Koso KGP2000 Series Instruction Manual
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Koso KGP2000 Series Instruction Manual

Koso KGP2000 Series Instruction Manual

Smart valve positioner
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KGP2000
series
Smart valve positioner
Model KGP2000 / 2003
Instruction Manual
~ The Most Cost Effective, Creative Valve Solutions ~
五校 11/9
ｘ
OME-KGP2-01C(Dec. 2024)

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  • Page 1 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ KGP2000 series Smart valve positioner Model KGP2000 / 2003 Instruction Manual ~ The Most Cost Effective, Creative Valve Solutions ~...

  • Page 2: Table Of Contents

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Table of Contents Table of Contents ........................... 2 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 ......................
  • Page 3 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 4.6.3. Setup for IP signal current bias ................... 56 4.7. Error messages ........................... 56 4.8. Detailed setup ..........................57 4.9. Function select ........................... 60 4.10. Memory management ........................ 61 4.10.1. Memory save ........................61 4.10.2. Restore set value .........................
  • Page 4 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 7.1. Online diagnostics ........................91 7.1.1. Summary of online diagnostics ................... 91 7.1.2. Online diagnostics setting / Confirmation and Clear of result ..........93 7.1.3. Clear of diagnosis logs....................... 104 7.2. Offline diagnostics ........................105 7.2.1.

  • Page 5: Introduction

    KGP2000 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.

  • Page 6: Safety Notices

    1.3. Product summary KGP2000 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. Position feedback control system which receives feedback signal mapped to the desired valve travel and compares both input signal and feedback signal enables accurate positioning of a control valve.

  • Page 7: Parts Description

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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 Processing Unit) receives a 4 to 20mA signal and the actual valve position feedback signal when the control valve is moved from a potential meter attached to the feedback lever by an ADC (A / D converter).
  • Page 8 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ ※1 ※2 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 －...

  • Page 9: Specifications

    KOSO diaphragm type : 5200LA Maximum voltage ; +40VDC KOSO cylinder type : 6300LA Polarity protection ; -40VDC KOSO high power type : 5300LA KOSO rotary type : 6300RC Pneumatic data ; Actuators manufactured in accordance with Supply pressure ;...

  • Page 10: Marking Label

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Pneumatic connections ; Rc1/4 or 1/4NPT Position control ※Exhaust plug can be removed, connection port G3/8 ; ±1.0% Linearity Electric connections ; Hysteresis ; 0.7% according to the specifications as below G1/2, 1/2NPT, M20x1.5 Position transmitter output ※ Model KGP2003 Mounting threads ;...

  • Page 11: Certificates And Approvals

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 1.6. Certificates and approvals Explosion protection： ：Ex ia IIC T5/T4 Ga CCC(NEPSI) ：Ex ia IIC T5/T4 Ga IECEx ：II 1 G Ex ia IIC T5/T4 Ga ATEX ：0 Ex ia IIC T5/T4 Ga X CE marking： EMC directive(2014/30/EU) ：EN61000-4-2,-3,-4,-5,-6,-8 ：EN61000-6-4 RoHS2 directive(2011/65/EU) +(EU)2015/863：EN IEC63000:2018...
  • Page 12 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ ① ① ➁ ① ① ① ④ ① ③ ① ➁ ① ① ① Figure 1.7 Parts to use tools ~ The Most Cost Effective, Creative Valve Solutions ~ page. 12...

  • Page 13: Storage

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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.

  • Page 14: Mounting

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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.

  • Page 15: Mounting To Linear Motion Actuator (5200La, 6300La, 5300La)

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Mount the positioner to a linear actuator in a position that the feedback lever is in the horizontal position at 50% of full travel. 50％ travel Figure 2.1b Mounting position（example of linear type） 2.2. Mounting to linear motion actuator (5200LA, 6300LA, 5300LA) Positioner mounting bracket...

  • Page 16: Mounting To Rotary Motion Actuator (6300Rc)

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Feedback pin Feedback lever Tension spring Feedback pin mounting plate 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.

  • Page 17: Namur Mounting To Rotary Motion Actuator (Vdi/Vde3845)

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 2.4. NAMUR mounting to rotary motion actuator (VDI/VDE3845) Vertical slotted groove Horizontal slotted groove type drive shaft type drive shaft VDI/VDE3845 Top view Stud screw Stud screw coupling VDI/VDE3845 Top view coupling Counter- Feedback clockwise shaft rotation Clockwise...

