 – Read Holding Reg

Hours Open 03 – Read Holding Reg

Hours Closed 03 – Read Holding Reg

Number of power up cycles 03 – Read Holding Reg

Serial Number 03 – Read Holding Reg

Analog I/P Value 03 – Read Holding Reg 40025 (0x0018) UINT16 R

Firmware Project Code 03 – Read Holding Reg 40026 (0x0019) UINT16 R Project code Firmware Document Reference 03 – Read Holding Reg 40027 (0x001A) UINT16 R Document reference Firmware Version 03 – Read Holding Reg 40028 (0x001B) UINT16 R Version, MSB 8bits = major, LSB 8bits = minor

Diagnostic Flags History 03 – Read Holding Reg 40029 (0x001C) UINT16 R

Reserved 03 – Read Holding Reg 40030 (0x001D) UINT16 R Read will return power up default of 0

06 – Write Single Reg 16 – Write Multiple Reg

03 – Read Holding Reg 06 – Write Single Reg 16 – Write Multiple Reg

40001 (0x0000) UINT16 R/W Value 0-100 = 0-100% Position

40002 (0x0001)

40003 (0x0002) UINT16 R/W

40004 (0x0003) UINT16 R/W 0 = Idle, 1 = Calibrate at 0%

40005 (0x0004) UINT16 R/W 0 = Idle, 1 = Calibrate at 100%

40013 (LSW) (0x000C) 40014 (MSW) (0x000D) 40015 (LSW) (0x000E) 40016 (MSW) (0x000F)

40017 (LSW) (0x0010)

40018 (MSW) (0x0011)

40019 (LSW) (0x0012)

40020 (MSW) (0x0013)

40021 (LSW) (0x0014) 40022 (MSW) (0x0015) 40023 (LSW) (0x0016) 40024 (MSW) (0x0017)

‐continued‐

UINT16 (BOOL)

UINT32† R Number of movements

UINT32† R

UINT32† R Number of times power is cycled successfully

UINT32† R Product Unique Identifier 0-4294967295

R/W 0 = Reset Idle, 1 = Reset Active

0 = Idle, 1 = Reset calibration request – unit will reset to non calibrated state and await calibration sequence

Read will return power up default of 45964 decimal (Binary/Hex

-0b10110001110001100 / 0xB38C)

Value 0-100 = 0-100% is demand to position loop from active control source

Bit Flags – see Description in section 5.2 and table 9

Total hours powered - version 4.13 Total minutes powered - version 4.21

Total hours in open position (at 100%) version 4.13 Total minutes in open position (at 100%) version 4.21

Total hours in closed position (at 0%) version 4.13 Total minutes in closed position (at 0%) version 4.21

0-50 = 0-5V (Voltage mode I/P) 0-200 = 0-20mA(Current Loop I/P)

Bit Flags – see Description in section 5.2. – This is a history of any faults that have occurred and is stored in memory

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Table 8. Register Summary (continued)

DATA LEGAL FUNCTION CODES REGISTER (PHYSICAL) TYPE R/W DESCRIPTION

Reserved 03 – Read Holding Reg 40031 (0x001E) UINT16 R Read will return power up default of 0

03 – Read Holding Reg

Valve type

Control Type 03 – Read Holding Reg 40033 (0x0020) UINT16 R 0 = On/Off, 1 = Proportional

Control Source

Loss of control input/comms default position

Deadband

Low travel cutoff

Communications Timeout

Communications Address

Communications Baudrate

Parity

Reset Statistics

Local Control Mode

06 – Write Single Reg 16 – Write Multiple Reg

03 – Read Holding Reg 06 – Write Single Reg 16 – Write Multiple Reg

40032 (0x001F) UINT16 R/W 1 = D3, 2 = D4

40034 (0x0021) UINT16 R/W

40035 (0x0022) UINT16 R/W

40036 (0x0023) UINT16 R/W

40037 (0x0024) UINT16 R/W Blanking from zero position in percent

40038 (0x0025) UINT16 R/W

40039 (0x0026) UINT16 R/W

40040 (0x0027) UINT16 R/W

40041 (0x0028)

