Koso KGP5000 Series Operation Manual
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Koso KGP5000 Series Operation Manual

Koso KGP5000 Series Operation Manual

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ME-KGP5HG-01C (September 2022)
KGP5000 series
Smart valve positioner
HART Communication
Operation Manual
For GUI type
~ The Most Cost Effective, Creative Valve Solutions ~

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  • Page 1 ME-KGP5HG-01C (September 2022) KGP5000 series Smart valve positioner HART Communication Operation Manual For GUI type ~ The Most Cost Effective, Creative Valve Solutions ~...

  • Page 2: Table Of Contents

    ME-KGP5HG-01C (September 2022) Table of Contents Introduction ......................... 4 1.1. Scope of this operation manual ....................4 1.2. Safety notices ..........................5 1.3. Product summary ......................... 5 1.4. Electrical connections ........................6 1.5. Preparation for HART communication ..................9 Menu tree on the HART communication ................10 2.1.
  • Page 3 ME-KGP5HG-01C (September 2022) 5.3.1. Summary of offline diagnosis ..................... 88 5.3.2. 25％ step response test ..................... 88 5.3.3. Pneumatic circuit span ......................89 5.3.4. Pneumatic circuit drift ......................90 5.3.5. Simple valve signature ......................92 5.4. Check and Save of online diagnosis results (Diag.test data) ............. 94 5.5.

  • Page 4: Introduction

    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 5: Safety Notices

    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 6: Electrical Connections

    ME-KGP5HG-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 7 ME-KGP5HG-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 8 ME-KGP5HG-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 1.4a The suitable Ex certificated cable glands and blanking elements for each proof type Proof type Thread form of Certification...

  • Page 9: Preparation For Hart Communication

    ME-KGP5HG-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 10: Menu Tree On The Hart Communication

    ME-KGP5HG-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 GUI (Graphical User Interface) type DD.
  • Page 11 ME-KGP5HG-01C (September 2022) ➁Device Root Menu Device Root Menu Alarm status <Set point> <Position> <Loop current> <Input> <P-sup.> <P-out1> <P-out2> 【Chapter / Section】 Information Monitor 【4.2.1.】 Alarm status 【4.2.2.】 Positioner info. 【4.2.3.】 Config. Parameter 【4.2.4.】 Diag. result 【4.2.5.】 Extended Menu Alarm status 【3.1.】...
  • Page 12 ME-KGP5HG-01C (September 2022) ③Diagnosis Root Menu 【Chapter / Section】 Diagnosis Root Menu Alarm status 【5.1.】 <Total Stroke> <Total Direction Change> <Total time> <Low Position Time> <Low Position Time Percentage> <Maximum Temperature> <Minmum Temperature> 【Chapter / Section】 Diagnosis Extended Menu Online diag.setup Total Stroke Setting 【5.2.】...

  • Page 13: Process Variables (Root Menu)

    ME-KGP5HG-01C (September 2022) 3. Process Variables (Root Menu) Instructions for information obtaining, setting, maintaining, alerting, and diagnosing are provided with reference to SDC625. 3.1. Alarm status The operator can confirm the alarm status as below. MENU) View > Process Variables Root Menu > Alarm status ...

  • Page 14: Trends

    ME-KGP5HG-01C (September 2022) 3.2. Trends The operator can confirm operating status of the positioner such as input signal, set point, valve position, Supply pressure, Output pressure, temperature. Display items:   Set point P-out2  Input※   Position Temperature ...

  • Page 15: Device (Root Menu)

    ME-KGP5HG-01C (September 2022) 4. Device (Root Menu) Instructions for information obtaining, setting, maintaining, alerting, and diagnosing are provided with reference to SDC625. 4.1. Alarm status The operator can confirm the alarm status as below. MENU) View > Device Root Menu > Alarm status ...

