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GE Becker 3.5M Series Instruction Manual

Digital natural gas positioner with modbus protocol.
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GE Oil & Gas
Becker
Gas Positioner (DNGP)
Series 3.5M with Modbus
Instruction Manual

Table of Contents

Sections
Introduction........................................................................................... 2
Scope of Manual ................................................................................. 2
T echnical Assistance ....................................................................... 2
Technical Specifications .................................................................. 4
Principle of Operation ..................................................................... 4
Wire Size Recommendations ....................................................... 4
Logic Board & Wiring Diagram ................................................... 5
Jumpers & Fuses ............................................................................... 5
Orifice Adjustment ............................................................................ 7
Pressure Control Override .......................................................... 10
Rotary Position Transmitter ....................................................... 14
Rotary Transmitter Calibration ................................................ 15
Linear Transmitter ........................................................................... 16
Replacing Electronic Module .......................................................22
Linear Transmitter Programming ............................................23
High Pressure 5/3 Solenoid Valve ............................................24
Replacement .....................................................................................25
*
Digital Natural
Page
Protocol
Sections
Low Pressure 2/2 Solenoid Valve ..............................................26
High Pressure 3/2 Solenoid Valve .............................................26
Troubleshooting ................................................................................27
The Run-Time Screen .............................................................28-29
Input Configuration Menu ...........................................................30
Valve Actions Menu ........................................................................31
Logging & Alarms Menu ........................................................31-32
The Firmware Menu .......................................................................32
Upgrading the DNGP Firmware ................................................34
DNGP Leak Test Procedure .........................................................37
Certifications & Approvals ............................................................38
Software Release Information....................................................38
Page

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Table of Contents

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   Summary of Contents for GE Becker 3.5M Series

  • Page 1: Table Of Contents

    GE Oil & Gas Becker Digital Natural Gas Positioner (DNGP) Series 3.5M with Modbus Protocol ™ Instruction Manual Table of Contents Sections Page Sections Page Introduction................... 2 Low Pressure 2/2 Solenoid Valve ..........26 Scope of Manual ................. 2 High Pressure 3/2 Solenoid Valve ..........26 T echnical Assistance ...............
  • Page 2: Introduction

    Should you have any questions concerning these bleed gas produced by I/P transducers and bleeds no instructions, you may contact your local GE sales gas until the valve is called upon to move. The DNGP representative, sales offi ce, or manufacturer before can even do this while maintaining a pressure difference proceeding.
  • Page 3 Table 1 - DNGP Technical Specifi cations (continued) Direct or Reverse Acting (selectable by accessing DNGP Menu and Input Signal Action Transmitter Switch) Pneumatic Action Double Acting or Single Acting Deadband Adjustable from 0.1% to 2.0% of full travel Hysteresis <2.0% full scale (with rotary position feedback transmitter Linearity <±1.0% full scale (with standard linear digital transmitter)
  • Page 4: Technical Specifications

    Principle of Operation In the case of single acting actuators, the pressure will The solenoid operated electro-pneumatic positioner be full power gas pressure or zero psig. If either the compares a 4-20 mA signal from a RTU to a 4-20 mA RTU signal or transmitter signal falls below 3.5 mA, the signal from a position transmitter.
  • Page 5: Logic Board & Wiring Diagram

    Logic Board & Wiring Diagram Jumpers & Fuses The DNGP is equipped with two terminal boards. Terminal A look at the logic board layout on page 7 shows the board #1 has 10 connections and terminal board #2 location of the jumpers JP1 and JP2. The selection of the has 14 connections.
  • Page 6 Terminal Board #1 Jumper between Pins 5 & 6 on (10 Connectors) Terminal Board #2 (Only used if RTU feedback is not connected) Pin #10 Pin #1 Pin #14 Terminal Board #2 (14 Connectors) F1 - 0.1 A, PTC Fuse for 4-20 mA Signal Manual Auto Current Loop...
  • Page 7: Orifice Adjustment

