Page 1 OME-KGP5-01O(Jun. 2024) KGP5000 series Smart valve positioner Model KGP5000 / 5003 Instruction Manual ~ The Most Cost Effective, Creative Valve Solutions ~ ...
Page 2: Table Of Contents
OME-KGP5-01O(Jun. 2024) Table of Contents INTRODUCTION ........................ 5 1.1. Scope of this instruction manual .................... 5 1.2. Safety notices .......................... 6 1.3. Product summary ......................... 6 1.3.1. Parts description ........................ 7 1.3.2. Principle of operation ...................... 7 1.4. Specifications .......................... 9 1.5. Marking label .......................... 10 1.6.
Page 3 OME-KGP5-01O(Jun. 2024) 4.5.2. Custom setting for PID parameter .................. 52 4.5.3. Setup for IP signal current bias ................... 55 4.6. Error messages ........................... 55 4.7. Detailed setup.......................... 56 4.8. Function select ........................... 59 4.9. Memory management ........................ 61 4.9.1. Memory save ........................ 61 4.9.2. Restore set value ......................... 62 4.9.3. Restore factory default ....................... 62 ...
Page 4 OME-KGP5-01O(Jun. 2024) 6.2.5. Low Sup‐pressure alarm ..................... 92 6.2.6. Pressure failure alarm ...................... 94 6.2.7. Alarm clear .......................... 95 6.3. Allocation of NAMUR indication .................... 95 DIAGNOSTICS ........................ 9 7 7.1. Online diagnostics ........................ 97 7.1.1. Summary of online diagnostics ................... 97 7.1.2. Online diagnostics setting / Confirmation and Clear of results .......... 99 7.1.2.1.
Page 5: Introduction
OME-KGP5-01O(Jun. 2024) 1. INTRODUCTION Please read carefully at first! This instruction manual includes specifications, installation & calibration, maintenance procedures, guide to the diagnosis and treatment of failure, troubleshooting, replacement of parts, and so on for the KGP5000 series smart valve positioner. Read carefully before installing and using the positioner. In order to get the support you need, contact your KOSO sales office. Please refer to this instruction manual on the reverse side for contact information. Please keep this instruction manual for future reference! Notes regarding this instruction manual;  The user should read and understand this publication.  The contents of this publication are subject to change without notice to improve specifications.  The contents of this publication may not be reproduced or duplicated in whole or in part, without prior consent.  This publication may not be revised so long as changes in structure and specifications have no ...
Page 6: Safety Notices
OME-KGP5-01O(Jun. 2024) 1.2. Safety notices This document describes safety notices by using warnings and cautions as below. The user should thoroughly review safety notices described in this instruction manual prior to installation, operation, maintenance for the positioner. Warning Death or severe personal injury can occur if the user fails to keep safety precautions. Caution Minor ...
Page 7: Parts Description
OME-KGP5-01O(Jun. 2024) 1.3.1. Parts description Figure 1.3.1 Product parts 1.3.2. Principle of operation The principle of operation and the process flow diagram are shown in figure 1.3.2a and 1.3.2b. The CPU(central process unit) receives a 4 to 20mA signal, an actual valve position feedback signal as control valve travel from a potentiometer attached to the feedback lever and pressure signal into which ADC(A/D converter) converts signal from pressure sensors (supply pressure Ps, output pressure Pout1 & Pout2). The deviation generated by the control algorithm is the difference between an input signal and a valve position feedback signal. ...
Page 8 OME-KGP5-01O(Jun. 2024) ※1 Figure 1.3.2a Principle of operation Input signal Setpoint [mA] 4-20mA Input current Input signal Input signal Input signal Cutoff/ signal calibration ranging Dir./Rev. transfer Limit Pressure IP signal Deadband [kPa,bar,psi] Pneumatic Valve Actuator amplify convert － Valve travel Valve travel Valve travel detection...
Page 9: Specifications
OME-KGP5-01O(Jun. 2024) 1.4. Specifications General specifications ; Alarm signal : ≦3.6mA or ≧21mA Available types of actuators for mounting; according to *NAMUR NE43 KOSO diaphragm type : 5200LA Burn‐out direction KOSO cylinder type : 6300LA LO or HI depending on setting KOSO high power type : 5300LA LO only under input signal failure ...
Page 10: Marking Label
OME-KGP5-01O(Jun. 2024) TÜV Rheinland Certificate No. AK 50363732 Performance specifications ; 0001 Position control IECEx, ATEX, EAC, CNS︓ Linearity ; ±1.2% TÜV Rheinland Certificate No. AK 50448750 Hysteresis ; 0.7% 0001 Pneumatic connections ; Rc1/4 or 1/4NPT Position transmitter output Electric connections ; ...
Page 11: Tools
OME-KGP5-01O(Jun. 2024) 1.7. Tools Warning  Keep away from a magnet material or a magnetic‐tripped screwdriver. It unexpectedly moves the control valve so that it may cause the death or serious damage. To install and operate the positioner, the following tools are required. ① Phillips screwdriver︓ No.2 Front cover, torque motor, pilot relay, A/M unit ② Flat screwdriver︓ 6×100mm Switching the screw of the A/M unit, switching the screw of the pilot relay ③ Hex key 3mm︓ lock screw of the terminal cover 4mm︓ pressure gauge block ④ Spanner︓10mm Adjusting the gap between nozzle and nozzle pad of the torque motor Figure 1.7 Parts to use tools ~ The Most Cost Effective, Creative Valve Solutions ~ ...
Page 12: Storage
OME-KGP5-01O(Jun. 2024) 1.8. Storage The following instructions must be observed in order to store the positioner. If the device is to be stored in unused state︔ １． Store it in the packed state of product shipment. ２． Keep away from the environment in where vibration and impact, noise, etc. may be caused and store it in an indoor environment free of flooding. If the used device is to be stored︔ １． Fasten tightly the terminal cover. In addition, block the electric conduit ports to prevent the intrusion of humidity, dust. ２． Block the pneumatic connection ports and the exhaust port with tape to prevent the intrusion of humidity, dust. ３． Keep away from the environment in where vibration and impact, noise, etc. may be caused and store it in an indoor environment free of flooding. 1.9. Warranty certificate We'll set a guarantee period without charge of our product to 1 year after payment at your designation ...
Page 13: Mounting
OME-KGP5-01O(Jun. 2024) 2. MOUNTING Warning  Prior to mounting the positioner on the actuator, be certain the air supply is locked out. The feedback lever movement during air supply may cause death or severe damage.  Perform the mounting after confirming that flammable, explosive gases are not present and the environment is not saturated with water or steam. Caution  When mounting the positioner, take care not to give a mechanical or physical shock caused by impact, drop etc. The shock may produce damage or readjustment.  Secure enough space for mounting.  Perform the mounting at the place to meet the environmental specification limits of the positioner.  IECEx and ATEX explosion proof type have a hexagon socket set screw in the bottom right of the four M8 screw holes on the backside to mount the positioner itself. Do not remove the screw to keep the waterproof and dustproof performance unless the screw hole is applied for mounting the positioner. ...
Page 14: Mounting To Linear Motion Actuator (5200La, 6300La, 5300La)
OME-KGP5-01O(Jun. 2024) Mount the positioner to a linear actuator in a position that the feedback lever is in the horizontal position at 50% of full travel. Figure 2.1b Mounting position（example of linear type） 2.2. Mounting to linear motion actuator (5200LA, 6300LA, 5300LA) Figure 2.2a Example of mounting to linear motion actuator ~ The Most Cost Effective, Creative Valve Solutions ~ page. 14 ...
Page 15: Mounting To Rotary Motion Actuator (6300Rc)
OME-KGP5-01O(Jun. 2024) Figure 2.2b Mounting position of tension spring Be sure the upper side of a tension spring hits a feedback pin． 2.3. Mounting to rotary motion actuator (6300RC) Mount the positioner to a rotary motion actuator in a position that the feedback lever is in the horizontal position at 50% of full travel. Figure 2.3 Example of mounting to rotary motion actuator ~ The Most Cost Effective, Creative Valve Solutions ~ page. 15 ...
Page 16: Namur Mounting To Rotary Motion Actuator (Vdi/Vde3845)
OME-KGP5-01O(Jun. 2024) 2.4. NAMUR mounting to rotary motion actuator (VDI/VDE3845) Figure 2.4 Example of NAMUR mounting to rotary motion actuator 2.5. Pressure connections Caution  Be certain the supply pressure does not exceed the maximum allowable pressure of the positioner and the actuator to apply.  Use a clean, dry, oil‐free instrument air. Refer to section 1.4 regarding air quality standards.  Excessive use of sealant on the thread connections can cause a failure of the positioner. Make sure the sealant is not mixed with the air.  Don’t use tape type sealant on the thread connections. Residues of the sealant may block the air flow inside the positioner and can cause malfunction of the positioner and accessories. Figure 2.5 shows pneumatic connections. ...