  • Page 16: Monitor

    ME-KGP5HG-01C (September 2022) 4.2.1. Monitor The operator can confirm the current status of the positioner. MENU) View > Device Root Menu > Information >Monitor Menu items: Status Pressure Input/posi etc Temperature 4.2.2. Alarm status The operator can confirm the alarm status as below. MENU) View >...
  • Page 17 ME-KGP5HG-01C (September 2022) 4.2.2.1. Position alarm The operator can confirm the Position alarm status as below. MENU) View > Device Root Menu > Information > Alarm status > Position alarm Menu items: Position : Valve position Position alarm : Position alarm Lo alarm : Lo position alarm Lo alarm threshold...
  • Page 18 ME-KGP5HG-01C (September 2022) 4.2.2.3. Temperature alarm The operator can confirm the value of the current temperature inside the positioner. MENU) View > Device Root Menu > Information > Alarm status > Temperature alarm Menu items: Temperature : Current temperature Temperature alarm : Temperature judgment [OK/NG] Temperature alarm : Enable / disable the temperature judgment setting...

  • Page 19: Positioner Info

    ME-KGP5HG-01C (September 2022) 4.2.3. Positioner info The operator can confirm the version of the positioner. MENU) View > Device Root Menu > Information > Positioner info ① Select the ' Positioner info’ and press ' Version ’ Menu items: Serial No. Universal rev(HART version) Manufacture Date ②...

  • Page 20: Config. Parameter

    ME-KGP5HG-01C (September 2022) 4.2.4. Config. parameter The operator can confirm the configuration parameter information as below． MENU) View > Device Root Menu > Information > Config. parameter ① Select the ' Config. parameter ' Menu items: Valve action Transfer Function Cutoff or Limit Packing friction Posi.
  • Page 21 ME-KGP5HG-01C (September 2022) 4.2.4.2. Actuator setup The operator can confirm the Actuator setup parameter information as below MENU) View > Device Root Menu > Information > Config. parameter > Acutuator setup Press OK to return to the information screen 4.2.4.3. PID parameter set The operator can confirm the PID parameter set information as below MENU) View >...

  • Page 22: Diag. Result

    ME-KGP5HG-01C (September 2022) 4.2.5. Diag. result The operator can confirm that the diagnostic result follows: MENU) View > Device Root Menu > Information > Diag. result Menu items: Total stroke Total time. PST setup info. Total dir. change 25%step response. Pneumatic drift Low position time Pneumatic span...
  • Page 23 ME-KGP5HG-01C (September 2022) 4.2.5.2. Pneumatic span The operator can confirm the Pneumatic span parameter information as below． MENU) View > Device Root Menu > Information > Diag. result > Pneumatic span Press OK to return to the information screen 4.2.5.3. PST setup info. The operator can confirm the PST setup info.
  • Page 24 ME-KGP5HG-01C (September 2022) 4.2.5.4. Pneumatic drift The operator can confirm the Pneumatic drift parameter information as below． MENU) View > Device Root Menu > Information > Diag. result > Pneumatic drift Press OK to return to the information screen 4.2.5.5. S-Valve signature The operator can confirm the S-Valve signature parameter information as below．...

  • Page 25: Setup

    ME-KGP5HG-01C (September 2022) 4.3. Setup 4.3.1. Setup and operation authority by HART communication To change the settings via HART communication, the "authority" must be HART. To operate auto-tuning, calibration, simulation and offline-diagnostics via HART communication, the "Control mode" must be "HART". 4.3.1.1.
  • Page 26 ME-KGP5HG-01C (September 2022) ➃ Select ‘Function select’ and press ‘Authority’. ➄ Select ‘Write’ and press ‘OK’. ⑥ Select ‘HART’ and press ‘OK’ to set. ※When ‘HART’ is selected, only ‘Information’ in the TOP menu can be accessed from the LUI. ~ The Most Cost Effective, Creative Valve Solutions ~ page.
  • Page 27 ME-KGP5HG-01C (September 2022) 4.3.1.2. Control mode permissions MENU) View > Device Root Menu > Extended menu > Setup >Function select > Authority > Control mode ➀ Select ‘Function select’ and press ‘Control mode’. ➁ Select ‘Write’ and press ‘OK’. ③ Select ‘HART’ and press ‘OK’ to set. ※When conduct operation with a 4-20mA input signal, select 4-20mA.