40042 (0x0029)

40043 (0x002A) UINT16 R/W

UINT16 (BOOL)

0 = Modbus RTU Register Commands, 1 = Local Control

Value 0-100 = 0-100% Position Valve 101 - Last Position

Value 0-100 = 0-100% Level of hysteretic dead band applied to position control demand

Timeout in seconds before loss of communications state is asserted

Modbus address in the range 1-247 (Default = 1)

0 = 300 Baud, 1 = 600 Baud, 2 = 1200 Baud, 3 = 2400 Baud, 4 = 4800 Baud, 5 = 9600 Baud, (Default) 6 = 19200 Baud, 7 = 38400 Baud

0 = Odd, 1 = Even, 2 = None

R/W

(“None” available in version 4.21 only)

R/W 0 = Reset Idle, 1 = Reset Active

On/Off 0 = L2e dual dry contact 1 = Single dry contact Proportional 0 = 1-5V 1 = 4-20 mA

UINT16 – unsigned 16 bit variable, can take value 0-65535. UINT32 – unsigned 32 bit variable, can take value 0-4294967295.

(Reserved) – registers used for development use only. † - 32bit register contains data that spans two registers – reads and write of data needs to be performed within the same Modbus command function to ensure coherency of data.

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D4 Valve with easy-Drive Actuator

Table 9. Fault Register – Fault Flags Summary Table

Diagnostic Flags – Bit Mask Value

0x8001 1000 0000 0000 0000 Fault in N.V. Memory – system has restored default settings

0x4000 0100 0000 0000 0000 Motor assembly stall

0x2000 0010 0000 0000 0000 Speed measurement fault

0x1000 0001 0000 0000 0000 System or Watchdog fault

0x0800 0000 1000 0000 0000 Overspeed condition

0x0400 0000 0100 0000 0000 Calibration span not in legal range

0x0200 0000 0010 0000 0000 Fault in N.V. Memory – system has recovered settings

0x0100 0000 0001 0000 0000 Communications Timeout

0x0080 0000 0000 1000 0000 Valve was shutdown while moving

0x0040 0000 0000 0100 0000 Valve span calibrated (informational)

0x0020 0000 0000 0010 0000 Valve position controller active (informational)

0x0010 0000 0000 0001 0000 Analog input – below 3mA/0.75V (informational)

0x0008 0000 0000 0000 1000 Motor Overspeed coast condition

0x0004 0000 0000 0000 0100 Modbus command has been sent (starts a calibrated system)

0x0002 0000 0000 0000 0010 Analog input initialized (system has seen input >3mA/1V

0x0001 0000 0000 0000 0001 Start delay active (within 10 second calibration window)

Diagnostic Flags – Binary Mask Value Description

October 2017

A.2 Diagnostic Flags

The diagnostic register holds a 16 bit value that represents 16 individual flags, when set (value ‘1’), this indicates the following conditions have occurred or are still present, the highest 7 bits are latching and will be present in the register even if the initial cause for the flag being set is removed. If these flags are set, a reset needs to be performed to clear the fault.

A.2.1 Fault in NV Memory

This is a severe fault and is usually seen when the firmware is upgraded with a program that uses a different EEPROM/Non-volatile memory map. If this is not the case then the probable cause is a fault in the memory hardware.

A.2.2 Motor Assembly Stall

The valve plug was unable to move to the commanded position. The drive has attempted to move the motor by applying a non-zero PWM signal, and the speed has not been detected as greater than 0 with a 400ms period. This fault latches and needs to be reset.

A.2.3 Speed Measurement Fault

The controller detected pulses that correspond to the motor going much faster than the speed the speed measurement system is designed for – the integrity of the measurement cannot be relied upon. This fault latches and needs to be reset.

A.2.4 System or Watchdog Fault

The software system has been reset and this flag is set at power up if the case of the reset was the onboard watchdog either timing out OR being forced by program function call. This flag is used as an indication that this type of reset has occurred.

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A.2.5 Overspeed Condition

The drive speed was detected as being over the speed 3300RPM. This fault latches and needs to be reset.

