Process Troubleshooting Webinar Series

Testing and troubleshooting 4 mA to 20 mA control loops

What will be covered in this session

What makes a 4 to 20 mA control loop tick

What things can go wrong with a 4 to 20 mA loop?

How do you troubleshoot? What tools are of most use? Measuring 4 to 20 mA signals and interpreting the measurements
Multiple measurement methods

Testing PLC, DCS and indicator inputs with 4 to 20 mA sourcing tools

Multiple methods and sourcing approaches Testing 1V to 5 V and 0 V to 10 V I/O

2010 Fluke Corporation

Troubleshooting 4 mA to 20 mA loops

What will be covered in this session

Measuring loop power supplies, troubleshooting suspect power supplies
Testing and isolating a transmitter with substitution power supply

Troubleshooting suspect transmitters

mA simulate used for substitution testing

Using a HART smart transmitter as a mA source

Using the Loop Test HART command to test a loop

Testing an I/P with 4 to 20 mA sourcing Testing a control valve with a 4 to 20 mA source

2010 Fluke Corporation

Troubleshooting 4 mA to 20 mA loops

What makes a 4 to 20 mA control loop tick

Transmitters:
Convert the measured temperature or pressure to a 4 to 20 mA signal. Typically are passive devices and draw their power from an external 24 V loop power supply.

Indicators/Controllers:
Interpret the 4 to 20 mA signal as the temperature or pressure being measured in the process. Often issue commands to a final control element such as a valve to regulate the process temperature or pressure to within acceptable limits Inputs to these devices is frequently a 1 V to 5 V input signal rather than 4 to 20 mA

Sensor input
Temperature Pressure Flow Frequency PH

4 to 20 mA signal
250 ohm input shunt

2200 C

ZERO SPAN

4 to 20 mA
Readout/Controller DCS/PLC/Recorder

24 V loop supply

2 Wire Transmitter

24 V loop power supply:

Provides power for the loop. Transmitters regulate the 4 to 20 mA signal in the circuit drawing power from this supply.

Example current loop

4 to 20 mA (dc) signal is proportional to sensor input or PV Series circuit dictates the current at one location must be identical to other locations Big advantage sending in sending mA signals over long distances compared to voltage or pressure signals
Sensor input
Temperature Pressure Flow Frequency PH
250 ohm input shunt

4 to 20 mA signal

2200 C

ZERO SPAN

4 to 20 mA
Readout/Controller DCS/PLC/Recorder

24 V loop supply

2 Wire Transmitter

Temperature transmitters convert measured temperature (PV) 4 to 20 mA signals

Measured PV:
The PV or primary/process variable in this example is the temperature of the process fluid being measured by the temperature transmitter.

Temperature transmitter:
Typically sense the temperature of the process via either a thermocouple or RTD sensor and convert the measurement to a 4 to 20 mA signal. The transmitter in this example has an input span (range) of 0 C to 300 C. The relationship of the measured temperature and mA signal is shown is the table.

Temperature transmitter
Temperature input 0 C 75 C 150 C 225 C 300 C Current output 4 mA 8 mA 12 mA 16 mA 20 mA Percent of span 0% 25 % 50 % 75 % 100 %

Temperature transmitters convert measured temperature (PV) 4 to 20 mA signals

Measured PV:
The PV or primary/process variable in this example is the temperature being measured by the temperature transmitter.

Temperature transmitter:
Typically sense the temperature of the process via either a thermocouple or RTD sensor and convert the measurement to a 4 to 20 mA signal. The transmitter in this example has an input span (range) of 0 C to 300 C. The relationship of the measured temperature and mA signal is shown is the table.

Temperature input 0 C 75 C 150 C 225 C

Current output 4 mA 8 mA 12 mA 16 mA

Percent of span 0% 25 % 50 % 75 %

300 C

20 mA

100 %

Temperature Transmitters convert measured temperature (PV) 4 to 20 mA signals

Indicator/Controller:
In this example, the temperature indicator/controller is programmed to interpret a 4 mA signal as 0 C and a 20 mA signal as 300 C.

Input/Output or I/O:
Refers to the input/output of the control system or controller. In this example the input to the controller is the 4 to 20 mA signal. The output from the controller is the signal that controls the control valve.
Temperature transmitter
Temperature input 0 C 75 C 150 C 225 C 300 C Current output 4 mA 8 mA 12 mA 16 mA 20 mA Percent of span 0% 25 % 50 % 75 % 100 %

Flow Control Valve

Final control element. Opens and closes based on commands from the controller to increase or decrease gas supplied to the burner as required to maintain temperature at the setpoint value.

Pressure Transmitters convert measured pressure (PV) to 4 to 20 mA signals

Measured PV:
The PV or primary/process variable in this example is the pressure being measured by the pressure transmitter.

Pressure Transmitter:
Senses the pressure of the process directly and converts the measurement to a 4 to 20 mA signal. The transmitter in this example has an input span (range) of 0 psi to 100 psi. The relationship of the measured pressure and mA signal is shown is the table.

