SED 024.16.720 User manual

Montageanleitung / Operating Instructions
Type 024.16.720
Elektropneumatischer Stellungsregler
Electropneumatic position controller

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We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
© 2011 SED Flow Control GmbH
Operating Instructions / BA11 0001 Rev. a
Type 024.16.720

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Type 024.16.720
Ta b l e o f Co n T e n T s
1. EC DECLARATION OF CONFORMITY....................................................................................................8
2. OPERATING INSTRUCTIONS .................................................................................................................9
2.1. Symbols ........................................................................................................................................9
3. AUTHORIZED USE................................................................................................................................10
3.1. Restrictions .................................................................................................................................10
3.2. Predictable Misuse .....................................................................................................................10
4. BASIC SAFETY INSTRUCTIONS ..........................................................................................................11
5. GENERAL INFORMATION.....................................................................................................................12
5.1. Scope of Supply .........................................................................................................................12
5.2. Contact Addresses .....................................................................................................................12
5.3. Warranty......................................................................................................................................12
5.4. Trademarks .................................................................................................................................13
5.5. Information on the Internet .........................................................................................................13
6. SYSTEM DESCRIPTION .......................................................................................................................14
6.1. Intended Application Area...........................................................................................................14
6.2. Function of the positioner and combination with valve types ....................................................14
6.3. Features of the valve types.........................................................................................................15
6.4. Structure of the positioner ..........................................................................................................16
6.4.1. Representation................................................................................................................16
6.4.2. Features..........................................................................................................................17
6.4.3. Function diagram of the positioner with single-acting actuator .....................................18
6.5. Type 024.16.720 Positioner with position controller ...................................................................19
6.5.1. Schematic representation of the position control Type 024.16.720 ...............................19
6.5.2. Properties of the position controller software.................................................................20
6.6. Interfaces of the positioner ........................................................................................................22

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Type 024.16.720
7. TECHNICAL DATA.................................................................................................................................23
7.1. Operating Conditions..................................................................................................................23
7.2. Conformity ..................................................................................................................................23
7.3. Mechanical data..........................................................................................................................23
7.4. Pneumatic data...........................................................................................................................24
7.5. Adhesive labels ...........................................................................................................................24
7.5.1. Label (example)...............................................................................................................24
7.5.2. Identicationlabeloftheignitionprotectionclasses ....................................................24
7.6. Electrical Data.............................................................................................................................25
7.6.1. Electrical data without bus control 24 V DC...................................................................25
7.6.2. Electrical data with AS interface bus control..................................................................25
7.7. Factory settings of the positioner ...............................................................................................26
8. CONTROL AND DISPLAY ELEMENTS .................................................................................................27
8.1. Operating status............................................................................................................................ 27
8.2. Control and display elements of the positioner ..........................................................................27
8.3. Congurationofthekeys .............................................................................................................. 28
8.4. Function of the DIP switches ........................................................................................................ 29
8.5. Display of the LEDs.......................................................................................................................30
8.6. Error Messages ............................................................................................................................. 31
8.6.1. Error messages in MANUAL and AUTOMATIC operating statuses .................................31
8.6.2. Error messages while the X.TUNE function is running ...................................................31
9. INSTALLATION ......................................................................................................................................32
9.1. Safety instructions ......................................................................................................................32
9.2. Installing the positioner Type 024.16.720........................................................................................ 33
9.3. Rotating the positioner for process valves .................................................................................37
10. FLUID INSTALLATION...........................................................................................................................38
10.1. Safety instructions ......................................................................................................................38
10.2. Installing the Process Valve ........................................................................................................38
10.3. Pneumatic connection of the positioner .....................................................................................39