A.2.6 Calibration Span Not in Legal Range

Following a calibration the detected mechanical travel was detected as being too short for the valve type. This fault latches and needs to be reset.

A.2.7 Fault in NV Memory – recovered settings

This fault is similar to Fault in NV Memory but is different in that the settings were recovered, however it is possible the fault was due to a setting being changed during a power cycle. The settings need to be validated before valve operation.

A.2.8 Communications Timeout

This flag is set after a timeout or loss of valid communications, it will be cleared if communications is reestablished with the valve controller. If this flag is set and the control demand is set to be taken from the Modbus then the valve will be commanded to the ‘Loss of communications position’ in setting accessed at Modbus register 40034.

A.2.9 Valve was Shutdown while Moving

The valve was actuating while power was removed, the position information may be unreliable. Command valve to 0% to assure position information is accurate.

A.2.10 Valve Span Calibrated

The valve is calibrated.

A.2.11 Valve Position Controller Active

The valve is being actively controlled to go to a demanded position. The speed and position control loop logic is setting the pwm and direction demands to the ValuDrive motor.

A.2.12 Analog Input Below 3mA/0.75V

The analog input is below a set threshold of 3mA. If since being powered up this level has been met the flag ‘Analog input initialized’ will be set. If the control source is the analog input and this flag is set then the valve will be commanded to actuate to the ‘Loss of control input’ position.

A.2.13 Motor Overspeed Coast Condition

The drive speed was detected as being over the speed 2500RPM. The flag is cleared if the speed falls below the coast threshold level. This flag is used purely as a diagnostic.

A.2.14 Modbus Command Initialized

The system has received a command to the Position demand register since being powered up. If Modbus is the selected control mode the valve will be commanded to this position after the startup period.

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D4 Valve with easy-Drive Actuator

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A.2.15 Analog Input Initialized

The analog input has been detected as having a control signal within the expected range of 3-20mA. If the analog input is the selected control signal then this will activate the valve after the startup period.

A.2.16 Start Delay Active

This is a flag set during the startup phase of operation, if this is set then the valve may be recalibrated by sending the calibration signal sequence (100% demand followed by 0%). It is cleared to indicate normal operation (recalibration will then require a command to Modbus register 40003).

A.3 Register Description

A.3.1 40001 Position Demand – Proportional [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a value between 0 and 100% to demand a valve position. This register will only be used by

the system if the control source (set by register 40035) is set for Modbus RTU control. If the control type (set by register 40034) is On/Off then value will be resolved with a boolean set operation for a Open/Closed position demand variable output (e.g. Values 0-49 = ’0’ and 50-100 = ‘100’). This variable needs to be set to 100% then 0% after a power-up to calibrate an un-calibrated system.

A.3.2 40002 Reset Diagnostics [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a modbus request to reset the system from a fault state (indicated if the Diagnostics flags

register has any set faults). Writing a decimal 1 to the register will start a reset process only if the system has a fault, otherwise the write will be ignored. Once the fault reset request has been acknowledged the register will be set to decimal 0. Bit assignments are shown in table 9.

A.3.3 40003 Recalibrate Demand [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: Writing a value of 1 to this register will force the system to clear any calibration information and

go through a cycle of calibration.

A.3.4 40004 Analog Cal at 0% [Read & Write]

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October 2017

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a register is used to initiate a calibration of the analog to digital circuit in the system. A

write of a ‘1’ will cause the system to store the value at the analog input. This action should be performed with a calibrated 1V or 4mA present at the analog input. If this is not performed the system uses defaults. Values outside the range 0-1 will return an exception code.

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A.3.5 40005 Analog Cal at 100% [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a register is used to initiate a calibration of the analog to digital circuit in the system. A

write of a ‘1’ will cause the system to store the value at the analog input. This action should be performed with a calibrated 5V or 20mA present at the analog input. If this is not performed the system uses defaults. Values outside the range 0-1 will return an exception code.

A.3.6 40004-40008 Reserved [Read Only]

Register: 40004-40008 Address 0x0003 (3) - 0x0007 (7). Function code: 0x03 – Read Holding registers. Description: Not used – reads will return a value of 0.