Indicators/Controller:
In this example, the pressure indicator/controller is programmed to interpret a 4 mA signal as 0 psi and a 20 mA signal as 100 psi.

Pressure transmitter
Pressure input
0 psi 25 psi 50 psi 75 psi 100 psi

Pressure relief valve:

Final control element. In this example if the measured pressure is too high, the controller instructs the valve to open to reduce the pressure in the vessel.

Current output
4 mA 8 mA 12 mA 16 mA 20 mA

Percent of span
0% 25 % 50 % 75 % 100 %

What can go wrong with a 4 to 20 mA loop?

Wiring problems:
Bad terminations, compromised insulation, corrosion and contamination can cause wiring to negatively impact 4 to 20 mA loop operation.
Temperature transmitter
Temperature input 0 C 75 C 150 C 225 C 300 C Current output 4 mA 8 mA 12 mA 16 mA 20 mA Percent of span 0% 25 % 50 % 75 % 100 %

24V loop power supplies:

Noisy, defective or overloaded power supplies can cause erratic mA loop operation or failures.

Bad I/O into the controller:

If the mA signal is correct and the controller does not interpret the mA signal correctly the control of the process is lost.

Pressure transmitter
Pressure input 0 psi 25 psi 50 psi Current output 4 mA 8 mA 12 mA Percent of span 0% 25 % 50 %

75 psi
100 psi

16 mA
20 mA

75 %
100 %

What can go wrong with a 4 to 20 mA loop

Bad transmitter:
If the transmitter does not change the mA signal to correctly to respond to the measured PV the control system will not correct to adjust the PV correctly.
Temperature transmitter
Temperature input 0 C 75 C 150 C 225 C 300 C Current output 4 mA 8 mA 12 mA 16 mA 20 mA Percent of span 0% 25 % 50 % 75 % 100 %

Bad sensor or clogged capillary:

If the temperature sensor is defective the transmitter cannot sense the temperature. In a pressure transmitter if the connection to the process is clogged the transmitter cannot measure the pressure accurately.

Pressure transmitter
Pressure input 0 psi 25 psi 50 psi Current output 4 mA 8 mA 12 mA Percent of span 0% 25 % 50 %

75 psi
100 psi

16 mA
20 mA

75 %
100 %

How do you troubleshoot? What tools are of the most use?

What can be measured or sourced
Measure 4 mA to 20 mA signals

Measurement and sourcing tool

DMM. Loop calibrator, mA clamp, ProcessMeter

What it tells the technician

If the measured mA value is the expected value

Source 4 mA to 20 mA signals
Simulate 4 mA to 20 mA signals Measure 24 V loop voltage Supply 24 V loop voltage Source 0 V to 10 V, 1 V to 5 V Continuity measurements

Loop calibrator, mA clamp, ProcessMeter

Loop calibrator, Fluke 772 or 773 mA Clamp, ProcessMeter DMM, Loop calibrator, Fluke 773 mA Clamp, ProcessMeter Loop calibrator, mA clamp, Fluke 789 ProcessMeter Loop calibrator with voltage source (715) or specialized mA Clamp (773) DMM, ProcessMeter, some multifunction process calibrators

If the I/O or other mA input device is working correctly

If the power supply, wiring and I/O is working correctly, perform transmitter substitution test If the full 24V supply available, if it is defective or being loaded down? If a substitution test for installed supply fixes the problem If the I/O or other voltage input device is working correctly Find open circuits, bad terminations, resistive connections and mis-wires

Measure the 4 mA to 20 mA signal

Temperature transmitter
Temperature input Current output 4 mA 8 mA 12 mA 16 mA 20 mA Percent of span 0% 25 % 50 % 75 % 100 % 0 C 75 C 150 C 225 C 300 C

In series, Break the loop

Compare measured mA signal to the expected value on the display

Pressure transmitter
Pressure input 0 psi 25 psi 50 psi Current output 4 mA 8 mA 12 mA Percent of span 0% 25 % 50 %

75 psi
100 psi

16 mA
20 mA

75 %
100 %

Measure the 4 mA to 20 mA signal; Dont break the loop

Temperature transmitter
Temperature input Current output 4 mA 8 mA 12 mA 16 mA 20 mA Percent of span 0% 25 % 50 % 75 % 100 % 0 C 75 C 150 C 225 C 300 C

Dont Break the loop

Compare measured mA signal to the expected value on the display

Pressure transmitter
Pressure input 0 psi 25 psi 50 psi Current output 4 mA 8 mA 12 mA Percent of span 0% 25 % 50 %

75 psi
100 psi

16 mA
20 mA

75 %
100 %

Source a 4 mA to 20 mA signal
Temperature transmitter
Temperature input Current output 4 mA 8 mA 12 mA 16 mA 20 mA Percent of span 0% 25 % 50 % 75 % 100 % 0 C 75 C 150 C 225 C 300 C

Tests the indicator, controller or PLC/Control system I/O directly. Verify the value on the display

Pressure transmitter
Pressure input 0 psi 25 psi 50 psi Current output 4 mA 8 mA 12 mA Percent of span 0% 25 % 50 %

75 psi
100 psi

16 mA
20 mA

75 %
100 %

Simulate a 4 mA to 20 mA signal
Temperature transmitter
Temperature input Current output 4 mA 8 mA 12 mA 16 mA 20 mA Percent of span 0% 25 % 50 % 75 % 100 % 0 C 75 C 150 C 225 C 300 C

Simulate a transmitter in a loop, regulate current

Tests the wiring, power supply, indicator, controller or PLC/Control system I/O. Verify the value on the display. Perform a transmitter substitution test.

