I/P and P/I Converter Trainer

Name: Gaytri Sachdeva

Entry number: 2021uch0008
Lab 2, Exp 3
DOE: 04/09/2024
DOS: 06/11/2024
I/P and P/I Converter Trainer

Description

The I/P and P/I Converter Trainer (ACE 501) is designed to understand the theory and working of a
Current to Pressure and Pressure to Current Converter. It consists of I/P converter, P/I converter, current
source/sink, pressure gauges and air filter regulator. In source mode current source/sink indicator is
used as current source to supply DC current to I/P converter and in sink mode it displays the output
current from P/I converter. This setup can be used to calculate the linearity, hysteresis, accuracy and
repeatability of I/P and P/I Converters. The P&I diagram of the setup is shown below.

Introduction
An I/P converter transforms electrical current into pneumatic pressure using a flapper- nozzle system.
The system converts electrical signals (typically 4-20 mA) from a controller into pneumatic signals
(20-100 kPa or 3-15 psi). The current flows through coils mounted on a pivoted beam, which are
attracted toward a magnet based on the current's strength. This movement causes the beam to rotate,
adjusting the gap between the flapper and the nozzle. The gap controls airflow, creating back pressure.
In the sensitive central region of operation, even small flapper movements produce significant changes
in output pressure, ensuring precise control. The system is designed to operate within this region for
optimal response.

Characteristics
Accuracy and error
 I/P and P/I Converter Trainer

Accuracy refers to how close a measurement system or element is to the true value. For instance, a
system with ±1% of full-scale deflection (f.s.d.) and a 15 psi range has an accuracy of ±0.15 psi.
Accuracy encompasses all possible errors and the system's calibration. Error is defined as the difference
between the measured value and the true value. Accuracy can be expressed in various forms:

1. As a measured variable, e.g., ±2°C, meaning any temperature reading has a ±2°C uncertainty.
2. As a percentage of full-scale (FS), e.g., ±0.5% FS in a 5V meter equals ±0.025V.
3. As a percentage of span, e.g., ±3% in a 20-50 psi device gives an accuracy of ±0.9 psi.
4. As a percentage of the actual reading, e.g., ±2% at 2V results in ±0.04V uncertainty.

Hysteresis
Hysteresis refers to the difference in outputs for the same measured value, depending on whether that
value is reached by increasing or decreasing the input. For example, a thermometer may show
different readings at the same temperature, depending on whether the liquid was warming up or
cooling down.

Repeatability is the ability of a measurement system to provide the same output for repeated
measurements of the same input value. Lack of repeatability is often caused by random environmental
fluctuations, like temperature and humidity changes. The repeatability error is usually expressed as a
percentage of full-range output. For instance, if a pressure sensor has a repeatability of ±0.1% of full
range and the range is 20 kPa, the repeatability error would be ±20 Pa. These concepts are crucial in
understanding the accuracy and reliability of measurement systems in practical applications.

References:
• W. Bolton, “Instrumentation and Control Systems”, ISBN: 0750664320, August 2004, Elsevier
Science & Technology Books.

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 I/P and P/I Converter Trainer

I/P converter
Generally I/P converter is calibrated for standard industrial signals as 4-20 mA input and 3- 15 psig
output. These are standard factory settings and need not to be changed.
Refer following steps to calibrate I/P converter:

1. Set digital calibrator in source mode.

2. Remove the top cover from the unit by gently prying up on the two snap-in cover tabs.

3. Connect 20-psig supply pressure and connect input signal i.e. 4-20 mA.

4. Set the input signal to 4 mA and check the output pressure on gauge as 3 psig.

5. If the pressure is showing more or less than 3 psig then adjust zero. Turn zero adjustment screw
slowly by very small turn to obtain 3-psig pressure. More turning of zero adjustment may damage
the I/P converter. Counterclockwise rotation increases the pressure, and clockwise rotation
decreases the pressure.