A.3.7 40009 Test Register [Read Only]

Register: 40009, Address 0x0008 (8). Function code: 0x03 – Read Holding registers. Description: A test register – can be used to confirm communications. Holds a power up default of 45964

(0xB38C Hex).

A.3.8 40010 Actual Position [Read Only]

Register: 40010, Address 0x0009 (9). Function code: 0x03 – Read Holding registers. Description: This is a value between 0 and 100% that indicates the physical position of a calibrated valve

system. If the valve is un-calibrated (indicated if the Diagnostics flags register has a cleared calibration informational flag), then this register will read 0.

A.3.9 40011 Actual Demand [Read Only]

Register: 40011, Address 0x000A (10). Function code: 0x03 – Read Holding registers. Description: This is a value between 0 and 100% that indicates the demand to the position control loop from

the active control source.

A.3.10 40012 Diagnostic Flags [Read Only]

Register: 40012, Address 0x000B (11). Function code: 0x03 – Read Holding registers. Description: This is a set of 16 bit flags that indicate the state of the system. The lower order byte contains

flags that cause the system to go to a fault state – actuation of the valve will not be possible

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until the cause of the fault condition has been removed and the fault condition reset by writing a reset request to register 40001. The upper order byte contains flags used to indicate the operational status of the valve actuator. See table 9 - Fault Register for details.

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A.3.11 40013-40014 Number of Open/Close Cycles [Read Only]

Register: 40013-40014, Address 0x000C (12) – 0x000D (13). Function code: 0x03 – Read Holding registers. Description: This is a pair of registers that hold a 32bit number indicating the number of actuations of the

valve. A cycle of moving the valve from closed to open and back closed will count as 2 cycles. The register needs to be read using a single read function command to ensure coherency of the data in the two registers.

A.3.12 40015-40016 Hours/Minutes Running [Read Only]

Register: 40015-40016, Address 0x000E (14) – 0x000F (15). Function code: 0x03 – Read Holding registers. Description: This is a pair of registers that hold a 32bit number indicating the number of hours the valve has

been powered. The register needs to be read using a single read function command to ensure coherency of the data in the two registers. If version 4.13 firmware is installed, hours are displayed. If version 4.21 firmware is installed, minutes are displayed.

A.3.13 40017-40018 Hours/Minutes Open [Read Only]

Register: 40017-40018, Address 0x0010 (16) – 0x0011 (17). Function code: 0x03 – Read Holding registers. Description: This is a pair of registers that hold a 32bit number indicating the number of hours the valve has

been in the open (100%) position. The register needs to be read using a single read function command to ensure coherency of the data in the two registers. If version 4.13 firmware is installed, hours are displayed. If version 4.21 firmware is installed, minutes are displayed.

A.3.14 40019-40020 Hours/Minutes Closed [Read Only]

Register: 40019-40020, Address 0x0012 (18) – 0x0013 (19). Function code: 0x03 – Read Holding registers. Description: This is a pair of registers that hold a 32bit number indicating the number of hours the valve has

been in the closed (0%) position. The register needs to be read using a single read function command to ensure coherency of the data in the two registers. If version 4.13 firmware is installed, hours are displayed. If version 4.21 firmware is installed, minutes are displayed.

A.3.15 40021-40022 Number of Power up cycles [Read Only]

Register: 40021-40022, Address 0x0014 (20) – 0x0015 (21). Function code: 0x03 – Read Holding registers. Description: This is a pair of registers that hold a 32bit number of times the system has been successfully

powered up. The register needs to be read using a single read function command to ensure coherency of the data in the two registers.

A.3.16 40023-40024 Serial Number [Read Only]

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Description: This is a pair of registers that hold a 32 bit number that can be used to hold a unique serial

number. The register needs to be read using a single read Modbus function transaction command to ensure coherency of the data in the two registers.

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A.3.17 40025 Analog I/P value [Read Only]

Register: 40025, Address 0x0018 (24). Function code: 0x03 – Read Holding registers. Description: This is a register that holds a 16 bit scaled representation of the analog input. It is scaled

according to input i.e. 0-200 for 0-20.0mA and 0-50 for 1-5 V.

