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Koso KGP5000 Series Operation Manual
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Koso KGP5000 Series Operation Manual

Koso KGP5000 Series Operation Manual

Smart valve positioner
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OME-KGP5HT-01C (September 2022)
KGP5000 series
Smart valve positioner
HART Communication
Operation Manual
For Text type
~ The Most Cost Effective, Creative Valve Solutions ~

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Summary of Contents for Koso KGP5000 Series

  • Page 1 OME-KGP5HT-01C (September 2022) KGP5000 series Smart valve positioner HART Communication Operation Manual For Text type ~ The Most Cost Effective, Creative Valve Solutions ~...
  • Page 2 OME-KGP5HT-01C (September 2022) Table of Contents Introduction ......................... 3 1.1. Scope of this operation manual ....................3 1.2. Safety notices ..........................4 1.3. Product summary ......................... 4 1.4. Electrical connections ........................5 1.5. Preparation for HART communication ..................8 Menu tree on the HART communication ................9 2.1.
  • Page 3 Please read carefully at first! This operation manual includes getting information, calibration, maintenance procedures, diagnosis and so on for the KGP5000 series smart valve positioner by HART communication. Read this operation manual and an instruction manual carefully before using the positioner.
  • Page 4 1.3. Product summary KGP5000 series smart valve positioner is a control device mounted on the pneumatic actuator for control valve, which positions a control valve according to a 4 to 20mA signal from a higher-level control system or a control device.
  • Page 5 OME-KGP5HT-01C (September 2022) 1.4. Electrical connections Warning  Disconnect the power supply before wiring connections.  Wiring connections must be done in accordance with national electrical code requirements.  Avoid wiring connection on wet weather days or in environments are saturated with water. They are liable to electric leakage or damage to the positioner.
  • Page 6 OME-KGP5HT-01C (September 2022) The positioner uses a 4-20mA loop current and the HART communication is carried out through the digital signal which is superposed on this loop current. Make wiring connections according to the following procedure. 1. Remove the terminal cover. 2.
  • Page 7 OME-KGP5HT-01C (September 2022) Supply power to the positioner according to the load resistance. It should be noted that the supply power must not be exceed 40VDC. Table 1.4 The suitable Ex certificated cable glands and blanking elements for each proof type Proof type Thread form of Certification...
  • Page 8 OME-KGP5HT-01C (September 2022) 1.5. Preparation for HART communication A personal computer or communicator and a HART modem are required to acquire the information of this unit via HART communication and perform installation / setting work, maintenance, alarm setting / diagnosis. In addition, the HART modem driver and device description (DD) for KGP5000 communication must be installed on the PC.
  • Page 9 OME-KGP5HT-01C (September 2022) 3) Connection According to section 1.4, connect the IN+ and IN- of this device to a communication tool. For example HART communicator or a terminal of host controller. 2. Menu tree on the HART communication 2.1. Menu type This document describes the text type DD.
  • Page 10 OME-KGP5HT-01C (September 2022) 2.2. Menu tree Root Menu Root Menu Alarm status Alarm status <Set point> <Position> <Loop current> <Input > <P-sup.> <P-out1> <P-out2> 【Chapter / Section】 Menu Information Monitor 【3.1.1.】 Alarm status 【3.1.2.】 Positioner info. 【3.1.3.】 Config. Parameter 【3.1.4.】 Diag.
  • Page 11 OME-KGP5HT-01C (September 2022) 3. Root menu Instructions for information obtaining, setting, maintaining, alerting, and diagnosing are provided with reference to SDC625. Left-click the menu tree displayed on the left side of the screen with the mouse to display selectable menus. Select the displayed menu to display the screen for checking the status of the positioner, setting, adjusting, and diagnosing.
  • Page 12 OME-KGP5HT-01C (September 2022) 3.1.1.2. Input signal/position etc, The operator can confirm operating status of the positioner such as input signal, set point, valve position, IP signal. MENU > Information > Monitor > Input / posi etc Loop current ：Loop current ：Set point 12.000 mA Set point...