Page 17: Supply Pressure Connection
OME-KGP5-01O(Jun. 2024) Figure2.5 Pneumatic connections 2.5.1. Supply pressure connection Connect either one 【IN】 input of two input ports of the positioner on the air supply. In addition, block the unused input port with screw plug. 2.5.2. Output pressure connections In case of factory shipment of the positioner mounted on an actuator, pneumatic installation of output connections is carried out together with the mounting. But in case of mounting at the customer’s facilities, connect pressure outputs of the positioner on an actuator inputs as followings. For single acting actuator︔ Connect the 【OUT‐1】 output of the positioner on the input of a single acting actuator. In addition, block the unused inlet port with screw plug. ...
Page 18: Electrical Connections
OME-KGP5-01O(Jun. 2024) 2.6. 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. Caution  Close the unused entries for flameproof enclosures with blanking elements to avoid the intrusion of humidity, dust, etc.  The entries shall be sealed with sealants to avoid the intrusion of water or rain  Earthing and bonding conductor shall be connected by terminal lugs (Tinning copper).  Earthing or bonding conductor shall be firmly connected by using screws with captive spring lock washer(M4) provided on the positioner in such a way to prevent loosening and twisting. ...
Page 19 OME-KGP5-01O(Jun. 2024) 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. Notes of the assembly of connection facilities are as follows. 1. Select correct wires. ・ The cross‐sectional area of the wire conductor for IN± and OUT± shall be less than or equal to that of the internal earthing conductor. 2. Select correct terminal lugs for the size of the wire you are using. ・ A terminal lug has an acceptable wire size range. Using too large terminal lug may cause the wire to slip out. ・ The width of the connection facilities for a terminal lug is 8.1mm and the fastener for a terminal lug is M4 screw, therefore the dimensions should be B＜8.1mm and d2＞4mm in case of ring terminal as Figure2.6b 3. Strip the insulation from insulated wire. ・ Stripping length depends on the terminal lug type and shape. Please follow the instructions for each terminal lug. Figure2.6b shows an example in case of non‐insulated ring terminal (JIS C 2805) Figure 2.6b Terminal lug example (non‐insulated ring terminal : JIS C 2805) 4. Crimp with the crimping tool ・ Select the correct crimping tool based on the size and type of the terminal lug. Please follow the instructions for each crimping tool. 5. Assemble the parts of connection facilities as shown in Figure2.6c. ...
Page 20 OME-KGP5-01O(Jun. 2024) Make wiring connections according to the following procedure. Refer to the above instruction on procedure 3 to 5. 1. Remove the terminal cover. 2. Lead a cable into the terminal box from the outside through the entries and the cable gland. 3. Connect wires of loop current, respectively, to IN+ and IN‐ of the positioner. 4. Connect wires of position transmitter, respectively, to OUT+ and OUT‐ of the positioner.※ Model KGP5003 only 5. As illustrated in figure 2.6a, two connection facilities for earthing and bonding conductors are available. ...
Page 21 OME-KGP5-01O(Jun. 2024) Normal Operation range Supply voltage（VDC） Figure 2.6f Load resistance to supply voltage relationship via the connection of position transmitter Supply power to the positioner according to the load resistance. It should be noted that the supply power must not be exceed 40VDC. Table 2.6a The suitable Ex certificated cable glands and blanking elements for each proof type Proof type Thread form of Certification Rated ambient Service temperature entries temperature range range ℃〜 ℃ ℃〜 ℃ TIIS G1/2 Ex d IIC Gb ‐20 ‐20 ...
Page 22: Restriction Plate (Optional): Hunting Suppression Parts In Small Actuator
OME-KGP5-01O(Jun. 2024) 2.7. Restriction plate (optional): Hunting suppression parts in small actuator If the actuator is small and the hysteresis due to packing friction is heavy, the control performance may be degraded, such as hunting, because the PID parameters preset in this positioner will not perform the expected control. In order to improve such a phenomenon, it is effective to use a restriction plate. 2.7.1．Guideline for applying restriction plate It is recommended to use a restriction plate when the hysteresis is more than the value (%) in the actuator size described below. ...
Page 23: Explosion Proof Type
OME-KGP5-01O(Jun. 2024) 3. EXPLOSION PROOF TYPE Warning  Please do a wiring work in the explosion protection area according to a prescribed guideline by an explosion protection guideline.  When doing a wiring work and an adjustment work, please work after it's confirmed that explosive gas doesn't exist in the environment.  In case of using explosion proof type, do not open the terminal cover when an explosive atmosphere is present.  The following special conditions of the flameproof joints are necessary for safety using. Please contact us for more details. ...
Page 24: Tiis Flame Proof Type
OME-KGP5-01O(Jun. 2024) 3.1. TIIS flame proof type ︓KGP51XX (Electrical entries: G1/2) A) Model No. ︓Ex d IIC T6 Gb (Certificate No. : TC22443X) Marking IIC : This equipment is intended for use in above‐ground industries with flammable gases, vapors, or mists. It has a flameproof enclosure classified as IIC suitable for use in explosive atmospheres such as hydrogen and acetylene. T6 : The maximum surface temperature of this equipment can rise to +85°C when the ambient temperature is +60°C. Gb : The practicable location of this device is hazardous areas of Zone1(First‐class dangerous place)and Zone2(Second‐class dangerous place). It can’t be used in hazardous area of Zone0. ︓4 to 20mA(Service input range) Input current ︓3.8 to 24mA(Maximum permissible input range ※1) ︓‐20℃ ≤ Tamb ≤ +60℃ D) Ambient temperature range ︓80kPaA to 110kPaA (absolute) Ambient atmospheric pressure ︓JNIOSH‐TR‐46:2015 Applicable standard G) Specification plate ...
Page 25: Ccc(Nepsi) Flame Proof Type
OME-KGP5-01O(Jun. 2024) 3.2. CCC(NEPSI) flame proof type ︓KGP52XX (Electrical entries: 1/2NPT) A) Model No. ︓Ex db IIC T6 Gb (CCC Certificate No. : 2020322307000438 Marking NEPSI Certificate No. : GYJ23.1345X) IIC : This equipment is intended for use in above‐ground industries with flammable gases, vapors, or mists. It has a flameproof enclosure classified as IIC suitable for use in explosive atmospheres such as hydrogen and acetylene. T6 : The maximum surface temperature of this equipment can rise to +85°C when the ambient temperature is +70°C. Gb : The practicable location of this device is hazardous areas of Zone1(First‐class dangerous place)and Zone2(Second‐class dangerous place). It can’t be used in hazardous area of Zone0. ︓4 to 20mA Input current ︓‐40℃ ≤ Tamb ≤ +70℃ D) Ambient temperature range ︓80kPaA to 110kPaA (absolute) Ambient atmospheric pressure ︓GB/T 3836.1‐2021，GB/T 3836.2‐2021 Applicable standard G) Specification plate H) Instruction for safe use: ...
Page 26: Kosha Flame Proof Type
OME-KGP5-01O(Jun. 2024) 3.3. KOSHA flame proof type ︓KGP53XX (Electrical entries: 1/2NPT) A) Model No. ︓Ex d IIC T6 (Certificate No. : 17‐AV4BO‐0350X) Marking IIC : This equipment is intended for use in above‐ground industries with flammable gases, vapors, or mists. It has a flameproof enclosure classified as IIC suitable for use in explosive atmospheres such as hydrogen and acetylene. T6 : The maximum surface temperature of this equipment can rise to +85°C when the ambient temperature is +60°C. The practicable location of this device is hazardous areas of Zone1(First‐class dangerous place)and Zone2(Second‐class dangerous place). It can’t be used in hazardous area of Zone0. ︓4 to 20mA Input current ︓‐20℃ ≤ Tamb ≤ +60℃ D) Ambient temperature range ︓80kPaA to 110kPaA (absolute) Ambient atmospheric pressure ︓2020‐33 Applicable standard G) Specification plate ...
Page 27: Iecex Flame Proof Type
OME-KGP5-01O(Jun. 2024) 3.4. IECEx flame proof type ︓KGP54XX (Electrical entries: 1/2NPT, M20) A) Model No. ︓Ex db IIC T6 Gb (Certificate No. : IECEx DEK 17.0037X) Marking IIC : This equipment is intended for use in above‐ground industries with flammable gases, vapors, or mists. It has a flameproof enclosure classified as IIC suitable for use in explosive atmospheres such as hydrogen and acetylene. T6 : The maximum surface temperature of this equipment can rise to +85°C when the ambient temperature is +70°C. Gb : The practicable location of this device is hazardous areas of Zone1(First‐class dangerous place)and Zone2(Second‐class dangerous place). It can’t be used in hazardous area of Zone0. ︓4 to 20mA Input current ︓‐40℃ ≤ Tamb ≤ +70℃ D) Ambient temperature range ︓80kPaA to 110kPaA (absolute) Ambient atmospheric pressure ︓IEC 60079‐0 : 2011, IEC 60079‐1 : 2014‐06 Applicable standard G) Specification plate ...
