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Becker Digital Natural Gas Positioner Instruction Manual | 79

7. Troubleshooting and Maintenance

This section discusses troubleshooting and maintenance issues.

Troubleshooting the Firmware Cold Restart

If any Firmware problems occur, cold restart the DNGP using the following steps:

1. Turn the DNGP power off.

2. Press and hold the

DOWN

and

ENTER

buttons.

3. Apply power to the DNGP. The alarm light goes on and the D17 LED flashes.

Alarm and Fault Handling

Explosion Hazard: Do not disconnect equipment unless power has been switched off or the area is

known to be non-hazardous.

Table 13 - DNGP Alarm and Fault Handling

Condition

Response

Action

Loss of Control Signal 1

(Current Loop) in 4-20 mA

Input Mode

Displays

CTRL:

Fault

Check the RTU output

Check wires # 1 and 2 on Terminal Board 2

Loss of Feedback Signal

Displays

FDBK Fault.

Disconnect any other wires from #5 and 6 on TB 2 and jump

# 5 and 6 instead

Checks the SCADA for internal power or external power

Check the DNGP board JP1 for external or internal power.

Summary of Contents for Becker Series

Page 1: ...Becker Digital Natural Gas Positioner DNGP Series 3 5 M with Modbus Protocol Instruction Manual Rev C Baker Hughes Data Classification Public...

Page 2: ...n whole or part shall not be transcribed or copied without Baker Hughes Company s written permission In no case does this manual guarantee the merchantability of the positioner or the software or its...

Page 3: ...E SITE THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION OPERATION OR MAINTENANC...

Page 5: ...stlock CS and DS Rotary Position Transmitters 43 Wiring diagram for Westlock CS and DNGP 44 Jumper Settings for DNGP with Rotary Transmitter CS 44 Rotary Transmitter 4 20 mA Calibration Procedure for...

Page 6: ...s 75 Remote Indicator 76 Reset Solenoid Counter 76 Firmware Menu 77 Version Info 77 7 Troubleshooting and Maintenance 79 Troubleshooting the Firmware Cold Restart 79 Alarm and Fault Handling 79 DNGP L...

Page 7: ...n Spring to Close Actuator w High Pressure 3 2 Solenoid Valve PSUPPLY 65 160 PSIG 39 Figure 18 Rotary Piston Spring to Open Actuator w Pressure Control Override PSUPPLY 65 160 PSIG 40 Figure 19 Rotary...

Page 8: ...ecifications 15 Table 2 Rotary Transmitter Technical Specifications 17 Table 3 Programmable Linear Position Transmitter Specifications Supplied 2006 and later 17 Table 4 DNGP Spare Parts List 18 Table...

Page 9: ...nformation Read the instructions carefully before installing and maintaining your instrument Total compliance with all DANGER WARNING and CAUTION notices is required for safe operation DANGER Indicate...

Page 10: ...onal codes and standards by qualified personnel using safe site work practices Personal Protective Equipment PPE must be used per safe site work practices Explosion Hazard Do not disconnect equipment...

Page 11: ...l of gases other than oxygen being present can lead to a risk of personnel asphyxiation Use only genuine replacement parts which are provided by the manufacturer to guarantee that the products comply...

Page 13: ...gnals the positioner energizes the open or close solenoid to drive the control valve toward the desired position If the signals are within an adjustable dead band neither solenoid is energized The sol...

Page 15: ...ected to function as Solenoid Counter or In Standby Manual In Counter mode it pulses whenever either solenoid activates In Standby Manual mode it is active whenever the DNGP is in Standby or Manual mo...

Page 16: ...ations Electrical Enclosure Explosion Proof for Class I Groups C and D Class II Groups E F G Class III hazardous locations RoHS compliant Enclosure Available in explosion proof housing with window or...

Page 17: ...20 mA DC Load Impedance 0 950 Ohms at 24 VDC Output Current Limit Internally limited to 33 mA Rotation Range 45 95 Linearity 1 0 Hysteresis 1 of full scale Repeatability 0 3 of full scale Measured Par...

Page 18: ...tter Refresh 01 9991 Balluff BTL7 10 12 stroke position transmitter Refresh 01 9992 Balluff BTL5 4 stroke replacement electronic module Legacy 01 8980 Balluff BTL5 6 stroke replacement electronic modu...

Page 19: ...y spring centered 1 4 NPT in pilot dual coil with manual override 20 3901 Versa VXX 4323 H NGST 16B PC XX D012 Solenoid Valve Brass 12 VDC 4 way spring cen tered 1 4 NPT in pilot dual coil 20 3902 Ver...

Page 20: ...ion 3 01 00 Aug 28 2011 Modbus protocol added 2 02 00 Nov 7 2008 Fault Alarm is disabled at 4 and 20 mA 2 01 00 Jul 14 2008 Pulse control mode added to menu 2 00 P6 Feb 18 2008 Enable Pulse Mode not a...

Page 21: ...ions which must be connected in compliance to all Local and National Electrical codes DNGP REM Plastic enclosure The DNGP REM contains the circuit board in a plastic enclosure that may be installed in...