  • Page 28: Basic Setup

    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 29 ME-KGP5HG-01C (September 2022) For example, Actuator motion setup procedure is shown as below . MENU) View > Device Root Menu > Extended menu> setup > Actuator motion ① Select ‘Basic Setup’ ② Select ‘Actuator motion’ ➂ Select ‘Write’ and press ‘OK’ ➃...

  • Page 30: Easy Tuning

    ME-KGP5HG-01C (September 2022) 4.3.3. Easy tuning Caution  HART communication takes more time than the operation using the LUI of this unit, so make sure that the operation is completed. Easy tuning is the setup to ensure that the positioner is operated smoothly relative to the actuator on which the positioner is mounted.
  • Page 31 ME-KGP5HG-01C (September 2022) ➁ Press ‘OK’ to execute. 2) Confirm the result of the execution (full autotune) MENU) View > Device Root Menu > Extended menu> setup > Easy tuning > Full autotune ① Press ‘Tuning result’ ① Press ‘OK’ on confirmation screen. ~ The Most Cost Effective, Creative Valve Solutions ~ page.
  • Page 32 ME-KGP5HG-01C (September 2022) 4.3.3.2. 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) View > Device Root Menu > Extended menu> setup > Easy tuning > Position setup > 0% or 100%MENU > ①...
  • Page 33 ME-KGP5HG-01C (September 2022) 2) Auto span MENU) View > Device Root Menu > Extended menu> setup > Easy tuning > Position setup > Auto span ① Select ‘Easy tuning’ and then ‘Span Autotune’. ※To abort autotune, select ‘Abort Autotune’. Progress are shown as below. Autotune status: In-progress autotune status.

  • Page 34: Expert Tuning

    ME-KGP5HG-01C (September 2022) 4.3.4. Expert tuning Caution  HART communication takes more time than the operation using the LUI of this unit, so make sure that the operation is completed. Use this setting in case in which the desired response has not been achieved through easy tuning. More suitable control parameters are configured according to each actuator by tuning individually parameters necessary to control the response.
  • Page 35 ME-KGP5HG-01C (September 2022) 4.3.4.2. 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 36 ME-KGP5HG-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 4.3.4.2．Gain switching (Example of proportional gain） The procedure is shown as followings． 1) Set PID parameter set to ‘Custom’ MENU) View >...
  • Page 37 ME-KGP5HG-01C (September 2022) ➁ Select ‘Write’ and press ‘OK’ ➂ Select ‘Custom’ and press ‘OK’ to set. 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) View >...
  • Page 38 ME-KGP5HG-01C (September 2022) 2-1) Set ‘Air-Out (not)= Air-In?’. Select whether or not Air-Out (decrease in output pressure) is same with Air-In (increase in output pressure). MENU) View > Device Root Menu > Extended menu> setup > Expert tuning > PID custom setup > Air-Out (not)= Air-In? ①...
  • Page 39 ME-KGP5HG-01C (September 2022) ② Input a P value of Air-In. ③ Press ‘OK’ ④ Input a I value of Air-In. ⑤ Press ‘OK ’ ⑥ Input a D value of Air-In. ⑦ Press ‘OK’ to set. ~ The Most Cost Effective, Creative Valve Solutions ~ page.
  • Page 40 ME-KGP5HG-01C (September 2022) 2-3) Set PID parameter Air-Out. MENU) View > Device Root Menu > Extended menu> setup > Expert tuning > PID custom setup > PID parameter Air-Out ’ ① Select ‘Write’ and press ‘OK’ ② Input an rP value of Air-Out. ③Press ‘OK’...
  • Page 41 ME-KGP5HG-01C (September 2022) ⑥ Input a rD value of Air-Out. ’ ⑦ Press ‘OK’ to set. ’ alue of Air-Out. 2-4) Set inside threshold value. MENU) View > Device Root Menu > Extended menu> setup > Expert tuning > PID custom setup > Inside threshold ①...
  • Page 42 ME-KGP5HG-01C (September 2022) 2-5) Set inside PID Air-In. MENU) View > Device Root Menu > Extended 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 43 ME-KGP5HG-01C (September 2022) ⑥ Input a inside D value of Air-In ⑦ Press ‘OK’ to set. 2-6) Set inside PID Air-Out parameters MENU) View > Device Root Menu > Extended menu> setup > Expert tuning > PID custom setup > Inside PID AO ①...
  • Page 44 ME-KGP5HG-01C (September 2022) 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. 4.3.4.3. 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.