Page 28: Atex Flame Proof Type
OME-KGP5-01O(Jun. 2024) 3.5. ATEX flame proof type ︓KGP55XX (Electrical entries: 1/2NPT, M20) A) Model No. ︓II 2 G Ex db IIC T6 Gb (Certificate No. : DEKRA 17ATEX0076 X) Marking IIC : This equipment is intended for use in above‐ground industries with flammable gases, vapors, or mists. It has a flameproof enclosure classified as IIC suitable for use in explosive atmospheres such as hydrogen and acetylene. T6 : The maximum surface temperature of this equipment can rise to +85°C when the ambient temperature is +70°C. Gb : The practicable location of this device is hazardous areas of Zone1(First‐class dangerous place)and Zone2(Second‐class dangerous place). It can’t be used in hazardous area of Zone0. ︓4 to 20mA Input current ︓‐40℃ ≤ Tamb ≤ +70℃ D) Ambient temperature range ︓80kPaA to 110kPaA (absolute) Ambient atmospheric pressure ︓EN 60079‐0 : 2012 +A11, EN 60079‐1 : 2014 Applicable standard G) Specification plate ...
Page 29: Eac Flame Proof Type
OME-KGP5-01O(Jun. 2024) 3.6. EAC flame proof type ︓KGP56XX (Electrical entries: 1/2NPT, M20) A) Model No. ︓1 Ex db IIC T6 Gb (Certificate No. : ЕАЭС RU C‐JP.AД07.В.04614/22) Marking IIC : This equipment is intended for use in above‐ground industries with flammable gases, vapors, or mists. It has a flameproof enclosure classified as IIC suitable for use in explosive atmospheres such as hydrogen and acetylene. T6 : The maximum surface temperature of this equipment can rise to +85°C when the ambient temperature is +70°C. Gb : The practicable location of this device is hazardous areas of Zone1(First‐class dangerous place)and Zone2(Second‐class dangerous place). It can’t be used in hazardous area of Zone0. ︓4 to 20mA Input current ︓‐40℃ ≤ Tamb ≤ +70℃ D) Ambient temperature range ︓80kPaA to 110kPaA (absolute) Ambient atmospheric pressure ︓ГОСТ 31610.0‐2014 (IEC 60079‐0: 2011) Applicable standard ГОСТ IEC 60079‐1‐2013 G) Specification plate H) Instruction for safe use: ...
Page 30: Cns Flame Proof Type
OME-KGP5-01O(Jun. 2024) 3.7. CNS flame proof type ︓KGP54XX (Electrical entries: 1/2NPT, M20) A) Model No. ︓Ex db IIC T6 Gb (Certificate No. : TD0401AE, TD04010D) Marking IIC : This equipment is intended for use in above‐ground industries with flammable gases, vapors, or mists. It has a flameproof enclosure classified as IIC suitable for use in explosive atmospheres such as hydrogen and acetylene. T6 : The maximum surface temperature of this equipment can rise to +85°C when the ambient temperature is +70°C. Gb : The practicable location of this device is hazardous areas of Zone1(First‐class dangerous place)and Zone2(Second‐class dangerous place). It can’t be used in hazardous area of Zone0. ︓4 to 20mA Input current ︓‐40℃ ≤ Tamb ≤ +70℃ D) Ambient temperature range ︓80kPaA to 110kPaA (absolute) Ambient atmospheric pressure ︓CNS 3376‐0/C 1038‐0 (IEC 60079‐0 : 2011), Applicable standard CNS 3376‐1/C 1038‐1 (IEC 60079‐1 : 2014‐06) G) Specification plate ...
Page 31: Setup And Information
OME-KGP5-01O(Jun. 2024) 4. SETUP AND INFORMATION Warning  Changes in parameters and so on owing to setup procedure may cause unexpected movements of the valve. Perform the setup in the conditions such as offline state which does not directly affect the process.  Don’t remove the terminal cover of the positioner during or after the passage of electric current. In case the terminal cover must be opened reluctantly, perform that after confirming that flammable, explosive gases are not present and the environment is not saturated with water or steam.  Don’t touch the moving parts during the setup procedure. It causes personal injury.  Keep away from a magnet material or a magnetic‐tripped screwdriver. It unexpectedly moves the control valve so that it may cause a serious damage.  Don’t use a wireless transceiver near the positioner. 4.1. Local user interface (LUI) 4.1.1.
Page 32: Operating Push Buttons
OME-KGP5-01O(Jun. 2024) 4.1.2. Operating push buttons The local user interface (hereinafter, referred to as LUI) may be operated to perform setting of the positioner, monitoring of operational status, maintenance, etc. LUI consists of an eight‐line liquid crystal display (hereinafter, referred to as LCD), four push buttons. Figure 4.1.2 Local user interface (LUI) ...
Page 33 OME-KGP5-01O(Jun. 2024) The possible configuration indications are shown as in figure 4.1.3b. Display password setting Display set point Display HART ♥ Set Point: 50.0% ∞ communication status Position: Good Display 50.0% Display NAMUR status measured value symbol Figure 4.1.3b Possible configuration indications Display of password setting; ∞ The password is set︓symbol Password setting is disabled︓symbol ...
Page 34: Menu Tree On The Lcd
OME-KGP5-01O(Jun. 2024) 4.1.4. Menu tree on the LCD MENU 1. Information 1. Status 2. Setup 2. Input /posi etc 3. Maintenance 3. Pressure 4. Diag. & Alarms 4. Temperature 5. IP correction 1. Information 1. Position alarm 1. Monitor 2. Deviation alarm 2. Alarm status 3.
Page 35 OME-KGP5-01O(Jun. 2024) MENU 1. Information 2. Setup 3. Maintenance 4. Diag. & Alarms 1. Actuator motion 2. Actuator type 2. Setup 3. Valve action 1. Basic setup 4. Packing friction 2. Easy tuning 5. Booster option 3. Expert tuning 6. Set point dir. 4.
Page 36 OME-KGP5-01O(Jun. 2024) MENU 1. Information 2. Setup 3. Maintenance 4. Diag. & Alarms 3. Maintenance 1. Input signal cal. 1. Calibration 2. Cross point cal. 2. Simulation test 3. Position transmit. 3. Memory save & res. 4. Pressure sensor 4. Service 5.
Page 37 OME-KGP5-01O(Jun. 2024) MENU 1. Information 2. Setup 1. Total stroke 3. Maintenance 2. Total dir. change 4. Diag. & Alarms 3. Low position time 4. Max. temp.time 4. Diag. & Alarms 5. Min. temp.time 1. Online diag. setup 6. Partial stroke T. 2.
Page 38: Flow Chart Of Settings Procedure
OME-KGP5-01O(Jun. 2024) 4.2. 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. ~ The Most Cost Effective, Creative Valve Solutions ~ page. 38 ...
Page 39: Basic Setup
Table 4.3 Basic setup parameters Key menu Description Parameters Default Actuator ※1 Set stem motion type of a actuator Linear / Rotary motion Actuator type Set acting type of a actuator 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 ATO Air to Close : ATC Packing Set packing material used for valve body friction Low Low friction material such as PTFE, etc.︓Low Low / High ※2 High friction material such as GRAFOIL, etc.︓ High Booster ...
Page 40: List Of Operation Setting Patterns For Actuator
OME-KGP5-01O(Jun. 2024) 4.3.2. List of operation setting patterns for actuator Table 4.3.2a Linear motion single acting type actuator・Operation list 【Push‐down close】 4→20mA　Valve close 4→20mA　Valve open Control valve operation （Signal to Close）（Signal to Open） Valve body operation Push-down close Direct acting Reverse acting Direct acting Reverse acting Actuator motion direction (DA) (RA) (DA) (RA) Pout1 Piping connection...
Page 41 OME-KGP5-01O(Jun. 2024) Table 4.3.2b(Reference table) Linear motion single acting type actuator・Operation list 【Push‐down open】 4→20mA　Valve close 4→20mA　Valve open Control valve operation （Signal to Close）（Signal to Open） Valve body operation Push-down open Direct acting Reverse acting Direct acting Reverse acting Actuator motion direction (DA) (RA) (DA) (RA) Pout1 Piping connection Valve action Reverse...
Page 42 OME-KGP5-01O(Jun. 2024) Table 4.3.2c Linear motion double acting type actuator・Operation list 【Push‐down close】 4→20mA　Valve close 4→20mA　Valve open Control valve operation （Signal to Close）（Signal to Open） Valve body operation Push-down close Pout2 Pout1 Pout2 Pout1 Stem rising side Pout1 Pout2 Pout1 Pout2 Stem down side Valve action Reverse Normal Set point dir.
Page 43 OME-KGP5-01O(Jun. 2024) Table 4.3.2d(Reference table) Linear motion double acting type actuator・Operation list 【Push‐down open】 4→20mA弁閉 4→20mA弁開調節弁動作（Signal to Close）（Signal to Open） Valve body operation Push-down open Pout2 Pout1 Pout2 Pout1 Stem rising side Pout1 Pout2 Pout1 Pout2 Stem down side Valve action Reverse Normal Set point dir. Open Close input...