6. Set the input current signal to 20 mA and check the output pressure on gauge as 15 psig.

7. Turn the span adjustment potentiometer very slowly by small turn to obtain 15-psig pressure. More
turning of span adjustment may damage the I/P converter.

8. Repeat step 4 to check that the desired low value (4 mA ~ 3 psig) has not changed after adjusting
the span. If necessary repeat steps 3 through 4 to fine-tune the unit.

9. Snap the top cover in the place.

(Note: It is strongly recommended NOT to change the calibration set per standard factory setting.)

P/I converter
Generally P/I converter is calibrated for standard industrial signals as 3-15 psig input corresponds to
4-20 mA DC output. These are standard factory settings and need not to be changed.

To adjust the zero and span settings proceed as follows:

Two adjustments for zero and span are provided in front face of unit.

1. Set digital calibrator on measure mode.

2. Connect input signal i.e. 3-15 psig.

3. Set the input signal to 3 psig and check the output current as 4 mA.

4. If the current is showing more or less than 4 mA then adjust zero on the isolator.

5. Set the input pressure signal to 15 psig and check the output current 20 mA.

6. Turn the span adjustment potentiometer on signal

7. Repeat step 3 to check that the desired low value (3 psig ~ 4mA) has not changed after adjusting
the span. If necessary repeat steps 3 through 4 to fine-tune the unit.
I/P and P/I Converter Trainer

Experiments

Hysteresis of I/P converter

• Start up the set up as mentioned in commissioning part above.

• Put digital calibrator in source mode.
• Give current input in the step 4 mA from 4 to 20 mA by slowly rotating the adjust knob on
digital calibrator.

• Note down corresponding output pressure on output pressure gauge in psig.

• Now note the output pressure in psig by applying input current in decreasing mode from 20 mA
to 4 mA.

• Tabulate above readings in the observation table given below. Observations

Hysteresis of I/P converter
Input current Output Input current Output
Sl. (mA) Pressure (mA) Pressure
No. (psig) (X) (psig) (Y)
Increasing input current Decreasing input current
1 4 3 4 3
2 8 5.9 8 6.3
3 12 8.8 12 9.1
4 16 12.4 16 13
5 20 15 20 15

The graph shows hysteresis as input (increasing and decreasing) on X axis and corresponding output on
Y-axis.

Advanced Control Equipments, Miraj, Maharashtra – All rights reserved

I/P and P/I Converter Trainer

Accuracy of I/P converter

• Now put the digital calibrator in source mode.

• Give current input in the step of 4 mA from 4 to 20 mA by slowly rotating the knob of digital
calibrator.

• Note down corresponding pressure on output pressure gauge in psig. Observations

Accuracy of I/P converter
Standard Actual
Sl. Input Output Output Deviation
No. current Pressure (psig) Pressure (psig) (X) -
(mA) (X) (psig) (Y) (Y)

1 4 3 3 0
2 8 6 5.9 -0.1
3 12 9 8.8 -0.2
4 16 12 12.4 0.4
5 20 15 15 0

The graph showing Standard Output Pressure on X axis and Actual Output Pressure on Y- axis.

Hysteresis of P/I converter

• Start up the set up as mentioned in commissioning part above.

• Now put digital calibrator on measure mode.
 I/P and P/I Converter Trainer

• Give pressure input in the step of 3 psig from 3 to 15 psig by slowly rotating the air
regulator.
• Note down corresponding current output on digital calibrator in mA.
• Now note the output current in mA by applying input pressure in decreasing mode from
15 psig to 3 psig.
• Tabulate above readings in the observation table given below. Observations

Hysteresis of P/I converter

Input Output Input Output
Sl. Pressure Current (mA) (X) Pressure Current (mA) Hysteresis mA
No. (psig) (psig) (Y) (Y)-(X)
Increasing input current Decreasing input current
1 3 4.1 3 4 -0.1
2 6 8.2 6 7.7 -0.5
3 9 12.1 9 11.8 -0.3
4 12 16 12 15.6 -0.4
5 15 20 15 20 0

The graph showing hysteresis as input (increasing and decreasing) on X axis and corresponding output
on Y-axis

Accuracy of P/I converter

• Now put digital calibrator measure mode.