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Type 024.16.720
11. ELECTRICAL INSTALLATION 24 V DC .................................................................................................40
11.1. Safety instructions ......................................................................................................................40
11.2. Electrical installation with circular plug-in connector .................................................................41
11.2.1. Designation of the contacts Type 024.16.720 ................................................................41
11.2.2. Connection of the positioner Type 024.16.720...............................................................41
11.3. Electrical installation with cable gland........................................................................................43
11.3.1. Designation of the screw-type terminals........................................................................43
11.3.2. Connection of the positioner Type 024.16.720...............................................................43
12. AS INTERFACE INSTALLATION ............................................................................................................45
12.1. AS Interface Connection.............................................................................................................45
12.2. Technical Data for AS Interface PCBs ........................................................................................45
12.3. Programming Data......................................................................................................................45
12.4. LED Status Display .....................................................................................................................46
12.5. Electrical installation AS interface...............................................................................................47
12.5.1. Safety instructions ..........................................................................................................47
12.5.2. Connection with circular plug-in connector M12 x 1, 4-pole, male................................47
12.5.3. Connection with multi-pole cable and ribbon cable terminal.........................................48
13. START-UP..............................................................................................................................................49
13.1. Safety instructions ......................................................................................................................49
13.2. Specifying the standard settings ................................................................................................49
13.2.1. Running the automatic adjustment X.TUNE: .................................................................50
14. OPERATION AND FUNCTION...............................................................................................................51
14.1. Basic functions..............................................................................................................................51
14.1.1. DIR.CMD - Effective Direction of the Position Controller Set-Point Value.....................52
14.1.2. CUTOFF - Sealing Function for the Position Controller.................................................53
14.1.3. CHARACT - Select the transfer characteristic between input signal (position set-point
value) and stroke.............................................................................................................54
14.2. Auxiliary Functions ........................................................................................................................ 55
15. SAFETY POSITIONS .............................................................................................................................56
15.1. Safety positions after failure of the electrical or pneumatic auxiliary power...............................56

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Type 024.16.720
16. MAINTENANCE.....................................................................................................................................57
16.1. Serviceattheairintakelter.......................................................................................................57
17. ACCESSORIES .....................................................................................................................................58
17.1. Communications software (PC SOFTWARE based on FDT/DTM technology):..........................58
17.1.1. PACTware 3.6..................................................................................................................58
17.1.2. Serial interface RS 232 ...................................................................................................58
17.1.3. Download........................................................................................................................58
18. PACKAGING AND TRANSPORT...........................................................................................................59
19. STORAGE .............................................................................................................................................59
20. DISPOSAL.............................................................................................................................................59

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Type 024.16.720

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EC Declaration of Conformity
Type 024.16.720
1. EC DECLARATION OF CONFORMITY
As manufacturer we hereby declare that the products with the designation:
Type 024.16.720
satisfyrequirementswhicharespeciedinthefollowingDirectivesoftheEuropeanCouncil:
2006/95/ EC Low Voltage Directive
2004/108/EC Electromagnetic Compatibility Directive
97/23/EC Pressure Equipment Directive
94/9/EC ATEX-Directive
The products have been subjected to the following conformity assessment procedure:
Module A Internal production control
The Pressure Equipment Directive for products with a nominal voltage < 50V is applied to the CE mark only
for equipment which has a nominal width > 25 mm and controls gases belonging to Group 1 or vapour or
equipment which has a nominal width > 32 mm and controls gases belonging to Group 2 and the product is
within the range > 1,000 and < 3,500 for the calculation nominal pressure x nominal width.
The products with a nominal voltage >= 50V with respect to Pressure Equipment Directive (97/23/EC) are
assessed in Article 1 Paragraph 3.6 of this directive, according to which the equipment is measured by the
Low Voltage Directive and therefore does not drop below the scope of the Pressure Equipment Directive.
The units are designed and built in a way that
•therewillnotbeanignitionsourceinnormaluseand
•themaximalsurfacetemperatureislessthanthelimitofthegiventemperaturecodeontheunit.
Depending on the marking the units may be used as a Category 3 unit in zone 2 or 22.
SED Flow Control GmbH
Am Schafbaum 2
D - 74906 Bad Rappenau
Bad Rappenau, 01. March 2011
(This document was issued electronically and is therefore valid without signature)

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Operating Instructions
Type 024.16.720
2. OPERATING INSTRUCTIONS
The operating instructions describe the entire life cycle of the device. Keep these instructions in a location which
is easily accessible to every user, and make these instructions available to every new owner of the device.
WARNING!
The operating instructions contain important safety information!
Failure to observe these instructions may result in hazardous situations.
The operating instructions must be read and understood.•
2.1. Symbols
DANGER!
Warns of an immediate danger!
Failure to observe the warning will result in a fatal or serious injury.•
WARNING!
Warns of a potentially dangerous situation!
Failure to observe the warning may result in serious injuries or death.•
CAUTION!
Warns of a possible danger!
Failure to observe this warning may result in a moderate or minor injury.•
NOTE!
Warns of damage to property!
Failure to observe the warning may result in damage to the device or the equipment.•
Indicates important additional information, tips and recommendations.
refers to information in these operating instructions or in other documentation.
→Designates a procedure which you must carry out.