Page 44 OME-KGP5-01O(Jun. 2024) Table 4.3.2e Rotary motion single acting type actuator・Operation list 【Counterclockwise open】 4→20mA　Valve close 4→20mA　Valve open Control valve operation （Signal to Close）（Signal to Open） Valve body operation Counterclockwise open Counterclockwis Counterclockwise Clockwise with Clockwise with Actuator motion direction e with Pout1 with Pout1 Pout1 increase Pout1 increase increase increase...
Page 45 OME-KGP5-01O(Jun. 2024) Table 4.3.2f(Reference table) Rotary motion single acting type actuator・Operation list 【Counterclockwise close】 4→20mA　Valve close 4→20mA　Valve open Control valve operation （Signal to Close）（Signal to Open） Valve body operation Counterclockwise close Counterclockwis Counterclockwise Clockwise with Clockwise with Actuator motion direction e with Pout1 with Pout1 Pout1 increase Pout1 increase increase increase...
Page 46 OME-KGP5-01O(Jun. 2024) Table 4.3.2g Rotary motion double acting type actuator・Operation list 【Counterclockwise open】 4→20mA　Valve close 4→20mA　Valve open Control valve operation （Signal to Close）（Signal to Open） Valve body operation Counterclockwise open Counterclockwise Counterclockwise Clockwise with Clockwise with Actuator motion direction with Pout1 with Pout1 Pout1 increase Pout1 increase increase increase Increased air pressure...
Page 47 OME-KGP5-01O(Jun. 2024) Table 4.3.2h Rotary motion double acting type actuator・Operation list 【Close counterclockwise】 4→20mA　Valve close 4→20mA　Valve open Control valve operation （Signal to Close）（Signal to Open） Valve body operation Counterclockwise close Counterclockwise Counterclockwise Clockwise with Clockwise with Actuator motion direction with Pout1 with Pout1 Pout1 increase Pout1 increase increase increase Increased air pressure...
Page 48: Easy Tuning
OME-KGP5-01O(Jun. 2024) 4.4. Easy tuning Easy tuning is the setup to ensure that the positioner is operated smoothly relative to the actuator on which the positioner is mounted. It is possible to perform easily zero/span adjustments of a control valve, selection of suitable PID parameters, setting of other parameters necessary to control. Note Before performing this operation (easy tuning), all parameters of basic setup described in section4.3 must be configured. If wrong parameters were configured, it is possible to choose unsuitable PID parameters. 4.4.1. Full autotune While performing a sequence of operations, it configures automatically settings such as detection and calibration ...
Page 49: Response Tuning
OME-KGP5-01O(Jun. 2024) 4.4.3. 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 ( 2‐2‐4 ) A．In case the higher response sensitivity is desired, i.e., you wish to reduce response time by making the response quicker, Select ‘Aggressive’ from ‘Response tuning’ menu and the most suitable stage among nine stages (+1〜+9). The response sensitivity increases in proportion to number of the stage. B. In case the lower motion sensitivity is desired, i.e., you wish to decrease the overshoot by making the response slower, Select ‘Stable’ from ‘Response tuning’ menu and the most suitable stage among five stages (‐1 〜‐9). The response sensitivity decreases in proportion to number of the stage. ...
Page 50: Expert Tuning
OME-KGP5-01O(Jun. 2024) 4．Additional adjustment If overshoot appears, make the following adjustments. A．Overshoot slowly (when pressure change is relatively slow) It is considered that this occurrs because the proportional gain is too small. Raise the rank or set the Response tuning in the positive direction. B．Overshoot immediately (when pressure change is fast) It is considered that this occurrs because the proportional gain is too big. Lower the rank or set the Response tuning in the negative direction. If you perform the full autotune again after changing the rank, the parameters of the originally inappropriate rank will be selected. To avoid this, select Custom after changing the rank. With this operation, the PID parameter will be set to the value of the selected rank. Change of rank by applying restriction plate The use of restriction plate reduces the supply and exhaust speed of the positioner. Therefore, by measuring the time during full autotune, the positioner will recognize that it is controlling a large actuator. By this reason, a PID parameter with a higher rank than the normally selected parameter is ...
Page 51 OME-KGP5-01O(Jun. 2024)  If you change the rank by two or more, unexpected behavior (too slow response, too fast response) may occur, so perform a thorough test operation in advance and confirm that there are no problems.  In general, lowering the proportional gain takes longer to start moving and delays reaching the target opening. On the other hand, increasing the proportional gain causes instability and hunting. It is possible to select preset values prepared previously as PID parameter sets inside the device. MENU > Setup >Expert tuning > PID parameter set ( 2‐3‐1 ) Parameter sets corresponding to maximum seven ranks defined as XS, SS, S, M, L, LL, XL are prepared previously in an ascending order of the proportional gain. Select the parameter set as necessary. If parameters are need to be specified individually through custom setting, select ‘custom’ menu. ...
Page 52: Custom Setting For Pid Parameter
OME-KGP5-01O(Jun. 2024) 4.5.2. 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.  In general, lowering the proportional gain takes longer to start moving and delays reaching the target opening. On the other hand, increasing the proportional gain causes instability and hunting. It is possible to tune individually PID parameters shown as below. MENU > Setup >Expert tuning > PID custom setup ( 2‐3‐2 ) Table 4.5. 2 ．Customizable PID parameters Type of pressure Value ...
Page 53 OME-KGP5-01O(Jun. 2024) ※Inside parameter means the parameters which are used when deviation is |e|≤b. 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 4.5.2．Gain switching (Example of proportional gain） The procedure is shown as followings． ① Select ‘Custom’ from ‘PID parameter set’ menu. Expert tuning ☛PID parameter set PID custom setup Sensitivity setup ⇩ PID parameter set ▲ ☛Custom ⇩ PID parameter set Complete ...
Page 54 OME-KGP5-01O(Jun. 2024) parameters will not be able to be changed through the following procedure ③． Air-Out ≠ Air-In? PID custom setup ☛Air-Out ≠ Air-In? PID value PID value Air-Out Inside threshold ☛Yes ▼ ③ Set PID parameters of Air‐In PID parameter PID custom setup Air-Out ≠ Air-In? P= 1.0 ☛PID value I=30.0 PID value Air-Out Inside threshold D=20.0 ▼...
Page 55: Setup For Ip Signal Current Bias
OME-KGP5-01O(Jun. 2024) 4.5.3. 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 inside the device. There are two different ways whether to determine IP signal current bias automatically or to specify it manually. ...
Page 56: Detailed Setup
OME-KGP5-01O(Jun. 2024) 4.7. Detailed setup Set values which need to be changed to achieve the desired response. MENU > Setup > Detailed setup ( 2‐4‐ ) Table 4.7. Item list of the detailed setup Key menu Description Parameters Default Set the control range which tracks the input signal 0% : If the input signal is lower than this value, IP signal will be cutoff to the low side. The range of values available is 0.1~50.0%. 100% : If the input signal is higher than this value, IP signal will be cutoff to the high side. ...
Page 57 OME-KGP5-01O(Jun. 2024) Key menu Description Parameters Default Low equal percentage characteristics (Rangeability 30:1) Equal percent Mid : Middle equal percentage characteristics (Rangeability 50:1) Equal percent Hig : 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”. Set the flow characteristic curve by specifying arbitrary 20 points. ...
Page 58 OME-KGP5-01O(Jun. 2024) Key menu Description Parameters Default 100% and 12mA to 0% Set 0%=4mA Set 100%=12mA and set point to Reverse Set the burnout direction of position transmitter, when a failure occurs. Low setting︓ When the current is lower than 3.6mA, the lower current (burnout signal) will flow PT burnout dir. Low/High Low High setting︓ When the current bigger than 21mA, the bigger current (burnout signal) will flow ※ If the input signal is zero, the current of Low setting will flow regardless of above setting. Set the full mechanical limit of valve travel over the ...
Page 59: Function Select
OME-KGP5-01O(Jun. 2024) 4.8. Function select You can configure individually the following functions. MENU > Setup > Function select ( 2‐5‐ ) Table 4.8. List of selectable functions Key menu Description Parameters Default Set access permission to HART communication. Select HART in case in which settings should be configured via not LUI but HART communication only. Once HART is selected, only ‘Information’ from ‘TOP’ menu will be able to be accessed through LUI. ...
Page 60 OME-KGP5-01O(Jun. 2024) ※・・・The parameters setup is carried out according to the specified model code at the factory. ~ The Most Cost Effective, Creative Valve Solutions ~ page. 60 ...
Page 61: Memory Management
OME-KGP5-01O(Jun. 2024) 4.9. Memory management 4.9.1. Memory save Since calibration and configuration data is not saved automatically, store the data in either of the following ways. A．Data storage by using ‘Memory save & res.’ menu on the LCD MENU > Maintenance > Memory save & res. (3‐3‐) The procedure is shown as followings. ① Select ‘Memory save & Res’ menu and press the right arrow key. Maintenance Calibration Simulation Test ☛Memory save &...
