Baker Hughes Becker Series User manual

Becker™
Digital Natural Gas
Positioner (DNGP)
Series 3.5 M with Modbus®Protocol
Instruction Manual (Rev. C)
Baker Hughes Data Classification : Public

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About this Guide
This instruction manual applies to the following instruments and approved software: DNGP rmware
version 3.5.
The information in this manual is subject to change without prior notice.
The information contained in this manual, in 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 adapt-
ability to a specic client needs.
Please report any errors or questions about the information in this manual to your local supplier or visit
www.valves.bakerhughes.com
Revisions Changes
Rev B - 03/2016 Revised to add GE Company.
Rev C - 10/2022 Revised to update and rebranded in Baker Hughes format.

Becker Digital Natural Gas Positioner Instruction Manual | 3© 2022 Baker Hughes Company. All rights reserved.
DISCLAIMER
THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC
REFERENCE INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION
AND MAINTENANCE PROCEDURES. SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY,
BAKER HUGHES DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC
LIMITATIONS AND REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.
THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING
OF THE REQUIREMENTS FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT
IN POTENTIALLY HAZARDOUS ENVIRONMENTS. THEREFORE, THESE INSTRUCTIONS SHOULD
BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY RULES AND REGULATIONS
APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER
EQUIPMENT AT THE 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 MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED
OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLY FOR THE
CUSTOMER/OPERATOR’S PURPOSES THE MATTER SHOULD BE REFERRED TO BAKER HUGHES.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BAKER HUGHES AND THE CUSTOMER/OPERATOR
ARE STRICTLY LIMITED TO THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE
SUPPLY OF THE EQUIPMENT. NO ADDITIONAL REPRESENTATIONS OR WARRANTIES BY BAKER
HUGHES REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE ISSUE OF THESE
INSTRUCTIONS.
THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE
INSTALLATION, TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED.
THIS DOCUMENT SHALL NOT BE REPRODUCED IN WHOLE OR IN PART TO ANY THIRD PARTY
WITHOUT THE WRITTEN APPROVAL OF BAKER HUGHES.
COPYRIGHT
Copyright 2022 by Baker Hughes Company. All rights reserved.
PN 720046629-779-0000 Rev. C

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Becker Digital Natural Gas Positioner Instruction Manual | 5© 2022 Baker Hughes Company. All rights reserved.
Table of Contents
1. Safety Information..................................................................................................................................9
Documentation Symbols ...................................................................................................................... 9
DNGP Product Safety .................................................................................................................. 10
2. Introduction ........................................................................................................................................ 13
Principle of Operation .................................................................................................................. 13
Scope of Manual .......................................................................................................................... 13
Technical Assistance ................................................................................................................... 13
3. Specications ..................................................................................................................................... 15
Technical Specications .............................................................................................................. 15
Certications and Approvals ........................................................................................................ 18
Software Release Information ..................................................................................................... 19
4. Installation ..........................................................................................................................................21
Mounting ...................................................................................................................................... 21
DNGP (Aluminum enclosure)................................................................................................. 21
DNGP-REM (Plastic enclosure) ............................................................................................ 21
Wire Size Recommendations ...................................................................................................... 22
Logic Board and Wiring Diagram ................................................................................................. 24
Jumpers and Fuses ..................................................................................................................... 25
Orice Adjustment ....................................................................................................................... 26
Electro-Pneumatic Positioner Pressure Control Override ............................................................ 33
5. DNGP with Position Transmitter ......................................................................................................... 43
Westlock 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 CS ................................................... 45
Wiring diagram for Westlock DS and DNGP ......................................................................... 46
Rotary Transmitter 4-20 mA Calibration Procedure for DS ................................................... 47
DNGP with Ballu󰀨 Linear Transmitter .......................................................................................... 51
BTL5 Position Sensor Conguring DNGP Positioner Action ................................................. 59
Calibrating the Linear Position Transmitter BTL5 ................................................................. 60
Calibrating the Linear Position Transmitter BTL7 ................................................................. 61
Installation of Calibration Tool on BTL7 .......................................................................... 62
Calibration BTL7 ............................................................................................................. 63
Fine Adjustment of End Points ....................................................................................... 65
How to Reset BLT7 ......................................................................................................... 66
Replacement Parts for BTL Position Transmitters .......................................................... 66
DNGP Accessories: ............................................................................................................... 67
Low Pressure 2/2 Solenoid Valve for Power Gas < 40 PSIG ......................................... 67
High Pressure 3/2 Solenoid Valve for Power Gas 60 - 160 PSIG .................................. 68
High Pressure 5/2 Solenoid Valve for Power Gas 60 - 160 PSIG .................................. 68