  • Page 13 OME-KGP5HT-01C (September 2022) 3.1.2. Alarm status The operator can confirm the alarm status as below. MENU > Information >Alarm status  Position alarm  Deviation alarm  Temperature alarm  S-pressure alarm  Other failure※  PST alarm ※For other failures, you can check the alarm status of the memory, angle sensor, and pressure sensor. 3.1.3.
  • Page 14 OME-KGP5HT-01C (September 2022) 3.2. Setup 3.2.1. Authority for setup and operation via HART communication To change setting via HART communication, ‘Authority’ should be HART. To do operations via HART communication , e.g. autotune, calibration and offline diagnosis, ‘Control mode’ of authority should be ‘HART’. 3.2.1.1.
  • Page 15 OME-KGP5HT-01C (September 2022) 3.2.1.2. Control mode permissions MENU > Setup >Function select>Authority>Control mode ① Select ‘Write’ and press ‘OK’. ② Select ‘HART’ and press ‘OK’ to set. ※When conduct operation with a 4-20mA input signal, select 4-20mA. ~ The Most Cost Effective, Creative Valve Solutions ~ page.
  • Page 16 Single acting actuator : Single Single / Double ※1 Double acting actuator : Double / 5300 KOSO high power actuator : 5300 Valve action Set direction of a valve when Pout1 is output Air to Open : ATO ATO / ATC...
  • Page 17 OME-KGP5HT-01C (September 2022) For example, Actuator motion setup procedure is shown as below . MENU > Setup >Basic setup>Actuator motion ① Select ‘Write’ and press ‘OK’. ② Select ‘Linear’ or ‘Rotary’, and press ‘OK’ to set. 3.2.3. Easy tuning Caution ...
  • Page 18 OME-KGP5HT-01C (September 2022) 3.2.3.1. Full autotune While performing a sequence of operations, it configures automatically settings such as detection and calibration of zero/span, selection of suitable PID parameters to apply the control, detection and calibration of IP signal current bias. Note The configuration time varies with actuator size．...
  • Page 19 OME-KGP5HT-01C (September 2022) 3.2.3.2. Position setup It is possible to perform Zero/span settings independently, otherwise full autotune. There are two different ways of Zero/span settings whether to specify Zero/span manually or to determine these automatically. 1) Manual calibration MENU > Setup >Easy tuning > Position setup > 0% or 100% ①...
  • Page 20 OME-KGP5HT-01C (September 2022) 3.2.3.3. Response tuning This operation is used to perform an additional fine adjustment relevant to the control response after performing PID tuning. MENU > Setup >Easy tuning > Response tuning A．In case the higher response sensitivity is desired, i.e., you wish to reduce response time by making the response quicker, Select ‘Aggressive’...
  • Page 21 OME-KGP5HT-01C (September 2022) To increase response sensitivity：select PID parameter set with higher proportional gain To decrease response sensitivity：select PID parameter set with lower proportional gain Table 3.2.4.1. Correspondence table between rank and each actuator size（※） Rank 5200LA 6300LA 63D0RC(6300RB) 5300LA Φ218 Φ150 AT201U...
  • Page 22 OME-KGP5HT-01C (September 2022) 3.2.4.2. Custom setting for PID parameter Caution  If you change the value of each parameter significantly, unexpected behavior (response is too slow, response is too fast) may occur, so please perform thorough testing in advance to confirm that there are no problems.
  • Page 23 OME-KGP5HT-01C (September 2022) If ‘b’ parameter is set, Gain P(e) is switched as shown below. Gain P(e) P(e)=Inside P+(P-Inside P)*e/b Inside P Figure 4.4.2．Gain switching (Example of proportional gain） The procedure is shown as followings． 1) Set PID parameter set to ‘Custom’ MENU >...
  • Page 24 OME-KGP5HT-01C (September 2022) 2) Set PID custom setup parameters ※If any other submenu except ‘Custom’ was selected in PID parameter menu, the value of parameters cannot be changed through the following procedure． MENU > Setup >Expert tuning > PID custom setup 2-1) Set ‘Air-Out (not)= Air-In?’.
  • Page 25 OME-KGP5HT-01C (September 2022) 2-2) Set PID parameter of Air-In. MENU > Setup >Expert tuning > PID custom setup > PID parameter ①Select ‘Write’ and Press ‘OK’. ② Input P value of Air-In. ③ Press ‘OK’. ④ Input I value of Air-In. ⑤...