A.3.18 40026 Firmware Project Code [Read Only]

Register: 40026, Address 0x0019 (25). Function code: 0x03 – Read Holding registers. Description: This is a register that holds the SRD project code (SRD422) – 422. This is the code used in

version control of SRD documents and source code.

A.3.19 40027 Firmware Document Reference [Read Only]

Register: 40027, Address 0x001A (26). Function code: 0x03 – Read Holding registers. Description: This is a register that holds the SRD document code (SRD422-5007) – 5007. This code along

with the project code is used in version control of SRD documents and source code.

A.3.20 40028 Firmware Version [Read Only]

Register: 40028, Address 0x001B (27). Function code: 0x03 – Read Holding registers. Description: This is a register that holds the hex encoded equivalent of a four digit decimal version number

of the firmware, the high order 8bits encode the whole number of the version and the low order 8 bits the fraction, e.g. v1.16 would be encoded 0x0110, v2.66 would be 0x0242. Together with the data from registers 40026- 40028 it is possible to determine the unique identity of the code being run in the processor.

A.3.21 40029 Diagnostic Flags [Read Only]

Register: 40029, Address 0x001C (28). Function code: 0x03 – Read Holding registers. Description: This is a set of 16 bit flags that show the accumulation of fault flags that have occurred – as

faults are self resetting. The register is stored in non-volatile memory. The mapping is the same as the diagnostic register at 40012. See table 9 - Fault Register for guide to values.

A.3.22 40030-40031 Reserved [Read Only]

Register: 40030-40031, Address 0x001D-0x001E (29-30). Function code: 0x03 – Read Holding registers. Description: Not used – reads will return a value of 0.

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A.3.23 40032 Valve Type [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a register that holds an enumeration of the three types of valve. This is used to set up

several internal variables and constants. Writes outside of the legal range 0-2 will be rejected with an exception code.

A.3.24 40033 Control Type [Read Only]

Register: 40033, Address 0x0020 (32). Function code: 0x03 – Read Holding registers. Description: This is a register that holds an enumeration of the control type – either 0 for On/Off, or 1 for

proportional control.

A.3.25 40034 Control Source [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a register that holds an enumeration of the control source – either 0 for Modbus RTU

control, or 1 for signals local to the system – decided by the contents of register 40032. Note that if the Modbus serial link is not the active mode then the faults associated with serial communications will be disabled, although serial communications for such activities as test and debug monitoring of the analog input will all still function. Writes outside of the legal range 0-1 will be rejected with an exception code.

A.3.26 40035 Loss of Control Default Position [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a register that holds a position demand 0-100% that will be applied to the position

control loop if the active control source is determined to be corrupt of out of normal operating specification, this applies to modbus communications messages being absent or the analog input being un-calibrated or below 3mA/0.75V(open control loop). Writes outside of the legal range 0-100 will be rejected with an exception code.

A.3.27 40036 Deadband [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a register that holds an integer value of percentage hysteresis used to discriminate

against noise entering the control system from the selected control source, this can take a value of 0-100%, e.g. a value of 100 would make the system only respond to 0 or 100% demands. Writes outside of the legal range 0-100 will be rejected with an exception code.

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A.3.28 40037 Low travel Cutoff [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a register that holds an integer value of percentage used as a clamp – any position

demand less than this value will be clamped to zero before being passed to the position control system.

A.3.29 40038 Communications Timeout [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a register that holds a value 0-65535 that is the number of seconds for a timeout before

the modbus serial communications channel is determined to be uncommunicative (0 - ~18Hrs). A valid addressed message must be received by the system within this time limit if the active control source is Modbus RTU communications. If the time without communications is exceeded the system will fault and the valve commanded to the default loss of communications position. A value of 0 can be used to disable this feature. If communications is resumed then the flag will be cleared and the valve will take the refreshed position as a demand. The use of this register is shown in table 9 - Fault Register.

A.3.30 40039 Communications Address [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a register that holds a value 1-247 that is the Modbus address used by the system on

power up. Values outside the range 1-247 will return an exception code

A.3.31 40040 Communications Baudrate [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a register that holds a value 4-6 that is an enumeration of the baudrate used by the

system on power up.