Page 22: ...L Ft Length of wire one way between power supply and DNGP R Ohm Resistance per 1000 ft of the wire I Amps DNGP current draw 1 A Equation 1 tells us that for longer distances of wire between the power...

Page 23: ...formation Note Check with wire manufacturer for more accurate resistance data Dedicated wiring for each DNGP unit is recommended Voltage drops greater than four Volts are not recommended Actual resist...

Page 24: ...ace signals limit switches power inputs position feedback inputs etc while terminal board 1 applies to other interface signals transmitter position inputs solenoid inputs heaters etc A complete logic...

Page 25: ...uses F1 and F2 may be reset by cycling the boards off and on F3 is a 3 A fuse for the voltage input power Finally F4 is a 3 A replacement fuse for F3 Jumper between Pins 5 6 on Terminal Board 2 Only u...

Page 26: ...fices should be set at maximum value If more precise valve positioning is required for the application decrease the orifice settings one or two numbers at a time and readjust the sensitivity As the va...

Page 28: ...Double Acting Cyliner with DNGP Cylinder Bore Size Stroke Orifice Size 4 6 all Small Standard Orifice Block Assy p n 25 1559 on cylinder and 20 2915 metering valve installed on solenoid exhaust 8 10...

Page 33: ...n 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 flow control Figure 11 Conventional Flow...

Page 34: ...uator High Select DNGP 2 0 with 4 20 mA Input Figure 12 Flow Control with Electro Pneumatic Positioner and PCOH High Pressure Override Note For double acting systems Becker double acting pilots are us...

Page 35: ...Becker Digital Natural Gas Positioner Instruction Manual 35 2022 Baker Hughes Company All rights reserved Figure 13 Double Acting Control Valve with PCO PSUPPL 55 PSIG High Pressure Override Y...

Page 39: ...Digital Natural Gas Positioner Instruction Manual 39 2022 Baker Hughes Company All rights reserved Figure 17 Rotary Piston Spring to Close Actuator w High Pressure 3 2 Solenoid Valve P SUPPL 65 160 P...

Page 41: ...Snap Acting Selector Relay P SUPPL 65 160 PSIG For Short Y Dynamic Systems such as Power Plants Note The control valve closes on ncreasing measured variable pressure The regulator is to open on loss o...

Page 43: ...less power has been switched off or the area is known to be non hazardous Westlock CS and DS Rotary Position Transmitters The Westlock Rotary Position Monitor is used in conjunction with the DNGP This...

Page 44: ...Jumper Settings for DNGP with Rotary Transmitter CS Option 1 Jump 1 and 2 of JP1 to power the loop from external source RTU provides the power Option 2 Jump 2 and 3 of JP1 to power the loop with DNGP...

Page 45: ...me care not to turn the main shaft gear to insure you maintain proper switch settings 5 With main shaft gear pressed turn the transmitter gear to the fully counterclockwise position and note the readi...

Page 47: ...It can be used in conjunction with a variety of travel switches and sensors This is a quick guide to it and how to set the basic functions For more complete information on the DS module please refer t...

Page 48: ...enter Low Calibration c Left LED will flash RED GREEN Press LO SELECT to confirm d If Selection not confirmed in 6 min it will time out e Right LED will flash RED GREEN while processing change f Both...

Page 49: ...old HI NEXT button to enter HI Calibration c Left LED will flash RED GREEN Press HI NEXT to confirm d If Selection not confirmed in 6 min it will time out e Right LED will flash RED GREEN while proces...

Page 50: ...at same time b Press HI NEXT to access CAL mode c Press HI NEXT to get to Reverse Current mode HICC d Press LO SELECT to confirm e Press HI SELECT to navigate to reverse option f Wait while mA reverse...

Page 51: ...able in a tail rod or standard configuration Figure 24 indicates the major components in a typical tail rod configuration for Refresh Actuators Figure 25 shows the same concept is used to show the sta...

Page 52: ...justment of 4 or 20 mA See Balluff manual for details Figure 26 Detailed View of the Linear Position Transmitter Standard Assembly for Refresh Actuators Item Part Description 1 98 3176 10 32 x 1 SHCS...

Page 53: ...8SS 7 07 2074 INSUL SHT BLF XMTR BOX 60A D RED 8 92186A633 SCREW 3 8 16 X 2 25 PT HHCS 316SS 9 98017A199 WASHER 3 8 SCREW 390 ID PASSIV 18 8SS 10 90715A145 NUT HEX 3 8 16 THRD NYLOCK 316SS 11 94 2704...

Page 54: ...aker Hughes 2022 Baker Hughes Company All rights reserved Figure 27 Linear Transmitter Overall Dimensions Figure 28 Linear Transmitter Adapter Flange and Magnet for Refresh Actuators Magnet Adapter Fl...

Page 58: ...8 Baker Hughes 2022 Baker Hughes Company All rights reserved Figure 32 Linear Transmitter BTL5 and BTL7 Note BTL5 and BTL7 modules are not interchangeable as they may lose their explosion proof rating...