  • Page 26 OME-KGP5HT-01C (September 2022) ⑥ Input D value of Air-In. ⑦ Press ‘OK’ to set. 2-3) Set PID parameter Air-Out. MENU > Setup >Expert tuning > PID custom setup > PID parameter Air-Out ’ ① Select ‘Write’ and press ‘OK’ ② Input rP value of Air-Out. ③...
  • Page 27 OME-KGP5HT-01C (September 2022) ④ Input rI value of Air-Out. ⑤ Press ‘OK’ ’ ’ ⑥ Input a rD value of Air-Out. ⑦ Press ‘OK’ to set. ’ 2-4) Set inside threshold value. MENU > Setup >Expert tuning > PID custom setup > Inside threshold ①...
  • Page 28 OME-KGP5HT-01C (September 2022) ② Input an inside threshold value. ③ Press ‘OK’ to set. 2-5) Set inside PID Air-In. MENU > Setup >Expert tuning > PID custom setup > Inside PID AI ① Select ‘Write’ and press ‘OK’ ② Input a inside P value of Air-In. ③...
  • Page 29 OME-KGP5HT-01C (September 2022) ④ Input a inside I value of Air-In. ⑤ Press ‘OK’ ⑥ Input a inside D value of Air-In ⑦ Press ‘OK’ to set. 2-6) Set inside PID Air-Out parameters MENU > Setup >Expert tuning > PID custom setup > PID parameter Air-Out ①...
  • Page 30 OME-KGP5HT-01C (September 2022) ② Input an inside rP value of Air-out. ③ Press ‘OK’ ④ Input a inside rI value of Air-out. ⑤ Press ‘OK’ ⑥ Input a inside rD value of Air-out. ⑦ Press ‘OK’ to set. ~ The Most Cost Effective, Creative Valve Solutions ~ page.
  • Page 31 OME-KGP5HT-01C (September 2022) 3.2.4.3. Setup for IP signal current bias IP signal current bias is the parameter necessary to determine the control output signal (IP signal) corresponding to an input signal. There are two different ways whether to determine IP signal current bias automatically or to specify it manually.
  • Page 32 OME-KGP5HT-01C (September 2022) 3.2.6. Detailed setup Caution  HART communication takes longer than the operation using the LUI of this unit, so be sure to complete the operation. Set values which need to be changed to achieve the desired response. MENU >...
  • Page 33 OME-KGP5HT-01C (September 2022) Key menu Description Parameters Default High equal percentage characteristics (Rangeability 100:1) Quick opening : Quick opening characteristics (Rangeability 30:1) Custom curve: Customized characteristics ※ In case of using equal percent characteristic besides the rangeability mentioned above, input the value directly to “Range ability”.
  • Page 34 OME-KGP5HT-01C (September 2022) Key menu Description Parameters Default High setting： When the current bigger than 21mA, the bigger current (burnout signal) will flow ※ If the input signal is zero, the current of Lo setting will flow regardless of above setting. Set the full mechanical limit of valve travel over the 100% travel position, when the positioner detects the 100% travel position.
  • Page 35 OME-KGP5HT-01C (September 2022) integer Once the password is set, only ‘Information’ from ‘TOP’ menu will be able to be accessed unless you type the password. If forgetting the password, please inquire to the business office of this manual end. Set the time for screen saver during which the LCD screen display will be turned off.
  • Page 36 OME-KGP5HT-01C (September 2022) 3.3. Maintenance Warning  If the exhaust port becomes clogged with contaminants, high pressure will be applied to the front cover. Then, removing it on the positioner causes of hazards. Before removing it, confirm that the exhaust port of the housing is surely opened. ...
  • Page 37 OME-KGP5HT-01C (September 2022) 3.3.1.2. Action switching of pilot relay The operator can switch the pilot relay between single action mode and double action mode by turning the screw attached to the pilot relay. Double Single Figure 3.3.1.2．Action switching of pilot relay Switching to single action mode;...
  • Page 38 OME-KGP5HT-01C (September 2022) 3.3.2. Calibration Since the operation described in this section is preset at the factory, generally, it is not necessary to repeat this. However, since there is a case in which a deviation is produced from long-term operation and so on, if necessary, perform this operation.