  • Page 45: Error Messages

    ME-KGP5HG-01C (September 2022) 4.3.5. Error messages If the problems cause during the operations such as full auto tune (Section 4.3.3.1), position setup 2) auto setup (Section 4.3.3.2), IP signal bias 1) automatic setting (Section 4.3.4.3), the following error messages will be displayed. and the performance will be stopped. Table 4.3.5 List of error messages Code Error description and solution...

  • Page 46: Detailed Setup

    ME-KGP5HG-01C (September 2022) 4.3.6. 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) View >...
  • Page 47 ME-KGP5HG-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 48: Function Select

    ME-KGP5HG-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 49: Memory Management

    ME-KGP5HG-01C (September 2022) 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. Screen saver Value/ Unused Unused It is possible to extend the life span of the LCD with a limited life by using screen saver.

  • Page 50: Maintenance

    ME-KGP5HG-01C (September 2022) 4.4. 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 51: Action Switching Of Pilot Relay

    ME-KGP5HG-01C (September 2022) 4.4.2. 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 4.4.2．Action switching of pilot relay Switching to single action mode;...

  • Page 52: Calibration

    ME-KGP5HG-01C (September 2022) 4.4.4. 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 53 ME-KGP5HG-01C (September 2022) 4.4.4.2. Cross point calibration Calibrate the position which the feedback lever is 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 54 ME-KGP5HG-01C (September 2022) 4.4.4.3. 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) View > Device Root Menu > Extended menu> Maintenance > Calibration > Position transmit cal. ①...

  • Page 55: Pressure Sensor Calibration

    ME-KGP5HG-01C (September 2022) 4.4.4.4. 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 56 ME-KGP5HG-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 57: Simulation Test

    ME-KGP5HG-01C (September 2022) 4.4.5. 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 58 ME-KGP5HG-01C (September 2022) ② Input a Moving value. (Value range: -10.0% - +10.0%) ③ Press ‘OK’ to execute. 2) Preset mode MENU) View > Device Root Menu > Extended menu> Maintenance > Simulation test > Preset input ① Select ‘Set Value’. ②...
  • Page 59 ME-KGP5HG-01C (September 2022) 4.4.5.2. Ramp response simulation It is possible to move the control valve by providing the ramp signal internally. 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 Set the one-way travel time of the ramp response Wait time...
  • Page 60 ME-KGP5HG-01C (September 2022) 2) Abort ramp resp. test.; ① Select ‘Abort Operation’. ② Select ‘OK’ on confirmation screen to abort the ramp resp test.. 4.4.5.3. Step response simulation It is possible to move the control valve by providing the step signal internally. Parameter Description Unit...
  • Page 61 ME-KGP5HG-01C (September 2022) ③ To escape from this screen, select ‘OK’ or ‘Abort’ ④ To modify the parameter, select each item. ➄ Confirm all parameters are correct. ➅ Press ‘OK’ ➆ Press ‘OK’ on confirmation screen to execution. 2) Abort step resp. test. ①...

  • Page 62: Service

    ME-KGP5HG-01C (September 2022) 4.4.6. Service 4.4.6.1. Identification of internal 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) View >...

  • Page 63: Hart Relation

    ME-KGP5HG-01C (September 2022) 4.4.7. HART relation Functions related with HART communication. 4.4.7.1. Find device By using this command, you can read device information from the armed device. ※ If no armed devices are found, communication may be disconnected. MENU) View > Device Root Menu > Extended menu> Maintenance > HART relation > Find device Commands: Find Device Device information:...
  • Page 64 ME-KGP5HG-01C (September 2022) 4.4.7.2. 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 65 ME-KGP5HG-01C (September 2022) Device information: Manufacture Long tag Dev id Message Final asmbly num Descriptor Model Date *Read only information Commands: Read Device information Write Tag Write Descriptor Write Date Write Long Tag Write Message Write Final assembly num 4.4.7.4. Reset Warning Reset causes the device shuts down for a few seconds.