  • Page 18: Supply Pressure Connection

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ OUT-2: Supply pressure port 2 Supply pressure port OUT-1: Supply pressure port 1 Supply pressure port 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.

  • Page 19: Electrical Connections

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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.
  • Page 20 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Figure 2.6b Entry type of screw and Connection facilities for bonding There are a few different types of thread for entries. You can identify the type of the thread by the engraved letter on the outside of entries. The letter“M” means M20X1.5, the letter”NPT”...
  • Page 21 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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 Figure 2.6d Connection facilities detail Make wiring connections according to the following procedure.
  • Page 22 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Field wiring diagram is shown in figure 2.6e and 2.6f ※1 Model KGP2003 only Figure 2.6e Field wiring diagram for 1 cable(4-core) ※1 Model KGP2003 only Figure 2.6f Field wiring diagram for 2 cable(2-core) ~ The Most Cost Effective, Creative Valve Solutions ~ page.
  • Page 23 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Normal Operation range Supply voltage（VDC） Figure 2.6g 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.

  • Page 24: Restriction Plate (Optional): Hunting Suppression Parts In Small Actuator

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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.

  • Page 25: Explosion Proof Type

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ EXPLOSION PROOF TYPE Warning  Please do a wiring work in the explosion protection area according to a prescribed guideline by an explosion protection guideline.  Expertise is required to maintain parts not listed in Chapter 5. It is not intended to be repaired by user.

  • Page 26: Ccc(Nepsi) Intrinsically Safe Explosion-Proof Type

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 3.1. CCC(NEPSI) Intrinsically safe explosion-proof type ：KGP2BXX (Electrical entries: 1/2NPT, G1/2, M20) A) Model No. ：Ex ia IIC T4/T5 Ga（CCC certificate No.：2024322307005863 Marking NEPSI certificate No.：GYJ24.1139X） IIC：This equipment is intended for use in above-ground industries with flammable gases, vapors, or mists.

  • Page 27: Iecex Intrinsically Safe Explosion-Proof Type

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 3.2. IECEx Intrinsically safe explosion-proof type ：KGP2DXX (Electrical entries: 1/2NPT, G1/2, M20) A) Model No. ：Ex ia IIC T4/T5 Ga（Certificate No.：IECEx NEP 23.0027X） 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.

  • Page 28: Atex Intrinsically Safe Explosion-Proof Type

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 3.3. ATEX Intrinsically safe explosion-proof type ：KGP2EXX (Electrical entries: 1/2NPT,G1/2,M20) A) Model No. ：Ex ia IIC T4/T5 Ga（Certificate No.：CML 23ATEX2668X） 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.

  • Page 29: Eac Intrinsically Safe Explosion-Proof Type ※Applying

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 3.4. EAC Intrinsically safe explosion-proof type ：KGP2FXX (Electrical entries: 1/2NPT,G1/2,M20) A) Model No. ：0 Ex ia IIC T4/T5 Ga X（Certificate No.：ЕАЭС RU С-JP.ПБ98.В.00491/24） 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.

  • Page 30: Setup And Information

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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.
  • Page 31 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ display (hereinafter, referred to as LCD), four push buttons. Figure 4.1.2 Local user interface (LUI) Symbol Name Description Return to the previous menu level Escape button Exit the current menu Enter button Execute the selection of a menu Up button Track menu while moving the cursor Increase or decrease a menu value...

  • Page 32: Lcd Screen And Features On The Lcd

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 4.1.3. LCD Screen and features on the LCD The examples of operating push buttons and the displayed screen on the LCD and operating push buttons are shown as below. Figure 4.1.3a Example of operating push buttons and the displayed screen on the LCD The measured values are displayed as below by pressing the down arrow key．...

