GE Becker 3.5M Series Instruction Manual

GE Oil & Gas

Becker* Digital Natural
Gas Positioner (DNGP)

Series 3.5M with Modbus™ Protocol
Instruction Manual

Table of Contents

Sections Page

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

High Pressure 5/3 Solenoid Valve Conversion and

Replacement .....................................................................................25

Sections Page

Low Pressure 2/2 Solenoid Valve ..............................................26

High Pressure 3/2 Solenoid Valve .............................................26

3/2 and 2/2 Solenoid Valve Maintenance &

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

Introduction

The DNGP is designed specifically for the needs of the
Natural Gas industry. By using solenoids to control the
actuator pressures, the DNGP eliminates the continuous
bleed gas produced by I/P transducers and bleeds no
gas until the valve is called upon to move. The DNGP
can even do this while maintaining a pressure difference
across the actuator. Additionally, the discharge can
be directed downstream, and the positioner is capable
of failing in last position on a loss of signal, DC power
or power gas. Reliability and simplicity have been
engineered into the DNGP, while features that make the
positioner versatile, easy to use, and fail safe, have been
retained.

Scope of Manual

This manual provides information on the installation,
adjustment, and maintenance of the DNGP-Digital
Natural Gas Positioner. For information concerning
actuators, valves, and accessories, refer to the
instruction manuals provided with the specific product.

Table 1 - DNGP Technical Specifi cations

Technical Assistance

Only those qualifi ed through training or experience
should install, operate, or maintain Becker position­ers. Should you have any questions concerning these
instructions, you may contact your local GE sales
representative, sales offi ce, or manufacturer before
proceeding.

GE Energy
Becker Control Valves
Attn: Technical Assistance
1550 Greenleaf Avenue
Elk Grove Village, IL 60007

Toll Free: [phone]
Telephone: [phone]
Fax: [phone]

web: ge.com/energy

Electrical Power Requirements

Over Current Protection

Position Input Signal (Selectable) Standard

Transmitter Feedback Signal

Remote Indicator Dual Function Output

Valve Position Feedback Module

Display

Input Mode Selection

Electrical Manual Override

Communications

Solenoid Bypass

Loss of Signal Options (Selectable)

Position Input Signal Impedance

Transmitter Feedback Input Signal Impedance transmitter)

VIN = 12 to 24 VDC nominal (11-30 VDC) 21 VDC min. for 24 VDC Sole­noid, 11 VDC min. for 12 VDC Solenoid 1 to 2 A including DNGP heater
and transmitter heater (3 A fuse line recommended)

20 Joule, 2000 A surge and lightning transient protection 3 A fuse for
Logic module 24 VDC power 50/150 mA PTC resettable fuses for posi­tion input signal and transmitter feedback signal

4-20 mA (Split Range: 4 mA min. up to 16 mA max. in 1 mA increments),
minimum 4 mA band

Analog Rotary: External or Internal Digital Linear: Internal only; RTU
Feedback must be dry

Outputs VIN-1.5V @ 20 mA max. (for example if VIN = 24 VDC, this
supplies 22.5 ± 0.5 V)
The remote Indicator function can be selected 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 modes.

Primary: Linear Digital Transmitter Analog Rotary Types Also Available:

80 (4 x 20) character Vacuum Fluorescent Display for: Command
Signal, Valve Position Feedback, Solenoid Cycle Count (stored in 10 year
non volatile memory), Dead Band value. Incorporates a user
navigational menu system.

Manual/Auto/Standby

Manual pushbutton positioning (must engage Manual Mode with Auto/
Manual/Standby Switch)

DNGP Dashboard PC Interface, Modbus

Can be ON or OFF within 1.5% of the end stroke (in full closed and
open position).

Drive to 4 mA position (open or closed valve position) Drive to 20 mA
position (open or closed valve position) Lock in last controlled position

120 to 220 Ω

120 to 220 Ω (additional operating voltage required for

™

communication protocol

2

Table 1 - DNGP Technical Specifi cations (continued)

Input Signal Action

Pneumatic Action

Deadband

Hysteresis

Linearity

Repeatability

Operating Temperature

Infl uence of Temperature on Valve Position

Steady State Gas Consumption

Recommended Supply Regulator Capacity

Electrical Classifi cations

Enclosure

Approximate Weight

Valve Position Limit Switches

Digital Control Inputs

Digital Control Inputs

Maximum Power Supply Gas
Pressure

Pneumatic Port Connection

Direct or Reverse Acting (selectable by accessing DNGP Menu and
Transmitter Switch)

Double Acting or Single Acting

Adjustable from 0.1% to 2.0% of full travel

<2.0% full scale (with rotary position feedback transmitter

<±1.0% full scale (with standard linear digital transmitter)

<±1.0% full scale (with standard linear digital transmitter)

-20 ºF to 150 ºF (-29 ºC to 66 ºC)

<0.01% per ºF (<0.02% per ºC)

ZERO - see Table 2.0 for additional information

100 SCFM at 250 psig (1724 kPa) - Natural Gas
45 SCFM at 100 psig (689 kPa) - Natural Gas
30 SCFM at 60 psig (414 kPa) - Natural Gas

Electrical Enclosure Explosion Proof for Class I Groups C and D
;Class II Groups E, F, G; Class III hazardous locations
CSA approved, RoHS compliant
Optional ATEX available

Available in explosion proof housing with window or NEMA-4 Poly
carbonate enclosure for remote control board mounting

15 lb. (5.6 kg); includes standard explosion proof DNGP enclosure and
High Pressure 5/3 Solenoid Valve.

Low limit settable from 0 to 45% closed
High limit settable from 55 to 100% of open
Contacts ratings (maximum)
Power: 180 W or 1800 VA
Current: 6A
Voltage: 150 VDC or 300 VAC
(UL 6 A @ 28 DC, VDE 5 A @ 250 VAC).

Low limit settable from 0 to 45% closed
High limit settable from 55 to 100% of open
Contacts ratings (maximum)
Power: 180 W or 1800 VA
Current: 6A
Voltage: 150 VDC or 300 VAC
(UL 6 A @ 28 VDC, VDE 5 A @ 250 VAC).

12 to 24 V nominal (11 to 30 V).
Digital input current: 3.5 mA at 24 V
One input controls Open, one input controls Close, and common Open/
Close return signal.