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6. Software Functionality ........................................................................................................................ 71
Run Time Screen ......................................................................................................................... 71
Current Loop Mode ............................................................................................................... 71
Digital Mode .......................................................................................................................... 72
Input Conguration Menu ............................................................................................................ 73
Input Select ........................................................................................................................... 73
Split Control .......................................................................................................................... 73
Valve Actions Menu ..................................................................................................................... 74
Bypass Mode ........................................................................................................................ 74
Pulse Mode ........................................................................................................................... 74
Logging and Alarms Menu.............................................................................................................75
Limit Alarms.............................................................................................................................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 Leak Test Procedure ........................................................................................................ 81
Replacing the Electronic Module of the Programmable Linear Transmitter ................................ 81
Valve Maintenance Instructions ................................................................................................... 82
Gas Line Filter ............................................................................................................................. 82
2/2 and 3/2 Solenoid Valve Maintenance and Troubleshooting Instructions ............................... 82
Cleaning ................................................................................................................................ 82
Preventative Maintenance .................................................................................................... 82
Causes of Improper Operation .............................................................................................. 83

Becker Digital Natural Gas Positioner Instruction Manual | 7© 2022 Baker Hughes Company. All rights reserved.
Table of Figures
Figure 1 DNGP-EXP Aluminum Enclosure and 5/3 Solenoid Valve .................................................... 23
Figure 2 DNGP-REM (Plastic Enclosure) ............................................................................................ 23
Figure 3 Terminal Board #1 (10 Pins) and Terminal Board #2 (14 Pins) ............................................. 24
Figure 4 DNGP Logic Board Layout .................................................................................................... 25
Figure 5 Variable Orice Assembly (Standard Assembly shown) ........................................................ 26
Figure 6 2” and 3” Valves Conguration .............................................................................................. 27
Figure 7 4” to 12” Valves Conguration ............................................................................................... 29
Figure 8 Valves Greater than 16” Conguration .................................................................................. 30
Figure 9 Single-Acting Control Valve, PSUPPLY ≥ 50 PSIG ............................................................... 31
Figure 10 Single-Acting Control Valve, PSUPPLY < 55 PSIG ............................................................... 32
Figure 11 Conventional Flow Control with Pressure Control Override (PCO) ...................................... 33
Figure 12 Flow Control with Electro-Pneumatic Positioner and PCOH High Pressure Override .......... 34
Figure 13 Double-Acting Control Valve with PCO, PSUPPLY ≥ 55 PSIG (High Pressure Override) .... 35
Figure 14 Double-Acting Control Valve with PCO, PSUPPLY > 55 PSIG (Low Pressure Override ....... 36
Figure 15 Single-Acting Control Valve with PCO, PSUPPLY≤60 PSIG ................................................ 37
Figure 16 Single-Acting Control Valve with PCO, PSUPPLY > 55 PSIG .............................................. 38
Figure 17 Rotary Piston 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 Piston Spring Return Actuator w/Snap Acting Selector Relay,
PSUPPLY 65-160 PSIG For Short Dynamic Systems such as Power Plants ....................... 41
Figure 20 Overall Dimensions of Rotary Transmitter ............................................................................ 43
Figure 21 Rotary Transmitter Wiring Diagram CS ................................................................................. 44
Figure 22 Components of Rotary Transmitter for Calibration Procedure .............................................. 45
Figure 23 Rotary Transmitter Wiring Diagram DS ................................................................................. 46
Figure 24 DNGP and Linear Transmitter Tail Rod Conguration for Legacy Actuators ......................... 51
Figure 25 Detailed View of Linear Position Transmitter Tail Rod Transducer for Legacy Actuators ...... 51
Figure 26 Detailed View of the Linear Position Transmitter Standard Assembly for Legacy Actuators...52
Figure 27 Linear Transmitter Overall Dimensions ................................................................................. 54
Figure 28 Linear Transmitter Adapter Flange and Magnet for Legacy Actuators .................................. 54
Figure 29 Reversible Linear Transmitter Connector ............................................................................. 55
Figure 30 Linear Transmitter Wiring Diagram for BTL3 ........................................................................ 56
Figure 31 Programmable Linear Transmitter Wiring Diagram for BTL5 and BTL7 ............................... 57
Figure 32 Linear Transmitter BTL5 and BTL7 ....................................................................................... 58
Figure 33 Linear Transmitter BTL5 DIP Switch Location ...................................................................... 60
Figure 34 Linear Transmitter Assembly with Programming Tool (BTL5) ............................................... 60