  • Page 33: Menu Tree On The Lcd

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 4.1.4. Menu tree on the LCD MENU 1. Information 1. Status 2. Authority 2. Input /posi etc 3. Setup 3. Temperature 4. Maintenance 4. IP correction 5. Diag. & Alarms 1. Information 1. Position alarm 1.
  • Page 34 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ MENU 1. Information 2. Authority 3. Setup 4. Maintenance 5. Diag. & Alarms 2. Authority 1. Authority Figure 4.1.4b Authority ~ The Most Cost Effective, Creative Valve Solutions ~ page. 34...
  • Page 35 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ MENU 1. Information 2. Authority 3. Setup 4. Maintenance 5. Diag. & Alarms 1. Actuator motion 2. Actuator type 3. Setup 3. Valve action 1. Basic setup 4. Packing friction 2. Easy tuning 5. Booster option 3.
  • Page 36 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ MENU 1. Information 2. Authority 3. Setup 4. Maintenance 5. Diag. & Alarms 4. Maintenance 1. Input signal cal. 1. Calibration 2. Cross point cal. 2. Simulation test 3. Position transmit. 3. Memory save & res. 4.
  • Page 37 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ MENU 1. Information 2. Authority 3. Setup 1. Total stroke 4. Maintenance 2. Total dir. change 5. Diag. & Alarms 3. Low position time 4. High temp.time 5. Diag. & Alarms 5. Low temp.time 1. Online diag. setup 6.

  • Page 38: Flow Chart Of Settings Procedure

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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.

  • Page 39: Operating Authority

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 4.3. Operating authority You can configure the Authority. MENU > Authority ( 2-1- ) Table 4.3 Authority Setting Item Key menu Description Parameters Default Set authority. Select HART if you don’t allow to change settings from the LUI, such as for HART communication only.

  • Page 40: 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 41: List Of Operation Setting Patterns For Actuator

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 4.4.2. List of operation setting patterns for actuator Table 4.4.2a 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...
  • Page 42 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Table 4.4.2b(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)
  • Page 43 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Table 4.4.2c 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...
  • Page 44 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Table 4.4.2d(Reference table) Linear motion double acting type actuator・Operation list 【Push-down open】 ~ The Most Cost Effective, Creative Valve Solutions ~ page. 44...
  • Page 45 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Rotary motion single acting type actuator・Operation list 【Counterclockwise open】 Table 4.4.2e 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...
  • Page 46 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Table 4.4.2f(Reference table) Rotary motion single acting type actuator・Operation list 【Counterclockwise close】 ~ The Most Cost Effective, Creative Valve Solutions ~ page. 46...
  • Page 47 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Table 4.4.2g 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...
  • Page 48 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Table 4.4.2h(Reference table) Rotary motion double acting type actuator・Operation list 【Counterclockwise close】 Table 4.4.2i Power off state Relay type De-energized Output OUT-2： air pressure 2 Single acting normal operation OUT-1 output air pressure 0 OUT-1 output air pressure 0 Double acting OUT-2 output air pressure Supply air Output...

  • Page 49: Easy Tuning

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 4.5. 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.

  • Page 50: Response Tuning

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 4.5.3. 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 ( 3-2-4 ) A．In case the higher response sensitivity is desired, i.e., you wish to reduce response time by making the response quicker, Select ‘Aggressive’...

  • Page 51: Expert Tuning

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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.
  • Page 52 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ  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. ...

  • Page 53: Custom Setting For Pid Parameter

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 4.6.2. 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 54 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ ※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 4.6.2．Gain switching (Example of proportional gain） The procedure is shown as followings．...
  • Page 55 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ parameters will not be able to be changed through the following procedure ③． PID custom setup Air-Out ≠ Air-In? ☛Air-Out ≠ Air-In? PID value PID value Air-Out ☛Yes Inside threshold ▼ ③ Set PID parameters of Air-In PID custom setup PID parameter Air-Out ≠...

  • Page 56: Setup For Ip Signal Current Bias

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 4.6.3. 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 57: Detailed Setup

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 4.8. Detailed setup Set values which need to be changed to achieve the desired response. MENU > Setup > Detailed setup ( 3-4- ) Table 4.8 Item list of the detailed setup Key menu Description Parameters Default Set the control range which tracks the input signal...
  • Page 58 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Key menu Description Parameters Default ※ 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. ※Since the 0% valve travel corresponds to the 0% input and the 100% valve travel corresponds to the Custom curve...
  • Page 59 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Key menu Description Parameters Default Set the full mechanical limit of valve travel over the 100% travel position, when the positioner detects the 100% travel position. Value 105% ※This value is valid only in condition when ‘Linear’ （100~150%）...