    Orifi ce Adjustment Table 3 - Orifi ce Part Numbers Orifices at each of the cylinder ports (double acting) or Orifi ce Size “Marking Part # flow control valve (single-acting) control the flow of gas Assembly 25-1559 Standard into the actuator, and therefore, the speed at which the (No Mark) Orifi...
  • Page 8 Figure 6 - 4” to 12” valves are used with “M” orifi ce blocks, 14” & 16” valves are used with “L” orifi ce blocks Figure 7 - For valves > 16” no orifi ces are needed.
  • Page 9 Figure 8 - Single Acting Control Valve, P ≥ 50 Psig SUPPLY Figure 9 - Single Acting Control Valve, P ≤ 40 Psig SUPPLY...
  • Page 10: Pressure Control Override

    Electro-Pneumatic Positioner Pressure Control Override* Conventional fl ow control with PCO (Pressure Control Override) is accomplished by sending a signal to the positioner from an I/P transducer or pneumatic controller. A HIGH SELECT RELAY determines if the positioner is controlled by the pneumatic controller (pressure control) or the I/P (fl...
  • Page 11 Figure 12 - Double Acting Control Valve with PCO, P ≥ 50 Psig (High Pressure Override) SUPPLY Figure 13 - Double Acting Control Valve with PCO, P > 50 Psig (Low Pressure Override) SUPPLY...
  • Page 12 Figure 14 - Single Acting Control Valve with PCO, P ≥ 40 Psia SUPPLY Figure 15 - Single Acting Control Valve with PCO, P > 50 Psia SUPPLY...
  • Page 13 Figure 16 - Rotary Piston Spring To Close Actuator with High Pressure 3/2 solenoid valve P 40 - 150 psig SUPPLY Figure 17 - Rotary Piston Spring To Open Actuator with Pressure Control Override, P 40 - 150 psig SUPPLY...
  • Page 14: Rotary Position Transmitter

    Figure 18 - Rotary Piston Spring Return Actuator with Snap Acting Selector Relay, P 40 - 150 psig SUPPLY For Short Dynamic Systems such as Power Plants Notes 1. Control valve will close on increasing measured variable pressure 2. Regulator is to open on loss of power gas 3.
  • Page 15: Rotary Transmitter Calibration

    Rotary Transmitter 4-20 mA Calibration Procedure 1. Mount the rotary transmitter to the actuator. Set limit changes no more than 0.5 mA from previous reading. switches if supplied per instructions provided with unit. Renegage gears (if equipped with mechanicals witches, depress switch plunger to allow gear to 2.
  • Page 16: Linear Transmitter

    Jumper Settings for DNGP with Rotary Transmitter Option 1. Jump 1 & 2 of JP1 in order to power the loop from external source; RTU provides the power. Option 2. Jump 2 & 3 of JP1 in order to power the loop with DNGP’s internal power source;...
  • Page 17 Table 5 - Tail Rod/Proportional Confi guration Part Numbers Item # Part # Description 98-3176 10-32 x 1” SHCS 98-2529 10-32 Hex Nut 31-2013 Bracket 98-2782 3/8” ID Lockwasher 98-2927 1/4-20 x 2” HHCS 98-3269 8-32 x 1/2” SHCS (Alloy) 01-8901 Magnet 98-3181...
  • Page 18 Table 6 - Riser Pipe Mount Confi guration Part Numbers Table 7 - Indicator Bar Part Numbers Item # Part # Description Cylinder Bar Part# 31-2005 Adjusting Bushing 6” 14-3114 98-2614 8-32 x 1/2 SHCS (316) 8” 14-3130 98-2538 8-32 Hex Nut (18.8) 10”...
  • Page 19 WARNING: This model was discontinued in 2007 Figure 24 - Linear Transmitter Overall Dimensions Figure 26 - Linear Transmitter Magnet Figure 25 - Linear Transmitter Adapter Flange Figure 27 - Reversible Linear Transmitter Connector...
  • Page 20 Figure 28 - Linear Transmitter Wiring Diagram Table 9 - Programmable Linear Position Transmitter Specifi cations (Supplied 2006 and later) Measured Parameter Specifi cation Analog Output Voltage-Output Versions 0.5 mV or 5 μm (whichever is greater) Repeatability (Resolution + Hysteresis) Current-Output Versions 1 μA or 5 μm (whichever is greater) For stroke lengths ≤...
  • Page 21 Figure 29 - Linear Transmitter Overall Dimensions Figure 30 - Programmable Linear Transmitter Wiring Diagram...
  • Page 22: Replacing Electronic Module