250 psig (1724 kPa) with 5/3 type DNGP Solenoid Valve
(Check Maximum Actuator Power Supply Pressure Limitations)
150 psig (1034 kPa) with 3/2 type DNGP Solenoid Valve
(Check Maximum Actuator Power Supply Pressure Limitations)

1/4” FNPT standard, larger sizes available for additional capacity

Electrical Conduit Connections

3/4” FNPT standard

3

Principle of Operation

The solenoid operated electro-pneumatic positioner
compares a 4-20 mA signal from a RTU to a 4-20 mA
signal from a position transmitter. Depending upon the
difference between the two signals, the positioner will
energize 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 will be
energized. The solenoid tubing is connected to the valve
actuator through a variable orifice. This orifice allows the
valve speed to be increased or decreased. The faster the
valve speed, the larger the positioner dead band must
be to prevent overshoot of the valve position. When the
input signal falls within 1.5% of either full open or full
closed, and bypass enable is selected, the positioner will
continually energize the appropriate solenoid to provide a
full pressure differential across the cylinder.

In the case of single acting actuators, the pressure will
be full power gas pressure or zero psig. If either the
RTU signal or transmitter signal falls below 3.5 mA, the
positioner will enter failure mode. In failure mode the
positioner will move the valve to fully open, fully close, or
hold the current position depending on the user specifi ed
failure confi guration.

Explosion Proof
Enclosure with
Window

5/3 High Pressure
Solenoid Valve

Wire Size Recommendations

Figure 1 - DNGP EXP Enclosure and High Pressure 5/3 Solenoid Valve

Wires of insuffi cient size will create a voltage drop
between the power supply in the control room and the
DNGP at the valve site. This voltage drop is created by
resistance in the wire carrying power to the DNGP. Smaller
diameter wires have more resistance than larger wires
and therefore produce a larger voltage drop. Resistance is
also function of the length of the wire. From this informa­tion, the equation needed to fi gure the proper wire size is
governed by equation (1):

(1) VDROP = (2*L*I*R)/1000

Where:

VDROP (Volts) = Voltage drop between the power supply
and DNGP

Table 2 - Wire Size, Wire Resistance, and Voltage Drop Information 1,2,3,4

Wire Size Resistance per 1000 ft Length of Wire (one way) for 4 Volts Drop

18 AWG

16 AWG

14 AWG

12 AWG

10 AWG

8.45 Ohms 240 Feet

5.29 Ohms 380 Feet

3.26 Ohms 610 Feet

2.05 Ohms 980 Feet

1.29 Ohms 1550 Feet

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 supply and the DNGP, larger sizes of
wire are required to keep the voltage drop to a minimum.
Voltage drops greater than 4 Volts are not recommended
for proper use of the DNGP. The user should note that
wire size increases as the gauge of wire decreases. Refer
to table 2.0 for all pertinent voltage information.

1 - Check with wire manufacturer for more accurate resistance data.

2 - Adding multiple DNGP’s to a single pair of power wires will increase the voltage drop proportionally.

3 - Voltage drops greater than 4 volts are not recommended.

4 - Actual resistance of wire may differ based on wire characteristics and manufacturer.

4

Logic Board & Wiring Diagram

The DNGP is equipped with two terminal boards. Terminal
board #1 has 10 connections and terminal board #2
has 14 connections. Terminal board #2’s connections
are associated with the main user interface 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 board layout, and wiring guide for both
terminals is given on pages 6 and 7 respectively.

Jumpers & Fuses

A look at the logic board layout on page 7 shows the
location of the jumpers JP1 and JP2. The selection of the
jumpers depends on the power of the transmitter. If the
transmitter doesn’t need external power, select JP1 - 1,

2. If the transmitter needs external power, select JP1 - 2,
3, or remove the jumper. The jumper JP2 functions only
as a spare replacement for JP1. There are 4 fuses on the
DNGP logic board. The first fuse F1 is 0.1 Amperes, and
serves as the PTC fuse for a 4-20 mA signal current loop.
F2 is 0.1 Amperes, and serves as the PTC fuse for a 4-20
mA transmitter/ positioner current loop. The fuses F1 and
F2 are resettable. F3 is a 3 Ampere fuse for the voltage
input power. Finally, F4 is a 3 ampere replacement fuse
for F3.

Figure 2 - Terminal Board #1 (10 Pins) & Terminal Board #2 (14 Pins)

Note 1: Check RTU manual for correct polarity before connecting to terminal.
Note 2: Jumper must be installed between pins 5 & 6 if feedback is not connected.

5

Jumper between Pins 5 & 6 on
Terminal Board #2 (Only used if
RTU feedback is not connected)

Terminal Board #1
(10 Connectors)

Terminal Board #2
(14 Connectors)

Manual Auto
Stand-by Switch

JP2 - Jumper, Spare
Replacement for JP1

JP1
Jump 1-2 when Digital Linear
Transmitter is used; RTU feedback
loop power must be off)

Pin #14

Pin #10

Pin #1

F1 - 0.1 A, PTC Fuse
for 4-20 mA Signal
Current Loop

F2 - 0.1 A, PTC Fuse for
4-20 mA
Transmitter/Positioner
Current Loop

F3 - 3 A, Fuse VIN
Input Power

F3 - 3 A Spare
Replacement for F3

JP1 for Analog 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; RTU does not power the loop

Figure 3 - DNGP Logic Board Layout

6

Orifi ce Adjustment

Orifices at each of the cylinder ports (double acting) or
flow control valve (single-acting) control the flow of gas
into the actuator, and therefore, the speed at which the
valve moves.

Initially, both orifices 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. Because the valve will
be moving slower, a smaller dead

Assembly
(Orifi ce included)

Orifi ce

Figure 4 - Variable orifi ce assembly (standard assembly shown)

Table 3 - Orifi ce Part Numbers

Orifi ce Size “Marking Part #

Standard

(No Mark)

Medium “M”

Large “L”

Assembly 25-1559

Orifi ce Only 25-1040

Assembly 25-8162

Orifi ce Only 25-8075

Assembly 25-8163

Orifi ce Only 25-8076

Figure 5 - For 2” & 3” valves an additional backpressure valve (metering valve) is used.

7

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.

8

Figure 8 - Single Acting Control Valve, P

SUPPLY

≥ 50 Psig

Figure 9 - Single Acting Control Valve, P

SUPPLY

≤ 40 Psig

9

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 ow control).

By exchanging the I/P with an electro-pneumatic
positioner, the pneumatic positioner can be eliminated.
Using the DNGP for the electro-pneumatic positioner
allows the unit to fail open, closed, or in last position on
loss of 4-20 mA signal. Becker high pressure VRP pilots
and Becker high pressure HIGH/LOW selector relays
ideally complement the DNGP electro-pneumatic
positioner for high or low pressure override.