  • Page 60: Function Select

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 4.9. Function select You can configure individually the following functions. MENU > Setup > Function select ( 3-5- ) Table 4.9 List of selectable functions Key menu Description Parameters Default Set password. Once the password is set, only ‘Information’ from ‘TOP’ menu will be able to be accessed unless you type the Three-digit password.

  • Page 61: Memory Management

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 4.10. Memory management 4.10.1. 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 >...

  • Page 62: Restore Set Value

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Save ☛Yes 4.10.2. 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. 4.10.3.

  • Page 63: Display Of Inner Information

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ The operator can confirm the value of the current temperature inside the positioner MENU > Information > Monitor > Temperature (1-1-3) Temperature +22℃ +22℃ 4.11.3. Display of inner information The operator can confirm the information as below. Serial number ※...

  • Page 64: Confirmation Before Operation

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 4.12. 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.

  • Page 65: Maintenance

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ In auto mode；the output pressure corresponding to the nozzle backpressure which is generated in the torque motor is outputted． In manual mode；the output pressure which reaches to the supplied pressure by bypassing the nozzle backpressure is outputted．...

  • Page 67: Action Switching Of Pilot Relay

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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. Double action Single action Figure 5.1.3．Action switching of pilot relay Switching to single action mode;...

  • Page 68: Calibration

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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．...

  • Page 69: Cross Point Calibration

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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.

  • Page 70: Position Transmitter Calibration

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 5.2.4. Position transmitter calibration Calibrate the position transmitter signal which the positioner may send．※Model KGP2003 only． MENU > Maintenance > Calibration > Position transmit cal. (4-1-3) The procedure to calibrate individually the position transmitter signal of each position in 0% and 100% is shown below.

  • Page 71: Potentiometer Calibration

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 5.2.5. Potentiometer calibration The operator may perform the calibration of potentiometer attached the positioner. Since the calibration is performing at the factory, in general, it is not necessary to do it again. But when the positioner is removed from the actuator, rotate the feedback lever 360 degrees clockwise or counterclockwise according to the following procedure before the calibration.．...

  • Page 72: 5.3.2. Ip Signal Simulation

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ ① Select ‘Yes’ confirmation and press the right arrow key. Manual input ☛Yes ⇩ ② If the screen is displayed as shown left, adjust the value until it Manual input becomes desired value by pressing the up or down arrow key to move a control valve.
  • Page 73 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ IP signal = 0.0% -> +26℃ Supplementary explanation) ※The operator can change the value in 50% interval while pressing the left or right arrow key. IP signal = 50.0% -> +26℃ ※The operator can change the value in 0.1% interval while pressing the left or right arrow key.

  • Page 74: 5.3.3. Simulation Of Position Transmitter Signal

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 5.3.3. Simulation of position transmitter signal It is possible to generate position transmitter signal which is similar to the desired signal. ※Model KGP2003 only MENU > Maintenance > Simulation test > Position transmit (4-2-4) Position transmit. = 50.0％...

  • Page 75: 5.3.5. Step Response Simulation

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Ramp resp. test Ramp time= 0sec ④ Set the wait time. Ramp resp. test Wait time= 10sec ⑤ Select the motion type (number of repetitions). Ramp resp. test Repeat= Once ⑥ Confirm the execution. Ramp resp. test ☛No ⑦...
  • Page 76 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ The procedure is shown as below. ① Set ‘Step’ (the interval). Step resp. test Step= 10.0% ② Set ‘Start’ (position). Step resp. test Start= 0% ③ Set ‘End’ (position). Step resp. test End=100% ④ Set ‘Step time’ (delay time) Step resp.

  • Page 77: Assembly(Unit) Cleaning ‧ Replacement

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Assembly(unit) cleaning ‧ replacement 5.4. 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 78: Nozzle Flapper Cleaning

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Filter Holder Figure 5.4.2c Ｏring Figure 5.4.2b 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 pilot relay and so on.

  • Page 79: Service Menu

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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 >...

  • Page 80: Factory Setup

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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...

  • Page 81: Alarms

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 5.5.4.2. Display of Factory Setup To display the Factory Setup menu, make the following settings. Factory Menu； MENU > Maintenance > Service > Factory Menu > (4-4-6) ① Select ON and press the button. ② The Factory Setup menu appears in MENU> Maintenance ALARMS This device has a self-diagnosis function that generates alarms.