    Replacing the Electronic Module of the Programmable Linear Transmitter Step 1: Turn off the power and remove the 4 connecting wires. Step 2: Remove the two retaining screws with a 3mm hex wrench. Step 3: Remove the Electronic Module from the housing and shaft. Step 4: The new transmitter Module can be either 20 mA Down or 20mA Up depending on the position of Dip Switch #2 (See Fig.
  • Page 23: Linear Transmitter Programming

    Confi guring the DNGP Positioner Action In order to change your valve from Close on Increase to Step 2. Select the “Positioner Action” option. Open on Increase and vice versa, access the DNGP valve state menu and the linear position transmitter as Input Config Menu the following: Input Selections...
  • Page 24: High Pressure 5/3 Solenoid Valve

    Gray Button Blue Button Part Number 01-8902 Transmitter Parts Figure 33 - Linear Transmitter Assembly with Programming Tool Complete Transmit- Electronic Stk. ter Assembly with Module Electronic Module 4” 01-8975 01-8980 6” 01-8976 01-8981 8” 01-8977 01-8982 12” 01-8978 01-8983 DNGP Accessories: High Pressure 5/3 Solenoid The high pressure 5/3 solenoid is used for DNGP applica- tions where P...
  • Page 25: High Pressure 5/3 Solenoid Valve Conversion And Replacement

    Table 10 - High Pressure 5/3 Solenoid Specifi cations Valve Seals: For Internal Pilot Operation: 160 psi line Some oils may swell the rubber seals in valves and pressure max., 50 psi line pressure min cylinders, and may cause binding. To determine if the Pressure Ratings* For External Pilot Operation: 160 psi line seals are swelled in AAA valves:...
  • Page 26: Low Pressure 2/2 Solenoid Valve

    DNGP Accessories: Low Pressure 2/2 Solenoid Valve for Power Gas < 40 psig For Valves with Spring and Diaphragm Actuators (See Figure 14 for Pipeline Schematic) Table 11 - Low Pressure 2/2 Solenoid Valve Specifi cations Two Low Pressure 2/2 solenoid valves are used in single- 7 - (A, B, C, &D) Explosion proof Class I, acting DNGP applications when the P <...
  • Page 27: 3/2 And 2/2 Solenoid Valve Maintenance & Troubleshooting

    2/2 and 3/2 Solenoid Valve Maintenance & Troubleshooting Instructions Causes of Improper Operation: WARNING To prevent the possibility of personal injury or 1. Faulty Control Circuit property damage, turn off electrical power, Check the electrical system by energizing the depressurize solenoid operator and/or valve, and solenoid.
  • Page 28: The Run-time Screen

    Run Time Screen 1. Current Loop Mode The Run-Time Screen contains all the real-time feedback data for the DNGP. The diagram below shows a screenshot of a DNGP Run-Time Screen. The boxes accompanying the diagram show all possible feedback symbols and their meanings. In Current Loop Mode the DNGP accepts the standard 4-20 mA input and energizes the solenoid to stroke the valve to the desired position.
  • Page 29 2. Digital Mode As opposed to the Current Loop Mode, the DNGP also has Digital Mode. In navigating the Run-Time Screen the only noticeable difference is the display of the Top Variable Feedback Bar. In this case there is no bar, only the current active input is displayed. All button commands have the same function as in Current Loop Mode.
  • Page 30: Input Configuration Menu