Page 59: ...on Increase BTL5 Position Sensor Configuring DNGP Positioner Action On the DNGP board you need to select the position action to change the valve from Close on Increase to Open on Increase or vice ver...

Page 60: ...ur seconds 4 Move the valve to the Top Position The Position Magnet will be close to the transmitter body Press the Blue button and hold for four seconds 5 Move the Valve to the Bottom Position The Po...

Page 61: ...remain energized for calibration except as noted herein When starting up valve may move Keep clear of hazardous areas All work should be done only by trained qualified personnel Note Remove power when...

Page 62: ...ker Hughes 2022 Baker Hughes Company All rights reserved 1 1 2 2 Installation of Calibration Tool on BTL7 Figure 36 Linear Transmitter Assembly with Programming Tool BTL7 Note BTL7 load resistance 500...

Page 63: ...r locking screw 2 Unscrew cover of Balluff 3 Install Calibration tool See Figure 37 4 Stroke actuator to within measuring range Approximately 50 is good 5 Hold down the blue button for at least 4 seco...

Page 64: ...bottom end as 20mA 10 Optional To change the action and put top as 20mA and bottom as 4mA a Hold down the blue and gray buttons at the same time for at least 4 seconds When released they are reversed...

Page 65: ...nto Adjust mode 6 Stroke actuator to bring magnet to the top near the head of the Balluff 7 Hold down the blue button for at least 2 seconds set the head of the Balluff as 4mA 8 If reading outside of...

Page 66: ...ting Replacement Parts for BTL Position Transmitters Replacement Magnet for BTL5 and BTL7 is part number 07 2003 Replacement Calibration Push Button Tool for BTL7 is part number 01 9997 Replacement Ca...

Page 67: ...pipeline schematic Figure 37 Low Pressure 2 2 Solenoid Overall Dimensions Figure 38 DNGP with 2 2 Solenoid Valves Two Low Pressure 2 2 solenoid valves are used in single acting DNGP applications when...

Page 68: ...Closed in other words the valve is closed when solenoid is de energized open when energized Figure 39 High Pressure 3 2 Solenoid Valve 60 160 PSIG High Pressure 5 2 Solenoid Valve for Power Gas 60 16...

Page 69: ...3 Solenoid Attached Figure 41 High Pressure 5 3 Solenoid Overall Dimensions Note Solenoid valves may be used on vacuum or pressures below or above the stated limits up to 250 psi however the external...

Page 71: ...figure the positioner Run Time Screen 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 box...

Page 72: ...g Current D Decreasing Current Bypass Limit i Increasing Current I Increasing Current Bypass Limit H Halted W Waking Solenoids on Not Yet Moving M Moving C Coasting Full Range Standard Split Range Sta...

Page 73: ...to select SPLIT CONTROL then press ENTER button Press UP or DOWN button to select UPPER LIMIT then press ENTER button Press UP or DOWN button to select LOWER LIMIT then press ENTER button Upper Split...

Page 74: ...ess UP or DOWN button to select VALVE ACTIONS then press ENTER button Press UP or DOWN button to select PULSE MODE then press ENTER button Press UP or DOWN button to make option selection then press E...

Page 75: ...on Press UP or DOWN button to select ADJUST UPPER then press ENTER button Press UP or DOWN button to select ADJUST LOWER then press ENTER button Upper Limit Alarm 98 Lower Limit Alarm 2 Press UP or DO...

Page 76: ...et Solenoid Count Are You Sure No Yes Press UP or DOWN button to select LOGGING ALARMS then press ENTER button Press UP or DOWN button to select RESET SOLENOID COUNT then press ENTER button Press UP o...

Page 77: ...FIRMWARE then press ENTER button Press UP or DOWN button to select VERSION INFO then press ENTER button Press UP or DOWN button to select VERSION INFO then press ENTER button Firmware Menu Version In...

Page 79: ...e alarm light goes on and the D17 LED flashes Alarm and Fault Handling Explosion Hazard Do not disconnect equipment unless power has been switched off or the area is known to be non hazardous Table 13...

Page 80: ...e time close the valve and check the CTRL and FDBK values which must be within 16 mA if not adjust the VP pot or magnet for the linear position transmitter DNGP doesn t move on change of signal CTRL a...

Page 81: ...ts If a leak is found tighten bolts or fittings If no leak is found check the solenoid valves Replacing the Electronic Module of the Programmable Linear Transmitter 1 Turn off the power and remove the...

Page 82: ...witched off or the area is known to be non hazardous Cleaning All solenoid operators and valves should be cleaned periodically The time between cleaning varies depending on medium and service conditio...

Page 83: ...e click indicates loss of power supply Check for loose or blown fuses open circuited or grounded solenoid broken lead wires or splice connections Burned Out Solenoid Check for open circuited solenoid...

Page 84: ...er Hughes logo and Becker are trademarks of Baker Hughes Company Modbus is a registered trademark of Schneider Electric USA Inc Other company names and product names used in this document are the regi...

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