  • Page 66: Alarms

    ME-KGP5HG-01C (September 2022) 4.5. 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 67 ME-KGP5HG-01C (September 2022) Alarm of is shown in Table4.5.1b. input signal level Table 4.5.1b. 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 68: Alarm Setting / Check And Clear Of Result

    ME-KGP5HG-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 69: Namur Status Select

    ME-KGP5HG-01C (September 2022) 4.5.3. 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) View > Device Root Menu > Extended menu> Diag. & Alarms > NAMUR status sel. ①...

  • Page 70: Diagnosis

    ME-KGP5HG-01C (September 2022) 4.6. 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 71 ME-KGP5HG-01C (September 2022) Items Summary of online diagnosis test its safety functions. It's possible to give a partial valve travel change and to check the defective performance of sticking of a valve periodically. Set value; Disable / Enable : Select a periodical execution or not Stroke size [%] : Set a position width to move Completion stroke [%]...
  • Page 72 ME-KGP5HG-01C (September 2022) 4.6.1.2. 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) View > Device Root Menu > Extended menu> Diag. & Alarms > Online diag. setup> Total Stroke Setting ①...
  • Page 73 ME-KGP5HG-01C (September 2022) 2) Check of results. MENU) View > Device Root Menu > Information > Diag. resutl > Total Stroke Total Stroke : Present total stroke value Criteria Set value 3) Erasing the total stroke log MENU) View > Device Root Menu > Extended menu> Diag & Alarms > Online diag. setup ①...
  • Page 74 ME-KGP5HG-01C (September 2022) 4.6.1.3. Clear of diagnosis logs The procedures for clearing diagnosis logs is as follows． MENU) View > Device Root Menu > Extended menu> Diag & Alarms > Online diag. setup > Diag. log clear Press ‘OK’ on confirmation screen to execute. ~ The Most Cost Effective, Creative Valve Solutions ~ page.

  • Page 75: Offline Diagnosis

    ME-KGP5HG-01C (September 2022) 4.6.2. Offline diagnosis 4.6.2.1. Summary of offline diagnosis Summary and set value of offline diagnosis is indicated in Table 4.6.2. Table4.6.2. 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 76 ME-KGP5HG-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 77 ME-KGP5HG-01C (September 2022) 4.6.2.2. 25％ step response test For setting and executing the 25％ step response test are as follows． 1) Setting the 25％ step response test. MENU) View > Device Root Menu > Extended menu> Diag & Alarms > Offline diag. set. > 25% step response ①...
  • Page 78 ME-KGP5HG-01C (September 2022) 4.6.2.3. Pneumatic circuit span The procedures for setting the Pneumatic circuit span test and executing are as follows． 1) Setting MENU) View > Device Root Menu > Extended menu> Diag & Alarms > Offline diag. set > Pneumatic span ①...
  • Page 79 ME-KGP5HG-01C (September 2022) ➄ Select ‘Criteria’ ⑥ Input a criteria value. ⑦ Press ‘OK’ 2) Execution MENU) View > Device Root Menu > Extended menu> Diag. & Alarms > Offline diag. test > Pneumatic span ① Press ‘OK’ on confirmation screen.to execute. 4.6.2.4.
  • Page 80 ME-KGP5HG-01C (September 2022) ➁ Select ‘Write’ and press ‘OK’ ③ Select ‘Ramp time’ ➃ Input a ramp time value. ➄ Select ‘Tolerance’ ➅ Input a tolerance value. ➆ Press ‘OK’ to set. 2) Execution MENU) View > Device Root Menu > Extended menu> Diag. & Alarms > Offline diag. test > Pneumatic drift ①...
  • Page 81 ME-KGP5HG-01C (September 2022) 4.6.2.5. Simple valve signature 1) Setting MENU) View > Device Root Menu > Extended menu> Diag. & Alarms > Offline diag. set. > S-valve signature ① Select ‘S-valve signature’ ➁ Select ‘Write’ and press ‘OK’ ➂ Select ‘Ramp time’ ➃...
  • Page 82 ME-KGP5HG-01C (September 2022) ➄ Select ‘Hysteresis limit’ Hysteresis limit(kPa)： Sets the pressure hysteresis tolerance. For details, ⑥ Input a hysteresis limit value. see Table 4.6.2. Offline diagnosis. ⑦ Select ‘Gradient limit H’ Gradient limit H(kPa)： Sets the upper limit of the pressure gradient ➇...