• Give pressure input in the step of 3 psig from 3 to 15 psig by slowly rotating the air regulator.
• Note down corresponding current output on digital calibrator in mA.
• Tabulate above readings in the observation table given below.

Advanced Control Equipments, Miraj, Maharashtra – All rights reserved

 I/P and P/I Converter Trainer

Observations
Accuracy of P/I conve ter
Standard Output Actual
Sl. Input current (mA) Output Deviation
No. Pressure (X) Current (mA) (X) -
(psig) (mA) (Y) (Y)

1 3 4 4.1 -0.1
2 6 8 8.2 -0.2
3 9 12 12.1 -0.1
4 12 16 16 0
5 15 20 20 0

The graph showing Standard Output Pressure on X axis and Actual Output Pressure on Y- axis.
I/P and P/I Converter Trainer

Results

During the hysteresis test, the I/P converter exhibited minor variations in output pressure as
the current input changed direction. At the maximum input of 20 mA, the output pressure
was stable at 15 psig, regardless of whether the current was increasing or decreasing,
indicating no hysteresis at this level. However, at mid-range currents, such as 16 mA, a
small amount of hysteresis was observed, with output pressures of 12.4 psig during
increasing current and 13 psig during decreasing current, resulting in a maximum hysteresis
value of 0.6 psig, which remains within acceptable limits.
The I/P converter demonstrated high accuracy, with deviations between standard and actual
output pressures remaining minimal. The largest deviation, observed at 16 mA, was 0.4
psig (actual output: 12.4 psig, standard: 12 psig). At lower inputs, such as 8 mA, the
deviation was only -0.1 psig, showcasing the converter’s precision across a range of current
inputs.
Similarly, the P/I converter showed minimal hysteresis, with small output current variations
based on the direction of pressure input. The highest hysteresis occurred at a 6 psig input,
where the output current was 8.2 mA while the pressure was rising and 7.7 mA while the
pressure was falling, resulting in a hysteresis of -0.5 mA. At 15 psig, the output current
remained constant at 20 mA, showing no hysteresis.
The P/I converter also demonstrated excellent accuracy, with the largest deviation from the
standard output being -0.2 mA at a 6 psig input. At other pressures, such as 3 psig and 15
psig, the actual output current aligned closely with standard values, with deviations of -0.1
mA and 0 mA, respectively, confirming the converter’s reliability in accurately maintaining
signal conversion.

Discussion

Both the I/P and P/I converters exhibited low hysteresis, suggesting minimal response delay
between increasing and decreasing inputs. This low hysteresis is essential for consistent
performance in dynamic environments where inputs may vary frequently. The I/P
converter’s maximum hysteresis of 0.6 psig and the P/I converter’s -0.5 mA confirm that
these converters maintain stable outputs despite minor input fluctuations.
Both converters achieved high accuracy, with deviations from standard values falling within
acceptable industrial standards. For the I/P converter, the maximum observed deviation was
0.4 psig, while for the P/I converter, it was -0.2 mA, which confirms that these converters
reliably perform signal transformations with minimal error. This level of precision makes
them well-suited for applications requiring accurate and stable control.
The experiment indicates that both I/P and P/I converters are capable of reliable, accurate
signal conversions with low hysteresis, making them valuable components in industrial
automation and control systems. The I/P converter’s precision in transforming electrical
currents to pneumatic pressure and the P/I converter’s ability to convert pneumatic inputs
into stable electrical outputs make them well-equipped for process control applications.
Their performance ensures consistent operation across fluctuating input values,
underscoring the importance of these converters in achieving responsive and stable system
control in industrial settings.

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