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Authorized use
Type 024.16.720
3. AUTHORIZED USE
Non-authorized use of the positioner Type 024.16.720 may be a hazard to people, nearby equipment
and the environment.
The device is designed to be mounted on pneumatic actuators of process valves for the control of•
media.
Do not expose the device to direct sunlight.•
Useaccordingtotheauthorizeddata,operatingconditionsandconditionsofusespeciedinthecon-•
tract documents and operating instructions. These are described in the chapter entitled “7. Technical
Data”.
The device may be used only in conjunction with third-party devices and components recommended•
and authorized by SED Flow Control.
In view of the large number of options for use, before installation, it is essential to study and if necessary•
to test whether the positioner is suitable for the actual use planned.
Correct transportation, correct storage and installation and careful use and maintenance are essential•
for reliable and faultless operation.
Use the positioner Type 024.16.720 only as intended.•
3.1. Restrictions
Devices which are designed for use in Zone 2/22:
The user is responsible for protection class IP54 in accordance with EN 60529 of this device.
If exporting the system/device, observe any existing restrictions.
3.2. Predictable Misuse
•The positioner Type024.16.720 maybe used inhazardousexplosive areasonly inaccordancewiththe
ignitionprotectionclassindicatedontheidenticationplateoftheignitionprotectionclasses.
•Donotfeedanyaggressiveorammablemediaintothepressuresupplyconnection.
•Donotfeedanyliquidsintothepressuresupplyconnection.
•Donotputanyloadsonthebody(e.g.byplacingobjectsonitorstandingonit).
•Donotmakeanyexternalmodicationstothedevicebodies.Donotpaintthebodypartsorscrews.

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Basic Safety Instructions
Type 024.16.720
4. BASIC SAFETY INSTRUCTIONS
These safety instructions do not make allowance for any
•contingencies and events which may arise during the installation, operation and maintenance of the
devices.
•localsafetyregulations–theoperatorisresponsibleforobservingtheseregulations,alsowithreferenceto
the installation personnel.
DANGER!
Danger – high pressure!
Before dismounting pneumatic lines and valves, turn off the pressure and vent the lines.•
Risk of electric shock!
Before reaching into the device or the equipment,• switch off the power supply and secure to prevent
reactivation!
Observe applicable accident prevention and safety regulations for electrical equipment!•
General hazardous situations.
To prevent injury, ensure:
that the system cannot be activated unintentionally.•
Installation and repair work may be carried out by authorized technicians only and with the appropriate•
tools.
After an interruption in the power supply or pneumatic supply, ensure that the process is restarted in a•
denedorcontrolledmanner.
The device may be operated only when in perfect condition and in consideration of the operating•
instructions.
The general rules of technology apply to application planning and operation of the device.•
NOTE!
Electrostatic sensitive components / modules!
The device contains electronic components, which react sensitively to electrostatic discharge (ESD).•
Contact with electrostatically charged persons or objects is hazardous to these components. In the worst
case scenario, they will be destroyed immediately or will fail after start-up.
Observe the requirements in accordance with EN 100 015 - 1 and 5 - 2 to minimize or avoid the possibility•
of damage caused by sudden electrostatic discharge!
Also ensure that you do not touch electronic components when the power supply is on!•
The positioner Type 024.16.720 was developed with due consideration given to the accepted safety
rules and is state-of-the-art. Nevertheless, dangerous situations may occur.
Failure to observe this operating manual and its operating instructions as well as unauthorized tampering
with the device release us from any liability and also invalidate the warranty covering the devices and
accessories!

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General Information
Type 024.16.720
5. GENERAL INFORMATION
5.1. Scope of Supply
Check immediately upon receipt of the delivery that the contents are not damaged and that the type and scope
agree with the delivery note and packing list.
Generally this consists of:
Pneumatically actuated valve with attached positioner, the operating instructions for the positioner and for
the valve with pneumatic actuator.
For the multipole version of the positioner we will provide you with cable connectors as suitable
accessories.
If there are any discrepancies, please contact us immediately.
5.2. Contact Addresses
SED Flow Control GmbH
Am Schafbaum 2
D - 74906 Bad Rappenau
P.O. Box 1306
D - 74900 Bad Rappenau
Phone: [phone]
Fax: [phone]
E-Mail:info@sed-owcontrol.com
Web:www.sed-owcontrol.com
5.3. Warranty
This document contains no promise of guarantee. Please refer to our general terms of sales and delivery. The
warrantyisonlyvalidifthepositionerType024.16.720isusedasintendedinaccordancewiththespecied
application conditions.
The warranty extends only to defects in the positioner Type 024.16.720 and its components. We accept
no liability for any kind of collateral damage which could occur due to failure or malfunction of the
device.