  • Page 83: Check And Save Of Online Diagnosis Results (Diag.test Data)

    ME-KGP5HG-01C (September 2022) 4.6.3. 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 84 ME-KGP5HG-01C (September 2022) 2) Save of result You can save a result data as a previous data or an initial data from following menu. MENU) View > Device Root Menu > Extended menu> Diag. & Alarms > Diag.test data > Step res. save ①...

  • Page 85: Diagnosis Root Menu

    ME-KGP5HG-01C (September 2022) 5. Diagnosis Root Menu The operation procedure of the alarm / diagnosis function is explained on the screen of SDC625. For an overview of online diagnosis, refer to 4.6.1.1 of this instruction manual. 5.1. Alarm status The operator can confirm the alarm status as below. ...
  • Page 86 ME-KGP5HG-01C (September 2022) ➂ Select the 'Total Stroke Setting' ➃ Select ‘Write’ and press ‘OK’ ➄ Select ‘Criteria' ⑥ Input a criteria value. (Value range: 1% - 50%) ⑦ Press ‘OK’ to set. ~ The Most Cost Effective, Creative Valve Solutions ~ page.
  • Page 87 ME-KGP5HG-01C (September 2022) 2) Check of results. MENU) View > Device Root Menu > Information>Diag. result>Total Stroke Total Stroke : Present total stroke value Criteria : Set value 3) Erasing the total stroke log MENU) View > Diagnosis Root Menu > Diagnosis Extended Menu >Online Diag. setup >Total Stroke Setting ①...

  • Page 88: Clear Of Diagnosis Logs

    ME-KGP5HG-01C (September 2022) 5.2.1. Clear of diagnosis logs The procedures for clearing diagnosis logs is as follows． MENU) View > Device Root Menu > Extended Menu > Diag. & Alarms > Online Diag. setup > Diag. log clear Select ‘OK’ on confirmation screen. 5.3.

  • Page 89: Pneumatic Circuit Span

    ME-KGP5HG-01C (September 2022) ➂ Input a step time value. ➃ Press ‘OK’ to set. 2) Executing the 25％ step response test. MENU) View > Diagnosis Root Menu > Diagnosis Extended Menu > Offline diag. test >25 step response Press ‘OK’ on confirmation screen to execute.. 5.3.3.

  • Page 90: Pneumatic Circuit Drift

    ME-KGP5HG-01C (September 2022) ② Select ‘Step time’ ③ Input a step time value. ➃ Select ‘Criteria’ ⑤ Input a criteria value. ⑥ Select ‘OK to set. 2) Execution MENU) View > Diagnosis Root Menu > Diagnosis Extended Menu > Offline diag. test > Pneumatic span Select ‘OK’...
  • Page 91 ME-KGP5HG-01C (September 2022) ➁ Select ‘Write’ and press ‘OK’ ➂ Select ‘Ramp time’ ➃ Input a ramp time value ➄ Select ‘Tolerance’ ⑥ Input a tolerance value. ⑦ Press ‘OK’ to set. 2) Execution; MENU) View > Diagnosis Root Menu > Diagnosis Extended Menu > Offline diag. test > Pneumatic drift Select ‘OK’...