*For double acting systems, Becker double acting pilots are used. See the sampling
of pneumatic schematics for specific pressure control override applications on the
next two pages.

Signal Selector

Figure 10 - Conventional Flow Control with Pressure Control Override (PCO)

10

Figure 11 - Flow Control with Electro-Pneumatic Positioner and PCOH High Pressure Override

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

11

Figure 14 - Single Acting Control Valve with PCO, P

SUPPLY

≥ 40 Psia

Figure 15 - Single Acting Control Valve with PCO, P

12

SUPPLY

> 50 Psia

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

13

Figure 18 - Rotary Piston Spring Return Actuator with Snap Acting Selector Relay, P

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. VRP-SB-PID and DNGP are non-bleeding in steady state, full open & full closed position

4. Control valve shown in full open position

40 - 150 psig

SUPPLY

DNGP with Rotary Position Transmitter (Standard)

The Rotary Position Monitor is used in conjunction with the DNGP. This polarity
independent, transient protected, transmitter can operate with any voltage
from 5 to 38 volts DC. CW and CCW rotation is easily accommodated as well
as long cable runs and multiple receivers. It has an easy set up, non-interactive
adjustment, and is available in 4-20 mA. For information on installation,
calibration, and wiring diagrams please refer to appendix A of this manual.
The rotary transmitter incorporates a 1/4% precision potentiometer
specifically design for DNGP positioner.

Table 4 - Rotary Transmitter Technical Specifi cations

Heater Power

Operating Temperature
Range

Recommended Power

Output Signal Range

Load Impedance

Output Current Limit

Ambient Temperature

Rotation Range

Linearity

Hysteresis

Repeatability

12 - 24 Volts DC

-40 ºF to 185 ºF

Loop Power 4-20 mA

4 to 20 mA DC

0-950 Ohms at 24 Volts DC

Internally limited to 33 mA

For a 100 ºF change in ambient temperature,
the maximum zero shift is ±0.3% and the
maximum span shift is ±0.4% of span

45º - 95º

±1.0%

1% of full scale

±0.3% of full scale

(153.9)

6.06

Figure 19 - Overall Dimensions of Rotary Transmitter

(149.3)

5.88”

*All Dimensions in [mm] in.

14

Rotary Transmitter 4-20 mA Calibration Procedure

1. Mount the rotary transmitter to the actuator. Set limit
switches if supplied per instructions provided with unit.

2. Connect a Loop Power source to terminal points
1 & 2. The multi-meter (set for mA readings) must be
connected in series with the terminal one (refer to unit
wiring diagram for the standard setup procedure)

3. Stroke the valve to fully clockwise extreme.

4. Depress the main shaft gear disengaging it from its
locking position, take extreme care Not to turn the
main shaft gear, in order to maintain proper switch
settings.

5. With main shaft gear depressed turn the transmitter
gear to the fully counterclockwise position, and
not the reading (mA) of transmitter. Next, turn the
transmitter gear clockwise until the transmitter

changes no more than 0.5 mA from previous reading.
Renegage gears (if equipped with mechanicals
witches, depress switch plunger to allow gear to
engage).

6. Turn the clockwise mA adjustment screw to adjust the
transmitter reading to the desired output for this valve
position (typically this is 4 mA or 20 mA).

7. Stroke the valve to the fully counter-clockwise
extreme.

8. Turn the counter-clockwise mA adjustment screw to
adjust the transmitter reading to the desired output for
this valve position (opposite of step 6).

9. Stroke the valve between the full clockwise and
counter-clockwise positions checking and readjusting
the (mA) output as necessary.

Main Shift Gear

Transmitter Gear

Figure 20 - Components of Rotary Transmitter or Calibration Procedure

Adjustment Screw 20mA
for close on increasing

Clockwise mA Adjustment
Screw 4 mA for close on
increasing

15

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; RTU should
not power the loop.

Figure 21- Rotary Transmitter Wiring Diagram

DNGP with Linear Transmitter Assembly (Tail Rod & Standard Confi gurations)

A linear digital proximity transmitter will be used
whenever linear motion is available. These transmitters
offer high resolution with a non-contact proximity design.
The linear transmitter is available in a tail rod or standard
confi guration. Figure 22 indicates the major components
in a typical tail rod confi guration, while in Figure 24
the same concept is used to show the standard
confi guration.

Linear Transmitter

High Pressure 5/3
Solenoid Valve

Tail Rod
Cylinder Top

Figure 22 - DNGP and Linear Transmitter Tail Rod Confi guration

DNGP inside Explosion
Proof Enclosure

16

Table 5 - Tail Rod/Proportional Confi guration Part Numbers

Item # Part # Description

1 98-3176 10-32 x 1” SHCS

2 98-2529 10-32 Hex Nut

3 31-2013 Bracket

4 98-2782 3/8” ID Lockwasher

5 98-2927 1/4-20 x 2” HHCS

6 98-3269 8-32 x 1/2” SHCS (Alloy)

7 01-8901 Magnet

8 98-3181 7/16 FT Washer (SS)

9 25-8145 Spacer

10 98-3281 7/16-20 x 3” HHCS

11 01-6592 Bushing

12 31-2014 Transmitter Block

Figure 23 - Detailed View of the Linear Position Transmitter Tail Rod Transducer

6

7

8

1

2

3

10

11

12

9

4

5

17

Table 6 - Riser Pipe Mount Confi guration Part Numbers

Table 7 - Indicator Bar Part Numbers

Item # Part # Description

1 31-2005 Adjusting Bushing

2 98-2614 8-32 x 1/2 SHCS (316)

3 98-2538 8-32 Hex Nut (18.8)

4 31-2004 Adjustment Block Probe

5 01-8901 Magnet

6 98-2579 1/4-20 x 1 HHCS (18.8)

7 98-2777 1/4” Lock Washer

8 98-3171 8-32 x 1/2 SHCS

9 Reference

Indicator Bar

Table 7

10 98-2638 1/4-20 x 5/8 SHCS (18.8)

NOTES:

1. Lock the screw (2) after any adjustments are completed.

2. Turn the magnet (5) with the adjustment bushing to align 4 or 20 mA.

1

2

3

Cylinder Bar Part#

6” 14-3114

8” 14-3130

10” 14-3121

12’ 14-3068

6

7

4

5

Figure 24- Detailed View of the Linear Position Transmitter Standard Assembly

8

WARNING: This Model Was Discontinued in 2007

Table 8 - Reversible Fixed Range Linear Position Transmitter Specifi cations

Measured Parameter Specifi cation Analog Output

Repeatability
(Resolution + Hysteresis)