A.3.32 40041 Parity [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a register that holds an enumeration of the parity type used by the Modbus serial

interface – either 0 for Odd, or 1 for Even in version 4.13 firmware (version 4.21 firmware defines 0=Odd, 1=Even, 2=None). Writes outside of the legal range will be rejected with an exception code.

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A.3.33 40042 Reset Statistics [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a register used to reset the non volatile system statistics (such as number of hours run).

Writing a value of 1 to these registers will reset the values that accessed in registers 40013-40022 to 0.

A.3.34 40043 Analog Input Mode [Read & Write]

0x06 – Write Single register, or 0x03 – Read Holding registers.

Description: This is a register that holds an enumeration 0-1 that sets the mode of operation for on/off and

proportional control. When in proportional mode (40033 = 1), a value of 0 sets the unit for using a 1-5V voltage input. 1 sets up the unit for using a 4-20 mA current command input. The scaling of the different modes is reflected in the scaling of the value reported in register at 40023 –‘Analog I/P value’. When in on/off mode (40033 = 0), a value of 0 sets the unit for using both digital inputs, optimized for using the L2e level controller. 1 sets up the unit for using a single digital input. See Operation for further details.

A.4 Example Modbus Protocol Transactions

A.4.1 Write to Position Demand Register (40002/0x0001/1)

Write of a position demand value of 100% to device at address 1 on the Modbus network – 8 characters.

FIELD

Index 0 1 2 3 4 5 6 7

Hex (Dec) 0x01 (1) 0x06 (6) 0x00 (0) 0x01 (1) 0x00 (0) 0x64 (100) 0xD9 (217) 0xE1 (225)

SLAVE

ADDRESS

Normal response, 8 characters:

FIELD

Index 0 1 2 3 4 5 6 7

Hex (Dec) 0x01 (1) 0x06 (6) 0x00 (0) 0x01 (1) 0x00 (0) 0x64 (100) 0xD9 (217) 0xE1 (225)

SLAVE

ADDRESS

Write of a position demand value of 101% to device at address 1 on the Modbus network, note that this value (101% is outside the legal range of values permitted to be written to this address, so an exception frame is generated – 8 characters.

FIELD

Index 0 1 2 3 4 5 6 7

Hex (Dec) 0x01 (1) 0x06 (6) 0x00 (0) 0x01 (1) 0x00 (0) 0x65 (101) 0x18 (24) 0x21 (33)

SLAVE

ADDRESS

FUNCTION

CODE

FUNCTION

CODE

FUNCTION

CODE

ADDRESS HI

ADDRESS LO

DATA HI

DATA LO

CRC LO CRC HI

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Exception response, write not OK – slave device failure (Code 4), error code is function code with 0x80 added, 5 characters returned:-

FIELD

Index 0 1 2 3 4

Hex (Dec) 0x01 (1) 0x06 (6) 0x00 (0) 0x18 (24) 0x21 (33)

SLAVE

ADDRESS

ERROR

CODE

EXCEPTION

CODE

CRC LO CRC HI

A.4.2 Read of Actual Position (40010/0x0009/9)

Read of actual position from device at address 1 on the Modbus network using read holding register function – 8 characters.

FIELD

Index 0 1 2 3 4 5 6 7

Hex (Dec) 0x01 (1) 0x03 (3) 0x00 (0) 0x09 (9) 0x00 (0) 0x01 (1) 0x54 (84) 0x08 (8)

SLAVE

ADDRESS

Normal response (returning a value of 0%), 7 characters returned:-

FIELD SLAVE ADDRESS

Index 0 1 2 4 5 6 7

Hex (Dec) 0x01 (1) 0x03 (3) 0x02 (2) 0x00 (0) 0x00 (0) 0xB8 (184) 0x44 (68)

FUNCTION

CODE

FUNCTION

CODE

ADDRESS HI

BYTE COUNT

ADDRESS LO

ADDRESS HI

QUANTITY OF

REGS HI

QUANTITY OF

REGS LO

ADDRESS LO

CRC LO CRC HI

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