Page 62: Restore Set Value
OME-KGP5-01O(Jun. 2024) Save ☛Yes 4.9.2. Restore set value Select ‘Restore’ menu in the same way shown as section 4.9.1. It restores current set‐values with the saved data. ※You’ll lose the contents of the temporary change before saving. 4.9.3. Restore factory default Select ‘Factory default’ menu in the same way shown as section 4.9.1. It resets to the factory settings. 4.10. Information 4.10.1. Display of status The operator can confirm the current status of the positioner. MENU > Information > Monitor >Status (1‐1‐1) ︓Existence of alarm Status Status No alarm ︓Access authority ...
Page 63: Display Of Inner Information
OME-KGP5-01O(Jun. 2024) The operator can confirm the values of the current pressure． MENU > Information > Monitor > Pressure (1‐1‐3) Pressure Supply ︓Supply pressure Supply 400kPa ︓Output pressure 1 Pout1 Pout1 300kPa ︓Output pressure 2 Pout2 Pout2 300kPa The operator can confirm the value of the current temperature inside the positioner. MENU > Information > Monitor > Temperature (1‐1‐4) Temperature 4.10.3. Display of inner information The operator can confirm the information as below. Serial number ※   Each version ( Positioner, electric board, software) HART version ※ ...
Page 64: Confirmation Before Operation
OME-KGP5-01O(Jun. 2024) 4.11. Confirmation before operation Caution  For normal operation, apply 3.8mA DC or higher. Also, do not apply more than 24mA DC.  Immediately after turning on the power, the response may slow down, so apply 3.8mA DC or more after turning on the power. Before operating, checking the specification on clause 1.4 on this documents and performing the following operation check.  Make sure a 4‐20mA DC is applied to the input signal.  Make sure that the air piping is supplied with the proper supply air pressure and that there are no air leaks.  Make sure that the feedback lever and pin are not damaged or broken.  Check the operation with the input signal that meets your needs in advance. ~ The Most Cost Effective, Creative Valve Solutions ~ page. 64 ...
Page 65: Maintenance
OME-KGP5-01O(Jun. 2024) 5. MAINTENANCE Warning  If the exhaust port becomes clogged with contaminants, high pressure will be applied to the front cover. It could blow off the cover when trying to remove it, and cause hazards. Before removing it, confirm that the exhaust port of the housing is surely opened. ...
Page 66: Torque Motor Adjustment
OME-KGP5-01O(Jun. 2024) 5.1.2. Torque motor adjustment Adjust the gap of nozzle flapper parts, namely, nozzle and nozzle pad. The procedure is shown as below. ① Set ‘Input/posi etc’ from ‘Monitor’ menu, then, the following screen will be shown. MENU >Information >Monitor >Input/posi etc (1‐1‐2) Signal 8.0mA Set point 25.0% Valve pos. 25.0% IP signal 43.0% ② Input the signal corresponding to the 50% travel position. Signal 12.0mA Set point 50.0% Valve pos. 50.0% IP signal 45.0% ③ While turning the nozzle of the torque motor clockwise or counterclockwise, adjust the value of ‘IP signal’ to 50±2%. Then, the procedure is now complete. ...
Page 67: Action Switching Of Pilot Relay
OME-KGP5-01O(Jun. 2024) 5.1.3. 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. Figure 5.1.3．Action switching of pilot relay Switching to single action mode; Turn the switch screw clockwise until it reaches its end position. Switching to double action mode; Turn the switch screw counterclockwise until it hits the fall prevention screw. Since a balance pressure becomes supply pressure at this time, subsequently, the operate need s to perform 「Adjustment of balance pressure」 operation described in next section. 5.1.4.
Page 68: Calibration
OME-KGP5-01O(Jun. 2024) 5.2. Calibration Since the operation described in this section is preset from 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. 5.2.1. Storage of calibration data Caution Since calibration data is not stored automatically, perform ‘memory save’ operation as following the procedure described in section 4.9. ...
Page 69: Cross Point Calibration
OME-KGP5-01O(Jun. 2024) 5.2.3. Cross point calibration Note It is possible for the precision not to be get enough even if the cross point calibration was performed because the degree of the precision varies with the potentiometer attached to the positioner. In that case, perform the cross point adjustment described in section 5.5.3. Calibrate the position which of the feedback lever becomes in the horizontal position. 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 70: Position Transmitter Calibration
OME-KGP5-01O(Jun. 2024) 5.2.4. Position transmitter calibration Calibrate the position transmitter signal which the positioner may send． ※Model KGP5003 only MENU > Maintenance > Calibration > Position transmit cal. (3‐1‐3) The procedure to calibrate individually the position transmitter signal of each position in 0% and 100% is shown below. 0% output calibration; Please adjust ① If the screen is displayed as shown left, adjust the shown the output signal value until the output signal becomes the value 0% -> xxxx correspondent to 0% while pressing the up or down arrow key. ⇩ ...
Page 71: Pressure Sensor Calibration
OME-KGP5-01O(Jun. 2024) 5.2.5. Pressure sensor calibration Calibrate three pressure sensors attached 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 (1st‐P) and the second order pressure (2nd‐P) for each sensors. MENU > Maintenance > Calibration > Pressure sensor (3‐1‐4) The procedure to calibrate the supply pressure sensor is showed as below. ① If the screen is displayed as shown left, select ‘Supply’ Press. sensor cal from ‘Press. sensor cal’ menu. ☛Supply Pout1 Pout2 ⇩ The first pressure calibration; Please set the ② If the screen is displayed as shown left, adjust the Sup-pressure to 1st-P value until AAA goes to the supplied pressure while 1st-P= AAAkPa ->xxx pressing the up ...
Page 72 OME-KGP5-01O(Jun. 2024) The procedure to calibrate the sensor for output pressure 1 is showed as below. ① If the screen is displayed as shown left, select ‘Pout 1’ Press. sensor cal from ‘Press. sensor cal’ menu. Supply ☛ Pout1 Pout2 ⇩ The first pressure calibration; ② If the screen is displayed as shown left, adjust the Please set the value until AAA goes to the supplied pressure while Po1-pressure to 1st-P pressing the up or down arrow key. 1st-P= AAAkPa ->xxx Generally, AAA is the atmosphere pressure. ※’xxxx’ represents an AD (converted digital) value ...
Page 73: Potentiometer Calibration
OME-KGP5-01O(Jun. 2024) 【Supplementary explanation on the pressure sensor calibration】 It is necessary to set individually the first pressure and second pressure while calibrating the pressure sensor. When knowing the correct value of supply pressure, the operator can perform the operation by following the procedure as below which is the relatively simple process without pressure measuring device. Calibration of the supply pressure sensor; Set the first pressure to zero after blocking the supply pressure to the positioner. When setting the second pressure to the supply pressure, provide the supply pressure to the positioner. ...
Page 74: Simulation Test
OME-KGP5-01O(Jun. 2024) 5.3. 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. It is possible to generate input signal, IP signal current and position transmitter output in similar manner with the desired control. And it is also possible to check simply the response by generating ramp and step input in a similar way. 5.3.1. Input signal simulation It is possible to move the control valve by providing the input signal which is similar to the desired signal. There are two modes in the simulation; manual mode or preset mode. The manual mode makes the positioner to detect continuously all the values among the process that the current value goes to the displayed ...
Page 75: Ip Signal Simulation
OME-KGP5-01O(Jun. 2024) ② If the screen is displayed as shown left, adjust the value until it becomes desired value by pressing the up or down arrow key. . ③ Press the right arrow key to move a control valve. 5.3.2. IP signal simulation It is possible to move the control valve by providing the IP signal directly to the torque motor unit. MENU > Maintenance > Simulation test > IP signal (3‐2‐3) The procedure is shown as below. ① Select whether or not to adjust temperature. In general, confirm the displayed indication as it is． IP signal Temp adju. = Yes ② Input an arbitrary IP signal. The present temperature value used for temperature correction is indicated at the same time. IP signal = 0.0% ->...
Page 76: Simulation Of Position Transmitter Signal
OME-KGP5-01O(Jun. 2024) 5.3.3. Simulation of position transmitter signal It is possible to generate position transmitter signal which is similar to the desired signal. ※Model KGP5003 only MENU > Maintenance > Simulation test > Position transmit (3‐2‐4) Position transmit. = 50.0％ ※The operator can change the value in 0.1% interval while pressing the left or right arrow key. ※The value will be changed as below. 0%→ set value → 100% → burn out Hi → burn out Lo → 0% ...
Page 77: Step Response Simulation
OME-KGP5-01O(Jun. 2024) ③ Set the ramp time . ④ Set the wait time. ⑤ Select the motion type (number of repetitions). ⑥ Confirm the execution. ⑦ If you confirm ‘Yes’, the test will start. If pressing the left arrow key, the test will be forcibly terminated. ...
Page 78 OME-KGP5-01O(Jun. 2024) The procedure is shown as below. ① Set ‘Step’ (the interval). ② Set ‘Start’ (position). ③ Set ‘End’ (position). ④ Set ‘Step time’ (delay time) ⑤ Set ‘Repeat’ (number of repetitions) ⑥ Confirm the execution. ~ The Most Cost Effective, Creative Valve Solutions ~ page. 78 ...
