4–20 mA Process Control Loops

In electrical signalling an analog current loop is used where a device must be

monitored or controlled remotely over a pair of conductors. Only one current level can
be present at any time. A major application of current loops is the industry de-facto
standard 4–20 mA current loop for process control applications, where they are
extensively used to carry signals from process instrumentation to PID controllers,
SCADA systems, and programmable logic controllers (PLCs).

They are also used to transmit controller outputs to the modulating field devices such
as control valves. These loops have the advantages of simplicity and noise immunity,
and have a large international user and equipment supplier base. Some 4–20 mA field
devices can be powered by the current loop itself, removing the need for separate
power supplies, and the “smart” HART protocol uses the loop for communications
between field devices and controllers. Various automation protocols may replace
analog current loops, but 4–20 mA is still a principal industrial standard.

4–20 mA Process Control Loops

In industrial process control, analog 4–20 mA current loops are commonly used for
electronic signalling, with the two values of 4 & 20 mA representing 0–100% of the
range of measurement or control. These loops are used both for carrying sensor
information from field instrumentation, and carrying control signals to the process
modulating devices, such as a valve.

Control Loops

The below figures Shows the evolution of analogue control loop signalling from the
pneumatic era to the electronic era.
The key advantages of the current loop are:
• The loop can often power the remote device, with power supplied by the
controller, thus removing need for power cabling. Many instrumentation
manufacturers produce 4–20 mA sensors which are “loop powered”.
• The “live” or “elevated” zero of 4 mA allows powering of the device even
with no process signal output from the field transmitter.
• The accuracy of the signal is not affected by voltage drop in the
interconnecting wiring.
• It has high noise immunity as it is low impedance circuit usually through
twisted pair conductors.
• It is self-monitoring; currents less than 3.8 mA or more than 20.5 mA are
taken to indicate a fault.
• It can be carried over long cables up to the limit of the resistance for the
voltage used.
• In line displays can be inserted and powered by the loop, as long as total
allowable loop resistance is not exceeded.
• Easy conversion to voltage using a resistor.
• Loop powered “I to P” (current to pressure) converters can convert the
4–20 mA signal to a 3–15 psi pneumatic output for control valves,
allowing easy integration of 4–20 mA signals into existing pneumatic
plant.
Field instrumentation measurements are such as pressure, temperature, level, flow,
pH or other process variables. A current loop can also be used to control a valve
positioner or other output actuator.

Since input terminals of instruments may have one side of the current loop input tied
to the chassis ground (earth), analog isolators may be required when connecting
several instruments in series.
The relationship between current value and process variable measurement is set by
calibration, which assigns different ranges of engineering units to the span between 4
and 20 mA.

The mapping between engineering units and current can be inverted, so that 4 mA
represents the maximum and 20 mA the minimum.

This example shows the versatility of the 4-20 mA current loop system in multiple
applications. It can be used to cascade a set point from another controller, and it can
both control and supply power to passive field devices which “sink” the current. In each
loop there has to be one source of current, usually the controller.

Here a current loop is connected directly to a modern “smart” valve positioner. This is
a local servo-controller that ensures the valve goes to the required position using a
mechanical feedback linkage.

Active and Passive Devices

Depending on the source of current for the loop, devices may be classified as active
(supplying or “sourcing” power) or passive (relying on or “sinking” loop power).

For example, a chart recorder may provide loop power to a pressure transmitter. The
pressure transmitter modulates the current on the loop to send the signal to the strip
chart recorder, but does not in itself supply power to the loop and so is passive.

Another loop may contain two passive chart recorders, a passive pressure transmitter,
and a 24 V battery. (The battery is the active device). Note that a 4-wire instrument
has a power supply input separate from the current loop.
Panel mount displays and chart recorders are commonly termed ‘indicator devices’ or
‘process monitors’. Several passive indicator devices may be connected in series, but
a loop must have only one transmitter device and only one power source (active
device).

History of Control Signals

The 4–20 mA convention was born in the 1950s out of the earlier highly successful 3–
15 psi pneumatic control signal standard, when electronics became cheap and reliable
enough to emulate the older standard electrically.

The 3–15 psi standard had the same features of being able to power some remote
devices, and have a “live” zero. However the 4–20 mA standard was better suited to
the electronic controllers then being developed.

The transition was gradual and has extended into the 21st century, due to the huge
installed base of 3–15 psi devices. As the operation of pneumatic valves over
motorised valves has many cost and reliability advantages, pneumatic actuation is still
an industry standard.

To allow the construction of hybrid systems, where the 4–20 mA is generated by the
controller, but allows the use of pneumatic valves, a range of current to pressure (I to
P) converters are available from manufacturers. These are usually local to the control
valve and convert 4–20 mA to 3–15 psi (or 0.2–1.0 bar).