Sampling Rate

Non-linearity

Pressure Rating (Rod)

Operating Temperature

Supply Voltage

Humidity

Voltage-Output Versions 0.5 mV or 5 μm (whichever is greater)

Current-Output Versions 1 μA or 5 μm (whichever is greater)

For stroke lengths ≤ 2000 mm 1 kHz

For stroke lengths > 2000 mm 500 Hz

For stroke lengths ≤ 500 mm ± 100 μm

For stroke lengths > 500 mm ± 0.02% of full-scale

Up to 600 bar

-40°F to +185°F

+24 VDC ± 20%

<90% non-condensing

10

9

18

WARNING: This model was discontinued in 2007

Figure 24 - Linear Transmitter Overall Dimensions

Figure 25 - Linear Transmitter Adapter Flange

Figure 27 - Reversible Linear Transmitter Connector

Figure 26 - Linear Transmitter Magnet

19

Figure 28 - Linear Transmitter Wiring Diagram

Table 9 - Programmable Linear Position Transmitter Specifi cations (Supplied 2006 and later)

Measured Parameter Specifi cation Analog Output

Repeatability
(Resolution + Hysteresis)

Sampling Rate

Non-linearity

Pressure Rating (Rod)

Operating Temperature

Supply Voltage

Humidity

Voltage-Output Versions 0.5 mV or 5 μm (whichever is greater)

Current-Output Versions 1 μA or 5 μm (whichever is greater)

For stroke lengths ≤ 2000 mm 1 kHz

For stroke lengths > 2000 mm 500 Hz

For stroke lengths ≤ 500 mm ± 100 μm

For stroke lengths > 500 mm ± 0.02% of full-scale

Up to 600 bar

-40°F to +185°F

+24 VDC ± 20%

<90% non-condensing

20

Figure 29 - Linear Transmitter Overall Dimensions

Figure 30 - Programmable Linear Transmitter Wiring Diagram

21

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. 32 )

To Program the transmitter to the 20mA Down mode (the 20mA signal will
be generated at the end of the shaft) : Dip Switch #2 is “down” or “off”

To Program the transmitter to the 20mA Up mode (the 20mA signal will be
generated close to the body) : Dip Switch #2 is “up” or “on”

Step 5: Insert the new Electronic Module back on the transmitter housing, connect the 4
wires and turn the power to “On”.

Step 6: Insert the two screws with hex wrench, connect the wires and power the unit.

Item # Description

1

2

3

4

1 Housing cover

2 Electronics model retaining

screws

3 Wiring terminal block

4 Electronic Module

5 Pressure Housing

6 Position magnet

5

6

Figure 31 - Linear Transmitter (Supplies 07/01/2006 and later)

22

Confi guring the DNGP Positioner Action

In order to change your valve from Close on Increase to
Open on Increase and vice versa, access the DNGP valve
state menu and the linear position transmitter as
the following:

Step 1. Hit the ENTER button and go to the “Input
Confi guration Menu”.

▼

Input Config
Valve Actions
Logging & Alarms
Firmware

▼

Step 2. Select the “Positioner Action” option.

Input Config Menu
Input Selections
Split Control
Positioner Action

▼

▼

Step 3. Choose the desired “Positioner Action” mode.
Hit ENTER. Press the EXIT button twice to go back to the
main screen.

Positioner Action

Close on Increase

▼

▼

Open on Increase

ENTER

EXIT

LEFT

UP

RIGHT

DOWN

Calibrating the Linear Position Transmitter

Step 1: Open and close the valve manually using the

pneumatic controller such as Becker MCV; check the
FDBK reading at the DNGP. When the valve moves and
the DNGP reads around 4mA at one extremity and
around 20mA at the other extremity, you are ready to
calibrate.

Note: In order to change the direction of the 4-20mA
signal, adjust the Dip Switch #2 located on the electronic
module. When Dip Switch #2 is “down” or “off”, the 20mA
signal will be generated at the end of the shaft. The
reverse is true when the switch is on the “on” position.

DIP SW #2

Step 2: Insert the Analog Programming Tool

Step 3: Set the Transmitter to the Program Mode.

Press the Blue button and hold for 4 sec

Press the Blue and Gray button and hold for 4 sec

Press the Blue button and hold for 4 sec

Step 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 4 sec

Step 5: Move the Valve to the Bottom Position (The
Position Magnet will be close to the end of the shaft).

Press the Grey button and hold for 4 sec

Step 6: Release the transmitter from the Program Mode.

Press the Blue and Gray button and hold for 6 sec

Press the Blue button and hold for 1 sec

Step 7: Remove the analog programming tool from the
transmitter

Figure 32 - Linear Transmitter Dip Switch Location

23

Blue Button

Part Number 01-8902

Gray Button

Transmitter Parts

Stk.

Complete Transmit-

ter Assembly with
Electronic 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 applica­tions where P
double solenoid, 3 position valve with a spring centered,
closed center spool. All ports are blocked when both
solenoids are de-energized. Also, looking from the two
hole side (below), the fl ow pattern is such that when the
solenoid on the left is energized, air fl ow comes from the
cylinder port on the left. This solenoid can be converted
from external to internal pilot operation and vice versa to
allow a greater pilot pressure range.

≥ 40 psig. The 5/3 is a threaded body,

SUPPLY

Figure 33 - Linear Transmitter Assembly with Programming Tool

Figure 34 - DNGP with 5/3 solenoid attached

All dimensions in (mm) in.

Figure 35 - High Pressure 5/3 Solenoid Overall Dimensions

24

Table 10 - High Pressure 5/3 Solenoid Specifi cations

For Internal Pilot Operation: 160 psi line
pressure max., 50 psi line pressure min

Pressure Ratings*

Weight

Fluid Media

Coil Voltage & Frequency

Inrush Current

Holding Current

Power Consumption

Conduit Connections

NOTE: Solenoid valves may be used on vacuum or pressures below or above the
stated limits, up to 250 psi, however, the pilot pressure range MUST be
50 psi - 160 psi.

For External Pilot Operation: 160 psi line
pressure max., for pilot 50 psi line pres­sure min. - 250 psi max.