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Figure 35 BTL7 Wiring and External View ............................................................................................ 61
Figure 36 Linear Transmitter Assembly with Programming Tool (BTL7) ............................................... 62
Figure 37 Low Pressure 2/2 Solenoid Overall Dimensions ................................................................... 67
Figure 38 DNGP with 2/2 Solenoid Valves ............................................................................................ 67
Figure 39 High Pressure 3/2 Solenoid Valve (60 - 160 PSIG) .............................................................. 68
Figure 40 DNGP with 5/3 Solenoid Attached ........................................................................................ 69
Figure 41 High Pressure 5/3 Solenoid Overall Dimensions .................................................................. 69
Table of Tables
Table 1 DNGP Technical Specications ............................................................................................. 15
Table 2 Rotary Transmitter Technical Specications ......................................................................... 17
Table 3 Programmable Linear Position Transmitter Specications (Supplied 2006 and later) .......... 17
Table 4 DNGP Spare Parts List ......................................................................................................... 18
Table 5 Certications and Approvals ................................................................................................. 19
Table 6 Software Release Information ............................................................................................... 20
Table 7 Wire Size, Wire Resistance and Voltage Drop Information1.................................................. 23
Table 8 Orice Part Numbers ............................................................................................................ 28
Table 9 Tail Rod/Proportional Conguration Part Numbers for Legacy Actuators ............................. 52
Table 10 Riser Pipe Mount Conguration Part Numbers for Legacy Actuators ................................... 53
Table 11 Transmitter Parts for Legacy Actuators ................................................................................. 66
Table 12 Transmitter Parts for Refresh Actuators ................................................................................ 66
Table 13 DNGP Alarm and Fault Handling .......................................................................................... 79

Becker Digital Natural Gas Positioner Instruction Manual | 9© 2022 Baker Hughes Company. All rights reserved.
1. Safety Information
This section provides safety information and denes the documentation symbols.
Documentation Symbols
DNGP instructions contain warnings, cautions and notes, where necessary, to alert you to safety related or
other important information. 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
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
could result in serious injury.
Indicates a potentially hazardous situation, which if not avoided could
result in property damage or data loss.
Note: Indicates important facts and conditions.

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DNGP Product Safety
For DNGP positioners intended for use with natural gas: Ensure that an adequate pressure relief provision is
installed when the application of system supply pressure could cause peripheral equipment to malfunction.
Installation must be in accordance with all local and national codes.
General installation, maintenance, or replacement
• Products must be installed in compliance with all local and national codes and standards by qualied
personnel using safe site work practices. Personal Protective Equipment (PPE) must be used per safe
site work practices.
Explosion Hazard: Do not disconnect equipment unless power has been switched o or the area is known
to be non-hazardous.
Do not remove the instrument cover or connect an electrical circuit unless the power is disconnected
(except as specically noted herein).
Note: Ensure the area is properly ventilated.
Do not disconnect a pneumatic connection unless the power is disconnected. Natural gas will escape
into the surrounding atmosphere on disconnection of the pneumatic connections or removal of pressure
containing component.