Page 79: Assembly(Unit) Cleaning ‧ Replacement
OME-KGP5-01O(Jun. 2024) 5.4. Assembly(unit) cleaning ‧ replacement Caution To use the positioner for a long time, it is necessary to clean or replace the assembly (unit) with scheduled maintenance. 5.4.1. Restriction cleaning Remove accumulated dust and so on around the restriction. If the restriction becomes clogged with dust, the flow of the back pressure which is generated in the torque motor becomes decrease so that this may result in a response delay of the pilot relay or the actuator. ...
Page 80: Nozzle Flapper Cleaning
OME-KGP5-01O(Jun. 2024) Figure 5.4.2 Wire mesh filter part 5.4.3. Nozzle flapper cleaning Remove accumulated dust and so on around the nozzle flapper. If the contaminant such as dust, etc. is accumulated around the nozzle flapper, the change in the back pressure which is generated in the torque motor becomes decrease so that this may cause an adverse effect on the operation of the positioner such as the pressure reduction of the output pressure from the ...
Page 81: Pilot Relay Restriction Cleaning
OME-KGP5-01O(Jun. 2024) 5.4.4. Pilot relay restriction cleaning Remove accumulated dust and so on around the restrictions. The pilot relay has two different restrictions. If, after torque motor adjustment has been done, the IP signal current bias setup is still not effective, then it is recommended to clean the restrictions. The diameter of the restrictions is 0.3mm or 0.34mm, so a piano wire smaller than that is suitable. Cleaning procedure) 1． Disconnect the device supply pressure. 2． Remove the front cover and the pilot relay. 3． Insert the wire into the restrictions and remove accumulated dust and so on. 4． Restore the pilot relay and the front cover. Then, cleaning will be completed. Restriction Φ0.3 Restriction Φ0.34 ...
Page 82: Service Menu
OME-KGP5-01O(Jun. 2024) 5.5. Service menu 5.5.1. Identification of inner parameters While entering the following menu as below, the operator can identify A/D converted values, value of potentiometer angle, set value of cross point, time stamp of software, current values of PID parameters. MENU > Maintenance > Service (3‐4‐) 5.5.2. 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 ...
Page 83: Factory Setup
OME-KGP5-01O(Jun. 2024) 5.5.4. Factory Setup Caution This setup is a menu for adjustments and settings made by the manufacturer. ※Normally, do not change the settings. 5.5.4.1. Summary of Factory Setup Summary of Factory Setup is indicated in Table 5.5.4.1 Table 5.5.4.1 Factory Setup Items Summary of Factory Setup This setting limits the output range of the IP signal. (※Normally, do not change the settings.) Set value; IP signal range Air‐In [%]︓Set the output range of the IP signal when the output pressure is increased. Air‐Out [%]︓Set the output range of the IP signal when the output pressure is decreased. This is the setting of the output coefficient of the IP signal. (※Normally, do not change the settings.) IP signal factor Set value; IP signal factor [‐]︓Set the output coefficient (magnification) of the IP signal. It is a manufacturer‐set switch in the positioner. (※Normally, do not change the settings.) Set value; Virtual DIP SW SW1︓Setting1~8 ...
Page 84: Alarms
OME-KGP5-01O(Jun. 2024) Factory Menu︔ MENU > Maintenance > Service > Factory Menu > (3‐4‐6) ①Select ON and press the button. ➁The Factory Setup menu appears in MENU> Maintenance． 6. ALARMS This device has a self‐diagnosis function that generates an alarm. Alarm conditions related to valve opening, deviation, temperature, and pressure can be set arbitrarily. Additionally, a status classification defined by NAMUR107 can be assigned to each alarm, and a symbol mark can be displayed on the LCD. In addition, when a severe failure of memory or sensors is detected, the IP signal is forcibly cut off and the system operates in a fail‐safe manner. Additionally, the position transmitter outputs a burnout signal. ...
Page 85: Summary Of Alarms
OME-KGP5-01O(Jun. 2024) 6.1. Summary of alarms Alarms unable to change setting; Alarms caused by a breakdown inside the positioner are shown in Table 6.1a. Table 6.1a. Alarms caused by a breakdown (unable to change setting) Contents Cause Action to take Memory failure Failure of EEPROM Replace the device or inquire to our office Potentiometer failure Failure of angle sensor After detecting these failures, the symbol marks of failure based on NAMUR107 are indicated on LCD. (Refer to right symbol mark) Alarm of is shown in Table 6.1b. input signal level Table 6.1b. Alarms caused by a breakdown (unable to change setting) Contents Description Purpose to use When the input signal of 4‐20mA drops To ...
Page 86 OME-KGP5-01O(Jun. 2024) Contents Description Purpose to use When the temperature exceeded an To detect use by the temperature upper and lower threshold, an alarm is outside the specification which leads to early degradation of parts occurred. Temperature alarm Set‐value; Low temp. threshold[ ° C, ° F ], High temp. threshold[ ° C, ° F ] ...
Page 87: Alarm Setting / Check And Clear Of Result
OME-KGP5-01O(Jun. 2024) Able to change the setting in the range of 1 to 100% Time: Determination time of the deviation occurrence Able to change the setting in the range of 1 to 999 sec ※ Set a deviation threshold over the cutoff value. Set the upper and lower threshold to give a temperature alarm. Low: As the temperature falls below a lower setting ...
Page 88 OME-KGP5-01O(Jun. 2024) ② Change the ０% side value by pressing button. threshold Position alarm 0% side= 5.0% ③ Change the 100% side value by pressing button. threshold Position alarm 0% side= 5.0% 100% side= 95.0% ...
Page 89 OME-KGP5-01O(Jun. 2024) 6.2.2. Deviation alarm Setting; MENU > Diag. & Alarms > Alarm setup (4‐4‐) ① Move by pressing button，and select Deviation alarm by button. Alarm setup Position alarm ☛Deviation alarm Temperature alarm High sup-pressure ▼ ② Change the Deviation threshold value by pressing button. Deviation alarm ...
Page 90 OME-KGP5-01O(Jun. 2024) ② Checking status of Alarm Dev and Time on the screen. Deviation alarm Deviation 0.0% Alarm Dev =50% OK Time=10s OK 6.2.3. Temperature alarm Setting; MENU > Diag. & Alarms > Alarm setup (4‐4‐) ① Move by pressing button，and select Temperature alarm by button. Alarm setup Position alarm ...
Page 91: High Sup-Pressure Alarm
OME-KGP5-01O(Jun. 2024) Check of results; MENU > Information > Alarm status (1‐2‐) ① Move by pressing button，and select “Temperature alarm” by button. Alarm status Position alarm Deviation alarm ☛Temperature alarm S-pressure alarm ▼ ② Checking status of Alarm Lo and Hi on the screen. Temperature alarm Temp. +25℃ Lo alarm -30℃...
Page 92: Low Sup-Pressure Alarm
OME-KGP5-01O(Jun. 2024) Check of result; MENU > Information > Alarm status (1‐2‐) ① Move by pressing button，and select “S‐pressure alarm” by button. Alarm status Position alarm Deviation alarm Temperature alarm ☛S-pressure alarm ▼ ② Checking status of Alarm Lo and Hi on the screen. S-pressure alarm Supply 400kPa Lo alarm Unused ...
Page 93 OME-KGP5-01O(Jun. 2024) Check of result; MENU > Information > Alarm status (1‐2‐) ① Move by pressing button，and select “S‐pressure alarm” by button. Alarm status Position alarm Deviation alarm Temperature alarm ☛S-pressure alarm ▼ ② Checking status of Alarm Lo and Hi on the screen. S-pressure alarm Supply 280kPa Lo alarm ...
Page 94: Pressure Failure Alarm
OME-KGP5-01O(Jun. 2024) 6.2.6. Pressure failure alarm Setting; MENU > Diag. & Alarms > Alarm setup (4‐4‐) ① Move by pressing button，and select Pressure failure by button. Alarm setup High sup-pressure Low sup-pressure ☛Pressure failure All alarm clear ▼ ② Move by pressing button，and select Enable by button. Pressure failure ...
Page 95: Alarm Clear
OME-KGP5-01O(Jun. 2024) 6.2.7. Alarm clear Setting︔ MENU > Diag. & Alarms > Alarm setup (4‐4‐) ① Move by pressing button，and select “All alarm clear” by button. ➁ Checking status of Alarm status and backup on the screen. ③ After pressing Ent button, “Alarm clear” is displayed. 6.3. Allocation of NAMUR indication The status category related to each alarm can be selected voluntarily. Setting; MENU > Diag. & Alarms > NAMUR status sel. (4‐5‐) Example of position alarm) ① Select the “Position alarm” and push button NAMUR status sel.
Page 96 OME-KGP5-01O(Jun. 2024) ③ If the following is indicated, it’s finished. Position alarm Complete ~ The Most Cost Effective, Creative Valve Solutions ~ page. 96 ...