2.5 lbs (1.1 kg)

Air, vacuum, and gases compatible with
aluminum and Buna-N or Viton rubber

24 VDC, 12 VDC

0.58 amps

0.58 amps

11 Watts

1/2”-14 NPT Electrical Conduit Connec­tions (2) For wiring convenience conduit
boss able to rotate 240°, and 24” wire
leads my be pulled from the conduit to
the nearest box

Valve Seals:

Some oils may swell the rubber seals in valves and
cylinders, and may cause binding. To determine if the
seals are swelled in AAA valves:

1. Remove one O-ring from the body and slip it over
the spool.

2. Measure the clearance between the O-ring and spool.

If the clearance between the O-ring and spool is 0.005
in. or more all around, the ring is swelled from its original
shape (the paper these instructions are printed on is ap­proximately 0.005 in. thick and can be used as a gauge.

A small amount of swelling will not usually impair valve
performance, and sometimes the valve will perform
reliably with as much as 1/32 in. clearance all around.

O-rings:

WARNING
Use Factory Designed O-Rings ONLY

External/Internal Pilot Conversion & Valve
Maintenance Instructions

Pilot Conversion:

For line pressure more than 160 psi, the solenoid valve
must be re-assembled to accept and external source of
air pressure within this range for shifting the spool. This
will allow the main ports to work at any pressure from
vacuum to 250 psi.

1. Remove 4 screws holding the solenoid structure to
the main valve body and remove the entire solenoid
assembly (leave the gasket as is).

2. Rotate the solenoid assembly 180°, and then
remount to the body.

3. Take careful note of the 1/8” NPT external pilot
port that was either on the top or side of the solenoid
structure. It should now be nearest to 3-porthole side
of the main body.

4. Connect a source of external pilot pressure to the
1/8” NPT port, 50 psi –160 psi, to the pilot port

Gas Line Filter:

For the longest life and best results, use an air line fi lter
installed no further than 10 feet from the valve. The fi lter
should be rated at 25 μm or fi ner.

The 5/3 solenoid valve uses 6, 3/4” I.D. x 15/16” O.D.,
Buna-N A O-rings. To replace these O-rings:

1. Remove the old O-rings using a sharp tool such as a
pick or scribe.

2. Use an air hose (and solvent if necessary), to
thoroughly clean out the grooves in the body.

3. Use a pair of tweezers* with and angle point, starting
ring in groove in one side and working around.

4. Lightly grease the spool and body bore before
assembly, using only valve grease, Moly Disulphide, or
O-ring grease.

NOTE: If tweezers are not available, slip the spool into the bore, as a guide, to just
below a groove, and work the ring into the groove with a small rod.

Remove these
4 screws

Figure 36 - High Pressure 5/3 Solenoid Valve

25

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)

Two Low Pressure 2/2 solenoid valves are used in single­acting DNGP applications when the P

< 40 psig.

SUPPLY

When the solenoid is energized the core is drawn into
the solenoid base sub-assembly. When the solenoid is
de-energized, the initial return force for the core, whether
developed by spring, pressure, or weight, must exert a
minimum force to overcome residual magnetism created
by the solenoid. Minimum return force for AC construc­tion is 11 ounces, and 5 ounces for DC construction.

Each solenoid is equipped with a valve that operates
Normally Closed, in other words, the valve is closed when
solenoid is de-energized; open when energized.

Table 11 - Low Pressure 2/2 Solenoid Valve Specifi cations

Enclosure Types

Operating Temperature

Valve Pressure Ratings

Insulation Class

Power Rating

Conduit Connections

7 - (A, B, C, &D) Explosion proof Class I,
Division 1, Groups (A, B, C & D)
9 - (E, F, & G) - Dust - Ignition proof Class
II, Division 1, Groups (E, F,& G)

Max. Ambient Temperature: (150°F) 66°C
Min. Ambient Temperature: (-20°F) -29°C
These temperatures only indicate maxi­mum application temperatures for fi eld
wiring rated at (90°C) 194°F.
To prevent fi re and explosion do not in­stall solenoid and/or valve where ignition
temperatures of hazardous atmosphere
is less than 165°C (329 °F)

Inlet Port (Marked with a 1): 40 psi Outlet
Port (Marked with a 2): 40 psi

F

11.6 Watts

1-1/2” NPT Conduit Connection Conduit
can be rotated 360°

Figure 37 - Low Pressure 2/2 Solenoid Valve Overall Dimensions

Figure 39 - DNGP with 2/2 solenoid valves

High Pressure 3/2 Solenoid Valve for Power Gas 40 - 150 psig

For Spring Return T-Ball Control Valves (See Figs.16 & 17 for Pipeline Schematic)

Two High Pressure 3/2 Solenoid Valves are used in DNGP
applications with P

from 40 to 150 psig. When the

SUPPLY

solenoid is energized the core is drawn into the solenoid
base sub-assembly. When the solenoid is de-energized,
the initial return force for the core, whether developed
by spring, pressure, or weight, must exert a minimum
force to overcome residual magnetism created by the
solenoid. Minimum return force for AC construction is 11
ounces, and 5 ounces for DC construction. Each solenoid
is equipped with a valve that operates Normally Closed,
in other words, the valve is closed when solenoid is
de-energized; open when energized.

Table 12 - High Pressure 3/2 Solenoid Valve Specifi cations

Enclosure Types

Operating Temperature

Valve Pressure Ratings

Insulation Class

Power Rating

Conduit Connections

7 - (A, B, C, &D) Explosion proof Class I,
Division 1, Groups (A, B, C & D)
9 - (E, F, & G) - Dust - Ignition proof Class
II, Division 1, Groups (E, F,& G)

Max. Ambient Temperature: (150°F) 66°C
Min. Ambient Temperature: (-20°F) -29°C
These temperatures only indicate maxi­mum application temperatures for fi eld
wiring rated at (90°C) 194°F.
To prevent fi re and explosion do not in­stall solenoid and/or valve where ignition
temperatures of hazardous atmosphere
is less than 165°C (329 °F)

Inlet Port (Marked with a 1): 150 psi
Outlet Port (Marked with a 2): 150 psi

F

11.6 Watts

1-1/2” NPT Conduit Connection Conduit
can be rotated 360°

26

Figure 38 - High Pressure 3/2 Solenoid Valve (40 - 150 psig)

2/2 and 3/2 Solenoid Valve Maintenance & Troubleshooting Instructions

WARNING
To prevent the possibility of personal injury or
property damage, turn off electrical power,
depressurize solenoid operator and/or valve, and

Cleaning:

All solenoid operators and valves should be cleaned
periodically. The time between cleaning will vary
depending on medium and service conditions. In general,
if the voltage to the solenoid is correct, sluggish valve
operation, excessive noise or leakage will indicate that
cleaning is required. Clean strainer or filter when cleaning
the valve.