  • Page 39 OME-KGP5HT-01C (September 2022) 3.3.2.2. Cross point calibration Calibrate the position which the feedback lever horizontal. It is necessary to perform it in order to precisely control the travel position. When a feedback lever isn't installed horizontally in the 50% position, this calibration will be required.
  • Page 40 OME-KGP5HT-01C (September 2022) 3.3.2.3. Position transmitter calibration Calibrate the position transmitter signal which the positioner send． The procedure to calibrate individually the position transmitter signal of each position in 0% and 100% is shown below. MENU > Maintenance > Calibration > Position transmit cal. ①...
  • Page 41 OME-KGP5HT-01C (September 2022) 3.3.2.4. Pressure sensor calibration Calibrate three pressure sensors in the positioner. It is necessary to connect the positioner to a pressure measuring device of gauge pressure type which is used for pressure reference. It is required to calibrate both of the first order pressure (lower side) and the second order pressure (upper side) for each sensors.
  • Page 42 OME-KGP5HT-01C (September 2022) ④Enter pressure value for lower side. ⑤ Press ‘OK’ ⑥ Set pressure for upper side and press ’OK’ ⑦ Enter pressure value for upper side ⑧ Press ‘OK’ to set ~ The Most Cost Effective, Creative Valve Solutions ~ page.
  • Page 43 OME-KGP5HT-01C (September 2022) 3.3.3. Simulation test Caution  Simulation test is the function which enables the positioner to be operated regardless of the signal from a higher-level control system connected with the positioner. Prior to operating this function, make sure that the simulation will not affect the process. ...
  • Page 44 OME-KGP5HT-01C (September 2022) 2) Preset mode MENU > Maintenance > Simulation test > Preset input ① Select ‘Set Value’. ② Input a value. (Value range: 0.0% - 100.0%) ③ Press ‘OK’ to execute. ~ The Most Cost Effective, Creative Valve Solutions ~ page.
  • Page 45 OME-KGP5HT-01C (September 2022) 3.3.3.2. Ramp response simulation It is possible to move the control valve by providing the ramp signal internally. MENU > Maintenance > Simulation test > Ramp resp. test Parameter Description Unit Start Position Set the start position of the valve travel Stop Position Set the end position of the valve travel Ramp time...
  • Page 46 OME-KGP5HT-01C (September 2022) 2) Abort ramp resp. test ① Select ‘Abort Operation’. ② Press ‘OK’ on confirmation screen to abort ramp resp test. 3.3.3.3. Step response simulation It is possible to move the control valve by providing the step signal internally. Parameter Description Unit...
  • Page 47 OME-KGP5HT-01C (September 2022) ③ To escape from this screen, select ‘OK’ or ‘Abort’ ➃ To modify the parameter, select each item. ➄ Confirm all parameters are correct. ➅ Press ‘OK’ ➆ Press ‘OK’ on confirmation screen to execute. 2) Abort step resp. test. ①...
  • Page 48 OME-KGP5HT-01C (September 2022) 3.3.4.2. Switching of factory setup Caution Since the suitable parameters are configured at the factory, in general, do not perform switching of factory setup and the reconfiguration on its menu. The reconfiguration of the values causes the case that the desired response may not be achieved.
  • Page 49 OME-KGP5HT-01C (September 2022) 3.3.5.2. Squawk By using this command, the ”Squawk ON !!” or " Squawk ONCE ON " is indicated(blinked) on a LCD screen of the device. To indicate the sign, screen on the LCD should be top menu or ‘HART relation > Squawk’...
  • Page 50 OME-KGP5HT-01C (September 2022) Device information: Manufacture Model Dev id Descriptor Date Long tag Message Final asmbly num *Read only information Commands: Read Device information Write Tag Write Descriptor Write Date Write Long Tag Write Message Write Final assembly num 3.3.5.4. Reset Warning Reset causes the device shuts down for a few seconds.
  • Page 51 OME-KGP5HT-01C (September 2022) 3.4. Alarms When detecting a breakdown of internal memory and sensors, this positioner announces an alarm by self-diagnostic function as well as shutdown an IP signal current off compulsorily and moves toward fail safe direction. Additionally, it's possible to set the alarm condition optionally about the valve position, the deviation, the temperature and the pressures.