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General Information
Type 024.16.720
5.4. Trademarks
Brands and trademarks listed below are trademarks of the corresponding companies / associations /
organizations
Loctite Henkel Loctite Deutschland GmbH
5.5. Information on the Internet
The operating instructions and data sheets for Type 024.16.720 can be found on the Internet at:
www.sed-owcontrol.com

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System Description
Type 024.16.720
6. SYSTEM DESCRIPTION
6.1. Intended Application Area
The positioner Type 024.16.720 is designed to be mounted on pneumatic actuators of process valves for
the control of media.
6.2. Function of the positioner and combination with valve types
Positioner Type 024.16.720 is an electropneumatic position controller for pneumatically actuated control valves
with single-acting actuators.
Together with the pneumatic actuator, the positioner forms a functional unit.
Thecontrolvalvesystemscanbeusedforawiderangeofcontroltasksinuidtechnologyand,dependingon
the application conditions, different process valves from the SED range can be combined with the positioner.
Angle-seatvalves,diaphragmvalvesorballvalvesttedwithacontrolconearesuitable.
“Fig. 1: ” shows an overview of the possible combinations of positioner and different pneumatically actuated
valves. Different actuator sizes and valve nominal widths, not illustrated here, are available for each type. More
precisespecicationscanbefoundontherespectivedatasheets.Theproductrangeisbeingcontinuously
expanded.
Positioner Type 024.16.720
with diaphragm valve
with angle seat valve
Fig. 1: Overview of possible combinations

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System Description
Type 024.16.720
The position of the actuator is regulated according to the position set-point value. The position set-point value
isspeciedbyanexternalstandardsignal.
Pneumatically actuated piston actuators and rotary actuators can be used as an actuator. Single-acting
actuators are offered in combination with the positioner.
For single-acting actuators, only one chamber is aerated and deaerated in the actuator. The generated pressure
works against a spring. The piston moves until there is an equilibrium of forces between compressive force
and spring force.
6.3. Features of the valve types
Angle seat control
valves / straight seat
control valves
Diaphragm valves Ball valves Flap valves
Features incomingowunder•
seat
no closing impact•
straightowpathof•
the medium
self-adjustingstufng•
box for high leak-
tightness
medium is hermeti-•
cally separated from
the actuator and
environment
cavity-free and self-•
draining body design
anyowdirection•
with low-turbulence
ow
steam-sterilizable•
CIP-compliant•
no closing impact•
actuator and dia-•
phragm can be
removed when the
body is installed
scrapable•
minimum dead•
space
unaffected by•
contamination
little pressure loss•
compared to other
valve types
seat and seal can•
be exchanged in
the three-piece ball
valve when installed
Note
can be used as
process controller
only
unaffected by•
contamination
little pressure•
loss compared
to other valve
types
inexpensive•
low construction•
volume
Typical
media
water, steam and•
gases
alcohols, oils, propel-•
lants,hydraulicuids
salt solutions, lyes•
(organic)
solvents•
neutral gases and•
liquids
contaminated,•
abrasive and
aggressive media
media of higher•
viscosity
neutral gases and•
liquids
clean water•
slightly aggressive•
media
neutral gases•
and liquids
slightly•
aggressive
media
Table 1: Features of the valve types

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System Description
Type 024.16.720
6.4. Structure of the positioner
The positioner Type 024.16.720 consists of the micro-processor controlled electronics, the position measuring
system and the control system. The device is designed using three-wire technology. The positioner is operated
via 2 keys and a 4-pole DIP switch. The pneumatic control system for single-acting actuators consists of 2
solenoid valves.
6.4.1. Representation
Pressure supply connection
(label: 1)
Exhaust air con-
nection (label: 3)
Electrical connection
(cable gland M16 x 1.5
or circular plug-in connector M12 x 1)
Body casing removed: Buttons
DIP Switches
LED
Transparent cap
Pressure limiting valve
(for protection against
too high internal
pressure in case of error)
Airintakelter
(exchangeable)
Body casing
Version 1
Circular plug-in connector
Version 2
AS interface
Cable gland
Communications
interface
Pressure supply connection
(label: 1)
Exhaust air con-
nection (label: 3)
LED
Communica-
tions interface
Airintakelter
(exchangeable)
Screw-
type
terminals
Fig. 2: Structure