Preventative Maintenance:

1. Keep the medium flowing through the solenoid opera
tor or valve as free from dirt and foreign material as
possible.

2. While in service, the solenoid operator or valve should
be operated at least once a month to insure proper
opening and closing.

3. Depending on the medium and service conditions,
periodic inspection of internal valve parts for damage
or excessive wear is recommended. Thoroughly clean
all parts. Replace any worn or damaged parts.

Causes of Improper Operation:

1. Faulty Control Circuit
Check the electrical system by energizing the
solenoid. A metallic click signifies that the solenoid is
operating. Absence of the click indicates loss of
power supply. Check for loose or blown fuses,
open - circuited or grounded solenoid, broken lead
wires or splice connections.

2. Burned - Out Solenoid
Check for open - circuited solenoid. Replace if
necessary. Check supply voltage; it must be the same
as specified on nameplate/retainer and marked on the
solenoid. Check ambient temperature and check that
the core is not jammed.

3. Low Voltage
Check voltage across the solenoid leads. Voltage must
be at least 85% or rated voltage

27

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. In this mode pressing the RIGHT button will
increase the input current signal and manually move the valve (the direction will depend on what positioner
action is selected). Pressing the LEFT button will decease the input current signal and manually move the
valve. Pressing the UP and DOWN buttons increase and decrease the deadband respectively to adjust the
sensitivity of the positioner. Pressing the ENTER button will take you to the Top Level Setup Screen (to be
further explained in another section).

Variable length bar indicating current
between 4-20 mA
Example:

CTRL = Using Digital Inputs
MAN = Under Manual Control
PGM = Under Program Control

= Full Range, Standard
= Split Range, Standard
= Full Range, Learned
♦ = Split Range, Learned

Cycles 1,875
Control ❚ ❚ ❚
Feedback ❚ ❚ ❚
Deadband 1.5% ♦ N

= 4 mA
❚ ❚ ❙ = 12 mA
❚ ❚ ❚ ❚ ❚ = 20 mA

A = Automatic, Analog
a = Automatic, Digital
M = Manual, Analog
m = Manual
P = Program Control
S = Standby

H = Halted
W = Waking (Solenoids on, Not Yet Moving
M = Moving
C = Coasting

- = Idle
d = Decreasing Current
D = Decreasing Current, Bypass Limit
i = Increasing Current
I = Increasing Current, Bypass Limit

28

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.

CTRL = Using Digital Inputs
MAN = Under Manual Control
PGM = Under Program Control

Cycles 1,875
Control Idle
Feedback ❚ ❚ ❚

= Full Range, Standard

Deadband 1.5% ♦ N

= Split Range, Standard
= Full Range, Learned
♦ = Split Range, Learned

H = Halted
W = Waking (Solenoids on, Not Yet Moving
M = Moving
C = Coasting

Idle = Input is Idle
Open = Open input is Active
Close = Close Input Active
FAULT = Both Inputs Active

A = Automatic, Analog
a = Automatic, Digital
M = Manual, Analog
m = Manual
P = Program Control
S = Standby

- = Idle
d = Decreasing Current
D = Decreasing Current, Bypass Limit
i = Increasing Current
I = Increasing Current, Bypass Limit

29

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. The diagram below, and on the following pages, show the actual process
needed to configure the inputs of the DNGP when already operating from the TOP LEVEL SETUP SCREEN

Input Config

▼

Valve Actions
Logging & Alarms
Utilities/Firmware

Press UP or DOWN button
to select INPUT CONFIG,
then press ENTER button

▼

Input Config Menu

▼

Input Selections
Split Control
Positioner Action

Press UP or DOWN button
to select INPUT SELECT
then press ENTER button

▼

Input Selection

▼

4-20 mA Curr Loop
Digital Inputs
Modbus Control

Press UP or DOWN button
to make option selection
then press ENTER button

2. Split Control

In some applications, split range control is needed instead of the standard 4-20 mA range. The DNGP can be
accomplish this feat through the INPUT CONFIGURATION MENU using the SPLIT CONTROL option. The DNGP
has the option to enable or disable the split control feature or set the upper and lower split limits with 4 mA
minimum range in 1 mA increments.

▼

Input Config

▼

Valve Actions
Logging & Alarms
Utilities/Firmware

Press UP or DOWN button
to select INPUT CONFIG,
then press ENTER button

▼

Input Config Menu
Input Selections
Split Control

▼

Positioner Action

Press UP or DOWN button
to select SPLIT CONTROL
then press ENTER button

Split Control Menu
Enable or Disable

▼

▼

Set Upper Limit
Set Lower Limit

Press UP or DOWN
button to select
UPPER LIMIT then
press ENTER button

Upper Split Limit

16 mA

▼

Press UP or DOWN
button to select
LOWER LIMIT then
press ENTER button

Lower Split Limit

12 mA

30

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

▼

Logging & Alarms
Utilities/Firmware

Press UP or DOWN button
to select VALVE ACTIONS
then press ENTER button

▼

Valve Actions Menu
Loss of Signal
Bypass Mode

▼

Pulse Mode

Press UP or DOWN button
to select BYPASS MODE
then press ENTER button

▼

Bypass Mode:

Disabled

▼

Enabled

Press UP or DOWN button
to make option selection
then press ENTER button

2. Pulse Mode

Pulse Mode is used for underdamped dynamic systems such as compressor recycle valve application.

Input Config
Valve Actions

▼

Logging & Alarms
Utilities/Firmware

▼

Valve Actions Menu
Loss of Signal
Bypass Mode
Pulse Mode

▼

▼

Pulse Mode
Threshold

▼

On Time
Off Time

▼

▼

Press UP or DOWN button
to select VALVE ACTIONS
then press ENTER button

Default Values
Threshold: 5%
On Time: 70 ms
Off Time: 80 ms
*Setting Threshold to 0% disables Pulse Mode

Press UP or DOWN button
to select PULSE MODE
then press ENTER button

Press UP or DOWN button
to make option selection
then press ENTER button

31

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.

Input Config
Valve Actions
Logging & Alarms

▼

Utilities/Firmware

Press UP or DOWN button
to select LOGGING &
ALARMS then press ENTER
button

▼

Logging & Alarms
Limit Alarms

▼

Remote Indicator
Reset Solenoid Cnt

Press UP or DOWN button
to select LIMIT ALARMS
then press ENTER button

▼

Limit Alarms

Adjust Upper Limit

▼

Adjust Lower Limit

Press UP or DOWN
button to select
ADJUST UPPER then
press ENTER button

Upper Limit Alarm

98%

Press UP or DOWN
button to adjust
value then press
ENTER button

▼

Press UP or DOWN
button to select
ADJUST LOWER
then press ENTER
button

Lower Limit Alarm

2%

Press UP or DOWN
button adjust value
then press ENTER
button

2. Remote Indicator

The DNGP remote indicator function can be selected to function in solenoid counter mode,
or standby/manual mode. In counter mode the indicator pulses whenever either solenoid
activates. In standby/manual mode, the indicator is active whenever the DNGP is in standby
or manual modes.