    Input Confi guration Menu 1. Input Select It is sometimes desirable to change the input of the DNGP from standard 4-20 mA to user defined digital inputs, or Modbus Control. This can be accomplished through the INPUT CONFIGURATION MENU using the INPUT SELECT option.
  • Page 31: Valve Actions Menu

    Valve Actions Menu 1. Bypass Mode In some cases a valve may need the solenoid on or off when in a full closed or full open position. The DNGP has the ability to energize (turn on) or de-energize (turn off) the solenoid using the bypass mode. Input Config Valve Actions Menu Bypass Mode:...
  • Page 32: The Firmware Menu

    Logging and Alarms Menu 1. Limit Alarms In some applications the valve may need to stay inside a specific prescribed region of operation. For this situation the DNGP can be configured to give alarms when these limits are reached. To set the upper and lower limit alarms follow the procedure given below.
  • Page 33 3. Reset Solenoid Counter The user can reset the solenoid counter of the DNGP for various reasons (count the number of cycles from a zero reference, etc). This is accomplished through the RESET SOLENOID COUNTER function on the LOGGING AND ALARMS MENU. Input Config Logging &...
  • Page 34: Upgrading The Dngp Firmware

    2. Firmware Update Occasionally the firmware of the DNGP may need rebooting, or updating. During this time the valve is inoperable. The new version is available from the Becker website. When the process is complete the currently installed version will be displayed on the screen. See the Upgrading DNGP Firmware section for additional instructions on FIRMWARE installation.
  • Page 35 11.It will bring up Open HEX File window. Browse to 6. Next, change the Baud Rate. Right click on the bottom the hex file to download, e.g. right box, and then select 115200. If any problems Dngp_download.version.dd_MMM_YYYY.hex. occur while downloading, try 57600 instead. Open file and in a few seconds it will display HEX File Imported.
  • Page 36 Table 12 - DNGP Alarm and Fault Handling Condition Response/Action Loss of Control Signal 1 Displays “CTRL: Fault” (Current Loop) in 4-20 mA Check the RTU output Input Mode. Check wires # 1 and 2 on Terminal Board 2 Display “FDBK: Fault” Disconnect any other wires from #5 &...
  • Page 37: Dngp Leak Test Procedure

    Table 13 - DNGP Spare Parts List Condition Response/Action High Pressure 5/3 Solenoid Valve - Complete Assembly 20-4500 High Pressure 5/3 Solenoid Valve Body 20-4506 High Pressure 5/3 Solenoid Coil - 24 VDC 20-4509 High Pressure 5/3 Solenoid Coil - 12 VDC 20-4518 Low Pressure 2/2 Solenoid Valve - 24 VDC (less than 40 psig) 20-4202...
  • Page 38: Certifications & Approvals

    Certifi cations and Approvals Part/Component Certifi cation RoHS Compliant DNGP Logic Board Tested per FCC Part 15.07 EN 61000-6-2, EN 61000-6-4 Class I, Groups B,C,D Class II, Groups E,F,G CSA C22.2 No. 25 & 30 DNGP Enclosure Optional ATEX Available DEMKO 03 ATEX 0303070U II G D EEx d IIB + H2 SIRA 05 ATEX M334...
  • Page 39 5. Warranty 5.1 Seller warrants that Products shall be delivered free from defects in material, workmanship and title and that Services shall be performed in a competent, diligent manner in accordance with any mutually agreed specifications. 5.2 The warranty for Products shall expire one (1) year from first use or eighteen (18) months from delivery, whichever occurs first, except that software is warranted for ninety (90) days from delivery.
  • Page 40 1550 Greenleaf Avenue Elk Grove Village, Illinois 60007 USA T: +1 847.437.5940 F: +1 847.437.2549 Inside US T: 800.323.8844 Email: becker@ge.com Visit us online at: www.ge.com/energy ©2012, General Electric Company All Rights Reserved *Trademark of General Electric Company GEA 19690 IM_DNGP...

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