Page 97: Diagnostics
OME-KGP5-01O(Jun. 2024) 7. DIAGNOSTICS This positioner is equipped with the on‐line diagnostics which acquires and estimates data during plant operation and the offline diagnostics performed in maintenance. Through appropriate diagnostic settings based on an operating condition of the installation environment and a process, it's possible to do efficient prevention and forecast preservation. 7.1. Online diagnostics 7.1.1. Summary of online diagnostics Summary and set value of online diagnostics is indicated in Table 7.1. Table 7.1 Online diagnostics Items Summary of online diagnostics When a valve travel change beyond a threshold has happened, its displacement is accumulated, ...
Page 98 OME-KGP5-01O(Jun. 2024) Items Summary of online diagnostics Abort time limit [s] : Set a time to judge movement cancellation before movement completion Start time limit [s] : Set a time to judge movement cancellation before movement start Abort pressure [kPa,bar,psi] : Set a output pressure 1(Pout1) change to judge movement cancellation ...
Page 99 OME-KGP5-01O(Jun. 2024) 7.1.2. Online diagnostics setting / Confirmation and Clear of results 7.1.2.1. Total stroke Setting; MENU > Diag & Alarms > Online diag. setup (4‐1‐) ① Input the set value. Set value can be changed using buttons. Total stroke Criteria=10% ② Select the “Continue”, and push button Total stroke Criteria=10% Log Erase ☛Continue ③ If the following is indicated, it’s finished. Total stroke Complete Check of result; MENU > Information > Diag. result (1‐5‐) ...
Page 100 OME-KGP5-01O(Jun. 2024) Clear of result; MENU > Diag & Alarms > Online diag. setup > Total stroke (4‐1‐1) Example of total stroke) ① Push button and go to ②. Total stroke Criteria=10% ② Select the “Log Erase”, and push button. Total stroke Criteria=10% ☛Log Erase Continue ③ If the following is indicated, it’s finished. Total stroke Complete ~ The Most Cost Effective, Creative Valve Solutions ~ ...
Page 101 OME-KGP5-01O(Jun. 2024) 7.1.2.2. Total direction change Setting; MENU > Diag & Alarms > Online diag. setup (4‐1‐) ① Input the set value. Set value can be changed using buttons. Total dir. change Criteria= 5% ② Select the “Continue”, and push button Total dir. change Criteria= 5% Log Erase ☛Continue ③ If the following is indicated, it’s finished. Total dir. change Complete Check of result; MENU > Information > Diag. result (1‐5‐) ...
Page 102 OME-KGP5-01O(Jun. 2024) Clear of result; MENU > Diag & Alarms > Online diag. setup > Total dir. change (4‐1‐2) ① Push button and go to ②. Total dir. change Criteria= 5% ② Select the “Log Erase”, and push button. Total dir. change Criteria= 5% ☛Log Erase Continue ③ If the following is indicated, it’s finished. Total dir. change Complete ...
Page 103 OME-KGP5-01O(Jun. 2024) 7.1.2.3. Low position time Setting; MENU > Diag & Alarms > Online diag. setup (4‐1‐) ① Input the set value. Set value can be changed using buttons. Low position time Criteria=5.0% ② Select the “Continue”, and push button Low position time Criteria=5.0% Log Erase ☛ Continue ③ If the following is indicated, it’s finished. Low position time Complete Check of result; MENU > Information > Diag. result (1‐5‐) ...
Page 104 OME-KGP5-01O(Jun. 2024) Clear of result; MENU > Diag & Alarms > Online diag. setup > Low position time (4‐1‐3) ① Push button and go to ②. Low position time Complete ② Select the “Log Erase”, and push button. Low position time Criteria=5.0% ☛Log Erase Continue ③ If the following is indicated, it’s finished. Low position time Complete ~ The Most Cost Effective, Creative Valve Solutions ~ ...
Page 105 OME-KGP5-01O(Jun. 2024) 7.1.2.4. Maximum temperature time Setting; MENU > Diag & Alarms > Online diag. setup (4‐1‐) ① Input the set value. Set value can be changed using buttons. Max. temp. time Criteria=+50℃ ② Select the “Continue”, and push button Max. temp. time Criteria=+50℃ Log Erase ☛Continue ③ If the following is indicated, it’s finished. Max. temp. time Complete Check of result; MENU > Information > Diag. result (1‐5‐) ...
Page 106 OME-KGP5-01O(Jun. 2024) Clear of result; MENU > Diag & Alarms > Online diag. setup > Max temp time (4‐1‐3) ① Push button and go to ②. Max. temp. time Criteria=+50℃ ② Select the “Log Erase”, and push button. Max. temp. time Criteria=+50℃ ☛Log Erase Continue ③ If the following is indicated, it’s finished. Max. temp. time Complete ~ The Most Cost Effective, Creative Valve Solutions ~ ...
Page 107 OME-KGP5-01O(Jun. 2024) 7.1.2.5. Minimum temperature time Setting; MENU > Diag & Alarms > Online diag. setup (4‐1‐) ① Input the set value. Set value can be changed using buttons. Min. temp. time Criteria=+0℃ ② Select the “Continue”, and push button M1n. temp. time Criteria=+0℃ Log Erase ☛Continue ③ If the following is indicated, it’s finished. Min. temp. time Complete Check of result; MENU > Information > Diag. result (1‐5‐) ...
Page 108 OME-KGP5-01O(Jun. 2024) Clear of result; MENU > Diag & Alarms > Online diag. setup > Min temp time (4‐1‐3) ① Push button and go to ②. M1n. temp. time Criteria=+0℃ ☛Log Erase Continue ② Select the “Log Erase”, and push button. Min.temp.time ➔ criteria +0℃ Min. +16℃ ③ If the following is indicated, it’s finished. Min. temp. time Complete ...
Page 109: Partial Stroke Test
OME-KGP5-01O(Jun. 2024) 7.1.2.6. Partial stroke test Setting; MENU > Diag & Alarms > Online diag. setup (4‐1‐) ① Select the “Enable/Disable”, and push button. Partial stroke T. ☛Enable/Disable Stroke size Completion stroke Start stroke ▼ ② Select the “Enable”, and push button. PST online enable Disable ...
Page 110 OME-KGP5-01O(Jun. 2024) Check of result; MENU > Information > Diag. result (1‐5‐) ① Select the “Partial stroke T.”, and push button Diag. result Pneumatic span Pneumatic drift S-valve signature ☛Partial stroke T. ▼ ② The following screen will be displayed, showing Enable and the number of days remaining .. PST setup info. Enable Remaining days ③ Push button, then go back to screen shown in ①. ...
Page 111: Clear Of Diagnosis Logs
OME-KGP5-01O(Jun. 2024) 7.1.3. Clear of diagnosis logs Clear of diagnosis logs; MENU > Diag & Alarms > Online diag. setup > Diag. log clear (4‐1‐7) ① Select ‘Yes’ confirmation and press the right arrow key. ② If the following is indicated, it’s finished. ~ The Most Cost Effective, Creative Valve Solutions ~ page. 111 ...
Page 112: Offline Diagnostics
OME-KGP5-01O(Jun. 2024) 7.2. Offline diagnostics 7.2.1. Summary of offline diagnostics Summary and set value of online diagnostics is indicated in Table 7.2. Table 7.2. Offline diagnostics Items Summary of offline diagnostics The 25% step response is executed, and the maximum overshoot (O.S.) and the final deviation (Dev.) are recorded. The degradation over time in step response can be checked by comparing initial values, previous values and present values. 25% step response Set value; Step time [s]: Set a waiting time per 1 step. Initial value: 60s Output pressure in the minimum value (IPmin) and the maxmummaximum value (IPmax) of the IP signal current used for control is measured, and it’s checked whether the enough air pressure span is obtained or not. ...
Page 113 OME-KGP5-01O(Jun. 2024) 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. Pneumatic circuit drift Set value; Ramp time [s]: Set a time to fully stroke by ramp input. Initial value: 30s Tolerance [%]: Set a tolerance of drifts of IP current. Initial value: 15% Output pressure at 25%, 50% and 75% ...
Page 114: 25％ Step Response
OME-KGP5-01O(Jun. 2024) 7.2.2. 25％ step response Setting; MENU > Diag & Alarms > Offline diag. set. > 25% step response (4‐2‐1) ① Select the “25% step response”, and push button. Offline diag.set. ☛ 25% step response Pneumatic span Pneumatic drift S-valve signature ▼ ② Input the set value. Set value can be changed using buttons. 25%step response Step time= 60sec ③ If the following is indicated, it’s finished. 25%step response Complete ...
Page 115: Pneumatic Circuit Span
OME-KGP5-01O(Jun. 2024) ④ After the test, the latest result is shown to the screen like below. < N ow > O .S . De v. 461 0. 0% 0-2 5 1. 0% 0. 1% 25- 50 1. 2% 0. 3% 50- 75 0. 8% 0. 4% 75- 10 0 0. 2% 0.
Page 116 OME-KGP5-01O(Jun. 2024) ④ If the following is indicated, it’s finished. Pneumatic span Complete Execution; MENU > Diag & Alarms > Offline diag. test > Pneumatic span (4‐3‐2) ① Select the “Pneumatic span”, and push button. Offline diag.test 25% step response ☛Pneumatic span Pneumatic drift S-valve signature ▼ ② Select the “Run”, and push button. Pneu. Span(kPa) ☛Run Exit ③ After the following is indicated, tests will be started. Pneu.