Pressure transmitter
Pressure input 0 psi 25 psi 50 psi Current output 4 mA 8 mA 12 mA Percent of span 0% 25 % 50 %

75 psi
100 psi

16 mA
20 mA

75 %
100 %

Measure 24V loop power

Temperature transmitter
Temperature input Current output 4 mA 8 mA 12 mA 16 mA 20 mA Percent of span 0% 25 % 50 % 75 % 100 % 0 C 75 C 150 C 225 C 300 C

Is the full 24 V available or is the power supply being loaded down

Pressure transmitter
Pressure input 0 psi 25 psi 50 psi Current output 4 mA 8 mA 12 mA Percent of span 0% 25 % 50 %

75 psi
100 psi

16 mA
20 mA

75 %
100 %

Test with external 24 V loop power supply

Temperature transmitter
Temperature input Current output 4 mA 8 mA 12 mA 16 mA 20 mA Percent of span 0% 25 % 50 % 75 % 100 % 0 C 75 C 150 C 225 C 300 C

Supply 24 V loop power, simultaneously measure mA signal. Substitution test for the power supply.

Pressure transmitter
Pressure input 0 psi 25 psi 50 psi Current output 4 mA 8 mA 12 mA Percent of span 0% 25 % 50 %

75 psi
100 psi

16 mA
20 mA

75 %
100 %

Using a HART smart transmitter as a mA source

Using loop test, the Fluke 744 issues the mA output command to the transmitter over the HART cable Transmitter sources a mA signal into the I/O Verify correct indication on the display Compare commanded output value to mA signal read by Fluke 744 Tests transmitter output, power supply, wiring and I/O

Smart transmitter output

Loop test output trim Instrument Output PVAO command
(from communicator or Fluke 744)

Temperature transmitter
Temperature input 0 C 75 C Current output 4 mA 8 mA 12 mA 16 mA 20 mA Percent of span 0% 25 % 50 % 75 % 100 %

4 to 20 mA output to PLC or DCS

150 C 225 C 300 C

HART cable

Troubleshooting, sourcing 1 V to 5 V and 0 V to 10 V

The input to many control systems and PLCs is a voltage signal 1 V to 5 V is most common as 4 to 20 mA through 250 ohms is 1 V to 5 V Some low power transmitters have 1 V to 5 V outputs Many older chart recorders and HVAC systems have 1 V to 5 V and 0 V to 10 V I/O
Ohms law

0.004 x 250 = 1.0 V 0.020 x 250 = 5.0 V

2200 C

Readout / Controller DCS / PLC / Recorder

Testing I to P devices
I to P converts a 4 mA to 20 mA signal to a 3 psi to 15 psi pneumatic signal
Often used with control valves Used as a bridge between 4 mA to 20 mA loop and 3 psi to 15 psi pneumatic technology Typically operate from a 20 psi or greater pressure supply Source 4 mA to 20 mA, verify/measure correct pressure output
Pressure output

4-20 mA current input

Current input 4 mA

Pressure output 3 psi

Percent of span 0%

8 mA

6 psi
9 psi

25 %
50 %

Supply pressure

12 mA

16 mA
20 mA

12 psi
15 psi

75 %
100 %

~20 PSI

Testing control valves

Flow control, final control element 4 mA to 20 mA or 3 psi to 15 psi input Normally closed or open Normally closed fails closed with loss of power Normally open fails open with loss of power Apply a 4 mA to 20 mA signal and check for operation per the applicable table below

Normally Closed
Pressure input 3 psi 6 psi 9 psi 12 psi Current output 4 mA 8 mA 12 mA 16 mA Percent of travel 0% 25 % 50 % 75 %
Closed

Normally Open
Pressure input 3 psi 6 psi 9 psi 12 psi
Open

Current output 4 mA 8 mA 12 mA 16 mA

Percent of travel 0% 25 % 50 % 75 %

Open Open

Closed

15 psi

20 mA

100 %

15 psi

20 mA

100 %

Closed

Review: Current loop devices and test methods

Transmitters
Apply input stimulus (temperature, pressure, etc) Measure for correct 4 to 20 mA output Use mA simulate for substitution testing

24 V loop power supplies

Measure for correct voltage, substitution test to verify

I to P, 4 mA to 20 mA input, 3 psi to 15 psi output

Source 4 to 20 mA, verify/measure correct pressure output

Control valves
Source 4 mA to 20 mA, verify position indication Use mA signal ramping to test for smooth operation

PLC, DCS, indicators, controllers, flow computers, and chart recorders analog inputs
Source 4 mA to 20 mA into the input and verify correct indication

Next steps
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