This signal is then fed to the valve actuator or more commonly, a pneumatic positioner.
The positioner is a dedicated controller which has a mechanical linkage to the actuator
movement. This ensures that problems of friction are overcome and the valve control
element moves to the desired position. It also allows the use of higher air pressures
for valve actuation.

With the development of cheap industrial micro-processors, “smart” valve positioners

have become available since the mid-1980s and are very popular for new installations.
These include an I to P converter, plus valve position and condition monitoring. These
latter are fed back over the current loop to the controller, using such as the HART
protocol.
4-20 mA Transmitter Wiring Types : 2-Wire, 3-Wire, 4-Wire

Transmitters are available with a wide variety of signal outputs. The 4-20mA analogue
signal is by far the most commonly used in industrial applications.

Several physical 4-20mA wiring options exist. This guidance note aims to outline these
options.

Table of contents

• 4-20 mA Transmitter Wiring

• Current source transmitter, non isolated (3 wire)
• Advantages
• Disadvantages
• Current sink transmitter, non isolated (3 wire)
• Advantages
• Disadvantages
• Fully isolated (4 wire)
• Advantages
• Disadvantages
• Two Wire Loop Powered Transmitters
• Advantages
• Disadvantages
• Basics of 4 – 20 mA
Industrial transmitters are available for monitoring many parameters these including
pressure, temperature and flow etc. Gas detectors / transmitters offer 4-20mA outputs,
where 4 mA equates to a zero reading and 20 mA equates a full scale reading of the
calibrated range. This signal is sent to a remotely located control panel. The control
panel uses this signal and activates executive actions via relay contacts. e.g. audible
and visual alarms or initiate some trips or even plant shut down procedures.
Transmitters typically require a 24Vdc supply. This supply can be derived local to the
transmitter or supplied direct from the associated control panel.

4-20 mA Transmitter Wiring

Several transmitter wiring options exist. The design of the associated control panel
dictates which option should be used.

These wiring options include:

• Current source transmitter, non isolated (3 wire)

• Current sink transmitter, non isolated (3 wire)
• Fully isolated (4 wire)
• Two wire loop powered transmitters
Most modern transmitters can be wired in a current sink or source format, selection is
often made by the use of specific terminals or the location of a link within the
transmitter. However some transmitters may be limited to either a sink or source
configuration. Check the transmitters technical manual for the available options. When
transmitters are wired in a current source configuration it follows that the control
system will be current sink, and vice versa. Therefore it is important to qualify whether
it is the transmitter or the control system that is to be wired in a specific configuration.

For the purposes for this guidance note it is assumed that both the transmitter and the
remote control panel require a 24Vdc supply.

Current source transmitter, non isolated (3 wire)

This is the most common configuration of modern 4-20mA transmitters.

The transmitter and control panel can use the same 24V and 0V dc supply lines.

The 4-20mA signal flows through the 24V dc line and the signal line to the controller.

Advantages

• Only three cable cores are required to the transmitter.

• A common power supply can be used for both the transmitter and the
control panel.

Disadvantages

• Any electrical interference or pick up may be transmitted along the signal

line, which could generate a spurious alarm in the control panel
Current sink transmitter, non isolated (3 wire)

The transmitter and control panel can use the same 0V and 24V dc supply lines.

The 4-20mA signal flows through the 0V dc line and the signal line to the controller.

Advantages

• Only three cable cores are required to the transmitter.

• A common power supply can be used for both the transmitter and the
control panel.

Disadvantages

• Any electrical interference or pick up may be transmitted along the signal

line, which may generate a spurious alarm in the control panel.

Fully isolated (4 wire)

The transmitter and control panel use separate power supplies. The 4-20mA signal
flows through two separate cable cores between the transmitter and control panel. It
is assumed that the power to drive the 4-20mA loop is derived from the control panel.
Advantages

• Electrical interference on the voltage supply lines will not be transferred

to the 4-20mA signal line, reducing the risk of spurious signals being
received at the controller.

Disadvantages

• An additional cable core is required for each transmitter compared to

current sink and source options.
• A separate power supply is required for both the transmitter and control
panel.

Two Wire Loop Powered Transmitters

This configuration supplies power and 4-20mA signal over a two wire loop connection
between the transmitter and the control panel. Not all transmitters can be wired in this
format and must be specifically designed to accommodate this configuration.

Advantages

• Has low power consumption.

• Only two cable cores are required to the transmitter.

Disadvantages

• Transmitter discrete fault signalling can not be set at 0mA as this

configuration continues to draw some current in a fault condition. This
configuration is not suitable for control panels that require a 0mA signal
for a fault indication.
Sub 4mA status signalling is limited due the reduced range of mA available between
fault and a zero reading. Not suitable for power hungry transmitters, e.g. catalytic gas
detectors, or Infrared gas detectors using optical heating elements.