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System Description
Type 024.16.720
6.4.2. Features
•Models
for single-acting valve actuators.
•Positionmeasuringsystem
Contactless and therefore wear-free position measuring system.
•Microprocessor-controlledelectronics
for signal processing, control and valve control.
•Controlmodule
The device is controlled via 2 buttons and a 4-pole DIP switch. 2x 2-colored LEDs indicate different sta-
tuses of the device.
•Controlsystem
The control system consists of 2 solenoid valves. One valve is used to aerate and another to deaerate the
pneumatic actuator. The solenoid valves operate according to the rocker principle and are controlled with
aPWMvoltageviathecontroller.Doingsoachievesahigherexibilitywithregardtoactuatorvolumeand
nalcontrolspeed.Thedirect-actionmodelhasanoriceofDN0.6.Inlargerpneumaticactuatorsthe
solenoidvalvesfeaturediaphragmamplierstoincreasethemaximumowandthereforetoimprovethe
dynamics (DN 2.5).
•Positionfeedback(optional)
The position of the valve can be transmitted to the PLC via an analog 0/4-20 mA output.
•Binaryinput
If a voltage > 10 V is applied, SAFE POSITION is activated, i.e. the valve is moved to the safety position
(factory setting, can be changed with communications software).
Pneumatic interfaces•
1/4“ connections with different thread
forms (G, NPT)
hose plug-in connection
Electrical interfaces•
Circular plug-in connector or cable
gland
•Body
The body of the positioner is protected from excessively high internal pressure, e.g. due to leaks, by a
pressure limiting valve.
•Communicationsinterface
Forcongurationandparameterization.

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System Description
Type 024.16.720
6.4.3. Function diagram of the positioner with single-acting actuator
The illustrated function diagram describes the function of the positioner (Type 024.16.720).
Control system
1
2
Position
controller
Control system
1: Aeration valve
2: Bleed valve
Pressure
supply
Exhaust air
Position
measuring
system
Actual
position
external
position
set-point value
Positioner
Pneumatic
actuator
(single-acting)
Valve
(actuator)
Fig. 3: Function diagram

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System Description
Type 024.16.720
6.5. Type 024.16.720 Positioner with position controller
The position measuring system records the current position (POS) of the pneumatic actuator. The position con-
trollercomparesthisactualpositionvaluewiththeset-pointvalue(CMD)whichisdenableasstandardsignal.In
case of a control deviation (Xd1), a pulse-width modulated voltage signal is sent to the control system as a manip-
ulated variable. If there is a positive control difference in single-acting actuators, the air inlet valve is controlled via
output B1. If the control difference is negative, the bleed valve is controlled via output E1. In this way the
position of the actuator is changed until control difference is 0. Z1 represents a disturbance variable.
Valve
opening
Control valve Control system
Solenoid valves
Position measuring system
Position
controller
Position
set-point
value
CMD Xd1 B1
E1 PK
Z1
POS
Position control
circuit
+-
Fig. 4: Signal ow plan of position controller
6.5.1. Schematic representation of the position control Type 024.16.720
4 ... 20 mA1)
0 ... 20 mA
CHARACT
SPLTRNG2)
DIR.CMD CUTOFF X.TIME2)
X.CONTROL
DBND
POS
CMD
INP
POS
CMD
DIR.ACT2) X.LIMIT2)
1) Default setting
2) can only be activated with communications software
Fig. 5: Schematic representation of position control

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System Description
Type 024.16.720
6.5.2. Properties of the position controller software
Functions I
•ActivationviaDIPswitches
•Parametersettingviacommunicationssoftware
Additional function Effect
Sealing function
CUTOFF
Valveclosestightoutsidethecontrolrange.Speci-
cation of the value (as %), from which the actuator is
completely deaerated (when 0 %) or aerated (when
100 %)
(see Chapter “8.4. Function of the DIP switches”).
Correction line to adjust the operating
characteristic
CHARACT
Linearization of the process characteristic can be
implemented (see Chapter “8.4. Function of the DIP
switches”).
Effective direction of the controller set-point
value
DIR.CMD
Reversal of the effective direction of the set-point
value
(see Chapter “8.4. Function of the DIP switches”).
Table 2: Functions I