  • Page 92: Simple Valve Signature

    ME-KGP5HG-01C (September 2022) 5.3.5. Simple valve signature 1) Setting MENU) View > Diagnosis Root Menu > Diagnosis Extended Menu > Offline diag. set > S-valve signature ① Select ‘S-valve signature’ ➁ Select ‘Write’ and ‘OK’ ➂ Select ‘Ramp time’ ➃ Input a ramp time value. ~ The Most Cost Effective, Creative Valve Solutions ~ page.
  • Page 93 ME-KGP5HG-01C (September 2022) ➄ Select ‘Hysteresis limit’ Hysteresis limit(kPa)： ⑥ Input a hysteresis limit value. Sets the pressure hysteresis tolerance. For details, see Table 4.6.2. Offline diagnosis. ⑦ Select ‘Gradient limit H’ Gradient limit H(kPa)： Sets the upper limit of the pressure gradient ➇...

  • Page 94: Check And Save Of Online Diagnosis Results (Diag.test Data)

    ME-KGP5HG-01C (September 2022) 5.4. 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 95: Advanced Diagnostics

    ME-KGP5HG-01C (September 2022) 5.5. Advanced Diagnostics 5.5.1. Valve signature The Valve signature shows the relationship between the operating pressure and the valve position when the valve is moved. And it shows the characteristics of a valve and an actuator. From the data, various events occurring in the valve, such as irregular frictional force, can be found. MENU) View >...

  • Page 96: Alarm Setup

    ME-KGP5HG-01C (September 2022) 5.6. Alarm setup For an overview of alarms, refer to 6.4.1of this instruction manual. 5.6.1. Alarm setting / Check and Clear of result It’s possible to operate setting, check of a result and clear of result of each alarm from following menu. 1) Setting MENU) View >...

  • Page 97: Namur Status Select

    ME-KGP5HG-01C (September 2022) 5.7. 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) View > Diagnosis Root Menu > Diagnosis Extended Menu > NAMUR status sel. ①...

  • Page 98: Troubleshooting

    ME-KGP5HG-01C (September 2022) 6. Troubleshooting When problems occurred at the operation starting or during operation, please refer to the following table and take an action appropriately. Table 6 Trouble shooting Phenomenon Assumed cause Action  Check input current Loss of electrical power, disconnection or miswiring ...

  • Page 99: Menu Item

    ME-KGP5HG-01C (September 2022) 7. Menu item reference 1st hierarchy 2nd hierarchy 3rd hierarchy 4th hierarchy 5th hierarchy 6th hierarchy （chapter） Process Variables Alarm status Root Menu <Set point> <Position> <Loop current> 3.1. <Input> <P-sup.> <P-out1> <P-out2> <Temperature> Trends 3.2. reference 1st hierarchy 2nd hierarchy 3rd hierarchy...
  • Page 100 ME-KGP5HG-01C (September 2022) Extended Menu Alarm status <Set point> <Position> <Loop current> <Input> <P-sup.> <P-out1> <P-out2> Setup Basic setup Actuator motion Linear Rotary Actuator type Single Double 5300 Valve action 4.3.2. Packing friction High Booster option Set point dir. Normal Reverse Position transmit.
  • Page 101 ME-KGP5HG-01C (September 2022) Extended Menu Setup Function select Password setup Disable/Enable Screen saver Disable/Enable Temperature unit Celsius 4.3.7. Fahrenheit Pressure unit Maintenance Calibration Input signal cal. 4.4.4.1. Cross point cal. 4.4.4.2. Position transmit 4.4.4.3. Pressure sensor Sup.press. Out1 press. 4.4.4.4. Out2 press.
  • Page 102 ME-KGP5HG-01C (September 2022) Extended Menu Diag. & Alarms Alarm setup Position alarm Deviation alarm Temperature alarm 4.5.2. High sup-pres. AL Low sup-pres. AL Pressure failure Error/Alarm clear NAMUR status sel. Position alarm NAMUR status Deviation alarm NAMUR status Temperature alarm NAMUR status 4.5.3.
  • Page 103 ME-KGP5HG-01C (September 2022) Diagnosis Extended Menu NAMUR status sel. Position alarm NAMUR status Deviation alarm NAMUR status Temperature alarm NAMUR status 5.7. High sup-pressure NAMUR status Low sup-pressure NAMUR status Diag.test data 25% Step response Step res. save Pneumatic span Pneu.

  • Page 104: A) Appendix / Flow Chart Of Settings Procedure

    ME-KGP5HG-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 105 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.

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