  • Page 82: Summary Of Alarms

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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...
  • Page 83 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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;...

  • Page 84: Alarm Setting / Check And Clear Of Result

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Low: As the temperature falls below a lower setting High side value, an alarm is occurred. Unused Able to change the setting in the range of -45 to 25℃ High: When the temperature exceeds an upper set-value, an alarm is occurred.

  • Page 85: Deviation Alarm

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ ④ After pressing Ent button, “Complete” is displayed. Position alarm Complete Check of result; MENU > Information > Alarm status (1-2-) ① Move by pressing button，and select Position alarm by button. ② Checking status of Lo alarm and Hi alarm on the screen. Position alarm Position 50.0%...

  • Page 86: Temperature Alarm

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ ③ Change the Time threshold value by pressing button Deviation alarm Deviation = 50％ Time= 10s ④ After pressing Ent button, “Complete” is displayed. Deviation alarm Complete Check of result; MENU > Information > Alarm status (1-2-) ①...
  • Page 87 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ ② Change the Low threshold value by pressing button.. Temperature alarm Low =-30℃ ③ Change the High threshold value by pressing button. Temperature alarm Low =-30℃ High =+70℃ ④ After pressing Ent button, “Complete” is displayed. Temperature alarm Complete Check of result;...

  • Page 88: Ip Deviation Alarm

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 6.2.4. IP deviation alarm Setting; MENU > Diag. & Alarms > Alarm setup (5-4-) ① Move by pressing button，and select IP dev. alarm by button. ② Change the IP dev. threshold value by pressing button. ③...

  • Page 89: Alarm Clear

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 6.2.5. Alarm clear Setting； MENU > Diag. & Alarms > Alarm setup (5-4-) ① Move by pressing button，and select All alarm clear alarm by button. ② The alarm status will be displayed as below. ③ When you press and the following is displayed, it is complete.
  • Page 90 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ ② The following screen is indicated, so choose the status assigned by button and push button. Position alarm 1.Maintenance req 2.Out of spec. ☛3.Check function ③ If the following is indicated, it’s finished. Position alarm Complete ~ The Most Cost Effective, Creative Valve Solutions ~ page.

  • Page 91: Diagnostics

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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.
  • Page 92 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Items Summary of online diagnostics Stroke size [%] : Set a position width to move Completion stroke [%] : Set a stroke to judge movement completion Start stroke [%] : Set a stroke to judge movement start Abort time limit [s] : Set a time to judge movement cancellation before movement completion...

  • Page 93: Online Diagnostics Setting / Confirmation And Clear Of Result

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 7.1.2. Online diagnostics setting / Confirmation and Clear of result 7.1.2.1. Total stroke Setting; MENU > Diag & Alarms > Online diag. setup (5-1-) ① Input the set value. Set value can be changed using buttons.
  • Page 94 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Clear of result; MENU > Diag & Alarms > Online diag. setup > Total stroke (5-1-1) 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...
  • Page 95 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 7.1.2.2. Total direction change Setting; MENU > Diag & Alarms > Online diag. setup (5-1-) ① Input the set value. Set value can be changed using buttons. Total dir. change Criteria= 5% ② Select the “Continue”, and push button.
  • Page 96 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Clear of result; MENU > Diag & Alarms > Online diag. setup > Total dir. change (5-1-2) ① Push button and go to ② Total dir. change Criteria= 5% ② Select the “Log Erase”, and push button.
  • Page 97 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 7.1.2.3. Low position time Setting; MENU > Diag & Alarms > Online diag. setup (5-1-) 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.
  • Page 98 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Clear of result; MENU > Diag & Alarms > Online diag. setup > Low position time (5-1-3) ① Push button and go to ②. Low position time Criteria=5.0% ② Select the “Log Erase”, and push button.
  • Page 99 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 7.1.2.4. Maximum temperature time/ Setting; MENU > Diag & Alarms > Online diag. setup (5-1-) ① Input the set value. Set value can be changed using buttons. High temp. time Criteria=+50℃ ② Select the “Continue”, and push button.
  • Page 100 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Clear of result; MENU > Diag & Alarms > Online diag. setup > High Temp. time (5-1-4) ① Push button and go to ②. High temp. time Criteria=+50℃ ② Select the “Log Erase”, and push button.
  • Page 101 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 7.1.2.5. Minimum temperature time Setting; MENU > Diag & Alarms > Online diag. setup (5-1-) ① Input the set value. Set value can be changed using buttons. Low temp. time Criteria=+0℃ ② Select the “Continue”, and push button.
  • Page 102 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Clear of result; MENU > Diag & Alarms > Online diag. setup > Low Temp. time (5-1-5) ① Push button and go to ②. Low temp. time Criteria=+0℃ ② Select the “Log Erase”, and push button.
  • Page 103 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 7.1.2.6. Partial stroke test Setting; MENU > Diag & Alarms > Online diag. setup (5-1-) 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.