  • Page 52 OME-KGP5HT-01C (September 2022) Alarm of is shown in Table 3.4.1b. input signal level Table 3.4.1b. Alarms caused by a breakdown (unable to change setting) Contents Description Purpose to use When the input signal of 4-20mA drops To detect a drop of the input signal below 3.6mA, an alarm is occurred.
  • Page 53 OME-KGP5HT-01C (September 2022) Contents Description Purpose to use and their correction is held. stopping integral terms accumulation. Set-value; Low pressure threshold[kPa,bar,psi] Default status category; Out of specification When the A/D value of pressure sensors To detect abnormality of pressure exceeded a threshold, an alarm is occurred. sensors.
  • Page 54 OME-KGP5HT-01C (September 2022) 3.4.3. NAMUR status select The NAMUR status category related to each alarm can be selected voluntarily. For example, the procedure for setting the position alarm is as follows. MENU > Diag. & Alarms > NAMUR status sel. ①...
  • Page 55 OME-KGP5HT-01C (September 2022) 3.5. Diagnosis Caution  HART communication takes longer than the operation using the LUI of this unit, so be sure to complete the operation. This positioner is equipped with the on-line diagnosis which acquires and estimates data during plant operation and the offline diagnosis performed in maintenance.
  • Page 56 OME-KGP5HT-01C (September 2022) Items Summary of online diagnosis Disable / Enable : Select a periodical execution or not Stroke size [%] : Set a position width to move Completion stroke [%] : Set a stroke to judge movement completion Start stroke [%] : Set a stroke to judge movement start Abort time limit [s] : Set a time to judge movement cancellation before...
  • Page 57 OME-KGP5HT-01C (September 2022) 3.5.1.2. Online diagnosis setup For example, the procedures for setting the total stroke parameter and erasing its log are as follows． 1) Setting the total stroke parameter. MENU > Diag & Alarms > Online diag. setup ① Select the 'Total Stroke Setting' ②...
  • Page 58 OME-KGP5HT-01C (September 2022) 2) Check of results. MENU > Information > Diag. resul > Total Stroke Total Stroke : Present total stroke value Criteria : Set value 3) Erasing the total stroke log MENU > Diag & Alarms > Online diag. setup ①...
  • Page 59 OME-KGP5HT-01C (September 2022) 3.5.1.3. Clear of diagnosis logs The procedures for clearing diagnosis logs is as follows． MENU > Diag & Alarms > Online diag. setup > Diag. log clear ① Select ‘OK’ on confirmation screen to execute. ~ The Most Cost Effective, Creative Valve Solutions ~ page.
  • Page 60 OME-KGP5HT-01C (September 2022) 3.5.2. Offline diagnosis setup 3.5.2.1. Summary of offline diagnosis Summary and set value of offline diagnosis is indicated in Table 6.5.2. Table3.5.2. Offline diagnosis Items Summary of offline diagnosis The 25% step response is executed, and the maximum overshoot (O.S.) and the final deviation (Dev.) are recorded.
  • Page 61 OME-KGP5HT-01C (September 2022) Items Summary of offline diagnosis IP signal current to control 25%, 50% and 75% position are measured, and it’s checked whether the drift is in tolerance or not. The degradation over time in a pneumatic circuit can be checked by comparing initial values, previous values and present values.
  • Page 62 OME-KGP5HT-01C (September 2022) 3.5.2.2. 25％ step response test For setting and executing the 25％ step response test are as follows． 1) Setting the 25％ step response test MENU > Diag & Alarms > Offline diag. set. > 25% step response ①...
  • Page 63 OME-KGP5HT-01C (September 2022) 3.5.2.3. Pneumatic circuit span 1) Setting MENU > Diag & Alarms > Offline diag. set. > Pneumatic span ① Select ‘Write’ and press ‘OK’ ② Select ‘Step time’ ③ Input a step time value. ➃ Select ‘Criteria’ ⑤...