Input Config
Valve Actions
Logging & Alarms

▼

Utilities/Firmware

Press UP or DOWN button
to select LOGGING &
ALARMS, then press

▼

Logging & Alarms
Limit Alarms
Remote Indicator

▼

Reset Solenoid Counter

Press UP or DOWN button
to select INPUT SELECT
then press ENTER button

▼

Remote Indication

Solenoid Counter

▼

Press UP or DOWN button
to make option selection
then press ENTER button

ENTER button

▼

32

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
Valve Actions
Logging & Alarms

▼

Utilities/Firmware

Press UP or DOWN button
to select LOGGING &
ALARMS, then press
ENTER button

▼

Logging & Alarms
Limit Alarms
Remote Indicator
Reset Solenoid Counter

▼

Press UP or DOWN button
to select RESET SOLENOID
COUNT, then press ENTER
button

▼

Reset Solenoid Count
Are You Sure?
No
Yes

▼

Press UP or DOWN button
to select YES, then press
ENTER button

Firmware Menu

1. Version Info

The DNGP is a dynamic software tool that undergoes constant changes and improvements as time goes on. Using
the FIRMWARE MENU the user is able to find out information about the current version they are using. It is impor­tant to keep up to date with the most current version of the software to ensure any added features or bug fixes are
implemented.

▼

Input Config
Valve Actions
Logging & Alarms
Utilities/Firmware

▼

Press UP or DOWN button
to select FIRMWARE, then
press ENTER button

▼

Firmware Menu
Version Info

▼

Firmware Update

Press UP or DOWN button
to select VERSION INFO,
then press ENTER button

▼

Becker DNGP
Valve Positioner
SW Version 2.01.00
Jul 14 2008 23:45:55

Press UP or DOWN button
to select VERSION INFO,
then press ENTER button

33

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.

Input Config
Valve Actions
Logging & Alarms
Utilities/Firmware

▼

Press UP or DOWN button
to select FIRMWARE, then
press ENTER button

Perform Firmware Update

Utilities & Firmware
Menu
Version Info

▼

▼

Firmware Update

Press UP or DOWN button
to select FIRMWARE
UPDATE, then press
ENTER button

Valve
*INOPERABLE* Until

▼

Reloaded
Cancel
Proceed

▼

Press UP or DOWN button
to select PROCEED, then
press ENTER button

Ready for Firmware Update

Rebooting...

Update Firmware
Are You Sure
NO
Yes, I Will Reupload

▼

▼

Press UP or DOWN button
to select YES, I WILL
REUPLOAD then press
ENTER button

▼

Upgrading DNGP Firmware

1. Using the menus on the DNGP, go to FIRMWARE -> FIRMWARE UPDATE and proceed with the update.
The unit should reboot, and the ERROR LED should come on. The HEARTBEAT LED will blink slowly.

2. Make sure that the P1618QP APPLICATION is installed. If not, it can be installed using the supplied
P1618QP zip file. If Windows asks about keeping any files, be sure to answer YES.

3. Connect the DNGP 3.5 device to be upgraded to PC via a 9-pin straight through serial cable.

4. Launch the P1618QP application.

5. You will be prompted to Select Microchip PIC Microcontroller. Choose PIC18F6720 from the dropdown
menu then click on the SELECT button.

34

6. Next, change the Baud Rate. Right click on the bottom
right box, and then select 115200. If any problems
occur while downloading, try 57600 instead.

7. Go over to the box where the serial port is shown as
COM1. Right click on this, and select the appropriate
COM PORT for where you have plugged your cable in.

8. Click on the CONNECT TO DEVICE icon.

9. In the left most box in the bottom of the PIC18F/
PIC16F QUICK PROGRAMMER BOX, you should see
DEVICE FOUND… You should also see that the box
to the right of DEVICE FOUND… will be filled in with a
version number, such as V1.2. If not, please re-check
your cabling, com port selection, or try a slower Baud
Rate, and click on CONNECT TO DEVICE again. Make
sure the button is down.

10.Click on the ERASE DEVICE icon. You will see
ERASING: and a progress count in the lower left
box. This takes about 2 minutes. Wait until you see
the FINISHED OPERATION… message.

11.It will bring up Open HEX File window. Browse to
the hex file to download, e.g.
Dngp_download.version.dd_MMM_YYYY.hex.
Open file and in a few seconds it will display HEX File
Imported.

12.Click on the WRITE DEVICE icon. You will see
WRITING: and a progress count in the lower left
box. This takes about 3 minutes. Wait until you see
the FINISHED OPERATION… message.

13.Click on the NORMAL EXECUTION MODE icon.

A box will pop up, asking if you wish to continue.
Click YES

14.The newly upgraded unit should start up on its own.
Go to the FIRMWARE -> VERSION INFO menu and
check that the unit is showing new software.

Troubleshooting for Firmware Upgrade

If any problems occur during software download, cold
restart the DNGP by the following steps.

Step 1: Turn the DNGP power off.

Step 2: Press and hold the UP, DOWN and ENTER buttons.

Step 3: Apply power to the DNGP. Alarm light will be on

and the D17 led will be flashing.

35

Table 12 - 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

Display “FDBK: Fault”

Loss of Feedback
Signal

Disconnect any other wires from #5 & 6 on TB 2 and jump # 5 & 6 instead
Checks the SCADA for Internal power or external power
Check the DNGP board JP1 for external or internal power: At JP1, Jump 1, 2
for external power, and 2, 3 for internal power (see page 16)

Display “CTRL: Idle”
If the Open and Close signal are present at the same time the display shows

If Digital Input Activated

CTRL: Fault Disconnect the wires to the TB2 # 7 open command, and 8 close
commands, if this clears the Display to Idle check the switches, DI on
SCADA should be open

Limit alarm ON minimum or
maximum

Controller display a flash­ing alarm screen, Error
Light ON normal operation
continues even
though this screen
is being displayed.