  • Page 104: Clear Of Diagnosis Logs

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Check of result; MENU > Information > Diag. result (1-5-) ① Select the “Partial stroke T.”, and push button. Diagnost. Result Total time 25% step response Pneumatic drift ☛Partial stroke T. ▼ ② The following screen will be displayed, showing Enable and the number of days remaining. PST setup info.

  • Page 105: Offline Diagnostics

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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.

  • Page 106: 25％ Step Response

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 7.2.2. 25％ step response Setting; MENU > Diag & Alarms > Offline diag. set. > 25% step response (5-2-1) ① Select the “25% step response”, and push button. Offline diag.set. ☛25% step response Pneumatic drift PST(offline) ▼...

  • Page 107: Pneumatic Circuit Drift

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ ④ After the test, the latest result is shown to the screen like below. < N o w > O . S . D e v . 561 0 . 0 % 0 - 2 5 1 .
  • Page 108 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Pneumatic drift Complete Execution; MENU > Diag & Alarms > Offline diag. test > Pneumatic drift (5-3-2) ① Select the “Pneumatic drift”, and push button. Offline diag.test 25% step response ☛Pneumatic drift PST(offline) ▼ ② Select the “Run”, and push button.

  • Page 109: Check And Save Of Online Diagnostics Results

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 7.2.4. 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;...

  • Page 110: Hart Communication

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ HART COMMUNICATION ※Model KGP2003 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.

  • Page 111: Troubleshooting

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ TROUBLESHOOTING When problems occurred at the operation starting or during operation, please refer to the following table d take an action appropriately. Table 9.1 Trouble shooting Phenomenon Assumed cause Action  Check input current Loss of electrical power, disconnection or miswiring ...

  • Page 112: Parts

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ PARTS 10.1. Assembly and parts list ~ The Most Cost Effective, Creative Valve Solutions ~ page. 112...
  • Page 113 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Table 10.1 Parts and units list Parts Title Qty. Notes Front cover assembly Board cover Cross recessed head screws with captive washer M4-L10 Main board Cross recessed head screws with captive washer M4-L10 Pilot relay assembly Cross recessed head screws with captive washer M4-L12 O-rings (for pilot relay)

  • Page 114: Check Cycle And Replacement Cycle

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ 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...

  • Page 115: Dimensions

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ DIMENSIONS Fig. 11a Linear motion standard type ~ The Most Cost Effective, Creative Valve Solutions ~ page. 115...
  • Page 116 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Fig. 11b Linear motion long stroke type ~ The Most Cost Effective, Creative Valve Solutions ~ page. 116...
  • Page 117 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Fig. 11c Rotary motion type ~ The Most Cost Effective, Creative Valve Solutions ~ page. 117...
  • Page 118 五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ Fig. 11d Rotary motion VDI/VDE3845 type ~ The Most Cost Effective, Creative Valve Solutions ~ page. 118...

  • Page 119: A) Appendix / Model Selection And Code Number

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ A) APPENDIX / MODEL Selection and CODE number ① ② ③ － ④ ⑤ ⑥ ⑦ － ⑧ Base model ① P roof type Standard connections (options) Air: 1/4NPT (Rc1/4) *1 Dust・water proof Electric: 1/2NPT (M20, G1/2) Air: 1/4NPT (Rc1/4) *1 Intrinsic safety (NEPSI)

  • Page 120: B) Appendix / Technical Support Checklist

    五校 11/9 OME-KGP2-01C(Dec. 2024) ｘ B) APPENDIX / Technical Support Checklist KGP2000 Technical Support Checklist Please have the following information ready before contacting our sales office. 1. Serial number on the plate of KGP2000 2. Construction number stated in the delivery specifications 3.
  • Page 121 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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