  • Page 64 OME-KGP5HT-01C (September 2022) 3.5.2.4. Pneumatic circuit drift 1) Setting MENU > Diag & Alarms > Offline diag. set. > Pneumatic drift ① Select ‘Write’ and press ‘OK’ ② Select ‘Ramp time’ ③ Input a ramp time value ➃ Select ‘Tolerance’ ⑤...
  • Page 65 OME-KGP5HT-01C (September 2022) 3.5.2.5. Simple valve signature 1) Setting MENU > Diag & Alarms > Offline diag. set. > S-valve signature ① Select ‘Write’ and press ‘OK’ ② Select ‘Ramp time’ ③ Input a ramp time value. Hysteresis limit(kPa)： ➃ Select ‘Hysteresis limit’ Sets the pressure hysteresis tolerance.
  • Page 66 OME-KGP5HT-01C (September 2022) ⑥ Select ‘Gradient limit H’ Gradient limit H(kPa)： Sets the upper limit of the pressure gradient ⑦ Input a gradient limit high value. tolerance. See Table 3.5.2.1 for more information. Offline diagnostics. ➇ Select ‘Gradient limit L’ Gradient limit L(kPa)：...
  • Page 67 OME-KGP5HT-01C (September 2022) 3.5.3. Check and Save of online diagnosis results (Diag.test data) In this section, confirmation and save of diagnosis results are explained. It’ll be the same operation with each diagnosis. Therefore, for instance, the 25% step response is explained here. 1) Check of result It’s possible to indicate a result data in following menu.
  • Page 68 OME-KGP5HT-01C (September 2022) 4. Troubleshooting When problems occurred at the operation starting or during operation, please refer to the following table and take an action appropriately. Table 4 Trouble shooting Phenomenon Assumed cause Action  Check input current Loss of electrical power, disconnection or miswiring ...
  • Page 69 OME-KGP5HT-01C (September 2022) 5. Menu item reference 1st hierarchy 2nd hierarchy 3rd hierarchy 4th hierarchy 5th hierarchy 6th hierarchy （chapter） Root Menu Alarm status Alarm status 3.1.2. <Set point> <Position> <Loop current > <Input > <P-sup. > <P-out1 > <P-out2 > Menu Information Monitor...
  • Page 70 OME-KGP5HT-01C (September 2022) reference 1st hierarchy 2nd hierarchy 3rd hierarchy 4th hierarchy 5th hierarchy 6th hierarchy （chapter） Setup Basic setup Actuator motion Linear Rotary Actuator type Single Double 5300 Valve action 3.2.2. Packing friction High Booster option Set point dir. Normal Reverse Position transmit.dir...
  • Page 71 OME-KGP5HT-01C (September 2022) reference 1st hierarchy 2nd hierarchy 3rd hierarchy 4th hierarchy 5th hierarchy 6th hierarchy （chapter） Setup Function select Authority Authority Control mode Password setup Disable/Enable Screen saver Disable/Enable 3.2.7. Temperature unit Celsius Fahrenheit Pressure unit Maintenance Calibration Input signal cal. 3.3.2.1.
  • Page 72 OME-KGP5HT-01C (September 2022) reference 1st hierarchy 2nd hierarchy 3rd hierarchy 4th hierarchy 5th hierarchy 6th hierarchy （chapter） Diag.& Alarms Online diag.setup Total Stroke Setting 3.5.1.2. Total Direction Change Setting Low Position Stting 3.5.1.1. Max./Min Tmperature Setting Partial stroke T. Diag. log clear 3.5.1.3.
  • Page 73 OME-KGP5HT-01C (September 2022) A) APPENDIX / Flow chart of settings procedure In case of the purchase of a control valve with the positioner, settings described in this section are completed at the factory. Accordingly, it is not necessary to repeat the settings. However, if the positioner is specified on the order or it is separated from the control valve for maintenance, if necessary, perform the setting according to the following procedure.
  • Page 74 Tel. (86) 510-85585118 Fax. (86) 510-85585119 Wuxi KOSO Valve Casting Co., Ltd., China Tel. (86) 510-85581109 Fax. (86) 510-85123093 Hangzhou Hangyang KOSO P & V Co., Ltd. Tel. (86) 571-85869508 Fax. (86) 571-85343203 KOSO-AACI (Anshan) Co., Ltd., China Tel. (86) 412-8812686 Fax.