DNGP doesn’t move on
change of signal CTRL:
and FDBK shows some mA

If valve not fully Close or Open check the settings at Logging and Alarms/
Limit Alarms =Adjust the alarm Upper Limit 55% to 100% and the Lower Limit
0% to 45%

Indicates that the valve is not responding to signal
Check Valve Position must be same position as the DNGP Input Config
Menu/Position Action = Close on Increase or Open on increase
If the valve is going to be on the close position most of the time close the
valve and check the CTRL: and FDBK: values must be within .16ma if not
adjust the VP pot or magnet for the linear position transmitter.

Minimum pressure for solenoid operation in 60 psi
Check the Air pressure block valve, the Standby/Manual Switch should be on Auto,
The MCV3L should be on Auto, and the solenoid manual on Auto if available

signal

Cycling of DNGP

Perform a Leak test on unit; check the Dead band on display move up if
necessary (see page 48)

3 Amp Fuse protects the

For 24VDC the impedance should be 58-65 Ohms; for 12VDC 14-17 Ohms

board not the Solenoids

Increased or Sudden

Perform leak test on unit (See Below)

Cycling of Positioner

Perform measurement of voltage power supply 12-24 VDC. Maximum
allowed voltage is 30 VDC. If supply voltage exceeds 24 V the fuse will

3A Fuse on Logic Board
Blown

protect the board, not the solenoids.

Measure the impedance of solenoid coils. For 24 VDC: If below 58-65
Ohms, the solenoid is shorted. For 12 VDC: If below 14-17 Ohms, the
solenoid is shorted. Change the solenoid coils. See spare parts list
below for coil part number.

36

Table 13 - DNGP Spare Parts List

Condition Response/Action

High Pressure 5/3 Solenoid Valve - Complete Assembly

High Pressure 5/3 Solenoid Valve Body

High Pressure 5/3 Solenoid Coil - 24 VDC

High Pressure 5/3 Solenoid Coil - 12 VDC

Low Pressure 2/2 Solenoid Valve - 24 VDC (less than 40 psig)

High Pressure 3/2 Solenoid Valve - 24 VDC (40 to 150 psig)

3 Amp Replacement Fuse (Input Power)

DNGP Control Board (includes display board and terminals)

20-4500

20-4506

20-4509

20-4518

20-4202

20-4221

31-9002

31-0016

DNGP Leak Test Procedure

1. Switch DNGP to standby from auto. Observe feedback mA indicator. If position of the valve changes follow
continue to step #2.

2. Move MCV to manual to close block valve or close cylinder block valves.

3. Check cylinder for decaying or equalizing pressure.

a) If cylinder pressure is decaying, check and repair leaks at fittings.

b) If cylinder pressure is equalizing, rebuild cylinder.

4. Check for external leak at gasket, NPT instrumentation ports.

a) If leak is found, tighten bolts or fittings.

b) If no leak is found, rebuild solenoid valve with O-ring kit by replacing lower valve body. See spare parts list
Table 12 for part numbers.

37

Certifi cations and Approvals

Part/Component Certifi cation

DNGP Logic Board

DNGP Enclosure

Linear Position Transmitter

Rotary Position Transmitter

High Pressure 5/3 Solenoid Valve

2/2 and 3/2 Solenoid Valves

RoHS Compliant

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

Optional ATEX Available

DEMKO 03 ATEX 0303070U

II G D EEx d IIB + H2

SIRA 05 ATEX M334

II 2 G EEX d IIC T6

Class I, Division 1, Groups A, B, C, and D

Class II/III, Groups E, F, and G

Enclosure Type 4X/6P

Class I, Group C and D

Class II, Groups E, F and G

Class I, Group C and D

Class II, Groups E, F and G

Class I, Div 1, Group A, B, C, & D

Class II, Div 1, Groups E, F and G

Nema Enclosure Types 3, 3S, 4, 4X, 6, 6P, 7, & 9

Optional ATEX Available

LCIE 00ATEX 6008 X

II G D EEx d IIC T6

Software Release Information

Version Release Date Feature

3.01.00 Aug 28 2011 *Modbus protool added

2.02.00 Nov 7 2008 * Fault Alarm is disabled at 4 & 20mA positions within 1.5% of feedback signal

2.01.00 Jul 14 2008 * Pulse control mode added to menu

2.00.P6 Feb 18 2008 * Enable Pulse Mode (not added to menu)

2.00.05 May 12 2005 * Initial fi rmware release

* Pulse Mode replaces Learn Mode

38

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.
The warranty for Services shall expire one (1) year after performance of the Service, except that
software-related Services are warranted for ninety (90) days.

5.3 If Products or Services do not meet the above warranties, Buyer shall promptly notify Seller in
writing prior to expiration of the warranty period. Seller shall (i) at its option, repair or replace
defective Products and (ii) re-perform defective Services. If despite Seller’s reasonable efforts, a
non-conforming Product cannot be repaired or replaced, or non-conforming Services cannot be
re-performed, Seller shall refund or credit monies paid by Buyer for such non-conforming Products
and Services. Warranty repair, replacement or re-performance by Seller shall not extend or renew the
applicable warranty period. Buyer shall obtain Seller’s agreement on the specifications of any tests it
plans to conduct to determine whether a non-conformance exists.

5.4 Buyer shall bear the costs of access for Seller’s remedial warranty efforts (including removal and
replacement of systems, structures or other parts of Buyer’s facility), de-installation, decontamination,
re-installation and transportation of defective Products to Seller and back to Buyer.

5.5 The warranties and remedies are conditioned upon (a) proper storage, installation, use, opera­tion, and maintenance of Products, (b) Buyer keeping accurate and complete records of operation
and maintenance during the warranty period and providing Seller access to those records, and (c)
modification or repair of Products or Services only as authorized by Seller in writing. Failure to meet
any such conditions renders the warranty null and void. Seller is not responsible for normal wear
and tear.

5.6 This Article 5 provides the exclusive remedies for all claims based on failure of or defect in
Products or Services, regardless of when the failure or defect arises, and whether a claim, however
described, is based on contract, warranty, indemnity, tort/extra-contractual liability (including
negligence), strict liability or otherwise. The warranties provided in this Article 5 are exclusive and are
in lieu of all other warranties, conditions and guarantees whether written, oral, implied or statutory.
NO IMPLIED OR STATUTORY WARRANTY, OR WARRANTY OR CONDITION OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE APPLIES.

39

GE Oil & Gas

1550 Greenleaf Avenue
Elk Grove Village, Illinois 60007 USA
T: +1 847. 437. 594 0 F: +1 8 47.437.25 49
Inside US T: 800.323.8844
Email: [e-mail]

Visit us online at: www.ge.com/energy
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All Rights Reserved

*Trademark of General Electric Company

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Rev 08.12