Page 117: Pneumatic Circuit Drift
OME-KGP5-01O(Jun. 2024) 7.2.4. Pneumatic circuit drift Setting; MENU > Diag & Alarms > Offline diag. set. > Pneumatic drift (4‐2‐3) ① Select the “Pneumatic drift”, and push button. Offline diag.set. 25% step response Pneumatic span ☛ Pneumatic drift S-valve signature ▼ ② Input the set value (Ramp time), and push button. Set value can be changed using ...
Page 118: Simple Valve Signature
OME-KGP5-01O(Jun. 2024) ③ After the following is indicated, tests will be started. ④ After the test, the latest result is shown to the screen like below. ⑤ By pushing button, result is indicated by scrolling ⑥ By pushing button, the previous value (<Prev.>) and the initial value (<Init.>) can be shown. 7.2.5. Simple valve signature Setting; MENU > Diag & Alarms > Offline diag. set. > S‐valve signature (4‐2‐4) ① Select the “S‐valve signature”, and push button. ② Select the “Ramp time”, and push button. ③ Input the set value, and push ...
Page 119 OME-KGP5-01O(Jun. 2024) ⑤ About the “Hysteresis limit”, “Gradient limit H”, “Gradient limit L”, by a procedure of ➀,➁,③, it’s also set. Execution; MENU > Diag & Alarms > Offline diag. test > S‐valve signature (4‐3‐4) ① Select the “S‐valve signature”, and push button. Offline diag.test 25% step response Pneumatic span Pneumatic drift ☛S-valve signature ▼...
Page 120: Check And Save Of Online Diagnostics Results
OME-KGP5-01O(Jun. 2024) 7.2.6. Check and Save of online diagnostics results In this section, confirmation and save of diagnostics results are explained. It’ll be the same operation with each diagnostics. Therefore, for instance, the 25% step response is explained here. Check of result; MENU > Diag & Alarms > Diag.test data > Step res. result (4‐6‐1) A list of result is indicated. < N ow > O .S . De v. 461 0. 0% 0-2 5 1. 0% 0. 1% 25- 50 1. 2% 0. 3% 50- 75 0. 8% 0.
Page 121: Hart Communication
OME-KGP5-01O(Jun. 2024) 8. HART COMMUNICATION ※Model KGP5003 only 8.1. Preparation for HART communication According to explanation in section 2.6, connect the IN+ and IN‐ of this device to a communication tool like HART communicator or a terminal of host controller. 8.2. Operation using HART communication This device can do the work of setting and adjustment by a communication tool of a HART communicator. 8.3. Confirmation of device By using the following commands, this device can be checked from a HART communication tool. Find Device; Setting of whether this device replies or not to the Find Device command sent from a HART communication tool is done. MENU > Maintenance > HART relation > Find device (3‐5‐1) ...
Page 122: Troubleshooting
OME-KGP5-01O(Jun. 2024) 9. TROUBLESHOOTING When problems occurred at the operation starting or during operation, please refer to the following table and take an action appropriately. Table 9.1 Trouble shooting Phenomenon Assumed cause Action  Check input current Loss of electrical power, disconnection or miswiring  Check wiring  Check supply pressure Drop of supply pressure or loss  Check air regulator  Leak from air piping Check piping Actuator abnormality  Set handle to auto mode Does not move / Handle is in manual mode Actuator abnormality  Replace packing / Packing sticking or wear out Move too slow  Lack of actuator output Replace actuator  Forced shut down by positioner alarm Check alarm status ...
Page 123: Parts
OME-KGP5-01O(Jun. 2024) 10. PARTS 10.1. Assembly and parts list Fig. 10.1. KGP5000 assembly and parts No. ~ The Most Cost Effective, Creative Valve Solutions ~ page. 123 ...
Page 124 OME-KGP5-01O(Jun. 2024) Table 10.1 Parts and units list Parts Title Qty. Notes No. 1 Front cover assembly 1 2 Pilot relay assembly 1 3 Cross recessed head screws with captive washer 4 M4‐L12 4 O‐rings (for pilot relay) 4,2 S‐3, S‐12.5 5 A/M unit assembly 1 6 Cross recessed head screws with captive washer 2 M4‐L12 7 O‐rings (for A/M unit) 2,1 S‐3, S‐5 8 Filter mesh 1 ...
Page 125: Check Cycle And Replacement Cycle
OME-KGP5-01O(Jun. 2024) 10.2. Check cycle and Replacement cycle Check points, recommended check cycle and recommended replacement cycle of the life‐limited parts/units are shown in table 10.2. Please do periodic maintenance or replacement work according to the environment that it's installed and the operating condition. Table 10.2.Life‐limited parts/unit Recommended Recommended Unit / Parts Check points check cycle replacement cycle (year) ...
Page 126: Dimensions
OME-KGP5-01O(Jun. 2024) 11. DIMENSIONS Fig. 11a Linear motion standard type ~ The Most Cost Effective, Creative Valve Solutions ~ page. 126 ...
Page 127 OME-KGP5-01O(Jun. 2024) Fig. 11b Linear motion long stroke type ~ The Most Cost Effective, Creative Valve Solutions ~ page. 127 ...
Page 128 OME-KGP5-01O(Jun. 2024) Fig. 11c Rotary motion type ~ The Most Cost Effective, Creative Valve Solutions ~ page. 128 ...
Page 129 OME-KGP5-01O(Jun. 2024) Fig. 11d Rotary motion VDI/VDE3845 type ~ The Most Cost Effective, Creative Valve Solutions ~ page. 129 ...
Page 130: A) Appendix / Model Selection And Code Number
OME-KGP5-01O(Jun. 2024) A) APPENDIX / MODEL Selection and CODE number ① ② ③ － ④ ⑤ ⑥ ⑦ － ⑧ Base model ① Proof type Standard connections (options) Air: Rc1/4 (1/4NPT) *Note1 Dust ・ water proof Electric: G1/2 (1/2NPT, M20) Air: Rc1/4 TIIS *Note2 Flameproof Electric: G1/2 Air: 1/4NPT Flameproof (NEPSI)
Page 131 OME-KGP5-01O(Jun. 2024) ① ② ③ － ④ ⑤ ⑥ ⑦ － ⑧ Base model ⑤ Pressure gauge block type Without gauge block With gauge block ⑥ Pressure gauge range 200kPa / (0.2MPa) / (30psi/2bar) / (200kPa/ 2kgf ／ cm2) / (2bar/0.2MPa) 400kPa / (0.4MPa) / (60psi/4bar) / (400kPa/ 4kgf ／...
Page 132: B) Appendix / Technical Support Checklist
OME-KGP5-01O(Jun. 2024) B) APPENDIX / Technical Support Checklist KGP5000 Technical Support C hecklist Please have the following information ready before contacting our sales office. 1. Serial number on the plate of KGP5000 2. Construction number stated in the delivery specifications 3. KGP5000 software version 4. Please let us know the current parameters below. Input signal ㎃ Pressure-sup. ...
Page 133 OME-KGP5-01O(Jun. 2024) ■WORLD‐WIDE NETWORK (Sales, Manufacturing, Services) Sales, Manufacturing, Services TEL FAX Nihon Koso Co., Ltd., Tokyo Japan Tel. (81) 3‐5202‐4300 Fax. (81) 3‐5202‐4301 Paris Office Tel. (33) 1‐73‐75‐23‐1 Fax. (33) 1‐73‐75‐23‐1 Moscow Office Tel. (7) 495‐775‐8531 Fax. (7) 495‐787‐2758 Abu Dhabi Branch Tel. (971) 2‐639‐06‐55 Fax. (971) 2‐639‐08‐89 Koso M‐Mac International Inc., CA, U.S.A. Tel. (1) 661‐942‐4499 Fax. (1) 661‐942‐0999 Koso America Inc. Boston, U.S.A Tel. (1) 774‐517‐5300 Fax. (1) 774‐517‐5230 Rexa Inc. Boston, U.S.A Tel. (1) 508‐584‐1199 Fax. (1) 508‐584‐2525 Pacific Seismic Products.Inc., CA, U.S.A. Tel. (1) 661‐942‐4499 Fax (1) 661‐942‐0999 Koso Kent Introl. Ltd., U.K. Tel. (44) 0‐1484‐710311 Fax. (44) 0‐1484‐407407 Koso Control Engineering (Wuxi) Co., Ltd., China Tel. (86) 510‐85101567 Fax. (86) 510‐85122498 Wuxi Koso Fluid Control Co., Ltd., China Tel. (86) 510‐85585118 Fax. (86) 510‐85585119 ...

This manual is also suitable for:

Kgp5000Kgp5003

Koso KGP5000 Series Instruction Manual

Quick Links

Need help?

Questions and answers

Related Manuals for Koso KGP5000 Series

Summary of Contents for Koso KGP5000 Series

This manual is also suitable for:

Table of Contents